OPERATOR'S MANUAL

Internal Combustion Balanced Forklift Truck

CONTENTS
INSTRUMENTS SWITCHES CONTROLS BODY & OTHERS SAFETY INSTRUCTIONS 8 HOURS(DAILY or EVERY SHIFT)CHECK STORING OPERATIONS PREVENTIVE MAINTENANCE SERVICE SCHEDULE 6 10 14 20 28 44 60 64 84

17

2 1 3 15 16 4

14 13 19 18 11

5 6 7 12 8

10 9

1 2 3 4 5 6 7

Outer Mast Inner Mast Lift Chain Lift Cylinder Load Backrest Fork Stopper Carriage

8 Fork 9 Drive Wheel 10 Steer Wheel 11 Fuel Reservoir Cap 12 Hood 13 Tilt Cylinder 14 Driver's Seat

15 16 17 18 19 20

Steering Handwheel Head Light Combination Lamp Overhead Guard Rear Combination Lamp Counter Whight

TORQUE CONVERTER TYPE

1 7

1 6

4
1 5

1 4

1 3 1 2

1 0

1 1

(1)Hour Meter (2)Coolant Temp.Gauge (3)Fuel Gauge (4)Parking Brake Lever (5)Forward-Reverse Lever (6)Steering Handwheel (7)Choke Button (Gas.type only) (8)Inching Pedal (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

.2.

FRICTIONAL CLUTCH TYPE

(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

1 7

1 6

1 5

6 1 3 4 1 2

1 4

1 8

1 0

1 1

1 9

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INSTRUMENTS
3
E F C

2
H

1
E F C H

QUARTZ HOUR METER

QUARTZ HOUR METER

00 0 0 0
FUEL WATER TEMP FUEL WATER TEMP

00 0 0 0

OIL

CHG

SEDIMENTER

GLOW

OIL

CHG

GLOW

1~3t Forklift

5~10t Forklift

HOUR METER(1)
This meter measures working time of engine.Use meter to schedule lubrication and maintenance periods.

CHG(B)
This lamp indicates the battery conditio n of charge.The lamp comes on when the ignition switch is set at ON ,bu t it goe s out as the engine start s and accelerator pedal in pressed. CAUTION If the light continues to stay lit or lights up during operation, the charging rate is low and should be checked immediately.

OIL(A)
This lamp indicates the pressure co ndition of engine lube oil. Although it lights up when the engine switch is set at O N ,once the engine starts up and th e accelerator pedal is depressed,this lamp goes out.

CAUTION
If this light continues to stay lift or lights during operation, the pressure is insufficient and shouldbe checked immediately.

SEDIMENTOR INDICATOR(C)
(only for to 3 ton forklift truck)

DIESEL TRUCK
This lamp lights up when water in sedimentor reaches to a certain level ,while the engine is running.In normal state,once the starter is setto ON position ,this lamp lights up.After the engine is started up,it goes out. If this lamp continues to stay lit or lights up during the engine running, CAUTION stop the engine and discharge water If the truck is operated when immediately. lamp continues to stay lit,the fuel injetion pump may be damaged.

.6.

GLOW INDICATOR(D) DIESEL TRUCK

This model truck has integral QUICK-ON-ST ART system as a cold startin aid and has no PREHEAT position at the starter switch. Turn the key 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 temperature engine coolant.Under normal 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.

CAUTION
If this pointer enters the red range,stop the operation instantly and slow down engine speed to cool the coolant and wait until the pointer goes into the 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.

CAUTION
Fill 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 key switch.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.

.8.

SWITCHES
OFF ON START

15

IGNITION SWITCH(15) OFF

This is position at which the key is inserted or drawn out. Gasoline engine and diesel engine stop at this position.

ON
The electric circuit is closed with the starter switch at ON engine is started,the key is at this position. , After the

START
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 is shut 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
.10.

Stage O (OFF) Light Clearance & OFF Parking light Tail light Number plate Light Head light OFF OFF OFF

1st ON ON ON ON

2st ON ON ON ON

CAUTION
The above lights are turned on or off by the light switch regardless of starter switch position.

L
1 7 1 6

HORN BUTTON(17)
Press the rubber cover at ghe center of steering wheel to sound horn.The horn sounds even when the key switch is OFF.
R

TURN SLGNAL LEVER(16)

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

R N l

Right turn Neutral Left turn

CAUTION
The turn signal lever does not automatically return to the Neutral position unlike general pa ss en ge r cars.Reset it by hand.

.12.

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 turn is made.with a little practice, this type teering will be easily mastered.

WARING
This 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

13

13

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 backwards will tilt the mast 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.

CAUTION
The tilt lock mechanism built in the hydraulic circuit does not allow the mast to tilt forwards while the engine is being shut down eve if the tilt lever is pushed forwards

.14.

PARKLNG BRAKE LEVER(4)

Use this parking brake lever to park the lift tru ck. And the parking brakes are applied on the front two wheels by pulling up on this lev er. To release the parking brakes, move the lever forwards.
4

WARNIIG
If parking on a grade is unavoidable,be sure to block the wheels.

SHIFT LEVER(5)(19) FRICTIONAL CLUTCH TYPE

FORWARD-REVERSE LEVER(5) F N R FORWARD NEUTRAL REVERSE SPEED SELECT LEVER(19) 1 N 2
5

LOW NEUTRAL HIGH

1 9

The transmission control is a floor boardmounted.ype and has two speeds at forward and reverse travel respectively. Before gearshifting, be sure to press the clutch pedal to the full. Always brake to a full stop before reversing the direction of travel. Shifting the lever in reverse turns on the back-up lights.

1
N N
R
2

FORWARD-REVERSE LEVER(5) TORQUE CONVERTER TYPE

F N R FORWARD NEUTRAL REVERSE
F
5

N
R

The transmission control is a steering .column-mounted type and has one speed at forward and reverse respectively.Always brake to a full stop before reversing the direction of travel.Shifting the lever in reverse turns on the back-up lights.

CAUTION
The neutral switch is equipped.Do not fail to place the for ward-reverse lever in the neutral position before starting the engine.

.16.

FOOT CONTROLS
See the right photo:Clutch pedal or inching pedal(left),brake pedal(center), and accelerator pedal(right).
1 0 1 8 8
1 1

CLUTCH PEDAL(18) CLUTCH TYPE

The purpose of the clutch is to permitthe operator to couple or uncouple the 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.

CAUTION
Do not run the lift truck with the clutch in a halfclutch condition 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.

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BODY&OTHERS

SEATADJUSTING LEVER

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 GUARD
The 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 to provide 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.

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

.20.

DAMPER

FORK STOPPER
Fork stoppers are lock the forks in position. To adjust forst spacing, pull up fork stoppers, turn, and shift the forks to the desired positions. The fork spacing should be adjusted according to loads to be handled.

WARNING
The forks should be set symmetrically to machine centerline and fork stoppers should always be se t.

SAFETY STEP&SAFETY GRIP

The safety steps are provided on both sides of the truck body.The safety grip is provided on the front left pillar of the overhead guard.Use the safety step and safety grip facing the truck when mount.

FUSH BOX(14)
The fuse box is located at the right side of the cabinet inner surface.

BRAKE FLUID RESERVOIR

The brake fluid reservoir is provided at the left inside of the cabinet. This translucent reservoir allows to inspect the fluid level from the outside.

.22.

HYDRAULICFLUID RESERVOIR CAP

The hydraulic fluid reservoir cap is located at the right side i n the h ood. 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.

CAUTION
The 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. FUEL HANDLING Stop the truck, shut down the engine and apply the parking brake securely. Make sure t hat there i s 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.

WARNING

RADIATOR CAP
The radiator cap is located under the cover plate at the rear of the hood. At daily maintenance, you need not remove the radiator cap.
FULL

COOLANT RESER VOIR

The reservoir is located near the battery.

LOW

WARNING
Do 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.

.24.

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 from being 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 a nd locked by turning it clockwise.

.26.

SAFETY INSTRUCTIONS
Safety is your business and your responsibility. The SAFETY 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

<GENERAL DESCRIPTION>

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 t he ope rator' s manual and name plates on the truck, and become familiar with your 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.

LI EC N SE

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4.DON'T NEGLECT ANY DEFECT

Any time you find that the truck are not functioning properly, operation of the 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.

<BEFORE & AFTER OPERATION>

5.AVOID FIRE HAZARD

Don't use an open flame to check level, or for leakage, of fuel, electrolyte or cooling water. Never smoke while inspecting the battery, handling fuel or working on the fuel system. There is 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 after work. When using your truck in an enclosed space, make sure there is en ough ventilation. If needed, use a ventilation fan.

7.MOUNT PROPERLY
Never mount of dismount the moving truc k, Use the safety step(s)and safety grip facin g the truck when mounting or dismounting the truck.

8.NEVER MOVE CONTROLS UNLESS PROPELY SEATED

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.
.30.

10.PARKING PROPERLY
Park the truck on a level surface and apply the parking brake securely. If parking on a grade is unavoidable, be sure to block the wheels. Put the forks on the ground or floor and tilt a little forwar ds. Sh ut down the engine and remove the key.
<DURING OPERATION>

11.NEVER HORSE PLAY

Never race or play games with the lift truck. Operate the controls smoothly-don't jerk the steering wheel. Avoid sudden stops,starts or truns.

12.OBEY TRAFFIC RULES

Observe speed and traffic control signs.Don't speed. When traveling on public roads or streets,obey all local traffic regulations. The unloaded truck should make way for other laden truck at narrow aisles or on a grade.

13.DON'TOFFER RIDES TO OTHERS

Never allow other person(s) to ride on the forks,pallets or on the truck.

14.DRIVING OVER A DOCKBOARD OR BRIDGE-PLATE

Before driving over a dockboard or bridge-plate,be sure that it is properly secured and strong enough to sustain the weight. Check the ground or floor condition of woriing area in advance.

15.DON'T DAYDREAM
Keep your mind on your work. Learn to anticipate danger before it arises.

.32.

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 SEATED
Keep 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 c areful of l oad 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 when working 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.

Stop!

21.WATCH YOUR ASSETS

Be 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.

.34.

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

It is dangerous to travel with forks higher than is 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 GRADE
When 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.

.36.

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 incl ine. 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 tips may 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 w orking 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).

.38.

When workin g the truck w ith 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.)

36.USE PROPER PALLET

The pallet and skid used should be strong enough to endure the load. Never use damaged or deformed ones.

37.NEVER LIFT A LOAD OVER ANYONE

Never permit anyone to stand or walk under upraised forks or other attachments if machine is so equipped. If unavoidable, use a safety stand or block to prevent a possibility of forks or attachments falling down or moving unexpectedly.

38.EASE INTO THE LOAD

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.

39.ENTER LOAD SOUARLY

When load is to be retrieved froma pile,enter the area squarly. Engage forks into the pallet carefully.

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.
.40.

41.DON'T STACK LOAD TOO HIGH ON FORKS

Don't stack loads on forks in such a way that the top of loads exceeds the load backrest height. If unavoidable, make the load stable secur ely. When handling bulky loads which restrict your vision, operate the truck in reverse or have a guide.

42.A VOID WORK ON A GRADE

Never lift loads with the truck inclined. Avoid loading work on a grade.

43.TOWING THE TRUCK

Don't attempt to tow a truck with engine failure, steer system malfunctioning or brake system damaged. Obey local traffic regulations when towing the truck on public roads.

44.FORK BRACKET & FORK

The fork can not be placed at the notch at the mid of the fork bracket. <OTHERS>

45.PROTECT YOURSELF
Wear all the protective clothing and personal safety gear devices called for by job conditions, suth as a helmet, safety shoes, reflective clothing, etc. Don't wear a necktie or pendant for your safety sake.

46.DECALS
Markings(Decals)on the machine describe warning and methods to operate the lift truck. When operating the machine, observe and follow all markings on the machine in addition to this operator's manual. Replace damaged or missing decals.

.42.

8.HOUR(DAILY or EVERY SHIFT)CHECK

Before starting your lift truck,be sure to inspect the following items for safety sake and efficient productivity.

GENERAL RULES ON INSPECTION:

(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.

(1)CHECK LEAKS OF OIL,FUEL OR WATER

Check joints of the hydraulic piping,engine ,radiator and driving system for oil and water leaks.Check leakage wit h your finger as well as visually.

WARNING
Don't attempt to operate the truck if leaked fuel is found through preoperational check .Correct the leak before starting engine.

.44.

TIRE INFLATION PRESSURE 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.

Underinflation

Good

Overinflation

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 surf ace 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 damag e at t he tre ad surface could cause an accident.

WARNING
All nuts and bolts should be properly installed and torqued before inflating tire and rim assembly. An inflated tire contains potentially explosive energy. DON'T OVER INFLATE.

WARNING
When using an air compressor, first adjust the air pressure of the compressor. Failure to do so will cause a serious accident, since the compressor delivers the maximum pressure.

(3)HUB NUT TORQUE CHECK

Check hub nuts for correct torque. All hub nuts should be tightened to the specified torque securely. Hub nut Divided rim bolt CAUTION Drive shaft bolt Do not dismantle diviede rim bolt Hub nut when detaching hub nut and . Divided rim bolt

and

.46.

(4)OVERHEAD GUARD CHECK

The overhead guard is for your protection. Make certain that it is securely mounted and all structural members are secure.

(5)BRAKE FLUID LEVEL CHECK

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 prevent dirt or water from entering the reservoir.
Air-vent hole

Open the hood...

Open the hood from the left side of the truck.

(6)BATTERY ELECTROLYTE CHECK

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.

DANGER
Never allow flame or sparks near the battery filler holes because explosive hydrogen gas may be present.

(7)COOLANT LEVEL CHECK

Check the radiator coolant reservoir fluid level.It should be between high and low level mark.Add coolant if necessary.
FULL LOW

WARNING
Use extreme care when removing the radiator pressure cap.In pre ssure system,the sudden re lease of pressure can cause a steam flash which would cause a se rious personal injury,Loosen cap slowly to allow steam to eacape. After that,tighten cap securely,It is good practice to use thick wast e 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 .

(8)ENGINE OIL LEVEL CHECK

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.

Oil lever range

.48.

FAN BELT TENSION CHECK WARNING

Fan belt deflection check should be made with engine shut down.

Check the fan belts for correct tension and damage. Pushed the midway between the water pump pulley and the generator pulley by the thumb.

(10) REAR COMBINATION LAMP CHECK

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

(11)HYDRAULIC OIL LEVEL

Check hydra ulic oil lev el 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.
H L

CAUTION
The oil level check should be done with engine shut down, fo rks on the ground or floor, and the truck itself on a level surface.

(12)PIPING & CYLINDERS

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

(13)POWERSHIFT TRANSMISSION FLUID LEVEL TORQUE CONVERTER TYPE

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.

(14)LOAD BACKREST CHECK

Check for loose mounting bolts of the load back-rest.Retighten where needed.

(15)FORKS & FORK STOPPERS

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

.50.

(16)HEAD LIGHTS & FRONT COMBINATION LAMPS

Check for dirty or damaged lens.

Close the hood sit on the seat and...

Take care not to catch your finger in the hood.

(17)DRIVERS SEAT ADJUSTMENT

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.

(18)SHIFT LEVER(S)CHECK
Check the shift lever(s)for looseness and operation.

(19)LOADING LEVERS CHECK

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

(20)PARKING BRAKE OPERATION CHECK

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

Start the engine...

Before starting the engine,make certain the shift lever(s)is in neutral and parking brake is securely applied.

(21)METERS & GAUGES

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.

(22)FUEL LEVEL CHECK

The fuel level gauge is provided o n the indicator panel.Check that fuel level is sufficient for the day's work.

(23)LIGHTS & LAMPS

Actuate each light or lamp switch to be certain that the respective light or lamp comes on properly.

.52.

(24)TURN SIGNAL CHECK

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

(25)HORN BUTTON OPERATION CHECK

Press the horn button to make certain the horn sounds.

(26)CLUTCH PEDAL CHECK FRLCTIONAL CLITCH TYPE

Check that the clutch pedal travels smootyly. On the truck with the optional power clutch device, star t the engin e, then proceed with this clutch pedal check.

(27)BRAKE PEDAL FREE TRAVEL

Press the brake pedal and i nching peda l(on torque converter type only)to make certain that each pedal can be pressed smoothly a nd that is also can restore without interference.

(28)MAST OPERATION
Sound hom, and actuate the lift and tilt levers to be certain that the carriage moves up and down properly and the mast can be tilted smoothly. Make certain that the relief valve operates accompanying its relieving sound when each cylinder piston reaches the stroke end .Pay attention to system operating sound.

(29)LIFT CHAIN TENSION CHECK

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 with the thumb. Make cert ain the ten sion for the right and left chains is even. If uneve n tension is found, loosen the lock nut(A)of anchor pin and adjust the chain, turning the adjusting nut(B)of the chain anchor pin.

CAUTION
A B

Don't use Grease Oil(ex.Hydraulic Oil) chain lubrication.

but Machine only for lift

(30)STEER HANDWHEEL FREE PLAY

Check the steer handwheel for play and vertical looseness.The normal play is 50 to 100 mm and vertical looseness it not permit ted.
100 m 5 0 to m

.54.

(31)EXHAUST GAS CHECK

Check condition of exhaust gas after the engine warm-up is finished. Colorless or bluish Norml:Complete co mbustion Black Abnormal:Incomplete combustion White Abnormal:Oil burns Check also the e ngine and driv ing system for clicking or any abnormal noise or vibration.

DANGER
Echaust 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 or paper inside the engin e room.Make sure you know where the fire extinguishers are kept and how to use them.

Run at a low speed

(at a safe place)

(32)CLUTCH OPERATION CHECK (FRICTIONAL CLUTCH TYPE ONLY)

Press the clutch pedal to be certain that the clutch is properly disengaged and does not drag.

INCHING PEDAL CHECK(TORQUE CONVERTER TYPE ONLY):

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

(33)BRAKE TEST
Run the truck slowly and press the brake pedal to check the braking effect. When the brake pedal is pressed, the stop lamp comes on.

(34)STEERING CHECK
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.

(35)PARKING BRAKE TEST

Make certain that the slowly running truck can be stopped by pulling on the arking brake lever.

(36)BACK-UP LAMP OPERATION

The back-up lamp comes on when the shift lever or directional control lever is placed in reverse position.

WHEN SEDIMENTOR INDICATOR LIGHTS Up... DIESEL

.56.

WATER DISCHARGE FROM SEDIMENTOR

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

WHEN ALR-BLEEDING FUEL SYSTEM DIESEL

C

AIR-BLEEDING PROCEDURE
Stop the engine and loosen the bleed plug(C)on the injection pump. Press the priming pu mp until fu el coming through the bleed pulg contains no bubble. Fasten the bleed plug to confirm that there is no fuel leakage from the plug screw.

.58.

STORING BEFORE STORING

Before stor ing your li ft truck, clean it thoroughly and perform inspection using the following procedures. Wipe away grease, oil .etc. adhering to the body of the truck with waste cloth, 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 or stones 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 full stroke. Drain off coolant completely in winter or cold weather, if antifreeze,or LLC is not used.

WARNING
If at any time your lift truck is found to be in need of repair, defective, or in any way uns afe,the con dition shou ld be reported to the supervisor, and the truck should be taken out of service until it has been resored to safe operating condition.

DAILY STORAGE
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 securely Shut down the engine by placing the key switch in OFF position. Actuate each loading lever several times to remove the residual pressure in the respective cylinders and hoses. Remove the key and keep it sure.

LONG TIME STORAGE

Perform the following service and checks in addition to the DAILY STORING services. Taking the rainy season into consideration,park the machine at a higher and hard ground. Dismount the battery from the machine. Even though the machine is parked indoors, if the place is hot or humid, the battery,should b e kept in a dry, cool place. Charge the battery once a month. Apply antir ust to the exposed part s 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 coo ling water is discharged,and mount the battery.Remove grease from the cylinde r rods and shafts.Start the engine and warm up thoroughly.Move the machine a little forwards and backwards.Ope rate the hydraulic controls several times. Avoid parking on soft grounds such as an as phalt ground in summer.
.60.

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 them and add new oil. Discharge fo reigh matte r and water from the hydraulic oil resservoir and fuel reservoir. Remove the cover from t he 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.

.62.

OPERATIONS
To operate the truck safely and get the most out of it,we describe the correct operating proce-dures on the following pages.

DURING BREAK-IN
We recommend to operate the machine under light load conditions for the first 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.

RELATIONSHIP BETWEEN LOAD AND STABILITY OF TRUCK

The lift truck keeps the balan ce of weight between the truck body and the load on the foks with the center of the front wheels as a f ulcrum 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 accident As 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 ca se,the case,the load weight is reduced accordingly.
SINGLE TYRE CAPACITY CHART DUAL TYRES 2.5t MAST STD LIFT HIGHT
400 425 450 475 500 425 450 475 500 2500 2000

160

140

120

100

80

50

LOAD CENTER cm

kg
6TY20-00-12

LOAD CENTER & RATED LDAD

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 ce nter 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.

CAPACITY

1000

.64.

WARNING
If 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 compared with that of a standard truck(without any attachment)due to the following reasons. 1)The load equal to the weight of attachment is reduced 2)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 is called lost load center Never exceed the allowable load indicated on the load chart attached onto the truck or attachment.

STABILITY OF LIFT TRUCK

The stabillity standard of lift trucks is specified by the ISO or other standards.However,the stability stated in these standards is not applicable in all operating conditions The stability of your lift truck varies according t the operating conditions 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.

<Standard unloaded conditions>

This means that the forks or other load engaging means are raised 30 cm above the ground and the mastis tilted fully backward without loads.
300 mm

<Standard loaded condition>

This means that the forks or other load engaging means are raised 30 cm above the ground and given capacity loads at the basic load center on it and the mast is tilted fully backward.

300 mm

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

WARNING
Use 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.

OPERATION BEFORE STARTING ENGINE

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

.66.

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.

STARTING GASOLINE ENGINE COLD ENGINE

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.

WARM ENGINE
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.

CAUTION
Do 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 .

STARTING DIESEL ENGINE

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.

AFTER ENGINE HAS STARTED

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.

CAUTION Gas model

After cran king the e ngine, push in the choke button step by step observing the warm-up condition and stability o f speed of the engine. Push in the choke button fully after making sure the engine is completely warmed up.

TRAVELING OPERATOR'S POSTURE

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.

BASIC STATE FOR TRAVELING

Set the botton of the fork 15 to 20 cm above the ground and fully tilt back the upright.

.68.

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

[CLUTCH TYPE]
Depress the clutch pedal and engage the shift levers. Release the parking brake Lever.

Gradually release the clutch pedal while depressing the accelerator pedal to start the machine.

CAUTION
Do not rest your foot on the clutch pedal while you are driving.

[TORQUE CONVERTER TYPE]

Depress brake pedal and engage the forward-reverse lever. Release the parking brake Lever.

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

.70.

WARNING
You must slow down at aisle intersections in crowded ares on rough ground or floor surfaces. when approaching loads or obstacles.

GEARSHIFTING
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.

<CLUTCH TYPE MACHINES>

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 the engine 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.

<TORQUE CONVERTER TYPE MACHINES>

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

SLOW-DOWN <CLUTCH TYPE MACHINES>

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.

<TORQUE CONVERTER TYPE MACHINES>

Release accelerator pedal depression a little, and pres s the brake pe dal, if needed.

STEERING
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.

STOPPING OR PARKING THE TRUCK

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.

CAUTION
Never 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.

.72.

To park the truck: Park the truck ina out-of-traffic area and...
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 of the diesel truck, pull out the engine stop button. 4)Remove the key and keep it.

WANING Safe parking

(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.

GROUND CONDITION
Lift truck performance depends 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 sure bo 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.

GROUNDS COVERED WITH SNOW ORICE

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.

WARNING
When equipped with tire chains, the truck get a larger driving power. However, sideway antislip performance is almost reduced so extreme care should be used .

PLCK UP
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.

.74.

5.To raise loads from the ground (1)Once lift the forks 5 to 10 cm off the ground or floor a nd make su re 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 visio n, operate t he truck in reverse except when climbing grades.

STACKING LOAD
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 ma st 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 ar ea and sto p the truck. 6.Make sure your load is just over the desired area Slowl y 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.

WARNING
Never tilt the mast with loads upraised 2m or more. Don't leave or dismount from the truck when the load is raised hith.

UNSTACKING LOAD
1)When approaching the area where the load is to be retrieved ,slow down your truck. 2)Stop the truck in front of the load so that dis tance betw een the loa d 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 f orks 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 following procedure:Move forward and insert 3/4 of the forks. Raise the forks 5 to 10 cm and move backward 10 to 20 cm with the pallet or skid on the forks, then lower the 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.

MEASURES AGAINST COLD & HOT WEATHERS OIL

Use the oil suitable for ambient temperature.
.76.

BATTERY In Cold Weather

Under normal charged conditions, the freezing point of electrolyte is about 35 Always keep the battery in a well-charged condition since there is danger of damaging the battery jar if electrolyte freezes. To prevent the freezing, charge at least 75% of the whole capacity. Also it is effective to keep the specified gravity up to 1.260,but not higher than this value.

In Hot Weather
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 regio n 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.

DANGER
GASES 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 SUI PHURIC ACID which causes severe burns. Do not get in eyes, on skin or clothing. In case of contact, flush immediately and thoroughly with cle an water, Obtain medical attention when eyes are affected.

RADIATOR COOLANT
Your lift truck is generally shipped with the cooling system filled with Loog life 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.

REPLACING FUSE
The fuse protects the electric system against overcurrent. Use the specific ampere rating of fuse. Check to see that the component s in each circuit ar e operating 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 a spare fuse of the same capacity. If a part of the components in the circuit does not function properly, it is suspected that a bulb has burnt out. The burnt bulb should be replaced with new one of the same capacity.
B 1 B 5 4 B 2 B B 3 6 B

.78.

REPLACING OR REPAIRING TIRE

Prepare tools and jack necessary for replacing or repairing tires.

Front Wheel
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 leave s off the gr ound, Remov e 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. The inflation pressure 7kg/cm2

Rear Wheel
Use the same manner as with the front wheel tire repair or replacement except for the position of t he jack which goes und er the counter weight. Tire inflation pressure 7kg/cm2

LIFTING PROCEDURE
2

Safety cage

FRONT SIDE(I)
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.

FRONT SIDE(II)
1. Place chocks behind rear wheels 2. Tilt the mast fully backward and put wooden blocks and steel plates under the outer mast as illustrated. 3. Tilt the mast forward to a vertical postiton, and place wooden blocks under both side frames.

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 f rames. Also place blocks under the counterweight for safety. Gradually lower the rear end to the ground. Be careful not to dislocate blocks while lowering.
2

1 3 2

.80.

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 a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.

.82.

PREVENTIVE MAINTENANCE SERVICE SCHEDULE

This 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 Engine service Required Visually inspect condition of engine rotation Check for working noise from engine Check that exhaust gas has 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 Thickness gauge Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

Torque wrench

All gas engines, for Ist time only

C240 diesel only

Check cylinders Compression fro proper gauge compression Check metering valve and pipe for clogging or damage(G)

PCV Device

Governor or Check no-load TachoInjection maximum rpm. meter Pump

.84.

ENGINE
Checking ltem service Required Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (1200hrs) (2400hrs) (600hrs)

Lubrication Check for engine oil leak. System Check engine oil for level and dirt Replace engine oil Replce engine oil filter cartridge Fuel System
Visually check for fuel leak from pice,pump or tank.

(at initial 25 hrs) (at initial 200 hrs)

Check fuel filter for clogging Clean fuel filter(G) Replace fuel filter cartridge(D) Check that injection nozzle has correct Inject press and pattern(D) Check carbureter link mechanisn for looseness or dirt(G) Check for ignition timing (G) Check for injection timing(D) Drain off water from fuel tank Clean fuel tank Check for fuel level

O(H20)

O(H20) (A15&H20)

.86.

ENGINE
Checking ltem Cooling System service Required Check for coolant level. Check for coolant leak. Check hoses for deterioration. Check radiator cap for contition and installation Clean and change coolant. Check fan belt for tension anddamage Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

POWER TRAIN
Checking ltem Frictional Clutch service Required Check clutch pedal for free travel and clearance between pedal surface and floor when clutch is unlocked Check for noise and operation Check for slipping and engagement Transmission Check change lever for operation and looseness Check for oil leaks Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

Change oil

.88.

POWER TRAIN
Checking ltem service Required Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

Cleck for Torque oil leaks converter Transmis- Check for oil sion level,or change oil Check change lever for operation and looseness. Check control valve and clutch for proper operation. Check inching valve for proper operation Check inching pedal for free travel and pedal travel. Replace line filter element. Front Axle Check for oil leak Change oil Check mounting bolts for Test hammer looseness (at intial 200 hrs)

WHEELS
Checking ltem Tires service Required Check for inflation pressure. Check for chracks or damage. Check for tread wear. Check for undue wear. Check for spikes,stones.or foreigh matter. Depth gauge Tools Tire gauge Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

.90.

WHEELS
Checking ltem service Required Check for looseness. Check for damage. Check rim,side ring and disk wheel for damage. Check for looseness and noise. Clean and repack grease. Cleck axle for deformation, cracks or damage. Tools Test hammer Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

Tire Fastners

Rim.Side ring

Wheel Bearing

Axle

STEERING SYSTEM
Checking ltem service Required Check for per -ipheral play. Check for ver -ticallooseness. Steer Handwheel Check for
sideways looseness. Check for proper operation.

Tools

Daily (8hrs)

Monthly (200hrs)

Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

Steering Gear Box

Check mounting bolts for looseness. Check king pins for looseness or damage. Check for deflection, derormation, cracks or damage. Check for mo- Test uting condition. hammer Check for operation. Check for oil leaks. Check for mounting parts and joints for looseness.

Knuckle Rear Axle

Power Steering

.92.

Checking ltem

service Required

Tools

Daily (8hrs)

Monthly (200hrs)

Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

Brake pedal

Check for free travel Check for pedal travel Scale Check for proper operation Check for air rnixed in brake piping Check that lever is scurely locked and has sufficient lever stroke. Check for proper operation Check for operation
Check connections for looseness.

Parking Brake Lever

Rod,Cable etc

Hoses and pipes

Check for dmage,leakage or collapse

Check for loose connec -tions or clam -ping parts

Check for fluid leaks Brake Master Cylinder Wheel Cylinder

Check for fluid level.Change brake fluid.

Ceck master cylinder and wheel cylinders for proper operation

Check master cylinder and wheel cylinders for fluidleaksordamage

Check master cylinderpiston cup,and check valve for wear or damage. Change

Check drum Test mouting part hammer for looseness Check lining Slide calipers for wear. Brake Drum& Brake Shoe
Check brake shoes for proper operation

Check anchor pin for rust Check return spring for deterioration Check automa -tic clearance adjuster for operation Check drum for wear or damage. Scale

.94.

BRAKE SYSTEM
Checking ltem Back Plate service Required
Check back plate for deformation

Tools

Daily (8hrs)

Monthly (200hrs)

Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

Check for craks.

Penetrant test

Check moun Test -ting parts for hammer looseness.

LOADING SYSTEM
Checking ltem Fork service Required
Check forks for damage,deforma -tion or wear Check for stopper pins for damage or wear

Tools

Daily (8hrs)

Monthly (200hrs)

Trimonthly Semiannually Annually (1200hrs) (2400hrs) (600hrs)

Check fork base and hook weldings for defective cracks or wear. Mast & Lift Bracket
Check cross me -mbers on outer and inner masts for defective weld,cracks or damage.

Check tilt cylin -der bracket and mast for defective weld,cracks or damage. Check outer and inner masts for defective weld, cracksordamage. Check for defective weld, cracks or damage of lift bracket.
Check roller bearings for looseness.

Check mast support bushings for wear or damage. Check mast s- Test upport bolts for looseness. hammer Check lift cylinder tail bolts,piston rod head bolts Test Ubolts,and hammer piston head guide bolts for loosecess. Check rollers, roller pins and welded parts for craks or damage

(for lst time only)

(for lst time only)

.96.

LOADING SYSTEM
Checking ltem service Required Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
Check Chains Chains & for tension, deformation , Sheave damage or rust Iubrication of chains Check connection of chain anchor pin and chain for looseness. Check sheaves for deformation or damage. Check sheave bearings for looseness. genOptional Perform inspecAttachment eral tion Check piston rod,rod screw Cylinders and rod end for Test looseness,de- hammer formation or damage.
Check cylindes for proper operation

Check for oil leaks.

Check pins and cylinder bushings for wear or damage.

Check hydraulic pump for oil leaks or Hydraulic noise Pump Check pump drive gear fo wear.

HYDRAULC SYSTEM
service Tools Required Check for Hydraulic oil level. Reservoir Change oil. Clean suction strainer Drain foreign matter. Replace return filter. levers Return Check for looseness Filter at link. Check levers for looseness Control at link. Check for Lever proper operation. Checking ltem Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (1200hrs) (2400hrs) (600hrs)

.98.

HYDRAULC SYSTEM
Checking ltem service Required Check for oil leaks. Control Vale
Check relief valve and tilt lock valve for proper operation.

Tools

Daily (8hrs)

Monthly (200hrs)

Trimonthly Semiannually Annually (1200hrs) (2400hrs) (600hrs)

Measure rel- Oil prief pressure. es gauge Check for oil leaks,loosenHose,pi- ess,collapse, ping Hose deformation Reel & S- and damage wivel Joint Change hoses. 1or2 years

ELECTRICALS
Checking ltem Ignition Device (for gasoline truck) service Required Check distributor cap for crack. Check spark plug for burn. Adjust spark plug clearance Clean spark plug Check distri -butor cap highvoltage cord for installation. Check distri -butor segm -ent for burn. Check distributor center piece for wear or damage Apply grease on shaft,cam heel and breakr fulcrum. Check highvoltage cord for breakage. Plug gap gause Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)

Tester

.100.

ELECTRICALS
Checking ltem Starter service Required Check pinion gear for correct engagement
Check battery electrolyte level. Clean battery.
Check specific gravity of el- Hydrometer ectrolyte Check wire ha -rness for dam -age andclamps for looseness.

Tools

Daily (8hrs)

Monthly (200hrs)

Trimonthly Semiannually Annually (1200hrs) (2400hrs) (600hrs)

Battery

Wiring

Check connec tions for loose -ness

SAFETY APPARATUS & ACCESSORIES

Checking ltem service Required Check for tight installation. Overhead Guard & Load Backrest Check fordeformation, cracks or damage. Check for prTurn Signal oper operation and tight installation. Horn Check for proper operation and tight installation. Check for proper operation and tight installation. Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (1200hrs) (2400hrs) (600hrs)

Test hammer

Light & Lamps

Check for prBuck-up oper operation and tight inBuzzer stallation. Check for dirt or damage Check for good field of vision. Check meters for proper operation.

Rear View Mirror

Meters

.102.

SAFETY APPARATUS & ACCESSORIES

Checking ltem Driver's Seat service Required Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs) Check for damage or loose bolts. Check frame and cross members for damage or cracks Check for lo- Test ose rivets or hammer bolts. Check items repaired in pr -eceding inspection if any.
Inspection general condition of body

Body

After cleaning, check for grea- Grease Grease-up sed condition pump of chassis. & Oil Check oil coChange
ndition of oil and fluid in reservoir

CAUTION
Local 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 desi gnated period in this manual. Multi-visco sity oils allow a wider temperature range for operation but must be changed m ore frequen tly as the addition that provides the multi-viscosity gradually deteriorates lowering the viscosity.Degradation of viscosity at the higher temperatures can be very detrimental to the hydraulic system.

.104.

: 2611 Address: 2611 Bao'an Highway, Shanghai, China (Tel): 86-21-69156666 (Fax): 86-21-69156000 (P.C.): 201801 (Website): http://www.salcn.com