No. OB-81BAE 23721 675 a fy ei Da iti IN TOWN. DVFB(Ib"15-25-00)7- (8-4) OPERATION MAINTENANCE MANUAL ELECTRIC FORKLIFT TRUCK Counter-balanced type FB10-7 FB25.7.8 FB15.7 FB25-7v FB20-7 FB30-7v FB25.7 FB30-7 « Itis the responsibility of the Operator & Supervisor to read and understand this manual. * Protect the earth and be kind to your lift truck. TCM CORPORATIONThank you very much for your purchase of TCM’s product. This Operation & Maintenance Manual was written to provide the owner/operator with information about the safe operation and maintenance of the TCM forklift truck. Read this manual thoroughly and become completely familiar with the lift truck before using it. If you have any questions, see your dealer. This manual was compiled based on the standard models. For trucks other than the standard models, only the differences are explained. Due to improvements in design, it is possible that the description contained herein may not completely apply to the truck delivered to you. Axcaution If the truck is to be leased, loaned or sold to anyone, this manual must be with the truck. CONTENTS 1. SAFETY 12. OPERATING CONTROLS 13. OPERATION 4. MAIN- TENANCE Flay (5. SPECIFICA- TIONS & SERVICE DATA1. SAFETY CONTENTS: FOR SUPERVISORS. vo Ve PROPER AND IMPROPER USES seine VB PLANNING AND WORKING AREA 1-3 TRAVELING ON PUBLIC ROADS. sovnnn T= OPERATORS, soninnn 2 7 ‘TYPES OF VEHICLES AND LOADS 1-9 INSPECTION. sn 1-12 ‘TRANSPORTING THE LIFT TRUCK... 1-13 HOW THE LIFT TRUCK WORKS? 1-14 TRAVELING, son 1-17, LOAD HANDLING vs 1-22 PARKING vo 1-26 INSPECTION AND SERVICE. 1-27 CAUTION PLATES. 1-33This manual and the decals affixed to the truck use the following safety alert indications, ‘SIGNAL WORD. Failure to follow the instructions in the AA DANGER | Cicely caone a serious accident or CLASSIFICATION Awarnine ‘may cause personal {tuck or ether property. “The information will help Yo prolong te service life of the truck. The message is not directly felated to accident prevention. Acaution @Pnote Forward ‘The diagram above indicates the meanings ofthe terms “forward, backward’, ight” and “left” used in this manual. FOR SUPERVISORS Lit truck accidents cause dozens or hundreds of deaths every year, and even greater numbers of personal injuries, TCM has steadily improved the design and fabrication of our tft trucks 80 they may be used more safely and efficiently, but many accidents stil occur due to improper use, Accidents are often the result of more than just "bad driving’. The use of Inappropriate types of equipment, the selection of inappropriate attachments of accessories, inappropriate operating environments, careless designation of operators, and failure to property train the operator are other common causes of accidents. ‘This chapter covers the methods of accident prevention which are primarily the responsibility of supervisory personnel. ‘= Pages 1- 2 through 1-13 contain instructions which should be enforced by the personnel supervising the operation of the lift truck. Please maka sure the operators also read these pages. ‘+ Page 1-14 and the following pages contain specific precautions directly related to the operation ofthe lit truck.FOR SUPERVISORS [PROPER AND IMPROPER USES @ PROPER USE OF THE LIFT TRUCK @ IMPROPER USE y ‘The proper use ofa lt truck is to transport a load which is placed (on the pallet and stacked within the prescribed height limit With @ proper attachment, a lit 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 ait truck. Uses which thie 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 a cable on the forks to suspend a load Towing another vehicle. Pushing a load or another vehicle with the forks. Using the forks or truck body to close or open the door of a freight vehicle,FUR SUPENVISUND [PLANNING ANU WORKING AREA) i MAKE AN OPERATING PLAN AND DISCUSSIT ™_ INSTALL CURBS OR RAILINGS ‘Before using the lit truck, plan out the travel routes and ope erating procedures, and thoroughly discuss the details with all personnel Involved @ SET SPEED LIMITS Yard Speed init (Example) It the truck is to be used on a loading dock, shore wall or other raised surface, Install curbs or railings. MARK THE TRAVEL LANES Set appropriate speed limits on your company grounds, and post signs that are clearly visible. 4-3 Designate the travel lanes forthe lift truck and mark them clearly, 0 they will be kept free of obstruction.FOR SUPERVISORS [PLANNING AND WORKING AREA KEEP PEOPLE OUT OF THE OPERATINGAREA ™ KEEP THE GROUND LEVEL AND DRY Closed to Pedestrians No other personnel should be allowed in areas where the lift truck Te sorter indies Surtsce is used. Where other people must be present, post a guide whose job is to Be sure that all areas where the lit ruck travels are level and regula. make sure people stay clear of moving vehicles. Clear away pools of ol or water KEEP UNAUTHORIZED VEHICLES OUT PROVIDE ADEQUATE LIGHTING Safe operation requires well traveling routes, so pedestrians and Unauthorized vehicles must be Kept out ofthe load handling aress. obstacles can be easily seen. Use headlights, tallights, helmet Post signs or give signals as required. lamps or other gts as appropriateFUR SUPEHVISUND | PLANNING AND WORKING AHEA | ASSIGN TRAFFIC GUIDES TO CONGESTED AREAS ™ PROVIDE AND MAINTAIN EMERGENCY EQUIPMENT Sl ee | Vanes ee 6 |\ Post a trafic guide in confined or congested aress where other people or vehi icles mey pass. All personnel must obey the guide. ™ KNOW WHO TO CALL IN AN EMERGENCY yet Giasu (Example) Fire extinguishers and first aid kits should be provide .d and ‘maintained for use in case ofa fire or accident. All personnel should Understand the location and use of emergency equipment, lm SAFETY MEASURES FOR DANGER SPOTS Emergency Number 2 Eartuaks 8 anbulance Keep informati ion on hand to allow immediate cals for help in case of a fire, accident or other emergency. 1-5 Post warning signs or take other appropriate measures to ensure that lit truck operators keep away from danger spots as they travel,FOR SUPERVISORS [TRAVELING ON PUBLIC ROADS) @ GOT A LICENSE? @ NOLOAD, NO TOWING Bofore traveling on a public road, be sure that the truck has It /s usually illegal to carry a load on a publle road. Its also not been licensed and inspected as required by local laws. allowed to tow another vehicle on a public road (with the possible exception of a cisabled 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 ight or tll amp.PUM SUPENVISUND | UPEKAIUHS ™@ WEAR PROTECTIVE GEAR + Always weer proper work clothes for driving. Work clothes should bbe designed to prevent any part from accidentally catching on knobs or other parts of the truck or equipment, For example, shirts and trousers should have tight cuts + Always wear a hard hat and safety shoes. ‘+ Wear other protective gear as appropriate to the conditions of the work site, Le., goggles or gloves.FOR SUPERVISORS [orerators ™ TRAIN YOUR STAFF TO STACK SAFELY @ TIRED OR UNWELL? SEND THEM HOME! ‘acing FEE “Stacking” means piling palleted load or materials directly on top Cf each other, without using racks or shelves to separate them. If the stacking work is not done properly, the loads may slip or fall, ‘endangering the operator as well as any other personnel in tho Safety classes should be held to tran all operators in the proper ‘methods of stacking and unstacking loads. (Your TCM dealer can provide information about training for safe stacking.) Do not let people take chances. An operator who is overworked or fatigued, an operator who is feeling unwell, or an operator who is Intoxicated must not be allowed In the driver's seat.FUR SUPERVIDUND | TYPES OF VEHICLES ANU LUAUS | @ USE THE RIGHT TRUCK FOR THE JOB Be sure the type and capacity of the lit truck is suitable for the work environment. (Check Point Load capacities range fom 0.5 to 42 tons. Pay particular attention tothe load center. (Tem Lit Truck Capacities: 0.5, 0.7, 0.9, 1, 1.36, 15,2, 225,25,275, 3,35, 4,45, 5,6, 7,8, 10, 408, 105, 12, 135,15, 18, 20, 2, 23,24, 25, 90, 87,07 42 tons.) (choice | Capacity Powsr Source ‘Gasaline, natural gas, ee}, and batar-powered ‘models are available, Fuel costs and exhaust ‘composton wil vary. ‘On counterbalanced modal, the counterweight fat the raar makes the vehicle Tanger than a reach tuck. A teach truck performs loading and Unloading by extending the font pat ofthe mast outward, which gives It the advantage of compactness. Balance For indoor use, thore ate models with soil tres (est or reach trucks) and cushion ures (engine 'ype orbattory type). Both are compact. For outdoor usa, pneumatic tos work wel. Solid Cushion tres, with the same dimensions as ‘pneumatic tes, may be the best choice in cases toner the load materials or surface conditions ‘ould puncture pneumate tras. Flammable Materlals | For handling flammable materials such as pstrachemicals, a combustion engine is too ‘angerous. An electric vohiele with explosion- ‘rool o salety-enforced constuction is required, {X battery nower soureo always offers better | rteton gaint re than a conbuston engine) @ USE THE PROPER ATTACHMENT Popular Attachment Examples o @ ©: Rot Clamp (For paper rll or drum handling) Fotating Fork (or dumaing work or narging ware) @ | @: Hinges Fore @ (fortumbar hancting) Side Shit (For praciee stacking in Containers or other harrow spaces) Grane Arm (Goringng wort) PRES ‘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.FOR SUPERVISORS [TyPEs OF VEHICLES AND LOADS | m NO OPERATION WITHOUT LIGHTS, m™ KEEP DECALS LEGIBLE OVERHEAD GUARD, OR LOAD BACKREST —— “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, The tit truck cannot be used i the headlights, tailights, overhead guard, load backrest, horn or tur signals have been removed. Any parts that have been temporarily removed for some reason must be reattachod immediately. Do not add counterweight Modifications or additions that affect the capacity, construction or The overhead guard is a protactive device that will moderate the strength of the ruck must not be performed by the user without the Impact of an object falling from overhead, but it cannot withstand OBTAIN APPROVAL FOR ANY MODIFICATION ™ DO NOT RELY ON THE OVERHEAD GUARD 7 without approval manutacturer’s prior permission. For example, don't add a every impact. i a heavy object seems likely to fll onthe tuck, I WS) l ky j (Oe counterweight make ovey efor to prevent item dong soPUM SUPEMVISUMD | 1YPES UF VENIULES ANU LUAUD| @ USE STURDY PALLET MATERIALS lm KNOW THE LOAD BEARING CAPACITY OF THE FLOOR Pallets and skids must be strong enough to withstand the weight of The lit ruck is heavier than it appears. For example, a 2-ton truck loads. Remove or repair any damaged pallets. ‘weighs almost 3.5 tons even when empty. Furthermore, when loaded, 80 to 90% of the total weight is concentrated on the front lm STACK LOADS SECURELY wheels. Check the strength of your floors and roadways, and if nacessary reinforce them. When stacking loads, place them in a stable manner that they will not easily come apart, and be sure the weight is evenly cistrbuted, ‘Secure the top layer with a cord wrapped lke @ headband or in a similar fashion. 1ettALWAYS INSPECT BEFORE OPERATING FOR SUPERVISORS [insPEcTION lm REPLACE SAFETY PARTS REGULARLY The operator should always inspect the truck before each use to voriy that all essential safety features are working. Any abnormality 's tobe reported to the supervisor, who is responsible for correcting a ™ PERIODIC INSPECTIONS ARE MANDATORY Monthly and annual inspections must be performed thoroughiy, and any abnormality promptly repalred. Only a certified expert who has the advanced skills and equipment is required to conduct the inspections. Preserve the inspection logs for at least three yoars, vere otscoy rom (oases 1 | SrSwnoeleyiegers nn 1 + Tie na a 1 [Set enor nba boon Cortain crtical parts must be replaced at requiar intervals. Since it is dificult to detect wear on the above parts by visual inspection, they must be replaced after a certain period of time. Fallure to do so would result in a falling load or runaway truck, @ NEVER USE AN UN-MAINTAINED TRUCK ‘A truck that has not passed an inspection must never be operated. Hang a sign on the truck and remove the igntion switch, to make sure no one uses it. Then report the problem to the supervisor and \wait forthe repair to be completed.PUR SUPENVISUMD | INSPECTION IHANSPUHT ™@ DESIGNATE A REPAIR AND ASSEMBLY SUPERVISOR Preparation Disassembly 1G IME LIFT ENUUR) lm TRANSPORTING THE LIFT TRUCK Repairs and the mounting and dismounting of attachments must be performed under the direction of a designated supervisor. The body and major parts of the lift truck are quite heavy and under very high pressure. Repair or assembly work undertaken without ‘careful and thorough preparation can lead to a serious injury. Use a level, hard road surface when loading the truck onto or Uunioading from a trailer. Be certain that the loading ramps have ‘sufficient length and width as well as strength. Do not load or unload the truck when itis raining, unless the ramps are fitted with an anti= slipping surfaces, Its safest to use a sel-loading trailor truck equipped with a jack and winch. For loading, it the pallet with the jack, attach the winch to the towing pin of the lift truck, start the engine, and pull it up. The operator must not ride on the lift truck while loading or unloadingHOW THE LIFT TRUCK WORKS? m™ KEEPING THE TRUCK BALANCED Lift trucks are equipped with load handling means including a mast and forks at thelr front. The front wheels of the truck work as a fulcrum to balance the center of gravity ofthe 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. im KNOW THE CENTER OF GRAVITY OF YOUR LOAD Materials of various shapes such as boxes or flat or cylindrical items may be loaded on the it truck. In order to accurately judge the stability of the truck, itis vitally important for the operator to know the location ofthe center of gravity for each type of load. | HOW THE CENTER OF GRAVITY SHIFTS ‘The stablily ofthe lit tuck is determined by the overall center of ‘ravity, which fs the product of the centers of gravity ofthe truck land the load. When the truck Is emply, this point is the same as the center of gravity forthe truck, and when itis loaded it shifts according to the center of gravity of the load. Since the center of ‘gravity of the load changes whenever the mast is tited forward or backward or the fork is raised or lowered, the overall center of . Safe operation . Warning for front guard CAUTION PLATES F. Warning for mast connecting members A WARNING D, E. Warning for load handling means 9 Entanglement (Bawarnane @ Do not ride forks oF pallet CVLAULIUN FLAIES H. Name plate J. Tire inflation pressure (example) K. Warning decal for handling | TCM _ MODEL. — (MAX. FORK HEIGHT = ——2) arena. weet = 8 ‘SERIAL NO. Tom enna MADE W JAPAN = | RS. FBIO so] reir | N- Load chart: Do not overload! ces)_| (es) (For load charts, see page 5-4.) Fults F520 ‘1980 bg FB25 mee 50 A CAUTION ‘The instructions on the caution plates carried in this manual may differ from those on the caution plates attached to the truck body. In such a case, observe the Instructions on the caution plates attached to the truck body.CAUTION PLATES 1 Caution plate for handling batteries It the battery is used or charged when the electrolyte level is below the LOWER LEVEL mark, the battery may be damaged. It may also reduce the battery life or cause an explosion. ‘Add electrolyte so that the level is between the UPPER, LEVEL and LOWER LEVEL marks. Hydrogen gas produced by a battery can explode. Keep all open flames and sparks away from the battery. To prevent sparks, when connecting or disconnecting the battery or charger cables, be sure to stop the engine and tur off the charger switch, ®BO®ABAA Nore Wearsalay Satuie Tipesve Hackiestock tho tery carefully oer ay allantion aan open fae o ta 5 Sulure noid wil cause pant and seri Touching a conducting pt wih bare hands wf eause an 9 + Do not connector astonnect the batay plugs wi the al wil get injure. lactny whic right cause an explosion ora tk. urs fgets onthe en. can cause Dindness Hi ges into eyes. lacie enock accent ery tuned ON; otherse you might get burt or an explosion might * Nore. Do not smoke. Keap spars or amas away tom batters. + State olctty: Do not clean bates wits a dust oy ‘Suri ani suftace ald comes income fh your Si oy lve proper at, ruber gloves, Yertiaton: Geta goed ventiston. Do ret use o charge balers in closed place or an area whare vediatin Is poo isu sea get lte your aye, wash your ayn uth m copious amount of water mma oth, ‘of clothing, wash away using copious amount of water immediatly Ivana gt toa costar, ‘iimos” ha tevel to low, he bata wl ould up heat the level end shoes wih ubber soles when sencing or inspecting batteriesNOTEThe following symbot '3, found throughout this manual, alert you to potentially hazardous conditions to the owner and the operator. Become completely f familiar with the truck before proceeding with operating, checking and servicing, ‘This manual and decals affixed to the truck use the following safely ale indications. ‘SIGNAL WORD pomeen | Awannine Axcaution nore | CLASSIFICATION Failure to fllow the instructions i will ikely cause a serious accie Fallureto follow the instructions in the message might cause a serious accident or death Fallureto follow the instructions in the message may cause personal injury or damage to the truck or other property. ng the sevice life of the truck. The meseage fa not directly ‘elated to accident prevention 2. OPERATING CONTROLS CONTENTS PICTORIAL NOMENCLATURE INSTRUMENTS AND CONTROLS: SWITCHES, LCD METER UNIT ns BATTERY CHARGE INDICATOR AND DISPLAY sonoma REGENERATIVE BRAKING LEVERS AND PEDALS ‘TAUCK BODY OPTIONAL EQUIPMENT. 2-4 2-3 2-4 2-7 2-8 2-10 2-16 2-20 2-28PIV TUMAL NUNICNULAFUNE sreennavnee, re cnn ae urromy wergume | anevewnvon i ves ovo cov meat eS i sear 1) Lt Mh By La FORKS tS —| 0) ream es, swvervser pou mee EME,PICTORIAL NOMENCLATUREIND INUMENTS ANY LUN INU HORN aUTTON ico METER UNrT ur Lever [STEERING WHEEL, TWTLEVER PIRLEVER: PRRKNG BRAKE LEVER CcowenaTion swrcH PATTER cHaRcen Contra SPE. swircH Key swe sc awircn: TEES RAKE PEDAL JeceveraroR PEDALSWITCHES INSTRUMENTS AND CONTROLS 0 \ Dos ov Ss a oh KEY SWITCH ‘B caution ‘= Disconnect the battery receptacle before working on the electric ‘components. The electric circuit is, live even if the key switch is turned OFF. + Before leaving the truck, make sure the key switch is turned off and remove the key. OFF... The key switch is OFF. Key insertion ‘and draw-out position. ON......The electric circuit is closed, After 1 second of solf-chock, the truck becomes ready for operation. The power indicator lights up. & wore tho folowing operation is caiod ou, the alot cat the tek acta inthis sat, he truck wor! stat you wanttpeatth tuck,relaaeo to cally eat «Tho FUR (Forward/Revers) lover i operated wth the Key such OFF. (hat ithe kay such tudo wth the forwardroverse lover in postions other ‘than neutral.) = Resetting the safety circuit - Place the FIP lever in neutral and turn the key switch OFF and then ON.INDINUMENTS ANY LUNINULS COMBINATION SWITCH (LIGHTING) ‘This light switch can be rotated in 2 steps. Ccouaivarion Serrcx (TURN SIGNAL) HORN BUTTON Use the turn signals (front and rear) to Press the horn button at the center of the indicate the traveling direction of the truck. steering whee! to sound the horn. ug | oF | @ | @ “The hom sounds regardless ofthe key switch Clearance light | OFF | ON | ON L_| Left lights turn on. Position. Tail igt OFF[-ON| ON _N [OFF Hoad ight [OFF [OFF [ON _F | Rightighis tin on & wore @F Note the truck. “The above lights turn on or off regardless of the postion ofthe key switch Remember to tum them off when leaving = The turn signal lever automatically returns to neutral when the steering wheel Is returned to the straight position. + The tum signal lever may be optionally located atthe right side of the steering column,INSTRUMENTS AND CONTROLS SPEED CONTROL (SC)SWITCH —S.R.E SWITCH When this switch is turned on, the gm. Every time the S/P/E switch Is pressed, the ‘mark appears on the display, indicating that letter 8, P, or E appears in turns on the LCD speed control isin action, ‘meter unit. Set the power mode of the truck ‘To release speed control turn the switch off. with tis switch, ‘The ~$@p- mark will disappear.INDINUMENTS ANY LUN INULo LCD METER UNIT ia B | eds agaa aa) = “1B \fapaa.f, em BATTERY ELECTROLYTE LEVEL WARNING LIGHT The light is usually off + If the light blinks, it indicates the battery electrolyte level is low, + Ifthe light comes on, itis suspected that the plug of the battery electrolyte level check cable Is disconnected. SPEED CONTROL SETTING INDICATOR ‘This indicator lights up when the speed control (SC) switch Is turned on, The maximum speed Is limited to about 50 percent. ‘SPEED METER ‘This meter indicates the traveling speed of the truck, If the traveling speed exceeds 19 ‘anh, the number "19" blinks.128456 | Wows &G ( (QnrPrT | 12845678 L@@ ets PARKING BRAKE INDICATOR ‘This indicator lights up when the parking brake is applied. The truck won't travel if this Indicator is on. NEUTRAL CHECK INDICATOR ‘This indicator lights up when the F/R lever is in neutral, It goes out when the F/R lever is placed in the forward or reverse postion. NEUTRAL SAFETY WARNING LIGHT ‘Tho light stats blinking when the key switch is tuned on with the F/R lever in positions other than neutral. The truck won't move. Place the FIR lever in neutral. CONTROLLER OVERHEAT WARNING LIGHT ‘This indicator blinks when the traveling or load handling operation is too much to the truck, It usually stays it If it starts blinking, stop the operation and wait until the indicator stops blinking. @& Note Ifyou ignore the blinking of the warring light and keep operating the truck, the truck will soon come toa stop.INSTRUMENTS AND CONTROLS i fo jens =e 7 fl E34] Mede "| u coal | ngaaea.tn MOTOR OVERHEAT WARNING LIGHT ‘This light blinks when the drive motor has ‘overheated. Itis usually it It it starts blinking, stop the operation Immediately and wait until the light stops blinking, HOUR METER The hour meter indicates the total time the key switch has been in the ON position FAILURE CODES fa fallure occurs, the “wrench” mark appears long with 2 3-digt number. Ifthiss the case, Consult your TCM dealer. @& note For more information, soe page 5 -7 of Service Data,IND INUMENTS ANY LUNN (@) \\ | (@)\| | fh} | | | rem | | POWER LAMP ‘The light comes on when the key switch is tured on.INSTRUMENTS AND CONTROLS LEVERS AND PEDALS F/R LEVER Use this lever to select the traveling direction of the truck. Forward Neutral (@D appears onthe display) Reverse (The back-up ight comes ‘on and the back-up buzzer sounds.) ™ Regeneration (switch-back regeneration) ‘This truck is equipped with regenerative brake system. The regenerative brake system automatically retums electric energy Created by braking to the batteries for better use of energy, Itoperates when the folowing conditions are met «The accelerator pedal is stepped on. «= The FIR laver is raversed while traveling | STEERING WHEEL STEERING WHEEL Bi caution Do not tun the ky switch OFF white traveling. When the key switch Is turned OFF, steering operation becomes har ‘When traveling the truck, hold the steering wheel knob with your left hand. Do not remove your hand from the knob while traveling. The truck comes with power ‘stooring to provide smooth, ight stooring with the key switch on.IND INUMENTS ANY LUININULS PARKING BRAKE LEVER TILT STEERING WHEEL LEVER B caution ‘Wen parking ona grade, be sure to block the wheels, « Before pulling the parking brake Tover,stopon the brake pedal Use the parking brakes to park the truck. Pulling the lover toward you applios the brakes to the two front wheels, The indicator (@®) ) lights up on the LCD. To release the parking brakes, push the parking brake lever forward. A caution * Set the steering column at the most ‘comfortable position before trying to start the truck. + After adjusting the steering column position, turn the lever in the direction of “A” to lock the steering column, «Never try to adjust the steering column position during operation. Tho steering wheel column can be tilted forward and backward according to the operator's physique. Turn the lever in the direction of "5" to loasen the steering whol column. After adjustment, turn the lever to "A" to lockINSTRUMENTS AND CONTROLS LIFT LEVER TILT LEVER A caution Seat youreet in the operators seat and make sure there is no one around the truck before trying to operate the littever A caution ‘Seat yourself in the operators seat and make sure there eno one around the truck before trying to operate the titlever, @& nore If the tit lever is operated with the key switch OFF, the mast won't tlt foward due to the operation of the tilt-lock ‘mechanism incorporated in the control valve. This is not the malfunction of the system. Pulling back the lever wil raise the forks and pushing forward it will lower the forks. The liting speed of the forks can be controlled by the tt angle ofthe lever. PPling the tit lever wil tit backward the mast and pushing forward it will tilt the mast forward. The tilting speed of the mast can be ‘controlled by the tit angle of tho tit lever,IND INUMCNIS ANY VUNInULS acceLeraTon JA ReBaL PEDALS The truck has 2 foot controls: brake pedal and accelerator pedal (from the left) BRAKE PEDAL ‘Stop on the brake pedal to slow down the truck, Brake lamps light up when the brake pedal is pressed Before stepping on the brake pedal, release the accelerator pedal fist. ACCELERATOR PEDAL The accelerator pedal controls the traveling speed of the truck ‘Turn the key witch ON and shift the F/R lever into forward or reverse, and step on the accelerator pedal. The traveling speed Is indicated on the display. B caution Brake switch Do not remove the brake suiteh. When the brake pedal is stepped on, the brake switeh operates to turn the brake lamp on and activates brake regeneration,INSTRUMENTS AND CONTROLS TRUCK BODY SUSPENSION SEAT RoIUSTMENT ENOB Tone SEAT BELT POCKET ‘SEAT ADJUSTIVENT LEVER Recunng, Box DRIVER'S SEAT SUSPENSION Bi caution ‘Adjust the susponsion ofthe driver's eat using the adjustment knob befor stating the das work or each shift, Do not try to adjust the suspension during operation, ‘Adjust the driver's seat suspension properly to suit the individual operator's physique and to provide best comfort. “Tum the adjustment knob tothe value of your weight. The seat absorbs shock and vibration to provide comfort during traveling and operation SEAT ADJUSTMENT LEVER RECLINING CONTROL LEVER Bi caumion ‘Adjust the seat position betore starting your day's workor each shit. Mako ore the seat securely locked. DOCUMENTS POCKET AND MAGAZINE BOX ‘Tho driver's seat has a document pookst and magazine box atts back. Usa ther fo storing the instruction Manual and others. Remember to close the dacument pocket before operation. SEAT BELT ‘Adjust the driver's seat to a position to sult the individual operator's physique. To unlock, pull up the lover. ‘After adjustment, try to move the seat back and forth to make sure that the seat is securely locked. PROS Be sure to fasten the seat belt before ‘starting traveling or operation; otherwise, ifthe tuck turns over the operator might be thrown out and, in the worst case, the ‘operator can be crushed by the truck ‘causing severe injury or even death, Pullout the connector at the ight sie andinsert Ihinto the recaptace a the let side unt i clicks. ‘To unfaston tha seat belt, press the red button by the receptacie, and the belt automaticaly Inds up into the Seat.IND INUMEINID ANY LUNINULS i: [SSP ‘OVERHEAD GUARD BRckREST HOOD STOPPER A caution ‘ Affer opening the hood, make sure ‘gas damper stopper is engaged. ‘+ Use caution not to get your fingers ‘caught in the hood when closing it. ‘The hood has a stopper at the middle of the ‘gas damper. After opening the hood, make sure the gas damper stopper is securely engaged. When closing the hood, hold the hood and push the gas damper stopper to bring the hood down slowiy. OVERHEAD GUARD LOAD BACKREST I The overhead guard is an important safety device which protects the ‘operator from falling objects. Make sure it is securely installed. Do not use the truck with the overhead guard removed or modified; otherwise it might cause a serious ident. A caution The load backrest Is an important safely device which protecte the perator oma faling lod the forks dlergage trom the eariegs Make sure the load backrost 1s Securely installed, Do not use the tTuck wth the toad backrest removed formodiied otherwise t might cause teers accident NOTE Keep the vinyl ran gutter aways clear of dustINSTRUMENTS AND CONTROLS STOPPERS TOW PIN FORK STOPPER FORK LOCK BOLT A caution Do not use the tow pin for towing another vehicle or for being towed by another vehicle. Use the tow pin for the following cases: ‘= When the truck has bogged down in the mud or a side ditch, ‘+ When loading onto or unloading from a traller for transportation A caution * The forks should be set symmetrically to the truck centerline, and fork stoppers should always be set. + When adjusting fork spacing, hold the load backrest and push the forks with your foot. Do not use your hand. A caution Do not remove the fork lock bolt other than the following cases; otherwise the forks might disengage from the carriage, causing personal Injury. ‘+ When removal of the forks is needed, ‘= When gathering the right and lett forks together to the center for any Secure the forks withthe fork stoppers. Pll up the fork stoppers a itie 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 going to carry, will come off the carriage. This bolt prevents the fork from being used at the center.INSIHUMENTS ANY LUNIMULS INT COMBINATION LAMP REAR COMBINATION LAMPS SAFETY STEP AND HAND GRIP LIGHTS AND LAMPS SIDEVIEW MIRRORS ‘A caution ‘ise the safety step and hand grip then mounting and dlsmounting. Do not hold the stoering whee! when getting on oF off. Do not mount or fismount wi the truck's in motion, B caution hock that ghts and lamps come on and off propery. If any light bulb is blown out, roplace witha now one. I the lene contaminated or damaged, clean of rpat ‘The truck is equipped with a safety step at {ont ft side of the body and a hand grip on. ‘one ofthe front poles of the overhead guard. ‘When mounting or dismounting, use the safety stop and hand grip. Front side The truck has head lamps and front ‘combination lamps (turn signals and clearance lamps) at its front side. Rear side The truck has rear combination lamps (tail lamps, brake lamps, back-up lamps, turn signals and rear reflector) at its rear. A caution * When traveling in reverse, always look in the direction of travel. Do not rely, ‘too much on the sideview mirrors. + Keep the mirror surfaces always clean. + Adjust the sideview mirrors to gain {ull rear vision. ‘The sideview mirears are provided on the front poles of the overhead guard, one for each.INSTRUMENTS AND CONTROLS hyoeAUUC o1 1K cance U\\ CORFE panes (\ Ot Pane BRAKE FLUID RESERVOIR HYDRAULIC OIL TANK CAP CHARGER CONTROL PANEL ‘The brake fluid reservoir is located under the The hydraulic ol tank cap is located under (EXB Option) front guard at the right side of the steering the floor mat. ‘The charger control panel is located at the left side of the dashboard. ‘column. The operator can check the brake fluid level from outside. ‘The tank cap is fitted with an ol dipstick for easy level checking @& nore For more information on the charger ‘control panel, see page 3 - 10.IND INUMENTS ANY CUNIEnuLS BATTERY RECEPTACLE A caution ‘Make sure the battery receptacles are disconnected before trying to touch any of the internal electric parts. + The voltage is present in the main circuit even if the key switch is tumed off. + Do not disconnect the battery receptacles while traveling. The power steering system becomes inoperative. ‘The battery receptactes couple and uncouple the connection between the battery and the truck’ electric parts, @ note *Whon disconnecting the battery receptacles, first turn OFF the key switch. + Before trying to connect the battery receptacles, make sure the key switch is in OFF. + When giving a charge tothe battery with the truck-mount charger, do not disconnect the battery receptacles. BATTERY LOCK PIN ‘A caution ‘take sure to set the battery lock pin. ‘The battery lock pin connects the battery ‘case tothe truck body, preventing the battery case from vibrating during traveling. To replace the battery with a new one, disengage the battery lock pin and remove the battery electrolyte tevel sensor witing.INSTRUMENTS AND CONTROLS UEveLiNoicaron BATTERY ELECTROLYTE LEVEL INDICATOR (EXB Option) The battery electrolyte level indicator is installed on the battery case for chacking the electrolyte level in the battery The green lamp stays on to indicate that the level indicator sensor is operating The red lamp comes on when the electrolyte level gets close to the lower limit. i the red lamp blinks, add purified water as soon as. possible. Check the electrolyte level in all cells, periodically.NOMUMIENIO ANY CUI nL OPTIONAL EQUIPMENT Here are some pieces of optional equipment which are deeply related to safe operation of the truck. For more information about optional ‘equipment, consult your local TCM dealer. REAR WORK LIGHT (RWL) B cavtion {tte adviable to use an optional rear twork ight when you are working ina place where sufficient ight ls not vale. ‘The rear work light iluminates the road of floor behind the truck at night to allow the ‘operator to recognize obstacles, if any, on the road or floor easly. BEACON LIGHT (YELLOW, RED) (RLY, RLR) Use an optional beacon light in the case ‘when the truck s required to work near fellow ‘workers or bystanders or when the work place is noisy SOUND VOLUME-ADJUSTABLE BACK-UP BUZZER (BBA) ‘You can switch over the sound volumes in two stages, according to the nolse level at the work place. FORWARD TRAVEL CHIME (TAF) When the truck travels forward, the chime ‘sound fo let fellow workers know the truck is, moving. PNEUMATIC CUSHION TIRE (UNIQUE TIRE, TRO1) Use tires of this type when you are going to work in an area where there are debris or anything that might blow the tires onthe road or floor surface. FIRE EXTINGUISHER (FE) Use the fire extinguisher for putting out a fre. ‘An optional fre extinguisher wil be attached to one of the rear supports of the overhead ‘guard.‘The following symbols, found throughout this manual, alert you to potentially hazardous conditions to the owner and the operator. Become completely familiar with the truck before proceeding with operating, checking and servicing This manual and decals affited tothe truck use the following safety aler indications. SIGNAL WORD Aoancer Awarnine Accaution @P nore CLASSIFICATION Failure to follow the instructions in the message ill kely cause a serious accidont or death, Failure to follow the instructions in the message might cause a serious accident or death. Failure to follow the instructions in the message may cause personal Injury or damage to the tuck or other property ‘The information will help to prolong the eorvice Ile of the truck. The message fs not eectly related to aceldent prevention, 3. OPERATION CONTENTS PROPER OPERATION DURING BREAKIN... RELATIONSHIP BETWEEN LOAD AND STABILITY OF TRUCK BASIC LOAD CENTER AND RATED LOAD. THE STABILITY OF LIFT TRUCK TRAVELING AND STARTING ON A SLOPE TRANSPORTING LIFT TRUCK OPERATING LIFT TRUCK, HANDLING THE BATTERY BATTERY CARE sn POWER SUPPLY EQUIPMENT FOR CHARGER, LOAD HANDLING PICK-UP STACKING. UNSTACKING .. STORING. BEFORE STORING; DAILY STORAGE LONG-TERM STORAGE; OPERATING AFTER LONG-TERM STORAGE PROHIBITION OF WASHING TRUCK BODY AND BATTERY WITH WATER, CLEANING, AFTER CLEANING WASHABLE ITEMS.PRUPCR UrcnaAniun ‘To operate the lift truck safely and get the most out of it, correct procedures are described on the following pages: DURING BREAK-IN We recommend to operate the truck under light load conditions for the frst stage of operation to get the most from it. Especially, the requirements given below should be observed while the truck isin a stage of 200 hours of operation. A. Aways warm up your truck before putting it into work regardless of the seasons. i. Perform specified preventive maintenance services carefully and completely. A Nover “race” or play games with the truck. Avoid sudden stops, starts or turns. A. Oil changes and lubrication are recommended to do than specified RELATIONSHIP BETWEEN LOAD AND STABILITY OF TRUCK ‘The lit truck keeps a balance of weight between the truck and the load on the forks with the center of the front wheels as a fulcrum when the rated capacity load is placed in postion. Due care should be paid to the woight and the load's center of gravity to maintain stabil Ifthe rated capacity is exceeded, there Is a danger of the rear ‘wheels being raised and in the worst case, the truck will tum over, resulting in a fatal accident. The load placed near the fork tips practically has the samo effect that the woight of the load is increased. In this case, the load weight must be reduced accordinglyBASIC LOAD CENTER AND RATED LOAD ‘A caution + When traveling with loads, keep the forks 15 to 20 cm (6 to 18 in.) above the ground surface and keep the Mast tilted back fully. +The allowable load of a truck equipped with an attachment is reduced in comparison with that of the ‘standard truck. Hf the truck is equipped with a load-handling means such inged fork, load grab, or rotating clamp, its allowable load will be reduced as compared with that of the standard truck (a truck without any attachment) for the following reasons: Never exceed the allowable load indicated on the load chart attached onto the truck or attachment. Reasons for a reduction in the allowable load: 41) The weight of an attachment is added. 2) The attachment shifts the basic load center position forward, and thus the allowable load is reduced. ‘The basic load center is the distance from the front face of the forks to the load’s center of gravity. The chart given above shows the relationship between the basic load center and the weight of, loads to be allowable for the 2-ton truck. This chart is called a load chart and is attached to the truck. PROPER OPERATION THE STABILITY OF LIFT TRUCK ‘The stability of lit trucks is stipulated in JIS (Japanese Industral ‘Standards) or in other national industrial standards, and TCM lift trucks are manufactured complying with these standards. However, note that the stably of lit trucks Is not assured at all times, but ‘only when the following conditions are properly observed. + The ground or floor surtace is level and hard. + The truck travels under standard loaded or unloaded condition, + The truck is operated carefully and the forks are properly manipulated; that is, the forks are not tilted forward more than necessary, when stacking or unstacking, Load handling is carried out carefully and slowly. In addition, keep the truck in good working condition for safe ‘operation and traveling ‘Standard unloaded condition This means that the forks are raised 20 cm (12 in.) above the ‘ground or floor surface and tited back fully without loads. ‘Standard loaded condition This moans that the forks are raised 90 cm (12 in.) above the ‘ground or floor surface with a load placed at the basic load center position of the forks. TRAVELING AND STARTING ON A SLOPE ‘When traveling on a slope with a load on the forks, have the load pointed up-hl ‘When traveling on a slope without load, have the rear end of the truck pointed up-hil to prevent the drive wheels from skidding,rPnvurcn vrenaiiun TRANSPORTING LIFT TRUCK A caution ‘Transporting the lift truck on a trailer truck + Securely lock the lift truck in place to prevent it from moving on the trailer truck by fastening with wire ropes and blocking the wheels. + When loading or unloading the lift truck onto or from a trailer truck or when traveling over public roads, pay attention to the overall length, overall height, and weight and observe the local traffic regulations. CAUTIONS TO BE TAKEN WHEN LOADING AND UNLOADING LIFT TRUCK ‘A caution Never try to move the steering wheel when halfway up a ramp; otherwise the truck might fall down, leading to a serious accident. Ay Use ramps of sufficient length, width, and strength. A. Botore loading or unloading the lift truck, make sure to apply the parking brake to the trailer truck and block its wheels. Ax Ramps must be securely locked to the trailer truck. Their surface must be clean and dry. A. Loading and unloading must be carried out on a level surface. The right and left ramps must be the same height. A. When loading the lift truck onto a trailer truck, back it up the ramps slowly with care. OPERATING LIFT TRUCK GETTING ON AND OFF ‘A caution Do not hold the steering whee! when getting on the truck. Do not jump on or off the truck. You might stip or tumble down, leading to personal injury. 1) Make sure there is no one around the truck 2) Using the safety step and hand grip, gat on the truck from the loft side ofthe truck. 3) Fasten the seat belt for your safoty's sake. It will help prevent you from getting injured when the tuck tips over.BEFORE STARTING LIFT TRUCK PROPER OPERATION STARTING LIFT TRUCK ‘A caution + It takes about 1 second after the key switch is turned on, to make the control circuit ready for functioning to allow the truck to start. + Do not place the FIR lever in forward “F* or reverse “A” botore the key switch is turned on; otherwise the truck might not start If this isthe case, roturn the FIR lever to neutral «Do not bottom the accelerator pedal rapidly. It is dangerous. ‘A caution Make sure there is no one around the truck and let other ‘workmen and bystanders know you are starting up by honking. 1) Pull back the lft lever to raise the forks § to 10 cm from the {ground oF floor surface. 2) Pull back the til ever fo tit back the mast fully 8) Pull back the lift lever again to raise the forks 16 to 20 cm from the ground or floor surface. 4) Make sure there Is no one around the truck and let other ‘workmen and bystanders know you are starting up by honking. ‘A caution Press the brake pedal fully before shifting the F/R lever into forward “F” (or reverse “R"). ‘A caution When traveling in reverse, look in the direction of travel and be alert for pedestrians, other trucks or obstacles in your path of travel. Do not rely too much on the sideview mirrors. 1) Step on the brake pedal 2) Place the FIR lever into forward “F* (or reverse") 3) Release the parking brake. 44) Flemove your foot from the brake pedal and step down tho accelerator pedal gradually 5) You can control the traveling speed by stepping on the accelerator pedal @& NOTE Do not keep your foot on the brake pedal after starting the truckPHUPER UPERAUN TURNING Note that the higher the traveling speed or the smaller the turning radius, the possibility of the truck rolling over sideways increases when making a travel turn. ‘A caution Note that the rear end (counterweight) of the truck swings when you tuen the truck. Unlike general passenger cars, the steer wheels are located at the rear of the truck. This causes the rear end of the truck to swing out when a turn is made. Slow down the truck and move toward a side to which you are turning. The stesring whee! should bbe turned a bit earlier than as with the front-wheel steering car. ‘+ Grab the steering wheel knob with your left hand. + Your right hand is used to operate the load handling levers. + Before making a tur, slow down to about § kwh and turn the steering wheel slowly, making sure there is no one around the truck SIMULTANEOUS OPERATION OF TRAVELING AND LOAD HANDLING (INCHING) + Simultaneous operation (inching operation) of trave and load handling requires skilfulness. The operator is required to know the shape of the load he is going to handle, the possibilty of slipping, deformation, and load’s center of gravity. In addition, he needs to lift the forks horizontally at a slow speed, ensuring the stability of the truck. Use due caution when carrying out inching operation. + Do not tilt the mast forward when the load is raised high Do not tilt the mast forward unless the load is over a stack or at low lft height. + To reduce the risk of the truck tipping over, do not liftthe load until the truck is close enough to the deposit area. 1) Under the usual traveling posture, approach the pick-up or deposit area up to 3 to 5 m from it. 2) Step on the brake pedal fully (bring the truck to a complete stop). 8) Step on the accelerator pedal to gain a traveling speed sultable for the work. 4) Operate the lift lever to lift the forks.PROPER OPERATION SLOWING DOWN Ease up on the accelerator pedal. If necessary, step on the brake pedal. If not in emergency, you can slow down and stop the truck by releasing the accelerator pedal. Rapidly releasing the accelerator ppadal will nt bring the truck to a rapid stop. I you need to stop the truck immediately, step on the brake pedal fully, PARKING ‘A caution Safe parking « Park the truck on a level ground, preferably in a wide If parking the truck without load on a slope is unavoidable, position the load handling means down- hill and block the wheels to prevent accidental roll. + Park the truck in a designated area or out-of-traffic area If necessary, put signposts or signal lights around the truck. + Park the truck on a hard ground. Avoid soft ground, deep mud or slippery surtaces. + If you cannot lower the forks on the ground due to a broken load handling system, put a caution cloth to the fork end and park in an out-of-traffic area. + Pay attention to the ground condition because it might bo slippory. + Dismount from the truck after making sure it has come to a complete stop. Do not dismount from the truck in ‘motion. + Never jump off the truck. + Dismount from the truck, facing the truck and using the safety step and hand grip. Ease up on the accelerator pedal and if necessary step on brake pedal to stop the truck. Place the F/R lever in neutralPRUPCH UrcnaAiiun Park the truck in an out-of-tratfic area and follow these steps: 41) Pull the parking brake lever fully to apply the parking brake. 2) Lower the forks on the ground. 8) Tur the key switch OFF 44) Flemove the key and keep it. '5) Dismount from the truck carefully. GROUND CONDITION A caUTION + Use due caution when traveling on a rough surface. ‘+ When crossing a railroad, be sure to stop and ensure the safety, and cross the railroad track at an angle. + Go around obstacles such as rocks and stumps, or pot holes. If unavoidable, reduce the speed and go over them slowly and carefully. Use caution not to damage the bottom of the truck. Cross a small bump diagonally if the aisle width is enough to do so. Lift truck performance depends upon the ground condition or floor ‘condition and travel speed should be adjusted properly. ‘TRAVELING ON SNOWY OR FROZEN ROAD When traveling on @ snowy or frozen road, avoid sudden acceleration, stops or turns; otherwise the truck might skid to causo a serious accident, Control the traveling speed carefully using the accelerator pedal.HANDLING THE BATTERY BATTERY CARE (A, DANGER Cautions to be taken when handling battery Gases produced by the battery can be explosive. Do ‘not smoke. Do not use open flame for inspection. ‘= No fire. Do not smoke. Keep sparks or open flame away from the battery. ‘+ Keep proper electrolyte level. If the level is too low (below LOWER LIMIT), the battery will build up heat, leading to an explosion. ‘+ Have a good ventilation. Do not use or store batteries in a closed place or an area where ventilation is poor. + Avoid electric shock accident. Wear rubber gloves when servicing and inspecting the battery. «Avoid static electricity. Do not clean the battery case with a duster or dry cloth. + Avoid sulfuric acid. The electrolyte is sulfuric acid and thus it might cause burns or blindness if it comes in contact with the skin, eye, or clothing, «If electrolyte comes in contact with your skin or clothing, wash it away using a copious amount of water immediately. + Ifelectrolyte gets into your eyes, wash your eyes with ‘@ copious amount of water immediately and get ‘medical attention. Cautions to be taken when charging batteries + In order to prevent an electric shock accident, be sure to ground the facility power source securely. ‘In order to prevent an electric shock accident, do not put your hand or anything inside the equipment; otherwise it will ead an accident if the power switch is ON or the battery receptacles are connected. «Charge in areas well ventilated and not exposed to rain water. Keep flammable materials away from the area. «tis recommended that the floor be covered with an acid- resistant material and be well drained, since there is a tear of acidic electrolyte spilling on the floor during charge. «Never smoke or use fire in the charging area especially at the termination of charging since explosive hydric gas Is released from the battery while being charged. «The hood should be kept open while charging. ‘« Donot disconnect the battery connectors while charging; otherwise sparks may be fired, leading to a fatal accident. ‘Switch over the input voltage switching taps according to the input voltage. Consult the battery manual for its operation. If the input voltage does not agree with the setting of the tap, a burned transformer or a short circuit due to deteriorated insulation might occur. «Keep the key switch turned OFF while charging, for safety’s sake. + Use fuses and non-use circuit breaker with the specitiod capacity. Do not use the power supply together with other kinds of equipment. Failure to do so will cause a damaged battery or charger.NANVLING Inc DAITeEnT ‘A caution ‘+ Make sure the electrolyte temperature is below 40°C when starting charging. If not, wait until the temperature drops below 40°C. If the electrolyte temperature exceeds 50°C while charging, the battery service life will be shortened. «Do not try to charge the battery when the ambient temperature is extremely low. Charging in a cold storage or outdoors in a cold region will shorten the battery service life. «+ Frequent overcharges or equalizing charges causes the battery's electrolyte temperature to rise, and if the electrolyte temperature exceeds 50°C, the battery service life will be shortened. * Use a charger appropriate for each battery capacity. Charging with an improper charger or using a charger for the other purposes will cause a trouble. = Do not disconnect the charger cable from the power source while charging. If the charger cable is disconnected by mistake, press the charge stop button without fail, The load handling or traveling circuit won't function unless this button is pressed. ‘= If the LCD won't operate when the key switch is turned ‘on after finishing the charge, press the charge stop button. * Use caution not to allow electrolyte splash over the truck body or electric components. If they are contaminated with electrolyte, contact your local TCM dealer, 3-9HANDLING THE BATTERY DAILY CHARGE (NORMAL CHARGE) (EXB Option) ‘A caution Charge the battery in a well ventilated place, free from rain drops, away from naked flames or fire. Aftor the day's work, or each shift or whenever the LD meter unit shows the low battary voltage alarm or the battery charge indicator drops to the level 3 or less, charge the battery in the following manner. If the battery has not discharged so much, the ‘microprocessor wil control the charging process property The length of time required for charging varies with the battery capacity and the amount of discharge. As a rough standard, when the battery has discharged 75 to 100%, it wil take B to 13 hours to charge the battery completely. ho White charging is in progress or when the charging cables are connected, do not try to touch any of the internal electrical parts. If you need to do so, make sure to stop the charger, remove the charger cables and disconnect the battery receptacles. ‘A caution Make sure the plugs are securely inserted into their respective receptacles. @& Note Note thatthe charge monitor does not necessarly show the accurata battery capacty and thus might not agree with the display level onthe LCD meter un. 41) Tum off the key switch ofthe truck 2) Make sure the line ewitch of the power supply is OFF 3) Insert the truck-side plug of the charger cable into the truck- side receptacle, 4) Insert the power supply plug ofthe charger cable info the power supply receptacle. '5) Turn on the power supply switch.HANULING Inc DAL enr 6) Pross the “Start button on the charger control panel. ‘The "Charging in progress" lamp lights up and charging starts. ‘While charging, you can hear the transformer buzzing. ‘The truck-mount type charger won't start charging if the AC power supply is not turned on or battery receptacles are not connected. 7) When the battery is fully charged in 8 to 13 hours after the start of charging, the charger automatically stops operation and the "Charging in progress" lamp goes out. ‘The length of time required for charging varies with the amount of discharge of the battery 8) After charging Is completed, make sure the "Charging in progress” lamp on the charger control panel goes out. Turn the power supply switch off and remove the plugs of the charger. 9) Before trying to start the truck, make sure to measure the specific ‘gravity of each coll ofthe battery. Fluid temperature | Specific gravity 10°C 1.287 20°C. 1.280 30°C. 1.273 40°C. 1.266 410) Do not remove the plugs while charging. Ifyou need to remove any plug while charging for any reason, follow the procedure below: Press the stop button. Q)Tum the power supply switch OFF @Remove the piugs. GP NOTE ‘When removing the plug, hold the plug body, not the cord ctherwise the wires may be broken,HANDLING THE BATTERY EQUALIZING CHARGE (EXB Option) ‘Tho truck-mount type charger automatically gives an equalizing ‘charge to the battery with the microprocessor. Therefore, there is, usually no need for the operator to do anything. However, give an ‘equalizing charge manually in any of the following cases. + The battery has been overdischarged. * Purified water has been added. * The discrepancy in specific gravity among cells Is more than 0.02 (at the electrolyte temperature of 20°C). Manual equalizing charge consists of normal charge plus super equalizing charge. ‘When performing manual equalizing charge, give normal charge to the battery and then give super equalizing charge by pressing the “Super equalizing charge” button. While super equalizing charge is in progress, the “Charging in progress" lamp and "Super equalizing charge” lamp on the chargor ‘control pane! stay on, AUXILIARY CHARGE (EXB Option) «I the residual capacity on the LCD meter unit shows level 3 or less after the day's work or each shift, give the battery an auxiliary ‘charge during a break. The procedure for giving a cycle charge is the same as the normal charge. + Ifyou want to stop an auxiliary charge, make sure to press the “Stop” button, tur the power supply switch off and then remove the charger cables. SUPER EQUALIZING CHARGE (EXB Option) ‘Super equalizing charge is composed of ordinary equalizing charge ‘and automatic auxiliary charge. Since auxiliary charge is ‘automatically carried out every 24 hours efter an equalizing charge is carried out, you don't need to worry about a low battery voltage even after the track is not used for several days. Super equalizing charge can be carried out by pressing the “Super ‘equalizing charge" button after normal charge is completed. ‘The “Super equalizing charge" lamp does not go out even after ‘charging is automatically completed ("Charging in progress" lamp ‘90es out). Tum off the lamp in the following manner: * When the "Charging in progress” lamp is on, press the button. ‘+ When the “Charging in progress” famp is off, press the "Super ‘equalizing charge” button or turn the key switch on. @& Note Frequent fullascharges ofthe battry wil shortn the battory series if. your task require fll discharge ofthe batory frequent itis advisable to use a high-capacty battery or have a spare baton [Lamp blinking while charging If the °Charging in progress” lamp on the contro panel is blinking it indicates that charging has not been completed successfully. + The 2nd timer of the charger functions and charging is forcefully discontinued In 15 to 17 hours. + The electric power fallure lasts for more than 120 hours while charging, & Nove While the “Charging in progress" lamp is inking, no charging s performed. Itis nacessary to check the cause of trouble and fc For he procedure for troubleshooting, consult your local TCM desler. top"NANVLINGS Pe oat POWER SUPPLY EQUIPMENT FOR THE CHARGER ‘A caution + The power supply equipment must be installed under the directions of a qualified electri or by a subcontractor designated by your local utilities company. «The power supply equipment for the charger must have a power supply line switch with a dedicated circuit breaker. «The capacities of the power supply equipment and fuses or breakers should be selected properly, se of fuses or circuit breakers with insufficient capacity will cause damage to the power supply equipment or charger or an accident might occur. referring to the table belo I engineer: (56 Ooi) (truck-mount type) supply equipment or breakers: Apel model 0 a nn i fro7 Eno m ae Te askin i roo [__—ineoo ea Wes ia — [ites ‘aka oa FBT a a (Note) The battery charger cable does not have a plug at its power-supply side.HANDLING THE BATTERY A caution Imperfect grounding wil ead to electric shock accident. Make sure to ground the earth poles of the plug on the power supply side. TRUGK-SIDE PLUG (©X8 Option) @ Note ower suppl lug ‘The battery chargers (M160B/N10SB) for the FB90-7, FARO- 7V, FB25-7LBN trucks require a current capacy of 40A and thus a special electrical ute wil be needed, For hi reason, the power-supply side plug isnot supplied wit the battery charger. tis advisable to atach apg suitable for your elect outlet iran appropriate pg isnot available, connect the battery charge cable crecty tothe switch, Inthis case, the green cable isa grounding cable. Battery electrolyte level Keep the battery electrolyte at the specified level at ail times. Due to evaporation and decomposition while charging, the water content of the electrolyte decreases. @& Note {ifthe spected electrolyte level is neglected the pole plates willgtdotrrated,causinga shor service Ife of he batty ithe electrolyte lovl is lou, add tiled or pured water + Addon of water sould be made before charging so thatthe electoyte and water added can be mixed wel inthe battery through charging,RANUUING Inc DAN CHECKING ELECTROLYTE LEVEL A Ui ti esnaiy el tneane ones ener en ire eas ran one sletays tava below the LOWER EVEL tne pola pnts wi gt deterred an inthe wove cat he tery might pode toc las a the gry evel at pperine ‘hetoner i Check the red float support rod in the cell plug to see if the electrolyte level is at the upper limi. PROCEDURE FOR ADDING WATER A caution Overtiling purtied water will cause electrical leakage of the battery. Do not exceed the specified upper limit. (Open the cap of each cell plug and pour puritied water through a funnel into the coll, Stop adding water when the red ring reaches ‘the top position. After adding water, close the call plug cap until it clicks. CCntralizad water fill unit (option) Remove the centralized water fll port cap and pour purified water using the purified water tank. Stop adding water when the red float rod reaches the top position. After adding water, do not leave the ‘cock of the purified water tank open for more than 90 seconds. 1HANDLING THE BATTERY CONVERSION OF SPECIFIC GRAVITY AT VARIOUS TEMPERATURES: The specific gravity of battery electrolyte varies with the temperature. To know the correct spectic gravity ofthe electrolyte, you should measure the electrolyte temperature, too, and convert the measured specific gravity into the value at the standard temperature, using the conversion table. ‘The standard specific gravity ofthe electroyte in a fully charged battery is 1.280 at the standard temperature of 20°C. How to read hydrometer RUBBER BALL CONVERSION TABLE READING OF HYOROMETER SPECIFIC GRAVITY AT 20 ‘TEMPERATURE"C Example: ‘Suppose the electrolyte temperature is 5°C and the hydrometor reads 1.250. When converted into the specific gravity at 20°C, the figure is 1.240, 0.040 lower than the standard value. Normal charge is needed.LUAU NANULING PICK-UP STACKING ‘A caution The fork spacing should be usually adjusted for more than 1/2 and less than 3/4 of the pallet width. 41) The fork spacing should be as wide as possible to maintain proper balence of the load 2) Place the truck right infront of the load to be handled. £2) The pallet should be positioned parallel with both forks. 4) Insert the forks into the pallet as far as possible. '5) To raise the load from the ground: Once lit the forks § to 10 cm off the ground or floor surface, ‘and make sure the load is stable. @ Alter making sure the load is stable and evenly positioned fon the forks, tit Back tho mast fully an lit the forks up to 15 to 20 em off the ground or floor surface. Start running. 6) When handling a bulky load which restricts your vision, drive the truck in reverse or sideways, ‘A caution + Never tilt the mast forward with the load upraised ‘except when the forks are over the rack or a stack. + Do not leave the truck with the load upraised 1). When approaching the deposit area, slow down your truck. 2). Stop the truck before the area where your load is to be deposited, 38) Confirm the safety of the deposit position. 4) Tit tho mast forward until the forks become horizontal '5) Raise the forks until they are a itl higher than the deposit, positon. 6) Move forward slowly to place the load directly over the desired ‘area and stop the truck. 7). Make sure the loads just over the desired area. Slowly lower the load into position, Make sure the load Is securely stacked, 8). Disengage the forks from the pallet or load using necessary litt operation, and then back away. 9) After making sure the fork tips leave the pallet or load, lower the forks to the basic traveling position (15 to 20 cm off the ground or floor surface) 40) Tilt back the mast.LOAD HANDLING UNSTACKING +1) When approaching the area where the load isto be retrioved, slow down the truck 2) Stop the truck right infront of the load where the distance between the fork tips and the load is about 30 em. 8) Check the condition of the stack. 4) Tilt the mast forward until the forks become horizontal and it Up to tho postion of the palit or sk. '5) Mako sure the forks are positioned property forth pallet. Move forward slowly to insert tho forks into the pallotas far as passblo. Stop the truck * Ifthe forks are hard tobe fully inserted, use the following procedure @ Move forward to insert 8/4 ofthe forks. Raise the forks 5 to 10 cm, back away 10 to 20 em with the pallet or skid on the forks. Lower the palit or skid on the stack © ‘Nove forward again to insor the forks into the pallt fully 6) Raise the forks 5 to 10 om off the stack 7) Confirm the safety behind the truck and back away slowly to the position where the load can be put safely 8) Slowly lower the load to a height of 15 to 20 cm above the ‘round or floor surace. Tit back the mast fully and move to tha desired area.DIUAING BEFORE STORING ‘A CAUTION ‘any time your lt truck is found to be in need of repair, dofective or unsafe, the condition should be reported to the supervisor, and the truck should be taken out of service until it has been restored to safe operating condition. Bofore storing the lift truck, clean it thoroughly and perform inspection using the following procedure: + Wipe away grease, ol, etc., adhering to the body of the truck with shop rag. Use water, if needed. ‘+ While washing the ruck, check the general condition ofthe truck, Especially check the truck body for dents or cracks, the tres for ‘wear or nails or stones in the tread. + Check for leakage of hydraulic ol * Apply grease, where needed. + Check for looseness of the hub nuts and cylinder piston rod joins. + Check the mast rollers to see that they rotate smoothly. «+ Lif the forks up to the top position and lower to the tower limi. Repeat this procedure to prime oil into the lit cylinders. DAILY STORAGE + Park the truck at a specified place and block the wheels. + Place the F/R lever in neutral "N" and pull the brake lover fully. ‘+ Remove the startor key and keep It in a safe place.STORING LONG-TERM STORAGE Perform the following checks in addition to “BEFORE STORING" and "DAILY STORAGE" operations. + Taking the rainy season into consideration, park the truck at a higher and hard ground. Flomove the battery from the truck. Even though the truck is parked indoors, if the place is hot or humid, the battery should be keptin a dry, coo! place, and charged ‘once a month, Apply anti-rust to the exposed parts such as cylinder rads and shafts that tend to rust + Cover components which may be caught with humidity, such as the air breather and air cleaner. + Put the truck in the operating state once a week and turn the key switch on. Warm it up sufficiently before moving the truck a litle back and forth, Avoid parking on a soft ground such as an asphalt ground in OPERATING AFTER LONG-TERM STORAGE + Remove covers used to seal off moisture Flemove antirust from the exposed parts. Drain foreign matter and water from the hydraulic oll tank, ‘Charge the battery and mount iton the truck. Connect the cables. Perform preoperational checks carefully.DIUMING PROHIBITION OF WASHING TRUCK BODY AND BATTERY WITH WATER «+ In general, do not wash the truck body or battory with water using a hose of staam cleaner. The tires may be washed with water, but floor board should be removed from the truck body before washing, While washing, use caution net fo splash water, ‘over the accelerator unit. f possible, remove the accelerator uit. + If water is splashed over the battery, water or foreign matter might enter through the cap, leading to a short battery service fe n addition, the electrolyte might spill to cause environmental pollution, Wipe any dirty battery case with a wet shop rag and dry it completely by blowing air. If necessary, leave it to a specialist. Ifthe battery case needs to be cleaned, dismount it from the truck Alter cleaning, the battery must be dried completely before mounted again on the truck Do not clean the following electrical components with water Controller and contactors Motors (drive, pump) Transformer (in the side cover) Charger control panel (in the hood) Battery unit and receptacles Meter panel box Accelerator unit (under floorboard) CLEANING ‘= Pullthe parking brake lever fully to stop the truck. + Turn the key switch OFF and disconnect the battery receptacles. AFTER CLEANING + Use compressed alr to blow away drops of water and make sure the washed areas are completed dry. ‘+ When operating the truck for the frst time after cleaning, perform a trial run and make sure the truck operates without any problem. WASHABLE ITEMS tem Washing with water Remaris Frame eurlases, 3 Use caution oto splash water mast fore, tres | lowed —_| USE, Suen ot and rear axe ‘Use caution nt ta aplach water Countereight towed | onthe covers ofthe batty | inside the rear cover: Inner euraces of = Use caution not to wet the sie cover Mtowed | components inside covers wash with water the motors ate located 2 floorboard. Clean Floorboatd and severely ‘ooreeard mat Nota ‘contaminated, remove them fand clean with water. Make a eee ven belore reinstating, Battery hood a4 | pot atowea | Clean them by blowing air oF battery case wiping th wel shop rag, Teter panel box| and steering) —Netallowed | Oito whee! _| Motors Netallowed | Dito4. MAINTENANCE The following symbols, found throughout this manual, alert you to potentially hazardous conditions to the ownar and the operator. Become completaly familiar with the truck before proceeding with CONTENTS. ‘operating, checking and servicing PREOPERATIONAL CHECKS a4 This manual and decals affixed othe tuck uso the folowing saaty — GaUrioN IN CHECKING eT alert indications. ITEMS TO BE CHECKED 4-3 ——S ——— PERIODICAL CHECK an SIGNAL WORD PERIODICAL REPLACEMENT OF SECURITY PARTS - 4 - 11 lionsinife message WEEKLY (60 OPERATING HOURS) CHECKS ane AL_DANGER | wily cause a serious accident or death MER Ga CRERATIA HELI crc a A warning ithe en 3 MONTHS (600 OPERATING HOURS) CHECKS... 4-17 ~~ | Failure to follow the instructions in the message fe RONTHE (herd OP Se aTINe Hour) ceca, 418 Aa CAUTION | hay cows prconlinryeramagetetge ANNUAL (@#00 OPERATING HOURS) CHECKS wn. 4-18 | kor ahd property. PERIODICAL CHECK SCHEDULE 4-20 Dé we | Me lnfomation wi ntp to proton he saran @ nore | hoarnoien ta ese me deat telat accident proverPREUPCRALUNAL UnoUnNS ‘To ensure the safety in operation and performance ofthe it ruck, be sure to check the following dally before starting the operation, ‘A CAUTION + If any abnormality is found in preoperational checks, hang a sign of DO NOT OPERATE on the control area, remove the start key, and report the condition to the supervisor. The operation should be halted until the truck is completely repaired. + Check for oil leaks as it may cause a fire. «Waste fluid due to lubricant changes should not be thrown away (Into sewage, earth, or incinerater, etc.). It will cause water, soil, and air pollution and the responsible personnel will be punished by law. CAUTION IN CHECKING ‘= Use TCM's genuine parts only. ‘+ Use TCM's genuine or recommended lubricants only + Gloan the ol fillers and grease fittings using a brush or cloth before supplying oll or greasing. + Oil level checks and supply should be performed with the truck parked on the level surface. + Preventive maintenance services should be done in an orderly ‘manner with utmost care to prevent personal injury. + Make sure to remove the battery receptacle before checking electrical equipment. + fan inspection should be carted out under the raised forks, fix thom by placing stable supports between the fork mast inner frame and the ground to prevent the forks from falling down. + Any time the truck or controls are found to malfunction, stop the ‘operation of the truck immediately and report the condition to the supervisor. Never operate a feuity truckPREOPERATIONAL CHECKS General condition Check the truck body for dents, cracks, and tires for wear or nails caught in the tread. m State of the truck Check the inclination ofthe truck. I the truck is tied to either side, it suggests that the ties or wheels are defective. Contact your local TCM dealer. Oil and water leaks (Check for oll and water leaks under the truck. If there is a pool of ol or water on the ground or floor, contact your local TCM dealer.PREUrCRAHUNNAL UneEnS ITEMS TO BE CHECKED [DIDEFECTS FOUND IN PREVIOUS CHECKING ‘B caution Never try to operate a faulty truck. Check to see if any defects found in the previous checking have been repaired propery. (2]TIRE CONDITION CHECK ‘B caUTION Ties of the lift truck have high inflation pressure. Make sure tires and rims are normal and set the inflation pressure to the standard level. Do not overinflate tires. When inflating tires with an air compressor, frst adjust the compressor air pressure. Failure to do so will cause a sorious accident since the compressor delivers the maximum pressure. ‘A-omall bend of the rim or a slightly damaged tire might ‘cause a flat tire, leading to a serious accident. if you find any failure, contact your local TCM dealer. Koop the inflation pressure ofthe tres always at a proper level. ®& nore Low air prossure shortens the service life of tires. Unevenness, of air pressure between right and left tires will cause hard steering or the truck to wander. 4-3 Underinflation Good Overinflation ‘The standard tire pressure is indicated on the decal on the left side of the front guard. nia om From eal | Frnt wie roar whoo! FB10,15 | _650(8.5) | 700(7.0) | 850 (85) FB20,25 | 1000 (10.0) | 850(8.5) | 900 (9.0) FBS0 00 (@.0) | 700(7.0) | 800 (8.0) Turn the tire valve cap counterclockwise and remove it. Measure the inflation pressure with the tre pressure gauge, and adjust it 10 the standard level “Then, cheok that there Is no air leakage from the tire valve before replacing the cap. Check that tires are not damaged on the tread surface or side wall, or the rim is not bent. ‘The lif truck needs tires wit high inflation pressure to carry heavy loads.HUB NUT CHECK ‘A caution ‘loose hub oth be dangerous: te wns! may come HUB NUT TIGHTENING TORQUE Teosiza | wimtka-my | Teese® | emia) | lithe | BB rae Bs, Be. {Doutiey | { Cuter nuts? J wenn | ae 7 (Binge) qo-sea | OPA | abin| Pavia... | ‘ou: ‘nuts! ‘The Order of Tightening Double Nuts ‘On the hub nuts for the double nuls, fix the inside tire's rims with the inner nuts (inside, square head) and then fix the outside tire's rims with the outer nuts (outside, hexagonal heads). Tighten the ‘square-headed inner nuts diagonally to the specified torque and then tighten the hex-headed outer nuts to the same torque. PREOPERATIONAL CHECKS ‘A caution Do not use tires with loose two-piece rim connecting bolts ‘Tho rear tires use two-piece rims which are composed of Inner and outer rims connected with bolts (B). Make sure to check. the rear tres for loose bolts ofthe two-piece rims before stating the truck. Do not operate the truck with loose rim bolts. any loose rim bolt is found, remove the core from the alr valve (C) and deflate the tire completely and remove the tice trom the truck body. AA special tool is required for loosening or tightening the bolts of two-piece rims. In addition, retightening of the connecting bolts, the disassembly and reassembly of the tires and rims, and the Inflating of the tires are dangerous. Leave such a work toa specialist. )) 2-3t0nPRCUrCNALUNAL UieEnNS (SJOVERHEAD GUARD Check the overhead guard for loose bolts or nuts or damage. (@1eRAKE FLUID ‘AIR HOLE { a ae st ‘The level ofthe brake fluid can be checked from outside without removing the cap of the reserve tank. Chock that the fluid is filed to the spect level. [3] REAR COMBINATION LAMPS REAR COMBINATION LAMPS. Make sure thatthe lens of the rear combination lamps (tall lamp, brake lamp, backup light, rear reflector) are not broken or diy(B] HYDRAULIC OIL LEVEL (Check the hydraulic cil level with a level gauge. (Open the check cover under the floor mat, remove the tank cap, and clean the level gauge with a clean cloth. Then insert the level {gauge and pull it out gently to read the maximum oll level. itis good ifthe oli up to the upper line on the gauge. If itis below the lower line, supply oil @& note ‘© Too much oll will cause ol leak. + Ifthe oil eval is above the upper ling, drain to raduce itto the proper level + Check the hydraulic oll level withthe truck parked on the lovel surface, the mast vertical and the forks on the ground surface. PREOPERATIONAL CHECKS HYDRAULIC OIL PIPING AND CYLINDERS ‘Check that oil is not leaking from the hydraulic oll piping and cylinders (it, tit), [8] LOAD BACKREST ‘A caution Do not modify or remove the load backrest. «+ The operator may get injured by a falling load. «The forks may come off the carriage. (Check that the load backrest is not damaged or mounting botts (4 (on the right and left) are not loose or missing,PRACUrCNAHUNAL VEEN (21 FORKS, FORK STOPPERS, AND FORK LOCK BOLT Fork sToPPEns FORK LOCK BOLT ‘Check that the fork stoppers are properly engaged, the forks are not bont or cracked, and the fork lock bot is not loose, [10] HEAD LAMP AND FRONT COMBINATION LAMP HEAD LAMP CORISINATION LAMP aS Check that the lens on the head lamp is not damaged or dirty. Check also the front combination lamp in the same manner. 47 (IL) BATTERY ELECTROLYTE LEVEL ‘A cauTiOn ‘+ Do not use or charge the battery with the electrolyte below LOWER LEVEL; otherwise, the plate will deteriorate faster, which may cause battery explosion. ‘Never use naked flame source to check the battery electrolyte level. It may ignite or explode Check the battery electrolyte level Look in the battary plug to confirm that the level mark is visible.[12] BATTERY STOPPER Make sure that the battery stopper is not loose. (Close the hood ‘A cauTion ‘Use due caution not to get your fingers pinched when losing the hood, Use caution not to get your fingers pinched between the hood and the truck body when closing the hood, (73) ADJUSTING DRIVER'S SEAT AND STEERING COLUMN ANGLE Got on the truck and adjust the driver's seat to the position which provides easy access to foot and hand controls. Also make sure that you can operate the steering wheel smoothly. After adjusting the seat position and steering column angle, lock ‘thom securely. PREOPERATIONAL CHECKS (4) SIDEVIEW MIRROR Check that the stdeview mirrors are not dirty or damaged. ‘Adjust the miror in the driver's seat to gain full rearview when you are seated (15) PARKING BRAKE OPERATION ‘Make sure that the brake works property The brake must be properly applied when you pull the lever fully toward you. yy switch ON [Turn the key (16) LOAD HANDLING LEVERS. Check that the load handling levers (it, tit, and attachment) are not loose and can be operated smoothly.PRCUrCNALUNAL UnbEnNS (Z Leb DISPLAY (2UIBRAKE PEDALS 2 BEBBBE.Bn kn) ond ‘Make sure that the LCD display is turned on when the starter key is switched from OFF to ON. [8] LIGHTS AND LAMPS (Operate the lighting switches to check that lights and lamps are tumed4 on and off property (19) TURN SIGNALS (Operate the turn signal lever to see I the tur signals blink properly. HORN Press the hom button on the steering whee to chock thatthe horn sounds propery ‘Step on the brake pedal to check that It moves smoothly. Remove your foot from the padal to see if it returns to its original postion. Play of the brake pedal is 5 mm. A: Hoight ofthe brake pedal from the floor. 90 mm [22] MAST OPERATION Operate aach of the lit and tit levers two or three times to check that the forks and mast operate smoothly without squeaking, and that they are not loose. (if the truck is equipped with a hydraulic attachment, check it and its control lever as well) @& Note WARMING UP CYLINDERS Before starting the work, warm up the cylinders, This ubicates packing and seas inthe cylinders to make them ready for operation,PREOPERATIONAL CHECKS (23) LIFT CHAIN TENSION (Run the truck at alow speed (in a safe place) Raise the forks 50 mm off the ground or floor surface and check that the right and left it chains have the same tension. Ifthe tension is not even, adjust it with the chain anchor bo Atter adjustment, securely tighten the lock nut 7 (24) STEERING WHEEL Turn the steering wheel counterclockowise and clockwise to check that the play is within the range of 20 - 30 mm. Check also that it does not move vertically. 25] BRAKE TEST <= Fun the truck slowly and press the brake pedal to check that the truck is braked property. Make sure that the brake lamps are lit when the brake pedal is stepped on, (26) STEERING WHEEL TEST (a) CY FRun the truck at a low speed and slighty tum the steering wheel to the right and left to check thatthe truck is staered smoothly without problem. [27] PARKING BRAKE TEST Check that the truck is stopped when the parking brake lover is pulled and that it stays in the same position after stopped, [28] BACKUP LIGHT CCheck thatthe backup light tums on when the change lever is shifted to the backward gear.PREUPCNAHUNAL UCU nRS REPLACING TIRES AND 3) Jackupthe trucktoan extent that the tre REPAIRING FLAT TIRE Get tools and jack necessary for replacing ties. (Front wheel ‘A caution ‘When removing a tire from the truck, remove air trom the tire completely and then remove the hub nuts, 41) Park the truck on a lovel, hard surface and turn off the key switch. Do not have any load on the forks. 2) Apply the parking brake and block the wheels. Put a jack under the truck frame. an sill femaine on the ground. Loosen the hub nuts (@)-@). Do not remove them yet 4) Jack up the truck uni the tie leaves off the ground. Remove the hub nuts. 5) Remove the tie from the hub 6) When reinstalling the ir, use the reverse order of removal. Tighten the hub nuts in a diagonal order and evenly Hub rut tightening torque: See page 4-4 -fter installing th te tothe truck, adjust the inflation pressure to the standard inflation pressure, f needed [Rear whesi) Proceed in the same manner as with the front ‘whee! ie, except that the position of the jack {goes under the counterweight, Hub mut tightening torque: See page 4-4 ‘Tre servicing roqulas spec Bont ake tes of track unt al ar presure fpout, Loosen only WHEEL LUG NUTS“ Bonet loosen wed assembly nets "2 et Bi alepreseur le out o tro. Sec FERarons aMUAL fr mere mpornt Hake Sore lt ants ren pi Néver ada ato ate that looks tow. Leta Sr cutand check for proper aecemby install treo monty cage. Soe MANUAL {or proper pressu S Saye Bais caePREOPERATIONAL CHECKS Remove a tire from the rim ‘A caution ‘+ Before removing a tire from the rim, remove the valve core to release the alr pressure from the tire completely. In the case of the split type rim, remove air from the tire before loosening the split rim connecting bolt (B); in the case of the side ring type rim, remove air from the tire before removing the side ring (lock Fing) ‘The assembling of a tire, tube, rim, and flap and inflating of a tire which has been removed from the truck should be done only by qualified Personnel. The lift truck uses tires which have an inflation pressure far higher than those of general passenger cars. The use of improper parts or work procedure will cause a serious accident. Tires should be inflated with them attached to the truck or by putting Ina safety cage, even if you are qualified to inflate tires. The split rim connecting bolts must be tightened to the specified torque using the special tool, with the tire inflation pressure removed completely. install the split rim on the truck with the rim connecting bolt head pointing outside. ADJUSTING OPERATING FORCE OF PARKING BRAKE Aduting paving bake lver Stans parting ore 160- 170N (15-17) ADJUSTMENT 1) Engage the spring scale to the parking brake lever as shown above and measure the force requited to operate the lever. Standard operating force: 150 ~ 170 N(15-17 kg). 2) IVthe measurement is not within the range of the standard operating force, turn the adjustment bolt with a screwdriver to adjust the operating force of the lever. Reduce by turning the bolt counterclockwise. Increase by turning the bolt clockwise. 8) The cable of a new truck tends to elongate. It is advisable to adjust it sometimes after the day's work or each shit.PeNMIVUIVAL Uncen A caution Be sure to read INSPECTION AND MAINTENANCE in this manual before checking or servicing the truck. PERIODICAL REPLACEMENT OF SECURITY PARTS Periodical checks are required to keep your truck in a safe and {good condition Continual use of a damaged or abnormal truck may cause a serious ‘accident. Even If it appears to be in a good condition, do not leave itas itis. Early dlscovery of trouble which may cause breakdown ‘poor performance will graatly improve the working efficiency ‘and operability, prolong its service Ife, and lower the maintenance cost. Preoperational checks, supply of oll and grease, and cleaning of filter elements should be carried out by the customer, and other ‘complicated checks should be left to your TOM dealer. If checking ‘or servicing is performed without enough knowledge, special tools ‘or equipment, personal injury may occur. Every one menth of operation is caleulated as 200 operating hours In this manual Name of Safety Pars ieee ies {| Cus and dust seals of master ender 1 and whee elinders 2_[ Power steering hoss 2 | Reserve tank bing 24 4 | steering actuator ruber boots 5 | Litehain 2-4 6 [Lead handing means hoses 2 In order to perform safe operation, the importance of preventive ‘maintenance of the truck cannot be too emphasized. Especially the parts listed in the table below must be replaced periodically since they are the most important parts for security of the truck and the operator. Moreover, these security parts are liable to be damaged and deteriorated inthe course of time, and ts dificult to determine by ‘ordinary maintenance whether they are beyond thelr respective service limits or not. The security parts must be replaced with new ‘ones when their respective service limits have been reached, even, if they appear to be good ‘Any time abnormalities are found, these parts should be replaced even during the replacement term. @& nove Replacement of security parts, however, is not subject to warranty claim.WEEKLY (50 OPERATING HOURS) CHECKS. Check the following itams In addtion to preoperational checks. Preoperational and weekly checks should be performed by the user of the TCM battery type fork truck. Check the truck thoroughly to ensure safe and comfortable operation, PERIODICAL CHECK tems to be checked * Cleaning the battery + Measurement and adjustment ofthe battar's specific gravity and the temperature of electrolyte m CLEANING THE BATTERY ‘A caution Do not clean the battery with dry or chemical cloth as it, may cause static electricity and explosion. Always use damp cloth for cleaning. ‘The top surface and joints of the battery must be kept clean and dry. Tighten the plugs securelyPEHIVUIVAL UNCUN MONTHLY (200 OPERATING HOURS) CHECKS Check the following items in addition to preoperational and weekly (60 operating hours) checks. ‘Adjustment and replacement of components and parts listed as monthly check items are difficult and need sufficient technical knowledge and spacial tools, lems to be checked * Battery — Equalizing charge + Battery receptacles ~ Damage and looseness. ‘Wiring ~ Damage and discoloration + Contactors ~ Rough surface of contact points Controller Cleaning and loose connections. + Battery charger — Proper operation ‘= Fuses - Flated capacity and proper installation + Front axle — oll leaks ‘= Front axle mount bolts — looseness (trst time only) ‘= Ties - Tread depth and foreign matter in tread + Front and rear axles — Deformation, cracks and damage + Steering gear box ~ Loose mounting bolts + Rod, arm and king pin — Looseness, bending, and damage tems to be checked ~ Rear axle — Proper installation «Brake piping — Mixing of alr + Brake system — Operation and looseness of rod and cable + Brake piping — Damage, cil leaks, interference with other parts, and looseness. + Brake fluid — Leakage + Brake drum ~ Loose mounting += Forks — Cracks and wear ‘Mast ~ Cracks and damage ‘= Mast support — Cap bolts (first time only) + (View Mast) - Looseness of it cylinder tall lock bolts, piston fod head mounting bolts, cylinder U-bolts, piston head guide ‘mounting bots (lest time only) « Lift bracket - Cracks and damage «+ Loading system rolls ~ Loose rollers and cracked or damage roller pins # Lift chains and anchor pins ~ Looseness * Lift chains ~ Elongation, lubrication, and tension + Pumps ~ Operation and oil leaks * Valves - Looseness of control levers + Valve control lever micro-switch — Operation and damage + Control valve ~ Operation of reli valve and titlock valve + Hydraulic oil piping — Oil leaks and damagePERIODICAL CHECK tems to be checked ‘Sheaves — Operation, damage and looseness + Rollers (end, side and retaining) - Operation, looseness and damage * Cylinders (ift and tit) — Operation and oil leaks * Attachments ~ General condition and installation ‘Major bolts and nuts — Retightening (new loaders only) * Chassis ~ Lubrication m LUBRICATING LIFT CHAIN ‘Apply engine ol tothe lit chains using a lubricator or brush. To allow oll to enter between each pin and link plate of the tft cchain, observe the following conditions: 1) Loosen the chain sutticiently. 2) After applying engine oil, move the mast up and down fully, at loast 10 times. & nore If your lift truck Is used near a port or coastal area, the lift chains might be damaged by salty breeze. After a storm or typhoon, its advisable to wash them with fresh water before lubricating in the mannar described above.FENIUUIVAL Uncen § GREASING POINTS MAST AND STEERING 8}PERIODICAL CHECK MAST REAR SLIPPER (FOR OPTIONAL MAST) Do not climb the mast. Do not pour your hand or foot on the connecting members or into the mast assembly. You ‘might get injured if the mast moves accidentally. ‘Apply grease an the U-shape guides shown inthe sketch (for masts with tree lit mechanism)PEMIUUIVAL UneUN 3 MONTHS (600 OPERATING HOURS) CHECKS Perform the following chacks in addition to preoperational, weekly (60 operating hours), and monthly (200 operating hours) checks. Ttems to be checked + Steering gear case - Oil leakage + Steering gear case - Looseness of mounting bolts + Gear box - Ol leakage, looseness of mounting bolts + Fork stopper pin - Damage and wear * Motors (pump and power steering) — Wear of brushes + Motors (pump and power steering) ~ Rough surface of commutatorPERIODICAL CHECK 6 MONTHS (1200 OPERATING HOURS) CHECKS Perform the following checks in addtion to preoperational, weekly (60 operating hours), monthly (200 operating hours) and 8 months (600 operating hours) checks. tems to be checked = Contactors - Checking contact points for wear and replacoment * Drive motor ~ Cleaning ‘= Drive motor ~ Lock current adjustment ‘+ Electrical equipment — Insulation ‘= Battery charger ~ Operation of voltage relay and voltage adjustment «= Battery charger electronic timer - Operation and adjustment + Steering gear case — Oil change ‘+ Hydraulic oll tank — Cleaning suction strainer ‘+ Hydraulic oll~ Change ‘+ Hydraulic oll system — Replacement of return fiter ‘+ Roliof valve ~ Adjustment of relief pressure ‘= Mast support ~ Loose cap bolts ‘= Accelerator pedal - Stopper adjustment + Driver's seat ~ Damage and loose mounting bolts ‘= Major bolts ~ RetighteningPONIVUIVAL Uncen ANNUAL (2400 OPERATING HOURS) CHECKS Porform the following checks in addition to preoperational, weekly (60 operating hours), monthly (200 operating hours), 3 months (600 operating hours), and 6 months (1200 operating hours) checks. tems to be checked ~ Parking brake — Operation, wear and damage of ratchet + Brake fluid ~ Change ‘Master cylinder and wheel cylinder ~ Operation, cil leaks and damage ‘+ Master cylinder and wheel cylinder ~ Replacement of piston cup and check valve ‘= Wheel brake ~ Disassembly, inspection, adjustment and replacement of brake drums and brake shoes + Mast support - Wear and damage of bushings + List eylinder Natural drop Tilt cylinder ~ Natural drop + Forks ~ Color chacks of bent area + Truck body frame and cross members ~ Damage, cracks and loose rivets and boltsPERIODICAL CHECK PERIODICAL CHECK SCHEDULE ‘This check schedule Is worked out on the assumption thatthe it ruck will be used under typical working conditions. Ifthe lift truck is used under severer working conditions, lar check is required. (The black dots in the table mean change or supply.) ELECTRIC SYSTEM een" Senos Regus Teovonacy [PPSIR| (Goh | Some) | Cooma} [traces | reo heck or conainaton a baer caso Gearing ofofofolo heck elec vel adit nacessany] © of[ofofo lo at aq) [Cheskepeae gravy nai eo, ofofolo [Give equalizing charge ° oO o 9° heck orinsiation ‘heck o [0 |_o [eek or contamina of he uae Gren o [oo fo fo heck or rogh ona ens fenton ‘Check eo fo fo l]o Contater [Check or worn conte pons of on epee noes o_|_o eck orinslaton Repne treed o_|_o [Check orlocseconactons Cheek eo fofo lo [Check buses for wear apace reed o | o |_o [Check or rughness of conmualor reat o | o | o uo ve, [Gk fr proper operation Cheek o [| o | 0 ant Sonn) | Check Tornese check o | o | o Sneckioek caret (or ave mein vara ena oe [0 [check orinsiaion Measure o | 0 [0 [Shek or contamination Cleaning o [0 Garey [Ghesk'or proper eperaton (ares) Check eo] o fo l]o 8B pion) [ee os proper operation and vakage of aa eulomino vorage rayPoMIVUIVAL Ucn euecrnicsvareu Stem Sens Required eatromesy PSH) eh | ashy | Tbteey |e | Aes Saati wa o [0 |o 2 (core eon oper | ra 3 (©XB option) | rack elocrone timer for operation Adjust oO oo ° coco wires [Oe ooo fo terminals, [Check or damage ‘Cheek © ° ° ° ° ° couplers: [Check for diacoloration Check ° o oO oO rome ran “ee” = eens ‘aay [| A Sarai ei o | o [0 Se aa oy 6 |e oreennesvareM Soaicapees mee fo |-o [0 | 0 | o | 0 rosie Denon o |e fo }3 rst es, create | Os o |e fe 0 Sees Ee, [ers vw | o |e feleleleo 4-23PERIODICAL CHECK STEERING SYSTEM hc Belong work] Wooky | Monty | Tientiy [Semiannuy] Analy ten Senos Required Tatremacy [PRersnit | (owe) | owe | (tee) | zune) | cascors) fips ana or damage of rine, side rngs. and | Yauqy A a 5 a S ‘wheal eck or Toosenass and nase © © © o Bearings [Disassemble wheel bearings and change areas e e ae (Check for deformation, creks and damage. Visual oe © ° ° contRots ct F Beier work] _Weeky | Moni [Reninmust] Annan Sram" | Service Rui wotrameay | orsnit "| (eons) | oot) (ida | etooa wck or pay Operaie © o ° o [| o | o (heck for looseness in axial recon Touch ° © ° o | o {| o heck or looseness in rade cect Toveh ° © © © © ° [eck ar proper operation Operate © © © ° ° ° Steering. ge" | check or nose mounting Bots operate ° o | o ° was [heck forieoseness Opera ° ° o ° iota [Check orbends, damage or wear Visuel ° © ° ° Kuekle | Cheok or looseness ane damage of ng pin Operate ° eo fo fo earaxe [SROETOrbends, detormation, cracks or damagel — Visuel ° of of 0 tar ave [ creak formounting condion Test hammer © o | o [oT [Cheek fororeper operation Operate o © ° o | o |_o Power [Cheek boots for ope Views ° ° © o [0 seeing [Check fr loose mounting or inkage Visual ° ° ° ° [Checklists Touch ° o [oo ©PEHIVVILAL UNEUR [Ghack return springs for dteroraton. [check automatic acste Tor proper operation BRAKE SYSTEM erg irswar] —wesiy | ay | asco aren] Aaah Seen Senco Required eoirmeny [Pee] RGR | oot | TeoSted | eau me] Become) ecko ay oe fo [oe ]olfolo fo stapaay [22 esa al sae | o | o | o [0 | o | 0 a | Check for braking effect or uneven braking ‘Operate o ° ° ° ° ° Check oar mbedn bak ppg Operate o |e fo | o ening ae [heat or ope opr of ever ‘owas | © | o | o | o | o | 0 lever [Check for braking effect Operate Oo oO oO o oO o Check for proper operation a o o_ [0 cosanocan rope op Ope ° Check oreo Inkage Touch o [0 | 0 | 0 check or daage leek or inareon o | o | o | o Mowe en pe check rose conection cap Touch oo [Po fo heck ori ea. eval o | o [0 | 0 hook ort vl a des waa [oo [o [oe |o |e |e yin ad whe! endorser om ist s pai © check sie yner and weal yin or file ake or mage. ul el ° ec mason ipa chook een ofasegren aay . heek un mounting paorlooconees. | Tamthanmer op>e ~o | o check ning for wen Se capers o Check shoes or oper person. Operate © Sake dem 8 [Chek anchor ps era ° © ° oO [Check drum for wear or damage,PERIODICAL CHECK BRAKE SYSTEM Cheat aeeer] any | ase, | enany [een] care on? Service Required ‘Tooter ‘orshift | (50 te) (200 | ey (600 hes.) | (1200 hrs.) | (2400 fey eckioretrmatons| Yau ° Backplate [Cheat tor rakes sual © eck instalation for owarane Tet naner 6 LOAD HANDLING SYSTEM Teen Batre non] Weary, | Monti, | Tmonhy [Seniannany] Arman tom” ‘Bandon Rauirod Tooiremesy |PEGME| (Soe) | cuoIn) | Tevet |tisvohe) | eGR) [check or damage, efomaton, oF wear wes | o | o | o | o | o | o rons | Oneek on stopper pin or damage wear eal o | o | o Chk fot root and tuthwalod aon for Shek ak oat vl o | o [| o | o eck ran esrb Saad wot] Vin oo [eo] 0 [Spec ot onder race and mad or racks srdemagy at welded por vival ° ° ° ° Shek ener andlaner mast Tor oreeked wal | —vnva ol roms one EG feck vtatane {ro caringe for acted weld or damage visua o fo foe ]o a Tous o [0 | o | 0 [Gheok ast syppor bung or wenrordarage| Veal ° heck ones suport bueingbotsorlccsaeee | Tes hammer Orme o [0 Geocoin ancwa reacts erdanape | Veal Cn eek eee. dr he, a See dR aRE| a enner Orme oe ejeck en ortersen,cbmaton dren er | toucn o | o | o | o | © Jen ina Sir [Geant Ta oe pes [Ghek or elongation Gauge o fo fo loPEMIUVIVAL UNcUnN LOAD HANDLING SYSTEM ‘heck Balorenem] Westy | ony | Tamenmy ena] Anas ‘en Seren quod eoronesy [Pt | Sims | ASH | Teoh [Ewe eters eck ows nage cichananchorpnardhan| Vial eo fol] o fo hain ans Shame"? [heck heaves for deformation o damage Visual of[o}o | o ‘hock sheave bearing for looseness Tous o | o | o | © ‘Miacmenia_| check fx operation and natalaton Spree oj] o |o | o ck ston ro bot eden forfoseness] Vial! Solomon a dameoe vesthanmer |_© ° ° ° 2 ° yinder | hestor eee operation omnes | o | o |.o | 0 | o | o heck or oaks vas [0 fo |o | o | o | o heck nnd cnr uma weerorsarane | Vial o fo fo | o ‘pres pan | Shak for of eae ornoee Veuiasioy[ of 0 [o | o [| o | 0 HYDRAULIC SYSTEM ‘Chacn Baorenon] west | om erie] Arc ten Service Required ootemady || me) | gave) (zoe | abo re) Terns [SPeIK evel ena ohange lt eotrinsied | Vial o | o | o ele tank | Change suction strainer Operate: ° oO inne er [change ior canine Operate ° le ‘conve [Shek er operon of conver nkage ome | o [o | 0 |.0 | o | 0 inn | Check for function of contral lever Operate [J ° ° ° oO ° chock or of leaks Via o | o | o]o | o | o contl vate [Checkrolevabe, lock vale for eperton | Audion o fo ]o fo sasue relict pressure Ot proseure Measure rte pa o | o [Shook ora ena, ioosness, delomaton ana Hose, ling, ooseess, ‘isuavauato o | o o | o ose fh samene oa ° ‘swiveljoint [Check load handling system hoses Operate: © were yse aoPERIODICAL CHECK ‘SAFETY DEVICE AND OTHERS aking ora ry] Tanenihy [Segiarrusty] Annual tae Serie Required oemeacy [PERN] Ci | AaB) | Eee) | CBoomred | ae) Overhead | heckorooee rauning Testhammer | _O ° ° ° oO ° backrest [Check ior deformation, cracks or damage Visual ° ° © oO o ° Tumsignal__ | Chesk for opertin and istalition Operaie ° © ° ° ° ° ‘arm [Check or eperation and instalation Operate ° ° ° ° ° o iis [Check or operation and instalation Operate o ° © o ° ° ‘Backup alarn] Check or operation and stallion Operate ° o ° o ° ° = [check or contamination or damage Visual ° © o © ° ° ‘mirors | Cheak ar proper viiiy Visual ° ° ° ° ° ° iWoters | Check for operation Operate ° ° ° ° o © Fear reecion Liege "| eck orconiamintion x damage visual ° ° ° ° ° ° [oheck or damage or loose mounting bole ‘icual o ° [Oheck rame and owas members lor damage or chest nae ‘visual ° “Truckbody [book or loose vets and bots Test harm © [Check he results of previous cheaks Visual o ° o ° ° ° [check general conaiion of ruck Visual o ° ° © ° ° Lupieane [Aer leaning, check or lubrication ofeach par | Grease pump ° ° ° ° 48n¢ ol e899 Check conciton of orcas ‘Cheek °The following symbo's, found throughout this manual, alert you to potentially hazardous conditions to the owner and the operator. Become completely familiar with the truck before proceeding with operating, checking and servicing. This manual and decals affixed tothe truck use the folowing safety aller indications, SIGNAL WORD & DANGER A warning A CAUTION & note Failure o follow the instructions in the message wil ikely cause a serlous accident or death Fallureto follow the instructions in the message might cause a serious accident or death Fellureto follow the instructions in the message ‘may eause personal injury or damage to the ruck or other property. 5. SPECIFICATIONS & SERVICE DATA CONTENTS: ‘SPECIFICATIONS. LOAD CHART. SERVICE DATA. AFTER-THE-SALE SERVICE. ‘TRUCK SERIAL NUMBER AND SERIAL NUMBERS OF MAJOR COMPONENTS TCM'S GENUINE PARTS FOR YOUR RECORDS 5. 5. 5. 3.SFEUITIVAIIUINGSPECIFICATIONS (ExB me raasav | ros07 | reso-70 rao | ro67 | razor | raas7 | rexsne 00 5 ira aay WGTuT We 1 Sat {Posie to stat tom eur ae er the mado 7 rT. arin nung res (SORE T x 00 2065. 210) 260 ‘nat ws “ase aes 505 35 ss T5 Zs aa a0 TORE 3 3 SSIS tele] {Opton) ze 7 00 2185-107 x800E. T0007SFEUIFIVAIIUINS (BE meca Fav? Ta Fa187 reas7 | Foas-nie | Fes e0o-7 | FaGO-y a0 a0 BUSH Tae 0 SS co a we aE [Poesiiete star tom 2.100 eye 2 2(e)5)3)58)3 812 60 Teas 230-1080 30 i B09) Tax os-10 “42507LOAD CHART ‘A caution ‘The load charts below refer to the lift trucks of standard specifi less than 5m. Lift trucks with a high mast whose load charts. jons, and those with high mast whose lifting height is ing height is Sm or higher, or those with an attachment have different FB10-7 FB25-7 FB25-7LB - FB25-7V FB30-7 - FB30-7VBRAKE PEDAL Height of brake pedal ~ Play of brake pedal S mm PARKING LEVER Basic operating power-- 150 - 170N (15 - 17kg) TIGHTENING TORQUE OF BOLTS AND NUTS Fear axle (axle - frame) 427 - 634N-m (43.1 - 64.7 kg-m) Mast suppor (mast - frame) 75 -111N-m (7.6 - 11.8 kg-m) Piston head guide mounting bolt 194 - 200Nem (13.6 - 20.4 kg-m) CONTROL VALVE Roll set pressure FBIONS FB20/25/90 ~ 14.2 MPa (145 kafom?) 17.2 MPa (175 kg/m?) REPLACING LIGHT BULBS Replace any blown-out bulb with a new one ofthe specified capacity, referring to the table given below. LAMP CAPACITY 48.V -40.W 48 V -25W Head lights ~ Clearance lights Tum signals Front 48.V -25W Rear 48.V-25.W Tall tights ~ 4a,V-10W License number plate lamp 48-10 (option) Rear work light; 48V-40W (option) Brake light 48V-25W Back-up light — 48V- 100 FUSE CAPACITY al —Truck model Faroirs | Faaoves |Fe25-7v| FB90 Fr (ortaveinginveren) | 276A | 260 | Sasa | a76R F2fetya pure eHEOR | aasn | asa | 205n | 2008 [Pers cea) wa _| aoa_| aoa [208 4 (48: contol power svppiy_| 108108 | 10A_|~10A 5 (lamp cul) 404 | 10A | Yor | 10a 5 (bation charger up crea} 1908 | 1S0A_| 200k | “1308 £7(72-V contrl power suppyh [= |= | ~ | 10a * For replacement any fuse is needed, consult yourlocal TCM dealerSERVICE DATA APPLICABLE BATTERY (EXB Option) Model Battery maker para? | rais7 | razor | raos7 | reasne | roszv| eao7 | rasor | shi-kove Battery secre | GS | YUASA ‘capac (AWSH) acinery 390 ° ° ° ° 0 o [| o ° ° ° 0 ° ° ° ° 5 o | o ° ° ° 38 ° ° ° ° ow 0s o | o ° ° ° 00 o | o ° ° ° 700 o | o ° ° ° aes ° ° ° ° ° 8s ° ° ° ° ° 0 o | o ° - ° 0 eo | o - - ° ma as o | o - ° - sis o | o ° ° °DENVILE VAIA BATTERY CHARGING TIME (STANDARD) ‘Truck-mount battery charger (EXB Option) + 48-V battery Baliory capaciy | Standard charging Charger model (AHisH) timo (*) 330 85 MB0B, C, D 400 10 485 ns | 450 a5 55 10 M1158, C, D 565; jos _| 600 i 700) 725 i608, CD co ae 935 115 + 72-V battery Ballory capacty | Standard charging Charger mode! (aHiSH) time (H). 1058, 6, D 450 __{ _@__ 5 105 Input voltage range B model © modal D model (60 Hz, 195-215 V) (60 Hz, 370-410 V) (60 Hz, 420-460 V) (60 Hz, 190-210 V) (50 Hz, 360-400 V) (50 Hz, 410 - 450 V) Ne 5-7 the supply voltage of your charging facility is not within the input voltage range specified above, you need to change the taSERVICE DATA DIAGNOSTICS Display Details How to reset & Fashng {at 0.5-second intervals) Drive motor overheating Pump motor overheating += Switch the key from OFF to ON. * Lower the temperature, Controller overheating *# Switch the key from OFF to ON. (at 0.5-second intervals) a Flashing + Flashing at 0.5-second intervals Lower the temperature, + Flashing at 0.8-second intervals Flashing Pump motor brush worn (Change brush. m a Flashing Warning of low battery fluid level Fill in the battery fluid. ® Flashing Neutral safety Return the change lever to the neutral position. Flashing Tanane7e Battery voltage ow + Warning: flashing at 0.5-second intervals ‘Low: flashing at 0.8-second intervals, ‘= Switch the key from OFF to ON, and rastore the voltage. ‘Switch the key from OFF to ON. It the display as shown or any of the following numbers appear in the LCD, ask your local TCM dealer for ~ BBBSE.Be ho. 801, 302, 903, 304, 305, 306, 307, 908, 401, 402, 408, 404, 405, 406, 407, 408, 501, 502, 503, 504SENVILE VAIA REFILL CAPACITY Ambient] Gradest Brand of Lubricant Speci __Serscty te) __| perature | seo tem FBIOns stSanng | APGass [Mooi [shel | Esso ria than obi Dre | Shel Telus arertten | iso vase | NSPLBTE | Shel Tels | rorosooa2 + | yarauteot tank | 18 righ an | Mob | Shel Telue | ares” | isovase | Mahl, | SHANTEIE | nto Hae | cso -2s-s5rc | SAE 10W20 | WobiDetc | snot Rotate | F582 cor | Hedorte00 | "SX ON | port Bh. 00 Twobi | Shot oale | Eeeo 2 [Reduction goa | 5 25-076 | SAE OW | pyjaato10 | TROHIOW | Lube b-3 | ow tigherthan | Saco |. moot | shettRotala | Lybe'6.0 é Co” | oewac'i900 | “Txorso | ‘whe obi Super 3 - FMVSS | Heavy Duty | See Note2 | See Note 2 dors Brake Fluid higher than NLGT mee Albania sing point woh. ease: ila | Beacon 4 | Greasing points Miore”” | Notor2 | 3°88 | grease ta) | Beacon) Note 1) The temperature in this table Is the ambient temperature at the start ofthe engine. Note 2) For more Information about lubricants to be used, contact your local TCM dealer.AFTER-THE-SALE SERVICE TRUCK SERIAL NUMBER SERIAL NUMBERS OF MAJOR COMPONENTS ‘The truck serial number Is imprinted on the top of the front fender _In addition to the truck serial number, the serial numbers (unit on the left side ofthe truck, umbers) of major components are Imprinted on the truck or Do not damage it as it should be referred to In servicing Indicated on decals. The picture above shows the serial number plate of the mast. These number plates should be retained for future reference in servicingAPIEh-INe-DALc ocnvive TCM'S GENUINE PARTS However excellent the product is, it datoriorates as used for ‘extended period of time, To ensure the best performance of the lift truck, use the same genuine TOM parts as those used for new trucks. ‘When ordering spare parts, be sure to designate TCM's genuine parts GENUINE TCM LUBRICANTS Use genuine TCM's lubricants for lubrication,AFTER-THE-SALE SERVICE FOR YOUR RECORDS MODEL SERIAL NUMBER ____ WEIGHT ALLOWABLE WEIGHT ____ MAST TYPE MAST SERIAL NUMBER ENGINE SERIAL NUMBER KEY NUMBER ‘TRUCK CONTROL NUMBER NAME OF SUPERVISOR _ ATTACHMENT ____ DRIVER'S LICENSE NO. ISSUED ON DATE OF PURCHASE AUTHORIZED TCM DEALER. PHONE NUMBER OF AUTHORIZED TCM DEALERor) No, 08-81BAE ISSUED: SEPT, 2002 TCM CORPORATION INTERNATIONAL MARKETING DIVISION: 4-155, Nist-shimbash, Minato-ku, Tokyo 105-0008, Japan FAX: Japan 481-2.95018152, 835070"69 ‘Aigner 51209080 (5) Pred pan