Safety:
Comprehensive safety rules, decal locations and descriptions, tipover prevention and survival, operator precautions, LP-Gas safety
Vehicle Identification:
Serial number plate, capacity plate, model views
Controls Operation:
Driving switches, controls (direction lever, turn signal, key switch, steering tilt, inching pedal), meter panel (warning lights, indicators, display), operating controls (lift, tilt levers), operator seat features, seat belt, engine hood, drawbar pin (option)
Stability And Handling:
Forklift truck stability principles, center of gravity, capacity, load center, tipover avoidance, tipover survival, stacking methods, load handling techniques, fork spread adjustment
Fueling:
Refueling procedures for gasoline, diesel, and LP-Gas equipped trucks, dual-fuel changeover instructions
Engine Operation:
Starting procedures (gasoline, LP-Gas, diesel), engine won't start troubleshooting (flooded engine, long idle), after starting procedures, before moving, engine break-in
Driving And Steering:
Forklift truck operation, changing speed, changing direction, operating techniques, steering, inching
Stopping And Parking:
Stopping procedures, parking procedures
Grade Operation:
Working on grades, normal travel position, traveling on a grade, stopping on a grade, starting on a grade
Storage:
End of shift storage, long-term storage (within 3 months, exceeding 3 months)
Transportation:
Loading and shipping, lifting and tiedown information
Special Situations:
Care in cold weather (fuels, lubricants, battery, coolant), care in hot weather (fuels, lubricants, battery, coolant), severe dust/lint conditions (air cleaner, engine oil, hydraulic oil, hydraulic filters)
Troubleshooting:
Tire blowouts, changing tires, stalled engine, warning lamp identification, LP-Gas equipment issues, starting with jumper cables, lamp and fuse checks, directional control issues, mast movement problems
Maintenance Schedule:
Detailed schedules based on service hours/days/weeks/months/years: Every 10 hours/daily, Every 50 hours/weekly, Every 200 hours/1 month, Every 500 hours/3 months, Every 1000 hours/6 months, Every 2000 hours/1 year
Preventive Maintenance Checks:
Daily (pre-start) checks: Fuel cap, tires, wheel nuts, tire pressure, lamps, assist grip, overhead guard, mast, forks, load backrest, lift chains, lift bracket, cylinders, battery, coolant, engine oil, fan, transmission, wiring, hydraulic oil, seat, steering, horn, brakes, pedals, seat belt, fuel level, meter panel, engine condition, mast strips, clutch. Also checks for leaks and faulty operation.
Specific Maintenance Tasks:
Brake hoses/pipes, fan/alternator belts, hydraulic hoses/pipes, air cleaner element, radiator cap/hose, alternator, starter, cylinder head bolts, intake/exhaust valves, engine oil, chassis bolts/nuts, fuel filters (diesel, gasoline, LP-Gas), hydraulic tank return filter, mast support, king pins, tie rod pins, differential, vaporizer, spark plugs, rear axle mounting bushes, radiator fins, engine idle speed, transmission service, brake fluid, engine coolant, hydraulic oil.
Service Data:
Fuel specifications (gasoline, diesel, LP-Gas), coolant specifications, recommended fuels and oils, standard model specifications, refill capacities, forklift truck weights
Parts And Service:
Importance of genuine parts, instructions for ordering parts, service registration
Operation:
Step-by-step instructions for daily operation, starting, stopping, traveling, loading, unloading, and special condition operation.
Maintenance:
Detailed preventive maintenance schedules and specific maintenance tasks for all major systems.
Troubleshooting:
Diagnostic guides for common operational problems and component failures.
Safety Training:
Essential safety rules, warnings, and procedures for safe forklift operation.
Refueling And Fuel Management:
Correct procedures for refueling all engine types and managing fuel changeover for dual-fuel models.
Storage And Transport:
Guidelines for proper storage and safe transportation of the forklift.
Depth:
Comprehensive coverage from basic operation and daily checks to detailed maintenance schedules, troubleshooting, and fluid/specification data.
Diagnostic Capability:
Provides information to diagnose and address common malfunctions, though detailed component-level repair procedures are implied rather than explicitly detailed as a full service manual.
Repair Level:
Focuses on maintenance and operational troubleshooting; advanced mechanical or electrical repair procedures may require a separate workshop manual.
Daily Checks:
Every 10 Service Hours or Daily (Pre-Start): Covers a wide range of visual and functional checks on fluids, tires, controls, mast, forks, chains, brakes, battery, etc.
Weekly Checks:
Every 50 Service Hours or Weekly: Includes checks on belts, hoses, pipes, and air cleaner element.
Monthly Checks:
One Month (30 days) or 200 Service Hours: Covers radiator, alternator, starter, engine bolts, valve checks, engine oil change, chassis bolt torque, fuel filters, mast support, kingpins, tie rod pins.
3 Month Checks:
Every 500 Service Hours or 3 Months: Includes radiator fins, battery service, engine idle speed adjustment, engine oil change, chassis bolt torque, vaporizer cleaning, spark plugs, lift chains, mast support, differential service.
6 Month Checks:
Every 1000 Service Hours or 6 Months: Covers alternator, starter, engine bolts, fuel filters, hydraulic system checks, air cleaner, powershift transmission, differential.
Annual Checks:
Every 2000 Service Hours or 1 Year: Includes replacement of service brake fluid, engine coolant, LP-Gas fuel filter, and hydraulic oil. Also lists other parts for periodic change.
Engine Oil:
Specifications for recommended engine oils are provided in the 'Service Data' section, likely multi-viscosity industrial oils meeting specific API classifications. Capacities will vary by engine.
Hydraulic Oil:
Specifications for recommended hydraulic oils are provided in the 'Service Data' section, typically AW hydraulic fluid meeting ISO VG standards. Capacity not specified in description but found in 'Service Data'.
Transmission Fluid:
Specifications for transmission fluid (likely for Powershift) will be in 'Service Data'. Capacity not specified in description but found in 'Service Data'.
Coolant:
Engine coolant specifications, including water and antifreeze solution ratios, are detailed in 'Service Data'.
Brake Fluid:
Specifications for service brake fluid are provided in 'Service Data', typically DOT 3 or similar. Capacity not specified in description but found in 'Service Data'.
Fuel Types:
Detailed specifications for Gasoline (Gas), Diesel Fuel, and Liquefied Petroleum (LP-Gas) are provided in 'Service Data'.
Common Problems Addressed In Manual:
Stalled engines, warning lamps illuminating, LP-Gas equipment trouble, difficulty changing direction, mast not moving, tire blowouts, starting issues.
Preventive Measures For Issues:
The detailed maintenance schedules and pre-start checks are designed to prevent many common issues by ensuring components are in good condition and fluids are at proper levels.
