UniCarriers FRSB14-8 Manual
No. OB-7E3DE
No. OB-7E3DE
ELECTRIC FORKLIFT TRUCKELECTRIC FORKLIFT TRUCK
It is the responsibility of the Operator and Supervisor to read and understand thisIt is the responsibility of the Operator and Supervisor to read and understand this
manual.manual.
Protect the earth and be kind to your lift truck.Protect the earth and be kind to your lift truck.
OPERATION &OPERATION &
MAINTENANCE MANUALMAINTENANCE MANUAL
FRSB14FRSB14-8-8
FRSB16FRSB16-8-8
FRSB20FRSB20-8-8
FRSB25FRSB25-8-8
ReReaach ch tytypepe
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CONTENTS
CONTENTS
1. SAFETY1. SAFETY
2. OPERATING2. OPERATING
CONTROLSCONTROLS
3. OPERATION3. OPERATION
4.4. MAINTENANCEMAINTENANCE
5.5. SPECIFICATIONSSPECIFICATIONS
& SERVICE DATA& SERVICE DATA
6. INDEX6. INDEX
Thank you very much for Thank you very much for your purchase of UniCarriers’your purchase of UniCarriers’
product.product.
This Operation & Maintenance Manual was written to provide the This Operation & Maintenance Manual was written to provide the owner/owner/
operator with information about the safe operation and maintenance ofoperator with information about the safe operation and maintenance of
the UniCarriers forklift truck. Read this manual thoroughly and becomethe UniCarriers forklift truck. Read this manual thoroughly and become
completely familiar with the lift truck before using it. If you have anycompletely familiar with the lift truck before using it. If you have any
questions, see your dealer.questions, see your dealer.
This manual was compiled based on the standard models. For trucksThis manual was compiled based on the standard models. For trucks
other than the standard models, only other than the standard models, only the differences are explained.the differences are explained.
Due to improvements in design, it is possible that the descriptionDue to improvements in design, it is possible that the description
contained herein may not completely apply to contained herein may not completely apply to the truck delivered to you.the truck delivered to you.
NOTENOTE
If the truck is to be leased, loaned or sold to anyone, this manualIf the truck is to be leased, loaned or sold to anyone, this manual
must be with the truck.must be with the truck.
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1-1
1-1
1. SAFETY1. SAFETY
CONTENTSCONTENTS
FOREWORD .......................................................1-2FOREWORD .......................................................1-2
FOR OPERATORFOR OPERATORS AND SUPERVISORS ..........S AND SUPERVISORS .......... 1-31-3
QUALIFIED QUALIFIED OPERAOPERATORS TORS ........................................................ 1-31-3
PLANNING PLANNING AND AND WORKING WORKING AREA AREA ................................ 1-51-5
PROPER PROPER AND AND IMPROPER IMPROPER USES USES ................................ 1-81-8
TYPES TYPES OF OF LIFT LIFT TRUCKS AND TRUCKS AND LOADS ......LOADS ......1-91-9
INSPECTION INSPECTION ................................................................................................ 1-121-12
TRANSPORTING TRANSPORTING THE THE LIFT LIFT TRUCK TRUCK ...................... 1-131-13
MODIFICAMODIFICATIONS TIONS .................................................................................. 1-141-14
HOW HOW THE LIFT THE LIFT TRUCK TRUCK WORKS? WORKS? .................................... 1-151-15
TRAVELING ......................................................1-17TRAVELING ......................................................1-17
LOAD HANDLING .............................................1-22LOAD HANDLING .............................................1-22
PPARKING ARKING ...................................................................................................................... 1-271-27
INSPECTION AND SERVICE ...........................1-28INSPECTION AND SERVICE ...........................1-28
PREVENTING VEHICLE FIRES .......................1-33PREVENTING VEHICLE FIRES .......................1-33
CAUTION PLATES CAUTION PLATES ........................................................................................ 1-351-35
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FOREWORD
FOREWORD
1-21-2
FOREWORDFOREWORD
••All operators and supervisors All operators and supervisors must read the safety instructions must read the safety instructions given on the following pages carefully given on the following pages carefully andand
understand them thoroughly, before operating or servicing the truck.understand them thoroughly, before operating or servicing the truck.
••Understand the characteristics of Understand the characteristics of the truck and follow the the truck and follow the operating and servicing procedures specioperating and servicing procedures specied.ed.
Work safely.Work safely.
••Always follow all the instructions, including all warning messages, in this OPERATION ANDAlways follow all the instructions, including all warning messages, in this OPERATION AND
MAINTENANCE MANUAL. Failure to do so may result in injury to people or may damage the truckMAINTENANCE MANUAL. Failure to do so may result in injury to people or may damage the truck
or other assets.or other assets.
The meanings of the safety The meanings of the safety symbols andsymbols and
messagesmessages
A variety of A variety of safety safety instructions are instructions are found found throughoutthroughout
this manual, and there are safety and warningthis manual, and there are safety and warning
decals on the truck. Follow all instructions for thedecals on the truck. Follow all instructions for the
safe operation and servicing of the truck. Safetysafe operation and servicing of the truck. Safety
instructions are accompanied by the safety alertinstructions are accompanied by the safety alert
symbols and signal words shown on the right.symbols and signal words shown on the right.
This is the safety alert symbol. It is used to warn theThis is the safety alert symbol. It is used to warn the
reader about a potential source of human injury. Toreader about a potential source of human injury. To
prevent injury or death, make sure you understandprevent injury or death, make sure you understand
and follow all the safety messages following this safetyand follow all the safety messages following this safety
alert symbol.alert symbol.
Signal wordSignal word
(designates the(designates the
degree of hazard)degree of hazard)
DenitionDenition
DANGERDANGER Indicates an imminently hazardousIndicates an imminently hazardous
situation which, if not avoided, willsituation which, if not avoided, will
result in death or result in death or serious injury.serious injury.
WARNINGWARNING In dic a tes a potential ly hazardo usI ndi c ate s a p ote nti a lly ha zardous
situation which, if not avoided, couldsituation which, if not avoided, could
result in death or result in death or serious injury.serious injury.
CAUTIONCAUTION In dic a tes a po tential ly haz ardo usI ndi c ate s a p ote nti a lly ha zardous
situation which, if not avoided, maysituation which, if not avoided, may
result in minor or moderate result in minor or moderate injuryinjury..
CAUTION CAUTION Indicates a hazardous situation which,Indicates a hazardous situation which,
if not avoided, may result in damage toif not avoided, may result in damage to
the truck or other the truck or other propertyproperty..
NOTENOTE Indicates information which will helpIndicates information which will help
extend the service life of the truck.extend the service life of the truck.
How the four sides of the truck in thisHow the four sides of the truck in this
manual are identiedmanual are identied
The front, back, right and left sides of the truck inThe front, back, right and left sides of the truck in
this manual are identied in the gure on the right.this manual are identied in the gure on the right.
ForwardForward
LeftLeft
RightRight
BackwardBackward
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS QUALIFIED OPERATORSQUALIFIED OPERATORS
1-31-3
FOR OPFOR OPERAERATORS ANDTORS AND
SUPERVISORSSUPERVISORS
Lift truck accidents cause dozens or hundreds ofLift truck accidents cause dozens or hundreds of
deaths every year, and even greater numbers ofdeaths every year, and even greater numbers of
personal injuries.personal injuries.
UniCarriers has steadily improved the design andUniCarriers has steadily improved the design and
fabrication of our lift trucks so they may be usedfabrication of our lift trucks so they may be used
more safely and efciently, but many accidents stillmore safely and efciently, but many accidents still
occur due to improper use. Accidents are oftenoccur due to improper use. Accidents are often
the result of more than just “bad driving”. The usethe result of more than just “bad driving”. The use
of inappropriate types of equipment, the selectionof inappropriate types of equipment, the selection
of inappropriate attachments or accessories,of inappropriate attachments or accessories,
inappropriate operating environments, carelessinappropriate operating environments, careless
designation of operators, and failure to properlydesignation of operators, and failure to properly
train the operator are other common causes oftrain the operator are other common causes of
accidents.accidents.
It is not possible to describe all potentiallyIt is not possible to describe all potentially
hazardous situations which may occur whilehazardous situations which may occur while
operating, inspecting or servicing a fooperating, inspecting or servicing a forklift truck.rklift truck.
The safety instructions including the warning andThe safety instructions including the warning and
caution messages in this manual and on the decalscaution messages in this manual and on the decals
attached to the forklift, are not intended to cover allattached to the forklift, are not intended to cover all
possible working hazards. If you operate, inspect orpossible working hazards. If you operate, inspect or
service the forklift in a manner not described in thisservice the forklift in a manner not described in this
manual, please be careful because you do so atmanual, please be careful because you do so at
your own risk.your own risk.
This chapter covers the methods of accidentThis chapter covers the methods of accident
prevention which are primarily the responsibility ofprevention which are primarily the responsibility of
supervisory personnel.supervisory personnel.
•• Pages 1-2 through 1-16 contain instructions Pages 1-2 through 1-16 contain instructions
which should be enforced by the personnelwhich should be enforced by the personnel
supervising the operation of the lift truck. Pleasesupervising the operation of the lift truck. Please
make sure the operators also read these pages.make sure the operators also read these pages.
•• Page 1-17 and the following pages contain Page 1-17 and the following pages contain
specific precautions directly related to thespecific precautions directly related to the
operation of the lift truck. Make sure the operatorsoperation of the lift truck. Make sure the operators
read all instructions carefully and understandread all instructions carefully and understand
them them completelycompletely..
■■TRAIN OPERATORS TO STACK SAFELYTRAIN OPERATORS TO STACK SAFELY
StackingStacking
UnstackingUnstacking
“Stacking” means piling up palletized loads or“Stacking” means piling up palletized loads or
materials directly on top of each other, without usingmaterials directly on top of each other, without using
racks or shelves to separate them.racks or shelves to separate them.
If loads are not properly stacked, they may slipIf loads are not properly stacked, they may slip
or fall, endangering the operator as well as fellowor fall, endangering the operator as well as fellow
workers in the area.workers in the area.
Safety classes should be held to train all operatorsSafety classes should be held to train all operators
in the proper method of stacking and unstackingin the proper method of stacking and unstacking
loads.loads.
■■PERIODIC REFRESHER TRAINING ISPERIODIC REFRESHER TRAINING IS
REQUIREDREQUIRED
The operator must undergo periodic refresherThe operator must undergo periodic refresher
training, by completing a practical training course.training, by completing a practical training course.
Forklift truck design is moving ahead rapidly,Forklift truck design is moving ahead rapidly,
including the use of new microprocessor technologyincluding the use of new microprocessor technology
and automatic controls. In addition, the standardsand automatic controls. In addition, the standards
and safety regulations for forklift trucks are alsoand safety regulations for forklift trucks are also
changing all the time. Even an experienced operatorchanging all the time. Even an experienced operator
should receive refresher training to ensure that theshould receive refresher training to ensure that the
operator has the knowledge and skills needed tooperator has the knowledge and skills needed to
operate a powered industrial truck operate a powered industrial truck safelysafely..
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS QUALIFIED OPERATORSQUALIFIED OPERATORS
1-41-4
■■TIRED OR UNWELL? SEND THEMTIRED OR UNWELL? SEND THEM
HOME!HOME!
Do not let people take chances. An operator who isDo not let people take chances. An operator who is
overworked or fatigued, an operator who is feelingoverworked or fatigued, an operator who is feeling
unwell, or an operator who is intoxicated must notunwell, or an operator who is intoxicated must not
be allowed in the driver’s seat.be allowed in the driver’s seat.
■■WEAR PROTECTIVE GEARWEAR PROTECTIVE GEAR
SafetySafety
ShoesShoes
WorkWork
ClothesClothes
SafetySafety
GogglesGoggles
Hard HatHard Hat
••Always wear proper Always wear proper work clothes for work clothes for driving.driving.
Work clothes should be designed to prevent anyWork clothes should be designed to prevent any
part from accidentally catching on levers or otherpart from accidentally catching on levers or other
parts of the truck or equipment. For example,parts of the truck or equipment. For example,
shirts and trousers should have tight cuffs.shirts and trousers should have tight cuffs.
••Always wear Always wear a hard a hard hat and safety hat and safety shoes.shoes.
••Wear other Wear other protectivprotective gear e gear as appropriate toas appropriate to
the conditions of the work site, i.e., goggles orthe conditions of the work site, i.e., goggles or
gloves.gloves.
■■PROVIDE AND MAINTAIN EMERGENCYPROVIDE AND MAINTAIN EMERGENCY
EQUIPMENTEQUIPMENT
Fire extinguishers and first aid kits should beFire extinguishers and first aid kits should be
provided and maintained for use in case of a fireprovided and maintained for use in case of a fire
or accident. All personnel should understand theor accident. All personnel should understand the
location and use of emergency equipment.location and use of emergency equipment.
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS PLANNING AND WORKING AREAPLANNING AND WORKING AREA
1-51-5
■■KNOW WHO TO CALL IN ANKNOW WHO TO CALL IN AN
EMERGENCYEMERGENCY
Contacts in emergencyContacts in emergency
..........................................................................
........................................................................
............................ ............................
............................ ............................
Keep information on hand to allow immediateKeep information on hand to allow immediate
calls for help in case of a fire, accident or othercalls for help in case of a fire, accident or other
emergency.emergency.
■■MAKE AN OPERATING PLAN ANDMAKE AN OPERATING PLAN AND
DISCUSS ITDISCUSS IT
Before using the lift truck, plan out the travel routesBefore using the lift truck, plan out the travel routes
and operating procedures, and thoroughly discussand operating procedures, and thoroughly discuss
the details with all personnel involved.the details with all personnel involved.
■■MARK THE TRAVEL LANESMARK THE TRAVEL LANES
Designate the travel lanes for the lift truck and markDesignate the travel lanes for the lift truck and mark
them clearlythem clearly, so they will be kept , so they will be kept free of obstruction.free of obstruction.
■■SET SPEED LIMITSSET SPEED LIMITS
(Example)(Example)
Yard SpeedYard Speed
LimitLimit
Set appropriate speed limits on your companySet appropriate speed limits on your company
grounds, and post signs that are clearly visible.grounds, and post signs that are clearly visible.
■■KEEP PEOPLE OUT OF THEKEEP PEOPLE OUT OF THE
OPERATING AREAOPERATING AREA
No PedestriansNo Pedestrians
Closed toClosed to
PedestriansPedestrians
No other personnel should be allowed in areasNo other personnel should be allowed in areas
where the lift truck is used.where the lift truck is used.
Where other people must be present, post a guardWhere other people must be present, post a guard
whose job is to make sure people stay clear ofwhose job is to make sure people stay clear of
moving vehicles.moving vehicles.
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS PLANNING AND WORKING AREAPLANNING AND WORKING AREA
1-61-6
■■KEEP UNAUTHORIZED VEHICLES OUTKEEP UNAUTHORIZED VEHICLES OUT
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Unauthorized vehicles must be kept out of theUnauthorized vehicles must be kept out of the
load handling areas. Post signs or give signals asload handling areas. Post signs or give signals as
required.required.
■■ASSIGN TRAFFIC GUARDS TOASSIGN TRAFFIC GUARDS TO
CONGESTED AREASCONGESTED AREAS
Post a trafc guard in conned or congested areasPost a trafc guard in conned or congested areas
where other people or vehicles may pass. Allwhere other people or vehicles may pass. All
personnel must obey the guide’s signals.personnel must obey the guide’s signals.
■■PROVIDE ADEQUATE LIGHTINGPROVIDE ADEQUATE LIGHTING
Safe operation requires well-lit traveling routes, soSafe operation requires well-lit traveling routes, so
pedestrians and obstacles can be easily seen. Usepedestrians and obstacles can be easily seen. Use
headlights, taillights, helmet lamps or other lights asheadlights, taillights, helmet lamps or other lights as
appropriate.appropriate.
■■KEEP THE GROUND LEVEL AND DRYKEEP THE GROUND LEVEL AND DRY
Be sure that all areas where the lift truck travels areBe sure that all areas where the lift truck travels are
level and regular. Clear away pools of oil or water.level and regular. Clear away pools of oil or water.
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS PLANNING AND WORKING AREAPLANNING AND WORKING AREA
1-71-7
■■SAFETY MEASURES FOR DANGERSAFETY MEASURES FOR DANGER
SPOTSSPOTS
Post warning signs or take other appropriatePost warning signs or take other appropriate
measures to ensure that lift truck operators keepmeasures to ensure that lift truck operators keep
away from danger spots as they travel.away from danger spots as they travel.
■■INSTALL CURBS OR RAILINGSINSTALL CURBS OR RAILINGS
If the truck is to be used on a loading dock, sea wallIf the truck is to be used on a loading dock, sea wall
or other raised surface, install curbs or railings toor other raised surface, install curbs or railings to
prevent the truck from falling off.prevent the truck from falling off.
■■DO NOT USE A LIFT TRUCK IN THEDO NOT USE A LIFT TRUCK IN THE
PRESENCE OF FLAMMABLE GASPRESENCE OF FLAMMABLE GAS
WARNINGWARNING
The FRSB14-25 reach trucks are not designedThe FRSB14-25 reach trucks are not designed
to prevent explosions. Do not use them in theto prevent explosions. Do not use them in the
presence of ammable gas.presence of ammable gas.
■■DO NOT RELY ON THE OVERHEADDO NOT RELY ON THE OVERHEAD
GUARDGUARD
The overhead guard is a protective device thatThe overhead guard is a protective device that
will moderate the impact of an object falling fromwill moderate the impact of an object falling from
overhead, but it cannot withstand every impact.overhead, but it cannot withstand every impact.
If a heavy object seems likely to fall on the truck,If a heavy object seems likely to fall on the truck,
make every effort to prevent it from make every effort to prevent it from doing so.doing so.
■■DO NOT USE LIFT TRUCKS INDO NOT USE LIFT TRUCKS IN
THE PRESENCE OF STRONGTHE PRESENCE OF STRONG
ELECTROMAGNETISMELECTROMAGNETISM
The electric and electronic control systems of theThe electric and electronic control systems of the
truck can be affected by a strong electromagnetictruck can be affected by a strong electromagnetic
field and may fail to operate normally, if thefield and may fail to operate normally, if the
truck is operated in the presence of strongtruck is operated in the presence of strong
electromagnetism. It is not advisable to use the liftelectromagnetism. It is not advisable to use the lift
truck in such an environment.truck in such an environment.
■■CAUTIONS REGARDING WATERCAUTIONS REGARDING WATER
••Avoid operating the lift Avoid operating the lift truck in the rain truck in the rain or leavingor leaving
it outdoors on rainy days.it outdoors on rainy days.
••When washing the lift When washing the lift truck take care truck take care to preventto prevent
water from splashing on the electrical parts.water from splashing on the electrical parts.
Cover the electrical parts with a vinyl tarp orCover the electrical parts with a vinyl tarp or
plastic bag if necessary. Getting the electricalplastic bag if necessary. Getting the electrical
parts wet might cause the electrical system toparts wet might cause the electrical system to
malfunction and make it difcult to control the liftmalfunction and make it difcult to control the lift
truck properly.truck properly.
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS PROPER AND IMPROPER USESPROPER AND IMPROPER USES
1-81-8
■■PROPER USES OF THE LIFT TRUCKPROPER USES OF THE LIFT TRUCK
The proper use of a lift truck is to carry a load thatThe proper use of a lift truck is to carry a load that
is placed on the pallet, and to stack the load onlyis placed on the pallet, and to stack the load only
within the prescribed stack height limit.within the prescribed stack height limit.
With the correct attachment, a lift truck may be usedWith the correct attachment, a lift truck may be used
to carry and stack loads that cannot be palletized.to carry and stack loads that cannot be palletized.
■■IMPROPER USESIMPROPER USES
Transporting a person, lifting a person, and towingTransporting a person, lifting a person, and towing
another vehicle are examples of improper use of aanother vehicle are examples of improper use of a
lift truck. The types of uses specied in this manuallift truck. The types of uses specied in this manual
as improper must never be requested or permitted,as improper must never be requested or permitted,
under any circumstances.under any circumstances.
(Examples of Improper Use)(Examples of Improper Use)
••Transporting or lifting a Transporting or lifting a person on the forks orperson on the forks or
pallet.pallet.
••Carrying a person on the Carrying a person on the pallet to control thepallet to control the
load.load.
••Attaching wire ropes to Attaching wire ropes to the forks to the forks to suspend asuspend a
load.load.
••TTowing owing another vehiclanother vehicle.e.
••Pushing a load Pushing a load or another vor another vehicle with ehicle with the forks.the forks.
••Using the forks Using the forks or truck body or truck body to open or to open or close theclose the
door of a freight vehicle.door of a freight vehicle.
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS TYPES OF LIFT TRUCKS AND LOADSTYPES OF LIFT TRUCKS AND LOADS
1-91-9
■■READ THE MANUAL AND DECALSREAD THE MANUAL AND DECALS
Read the Operation & Maintenance Manual andRead the Operation & Maintenance Manual and
caution plates on the truck, and become familiarcaution plates on the truck, and become familiar
with your truck and its specific operating andwith your truck and its specific operating and
servicing procedures. Remember that individual liftservicing procedures. Remember that individual lift
trucks may differ in design and construction, onetrucks may differ in design and construction, one
from another. Follow the instructions on the cautionfrom another. Follow the instructions on the caution
decals on the truck.decals on the truck.
Keep this Operation and Maintenance Manual onKeep this Operation and Maintenance Manual on
the truck as a ready reference for anyone who maythe truck as a ready reference for anyone who may
drive or service it.drive or service it.
■■KEEP DECALS LEGIBLEKEEP DECALS LEGIBLE
YOU MUST FOLLOW THESE RULES TO AVOIDYOU MUST FOLLOW THESE RULES TO AVOID
SEVERE INJURY OR DEATH TO YOURSELF ANDSEVERE INJURY OR DEATH TO YOURSELF AND
OTHERS.OTHERS.
••Operate truck only if trained and authorized by yourOperate truck only if trained and authorized by your
employer. Know Operation & Maintenance Manualemployer. Know Operation & Maintenance Manual
and all work rules.and all work rules.
••Safety check truck every day. Do not start if damagedSafety check truck every day. Do not start if damaged
or faulty; stop if problems start. Repair allowed onlyor faulty; stop if problems start. Repair allowed only
by trained, authorized mechanics.by trained, authorized mechanics.
•• Turn, start, stop, and handle loads smoothly and Turn, start, stop, and handle loads smoothly and
slowly. Carry loads low and tilted back; stack only onslowly. Carry loads low and tilted back; stack only on
level using minimum tilt.level using minimum tilt.
•• Look where you are going. Watch out for people, Look where you are going. Watch out for people,
hazards on oors and overhead, drop-offs and tallhazards on oors and overhead, drop-offs and tall
swing clearance.swing clearance.
••Truck overturn can kill you. Slow for turns even whenTruck overturn can kill you. Slow for turns even when
empty. Never turn on inclines.empty. Never turn on inclines.
•• Do not tilt overweight or loose loads. Move slowly Do not tilt overweight or loose loads. Move slowly
with wide, high, or long loads. Keep forks wide andwith wide, high, or long loads. Keep forks wide and
fully under loads. Travel in reverse if loads blockfully under loads. Travel in reverse if loads block
view. Attachments require special training, ask yourview. Attachments require special training, ask your
employer.employer.
•• Keep loads upgrade on all inclines. Stay clear of Keep loads upgrade on all inclines. Stay clear of
ramp and dock edges. Make sure dockboards andramp and dock edges. Make sure dockboards and
trailers are secure before going on them.trailers are secure before going on them.
••Overhead guard and load backrest must be on truck.Overhead guard and load backrest must be on truck.
Always keep yourself completeAlways keep yourself completely inside guard.ly inside guard.
••Stop engine when refueling. Follow Operation &Stop engine when refueling. Follow Operation &
Maintenance Manual and employer’s work rulesMaintenance Manual and employer’s work rules
about fuel, battery and tire about fuel, battery and tire maintenance hazards.maintenance hazards.
•• Forks can fall rapidly even with light loads. DoForks can fall rapidly even with light loads. Do
not raise people or allow them under forks. Nonot raise people or allow them under forks. No
passengers allowed on truck.passengers allowed on truck.
••Park only in authorized areas, never on inclines.Park only in authorized areas, never on inclines.
Lower forks to bottom, put direction control in neutral,Lower forks to bottom, put direction control in neutral,
turn off key and make sure parking brake is turn off key and make sure parking brake is set.set.
WARNINGWARNING
The decals on the truck describe safety precautionsThe decals on the truck describe safety precautions
and operating instructions. Replace any damagedand operating instructions. Replace any damaged
or missing decals. Check that the decals areor missing decals. Check that the decals are
present and legible during regular inspections.present and legible during regular inspections.
■■USE THE RIGHT TRUCK FOR THE USE THE RIGHT TRUCK FOR THE JOBJOB
Be sure the type and capacity of the lift truck isBe sure the type and capacity of the lift truck is
suitable for the work environment.suitable for the work environment.
CChheecck k PPooiinnttCChhooiiccee
CapacityCapacity
Load capacities range from 0.5 to 42 tons.Load capacities range from 0.5 to 42 tons.
Pay particular attention to the Pay particular attention to the load center.load center.
(UniCarriers Lift Truck Capacities: 0.5, 0.7,(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, 4,0.9, 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, 15,4.5, 5, 6, 7, 8, 10, 10.5, 11.5, 12, 13.5, 15,
18, 20, 22, 23, 24, 25, 30, 37, or 42 tons.)18, 20, 22, 23, 24, 25, 30, 37, or 42 tons.)
PowerPower
SourceSource
Gasoline (including LPG), natural gas,Gasoline (including LPG), natural gas,
diesel, and battery-powered modelsdiesel, and battery-powered models
are available. Fuel costs and exhaustare available. Fuel costs and exhaust
composition will vary.composition will vary.
CounterbalanceCounterbalance
O n c o u n t e r b a l a n c e d m o d e l s , t h eO n c o u n t e r b a l a n c e d m o d e l s , t h e
counterweight at the rear makes thecounterweight at the rear makes the
vehicle longer than an ordinary reachvehicle longer than an ordinary reach
truck. A reach truck performs loading andtruck. A reach truck performs loading and
unloading by extending the front part of theunloading by extending the front part of the
mast outward, which gives it the advantagemast outward, which gives it the advantage
of of compactnesscompactness..
TiresTires
For indoor use, there are models with solidFor indoor use, there are models with solid
tires (best for reach trucks) and cushiontires (best for reach trucks) and cushion
tires (engine type or battery type). Both aretires (engine type or battery type). Both are
compact. For outdoor use, pneumatic tirescompact. For outdoor use, pneumatic tires
work well.work well.
Solid cus hion tir es , wit h the sam eSolid cus hion tir es , wit h the sam e
dimensions as pneumatic tires, may bedimensions as pneumatic tires, may be
the best choice in cases where the loadthe best choice in cases where the load
materials or surface conditions couldmaterials or surface conditions could
puncture pneumatic tires.puncture pneumatic tires.
FlammableFlammable
MaterialsMaterials
For handling flammable materials suchFor handling flammable materials such
as petrochemicals, a combustion engineas petrochemicals, a combustion engine
is too dangerous. An electric vehicle withis too dangerous. An electric vehicle with
explosion-prevention or safety-reinforcedexplosion-prevention or safety-reinforced
construction is required. (A battery powerconstruction is required. (A battery power
source always offers better protectionsource always offers better protection
against re than a combustion engine.)against re than a combustion engine.)
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS TYPES OF LIFT TRUCKS AND LOADSTYPES OF LIFT TRUCKS AND LOADS
1-101-10
■■USE THE PROPER ATTACHMENTUSE THE PROPER ATTACHMENT
A few examples of attachments are shown below:A few examples of attachments are shown below:
PRPR
LGLG
SSSS
PR: PR: Paper roll Paper roll clamp (for clamp (for handling paper handling paper rollsrolls
or drums)or drums)
LG: LG: Load Load grab grab (for (for handling handling boxes boxes and and bags)bags)
SS: SS: Side shifter Side shifter (for (for vanning or vanning or devanning ordevanning or
handling loads in other narrow spaces)handling loads in other narrow spaces)
WARNINGWARNING
Avoid hoisting a load with wire rope hungAvoid hoisting a load with wire rope hung
from the forks or an attachment, and avoidfrom the forks or an attachment, and avoid
lifting a freight container with forks, becauselifting a freight container with forks, because
there is danger of there is danger of the truck's tipping over.the truck's tipping over.
If necessary, have a qualied operator use aIf necessary, have a qualied operator use a
hook or crane arm attachment.hook or crane arm attachment.
■■USE STURDY PALLETSUSE STURDY PALLETS
Pallets and skids must be strong enough toPallets and skids must be strong enough to
withstand the heavy weights of loading andwithstand the heavy weights of loading and
unloading. Remove or repair any damaged pallet.unloading. Remove or repair any damaged pallet.
■■STSTACK LOACK LOADS SECADS SECURELURELYY
When stacking loads on the pallet, place items soWhen stacking loads on the pallet, place items so
they are stable and will not fall over easily, and bethey are stable and will not fall over easily, and be
sure the weight is evenly distributed. Secure the topsure the weight is evenly distributed. Secure the top
layer with a cord wrapped around it or with somelayer with a cord wrapped around it or with some
other such method.other such method.
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS TYPES OF LIFT TRUCKS AND LOADSTYPES OF LIFT TRUCKS AND LOADS
1-111-11
■■KNOW THE WITHSTAND LOAD OFKNOW THE WITHSTAND LOAD OF
YOUR FLOORYOUR FLOOR
The lift truck is heavier than you might think. ForThe lift truck is heavier than you might think. For
example, a 1.5-ton truck weighs almost 2 tons,example, a 1.5-ton truck weighs almost 2 tons,
when empty. And then, when loaded, 80 to 90%when empty. And then, when loaded, 80 to 90%
of the total weight of the reach truck is usuallyof the total weight of the reach truck is usually
concentrated on the trailing wheels. Check theconcentrated on the trailing wheels. Check the
strength of your floors and roadways, and ifstrength of your floors and roadways, and if
necessary reinforce them.necessary reinforce them.
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FOR OPERATORS AND SUPERVISORS
FOR OPERATORS AND SUPERVISORS INSPECTIONINSPECTION
1-121-12
■■ALWALWAAYS IYS INSPECT NSPECT BEFOREBEFORE
OPERATINGOPERATING
The operator should always inspect the truck beforeThe operator should always inspect the truck before
each work shift to ensure that all essential safetyeach work shift to ensure that all essential safety
features are working. Any abnormality must befeatures are working. Any abnormality must be
reported to the supervisor, who is responsible forreported to the supervisor, who is responsible for
correcting it.correcting it.
■■PERIODIC INSPECTIONS AREPERIODIC INSPECTIONS ARE
MANDATORYMANDATORY
Monthly and annual inspections must be performedMonthly and annual inspections must be performed
thoroughly, and any abnormality promptly repaired.thoroughly, and any abnormality promptly repaired.
Only a certied expert who has the advanced skillsOnly a certied expert who has the advanced skills
and equipment is allowed to conduct inspections.and equipment is allowed to conduct inspections.
■■REPLACE SAFEREPLACE SAFETY PARTS REGULARLTY PARTS REGULARLYY
Names of the safety partsNames of the safety parts
RecommendedRecommended
replacement intervalreplacement interval
(year)(year)
Load handling systemLoad handling system
hydraulic hosehydraulic hose 1 – 21 – 2
LLiifft t cchhaaiinn2 2 – – 44
EElleeccttrroommaaggnneettiic c bbrraakkee9 9 – – 1100
Certain critical parts must be replaced at regularCertain critical parts must be replaced at regular
intervals. Since it is difcult to detect wear on theseintervals. Since it is difcult to detect wear on these
parts by visual inspection, they must be replacedparts by visual inspection, they must be replaced
at the specied intervals, because a failure wouldat the specied intervals, because a failure would
result in a falling load or runaway truck.result in a falling load or runaway truck.
■■NEVER USE AN UN-MAINTAINEDNEVER USE AN UN-MAINTAINED
TRUCKTRUCK
DO NOTDO NOT
OPERATEOPERATE
A A truck truck that that has has failefailed d an an inspeinspection ction must must not not bebe
operated. Hang a sign in the control area that saysoperated. Hang a sign in the control area that says
DO NOT OPERATE and remove the key, to makeDO NOT OPERATE and remove the key, to make
sure no one uses it. Then report the problem to thesure no one uses it. Then report the problem to the
supervisor and wait for repairs to be completed.supervisor and wait for repairs to be completed.
■■DESIGNATE A REPAIR AND DESIGNATE A REPAIR AND ASSEMBLYASSEMBLY
SUPERVISORSUPERVISOR
1. Preparation1. Preparation
2. Removal2. Removal
3. Disassembly3. Disassembly
4.4.
Repairs and the mounting and dismounting ofRepairs and the mounting and dismounting of
attachments must be performed under the directionattachments must be performed under the direction
of a designated supervisor. The body and majorof a designated supervisor. The body and major
parts of the lift truck are quite heavy and under veryparts of the lift truck are quite heavy and under very
high pressure. Repair or assembly work undertakenhigh pressure. Repair or assembly work undertaken
without careful and thorough preparation can leadwithout careful and thorough preparation can lead
to serious to serious injuryinjury..
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FOR OPERATORS AND SUPERVISORSFOR OPERATORS AND SUPERVISORS TRANSPORTING THE LIFT TRUCKTRANSPORTING THE LIFT TRUCK
1-131-13
■■NEVER RUN ON PUBLIC ROADSNEVER RUN ON PUBLIC ROADS
Use of the reach-type forklift truck should be limitedUse of the reach-type forklift truck should be limited
to special applications in warehousing and in-plantto special applications in warehousing and in-plant
assignments.assignments.
Never run the truck or work using the truck onNever run the truck or work using the truck on
public roads.public roads.
Being com pact, the truck cannot negotiateBeing compact, the truck cannot negotiate
irregularities or gradients. If you venture to do so,irregularities or gradients. If you venture to do so,
the truck might tip over. The truck may also impedethe truck might tip over. The truck may also impede
the passage of other vehicles and pedestrians,the passage of other vehicles and pedestrians,
since it runs since it runs slowly and turns sharply.slowly and turns sharply.
■■LOADING THE LIFT LOADING THE LIFT TRUCK ONTO ATRUCK ONTO A
TRUCK TRAILER (USE RAMPS)TRUCK TRAILER (USE RAMPS)
Work on a hard, level road surface when loadingWork on a hard, level road surface when loading
the lift truck onto or unloading it from a trailer:the lift truck onto or unloading it from a trailer:
••Be certain that the ramps are long Be certain that the ramps are long and wideand wide
enough, as well as strong enough.enough, as well as strong enough.
••Do not load or Do not load or unlounload the lift truck when it isad the lift truck when it is
raining, unless the ramps have araining, unless the ramps have anti-slip surfaces.nti-slip surfaces.
••Jack up the Jack up the trailer secureltrailer securely to y to prevenprevent it t it fromfrom
upending during loading or unloading.upending during loading or unloading.
■■LOADING THE LIFT TRUCK LOADING THE LIFT TRUCK ONTO AONTO A
TRUCK TRAILER (USE A CRANE)TRUCK TRAILER (USE A CRANE)
Load or unload the lift truck on a hard, flat roadLoad or unload the lift truck on a hard, flat road
surface, and follow these precautions:surface, and follow these precautions:
••Use a crane Use a crane to hoist the lito hoist the lift truck to lft truck to load or unloadoad or unload
it from the it from the truck trailer.truck trailer.
••When hoisting the lift truck, When hoisting the lift truck, attach wire ropes toattach wire ropes to
the lifting hooks at the top of the mast.the lifting hooks at the top of the mast.
••Do not attach Do not attach a wire ra wire rope to the overhead ope to the overhead guardguard
to hoist the lift truck. The lift truck could fall over.to hoist the lift truck. The lift truck could fall over.
••Use strong enough wire Use strong enough wire rope to support therope to support the
entire weight of the lift truck. Do not use kinked,entire weight of the lift truck. Do not use kinked,
deformed or frayed wire rope.deformed or frayed wire rope.
••Never stand Never stand or walk or walk under a hoisted under a hoisted lift truck.lift truck.
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FOR OPERATORS AND SUPERVISORSFOR OPERATORS AND SUPERVISORS MODIFICATIONSMODIFICATIONS
1-141-14
■■NEVER OPERATE WITHOUT LIGHTS,NEVER OPERATE WITHOUT LIGHTS,
THE OVERHEAD GUARD, OR THETHE OVERHEAD GUARD, OR THE
LOAD BACKRESTLOAD BACKREST
The lift truck must not be used if the work lights,The lift truck must not be used if the work lights,
overhead guard, load backrest, or horn have beenoverhead guard, load backrest, or horn have been
removed. Any parts that have been temporarilyremoved. Any parts that have been temporarily
removed for some reason must be reattachedremoved for some reason must be reattached
immediately.immediately.
■■DO NOT MAKE MODIFICATIONSDO NOT MAKE MODIFICATIONS
WITHOUT PRIOR APPROVALWITHOUT PRIOR APPROVAL
Modifications or additions that affect the capacity,Modifications or additions that affect the capacity,
construction or strength of the lift truck must not beconstruction or strength of the lift truck must not be
performed by the user without the manufacturer’sperformed by the user without the manufacturer’s
or his authorized representative’s prior writtenor his authorized representative’s prior written
permission.permission.
For example, don’t add a counterweight.For example, don’t add a counterweight.
■■IMPLEMENTATION OF MODIFICATIONSIMPLEMENTATION OF MODIFICATIONS
Only in the event that the truck manufacturer is noOnly in the event that the truck manufacturer is no
longer in business and there is no successor in thelonger in business and there is no successor in the
interest to the business, the user may arrange forinterest to the business, the user may arrange for
a modication or alteration to a powered industriala modication or alteration to a powered industrial
truck, provided, however, that the user shall:truck, provided, however, that the user shall:
a) arrange for the modification or alteration toa) arrange for the modification or alteration to
be designed, tested and implemented by anbe designed, tested and implemented by an
engineer(s) expert in industrial trucks and theirengineer(s) expert in industrial trucks and their
safety;safety;
b) maintain a permanent record of the design,b) maintain a permanent record of the design,
test(s) and implementation of the modication ortest(s) and implementation of the modication or
alteration;alteration;
c) approve and make appropriate changes to thec) approve and make appropriate changes to the
capacity plate(s), decals, tags and instructioncapacity plate(s), decals, tags and instruction
handbook;handbook;
d) affix a permanent and readily visible label tod) affix a permanent and readily visible label to
the truck stating the manner in which the truckthe truck stating the manner in which the truck
has been modified or altered together with thehas been modified or altered together with the
date of the modification or alteration, and thedate of the modification or alteration, and the
name and address of the organization thatname and address of the organization that
accomplished the tasks.accomplished the tasks.
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HOW THE LIFT TRUCK WORKS?HOW THE LIFT TRUCK WORKS?
1-151-15
■■HOW TRUCK BALANCE IS MAINTAINEDHOW TRUCK BALANCE IS MAINTAINED
Truck’s center of gravityTruck’s center of gravity
TrailingTrailing
wheelwheel
Load’s center of gravityLoad’s center of gravity FulcrumFulcrum
Reach trucks have load handling equipment,Reach trucks have load handling equipment,
including a mast assembly, which travels back andincluding a mast assembly, which travels back and
forth along the outriggers. The trailing wheels of theforth along the outriggers. The trailing wheels of the
truck work as a fulcrum to achieve balance betweentruck work as a fulcrum to achieve balance between
the truck's center of gravity and the load's center ofthe truck's center of gravity and the load's center of
gravity. The relationship between the locations ofgravity. The relationship between the locations of
those two centers of gravity is vitally important forthose two centers of gravity is vitally important for
safety. The stability of the reach truck is maintainedsafety. The stability of the reach truck is maintained
best when the mast assembly is best when the mast assembly is fully retracted.fully retracted.
■■KNOW THE CENTER OF GRAVITY OFKNOW THE CENTER OF GRAVITY OF
YOUR LOADYOUR LOAD
Load center (from fork root) mmLoad center (from fork root) mm
Load’s centerLoad’s center
of gravityof gravity
DistanceDistance
AA
ll
ll
oo
ww
aa
bb
ll
ee
ll
oo
aadd
((
kk
gg
))
Weight x distance =Weight x distance =
moment (constant)moment (constant)
Basic load centerBasic load center
Materials of various shapes such as boxes or at orMaterials of various shapes such as boxes or at or
cylindrical items may be loaded on the lift truck. Incylindrical items may be loaded on the lift truck. In
order to accurately judge the stability of the truck,order to accurately judge the stability of the truck,
it is vitally important for the operator to know theit is vitally important for the operator to know the
location of the center of gravity for each type of load.location of the center of gravity for each type of load.
■■HOW THE CENTER OF GRAVITY SHIFTSHOW THE CENTER OF GRAVITY SHIFTS
The stability of the lift truck is determined by theThe stability of the lift truck is determined by the
combined center of gravity, which is the product ofcombined center of gravity, which is the product of
the centers of gravity of the truck and the load.the centers of gravity of the truck and the load.
When the truck is empty, this point is the same asWhen the truck is empty, this point is the same as
the center of gravity for the truck, and when it isthe center of gravity for the truck, and when it is
loaded it shifts according to the center of gravityloaded it shifts according to the center of gravity
of the load. Since the center of gravity of the loadof the load. Since the center of gravity of the load
changes whenever the mast assembly is advancedchanges whenever the mast assembly is advanced
or retracted along the outriggers or the forks areor retracted along the outriggers or the forks are
raised or lowered, the combined center of gravityraised or lowered, the combined center of gravity
also changes. The center of gravity is also governedalso changes. The center of gravity is also governed
by the following factors:by the following factors:
••Size, weight Size, weight and shape and shape of the of the loadload
••Acceleration, deceleration Acceleration, deceleration and turning and turning radiusradius
••Loading Loading or or unloading unloading heightheight
••Surface condition Surface condition and gradient and gradient of the of the roadroad
••Tilt Tilt angle of angle of the forksthe forks
••Type Type of of attachment usedattachment used
••Tire Tire materialmaterial
Rear view of the truck with loadRear view of the truck with load
The higherThe higher
the load, thethe load, the
higher thehigher the
combinedcombined
center ofcenter of
gravitygravity
CombinedCombined
center of gravitycenter of gravity
with truck tiltedwith truck tilted
Center of loadCenter of load
CombinedCombined
center ofcenter of
gravitygravity
Truck’s centerTruck’s center
of gravityof gravity
Center of loadCenter of load
Combined centerCombined center
of gravityof gravity
Center of the truckCenter of the truck
■■THE TRUCK TIPS WHEN THE CENTERTHE TRUCK TIPS WHEN THE CENTER
OF GRAVITY IS OUTSIDE THEOF GRAVITY IS OUTSIDE THE
STABILITY TRIANGLESTABILITY TRIANGLE
For a reach truck to remain stable, the combinedFor a reach truck to remain stable, the combined
center of gravity must be inside the triangle formedcenter of gravity must be inside the triangle formed
by the ground contact points of the left and rightby the ground contact points of the left and right
trailing wheels and the ground contact point of thetrailing wheels and the ground contact point of the
drive wheel. This is called the stability triangle.drive wheel. This is called the stability triangle.
If the combined center of gravity moves back furtherIf the combined center of gravity moves back further
than the trailing wheels, the truck will tip overthan the trailing wheels, the truck will tip over
backward with the trailing wheels as the fulcrum. Ifbackward with the trailing wheels as the fulcrum. If
the combined center of gravity moves outside thethe combined center of gravity moves outside the
stability triangle to the left or the right, the truck willstability triangle to the left or the right, the truck will
fall over to that side.fall over to that side.
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HOW THE LIFT TRUCK WORKS?HOW THE LIFT TRUCK WORKS?
1-161-16
The load center is determined by the distance fromThe load center is determined by the distance from
the face of the forks (or the front face of the loadthe face of the forks (or the front face of the load
backrest) to the center of gravity of the load. Thebackrest) to the center of gravity of the load. The
maximum load is the maximum weight allowablemaximum load is the maximum weight allowable
with that nominal load center.with that nominal load center.
The Load Chart, showing the relationship betweenThe Load Chart, showing the relationship between
the load center and the maximum permissible load,the load center and the maximum permissible load,
is attached to is attached to the truck as the truck as a decal. a decal. When the loadWhen the load
center moves closer toward the tips of the forks, thecenter moves closer toward the tips of the forks, the
combined center of gravity also moves further to thecombined center of gravity also moves further to the
rear, which reduces the rear, which reduces the truck’s lifting capacity.truck’s lifting capacity.
■■ACCELERATING, DECELERATING ANDACCELERATING, DECELERATING AND
TURNINGTURNING
Inertia refers to the principle that a stationary objectInertia refers to the principle that a stationary object
remains stationary as long as there is no externalremains stationary as long as there is no external
force acting to move it, and that a moving objectforce acting to move it, and that a moving object
continues moving at a constant speed as long ascontinues moving at a constant speed as long as
there is no external force acting to stop it.there is no external force acting to stop it.
When the lift truck starts to move there is aWhen the lift truck starts to move there is a
momentary backward force (resistance to moving)momentary backward force (resistance to moving)
due to inertia, and when it stops there is adue to inertia, and when it stops there is a
momentary forward force (resistance to stopping).momentary forward force (resistance to stopping).
As a result, if As a result, if the brakes are applied the brakes are applied suddenly whilesuddenly while
the truck is traveling in reverse, the backward forcethe truck is traveling in reverse, the backward force
will become strong enough to tip the truck overwill become strong enough to tip the truck over
backward. Likewise, when the truck is turning therebackward. Likewise, when the truck is turning there
is a centrifugal force that pulls it outward from theis a centrifugal force that pulls it outward from the
turning center. This force can cause the truck to tipturning center. This force can cause the truck to tip
over sideways. Since the zone of sideways stabilityover sideways. Since the zone of sideways stability
is especially narrow, it is necessary to slow down ais especially narrow, it is necessary to slow down a
lot when turning, in order to prevent the truck fromlot when turning, in order to prevent the truck from
tipping.tipping.
When the load is elevated the combined centerWhen the load is elevated the combined center
of gravity is raised, increasing the danger that theof gravity is raised, increasing the danger that the
truck will tip over backward or sideways.truck will tip over backward or sideways.
■■MAXIMUM LOAD (LOAD WEIGHT AND MAXIMUM LOAD (LOAD WEIGHT AND LOAD CENTER)LOAD CENTER)
50005000
66000 0 880000 1000 1000
ＦＲＳＢ１６－８ＦＲＳＢ１６－８
16001600
12701270
10501050
(1,600kg)(1,600kg)
600mm600mm
(1,050kg)(1,050kg)
1,000mm1,000mm
mmmm
mmmm
kgkg
When the load is raised higher, or the load’s center of
When the load is raised higher, or the load’s center of
gravity is moved further backward (toward the trailinggravity is moved further backward (toward the trailing
wheels), the allowable load iwheels), the allowable load is reduced accordingly.s reduced accordingly.
HOW TO READ THE LOAD CHARTHOW TO READ THE LOAD CHART
PointPoint AA PointPoint BB
LOAD CENTERLOAD CENTER
ACTUAL ACTUAL CAPCAPACITYACITY
MAX. FORK HEIGHTMAX. FORK HEIGHT
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