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Internal Combustion Balanced

Forklift Truck

OPERATOR'S MANUAL

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INSTRUMENTS 6

SWITCHES 10

CONTROLS 14

BODY & OTHERS 20

SAFETY INSTRUCTIONS 28

8 HOURS(DAILY or EVERY SHIFT)CHECK 44

STORING 60

OPERATIONS 64

PREVENTIVE MAINTENANCE SERVICE SCHEDULE 84

CONTENTS

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(1)Hour Meter

(2)Coolant Temp.Gauge

(3)Fuel Gauge

(4)Parking Brake Lever

(5)Forward-Reverse Lever

(6)Steering Handwheel

(9)Light Switch

(10)Brake Pedal

(11)Accelerator Pedal

(12)Tilt Lever

(13)Lift Lever

(14)Fuse Box

(15)Ignition Switch

(16)Turn Signal Lever

(17)Horn Button

(18)Clutch Pedal

(19)Speed Select Lever

FRICTIONAL CLUTCH TYPE

14

13

12

195111018

9

4

6

3 2 17 1 16 15

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GLOW INDICATOR(D)

DIESEL TRUCK

This model truck has integral QUICK-ON-START system as a cold

startin aid and has no PREHEAT position at the starter switch. Turn thekey to ON position and the indicator lights up for a moment.After the

indicator goes out,turn the key to START position.

ENGINE COOLANT TEMPERATURE(2)

This gauge indicates the temperaturee n g i n e c o o l a n t . U n d e r n o r m a l

conditions, the pointer should be in the

green range 77 -113 .If the pointer

stays in the white range,idle the engine until

itenters the green range.

CAUTIONIf this pointer enters the redrange,stop the operationinstantly and slow down enginespeed to cool the coolant andwait until the pointer goes intothe green range.

FUEL GAUGE(3)When ignition switch is set to the

position ON ,the gauge informs operator

how much fuel remains in the fuel tank .

E mark stands for Empty , F

Filled .The pointer enters red zone

when the fuel level drops to a 1/8 capacity.

CAUTIONFill the fuel tank at the end

of each workday(or each shift).

This practice will reduce the

conden sation of moisture

within the tank.

CHOKE BUTTON(7)

Gasoline Truck

When starting a cold engine,first pull out this choke button and turn the keyswitch.After the engine is started up,do not fail to return the choke button into the

original position;otherwise,there will occur engine trouble or increased fuel

consumption.

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ON

START

SWITCHES

IGNITION SWITCH(15)

OFF

This is posit ion at which the key is inserted or drawn out.

Gasoline engine and diesel engine stop at this position.

The electric circuit is closed with the starter switch at ON , After the

engine is started,the key is at this position.

As the key is placed in the START position,the starter motor is engaged.

When removing hand off key,it is automatically returned to the ON position

by spring force.

CAUTION

1 Do not keep the starter switch in the ON position while the engine isshut down.This results is a discharged battery.

2 With the engine running,do not turn the starter switch into the START

positon,since there is a danger of the starter motor being damaged.

3 Do not keep the starter engaged for more than 15 seconds at a time. Wait

about 20 seconds before trying again.

LIGHT SWITCH(9)

This light switch can be pulled out at two steps

15

OFF

ON

START

9

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1st 2stStage O(OFF)Light

Number plateLight

Clearance &Parking light

OFF ON ON

Head light

Tail light OFF ON ON

OFF ON ON

OFF ON ON

CAUTIONThe above lights are turned

on or off by the light switch

regardless of starter switch

position.

HORN BUTTON(17)Press the rubber cover at ghe center

of steering wheel to sound horn.The hornsounds even when the key switch is OFF.

TURN SLGNAL LEVER(16)

Use this lever to indicate the turning direction of the truck. When thislever is placed in a turn position the turn signal l ight blinks.

R Right turn

N Neutral

l Left turn

CAUTIONThe turn signal lever does not

automatically return to the Neutral

position unlike general pa ssen ge r

cars.Reset it by hand.

16

L

N

R

17

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CONTROLS

STEERING HANDWHEEL(6)The steering handwheel is operated in the

conventional manner,that is,when the wheel

is turned right the truck will turn to the

right;when the wheel is turned left, the truck

will turn to the left.The steer wheels are

located at the rear of the truck.These cause

the rear of the truck to swing out when a turnis made.with a little practice, this type teering

will be easily mastered.

WARINGThis truck is provided with

the power steering, so heavy

handwheel operation is caused

when the engine comes to a

stall.To put th e power steering

in operation again, restart the

engine without delay

LIFT LEVER(13)

The forks can be raised or lowered by pulling backwards or pushing

forwards on this lever.The lift speed is controlled by tilt angle of the lever

and accelerato r pedal effort.The lowering speed can be controlled by tilt

angle of the lever.The engine speed ,or accelerator pedal does not have to

do with the lowering speed of the forks.

TILT LEVER(12)

The mast can be tilted by operation of

this tilt lever.Pulling on this lever

b a c k w a r d s w i l l t i l t t h e m a s t

backwards,and pushing it forwards will

tilt the mast farwards.The tilt speed can

be controlled by tilt angle of the lever

and accelerat or pedal effort.

CAUTIONThe tilt lock mechanism built

in the hydraulic circuit does not

allow the mast to tilt forwardswhile the engine is being shut

down eve if the tilt lever is

pushed forwards

6

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FOOT CONTROLS

See the right photo:Clutch pedal or

inching pedal(left),brake pedal(center), and

accelerator pedal(right).

CLUTCH PEDAL(18)

CLUTCH TYPE

The purpose of the clutch is to

permitthe operator to couple or uncouplethe engine and transmission.When the

clutch pedal is pressed,the engine and

transmission are uncoupled, and when

released,it allows power to flow through

the clutch from the engine to transmission.

CAUTIONDo not run the lift truck with

the clutch in a halfclutch cond-

ition as much as possible.

INCHING PEDAL(8)

TORQUE CONVERTER TYPE

As the inching pedal is pressed,the oil presure in the hydraulic clutch drops

accordingly(the needle of the oil pressure gauge swings to the left) allowing the

operator to perform inching operation.Use this pedal to inch the truck while

operating the hoist system at a high speed.

When pressed to the full,this inching pedal serves as a brake pedal.

ACCELERATOR PEDAL(11)The accelerator pedal increases the engine speed.With this pedal released,

the engine runs at idle rpm.

BRAKE PEDAL(10)Press this brake pedal to slow or stop the truck.At the same time,t he brake

lights come on.

10

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BODY&OTHERS

SEAT

An operator-oriented operator's seat is equipped.

SEAT ADJUSTING LEVER

Adjust operator's seat to position which is comfor-table for you and

provides easy access to all hand foot controls.The seat is unlocked by moving

the adjusting lever to the right.Before proceeding with work,adjust operator's

seat and make sure that it is securely locked.

OVERHEAD GUARDThe overhead guard used is strong enough to meet safety standard,and protects

the operator from falling materials.

HOOD

The hood can be swung up fully toprovide easy maintenance service.

To swing up the hood,lift upward on the

arrowed hood lock lever and the hood can

be lifted u p with little effort with an aid of

hood damper.

To lock the hood,push down on the front

of hooduntil it locks.

WARNLNGUse caution not to catch your fingers in the hood when closing it.

SEATADJUSTINGLEVER

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HYDRAULICFLUID RESERVOIR CAP

The hydraulic fluid reservoir cap is located at the

right side in the hood. Fill hydraulic fluid through this

filler port. The cap is provided with the dipstick.

FUEL RESERVOIR CAP

The fuel reservoir cap is located at the rear lefs side

of the truck body. To open, turn it counterclockwise.

CAUTIONThe fuel reservoir cap has the breather inside it to allow air to enter into the

reservoir. If the breather is damaged or clogged, the fuel system will get troubled.

Check to see that the breather is in good condition every time addition of fuel is

made.

WARNING FUEL HANDLINGStop the truck, shut down the engine and apply the parking brake securely.

Make sure that there is no naked flame near the area. Never smoke. The driver

should not remain seated when adding fuel.

After addition of fuel is finished, securely close the reservoir cap. A

loose cap could cause fuel leak or fire hazard in the worst case.

Before attempting to start the engine, make certain that the fuel

reservoir cap is securely tightened and that no fuel is spilt on or around the truck.For the purpose of fuel level inspection, never use naked flame such as

a match or lighter.

RADIATOR CAPThe radiator cap is located under the

cover plate at the rear of the hood. At

daily maintenance, you need not removethe radiator cap.

COOLANT RESER VOIRThe reservoir is located near the

battery.

WARNINGDo not remove the radiator cap abruptly while the engine is hot. Turn the

cap a little to the left to relieve the pressure in the radiator, then remove the cap.

Do not wear glove when removing radiator cap.

Y CM

FULL

LOW

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FRONT LIGHTS(B)(C)

Two head lights(B)and combination

lights (C)(turn signal, parking & clearance)

are Installed at the front side of the truck.

Take care of the lights, and wipe dirt, if any,and replace any damaged light immediately.

REAR COMBINATION

LIGHTS(A)

The combination lights at the

rear side serve as turn signal, tail

lamp, brake lamp, parking lamp,

back-up lamp and rear reflector.

pay attention to keep them frombeing damaged or covered with dust.

STEERING COLUMN TILTING

ANGLE ADJUSTMENT

The tilting angle of the steering

wheel is adjustable within a range of

4.5 degrees to suit individual operators.

The steering column is unlocked by

turning the lever counterclockwise andlocked by turning it clockwise.

A

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SAFETY INSTRUCTIONSS a fe t y is y ou r b u si n es s an d y ou r r e sp o ns i bi l it y . T h e S A FE T Y

INSTRUCTIONS covers basic safety procedures and warning of general application

to the typical forklift truck. However, safety precautions given on the following pages are

also applicable to lift trucks that have special specifications or attachments. Read this

manual thoroughly and become completely familiar with your truck to get ghe most

out of it.

SAFETY ALERT SYMBOL

1.KNOW YOUR TRUCK

For the purpose of doing material handling job, the forklift truck is different from general

passenger cars in structure as follows:

Poor front view due to the hoist system.

Pear wheel steering lets the rear of the truck swing outwards when going round corners.

Compactly designed,the forklift truck is heavy. Most of the weight of the truck and loads

is on the front wheels when loaded so the truck lacks stability.

Read the operator's manual and name plates on the truck, and become familiar withyour truck and operating procedures. If there i s something in the manual yo do not

understand, ask your supervisor to explain it to you.

2.GET PERMISSION

FROM SUPERVISOR

Only trained and authorized

operator shall be permitted to

operate the truck.

3.LMADE PERIODIC

CHECKS

Inspect the truck at periodic intervals for

oil or water leak, deformation, looseness, etc. If

neglected, short life of components will be

caused and in the worst case a fatal accident

would occur.

Wipe off oil, grease or water from the

floor board and foot and hand controls, if any.

Shut down the engine before inspecting

the engine and its allied components. Especially

use caution to the engine fan.

When inspecting the radiator or muffler,

exercise caution not to get burnt.

L

IECNSE

LIECNSE

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4.DON'T NEGLECT ANY DEFECT

Any time you find that the truck are not functioning properly, operation ofthe truck should be halted and the condition reported to the supervisor.

If any warning lamp comes on,move to a safe place and check or repair the

trouble.

5.AVOID FIRE HAZARD

Don't use an open flame to check level, or forleakage, of fuel, electrolyte or cooling water.

Never smoke while inspecting the battery,handling fuel or working on the fuel system. Thereis a danger of explosion.

Never fill the fuel tank with the engine running.

6.WARMING-UP & COOLING-DOWN

Warm up and cool down the truck for about 5 minutes before and afterwork.

When using your truck in an enclosed space, make sure there is enoughventilation. If needed, use a ventilation fan.

7.MOUNT PROPERLY

8.NEVER MOVE CONTROLS UN-LESS PROPELY SEATED

Never mount of dismount the moving truck,Use the safety step(s)and safety grip facin g thetruck when mounting or dismounting the truck.

Never attempt to work the controls unless properly seated.Before starting,adjust the seat so you can get easy access to all hand and foot

controls .

9.START SAFELY

Before starting up,make sure that:the parking brake lever is applied securely.the for ward-reverse lever is in neutral.Before starting,make sure no one is under,on and

close to the truck.

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16.KEEP EYES FRONT

Look in the direction of, and keep a clear view of the path of travel.

Wandering eyes mean a wandering truck, and that could be dangerous.

17.REMAIN SEATEDKeep your head, hands, arms, feet and legs

within the confines of the operator's compartment,

Never.

18.TO HANDLE BULKY LOADS

When handling bulky loads which restrict your vision, operate the machie

is reverse or have a guide, when you have a guide make sure you understand hand,flag, whistle or other signals. When operating with long loads such as lumber,

pipe, etc, or in the case of the large-sized model or the truck with spreader, be

extremely careful of load end swing at corners or in narrow aisles, Be alert for

fellow worker.

19.WATCH FOR DOOR WAYS

Watch for branches, cables, door ways, or overhangs. Use caution whenworking in congested areas.

20.SLOW DOWN AT CORNERS

Slow down and sound horn at cross aisles

and other locations where vision is restricted.

Slow down when steering.

21.WATCH YOUR ASSETSBe especially careful when traveling in reverse and turnin g, Be alert to

prevent striking anything with fork tips.

The lift truck with an attachment for long-sized loads requires larger truning

radius.

Make sure your load is well stacked and evenly positioned across both forks.

Use extreme caution when traveling on a bad ground or floor condition.

22.KEEP FLAMMABLE AWAY

Keep fluid cans, row cotton, paper or chemicals away from the truck during

operation since there is a danger or their firing or exploding due to exhaut gas

from the muffler.

Never approach overhead power cables with any part of your truck.

23.SLOW DOWN AT NIDHT

The operator is likely to have an illusion for distance or unevenness of the

ground, Travel at a speed that will permit the truck to be brought to a stop in a

safe manner.

Use head lights and required work light and clearance lights.

Stop!

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It is dangerous to travel with forks higher

than i s appropriate regardless of whether loaded

or not.Keep the good traveling posture.(When

traveling, the forks should be 15 to 30 cm above

the ground or floor.)

Do mot operate the side shift mechanism,

if equipped, when the forks are raised and loaded,since this will cause the truck to be unbalanced.

26.TILT BACKWARD WHEN LOADED

Travel with load as low as possible and tilted

back. If operating with steep pallet or the

like,besure to tilt back the mast to prevent it from

slipping off the forks.On trucks with a bucket, hinged forks,

dumping forks, or logger, the attachment control

is placed in UP position when loaded.

27.AVOID BRAKING TOO SHARPLY

Avoid braking too sharply or descending on a grade at a high speed.

There is danger of loads falling down or the truck truning over.

28.STOP,THEN BACK UP

Always brake to a full stop before reversing

direction of travel.

29.PRECAUTIONS ON GRADEWhen running down on a grade,use engine brake.While using engine

brake, don't operate directional and speed control levers.If the truck

exceeds the gear speed range,use the brake pedal.

24.CHECK WORK AREA

Inspect the surface over which you will run.

Look for holes, drop-offs, obstacles. And look for

rough spots. Look for anything that might cause you

to lose control, bog down or upset.Clear away trash and debris. pick up an ything

that might puncture a tire or let the load lose

balance.

Slow down for wet and slippery roads. Stay

away from the edge of the road. If unavoidable, use

extreme caution.

25.DARRY THE LOAD LOW

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30.BACK DOWN&DRIVE UP

When operating loaded truck, have the rear end of your machine pointed

down-hill.When climbing grades, use forwrd gears, and when descending, use

reverse gears.

Never turn sideways on an incline. There is danger of the truck turning over.

31.KNOW CAPACITY OF TRUCK

Know the rated capac ity of your lift truck

and its attachment, if any ,and never exceed it.

Do not use a man as an additional counter

weight. It's quite dangerous.

32.KNOW THE LOAD TO BE HANDLED

Taking account of the shape and material of loads to be handled, use a

proper attachment and tools.

Avoid hoisting the load, with wire rope hung on the forks or attachment,

since the wire rope may slide off. If needed, a qualified personnel for slinging

operation should perform, making use of a hook or crance arm attachment.

Take care not to protrude the forks out of the load. The protruded fork tipsmay damage or turn over the adjacent load.

33.WEAR GOGGLES,IF NEEDED

The operator may get a speck of dust or sand in his eye when working in a

dusty working area. Take care to the direction of wind, and wear goggles, if

needed.

34.USE PROPER ATTACHMENT

We offer users a variety of attachments, such as forks, bucket, rotating roll

clamp, load grab or hinged forks. Don't use such attachments and special

equipment for applications other than specified.

35.DON'T LIFT UNSTABLE LOADS

Make certain that your load is well stackd and evenly positioned across both

forks. Don't attempt to lift a load with only one fork.

On the truck with an attachment such as a load grab, make certain that the

load is securely and correctly grabbed, and pull the loading control lever to the

full(increase to relief pressure).

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When working the truck with a side shift or an attachment for longsized load

such as spreader, pole carrier, wide finger bar, hinged fork or logger, be especially

careful of load deflection.(The center of gravity of the load should be aligned with

the center of the truck as much as possible.)

The pallet and skid used should be strong enough to endure the load. Never

use damaged or deformed ones.

Never permit anyone to stand or walk under

upraised forks or other attachments if machine is

so equipped. If unavoidable, use a safety stand orblock to prevent a possibility of forks or

attachments falling down or moving unexpectedly.

Don't enter into loads at a high speed. Always

make certain that your load is stable before lifting

the forks.

Be sure to once stop in front of the load to be

lifted, and make certain that there is no obstacle , then

engage the load by driving forwards.

When load is to be retrieved froma

pile,enter the area squarly. Engage forksinto the pallet carefully.

36.USE PROPER PALLET

37.NEVER LIFT A LOAD OVER ANYONE

38.EASE INTO THE LOAD

39.ENTER LOAD SOUARLY

40.DON'T TILT THE MAST WITH

LOAD HIGH

Use minimum forward and reverse tilt when

stacking and unstacking loads. Never tilt forward

unless load is over stack or at low lift height.

When stacking loads on a high place, once

make the mast vertical at a height of 15 to 20 cm

above the ground and then lift the load farther.

Never attempt to tilt the mast beyond vertical when

the load is raised high.

To unstack loads from a high place, insert

forks into the pallet and drive backwards, then

lower the load. Tilt the mast backwards after

lowering .Never attempt to tilt the mast with the

load raised high.

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8.HOUR(DAILY or EVERY SHIFT)CHECK

GENERAL RULES ON INSPECTION:

(1)CHECK LEAKS OF OIL,FUEL OR WATER

Before starting your lift truck,be sure to inspect the following items for

safety sake and efficient productivity.

(1)Use genuine parts only.

(2)Use genuine or recommended oil only.

(3)Clean oil fillers and grease fittings with a brush or waste cloth before

adding oil or greasing.

(4)Oil level check and addition of oil should be made with the truck parked

on a level surface.

(5)Preventive maintenance services should be done in an orderly manner

and due care taken not to injure yourself.(6)If unavoidable to work under the raised forks or attachment, use a stable

support to prevent the forks and inner mast from falling down.

(7)If any damage or fault is found, the matter should be reported to your

supervisor and the truck should not be operated until corrected.

Check joints of the hydraulic

piping,engine ,radiator and driving

system for oil and water leaks.Checkleakage with your finger as well as

visually.

WARNING

Don't attempt to operate the truckif leaked fuel is found through pre-

operational check .Correct the leak

before starting engine.

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2 TIRE INFLATION PRESSURE CHECK

(3)HUB NUT TORQUE CHECK

Check condition of tires. Low air pressure reduces tire service l ife and

increase fuel consumption . Uneveness of air pressure between right and left tires

or unevenly worn or badly damaged tires will cause uneven steer ing fo rces.

The standard tire pressures are indicated on the decal at the front left side of

the hood.Turn the tire valve cap counter clock wise and remove it. Using a tire

pressure gauge, measure the inflation pressure, and adjust it to the specified

pressure, if needed. After making sure there is no air leakage from the tire valve,

reinstall the cap.

Check that each tire does not get damaged at the tread surface or side

face or bending at the rim.

Since the forklift truck needs tires that have a high inflation pressure

to carry heavy loads, even a small bending of rims or damage at t he tre ad

surface could cause an accident.

WARNINGAll nuts and bolts should be

properly installed and torqued

before inflating tire and rim

assembly. An inflated tire containspotentially explosive energy.

DON'T OVER INFLATE.

WARNINGWhen using an air compressor,

first adjust the air pressure of the

compressor. Failure to do so will

cause a serious accident, since thecompressor delivers the maximum

pressure.

Check hub nuts for correct torque.

All hub nuts should be tightened to the specified torque securely.

Hub nutDivided rim bolt

Drive shaft bolt

Hub nut

Divided rim bolt

CAUTIONDo not dismantle diviede rim bolt and

when detaching hub nut and .

Underinflation Good Overinflation

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(4)OVERHEAD GUARD CHECK

(5)BRAKE FLUID LEVEL CHECK

Open the hood...

(6)BATTERY ELECTROLYTE CHECK

(7)COOLANT LEVEL CHECK

(8)ENGINE OIL LEVEL CHECK

The overhead guard is for your protection.

Make certain that it is securely mounted and all

structural members are secure.

Check the fluid level in the brake fluid reservoir. The

level should be between the two seams of the reservoir.

When adding fluid, due care should be taken to preventdirt or water from entering the reservoir.

Open the hood from the left side of the truck.

Check electrolyte level in the battery.

The battery case is given upper and lower level marks to allow the operator

to see the electrolyte level.The level shoule be between the two marks.

The dipstick is located on the left side of the engine. Remove the dipstick,

clean the rod and reinstall. Pull it out again and check the oil level. The level should

be within the mark on the dipstick.

WARNINGUse extreme care when removing the radiator pressure cap.In pressure

system,the sudden re lease of pressure can cause a steam flash which would

cause a serious personal injury,Loosen cap slowly to allow steam to eacape.

After that,tighten cap securely,It is good practice to use thick waste cloth or

the like when removing the cap.Avoid putting on gloves,since you may get

burnt at your hand if hot water splashes on it .

Check the radiator coolant reservoir fluid

level.It should be between high and low level

mark.Add coolant if necessary.

DANGERNever allow flame or sparks near

the battery filler holes because

explosive hydrogen gas may be present.

FULL

LOW

Air-vent hole

Oilleverrange

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9 FAN BELT TENSION CHECK

(10) REAR COMBINATION LAMP CHECK

(11)HYDRAULIC OIL LEVEL

(12)PIPING & CYLINDERS

(13)POWERSHIFT TRANSMISSION FLUID LEVEL

TORQUE CONVERTER TYPE

(14)LOAD BACKREST CHECK

(15)FORKS & FORK STOPPERS

Check the fan belts for correct

tension and damage. Pushed the midway

between the water pump pulley and

the generator pulley by the thumb.

WARNINGFan belt deflection check should

be made with engine shut down.

Check rear combination lamps(tail,brake,back-up)for damage or contamination.

Check hydraulic oil level by means of the oil level dipstick: Remove the oil

level dipstick and clean it. Reinsert is and remove again to see if the oil level is

between two slots: High and Low.

CAUTIONThe oil level check should be

done with engine shut down, fo rkson the ground or floor, and the

truck itself on a level surface.

Visually check hydraulic oil pipings and lift and tilt cylinders for oil leaks.

Open the inspection corer and remove

the filler cap. Inspect the level gauge to make

sure that the fluid level is on the upper mark of

the gauge. Add specified fluid, if necessary.

Check for loose mounting bolts of the

load back-rest.Retighten where needed.

Check fork stoppers for correct installation and forks for bending or cracks.

H L

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(16)HEAD LIGHTS & FRONT COMBINATION LAMPS

(17)DRIVERS SEAT ADJUSTMENT

Close the hood sit on the seat and...

(18)SHIFT LEVER(S)CHECK

(19)LOADING LEVERS CHECK

(20)PARKING BRAKE OPERATION CHECK

Start the engine...

(21)METERS & GAUGES

(22)FUEL LEVEL CHECK

(23)LIGHTS & LAMPS

Check for dirty or damaged lens.

Take care not to catch your finger in the hood.

Make sure the driver's seat is properly located.If not properly,shift the

adjusting lever to the right and move the driver's seat to a position which provides

easy access t o all foot and hand controls.After adjustment,shake the driver's seat a

little to be sure that it is securely locked.

Check the shift lever(s)for looseness and operation.

Check the loading levers(for lift, tilt & optional attachment)for looseness and

smooth operation.

Make sure that the parking brake is securely applied by operating the

parking brake lever.

Before starting the engine,make certain the shift lever(s)is in neutral and

parking brake is securely applied.

The hour meter, coolant temperature gauge and fuel level gauge are provided

to inform the operator of the operating condition of the truck during operation.

The fuel level gauge is provided on the indicator panel.Check that fuel level is

sufficient for the day's work.

Actuate each light or lamp switch to be certain that the respective light or

lamp comes on properly.

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(24)TURN SIGNAL CHECK

(25)HORN BUTTON OPERATION CHECK

(26)CLUTCH PEDAL CHECK

FRLCTIONAL CLITCH TYPE

(27)BRAKE PEDAL FREE TRAVEL

(28)MAST OPERATION

(29)LIFT CHAIN TENSION CHECK

(30)STEER HANDWHEEL FREE PLAY

Make sure that the turn signal operates properly by moving the turn signallever.

Press the horn button to make certain the horn sounds.

Check that the clutch pedal travels smootyly.On the truck with the optional power clutch device, star t the engine, then

proceed with this clutch pedal check.

Press the brake pedal and inching pedal(on torque converter type only)tomake certain that each pedal can be pressed smoothly and that is also can restorewithout interference.

Sound hom, and actuate the lift and tilt levers to be certain that the carriagemoves up and down properly and the mast can be tilted smoothly. Make certainthat the relief valve operates accompanying its relieving sound when eachcylinder piston reaches the stroke end .Pay attention to system operating sound.

Check the tension and abnormality of the lift chains. To check the tension,raise the fork about 5 cm above the ground and push the middle of the chain withthe thumb. Make certain the tension for the right and left chains is even. If uneventension is found, loosen the lock nut(A)of anchor pin and adjust the chain,turning the adjusting nut(B)of the chain anchor pin.

CAUTIONDon't use Grease but Machine

Oil(ex.Hydraulic Oil) only for liftchain lubrication.

Check the steer handwheel forplay and vertical looseness.Thenormal play is 50 to 100 mm and

vertical looseness it not permit ted.

AB

50to100

mm

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(31)EXHAUST GAS CHECK

Run at a low speed (at a safe place)

(32)CLUTCH OPERATION CHECK

(FRICTIONAL CLUTCH TYPE ONLY)

INCHING PEDAL CHECK(TORQUE CONVERTER TYPE ONLY):

(33)BRAKE TEST

(34)STEERING CHECK

(35)PARKING BRAKE TEST

(36)BACK-UP LAMP OPERATION

WHEN SEDIMENTOR INDICATOR LIGHTS Up...

DIESEL

Check condition of exhaust gas after the engine warm-up is finished.

Colorless or bluish Norml:Complete combustion

Black Abnormal:Incomplete combustion

White Abnormal:Oil burns

Check also the engine and driving system for clicking or any abnormal noise

or vibration.

DANGEREchaust fumes are very dangerous.When starting the lift truck in

enclosed space,make sure there is enough ventilation.The exhaust gas check

should be done outdoors.Especially use caution to avoid fire hazards.Pay

special attention to signs of oil orfuel leaks and never leave waste cloth orpaper inside the engine room.Make sure you know where the fire

extinguishers are kept and how to use them.

Press the clutch pedal to be certain that the clutch is properly disengaged

and does not drag.

Press the inching pedal a little (3mm or less)and check that the truck speed

decreases.

Run the truck slowly and press the brakepedal to check the braking effect. When the

brake pedal is pressed, the stop lamp comes

on.

Turn the steering wheel traveling slowly

to see that the steering forces ate equal in right

and left or that any abnormality does not exist.

Make certain that the slowly running truck can be stopped by pulling on the

arking brake lever.

The back-up lamp comes on when the shift lever or directional control lever

is placed in reverse position.

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WATER DISCHARGE FROM SEDIMENTOR

WHEN ALR-BLEEDING FUEL SYSTEM

DIESEL

AIR-BLEEDING PROCEDURE

Stop the engine, loosen the drain plug by turning 4 to 5 turns(A)and

press the priming pump(B).Continue pressing the priming pumg(B)until water

is entirely discharged through the sedimentor.

Fasten the drain plug and press the priming pump several times to see

that there is no fuel leakage form the plug.

Start the engine to confirm that the indicator doesnot light up.

Stop the engine and loosen the bleed plug(C)on the injection pump.

Press the priming pump until fuel coming through the bleed pulg contains no

bubble.

Fasten the bleed plug to confirm that there is no fuel leakage from the plug

screw.

B

A

C

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STORING BEFORE STORING

DAILY STORAGE

LONG TIME STORAGE

Before stor ing your li ft truck, clean it thoroughly and perform inspectionusing the following procedures.

Wipe away grease, oil .etc. adhering to the body of the truck with wastecloth, and use water, if needed.

While washing the truck body, check general condition of the truck,Especially check the truck body for recess or damage and tires for wear or nails orstones in the tread.

Fill the fuel reservoir whit fuel specified.Check for leakage of hydraulic oil, engine oil, fuel.or.coolant.Apply grease,where needed.Check for looseness of hub nuts, cylinder piston rod joint.Check mast rollers to see that they rotate smoothly.

Prime oil into the lift cylinders by actuating the lift cy linders at the fullstroke.

Drain off coolant completely in winter or cold weather, if antifreeze,orLLC is not used.

WARNINGIf at any time your lift truck is found to be in need of repair, defective, or in

any way unsafe,the con dition should be reported to the supervisor, and the truck

should be taken out of service until it has been resored to safe operatingcondition.

Park the lift truck at a specified place and block the wheels.Place theshift lever(s)in the neutral position and apply the parking brake

securelyShut down the engine by placing the key switch in OFF position. Actuate

each loading lever several times to remove the residual pressure in the respectivecylinders and hoses.

Remove the key and keep it sure.

Perform the following service and checks in addition to the DAILYSTORING services.

Taking the rainy season into consideration,park the machine at a higher andhard ground.

Dismount the battery from the machine.Even though the machine is parked indoors, if the place is hot or humid, the

battery,should be kept in a dry, cool place. Charge the battery once a month.Apply antirust to the exposed parts such as cylinder rods and shafts

which tends to rust.Cover components such as the breather and air cleaner which may be caught

with humidity.The Machine should be operated at least once a week.Fill the cooling

sytem, if cooling water is discharged,and mount the battery.Remove grease fromthe cylinder rods and shafts.Start the engine and warm up thoroughly.Move themachine a little forwards and backwards.Ope rate the hydraulic controls severaltimes.

Avoid parking on soft grounds such as an as phalt ground in summer.

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TO OPERATE THE LIFT TRUCK AFTER

A LONG TIME STORAGE

Remove antirust from the exposed parts.

Drain the engine crankcase, transmission (clutch type machine),

differential, torque converter(torque converter type),clean the inside of themand add new oil.

Discharge foreigh matter and water from the hydraulic oil resservoir

and fuel reservoir.

Remove the cover from the engine cylinder-head.Oil valves and

rocker shaft and check each valve for proper operation.

Add cooling water to the specified lever.

Charge the battery and mount it on the machine. Connect the cables.

Perform pre-operational checks carefully.

Warm up the machine.

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OPERATIONS

DURING BREAK-IN

RELATIONSHIP BETWEEN LOAD ANDSTABILITY OF TRUCK

LOAD CENTER & RATED LDAD

To operate the truck safely and get the most out of it,we describe the correct

operating proce-dures on the following pages.

We recommend to operate the machine under light load conditions for thefirst stage of operation to get the most from it. Especially the require ments given

below should be observed while the machine is in a stage of 100 hours of

operation.

Always warm up your machine before putting it to work irrespective of

season.

Perform specified preventive maintenance services carefully and

completely.

Avoid sudden stop, starts or turns.Oil chnges and lubrication are recommended to do earlier than specified.

Don't run engine at high rpm without load need lessly.

The lift truck keeps the balance of

weight between the truck body and the load

on the foks with the center of the frontwheels as a fulcrum when the rated capacity

load is placed in position.Due care should be

paid to the weight and the center of gravity

of loads to maintain the stabillty of the t ruck.

WARNING

If the rated capacity is exceeded,there is a danger of the rear wheels being

raised and in the worst case,the truck will turn over ,resulting a fatal accidentAs seen from the above sketches,the load placed near the fork tips practically

has the same effect that the weight of the load is increased.In this case,the

case,the load weight is reduced accordingly.

The load center is the distance from the front face of the forkx to the center of

gravity of the load.The chart given above shows the relation between the load center

and the weight of loads to be allowable for the CPQ25 CPC25 lift truck

(Allowable Load).The load Chart will be attached onto the truck. Replace

damaged or missing load chart with new one.

SINGLE TYRE

DUAL TYRES

CAPACITY CHART

2.5t LIFT HIGHT

M AS T S T D

400 425

450500

425

475

450

475500

160 140 120 100 80 50

L OA D CE NT ER c m6TY20-00-12

kg

2500

2000

1000

CAPACITY

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STABILITY OF LIFT TRUCK

OPERATIONBEFORE STARTING ENGINE

WARNINGIf at truck is equipped with a load-handling attachment such as a side

shifter,load grab or rotating clamp,its allowable load is reduced as comparedwith that of a standard truck(without any attachment)due to the followingreasons.

1)The load equal to the weight of attachment is reduced2)Since the width of attachment causes the load center to move forward the

allowable load is reduced on the same principle as a seesaw.The installation of attachment causes the load center to mo ve forware, which iscalled lost load center

Never exceed the allowable load indicated on the load chart attached ontothe truck or attachment.

The stabillity standard of lift trucks is specified by the ISO or otherstandards.However,the stability stated in these standards is not applicable in alloperating conditions The stability of your lift truck varies according t the operatingconditions In the following operating conditions,the maximum stability is secured:1)Ground or floor is level and hard.

Traveling under standard unloaded or loaded condition.

This means that the forks or other loadengaging means are raised 30 cm above theground and the mastis tilted fully backwardwithout loads.

This means that the forks or other loadengaging means are raised 30 cm above theground and given capacity loads at the basicload center on it and the mast is tilted fully

backward.

WARNINGUse minimun forward and reverse tilt when stacking and unstacking

loads.Never tilt forware unless load is over stable stack or rigid rack or at

low lift height.

Before operating the truck, check all controls and warming devices forproper operation . If any damage or fault is found don't operate truck untilcorrected.

300 mm

300 mm

In addition,the lift truck should be put in a good servicing condition to do the

job safely.

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Check the safety around the machine.

If water,grease or soil is sticking to the floor,pedals levers or operator's

hands,clean it off.

Make sure that the shift lever(s)and loading levers are in NEUTRAL and

HOLD positions and that the parking brake lever is fully engaged.

Pull out the choke button fully.Depress the accelerator pedal to the floor two

or three times and release it.With your foot OFF the pedal,crank the engine by

turning the ignition key to START Release key when engine starts.

Do not pull out the choke button.Press down the accelerator pedal halfway

and hold.Crank the engine by turning the ignition key to START .Release key

when engine starts.

CAUTIONDo not press down the accelerator pedal fully when starting warm engine

This operation may harden the engine starting.Pressing down the accele rator

pedal several times will cause harder starting .

Turn the ignition switch to ON position untio the GLOW indicator goes

out,then turn the ignition switch to STARK position.

If the engine is hard to start,check for low fuel level,air mixed in the fuel

system or broken wire of the glow plug.

Warm up the engine(for about 5 minutes)

Check the rotaion(sound or gear)of the engine.

Check the combustion(or misfiring)sound.

Check the condition(density)of exhaust.

Make sure that all the warning lamps are off.

After thoroughly warming up the engine.operate the loading leven 2 to 3

times in their full stroke and check their working conditions.

CAUTIONAfter cranking the engine, push in the choke button step by step

observing the warm-up condition and stability of speed of the engine. Push

in the choke button fully after making sure the engine is completely warmed up.

Hold the knob on the steering

wheel with you left hand and get the

right hand ready for loading

work,lightly putting it on the wheel.

Set the botton of the fork 15 to20 cm above the ground and fully

tilt back the upright.

STARTING GASOLINE ENGINECOLD ENGINE

WARM ENGINE

STARTING DIESEL ENGINE

AFTER ENGINE HAS STARTED

TRAVELINGOPERATOR'S POSTURE

BASIC STATE FORTRAVELING

Gas model

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Check the safety around the machine and give a signal when starting the machine.

Gradually release the clutch pedal

while depressing the accelerator pedal

to start the machine.

CAUTIONDo not rest your foot on the clutch

pedal while you are driving.

Release brake pedal and depress theacelerator pedal to start the machine.

[TORQUE CONVERTER TYPE]

[CLUTCH TYPE]Depress the clutch pedal and engage

the shift levers.

Release the parking brake Lever.

Depress brake pedal and engage

the forward-reverse lever. Release the parking brake Lever.

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GEARSHIFTING

SLOW-DOWN

STEERING

STOPPING OR PARKING THE TRUCK

WARNINGYou must slow down

at aisle intersections in crowded ares

on rough ground or floor surfaces. when approaching loads or obstacles.

Without loads, the truck can start even with gears in high speed, However,

under loaded condition, Place the grea in low speed to start the truck.

1) Always stop the truck before reversing the direction of travel.

2) When gear shifting from high to low speed or vice versa, once increase theengine speed and release accelerator pedal. At the same time, press the clutch

pedal while shifting the shift lever ingo the desired position. Then press the

accelerator pedal while releasing the clutch pedal.

1)Always stop the truck before reversing the direction of travel.

Since this machine uses the synchromesh transmission, it is not necessary

to perform the double clutch operation. Remove your foot from the acce lerator

pedal, press the clutch pedal to the full, place the speed shift lever into the first

speed position,and press the accelerator pedal while releasing the clutch pedal.

Release accelerator pedal depression a little, and press the brake pedal, if

needed.

Nlike general passenger-cars,the steer wheels are located at the rear of the

truck, These cause the rear of the truck to swing out when a turn is made. Slow

down the truck and move toward the side to whi ch you are turning. The steer

handwheel should be turned a bit earlier than as with the front wheel steering car.

Slow down and press the brake pedal to stop the truck(in the case of clutch

type machine, the clutch pedal is used).place the shift lever in NEUTRAL.

CAUTIONNever stop the truck in ascending on a grade by pressing the accelerator

pedal with the clutch in half-clutch and torque converter i n operaiton This

will cause undue wear of clutch plates and abnormal rise of torque converter

oil temperature, resulting in short life of clutch or torque converter.

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To park the truck:

Park the truck ina out-of-traffic area and...

WANINGSafe parking

GROUND CONDITION

GROUNDS COVERED WITH SNOW ORICE

PLCK UP

1)Apply the parking brake by pulling up on the parking brake lever.

2)Down the forks on the ground.

3)Place the key switch in OFF to shut down the engine. In the case ofthe diesel truck, pull out the engine stop button.

4)Remove the key and keep it.

(1)Park your truck on a level ground-preferably in a wide area. If parking on

a slope is unavoidable, position the truck so that it cross the slope and block the

wheels to prevent accidental roll.(2)park your truck in a designated area or out-of-traffic.If necessary. put a

signpost or signal lights around the truck.

(3)park your truck on a hard ground. Avoid soft ground, deep mud or slippery

surfaces.

(4)If you can not lower the forks on the ground due to break-down of the

loading system. Put a caution cloth to the fork end and park in an out-of traffic

area.

WARNING(1)Check for slippery steps and floor.

(2)Don't dismount from the moving machine.

(3)Never jump off the machine.

Lift truck performancedepends on the ground or floor

conditions and travel speed

should be ajusted properly.Use

extreme care when operating on a

ramp or rough ground or floor.

WARNING

(1) When crossing the railroad, be surebo once stop and make sure to be safe.

(2)Go around rocks and stumps. If

unavoided, reduce speed and go slowly

and carefully. Use caution not to damage

the bottom of the truck.

When traveling on grounds

covered with snow or ice, use tire

chains. On such ground conditions,

avoid sudden accelerations, stops, or

turns. It is good practice to control the

travel speed by accelerator pedal effort.

WARNINGWhen equipped with tire chains,

the truck get a larger driving power.

How ever , s i dewa y an t is l ip

performance is almost reduced so

extreme care should be used.

1.The forks should be adjusted sidewise to maintain proper balance of load.

2.Place the machine right in front of the load to be handled.

3.The pallet should be evenly positioned across both forks.

4.Insert forks into the pallet as far as possible.

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STACKING LOAD

UNSTACKING LOAD

MEASURES AGAINST COLD & HOT WEATHERSOIL

Use the oil suitable for ambient temperature.

1)When approaching the area where the load is to be retrieved ,slowdown your truck.2)Stop the truck in front of the load so that dis tance betw een the load

and fork tips is about 30 cm.3)Check the condition of the load.4)Tilt the mast forward until forks become horizontal. Elevate forks up to

the position of the pallet or skid.5)Make sure forks are posi tioned properly for the pallet. Move forward

slowly to insert forks into the pallet as far as possible and then stop the truck.

*If the forks are hard to be fully inserted, use the followingprocedure:Move forward and insert 3/4 of the forks. Raise the forks 5 to 10 cmand move backward 10 to 20 cm with the pallet or skid on the forks, then lowerthe pallet or skid on the stack. Move forward again to insert the forks fully.

6 Raise the forks 5 to 10 cm off the stack.7)Check all around the truck to insure that the path of travel is

unobstructed and back away slowly.8)Lower forks to a height of 15 to 20 cm above the ground. Tilt the mast

backward fully and move to the desired area.

WARNINGNever tilt the mast with loads upraised 2m or more.Don't leave or dismount from the truck when the load is raised hith.

1.When approaching the deposit area slow down your truck.2.Once stop the truck right in front of the area where your load is to be

deposited.3.Check the condition of the deposit position.4.Tilt the mast forward until forks become orizontal. Raise forks until they are

a little higher than the deposit position.5.Move forward to place the load directly over the desired area and sto p the

truck.6.Make sure your load is just over the desired area Slowly lower the load

into position. Make sure the load is securely stacked.7.Disengage forks from the load by using necessary lift-tilt opeation and then

back away.8.After making sure the fork tips leave the load,lower the forks to the basic

position (15 to 20 cm off the ground)9.Tilt the mast backward.

5.To raise loads from the ground(1)Once lift the forks 5 to 10 cm off the ground or floor and make sure

loads rest stably.(2)Then,tilt the mast backwards fully and lift forks up to 15 to 20 cm off

ground then start running.

6.When handling bulky loads which restrict your vision, operate the truckin reverse except when climbing grades.

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BATTERY

In Cold Weather

In Hot Weather

RADIATOR COOLANT

REPLACING FUSEThe fuse protects the electric system against overcurrent. Use the specific

ampere rating of fuse. Check to see that the components in each circuit areoperating properly. If every component in a circuit is not functioning, it is an

indication that the corresponding fuse is blown out. Replace the blown fuse with aspare fuse of the same capacity. If a part of the components in the circuit doesnot function properly, it is suspected that a bulb has burnt out. The burnt bulbshould be replaced with new one of the same capacity.

Your lift truck is generally shipped with the cooling system filled with Looglife coolant(LIC)of 50% volumetric mixture.The freezing point of the coolant of

such a mixing ratio is -35 .In Hot Weather :To maintain good cooling effect,special care should be paid

to radiator and cooling system.Parking in the shade is recommended.

DANGERGASES produced by the battery can be explosive. Do not smoke, use an

open flame, create an arc or sparks in the vicinty of the battery. Ventilate well

when in an enclosed space and when charging The battery contains SUIPHURIC ACID which causes severe burns. Do not get in eyes, on skin orclothing. In case of contact, flush immediately and thoroughly with cleanwater, Obtain medical attention when eyes are affected.

As the water of electrolyte is especially likely to evaporate in hot weather,replenish distilled water from time to time.

Check the battery once a week, and supply distilled water.In a region where the ambient temperature is intensely hot, it is practicable to

lower the specified gravity of a completely charged battery down to 1.220 0.01.Since the battery is better in efficiency under hot temperatures, no other

cares are needed.

Under normal charged conditions, the freezing point of electrolyte is about35

Always keep the battery in a well-charged condition since there is danger ofdamaging the battery jar if electrolyte freezes. To prevent the freezing, charge atleast 75% of the whole capacity.

Also it is effective to keep the specified gravity up to 1.260,but not higherthan this value.

BB

B

BB

B

1

2

3

45

6

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REPLACING OR REPAIRING TIRE

Front Wheel

Rear Wheel

LIFTING PROCEDURE

FRONT SIDE(I)

FRONT SIDE(II)

REAR SIDE

1.Place chocks in front of front wheels.

2.Jack up or lift the counterweight with a hoist.

3.Place wooden blocks under both side frames.Also place blocks under the counterweight for

safety. Gradually lower the rear end to the ground. Be

careful not to dislocate blocks while lowering.

1. Place chocks behind rear wheels

2. Tilt the mast fully backward and put wooden blocks and steel plates underthe outer mast as illustrated.

3. Tilt the mast forward to a vertical postiton, and place wooden blocks

under both side frames.

1.Place chocks behind rear wheels.

2.Lift or jack up the outer mast with a hoist or jack.

3.Place wooden blocks under both side frames. Gradually lower. the front end

to the ground. Be careful not to dislocate blocks while lowering.

Use the same manner as with the front wheeltire repair or replacement except for the position of the

jack which goes under the counter weight. Tireinflation pressure 7kg/cm2

Stop the truck on a level, hard surface and shut down the engine. All

loads should be unloaded from the truck.Apply the parking brake and block the wheels. Put the jack under the

truck frame.Jack up the truck to the extent that the tire still remains on the ground.

Loosen the hub nuts. Do not remove them.Again jack up the truck until the tire leaves off the ground, Remove the

hub nuts, and detach the wheel.The wheel should be reinstalled in the reverse order: The hub nuts should be

tightened in the diagonal order evenly.

After reinstallation, check the tire for proper inflation pressure.2

The inflation pressure 7kg/cm

Prepare tools and jack necessary for replacing or repairing tires.

Safety cage

32

2

2

13

1

3 2

2

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After supporting the lift truck with blocks, push and pull it from all directions

to make sure it is securely blocked.

WARNING

Do not work on or under any truck that is supported only by lift jacks or ahoist. Always use blocks or jack stands to support the truck before

performing any disassembly.

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PREVENTIVE MAINTENANCE SERVICE SCHEDULEThis service schedule is worked out on the assumption that the lift truck will

be used under typical working conditions. If the lift truck is used under severer

working conditions, earlier preventive maintenance services are required.(The

black dots in the table means Replacement .)

G:Gasloine Truck

D:Diesel Truck

ENGINE

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Engine Visually inspect

condition of

engine rotation

Check for

working noise

from engine

Check that

exhaust gashas proper-color

Check air cleaner

element for dirt

and clean

Check crankcase

air breather for

dirt and clean(C240 Diesel)

Check that

valve clearance

is correct

Retighten

cylinder

head bolt

Check cylinders

fro proper

compression

PCV

Device

Check metering

valve and pipe

for clogging

or damage(G)

Governor

or

Injection

Pump

Check no-load

maximum rpm.

Tacho-

meter

Compr-

ession

gauge

Torque

wrench

Thick-

ness

gauge

All gas

engines, for

Ist time only

C240

diesel

only

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ENGINE

Checkingltem

serviceRequired Tools

Daily(8hrs)

Monthly(200hrs)

Trimonthly(600hrs)

Semiannually(1200hrs)

Annually(2400hrs)

Lubrication

System

FuelSystem

Check for en-

gine oil leak.Check engineoil for leveland dirt

Replace en-gine oil

Replce engineoil filter ca-rtridge

Visually ch-

eck for fuelleak from p-ice,pump ortank.

Check fuelfilter forclogging

Clean fuelfilter(G)

Replace fuelfilter cart-ridge(D)

Check thatinjectionnozzle hascorrect I-nject pressand patte-rn(D)

Check carb-ureter linkmechanisn forlooseness ordirt(G)

Check for

ignitiontiming (G)

Check forinjectiontiming(D)

Drain offwater fromfuel tank

Clean fueltank

Check forfuel level

(at initial 25 hrs)

(at initial 200 hrs)

O(H20) O(H20)

(A15&H20)

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POWER TRAIN

WHEELS

TiresCheck forinflationpressure.

Check forchracks ordamage.

Check fortread wear.

Check forundue wear.

Check forspikes,s-tones.orforeighmatter.

Tiregauge

Depthgauge

Cleck for

oil leaksCheck for oillevel,orchange oil

Check changelever for ope-ration andlooseness.

Check control

valve and cl-utch for properoperation.

Check inchingvalve for properoperation

Check inchingpedal for freetravel andpedal travel.

Replace linefilter element.

Check foroil leak

Change oil

Check moun-ting bolts forlooseness

Torque

converterTransmis-sion

FrontAxle

(at intial 200 hrs)

Testhammer

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

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WHEELS

STEERING SYSTEM

Check for

looseness.

Check fordamage.

Check rim,sidering and diskwheel fordamage.

Check for

loosenessand noise.

Clean andrepackgrease.

Cleck axle fordeformation,cracks ordamage.

TireFastners

Rim.Sidering

WheelBearing

Axle

Test

hammer

Steer

Handwheel

SteeringGear Box

KnuckleRear Axle

PowerSteering

Check for per-ipheral play.

Check for ver-ticallooseness.

Check forsidewayslooseness.

Check forproperoperation.

Check mount-ing bolts forlooseness.

Check kingpins for

loosenessor damage.

Check fordeflection,derormation,cracks ordamage.

Check for mo-uting condition.

Check foroperation.

Check foroil leaks.Check formountingparts andjoints forlooseness.

Testhammer

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

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Brakepedal

ParkingBrake

Lever

Rod,Ca-ble etc

Hosesandpipes

BrakeMasterCylin-derWheelCylin-

der

BrakeDrum&BrakeShoe

Check forfree travel

Check forpedal travel

Check for pr-oper operation

Check for airrnixed in br-ake piping

Check that l-ever is scur-ely locked andhas sufficientlever stroke.

Check foroperationCheck conne-ctions forlooseness.

Check for dm-age,leakageor collapse

Check for lo-ose connec-tions or clam-ping parts

Check forfluid leaksCheck for fl-uid level.Ch-ange brake fluid.

Ceck master cyl-inder and wheelcylinders for p-roper operation

Check master cy-linder and wheelcylinders for fl-uidleaksordamage

Check mastercylinder pistoncup,and checkvalve for wearor damage.Change

Check drummouting partfor looseness

Check liningfor wear.Check brake s-hoes for properoperation

Check anchorpin for rust

Check returnspring fordeterioration

Check automa-tic clearanceadjuster foroperation

Check drum forwear or damage.

Testhammer

Slidecalipers

Scale

Scale

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Check for pr-oper operation

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BRAKE SYSTEM

BackPlate

Check backplate fordeformation

Check forcraks.

Check moun-ting parts forlooseness.

Pene-tranttest

Testhammer

Fork

Mast &LiftBracket

Check forks fordamage,deforma-tion or wearCheck for sto-

pper pins fordamage or wear

Check fork baseand hook weldi-ngs for defectivecracks or wear.Check cross me-mbers on outer

and inner mastsfor defectiveweld,cracks ordamage.

Check tilt cylin-der bracket andmast for defec-tive weld,cracksor damage.

Check outer andinner masts fordefective weld,

cracks ord amage.Check for de-fective weld,cracks or da-mage of lift

bracket.Check rollerbearings forlooseness.

Check mast s-upport bushi-ngs for wear

or damage.

Check mast s-upport boltsfor looseness.

Check lift cy-linder tail

bolts,pistonrod head boltsUbolts,and

piston head g-uide bolts for

loosecess.

Check rollers,roller pinsand welded p-arts for craksor damage

Testhammer (for lst time only)

LOADING SYSTEM

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Testhammer

(for lst time only)

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LOADING SYSTEM

HYDRAULC SYSTEM

Chains &

Sheave

OptionalAttachment

Cylinders

Hydraulic

Pump

Check Chainsfor tension,deformation ,

damage or rustIubricationof chainsCheck connection ofchain anchor pin andchain for looseness.Check sheavesfor deformationor damage.

Check sheavebearings forlooseness.Perform gen-eral inspec-tionCheck pistonrod,rod screwand rod end forlooseness,de-formation ordamage.

Check cylind-es for properoperation

Check foroil leaks.

Check pinsand cylinderbushings forwear or dam-age.

Check hydra-ulic pump foroil leaks ornoise

Check pumpdrive gearfo wear.

Testhammer

Check foroil level.Change oil.Clean suctionstrainer Drainforeign matter.

Replacereturnfilter.

Check leversfor loosenessat link.

Check leversfor loosenessat link.Check forproper o-peration.

HydraulicReservoir

ReturnFilter

ControlLever

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

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HYDRAULC SYSTEM

ControlVale

Hose,pi-ping HoseReel & S-

wivel J-oint

Check foroil leaks.

Check reliefvalve and t-ilt lock va-lve for pro-

per operation.

Measure rel-ief pressure.

Check for oilleaks,loosen-ess,collapse,deformationand damage

Change hoses.

ELECTRICALS

IgnitionDevice(for ga-solinetruck)

Oil pr-es gauge

Check dist-

ributor capfor crack.

Check sparkplug forburn.

Adjust sparkplug cleara-nce

Clean sparkplug

Check distri-butor caphighvoltagecord for in-stallation.

Check distri-butor segm-ent for burn.

Check dist-ributor ce-nter piecefor wear ordamage

Apply greaseon shaft,camheel and br-eakr fulcrum.

Check high-voltage co-rd for bre-akage.

Tester

Pluggapgause

1or2 years

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

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ELECTRICALS

SAFETY APPARATUS & ACCESSORIES

Starter

Battery

Wiring

Check piniongear for correct

engagementCheck batteryelectrolyte level.Clean battery.

Check specificgravity of el-ectrolyte

Check wire ha-rness for dam-age andclampsfor looseness.

Check connections for loose

-ness

OverheadGuard &LoadBackrest

Turn Signal

Horn

Light &Lamps

Buck-upBuzzer

Rear ViewMirror

Meters

Check fortight in-stallation.

Check ford-eformation,cracks or d-amage.

Check for pr-oper operationand tight in-stallation.

Check fordirt ordamage

Check for

good fieldof vision.

Check metersfor properoperation.

Check for pr-oper operationand tight in-stallation.

Check for pr-oper operationand tight in-stallation.

Check for pr-oper operationand tight in-stallation.

Testhammer

Hydro-meter

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

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SAFETY APPARATUS & ACCESSORIES

Driver's

Seat

Body

Grease-up& OilChange

Check for d-amage or lo-

ose bolts.Check frame andcross members fordamage or cracks

Check for lo-ose rivets orbolts.

Check itemsrepaired in pr-eceding ins-pection if any.

Inspection g-eneral condi-tion of body

After cleaning,check for grea-sed conditionof chassis.Check oil co-ndition of oiland fluid inreservoir

Testhammer

Greasepump

CAUTIONLocal refined oils and cooling water,coolant.or anti-freeze do not allow

the same operation period desingnated in this manual.So must be changed more

frequently as half or quarter o f the designated period in this manual.

Multi-visco sity oils allow a wider temperature range for operation but must

be changed more frequently as the addition that provides the multi-viscosity

gradually deteriorates lowering the viscosity.Degradation of viscosity at thehigher temperatures can be very detrimental to the hydraulic system.

Checking

ltem

service

RequiredTools

Daily

(8hrs)

Monthly

(200hrs)

Trimonthly

(600hrs)

Semiannually

(1200hrs)

Annually

(2400hrs)

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: 2611

Address: 2611 Bao'an Highway, Shanghai, China