No.

OMFBE-30C170

OPERATION &
MAINTENANCE MANUAL
FORKLIFT TRUCK
Diesel powered

FD60-100Z8/1F6F60-100U

xIt is the responsibility of the Operator and Supervisor to read and understand this manual.
xProtect the earth and be kind to your lift truck.
 TO OWNERS
Thank you very much for your purchase of Mitsubishi Logisnext’s CONTENTS
product.
This manual has been written for operators, mechanics and SAFETY 1
supervisors of our forklift truck. This operator’s manual is your
guide to safe operation and regular preventive maintenance.
R E A D A N D U N D E R S TA N D T H I S M A N U A L B E F O R E BEFORE USE 49
OPERATING YOUR LIFT TRUCK. If any problem or complicated
trouble occurs, contact our dealer without hesitation. PICTORIAL NOMENCLATURE 51
Due to continuous improvements in design, it is possible that INSTRUMENTS & CONTROLS 53
the latest description contained herein may differ slightly from
the truck delivered to you. Moreover, the specification of the
forklift truck may be changed insignificantly depending on its 8-HOUR (DAILY) CHECK 73
destination.
•• T H I S M A N U A L S H O U L D B E C O N S I D E R E D A STORING 87
PERMANENT PART OF THIS LIFT TRUCK. IT SHOULD
STAY WITH THE TRUCK WHEN SOLD TO PROVIDE THE
NEXT OWNER WITH IMPORTANT OPERATING, SAFETY
OPERATIONS 89
AND MAINTENANCE INFORMATION.
PERIODICAL MAINTENANCE 105

OPTIONAL ITEM MAINTENANCE 127

SERVICE SPECIFICATIONS 129

REFILL CAPACITIES 131

SPECIFICATIONS 135
 IMPORTANT

The specifications and attachments of the trucks vary with different destinations.

Model Coding System

1F6 F 60 U

DESTINATION
U : General areas

FUEL TYPE
_ : Diesel Engine

LOAD CAPACITY RANGE

60 : 6.0 tons
70 : 7.0 tons (15500 lbs)
80 : 8.0 tons (17500 lbs)
100 : 10.0 tons (22000 lbs)

TRANSMISSION
F : Automatic Transmission (2-speed)

CAR MODEL
1F6 : 6-ton Series

ENGINE
_ : 6BG1
SAFETY

CONTENTS

FOR SUPERVISORS.................................................................... 2
QUALIFIED OPERATORS....................................................... 3
Planning and Working Area.......................................... 4
PROPER AND IMPROPER USES........................................... 7
Types of Vehicles and Loads....................................... 8
Inspection...........................................................................11
Transporting the Lift Truck..................................... 12
TRAVELING ON PUBLIC ROADS......................................... 14
MODIFICATIONS................................................................... 15
How the Lift Truck Works?............................................. 16
Traveling................................................................................ 19
Load Handling....................................................................... 26
Parking..................................................................................... 31
Inspection and Service..................................................... 33
PREVENTING VEHICLE FIRES................................................. 43
CAUTION PLATES...................................................................... 45

1
The following symbols, found throughout this manual, alert you to FOR SUPERVISORS
potentially dangerous conditions to the owner and the operator.
Become completely familiar with the truck before proceeding with Lift truck accidents cause dozens or hundreds of deaths every
operating, checking and servicing the truck. year, and even greater numbers of personal injuries.

This manual and the decals affixed to the truck use the following We have steadily improved the design and fabrication of its lift
safety alert indications. trucks so they may be used more safely and efficiently, but many
SIGNAL WORD CLASSIFICATION accidents still occur due to improper use. Accidents are often the
Failure to follow the instructions in the result of more than just “bad driving”. The use of inappropriate
DANGER message will likely cause a serious accident or types of equipment, the selection of inappropriate attachments
death. or accessories, inappropriate operating environments, careless
Failure to follow the instructions in the designation of operators, and failure to properly train the operator
WARNING message might cause a serious accident or
death. are other common causes of accidents.
Failure to follow the instructions in the
CAUTION message may cause personal injury or damage It is not possible to describe all potentially hazardous situations
to the truck or other property.
which may occur while operating, inspecting or servicing a
The information will help to prolong the service forklift truck. The warnings and cautions in this manual, including
NOTE life of the truck. The message is not directly
related to accident prevention. the decals attached to the forklift, are not intended to cover all
possible working hazards.
Right 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.
Forward Backward
This chapter covers the methods of accident prevention which are
primarily the responsibility of supervisory personnel.

Left • Pages 3 through 15 contain instructions which should be

The diagram above indicates the meanings of the terms “forward”, enforced by the personnel supervising the operation of the lift
“backward”, “right” and “left” used in this manual. truck. Please make sure the operators also read these pages.
• Page 16 through 48 and the following pages contain specific
precautions directly related to the operation of the lift truck.
2
 FOR SUPERVISORS QUALIFIED OPERATORS

■■TRAIN OPERATOR TO STACK SAFELY ■■WEAR PROTECTIVE GEAR

Hard Hat
Goggles
Unstacking Stacking Work
Clothes

Gloves Safety
Shoes

“Stacking” means piling up a palleted load or material directly on

• Always wear proper work clothes for driving. Work clothes
top of each other, without using racks or shelves to separate them.
should be designed to prevent any part from accidentally
If stacking work is not done properly, the loads may slip or fall,
catching on knobs or other parts of the truck or equipment. For
endangering the operator as well as fellow workers in the area.
example, shirts and trousers should have tight cuffs.
Safety classes should be held to train all operators in the proper
• Always wear a hard hat and safety shoes.
method of stacking and unstacking loads.
• Wear other protective gear as appropriate to the conditions of
(Your dealer can provide information about safety stacking
the work site, i.e., goggles or gloves.
training.)
■■PROVIDE AND MAINTAIN EMERGENCY EQUIPMENT
■■TIRED OR UNWELL? SEND THEM HOME!

Fire extinguishers and first aid kits should be provided and

Do not let people take chances. An operator who is overworked
maintained for use in case of a fire or accident. All personnel
or fatigued, an operator who is feeling unwell, or an operator who
should understand the location and use of emergency equipment.
is intoxicated must not be allowed in the driver’s seat.
3
FOR SUPERVISORS PLANNING AND WORKING AREA

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

Contacts in emergency
......................................
......................................
..............................
............................

Keep information on hand to allow immediate calls for help in case Designate the travel lanes for the lift truck and mark them clearly,
of a fire, accident or other emergency. so they will be kept free of obstruction.

■■MAKE AN OPERATING PLAN AND DISCUSS IT ■■SET SPEED LIMITS

(Example)

Yard Speed
Limit

Before using the lift truck, plan out the travel routes and operating Set appropriate speed limits on your company grounds, and post
procedures, and thoroughly discuss the details with all involved signs that are clearly visible.
personnel.
4
 FOR SUPERVISORS PLANNING AND WORKING AREA

■■KEEP PEOPLE OUT OF THE OPERATING AREA ■■ASSIGN TRAFFIC GUIDES TO CONGESTED AREAS

Closed to
Pedestrians

No
Pedestrians

No other personnel should be allowed in areas where the lift truck

is used. Post a traffic guide in confined or congested areas where other
Where other people must be present, post a guide whose job is to people or vehicles may pass. All personnel must obey the guide’s
make sure people stay clear of moving vehicles. signals.

■■KEEP UNAUTHORIZED VEHICLES OUT ■■PROVIDE ADEQUATE LIGHTING

unauthorized
No entry of

vehicles

Unauthorized vehicles must be kept out of the load handling Safe operation requires well-lit traveling routes, so pedestrians
areas. Post signs or give signals as required. and obstacles can be easily seen. Use headlights, taillights,
helmet lamps or other lights as appropriate.

5
FOR SUPERVISORS PLANNING AND WORKING AREA

■■KEEP THE GROUND LEVEL AND DRY ■■INSTALL CURBS OR RAILINGS

Be sure that all areas where the lift truck travels are level and If the truck is to be used on a loading dock, shore wall or other
regular. Clear away pools of oil or water. raised surface, install curbs or railings.

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

Post warning signs or take other appropriate measures to ensure The overhead guard is a protective device that will moderate the
that lift truck operators keep away from danger spots as they impact of an object falling from overhead, but it cannot withstand
travel. every impact. If a heavy object seems likely to fall on the truck,
make every effort to prevent it from doing so.
6
 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 which is placed

on the pallet and stacked within the prescribed height limit.
With a proper attachment, a lift truck may be used to transport a
load which is stacked elsewhere than on the pallet.

Transporting a person, elevating a person, and towing another

vehicle are examples of the improper use of a lift truck. Uses
which this manual specifies as improper must never be requested
or permitted, under any circumstances.
(Examples of Improper Use)
• Transporting or elevating a person on the forks or pallet.
• Carrying a person on the pallet to control the load.
• Hanging wire ropes from forks to lift a load.
• Towing another vehicle.
• Pushing a load or another vehicle with the forks.
• Using the forks or truck body to close or open the door of a
freight vehicle.
7
FOR SUPERVISORS TYPES OF VEHICLES AND LOADS

■■Read manual and decals ■■USE THE RIGHT TRUCK FOR THE JOB
Be sure the type and capacity of the lift truck is suitable for the
work environment.

Check Point Choice

Capacity Load capacities range from 1.25 to 10.0 tons. Pay

particular attention to the load center.
(Our Forklift Truck Capacities: 1.25, 1.5, 1.6, 1.75,
1.8, 2, 2.5, 2.75, 3, 3.2, 3.25, 3.5, 3.6, 4, 4.5, 5, 6, 7,
8 or 10 tons.)

Power Source Gasoline, natural gas, diesel, and battery- powered

models are available. Fuel costs and exhaust
composition will vary.
Read the Operation & Maintenance manual and caution plates
Balance On counterbalanced models, the counterweight at
on the truck, and become familiar with your truck and operating the rear makes the vehicle longer than reach trucks.
procedures. Remember that individual lift trucks might be different A reach truck performs loading and unloading by
in design and construction from one another. Observe the caution extending the front part of the mast outward, which
gives it the advantage of compactness.
decals on the truck. Keep this Operation and Maintenance manual
on the truck as a ready reference for anyone who may drive or Tires For indoor use, there are models with solid tires (best
service it. for reach trucks) and cushion tires (engine type or
battery type). Both are compact.
For outdoor use, pneumatic tires work well. Solid
■■KEEP DECALS LEGIBLE cushion tires, with the same dimensions as
pneumatic tires, may be the best choice in cases
where the load materials or surface conditions could
puncture pneumatic tires.

Flammable Materials For handling flammable materials such as

petrochemicals, a combustion engine is too
dangerous. An electric vehicle with explosion-proof
or safety-reinforced construction is required. (A
battery power source always offers better protection
against fire than a combustion engine.)

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.
8
 FOR SUPERVISORS TYPES OF VEHICLES AND LOADS

■■USE THE PROPER ATTACHMENT Popular Attachment Examples

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 : Roll Clamp ② : Rotating Fork
(For paper roll or drum handling) (For damping work or charging work)

③ : Hinged Fork ④ : Side Shift

(for lumber handling) (For precise stacking in containers
or other narrow spaces)

⑤ : Crane Arm
(For slinging work)

9
FOR SUPERVISORS TYPES OF VEHICLES AND LOADS

■■HAVE A GOOD VENTILATION ■■STACK LOADS SECURELY

When the engine is run indoors such as in an enclosed When stacking loads, place them in a stable manner that they will
warehouse, have a fresh-air ventilation. Exhaust fumes can not easily come apart, and be sure the weight is evenly distributed.
cause chemical poisoning, and in the worst case exhaust fumes Secure the top layer with a cord wrapped like a headband or in a
can kill. When warming up or operating the truck indoors, open similar fashion.
the windows and doors or use a fan to make sure there is a good
ventilation.
■■KNOW THE WITHSTAND LOAD OF YOUR FLOOR
■■USE STURDY PALLET MATERIALS

The lift truck is heavier than it appears. For example, a 2-ton truck
Pallets and skids must be strong enough to withstand the heavy weighs almost 3.5 tons even when empty. Furthermore, when
weights of loading and unloading. Remove or repair any damaged loaded, 80 to 90% of the total weight is concentrated on the front
pallet. wheels. Check the strength of your floors and roadways, and if
necessary reinforce them.
10
 FOR SUPERVISORS INSPECTION

■■ALWAYS INSPECT BEFORE OPERATING ■■REPLACE SAFETY PARTS REGULARLY

Recommended replace-
Name of safety parts
ment interval (year)
Master cylinder and wheel cylinder cups and
1 1
dust seals
2 Power steering hose 2
3 Reserve tank tubing 2–4
4 Fuel hose 2–4
5 Torque converter rubber hose 2
6 Rubber parts inside power steering unit 2
7 Lift chain 2–4
8 Load handling means hoses 1–2

Certain critical parts must be replaced at regular intervals. Since

The operator should always inspect the truck before each use it is difficult to detect wear on the above parts by visual inspection,
to verify that all essential safety features are working. Any they must be replaced at the intervals specified, because a failure
abnormality is to be reported to the supervisor, who is responsible would result in a falling load or runaway truck.
for correcting it.
■■NEVER USE AN UN-MAINTAINED TRUCK
■■PERIODIC INSPECTIONS ARE MANDATORY
Monthly and annual inspections must be performed thoroughly,
and any abnormality promptly repaired. Only a certified expert
who has the advanced skills and equipment is allowed to conduct
Out of
inspections. Service

A truck that has not passed an inspection must never be operated.

Hang a sign on the truck and remove the ignition switch, to make
sure no one uses it. Then report the problem to the supervisor
and wait for the repair to be completed.
11
FOR SUPERVISORS TRANSPORTING THE LIFT TRUCK

■■DESIGNATE A REPAIR AND ASSEMBLY ■■TRANSPORTING THE LIFT TRUCK

SUPERVISOR

Repairs and the mounting and dismounting of attachments must Use a level, hard road surface when loading the truck onto or
be performed under the direction of a designated supervisor. The unloading from a trailer and when unloading it. Be certain that the
body and major parts of the lift truck are quite heavy and under ramps have sufficient length and width as well as strength. Do not
very high pressure. Repair or assembly work undertaken without load or unload the truck when it is raining, unless the ramps are
careful and thorough preparation can lead to serious injury. 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.

12
 FOR SUPERVISORS TRANSPORTING THE LIFT TRUCK

■■USE OPTIONAL “LIFTING EYES” FOR LIFTING

YOUR LIFT TRUCK
WARNING
Never hoist your lift truck at its overhead guard or
counterweight; otherwise there is a danger of the truck
falling.
If hoisting the lift truck is necessary for any reason, use
the optional “Lifting Eyes.”
However, note that the “Lifting Eyes” are not available for
trucks that have a lifting capacity greater than 6 tons.

WARNING
Observe the following conditions when lifting the lift truck:
• Use optional “Lifting Eyes”.
• Use ropes strong enough to withstand the weight of the LIFTING
truck. EYES

• Do not use any wire rope which is kinked, deformed or

frayed.
• Lifting the truck should be performed only by qualified
personnel.
• Do not enter under a lifted truck.

13
FOR SUPERVISORS TRAVELING ON PUBLIC ROADS

■■GOT A LICENSE? ■■NO LOAD, NO TOWING

Before traveling on a public road, be sure that the truck has been It is usually illegal to carry a load on a public road. It is also not
licensed and inspected as required by local laws. allowed to make a sideways travel or tow another vehicle on a
public road (with the possible exception of a disabled vehicle).
Never tow another vehicle, even on company property.

■■OBEY TRAFFIC LAWS, AND TURN OFF YOUR LIGHTS

On a public road, the lift truck must obey the same laws as any
other vehicle. Do not use rear working light.

14
 FOR SUPERVISORS MODIFICATIONS

■■NO OPERATION WITHOUT LIGHTS, OVERHEAD ■■IMPLEMENTATION OF MODIFICATIONS

GUARD, OR BACKREST Only in the event that the truck manufacturer is no longer in
business and there is no successor in the interest to the business,
Load Overhead
Lamps
backrest guard the user may arrange for a modification or alteration to a powered
industrial truck, provided, however, that the user shall:
a) arrange for the modification or alteration to be designed, tested
and implemented by an engineer(s) expert in industrial trucks
and their safety;
b) maintain a permanent record of the design, test(s) and
implementation of the modification or alteration;
c) approve and make appropriate changes to the capacity
plate(s), decals, tags and instruction handbook;
The lift truck cannot be used if the headlights, taillights, overhead d) affix a permanent and readily visible label to the truck stating
guard, backrest, horn or turn signals have been removed. Any the manner in which the truck has been modified or altered
parts that have been temporarily removed for some reason must
together with the date of the modification or alteration, and the
be reattached immediately.
name and address of the organization that accomplished the
■■OBTAIN APPROVAL FOR ANY MODIFICATION tasks.

Modifications or additions that affect the capacity, construction or

strength of the truck must not be performed by the user without
the manufacturer’s or his authorized representative’s prior
permission. For example, don’t add a counterweight.
15
HOW THE LIFT TRUCK WORKS?

■■KEEPING THE TRUCK BALANCED ■■HOW THE CENTER OF GRAVITY SHIFTS

The higher the

load, the higher
the truck’s center
of gravity Truck’s center of
gravity with truck
tilted

Truck’s center of
gravity with high
mast raised
Truck’s center of gravity
Lift trucks are equipped with load handling means including a mast with standard mast
raised

and forks at its front part. The front wheels of the truck work as a Lift truck viewed from front

fulcrum to balance the center of gravity of the truck and the center
of gravity of the load. The relationship between the locations of
those two centers of gravity is vitally important for safety. The stability of the lift truck is determined by the overall center of
gravity, which is the product of the centers of gravity of the truck
■■KNOW THE CENTER OF GRAVITY OF YOUR LOAD and the load. When the truck is empty, this point is the same as
the center of gravity for the truck, and when it is loaded it shifts
according to the center of gravity of the load. Since the center of
Load’s
center gravity of the load changes whenever the mast is tilted forward
gravity

or backward or the fork is raised or lowered, the overall center of

Distance Weight x distance x moment
gravity also changes. The center of gravity is also governed by
(constant)
the following factors:
Allowable load (kg)

Basic load center

• Size, weight and shape of • Acceleration, deceleration
Load center (from fork root) mm the load and turning
• Unloading height • Surface condition and
Materials of various shapes such as boxes or flat or cylindrical
• Tilt angle of the fork gradient of the road
items may be loaded on the lift truck. In order to accurately judge
• Tire material • Type of attachment
the stability of the truck, it is vitally important for the operator to
know the location of the center of gravity for each type of load.

16
 HOW THE LIFT TRUCK WORKS?

■■OUTSIDE THE TRIANGLE OF BALANCE, THE ■■RATED LOAD (LOAD WEIGHT AND LOAD CENTER)
TRUCK TIPS
HOW TO READ THE LOAD CHART
The higher the load is raised, and the further forward
from the front wheels the load is moved, the more the
Rear weight of the load increases.
wheels (Slightly heavier loads can be carried with dual tires)
Axis of lateral stability
Point A Point C
If the center of gravity W1 moves
outward past the axis of lateral
stability, the truck will roll.
(As the center of gravity comes
closer to the rear axle, the space
between the centerline of the truck
Front and the axis of lateral stability
wheels narrows, and the truck will roll more
easily.)

Lift truck Viewed from Above

Point B Point D

For a lift truck to remain stable, the overall center of gravity must
be inside the triangle formed by the contact points of the left and
right front tires and the center point between the steering wheels.
The triangle defines the area of stability for the center of gravity.
If the overall center of gravity moves further forward than the The load center is the distance from the front face of the forks to
front wheels, the truck will tip forward with the front wheels as the the center of gravity of the load. The rated load is the maximum
fulcrum. If the overall center of gravity moves outside the triangle weight allowable with the nominal load center.
to the right or the left, the truck will fall over in that direction. The Load Chart, showing the relationship between the load center
and the rated load, is attached to the truck as a decal. The rated
load decreases as the load center moves toward the tip of the
forks, and as the overall center of gravity moves forward.

17
HOW THE LIFT TRUCK WORKS?

■■ACCELERATING, DECELERATING AND TURNING

The principle of inertia provides that a stationary object will remain
stationary as long as there is no external force acting on it, and
that a moving object will continue moving at a constant speed as
long as there is no external force acting on it.
Due to inertia, when the lift truck starts to move 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.

18
 TRAVELING

Do not operate the lift truck until preoperational checks 3) Adjust the steering column angle and driver’s seat position
are finished before starting the engine.
If any defect is found during checking, report it to the supervisor Do not try to adjust them during operation; otherwise a serious
and have it repaired. accident might occur.
Do not operate the truck until the malfunction or damage is After adjustment, make sure they are securely locked.
properly repaired. 4) Seat yourself in the operator’s seat and fasten the seat belt.
5) Press the clutch pedal (trucks with clutch) or brake pedal (trucks
Mount properly with torque converter).
6) Make sure there is no one under or around the truck, and start
the engine.

Do not move controls unless properly seated

Never mount or dismount a moving truck. When getting on and

off the truck, make sure the truck is at a complete stop and use
the recommended hand holds and steps with at least three points
of support (for example, put your left foot on a step, and hold a
hand hold with your left hand and the backrest of the seat with
your right hand). Keep the steps, hand holds and the seat always
clean. Repair if damaged. Do not operate the controls (levers and pedals) unless you are
properly seated.
When starting the engine
When starting the engine, make sure to:
1) Apply the parking brake securely.
2) Place the direction shift lever and speed range shift lever into
neutral.

19
TRAVELING
Sound horn when starting Never use persons as an additional counterweight

Before starting, make sure no one is near the truck. Let other
workmen and bystanders know you are starting up by sounding
horn. Do not use persons as an additional counterweight. Do not offer
rides to others.
Keep your hands clean
Avoid sudden starts, stops and sharp turns
It is dangerous to operate the steering wheel and levers with
greasy hands. If grease, oil or soil is sticking to your hands, clean
if off.

Keep the truck’s center of gravity low during traveling

(when loaded in particular)

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.
About 20 cm above ground
Before reversing the direction of travel, bring the truck
When traveling (when loaded in particular), keep the forks 20 to a complete stop
cm above the floor or ground and tilted back, so as to lower the
truck’s center of gravity as far as possible. It is dangerous to reverse the direction of travel abruptly.

20
 TRAVELING

Carry the load low Do not get into a soft ground area
It is dangerous to travel with forks lifted higher than is appropriate,
regardless of whether loaded or not. Keep the load as low as
possible while traveling. Do not turn the truck with the load raised
high.

Stay away from the edge of road

Avoid running on a slippery surface

Do not ride on obstacles (curb, railroad tracks, ditches)

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.

If unavoidable, be careful.

21
TRAVELING
Safe traveling: When going into areas where there are limits in height
and width, use the following cautions:

• Always look in the direction of travel

• Make sure there is enough height and width for the truck to pass.
Always look in the direction of travel; failure to do so will lead
• Do not put your hands and feet outside the truck.
to an accident. When passing an oncoming truck each other,
• Make sure there is no one around the truck.
slow down and use caution to have a safe distance. Moreover,
• Watch out for outdoor electric cables and other obstacles.
maintain a safe distance from the truck ahead of you at all
times.
Rear steer, rear swing
• 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 restricted
Do not go past other trucks at intersections, 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
When the truck is turned in forward driving, the rear of the truck
corners
swings outwards. Before turning, make sure there is enough
clearance from the wall and other obstacles.

22
 TRAVELING

Have a guide when handling bulky loads Traveling on slopes:

When loaded

When handling bulky loads which restrict your vision, operate the When unloaded
truck in reverse and have a guide.
• Do not make turns on a gradient. There is danger of the truck
Reverse travel upsetting.
• Keep the forks and pallet at an appropriate ground clearance
height.
• When operating an unloaded truck on grades, have the rear
end of your truck pointed up-hill.
• When operating a loaded truck on grades, have the rear end of
your truck pointed down-hill.
• When descending a grade, use engine braking.
If the truck goes faster than you want, press the foot brake
pedal from time to time. While using engine braking, do not
operate the shift lever(s) nor press the inching pedal.
When traveling in reverse, always look in the direction of travel.
Do not rely too much on the sideview mirrors (if so equipped) and
backup buzzer.

23
TRAVELING
Brake the truck in good time When driving over a dockboard:
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.
In addition, the stopping distance of the truck is longer on a
downhill. Keep the traveling speed under your control.

Do not shut off the engine during traveling

(trucks with power steering and power brake)
If the engine stops during traveling, both the power steering unit
and the power brake goes inoperative.

Engine braking is not available when the inching pedal • Do not ride on the edge of the dockboard or bridgeplates;
is pressed
otherwise the truck might fall down, leading to personal injury or
When the inching pedal is pressed to the bottom, the brake is even death.
applied to the truck, but engine braking is not available because
• Before driving over a dockboard or bridgeplate, make sure it is
the clutch unit is disengaged. 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.
• Drive carefully and slowly across the dockboard or bridgeplate.
• Watch for bystanders.
• Give instructions to the trailer driver not to move the trailer until
load handling is finished.
• Make sure the dockboard or bridgeplate is secured.

24
 TRAVELING

Know the load bearing capacity of the floor Stay inside if the truck seems like it is about to turn
Before entering a building or going into an elevator, make sure the over
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 The operator must always fasten his seat belt. If the truck turns
controls have their own characteristics even if the trucks are of the over, the operator might be thrown out and, in the worst case, the
same specification. If you change the trucks, keep this point in operator can be crushed under the truck causing severe injury or
mind. In particular, pay attention to the brake system. even death.
If it seems like the truck is about to turn over, stay in the operator’s
seat. Hold on to the steering wheel firmly, brace your feet firmly
on the floor, lean your body away the direction in which the truck
seems like it is going to turn over. Never jump out of the truck!

25
LOAD HANDLING
Keep anyone but a guide away from the working area • Do not use the truck to open or close the doors of freight cars
or warehouses.
• Do not push other trucks.
• Do not hoist loads, using ropes hung on the forks.
• Do not tow another vehicle using the draw bar.
• Do not push or pull loads with forks; otherwise, 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 that.

Pay attention to the fork tips

The fork tips are sharp and could cause personal injury. In
addition, if they catch on obstructions, the truck might lose control,
Do not let other persons or truck approach your lift
truck during operation leading to an accident.

When working in a group, have a person present to Adjust fork spacing properly
give guidance and follow his instructions Adjust the fork spacing suitable according to the size of the load.

Do not use your truck for purposes other than Adjust fork spacing with your feet
specified:

Adjust the fork spacing with your feet. Do not use your hands.
Your hands might get pinched between the forks and carriage.

26
 LOAD HANDLING

Make sure forks are securely locked Never lift a load over anyone
After adjusting the fork spacing, lock the forks with fork stoppers. WARNING
Unlocked forks will slide during traveling, causing the load to fall
off. Never permit anyone to stand under raised forks. The
forks might fall down unexpectedly, thus causing a
Do not put your hands or feet into the load handling personal injury.
system
WARNING
Never put your hands or feet on the mast or mast
connecting members; otherwise your hands or feet might
be cut if the mast moves unexpectedly.
WARNING

Never elevate a man Do not ride on front guard

WARNING
WARNING
Never allow other person(s) to ride on the forks. He might
fall off the forks, getting injured.

It is dangerous to use the truck body or mast as a ladder to ride

on a high place.
You might be caught between the mast and truck body, resulting
in a serious accident.

27
LOAD HANDLING
Do not pick up loads from other truck Use special caution when stacking or unstacking loads
Do not pick up loads from raised forks of other truck. This might When stacking or unstacking loads, stabilize them with ropes or
cause an off-centered load or the load to fall off. others, to prevent from falling off.

Do not hold loads on the forks by hand Use pallets and skids strong enough
Pallets and skids must be strong enough to withstand the weight
of loads. Use of a damaged pallet or skid might let the load fall off
the forks.

Use extreme caution when handling long or bulky

loads

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. Lift and lower the load carefully so as not to hit it against
something around the truck. Keep the load as low as possible.
Do not stack loads too high on forks Be careful when turning the truck, to prevent it from moving out of
Do not stack loads on forks in such a way that the top of loads position or falling off.
exceeds the load backrest height; otherwise, loads might fall on
the part of the operator, and in the worst case lead to a serious
Be alert for overhead hazards
injury or death. 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 comes in contact with them, the load
Do not lift unstable loads
might fall off the forks or the truck tip over. Remember that the
Do not handle unstable loads. When handling loose loads, make mast height becomes higher when the forks are raised.
sure they are stable enough before lifting.
28
 LOAD HANDLING

Never overload Do not tilt the mast with loads high

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 also danger of the truck tipping over.

Use minimum forward and reverse tilt when stacking and

unstacking loads. Never tilt forward unless the load is over stack;
otherwise the truck might tip over.

Do not lift or start with mast tilted forward

When the mast is tilted forward, do not perform the following
operations: lifting the forks and starting and traveling the truck.

Do not stack or unstack loads on a sloping grade

Do not jerk the forks (lift, down, and tilt) when loaded
The truck might tip over.
Do not squeeze loads into the stack
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.

Do not lift off-centered loads

Make sure that the loads are evenly positioned 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.

29
LOAD HANDLING
Keep the chains tight A strong wind might cause loads to spill or the truck
A slack chain means a mast rail or carriage hang-up, which might to tip over.
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:

Loads might spill or the truck could tip over due to a strong wind.
In particular, the risk of such an accident increases when the loads
are raised high. Stop the operation or take necessary measures
when a strong wind is blowing.

• 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, the truck might turn over. Keep
the load as low as possible.

30
 PARKING

Park at the specified area Do not park near flammables

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.

Block the wheels when parking on a slope

When parking a faulty truck

If unavoidable to park on a slope, apply the parking brake securely

Faulty
and block the wheels.

When it is not possible to lower the forks on the 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.

31
PARKING
Remove the key from a faulty truck and put up a sign When leaving the truck, observe the following
conditions:

erate
Do not op

Remove the starter key and attach a sign saying DO NOT

OPERATE. 1) Park the truck on an out-of-traffic area and lower the forks on
the ground.
2) Tilt the mast a little forward and make the fork tips in contact
with the ground surface.
3) Apply the parking brake.
4) Place the shift levers (direction and speed range) in neutral.
5) Turn the starter switch to the OFF position to shut off the
engine.
6) Remove the key.

32
 INSPECTION AND SERVICE

Inspection and maintenance must be performed only Wipe any spilt oil or grease
by qualified personnel Wipe any spilt oil or grease. If the truck is contaminated with oil
WARNING or grease, it is difficult for you to find possible cracks or other
defects.
Inspection and maintenance of the truck should be
performed only by qualified and authorized personnel.
Improper inspection, maintenance or repairs will cause No fire (when handling lubricants, batteries, cloth
damage to the truck or a serious accident. wetted with oil)
No fire. Never smoke or use fire or naked flame 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

Park on a hard, level ground
Do not use tools for purposes other than specified. It can cause a
Before performing inspection and maintenance, make sure to park serious accident.
the truck on a hard, level surface. Also make sure the place is dry
and without dust.
Avoid loose fitting clothing
Have a good ventilation Wear protective clothing called for by job conditions.
When performing inspection and maintenance indoors, have a
good ventilation. Wear safety gear devices (hard hat, safety shoes, safety
glasses, gloves)
Have a fire prevention equipment handy
Hard Hat
Goggles
Work
Clothes

Gloves Safety
Shoes

Have a fire prevention equipment handy whenever working

indoors. Know how to use it.
33
INSPECTION AND SERVICE
When working in a group, have a leader and follow his Make sure the forks and other attachment (if any) are
instructions on the ground

Before starting inspection, shut off the engine

If unavoidable to work under raised forks or
Make sure the engine is shut off before trying to start inspection or attachment, use a stable support under the inner mast
maintenance. and/or the carriage to prevent the forks or attachment
from falling down unexpectedly
Unless otherwise specified, shut off the engine
Unless otherwise specified, inspection or maintenance should be
performed with the engine shut off.

Before starting inspection or maintenance, place the

control levers in neutral

Do not put your feet under the forks

34
 INSPECTION AND SERVICE

Use caution not to get your fingers pinched in the • When carrying out checks or adjustment, do not use the
floor plates or hood connecting member or load backrest as a ladder. The mast
Be careful so as not to get your fingers caught when closing the might move unexpectedly, pinching or cutting your hands or
battery cover or doors. feet.
• Do not use the mast as a ladder. You might fall down from the
Use caution when making checks in elevated locations mast, leading to a serious accident.

Shut down the engine before working on rotating parts

Do not climb on the truck frame to inspect or service the truck. If

you must climb up on the truck, wear a hard hat and use caution
not to fall. When making checks or servicing in an elevated
location, use an appropriate step stool or work platform and wear Use due caution when working on rotating parts, not to get your
a hard hat, a safety belt and safety rope. body or fingers entangled in them. Before checking a rotating
part, make sure the engine is shut down. Do not bring something
Do not use the mast as a ladder: near rotating parts.

35
INSPECTION AND SERVICE
Make sure the engine is cool enough before servicing it Loosen radiator cap slowly to allow steam to escape

Hydraulic oil is hot immediately after the engine is shut

down
Immediately after the engine is shut down, the hydraulic oil is
hot and in high pressure. Do not try to drain the hydraulic oil or
replace the filter. Hot oil might spout out to cause burns.

Release oil pressure before working

The hydraulic circuit has residual pressure. Before working on the
system, release the pressure. To check for oil leaks, wear safety
Immediately after the engine is shut down, the engine oil is hot glasses and gloves and use a piece of cardboard or wood. High
and in high pressure. Do not try to drain oil or replace the filter. pressure oil penetrates the skin. It can cause blindness.
Hot engine oil might spout out to cause burns.
Use caution when removing the accumulator and its
Do not remove radiator cap when the cooling water hydraulic lines
temperature is high Before removing the accumulator or hydraulic lines from the
truck, make sure to shut off the engine and pump the brake pedal
at least 10 times to remove the oil pressure from the accumulator
and lines.
Incomplete removal of the accumulator oil pressure might cause
a burst line or a spurt of oil under high-pressure.

Precautions to take when handling the hood gas damper

• Do not disassemble the hood gas damper (high-pressure gas is
sealed inside it).
• Disposal of a used hood gas damper must be left to your
Immediately after the engine is shut down, the cooling water is hot distributor or to a specialist. Do not throw it in the trash.
and in high pressure. • Never throw a used hood gas damper into a fire.
Do not try to remove the radiator cap in this state. Hot cooling
water might spout out to cause a serious personal injury or burns.

36
 INSPECTION AND SERVICE

When high pressure oil comes in contact with your Use the specified brake fluid
body, immediately get medical attention
Use caution not to allow the entrance of dust into the
Do not try to jump start the truck. The truck might jerk, brake fluid reservoir
causing an accident
Use caution to keep the breather of the brake fluid
reservoir cap from clogging
Caution to be taken when starting the engine using a
booster cable:
Handling Long Life Coolant (LLC)
The LLC is flammable and poisonous. When storing it, attach
a label “Dangerous substance” and keep it out of reach of
children.
• The LLC is flammable. When handling the LLC, never smoke
or use fire or naked flame near the LLC.
• The LLC is poisonous. Do not swallow it. If anyone swallowed
it accidentally, let him drink a lot of water, induce vomiting and
get medical attention immediately.

Caution to be taken when jacking up the truck

• When starting the engine using a booster cable, wear safety
glasses. When starting the engine using the battery of another WARNING
vehicle, use caution to prevent the truck whose battery is dead Do not enter under the truck while it is jacked up. The
from coming in contact with the vehicle with a charged battery. truck might fall, getting you caught under it.
• Shut down the engine and connect the cable.
• Use caution to prevent the cable from getting entangled in the
fan or fan belt.
• Do not have the wrong connections of the booster cable. Use
due caution to prevent the positive (+) terminal from coming in
contact with the negative (-) terminal.

37
INSPECTION AND SERVICE
Cautions to be taken when handling batteries:
WOOD
BLOCK • If electrolyte gets on your skin, flush it off with a copious
amount of water
SAFETY
GLASSES

WEDGE

• Before jacking up the truck, remove the loads from the truck.
• When jacking up the truck, the operator must leave the truck.
Lift the truck a little off the ground surface and put supports at
both sides of the frame to prevent the truck from falling. The battery electrolyte contains dilute sulfuric acid, a very
• Before jacking up, block the wheels to prevent them from corrosive material. It can destroy most things it touches. It will
rotating unexpectedly. cause painful and serious burns if it gets on the skin. It can
cause blindness if it gets into eyes. If battery electrolyte comes
When hoisting the lift truck, use “Lifting Eyes” in contact with the skin or clothing, wash it away immediately
WARNING with a copious amount of water.
• If electrolyte gets into your eyes, get medical attention
Never hoist your lift truck by attaching ropes or wires to its If electrolyte gets into your eyes, flush it off immediately with a
overhead guard or counterweight; otherwise there is the
copious amount of water and get medical attention.
possibility of the chassis getting damage or falling.
If hoisting the lift truck is necessary for any reason such • If anyone swallowed electrolyte accidentally:
as transportation, use an optional “Chassis Lifting Eye”. Let him drink a copious amount of water or milk with egg white
For the Chassis Lifting Eye, consult your dealer. and salad oil mixed in it and take a rest. Send for a doctor.
• Wear safety glasses when handling batteries
• Lifting the truck must be performed only by qualified personnel Wear rubber gloves, rubber boots, safety glasses when
(for crane or slinging work). changing or charging batteries, adding battery electrolyte, or
• The truck must be lifted by attaching wire ropes to the adjusting the specific gravity of the battery electrolyte.
designated parts.
• Use strong wire ropes
Make sure the wire ropes are strong enough to lift the truck and
free from damage.

38
 INSPECTION AND SERVICE

• No fire • When charging the battery, follow the instructions in the

Since explosive hydrogen gases are always being released Instruction Manual of the charger
from the battery, there is a danger of causing an explosion. • No fire during charging
Never smoke or use fire or naked flame near the battery. No Batteries give off hydrogen gases during charging. No fire. No
sparks. sparks.
To prevent the generation of sparks, turn off the charger switch
before connecting or disconnecting the battery or charger cable.
• Do not put any metal tool on the battery case
• Do not short the battery terminals

is being
Battery ged
char

• Make sure the battery electrolyte temperature is below

40°C
Do not short the battery terminals by placing a piece of metal Hydrogen gases are released from the battery during charging,
between the positive and negative terminals. A loose terminal causing the battery to heat. Before trying to charge the battery,
might cause sparks, causing an explosion. Make sure the make sure the battery electrolyte temperature is below 40°C.
terminals are tight. Use caution not to have the wrong (If the electrolyte temperature reaches 50°C or more,
connections of the battery terminals. discontinue charging and wait until the electrolyte temperature
• When turning the screw of the positive pole of the battery, drops to 40°C or lower.)
use caution not to allow the tool to touch the metal parts of • Have a good ventilation when charging
the truck, such as the engine Since hydrogen gases are released from the battery during
If the tool touches metal parts, there might occur sparks, charging. Have a good ventilation; otherwise an explosion
causing an accident. might result. Keep the battery case cover open.
• Remove the negative (-) terminal of the battery first and • When cleaning the battery, make sure the battery caps are
reinstall it last securely tightened
When removing the battery, disconnect the negative (-) terminal
first. When reinstalling, connect the positive (+) terminal first,
and then connect the negative (-) terminal.

39
INSPECTION AND SERVICE
• Static electricity is hazardous Obey regulations
Static electricity is generated when cleaning the top surface
or connections of the battery with a dry cloth, or covering the
battery with a vinyl sheet. It might cause an explosion.
• 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

When disposing of waste oil, solvent, or discharged battery, obey

the regulations and rules.

Caution to be taken when adjusting tire inflation

pressure (rim, compressor):

Do not operate the truck or charge the battery when the

battery electrolyte level is below the LOWER LEVEL marking;
otherwise, the components inside the battery may be
deteriorated and the battery life shortened, and in the worst
case an explosion might occur. Keep the battery electrolyte
level between the UPPER LEVEL and LOWER LEVEL
markings at all times. Add purified water if the level is low.
• Prohibit to connect the battery that has over the specified
voltage. • When checking tire inflation pressure, position yourself in the
• When connecting the booster cable to the battery, pay path of rotation, not on the side of the tire.
attention to the polarity of the pole. • When inflating a tire using a compressor, first adjust the air
Two batteries shall be connected in parallel, not in series. pressure of the compressor; otherwise the air pressure will
rise to the maximum pressure of the compressor, leading to a
serious accident.
40
 INSPECTION AND SERVICE

• Inflating tires to a high pressure requires special skill. If the bolts and nuts of the split rim assembly are removed, the
Inflating tires requires special skill. Tires must be inflated only rims, bolts or nuts might blow off due to the internal pressure of
by a qualified person. the tire, to cause a serious personal injury.
• When using compressed air, wear safety glasses and mask. • When replacing the rim assembly, install a new rim assembly
When inflating tires, wear safety glasses and mask because with the head of each of the dowel bolts of the rim assembly
dust might get into your eyes or mouth. pointing outside. (This helps make it difficult to loosen the rim
bolts with the tire attached to the truck. Some bolts have a
Do not loosen the wheel assembly nuts when special shape for this purpose.)
changing a tire • After replacing tires, test run the truck to check to see if the hub
The wheel assembly is locked in two ways: Hub nut type and nut nuts are securely tightened. If a loose hub nut is found, tighten
type. In the hub nut type wheel assembly, the wheel is installed it to the specified torque.
to the hub; in the nut type, a wedge ring is inserted between the
wheel and the hub to lock the wheel assembly. Leave the disassembly and reassembly of tires, tubes
The tire is secured with the side ring and the lock ring. and rims to a specialist
When removing a tire from the truck, make sure the lock ring is The inflation pressure of tires of the lift truck is very high (about
securely installed; otherwise, the side ring, tire, and wedge ring 700 - 1,000 kPa) and thus due caution must be required to
might burst out, resulting in a severe accident. disassemble or reassemble the tires. An improperly reassembled
tire might cause explosion to let parts fly into pieces, resulting in a
Do not loosen bolts and nuts of split rim assembly: serious personal injury.

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
• The wheel has hub nuts that secure the wheel to the hub and sound when the direction change lever is placed in the reverse
rim nuts and bolts that assemble two rims together. When position. If the buzzer fails to sound, have it repaired. Make sure
removing a tire from the truck, do not loosen the bolts and nuts the lamps turn on and off properly. Burned-out bulbs must be
of the split rim assembly. replaced with new ones.
41
INSPECTION AND SERVICE
Avoid fire hazards your employer so he can monitor threshold limit values.
• Wipe away any spilt lubricant or fuel inside the engine room. (Consideration should be given to shutting off the operator’s
• Do not leave waste cloth or paper contaminated with fuel or internal combustion engine.)
lubricant inside the engine room; it can cause fire hazards.
• The exhaust pipe, muffler and exhaust manifold are hot ■
■Control of noxious gases and fumes
immediately after the engine has been shut off or while the • Source of carbon monoxide gas
engine is running. Carbon monoxide is the product of incomplete burning of any
material containing carbon, such as gasoline, LP and natural
CARBON MONOXIDE POISONING gas, and diesel fuel. Internal combustion engines that use these
The following carbon monoxide control to avoid its poisoning fuels are sources of exposure in the workplace.
is the user’s responsibility. • Control of carbon monoxide gas
Control of carbon monoxide levels in the workplace is
■
■Characteristics of carbon monoxide dependent on ventilation and proper maintenance of carbon
The exhaust from all internal combustion engines contain carbon monoxide producers including internal combustion-powered
monoxide, a colorless, odorless, tasteless, poisonous gas. equipment. See periodical maintenance of this manual.
Exposure to carbon monoxide can cause serious injury or health Properly running internal combustion engines will still produce
problems, including death. carbon monoxide emissions.
• Places where carbon monoxide gas concentrated • Ventilation
Carbon monoxide can become concentrated in areas such Ventilation shall be provided in enclosed areas where internal
as trailers, containers, coolers, freezers, and poorly ventilated combustion-powered equipment is used to maintain an
rooms or buildings. Therefore, limit internal combustion engine atmosphere that shall not exceed the contamination levels
usage in those areas. specified by the American Conference of Governmental
• Symptoms of carbon monoxide exposure Industrial Hygienists Threshold Limit Values of Airborne
Common symptoms of carbon monoxide exposure may Contaminants.
include headache, dizziness, and nausea. The smell of internal
combustion engine exhaust means carbon monoxide could be
present.
• Treatment for carbon monoxide gas poisoning
If an operator experiences these symptoms, move him into
fresh air, seek medical attention as required, and contact

42
 PREVENTING VEHICLE FIRES

Observe the following precautions to prevent the possibility of fires Electrical wires that short can cause a fire.
in your forklift truck, or in the facility where the truck is stored or •• Clean all the wiring connections and ensure the plugs are
operated. Before starting the day’s work or before each shift, always securely connected.
make sure to perform the following checks. If any problem is found, •• Before starting the day’s work or before each shift, check the
operation of the truck should be halted until the problem is corrected. cables and wiring for looseness, twists, stiffened or cracked
insulation, and fraying.
Check for any spilt fuel or oil •• Also check for missing or damaged terminal caps.
•• If any problem is found or you are not sure about the safety of
the truck, consult your local dealer.

Check for oil leaks

EXHAUST MANIFOLD

MUFFLER

Wipe up any spilt fuel, oil, anti-freeze, or windshield washer liquid.

Remove any deposits or accumulation of flammable debris (paper,
leaves or wood waste). They can be a fire hazard.
•• Before starting the day’s work or before each shift, check the
truck, in particular the hot components (muffler, exhaust pipe, Fuel leaks, hydraulic oil and lubricant leaks can cause a fire.
tail pipe) and the parts around them, for spilt fuel, or other •• Before starting the day’s work or before each shift, check all the
flammables. Remove any if found. hose clamps for looseness. Notice if any are missing. Check
the hoses for twists, friction wear or damage.
Check for electrical shorts •• If any problem is found or you are not sure about the safety of
the truck, consult your local dealer.

43
PREVENTING VEHICLE FIRES
Check the work area for flammables around the truck How to escape from a truck on fire

Any flammables around the truck, in particular those near the A vehicle fire might cause a serious personal injury or even death.
muffler, exhaust pipe and tail pipe can ignite or explode due to the If the truck catches on fire during operation, get out of the burning
heat of the exhaust gas. If you cannot avoid working in an area vehicle observing the following procedure:
where there are flammables, use caution not to allow the muffler, •• Lower the forks on the ground, apply the parking brake, and
exhaust pipe or tail pipe to come close to those flammables. turn off the starter switch to shut off the engine.
•• Get out of the burning vehicle quickly using the steps and
Precaution about smoking in the operator’s compartment handrails.
Do not jump off the truck.
•• If possible, fight the fire using a fire extinguisher.

Never make modifications without prior approval

Modifications performed without prior approval can cause a fire
hazard. Do not make any modification to your truck without getting
prior approval from the manufacturer. If you need a modification
of your truck, consult your dealer. Modifications made without
Mitsubishi Logisnext’s prior approval will void your vehicle’s
Any flammable objects inside the operator’s compartment can warranty.
catch fire from a cigarette or cigarette butt, leading to a vehicle fire.
•• Never smoke in the truck if it is not equipped with an ash tray.
Never smoke in a work area where there are flammables.
•• The ash tray, if any, must be cleaned daily or more frequently.

44
 CAUTION PLATES

WARNING The safety decals and name plates describe basic instructions for safety operation of your lift truck.
Read and understand these instructions and the other messages in this manual and on the lift truck.

O
2
H
C
I
3
1 L
1
M
P
OVERHEAD GUARD
THIS FACTORY OVERHEAD GUARD MEETS
THE REQUIREMENTS OF DESIGN AND
CONSTRUCTION STANDARDS ESTABLISHED
OR AS REQUIRED BY ANSI B56.1 PART
AND OSHA.

G
A

3 J
B
K
F
N
E 2
45
CAUTION PLATES
A. Safety Decal B. Do not Ride on Forks Decal D. Mast Connecting Member Decal

YOU MUST FOLLOW THESE RULES TO

AV O I D S E V E R E I N J U RY O R D E AT H TO
YOURSELF AND OTHERS.
1. Operate truck only if trained and authorized by
your employer. Know Operation & Maintenance
Manual and all work rules.
2. Safety check truck every day. Do not start if dam-
aged or faulty; stop if problems start.
Repair allowed only by trained, authorized me-
chanics.
3. Turn, start, stop, and handle loads smoothly and AVOID SEVERE INJURY
slowly.
Carry loads low and tilted back; stack only on level • KEEP HANDS AND FEET OUT OF MAST.
using minimum tilt. • BLOCK OR CHAIN RAILS BEFORE
4. Look where you are going. Watch out for people, SERVICING.
hazards on floors and overhead, drop-offs and tail
swing clearance. C. Load Handling Means Decal
5. Truck overturn can kill you. Slow for turns even
when empty. Never turn on inclines.
6. Do not lift overweight or loose loads.
Move slowly with wide, high, or long loads.
E. Fan Warning Decal
Keep forks wide and fully under loads.
WARNING
Travel in reverse if loads block view.
Attachments require special training, ask your em-
ployer.
7. Keep loads upgrade on all inclines. Stay clear of
ramp and dock edges. Make sure dockboards and
trailers are secure before going on them. WARNING Stay clear of fan when
8. Overhead guard and load backrest must be on engine is running.
truck. To avoid injury, keep
Always keep yourself completely inside guard.
9. Stop engine when refueling. Follow Operation & fingers and objects
Maintenance Manual and employer’s work rules away from fan.
about fuel, battery and tire maintenance hazards.
10. Forks can fall rapidly even with light loads.
Do not raise people or allow them under forks.
No passengers allowed on truck.
11. Park only in authorized areas, never on inclines.
Lower forks to bottom, put direction control in neu-
tral, turn off key and make sure parking brake is
set.
12. Fasten the seat belt, when operating the lift truck.
AVOID SEVERE INJURY OR DEATH
• DO NOT GET UNDER FORKS OR LOAD.
• DO NOT RIDE FORKS.

46
 CAUTION PLATES
F. Lubricants Capacities Decal J. Truck Serial Number Plate O. Tire Inflation Pressure Decal
6-ton model
G. Fuel Decal
700 700
(7) (7)
H. Parking Brake Adjusting Procedure
Decal kPa
(kgf/cm2)

00000-00000

I. Warning Decal for Front Guard 7-ton model

800 800
(8) (8)

WARNING kPa
(kgf/cm2)

00000-00000

8-ton model
750 750
(7.5) (7.5)

kPa
(kgf/cm2)

00000-00000

AVOID SEVERE INJURY OR 10-ton model

DEATH. DO NOT CLIMB ON
FRONT GUARD. K. Greasing Points List Decal 750
(7.5)
750
(7.5)

L. Turn Signal Decal kPa

(kgf/cm2)

00000-00000
M. Traveling Speed Select Switch

N. LLC Label

47
CAUTION PLATES
P. Battery Warning 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 booster cable. Keep away from children.
• Electrolyte (Sulphuric Acid) causes severe burns to eyes, skin, or
clothing.
If in contact with the skin or eyes, rinse with cold water and seek Do not allow contact with electrolyte.
immediate medical advice.
• Do not use the battery when the electrolyte level is below the LOWER Read instruction carefully.
LEVEL, it may cause an explosion.
• Do not use the battery while the electrolyte level is over the UPPER
LEVEL, it may cause the battery to leak. Hazardous Explosive

48
 BEFORE USE

② ③
① A A

B B

Plate on the truck manufactured

in Japan for general district

CERTIFICATE SERIAL NUMBER PLATE TRUCK SERIAL NUMBER

The truck serial number plate gives model Serial number of the truck is also stamped on
•• The decal A is to certify that the truck is number and serial number of the truck. the left, upper face of the rear frame.
a brand new forklift truck which has been
manufactured for export by Mitsubishi
Logisnext Co., Ltd. Always give us:
•• Truck Mode............................................. A
•• The mark B is to certify that the truck •• Truck Serial No. ..................................... B
satisfies the EEC Directive 89/392 on Self- •• Engine Model & Serial No.
Propelled Industrial Trucks. •• Attachment Model & Serial No.
GENUINE PARTS HANDLING A BRAND NEW TRUCK •• Regardless of ambient temperature,
However excellent the part is, it inevitably Although the truck delivered to you has been be sure to warm up the truck before
deteriorates in performance with a long-term use. carefully checked and subjected to thorough operating.
Therefore for best performance we recommend running-in procedures before shipping, it •• Avoid high idling (rotation of engine at
that you use genuine our parts which are is essential to follow through with further high speed without load), especially while
employed in new trucks. When ordering spare running-in during the first stage of operation the engine is cold.
parts for your truck, be sure to designate our to ensure best performance. To operate the •• Avoid jerky starts, sharp turns and unduly
genuine parts only. brand new truck, follow the requirements hard braking.
given below. •• Perform checking and maintenance
services carefully as specified

49
BEFORE USE
ENGINE SERIAL NUMBER
The engine serial number is stamped on the right-
hand side of engine block.

ENGINE SERIAL NUMBER

6BG1

50
 PICTRIAL NOMENCLATURE

12

6
7

3 5
4
15

8
2

10

11
1

51
PICTRIAL NOMENCLATURE
1. FORK
2. LOAD BACKREST
3. LIFT CHAIN
4. STEERING HANDWHEEL
5. FRONT COMBINATION
LIGHT
6. HEADLIGHT
7. SIDE VIEW MIRROR 17
8. HOOD, HINGED
9. STEER WHEEL
10. STEP 4
11. DRIVE WHEEL 15
12. OVERHEAD GUARD
13. REAR COMBINATION 16
LIGHT
14. COUNTERWEIGHT 14
15. OPERATOR’S SEAT
16. METER, CLUSTER
17. AIR INTAKE

10 13

52
INSTRUMENTS & CONTROLS
1. STEERING HANDWHEEL
2. METER, CLUSTER
3. IGNITION SWITCH
4. TURN SIGNAL LEVER
5. LIFT LEVER
6. TILT LEVER
7. GLOVE COMPARTMENT /
PEN HOLDER
8. GLOW INDICATOR
9. TRAVELING SPEED SELECT SWITCH
10. ACCELERATOR PEDAL
11. BRAKE PEDAL
12. INCHING PEDAL
13. HOOD OPENING LEVER
14. GRIP
15. PARKING BRAKE LEVER
16. SHIFT LEVER
17. LIGHT SWITCH
18. STEERING COLUMN TILT LEVER
19. HORN BUTTON

53
INSTRUMENTS & CONTROLS

16

15

18
17

54
 INSTRUMENTS & CONTROLS

INSTRUMENTS
METER PANEL
(Meters)
1. FUEL GAUGE
2. HOUR METER
3. COOLING WATER TEMPERATURE
GAUGE

(Warning lights, indicator lights)

4. ENGINE OIL PRESSURE WARNING
LIGHT
5. AIR CLEANER CLOGGING WARNING
LIGHT
6. COOLING WATER LEVEL WARNING
LIGHT (OPTION)
7. CHARGE WARNING LIGHT
8. BATTERY ELECTROLYTE LEVEL
WARNING LIGHT (OPTION)
9. FUEL LEVEL WARNING LIGHT
10. PARKING BRAKE WARNING LIGHT
(OPTION)

55
INSTRUMENTS & CONTROLS
METERS

FUEL GAUGE [1] HOUR METER [2] COOLING WATER TEMPERATURE

The fuel gauge indicates the fuel level in the The hour meter operates while the engine GAUGE [3]
fuel tank. is running, and records total operating time This gauge indicates the temperature of
of the truck in hours and tenth of an hour (6 the engine cooling water. Under the normal
NOTE minutes). Use it to determine maintenance operating conditions, the pointer should stay
•• When checking the fuel level, park the schedule. in the range “A”. If the pointer enters the red
truck on a level surface; otherwise you range “B”, park the truck in an out-of-traffic
cannot get the correct fuel level. area and let the engine run at idle rpm until
• Don’t drive low on fuel. Add fuel before
• the pointer returns to the range “A”.
the fuel level drops to the minimum.
NOTE
Do not shut off the engine even if the
pointer enters the red range “B”; otherwise
failure of the engine might result.

56
 INSTRUMENTS & CONTROLS
WARNING LIGHTS AND INDICATOR AIR CLEANER CLOGGING
LIGHTS WARNING LIGHT
CHARGE WARNING LIGHT
Light comes on when the air cleaner element
becomes clogged. If light comes on during Light comes on if the power generating
operation, stop the engine immediately and system fails to function normally during
FUEL LEVEL WARNING LIGHTS clean the element. For the element cleaning operation.
Light comes on when the fuel level is low. If procedure, see page 108. The light also comes on when the starter
the light comes on, add fuel. switch is turned to “ON” and goes out when
the engine has started up.

BATTERY ELECTROLYTE LEVEL NOTE

PARKING BRAKE WARNING LIGHT WARNING LIGHT (OPTION)
If the light does not go out after the
(OPTION) Light comes on when the electrolyte level engine has started up, it suggests a loose
Light comes on when the parking brake is drops below the “LOWER LEVEL”. or broken fan belt or a defective power
applied. If light comes on, add purified water for the generating system. Stop the operation
battery to the “UPPER LEVEL”. immediately and ask your dealer to check
the truck.
ENGINE OIL PRESSURE WARNING
LIGHT RADIATOR WATER LEVEL
Light comes on when the engine oil pressure WARNING LIGHT (OPTION)
is low. Light also comes on when the starter Light comes on when the cooling water in the
switch is turned to “ON” and goes out when radiator reservoir tank drops below the lower
the engine has started up. limit. If light comes on, check the engine
cooling water level and add cooling water to
NOTE the proper level.
If light comes on during operation, it
suggests that the engine oil level is low or
the lubricating oil system is defective. Stop
the operation immediately and ask your
dealer to check your truck.

57
INSTRUMENTS & CONTROLS

SPEED METER [26]

[OPTION]
Indicates the traveling speed (km/h) of the
truck.

58
 INSTRUMENTS & CONTROLS

SWITCHES

IGNITION SWITCH [3] H (PREHEAT)

NOTE
OFF · STOP This is a position to make the engine easier to
start, preheating the glow plug which in turn Oil Pressure Alarm : When the alarm
The position in which the key is inserted or sounds as the ignition switch is turned “ON’,
drawn out. heats the inside of the combustion chamber
of the engine when it is cold. step on the brake pedal several times until
The engine stops when the ignition switch is the alarm stops sounding.
returned to this position. The key switch returns to the “OFF/STOP”
position automatically if released.
1. Do not keep the ignition switch in the “ON”
ON
WARNING position while the engine is shut down.
The electric circuit is closed with the ignition This results in a discharged battery.
switch at “ON”. After the engine is started, the Do not run the truck when the alarm
2. With the engine running, do not turn the
key is at this position. sounds as the ignition switch is turned
ignition switch into the “START” position
to the “ON” position. Because the brake
to avoid a damage of the starter motor.
START is ineffective at such time, it is very
3. Do not keep the starter engaged for more
As the key is placed in the “START” position, dangerous to run the truck.
than 10 seconds at a time. Wait about 20
the starter motor is engaged. When removing seconds before trying again.
the key. It is automatically returned to the “ON” 4. The neutral start system is standard
position by spring force. equipped. Do not fail to place the shift
lever in neutral before starting the engine.

59
INSTRUMENTS & CONTROLS

LIGHT SWITCH [17] TRAVELING SPEED SELECT HORN BUTTON [19]

This light switch can be pulled out in 3 steps. SWITCH [9] Press the rubber cover at the center of
Stage 0 Use this switch to select the speed change steering wheel to sound the horn. The horn
1st 2nd 3rd sounds even when the key switch is OFF.
Light (OFF) pattern of the transmission. Select the mode
Clearance light OFF ON ON ON according to the working conditions.
Tail Light OFF ON ON ON [Unit: km/hr] TURN SIGNAL LEVER [4]
Gauge illumination OFF ON ON ON Use this lever to indicate the turning direction
Headlight, low Shift Up Shift Down of the truck. When this lever is placed in a
OFF OFF ON OFF MODE
beam turn position, the turn signal light blinks.
Headlight, high NORMAL 6 3
OFF OFF OFF ON R Right turn
beam GRADIENT Fixed in the 1st speed.
HIGH SPEED 7 4
N Neutral
NOTE L Left turn
The above lights are turned on or off by the Use GRADIENT MODE when climbing a
light switch regardless of ignition switch slope or when applying the engine brake. NOTE
position, so use this switch to turn off the The turn signal lever does not automatically
lights. return to the neutral position unlike general
passenger cars. Reset it by hand. The turn
signal lever may be located at the left side
of the steering column

60
 INSTRUMENTS & CONTROLS

GLOW INDICATOR [8]

In such a case that the engine is hard to
start in cold weather, turn the ignition switch
counterclockwise from the “OFF · STOP”
position to the “H” position. Then, this glow
indicator, a heater signal, glows red hot in
about 40 seconds, indicating that the glow
plug is in the preheating state. As the glow
indicator glows red hot, preheating of the glow
plug is completed.

61
INSTRUMENTS & CONTROLS
CONTROLS

STEERING HANDWHEEL [1] LIFT LEVER [5] TILT LEVER [6]

WARNING WARNING WARNING
This truck is provided with power Operate the lift lever only after you are Operate the tilt lever only after you are
steering, so heavy handwheel operation seated in the operator’s seat and the seated in the operator’s seat and the
will be caused if the engine comes to a safety of the surroundings is confirmed. safety of the surroundings is confirmed.
stall. To put power steering in operation
again, restart the engine without delay. The forks can be raised or lowered by pulling The mast can be tilted by operation of this tilt
this lever backward or pushing it forward. The lever. Pulling on this lever backward will tilt
The steering handwheel is operated in the lift speed is controlled by tilt angle of the lever the mast backward, and pushing it forward
and accelerator pedal effort. The lowering will tilt the mast forward. The tilt speed can
conventional manner. That is, when the wheel
speed can be controlled by tilt angle of the be controlled by tilt angle of the lever and
is turned right, the truck will turn to the right; lever. The engine speed or accelerator pedal accelerator pedal effort.
when the wheel is turned left, the truck will does not have to do with the lowering speed
turn to the left. The steer wheels are located of the forks. The forks can be lowered while
at the rear of the truck. These cause the rear
NOTE
the engine is at rest.
of the truck to swing out when a turn is made. The tilt lock mechanism built in the hydrau-
With a little practice, steering of this type will lic circuit does not allow the mast to tilt for-
Optional LIFT LOCK mechanism prevents ward while the engine is being shut down
be easily mastered. the forks from lowering even if the lift lever is even if the tilt lever is pushed forward.
pushed forward while the engine is at rest.
62
 INSTRUMENTS & CONTROLS

Depress

LOCK BUTTON

PARKING BRAKE LEVER [15] SHIFT LEVER [16] Be sure to brake to a full stop of the truck
before reversing the direction of travel, shifting
WARNING WARNING the lever from the “F” (forward) position to the
Be sure to block the wheels if parking When operating this lever, be sure to “R” position or vice versa.
on a grade. step on the brake pedal fully.
With this lever shifted in other than the NOTE
Use this brake lever to park the truck. Pull this “N” (neutral) position, the truck begins The neutral safety switch is equipped
lever to apply the parking brakes. to move slowly if the brake pedal is to the shift lever. Do not fail to place the
To release the parking brakes, push the lever released. lever in the “N” position before starting
forward while depressing a lock button found (This phenomenon is called creeping.) the engine. The engine could not start if
on the top of the lever. Do not ease off stepping on the brake the lever is placed in other (the “F” or “R”
pedal until starting the truck. position) than the “N” position.

The shift lever is of the column shift type and

the transmission has two speeds for forward
and two speeds for reverse. (Refer to the
Specifications on page 135 and after.)
Shifting the lever in the “R” (reverse) position
turns on the back-up lights and sounds the
back-up alarm.

63
INSTRUMENTS & CONTROLS
BRAKE PEDAL [11]
Press this brake pedal to slow or stop the truck.
At the same time, the brake lights come on.
WARNING
Do not run the truck while the brake hy-
draulic oil alarm is sounding. When the
alarm is sounding, the brake hydraulic
oil pressure drops, and the brake is
hardly effective, making running of the
truck very dangerous. Run the truck
only after the alarm stops sounding.
6- to 8-ton models

WARNING
This truck is equipped with the power
FOOT CONTROLS inching operation. Use this pedal to inch the brake. It uses, not a usual brake fluid
truck while operating the hoist system at a (vegetable oil), hydraulic fluid (mineral
See the above figure for inching pedal (left),
high speed. When pressed to the full, this oil). Consequently, parts for usual brake
brake pedal (center) and accelerator pedal
inching pedal serves as a brake pedal. fluid can not be used for rubber parts
(right).
for such as the cylinder cup. Never use
ACCELERATOR PEDAL [10] other than power brake exclusive parts.
INCHING / BRAKE PEDAL [12] 6- to 8-ton models
The accelerator pedal increases the engine
WARNING speed. With this pedal released, the engine
runs at idle rpm. NOTE
Do not use this inching pedal in
deceleration during traveling, starting Brake Alarm
on an uphill nor in deceleration on •• In the case where the alarm sounds at
turning ON of the ignition switch, start the
a downhill. Otherwise, the hydraulic engine, and step on the brake pedal sev-
clutch is disengaged and the engine eral times until the alarm stops sounding.
brake becomes ineffective as this pedal 6- to 8-ton models
is stepped on.

As the inching pedal is pressed, the oil CAUTION 8- and 10-ton models
pressure in the hydraulic clutch drops The 8- and 10-ton trucks have no automatic
accordingly following the operator to perform brake shoe clearance adjusting system.
Check the shoe clearance monthly.
64
 INSTRUMENTS & CONTROLS

TRUCK BODY

Unlock
A Lock

C 2 3
Unlock

Lock
B

OPERATOR’S SEAT [1] SEAT POSITION ADJUSTMENT LEVER B SEAT BELT [2]
SEAT SUSPENSION ADJUSTMENT KNOB A RECLINING CONTROL LEVER C
WARNING

CAUTION CAUTION Be sure to fasten the seat belt before

Adjust the seat position before starting starting the truck; otherwise, if the
Adjust the suspension of the operator’s
the day’s work or each shift. After truck turns over, the operator might be
seat using the adjustment knob before
adjustment, make sure the operator’s thrown out and, in the worst case, the
starting the day’s work or each shift. Do
seat is securely locked. operator can be crushed by the truck.
not try to adjust the suspension during
operation.
Adjust the operator’s seat to a position that is Pull out the connector [3] at the right side and
comfortable for you and provides easy access insert it into the receptacle [4] at the left side
Adjust the operator ’s seat suspension
to all hand and foot controls. To unlock, pull until it clicks into place.
properly to suit the individual operator’s
the lever upward. After adjustment, try to To unfasten the seat belt, press the red
physique and to provide best comfort. Turn
move the seat back and forth to make sure button by the receptacle [4], and the belt will
the adjustment knob to the value of your
that it is securely locked. automatically wind up into the seat.
weight. The operator’s seat absorbs shock
and vibration to provide comfort during
traveling and operation.

65
INSTRUMENTS & CONTROLS
HOOK
1

Push

DOCUMENT POCKET [1] HOOD OPEN LEVER[13] IN CASE THE HOOD OPEN LEVER
BECOMES INOPERATIVE..
MAGAZINE BOX [2] WARNING Prepare a flat steel bar of approx. 20 cm (8
The operator’s seat has a document pocket in.) length. Insert the bar as shown in the
and magazine box at its back. Use them for Use caution not to catch your fingers in
the hood when closing it. figure. Push the hood locking hook, and the
storing this Operation & Maintenance Manual hood will be unlocked to open.
and others. Remember to close the document
pocket before operation. The hood can be swung up fully to provide
easy maintenance service. To swing up the
hood, pull on the hood open lever (13), and
then the hood can be lifted up with little effort
with an aid of the hood damper. To lock the
hood, push down the front of the hood until it
locks.

NOTE
If the hood open lever becomes inopera-
tive, see the right.

66
 INSTRUMENTS & CONTROLS

Lock
FORK STOPPER

Release

FORK LOCK BOLT

FORK STOPPER FORK LOCK BOLT TORQUE CONVERTER FLUID

FILLER
CAUTION CAUTION The torque converter fluid filler is provided
•• The forks should be set symmetrically Do not remove the fork lock bolt other near the center as the floor mat and
to the truck centerline, and fork than the following cases; otherwise the floorboard are removed.
stoppers should always be set. forks might disengage from the carriage, It is capped, and as it is uncapped, a dipstick
•• When adjusting fork spacing, hold causing personal injury. is provided inside the cap.
the load backrest and push the forks •• When removal of the forks is needed.
with your foot. Do not use your hand. •• When gathering the right and left
forks together to the center for any
Secure the forks with the fork stoppers. reason.
Pull up the fork stoppers a little and turn 90°.
Then adjust the fork spacing using your foot When a fork prong is moved to the center, it
according to the size of the load you are will come off the carriage. This bolt prevents
going to carry. the fork from being used at the center of the
carriage.

67
INSTRUMENTS & CONTROLS

SAFETY STEP & SAFETY GRIP FUSE BOX HYDRAULIC FLUID RESERVOIR
The safety steps are provided on both sides The fuse box is located inside the hood at the CAP
of the truck body. The safety grip is provided left side. The hydraulic fluid reservoir cap is located on
on the front left pillar of the overhead guard. Refer to page 99 for fuse replacing procedure. the right side in the hood. Fill hydraulic fluid
Use the safety step and safety grip as facing through this filler The cap is provided with the
the truck when mounting and dismounting the dipstick.
truck.

68
 INSTRUMENTS & CONTROLS

OVERHEAD GUARD

LOAD BACKREST

OVERHEAD GUARD & LOAD FUEL RESERVOIR CAP The fuel reservoir cap is located at the rear
BACKREST left side of the truck body. To open, turn it
WARNING counterclockwise.
WARNING
- FUEL HANDLING -
Use overhead guard and load backrest •• Stop the truck, shut down the engine, NOTE
extension. Be extremely careful when and apply the parking brake securely. •• The fuel reservoir cap has the breather
unable to use an overhead guard or Make sure that there is no open flame inside it to allow air to enter into the
load backrest extension. near the area. Never smoke. The reservoir. If the breather is damaged or
driver should not remain seated when clogged, the fuel system will malfunction.
adding fuel.
The overhead guard used is strong enough Check to see that the breather is in good
•• After addition of fuel is finished,
to meet safety standard and protects the securely close the reservoir cap. A condition every time addition of fuel is
operator from falling materials. loose cap could cause fuel leak or made.
The load backrest is for the protection of the fire hazard in the worst case.
driver, fork stopper pins, lift chains or uprights. •• Before attempting to start the engine,
It prevents the lateral disengagement of forks make certain that the fuel reservoir
from the carriage. cap is securely tightened and that no
fuel is spilt on or around the truck.
•• For the purpose of fuel level inspec-
tion, n ever use open flame such as a
match or lighter.

69
INSTRUMENTS & CONTROLS

C A

TOW PIN COOLANT RESERVOIR SIDE VIEW MIRRORS (A)

WARNING WARNING WARNING
Do not use the tow pin in towing a Do not remove the radiator cap abruptly The total area around the truck is not
trailer, wagon or the like and being while the engine is hot. Turn the cap a visible in mirrors. Always look in the
towed. little to the left while pressing down to direction of travel, especially in reverse;
relieve the pressure in the radiator, and failure to do so could result in injury to
It is for use in pulling the truck out of a side then remove the cap. you or others.
ditch or gutter and the mire where its tires Do not wear glove when removing
dropped in or got stuck and the truck could radiator cap. The truck is provided with two side view
mirrors on both front supports of the overhead
not move and for use in loading the truck on a
guard. Adjust the side view mirrors to gain a
trailer. The reservoir is located near the battery. good side view.

LIGHTS & LAMPS (B, C)

Front Side
Two headlights (B) and combination lights (C)
(turn signal, parking & clearance) are installed
at the front side of the truck. Take care of
the lights, wipe dirt, if any, and replace any
damaged light immediately.
70
 INSTRUMENTS & CONTROLS

H
D·E
G
F

LIGHTS BACK-UP ALARM WARNING

Rear Combination Lights (D ∙ E ∙ F ∙ G ∙ H)
WARNING •• Be sure to adjust the steering column
The combination lights at the rear side
serve as turn signals (G), tail lamps (D), Watch out people around your truck tilting angle before proceeding to
brake lamps (E), back-up lamps (F) and rear even if it has warning alarms or lights. your work.
reflectors (H). Pay attention to keep them They may not be watching. •• Once the adjustment is accomplished,
from being damaged or covered with dust. Always look in the direction of travel, turn the lever in the “A” direction to
especially in reverse. lock the steering column securely.
•• Do not make the adjustment during
When the shift lever is placed in the “R” your work as it is dangerous.
position, the back-up alarm sounds to let
other workmen and bystanders know you are The position of the steering handwheel
moving backward. can be adjusted to suit to your comfortable
The back-up alarm is located under the air operating position by tilting the steering
cleaner. column backward and forward.
Turning of this lever in the “B” direction is
unlocking the steering column; in the “A”
direction, locking.

71
INSTRUMENTS & CONTROLS

SAFETY CONSIDERATIONS ON REAR WORK LIGHT

BACK-UP ALARMS/LIGHTS Optional rear work light is provided on the
rear right pillar and/or on the rear left pillar.
WARNING
Multiple alarms and/or lights can cause
confusion.
Workers may ignore the alarms and/
or lights after day-in and day-out
exposure.
Operators must not transfer the
responsibility on “looking out” to the
pedestrians.

72
 8-HOUR (DAILY) CHECK
•• Before starting your lift truck, be sure to inspect the following items
for safety sake and efficient productivity:

GENERAL RULES ON INSPECTION

(1) Use our genuine parts only.
(2) Use our genuine or recommended oil only.
(3) Clean oil fillers and grease fittings with a brush or waste cloth
before adding oil or greasing.
(4) Oil level check and addition of oil should be made with the truck
parked on a level surface.
(5) Preventive maintenance services should be done in an orderly
manner, and due care should be taken not to injure yourself.
(6) If unavoidable to work under the raised forks or attachment, use
a stable support to prevent the forks and inner mast from falling
down.
(7) If any damage or fault is found, the problem should be reported
to your supervisor, and the truck should not be operated until
corrected.

73
8-HOUR (DAILY) CHECK
DAILY OR EVERY SHIFT CHECKLIST (DAILY Y CHECKLIST FORM)

Truck ID No.
Year , Month , Date

Check Check
here here
1. Result of remedy found, if any, on previous checking 19. Shift lever(s)
2. Leaks of oil, fuel or water 20. Loading levers
3. Tire inflation pressure FL/FR 21. Parking brake lever
RL/RR 22. Monitoring lamps
4. Hub nut torque FL/FR 23. Meters and gauges
RL/RR 24. Fuel level
5. Overhead guard 25. Lights and lamps
6. Battery electrolyte level 26. Turn signal
7. Coolant level 27. Horn button test
8. Engine oil level 28. Brake pedal free travel
9. Fan belt tension 29. Mast test
10. Rear combination lights 30. Lift chain tension
11. Hydraulic oil level 31. Steering handwheel free play
12. Piping and cylinders 32. Exhaust gas condition
13. Automatic transmission fluid level 33. Inching pedal test
14. Load backrest 34. Brake test
15. Forks and fork stoppers 35. Steering test
16. Headlights and front combination lights 36. Parking brake test
17. Operator’s seat adjustment 37. Back-up lamp/back-up alarm test
18. Side view mirrors

○ ; Normal, × ; In need of repair, ×; Repair completed

COMMENTS Checked by

74
 8-HOUR (DAILY) CHECK
1 RESULT OF REMEDY FOUND, IF ANY, ON 2 LEAKS OF OIL, FUEL OR WATER
PREVIOUS CHECKING
WARNING
WARNING
Don’t attempt to operate the truck if leaked fuel is found
Don’t make repairs or adjustment unless specifically through pre-operational check. Correct the leak before
authorized to do so. starting the engine.

If at any time a powered industrial truck is found to be in need of Check joints of the hydraulic piping, engine radiator and driving
repair, defective or in any way unsafe, the matter should be reported system for oil and water leaks. Check leakage with your finger as well
immediately to the designated authority, and the truck should be as visually.
taken out of service until it has been restored to safe operating
condition.

75
8-HOUR (DAILY) CHECK
3 TIRE INFLATION PRESSURE Turn the tire valve cap counterclockwise, and remove it. Using a
tire pressure gauge, measure the inflation pressure, and adjust it to
WARNING the specified pressure, if needed. After making sure there is no air
All nuts and bolts should be properly installed and torqued leakage from the tire valve, reinstall the cap.
before inflating tire and rim assembly. An inflated tire contains Check that each tire does not get damaged at the tread surface or
potentially explosive energy. side face or bending at the rim.
DON’T OVERINFLATE. Since the forklift truck needs tires that have a high inflation pressure
to carry heavy loads, even as mall bending of rims or a damage at the
tread surface could cause an accident. If the operator finds any defect
WARNING on the tires, consult your dealer or distributor.
When using an air compressor, first adjust the air pressure of *For tire replacement procedure, see Paragraph “REPLACING OR
the compressor. Failure to do so will cause a serious accident REPAIRING TIRE” → See page 100.
since the compressor delivers the maximum pressure.
WARNING DECAL
Check condition of tires: Low air pressure reduces tire service life and
increases fuel consumption. Unevenness of air pressure between
right and left tires or unevenly worn or badly damaged tires will cause
uneven steering forces.

AVOID SEVERE INJURY OR DEATH.

Tire servicing requires special training.
Do not take tires off truck until all air pressure
is out. Loosen only WHEEL LUG NUTS “A”.
Do not loosen wheel assembly nuts “B” until all
air pressure is out of tire.
See OPERATORS MANUAL for more important
instructions for wheel service and reassembly.
Underinflation Good Overinflation Make sure all nuts and bolts are in place and
tight.
Never add air to a tire that looks low. Let all air
out and check for proper assembly.
Inflate all tires in a safety cage. See MANUAL
for proper pressures.
The standard tire pressure is indicated on the decal at the rear right
side of the floor board.

<Inflation Pressure................................................ Refer to page 129.>

Split-type Safety cage

76
 8-HOUR (DAILY) CHECK
4 HUB NUT TORQUE STEER
Check hub nuts for correct torque.
All hub nuts should be tightened securely to the specified torque.
See page 129 for HUB NUT TIGHTENING TORQUE.
① ; Hub Nut,
② ; Planet Spider – Sun Gear Thrust Cap,
③ ; Hub -Planet Spider,
④ ; Rim Nut

DRIVE (Typical)

Rear Wheel

5 OVERHEAD GUARD
The overhead guard is for your protection. Make certain that it is
securely installed.

Front Wheel

77
8-HOUR (DAILY) CHECK
Open the hood... 7 COOLANT LEVEL
Open the hood from the left side of the truck. WARNING

6 Take extreme care when removing the radiator pressure cap.

BATTERY ELECTROLYTE LEVEL
In the pressure system, a sudden release of the pressure can
WARNING cause a steam flush which would cause a serious personal
injury. Loosen the cap slowly to allow steam to escape. After
Never allow flame or sparks near the battery filler holes where that, tighten the cap securely. It is good practice to use a thick
explosive hydrogen gas may be present. waste cloth or the like when removing the cap. Avoid putting
on gloves since you may get burnt at your hand if hot water
Check the electrolyte level in the battery. splashes on it.
The typical battery case is given with the upper and lower level marks
to allow the operator to see the electrolyte level. The level should be Check the radiator coolant reservoir fluid level. It should be between
between the two marks. high and low level marks. Add coolant if necessary.

WARNING RESERVOIR TANK

Low level with plate protruding above electrolyte can cause

an explosion, It can also reduces battery life. MAX.

NOTE
For addition of water to the radiator, use tap water. Do not use sea
water nor turbid water. If the radiator uses antifreeze-contained
cooling water or long life coolant, add antifreeze or long life coolant
to water properly.

78
 8-HOUR (DAILY) CHECK
8 ENGINE OIL LEVEL 9 FAN BELT TENSION
The dipstick is located on the right side of the engine. Remove the
WARNING
dipstick, clean the rod, and reinstall. Pull it out again, and check the
oil level. The level should be within the marks on the dipstick. Fan belt deflection check is to be made with engine shut
down. (Refer to a decal on page 82.)
NOTE
To check the oil level when the oil is cold, don’t run the engine first. Check the fan belts for correct tension and damage. The deflection of
The cold oil will not drain back to the pan fast enough to give at the belts when the midway between the water pump pulley and the
rue oil level. generator pulley is pushed by 10 kg (22 Ibs) force is 10 mm (0.4 in.):

FAN BELT

DIPSTICK

ENGINE OIL FILLER

79
8-HOUR (DAILY) CHECK
10 REAR COMBINATION LIGHTS 12 PIPINGS & CYLINDERS
Check rear combination lights (tail, brake, back ← up & rear reflector) Visually check hydraulic oil pipings and lift and tilt cylinders for oil
for damage or smears. leaks.

11 HYDRAULIC OIL LEVEL 13 AUTOMATIC TRANSMISSION FLUID LEVEL

Check hydraulic oil level by means of the oil level dipstick. Open the inspection cover, and remove the filler cap. Inspect the
Remove the oil level dipstick, and clean it. Reinsert it, and remove level gauge to make sure that the fluid level is on the upper mark of
again to see if the oil level is between two slots, High and Low. the gauge. Add specified fluid, if necessary. (Refer to pages 67, 131
Mark “S”: Use “S” mark if your truck is equipped with a high upright and 133.
exceeding 6 m lift height or a special attachment specified by
Mitsubishi Logisnext. In such at ruck, the oil level should be between
10 mm above the mark “S” and 10 mm below it.

NOTE
The oil level check should be done with engine shut down, forks
on the ground or floor, and the truck itself on a level surface.

80
 8-HOUR (DAILY) CHECK
14 LOAD BACKREST 16 HEADLIGHTS & FRONT COMBINATION LIGHTS
Check for loose mounting bolts of the load backrest. Retighten where Check for dirty or damaged lens. (Refer to page 70.)
needed.
Close the hood, sit on the seat and…
B
Take care not to catch your finger in the hood.

17 OPERATOR’S SEAT ADJUSTMENT

Make sure the operator’s seat is properly located. If not, shift the
adjusting lever to the right, and move the operator’s seat to a position
which provides easy access to all foot and hand controls. After
adjustment, shake the operator’s seat a little to be sure that it is
securely located.

18 SIDE VIEW MIRRORS

Check the side view mirrors for dirt and damage. Adjust the angle of
the mirrors to gain a good side vision. (Refer to page 70.)

15 FORKS & FORK STOPPERS 19 SHIFT LEVER

Check for stoppers for correct installation and forks for bending or Check the shift lever for looseness and operation.
cracks.
20 LOADING LEVERS
Check the loading levers (for lift, tilt and optional attachment) for
looseness and smooth operation.

21 PARKING BRAKE LEVER

Make sure that the parking brake is securely applied by operating the
parking brake lever. (Refer to page 63.)

Start the engine ....

Before starting the engine, make certain the shift lever is in neutral
and parking brake is securely applied.

81
8-HOUR (DAILY) CHECK
22 MONITORING LAMPS 28 BRAKE PEDAL FREE TRAVEL
When the starter switch is turned ON, monitoring lamps (OIL & CHG) Press the brake pedal and inching pedal to make certain that each
come on. These lamps go off soon after the engine is started. (Refer pedal can be pressed smoothly and that it can also restore without
to page 57.) interference.

23 METERS& GAUGES FAN WARNING DECAL

The hour meter, coolant temperature gauge, automatic transmission
oil temperature gauge and fuel level gauge are provided to inform the
operator of the operating condition of the truck during operation. (Refer WARNING Stay clear of fan when
to page 55.) engine is running.
To avoid injury, keep
fingers and objects away
24 FUEL LEVEL from fan.
The fuel level gauge is provided on the indicator panel. Check that
fuel level is sufficient for the day’s work. (Refer to page 56.)

NOTE
Fill the fuel tank at the end of each work day. This practice will
reduce the condensation of moisture within the tank.

25 LIGHTS & LAMPS

Actuate each light or lamp switch to be certain that the respective
light or lamp comes on properly. (Refer to pages 70 & 71.)

26 TURN SIGNAL
Make sure that the turn signal operates properly by moving the turn
signal lever.

27 HORN BUTTON TEST

Press the horn button to make certain the horn sounds. (Refer to
page 60.)

82
 8-HOUR (DAILY) CHECK
29 MAST TEST 30 LIFT CHAIN TENSION
Check the tension and abnormality of the lift chains.
To check the tension, raise the fork about 5cm (1.97 inch) above
the ground, and push the middle of the chain with the thumb. Make
certain the tension for the right and left chains is even. If uneven
tension is found, loosen the lock nut (A) of anchor pin, and adjust the
chain, turning the adjusting nut (B) of the chain anchor pin.

Sound horn, and actuate the lift and tilt levers to be certain that the
carriage moves up and down properly and the mast can be tilted
smoothly. Make certain that the relief valve operates accompanying
its relieving sound when each cylinder piston reaches the stroke end.
Pay attention to the system operating sound.

NOTE
- WARM UP CYLINDERS –
Before proceeding the work, warm up the hydraulic cylinders. This
lubricates packings and seals in the cylinders to make them ready
for operation.
NOTE
Don’t use Grease but use Machine Oil (ex. Hydraulic Oil) only for
WARNING lift chain lubrication.
Don’t tilt the mast forward while the carriage is lifted high,
especially when a clamp attachment is fitted to the truck.

83
8-HOUR (DAILY) CHECK
31 STEERING HANDWHEEL FREE PLAY Run at a low speed…. (at a safe place)
Check the steering handwheel for play and vertical looseness. The 33 INCHING PEDAL TEST
normal play is 50 to 100 mm( 2 to 4 inches), and vertical looseness is
not permitted. Press the inching pedal a little (0-10 mm, 0 -0.4 inch) and check that
the truck speed decreases.

34 BRAKE TEST
Run the truck slowly, and press the brake pedal to check the braking
effect. When the brake pedal is pressed, the stop lamp comes on.
50 to 100 mm
(2 to 4 in.)

32 EXHAUST GAS CONDITION

WARNING
Exhaust fumes are very dangerous. When starting the lift
truck in an enclosed space, make sure there is enough
ventilation. The exhaust gas check should be done outdoors.
Especially take caution to avoid fire hazards. Pay special
attention to signs of oil or fuel leaks, and never leave waste
cloth or paper inside the engine room. Make sure you know
where the fire extinguishers are kept and how to use them.

Check condition of exhaust gas after the engine warm-up is finished.

Colorless ............................................. Normal: Complete combustion
Black .............................................. Abnormal: Incomplete combustion
White or bluish ..................................................... Abnormal: Oil burns
Check also the engine and driving system for clicking or any
abnormal noise or vibration.

84
 8-HOUR (DAILY) CHECK
35 STEERING TEST 37 BACK-UP LAMP AND ALARM TEST
Turn the steering handwheel while traveling slowly to see that the The back-up lamp comes on and the back-up alarm sounds when the
steering forces are equal in right and left or that any abnormality does shift lever is placed in the reverse position.
not exist.

NOTE
The steering system employs the power steering. While the engine
is shut down, the power steering becomes ineffective, causing a
heavy steering operation.

36 PARKING BRAKE TEST

Make certain that the slowly running truck can be stopped by pulling
on the parking brake lever. And also make sure the truck does not
move and keeps its stopping position.

85
MEMO

86
 STORING

BEFORE STORING DAIL Y STORAGE

Before storing your lift truck, clean it thoroughly, and perform •• Park the lift truck at a specified place, and block the wheels.
inspection using the following procedures: •• Place the shift lever(s) in the neutral position, and apply the
parking brake securely.
WARNING •• Shut down the engine by placing the key switch in OFF position.
If at any time your lift truck is found to be in need of repair, Actuate each loading lever several times to remove the residual
defective or in any way unsafe, the condition should be pressure in the respective cylinder and hose.
reported to the supervisor, an d the truck should be taken •• Remove the key, and keep it in a safe place.
out of service until it has been restored to safe operating
condition.

•• Wipe away grease, oil, etc. adhering to the body of the truck with
waste cloth, and use water, if needed.
•• While washing the truck body, check general condition of the truck.
Especially check the truck body for dent or damage and tires for
wear or nails or stones in the tread.
•• Fill the fuel reservoir with fuel specified.
•• Check for leakage of hydraulic oil, engine oil, fuel or coolant.
•• Apply grease, where needed.
•• Check for looseness of hub nuts, cylinder piston rod joints.
•• Check mast rollers to see that they rotate smoothly.
•• Prime oil into the lift cylinders by actuating the lift cylinders at the
full stroke.
•• Drain off coolant completely in winter or cold weather if antifreeze
or LLC is not used.

87
STORING
LONG-TERM STORAGE TO OPERATE THE LIFT TRUCK AFTER A
Perform the following service and checks in addition to the “DAILY LONG-TERM STORAGE
STORING” services: •• Remove covers used to seal off moisture.
•• Taking the rainy season into consideration, park the truck at a •• Remove antirust from the exposed parts.
higher and hard ground. •• Drain the engine crankcase, automatic transmission and
•• Remove the battery negative cable first, and dismount the battery differential; clean the inside of them; and add new oil.
from the truck. • Discharge foreign matter and water from the hydraulic oil reservoir
•
•• Even though the truck is parked indoors, if the place is hot or and fuel reservoir.
humid, the battery should be kept in a dry, cool place. Charge the • Remove a cover from the engine cylinder head, oil valves and
•
battery once a month. rocker shaft; and check each valve for proper operation.
•• Apply antirust to the exposed parts such as cylinder rods and • Add cooling water to the specified level.
•
shafts that tend to rust. •• Charge the battery, and mount it on the truck. Connect the cables.
•• Cover components such as the breather and air cleaner which may •• Perform preoperational checks carefully.
be caught with humidity. •• Warm up the truck
•• The truck should be operated at least once a week. Fill the cooling
system if cooling water is discharged, and mount the battery.
Remove grease from the cylinder rods and shafts. Start the engine
and warm up thoroughly. Move the truck a little forward and
backward. Operate the hydraulic controls several times.
•• Avoid parking on a soft ground such as an asphalt ground in
summer.

88
 OPERATIONS
To operate the truck safely and get the most out of it, correct RELATIONSHIP BETWEEN LOAD AND
operating procedures are described on the following pages:
STABILITV OF TRUCK
The lift truck keeps a balance of weights between the truck body and
DURING BREAK-IN the load on forks with the center of front wheels as a fulcrum when
It is recommended to operate the truck under light load conditions the rated capacity load is placed in position. Due care should be
for the first stage of operation to get the most from it. Especially the taken to the weight and the center of gravity of loads to maintain the
requirements given below should be observed while the truck is in a stability of the truck.
stage of 100 hours of operation.
•• Always warm up your truck before putting it to work irrespective of WARNING
season.
If the rated capacity is exceeded, there is ad anger of the rear
•• Perform specified preventive maintenance services carefully and
wheels being raised, an d in the worst case, the truck will turn
completely.
over, resulting in a fatal accident. As seen from the below
•• Avoid a sudden stop, start or turn.
sketch, the load placed near the fork tips practically has the
•• Oil changes and lubrication are recommended to do earlier than
same effect as the weight of the load being increased. In this
specified.
case, the load weight is reduced accordingly.
•• Don’t run engine needlessly at high rpm without load.

89
OPERATIONS
LOAD CENTER & RATED LOAD The load center is a distance from the front face of forks to the center
of gravity of the load. The chart given above shows the relation
WARNING between the load center and the weight of loads to be allowed for
the lift truck (Allowable Load). The Load Chart will be attached to the
The allowable load of the attachment equipped truck is
truck. The load charts for trucks with the two-stage mast are shown
reduced in comparison with that of the standard truck. If the
on pages 137. If your truck is equipped with an attachment or three-
truck is equipped with a load-handling attachment such as a
stage mast, the load chart should be replaced since the allowable
side shifter, lo ad grab or rotating clamp, its allowable load is
load reduces. Replace damaged or missing load chart with the new
reduced as compared with that of the standard truck (without
one.
any attachment) due to the following reasons:
Never exceed the allowable load indicated on the load chart
attached to the truck or attachment.
Reasons to reduce the allowable load:
1) The load equal to the weight of attachment is reduced.
2) Since the length of attachment causes the load center to
move forward, the allowable load is reduced on the same
principle as a seesaw.
The installation of attachment causes the load center to move
forward. This is called the “lost load center”.

90
 OPERATIONS

STABILITY OF LIFT TRUCK <Standard loaded condition>

The stability standard of lift trucks is specified by the ISO or other WARNING
standards. However, the stability stated in these standards is not
Use the minimum forward and reverse tilt when stacking and
applicable in all operating conditions. The stability of your lift truck
unstacking loads. Never tilt forward unless the load is over
varies according to the operating conditions.
stable stack or rigid rack or at low lift height.
In the following operating conditions, the maximum stability is
secured: This means that the forks or other load engaging means are raised
1) Ground or floor is level and hard. 30 cm (12 inches) above the ground, the given capacity load at the
2) Traveling under standard unloaded or loaded condition. basic load center, and the mast is tilted fully backward.

<Standard unloaded conditions>

This means that the forks or other load engaging means are raised 30
cm (12 inches) above the ground and the mast is tilted fully backward
without loads.

300 mm (12 in.)

In addition, the lift truck should be put in a good servicing condition to

do the job safely.
300 mm (12 in.)

91
OPERATIONS
OPERATION AFTER ENGINE HAS STARTED
•• Warm up the engine (for about 5 minutes.)
BEFORE STARTING ENGINE •• Check the rotation (sound or gear) of the engine.
•• Check the combustion (or misfiring) sound.
•• Before operating the truck, check all controls and warning devices
•• Check the condition (density) of exhaust.
for proper operation. If any damage or fault is found, don’t operate
•• Make sure that all the warning lamps are off.
the truck until corrected. Refer to pages 73 to 85.
•• After thoroughly warming up the engine, operate the loading levers
•• Check the safety around the truck.
2 or 3 times in their full stroke, and check their working conditions.
•• If grease or oil is sticking to the floor, pedals, levers or operator’s
hands; clean it off.
•• Make sure that the shift lever(s) and loading levers are in the
NEUTRAL and HOLD positions and that the parking brake lever is
fully engaged.

NOTE
Engine will not start unless the shift lever is in neutral.
(Manual transmission type)

STARTING THE ENGINE

Turn the ignition switch to the ON position until the GLOW indicator
goes out, and then turn the ignition switch to the START position.

•• If the engine is hard to start, check for a low fuel level, air mixed in
the fuel system or broken wire of the glow plug.
•• There is a case of the engine failing to start up even if the starter
motor is engaged. In such a case, start the engine by making use
of the auxiliary battery. When connecting the auxiliary battery,
follow the “EMERGENCY STARTING” procedure written on page
103.

92
 OPERATIONS

TRAVELING
OPERATOR’S POSTURE Depress the brake pedal, and
Hold the knob on the steering engage the forward-reverse lever.
wheel with your left hand, and get
the right hand ready for loading
work, lightly putting it on the
wheel.

BASIC STATE FOR TRAVELING Release the parking brake lever.

Set the bottom of forks 15 to 20
cm (6 to 8 inches) above the
ground, and fully tilt back the
upright.

Check for the safety around the Release the brake pedal, and
truck, and give a signal when depress the accelerator pedal to
starting the truck. start the truck.

93
OPERATIONS

WARNING STOPPING OR PARKING THE TRUCK

You must slow down WARNING
•• at aisle intersections, Safe Parking
•• in crowded areas, •• Park your truck on a level ground -preferably in a wide
•• on rough ground or floor surfaces, and area. If parking on as lope is unavoidable, direct the load
•• when approaching loads or obstacles. engaging means downgrade, an d block the wheels to
prevent an accidental roll.
•• Park your truck in a designated area or out-of-traffic. If
GEARSHIFTING necessary, put a signpost or signal lights around the truck.
Without loads, the truck can start even with gears in a high speed. •• Park your truck on a hard ground. Avoid soft ground, deep
However, under the loaded condition, place the gear in a low speed mud or slippery surfaces.
to start the truck. •• If you can not lower forks on the ground due to a
1) Always stop the truck before reversing the direction of travel. breakdown of the loading system, put a caution flag on the
fork end, an d park in an out-of-traffic area.
SLOWDOWN
Release the accelerator pedal depression a little, and press the brake Slow down, and press the brake pedal to stop the truck (in the case
pedal, if needed. of the clutch type, the clutch pedal is used). Place the shift lever in
NEUTRAL.
STEERING
Unlike general passenger cars, the steer wheels are located at the
rear of the truck. This causes the rear of the truck to swing out when
at urn is made. Slow down the truck, and move toward a side to
which you are turning. The steering handwheel should be turned a bit
earlier than as with the front-wheel steering car.
1) Grab the handwheel knob by your left hand. Your right hand is
used to operate the loading levers.

94
 OPERATIONS

NOTE GROUND CONDITION

Never stop the truck in ascending on a grade by pressing the WARNING
accelerator pedal with the clutch in the “half-clutch” and torque
•• When crossing a railroad truck, be sure to stop, an d make
converter in operation. This will cause undue wear of clutch plates
sure it is safe to cross.
and abnormal rise of torque converter oil temperature, resulting in
•• Go around rocks and stumps. If unavoidable, reduce the
a short life of the clutch or torque converter.
speed, and go slowly and carefully. Take caution not to
damage the bottom of the truck.
To park the truck: Park the truck in an out-of-traffic area and ...
Lift truck performance depends on the ground or floor conditions, and
1) Apply the parking brake by pulling back the parking brake lever.
travel speed should be adjusted properly. Take extreme care when
2) Down the forks to the ground.
operating on a ramp or rough ground or floor.
3) Place the key switch in the “OFF” position to shut down the
engine. Pull out the engine stop button.
4) Remove the key, and keep it.
5) Dismount from the truck carefully, using the safety step.

WARNING
•• Check for slippery steps and floor.
•• Don’t dismount from the moving truck.
•• Never jump off the truck.
•• Dismount carefully step by step.

95
OPERATIONS
GROUNDS COVERED WITH SNOW OR ICE 2. Place the truck right in front of the load to be handled.
3. The pallet should be evenly positioned across both forks.
WARNING 4. Insert forks into the pallet as far as possible.
5. To raise loads from the ground,
When equipped with tire chains, the truck gets a larger driving
(1) Once lift the forks 5 to 10 cm (2 to 4 inches) off the ground or
power. However, sideway antislip performance is almost
floor, and make sure loads are stable.
reduced; so extreme care should be taken.
(2) Tilt the mast fully backward, lift forks up to 15 to 20 cm (6 to 8
inches) off ground, and then start running.
When traveling on grounds covered with snow or ice, use tire chains.
6. When handling bulky loads which restrict your vision, operate the
On such ground conditions, a void sudden accelerations, stops or
truck in reverse except when climbing grades.
turns. It is a good practice to control the travel speed by accelerator
pedal effort.
STACKING LOAD
PICK-UP WARNING
1. The forks should be adjusted laterally to maintain the proper
•• Never tilt the mast with loads upraised 2 m (6 1/2 feet) or
balance of loads.
more.
To spread or to close the forks, tilt the mast forward, and lower
•• Don’t leave or dismount from the truck when the load is
the forks a little above the floor. Use hands and foot as illustrated
raised high.
to move the fork.
1. When approaching the deposit area, slow down your truck.
2. Once stop the truck right in front of the area where your load is to
be deposited.
3. Check the condition of the deposit position.
4. Tilt the mast forward until forks become horizontal. Raise forks
until they are a little higher than the deposit position.
5. Move forward to place the load directly over the desired area, and
stop the truck.
6. Make sure your load is just over the desired area. Slowly lower
the load onto position. Make sure the load is securely stacked.
7. Disengage forks from the load by using necessary lift-tilt
operation, and then back away.
8. After making sure the fork tips leave the load, lower the forks to
the basic position, 15 to 20 cm (6 to 8 inches) off the ground.
9. Tilt the mast backward

96
 OPERATIONS
UNSTACKING LOAD MEASURES AGAINST COLD & HOT WEATHERS
1. When approaching the area where the load is to be retrieved,
slow down your truck. OIL
2. Stop the truck in front of the load so that the distance between the Use the oil suitable for ambient temperature, referring to “List of
load and fork tips is about 30 cm (12 inches). Lubricants” on pages 132 & 133.
3. Check the condition of the load.
4. Tilt the mast forward until forks become horizontal. Elevate forks BATTERY
up to the position of the pallet or skid.
5. Make sure forks are positioned properly for the pallet. Move
WARNING
forward slowly to insert forks into the pallet as far as possible, and GASES produced by the battery can be explosive. Do NOT
then stop the truck. smoke, use an open flame, NOR create an arc or sparks in
* If the forks are hard to be fully inserted, use the following the vicinity of the battery. Ventilate well when in an enclosed
procedure: Move forward, and insert 3/4 of the forks. Raise the space and when charging. The battery contains SULPHURIC
forks 5 to 10 cm (2 to 4 inches), move backward 10 to 20 cm (4 ACID which causes severe burns. Do not get it in eyes nor
to 8 inches) with the pallet or skid on the forks, and then lower on skin or clothing. In case of contact, flush immediately and
the pallet or skid on the stack. Move forward again to insert the thoroughly with clean water. Obtain medical attention when
forks fully. eyes are affected.
6. Raise the forks 5 to 10 cm (2 to 4 inches) off the stack.
7. Check all around the truck to ensure that the path of travel is •• In Cold Weather
unobstructed, and back away slowly. Under normal charged condition, the freezing point of the electrolyte
8. Lower forks to a height of 15 to 20 cm (6 to 8 inches) above the is about -35ºC (-31ºF).
ground. Tilt the mast fully backward, and move to the desired Always keep the battery in a well charged condition since there is a
area. danger of damaging the battery container if electrolyte freezes.
To prevent the freezing, charge at least 75 % of the whole capacity.
Also it is effective to keep the specified gravity up to 1.260, but
not higher than this value.

•• In Hot Weather
As the water in the electrolyte is likely to evaporate particularly in hot
weather, replenish distilled water from time to time.
Check the battery once a week, and supply water.
In a region where the ambient temperature is extremely high, it is
practicable to lower the specified gravity of a completely charged
battery down to 1.220±0.01.
Since the battery is better in efficiency under hot temperatures,
no other cares are needed.
97
OPERATIONS
RADIATOR COOLANT BULB IDENTIFICATION
WARNING Light

Permanent antifreeze may contain a harmful or fatal Headlight 24V – 60W

compound if swallowed. Read carefully cautions on antifreeze Turn Signal Light, Front 24V – 25W
container. Don’t drink. If swallowed, induce vomiting Turn Signal Light, Rear 24V – 25W
immediately, and call a physician. Don’t store in opened or
Clearance Light 24V – 12W
unlabeled containers. Keep out of reach of children.
Tail Light 24V – 12W
Your lift truck is generally shipped with the cooling system filled Brake Light 24V – 25W
with Long Life Coolant (LLC) of 50 volumetric % mixture. The Back-up Light 24V – 15W
freezing point of the coolant of such a mixing ratio is -37°C (-34°F).
This coolant is permanent type antifreeze of ethylene glycol base License Plate Light (*) 24V – 12W
containing antirust and anticorrosion additives. You need not change Rear Work Light (*) 24V – 60W
coolant, in general, for about 2 years. But, when the coolant level is
low, add the required mixing ratio coolant of ethylene glycol base to
the specified level.

Freezing Point of Glycol Base Antifreeze

Vol. % Antifreeze Freezing Point

0 0°C (32°F) In hot weather: To maintain
25 -12°C (10°F) a good cooling effect, spe-
cial care should be taken to
30 -15°C (5°F)
radiator and cooling system.
33-1/3 -18°C (0°F) Parking in the shade is rec-
40 -24°C (-12°F) ommended.
50 -37°C (-34°F)

NOTE
When permanent antifreeze of the ethylene glycol type is used,
the coolant solution must contain at least 25% antifreeze, but not
exceeding 60%.

98
 OPERATIONS
WHEN REQUIRED Fuse See Key Below
③ (30A) A, C, D, E, F
④ (10A) J
⑤ (10A) Q
⑥ (10A) B, P, S, T, W, AB, AE
⑦ (10A) K, L, M, AC, AD
⑧ (10A) AE
① (30A), ② (10A) OPTION

[Key]
A: Headlight Q: Optional monitors (parking
B: CHG indicator brake, radiator, battery, fuel)
C: Clearance light S: Water temp. gauge
D: Brake light T: Hour meter
E: Taillight W: Torque conv. oil temp.
F: Plate light (*) gauge(*)
G: Work light (*) Y: OIL press. indicator
J: Horn AB: Buzzer acc. warning
K: Turn signal AC: F/R switch
L: Back-up light AE: Speed controller
M: Back-up alarm
① thru ⑤ have nothing to do with the key switch operation. ⑥⑦ & ⑧ P: Fuel gauge (*): Option
can be put in operation when the key switch is on.
Look through here
REPLACE FUSE
The fuse protects the electric system against overcurrent. Use a fuse
of the specific ampere rating. Check to see that the components in
each circuit are operating properly. If every component in a circuit is
not functioning, it is an indication that the corresponding fuse is blown
out. Replace the blown fuse with a spare fuse of the same capacity.
If a part of the components in the circuit does not function properly,
it is suspected that a bulb has burnt out. The burnt bulb should be Good Fuse Blown Fuse
replaced with new one of the same capacity. Side View of Fuse

99
OPERATIONS
•• Jack Up the truck to an extent that the tire
ARRANGEMENT OF SERRATED
still remains on the ground. Loosen the hub
ROUND HEAD BOLTS
nuts 1. Do not remove them.

OUTSIDE
1: Inside rim 3: Rim bolt 5: Nut
AVOID SEVERE INJURY OR DEATH. 2: Outside rim 4: Spring washer 6: Tire
Tire servicing requires special training.
Do not take tires off truck until all air pressure is
out. Loosen only WHEEL LUG NUTS “A”. WARNING
Do not loosen wheel assembly nuts “B” until all SAFETY CAGE
air pressure is out of tire. On some split type wheels, nuts are
See OPERATORS MANUAL for more important welded on the wheel or serrated round •• Again jack up the truck until the tire leaves
instructions for wheel service and reassembly.
Make sure all nuts and bolts are in place and head bolts are used. The split wheel off the ground. Remove the hub nuts, and
tight. half with welded nuts should be used as detach the wheel.
Never add air to a tire that looks low. Let all air the outside wheel. Serrated round head •• The wheel should be reinstalled in the
out and check for proper assembly. bolts should be arranged outside when reverse order. The hub nuts should be
Inflate all tires in a safety cage. See MANUAL for installed on the truck. Use special tool to tightened evenly in the diagonal order.
proper pressures. loosen/tighten serrated round head bolts. •• After reinstallation, check the tire for the
proper inflation pressure.
•• Tire inflation pressure
.............................................See page 129.
REPLACING OR REPAIRING TIRE
Prepare tools and jack necessary for replac- Rear Wheel
ing or repairing tires. Proceed in the same manner as with the front
Split-type Safety cage
wheel tire repair or replacement except for
Front Wheel the position of the jack which goes under the
•• Stop the truck on a level, hard surface, and counterweight.
shut down the engine. All loads should be Tire inflation pressure
unloaded from the truck. .............................................See page 129.
•• Apply the parking brake and block the See SERVICE SPECIFICATIONS on page
wheels. Put a jack under the truck frame. 129 for the hub nut and rim nut torque.
Refer to page 77 for hub nuts configuration.
100
 OPERATIONS

LIFTING PROCEDURE
I II

WOOD STEEL PLATE

BLOCKING

WARNING
•• Do not work on or under any truck that is supported only
by lift jacks or a hoist. Always use blocks or jack stands to
support the truck before performing any disassembly.
•• After supporting the lift truck with blocks, push and pull it
from all directions to make sure it is securely blocked.

FRONT SIDE (I)

1. Place chocks behind rear wheels.
2. Lift or jack up the outer mast with a hoist or a jack.
3. Place wooden blocks under both side frames. Gradually lower the
front end to the ground. Be careful not to dislocate blocks while
lowering.

FRONT SIDE (II) REAR SIDE

1. Place chocks behind rear wheels. 1. Place chocks in front of front wheels.
2. Tilt the mast fully backward, and put wooden blocks and steel 2. Jack up or lift the counterweight with a hoist.
plates under the outer mast as illustrated. 3. Place wooden blocks under both side frames. Also place blocks
3. Tilt the mast forward to the vertical position, and place wooden under the counterweight for safety. Gradually lower the rear end
blocks under both side frames. to the ground. Be careful not to dislocate blocks while lowering.
101
OPERATIONS

LIFTING
EYES

WARNING
Never hoist your truck at its overhead guard or counterweight,
otherwise there is the possibility of the chassis damage or FUSIBLE LINK WIRE
fall. An optional device termed the “chassis lifting eye” is
As a main fuse, a fusible link wire is provided between the battery
necessary in such use application requiring frequent hoisting
plus terminal and the truck electrical system sources excepting the
of the truck for relocation, for instance. If this is your case,
engine cranking system. If the truck electrical system does not work
consult our authorized dealer.
at all, check the fusible link wire condition.

Hoisting Your Truck

•• Use the Truck with Optional Lifting Eye.
•• Use wire rope strong enough to bear the weight of the
truck.
•• Do not use wire rope with kink, deformation, cuts of
elements or wear.
•• Hoist operation should be performed by trained personnel
only.
•• Never enter under the hoisted truck.

102
 OPERATIONS

EMERGENCY STARTING
WARNING
Do not push or tow this truck to start it, as you cannot steer
or, on some models, cannot brake the truck with the engine
stopped.

If your truck has a discharged battery, it can be started by using

energy from another battery - a procedure called “jump starting.

JUMP STARTING
WARNING
•• The major safety precaution is to make the final connection
to the ground (a solid, stationary metallic object) on the
engine at some distance from the battery. This helps reduce
a chance of explosion due to sparks.
•• Never expose the battery to an open flame. Wear eye
protection when working near any battery. Do not allow
battery fluid to contact eyes, skin or fabrics. Flush any 4. Instruction for Jumper Cable Connection
contacted area with water immediately and thoroughly. •• Connect the first jumper cable from the “+” (red) terminal ① on
one battery to the “+” (red) terminal ② on the other battery.
•• Never connect the “+” to the “-” (black), or the ‘“-”to the “+”.
1. The truck has two 12-volt batteries connected in series and a
•• Next, connect one end of the second cable to the grounded “-”
negative ground electrical system. Make sure that the other
(black) terminal ③ of a good battery.
vehicle has a same voltage and that the negative terminal is
•• Lastly connect the other end of the second cable to a stationary
grounded.
metallic point ④ on the truck with a discharged battery but at a
2. Position the vehicle with a good battery so that the jump starting
point away from the battery.
cable will reach. Do not allow the vehicles to touch.
5. Start the engine on the truck with a good battery, and run it at a
3. Turn off all electric accessories. Turn off the ignition switch, apply
moderate speed.
the parking brake firmly, and put the transmission in the “N”
6. Start the engine of the truck that has a discharged battery.
(neutral) state in both vehicles.
7. Remove the battery cable by reversing the above sequence.
WARNING
Check battery electrolyte level. Low level with plates
protruding above electrolyte can cause an explosion.
103
OPERATIONS
2. Loosen the priming pump from the fuel ADJUSTING PROCEDURE
injection pump, and continue pumping 1. Measure the pulling force on the lever
BLEED until bubbles no longer come out of the grip center by using a spring balance as
PLUG bleed plug. illustrated.
3. Fasten the bleed plug firmly. 2. If the force is not in the range specified on
4. Faster the priming pump securely. the decal, adjust it by turning the screw as
illustrated.
WHEN ADJUSTING PARKING BRAKE … 3. When the brake cable is newly replaced,
the initial elongation may occur, so
adjustment should be performed after
PRIMING PUMP
operating the lever several times.

View from G

AIR BLEEDING OF THE FUEL

SYSTEM
WARNING
•• Check whether fuel is leaking from
the bleed plug or not as there is a
danger of fire.
•• Neatly wipe off fuel sticking on
surroundings; otherwise, it causes an
outbreak of fire.

AIR BLEEDING PROCEDURE

In the case where the air enters the fuel
system when the fuel filter is changed or the
fuel tank is emptied, be sure to execute the
following air bleeding:
1. Loosen the bleed plug on the fuel injection
pump.
104
 PERIODICAL MAINTENANCE
Just as your body needs to undergo physical examinations, your WARNING - MAINTENANCE
truck needs periodical checks and maintenance.
When the truck appears to be in good condition, checks and Repair is allowed only by trained and authorized mechanics.
maintenance are likely to be neglected. But early discovery of a
Completely deflate tires before removing split rim nuts or lock
trouble which may decrease truck efficiency and immediate correction ring. Before inflating tire, torque all bolts and nuts properly. Do
will greatly. Increase the working capacity of the truck, bring about not overinflate.
more effective productivity, prolong its life span and make it more
economical. To charge the battery or to check electrolyte level, never allow
flame or sparks. Lead acid battery produces flammable and
explosive gases. No smoking in charging area.
PERIODICAL REPLACEMENT OF SECURITY PARTS
In order to perform safety operation, the importance of preventive Battery acid causes severe burns. When maintaining battery,
maintenance of the truck cannot be overemphasized. Especially, the wear protective clothing such as eye protection, long sleeve and
gloves.
parts listed in the table below must be replaced periodically since they
are the most important parts for security of the truck and operator. If acid contact eyes, skin or clothing, flush well with water.
Moreover these security parts are liable to be damaged and For contact with eyes, get immediate medical attention.
deteriorated in the course of time, and it is difficult to determine by
ordinary maintenance whether they are beyond their respective When diluting concentrated sulfuric acid to make up electrolyte,
ALWAYS add acid to water and not the water to the acid.
service limits or not. The security parts must be replaced with new
ones when their respective service limits have been reached, even if When charging batteries, the vent caps shall be kept in place to
their appearances are good. The security parts are, however, not the avoid electrolyte spray. Assure that vent caps are functioning.
objects of warranty claim. The battery cover shall be open to dissipate heat and gas.

Recommended Service Limit Disconnect battery terminals when servicing or checking electric
Name of Security Part system parts.
(year)
Cups and dust seals of master cylinder and Pay particular attention when jacking up the truck. Fix it safety
1
wheel cylinder by using stands or blocks.
Power steering hoses 2
Set up a sign post or a warning board to arouse attention for
Fuel hoses 2 to 4 prohibition of key switch or lever operation when servicing.
Rubber parts inside the power steering
2 Never stands beneath upraised carriage or forks. Block the mast
cylinder
rails and carriage while servicing.
Hydraulic hoses for loading 1 to 2
Brake fluid reservoir tubes 2 to 4 Keep body and loose objects and clothing away from the electric
contacts or moving parts.
Lift chains 2 to 4
Leaks from high pressure hydraulic systems can cause injury.
Use gloves and cardboard, not hands, to locate leaks.

105
PERIODICAL MAINTENANCE
ENGINE ROOM 1. BATTERY
2. AIR CLEANER
11 4 15 3 18 12 5 8 9 2 11 3. ENGINE OIL FILL PORT
4. EXHAUST PIPE
5. INJECTION NOZZLE
6. HYDRAULIC OIL RESERVOIR CAP
7. HYDRAULIC OIL SUCTION PIPE
8. BLOW-BY GAS HOSE
9. ENGINE OIL FILTER
10. RADIATOR RESERVE TANK
11. HOOD DAMPER
12. CRANKCASE BREATHER
13. HYDRAULIC OIL RESERVOIR
BREATHER
14. HOOD CATCH
10 15. HYDRAULIC RETURN FILTER
16. FUEL TANK
17. FUSE
18. ENGINE OIL DIPSTICK

6 7 13 1 14 16 17

6BG1

106
 PERIODICAL MAINTENANCE

200-HOUR OPERATION (MONTHLY) CHECK 19. Forks – Check for bends, cracks and wear.
20. Mast cross members – Check cracks or bends on welding parts.
21. Mast support cap bolts – Check for looseness (first time only).
Perform 8-hour (Daily or Every Shift) Checks in addition to the
22. Mast – Check for defective weld, cracks or damage.
following. Refer to the text or SERVICE SCHEDULE chart for details.
23. Mast – Check rollers, roller pins and weld parts for cracks or
damage.
1. Air cleaner – Clean the element.
24. Fork carriage – Check for bends and cracks on welding parts.
2. Engine oil – Drain and refill with the specified new oil.
Check fork stopper pins.
3. Engine oil filter – (New engine only) Replace the oil filter
25. Lift chains – Check for deformation, and lubricate with hydraulic
cartridge with the new one at initial 200-hour operation.
oil if needed.
4. Radiator hose – Check deterioration.
26. Chain anchor bolts – Check for lashes between anchor bolts and
Radiator cap – Check springs and packing.
chain connecting links.
5. Shift lever(s) – Check for operation and lashes.
27. Chain wheel and bearing – Check for wear and lashes.
6. Automatic transmission – Check the oil level.
28. Attachment (if equipped) – Check for correct installation and
Replace the in-line filter cartridge at initial 200-hour operation.
check for bends and cracks on parts.
7. Front axle – Check for oil level and leakage.
29. Hydraulic cylinders – Check rod end fasteners for correct torque
8. Front axle mounts – Check for looseness of mount bolts.
and rod for bends or damage.
9. Wheels – Check for tread depth, cracks or defects.
30. Control valve – Check for relief valve operation. Check for tilt
10. Wheel bearing – Check for looseness or noise
lock valve operation.
11. Front axle tube and rear axle housing – Check for deformation,
31. Wiring harness – Check for damage or loose wire clamps.
cracks and poor welding.
32. Grease fittings – Lubricate with lithium base multipurpose
12. Steering gear box – Check for oil leakage and looseness of
grease.
mount bolts, and retighten, where necessary.
•• Mast support bearing – 2 fittings.
13. Steering linkage – Check for lashes, bends or cracks.
•• Tilt cylinder bushings – 4 fittings.
14. Rear axle mounts – Check for bolt torque.
•• Rear axle steering linkage – 7 or 8 fittings.
15. Brake pedal – Check for spongy reaction. (Bleed air if
•• Brake pedal shaft – 1 fitting.
necessary).
•• Steering handwheel shaft – 1 fitting each
Inching pedal – Check the booster or the release cylinder for
33. Piston head guide and outer mast top slippers – Lubricate.
leaks.
16. Parking brake cable and linkage – Check for proper operation or
loose fasteners.
17. Brake hydraulic piping – Check piping for damages, leakage or
contact with moving parts.
18. Brake drum & brake shoe – Check the drum mounting part for
looseness.
8- and 10-ton models only Check the clearance between the
brake drum and the brake shoe.
107
PERIODICAL MAINTENANCE

AIR CLEANER ELEMENT CHECK [1]

The air drawn into the air cleaner is made a high-speed whirl by Clean the element and case of the air cleaner at every 200-hour
plastic fins provided at the outer case. At this time, most of dust is operation. Remove the cup and take out the element. Clean the
separated from the air flow by centrifugal force and collected into the element with air blow from inside or by tapping the side to remove
dust cup. The dust remaining in the air is removed by the element. dust sticking to it. Change the element at every 1200 operating hours
in usual operating conditions. A close observance will determine the
most adequate frequency of air cleaner maintenance.

108
 PERIODICAL MAINTENANCE

6BG1

ENGINE OIL CHANGE (8) Clean the drain plug.

Change engine oil every month (200 operating hours). For new (9) After oil is drained off, reinstall the drain plug.
trucks, engine oil change should be performed at the first 50 hours or (10) Wipe clean on and around the drain plug.
after one week. (11) Wind a clean cloth around the drain plug hole neck to catch spilt
oil.
Before Changing Oil (12) Add oil up to the specified level, leaving a room of one liter, and
Start the engine, and warm it up until engine oil warms. Move the then gradually add oil, observing the oil level gauge.
truck to a level surface, and fully pull up the parking brake lever. Shut (13) Wipe clean around the filter port, and reinstall the oil filler cap
down the engine, and remove the key. Swing open the hood. securely.
(14) Start the engine, and run it at idle rpm to prime oil throughout
Oil Changing Procedure the engine.
(1) Engine oil fill port (A). (15) Shut down the engine. After a while, check the level gauge to
(2) Wipe it clean with a cloth. make certain that the oil level is between “L” and “H” on the level
(3) Put a pan around the drain plug of the oil pan to catch drained gauge. Add oil if, necessary.
oil.
(4) Clean the drain plug and oil pan with a cloth. SAVE THE EARTH
(5) Loosen the plug with a socket wrench. Do not drain waste oil into a waterway nor throw it away
(6) Once the plug becomes loose, turn it with fingers. on the ground. Disposal of waste oil should be left to a
(7) Oil will eject out of the drain hole. Place an oil catching pan specialist. Forklift truck dealer will undertake oil change job, if
properly. requested.

109
PERIODICAL MAINTENANCE
GREASE-UP PROCEDURE

•• Add grease suitable for ambient temperature to each part.

•• When supplying new grease or adding grease, take care to prevent
any foreign matter from mixing in.

(1) A grease gun is optionally attached to your lift truck.

Pull out the grease gun rod to the full, and lock by twisting it.
(2) Remove the gun head from the cylinder.
(3) Fill the cylinder with a good quality chassis grease.
(4) Screw the grease gun head into the cylinder.
(5) Apply grease through all fittings shown on the next page.

110
 PERIODICAL MAINTENANCE

GREASE FITTING LOCATION

Fully hydrostatic steering
Mast support: 2 fittings
Tilt cylinders: 4 fittings

Rear axle
(Semi-integral type): 7 fittings
(Fully hydrostatic type): 8 fitting

Semi-integral Type Steering

111
PERIODICAL MAINTENANCE
Steering handwheel shaft: 1 fitting ④ PISTON HEAD GUIDE & OUTER MAST TOP SLlPPERS

Lubricate the guide channels and the mast top slippers with lithium
Brake pedal shaft: 1 fitting base multipurpose grease.

112
 PERIODICAL MAINTENANCE

600-HOUROPERATION (3-MONTH) CHECK 1200-HOUR OPERATION (6-MONTH) CHECK

Perform following checks in addition to 8-HOUR& 200-HOUR Perform following checks in addition to 8-HOUR, 200-HOUR &
CHECKS. Refer to the text or SERVICE SCHEDULE chart for details. 600-HOUR CHECKS. Refer to the text or SERVICE SCHEDULE
chart for detail.
1. Engine oil filter – Change the element.
2. Fuel filter – Change the element. 1. Air cleaner – Change the air cleaner element.
3. Fuel tank – Drain. 2. Valve clearance – Check.
4. Radiator – Drain & refill water or coolant other than permanent 3. Injection nozzle – Check injection start pressure & spray pattern.
type. 4. Automatic transmission line filter – Change.
5. Fork stopper pin & fork stopper bolt – Check for damage and 5. Automatic transmission fluid – Change.
wear. 6. Differential – Change the gear oil.
6. Distributor – Check for cracks of the cap, air gap between the 7. Hydraulic oil tank – Clean the suction strainer. Change the oil.
rotor and the stator and the condition of the rotor. 8. Hydraulic line return filter – Change.
7. Engine starter motor – Check the pinion gear and for meshing 9. Mast support cap bolt – Check for looseness.
condition with the ring gear. 10. Hydraulic control valve – Check relief valve setting pressure.
8. Battery – Check the specific gravity of the electrolyte. Check the 11. Operator’s seat – Check damage, and check for loose fasteners.
charger (generator) operation. 12. Wheel bearing – Disassemble, clean the front and rear wheel
9. Brake – Check automatic clearance adjuster for proper operation bearings, and repack using a wheel bearing grease.
[6- and 7-ton models] – Refer to page 115.
Adjust the drum and shoe clearance [8- and 10-ton models] –
Refer to SERVICE MANUAL.
10. Crankcase air breather – Clean

113
PERIODICAL MAINTENANCE

6BG1 FUEL FILTER CARTRIDGE

ENGINE OIL FILTER FUEL FILTER CHANGE

In general, the engine oil filter should be replaced or cleaned when WARNING
the engine oil is changed. Under usual operating conditions, the
engine oil filter should be replaced at initial 200 operating hours and •• Carry out cleaning and change work of the fuel filter after
afterward every 600 operating hours. After replacement, start the stopping the engine and under the atmosphere of no fire.
engine, and run at idle rpm for a while to check that there is no leak •• When removing the fuel filter cartridge, pay attention to
from the filter mounting position. Inspect the engine oil level to make handling of the cartridge because fuel is remaining inside
certain that the level is between “H” and “L” on the level gauge. the cartridge.

Replace the cartridge type filter (A) with the new one. Use an oil filter 1. Using a filter wrench, remove the cartridge.
wrench to remove the cartridge. For catching spilt oil, put a cloth 2. To fit the new cartridge, apply fuel to the packing thinly, and screw
under the cartridge when removing it. (The cartridge contains about in the new cartridge.
0.4 liters of oil.) Wipe off dirt and foreign matter from the engine side Using the filter wrench, tighten the new cartridge about 2/3 of a
mounting surface. Then install a new cartridge filter as follows: Apply turn further after the packing comes in contact with the seal face.
oil on the oil seal surface of the filter about 1 1/4 of a turn.

114
 PERIODICAL MAINTENANCE
BRAKE SHOE AUTOMATIC CLEARANCE ADJUSTER CHECK AUTOMATIC TRANSMISSION IN-LINE FILTER CHANGE
6- and 7-ton models

Check the brake shoe automatic clearance adjuster for proper

operation using the following procedures:
(1) While rotating the engine at high idle, press the brake pedal for
about 10 seconds to accumulate the pressure.
(2) Stop the engine and place the starter switch to ON. (Do not star
the engine.)
(3) Repeat the operation of pressing the brake pedal fully to the
stopper and count how many times the pedal should be pressed
until the alarm sounds.
(4) If the times of pressing the pedal are 6 or more, the brake system
is normal.
If the times of pressing the pedal are 5 or more, the brake system
is abnormal.
(Troubleshooting: Refer to SERVICE MANUAL.)
Stop the engine, after relieving the pressure, remove the filter shown
above, and change with the new one.
Usually change the filter at every 1,200 operating hours, but change
it at the initial 200 operating hours only while the truck is new.

115
PERIODICAL MAINTENANCE
2400-HOUR OPERATION (1-YEAR) CHECK 12. Distributor – Check the high-voltage cord for breakage. Check
installation of the cap and high-voltage cord. Check also the
Perform following checks in addition to 8-HOUR, 200-HOUR,
segment for burnt and the center piece for wear and damage.
600-HOUR& 1200-HOUR CHECKS. Refer to the text or SERVICE
13. Major bolts and fasteners -Check for proper torque.
SCHEDULE chart for details.

1. Cylinder head bolts – Retighten.

2. Cylinder block – Measure compression pressure.
3. Injection pump – Check injection timing.
4. Governor – Check operation.
5. Parking brake (center brake) – Check the drum and the lining for
clearance, wear or damage. [6- thru 10-ton models]
6. Brake booster cylinder and wheel cylinder – Check for proper
function, leakage or damage.
7. Brake booster cylinder and wheel cylinder –Disassemble and
check following parts. Change if necessary.
•• Cylinder bore – Rust, damage or wear.
•• Compression spring – Wear or deformation.
•• Cylinder cup, piston cup, outlet check valve – Change.
•• Push rod – Deformation.
•• Cylinder boots – Damage.
8. Brake drum and shoe – Disassemble and check following items:
•• Drum fasteners – Torque.
•• Linings -Wear.
•• Shoe – Check for operation; adjust if necessary.
•• Anchor pin – Check for rust, and lubricate, where necessary.
•• Return spring – Wear and deformation. Change, if necessary.
•• Automatic adjuster – Check lever or wire. Change, if
necessary.
•• Drum – Uneven wear or slots. Grind if, necessary.
•• Backing plate – Check for deformation and cracks. Check for
loose fasteners.
9. Hydraulic pump drive coupling – Check for wear. Lubricate.
10. Mast support bearing – Check for wear. Check the support
member for deformation or cracks.
11. Main frame members – Check for damage and cracks.

116
 PERIODICAL MAINTENANCE

PREVENTIVE MAINTENANCE SERVICE SCHEOULE

This service 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 preventive maintenance services are required. (The black dots in the table means “Replacement”.)

ENGINE
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)

Visually inspect condition of engine rotation. ○ ○ ○ ○ ○

Check for working noise from engine. ○ ○ ○ ○ ○

Check that exhaust gas has proper color. ○ ○ ○ ○ ○

Clean or change air cleaner element. ○ ○ ● ●

Engine
Check crankcase air breather for dirt and clean. ○ ○ ○

Check that valve clearance is correct. Thickness gauge ○ ○

Retighten cylinder head bolt. Torque wrench ○

Compression
Check cylinders for proper compression. ○
gauge

Governor or
Check no-load maximum rpm. Tachometer ○
injection pump

Check for engine oil leak. ○ ○ ○ ○ ○

Check engine oil for level and dirt. ○ ○ ○ ○ ○

Lubrication
● (at initial
system Change engine oil ● ● ●
50 hrs.)

Change engine oil filter cartridge. ● (at initial ● ● ●

200 hrs. only)

117
PERIODICAL MAINTENANCE

ENGINE
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Visually check for fuel leak from pipe, pump or tank. ○ ○ ○ ○ ○

Check fuel filter for clogging. ○ ○ ○

Replace fuel filter cartridge. ● ● ●

Check that injection nozzle has correct injection pressure and pattern. Nozzle tester ○ ○
Fuel system
Check for injection timing. ○

Drain off water from fuel tank. ○ ○ ○

Clean fuel tank. ○ ○

Check for fuel level. ○ ○ ○ ○ ○

Check for coolant level. ○ ○ ○ ○ ○

Check for coolant leak. ○ ○ ○ ○ ○

Check hoses for deterioration. ○ ○ ○ ○

Cooling system
Check radiator cap for condition and installation. ○ ○ ○ ○

Clean and change coolant. ● (every 2

● ●
yrs. for LLC)

Check fan belt for tension and damage. ○ ○ ○ ○ ○

118
 PERIODICAL MAINTENANCE

POWER TRAIN
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check for fluid leaks. ○ ○ ○ ○ ○
Check for fluid level or change fluid. ○ ○ ● ●
Check shift lever for operation and looseness. ○ ○ ○ ○
Automatic Check control valve and clutch for proper operation. ○ ○ ○ ○ ○
transmission
Check inching valve for proper operation. ○ ○ ○ ○ ○
Check inching pedal for free travel and pedal travel. ○ ○ ○ ○ ○
● (at initial
Replace in-line filter element. ● ● ●
200 hrs.)
Check for oil leak. ○ ○ ○ ○ ○
Front axle Check oil level. Change oil. ○ ○ ● ●
Check mounting bolts for looseness. Test hammer ○ ○ ○ ○

AXLES
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check for inflation pressure. Tire gauge ○ ○ ○ ○ ○
Check for cracks or damage. ○ ○ ○ ○ ○
Tires Check for tread wear. Depth gauge ○ ○ ○ ○
Check for undue wear. ○ ○ ○ ○ ○
Check for spikes, stones or foreign matter. ○ ○ ○ ○
Check for looseness. Test hammer ○ ○ ○ ○ ○
Tire fastners
Check for damage. ○ ○ ○ ○ ○
Rim, side ring Check rim, side ring and disk wheel for damage. ○ ○ ○ ○ ○
Check for looseness and noise. ○ ○ ○ ○
Wheel bearing
Clean and repack grease. ● ●
Axle Check axle for deformation, cracks or damage. ○ ○ ○ ○

119
PERIODICAL MAINTENANCE

STEERING SYSTEM
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check for peripheral play. ○ ○ ○ ○ ○

Steering Check for vertical looseness. ○ ○ ○ ○ ○

handwheel Check for sideways looseness. ○ ○ ○ ○ ○

Check for proper operation. ○ ○ ○ ○ ○

Steering gear
Check mounting bolts looseness. ○ ○ ○ ○
box

Check for looseness. ○ ○ ○ ○

Rod, arm, etc.
Check for deflection, damage or undue wear. ○ ○ ○ ○

Check king pins for looseness or damage. ○ ○ ○ ○

Knuckle & rear
Check for deflection, deformation, cracks or damage. ○ ○ ○ ○
axle
Check for mounting condition. Test hammer ○ ○ ○ ○

Check for operation. ○ ○ ○ ○ ○

Power steering Check for oil leaks. ○ ○ ○ ○ ○

Check for mounting parts and joints for looseness. ○ ○ ○ ○

Check for free travel. ○ ○ ○ ○ ○

Check for pedal travel. Scale ○ ○ ○ ○ ○

Brake pedal
Check for proper operation. ○ ○ ○ ○ ○

Check for air mixed in brake piping. ○ ○ ○ ○

Parking brake Check that lever is securely locked and has sufficient lever stroke. ○ ○ ○ ○ ○
lever Check for proper operation. ○ ○ ○ ○ ○

Check for operation. ○ ○ ○ ○

Rod, cable, etc.
Check connections for looseness. ○ ○ ○ ○

Check for damage, leakage or collapse. ○ ○ ○ ○

Hoses and pipes
Check for loose connections or contacts with moving parts. ○ ○ ○ ○

120
 PERIODICAL MAINTENANCE

STEERING SYSTEM
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check for oil leaks. ○ ○ ○ ○ ○

(Check for oil level. Change hyd. oil.) ○ ○ ○ ● ●

Brake booster
Check booster cylinder and wheel cylinders for proper operation. ○
cylinder, wheel
cylinder Check booster cylinder and wheel cylinders for fluid leaks or damage. ○

Check booster cylinder piston cup, and check valve for wear or
●
damage. Change.

Check drum mounting part for looseness. Test hammer ○ ○ ○ ○

○ ○
Check lining for wear. Slide calipers (8- and 10- (6- and 7-ton ○ ○
ton models) models)

Check brake shoes for proper operation. ○

Brake drum &
brake shoe Check anchor pin for rust. ○

Check return spring for deterioration. Scale ○

Check auto. clearance adjuster (6- and 7-ton models).

○ ○ ○
Adjust shoe clearance (8- and 10-ton models).

Check drum for wear or damage. ○

Check back plate for deformation. ○

Back plate Check for cracks. Penetrant test ○

Check mounting parts for looseness. Test hammer ○

Check clearance between drum and lining. Thickness gauge ○

Check drum mounting part for looseness. Test hammer ○

Center brake
Check lining for wear. Slide calipers ○●

Check drum and cam for wear, damage or cracks. ○

Check for function. ○

Boosting device
Check for proper operation. ○ ○ ○ ○ ○

121
PERIODICAL MAINTENANCE

LOADING SYSTEM
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check forks for damage, deformation or wear. ○ ○ ○ ○ ○

Forks Stopper pins & bolts for damage or wear. ○ ○ ○

Check fork base and hook welding for defective cracks or wear. ○ ○ ○ ○

Check cross members on outer and inner masts for defective weld,
○ ○ ○ ○
cracks or damage.

Check tilt cylinder bracket and mast for defective weld, cracks or
○ ○ ○ ○
damage.

Check outer and inner masts for defective weld, cracks or damage. ○ ○ ○ ○

Check for defective weld, cracks or damage of lift bracket. ○ ○ ○ ○

Mast & lift bracket Check roller bearings for looseness. ○ ○ ○ ○

Check mast support bushings for wear or damage. ○ ○

○ (for 1st
Check mast support cap bolts for looseness. Test hammer ○ ○
time only)

Check lift cylinder tail bolts, piston rod head bolts, U-bolts, and piston ○ (for 1st
Test hammer ○ ○ ○
head guide bolts for looseness. time only)

Check rollers, roller pins and welded parts for cracks or damage. ○ ○ ○ ○

Check chains for tension, deformation, damage or damage. ○ ○ ○ ○ ○

Lubrication of chains. ● ● ● ●

Chains & sheave Check connection of chain anchor pin and chain for looseness. ○ ○ ○ ○

Check sheaves for deformation or damage. ○ ○ ○ ○

Check sheave bearings for looseness. ○ ○ ○ ○

Optional
Perform general inspection. ○ ○ ○ ○
attachment

122
 PERIODICAL MAINTENANCE

LOADING SYSTEM
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check piston rod, screw and rod for looseness, deformation or
Test hammer ○ ○ ○ ○ ○
damage.

Cylinders Check cylinders for proper operation. ○ ○ ○ ○ ○

Check for oil leaks. ○ ○ ○ ○ ○

Check pins and cylinder bushings for wear or damage. ○ ○ ○ ○

Check hydraulic pump for oil leaks or noise. ○ ○ ○ ○ ○

Hydraulic pump
Check pump drive gear for wear. ○

HYDRAULIC SYSTEM
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check for oil level. Change oil. ○ ○ ○ ● ●
Hydraulic
Clean suction strainer. ● ●
reservoir
Drain foreign matter. ○ ○

Return filter Replace return filter. ● ●

Check levers for looseness at link. ○ ○ ○ ○ ○

Control lever
Check for proper operation. ○ ○ ○ ○ ○

Check for oil leaks. ○ ○ ○ ○ ○

Control valve Check relief valve and tilt lock valve for proper operation. ○ ○ ○ ○

Measure relief pressure. Oil pres. gauge ○ ○

Hose, piping Check for oil leaks, looseness, collapse, deformation and damage. ○ ○ ○ ○ ○
hose reel & ● (1 or 2
swivel joint Change hoses.
years)

123
PERIODICAL MAINTENANCE

ELECTRICALS
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Starter Check pinion gear for correct engagement. ○ ○ ○

Charger Check charger for proper operation. Ammeter ○ ○ ○

Check battery electrolyte level.

○ ○ ○ ○ ○
Battery Clean battery.

Check specific gravity of electrolyte. Hydrometer ○ ○ ○

Check wire harness for damage and clamps for looseness. ○ ○ ○ ○

Wiring
Check connections for looseness. ○ ○ ○

SAFETY APPARATUS & ACCESSORIES

Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)

Overhead guard Check for tight installation. Test hammer ○ ○ ○ ○ ○

& load backrest Check for deformation, cracks or damage. ○ ○ ○ ○ ○

Turn signal Check for proper operation and tight installation. ○ ○ ○ ○ ○

Horn Check for proper operation and tight installation. ○ ○ ○ ○ ○

Light & lamps Check for proper operation and tight installation. ○ ○ ○ ○ ○

Back-up alarm Check for proper operation and tight installation. ○ ○ ○ ○ ○

Check for dirt or damage. ○ ○ ○ ○ ○

Side view mirror
Check for good field of vision. ○ ○ ○ ○ ○

Meters Check meters for proper operation. ○ ○ ○ ○ ○

Reflex reflector Check for dirt or damage. ○ ○ ○ ○ ○

Seat belt (if fitted) Check for damage. ○ ○ ○ ○ ○

Operator’s seat Check for damage or loose bolts. ○ ○

124
 PERIODICAL MAINTENANCE

SAFETY APPARATUS & ACCESSORIES

Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
item (8 hrs.) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check frame and cross members for damage or cracks. ○

Check for loose rivets or bolts. Test hammer ○

Body
Check items repaired in previous inspection, if any. ○ ○ ○ ○ ○

Inspect general condition of body. ○ ○ ○ ○ ○

Grease-up & oil After cleaning, check for greased condition of chassis. Grease pump ● ● ● ●
change Check condition of oil and fluid in reservoir. ○

CAUTION
Local refined oil and cooling water, coolant, or anti-freeze do not allow the same operation period designated in this manual.
So they must be changed more frequently as half or quarter of the period designated in this manual.

Multi-viscosity oils allow a wider temperature range for operation but must be changed more frequently as an additive that provides
the multi-viscosity gradually deteriorates, lowering the viscosity. Degradation of viscosity at a higher temperature can be very
detrimental to the hydraulic system.

125
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126
 OPTIONAL ITEM MAINTENANCE
EXHAUST GAS PURIFIER/CATALYST TYPE MUFFLER ATTACHMENTS
These are designed to remove CO and HC contained in exhaust gas
from the engine with the aid of a catalyst. It is recommended to use CAUTION
these devices in in-plant works. In these trucks, the relief pressure of hydraulic control
valve is raised to a relatively high value. (Refer to SERVICE
SPARK ARRESTER MUFFLER SPECIFICATIONS on the next page.) Pay keen attention to
This removes sparks and soot from exhaust gas from the engine. this regard whenever the attachment having any hydraulic
For safety sake, use this muffler for your truck. component is mounted.

Reference Data
• Replace the catalyst with a new one every 600 hrs.
• Remove soot from the spark arrester muffler every 600 hours.

NOTE
When replacement of the catalyst is required, it is necessary to
dismount the counterweight from the truck before removing the
muffler. For this purpose, a crane or the like should be prepared.

127
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128
 SERVICE SPECIFICATIONS

ENGINE “6BG1” Diesel AXLES

Tire inflation pressure:
Idle r.p.m. rpm 700 – 750 6-ton model 700 kPa [7.0 kg/cm2] (front & rear)
High idle r.p.m. rpm 2200 – 2300 7-ton model 800 kPa [8.0 kg/cm2] (front & rear)
Firing (injecting) order 1-5-3-6-2-4 8-ton model 750 kPa [7.5 kg/cm2] (front & rear)
10-ton model 750 kPa [7.5 kg/cm2] (front & rear)
Ignition (injection) timing °/rpm 14°B.T.D.C.
Injection start press. MPa [kg/cm ] (psi) 14.7 [50] (2133)
2

Spark plug - STEERING

Steering handwheel peripheral play:
Spark plug gap mm (in.) -
50 to 100 mm (2 to 4 in.)
Valve clearance mm (in.) 0.40 (0.016)
CONVERSION TO SI UNITS
- cold engine - SI: The international System of Units
Cylinder head bolt torque N-m [kg-m] (ft-lbs) Force: 1 kg = 9.81 N
* See Engine Shop Manual Torque: 1 kgm = 9.81 N-m
Pressure: 1 kg/cm2 = 0.0981 MPa
Power: 1 PS = 0.7355 kW
HUB NUT TIGHTENING TORQUE
Unit: N-m [kg-m]
6- and 7-ton 8- and 10-ton BRAKES
Model
models models
Automatic transmission Type
Front hub nuts, inner and outer 470 - 550 [48 - 56]
Brake pedal upheight: Ask your dealer/distributor.
16 - 25 30 - 45 Inching pedal upheight: Ask your dealer/distributor.
Planet spider - sun gear thrust cap
[1.6 - 2.5] [3.08 - 4.62] Brake pedal free travel: Ask your dealer/distributor.
96 - 111 91 - 154 Inching pedal free travel: Ask your dealer/distributor.
Front hub - planet spider
[9.8 - 11.3] [9.3 - 15.7]
Rear wheel 470 - 550 [48 - 56]

129
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130
 REFILL CAPACITIES

LUBE POINTS 6- and 7-ton models 8- and 10-ton models

1 Engine crankcase 13 (3.4)

2 Cooling system 26 (6.9)

3 Fuel tank 140 (37.0)

4 Automatic transmission 23.5 (6.2)

5 Reduction gear & differential 10 (2.64)

6 Final reduction gear (each) 4 (2.1) 5 (2.64)

7 Hydraulic oil tank 60 (15.85)

FUEL RECOMMENDATION
Use diesel fuel at 40 cetane rating or higher.
Suitable are all usual diesel fuels in line with DIN 51601, SAE No. 2-D and BS Class A-1.

DIESEL FUELS
APPLICABLE STANDARD RECOMMENDATION
JIS (JAPANESE INDUSTRIAL STANDARD) No. 2
DIN (DEUTSCHE INDUSTRIE NORMEN) DIN 51601
SAE (SOIETY OF AUTOMOLTVE ENGINEERS) No. 2-D
Based on SAE J-313C
BS (BRITISH STANDARD) Class A-1
Based on BS/2869-1970

131
REFILL CAPACITIES
LIST OF LUBRICANTS [Refer to CAUTION on page 125.]
Ambient temperature when starting
Section Lubricant to be used Grade of viscosity
engine

0°C & above SAE 30

General use
Engine crankcase & oil clutch -25°C to 0°C SAE 10W
Engine oil
case -25°C & above SAE 10W-30, 10W-40, 10W-50, 15W-40
Cold area
-40°C & above SAE 5W-20, 5W-40

Engine oil SAE 10W

-25°C & above
Hydraulic oil ISO VG32
Hydraulic oil reservoir
Engine oil SAE 5W-20
-40°C & above
Hydraulic oil ISO VG22

-25°C & above Engine oil SAE10W

Automatic transmission
-40°C & above ATF -

-10°C & above SAE 90

Differential, final reduction gear
-25°C & above Gear oil SAE 80W
& steering gear case
-40°C & above SAE 75W

-25°C & above Lithium base multi- Consistency number: NLGI No. 0, 1, or 2
Grease fittings
-40°C & above purpose grease

132
 REFILL CAPACITIES
Brands of Lubricants
Class API Class CC and Higher
Supplier CC (for Diesel) CD (for Diesel)
MOBIL Delvac 1100 Series (10W, 20W-20, 30) MOBIL Delvac 1300 Series (10W-20, 20W-20, 30)
MOBIL MOBIL Delvac 1200 Series (10W, 20W-20, 30) MOBIL Delvac Super (15W-40), MOBIL Delvac 1 (5W-30)
MOBIL Delvac Special (10W-30, 20W-40) MOBIL Delvac SHC (5W-30)
SHELL Rotella TX Oil (10W-30, 20W-50) SHELL Rimula X Oil (10W, 20W-20, 30)
DIESEL ENGINE SHELL
OIL SHELL Rotella SX Oil (20W-20, 30 ) SHELL Myrina Oil (20W-40, 20W-20, 30)
ESSO Lube D-3 (10W, 30)
ESSO ESSO Lube HDX (10W, 20W, 30)
ESSO Lube XD-3 Extra (10W, 30)
RPM Delo 400 Oil (15W-40, 10W, 20-20W, 30) RPM Delo 400 Oil (15W-40, 10W, 20-20W, 30)
RPM Delo 200 Oil (10W-30, -40, 20W-40, -50, 10W, RPM Delo 300 Oil (10W, 20-20W, 30)
CALTEX 20-20W, 30)
RPM Delo 100 Oil (10W, 20-20W, 30)
Class R&O ANTIWEAR
Supplier
MOBIL MOB DTE Oil Light MOBIL DTE 24
HYDRAULIC OIL
SHELL SHELL Tellus Oil C-32 SHELL Tellus Oil C-32
ESSO Teresso 32 Nuto HP-32
CALTEX Rando Oil 32 Rando Oil HD 32
Class GM-make DEXRON or equivalents
Supplier
MOBIL MOBIL ATF220
ATF DEXRON SHELL SHELL Dexron
ESSO ESSO ATF
CALTEX Texamatic Fluid (Dexron I)
Class API Class GL-4 and Higher
Supplier GL-4 GL-5
MOBIL Mobilube 40 Series (75W, 80W, 90) Mobilube HD (75W, 80W, 80W-90, 90)
GEAR OIL
SHELL SHELL Spirax EP (80W, 90) SHELL Spirax HP (80W, 90)
ESSO ESSO Gear Oil GP ( 80W, 80W-90, 85W-90) ESSO Gear Oil (80W, 80W-90, 85W-90)
CALTEX Universal Thuban (80W, 90) Muitipurpose Thuban EP (80W-90, 80W, 90)
Class Lithium Base Mult-purpose Grease (NLGI No. 0, 1 or 2)
Supplier
MOBIL MOBIL Grease 70 Series, MOBIL Grease MP
GREASE SHELL SHELL Albania Grease R Series, SHELL Albania Grease EPR Series, SHELL Retinax A
ESSO Beacon Series
CALTEX Marfak AII Purpose 2, 3, Marfak Multipurpose 2, 3, Multifak EP 0, 1, 2

133
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134
SPECIFICATIONS

135
SPECIFICATIONS
SPECIFICATIONS
Characteristics
1 Manufacturer Mitsubishi Logisnext’s Forklift
2 Model Manufacturer’s designation 6-ton model 7-ton model 8-ton model 10-ton model
3 Capacity Q Rated capacity kg 6000 7000 8000 10000
4 Load center C Distance mm 600
5 Power type Electric (battery), Diesel, Petrol Diesel
6 Control type Hand, Pedestrian, stand-on, rider seated Rider seated
7 Tire equipment V = Cushion, L = Pneumatic front/rear L/L
8 Wheels (x = driven) Number front/rear 4x/2
Dimensions
9 h3 Lift height mm 3000
Lift telescopic
10 h2 Standard free lift mm 205 215 205
L1 Length mm 1220
13 Fork size B1 Width mm 150 170 175
S Thickness mm 60 70 75
14 Tilt angle α = Forward / β = Backward ° 6/12
15 L2 Length to face of forks mm 3535 3600 3940 4255
16 B Width mm 1995 2165 2245
17 h1 Height, upright lowered mm 2500 2700 2850
Overall dimension
18 h4 Height, upright extended mm 4420 4330
19 h6 Height, overhead guard mm 2450 2560
20 h7 Seat height mm 1310 1415
21 Turning radius Wa mm 3300 3360 3650 3900
22 Load distance X From center of front axle mm 615 625 720 710
Ast3 Min. intersecting mm 2980 3020 3290 3540
23 Aisle width
Ast4 Right angle slacking mm 5335 5405 5790 6030
Performance
with load km/h 26 25 24
24 Travel speed
without load km/h 30 29
with load mm/s 500 460 450 310
25 Speeds Lift speed
without load mm/s 550 470 410
with load mm/s 450 470
26 Lowering speed
without load mm/s 500 450 340
with load kN (kgf) 53.9 (5500) 52.9 (5400) 57.3 (5850)
27 Max. drawbar pull
without load kN (kgf) 22.1 (2250) 21.6 (2200) 27.4 (2800) 31.4 (3200)
with load (at 1.6 km/h) % 33 29 27 22
29 Gradeability
without load % 19 20
Weight
32 Service weight kg 8630 9360 10960 12300
front kN (kgf) 127.9 (13040) 142.3 (14530) 167.0 (17030) 197.1 (20100)
33 with load
rear kN (kgf) 15.6 (1590) 17.9 (1830) 18.9 (1930) 21.6 (2200)
Axle loading
front kN (kgf) 37.4 (3810) 36.8 (3750) 47.2 (4810) 53.2 (5420)
34 without load
rear kN (kgf) 47.3 (4820) 55.0 (5610) 60.3 (6150) 67.5 (6880)
Chassis
35 Number front/rear 4/2
36 Tires front
Size 8.25-15-14PR(I) 9.00-20-14PR(I)
37 rear
38 Wheel base y mm 2250 2500 2800
front mm 1470 1600
39 Tread Center of tires
rear mm 1700
40 at lowest point mm 190 245
Ground clearance
41 Center of frame mm 225 320
42 Mechanical/Hydraulic/Electronic Hydraulic/Mechanical
Brakes
43 Foot (pedal)/Parking (hand) Foot/Parking
Power train
45 Battery Number-Volts/Ampere hrs. (capacity) V/Ah 2-12/80
49 Make-Model ISUZU “6BG1” ISUZU “6BG1QC”
Rated output kW (PS) 82.4 (JIS 112) 84.6 (JIS 115) JIS 68.4 (93)
50
Governed speed rpm 2000 2100 2000
Internal combustion engine
51 Torque N-m (kgf-m)/rpm 417 (JIS 42.5)/1500 333 (34)/1500
Number of cylinders-Bore x stroke mm 6-105 x 125
52
Displacement cc 6494
55 Transmission Type-Number of speeds (forward/reverse) Automatic Power shift-2/2
57 Working pressure For attachment MPa (kgf/cm2) 19.6 (200)

136
 SPECIFICATIONS

CAPACITY CHART
WARNING
The load charts given here refer to the forklift trucks of standard specifications and those with high masts of less than 5 m lifting
height. The load charts differ from those attached to forklift trucks with high masts exceeding a lifting height of 5 m or forklift
trucks with an attachment.

6-ton model 7-ton model

8-ton model 10-ton model

137
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138
WRITE DOWN DATA OF YOUR TRUCK HERE:

TRUCK
ENGINE
Model..........................................................................
Manufacturer..............................................................
Truck Serial No...........................................................
Model..........................................................................
Service Weight............................................... kg (lbs)
Engine Serial No........................................................
Max. Load ......................mm (in.) ................. kg (lbs)

DATE OF PURCHASE .................................................................................................................................................

DEALER’S NAME .................................................................................... PHONE.......................................................
DEALER’S ADDRESS...................................................................................................................................................
No. OMFBE-30C170
ISSUED: OCT., 2017

1-1, 2-Chome, Higashikotari, Nagaokakyo-shi,

Kyoto, 617-8585, JAPAN
All rights reserved JB-1710001(AN) Printed in Japan