REFUELING

 REFUELING
Gasoline and Diesel Engine Equipped

R WARNING
- BE SURE to use the proper fuels specified in the SERVICE DATA. If not, the engine could fail.
- Forklift trucks must be refueled only at designated safe locations. Safe outdoor locations are preferable to those indoors.
- Stop the engine and get off the forklift truck during refueling.

R WARNING
- Explosive fumes could be present during refueling.
- DO NOT smoke in refueling areas.

R WARNING
Fire caused by static electricity!
- In dry seasons, there is a lot of static electricity. The fuel could catch fire due to the static electrical spark.
- When refueling, touch grounded metals with bare hand to discharge the static electricity before opening the filler cap.

R CAUTION
- Do not allow the forklift truck to become low on fuel or
completely run out of fuel. Sediment or other
impurities in the fuel tank could be drawn into the fuel
system. This could result in difficult starting or damage
to components.
- Fill the fuel tank at the end of each day of operation to
drive out moist air and to prevent condensation.
- Do not fill the tank to the top. Fuel expands when it
gets warm and may overflow.

E00549

Refueling steps
(1) Park the forklift truck only at a safe location.
(2) Lower the forks until the fork tips touch the floor or
ground.
(3) Apply the parking brake.
(4) Place the direction lever in the NEUTRAL position.
(5) Stop the engine.
(6) Block the wheels.
(7) Open the filler cap.
(8) Fill the fuel tank slowly. E00418
(9) Close and tighten the filler cap.
(10) If spillage occurs, wipe off excess fuel.

Note: Drain water and sediment from the fuel tank as needed. Also, drain water and sediment from the main fuel storage tank
before it is filled and as a weekly routine. This will help prevent water or sediment from being pumped from the storage
tank into the forklift truck fuel tank.

4-1
REFUELING
LP-Gas Equipped

R WARNING
BE SURE to use the proper fuels specified in Chapter “SERVICE DATA”. If not, the engine could fail.

R WARNING
- Only trained and authorized personnel must fill or exchange LP-Gas tanks.
- Personnel engaged in filling LP-Gas tanks must wear protective equipment such as a face shield, long sleeves, and
gauntlet gloves.
- DO NOT refuel or store LP-Gas powered forklift trucks near underground entrances, elevator shafts, or other places where
LP-Gas could collect in a pocket and cause an explosion.
- Inspect all LP-Gas tanks before filling, and again before reuse for damage to the valves, liquid gauge, fittings, and hand
wheels.
- All defective or damaged LP-Gas tanks must be removed from service.
- The careless handling of LP-Gas tanks could result in a serious accident.
- To reduce the risk of damage to tanks, use extreme care when transporting them.

R WARNING
The LP-Gas tank must not extend past the counterweight and must be inside the confines of the forklift truck.

R WARNING
Reduce the risks of fire caused by static electricity!
Touch grounded metals with bare hand to discharge the static electricity before changing compressed LP-Gas tanks. If not, the
fuel could catch fire due to the static electrical spark.

R CAUTION
LP-Gas tanks can be heavy. Follow the instructions below:
- DO NOT insert fingers into the straps or brackets. If this warning is not adhered to, fingers may be pinched.
- DO NOT lift LP-Gas tank with your body in an improper position. You may injure your back.
- Take care not to drop an LP-Gas tank. It may fall on your body and lead to serious injury including bone fractures.
- Wear appropriate personal protective equipment.

R CAUTION
Be careful not to pinch fingers in the bands when installing a LP-Gas tank.

Note:
- MOUNT THE TANK PROPERLY. To insure full usage of fuel, use the mounting holes located on the collar for horizontal
mounting and the slot in the foot ring for vertical mounting.
- Open the valve slowly so that hose and tank pressure can equalize. Or the valve may shut off.
- For proper operation of LP-Gas system, use HD-5 LPG fuel.

4-2
 REFUELING
 For Standard LP-Gas Tank
(1) Park the forklift truck on level ground.
(2) Lower the forks until the fork tips touch the ground.
(3) Apply the parking brake.
(4) Place the direction lever in the NEUTRAL position.
(5) Run the engine at low idle.
(6) Discharge the static electricity.
(7) Close the fuel valve on the LP-Gas tank. Run the engine
until it stops, then turn the key switch to the z (OFF)
position.
(8) Disconnect the fuel supply line.
(9) Loosen the retaining clamps, and remove the tank. D00388
(10) Make sure the replacement tank is the correct type.

(11) Inspect the replacement tank for damage such as dents, scrapes, or gouges and for leakage at valves or threaded
connections.
(12) Check for debris in the relief valve and for damage to various valves and the liquid level gauge.
(13) Inspect the couplings for deterioration, damage, or missing flexible seals.
(14) When lifting the tank for mounting, hold with both hands to prevent injury, and check the tank clamp lock.
(15) Clamp the tank securely.
(16) Connect the fuel supply line.
(17) Open the fuel valve by turning it slowly counterclockwise. If the fuel valve is opened too quickly, a back pressure check
valve will shut off the fuel supply. If this happens, close the fuel valve completely, wait five seconds, and then open the fuel
valve very slowly.
(18) Check the LP-Gas fuel lines and fittings with a soap solution after filling the tank or when looking for leaks.

4-3
REFUELING
 For Optional LP-Gas Tank
(1) Park the forklift truck on level ground.
(2) Lower the forks until the fork tips touch the ground.
(3) Apply the parking brake.
(4) Place the direction lever in the NEUTRAL position.
(5) Run the engine at low idle.
(6) Discharge the static electricity.
(7) Close the fuel valve on the LP-Gas tank. Run the engine until it stops, then turn the key switch to the z (OFF) position.
(8) Disconnect the fuel supply line.

(9) While pulling the lock pin 1, pull the LPG tank.
(10) Release your hand from lock pin 1, then down the LPG 4) 2)
tank to the lower left.
(11) When move the LPG tank approximately 180°, lock the 1)
striker 3 of cradle 2 to the snatch lock 5 of rotating shaft
4.
(12) Check that the cradle 2 is locked, then release your
hand. 3)
Note: If unlocked, the LPG tank will move up. 5)

G00003
1. Lock pin 4. Rotating shaft
2. Cradle 5. Snatch lock
3. Striker

(13) Loosen the retaining clamps, and remove the tank.

(14) Make sure the replacement tank is the correct type.
(15) Inspect the replacement tank for damage such as dents, scrapes or gouges and for leakage at valves or threaded
connections.
(16) Check for debris in the relief valve and for damage to various valves and the liquid level gauge.
(17) Inspect the couplings for deterioration, damage or missing flexible seals.

(18) Press the LPG tank with your hand, and move up the
snatch lock lever 6, then release the lock.
(19) Move up the cradle 2 to the upper right slowly.
7) 8)
(20) Mount the cradle 2 to the bracket 7, and press the right
side of LPG tank to lock with the lock pin 1. 1)
(21) Check that the cradle 2 is locked, then release your
hand.

2)
6)
G00004
6. Snatch lock lever 8. Rear side
7. Bracket

R CAUTION
- DO NOT move the forklift truck if unlocked.
- The lock pin 1 is not fixed with open position.

(22) Connect the fuel supply line.

(23) Open the fuel valve by turning it slowly counterclockwise. If the fuel valve is opened too quickly, a back pressure check
valve will shut off the fuel supply. If this happens, close the fuel valve completely, wait five seconds, and then open the fuel
valve very slowly.
(24) Check the LP-Gas fuel lines and fittings with a soap solution after filling the tank or when looking for leaks.

4-4