Use and Maintenance Manual

使用和维护手册 use and maintenance manual
CONTENTS
Standby manipulative formality strictly..............................................................1
Remove method of familiar fault.......................................................................3
Hydrokinetic vehicle..........................................................................................4
Remove method of familiar fault list:.................................................................6
Trouble of Turning system and method............................................................8
Other Remove method of familiar fault...........................................................13
Use and maintain of Fork lift Trucks...............................................................14
(一)Use of Fork lift Trucks...............................................................................25
ENGINE..........................................................................................................27
POWER TRAIN.............................................................................................. 29
ENGINE..........................................................................................................29
WHEELS........................................................................................................ 30
STEERING SYSTEM..................................................................................... 31
BRAKE SYSTEM............................................................................................31
LOADING SYSTEM........................................................................................32
HYDRAULIC SYSTEM...................................................................................33
BRAKE SYSTEM............................................................................................33
LOAKING SYSTEM........................................................................................33
HYDRAULIC SYSTEN................................................................................... 34
ELECTRICALS...............................................................................................34
ELECTRICALS...............................................................................................35
SAFETYAPPARATUS &ACCESSORIES.......................................................36
Standby manipulative formality strictly
Fork lift Trucks driver must be familiar with manipulative

formality, must be stand by strictly, ensure the safety of equipment
and oneself.
1、Driver must be trained eligibility. He can driver when he has
driver's license.
2、When loading, forbid anyone to adjust works and maintain
Fork lift Trucks.
3、When tilting the mast forward,strictly prohibit from stepping
up cargo. When running,tilting must mast backward.
4 、 When working, cargo's rock bottom should away from
ground about 300-350 mm.
5、Prohibit from running with man.
6、Prohibit from stepping up cargo at the same time travelling
crane.
7、When check up fule, engine must be flameout.
8、At the center of rating load ,Prohibit from over loading task.
when cargo locate non-center of rating load,confirm load according
to load curve, the center of rating load should be consistent with
the center of bodywork, disallow polarize.
9、Disallow anyone stand on the truck and make sure no one
under the truck.
10 、 In a state of loading, forbid apply the brake abruptly lest
cargo hurt someone.
11、Forbid swerving in rapid rate.
1
12、When climbing up about 3 meter, notice cargo which from

altitude, adopt protection measure.
13、Forbid that handle vehicle beyond the chair of motorman.
14、Be care to run on ramp, run forward on ramp which have
10 angle at least, run backward on declivity, disallow swerve when
running.
15、If parking in ramp, should use apply the brake with hand. if
parking time is long, should be adopt attrition measure.
16 、 Working time, can't leave work post, leave with key after
flameout.
17 、Running on wet or velvet road surface,swerving must
be speed-down.
18 、Driver's driver a pithy formula:
First gear start, second gear swerve. speedup with careful.
Loading run should memorize safety is foremost. (mechanical
vehicle)
Step on the gas lightly at the very start, should be slow when
swerving.
Accelerated motion with careful, make sure be safe when
loading running. (hydrokinetic vehicle)
2
Remove method of familiar fault
Our company produce 2 to 3 Ton Balance weight Type Forklift

Truck with fuel with japonic technology. Configure diesel oil
engine and homebred engine, type and parameter refer to
《 Use and maintenance manual》、《operator's manual》.
The reason of Engine non-launch:
1、jump-start switch's electric socket be likely to flexible.
2、The fusion of fuse.
3、Electric battery connection become flexible.
4、Capacity of Electric battery is not enough.
5、Forward and backward manipulate not be right post.
6、Diesel oil engine‘s filtrate net is air-logged.
7、Quantity of fuel is not enough.
8、Diesel oil engine be out of warm-up.
Seriatim repair、replace or deal with aim at the reason so you
say.
3
Hydrokinetic vehicle
Cause Debar method

1.jiggle valve oil pipeline jam;(its
Rinse jiggle valve oil pipeline
installation place and sketch refer to
and find out the reason
manual)
2.clutch control patch's snap ring
Reship proper
brake away clutch's groove;
3.clutch's backhaul spring 's plane is

instead
not parallel or length is wrong
4.clutch piston's ring abrasion badly

Instead ring
or damnification
Rinse oil pipeline, examine and

5.oil axle jam or ring damnification
replace ring
6.Tor-con cut in ,pump claw rupture Replace pump,examine

so as to pump be incapable of work whether or not lock
Overhaul disrepaired
7.oil quantity is not enough
position,add fuel
6 degree hydrokinetic oil
8.hydrokinetic oil's type is wrong
instead or SAE10W
9.Gear damnification overly result in

Replace Pump
lack of oil
10.valve link and shift adjust

improperly lead to oil pipeline unfold Adjust post anew
completely when;
11.haft of axle rupture: Replace haft of axle
12.clearance between drum brake

and wheel brake plate friction is too No less than 0.25 clearance
little or nonentity;
13.clutch's plate of friction fray badly Replace plate of friction
14.the position of valve,inching is Footplate, inching's journey 1-

wrong 3mm
15.temperature of oil is higher Parking for cooling
4
Familiar malfunction of hand 、foot brake and its resolvent 2 to

3 Ton Forklift Truck parking brake unit、brake piping system
Tonnage 2 to 3 Ton
Set infront-wheel 、
brake piping system
swell inner、hydrokinetic
Set in front-wheel、
parking brake unit
swell inner、hydrokinetic
Remove method of familiar fault list:
Trouble Cause Method
1.brake footplate position error adjust

2.brake system non-pressurized overhaul
3.intermix air in brake system exhaust
4.clearance of brake hoof be out of

Adjust modem
mix up
Brake not
do one's
best 5.chief pump and partial pump
Examine
bowl distortion、damnification or
reason
abrasion
6.drum hole surface Repair to 6.3△
1.surface of plate of friction have

Clear up
oil
Polish hole
Brake 2.drum hole flat, no-homocentric assure
asymmetric homocentric
5
3.clearance of brake hoof be out of Adjust

mix up modem
4.spring of brake hoof shatter replace
Repair or
5.partial pump glitch
replace
Spring
6.adjustive framework glitch
repair.replace
1.surface of plate of friction

Replace
induration or have impurity
2.plate distortion or error set-up Examine

Noise come
from brake 3.plate of brake hoof abrasion Replace
4.plate friction abrasion Replace
5.hub bearing become flexible Replace

Examine
1.wheel brake is too hot
whether skid
Examine,
Other
2.impurity inner brake Liquid replace
badness of
brake liquid
brake
3.hand brake distortion.tie-in Examine

become flexible replace
6
Trouble of Turning system and method
Problem Cause Method
1.hydraulic pressure pipeline exhaust
Exhaust add
2.position of oil is too low
oil
3.shunt valve's hole wall up, Cleanout ,
core of valve lock replace
4.turning cylinder rod bend Replace rod
5.turning node intervene Pin Axle whether

posterior swing
6.relative surface lock agilely
Problem 7.steel bell of turning implement
Of Turning valve body seize up Backout. repair
8. restoration of turning
Replace spring
implement、rupture of spring
Examine
9.turning cylinder leak Piston ring
and replace
10.diffluent valve pressure less than Adjust
working pressure,flux is too little pressure.flux
Use pres
11.oil is mucilaginous
criptive oil
12.core of valve ,body of valve fray

Replace
excessively
13.pump fray excessively Replace
1.tie-in is lax Chain up
2.turning implement valve body

septa, stator and conjunct surface Cleanout
are dirty
Examine guide
3.oil cylinder leak
sed tie-in
7
8.restoration of turning
Replace spring
implement、rupture of spring
Examine
9.turning cylinder leak piston ring and
replace
10.diffluent valve pressure less Adjust

than working pressure,flux is too pressure.
little flux
Use
11.oil is mucilaginous prescriptive
oil
12.core of valve ,body of valve fray

Replace
excessively
13.pump fray excessively Replace
1.tie-in is lax Chain up
2. Turning implement valve

Oil leak body,septa, stator and conjunct Cleanout
surface are dirty
1.position of oil of gasoline tank is Exhaust ,add

low oil
Unnatural
noise
Cleanout
2.box which drink in oil or strainer
replace
8
Rise system remove method of familiar fault
trouble cause method

1.the clearance between side
roller of tilting outer and slotware Decrease shim
of tilting inner is too big(>1mm)
2.the clearance between side
roller of tilting inner and slotware Add shim
Rise of tilting outer is too big(>1mm)
Descend 3.the clearance between side
Unsteadily, roller of forks and tilting inner is Decrease shim
Noise loud too big(>1mm)
4.boltof side rolleraxle become
Screw down
flexible
Clean out,
5.slide Frame、slotware of tilting
lubricate termly
inner have impurity
Reinforce gas,
1.tyre pressure both sides is
Pressure
inconsistent
consistent
Forks 2.chains both sides loosen and

adjust
take place tight inconsistent
deflection
3.hole of control valve be plugged Cleanout ,
up replace
4.rise cylinder's import be plugged Examine ,
up partially cleanout
1.journey of oil cylinder both sides Adjust make
is inconsistent use of cover
Rise both 2.height of cylinder both sides is Adjust make
sides inconsistent use of bolt
dissimilar
3.journey of cylinder both sides is Add shim on
inconsistent ,exceed natural the surface of
bound rod
1.oil quantity is not enough Add oil

Speed
when
2.hole of control valve be plugged
loading clean
up by impurity
fall short of
request
3.safety valve be plugged up clean
9
4.pipe which lie in filtrate net leak

weld
gas
5.tie-in of pipe become flexible screw down
Examine the
degree of
6. gear wheel and pump body
cleanness,
fray,
require
clearance is too big
9-11level,
repacepump
7.ring of rise cylinder scathe Replace ring

8.valve body and valve of control
valve ,the clearance is too Replace adjust
big ,pressure is too low
9.control valve lapse Adjust
10
Electric system remove method of familiar fault
1.turn-on inflame switch, pointer watch which measure

of watch which measure temperature of water,plug
temperature of water is fixedly or link line open circuit
2.turn-on inflame switch,pointer watch which measure

of watch which measure temperature of water,plug
temperature of water or link line open circuit
a.line which between pointer

3.turn-on inflame switch,
of watch and transducer have
whether how mach oil box
halt
have ,pointer of watch always
b.transducer transducer
is“1”
c.pointer of watch trouble
a.two pillars of pointer of
4.turn-on inflame switch, watch head connect
whether how mach oil box have, by contraries
pointer of watch always is“0” b.line short
c.transducer transducer
5.bugle ringing frequently Button of bugle short
link line open circuit,bugle
6.bugle can't ringing
bad
7.lamp always burn out Pressure of engine very high
8. turn-on one switch or

Line open circuit,lamp spoil
several ,lamp can't light
9.turn-on lamp switch,a fuse has
Lump line short.
blown
10.light is dark Tie-in contact not all right
a.buzzer spoil
b.switchof back a car
11.back buzzer no noise
contact not all right
c.line contact not all right
11
Other Remove method of familiar fault
Problem Cause Method
1.oil of engine ,oil of gear-

Add oil as far as accord
box, oil of differential and
request
so on fall short of request
Screw down bearing ,lock

nut, when drop back eighth
2.hub bearing become
circuit,hub can running.if
flexible disintegrate
disintegrate ,replace
bearing
Have
Exceptional
noise 3.gear-box,gear,plate of
Replace
friction spoil
3.differential and bearing of

Replace
cross-shaped spoil
5.vent-pipe leak Screw down
6.hardware become
Screw down
flexible
1.tie-in of pipe leak ,seal Replace

spoil and snap pipe Screw down
become flexible Obviate
hydrokinetic component
leak, claw of
Replace
Leak oil gearquadrature,
Screw down
destroy seal of pump, bolt
become flexible
3.connective façade leak

moment of bolt is Examine
inconsistent
12
Use and maintain of Fork lift Trucks
Right use of Fork lift Trucks and maintain help to prolong its
life, reduce opportunity of trouble, advance efficiency.
(一)Use of Fork lift Trucks
1. driver must abide 《handle safely regulations》.
2. driver must know knowledge, attentive proceeding of Fork
lift Trucks,maintain of Fork lift Trucks.
3. before use new vehicle, should be clean, examine, and
examine apiece part stand by 《preparative of before drive》.
4. preparative of before drive
4.1 examine radiator whether fill with water. (overseas engine
already configure antifreezing fluid FD-2-35 degree) should
reinforce clean water at any moment after using. for example, leak
or replace water-box,need immit relevant antifreezing fluid.
4.2 examine if the position of engine oil,working oil,gear-box
oil,gear oil is on the middle.
4.3 examine if tie-in of hydrokinetic system is oozy.
4.4 examine brake piping
4.4.1 brake footplate journey;
4.4.2 clearance between soleplate and footplate more than
20mm:
4.4.3 examine if brake piping is agile,symmetrical;
4.5 examine parking brake,should stop loading on the ramp of
15 degree when lever draw complete,force of brake by hand less
than 300 Newton;
13
4.6 examine liquid level and status of the point of oil;
4.7 examine if turn system link level and tie-in fall off, whether
appear unusual noise when woring;
4.8 examine if batteries electrode fall off and engine
electricize;
4.9 examine if tie-in, light is good,equipment and signal is
natural(big lamp.small lamp.back lamp. brake lamp.turn lump.
bugle and so on);
4.10 examine if pressure of tyre accord with request, clean out
the impurity in inter space;
tonnage 2-3t
Pressure of tyre (Mpa) 0.70
4.11 examine if bolt or nut fall off. moment refer to list 3

《moment of pivotal part》;
5. attentive proceeding when start-up.
Must notice:
direction of travelling crane manipulate or lever lie in
bare:can't start over again within 5 second,must wait 2 minute over
again,consecutive working time can't exceed 15 second;
6. attentive proceeding when running.
6.1 should slow-velocity when start,try out if brake and turn
work well;
6.2 step on clutch before alter velocity, and then
counterchange lever (mechanical vehicle );
14
6.3 Fork lift Trucks stop stably before running ,when charge
way;
6.4 when down in ramp of steep gradient, adopt slow speed,

and step on brake plate spiccato at some time.when climb in ramp,
slow running timely;
6.5 swerve,decelerate in advance;
6.6 forbid sliding go with separate clutch, forbid putting foot on
the footplate also when working. when step on clutch, separate
swift and combine stably;
7. attentive proceeding when load and unload.
7.1 weight of cargo should less than rule of load curve, don't
loading imbalance. Loading imbalance.
7.2 when forks insert cargo , tilting should be onwards.
Loading accomplish, tilting should be backwards and cargo abut
against wall of forks.
7.3 load and unload,must use hand brake in order to stop
stably.
7.4 when rise and descend,can't too rapid;
7.5 when line of sight be affected for large volume cargo,forks
reverse in low speed.;
7.6 according to 《safely handle regulations》working;
8.attentive proceeding when stop forks;
8.1 draw level complete ,level lie in free;
8.2 forks touchdown;
8.3 engine flameout;
15
8.4 batteries should placed in warm house in cold

environment:
(二) maintain of Fork lift Trucks

1. Daily maintenance (after 8 hr.) and examine:
1.1 use oil of stated type;
1.2 cleanout edimenter with brush,lubricate surface with lube:
1.3 oil position examination and forks be parked on even
ground when add oil;
1.4 if need work below uplifted forks in faith,ought to avoid
forks downing with support;
1.5 if find out disfigurement,should apprize correlative
department,and use after repair;
8 hr. examination point:
place of repair and adjust before examine;
examine leak of oil, fuel,water;
examine tie-in,engine,water-box and leak of oil ,
water in drive system with eye;
3 ) examine pressure of tyre;
pressure of tyre reduce life of tyre, increase quantity of oil.
The pressure of tyre both sides is differ,abrasion asymmetric result
in turn power asymmetric. lift down cap, measure pressure by
manometer.Make sure no air leak,install cap newly. Examine
whether tyre outward and side face have damnification. whether
rim have distortion.
16
Because tyre be requested can endure higher pressure. So it

is possible that small distortion in bend part of rim arouse
accident.If find out rim occur any distortion,ought to apprize
instantly.Before puff, use stated nut,bolt.And exactly install. less
than stated pressure.when use inflator, should adjust inflator
pressure.
4) examine moment of rim nut;

according to list screw down all nuts.
5 ) examine overhead guard;
examine if the installation is firm,fabric is reliable.
6)examine altitude of brake fluid;
altitude of brake fluid should be between two scales of
jar.when add fluid,should avoid interfusing water and impurity.
7)examine combined lamp backward;examine combined
lamp backward ( if taillight, brake lamp, backup light be polluted ).
8)examine water-box;
take down cover,look into by hole.if keep the altitude of
fluid,install cover newly. If altitude of fluid descend, want to add
water.require add tap water,don't makeup seawater or other
polluted water. Notice the hot steam from water-box.
9)examine position of fluid;
draw out staff guage and clean ,insert newly and draw out,
examine if position of fluid is between high scale and low scale.
Notice: examine position of fluid before flameout, forks fall
completely,forks lie in flat ground.
10)examine pipe and oil cylinder;
examine if hydrokinetic pipe and three cylinder leak.
17
11)examine transmission position of fluid;

Hydrokinetic vehicle: open the soleplate, take down cover,
examine if position of fluid lie in scale. if not enough,add oil.
12) examine load backrest;
examine the bolt of load backrest and forks , if become
flexible.screw down
13) examine forks and forks pin;
examine if installation of forks pin is right,jointing between

forks and slip block craze.
14) examine if lamp forward and combined lamp be polluted;
15) examine electrolyte of battery;
look into if electrolyte lie in between the scale of box body,
notice avoid flame about hole. because there have volatile
hydrogen possible
16) examine engine position of fluid;
rule lie in left but C240 diesel engine. Draw out rule, clean and
inset, follow examine position of oil which should be between the
scale. When examine position of oil, if oil is cold, can't .because
cold oil can't back bottom of hull instantly so can't reflect exactly.
17) examine tensile force of fan strap;
examine if tensile force of fan strap is appropriate. after
engine flameout, press strap which between block of engine and
block of fan with thumb. Strap of ascend bound should be 10-
15mm;
18) adjust driver seat;
make sure that position of driver seat is appropriate. if not,
adjust.Shake seat in order to whether be lock.
18
19) examine rearview mirror;

examine if rearview mirror be polluted,adjust angle for the
sake of look on all position.
20) examine gearlever
examine rise,incline lever.
21) examine parking brake
before hand brake should make sure.
22) examine stopwatch and other instruments;
examine if stopwatch,thermometer is normal
23) examine position of fuel;add enough oil after 8hr.daily in

order to decrease damp.
24) examine if each lamp is normal;
25) examine signal;
26) examine bugle;
27) examine clutch footplate ;
28) examine journey and altitude of footplate;
toward hydrokinetic vehicle,
29) examine tilting manipulate
examine if tilting glide stably.when oil piston level be
end ,listen sound of control valve.before examination,hot up oil.
avoid inclining forward when forks rising.
30) examine tensile force of chains;
examine if chains have been distorted. Distance between
forks and ground about 5cm, press the middle of chains with
thumb. Examine if tensile force of chains both sides is consistent.If
not,loosen nut and adjust.use lubricant grease but lubricant oil.
31) examine clearance of steering wheel
19
clearance of normal steering wheel should be between 50-

100mm(steering wheel revolving direction), should be lock at
upright direction.
32) examine exhaust gas let examine exhaust gas let when
engine have been hot. colorless or baby blue engine is normal:
burning completely.
black:deviant,burning incompletely.
white:deviant,oil burning.
examine if engine and drive system occur deviant sound at
some time. exhaust gas examination had better go along room
outside.if go along room inside, must have nicer condition of

aeration and notice avoid fire,especially leak of fuel , oil.driver
need know how to use fire extinguisher and where it is.
33) examine clutch;
mechanical vehicle :step on footplate, ensure clutch
disengage. hydrokinetic vehicle:examine jiggle footplate:step on
jiggle footplate a bit, then examine whether speed educe.
34) brake piping examination;
examine brake piping when at slow speed and step on foot
plate. notice lamp whether is light.
35) Turning examination;
at slow speed,turn steering wheel, examine if force both sides
is consistent. Turning system adopt power turning.when engine
stop,power turning can't work result in handle heavily.
36) parking brake examination;
at slow speed,pull brake level,make sure forks can't run and keep
standing.
20
37) backup light examination;

when speed alter or back a car,backup light shine maintain after
100hr.(one month)
2.1 air filter:
2.2 oil of engine:take out ,replace new oil;
2.3 omit:
2.4 tube of water-box -----examine whether aging;
2.5 cover of water-box -----examine spring and seal;
2.6 level ----------------------examine manipulation
2.7 drive setting ---------------examine position of oil;
2.8 bridge forward -----------examine oil leak;
2.9 bridge forward setting----examine nuts installation;

2.10 tyre -----------examine if grain have disfigurements;
2.11 bearings of wheels-----examine degree of tightness and
sound;
2.12 hull of bridge ----------examine distortion,crackle
2.13 turn setting -------------examine bolt degree of tightness;
2.14 turn connect ------------examine clearance. bend.or crackle;
2.15 bridge backward -----------examine moment of distortion:
2.16 brake footplate -------------examine if relax thanks to gas
consist in brake pipeline. If have, let gas;
2.17 brake manual cable and connection---whether force of
manual brake is appropriate and connection become flexible;
2.18 brake pipeline-------examine if leak exist;
2.19 brake drum and piece of hoof ------examine installation;
2.20 forks---------examine if bend exist;
2.21 tilting---------examine if bend exist;
21
2.22 bolt in hull of bridge of tilting ass'y -----examine setting; (only

first time)
2.23 tilting---------examine if bend exist;
2.24 tilting--------examine if roller, bearings and weld of bearings
2.25 forks --------examine if bend exist and weld craze;
2.26 chains-----examine crackle, lubricate. if nee, add lubricant oil:
2.27 bolt of chains-----examine clearance;
2.28 wheel and bearing-------examine clearance and abrasion:
2.29 accessory---------examine if installation is right;
2.30 hydrokinetic cylinder-----examine piston level setting; 2.31

control valve---------examine working circumstances. after engine
flame out, tilting can't pitch even if push levelfiercely;
2.32 wiring harness----examine if clip fall off;
2.33 add lubricant grease -------lithium lubricant grease
a. bridge backward turn system 7 departments.
b. brake piping brake footplate bearing 1 department.
c. Place of installation in tilting 2 departments.
Where in: a,c 5 departments. in all ( look sketch map )
2.34 block between tilting inside and tilting outside and board
between tilting inside and girder need add lubricant grease;
2.35 tilting and turn system point of lubricant grease;
Illustration
22
1)air filter;
examine if component be polluted,seal mat be destroyed.
Component cleanout:compress air and blow dust ,examine
drape if attaint.clean once one month ,every 600 hr.should
bereplaced a new filter.
.toward C240 diesel engine:
every 300 hr.should be cleaned core and hull. Loosen bolt,
take cover and plate, take core after put off hook,wash dirt in core
with gas or tap water. if dirt adhibit core, core dip attenuated
cleanser about 30 minutes.then clear with water, dry in air notice
don't use constringent air.under normal working condition, replace
core every 600 hr. in actual working,
according to circs,decide the period of maintenance.
toward other model engines:
loosen the hook of hull,then take bolt,cover of filter be capable
of unload.
replace oil of engine;
.replace oil of engine every on month, toward new one, should
replace at foremost 25 hr.
.before replacing engine start, and raise the temperature of oil,
pull down
parking brake, turn off engine,
Take down key. open cover of machine.
.steps:
23
(1) take down oil filter cover;

(2) rub-up by cloth:
(3) put a basin under oil plug;
(4) rub-up oil plug and basin;
(5) loosen plug by spanner
(6) once plug loosen,revolve by hand;
(7) oil get out from hole,put in basin;
(8) clean out plug:
(9) oil get out from hole completely, set up plug newly: notice
avid attaint seal;
(10)clean out plug and remainder ambient;
(11)clean out plug with a block of cloth;
(12)add oil up to stated altitude, notice save empty place,and

then add gradually
(13)Clean out brim of hole, put down cover
(14)Engine start, run with slow speed, made oil enter in
engine;
(15)Turn off engine, make sure the position between“high (H)”
and “low(IJ)”. If not enough, add oil again.3)add lubricant grease:
(1)offer butter gun with accessories;
(2)take down cover of gun;
(3)immit lubricant grease in body;
(4)revolve cover of gun;
(5)make up lubricant grease at stated places;
2.point of examination (after 300hr ):
after 8 hr. accomplishment and 100 hr. examination, add
working as follows.
24
3.1 hole of carve bearing box ……… cleanout ( C240 diesel

engine);
3.2 filter of engine oil …… replacecore ( C240 diesel engine);
3.3 fuel filter …………… letcompletely;
3.4 fuel box ………………letcompletely;
3.5 pump …………letcompletely, replace septumoil ( C240
diesel engine) or engine oil;
3.6 engine start ……………examinethestatusofmeshwhich
small gear and annular gear.
3.7 battery ……………examine the specific gravity of
electrolyte.
3.8 besides point of examination: 8 hr. 100hr.300 hr. Add
working as follow:
4.1 filter ………………… replacecore;

4.2 clearance of valve …………………examine;
4.3 muzzle ……………………………examine the pressure;
4.4 water box……………… let completely , add water newly or
other antifreezes;
4.5 fuel filter ………………replace core;
4.6 driver fluid …………… replace ( only after first 600hr.)
4.7 distinctness implement ………………… examine position
of oil, replace gear oil ( only after first 600hr.)
4.8 hydrokinetic oil box ……… clean out net of filter, replace
new oil;
4.9 bolt of tilting…………………examine if become flexible:
4.10 control valve……………… examine the pressure of
valve;
25
4.11 seat of driver………………examine if become flexible;

point of examination: 300hr . 600hr :
Commonly, replace the oil of engine at some time, should
replace and clean out filter of engine.commonly, replace filter of
engine. After replacing, start-up engine and working for a while
with slow speed , examine if setting of oil filter leak and examine
altitude of oil. the maintenance. servicing. replacing in form be
assumed the environment of forks is normal, consumer can alter
appreciably.
Black “ ●” represent replacing;
“〇” represent maintenance and servicing.
ENGINE
Checking Daily Monthly Trimonthly Semiannually Annually
Service Required Tools
Item (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Visually inspec
condition of engine
rotation. 〇〇〇〇〇
Check for working

noise from engine 〇〇〇〇〇
Check that exhaust gas
has prope-color 〇〇〇〇〇
Check air cleaner
element for dirt and
clean. 〇〇 ● ●
Check crankcase air
Engine breather for dirt and
clean(C240 Diesel) 〇〇〇
Thick
Check that valve clear-
ness
ance is corect 〇〇
gauge
26
〇
〇
All gas
Retighten cylindet head C240
Torque engines,
bolt diese
wrench for lst
only
time only
Campe
Checd cylinders for
ssion
proper compression
gauge
〇
ENGINE
Service Required Tools (8 hrs)
Item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check for engine oil

leak
〇〇〇〇〇
Check engine oil for level

and dirt.
〇〇〇〇〇
Lubri- Replace engine oi filter ●

cation
System
cartridge
At initial ● ● ●
25 hrs
Replace engine oil filter ●
cartridg
At initial ● ● ●
200 hrs
Visually check for fuel
leak from pipe pump or 〇〇〇〇〇
27
tank
Check fuel filter for

clogging
〇〇〇
Clean fuel filter(G) 〇

(H20)
〇
(H20)
●
(A15&H20)
Replace fuel filter
cartridge(D) ● ● ●
Check that injection
nozrle has coret inject Nozle
press and pattem(D) testre
〇〇
Check carburete link

Fuel mechanism for looseness
or dirt(G) 〇〇〇
System
Check for ignition Timing

timing(G) light
〇〇
Check for igjection

timing(D
〇
Drain off water from

fuel tank.
〇〇〇
Clean fuel tank

〇〇
Check forfuel level
〇〇〇〇〇
ENGINE
Item (8hrs) (200hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check for coolant level

〇〇〇〇〇
28
Check for coolant leak

〇〇〇〇〇
Check hoses for

deterioration. 〇〇〇〇
Cooling Check radiator cap for
System oon- dition and
installation 〇〇〇〇
Clean and change

coolant. ● ●
Check fan belt for
tenston and damage 〇〇〇〇〇
POWER TRAIN

Item Service Required Tools (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check dutch pedal for

free travel ane
ceerance between Scale
pedai surface and floor 〇〇〇〇〇
when clutch is unlocked
Fric- Tional
Clutch Check for noise and
operation. 〇〇〇〇〇
Check for slipping and

engagement 〇〇〇〇〇
Check change lever far
operation and
looscness 〇〇〇〇
Trans-
Check for oil leakd
mission 〇〇〇〇〇
Change oil ● ●
ENGINE
29

ltem Service Required Tools (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
〇〇〇〇〇
Check for oil leaks
Check for oil level or

change oil
〇〇 ● ●
Check change lever for
operation and 〇〇〇〇
looseness
Torque Check control valve and

〇〇〇〇〇
converter clutch for proper
transmission openation
Check inching valve for 〇〇〇〇〇

proper operation
Check inching pedal for

free travel and pedal 〇〇〇〇〇
travel.
Replace line filter

clement ●
〇〇〇〇〇
Check for oil leak
Front Axle
Change oil ● ●
Check mounting bolts Test 〇〇〇〇
for looseness hammer
WHEELS
30

Item (8 hrs) (200 hrs) (600hrs) (1200hrs) (2400 hrs)
Test
Tire Check for looseness hammer 〇〇〇〇〇
Fastners
Check for damage 〇〇〇〇〇
Rim,side Check rim,side ring
Ring and disk wheel for 〇〇〇〇〇
damage
Check for looseness
Wheel and noise 〇〇〇〇〇
Bearing
Check and repack
grease ● ●
Check axle for
Axle 〇〇〇〇
deformation,cracks or
damage
STEERING SYSTEM
Item (8hrs) (200hrs) (600hrs) (1200hrs) (2400 hrs)
Check for peripheral
Steer play 〇〇〇〇〇
Handwheel Check for vertical
looseness 〇〇〇〇〇
Check for sideways
looseness 〇〇〇〇〇
Check for proper
operation. 〇〇〇〇〇
Steering Check mounting bolts
Gear Box for looseness. 〇〇〇〇
Check king pins for
Knuckle looseness or damage 〇〇〇〇
Rear
Axle Check for deflection
deformation,cracks or 〇〇〇〇
damage.
Check for mounting Test
condition hammer 〇〇〇〇
Power Check for operation

〇〇〇〇〇
Steering
Check for oil leaks
〇〇〇〇〇
Check for mounting
parts and joints for 〇〇〇〇
looseness
31
BRAKE SYSTEM
Check for free travel O O O O O
Check for Pedal travel Scale O O O O O
Brake Check for proper
operation O O O O O
Pedal
Check for air mixed in
brake piping O O O O O
Check that lever is Se
Parking Curely locked and has O O O O O
Brake Lever suf- FicientLever stroke
Check for proper
operation O O O O O
Check for operation O O O O
Rod,
Check connectionw for
Cable, etc.
looseness O O O O
Check for damage,leak-
Hoses and age or collapse. O O O O
Pipes Check for damage,lek-
Tionw or clamping parts O O O O
Check for fluid leaks O O O O
Check for fluid level
Change brake fluid O O O ● ●
Check master cylinder
Brake Andwheel cylinder For
Mawter proper operation
O
Cylinder,
Wheel
and wheel cylinders for
Cylinder
luid leaks or damage O
piston cup and check
valve for wear or ●
damage change
Check drum mounting Test
part for looseness hammer O O O O
Slide
Check lining for wear calipers O
Check brake shoes for
proper operation. O
Check lining for wear O
Brake Check return spring for
Drum& deterioration Scale O
Brake Shoe Check autonatic
clearance adjuster for O
operation
Check drum for wea or O
damage
32
LOADING SYSTEM

Item (8hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check chains for
tension,deformation O O O O O
damage or rust.
Lubriction of chains O O O O
Check connection of
Chains chain anchor pin and O O O O
& chain for looseness
Sheave Check sheaves for
deformation or damage O O O O
Check sheaves bear-
ings for looseness O O O O
Optional Perform general
Attachment inspection. O O O O
Check piston rod,rod
serew and rod end for Test
looseness,deformation hammer O O O O O
or damage
Check cylinders for
O O O O O
Cylinders proper operation
Check for oil leaks O O O O O
Check pins and cylinder
bushings for wear or
damage O O O O
Check hydraulic pump
Hydraulic for oil leaks or noise
O O O O O
pump Check pump drive gear
for wear. O O O O
HYDRAULIC SYSTEM

33
Check for oil level

Hydraulic .Change oil
O O O ● ●
Reservoir Clean suction strainer
Drain foreign matter O
Return
Filter
Replace return filter. ● ●
Check levers for
Control looseness at link O O O O O
Lever Check for proper
operation O O O O O
BRAKE SYSTEM
Item (8 hrs) (200hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check back plate for
deformation. O
Penetra
Back Plate Check for cracks. nt test O
Check mounting parts Test
for looseness. hammer O
LOAKING SYSTEM
Item (8hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check forks for damage
Deformation or wear O O O O O
Check for stopper pins
for damage or wear O O O
Fork Check fork base and
hook weldings for O O O O
defective cracks or wear
Check cross members
on outer and inner masts
for defective tiye O O O O
weld.cracks or damage
Check tilt cylinder
bracket and mast for
defective O O O O
weld,cracks,damgae
Check outer and inner
Mast& masts for defective wild O O O O
Lift cracks or damage
Bracket Check for defective
weld,cracks or damage O O O O
Of lift bracket.
Check roller bearings for O O O O
looseness.
34
Check mast supper

bushingw for wiar or O
damage
Check mast support cap Test O
bolts for looseness. hammer (For lst O O
time only)
Check lift cylinder tail O
bolts,piston rod head (For lst
bolts,U-bolts,and piston Test time only)
head guide bolts for hammer O O
looseness
Check rollers, roller
pins and welded parts for O
cracks or damage O O O
HYDRAULIC SYSTEN
Check for oil leacs. O O O O ○
Check relief valve and
Control
Valve
tilt lock valve for proper O O O O
operation
Oil pes
Measure relief pressure gauge O O
Check for oil leaks
Hose,Pip looseness,collapse
ing Hose edformation and O O O O O
Recl & damage
Swivel
Joint Change hoses. ●
(lor2 vears)
ELECTRICALS

Item (8 hrs) (200hrs) (600hrs) (1200 hrs) (2400hrs)
Check distributor eap

for crack O O O
Check spark plug for

burn. O
Plug
Adjust spark plug gap
clearance. O O O
gauge
Ignition
Device Clean spark plug. O O O

(for gasoline
truck) Check distributor eap
high-voltage cord for
installation. O
35
Check distributor
segment for burn O
Check distributor
O
center piece for wear of
damage.
Apply grease on
shaft,cam heel and O O O

breaker fulcrum.
Check high-voltage
cord for breakage Tester O
ELECTRICALS

Ttem Service Required Tools (8 hrs) )(200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
Check pinion gear for

Starter correct engagement O O O O
Check battery electrolyte Hydro-

level.Clean battery meter O O O
Battery
Check specific gravity

ofelectrolyte O O O O
Check wire harness for

demage and clairps for O O O
Wiring
looseness
Check connections for

looseness O O O
36
SAFETYAPPARATUS &ACCESSORIES
Item Service Required Tools (8 hrs) (200 hrs) (600hrs) (2400 hrs)
(1200hrs)
Check for tight Test

Overhead installatior hammer O O O O O
Guard&
Load
Check for deformation
Backrest cracks of damage
O O O O O
Check for proper

Turn operation and tight
Signal O O O O O
installation
Check for proper

Hom operation and tight
installation
O O O O O
Lights Check for proper

&Lamps operation and tight O O O O O
installatior
Check for proper

Buck-up
operation and tight O O O O O
Buzzer
installation
Check for dirt or damage O O O O O

Rear View
Check for good field of
Mirror vision O O O O O
Check meters for

Meters proper operation. O O O O O
37

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使用和维护手册 use and maintenance manual

Standby manipulative formality strictly

Fork lift Trucks driver must be familiar with manipulative

12、When climbing up about 3 meter, notice cargo which from

Remove method of familiar fault

Our company produce 2 to 3 Ton Balance weight Type Forklift

Cause Debar method

3.clutch's backhaul spring 's plane is

4.clutch piston's ring abrasion badly

Rinse oil pipeline, examine and

6.Tor-con cut in ,pump claw rupture Replace pump,examine

9.Gear damnification overly result in

10.valve link and shift adjust

11.haft of axle rupture: Replace haft of axle

12.clearance between drum brake

13.clutch's plate of friction fray badly Replace plate of friction

14.the position of valve,inching is Footplate, inching's journey 1-

15.temperature of oil is higher Parking for cooling

Familiar malfunction of hand 、foot brake and its resolvent 2 to

Remove method of familiar fault list:

Trouble Cause Method

1.brake footplate position error adjust

3.intermix air in brake system exhaust

4.clearance of brake hoof be out of

6.drum hole surface Repair to 6.3△

1.surface of plate of friction have

3.clearance of brake hoof be out of Adjust

1.surface of plate of friction

2.plate distortion or error set-up Examine

4.plate friction abrasion Replace

5.hub bearing become flexible Replace

3.hand brake distortion.tie-in Examine

Trouble of Turning system and method

Problem Cause Method

1.hydraulic pressure pipeline exhaust

5.turning node intervene Pin Axle whether

12.core of valve ,body of valve fray

13.pump fray excessively Replace

1.tie-in is lax Chain up

2.turning implement valve body

10.diffluent valve pressure less Adjust

12.core of valve ,body of valve fray

13.pump fray excessively Replace

1.tie-in is lax Chain up

2. Turning implement valve

1.position of oil of gasoline tank is Exhaust ,add

Rise system remove method of familiar fault

trouble cause method

Forks 2.chains both sides loosen and

1.oil quantity is not enough Add oil

4.pipe which lie in filtrate net leak

7.ring of rise cylinder scathe Replace ring

Electric system remove method of familiar fault

1.turn-on inflame switch, pointer watch which measure

2.turn-on inflame switch,pointer watch which measure

a.line which between pointer

8. turn-on one switch or

10.light is dark Tie-in contact not all right

Other Remove method of familiar fault

Check inching valve for 〇〇〇〇〇