MHE I.C.

Forklift Trucks
Operation & Maintenance Manual

Operation Manual – Internal Combustion Forklifts Page 1

 Type: _________________________________________

Serial number: _______________________________

Manufacturing year: _________________________

Note: Please read this manual before operating or performing any maintenance on
the forklift. This instruction will improve safety and enable unnecessary dangerous
situations while avoiding accidents.

MHE-DEMAG GROUP

Page 2 Operation Manual – Internal Combustion Forklifts

 Contents

I. Strict Compliance with Safety Operating Procedures ........... 4

II. Common Faults and Troubleshooting .......................................... 6

III. Application and Maintenance of Forklift ............................... 13

1. Routine Maintenance (After operation of every 8-hour shift)

....................................................................................................................... 15

2. Maintenance and inspection after 100-hour (1-month)

operation ................................................................................................. 19

3. 300-hour operation (3-month) check point .................... 23

4. 600-hour operation (6-month) check point .................... 23

IV. Maintenance and Inspection List for 1-10T Internal Combustion

Forklift ............................................................................................................. 25

V. Forklift Oil Table and Tightening Torque Table for Key Parts 32

VI. Forklift Lubricating System Diagram ....................................... 32

Operation Manual – Internal Combustion Forklifts Page 3

 FOREWORD

This manual is primarily about basic knowledge for the

operation and routine maintenance as well as
troubleshooting instructions of common faults for
MHE-Demag 1.5T to 10.0T Internal Combustion
Counterbalanced Forklifts which are manufactured by our
company. They are made with Japanese engines.

This manual should be made available to all forklift

operators and technicians. If you would like and fur ther
details or clarification, please feel free to contact the
MHE-Demag Sales or Ser vice office nearest to you. We will
be glad to assist you in any way possible.

Page 4 Operation Manual – Internal Combustion Forklifts

I. Strict Compliance with Safety Operating Procedures
Forklift operators should be familiar with safety operating procedures and comply
with it strictly for his own safety and equipment safety.
1. Forklift operators should pass relevant trainings and drive with licenses.
2. During loading and unloading operations, forklift operator is not allowed to
adjust machine parts or repair and maintain forklift.
3. When mast is inclined forward, lifting of cargo is not allowed. During forklift
movement, mast should be inclined backward.
4. During movement, the distance between the lowest point of forklift and ground
should be 300-500mm approximately.
5. Carrying personnel on forks is prohibited.
6. It is not allowed to lift cargoes during forklift movement.
7. In the case of fuel inspection, engine should be shut down. Approaching to open
flame or smoking during driving is prohibited.
8. Overload operation is not allowed at rated load center. When cargoes are located
at non-rated load center, loading capacity should be determined according to
load curves and cargo center should be in accordance with body center.
Unbalance loading is not allowed.
9. It is not allowed to stand on fork, walk or remain under the fork.
10. It is not allowed to apply emergency brake with load or under non-emergencies
to avoid cargo damage due to throwout or personal injury.
11. It is not allowed to take a sudden turn when running at high speed.
12. In the case of operation height over 3m approximately, pay attention to prevent
cargoes from falling down and take precautionary measures if possible.
13. It is not allowed to operate forklift or its attachments at a position other than
driver’s seat. Be carefully when driving on slopes. In the case of gradient larger
than 10%, drive forward for uphill condition and drive backward for downhill
condition. Do not reverse these two to avoid rollover.
14. In the case of parking on slope, hand brake should be applied. When parking
time is long, anti-slip measures should be taken.
15. Do not leave operating post during work hours. Shut down engine and take the
key with you after getting off.
16. In the case of running on wet or slippery road surface, reduce the speed during
steering.

Operation Manual – Internal Combustion Forklifts Page 5

17. Pithy formulas for forklift operators:
Start with the 1st gear, turn with the 2nd. Make several observations for
acceleration;
Load limit for running should be kept in mind, operating safety comes first. (For
mechanical vehicles)
Depress accelerator pedal gently for starting; slow down at sharp turns;
Observe repeatedly for acceleration and it is the same for heavy-load running.
(For hydraulic vehicles)

II. Common Faults and Troubleshooting

Our 1-10T internal combustion counter balanced forklifts adopt Japanese
technologies as well as Japanese diesel engines and Chinese diesel engines generally.
For engine models and relevant parameters, please refer to Operation and
Maintenance Manual and Engine Manual.
(I) Cause for engine start failure of difficult engine start
1. Looseness or falling-off for starting switch electrical connector
2. Fuse blowout
3. Looseness of battery connecting wire
4. Insufficient battery power
5. Absence of forward and reverse gear shift lever at proper position
6. Clogged diesel engine fuel filter screen
7. Insufficient fuel
8. No preheating of diesel engine
Carry out repair, replacement or handling according to above causes one by one.
(II) In the case of hydraulic vehicle gear engagement, arduous running or no
running of forklift

Cause Troubleshooting
1. Oil duct of inching valve is clogged. (For its Clean inching valve oil duct and find out
installation position and diagram on the forklift, cause of clogging.
please refer to relevant manual)
2. Clutch friction plate retainer ring jumps out Reinstall it.
from clutch groove.
3. Both end faces of clutch return spring are not Carry out replacement.
parallel or their lengths are incorrect.

Page 6 Operation Manual – Internal Combustion Forklifts

 Cause Troubleshooting
4. Clutch piston sealing ring is seriously worn or Replace the sealing ring.
damaged.

5. Oil distribution shaft oil duct is clogged or
damaged.
6. Fractured torque converter claw that is inserted
into oil charge pump leads to oil charge pump
out-of-operation.
7. There is insufficient hydraulic fluid.
8. Hydraulic transmission oil model is incorrect.
9. There is excessive gear wear of oil charge pump
which leads to insufficient oil supply.
10. Adjustment between control valve linkage and
shift lever is improper which leads to incomplete
opening of oil duct in the case of forward or
reverse gear engagement.
11. Axle shaft is fractured.
12. There is excessive clearance, no clearance or
full-expansion between brake drum and brake
linings.
13. There is excessive wear of clutch friction plate.
14. Inching valve rod position is incorrect.
15. Oil temperature is too high.
Clean oil duct, check and replace sealing ring.
Replace the torque converter and check
whether oil charge pump is stuck.
Check and repair leaky position and add oil.
Change into 6° hydraulic transmission oil or
SAE10W oil.
Replace the oil charge pump.
Readjust the position.
Replace the axle shaft.
Adjusting clearance should not less than 0.25.
Replace the friction plate.
Inching pedal idle travel should be 1-3MM.
Stop running for cooling.

(III)Common faults and troubleshooting for hand brake and foot brake
Forklift service brake and parking brake types are:

Tonnage 1-10T
It is installed at front wheel and it is an internal
Service brake
expanding and hydraulic brake.
It is at front wheels and it is an internal
Parking brake
expanding and hydraulic brake.

Operation Manual – Internal Combustion Forklifts Page 7

Common faults and corresponding troubleshooting are shown in the table below:

Fault Cause Troubleshooting

1. Brake pedal position is improper. Carry out adjustment.
2. There is brake system oil leakage. Carry out repair or replacement.
3. There is mixed air in brake system. Carry out air bleeding.

Weak 4. Brake shoe clearance is adjusted

Adjust the adjuster.
braking improperly.
force 5. There is deformation, damage or
Check the cause for damage and carry
excessive wear in master cylinder or
out replacement.
wheel cylinder cup.
6. There are oil stains on brake drum
surface.
▽
Carry out repair 6.3( 5)

1. There are oil stains on friction plate

Carry out cleaning or replacement.
surface.
2. There is brake drum hole
Carry out buffing to the large hole and
misregistration, that is, the large hole is
ensure roundness and concentricity.
not concentric with the small one.
Uneven
braking 3. Brake shoe clearance adjusted
Adjust the adjuster.
force improperly.
4. Brake shoe return spring is damaged Carry out replacement.
5. There is wheel cylinder failure. Carry out repair or replacement.
6. There is self-adjusting mechanism There is return spring deformation.
failure. Carry out repair or replacement.
1. There is friction plate surface
hardening or foreign matters on the Carry out replacement.
surface.
2. There is bottom plate deformation or
Carry out repair.
Brake bolt looseness.
noise
3. There is deformation or incorrect
Carry out repair or replacement.
installation of brake shoe.
4. There is friction plate excessive wear. Carry out replacement.
5. There is hub shaft looseness. Carry out replacement.
1. Brake is overheated. Check the brake for slip.
Other 2. There are mixed foreign matters in Carry out inspection and change brake
brake brake fluid. fluid.
defects
3. There is hand brake cable deformation Carry out repair or replacement.
and joint falling-off

Page 8 Operation Manual – Internal Combustion Forklifts

(IV) Common faults and troubleshooting for steering system

Fault Cause Troubleshooting

1. There is mixed air in steering system Carry out air bleeding.
hydraulic line element.
2. There is too low operating fluid level Add oil and bleed air.
which leads to air entrainment.
3. Diverter valve opening is clogged and Carry out cleaning or replacement.
spool is stuck.
4. Steering cylinder piston rod is bent. Replace the piston rod.
5. There is seizure between steering Inspection method: Lift rear axle to
knuckle and steering knuckle pin. check its flexible swing to the left and
right.
6. There is seizure at other relative
surfaces during steering.
Steering
7. Steel balls in steering gear valve body Carry out removal or repair.
faults
are failed or clogged.
8. There is steering gear return failure Replace the spring leaf.
and spring leaf is fractured.
9. There is excessive steering cylinder Check piston sealing ring and carry out
internal leakage. replacement accordingly.
10. Diverter valve pressure is lower than Adjust the pressure and flow.
operating pressure and flow is too small.
11. Oil viscosity is too large. Apply specified oil.
12. There is excessive wear of spool and Carry out replacement.
valve body and clearance is too large.
13. There is excessive oil pump wear. Carry out replacement.
1. Joints are not tightened completely. Carry out tightening.
2. There are contaminants on steering Carry out cleaning.
gear valve body spacer disc stator and
Oil leakage rear cover faying surface.

3. There is oil cylinder external leakage.
1. Oil level in oil tank is too low and there
Abnormal is hydraulic noise.
sound
2. Oil suction tank or oil filter is clogged.
Check tightness of guide sleeve seal
joint.
Add oil and bleed air.
Carry out cleaning or replacement.

Operation Manual – Internal Combustion Forklifts Page 9

(V) Common faults and troubleshooting for lifting system

Fault Cause Troubleshooting

1. Clearance between side roller at upper Reduce adjusting shims.
end of outer mast and inner mast channel

Instability
＞
steel 1mm
2. Clearance between side roller at lower Add adjusting shims.
and large
end of outer mast and inner mast channel
noise
during
＞
steel 1mm
3. Clearance between fork arm carrier side Reduce adjusting shims.
lifting and
lowering
roller and inner mast channel steel 1mm＞
4. Side roller shaft fixing bolts are loose. Tighten them.
5. There are foreign matters in slide block Carry out cleaning for rails and add
and inner mast channel steel. engine oil regularly.
Tire pressures for left and right tires are Carry out reinflation until tire pressure
different. is the same.
Fork arm
Tensions for left and right chains are Adjust chain tensions until chain
carrier
different. tension is the same.
deflection
Oil duct in governor valve is clogged. Carry out cleaning or replacement.
Oil inlet of lift cylinder is clogged. Carry out maintenance and cleaning.
1. Travels for left and right lift cylinders are Carry out 180°adjustment with the
different. use of cylinder head.
Desynchron
2. Heights for left and right lift cylinders Carry out adjustment with adjusting
ized lifting
are different. bolts on cylinders.
at left and
3. Travel difference for left and right lift Add adjusting shims onto lift cylinder
right sides
cylinders is excessive and it exceeds piston rod.
adjusting range of cylinder head.
1. Operating fluid is insufficient. Add hydraulic fluid.
2. Governor valve throttle orifice is Carry out removal and cleaning.
clogged by contaminants.
3. Relief valve is clogged or stuck. Carry out cleaning and repair.
Lifting
4. Oil tank internal filter screen oil suction Carry out repair welding and
speed
pipe weld joint leaks air. plugging.
under full
5. Pipe joint is loose. Tighten it.
load fails to
6. There is excessive wear between oil Check hydraulic fluid for its cleanness
meet
pump gear and pump body and clearance and it should reach Level 9~11.
specified
is too large.
requiremen
7. There is damage, excessive wear or Replace the sealing ring.
t or there is
internal leakage of sealing ring in lift
lifting
cylinder.
failure.
8. Clearance between multi-way valve Carry out replacement and
body and slide valve spool is too large. adjustment.
Main valve pressure is too low.
9. Diverter valve distributes improperly. Carry out adjustment.

Page 10 Operation Manual – Internal Combustion Forklifts

(VI) Common faults and troubleshooting for electrical system
1. When ignition switch is turned on, pointer of
coolant temperature gauge remains at the same
position.
2. When ignition switch is turned on, pointer of
coolant temperature gauge moves from the zero
position to full scale position.
3. When ignition switch is turned on, pointer of
fuel gauge always points to 1 regardless of fuel
amount in fuel tank.
4. When ignition switch is turned on, pointer of
fuel gauge always points to 0 regardless of fuel
amount in fuel tank.
5. Horn keeps making sound.
6. Horn does not make sounds.
7. Lamps are easily burned.
8. Turn on one or several switches, lamps is
lightened.
9. Turn on a switch, fuse is blown immediately.
10. Lamplight is dim.
11. Reversing buzzer does not make sounds.
Operation Manual – Internal Combustion Forklifts
There is open circuit failure in coolant
temperature gauge sensor plug or its
connecting wire.
There is short circuit failure in coolant
temperature gauge sensor plug or its
connecting wire.
A. Connecting wire between fuel gauge and
sensor is disconnected.
B. There is sensor fault.
C. There is fuel gauge fault.
A. Two terminals of fuel gauge are connected
reversely.
B. There is short circuit failure in connecting
wire.
C. There is sensor fault.
There is short circuit failure in horn button.
There is open circuit failure and horn is broken
down.
Engine voltage is too high and there is speed
regulator fault.
There is open circuit failure in lamp circuit and
bulbs are burned.
There is lamp circuit failure.
There is poor contact at wiring position or
lamp installation position.
A. The buzzer is broken down.
B. Reversing switch is poorly contacted.
C. Circuit is poorly connected.
Page 11
(VII) Other common faults and troubleshooting

Fault Cause Troubleshooting

1. Engine oil, transmission oil and Add oil until oil amount reaches
differential oil amounts do not meet specified requirement.
requirements.
2. Front and rear hub bearings are loose Tighten bearings and locknuts, unscrew
and fractured. by about 1/8 circle and hub should
rotate freely. In the case of fracture,
Abnormal replace with new bearings.
sound during
running 3. Gearbox, gear and friction plate are Replace them.
damaged.
4. Differential and cross shaft are Replace them.
damaged.
5. There is leakage at exhaust pipe. Tighten it.
6. Fasteners are loose. Tighten them.

Fault Cause Troubleshooting

1. There is oil leakage at pipe joint. Carry out replacement.
Seals are worn or damaged by impact. Carry out troubleshooting.
There are foreign matters in oil. Tighten it.
Pipe clamp is loose.
2. There is oil leakage at hydraulic Carry out replacement.
element.
There is too much hydraulic Tighten it.
transmission oil.
Torque converter claw is fractured and
Oil leakage it damage oil charge pump seal.
Oil charge pump bolt is loose.
3. There is oil exudation at faying
surface. Carry out repair.
Tightening torques for connecting bolts
are different.
There are foreign matters on faying
surface.
Faying surface machining precision is
poor and the surface is not flat.

Page 12 Operation Manual – Internal Combustion Forklifts

 III. Application and Maintenance of Forklift
Correct application and maintenance of forklift may prolong forklift service life,
reduce failure rate and increase efficiency.
(1) Correct Application of Forklift
1. Forklift operators should comply with Safety Operating Procedures.
2. Forklift operators should know application knowledge and precautions about
forklift and carry out maintenance.
3. Prior to application of a new forklift, forklift operator should clean, check the new
forklift and check all components carefully before driving
4. Preparations before driving
4.1 Check radiator for full filling with water. (Imported engines are filled with FD-2
long-acting anti-rust antifreeze with temperature limit of 35℃). During application,
users should refill the radiator with clean water after cooling and evaporation. In the
case of coolant leakage of the system or coolant tank replacement, anti-rust
antifreeze with corresponding freeze point which is determined in accordance with
local climatic conditions should be filled.
4.2Check whether oil level of engine oil, hydraulic operating fluid, transmission oil,
torque converter oil and gear oil is at middle position between upper and lower scale
marks; check whether brake fluid level is in specified range;
4.3 Check hydraulic system pipe joints for oil exudation;
4.4 Check service brake.
4.4.1 Brake pedal idle travel (free travel range)
4.4.2 The minimum clearance between front bottom plate and pedal should be larger
than 20mm.
4.4.3 Check service brake for flexibility, reliability and uniformity.
4.5 Check parking brake. Pull the handle up completely for parking on a slope with
gradient of 15% under full load, operating force for hand brake should not larger than
300N;
4.6 Check lubricant level and lubrication at lubricating points;
4.7 Check steering system linkage and joint for looseness and abnormal sound during
steering;
4.8 Check battery terminal wire for looseness and generator for charging;
4..9Check electrical connectors, connecting wires and lighting devices for intactness
and firmness; check electrical appliances and signals for normal state (headlamps,

Operation Manual – Internal Combustion Forklifts Page 13

small lamps, brake lamps, turn signal lamps, horn and etc);
4.10 Check front and rear tire pressure for compliance with specified requirements.
Clear pebbles and foreign matters between tire patterns;

Tonnage 1-10T

Tire pressure (Mpa) Front wheel 0.7, rear wheel 0.7

4.11 Check fixing bolts and nuts for looseness. For relevant torques, please refer to
Attached Table III Tighten Torque for Key Parts;
5. Precautions for starting
1) Operate the forklift according to running direction (for hydraulic vehicles) or place
forward and reverse gear shift level (for mechanical vehicles) at neutral gear.
2) It is not allowed to start the starter continuously within 5 sec Please restart it after 2
min of waiting and continuous operating time of starter should not exceed 15 sec.
6. Precautions for forklift running
6.1 Apply low gears for starting (for mechanical vehicles) and check brake and
steering system for normal operation right after starting;
6.2 In the case of speed change during running depress clutch pedal firstly and then
change shift lever position (for mechanical vehicles).
6.3 In the case of running direction change for forklift, (means forward running and
reversing), stop the forklift completely and then carry out direction changing.

6.4 In the case of downhill driving, apply low-speed running and depress brake pedal
from time to time. In the case of uphill driving, shift to low-speed running timely;
6.5 In the case of turning, it is necessary to reduce running speed in advance.
6.6 It is not allowed to slide with clutch separated and it is not allowed to place foot
on clutch pedal during running. In the case of clutch application, depress it rapidly
with steady clutch engagement.
7. Precautions for loading, unloading and stacking
7.1 Cargo weight should be lower than that specified on load curve sign plate
(according to center of gravity position of cargo on the fork) and no unbalance
loading is allowed.
7.2 Mast should be inclined forward when fork is inserting into cargo piles. After
cargo loading, mast should be inclined backward. Do not drive before cargo lean
against fork arm.

Page 14 Operation Manual – Internal Combustion Forklifts

7.3 During loading or unloading, hand brake should be applied to stop the forklift
completely.
7.4 Do not lift or lower cargo at a high speed.
7.5 In the case of transporting large-scale cargoes which may impact visual line of
forklift operator, drive the forklift reversely at a low speed.
7.6 Carry out operations according to relevant requirements of Safety Operating
Procedures.
8. Precautions for parking
8.1 Pull up hand brake handle completely and place shift lever at neutral gear
position.
8.2 Lower the fork to ground.
8.3 Shut down the engine.
8.4 Move battery into a warm house under cold circumstances.

(2) Maintenance of Forklift

1. Routine Maintenance (After operation of every 8-hour shift)
1.1 Apply oils with specified models.
1.2 Clean oil filters with a hair brush or long-fiber rag. Lubricate surfaces with grease.
1.3 Park the forklift on horizontal ground in the case of oil level inspection and oil
filling.
1.4 In the case of inevitable operations under lifted fork or attachments, apply reliable
support to prevent fork inner mast from falling down.
1.5 In the case of detected damage or defect, it is necessary to report to relevant
department for repair before application.
8-hour check point
1) Check repaired or adjusted positions.
2) Check operating fluid, fuel and coolant for leakage.
Check hydraulic line joint, engine, coolant tank and drive system for oil and coolant
leakage with visual and hand feel inspection.
3) Tire pressure inspection
Low tire pressure will shorten tire service life and increase fuel consumption. Uneven
tire pressure, uneven tire wear or damage at left and right sides will lead to uneven
steering force. Take down tire valve cap and measure tire inflation pressure with tire

Operation Manual – Internal Combustion Forklifts Page 15

pressure gauge. Reinstall the tire valve cap when it is confirmed that no air leakage is
existed. Check tire surface and side for damage due to rim edge puncture and check
rim for deformation. Since there is a high tire pressure requirement for forklift in load
bearing, any tiny damage or deformation of rim bend part may lead to accidents.
Therefore, forklift operator should report tire damage once it is detected. Rim
assembly should be installed with specified bolts and nuts according to specified
tightening torque value prior to tire inflation. Inflation pressure should not exceed
specified one. In the case of inflation with air compressor, please adjust air
compressor pressure for it supplies the maximum pressure only.
4) Tightening torque inspection for hub nut All hub nuts should be tightened
according to torque values indicated in attached table.
5) Overhead guard inspection Check overhead guard for firm installation and
reliable structure.
6) Brake fluid level inspection
Fluid level should be between two scale marks on fluid reservoir and this inspection
should be carried out in the case of adding brake fluid and brake fluid mixing with
water.
7) Rear combination lamp inspection
Check rear combination lamps, tail lamps, brake lamps and reversing lamps for
damage or contamination to avoid contaminants.
8) Coolant tank inspection Take down coolant tank cap and check whether coolant
level remains at proper level through filler hole and then reinstall coolant tank cap. In
the case of dropped coolant level, it is necessary to replenish coolant (tap water)
other than sea water or other contaminated water. Meanwhile, pay attention to vapor
spray which is easy to cause accident.
9) Hydraulic fluid level inspection
Pull out dip stick and clean it completely and repeat inserting and then pulling out to
check whether oil level is between upper and lower scale marks (Check oil level with
engine shutdown , fork on the ground and forklift parking on flat place).
10) Line and cylinder inspection
Check hydraulic line and three cylinders for oil leakage.
11) Transmission oil level inspection
Hydraulic vehicle: Open inspection cover plate on bottom plate, take down filler cap
to check oil level for compliance with scale marks on dip stick. Add oil when oil is
insufficient.

Page 16 Operation Manual – Internal Combustion Forklifts

12) Load-backrest inspection
Check load-backrest and fork arm carrier mounting bolt for tightness. In the case of
any looseness, carry out retightening.
13) Fork and fork pull pin inspection
Check for pull pin for correct installation and check welding position between fork
and slide block and fork bend for crack or deformation.
14) Check headlamps and combination lamps for damage or contamination.
15) Battery electrolyte inspection
Check whether battery electrolyte level is between scale marks on battery
compartment body and flames or sparks should be avoided for the reason of
explosive gas which may exist.
16) Engine oil level inspection
For C240, oil level mark should be located at right side of dip stick should be and for
other engine models, the mark should be on the left side. Pull out the dip stick, wipe
it up, reinsert it and take it out to check oil level. The oil level should be between scale
marks on dip stick. In the case of oil under cold state, oil level can not be indicated
correctly for oil under cold state can not be drawn back to oil pan rapidly.
17) Fan belt tension inspection
Check whether fan belt tension is proper and check belt for damage. After engine
shutdown, press belt which is between engine pulley and fan pulley with your thumb,
belt settlement should be: 10-15mm
18) Adjustment of driver’s seat
Check driver’s seat for proper position. In the case of improper seat position, carry out
adjustment until forklift operator feels easy to control and operate the forklift with his
hands and feet. After adjustment, shake the seat to confirm that it is locked.
19) Rear-view mirror inspection
Check rear-view mirror for damage and contamination. Adjust mirror angle until all
rear positions can be seen.
20) Shift lever inspection
Carry out inspection via lifting and tilting (attachment) lever.
21) Parking brake operation inspection
Check hand brake application prior to driving.
22) Inspection for chronograph and other instruments
Check chronograph, coolant temperature gauge and fuel gauge for normal operation.

Operation Manual – Internal Combustion Forklifts Page 17

23) Fuel level inspection
Fill fuel tank up with fuel after daily operation to reduce moisture condensation in fuel
tank.
24) Check various lamps for normal operation.
25) Turn signal inspection
26) Horn inspection
27) Clutch pedal inspection
28) Brake pedal height and free travel inspection
For hydraulic vehicles, it is necessary to check inching pedal and its free travel. Check
brake pedal and inching pedal for smooth operation, normal return and existence of
interference.
29) Mast operation inspection
Check slide block for stable movement during mast lifting and tilting. When cylinder
piston rod reaches the bottom, check multi-way valve for overflow sound. Prior to this
inspection, please heat hydraulic fluid. Do not carry out mast forward tilting operation
when fork arm carrier is lifted, especially for meat with attachment.
30) Hoisting chain tension inspection
Check hoisting chain tension for deviation. Keep the fork at the position about 5cm
off the ground, press middle part of chain with your thumb to check whether chain
tensions on both sides are proper and uniform. In the case of improper or ununiform
chain tension, loosen locknuts and carry out adjustment accordingly. Lubricate
hoisting chain with lubricating oil (such as hydraulic fluid) other than grease.
31) Steering wheel free clearance inspection
Normal steering wheel free clearance should be in the range of 50-100mm (on
steering wheel rotation direction) while vertical direction of steering wheel should be
locked.
32) Exhaust emission inspection
Exhaust emission inspection should be carried out after engine temperature rises.
Colorless or light blue exhaust of engine indicates normal engine combustion.
Black: abnormal and incomplete combustion
White: Abnormal engine oil burning
Check engine and drive system for abnormal sound like “clatter” or abnormal
vibration. It is preferred to carry out exhaust inspection outside. In the case of
inevitable indoor exhaust inspection, good ventilation condition is necessary. Please
pay attention to avoid fire disasters especially for engine oil and fuel leakage. No rags

Page 18 Operation Manual – Internal Combustion Forklifts

or waste paper is allowed to exist in the room. Forklift operator should know where
the fire extinguisher is and how to apply it.
33) Clutch operation inspection
Mechanical vehicle: Depress clutch pedal and confirm that clutch is completely
separated and there is no drag effect.
Hydraulic vehicle: Carry out inching pedal inspection; depress inching pedal a little bit
to check forklift for speed reduction, that is, inching.
34) Service brake inspection
Keep forklift running at low speed and turn steering wheel to the left and right to
check left and right steering force for uniformity and existence of other abnormities.
Forklift steering system adopts power steering. In the case of engine shutdown, power
steering looses its effect and this will lead to hard steering operation.
36) Parking brake test inspection
Keep forklift running at low speed and pull up hand brake handle until it is confirmed
that forklift stops completely and remains at its parking position.
37) Reversing lamp inspection
In the case of shift lever operation or forklift reversing, reversing lamp should be
lightened.
2. Maintenance and inspection after 100-hour (1-month) operation
(Carry out inspection items besides those for inspection after 8-hour operation)
2.1 Air filter
2.2 Engine oil: Draw engine oil out and change with new oil (according to specified
brand and grade)
2.3 Omitted
2.4 Check coolant tank hose for aging.
2.5 Check coolant tank cover spring and air tightness.
2.6 Check control lever for normal controllability.
2.7 Check transmission oil level.
2.8 Check front axle mounting bolt for tightness.
2.9 Check front axle for oil leakage.
2.10 Check tire pattern depth and check tire for crack and other defects.
2.11 Check front and rear wheel bearings for looseness and sound.

Operation Manual – Internal Combustion Forklifts Page 19

2.12 Check front and rear axle housings for deformation, crack or weld defect.
2.13 Check steering gear fixing bolt for looseness.
2.14 Check steering linkage for clearance, bending or crack.
2.15 Check rear axle mounting bolt for proper tightening torque.
2.16 Check brake pedal for spongy brake pedal feel due to mixed air in brake line. In
the case of spongy brake pedal feel, it is necessary to carry out air bleeding at once.
2.17 Hand brake cable and connection—Check hand brake for proper feel and check
connection for looseness or falling-off.
2.18 Check brake line for damage, leakage or interference with other moving parts.
2.19 Check brake drum and brake shoe for firm installation.
2.20 Check fork for bending, crack or serious wear.
2.21 Check mast welds for deformation and crack.
2.22 Check mounting bolt which is applied in mast assembly installation on axle
housing for tightness.
2.23 Mast—Check it for damage and deformation; (for the first time application)
2.24 Mast—Check roller, roller shaft and roller shaft weld for crack and damage.
2.25 Fork arm carrier —Check it for deformation and check weld for crack.
2.26 Hoisting chain— Check it for deformation and check its lubrication and add
some hydraulic fluid if necessary.
2.27 Hoisting chain fixing bolt—Check relevant clearance (at cross girder of outer
mast)
2.28 Chain wheel and bearing— check their wears and clearances.
2.29 Attachment—Check it for correct installation, bending deformation or crack at
components.
2.30 Hydraulic cylinder—Check tightness at piston rod end and check piston rod for
bending and damage.
2.31 Multi-way valve—Check overflow valve for normal operation. Check tilt latching
valve (tilt latching valve is applied to prevent potential vibration cause by internal
negative pressure of tile cylinder in order to avoid serious results due to misoperation.
After engine shutdown, even though push of control valve rod fiercely, mast can not
tilt.
2.32 Check harness for damage or check harness clip for falling-off.
2.33 Lubricating oil filling—lithium base grease should be applied.

Page 20 Operation Manual – Internal Combustion Forklifts

A Rear axle steering system 7 lubricating positions
B Service brake pedal bearing 1 lubricating position
C Installation of mast on front axle 2 lubricating positions
Where: There are totally 9 lubricating positions for A and C (see the schematic
diagram below)
2.34 masts (at upper side of outer mast channel steel interior) and guide groove plate
between inner mast and moveable girder
3.34 Grease filling points at mast and steering system

Schematic diagram

1) Air filter
Check fir filter for component contamination, damage or serious aging of sealing
gasket.
Component cleaning: Blow off dust with compressed air or wipe out contaminant with
hair brush and check folded parts for damage. Carry out cleaning once for every
100-hour (1-month) operation and replace with a new filter element (or the whole
filter) for every 600-hour (6-month) operation.
For C240 diesel engine
Clean filter element and housing for every 300 hours. Loosen clamping bolt, take
down cover and spacer plate, release hook, take out filter element and clean
contaminants on it, like oil contamination or carbon soot. Keep the filter element in
diluted washing agent for about 30 min, wash it with clean water and air dry it. Do not
apply compressed air for cleaning. Under general operating condition, replace filter
element every 600 hours. In actual operation, maintenance interval for air filter should
be determined according to specific conditions.

Operation Manual – Internal Combustion Forklifts Page 21

For engines of other models:
Loosen connecting hook between air filter cover and housing, take out lock bolt and
then carry out removal.
2) Engine oil change:
Change engine oil once a month. For a new vehicle, change engine oil after the initial
25-hour operation (or 1 week).
Prior to oil change:
Start the engine, wait for oil temperature rise, take down key and open engine hood.
Oil change procedures:
(1) Take down oil filter cover.
(2) Clean it with cloth.
(3) Place a basin under oil pan drain plug for oil collection.
(4) Clean oil pan and oil plug with cloth.
(5) Loosen drain plug with socket wrench.
(6) Once the drain plug gets loose, screw it off manually.
(7) Drain oil into the basin from oil outlet.
(8) Clean the oil plug.
(9) After oil draining, reinstall oil plug in placer: do not damage oil plug seals.
(10) Wipe off residual oil on oil plug and surrounding.
(11) Wipe off oil at oil plug surrounding with clean cloth.
(12) Add oil until oil level reaches specified one. Firstly, add oil to the level with an
allowance about 1L and then observe oil level mark while adding oil until
specified level is reached.
(13) Wipe off oil at surrounding of oil filler and install filler plug in place.
(14) Start the engine and run it at high speed to make engine oil to get into the
engine.
(15) Shut down the engine and check whether oil level is between oil level marks “H”
(high) and “L” (low). In the case of insufficient oil, replenish oil accordingly. After
oil change, do not splash waste oil on the floor or drain it into sewer directly.
3) Grease filling procedures:
(1) Grease gun is offered in vehicle accessories.
(2) Take down gun cover from cylinder body.

Page 22 Operation Manual – Internal Combustion Forklifts

(3) Fill grease with specified model into cylinder body.
(4) Screw on gun cover.
(5) Replenish grease at specified lubricating points.
3. 300-hour operation (3-month) check point
Add following operations after completion of inspection and maintenance items for
8-hour and 100-hour inspections.
3.1 Clean C240 diesel engine crankcase air vent.
3.2 Replace filter element for C240 diesel engine.
3.3 Drain fuel filter completely.
3.4 Drain fuel tank completely.
3.5 Injection pump—Drain it completely and change diaphragm oil or engine oil.
3.6 Check engine pinion and flywheel ring gear for gear engagement.
3.7 Check battery electrolyte for proportion.
4. 600-hour operation (6-month) check point
Add following operations after completion of inspection and maintenance items for
8-hour, 100-hour and 300-hour inspections.
4.1 Replace air filter element.
4.2 Check valve clearance.
4.3 Check initial injection pressure of nozzle and spray condition (for diesel engine).
4.4 Drain coolant tank completely and refill the tank with water or other long-acting
antifreeze.
4.5 Replace fuel filter element (for diesel engine).
4.6Change transmission oil (change it only after the first 600-hour operation)
4.7 Differential 6S—Check oil level and change gear oil (change it only after the first
600-hour operation)
4.8 Hydraulic fluid reservoir—Clean oil filter screen, drain used oil completely and
refill with new oil.
4.9 Mast support mounting bolt—Check it for looseness.
4.10 Multi-way valve —Check overflow valve set pressure.
4.11 Driver’s seat—Check it for damage and looseness.

Operation Manual – Internal Combustion Forklifts Page 23

Check point after 300-hour and 600-hour operations
In general, engine oil filter should be replaced or cleaned while engine oil changing.
Engine oil filter of diesel engine should be replaced every season or every 300-hour
operation generally. After replacement, start the engine and keep engine idling for a
while to check installation position of oil filter for leakage. At the same time, check
and confirm oil level.

Page 24 Operation Manual – Internal Combustion Forklifts

 IV. Maintenance and Inspection List for 1-10T Internal
Combustion Forklift
In the following table, maintenance, repair and replacement items are determined
under the assumption of normal operating condition and normal operating
environment of forklift and they can be modified by customers according to actual
conditions. Black ● indicates replacement while 〇 indicated maintenance or repair.

Engine

Daily Semi
Monthly Annual
Inspection Quarterly annual
Requirement Tool (8 (100 (1200
item (300 hours) (600
hours) hours) hours)
hours)

Check engine for normal operation. 〇 〇 〇 〇 〇

Check engine for normal operating noise. 〇 〇 〇 〇 〇
Check engine for proper exhaust color. 〇 〇 〇 〇 〇
〇 〇
Engine Check air filter element for contamination and
● ●
carry out cleaning accordingly.

Check valve clearance for correctness. 〇 〇 〇

Check cylinder for proper pressure. 〇 〇
Overspeed Check max speed under no load. 〇
regulator
injection
pump
Change diaphragm oil or injection pump
lubricant
〇 〇 〇
Check it for oil leakage. 〇 〇 〇 〇 〇
Lubricating Check oil level and contamination. 〇 〇 〇 〇 〇
system Change engine oil. ● ● ● ●

Replace engine oil filter. ● ● ●

Check oil pump, oil tank and oil line for leakage. 〇 〇 〇 〇 〇
Clean fuel filter element. 〇 〇 ●

Clean fuel filter element. ● ●

Check nozzle for normal operation and pressure

characteristic.
〇 〇
Fuel system
Check injection timing. 〇
Check injection pump bolt filter screen. 〇
Drain water in fuel tank. 〇 〇 〇
Clean fuel tank. 〇 〇
Check fuel level. 〇 〇 〇 〇 〇
Cooling Check coolant level. 〇 〇 〇 〇 〇

Operation Manual – Internal Combustion Forklifts Page 25

 Daily Semi
Monthly Annual
Inspection Quarterly annual
Requirement Tool (8 (100 (1200
item (300 hours) (600
hours) hours) hours)
hours)
system Check coolant for leakage. 〇 〇 〇 〇 〇
Check rubber hose for aging 〇 〇 〇 〇
Check coolant tank cover and its proper 〇 〇 〇 〇
installation.

Change coolant. ● ●

Check fan belt for its tension and damage. 〇 〇 〇 〇 〇

Transmission and powertrain

Check clutch pedal free travel and the min

distance between pedal and bottom plate.
〇 〇 〇 〇 〇
Check operating noise and controllability. 〇 〇 〇 〇 〇
Mechanical Check clutch release and clutch engagement. 〇 〇 〇 〇 〇
〇 〇 〇 〇 〇
clutch
Check booster operation.

〇 〇 〇 〇 〇
〇 〇 〇 〇 〇
Check booster for oil leakage.

Check shift lever for flexibility and bolt for

tightness.
〇 〇 〇 〇
Gearbox
Check it for oil leakage. 〇 〇 〇 〇 〇
Change the oil. ● ●

Check it for oil leakage. 〇 〇 〇

Check oil level. 〇 ● ●

Check shift lever for flexibility and bolt for

tightness.
〇 〇 〇 〇
Hydraulic
transmission Check control valve and clutch controllability. 〇 〇 〇 〇 〇
Check inching pedal travel and idle travel. 〇 〇 〇 〇 〇
Check inching valve controllability. 〇 〇 〇 〇 〇
Replace filter element. ●

Front axle Check for oil leakage. 〇 〇 〇 〇 〇

Check oil level. ● ●

Check mounting bolt for tightness. 〇 〇 〇 〇

Wheel

Check tire pressure.

Pressure
gauge
〇 〇 〇 〇 〇
Tire
Check it for looseness and damage. 〇 〇 〇 〇 〇
Check tire wear. 〇 〇 〇 〇

Page 26 Operation Manual – Internal Combustion Forklifts

 Daily Semi
Monthly Annual
Inspection Quarterly annual
Requirement Tool (8 (100 (1200
item (300 hours) (600
hours) hours) hours)
hours)

Check tire tread for foreign matters like nails

and pebbles.
〇 〇 〇 〇 〇 〇
Check it excessive wear.
Depth
meter
〇 〇 〇 〇 〇
Check it for tightness.
Test
hammer
〇 〇 〇 〇 〇
Tire tightness
Check it for damage. 〇 〇 〇 〇 〇
Rim retainer
ring
Check rim and retainer ring for damage. 〇 〇 〇 〇 〇
Check it for tightness. 〇 〇 〇 〇
Wheel bearing
Check it for sound. 〇 〇 〇 〇
Front axle
housing
Check axle housing for deformation, crack and
damage.
〇 〇 〇 〇
Steering system

Check it for clearance on circle direction. 〇 〇 〇 〇 〇

Check it for tightness on vertical direction. 〇 〇 〇 〇 〇
Steering wheel
Check it for side tightness. 〇 〇 〇 〇 〇
Check it for operating comfort. 〇 〇 〇 〇 〇
Steering gear Check steering gear bolt for tightness. 〇 〇 〇 〇
Steering Check it for tightness. 〇 〇 〇 〇
linkage arm Check it for bending operation or excessive wear. 〇 〇 〇 〇
Check kingpin for tightness and damage. 〇 〇 〇 〇
Steering
knuckle Rear
Check it for bending deformation, crack or
damage.
〇 〇 〇 〇
axle
Check it for installation. 〇 〇 〇 〇
Check it for controllability. 〇 〇 〇 〇 〇
Power
steering
Check it for oil leakage. 〇 〇 〇 〇 〇
Check installation and connection for tightness. 〇 〇 〇 〇
Brake system

Check pedal free travel.

Straight
scale
〇 〇 〇 〇 〇
Check pedal travel.
Straight
scale
〇 〇 〇 〇 〇
Brake pedal Check it for controllability. 〇 〇 〇 〇 〇
Check brake line for air leakage. 〇 〇 〇 〇
Check brake handle for locking. 〇 〇 〇 〇 〇
Check it for controllability. 〇 〇 〇 〇 〇

Operation Manual – Internal Combustion Forklifts Page 27

 Daily Semi
Monthly Annual
Inspection Quarterly annual
Requirement Tool (8 (100 (1200
item (300 hours) (600
hours) hours) hours)
hours)

Check ratchet wheel for its controllability and

wear.
〇
Check it for controllability. 〇 〇 〇 〇
Rubber hose Check connection for tightness. 〇 〇 〇 〇
and line Check it for damage, leakage or bump. 〇 〇 〇 〇
Check clamp for firm connection. 〇 〇 〇 〇
Check it for oil leakage. 〇 〇 〇 〇
Check oil level. 〇 〇 〇 〇 〇
Master
Check master cylinder and wheel cylinder for
cylinder and ●
controllability, damage and leakage.
wheel cylinder
Check master cylinder head and check valve for
damage and wear. In the case of such defects, 〇 〇 〇 〇
carry out replacement.

Check brake drum for proper installation. Test

hammer
〇
Check friction plate for wear. Vernier
caliper
〇
Brake drum
and brake
Check supporting pin for rust. 〇
shoe Check return spring for deformation. 〇
Check automatic slack adjuster for normal Straight
operation. scale
〇
Check brake drum for wear. 〇
Check brake bottom plate for deformation. 〇
Brake bottom Check bottom plate for crack. 〇
plate
Check installation parts for tightness. Test
hammer
〇
Lifting system

Check fork for damage, deformation or wear. 〇 〇 〇 〇 〇

Fork
Check pull pin and fork wear. 〇 〇 〇
Check for crack between slid block and fork
body welding part.
〇 〇 〇 〇
Check inner and outer mast weld joints for
crack and damage.
〇 〇 〇 〇
Mast and fork Check tile cylinder base. 〇 〇 〇
〇 〇 〇 〇
arm carrier
Check inner and outer masts foe damage.

Check fork arm carrier weld joint. 〇 〇 〇 〇

Page 28 Operation Manual – Internal Combustion Forklifts

 Daily Semi
Monthly Annual
Inspection Quarterly annual
Requirement Tool (8 (100 (1200
item (300 hours) (600
hours) hours) hours)
hours)

Check roller for firm installation. 〇 〇 〇

Check mast support bearing for wear and
damage.
〇 〇 〇
Check mast support bolt for tightness. Test
hammer
〇 〇
Check lift cylinder bottom and top bolts, U bolt
and piston rod top bolt for tightness.
Test
hammer
〇 〇
Check roller and roller shaft welding parts for
crack.
〇 〇 〇 〇 〇
Check hoisting chain tension and check it for
deformation and rust.
〇 〇 〇 〇
Hoisting chain
Add some lubricant into the chain. 〇 〇 〇 〇
and pulley Check hoisting chain for tightness. 〇 〇 〇 〇
Check chain for deformation and damage. 〇 〇 〇 〇
Check chain wheel bearing for tightness. 〇 〇 〇 〇
Attachment Carry out general inspection items. 〇 〇 〇 〇
Check piston rod screw thread for deformation
or damage due to excessive tightness.
Test
hammer
〇 〇 〇 〇 〇
Oil cylinder Check oil cylinder for controllability. 〇 〇 〇 〇 〇
Check it for oil leakage. 〇 〇 〇 〇 〇
Check pin roll for wear. 〇 〇 〇 〇
Master Check oil cylinder for leakage. 〇 〇 〇 〇 〇
cylinder Check main gear of the cylinder for wear. 〇 〇 〇 〇
Hydraulic system

Hydraulic fluid Check oil level and carry out oil change. 〇 〇 〇 〇 ●
reservoir Clean contaminants on oil filter screen. 〇 〇
Oil filter Replace it. 〇 〇 〇 〇 〇
Control lever Check the rod for firm connection.
valve rod Check it for controllability. 〇 〇 〇 〇 〇
Check it for oil leakage. 〇 〇 〇 〇 〇
Multi-way
Check tilt latching valve for controllability. 〇 〇 〇 〇
valve Hydraulic
Measure overflow pressure. pressure 〇 〇
gauge

Pipe joint
Check it for oil leakage, pipe deformation and
damage.
〇 〇 〇 〇 〇

Operation Manual – Internal Combustion Forklifts Page 29

 Daily Semi
Monthly Annual
Inspection Quarterly annual
Requirement Tool (8 (100 (1200
item (300 hours) (600
hours) hours) hours)
hours)

Replace rubber hose. ●

Electrical system

Starting motor
Check starting
engagement.
motor pinion for gear
〇 〇
Battery
charger
Check battery charger for normal operation. 〇 〇 〇 〇 〇
Battery Check electrolyte proportion. 〇 〇 〇 〇
Check harness for damage and check clip for
Harness firm clamping.

Check harness for firm installation.

Daily Semi
Monthly Annual
Inspection Quarterly annual
Requirement Tool (8 (100 (1200
item (300 hours) (600
hours) hours) hours)
hours)

Inspection for safety device and others

Overhead Check it for firm installation.

Test
hammer
〇 〇 〇 〇 〇
guard
load-backrest Check it for deformation, crack or damage. 〇 〇 〇 〇 〇
Turn signal Check it for normal operation. 〇 〇 〇 〇 〇
Horn Check it for normal operation. 〇 〇 〇 〇 〇
Lamp Check it for normal operation. 〇 〇 〇 〇 〇
Reversing
buzzer
Check it for normal operation. 〇 〇 〇 〇 〇
Rear-view Check it for contamination or damage. 〇 〇 〇 〇 〇
mirror Check forklift operator's visual field. 〇 〇 〇 〇 〇
Instrument Check it for normal operation. 〇 〇 〇 〇 〇
Reflector and
license plate Check them for contamination or damage. 〇 〇 〇 〇 〇
lamp.

Driver’s seat Check it for damage or looseness. 〇 〇

Check frame and welding parts for damage or
crack.
〇
Test
Check connection for looseness.
Body hammer
Check parts with faults which have been
detected previously.
〇 〇 〇 〇 〇
Carry out other inspections. 〇 〇 〇 〇 〇

Page 30 Operation Manual – Internal Combustion Forklifts

 Daily Semi
Monthly Annual
Inspection Quarterly annual
Requirement Tool (8 (100 (1200
item (300 hours) (600
hours) hours) hours)
hours)

Add grease Check lubrication after cleaning.

Grease
gun
〇 〇 〇 〇
and carry out
oil change. Check hydraulic fluid and other fluid in the
container for deterioration.
〇

Operation Manual – Internal Combustion Forklifts Page 31

 V. Forklift Oil Table and Tightening Torque Table for Key
Parts
(I) Attached Table II Oil List for Forklift

Name Brand/Code (in China) Brand/Code (Overseas)

Diesel RC30-10 (Ordinary area) JISK2204, 2#
For winter: 10#, for summer: 0# (Ordinary area) JISK2204, 3#
Lubricating oil (HQ-10# for both winter and summer) SAE10W for winter
HQ-15 (for summer) SAE30W for summer
Hydraulic fluid N32# or N46# ISOVG30
Hydraulic 6# hydraulic transmission oil SAE10W
transmission oil
Gear oil 85W/90 SAE90. SAE80E
Brake fluid 4604 synthetic brake fluid JISK-2233
Grease 3# lithium base grease with dropping point JISK-2220. 1#. 2#
of 170

(II) Attached Table III Tighten Torque for Key Parts

SN Part 4T
1 Front hub nut single tire/twin tire 48-56
2 Front rim bolt (nut) 20-30
3 Rear hub nut 13-19.4
4 Rear rim bolt 6.2-9.2
5 Axle shaft bolt 9.8-11.3
6 Locknut between steering piston rod and linkage 14-21
7 Locknut between steering piston rod and connecting plate 19-28.6
8 Steering knuckle nut 16-20
9 Nut between three connecting plate and joint 11-15
10 Clamping nut between brake and axle housing 12-24
11 Mounting bolt between mast and axle housing 7.6-11.3
12 Mounting nut between mast and axle housing 7.6-11.3
13 Engine mounting bolt 3.3-5
14 Rear axle mounting bolt 15.6-23
15 Mounting bolt for gearbox and drive axle 9.9

Page 32 Operation Manual – Internal Combustion Forklifts

Operation Manual – Internal Combustion Forklifts Page 1
Page 2 Operation Manual – Internal Combustion Forklifts