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CONTENTS
INSTRUMENTS SWITCHES CONTROLS BODY & OTHERS SAFETY INSTRUCTIONS 8 HOURS(DAILY or EVERY SHIFT)CHECK STORING OPERATIONS PREVENTIVE MAINTENANCE SERVICE SCHEDULE 6 10 14 20 28 44 60 64 84
17
2 1 3 15 16 4
14 13 19 18 11
5 6 7 12 8
10 9
1 2 3 4 5 6 7
Outer Mast Inner Mast Lift Chain Lift Cylinder Load Backrest Fork Stopper Carriage
8 Fork 9 Drive Wheel 10 Steer Wheel 11 Fuel Reservoir Cap 12 Hood 13 Tilt Cylinder 14 Driver's Seat
15 16 17 18 19 20
Steering Handwheel Head Light Combination Lamp Overhead Guard Rear Combination Lamp Counter Whight
1 7
1 6
4
1 5
1 4
1 3 1 2
1 0
1 1
(1)Hour Meter (2)Coolant Temp.Gauge (3)Fuel Gauge (4)Parking Brake Lever (5)Forward-Reverse Lever (6)Steering Handwheel (7)Choke Button (Gas.type only) (8)Inching Pedal (9)Light Switch (10)Brake Pedal (11)Accelerator Pedal (12)Tilt Lever (13)Lift Lever (14)Fuse Box (15)Ignition Switch (16)Turn Signal Lever (17)Horn Button
.2.
1 7
1 6
1 5
6 1 3 4 1 2
1 4
1 8
1 0
1 1
1 9
.4.
INSTRUMENTS
3
E F C
2
H
1
E F C H
00 0 0 0
FUEL WATER TEMP FUEL WATER TEMP
00 0 0 0
OIL
CHG
SEDIMENTER
GLOW
OIL
CHG
GLOW
1~3t Forklift
5~10t Forklift
HOUR METER(1)
This meter measures working time of engine.Use meter to schedule lubrication and maintenance periods.
CHG(B)
This lamp indicates the battery conditio n of charge.The lamp comes on when the ignition switch is set at ON ,bu t it goe s out as the engine start s and accelerator pedal in pressed. CAUTION If the light continues to stay lit or lights up during operation, the charging rate is low and should be checked immediately.
OIL(A)
This lamp indicates the pressure co ndition of engine lube oil. Although it lights up when the engine switch is set at O N ,once the engine starts up and th e accelerator pedal is depressed,this lamp goes out.
CAUTION
If this light continues to stay lift or lights during operation, the pressure is insufficient and shouldbe checked immediately.
SEDIMENTOR INDICATOR(C)
(only for to 3 ton forklift truck)
DIESEL TRUCK
This lamp lights up when water in sedimentor reaches to a certain level ,while the engine is running.In normal state,once the starter is setto ON position ,this lamp lights up.After the engine is started up,it goes out. If this lamp continues to stay lit or lights up during the engine running, CAUTION stop the engine and discharge water If the truck is operated when immediately. lamp continues to stay lit,the fuel injetion pump may be damaged.
.6.
CAUTION
If this pointer enters the red range,stop the operation instantly and slow down engine speed to cool the coolant and wait until the pointer goes into the green range.
FUEL GAUGE(3)
When ignition switch is set to the position ON ,the gauge informs operator how much fuel remains in the fuel tank . E mark stands for Empty , F Filled .The pointer enters red zone when the fuel level drops to a 1/8 capacity.
CAUTION
Fill the fuel tank at the end of each workday(or each shift). This practice will reduce the conden sation of moisture within the tank.
.8.
SWITCHES
OFF ON START
15
ON
The electric circuit is closed with the starter switch at ON engine is started,the key is at this position. , After the
START
As the key is placed in the START position,the starter motor is engaged. When removing hand off key,it is automatically returned to the ON position by spring force.
CAUTION
1 Do not keep the starter switch in the ON position while the engine is shut down.This results is a discharged battery. 2 With the engine running,do not turn the starter switch into the START positon,since there is a danger of the starter motor being damaged. 3 Do not keep the starter engaged for more than 15 seconds at a time. Wait about 20 seconds before trying again.
LIGHT SWITCH(9)
This light switch can be pulled out at two steps
.10.
Stage O (OFF) Light Clearance & OFF Parking light Tail light Number plate Light Head light OFF OFF OFF
1st ON ON ON ON
2st ON ON ON ON
CAUTION
The above lights are turned on or off by the light switch regardless of starter switch position.
L
1 7 1 6
HORN BUTTON(17)
Press the rubber cover at ghe center of steering wheel to sound horn.The horn sounds even when the key switch is OFF.
R
R N l
CAUTION
The turn signal lever does not automatically return to the Neutral position unlike general pa ss en ge r cars.Reset it by hand.
.12.
CONTROLS
STEERING HANDWHEEL(6)
The steering handwheel is operated in the conventional manner,that is,when the wheel is turned right the truck will turn to the right;when the wheel is turned left, the truck will turn to the left.The steer wheels are located at the rear of the truck.These cause the rear of the truck to swing out when a turn is made.with a little practice, this type teering will be easily mastered.
WARING
This truck is provided with the power steering, so heavy handwheel operation is caused when the engine comes to a stall.To put th e power steering in operation again, restart the engine without delay
13
13
LIFT LEVER(13)
The forks can be raised or lowered by pulling backwards or pushing forwards on this lever.The lift speed is controlled by tilt angle of the lever and accelerato r pedal effort.The lowering speed can be controlled by tilt angle of the lever.The engine speed ,or accelerator pedal does not have to do with the lowering speed of the forks.
TILT LEVER(12)
The mast can be tilted by operation of this tilt lever.Pulling on this lever backwards will tilt the mast backwards,and pushing it forwards will tilt the mast farwards.The tilt speed can be controlled by tilt angle of the lever and accelerat or pedal effort.
CAUTION
The tilt lock mechanism built in the hydraulic circuit does not allow the mast to tilt forwards while the engine is being shut down eve if the tilt lever is pushed forwards
.14.
WARNIIG
If parking on a grade is unavoidable,be sure to block the wheels.
The transmission control is a floor boardmounted.ype and has two speeds at forward and reverse travel respectively. Before gearshifting, be sure to press the clutch pedal to the full. Always brake to a full stop before reversing the direction of travel. Shifting the lever in reverse turns on the back-up lights.
1
N N
R
2
N
R
The transmission control is a steering .column-mounted type and has one speed at forward and reverse respectively.Always brake to a full stop before reversing the direction of travel.Shifting the lever in reverse turns on the back-up lights.
CAUTION
The neutral switch is equipped.Do not fail to place the for ward-reverse lever in the neutral position before starting the engine.
.16.
FOOT CONTROLS
See the right photo:Clutch pedal or inching pedal(left),brake pedal(center), and accelerator pedal(right).
1 0 1 8 8
1 1
CAUTION
Do not run the lift truck with the clutch in a halfclutch condition as much as possible.
ACCELERATOR PEDAL(11)
The accelerator pedal increases the engine speed.With this pedal released, the engine runs at idle rpm.
BRAKE PEDAL(10)
Press this brake pedal to slow or stop the truck.At the same time,t he brake lights come on.
.18.
BODY&OTHERS
SEATADJUSTING LEVER
SEAT
An operator-oriented operator's seat is equipped.
OVERHEAD GUARD
The overhead guard used is strong enough to meet safety standard,and protects the operator from falling materials.
HOOD
The hood can be swung up fully to provide easy maintenance service. To swing up the hood,lift upward on the arrowed hood lock lever and the hood can be lifted u p with little effort with an aid of hood damper. To lock the hood,push down on the front of hooduntil it locks.
WARNLNG
Use caution not to catch your fingers in the hood when closing it.
.20.
DAMPER
FORK STOPPER
Fork stoppers are lock the forks in position. To adjust forst spacing, pull up fork stoppers, turn, and shift the forks to the desired positions. The fork spacing should be adjusted according to loads to be handled.
WARNING
The forks should be set symmetrically to machine centerline and fork stoppers should always be se t.
FUSH BOX(14)
The fuse box is located at the right side of the cabinet inner surface.
.22.
CAUTION
The fuel reservoir cap has the breather inside it to allow air to enter into the reservoir. If the breather is damaged or clogged, the fuel system will get troubled. Check to see that the breather is in good condition every time addition of fuel is made. FUEL HANDLING Stop the truck, shut down the engine and apply the parking brake securely. Make sure t hat there i s no naked flame near the area. Never smoke. The driver should not remain seated when adding fuel. After addition of fuel is finished, securely close the reservoir cap. A loose cap could cause fuel leak or fire hazard in the worst case. Before attempting to start the engine, make certain that the fuel reservoir cap is securely tightened and that no fuel is spilt on or around the truck. For the purpose of fuel level inspection, never use naked flame such as a match or lighter.
WARNING
RADIATOR CAP
The radiator cap is located under the cover plate at the rear of the hood. At daily maintenance, you need not remove the radiator cap.
FULL
LOW
WARNING
Do not remove the radiator cap abruptly while the engine is hot. Turn the cap a little to the left to relieve the pressure in the radiator, then remove the cap. Do not wear glove when removing radiator cap.
.24.
FRONT LIGHTS(B)(C)
Two head lights(B)and combination lights (C)(turn signal, parking & clearance) are Installed at the front side of the truck. Take care of the lights, and wipe dirt, if any, and replace any damaged light immediately.
.26.
SAFETY INSTRUCTIONS
Safety is your business and your responsibility. The SAFETY INSTRUCTIONS covers basic safety procedures and warning of general application to the typical forklift truck. However, safety precautions given on the following pages are also applicable to lift trucks that have special specifications or attachments. Read this manual thoroughly and become completely familiar with your truck to get ghe most out of it.
<GENERAL DESCRIPTION>
LI EC N SE
.28.
7.MOUNT PROPERLY
Never mount of dismount the moving truc k, Use the safety step(s)and safety grip facin g the truck when mounting or dismounting the truck.
9.START SAFELY
Before starting up,make sure that: the parking brake lever is applied securely. the for ward-reverse lever is in neutral. Before starting,make sure no one is under,on and close to the truck.
.30.
10.PARKING PROPERLY
Park the truck on a level surface and apply the parking brake securely. If parking on a grade is unavoidable, be sure to block the wheels. Put the forks on the ground or floor and tilt a little forwar ds. Sh ut down the engine and remove the key.
<DURING OPERATION>
15.DON'T DAYDREAM
Keep your mind on your work. Learn to anticipate danger before it arises.
.32.
17.REMAIN SEATED
Keep your head, hands, arms, feet and legs within the confines of the operator's compartment, Never.
Stop!
.34.
28.STOP,THEN BACK UP
Always brake to a full stop before reversing direction of travel.
29.PRECAUTIONS ON GRADE
When running down on a grade,use engine brake.While using engine brake, don't operate directional and speed control levers.If the truck exceeds the gear speed range,use the brake pedal.
.36.
30.BACK DOWN&DRIVE UP
When operating loaded truck, have the rear end of your machine pointed down-hill.When climbing grades, use forwrd gears, and when descending, use reverse gears. Never turn sideways on an incl ine. There is danger of the truck turning over.
.38.
When workin g the truck w ith a side shift or an attachment for longsized load such as spreader, pole carrier, wide finger bar, hinged fork or logger, be especially careful of load deflection.(The center of gravity of the load should be aligned with the center of the truck as much as possible.)
45.PROTECT YOURSELF
Wear all the protective clothing and personal safety gear devices called for by job conditions, suth as a helmet, safety shoes, reflective clothing, etc. Don't wear a necktie or pendant for your safety sake.
46.DECALS
Markings(Decals)on the machine describe warning and methods to operate the lift truck. When operating the machine, observe and follow all markings on the machine in addition to this operator's manual. Replace damaged or missing decals.
.42.
WARNING
Don't attempt to operate the truck if leaked fuel is found through preoperational check .Correct the leak before starting engine.
.44.
Check condition of tires. Low air pressure reduces tire service l ife and increase fuel consumption . Uneveness of air pressure between right and left tires or unevenly worn or badly damaged tires will cause uneven steer ing fo rces.
Underinflation
Good
Overinflation
The standard tire pressures are indicated on the decal at the front left side of the hood. Turn the tire valve cap counter clock wise and remove it. Using a tire pressure gauge, measure the inflation pressure, and adjust it to the specified pressure, if needed. After making sure there is no air leakage from the tire valve, reinstall the cap. Check that each tire does not get damaged at the tread surf ace or side face or bending at the rim. Since the forklift truck needs tires that have a high inflation pressure to carry heavy loads, even a small bending of rims or damag e at t he tre ad surface could cause an accident.
WARNING
All nuts and bolts should be properly installed and torqued before inflating tire and rim assembly. An inflated tire contains potentially explosive energy. DON'T OVER INFLATE.
WARNING
When using an air compressor, first adjust the air pressure of the compressor. Failure to do so will cause a serious accident, since the compressor delivers the maximum pressure.
and
.46.
DANGER
Never allow flame or sparks near the battery filler holes because explosive hydrogen gas may be present.
WARNING
Use extreme care when removing the radiator pressure cap.In pre ssure system,the sudden re lease of pressure can cause a steam flash which would cause a se rious personal injury,Loosen cap slowly to allow steam to eacape. After that,tighten cap securely,It is good practice to use thick wast e cloth or the like when removing the cap.Avoid putting on gloves,since you may get burnt at your hand if hot water splashes on it .
.48.
Check the fan belts for correct tension and damage. Pushed the midway between the water pump pulley and the generator pulley by the thumb.
CAUTION
The oil level check should be done with engine shut down, fo rks on the ground or floor, and the truck itself on a level surface.
.50.
(18)SHIFT LEVER(S)CHECK
Check the shift lever(s)for looseness and operation.
.52.
(28)MAST OPERATION
Sound hom, and actuate the lift and tilt levers to be certain that the carriage moves up and down properly and the mast can be tilted smoothly. Make certain that the relief valve operates accompanying its relieving sound when each cylinder piston reaches the stroke end .Pay attention to system operating sound.
CAUTION
A B
.54.
DANGER
Echaust fumes are very dangerous.When starting the lift truck in enclosed space,make sure there is enough ventilation.The exhaust gas check should be done outdoors.Especially use caution to avoid fire hazards.Pay special attention to signs of oil orfuel leaks and never leave waste cloth or paper inside the engin e room.Make sure you know where the fire extinguishers are kept and how to use them.
(33)BRAKE TEST
Run the truck slowly and press the brake pedal to check the braking effect. When the brake pedal is pressed, the stop lamp comes on.
(34)STEERING CHECK
Turn the steering wheel traveling slowly to see that the steering forces ate equal in right and left or that any abnormality does not exist.
AIR-BLEEDING PROCEDURE
Stop the engine and loosen the bleed plug(C)on the injection pump. Press the priming pu mp until fu el coming through the bleed pulg contains no bubble. Fasten the bleed plug to confirm that there is no fuel leakage from the plug screw.
.58.
WARNING
If at any time your lift truck is found to be in need of repair, defective, or in any way uns afe,the con dition shou ld be reported to the supervisor, and the truck should be taken out of service until it has been resored to safe operating condition.
DAILY STORAGE
Park the lift truck at a specified place and block the wheels. Place theshift lever(s)in the neutral position and apply the parking brake securely Shut down the engine by placing the key switch in OFF position. Actuate each loading lever several times to remove the residual pressure in the respective cylinders and hoses. Remove the key and keep it sure.
.62.
OPERATIONS
To operate the truck safely and get the most out of it,we describe the correct operating proce-dures on the following pages.
DURING BREAK-IN
We recommend to operate the machine under light load conditions for the first stage of operation to get the most from it. Especially the require ments given below should be observed while the machine is in a stage of 100 hours of operation. Always warm up your machine before putting it to work irrespective of season. Perform specified preventive maintenance services carefully and completely. Avoid sudden stop, starts or turns. Oil chnges and lubrication are recommended to do earlier than specified. Don't run engine at high rpm without load need lessly.
160
140
120
100
80
50
LOAD CENTER cm
kg
6TY20-00-12
CAPACITY
1000
.64.
WARNING
If at truck is equipped with a load-handling attachment such as a side shifter,load grab or rotating clamp,its allowable load is reduced as compared with that of a standard truck(without any attachment)due to the following reasons. 1)The load equal to the weight of attachment is reduced 2)Since the width of attachment causes the load center to move forward the allowable load is reduced on the same principle as a seesaw. The installation of attachment causes the load center to mo ve forware, which is called lost load center Never exceed the allowable load indicated on the load chart attached onto the truck or attachment.
300 mm
In addition,the lift truck should be put in a good servicing condition to do the job safely.
WARNING
Use minimun forward and reverse tilt when stacking and unstacking loads.Never tilt forware unless load is over stable stack or rigid rack or at low lift height.
.66.
Check the safety around the machine. If water,grease or soil is sticking to the floor,pedals levers or operator's hands,clean it off. Make sure that the shift lever(s)and loading levers are in NEUTRAL and HOLD positions and that the parking brake lever is fully engaged.
WARM ENGINE
Do not pull out the choke button.Press down the accelerator pedal halfway and hold.Crank the engine by turning the ignition key to START .Release key when engine starts.
CAUTION
Do not press down the accelerator pedal fully when starting warm engine This operation may harden the engine starting.Pressing down the accele rator pedal several times will cause harder starting .
.68.
Check the safety around the machine and give a signal when starting the machine.
[CLUTCH TYPE]
Depress the clutch pedal and engage the shift levers. Release the parking brake Lever.
Gradually release the clutch pedal while depressing the accelerator pedal to start the machine.
CAUTION
Do not rest your foot on the clutch pedal while you are driving.
Release brake pedal and depress the acelerator pedal to start the machine.
.70.
WARNING
You must slow down at aisle intersections in crowded ares on rough ground or floor surfaces. when approaching loads or obstacles.
GEARSHIFTING
Without loads, the truck can start even with gears in high speed, However, under loaded condition, Place the grea in low speed to start the truck.
STEERING
Nlike general passenger-cars,the steer wheels are located at the rear of the truck, These cause the rear of the truck to swing out when a turn is made. Slow down the truck and move toward the side to whi ch you are turning. The steer handwheel should be turned a bit earlier than as with the front wheel steering car.
CAUTION
Never stop the truck in ascending on a grade by pressing the accelerator pedal with the clutch in half-clutch and torque converter i n operaiton This will cause undue wear of clutch plates and abnormal rise of torque converter oil temperature, resulting in short life of clutch or torque converter.
.72.
To park the truck: Park the truck ina out-of-traffic area and...
1)Apply the parking brake by pulling up on the parking brake lever. 2)Down the forks on the ground. 3)Place the key switch in OFF to shut down the engine. In the case of the diesel truck, pull out the engine stop button. 4)Remove the key and keep it.
WARNING
(1)Check for slippery steps and floor. (2)Don't dismount from the moving machine. (3)Never jump off the machine.
GROUND CONDITION
Lift truck performance depends on the ground or floor conditions and travel speed should be ajusted properly.Use extreme care when operating on a ramp or rough ground or floor.
WARNING
(1) When crossing the railroad, be sure bo once stop and make sure to be safe. (2)Go around rocks and stumps. If unavoided, reduce speed and go slowly and carefully. Use caution not to damage the bottom of the truck.
WARNING
When equipped with tire chains, the truck get a larger driving power. However, sideway antislip performance is almost reduced so extreme care should be used .
PLCK UP
1.The forks should be adjusted sidewise to maintain proper balance of load. 2.Place the machine right in front of the load to be handled. 3.The pallet should be evenly positioned across both forks. 4.Insert forks into the pallet as far as possible.
.74.
5.To raise loads from the ground (1)Once lift the forks 5 to 10 cm off the ground or floor a nd make su re loads rest stably. (2)Then,tilt the mast backwards fully and lift forks up to 15 to 20 cm off ground then start running. 6.When handling bulky loads which restrict your visio n, operate t he truck in reverse except when climbing grades.
STACKING LOAD
1.When approaching the deposit area slow down your truck. 2.Once stop the truck right in front of the area where your load is to be deposited. 3.Check the condition of the deposit position. 4.Tilt the ma st forward until forks become orizontal. Raise forks until they are a little higher than the deposit position. 5.Move forward to place the load directly over the desired ar ea and sto p the truck. 6.Make sure your load is just over the desired area Slowl y lower the load into position. Make sure the load is securely stacked. 7.Disengage forks from the load by using necessary lift-tilt opeation and then back away. 8.After making sure the fork tips leave the load,lower the forks to the basic position (15 to 20 cm off the ground) 9.Tilt the mast backward.
WARNING
Never tilt the mast with loads upraised 2m or more. Don't leave or dismount from the truck when the load is raised hith.
UNSTACKING LOAD
1)When approaching the area where the load is to be retrieved ,slow down your truck. 2)Stop the truck in front of the load so that dis tance betw een the loa d and fork tips is about 30 cm. 3)Check the condition of the load. 4)Tilt the mast forward until forks become horizontal. Elevate forks up to the position of the pallet or skid. 5)Make sure f orks are posi tioned properly for the pallet. Move forward slowly to insert forks into the pallet as far as possible and then stop the truck. *If the forks are hard to be fully inserted, use the following procedure:Move forward and insert 3/4 of the forks. Raise the forks 5 to 10 cm and move backward 10 to 20 cm with the pallet or skid on the forks, then lower the pallet or skid on the stack. Move forward again to insert the forks fully. 6 Raise the forks 5 to 10 cm off the stack. 7)Check all around the truck to insure that the path of travel is unobstructed and back away slowly. 8)Lower forks to a height of 15 to 20 cm above the ground. Tilt the mast backward fully and move to the desired area.
In Hot Weather
As the water of electrolyte is especially likely to evaporate in hot weather, replenish distilled water from time to time. Check the battery once a week, and supply distilled water. In a regio n where the ambient temperature is intensely hot, it is practicable to lower the specified gravity of a completely charged battery down to 1.220 0.01. Since the battery is better in efficiency under hot temperatures, no other cares are needed.
DANGER
GASES produced by the battery can be explosive. Do not smoke, use an open flame, create an arc or sparks in the vicinty of the battery. Ventilate well when in an enclosed space and when charging The battery contains SUI PHURIC ACID which causes severe burns. Do not get in eyes, on skin or clothing. In case of contact, flush immediately and thoroughly with cle an water, Obtain medical attention when eyes are affected.
RADIATOR COOLANT
Your lift truck is generally shipped with the cooling system filled with Loog life coolant(LIC)of 50% volumetric mixture.The freezing point of the coolant of such a mixing ratio is -35 . In Hot Weather :To maintain good cooling effect,special care should be paid to radiator and cooling system.Parking in the shade is recommended.
REPLACING FUSE
The fuse protects the electric system against overcurrent. Use the specific ampere rating of fuse. Check to see that the component s in each circuit ar e operating properly. If every component in a circuit is not functioning, it is an indication that the corresponding fuse is blown out. Replace the blown fuse with a spare fuse of the same capacity. If a part of the components in the circuit does not function properly, it is suspected that a bulb has burnt out. The burnt bulb should be replaced with new one of the same capacity.
B 1 B 5 4 B 2 B B 3 6 B
.78.
Front Wheel
Stop the truck on a level, hard surface and shut down the engine. All loads should be unloaded from the truck. Apply the parking brake and block the wheels. Put the jack under the truck frame. Jack up the truck to the extent that the tire still remains on the ground. Loosen the hub nuts. Do not remove them. Again jack up the truck until the tire leave s off the gr ound, Remov e the hub nuts, and detach the wheel. The wheel should be reinstalled in the reverse order: The hub nuts should be tightened in the diagonal order evenly. After reinstallation, check the tire for proper inflation pressure. The inflation pressure 7kg/cm2
Rear Wheel
Use the same manner as with the front wheel tire repair or replacement except for the position of t he jack which goes und er the counter weight. Tire inflation pressure 7kg/cm2
LIFTING PROCEDURE
2
Safety cage
FRONT SIDE(I)
1.Place chocks behind rear wheels. 2.Lift or jack up the outer mast with a hoist or jack. 3.Place wooden blocks under both side frames. Gradually lower. the front end to the ground. Be careful not to dislocate blocks while lowering.
FRONT SIDE(II)
1. Place chocks behind rear wheels 2. Tilt the mast fully backward and put wooden blocks and steel plates under the outer mast as illustrated. 3. Tilt the mast forward to a vertical postiton, and place wooden blocks under both side frames.
REAR SIDE
1.Place chocks in front of front wheels. 2.Jack up or lift the counterweight with a hoist. 3.Place wooden blocks under both side f rames. Also place blocks under the counterweight for safety. Gradually lower the rear end to the ground. Be careful not to dislocate blocks while lowering.
2
1 3 2
.80.
After supporting the lift truck with blocks, push and pull it from all directions to make sure it is securely blocked.
WARNING
Do not work on or under any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.
.82.
ENGINE
Checking ltem Engine service Required Visually inspect condition of engine rotation Check for working noise from engine Check that exhaust gas has proper-color Check air cleaner element for dirt and clean Check crankcase air breather for dirt and clean (C240 Diesel) Check that valve clearance is correct Retighten cylinder head bolt Thickness gauge Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
Torque wrench
Check cylinders Compression fro proper gauge compression Check metering valve and pipe for clogging or damage(G)
PCV Device
.84.
ENGINE
Checking ltem service Required Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (1200hrs) (2400hrs) (600hrs)
Lubrication Check for engine oil leak. System Check engine oil for level and dirt Replace engine oil Replce engine oil filter cartridge Fuel System
Visually check for fuel leak from pice,pump or tank.
Check fuel filter for clogging Clean fuel filter(G) Replace fuel filter cartridge(D) Check that injection nozzle has correct Inject press and pattern(D) Check carbureter link mechanisn for looseness or dirt(G) Check for ignition timing (G) Check for injection timing(D) Drain off water from fuel tank Clean fuel tank Check for fuel level
O(H20)
O(H20) (A15&H20)
.86.
ENGINE
Checking ltem Cooling System service Required Check for coolant level. Check for coolant leak. Check hoses for deterioration. Check radiator cap for contition and installation Clean and change coolant. Check fan belt for tension anddamage Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
POWER TRAIN
Checking ltem Frictional Clutch service Required Check clutch pedal for free travel and clearance between pedal surface and floor when clutch is unlocked Check for noise and operation Check for slipping and engagement Transmission Check change lever for operation and looseness Check for oil leaks Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
Change oil
.88.
POWER TRAIN
Checking ltem service Required Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
Cleck for Torque oil leaks converter Transmis- Check for oil sion level,or change oil Check change lever for operation and looseness. Check control valve and clutch for proper operation. Check inching valve for proper operation Check inching pedal for free travel and pedal travel. Replace line filter element. Front Axle Check for oil leak Change oil Check mounting bolts for Test hammer looseness (at intial 200 hrs)
WHEELS
Checking ltem Tires service Required Check for inflation pressure. Check for chracks or damage. Check for tread wear. Check for undue wear. Check for spikes,stones.or foreigh matter. Depth gauge Tools Tire gauge Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
.90.
WHEELS
Checking ltem service Required Check for looseness. Check for damage. Check rim,side ring and disk wheel for damage. Check for looseness and noise. Clean and repack grease. Cleck axle for deformation, cracks or damage. Tools Test hammer Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
Tire Fastners
Rim.Side ring
Wheel Bearing
Axle
STEERING SYSTEM
Checking ltem service Required Check for per -ipheral play. Check for ver -ticallooseness. Steer Handwheel Check for
sideways looseness. Check for proper operation.
Tools
Daily (8hrs)
Monthly (200hrs)
Check mounting bolts for looseness. Check king pins for looseness or damage. Check for deflection, derormation, cracks or damage. Check for mo- Test uting condition. hammer Check for operation. Check for oil leaks. Check for mounting parts and joints for looseness.
Power Steering
.92.
Checking ltem
service Required
Tools
Daily (8hrs)
Monthly (200hrs)
Brake pedal
Check for free travel Check for pedal travel Scale Check for proper operation Check for air rnixed in brake piping Check that lever is scurely locked and has sufficient lever stroke. Check for proper operation Check for operation
Check connections for looseness.
Rod,Cable etc
Check master cylinderpiston cup,and check valve for wear or damage. Change
Check drum Test mouting part hammer for looseness Check lining Slide calipers for wear. Brake Drum& Brake Shoe
Check brake shoes for proper operation
Check anchor pin for rust Check return spring for deterioration Check automa -tic clearance adjuster for operation Check drum for wear or damage. Scale
.94.
BRAKE SYSTEM
Checking ltem Back Plate service Required
Check back plate for deformation
Tools
Daily (8hrs)
Monthly (200hrs)
Penetrant test
LOADING SYSTEM
Checking ltem Fork service Required
Check forks for damage,deforma -tion or wear Check for stopper pins for damage or wear
Tools
Daily (8hrs)
Monthly (200hrs)
Check fork base and hook weldings for defective cracks or wear. Mast & Lift Bracket
Check cross me -mbers on outer and inner masts for defective weld,cracks or damage.
Check tilt cylin -der bracket and mast for defective weld,cracks or damage. Check outer and inner masts for defective weld, cracksordamage. Check for defective weld, cracks or damage of lift bracket.
Check roller bearings for looseness.
Check mast support bushings for wear or damage. Check mast s- Test upport bolts for looseness. hammer Check lift cylinder tail bolts,piston rod head bolts Test Ubolts,and hammer piston head guide bolts for loosecess. Check rollers, roller pins and welded parts for craks or damage
.96.
LOADING SYSTEM
Checking ltem service Required Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
Check Chains Chains & for tension, deformation , Sheave damage or rust Iubrication of chains Check connection of chain anchor pin and chain for looseness. Check sheaves for deformation or damage. Check sheave bearings for looseness. genOptional Perform inspecAttachment eral tion Check piston rod,rod screw Cylinders and rod end for Test looseness,de- hammer formation or damage.
Check cylindes for proper operation
Check hydraulic pump for oil leaks or Hydraulic noise Pump Check pump drive gear fo wear.
HYDRAULC SYSTEM
service Tools Required Check for Hydraulic oil level. Reservoir Change oil. Clean suction strainer Drain foreign matter. Replace return filter. levers Return Check for looseness Filter at link. Check levers for looseness Control at link. Check for Lever proper operation. Checking ltem Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (1200hrs) (2400hrs) (600hrs)
.98.
HYDRAULC SYSTEM
Checking ltem service Required Check for oil leaks. Control Vale
Check relief valve and tilt lock valve for proper operation.
Tools
Daily (8hrs)
Monthly (200hrs)
Measure rel- Oil prief pressure. es gauge Check for oil leaks,loosenHose,pi- ess,collapse, ping Hose deformation Reel & S- and damage wivel Joint Change hoses. 1or2 years
ELECTRICALS
Checking ltem Ignition Device (for gasoline truck) service Required Check distributor cap for crack. Check spark plug for burn. Adjust spark plug clearance Clean spark plug Check distri -butor cap highvoltage cord for installation. Check distri -butor segm -ent for burn. Check distributor center piece for wear or damage Apply grease on shaft,cam heel and breakr fulcrum. Check highvoltage cord for breakage. Plug gap gause Tools Daily (8hrs) Monthly (200hrs) Trimonthly Semiannually Annually (600hrs) (1200hrs) (2400hrs)
Tester
.100.
ELECTRICALS
Checking ltem Starter service Required Check pinion gear for correct engagement
Check battery electrolyte level. Clean battery.
Check specific gravity of el- Hydrometer ectrolyte Check wire ha -rness for dam -age andclamps for looseness.
Tools
Daily (8hrs)
Monthly (200hrs)
Battery
Wiring
Test hammer
Check for prBuck-up oper operation and tight inBuzzer stallation. Check for dirt or damage Check for good field of vision. Check meters for proper operation.
Meters
.102.
Body
After cleaning, check for grea- Grease Grease-up sed condition pump of chassis. & Oil Check oil coChange
ndition of oil and fluid in reservoir
CAUTION
Local refined oils and cooling water,coolant.or anti-freeze do not allow the same operation period desingnated in this manual.So must be changed more frequently as half or quarter o f the desi gnated period in this manual. Multi-visco sity oils allow a wider temperature range for operation but must be changed m ore frequen tly as the addition that provides the multi-viscosity gradually deteriorates lowering the viscosity.Degradation of viscosity at the higher temperatures can be very detrimental to the hydraulic system.
.104.
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