Electric Forklift Truck: Operation & Maintenance Manual Maintenance Manual

No.
OB-7A0EE
OPERATION &
OPER. & MAINT. MANUAL

MAINTENANCE MANUAL
ELECTRIC FORKLIFT TRUCK

Reach Type
FRB10-8C - FRHB30-8
• 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.
No. OB-7A0EE
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.
This manual was compiled based on the standard models. For trucks other than the standard
models, only the differences are explained.
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.
IMPORTANT
The specifications and attachments of the trucks vary with different destinations.
The following symbols are used to indicate their destinations in this manual.
Code Destination
EXB All regions excluding North America and EU member countries and China
EXC Oceania
EXE EU member countries
EXP China
CONTENTS
1. SAFETY TRUCK-MOUNTED BATTERY CHARGER..........3-9

FOR SUPERVISORS...........................................1-1 CYCLE CHARGING (NORMAL CHARGE).....3-9
QUALIFIED OPERATOR.................................1-2 EQUALIZING CHARGE................................3-11
PLANNING AND WORKING AREA.................1-3 AUXILIARY CHARGE....................................3-12
PROPER AND IMPROPER USES .................1-6 CHARGING BEFORE LONG-TERM
TYPES OF VEHICLES AND LOADS..............1-7 STORAGE.....................................................3-12
INSPECTION . ..............................................1-10 POWER SUPPLY EQUIPMENT FOR
TRANSPORTING THE LIFT TRUCK ...........1-11 BATTERY CHARGER...................................3-13
HOW THE LIFT TRUCK WORKS?....................1-12 BATTERY ELECTROLYTE CARE......................3-14
TRAVELING ......................................................1-14 BATTERY ELECTROLYTE LEVEL................3-14
LOAD HANDLING..............................................1-19 STATIONARY BATTERY CHARGER.................3-17
PARKING ..........................................................1-23 PICTORIAL NOMENCLATURE.....................3-17
INSPECTION AND SERVICE ...........................1-24 CHARGER CONTROL PANEL......................3-17
PREVENTING VEHICLE FIRES........................1-29 USING STATIONARY BATTERY
CAUTION PLATES.............................................1-31 CHARGER.....................................................3-18
INSPECTION AND TROUBLESHOOTING
GUIDE...........................................................3-20
2. OPERATING CONTROLS
POWER SUPPLY EQUIPMENT FOR
PICTORIAL NOMENCLATURE . .........................2-1
BATTERY CHARGER...................................3-22
INSTRUMENTS AND CONTROLS .....................2-5
PICK-UP.............................................................3-23
METER PANEL . .............................................2-5
PICK-UP AND STACKING.............................3-23
SWITCHES....................................................2-13
UNSTACKING...............................................3-24
LEVERS AND PEDALS . ..............................2-15
STORING...........................................................3-25
TRUCK BODY...............................................2-19
BEFORE STORING; DAILY STORAGE........3-25
INTERLOCK SYSTEM..................................2-21
LONG-TERM STORAGE; OPERATING
OPTIONAL EQUIPMENT..............................2-24
AFTER LONG-TERM STORAGE..................3-25
3. OPERATION
4. MAINTENANCE
PROPER OPERATION........................................3-1
PREOPERATIONAL CHECKS ............................4-1
DURING BREAK-IN AND RELATIONSHIP
CAUTION IN CHECKING................................4-1
BETWEEN LOAD AND STABILITY OF
PERIODIC INSPECTION.....................................4-8
TRUCK............................................................3-1
PERIODICAL REPLACEMENT OF
BASIC LOAD CENTER AND RATED
SAFETY PARTS .............................................4-9
LOAD...............................................................3-2
WEEKLY (50 OPERATING HOURS)
THE STABILITY OF LIFT TRUCK...................3-2
CHECKS . .....................................................4-10
TRANSPORTING LIFT TRUCK......................3-3
MONTHLY (200 OPERATING HOURS)
OPERATING LIFT TRUCK..............................3-3
CHECKS . .....................................................4-11
REMOVING AND REINSTALLING THE
GREASING . .................................................4-12
BATTERY........................................................3-5
3 MONTHS (600 OPERATING HOURS)
CHARGING THE BATTERY.................................3-8
CHECKS........................................................4-13
CONTENTS

CHECKS........................................................4-13
ANNUAL (2400 OPERATING HOURS)
CHECKS........................................................4-13
PERIODICAL CHECK SCHEDULE...............4-14
5. SPECIFICATIONS & SERVICE DATA

SPECIFICATIONS . .............................................5-1
LOAD CHART......................................................5-7
SERVICE DATA..................................................5-10
REFILL CAPACITY........................................5-10
TRUCK SERIAL NUMBER AND SERIAL
NUMBERS OF MAJOR COMPONENTS......5-12
UniCarriers’ GENUINE PARTS......................5-12
FOR YOUR RECORDS.................................5-13
6. INDEX
INDEX..................................................................6-1
1. SAFETY
CONTENTS
FOR SUPERVISORS........................................... 1-1

QUALIFIED OPERATOR . .............................. 1-2
PLANNING AND WORKING AREA................. 1-3
PROPER AND IMPROPER USES ................. 1-6
TYPES OF VEHICLES AND LOADS ............. 1-7
INSPECTION................................................. 1-10
TRANSPORTING THE LIFT TRUCK............ 1-11
HOW THE LIFT TRUCK WORKS? ................... 1-12
TRAVELING....................................................... 1-14
LOAD HANDLING.............................................. 1-19
PARKING............................................................ 1-23
INSPECTION AND SERVICE............................ 1-24
PREVENTING VEHICLE FIRES........................ 1-29
CAUTION PLATES............................................. 1-31
FOR SUPERVISORS
The following symbols, found throughout this FOR SUPERVISORS

manual, alert you to potentially hazardous Lift truck accidents cause dozens or hundreds of
conditions to the owner and the operator. deaths every year, and even greater numbers of
personal injuries.
Become completely familiar with the truck before
proceeding with operating, checking and servicing. UniCarriers has steadily improved the design and
fabrication of our lift trucks so they may be used
This manual and decals affixed to the truck use the more safely and efficiently, but many accidents still
following safety alert indications. occur due to improper use. Accidents are often
SIGNAL WORD CLASSIFICATION the result of more than just “bad driving”. The use
Failure to follow the instructions of inappropriate types of equipment, the selection
DANGER in the message will likely cause a of inappropriate attachments or accessories,
serious accident or death.
inappropriate operating environments, careless
Failure to follow the instructions in
WARNING the message might cause a serious designation of operators, and failure to properly
accident or death. train the operator are other common causes of
Failure to follow the instructions in accidents.
the message may cause personal
CAUTION injury or damage to the truck or
other property. It is not possible to describe all potentially
The information will help to prolong hazardous situations which may occur while
the service life of the truck. The
NOTE message is not directly related to operating, inspecting or servicing a forklift truck.
accident prevention. The warnings and cautions in this manual,
including the decals attached to the forklift, are not
intended to cover all possible working hazards.
Forward
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 1-1 through 1-11 contain instructions

Left Right
which should be enforced by the personnel
supervising the operation of the lift truck. Please
make sure the operators also read these pages.
• Page 1-12 and the following pages contain
specific precautions directly related to the
operation of the lift truck.
Backward
The diagram above indicates the meanings of the

terms “forward”, “backward”, “right” and “left” used
in this manual.
1-1
FOR SUPERVISORS QUALIFIED OPERATOR
■ TRAIN OPERATOR TO STACK SAFELY ■ WEAR PROTECTIVE GEAR
Unstacking Stacking Hard Hat
Safety
goggles
Work
Clothes
“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 Safety
Shoes
is not done properly, the loads may slip or fall,
endangering the operator as well as fellow workers
in the area. • Always wear proper work clothes for driving.
Safety classes should be held to train all operators Work clothes should be designed to prevent any
in the proper method of stacking and unstacking part from accidentally catching on knobs or other
loads. parts of the truck or equipment. For example,
(Your UniCarriers dealer can provide information shirts and trousers should have tight cuffs.
about safety stacking training.) • Always wear a hard hat and safety shoes.
• Wear other protective gear as appropriate to
■ TIRED OR UNWELL? SEND THEM the conditions of the work site, i.e., goggles or
HOME! gloves.
■ PROVIDE AND MAINTAIN

EMERGENCY EQUIPMENT
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. 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.
1-2
FOR SUPERVISORS PLANNING AND WORKING AREA
■ KNOW WHO TO CALL IN AN ■ MARK THE TRAVEL LANES

EMERGENCY
Contacts in emergency
.....................................
....................................
............................
............................
Designate the travel lanes for the lift truck and mark
Keep information on hand to allow immediate them clearly, so they will be kept free of obstruction.
calls for help in case of a fire, accident or other
emergency. ■ SET SPEED LIMITS
■ MAKE AN OPERATING PLAN AND (Example)

DISCUSS IT
Yard Speed
Limit
Set appropriate speed limits on your company

grounds, and post signs that are clearly visible.
Before using the lift truck, plan out the travel routes
and operating procedures, and thoroughly discuss ■ KEEP PEOPLE OUT OF THE
the details with all personnel involved. 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.
1-3
■ KEEP UNAUTHORIZED VEHICLES ■ PROVIDE ADEQUATE LIGHTING

OUT
unauthorized
No entry of
vehicles
Safe operation requires well-lit traveling routes,

Unauthorized vehicles must be kept out of the so pedestrians and obstacles can be easily seen.
load handling areas. Post signs or give signals as Use headlights, taillights, helmet lamps or other
required. lights as appropriate.
■ ASSIGN TRAFFIC GUIDES TO ■ KEEP THE GROUND LEVEL AND DRY

CONGESTED AREAS
Be sure that all areas where the lift truck travels

Post a traffic guide in confined or congested areas are level and regular. Clear away pools of oil or
where other people or vehicles may pass. All water.
personnel must obey the guide’s signals.
1-4
■ SAFETY MEASURES FOR DANGER ■ DO NOT RELY ON THE OVERHEAD

SPOTS GUARD
Post warning signs or take other appropriate The overhead guard is a protective device that
measures to ensure that lift truck operators keep will moderate the impact of an object falling from
away from danger spots as they travel. overhead, but it cannot withstand every impact.
If a heavy object seems likely to fall on the truck,
■ INSTALL CURBS OR RAILINGS make every effort to prevent it from doing so.
If the truck is to be used on a loading dock,

shore wall or other raised surface, install curbs or
railings.
1-5
FOR SUPERVISORS PROPER AND IMPROPER USES
■ PROPER USE OF THE LIFT TRUCK ■ IMPROPER USE
The proper use of a lift truck is to transport a load Transporting a person, elevating a person, and
which is placed on the pallet and stacked within towing another vehicle are examples of the
the prescribed height limit. improper use of a lift truck. Uses which this
With a proper attachment, a lift truck may be used manual specifies as improper must never be
to transport a load which is stacked elsewhere requested or permitted, under any circumstances.
than on the pallet. (Examples of Improper Use)
• Transporting or elevating a person on the forks
or pallet.
• Carrying a person on the pallet to control the
load.
• Touching a cable with the forks to suspend 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.
1-6
FOR SUPERVISORS TYPES OF VEHICLES AND LOADS
■ READ MANUAL AND DECALS ■ NO OPERATION WITHOUT LIGHTS,

OVERHEAD GUARD, OR BACKREST
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. The lift truck cannot be used if the headlights,
Keep this Operation and Maintenance manual on taillights, overhead guard, backrest, horn or turn
the truck as a ready reference for anyone who may signals have been removed. Any parts that have
drive or service it. been temporarily removed for some reason must
be reattached immediately.
■ KEEP DECALS LEGIBLE
■ OBTAIN APPROVAL FOR ANY
WARNING MODIFICATION
Modifications or additions that affect the capacity,
YOU MUST FOLLOW THESE RULES TO AVOID SEVERE
INJURY OR DEATH TO YOURSELF AND OTHERS.
• Operate truck only if trained and authorized by your
construction or strength of the truck must not be

employer. Know Operation & Maintenance Manual and
all work rules.
• Safety check truck every day. Do not start if damaged
or faulty; stop if problems start. Repair allowed only by
trained, authorized mechanics.
• Turn, start, stop, and handle loads smoothly and slowly. performed by the user without the manufacturer’s
Carry loads low and tilted back; stack only on level using
minimum tilt.
• Look where you are going. Watch out for people,
hazards on floors and overhead, drop-offs and tall swing
prior permission. For example, don’t add a
counterweight.
clearance.
• Truck overturn can kill you. Slow for turns even when
empty. Never turn on inclines. Use seat bolt and stay in
truck if it tips.
• Do not tilt overweight or loose loads. Move slowly
with wide, high, or long loads. Keep forks wide and
fully under loads. Travel in reverse if loads block view.
Attachments require special training, ask your employer.
• Keep loads upgrade on all inclines. Stay clear of ramp
and dock edges. Make sure dockboards and trailers are
secure before going on them.
• Overhead guard and load backrest must be on truck.
Always keep yourself completely inside guard.
• Stop engine when refueling. Follow Operation &
Maintenance Manual and employer’s work rules about
fuel, battery and tire maintenance hazards.
• Forks can fall rapidly even with light loads. Do not
raise people or allow them under forks. No passengers
allowed on truck.
• Park only in authorized areas, never on inclines. Lower
forks to bottom, put direction control in neutral, turn off
key and make sure parking brake is set.
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.
1-7
■ USE THE RIGHT TRUCK FOR THE JOB ■ USE PROPER ATTACHMENT
Be sure the type and capacity of the lift truck is A few examples of attachment will be shown
suitable for the work environment. below:
Check Point Choice
Load capacities range from 0.5 to 42 tons. Pay
PR SS
particular attention to the load center.
(UniCarriers Lift Truck Capacities: 0.5, 0.7, 0.9, 1,
Capacity 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.)
Gasoline, natural gas, diesel, and battery-
Power Source powered models are available. Fuel costs and
exhaust composition will vary.
On counterbalanced models, the counterweight
at the rear makes the vehicle longer than a
reach truck. A reach truck performs loading and
Balance unloading by extending the front part of the
mast outward, which gives it the advantage of
compactness. LG
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.
Tires 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.
For handling flammable materials such as

PR: Paper roll clamp (for handling paper rolls or
petrochemicals, a combustion engine is too drums)
dangerous. An electric vehicle with explosion-
Flammable SS: Side shifter (for vanning or devanning or
proof or safety-reinforced construction is
Materials required. (A battery power source always offers
better protection against fire than a combustion handling loads in other narrow spaces)
engine.) LG: Load grab (for handling boxes and bags)
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 qualified operator use a
hook or crane arm attachment.
1-8
■ USE STURDY PALLET MATERIALS ■ KNOW THE WITHSTAND LOAD OF

YOUR FLOOR
Pallets and skids must be strong enough to

withstand the heavy weights of loading and
unloading. Remove or repair any damaged pallet.
The lift truck is heavier than it appears. For
■ STACK LOADS SECURELY example, a 1.5-ton truck weighs almost 2 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.
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.
1-9
FOR SUPERVISORS INSPECTION
■ ALWAYS INSPECT BEFORE ■ NEVER USE AN UN-MAINTAINED

OPERATING TRUCK
Out of service
The operator should always inspect the truck A truck that has not passed an inspection must
before each use to verify that all essential safety never be operated. Hang a sign on the truck and
features are working. Any abnormality is to be remove the ignition switch, to make sure no one
reported to the supervisor, who is responsible for uses it. Then report the problem to the supervisor
correcting it. and wait for the repair to be completed.
■ PERIODIC INSPECTIONS ARE ■ DESIGNATE A REPAIR AND

MANDATORY ASSEMBLY SUPERVISOR
Monthly and annual inspections must be performed
thoroughly, and any abnormality promptly repaired. 1. Preparation
Only a certified expert who has the advanced skills 2. Removal
and equipment is allowed to conduct inspections. 3. Disassembly
4.
Preserve the inspection logs for at least three
years.
■ REPLACE SAFETY PARTS REGULARLY
Recommended
Name of safety parts replacement interval
(year)
Repairs and the mounting and dismounting
Load handling means
1–2 of attachments must be performed under the
hydraulic hose
direction of a designated supervisor. The body and
Lift chain 2–4 major parts of the lift truck are quite heavy and
Steering unit chain 2–4 under very high pressure. Repair or assembly
work undertaken without careful and thorough
Certain critical parts must be replaced at regular preparation can lead to serious injury.
intervals. Since it is difficult to detect wear on
the above parts by visual inspection, they must
be replaced at the intervals specified, because
a failure would result in a falling load or runaway
truck.
1-10
FOR SUPERVISORS TRANSPORTING THE LIFT TRUCK
■ TRANSPORTING THE LIFT TRUCK ■ NEVER RUN ON PUBLIC ROADS

Use of the reach-type forklift truck should be
limited to special applications in warehousing and
in-plant assignments.
Being compact, the truck cannot negotiate
irregularities or gradients. If you venture to do so,
the truck might tip over.
The truck may also impede the passage of other
vehicles and pedestrians, since it runs slowly and
turns suddenly.
Never run the truck or work using the truck on
public roads.
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
sufficient length and width as well as strength.
Do not load or unload the truck when it is raining,
unless the ramps are fitted 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.
1-11
HOW THE LIFT TRUCK WORKS?
■ KEEPING THE TRUCK BALANCED 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

• Acceleration, deceleration and turning
Front wheel Rear wheel
• Unloading height
• Surface condition and gradient of the road
Load Fulcrum Rear wheel load
• Tilt angle of the fork
Lift trucks are equipped with load handling means • Type of attachment
including a mast and forks at its front part. The • Tire material
front wheels of the truck work as a fulcrum to Center of load
balance the center of gravity of the truck and the

center of gravity of the load. The relationship Composite center
of gravity
between the locations of those two centers of The higher
gravity is vitally important for safety. the load, the
higher the
truck’s center
of gravity
■ KNOW THE CENTER OF GRAVITY OF

YOUR LOAD Truck’s center
of gravity with
truck tilted
Lift truck viewed from front

Truck’s center of gravity
Load’s center Composite
gravity center of gravity
Center of load Center of the truck
Distance
Weight x distance
Allowable load (kg)
= moment (constant)
Basic load center
Load center (from fork root) mm
■ OUTSIDE THE TRIANGLE OF

Materials of various shapes such as boxes or flat BALANCE, THE TRUCK TIPS
or cylindrical items may be loaded on the lift truck. For a lift truck to remain stable, the overall center
In order to accurately judge the stability of the of gravity must be inside the triangle formed by the
truck, it is vitally important for the operator to know contact points of the left and right front tires and
the location of the center of gravity for each type of the center point between the steering wheels. The
load. triangle defines the area of stability for the center
of gravity.
■ HOW THE CENTER OF GRAVITY If the overall center of gravity moves further
SHIFTS forward than the front wheels, the truck will tip
The stability of the lift truck is determined by the forward with the front wheels as the fulcrum. If the
overall center of gravity, which is the product of overall center of gravity moves outside the triangle
the centers of gravity of the truck and the load. to the right or the left, the truck will fall over in that
When the truck is empty, this point is the same as direction.
the center of gravity for the truck, and when it is
loaded it shifts according to the center of gravity
1-12
HOW THE LIFT TRUCK WORKS?
■ RATED LOAD (LOAD WEIGHT AND LOAD CENTER)
HOW TO READ THE LOAD CHART

The higher the load is raised, and the further forward
Point from the front wheels the load is moved, the more the Point
weight of the load increases.
(Slightly heavier loads can be carried with dual tires)
Point Point
The load center is the distance from the front face ■ ACCELERATING, DECELERATING
of the forks to the center of gravity of the load. AND TURNING
The rated load is the maximum weight allowable The principle of inertia provides that a stationary
with the nominal load center. object will remain stationary as long as there is
The Load Chart, showing the relationship between no external force acting on it, and that a moving
the load center and the rated load, is attached to object will continue moving at a constant speed as
the truck as a decal. The rated load decreases as long as there is no external force acting on it.
the load center moves toward the tip of the forks, Due to inertia, when the lift truck starts to move
and as the overall center of gravity moves forward. there is a momentary backward force, and when
it stops there is a momentary forward force. As
a result, if the brakes are applied suddenly, there
is a very strong hazard that the forward force will
become strong enough for the truck to tip forward.
Likewise, when the truck is turning there is a
centrifugal force that pulls it outward from the
turning center. This force can cause the truck to
fall sideways. Since the zone of lateral stability
is especially narrow, it is necessary to slow down
substantially when turning in order to prevent the
truck from tipping.
When the load is elevated the overall center of
gravity is raised, increasing the danger of the truck
tipping over to the front or side.
1-13
TRAVELING
Do not operate the lift truck until Do not move controls from outside the
preoperational checks are finished operator’s compartment
If any defect is found during checking, report it to
the supervisor and have it repaired.
Do not operate the truck until the malfunction or
damage is properly repaired.
Mount properly
• Do not operate the controls (levers and pedals)

from outside the operator’s compartment.
• Place your body always under the overhead
guard.
• Keep your arms, legs, and hands within the
operator’s compartment. Use special caution to
keep your heels inside the rear of the operator’s
Never mount or dismount a moving truck. When
compartment.
mounting or dismounting the truck, make sure the
truck is at a complete stop and use assist grips
Sound horn when starting
properly.
When starting
WARNING
Operate the reach lever peroperly:
• Never operate the reach lever with your
body between the mast and the frame.
Otherwise, you might get injured seriously
or be killed.
• S t a n d i n p o s i t i o n i n t h e o p e r a t o r ’s
compartment whenever you operate the
reach mechanism (advance or retract it). Before starting, make sure no one is near the
truck. Let other workmen and bystanders know
Before starting your lift truck (before turning the you are starting up by sounding horn.
key switch on), follow the procedure given below:
• Make sure the accelerator lever (forward/reverse Keep your hands clean
lever) is in neutral. It is dangerous to operate the steering wheel and
• Make sure the brake pedal is released (brake is levers with greasy hands. If grease, oil or soil is
applied). sticking to your hands, clean if off.
• Make sure there is no one around the truck and
stand in position in the operator’s compartment. Keep the truck’s center of gravity
low during traveling (when loaded in
particular)
When traveling (when loaded in particular), keep
the forks 20 cm above the floor or ground and tilted
1-14
TRAVELING
back, so as to lower the truck’s center of gravity as Carry the load low
far as possible. It is dangerous to travel with forks lifted higher than
is appropriate, regardless of whether loaded or not.
Never use man as an additional Keep the load as low as possible while traveling.
counterweight Do not turn the truck with the load raised high.
Stay away from the edge of road
Do not use man as an additional counterweight.

Do not offer rides to others.
Avoid sharp starts, stops and turns There is a fear of the edge of a soft ground
breaking. Stay away from such a place. Keep
appropriate distance from the edge of a narrow
road or a platform.
Do not travel over a floor or ground

surface covered with water
Do not travel over a floor or ground surface
covered with water. Go round any pothole in the
road.
Start, stop and turn slowly. Before turning, slow

down the truck sufficiently. In particular, an
unloaded truck might tip over when it is turned
sharply, because the rear of the truck is heavy.
A loaded truck might tip over when the mast is
advanced, resulting in injury or damage to the
load.
Before reversing the direction of

travel, bring the truck to a complete
stop
It is dangerous to reverse the direction of travel
abruptly.
1-15
TRAVELING
Avoid running on a slippery surface When going into areas where there
are limits in height and width, use the
following cautions:
Do not ride on obstacles (curb,
railroad tracks, ditches) • Make sure there is enough height and width for
If unavoidable, be careful. the truck to pass.
• Do not put your hands and feet outside the
truck.
Safe traveling:
• Make sure there is no one around the truck.
• Watch out for outdoor electric cables and other
obstacles.
Rear steer, rear swing

When the truck is turned in forward driving, the
rear of the truck swings outwards. Before turning,
make sure there is enough clearance from the wall
and other obstacles.
• Always look in the direction of travel Have a guide when handling bulky
Always look in the direction of travel; failure to
loads
do so will lead to an accident. When passing
an oncoming truck each other, slow down and
use caution to have a safe distance. Moreover,
maintain a safe distance from the truck ahead of
you at all times.
• Observe speed limits
Observe the specified speed limits.
• Make sure there is no one or obstacle around
the truck and in the direction of travel or
turning
• Do not go past other trucks where vision is When handling bulky loads which restrict your
restricted vision, operate the truck in reverse and have a
Do not go past other trucks at intersections, guide.
corners, narrow aisles and other locations where
your vision is restricted.
• Slow down at corners
Slow down and sound horn at intersections and
other locations where your vision is restricted.
• Come to a complete stop before crossing
roads or at corners
1-16
TRAVELING
Reverse travel Brake the truck in good time

• The stopping distance of the truck is longer
on a downhill than on a flat surface. Keep the
traveling speed under your control.
• The truck takes a little longer to come to a stop
on a slippery surface than on a usual surface.
Brake the truck in good time.
Do not turning off key switch during

traveling
If the key switch is turned off during traveling,
power steering becomes disabled to make steering
When traveling in reverse, always look in the hard.
direction of travel. Do not rely too much on the
sideview mirrors (if so equipped) and backup
buzzer. When driving over a dockboard:
• Do not ride on the edge of the dockboard or
Back down and drive up: bridgeplates; otherwise the truck might fall
down, leading to personal injury or even death.
• Before driving over a dockboard or bridgeplate,
make sure it is properly secured. Never exceed
its rated capacity. Do not use a damaged
dockboard or bridgeplate.
• Have the brakes set and wheels blocked in
place to prevent the trailer from moving.
• Jacks must be installed to support the trailer
when the truck goes into the trailer.
• Do not make turns on a gradient. There is • Drive carefully and slowly across the dockboard
danger of the truck upsetting. or bridgeplate.
• Keep the forks and pallet at an appropriate • Watch for bystanders.
ground clearance height. • Give instructions to the trailer driver not to move
• When operating an unloaded truck on grades, the trailer until load handling is finished.
have the rear end of your truck pointed up-hill. • Make sure the dockboard or bridgeplate is
• When operating a loaded truck on grades, have secured.
the rear end of your truck pointed down-hill.
• When descending a grade, use the brake.
When descending a grade, use the foot brake
and drive carefully. When you drive a truck
equipped with the regenerative braking system,
use the foot brake concurrently.
• Never turn the key switch OFF while running on
a gradient.
1-17
TRAVELING
Know the load bearing capacity of the

floor
Before entering a building or going into an elevator,
make sure the floor is strong enough to withstand
the weights of the truck and the loads.
Practice safe driving and load handling

techniques
Before using the lift truck, you must practice
safe driving and load handling techniques. Even
after getting familiar with the operation of the
truck, operate the truck carefully; reckless driving
and operation will cause a personal injury or an
accident.
When using multiple trucks

When operating multiple trucks, remember
that their operating controls have their own
characteristics even if the trucks are of the same
specification. If you change the trucks, keep this
point in mind. In particular, pay attention to the
brake system.
1-18
LOAD HANDLING
Keep anyone but a guide away from Adjust fork spacing with your feet
the working area
Do not let other persons or truck

approach your lift truck during
operation
When working in a group, have a

person present to give guidance and
follow his instructions
Do not use your truck for purposes

other than specified:
Adjust the fork spacing with your feet. Do not
• Do not use the truck to open or close the doors
use your hands. Your hands might get pinched
of freight cars or warehouses.
between the forks and carriage.
• Do not push other trucks.
• Do not hoist loads, using ropes hung on the
Make sure forks are securely locked
forks.
After adjusting the fork spacing, lock the forks with
• Do not tow another vehicle using the draw bar.
fork stoppers. Unlocked forks will slide during
• Do not push or pull loads with forks; otherwise,
traveling, causing the load to fall off.
the load might fall off or get damaged. In
particular, the truck with the max. lift height of
more than 150 cm might tip over, if you try to do Do not put your hands or feet into the
load handling system
that.
WARNING
Pay attention to the fork tips Never put your hands or feet on the mast or
The fork tips are sharp and could cause personal mast connecting members; otherwise your
injury. In addition, if they catch on obstructions, hands or feet might be cut if the mast moves
the truck might lose control, leading to an accident. unexpectedly.
Adjust fork spacing properly

Adjust the fork spacing suitable according to the
size of the load.
WARNING
1-19
LOAD HANDLING
Never elevate a man Do not pick up loads from other truck

WARNING • Do not pick up loads from raised forks of other
Never allow other person(s) to ride on the truck. This might cause an off-centered load or
forks. He might fall off the forks, getting the load to fall off.
injured. • Do not pick up a load on the forks by hand.
Do not hold loads on the forks by

hand
Do not hold loads on the forks by hand. If the
truck moves unexpectedly, the load might fall off,
getting the person caught under it.
Make loads in contact with load

backrest
Insert the forks into the pallet as far as possible to
make the loads in contact with the load backrest.
WARNING
• Never overload
Do not stack loads too high on forks
Know the rated capacity of your lift truck Do not stack loads on forks in such a way that the
and its attachment, if any, and never top of loads exceeds the load backrest height;
exceed it; otherwise the rear wheels will otherwise, loads might fall on the part of the
be raised, thus making it difficult to travel operator, and in the worst case lead to a serious
and turn. There is also danger of the truck injury or death.
tipping over.
Do not lift unstable loads
Do not handle unstable loads. When handling
loose loads, make sure they are stable enough
before lifting.
Use special caution when stacking or

unstacking loads
When stacking or unstacking loads, stabilize them
• Never lift a load over anyone with ropes or others, to prevent from falling off.
Never permit anyone to stand under
raised forks. The forks might fall down Use pallets and skids strong enough
unexpectedly, thus causing a personal Pallets and skids must be strong enough to
injury. withstand the weight of loads. Use of a damaged
pallet or skid might let the load fall off the forks.
WARNING
1-20
LOAD HANDLING
Use extreme caution when handling Never operate the reach mechanism
long or bulky loads with load in contact with the ground
Lift and lower the load carefully so as not to hit Never operate the reach mechanism with the load
it against something around the truck. Keep the in contact with the ground (with the forks not lifted).
load as low as possible. Be careful when turning
the truck, to prevent it from moving out of position Do not push or pull loads by using the
or falling off. reach mechanism
Do not push or pull the load by using the force of
Be alert for overhead hazards the reach mechanism cylinder.
Use caution not to let the mast or overhead guard
contact overhead power cables, piping, sprinklers
or overhead cross beams. If part of the truck Do not tilt the mast with loads high
comes in contact with them, the load might fall off
the forks or the truck tip over. Remember that the
mast height becomes higher when the forks are
raised.
Never overload
WARNING
Know the rated capacity of your lift truck and
its attachment, if any, and never exceed it;
otherwise the rear wheels will be raised, thus
making it difficult to travel and turn. There is Use minimum forward and reverse tilt when
also danger of the truck tipping over. stacking and unstacking loads. Never tilt forward
unless the load is over stack; otherwise the truck
might tip over.
Do not jerk the forks (lift, down, and
tilt) when loaded Do not lift or start with mast tilted
forward
When the mast is tilted forward, do not perform the
following operations: lifting the forks, advancing
and retracting the mast, and starting and traveling
the truck.
Do not stack or unstack loads on a

sloping grade
Do not squeeze loads into the stack

The truck might tip over. Do not squeeze loads into the stack using the
truck’s traction force. This will cause damage to
the truck or loads, causing the truck to tip over.
1-21
LOAD HANDLING
Do not lift off-centered loads the truck might turn over. Keep the load as
Make sure that the loads are evenly positioned low as possible.
across the forks and that the load’s center of
gravity is aligned with the truck’s center of gravity.
Off-centered loads might cause the truck to turn
over.
Keep the chains tight

A slack chain means a mast rail or carriage hang-
up, which might cause the sudden fall of loads
or carriage or the truck to tip over. Keep the lift
chains stretched tight at all time.
Do not hang loads with wire ropes

attached directly on the forks:
• Do not hang loads with wire ropes attached

directly on the forks or attachment. If the wire
ropes break or slide off, a personal injury might
result. In particular, the use of a wire rope hung
on one of the forks might cause the truck to turn
over.
• Use a hook attachment or crane arm attachment

to hang loads.
◎ Make sure that the wire ropes are strong
enough to withstand the weight of the load
and properly attached. The length of the
ropes should be as short as possible but with
adequate spread angle between legs.
◎ Carefully travel and turn when hanging a load
with wire ropes; otherwise, if the load swings,
1-22
PARKING
Park at the specified area Remove the key from a faulty truck
and put up a sign
Park on a hard surface
Park at an out-of-traffic area

Park at an out-of-traffic area. Avoid parking near
emergency exits, stairs, or fire hydrants.
DO NOT
OPERATE
Block the wheels when parking on a

slope
If unavoidable to park on a slope, apply the parking
brake securely and block the wheels.
Remove the starter key and attach a sign saying

Do not park near flammables
DO NOT OPERATE.
When parking a faulty truck

When leaving the truck, observe the
When it is not possible to lower the forks on the following conditions:
ground due to a faulty load handling mechanism,
attach a sign to the tip of the forks to prevent
pedestrians and other vehicles from bumping
against the forks. Park the truck at an out-of-traffic
area and take measures so as not to let people
pass under the raised forks.
• Retract the mast fully.

• Park the truck on an out-of-traffic area and lower
the forks on the ground.
• Tilt the forks a little forward and make the fork
tips in contact with the ground surface.
• Remove your foot from the brake pedal.
• Release the accelerator lever.
• Turn the key switch OFF.
• Remove the key.
1-23
INSPECTION AND SERVICE
Inspection and maintenance must be Avoid loose fitting clothing

performed only by qualified personnel We a r p r o t e c t i v e c l o t h i n g c a l l e d f o r b y j o b
WARNING conditions.
Inspection and maintenance of the truck
should be performed only by qualified and Wear safety gear devices (hard hat,
authorized personnel. Improper inspection, safety shoes, safety glasses, gloves)
maintenance or repairs will cause damage to
the truck or a serious accident. When working in a group, have a
leader and follow his instructions
Park on a hard, level ground Turn the key switch off

Before performing inspection and maintenance, Make sure to turn the key switch off and disconnect
make sure to park the truck on a hard, level the battery receptacle.
surface. Also make sure the place is dry and
without dust. Unless otherwise specified, key switch
must be off
Have a good ventilation Unless otherwise needed, the truck is to be parked
When performing inspection and maintenance with the key switch off, and battery receptacle
indoors, have a good ventilation. disconnected.
Have fire prevention equipment handy Before starting inspection or

Have a fire prevention equipment handy whenever
maintenance, place the control levers
in neutral
working indoors. Know how to use it.
Make sure the forks and other

Wipe any spilt oil or grease attachment (if any) are on the ground
Wipe any spilt oil or grease. If the truck is
contaminated with oil or grease, it is difficult for
If unavoidable to work under raised
you to find possible cracks or other defects. forks or attachment, use a stable
support under the inner mast and/
No fire (when handling lubricants, or the carriage to prevent the forks
batteries, cloth wetted with oil) or attachment from falling down
No fire. Never smoke or use fire or naked flame unexpectedly
when handling lubricants, batteries or cloth wetted
with oil.
Use appropriate tools

Use appropriate tools suitable for the job you have
been assigned. Use of inappropriate tools might
cause a serious accident.
Do not use tools for purposes other

than specified
Do not use tools for purposes other than specified.
It can cause a serious accident.
1-24
Do not put your feet under the forks Hydraulic oil is hot immediately after
the operation of the truck is stopped
Use caution not to get your fingers Immediately after the operation or running of the
pinched in the floor plates or hood truck is stopped, the hydraulic oil is hot and in high
Be careful so as not to get your fingers caught pressure. Do not try to drain the hydraulic oil or
when closing the battery cover or doors. replace the filter. Hot oil might spout out to cause
burns.
Use caution not to fall down from the
truck when working on the truck Release oil pressure before working
The hydraulic circuit has residual pressure. Before
Do not use the mast as a ladder: working on the system, release the pressure.
• When carrying out checks or adjustment, do not
use the connecting member or load backrest as How to release oil pressure:
a ladder. The mast might move unexpectedly, Lower the forks on the ground, turn off the key
pinching or cutting your hands or feet. switch and move each of the valve levers back and
• Do not use the mast as a ladder. You might forth.
fall down from the mast, leading to a serious
accident. To check for oil leaks, wear safety glasses and
gloves and use a piece of cardboard or wood.
Remove the battery receptacles before High pressure oil penetrates the skin. It can cause
working on rotating parts blindness.
Checking of accumulator and piping is

hazardous
Inspection of piping where an accumulator is
installed is hazardous. When it needs to be
inspected, ask your UniCarriers dealer.
When high pressure oil comes in

contact with your body, immediately
get medical attention
Use due caution when working on rotating parts,
not to get your body entangled in them. Before Avoid fire hazards
checking a rotating part, make sure to turn the key • Do not store flammable fluids near sources of
switch off and disconnect the battery receptacles. heat or ignition.
Do not bring something near rotating parts. • Do not throw aerosol cans into a fire or do not
try to crush them.
1-25
WARNING • Wear safety glasses when handling batteries

Cautions to be taken when using the jack: Wear rubber gloves, rubber boots, safety
Do not enter under the truck while it is glasses when changing or charging batteries,
jacked up. The truck might fall, getting you adding battery electrolyte, or adjusting the
caught under it. specific gravity of the battery electrolyte.
• Before jacking up the truck, remove the • The electric truck’s batteries are high voltage
loads from the truck. The batteries used for electric trucks are high
• When jacking up the truck, the operator voltages more than 48 V. If anyone touches it
must leave the operator’s seat. inadvertently, he can get an electrical shock
• Lift the truck a little off the ground surface accident or burn.
and put supports under the frame at both • No fire
sides of the truck to prevent the truck from Since explosive hydrogen gases are always
falling. being released from the battery, there is a
danger of causing an explosion. Never smoke
or use fire or naked flame near the battery. No
Cautions to be taken when handling sparks.
batteries: To prevent the generation of sparks, turn
• If electrolyte gets on your skin, flush it off off the charger switch before connecting or
with a copious amount of water disconnecting the battery or charger cable.
• Do not put any metal tool on the battery case
SAFETY • Do not short the battery terminals
GLASSES
The battery electrolyte contains dilute sulfuric

acid, a very corrosive material. It can destroy
most things it touches. It will cause painful Do not short the battery terminals by placing a
and serious burns if it gets on the skin. It can piece of metal between the positive and negative
cause blindness if it gets into eyes. If battery terminals. A loose terminal might cause sparks,
electrolyte comes in contact with the skin or causing an explosion. Make sure the terminals
clothing, wash it away immediately with a are tight. Use caution not to have the wrong
copious amount of water. connections of the battery terminals.
• If electrolyte gets into your eyes, get medical • Poor connection of the receptacles might
attention cause sparks or an overheated plug,
If electrolyte gets into your eyes, flush it off resulting in an explosion or burning
immediately with a copious amount of water and accident.
get medical attention.
• W h e n c h a r g i n g t h e b a t t e r y, f o l l o w t h e
• If anyone swallowed electrolyte accidentally: instructions in the Instruction Manual of the
Let him drink a copious amount of water or milk charger
with egg white and salad oil mixed in it and take
a rest. Send for a doctor.
1-26
• No fire during charging • Static electricity from the body

Before checking or cleaning the battery, remove
static electricity from your body by touching
metallic parts at a place away from the battery.
• Pay attention to battery electrolyte level
Battery is bei
ng
charged
Batteries give off hydrogen gases during

charging. No fire. No sparks.
• Make sure the battery electrolyte temperature
is below 40°C Do not operate the truck or charge the battery
Hydrogen gases are released from the battery when the battery electrolyte level is below
during charging, causing the battery to heat. the LOWER LEVEL marking; otherwise,
Before trying to charge the battery, make sure the components inside the battery may be
the battery electrolyte temperature is below deteriorated and the battery life shortened, and
40°C. in the worst case an explosion might occur.
(If the electrolyte temperature reaches 50°C or Keep the battery electrolyte level between
more, discontinue charging and wait until the the “UPPER LEVEL” and “LOWER LEVEL”
electrolyte temperature drops to 40°C or lower.) markings at all times. Add purified water if the
• Have a good ventilation when charging level is low.
Since hydrogen gases are released from Do not overfill beyond the “UPPER LEVEL”
the battery during charging. Have a good marking; otherwise electrolyte spills to cause
ventilation; otherwise an explosion might result. electric leakage.
Keep the battery case cover open. • Do not connect or disconnect the battery
• If any of the following problem is found, receptacles with the battery circuit
contact your local UniCarriers dealer: conducting
◎ Loose or excessively discolored battery plug • Neutralize any spilled electrolyte with
or charger plug (overheated plug) sodium bicarbonate, soda ash, lime or other
◎ Battery electrolyte temperature is excessively neutralizing agent until fizzing stops and
high or battery electrolyte is consumed wash away with a copious amount of water;
excessively. otherwise the floor surface might corrode.
◎ Charging safety timer functions (or the • Repair of battery terminals, cables or plugs
charging lamp blinks) must be taken care of by a specialist.
• When cleaning the battery, make sure the Repair of battery terminals, cables or plugs
battery caps are securely tightened requires a high level of skill. If they are repaired
• Static electricity is hazardous in a proper order or manner, the worker might
Static electricity is generated when cleaning the get injured or the battery might malfunction.
top surface or connections of the battery with • Any used battery should be recycled. Do
a dry cloth, or covering the battery with a vinyl not dispose of it and consult your local
sheet. It might cause an explosion. UniCarriers dealer.
1-27
Obey regulations
When disposing of waste oil, solvent, or
discharged battery, obey the regulations and rules.
Keep the tension of the right and left

chains even
Uneven tension of the right and left chains means
uneven loads even if they are properly placed on
the forks. It may also lead to broken chains.
Keep sideview mirrors, backup alarm,

and lamps in good working condition
Adjust the sideview mirrors to gain a full rear
vision and keep the mirror’s surface clean (if so
equipped). The backup buzzer should sound
when the direction change lever is placed in the
reverse position. If the buzzer fails to sound, have
it repaired. Make sure the lamps turn on and off
properly. Burned-out bulbs must be replaced with
new ones.
1-28
PREVENTING VEHICLE FIRES
PREVENTING VEHICLE FIRES Check for charger cable

Observe the following precautions to prevent
the possibility of fires in your forklift truck, or in
the facility where the truck is stored or operated.
Before starting the day’s work or before each shift,
always make sure to perform the following checks.
If any problem is found, operation of the truck
should be halted until the problem is corrected.
DEFOR-
Check for any spilt oil DISCOLOR-
ATION MATION
Wipe up any spilt oil. Remove any deposits or
accumulation of flammable debris (paper, leaves
or wood waste). They can be a fire hazard. A discolored or deformed connector, socket or
• Before starting the day’s work or before each cable of the charger can cause a fire.
shift, check the truck for flammables. Remove • Before charging, check connectors, socket and
any if found. cable of the charger.
• If any problem is found or you are not sure
Check for electrical shorts about the safety of the charging system, consult
your local UniCarriers dealer.
Check for oil leaks

Hydraulic oil and lubricant leaks can cause a fire.
• Before starting the day’s work or before each
shift, check all the hose clamps for looseness.
Notice if any are missing. Check the hoses for
twists, friction wear or damage.
about the safety of the truck, consult your local
UniCarriers dealer.
Electrical wires that short can cause a fire.

• Clean all the wiring connections and ensure the
plugs are securely connected.
• Before starting the day’s work or before each
shift, check the cables, wiring and electrical
components for looseness, twists, stiffened or
cracked insulation, and fraying.
• Also check for missing or damaged terminal
caps.
about the safety of the truck, consult your local
UniCarriers dealer.
1-29
PREVENTING VEHICLE FIRES
Ensure that there is good ventilation How to escape from a truck on fire
during charging
A vehicle fire might cause a serious personal injury

Never allow sparks or open flame near a charging or even death. If the truck catches on fire during
battery. Have a good ventilation. Batteries produce operation, get out of the burning vehicle observing
explosive hydrogen gas while charging, which the following procedure:
could cause an explosion resulting in injury or • Immediately lower the forks on the ground, apply
death. the parking brake, and turn off the key switch to
• Charge batteries in a well ventilated area, free shut off the power supply.
of rainwater, sparks or open flame. • Get out of the burning vehicle quickly using the
• M a k e s u r e t h a t t h e r e i s c o n s t a n t , g o o d steps and handrails. Do not jump off the truck.
ventilation during charging, when charging the • If possible, fight the fire using a fire extinguisher.
battery indoors.
Never make modifications without
Never smoke in the operator’s prior approval
compartment or around the truck (No Modifications performed without prior approval can
fire) cause a fire hazard. Do not make any modification
Any flammable objects inside the operator ’s to your truck without getting prior approval from
compartment or hydrogen gas produced from the the manufacturer. If you need a modification of
battery can catch fire from a cigarette or cigarette your truck, consult your local UniCarriers dealer.
butt, leading to a vehicle fire. Modifications made without UniCarriers’ prior
• Never smoke in the operator’s compartment or approval will void your vehicle’s warranty.
around the truck.
1-30
CAUTION PLATES
The caution plates attached to the lift truck explain cautions to be taken when using the truck, and
procedures for operating the truck. Read messages on the caution plates as well as the description in this
manual. Damaged or missing decals must be replaced with new ones.
E Name plate
J List of lubrication points
L Hydraulic oil
E F E F
H
G A D L
H
A K ԙ Ԛ
K
N
with battery charger without battery charger
Ԙ ᮮⴕ䊝䊷䊄䈻ಾ឵ᤨ䈲䊊䊮䊄䊦䊖䉟䊷䊦䉕
Ꮐᣇะ䈻࿁䈚䈩䈒䈣䈘䈇䇯
䌔䌃䌍䇭䋲䋷䋹䌍䋴䋭䋱䋲䋳䋰䋱
50
ԛ
C
ԛ Ԝ
B
I
Ԛ
ԙ
Ԙ
J
Ԝ
1-31
CAUTION PLATES
A. Safe operation F. Load chart – avoid overload (see

Chapter 5 for the Load chart.)
WARNING
YOU MUST FOLLOW THESE RULES TO AVOID
SEVERE INJURY OR DEATH TO YOURSELF AND
OTHERS. G. Battery charger instructions
• Operate truck only if trained and authorized by your
employer. Know Operation & Maintenance Manual and
all work rules.
• Safety check truck every day. Do not start if damaged CAUTION 1. Start charging
Charging procedure:
or faulty; stop if problems start. Repair allowed only by Observe the following precautions when handling the battery Press the START button. The green “Charging” lamp will come on and the remaining
trained, authorized mechanics. charger. operation is controlled automatically by a microprocessor.
Failure to do so can cause injury, electric shock, fire, or damage (It is advisable to recharge the battery after the day’s work or at the end of the shirt,
• Turn, start, stop, and handle loads smoothly and slowly. to property. even if very little discharge occurred.)
If the battery charger won’t operate, make sure that the battery charge is plugged into
Carry loads low and tilted back; stack only on level the power supply.
using minimum tilt. 1 Read the operation manual of the battery charger before using 2. Charging monitor
it. During charging, you can monitor the operating status of the battery charger by looking
• Look where you are going. Watch out for people, 2. Make sure the battery charger and the power supply are turned at the capacity indicator on the battery charger meter.
hazards on floors and overhead, drop-offs and tall off before connecting or disconnecting the battery charger 3. Completion of charging and stopping charging
cables. Never, under any circumstances, disconnect the battery When the battery has been fully charged, charging will stop automatically and the
swing clearance. “Charging” lamp will go out.
charger cables or the battery connector during charging.
• Truck overturn can kill you. Slow for turns even when 3. When disconnecting the battery cables, pull on the plug, not To stop charging before the battery is fully charged, press the STOP button.
4. Super equalizing charge
empty. Never turn on inclines. Use seat bolt and stay the cable. A super equalizing charge may be required if electrolyte is added, if there is a large
in truck if it tips. 4. Do not try to touch any component inside the battery charger variation in specific gravity between the cells, or if the battery capacity needs to be
while the power cable is connected. brought up to 100% after the truck is out of service for several days.
• Do not tilt overweight or loose loads. Move slowly 5. Note that hydrogen gas is released from batteries while they Press the START button. After making sure that the “Charging” lamp comes on,
with wide, high, or long loads. Keep forks wide and are charging and immediately after charging. Have appropriate press the SUPER EQUALIZING button. When the battery charger is put in the super
equalizing charge mode, the orange “Super Equalizing Charge” lamp will come on and
fully under loads. Travel in reverse if loads block ventilation and keep all open flames away from the battery;
an ordinary equalizing charge will be performed. One day after the ordinary equalizing
otherwise there is danger of an explosion.
view. Attachments require special training, ask your 6. The charging operation must be done in a place that is not
charge has finished, the “Charging” lamp will come on automatically and the battery will
be given an auxiliary charge every day thereafter. The “Super Equalizing Charge” lamp
employer. exposed to rain. won’t come on during the auxiliary charge stand-by period.
• Keep loads upgrade on all inclines. Stay clear of ramp 7. If the charging time exceeds 15 to 17 hours for any reason, 5. Releasing the super equalizing charge mode
the timer will automatically stop the charging. If this happens, To release the super equalizing charge mode, press the STOP button while charging or
and dock edges. Make sure dockboards and trailers the “Charging” lamp will blink. Contact your local UniCarriers press the SUPER EQUALIZING button again when the battery charger is in the auxiliary
are secure before going on them. dealer. charge stand-by mode.
• Overhead guard and load backrest must be on truck.
Always keep yourself completely inside guard.
• Stop engine when refueling. Follow Operation &
Maintenance Manual and employer’s work rules about
fuel, battery and tire maintenance hazards.
• Forks can fall rapidly even with light loads. Do not
raise people or allow them under forks. No passengers
H. Warning for removing and returning
allowed on truck.
• Park only in authorized areas, never on inclines. Lower battery back
forks to bottom, put direction control in neutral, turn off
key and make sure parking brake is set.
CAUTION
The operation method for the battery exchange and
cautions
● Withdrawal of the battery
1. Pull the reach lever to retract the mast and depress the
battery lock release pedal to the lowest position.
B. Warning for load handling means

2. With the lock release pedal depressed, push the reach
lever and the battery will be drawn out with the mast.
● Relocation of the battery
1. Check that the hydraulic oil hose is correctly mounted
on the hose guide of the battery case.
2. With the lock release pedal depressed to the lowest
WARNING
position, pull the reach lever to draw the mast and
battery into position.
Do not ride 3. When withdrawing/relocating the battery, the hydraulic
hose may become detached from its guide on the
battery tank.
forks or Ensure that the hose is correctly positioned before

securing the battery in the truck.
Checking and refilling the battery electrolyte should be done

pallet. with the battery plug disconnected and the battery removed
from the frame.
Always ensure that the battery withdrawal/relocation is

carried out on a level surface.
I. “Do not enter space between mast and

frame”
C. Warning for mast connecting members WARNING

WARNING
D. Danger against high-voltage current

K. “Keep your body inside operator’s
compartment while driving or handling
loads.”
CAUTION
Keep arms, legs, and hands inside
the operator’s compartment while
traveling or load handling; otherwise
there is danger of being injured due
to entanglement and other types of
accidents.
1-32
CAUTION PLATES
M. Battery caution decal (EXE, EXN) N. FRB15/20/25-8M

CAUTION
To travel sideways, shift in sideways
travel mode, turn drive wheel 90°
counterclockwise, and hold there
before operating accelerator lever.
•• Do not put a dead battery into

the trash without permission.
•• Recycle dead batteries.
Battery decal
DANGER!! Keep away from naked flame, sparks, and cigarettes.

• Hydrogen gas produced by the battery can explode.
Do not short circuit, prevent sparks. Shield eyes with goggles.
When charging the battery open all windows or do so
outside.
Follow the instructions correctly when using the Keep away from children.
booster cable.
• Electrolyte (Sulphuric Acid) causes severe burns to
eyes, skin, or clothing. Do not allow contact with electrolyte.
If in contact with the skin or eyes, rinse with cold water
and seek immediate medical advice.
• Do not use the battery when the electrolyte level is Read instruction carefully.
below the LOWER LEVEL, it may cause an explosion.
• Do not use the battery while the electrolyte level is over
Hazardous Explosive
the UPPER LEVEL, it may cause the battery to leak.
1-33
2. OPERATING
CONTROLS
CONTENTS
PICTORIAL NOMENCLATURE . ......................... 2-1

INSTRUMENTS AND CONTROLS ..................... 2-5
METER PANEL................................................ 2-5
SWITCHES.................................................... 2-13
LEVERS AND PEDALS . .............................. 2-15
TRUCK BODY............................................... 2-19
INTERLOCK SYSTEM.................................. 2-21
OPTIONAL EQUIPMENT.............................. 2-24
The following symbols, found throughout this

manual, alert you to potentially hazardous
conditions to the owner and the operator.

proceeding with operating, checking and servicing.
This manual and decals affixed to the truck use the

following safety alert indications.
SIGNAL WORD CLASSIFICATION

Failure to follow the instructions
DANGER in the message will likely cause a
WARNING the message might cause a serious
accident or death.
other property.
The information will help to prolong
NOTE message is not directly related to
accident prevention.
PICTORIAL NOMENCLATURE
1. HEAD LIGHT
2. LIFT CHAIN
3. MAST
4. LOAD BACKREST
5. FORK STOPPER PIN
6. TILT CYLINDER
7. GUIDE RAIL (OUTRIGGER)
8. FORKS
9. TRAIL WHEEL (FRONT
WHEEL)
10. OUTRIGGER
11. HYDRAULIC PIPING (TRUCK
BODY TO MAST)
12. BATTERY CASE
13. FRONT COVER
14. LIFT CYLINDER
15. TURN SIGNAL
16. OVERHEAD GUARD
17. BATTERY CHARGER

CONTROL PANEL
18. POWER OUTLET
19. COVER
20. DRIVE WHEEL
21. OPERATOR’S
COMPARTMENT
22. BRAKE PEDAL
23. LOCK RELEASE PEDAL
24. CASTOR WHEEL
25. CUSHIONING PAD
26. BATTERY RECEPTACLE
COVER
2-1
FRB15/20/25-8M
46
45 29 30 31 32 33 34 35 36
37
41
42
43
44
25
38
40 39 22 21 23
29. METER PANEL 35.

ASSIST GRIP 42.
TILT LEVER
30. KEY PAD 36.
POWER SHUT-OFF KNOB 43.
LIFT LEVER
31. HEAD LIGHT SWITCH 37.
ARMREST 44.
KEY SWITCH
32. TURN SIGNAL SWITCH 38.
MOUNTING ASSIST GRIP 45.
DOCUMENT CLIP
33. HORN BUTTON (RIGHT) 46.
FRONT-WHEEL ANGLE
34. ACCELERATOR 39. MOUNTING ASSIST GRIP CONTROL LEVER
LEVER (DOUBLING AS (LEFT) (FRB15/20/25-8M)
FORWARD/REVERSE 40. STEERING WHEEL
TRAVEL CONTROL) 41. REACH LEVER
* For EXE and EXP specifications, see the next page.
2-2
EXE and EXP specifications
45 29 30 31 32 33 34 35 36
37
43
41
42
44
25
38
40 39 22 21 23
29. METER PANEL 35.

ASSIST GRIP 42. TILT LEVER
30. KEY PAD 36.
POWER SHUT-OFF KNOB 43. LIFT LEVER
31. HEAD LIGHT SWITCH 37.
ARMREST 44. KEY SWITCH
32. TURN SIGNAL SWITCH 38.
MOUNTING ASSIST GRIP 45. DOCUMENT CLIP
33. HORN BUTTON (RIGHT)
34. ACCELERATOR 39. MOUNTING ASSIST GRIP
LEVER (DOUBLING AS (LEFT)
FORWARD/REVERSE 40. STEERING WHEEL
TRAVEL CONTROL) 41. REACH LEVER
2-3
FRB15/20/25-8M
7
28
27
27. FRONT WHEEL

(FRB15/20/25-8M)
28. CASTER WHEEL
(FRB15/20/25-8M)
2-4
INSTRUMENTS AND CONTROLS
METER PANEL
1 2 3 4 5 6 7
11 10 9 8 12
1. PARKING BRAKE 5. HOUR METER 8. TIRE ANGLE INDICATOR 10. LOW-SPEED TRAVEL
INDICATING LIGHT 6. DATE AND TIME 9. BATTERY DISCHARGE MARK (TURTLE)
2. INTERLOCK WARNING 7. KEY PAD INDICATOR 11. S.P.E. MODE
LIGHT INDICATOR
3. NEUTRAL STATUS 12. FRONT-WHEEL ANGLE
INDICATING LIGHT INDICATOR
4. TRAVEL SPEED METER (FRB15/20/25-8M)
KEY PAD (7)

S.P.E. BUTTON (8)
Every time the S.P.E. button is pressed, the operating
power mode changes, with the letter S, P or E
appearing (S → P → E → S). Use this button to set the
operating power mode of the truck.
SCREEN SELECTION “MODE” BUTTON (9)

Every time this button is pressed, the meter
Screen panel screen changes:
selection Main screen → Power consumption screen →
Hour meter → Main screen
Date and time If this button is pressed for more than 3
screen seconds, the Date and Time screen appears.
LOW-SPEED TRAVEL (TURTLE) BUTTON (10)

When you press the turtle mark button on the key pad,
the truck gets in the low-speed travel mode. To release
the low-speed travel mode, press the button again.
· Normal-speed travel mode
When the turtle mark button on the key pad is turned
off, the low-speed (turtle) mark on the meter panel
disappears.
· Low-speed travel mode
When the turtle mark button on the key pad is turned
on, the low-speed (turtle) mark appears on the meter
panel.
+/- BUTTONS (11)

Change the date and time using the +/- buttons on the
key pad.
2-5
METER PANEL
This section explains the operation of the meter panel.
Turn the key switch to the “ON” position. The screen
shows the PASSWORD screen.
PASSWORD INPUT SCREEN

If the truck is password-protected, this screen is shown
on the meter panel when the key switch is turned to
“ON”.
The truck won’t to operate unless the specified 4-digit
password is entered properly.
For the procedure for canceling the current password,
see page 2-12.
INITIAL SCREEN SHOWN WHEN KEY SWITCH IS

TURNED TO ON
MAIN SCREEN 2 - 3 SECONDS AFTER

The Main screen (which is usually shown during
operation) appears. If there is something unusual in
the system, the error screen is shown.
CAUTION
If the error screen is shown on the meter panel,
contact your local UniCarriers dealer.
BATTERY DISCHARGE INDICATOR (9)

The battery discharge indicator indicates the battery’s
condition of charge. If the battery charge level drops to
overdischarge level (factory set to level 1 ), the frame
of the indicator blinks.
NOTE
The battery discharge indicator usually does not
quickly respond to the current operating status of
the battery, because it reads and processes voltage
data of the battery that is in the “off “ state.
If the truck is used for traveling and load handling
continuously, the battery discharge indicator cannot
read voltage data from the battery, so that the
indicator might not progress correctly.
2-6
LOW-SPEED TRAVEL (TURTLE) MONITOR

When you press the turtle switch, the turtle icon
appears on the meter panel. In this mode, the truck’s
travel speed is limited to 5 km/h (factory setting).
TRAVEL SPEED METER

This meter indicates the travel speed of the truck.
DATE AND TIME

The current date and time are shown on the right
corner of the screen.
HOUR METER
The hour meter indicates the total time the key switch
has been in the “ON” position.
S (SUPER) MODE
Use the S mode when your task requires large power
in a short time, such as speedy running or carrying
heavy loads.
2-7
P (POWER) MODE
Use this mode when you need to carry loads a long
distance at a high speed.
E (ECONOMY) MODE
Use the E mode when your task takes a long time
to finish. The truck can work a long time on a single
battery charge in this mode. The E mode is suitable
for handling loads carefully or carrying a fragile load
slowly.
PARKING BRAKE INDICATING LIGHT

Light comes on when the parking brake is applied.
The truck won’t move when this light is ON.
NEUTRAL STATUS INDICATING LIGHT

Light comes on when the accelerator lever is in the
neutral position and goes out when the accelerator
lever is placed in the forward or reverse position.
NEUTRAL SAFETY INDICATING LIGHT

The neutral safety indicating light blinks if any of the
accelerator lever and load handling levers is not in
neutral when the key switch is turned to “ON”. If this is
the case, the truck won’t travel and the load handling
system won’t operate.
DRIVE-WHEEL ANGLE INDICATOR

The indicator shows the direction of the drive wheel.
Forward travel: Black arrow on the white background
Reverse travel: White arrow on the black background
Neutral: Black bar on the white background
2-8
INTERLOCK WARNING LIGHT

Light comes on when the operator leaves the
operator’s compartment. With the interlock warning
light ON, the truck won’t travel and the load handling
system won’t operate.
NOTE
Interlock system
If the key switch is turned to the “ON” position with
no operator present in the operator’s compartment,
the neutral status indicating light blinks and the
interlock warning light comes on. The truck won’t
travel. When the interlock system is activated,
number 105 or 106 is shown on the screen. For the
procedure for releasing the interlock system, see
page 2-21.
FRONT-WHEEL ANGLE INDICATOR

FRB15, 20, 25-8M
The indicator shows the turning angle of the right front
wheel.
2-9
ERROR SCREEN
ERROR CODES
If a failure occurs with the truck, the “wrench” icon
appears along with a 3-digit error code. If an error code
appears, consult your local UniCarriers dealer.
CONTROLLER OVERHEAT WARNING LIGHT

The controller overheat icon blinks when the traveling
or load handling operation is too much to the truck,
with the corresponding error code “203” indicated. It
usually stays off. If the icon starts blinking, stop the
operation immediately and wait until the light goes out.
MOTOR OVERHEAT WARNING LIGHT

The motor overheat icon blinks when the drive motor
has overheated, with the corresponding error code
“206” indicated.
It usually stays off. If the icon starts blinking, stop the
operation immediately and wait until the light goes out.
NOTE
If neglect of such warning lights will cause the truck
to stop eventually.
BRUSH WEAR WARNING LIGHT (OPTION)

The brush wear icon comes on when the pump motor
brush is worn out.
2-10
POWER CONSUMPTION SCREEN

On the Main screen, press the “Mode” button (4) at the
center of the key pad to display the power consumption
indicator.
· The power consumption (2) represents the power
consumption per hour.
· The remaining battery time (3) represents the length
of time the truck can operate in the future without
recharging, estimated by calculating from the
average operating rate of the truck so far.
· After recharging the battery, reset the remaining
battery time (3) counter by pressing the + button (5)
and holding it down for a while. The counter starts 1. Power consumption
counting down when the key switch is turned to “ON”. indicating area
2. Power consumption
· The readings of the power consumption (2) and 3. Remaining battery
remaining battery time (3) are updated every 6 time
4. “Mode” button
minutes. 5. + button
NOTE
· The power consumption and remaining battery
time should be used as a rough guide, because
they are roughly calculated from the reading of
the battery discharge indicator.
· If the battery is recharged midway through
an operation, data stored in memory before
recharging will be lost.
· The battery capacity used for the basis of
calculation is factory set.
If the battery is switched to a battery whose
capacity is different from the factory setting,
consult your local UniCarriers dealer.
HOUR METER SCREEN

Every time the “Mode” button (12) is pressed, the
screen changes as follows:
→ Main screen → Power consumption screen → Hour meter
· The current hour meter data can be reset by

pressing the + button (13) and holding it down for a
while. The current data will be shifted to the left row
in the history table.
· Three rounds of past data can be stored in the 5. Distance traveled
history table. 6. Operating rate
7. Total time
8. Date on which
NOTE 1. Key switch “ON” recording of data
time was started
· Actual operating time: the total conduction time of 2. Drive motor 9. Past data
the drive motor or pump motor conduction time 10. Current data
3. Pump motor 11. 3 rounds of past
· Operating rate: Actual operating time/the total conduction time data
time the key switch is kept in the “ON” position 4. Actual operating 2.
1 “Mode” button
time 13. + button
2-11
SETTING AND CHANGING THE DATE AND TIME

On the Main screen, press the “Mode” button (8) in the
center of the key pad and hold it down for 3 seconds to
display the Date and Time screen.
You can change any item when it is underlined (7).
· The underline (7) shifts one digit to the right every time
the “Mode” button (8) is pressed.
· If the “Mode” button (8) is pressed when the underline
(7) is located under the time format (6) item, the
change will be stored in memory and the display will
return to the Main screen.
· An underlined (7) number can be increased and
decreased using the + and - buttons.
For example, PM10:34, (WED) October 15, 2008 can
be shown as follows:
→ 08 / 10 / 15 / 22 / 34 / 12 4. Current time (hours)
· If the low-speed travel (turtle) button is pressed, the 5. Current time (mins)
6. Time format: 12 or
display will return to the Main screen. Then, you can 24
start all over again. (12-hour format or
24-hour format)
7. Underline
NOTE 8. “Mode” button
1. Year (right-most 2 9. Low-speed travel
· Even when the 12-hour format is selected, enter the digits) (turtle) button
current time in the 24-hour format. 2. Month 10. + button
· The day of the week will be added automatically. 3. Date 11. - button
CANCELING A PASSWORD
If the truck is password-protected, the PASSWORD screen PASSWORD INPUT SCREEN
will appear when the key switch is turned to the “ON” position.
Enter the 4-digit password on the PASSWORD screen.
The truck won’t operate unless the correct password is
entered.
· Every time the “Mode” button (1) is pressed, the digit
that can be changed shifts one digit to the right.
· The value of a digit (0 - 9) can be increased or
decreased using the + and - buttons (2).
· After entering the password, press the “Mode” button 1. “Mode” button
(1) and hold it down for 3 seconds to confirm the entry. 2. + and - buttons
If the password is accepted, the Main screen will appear
and you will be able to operate the truck.
If the password is wrong, the ERROR screen appears
and then the PASSWORD screen will be displayed again.
· The password will be remembered for 2 hours after the
key switch is turned “OFF”.
If the key switch is turned to the “ON” position within 2
hours after the key switch is turned “OFF”, the meter
panel will be displayed immediately on the Main screen,
PASSWORD ERROR SCREEN
bypassing the PASSWORD screen, and you will be able
to operate the truck.
If two hours have passed after the key switch is turned
“OFF”, you will need to enter the password again.
NOTE
· If you want a password protection system for the truck,
contact your local UniCarriers dealer. Your UniCarriers
dealer will set the passwords for the system.
· Two different passwords can be used.
2-12
SWITCHES
KEY SWITCH (44)
CAUTION
· Disconnect the battery receptacle before
working on the electric components. The
electric circuit is live even if the key switch is
turned OFF.
· Before leaving the truck, make sure the key 44
switch is turned off and remove the key.
OFF: Key insertion and draw-out position

ON: The electric circuit is closed. Self-check takes
places for about 2 seconds and the truck will be
ready for operation.
NOTE
AUTO POWER OFF FUNCTION
If no operation is carried out for 15 minutes after
the power of the truck is turned on, the power will
automatically be turned OFF.
If you want to turn the power ON again, turn the key
to the “OFF” position and then to the “ON” position
again.
POWER CUT-OFF KNOB (36)
CAUTION
· Before you are going to touch any internal
electronic parts, be sure to press this knob to
36
disconnect the battery receptacles; otherwise,
you might get injured.
· Except in an emergency, turn off the key
switch before you press the power cut-off
knob. In addition, make sure the key switch
is in the OFF position before you connect the
battery receptacles.
Press the knob to disconnect the battery receptacles.

Use this knob when you want to disconnect the battery
receptacles in an emergency.
Push forward the knob completely to disconnect the
battery receptacles.
NOTE
Do not disconnect the battery receptacles when you
want to charge the battery using the battery charger
installed on the truck. Otherwise, you cannot
recharge the battery.
2-13
HORN BUTTON SWITCH (33)

Press this button to sound the horn.
The horn sounds regardless of the ON/OFF position of
the key switch. 33
HEAD LIGHT SWITCH (31)

Push forward on the switch to turn the head lights on.
31 32
To turn them off, pull back on the switch.
The head lights come on regardless of the ON/OFF
position of the key switch.
TURN SIGNAL SWITCH (32)

Tilt the switch to the direction you want to turn, and the
turn signal will blink.
When the switch is returned to the center, the turn
signal will go out.
The turn signal switch operates regardless of the ON/
OFF position of the key switch.
2-14
LEVERS AND PEDALS

ACCELERATOR LEVER (34)
(DOUBLES AS DIRECTIONAL CONTROL) 34
Push forward on the lever to move forward and pull
back on it to move in reverse.
You can increase or decrease the travel speed
steplessly by controlling the tilt angle of the lever. The
travel speed is displayed in directly readable numerals
on the meter panel. If you remove your hand from the
lever, it will automatically return to neutral. When you
pull the lever “backward”, the back-up buzzer sounds.
REGENERATIVE BRAKING (ELECTRIC BRAKING)

Regenerative braking can be applied by reversing the
accelerator lever or putting the accelerator lever into
neutral.
· When accelerator lever is off

Regenerative braking occurs when the accelerator
lever is moved to the neutral position while the reach
truck is traveling.
· During switch back

Regenerative braking occurs during switchback
operations or when the accelerator lever is reversed.
The braking force can be adjusted by the tilting angle
of the accelerator lever.
STEERING WHEEL (40)

When traveling the truck, hold the steering wheel knob
with your left hand. Do not remove your hand from the
knob while traveling.
POWER STEERING 40
CAUTION
Do not turn the key switch OFF while traveling.
When the key switch is turned OFF, steering
operation becomes hard.
The truck comes with electric power steering to provide

smooth, light steering with the key switch on.
2-15
LIFT LEVER (43) 43 42

41
CAUTION
Make sure to obey the following instructions
when you operate levers (lift, tilt and reach).
· Stand on operator’s compartment.
· Make sure there is no one around the truck.
Pull back on the lift lever to raise the forks and push it
forward to lower the forks.
The lifting speed of the forks can be controlled by the
tilt angle of the lever.
TILT LEVER (42)

42 41
Pull back on the tilt lever to tilt the forks backward and 43
push it forward to tilt the forks forward.
The tilting speed of the forks can be controlled by the
tilt angle of the lever.
REACH LEVER (41)

Pull back on the lever to retract the mast and push it
forward to advance.
The advancing and retracting speed of the mast can
be controlled by the tilt angle of the lever. EXE and EXP specifications
This lever is also used to remove and return the battery
back.
NOTE
If the operator leaves the operator’s compartment
during operation and does not return onto the
operator ’s compartment within 3 seconds, the
interlock system is actuated to stop the load
handling system. If this is the case, return the load
handling levers to neutral or release your hand from
any load handling lever. If the operator returns onto
the operator’s compartment with any load handling
lever kept in an operating position, the interlock
system will be released so that the load handling
system might move abruptly, causing a serious
accident.
2-16
BRAKE PEDAL (22)

Step on the brake pedal to release the brake and close
the travel circuit at the same time. Release the brake
pedal to apply the brake and open the travel circuit
automatically.
The service brake pedal also functions as the parking
brake pedal.
NOTE
Turn the key switch ON, and then step on the brake
pedal.
LOCK RELEASE PEDAL (23)

This pedal is used to remove and return the battery
back.
Step on the pedal and hold while pressing the reach
lever to advance the mast.
Then remove or return the battery back.
FLOOR SWITCH (A)

There is a switch under the floor in the operator’s
compartment to detect the entry and exit of the
operator.
2-17
FRONT-WHEEL ANGLE CONTROL LEVER (46)

46
FRB15-8M, FRB20-8M, FRB25-8M A
The direction of the right front wheel can be changed
using the front-wheel angle control lever. Three
positions are possible: straight-ahead, sideways, and B
at an angle (45°).
C
From neutral, press the lever all the way forward (A) to
put the right front wheel in the straight-ahead travel
position. The front-wheel angle indicator on the
instrument panel will look like this .
Pull the lever slightly back from neutral to put the right
front wheel at an angle (45°).
The front-wheel angle indicator on the instrument panel
will look like this .
Pull the lever all the way backward from neutral to put
the right front wheel in the sideways travel position.
The front-wheel angle indicator on the instrument panel
will look like this .
After changing the direction of the front wheel, check

the front-wheel angle indicator to make sure that
the front wheel direction has changed the way you
expected.
NOTE
· The top speed of the truck is automatically
restricted to 6 km/h if the front wheel is sideways
or at an angle.
· The operation of the lift, tilt, reach, and accelerator
levers is the same as that on standard reach
trucks.
2-18
TRUCK BODY
ARMREST (37)
ASSIST GRIP (35)
When operating the truck, put your right elbow on the 35
armrest (37) and hold the assist grip (35) with your 37
right hand.
This way, you can drive the truck more efficiently with
less fatigue.
COVER (19)
CAUTION
Make sure the cover is securely closed before
starting the truck.
An incompletely locked cover might open while
operating, causing an accident.
The cover can easily be opened and closed.

Pull the cover opening/closing lever (A) toward you to
open the cover. To close, press the cover until it clicks
to lock. A: OPENING/CLOSING LEVER
CUSHIONED PAD (25)
CAUTION
· Press your body against the cushioned pad
(25) while traveling.
If you become unstable while making a turn,
the brake pedal might be released and stop the
truck abruptly, which can cause an accident.
· Adjust the height of the cushioned pad to fit
you before starting the day’s work or before
each shift.
B: ADJUSTMENT BOLT
C: ADJUSTMENT RANGE
The cushioned pad supports your body while traveling.
Press your waist against the cushioned pad to remain
stable while traveling.
The cushioned pad is secured with two adjustment
bolts (B). Its height can be adjusted within a range of
70 mm (C). Adjust it to fit your body.
2-19
OVERHEAD GUARD (16)
CAUTION
· The overhead guard is an important safety
device which protects the operator from falling
objects.
· Make sure it is securely installed.
Do not use the truck with the overhead guard
removed or modified; otherwise it might cause
a serious accident.
2-20
INTERLOCK SYSTEM Interlock operation and how to

The interlock system is a safety device that cuts off release the interlock
the power to the drive and load handling circuits · If the key switch is in the “OFF” position:
when the operator leaves the compartment during Interlock operation
operation. This system helps prevent an accident ○ The forks won’t lower if the lift lever is placed
from happening if the operator is not in the correct in the “down” position.
driving position or if the controls are moved
unintentionally when no one is in the operator’s How to release the interlock
compartment. ○ Get on the operator’s compartment and turn
The truck won’t travel and the load handling the key switch to the “ON” position.
system won’t operate if the operator is not standing
in the operator’s compartment. The operator’s · If the key switch is turned from the “OFF”
presence is detected by a floor switch under the position to the “ON” position when you are
operator’s compartment floor. not standing in the operator’s compartment.
Interlock operation
○ The load handling system won’t operate if the
CAUTION
load handling levers are operated.
· Do not leave the operator’s compartment
○ The neutral status indicating light blinks,
while the forks are lowering. If the
interlock indicating light comes on, and the
interlock system is activated while the
error code “106” is displayed on the meter
forks are lowering, they will stop suddenly
panel.
and the load may shift or fall off the forks.
· D o n o t r e s t a n y t h i n g h e a v y i n t h e
How to release the interlock
operator’s compartment; otherwise the
○ Turn the key switch to the “OFF” position. Get
interlock system may fail to operate as it
in the operator’s compartment and then turn
should.
the key switch to the “ON” position.
· Do not modify the floor switch in the
The neutral status indicating light, interlock
operator’s compartment. The floor switch
indicating light and error code will go out.
is designed to turn on when the operator
gets into the compartment.
· If you leave the operator’s compartment with
· S t a n d p r o p e r l y i n t h e o p e r a t o r ’ s
the key switch in the “ON” position
compartment. An improper driving
Interlock operation
position may cause the interlock system
○ The interlock indicating light comes on and
to be activated.
the error code “105” is displayed on the meter
· If the interlock system is activated while
panel.
the truck is going up a ramp and the
○ The load handling system remains operative
truck stops, do not operate the reach
for 3 seconds after the operator leaves the
lever because the mast might move
operator ’s compartment. If more than 3
unexpectedly due to its own weight.
seconds passes, the load handling levers
· If the brakes are applied by the interlock
will become inoperative from outside the
system on a truck with an optional load
operator’s compartment.
handling attachment, do not operate the
attachment lever. The attachment might
How to release the interlock
move unexpectedly due to its own weight.
○ Get on the operator’s compartment properly,
and you will be able to actuate the load
handling system.
2-21
FORK STOPPER PIN (5)
CAUTION
· The forks should be set symmetrically to the
truck centerline, and the fork stopper pin
should always be set.
· When adjusting fork spacing, hold the load
backrest and push the forks with your foot. Do
not use your hand.
Pull out the fork stopper pin. Then adjust the fork
spacing in five stages laterally according to the size of
the load you are going to carry.
HYDRAULIC OIL TANK CAP/OIL DIPSTICK

The hydraulic oil tank cap is located under the front
cover.
Remove the cap and pour hydraulic oil through the fill
port.
The tank cap is fitted with an oil dipstick.
BATTERY ELECTROLYTE LEVEL INDICATOR (For

truck with optional battery)
The battery electrolyte level indicator is installed on the
battery case for checking the electrolyte level in the
battery without drawing out the battery.
The green lamp stays on to indicate that the level
indicator sensor is operating.
The red lamp comes on when the electrolyte level
gets close to the lower limit. If the red lamp blinks, add
purified water as soon as possible.
Check the electrolyte level in all cells periodically.
2-22
BATTERY RECEPTACLE (A)

36
CAUTION
· M a k e s u r e t h e b a t t e r y r e c e p t a c l e s a r e
disconnected before trying to touch any of the
internal electric parts. (A)
· The voltage is present in the main circuit even 26
if the key switch is turned off.
· Do not disconnect the battery receptacles
while traveling. The power steering system
becomes inoperative.
The battery receptacles couple and uncouple the

connection between the battery and the truck’s electric
parts.
NOTE
· When disconnecting the battery receptacles, first
turn the key switch “OFF” and press the power
cut-off knob (36).
· Before trying to connect the battery receptacles,
make sure the key switch is in “OFF”.
· When giving a charge to the battery with the truck-
mount charger, do not disconnect the battery
receptacles.
LIGHTS AND LAMPS
CAUTION
Check that lights and lamps come on and off
properly. If any light bulb is blown out, replace
with a new one. If the lens is contaminated or
damaged, clean or repair.
HEAD LIGHTS (1), TURN SIGNALS (15)

The truck has head lights and turn signal lights as
standard equipment. Keep the lenses clean and free
from damage at all times.
2-23
OPTIONAL EQUIPMENT CENTER MIRROR (BMC)

Here are some pieces of optional equipment which CAUTION
are deeply related to safe operation of the truck.
When traveling in reverse, turn your body
For more information about optional equipment,
and always look in the direction of travel. Do
consult your local UniCarriers dealer.
not rely too much on the center mirror.
STOP LIGHT
The center mirror is installed near the center of
STOP BACK-UP LIGHT (SBL)
the overhead guard to look behind for traffic and
· The stop light comes on when the brake pedal
obstacles.
is released (or when the brake is applied) to let
fellow vehicles in the rear of the truck know that
FIRE EXTINGUISHER (FE)
the brake is working.
Use the fire extinguisher for putting out a fire. An
optional fire extinguisher will be attached to one of
BACK-UP LIGHT (BUL)
the rear supports of the overhead guard.
· T h e b a c k - u p l i g h t c o m e s o n w h e n t h e
accelerator lever is placed in the backward
travel position to indicate the truck is traveling
backward.
REAR WORK LIGHT (RWL)
CAUTION
It is advisable to use an optional rear work
light when you are working in a place where
sufficient light is not available.
The rear work light illuminates the road or floor

behind the truck at night to allow the operator to
recognize obstacles, if any, on the road or floor
easily.
BEACON LIGHT
(RED, YELLOW) (RLR, RLY)
Use an optional beacon light in the case when the
truck is required to work near fellow workers or
bystanders or when the work place is noisy.
FORWARD TRAVEL CHIME (TAF)

When the truck travels forward, the chime sound
to let fellow workers know the truck is moving.
2-24
LOAD METER (OPTION)

The load meter measures the weight of the load being
carried on the forks.
The weight of the load is measured based on the
hydraulic pressure applied on the lift cylinders. The
measurement (1) should be used as a rough guide.
· The load meter measures the weight of the load
applied on the forks when the truck is stationary.
· The load meter function is available on the Main
screen and Fuel Consumption screen. 1. Measurement
· The load meters starts measuring the weight of

the load on the forks at 3 seconds after both the
traveling and load handling systems have come to a
complete stop. The measurement is performed for 4
seconds at a time with an interval of 0.5 seconds.
· During measurement, the meter panel indicates the
most-recent measurement result.
ZERO RESETTING
With the truck stationary and the Main screen
displayed, press the + button (2) and hold it down for a
while to reset the load meter.
2. + button
2-25
FORK POSITIONING LASER UNIT (OPTION)

A fork positioning laser unit is installed on the carriage.
It emits a visible laser beam to help the operator check
the fork height by looking at the meter panel to make it
easy to insert the forks into the openings in a pallet.
OPERATION
· Push the laser switch (2) forward to the “ON”
position and tilt the forks until they are horizontal and
a laser beam will be visible. The “Forks are level”
icon (1) is displayed on the meter panel.
· The “Forks are level” icon (1) can be found on the
Main screen and on the Fuel consumption indicator
screen.
NOTE
Remember that the forks may not be level even
if the “Forks are level” icon (1) is lit when there is
a heavy load on the forks, because the forks may
bend to some extent.
1. “Forks are level” icon 2. Laser switch
PRECAUTIONS WHEN USING THE FORK

POSITIONING LASER UNIT Laser beam caution decal
The fork positioning laser unit emits a laser beam. Make
sure to observe the following cautions when using the
unit to protect yourself and your fellow workers.
CAUTION
· Do not look directly at the laser light source or
a reflected laser beam in a mirror; otherwise
you may damage your eyes. If you accidentally
look at the laser beam and experience any
problem with your vision or feel discomfort in
your eyes, seek medical attention immediately.
· Let fellow workers know about the hazard of
the laser unit and make sure they do not look
directly at the laser beam.
· Verify that the fork positioning laser unit is
functioning properly before starting the day’s
work, or before each shift. If it is not working
correctly, contact your local UniCarriers
dealer. A laser beam is emitted from here.
· Do not try to disassemble or modify the fork
positioning laser unit. You may cause an
accident.
2-26
Laser beam width

CAUTION
· Do not use the laser unit in a place where
it will be subject to water splashes or
condensation will occur.
· Do not use the laser unit in a place where the
laser beam might cause equipment around it
to malfunction.
· The fork positioning laser unit is intended
to improve work efficiency, especially when
retrieving loads from an elevated position. The
operator is required to check the fork position
Max. A:B ≒ 1:0.8
by direct observation as well as by looking at
Min. A:B ≒ 1:0.35
the meter panel. C = The beam is less than 2 mm wide at a distance
· The fork positioning laser unit should only be of 5 m or less
used while the truck is on a flat surface. The A: Distance B: Beam length C: Beam width
fork position cannot be correctly monitored
on an inclined surface.
INSTALLING THE FORK POSITIONING LASER UNIT

· Install the laser unit (2) so that the laser beam
source is 30 mm above the surface of the forks (3).
· Adjust the limit switch (1) so that the laser beam is
only emitted when the forks are level.
CAUTION
The installation and adjustment of the laser unit
requires a high level of skill. Leave it to your
local UniCarriers dealer.
(Detail of area “A”)
1. Limit switch 3. Fork

2. Laser marker
2-27
LASER BEAMS
The fork positioning laser unit uses a laser. Laser safety requirements are defined in JIS C6802.
1) Laser safety
Unlike incandescent lamps, lasers can damage your skin or eyes if not used properly. The operator and
his fellow workers must be careful.
In particular, special care must be taken to protect the eyes. Do not look directly at a laser light source or
a laser beam reflected in a mirror. If you accidentally look at the laser beam and experience any problem
with your vision or feel discomfort in your eyes, seek medical attention immediately.
Do not look directly at the laser. Do not look a laser reflected in a mirror.
1. Laser beam source 2. Eye 3. Mirror
2) Laser classification by JIS (Japan Industrial Standard)

Light from lasers is classified into seven categories, according to the degree of hazard.
The UniCarriers fork positioning laser unit uses a laser to produce light that is in Class 3R.
Use caution when using the laser unit.
Class Degree of hazard

1 Class 1 lasers are safe for use under all reasonably-anticipated conditions of use.
Class 1M lasers are safe for use under all reasonably-anticipated conditions of use. However
1M
they may be hazardous if the user uses an optical apparatus within the beam.
Class 2 lasers are lasers emitting radiation in the visible portion of the spectrum. The power of
2 these lasers is such that they will normally be protected by a physiological aversion response
(blink reflex).
Class 2M lasers emit in the visible region in the form of a large diameter or divergent beam. It is
2M presumed that the human blink reflex will be sufficient to prevent damaging exposure, but if the
user places an optical apparatus within the beam, the laser output may become dangerous.
Class 3R lasers are potentially dangerous to observe directly, but the degree of risk is lower
3R
than a Class 3B laser.
Class 3B lasers are usually dangerous to observe directly. A diffuse reflection is usually not a
3B
hazard.
Class 4 lasers are dangerous to the eye if there is direct exposure to laser beam and may
4 cause a dangerous diffuse reflection. The direct beam can produce skin damage and can also
be a fire hazard. Due caution must be taken when using Class 4 lasers.
2-28
MEMO
3. OPERATION
CONTENTS
PROPER OPERATION........................................ 3-1

DURING BREAK-IN AND RELATIONSHIP
BETWEEN LOAD AND STABILITY OF
TRUCK............................................................ 3-1
BASIC LOAD CENTER AND RATED
LOAD............................................................... 3-2
THE STABILITY OF LIFT TRUCK................... 3-2
TRANSPORTING LIFT TRUCK...................... 3-3
OPERATING LIFT TRUCK.............................. 3-3
REMOVING AND REINSTALLING THE
BATTERY........................................................ 3-5
CHARGING THE BATTERY................................. 3-8
TRUCK-MOUNTED BATTERY CHARGER.......... 3-9
The following symbols, found throughout this CYCLE CHARGING (NORMAL CHARGE)..... 3-9
EQUALIZING CHARGE................................ 3-11
AUXILIARY CHARGE.................................... 3-12
conditions to the owner and the operator. CHARGING BEFORE LONG-TERM
STORAGE..................................................... 3-12
Become completely familiar with the truck before POWER SUPPLY EQUIPMENT FOR
proceeding with operating, checking and servicing. BATTERY CHARGER................................... 3-13
BATTERY ELECTROLYTE CARE...................... 3-14
BATTERY ELECTROLYTE LEVEL................ 3-14
STATIONARY BATTERY CHARGER................. 3-17
following safety alert indications. PICTORIAL NOMENCLATURE..................... 3-17
CHARGER CONTROL PANEL...................... 3-17
USING STATIONARY BATTERY
Failure to follow the instructions CHARGER..................................................... 3-18
serious accident or death. INSPECTION AND TROUBLESHOOTING
GUIDE........................................................... 3-20
WARNING the message might cause a serious POWER SUPPLY EQUIPMENT FOR
accident or death. BATTERY CHARGER................................... 3-22
Failure to follow the instructions in PICK-UP............................................................. 3-23
CAUTION the message may cause personal PICK-UP AND STACKING............................. 3-23
injury or damage to the truck or UNSTACKING............................................... 3-24
other property.
STORING........................................................... 3-25
the service life of the truck. The BEFORE STORING; DAILY STORAGE........ 3-25
NOTE message is not directly related to LONG-TERM STORAGE; OPERATING
accident prevention. AFTER LONG-TERM STORAGE.................. 3-25
PROPER OPERATION
To operate the lift truck safely and get the most

out of it, correct procedures are described on the
following pages:
DURING BREAK-IN
We recommend to operate the truck under light
load conditions for the first stage of operation to
get the most from it. Especially, the requirements
given below should be observed while the truck is
in a stage of 200 hours of operation.
★ Perform specified preventive maintenance
services carefully and completely.
★ Never “race” or play games with the truck.
Avoid sudden stops, starts or turns.
★ Oil changes and lubrication are recommended
to do earlier than specified.
RELATIONSHIP BETWEEN LOAD

AND STABILITY OF TRUCK
The lift truck keeps a balance of weight between
the truck and the load on the forks with the center
of the front wheels as a fulcrum when the rated
capacity load is placed in position.
Due care should be paid to the weight and the
load’s center of gravity to maintain stability.
If the rated capacity is exceeded, there is a danger FRONT REAR

WHEEL WHEEL
of the rear wheels being raised and in the worst
case, the truck will turn over, resulting in a fatal
LOAD FULCRUM REAR WHEEL LOAD
accident. The load placed near the fork tips
practically has the same effect that the weight of
the load is increased. In this case, the load weight
must be reduced accordingly.
3-1
PROPER OPERATION
BASIC LOAD CENTER AND RATED THE STABILITY OF LIFT TRUCK

LOAD The stability of lift trucks is stipulated in JIS
(Japanese Industrial Standards) or in other
CAUTION national industrial standards, and UniCarriers lift
· When traveling with loads, keep the forks trucks are manufactured complying with these
5 to 10 cm (2 to 4 in.) above the upper standards. However, note that the stability of lift
surface of the outriggers, retract the mast trucks is not assured at all times, but only when
fully and keep the forks tilted back fully. the following conditions are properly observed.
· The allowable load of a truck equipped with
an attachment is reduced in comparison · The ground or floor surface is level and hard.
with that of the standard truck. · The truck travels under standard loaded or
If the truck is equipped with a load- unloaded condition.
handling means such as a side shifter, · The truck is operated carefully and the forks
load grab, or rotating clamp, its allowable are properly manipulated; that is, the forks
load will be reduced as compared with are not tilted forward more than necessary,
that of the standard truck (a truck without when stacking or unstacking.
any attachment) for the following reasons: Load handling is carried out carefully and
Never exceed the allowable load indicated slowly.
on the load chart attached onto the truck
or attachment. In addition, keep the truck in good working
condition for safe operation and traveling.
Reasons for a reduction in the allowable
load: CAUTION
○ The weight of an attachment is added. Standard unloaded condition
○ The attachment shifts the basic load This means that the forks are raised 30 cm (12
center position forward, and thus the in.) above the ground or floor surface and tilted
allowable load is reduced. back fully without loads.
Standard loaded condition

This means that the forks are raised 30 cm (12
in.) above the ground or floor surface with a
load placed at the basic load center position of
the forks.
The basic load center is the distance from the front

face of the forks to the load’s center of gravity. The
chart given above shows the relationship between
the basic load center and the weight of loads to be
allowable for a reach truck with a capacity of 1 ton.
This chart is called a load chart and is attached to
the truck.
3-2
PROPER OPERATION
TRANSPORTING LIFT TRUCK OPERATING LIFT TRUCK

STARTING OPERATION
CAUTION
Transporting the lift truck on a trailer truck CAUTION
· Securely lock the lift truck in place to · P l a c e y o u r s e l f i n t h e o p e r a t o r ’ s
prevent it from moving on the trailer truck compartment properly when you turn the
by fastening with wire ropes and blocking key switch to “ON” to start the lift truck.
the wheels. · Make sure there is no one around the
· When loading or unloading the lift truck truck.
onto or from a trailer truck or when
traveling over public roads, pay attention 1) Turn the key switch to “ON”. (All items are
to the overall length, overall height, shown on the meter panel.)
and weight and observe the local traffic 2) Hold the steering wheel knob lightly with your
regulations. left hand.
3) Raise the forks 30 cm from the ground or floor
surface.
CAUTIONS TO BE TAKEN WHEN 4) Retract the mast fully.
LOADING AND UNLOADING LIFT TRUCK 5) Tilt back the forks fully.
CAUTION STARTING THE LIFT TRUCK

Never try to move the steering wheel when
halfway up a ramp; otherwise the truck might CAUTION
fall down, leading to a serious accident. · Make sure there is no one around the truck
and let other workmen and bystanders
· Use ramps of sufficient length, width, and know you are starting up by honking.
strength. · Slow down:
· Before loading or unloading the lift truck, make ○ at aisle intersections
sure to apply the parking brake to the trailer ○ in crowded areas
truck and block its wheels. ○ on rough ground or floor surfaces
· Ramps must be securely locked to the trailer ○ when approaching a load or an obstacle.
truck. Their surface must be clean and dry. · Traveling in reverse
· Loading and unloading must be carried out on a When you travel in reverse, look in
level surface. The right and left ramps must be the direction of travel and be alert for
the same height. pedestrians, other trucks or obstacles in
· When loading the lift truck onto a trailer truck, your path of travel. Do not rely too much
back it up the ramps slowly with care. on the sideview mirrors.
1) Press the brake pedal fully.

2) Tilting the accelerator lever gradually either
forward or backward will move the truck forward
or backward.
You can control the traveling speed by the
tilt angle of the accelerator lever.
3-3
PROPER OPERATION
TURNING
CAUTION
CAUTION · P a r k t h e t r u c k o n a l e v e l g r o u n d ,
Note that the rear end (counterweight) of the preferably in a wide area.
truck swings when you turn the truck. If parking the truck without load on a slope
is unavoidable, position the load handling
Unlike general passenger cars, the steer wheels means down-hill and block the wheels to
are located at the rear of the truck. This causes prevent accidental roll.
the rear end of the truck to swing out when a turn · Park the truck in a designated area or out-
is made. Slow down the truck and move toward a of-traffic area. If necessary, put signposts
side to which you are turning. The steering wheel or signal lights around the truck.
should be turned a bit earlier than as with the front- · Park the truck on a hard ground. Avoid
wheel steering car. soft ground, deep mud or slippery
· Grab the steering wheel knob with your left surfaces.
hand. · If you cannot lower the forks on the
· Your right hand is used to operate the load ground due to a broken load handling
handling levers. system, put a caution cloth to the fork end
and park in an out-of-traffic area.
· Pay attention to the ground condition
PARKING
because it might be slippery.
· Return the accelerator lever to neutral to lower
· Dismount from the truck after making sure
the speed.
it has come to a complete stop. Do not
· Release the brake pedal gradually to stop the
dismount from the truck in motion.
truck.
· Never jump off the truck.
· Dismount from the truck, facing the truck
When you park the truck, stop it in an out-of-traffic
and using the safety step and hand grip.
area and follow the procedure given below:
1) Retract the mast fully using the reach lever.
2) Tilt the forks forward fully using the tilt lever.
GROUND CONDITION
3) Lower the forks to make them in contact with
the ground or floor surface using the lift lever.
CAUTION
4) Turn the key switch to OFF, remove the key
and keep it sure. · Use due caution when traveling on a
5) Get off the truck carefully. rough surface.
· When crossing a railroad, be sure to
stop and ensure the safety, and cross the
railroad track at an angle.
· Go around obstacles such as rocks and
stumps, or pot holes. If unavoidable,
reduce the speed and go over them
slowly and carefully. Use caution not to
damage the bottom of the truck. Cross a
small bump diagonally if the aisle width is
enough to do so.
Lift truck performance depends upon the ground

condition or floor condition and travel speed should
be adjusted properly.
3-4
PROPER OPERATION
REMOVING AND REINSTALLING

THE BATTERY
CAUTION
· Never place yourself between the battery
and the mast or the truck body.
· Make sure to remove and reinstall the
battery with the truck parked on a level
surface and in an area with no obstacles
in front.
· Keep the forks at a height of 100 to 300
mm and be sure the truck is unloaded.
· Make sure the key switch is “OFF”, the
forks are lowered to the ground or floor
surface and the battery receptacles are
disconnected before inspecting the
battery, adding battery electrolyte or water,
or replacing the battery.
· When mounting the battery, make sure the
hydraulic hose is placed on the hose guide
of the battery case and that the battery
cable is not twisted, kinked, or caught in
the battery case or the truck body.
41
REMOVING THE BATTERY
1) Pull back the reach lever (41) to retract the
mast fully.
2) Step on the battery lock release pedal (23) fully,
with the mast retracted fully.
3) Keeping the battery lock release pedal pressed
fully, push the reach lever forward. The battery
will come out as the mast moves forward.
REINSTALLING THE BATTERY

1) Make sure the hydraulic hose is properly placed
on the hose guide of the battery case.
2) Keeping the battery lock release pedal fully 41
pressed, pull the reach lever to retract the mast.
The battery case will be returned to its original
position by the mast movement.
3) When the battery case is returned back, the
hydraulic hose may come off the hose guide or
be raised from the hose guide. In that case, first
correct the position of the hydraulic hose and
push in the battery.
4) After making sure the mast has been completely
retracted, release the battery lock release pedal.
NOTE EXE and EXP specifications

If the battery lock release pedal does not return
fully when you release the pedal, step on the
pedal again and pull the reach lever to retract
the mast again.
3-5
PROPER OPERATION
FRB15-8M, FRB20-8M, FRB25-8M
CAUTION (Safety rules to observe

when operating the
FRB15-8M, FRB20-8M and
FRB25-8M)
· Do not turn, travel at an angle or handle
loads on an incline; there is danger of the
truck tipping over.
· Make sure there is no one near the truck
before trying to make a turn. In particular,
when making a pivot turn, the turning
radius is so small that the turning speed
tends to increase. Make turns slowly.
· C h e c k t o i n s u r e t h a t t h e r e i s a n
unobstructed path of travel when moving
sideways or at an angle. Travel sideways
or at an angle at low speed.
· Do not make sudden starts or stops when
moving sideways or at an angle; there is
danger that the load will fall off the forks.
· Keep the forks less than 30 cm above
the outriggers while the truck is traveling
sideways or at an angle.
· Do not operate the front-wheel angle
control lever while moving. If you want
to change the front-wheel angle, use the
following procedure:
1) Place the accelerator lever in neutral.
2) Release the brake pedal (to apply the
brake).
3) Make sure that the truck has come to a
complete stop.
4) Use the front-wheel angle control lever
to place the right front wheel in the
position you want (sideways, angled, or
straight-ahead). Check the front-wheel
angle indicator on the instrument panel
to make sure the front wheel is pointing
the way you expected.
· Whenever the front-wheel angle has
been changed, turn the steering wheel
counterclockwise slightly to check the
direction the truck will travel by looking
at the drive-wheel angle indicator on the
meter panel.
3-6
PROPER OPERATION
Changing the direction of the right front

wheel 46
A
The direction of the right front wheel can be
B
changed using the front-wheel angle control lever
C
(46). Three positions are possible: straight-ahead
(A), at an angle (C) and sideways (D).
D
Meter panel (example)
Front-wheel angle indicator
Drive-wheel angle indicator
Lever Indication Direction of wheel

position (front wheel) (front wheel)
A : Straight-ahead
Straight-
ahead
D : Sideways
Sideways
C : At an angle
At an angle
* B: Neutral
3-7
CHARGING THE BATTERY
CAUTION NOTE
· In order to prevent an electric shock · Make sure the electrolyte temperature is
accident, be sure to ground the power below 40°C when starting charging. If not,
supply equipment securely. wait until the temperature drops below 40°C.
· In order to prevent an electric shock · If the electrolyte temperature exceeds 50°C
accident, do not put your hand or anything while charging, the battery service life will be
inside the equipment; otherwise it will lead shortened.
to an accident if the power switch is ON or · Do not try to charge the battery when the
the battery receptacles are connected. ambient temperature is extremely low.
· Charge the battery in areas well ventilated Charging in a cold storage or outdoors in a
and not exposed to rain water. Keep cold region will shorten the battery service
flammable materials away from the area. life.
· I t i s r e c o m m e n d e d t h a t t h e f l o o r b e · Frequent overcharges or equalizing charges
covered with an acid-resistant material causes the battery’s electrolyte temperature
and be well drained, since there is a fear to rise, and if the electrolyte temperature
of acidic electrolyte spilling on the floor exceeds 50°C, the battery service life will be
during charge. shortened.
· Never smoke or use fire in the charging · Use a battery charger appropriate for each
area especially at the termination of battery capacity.
charging since explosive hydrogen gas Charging with an improper battery charger or
is released from the battery while being using a battery charger for the other purposes
charged. will cause a trouble.
· Do not disconnect the battery connectors · Do not disconnect the battery charger cable
while charging; otherwise sparks may be from the power source while charging. If the
fired, leading to a fatal accident. charger cable is disconnected by mistake,
· Switch over the input voltage switching press the charge stop button without fail.
taps according to the input voltage. · Check the battery charger and battery for
Consult the battery manual for its damaged or discolored plug or cable. Check
operation. If the input voltage does not the connectors for looseness. If any defect
agree with the setting of the tap, a burned is found, operation of the battery charger or
transformer or a short circuit due to battery should be halted until the problem is
deteriorated insulation might occur. corrected.
· Keep the key switch turned OFF while · Before trying to recharge the battery, check
charging, for safety’s sake. the electrolyte level of the battery. (For detail,
· Use fuses and non-fuse circuit breaker see section “BATTERY ELECTROLYTE
with the specified capacity. Do not use the LEVEL”.
power supply together with other kinds of · Use caution not to allow electrolyte to splash
equipment. Failure to do so will cause a over the truck body or electric components.
damaged battery or charger. If they are contaminated with electrolyte,
contact your local UniCarriers dealer.
3-8
TRUCK-MOUNTED BATTERY CHARGER
TRUCK-MOUNTED BATTERY
CHARGER Truck-mounted battery charger
CYCLE CHARGING (NORMAL CHARGE)

After the day’s work or each shift or whenever the meter
panel shows the low battery voltage alarm or the battery
discharge indicator drops to the level 4, recharge the
battery in the following manner.
If the battery has not discharged so much, the
microprocessor will control the charging process properly.
The length of time required for recharging varies with
the battery capacity and the amount of discharge. As a
rough standard, when the battery has discharged 75 to
100%, it will take 8 to 13 hours to recharge the battery
completely. 17. Battery charger control panel
18. Truck-side charger receptacle
NOTE
Remember that the battery discharge indicator does
not necessarily show the remaining battery time
accurately, and thus might not agree with the battery’s
state of charge displayed on the meter panel.
1) Turn the key switch to the “OFF” position.
CAUTION
Recharge the battery in a well ventilated place,
free from rain drops and naked flame.
2) Make sure the power supply equipment is OFF.

3) Connect the truck-side plug (3) of the battery
charger cable to the truck-side receptacle. 1. Ground pole
4) Connect the power supply plug (2) of the battery 2. Power supply equipment plug
3. Truck-side plug
charger cable to the receptacle (4) of the power 4. to power supply receptacle
supply equipment.
Battery charger control panel
CAUTION
· Make sure that the plugs are connected to the
receptacles securely.
· C h e c k t h e p l u g s a n d r e c e p t a c l e s f o r
deformation or discoloration. If any defect is
found, do not use the battery charger.
5) Turn on the power supply equipment.

6) Press the “START” button (3) on the battery charger
control panel.
The “Charging in progress” light (1) comes on and
charging starts.
While charging, you can hear the transformer 1. “Charging in progress” light
buzzing. The truck-mount type battery charger won’t 2. Super equalizing charge indicating light
start charging if the AC power supply is not turned 3. “START” button
4. “STOP” button
on or if the battery receptacles are not connected. 5. Super equalizing charge button
3-9
7) When the battery is fully charged in 8 to 13 hours Battery charger control panel
after the start of charging, the battery charger
automatically stops operation and the “Charging in
progress” light (1) goes out.
The length of time required for charging varies with
the amount of discharge of the battery.
8) After charging is completed, make sure the
“Charging in progress” light (1) on the charger
control panel goes out. Turn off the power supply
equipment and disconnect the batter charger cables.
NOTE
When removing the plugs, hold the plug body, not
the cord; otherwise the wires may be broken. 1. “Charging in progress” light
2. Super equalizing charge indicating light
3. “START” button
9) Before trying to start the truck, make sure to measure 4. “STOP” button
the specific gravity of each cell of the battery. 5. Super equalizing charge button
Fluid temperature Specific gravity

10°C 1.287
20°C 1.280 Battery charge level
30°C 1.273
40°C 1.266
CAUTION
· Never disconnect the battery charger plug, the
power supply plug or the battery plug while
charging.
· Do not run the truck or operate hydraulic
controls while charging.
· When you want to stop charging halfway,
press the “STOP” button.
· M a k e s u r e y o u r h a n d i s n o t w e t w h e n
connecting or disconnecting the plugs. Dry
your hand or put on a glove, if it is wet.
· The battery charger is a high-voltage device.
Never put your hand inside the equipment.
Otherwise, you might get injured.
The relationship between battery charge level and

battery voltage is as follows:
Level Battery voltage Level Battery voltage
1 52.4 V or less 6 55.7 V – 56.4 V
2 52.5 – 53.2 V 7 56.5 V or more
3 53.3 – 54.0 V 8 Timer starts operating
4 54.1 – 54.8 V 9 Time remaining until
interval is up: 2 hours
5 54.9 – 55.6 V
Time remaining until
10 Blinks interval is up: 30 min.
The charge level indicator goes out after the battery

has been completely charged.
3-10
EQUALIZING CHARGE Battery charger control panel

There will be some difference in voltage among the cells
of the battery if only automatic charge is repeated. (The
difference can be detected easily by unequal readings of
the hydrometer.) Equalizing charge is given to equalize
the all the cell voltages by attaining a complete of state of
charge.
AUTOMATIC EQUALIZING CHARGE

The truck-mount type charger automatically gives an
equalizing charge to the battery with the microprocessor.
Therefore, there is usually no need for the operator to do
anything.
MANUAL EQUALIZING CHARGE 1. “Charging in progress” light

2. Super equalizing charge indicating light
You can also give an equalizing charge manually. 3. “START” button
Give an equalizing charge in any of the following cases: 4. “STOP” button
· The battery has been overdischarged. 5. Super equalizing charge button
· Purified water has been added.
· The discrepancy in specific gravity among cells is more
than 0.02 (at the electrolyte temperature of 20°C).
Manual equalizing charge consists of normal charge plus
super equalizing charge.
When performing manual equalizing charge, give normal
charge to the battery and then give super equalizing
charge by pressing the “SUPER EQUALIZE” button (5).
While super equalizing charge is in progress, the
“Charging in progress” light (1) and “SUPER EQUALIZE”
light stay on.
SUPER EQUALIZING CHARGE

Super equalizing charge is composed of equalizing
charge and automatic auxiliary charge. Since auxiliary
charge is automatically carried out every 24 hours after
an equalizing charge is carried out, you don’t need to
worry about a low battery voltage even after the track is
not used for several days.
Super equalizing charge can be carried out by pressing
the “SUPER EQUALIZE” button (5) after normal charge is
completed.
NOTE
Frequent full-discharges of the battery will shorten the
battery service life. If your task requires full discharge
of the battery frequently, it is advisable to use a high-
capacity battery or have a spare battery.
The “SUPER EQUALIZE” light (2) does not go out even

after charging is automatically completed (“Charging
in progress” light (1) goes out). Turn off the light in the
following manner:
· When the “Charging in progress” light (1) is on, press
the “STOP” button (4).
· When the “Charging in progress” light (1) is off, press
the “SUPER EQUALIZE” button (5) or turn the key
switch to the “ON” position.
3-11
“Charging in progress” light blinking
If the “Charging in progress” light on the control panel

is blinking, it indicates that charging has not been
successfully completed.
· The “Fail” timer of the battery charger functions and
charging is forcefully discontinued in 14 to 16 hours.
· The electric power failure lasts for more than 120
hours while charging.
NOTE
While the “Charging in progress” light is blinking,
you cannot recharge the battery. It is necessary to
check the cause of trouble and fix it.
For the procedure for troubleshooting, consult your
AUXILIARY CHARGE
CAUTION
Press the “STOP” button when you want to stop
charging halfway.
If the remaining battery time on the meter panel unit

shows level 4 or less after the day’s work or each shift,
give the battery an auxiliary charge during a break. The
procedure for giving an auxiliary charge is the same as
that for normal charge.
Deep discharging will harm the battery. Give an
auxiliary charge in good time.
CHARGING BEFORE LONG-TERM STORAGE

Give the battery an equalizing charge if the truck is to
be placed out of service for two weeks or longer. Give
an equalizing charge once in every 15 to 30 days while
the truck is out of service.
3-12
POWER SUPPLY EQUIPMENT FOR BATTERY CHARGER
CAUTION
· The power supply equipment must be installed
under the directions of a qualified electrical
engineer or by a subcontractor designated by
your local utilities company.
· The power supply equipment for the charger
must have a power supply line switch with a
dedicated circuit breaker.
· The capacities of the power supply equipment
and fuses or breakers should be selected
properly, referring to the table below; use
of fuses or circuit breakers with insufficient
capacity will cause damage to the power
supply equipment or charger or an accident
might occur.
· Imperfect grounding will lead to electric shock
accident.
· M a k e s u r e t o g r o u n d t h e e a r t h p o l e s o f
the receptacle on the power supply side;
otherwise there is a danger of causing electric
shock accident.
Power supply equipment for truck-mounted battery charger

Power supply- Fuse or circuit
Applicable truck Battery capacity Capacity
side plug of Model breaker capacity
model (Ah/5h) (kVA)
charger cable (A)
201
FR(H)B10/13-8C 220
K47-215C048 3.6
201
FR(H)B10/13-8
Ground 3P20A, 225 15
250V FR(H)B14/15/18-8 280
FRB15-8M K47-227C048 4.8
312
FRHB14/15/18-8W1
FR(H)B14/15/18-8 370
320 K47-230C048-428 5.4
FR(H)B20/25-8 345
Ground 3P 30A, 20
FRB20/25-8M 390
250V FR(H)B30-8 440 K47-240C048-421 7.4
445
3-13
BATTERY ELECTROLYTE CARE
BATTERY ELECTROLYTE CARE BATTERY ELECTROLYTE LEVEL

Keep the battery electrolyte level at the
CAUTION specified value at all times.
The battery electrolyte contains dilute sulfuric Due to evaporation and decomposition while
acid, a very corrosive material. Use special charging, the water content of the electrolyte
caution when you handle it. decreases.
If an accident takes place, take the following
emergency measures and get medial attention. NOTE
Battery electrolyte will cause painful and · If a low electrolyte level is neglected, the
serious burns if it gets on the skin. It can cause pole plates will get deteriorated, causing
blindness if it gets into eyes. a short service life of the battery. It the
· If battery electrolyte comes in contact with the electrolyte level is low, add distilled or
skin, flush it off immediately with a copious purified water. Do not use tap water.
amount of water. · Addition of distilled water or purified
· It electrolyte gets into you eyes, flush it off water should be made before charging
immediately with a copious amount of water so that the electrolyte and water added
for about 15 minutes. can be mixed well in the battery through
· If anyone swallows electrolyte accidentally, charging. If water is added, there usually
let him rinse out his mouth with a copious occur discrepancies in specific gravity
amount of water and drink a copious amount among cells. It is advisable to give the
of water or milk with egg white. Let him lie battery an equalizing charge.
quietly. · The electrolyte is consumed more
· If electrolyte comes in contact with clothing, quickly in the summer than in the
take off the clothing immediately. Wash the winter. In addition, remember that a
closing with water and then neutralize it with battery close to the end of its useful life
weak alkaline liquid soap. consumes more electrolyte.
· If a lot of electrolyte scatters or flows out, · D o n o t u s e a c o m m e r c i a l b a t t e r y
neutralize it with sodium bicarbonate or flush electrolyte additive. It might cause
it off with water. Report to the authorities damage to the battery.
concerned if necessary.
CHECKING ELECTROLYTE LEVEL
CAUTION Checking electrolyte level

· I f t h e b a t t e r y i s u s e d f o r a l o n g t i m e o r
Proper level Improper level
charging is performed with the electrolyte
Red float rod is visible. Red float rod is not
level below the “LOWER LEVEL”, the pole visible. Add water.
plates will get deteriorated and in the worst
case the battery might explode.
· Do not use open flame for checking the
electrolyte level; otherwise there is a fear of
ignition or explosion.
Check the red float rod in the vent plug to see if its top
end is visible.
3-14
ADDING WATER TO ELECTROLYTE
CAUTION
Overfilling purified water will cause a low
Adding water
specific gravity of the electrolyte.
Do not exceed the specified upper limit. Addition of water Overfilling of water
completed The white line on the
Open the vent cap of each cell and pour purified water The white line on the float rod is too high.
through the attached funnel into the cell. Stop adding float rod is just visible.
water when the white line on the red float rod in the
vent plug is visible. After adding water, close the vent
cap until it clicks. If the battery is charged with any vent
plug opened, the electrolyte splashes to contaminate
the battery case.
IF VENT PLUG IS CONTAMINATED

1. Float rod 2. White line
NOTE
The inside of vent plug may be contaminated. Clean
any contaminated vent plug with a neutral detergent
to keep the float visible.
Removing:
Turn the vent plug counterclockwise and remove it
from the vent cap.
Reinstalling:
Reinstall the vent plug in the reverse order of
removing. Make sure the vent plug and vent cap are
securely assembled.
When cleaning vent plugs, wear protective gears
such as protective glasses, rubber gloves, and
rubber-soled shoes.
CENTRALIZED WATER FILL UNIT (OPTION)

Remove the centralized water fill port cap and pour
purified water using the purified water tank. Stop
adding water when the red float rod reaches the top
position. After adding water, do not leave the cock of
the purified water tank open for more than 30 seconds;
otherwise overfilling of purified water will result.
3-15
CONVERSION OF SPECIFIC GRAVITY AT VARIOUS How to read hydrometer

TEMPERATURES
The specific gravity of battery electrolyte varies with
the temperature. To know the correct specific gravity
RUBBER BALL
of the electrolyte, you should measure the electrolyte
temperature, too, and convert the measured specific
gravity into the value at the standard temperature,
using the conversion table.
The standard specific gravity of the electrolyte in a fully
charged battery is 1.280 at the standard temperature
of 20°C. HYDROMETER
CONVERSION TABLE
Example:
Suppose the electrolyte temperature is 5°C and the
hydrometer reads 1.250. When converted into the
HYDROMETER READING
specific gravity at 20°C, the figure is 1.240, 0.040 lower
SPECIFIC GRAVITY AT 20°C
than the standard value. Normal charge is needed.
TEMPERATURE °C
3-16
STATIONARY BATTERY CHARGER
STATIONARY BATTERY CHARGER (Standard type) (Fast-charge type)

(OPTION)
The battery can be recharged using either of a truck-
mounted battery charger or a stationary battery
charger. This section covers the operating instructions
of the stationary battery charger. For handling the
battery, see the section “TRUCK-MOUNTED BATTERY
CHARGER.”
1. Charger
The stationary charger can be divided into two types: 2. Cover
standard and fast-charge types. 3. Air vent
4. Charger control panel
5. Input ground-fault circuit breaker
6. Maintenance cover
CHARGER CONTROL PANEL
Automatic charge switch (8) and indicating light (7)
When the automatic charge switch (8) is pressed, a
normal charge is started.
During the normal charge process, the indicating light
(7) stays on.
Equalizing charge switch (10) and indicating light (9)

When the equalizing charge switch (10) is pressed, an
equalizing charge is started.
During the equalizing charge process, the indicating
light (9) stays on.
7. Automatic charge indicating light
Stop switch (11) 8. Automatic charge switch
When the stop switch (11) is pressed, the charging 9. Equalizing charge indicating light
10. Equalizing charge switch
process is stopped.
11. Stop switch
12. Charge status indicating lights
Charge status indicating lights (12) 13. Error light
The indicating lights come on in sequence according to 14. Timer test light
the charge level.
Comes on when the charge level is 53.0 V
1st light (bottom) or more.
Comes on when the charge level is 55.0 V
2nd or more.
Comes on when the pole changing point is
3rd reached.
Comes on at the end of a timer interval of
the timer. Light does not come on when the
4th (top) battery becomes fully charged by the total
timer.
* The charge status indicating lights (12) stay on after

the end of a timed interval of the timer.
Error light (13)

Light comes on when an error occurs.
Timer test light (14)

Light comes on when a timer test is performed.
3-17
USING STATIONARY BATTERY CHARGER

· Recharging the lift truck battery using the stationary
battery charger should be performed only by
qualified personnel.
· Park the truck near the battery charger and turn the
key switch to the “OFF” position.
· Check the electrolyte level.
· Make sure that the battery charger is suitable for
the battery you are going to recharge, in particular
regarding the voltage and capacity, referring to the
name plate of the charger.
Connect the output plug of the charger to the battery
plug of the truck.
Turn on the ground-fault circuit breaker.
CAUTION
Make sure the output plug of the charger is
securely connected to the battery plug of the
truck. Improper connection of the plugs might
cause an overheated plug, lead to a fire.
· The automatic charge light (7) and equalizing

charge light (9) on the control panel come on. If the
automatic charge switch (8) is pressed, an automatic
charge will start. If the equalizing charge switch (10)
is pressed, an equalizing charge will start.
· Usually give an automatic charge, and give an
equalizing charge once a week.
AUTOMATIC CHARGE
1) Press the automatic charge switch (8). The 8. Automatic charge switch
automatic charge indicating light (7) comes on and 9. Equalizing charge indicating light
an automatic charge starts. 10. Equalizing charge switch
2) As charging progresses, the charge status 11. Stop light
12. Charge status indicating lights
indicating lights (12) come on in sequence from the
E side to the F side.
3) When charging is completed, all the charge status
indicating lights (12) come on with the other
indicating lights going out.
4) After charging is completed, turn off the ground-
fault circuit breaker and disconnect the battery plug.
5) If you want to stop an automatic charge halfway,
press the “STOP” switch (11).
If an automatic charge is stopped halfway, all
the charge status indicting lights (12) will go out
and both the automatic charge light (7) and the
equalizing charge light (9) will come on. After
making sure both lights (7, 9) come on, turn off
the ground-fault circuit breaker and disconnect the
battery plug.
3-18
CAUTION
· Never disconnect the power supply plug or
the battery plug while charging.
· Do not run the truck or operate hydraulic
controls while charging.
· When you want to stop charging halfway,
press the “STOP” swtich.
· M a k e s u r e y o u r h a n d i s n o t w e t w h e n
connecting or disconnecting the plugs. Dry
your hand or put on a glove, if it is wet.
· The battery charger is a high-voltage device.
Never put your hand inside the equipment.
Otherwise, you might get injured.
EQUALIZING CHARGE
1) Press the equalizing charge switch (10). The
equalizing charge light (9) comes on and an
equalizing charge starts.
2) As charging progresses, the charge status
indicating lights (12) come on in sequence from the
E side to the F side.
3) When charging is completed, all the charge status
indicating lights (12) come on with the other
indicating lights going out.
4) After charging is completed, turn off the ground-
fault circuit breaker and disconnect the battery plug. 8. Automatic charge switch
5) If you want to stop an equalizing charge halfway, 9. Equalizing charge indicating light
press the “STOP” switch (11). 10. Equalizing charge switch
11. Stop light
If an automatic charge is stopped halfway, all 12. Charge status indicating lights
the charge status indicting lights (12) will go out
and both the automatic charge light (7) and the
equalizing charge light (9) will come on. After
making sure both lights (7, 9) come on, turn off
the ground-fault circuit breaker and disconnect the
battery plug.
CHANGING CHARGING MODE

Stop charging once before changing the charging
mode.
3-19
INSPECTION AND TROUBLESHOOTING

GUIDE
Periodic inspection
· Inspect the stationary battery charger for damaged
input and output cables, cracked battery plug,
broken wire of the battery plug terminal, or defective
cooling fan at periodic intervals (every month),
replacing any defective part with a new one.
· Inspect the electromagnetic switch for poor contact,
replacing any defective electromagnetic switch with
a new one.
· Clean the exterior of the battery charger case every
three months.
Replacing the cooling fan (fast charge type battery

charger):
· The useful life of the cooling fan is about five years.
However it varies with the ambient temperature and
working environment. It is recommended to replace
with a new one earlier than that.
· For replacement of the cooling fan, consult your
Overhauling the battery charger

· It is recommended to overhaul the battery charger
every 10 years, replacing the control circuit board,
capacitor and other components with new ones.
· For overhauling, consult your local UniCarriers
dealer.
Troubleshooting guide
Standard type
1) If the check light (13) comes on, turn off the ground-
fault circuit breaker and disconnect the battery plug.
Electromagnetic switch Fuse

2) Remove the left-side cover of the battery charger
and check for a blown fuse or tripped thermal relay
of the electromagnetic switch. If any defect is found,
call your local UniCarriers dealer and let him know
the details of the trouble.
3) Do not turn on the ground-fault circuit breaker until
the cause of the trouble is removed.
A: Press to reset
B: Tripped state (black); normal (white)
3-20
Fast charge type

1) If the check light (13) comes on, check the charge
status indicating lights (12), turn off the ground-fault
circuit breaker and disconnect the battery plug.
2) Call your local UniCarriers dealer and let him know
the lighting of the four charge status indicating lights
(12).
3) Do not turn on the ground-fault circuit breaker until
the cause of the trouble is removed.
INSTALLING BATTERY CHARGER

· Install the battery charger in a dry, well-ventilated
area.
· Do not install the battery charger in a place exposed
to water including rain; otherwise there is a danger
of causing an electric shock accident or a fire.
· When a charging process reaches its end, a lot of
hydrogen gas is released from the battery. If the gas
density increases, there is a danger of an explosion.
The battery charger should be installed in a well-
ventilated area.
· When carrying the battery charger, hold the bottom
of the chassis.
· The battery charger generates heat during operation.
Make sure that adequate space is provided around
the battery charger, more than 10 cm at both sides
and rear side (A) and more than 30 cm above the
top surface.
· Working conditions:
Storage temperature -20°C to 60°C
Operating temperature 0°C to 40°C
30% to 90%(No condensation of
Humidity range
moisture allowed)
· The battery charger should be provided separately

with a 3-phase, 200V AC ground-fault circuit breaker
(MCB) at the input side.
· T h e i n p u t c a b l e s h o u l d b e c o n n e c t e d a n d
disconnected by qualified or authorized personnel.
· The input cable should be connected after all the
MCBs are turned off. The ground lead must be
grounded.
· Selecting and switching over input taps:
Standard battery charger
It is necessary to switch over the taps of the
charging transformer according to the AC input
voltage for charging.
Fast-charge type charger
It is necessary to switch over the settings inside the
charger according to the capacity of the battery to be
recharged. For selecting and switching over the taps
or settings, consult your local UniCarriers dealer.
3-21
POWER SUPPLY EQUIPMENT FOR BATTERY CHARGER
CAUTION
· The power supply equipment must be installed under
the directions of a qualified electrical engineer or by a
subcontractor designated by your local utilities company.
· The power supply equipment for the charger must have a
power supply line switch with a dedicated circuit breaker.
· The capacities of the power supply equipment and fuses
or breakers should be selected properly, referring to
the table below; use of fuses or circuit breakers with
insufficient capacity will cause damage to the power
supply equipment or charger or an accident might occur.
· Imperfect grounding will lead to electric shock accident.
· Make sure to ground the earth poles of the receptacle
on the power supply side; otherwise there is a danger of
causing electric shock accident.
Power supply equipment for the standard stationary battery charger

Battery Capacity (kVA) Recommended circuit
Applicable truck Power supply-side
capacity Model breaker capacity
model 50 Hz 60 Hz plug of charger cable
(Ah/5h) (A)
201
FR(H)B10/13-8C 220
K43-220C048-432 4.2 3.8
201
FR(H)B10/13-8 225 20
FR(H)B14/15/18-8 280
FRB15-8M K43-230C048-464 5.2 4.7
312 Ground 3P20A, 250V
FRHB14/15/18-8W1
FR(H)B14/15/18-8 370 K43-240C048-458 6.9 6.5 30
320 K43-230C048-464 5.2 4.7 20
FR(H)B20/25-8
FRB20/25-8M 390
FR(H)B30-8 440 K43-240C048-458 6.9 6.5 30
445
Power supply equipment for the fast-charge battery charger

Battery Recommended circuit
Applicable truck Power supply-side
capacity Model Capacity (kVA) breaker capacity
model plug of charger cable
(Ah/5h) (A)
201
FR(H)B10/13-8C 220
201
FR(H)B10/13-8 225 K29-250C048-401 7.0 30 Ground 3P30A, 250V
FR(H)B14/15/18-8
FRB15-8M 280
FRHB14/15/18-8W1
312
FR(H)B14/15/18-8 370
320
FR(H)B20/25-8 345 K29-250C048-401 11.0 50 Round terminal
FRB20/25-8M 390
FR(H)B30-8 440
445
Caution to take when disposing of the battery charger:

Used battery chargers are industrial waste. Disposal of used battery chargers should be taken care of by a
qualified industrial waste management contractor.
3-22
PICK-UP
PICK-UP STACKING
· The fork spacing should be as wide as possible
to maintain proper balance of the load. CAUTION
· Place the truck right in front of the load to be · Never tilt the mast forward with the load
handled. upraised except when the forks are over
· The pallet should be positioned parallel with the rack or a stack.
both forks. · D o not le a v e t he tr uc k wit h t he loa d
· Insert the forks into the pallet as far as possible. upraised.
· To raise the load from the ground:
Once lift the forks 5 to 10 cm off the ground or 1) When approaching the deposit area, slow down
floor surface, and make sure the load is stable. your truck.
Raise the load 5 to 10 cm above the outriggers. 2) Stop the truck before the area where your load
After making sure the load is stable and evenly is to be deposited.
positioned on the forks, tilt back the forks fully 3) Confirm the safety of the deposit position.
and retract the mast completely. Start running. 4) Tilt the forks forward until the forks become
· When handling a bulky load which restricts your horizontal and raise them until they are a little
vision, drive the truck in reverse. higher than the deposit position.
5) Move forward slowly to place the load directly
over the desired area and stop the truck.
6) Advance the load to the deposit position by
operating the reach mechanism.
7) Make sure the load is just over the desired
area. Slowly lower the load into position. Make
sure the load is securely stacked.
* If the pallet or load is not placed properly,
use the following procedure:
Pull about 1/4 of the forks off the load by
retracting the forks and raise the forks 5 to
10 cm. Advance the forks to the correct
deposit position and slowly lower the load
into position.
8) Fully retract the mast using caution not to hit
the pallet or load with forks. Make sure there is
no one or obstacle behind the truck and back
away.
9) After making sure the fork tips leave the pallet
or load, lower the forks to the basic traveling
position (20 to 30 cm off the ground or floor
surface).
10) Tilt back the mast.
3-23
PICK-UP
UNSTACKING
1) When approaching the area where the load is
to be retrieved, slow down the truck.
2) Stop the truck right in front of the load where
the distance between the fork tips and the load
is about 30 cm.
3) Check the condition of the stack.
4) Tilt the mast forward until the forks become
horizontal and lift up to the position of the pallet
or skid.
5) Make sure the forks are positioned properly for
the pallet. Move forward slowly and stop the
truck.
6) Insert the forks into the pallet as far as
possible.
* If the forks are hard to be fully inserted, use
the following procedure:
Insert 3/4 of the forks and raise them 5 to10
cm. Pull back the pallet or skid about 10 to
20 cm and lower the pallet or skid on the
stack. Insert the forks into the pallet fully.
7) Raise the forks 5 to 10 cm off the stack and
fully retract the mast by operating the reach
mechanism.
8) Make sure there is no one or obstacle behind
the truck and back away slowly to the position
where the load can be lowered to a safe
height.
9) Slowly lower the load to a height of 5 to 10 cm
above the upper surface of the outriggers. Tilt
back the forks fully and move to the desired
area.
3-24
STORING
BEFORE STORING LONG-TERM STORAGE

Perform the following checks in addition to
CAUTION “BEFORE STORING” and “DAILY STORAGE”
If any time your lift truck is found to be operations.
in need of repair, defective or unsafe, · Taking the rainy season into consideration, park
the condition should be reported to the the truck at a higher and hard ground.
supervisor, and the truck should be taken · Dismount the battery from the truck.
out of service until it has been restored to If the truck is out of service for more than two
safe operating condition. weeks, give an equalizing charge to recharge
t h e b a t t e r y f u l l y. D i s c o n n e c t t h e b a t t e r y
Before storing the lift truck, clean it thoroughly and receptacles.
perform inspection using the following procedure: · Even though the truck is parked indoors, if the
· Wipe away grease, oil, etc., adhering to the place is hot or humid, the battery should be
body of the truck with shop rag. Use water, if kept in a dry, cool place, and give the battery an
needed. auxiliary charge once a month.
· While washing the truck, check the general · Apply anti-rust to the exposed parts such as
condition of the truck. Especially check the truck cylinder rods and shafts that tend to rust.
body for dents or cracks, the tires for wear or · Cover components which may be caught
nails or stones in the tread. with humidity, such as the air breather and air
· Check for leakage of hydraulic oil. cleaner.
· Apply grease, where needed. · Put the truck in the operating state once a
· Check for looseness of the cylinder piston rod week and turn the key switch on. Warm it up
joints. sufficiently before moving the truck a little back
· Check the mast rollers to see that they rotate and forth.
smoothly. · Avoid parking on a soft ground such as an
· Lift the forks up to the top position and lower to asphalt ground in summer.
the lower limit. Repeat this procedure to prime
oil into the lift cylinders.
OPERATING AFTER LONG-TERM
STORAGE
DAILY STORAGE · Remove covers used to seal off moisture.
· Park the truck at a specified parking place and · Remove antirust from the exposed parts.
block the wheels. Charge the battery. · Drain gear oil from the drive unit. Wash inside
· Turn the key switch to OFF and slowly operate of the drive unit and pour new gear oil into the
each load handling control lever 2 to 3 times to drive unit.
let out the remaining pressure in the cylinders · D r a i n f o r e i g n m a t t e r a n d w a t e r f r o m t h e
and hoses. hydraulic oil tank.
· Remove the starter key and keep it sure. · Mount a fully-charged battery on the truck and
connect the cables.
· Perform preoperational checks carefully.
3-25
4. MAINTENANCE
CONTENTS
PREOPERATIONAL CHECKS............................. 4-1

CAUTION IN CHECKING................................ 4-1
PERIODIC INSPECTION..................................... 4-8
PERIODICAL REPLACEMENT OF SAFETY
PARTS............................................................. 4-9
CHECKS........................................................ 4-10
MONTHLY (200 OPERATING HOURS)
CHECKS........................................................ 4-11
GREASING.................................................... 4-12
The following symbols, found throughout this CHECKS........................................................ 4-13
manual, alert you to potentially hazardous 6 MONTHS (1200 OPERATING HOURS)
conditions to the owner and the operator. CHECKS........................................................ 4-13
Become completely familiar with the truck before CHECKS........................................................ 4-13
proceeding with operating, checking and servicing. PERIODICAL CHECK SCHEDULE . ............ 4-14


accident or death.
other property.
PREOPERATIONAL CHECKS
Before starting the lift truck, be sure to inspect

Items to be checked
the following items for safety sake and increased
productivity. 1 Defects found in previous checking
2 Caster wheels
3 Wiring
CAUTION 4 Battery electrolyte level
· I f a n y f a u l t i s f o u n d b y p r e o p e r a t i o n a l 5 Battery stopper
inspection, attach a sign in the control area 6 Load backrest
stating DO NOT OPERATE, remove the starter 7 Forks
key and report the condition to the supervisor. 8 Trail wheel
Operation of the truck should be halted until 9 Piping
the truck is completely repaired. 10 Drive wheel
· Check for oil leaks. Remember that oil leaks 11 Hydraulic oil
might cause a fire. 12 Brake pedal
· Before checking electrical equipment, make 13 Play of steering wheel
sure the battery receptacles are disconnected. 14 Meter panel
· If avoidable to check the truck with the forks 15 Horn
raised, make sure to put safety blocks between 16 Lights and lamps
the bottom of the inner mast and the ground 17 Load handling levers
surface to prevent the forks from falling. 18 Lift chain tension
· W h e n c h e c k i n g t h e t r u c k w i t h t h e m a s t 19 Overhead guard
advanced, put a pallet or something rigid 20 Brake test
between the mast and the truck frame, so that 21 Steering test
you will not be caught in between.
· Waste fluid caused from lubricant change
services must not be thrown away
thoughtlessly, because they will be a cause of
air, water, earth pollution. The service personnel
or employer is required to dispose of it properly.
CAUTION IN CHECKING
· Use UniCarriers’ genuine parts only.
· U s e U n i C a r r i e r s ’ g e n u i n e o r r e c o m m e n d e d
lubricants only.
· Clean the oil fillers and grease fittings using a brush
or cloth before supplying oil or greasing.
· Oil level checks and supply should be performed
with the truck parked on the level surface.
· Preventive maintenance services should be done
in an orderly manner with utmost care to prevent
personal injury.
4-1
General condition
Check the general condition of the truck, in particular,
the truck body for dents or cracks and tires for wear or
nails caught in the tread.
State of the truck

Check the inclination of the truck. If the truck is tilted
to either side, it suggests that the tires or wheels are
defective. Contact your local UniCarriers dealer.
Oil leaks
Check for oil leaks under the truck. If there is a pool
of oil on the ground or floor surface, contact your local
UniCarriers dealer.
1 DEFECTS FOUND IN PREVIOUS

CHECKING
CAUTION
Never try to operate a faulty truck.
Check to see if any defects found in the previous

checking have been repaired properly.
2 CASTER WHEELS
Check caster wheels for undue wear, damage or
cracks.
3 WIRING
Check that the battery cable, truck wiring, charger
cable and receptacles are properly installed and not
damaged.
4 BATTERY ELECTROLYTE LEVEL

Check that the battery electrolyte is at the specified
level using the battery electrolyte level indicators (green
and red lights).
5 BATTERY STOPPER
Check that the battery case is securely fastened to the
hook on the truck body.
A loose battery case will lead to an unstable operation
of the truck.
4-2
6 LOAD BACKREST
CAUTION
Do not modify or remove the load backrest. The
operator may get injured by a falling load.
Check that mounting bolts are not loose or missing.
7 FORKS
Check that the forks are installed securely and they are 1 : LOAD BACKREST
2 : FORKS
free from cracks or bends. 3 : TRAIL WHEEL
8 TRAIL WHEELS (FRONT WHEELS)

Check that trail wheels are not excessively worn,
damaged or cracked.
9 PIPING
Check that oil is not leaking from the piping and
cylinders (lift, tilt and reach).
10 DRIVE WHEEL
Check that the drive wheel is not excessively worn,
damaged or cracked.
4 : DRIVE WHEEL
4-3
11 HYDRAULIC OIL LEVEL

Check that the hydraulic oil is at the specified level.
Open the front cover, remove the hydraulic oil tank
cap and clean the oil dipstick with a clean waste cloth.
Reinstall it into the dipstick tube and remove again
to check the oil level by seeing the oil adhered to the
dipstick. The oil level should be between two slots on
the dipstick : H and L.
NOTE
The hydraulic oil level check should be made on a 1 : HYDRAULIC OIL TANK CAP / OIL DIPSTICK
level surface. You cannot check the level correctly 2 : H mark
3 : L mark
when the truck is inclined.
12 BRAKE PEDAL
Step on the brake pedal fully (to release the brake) and
then return the pedal to the original position slowly.
Check that the brake pedal moves smoothly.
4-4
Get into the operator’s compartment and turn

the key switch to “ON”.
NOTE
Make sure the brake pedal is released (or the brake
is applied) when turning the key switch to “ON”.
13 PLAY AT STEERING WHEEL

Turn the steering wheel (2) counterclockwise and
clockwise slightly to check for play in the peripheral
direction.
Check also that it does not have vertical looseness.
Play at the steering wheel in the peripheral direction:
30 – 70 mm.
1 : PLAY
2 : STEERING WHEEL
3 : KEY SWITCH
14 METER PANEL
Make sure that all items are displayed on the meter
panel when the key switch is turned to the “ON” position.
15 HORN
Press the horn button (6) to check that the horn sounds
properly.
4 : HEAD LIGHT SWITCH

5 : TURN SIGNAL SWITCH
6 : HORN BUTTON
16 LIGHTS
Turn on the head light switch (4) and turn signal switch
(5) to check that the head lights (7) and turn signal
lighs (8) are turned on and off properly. Check also that
the lenses are not dirty or damaged.
7 : HEAD LIGHT
8 : TURN SIGNAL LIGHT
4-5
17 LOAD HANDLING LEVERS

Move the load handling levers (lift, tilt and reach) twice
or three times to check that the forks operate smoothly
without squeaking.
Also check the levers for looseness.
NOTE
WARMING UP CYLINDERS
Before starting the day’s work or your shift, warm up
the cylinders. This lubricates packings and seals in
the cylinders to make them ready for operation.
18 LIFT CHAIN TENSION
CAUTION
Make sure the tension is the same on each chain
of the chain set; otherwise, uneven load will
occur so that the truck might tip over.
Raise the forks 5 cm off the ground or floor surface and

check that the tension will be the same on each chain
of the chain set.
If the tension is not equal, adjust it with the chain
anchor bolt.
After adjustment, securely tighten the lock nut of the
chain anchor bolt.
19 OVERHEAD GUARD
Check the overhead guard for loose mounting bolt or
nut and for cracks.
4-6
Run the truck at a low speed (in a safe place)
20 BRAKE TEST
Release the brake pedal to check that the truck slows
down and comes to a stop.
21 STEERING WHEEL TEST

Slightly turn the steering wheel to the right and left to
check that the truck is steered smoothly without any
problem.
4-7
PERIODIC INSPECTION
CAUTION
Be sure to read the section “INSPECTION AND
SERVICE” in this manual before checking or
servicing the truck.
Periodical checks are required to keep your truck in a

safe and good condition. Continual use of a damaged
or abnormal truck may cause a serious accident. Even
if it appears to be in a good condition, do not leave it
as it is. Early discovery of trouble which may cause
breakdown or poor performance will greatly improve
the working efficiency and operability, prolong its
service life, and lower the maintenance cost.
Preoperational checks, supply of oil and grease, and

cleaning of filter elements should be carried out by the
customer, and other complicated checks should be left
to your UniCarriers dealer. If checking or servicing is
performed without enough knowledge, special tools
or equipment, personal injury might occur. Every one
month of operation is calculated as 200 operating
hours in this manual.
4-8
PERIODIC INSPECTION
PERIODICAL REPLACEMENT OF
SAFETY PARTS
Recommended
Name of Safety Parts replacement
interval (years)
Load handling system hydraulic

1–2
hoses
Lift chain 2–4
Steering wheel chain 2–4
In order to perform safe operation, the importance

of preventive maintenance of the truck cannot be
overemphasized. Especially, the parts listed in the
above table must be replaced periodically since they
are the most important parts for safety of the truck
and operator. Moreover these safety parts are liable
to be damaged and deteriorated in the course of time,
and it is difficult to determine by ordinary maintenance
whether they are beyond their respective service limits
or not. The safety parts must be replaced with new
ones when their respective service limits have been
reached, even if their appearances are good.
NOTE
The safety parts are, however, not the objects of
warranty claim.
4-9
PERIODIC INSPECTION

CHECKS
Check the following items in addition to preoperational
checks.
Items to be checked
· Battery – Clean.
· Battery – Check battery electrolyte for specific
gravity and temperature and adjust if needed.
· Outriggers – Apply grease.
Preoperational and weekly checks should be

performed by the user of the UniCarriers battery type
fork truck.
Check the truck thoroughly to ensure safe and

comfortable operation.
■ CLEANING THE BATTERY

The top surface and joints of the battery must be kept
clean and dry. Tighten the plugs securely.
CAUTION
Do not clean the battery with dry or chemical
cloth as it may cause static electricity and
explosion. Always use damp cloth for cleaning.
For the procedure for checking the specific gravity,

temperature and adjustment of the electrolyte, see the
section “BATTERY ELECTROLYTE LEVEL”.
■ APPLYING GREASE ON OUTRIGGERS

Apply grease thinly to the central area inside of each of
the right and left outrigger frames (reach guides).
4-10
PERIODIC INSPECTION
MONTHLY (200 OPERATING HOURS) Items to be checked (in addition to

CHECKS preoperational and weekly (50 operating hours)
cheks)
Check the following items in addition to preoperational
and weekly (50 operating hours) checks. · Battery – Give an equalizing charge
· Battery – Check battery receptacles for
damage and looseness.
Adjustment and replacement of components and parts · Wiring – Check for damage and discoloration.
· Contacts – Check for roughness.
listed as monthly check items are difficult and need · C o n t r o l l e r – C l e a n a n d c h e c k f o r l o o s e
sufficient technical knowledge and special tools. connections.
· Accelerator lever – Check for proper operation
and looseness
· Battery charger – Check for proper operation
· Safety circuit – Check for operation.
■ LUBRICATING LIFT CHAIN · Brake linkage – Check for looseness
· B r a k e m i c r o - s w i t c h – C h e c k f o r p r o p e r
Apply engine oil to the lift chains using a lubricator or operation
brush. To allow oil to enter between each pin and link · Steering wheel – Check for play, looseness
and proper operation
plate of the lift chain, observe the following conditions: · Steering wheel chain – Check for tension and
lubrication
1) Loosen the chain sufficiently. · Greasing
2) After applying engine oil, move the mast up and ·. Drive unit support ....................................(1)
·. Greasing block ........................................(5)
down fully at least 10 times. ·. Steering shaft ..........................................(1)
·. Applying a thin coat of grease on the surface
of the brake cam
NOTE ·. Apply a thin coat of grease on the piston
head guide.
If your lift truck is used near a port or coastal area, · D r i v e u n i t – C h e c k o i l f o r l e v e l a n d
the lift chains might be damaged by salty breeze. contamination
· Drive unit – Check for noise
After a storm or typhoon, it is advisable to wash · Drive wheel, caster wheels, trail wheels (front
them with fresh water before lubricating in the wheels) – Check for damage and wear
· Wheel mounting nuts and bolts – Check for
manner described above. looseness
· Wheel bearings – Check for looseness, noise
and lubrication
· Rear axle – Check for proper operation and
looseness
· H y d r a u l i c o i l – C h e c k o i l f o r l e v e l a n d
contamination
· Pumps – Check for proper operation and oil
leaks
· Valves – Check for proper operation and oil
leaks
· Valve control lever – Check for looseness
· Valve control lever micro-switch – Check for
proper operation and damage
· Relief valve – Check for proper operation
· Hydraulic piping – Check for oil leaks and
damage
· Mast – Check for proper operation, damage
and looseness
· Reach guide – Check for looseness
· Sheaves – Check for proper operation, damage
and looseness
· Rollers (end, side and retaining) – Check for
proper operation, looseness and damage
· Cylinders (lift, tilt and reach) – Check for proper
operation and oil leaks
· Lift chains – Lubricate and adjust tension
· Forks – Check for cracks and deformation
· Overhead guard and load backrest – Check for
looseness, cracks and deformation
· Outrigger – Check for damage and deformation
· Major bolts and nuts – Retighten (new lift trucks
only)
· Attachment – Check for operation, oil leakage,
damage or deformation.
· Attachment – Check for proper installation.
4-11
PERIODIC INSPECTION
■ GREASING
(1) Drive unit support ..................................................1
(2) Greasing block . .....................................................5
(3) Steering shaft ........................................................1
Apply a thin coat of grease on the surface of the
brake drum and steering chain. 3
(4) Caster wheel (rear axle) ......................................1
Apply grease through the grease nipple indicated
by the arrow in the figure below. 1
(5) Lower likage . .......................................................2
You can find grease fittings under the floor mat.
2 4
MAST REAR SLIPPER

Apply grease on the guide areas indicated by the
arrows.
CAUTION
Do not climb the mast. Do not put your hand
or foot on the connecting members or into the
mast assembly. You might get injured if the mast
moves accidentally.
4-12
PERIODIC INSPECTION
3 MONTHS (600 OPERATING HOURS) Items to be checked

CHECKS
Perform the following checks in addition to · Motor (pump, power steering) – Check
preoperational, weekly (50 operating hours), and brushes for wear.
monthly (200 operating hours) checks. · Motor (pump, power steering) – Check
commutator for roughness.
· Motor – Check for operation or noise.
· Drive unit – Change gear oil (new lift
trucks only)
· E l e c t r o n i c e q u i p m e n t – C h e c k f o r
insulation
· Battery charger – Check magnet switch
for operation.
6 MONTHS (1200 OPERATING HOURS) Items to be checked

CHECKS
Perform the following checks in addition to · Battery receptacles – Check spring
preoperational, weekly (50 operating hours), monthly contact for surface roughness and
(200 operating hours) and 3 months (600 operating spring effect.
hours) checks. · Drive motor – Clean.
· Hydraulic oil tank – Change hydraulic
oil.
· Drive unit – Change gear oil.
· Hydraulic oil tank – Clean suction
strainer.
· Brake disk rotor – Check clearance
between the rotor and pads
· Relief valve – Adjust relief pressure.
· M a j o r b o l t s o f t h e t r u c k b o d y –
Retighten.

CHECKS Items to be checked
Perform the following checks in addition to · Battery charger – Check magnet switch
preoperational, weekly (50 operating hours), monthly for operation.
(200 operating hours), 3 months (600 operating hours), · Contactors – Check contact gap and
and 6 months (1200 operating hours) checks. adjust.
· Lift cylinder – Check for natural drop.
· Tilt cylinder – Check for natural drop.
· B r a k e p a d s – C h e c k f o r w e a r a n d
looseness
· Forks – Check for cracks in bent area
(color checks)
4-13
PERIODIC INSPECTION
PERIODICAL CHECK SCHEDULE

This check schedule is worked out on the assumption that the lift truck will be used under typical working
conditions. If the lift truck is used under severer working conditions, earlier check is required.
( ○ : Check and adjust, ● : Replace or add)
ELECTRIC SYSTEM
Before work Weekly Monthly Trimonthly Semiannualy Annually

Checking item Service Required Tool/remedy or shift (50 hrs.) (200 hrs.) (600 hrs.) (1200 hrs.) (2400 hrs.)
Check for contamination of battery case Cleaning ○ ○ ○ ○ ○
Add if
Check electrolyte level. ○ ○ ○ ○ ○ ○
necessary
Battery Measure and
Check specific gravity ○ ○ ○ ○ ○
adjust
Give equalizing charge ○ ○ ○ ○
Check for insulation Check ○ ○ ○
Check for contamination of the surface Cleaning ○ ○ ○ ○
Check for rough contact points of Check ○ ○ ○ ○
contactor
Controller Check for the gap between contacts Check / Adjust ○
Check for insulation Measure ○ ○ ○
Check for loose connections Check ○ ○ ○ ○
Check brushes for wear (pump, power Replace if
steering) needed ○ ○ ○
Check for roughness of commutator Adjust ○ ○ ○

(pump, power steering)
Motors Check for proper operation Check ○ ○ ○
Check for noise Check ○ ○ ○
Check for insulation Measure ○ ○ ○
Check for contamination Cleaning ○ ○
Check for proper operation (lamps) Check ○ ○ ○ ○
Check for proper operation and voltage Adjust ○ ○ ○
of voltage relay
Battery Check for insulation Measure ○ ○ ○
charger
Check for proper operation of magnet Adjust ○
switch
Check electronic timer for operation Adjust ○ ○ ○
Check for looseness Retighten ○ ○ ○ ○ ○ ○
Check for spring effect of contacts of Check ○ ○
Wiring, battery receptacles
terminals, Check for damage Check ○ ○ ○ ○ ○ ○
receptacles,
couplers Check for discoloration Check ○ ○ ○ ○
Check for surface roughness of contacts Check ○ ○
of battery receptacles
Check meter panel for operation Check ○ ○ ○ ○ ○ ○
Check for proper operation of horn Check ○ ○ ○ ○ ○ ○
Check head lamps for proper operation Cleaning ○ ○ ○ ○ ○ ○
Lights, lamps and contamination
and horn
Check rear lamp for proper operation Cleaning ○ ○ ○ ○ ○ ○
and contamination
Check turn signal for proper operation Cleaning ○ ○ ○ ○ ○ ○
and contamination
Check accelerator lever for proper Check ○ ○ ○ ○
operation and looseness
Others
Check safety device circuit for proper Check ○ ○ ○ ○
operation (test fuses)
4-14
PERIODIC INSPECTION
BRAKE SYSTEM

Brake Check for braking effect and looseness Check ○ ○ ○ ○ ○ ○
Brake pedal Check for height Check ○ ○ ○ ○ ○ ○
Check for proper operation of micro- Adjust ○ ○ ○ ○ ○ ○
switch
Linkage, rod Check for looseness and damage Adjust ○ ○ ○ ○
Check for greasing condition Apply grease ○ ○ ○ ○
Check for wear and looseness Check ○
Brake shoe
Check for clearance Adjust ○ ○
STEERING SYSTEM

Check for play, looseness and proper Check ○ ○ ○ ○ ○ ○
operation
Steering Check for chain tension Adjust ● (2 or 4

○ ○ ○ years)
wheel
Check for greasing of chain Apply grease ○ ○ ○ ○
Check of grease of steering shaft Apply grease ○ ○ ○ ○
Check for wear and damage Check ○ ○ ○ ○ ○ ○
Wheels (drive, Check for mounting condition Retighten ○ ○ ○ ○

caster and Check for looseness and noise of wheel
trail) Check ○ ○ ○ ○
bearings
Check for grease of wheel bearings Change ● ●
Check for oil leaks from drive unit gear Check ○ ○ ○ ○ ○ ○
case
Check for oil level of drive unit Change ● (1st

time only) ● ●
Check for noise, damage and cracks in

Rear axle drive unit gear case Check ○ ○ ○ ○
Check for lubrication of each linkage Apply grease ○ ○ ○ ○

Check for mounting condition
(deformation and damage of mounting Adjust ○ ○ ○ ○
bolts and coil springs)
4-15
PERIODIC INSPECTION
LOAD HANDLING SYSTEM

Check for oil level and contamination of Change ○ ○ ○ ○ ● ●
hydraulic oil
Hydraulic oil
tank Return filter Replace ● ●
Check suction strainer Cleaning ○ ○
Check for tension, damage and Adjust ○ ○ ○ ○ ○ ○
deformation
Lift chain and Check for lubrication Lubricate ○ ○ ○ ○
anchor pin
Check lift chain Change ● (2 or 4
years)
Hydraulic Check for proper operation, oil leaks, Check ○ ○ ○ ○ ○ ○
pump damage and mounting condition
Check for proper operation, oil leaks, Check ○ ○ ○ ○ ○ ○
damage and mounting condition
Check for proper operation of relief Measure
valve pressure ○ ○ ○ ○
Valve
Check for proper operation, looseness Check ○ ○ ○ ○ ○ ○
and damage of control lever
Check for damage, looseness and Check ○ ○ ○ ○
proper operation of micro-switch
Check for leaks, looseness, deformation Retighten ○ ○ ○ ○ ○ ○
Hydraulic and damage
piping ● (1 or 2
Check load handling system hose Change years)
Check for proper operation, cracks, Check ○ ○ ○ ○ ○ ○
looseness and bent
Check for proper operation, cracks and Check ○ ○ ○ ○
looseness of sheave (chain wheel)
Check for proper operation, looseness Retighten ○ ○ ○ ○
and cracks of hose real
Mast Check for looseness of reach guide Check ○ ○ ○ ○
Check for proper operation, looseness
and damage of each roller (end, side Retighten and
and retaining) and check for loose change ○ ○ ○ ○
mounting bolts
Check for proper operation, looseness, Check ○ ○ ○ ○
cracks and bent
Check for proper operation and oil leaks Check ○ ○ ○ ○ ○ ○
Cylinders (lift, Check for damage of piston rod, rod Check ○ ○ ○ ○ ○ ○
tilt and reach) screw and rod end
Check for natural drop Measure ○
Check for cracks in bent area Color check ○
Check for bent, crack and wear Check ○ ○ ○ ○ ○ ○
Forks
Check for bent, cracks, wear and Check ○ ○ ○ ○ ○ ○
damage of stopper pin
Check for cracks, deformation and Check ○ ○ ○ ○ ○ ○
Load backrest damage
Check for loose mounting bolts Retighten ○ ○ ○ ○ ○ ○
4-16
PERIODIC INSPECTION
TRUCK BODY AND OTHERS

Overhead Check for cracks and deformation Check ○ ○ ○ ○ ○ ○

guard Check for loose mounting bolts Retighten ○ ○ ○ ○ ○ ○
Check for cracks, damage and Check ○ ○ ○ ○ ○ ○
Outrigger deformation
Check for greasing condition Apply grease ○ ○ ○ ○ ○
Check for loose major bolts Retighten ○ (1st

time only) ○ ○
Truck body
Check for missing rubber of battery Check ○ ○ ○ ○ ○ ○
stopper
Check for proper operation, oil leaks, Check ○ ○ ○ ○
Attachment damage and deformation
Check for mounting condition Check ○ ○ ○ ○
Check for defects found in previous
Others Check ○ ○ ○ ○ ○ ○
checking
4-17
5. SPECIFICATIONS
& SERVICE DATA
CONTENTS
SPECIFICATIONS . ............................................. 5-1

LOAD CHART ..................................................... 5-7
SERVICE DATA.................................................. 5-10
REFILL CAPACITY........................................ 5-10
TRUCK SERIAL NUMBER AND SERIAL
NUMBERS OF MAJOR COMPONENTS...... 5-12
UniCarriers’ GENUINE PARTS...................... 5-12
FOR YOUR RECORDS . .............................. 5-13
The following symbols, found throughout this

conditions to the owner and the operator.

proceeding with operating, checking and servicing.


accident or death.
other property.
SPECIFICATIONS
Unit: mm
The specifications are subject to change without notice due to the improvement of quality.
5-1
Truck model Compact model Standard model
Leading particulars FRB10-8C FRB13-8C FRB10-8 FRB13-8 FRB14-8 FRB15-8 FRB18-8 FRB20-8 FRB25-8 FRB30-8
Max. load capacity kg 1000 1250 1000 1250 1350 1500 1800 2000 2500 3000
Load center mm 500
Max. fork height A mm 3000
Reach stroke B mm 405 555 405 555 580 725 650 795 685
Free lift C mm 105 110 410
Fork lifting speed (No load/Loaded) mm/S 540 / 330 540 / 340 540 / 330 540 / 320 540 / 310 540 / 290 480 / 270 480 / 250 400 / 210
Traveling speed (both forward and backward) S: 11 / 9,
S: 11.5 / 9.5, P: 11 / 9, P: 10..5 / 8.5, E:
(No load/Loaded) km/h S: 10.5 / 9.5, P: 10.0 / 9.0, E: 9.5 / 8.5 E: 10.5 / 8.5 10 / 8
Max gradability* (No load) % S: 14.3, P: 12.5, E: 10.0
(Loaded) % 10
Min. turning radius (most outside of body) D mm 1335 1480 1350 1490 1560 1750 1795 1965 2065
Overall length E mm 2000 2070 2110 2200 2225 2585
Overall height (mast) F mm 1995 2035 2085
(overhead guard) G mm 2245 2300
(Max. height during work) H mm 3845 3930
Overall width I mm 990 1090 1200
Wheel base J mm 1095 1245 1095 1245 1345 1525 1530 1700 1800
Tread (front wheel (K)/rear wheel (L)) mm 875 / 600 975 / 680 1065 / 725
Fork size (Length (M) x Width (N) x Thickness (O)) mm 920 x 100 x 35 920x100x38 920 x 122 x 40 1070x125x45
Fork spacing P mm 250 – 610 250 – 710 290 – 735
5-2
Weight (with battery)** kg 1820 1955 1865 2000 2055 2170 2245 2690 2825 3155
Brake Mechanical Disc
Controller (Drive / Load handling / Steering) FET inverter / FET DC chopper
SPECIFICATIONS
Drive motor (AC)

Rated output kW/min 4.3 / 60 6.1 / 60
Load handling motor
Power steering motor
Rated output kW/min 0.3 / 60
Storage battery**
Capacity AH/5h 201 280 320 390
Voltage V 48
Battery charger (option)
Type and charge method Truck-mounted quasi-stable voltage automatic charger
Input, phase and voltage V 3 / 200
Transformer capacity (50/60 Hz) kVA 3.6/3.0 4.8/4.3 5.4/4.5 7.4/6.2
Wheel
Front wheel ø255 x 114 (rubber) ø254 x 114 (urethane) ø267 x 135 (urethane)
Drive wheel ø330 x 145 (rubber) ø334 x 145 (rubber) ø380 x 165 (rubber)
Caster wheel ø178 x 73 (rubber) ø204 x 76 (rubber)
NOTE: * Computed values. ** With batteries specified by UniCarriers as a standard type for this series.
Truck model Compact model Standard model
Leading particulars FRHB10-8C FRHB13-8C FRHB10-8 FRHB13-8 FRHB14-8 FRHB15-8 FRHB18-8 FRHB20-8 FRHB25-8 FRHB30-8
Max. load capacity kg 1000 1250 1000 1250 1350 1500 1800 2000 2500 3000
Load center mm 500
Reach stroke B mm 555 580 725 795 685
Free lift C mm 105 110 410
Fork lifting speed (No load/Loaded) mm/S 540 / 330 540 / 340 540 / 330 540 / 320 540 / 310 540 / 290 480 / 270 480 / 250 400 / 210
Traveling speed (both forward and backward) S: 11 / 9,
S: 11.5 / 9.5, P: 11 / 9, P: 10.5 / 8.5,
(No load/Loaded) km/h S: 10.5 / 9.5, P: 10 / 9, E: 9.5 / 8.5 E: 10.5 / 8.5 E: 10 /8
Max gradability* (No load) % S: 14.3, P: 12.5, E: 10
(Loaded) % 10
Min. turning radius (most outside of body) D mm 1480 1490 1560 1750 1965 2065
Overall length E mm 2000 2070 2105 2740 2225 2585
Overall height (mast) F mm 2495 2535 2585
Overall width I mm 990 1090 1200
Wheel base J mm 1245 1345 1525 1700 1800
Tread (front wheel (K)/rear wheel (L)) mm 875 / 600 975 / 680 1065 / 725
Fork size (Length (M) x Width (N) x Thickness (O)) mm 920 x 100 x 35 920x100x38 920 x 122 x 40 1070x125x45
Fork spacing P mm 250 – 610 250 – 710 290 – 735
5-3
Weight (with battery)** kg 1910 2035 1960 2080 2140 2160 2330 2825 2940 3270
Brake Mechanical Disc
SPECIFICATIONS
Drive motor (AC)

Load handling motor
Storage battery**
Capacity AH/5h 201 280 320 390
Voltage V 48
Transformer capacity (50/60 Hz) kVA 3.6/3.0 4.8/4.3 5.4/4.5 7.4/6.2
Wheel
Front wheel ø255 x 114 (rubber) ø254 x 114 (urethane) ø267 x 135 (urethane)
Drive wheel ø330 x 145 (rubber) ø334 x 145 (rubber) ø380 x 165 (rubber)
Truck model FRHB14-8W1 FRHB15-8W1 FRHB18-8W1
Leading particulars
Max. load capacity kg 1350 1500 1800
Load center mm 500
Reach stroke B mm 515 655
Free lift C mm 1175
Fork lifting speed (No load/Loaded) mm/S 480 / 260 480 / 250
Traveling speed (both forward and backward) S: 10.5, P: 10.0, E: 9.5/
(No load/Loaded) km/h S: 9.5, P: 9.0, E: 8.5
Max gradability* (No load) % S: 14.3, P: 12.5, E: 10
(Loaded) % 10
Min. turning radius (most outside of body) D mm 1560 1750
Overall length E mm 2145 2185
Overall height (mast) F mm 1995
(overhead guard) G mm 2245
(Max. height during work) H mm 5195
Overall width I mm 1300
Wheel base J mm 1345 1525
Tread (front wheel (K)/rear wheel (L)) mm 1185 / 680
Fork size (Length (M) x Width (N) x Thickness (O)) mm 920 x 100 x 35 920 x 100 x 38
Fork spacing P mm 250 – 710
5-4
Weight (with battery)** kg 2380 2395 2520
Drive motor (AC)
SPECIFICATIONS
Load handling motor

Storage battery**
Capacity AH/5h 280
Voltage V 48
Transformer capacity (50/60 Hz) kVA 4.8 / 4.3
Wheel
Front wheel ø254 x 114 (urethane)
Drive wheel ø334 x 145 (rubber)
Caster wheel ø178 x 73 (rubber)
SPECIFICATIONS

Unit: mm
The specifications are subject to change without notice due to the improvement of quality.
5-5
Truck model FRB15-8M FRB20-8M FRB25-8M
Leading particulars
Max. load capacity kg 1500 2000 2500
Load center mm 500
Reach stroke B mm 580 650 795
Free lift C mm 105 410
Fork lifting speed (No load/Loaded) mm/S 540 / 310 480 / 270 480 / 250
Traveling speed (both forward and backward) S: 10.5, P: 10.0, E: 9.5/ S: 11.5, P: 11.0, E: 10.5/
(No load/Loaded) km/h S: 9.5, P: 9.0, E: 8.5 S: 9.5, P: 9.0, E: 8.5
Max gradability* (No load) % S: 14.3, P: 12.5, E: 10.0
(Loaded) % 10
Min. turning radius (most outside of body) D mm 1560 1790 1055
Overall length E mm 2070 2200 2225
Overall height (mast) F mm 1995 2035
Overall width I mm 1510 1655
Wheel base J mm 1345 1520 1690
Tread (front wheel (K)/rear wheel (L)) mm 1230 / 680 1340 / 725
Fork size (Length (M) x Width (N) x Thickness (O)) mm 920 x 100 x 35 920 x 122 x 40
Fork spacing P mm 250 – 710 290 – 735
5-6
Weight (with battery)** kg 2290 2970 3005
Drive motor (AC)
SPECIFICATIONS
Load handling motor

Storage battery**
Capacity AH/5h 280 320
Voltage V 48
Transformer capacity (50/60 Hz) kVA 4.8 / 4.3 5.4 / 4.5
Wheel ø254 x 114 (urethane) / ø267 x 135 (urethane) /
Front wheel 2 -ø254 x 65 (urethane) 2- ø267 x 75 (urethane)
Drive wheel ø334 x 145 (rubber) ø380 x 165 (rubber)
LOAD CHART
CAUTION
The load charts below refer to the lift trucks of standard specifications, and those with high mast
whose lifting height is less than 5m. Lift trucks with a high mast whose lifting height is 5m or
higher, or those with an attachment have different load charts.
FRB10-8C・FRHB10-8C FRB10-8・FRHB10-8
FRB13-8C・FRHB13-8C FRB13-8・FRHB13-8
FRB14-8・FRHB14-8 FRHB14-8W1
5-7
LOAD CHART
FRB15-8・FRHB15-8・FRB15-8M FRHB15-8W1
FRB18-8・FRHB18-8 FRHB18-8W1
FRB20-8・FRHB20-8・FRB20-8M FRB25-8・FRHB25-8・FRB25-8M
5-8
LOAD CHART
FRB30-8・FRHB30-8
5-9
REFILL CAPACITY
Capacity Oil Supplier & Class
Item FR(H)B10/13-8C
FR(H)B10/13/14/15/18-8 FR(H)B20/25/30-8 Lubricant
Location Standard Specification Trucks
FRB15-8M FRB20/25-8M
FRHB14/15/18-8W1
Class
R&O ANTIWEAR
Supplier
Hydraulic oil HYDRAULIC MOBIL Mobil DTE Oil Light Mobil DTE 24
16 ℓ 22 ℓ
tank OIL
SHELL SHELL TELLUS OIL C32 SHELL TELLUS OIL 32
ESSO TERESSO 32 NUTO HP 32
CALTEX Rando Oil 32 Rando Oil HD32
Class API Class GL-4 and Higher
Drive unit 2.1 ℓ 3.2 ℓ
Supplier GL-4 GL-5
Mobilube 40 Series Mobilube HD
MOBIL
(75W, 80W, 90) (75W, 80W, 60W-90, 90)
GEAR OIL
SHELL SHELL SPIRAX EP (80W, 90) SHELL SPIRAX HP (80W, 90)
Power steering
0.35 ℓ 0.35 ℓ ESSO GEAR OIL GP ESSO GEAR OIL GX
actuator case
5-10
ESSO
(80W, 80W-90, 85W-90) (80W, 80W-90, 85W-90)
Multipurpose Thuban EP
CALTEX Universal Thuban (80W, 90)
SERVICE DATA
(80W-90, 80W, 90)

Class
Lithium Base Multi-Purpose Grease (NLGI No. 0, 1 or 2)
Supplier
Greasing points MOBIL Mobil grease 70 Series, Mobil grease MP
[Chassis,
Proper amount Proper amount GREASE SHELL ALBANIA GREASE R Series, SHELL ALBANIA
bearings and SHELL
GREASE EPR SHELL RETINAX A
others]
ESSO BEACON Series
Marfak All Purpose 2, 3, Marfak Multipurpose 2, 3, Multifak EP
CALTEX
0, 1, 2
Note 1: Consult your local UniCarriers dealer for the details of specified lubricant brands.
SERVICE DATA
SERVICE DATA
Deflection of lift chain: ................................................. No difference in deflection between the right and left
chains when they are pressed by the thumbs of both
hands at the same time
Deflection of steering chain: ........................................ 3 – 8 mm (when the central area is pressed by a
finger with the force of 2 – 8 kg)
Height of brake pedal: ................................................. 50 – 55 mm
Clearance between brake disk rotor and brake pad: . . 0.5 – 0.6 mm (when the pedal is pressed; the
narrowest area between rotor and each pad)
Play of steering wheel: ................................................ 30 – 70 mm
(when the key switch is on)
LAMP CAPACITY
Head light .............................................. 48 V – 40 W
Turn signal . ........................................... 48 V – 25 W
* Work light............................................. 48 V – 40 W
* The light and signal marked with an asterisk are optional equipment.
FUSE CAPACITY
Truck model FR(H)B14/15/18-8
FR(H)B10/13-8C FR(H)B20/25/30-8
FRB15-8M
FR(H)B10/13-8 FRB20/25-8M
Fuse circuit FRHB14/15/18-8W1
F1 (drive) 225 A 225 A 225 A
F2 (pump) 225 A 225 A 225 A
F3 (EPS) 40 A 40 A 40 A
F4 (control) 10 A 10 A 10 A
F5 (lamp) 10 A 10 A 10 A
F6 (charge) 130 A 130 A 130 A
F7 (solenoid) 10 A 10 A 10 A
* As for the models marked with an asterisk, compact models are included.
5-11
SERVICE DATA
TRUCK SERIAL NUMBER

The truck serial number is imprinted at the front end
inside of the right outrigger as well as on the truck
decal.
When you make contact with your local UniCarriers

dealer about trouble or place orders, be sure
to notify the dealer of the truck serial number in
addition to the truck model.
A : TRUCK SERIAL NUMBER
SERIAL NUMBERS OF MAJOR

COMPONENTS
In addition to the truck serial number, the serial
numbers (unit numbers) of major components are
imprinted on the truck or indicated on decals. The
picture above shows the serial number plate of the
motor. These number plates should be retained for
future reference in servicing.
B: DRIVE MOTOR
C: PUMP MOTOR
UniCarriers’ GENUINE PARTS
However excellent the product is, it deteriorates as
used for an extended period of time. To ensure the best
performance of the lift truck, use the same genuine
UniCarriers parts as those used for new trucks.
When ordering spare parts, be sure to designate
UniCarriers’ genuine parts.
GENUINE UniCarriers LUBRICANTS

Use genuine UniCarriers lubricants for lubrication.
5-12
AFTER-THE-SALE SERVICE
FOR YOUR RECORDS
MODEL DATE OF PURCHASE
SERIAL NUMBER AUTHORIZED UniCarriers DEALER
WEIGHT (WITH BATTERY)
ALLOWABLE WEIGHT
MAST TYPE PHONE NUMBER OF AUTHORIZED

UniCarriers DEALER
MAST SERIAL NUMBER
NAME OF BATTERY MAKER AND

TYPE OF BATTERY
BATTERY CAPACITY
BATTERY SERIAL NUMBER
KEY NUMBER
TRUCK CONTROL NUMBER
NAME OF SUPERVISOR
ATTACHMENT
5-13
6. INDEX
INDEX
0 - 9
3 MONTHS (600 OPERATING HOURS) CHECKS................................................................................ 4-13
6 MONTHS (1200 OPERATING HOURS)CHECKS............................................................................... 4-13
A
ANNUAL (2400 OPERATING HOURS) CHECKS.................................................................................. 4-13
AUXILIARY CHARGE............................................................................................................................ 3-12
B
BASIC LOAD CENTER AND RATED LOAD............................................................................................ 3-2
BATTERY ELECTROLYTE CARE.......................................................................................................... 3-14
BATTERY ELECTROLYTE LEVEL........................................................................................................ 3-14
BEFORE STORING............................................................................................................................... 3-25
C
CAUTION IN CHECKING......................................................................................................................... 4-1
CAUTIONS TO BE TAKEN WHEN LOADING AND UNLOADING LIFT TRUCK..................................... 3-3
CHARGER CONTROL PANEL............................................................................................................... 3-17
CHARGING BEFORE LONG-TERM STORAGE................................................................................... 3-12
D
DAILY STORAGE................................................................................................................................... 3-25
DURING BREAK-IN................................................................................................................................. 3-1
E
EQUALIZING CHARGE......................................................................................................................... 3-11
F
FOR SUPERVISORS............................................................................................................................... 1-1
FOR YOUR RECORDS.......................................................................................................................... 5-13
G
GENUINE UniCarriers LUBRICANTS.................................................................................................... 5-12
GREASING............................................................................................................................................ 4-12
I
INSPECTION AND TROUBLESHOOTING GUIDE................................................................................ 3-20
INTERLOCK SYSTEM........................................................................................................................... 2-21
L
LEVERS AND PEDALS.......................................................................................................................... 2-15
LONG-TERM STORAGE....................................................................................................................... 3-25
6-1
INDEX
M
METER PANEL........................................................................................................................................ 2-5
MONTHLY (200 OPERATING HOURS) CHECKS................................................................................. 4-11
O
OPERATING AFTER LONG-TERM STORAGE..................................................................................... 3-25
OPERATING LIFT TRUCK....................................................................................................................... 3-3
OPTIONAL EQUIPMENT....................................................................................................................... 2-24
P
PERIODICAL CHECK SCHEDULE........................................................................................................ 4-14
PERIODICAL REPLACEMENT OF SAFETY PARTS.............................................................................. 4-9
PICK-UP................................................................................................................................................. 3-23
POWER SUPPLY EQUIPMENT FOR BATTERY CHARGER...................................................... 3-13, 3-22
R
REFILL CAPACITY................................................................................................................................. 5-10
RELATIONSHIP BETWEEN LOAD AND STABILITY OF TRUCK........................................................... 3-1
REMOVING AND REINSTALLING THE BATTERY................................................................................. 3-5
S
SERIAL NUMBERS OF MAJOR COMPONENTS................................................................................. 5-12
SERVICE DATA...................................................................................................................................... 5-11
STACKING............................................................................................................................................. 3-23
STATIONARY BATTERY CHARGER (OPTION).................................................................................... 3-17
SWITCHES............................................................................................................................................. 2-13
T
THE STABILITY OF LIFT TRUCK............................................................................................................ 3-2
TRANSPORTING LIFT TRUCK............................................................................................................... 3-3
TRUCK BODY........................................................................................................................................ 2-19
TRUCK-MOUNTED BATTERY CHARGER.............................................................................................. 3-9
TRUCK SERIAL NUMBER..................................................................................................................... 5-12
U
UNSTACKING........................................................................................................................................ 3-24
UniCarriers’ GENUINE PARTS............................................................................................................... 5-12
USING STATIONARY BATTERY CHARGER......................................................................................... 3-18
W
WEEKLY (50 OPERATING HOURS) CHECKS..................................................................................... 4-10
6-2
No. OB-7A0EE
ISSUED: September, 2008
REVISED: March, 2009
REVISED: December, 2011
REVISED: April, 2013
REVISED: September, 2013
MARKETING GROUP: Bellport E 6-22-7, Minami-Oi, Shinagawa-ku, Tokyo

140-0013, Japan
FAX:Japan +81-3-6730-3371
All rights reserved JB-1309001(SJ) Printed in Japan

Electric Forklift Truck: Operation & Maintenance Manual Maintenance Manual

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OPER. & MAINT. MANUAL

ELECTRIC FORKLIFT TRUCK

1. SAFETY TRUCK-MOUNTED BATTERY CHARGER..........3-9

6 MONTHS (1200 OPERATING HOURS)

5. SPECIFICATIONS & SERVICE DATA

FOR SUPERVISORS........................................... 1-1

The following symbols, found throughout this FOR SUPERVISORS

This chapter covers the methods of accident

• Pages 1-1 through 1-11 contain instructions

The diagram above indicates the meanings of the

■ TRAIN OPERATOR TO STACK SAFELY ■ WEAR PROTECTIVE GEAR

Unstacking Stacking Hard Hat

“Stacking” means piling up a palleted load or

■ PROVIDE AND MAINTAIN

Do not let people take chances. An operator who

■ KNOW WHO TO CALL IN AN ■ MARK THE TRAVEL LANES

■ MAKE AN OPERATING PLAN AND (Example)

Set appropriate speed limits on your company

No other personnel should be allowed in areas

■ KEEP UNAUTHORIZED VEHICLES ■ PROVIDE ADEQUATE LIGHTING

Safe operation requires well-lit traveling routes,

■ ASSIGN TRAFFIC GUIDES TO ■ KEEP THE GROUND LEVEL AND DRY

Be sure that all areas where the lift truck travels

■ SAFETY MEASURES FOR DANGER ■ DO NOT RELY ON THE OVERHEAD

If the truck is to be used on a loading dock,

■ PROPER USE OF THE LIFT TRUCK ■ IMPROPER USE

■ READ MANUAL AND DECALS ■ NO OPERATION WITHOUT LIGHTS,

Read the Operation & Maintenance manual

construction or strength of the truck must not be

The decals on the truck describe safety

For handling flammable materials such as

■ USE STURDY PALLET MATERIALS ■ KNOW THE WITHSTAND LOAD OF

Pallets and skids must be strong enough to

When stacking loads, place them in a stable

■ ALWAYS INSPECT BEFORE ■ NEVER USE AN UN-MAINTAINED

■ PERIODIC INSPECTIONS ARE ■ DESIGNATE A REPAIR AND

■ REPLACE SAFETY PARTS REGULARLY

■ TRANSPORTING THE LIFT TRUCK ■ NEVER RUN ON PUBLIC ROADS

Use a level, hard road surface when loading the

• Size, weight and shape of the load

balance the center of gravity of the truck and the

■ KNOW THE CENTER OF GRAVITY OF

Lift truck viewed from front

Basic load center

Load center (from fork root) mm

■ OUTSIDE THE TRIANGLE OF

■ RATED LOAD (LOAD WEIGHT AND LOAD CENTER)

HOW TO READ THE LOAD CHART

• Do not operate the controls (levers and pedals)

Stay away from the edge of road

Do not use man as an additional counterweight.

Do not travel over a floor or ground

Start, stop and turn slowly. Before turning, slow

Before reversing the direction of

Rear steer, rear swing

Reverse travel Brake the truck in good time

Do not turning off key switch during

Know the load bearing capacity of the