|
Manual Coverage
|
|
Systems Covered
|
|
Engine Systems:
|
Engine overhaul, fuel system, ignition system (if applicable for diesel), cooling system, lubrication system, exhaust system.
|
|
Transmission Systems:
|
Automatic transmission (e.g., torque converter type), hydraulic transmission control, clutch system, drive axle.
|
|
Hydraulic Systems:
|
Hydraulic pump, control valve, lift/tilt cylinders, power steering system, hydraulic fluid specifications and maintenance.
|
|
Electrical Systems:
|
Wiring diagrams, starter motor, alternator, battery, lighting, instrument panel, safety interlocks, diagnostic codes.
|
|
Chassis And Steering:
|
Frame, steering mechanism, front axle, rear axle, suspension components.
|
|
Braking Systems:
|
Brake system operation, brake linings, hydraulic brake components, parking brake.
|
|
Safety Systems
|
|
Safety Features Coverage:
|
Operator presence system, load capacity information, mast safety interlocks, operator restraint systems.
|
|
Procedures Included
|
|
Maintenance Procedures:
|
Scheduled maintenance intervals, lubrication points and schedules, filter replacement, fluid checks and changes.
|
|
Diagnostic Procedures:
|
Troubleshooting guides for common and uncommon faults, diagnostic trouble codes (DTCs) and their meanings, systematic fault finding.
|
|
Repair Procedures:
|
Step-by-step disassembly and reassembly instructions for all major components (engine, transmission, hydraulics, mast, etc.), torque specifications for fasteners.
|
|
Overhaul Procedures:
|
Detailed instructions for rebuilding major assemblies, including engine, transmission, and hydraulic pump.
|
|
Component Replacement:
|
Guidance on replacing wear items such as filters, seals, bearings, and specific forklift components.
|
|
Technical Depth
|
|
Technical Depth Level:
|
In-depth, covering from routine maintenance to complete engine and transmission overhauls, including electrical diagnostics.
|
|
Safety Features
|
|
Ratings
|
|
Safety Standards Compliance:
|
Designed to meet relevant industry safety standards (e.g., ANSI B56.1, EN standards).
|
|
Active Features
|
|
Active Safety Features:
|
Operator presence system (senses operator), audible backup alarm, parking brake, responsive hydraulic controls.
|
|
Passive Features
|
|
Passive Safety Features:
|
Operator overhead guard, seat belt, sturdy mast construction, load backrest, brake lights, warning lights.
|
|
Maintenance
|
|
Service Intervals
|
|
Daily Checks:
|
Check fluid levels (engine oil, hydraulic oil, coolant, brake fluid), tire pressure, horn, lights, brakes, lift mechanism for proper operation. Inspect for leaks.
|
|
Scheduled Maintenance Intervals:
|
Intervals typically range from 250 hours to 500 hours or annually, depending on operating conditions. Key items include oil changes, filter replacements (oil, fuel, air, hydraulic), greasing points, and inspection of wear items.
|
|
Fluid Specifications
|
|
Engine Oil Specification:
|
API CG-4 or higher, SAE 15W-40 diesel engine oil recommended (verify with manual for specific engine).
|
|
Hydraulic Fluid Specification:
|
ISO VG 46 or equivalent anti-wear hydraulic fluid.
|
|
Transmission Fluid Specification:
|
Refer to manual for specific ATF type (e.g., Dexron III or equivalent for torque converter transmissions).
|
|
Coolant Specification:
|
Ethylene glycol-based antifreeze/coolant mixture (e.g., 50/50 mix) for freeze and corrosion protection.
|
|
Known Issues
|
|
Common Wear Items:
|
Fork wear, mast rollers, hydraulic cylinder seals, brake pads/linings, tires, steering components, lift chains.
|
|
Typical Faults To Monitor:
|
Hydraulic system leaks, engine starting issues, transmission hesitation, brake system wear, electrical connection corrosion.
|
