ÇUKUROVA

FORKLIFT

MEK 15 ET

OPERATION AND MAINTENANCE

MANUAL
 ÇUKUROVA FORKLIFT
MEK 15 ET

OPERATION AND MAINTENANCE MANUAL

PART NO: 860A03R02

ÇUKUROVA MAKİNA İMALAT VE TİC.A.Ş.

ADANA YOLU ÜZERİ PK.61
33470 TARSUS/MERSİN
TEL: 00 90 324 6138640
FAX: 00 90 324 6242894

BASIM YILI / ISSUE DATE: 04/2010

FOREWORD

This manual was prepared by our plant in order to present our customers the necessary information
necessary assure the proper operation and the regular maintenance of the truck, operation of the
truck, safety rules, settings, locations of lubrication points, and lubricating oil used is included in this
issue.

This manual, as well as the spare parts manual, should be placed so as to provide easy access of the
truck operator in case needed.

Care should be taken to assure the regular and punctual performance of the maintenance. This
information will be helpful in understanding, which previous maintenance was done and which
maintenance should be done. For this reason, frequent comparison of truck working hours and
maintenance periods are recommended. Periodical maintenances have been explained stepwise
using pictures according to their time points. For the periodical maintenances, service hours or
calendar based (daily, weekly, monthly, etc.) periods were considered.

Service and maintenance time points were arranged according to normal working conditions. Under
extreme dusty or humid working conditions, the maintenances may be done more frequently than that
specified in the “Lubrication and Maintenance Table”.

Service members have the adequate technical training and technical service experience. In case more
information is required, you may apply Cukurova branch offices and ask service members for
consultancy.

Technical consultancy services is provided by Cukurova branch offices in case required for the proper
operation of the truck and selection of appropriate parts for the truck and supply of genuine spare
parts. In case there is a problem with the motor or the battery, one must apply the corresponding
services of the motor and the battery.

The information about the truck properties should be filled below. This information must be informed
during any service or spare part demand from Cukurova branch offices.

Truck model ..............................................

Serial number............................................
Engine model ............................................
Engine serial number ................................
Delivery date .............................................
Company name and address....................

ÇUKUROVA MAKİNA İMALAT VE TİC.A.Ş.

ADANA YOLU ÜZERİ PK.61
33470 TARSUS/MERSİN
TEL: 00 90 324 6162678
FAX: 00 90 324 6163220

1
INDEX

FOREWORD ..........................................................................................................................................................
...............................................
1
INDEX ....................................................................................................….....................................
...............................................
2
DECLARATION OF CONFORMITY ...............................................................................................................................
...............................................
4
INTENDED USE OF MEK15 ET ................................................................................................. ...............................................
5
WARANTY REGISTRATION FORM ....................................................................................................….......................
...............................................
6
TECHNICAL PROPERTIES ................................................................................................ 7
LIFTING CAPACITIES…………...................................................................................................8
DIMENSIONS ....................................................................................................….........................................
...............................................
9
MAIN COMPONENTS ....................................................................................................…..... ...............................................
10
POSITION OF THE MACHINE ....................................................................................................…. ...............................................
11
SAFETY INFORMATION ....................................................................................................…. 12
General safety information...............................................................................................................................................
...............................................
13
Fire and explosion prevention...................................................................................................................................
...............................................
13
Machine start up safety.............................................................................................................................................
...............................................
14
Machine start up and operating safety.............................................................................................................................
...............................................
14
Machine operating safety..............................................................................................................................................
...............................................
14
Machine parking safety..................................................................................................................................................
15
Machine transporting safety........................................................................................................................................
15
Machine towing safety......................................................................................................................................................
16
CLEANING THE MACHINE.................................................................................................. 16
MACHINE MAINTENANCE SAFETY...............................................................................................................................
...............................................
16
HYDRAULIC LINES and HOSES.................................................................................................................................
...............................................
18
IMPROPER USE......................................................................................................................... 19
SIGNS ON THE ELECTRICAL FORKLIFT................................................................................................ ...............................................
20
CONTROL AND INSTRUMENTATION ..........................................................................................................................
21
STARTER KEY........................................................................................................................................
...............................................
21
DIRECTION OF CONTROL AND HEADLIGHT LEVER..................................................................................................
...............................................
22
BATTERY CHARGE WARNING GAUGE .................................................................................................………………
...............................................
22
HOURMETER .................................................................................................................................
...............................................
22
ENGINE ACCELERATOR PEDAL....................................................................................................................
...............................................
22
BRAKE PEDAL ............................................................................................................................
...............................................
23
PARKING BRAKE LEVER......................................................................................................................................
...............................................
23
CONTROL LEVERS ......................................................................................................................
...............................................
23
OPERATION INFORMATIONS .............................................................................................................................
...............................................
24
BEFORE STARTING THE MOTOR ..........................................................................................................
...............................................
24
STARTING THE MOTOR .................................................................................................................................
...............................................
24
STOPPING THE MOTOR ........................................................................................................................................
...............................................
26
OPERATION MANUAL .................................................................. ................................................................................
...............................................
27
OPERATING TECHNIQUES ...........................................................................................................................
...............................................
27
ADJUSTING THE FORKS .........................................................................................................................
...............................................
30
CHARGING THE BATTERY .........................................................................................................................
...............................................
30
GENERAL SERVICE INFORMATION ............................................................................................................................
...............................................
31
GENERAL SERVICE INFORMATION ............................................................................................................................
...............................................
31
GENERAL TORQUE VALUES ...................................................................................................................................
...............................................
31
HYDRAULIC SYSTEM ....................................................................................................................................................
...............................................
36
HYDRAULIC CYLINDERS ...............................................................................................................................
...............................................
37
LIFTING CHAINS .............................................................................................................................................
...............................................
37
WEAR AND ELONGATION ....................................................................... ....................................................................
...............................................
37
RUSTING AND CORROSION ........................................................................................................................................
...............................................
38
LUBRICATION..................................................................................................................... ...............................................
38
REPLACING THE CHAINS .............................................................................................................................................
...............................................
38
COOLER FAN ..........................................................................................................................
...............................................
38

2
LUBRICATION AND MAINTENANCE INFORMATION .................................................................................................
...............................................
39
LUBRICATE AND MAINTENANCE INFORMATION ......................................................................................................
...............................................
39
LUBRICATE , MAINTENANCE CHART ........................................................................................................................
40
MAINTENANCE PROCEDURE................................................................................................................ 41
10 Working hours or daily maintenance .....................................................................................................................
...............................................
41
Charge of battery .........................................................................................................................
...............................................
41
Check tire pressures and wheels ....................................................................................................................................
...............................................
41
Checking drive motor .........................................................................................................................
...............................................
41
Check truck visually ................................................................................................................................................
...............................................
41
50 Working hours or weekly maintenance .................................................................................................................
...............................................
41
Check hydraulic system oil level .....................................................................................................................................
...............................................
41
Check battery fluid level ................................................................................................................................................
...............................................
42
Check and lubricate the chains .......................................................................................................................................
...............................................
42
Check transmission oil level ............................................................................................................................
...............................................
42
250 Working hours or monthly maintenance .............................................................................................................
...............................................
43
Check and lubricate the lifting system .............................................................................................................................
...............................................
43
Check and adjust the brake system ................................................................................................................................
...............................................
43
Check hydraulic system oil level .....................................................................................................................................
...............................................
44
Check rear driving system ................................................................................................................................
...............................................
44
Check the electric system ...............................................................................................................................................
...............................................
44
Change the transmission oil ....................................................................................................................
...............................................
45
500 Working hours or 3-months maintenance ...........................................................................................................
...............................................
45
Lubricate the tilt cylinders ................................................................................................................................................
...............................................
45
Replace the hydraulic filter ..............................................................................................................................................
...............................................
45
Check and adjust lifting system ......................................................................................................................................
45
1000 Working hours or 6-months maintenance .........................................................................................................
...............................................
46
Check the chains and rollers ..........................................................................................................................................
...............................................
46
Check and adjust lifting system ......................................................................................................................................
...............................................
46
2000 Working hours or annual maintenance ..............................................................................................................
...............................................
47
Replace the hydraulic circuit oil and strainer ...................................................................................................................
...............................................
47
Change the transmission oil ....................................................................................................................
...............................................
47
ACCUMULATOR SPECIFICATIONS................................................................................................................................
48
CHARGING THE ACCUMULATOR ............................................................................................................................
48
NORMAL OPERATING ............................................................................................................................
48
CHARGING AGAIN ............................................................................................................................49
MAINTENANCE OF ACCUMULATOR ...........................................................................................................................
49
IMPROPER USE OF ACCUMULATOR.........................................................................................................................
50
TRANSPORTING THE ACCUMULATOR ......................................................................................................................
50
STORING AND USING OF DRY CHARGE BATTERIES..................................... 50
CHANGING THE BATTERY...................................................................................................... 51
PREPARING THE TRUCK FOR LONG TERM STORAGE......................................................................................................................................
52
PREPARING TO OPERATE THE TRUCK AFTER LONG TERM STORAGE............................................................... ...............................................
52
GENERAL FAILURES............................................ ........................................................... 53
FAULT FINDING CHART............................................ ........................................................... 60
MAINTENANCE CHART............................................ ........................................................... 62

3
4
INTENDED USE OF MEK15 ET

This machine is a three wheel electric forklift with 1500 kg load capacity. This truck includes a main
electrical motor which feeds traveling system and steering system and a hydraulic pump feeding
hydraulic circuit. It is only used to load, transport and to stow.

Special features of MEK15 ET, ergonomically designed operators compartment. Hydraulic controls
are within easy reach of the drivers. multicolor LED display shows the state of charge.

High visibility mast system, hydrostatic steering system, rear steer wheels turns 90 degrees either
direction. Three spool hydraulic valve. Low noise double gear pump. Microprocessor control for
hydraulic system.

Three independent brake systems; electronic braking by reversing the direction lever. Self-adjusting
hydraulic service brake acting on three wheel. Mechanical parking brake acts on the rear wheel.
Strong series wound drive motors(5 kW) integrated with transmission on rear wheel.
MEKET traction and pump controller combines the latest state of the mosfet and microprocessor
technologies. Pneumatic tyres(front2, rear 1)

Modem programmable microprocessor control system for drive and hydraulic system.

We recommend that you fill in the following table as soon as you receive your forklift truck. This will
also be helpful when you order parts.

Model:

Serial number:

Manufacturing Date:

Delivery Date: ../../..

We reserve the right to make any technical changes compared to data

and illustrations given in this manual.

Warranty and liability are subject to ÇUKUROVA’s general business

terms and conditions aren’t changed in any way by instructions in this
manual.

Instructions and photos or drawings in this manual may not be

reproduced, used for any reason and/ or distributed without written
permission from the publisher. All rights reserved.

Manufacturer:

CUKUROVA MAKINA IMALAT VE TIC.A.S.

Adana Yolu PK.61 Tarsus 33470 Mersin-TÜRKİYE

5
At the delivery, the following document is completed by the our company and it is signed
by the costumer to take delivery of the machine :

6
 TECHNICAL PROPERTIES

CUKUROVA MEK15ET FORKLIFT

MODEL - MEK15ET
LOAD CAPACITY kg 1000 Q
LOAD CENTER mm 500 C
POWER TYPE - BATTERY
OPERATOR POSITION - SEATED
TYRES - P
WHEELS FRONT/REAR (X=DRIVEN) - 2/1X
MAXIMUM FORK HEİGHT mm 3300 h3
FORKS mm 80X40X1100 bxsxl
TILT OF MASS (FRONT/ REAR) Degrees 4/6
LENGTH TO FORK FACE mm 1936 L2
OVERALL WIDTH mm 1040 B
HEIGHT (LOWERED MAST) mm 2180 h1
HEIGHT (EXTENDED MAST) mm 3830 h4
HEIGHT (OVERHEAD GUARD) mm 2000 h6
TURNING RADIUS mm 1579 Wa
LOAD DISTANCE mm 357 X
90 STACKING AISLE mm 3236 ASt
STABILITY DIN/ISO YES
TRAVEL: WITH / WITHOUT LOAD km/h 10
LIFT: WITH / WITHOUT LOAD m/s 0.25/0.40
LOWERING: WITH / WITHOUT LOAD m/s 0.40
DRAWBAR PULL MAX N 5210
DRAWBAR PULL NOM N 2860
GRADEABILITY 5 MIN % 10.4/16.7
GRADEABILITY 30 MIN % 8/12.8
UNLADEN WEIGHT kg 2800
UNLADEN FRONT AXLE kg 1200
UNLADEN REAR AXLE kg 1600
LADEN FRONT AXLE kg 3710
LADEN REAR AXLE kg 590
FRONT TYRES 2 - 18X7-8
REAR TYRE (SINGLE) - 18X7-8
WHEEL BASE mm 1275 Y
TREAD WIDTH FRONT mm 885 t1
UNDER CLEARANCE MAST mm 75 m1
UNDER CLEARANCE COW mm 103 m2
SERVICE BRAKE - HYDRAULIC
PARKING BRAKE (HAND) - MECHANIC
BATTERY VOLT-CAPACITY V/ah 12/105 no need maintenance
MOTOR POWER/ VOLT S2 60 MIN kW/V 5/48
PUMP MOTOR POWER/ VOLT kW/V 5/48
BATTERY VOLTAGE - CAPACITY v/Ah 48/400
BATTERY WEIGHT kg 760
BATTERY COMPARTMENT mm 535X875X750h
BATTERY circuit A YES

NOTE:
h2: Free lift
h5: Full free lift

7
LIFTING CAPACITIES

The following diagram shows the lifting capacities of the models MEK15ET , at different load
centers.The exact capacities given at the tables left are based on calculations for structural strenght of
the lifting system and minimum axle weight required on the steering axle.These figures are for
standart machines.For more information please, contact the nearest Çukurova Regional Director ship
or officies.
Capacity(Kg)

Load Center (MM)

8
DIMENSIONS

MEK15ET

9
 MAIN COMPONENTS

5 6

3 7

1. TRANSMISSION
2. WEIGHT
3. OPERATOR’S SEAT
4. BATTERY
5. OVERHEAD GUARD
6. CHAIN
7. MAST
8. FORKS

10
FORKLIFT-TRUCK POSITIONS

Left-right, front- back and top-bottom terms are arranged according to the sitting position of the operator
on the seat.

1. FRONT
2. REAR
3. RIGHT
4. LEFT

11
SAFETY INFORMATION
The information given in this manual provides safe operation and maintenance of the machine and should
be fully understood in order to prevent serious injury or death while working with the machine. Don’t forget
that your safety and the people around you depends on you. Therefore to develope your skill for the
correct operation, inspection, lubrication and maintenance:

• You should read this manual carefully and familiarize yourself with the position of controls and of the
operations that their movement causes.
• You should understand the warnings and operating procedures used in this manual and on the
machine.
• You should understand the capabilities and limitations of the machine.

In this manual safety signs are classified according to the relative seriousness of the hazard situation by
the use of the signal word. Two signal words are used: DANGER and WARNING. The signal word alerts
you to the existence and relative seriousness of a hazard and it is essential that you understand these
signal words fully.

DANGER: used for the situations presenting the most serious hazards and if not avoided, will
result in death or serious injury.

WARNING: used for the situations presenting a lesser degree of risk of injury or death than those
identified by the signal word DANGER and if not avoided could result in death or serious injury.

In addition to these instructions you must follow the safety regulations applicable to your work
environment and job site and any federal, state and local safety requirements.

Keep this manual in good condition and store it in a compartment where you can easily reach.

12
GENERAL SAFETY INFORMATION
• Study the Operation and Maintenance Manual
before operating or working on the forklift
truck, make sure that you have additional
information for special attachements of your
machine, read it and understand it!
• Allow only authorized personnel informed
about the safety rules to operate, service or
repair the forklift truck, make sure to observe
any minimum applicable age requirement.
• Allow only properly trained personnel to
operate or work on the forklift truck, make
sure to clearly specify the person who is
responsible for set up, maintenance and
repairs.
• Make sure the operator knows his
responsibility regarding the observance of
traffic regulations and permit him to refuse any
unsafe instructions given by a third person.
• Any person still in training should only operate
or work on the machine under the supervision
and guidance of an experienced person.
• Check and observe any person working or
operating the forklift truck periodically and
regularly, if they observe safety instructions
and guidelines given in the Operation and
Maintenance Manual.
• Wear proper work clothing when operating or
working on the forklift truck. Ring, watches,
bracelets and loose clothings such as ties,
scarves, unbuttoned or unzipped shirts and
jackets are dangerous and could cause injury!
Wear proper safety equipment, such as safety
glasses, safety shoes, hard hats, work gloves,
reflector vests and ear protection.
• Consult your employer or supervisor for
specific safety equipment requirements and
safety regulations on the job site.
• Do not carry tools, replacements parts or
other supplies while climbing on or off the
forklift truck. Never use the steering column,
control levers or control levers as handholds.
• If no other guidelines are given, perform
maintenance and repairs utilizing the following
precautions:
− Park forklift truck on firm and level ground.
Rest the forks on the ground.
− Place all control in neutral position and
engage park brake.
− Turn the motor off and remove the ignition
key.
• Secure all loose parts on the forklift truck.
• Never operate the forklift truck without a
complete walk around inspection. Check if all
warning decals are on the machine and if they
are legible.
• Observe all danger and safety guidelines.
• For certain applications, the forklift truck must
be equipped with specific safety equipment.
Use the forklift truck only, if they are installed
and functioning properly.
• Never perform any changes, additions or
modifications on the machine, which could
influence the safety, without obtaining the
written permission from the manufacturer.
This also applies to the installation and
adjustment of safety devices and safety
valves as well as to any welding on load
carrying parts.
• Do not install any equipment or attachments
made by other manufacturers or any which
are not specifically authorized by CUKUROVA
for installation without first obtaining the
written permission from CUKUROVA.
CUKUROVA will issue any required technical
documentation for approved installations.
• Should the electrical circuit be modified or
additional components be installed, so the
modification must be performed according to
the national standards and safety regulations.
The installation must be certificated by an
approved organization and a copy of the
certification has to be sent to the CUKUROVA
company.
FIRE AND EXPLOSION PREVENTION
• Always start the motor as described in the
Operation and Maintenance Manual.
• Never use damaged or insufficent wire ropes,
slings or chains. Always wear gloves when
handling wire ropes.
• Never reach into bores during attachment
installation or removal. Never align bores with
fingers or hands. Use proper alignment tools
when installing, changing or servicing
attachments.
• Always wear safety glasses and protective
gloves when handling batteries. Keep sparks
or open flames away!
• Never smoke or allow an open flame in where
batteries are being charged, or where
batteries or flammable materials are stored.
• Check the electrical system regularly and
frequently. All defects, such as loose
connections, burnt out fuses and bulbs, burnt
or damaged cables must be repaired
immediately by an electrician or especially
trained personnel.
• Never store flammable fluids on the machine.
13
• Inspect all component, lines, tubes and hoses
for oil leaks and / or damage. Replace or
repair any damaged components immediately.
Any oil, which escapes from leaks, can easily
cause fire.
• Be certain that all clamps , guards and heat
shields are installed. These components
prevent vibration, rubbing, chafing and heat
build-up. Install tie wraps to fasten hoses and
wires, as required.
• In order to prevent a fire,always disconnect
the battery cable before working on the
electrical system or before any arc welding on
the machine.Always disconnect the negative
(-) cable first and reconnect it last.
• While charging ,explosive gas
occurs.Therefore,don’t approach to the
machine with a cigar, fire and don’t weld near
the machine .
• Know the location of the forklift truck’s fire
extinguisher and be familiar with its operation.
Make sure you know your local fire regulations
and fire reporting procedures.
MACHINE START UP SAFETY
• Before starting up forklift truck, perform a
thorough walk around inspection.
• Visually inspect the forklift truck, look for loose
bolts, cracks, wear, any leaks and any
evidence of vandalism.
• Never start or operate an unsafe forklift truck.
• Make sure all covers and doors are closed
and locked and all warning decals are on the
machine.
• Make sure all windows( if there is), as well as
all mirrors are clean, and secure all doors and
windows to prevent any unintentional
movement in cab application.
• Be certain that the area surrounding the forklift
truck is free of other personnel, and that no
one is working on or under the forklift truck
before starting the motor.
• After entering the forklift truck, adjust the
operator’s seat and controls, Be certain that
all controls can be reached comfortably.
MACHINE START UP AND OPERATING
SAFETY
• Before start up, check if all indicator lights and
instruments are functioning properly, place all
controls in neutral position.
• Before starting the motor, alert any nearby
personnel that the forklift truck being started
by sounding the horn.
• Start machine only when seated in the
operator’s seat, and with the seat belt
fastened.
• If you have no other instructions, start the
motor as outlined in the Operation and
Maintenance Manual.
• Check all indicators, gauges, warning devices
and controls for their proper indication.
• Check that all attachment functions are
operating properly.
MACHINE OPERATING SAFETY
• Familiarize yourself with jobsite rules. Be
informed about traffic and hand signals and
safety signs. Ask who is responsible for
signaling.
• Check your surrounding for any obstacles in
the working and movement range, check the
load carrying capacity of the terrain, and
secure the job site to shield it from any public
higway traffic.
• Always keep a safe distance from overhangs,
walls, drop offs, and unstable ground.
• Be alert of changing weather conditions, bad
or insufficient visibility and of changing ground
conditions.
• Keep sufficient distance to electrical lines.
When working in the vicinity of high voltage
electrical lines, keep proper distance to assure
that the attachment does not come close to
the lines.
DANGER! You must inform yourself about
safe distances.
If the voltage is less than 57.000v,your
distance from electric cables musn’t be less
than 3.5 meter.
If the voltage is more than 57.000v, your
distance from electric cables musn’t be less
than 5.5 meter.
• In case you do touch a high voltage line by
accident, proceed as follows:
− Do not leave the machine,
− Move the machine, if possible, from the
danger zone until you obtain sufficient
distance,
− Warn any personnel in the vicinity not to
come close to the forklift truck and not to
touch it,
− Instruct or initiate that someone turns off
the voltage,
− Do not leave the machine until you are
absolutely sure that voltage in the line,
which had been touched or damaged, has
been turned off!
14
• When travelling on public roads or highways,
make sure to observe traffic regulations, and
make sure that the machine meets federal
and local public highway standards.
• Always turn on the lights if visibility is bad or if
you are still working during dusk.
• Never allow other personnel on the forklift
truck.
• Operate the forklift truck only while seated and
with the seat belt fastened.
• Report any problems or needed repairs to
your foreman or supervisor and make sure
they are corrected immediately.
• Do not move the forklift truck until you are
certain that no one is endangered by moving
the forklift truck.
• Check the brake system before starting to
work, as outlined in the Operation and
Maintenance Manual.
• Never leave the machine unattended (within
view of machine), with the motor running.
• Prevent any working movements, which could
tip the machine over. If the forklift truck begins
to tip or slip on a grade, immediately lower the
attachments. If possible, always operate the
forklift truck with the attachment positioned
uphill.
• Always travel slowly on rough or slippery
ground and on slopes, and on loose soils.
• Always travel downhill at permissible speed,
so you don't loose control over the machine.
The motor must run at nominal speed, use
only the foot pedals to brake and slow down
the machine.
• If operating in visually obstructed terrain or
whenever necessary, have another person
guide you. Always have only one person
signal you.
• Allow only experienced persons to attach
loads or to guide operators. The guide must
be visible by the operator and / or must be in
voice contact with him.
• Auxiliary control units can have various
functions. Always check their functions when
starting up the machine.
• Inspect the machine for damage if the
attachment has been swung into a wall or
any other obstacles.
• Before leave the forklift truck, lower the forks
to the ground,remove the main battery socket
and engage the parking brake.
MACHINE PARKING SAFETY
• Park the forklift truck only on firm and level
ground.
If it becomes necessary to park the machine
on a grade, properly block and secure it with
wedges.
• Lower the attachments to the ground.
• Bring all operating levers in neutral position
and engage the parking brake.
• Turn the motor off as outlined in the
Operation and Maintenance Manual before
you leave the operator's seat.
• Lock the machine, remove all keys and
secure the forklift truck against vandalism,
unauthorized use, and any attractive
nuisance.
MACHINE TRANSPORTING SAFETY
Loading procedure
• Use only suitable transporting and lifting
devices with sufficient capacity.
• If necessary, remove part of the attachments
during transport.
• Park the truck transporting the forklift truck at
the front of the loading ramp.
• Remove all mud, snow or ice from forklift truck
components before moving up the ramp.
• Align the machine with the loading ramp.
• Have another person guide and signal the
operator.
• Lift the forks about 20-25 cm above the
ground.
• Run the forklift to the truck slowly.
• Park the forklift on the truck,lower the forks,
engage the parking brake and remove the
main battery socket.
• Have blocks or wedges ready to block the
machine, if necessary, to prevent the machine
from rolling backwards. Be careful to crushing
risks when handling and applying these
wedges. Keep clear of wheels and do not
attempt to block the machine before its
complete standstill.
NOTE: At rainy weather or slippery ground,place
the wedges to the sides of the forklift’s tyres, too.
15
Unloading procedure
• During the unloading procedure, proceed with
the same care and caution as during the
loading procedure. Remove all chains and
wedges. Start the motor as outlined in the
Operation and Maintenance
Manual.Disengage the parking brake,lift the
forks about 20-25 cm above the ground.
Carefully drive off the loading platform. Have
another person guide and signal you.
NOTE NOTE: If there is no a special loading
ramp, load or un load the forklift by a sufficient
crane.While transporting the forklift by the crane,
tie the lifting ropes to the lifting points (one of
lifting point is on the counterweight, other two
points are at the sides of the mast.)
MACHINE TOWING SAFETY
• Observe the correct procedure: check the
index in your Operation and Maintenance
manual and refer to the appropriate section :
"Towing the Forklift truck".
• Only tow the forklift truck if absolutely
necessary, for example to remove it for
repairs from a dangerous job site.
• Be sure all towing and pulling devices such as
cables, hooks, and couplers are safe and
adequate.
• Make sure that the cable or the towing rod are
strong enough. Be aware that any damage to
the machine caused by towing is never
covered by the manufacturer's warranty.
• Strength of the chain or rope which tows the
forklift must be able to pull the 1,5 times of the
machine’s weight which will be towed.
• Never allow anyone to stand near the cable
when pulling or towing the forklift truck.Keep
the cable tight and free of kinks.
• Engage travel slowly, and do not jerk. With a
slack cable, the sudden impact of the load
being towed couId snap and break.
• Keep personnel out of area. If cable breaks
while under stress, it could cause severe
injury.
• During the towing procedure, keep within the
required transport position, permissible,
speed and distance.
• After the towing procedure is completed,
return the machine to its previous state.
• Proceed as outlined in the Operation and
Maintenance Manual when putting the forklift
truck back in service.
• Don’t tow the machine more than 30˚
horizontally throughout the travelling way.
• The puller weight and capacity of the puller
brake system must be enough to brake both
the puller and the forklift.
• During towing the machine,remove the main
battery socket, disengage the parking brake
and turn the ignition key to the “off” position.
• The speed of vehicle towing the loader
should be 2 km/h and towing distance should
be as short as it can be.
CLEANING THE MACHINE
Never wash the machine!Clean the machine by air
and after air ,wipe the machine with a dry cloth.
MACHINE MAINTENANCE SAFETY
• The machine may not be made unsafe when
performing maintenance work. Never attempt
maintenance procedures or repairs you do
not understand.
• Check the Operator's and Maintenance
Manual for service and maintenance
intervals. Make sure you use only appropriate
tools for all maintenance work.
• Refer to your Operator's and Maintenance
Manual to see, who is authorized to perform
certain repairs. The operator should only
perform the daily / weekly maintenance
procedures.
The remaining work may only be performed
by especially trained personnel.
• Use only replacement parts corresponding to
the technical requirements specified by the
manufacturer. This is assured by using only
original CUKUROVA replacement parts.
• Always wear proper work clothing when
maintaining the forklift truck. Certain work may
only be performed with a hard hat, safety
shoes, safety glasses and gloves.
• During maintenance, do not allow unautho-
rized personnel to enter the maintenance
area.
• Secure the maintenance area, as necessary.
• Inform the operator before any special or
maintenance work. Make sure he knows the
person, who is in charge of the work.
• If not otherwise noted in the Operation and
Maintenance Manual, always make sure the
forklift truck is parked on firm an level ground
and the motor is turned off and parking brake
is engaged.
16
• During maintenance and service work, make
sure you always retighten any loosened screw
connections!
• If it is necessary to disconnect or remove any
safety devices during set up, maintenance or
repair, make sure that after completion of
repairs, the safety devices are reinstalled and
checked for proper function.
• Before any maintenance work make sure a
"Do not operate' tag is attached to the starter
switch. Remove the ignition key.
After end of maintenance works or repair,
restart the machine according to the
instructions "Machine start up", in this
manual.
• Before any repairs or maintenance work,
clean any oil or cleaning substances from any
fittings and connections. Don't use any harsh
cleaners and use only lint free cloths.
• Any welding, torch or grinding work on the
machine must be explicitly authorized.
Written authorization is necessary for welding
on carrying structures. Before any using a
welder, torch or grinder, clean off any dust
and dirt and remove any flammable materials
from the surrounding area. Make sure the
area is sufficiently ventilated. Danger of Fire
and Explosion!
• If you use a high pressure cleaner with steam
to clean the machine, observe following
recommendations:
− the distance between the nozzle and the
surface to be cleaned must be no lower
than 20 (50 cm) inches
• Never employ high pressure cleaning
apparatus during the two first months
following machine delivery or repainting.
• Observe all product safety guidelines when
handling oils, grease, and other chemical
substances.
• Make sure service fluids and replacement
parts are disposed of properly and in an
environmentally sound manner.
• When using hot service fluids, be very
careful. (They can cause severe burns and
injury!).
• Never work underneath the machine if it is
raised or propped up with the attachment.
• Only qualified, especially trained personnel
may work on travel gear, brake and steering
systems.
• Only qualified, especially trained personnel
may work on the hydraulic system.
• Never check for leaks with your bare hands,
always wear gloves. Fluid escaping from a
small hole can have enough force to
penetrate the skin.
• Always disconnect the battery cable before
working on the electrical system or before any
arc welding on the machine. Always
disconnect the negative (-) cable first and
reconnect it last.
• Check the electrical system regularly.
Make sure that any problems, such as loose
connections, burnt out fuses and bulbs,
scorched or chafed cables are fixed
immediately by an electrician or qualified
personnel.
• Use only Original fuses with the specified
amperage. Never use a different size or
stronger fuse than the original fuse.
• On machines with electrical medium or high
voltage systems:
− If there is any problem with the electrical
energy supply, turn the machine off
immediately.
− Follow established lockout / tagout
procedures where applicable.
− Any work on the electrical system may
only be performed by a qualified
electrician or qualified personnel under
the guidance and supervision of an
electrician, according to electro-technical
regulations.
• If any work is required on any parts which
carry current, use a second person to turn off
the main battery switch, if necessary. Rope
the work area off with a safety rope or chain,
and set up warning signs. Use only insulated
tools.
• When working on medium and high voltage
components, shut off the voltage and connect
the supply cable to the ground and ground the
components.
• Check all disconnected parts if they are truly
free of current, ground them and close them
off quickly. Insulate any close-by, current
carrying parts.
17
HYDRAULIC LINES AND HOSES • Route or install the hoses and lines properly.
Do not mix up the connections!
• Hydraulic lines and hoses may never be
repaired! • Always take care to avoid torsionaI strain
• All hoses, lines and fittings must be checked when installing a new hose. On high pressure
daily, but at least every 2 weeks for leaks and hydraulic hoses, the mounting screws must
any externally visible damage! Any damaged be first mounted on both hose ends (full
sections must be replaced immediately! flange or half clamp) and tightened only
Escaping oil can cause injuries and fires! thereafter.
On high pressure hoses having one curved
• Even if hoses and lines are stored and used
end, always tighten first the screws on the
properly, they undergo a natural aging
curved hose end and only then the screws on
process. For that reason, their service life is
the straight hose end.
limited. Improper storage, mechanical
damage and improper use are the most Install and tighten the hose clips that may be
frequent causes of hose failures. mounted on the hose middle only when the
both hose ends are already tightened.
The service life of a hose may not exceed six
years, including a storage period of not more • Always install hoses so to avoid any friction
than two years (always check the with other hoses and parts.
manufacturer's date on the hoses). We recommend to keep a distance between
Using hoses and lines close to the limit ranges hose and other parts of at least one half of
of permitted use can shorten the service life the hose outer diameter. Keep a minimum
(for example at high temperatures, frequent gap of 1/2 inch (1.2 cm) in any case.
working cycles, extremely high impulse
frequencies, multi shift or around the clock After mounting a hose connecting two parts
operations). that are movable to each other, check during
the return to service that the hose is not
• Hoses and lines must be replaced if any of rubbing in the whole moving range.
the following points are found during an
inspection:
− Damage on the external layer into the
inner layer (such as chaffings, cuts and
rips);
− Brittleness of the outer layer (crack
formation of the hose material);
− Changes in shape, which differ from the
natural shape of the hose or line, when
under pressure or when not under
pressure, or in bends or curves, such as
separation of layers, blister or bubble
formation;
− Leaks;
− Non observance of installation
requirements;
− Damage or deformation of hose fittings,
which might reduce the strength of the
fitting or the connection between hose
and fitting;
− Any movement of hose away from the
fitting;
− Corrosion on fittings, which might reduce
the function or the strength of the fitting;
− Storage or service life has been
exceeded.
When replacing hoses or lines, always use
Original replacement parts.

18
IMPROPER USE

• During travelling, the forks should be kept in the lowest position with the safe height from the floor
with or without load
• The fork spread should be as wide as the load permits to make sure that the load is carried
safely. Make sure that the load is balanced by both forks.
• Don’t connect the rectifier socket to the socket on the frame!
• Make sure that the added oil to the hydraulic system is compatible with the oil in the tank. If the
oil has lost its bright color and become smoky, this implies air leach into the circuit; in this case a
pump failure may occur. The circuit should be drained, cleaned and refilled immediately. The
connections in the intake line should be checked.
• Battery level should be checked when the motor is stopped.Never approach with flame while
checking battery electrolyte level.
• Lubricate the chains more frequently under conditions that may lead to excessive corrosion or
where lifting operation is very frequent.
• Before any control or maintenance, take the battery connection socket out.
• Before connecting battery, make sure that the starter key is off and the parking brake is
engaged.

• The oil and filter are changed by authorized personnel at CUKUROVA services. If this operation
will be carried by your personnel, the nearest CUKUROVA service should be contacted and
asked for assistance.
• On a day, one charge and one discharge period is suitable.If you do them more than one period,
the accumulator life shortens.charge the accumulator without noticing discharge level during
operation.
• Automatic float system or adding distilled water by hand should be done at the end of the
charging. Never add electrolyte before referring MUTLU.
• While adding electrolyte,remove the band and nylon on the plugs.
• It is important that the first charge should be continuous.
• All cells include oxi-hydrogen gas.Don’t use flammable material near the battery.
• Make sure that the capacity of lifting device or crane should be more than the battery weight.The
battery weight is shown on the battery box.The lifting device shouldn’t be metal or it should be
insulated by band.The batteries are heavy, because of this, be careful to protect them any
damage.
• Always replace the filter with a genuine one. The genuine filter can be supplied from any
CUKUROVA service. In case any filter other than genuine filter is mounted, the hydraulic system
will go out of warranty coverage.

19
SAFETY SIGNS AND LABELS

There are safety labels on the truck. In this section, potential hazards that may happen in case these
warnings are ignored are mentioned. Time should be spent on noticing, understanding and learning these
signs. All safety signs should be easily readable. Signs that are hard to read or with illegible pictures
should be cleaned, or replaced if necessary. A piece of cloth, water and soap should be used while
cleaning the labels; use of solvent or gasoline should be avoided. Lost, illegible, or damaged labels
should be replaced. Apply CUKUROVA services for supply of new labels.

WARNING: The truck should not be operated before the instructions in the “Operation and
Maintenance” are read thoroughly and understood. Improper operation of the truck is dangerous
and may cause injuries or even death. The proper operation of the truck is entirely operator’s
responsibility.
WARNING: The improper lubrication and maintenance of the truck can be dangerous. The
personnel assigned with this task should have the sufficient ability, knowledge and suitable tools
and equipment. Make sure the method applied is correct and safe.

Keep away from attachment Do not touch attachment

Part no: 356E11

Lubrication and maintenance chart

Part no: 356E22

Lifting points

Part no: 856A45

Part no: C56C34

20
Hydraulic oil properties Use SAE J1703 hydraulic oil.

Part no: 156E15 Part no: 356E31

Don’t travel before disengage the brake. CONTROLS AND INSTRUMENT

Starter key

II

Part no: 756A07

Only trained personnel may operate this

It has two position“I ve II”:
machine .

Position "Ι": on
Position "ΙΙ": off

Part no: 756A06

21
 Direction control and headlight lever Hourmeter

1
4
3

5 N

This lever is located the left side of steering This displays the working hours of the
wheel.When the lever is pushed forward (1),the truck.Changing every number shows 6 minutes.
forklift moves forward direction.When the lever is When the starter key is turned “I”
pulled back,the forklift moves reverse direction position,hourmeter’s lamp lights up.
and at that time hazard warning sounds.when the
end part of the lever is turned once forwards (3),
front headlights light up; when it is turned twice,
the rear headlights light up.Pressing the switch on Accelerator pedal
the lever sounds horn.

Battery charge warning gauge

Pushing pedal down increases machine speed.

This gauge shows the battery charge.At the gauge

towards the right, the battery charge decreases.

22
Brake pedal
Pushing down pedal decreases machine speed.It
is located the left side of steering column.It is drive
by hydraulic system, it impresses all tyres.
Parking brake lever
It is operated mechanically independent from the
brake pedal.
Control levers
2 1
There are two control levers for standard use, two
for optional use. Pulling back the one on the right
(outer-1) elevates the mast while pushing it
forward lowers it. Pulling back left (inner-2) tilts the
fork back while pushing it forward tilts the fork
forward.
23
OPERATING INFORMATION
BEFORE STARTING THE MOTOR WARNING: When your machine is
loaded, you should climb down reverse
• The truck should be checked visually before direction and straight ahead from inclined
operation. area.
• All the lights and gauges should be checked
for operation.
• Before starting the truck make sure that there Starting The Motor
is no one working on or around the truck.
• Make sure that no one will be harmed before 1- Fasten battery main socket.At that time,
moving. machine functions can be used but the machine
• The motor should be operated in a ventilated don’t move. In order to move the machine,
environment. operator should seat completely, so seating switch
• The obstacles on the way of the truck should under the seat completes the circuit.
be removed.
• Be careful about hazards like wires, ditches,
etc.
• All control systems should be checked while
operating slowly in an open area.
• The truck should be operated only in seated
position. If you don’t seat completely, the
seating switch under the seat can’t complete
the electrical circuit and the machine can’t
move.
• The maximum lifting height of the truck should
be known.
• The forks should be as high as 20 cm from the
ground.
• A safe distance should be kept between the
truck and the ditches and canals.
• The truck should be kept under continuous 2- Adjust the seat.
control and should not be overrun.
• Hydraulic oil level should be checked and
completed if necessary.
• Air filter oil level should be checked and
completed if necessary.
• Battery fluid level should be checked and
completed if necessary.
• Battery charge warning gauge should be
checked continuous.
• The seat should be adjusted so that the
operator can fully press the brake in leaned-
back position.
Note: The machine’s max speed is 10km/h.

WARNING: All forklifts should be use by

only person who has forklift driving
licence.
NOTE:
1. This electrical forklift can be used the area
where temperature is from -30C° to +40 C°
and you shouldn’t use these machines at
rainy, snowy and moist area.
2. Angle of climbing is 4.6 - 7.3° for 30 minutes,
Max. angle of climbing is 6° for 5 minutes.
3. These machines can be used open area,
closed area and allowed inclined area.
4. On windy weathers, drive the truck to the
same direction with blow direction.

24
3- Turn the direction control lever to neutral 7- Select direction using the direction control
position. (forward-reverse) lever, press the accelerator
pedal down and start moving.

4- Release the parking brake.

5- Turn the starter key “ on” position.

8- Press the accelerator pedal down until you get

wanted speed.

6- Raise the forks about 20 cm from the ground

before moving.
9- To slow down, stop pressing down the
accelerator pedal and press down brake pedal.

10- When you press down brake pedal

completely, the machine stops.

25
Stopping the motor

1- Engage the parking brake.

2- Lower the forks.

3- Bring the starter to “off” position.

In order to stop the motor, the control levers

should be brought to neutral position, the
accelerator pedal should be brought to the
minimum position, and the starter should be
brought to “0” position.

WARNING: All forklifts should be use by

only person who has forklift driving
licence.

26
OPERATION MANUAL

Check the truck for anyone working around or on top of the truck making sure that there is no one in close
vicinity. Speed should be reduced during maneuvers. Do not let the truck accelerate downhill. The truck
should not be left while the engine is running. All attachments should be lowered when leaving the truck.

OPERATING TECHNIQUES
Inching to the load

1. Approach to the load directly from the 6. Lower the load slowly to where it was taken
opposite with the mast in perpendicular position from.
and stop in front of the load. Make sure that
there is appropriate distance between the forks.
It is very important for the balance that the forks
are as aside as the load permits.

7. Inch forward and take the whole load onto

the forks in balance. .

2. Press gently on the brake pedal, till the load

touches the table while moving the lift truck by
pressing the accelerator at the same time.

3. Lift the load to appropriate height

considering the height of the load from the floor.

8. Relift the load as high as 5-10 cm.

4. Move forward so as that 2/3 of the forks

cover 3/4 of the load and lift as high as 5-10 cm.

9. Move the truck backwards for enough

distance to lower the load.

5. Move back for 15-20 cm with the load.

27
10. Lower the load to 15-20 cm high from the
floor.
11. Fully tilt back the mast
12. Now the truck can take the load to its
destination.
Travel
NOTE: During travelling, the forks should be
kept in the lowest position with the safe height
from the floor with or without load
1. The load should be carried as close to the
floor as possible. However it must be of a safe
height from the floor.
2. When loaded, the mast should be tilted
backwards while travelling.
3. While carrying bulky loads, travelling in
reverse direction is necessary to have a clear
sight.
Travelling downhill
On steep and short distance inclinations,
travelling in reverse direction is necessary for
easiness and preventing the load to slip.
Turns
1. When having sharp turns, the inner side of
the turn should be taken. The turn should start
as soon as the drive wheel reaches the corner
2. While turning in a narrow corridor, the area
the back load will sweep during the maneuver
should be considered
3. Lower your speed at turnings.
Unloading
1. Stop slowly when the unloading point is
reached.
28
2. Tilt the mast forward and position 7. Relift the load as high as 5-10 cm.
perpendicularly.

8. Position the load exactly over the unloading

3. Stop in front of the unloading point and lift as point.
much as 5-10 cm over it.

4. Inch forward so as to reach over the exact

point of stocking.
9. Lower the load to the unloading point.

5. Put the load down intermediately right on the

unloading point.

10. Leave the load and move back the truck

slowly.

6. Move back, so as 1/4 of the fork will unload

1/3 of the load.
11. Bring the mast to the travel position and turn
the truck and go.

29
Lifting round objects
1. Block the round object to constrain its
movement. Tilt the forks to the very front and get
them under the object.
2. Before lifting off, tilt the forks back stabilizing
the load on the table.
3. For a safe travel, the load should be lifted as
high as required.
Loading and unloading with attachment
While using attachments, instructions of the
manufacturer and corresponding manuals
should be taken into consideration. Contact the
relevant service, if necessary.
ADJUSTING THE FORKS
NOTE: The fork spread should be as wide as
the load permits to make sure that the load is
carried safely. Make sure that the load is
balanced by both forks.
1. Remove the fork stopper knob and slide the
fork to the appropriate position
2. Insert the fork stopper knob making sure
that it fits in the slot. Repeat the same operation
for the other fork.
CHARGING THE BATTERY
The rectifier is delivered with the machine.
Connect the rectifier socket (1) to battery
socket.Connect The rectifier plug to the
electrical soket capacity 380v.At that time, the
rectifier charges the battery automatically.
WARNING:
Don’t connect the rectifier socket to the
socket on the frame! It may damage
rectifier and system!
1
30
GENERAL SERVICE INFORMATION

NOTE: Grease or oil accumulated on the truck, causes potential fire hazard. Under normal working
conditions it must be cleaned every 1000 hours. In case there is excessive oil spilt on the truck the oil and
grease sediments should be removed by pressured steam and a cloth.

The program for protective maintenance should be implemented. Any kind of help on this issue may be
demanded from CUKUROVA services. A certain place should be allocated for truck maintenance.
Greasers, caps and plugs should be cleaned before the service. The truck should be checked for oil
leakage and any leakage should be fixed. In case of a doubt about leakage, oil, water and fuel levels
should be checked more frequently. When a hazardous situation occurs or the system is drained, a
warning tag should be put on the truck mentioning that the truck should not be used.

GENERAL TORQUE VALUES

You may contact CUKUROVA services about the torque specifications not mentioned here. In general,
metric system is used in trucks. Care should be taken that the keys to be used are also in metric system.

NOTE: The torque values below apply to nuts and bolts of SAE Grade 5 and above.

THREAD
TORQUE SPECIFICATIONS
SIZE
INCH Nm lbin
1/4 8±3 6±2
5/6 17±5 13±4
3/8 35±5 26±4
7/16 45±10 33±7
1/2 65±10 48±7
9/16 902±15 65±11
5/8 110±15 80±11
3/4 170±20 125±15
7/8 260±30 190±22
1 400±40 300±30
1 1/8 500±40 370±30
1 1/4 650±50 480±37
1 3/8 750±50 550±37
1 1/2 870±50 640±37

31
 Torque specifications for nuts and bolts

THREAD SIZE TORQUE SPECIFICATIONS

INCH Nm lbin
1/4 12±4 9±3
5/6 25±7 18±5
3/8 45±7 33±5
7/16 70±15 50±11
1/2 100±15 75±11
9/16 150±20 110±15
5/8 200±25 150±18
3/4 360±50 270±37
7/8 570±80 420±60
1 875±100 640±75
1 1/8 1100±150 820±10
1 1/4 1350±175 1000±110
1 3/8 1600±200 1180±150
1 1/2 2000±275 1480±200

32
 Standard metric thread

SIZE QUALITY TIGHTENING

TORQUE
(Nm)
8.8 3.1
M4 10.9 4.5
12.9 5.3
8.8 6.1
M5 10.9 8.9
12.9 10.4
8.8 10.4
M6 10.9 15.5
12.9 18
8.8 17
M7 10.9 25
12.9 30
8.8 25
M8 10.9 37
12.9 43
8.8 51
M10 10.9 75
12.9 87
8.8 87
M12 10.9 130
12.9 150
8.8 140
M14 10.9 205
12.9 240
8.8 215
M16 10.9 310
12.9 370
8.8 300
M18 10.9 430
12.9 510
8.8 430
M20 10.9 620
12.9 720
8.8 580
M22 10.9 830
12.9 970
8.8 740
M24 10.9 1060
12.9 1240
8.8 1100
M27 10.9 1550
12.9 1850
8.8 1500
M30 10.9 2100
12.9 2500
8.8 2000
M33 10.9 2800
12.9 3400
8.8 2600
M36 10.9 3700
12.9 4300
8.8 3400
M39 10.9 4800
12.9 5600

33
 Thin metric thread

SIZE QUALITY TIGHTENING

TORQUE
(Nm)
8.8 27
M8x1 10.9 40
12.9 47
8.8 40
M9x1 10.9 58
12.9 68
8.8 57
M10x1 10.9 84
12.9 98
8.8 54
M10x1.25 10.9 79
12.9 93
8.8 96
M12x1.25 10.9 140
12.9 165
8.8 92
M12x1.5 10.9 135
12.9 155
8.8 150
M14x1.25 10.9 220
12.9 260
8.8 230
M16x1.5 10.9 340
12.9 390
8.8 350
M18x1.5 10.9 490
12.9 580
8.8 480
M20x1.5 10.9 690
12.9 800
8.8 640
M22x1.5 10.9 920
12.9 1070
8.8 830
M24x1.5 10.9 1180
12.9 1380
8.8 810
M24x2 10.9 1160
12.9 1350
8.8 1200
M27x1.5 10.9 1710
12.9 2000
8.8 1190
M27x2 10.9 1700
12.9 2000
8.8 1670
M30x1.5 10.9 2370
12.9 2780
8.8 1610
M30x2 10.9 2300
12.9 2690
8.8 2220
M33x1.5 10.9 3170
12.9 3710

34
 8.8 1610
M33x2 10.9 2300
12.9 2690
8.8 2910
M36x1.5 10.9 4140
12.9 4850
8.8 2800
M36x3 10.9 3900
12.9 4600
8.8 3720
M39x1.5 10.9 5300
12.9 6200
8.8 3600
M39x3 10.9 5100
12.9 5900

WARNING: Metric and inch bolts and nuts should not be confused. Use of wrong or incompliant
material will result damage to the truck and accidents with potential death hazard.

After the original bolts are removed, they should be kept to use in the assembly. If new bolts or nuts are
required, make sure that they have the same size and thread size with the originals.

The strength of the bolt material is shown by the numbers (e.g., 8.8, 10.9, 12.9, etc.) on the bolt head.

35
HYDRAULIC SYSTEM

Make sure that the added oil to the hydraulic

system is compatible with the oil in the tank. If the
oil has lost its bright color and become smoky, this
implies air leach into the circuit; in this case a
pump failure may occur. The circuit should be
drained, cleaned and refilled immediately. The
connections in the intake line should be checked.

Hydraulic system oil

CLIMATIC ISO SAE SHELL MOBIL P.OFISI

CONDITION
Less than VG 32 10 W TELLUS 32 DTE OIL 24 HD 32
temperature 0°C
Temperature from 0°C VG 46 10 W 30 TELLUS 46 DTE OIL 25 HD 46
to +30°C
Higher than VG 68 20 W 20 TELLUS 68 DTE OIL 26 HD 68
temperature to +30°C

NOTE: These oil types must be used to prevent unwanted failures in the hydraulic system. The table
above will be helpful in the selection of the correct oil. For all trucks manufactured in our plant, Mobil DTE
25 is used in the hydraulic system.

PLACE OF USE OIL VISCOSITY

HYDRAULIC OIL SAE 10W, 10W30, 20W20
CHAINS SAE 10W, 10W30, 20W20

PLACE OF USE CAPACITY (lt)

HYDRAULIC OIL MEK15 ET 40

NOTE: Industrial oils containing additives against wear, rust, foaming and oxidation should be used in the
truck.

WARNING: Make sure that the added oil to the hydraulic system is compatible with the oil in the
tank. If the oil has lost its bright color and become smoky, this implies air leach into the circuit; in
this case a pump failure may occur. The circuit should be drained, cleaned and refilled
immediately. The connections in the intake line should be checked.

36
For the lubricants, multi purpose grease containing 3 - 5% molibdensulphide should be used. NLGI No.2
is the most suitable lubricant under standard conditions. If the truck is operating under extreme low
temperatures, NLGI No. 1 or NLGI No.0 should be used.
PLACE OF USE
LIFTING SYSTEM
TILT CYLINDERS
WHEEL BEARINGS
HYDRAULIC CYLINDERS
All the seals on the hydraulic cylinders mounted
on the truck adapt easily to the cylinder
movements and provide isolation. For this reason,
the adjustment of the seals for piston or rod
isolation is not necessary. In case of a
deformation due to wear, the cylinders are
disassembled and the seals are replaced. Care
must be taken that no foreign substance gets into
the cylinders.
The order of disassembly of the cylinders is as
follows: The cylinder head is loosened (2). Rod
(10) and head (2) is removed from the cylinder
block (16). Cylinder rod is fixed to the vice by the
pin. To protect the rod from harm, aluminum,
copper, or plastic etc. material should be put
between the jaws and the rod. The piston nut (15)
tightened with Loctite for safety is removed to take
out the seals (4,19,7,6,11,12,14). The seals
should be replaced if they are deformed.
WARNING: The seals and dust gaskets
should be examined carefully. They should
be replaced in the smallest suspicion about
their sealing properties. All the removed parts
should be cleaned carefully and the assembly
should be carried on in the reverse order. O-rings
should be greased and inserted.
GREASE
NLGI No. 2
NLGI No. 2
NLGI No. 2
LIFTING CHAINS
The lifting chains are one of the essential parts of
the truck. The chain system on the truck is
selected as appropriate and safe for the load.
Safe and uninterrupted load lifting and handling
greatly depends on the appropriate and regular
maintenance of the chains. Most of the complaints
sourced from chains are based on insufficient
maintenance. In high-strength chains, periodical
maintenance instructions should be followed to
provide maximum operating life.
A- The lifting chains should be checked and
lubricated at the end of every 50 working
hours. This period should be decreased in
environments highly available for rusting. The
operator or the maintaining technician should
perform these checks in these periods.
1. Wear and elongation:
Due to operation under load, the chains become
worn by time. This wear should be monitored and
the chains with over 3% elongation should be
replaced.
The elongation check of the chains should be
carried out according to the table below.
The measurements will be carried out based on
16 links.
The measurement between 16 links in any
st
location (the measurement from the 1 pin center
th
to the 17 pin center)
37
If the elongation of the chains is above these
measurements the chains should be replaced as a
whole, the replacement of only the worn ones
should not be implemented. In general, if a certain
part of the chain is worn, the chain should be
replaced as a whole.
2. Rusting and corrosion:
Rusting causes cracks on the side plates of the
chains decreasing the load bearing capacities to a
great extent. For this reason, the rusting of the
chains should be prevented both during operation
and while storing. The outer surfaces of the chain
links should be thoroughly examined during
check. The outer surfaces of the links should be
greased. They should be lubricated in every 50
hours under normal operating conditions, and less
than 50 hours under worse conditions. Engine oil
can be used on chains as both lubricant and anti-
rust material. If the chains are excessively rusted
during check, the crack examine should be carried
out with extreme care. If there is a cracked link,
the entire chain should be replaced.
3. The huge friction force produced on the chain
pins during non-lubricated operation and
overloading forces the pin to move on either side
and as a result of this the pin dashes out or twists
in the link. In such cases it should be avoided to
hammer the pin back to its place, but the insertion
of a new pin on application to CUKUROVA
services is required.
4. The wearing of the chain pins and side plates
show that the chain is operated eccentrically and
requires adjustment. Adjustment should be
provided on application to CUKUROVA services.
B- Chain holders and their housings and nuts
should be checked. They should be checked for
wear, cracks, crush, etc., and replaced if
necessary. Faults in these parts hinder the chains
to work on their correct axis and cause
accelerated wears.
C- Lubrication:
The most important issue of chain maintenance is
the lubrication. Satisfactory wear life cannot be
expected from those chains that the scheduled
periodical maintenance and lubrication are not
carried out. The film plate provided by lubrication
prevents corrosion, wears and pin twists in the
chains, provides proper operation, and long chain
life.
For maximum chain life, the oil should enter the
inner parts of the chain. The best method of
lubrication is to apply the lubricant to the chain
using a small paintbrush.
The lubrication period is 50 working hours or one
week under normal working conditions. In
outdoor-duty and parked trucks, this period should
be shorter.
In extreme dusty environment the oily chains will
collect the dust and form a thick layer of dust.
Even in this case, periodical and frequent
lubrication will provide longer chain life in
comparison to the case with no lubrication at all.
Under these conditions frequent lubrication and
cleaning of the accumulated dirty oil prior to
lubrication is necessary.
D- Replacing the chain:
The chains should be replaced as a complete set,
the use of one old and one new together should
be avoided. Although the chain tension and load
distribution is adjusted correctly, deterioration and
deformation in the old chain will be fast due to
wear. Afterwards it will cause the new chain to
deform in a short time. While replacing the chains,
the chain holders and blocks should be check,
and replaced if necessary. A new pin should be
used with a new chain. After the new chain is
mounted, the table should be lifted 15-20 cm high
from the ground with the forks free. The strain of
the chain should be checked by pushing forward
the chain with fingertip. The tension should be
adjusted using chain holder nuts so as both
chains have the same tension and the counter-
nuts should be tightened. The chains should not
be painted, should just be lubricated.
Cooler Fan
It is used to cool the control panel.It is located the
right side of the machine under the shutter.The
machine uses the air capturing from left shutter to
cool control panel and the system and removes
the heated air by using fan.So, the good air
circulation is obtained.
38
LUBRICATION AND MAINTENANCE INFORMATION

LUBRICATION AND MAINTENANCE

1- The maintenance performed during the operation life of the truck will increase its operation efficiency
and provide a long life. The operation and maintenance time of the truck is determined by dividing
into intervals.
2- Every truck has an operation and maintenance manual.
3- Oil level checks should be done on a flat surface. Before checking, the regions of inspection and
maintenance should be cleaned.
4- Joint bushing lubrication point should be cleaned before lubrication. The new lubricant should be
pumped until all the old lubricating oil comes out.
5- The lubricants used in the truck are specified in the maintenance table mounted on the truck. The
manufacturer company recommends these oil types to be used. Using or mixing oils of different
properties may result in costly repairs.
6- It is preferred that the maintenance of a truck is carried out always by the same person. The person
to carry out the maintenance should know well the truck and its entire properties.

39
MAINTENANCE, LUBRICATION AND OPERATION CHART (856A58)

40
MAINTENANCE PROCEDURE 50-WORKING-HOURS OR WEEKLY
MAINTENANCE
10 WORKING-HOURS OR DAILY MAINTENANCE
1- CHECK HYDRAULIC SYSTEM OIL LEVEL:
1. CHARGE OF BATTERY:

Check the battery level, add pure water if

necessary.Daily, one period about charge- discharge
is suitable.If one period time is exceeded, the battery
life decreases.Don’t forget that the battery charging
period is as much as its discharging period!

2. CHECK TIRE PRESSURES AND WHEELS:

The tires and wheels should be checked visually

every day. The extent of tire wear, the presence of a
penetrated substance into the tire, the existence of a
torn off part should be checked thoroughly. The tires
that are not eligible to use should be changed. Also
check that the wheel bolts are tightened to the
appropriate torques (specified in the table). The tire
pressures should be as follows:
1. Park the truck on a flat surface. Lower the forks
Tire pressure: and retract the mast fully. Apply parking brakes
Front = 10 bar , Rear = 10 bar and turn off the starter.
2. Check the oil level by looking the gauge front of
the hydraulic tank.
3. CHECKING DRIVE-MOTOR: 3. If the oil level is low, add the oil.The oil level
should be middle of the gauge.
All connections’ bolts are checked and if they loosen, 4. If the oil has lost its bright color and become
they should be tigthened to suitable torque. smoky, this implies air leach into the circuit; in
this case a pump failure may occur. The circuit
4. CHECK THE TRUCK VISUALLY: should be drained, cleaned and refilled
immediately. The connections in the intake line
1. Check the operator’s cabinet for anything left. should be checked.
Mud, dirt, etc. in the floor mat should be cleaned. 5. Close the tank cap.
2. Check the gauges and the dashboard for any 6. Check all the hoses, connecting clamps, and
visible damage. pipes and make sure that there is no any
3. Check the rails and the chains for any visible leakage.
failure like looseness, cracked or broken pin or 7. Close the front frame plate.
loose rollers.
4. Check the fork table and forks and any
attachments, if there is any, for loose or missing
bolts or any visible crack or looseness.
5. Check the tires and wheels visually for excessive
wear, torn out pieces, foreign material or cracks.
6. Check the overhead for missing bolts or cracks or
broken parts.
7. Check the hydraulic system for any leakage or
any visible damage in the hose.
8. Check the battery section for any loose
connection, damaged cables or loose caps.
9. Start the truck and check for proper functionality.
In particular check the presence of abnormal
noise.
10. Check the work hour gauge to determine
maintenance periods easily.

41
 2- CHECK BATTERY FLUID LEVEL :
1. Check the battery section for any loose
connection, damaged cables, and loose caps.
2. Check the electrolyte level making sure that the
level is 1-2 mm above the upper section of the
plates. The only purified water should be added .
3. Always keep the ventilation holes in the battery
caps open. Keep the battery caps closed unless
there is connected to charge from an external
supply.
4. Always keep the battery clean.
5. The efficient operation depends on that the fluid
(electrolyte) inside is in sufficient amount density.
The density check should be done by the
authorized service of the truck or the battery.
WARNING: Never approach with flame while
checking battery electrolyte level.
NOTE: Battery level should be checked when the
motor is stopped.
3- CHECK AND LUBRICATE THE CHAINS:
1. Check the lifting chains. Both chains should be
equal. If there is a difference, adjust the tension
using adjusting nuts.
2. Apply lubricant to the grease fittings. Check the
“Lubrication and Maintenance Table” for selection
of the lubricant types.
3. Check and adjust the tightness of the stay bolts
on the fork table and the side support blocks on
the rails. Make sure that the rail and the fork table
can operate freely while adjusting.
4- CHECK THE TRANSMISSION OIL LEVEL:
Park the truck on a flat ground, lower the forks to the
ground.Remove the cover on the
counterweight.Remove the plastic plug in the hole on
the drive-motor’s sitting plate.Level checking plug
gets into line with the hole by turning the steering.
Remove the plug on the transmission and check the
oil level: oil should be level with the orifice.If the level
is low, add the oil.
42
250-WORKING-HOURS OR MONTHLY 10- Check and adjust the tightness of the stay bolts
MAINTENANCE on the fork table and the side support blocks on
the rails. Make sure that the rail and the fork
1- CHECK AND LUBRICATE THE LIFTING table can operate freely while adjusting.
SYSTEM: NOTE: Lubricate the chains more frequently under
conditions that may lead to excessive corrosion or
where lifting operation is very frequent.

NOTE: For necessary adjustment and repair

operations, you may contact CUKUROVA services
for assistance.

2- CHECK AND ADJUST THE BRAKE SYSTEM:

Check and lubricate the mast, fork table, and the

chains.

Check the oil level of the oil tank for the brake
system; if there is a drop in the oil level, add oil.
Adjust the clutch disc on the wheel engine so as to be
1.5 mm from the drum. The diameter increases as
the brake crown wheel is rotated clockwise, and it
decreases in the opposite way. The adjustment is
carried on so.
In addition, check the drum on the brake system for
cleanness, and clean it if necessary. Check the hand
brake cables, and replace if there is excessive wear.
Check the brake hoses, and replace if the punctured
ones.

1- Operate the tilt and lift circuits and check for any
abnormal noise.
2- Clean the rails and the table. Check the bolts for
tightness and tighten any loosened ones if any is
present.
3- Check the forks and attachments, if present, and
repair if there is any visible damage.
4- Apply a thin layer of grease on the chain by
using a thin brush.
5- Lower and lift the forks a couple of times to
ensure that the oil is applied thoroughly on all
chain links.
6- Check the chains and links one by one for the
presence of any damaged part.
7- Apply grease to all grease fittings.
8- Lift the forks up to the maximum course of the
lifting cylinder to make sure that the movement
of the chains on the rollers is normal.
9- Check the chain rollers for any blow or damage.
Replace parts if necessary.
Bleeding the air from the brake system:
It is essential for the assurance of security that the
brake system of the truck operates well. For proper
operation, the air in the brake system should be taken
out. There are breathers on the hydromotors.
Pumping is applied by pressing on the brake pedal
repeatedly. While the operator’s foot is hold pressing
on the pedal, another technician should open the
breather on the hydromotor. Oil starts to come out of
the breather. The pumping is continued until there is
no air bubble in the oil coming out of the breather.
Again while the operator’s foot is hold pressing on the
pedal, another technician inserts the breather screw.
The same procedure is applied to the other
hydromotor as well. By repeating these steps two or
three times, the air of the system is completely bled.
These steps are enough to bleed the air from the
system for the table breather on the drive-motor and
transmission. Consequently there is no air left in the
system.
43
3- CHECK HYDRAULIC SYSTEM OIL LEVEL:
8. Park the truck on a flat surface. Lower the forks
and retract the mast fully. Apply parking brakes
and turn off the starter.
9. Check the oil level by looking the gauge front of
the hydraulic tank.
10. If the oil level low, add the oil.The oil level should
be middle of the gauge.
11. If the oil has lost its bright color and become
smoky, this implies air leach into the circuit; in
this case a pump failure may occur. The circuit
should be drained, cleaned and refilled
immediately. The connections in the intake line
should be checked.
12. Close the tank cap.
13. Check all the hoses, connecting clamps, and
pipes and make sure that there is no any
leakage.
14. Close the front frame plate.
4- CHECK REAR DRIVING SYSTEM :
At driving system, check the bolts for tightness and
tighten to suitable torque any loosened ones if any is
present.
5- CHECK THE ELECTRICAL SYSTEM :
a) The electrical system of the truck is (-) negatively
earthed. This should never be changed. Earthing
reversibly will cause damage in the alternator and
the whole electrical system.
b) Detect the worn out wires in the electric circuit
and replace them. Pay attention on the plugged
connections that may dislocate.
WARNING:Before any control or
maintenance, take the battery connection
socket out.
WARNING: Before connecting battery, make
sure that the starter key is off and the parking
brake is engaged.
c) Contactors: Connection surface is silver alloy on
copper floor.Normally during operation, their
connection surfaces are black and rough.Don’t need
cleaning.Don’t use file or abrasive at
connections.Change the connections when
connection surface corrode throughout the copper
floor.Always adjust the connections while changing
them.If the connections don’t corrode orderly, check
whether spring tensions are equal or not.
d) At electrical forklifts, check commutator and
dynamo carbon brush. Make sure that commutator
surface is ok and the motor operates correctly.
Damaged dynamo carbon brush should be change
before they harm the commutator surface. Before
removing the carbon, take its spring out. Change the
carbon before carbon abrasion thickness doesn’t
exceed about 1,5 mm.Check the carbon conservative
that there is any fire and any damage. Make sure that
carbon conservative is connected in its plate tightly.
Make sure that carbon can be removed from the
carbon conservative easily. Check the carbon spring
that there is any damage because of heat or
abrasion, change the damaged springs.
1 2 3
44
 4 5
500-WORKING-HOURS OR 3-MONTHS
MAINTENANCE
1- LUBRICATE THE TILT CYLINDERS:

1. HYDRAULIC CONTROL UNIT

2. MAINCONTACTOR
3. TRAVELLING CONTROL UNIT
4. FUSE OF FORWARD-REVERSE
5. FUSE OF HYDRAULIC PUMP Apply grease to all grease fittings in the tilt cylinders.

6- CHANGE THE TRANSMISSION OIL: 2- REPLACE THE HYDRAULIC FILTER:

Park the truck on a flat surface. Adjust the

transmission to level checking position. Remove the
draining plug (at the bottom of the taransmission by
using allen wrench 7 mm) and drain the oil. Place the
plug and tighten it to 22Nm. Adjust the transmission
to level checking position and remove the level
checking plug. add the oil (SAE 90) by using the hose
which is given you. Add the oil until the oil is level
with the orifice. Be careful about bubbles while
adding the oil. Check the oil level after a short
working interval.

Note: First oil changes at 250 hours, further oil

changes at every 2000 hours or once a year.

Check the hydraulic system filter for cleanness and

replace the dirty filter. Remove the filter by removing
the body bolts. Mount the new filter. Hydraulic filter
can be supplied from CUKUROVA services.

3- LIFTING SYSTEM CONTROLS AND SETTINGS:

a) Stop the truck, lower the forks and perform the

necessary checks.
b) Check the rail connection pins (on the rails and
chassis).
c) Check the adjusting bolts of the rod heads of the
tilt cylinders for tightness, and tighten them if
necessary.
d) Check the chains for wear and perform the
necessary maintenance.
e) Check the bolts and nuts for tightness, and
tighten them if necessary.

45
f) Lift the forks up to the maximum course of the
lifting cylinder to make sure that the movement of
the chains on the rollers is normal.
g) Check the chain rollers for blow or damage.
h) Apply grease through the grease fittings on the
chain roller bearings.
i) Keep the rails, fork table, and the chains clean.
j) Check the forks, the attachments, if there is any,
and repair any visible damage.
k) Check the operation of the tilt and lift circuits.
l) Adjust by tightening the stay bolts on the fork
table and the side support blocks on the rails.
NOTE: For detailed information on maintenance and
lubrication of the chains, refer to “Lifting chains”
1000 WORKING HOURS OR 6- MONTHS
MAINTENANCE
1- CHECK CHAINS AND ROLLERS :
a) Park the truck on a flat ground, engage the parking
brake, lower the forks to the ground.
b) Bring the direction lever to the neutral position and
turn off the starter.
c) Check the chains for wear.For detailed information
about the maintenance of the chains, refer to section
“ lifting chains”.
d) Check the bolts for tightness.If there are any
loosen bolts, tight them.
e)Apply grease using the grease pump to the grease
fittings of the middle and inner rail.
2- LIFTING SYSTEM CONTROLS AND SETTINGS:
a) Stop the truck, lower the forks and perform the
necessary checks.
b) Check the rail connection pins (on the rails and
chassis).
c) Check the adjusting bolts of the rod heads of the
tilt cylinders for tightness, and tighten them if
necessary.
d) Check the chains for wear and perform the
necessary maintenance.
e) Check the bolts and nuts for tightness, and
tighten them if necessary.
f) Lift the forks up to the maximum course of the
lifting cylinder to make sure that the movement of
the chains on the rollers is normal.
g) Check the chain rollers for blow or damage.
h) Apply grease through the grease fittings on the
chain roller bearings.
i) Keep the rails, fork table, and the chains clean.
j) Check the forks, the attachments, if there is any,
and repair any visible damage.
k) Check the operation of the tilt and lift circuits.
l) Adjust by tightening the stay bolts on the fork
table and the side support blocks on the rails.
NOTE: For detailed information on maintenance and
lubrication of the chains, refer to “Lifting chains”
46
 NOTE (Optional):
2000-WORKING-HOURS OR ANNUAL
MAINTENANCE Loosening may occur in the hoses to the side shifter
and center lifting cylinder. In this case, loosen the
clamps holding the hoses, stretch the hoses and
1- DRAIN THE HYDRAULIC CIRCUIT OIL AND tighten the clamps again. Lubricate the side shifter
REPLACE THE STRAINER: and the upper bearings.

1- Replace the hydraulic oil with the truck parked on 2- CHANGE THE TRANSMISSION OIL:
a flat surface and in a closed and dustless
environment. Park the truck on a flat surface. Adjust the
2- Clean the truck thoroughly before changing the
transmission to level checking position. Remove the
oil.
draining plug (at the bottom of the transmission by
3- Place the truck on a flat surface, lower the forks
using allen wrench 7 mm) and drain the oil. Place the
and tilt the rails to the far back. Bring the steering
lever to neutral position, apply the parking brake, plug and tighten it to 22Nm. Adjust the transmission
and switch off the starter. to level checking position and remove the level
4- Make sure all the cylinders are closed. checking plug. Add the oil (SAE 90) by using the
5- Open the engine hood. hose which is given you. Add the oil until the oil is
6- Remove the hydraulic tank drain plug and drain level with the orifice. Be careful about bubbles while
the tank. The drained tank inner and its filter adding the oil. Check the oil level after a short
connected with front flange should be cleaned by working interval.
air or a solvent.
7- Remove the filter on the flange using the filter Note: First oil changes at 250 hours,furter oil
wrench and replace it with a new one. changes at every 2000 hours or once a year.
8- Changed filter and flange connect to each other
by hand.Then, they mount to the hydraulic tank.
9- Check the hoses’ connections properly.fill up the
tank with suggested oil.The level of the oil should
be at the middle of the gauge.
10- Check for presence of oil leakage, repair if there
is any.
11- Check all the hoses, pipes, and clamps on the
truck for oil leakage.

WARNING: It is recommended that the oil and

filter be changed by authorized personnel at
CUKUROVA services. If this operation will be carried
by your personnel, the nearest CUKUROVA service
should be contacted and asked for assistance.

47
1-ACCUMULATOR SPECIFICATIONS

CELL TYPE : 4 PZS 400

VOLTAGE : 48V
CAPACITY : 400Ah
CELL NUMBER : 24

The capacity at discharge for 5 hours (with 80 A) is 400 Ah and voltage after the discharge is 1,75 V/cell.

Nominal temperature of the electrolyte is 30°C. The temperature exceeds 40°C at very short period.(it
shouldn’t exceed 55 °C.) the service life decreases at high temperatures.

Electrolyte density of the accumulator which is charged completely at max. level is 1,270±0,01gr/cm³. At Higher
than temperature to 30°C and less than temperature 30°C the followings are performed:
At Higher than temperature to 30°C,add 0,0007 to the gauge density for each degree which is higher than
temperature to 30°C .
At less than temperature 30°C,subtract 0,0007from the gauge density for each degree which is less than
temperature 30°C.
Max. Charge current at voltage ≤2,4±0,02V/cell is 68A.At higher than voltage to 2,4V/cell, charge current is
decreased to 20A.Maximum charge voltage is 2,7 V/ cell.

2-CHARGING THE ACCUMULATOR

Check the electrolyte level in the cells, the level should be higher than min. level and it should be lower than
max. level.
Check the all plugs for tightness. Adjust charge level to 2,35-2,40 V/cell. Begin to charge.when the current
decreases to 0,25I5, adjust the charge level to 2,60-2,70 V/cell.Continue to charge until the current of which
measurement is repeated every hour doesn’t change at consecutive two measurements. Different charge
sistem could be used without exceeding the current limits.Check the temperature while charging the
accumulator.If the temperature exceeds 40°C, stop charging until the temperature is 35°C or less than
35°C.Charges from 2,4 to 2,7V/cell cause to occur much gas.check the charge place weather. When the
accumulator is charged completely , fill up the accumulator with pure water about max level. Charge the
accumulator further 30 minutes to circulate the electrolyte.

Never add electrolyte before referring MUTLU.

At the end of the charge, electrolyte density is less than 1,260 gr/cm³ according to 30°C . If the problem isn’t
solved, refer the MUTLU.

3-NORMAL OPERATING

Accumulators could be used for different applications:

a. During operation, operating types which don’t charge accumulator.
Here, Charging accumulator,regular or irregular current attractions are mentioned.If the truck has no min.
shears voltage K 5, accumulator should be charged after operating the truck about periods which is equal to
%80 of the total capacity .

Even if there is min. shears voltage, using more than %80 of the capacity causes to decrease the
accumulator life.
Check the current and min. shears voltage every three or four months.Blows and shakes except normal
operating blows or shakes shorten the accumulator life.

On a day, one charge and one discharge period is suitable.If you do them more than one period, the
accumulator life shortens.charge the accumulator without noticing discharge level during operation.

48
 b. Types of operations which are both operating and charging at the same time;
First moving,regular or irregular current attractions are mentioned. Charge voltage shouldn’t exceed max.
2,38V/cell and it shouldn’t become less than 2,3V/cell. Check and adjust the truck’s charge voltage and min.
shear voltages once every 3-4 months.

4- CHARGING AGAIN

If the accumulator discharges completely or partly because of any reason, it should be charged.Charge period
of accumulator changes according to charge system. Accumulators should be charged as much as %105-120
of the discharged current. Stop charging when the last two reading measurements of current, density and
voltage which is measured once an hour are approximately the same.
Charge is performed with 20A for every 100 Ah until charge will be 2,4V/cell on condition that the temperature
doesn’t exceed 40°C except very short periods.
When the charge reaches 2,4 V/cell, charge current for each 100 Ah (K5 ) shouldn’t exceed 8A. When Charge
with stable current IUIA ,less than 2,4V/cell and for 100 Ah the current is 20 A, when the charge is higher than
2,4 V/ cell, the current shouldn’t be exceed 5 A.

5- MAINTENANCE OF ACCUMULATOR

At the weekend, for operations which are required complete charge should be done these followings after this
charge:

• Checking the electrolyte level: check the electrolyte level of the accumulator which has waited for half an hour.
Rising because of boiling can mislead you.
If necessary, add distilled water and charge it about 30 minutes at boiling level.

Automatic float system or adding distilled water by hand should be done at the end of the charging.
Never add electrolyte before referring MUTLU.

• Measuring of density: Unless density of cell is equal to 1,270+0,01 gr/cm³ ,search its reasons.If you don’t find
the solutions, consult MUTLU .You should measure the density when the electrolyte level is max or a little below
the max level.
• Measuring of voltage: If voltage difference between the cells is higher than 0,05 V, search its reasons. If you
don’t find the solutions, consult MUTLU .

If the density is less than 1,260 gr/cm³(30°C) and the difference of voltage is higher than 0,05V, compensating
charge is needed.
• Compensating charge: Charge the battery min. 6 hours with charge current 5%, too. If repeated
measurements of density and voltage aren’t in required limits,consult MUTLU

If the density at 30°C is higher than 1,28 gr/cm³ , drain the electrolyte by measuring its quantity and add purified
water in stead of the drained electrolyte. Consult MUTLU about the quantity of electrolyte. These measurements
should be done once a week.Apply compensating charge when required.Before general control and
measurements, clean the batteries, check tightening of the connections.

49
6-IMPROPER USE

• when it is necessary to consult MUTLU, not performing

• As charging the battery, exceeding the limits of current.
• being battery charge voltage higher than 2.7 V/ cell
• Electrolyte level not being in desired limits.
• Current and voltage being low as much as they couldn’t charge the battery .
• Being operated the battery at the temperature which is higher than permissible value.
• Stocking conditions being unreasonable.
• If you don’t obey above mentioned, the batteries will damage and being obeyed the other rules don’t prevent
to damage the battery.

Improper use of batteries is out of the guarantee.

7-TRANSPORTING

• The batteries are transported in boxes

• Don’t put anything on the batteries.
• Take all measures batteries not to fall over.
• If package of batteries or batteries suffer damage during transporting, consult MUTLU..

8- STORING AND USING OF DRY CHARGE BATTERIES

Dry charge batteries could be stored for along time. To be useful of pre-charge, store the cells at dry and cool
places.The temperature of the storage should be from 5°C to 35 °C and it shouldn’t change suddenly.We
suggest that you store the batteries in its orginal packet.

While adding electrolyte,remove the band and nylon on the plugs.

The cells should be perpendicular to the ground and they shouldn’t be stowed as one on the top of the other. To
add electrolyte, consult Mutlu. Check the electrolyte density which will be used. It should be 1,260 gr/cm³ at 30
C° . Before adding waited electrolyte shake and mix it. The electrolyte temperature should be between 15 °C
and 25C°. After filling last cell, wait at least two hours( you shouldn’t wait more than 12 hours.) and begin to
charge the battery. Fill the all cells completely , wait one hour and check every cell’s heat and density.And
record them. After this waiting the cell level will drop. Refill the cells completely. Before charge, check the poles
and connections. Connect the battery and converter when the charging system is off. At dry battery, charge
quantity changes according to waiting periods and conditions.Because of this, you should be careful about
followings:
I- The capacity of dry charge cells which are filled with electrolyte are approximately %80 K10. At the
measurement after one hour , if increasing of temperature is less than 5°C or decreasing of density is less than
3 ,
0,02 gr/cm the charge should be performed by charge system which increases the voltage 2,6 -2,7 V.But at
that time, the charge current should be accord to the given value.

II- If increasing of temperature at the electrolyte is more than 5 C° or decreasing of density is more than 0.02
3
gr/cm , it should be used with extended charge.

It is important that the first charge should be continuous.

Charge could be performed any methods of which current is accord to max.current. During first charge or
normal charge , continue to charge until change of last two read value is little.The cells’ electrolyte density
should be 1,270+0,01 gr/cm³ at 30 C°.After charge, the battery group should be rested at least one hour. The
present battery is wiped and is dried.

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9-WARNING

Sulphuric acid is abrasive.During working on battery, use protecive glasses and gloves.If your skin comes in
contact with electrolyte, wash your skin with water.When the electrolyte comes in contact with your eyes, wash
and immediately consult a doctor
After working on battery, wash your hands absolutely.

All cells include oxi-hydrogen gas.Don’t use flammable material near the battery.

If the connections aren’t protected, short circuit may occur. Always use the insulated devices on the battery. At
the groups of which total voltage is more than 60 v, while disconnecting the connections create at least three
points which are decreased the voltage. Unused battery should be stored with full charge and their surfaces
should be clean and dry. Every 30-60 days, the batteries should be recharged. According to operation
conditions,the plugs should be cleaned regularly.

CHANGING THE BATTERY

WARNING: Make sure that the capacity of lifting device or crane should be more than the battery
weight.The battery weight is shown on the battery box.The lifting device shouldn’t be metal or it should
be insulated by band.The batteries are heavy, because of this, be careful to protect them any damage.

New battery should be suitable in its place.To prevent the battery movement, use plates.

Make sure that new battery weight are in limits max. and min. value.

WARNING: Before connect the battery, make sure that the battery switch is off and the parking brake is
engaged.

1. Disconnect the battery charge socket at the left of the operator seat.Open the bonnet.The support lever
supports the bonnet.
2. Remove the both panels at the sides of the battery place.
3. Disconnect the connections and cables as the battery won’t damage them.
4. To remove the battery out of the forklift, use a crane. Tie the rope to lifting points.Check the battery
measurement.

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PREPARING THE TRUCK FOR LONG TERM STORAGE

If the truck will be stored for along time, the following procedure should be followed to protect the truck and its
parts.

1- Clean the truck and complete its paint to avoid rust.

2- Drain the fluids in the hydraulic system and replace them.
3- Remove the battery and fill up the fluid. If it is fully charged, store it in a warm place.
4- Put supports under the axles to prevent side wall wear of the tires.
5- Apply parking brake
6- Lubricate all grease fittings.

PREPARING TO OPERATE THE TRUCK AFTER LONG TERM STORAGE

If the truck has not been operated for a long time and it is prepared to be operated, following steps should be
followed:

1- Mount the battery and check for charge.

2- Check the tire pressures.
3- Check the headlights, warning lamps, etc for operation before moving the truck.

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 GENERAL FAILURES

RELAYS

FUSES

F1 : 10A FORWARD-REVERSE
F2 : 10A FAN
F3 : 10A SEAR
F4 : 15A FRONT HEADLIGHT

NOT: When changing the control card, calibrate the system.

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1- HEADLAMP
Front and/or rear headlamps are not functioning.

Check bulbs Replace

Check power connections, fuses etc Repair / Replace

Check relays and electrical card Repair / Replace

Check headlamp switch

Replace controller

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2- HORN
Horn is not functioning

Check if there is an electrical current on Replace

horn connections

Check power connections, fuses etc Repair / Replace

Check relays and electrical card Repair / Replace

Check horn switch

Replace controller

3- BACKUP ALARM
Backup alarm is not functioning

İf there is an electrical current on backup Replace

alarm

Replace controller

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4- FAN
If fan is not functioning properly in lift,tilt,attachment and forward – reverse directions
positions.

Check if there is an electrical current on Replace

fan connections

Check power connections, fuses etc Repair / Replace

Check relays and electrical card Repair / Replace

Check diodes of lift, tilt attachment and Replace

forward and reverse direction line

Replace controller

56
5- STEERING WHEEL SWITCH
Steering wheel is not functioning properly

If there is an electrical current on switch Replace

connections

Check power connections and Repair / Replace

control fuse etc.

Replace controller.

6- HOURMETER AND BATTERY CHARGE INDICATOR

Hourmeter an battery charge indicator are not functioning.

If there is an electrical current Replace

on hourmeter connections

Check power connections and Repair / Replace

control fuse etc.

Replace controller.

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7- FORWARD – REVERSE DIRECTIONS
Forward – reverse directions are not functioning.

Check seat switch Check connections and repair

Check power connections, fuses etc Repair / Replace

Check relays and electrical card Repair / Replace

Check accelerator Replace

Check forward – reverse arm Replace

If there is an electrical current on Check coal

traction motor

Check flash number of green light Apply producere on fault

electrical card finding flow chart

Replace controller

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8- TILT , LIFT , ATTACHMENT
Tilt ,lift attachment are not functioning.

Check power connections and . Repair / replace

control fuse

Lift is not functioning properly Check potentiometer and

adjust potantiometer 4,2KΩ

Check microswitch under control valve Replace

If tilt is not functioning properly Replace

check microswitch under control valve

If attachment is not functioning properly Replace

check microswitch under valve

If there is an electrical current Check coal

on pump motor

Replace controller.

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FAULT FINDING FLOW CHARTS
HYDRAULIC CONTROL UNIT – FAULT FINDING

OPEN No fault, normal condition

CLOSE Internal controller fault
1 FLASH Personality out of range
2 FLASH Illegal start condition (Traction)
3 FLASH MOSFET Short Circuit
4 FLASH Contactor fault or Motor Open Circuit
5 FLASH Not used
6 FLASH Accelerator wire off fault
7 FLASH Low or High battery voltage
8 FLASH Over temperature protection active

Flash
NO Fault Description
Fault
0 System OK On
Maximum power available to the motor has
1 Thermal Cutback been reduced due to excessive Heatsink 8
temperature.
Maximum power available to the motor has
Dynamic Power
2 been reduced by the Dynamic Power 8
Reduction Active
Monitoring function.
Input wire from accelerator has been
3 Accelerator Wire Off 6
disconnected.
Accelerator Pressed at
4 Accelerator pedal pressed at power up 6
Power Up
5 Belly Fault The Belly switch function has occurred 2
6 Seat Fault Drive selected and no seat switch closed. 2
Direction switch selected for greater than 2
7 SRO Fault 2
seconds with FS1 open.
8 Two Direction Fault Two directions selected together. 2
9 Sequence Fault Direction or FS1 switch closed at power up. 2
10 Low Battery Fault Battery voltage is too low. 7
11 High Battery Fault Battery voltage is too high. 7
High Battery Fault with Battery voltage is too high before the line
12 7
Line Contactor Open contactor is closed
Configuration Range
13 A personality is out of range. 1
Fault
Configuration CRC
14 The personality CRC is incorrect 1
Fault
Line Contactor Welded
15 Line contactor is welded. 4
Fault
Line Contactor did not
16 Line contactor is open circuit. 4
Close Fault
Bypass Contactor
17 Bypass contactor is welded at end of Bypass. 4
Welded Fault
18 MOSFET Short Circuit Short circuit Armature MOSFETs detected. 3
19 VA Detect Fail 12V Supply Failure 0
MOSFETs did not pulse during power on
20 MOSFET Off 0
failsafe checks (failsafe circuit enabled).
MOSFETs pulsed during power on failsafe
21 MOSFET On 0
checks (failsafe circuit disabled).
MOSFET Short Circuit Short circuit Armature MOSFETs detected
22 3
during Power Up during power on failsafe checks.

60
 Contactor 2 did not pulse during power on
23 Drive 2 Off 0
failsafe checks (failsafe circuit enabled).
Contactor 2 pulsed during power on failsafe
24 Drive 2 On 0
checks (failsafe circuit disabled).
Contactor 1 did not pulse during power on
25 Drive 1 Off 0
failsafe checks (failsafe circuit enabled).
Contactor 1 pulsed during power on failsafe
26 Drive 1 On 0
checks (failsafe circuit disabled)
Contactor 3 did not pulse during power on
27 Drive 3 Off 0
failsafe checks (failsafe circuit enabled).
Contactor 3 pulsed during power on failsafe
28 Drive 3 On 0
checks (failsafe circuit disabled).

Traveling Control Unit - Fault Finding

This is mounted between the connectors on the front of the controller. It serves as a simple diagnostic tool
as explained below:

LED extinguished Internal controller fault

1 Flash Personality out of range
2 Flashes Illegal start condition
3 Flashes MOSFET Short Circuit
4 Flashes Contactor fault or Motor Open-Circuit
5 Flashes Not used
6 Flashes Accelerator or Speed Probe wire off fault
Low or High battery voltage or BDI cut-out
7 Flashes operating
8 Flashes Over temperature
9 Flashes Contactor coil s/c

61
 MAINTENANCE CHART

Maintenance repairman
Service points lubricate adjust Charge drain replace
interval
every Battery x Consumer
8 hours tyre pressure x Consumer
daily Check the truck visually x Consumer
Transmission bolts x Consumer
every Hydraulic system oil level x Consumer
50 hours Battery fluid level x Consumer
weekly Chains x x Consumer
every Lifting system x Service
250 hours Brake system oil level x Consumer
Hydraulic system oil level x Consumer
Electrical system x Service
Rear march system x Service
Transmission oil Service
every Lifting system x Consumer
500 hours Transmission oil level x Consumer
Tilt cylinders x Service
Hydraulic filter x Service
every Chains and rollers x x Consumer
1000 hours Lifting system x Consumer
Transmission oil level x Consumer
per year-every Hydraulic circuit oil Service
2000 hours Hydraulic circuit strainer x Service
Transmission oil x x Service

NOTE:
First and only interval
x Repeat interval

62