Baoli CPCD 80 Owner's manual

Original
instructions

OPERATION & SERVICE
MANUAL
8-10t Internal Combustion
Counterbalanced Forklift Truck
KION Baoli (Jiangsu) Forklift Co., Ltd.

PREFACE
Thank you for selecting BAOLI forklift truck! Your trust is a great honor to us!
8-10 ton internal combustion counterbalanced forklift trucks adopt hydraulic
transmission with advanced TCM continuous speed control and integral drive axle with
wheel reducer, so they have a lot of advantages such as good traction and travel
performance, easy operation, reliable brake, wide visibility and safe performance.
These trucks are all suit for handling and stacking packed goods in stations, ports,
goods yards and warehouses and used widely in food processing, light and textile,
mining industries and other factories, with some of attachments fitted, the trucks can be
applied more and more.
This manual states the trucks’ specifications, operation, maintenance, service,
main assemblies’ constructions and working principles so as to be completely familiar
with the truck to get the most of it, and to help the operators to use the trucks correctly
and attain the highest functions. It is necessary to read over the manual before they
operate the trucks or service personnel serve these trucks.
Besides this Operation and Service Manual, there is Operator’s Manual, which
includes important information of safety driving and periodic maintenance. And, the
manual of some important parts is provided.
We suggest you to give the manual a proper storage. If there is something in the
manual you do not understand, ask the distributor to explain it to you. Suggestion and
criticisms are welcome.
This manual content might not correspond with the actual condition because of the
improving of our products. Our products are subject to improvements and changes
without notice.
We heartily wish you keep everything running smoothly during operation of BAOLI
forklift truck!

CONTENTS
Ⅰ. About the forklift truck..........…….………………………................................1
1. External view and specification……………………………………………………1
2. Characteristic of forklift truck………………………………………………………3
Ⅱ. Safety instruction and operation of forklift truck………………………5
1. Handling a new forklift truck………………………………………………………5
2. Inspection before operation………………………………………………………5
3. Start and stop of the engine………………………………...................................6
4. Shipping, loading and unloading, slinging and towing of forklift truck…………7
5. Parking and storing…. . ……………………………………………………………8
6. Information of safety operation…. …………………………...... ………………10
7. Operation device and meter………………………………………………………16
8. Caution plate……………………………………………………..........................18
Ⅲ. Periodic inspection and servicing…………………………………………23
1. General rules on inspection and maintenance…………………………………23
2. Essentials of servicing..............…………………………..............................24
3. Recommended oil...........................……………………............................25
4. Lubrication system..................................………………………..................25
5. Routine check before daily operation...........……………............................27
6. Precautions of cooling system……………………………………………………27
7. Notes during brake-in...........................…………………….............................27
Ⅳ. Construction, principle, adjustment and maintenance of forklift truck…28
1. Power system………………………………………………………………………..28
1.1 General description…………………………………………………………….28
1.2 Engine disposition………………………………………………………………..29
1.3 Inspection and adjustment of engine…………………………………………..31
1.4 Fuel system……………………………………………………………………..31
1.5 Coolant system…………………………………………………………………..33
1.6 Check and adjustment………………………………………………………….33
1.7 Precautions of cooling system…………………………………………………..38
2. Drive unit……………………………………………………………………………39
2.1 General description…………………………………………………………….39

2.2 Torque converter…………………………………………………………………41
2.3 Charging pump……………………………………………………………………42
2.4 Hydraulic clutch…………………………………………………………………..43
2.5 Control valve and inching valve…………………………………………………43
2.6 Hydraulic circulation system…………………………………………………….45
2.7 Principle……………………………………………………………………………46
2.8 Caution when the trouble occurs………………………………………………46
2.9 Trouble shooting…………………………………………………………………47
3. Front axle……………………………………………………………………………50
3.1 General description…………………………………………………………….50
3.2 Main reduction gear & differential……………………………………………….50
3.3 Final reduction gear………………………………………………………………50
3.4 Troubleshooting…………………………………………………………………53
3.5 Service data……………………………………………………………………….53
4. Brake system……………………………………………………………………...54
4.1 General description…………………………………………………………….54
4.2 Power brake……………………………………………………………………..54
4.3 Parking brake……………………………………………………………………58
4.4 Wheel brake……………………………………………………………………..58
4.5 Troubleshooting………………………………………………………………….60
5. Steering system…………………………………………………………………….61
5.1 General description…………………………………………………………….61
5.2 Hand wheel……………………………………………………………………….60
5.3 Cycloid gear type powered steering unit……………………………………..62
5.4 Steering system troubleshooting……………………………………………...70
5.5 Rear axle…………………………………………………………………………..71
6. Hydraulic system…………………………………………………………………..73
6.1 General description………………………………………………………………73
6.2 Main pump……………………………………………………………………….73
6.3 Control valve…………………………………………………………………….73
6.4 Control valve operation………………………………………………………….74

6.5 Main safety valve operation……………………………………………………..76
6.6 Tilt lock valve operation…………………………………………………………77
6.7 Hydraulic circulation system (Main circuit)……………………………………..78
6.8 Troubleshooting………………………………………………………………….79
6.9 Maintenance……………………………………………………………………...80
7. Lift Cylinder & tilt Cylinder……………………………………………………….81
7.1 Lift cylinder……………………………………………………………………….81
7.2 Flow regulator…………………………………………………………………….83
7.3 Tilt cylinder……………………………………………………………………….84
8. Lifting system……………………………………………………………………….85
8.1 General description…………………………………………………………….85
8.2 Inner & outer mast………………………………………………………………..85
8.3 Lift bracket………………………………………………………………………..85
8.4 Roller position…………………………………………………………………..86
8.5 Adjustment of lifting system………………………………………………...88
8.6 Maintenance and adjustment…………………………………………………...88
9. Electric system………………………………………………………………………91
9.1 General description……………………………………………………………. 91
9.2 Brief explanation for operation…………………………………………………..95
9.3 Precautions when using the battery……………………………………………97
9.4 Harness…………………………………………………………………………...97
Product improve suggestion sheet…………………………………………………102
NOTE……………………………………………………………………………………103
EC DECLARATION OF CONFORMITY………………………………………………104

1
Ⅰ. About the forklift truck
1. External view and specification
External view of internal forklift truck

2
Main specification
General
Model
CPCD80
-C
CPCD80-W
CPCD100
-C
CPCD100-W
CPCD80-CU1
CPCD100-CU1
Power type
Diesel
Operating way
Sitting
Rated capacity
kg
8000
10000
Load center
mm
600
Dimensions
Lift height
H
mm
3000
Free lift height
H4
mm
205
210
Fork size L×W×T
mm
1500×160×75
1500×160×80
Fork outside spread (Min./Max.)
mm
320/2015
420/2144
Mast tilt angle
α/β
deg
6/12
6/12
Front overhang
X
mm
700
733
Overall
dimensions
Length to fork face
L1
mm
3940
4258
Overall width
B1
mm
2245
Mast lowered height
H1
mm
2695
2845
Mast extended height
H3
mm
4445
4307
Overhead guard height
H2
mm
2565
Turning radius
R
mm
3700
3900
Performance
No load/full load
Travel speed
km/h
28 / 24
28 / 22
Lift speed
mm/sec
480/350
410/350
390/280
390/300
Max. gradeability
%
20
Self weight
kg
11080
12860
Chassis
Tyre
Front
9.00-20-14PR
Rear
9.00-20-14PR
Tread
Front
B2
mm
1600
Rear
B3
mm
1700
Wheelbase
Y
mm
2500
2800
Min. mast ground
clearance
(no load/full load)
Mast
M
mm
245/205
Frame
F
343/323
Drive units &
control
Battery
V/AH
2×12/100

3
2. Characteristic of forklift truck
The forklift truck has advantages as follows:
1. The hydraulic steering device makes steering flexible and the double ladder like
steering bridge makes the turning radius minor.
2. The braking system employs oil brake, makes it possible to manipulate
conveniently and brake reliably.
3. Employed wide-vision extension type mast, the truck is high intensity.
4. Hydraulic transmission type forklift trucks are provided with a drive unit including
a torque converter and a hydraulic transmission. They feature the following:
a. Hydraulic torque converter can change the speed automatically with no limitation
and output torque makes the forklift truck have good performance of drawing.
b. The slight travel device makes it easy for the drivers to aim the truck to the
position of cargo.
c. At work, for the forklift truck that need starting and shifting frequently,
achievement of smooth gear shifting control can raise working efficiency, simplify
operation, reduce the driver’s labor intensity and reduce requirement of the driver’s
operation skill.
5. The trucks’ braking system employs oil brake, make it possible to manipulate
conveniently and brake reliably.
6. Employed wide-vision type mast, and it’s frame is two stage CJ extension type
mast. The truck is high intensity and has wide vision. The mast adopts series design,
having different lifting height according to the needs of the client.
7. Specific outline adopts streamline design, it has advantages such as low noise,
small libration, comfortable operation, safety and reliability.

4
Main parts of forklift truck:
No.
Name
Contents
1
Power system
engine mounting, system of fuel, exhaust and
coolant etc.
2
Transmission
torque converter, transmission, transmission shaft,
etc.
3
Drive axle
housing, half shaft, differential, wheel reducer,
brake, front wheel etc.
4
Brake system
wheel brake and parking brake
5
Steering system
steering wheel, steering shaft, cycloid gear type
powered steering unit and steering axle assy etc.
6
Hydraulic system
pump, valve, HP oil pipe, LP oil pipe, connectors
etc.
7
Electric system
lamps and lanterns, battery, meter, harness etc.
8
Load system
mast, fork, carriage, load backrest, tilt cylinder, lift
cylinder, lift chain, mast roller etc.
Weight of the main parts that can be disassembled
Model
Specification
8T
10T
Balance
weight
Slinging capacity
(kg)
>4500
>5000
Overhead
guard
Slinging capacity
(kg)
>150
Mast
Slinging capacity
(kg)
>2000
>2100
Carriage
Slinging capacity
(kg)
>1000
>1200
Fork
Slinging capacity
(kg)
>220
>250

5
Ⅱ. Safety instruction and operation of forklift truck
It is important for drivers and managers to remember the principle of “first safety”
and ensure the safety operation as the description of Operation & Service Manual.
Please read this manual thoroughly. This will give you a complete understanding of
Baoli forklift truck and you will operate them correctly and safely.
1. Handling a new forklift truck
The performance and service life of the forklift truck depends heavily upon the way
you handle it during the break-in period. Drive with special caution while becoming
familiar with a new forklift truck.
(1) Always warm up your vehicle before putting it to work irrespective of season.
Don’t run engine at high rpm without load needlessly. Operate the vehicle under the
light load, avoid sudden speeding and braking.
(2) Replace gear oil in the differential and reducer after the new forklift truck
working for 100 hours.
(3) Renew the oil in engine oil pan, transmission, driving axle and hydraulic oil tank;
check and readjust the clearance of the driving and driven gear in the reducer after the
new forklift truck working for 200 hours.
2. Inspection before operation
Please pay attention to the following items in order to make the vehicle working
with high efficiency and lengthen its service life.
(1) The forklift truck adopts the home or imported engine, please read the manual
accompanied with the engine carefully when using and maintenance.
(2) Check the tyre inflation pressure, if doesn’t enough, charge air in time. Check
the bolts of all wheels for tightness.
(3) Check the amount of oil in the working oil tank for sufficiency, the position of
lubrication should be lubricated. The oil level should be at the middle position between
the upper and lower scale marks of oil level meter. The contamination level of the
hydraulic oil should be lower than Grade 12.
(4) Check the radiator, and add antifreeze if necessary.
(5) Check hydraulic oil and brake fluid for leakage. Check if any leak or damage
found on the oil pipes, water hoses, vent-pipes and the piping joints, pumps and valves

6
etc.
(6) Check for all the terminals and plugs in normal state. Check the meters, lamps,
switches and electric circuit if they are running properly.
(7) Check every pedal for free stroke and the levers for looseness and smooth
operation. Check lifting system, actuate the lifting and tilting levers to be certain that the
lift bracket moves up and down properly and the mast can be tilted smoothly. Check
brake system and steering system for flexibility and reliability.
(8) Check the wheel brake: the free stroke of brake pedal is 4-8 mm, when
achieving effective brake, the clearance between the front floor and the pedal should be
more than 20mm.
(9) Check the parking brake: the unload forklift truck can park on 20% slope, when
the parking brake is locked.
(10) Check all connectors and fasteners for looseness.
3. Start and stop of the engine
(1) Start of the engine
(a) First set the shift lever at the neutral position and the parking brake at the
braking position.
(b) When starting, put the key into the start switch, turn it in the counter clockwise,
preheat 15-20 seconds, and then turn it in the clockwise to “START” so the starting
motor works. When your hand is away from the key, it automatically returns to “ON” by
spring force. Every starting time shouldn’t morn than 15 seconds. Restarting should be
after 30 seconds. As the engine doesn’t work after some times starting, should check
and remove the trouble, do not keep the starting motor engaged for a long time.
(c) Following the start of the engine, it’s necessary to set the engine on idle running
for five minutes. Full load operation can’t be started until water temperature of the
engine rises above 60℃.
When the engine is on idle running, you must check water thermometer, oil
manometer, ammeter, fuel measurer, and so on for the data, whether to meet the
specification, and check each pedal for free stoke, braking performance for its reliability,
steering operation for its flexibility, tyre pressure for its conformance to the standard. If
there is no trouble, operation may be allowed.

7
(2) Stop the engine
First set the engine on idle running for five minutes, so as to cool the engine
gradually, and then turn off the ignition switch, so the engine is stopped to work.
Notice：
．While the engine running, does not turn the start switch to “START” position, or it
will damage the starting motor.
．Do not keep the start switch at the “ON” position while the engine is shut down.
This will result in battery discharge.
4. Shipping, loading and unloading, slinging and towing of forklift truck
(1) Ship the forklift truck
(a) Apply the parking brake when shipping the forklift trucks by container or freight
car.
(b) Fix the mast and the balance weight with steel wire and use jacks to prevent the
forklift trucks from moving in the cabin.
(c) Pay attention to the overall length, width, height when loading, unloading and
shipping and conforming the regulations is necessary.
(d) Single transporting if necessary after disassembling the mast and balance
weight.
Model
Mast
Balance weight
Dimension(mm)
Weight(kg)
Dimension(mm)
Weight(kg)
8T
2450×2175×850
2423
1980×1166×1325
4193
10T
Mast
2600×1201×695
1864
1980×1610×1169
4826
Carriage
2238×1330×435
1330
Notice:
Dismantling and slinging the component shall not be performed without the
approval of our company. Under special circumstances, the appointed sling position
should be used. The balance weight, fork and mast of the forklift truck all have their
appointed sling position. The above-mentioned data is only for a reference, which
may be adjusted because of configuration or technology optimization.

8
(2) Load and unload the forklift truck
(a) Use the plate with enough length, width and strength.
(b) Pull the parking brake and use jacks to stop the wheel.
(c) Fasten the plate on the center of the cabin, there must be no grease on the
plate.
(d) The left and right height of the plate must be equal to make the loading and
unloading smooth.
(e) Don’t change the direction on the plate to prevent the danger.
(f) Reverse the forklift truck slowly when loading it on the freight car.
(3) Sling the forklift truck
(a) Only the specially trained personnel can sling the truck.
(b) Sling points should be always at the positions specified in sling nameplate.
(c) The slinging cable must be enough to hang the forklift truck.
(d) Disassembled parts of forklift truck must be slung in the appointed position.
(4) Towing of forklift truck
(a) The towing pin is installed below the counter weight. When towing the forklift
truck, first extract the pin and fasten a steel wire, then install the pin back.
(b) When towing the forklift truck, release the hand brake lever.
(c) The towing pin only used for following situation, while the forklift truck can’t
move or while transporting the forklift truck.
(d) Fasten the towing steel wire at the appointed position.
(e) Don’t apply capacity abruptly when towing the forklift truck.
(5) Repair the broken-down forklift truck
If the forklift truck broken-down suddenly during using, drag it away and repair in
time to avoid hindering other vehicles or workers.
5. Parking and storing
(1) Safe parking
(a) Park your forklift truck on a level ground preferably in a wide area. If parking on
a slope is unavoidable, pull the parking brake device and block the wheels to prevent

9
accidental roll. The forklift truck is forbidden parking on a steep slope.
(b) Park your forklift truck in the area where designated or traffic conditions permit.
If necessary, put a signpost or signal lights around the truck.
(c) Park your forklift truck on the solid ground. Avoid soft ground, deep mud or
slippery surfaces.
(d) If you can not lower the forks on the ground due to break-down of the lifting
system, put a warning flag to the fork end and park in the traffic conditions permitting.
(2) Storing
·Before storing
Before storing your forklift truck, clean it thoroughly and perform inspection using
the following procedures.
(a) Wipe away grease, oil, etc. adhering to the body of the truck with waste cloth
and water, if needed.
(b) While washing the body of the truck, check general condition of the truck.
Especially check the truck’s body for recess or damage and tyres for wear and nails or
stones in the tread.
(c) Fill the oil tank up with the appointed fuel.
(d) Check for leakage of hydraulic oil, engine oil, fuel or coolant.
(e) Apply grease where needed.
(f) Check for looseness of hub nuts and cylinder piston rod joints. Check the
surface of piston rod for damage.
(g) Check mast rollers to see that they rotate smoothly.
(h) Full oil into the lift cylinders by lifting the lift cylinders at the full stroke.
(i) In cold weather, don’t draw off long antifreeze, if there is cooling water, run it
away.
·Daily storage
(a) Park the forklift truck at a specified place and block the wheels.
(b) Place the shift lever in the neutral position and pull the parking brake lever.
(c) Put the key switch in “OFF” position and turn off the engine, operate the lever of
the control valve several times and release the residual pressure of the cylinder or
pipes.
(d) Remove the key and keep it in a secure place.
·Long time storage

10
Perform the following service and checks in addition to the “Daily storage” service:
(a) Taking the rainy season into consideration, park the truck at a higher and hard
ground.
(b) Apply antirust oil to the exposed parts such as piston rods and shafts which
tends to rust.
(c) Cover components which may be caught with humidity.
(d) The truck should be operated at least once a week. Fill the cooling system, if
cooling water is discharged. Remove grease from the piston rods and shafts. Start the
engine and warm up thoroughly. Move the truck slowly forwards and backwards.
Operate the hydraulic controls several times.
(e)Avoid parking on soft grounds such as asphalted road in summer.
·Operate the forklift truck after long time storage
(a) Remove antirust oil from the exposed parts.
(b) Discharge the engine oil in crankshaft case of the engine, discharge the gear oil
or hydraulic transmission oil in differential and gear box, after cleaning up then renew
oil.
(c) Discharge foreign matter and water from the hydraulic reservoir and fuel tank.
(d) Remove the cylinder cap, the valves and the rocker shafts, check for the
clearance in normal data.
(e)Add cooling fluid to specified level.
(f) Perform pre-operation checks carefully.
(g) Warm up the engine before operation.
Warning:
If at any time your forklift truck is found to be in need of repair, defective, or in any
way unsafe, the condition should be reported to the supervisor, and the truck should be
taken out of service until it has been restored to safe operating condition.
6. Information of safety operation
(1) The forklift truck belongs to special equipment. Only trained and authorized
operator shall be permitted to operate and service the truck.
(2) Wear the safety guards, such as clothing, shoes, helmet and gloves while
operating the truck.

11
(3) When operating the truck, observe and follow all nameplates stuck on the truck.
The nameplates must be replaced if lost or damaged.
(4) Daily maintenance should be done before or after using the truck. Anytime you
find that the truck is not functioning normally, operation of the truck should be halted and
check or repair at once.
(5) When the distance between the gravity center of loads and the fork arms is
600mm, the max. capacity is the rated capacity. When the distance exceeds 600mm,
the capacity shall be reduced according to the load chart. Overloading is strictly
prohibited.
(6) Operate your forklift truck on a hard ground. Operate on other ground, the lift
capacity and travel speed must be decreased. Wipe off the oil and grease from the floor.
(7) If the forklift truck is equipped with attachment, its usage sphere will be wider,
but its allowable load and stability is reduced. The attachment and special device is not
to be diverted to any other purpose. It’s very dangerous to rebuild the attachment.
Please read the additional instruction we supplied and operate the truck following it
strictly.
(8) Users select “Lengthening fork” in order to carry widening loads. Pay much
attention not to overload and observe the allowable load and the capacity chart stuck on
the truck. Careful driving should be taken when traveling and turning.
(9) The unloaded forklift truck with attachment should be operated as a loaded
truck.
(10) Connect the power and turn on the key switch, select the position of direction
switch, check the truck for normal operation by turning steering wheel, depress the
speed-adjusting pedal softly to keep proper acceleration.
(11) During operation, pay attention to the performance and condition of the system
of machinery, hydraulic, electric and speed-adjuster etc.
(12) When operate one lever, pay attention not to shift another lever. Don’t operate
the lever at any position out of the driver’s seat.
(13) The shift distance of control valve lever can control the speed of the lifting or
descending of the goods. When the goods are lifted or descended, the initial speed
shouldn’t be too fast in either case.
(14) When tilting the mast forward or backward to the limit or lifting the fork to the
maximum height, return the directional lever to neutral.

12
(15) The starting, turning, driving, braking and stopping of the truck should be done
smoothly. When turning on the humid or slippery road, the truck should be decelerated.
(16) Because the forklift truck turns by the rear wheels, the end counterweight may
swing widely when turning. Use care in narrow aisles and other workplaces.
(17) Operate the forklift truck smoothly, don’t jerk the steering wheel. Avoid sudden
stop, acceleration, stop or turn. In the case of improper operation, the truck will turn over.
In case of this, the driver must keep calm, don’t jump off the truck. The driver must hold
tightly the control wheel with two hands; meanwhile, his body must incline in opposite
direction of truck’s turning over.
(18) Turning, lateral or deflective traveling shall not be taken on a slope. It could
cause overturning of the truck, it is very dangerous. On a slope, drive the truck with load
forward to ascend and backward to descend. When the truck goes down on a slope,
drive slowly with the brakes on. Make sure that the engine should not be shut down
when traveling on a slope.
(19) The stability of the truck is influenced by the wind-force during outside
operation, you must notice specially.
(20) Be careful and slow driving over a dock or temporary paving slab.
(21) Insert forks deeply under goods. Adjust fork’s distance according to the
dimension of goods. Make the loads distribute on the forks evenly to avoid tilt and slide
of goods.
(22) Don’t pick the loads with single fork. Fork can not be used to pull out any
embedded goods, if necessary, the pulling force should be estimated.
(23) Don’t handle unfixed or loose goods. Be careful to handle bulky goods. To
prevent the collapse of stacked goods, tighten them. Forbid loading loose or little
volume goods without pallet.
(24) When loading the goods, lower the forks to the floor. After the fork inserting
stacked goods, the fork arms should be in contact with the goods. Drive the truck with
mast tilting back for stabilizing the load. Before traveling, raise the forks for
200mm-300mm from the floor.
(25) When handling bulky loads which block your view, operate the forklift truck in
reverse or have a guide.
(26) While mast’s lifting and lowering, anyone is absolutely prohibited from standing
under the lift bracket or being lifted with forks. Never permit anyone to stand or walk

13
under upraised forks.
(27) When lifting the load, according to the weight of the load, accelerate properly
and then pull the lifting lever.
(28) The load descends for the gravity, at this time, the engine must be in idle
position, and the lever must be pulled slowly to prevent the load from sudden falling.
(29) When loading and unloading goods, keep the mast vertical and the truck is in
braking state.
(30) Load should cling to the load backrest. Do not handle the load which exceeds
height of the backrest, or else there is a danger of load’s falling against operator.
(31) When travel with load, don’t tilt mast forward, don’t do handling. Don’t brake
abruptly to prevent goods from slipping off the forks.
(32) It is necessary to brake before tilting the mast forward or backward. It’s also
necessary to decelerate and tilt forward slowly so as to prevent the goods from slipping
off the forks.
(33) Don’t make a sudden braking when the truck traveling with loads.
(34) Drive the forklift truck to the stacked goods at a low speed, at the same time,
pay much attention to sharp and hard objects near the goods, otherwise, the tyres will
be pricked.
(35) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay
attention to the clearance over the forklift truck.
(36) Keep your head, hands, arms, feet and legs within the confines of the cab.
Never allow other persons on the forklift truck.
(37) Tilt the mast of the high lift forklift truck as backward as possible when
operating the truck. Use minimum forward and backward tilt when loading and
unloading. It is dangerous to travel or turn when lifting the goods at high levels.
(38) It is noted that the goods will fall down when the forks of the truck with lifting
height more than 3m lift, take the protection measures if necessary.
(39) Before the truck decelerating and stopping, don’t change gear to reverse shift,
so as to ensure the safe loading.
(40) When the truck stops and the engine is on idle position, the mast must be tilted
backward. You shouldn’t leave the truck with idling engine or hanged goods unattended.
(41) When adding fuel, make the driver leave the truck and the engine flameout.
Don’t ignite when checking the level of fuel tank.

14
(42) Don’t open the radiator cap when the engine is very hot.
(43) After one day’s working, the fuel tank should be added oil to prevent the
humidity in the fuel tank from becoming the blob and then interfusing the fluid.
(44) When leaving, engage the hand brake, lower the forks on the ground and let
the shift lever to neutral, make the engine flameout or cut down the electric supply. If
parking on a slope with smaller gradient, apply the parking brake and block the wheels.
The truck is forbidden parking on a slope with bigger gradient.
(45) Don’t adjust the control valve and relief valve at will to prevent the damage of
hydraulic system and its components because of excessive pressure passing them.
(46) Tyres should be inflated according to the pressure value specified in the
nameplate of “Tyre Pressure”.
(47) Check the chains periodically to make sure that good lubrication condition
exists between the chain elements, the degree of tightness between left and right chain
is identical. If the variation value of the chain pitch exceeds 2% standard value, it
indicates that the chains have been worn excessively, replace it immediately.
(48) The overhead guard is main part which is strong enough to meet safety
standard, and protect the operator from falling materials. It’s very dangerous to
dismantle or rebuild the overhead guard, because these conditions could lead to an
accident.
(49) A load backrest shall be used as protection against back falling objects on the
fork. It’s very dangerous to dismantle or rebuild the load backrest, because these
conditions could lead to an accident.
(50) You can’t change or add other working equipments on the truck without our
company’s permission, or the rated capacity and safety operation will be affected.
(51) Keep safety when serving on high position.
(52) The forklift truck must be operated under the following environment: below an
elevation of 1000 meters and temperature between -20℃and 40℃, relative humidity is
95%. Careful operation must observe under other adverse circumstances.
(53) Because of the danger for the people, the forklift is forbidden operating in
airtight space, or you may be choked by the tail gas. The tail gas’s exhausting standard
shouldn’t be lower than the no-load mechanical vehicle exhaust standard ruled by the
nation that users are in. If in Europe nation, the adopted tail gas’s exhausting index
should be applied Europe StageⅢA standard.