# FoxBot Autonomous Forklift ## Installation, Operation, and Maintenance Manual ## Fox Robotics References Manual #: FoxBot-IOM-001 Revision Level: Release Date: March 2023 --- TECHNICAL RELEASE LOG | Author | Rev | Modification | Date | | --- | --- | --- | --- | | Fox Robotics Inc. | 0 | Original Release | 04/2021 | | Fox Robotics Inc. | 1 | 2023 Update | 03/2023 | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | IMPORTANT SAFETY INSTRUCTIONS NOTICE Read this manual in its entirety before commencing work of any kind. Only qualified personnel who are well versed in all operational aspects of this equipment should install, operate, and maintain this equipment. All operators should abide by all applicable safety rules and practices contained herein. --- ### FoxBot Autonomous Forklift Introduction 3 ## ALL RIGHTS RESERVED © COPYRIGHT 2021 by Fox Robotics Inc. This publication contains proprietary information and is the intellectual property of Fox Robotics Inc. (Fox **Robotics). Neither this document nor any other information disclosed herein shall be reproduced or distributed** in any form, for any purpose, without express written consent from Fox Robotics Inc. ### For immediate assistance with sales, service, or parts for this equipment contact: ### Support: +1 (512) 777-2898 # NOTICE **The equipment serial number should be recorded below for future reference. The serial number** **can be found on the Data Plate (mounted on the equipment). Reference the serial number when** **contacting Fox Robotics Inc. for assistance.** ### Serial Number: ## Fox Robotics, Inc. (Fox Robotics) 4101 Smith School Road, Bldg 2, Suite 100 Austin, TX 78744 www.foxrobotics.com Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- TABLE of CONTENTS 1 Introduction 1.1 Scope of this Manual 1.2 Operational Limitations 1.3 How to Use this Manual 1.4 Technical Documentation 1.5 Limited Warranty 1.6 Safety Awareness 1.7 Typical Safety Labels 1.8 Personal Protective Equipment (PPE) 2 Unit Description 2.1 Performance Data 2.2 Associated “Build-To” Standards 2.3 Features 2.4 Reference Material 2.5 Unit Components 3 Shipping, Receiving, and Setup 3.1 Shipping 3.1.1 Prepare the Robot for Transportation 3.1.2 Load the Robot 3.1.3 Secure the Robot 3.1.4 Secure the Batteries/Chargers 3.2 Receiving and Inspections 3.3 Required Site-Service Connections 3.4 Designate an Operational Area and Setup 3.5 Pre-Run Setup 4 Pre-operational Inspections and Testing 4.1 Visual Inspection(s) 4.2 Function Tests 5 Operation 5.1 Stack Light Descriptions 5.2 UPS and Battery System 5.2.1 Theory of Operation 5.2.2 To Isolate Power 5.2.3 To Restore Power 5.3 Safe Operation Parameters 5.4 FoxBot Start-Up 5.5 Manual Mode 5.6 Autonomous Mode - FoxLift App 5.7 Shutdown Procedures 6 6 6 6 6 6 8 9 10 11 12 12 12 12 13 17 17 17 17 17 18 19 19 20 24 30 30 30 31 33 34 34 34 35 35 35 35 36 41 --- 5.8 Long-Term Deactivation 43 5.8.1 Outside Storage (exposed to the elements) 43 5.8.2 Inside Storage (protected from the elements) 43 5.9 Reactivation 43 6 Maintenance 44 6.1 Lock Out, Tag Out Procedure 45 6.2 Preventative Maintenance (PM) Schedule (General) 45 6.3 Troubleshooting 47 6.3.1 FoxBot Autonomous Forklift 47 6.3.2 Charging Station/Unit 48 6.4 Maintenance Procedures 49 6.5 General Precautions 49 6.5.1 Battery Charging 49 6.5.2 Parking Brake 49 6.6 Post Maintenance Results 50 6.7 Results and Witness Sign-offs 50 7 Drawings and Bills of Materials 52 7.1 Drawing List 52 8 Appendix 57 8.1 Terms and Abbreviations 57 8.2 Inspection, Tests & Maintenance Logs 58 8.2.1 Daily Inspections 58 8.2.2 Daily Function Tests 58 8.2.3 Weekly Inspections 58 8.3 OEM Forklift Specifications | FBCS14N 59 8.4 OEM Forklift Operation and Maintenance Manual 63 --- 1 Introduction 1.1 Scope of this Manual In accordance with ANSI B56.1 (7.2.1) and B56.5, this manual has been developed to guide the user in the safe In accordance with ANSI B56.1 (7.2.1) and B56.5, this manual has been developed to guide the user in the safe operation of this FoxBot Autonomous Forklift (FoxBot). The manual is divided into several logically-ordered sections for ease of use. The scope of material included in this manual is limited to account only for specific operations and recommended procedures considered to be routine. The intent of this manual is to guide the operators and service technicians in the basic setup, operation, and maintenance of this equipment. This manual is NOT provided as a reference on mechanics, electronics, or hydraulics. 1.2 Operational Limitations This manual is provided as a guide for most normal operations and the care and proper operating specifications This manual is provided as a guide for most normal operations and the care and proper operating specifications of the equipment. Due to the varying environmental conditions and the nature of equipment operation, it is not possible to account for every possible unknown variable. Therefore, it is requested that when situations arise outside of the scope of this publication, operators should contact Fox Robotics directly for further assistance. Fox Robotics reserves the right to make design changes without incurring any obligation for the equipment or manual previously delivered. 1.3 How to Use this Manual To the extent it is practical, this manual will cover all of the additions and components added to the base model To the extent it is practical, this manual will cover all of the additions and components added to the base model forklift. For specifics on the base model forklift and other system components, see the Appendix for the specific OEM Manual. NOTICE Certain OEM User Manuals have been provided by Fox Robotics as a courtesy to our customers. Fox Robotics, however, does NOT maintain these OEM Manuals and therefore, cannot speak to the accuracy or version(s) of those manuals. If in doubt about any of the provided OEM Manuals, please visit the respective OEM’s website for the most current version(s) of their manuals. 1.4 Technical Documentation All information contained in this manual has been reviewed and approved by Fox Robotics engineering Fox Robotics Inc. warrants that each unit sold shall, at the time of shipment (i) conform to applicable specifications and (ii) be free of defects in material and workmanship during normal and ordinary use and service (the “Warranty”). For specific client warranty information, refer to the relevant Supplier Agreement or Purchase Order (PO). --- FoxBot Autonomous Forklift Introduction 7 Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- ### FoxBot Autonomous Forklift Introduction 8 ## 1.6 Safety Awareness Safety is YOUR responsibility and must be of primary concern. Knowing the guidelines covered in this manual will greatly improve your ability to safely install, operate, and maintain this equipment. Promote good safety around the equipment and throughout all phases of operation. It is the equipment owner’s/operator’s responsibility to establish good safety measures, including equipment and personnel training, as well as strict enforcement of safety policies. Only qualified personnel, who are well versed in safety procedures and all operational aspects of this equipment, should install, operate, and maintain this equipment. Safety summaries and safety procedures ***can never replace good common sense. Be aware of your surroundings at all times.*** ### Personnel Involvement - ***ENSURE that all involved personnel have been successfully instructed on the operational hazards this*** equipment presents prior to commencing work. - ***ENSURE all involved personnel are wearing proper Personal Protective Equipment (PPE), as applicable.*** - ***ENSURE that all uninvolved personnel are cleared from the area during operation.*** - ***ALL personnel should keep all loose items (clothing, rags, jewelry, etc.) and long hair away from*** moving/rotating parts. - Do NOT operate this equipment if you are not professionally trained in its use. - Do NOT operate this equipment if you are under the influence of alcohol or drugs (illegal or prescription). ### Area Awareness - ***ALWAYS be aware of your surroundings when using this equipment.*** - ***NEVER allow personnel to go underneath a lifted load.*** - ***NEVER lift loads over personnel.*** - ***NEVER enter a box trailer without properly securing the trailer (with chocks or a dock lock, for example).*** - Do NOT operate this equipment in poorly lit environments or with limited visibility. # NOTICE **It is the user's responsibility to ensure that the operating area is sufficiently lit for operators, per** **ANSI/IES RP7. This requirement is for the benefit of the operator, not the robot. The robot is** **equipped with lighting for its own benefit and for the benefit of a manual operator.** - *Do NOT operate this equipment on unstable ground.* - *Do NOT operate this equipment on slopes or grades in excess of 15%.* ### Lifting Operations - ***ALWAYS inspect and use adequately rated wooden/plastic pallets for every lift.*** - ***ALWAYS use proper lifting techniques for every lift.*** ### Equipment Operation - Do NOT use this equipment in a manner for which it was not specifically designed. - Do NOT exceed the rated performance/capacity of this equipment. - ***ENSURE that all safety/warning labels are present and obeyed.*** - Do NOT remove (or bypass) any safety guards and/or warning labels/stickers from this equipment. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- ## FoxBot Autonomous Forklift Introduction 9 - ***ENSURE that this equipment has been isolated from its power source (electrical, etc.) and that any residual*** power is bled/drained prior to performing maintenance. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 1.7 Typical Safety Labels Labels are provided for a variety of safety-related and/or equipment operational reasons. Some reasons may be Labels are provided for a variety of safety-related and/or equipment operational reasons. Some reasons may be more serious than others, but ALL labels should be observed, read, and fully understood. Below are typical examples. ⚠ DANGER Indicates a hazardous situation that, if not avoided, WILL result in death or serious injury. ⚠ WARNING Indicates a hazardous situation that, if not avoided, COULD result in death or serious injury. ⚠ CAUTION Indicates a hazardous situation that, if not avoided, COULD result in minor or moderate injury. NOTICE Provided to inform personnel of helpful information and identify potential damage to equipment. This label is not related to personal injury or hazardous conditions. STOP Provided to alert personnel that important instructions will follow. Typically, these labels will fall directly after or just prior to mission-critical tasks. This can also be used to indicate a good place for a team meeting to occur to discuss the completed task(s) or upcoming tasks. 1.8 Personal Protective Equipment (PPE) All personnel should wear suitable Personal Protective Equipment (PPE), when applicable and as instructed by Protect the Head 1.8 Personal Protective Equipment (PPE) All personnel should wear suitable Personal Protective Equipment (PPE), when applicable and as instructed by their site safety guidelines and/or as conditions dictate. Protect the Eyes Protection Protect the Ears Protect the Hands Protect the Feet Release Date: March 2023 --- ## FoxBot Autonomous Forklift Unit Description 11 # 2 Unit Description The FoxBot Autonomous Forklift is an autonomous, self-driving forklift engineered and designed to unload semi-truck box trailers with minimal or limited human interaction. It can be operated in one (1) of two (2) modes: Autonomous or Manual. In Autonomous mode (without an onboard operator) the FoxBot requires minimal setup and then can be set free to do its work. In Manual mode, the FoxBot can be driven by an onboard operator that controls the FoxBot using local controls, much like a standard forklift. The FoxBot Cabin (Cab) area can accommodate a single user, in the vertical (standing up) position. All controls are positioned well within the operator’s line of sight and are easily manipulated/functioned. The FoxBot is battery-powered and will hold a charge for approximately eight (8) hours, under general workload. Battery life may vary substantially with the level of use. In Autonomous mode, the FoxBot can be controlled and monitored remotely, if necessary. There are five (5) Emergency Stop (E-Stop) buttons located around the FoxBot in case an emergency situation arises. Additionally, there are other sensors that constantly monitor real-time operating conditions of the FoxBot, such as sensor connection, battery power, and loss of power. **Figure 1 – FoxBot Autonomous Forklift (FoxBot)** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 2.1 Performance Data For additional Forklift Specifications see (8.3 OEM Forklift Specifications | FBCS14N), in the Appendix of this manual. | Model: | Mark II | | --- | --- | | Rated Capacity: | 3,000 lbs. | | Net Weight: | 7,189 lbs. (3,260kg)±5%/excluding Battery | | Load Center Distance: | 24in(600mm) | | Power Source: | Battery(36V) | | Battery Weight: | Min:2,300lbs.(1,045kg)|Max:2,600(1,182kg) | | Hour Rate: | 6hour | | Controls: | Local&Remote/Autonomous | | Temp Limitations: | 34°F(1℃)to+104°F(+40℃) | | Towing Rating: | NO TOWING* | 34^{\circ}F(1^{\circ}C)+0+104^{\circ}F(+40^{\circ}C) * The FoxBot is not rated to tow loads. If needed, the FoxBot may be towed a short distance. Contact support for guidance if towing is required. 2.2 Associated “Build-To” Standards | ANSI B56.1 Safety Standard for Low Lift and High Lift Trucks | ANSI B56.5 Safety Standard for Guided Industrial Vehicles | UL 583 Electric-Battery-Powered Industrial Trucks | | --- | --- | --- | | Part III | Part III | For Type“E”Industrial Trucks | ● Self-driving technology ● 360° safety-certified sensing 2.3 Features ● Self-driving technology ● 360° safety-certified sensing ● Light Detection and Ranging (LiDAR) 360^{\circ} ● Light Detection and Ranging (LiDAR) ● Active stereo depth camera ● Active stereo depth camera ● Real-time pallet detection and localization 2.4 Reference Material ● Real-time pallet detection and localization ● Redundant encoder and position sensing Appendix ● 8.3 OEM Forklift Specifications | FBCS14N ● 8.4 OEM Forklift Operation and Maintenance Manual ● Installs in just 30 minutes (Pick and place zones can easily be configured, allowing for flexibility in resource allocation and use). ● Fewer employees in harm’s way ● Installs in just 30 minutes (Pick and place zones can easily be configured, allowing for flexibility in resource --- ## FoxBot Autonomous Forklift Unit Description 13 # 2.5 Unit Components **Figure 2 – Complete FoxBot Assembly (Side Views)** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Unit Description 14 **Figure 3 – Complete FoxBot Assembly (Front & Top Views)** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- Figure 4 – FoxBot Computer Enclosure --- ## FoxBot Autonomous Forklift Unit Description 16 1) The “Mode Selector” switch puts the FoxBot in either Autonomous or Manual mode. 2) The “Home” Button brings everything into the start/run position for Autonomous mode. 3) The “Reset” Button clears all previous states and readies the FoxBot for new input. 4) The “Safety Bypass Switch” disables autonomous mode and allows the robot to drive at severely reduced speeds, even if E-Stop switches have been damaged. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 17 # 3 Shipping, Receiving, and Setup ## 3.1 Shipping If shipping the FoxBot becomes necessary, it should be prepared, loaded, and secured according to the directions below. ### 3.1.1 Prepare the Robot for Transportation - Ensure the electronic backpack cover is latched and taped closed, with all wires and cables tucked within the cover - Perform an operational check of all mechanical capabilities - Check the battery conditions (electrolyte levels, terminal connections, leaks, security, and charge) - Perform a walk-around inspection, checking for any visible damage or disconnected harnesses - Check the condition of all LiDAR sensory units - Ensure the tablet is powered off and secured in the docking station for shipping ### 3.1.2 Load the Robot - Safely drive the robot in reverse onto the transport vehicle. Tines should be facing away from the cab of the transport vehicle. - Place the robot within the area of installed D-ring tie-downs. - E-track straps may be used to secure the robot instead of chains and binders. - Ensure the area around the robot is free of loose or unsecured items. - Lower tines to the floor and power off the robot. - Remove the keys and disconnect main battery power. ### 3.1.3 Secure the Robot - Chock wheels with wood wheel chocks, with the angled portion of the wheel chock in contact with the wheels and chassis. - Secure the following wheels and chassis: Front left wheel, front right wheel, steer-side chassis left of the operator cabin, steer-side chassis right of the operator cabin, left-side chassis (NOT under LiDAR fenders), and right-side chassis (NOT under LiDAR fenders) - Secure each wheel chock with 2x T25 deck screws, angled so they make contact with the trailer floor. Do not reuse old screws. - Securely chain or strap the mast to the floor, if possible. - Secure the front carriage to each, D-ring, E-clip, or securing location with chain, binders, or load-rated equivalent ratchet straps. - Pull chain, binders, or straps in opposite directions, if possible. - Use 4 chains, binders, or straps at a MINIMUM (2 for the mast/side-shifter assembly and 2 inside the battery well tensioned on the chassis, NOT the battery itself). - Install rear shipping hooks, if available, by threading into lower mounting point facing the hooks in opposite directions. Use chain and load-equivalent straps to secure to D-rings, pulling in opposite directions. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 18 ## 3.1.4 Secure the Batteries/Chargers - Load the battery on a pallet, preferably one with battery retaining boards. - Position the pallet near the trailer wall with available E-track spots. - Use 2 load-rated ratchet straps to secure the long side of the battery against the trailer wall. - If you are shipping the chargers before initial use, they will be bolted to a pallet. Ensure the cardboard cover is in place with the cabling tucked inside. - Secure the charger with one load-rated ratchet strap against the trailer wall, in the same fashion as the batteries. # ⚠ WARNING **ALWAYS transport the FoxBot with the “forks” facing the rear of the trailer, away from the truck** **cab. This is to prevent forks from being thrust into the truck cab in the event of an accident! Failure** **to observe this label could result in serious bodily injury or DEATH!** **Figure 5 – Shipping a Single FoxBot** **Figure 6 – Shipping Multiple FoxBots** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 19 ## 3.2 Receiving and Inspections - Remove all shipping/packaging material and verify that there are no signs of “in-transit” damage. - Ensure that all “shipping only” brackets/braces are removed, as required. - Ensure that all unit fasteners are tight and did not vibrate loose during transportation. # NOTICE ### If damage is discovered, take plenty of pictures to adequately document the damage. ## 3.3 Required Site-Service Connections # ⚠ WARNING **Electric Forklift Charging Stations can be extremely dangerous. Ensure that only qualified,** **well-trained operators connect and disconnect the charging station cables. Failure to observe this** **label could result in serious bodily injury or DEATH!** # ⚠ WARNING **The user shall maintain batteries and changing and charging systems in accordance with** **ANSI/NFPA 505. Battery types and charging systems supplied or specified by the vehicle** **manufacturer (e.g., opportunity charging) but not referenced in ANSI/NFPA 505 shall be** **maintained in accordance with instructions supplied by the vehicle manufacturer. Failure to** **observe this label could result in serious bodily injury or DEATH!** # ⚠ WARNING **Battery types and charging systems supplied or specified by the vehicle manufacturer (e.g.,** **opportunity charging) but not referenced in ANSI/NFPA 505 shall have safe operating and charging** **instructions supplied by the vehicle manufacturer. Failure to observe this label could result in** **serious bodily injury or DEATH!** **Figure 6 – Sample Battery Charger** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 3.4 Designate an Operational Area and Setup ● Ensure that the operational area is prepared to accept this equipment. ● Ensure that the operational area provides ample room to operate. ● Ensure that the operational area provides ample room to operate. ● Ensure that the operational area is well lit, per ANSI/IES RP7. ● Ensure that the operational area is well lit, per ANSI/IES RP7. ● Ensure that the operational area is level (within a ±5% grade) and free of debris, and/or unnecessary ● Ensure that the operational area is level (within a ±5% grade) and free of debris, and/or unnecessary obstructions. ● Ensure that the operational area provides enough strength to support the weight of the equipment being ● Ensure that the operational area provides enough strength to support the weight of the equipment being placed upon it. ● Ensure that the FoxBot does NOT carry any hazardous loads. ● Ensure that the FoxBot does NOT carry any hazardous loads. ● Ensure that all loads to be picked by the FoxBot fit with the confines of a standard Grocery Manufacturers ● Ensure that all loads to be picked by the FoxBot fit with the confines of a standard Grocery Manufacturers Association (GMA) sized pallet (48” x 40”). NOTICE The FoxBot’s primary safety and navigation sensors are positioned to sense objects 10 cm above The FoxBot’s primary safety and navigation sensors are positioned to sense objects 10 cm above the ground. The operational area should be kept clear of obstacles that cannot be sensed at this height, such as overhanging obstacles or holes. ⚠ CAUTION Caution should be exercised with changed environments. Changes in weather, surface conditions, or applications may affect the vehicle stopping distance; speeds, loads, brake settings, and/or operation should be adjusted accordingly. Failure to observe this label could result in minor or moderate injury. ⚠ WARNING It is also important to remember that the FoxBot is a robot and as such can turn “off” its “safety” All operational areas of the FoxBot should be considered “hazardous zones” and precautions should be taken to avoid unnecessary safety risks. Failure to observe this label could result in serious bodily injury or DEATH! --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 21 ## NOTE: A 15 ft clearance to adjacent obstacles is required for approach directions and 2 ft clearance is required for other directions. **Figure 7 – Sample Operational Area** # NOTICE ## The customer is ultimately responsible for determining a suitable operational area. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 22 # ⚠ WARNING **The customer facility should be equipped with various signs, warning devices, and other safety** **devices to alert and protect personnel from contact with the vehicle or items actuated by the** **vehicle. This includes equipment that is designed to interact with the vehicle system. Failure to** **observe this label could result in serious bodily injury or DEATH!** **Figure 8 – Typical Dock Measurements** # NOTICE **Record the dimensions above as they will need to be entered into the FoxLift App prior to** **operation.** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 23 # ⚠ WARNING **The customer is responsible for marking off a “safe travel” zone for the FoxBot. The area should be** **clearly marked and easily distinguishable from its surrounding area(s). Failure to observe this label** **could result in serious bodily injury or DEATH!** **Figure 9 – Sample “Safe Travel Zone” Markings** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 24 # ⚠ WARNING **The FoxBot should always be driven at safe speeds, when operated in “Manual” mode, by a** **qualified operator. Failure to observe this label could result in serious bodily injury or DEATH!** ## 3.5 Pre-Run Setup # NOTICE **The following setup instructions will only need to be done once per dock location. If multiple** **FoxBots will be in use at multiple dock locations, setup will have to be carried out at each location.** # NOTICE **If the FoxBot cannot be localized (spatially) by the app (an error note within the app will indicate** **this), verify the condition of the sensors. They may simply need to be cleaned.** 1) Connect all Tablets to the same WiFi network as the FoxBot. This may be a customer-provided WiFi network or the “FoxLTE” Wifi network. 2) Turn “ON” the onboard tablet and launch the FoxLift App. **Figure 10 – Sample Tablet (and APP)** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 25 Enter your Dock Dimensions (from section 3.4 Designate an Operational Area and Setup) **Figure 11 – Setup Step 1** 3) Select your FoxBot (by name, if applicable) and “Start Run”. 4) Press the “Green” Button (on the Computer Enclosure) to “Home” the FoxBot. 5) Point the FoxBot at the “Right” Dock Tag. A “tag” is a small pole mounted sign consisting of a QR code placard sitting atop a small 4-foot pole. # STOP **If, at any time, the operator or nearby personnel feel there is something wrong or an unsafe** **condition exists, any of the 5 E-Stops may be depressed (activated) to immediately stop all FoxBot** **function(s).** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 26 **Figure 12 – Setup Step 1** # NOTICE **Once the FoxBot finds the “tag,” it will appear as a gray box on the tablet (app) UI.** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 27 Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 6) Point the FoxBot at the “Left” Dock Tag. Figure 13 – Setup Step 2 7) Slowly drive the FoxBot inside the trailer until the camera recognizes a pallet. ⚠ WARNING Inside the Truck Trailer is a hazardous area and should never be entered without first securing the Inside the Truck Trailer is a hazardous area and should never be entered without first securing the FoxBot. NEVER allow the FoxBot to block easy egress from the trailer. Failure to observe this label could result in serious bodily injury or DEATH! --- **FoxBot Autonomous Forklift** Preoperational Inspections and Testing 29 **Figure 14 – Setup Step 3** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 4 Pre-operational Inspections and Testing NOTICE Visual inspections should occur at the beginning of each shift and/or as issues arise during use. If Visual inspections should occur at the beginning of each shift and/or as issues arise during use. If any of these instructions are unclear, call Fox Robotics Engineering for resolution. ⚠ WARNING Prior to inspection(s) ensure that the FoxBot is resting in a safe, powered-down state. Failure to Prior to inspection(s) ensure that the FoxBot is resting in a safe, powered-down state. Failure to observe this label could result in serious bodily injury or DEATH! 4.1 Visual Inspection(s) STOP Prior to operating the FoxBot, the “Daily Inspections” need to be performed. Refer to the Daily Inspection Log in the Appendix (8.2 Inspection, Tests & Maintenance Logs). If necessary, Refer to sections (2.5 Unit Components or 7 Drawings and Bills of Materials) for locations of inspection items. 4.2 Function Tests STOP Prior to operating the FoxBot, the “Daily Function Test” needs to be performed. Refer to the Daily Function Test Log in the Appendix (8.2 Inspection, Tests & Maintenance Logs). If necessary, Refer to sections (2.5 Unit Components or 7 Drawings and Bills of Materials) for locations of inspection items. --- 5 Operation STOP If, at any time, the operator or nearby personnel feel there is something wrong or an unsafe condition exists, any of the 5 E-Stops may be depressed (activated) to immediately stop all FoxBot function(s). ⚠ WARNING Fox Robotics Inc. has made every attempt to make this equipment as safe as possible. To keep this Fox Robotics Inc. has made every attempt to make this equipment as safe as possible. To keep this equipment operating safely, never remove (or modify) safety guards or safety labels or bypass any system put in place by Fox Robotics Inc. Failure to observe this label could result in serious bodily injury or death. ⚠ WARNING Only trained and authorized persons shall operate this equipment. Failure to observe this label Only trained and authorized persons shall operate this equipment. Failure to observe this label could result in serious bodily injury or death. ⚠ WARNING Never use this equipment in any manner for which it was not designed. Improper use can severely Never use this equipment in any manner for which it was not designed. Improper use can severely impact user safety. Failure to observe this label could result in serious injury or death. ⚠ WARNING Any unauthorized modifications made to the components in this system can dramatically affect the overall performance of the system. Failure to observe this label could result in serious bodily injury or death. Rev 0 --- ## FoxBot Autonomous Forklift Operation 44 # NOTICE ## Following these instructions will minimize the risk of damaging this equipment or associated **system(s).** # NOTICE ## Allowing untrained persons to operate this equipment may result in damage to this equipment ## and/or associated system(s). Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 5.1 Stack Light Descriptions GREEN - Communicates the operational mode. SOLID - The FoxBot is “ON” and in “Manual” mode. BLINKING - THE FoxBot is “ON” and in “Autonomous” mode. YELLOW - Communicates a hazardous condition. SOLID - The FoxBot is in “Autonomous” mode but has not gone through its startup procedure. BLINKING - A hazard is present: Figure 15 - Typical Stack Light Color Codes ● One or more safety scanners has been disabled (The FoxBot must be moving slowly) ● The FoxBot is going through its startup procedure ● The FoxBot is going through its startup procedure (5 seconds of lights and sounds) ● The safety bypass switch is active ● The safety bypass switch is active RED - Communicates a fault in the system that requires human intervention. (If the red light is “ON,” the FoxBot is safe to approach and will not resume moving on its own without operator intervention.) SOLID - The red light will turn on if: SOLID - The red light will turn on if: ● A chassis-mounted E-Stop (5) is pressed ● A chassis-mounted E-Stop (5) is pressed ● An internal fault is detected by the robot that BLINKING - The red light will flash if the reset button needs to be pressed to acknowledge the internal fault. The red light will extinguish when both the original event has cleared and the reset button has been pressed, at which point the FoxBot may resume motion. BLUE - Provides a means for the FoxBot to ask for help from the operator. SOLID – The FoxBot is actively requesting an intervention. SOLID – The FoxBot is actively requesting an intervention. --- ### FoxBot Autonomous Forklift Operation 44 # NOTICE **1) During normal operations, one or more Stack Light(s) should always be on or blinking. During** **system power-on or in the presence of a severe fault, the Stack Light may not illuminate.** **2) A red light indicates that the FoxBot will not resume without human intervention. Even when** **the fault conditions are clear, the FoxBot must go through a startup procedure, indicated by a** **yellow blinking light (which indicates a hazard), for a period of time before resuming movement in** **“Autonomous” mode.** # ⚠ WARNING **NEVER approach a FoxBot while it is in autonomous operation unless a red light is showing. If you** **must approach a FoxBot while it is in autonomous operation use a tablet to cancel the current** **operation. Failure to observe this label could result in serious bodily injury or DEATH!** ## 5.2 UPS and Battery System ### 5.2.1 Theory of Operation To facilitate keeping the autonomy system alive through loss of power events, such as a changing of the primary 36V battery, the FoxBot is equipped with an Uninterruptible Power Supply (UPS) that protects the primary autonomy computer. This UPS can select between two energy sources: 1) The primary forklift battery, as described in Section 2.1 (Performance Data). This battery provides power for the entire forklift during normal operation(s). 2) A secondary, 24V backup battery. The UPS continuously monitors its own input power channel and, if it detects loss of power, will switch to the battery backup. The input power channel of the UPS is sourced from one of two locations: 1) If the 110V plug on the backpack is plugged in and active, then the robot is said to have shore power. The robot will use this channel to power the UPS. Otherwise, 2) The primary 36V battery is used if no shore power is present. The battery backup can keep the autonomy computer alive for approximately 45 minutes on a full charge. When the backup is engaged, the system will beep slowly. Connecting the primary battery or shore power will silence this. ### 5.2.2 To Isolate Power 1) Remove the 110V plug into the backpack to remove shore power. ### Disconnect the primary 36V battery. Press and hold the UPS/Reset Button on the dash for 5 seconds. An audible beep should sound and the light on the switch will extinguish. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- ⚠ WARNING Power from the backup battery into the UPS remains present even if the UPS is disabled. Complete isolation requires removal of the backup battery. Failure to observe this label could result in serious injury or DEATH! 5.2.3 To Restore Power 1) Press and hold the UPS/Reset Button on the dash for 5 seconds. An audible beep should sound and the light on the switch will illuminate. 2) Reconnect the primary 36V battery. 2) Reconnect the primary 36V battery. 3) Ensure the backpack is closed and secured. 3) Ensure the backpack is closed and secured. 5.3 Safe Operation Parameters 1) Do NOT approach the FoxBot unless the stack light is red (or solid green). 1) Do NOT approach the FoxBot unless the stack light is red (or solid green). 2) Do NOT approach the FoxBot when the stack light is blinking or there is an audible “beeping”. 3) Do NOT enter the trailer while the FoxBot is active. 4) If you must approach a FoxBot while it is in autonomous operation, use a tablet to cancel the current operation. 2) Do NOT approach the FoxBot when the stack light is blinking or there is an audible “beeping”. 3) Do NOT enter the trailer while the FoxBot is active. 4) If you must approach a FoxBot while it is in autonomous operation, use a tablet to cancel the current operation. 5) If the vehicle is stuck, follow instructions on the tablet screen or if in doubt pick and place the next pallet 5) If the vehicle is stuck, follow instructions on the tablet screen or if in doubt pick and place the next pallet manually. 5.4 FoxBot Start-Up 1) Ensure the FoxBot is disconnected from shore power. 1) Ensure the FoxBot is disconnected from shore power. 1) Connect the primary 36V battery to the FoxBot (via Anderson, “Main Power” Plug). 1) Connect the primary 36V battery to the FoxBot (via Anderson, “Main Power” Plug). 2) Ensure the UPS is ON by inspecting the light switch on the dash.. 2) Ensure the UPS is ON by inspecting the light switch on the dash.. 3) Wait for the stack light to illuminate. This indicates that the system is booted up. 3) Wait for the stack light to illuminate. This indicates that the system is booted up. 4) When the FoxBot first starts, it will automatically fault to prevent unintended motion. Press the reset button to 4) When the FoxBot first starts, it will automatically fault to prevent unintended motion. Press the reset button to clear it. 5) The FoxBot is ready to run in either manual or autonomous mode. 5.5 Manual Mode Refer to the Appendix (8.4 OEM Forklift Operation and Maintenance Manual) for specific instructions on how to operate 5) The FoxBot is ready to run in either manual or autonomous mode. Refer to the Appendix (8.4 OEM Forklift Operation and Maintenance Manual) for specific instructions on how to operate this FoxBot in manual (rider) mode. STOP If, at any time, the operator or nearby personnel feel there is something wrong with the FoxBot or If, at any time, the operator or nearby personnel feel there is something wrong with the FoxBot or an unsafe condition exists, any of the 5 E-Stops may be depressed (activated) to immediately stop all FoxBot function(s). --- ⚠ WARNING The FoxBot should be always driven at safe speeds by a qualified operator when used in “Manual” mode. Failure to observe this label could result in serious bodily injury or death. ⚠ WARNING The FoxBot is designed to carry loads that measure 40 x 48 inches or 1 x 1.2 meters, in either orientation. It is the operator's responsibility to ensure that loads do not exceed this size. A tolerance of 6 inches or 15 cm in each direction is permissible to account for loads that do not exactly conform to the pallet. The stability of the load is the operator's responsibility. ⚠ WARNING If the unit stops and requires troubleshooting or any other type of human intervention, the FoxBot If the unit stops and requires troubleshooting or any other type of human intervention, the FoxBot must be in an open space, outside of the trailer, when attempting restart procedures. This ensures both the safety of the operator and nearby personnel and proper functionality of the unit. If the unit cannot be restarted outside of the trailer, refer to section 5.7 Rescue (Tow) Procedures for more guidance. Failure to observe this label could result in serious bodily injury or death. 5.6 Autonomous Mode - FoxLift App If the unit stops and requires troubleshooting or any other type of human intervention, the FoxBot shall be in an open space, outside of the trailer, when attempting restart procedures. This both ensures safety of operator and nearby personnel, and proper functionality of the unit. If the unit cannot be restarted outside of the trailer, then refer to section 5.7 Rescue (Tow) Procedures for more guidance. Failure to observe this label could result in serious bodily injury or DEATH! Ensure that the pre-operational warehouse and dock location setup steps have been completed prior to continuing with the App setup. NOTICE Each FoxBot delivered comes with two (2) Control Tablets. One is mounted locally on the FoxBot --- ## FoxBot Autonomous Forklift Operation 44 **Figure 16 – Sample Tablet (and APP)** **Figure 17 – Generic Tablet Home Screen (FoxLift App)** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- ## FoxBot Autonomous Forklift Operation 44 2) Select the FoxBot being set up for use. **Figure 18 – Forklift Selection Screen** # NOTICE ## The names shown above are simply for illustration purposes. Your FoxBot name(s) will be **different.** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- ## FoxBot Autonomous Forklift Operation 44 3) **Click “START (INSERT NAME)”** **Figure 19 – Start Forklift Screen** # NOTICE ## The “Run Config” dropdown is for developers ONLY and should NOT be adjusted or modified. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 4) Click “PLACE ZONE”. Figure 20 – Select Place Zone Screen 5) Click “PICK ZONE”. Figure 21 – Select Pick Zone Screen --- ### FoxBot Autonomous Forklift Operation 44 6) **Click “SUBMIT GOAL”.** **Figure 22 – Submit Goal (Run)** # NOTICE **When the FoxBot has completed its “run”, it will simply stop where it dropped the last pallet and** **remain in a stopped state until either moved manually by an operator or a new goal is submitted.** ## 5.7 Shutdown Procedures 1) From the Tablet, select "SHUTDOWN". 2) From the Computer Enclosure, turn the selector switch to the “Manual” mode. 3) From the Computer Enclosure, press the “Reset” button. 4) Manually drive the FoxBot to the designated “charging” station/location. 5) Lower the forks to the floor. 6) Turn off FoxBot using the key switch (turn the key CCW). 7) Plug in 110v shore power (if present) for the computer. 8) Charge the FoxBot Battery per the OEM charger instructions. 9) Charge the e-stop, tablet, and any other accessories. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- ## FoxBot Autonomous Forklift Operation 44 Rescue (Tow) Procedures If the FoxBot loses power and/or communications while inside a box trailer, it may become necessary to initiate “Rescue Tow” procedures. Use caution when executing a rescue towing procedure. When possible, minimize the distance that the FoxBot is towed, to reduce wear on tires and brakes. Attach one end of an appropriately rated tow strap to the designated connection point on the FoxBot. 10) Attach the other end of the tow strap to a vehicle, capable of “pulling/towing” the FoxBot. 11) Carefully pull the FoxBot to the desired location. # NOTICE ## The brakes on the FoxBot automatically engage. **Figure 23 – Typical Rescue Tow Set-up** Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- ### FoxBot Autonomous Forklift Operation 44 ## 5.8 Long-Term Deactivation It may be necessary to remove this equipment from service for extended periods of time. It is highly recommended to perform some basic preservation tasks to maximize the storage life of the equipment and minimize the expense of re-activating the equipment after prolonged storage. Aside from specific requirements, regular visual inspections should occur to ensure that the unit is protected from the harsh elements during storage. Prior to storage, this unit should be washed with water and mild detergent and dried. This unit should be stored in a climate controlled, dry environment. ### 5.8.1 Outside Storage (exposed to the elements) This unit is NOT rated for outside storage. ### 5.8.2 Inside Storage (protected from the elements) All load(s) must be removed from the forks and the forks lowered to rest on the ground during long-term storage. Disconnect the main 36V battery by unplugging. (Press and hold the UPS/Reset Button on the dash for 5 seconds. An audible beep should sound and the light on the switch will extinguish.) ## 5.9 Reactivation # ⚠ WARNING **Do not use worn or outdated parts. When in doubt, contact Fox Robotics Inc. for the appropriate** **replacement part. Failure to observe this label could result in serious bodily injury or DEATH!** # NOTICE ### Additionally, using worn or outdated parts may result in damage to this equipment and/or ### associated system(s)! All assemblies (partial or fully assembled) require a full and detailed inspection prior to re-activation. Some equipment may require only minor adjustments while others may need to be completely refurbished with new seals and/or other perishable parts depending on the length of time the equipment was in storage and how well the periodic inspections/maintenance was carried out. Key items to inspect include all rubber products, seals of any kind and all equipment components with moving parts. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 6 Maintenance ⚠ WARNING Prior to performing any maintenance activities, of any kind, confirm that all energized or pressurized circuits are off and/or bled to zero. Failure to observe this label could result in serious injury or DEATH! ⚠ WARNING Maintenance should be performed by well qualified technicians, who are familiar with all operational aspects of this equipment. Failure to observe this label could result in serious injury or DEATH! This section provides general guidelines for the maintenance of the Fox Robotics, FoxBot Autonomous Forklift (FoxBot). For maintenance activities that fall outside the scope of this manual, refer to the Appendix (8.4 OEM Forklift Operation and Maintenance Manual) for specific maintenance instructions on the basic model “forklift”. ⚠ WARNING Any component modification and/or configuration change to the components in this system, Any component modification and/or configuration change to the components in this system, without approval from Fox Robotics, can dramatically affect the overall performance of the system. Failure to observe this label could result in serious bodily injury or DEATH! ⚠ WARNING In the event that the system supplier is no longer in business and there is no successor to the In the event that the system supplier is no longer in business and there is no successor to the business, the user may arrange for a modification or alteration to this FoxBot provided the user: (a) arranges for modification or alteration to be designed, tested, and implemented by an (a) arranges for modification or alteration to be designed, tested, and implemented by an engineer(s) expert in Automatic Guided Industrial Vehicles and their safety, (b) maintains a permanent record of the design test(s), and implementation of the modification or (b) maintains a permanent record of the design test(s), and implementation of the modification or alteration, (c) makes appropriate changes to the capacity plate(s), decals, tags, and operation and (c) makes appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals. (d) affixes a permanent and readily visible label on the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name of the organization that accomplished the tasks. Failure to observe this label could result in serious bodily injury or DEATH! --- 6.1 Lock Out, Tag Out Procedure ⚠ WARNING Follow your site’s Lock Out, Tag Out (LOTO) procedures to ensure that this equipment is put into a “safe” state. If no procedure(s) exist, then follow the below instruction. Failure to observe this label may result in death or serious injury. 1) From the FoxBot operator cabin (area), turn the key to the “OFF” position. 2) Disconnect the Anderson (main power) Plug from the battery. 2) Disconnect the Anderson (main power) Plug from the battery. 3) If present, install a LOTO lock on the main battery connector cover. Otherwise, install an Anderson plug lockout 3) If present, install a LOTO lock on the main battery connector cover. Otherwise, install an Anderson plug lockout device to prevent inadvertent power-up. 4) Attach a “Out of Service” tag (or similar) in a highly visible location. Such as steering wheel or key. 4) Attach a “Out of Service” tag (or similar) in a highly visible location. Such as steering wheel or key. 5) Once Maintenance activities are complete, remove all lock out devices and tags. 5) Once Maintenance activities are complete, remove all lock out devices and tags. 6) Reconnect the Battery’s Anderson Plug back to the battery. 7) From the FoxBot’s operator cabin (area), turn the key to the “ON” position, to operate or test as desired. 6) Reconnect the Battery’s Anderson Plug back to the battery. 7) From the FoxBot’s operator cabin (area), turn the key to the “ON” position, to operate or test as desired. 6.2 Preventative Maintenance (PM) Schedule (General) NOTICE To satisfy all warranty conditions, the customer is responsible for carrying out all recommended To satisfy all warranty conditions, the customer is responsible for carrying out all recommended preventative maintenance below unless otherwise noted in a Supplier Agreement or Purchase Order. Monthly, Quarterly, 6 Month, and Annually | | Maintenance Task | | --- | --- | | Daily | | | | All regular maintenance recommended by the OEM. See Appendix, (8.4 OEM Forklift Operation and Maintenance Manual) for guidance.See section(8.2 Inspection, Tests & Maintenance Logs). | | Weekly | | | | All regular maintenance recommended by the OEM. See Appendix,(8.4 OEM Forklift Operation and Maintenance Manual) for guidance.See section(8.2 Inspection,Tests&Maintenance Logs). | All regular maintenance recommended by the OEM. See the Appendix, (All regular maintenance recommended by the OEM. See Appendix, (8.4 OEM Forklift Operation and Maintenance Manual) for guidance.) for guidance. *The time intervals presented are only suggested maintenance levels and are not necessarily the only time inspection or maintenance may be *The time intervals presented are only suggested maintenance levels and are not necessarily the only time inspection or maintenance may be necessary for safe operation. If abnormal conditions arise, stop and inspect / repair immediately. --- NOTICE Function Testing should be carried out after any repairs, adjustments, or component replacements Function Testing should be carried out after any repairs, adjustments, or component replacements to this equipment, to ensure satisfactory FoxBot operation. ⚠ WARNING Prior to re-energizing/activating this unit, ensure that all associate maintenance personnel have removed their Lock Out Device, as per your site’s LOTO program. Failure to observe this label could result in serious injury or DEATH! Maintenance and Support Services (Optional Service) Additionally, Fox Robotics will provide the following Preventative Maintenance Services (subject to the conditions and payments specified in a Supplier Agreement or Purchase Order). NOTICE Fox Robotics will NOT provide “daily, weekly, or monthly” PM services. The customer is solely Fox Robotics will NOT provide “daily, weekly, or monthly” PM services. The customer is solely responsible for performing the “daily, weekly, and/or monthly” PM tasks. Maintenance Task All regular maintenance recommended by the OEM. See the Appendix, (All regular maintenance recommended by the OEM. See Appendix, (8.4 OEM Forklift Operation and Maintenance Manual) for guidance.) for guidance. Annually Visually inspect all Automation Equipment and Vehicle Components. Lubricate the Mast Rollers, Lift Brackets, Lift Chain, Tilt Socket, Tilt Cylinder, and Main Drive Gear. Calibrate and Maintain all onboard components, in accordance with the OEM’s recommended service intervals --- NOTICE Fox Robotics will carry out functional testing on the FoxBot and offboard equipment to verify that Fox Robotics will carry out functional testing on the FoxBot and offboard equipment to verify that any component repairs or revisions made during the inspection service satisfy acceptable standards for operational performance, as determined by Fox Robotics. NOTICE Fox Robotics will provide maintenance and testing of the following components: Fox Robotics will provide maintenance and testing of the following components: Drive Components, Safety Lasers, Optical Lenses, Position Sensors, Hydraulic Attachments, Operator Interface, and all Offboard Equipment, as required by the FoxBot application (FoxLift App). 6.3 Troubleshooting NOTICE For general “forklift” troubleshooting, refer to the Appendix, 8.4 OEM Forklift Operation and For general “forklift” troubleshooting, refer to the Appendix, 8.4 OEM Forklift Operation and Maintenance Manual for guidance. ⚠ WARNING If the unit stops and requires troubleshooting or any other type of human intervention, the FoxBot 6.3.1 FoxBot Autonomous Forklift | Symptom | Possible Cause | Remedy | | --- | --- | --- | | FoxBot loses its path(clear path) duringAutonomous operation | Obstruction in the way | Remove obstruction | | Dirty/damaged LiDAR Sensor | Clean/replace Sensor | | | FoxBot won't move | Active E-Stop | Find active E-Stop and deactivate | | Weak battery | Charge/replace battery | | | Loose/bad battery connection/cable | Replace/repair cable/connector | | --- | FoxBot no power | Dead battery | Replace battery | | --- | --- | --- | | Loose/bad battery connection/cable | Replace/repair cable/connector | | 6.3.2 Charging Station/Unit | Symptom | Possible Cause | Remedy | | --- | --- | --- | | | | | | | | | | | | | | | | | | | | | | | | | --- ### FoxBot Autonomous Forklift Maintenance 49 ## 6.4 Maintenance Procedures # ⚠ WARNING **Prior to performing maintenance of any kind, ensure that this equipment is isolated from its power** **source and “Tagged” and “Locked” OUT of SERVICE to prevent inadvertent operation. Refer to your** **company’s Lock Out, Tag Out (LOTO) Procedure, for guidance. Failure to observe this label could** **result in serious bodily injury or DEATH!** # ⚠ WARNING **Prior to performing maintenance of any kind, ensure that the “Parking Brake” is applied to prevent** **the unit from moving. Failure to observe this label could result in serious bodily injury or DEATH!** ## 6.5 General Precautions - Unless being actively worked on, keep all electrical enclosures properly closed and labeled. - Before servicing electrical equipment, ensure that power is OFF by means of a voltmeter or other approved indicator. - Be aware that there may be more than one means of power isolation to electrical components. - If the FoxBot needs to be raised to perform maintenance, then ensure that it is sufficiently blocked/choked to prevent it from unexpectedly falling/rocking/ tipping, etc. ### 6.5.1 Battery Charging # ⚠ DANGER **Charging lead acid batteries is a hazardous activity and extreme care must be used when dealing** **with charging batteries. Failure to observe this label will result in death or serious injury.** # ⚠ WARNING **Battery types and charging systems supplied or specified by the vehicle manufacturer (e.g.,** **opportunity charging) but not referenced in ANSI/NFPA 70 shall have safe operating and charging** **instructions supplied by the vehicle manufacturer. Failure to observe this label could result in** **serious bodily injury or DEATH!** ### 6.5.2 Parking Brake Aside from the daily inspections, the Parking Brake should be tested regularly for functionality. It should be capable of holding back the entire weight of the unit (unloaded), independently of the primary braking systems and with the power source removed. Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- 6.6 Post Maintenance Results ● Perform a thorough, visual inspection of the unit for signs of leaks/abnormalities/damage resulting from ● Perform a thorough, visual inspection of the unit for signs of leaks/abnormalities/damage resulting from maintenance. ● All test equipment calibration certificates should be kept with these test results for future reference, if ● All test equipment calibration certificates should be kept with these test results for future reference, if applicable. ● All post-maintenance test results should be kept with this manual for future reference. ● All post-maintenance test results should be kept with this manual for future reference. Comments: 6.7 Results and Witness Sign-offs | Equipment Identification | | | --- | --- | | Date of Maintain:// | Maint. Performed By: | | Serial Number: | Equip Description: | | Procedure Step # | Pass or Fail | Maintenance Supervisor | Remarks | | --- | --- | --- | --- | | | P/F | | | | | P/F | | | | | P/F | | | | | P/F | | | --- MAINTENANCE WITNESSED AND ACCEPTED BY | Organization | Witness | Signature | | --- | --- | --- | | | | | | | | | | | | | --- 7 Drawings and Bills of Materials Drawings, schematics, and diagrams provide a general view of overall equipment layout, components, location, dimensions, and other useful information required for installation, operation, and maintenance activities. NOTICE All information provided on these drawings is “As Built”. Any changes or field modifications that All information provided on these drawings is “As Built”. Any changes or field modifications that may have taken place, WILL NOT be reflected on these drawings. 7.1 Drawing List | DRAWING NUMBER | DESCRIPTION | PAGE | | --- | --- | --- | | | | | | | | | | | | | | | | | | | | | --- **FoxBot Autonomous Forklift (FoxBot)** Drawings and Bills of Materials 53 Release Date: March 2023 Manual Number: FoxBot-IOM-001 --- **FoxBot Autonomous Forklift (FoxBot)** Drawings and Bills of Materials 54 Release Date: March 2023 Manual Number: FoxBot-IOM-001 --- **FoxBot Autonomous Forklift (FoxBot)** Drawings and Bills of Materials 55 Release Date: March 2023 Manual Number: FoxBot-IOM-001 --- **FoxBot Autonomous Forklift (FoxBot)** Drawings and Bills of Materials 56 Release Date: March 2023 Manual Number: FoxBot-IOM-001 --- 8 Appendix 8.1 Terms and Abbreviations --- 8.2 Inspection, Tests & Maintenance Logs NOTICE Copies of the Daily and Weekly logs shall be provided as stand-alone documents. Completed logs Copies of the Daily and Weekly logs shall be provided as stand-alone documents. Completed logs should be completed and stored where other maintenance records are kept. 8.2.1 Daily Inspections ● FOX-ENG-SOP-001 - Daily Inspections 8.2.2 Daily Function Tests ● FOX-ENG-SOP-002 - Daily Function Tests 8.2.3 Weekly Inspections ● FOX-ENG-SOP-003 - Weekly Inspections --- 8.3 OEM Forklift Specifications | FBCS14N --- | CHARACTERISTICS | | | | FBCS14N | | | --- | --- | --- | --- | --- | --- | | 1 | Capacity at rated load center | lb | kg | 3,000 | 1,364 | | 2 | Capacity load center - distance from fork face | in | mm | 24 | 600 | | 3 | Power voltage | V | | 36 AC electric | | | 4 | Tire type, drive / steer | | | solid rubber / poly | | | 5 | Wheels (x=driven) | | | 2x/2 | | | 6 | Maximum fork height lift with standard triplex mast | in mm | 188 | 4,775 | | --- | --- | --- | --- | --- | | 7 | Free fork height lift with standard triplex mast | in mm | 35 | 889 | | 8 | Fork width | in mm | 3.9 | 100 | | 9 | Fork thickness | in mm | 1.4 | 35 | | 10 | Fork spacing-out-to-out minimum | in mm | 9.5 | 240 | | 11 | Fork spacing-out-to-out maximum | in mm | 36.5 | 920 | | 12 | Tilt angle, forward/backward | deg | | 3/5 | | 13 | Mast width | in mm | 22 | 570 | | 14 | Length to fork face | in mm | 63.0 | 1,601 | | 15 | Overall chassis width | in mm | 41 | 1,041 | | 16 | Overall lowered height(mast) | in mm | 82.9 | 2,105 | | 17 | Overall lowered height to top of overhead guard | in mm | 88.0 | 2,240 | | 18 | Overall height with extended mast | in mm | 236.6 | 6,009 | | 19 | Step height | in mm | 9.4 | 240 | | 20 | Battery roller height | in mm | 7.0 | 178 | | 21 | Load moment constant $ ^{[2]} $ | in mm | 12.2 | 310 | | 22 | Minimum outside turning radius $ ^{[3]} $ | in mm | 50.8 | 1,291 | | 24 | Travel speed, loaded / empty | mph | kph | 8/8 | 12.9/12.9 | | --- | --- | --- | --- | --- | --- | | 25 | Lift speed, loaded (triplex) | mph | kph | 83 | 0.42 | | 26 | Lift speed, empty (triplex) | fpm | m/s | 118 | 0.60 | | 27 | Lower speed, loaded (triplex) | fpm | m/s | 102 | 0.52 | | 28 | Lower speed, empty (triplex) | fpm | m/s | 98 | 0.50 | | 29 | Gradeability, loaded (maximum) at 1 mph/1.6km/h | % | | 15 | | | 30 | Gradeability, empty (maximum) at 1 mph/1.6km/h | % | | 15 | | | 31 | Truck weight-empty with minimum weight battery | lb | kg | 8,424 | 3,829 | | --- | --- | --- | --- | --- | --- | | 32 | Battery weight(minimum) | lb | kg | 1,700 | 773 | | 33 | Battery weight(maximum) | lb | kg | 2,000 | 909 | | 34 | Chassis type, stand / sit | | stand | | | --- | --- | --- | --- | --- | | 35 | Wheelbase[4] | in mm | 41.7 | 1,059 | | 36 | Ground clearance – center of wheelbase | in mm | 4.0 | 102 | | 37 | Ground clearance – lowest point at mast | in mm | 3.0 | 76 | | 38 | Tire size, drive | in | 16 x 7 x 10.5 | | | 39 | Tire size, steer | in | 10 x 5 x 6.5 | | | 40 | Brake type | | electromagnetic disc | | | 41 | Traction motor type | | | AC induction | | | --- | --- | --- | --- | --- | --- | | 42 | Traction motor output kW(60 minute rating) | HP | kW | 5.4(x2) | 4.0(x2) | | 43 | Pump motor type | | | AC induction | | | 44 | Pump motor output kW(15% rating) | HP | kW | 17.4 | 13.0 | | 45 | Steer motor type | | | AC induction | | | 46 | Steer motor output kW(60 minute rating) | HP | kW | 0.9 | 0.7 | | 47 | Battery maximum capacity-A/H(6 hour rating) | AH | | 1,240 | | | 48 | Battery compartment length(front-back) | in | mm | 14.25 | 362 | | 49 | Battery compartment width(side-side) | in | mm | 38.50 | 978 | | 50 | Battery compartment height | in | mm | 32.00 | 813 | --- --- --- **FoxBot Autonomous Forklift** Appendix 63 # 8.4 OEM Forklift Operation and Maintenance Manual Release Date: March 2023 Manual Number: FoxBot-IOM-001 Rev 0 --- # Operation & Maintenance Manual ## Stand-Up Counterbalance Forklift Truck **Keep this manual in your stand-up counterbalance forklift truck as a** **ready reference.** OMFEA-AFB50-180 --- --- FOREWORD (3) Safe driving and load handling procedures. It is the employer's responsibility to make sure the operator can see, hear and has the physical and mental ability to operate the forklift truck safely. mental ability to operate the forklift truck safely. It is also important that a qualified person experienced in forklift truck operation should guide new operators through several driving and load handling operations before they attempt to operate the forklift truck on their own. truck on their own. Note: Note: - -This manual contains information necessary for the operation and "Do-it-yourself" maintenance of standard forklift trucks. -Optional equipment is sometimes installed; it can change some operating characteristics described in this manual. Before operating such a forklift truck, make sure the necessary instructions are available and understood. -Forklift truck operator training is provided through your authorized dealer. They will be glad to help you and answer any questions you may have about operating your new forklift truck. Forklift Note: -If you resell a forklift truck, be sure to attach the original Operation & Maintenance Manual to the forklift truck. In some countries, strict regulations do not allow imported forklift trucks for resale. For resale information, contact your authorized dealer. For resale information, contact your authorized dealer. -If a forklift truck is resold from another country, an Operation & Maintenance Manual attached to the forklift truck may not meet your country's rules and regulations. For manual information, contact your authorized dealer. contact your authorized dealer. -If your forklift truck has an attachment, refer to the attachment supplier for the proper attachment operating instructions. - If you resell a forklift truck, be sure to attach the original Operation & Maintenance Manual to the forklift truck. In some countries, strict regulations do not allow imported forklift trucks for resale. For resale information, contact your authorized dealer. - If a forklift truck is resold from another country, an Operation & Maintenance Manual attached to the forklift truck may not meet your country's rules and regulations. For manual information, contact your authorized dealer. - If your forklift truck has an attachment, refer to the attachment supplier for the proper attachment operating instructions. --- ## HOW TO USE THIS MANUAL The following safety signs and NOTE are used in this manual to emphasize important and critical instructions. This is the safety alert symbol. It is used to alert you of potential personal injury hazards or damage that could occur to property or the environment. Obey all safety messages that follow this symbol to reduce the risk of serious injury, death, or damage. Be sure to read these precautionary instructions and all safety related decals installed on your forklift truck before you operate it. **DANGER** DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. **WARNING** WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. **CAUTION** CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. **NOTE: Note indicates important matters and useful information on operation and maintenance.** This sign indicates prohibited matters. We cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique is not specifically recommended, you must satisfy yourself that it does not pose a safety hazard to yourself and others. You should also ensure the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. All information, specifications, and illustrations in this manual are based on the latest data available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the most complete and current information from your authorized dealer before starting any job. Additional manuals are available from your authorized dealer. **Directional terms:** The directions "Left", "Right", "Front" and "Rear" are given from the viewpoint of the operator facing forward. **iv** --- Forklift Truck Models Covered in This Manual | Model | Serial Number | | --- | --- | | FBCS14N | AFB50-00011-09999 | | FBCS16N | AFB51-00011-09999 | | FBCS18N | AFB52-00011-09999 | --- **LOCKOUT/TAGOUT** LOCKOUT is not only used to disconnect a power supply, but also to physically isolate power sources from supplying power to the forklift truck, with a lockout device, disabling the forklift truck. TAGOUT also reduces the risk of operating the machine during LOCKOUT with the use of a "DO NOT OPERATE" or similar warning tag. Warning tags are ideally placed on the lockout device to indicate the forklift truck must not be operated until the tag is removed. Combined use of LOCKOUT/TAGOUT reduces the risk of accidental or inadvertent operation. A forklift truck that has been LOCKED OUT and TAGGED OUT must not be operated until the required service has been completed and the forklift truck is no longer LOCKED OUT and TAGGED OUT. **NOTE: In the United States, employers have a responsibility to provide a safe workplace under the** regulations of the Occupational Safety and Health Administration (OSHA). For more information on OSHA LOCKOUT/TAGOUT see the 29 CFR 1910.147 and Appendix A to 29 CFR 1910.147 (available at www.osha.gov). **WARNING** -Personnel could be exposed to death or serious injury if LOCKOUT/TAGOUT procedure is not performed prior to servicing the forklift truck. -Only the trained technician who performs the LOCKOUT/TAGOUT procedure must release the forklift truck back into service. -Only proper LOCKOUT/TAGOUT devices must be used. **WARNING** Basic requirements before servicing equipment: -Wear appropriate personal protective equipment. -Move equipment to secure maintenance area. -Park the forklift truck on a hard and level surface with the forks lowered until the forktips touch the ground, parking brake applied, direction lever in the NEUTRAL position, engine stopped, and the wheels blocked. -Turn the key switch to the OFF position. -Remove the key from the key switch. Typical LOCKOUT/TAGOUT procedures are shown below: **Battery forklift truck** (1) Remove the key to the forklift truck from the key switch and access the battery compartment. (2) Disconnect the battery plug/connector and their connections from the forklift truck and place in the proper lockout device. (3) Lock the lockout device. (4) TAGOUT the forklift truck by placing a “DO NOT OPERATE” or similar warning tag where it can be visibly seen. (5) After the work is finished, the technician with the key to the forklift truck must unlock the lockout device and remove the tag. **vi** --- TABLE OF CONTENTS CHAPTER 1 SAFETY RULES FOR FORKLIFT TRUCK OPERATORS 1.1 General.....1 - 1 1.2 Operating Environment.....1 - 2 1.3 Location of Warning and Safety Decals.....1 - 2 1.4 Description of Danger, Warning, and Caution Decals.....1 - 4 1.4.1 Load Forks and Mast Warning Decal.....1 - 4 1.4.2 General Warning Decal.....1 - 5 1.4.3 Alarm Must Sound Decal.....1 - 7 1.4.4 Overhead Guard Impact Decal.....1 - 7 1.4.5 Pinch Point Decal.....1 - 7 1.4.6 High Voltage Danger Decal.....1 - 7 1.4.7 Load Backrest Extension Warning Decal.....1 - 8 1.4.8 Warning Operation Without This Device Decal.....1 - 8 1.4.9 Multi-function Control Handle Decals.....1 - 8 1.4.10 Fuse Label Decal..... CHAPTER 2 KNOW YOUR FORKLIFT TRUCK 2.1 Controls and Indicators.....2 - 1 2.2 Operator Display.....2 - 9 2.2.1 Display Unit.....2 - 9 2.2.2 Setting the Display Unit.....2 - 10 2.2.3 Keyless Access Systems.....2 - 15 2.2.4 General Information About Operation with Keyless Access Systems.....2 - 15 2.2.5 Operating the Keypad.....2 - 15 2.2.6 Operation of the Display Unit.....2 - 19 2.3 Functionality of Operator Presence System.....2 - 22 2.3.1 Preventing Operator’s Absence.....2 - 22 2.3.2 Mast Operation.....2 - 22 2.3.3 Travel Operation.....2 - 22 2.4 Controlled Roll Back Function.....2 - 23 2.5 Battery Disconnect.....2 - 23 2.6 Fork Pins.....2 - 23 2 --- ***TABLE OF CONTENTS*** ## CHAPTER 3 HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE 3.1 Know What Forklift Truck Stability Is ... 3 - 1 3.2 Do's and Don't's to Avoid Tip Over ... 3 - 3 ## CHAPTER 4 OPERATION 4.1 New Forklift Truck Break-In ... 4 - 1 4.2 Before Starting Operations ... 4 - 1 4.3 Before Moving the Forklift Truck ... 4 - 1 4.3.1 Before Moving the Forklift Truck-Overview ... 4 - 1 4.3.2 Start-Up Procedure ... 4 - 1 4.4 Adjustable Comfort Operator Platform ... 4 - 2 4.5 Adjusting the Arm Rest ... 4 - 3 4.6 Forklift Truck Operation ... 4 - 3 4.7 Changing Speed ... 4 - 4 4.8 Travel Direction ... 4 - 4 4.8.1 Travel Direction Definition ... 4 - 4 4.8.2 Parking Brake Warning Icon ... 4 - 5 4.9 Changing Directions ... 4 - 5 4.10 Braking ... 4 - 5 4.11 Plugging ... 4 - 8 4.12 At the End of Each Shift ... 4 - 8 ## CHAPTER 5 OPERATING TECHNIQUES 5.1 Stacking Methods ... 5 - 1 5.1.1 Stacking Loads Differing in Size ... 5 - 1 5.1.2 Stacking Small Identical Loads ... 5 - 1 5.1.3 Stacking Large Identical Loads ... 5 - 1 5.2 Lifting the Load ... 5 - 1 5.3 Traveling with the Load ... 5 - 3 5.4 Unloading ... 5 - 4 5.5 Working on Grades ... 5 - 5 ## CHAPTER 6 STORING THE FORKLIFT TRUCK 6.1 End of Shift Storage ... 6 - 1 6.2 Long-term Storage ... 6 - 1 ## CHAPTER 7 TRANSPORTATION HINTS 7.1 Forklift Truck Shipping ... 7 - 1 7.2 Forklift Truck Lifting and Tiedown Information ... 7 - 1 ## CHAPTER 8 SPECIAL SITUATIONS 8.1 Care in Cold Weather ... 8 - 1 8.1.1 Battery ... 8 - 1 8.2 Care in Hot Weather ... 8 - 1 8.2.1 Hot Weather Battery Service ... 8 - 1 **viii** --- 8.3 Cold Storage Specifications..... 8-1 8.3.1 Description of the Environment and Operation of the Forklift Trucks.....8-1 8.4 Care in Severe Dust or Lint Conditions..... 8-2 CHAPTER 9 MAINTENANCE 9.1 General.....9 - 1 9.2 Inspection Precautions.....9 - 2 9.3 Maintenance Schedule.....9 - 3 9.3.1 Maintenance Schedule - Overview.....9 - 3 9.3.2 Pre-start Inspection.....9 - 3 9.3.3 Service Intervals.....9 - 4 9.4 Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First.....9 - 5 9.5 Every 50 Service Hours or Weekly, Whichever Comes First.....9 - 7 9.6 One Month After Delivery of Forklift Truck.....9 - 7 9.7 Every 1000 Service Hours or 6 Months, Whichever Comes First.....9 - 7 9.8 Every 2000 Service Hours or 12 Months, Whichever Comes First.....9 - 8 9.9 Ready to Operate.....9 - 8 9.9.1 Now Your Forklift Truck is Ready 10.1 Refill Capacities.....10 - 1 10.2 Battery Compartment Dimensions.....10 - 1 10.3 Lubrication Chart.....10 - 2 10.4 Fluids.....10 - 3 10.5 Electrical Fuses.....10 - 3 10.5.1 Checking the Electrical Fuses.....10 - 3 10.6 Usage Conditions.....10 - 4 10.7 Forklift Truck Weights.....10 - 5 CHAPTER 11 TO THE MITSUBISHI FORKLIFT TRUCK OWNE 11.1 Instructions for Ordering Parts.....11-1 11.2 To the Mitsubishi Forklift Truck Owner.....11-2 11.3 Transfer of Ownership Report for Mitsubishi Customers Only.....11-3 --- Your forklift truck was manufactured in accordance with the National Fire Protection Association 1.1 GENERAL Standards Development Foundation (ANSI/ITSDF) B56.1, Safety Standard for Low and High Lift Trucks. Operate this forklift truck in accordance with local regulations. See www.itsdf.org web site for more information on the B56.1 Safety Standards for Low Lift and High the B56.1 Safety Standards for Low Lift and High Lift Trucks. The most effective way of reducing the risk of serious injuries, or even death, to you and others, is for you to know how to operate the forklift truck properly. Drive alertly and avoid maneuvers or conditions that could cause accidents. As the operator, you are responsible for the safe As the operator, you are responsible for the safe operation of this forklift truck. Be professional. DO NOT operate a forklift truck if it is in need of DO NOT operate a forklift truck if it is in need of maintenance, repair or appears to be unsafe in any way. Report all unsafe conditions immediately to your supervisor, then contact your authorized forklift truck dealer. DO NOT attempt any adjustments or repairs unless (NFPA) No. 505 and the American National Standards Institute, Inc. / Industrial Truck Standards Development Foundation (ANSI/ITSDF) B56.1, Safety Standard for Low and High Lift B56.1, Safety Standard for Low and High Lift Trucks. Operate this forklift truck in accordance See www.itsdf.org web site for more information on DO NOT attempt any adjustments or repairs unless you are trained and authorized to do so. Continuing improvement and advancement of Be professional. product design may have caused changes to your forklift truck, which are not included in this publication. Whenever a question arises regarding your forklift truck, or this publication, please contact your authorized forklift truck dealer for the latest available information. States users should be familiar with the Occupational Safety and Health Administration (OSHA), and ANSI/ITSDF B56.1, Safety Standard for Low and High Lift Trucks. All forklift truck users should be familiar with their Local, Regional, and National regulations. United States users should be familiar with the Occupational Safety and Health Administration (OSHA), and ANSI/ITSDF B56.1, Safety Standard for Low and High Lift Trucks. --- (crossbar) underride. Horizontal rack-beam underride and potential “forks-trailing,” direction is a recognized potential hazard, due to the rack system design in certain warehouses. Specifically, the potential for rack underride is created by a horizontal rack-beam positioned at a height that the beam can “fit” between the top of the unit’s chassis/frame and between the top of the unit’s chassis/frame and the bottom of its overhead guard, and there are no corresponding ground level racks or guard rails. On July 27, 2009, the U.S. Department of Labor’s Occupational Safety and Health Administration (“OSHA”) published an important Safety and Health Information Bulletin (“SHIB”) specifically addressing this potential hazard. This bulletin, entitled “Standup Forklift Under-Ride Hazards” (the "SHIB"), is available for review at https:// www.osha.gov/dts/shib/shib072709.pdf. Always look in the direction of travel and have a clear view of the area ahead. Never drive into clear view of the area ahead. Never drive into another object. If you see horizontal rack-beams that could introduce a potential rack-beam intrusion, immediately notify your employer and provide them with the above OSHA SHIB information Always look in the direction of travel and have a clear view of the area ahead. Never drive into another object. Horizontal rack-beam underride and potential control measures to remove or minimize the risk. rack-beam intrusion into the operator’s A key resource is your local dealer. compartment of a stand-up end control forklift truck traveling in tight confines in the “reverse,” or If you or your workplace safety engineers or “forks-trailing,” direction is a recognized potential consultants are concerned about potential hazard, due to the rack system design in certain hazards in the workplace involving the use of warehouses. Specifically, the potential for rack forklift trucks, we encourage you to contact your underride is created by a horizontal rack-beam local dealer who can advise you about various positioned at a height that the beam can “fit” optional accessories available that may help you between the top of the unit’s chassis/frame and minimize such potential risk in your application. the bottom of its overhead guard, and there are no corresponding ground level racks or guard Don’t wait! Evaluate your forklift truck and work If you see horizontal rack-beams that could introduce a potential rack-beam intrusion, immediately notify your employer and provide them with the above OSHA SHIB information no corresponding ground level racks or guard Don’t wait! Evaluate your forklift truck and work environment today and contact your local dealer if environment today and contact your local dealer if you think there are potential hazards that need to On July 27, 2009, the U.S. Department of Labor’s be discussed further. To find an MCFA dealer near Occupational Safety and Health Administration you visit www.mcfa.com. (“OSHA”) published an important Safety and Health Information Bulletin (“SHIB”) specifically addressing this potential hazard. This bulletin,1.3 LOCATION OF WARNING AND entitled “Standup Forklift Under-Ride Hazards”SAFETY DECALS (the "SHIB"), is available for review at https:// www.osha.gov/dts/shib/shib072709.pdf. There are several specific warning decals on your forklift truck. Their exact location and description of Always look in the direction of travel and have a the potential hazard are reviewed in this section. clear view of the area ahead. Never drive into Please take the time to familiarize yourself with these decals. If you see horizontal rack-beams that could Be sure you can read all warning and instruction introduce a potential rack-beam intrusion, decals. If you cannot, clean or replace them. Use immediately notify your employer and provide soap and water to clean them. them with the above OSHA SHIB information You must replace a decal if it is damaged, missing or cannot be read. If a decal is on a part that is replaced, make sure a new decal is placed on the new part. Contact your dealer for new decals. Be sure you can read all warning and instruction decals. If you cannot, clean or replace them. Use soap and water to clean them. --- 8. LOAD CAPACITY PLATE 5. 6. 3. OVERHEAD GUARD IMPACT WARNING DECAL 4. ALARM WILL SOUND WARNING DECAL 7. LOAD FORKS AND MAST WARNING DECAL FUSE DECAL GENERAL WARNING 6. GENERAL WARNING DECAL MAST WARNING DECAL 15. LOAD CAPACITY PLATE 16. 13. LOAD BACKREST EXTENSION WARNING DECAL 12. HIGH VOLTAGE DANGER DMECAL 14. RE-INSTALL MANUAL DECAL 15. COLD STORAGE DECAL 16. UL DECAL EXTENSION WARNING DECAL RE-INSTALL MANUAL RE-INSTALL MANUAL DECAL COLD STORAGE DECAL UL DECAL 22. LUBRICATION AND MAINTENANCE CHART UL DECAL 23. BATTERY COMPARTMENT LIMITS --- -DO NOT stand or walk under the forks. -DO NOT place any part of your body between the mast and -DO NOT place any part of your body between the mast and the chassis. | WARNING | | | --- | --- | | - | DO NOT stand or ride on the forks. | | - | DO NOT stand or ride on a load or pallet on the forks. | | - | DO NOT stand or walk under the forks. | | - | DO NOT place any part of your body between the mast and the chassis. | --- Battery(s), Controller, Lift and Tilt systems, including forks or attachments, chains, cables and limit switches, brakes, steering | WARNING | | | --- | --- | | FOR SAFE OPERATION OBSERVE THE FOLLOWING WARNINGS: | | | 1. | Do not operate this forklift truck unless you have been trained and authorized to do so. Read all warnings and instructions in operator's manual and on this forklift truck. Operation and Maintenance Manual is supplied with this forklift truck or available from our dealers. | | 2. | Do not operate this forklift truck until you have checked its condition. Give special attention to Warning devices, Tires, Rims, Horn, Lights, Battery(s), Controller, Lift and Tilt systems, including forks or attachments, chains, cables and limit switches, brakes, steering mechanisms, fuel system, hydraulic hoses and guards. | | 3. | Operate forklift truck only in the normal operating position. Never place any part of your body into the mast structure or outside the forklift truck. Do not carry passengers. | | 4. | Do not operate this forklift truck without overhead guard. | | 5. | Do not handle loads which are higher than the load backrest or load backrest extension unless load is secured so that no part of it could fall backward. | | 6. | Do not handle unstable or loosely stacked loads. Use special care when handling long, high or wide loads to avoid losing the load, striking bystanders, or tipping the forklift truck. | | 7. | Protruding racks or other objects can enter the operator area trapping or crushing you, resulting in serious injury to you or others. Know you work zone, be alert for changed conditions | | 8. | Do not overload forklift truck. Check capacity plate for load weight and load center information. | | 9. | Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause forklift truck to slide or overturn. Use special care when traveling without load as the risk of overturn is greater. | | 10. | Elevate forks or other lifting mechanism only to pick up to stack a load. Lift and lower with mast vertical or tilted slightly back—NEVER FORWARD. Watch out for obstructions, especially overhead. | | 11. | Operate tilting mechanism slowly and smoothly. Do not tilt forward when elevated except to pick up or deposit a load. When stacking, use only enough backward tilt to stabilize load. | | 12. | Travel with load or lifting mechanism as low as possible and tilted back. Always look in direction of travel. Keep a clear view, and when load interferes with visibility travel with load or lifting mechanism trailing (except when climbing ramps). | attachments, chains, cables and limit switches, brakes, steering mechanisms, fuel system, hydraulic hoses and guards. 3. Operate forklift truck only in the normal operating position. Never place any part of your body into the mast structure or outside the forklift truck. Do not carry passengers. 4. Do not operate this forklift truck without overhead guard. 4. Do not operate this forklift truck without overhead guard. 5. Do not handle loads which are higher than the load backrest or load backrest extension unless load is secured so that no part of it could fall backward. 6. Do not handle unstable or loosely stacked loads. Use special care when handling long, high or wide loads to avoid losing the load, when handling long, high or wide loads to avoid losing the load, striking bystanders, or tipping the forklift truck. 7. Protruding racks or other objects can enter the operator area trapping or crushing you, resulting in serious injury to you or others. Know you or crushing you, resulting in serious injury to you or others. Know you work zone, be alert for changed conditions attachments, chains, cables and limit switches, brakes, steering mechanisms, fuel system, hydraulic hoses and guards. work zone, be alert for changed conditions 8. Do not overload forklift truck. Check capacity plate for load weight and load center information. 9. Start, stop, travel, steer and brake smoothly. Slow down for turns and 9. Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause forklift truck to slide or overturn. Use special care when traveling without load as the risk of overturn is greater. of overturn is greater. 10. Elevate forks or other lifting mechanism only to pick up to stack a load. Lift and lower with mast vertical or tilted slightly back—NEVER FORWARD. Watch out for obstructions, especially overhead. FORWARD. Watch out for obstructions, especially overhead. 11. Operate tilting mechanism slowly and smoothly. Do not tilt forward when elevated except to pick up or deposit a load. When stacking, Do not overload forklift truck. Check capacity plate for load weight and Protruding racks or other objects can enter the operator area trapping or crushing you, resulting in serious injury to you or others. Know you Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause forklift truck to slide when elevated except to pick up or deposit a load. When stacking, use only enough backward tilt to stabilize load. 12. Travel with load or lifting mechanism as low as possible and tilted back. Always look in direction of travel. Keep a clear view, and when load interferes with visibility travel with load or lifting mechanism or crushing you, resulting in serious injury to you or others. Know you Do not overload forklift truck. Check capacity plate for load weight and angle or turn. When forklift truck is loaded, travel with load uphill. When forklift truck is empty, travel with lifting mechanism downhill. 13. Use special care when operating on ramps—travel slowly, and do not angle or turn. When forklift truck is loaded, travel with load uphill. When forklift truck is empty, travel with lifting mechanism downhill. --- ***CHAPTER 1 SAFETY RULES FOR FORKLIFT TRUCK OPERATORS*** 14. Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at cross aisles and wherever vision is obstructed. 15. When using forks, space forks as far as part as load will permit. Before lifting, be sure load is centered and forks are completely under load. 16. Do not allow anyone to stand or pass under load or lifting mechanisms. 17. Do not lift personnel except on a securely attached specially designed work platform. Use extreme care when lifting personnel. Place forklift truck controls in neutral and apply brakes. Lift and lower smoothly. Be available to operate controls as long as personnel are on the work platform. Never transport personnel on forks or work platform. 18. Before getting off forklift truck, neutralize control, fully lower lifting mechanism and set parking brake. When leaving forklift truck unattended, also shut off power. 19. Stay inside compartment until forklift truck comes to a complete halt. 20. Be aware of steering direction inherent to specific chassis. 21. Extend forks/attachments only to pick up or discharge loads. **1-6** --- The operator is responsible for the safe operation of this vehicle. | WARNING | | | --- | --- | | This vehicle is equipped with a travel alarm.ALARM MUST SOUND when operating this vehicle.Failure to maintain a clear view in the direction of travel could result in injury or death.The operator is responsible for the safe operation of this vehicle. | | | WARNINGThis vehicle is equipped with a travel alarm.ALARM MUST SOUNDwhen operating this vehicle.Failure to maintain a clear view in the direction of travel could result in injury or death.The operator is responsible for the safe operation of this vehicle。EN 51258943 | | | WARNING | | | --- | --- | | Moving mast-crush points. Keep all body parts clear of mast. | | | WARNING Moving Mast-Crush Points. Keep All Body Parts Clear Of Mast. | | | WARNING | | | --- | --- | | Operation without this device in place may be hazardous. This overhead guard conforms to ANSI/ITSDF B56.1. This design also passed a vertical impact test of 8,000 foot pounds. | | | WARNING Operation without this device in place may be hazardous. This overhead guard conforms to ANSI/ITSDF B56.1. This design also passed a vertical impact test of 8,000 foot pounds. EN 51360744 | | The operator is responsible for the safe operation 1.4.6 --- toward the operator. • Contact your servicing dealer for details on expanding “Aux 2” functionality. Standard Decal - P/N 51656110a - Contact your servicing dealer for details on expanding "Aux 2" functionality. - Shipped standard from factory when equipped with or without a side shifter. • For future expansion to this functionality, contact your servicing dealer. contact your servicing dealer. WARNING OPERATION WITHOUT THIS DEVICE DECAL WARNING Operation without this device in place may be Operation without this device in place may be Push and Pull Decal - P/N 517042195 HANDLE DECALS • Parameter setting accomplished via laptop using Truck Tool by trained service using Truck Tool by trained service Standard Decal - P/N 51656110a professional if needed. Shipped standard from factory when • Move the switch to the left to pull in the equipped with or without a side shifter. attachment. Move the switch to the right to secondary auxiliary function is needed for • For future expansion to this functionality, contact your servicing dealer. Contact your servicing dealer for details - Move the switch to the left to pull in the attachment. Move the switch to the right to push out the attachment. - For future expansion to this functionality, contact your servicing dealer. --- Clamp Decal - P/N 51704222 release the load. • Note that the multi-function control handle must return to neutral between clamp and unclamp functions. unclamp functions. • For future expansion of this functionality, contact your servicing dealer. 1.4.10 FUSE LABEL DECAL | STANDARD | | | | | --- | --- | --- | --- | | 2F16 | 5A/58V | 4F7 | 2A/58V 6F6 2A/58V | | 1F13 | 5A/58V | F4 | 2A/58V 4F8 2A/58V | | F25 | 2A/58V | 5F11 | 2A/58V 1F12 2A/58V | | OPTIONS | | | | | 6F9 | 2A/58V | 5F1 | 2A/58V 5F7 2A/58V | | 5F2.2 | 10A/58V | 5F2.1 | 10A/58V 6F9 2A/58V | | | | | 5F2.3 10A/58V | 1.4.10 FUSE LABEL DECAL | STANDARD | | | | | | --- | --- | --- | --- | --- | | 2F16 | 5A/58V | 4F7 | 2A/58V | 6F6 2A/58V | | 1F13 | 5A/58V | F4 | 2A/58V | 4F8 2A/58V | | F25 | 2A/58V | 5F11 | 2A/58V | 1F12 2A/58V | | OPTIONS | | | | | | 6F9 | 2A/58V | 5F1 | 2A/58V | 5F7 2A/58V | | 5F2.2 | 10A/58V | 5F2.1 | 10A/58V | 6F9 2A/58V | | 5F2.3 10A/58V | | | | | System must return to neutral between clamp and Gearbox unclamp functions. Oil For future expansion of this functionality, Grease contact your servicing dealer. | Part | Lubricant | | Period(Hours) | | --- | --- | --- | --- | | FreezerApplication | Normal | | | | HydraulicSystem | 1 | 2 | 2000 | | GearboxOil | 3 | 4 | 2000 | | GreasePoints | 5 | 5 | SeeOMMfordetails | | GreaseMastChannels | 6 | 6 | 2000 | | Chains | 7 | 7 | 1000 | Renolin CLP 100 (50%) + Shell Tellus S2 MA 10 (50%) 4- Shell Omala Oil 100 or Renolin CLP 100 4 - Shell Omala Oil 100 or Renolin CLP 100 4- Shell Omala Oil 100 or Renolin CLP 100 5- Mobil Ronex MP NLGI 2 6- Mobil Grease XHP 460 (462 Moly) NGLl2 6 - Mobil Grease XHP 460 (462 Moly) NGLI2 Consult factory for unusual operating conditions. --- LUBRICATION INSTRUCTIONS | Part | Lubricant | | Period (hours) | | --- | --- | --- | --- | | Fresher Application | Normal | | | | Hydraulic System | 1 | 2 | 2000 | | Gearbox Oil | 3 | 4 | 2000 | | Gearbox Pumps | 5 | 5 | See CAM for details | | Grease Mast Channels | 6 | 6 | 2000 | | Chains | 7 | 7 | 1000 | | Lubricant Interpretations (Commercial CAM for Noncommercial Brands and Detail Information) | | | | | 1. Model DTE 10 Excelleration MR 310 | | | | | 2. Model DTE 10 Exceleration MR 310 | | | | | 3. Model DTE 10 Exceleration LFT 22 | | | | | 4. Shell Grease Oil 100 (50%) or Shell Grease Oil 100 (100%) | | | | | 5. Shell Grease Oil 100 or Shell Grease Oil 100 (100%) | | | | | 6. Shell Grease Oil 100 or Shell Grease Oil 100 (100%) | | | | | 7. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 8. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 9. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 10. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 11. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 12. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 13. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 14. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 15. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 16. Model DTE 100 (50%) or Model DTE 100 (100%) | | | | | 17. CAT Chain and Cable Lubricator or Turbine LT 22 | | | | 1.4.12 UL DECAL Classified UL $ ^{\circ} $ 1.4.13 REINSTALL MANUAL DECAL Reinstall operation & maintenance manual in manual pocket when not in use. 1.4.14 NAMEPLATE | Item | Designation | Item | Designation | | --- | --- | --- | --- | | 52 | Type | 59 | Hour rate | | 53 | Rated capacity | 60 | Max. battery weight in kg/lb | | 54 | Net weight excl battery +/-5% | 61 | Manufacturer | | 55 | Serial number | 62 | Manufacturer's logo | | 56 | Load center distance | 63 | Battery voltage | | 57 | Attachment | 64 | Min. battery weight in kg/lb | | 58 | Battery ID | 65 | Max. battery capacity in Ah | Reinstall operation & maintenance manual in manual pocket when not in use. Contact dealer or manufacturer for replacement. Contact dealer or manufacturer for replacement. | Item | Designation | Item | Designation | | --- | --- | --- | --- | | 66 | Type | 70 | Load center D-Offset | | 67 | Serial number | 71 | B-Fork height | | 68 | Load center A-Horizontal | 72 | Capacity | | 69 | Load center B-Vertical | | | --- 1.4.16 FUSE WARNING DECAL | WARNING | | | --- | --- | | To reduce the risk of fire, replace with the same DC fuse type and current rating. Fuse must have a minimum voltage rating of 36 Volts. | | | WARNINGTO REDUCE THE RISK OF FIRE,REPLACE WITH THE SAME DC FUSETYPE AND CURRENT RATING.FUSE MUST HAVE A MINIMUMVOLTAGE RATING OF 36 VOLTS。 | | 1.4.18 | WARNING | | --- | | Capacity specified for forklift truck requires tires authorized by the manufacturer. | | CAPACITY SPECIFIED FOR THE TRUCK REQUIRES TIRES AUTHORIZED BY THE MANUFACTURER | 1.4.19 BATTERY COMPARTMENT LIMITS Machines rated UL Type EE must utilize enclosed and lockable battery enclosure. | BATTERY COMPARTMENT LIMITS | | | | | | | | | | --- | --- | --- | --- | --- | --- | --- | --- | --- | | MODEL | | MAX. LENGTH | | | MAX. WIDTH | | | | | R | R | R | R | R | R | | | | | ET0214 | FBC536 EIS414 | ST0. | 382 | 14.25 | | | | | | OPT | 413 | 16.25 | | | | | | | | OPT | 464 | 16.25 | | | | | | | | OPT | 464 | 16.25 | | | | | | | | ET0216 | FBC536 EIS414 | ST0. | 382 | 14.25 | 980 | 38.5 | 805 | 31.6 | | OPT | 464 | 16.25 | | | | | | | | ET0388 | FBC538 EIS588 | ST0. | 540 | 21.25 | | | | | | OPT | 540 | 21.25 | | | | | | | | BATTERY LENGTH AND WIDTH MUST be 12mm (0.5") SMALLER FOR INSTALLATION AND RADIAL CLEARANCE. | | | | | | | | | | MACHINE SETTED LIKE TYPE MEIST MUST USETEN ENCLOSSED AND LOOKABLE BATTERY EXLOUSURE. | | | | | | | | | | SIDE BATTERY SET SCREW MUST BE TIGHTENED AT THEM TO ELIMINATE LATERAL BATTERY MOVEMENT, MINIMUM BATTERY WEIGHT MUST BE INSTALLED FOR PHONE MANAGER STABILITY. | | | | | | | | | | | | | | | ENG | JHD81-0500G | | | Capacity specified for forklift truck requires tires authorized by the manufacturer. Always charge the battery in a well-ventilated area. Flammable gas comes out of the battery while charging.DO NOT smoke,keep flames away.DO NOT use equipment that is liable to produce sparks in this area. --- Dress properly for the job! Dress properly for the job! Wear personal protective equipment appropriate for the conditions of your work places. WARNING dealer or manufacturer for replacement. WARNING WARNING Know how to use a first aid kit and a fire extinguisher, and where to get prompt assistance. Know all signals and traffic rules! Know who is responsible for signaling. Learn to tell at a glance what the signal means, and what action you should take. --- Operate only in approved areas! Certain areas such as those containing hazardous flammable gases, liquid or other combustibles require a Safety Rated forklift truck if your forklift truck is not Safety Rated,the area must be avoided. no successor in the interest to the business, may the user arrange for a modification or alteration to a forklift truck, provided, however, that the user. -Arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in forklift truck and their safety -Maintains a permanent record of the design, test(s) and implementation of the modification or alteration -Approves and makes appropriate changes to the capacity plate(s), decals, changes to the capacity plate(s), decals, tags and instruction handbook -Affixes a permanent and readily visible label to the forklift truck stating the manner in which the forklift truck has manner in which the forklift truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those organization that accomplished those tasks - Affixes a permanent and readily visible label to the forklift truck stating the manner in which the forklift truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks --- D00661 970023 Always protect against acid burns! WARNING WARNING Inspect your forklift truck prior to operation! Inspect your forklift truck prior to operation! At the beginning of each shift, fill out a daily inspection sheet. Defects when found must be immediately reported and corrected before operating the forklift truck, or the forklift truck must be taken out of service. --- DO NOT remove the overhead guard! DO NOT operate a damaged or defective forklift truck! Keep operator compartment clean! Keep your hands and shoes, as well as the floor, and controls (steering wheel, multi-function control handle, operator presence and traction pedals) clean and free of grease, mud and other materials. A slip may cause an accident. Contact your authorized dealer for repairs. WARNING DO NOT operate an unsafe forklift truck If the forklift truck has an "OUT OF SERVICE" or similar warning tag, the forklift truck must not be operated until it has been restored to a safe operating condition. Inspect a forklift truck before you operate it to be sure that it is properly maintained and in good working order. --- WARNING baking soda to help neutralize the acid. If acid gets in your eyes, flush them Handle batteries carefully! and see a doctor at once. WARNING Always check overhead clearance! Use lights in dark, dim areas! 15_4 If acid gets in your eyes, flush them immediately with large amounts of water and see a doctor at once. WARNING Stay within the confines of the forklift truck! Keep your arms, feet, legs etc. inside the operator's compartment. DO NOT put any part of the body outside the operator compartment of the forklift truck. --- handling loads. - and attachment warning labels carefully and understand its function fully before using it. - When using an attachment, BE SURE to read the attachment instructions manual and attachment warning labels carefully and understand its function fully before using it. Check fork pins for engagement! If the fork pins are not properly engaged, the forks can get out of position. This may cause loads or forklift truck to become unstable. --- ability to properly operate the forklift truck. WARNING Keep all parts of your body away from moving parts such as the mast, carriage and attachments. DO NOT place any part of your body between the overhead guard and the mast. If the mast moves unexpectedly, you could get caught between the mast and overhead guard and a serious accident could occur. overhead guard and the mast. If the mast moves unexpectedly, you could get caught between the mast and overhead guard and a serious accident --- dock accident, step off and away from the forklift truck as quickly as possible. truck as quickly as possible. If your forklift truck is equipped with an optional rear operator guard (“door”) you need to be aware Avoid off-center loading! that while this option offers additional protection in Set the forks as far apart as possible for certain applications, where bar-type materials Set the forks as far apart as possible for certain applications, where bar-type materials maximum support of the pallet or load. Too small could intrude into the operator’s compartment, of forks spread could cause instability of the load. this option necessarily increases the exit time and DO NOT pick up an off-center load. thus the potential for serious injury to the operator Check work places for high risk! When working on docks,ramps, platforms and other high-risk areas, use adequate blocks to reduce the risk of the forklift truck from falling off. DO NOT pick up an off-center load. thus the potential for serious injury to the operator in emergencies such as tip-over and off-dock accidents, and may create potential shear and WARNINGpinch points, increase compartment heat, and pinch points, increase compartment heat, and contribute to operator fatigue. WARNING This forklift truck is equipped with a travel alarm. The alarm must sound when operating this forklift truck! Make sure the alarm is in working order. The horn can also be used to alert other forklift trucks or pedestrians. Always look in the direction of travel --- Read and understand all of the following safety guidelines for maximum operation of the forklift 2. Do not operate this forklift truck until you Wear a hard hat if recommended or required have checked its condition. Give special attention to Warning devices, Tires, truck. 1.6 OPERATING PRECAUTIONS | WARNING | | --- | | Read and understand all of the following safety guidelines for maximum operation of the forklift truck. | WARNING by your employer or applicable regulations. attention to Warning devices, Tires, Rims, Horn, Lights, Battery(s), Controller, Lift and Tilt systems, including WARNING forks or attachments, chains, cables and limit switches, brakes, steering mechanisms, fuel system, hydraulic hoses and guards. 3. Operate forklift truck only in the normal 3. Operate forklift truck only in the normal operating position. Never place any part of your body into the mast structure or outside the forklift truck. Do not carry passengers. 4. Do not operate this forklift truck without overhead guard. 5. Do not handle loads which are higher than the load backrest or load backrest than the load backrest or load backrest extension unless load is secured so that DO avoid slippery surfaces! no part of it could fall backward. Slow down for wet and slippery surfaces. 6. Do not handle unstable or loosely stacked loads. Use special care when OPERATING PRECAUTIONS handling long, high or wide loads to handling long, high or wide loads to avoid losing the load, striking WARNING bystanders, or tipping the forklift truck. Read and understand all of the following safety 7. Protruding racks or other objects can guidelines for maximum operation of the forklift enter the operator area trapping or crushing you, resulting in serious injury to you or others. Know you work zone, be alert for changed conditions be alert for changed conditions 8. Do not overload forklift truck. Check capacity plate for load weight and load center information. 8. Do not overload forklift truck. Check capacity plate for load weight and load center information. --- back—NEVER FORWARD. Watch out for obstructions, especially overhead. 11. Operate tilting mechanism slowly and smoothly. Do not tilt forward when elevated except to pick up or deposit a load. When stacking, use only enough backward tilt to stabilize load. backward tilt to stabilize load. 12. Travel with load or lifting mechanism as low as possible and tilted back. Always look in direction of travel. Keep a clear view, and when load interferes with visibility travel with load or lifting visibility travel with load or lifting mechanism trailing (except when climbing ramps). 13. Use special care when operating on ramps—travel slowly, and do not angle or turn. When forklift truck is loaded, or turn. When forklift truck is loaded, travel with load uphill. When forklift truck is empty, travel with lifting mechanism downhill. 14. Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at cross aisles and wherever vision is obstructed. 17. Do not lift personnel except on a securely attached specially designed work platform. Use extreme care when lifting personnel. Place forklift truck controls in neutral and apply brakes. Lift and lower smoothly. Be available to operate controls as long as personnel are on the work platform. Never transport personnel on forks or work platform. wherever vision is obstructed. 15. When using forks, space forks as far as part as load will permit. Before lifting, be sure load is centered and forks are completely under load. 16. Do not allow anyone to stand or pass back—NEVER FORWARD. Watch out 21. Extend forks/attachments only to pick up for obstructions, especially overhead. or discharge loads. 11. Operate tilting mechanism slowly and smoothly. Do not tilt forward when WARNING elevated except to pick up or deposit a elevated except to pick up or deposit a load. When stacking, use only enough backward tilt to stabilize load. backward tilt to stabilize load. 12. Travel with load or lifting mechanism as low as possible and tilted back. Always low as possible and tilted back. Always look in direction of travel. Keep a clear view, and when load interferes with visibility travel with load or lifting work platform. Use extreme care when lifting personnel. Place forklift truck controls in neutral and apply brakes. Lift and lower smoothly. Be available to operate controls as long as personnel are on the work platform. Never transport are on the work platform. Never transport personnel on forks or work platform. mechanism trailing (except when Mounting the forklift truck! -Never get on or off a moving forklift 15. When using forks, space forks as far as truck. part as load will permit. Before lifting, be -Never jump off or jump on a forklift truck. sure load is centered and forks are-Never jump off or jump on a forklift truck. completely under load. Dismounting the forklift truck! 16. Do not allow anyone to stand or pass-When leaving the operator compartment under load or lifting mechanisms. under load or lifting mechanisms. face the rear of the forklift truck. 17. Do not lift personnel except on a-Power down forklift truck before securely attached specially designed dismounting. work platform. Use extreme care when dismounting. work platform. Use extreme care when lifting personnel. Place forklift truck-Do not use any of the controls as controls in neutral and apply brakes. Lift handholds when leaving the forklift truck controls in neutral and apply brakes. Lift handholds when leaving the forklift truck and lower smoothly. Be available to and use three-points of contact. operate controls as long as personnel are on the work platform. Never transport are on the work platform. Never transport stepping down from the operator personnel on forks or work platform. compartment. - Power down forklift truck before dismounting. - Look both ways and down before stepping down from the operator compartment. --- Look where you are going! DO NOT MOVE Move your forklift truck safely! and activate the horn at cross aisles and other locations where vision is obstructed. -Yield the right of way to pedestrians. - The operator is required to slow down and activate the horn at cross aisles and other locations where vision is obstructed. DO NOT pass another forklift truck! and activate the horn at cross aisles and other locations where vision is Yield the right of way to pedestrians. DO NOT allow any riders! Do not allow anyone to ride on the forks or on any other part of the forklift truck, at any time. --- DO NOT engage in stunt driving or horseplay! Stunt driving and horseplay is hazardous for both DO NOT engage in stunt driving or horseplay! Stunt driving and horseplay is hazardous for both the forklift truck operator and fellow workers. WARNING Always be aware of people near your forklift Always be aware of people near your forklift truck. DO NOT move until they are at a safe distance WARNING --- Travel safely on grades with a loaded forklift truck! When traveling with a load, load shall always point up the grade regardless of direction. zone, be alert for changed conditions Do not drive into another object. When using the forklift truck, always look behind you before going in reverse. Protruding racks or other objects can enter the operator area trapping or crushing you, resulting in serious injury to you or others. Know your work zone, be alert for changed conditions Do not drive into another object. --- Use forks properly! Use forks properly! Always stay within the capacity! Danger! Keep out! DO NOT use damaged pallets! Make sure pallets and skids are sturdy and in DO NOT move! Read the capacity plate to make sure a load is If someone is standing next to your forklift truck, --- SLOW DOWN and DO NOT speed when approaching loads! Also, it could damage the load. When lifting a pallet! 100761 DO NOT allow anyone to walk or stand under raised forks! When lifting a pallet! DO NOT allow unloading from raised loads! Failure to follow this rule could cause serious Also, it could damage the load. WARNING Ensure the load is not too high! Set the forks as far apart as possible for maximum support of the pallet or load. Too small maximum support of the pallet or load. Too small a fork spread could cause instability of the load. Do not lift loads without the load backrest as it can be hazardous. --- position to control the forklift truck as long as personnel are on the work platform. DO NOT WARNING transport personnel on forks or work platform. WARNING Handle only stable and safely arranged loads! Park in authorized areas only! transport personnel on forks or work platform. WARNING NEVER park this forklift truck on a ramp or grade! button IN. WARNING • Remove the key from the key switch. • When leaving the forklift truck • When leaving the forklift truck unattended, disconnect the battery. DO NOT abuse your forks! Fork misuse could cause accidents, serious --- Parking a disabled machine safely! OPERATE or similar warning tag to the forklift truck. • Disconnect or remove battery from forklift truck. • Contact your authorized dealer. D00384V Disconnect or remove battery from Contact your authorized dealer. 1-28 D00317V --- -Before starting work, check the allowable load of dock plate, and if it does not have enough strength to withstand the weight of the forklift truck carrying a load, DO NOT use it. -When entering a trailer, use outriggers -When entering a trailer, use outriggers so that trailer will not sink. -Travel slowly on dock plate when getting in or out of trailers or railroad. in or out of trailers or railroad. -Ask the driver of the trailer not to move the trailer until the work is completed. -Use any anchoring equipment available in the dock to secure the trailer or railroad, and also secure the dock plate -Obey the instructions of the supervisor when working as a team. - Ask the driver of the trailer not to move the trailer until the work is completed. - Use any anchoring equipment available in the dock to secure the trailer or railroad, and also secure the dock plate to prevent it from falling off. Before starting work, check the allowable load of dock plate, and if it does not have enough strength to withstand the weight When entering a trailer, use outriggers D00403V when working as a team. DO NOT side shift the forks with the load raised higher than 150 cm (59 in.) unless safety is assured by the load stack or carrier deck just below the forks. --- REVERSE with a load, always pay attention to the position of the load. If not, the load could collide with nearby objects. objects. 1-30 F00071V not, the load could collide with nearby D00083V loaded or unloaded forklift truck! When making turns, reduce speed to a safe level When making turns, reduce speed to a safe level consistent with the operating environment. --- | WARNING | | --- | | During operation, do not extend any parts of your body outside the operator compartment and never place any part of your body between objects when one of the objects is moving. | | Always stay clear of drop-offs and edges (e.g. loading docks). | | In the event of an imminent tip over, or off the dock accident, step off and away from the forklift truck as quickly as possible. | | If your forklift truck is equipped with an optional rear operator guard (“door”) you need to be aware that while this option offers additional protection in certain applications, where bar-type materials could intrude into the operator's compartment, this option necessarily increases the exit time and thus the potential for serious injury to the operator in emergencies such as tip-over and off-dock accidents, and may create potential shear and pinch points, increase compartment heat, and contribute to operator fatigue. | certain applications, where bar-type materials could intrude into the operator’s compartment, this option necessarily increases the exit time and thus the potential for serious injury to the operator allows the operator to shift body weight and position to maintain maximum comfort. The open rear design minimizes operator fatigue by making it easy to get on and off the forklift truck. It also allows for the quickest exit from the forklift truck— allows for the quickest exit from the forklift truck— an important safety feature should the forklift truck begin to tip or fall from an elevated height, such as a loading dock or ramp. Location and function of the controls in the operator compartment are shown on the following pages. Location and function of the controls in the operator compartment are shown on the following pages. --- ***CHAPTER 2 KNOW YOUR FORKLIFT TRUCK*** **Description of Indicators and Controls** **2-2** --- | Item | Control and Display Element | Standard/Optional | Function | | --- | --- | --- | --- | | 1 | Key switch | ● | Switches control current ON and OFF. Removing the key prevents the forklift truck from being switched ON by unauthorized personnel. | | | Code lock | ○ | Turns the forklift truck ON. | | 2 | Control and display unit | ● | Display of steering direction, warning indicators, event messages and mode indicators. | | 3 | Headlight drive direction switch | ○ | Switches light ON and OFF. | | 4 | Multi-function control handle | ● | Operates the following functions: - Travel direction forward/reverse - Mast lifting/lowering - Horn button | | 4A | AUX 2 | ○ | Shipped standard from factory when equipped with or without a side shifter. Aux 2 button is not used, but available if a secondary auxiliary function is needed. For future expansion to this functionality, contact your servicing dealer. Options are: - Fork Positioner Attachment - Used to widen or narrow the fork spread. Move the switch to the left to narrow the fork spread. Move the switch to the right widen the fork spread. - Push Pull Attachment - Used to push out and pull in the attachment. Verify the “Aux Lock Option” parameter is properly set. Parameter setting accomplished via laptop using Truck Tool by trained service professional, if needed. Move the switch to the left to pull in the attachment. Move the switch to the right to push out the attachment. - Clamp Attachment - Used to clamp and release a load. Move the switch to the left and then push the Multi-pilot forward to clamp the load. Move the switch to the right and then push the multi-function control handle forward to release the load. Note that the multi-function control handle must return to neutral between clamp and unclamp functions. | | 5 | Horn button | ● | Activates the horn. | | 6 | Fan switch | ○ | Switches fan ON and OFF. | | 7 | Operator reading light switch | ○ | Switches operator light ON and OFF. | | 8 | Headlight fork direction switch | ○ | Switches light ON and OFF. | --- CHAPTER 2 KNOW YOUR FORKLIFT TRUCK | Item | Control and Display Element | Standard/Optional | Function | | --- | --- | --- | --- | | 9 | Steering wheel | ● | Travel direction command | | 10 | Cross switch | ● | Tilting the forks forward/back. Side shifter to the left/right. | | 11 | Operator presence pedal | ● | - Pedal pressed down hydraulic functions fully functional. - Pedal pressed down simultaneously with Traction Pedal - forklift truck fully functional. - Pedal up - Driving and hydraulic functions disabled, forklift truck brakes activated. | | 12 | EMERGENCY STOP switch | ● | Turns the power supply ON and OFF. | | 13 | Traction pedal | ● | - Pedal pressed down simultaneously with Operator Presence Pedal - forklift truck fully functional. - Pedal up - forklift truck brakes activated. | | | Lever | ● | Adjust the adjustable Comfort operator platform to the operator's weight. | | ● | Standard equipment | ○ | Optional equipment | --- | Item | | Description | Item | | Description | | --- | --- | --- | --- | --- | --- | | 14 | ● | Mast | 17 | ● | Fork carriage | | 15 | ● | Free lift cylinder | 18 | ● | Load wheels | | 16 | ● | Load back rest | 19 | ● | Load forks | | | ● | Standard equipment | | ○ | Optional equipment | | 20 | ○ | Warning beacon | 23 | ○ | Parabolic mirror | | 21 | ○ | Floor spot | 24 | ○ | Screen | | 22 | ○ | Fan | 25 | ○ | Fire extinguisher | | | ● | Standard equipment | | ○ | Optional equipment | --- | Control | Operator Action | Forklift Truck Response | | --- | --- | --- | | Battery Connector | | Vehicle is ready for operation | | FunctionThe Battery disconnect provides a mechanical joint to connect or disconnect from the battery.ActivationTo connect battery, align mating connector halves and push together. To disconnect battery, pull connector halves apart. | | | | Emergency Power Off(EPO)Button | | Push down to stop all forklift truck function. | | | Turn clockwise and pull up,and cycle key ONto allow forklift truck function. | | | Key Switch(OFF)0(ON)1 | (OFF)0(ON)1 | Forklift truck performs SelfTest-then forklift truck is ready for operation. | | FunctionThe key switch turns electrical power to control circuits ON or OFF.SelfTest-Then forklift truck is ready for operation.ActivationTo turn power on,rotate key to the right.To turn power OFF,rotate key to the left.In an emergency,press the Emergency Power Off Button located to the right of the multi-function control handle. | | | | Traction Pedal | | 1.Brake is released. 2.Travel system is enabled when pressed down simultaneously with Operator Presence Pedal. | | | 1.Brake is applied. 2.Travel system is disabled. | | | | | 1.Mast Interlock is released. 2.Mast system is enabled. 3.Brake is released. 4.Travel system is enabled when pressed down simultaneously with Traction Pedal. | --- | Control | | Operator Action | Forklift Truck Response | | --- | --- | --- | --- | | Operator Presence Pedal | | Upward foot icon | 1. Mast Interlock is applied. 2. Mast system is disabled. 3. Brake is applied. 4. Travel function is disabled. | | Horn | Press Button | | Horn icon | | Directional/Speed Control | Move multi-function control handle toward forks to move forklift truck | | Horn icon | | Move multi-function control handle away from forks to move forklift truck | | Horn icon | | | Directional Reverse Steering Control | | Circular arrow | Circular arrow | | Circular arrow | Circular arrow | | | | Directional Forward Steering Control (Optional) | | Circular arrow | Circular arrow | | Circular arrow | Circular arrow | | | \dd{}ddplus{\ddag} --- | Control | | Operator Action | Forklift Truck Response | | --- | --- | --- | --- | | Lift | Pull multi-function control handle back toward the right side of forklift truck to lift forks. | | | | Lower | Push multi-function control handle forward toward left side of forklift truck to lower forks. | | | | Sideshift Right(Optional) | Press bottom control pad button to sideshift forks right. | | | | Sideshift Left(Optional) | Press top control pad button to sideshift forks left. | | | | Tilt Mast Forward | Press right control pad button to tilt mast forward. | | | | Tilt Mast Back | Press left control pad button to tilt mast back. | | | 2.2 OPERATOR DISPLAY 2.2.1 DISPLAY UNIT Description The display unit represents the operator-forklift truck interface. It acts both as a display and control unit for the operator. --- | Item | Control or Display | Function | | --- | --- | --- | | 20 | Direction display | The arrow displays the current travel direction of the forklift truck and the current wheel position in 15° segments. | | 21 | Travel direction preselection | Displays the selected travel direction. | | 22 | Information field | Shows event messages and optional information such as speed, lift height, load weight and remaining operating time. | | 23 | Clock | Time display | | 24 | Power display | Shows the available power in the travel program selected. | | 25 | Pictogram field | Displays the pictograms. | | 26 | Operating program | Shows the operating program selected. | | 27 | Hour meter | Operating hours are counted while the forklift truck is operational and the operator presence pedal is activated. | | 28 | Button allocation | See Button Assignment of the Display Unit. | | 29 | Battery capacity display | Battery discharge status | | 30 | Button | Selection button for the corresponding functions | | 31 | Settings | Changes to the menu to administer the codes or transponders | | 32 | MPH display | Shows miles per hour. | 15^{\circ} --- Main Menu Icons | Symbol | Meaning | | --- | --- | | | Information field toggleAllows the information displayed in the information field to be changed. | | | Slow travelReduced travel speed | | | Travel program downChanges the travel program | | | Travel program upChanges the travel program | | | SettingTo change to the menu to administer the codes or transponders | | | Switching OFF additional equipment(○):Switching OFF(○)is only available in the display if the forklift truck is switched ON with an access code.Switches OFF forklift truck | | | Parking BrakeShows parking brake status. | Additional Symbols | Symbol | Meaning | | --- | --- | | | Lighting(○): Switches the lighting ON/OFF | | | Floor spot(○): The floor spot projects a colored dot onto the ground4-4,5m in front of the forklift truck when driving forwards.The floor spot is intended to make people aware of the route being taken by the forklift truck. | (\mathrm{}\mathrm{O}),) --- | Symbol | Meaning | | --- | --- | | 雨滴 | Working light(○): Switches the working light ON/OFF | | 齿轮 | Setting(○): To change to the menu to administer the codes | | 机械 | Change master code(○): To change the master code and to activate the keypad | | 钥匙 | Edit access code(○): To add or delete access codes | | 向上箭头 | Selection up(○): To choose access codes | | 向下箭头 | Selection down(○): To choose access codes | | C | Delete(○): To delete access codes selected | | 加号 | Add(○): To add a new access code | | Back箭头 | Back(○): Cancels the current procedure and returns to the previous menu. | | √ | Confirm(○): To confirm an entry | --- yellow Operating error Warning red Forklift truck malfunction | Symbol | Meaning | Color | Function | | --- | --- | --- | --- | | STOP | Stop notice | red | Functions deactivated due to forklift truck malfunction | | Warning | Warning | yellow | Operating error | | red | Forklift truck malfunction | | | | Operator platform Operator presence pedal | Operator platform Operator presence pedal | yellow | Operator platform is not occupied and the travel switch is being pressed. (The yellow symbol does not light up if the forklift truck is equipped with pedestrian mode.) | | Service mode indicator | Service mode indicator | yellow | Maintenance is due, see Maintenance Section | | red | Safety inspection is due see Safety Section | | | | Battery capacity display | Battery capacity display | yellow | Battery capacity ≤30% | | red | Battery capacity ≤20% | | | | Overheat indicator | Overheat indicator | yellow | Lifting, lowering and travel speeds reduced due to overtemperature. | | red | Lifting, lowering and travel functions disabled due to overtemperature. | | | | Slow travel | Slow travel | green | Reduced travel speed | | Parking Brake | Parking Brake | red | Parking brake set. | | green | Parking brake released. | | | --- | Symbol | Procedure | | --- | --- | | | Press setting. | | | Press clock. | | | Set the time by pressing the selection down/up. | | | Press confirm to move to the next digit or to confirm the time. | --- | Item | Description | | --- | --- | | 84 | Display unit(EasyAccess softkey):- Description, see Setting the Display Unit- Entry 4-place master code and access code- Storage locations for a maximum of 10 access codes- For master and access codes consisting of the numbers 1 to 4 | | 85 | Keypad(EasyAccess PIN Code):- Consisting of keys 0 to 9 and C(delete)- Entry 4-place master code and access code- Storage locations for a maximum of 100 access codes | NOTE: After a valid code is entered or a valid transponder is used, a green check mark appears in the display unit. After an invalid code is entered or an - Factory setting master code: 2-4-1-2 After an invalid code is entered or an invalid transponder is used, a red x appears and the entry must be repeated. 2.2.5.1 TURNING ON THE FORKLIFTTRUCK WITH AN ACCESS CODE appears and the entry must be repeated. (85). 2. Enter the access code with the keypad (85). --- 85. KEYPAD The forklift truck is turned on. 86. TURN OFF ICON 86. TURN OFF ICON The forklift truck is turned off. 87. 88. CHANGE MASTER CODE ICON 3. Press the button under the "Change master code" icon (88). 87. SETTING ICON The forklift truck is turned on. 85. KEYPAD TURNING OFF THE FORKLIFT TRUCK The master code that was entered appears in the Press the button under the "Setting" icon The master code is deleted. 6. Enter the new master code (85) using the master code" icon (88). 85. KEYPAD NOTE: The new master code must be distinct from --- The new master code is displayed. NOTE: If the new master code was entered 90. CONFIRM ICON 2. Press the button under the "Setting" icon (87). 91. BACK ICON 87. The new master code is displayed. The master code is queried. NOTE: If the new master code was entered 4. Enter the master code (85) using the The master code is changed. 85. KEYPAD All access codes appear in the display unit (84). Press the button under the "Setting" icon --- 90. CONFIRM ICON 91. BACK ICON 93. ADD ICON 85. KEYPAD NOTE: The new access code must be distinct from 85. KEYPAD 90. CONFIRM ICON 90. CONFIRM ICON The new access code appears in the display unit (84). 90. CONFIRM ICON 2.2.5.5 DELETING AN ACCESS CODE 1. Switch forklift truck on. Enter the new access code (85) using the 2. Press the button under the "Setting" icon (87). (87). 87. 3. Press the button under the "Edit access NOTE: The new access code must be distinct from code" icon (92). existing access codes. 92. EDIT ACCESS CODE ICON The master code is queried. --- 85. KEYPAD All access codes appear in the display unit (84). 85. KEYPAD 84. DISPLAY UNIT 89. DELETE ICON 6. Press the button under the "Delete" icon (89). 2. Enter the access code using the keys under the display (84). All access codes appear in the display unit (84). 91. BACK ICON 94. SELECT DOWN ICON The access code was deleted. All access codes appear in the display unit (84). 86. TURN OFF ICON 86. TURN OFF ICON The forklift truck is turned off. 1. Switch forklift truck on. --- 3. Press the button under the "Change master code" icon (88). 87. SETTING ICON 4. Enter the master code using the buttons under the display unit (84). 89. DELETE ICON The master code is deleted. 1. DISPLAY UNIT 89. DELETE ICON 6. Enter the new master code using the buttons under the display unit (84). The master code is deleted. The master code is deleted. 6. Enter the new master code using the NOTE: The new master code must be distinct from existing access codes. Press the button under the "Change The new master code is displayed. master code" icon (88). NOTE: If the new master code was entered CHANGE MASTER CODE ICON Enter the master code using the buttons under the display unit (84). under the display unit (84). The master code is deleted. Enter the new master code using the buttons under the display unit (84). buttons under the display unit (84). NOTE: The new master code must be distinct from existing access codes. 87. 2. Press the button under the "Setting" icon (87). 87. SETTING ICON --- The master code is queried. 4. Enter the master code using the buttons The master code is queried. 84. DISPLAY 90. CONFIRM ICON NOTE: If the new access code was entered The master code is queried. incorrectly, delete the access code see Enter the master code using the buttons Deleting an Access Code and add a new access code. under the display unit (84). access code. 8. To return to the main menu, press the button under the "Back" icon (91). 93. ADD ICON button under the "Back" icon (91). A new access code was added. 2.2.6.5 2.2.6.5 DELETING AN ACCESS CODE 1. Switch forklift truck on. 2. Press the button under the "Setting" icon (87). (87). A new access code was added. All access codes are displayed. Press the button under the "Add" icon 87. 3. Press the button under the "Edit access code" icon (92). The master code is queried. 92. EDIT ACCESS CODE ICON The master code is queried. --- 84. DISPLAY All access codes are displayed. 2-22 This function prevents the forklift truck from traveling or lifting without the operator pressing the operator presence pedal and traction pedal. For 6. Press the button under the "Delete" icon (89). The access code was deleted. details, see the tables below. 2.3.2 MAST OPERATION When the operator raises their foot from the 89. DELETE ICON Switch Pedal Not ON Pressed Pressed ON Pressed Pressed When the operator raises their foot from the operator presence pedal, the mast will not lift, All access codes are displayed. lower, or tilt even if the multi-function control handle Select the access code you want to delete is operated. To activate the mast functions, press 91. BACK ICON Select the access code you want to delete with the button under the "Selection down" the operator presence pedal. Mast Function Operator Key Traction 94. SELECT DOWN ICON | Key Switch | Traction Pedal | Operator Presence Pedal | Fork Lift | Fork Tilt | | --- | --- | --- | --- | --- | | ON | Not Pressed | Pressed | Active | Active | | ON | Pressed | Not Pressed | Not Active | Not Active | When the operator raises their foot from the traction pedal, the system cuts power to the traction motors. traction pedal, the system cuts power to the traction button under the "Back" icon (91). motors. To activate the traction motors and start traveling, press the operator presence pedal and the traction 2.3.3 TRAVEL OPERATION press the operator presence pedal and the traction pedal simultaneously. --- Travel Function | Key Switch | Traction Pedal | Operator Presence Pedal | Travel | | --- | --- | --- | --- | | ON | Pressed | Not Pressed | Not Active | | ON | Pressed | Pressed | Active | | ON | Not Pressed | Pressed | Not Active | | WARNING | | | --- | --- | | - | Check the function of the operator presence system at the daily(prestart) inspection. | | - | Lower the load completely to the ground，apply the parking brake,and turn the key switch to the OFF position. | | - | The parking brake is not automatically applied. | grade and the weight of the load. NOTE: This function is activated only in the output torque range of the traction motor. If the Pressed Not Active Pressed forklift truck can be decelerated until it stops in the output torque range, the electromagnetic brake will also be activated when the forklift truck stops. Forklift truck descends slowly when traction lever is shifted into neutral position or traction pedal is | DANGER | | --- | | This forklift truck contains high voltage. Disconnect the battery before servicing. | When adjusting the fork spread, be careful not to pinch your hand between forks and lift bracket. | WARNING | | --- | | When adjusting the fork spread, be careful not to pinch your hand between forks and lift bracket. | --- the original position to lock the forks. Position each fork the same distance from the center of the backrest. 2.7 REPLACING THE FORKS ON A FORKLIFT TRUCK | CAUTION | | --- | | After adjusting the fork spread, restore the pins to the original position to lock the forks. Position each fork the same distance from the center of the backrest. | lifting device. Each fork could weigh in excess of 45 kg (100 lb.). How to remove forks (1) Slide the forks, one at a time, to the installation/removal recess on the bottom (2) (3) Use a lifting device to move the forks away from the forklift truck. 2-24 | DO NOT try to install or remove a fork without a lifting device. Each fork could weigh in excess of 45kg(100lb.) | | --- | How to remove forks After adjusting the fork spread, restore the pins to the original position to lock the forks. Position each fork the same distance from the 3. WOOD BLOCKS REPLACING THE FORKS ON A FORKLIFT TRUCK (3) Carefully slide the forks, one at a time, FORKLIFT TRUCK onto the lift bracket so the top hook of the fork is placed above the top carriage bar. Remove a fork from the lift bracket to replace it or to access other parts of the forklift truck for (4) Raise the lift bracket to engage the top hooks allowing the bottom hooks to pass hooks allowing the bottom hooks to pass through the installation/ removal recess. WARNING (5) Carefully slide each fork on the carriage DO NOT try to install or remove a fork without a bar so both the upper and lower hooks lifting device. Each fork could weigh in excess of engage the lift bracket. lifting device. Each fork could weigh in excess of engage the lift bracket. (6) Lock the forks in place by engaging the fork lock pins. 2.8 SAFETY EQUIPMENT Slide the forks, one at a time, to the installation/removal recess on the bottom center of lift bracket bar. • Operator presence pedal center of lift bracket bar. Tilt the lift bracket FORWARD, then lower • Traction pedal it until the fork hook disengages the forks • Overhead guard from the lift bracket. from the lift bracket. • Load Backrest extension Use a lifting device to move the forks away from the forklift truck. • Horn - Operator presence pedal - Load Backrest extension - Horn · Warning decals --- • Alarm, travel, reverse (optional) • Strobe (optional) • Lights: mast mounted (optional) • Rear spot light (optional) - Electronic back up smart alarm (optional) - Alarm, travel, forward and reverse (optional) - Alarm, travel, reverse (optional) - Strobe (optional) - Lights: mast mounted (optional) - Rear spot light (optional) --- of the forklift truck, the balance point is the drive tires of the vehicle. Because the forklift truck and its weight are fixed, when you increase the load distance from the balance point or increase the weight of the load, you will decrease the capacity rating of the vehicle. The load on the forks must be rating of the vehicle. The load on the forks must be balanced by the weight of the forklift truck and the battery. The location of center of gravity of both the battery. The location of center of gravity of both the forklift truck and the load is also a factor. This basic principle is used for picking up a load. The ability of the forklift truck to handle a load is discussed in terms of center of gravity and both forward and sideways stability. 3.1.1.2 CENTER OF GRAVITY Center of Gravity (CG) is defined as the point of an object where its weight is evenly distributed. If the object is uniform, its geometric center will be the same as its CG. If it is not uniform, the CG could be a point on either side of the geometric center. When the forklift truck picks up a load, the forklift truck and load have a new, combined CG. 3.1.1.1 STABILITY AND CENTER OF GRAVITY The stability of the forklift truck is determined by the location of its CG, or if the forklift truck is loaded, the combined CG. The forklift truck has moving parts and, therefore, has a CG that moves. The CG moves up and down as the mast moves up and 1. CENTER OF GRAVITY weight are fixed, when you increase the load distance from the balance point or increase the • condition and grade of surfaces on which weight of the load, you will decrease the capacity the forklift truck is operated. rating of the vehicle. The load on the forks must be 3.1.1.4 FORKLIFT TRUCK STABILITY BASE balanced by the weight of the forklift truck and the 3.1.1.4 FORKLIFT TRUCK STABILITY BASE battery. The location of center of gravity of both the forklift truck and the load is also a factor. This basic Stability is a measure of the forklift truck's forklift truck and the load is also a factor. This basic Stability is a measure of the forklift truck's principle is used for picking up a load. The ability of resistance to overturning. For the forklift truck to be stable, the CG must stay within the area of the the forklift truck to handle a load is discussed in stable, the CG must stay within the area of the terms of center of gravity and both forward and forklift truck stability base—a triangular area between the drive tires and the steer tires. If the between the drive tires and the steer tires. If the CG moves outside of the line on either side of the CENTER OF GRAVITY stability base, the forklift truck will tip to the side. When lift height is added a stability pyramid is When lift height is added a stability pyramid is Center of Gravity (CG) is defined as the point of an formed—a triangular area between the top of the mast, down to the drive tires and steer tires. object where its weight is evenly distributed. If the mast, down to the drive tires and steer tires. object is uniform, its geometric center will be the same as its CG. If it is not uniform, the CG could be 3.1.1.5 CAPACITY (WEIGHT AND LOAD a point on either side of the geometric center. CENTER) When the forklift truck picks up a load, the forklift truck and load have a new, combined CG. The capacity of the forklift truck is shown on the capacity plate. It is determined by the weight and load center. The load center is determined by the location of the CG of the load. The load center shown on the capacity plate is the horizontal distance from the front face of the forks, or the load face of an attachment, to the CG in the load. The location of the CG of the vertical direction is the same as the horizontal dimension. CENTER OF GRAVITY read. STABILITY AND CENTER OF GRAVITY The stability of the forklift truck is determined by the parts and, therefore, has a CG that moves. The CG moves up and down as the mast moves up and have to reduce the safe operating load because the forklift truck stability may be reduced. The forklift truck should not be operated if its capacity plate does not indicate capacity. 3.1.1.6 CAPACITY NAME PLATE 3.1.1.7 ATTACHMENTS Keep in mind that, unless otherwise indicated, the capacity of the forklift truck at the load center involved. The capacity is also affected by the 3-2 Keep in mind that, unless otherwise indicated, the WARNING capacity shown on the capacity plate is for a Make sure the capacity name plate is correct if an standard forklift truck with standard lift bracket, tires attachment has been installed. authorized by the manufacturer, forks and mast, attachment has been installed. authorized by the manufacturer, forks and mast, and having no special-purpose attachment. In addition, the capacity presumes the load center is If an attachment is installed on the forklift truck, no further from the top of the forks than it is from make sure the attachment operating instructions the face of the lift bracket. If these conditions do not exist, the operator may have to reduce the safe operating load because the forklift truck stability may be reduced. The forklift | WARNING | | --- | | Make sure the capacity name plate is correct if an attachment has been installed. | CAPACITY NAME PLATE Exit from a stand-up type forklift truck with rear entry access by stepping backward if a tipover occurs. CAUTION forklift trucks sold by the manufacturer shall not be removed, altered or replaced without prior written approval from MCFA. 2. The manufacturer assumes no responsibility for forklift trucks placed in service without a valid manufacturer The capacity name plate shown is for a 1.5 ton 3. If it is necessary to change your model forklift truck whose capacity is 794 Kg (1,750 specifications, contact your dealer. lb.) with a 4785 mm (188 in.) mast installed. The chart specifies this forklift truck can lift up to 794 Kg (1,750 lb.) if the load center is not more than 600 mm (24 in.) forward from the face of the backrest mm (24 in.) forward from the face of the backrest and 600 mm (24 in.) measured vertically from the top of the forks. Before attempting to pick up a load, make sure that its weight is within the capacity of the forklift truck at the load center involved. The capacity is also affected by the overhang (horizontal distance from the center of the front axle to the vertical faces of the forks). Before attempting to lift any load, make sure the weight and load center combination is within the capacity of the attachment as shown on its capacity name plate. access by stepping backward. WARNING | WARNING | | | --- | --- | | - | In case of tip over, jump clear of the forklift truck. | | - | Exit from a forklift truck with rear entry access by stepping backward. | special-purpose attachment, the capacity is varied by the weight of the attachment and the front DO NOT turn on a ramp or grade! overhang (horizontal distance from the center of Turning on a ramp or grade could cause a forklift Be aware of the stability of an empty Be aware of the stability of an empty forklifttruck! An empty forklift truck could tip over more easily than a loaded one. WARNING In case of tip over, jump clear of the Exit from a forklift truck with rear entry Be aware of the stability of an empty Be aware of the stability of an empty An empty forklift truck could tip over more easily An empty forklift truck could tip over more easily In the event of an imminent tip over step off and away from the forklift truck as quickly as possible. away from the forklift truck as quickly as possible. --- WARNING kept under control at all times. Use special care when traveling without a load as the risk of tip Avoid fast starts, turns,and sudden stops! These movements could cause the forklift truck to tip over. D00073V over is greater. WARNING WARNING In the event of an imminent tip over step off and away from the forklift truck as quickly as possible. F00080V DO NOT raise FORWARD titled loads! This could also cause the forklift truck to tip over. In the event of an imminent tip over step off and away from the forklift truck as quickly as possible. --- D00079V WARNING Avoid sudden stops. This could cause the load to J00040V Avoid sudden stops. This could cause the load to fall off the forks or the forklift truck to tip over. You need a greater stopping distance on wet surfaces. -Apply brakes earlier on slippery surfaces than on dry surfaces. DO NOT drive into a flooded area. WARNING -Wet spots could cause a skid or tip over. You need a greater stopping distance on a flooded area. In the event of an imminent tip over step off and In the event of an imminent tip over step off and away from the forklift truck as quickly as possible. Avoid sudden stops. This could cause the load to Avoid sudden stops. This could cause the load to fall off the forks or the forklift truck to tip over. - Apply brakes earlier on slippery surfaces than on dry surfaces. DO NOT drive into a flooded area. In the event of an imminent tip over step off and away from the forklift truck as quickly as possible. --- J00100V Always be alert for tip overs! WARNING D00190V WARNING or placing a long or wide load, or when turning with such a load. In the event of an imminent tip over step off and In the event of an imminent tip over step off and away from the forklift truck as quickly as possible. away from the forklift truck as quickly as possible. Slowly operate the forklift truck when picking up or placing a long or wide load,or when turning with such a load. In the event of an imminent tip over step off and away from the forklift truck as quickly as possible. --- ***CHAPTER 3 HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE*** **WARNING** **Avoid fast starts, turns, and sudden stops!** These movements could cause the forklift truck to tip over. In the event of an imminent tip over step off and away from the forklift truck as quickly as possible. **3-7** --- Chapter 4 Operation slow, break in the forklift truck under a simulated working condition. 2. Change oils and relubricate at shorter intervals than the normal recommended intervals when in dirty environments. 3. | CAUTION | | | --- | --- | | 1. | If the forklift truck cannot be put to work immediately, or the operation is light and slow, break in the forklift truck under a simulated working condition. | | 2. | Change oils and relubricate at shorter intervals than the normal recommended intervals when in dirty environments. | | 3. | Hydraulic tank return line filter should be replaced after the first fifty (50) hours of operation and at the recommended intervals thereafter. | | 4. | Carefully check on and around the forklift truck for loose bolts and nuts. Retighten them. | replaced after the first fifty (50) hours of operation and at the recommended intervals thereafter. 4. Carefully check on and around the forklift truck for loose bolts and nuts. Retighten slow, break in the forklift truck under a WARNING simulated working condition. 1. Operate this forklift truck slowly and in an Change oils and relubricate at shorter open area until you are thoroughly | WARNING | | --- | | BE SURE TO READ the SAFETY RULES FOR FORKLIFT TRUCK OPERATORS for your safety and the safety of fellow workers. | Change oils and relubricate at shorter open area until you are thoroughly intervals than the normal recommended familiar with all the controls. intervals when in dirty environments. 2. Operate this forklift truck only from the BE SURE to perform daily PRE-START INSPECTION. 2. Operate this forklift truck only from the Hydraulic tank return line filter should be designated operating position. Never replaced after the first fifty (50) hours of place any part of your body between the operation and at the recommended mast upright or outside the operator intervals thereafter. compartment while operating this forklift WARNING Carefully check on and around the forklift Carefully check on and around the forklift space in which the operator stands to truck for loose bolts and nuts. Retighten operate the forklift truck.) 3. Avoid sudden stops or changes in direction which could cause the vehicle direction which could cause the vehicle BEFORE STARTING OPERATIONS to tip or the load to shift. WARNING 4.3.2 START-UP PROCEDURE 1. Make sure battery is charged. 2. Make sure both battery gates are in place 3. Make sure battery cannot move more than ½ inch (13mm) in any horizontal direction. ½ inch (13mm) in any horizontal direction. 4. Connect battery to forklift truck. NOTE: Battery cable should not be routed outside the profile of the truck. BE SURE to perform daily PRE-START 5. BE SURE to perform daily PRE-START 5. Turn the key switch clockwise to the ON position or enter the code in the key pad position or enter the code in the key pad (optional). Start PIN 2580. SelfTest will start and readings will be shown on the WARNING start and readings will be shown on the WARNING display. Do not activate any control BE SURE TO READ the SAFETY RULES FOR elements, such as the operator presence elements, such as the operator presence FORKLIFT TRUCK OPERATORS for your safety pedal during SelfTest. and the safety of fellow workers. and the safety of fellow workers. 6. After the SelfTest is complete, step into the operator compartment. Depress the operator presence pedal with right foot operator presence pedal with right foot and the traction pedal with left foot. --- follows: a. Pull the EPO button OUT while twisting it clockwise. b. Turn the key switch clockwise to ON. c. Push the EPO button IN. This should completely shut down the forklift truck. completely shut down the forklift truck. You should not be able to drive the forklift truck, lift the forks, tilt the forklift truck, lift the forks, tilt the carriage, etc. d. Turn the EPO button clockwise and d. Turn the EPO button clockwise and pull up to release. 9. Release parking brake by pressing the 9. Release parking brake by pressing the button directly below the parking brake button directly below the parking brake icon on the console display screen. 10. Use your left hand to steer the forklift truck and your right hand to control travel, lift and auxiliary functions. See Forklift Truck Operation, Page 4-3 Operation, Page 4-3 11. Test the steering. 12. Test the brakes. 12. Test the brakes. 13. Test the parking brake. 14. Test the horn button. 14. Test the horn button. 15. Check the operator presence pedal for functionality. 16. Test the drive function. lever to adjust to the operator's weight (79). Pull the EPO button OUT while NOTE: The gas pressure springs 5 and 6 have twisting it clockwise. double the pressure force. 11. Test the steering. 4-2 12. Test the brakes. NOTE: The forklift truck can be driven either forks Turn the key switch clockwise to ON. Adjustment recommendation for adjustable Comfort Push the EPO button IN. This should operator platform completely shut down the forklift truck. Operator Switched Number of Gas Springs You should not be able to drive the weight Recommendation forklift truck, lift the forks, tilt the carriage, etc. 115 lb 0 Turn the EPO button clockwise and (52 kg) 16. Test the drive function. 17. Check the lift function. Turn the EPO button clockwise and (52 kg) pull up to release. 137 lb (62 kg) Release parking brake by pressing the Release parking brake by pressing the button directly below the parking brake 165 lb 1 icon on the console display screen. (75 kg) | Operator weight | Switched Number of Gas Springs | | | --- | --- | --- | | Recommendation | Recommendation | | | 115 lb(52kg) | 0 | 0 | | 137lb(62kg) | 0 | 0 to 1 | | 165lb(75kg) | 1 | 0 to 2 | | 192lb(87kg) | 2 | 1 to 3 | | 220lb(100kg) | 3 | 2 to 4 | | 276lb(125kg) | 4 | 3 to 5 | | 331lb(150kg) | 5 | 3 to 5 | way the forklift truck will move, slowly move the multi-function control handle forward or reverse to determine which way the forklift slight or no reduction during travel of human vibrations affecting the operator. 3. Comfort operator platform is adjusted. NOTE: Selecting too few gas pressure springs or too little spring power can cause touchdown of the sprung platform. Selecting too many gas pressure springs or too much spring power can cause only slight or no reduction during travel of human vibrations affecting the operator. --- 79. LEVER ADJUSTING THE ARM RESTTurning with the forks elevated, with or without a 1. ROCKER SWITCH Use extreme care when turning without a load. --- travels. This is true when accelerating and travels. This is true when accelerating and | Item | Travel Direction | | --- | --- | | 75 | Forks first left | | 77 | Drive direction | | 76 | Load direction | | 78 | Forks first right | --- 4.8.2 PARKING BRAKE WARNING ICON When released, the 4.9 CHANGING DIRECTIONS When set, the through neutral to the direction opposite of your current travel. This action is called When released, the moving in the opposite direction. Plugging is the recommended method of slowing travel speed and changing direction during operational maneuvers. 4.10 BRAKING The forklift truck's braking response depends largely on the travel surface conditions. The largely on the travel surface conditions. The operator should adapt his or her driving style accordingly. The forklift truck can be stopped in three ways: -With the traction pedal 4.10 BRAKING -With the reverse brake (multi-function control handle) Risk of accidents due to individually set parameters modified braking and driving response due to individually set parameters! parameters If the forklift truck is driven by several operators If the forklift truck is driven by several operators (for example in multi-shift operation), be aware of modified braking and driving response due to | WARNING | | --- | | Risk of accidents The braking response of the forklift truck depends largely on the travel route conditions. | “plugging.” The farther you move the multifunction control handle, the faster you The forklift truck slows, stops, and starts The forklift truck slows, stops, and starts moving in the opposite direction. Plugging is the recommended method of slowing moving in the opposite direction. Plugging is the recommended method of slowing travel speed and changing direction during operational maneuvers. operational maneuvers. --- ***CHAPTER 4 OPERATION*** **4.10.1.1 BRAKING WITH THE SERVICE** **BRAKE** 1. Take foot slightly off the traction pedal (13). The forklift truck decelerates slightly. 2. Lift foot off the traction pedal (13). The forklift truck decelerates. **4-6** --- ***CHAPTER 4 OPERATION*** **4.10.1.2 BRAKING WITH THE COASTING** **BRAKE** 1. Release the multi-function control handle to the neutral position (83). The forklift truck decelerates. **4-7** --- - Move the multi-function control handle through the neutral position in the direction opposite direction the forklift truck is traveling. 4-8 forklift truck. Plugging provides the means to bring the forklift truck to a smooth, controlled stop. • Move the multi-function control handle through the neutral position in the direction through the neutral position in the direction opposite direction the forklift truck is traveling. 4.11 PLUGGING forklift truck. Plugging provides the means to bring 4.12 AT THE END OF EACH SHIFT the forklift truck to a smooth, controlled stop. Move the multi-function control handle 1. Park the forklift truck in a secure and through the neutral position in the direction authorized parking area. opposite direction the forklift truck is 2. Stop the forklift truck. 4.12 AT THE END OF EACH SHIFT 3. Lower the forks completely. 4. Turn the key switch OFF (O). 3. Lower the forks completely. 4. Turn the key switch OFF (O). --- Never park this forklift truck on a ramp or a slope. DO NOT park this forklift truck in a cold storage DO NOT park this forklift truck in a cold storage area overnight. 7. Disconnect the battery. 8. Check around forklift truck for leaking hydraulic fluid. | WARNING | | --- | | Never park this forklift truck on a ramp or a slope. DO NOT park this forklift truck in a cold storage area overnight. | --- heavier containers at the bottom and lighter ones at the top. 5.1.2 STACKING SMALL IDENTICAL 5.1.3 STACKING LARGE IDENTICAL STACKING SMALL IDENTICAL (3) Tilt the mast FORWARD to the VERTICAL position, and make sure the forks are at the correct height. --- WARNING Only stable or safely arranged loads must be handled. DO NOT pick up an off-center load. Make sure the weight of the load is centered (6) Carefully lift the load about 10 cm (4 in.) --- 1. STEERING WHEEL - NEVER travel with the lift bracket tilted forward or with the load in the elevated position. This could increase the possibility of the forklift truck tipping over. 101525 position 15 to 20 cm (6 to 8 in.) above the ground. 4. Look around to make sure your drive area is clear 11_3B is clear WARNING MULTI-FUNCTION CONTROL HANDLE Slack lift chains mean there is a rail or lift bracket --- In the event of an imminent tip-over step off and away from the forklift truck as quickly as possible. 5.4 UNLOADING Only stable or safely arranged loads must be Keep the center of gravity low and avoid off- WARNING 4. Watch your drive tires and do not hit the rack. --- Carefully lower the load onto the rack 6. Look behind and around the forklift truck and to see that it is safe to carefully back the forklift truck away from the rack. Proceed to your next load. • NEVER travel across a grade • Always make sure the forklift truck is square with the ramp before ascending square with the ramp before ascending or descending. - NEVER travel with the load elevated when the forklift truck is on a ramp. - NEVER turn on a ramp. - NEVER travel across a grade - Always make sure the forklift truck is square with the ramp before ascending or descending. --- truck that has a maintenance problem. 1. Park the forklift truck in an authorized area. | WARNING | | --- | | Perform a thorough walk-around inspection for any damage. Report all damage or faulty operation immediately.DO NOT operate a forklift truck that has a maintenance problem. | Do not expose controller units to water. Take care not to sprinkle water over controller units when not to sprinkle water over controller units when washing your machine. WARNING • NEVER splash water over the forklift truck. Park the forklift truck in an authorized | CAUTION | | --- | | Do not expose controller units to water. Take care not to sprinkle water over controller units when washing your machine. | to clean the forklift truck. 6.2 LONG-TERM STORAGE Check under the forklift truck for oil leaks. Clean the forklift truck to keep it free of dirt If your forklift truck is to be put in storage for any length of time, take the following precautions for length of time, take the following precautions for safety and to reduce the risk of deterioration of forklift truck components. After positioning your forklift truck for storage, retract all the hydraulic cylinders to minimize rod exposure. This will reduce the risk of rusting of the sliding contact surfaces of the rods. This will make it easier to spot loose or CAUTION 6.2.1.1 HYDRAULIC SYSTEM After positioning your forklift truck for storage, retract all the hydraulic cylinders to minimize rod exposure. This will reduce the risk of rusting of the --- 3. Fully lower forks or attachment to the floor. 4. Place the multi-function control handle in the neutral position 5. Turn the key switch to the OFF position 5. Turn the key switch to the OFF position and remove the key. 6. Block the wheels and block in the truck to 6. Block the wheels and block in the truck to secure the forklift truck. CAUTION CAUTION DO NOT turn steering wheel after the forklift truck DO NOT turn steering wheel after the forklift truck has been secured. It may loosen the tie-downs. | CAUTION | | --- | | DO NOT turn steering wheel after the forklift truck has been secured. It may loosen the tie-downs. | the neutral position Incorrect lifting or tie-downs could cause a load to Turn the key switch to the OFF position shift and could cause injury and/or damage. and remove the key. Block the wheels and block in the truck to NOTE: Check the state and local laws governing secure the forklift truck. weight, width, and length of a load. Contact 7.2 FORKLIFT TRUCK LIFTING AND TIEDOWN INFORMATION your authorized dealer for shipping CAUTION instructions for your forklift truck. TIEDOWN INFORMATION Take the following safety precautions when lifting or tying down forklift trucks. Take the following safety precautions when lifting or tying down forklift trucks. DO NOT turn steering wheel after the forklift truck has been secured. It may loosen the tie-downs. | CAUTION | | --- | | Incorrect lifting or tie-downs could cause a load to shift and could cause injury and/or damage. | --- overnight, leaving it outside a garage, remove the battery and keep it warm. 8.1.1 BATTERY 27^{\circ}\mathsf{C}\left(80^{\circ}\mathsf{F}\right) -35^{\circ}C(-31^{\circ}F) 8.2.1 HOT WEATHER BATTERY SERVICE - Use hydraulic and gear oil suitable for the ambient temperatures. In hot dry weather, check the battery cells for proper electrolyte level more often than in cold weather. Add distilled water whenever the level is low. | CAUTION | | | --- | --- | | After distilled water has been added to the battery, drive the forklift truck. This mixes the added water with the electrolyte and will reduce the risk of freezing and damaging the battery. | | | DO NOT attempt to restore a battery's charge by pouring boiling water over it. This can break the battery case, resulting in acid contact with skin or eyes. | | The electrolyte of a fully charged battery will not freeze to -35°C (-31°F). 8.3.1 DESCRIPTION OF THE Do not leave the forklift truck in a freezer ENVIRONMENT AND OPERATION OF THE FORKLIFT TRUCKS Cold storage conditioning is required when a forklift truck operates in cold storages such as coolers or freezers. Condensation, especially when frozen, is a primary issue in this environment. Cold storage conditioning is also recommended when a forklift truck operates in a high humidity environment. Cold storage applications are divided into two groups: COOLER (High Temperature Freezer Forklift COOLER (High Temperature Freezer Forklift Truck) Applies to forklift trucks operating in: • Environments where ambient CAUTION temperatures fluctuate from +20°F (-7°C) to +70°F (21°C). After distilled water has been added to the battery, drive the forklift truck. This • Continuous duty cycle in cooler or high the battery, drive the forklift truck. This • Continuous duty cycle in cooler or high mixes the added water with the temperature freezer. electrolyte and will reduce the risk of • Applications where forklift trucks go in and electrolyte and will reduce the risk of • Applications where forklift trucks go in and freezing and damaging the battery. out of freezers for short periods of time. A DO NOT attempt to restore a battery’s short period of time is defined as 5 DO NOT attempt to restore a battery’s charge by pouring boiling water over it. +20^{\circ}\mathsf{F}\;(\lnot7^{\circ}\mathsf{C}) charge by pouring boiling water over it. minutes. This can break the battery case, • Very wet environments resulting in acid contact with skin or FREEZER (Low Temperature Freezer Forklift Truck) +70^{\circ}\mathsf{F}\,(21^{\circ}\mathsf{C}) Truck) Applies to forklift trucks operating in: CARE IN HOT WEATHER • An environment where temperatures • An environment where temperatures HOT WEATHER BATTERY SERVICE fluctuate from +40°F (4°C) to -40°F (-40°C). This would be where the forklift In hot dry weather, check the battery cells for truck operates between a cooler and low proper electrolyte level more often than in cold temperature freezer. weather. Add distilled water whenever the level is weather. Add distilled water whenever the level is • A continuous temperature of -20°F (-29°C) for an entire shift. Use hydraulic and gear oil suitable for the ambient temperatures. - An environment where temperatures fluctuate from +40°F (4°C) to -40°F (-40°C). This would be where the forklift truck operates between a cooler and low temperature freezer. 1+40^{\circ}\mathsf{F}\,(4^{\circ}\mathsf{C}) ambient temperatures. - A continuous temperature of $ - 2 0^{\circ} \mathrm{F} $ $ (- 2 9^{\circ} \mathrm{C}) $ for an entire shift. --- ***CHAPTER 8 SPECIAL SITUATIONS*** The most extreme usage of the forklift truck includes frequent driving between low temperature freezer and warm warehouse areas with high humidity. In such usage, heavy condensation, formation of ice and corrosion can occur. It is preferable that when low temperature freezer forklift trucks are not used, they are kept in an area where the temperature is between 30°F (-1°C) and 23°F (-5°C) and the humidity is low. Cold storage applications require well-trained forklift truck drivers and regular forklift truck maintenance. **COLD STORAGE MODIFICATIONS** When preparing the forklift truck for cold storage conditioning, the number of modifications should be kept to a minimum. - Water drainage is already considered in the standard chassis design. - Some preconditioning and painting of the components will be used. - All hinges, axles, and bearings are surface treated or equipped with grease fittings. - Replacement of the hydraulic oil is not required in Cooler (High Temperature Freezer Truck) in some cold storage applications. **8.4 CARE IN SEVERE DUST OR LINT** **CONDITIONS** For operating the forklift truck in severe dust or lint conditions, consult your dealer. **8-2** --- 9.1 GENERAL Mitsubishi forklift truck dealers are well trained and know how to safely make repairs. WARNING WARNING • Make sure the service area is safe. • Follow the recommended safe • Follow the recommended safe procedures. • Use only the right tools for the job. • Park the forklift truck on a level surface with the forks lowered, multi-function control handle in NEUTRAL and battery WARNING | WARNING | | --- | | Make sure the service area is safe. | | Follow the recommended safe procedures. | | Use only the right tools for the job. | | Park the forklift truck on a level surface with the forks lowered, multi-function control handle in NEUTRAL and battery disconnected. | • All repairs must be made by authorized personnel. properly. WARNING Should the forklift truck become unsafe during operation in any way whatsoever, you must report personnel. Follow these rules to save yourself and others -Repair loose or damaged oil lines, tubes, Taking proper care of your forklift truck is a vital or hoses. part of the overall planned maintenance program. -DO NOT use your bare hands to check Your participation in this program will provide an for leaks, use a board or cardboard. operation in any way whatsoever, you must report it immediately to the designated authority. The forklift truck must not be used again until it has Should the forklift truck become unsafe during operation in any way whatsoever, you must report it immediately to the designated authority. The forklift truck must not be used again until it has been restored to safe operational condition. Your participation in this program will provide an for leaks, use a board or cardboard. early warning to help identify potential maintenance -Tighten connections to the recommended torque. Do-it-yourself maintenance does not include Do-it-yourself maintenance does not include repairs. If your forklift truck requires any repairs,-Make sure all clamps, guards, and heat contact your authorized dealer. The mechanics of shields are installed correctly to reduce the risk of vibration, rubbing against Mitsubishi forklift truck dealers are well trained and the risk of vibration, rubbing against know how to safely make repairs. other parts, and excessive heat during operation. -Outer covering chafed or cut and wire Use only the right tools for the job. reinforcing exposed Park the forklift truck on a level surface-Outer covering ballooning locally with the forks lowered, multi-function -Evidence of kinked or crushed hose control handle in NEUTRAL and battery -Metal embedded in the outer cover operation. WARNINGIf any of the following is found on a part, replace the part. Make sure the service area is safe. replace the part. Make sure the service area is safe. Follow the recommended safe- - -Metal embedded in the outer cover All repairs must be made by authorized-End fittings displaced - End fittings damaged or leaking Follow these rules to save yourself and others from injury and to service your forklifttruck WARNING Should the forklift truck become unsafe during operation in any way whatsoever, you must report it immediately to the designated authority. The --- - BE SURE to perform inspections. flapping cuffs, dangling chains, neckties, scarves, or rings that could catch in moving parts. -Wear personal protective equipment appropriate for the conditions of your work places. 9.2 INSPECTION PRECAUTIONS You must read and understand the warnings and instructions contained in this manual before performing maintenance procedures. Turn the key switch to OFF and disconnect the battery before lubricating or performing any maintenance on the forklift truck (unless instructed otherwise in this manual or in the Dress properly for the job. DO NOT wear loose clothing or accessories such as Service Manual). The recommended maintenance intervals are for the forklift truck operating under normal conditions. If operation is in adverse conditions or performing maintenance procedures. wheels need replacement contact your dealer. WARNING CAUTION Turn the key switch to OFF and disconnect the battery before lubricating or performing any • Avoid mixing lubricants. In some cases, corrosive environments, inspect the forklift truck more frequently. | WARNING | | --- | | Turn the key switch to OFF and disconnect the battery before lubricating or performing any maintenance on the forklift truck(unless instructed otherwise in this manual or in the Service Manual).The recommended maintenance intervals are for the forklift truck operating under normal conditions.If operation is in adverse conditions or corrosive environments, inspect the forklift truck more frequently. | forklift truck is turned on, ALWAYS USE TWO WORKERS— one, the operator, at the controls and the other checking where the operator can instructed otherwise in this manual or in the deteriorate when mixed. It is best to stick The recommended maintenance intervals are for with the same brand at successive the forklift truck operating under normal service intervals. conditions. If operation is in adverse conditions or • Before refilling, clean filler holes. After corrosive environments, inspect the forklift truck WARNING 9-2 WARNING If it is necessary to make an inspection while the forklift truck is turned on, ALWAYS USE TWO WORKERS— one, the operator, at the controls and the other checking where the operator can and the other checking where the operator can --- -Wheels blocked. - Mast in vertical position - Forktips on ground - All motors stopped disposal of wastes accumulated after replacement of tires, batteries, oils, and fluids. 9.3 MAINTENANCE SCHEDULE - Wheels blocked. | CAUTION | | --- | | Contact your authorized dealer for the proper disposal of wastes accumulated after replacement of tires, batteries, oils, and fluids. | Maintenance Intervals Chart to keep your forklift truck in proper working condition. For periodic inspection and periodic change of parts, however, rely on the expert knowledge of the factory-trained servicemen, and the service facilities at your dealer's workshop. | Periodic Inspection Time Intervals | One month(30 days)or200 service hours after delivery of a new forklift truck,(whichever comes first) | | --- | --- | | Every 1000 hours or6 months (whichever comes first) | | | Every 2000 hours or1 year (whichever comes first) | | CAUTION Contact your authorized dealer for the proper disposal of wastes accumulated after replacement of tires, batteries, oils, and fluids. MAINTENANCE SCHEDULE Fill out a pre-start inspection sheet. Remember, a complete and thorough pre-start inspection is the best insurance against personal injury and property damage. --- Operator Compartment, Page 9-7 9.3.3 SERVICE INTERVALS | Component Group | Item | Service | | --- | --- | --- | | General | Damage or faulty operation found the day before, Page 9-5 | Check | | Loose Components and Hardware, Page 9-7 | Check | | | Decals and Warning Labels, Page 9-7 | Check | | | Fire Extinguisher (if equipped), Page 9-7 | Check | | | Ventilation Slots, Page 9-7 | Check | | | Operator Compartment, Page 9-7 | Check | | | Hydraulic System | Hydraulic Connections, Page 9-6 | Check | | Hydraulic Reservoir, Page 9-6 | Check | | | Electrical | Battery, Page 9-5 | Check | | Battery Connector & Emergency Power Off(EPO),Page 9-5 | Check | | | Battery Gates, Page 9-5 | Check | | | Lights(if equipped),Page 9-6 | Check | | | Switches,Page 9-6 | Check | | | Horn,Page 9-6 | Check | | | Optional Warning Devices(if equipped),Page 9-7 | Check | | | Frame and Chassis | Static Strap(if equipped),Page 9-6 | Check | | Overhead Guard,Page 9-6 | Check | | | Driving System | Function Controls on multi-function control handle,Page 9-6 | Check | | Steering,Page 9-7 | Check | | | Operator Presence Pedal(Brakes),Page 9-5 | Check | | | Traction Pedal,Page 9-5 | Check | | | Mast and Forks | Mast,Page 9-6 | Check | | Lift Chains,Page 9-6 | Check | | | Forks,Page 9-6 | Check | | | Wheel | Steer Tire,Drive Tires,Page 9-6 | Check | 9.3.3.2 EVERY 50 HOURS OR WEEKLY | Component Group | Item | Service | | --- | --- | --- | | Electrical | Battery，Page9-7 | Clean | | Cables/Hoses，Page9-7 | Inspect | | | Mast and Forks | Mast，Page9-7 | Lubricate | | Forks，Page9-7 | Inspect | | --- 9.3.3.4 EVERY 1000 SERVICE HOURS OR 6 MONTHS, WHICHEVER COMES FIRST Component Group | Component Group | Item | Service | | --- | --- | --- | | Electrical | Battery, Page 9-7 | Check Specific Gravity | | General | Loose Hardware, Page 9-7 | Check | | Driving System | Drive Axles, Page 9-7 | Change Oil | Mast and Forks 9.3.3.5 EVERY 2000 SERVICE HOURS OR 12 | Component Group | Item | Service | | --- | --- | --- | | Hydraulic System | Hydraulic Reservoir, Page 9-8 | Change Filter | | Driving System | Drive Axles, Page 9-8 | Check Oil Level | | Electrical | Contactor Tips, Page 9-7 | Check | | General | Loose Hardware, Page 9-8 | Check | | Mast and Forks | Mast, Page 9-7 | Lubricate | COMES FIRST Damage or Faulty Operation Found the Day | Component Group | Item | Service | | --- | --- | --- | | Hydraulic System | Hydraulic Reservoir，Page 9-8 | Change Filter & Fluid | | Driving System | Drive Axles，Page 9-8 | Change Oil | on floor. -Is the battery weight within the range 1. Battery - Is the battery weight within the range specified on the battery size label decal? - Battery weight must meet minimum requirements listed on the forklift truck capacity plate. -Battery weight must meet minimum requirements listed on the forklift truck capacity plate. -Are battery gates properly installed and Was battery fully charged before start of securely locked into place. 4a. Operator Presence Pedal (Brakes) Was water level checked after charging?-Does operator presence pedal operate Check for leakage—look for battery acid smoothly with no binding? -Does it stop the forklift truck within specific Is the battery weight within the range limits? -Does it disable the travel function when Battery weight must meet minimum pedal is released? requirements listed on the forklift truck 4b. Traction Pedal -Does it disable the travel function when Battery weight must meet minimum pedal is released? requirements listed on the forklift truck 4b. Traction Pedal - Does traction pedal operate smoothly with no binding? --- 7. Mast -Does the mast tilt forward and backward smoothly when you operate the tilt function on the multi-function control function on the multi-function control handle? handle? -Is the load backrest extension properly secured to the mast? secured to the mast? -Inspect the load backrest extension for cracks and distortions. (Special attention should be given to all welds). cylinders or hydraulic lines? multi-function control handle? Does the mast move up and down-Does the mast tilt forward and backward smoothly when you operate the multi-when you operate the tilt function on the -Are lift chains properly lubricated? -Are lift chains adjusted to the correct length? 8. Lift Chains should be given to all welds). -Shake the backrest extension to check for excessive rattle. -Are lift and lower stops installed and in good condition? good condition? 8. Lift Chains -Inspect lift chains for lubrication and visible damage. -Are lift chains properly lubricated? -If the chains are loose or the tension is not equal, have the chains adjusted. - Are the fork stopper pins properly engaged? equal, have the chains adjusted. 11. Forks -Are the fork stopper pins properly smoothly when you operate the multi-when you operate the tilt function on the function control handle? multi-function control handle? Does the mast tilt forward and backward 13. Horn smoothly when you operate the tilt -Does the horn sound when you press the function on the multi-function control horn button? 12. Function Controls on multi-function control handle 11. Forks handle -Does the multi-function control handle -Are the fork stopper pins properly engaged? 12. Function Controls on multi-function control function on the multi-function control horn button? 14. Hydraulic Connections Is the load backrest extension properly secured to the mast?-Check all hydraulic connections to secured to the mast?-Check all hydraulic connections to cylinders and hoses. Inspect the load backrest extension for cracks and distortions. (Special attention-Check floor around and under forklift truck should be given to all welds). for hydraulic oil leaks. should be given to all welds). Shake the backrest extension to check for Shake the backrest extension to check for 15. Hydraulic Reservoir -Check hydraulic fluid level. Are lift and lower stops installed and in 16. Lights (if equipped) Inspect lift chains for lubrication and -Do the lights come on illuminate when you switch them on? Are lift chains properly lubricated? Are lift chains adjusted to the correct - -Are the lights in safe working condition? -Are the lenses clean and not defective? Inspect lift chains for lubrication and Are lift and lower stops installed and in good condition? Are lift chains properly lubricated? Are lift chains adjusted to the correct Inspect chains for proper tension and Are lift chains equal in tension?-Are the tires in good condition? Check by pushing the chains midway.-There should be NO cracks, NO flat spots, 18. Steer Wheel, Drive Tires Are lift chains equal in tension?-Are the tires in good condition? Check by pushing the chains midway.-There should be NO cracks, NO flat spots, NO missing chunks or No bond failure. If the chains are loose or the tension is not equal, have the chains adjusted.-Tires should have adequate tread. 19. Static Strap (if equipped) Are the fork stopper pins properly-Is the static strap attached? 20. Overhead Guard 12. Function Controls on multi-function control 12. Function Controls on multi-function control -Check the front and rear overhead guard mounting bolts on each side. mounting bolts on each side. Does the multi-function control handle move smoothly, without binding? - Tires should have adequate tread. - Is the static strap attached? 20. Overhead Guard --- -Check forklift truck for loose or missing hardware. (Tighten loose hardware). hardware. (Tighten loose hardware). 22. Decals and Warning Labels 22. Decals and Warning Labels -All Decals - (Warning/Safety/Operational) in place and legible. in place and legible. 23. Fire Extinguisher (if equipped) 23. Fire Extinguisher (if equipped) -Is the extinguisher charged and secured? 24. Ventilation Slots 24. Ventilation Slots -Are the ventilation slots free of obstructions? 26. Optional Warning Devices (if equipped) 26. Optional Warning Devices (if equipped) -Do all optional warning devices operate properly? Optional Warning devices 23. Fire Extinguisher (if equipped) include such items as: -Lights 24. Ventilation Slots 27. Steering -Check the steering angle indicator by -Backup Alarms -Strobe Lamp 27. Steering -Check the steering angle indicator by turning the steering wheel in both directions until it stops and check that the wheel position is displayed on the control - Lights - Backup Alarms Check for damage to components. -Check to see that all electrical cables and Check all welded components. There hydraulic cables are in good condition. should be no cracks. 7. Mast Check forklift truck for loose or missing - Check the steering angle indicator by turning the steering wheel in both directions until it stops and check that the wheel position is displayed on the control panel. hardware. (Tighten loose hardware). - Strobe Lamp 22. Decals and Warning Labels 11. Forks All Decals - (Warning/Safety/Operational)-Inspect the forks for cracks and distortions. in place and legible. 23. Fire Extinguisher (if equipped) * (Special attention should be given to the heel section and all welds). Is the extinguisher charged and secured? 7. Mast FORKLIFT TRUCK Are the ventilation slots free of 11. Forks 26. Optional Warning Devices (if equipped) -Check the specific gravity of battery cells. Do all optional warning devices operate 21. Loose Hardware 21. Loose Hardware properly? Optional Warning devices include such items as:-Check hardware on forklift truck and retighten loose hardware. 25. Drive Axle Backup Alarms -Change drive axle oil. 1. Battery 9.7 EVERY 1000 SERVICE HOURS OR Check the steering angle indicator by6 MONTHS, WHICHEVER COMES FIRST Check the steering angle indicator by turning the steering wheel in both directions until it stops and check that the directions until it stops and check that the wheel position is displayed on the control 5. Contactor Tips -Check for burnt contactor tips, pitting and 28. Operator Compartment Make sure the operator compartment and 7. Mast the controls are clean for a safe operation. -Lubricate mast strips and roller surfaces (each side). -Lubricate bracket side rollers (each side). - Lubricate bracket side rollers (each side). - Lubricate mast strips and roller surfaces (each side). - Lubricate chain (each side). -Lubricate tilt socket (each side). -Lubricate tilt cylinder (each side). - Lubricate tilt socket (each side). - Lubricate tilt cylinder (each side). --- ***CHAPTER 9 MAINTENANCE*** -Lubricate main gear (thin layer around **9.10 HYDRAULICS** perimeter). **15. Hydraulic Reservoir 9.10.1 HYDRAULIC OIL LEVEL (FORKLIFT** **TRUCK LEVEL) CHECK** -Change hydraulic reservoir oil filter. Hydraulic tank is located in the center front tractor **25. Drive Axle** (from the operator’s position). -Check drive axle oil level. **9.8 EVERY 2000 SERVICE HOURS OR** **12 MONTHS, WHICHEVER COMES** **FIRST** **15. Hydraulic Reservoir** -Change hydraulic oil -Change hydraulic oil filter **25. Drive Axle** -Change drive axle oil. **9.9 READY TO OPERATE** **9.9.1 NOW YOUR FORKLIFT TRUCK IS** **READY TO OPERATE** **WARNING** Remember, a complete and thorough pre-start inspection is the best insurance against personal injury and property damage. **9-8** --- • Avoid hydraulic oil spill. | WARNING | | | --- | --- | | The hydraulic oil is under pressure during operation and is hazardous to health and the environment. | | | ·Do not touch hydraulic lines under pressure. ·Dispose of used oil according to specifications and regulations. Store used oil safely until it is disposed of in accordance with regulations. ·Avoid hydraulic oil spill. ·Remove spilled and/or escaped liquids immediately using a suitable binding agent. ·Dispose of the mixture of binding agent and consumables in compliance with applicable regulations. ·Legal requirements for handling hydraulic oil must be observed. ·Wear safety gloves when handling hydraulic oil. ·Wear safety glasses when handling hydraulic oil. ·Do not allow hydraulic oil to touch hot motor parts. ·Do not smoke when handling hydraulic oil. ·Avoid contact and consumption. If swallowed do not induce vomiting. Instead find a physician immediately. ·If you inhale oil mist or vapors, let in fresh air. ·If oil comes in contact with the skin, wash off oil with soap and water. ·If oil comes in contact with the eyes, rinse them out with water and find a physician immediately. ·Change soaked clothes and shoes immediately. | | --- 108. FULL/ADD LEVEL NOTE: Do not fill above the "FULL" mark. --- forks to release snaplocks on both sides, then remove. 4. Remove the hydraulic tank filler cap by turning it counterclockwise. 5. Remove hydraulic oil filter from hydraulic tank. tank. 6. Add hydraulic oil to the hydraulic tank. 7. Replace hydraulic oil filter and filler cap. 7. Replace hydraulic oil filter and filler cap. 8. Replace top and lower hood covers. When adding hydraulic oil: • Clean the filler hole to prevent dirt from • Clean the filler hole to prevent dirt from dropping into the tank. • DO NOT overfill. • Clean up spillage. • Clean up spillage. | CAUTION | | --- | | When adding hydraulic oil: • Clean the filler hole to prevent dirt from dropping into the tank. • DO NOT overfill. • Clean up spillage. | 9.11 BATTERY 1.225 to 1.240 | Specific gravity corrected to 27℃(80°F) | Battery charge | | --- | --- | | Below 1.225 Completely discharged | CAUTION | | Operating the forklift truck with a battery in this state of discharge may cause permanent damage to the forklift truck components or the battery. | | 27^{\circ}\mathbf{c} 27\dot{\circ}\mathbf{c} Clean the filler hole to prevent dirt from dropping into the tank. DO NOT overfill. DO NOT overfill. Clean up spillage. securely. WARNING If acid gets in your eyes, FLUSH THEM Using a battery hydrometer, check the specific If acid gets in your eyes, FLUSH THEM Using a battery hydrometer, check the specific IMMEDIATELY WITH LARGE AMOUNTS OF gravity of the battery cells. Take the reading at eye WATER AND SEE A DOCTOR AT ONCE. Battery charge | If acid gets in your eyes, FLUSH THEM IMMEDIATELY WITH LARGE AMOUNTS OF WATER AND SEE A DOCTOR AT ONCE. | | --- | --- 1. Loosen the retaining screw (117) on the battery gate (116). battery gate (116). Loosen the retaining screw (117) on the Remove the battery covering plate. push the EPO button in and remove key. INSTALLING BATTERY GATE 2. Make sure both battery gates are properly INSTALLING BATTERY GATE 2. Make sure both battery gates are properly installed. 3. Before removing the battery gate, usually the battery gate on the side where the battery connector is located make sure the battery connector is located make sure the opposite battery gate is locked in place. 4. Pull up on the battery gate handle and set 3. Before removing the battery gate, usually the battery gate on the side where the battery connector is located make sure the opposite battery gate is locked in place. 5. Disconnect the battery and then remove the battery. 5. Disconnect the battery and then remove the battery. --- handling equipment. If acid gets in your eyes, FLUSH THEM IMMEDIATELY WITH LARGE AMOUNTS OF plug. 3. Install battery gate. Take precautions not to jam or cut the battery Take precautions not to jam or cut the battery cables during installation of the battery as this may result in a short that could cause a fire or battery explosion. battery explosion. When installing a battery, always be sure that it is fully charged before placing the forklift truck into Never operate the forklift truck without the correct operation. WARNING Never use chain or other items for lifting a battery that is not specifically designed for the task. When removing a battery from a forklift truck, always use a battery stand or equivalent material Never operate the forklift truck without the correct size and weight of battery in the forklift truck. - Contact the manufacturer's service department when replacing the factory-fitted battery. NOTE: A battery extraction device and Allen key will be need to perform this procedure. | CAUTION | | --- | | Crushing may result in damage to the battery cable. Crushing may occur when inserting the battery if the battery cable is inserted without a cable guide. • Always install the battery with a cable guide. • Contact the manufacturer's service department when replacing the factory-fitted battery. | WARNING When removing a battery from a forklift truck, always use a battery stand or equivalent material If acid gets in your eyes, FLUSH THEM guide. • Contact the manufacturer's service - Always install the battery with a cable guide. • Check Contact the manufacturer's service -Voltage of charger. department when replacing the factory- -Voltage of battery. -Size or power output of charger is correct. NOTE: A battery extraction device and Allen key NOTE: A battery extraction device and Allen key will be need to perform this procedure. • Type of Charge - Voltage of charger. - Check - Size or power output of charger is correct. - Type of Charge --- ***CHAPTER 9 MAINTENANCE*** -Daily charge. This should be done every day and normally takes eight hours to fully charge a battery. -Equalizing charge. This charges the battery at a slow rate and balances the charge in all the cells. This should normally be done once per week. The most accurate check of specific gravity is obtained after the equalizing charge is complete. - Check the battery charge -Use a hydrometer. -Complete the pre-start inspection procedure. **WARNING** Explosive gases are generated when batteries are being charged. Always ensure adequate ventilation for battery charging. Do not smoke, keep flames and sparks away. **CAUTION** - Always turn off charger before connecting or disconnecting the battery. - Always check the water level before charging to make sure the plates are covered. - Never overfill before charging. The electrolyte will expand during charging and may overflow. - After charging, add water to the battery manufacturer’s full mark. - Do not plug a battery charger into the forklift truck. This severely damages the forklift truck's electrical systems. **9-14** --- 10.2 BATTERY COMPARTMENT DIMENSIONS 10.1 REFILL CAPACITIES | REFILL CAPACITIES | ITEM | QUANTITY | | --- | --- | --- | | Liters(approx.U.S.gallons) | Drive Axle Boxes(per side) | 1.0 liter(0.26 gallon) | | Liters(approx.U.S.gallons) | Hydraulic System | 19.0 liters(5.01 gallons) | | BATTERY COMPARTMENT LIMITS | | | | | | | | | | --- | --- | --- | --- | --- | --- | --- | --- | --- | | MODEL | | | MAX LENGTH | MAX WIDTH | MAX RI | MAX LEFT | MAX RIGHT | | | SST. | 362 | 14.25 | | | | | | | | ET0214 | FBCS18N | ESCS14N | OPT. | 413 | 18.25 | | | | | OPT. | 464 | 18.25 | | | | | | | | ET0216 | FBCS18N | ESCS16N | OPT. | 464 | 18.25 | | | | | OPT. | 464 | 18.25 | | | | | | | | ET0318 | FBCS18N | ESCS18N | STD. | 540 | 21.25 | | | | Length Width Height in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) Standard 14.25 (363) 38.6 (980) 31.7 (805) | The BATTERY LENGTH AND WIDTH MUST be 12mm (0.5") SMALLER FOR INSTALLATION AND REMOVAL CLEARANCE. | | --- | | MACHINES RATED UL TYPE EE MUST UTILIZE AND LOOKABLE BATTERY | | SIDE SET BATTERY SCREW MUST BE ENHANCED against the BATTERY TO ELIMINATE LATERAL, BATTERY MOvement, MINIMUM BATTERY WEIGHT MUST BE INSTALLED FOR PROPER MODEL STABILITY. | | ENG JHBJ-05000 | | Model | | Length in. (mm) | Width in. (mm) | Height in. (mm) | Minimum Battery Weight lbs.(kg) | Maximum Battery Weight lbs.(kg) | | --- | --- | --- | --- | --- | --- | --- | | FBCS14N | Standard | 14.25(363) | 38.6(980) | 31.7(805) | 1600(727) | 1900(864) | | FBCS14N | Option | 16.25(413) | 38.6(980) | 31.7(805) | 2000(909) | 2300(1045) | | FBCS14N | Option | 18.25(464) | 38.6(980) | 31.7(805) | 2300(1045) | 2600(1182) | | FBCS16N | Standard | 16.25(413) | 38.6(980) | 31.7(805) | 2000(909) | 2300(1045) | | FBCS16N | Option | 18.25(464) | 38.6(980) | 31.7(805) | 2300(1045) | 2600(1182) | | FBCS18N | Standard | 21.25(540) | 38.6(980) | 31.7(805) | 2600(1182) | 2900(1318) | --- | Part | Lubricant | | Period(Hours) | | --- | --- | --- | --- | | Freezer Application | Normal | | | | Hydraulic System | 1 | 2 | 2000 | | Gearbox Oil | 3 | 4 | 2000 | | Grease Points | 5 | 5 | 1000 | | Grease Mast Channels | 6 | 6 | 2000 | | Chains | 7 | 7 | 1000 | --- Lubrication point 10.4 FLUIDS | 106 | Mast(both sides) | | Hydraulic oil filler neck | | --- | --- | --- | --- | | ◇ | Drain plug | ☆ | Hydraulic oil drain plug | | ▼ | Sliding surfaces | ◆ | Transmission oil filler neck | | ↓ | Lubrication point | ◇ | Drain plug | 10.4 FLUIDS Thickener Code Thickener Code °C (°F) penetration NLG1 class Type ASTM D2265 at 25 °C (77 °F) E Lithium-280 265 - 295 H Complex (536) (509 - 563) 10.5 ELECTRICAL FUSES | Grease Reference Values | | | | | | | --- | --- | --- | --- | --- | --- | | Code | Thickener Type | Dropping point $ ^{\circ} \mathrm{C} $ ($ ^{\circ} \mathrm{F} $) ASTM D2265 | Working penetration at 25 $ ^{\circ} \mathrm{C} $ (77 $ ^{\circ} \mathrm{F} $) | NLG1 class | Operating temperature $ ^{\circ} \mathrm{C} $ ($ ^{\circ} \mathrm{F} $) | | E | Lithium-Complex | 280 | 265-295 | 2 | -35/+120 H | | H | (536) | (509-563) | (-31/+248) | | | ^circ\\mathbf{}!mathbf c^{(circ\ \mathbf{})} 1. 2. Check the fuses ratings (109) against the table and replace if necessary. | WARNING | | --- | | To reduce the risk of fire, replace with the same DC fuse type and rating. | 1. Remove hood. 2. Check the fuses ratings (109) against the table and replace if necessary. --- ***CHAPTER 10 SERVICE DATA*** **Fuse ratings** **STANDARD** 2F16 **5A/58V** 4F7 **2A/58V** 6F6 **2A/58V** 1F13 **5A/58V** F4 **2A/58V** 4F8 **2A/58V** F25 **2A/58V** 5F11 **2A/58V** 1F12 **2A/58V** OPTIONS 6F9 **2A/58V** 5F1 **2A/58V** 5F7 **2A/58V** 5F2.2 **10A/58V** 5F2.1 **10A/58V** 6F9 **2A/58V** 5F2.3 **10A/58V** **10.6 USAGE CONDITIONS** **Environmental Temperature** Ambient temperature during operation should be -28°C (-18°F) to +40°C (+104°F). **NOTE: During constant use when there are** extreme temperature fluctuations and relative humidity condensation, special equipment and approval is required for forklift trucks. During constant use under 5°C (41°F), special modification and approval is required for forklift trucks. **10-4** --- Service weight with minimum weight battery, no load | Model | FBCS14N | FBCS16N | | --- | --- | --- | | Service weight without battery | 3181kg(6999lb) | 3211kg(7065lb) | | Service weight with maximum weight battery, no load | 4045kg(8899lb) | 4257kg(9365lb) | | Service weight with minimum weight battery, no load | 3908kg(8599lb) | 4120kg(9065lb) | | Model | FBCS18N | | --- | --- | | Service weight without battery | 3291kg(7241lb) | | Service weight with maximum weight battery, no load | 4609kg(10141lb) | | Service weight with minimum weight battery, no load | 4473kg(9841lb) | | Axle loading with maximum battery weight, rated load, front (drive) | 5503kg(12107lb) | | Axle loading with maximum battery weight, rated load, rear (steer) | 831kg(1828lb) | | Axle loading with maximum battery weight, no load, front (drive) | 2262kg(4977lb) | | Axle loading with maximum battery weight, no load, rear (steer) | 2236kg(4919lb) | --- Chassis nameplate Each forklift truck has a nameplate. It tells you the: • Forklift truck serial number • Forklift truck model designation Chassis nameplate - Forklift truck model designation Forklift truck serial number found on the Manufacturer Name Plate or the Forklift truck model designation Capacity Name Plate. The forklift truck serial number can also be found stamped on the inside of the front mini door, right side, under the battery connector. --- ***CHAPTER 11 TO THE MITSUBISHI FORKLIFT TRUCK OWNER*** **11.2 TO THE MITSUBISHI FORKLIFT TRUCK OWNER** **11-2** --- ***CHAPTER 11 TO THE MITSUBISHI FORKLIFT TRUCK OWNER*** **11.3 TRANSFER OF OWNERSHIP** Please help us ensure that we always have the **REPORT FOR MITSUBISHI** current owner on file. If the forklift truck is sold, **CUSTOMERS ONLY** please submit the following information to the MCFA address provided below. **11-3**