Introduction

The manual should be kept and read repeatedly by the operators.

The content of this operation manual includes: Correct operation, simple maintenance and
daily inspections.
Before operation, please carefully read this manual, to ensure the safe and efficient
material transportation through the correct driving and proper maintenance.
Owing to the improvement of product, the operation in this manual can be different from
the actual operation.
When you rent or transfer the forklift truck, this manual should be rented or transferred
with truck.
If you have some questions, please contact with our sales department.

Information about the signs

Indicate the approaching dangers which will cause death or severe

Danger injuries if not prevented. People should obey the instructions.

Indicate potential dangers which will cause death or severe injuries

Warning if not prevented. People should obey the instructions.

Indicate potential dangers which will cause mild or moderate

Caution injuries if not prevented. People should obey the instructions.

Words or sentences that are directly or indirectly related to the

personnel safety and the maintenance of the forklift.
Explanation:

1
 Content
Description of the forklifts and their device.................................................................................. 1
. About safety.............................................................................................................................2
1. Main use of forklift truck...................................................................................................2
2. Use site and working environment of forklift truck...........................................................2
3. Safety issues before use..................................................................................................... 4
4. Safety issues in the use operation...................................................................................... 6
5. Safety issue in the maintenance and service.................................................................... 14
6.Safety issues when using the accumulator........................................................................15
7.Safety issues in the installation, debugging and the use of attachment............................ 17
8. Problem about safety of using liquefied petroleum gas forklift.......................................19
9. Label................................................................................................................................ 21
II.Operation device and use method............................................................................................ 26
1. Liquid crystal meter......................................................................................................... 29
2. Switch part....................................................................................................................... 31
3.Control part.......................................................................................................................32
4. Truck body part................................................................................................................35
III. Driving and operation............................................................................................................ 40
1.The use of new truck.........................................................................................................40
2.Relation of load and stability of forklift........................................................................... 40
3.Load center and load curve...............................................................................................41
4.Stability of forklift truck................................................................................................... 41
5.Transportation and loading and unloading of forklift....................................................... 41
6.Before and after starting the engine.................................................................................. 42
7.Operation Posture of operator...........................................................................................42
8. Loading............................................................................................................................ 45
9. Stacking........................................................................................................................... 45
10.Unstacking...................................................................................................................... 46
11.Storage............................................................................................................................ 47
IV. Periodic inspection and maintenance..................................................................................... 49
1.Inspection requirement..................................................................................................... 49
2.Test content....................................................................................................................... 49
3.Maintenance......................................................................................................................55
4.Periodical maintenance schedule...................................................................................... 57
. Others.....................................................................................................................................66
1.Lubrication system chart...................................................................................................66
2.Forklift truck oil................................................................................................................67

2
Description of the forklifts and their device

This book is about 1-10t balance weight type forklift trucks, which can do the actions such as
lifting and landing, forward or reverse tilting, clamping, pushing and so on. It also can load
and unload, carry and stow. If it is assembled another attachment, it can be used to load or
unload some no casing products.
Several functions of forklift :
1. It can alleviate the work intension , save the labour force , enhance the productivity ,
according to some foreign ducuments , a forklift truck can do the work , which need 8-15
persons to finish .
2. Because of enhancing the productivity and shorting the work time , so accelerate the work
speed of trucks and ship .
3. using the forklift to work , the goods can be stowed higher , for example now it can stow 3m
or even higher , so the rate of using the storage can be enhanced about 30% or 40%
4. It can use stock and container to fill goods , it makes packing simple , and save the cost of
packing , cut down the cost of loading and unloading , enhance work efficiency and safety .
5.it can instend of body work , reduce damageing the workers and goods , enhance work
safety .

1
.. About safety
Safety is your happy partner, and this
chapter mainly introduces the basic
safety rules and warnings of standard
forklift truck in the general use, and also
applies to the forklift truck with the mast
and attachments with special specs.
1. Main use of forklift truck
1) Main use of forklift truck
This forklift truck is mainly used for
loading and unloading, stacking
conveying the goods on the pallet, in
addition, if the forklift truck is equipped
with appropriate attachments, it can also be
used for loading and unloading, stacking
and conveying the goods not placed on the
pallet.
2) Other usages is forbidden except for the
allowable use
The use, except for allowable use, refers to
the use of driving with person, high lifting
with person and drawing other vehicle etc.,
the use method forbidden in this manual is
also not allowed.
Example for other usage
usage::
Fork or pallet standing person is lifted
high.
Pallet standing person presses the goods.
Lift the goods with fork which is directly
connected with the steel rope.
Drawing other vehicle.
The fork pushes the goods or other
vehicle.
The fork opens or closes the door of other
truck etc..
and
2. Use site and working environment
of forklift truck
1) Ground status
The use site of forklift truck should be flat
and firm road or ground, and the ventilation
is good.
The performance of forklift truck depends
on the ground status, traveling on the ramp
or rough ground should be very careful,
and the deceleration should be done.
Warning
The truck traveling on the dirt road
should not fall into the dirt.
Bypass the barrier, if unavoidable, the
deceleration should be done, and you
should pay attention to not damage the
chassis of truck.
2
 The anti-skid chain should be used when
the truck is traveling on the snow and ice
road, the rapid acceleration, hard braking
and sharp turning should be avoided, and
the traveling speed should be controlled
through the accelerator pedal.
Warning
After the anti-slid chain is installed, the
adhesive power between the forklift
truck and the ground should
increased, but you should especially pay
attention to that the side-slide
performance should be reduced.
2) Climatic conditions
Warning
In the case of a great wind, the
high-lifting should be avoided when the
truck is working outdoors, to prevent
the falling of goods, and to avoid the
accidental injury to the driver.
3) Measures to deal with cold and hot
weather
a) Oil
The oil which is adaptable the
surrounding temperature should be
selected according to the changed
reason.
b) Accumulator
In the cold season, under the normal
charging conditions, the freezing point of
electrolyte is about -35, the charging of
accumulator should be kept under the
better condition, the volume expansion
can damage the accumulator case after
the electrolyte is frozen, in order to
prevent the freezing and better charge the
accumulator, the electrolyte can not be
added too much but at least the added
volume should be 75% of the total
volume, that the specific density is 1.260
is the effective method, and this value
should be exceeded.
In the hot season, the water in the
electrolyte is easily evaporated, so the
inspection is done once a week, if
be necessary add the distilled water, when
the ambient temperature is high, the
specific density of battery electrolyte
should be reduced to 1.2200.01, owing
to the accumulator has higher efficiency
at the high temperature, so the other
maintenance is not needed.
Danger
The gas produced by the accumulator
can explode, so the smoking and the
naked fire is forbidden, and the electric
arc and spark should not be produced
near the accumulator, when it is stored
or recharged in the close space, the
ventilation should be better, the sulfuric
acid in the electrolyte can cause burn, so
the electrolyte can not contact the eyes,
skin and clothes, if there contact the
sulfuric acid, you should immediately
wash with water, and you should go to
hospital if the eye is contacted with the
sulfuric acid.
c) Cooling liquid in the water tank
If the cooling system of forklift is filled
with the long-term antifreeze, the freezing
point of this antifreeze should be -35.
In the hot season, in order to get a good
cooling effect, you should frequently
3
 wash the external tank, and the outdoors
parking should be in the shade place.
Attention: The forklift can't be operated in
the flammable and explosive place.

4
3. Safety issues before use
1) Obtain the operation qualification
Only the operator who is trained and gets
the certificate can operate the forklift
truck.
4)
The characteristics of brake, accelerator
and hydraulic control handle of each
forklift truck with the same technical
parameters may not be different, so you
should operate the forklift truck after
carefully read this manual and the rating
plate and be familiar with all operations.
2) Wearing when operating the forklift
truck
Caution
You should wear work clothes, shoes
5)
and safety cap.
In order to ensure the safety, do not
wear the loose clothes, to avoid being
caught and unpredictable danger.
6)
3) Drink-driving is strictly forbidden
5
Caution
When you feel tired, do not focus on
your thought, or use anesthetic or drink,
do not drive the forklift.
Safety at the work place
Caution
Keep a better road condition, and the
road should be unobstructed.
In order to ensure safety, the working
site should be enough lighting.
When operating on the platform or on
the access board of dock, there is the
tilting danger, so you should use the
spacer block or other protective
measures to prevent tipping.
Keep the cab clean
Caution
The cab should be kept clean.
When the hands are wet or have oil, do
not operate the forklift truck.
The tools or other metal objects should
not be placed in the cab, because these
parts can hinder the operation of control
lever or pedal.
Integrity of the forklift
Caution
When leaving the factory, the standard
forklift truck should be equipped with the
overhead guard and the load-backrest.
Explanation
The overhead guard is used to prevent
the falling of goods, there should pay
attention to that the overhead guard is
used to prevent the falling and
impacting of the small object, but can
not prevent the falling and impacting of
related load, so the load should be used
the pre-protective measure.
 Warning 8) Avoid fire
Without our written permission, that the Caution
forklift is modified or equipped with In order to prevent the fire, the
any other work device is not allowed, or extinguisher should be set, and you
wise there may affect the related load or should operate it according to the use
safety operation. requirement of extinguisher.
Do not install any parts which can block 9) Overloading is forbidden
the line of sight of driver.
Caution
7) Periodic Maintenance Do not overload, the overloading can
result in the tilting of truck, and the
Caution
allowable load can be confirmed
Daily maintenance and periodic
according to the load center.
maintenance should be done.

Explanation
The allowable load is a maximum load
placed at the center of fork and load.

Warning
When there found that the forklift is
damaged or faulted, stop the forklift truck
and immediately inform the maintenance
personnel, you can not operate the 10) Use the appropriate pallet
forklift before the forklift truck is
thoroughly inspected and repaired.

6
 person.
Caution
When reversely traveling, turn your face
The pallet with the available dimension
backwards, and you can drive after you
and strength can be chosen according to
confirm no person or barrier at the back
the load.
place, and the rearview mirror and the
Ensure that the load is fixed on the
reversing buzzer are the auxiliary
pallet and there should be a suitable
device.
shape.
Conveying a small and scattered load
without pallet is forbidden.

4. Safety issues in the use operation

1) Points for attention when starting up

Pull on the hand brake.
The shift control lever is placed at the
neutral position.
Step down the inching pedal or brake
pedal.
Adjust the seat to easily control by
hands and feet.
Ensure that there is nobody at the upper,
lower, front and back of forklift truck.
When driving the forklift truck on the
small channel, there should be guided
by other person.
The driver should stop the truck at the
cross road or other place of limiting the
sight, and he can drive the truck after
confirm that there is nobody around the
truck.

2) Points for attention when the forklift

truck is traveling
Caution
When conveying the huge load which
hinders the line of sight, please
reversely drive or being guided by other
7
You should ensure that there is enough
safety space around the forklift or at the
edge of platform, to prevent the falling
of forklift.
The forklift truck is different from the
 car, it is turned by the rear wheel, and
the traveling speed should be reduced
when turning, and then the steering
wheel is rotated to turn the forklift
truck.

Explanation
Do not travel on the road with baffle or
barrier.

3) Wildly driving is forbidden

Caution
The key switch should not be opened
when you step down the accelerator
pedal.
Do not suddenly start up, brake or turn,
the suddenly starting up or braking can
cause the falling of load, and the
suddenly turning can make the forklift
turn-over and result in the serious
accident.
Whether under the full load or the
unload condition, you should slowly
operate the hydraulic control handle, if
you suddenly operate the handle when
the load is at the high position, there can
cause the falling of load or the turning
over of forklift truck. When traveling near the other vehicle,
you should reduce the traveling speed
and give a horn.
Do not enter the soft ground.
When traveling on the wet, sliding,
uneven or tilted road, you should reduce
the traveling speed.

8
 Ensure that there should be a certain gap
between the mast and indoor load and
entrance.
4) Traveling when the fork is lifted high is
forbidden
6) Pushing or pulling operation is forbidden
Caution
Caution
Do not drive the forklift truck when the
Do not push or pull the load with the
fork is lifted, or wise there may cause
forklift, or wise the load may be
the instability and may lead to the
damaged o fallen.
tipping of forklift.

7) Driving on the ramp

5) Operation with fork tip is forbidden
Caution
Piling or lifting the load with fork tip is
not allowed, when the load is lifted with
the fork tip, there may cause the damage
to the forklift or load.
Caution
When traveling on the ramp, you should
follow the following rules:
With load: Driving forward when climbing
up the ramp, and driving backward
when climbing down the ramp.
Without load: Driving backward when
climbing up the ramp, and driving
forward when climbing down the ramp.

9
 Conveying the offset load can cause the
falling of load and the tilting of forklift.

When climbing down the ramp, the

brake should be used and you should
carefully drive, to ensure that the fork is
not impacted with the ground.
Turning or loading operation at the
ramp is not allowed, or wise there is a
tilting danger.
9) Standing on and under the forklift truck
8) Offset stacking is forbidden is forbidden
Caution Warning
When stacking, there must ensure that The traveling and lifting of fork and
the load is arranged safely and steadily, pallet standing person is forbidden.
the fork should be accurately inserted
into the pallet, simultaneously the center
of gravity of load should be consistent
with the center of forklift truck.

That the other person, except for the

driver, operates the forklift is forbidden.
That the person balances the overloaded
forklift truck is not allowed.

10
 Standing on the load and walking under
the fork is forbidden.

11) Lifting the fork when the mast is

inclined forward is forbidden

10) Entering the mast mechanism is
forbidden
Warning
That any part of body enters the mast
mechanism or place between the mast
and body is forbidden.
Caution
The body should be in the overhead
guard, that the any part of body goes out
of the truck is not allowed.
Caution
When the mast is inclined forward, that
the load is lifted and the forklift is
operated is not allowed, before lifting
the load or driving the forklift, you
should make the mast incline backward
to the proper place to steady the load,
when driving (with load or without
load), the distance between the fork and
the ground should be kept 150~200mm.

11

13) Enter and leave the forklift
When loading the goods with fork, the
mast can not be inclined forward.
When lifting and lowering the goods,
you first stop the truck.
When the mast is in the tilting condition,
do not load or unload the goods.
12) Carriage operation
14) Forbid: The height of goods can not
Caution
The forklift only can be done the
loading and unloading operation when
12
the trailer is fixed on the goods
platform.
Before starting the operation, you
should fix the overbridge board and test
its strength.
The speed should be reduced when
entering or leaving the carriage, and you
should pay attention to whether the
overbridge board is steady.
Caution
Jumping on and down the forklift truck
is forbidden.
When entering or leaving the forklift,
the hands should hold the handle, and
the feet should step down the pedal.
When entering or leaving the forklift,
you can not hold the steering wheel or
the control lever.
exceed the specified height.
Caution
The goods should lean the load-backrest,
the height of goods can not exceed the
height of load-backrest, or wise that the
goods are slid to the direction of
operator may occur, and the driver may
be damaged by the goods.
 In order to prevent the collapse, the
overlapped stacking goods should be
conveyed after they are fixed.
If the wearing phenomenon occurs in
the use of chain, and when the changed
value of chain pitch exceeds the 2% of
the standard value, the chain must be
replaced to ensure the loading safety.

16) Fork adjustment

Caution
According to the size of loading pallet,
the space of fork should be adjusted to
the most appropriate position, when
adjusting, you should pay attention to
that the hands can not be pressed.

15) Chain status

Caution
When the chain is loose, the fork can
not be drawn from the pallet, or wise the
falling of goods or the tilting of forklift
can occur.

After the fork space is adjusted, the fork

is fixed with the fixed pin, if it is not
fixed, the fork is easy to move in the
traveling process, and the good may fall
and may be broken.

Explanation
When the chain is loose, pull up the
lifting handle slightly to lift the fork and
to correct the loosing of chain, and then
17) Convey the goods which exceed the limit
the fork is drawn from the pallet.

13
 Caution
When conveying the over-long or the
over-wide goods, the driver should be
very careful.
When turning and lifting and lowering
the goods, the speed should be reduced,
to avoid the moving of goods, and
simultaneously you should pay attention
to the surrounding safety.
When conveying over-wide goods, the
forklift truck should be equipped with
the appropriate widening fork arm
carriage and the lengthening fork, the
supporting capacity of lengthening fork
should be strictly confirmed according
to the requirement of load curve, within
the specified load center, its bearing
capacity is the same with that of
standard fork, the bearing capacity
should be lowered when the load center
goes forward.

18) Unloading goods with hands is forbidden

Caution
Do not unload the goods with hands, to
prevent the accidental injury.

14
19) Parking the fault truck
Explanation
If the forklift truck is stopped at the side
of road, the warning or the Fault mark
should be hung on the truck, and the key
should be pulled out.
21) Parking
When the fork can not be lowered
because of the fault, the more obvious
mark should be done at this place, to
prevent the collision of other vehicle
and people.
20) Points for attention before leaving the
forklift after the work is over
Explanation
The mast should be inclined forward
slightly, and the fork is naturally placed
down, or wise there is a risk of tripping
and body injury.
The direction handle should be placed at
15
the neutral position.
Pull on the brake parking handle.
Turn off the key switch and pull out the
key.
Caution
Please park the forklift at the specified
place.
The parking place must have enough
strength and can not hinder the traffic
safety.
Parking at or nearby the inflammable
place is forbidden.
Parking at the ramp is forbidden,
because the unexpected movement of the
forklift truck may occur, if parking at
ramp can not be avoided, besides the
general parking procedures are carried
out, the stop block should be padded
under the tire to prevent the movement
of forklift.

22Noise
Do the test following the standard PrEN
12053On the flat solid surface road, test
the noise according to the sound power
test , the noise number is 109.9db A
exterior the forklift.
At the driver 's position the highest noise
number is 89.8dbA,calculate the noise by
sound pressure grade, around the vehicle
calculate it by sound ratio grade .
Caution
If on the coarse and irregular road, the
tyres will distort, and the noise number
will be higher.
23) Vibration:
Do the test following the standard PrEN
13059At the maximal running speed on
the unloading condition, the vibration
number is 2.04m/s.
5. Safety issue in the maintenance
and service
(1) Maintenance and service site
The site should have the maintenance
device and the safety protective facility.
The ground of site should be level.
The ventilation condition of site should
be better.
16
The site should have the
fire-extinguishing equipment.
(2) Points for attention before maintenance
and service
Caution
Smoking is forbidden.
Wear the protective articles.
Immediately wipe up the overflowed
oil.
Before the lubrication grease is added,
you should clean the dirty oil or dust
from the joint or the nozzle tip with
brush or cloth, and then the lubrication
grease can be added.
Except for the conditions of
maintenance condition, the key switch
should be turned off.
When the maintenance of forklift, the
forks should reach the ground.
When maintain the high idler wheels of
mast, should take your safeguard,
protect from slipping and dropping.
Clean the electrical components with
compressed air.
(3) Points for attention for maintenance and
service
Caution
The feet should not be placed under the
fork, and not be tripped by the fork.
When the fork is lifted, the spacer block
or other pad should be padded under the
inner mast to prevent suddenly falling of
fork and mast.
You should carefully open and close the
front bottom plate and the cover of
accumulator box, to avoid pressing the
 figures.
When the work can not be finished one
time, the mark should be made to
continue the next work.
Use the appropriate tool, and do not use
the temporary tool.
Because the hydraulic oil circuit has a
very high pressure, the maintenance
work should not be done before the
internal pressure of oil circuit is
reduced.
The mast can not be used as the ladder.
When maintaining or servicing the hot
machine, you should pay attention to
that the temperature of drive device or
hydraulic system may be high, so the
truck should be cooled before
maintenance and service, to avoid the
accidental scald.
(4) Test and replace tire
Caution
The dismantling and installing work
should be done by the professional
personnel.
You should wear protective glasses
when using the compressed air.
When charging the tire, you should test
whether the rim lock ring is assembled,
and the incorrect assembly of lock ring
can cause risk.
(5) Use the jack (when replacing tire)
Warning
When the forklift truck is lifted with
jack, your body should not enter the
under of forklift.
Caution
Before the forklift is lifted with the jack,
17
you should ensure that there are no
people or load on the forklift truck.
When the wheel is lifted from the
ground, the use of jack should be
stopped, and the spacer block should be
padded under the forklift, to avoid the
falling of forklift.
Before the forklift is lifted with jack, the
measures should be taken to prevent the
sliding of forklift.
(6) Exhaust waste (waste electrolyte and oil
etc.) requirements
The waste liquid and waste oil from the
forklift should be restored according to
the requirement of the local government,
and exhausting without permission is
not allowed.
6.Safety issues when using the
accumulator
(1) Smoking is forbidden
Caution
The battery can produce the hydrogen,
and the electric spark can be produced
when the short circuit occurs, when the
igniting cigarette is near the
accumulator, the explosion and fire can
occur.
(2) Electric shock is forbidden and that the accumulator is covered with
the polythene film is not allowed.
Caution
The accumulator has high voltage, when The static can cause the explosion.

the installation and maintenance are The uncovered top of accumulator

done, you do not contact the conductive should be cleaned with the wet cloth.

body of accumulator, which can cause (7) Wear the protective clothes
the serious burn.
Caution
(3) Correct connection When maintaining the accumulator, you
should wear protective glasses, rubber
Caution
glove and rubber shoes.
When the accumulator is charged, the
positive and negative poles can not be
connected inversely, or wise there can
cause high temperature, burning and
smoking or explosion.
(4) That the metal objects are placed on the
accumulator is forbidden

Caution
That the short circuit occurs because of
the contact of positive and negative poles
by the bolt or tool is not allowed, which
(8) The electrolyte of accumulator is
can cause the injury and the explosion.
harmful.
(5) Over-discharging is forbidden
Caution
Caution
The electrolyte of accumulator is made
The over-discharging of accumulator of diluted sulfuric acid, so you should
can cause the short service life of be careful when conveying.
battery, when frequently starting up and When the electrolyte is adhesive on the
the spacing interval is often short, the eye and skin, the vision loss and scald
voltage of accumulator should be often may occur.
inspected and the re-charging should be
(9) Emergency treatment method
immediately done.
Explanation
(6) Keep clean
When the accident occurs, the following
Caution emergency treatment should be done and
Keep the surface of accumulator clean. you should contact the doctor
Do not clean the surface of accumulator immediately
with dry cloth and chemical fiber cloth, Splashing on the skin: wash with water
18
 for 10 ~ 15 minutes. our sales department.
Splashing into the eyes: wash with Accumulator stinks.
water for 10 ~ 15 minutes. Electrolyte is dirty.
There is large-area pollution: neutralize The concentration of electrolyte is high.
the electrolyte of accumulator with soda The reduced speed of electrolyte is too
(sodium bicarbonate) or wash it with the fast.
water.
(14) Dismantling is forbidden
Drink: Drink plenty of water and milk.
Splashing on the clothes: immediately Caution
remove the clothes. Do not drain the electrolyte from the
accumulator.
(10) The upper cover of accumulator should Do not dismantle the accumulator.
be closed tightly Do not repair the accumulator.
Caution (15) Storage
The upper cover of accumulator should Caution
be closed tightly to prevent the leakage When the accumulator is not used for a
of electrolyte of accumulator. long time, it should be kept at the place
The electrolyte should not be added too with better ventilation and without
much, and the splashed electrolyte can unexpected fire.
cause the electric leakage.
(16) Treatment for the discarded accumulator
(11) Wash
Caution
Caution When disposing the discarded
The forklift can not be washed when the accumulator, you should contact with
accumulator is on the forklift, or wise our company or the authorized server
the accumulator can be damaged. department.
The upper cover of accumulator should
be closed tightly to prevent the water. 7.Safety issues in the installation,
debugging and the use of attachment
(12) Sea water

Caution (1) Installation of attachment

The sea water can erode the In order to ensure that the attachment can
accumulator case, which can damage not slide from the right to left along with
the accumulator or cause the fire. the fork arm carriage in the use process to
cause safety issue, the attachment must be
(13) Abnormal phenomena of accumulator
installed and located reasonably, reliably
Caution
and safely.
When the following conditions of
After the attachment is equipped, the block
accumulator occurs, please contact with
of upper hook equipped with the

19
 attachment should be inserted in the gap of detailed understanding for the allowable
cross beam, to make the offset between the load of forklift, lifting height, size of
center lines of attachment and fork arm goods and available range of
lower 50mm, if not the cross stability can attachment.
be affected; after the attachment (paper b. When you operate the attachment of
clip, soft clip, multi-purpose steel arm clip forklift with many functions (side-move,
and barrel clip etc.) with rotary function is clamping or rotary etc. functions), the
installed, the stop block should be weld at two actions should not be
the two sides of connection of cross beam simultaneously done, the action should
of fork arm carriage and attachment, to be done after the other action is
prevent the left and right sliding of finished.
attachment in the operation process; when c. The overload of forklift with attachment
the attachment with lower hook is installed, is forbidden, the offset is not allowed
the clearance at the mating place of the when the load is lifted at high position,
lower hook and lower cross beam of fork for the offset load operation at high
should be properly adjusted. position (especially the side-move type
All attachments in the world adopt the flat clamp with combination valve, that
hook installation, the mating installation of is the shared flat clamp of side-movable
attachment and forklift truck should not oil cylinder and adjustable oil cylinder),
have any issue, you should choose the there only is allowed a short time
attachment of mating the forklift truck operation, the offset should be strictly
strictly according to the internal standard controlled within the range of about
ISO 2328 Installation size of hook-type 100mm;
fork and for arm carrier. d. That the forklift with attachment is
(2) The use of attachment driving at high position is forbidden;
a. The operator who operates the e. Standing under the attachment of
attachment of forklift should have the forklift and the 1.5m range out of the
practical experience of operation, at the shadow area of goods is forbidden, to
same time the operator first should be avoid the accident.
familiar with the related indication on f. Without our companys technical
the nameplate of forklift, read the permission, any modification for the
related use instruction (especially for safety and performance of attachment of
the use guideline and installation forklift is strictly forbidden.
instruction of professional attachment
company,) fully know the basic Caution
The bearing capacity on the sample
performance and operation method of
instruction issued by all attachment
attachment, and especially have a more
20
manufacturers only is an evaluated value
for the attachment itself, and is not the
bearing capacity when the whole forklift is
equipped with the attachment. The bearing
capacity of forklift equipped with
attachment should be that the bearing
capacity of forklift without attachment
subtracts the weight of attachment when
the load center is not changed, when the
load center is changed, the bearing
capacity should be confirmed according to
the load curve chart.

21
8. Problem about safety of using liquefied petroleum gas forklift
1) Notice about charging the gas.
a).Two kinds of methos to charge gas for
quefied petroleum gas forklift : the one is
change the gas bottle , the other is
charging gas into the steel bottle directly .
You should charge or change the gas in
the outer use site with good ventilation ,
safety and according with
regulations of fire protection constituted
by local government .
Before the operator leaving the cab , the
forklift should stop stably , and
flameout the engine .
It is forbidden that there
pyrotechnical , hot power , fire material
and low-lying (to aviod the
depositing ) near the gas forklift .
Carry the steel bottle carefully , after
disassembling it from the truck , don't
collide , throw or roll it on the ground .
Only the professional operators can
charge the gas .
When charging the gas , the worker
should stay at the site to supervise the
whole course .
b) The operator should have a habit of
checking the steel bottle ,while change
the bottle or charge the gas .
If there is serioue concave , scrap and
rust on the steel bottle ;
If there is obvious damnify or leakage
gas about the appearance of the bottle
fitting ;
If there is something block the safety
pressure valve on the bottle ;
If the steel bottle is in the period of
validity , if it is at term , you should
supply to some relevant derpartment as
soon as possible . If there is no denitrify
from relevant department to the bottle
that more than 15 years old , you should
take the bottle away .
the
Caution
If there is one of the problem above all ,
the steel bottle should not be used , and
should be repaired or even changed on
time .
is 2) The quality and componentof the liquefied
petroleum gas
gas The purity of liquefied petroleum gas
effect the operation of forklift directly ,if
there is some impurity , eyewinker, water
and tar , the pipe and fitting will be block
in the gas system . This problem will cause
the barrier , which will make the engine
running unstably and the output decreased,
and even make the engine flamout and
start difficultly .
You Should use the liquefied petroleum
with high purity and less impurity ,water
and tar ,especial the propylene must be
less than 5%.
If the climate is bad at the truck use site ,
please maintain it termly to clean the
eyewinker and tar in the liquefied
petroleum system , you also need
change the filter net or some other
22
 fitting to make sure the engine running
smoothly ; the worse is the purity of the
gas , the shorter is the period of
repairing ;
When the temperature is under freezing ,
because the vaporizing speed
liquefied petroleum gas , you should
add the dimethylmethane into the gas to
help it volatilization.
3) The measure for solving urgency
aGenerally some olid medicament will add
into the gas , so we can test the leakage
easily , if you smell the peculiar smell :
Drive the truck to some place with good
ventilation and flameout the engine ,
make sure there is no fire nearby .
Turn off the switch and turn it tightly ;
Check every pipe and fitting and the
liquefied petroleum changing device ,
and find out all the leakage parts , and
let the professinal operator to repair it .
bIf happens emergence :
Stop the truck and flamout the
engine ;Turn off the handle switch
tightly ;
Make sure there is no fire around the
truck , if need you can take a fan to help
blow away the leakage smell ;
Let regular and professional operators to
check and repair it ;
cIf it happens a fire :
If you have a chance , turn off the
handle switch tightly ;
If there is some water , pour it to the
steel bottle to make the bottle cool ;
Report to the fire protection department
at once ;
If the steel bottle fires , you should
evacuate the people nearby .
4) Notice of using
Don't use the truck near fire ;
All the electrical wire fittings should be
of tight , that will protect from being short
circuit or some other barrier ;
Don't use the LPG fuel indicator on the
forklift meter , please refer the fluid
indicator on the steel bottle ;
Don't inpour flammabily fluid into the
LPG fuel tank . But after cleaning the
tank , you can inpour some prevent
frostbite material without flammability
then close the tank .
Use the high purity , qualify and good
component liquefied petroleum gas as
you can ;
Follow the measures suggested by the
engine manufacturers , maintain it
termly , including the fire system ,
cooling system , inspiration system and
exhaust system , body of the engine and
other mechanical device , you also
should change the petrol , spark plug
and air filter ;
The liquefied petroleum gas system
should be maintained ternly ;
If there is some barrier in the liquefied
petroleum gas system , you should
report it to the primary assembly
factory , and sent it to the appointed
factory to repair .
23
9. Label

The label plate on the truck can show the use method and notes of truck, which is not only for
your sake, but also for the sake of the truck, please immediately re-past it after the label plate
is fallen.

1) Load curve label plate

2Handle
Handle position lable

24
3) Use information label plate

4) Forklift nameplate

25
5) Lubrication system label plate

6Shift
Shift gears label plate 7Reversing
Reversing label plate

26
8) Safety label plate 11
11Tyre pressure label plate (inflated tyre)

12) Hands injury label

9) Lifting label

13 Fuel label
13Fuel

10 Lifting label
10Lifting

27
14 Hydraulic oil lable
14Hydraulic 17 No Lifting label
17No

15 Fan safety label

15Fan

16 No swash lable
16No

28
II.Operation device and use method

1. Outer mast 8.Frame 15. Overhead guard

2. Inner mast 9. Engine cover 16. Head lighting

3. Load-backrest 10. Tilting cylinder 17. Front combination lamp

4. Fork arm carriage 11. Seat 18. Rear combination lamp

5. Fork 12. Steering wheel 19. Counterweight

6. Drive wheel 13. Foot pedal

7. Steering wheel 14. Parking bake

29
1. Fork 8. Liquefied gas steel cylinder

2. Load backrest 9. Blanceweight

3. Mast 10. Rear wheel (steering wheel)

4. Steering wheel 11. Frame

5. Rear-view mirror 12. Engine hood

6. Seat 13. Front wheel (driving wheel)

7. Roof steel grid

30
 Hydrodynamic drive forklift

1. Water temperature indicator 7. Turning signal handle 13. Inching pedal

2. Hour meter 8. Ignition switch 14. Steering wheel
3. Indicator light 9. Lifting handle 15. Extinction cable
4. Fuel gauge 10. Tilting handle 16. Front and back handle
5. Horn button 11.Throttle accelerator pedal 17. Cover cable
6. Lamp switch 12. Brake pedal 18. Brake parking handle

31
 Mechanical drive forklift

1.hour meter 7.horn bottom 13.lift handle

2.water temperature indicator 8.shift handle 14.warm-up start switch
3.fuel gauge 9.lamp switch 15.turning signal handle
4.brake packing handle 10.brake pedal 16.clutch pedal
5.front and back handle 11.accelerator pedal
6.steering wheel 12.tilt handle

32
1. Liquid crystal meter

Chart 2.3 ZB908 combination meter

1.hour meter 5.warm-up indicator light

2.electricize indicator light 6.water temperature meter
3.oil pressure indicator light 7.fuel meter
4.grease abruption indicator light

Indicator specification
1) Hour meter
This meter is used to measure the working time of truck, and the lubrication and maintenance
should be arranged according to this meter.
2) Rechargeable light show
This light can show the charged situation of battery, when the preheat starting switch is
33
 turned to the ON position, the light is on, however when the engine is started and is stably
running, the light is off.
Caution
If the light is continuously on or flashes in the operation process, there show that the electric
system has fault, and it should be immediately inspected.
3) Oil pressure warning show
This light can show the pressure situation of engine lubricating oil, when the starting switch
is turned to the ON position, the light is on, however when the engine is started and is
stably running, the light is off.

Caution
If the light is continuously on or flashes in the operation process, there show that the oil
pressure is insufficient, and it should be immediately inspected.
4) Oil-water separation show
In the running process of engine, when the water in the oil-water separator reaches a certain
height, this light is off.
In the running process of engine, if the light is continuously on or flashes, you should
immediately turn off the engine and drain the water in the oil-water separator.
Caution
If the truck is being operated when the light is on, the filling pump may be damaged.
5) Engine Preheat show
There is a set of complete QUICKONSTART system when the forklift truck is
cold-started, and the start switch is not set the Preheat position.
The key is turned to the ON position, the display light is on for some time, and the key can
turned to the START position after the light is off.
6) Water temperature indicator
This water temperature indicator can show the temperature of the cooling liquid of engine,
under the general situation, the needle pointer should be in the normal area (75~ 110).
Caution
If the needle pointer is in the warning area (110~145), the operation should be
immediately stopped, reducing the engine speed can lower the temperature of cooling
liquid until the needle pointer is returned back to the normal area.
7) Fuel gauge
When the preheat starting switch is turned to the ON position, this gauge can inform the
remaining fuel in the fuel tank, E indicates empty, F indicates full, when the height
of fuel is reduced to the 1/8, the needle pointer can enter the warning area.
Caution
The fuel tank should be fully added after every working day (or each shift), which can reduce
the condensation of water in the oil tank.

34
2. Switch part

1) Preheat starting switch

OFF
This is the position of inserting or pulling out the
key, the engine can stop the operation when the
key is in this position.

ON
When the starting switch is in the ON position,
the circuit is closed, the key should be in this
position after the engine is started up.

START
When the key is turned to the START position, the starting motor is meshed, when the hand
loose the key, the key can automatically return to the ON position by its elasticity.

Caution
When the engine is turned off, the starting switch can not be at the ON position, which can
cause the leakage of battery.
When the engine is running, the starting switch can not be turned to the START position,
which can make the starting motor damage.
The meshing time can not exceed 15s for each startup of engine, and you should wait about
20s before re-start.

2) Lighting switch
The lighting switches have three gear switches.

Gear
0 1 gear 2 gear 3 gear
Light
Wide light OFF ON ON ON
Taillight OFF ON ON ON
Head light (short-distance) OFF OFF ON OFF
Head light (long-distance) OFF OFF OFF ON

35
3.Control part
(1) Steering wheel
The steering wheel can be operated in the
normal way, that is, when the steering
wheel is rotated to the right, the forklift is
turned to the right; when the steering
wheel is rotated to the left, the forklift is
turned to the left; the steering wheel is
installed at the rear of forklift, which can
make the rear of forklift can swing out
when turning. Through a little practice, the
turning in this way can be easily grasped.
Warning
The power of hydraulic steering device is
provided by the engine, so the steering is
difficult when the engine is turned off, if
the hydraulic steering is carried out, the
engine must be re-started, do not delay.
(2) Horn button
36
Pressing the horn with plastic cover at the
center of steering wheel can give a voice,
even if the starting switch is turned off, the
horn can give a voice.
(3) Switch handle of turning signal light
This handle can be used to control the
switch turning signal light when the forklift
truck is turning, when the handle is in the
turning position, the turning signal light
flashes.
R Right turning lamp is on
N Middle position (turn off)
L Left turning lamp is on
Caution
The switch handle of turning signal light
can not be automatically returned to the
middle position, and the hands can make it
reset.
(4) Lifting handle
The pulling backward or pushing forward
of this handle can lift or lower the fork, the
lifting speed can be controlled by the tilting
angle of handle and the force of accelerator
pedal, and the lowering speed can be
controlled by the tilting angle of handle, the
larger a, the larger speed. The engine speed
or the accelerator pedal is independent of
the lowering speed of fork.
(5) Tilting handle
The mast can be inclined through the
operation of this tilting handle, pulling
Warning
backward this handle can make the mast
If the parking on the ramp is not
incline backward, pushing forward this
avoided, the wedge block should be
handle can make the mast incline forward,
padded under the wheel.
the tilting speed can be controlled by the
(7) Shift handle
inclined angle of the handle and the force
Mechanical drive forklift
of the accelerator pedal, the larger angle,
the larger speed. Forward-backward handle

Caution F Forward
When the engine is turned off, even if N Neutral
the tilting handle is pushed forward, the
R Backward
mast in the self-locking condition can
not be inclined forward because of the Shifting handle
tilting lock device installed on the
multiple-way valve. 1 Low speed

(6) Brake parking handle N Neutral

When braking, pulling backward this handle
can make the brake installed on the output
shaft of gearbox or input shaft of drive axle
work, this handle can be pushed forward
after the brake parking is disconnected.
2 High speed
Transmission control is the bottom fixed
installations, and have two steps forward
and backward speed, we must shifting after
the clutch pedal fully depressed, change the
direction of completely braking operation.
Move the handle reversing and lights the
reversing light.

37
 position before the engine is started.
(8) Foot control
Clutch pedal or Inching pedal , brake
pedal and accelerator pedal .

Hydrodynamic drive forklift

Forward-backward handle

F2 Forward first gear

F1 Forward second gear
N Neutral position Mechanical drive forklift

R1 Backward first gear Clutch pedal

R2 Backward second gear
The direction control device is a steering
pipe column fixed device, and the forward
and backward separately has two gear
speeds, the truck should be completely
stopped before changing the direction, the
reversing light should be on when the
truck is reversed by the movement of
handle.
Hydrodynamic drive forklift
Inching pedal
Caution
Since the neutral switch is installed, do not
forget push this handle to the neutral
38
The purpose of the clutch allows the operator
bonding or separation the engines and
transmissions, clutch pedal depressed, the
engine and gearbox transmission separation,
release the clutch pedal, power transmission
from the engine through the clutch to the
gearbox.
Caution
Do not allow operating forklift when the
clutch half on and half off.
When the inching pedal is stepped down,
the oil pressure of hydraulic clutch should
be accordingly reduced, to reach the
inching operation, when the lifting system
is operated with high speed, the truck can
be slowly moved with this pedal.
When the pedal is completely stepped
down, this inching pedal can also be used
as the brake pedal.
Warning
 When climbing down the ramp or starting
up at the ramp, the inching pedal can not
be used and the brake pedal should be
used. If the inching pedal is used when
climbing down the ramp, the engine
should not have the braking function, and
the truck can slide down the ramp
because of inertia, therefore, the braking
effect of truck is poor, if the inching
pedal is used when starting up at the
ramp, the truck can slide down because
of inertia, it is very danger.
Accelerator pedal
Stepping down the accelerator pedal can
increase the engine speed, loose this pedal
and the engine can be idly running.
Brake pedal
Stepping down the brake pedal can make
the truck speed reduce or stop, at the same
time, the brake lamp is on.

39
4. Truck body part
1) Seat
Caution
If the seat is equipped with seat belt,
please fasten this seat belt, in case of
turning-over of the truck, the driver should
hold the steering wheel, and the body is
inclined to other side, jumping off the
vehicle is not allowed.
2) Adjustable handle of seat
Through adjusting the adjustable handle of
seat, the position of seat can be adjusted to
the proper position adapting with the body
of operator, which can easily contact all
parts controlled by hands and feet. If the
adjustable handle is moved to the right, the
seat can be unlocked, and you should
adjust the seat and ensure that the seat has
already locked tightly before operation.
3) Over-head guard
40
Warning
The over-head guard can prevent the falling
of upper parts, and is a safety part for
operator, loose installation and dismantling
or remodeling this guard is very dangerous,
which can result in the great personal injury
accident.
4) Load-backrest
Caution
The load-backrest is an important safety
part which can prevents the sliding of load
on the fork to the operator, loose
installation and the use after it is
dismantled or remodeled are very
dangerous.
5) Engine cover
The engine cover can be fully opened to
maintain, pull out the starting handle
installed at the left side of engine cover of
meter frame, with the help of the spring of
engine cover, the engine cover can be
opened with the little force, when the
engine cover is closed, the foreside of
engine cover should be pressed down until
it is locked tightly.
Warning
When the engine cover is closed, do not
put the finger inside.
(6
(6) Locating pin of fork
 The fork is locked at a certain position
with locating pin, when the space of fork
needs to be adjusted, you should pull up
the locating pin and rotate it 1/4 circle, and
then adjust the fork to the required
position, the adjustment of the space of
fork should be done according to the
goods to be loaded and unloaded.
safety pedals, the safety handle is installed
at the left and front supporting rod of
over-head guard, the safety pedal and
safety handle should be used when
climbing up or down the truck.

(9) Fuse box

Fuse box is installed at the inner and right
side of meter frame.

Warning
The fork is set symmetrically at the
center line of truck, and the locating pin
should be locked tightly.
(7) Traction pin
Traction pin only is used for the following
situation:
When the use of getting off the difficult
situation when there can not drive (such
as falling of tire and tilting);
(10) Brake liquid tank
When loading and unloading the forklift
truck for transportation.
Absolutely not be used for traction or
trailed operation.
Caution
Don't use the forklift truck for towing or
being towed .

(8) Safety pedal and safety handle

Both sides of body are equipped with the

41

The brake liquid tank is installed under the
engine cover, and the level of brake liquid
can be inspected from the outside of the
semi-opaque tank.
(11) Cover of hydraulic oil tank
The cover of hydraulic oil tank is installed
under the engine cover, and the hydraulic
oil can be added from this oil filler hole,
and the cover is installed with the oil ruler.
(12) Cover of fuel tank
The cover of fuel tank is in the left and
rear side of body, it can be opened with the
counterclockwise rotation.
42
Caution
There is air hole in the cover of fuel
tank, to let the air go into the fuel tank,
if the air hole is plugged, the fuel
system can not work, so you should test
whether the air hole is free when adding
oil.
Warning
Add fuel
Stop the truck and turn off the engine
and pull on the brake parking handle,
and ensure that there is no naked fire
nearby, do not smoke, and the driver
should not be on the truck when adding
the fuel.
The cover should be closed tightly when
the fuel is added, the loosing of cover
can cause the leakage of fuel, or cause
fire under the bad condition.
Before starting up the engine, you
should ensure that the cover of fuel tank
is closed tightly, and there is no
overflowed fuel on the truck or around
the truck.
When test oil level, you can not use the
naked fire, such as match or lighter.
Don't touch the fuel without safeguard,
or else your skin will be damaged .after
your skin touching fuel, you should
clean your skin with cleaner on time.
(13) Water tank cover
The cover of water tank is under the cover
board at the rear of engine, this cover
board should not be opened when the daily
inspection is done.

43
(14) Fluid infusion tank (16) Rearview mirror A
The fluid infusion tank is at the lower
Caution1
left side of engine cover, and the liquid
The surface of rearview mirror should
level is at the middle position of two
be kept clean.
scales.
The rearview mirror should be adjusted
Warning to the position which can better watch
When the temperature of engine is high, the rear.
do not suddenly open the cover of water
tank, and the cover is slightly rotated to
the left to reduce the pressure in the
water tank, and then open the cover.
Do not open the cover of water tank
with gloves.
(15) Lamps
Caution
Confirm the working situation of lamps,
if the bulb is burnt out, the lamp shade
is damaged or is not clean, they should
be immediately replaced or repaired.

Two pieces of headlight B and front

combination lamp C (turning signal light
and wider light) are installed at the front
side of truck.
The rear combination lamp D is installed
at the back side of truck, this combination
lamp consists of turning signal light,
taillight , stoplight, reversing lamp and
flasher.

44
Record

45
III. Driving and operation

In order to keep a better performance, safety use and economical operation of your truck,
there introduce some items of correct operation.
1.The use of new truck

The service life of truck depends on the beginning use of new truck, when running at the
original 200h, please pay attention to the following items.
Caution
Whatever in any season, the engine must be heated for 5-10 minutes before operation.
Maintenance and service what you think should be done.
Do not rudely operate and unreasonably use.
Immediately add lubricating oil, lubricating grease and replace oil.
Do not let the engine idly run at high speed.
2.Relation of load and stability of forklift

In the load curve, the fulcrum of forklift is the center of front wheel, keep the balance of truck
body and load on the fork, pay attention to the loading and the load center, to keep the
stability of forklift truck.

Warning
When there exceed the value specified in the load
curve in operation, the rear wheel has the raised
danger and should be in the bad situation, and the
forklift may be turned over to result in the serious
accident. As shown in the chart, that the load is near
the fork tip or adding the load should have the same
result, in this situation, the loading should be
accordingly reduced.

46
3.Load center and load curve
The load center is a distance from the front
face of vertical part of fork to the gravity
center of goods. The above load curve
chart indicates the relation of load center
of forklift and allowable loading
(allowable load), the label plate of load
curve is pasted on the truck, if this label is
damaged or lost, and the replacement of a
new label should be done.
Warning
If the truck is equipped with
attachments for goods, such as side
shifter, bucket or rotary fork etc. its
allowable loading should be reduced
than the corresponding standard truck
(without any attachment), the reasons
are as follows:
a. Reducing the load which is equal
to the weight of attachment.
b. Owing to the movement forward of
load center because of the length of
attachment, the allowable load
should be reduced as the same
principle.
The movement forward of load center
by the installation of attachment is
known as the Load center loss.
The allowable load which exceeds the
value specified in the load curve should
not be pasted on the truck or the
attachment.
4.Stability of forklift truck
The stability standard of forklift is
specified in the ISO or national related
standard, however, the stability described
in these standards is not available for all
operation conditions, and the stability of
47
forklift is different with the difference of
operation.
Under the following operation condition,
the maximum stability is ensured:
a. On the level and hard ground;
b. Operate under the standard
unloading or loading status.
Standard unloading status: The fork or
other supporting accessory is 300mm from
the ground, and the mast is inclined to the
proper position without load.
Standard loading status: The fork or other
supporting accessory is 300mm from the
ground, and the allowable load is
supported at the standard load center, the
mast is inclined to the proper position.
Warning
When loading and unloading goods, the
forward and backward tilting should be
done with the minimum degree, the
forward tilting must be done unless the
load is fixed firmly or the lifting height
is reduced.
5. Transportation and loading and
5.Transportation
unloading of forklift
(1) Transportation of forklift
Caution
For the transportation of forklift, in
order to prevent the movement of
forklift in the carriage, the wheel should
be stopped and the forklift should be
completely fixed with rope etc..
When loading and unloading and
transporting on the highroad, you should
pay attention to the full length, full
width and full height, and comply with
the related rules.
(2) Loading and unloading of forklift Test the safety situation around the

Caution truck.
If there is grease or oil on the bottom
Please use the butt strap with enough
plate, pedal, control lever or hands, you
length, width and strength.
should clean it.
Effectively pull up the stop brake of
Confirm that the shifting handle and
forklift to be transported to stop the
multi-way valve handle are at the
wheel.
neutral position, and the brake parking
The board is tightly fixed at the center of
handle is in the braking condition.
carriage, and the oil grease should not be
Start up the diesel engine.
adhesive on the butt strap.
Turn the preheat starting switch to the
The left and right heights of butt strap
ON position until the preheat indicator
should be equal, so the truck can stably
light is off, and then the preheat starting
operate when loading and unloading.
switch is turned to the START position.
In order to prevent danger, turning or
If the starting of engine is difficult, test
laterally moving at the butt strap is not
whether the fuel level is lower, and
allowed.
whether the air goes into the fuel system or
When the forklift is moved to the carriage,
the preheat wire is broken.
in order to ensure that the left and right
tires on the butt strap simultaneously are (2) After the engine is started
mounded on the carriage, there should be Preheat the engine (about 5 minutes).
slowly operated. Test the engine sound (rotating or gear).

(3) Lifting forklift Caution

Caution Test the exhaust status (concentration or
The person who is specially trained can color).
operate the forklift. Confirm that all indicator lights are off.
The rope should be hooked at the specified After the engine is completely preheated,
lifting position of forklift. operate the multi-way control lever 2~3
All ropes should have enough supporting times in full range, test its working
capacity. situation.
The dismountable parts of forklift have
7.Operation Posture of operator
also the lifting position.
1) Operator posture
6.Before and after starting the engine

(1) Before starting the engine

Before the truck is running, test whether
all control devices and warning devices
are normal, if there found damaged or
faulted parts, the starting of forklift is
forbidden before they are repaired.

48
 Hold the steering wheel joystick with left
hand and put right hand on the steering
wheel to make preparation for loading
and unloading operation.

2) Basic state of operation

The fork is at the 150-200mm from the
ground, and the mast is inclined to the
While you step the accelerator pedal, loose
proper position.
the clutch pedal, then the truck running.

Look around the forklift, and test the

safety and the signal before the running of Caution
truck. Don't put your feet on the clutch pedal
while the truck is running

Hydrodynamic drive forklift

Step down the brake pedal, and operate
the front-back shifting handle.

Mechanical drive forklift

Step the clutch pedal, operate the shift
handle.

Loose the brake parking handle.

Loose the brake parking handle.

Loose the brake pedal, step down the

accelerator pedal, so the truck is
49
 traveling.
3) Gear shift
The truck should be stopped before
changing the traveling direction.
Mechanical drive forklift
a) Before you truning , stop your truck .
b) If you want to change the fast gear
position to low or low to fast , loose the
accelerator pedal after accelerating the
engine , meanwhile ,step the clutch
pedal ,change the shift handle to the
position you want , then loose the clutch
pedal ,step the accelerator pedal .
Hydrodynamic drive forklift
aBefore you truning , stop your truck .
4) Deceleration
Mechanical drive forklift
Since this forklift uses a synchronous
transmission,double clutch operation is not
required.Release the accelerator pedal,
step on the clutch pedal down in the end,
put the shift lever in position I, release the
clutch pedal and then step on the
accelerator pedal.
Hydrodynamic drive forklift
Slightly loose the accelerator pedal, and
step down the brake pedal if necessary.
Warning
The speed must be reduced:
At cross road
At crowed place
50
On the rough ground or other uneven
ground
Near the goods or barrier
5) Turning
Different from the general vehicle, the
steering wheel of forklift is installed at the
rear of forklift truck, which can let the rear
rotate outside when turning. When turning,
the speed should be reduced, and the
steering wheel is turned to the side you
want, furthermore, the steering wheel
should be slightly advanced than the
vehicle which turns with front wheel.
6) Stopping or parking
Decelerate or step down the brake pedal to
let the truck stop, and the shift handle is at
the neutral position.
Caution
When climbing up the ramp, that the truck
is stopped through stepping down the
accelerator pedal in the running condition
is not allowed, which can cause the
abnormal wearing of friction plate or the
abnormal rising of oil temperature of
torque converter, thus the service life of
torque converter is shortened.
When the truck is stopped, stop the truck
at the place not affecting the traffic, and:
a. Pull on the brake parking handle;
b. Lower the fork to the ground;
c. Turn the key switch to the OFF
position, pull out the extinction handle
of engine, and turn off the engine;
d. Pull off the key and keep it.
Warning
Safely stop the truck
a. The truck should be stopped at the level
ground-better at the wider place, if
 parking at the ramp is avoided, the truck
should be crossly stopped at the ramp,
and the wheel is blocked with the wedge
block to prevent the sliding;
b. The truck should be stopped at the
specified area or the place of not
hindering the transportation, if
necessary the mark or signal light
should be set around the truck;
c. The truck should be stopped on the hard
ground, and parking on the soft, mud
and sliding ground should be avoided;
d. If the lifting system is damaged, and
when the fork can not be lowered to the
ground, a warning flag should be hung
at the end of fork, and the truck should
be stopped at the place which can not
hinder the traffic.
7) Repair the faulted forklift truck
the ground, and confirm whether the
goods is stable;
b. Then the mast is inclined backward to
the proper position, lift the goods
150~300mm from the ground, and then
start traveling.
6) Except for climbing up the ramp, the
reversely traveling should be done when
the larger goods hinder the line of sight.
Caution
The loading direction of fork must not be
opposite with the designed loading
direction;
That the fork singly lifts the goods is not
allowed;
The fork can not be used to drag the
goods;
All parts of fork body can not be welded.

Caution
9. Stacking
If the forklift suddenly goes wrong in the
Caution
use, it should be immediately dragged
Before operating the forklift truck, you
and repaired, to avoid hindering other
should test the following items:
truck or the operation.
a. Confirm that there is not the falling of
8. Loading good and the damaged goods in the
loading area;
1) In order to keep a better lateral stability, b. Confirm that no goods and stacking
the space between the forks should be affect the safety.
larger as possible.
2) When the fork is inserted into the pallet
or directly inserted into the goods, the
center of forklift should be at the same
level with the center of goods.
3) The fork should be horizontally inserted
into the pallet.
4) The fork should be completely inserted
to the bottom of fork.
5) Lift the good:
a. First the fork is lifted 50~100mm from When stacking, the following produce should

51
be done:
Explanation
1) The deceleration should be done when
When the goods are not completely placed
the forklift is near the stacking.
on the fork or pallet:
2) Stopping the truck at the front of the
a. Lower the fork until the fork can not
stacking area.
support the load;
3) Test whether the around area of stacking
b. The forklift goes back 1/4 of the length of
is safe.
fork;
4) Adjust the position to let the forklift at
c. And then lift the fork 50~100mm, move
the front of stacking area.
the fork forward and then put the goods
5) The mast is vertical with the ground and
at the proper position.
the lifted fork exceeds the height of
8) Observe the rear space of forklift, and
stacking.
drive backward the forklift to avoid the
6) Test the stacking position and drive
collision of fork and pallet or goods.
forward, and stop the truck at the
appropriate position.
7) Ensure that the goods are at the upper of
stacking, slowly lower the fork and
ensure that the goods is placed the
proper position.

9) Confirm that the front of fork leaves the

goods or pallet, lower the fork to drive
(150~200mm from the ground).

10.Unstacking

When unstacking, the following procedure

should be carried out:
1) The deceleration should be done when
the forklift is near the stacking.
2) Stop the truck at the front of goods (the
distance from the goods to the fork tip is
300mm).
3) Adjust the position of forklift at the
front of goods.
4) Ensure that the overload can not be
done.

52
5) The mast should be vertical with the lowered.
ground. 9) Lower the goods to the 150~200mm
from the ground.
10) The mast is inclined backward to ensure
the stability of goods.

6) Observe the fork position and

simultaneo-usly move the forklift forward
until the fork is completely inserted into
the pallet.
11) Convey the goods to the destination.

11.Storage

1) Before storage
Explanation Before the forklift is stored, it should be
When the fork is difficult to completely
thoroughly washed, and be tested
insert into the pallet:
according to the following procedure:
a. Insert the fork of 3/4 length and slightly
a. According to the requirement, the oil
lift the pallet (50~100mm), pull out the
and grease on the truck body should be
pallet about 100~200mm, and then
cleaned with cloth and water;
lower the pallet;
b. When washing the truck body, test the
b. The fork is completely inserted into the
overall situation of truck, especially test
pallet.
7) After the fork is inserted into the pallet, whether there is depression or damage
lift the pallet (50~100mm). on the body, whether the tire is broken,
8) Observe the around space and move the and whether the iron nail or stone is
forklift backward until the goods is inserted into the tread pattern;

53
 c. The specified fuel is used to fully add
the oil tank;
d. Test whether the oil leakage occurs;
e. Add the lubricating grease according to
the requirement;
f. Test whether the hub nuts and the
connecting face of piston rod of cylinder
are loose, and whether the surface of
piston rod has the damaged and pulling
trace phenomenon;
g. Test whether the running of roller of
mast is steady;
h. In the winter or cold season, the
long-term antifreeze is not needed to
drain, if there is cooling water, there
should be drained.
Warning
If there found that the forklift is needed to
repair, faults or has unsafe factor, you
should report this situation to the manger,
and repair the forklift until the forklift is
in the safety condition again.
2) Daily storage
a. The forklift is stopped at the specified
place, and the wheel should be padded
with wedge block;
4) Starting after long-term storage
b. Put the shift handle at the neutral position,
and pull on the brake parking handle;
c. Turn off the engine when the key switch
is at the OFF position, operate the
multi-way valve lever many times,
release the remained pressure of oil
cylinder and pipeline;
d. Take off the key and store it safely.
3) Long-term storage
The following adjustment and
maintenance is done based on the Daily
54
storage:
a. Considered of the rainy season, the
truck should be parked at the higher and
harder ground;
b. The accumulator should be removed from
the forklift, even if the forklift is parked
in the room, if the parked place is wet
and hot, the accumulator should also be
parked at the dry and cool place, and it
should be charged one time per month;
c. Paint the anti-rust oil on the exposed
parts, such as the piston rod of oil
cylinder and the axles which probably
rust;
d. Cover the parts which easily damp;
e. The truck is started up one time per week,
if the cooling water is drained, add the
cooling water and install the accumulator,
remove the oil grease from the piston rod
and the axle, start up the engine and fully
preheat it, make the truck slowly operate
forward and backward, operate the
hydraulic control device many times;
f. In summer, that the forklift is parked on
the soft road, such as asphalt road, is
avoided.
a. Remove the anti-rust oil from the exposed
parts;
b. Drain the machine oil form the crankcase
of engine, drain the hydraulic drive oil
from the gearbox and the oil from the
drive axle, add the new oil after the
internals are cleaned;
c. Remove the impurity and water from the
hydraulic oil box and fuel box;
d. Dismantle the cylinder head cover, valve
and rocker arm shafts, and test whether
 each valve clearance is normal;
e. Add the cooling liquid to the specified
level;
f. Charge the accumulator and install it on the
forklift, and connect the lead wire of
accumulator;
g. Carefully test the forklift before starting;
h. Preheating the forklift.

55
IV.. Periodic inspection and maintenance
IV

The previous full inspection for the forklift

2.Test content
should be done, which can avoid the fault
of forklift and extend its service life, the 1) Hydraulic oil, fuel and water leakage
number of hour in the periodic inspection test
and maintenance is based on the 8 hours of Test whether there is oil and water
each day and 200 hours of each month. leakage on the joint of hydraulic pipe,
The detailed inspection records should be engine, water tank and drive system;
done after inspection, and the records touching with hands or visually
should be stored. inspecting is the test method.
Test whether there is impurity in the fuel
Caution oil.
The person who is trained or with
certificate can maintain and repair the
forklift truck;
The daily and monthly inspection and
maintenance can be done by the
operator.

1.Inspection requirement
Caution
1) Use the specified parts. You can not drive the truck if there
2) Use the pure or specified oil and grease. found the fuel leakage before work, and
3) The oil filter and the grease fitting the engine can be started after the
should be cleaned with brush or leakage is eliminated.
dishcloth before adding oil or grease.
2) Tire pressure inspection (Charged tire)
4) When testing the oil level and add oil,
you should park the truck on the
horizontal ground.
5) Periodic pre-maintenance and
service should be done.
6) If working under the lifted fork or
attachment is not avoided, you
should use the supporting rod to support
the fork or attachment to prevent the Test the situation of tire, low air pressure
sliding of fork and mast. can reduce the service lift of tire and
7) If there found the damaged or fault parts, increase the fuel consumption, the
you should report this situation to the different left and right air pressures or the
manager, using this forklift before repair damaged tire can cause the different
is forbidden. turning force, and the air pressures of tires

56
 also meet the value specified on the air 3) Test the torque of nuts of hub
pressure label of tire. Test whether the torque of nuts of hub is
Anticlockwise screw down the valve cap, correct.
the air pressure of tire is measured with All hub nuts should be screwed to the
barometer, if necessary adjust it to the specified torque value of 180~560N.m.
specified value, screw the cap on after
Caution
there confirm no air leakage.
When the hub nut and are
Test whether the contacted ground and
disassembled, don't disassemble the
side face of tire are broken, and whether
split-type wheel rim bolt and .
the rim is distorted.
It'll be very dangerous if the hub nut is
Owing to the tire needs high air pressure to
loosened, once it's loosened, the wheel
support the heavy load, the minimal
will be probably disconnected to cause
distortion of rim or the broken contacted
roll-over of vehicle.
ground can cause the accident.

Ton
1T - 7T
Tyre pressure
Front wheel 0.7MPa
Rear wheel 0.7MPa

Ton
8T - 10T
Tyre pressure
Front wheel 0.8MPa
Rear wheel 0.8MPa

Warning
After the tire and rim are assembled and
all bolts and nuts are screwed tightly to
the specified torque, the tire can be
charged, the charged tire has expansion
energy, so the air pressure of tire can not Hub nut
exceed the specified value. Split-type front wheel rim bolt
When the tire is charged with air Driving axle half-shaft bolt
compressor, the pressure should be first Rear wheel rub nut
adjusted, because the maximum output Split-type rear wheel rim bolt
pressure of air compressor is high, the 4) Test the overhead guard
improper adjustment can cause the The overhead guard has a protective
serious accident. function, and it should be fixed firmly
57
 and its structural pars are fixed firmly.
5) Brake liquid level test
Test the oil level of brake oil tank, the oil
level should be between two scales, when
adding oil, that the dust or water goes
into the oil tank should be avoided.
6) Test the electrolyte of accumulator
The accumulator has the upper and lower
liquid level scale lines, the operator can
observe the liquid level, and the liquid
level should be between the two scale
lines.
Danger
That the naked fire is near the adding place
of accumulator is not allowed, because this
58
place can produce the explosive hydrogen.
7) Cooling liquid test
Test the liquid level of fluid infusion tank,
the level should be between the upper and
lower scale lines, if necessary the cooling
liquid should be added.
Warning
You should be very careful when open
the pressure cove of water tank, the
cover is opened under the pressure
condition, the sudden released pressure
can produce steam flow, to cause the
personnel injury, pack the cover with
thin cloth or similar object, slowly loose
the cover and let the steam overflow,
and then screw down the cover, do not
wear the glove to avoid that the ejected
hot water burns the hands.
8) Engine oil level test
The oil ruler of engine is at the left side
of engine body, pull out the oil ruler and
wipe up the ruler and re-insert it and pull
out, test whether the oil level is between
the two scales.
9) Test tension of fan belt
Test the tension of fan belt and whether
the belt is damaged, press the middle of
belt which is between the water pump
and generator with the thumb.
Warning
The engine must be turned off when the
tension of fan belt is tested.
10) Rear combination lamp test
Test whether the combination lamp (rear
lamp, parking lamp and reversing lamp)
is damaged or dirty.

11) Hydraulic oil level

Test the hydraulic oil level with oil ruler,
pull out the oil ruler and wipe up it, and
re-pull out it after re-insert it, watch
whether the oil level is between the high
and low scale lines.
Hydrodynamic drive forklift
Pull out the oil cover and test oil ruler,
ensure that the oil level is between the
scale lines, if necessary, add the specified
hydraulic oil.

14) Load-backrest test

Test whether the installation bolts of
load-backrest is loose, if necessary screw
Caution
them.
When the oil level is tested, the engine
should be turned off, and the fork is
lowered to the ground and the forklift
truck is parked on the level ground.

12) Pipeline and oil cylinder

Visually test whether the hydraulic
pipeline and tilting cylinder have oil
leakage phenomenon.

13) Hydraulic gearbox oil level

15) Fork and locating pin
Test the installation situation of locating
pin of fork, and whether the fork is
distorted or cracked.

59
16) Headlight and front combination light 24) Turning signal test
Test whether the lamp cover and bulb are Operate the turning signal handle to confirm
cleaned and damaged. that all turning signal lamps are normal.

17) Seat adjustment 25) Horn button operation test

Test whether the seat position is proper, if
improper, the adjustable handle is pulled
to the right, and the seat is adjusted to the
position which the feet and hands are easy
to operate, after adjustment, the seat is
slightly moved forward and backward to
ensure that it is locked tightly.
18) Shifting handle test
Test whether the shifting handle is loose
and the handle feeling.
19) Test the operating handle of multi-way
valve
Test whether the operating handle (lifting,
tilting and attachment) is loose and the
operation is easy.
20) Test the brake parking operation
After the brake parking lever is pulled up,
confirm that the brake is safe and reliable.
Start engine
Before starting the engine , Make sure the
shifting handle in the no gear position ,
and brake stably .
21) Instrument
Hour meter, water temperature indicator
and fuel gauge can make the operator
know the operation situation of truck.
Press the horn button to confirm whether
the operation of horn is normal.
26) Clutch pedal test
Mechanical drive forklift
Test whether the action of the clutch pedal
is stable or not .
Test the clutch pedal of some forklift truck
after starting the engine .
27) Brake pedal no stroke
Step the brake pedal and park pedal (only
for hydrodynamic drive forklift truck ) ,
Make sure every pedal action is stable ,
and can't be effected .
28) Mast operation
Press the horn, operate the lifting and
tilting handle, confirm that the lifting and
lowering of fork arm carriage is normal,
and that the mast is inclined stably.
Confirm whether the piston of oil
cylinder travels to the end, the operation
of overflow valve and the sound with the
overflow are normal, pay attention to the
operating sound of system.
29) Tension of lifting chain test

22) Fuel level test

The fuel gauge is installed on the
instrument board, and test whether the oil
can meet the operation of one day.

23) Lamp and lighting

Turn on the lamp, and confirm that all
corresponding lamps are normal.
60
 Test whether the tension of lifting chain
is normal.
When test the tension, the fork is lifted
about 50mm from the ground, and press
the middle of chain with thumb, confirm
whether the tension of left and right
chains is concordant, if found
un-conformability, you should loose the
locked nut (A) of fixed pin, and screw the
adjustable nut (B) to adjust the chain.
Caution
Please use the machine oil (such as
hydraulic oil) to lubricate the lifting
chain, do not use lubricating grease.
30) Free range of steering wheel
Test the rotary and axial loose situation of
the steering wheel, the normal free range
is 50~100mm, and the loosing of axial is
not allowed.
engine and drive system
Danger
The exhaust gas from the engine is harmful,
when the forklift is started or used in the
closed space, the drained exhaust gas from
the engine can cause the toxic risk, so
there should ensure enough oxygen, and
regularly test the value of exhaust gas, and
the exhaust test should be done outdoors,
pay attention to the fire, especially pay
attention to the leakage of oil or fuel, do
not leave the waste cloth and paper on the
engine body, confirm the placed site of
fire-extinguishing equipment and know
how to use this equipment.
32) Inching pedal test
Slightly step down the inching pedal, and
test the deceleration situation of truck.
33) Brake test
Slowly drive the truck and step down the
brake pedal to test the braking effect,
after the brake pedal is stepped down, the
brake lamp is on.

31) Exhaust test

Test the exhaust situation after the engine
is pre-heated:

No color or
Normal: Completely burning 34) Turning test
light blue
Abnormal: Incompletely
Black
burning
Abnormal: There is water in
White the fuel or poor atomization
of fuel nozzle
Blue Abnormal: Burn machine oil

Test the abnormal noise or vibratory of

61
 When the truck is slowly traveling, turn
the steering wheel and observe whether
the left and right steering forces are
consistent, and whether there is abnormal
2) Exhaust of fuel system
phenomenon.
a. Turn off engine, loose the exhaust plug
35) Brake parking test on the injection pump.
After the brake parking handle is pulled up, b. Screw tightly drain plug and confirm
confirm that the truck which is slowly that there is no fuel leakage.
traveling can be stopped by the brake c. Press the pump for draining air until the
36) Reversing lamp test fuel is flowed out of plug.
The reversing lamp is on when the shifting
handle is put at the backward position.

3.Maintenance

1) Discharge water from oil water separator

When the indicator lamp of oil water
separator is on:
a. Shut down the engine, rotate (A) part
for 4~5 circles, press pump (B)
continually until the water in the oil
water separator is drained;
b. Tighten the water drain screw plug,
press the pump (B) several times and
check whether the screw plug position
leaks water;
c. After the engine is started, confirm the
indicator lamp won't be on.
3) Replace fuse
The fuse can protect the electric system,
preventing the over-high current to
damage the electric component, test
whether the operations of all parts in the
circuit are normal, if any part can not be
operated, the corresponding fuse may be
broken, and the new fuse with the same
capacity should replace it, if any part in
the component can not normally work, the
ball contact may be broken, so the new

62
 contact with the same capacity should
replace it.

4) Replace or repair tire

The tool and jack should be prepared
before replacement or repair.
a. Front wheel
Stop the truck on the hard road and turn
off the engine, and unload all loads.
Pull up the brake parking handle and
pad the wheel with the wedge block,
and the jack is placed under the body.
Lift the truck and keep the wheel
contact the ground, loose the hub nuts
but do not dismantle them.
Continuously lift the truck until the
wheel is left the ground, remove the
nuts and dismantle the tire.
The installation order of tire is opposite
with the dismantling order, the hub nuts
are screwed in the diagonal order.
After installation, test the air pressure of
tire.
b. Rear wheel
Except the jack is placed under the
counterweight, other repair and replacement
methods are the same with that of the front
wheel.

63
4.Periodical maintenance schedule

This schedule is set under the standard working time and operation condition, if the forklift
truck is working in the bad condition, the maintenance ("" indicates replacement) should be
done in advance.

Engine
Per Every 3 Every 6
Per day Each year
Test item Test content Tool month months months
(8h) (2400h)
(200h) (600h) (1200h)
Visually test the operative

status of engine

Engine sound
Exhaust air color
Clean or replace the

filter core

Test whether there is dirt

Engine
in the crankcase

Test and adjust the valve

Plug gage
clearance

Screw tightly the bolts at

Torque wrench
the cylinder head

Test the compressed

Manometer
pressure of cylinder
Ventilation
Test the plug and damaged
device of
situation of valve and pipe
crankshaft
Speed governor
Test the maximum speed Speed
or injector
without load indicator
pump
Whether the engine leaks

oil

Test oil level and

cleanliness

Lubrication
50h for
system Replace the engine oil
the first
time

Replace the oil filter core 200h for

of engine the first
time

64
Engine
Test Every 3 Every 6
Per day Per month Each year
Test content Tool months months
item (8h) (200h) (2400h)
(600h) (1200h)
Visually test whether the oil pipe, oil

pump and oil tank leak the oil

Test whether the fuel oil filter is

blocked
Replace fuel filter
Fuel
Test the nozzle and adjusted
system
pressure condition

Ejecting time

Fuel tank drains water

Wash the oil tank

Test oil volume

Cooling fluid volume

Leakage situation

Hose aging situation

Cooling Performance and installation

system situation of water tank cover

Clean and replace the cooling liquid

Test the tension and damaged

situation of fan belt

65
Drive system
Each
Every 3 Every 6
Per day Per month year
Test item Test content Tool months months
(8h) (200h) (2400h
(600h) (1200h)
)
Leakage condition

Test oil volume or replace oil

Operation and loose situation of

gearlever

Hydraulic Control valve and hydraulic clutch

transmission performance
box
Inching valve performance

Idle stroke and power situation of

inching pedal

Replace the oil filter core 200h for the
first time
Leakage situation

Drive axle Replace oil

Loose situation of installed bolts

Wheel
Each
Per Every 3 Every 6
Per day year
Test item Test content Tool month months months
(8h) (2400h
(200h) (600h) (1200h)
)
Pressure
Charged pressure
indicator
Crack or damage

Tire Wearing situation of touched ground Depthometer

Abnormal wearing situation

Whether there is nail, stone or other

impurity on the tire

Test whether the bolts are loose

Install tire
Test damaged situation

Rim and Damaged situation of rim, spoke rim

spoke rim and lock ring

Axle Test the loosing and noise condition

bearing Wipe up and re-add the lubrication oil

Axle Test the distortion, crack or damaged

body situation

66
Steering system
Each
Per Every 3 Every 6
Test Per day year
Test content Tool month months months
item (8h) (2400h
(200h) (600h) (1200h)
)
Test the gap

Steering Test the axial loose condition

wheel Test the radial loose condition

Test the operation status

Steering Test whether the installation

device bolts are loose

Test whether the main pin is

loose or damaged
Steering
knuckle Test the bending, distortion,

of rear crack or damaged situation
axle
Detection
Test installation situation
hammer

Test the operation situation

Steering Test whether there is leakage

cylinder
Test whether the installation and

hinged places are loose

Electric
Per Every 3 Every 6 Each
Per day
Test item Test content Tool month months months year
(8h)
(200h) (600h) (1200h) (2400h)
Start up the
Meshing situation of small gear
motor

Electrolyte liquid volume and wash

Accumulator Test the specific density of

electrolyte

Damaged and loosing situations of

wires
Wires
The loosing situation of circuit

connection

67
Brake system
Per Every 3 Every 6 Each
Test Per day
Test content Tool month months months year
item (8h)
(200h) (600h) (1200h) (2400h)
Idle stroke

Brake Pedal stroke Ruler

pedal Operation status

Whether there is air in the pipeline

Parking Whether the brake is safe and reliable and

brake there is enough range
control Control performance

Rod and Control performance

cable etc. Whether the connection is loose

Damaged, leakage and broken situation

Pipeline Loosing situation of connecting and

clamped places

Leakage situation
Divided Test oil level and oil replacement
pump of
brake Action situation of total pump and

total divided pump
pump Damaged situation and replacement of

total pump, piston cup and one-way valve

Whether the installed parts of brake drum Detection

are loose hammer

Vernier
Wearing situation of wearing plate
caliper

Brake Action situation of brake shoe

drum and
Whether there is rust on the fixed pin
brake
shoe Damaged situation of release spring Ruler

Test whether the gap is proper when the

self-adjustment device is operated

Wearing and damaged situation of brake

drum

Whether the bottom plate is distorted

Bottom
plate of Whether there is crack
brake
Whether there is loose situation when Detection
device
installation hammer

68
Lifting system
Per Per Every 3 Every 6 Each
Test item Test content Tool day month months months year
(8h) (200h) (600h) (1200h) (2400h)
Damaged, distortion and wearing

situation of fork
Damaged and wearing situation of

Fork locating pin
The cracking and wearing situation of

welding part of bottom hook of fork

Whether the welding places at the inner

mast, outer mast and cross beam are
cracked and damaged
Whether there is bad welding, cracked
and damages phenomenon on the

welding places of tilting cylinder
bracket and mast
Whether there is bad welding, cracked
and damages phenomenon on the inner
and outer masts
Whether there is bad welding, cracked
and damages phenomenon on the fork
arm carriage
Mast and
fork arm Whether the roller is loose
carriage
Wearing and damaged situation of the

supporting bush of mast

Whether the bearing cover of mast is Detection Only for

loose hammer the first
time
Whether the bottom bolts of lifting
cylinder, top bolts of piston rod, Detection Only for

U-bolts and bolts of guide rail of hammer the first
movable beam are loose time
The cracking and damaged situation of

roller, roller shaft and the welding part
Test the tension status of chain to see
whether there is distortion, damage and
rust phenomenon
Add oil on the chain
Chain
sprocket Riveting pin and loosing situation
Distortion and damage situation of

sprocket
Whether the sprocket bearing is loose

Attachments Test whether the condition is normal

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Lifting system
Per Per Every 3 Every 6 Each
Test item Test content Tool day month months months year
(8h) (200h) (600h) (1200h) (2400h)
Whether the piston rod, the thread of piston
and connecting rod have loosing, distortion
and damaged situations
Lifting Operation situation
cylinder
Leakage situation

The wearing and damaged situations of pin

and steel backing bearings of oil cylinder

Whether there is oil leakage or stray noise

Hydraulic in the hydraulic pump
pump Wearing situation of drive gear of hydraulic

pump

Hydraulic system
Per Per Every 3 Every 6 Each
Test item Test content Tool day month months months year
(8h) (200h) (600h) (1200h) (2400h)
Oil level test

Hydraulic tank Clean oil filter core

Remove impurity and replace oil

Oil return filter Replace oil return filter

Control valve Whether the connection is loose

level Operation situation

Oil leakage

Multi-way Operation situations of safety valve

valve and tilted latching valve

Measure the pressure of safety valve

Leakage, loosing, breakage, distortion

and damage situations
Pipeline joint
1-2
Replace the pipe
year

70
Safety device and accessories
Per Per Every 3 Every 6 Each
Test item Test content Tool day month months months year
(8h) (200h) (600h) (1200h) (2400h)
Detection
Whether the installation is firm
Overhead guard hammer
and load-backrest Test the distortion, cracking

and damaged situations

Turning indicator
Work and installation situation
light

Horn Work and installation situation

Lamps and light

Work and installation situation
bulbs

Reversing buzzer Work and installation situation

Rearview mirror Dirt and damaged situation

Instrument Work situation of instrument

Test whether the bolts are loose

Seat
or damaged
Whether the truck frame and
cross beam are damaged and
cracked
Whether the rivet and bolts are Detection

Truck body loose hammer
If necessary, test the part which

ever be repaired

Completely test

Add the Test the lubricating situation of

Grease gun
lubricating grease chassis after wash
or replace oil Test the oil in the oil tank

Caution
When the oil, cooling fluid and antifreeze which are different with the specified products
in this truck are used, the replacement period can not be the same with the specified period
in the manual. Therefore, the replacement period should be shortened half or 1/4 of the
specified period in this manual.
Although the high-viscosity oil has a wider operating temperature range, the replacement
should be needed. Owing to the additive can slowly deteriorate, the oil viscosity can reduce,
and the hydraulic system can be seriously damaged at the high temperature.

71
Record

72
.. Others
1.Lubrication system chart

73
2.Forklift truck oil

Name Brand, code and use oil

Light diesel oil
0# -10# -20# -35#
brand
Diesel oil
Service
4 -5 -5-14 -14-29
temperature ()
Brand or code 5W/30 10W/30 15W/40 20W/50
Diesel engine
oil (CD) Service
-30+30 -25+30 -20+40 -15+50
temperature ()
L-HM32 anti-wear L-HV32 low-temperature
Brand or code
hydraulic oil anti-wear hydraulic oil
Hydraulic oil
Service
-5 -20 (Open and cold area)
temperature ()
Hydraulic
transmission 6# hydraulic transmission oil
oil
Brake fluid Synthetic brake fluid GB12981 HZY4 (car brake fluid)
Lubrication
3# general lithium-based grease (-20+120)
grease
Heavy-duty Brand or code 85W/90GL-5 80W/90GL-5
vehicle gear Service
oil -15+49 -25+49
temperature ()
Code FD-1 FD-2 FD-2A FD-3
Antifreezing
fluid Service
-25 -35 -45 -50
temperature ()

Caution
The Changcheng brand product is recommended.
The mixed oil with different bands can not be used.

74