Unit of Competency: OBSERVE PROCEDURES, SPECIFICATIONS AND

MANUAL INSTRUCTIONS
Module Title: OBSERVING PROCEDURES,
Module No.: 1 SPECIFICATIONS and MANUAL
INSTRUCTIONS
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module in “OBSERVE PROCEDURES, SPECIFICATIONS

AND MANUALS OF INSTRUCRTION”. This module contains training
materials and activities for you to complete.

The unit of competency OBSERVE PROCEDURES, SPECIFICATIONS

AND MANUALS OF INSTRUCRTION is designed to enhance the knowledge,
skills and attitude of the trainees in OBSERVING PROCEDURES,
SPECIFICATIONS AND MANUALS OF INSTRUCRTION. It is one of the
specialized modules required to complete the HEAVY EQUIPMENT
OPERATION (FORKLIFT) NC II

This module will lead you through different learning activities in

order to complete each learning outcome of the module. Each learning
outcomes is provided with Information Sheets (Reference Materials for
further reading to help you better understand the required activities).
Follow these activities and answer the self-check at the end of each
learning outcome. You may remove a blank answer sheet at the end of
each module (or get one from your facilitator/trainer) to write your
answers for each self-check. If you have questions, don’t hesitate to ask
your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills
covered in this learner's guide because you have:
been working for some time
already completed training in this area.

If you can demonstrate to your trainer that you are competent in a

particular skill or skills, talk to him/her about having them formally
recognized so you don't have to do the same training again. If you have a
qualification or Certificate of Competency from previous trainings, show it
to your trainer. If the skills you acquired are still current and relevant to
the unit/s of competency they may become part of the evidence you can
present for RPL. If you are not sure about the currency of your skills,
discuss this with your trainer.
At the end of this module, after having complied the requirement for
the learning outcome or unit of competency, your achievement will be
recorded in the progress chart and achievement chart then you will
be awarded with the Certificate of
Achievement. Thereafter, you can proceed to the next learning outcome
or unit of competency should you have completed the required learning
outcomes intended for every unit of competency.
This module was prepared to help you achieve the required
competency in OBSERVING PROCEDURES, SPECIFICATIONS AND
MANUALS OF INSTRUCRTION specifically in OBSERVE PROCEDURES,
SPECIFICATIONS AND MANUALS OF INSTRUCRTION
This module will be the source of information for you to acquire
knowledge and skills in this particular trade independently and at your
own pace, with minimum supervision or help from your trainer.

 Talk to your trainer and agree on how you will both organize the
Training of this unit. Read through the module carefully. It is divided
into sections, which cover all the skills, and knowledge you need to
successfully complete this module.

 Work through all the information and complete the activities in each
section. Read information sheets and complete the self-check.
Suggested references are included to supplement the materials
provided in this module.

 Use the self-check questions at the end of each section to test your
own progress.

 When you are ready, ask your trainer to watch you perform the
activities outlined in this module.

 As you work through the activities, ask for written feedback on your
progress. Your trainer keeps feedback/ pre-assessment reports for
this reason. When you have successfully completed each element,
ask your trainer to mark on the reports that you are ready for
assessment.

 When you have completed this module (or several modules), and
feel confident that you have had sufficient practice, your trainer will
arrange an appointment with registered assessor to assess you. The
results of your assessment will be recorded in your competency
Achievement Record.
PARTS OF A COMPETENCY-BASED LEARNING MATERIAL

References/Further

Reading Performance Criteria

Checklist Operation/Task/Job

Sheet

Self-Check Answer

Key Self-Check

Information
Sheet

Learning Experiences
Module Content
Learning Outcome Summary
Module Content
Module Content

List of Competencies

Module Content

Front Page
In our efforts to standardize CBLM,
the above parts are recommended
for use in Competency Based
Training (CBT) in Skill
Technical
Development s
Authority (TESDA
sections will show you the
components and features of each
 (HEO) Hydraulic Excavator NCII
COMPETENCY-BASED LEARNING MATERIALS

List of Competencies

No. Unit of Competency Module Title Code

Prepare Preparing CON93120

1.
construction construction 1
materials and materials and tools
tools

Observe procedures, Observing procedures,

CON311201
2. specifications and specifications and
manuals of instruction manuals of instruction

Interpret Interpreting CON31120

3.
technical technical 2
drawings and drawings and
plans plans

Perform Performing CON31120

4.
mensuration’s and mensuration’s and 3
calculations calculations
Maintain Tools and Maintaining Tools and CON31120
5. Equipment Equipment 4
 MODULE CONTENT

UNIT OF COMPETENCY:

Observe procedures, specifications and manuals of instruction

MODULE TITLE
Observing procedures, specifications and manuals of instruction

MODULE DESCRIPTOR:
This unit covers knowledge, skills and attitudes on identifying,
interpreting, applying services to specifications and manuals and storing
manuals

NOMINAL DURATION:
10 hours

LEARNING OUTCOMES:
At the end of this module, you MUST be able to:
1. Identify and access specification/ manuals
2. Interpret manuals
3. Apply information in manual
4. Store manuals

ASSESSMENT CRITERIA:
 Appropriate manuals are identified and accessed as per job requirements
 Version and date of manual are checked to ensure that correct
specification and procedures are identified
 Relevant sections, chapters of specifications/ manuals are located in
relation to the work to be conducted
 Information and procedure in the manual are interpreted in accordance
with industry practices
 Manual is interpreted according to job requirements
 Work steps are correctly identified in accordance with
manufacturer's specification
 Manual data are applied according to the given task
 All correct sequencing and adjustments are interpreted in accordance
with information contained on the manual or specifications
 Manual or specification is stored appropriately to prevent damage,
ready access and updating of information when required in accordance
with company requirements
 Learning Outcome #1 Identify and access specification/ manuals

LEARNING GUIDE
Learning Steps Resources
 Read Information Sheet 1.1 o Information sheet 1.1
 Answer self-check 1.1 o Self-check 1.1
 Compare answers with answer key 1.1 o Answer sheet 1.1

 Listen to lecture
 Participate in the discussion o Multimedia equipment
 Answer oral question o Whiteboard
 Receive feedback from instructor o Whiteboard markers

 Read Information Sheet 1.2 o Information sheet 1.2

 Answer self-check 1.2 o Self-check 1.2
 Compare answers with answer key 1.2 o Answer sheet 1.2

 Listen to lecture
 Participate in the discussion o Multimedia equipment
 Answer oral question o Whiteboard
 Receive feedback from instructor o Whiteboard markers
 INFORMATION SHEET NO. 1.1
(Appropriate manuals are identified and accessed as per job requirements)

Learning Objective/s:
After reading this information sheet the student must be able to:

1. Identify and access appropriate manuals as per job requirements

Handbooks and Manuals

Handbooks and manuals are the most common form of documentation in the business
environment. Many now come in electronic forms, such as documentation stored on a corporate
intranet, but in whatever form they appear, they are used to instruct and guide employees on technical
procedures, corporate policies, and many other kinds of information that is not intuitively obvious or
easy to remember. Without them, employees would lose a valuable reference source and businesses
would suffer from a variety of problems, ranging from untrained workers to liability lawsuits.
Some people make sharp distinctions between what is a manual and what is a handbook, but
in practice there is substantial overlap. By convention, certain types of publications are more frequently
called manuals, notably in technical documentation for software programs and for machine operation.
However, these same sorts of publications may be termed users' guides, help guides, reference books,
or something else altogether.
Ambiguity in the nomenclature should not obscure the importance of good documentation or the
need to target such documentation to a specific audience. All manuals and handbooks are not alike;
authors and designers must consider

 why the reader will be using the publication;

 what their existing knowledge of the subject is:
 what subject-area conventions they are used to; and
 what physical surroundings the documentation will be used in.

For example, if a manual is intended to be a quick, at-a-glance reference for factory workers, it
probably should not be a bulky, text-heavy, hardcover book, unless an analysis of the users' work
habits indicate that such a format would be convenient. More likely, a manual for this purpose should be
short, graphical, possibly tabbed or color-coded for fast access, and provided in a physical format that
is compatible with the way its users work. The same kinds of usability considerations apply to most
types of manuals and handbooks.
MAJOR AREAS OF USE

 CORPORATE DOCUMENTATION
Businesses need handbooks and manuals to keep employees, suppliers, customers, shareholders,
and anyone else who has an interest in their business apprised of policies, procedures, and regulations.
The documents in some cases represent the company's survival. In today's litigious society, companies
often become the targets of lawsuits that can cost them millions of dollars. Some of these lawsuits, e.g.,
those regarding sexual harassment and product liability, can be avoided if companies include in their
handbooks explanations of their policies regarding those issues.

 TECHNICAL DOCUMENTATION
The second important class of documentation concerns how to use technology. For example, a
company that purchases machinery of any type, from punch presses to computers, needs manuals to
explain to the people who will be using it how the equipment operates, when it is to be serviced, what to
do when it fails, and so on. Likewise, if a company purchases software for its operations, it must also
acquire manuals which explain how the software operates and provide instructions to employees on
how to use it. Manufacturing concerns need extensive documentation to stay abreast of government
regulations, safety standards, and other issues legislated by local federal, and state agencies.

 TUTORIALS AND INSTRUCTION

Handbooks and manuals are also used in training programs, often in the form of tutorial or
instructional guides. Here the object is not merely to document a process or procedure, but to actively
teach something. Many policies, particularly those that have a direct impact on the employee and the
company, may require follow-up training as well. Such topics might include sexual harassment policies
and codes of ethics. Also, computer users may require in-class training on different functions of
computer hardware and software. Thus, handbooks and manuals are integral parts of in-house training
programs. There is seemingly no end to the number and types of documents needed to support a
company's operations.

COMPUTERS IN THE DOCUMENTATION PROCESS

Computers have greatly facilitated the production of manuals and handbooks, as well as
providing an efficient medium for disseminating their content. Simple printed manuals, such as those for
internal use, can be easily and cheaply produced using standard word processing software. With more
advanced desktop publishing software—and someone who knows how to use it—a company can also
produce highly formatted, professional-quality publications using source files generated on a desktop
computer and shipped out for printing and binding. If the documentation is to be hosted on a corporate
intranet or other electronic medium, the process may even be simpler, requiring only a conversion of
the files to a readily viewable format like HTML.
WHO PRODUCES HANDBOOKS?
Handbooks and manuals are written by anyone from entry-level custodians to the chief
executive officers of corporations. Who writes a particular document depends on the size of the
corporation, the expertise of the employees, and the purpose of the manual. There are also specialists
who are employed full-time or on a contract basis to produce manuals. Many of them fall under the
broad headings of technical writers and graphics artists.
Graphics artists produce the illustrations that accompany the text in handbooks and manuals.
Technical writers specialize in producing scientific or industry-specific information in readable form for
lay persons. "Scientific" in this case can mean anything from data processing language to engineering
terms to astrophysics. Often, scientists rely on technical writers to translate the special terminology they
use in their fields of expertise into understandable terms for non-scientists or product users.
The purpose of technical writing is to reduce to understandable terms language that might be
hard for the average person to comprehend. For example, data processing technical writers produce a
wide range of manuals. They might produce user manuals for computer users and systems manuals for
programmers and analysts. Technical writers in scientific fields might produce research proposals for
professors and consultants or a procedural manual for a geological team to follow.
Not all manuals and handbooks are written by technical writers. An administrative assistant
might be asked to write a handbook explaining to coworkers or temporary workers how to use a
switchboard or a computer. The chief executive officer of a small corporation may put together an
informal handbook for managers on how to supervise people, handle customer returns, etc. Generally,
who writes a manual is less important than whether the manual serves a practical purpose, by teaching
employees, customers, and other audience members about a procedure, policy, technique, etc.

THE ART OF MANUAL WRITING

Handbooks and manuals are only as effective as the manner in which they are presented. The
same rules that apply to any form of writing apply to manuals and handbooks. They must be written
clearly, concisely, consistently, and accurately. If they are not, the audience for whom they are intended
will ignore them, which can lead to problems for some companies.
Document writers must define three things before they write a manual or handbook: audience,
purpose, and scope. Once they have defined each, they can begin the writing process.

 AUDIENCE
The audience is important because different groups of people have varied levels of understanding
about certain topics. Or, an audience may not be fluent in the language in which the manual is being
written. This is particularly true in today's emerging global market environment.
Many products are not manufactured in the countries in which they are sold. This practice, although
perhaps cost-efficient, can lead to poor documentation when product documentation is written by
individuals who aren't fluent in the export country's language. A company based in Taiwan, for example,
may include with its products instructions written in hard-to-understand English. In such cases, the
documents may be useless to consumers. This can lead to lost sales and/or customer dissatisfaction.
 Even if the writer and the audience do speak the same language, there is a critical need for
audience definition. Depending on the anticipated reader, manual writers must choose relevant
terminology and make assumptions about what needs to be explained and what is considered obvious.
If it's necessary to use technical terms, they may need to be defined. Similarly, the use of illustrations
should also be dictated by the intended audience's profile, with diagrams or screen shots being chosen
to clarify points that are most crucial or difficult to understand.

 PURPOSE
Defining the audience is only the first step in producing a manual. The writer must also understand
the manual's purpose. Is it meant to be instructional? Informative? Does it present the solution to a
problem? The manual's purpose dictates to a great extent how its contents will be presented. For
example, if it is instructional, the writer must be able to perform the procedures contained in the manual,
because if a "how to" writer is unfamiliar with the procedure being documented, there will be inevitable
errors in the manual that will defeat its purpose.

 SCOPE
Manuals should also be as comprehensive as possible within a defined scope of coverage; in other
words, the manual should have defined boundaries of coverage and should observe these boundaries.
This means not including too much or too little. The scope is mostly determined by the purpose, e.g., to
teach a user how to use the major functions of a software application. However, the audience may also
influence scope, e.g., an intermediate-level audience doesn't need rudimentary information. A writer
should make every effort td include all the information that is required by the audience to understand
the topic or follow instructions. For instance, if a manufacturer encloses with a product a manual
explaining how to assemble it, unpack it, install it, or maintain it—the manual's scope—each of these
aspects should be addressed fully.

THE WRITING AND EDITING PROCESS

 OVERVIEW
Once a manual's audience, purpose, and scope are determined, common principles of good writing
come into play. The writer should follow an appropriate style guide, whether an in-house standard or an
externally published guide, for the subject matter. The project manager should also ensure there is an
adequate system of editorial control to avoid errors in the development process. This normally includes
going through at least one cycle of copyediting for spelling, grammar, punctuation, and other basic
mechanics. It is also beneficial to enlist one or more persons—possibly both experts and lay readers—
to proofread the document and its illustrations for clarity, accuracy, and ease of use. A major manual
development project, such as a lengthy reference guide for customers, may also require at least one
phase of audience review, during which a small group, e.g., a five-member focus group or panel, of
real-life users (or potential users) from outside the company are asked to review and comment on the
documentation while there is still time to revise it.
  WRITER COMPETENCY AND ACCURACY
Perhaps the most basic consideration at the outset of the manual writing process is to ensure that
the writer is capable of producing the intended documentation. This involves ascertaining not only
whether the writer's general capabilities relate to the project, but also that the writer is equipped with the
resources and information he or she needs to be successful. Though seemingly obvious, this is a
common concern in technical product documentation, particularly when a new product is being fine-
tuned at the last minute. Often in these cases the manual writer will begin working before the product is
finalized. At other times there may not be a functioning model of the product for the writer to observe or
test in the beginning. A well-designed development process will ensure that as product changes are
implemented the writer has sufficient access to this information to write competently about the subject.

 CONCISENESS
One of the keys to the success of any manual or handbook is conciseness. Readers do not want to
read any more than is absolutely necessary in order to learn how to perform a procedure, accept or
evaluate a proposal, or assimilate information.

 CLARITY AND ORGANIZATION

The next step is clarity. The language used should consist of commonly used words, rather than
complex, seldom-used words that will confuse the readers. Moreover, sentences should be constructed
to maximize readability. A common complaint about technical manuals is that they contain all the
information a user may need, but the material is difficult, if not impossible, to digest. The writer may
have achieved factual accuracy and comprehensiveness, but if the information is buried in awkward
sentences and unorganized paragraphs, the manual's purpose will be defeated.

 CONSISTENCY
Another factor to consider is consistency. Manuals should be consistent in terminology, format, and
presentation. If a writer starts with a numbering system for paragraphs and sections, it should be
followed throughout. If visual aids such as charts, graphs, and diagrams, which are used to enhance,
clarify, and supplement the material, don't refer to the contents of the manual, they, too, will be
distracting.

HANDBOOK AND MANUAL ILLUSTRATIONS

Illustrations are important components of manuals and handbooks. Illustrations in many forms
can be used, ranging from simple hand-drawn charts and graphs to three-dimensional computer-
generated designs. They can be produced by engineers, graphics artists, freelance artists, or
secretaries working with computer graphics software packages. Illustrations can be changed at any
stage of the production process, especially when computers are used to create them.
THE PHYSICAL PRODUCT
For printed manuals, the project manager must determine the manual's physical format. This
includes three main areas:

 layout, presentation, and size

 material
 binding and cover

As with other aspects of manual production, these features should be directed by audience needs
and the manual's purpose. Layout and presentation include the page format, typography, and, if
necessary, colors. Color is visually stimulating and increasingly affordable, and it may also serve
audience needs. For instance, various sections of the manual may be color coded to enable speedy
retrieval of information. In some cases, it may also be helpful to include complex illustrations in color.
Size is another key consideration. For product manuals, one basic requirement is that the manual must
fit within the product packaging. Size may also be related to usability issues.
Choosing the material is relatively straightforward, although some manuals will have special
material requirements. Most manuals are printed on uncoated medium or lightweight paper. Some,
however, may be produced on glossy magazine-style pages or on thicker cardstock for special
purposes. For example, a short, flip-tab reference guide for a specialized software package may
employ rigid, laminated pages to maximize ease of use and durability.
The cover and binding also impact longevity and ease of use. The typical product manual has a
thick, coated paper cover and what is known as perfect binding. Perfect binding uses a flexible glue on
the manual's spine to hold the pages together; this is used on many commercial softcover publications.
Pages in longer manuals or ones that require special longevity may also be stitched together before
binding glue is applied. For manuals that should lie flat while open, such as software tutorials in which
the user reads from the manual while working at the computer, a mechanical binding, such as plastic
comb/spiral binding, is best.

EVALUATION
A good practice recommended by documentation experts is to follow up production of a
handbook or manual with an evaluation stage. This may involve reviewing the final product against the
original goals or conducting a more formal assessment that solicits user feedback.

TYPES OF HANDBOOKS AND MANUALS

From the moment employees are hired to the time they leave a company, they will be using
different types of handbooks and manuals. When they are initially hired, for example, they will probably
be handed an orientation manual that includes extensive information they will need to fit into the
corporate culture. Upon retiring, they will be given a handbook that spells out everything from benefits
to payment schedules and how to ease the transition between work and retirement. In between, they
will use many other handbooks and manuals, some of which are discussed below.
ORIENTATION HANDBOOKS
Orientation handbooks are provided to new employees of corporations. They are often
combined with employee handbooks. These documents might include the company's mission
statement, history, and code of ethics. Many corporations pay particular attention to these three
categories.
The mission statement is a broad declaration of the basic, unique purpose and scope of
operations that distinguishes the organization from others of its type. Employees must know from the
beginning of their careers what their roles within the organization will be. The mission statement defines
that role. It also defines a common purpose, encourages company loyalty, and creates a sense of
community among workers. The mission statement provides managers a benchmark against which
they can measure individual and organizational success. Finally, the mission statement provides insight
into the company's operation for investors, customers, and anyone else who has an interest. Since
most employers want to inculcate the company's culture in employees at the beginning of their careers,
they see the orientation handbook as the proper place to start the process.
Of equal importance is the employer's code of ethics, which is a document prepared to guide
organization members when they encounter an ethical dilemma. This is sometimes a stand-alone
document given to each company employee. In some cases, employees must sign a statement
acknowledging that they have read, understand, and agree to abide by the code. Nearly three-quarters
of the major corporations in the United States have written codes of ethics.
A company history is a common inclusion in an orientation handbook to provide employees
with an insight into the company's growth and importance to the community. This is particularly true of
older firms such as Procter & Gamble Co., which has been around since 1837, and Dexter
Manufacturing, which opened its doors in 1767. Both of these companies have gone through major
changes in their histories and will no doubt experience more. Employees should be made aware of the
companies' vicissitudes and the sacrifices their predecessors have made to ensure the firms' futures.
Eliciting a feeling of belonging can be done through company histories.
Orientation handbooks include a variety of other information that human resources and
management specialists consider necessary to the starting employee. This information can range from
the location of local banks and grocery stores to a description of the employers' physical plant layouts.
The contents of such handbooks vary from company to company, but their intent is always the same: to
welcome new employees and help them fit into the company's culture and workforce as quickly as
possible.

EMPLOYEE HANDBOOKS
Employee handbooks are logical extensions of orientation documents. They are intended to
present more in-depth information for employees who have been with the employer for a while and who
are expected to stay for the foreseeable future. These documents may contain some of the same
information included in orientation handbooks. For the most part, however, they are designed to keep
employees informed of topics of continuing and significant interest, such as work hours, benefit
programs, affirmative action policies, grievance procedures, counseling programs, etc. They may also
include information concerning company-sponsored social activities, location of company stores,
restaurants, and fitness centers, local business firms that provide discounts for employees, and the like.
The contents of employee handbooks are often dictated by the size of the company, number of
employees, and other factors. Regardless of the scope of the handbook, however, it is always intended
to be as complete a compendium as possible regarding information employees need to function
effectively within the corporate environment. These documents may be considerably larger in union
environments.

HANDBOOKS AND MANUALS IN A UNION ENVIRONMENT

Companies which have agreements with labor unions are likely to have a broader range
of material included in employee handbooks. Sometimes union agreements are stand-alone
documents. Some employers, however, prefer to include essential union-related information in
employee handbooks and treat the union contract as a separate document. Both management and
labor representatives maintain extensive handbooks and manuals to monitor one another's activities.
Manuals can include descriptions of virtually every activity covered under contract
administration. There are sections addressing discipline, incentives, work assignments, individual
personnel assignments, hours of work, supervisors performing production work, production standards,
working conditions, sub-contracting, past practice, rules, and so on. These manuals might also include
the actual contracts negotiated between labor and management. It is essential that both sides have
copies of these documents—and that they adhere to the information therein.
It is particularly important that management have on hand readily accessible union contracts
and relevant documentation. Union stewards, the elected or appointed shop floor union representatives
responsible for interpreting the contract for union members and processing grievances, are generally
extremely knowledgeable about the contents of labor contracts. Management should be equally
knowledgeable. Historically, however, that is not the case. Managers who do not pay attention to union
contracts can hurt themselves and their employers.
There are other documents extant in union environments. For example, there are bargaining
books, which are cross-referenced files enabling negotiators to determine quickly what contract clauses
would be affected by involved parties' demands. These books contain information like the general
history of specific contract terms and a code to indicate the proposals' relative importance to
management. Many bargaining books today are automated and keyed to spread-sheets. This allows
negotiators to answer "what if questions immediately and calculate the cost implications of demands
and concessions. Such books contain much valuable information. For example, they include the history
and text of the particular clause as it was negotiated in previous contracts, comparisons of the
company's experience with that of other companies in the industry, the company's experience with the
particular clause, both in operation and the grievances, and legal issues pertaining to the clause

SUPERVISORS' AND MANAGERS' HANDBOOKS

Some companies produce these handbooks separately. Others will combine them. In some
cases, firms will produce three separate handbooks, one for each level of management. Those
distributed to senior-level executives might deal exclusively with topics like public policy, government
regulation, etc. These are issues not likely to affect middle- and first-level managers to any great extent.
How the documents are produced and for which levels of management they are intended is dependent
on a company's size, number of employees, etc. In large companies, however, they are frequently
produced separately.
Not all managers are responsible for subordinates. Managers are not necessarily leaders of
people, whereas supervisors are. In general, supervisors are responsible for production in a workplace.
They are the first-line supervisors. Managers are generally considered to be middle level. More often
than not, they manage other managers, including supervisors. Therefore, the contents of a supervisor's
manual may differ greatly from those of a manager's manual. A general overview of the two types of
manuals reveals that they may contain information about how to: handle grievances; enforce company
policies concerning work hours and dress codes; administer discipline; reward and motivate employees;
and recognize employees' personal problems such as substance abuse, financial difficulties, etc., that
might have an impact on their work performances.

PERSONNEL MANUALS
Personnel manuals traditionally have been the corporate bible. They contain information that
explains the rules, policies, procedures, etc., that govern a company's day-to-day operations. Without
them, no company can survive.
The list of topics included in personnel manuals is seemingly endless. The issues discussed
cover every facet of a company's operations. In many cases, the manuals are so thick that they can be
maintained only at certain locations within a company. They are too cumbersome and expensive to
produce and to distribute them to every employee. Thus, they may be maintained only in the human
resources department, on selected executives' desks, or in the company library. Wherever they are
housed, they must be accessible to all employees at all times.
Human resource management is the management of various activities designed to enhance
the effectiveness of an organization's work force in achieving organizational goals. The activities
include functions like planning, staffing, employment development and evaluation, compensation, and
maintaining effective work force relationships. Manuals must reflect these activities.
A basic personnel manual is likely to include job descriptions, job specifications, organizational
charts, affirmative action rules, job posting procedures, employee selection guidelines, training and
development policies, compensation and benefit schedules, sexual harassment guidelines,
and employee assistance programs (EAPs). This list is by no means inclusive of all the topics that
might be
The key to maintaining personnel manuals is constant updating. Often, personnel manuals
and/or employee handbooks are considered legal contracts to which the corporation is liable for
violations of company policies, procedures, and rules. It is important to note that the three terms are not
synonymous.
A policy is a general guide that specifies the broad parameters within which organization
members are expected to operate in pursuit of organizational goals. A procedure is a prescribed series
of related steps to be taken under certain recurring circumstances. A rule spells out specific actions to
be taken or not taken in a given situation. The company may have some flexibility in each of these
areas, but if nothing regarding policies, procedures, and rules is written in some type of readily
accessible document, it may be subject to legal action from disgruntled or displaced workers. In light of
this, it is important that personnel manuals be updated to reflect the most recent changes in company
policies, procedures, rules, and outside influences that might impact its operations. For example, it is
crucial that companies update affirmative action guidelines and sexual harassment policies immediately
if changes to them should be necessary. It is especially important to update policies dictated by local,
state, or federal governments

SUBSETS OF PERSONNEL MANUALS

Occasionally, personnel manuals are simply too extensive to distribute to every staff member.
Therefore, it is prudent to produce mini-manuals which include the issues that most directly concern
workers. These might include benefits, job posting, employee assistance, etc. (These subsets illustrate
clearly the subtle difference between a manual and a handbook. In this case, the personnel manual
includes all the relevant human resources topics. The handbooks are dedicated to a limited number of
those topics individually or in combination.)
There are several advantages to personnel handbooks. Employees have immediate access to
them. That also makes it more likely that employees will become aware of critical changes in pertinent
issues as soon as they are distributed. For example, if an employer distributes a Grievance Procedure
Handbook which includes sexual harassment and Affirmative Action guidelines, any changes to one or
all of the policies will reach employees' attention immediately. Occasionally, companies may ask
employees to acknowledge changes by signing distribution forms that act as contracts. This is one way
of ensuring that employees read and understand critical handbooks.

DATA PROCESSING HANDBOOKS AND MANUALS

Documentation is particularly important in EDP operations. Virtually every aspect of a data
processing system is documented. For example, there is extensive documentation involved in the EDP
life cycle. Developing an EDP system comprises several stages: analysis and design (when the basic
concepts of the system are laid out by analysts and designers), development (when the programs are
being written), integration (when the programs are assembled into a cohesive system), implementation
(when the system is up and running), and maintenance and enhancement (making sure the system
runs smoothly to its logical demise). There is also the ultimate document to be produced in the EDP
arena: the user manual.
Users are often unfamiliar with many of the concepts used in EDP. Their sole interest at times
is simply to acquire an end product that will facilitate their operations. Generally, they have a
representative on the system development team, but often just in an advisory capacity. The system
developers themselves may not be too eager to produce reams of documentation. The ultimate
responsibility, then, rests on the shoulders of technical writers. They are generally the people
responsible for producing the large number of manuals and handbooks that are natural by-products of
EDP projects.
 However, the manuals produced by EDP developers are by no means restricted to in-house
users and other people. Software developers and hardware manufacturers must produce concise,
easy-to-understand handbooks and manuals for purchasers of computers. More and more people are
buying computers today for home use. Each computer and its software must be accompanied by a user
manual instructing users how to install and use them. This is a daunting task for technical writers, since
many home computer users are not EDP experts. This same idea applies to other instruction and
information manuals produced by manufacturers for consumers.

BUSINESS MANUALS FOR CONSUMERS

Virtually every manufacturer that sells products to consumers today must include as part of the
package a manual or handbook outlining how to use the product, the hazards associated with it, and
other valuable information. Much of the information contained in these consumer manuals is mandated
by various governmental agencies and must include all possible hazards associated with each product
and contain numbers where consumers can talk to company representatives. Many of the documents
provided by manufacturers are included simply to protect the companies as much as possible from
consumer lawsuits.

THE INFLUENCE OF GOVERNMENT AGENCIES ON HANDBOOKS AND MANUALS

Many handbooks and manuals are the direct result of government legislation and policies. Companies
must, maintain a variety of documentation dealing with federal and state regulations regarding clean
water, clean air, noise pollution, workplace safety, etc. Such manuals are especially prevalent in the
industrial section of the business environment.
The increased involvement of society and government in business affairs has necessitated a
greater demand for laws to protect the environment and increase worker safety. Chemical
manufacturers, for example, must adhere to strict federal and state environmental pollution guidelines
which are part of various clean air and water acts. In order to do so, they must maintain comprehensive
manuals and handbooks outlining policies, fines for violating the acts, reporting regulations, etc.

STORAGE OF HANDBOOKS AND MANUALS

Today, handbooks and manuals can be stored in a variety of mediums. There are still large
numbers of them in hard copy resident on employees' desks. Some companies prefer to store them in
collections at central points such as libraries and selected department offices. There has been a trend
toward storing documents on-line via computer. People who want access to them can gain it via
computer. Other companies store all or part of their handbooks and manuals on microfiche. Regardless
of which medium is used, handbooks and manuals will not go out of style.
 SELF-CHECK NO. 1.1
Identification:
Identify the following questions. Use answer sheet no. 1.1 for this test

1. Handbooks and manuals are the most common form of

documentation in the business environment
2. Handbooks and instruction are used in training
programs, often in the form of tutorial or instructional guides
3. Handbooks and manuals are written by anyone from entry-
level custodians to the chief executive officers of corporations
4. The audience is important because different groups of
people have varied levels of understanding about certain topics
5. Manuals should be consistent in terminology, format, and
presentation
6. Illustrations in many forms can be used, ranging from simple
hand-drawn charts and graphs to three-dimensional computer- generated
designs
7. For printed manuals, the project manager must
determine the manual's physical format this include a printer
8. From the moment employees are hired to the time they leave a
company, they will be using different types of handbooks and manuals
9. Orientation handbooks are provided to old employees of
corporations
10. Employee handbooks are logical extensions of
orientation documents
 ANSWER KEY NO. 1.1

1. T
2. T
3. T
4. T
5. T
6. T
7. F
8. T
9. F
10. T
 INFORMATION SHEET NO. 1.2
(Version and date of manual are checked to ensure that correct specification
and procedures are identified)

Learning Objective/s:
After reading this information sheet the student must be able to:

1. Check and ensure that the version and date of manual is correct specification
and identify the procedures

Version Control Guidelines

Refer to the Version Control Flow Chart following the guidelines.

1. Document dates

a. The author of the document will ensure the date of the document is created or revised is
identified on the first page and, when possible, is incorporated into the header or footer of
the document and appears on every succeeding page.

2. Version numbers

a.The author of the document will ensure the current version number is identified on the
first page and, when possible, is incorporated into the header or footer of the document
and appears on every succeeding page.

3. Draft document version number

a. The first draft of a document will be Version 0.1.

b.Subsequent drafts will have an increase of “0.1” in the version number (e.g., 0.2, 0.3, 0.4,
…0.9, 0.10, 0.11).

4. Final document version number and date

a.The author (or investigator) will deem a protocol or other document (consent/assent form,
case report form, manual of procedures) final after all reviewers have provided final comments
and the comments have been addressed.

b. The first final version of a document will be Version 1.0. Include the date when the
document becomes final. Generally, the final version is submitted to the Institutional Review
Board (IRB) and/or FDA.
etc.) c.Subsequent final documents will have an increase of “1.0” in the version number (1.0, 2.0,
5. Final documents undergoing revisions

a. Final documents undergoing revisions will be Version X.1 for the first version of
the revisions. While the document is under review, subsequent draft versions will increase by
“0.1” (e.g., 1.1, 1.2, 1.3, etc.). When the revised document is deemed final, the version will
increase by “1.0” over the version being revised (e.g., the draft 1.3 will become a final 2.0).

6. Documenting substantive changes

a.A list of changes from the previous draft or final documents will be kept. The list will be
cumulative and identify the changes from the preceding document versions. The list of changes
made to a protocol and consent/assent should be submitted to the IRB with the final
protocol and consent/assent documents.

Generally, the first final protocol version submitted to the FDA is 1.0 if it is an investigational
new drug (IND) study. If it is not an IND study, the first final protocol version to be implemented is 1.0.
 Version Control Flow Chart

Version Control

Document Date
Date the document is created or revised is identified on the first page and, when
possible, is incorporated into the header or footer of the document and appears on
every succeeding page.

Version Number
Current version number is identified on the first page and, when possible, is
incorporated into the header or footer of the document and appears on every
succeeding page.

First Draft
1st draft is Version 0.1- subsequent drafts will increase by “0.1”

First Final
First final version will be Version 1.0

Revision to a Final Version

Final documents undergoing revisions will be Version X.1 For the 1st revision;
subsequent drafts will increase by “0.1” E.g., 1.1, 1.2, 1.3.
All changes will be documented

Subsequent Finals
Version number will increase by “1.0” above the version being revised e.g., 1.x
becomes 2.0, 2.x becomes 3.0.
 SELF-CHECK NO. 1.2
Identification:
Identify the following questions. Choose your answer on the box below. Use
answer sheet no. 1.2 for this test

1. The author of the document will ensure the date of the

document is created or revised is identified on the first page
2. The author of the document will ensure the current
version number is identified on the first page and, when possible, is incorporated into
the header or footer of the document and appears on every succeeding page
3. This revision will be Version X.1 for the first version of the
revisions. While the document is under review, subsequent draft versions will
increase by “0.1”
4. A list of changes from the previous draft or final
documents will be kept
5. The list of changes made to a protocol and
consent/assent should be submitted to the

Version number Documenting substantive changes

IRB Final documents undergoing revisions
Document dates
 ANSWER KEY NO. 1.2

1. Document dates
2. Version number
3. Final documents undergoing revisions
4. Documenting substantive changes
5. IRB
 Learning Outcome #2 Interpret manuals

LEARNING GUIDE
Learning Steps Resources
 Read Information Sheet 2.1 o Information sheet 2.1
 Answer self-check 2.1 o Self-check 2.1
 Compare answers with answer key 2.1 o Answer sheet 2.1

 Listen to lecture
 Participate in the discussion o Multimedia equipment
 Answer oral question o Whiteboard
 Receive feedback from instructor o Whiteboard markers

 Read Information Sheet 2.2 o Information sheet 2.2

 Answer self-check 2.2 o Self-check 2.2
 Compare answers with answer key 2.2 o Answer sheet 2.2

 Listen to lecture
 Participate in the discussion o Multimedia equipment
 Answer oral question o Whiteboard
 Receive feedback from instructor o Whiteboard markers
 INFORMATION SHEET NO. 2.1
(Relevant sections, chapters of specifications/ manuals are located in relation
to the work to be conducted)

Learning Objective/s:
After reading this information sheet the student must be able to:

1. Locate relevant sections and chapter of specifications/ manuals in relation

to the work to be conducted

Identifying the parts of a publication

1.Chapters
Number consecutively throughout the publication using Arabic numbers (for example,
CHAPTER 1, CHAPTER 2)

2.Paragraphs
Number consecutively within chapters, using two-part Arabic numbers. The first
number represents the chapter, the second represents the numerical sequence of the paragraph
within the chapter (for example, 1-1, 1-2; 2-1, 2-2).

3.Sub-paragraphs
First level: Identify within each paragraph using lowercase letters in alphabetical sequence (for
example, a, b, c,...z; aa, ab, ac).
Second level: Number consecutively within each subparagraph, using Arabic numbers in
parentheses (for example within sub paragraphs) a, (1), (2); within subparagraph b, (1), (2))
Third level: Identify within each subparagraph, using lowercase letters in parentheses and in
alphabetical sequence (for example, within subparagraph a (1), (a), (b); a(2), (a), (b)).

4.Illustrations and tables

Number consecutively within each chapter, using two-part Arabic numbers. The first number
represents the chapter, the second number represents the numerical sequence of the illustration or
table within the chapter (for example, Figure 1-1, Figure 1-2; Figure 2-1, Figure 2-2; Table 1-1, Table 1-
2; Table 2-1, Table 2-2).
5.Appendixes
Identify with capital letters in alphabetical sequence (for example APPENDIX A, APPENDIX B)

a. Paragraphs within a letter appendix

Identify with a capital letter and an Arabic number. The represents the appendix; the
number represents the numerical sequence of the paragraph within appendix (for example, A-1, A-2; B-
1, B-2).
b. Subparagraphs within an
appendix Same as item 3.
Above
c.Illustration and tables within an appendix
Identify with a capital letter and an Arabic number. The letter represents the appendix.
The number represents the numerical sequence of the illustration or table in the appendix (for example,
Figure A-1, Figure A-2; Table A-1, A-2).

6.Glossary
Unnumbered

7.Bibliography
Unnumbered
 SELF-CHECK NO. 2.1
Identification:
Identify the following questions. Use answer sheet no. 2.1 for this test

1. One of the parts of a publication that the number is

consecutively throughout the publication using Arabic numbers (for example,
Chapter 1, Chapter 2)
2. One of the level of subparagraphs that identify within each
paragraph using lowercase letters in alphabetical sequence (for example, a, b,
c,...z; aa, ab, ac).
3. Number of consecutively within chapters, using two part- part
Arabic numbers. The first number represents the chapter, the second represents the
numerical sequence of the paragraph within the chapter (for example, 1-1, 1-2; 2-1,
2-2)
4. Number consecutively within each chapter, using two-
part Arabic numbers. The first number represents the chapter, the second number
represents the numerical sequence of the illustration or table within the chapter (for
example, Figure 1-1, Figure 1-2; Figure 2-1, Figure 2-2; Table 1-1, Table 1-2; Table
2-1, Table 2-2)
5. Identify with capital letters in alphabetical sequence (for example
APPENDIX A, APPENDIX B)
 ANSWER KEY NO. 2.1

1. Chapters
2. First level
3. Paragraphs
4. Illustrations and tables
5. Appendixes
 INFORMATION SHEET NO. 2.2
(Information and procedure in the manual are interpreted in accordance with
industry practices)

Learning Objective/s:
After reading this information sheet the student must be able to:

1. Interpret information and procedure manual in accordance with industry

practices

Interpret technical specifications and manuals

1.Unit descriptor
This unit covers identifying, accessing, interpreting and analyzing technical information in an
enterprise, including quality documentation, equipment manufacturer specifications, engineering data
sheets and national standards. It also covers explaining and using the information, and identifying
implications of changes to technical information.

2.Application of the unit

This unit goes beyond routine accessing and interpretation of technical information. This
unit applies to the identification, access, interpretation and analysis of technical information to
enable carrying out engineering or manufacturing activities.
For routine accessing, organizing and communication of information related to processes or
tasks, MEM16006A
Organize and communicate information should be regarded as sufficient.

3.Licensing/ regulatory information

4.Pre-requisites
5.Employability skills information
6.Elements and performance criteria pre-content
Performance criteria describe the performance needed to demonstrate achievement of the
element. Where bold italicized text is used, further information is detailed in the required skills and
knowledge section and the range statement. Assessment of performance is to be consistent with
the evidence guide
7.Elements and performance criteria
a.Identify and locate technical information resources
 Information needs are identified and confirmed with appropriate persons.
 Workplace information resources are identified and their location is determined
in the information system.
 Appropriate technical information is obtained.
b.Access technical information
 Relevant technical information is located using search techniques appropriate
to the resource and information requirements.
 Symbols, codes, legends, and abbreviations are interpreted correctly.
 Technical information is accessed and relevant application is understood.
 Clarification or further explanation of technical information is obtained,
where required.
 If applicable, the revision status of the technical information is verified to
ensure current status.
c. Interpret and analyze technical information
 Technical information/data appropriate to work requirements and/or application
is checked for currency and authenticity
 Technical information is interpreted and analyzed for use in given engineering
or manufacturing applications.
 Technical information is used according to the specific engineering or
manufacturing application.
d.Explain and use information
 Information and analyses are explained and distributed to appropriate
personnel.
 Information resources are used according to work requirements.
 Where applicable, work is undertaken in accordance with acquired technical
information.
e.Identify implications of changes to technical information
 Technical information systems are monitored for changes.
 Personnel affected by changes to internal or external specifications or other
technical information are identified.
 Means of distributing changed information are established.
 Changes to technical information are documented
8.Require skills and knowledge
Look for evidence that confirms skills in:
 accessing, reading and following information on written job instructions, specifications,
standard operating procedures, charts, lists, drawings and other applicable reference
documents
 planning, sequencing operations
 following oral/written instructions
 checking and clarifying task-related information
 checking for conformance to specifications
 undertaking numerical operations and calculations/formulae within the scope of this unit
 entering information onto workplace documents
 accessing and using technical documentation
 identifying and using correct specifications for process and/or systems
 using components of system, where appropriate
 completing formal documentation and reporting as required
 adopting appropriate communication strategy, including confirmation of received
information and distribution of instructions
 communicating information in ways appropriate for the audience
 maintaining appropriate records
 identifying and analysing implications of changes to information systems

Require knowledge:
Look for evidence that confirms knowledge of:
 available industry information resources
 uses and applications of information resources
 range of formats that information can be presented
 safe work practices and procedures
 location and retrieval requirements of system information
 correct process used to identify relevant specifications
 quality improvement processes for information systems
  interpretation of technical data and information
 appropriate communication strategies
 dissemination of information regarding information systems
 a range of instructional techniques
 implications of changes to technical information
 procedures for responding to information changes
 hazards and control measures associated with changes to technical information, including
housekeeping
 safe workplace practices and procedures

9.Evidence guide
The evidence guide provides advice on assessment and must be read in conjunction with the
performance criteria, required skills and knowledge, range statement and the Assessment Guidelines
for the Training Package.

a.Overview assessment
A person who demonstrates competency in this unit must be able to interpret and
analyse information from specifications and manuals.
b.Critical aspects for assessment and evidence required to demonstrate competency in
this unit
Assessors must be satisfied that the candidate can competently and consistently
perform all elements of the unit as specified by the criteria, including required knowledge, and be
capable of applying the competency in new and different situations and contexts.
c.Context of and specific resources for assessment
This unit may be assessed on the job, off the job or a combination of both on and off
the job. Where assessment occurs off the job, that is the candidate is not in productive work, then an
appropriate simulation must be used where the range of conditions reflects realistic workplace
situations. The competencies covered by this unit would be demonstrated by an individual working
alone or as part of a team. The assessment environment should not disadvantage the candidate.
This unit could be assessed in conjunction with any other units addressing the
safety, quality, communication, materials handling, recording and reporting associated with
interpreting and analysing information from specifications and manuals or other units requiring
the exercise of the skills and knowledge covered by this unit.
 d.Method assessment
Assessors should gather a range of evidence that is valid, sufficient, current and
authentic. Evidence can be gathered through a variety of ways including direct observation,
supervisor's reports, project work, samples and questioning. Questioning techniques should not require
language, literacy and numeracy skills beyond those required in this unit of competency. The candidate
must have access to all tools, equipment, materials and documentation required. The candidate must
be permitted to refer to any relevant workplace procedures, product and manufacturing specifications,
codes, standards, manuals and reference materials.

10. Range statement

The range statement relates to the unit of competency as a whole. It allows for different work
environments and situations that may affect performance. Bold italicised wording, if used in the
performance criteria, is detailed below. Essential operating conditions that may be present with training
and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and
local industry and regional contexts) may also be included.
a.Information resources
Documented management system (manufacturing, quality, environmental,
occupational health and safety), manufacturers' manuals, specifications, Australian and international
standards, customer requirements, industry manuals, codes of practice, legislation etc. in hard and soft
copy
b.Location
Reference libraries, workplace storage areas, internet, site
c.Information resources
Internal and/or external. The system would typically have documentation tiers
d.Technical information
Technical information and data suitable and appropriate for advanced trade and
technician applications within the enterprise. This unit does not cover documentation written for
professional engineering or scientist applications
e.Search techniques
 Computer database and internet search/look-up
 Standard techniques to identify relevant information including skimming and
scanning, identifying key words/ideas, using index, table of contents, numbering and
classification systems etc.
f. Analyzes
Conclusions made from the analysis of technical information
 SELF-CHECK NO. 2.2
Identification:
Identify the following questions. Choose your answer on the box below. Use
answer sheet no. 2.2 for this test

1. This unit covers identifying, accessing, interpreting and analyzing

technical information in an enterprise, including quality documentation, equipment
manufacturer specifications, engineering data sheets and national standards
2. Provides advice on assessment and must be read in conjunction
with the performance criteria, required skills and knowledge, range statement and
the Assessment Guidelines for the Training Package
3. A person who demonstrates competency in this unit must be able
to interpret and analyse information from specifications and manuals.
4. Assessors should gather a range of evidence that is valid, sufficient,
current and authentic. Evidence can be gathered through a variety of ways
including direct observation, supervisor's reports, project work, samples and
questioning
5. The unit of competency as a whole, it allows for different work
environments and situations that may affect performance
6. Documented management system (manufacturing, quality,
environmental, occupational health and safety), manufacturers' manuals,
specifications, Australian and international standards, customer
requirements, industry manuals, codes of practice, legislation etc. in hard and
soft copy
7. Reference libraries, workplace storage areas, internet, site
8. Internal and/or external. The system would typically
have documentation tiers
9. Data suitable and appropriate for advanced trade and technician
applications within the enterprise. This unit does not cover documentation written
for professional engineering or scientist applications
10. Conclusions made from the analysis of technical information

Unit descriptor Information resources

Analyzes Overview assessment
Evidence Guide Location
Range statement Method assessment
Information resources Technical information
 ANSWER KEY NO. 2.2

1. Unit descriptor
2. Evidence guide
3. Overview assessment
4. Method assessment
5. Range statement
6. Information resources
7. Location
8. Information resources
9. Technical Information
10. Analyzes
 Learning Outcome #3 Apply information in manual

LEARNING GUIDE
Learning Steps Resources
 Read Information Sheet 3.1 o Information sheet 3.1
 Answer self-check 3.1 o Self-check 3.1
 Compare answers with answer key 3.1 o Answer sheet 3.1

 Listen to lecture
 Participate in the discussion o Multimedia equipment
 Answer oral question o Whiteboard
 Receive feedback from instructor o Whiteboard markers

 Listen to and to observe o Task sheet 3.2

instructor’s operation manual
reading demonstration
o Inventory checklist form
 Perform operation manual writings o Whiteboard
as demonstrated using task sheet o Whiteboard markers
3.2 o Multimedia equipment

 Submit output to instructor for

constructive critiquing
 INFORMATION SHEET NO. 3.1
(Manual is interpreted according to job requirements)

Learning Objective/s:
After reading this information sheet the student must be able to:

1. Apply information in manual

1. Name of main parts or component

1. Fork 2. Fork carriage 3. Mast 4.Lifting cylinder

5. Overhead 6.Steering wheel 7. Seat 8. Counterbalance
guard
11. Left and Right 12. Front wheel
9. Rear wheel
battery 10. Chassis
cover hood
 2. Instrument and Controls

1. Steering wheel 2. Direction 3. Parking brake 4.Emergency disconnect

switches lever switch
5. Adjusting lever 6. Brake pedal 7. Accelerator 8. Key switch
9.Turning signal 10. Lifting lever 11. Tilting lever 12. Meter panel
switch
13. Horn button
 Meter Panel respectively；
CPD10/15/18/20/25/30/ Mode S is super mode, thus the
35JC1 truck‟s max climbing
CPD10/15/18/20/25/30/
35JC2
CPD10/15/18/20/2
5/30J
CPD40/45/50J
C2

A、Battery warning
As the following diagram
shows, from
the left to the right, the battery
decreases from full state to the
only one case, which represents
that the battery leaves only 20%.
Thus the whole battery indicator
bar will twinkle, and the state
indicator lamp will be bright, now
please stop working and charge
immediately.

Notice ： Charging in time is very

important, otherwise it will affect
the lift-span of battery！

B、Mode indication

As the diagram shows, the

pictures from the left to the right
represent the mode of S, P, E, SPE
acceleration, deceleration rate,
gradient and so on is much
higher. It is applied for
transporting mass of good in
short time and climbing big
gradient slop， but it costs more
energy ， so the mode will not be
used in normal state except
emergency.
Mode P is power mode. All
kinds of index are lower than
that of super mode. It is applied
for the case of long distance
transporting and needing
higher power or speed.
Mode E is economical
mode. All the parameters are
optimized. Working in this
mode can save power so it is
applied for a long time work
after charging, and it is
suggested to work in this mode
in normal work-time.
Mode SPE is safe mode.
Thus the max vehicle speed is
limited to about 7km/h. It is
applied for working in busy
storage and cabined room.
Notice: the default mode is
mode E. after power cutting
every time, the work mode
resets to mode E no matter
which mode it is before power
cutting, but the switch key is
still in the mode before turn off.

The mode can be switched

through the mode switch
button (G) among the mode of
S, P, E, SPE, as the above
diagram shows.
C、Parking brake indicator lamp

When using the parking brake,

the lamp will be bright.

D、State indicator lamp

 When there is something wrong
with the electrical controller, or
operate improperly, the battery is
in lower power, the lamp will be
bright and twinkles.

E、Error code display area

Display the error code of electrical

controller.

Notice：“TRAVEL” is the error code

of tow electrical controller, “HYD”
is the error code of pump
controller. “TRAVEL OK”
means it works without error。
Notice ： the error code of tow
electrical controller refers to the
appendix.

F、Work-time accumulate timer

When the truck key switch
turns on, the left hour timer will
start to time. The minimal
resolution is 10% of an hour, the
other two hour timers are not used.
CPD10/15/20/25/30/
35J D1
CPD40/45/50J
D1
C M D
A B
F

S P EED 12 k m/h
B AT% 80

1 2 3 4 5

G L
H J K
I

The meanings of 6 indicators: Low battery warning (C)

When battery quantity is lower
than 20% of maximum capacity,
the indicator lights are on, at the
same time, buzzer beep. When
Communicate indicator (A) LED shows no power, please
charge battery as quick as
Only lights on when record possible.
program, usually it is no use.

Speed limited indicator (D)

When this lamp lights, it
meanings the truck working at
low speed mode. The maximum
Error indicator (B) speed of truck decreased. Press
When operation is wrong or the button 1, you can switch the
truck is in trouble, error code will high speed and low speed mode.
display on the dashboard. The
error indicator lights on.
Accelerate indicator (E) Backup button (J)
When this lamp lights on, it This button is no use for operator.
means the
truck working at low acceleration mode.
The maximum acceleration decreased.
Press button 2, you can switch
the high acceleration and low
4
acceleration mode.

P Backup button (K)

This button is no use for operator
Parking brake indicator (F)
When pulling on the parking brake
lever, this lamp lights on.
5
Switch button of hour
indication（L） Push this button,
it will display the total hours of
truck, as follow figure:
Entrance button (G) ME 28H
This button is no use for K E Y ON TI BAT% 80
operator.
Push again, it switch to the total
traction hour.
1
T R AC T T IME 18H
BAT% 80

Speed limited button (H)

Push the button once again, it
Press this button to switch the switch to speed display mode.
high speed and low speed.
Dashboard display LED (M)
When turn on the key switch, the
2 system will self-diagnose, the
lamp will lights on one by one.
After self-diagnose, LED will
display truck speed and battery
Accelerator limited button (I) capacity. You can know your
Press this button to switch truck‟s working condition
the high acceleration and low through the LED dashboard.
acceleration. Key switch
The key switch has two “on/ off”

3 position, you should push the

Direction switch lever to neutral
and loose the accelerator pedal,
then turning the key switch to
“on” position clockwise.
Caution! Rear big lamp switch (optional)
1. Turning the key switch “on” Rear big lamp switch (push\
does not make the forklift truck pull) has only one shift.
move, if the Direction switch lever Connect battery Far light
is not in the neutral position or the or Position
accelerator pedal is pushing. 0 ×
2. Error code maybe appear, don‟t 1 × ×
worry about it. × Means connected
3. The Direction switch lever Caution!
should be returned to neutral and This light does not relate to key
move you foot from the accelerator switch position, so please don‟t
pedal. Then the truck can be forget to turn off the rear big
operated. lamp when you leave the truck.
Horn button [13] Fuse box J\
Press the rubber cover at the JC1\JC2 Series
center of steering wheel to
sound horn. The horn sounds
even when the key switch is in
the “off” position.
Combined light switch [9]
This combined light switch is
composed of turning light switch
and big/small lamp switch.
Turning light indicates the
traveling direction. When turn on
the switch, the lamp flashes.
1st is a diode preventing from
Forward Left turning lamp connecting in reverse.
flashes 2nd is a control circuit fuse (10A).
Neutral Lamp goes off 3rd and 4th are fuses for light
Backward Right turning lamp and horn circuit. (10A
flashes respectively)
5th is light fuse
Caution!
10A. 6th is spare
The turn signal lever does not fuse 10A.
automatically return to the
neutral position. Reset it by your JD1 系列
hand.
Big/small lamp switch has two 1st is control circuit10A.
shifts. First shift small lamp 2nd is main contact circuit fuse
lights on; second shift big and 10A. 3rd is instrument fuse
small lamp both light up. 10A.
Emergency disconnect switch [4] 4th and 5th is light fuse
10A. 6th is spare fuse
When happen emergency, 10A.
Caution!
presses down the emergency When replace a new fuse, please
disconnect switch, and then the choose the same capacity fuse of the
main power of the truck will be old one.
cut off, the truck stops working.
 Controls pressed, the forklift trucks
Steering wheel [1] moved forward. When the lever
is pushed backward, the forklift
The steering hand-wheel is trucks moved backward.
operated in the conventional Caution!
manner, that is, when the wheel While traveling, if change the
is turn right, the truck will turn to Forward- Reverse lever, electric
the right; when the wheel is turn braking will operate，speed will
left, the truck will turn to the left. lower until stop， then travel to
The steer wheels are located at the opposite direction.
the rear of the truck. These Warning!
cause the rear of the truck to Turning the key switch “on”
swing out when a turn is made. does not make the forklift truck
Warning! move, if the Forward-Reverse
This truck is provided with lever is not in the neutral
the power steering, so heavy position or the accelerator pedal
hand-wheel operation is caused is being pressed. In this case,
when the steering motor comes the Forward-Reverse lever
to a stall. To put the power should be returned to neutral
steering in operation again, and move you foot from the
restart brake
Parking the lever
steering
[3] motor accelerator pedal. Then the

Use this parking brake lever

to park the lift truck. And the Lifting lever [10]
parking brakes are applied on
the front two wheels by pulling
up on this lever. To release the
parking brakes, move the lever
forwards.
There is a micro switch at the
left side of the parking brake
lever, tense the lever makes
running invalid.
For the truck of CE: if you leave
the seat without tensing the lever, it
Warning!
will
If warn and
parking on aremind you
grade is to tense the
unavoidable,
lever.
be sure to block the wheel.
Forward-reverse lever [2]
The forward-reverse lever is used for
switching between forward and
backward moves. When the lever is
pushed forward and
accelerator pedal
The forks can be
raised or fell by pulling
backwards or pushing
the lever. Lifting speed
can be controlled by tilt
backwards angle of
lever and the lowering
speed can be controlled
by tilt forwards angle of
the lever.
Tilting lever [11] Caution!
Loosen the accelerator pedal
when truck
is working, truck can make soft
1. Body and Others
Seat
Adjust operator‟ seat to the
position where is comfortable
for you and provides easy
controls. Before proceeding
The mast can be tilted by with work, adjust operator‟s
operation of this tilt lever. Pulling seat and make sure that it is
on this lever backwards will tilt securely locked. Adjust the
the mast backwards, and operator‟ weight through rock-
pushing it forwards will tilt the suspends system level. The
mast forwards. The tilt speed rear of the seat is adjustable.
can be controlled by tilt angle of Seat switch (only for trucks exporting to Europe or
the lever. option)
For the safe of truck, when
Caution! you leave the seat longer than
The tilt lock mechanism built in 5 seconds, the truck will stop
the hydraulic control valve does traveling.
not allow the mast to tilt Safety belt
forwards while the electricity is Please keep back and waist
being shut down even if the tilt close to seat as far as possible,
lever
Pedals
is pushed forwards. and fix safety belt at the same
time.
Brake pedal [6]
Inspect whether bolts fixed
Press this pedal to slow or belt are loose or not. Do not
stop the truck. At the same time, use belt with a knot. Do not
make belt press on stiff or
Caution! fragile things, and do not make
No permitted to press the brake belt attrite with sharp things to
pedal and the accelerator pedal avoid wearing. Do not make
at same time, otherwise, it is seat backrest too be tilted;
harmful to the traveling motor. otherwise safety belt may not
the brake light comes on. extend correctly.
Accelerator pedal [7] Do not remove any part of
belt at will. Please often
As the accelerator pedal is inspect the belt used
slowly pressed, the drive motor frequently, if found any
start turning and the forklift abnormal, replace it at once.
truck will start to move. And the life for use is 3-5
According to the force applied to years, scrap it ahead of
the pedal, the speed is adjusted schedule if found any
with not steps. abnormal.
There is a safety belt on the
Warning!
seat, before you operate the
Before open the key switch to
forklift truck, please fasten the
press the accelerator pedal, the
seat belt to protect yourself.
more function digital indicator
Overhead safe guard
shall show alarm information.
The overhead guard used is
Then you must release the
strong enough to meet safety
accelerator pedal.
Hood Caution!
The hood can be swung up fully Be careful do not to catch you
to provide easy examining and fingers in the hood when closing it.
maintenance of the storage Depress the spring insurance before
you close the hood, then press the
batteries. head of the hood.
You can lift up the
Warning!
hoodThe with
forkslittle effortbe set
should
with an
symmetrically aid ofto hoodmachine
damper. To
centerline and lock
fork the
stoppers
hood, always
should push down on theagain.
be locked
front of are
There hoodone until
gap it on the
covered.
below beam. It is used to attach
goods.
It is forbidden to lock the fork on Change fork
the gap position, to prevent the
Take down the old fork: Firstly, locate
fork fall off from the gap.
the fork to the middle, decline it to the
In the middle of the above
ground and make the mast forward, then
beam, a bolt used to prevent
operate the truck traveling backward,
fork works here. Please change
the fork will be taken down.
Change new fork: Firstly, make the
Left
fork& Right
deadbattery cover
against hood
the truck and forklift‟s
mast to the Thebottom,
batterythen operate the
truck traveling
is covered aim at the two
forward,
gaps and hood,beams,
one and
left raise the mast.
Adjust the position
and one right. of the fork.
Safety step and safety When
grip you want
to take off the
The hood,
safely steps youare provided on
both side should take off body. The safely
of the truck
grip is provided
the knob on theat front left pillar of
the overhead
first. guard. Use the safely step
and safely grip when mounting and
Fork stopper
dismounting the truck.
Brake fluid reservoir cup
Fork stoppers are locked the forks
The brake
in position. fluid
To adjust fork reservoir
spacing, cup is
located
pull at stoppers,
up fork the meter board.
turn 90°and
shift the forks to the desired
Caution!
position. The fork spacing should
The brake
be adjusting fluid istopoisonous,
according loads to
be careful do not drop down.
be handled.
When add brake fluid, be careful
do not let dirt and other thing
drop into reservoir cup.

Head lights and combination lights

Two headlights and combination
lights (turn signal, show width lamp) are
installed at the front side of the truck.
Take care of the lights, and wipe dirt, if
 any, and replace any damaged
light immediately.
Rear combination lights The tilting angle of the
steering column is adjustable to
The combination lights at the
suit individual operators. Turn
rear side serve as turn signal,
the hand lever upward to release
show width lamp, brake lamp,
the steering column and locked
and back-up lamp. Pay attention
by turning it downward.
to keep them from being
damaged or covered with dust, if Hydraulic oil reservoir cap
any, clean or replace The hydraulic oil reservoir
immediately. cap is located at the right rear
end, below the battery hood;
open the right side battery hood
Steering column tilting angle adjuster
when adding oil. After fill in
clean hydraulic fluid, tighten lock
the cap.
Air leakage plug
There is an air leakage plug
on the oil tank to let air in the
tank goes out. You‟d better
often check the plug and see
whether been jammed.
Chair disconnecting switch
When the operator leaves
The tilting angle of the steering column is
seat, this switch cut off, and the
adjustable to suit individual operators. Turn
the hand lever upward to release the power of truck is cut off.
steering column and locked by turning it Safety seat belt (for the trucks exporting
downward. to Europe or option)

Hydraulic oil reservoir cap There is a safety belt on the

seat, before you operate the
The hydraulic oil reservoir cap is located at forklift truck, please fasten the
the right rear end, below the battery hood; seat belt to protect yourself.
open the right side battery hood when
Rear big lamp (for the trucks exporting to
adding oil. After fill in clean hydraulic fluid,
Europe or option)
tighten lock the cap.
The rear big lamp is set on
Air leakage plug the safeguard. If it is broken,
please replace a new one at
There is an air leakage plug on the oil tank once.
to let air in the tank goes out. You‟d better
often check the plug and see whether been
jammed.

Chair disconnecting switch

When the operator leaves seat, this switch

cut off, and the power of truck is cut off.
Safety seat belt (for the trucks exporting to
Europe or option)
There is a safety belt on the seat, before
you operate the forklift truck, please fasten
the seat belt to protect yourself.

Rear big lamp (for the trucks exporting to

 3. Safety instructions
1. Only trained and
authorized operator shall be
permitted to operate the truck.

the brake fluid has the revelation, please

organizes the personnel to repair
immediately.

2. Inspect the truck at

periodic intervals for oil or water
leak, deformation, lousiness, etc.
If neglected, short life of
components will be caused and
in the worst case a fatal accident
would occur.
·m a k e sure having replaced
good parts during periodic
check.
·Wi p e off oil, grease or water
from the floor board and foot
and hand controls, if any.
·Strictly prohibit smoking
and spark nearby the storage
battery when checking it.
·If maintenance on high
position, such as mast, front and
rear lamp, please be careful to
prevent fall down or be clamped.
·B e careful do not be
scalded when inspect the
motor, controller and etc.
3·whatsoever in trouble, you
must stop the forklift, hang a
mark of “danger” or “trouble”
and take off the key, at the same
time inform the manager. Only
after the trouble is removed, you
may use the forklift.
·I f trouble occurs when
lifting cargo, to Climb or
descend, or the storage battery
electrolyte, the hydraulic fluid,
 4.Operator must
wear helmet, safety
shoes and work clothes.
5. Because there
will bring exploding gas
in the bosom of the
battery, prohibit any
flame nearby it
absolutely.
·D o not let any tools
close the two terminal
of the battery to avoid
spark or short circuit.
6. The movement
road of forklift should be
solid and smooth
coagulation road or
similar to the road
suitable for vehicle.
Recheck the state of
working ground.
The considered
climatic conditions when
the forklift designs are:
Temperature - 20℃-
50℃; the wind speed
does not surpass 5m/s;
the air relative humidity
is not bigger than 90%
(temperature 20℃). The
forklift is not suitable in
the flammable explosive
working conditions.
7. Never mount or
dismount the moving
truck. Use the safety
step(s) and safety grip
facing the truck when
mounting or
dismounting the truck.
 8. Never attempt to work capacity of your lift truck and its
the controls unless properly attachment, if any, and never exceed it.
seated. ·D o not use a man as an additional
Before starting, adjust the counterweight. It‟s quite dangerous.
seat so you can get easy access
to all hand and foot control.
9.Before starting up, make
sure that:
·Please fasten seat bolts.
·T h e parking brake lever is
applied securely.
·T h e forward-reverse lever
is in neutral.
·Before staring, make sure
no one is under, on and close to
the truck.
·Don‟t step the accelerate
pedal or control the lifting lever
or tilting lever before turning on
power.
10. Operate the controls
smoothly. Avoid sudden stops or
turns.
·It is dangerous to make a
sharp brake. Otherwise the truck
has the possibility of overturn.
11. Pay attention to the
route of the truck; be sure to
make a wide sight.
12. Never allow other
person(s) to ride on the forks,
pallets or on the truck.
13. Taking account
of the shape and material of
loads to be handled, use a
proper attachment and tools.
·Avoi d hoisting the load, with
wire rope hung on the forks or
attachment, since the wire rope
may slide off. If needed, a
qualified personnel for slinging
operation should perform,
making use of a hook or crane
arm attachment.
·Ta k e care not to protrude
the forks out of the load. The
protruded fork tips may
damage or turn over the
adjacent load.
14. Know the rated
 15. Keep your mind on
your work.
16. Keep your head,
hands, arms, feet and
legs within the confines
of the operator‟s
compartment. Never
stretch out for any
reason.

17.The pallet and

skid used should be
strong enough to
endure the load. Never
use damaged or
deformed ones.
18. We afford all
type of attachment,
such as rotating roll
clamp, bale clamp, side
shifter, and crane jib
etc. You should refit the
truck under ours license
if you want. It is
forbidden to refit it by
yourself.
19.Safeguard
protect you do not be
hurt by the goods fallen.
Load bracket protect
you load goods
smoothly. It is forbidden
to use truck without
safeguard or load
bracket.
20.It is forbidden to
walk down the fork or
the attachment.
·I t is forbidden to
walk up the fork or
stand on the fork.
 the case of the Large-sized model, or
operate with long attachment, be
extremely careful of load end swing at
corners or in narrow aisles. Be alert
for others.

24. Use minimum forward and

reverse tilt when

stacking and un-
stacking loads. Never tilt
forward unless load is
over stack or at low lift
height.
· When stacking loads on a
21. It is forbidden to put high place, once make the
your hands, arms or head mast vertical at a height of
stretch between the mast and 15 to 20 cm above the
safeguard. Once clamped, the ground and then lift the load
life has danger. farther. Never attempt to tilt
·I t is forbidden to put your the mast beyond vertical
hands in inner and outer mast. when the load is raised high.
·T o un-stack loads from a high
place, insert forks into the
pallet and drive backwards,
then lower the load. Tilt the
mast backwards after
lowering. Never attempt to tilt
the mast with the load raised
22. The goods is liable to high.
drop turning or passing rough
road when it departures the 4. It is dangerous to travel with
center. And the forklift may turn forks higher than appropriate
over more probably. position regardless of whether
loaded or not. Keep the good
23. Don‟t stack traveling posture. (When
loads on forks in such a way traveling, the forks should be
that the top of loads exceeds 15 to 30 cm above the ground
the load backrest height. If or floor and the mast tilted
unavoidable, make sure the backward)
load is fastened. When ·D o not operate the side shift
handling bulky loads that mechanism, if equipped,
restrict your vision operate when the forks are raised and
the truck in reverse or have loaded, since this will cause
a guide. When lead by a the truck to be unbalanced.
guide, make sure you
understand hand, flag, 5. Watch for branches, cables,
whistle or other signals. doorways, or overhangs. Pay
When handling long loads caution when working in
such as pipe, lumber etc or in congested areas.
·S l o w down and sound
horn at cross aisles and other
locations where vision is
restricted.
·W h en make a turn, be
Before driving over a dock-board or bridge- 27. Never lift loads with the
plate, be sure that it is properly secured and
truck inclined. Avoid loading
strong enough to sustain the weigh.
work on a grade.
25. When operating loaded
28. Never permit anyone
truck, have the rear end of your
to stand or walk under upraised
machine pointed downhill.
forks or other attachments if
·W h en operating unloaded
machine is so equipped. If
truck, have the rear end of
unavoidable, use a safety stand
your machine pointed upgrade.
or block to prevent a possibility
Do not make a turn on the
of fork attachments falling down
grade, in order to avoid
or moving unexpectedly.
overturn.
29. Inspect the surface over
which you will run. Look for
holes, drop-offs, obstacles, and
look for rough spots. Look for
anything that might cause you to
lose control, bog down or upset.
·Clear away trash and debris.
Pick up anything that might
puncture a tire or let the load
lose balance.
·S l o w down for wet and
slippery roads. Stay away from
the edge of the road. If
unavoidable, pay more
attention.
·D o not operate the truck
when the weather is execrable,
such as windy, thunder storm,
snow and etc. Especially when
wind speed is higher than 5m/s,
don‟t operate the truck outside.
26. the goods is liable to
drop turning or passing rough road 30. An accumulator is
when it departures the center. And required for controller. Forbid to
the forklift may turn over more touch within B+ and B- to
probably. prevent from wounding by
electricity. Before checking or
cleaning, please connect loads
(contactor circuit or horn for
example) between B+ and B-
first to discharge for capacitor of
controller.
31. Pulling the hand brake
when parking on flat. If
necessarily parking on ramp,
you should place the wedges
under wheels.
 ·Descending the fork
to the ground and
keeping a little forward
tilting, shut off key
switch and take off key.
·Pull out the battery plug.
·T h e parking place must be
far away from
fireworks.
 32. You can tow the forklift to the safe place with towing pin when the forklift
can‟t run.
·Don‟t tow the truck which steering system or brake system has been
damaged.

33. There is operating method and warning label on the truck. Please operate
the truck obey the rules on the label and this manual. Often inspect the nameplate,
when damaged or lost please replace it.

34. Fire extinguisher must be prepared at working place. Users can select fire
extinguisher along with truck, and it usually is fixed on rear supported leg of safety
shelf, it is easy to pick.
Driver and manager should be familiar with the position and operation of fire
extinguisher.

35. Please use stock when conveying little goods, it is forbidden to use
fork directly.

36. The work road surface for forklift should be stability and unknit, cement,
blacktop or beton. If there are snow, ice, water or other eyewinker, bar. Eliminate
all, then work. Otherwise the truck will be out of control and lead the safety
accident.

37. Move the truck to the place which respects traffic when it anchors. If the
reason is brake or turn system, move it by a suitable truck (Reference the part
of truck move); Other reasons, use a suitable truck to traipse, tie the cord
outside of truck. Please abide by the traffic regulations when traipse the truck
on calzada.

38.After take-down the hood, water tank cover board, overhead, backrest of
mast, unallowed to operate the truck or load cargo.
39. There are enough light at truck work ground. At night, open the
head lamp to collocate enough lamp-house.

40.Only in the event that the truck manufacturer is no longer in

business and there is no successor in the interest to the business, the user
may arrange for a modification or alteration to a powered industrial truck
provided, however, that the user shall:
a) Arrange for the modification or alteration to be designed, tested and
implemented by an engineer(s) expert in industrial trucks and their safety;
b) Maintain a permanent record of the design, test(s) and
implementation of the modification or alteration;
c) Approve and make appropriate changes to the capacity plate(s),
decals, tags and instruction handbook;
d) Affix a permanent and readily visible label to the truck stating the
manner in which the truck has been modified or altered together with the
date of the modification or alteration, and the name and address of
theorganisation that accomplished the tasks.
The structure and stability of truck（Prevent the forklift
to turn over!）
It is very important for operator to know the truck‟s structure and
relationship between load and stability.

Caution the structure of the truck

The basic structure of the truck is mast
(include mast and forks) and body (include
tire).
The lift truck keeps the balance of weight
between the truck body and the load on the
forks with the center of the front wheels as
a fulcrum when the rated capacity load is
placed in position.
Due care should be paid to the gravity
center of loads and forklift to maintain the
stability of the truck.

Caution Load center

There is difference in gravity because of

the loads‟ shape, such as box, board and
large roller. It is very important to
distinguish the difference of the gravity
center of loads for evaluating the truck‟s
stability.

Warning!
If the truck will turn over, do not attempt to get out of the truck
because the speed of overturn is much faster than your speed. You should
hold the steering wheel handle, stretch your feet, and this practice will let
you in the seats. Operator fastens the safety belt please.
Caution Gravity center and stability
The combined gravity center that
is composed of the forklift center and
the load gravity center determine the
stability of lift trucks.
When unloaded, the barycenter
does not change; when loaded, the
barycenter is determined by the truck
and the load‟s center.
The barycenter is also determined
by the tilting and lifting of the mast.
The combined center is
determined by these factors:
Load‟s size, weight and
shape The lifting height
The tilting
angle The
acceleration
The radius of turning
The road and grade‟s
angle The attachments

Caution! The stability zone of the

barycenter
In order to make the truck stable, the
combined center must be in the triangle
which is made up of two points that the
two front wheels attach ground and the
midpoint of the back axle.
If the combined center is in the front
driving axle, the two front wheels
become two fulcrums, the truck will
overturn. If the combined center
departures the triangle, the trucks shall
overturn in the corresponding direction.

Caution The max. load（weight and load center distance）

The load center distance is defined

that: the distance between the load
center and the fork carriage or the front
of the fork carriage. The max. load means
the maximum load the truck can charge
at the normal load center distance. The
relation between the max. load and load
center distance shows on the capacity
chart. You should reduce the weight of
load if the load center distance inclines to
the fork carriage.
！ Capacity
chart

Caution
The chart given shows the relation
between the load center and the weight
of loads.
Before loading, make sure that the load
and the load center distance in the
range of capacity chart. If the load‟s
shape is complex, put the most
weightily part on the middle of the
forks, and close to the fork carriage.

！ Velocity and acceleration

Caution
One object will keep quiescence until force works on it. Also, a
moving object will
keep moving until force works on it .This is just inertia.
According to inertia, when truck starts moving, one force works
backwards, and when truck stops moving, one force works forwards. So,
it‟s dangerous to brake suddenly, because it causes one large force
works forwards, and it‟s easy to cause truck overturn or load slide off.
When the forklift makes a turn, will exert a centrifugal force outward
from the curve center. This strength pushes forklift outwards and causes
it to turn over. About stability region is very small, so decelerate when
turning. If the cargo transported at the high position, it‟s easier to turn
over.
 4. Running-in of the new truck
We recommended operating the machine under light load conditions
for the first stage of operation to get the most from it. Especially the
requirements given below should be observed while the machine is in a
stage of 100 hours of operation.
1. Must prevent the new battery from over discharging when early
used. Usually should recharge when discharging down to 20%.
2. Perform specified preventive maintenance services carefully and
completely.
3. Avoid sudden stop, starts or turns.
4. Oil changes and lubrication are recommended to do earlier than
specified.
5. Limited load is 70～80% of the rated load.
 7. Daily maintenance Warning!
The earnest complete When using an air compressor,
maintenance, can keep the forklift at first, adjust the air pressure of
to be at the good status. And the the compressor. Otherwise it will
safety of the truck is related with cause a serious accident, since the
your job and your life. maximum pressure of compressor
! Warning
·except checking lights and
operating capability, you should Tire Pressure (GB/T2982-2001)
shut off the key switch and pull out
the plug before checking electric Drivin
Truc Turning
system. g
k wheel (rear
·prohibit operate forklift with wheel
typ wheel)
trouble.
1. Inspect oil leakage: include (front
e wheel)
hydraulic oil, electrolyte and brake fluid
1-1.5t 860KPa 1000KP
Inspect connector of the oil pipe and a
storage battery to see whether there is any 1.8t 1000KP 1000KP
leakage. Use your hand or eyes to inspect, a a
Forbid to use a flame.
2-2.5t 850KPa 900
KPa
2. Inspect tire 3.0t 850KPa 900KPa
Turn the tire valve cap Caution!
counter clock-wise and move it. Above for the pneumatic tire pressure,
Using a tire pressure gauge,
is not suitable the solid tire.
measure the inflation pressure, and
adjusting it to the specified
pressure, if needed. After making
sure there is no air leakage from
the tire valve, reinstall the cap.
Check that each tire does not get
damaged at the tread surface or
side face. Make sure the wheel
felloe is not bended.

21
 Warning!
Since the tires of forklift truck need
have a high inflation pressure to
carry heavy loads, even a small
bending of rims or a little damage
at the tread surface could cause an
accident.

22
 Warning!
All bolts and nuts should be
screw tight to the stipulation torque
after the tire and the wheel felloe
was assembled, then charge is
allowed. Types have expansion
energy after changing, so the tire
pressure does not surpass the
rating.
Tighten torque refers to <<Bolt
Please put the tire in a tighten torque force table>>
protection frame or tie it with a
3. Replace tire
When the tire is damaged, you
5. Check brake pedal
should replace it in time. Use a jack
Step the brake pedal, check it
to make the tire just beyond
for slowness or block. The proper
ground, then put a wood block
brake distance is 2.5m when free
under the chassis. Loosen nut ① or
load. Adjust the height of pedal to
④, replace a new tire. Tighten the
115 ～ 125mm. Adjust brake booster
nut crossly and symmetrically.
push rod clearance to 1-3mm. The
brake lamp should be lighted when
4. Inspect the torque of hub nut the brake pedal steps on 10-20mm.
Check the torque of hub nut
whether meet the requirement.
①Hub nut 6. Check the parking brake lever
②Divided rim bolt (some trucks
do not have ) The force of hand brake lever is
③Driving axle bolt adjusted by the bolt on the top of
④Rear hub nut lever. The force increases clock-
⑤Divided rim bolt wise screwing, and decreases
counter lock-wise screw.
Driving wheel (front wheel, expect 1-
1.5t)
Truck Front nut Rear nut
type
1-1.8t 157-176 76-107
N.m N.m
2-3.5t 441- 157-176
588N.m N.m
4-5t 441- 157-176
588N.m N.m
turning wheel(rear wheel), driving
wheel(1.5t)
23
 Caution
To step the brake pedal is helpful to
tighten or loose the hand brake
lever.

24
7. Check accelerate pedal bottom, and fall the forks to the
The acceleration changes as ground
the stroke changes. 4) Pull on the hand brake

8. Brake fluid level check

Open the brake lubricated cap
cover. Check the fluid level in the
range allowed. If lack, please add,
and check if there is air mix into the
pipe.
Caution
·Please use brake fluid with one
type, do not mix.
·Don‟t spatter the brake oil onto
the surface of paint otherwise the
paint will be damaged.
·W h en adding fluid, due should be
taken to prevent dirt or water
from entering the reservoir.

9. Check hydraulic oil

Loose the cap of hydraulic oil inside
of right frame, pull out dipstick and
check it if the oil level is between
the scales. Add oil when lack.

10. Replace hydraulic oil

Replace hydraulic oil once half year
on schedule.
1) Stop the truck on smooth
ground;
2) Turn steering wheel right to
the bottom, and enable the fuel
drain plug to have the enough
space;
3) Tilt mast backwards to the
25
 5) Loose the cap of hydraulic oil,
pull out dipstick
6) Set a plate under the chassis,
then loose the fuel drain plug, and put
the old oil;
7) Dispose the old oil according to
local environmental protection laws;
8) Twist the fuel drain plug, join the
new hydraulic fluid, and inspect
whether have a leakage;
9) Start the truck, lifting for 3-5
times, and tilting for 3-5 times;
10) Add hydraulic oil to required scale.

11. Drivers seat adjustment

Make sure the driver‟s seat is properly
located. If not properly, shift the
adjusting lever to the right and move
the driver‟s seat to a position which
provides easy access to all foot and
hand controls. After adjustment, shake
the driver‟s seat a little to be sure that
it is securely locked. Adjust the weight.

12. Check battery

Check the battery whether be
installed firmly.
Check proportion of electrolyte.
Refer to “battery” section.
Check the terminal for loose or
damage.
Otherwise it will be adjust or replace.

Pull in the plug and close

the hood.
Turn on the key
switch 26
13. Instrument check (include battery with the thumb. Make sure the
capacity and error diagnose) tension for the right
Refer to instrument section.

14. Lifting lever, tilting lever,

attachment lever
Check the lifting lever, tilting
lever and attachment lever for
looseness. Return position well.

15. Mast
Check the mast and the forks
to insure that:
1) The fork does not have crack
and distortion. Forks were
installed firmly and correctly.
2) Check the oil cylinder, oil
pipes for leakage.
3) Check the rotation of idler
wheel
4) Check the mast for crack or
distortion
5) Lifting lever, tilting lever,
attachment lever
Check the mast whether works
normally, whether have unusual
sounds.

16. Mast lubrication

You should grease lubrication to
the orbit of mast on schedule base
on requirement.
Adjust the lubricate schedule
according to your working
condition. Add times when busy.
To coordinate forklift's
operation, grease lubrication to the
guide pulley and in outer upright
mounting.

17. Lift chain tension check

① Raise the fork about 10-15
cm above the ground vertically.
② Push the middle of the chain
27
and left chains are equal.
③ Adjust the chain tension: loosen
the lock nut (1) and adjust the chain by
nut (2), then locked nut (1).

18. Check steering system

Turn the wheel right and left
separately to check steering system.

19. Turn signal, horn and other lamp

check
Make sure that the turn signal operates
properly by pull/push turn signal switch.
Make sure that the sound of horn is
properly by press the horn button
Check the other lamp and back-up
buzzer.

20. Battery maintenance

Refer to battery section.

21. Other
For instance, pay attention to
abnormal noise.

28
8. Driving and operation Backward ： Pull the
direction lever

△ ! Warning
Before operating the truck, check all
controls
and warning devices for proper
operation. If any damage or fault is
found, don‟t operate truck until
Driving
（1） Open the cap, and insert the
storage battery plug, then close the
cap.

（2） Set the direction switch to

neutral position
（3） Turn on key switch
Hold the steering wheel with
left hand and turn on the key
switch with right hand.

（4） Tilt back the mast

Control the lifting lever to set
the bottom of the fork 150-
200mm above the ground.
Control the tilting lever to fully tilt
back the mast.

（5） Control direction lever

Forward ： Push the direction
lever forward.
29
 backward.
（6） Loosen the hand brake lever
Step the brake pedal and push
the hand brake lever to the front
position.
Hold the steering wheel with your
left hand and attach your right hand.

Traveling
Step the accelerate pedal slowly,
the truck will travel forward or backward.

Decrease speed
Loosen the accelerate pedal slowly,
the truck will decelerate.
Warning:
Don‟t step the accelerate pedal
and brake
pedal at the same time.

Caution:
Turning
Decelerate the truck in the
Unlike general passenger-cars, situations following:
the turning wheels are located at the ·turning;
rear of the truck. This cause the ·close the goods or pallet;
counterbalance swing out when ·close the deposit area;
turning. ·enter a narrow passage
Slow down the truck and turn the ·t h e condition of road surface is
steering wheel toward the side which bad.
you are turning. The steering wheel
should be turned a bit earlier than as
with the front wheel steering car.

30
 be handled.
! Caution ·T h e pallet should be evenly
Drive the truck slowly and positioned across both forks.
control the steering wheel ·Insert forks into the pallet as far
carefully, assure there is as possible.

Stopping or parking ·T o raise loads from the ground：

①Slow down and press the brake ① Firstly, lift the forks 5 to 10
cm off the ground or floor and
pedal to stop the truck.
make sure loads lay stably.
② Place the shift lever in neutral.
② Then tilt the mast backwards
③ Pull up the parking brake lever.
fully and lift forks up to 15 to 20 cm
④ Down the forks on the ground,
off ground then start running.
tilt mast forwards fully.
·W hen handling bulky loads
⑤ Place the key switch in “OFF” to
which restrict your vision,
shut off the battery. Remove
operate the truck in reverse
the key and keep it.
except when climbing grades.
Caution
·Don‟t dismount from the
moving truck, never jump from the
truck.
·Don‟t parking the truck on the
working

Loading
·T h e forks should be adjusted
properly to maintain the balance of
load.
31
·Place the truck right in front of the load to

32
 Stacking load basic position (15 to 20 cm off

·W h en approaching the deposit the ground).

area slow down your truck. ·Tilt the mast backwards.

·St o p the truck right 30 cm far Caution:

Decelerate the truck in the
away from the position where
situations following:
your load is to be deposited. ·turning;
·Check the condition of the ·close the goods or pallet;
deposit area. ·close the deposit area;
·enter a narrow passage
·Ti l t the mast forward until ·t h e condition of road surface is
forks become to horizontal.
Un-stacking load
Raise forks until they are a little
·W h en approaching the area
higher than the deposit position.
where the load is to be
·M o v e forward to place the load
retrieved, slow down your truck.
directly over the desired area
·Stop the truck 30 cm far from the
and stop the truck. load.
·M a k e sure your load is just over ·Check the condition of the load.
the desired area. Slowly lower ·Ti l t the mast forward until
the load into position. Make sure forks become horizontal. Elevate
the load is securely stacked. forks up to the position of the
·D o necessary lift-tilt operations pallet.
and then back away to make the ·M a k e sure forks are positioned
forks leave loads. properly to the pallet. Move
·After making sure the forks leave forward slowly to insert forks
the load, lower the forks to the into the pallet as far as possible.
Caution
If the forks are hard to be fully
inserted, use the following
procedure: Move forward and
insert 3/4 of the forks. Raise the

10 to 20 cm with the on
pallet the 33
forks, and then fall the pallet to
the stack. Move forward again to
 ！ Warning!
·Never tilt the mast with loads
upraised 2m or more.
·Don‟t leave or dismount from
the truck
when the load is raised high.

Raise the forks 5 to 10 cm off the stack

Check all around the truck to

insure that the path of travel is
unobstructed and back away
slowly.
·Lower forks to a height of 15 to
20 cm above the ground. Tilt the
mast backward fully and move to
the desired area.

Check after operation

Clean and check the truck after operation:
·Damage or leakage.
·A d d grease if necessarily.
·Check the tire if it is damaged or
inset with foreign body.
·Check the wheel hub nut if it is loose.
·Check the height of electrolyte surface.
·If you haven‟t lift the fork to the
max. height in the day, you
should lift it to the max. height 2～
3 times.

·
34
9. Deposit ！ Warning
a. The stow-wood must be
Daily Depositing
single and hard enough to support
①Park your truck at the area
appointed, and block the the truck.
wheels to prevent accidental b. Don‟t use a stow-wood
roll. higher than 300mm（11.81 inch）.
②Make sure the shift lever on c. Lift the truck to the height
neutral position.
of placing on the stow-wood.
③Pull up the hand brake lever.
④Shut off key switch and operate d. Place two same size stow-
the lift and tilt lever several woods under the left and right
times so that the inner pressure sides of the truck.
in the hydraulic tube will
e. After supporting the truck
decrease.
with stow-wood, swings the truck
⑤Cramp out the electrical outlet.
⑥Take out the key and deposit it forward, backward, left and right,
in a safe position. check its safety.
Deposit the truck for a long time ① Operate the forklift once a
On the basic of the “daily week, and be required to lift the
forks to its max. height many
depositing” you should do these
times .
checks and maintenance ② Check the proportion and
additional:
①Take out plug to prevent
Working after long deposit
discharge and
① Get rid of antirust oil.
place in shade.
②Brush antirust oil on those parts ② Discharge the gear oil from
which is exposed such as piston driving axle, decelerator box,
rod and axle easy-rusted. and clean up the internal of
③Cover breather hole and so on them. Add new oil.
which humidity easy to enter. ③ Charge the battery then install
④Cover the whole truck with it to truck, and do not forget to
mantle
connect the down-lead.
⑤All lubrication points add the oil
(grease). ④ Check carefully before
⑥Fill up the truck body and starting, include start,
counter weight with stow-wood advance, and back off, turning,
to reduce bearing of the two lift, fall, tilt and so on.
rear wheels.

35
 10. Storage battery ·When electrolyte level is low，you
must add distilled water to the
Attention for using battery:
level appointed.
1. No firing
·Explosive gas can be produced
in the internal of
battery ， smoking ， flame and
sparkle ,each can easily cause
battery explosion.

2. Protection against electric shock

Warning
·Battery has high voltage and
energy.
every week.
·D o not bring short circuit.
·D o not approach tools to the two
poles of the battery，which can

3. Correct wire connection

Not allowing instead anode of
cathode ， otherwise ， resulting in
sparkle or burning or explosion.

4. Do not over-discharge
·I f you use the energy of battery
till the forklift can‟t move, you
will shorten its working hours.
·W h e n the display of battery
shows low capacity, please
charge it quickly.

5. Inspection for electrolyte

·Forbidden to use the truck
when the electrolyte is shortage.
·Inspection for electrolyte level
30
 water 15~20 minutes;
·Splashing to the clothes ： take
it off immediately
·Careless drinking：Instead of

Remaining clean battery

Keep dryness and
cleanness on the surface
of battery .the poles for
connection are also dry
and clean. Operator must
screw down the vent-
cover of battery.

Warning
1. Do not use dry cloth or fiber
cloth to clean the
battery ， avoiding static to cause
the explosion.
2. Pull out battery plug.
3. Cleaning with wet cloth.
4. Wearing glasses、rubber
overshoes and rubber glove.

31
 ·Before charging ， please examine wire
and electrical outlet whether been
damaged.

to prevent the charge from destroy caused

by high temperature. Stop the charge in
short time when it is necessary.
1. If a non-automatic charger is used, the
Measure in summer charge voltage, current and charge time
In summer ， water in the should be adjusted, and check the rate of
battery electrolyte timely, so as to make
electrolyte is easy to
sure that the charge of battery group is in
evaporate ， therefore ， electrolyte good condition. The adjust parameters
must often be inspected if please refer to “battery charging” in the
electrolyte is low ， you must add follow.
2. Do not continuously charge.
distilled water to the level
·Continuously charge several batteries will
appointed. cause charger overheat even be damaged.
You can use the charger again after it has
！ Warning
been rested for an hour.
3. Select the charger according to battery‟s
Filling with distilled water beyond voltage and capacity (refer to parameter
the regulated range, Spilt table)

electrolyte will cause corrosion Battery charging

and electricity
Measure leakage.
in winter 1. There are two charge mode can be
·Keep effective and good adopted, including intelligent charging
and constant current charging. For the
surrounding for charging.
first charging, adopt the constant
· To prevent current charging.
discharging，when it is cold ·A l l the batteries of the new truck are
，pull out the battery pin.
not added electrolyte.
Electrolyte confect
·Take measures，such as，covering Type D-500
battery for warmth. Paramet D-420 D-
er
·Charge in time after work. 630B
Name D-700
Attentions for charging Specific
1.265g/ 1.275g/
gravity cm3 cm3
1. Please charge in the well-
of acid
ventilated and appointed site. Volum
Wat 3.1:1 2.6:1
2. Mark „no smoking‟ when e
charging. er ratio
3. Inspect wire and electrical and Qualit
outlet. vitri 1.7:1 1.65:1
32
ol y
Ratio Caution
Vitriol Ratio 1.835g/cm3 The time that is from
pouring the electrolyte into the
Suitable for battery to starting first charging
Vitriol GB4554-84 or can‟t be exceeded 12 hours.
standard special for battery ⑤ The specific charging cable should be
connected to charging machine.

Caution
Be sure to notice that the
polarity sign on the plug must
keep comfortably to the out
specific charging end node.
When the charging cable is
connected to the storage
batteries, please pay attention
to keeping comfortably on the
polarity sign. Otherwise maybe

⑥ Inspect
The voltage value that the power
needed is the number of the serial
battery three times.
Battery
Truck type Batter
voltage
y
（V）
1-1.8t D-420 48

2-2.5t D- 48
630B
3t,3.5t D-500 80

4-5t D-700 80

Inspect the charging machine.

·Inspect every battery‟s polarity.
⑦ Charging ways ： （ time, current as the
form）
a. 1st phase：most of the single battery‟s
terminal voltage steps up to 2.4 V；
b. 2nd phase ： the electrode give off a
large number of bubbles, the voltage
and the specific gravity steadies 4
hours and the charging value gets to
33
4.5-5 times than rated capacity.

Chargi Charging Caution

Truc Batte current(A)
During the charging, the
ng
k ry 1st 2nd temperature of electrolyte
voltage
typ type phas phas should not be exceeded 45℃ 。
(V)
e e e Otherwise you should low the
1- D-420 72 40 20 temperature. If the temperature
1.8t do not lowing, you should stop
2- D- 72 63 32 recharging， till the temperature
2.5t 630B

3t,3. D-500 120 50 25

5t Daily charging

4-5t D- 120 70 35
·T h e battery that has been made
700 the first charging and used
Charging time（h） 35-45 35-45 regular, then charged again, is
named daily charging.
c. Adjusting the specific ·I t s way is almost same as the first
density and height charging.
for the electrolyte ·T h e recharging value is 1.2 times
·I f the specific gravity is than the last electric discharging.
smaller, it will be adjusted as But the electric-change for new
follow: then take out some battery‟s fore five times should
electrode from the battery, be 1.5 times than the last electric
pour the compounded sulfuric discharging.
acid that its specific gravity is ·During any charge, the temperature of
1.400g/cm3. electrode should not be exceeded
·I f the specific gravity is 450C ， otherwise it should be taken
larger, it will be adjusted as measures such as reducing
follow: then take out some artificially charging current or
electrode from the battery, lowing the temperature. If the
pour some distilled water, but temperature doesn‟t drop, you
you must keep the electrode should stop charging, till the
height accord with demand temperature dropping down.
d. After adjusting, you should Charging
Chargi
current(A)
keep charging on 1 hour; Truc Batte
ng
make the density of k ry 1st 2nd
voltage
electrode even upper and typ type phas phas
(V)
under. At this time we have e e e
finished the first charging. 1- D-420 72 55 25
e. Close the pouring plug and 1.8t

clean the battery surface 2- D- 72 88 44

2.5t 630B
acid, then you can use it.
3t,3. D-500 120 70 35
5t 34

4-5t D- 120 96 47
700
 battery normally, and then
rest for 1 hour after the end
occur disequilibrium
of charge.
among the voltage, the
② Charge it again with the
density and the
current belongs to the
capacity.
second normally charge
·Compared to most
until the electrolyte gives
of the batteries , often
off a large number of
finds that single
bubbles, then stop charging
battery‟s proportion of
for 1 hour.
voltage and electrolyte
③ Repeat it several times as
rises slowly during the
mentioned above until the
course of charge and
voltage and the density keep
during the course of
invariable and the battery
discharge, its battery‟s
gives off a large number of
proportion of voltage
bubbles immediately when
and electrolyte declines
charge again.
faster than most of
other batteries. Complementarity Charge
·M a k e equilibrium ·I Use
f one
theday‟s
properwork cannot
tools to pull upbe fulfilled
charge in the following the battery
case： The weight and dimension of
Battery
a. discharge voltage
Model
often drop down
ending voltage； Weight (kg)
b. discharge current is often
1-1.8t
larger；
Min. 700
c. Not charge in time after Max. 900
discharge Dimension(mm)
d. The electrolyte is mixed 465×980×780
with impurity
Model Weight (kg)
with a little harm. 2-2.5 t
e. It often be charged Min. 800
deficient or has not Max. 1000
Dimension(mm)
been used for a 570×1028×780
long time；
f. After taking out Model Weight (kg)
3 -3.5t
the battery group Min. 1200
for checking or Max. 1500
cleaning settling. Dimension(mm)
710×1028×780
The method of Equilibrium
Charge： Model
① Firstly, charge the Weight (kg)
35
4-5 t
Min. 1900
Max. 2200
Dimension(mm)
 with one charge, carry out opportunity charge during breaks.
·W h en the temperature of circumstance is low, carry out opportunity charge.

Charge for long-term storage

·Carry out equilibrium charge before storing.
· Carry out equilibrium charge once every 15 to 30 days during the storage period.
· The special orders storage battery carries on the charge according to
"Accumulator Instruction for use".

Battery replacement

Caution
Be sure that the voltage,
the capability, the size and the
weight of the new battery are
according with the forklift truck
before replacing the battery.
Forbid to use battery with
different voltage or capacity or
weight except being promised
by factory.

Replacement step
1. Stop the forklift truck on the plain ground， pull up the hand brake lever.
2. Open the hood cover.
3. Disconnect the battery plug.

4. Remove the lock pin.

36
 Caution
·T h e box must be pulled
up with using 4 holes of the
pothook at the same time. It is
not allowed to pull up with
only two holes. Otherwise,
the asymmetric power will
cause the battery damaged.
·T h e steering wheel and
other equipment should not be
bumped, avoid being damaged
when pulling up the battery 2. Replenish the distilled water
5. After exchange the full ·Wear the blinkers, rubber
electricity of battery, plug into overshoes and rubber glove.
the lock pin, shut to the hood
① Using the measuring
cover, and plug into the pin of
cylinder to take out the
the battery hard.
The waste electrolyte of the distilled water with a
replaced battery should be dealt certain quantity.
according to environment and ② Open the battery cover for
protection law rather than reject every battery cell.
at will. ③ Imbibe distilled water with
injector and then supply it
The proportion and level of electrolyte into the battery.
The battery with a
dobber
When the red dobber
Caution rises, the white line is
If the level of the electrolyte is appeared, please stop to
low, using the battery will
replenish the distilled water.
cause the battery over-heat
and shorten the battery‟s life.
1． Inspect electrolyte
The battery without a
Itdobber
is proper to pour the electrolyte
15-20mm above the electrode plate.
The battery with a
dobber
Depending on the dobber of the
winded cover, and read the
level position of the electrolyte.

37
 The battery without a
dobber the
When electrolyte is
above 15-20mm of the
electrode plate, stop
replenishing the distilled
water.
④ After replenishing the distilled
water, close the pouring
plug and battery cover.
⑤ Using the damp cloth to clean
the surface of every battery
cell.

CAUTION
It is not permitted to
overrun the appointed tiptop
2） Specific gravity measure
level when replenishing the
Using the densimeter to
distilled water. Adding it too
measure the specific gravity.
much will result in leakage of
electrolyte, and it will damage
the truck when charging and
discharging.
Draw it out with injector if
adding it too much.
1. Read the specific
gravity
1 ） The specific gravity
of the electrolyte should
change follow the
3） Conversion of the specific
temperature.
① Use thermometer to gravity The specific
measure the temperature gravity at the
of electrolyte. standard temperature of 300C
② Put the straw of should be converted as follow：
densimeter into D30= Dt + 0.0007(t - 30)
electrolyte uprightly,
Where ：D30 ——the specific
extrude rubber tube with
hand and the electrolyte gravity at the standard
will be sucked into the temperature of 300C
glasses tube and then the Dt ——the specific gravity
floater of the densimeter at the temperature of t0C.
will float.
t —— the temperature of
③ Numerate the reading
of the densimeter. the distilled water during convert.
Notice ： The dobber of · The specific gravity that
densimeter must was refered in this book is
rise uprightly without 38
depending on the
glass pipe.
measured all at the
temperature of 30℃.

39
 The Automatic Watering System of the Forklift Battery

1. Automatic Watering System

Makeup of the Automatic Watering
System：

 Automatic Watering Plug

 End Plug
 Floater
 T-piece & L-piece
 Flow Indicator（with filter）
 6mm, 8mm ,10mm watering pipe
 Male & Female couplings (Kv10 and KV6, etc.)
 Water Tank

2. Application Specification & Installation

During the period of development and long-term

practical usage, the leak tightness of automatic
watering system has received complete recognition.
But when you use it, you need to keep the
automatic watering system clean and there can‟t be
any filth on the surface.
How to properly install the automatic watering system：
Our automatic watering system is easy to operate, no
need to finish watering the electrolyte in the storage
battery by hand,
time saving and labor saving, besides, it can extend
the service life. How to correctly install the water
tank, choose proper floaters,
how to confirm the specification & quantity of the
installed accessories according to different types of
battery, including correct application rules for
automatic watering plug, watering pipe, T/L- pieces
and male/female couplings as well as the cleaning of
the flow indicator. We will give you a brief introduction
for the above items as follows:
Meanwhile we will offer detailed installation drawings to ensure that
the clients can correctly install and standardize the operation.
batte Watering T-piece Flow 6mm 10mm en Male/ Water
ry head （6-10-6） indicator Water Wateri d female tank
spec T-piece （filter） in g ng pipe plu K10 specificati
. pipe g on
24 12 pcs 1 pcs 1 pcs 3m 5m 2pcs 1pcs 30L 1pcs
40
V
48 24 pcs 1 pcs 1 pcs 5m 5m 2pcs 1pcs 30L 1pcs
V
80 40 pcs 1 pcs 1 pcs 10m 5m 2pcs 1pcs 60L 1pcs
V

41
 Automatic Watering System of Forklift Storage Battery-48V battery group

Floater

How to choose proper floaters correctly：

 According to different storage battery, we have five kinds of floaters for

you to choose. In order to achieve our expected standard and completely
reflect the effectiveness of the automatic watering system, the most
important thing is to choose proper floaters.

At present our company can offer a rule for the client to make judgment
and choose the type of floater. (see diagram)
 The diagram the installation way of the floaters：

T =T1-(5~17mm)

42
 T approaching 4 50. 58 61 7
7 5 2
Floa 1 16. 24 27 3
t 3 5 8

Watering Pipe
 Our company offers watering pipes of different types and the clients
can choose what they need according to the specification of the
battery.
The watering pipe must be perfectly sealed with T-piece and L-piece.

Notes during the filling process:

1. In order to ensure a safe watering process, we hereby recommend
you to use flow indicator (with filter), the flow indicator with filter can not
only timely indicate whether it finishes watering, but also avoid unclean
impurities entering the battery to result interruption.
2. The watering pressure should be within the range of 0.2-0.6, no less than
200mbar。
3. You‟d better conduct watering within the specified periods, because
frequent filling will lead to overflowing for too much water, which will do
great damage to the storage battery.

Note：Filling after finishing charging is the best ideal state, besides, do not
filling before charging.

Cleaning
During the period of development and long-term practical application,
the leak tightness of automatic watering system has been completely
approved.
When you use it, you must pay much attention to keep the automatic
watering system clean. No filth remaining on the surface.
The users should regularly clean the watering plug for the plug is a kind of
plastic good.
Clean the surface directly with tap water and no need to use other detergent.

Structure Diagram of the Watering Plug：

43
open close

44
 11. Truck’s convey, lifting, towing
Convey
·T h e Fork Lift Truck is designed for material handling only, It is
inappropriate for long-distance transportation. If needed, the Fork Lift
Truck must be transported by ship, train or lorry, of 5T loading. Use a
lifting pallet to hoist the truck.
• Use the steel wire ropes to tie the holes in the two side of the outside
mast‟s beam and the rear of truck‟s body, and then use the lifting device
to hoist the truck.

Hoist the truck

·Use the steel wire ropes to tie the holes in the two side of the outside
mast‟s beam and the hook of the counter balance, and then use the lifting
device to hoist the truck. The steel wire rope attach to the counterweight
should through the safeguard gap, and make the safeguard not be
distorted.

Warning
·When hoist the truck, don‟t coil the overhead guard with the steel wire.
·T h e steel wire ropes and the lifting device must be very firm to
support the truck because the truck is very heavy.
·Don‟t lift the truck by hoist the overhead guard.
·When lifting the truck, don‟t take yourself below the truck.

Towing
·T h e towing rod on the bottom of the counter balance is used to pull and drag
the truck.
·Loosen the brake lever and turn off key switch.
·S e t switch lever to neutral position

Warning
a. Don‟t tie the steel wire ropes on the unfixed position.
b. Don‟t carry a load to steel wire ropes suddenly.
c. The truck would be damaged if you tow it with the electric lock working.

45
12. Scutcheon
There are many scutcheons and labels on the different position of the truck.

46
 E P
M
ER SO
GENCY T

USE
SPECIFIED

1.tonnage label 2. typeface label 3. ac label 4. danger label

5.danger label 6. danger label 7. CE label 8. hanging label

9. danger label 10. danger label 11. load scutche 12. warning
curve on label
13. product 14. hydraulic oil 15.tight label 16.hand brake
nameplate label point label
17. urgent stop 18. noise label 19.fuse
label label

47
 Learning Outcome #4 Store manuals

LEARNING GUIDE
Learning Steps Resources
 Read Information Sheet 4.1 o Information sheet 4.1
 Answer self-check 4.1 o Self-check 4.1
 Compare answers with answer key 4.1 o Answer sheet 4.1

 Listen to lecture
 Participate in the discussion o Multimedia equipment
 Answer oral question o Whiteboard
 Receive feedback from instructor o Whiteboard markers

 Listen to and to observe o Task sheet 4.2

instructor’s operation manual
reading demonstration
o Inventory checklist form
 Perform operation manual writings o Whiteboard
as demonstrated using task sheet o Whiteboard markers
4.2 o Multimedia equipment

 Submit output to instructor for

constructive critiquing
 INFORMATION SHEET NO. 4.1
(Manual or specification is stored appropriately to prevent damage, ready
access and updating of information when required in accordance with
company requirements)

Learning Objective/s:
After reading this information sheet the student must be able to:

1. Store manuals

Topic: Introduction to Machine Productivity

Factors
PRODUCTIVITY
An overall objective of the Performance Handbook is to provide you with the data and
process to estimate productivity of machines. While there are innumerable charts,
tables and formulas throughout the book which factor into productivity, it is easier to
break down the information into two categories:
productivity related factors
estimating productivity.
Productivity Related Factors
Each machine family has a specialized way of calculating or estimating productivity
based on the function of the machine. But the bottom line for any process is finding
the lowest cost per unit of production (ton, bank cubic meter, etc.)
The factors which go into production estimation can be categorized as follows:
speed
time
load.
 Direction: Explain the given cart
1) Define speed and interpret speed
charts.

2) Define productivity

Task sheet Criteria Percentage

1) Did the trainee choice the right Manual? 20%

2) Did the trainee choice the right term to used? 20%
3) Did the trainee read the operation Manual properly 40%
 Performance Criteria Checklist 4.2

Criteria YES NO
Did you …
1. Are task to be addressed by the Task Sheet
identified?
2. Is the task related to the performance objective?
3. Are safety precautions and procedures to be observed, and
sanitary conditions to be maintained and
directions for checking the accuracy of the job indicated?
4. Are operations that cover the manipulative skills needed to
perform the job listed?
5. Are critical points that are essential to the success of the
operation indicated?