Operation Manual for

Internal Combustion
Counterbalance Forklift
Operation Manual for Internal Combustion Counterbalance Forklift

Table of Contents

Brief introduction .................................................................................................................................................... 2

I. Safety............................................................................................................................................................... 3
1. Main application of forklift...................................................................................................................... 3
2. Operating site and working environment of the forklift .......................................................................... 3
3. Safety problems before operation ............................................................................................................ 5
4. Safety problems in operation ................................................................................................................... 8
5. Safety problems during the course of maintenance ............................................................................... 17
6. Safety problems when using the battery ................................................................................................ 19
7. Nameplate .............................................................................................................................................. 22
Ⅱ. Operating device and methods ................................................................................................................... 30
1. Liquid crystal instrument ....................................................................................................................... 34
2. Switches ................................................................................................................................................. 37
3. Control ................................................................................................................................................... 38
4. Body....................................................................................................................................................... 43
Ⅲ. Driving and operation ................................................................................................................................. 50
1. Operating new forklift ........................................................................................................................... 50
2. Relations between load and fork stability .............................................................................................. 50
3. Load center and load curve .................................................................................................................... 50
4. Forklift stability ..................................................................................................................................... 51
5. Forklift transportation, loading and unloading ...................................................................................... 51
6. Before and after starting the engine ....................................................................................................... 52
7. Operation ............................................................................................................................................... 53
8. Loading .................................................................................................................................................. 56
9. Stacking ................................................................................................................................................. 57
10. Unstacking ............................................................................................................................................. 58
11. Storage ................................................................................................................................................... 59
IV. Regular inspection and maintenance ......................................................................................................... 61
1. Inspection requirements ......................................................................................................................... 61
2. Inspection contents ................................................................................................................................ 61
3. Maintenance........................................................................................................................................... 69
4. Regular maintenance schedule............................................................................................................... 71
Ⅴ. Other ............................................................................................................................................................. 87
1. Lubrication system chart ............................................................................................................................ 87
2. Forklift oil ..................................................................................................................................................... 88

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 Operation Manual for Internal Combustion Counterbalance Forklift

Brief introduction

This manual shall be kept by the operator and read repeatedly.

• This manual including: correct operation, simple maintenance and daily check.

• Before operation, please read this manual carefully so as to ensure safe and effective handling by appropriate
driving and maintenance.

• Due to product improvement, this manual may be different from actual conditions.

• When renting or transferring the forklift, please rent or transfer wooden handle with the forklift.

• If you have any question, please contact our sales department.

or mark is very important for your and others’ safety , please follow the description.

It means incoming dangerous conditions. If it is not avoided, it will lead to death or serious
Danger hurt. You have to follow this instruction.

It means potential dangerous conditions. If it is not avoided, it will lead to death or serious
Warning hurt. You have to follow this instruction.

It means potential dangerous conditions. If it is not avoided, it may lead to slight or

Caution moderate hurt. You have to follow this description.

Note It refers to sentences directly or indirectly related to person safety and forklift maintenance.

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Operation Manual for Internal Combustion Counterbalance Forklift

I. Safety
Safety is your career and responsibility. This chapter mainly describes basic safety regulations and
warnings during normal operation of the forklift. But, it is also applicable to vehicles of special
specification, with mast and attachment.

1. Main application of forklift

(1) Main application of forklift

Main application of forklift is to transport goods on the pallet and stack them to a certain height. In addition,
after the forklift is provide with appropriate attachments, it can transport and stack goods not placed on the
pallet.

(2) The forklift shall not be used for other purposes

Other purposes mean carrying passengers, lifting up persons or towing other vehicles, etc. Operation
methods that are forbidden in this manual shall not be used.

Examples except specified purposes:

• Any person on the fork and the pallet is lifted up.

• Any person on the pallet holds down the goods.

• Place steel wire on goods directly to lift up the goods.

• Tow other vehicles.

• Push goods or other vehicles with the fork.

• Open or close doors of other trucks with the fork.

2. Operating site and working environment of the forklift

(1) Ground conditions

Operating site of the forklift shall be flat and firm road or ground, and well-ventilated.

The performance of forklift depends on ground conditions and running speed shall be appropriate. Be
careful when driving on the slope or rough road.

Warning

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 Operation Manual for Internal Combustion Counterbalance Forklift

• The forklift running on a muddy road shall stop in time. .

• The forklift bypasses stones and stumps. If it is inevitable, the forklift shall slow down. Note: do
not damage vehicle chassis.

When the forklift runs on an ice-snow road, tire chain shall be used. Abrupt acceleration, parking and
turning shall be avoided. Driving speed shall be controlled by accelerator pedal force.

Warning

• After tire chain is installed, driving force of the forklift can be increased. But sideslip
performance is reduced. Be careful.

(2) Climate conditions

Warning

• In heavy wind, the mast shall not be lifted up to avoid goods from falling off, which leads to
unintentional injury of the driver.

(3) Measures taken in cold and hot weather

a) Oil

Oil that adapts to ambient temperature is used.

b) Battery

• In cold season

In normal charging conditions, solidifying point of electrolyte is about -35°C.

The battery is charged in good conditions. If the electrolyte is solidified, the battery case will be
damaged. In order to prevent the battery from being solidified, 75% of total capacity shall be charged.

The most effective method is to keep specific gravity 1.260. But it shall not exceed this value.

• In hot seasons

Because electrolytic water is easily evaporated in hot seasons, please fill distilled water at any time and
check it once a week to fill distilled water.

When ambient temperature is very high, specific gravity of the battery shall be reduced to 1.220±0.01.

Because the battery efficiency is high at high temperature, other maintenances are required.

Danger

• Gas from the battery will explode. Do not smoke or use open fire. Do not generate electric arc
and spark near the battery. When the battery is stored or charged, it shall be well-ventilated.
Sulfuric acid in the battery may cause burn. Do not let sulfuric acid spray on eyes, skin and
clothes. If you are exposed in sulfuric acid, please wash if off by water. If sulfuric acid splashes
into eyes, please go to see a doctor immediately.

c) Coolant in water tank

Cooling system of the forklift contains 50% long-acting antifreeze solution. Freezing point of the
antifreeze solution is -35°C.
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Operation Manual for Internal Combustion Counterbalance Forklift

In hot season, in order to obtain good cooling result, please pay special attention to water tank and
cooling system. The forklift shall be parked in a shade place.

3. Safety problems before operation

(1) Obtain operation qualification

Caution

• Only the operator who has been trained and approved can operate the forklift.

• Brake, accelerator and hydraulic control handle performances of each forklift with the same
technical parameters may be different. Please read this manual and nameplates on the forklift
carefully and know each operation item well and then drive the forklift.

(2) Dress required when driving the forklift, you shall

Caution

• Wear working clothes, safety shoes and helmet.

• For the sake of safety, do not wear loose clothes to avoid them from being hung, which may lead
to unexpected danger.

Safety helmet

Goggles

Work clothes

Safety shoes

(3) It is strictly forbidden to drive the forklift after drinking wine.

Caution

• When you feel tired, absent-minded, use anesthetic or drink wine, do not drive the forklift.

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 Operation Manual for Internal Combustion Counterbalance Forklift

(4) Workplace safety

Caution

• Keep the road in good conditions and unobstructed.

• For safety needs, sufficient light source shall be provided in workplace.

• When it operates on a platform or wharf access board, there is tip-over danger of the forklift.
Please use a block or other protection measures to prevent tip-over.

(5) Keep the cab clean

Caution

• The cab shall be always kept clean.

• When the hands are wet or oily, please do not operate the forklift.

• Do not put any tool or other metal object in the cab because these objects will obstruct control
handle or pedal.

(6) Forklift completeness

Caution

• When the forklift is delivered, it shall be provided with overhead guard and load backrest.

Note

• Overhead guard is used to prevent goods from falling off. Note: overhead guard is used to
prevent small objects and boxes from falling off, but it cannot prevent falling impact from rated
load. Protection measures shall be taken for falling objects.

Warning

• Without written approval of our company, it is forbidden to modify the forklift or add any
working device on it. Otherwise, it may affect rated load or safety operation.

• Do not install any part that may obstruct the driver’s sight.

(7) Regular overhauling

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Operation Manual for Internal Combustion Counterbalance Forklift

Caution

• Make daily repair and regular overhauling.

Warning

• When the forklift is damaged or has a fault, stop the forklift and inform maintenance staff of the
forklift conditions immediately. Before the forklift is overhauled, do not operate the forklift.

(8) Fire prevention

Caution

• In order to prevent fire, accident or other unpredicted state, fire extinguisher shall be provided
and operating requirements shall be followed.

(9) Overload forbidden

Caution

• Do not overload the forklift and follow permissible load and load curve of the forklift, and keep
center of gravity on the goods at load center.

Note

• Permissible load refers to the maximum load at load center of the forklift.

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 Operation Manual for Internal Combustion Counterbalance Forklift

(10) Use appropriate pallet

Caution

• Use the pallet of appropriate dimension and strength to bear the goods.

• Make sure the goods are fixed on the pallet and have appropriate shape.

• It is forbidden to convey goods without pallet.

4. Safety problems in operation

(1) Starting notes

Caution

• Pull up hand brake.

• Gear shift lever is at neutral gear.

• Step on clutch pedal or brake pedal.

• Adjust the seat so that the forklift can be

operated by hand and foot.

• Make sure there is nobody above, below, in

front and rear of the forklift.

(2) Safety conditions around the forklift

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Operation Manual for Internal Combustion Counterbalance Forklift

Caution

• When carrying huge goods and the sight is

poor, please drive at reverse gear or with the
guidance of another person.

• When driving at reverse gear, the driver faces

backwards to confirm there is no danger in
rear, and drives the forklift. Rearview mirror
and reversing buzzer are auxiliary devices.

• When driving the forklift on a narrow road,

someone shall provide guidance.

• At the crossroad or at other position where the

sight is obstructed, the driver shall confirm
nobody on the left and right of the forklift
before driving.

• Make sure there is safety distance between the

forklift and road side or platform edge to
prevent the forklift from falling off.

• The forklift is different from automobile. It is

driven by rear wheels. When it is near turning
point, reduce the speed, turn steering wheel to
rotate the rear of forklift.

(3) Uncivilized driving forbidden

Caution

• Do not turn on the key switch with accelerator

pedal stepped on.

• Do not start, brake or turn suddenly. Sudden start

or brake will make goods fall off. Sudden turn will
make the forklift tip over and lead to serious
accident.

• In full load or idle load state, hydraulic control

handle shall be operated slowly. When forklift is in

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 Operation Manual for Internal Combustion Counterbalance Forklift

high position, control handle is operated suddenly

so that goods fall off or the forklift tips over.

Note

• Do not run over the baffle or obstacle on the road.

• When passing other forklifts, reduce the speed and

use the horn.

• Do not drive on soft ground.

• When driving on wet, slipping, uneven or lean

road, please reduce the speed.

• Keep there is a certain clearance between the mast

and the roof or other outlets/inlets.

(4) It is forbidden to drive with the fork lifted up.

Caution

• When the fork is lifted up, do not drive the forklift. Otherwise, unstable conditions may occur or
the forklift tips over.

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Operation Manual for Internal Combustion Counterbalance Forklift

(5) It is forbidden to work with fork tip.

Caution

• Push or lift goods with fork tip. When lifting goods with fork tip, the forklift or goods may shake.

(6) It is forbidden to push or pull with the forklift

Caution

• Do not use the forklift to push or pull goods. Otherwise, goods may be damaged or fall off.

(7) Driving on the slope

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 Operation Manual for Internal Combustion Counterbalance Forklift

Caution

• When driving the forklift on the slope, the

following rules shall be observed:

With load: drive forward on the uphill, and

reverse on the downhill.

Without load: reverse on the uphill and drive

forward on the downhill.

• When the forklift drives on the downhill,

drive carefully with a little braking to ensure
the fork does not touch the ground.

• Do not turn or load/unload on the slope.

Otherwise, the forklift may tip over.

(8) It is forbidden to stack with unbalancing load

Caution

• When the forklift is stacking, make sure goods are safe and fixed. The fork shall insert into the
pallet correctly and center of gravity on the goods shall coincide with the forklift center.

• When carrying unbalanced goods, the goods may fall off and the forklift tips over easily.

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Operation Manual for Internal Combustion Counterbalance Forklift

(9) Any one is forbidden on or below the forklift

Warning

• It is forbidden to carry persons on the fork or

pallet.

• Others except the driver are forbidden to ride the

forklift.

• Persons shall not be used to replace balance

weight.

• It is forbidden to stand on goods and pass through

below the fork.

(10) It is forbidden to go into the mast.

Warning

• Any part of the body is forbidden to go into the mast or area between the mast and the body.

Caution

• Please put your body under overhead guard. Do not stretch any part of the body out of the
forklift.

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 Operation Manual for Internal Combustion Counterbalance Forklift

(11) When the mast leans forward, the fork is forbidden to rise.

Caution

• When the mast leans forward, it is forbidden to lift goods and start the forklift. Before lifting the
goods or starting the forklift, the mast shall be in place to stabilize goods. When driving (with
load or without load), the distance between the fork and the ground shall keep 150-200mm.

• When the fork is carrying goods, the mast shall not lean forward.

• When lifting goods, first stop the forklift.

• When the forklift is leaning, do not load/unload goods.

(12) Operation in the compartment

Caution

• The forklift can load/unload goods on a platform

with a trailer fixed.

• Before operation, fix access bridge plate and check

its strength.

• When getting in/out of the compartment, the forklift

shall reduce the speed. Pay attention to the safety of
access bridge plate.

(13) Get on/off the forklift

Caution

• It is forbidden to jump on/off the forklift.

• When getting on/off the forklift, grab the handle

and step on the pedal.

• When getting on/off the forklift, do not grab

steering wheel or control lever.

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Operation Manual for Internal Combustion Counterbalance Forklift

(14) Over-height of goods is forbidden

Caution

• The goods shall be against load backrest. The height

of goods shall not exceed load backrest. Otherwise,
the goods may slide down to the operator side. As a
result, the driver may be hurt by goods.

• Stacked goods are fixed by rope and then

transferred in order to prevent them from falling
down.

(15) Locking chain

Caution

• When the chain is loose, do not pull out the fork of

the pallet. Otherwise, goods may fall off or the
forklift rolls over.

Note

• When the chain is loose, pull up lifting handle a

little to lift the fork in order to change loose state of
the chain, then pull out the fork of the pallet.

• If the chain is worn and chain pitch change value

exceeds 2% of standard value, the chain shall be
replaced to ensure loading safety.

(16) Fork adjustment notes

Caution

• The fork distance is adjusted to the most

appropriate position according to pallet size. When
adjusting, do not press the hands.

• After fork distance is adjusted, the fork is fixed by

fork pin. If it is not fixed, it is easy to move during
the course of driving. Goods may fall off and even
be smashed.

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 Operation Manual for Internal Combustion Counterbalance Forklift

(17) Carrying over-wide goods

Caution

• When carrying over-long and over-wide

goods, the driver shall be careful.

• When turning and lifting/lowering goods,

the speed shall be low to avoid goods from
moving. At the same time, the driver shall
pay attention to safety around the forklift.

• When carrying over-wide goods, the forklift

shall be provided with widening fork arm
carrier and lengthened fork. Bearing
capacity of lengthened fork shall conform to
load curve. Within specified load center, its
bearing capacity is the same as that of
standard fork. Once load center moves
forward, the load shall be reduced.

(18) It is forbidden to unload goods by hand

Caution

• Do not unload goods by hand because the

goods may fall off.

(19) Park the faulty forklift

Note

• If the forklift stops on roadside, a warning

or “fault” mark is made on the forklift and
the key is pulled out.

• When the fork cannot be lowered due to

fault, an obvious mark is made to avoid
colliding with other vehicles and
pedestrians.

(20) Notes after working and before leaving the forklift.

Note

• The mast bends forward slightly and the

pallet fork lowers naturally. Otherwise,
there is danger about tripping over and
personal hurt.

• Direction handle is at neutral gear.

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Operation Manual for Internal Combustion Counterbalance Forklift

• Pull up parking brake handle.

• Turn off key switch and pull out the key.

Parking brake
handle

(21) Parking

Caution

• Park at the specified position.

• The parking position shall be enough strong and not obstruct traffic safety.

• It is forbidden to park in the place where inflammables exist or near inflammables.

• It is forbidden to park on the slope because the forklift will happen to move. If it has to park on
the slope, stop blocks shall be used to support the tires to prevent the forklift from moving except
parking procedures.

(22) Noise

Maximum noise value outside the forklift shall not be greater than 89dB (A). Measuring method shall
conform to JB/T3300 standard.

Caution

• If road surface is rough or uneven, tire deformation is larger and the noise is higher.

5. Safety problems during the course of maintenance

(1) Maintenance site

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 Operation Manual for Internal Combustion Counterbalance Forklift

Caution

• It shall be specified site and provide enough equipment and safety protection measures.

• This site shall be level ground.

• This site shall be well-ventilated.

• This site shall be provided with fire extinguisher.

(2) Precautions before maintenance

Caution

• No smoking.

• Wear various protective equipment (helmet, safety shoes, spectacles, gloves and boots) and
appropriate clothes.

• Wipe off overflowing oil.

• When filling lubrication oil, first remove dirty oil or dust from the joint with brush or cloth, and
then fill lubrication oil.

• Except it is required in some conditions, turn off key switch and pull out the plug of the battery.

• When maintaining the forklift, the fork shall be lower to the ground.

• Clean electric components with compressed air.

(3) Maintenance notes

Caution

• Do not put your foot under the fork. Do not trip over by the fork.

• When the fork is lifting up, a block or other object is put under inner mast to avoid the fork and
mast from falling off suddenly.

• When opening and closing front base plate and the battery box cover plate, be careful to avoid
your fingers from being pinched.

• When the work is not finished once, marks shall be made for easy work in the future.

• Use appropriate tools; do not use temporarily substitutive tools.

• Because there is high pressure in hydraulic circuit, maintenance shall not be made before
internal pressure in oil circuit is reduced.

• When you get electric shock from high voltage, you shall go to see a doctor immediately.

• Do not use mast assemble as a ladder.

• Do not put your hands, feet and body between the frame and mast.

• When maintaining the forklift in hot state, the temperature for drive device or hydraulic system
may be very high. Therefore, cool the forklift before maintenance to avoid accidental scald.

(4) Check and replace the tire

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Operation Manual for Internal Combustion Counterbalance Forklift

Caution

• Removal and installation of tires shall be made by service station authorized by our company.

• High pressure air shall be carried by professionals.

• When using compressed air, the operator shall wear goggles.

• When removing the tires, do not loosen bolts and nuts at the joint of the rim because there is
high pressure air in the tire. If bolts, nuts and rims are loose, it is very dangerous.

(5) Use jacks (when replacing the tires)

Warning

• When the forklift is jacked up, the body shall not go under the forklift.

Caution

• Before the forklift is jacked up, make sure there is nobody or no load on the forklift.

• When the forklift wheels leave the ground, the jacks shall stop and blocks shall be put under the
forklift to avoid it from falling down.

• Before the forklift is jacked up, some measures shall be taken to prevent the forklift from sliding.

(6) Waste discharge (waste electrolyte and oil) requirements

Caution

• Waste electrolyte on the forklift shall be recycled according to local regulations of the
government, without discharging at will.

6. Safety problems when using the battery

(1) No smoking

Caution

• The battery can generate hydrogen. Electric spark is generated at the time of short circuit. When
lit cigarette is close to the battery, it may lead to explosion and fire.

(2) Prevent electric shock

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 Operation Manual for Internal Combustion Counterbalance Forklift

Caution

• The battery has high voltage. When installing and maintaining, the operator does not contact
electric conductor of the battery, which may lead to serious burn.

(3) Correct connection

Caution

• When the battery is charging, positive and negative electrodes shall not be reversed. Otherwise,
it will generate high temperature, burning, smoke or explosion.

(4) It is forbidden to put metal objects on the battery.

Caution

• The bolt or tool shall not contact positive and negative electrodes which may lead to short circuit
and then cause personal hurt and explosion.

(5) Over discharge forbidden

Caution

• Do not use up the forklift battery. Otherwise, the battery service life will be shortened. When the
battery capacity warning indicator flashes continuously, the battery requires charging.

(6) Keep clean

Caution

• Keep the battery surface clean.

• Do not clean the battery surface with dry cloth and chemical fiber cloth. Do not use polyethylene
film to cover the battery.

• Static electricity will lead to explosion.

• Clean the top of the battery with wet cloth.

(7) Wear protective clothes

Caution

• When maintaining the battery, you have to wear goggles, rubber gloves and rubber boots.

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Operation Manual for Internal Combustion Counterbalance Forklift

(8) Battery electrolyte is harmful

Caution

• Battery electrolyte is made of diluted sulfuric acid. Be careful when it is carried.

• When the electrolyte adheres to eyes, skin and clothes, the loss of vision and scald may occur.

(9) Emergency treatment method

Note

When accident occurs, make emergency treatment and timely contact your doctor according to the
following methods.

• Splash on the skin: wash it for 10-15 minutes.

• Splash into eyes: wash it for 10-15 minutes.

• Large-area pollution: Use dry soda (sodium hydrogen carbonate) to neutralize the battery
electrolyte or wash off by water.

• Swallow: drink a lot of water and milk.

• Splash on the clothes, and take them off immediately.

(10) Tighten upper cover of the battery

Caution

• Tighten upper cover of the battery to prevent the battery electrolyte from leaking.

• When filling the electrolyte, the electrolyte shall not overflow. Otherwise, leakage of electricity
will occur.

(11) Cleaning

Caution

• When the battery is on the forklift, do not wash the forklift. Otherwise, the battery may be
damaged.

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 Operation Manual for Internal Combustion Counterbalance Forklift

• Tighten upper cover of the battery to prevent the water.

(12) Sea water

Caution

• The battery shall not get wet in the rain or sea water. Otherwise, it will be damaged or catch fire.

(13) Abnormal conditions of the battery

Caution

When the battery has the following conditions, please contact our sales department:

• The battery becomes smelly.

• The electrolyte becomes dirty.

• The electrolyte temperature becomes high.

• The electrolyte reduction speed becomes fast.

(14) It is forbidden to dismantle the battery

Caution

• The electrolyte shall not be pumped from the battery.

• Do not dismantle the battery.

• Do not repair the battery .

(15) Storage

Caution

• When the battery is not used for a long period, it shall be stored in a well-ventilated place,
without potential fire risk.

(16) Waste battery

Caution

• For waste batter, please contact our sales department.

(17) Maintenance-free battery

7. Nameplate
The nameplate on the forklift is used to describe operation methods and notes. This is not only helpful to
you, but also helpful to your forklift. After the nameplate falls off, please attach it again.

(1) Safety mark nameplate

Warning

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Operation Manual for Internal Combustion Counterbalance Forklift

Prohibit staying under / above fork

(2) Operation notice nameplate

Caution

Instructions
Forbid untrained or unlicensed personnel to operate a forklift truck.
Please inspect various control and alarm devices before startup and do not drive a defective forklift
truck.
During startup, steering, driving, braking and stopping, make the forklift truck operate stably as
much as possible.
When filling fuel or inspecting storage battery or the level of oil tank, the operator cannot stay on
the forklift and should shut off the engine, and free running of a forklift truck with accessories shall
be regarded as on-load forklift truck operation at end.

 When driving on damp and  Be especially careful when driving on

slippery road, pay attention to wharf or temporary board.
decelerating during steering.
 It is prohibited to carry person on any
part of forklift truck.
 Take care when driving on
 No turning movement during going up
ramp, and in case of driving on a
and down a slope
ramp with gradient greater than
1/10, drive forward when going  During driving with cargo, lower the
up the slope, while drive back cargo as far as possible and make the
when going down the slope. mast tilt back.

Make the fork fall down to the ground, place gear handle in neutral position, and shut
off the engine or disconnect power supply.
When stopping on ramp, pull stopping device properly.
Make sure to cushion tires in case of long-term stopping

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 Operation Manual for Internal Combustion Counterbalance Forklift

(3) Forklift nameplate

Caution

ZOOMLION

ZOOMLION ANHUI INDUSTRIAL VEHICLE CO., LTD

(4) Lubrication chart nameplate

Radiator

Rear wheel bearing Oil pump drive

Cooling water pump Crankcase

Hydraulic oil Distributor

Torque converter oil (for gasoline truck)
(used for torque
converter type) Steering cylinder
Transmission (used Injection pump
for clutch type) (for diesel forklift
trucks)
Front wheel bearing
Rear pin of tilting
Brake cylinder
Clutch Pedal
Inching Brake fluid

Transmission shaft
Front pin of tilting
cylinder Mast support cap

Shift control lever Differential

Lifting chain

Grease Engine lubricating oil Brake fluid

Wheel bearing grease Gear oil Torque converter oil
Cooling water pump Clean soft water
grease Hydraulic oil

Supply Replace

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Operation Manual for Internal Combustion Counterbalance Forklift

(5) Load chart nameplate

Caution

(6) Nameplate for check essentials before starting

Caution

Check essentials before starting

Before starting, check as follows:

1. Hydraulic oil level: oil level shall be in
the middle position between upper and
lower limits of oil level indicator;
2. Check if pipe, joint, pump valve leak or
are damaged;
3. Check service brake:
(1) Idle stroke of brake pedal shall be
20-30mm;
(2) The clearance between front base
plate and the pedal shall be higher
than 20mm;
4. Check parking brake frequently. When
hand brake is pulled down completely,
the forklift can park with full load on
15% slope;
5. Check if instrument, lighting, switch
and electric circuit are normal.

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(7) Parking brake adjustment nameplate

Caution

Parking brake adjustment

(Decrease)

(Increase)

Standard operating force of

pull rod

(8) Filling nameplate

Note

Hydraulic oil

(9) Tire safety nameplate (pneumatic tire)

Warning

Warning

 If the pressure of forklift truck tire is high, it will be very

dangerous during disassembly and assembly.
 Specially trained personnel shall be allocated for disassembly
and assembly, air filling, etc. of outer tire, inner tire, hub and
retaining collar of wheel.
 Remove the rim bolt (A) after fully exhausting the pressure in
tire when removing the wheel from frame.
 When removing wheels from frame, first remove air valve and
release air pressure in inner tire.
 Never give away bolt until completely releasing air pressure in
tire (B).
 Tire inflation shall be conducted under loading condition or in a
solid safety fence.
 Tire inflation pressure cannot exceed specified value.

Air filling

Hub during division Safety fence

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Operation Manual for Internal Combustion Counterbalance Forklift

(10) Lifting nameplate

Caution

Lifting here

(11) Nameplate of forbidding to enter into the rear of mast

Warning

Prohibit entering the space behind mast

(12) Tire pressure nameplate (pneumatic tire)

Tire pressure

Front wheel: 700 kPa

Rear wheel: 700 kPa

(13) Injured hand nameplate

Warning

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 Operation Manual for Internal Combustion Counterbalance Forklift

Be careful not to injure hand

(14) Fuel filling nameplate

Note

Fuel

(15) Antifreeze solution filling nameplate

Note

Antifreeze

(16) Fan safety nameplate

Warning

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Operation Manual for Internal Combustion Counterbalance Forklift

Be careful not to injure

hand

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Ⅱ. Operating device and methods

1. Outer mast 11. Fuel tank cap

2. Inner mast 12. Internal combustion engine hood

3. Lifting chain 13. Tilting oil cylinder

4. Lifting oil cylinder 14. Driver seat

5. Load backrest 15. Steering wheel

6. Fork locating pin 16. Headlamp

7. Fork arm carrier 17. Front combination lamp

8. Fork 18. Overhead guard

9. Driving wheel 19. Rear combination lamp

10. Steering wheel 20. Counterweight

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1. Chronograph 10. Brake pedal

2. Water temperature gauge 11. Accelerator pedal

3. Fuel gauge 12. Tilting handle

4. Parking brake handle 13. Lifting handle

5. Forward-reverse handle 14. Fuse box

6. Steering wheel 15. Pre-heating start switch

8. Inching pedal 16. Steering signal handle

9. Light switch 17. Horn button

Hydraulic drive forklift

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R series forklift

1. Adjusting handle 14. Attachment control handle (optional parts)

2. Reversing handle 15. Function symbol nameplate

3. Horn button 16. Function symbol nameplate (optional part)

4. Ignition switch with start key 17. Function symbol nameplate (optional part)

5, Light switch 18. Load curve table

6. Direction indicator switch 19. Indication nameplate

7. Parking brake lamp 20. Accelerator pedal

8. Brake fluid warn lamp 21. Service brake pedal

9. Combination instrument 22. Inching pedal

10. Fuse (with cover) 23. Parking brake pedal

11. Lifting/ lowering control handle 24. Noise value

12. Bending forward/backward control handle 25. Steering wheel

13. Attachment control handle (optional parts)

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1. Chronograph 12. Tilting handle

2. Water temperature gauge 13. Lifting handle

3. Fuel gauge 14. Fuse box

4. Parking brake handle 15. Pre-heating start switch

5. Forward-reverse handle 16. Steering signal handle

6. Steering wheel 17. Horn button

9, Light switch 18. Clutch pedal

10. Brake pedal 19. Gear shift handle

11. Accelerator pedal

Mechanical drive forklift

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1. Liquid crystal instrument

For diesel forklift

For gasoline forklift

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Operation Manual for Internal Combustion Counterbalance Forklift

Welcome to use
ZOOMLION Forklift

Optional part

R series forklift instruments

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 Operation Manual for Internal Combustion Counterbalance Forklift

(1) Chronograph

This chronograph is used to record work time of the forklift. Then lubrication and maintenance time will be
determined.

(2) Charging indicator

This indicator is used to indicate charging conditions. When preheat starting switch is turned to “ON”, this
indicator is lit. But, when the engine starts and accelerator pedal is stepped on, this indicator is off.

Caution

• If this indicator is still lit or flashes during the course of operation, it means charging circuit has
a fault. Check it immediately.

(3) Oil pressure alarm indicator

This indicator is used to indicate lubrication oil pressure of the engine. Although the indicator is lit with
starting switch “ON”, it goes off after the engine starts and accelerator pedal is stepped on.

Caution

• If this indicator is still lit or flashes during the course of operation, it means oil pressure is low.
Check it immediately.

(4) Oil water separation indicator

Diesel engine

During the course of the engine running, when water in oil-water separator reaches to a certain height, this
indicator is lit.

Normally, once starting switch is turned to “ON”, this indicator is lit. After the engine starts, this indicator is
off.

If this indicator is still lit or flashes during the course of operation, shut down the engine immediately and
discharge water in oil-water separator.

Caution

• If this indicator is lit and the forklift still operates, filling pump may be damaged.

(5) Engine preheat indicator

Diesel engine

For this kind of the forklift, at the time of cold start, there is a complete set of system “QUICK－ON－
START”, i.e., “Quick Start” system. There is no “preheat” position on starting switch.

Turn the key to “ON”, and then the indicator on the display will be lit for a period of time; after the
indicator is off, turn the key to “START”.

(6) Engine coolant temperature gauge

This gauge is used to indicate the engine coolant temperature. Normally, the pointer shall be within normal
area (75°C~110°C). If the pointer is in alarm area (110°C~145°C), run the engine idly until the pointer
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Operation Manual for Internal Combustion Counterbalance Forklift

returns to normal area.

Caution

If the pointer goes into alarm area, stop operating, reduce the engine speed and cool the coolant until
the pointer returns to normal area.

(7) Fuel gauge

When preheat starting switch is turned to “ON”, this gauge tells the operator how much fuel there is in fuel
tank. “E” represents “Empty”, “F” represents “Full”. When fuel height reduces to 1/8, the pointer goes into
alarm area.

Caution

Fuel tank is filled every working day (or every work shift). In this way, water condensation in fuel
tank will be reduced.

2. Switches

(1) Preheat starting switch ⑮

OFF

This is the position where the key is inserted or pulled out. At this position, both gasoline engine and diesel
engine stop running.

ON

When starting switch is turned to “ON”, the circuit is closed. After the engine starts, the key is at this
position.

START

When the key is turned to “START”, starting motor is engaged. When your hand leaves the key, the key
returns to “ON” automatically with the spring action.

Caution

• When the engine is shut down, starting switch shall not stay at “ON”. Otherwise, the battery
may leak electricity.

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• When the engine runs, starting switch shall not be turned to “START” because starting motor
may be damaged.

• Engagement time of the engine shall not exceed 15 seconds every time. Before starting, wait for
20 seconds.

(2) Light switch ⑨

Light switch has two positions

Gear
O (OFF) Gear 1 Gear 2
Lamp
Width lamp and parking lamp OFF ON ON
Tail lamp OFF ON ON
Instrument panel lamps OFF ON ON
Headlamp OFF OFF ON

Caution

• The above lamps are controlled by light switch, independent of starting switch position.

3. Control
(1) Steering wheels ⑥

Steering wheel is operated in normal way. That is to say, when steering wheels turn right, the forklift turns
right; when steering wheels turn left, the forklift turns left. Steering wheels are installed in the rear of the

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forklift. The rear of the forklift can swing outside at the time of steering. You practice it a little and then
grasp this steering method.

Warning

• Hydraulic steering device driven by the engine is provided on the forklift. Therefore, when the
engine is shut down, steering is difficult. If hydraulic steering is made again, the engine shall be
restarted.

(2) Horn button ⑰

Press rubber cap in the middle of steering wheels, and it sounds. Even if starting switch is off, the horn can
also sound.

(3) Turn signal handle ⑯

This handle is used to turn the forklift. When the handle is located at turning position, turn signal lamp
flashes.

R Right turn signal light

N Middle position
L Left turn signal light

Caution

• Turn signal handle cannot return to middle position automatically like common vehicles. It shall
be reset manually.

(4) Lifting handle ⑬

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This handle is pulled backwards or pushed forwards to lift or lower the fork. Lifting speed is controlled by
tilting angle of the handle and accelerator pedal force. Lowering speed is controlled by tilting angle of the
handle. The larger the angle is, the higher the speed is. The engine speed or accelerator pedal is independent
of lowering speed of the fork.

(5) Tilting handle ⑫

The mast can tilt by this tilting handle. Pull backwards this handle to tilt the mast backwards and push
forwards this handle to tilt the mast forwards. Tilting speed can be controlled by tilting angle of the handle
and accelerator pedal force. The larger the angle is, the higher the speed is.

Caution

• When the engine is shut down, even if tilting handle is pushed forwards, tilting locker installed in
multi-way valve keeps the mast in self-locked state.

(6) Parking brake handle ④

At the time of parking braking, this handle applies on two front wheels so that the brake stops working. To
disconnect parking braking, push this handle forwards.

Warning

• If the forklift has to park on a slope, wedges shall be used to block wheels.

(7) Gearshift handle ⑤⑲

Mechanical drive forklift

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Forward – reverse handle ⑤ Speed change handle ⑲

F Forward 1 Low speed

N Neutral gear N Neutral gear

R Backward 2 High speed

Drive control is fixed device of base plate column, with two different speeds for forward gear and reversing
gear, respectively. Before gear shifting, clutch pedal shall be stepped on completely. Before changing the
direction, full application of brake shall be made on the forklift. When the forklift is reversed by gear shift
handle, reversing lamp is lit.

Hydraulic drive forklift

Forward – reverse handle ⑤

F Forward

N Neutral gear

R Backward

Drive control is fixed device of steering column, with one forward gear and one reverse gear. Before
changing the direction, full application of brake shall be made on the forklift. When the forklift is reversed
by gear shift handle, reversing lamp is lit.

Caution

• Neutral gear switch is installed. Before starting the engine, this handle shall be turned to neutral
gear.

(8) Foot brake

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See the above Fig.: clutch pedal or inching pedal (left), brake pedal (middle) and accelerator pedal (right).

Mechanical drive forklift

Clutch pedal ⑱

The purpose of clutch is to allow the operator to engage or disengage the engine and the transmission. Step
on clutch pedal, and then the engine and the transmission are disengaged. Release clutch pedal, and the
power is transferred through the clutch from the engine to the transmission.

Caution

• It is forbidden to run the forklift with the clutch in semi-disengagement or semi-engagement

state.

Hydraulic drive forklift

Inching pedal ⑧

When stepping on inching pedal, oil pressure in fluid clutch is reduced correspondingly (the pointer of oil
pressure gauge turns left) to achieve inching operation. When lifting system is operated at high speed, the
forklift can move slowly by this pedal.

When the pedal is stepped on completely, it can also be used as brake pedal.

Danger

• When starting on a downhill or slope, use brake pedal instead of inching pedal. If inching pedal
is used on a downhill, the engine has no braking action. The forklift will go down by inertia.
Therefore, braking result is very poor. When starting on a slope with inching pedal, it is very
dangerous because the forklift will go down by inertia.

Accelerator pedal ⑪

Step on accelerator pedal to increase the engine speed; release the pedal, and the engine runs idly.

Brake pedal ⑩

Step on brake pedal to reduce the speed or stop the forklift. At the same time, braking lamp is lit.

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4. Body
(1) Seat

Seat adjusting
handle

One seat that is applicable to the operator is installed on the forklift.

Caution

• If the seat is provided with seat belt, seat belt shall be tied. Once the forklift turns over, the
driver shall grasp steering wheel and the driver’s body tilts to the other side and jumping from
the forklift is forbidden.

(2) Seat adjusting handle

Adjusting handle is used to adjust the seat so that it is applicable to the operator’s shape. The impact and
vibration from forklift can be absorbed and all hand control and foot control can be accessible. Adjust the
handle to the right, and the seat is unlocked. Before working, adjust the seat and make sure the seat is
locked reliably.

(3) Overhead guard

Warning

• Overhead guard is an important part to prevent upper goods from falling down and protect the
operator safety. After it is loose or removed or modified, it is dangerous to the operator. Serious
accident may occur.

(4) Load backrest

Caution
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• Load backrest is an important part to prevent goods on the fork from falling off to the operator.
After it is loose, removed or modified, it is dangerous to the operator.

(5) Internal combustion engine hood

Air spring

Locking handle of engine cover

Internal combustion engine hood can be opened completely for easy maintenance. When opening internal
combustion engine hood, lift up internal combustion engine hood lock handle with arrow, with the help of
air spring of internal combustion engine hood, open internal combustion engine hood with a little force.
When closing internal combustion engine hood, press down the front of internal combustion engine hood
until it is locked.

Warning

• When closing internal combustion engine hood, your finger shall not be stuck inside.

(6) Fork locating pin

Fork locating pin locks the fork at a certain position. When adjusting the distance of the fork, pull up fork
locating pin and rotate by 1/4 turn, to adjust the fork to required position. The adjustment of fork distance
depends on loaded and unloaded goods.

Warning

• The fork is symmetric on centerline of the forklift and fork locating pin is locked.

(7) Towing pin

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Towing pin is only applicable to the following occasions:

• It is used in difficult situation of unable to drive (for example, the tire is stuck in side trench):

• When the forklift is loaded on the truck or unloaded from it.

Caution

• Do not use it for towing or being towed.

(8) Safety pedal and safety handle

Safety pedals are provided on both sides of the body. Safety handle is on FL support bar of overhead guard.
When getting on/off the forklift, safety pedals and safety handle will be used.

(9) Fuse box

Fuse box is installed on the right of inner surface of instrument stand.

(10) Brake fluid tank

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Brake fluid tank is installed on the left inside instrument stand. The tank is semitransparent so that we can
check brake fluid level from the outside.

(11) Hydraulic oil tank cap

Hydraulic oil tank cap is installed on the right inside internal combustion engine hood. Hydraulic oil is
filled through this oil filler hole. The cap is provided with oil dipstick.

(12) Fuel tank cap

Fuel tank cap is on left rear of the body. Rotate it counter clockwise to open it.

Caution

• There is air vent hole in fuel tank cap to let air go into fuel tank. If air vent hole is blocked, fuel
system may be in trouble. Check if air vent hole is in good state when filling fuel every time.

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Warning

—Fill fuel—

• Stop, shut down the engine and pull up parking brake handle. Make sure there is no open fire
near the forklift. Smoking is prohibited. The driver shall not stay on the forklift when filling fuel.

• Tighten the cap after filling fuel. If the cap is loose, fuel leakage occurs or fire breaks out in
extremely bad conditions.

• Before starting the engine, make sure fuel tank cap is tightened and no fuel is overflowed on the
forklift or around it.

• When checking fuel level, you never use a match or lighter.

(13) Water tank cap

Water tank cap is on the lower section of rear cover plate of internal combustion engine hood. For daily
check, it is not required to open this cap.

(14) Water tank

Feeding tank is near the battery.

Warning

• When the engine temperature is very high, you do not open water tank cap suddenly. Turn the
cap to the left slightly to reduce the pressure in the radiator, and then open the cap.

• Do not open radiator cap with gloves.

(15) Lamps

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Caution

• Confirm working conditions of lamps. If the bulb is burnt, lamp shade is damaged or unclean,
replace or repair immediately.

• If rear lamp is required, contact our sales department. Our company will dispatch a person to
install it.

Two headlamps B and front combination lamps C (turn signal lamp and width lamp) are installed on front
side of the forklift.

Rear combination lamps are installed in the rear of the forklift, including turn signal lamp G, tail lamp D,
braking lamp E, reversing lamp F and flasher.

(16) Rearview mirror A

Caution

• Rearview mirror shall keep clean.

• Adjust rearview mirror to the position where the operator can see rear conditions clearly.

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Record

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Ⅲ. Driving and operation

In order to keep good performance, safe operation and economical running, there are some notes about
correct driving.

1. Operating new forklift

Service life of your forklift depends on operation of new forklift. For initial 200 hours, pay attention to the
following items.

Caution

• Before operation, it is necessary to heat the engine in any season.

• Maintenance is necessary and maintenance interval shall be followed.

• Do not operate the forklift gruffly and unreasonably.

• Fill lubrication oil, grease and replace oil in time.

• Do not run the engine idly at high speed.

2. Relations between load and fork stability

In load curve, the forklift uses front wheel centers as pivot point to keep the body and load on the fork
balanced. Pay attention to load capacity and load center to keep the forklift stable.

Warning

• If the load exceeds load curve, rear wheels may be lifted up and in bad conditions. The forklift
may turn over, which leads to a serious accident. As shown in the Fig, goods are close to the fork
tip or the weight of goods is increased. The result is the same. In this case, load weight shall be
reduced.

3. Load center and load curve

Load center is the distance from front end of the fork to center of gravity for goods. The above load curve
examples indicate the relation between forklift load center and allowable load. Load curve nameplate is
stuck on the forklift. If this nameplate is damaged or lost, replace it with a new one.

Warning

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• If the forklift is provided with accessories, such as side shifter, bucket or rotary fork, allowable
load shall be lower than that of standard forklifts (without any attachment). The reasons as
follows:

a) Reduce the load that is equal to the weight of attachments.

b) Because attachment length makes load center move forward, allowable load will be reduced in the
same principle.

• Attachment installation makes load center move forward. It is called “load center loss”.

• Do not exceed allowable load on load curve stuck on the forklift or attachment.

4. Forklift stability
Forklift stability standards refer to ISO or other standards. However, the stability in these standards is not
applicable to all running states. The forklift stability is different with different running states.

In the following running states, the maximum stability shall be ensured:

a) The ground shall be level and hard.

b) It runs in standard idling or loading state.

Standard idling state: the fork or other bearing accessories shall be 30cm above the ground. The mast is
non-loaded and tilts backwards to the position.

Standard loading state: the fork or other bearing accessories shall be 30cm above the ground. Allowed load
is at standard load center. The mast tilts backwards to the position.

Warning

• When loading and unloading goods, the forklift tilts forwards/backwards to the minimum.
Except that the load is fixed reliably or steel shelf is used or lifting height is low, the forklift shall
not tilt forwards.

5. Forklift transportation, loading and unloading

(1) Forklift transportation

Caution

• When the forklift is transported in a truck, the wheels shall be blocked and the forklift is fixed
by rope so as to prevent it from moving in the compartment.

• When loading, unloading and transporting the forklift, pay attention to overall length, overall
width, overall height and follow related regulations.

(2) Forklift loading and unloading

Caution

• Use a joint plate with enough length, width and strength.

• Pull up parking brake of the truck feasibly and effectively, and block wheels.

• A joint plate is fixed in the middle of the compartment. No grease is allowed on the joint plate.

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• The joint plate height on the left and right is the same so that the forklift can run stably at the
time of loading and unloading.

• In order to prevent the risk, do not change the direction or move horizontally on joint plate.

• When the forklift is loaded on the truck, it can be reversed slowly so that left and right tires can
go onto the joint plate at the same time.

(3) Forklift lifting

Caution

• The operator who has been specially trained can lift the forklift.

• The rope shall hook specified lifting positions on the forklift.

• The ropes shall have enough bearing capacity.

• Removable parts on the forklift have specified lifting positions.

6. Before and after starting the engine

(1) Before starting the engine

• Before the forklift runs, check all control devices and alarm devices run normally. If any damage or
failure exists, it is forbidden to start the forklift before repairing.

• Check safety conditions around the forklift.

• If grease or oil pollutes base plate, pedal control handle or the operator’s hands, please wash it off.

• Confirm gearshift handle and multi-way valve handle are at neutral gear, and parking brake handle is
completely engaged.

a) Start gasoline engine

• Cold engine

Step on accelerator pedal 2~3 times, and the foot leaves the pedal; turn preheat starting switch to
“START” and start the engine; after starting, release the key.

• Heat engine

Step on accelerator pedal to the half and keep it; turn preheat starting switch to “START” and start the
engine; after starting, release the key.

Caution

• When starting in hot state, do not step on accelerator pedal completely. In this way, difficult start
may be caused. Stepping on the pedal several times may cause difficult start.

b) Start diesel engine

Turn preheat starting switch to “ON” until preheat indicator goes out, and then turn preheat starting switch
to “START”. If it is difficult to start the engine, check if fuel level is too low and check air mixture in fuel
system or preheat wire is broken.

(2) After starting the engine

• Preheat the engine (about 5 minutes).

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• Check the engine running (noise or gear).

Caution

• Check ignition (or misfiring) noise.

• Check exhaust conditions (concentration).

• Confirm all indicators have been off.

• After the engine is preheated, multi-way valve control handle is operated 2~3 times at full stroke
and check its working conditions.

7. Operation
(1) Posture of operator

Hold the handle of steering wheel with left hand, while place right hand gently on the steering wheel and
get ready for loading and unloading operations.

(2) Basic state of operation

Keep fork underside 15 to 20 cm away from the ground and make the mast tilt backward to place.

Look around the forklift to check the safety. And give a signal before starting up the truck.

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Mechanical drive forklift

Step on clutch pedal and operate gearshift handle.

Loosen parking brake handle.

When depressing accelerator pedal, loosen clutch pedal slowly to make the truck run.

Caution

• Avoid putting foot on clutch pedal during running.

Hydraulic drive forklift

Step on brake pedal and operate front-back gearshift handle.

Loosen parking brake handle.

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Loosen brake pedal and step on accelerator pedal to make the truck run.

(3) Gear shifting

If there is no load, it is allowed to start up the truck at high gear, while in case of load condition, it is
necessary to start up the truck at low gear.

Mechanical drive forklift

a) It is necessary to make the truck stop before changing driving direction.

b) In case of shifting between high gear and low gear, make the engine accelerated and then loosen
accelerator pedal, meanwhile step on clutch pedal and change gearshift handle to the required gear,
afterwards loosen clutch pedal and step on accelerator pedal.

Hydraulic drive forklift

a) It is necessary to make the truck stop before changing driving direction.

(4) Deceleration

Mechanical drive forklift

Secondary clutch operation is unnecessary as synchromesh transmission is used for this kind of forklift, and
the operator is required to loosen accelerator pedal, floor clutch pedal, put gear change hand lever to I-gear
position, and step on accelerator pedal after loosening clutch pedal.

Hydraulic drive forklift

Loosen accelerator pedal slightly and when necessary, step on brake pedal.

Warning

Deceleration is required

• at a cross-road

• in a crowded place

• on rough ground or other uneven surface

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• nearby cargo or obstacle.

(5) Steering

Different from conventional vehicles, the tumbler of a forklift is mounted in the rear part, so the rear part
will rotate outward during steering, and it is necessary to reduce truck speed, turn to the expected side, and
make steering wheel of the forklift rotate slightly ahead of rotation of the vehicle with front wheel steering.

(6) Stopping or parking

Decelerate, step on brake pedal to make the truck stop (stepping on clutch pedal simultaneously for
mechanical drive forklift) and place gearshift handle in neutral position

Caution

• In case of going up the slope, avoid making the truck stop under the condition that the clutch is
in semi-clutch state or torque converter is running by stepping on accelerator pedal, which will
induce abnormal wear of friction plate or abnormal rise of torque converter oil temperature and
further shorten service life of the clutch or torque converter.

Stopping: Stop the truck in a place not hindering the traffic and …

a) Pull on parking brake handle;

b) Make the fork fall to the ground;

c) Turn key switch to "OFF" position and shut off engine. For diesel forklift, pull out engine flame-out
handle;

d) Remove the key and keep it properly.

Warning

• Safe stopping

a) Stop the truck on a level ground, best in a spacious place. If you have to stop the truck on a slope,
make the truck across the scope and block the wheels with wedges to avoid accidental slipping.

b) Stop the truck in the specified area or a place not hindering the traffic, and if required, establish signs
or signal lights around the truck.

c) Stop the truck on solid ground and avoid stopping it in soft, muddy or slippery road.

d) If lifting system is damaged so that the fork cannot fall down to the ground, it is required to hang a
warning flag on tail end of the fork and stop the truck in a place not hindering the traffic.

(7) Urgent repair of faulted forklift

Caution

• If a fault suddenly occurs to the forklift during service, the faulted forklift shall be towed away
timely for repair, so as not to interfere with the operation of other vehicles or personnel.

8. Loading
(1) Adjust fork distance to make the cargo balanced.

(2) Make the truck face cargo for the convenience of loading.
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(3) Place the pallet symmetrically on two forks.

(4) Put the fork into the pallet as much as possible.

(5) Lift the cargo.

a) First lift the fork 5 cm to 10 cm distant from the ground to confirm whether the cargo is steady.

b) And then make the mast tilt backward to place, lift the cargo 15 cm to 20 cm away from the ground
and afterwards begin driving.

(6) Volume cargo obstructs the view, so during handling of volume cargo, it is required to back up, except
climbing.

9. Stacking

Caution

• Before operating a forklift, inspect the following items:

a) Ensure the cargo will not fall or be damaged in loading

area.

b) Ensure the safety is not impaired by any article or

stockpile.

When stacking, follow the procedures below:

(1) Decelerate when approaching stacking area.

(2) Stop the truck in front of the stacking area.

(3) Check the safety around the stacking area.

(4) Adjust the position of forklift to make it located in front of

cargo placing position in the stacking area.

(5) Let the mast be vertical to the ground and lift the fork to go
beyond stacking height.

(6) Inspect stacking position, drive forward and stop at an

appropriate position.

(7) Ensure the cargo is above stacking position, lower the fork
slowly and ensure the cargo has been placed properly.

Note

• In case the cargo is not fully placed above a carrier or a

bracket:

a) Lower the fork until the fork no longer bears load.

b) Make forklift draw back by 1/4 of fork length.

c) Lift the fork again by 50 mm to 100 mm, move forklift

forward and then place the cargo on an appropriate

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stacking position.

(8) Observe the space in the rear of forklift and drive the
forklift backward to avoid the fork colliding with pallet or
cargo.

(9) Ensure the front of the fork has departed from cargo or
pallet and lower the fork for the convenience of driving.
(150 mm to 200 mm above the ground).

10. Unstacking
When unstacking, follow the procedures below:

(1) Decelerate when approaching the cargo to be handled.

(2) Stop in front of the cargo (with 30 cm distance between

cargo and fork tip).

(3) Adjust the position of forklift in front of the cargo.

(4) Ensure the cargo will not overload.

(5) Keep the mast vertical to the ground.

(6) Observe fork position and meanwhile move forklift

forward until the fork is fully inserted into the pallet.

Note

• If case it is difficult to insert the fork fully into the

pallet:

a) Insert the fork by 3/4 of its length and lift the pallet
slightly (50 mm to 100 mm), pull out the pallet by
about 100 mm to 200 mm and then lower the pallet.

b) Insert the fork fully into the pallet.

(7) After inserting the fork into the pallet, lift the pallet (50
mm to 100 mm).

(8) Observe the surrounding space and move the forklift

backward until the cargo is lowered.

(9) Lower the cargo until it is 150 mm to 200 mm above the

ground.

(10) Make the mast tilt backward in order to ensure cargo

stability.

(11) Handle the cargo to destination place.

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11. Storage
(1) Before storage

Before storing a forklift, clean it thoroughly and check it as per the following procedures:

a) Clear away oil and grease attached to the truck with cloth and water as required.

b) When cleaning the truck, inspect overall condition of the truck, and especially check whether the truck
has dimple or damage, the tire is broken and iron nail or stone is embedded into tread pattern.

c) Charge oil tank with specified fuel.

d) Inspect whether there is oil leakage.

e) Fill lubricating grease as required.

f) Inspect whether joint surface between hub nut and oil cylinder piston rod is loose and whether the
surface of piston rod is bruised or has any drawing stamp.

g) Inspect whether mast roller rotates stably.

h) Lift hoisting cylinder to the top to make oil cylinder filled with oil.

i) In winter or cold days, do not drain long-acting antifreeze, but drain off all cold water if any.

Warning

• As long as it is found that a forklift needs to be repaired, is ineffective or has any unsafe factor, it
is necessary to report relevant information to management personnel and stop using the forklift
until it returns to safe condition.

(2) Daily storage

a) Stop forklift in a specified place and chock the wheels.

b) Turn gearshift handle to neutral position and pull on parking brake handle.

c) Turn key switch to "OFF" position and shut off engine, operate multi-way valve operating rod many
times and release residual pressure in oil cylinder or pipeline.

d) Remove the key and preserve it in a safe place.

(3) Long-term storage

Conduct the following maintenance and inspection on the basis of "daily storage":

a) In view of rainy days, stop the truck on high and solid ground.

b) Remove storage battery from the forklift. Even if the forklift is placed indoors, if the stopping place is
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damp and hot, storage battery also should be placed in a dry, shady and cool position and charged once
a month.

c) Apply rust-preventive oil on exposed parts like oil cylinder piston rod and the axles prone to rust.

d) Cover spare parts subject to moisture.

e) Start up the truck at least once a week. If cooling water has been drained, it is required to fill the
cooling water, mount storage battery, remove grease on piston rod and axles, start up the engine and
warm it up fully, let the truck run slowly forward and backward and operate hydraulic controller
several times.

f) In summer, avoid stopping forklift in a road as soft as asphalt.

(4) Forklift truck operation after long-term storage

a) Remove rust-preventive oil on exposed parts.

b) Discharge engine oil in engine crankcase, discharge gear oil or hydraulic transmission oil in
mechanical transmission box (for Mechanical drive forklift), differential and hydraulic transmission
box (for hydraulic transmission forklift) and fill new oil after cleaning the interior.

c) Clear away foreign matters and water in hydraulic oil tank and fuel tank.

d) Dismount engine cylinder head, valve and rockshaft to check whether each valve clearance is normal.

e) Add coolant to specified level.

f) Charge storage battery, mount it in forklift and connect battery lead wire.

g) Conduct careful inspection before startup.

h) Warn up the forklift.

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IV. Regular inspection and maintenance

Inspect a forklift comprehensively in advance to avoid the forklift having any fault or failing to achieve the
expected service life. The numbers of hours given in regular maintenance schedule are determined based on
the situation that a forklift is operating for 8 hours every day and for 200 hours every month.

Caution

• Only the trained or qualified personnel are allowed to maintain and repair forklifts.

• Operators are able to accomplish daily and monthly inspection and maintenance.

1. Inspection requirements
(1) Use only unadulterated spare parts.

(2) Use only unadulterated or specified grease.

(3) Before filling oil or applying grease, clean oil filler and grease nipple with brush or rag.

(4) During oil level inspection and oil filling, it is necessary to stop the truck on a level ground.

(5) Conduct regular prevention, maintenance and repair and avoid hurting yourself.

(6) If you have to work below a lifted fork or attachment, you should use a jackstay to support the fork or lift to
prevent the fork and inner mast sliding down.

(7) If finding any damaged or failed part, report to management personnel and prohibit using corresponding
forklift before repair.

2. Inspection contents
(1) Inspection on hydraulic oil, fuel and water leakage

Inspect whether hydraulic pipe joint, the engine, water tank and driving system leak oil or water by
touching with hand or through visual inspection.

Warning

• If finding fuel leakage before working, do not start up the truck, and do not start up the engine
until eliminating leakage.

(2) Tire pressure inspection (pneumatic tire)

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Low pressure Normal High pressure

Inspect tire condition. Low tire pressure will reduce service life of the tire and increase fuel consumption.
Different pressures of left and right tires or tire damage will induce to different steering forces.

The label attached to left front side of engine cover indicates standard pressure of tire.

Screw off valve cap counterclockwise, measure tire pressure with pressure gauge, adjust the pressure to
specified value if necessary, and after ensuring there is no air leakage, screw on the cap.

Inspect whether ground plane and sides of tire are damaged and whether wheel rim is deformed.

The tires of a forklift require very high pressure to bear heavy load, so tiny deformation of wheel rim or
damage of tire ground plane will induce to an accident.

Warning

• After assembly of tires and wheel rims, all bolts and nuts should be tightened to reach the
specified torque and then tires can be filled with air, and air-filled tires will have expansion
energy. Tire pressure cannot exceed the specified value.

• If using air gun for filling air, first adjust the pressure of air gun properly. Maximum output
pressure of air gun is very high, so improper adjustment will lead to serious accident.

(3) Inspection on hub nut torque

Inspect whether hub nut torque is correct.

All hub nuts shall be tightened to reach specified torque.

Driving wheel Steering wheel

① Hub nut ② Split-type front ③ Axle shaft bolt, ④ Hub nut ⑤ Split-type rear rim
rim bolt drive axle bolt

Caution

• When removing hub nuts ① and ④, be sure not to removing split-type rim bolt ② or ⑤

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mistakenly.

(4) Inspection on overhead guard

Overhead guard plays a role of protection, so it is necessary to ensure it is installed firmly and all structural
parts are firm.

(5) Inspection on brake fluid level

Air vent
Oil level range

Inspect oil level in brake oil tank to ensure it is between two lattices, and when adding oil, avoid dust or
water entering into oil tank.

Open internal combustion engine cover

Open engine cover from left side of truck body.

(6) Inspection on battery electrolyte

Inspection the quantity of battery electrolyte

There are upper and lower level scale marks on battery box, and operators can observe liquid level, which
shall be between two marks.

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Danger

• It is prohibited to take open flame close to battery filler opening as hydrogen will be generated at
the opening and further induce explosion.

(7) Inspection on coolant level

Inspect the level of feeding tank to ensure it is between upper and lower scale marks, and when necessary,
add coolant.

Warning

• Take particular care when opening pressure cap of water tank. If the cap is opened suddenly
under pressure condition, the sudden pressure release will generate steam flow and injure
personnel. Wrap the cap with thin cloth or similar article, loosen the cap slowly to make steam
spill over, and then unscrew the cap. In this process, do not wear any glove to avoid injected hot
water scalding hand.

(8) Inspection on engine oil level

Engine oil level gauge is located on left side of engine body. Pull out oil level gauge, clean gauge head and
then insert and pull it out again, to inspect whether oil level is between two scale marks.

(9) Inspection on tension degree of fan belt

Inspect tension degree and damage (if any) of fan belt by pressing the middle of belt between water pump
and generator with thumb.

Warning

• The engine must be shut off during inspection on tension degree of fan belt.

(10) Inspection on rear combination lamps

Inspect whether rear combination lamps (including tail lamp, stop lamp and backup lamp) are damaged or
polluted.

(11) Hydraulic oil level

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Operation Manual for Internal Combustion Counterbalance Forklift

Inspect hydraulic oil level with oil level gauge. Pull out oil level gauge and clean it, insert it again and the
pull it out to check whether oil level is between higher and lower scale marks.

Caution

• During inspection on oil level, make sure to shut off the engine, make the fork fall to the ground
and stop forklift on a level ground.

(12) Pipeline and oil cylinder

Inspect whether oil leaks from hydraulic pipeline and hoisting and tilting cylinder through visual
observation.

(13) Oil level of power shift transmission

Hydraulic drive forklift

Open inspection cover and pull out filler cap, check oil level gauge to ensure oil level is at a scale mark, and
if necessary, supplement the specified hydraulic oil.

(14) Inspection on load backrest

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Inspect whether mounting bolt of load backrest is loose, and when necessary, tighten the bolt.

(15) Fork and fork locating pin

Inspect the installation condition of fork locating pin and whether the fork has deformation or crack.

(16) Head lamp and front combination lamps

Inspect whether lamp shades are clean and damaged.

Close engine cover and sit on the seat.

Take care to avoid engine cover bruising finger.

(17) Seat adjustment

Ensure seat position is appropriate. If not, pull adjustment handle rightwards to adjust the seat to a position
convenient for operation by feet and hands, and after adjustment, move the seat slightly forward and
backward to make it locked reliably.

(18) Inspection on gearshift handle

Inspect whether gearshift handle is loose and operation hand feeling is good.

(19) Inspection on multi-way valve operating handle

Inspect the operating handle (lifting, tilting and bending) is loose and whether the operation is easy.

(20) Inspection on parking brake operation

Ensure safe and reliable parking brake after pulling on parking brake handle.

Start up the engine

Before starting up the engine, ensure gearshift handle is in neutral position and parking brake is reliable.

(21) Instruments
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Chronograph, water temperature gauge and fuel gauge will enable the operators to know truck condition
during operation.

(22) Inspection on fuel quantity

Install fuel gauge on instrument panel to check whether the fuel can meet a day's work need.

(23) Lamps and light

Open light switches to confirm corresponding lamps are normal.

(24) Inspection on turn signals

Operate turn signal handle to confirm turn signal lamps are operating normally.

(25) Inspection on horn button operation

Pressure horn button to check whether the horn is sounding.

(26) Inspection on clutch pedal

Mechanical drive forklift

Inspect whether clutch pedal operates stably.

For forklift with hydraulic clutch device, inspect clutch pedal after starting up the engine.

(27) Idle stroke of brake pedal

Step on brake pedal and inching pedal (limited to hydraulic transmission forklift only) to confirm whether
each pedal operates stably and can be reset without suffering any interference.

(28) Mast operation

Honk the horn, operate lifting and tilting handles, and confirm fork arm carrier is lifted and lowered
normally and the mast tilts stably. Confirm oil cylinder piston is operated to stroke end and whether the
sound of overflow valve operating and accompanying overflow is normal. And pay attention to system
running sound.

(29) Inspection on tension degree of lifting chain

Inspect the tension degree of lifting chain and whether there is abnormality.

When inspecting tension degree, lift the fork about 5 cm above the ground, press the middle of lifting chain
with thumb to confirm whether tension degrees of left and right chains are consistent, and in case of
inconsistency, loosen locknut (A) of fixing pin and tighten adjusting nut (B) to adjust the chains.

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Caution

• Use mechanical oil (such as hydraulic oil) rather than lubricating grease for lubricating lifting
chain.

(30) Free stroke of steering wheel

Inspect the rotation and axial looseness of steering wheel. Normal free stroke is between 50 mm and 100
mm and axial looseness is prohibited.

(31) Exhaust inspection

Inspect exhaust condition after warming up the engine.

Colorless or light blue Normal: complete combustion

Black Abnormal: incomplete combustion

White Abnormal: combustion of engine oil

Inspect whether engine and driving system have abnormal noise or vibration.

Danger

• Exhaust gas of the engine is harmful, so it is necessary to ensure adequate oxygen when a forklift
is started up and used in an enclosed space. It is required to conduct exhaust inspection outdoors,
pay attention to avoid fire, pay special attention to leakage of oil or fuel, do not leave waste cloth
or paper on engine body, confirm placement position of fire extinguishing equipment and know
how to use such equipment.

Low-speed operation - (in a safe place)

(32) Inspection on clutch operation (mechanical drive forklift)

Step on clutch pedal to confirm the clutch has normal engagement and is free of slipping.

Inspection on inching pedal (hydraulic transmission forklift)

Step on inching pedal slightly to inspect reduction of truck speed.

(33) Braking inspection

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Drive the truck at low speed and step on brake pedal to inspect braking effect. After brake pedal is stepped
on, brake light will turn on.

(34) Steering inspection

During driving at low speed, rotate steering wheel to observe whether left and right steering forces are
consistent and whether there is any other abnormalities.

(35) Inspection on parking braking

Confirm that the truck running at low speed can be braked to stop after parking brake handle is pulled on.

(36) Inspection on backup lamp

Backup lamp will turn on if gearshift handle or direction control lever is put in backup gear position.

3. Maintenance
(1) Drainage of water from oil-water separator

Diesel engine

In case oil-water separator indicator is on:

a) Shut off the engine, rotate part (A) for 4 to 5 circles, loosen drain plug, press pump (E), and
continuously press pump (B) till draining off the water in oil-water separator.

b) Tighten drain plug and press pump (B) several times to observe whether there is leakage at plug.

c) After starting up the engine, confirm that the indicator is no longer on.

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(2) Fuel system exhaust

Diesel engine

a) Shut off the engine, loosen air release plug (C) on injection pump, and press pump for exhaust until
fuel flows out of the plug.

b) Tighten air release plug to confirm that there is no fuel leakage.

(3) Fuse replacement

The fuse can protect electrical system and prevent high current. It is required to use the current of specified
ampere and inspect whether all components in a circuit operate normally. If any component fails to operate,
perhaps corresponding fuse has been burnt out and should be replaced by the fuse with the same capacity.
And if any spare part of a component cannot operate normally, perhaps spherical contact has been burnt out
and should be replaced by a contact with the same capacity.

(4) Tire replacement or repair

Prepare relevant tools and jack before replacement or repair.

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Safety
bracket

a) Front wheel

• Stop the truck on a rigid pavement and shut off its engine, and then remove all loads.

• Pull on parking brake handle and chock the wheel, and then place the jack below the truck.

• Jack the truck and keep the tire touch down, loosen hub nut, but do not remove it.

• Keep on jacking the truck until the tire gets off the ground, and then remove the nut and the tire.

• Install tire in the order opposite to dismantling order, and tighten hub nut in diagonal order.

After installation, inspect tire pressure. Tire pressure is 700 k Pa.

b) Rear wheel

The methods for repair and replacement of rear wheel are the same as those for front wheel, except that the
jack needs to be placed below counterweight.

Tire pressure is 700 k Pa.

4. Regular maintenance schedule

This schedule is established according to standard working hours and operating conditions. In case the
forklift is operating under bad conditions, it should be maintained ahead of schedule (“”means
replacement).

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Engine
Three Six months Annual
Inspection Daily Monthly
Inspection contents Tools months (1,200 (2,400
items (8 hours) (200 hours)
(600 hours) hours) hours)
Visual inspection of
engine running 〇 〇 〇 〇 〇
condition
Engine sound 〇 〇 〇 〇 〇
Exhaust color 〇 〇 〇 〇 〇
Cleaning or
replacement of air 〇 〇  
filter elements
Inspection of
crankcase for dirt 〇 〇 〇
removal
Engine Inspection and
Thickness
adjustment of valve 〇 〇
plug gage
clearance
〇
Gasoline 〇
Tightening of Torque engine Only C240
cylinder head bolts wrench (only for diesel
the first engine
time)
Inspection of
cylinder Pressure
〇
compression gauge
pressure
Ventilating Inspection of valves
device of and pipes for 〇 〇
crankshaft blocking or damage
Governor
Maximum non-load
or injection Tachometer 〇
speed inspection
pump
Inspection of engine
〇 〇 〇 〇 〇
for oil leakage
Inspection of oil
Lubrication
quantity and 〇 〇 〇 〇 〇
system
cleanliness

Engine oil change   
Initial 50
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Engine
Three Six months Annual
Inspection Daily Monthly
Inspection contents Tools months (1,200 (2,400
items (8 hours) (200 hours)
(600 hours) hours) hours)
hours

Replacement of 
engine oil filter Initial 20   
element hours
Visual inspection of
oil tube, oil pump
〇 〇 〇 〇 〇
and oil tank for
leakage
Inspection of fuel
〇 〇 〇
filter for blockage
Cleaning of fuel
filter (gasoline 〇 〇 
engine)
Replacement of fuel
  〇
filter (diesel engine)
Nozzle inspection,
pressure adjustment
and state Jet tester 〇 〇
optimization (diesel
Fuel
engine)
system
Inspection of
carburetor
connection for
〇 〇 〇
looseness and
cleanliness (gasoline
engine)
Ignition timing
Timer 〇 〇 〇
(gasoline engine)
Injection timing
〇
(diesel engine)
Fuel tank drainage 〇 〇 〇
Fuel tank cleaning 〇 〇
Fuel quantity
〇 〇 〇 〇 〇
inspection
Coolant quantity 〇 〇 〇 〇 〇
Cooling
Leakage situation 〇 〇 〇 〇 〇
system
Rubber tube aging 〇 〇 〇

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Engine
Three Six months Annual
Inspection Daily Monthly
Inspection contents Tools months (1,200 (2,400
items (8 hours) (200 hours)
(600 hours) hours) hours)
Performance and
installation of water 〇 〇 〇 〇
tank cap
Clearing and change
  
of coolant
Inspection of fan belt
for tension and 〇 〇 〇 〇 〇
damage

Power transmission
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (1,200 (2,400
items contents (8 hours) (200 hours)
(600 hours) hours) hours)
Inspection of
clutch pedal for
idle travel and of
clearance Graduated
〇 〇 〇 〇 〇
between the pedal scale
surface and
Clutch baseplate upon
clutch out
Sound and
operating 〇 〇 〇 〇 〇
condition
Slide and joint 〇 〇 〇 〇 〇
Operation and
looseness of gear 〇 〇 〇 〇
shift lever
Mechanical
gearbox Leakage
〇 〇 〇 〇 〇
inspection
Oil change  

Leakage situation 〇 〇 〇 〇 〇
Oil quantity
inspection or oil 〇 〇  
Hydrodynamic
change
gearbox
Operation and
looseness of gear 〇 〇 〇 〇
shift lever

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Power transmission
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (1,200 (2,400
items contents (8 hours) (200 hours)
(600 hours) hours) hours)
Performance of
control valve and 〇 〇 〇 〇 〇
hydraulic clutch
Inching valve
〇 〇 〇 〇 〇
performance
Idle travel and
movement of 〇 〇 〇 〇 〇
inching pedal

Oil absorbing 
element (Initial 200  
replacement hours)
Leakage
〇 〇 〇 〇 〇
inspection
Front axle Oil change  

Mounting bolts Detecting

〇 〇 〇 〇
looseness hammer

Wheel
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (1,200 (2,400
items contents (8 hours) (200 hours)
(600 hours) hours) hours)
Inflation
Barometer 〇 〇 〇 〇 〇
pressure
Crack or
〇 〇 〇 〇 〇
damage
Depth
Ground wear 〇 〇 〇 〇
gauge
Tire
Abnormal wear 〇 〇 〇 〇 〇
Inspection of
tire for any nail,
stone or other 〇 〇 〇 〇
foreign matters
thereon
Inspection of
Tire Detecting
bolts for 〇 〇 〇 〇 〇
installation hammer
looseness

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Wheel
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (1,200 (2,400
items contents (8 hours) (200 hours)
(600 hours) hours) hours)
Damage
〇 〇 〇 〇 〇
inspection
Rim, spoke and
Rim and
plate wheel 〇 〇 〇 〇 〇
spoke
damage
Inspection for
looseness and 〇 〇 〇 〇
Axle noise
bearing Wiping and
re-filling of  
lubricant
Inspection of
axle body for
Axle 〇 〇 〇 〇
deformation,
crack or damage

Steering system

Three Six months Annual

Inspection Inspection Daily Monthly
Tools months (600 (1,200 (2,400
items contents (8 hours) (200 hours)
hours) hours) hours)
Clearance
〇 〇 〇 〇 〇
inspection
Axial looseness
〇 〇 〇 〇 〇
inspection
Steering
wheel Radial looseness
〇 〇 〇 〇 〇
inspection
Operating
condition 〇 〇 〇 〇 〇
inspection
Inspection of
Steering
mounting bolts 〇 〇 〇 〇
gear
for looseness
Inspection of
master pin for
Rear axle 〇 〇 〇 〇
looseness or
knuckle damage

Inspection for 〇 〇 〇 〇

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bending,
deformation,
crack or damage
Installation Detecting
〇 〇 〇 〇
inspection hammer
Operation
〇 〇 〇 〇 〇
inspection
Inspection for
〇 〇 〇 〇 〇
Steering leakage
cylinder
Inspection for
looseness upon
〇 〇 〇 〇
installation and
hinged joint

Brake system
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (1,200 (2,400
items contents (8 hours) (200 hours)
(600 hours) hours) hours)
Idle travel 〇 〇 〇 〇 〇
Graduated
Pedal travel 〇 〇 〇 〇 〇
scale
Brake Operation
pedal 〇 〇 〇 〇 〇
situation
Inspection of
braking piping for 〇 〇 〇 〇 〇
air existence
Inspection of
brake for safety,
Parking 〇 〇 〇 〇 〇
reliability and
brake adequate travel
control
Control
〇 〇 〇 〇 〇
performance
Control
Lever and 〇 〇 〇 〇
performance
cables, etc.
Looseness 〇 〇 〇 〇
Damage, leakage
〇 〇 〇 〇
and fracture
Piping Connection,
clamping part and 〇 〇 〇 〇
looseness

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Brake system
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (1,200 (2,400
items contents (8 hours) (200 hours)
(600 hours) hours) hours)
Leakage situation 〇 〇 〇 〇
Oil level
inspection and oil 〇 〇 〇  
change
Master cylinder
and wheel 〇
Brake
cylinder action
master
cylinder Master cylinder
and wheel and wheel
〇
cylinder cylinder leakage
and damage
Wear, damage and
replacement of
master cylinder, 
piston cup and
one-way valve
Inspection of
mounting parts of Detecting
〇 〇 〇 〇
brake drum for hammer
looseness
Friction lining Vernier
〇
wear caliper
Brake toe action 〇
Inspection of
Brake fixing pin for 〇
drum and corrosion
brake shoe
Return spring Graduated
〇
damage scale
Inspection of
self-adjustable
device for proper 〇
gap during
operation
Brake drum wear
〇
and damage
Inspection of base
Brake
plate for 〇
base plate
deformation

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Brake system
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (1,200 (2,400
items contents (8 hours) (200 hours)
(600 hours) hours) hours)
Inspection for Flaw
〇
cracking detection
Looseness upon Detecting
〇
installation hammer

Lifting system
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (600 (1,200 (2,400
items contents (8 hours) (200 hours)
hours) hours) hours)
Fork damage,
deformation and 〇 〇 〇 〇 〇
wear
Locating pin
〇 〇 〇
Fork damage and wear
Cracking and
wear at welding
〇 〇 〇 〇
part of hook at
root of fork
Inspection of
internal and
external mast for
cracking and 〇 〇 〇 〇
damage at
welding part with
beam
Inspection of lean
cylinder support
Mast fork for poor welding,
carrier cracking and 〇 〇 〇 〇
damage at
welding part with
mast
Inspection of
internal and
external mast for
〇 〇 〇 〇.
poor welding,
cracking or
damage

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 Operation Manual for Internal Combustion Counterbalance Forklift

Lifting system
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (600 (1,200 (2,400
items contents (8 hours) (200 hours)
hours) hours) hours)
Inspection of fork
carrier for poor
〇 〇 〇 〇
welding, cracking
or operation
Inspection of
roller for 〇 〇 〇 〇
looseness
Wear and damage
of supporting 〇
bearing of mast

Inspection of 〇
supporting cap Detecting (Only for
〇 〇
bolts of mast for hammer the first
looseness time)
Inspection of
lifting oil cylinder
bottom bolts, 〇
piston rod head Detecting (Only for
〇 〇
bolts, U-bolts and hammer the first
guide rail bolts of time)
walking beam for
looseness
Cracking and
damage of roller,
〇 〇 〇 〇
roller shaft and
welding part
Inspection of
chain for
tensioning,
〇 〇 〇 〇 〇
deformation,
damage and
corrosion
Chain and
Chain refueling 〇 〇 〇 〇
chain
wheel Riveting pin and
〇 〇 〇 〇
looseness
Chain wheel
deformation and 〇 〇 〇 〇
damage

Inspection of 〇 〇 〇 〇

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Lifting system
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (600 (1,200 (2,400
items contents (8 hours) (200 hours)
hours) hours) hours)
chain wheel
bearing for
looseness
Inspection for
Attachment 〇 〇 〇 〇
normal status
Inspection of
piston rod, piston
rod thread and
Detecting
connection for 〇 〇 〇 〇 〇
hammer
looseness,
deformation and
damage
Hoisting Operation
cylinder 〇 〇 〇 〇 〇
situation
Leakage situation 〇 〇 〇 〇 〇
Wear and damage
of pin and oil
cylinder 〇 〇 〇 〇
steel-backed
bearing
Inspection of
hydraulic pump
〇 〇 〇 〇 〇
for oil leakage or
Hydraulic noise
pump Inspection of
hydraulic pump
〇 〇 〇 〇
for driving gear
wear

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Hydraulic system
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (600 (1,200 (2,400
items contents (8 hours) (200 hours)
hours) hours) hours)
Oil quantity
inspection and oil 〇 〇 〇 〇 〇
change
Hydraulic
Oil absorbing
oil tank 〇 〇
element clearing
Foreign matters
〇 〇
removal
Return oil Return oil filter
 
filter replacement
Inspection for
connection 〇 〇 〇 〇 〇
Control looseness
valve stem
Operation
〇 〇 〇 〇 〇
situation
Oil leakage 〇 〇 〇 〇 〇
Safety valve and
tilt self-locking 〇 〇 〇 〇
Multi-way
valve operation
valve
Safety valve Oil
pressure pressure 〇 〇
measurement gauge
Leakage,
looseness,
fracture, 〇 〇 〇 〇 〇
Piping joint deformation and
damage

Tube replacement
1-2 years

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Electrical
Three Six months Annual
Inspection Inspection Daily Monthly
Tools months (600 (1,200 (2,400
items contents (8 hours) (200 hours)
hours) hours) hours)
Inspection of
distributor cover 〇 〇 〇
for cracking
Inspection of
spark plug for 〇
ablation
Spark plug gap Plug
〇 〇 〇
adjustment gauge
Spark plug
〇 〇 〇
Ignition clearing
device
Cap and HV line
(gasoline 〇
installation
engine)
Inspection of
distributor for 〇
ablation
Wear and damage
of central part of 〇
distributor
Rotating shaft
〇 〇 〇
lubrication adding
HV line damage Tester 〇
Starting Pinion
〇 〇 〇
motor engagement
Electrolyte
amount and 〇 〇 〇 〇
cleaning
Battery
Inspection of
Hydrome
electrolyte for 〇 〇 〇
ter
specific gravity
Inspection for
harness damage
〇 〇 〇 〇
and jumper
Wire looseness
Circuit
connection 〇 〇 〇
looseness

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Safety device and accessories

Six months Annual
Inspection Inspection Daily Monthly 3 months
Tools (1,200 (2,400
items contents (8 hours) (200 hours) (600 hours)
hours) hours)
Inspection for
Detecting
installation
Overhead hammer
firmness
guard and
load- Inspection for
backrest deformation,
〇 〇 〇 〇 〇
cracking and
damage
Working and
Turning
installation 〇 〇 〇 0 〇
indicator
condition
Working and
Horn installation 〇 〇 〇 〇 〇
condition
Working and
Light and
installation 〇 〇 〇 〇 〇
bulbs
condition
Working and
Back-up
installation 〇 〇 〇 〇 〇
buzzer
condition
Dirt and damage 〇 〇 〇 〇 〇
Rearview
mirror Rear field of
〇 〇 〇 〇 〇
view
Instrument
Instrument working 〇 〇 〇 〇 〇
condition
Inspection of
Seat bolts for damage 〇 〇
or looseness
Inspection of
frame and beam
〇
for damage and
cracking
Body Inspection of
Detecting
rivets and bolts 〇
hammer
for looseness
Inspection of
〇 〇 〇 〇 〇
repaired part, if
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Safety device and accessories

Six months Annual
Inspection Inspection Daily Monthly 3 months
Tools (1,200 (2,400
items contents (8 hours) (200 hours) (600 hours)
hours) hours)
necessary
Overall
〇
inspection
Inspection of
chassis Grease
〇 〇 〇 〇
Greasing or lubrication after gun
oil change cleaning
Inspection oil
〇
fluid in oil tank

Caution

• When the oil, coolant or antifreeze solution that is different from what specified for the equipment is
used, its change period shall be not the same with that stipulated herein. Therefore, the change interval
should be shortened to half or 1/4 of that specified herein.

• Although high viscosity oil is available in wide operating temperature range, it should be changed
frequently. The reason lies in that the additive will deteriorate slowly, resulting in reduced oil viscosity
and severe damage to hydraulic system at high temperature.

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Ⅴ. Other
1. Lubrication system chart

Radiator

Rear wheel bearing Oil pump drive

Cooling water pump Crankcase

Distributor
Hydraulic oil
(for gasoline forklift)
Torque converter oil
(used for torque Steering cylinder
converter type)
Transmission (used Injection pump
for clutch type) (for diesel forklift)

Front wheel bearing Rear pin of tilting

cylinder
Brake Brake fluid
Clutch Pedal
Inching Transmission shaft

Front pin of tilting Mast support cap

cylinder
Differential
Shift control lever

Lifting chain

Grease Engine lubricating oil Brake fluid

Wheel bearing grease Gear oil Torque converter
oil
Cooling water pump Hydraulic oil
grease Clean soft water

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2. Forklift oil

Name Original oil Trademark, designation and operating temperature

Gasoline 93# or 97#
Light diesel
0# -10# -20# -35#
trademark
Diesel
Operating
≥4 ≥-5 ≥-5~-14 ≥-14〜-29
temperature (°C)
Gasoline engine Viscosity grade 5W/30 10W/40 10W/30 15W/40
oil (SF)
Electronic fuel Sinopec Operating
-30〜+30 -25〜+40 -25〜+30 -20〜+40
injection type temperature (°C)
(SG)
Viscosity grade 5W/30 10W/30 15W/40 20W/50
Diesel engine
Sinopec Operating
oil (CD) -30〜+30 -25〜+30 -20〜+40 -15〜+50
temperature (°C)
L-HM32 anti-wear hydraulic L-HV32 low-temperature
Viscosity grade
oil anti-wear hydraulic oil
Hydraulic oil Sinopec
Operating
≥-5 ≥20 (open cold area)
temperature (°C)
Hydraulic
transmission Haipai 6# hydraulic transmission fluid
fluid
Chongqing
Brake fluid 4604 synthetic brake fluid GB12981 HZY4
Yiping
Grease Sinopec 3# general purpose lithium lubricating grease (-20°C - +120°C)
Viscosity grade 85W/90GL-5 80W/90GL-5
Heavy duty
Haipai Operating
vehicle gear oil -15〜+49 -25〜+49
temperature (°C)
Code FD-1 FD-2 FD-2A FD-3
Antifreeze
Jinbai Operating
solution ≥-25 ≥-35 ≥-45 ≥-50
temperature (°C)

Caution

• Sinopec brand products are recommended.

• Do not mix oils of different brands.

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