Operation and Maintenace Manual (5-10T)

User Manual of 5-10 Ton Diesel Balance Weight Forklift
Contents
Foreword
I. The Main Technical Parameters of Forklift.............................................3
II. Introduction to the Main Parts of Forklift..............................................7
III. Structure, Principle, Adjustment and Maintenance of Forklift.............7
1. The Power System..........................................................................7
1.1 Outline.....................................................................................8
1.2 Engine configuration.............................................................8
1.3 Fuel System.........................................................................10
1.4 the cooling system...............................................................12
1.5 Inspection and adjustment..................................................12
2. Electrical System............................................................................19
2.1 Outline...................................................................................19
2.2 A brief description of manipulation.......................................20
2.3 Batteries.................................................................................23
3. Transmission Device.......................................................................25
3.1 Outline...................................................................................26
3.2 torque converter....................................................................26
3.3 Oil Feed Pump........................................................................30
3.4 Hydraulic Clutch.....................................................................31
3.5 Operating Valve and Inching Valve........................................33
3.6 Torque Converter Oil Way.....................................................34
3.7 Notes When Forklift Failure...................................................36
3.8 Trouble Shooting....................................................................36
4. Driving Axle....................................................................................42
4.1 General...................................................................................43
4.2 Main Reducer and Differential Mechanism...........................43

4.3 Hub Reduction Gear...............................................................44
4.5 Maintenance Data.................................................................49
5. Braking System...............................................................................51
5.1 Outline...................................................................................52
5.2 Dynamic Braking....................................................................52
5.3 Vacuum dynamic braking......................................................56
5.4 Service brakes........................................................................62
5.5 Parking brakes........................................................................68
5.6 Trouble Shooting....................................................................70
6. steering system..............................................................................71
6.1 Steering gear..........................................................................73
6.2 Checking after the steering system reload............................80
6.3 Steering system troubleshooting...........................................82
6.4 Steering axle...........................................................................83
7. Hydraulic system............................................................................85
7.1 Overview.................................................................................87
7.2 The Oil Pump...........................................................................87
7.3 The Multitandem Valve...........................................................87
7.4 The Operation of Multitandem Valve.......................................88
7.5 The Operation of Main Safety Valve.........................................90
7.6 The Operation of Tilt Self-locking Valve....................................91
7.7 The Operating Device of Multitandem Valve............................92
7.8 Oil Tank...................................................................................93
7.9 The Oil Way of Hydraulic System (the Main Oil Way )...............94
7.10 Maintenance.........................................................................97
8. The Lifting Oil Cylinder and the Tilt Oil Cylinder.................................99

8.1 Lifting Oil Cylinder....................................................................99
8.2 Stop Valve.............................................................................100
8.3 Governor Valve......................................................................103
8.4 Tilt Oil Cylinder......................................................................104
9. Lifting System................................................................................106
9.1 Overview...............................................................................107
9.2 Inner and Outer Door Frame.................................................107
9.3 Pallet Fork Carrier..................................................................107
9.4 The Adjustment of Lifting System...........................................108
9.5 The Installation Position of Rollers.........................................110
I. The Main Technical Parameters of Forklift

The table for the main technical parameters of forklift
par
5t 6t 7t 8t 10t
ameters
Rated weight kg 5000 6000 7000 8000 10000
Load center 600
Maximum lifting height
3000
B mm
Free lifting height E
197 202 207 155 220
Gantry angle Y/Y 。 6/12
Minimum turning
3250 3370 3370 3500 3900
radius W
The minimum width of
the channel at right 2960 3020 3020 3150 3540
angles X
The lowest ground
160 245 245
clearance G
Wheelbase L 2250 2250 2250 2250 2800
Wheelbase
1470/1700 1470/1500 1600/1700
before/behind S/T
Before K 590 595 600 670 718
Overhang Behind M 600 675 675 900 740
Full length H 4660 4800 4800 5180 5480
Full width Q 1995 2000 2230
Full Mast C 2500 2580 2850
height Retaining
2450 2510 2600
key frame P mm
Lifting height of shelves
4420 4130 4330
A
Fork Length J 1220 1370 1220
Width U 150*5
150*60 150*65 170*70 175*80
*Thicknes s F 5
Fork adjustment range
300-1800 310-1440 410-2140
R
Truck weight 8250 8910 9620 10180 12510
Axle Loaded before 11870 13260 14780 14630 20380
load behind 1380 1650 1840 2610 2130
Load before 4150 4040 4020 3780 5700
Kg
behind 4100 4870 5600 6400 6800
5t 6t 7t 8t 10t
parameters
Tire Before4 8.25-15-14PR 9.00-20-
14PR
Behind2 8.25-15-14PR 9.00-20-
14PR
Battery V/ 24/80
voltage /capacity Ah
Model A-6BGIQC- Chaochai6102BG31 Xichai61
02 10
Number of mm 6-105*125 6-102*118 6-
cylinders- 110*12
Bore*Itinera 5
ry
Engine Rated Kw/mm 82.4/2000 81/2500 83/2000
power
speed
Maximum Nm/mm 416.8/1500 353/1650 450/145
torque 0
speed
Minimum g/kw*h 232 231 227
fuel
consumptio
n rate
Transmission gear 2/2Power Shift
number
Brake mode Vacuum booster/Dynamic Dynamic
braking braking
Lifting Loaded Mm/s 390 390 325 390 340
speed Load 450 450 380 415 370
Maximum operating Km/h 26/28 26/30
capacity
Maximum % 20
gradeability
Maximum traction km 53 53 52 51 57
RASA: right angle stacking channel width a: gap b: Payload Length

II. Introduction to the Main Parts of Forklift
Forklift main components are as follows:

No. Name Content
1 Power system Mainly including engine installation, fuel, exhaust and
cooling (including torque converter oil cooling) systems
2 Transmission containing torque converter, transmission, drive shaft,
system variable speed control
3 Drive axle containing axle, differential, wheel deceleration, brakes,
wheel, etc.
4 Steering system containing the steering wheel, hydraulic steering systems,
etc.
5 Steering axle Including steering axle, steering cylinder, rear
6 Lifting system containing door frame, fork, fork frame, backrest, tilt
cylinder, lifting cylinder, lifting chain, mast sprocket,
roller, etc.
7 Body system containing frame, the instrument rack, engine cover,
radiator cover, counterweight, chassis, seat, etc.
8 Operating system Including: (1) the service brake and micro manipulation
(2) the parking brake control
(3) throttle control
9 Hydraulic system Mainly including pumps, valves, high and low pressure
tubing, fittings
10 Electrical system containing lamps, batteries, instrumentation, wiring
harness and other electrical components
11 Retaining key Retaining key frame (cab is optional part)
frame
III. Structure, Principle, Adjustment and Maintenance of Forklift
1. The Power System

1.1 Outline
Power system includes an engine installation, fuel system, cooling

system and exhaust system. An engine mounts the cushion rubber to the
frame to reduce vibration. Engine and torque converter, transmission,
drive shaft and drive axle compose one, and they are shown in figure
1.1.
1.2Engine
configuration
5-7t forklift, domestic engine is configured with Chaochai 6102BG31.
8-10t forklift, domestic engine is configured with Xichai CA6110. 5-10 ton
forklift, the imported engine is configured with Isuzu 6BG1QC-02 engine.
The structure is shown in figure 1.2. The main performance parameters
and configuration of the above engines are shown in table 1.1.
Table
1.1 The
main
technical
parameters
of engine
6110125G5-
Name CY6102BG31 A-6BG1QC
2
4-stroke,
4-stroke,
water-
water-
4-stroke, water- cooled, in-
cooled, in-
Form cooled, in-line, self- line, direct
line, self-
priming diesel injection
priming
combustion
diesel
chamber
Number of cylinders - Bore 6-105mm X 6-110mm X
6-102mm X 118mm
X Stroke 125mm 125mm
Working volume (L) 5.785 6.494 7.127
Compression ratio 17.5 17 17

Rated speed
2500 2000 2000
(rpm)
Rated power
81 82.3 83
(kw)
Maximum
416/1400- 432/1300-
torque 353/1600
1600 1400
(Nm / rpm)
Fuel
consumption
231 233 227
at full load
Performance (g / kwh)
Idle speed
彡 700 700 700
(rpm)
Weight (kg) 480 450 600
Dimensions 1129.5x672. 1185 x658.5
1122.6x662x846.2
(mm) 0 x 860.0 x878.5
Ignition
1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
sequence
from the fan from the fan
Direction of from the fan side,
side, side,
rotation Clockwise
Clockwise Clockwise
Plunger
9.5mm X 10.5mm X
diameter X 9.5mm X 8mm
8mm 8mm
stroke
Fuel Spray
Perforated Perforated Perforated
Equipment nozzles
Supply pump Plunger Plunger Plunger
Paper Paper
Fuel Filters Paper Cartridge
Cartridge Cartridge
Centrifugal, full Centrifugal, Centrifugal,
Speed mode
Speed control full control full control
governor Forced Forced
Lubrication Forced circulation
circulation circulation
Lubricating Pump Type Gear type Gear type Gear type
Equipment Camshaft Camshaft
Drive form Camshaft drive
drive drive
Hydraulic
Piston,
adjustment Piston, spring Piston, spring
spring
device
Oil pressure Switching
Switching (0.3kg / Switching
indicating (0.3kg /
cm2) (0.3kg / cm2)
device cm2)
Full-flow Full-flow
Filter Full-flow filter type
filter type filter type
Coolers Built-in water- Built-in Built-in
water-
cooled water-cooled
cooled
Water- Water-
Cooling Water-cooled
cooled cooled
Exhaust
Exhaust type,
Cool down type, seven
Exhaust type, seven seven blades,
Equipment blades, an
Cooling fan blades, an outer an outer
outer
diameter of 550mm diameter of
diameter of
550mm
550mm
Wax ball Wax ball
The way Wax ball style
style style
Water Thermostat
temperature opening 82^ 82^ 76^
adjustment temperature
device Full opening
temperature 951 95^ 86^
thermostat
Start up Voltage 24V 24V 24V
Electric Output
4.5kw 4.5kw 5kw
motor Power
Charging Voltage 24V 28V 28V
Generator Output 25A 25A 45A
Maximum:
The oil in oil Maximum: 13,
13, 15
Reference pan (1) Minimum: 10
Minimum: 10
Parameters
Cooling
12 12 14
water (1)
0.4mm 0.3mm
Intake valve 0.4mm (when cold)
(when cold) (when cold)
Valve Gap
Exhaust 0.4mm 0.35mm
0.4mm (when cold)
valve (when cold) (when cold)
1.3Fuel System
Fuel system consists of the fuel tank, fuel filter and the sensor device.
1.3.1 Fuel Tank
Fuel tank is a connection of welded structure and frame and is
placed on the left side of the frame. There is the tank cover above, which
tops the fuel sensor, and it is shown in figure 1.3.
1.3.2 Fuel sensing devices
The working principle of the fuel sensing means is: By position
changes of float floating on the oil surface inside the tank,it can change
the variable resistor to change the loop current, and reflect a change in
the fuel gauge pointer instrument panel.You can have an intuitive

understanding of fuel within the tank. Figure 1.4.
1.3.3 Fuel
Filter
Fuel filter is mounted on the engine’s inlet manifold, for filter the
oil supplying to the engine. Filter is also equipped with a bypass valve
which may be the engine fueling in the filter blockage
1.4the cooling system
Cooling system consists of pumps, fans, water tanks and deputy
water tanks, pump is mounted on the engine and crankshaft drives
pumps to work by v belt.
1.5Inspection and adjustment
In order to keep the engine in good working condition, it needs
regular inspection and adjustment on the engine. The following
essentials:
1.5.1 Air filter: Figure 1.5
(1) Remove the filter;
(2) Check the dust and damage of the filter. First blow with a low-
pressure air to the outside from the inside for cleaning. If it can not
be cleaned because of serious obstruction or damaged, you will need
to change it.
(3) Cleaning the dust in the cover.
1.5.2 Fuel
Filter
Figure 1.6
(1) remove the filter with a special wrench, and if there is
damage or blocks, it needs to be replaced
(2) Add a few drops of fuel along the new oil filter seal around
and then loaded. After the seal is exposure to the oil filter body, and
then screw into the 2/3 circle.
1.5.3 Oil filters
See picture 1.7
(1) Using wrench specially used by filters to remove and change it.
(2) Adding a few drops of lubricant along seal of the new oil filter
and then install it. After touching its body, screw it for 2/3 circle.
1.5.4 Cooling system

(1) Check the cooling liquid in the vice-
tank
The vice- tank is just like that in picture 1.8. When the cooling liquid
is lower than the engraved lines “LOW”, it shows that the tank
supplemental amount is reduced and more cooling liquid should be put in
until it amounts onto the 2/3 mark of the upper and lower lines when the
machine is cool.
(2) Change the

cooling liquid
A. After the
machines are turned off
for at least half an hour,
open the cover of the
water tank after it is
cooled. At the same
time, loosen the
discharge sluice under
the water tank;
B. Loosen the discharge sluice of the engine and leg all the cooling
liquid go;
C. After all the cooling liquid is let go, tighten the above two
discharge sluices;
(3) adjust the tension degree of the pulley fan
If the pulley fan becomes loose, tighten it. See picture 1.9.
Steps: firstly, loosen mounting bolts B, C of the engine, move the
generator outward. Then use 10kg of your strength to press with your
fingers at A belt with deflection at about 10mm, then tighten bolts B, C in
order.
1.5.5 Fastening of bolts in the cylinder head of the engine

(1) According to the orders showed in picture 1.10, tighten the
cylinder head bolts one by one in 68Nm torques;
(2) tighten the torque increasing to 93Nm in the order , then tighten
the bolts one by one;
(3) After the engine has worked for 15 minutes, rotate the bolts at 90
degrees and tighten them.
1.5.6 Adjustment of valve clearance
Adjust the valve clearance for two times.
(1) Rotate the crankshaft at the clockwise direction, making the “TC”
mark of the pulley damper coincided with the pointers, seeing picture
1.11;
(2) Open the cover of the check hole to ensure the position of the
bottom plate mark and pointers, seeing picture 1.12; if the bottom plate
mark is in accord to the position of the pointers, it demonstrates that it is
just the upper line of the compression stroke in the first cylinder. Adjust
the valve clearance of the marking, use a feeler to ensure the valve
clearance value: 0.30-0.4mm (see Table 1.2), and then tighten and adjust
the screws, seeing picture 1.13.
(3) Continue rotating the crankshaft for 360 degrees to make sure
that the pointers is in line with the marks, adjusting other valve
clearances marked with“※”.
Orders of cylinders 1 2 3 4 5 6
Orders of I:Suction valve I E I E I E I E I E I E
valves E: exhaust
valve
The upper line of the △ △ △ △ △ △
compression stroke in the
first cylinder
The upper limit of the

compression in the sixth
cylinder
Table 1.2
1.5.7 Affordance of the ignition time of the injection

(1) Firstly make sure "assembled marks" in the fuel pump flange are
consistent; see picture 1.14.
(2) Place the first cylinder in the position in the upper limit of the
compression stroke. From this place, rotate the crankshaft at the
counterclockwise direction of 30 degrees, as shown in Figure 1.15.
(3) Release the fuel injection pipe in the first cylinder, remove the
springs and drain valve in the bleed valve seat , and then place the drain
valve seat on the pump; see Figure 1.16.
(4) When supply pump pressure feeds fuel, slowly rotate the
crankshaft at the clockwise direction. When the oil in the tip of the
discharge valve seat rises to the position when it stops, stop turning the
crank. Ensure the mark flagged by pointers; see picture 1.17.
1.5.8 The adjustment of the ignition time of the fuel
(1) remove the pipe installed on the fuel pump( fuel and lubricating
oil);
(2) Loosen the installed bolts in the fuel pump;
(3) When ensuring the ignition time according to main points of
1.5.7, make adjustments away from the engine ahead of time and make
adjustments outskirt the engine in detention.
(4) After adjustment, tighten all the installed bolts in the fuel pump
and ensure the ignition time again;
(5) Build up the discharge pump used by the first cylinder and
assemble and install all the pipes in their original position.
1.5.9 Determination of compression pressure
(1) remove spark plugs and fuel pipes;
(2) Install an manometer(standard value:500N/cm2 ) in the
assembling part of the spark plugs in the first cylinder;
(3) Make the starting device rotate using a fully charged battery and
measure the present pressure;
(4) Using the same method to measure the sixth cylinder for at least
two times. Then calculate separative average value;(compression
pressure:304 N/cm2 (limit value: 255 N/cm2 )
1.5.10 Exhaust of fuel pump

(1) Loosen the vent plug of the fuel pump;
(2) Slowly handle the hand pump until bubbles don’t go up from the
vent plug;
(3) Then tighten the vent plug.
2. Electrical System
2.1 Outline
Electrical system is negative-ground single-line circuit, which is

mainly composed of the following several systems (the principle of
electrical system is as picture 2.1):
(1) Charging system
It is composed of generator, battery and charge indicator, offering
power of the electrical equipment of forklift. Voltage: DC24V.
(2) Start system
It is mainly composed of preheating system, starter switch, starter
protection circuit, starter relay, the starter itself and so on. Its main
function is to start the engine.
(3) Instrumentation system
It is mainly composed of hour meter, fuel gauge, water temperature
gauge and charging indicator light, low oil pressure indicator, oil
temperature indication, clogged air filter warning light, oil-water
separators lights, etc.. It is the test device on the forklift.
(4) Lighting signal equipment
It includes lighting, lights, horn and buzzer.
Headlights: 70W
Front combination lamp (steering / sight width): 21W / 5W
Rear combination lamps (steering / sight width / reverse / brake): 21
W (yellow) / 5 W (red) / 10 W (White) / 21 W (red)
2.2 A
brief
description of manipulation
1) Starting
After the engine starts, the shift lever should be set to zero gear (in
which case the neutral indicator comes into light). Otherwise the engine
won’t start. The reason is that forklift has the function of safely starting
and protection when starting the protection circuit.
The characteristics of the electrical parts in this product is that it
uses the electromagnetic power switch, avoiding burning down the
motor if going wrong when starting the motor electromagnet. At the
same time it can protect the electrical components of the truck from
producing blacksmith and battery discharge phenomenon due to misuse
when at a standstill.
When you turn the key switch to one file, all indicators brighten
after the instrument power is on. At the same time, the preheater on the
engine automatically preheat and the preheat indicator brightens. After
ten seconds, the preheater finisher its work and the indicator will
extinguish. The preheater is to help the engine start. At this time the key
switch can be rotated into the start file at the clockwise direction. Then
release the switch after the engine starts. Otherwise the engine may be
hurt. The diagram of the starter switch gear is shown in Figure 2.2.
2) After the engine starts, for electronic liquid, return it into

automatic shift transmission: turn the direction switch to a file forward
and then forklift forward. At this time it runs slow. Then move it forward
again for second gears, the speed increases and it runs faster. Also there
are two stalls for moving back. If move back one gear, it moves slower
while faster if two gears.
3) Extinguishing of engine
When the starting task is finished, if electric flame failure device is
used, you only need to turn the start switch into “OFF”, then the engine
will extinguish. If pull flame failure device is used, you should pull out the
flame failure cable until the engine stops running.
4) Turning signal: when pulling back the switch of the turning light,
the combination signal lamp and rear combination signal lamp on the
right front of the forklift flash. When pulling forward the switch, the two
signal lamps on the left front flash.
5) Brake signal: when the forklift needs brakes, step onto the brake
pedal and then rear combination brake lamps lights (red light).
6) Reversing signal: when the forklift needs reversing the direction,
turn the shift lever or direction switch onto the rear gear position and
then the transmission will be placed in reverse gear, rear combination
reversing lights (white light) and reversing buzzer sounds.
7) Charging signals: before the engine starts, rotate the starting
switch onto one file (Energizing file) at the clockwise direction. At this
time, the signal light of the oil pressure light and after the engine starts, it
will extinguish automatically. When the engine is at work, the charging
signal light, which demonstrates that the charging circuit malfunctions
and the start engine can’t generate electricity. Then, you should contact
our after-sale service department to keep it in repair.
8) Oil pressure signal of the engine: before starting the engine,
rotate the start switch onto one file (energizing file) at the clockwise
direction. At this time, the signal light of the oil pressure flashes and after
the engine starts, it will extinguish automatically. When the engine is at
work, the signal light of the oil pressure flashes, which demonstrates that
the oil pressure of the engine is too low and the lubricating is not good.
You should stop and have a check.
9) Signal display of water separator: before starting the engine, rotate
the start switch onto one file (energizing file) at the clockwise direction.
At
B R G Y U W N Lr V this
black red green yellow blue white brown Light purple

green
B R G Y U W N Lr V
black red green yellow blue white brown Light purple

green
time, the water
sink signal light
flashes and after the engine starts, it will extinguish automatically. When
the engine is at work, the signal light flashes, which demonstrates that
water in the oil-water separator has exceeded the alarm level and the
water should be discharged. After draining the light will automatically
turn off.
10) Fuel gauge: it shows the storage volume of the fuel in the tank.
11) Water temperature gauge: it shows the temperature of the
cooling liquid in the engine. When it is too hot, the gauge will alarm and
you should stop. When the temperature returns normal condition, you
can use it again to avoid causing boiling state.
12) Hour gauge: accumulating the working hours of engine.
A schematic diagram is as picture 2.3.
2.3 Batteries
Precautions:
(1) Battery can produce flammable gases, having the danger of
exploding. As a result, you should make it avoid producing short circuit
and sparks.
Electrolyte is sulfuric acid. It is very dangerous if touching the skin or eyes
(burns and blindness). If touching the skin, you should rinse it with water.
If touching the eyes, you should rinse it with water and then visit a
doctor.
2.4 Beams
(1) Comparison chart of colors:
GY, GR, GW, WB, YR, RY, RB and LB represent bi-color lines.
The numbers behind bi-color lines represent cross-sectional area of
wire nominal, for example 0.8 shows that the cross-sectional area of wire
nominal is 0.8mm2.
(2) The load-permissible current nominal value in the low-voltage wire

section.
Cross 0.5 0.8 1.0 1.5 2.5 3.0 4.0 5.0 6.
section(m 0
m2)
Ampacity 11 14 20 22 25 25 35
3. Transmission Device
The gearing mainly includes torque converter and transmission. Its

main parameter is as table 3.1 and the transmission structure is as
picture 3.1.
Table 3.1
Program Unit Structural
characteristics
Converter Type Three elements,
single-stage, two-
phase
Loop diameter, the torque ratio MPa 12.5 "($ 315) torque
ratio 3.1
Adjustment of oil pressure 1/min 0.5 to 0.7
Pump Type Internal gear pump;
transmission power
output
Flow 40 (when reaching

2000rpm, 2MPa )
Transmissio Type Power shift
n Gear number 2 tranches separately
before and behind
Speed ratio (same before and behind) I ： 1.621/n ： 0.526
Hydraulic Friction plate mm Outside diameter:
clutch $134/internal
diameter:
$90/thickness: 2.8
Area of friction plate Cm2 77.4
Set pressure M Pa 1.2-1.6
Quality Kg About 296
Oil volume 1 About 20
Oil grades 6 # hydraulic
transmission oil
(equivalent to
SAE10W)
3.1 Outline
The hydraulic transmission of the forklift is composed of torque

converter and power shift transmission. It has the following
characteristics:
(1) Fretting brakes have been installed, improving its fretting
performance. So when the forklift starts to work, it can keep good
fretting performance.
(2) The friction plate of the hydraulic clutch is composed of seven
steel sheets and six paper friction plates which is particularly dealt with
and use pressure lubrication. So it is very durable.
(3) There is one-way clutches in the transmission, improving the
transmission efficiency.
(4) Oil filters are installed in the oil circuit of the torque converter,
improving the oil cleanliness and extending the life of torque converter.
3.2 torque converter
Torque Converter is the integrated hydraulic converter who is single-

stage two-phase-three working round. It is composed of the impeller
installed on the input shaft, the turbine on the output shaft and the guide
wheel on the case in torque converter.
Hydraulic torque converter makes the transmission have a self-
adaptive nature of output, changing its output torque and speed in
accord to the changes of external load. It can also take in and remove the
shock and vibration of transmission system from the engine and external
load. The adopted shifting method is power shift with cushion valve,
which makes the operation simple and convenient, the starting process
smooth and greatly reduce the labor of the drivers. The gearbox has four
stalls including two stalls for forwarding and two stalls for backward.
The impeller is driven by an elastic plate, which is connected with
the flywheel. When the engine starts to rotate, so does the impeller.
Because of the centrifugal force, liquid in the impeller is ejected along the
cascades of the impeller (at this time the mechanical energy is converted
into fluid kinetic energy0.
As a result, the cascades along which liquid flows into the turbine
make the moment transfused into the output axis. The direction of liquid
leaving turbine changed for the impact of guide wheel, making the liquid
flow into the impeller at the best angle. At the same time, a reaction
torque is produced to pull forward the guide wheel, making the output
torque outnumber the input torque for moment equivalent to the
reaction torque.
1. Control valve 2. supply pump 3. Radical bearing 4. Shaft 5. Radical

bearing 6. Torque converter
7. Ball bearing 8. Gear 9. The parking brake 10. Filter 11. Oil seal 12.
gear
13. Ball bearing 14. Brake shaft 15. The bearing cap 16. Output shaft 17.
Oil seal
18. Ball bearing 19. Gear 20. Reverse speed clutch assembly
21. Forward clutch assembly 22. Elastic plate (input board)
23 gearbox input shaft
Diagram 3.2 Torque Converter
When turbine rotation speed increases and approaching to input

rotation speed, angle variation of liquid flow will become smaller, and
torque on output shaft will decrease accordingly. Then, liquid starts
flowing to guide wheel blade grid in reversed direction, which makes
above mentioned counteractive torque act backwards. Under this
operation case, torque on output shaft is smaller than that on input
shaft. In order to avoid this from happening, a one-way clutch will be
equipped in the guide wheel. When above mentioned counteractive
torque act backwards, guide wheel rotates freely. Under this operation
case, input torque equals to output torque, which ensures a high
efficient operation.
Torque converter changes the transmittal of torque via above principle.
It acts as both coupler and torque converter. It called “two-phase” and it
has features of operation stability and higher efficiency.
Torque converter is installed with one-way clutch, turbine, pump

impeller and guide wheel. Torque converter is internally filled with
torque converter oil.
End of pump impeller is equipped with gear, which is to mesh with the
driving gear of oil feed pump, in order to drive the oil feed pump.
Use splined joint as the connection between turbine and (gear box)
input shaft. This splined joint can transmit power to hydraulic clutch.
Refer to Diagram 3.2 for the structure of torque converter.
3.3 Oil Feed Pump
Refer to Diagram 3.3 for the structure of oil feed pump.

Oil feed pump is installed on the top of torque converter, which consists
of driving gear, internal gear (driven gear), shell and cover. Driving gear
is driven by torque converter pump impeller, neutral gear and oil pump
driving gear. Oil feed pump delivers oil to all parts of the pump from
bottom of gear box.
Diagram 3.3 Oil Feed Pump
3.4 Hydraulic Clutch
For forward gear clutch please refer to diagram 3.4. For reverse gear
clutch please refer to diagram 3.5.
Hydraulic clutch is installed in gear box. Driving gear of wet multiple disc
clutch meshes with its corresponding driven gear. While driving gear of
reverse gear clutch meshes with its corresponding shaft gear.
Totally 6 pieces of friction plates made of sintered material and 7 pieces
of steel spacers are in one set of clutch. Friction plates and steel spacers
assembled in turn together with piston.
Sealing performance of piston internal ring and external ring during
operation is ensured by sliding grease seal and O type sealing ring. Disc-
type return spring disconnects to hydraulic clutch when non-operation.
Under this case, there’s always oil back from oil cooling system to
lubricate surface of clutch to avoid clutch surface adhesion and wearing.
When pressure oil acts on piston, sintered friction plates and steel
spacers, which are assembled in turn, are pressed. This enables the
clutch, as an integral part, transmit power from torque converter to
driving gear.
Therefore, here below is the power transmit procedure from torque
converter to gear box:
Turbine -- Input Shaft -- Clutch Drum – Steel Spacers – Sintered Friction
Plates – Forward or Reverse Gear – Output Shaft
Diagram 3.4 Forward Gear Clutch

Diagram 3.5 Reverse Gear Clutch
3.5 Operating Valve and Inching Valve
Operating valve is installed on the upper part of gear box shell. Shift gear
valve and inching valve are both installed inside the operating valve.
Please refer to Diagram 3.6 for operating valve.
Hydraulic clutch relief valve is to adjust oil pressure inside gear box,
while torque converter’s relief valve is to adjust pressure of oil that flow
into torque converter.
Inching valve stem is connected to connecting rod of inching control
paddle. When step the paddle, valve stem is pressed down. Therefore,
oil pressure of clutch decreases and clutch disengages.
Diagram 3.6 Operating Valve
3.6 Torque Converter Oil Way
Oil feed pump starts immediately after engine starts. Torque converter
oil is pressed to operating valve from oil tank (bottom of gear box), via
oil feed pump, to operating valve. Please refer to Diagram 3.7.
Torque converter oil from feed oil pump will later separates into two
streams. One stream is for torque converter, the other one is for gear
box.
Diagram 3.7 Torque Converter Oil System
Oil pressure of gear box clutch is adjusted to 1.2 to 1.5MPa by pressure

regulating valve. Oil pressure of torque converter is adjusted to 0.5 to
0.7MPa by its regulating valve. Then pressure oil flows to blade grid of
torque converter. Pressure oil can lubricate clutch set after cooling in oil
cooling system, then flow back to oil tank via oil filter. This is a
circulation.
When shift gear valve stem is in middle position (neutral position), oil
path between shift gear valve to clutch is shut off. At this time, all fluid
will flow to torque converter. Clutch is idling.
When shift gear valve stem is in forward or reverse position, oil will flow
into pressure accumulator due to regulating valve. Therefore, oil
pressure will increase gradually from clutch starts work to completely be
pressed.
When pressure accumulator is filled with pressure oil, oil pressure will
increase intensively, which makes hydraulic clutch completely meshes.
When forward or reverse gear clutch works, the other one (reverse or
forward gear clutch) is in separate position. Oil from oil cooling system
will lubricate it to avoid adhesion and cooling it down.
Inching valve starts work when step on the inching paddle. Most of oil in
clutch will be extracted from inching valve back to bottom of gear box
(oil tank). Oil way is the same as idling clutch.
3.7 Notes When Forklift Failure
When use other equipment to drag the forklift due to some failure
which causes the forklift cannot operate itself, below notes must be
observed:
1. Remove the transmission shaft between gear box and differential
mechanism
2. Gear selecting lever to be in middle position (neutral position)
Normal lubrication is not going to work when oil feed pump is off work.
Therefore, if driving wheel’s transmission delivered to gear box gear and
clutch, adhesion might happen.
3.8 Trouble Shooting
1. Oil temperature increase to an abnormal level: refer to table 3.2

2. Power shortage: refer to table 3.3
3. Gear box noise increase: refer to table 3.4
4. Low transmission efficiency: refer to table 3.5
5. Oil leakage: refer to table 3.6
Table 3.2 Oil Temperature Increase to An Abnormal Level

Part Cause of Failure Check Method Trouble Shooting
1. Low oil level Check oil level Charge oil
2. Block in oil filter Disassemble and check Clean or replace
Discharge oil in oil filter or tank
3. Fly wheel has collision
and check if there is any Replace
with other parts
foreign material inside
Torque
Check joints and oil line at Tighten the joint or
converter 4. Air suction
suction side replace gasket
5. Water into oil Discharge oil and check Replace oil
Check pipe line to see if there
6. Low oil flow Repair or replace
is damage or bend
7. Bearing wearing or stuck Disassemble and check Repair or replace
Put shift gear lever in neutral
Replace friction
1. Clutch slipping position, check if the forklift
Gear Box plates of clutch
can operate or not
2. Bearing wearing or stuck Disassemble and check Replace
Table 3.3 Power Shortage

Part Cause of Failure Check Method Trouble Shooting

1. Low oil level Check oil level Charge oil
Check joint and oil Tighten the joint or
2. Air into oil suction side
line replace pipe line
Disassemble and
3. Oil filter block Clean or replace
check
Low Oil 4. Oil feed pump Disassemble and
Replace
Pres. displacement shortage check
5. Main relief valve disc Check spring
Replace
Torque spring deformation tension
Converter 6. Damage or wearing of
Disassemble and
sealing ring or O type Replace
check
sealing ring
Extract bit oil and

Fly wheel damage or collision with other check if there is
Replace
parts foreign material
inside
Check joint and oil Tighten the joint or

1. Air into oil suction side
line replace
Oil
2. Two low oil pressure or
bubble
oil bubbling at torque Measure pressure Adjust pressure
converter
1. Low oil pressure Measure pressure Adjust pressure
Disassemble, check
2. Sealing ring wearing Replace
and measure
3. Clutch piston ring Disassemble and
damage check
Check engine, put
Gear Box
shift gear lever at
Clutch
forward, reverse
slipping
and neutral
4. Friction plate wearing or position. Forklift
Replace
steel spacer deformation runs at neutral
position while
stops at forward
and reverse
position
Inching rod and shift gear valve stem in
Check and measure Replace
wrong position
Check rotation
when lost speed,
Adjust or repair
Engine Engine power decrease check operation
engine
sound, check max.
rotation speed
Table 3.4 Gear Box Noise Increase

Parts Cause of Failure Check Method Trouble Shooting
Check rotation sound under low Replace elastic
1. Elastic plate fracture
rotation speed plate
2. Bearing damage or
Disassemble and check Replace
wearing
Torque
3. Gear breaks Disassemble and check Replace
Converter
4. Spline wearing Disassemble and check Replace
5. Big noise of oil feed
Disassemble and check Repair or replace
pump
6. Bolts loosen Disassemble and check Tighten or replace
1. Bearing wearing or
stuck
Gear Box 2. Gear breaks Disassemble and check Replace
3. Spline wearing Disassemble and check Replace
4. Bolts lossen Disassemble and check Tighten or replace
Table 3.5 Low Transmission Efficiency

1. Elastic plate fracture Check rotation sound under low
rotation speed, and check if the Replace
protegulum is rotating or not
2. Oil in short Check oil level Charge oil
Torque 3. Oil feed pump drive
Converter system failure
4. Shaft breaks Disassemble and check Replace
5. Too low oil pressure Check if there is suction
pressure at oil inlet side of oil Replace
feed pump
1. Oil in short Check oil level Charge oil
2. Sealing ring damage Disassemble and check Replace
3. Clutch disc slipping Check clutch oil pressure Replace
4. Shaft breaks Disassemble and check Replace
5. Clutch cover breaks Disassemble and check Replace
Gear Box 6. Clutch cover’s spring
check ring breaks
7. Clutch oil tank has
Disassemble and check Clean or replace
foreign material
8. Shaft spline partially
wearing
Table 3.6 Oil Leakage

Torque 1. Oil sealing ring damage Disassemble and check if there Replace oil sealing
is any wearing on oil sealing lip

or other sliding parts
2. Wrong connecting of Tighten or replace
Check
shell gasket
Tighten or replace
3. Joints or oil line loosen Check
pipe
4. Oil discharge plug
Converter and Check Tighten or replace
loosen
Gear Box
Discharge oil and check if there Replace oil
is water mixed into.
5. Oil sprays via vent hole Check oil suction joint has air Tighten or replace
inlet. sealing
Check vent hole on vent system repair
Discharge
6. Overmuch oil Check oil level
overmuch oil
4. Driving Axle
Refer to table 4.1 for main parameters of the driving axle.
Table 4.1 Driving Axle Parameter

Item Forklift tonnage 5~7t 8~10t
Driving Axle Type Full-floating Type, Cast Steel Axle
Type Spiral bevel gear type
Main reduction gear
Reduce ratio 4.875 6.33
Type Planetary gear type
Hub reduction gear
Reduce ratio 4.25 3.67
Total reduction ratio 20.72 23.23
Main reduction and 101
differential mechanism
Oil capacity
Left and right Left and right
Hub reduction gear
side totally 81 side totally 101
Wheel 8.25-15-14PR 9.00-20-14PR
Wheel Wheel rim 6.50-15 7.0-20
Pressure Kpa 830 760
4.1 General
Driving axle is consist with main reducer, differential mechanism, hub

reduction gear, service brake and semi-axis etc. Please refer to Diagram
4.1 and Diagram 4.2. Use bolt connection to connect driving axle and
segment plate in front of car frame. Portal frame is installed on shell of
driving axle.
4.2 Main Reducer and Differential Mechanism
Main reducer and differential mechanism mainly include left and right
differential mechanism shell, gear ring (spiral bevel gear) and driving
pinion etc. They are all installed inside the main reducer, and installed on
driving axle with a gasket. Please refer to Diagram 4.3 for reference.
Differential mechanism shell is in split type. Left and right shell are
connected by bolt. Half shaft gear and (fixed on the cross gear) planetary
gear are installed inside shell. These two gears meshes with each other,
which enables the differential operation of left and right wheel when
vehicle is steering.
Driving pinion is supported by two tapered roller bearings installed
inside bearing support. Bearing support is fixed by gasket & packing and
main reducer shell. Gear ring is spiral bevel gear type and is installed on
right differential mechanism shell by bolts. Power from gear box
decreases through driving pinion (shaft) and gear ring.
4.3 Hub Reduction Gear
Hub reduction gear includes one sun gear, one set of planter gear and
one annular gear. Two sets of hub reduction gear are installed
respectively on two sides of driving axle shell. Sun gear is installed on
half shaft by spline and is block by spring collar. Planet carrier is installed
on wheel shell. One set of planetary gear is installed on one set of
planetary gear shaft in planet carrier. Annular gear is installed on driving
axle by spline (or by annular gear support).
Power transmission philosophy is as below Diagram 4.4.
When sun gear rotates (half shaft rotation), rotation will transmit to
planetary gear and annular gear. However, since annular gear is fixed on
two ends of driving axle shell, planetary gear is circling around sun gear
and is self-rotating at the same time. Planetary gear is installed on
planetary gear support which is connected to wheel hub. And wheel hub
is connected to wheel rim. Therefore, the power of half shaft enables the
rotation of wheel.
Diagram 4.1 Driving Axle (5~7 tons Forklift)
1. Driving Axle Shell 7. Hub 13. Shaft

2. Half Shaft 8. Tapered Roller 14. Steel Ball
Bearing
3. Brake 9. Regulating Nut 15. Planetary Gear
4. Brake Drum 10.Lock Nut 16. Gear Ring
5. Oil Sealing 11. Planetary Gear 17. Sun Gear
Support
6. Tapered Roller 12. End Cover
Bearing
Diagram 4.2 Driving Axle (8~10 tons Forklift)
1. Driving Axle Shell 7. Hub 13. Steel Ball

2. Half Shaft 8. Tapered Roller 14. Shaft
Bearing
3. Brake 9. Regulating Nut 15. Sun Gear
4. Brake Drum 10.Lock Nut 16. End Cover
5. Oil Sealing 11. Planetary Gear 17. Gear Ring
Support
6. Tapered Roller 12. Planetary Gear
Bearing
Diagram 4.3 Main Reducer & Differential Mechanism
1. Regulating Nut 11.Differential 21. O Type Ring

mechanism Shell
(left)
2. End Cover 12.Half Shaft Gear 22. Sleeve
3. Lock Plate 13.Thrust Washer 23. Regulating Pad
4. Tapered Roller 14.Roller Bearing 24. Tapered Roller
Bearing Bearing
5. Differential 15.Main Reducer Shell 25. Oil Sealing Frame
mechanism Shell
(left)
6. Half Shaft Gear 16.Lock Nut 26. Oil Sealing
7. Planetary Gear 17.Regulating Bolt 27. Flange
8. Spiral Bevel Gear 18.Driving Gear Shaft 28. O Type Ring
9. Cross Bearing 19.Tapered Roller 29. Gasket

Bearing
10. Thrust Washer 20.Bearing Support 30. Lock Nut
Diagram 4.4 Hub Reduction Gear
4.1Trouble Shooting
Table 4.2 Common Failures and Remedy Method of Driving Axle
Failure Cause of Failure Trouble Shooting
Main reducer shell’s connecting bolts
Oil leak from Tighten or replace
loosen or gasket damage
main reducer
Vent hole block Clean or replace
shell
Wearing or damage of oil sealing Replace
Wearing, damage or break of gear Replace
Wearing, damage or break of bearing Replace
Big noise of
Unsuitable backlash Modification
differential
Loose match between connecting half shaft
mechanism Replace
gear and half shaft spline
Un-enough gear grease Charge oil as per need
4.5 Maintenance Data
Table 4.3 Maintenance Data of Driving Axle

Standard Value
Parts Item
(mm)
Gasket thickness of bearing support 0.1, 0.2, 0.5
Match diameter of flange and oil sealing 69.95~70
Spline backlash of flange and driving pinion (shaft) 0.036~0.067
Backlash of driving pinion and gear ring 0.20~0.30
Differential Preliminary load of driving pinion 2.5~3.5 (Nm)
mechanism Backswing of gear ring 0.25~0.38
Tighten torque of bolt fixing gear ring 100~150 (Nm)
Tighten torque of bolt fixing differential mechanism shell 100~150 (Nm)
Gasket thickness of planetary gear 1.562~1.613
Backlash of connecting half shaft gear and half shaft spline 0.038~0.130
Tighten torque of bolt fixing driving axle shell and main reducer
150-175（Nm）
shell
Match diameter of small bearings on both driving axle ends and
89.66-89.88
driving axle shell
Driving Match diameter of oil sealing on driving axle both ends and
109.913-110
axle shell driving axle shell
Tighten torque of bolt fixing driving axle shell and car frame 630-946（Nm）
Tighten torque of bolt fixing brake bottom plate and driving axle
280-330（Nm）
shell
Match diameter of driving axle shell and portal frame 189.2-190
Match diameter of hub and small bearing 159.32-159.72
Match diameter of hub and big bearing 179.32-179.72
Match diameter of hub and oil sealing 164.6-165
Hub
Tighten torque of bolt fixing brake drum and hub 280-330（Nm）
Tighten torque of bolt fixing hub and planetary gear support 98-113（Nm）
Tighten torque of hub nut 480-560（Nm）
5. Braking System
Table 5.1 Braking System Basic Parameters

Forklift type FD 50, 60, 70 FD 80, 100

Item Domestic Imported
engine engine
Service Braking form Vacuum assisted brake Dynamic brake
brake Brake form Front wheel, internal expanding, shoe
brake
Brake drum internal diameter φ317.5 φ438.15
mm
Pump internal diameter mm φ31.75 φ47.62
Shoe disc size 324*100*10 489*100*12.7
(length*width*thickness)
mm
Shoe disc surface area 4*324 4*489
Parking Form Installed on the intermediate shaft of the
brake transmission, mechanical, internal
expanding
Brake drum internal φ160
diameter mm
Shoe disc size 140*36*3.5
(length*width*thickness
) mm
Shoe disc surface area 50.4
Brake pump, Brake master cylinder φ31.75 /
valve Vacuum booster φ9″ / φ10″ /
diameter front shell/
back shell
Brake Form, / Open center type,
valve primary closed center type
valve/
safety valve
Moving / Spring type
form
Input flow / 27
l/min
Maximum / 10.5
working oil
MPa
Accumulator Form / Spring type
Volume, maximum/ / 100/ 64
working ml
Piston diameter mm / φ50*34
Oil pressure, maximum/ / 7.2/ 4.9
working MPa
Overflow oil pressure / 13
MPa
5.1 Outline
The braking system consists of service braking system and stopping

braking system. The service braking system is installed in the driving
wheel, while the stopping braking system is installed in the intermediate
shaft behind the transmission.
There are two kinds of service braking actuators, vacuum assisted
braking and dynamic braking. 5-7 ton forklifts with domestic engine
always use vacuum assisted braking, while those with imported engine
always use dynamic braking, and all kinds of 8-10 ton forklifts use
dynamic braking.
5.2 Dynamic Braking
A service braking system that uses dynamic braking consists of a

brake pedal, a brake valve, an oil pump, an accumulator, a brake, etc. The
system is shown in chart 5.1.
The dynamic braking passes hydraulic oil using a small gear wheel that is
special for the hydraulic system of the forklift, going all the way into the
brake valve. When the driver presses down the brake pedal, the
hydraulic oil goes into the brake valve and pushes out the plunger, and
then pushes the brake shoes to brake. Another stream of hydraulic oil
goes into the accumulator, accumulating energy for backup. The two
streams are both controlled by the stroke of the brake pedal.
Chart 5.1 Braking System

5.2.1The Brake Pedal
The brake pedal and the inching pedal are installed on the left of the
frame through a bracket. The brake pedal on the right pushes the piston
of the brake valve through the rod, allowing the pedal to control the
hydraulic oil. The inching pedal on the left works together with the brake
pedal on the right. It can also control the brake valve and the inching
valve of the transmission at the same time. It is shown in Chart 5.2.
5.2.2 The Brake Valve
The brake valve and the steering system use the same source of
hydraulic oil. They can work independently or together without
interference to each other. The braking force of the foot increases
proportionately with the brake oil pressure, making the operation easy
and comfortable. It reduces the labor intensity of the operator with
sensitive brake and without stagnation. It is shown in Chart 5.3.
(1) Non-braking Status
In non-braking status, because brake valve A is open, the interface
of the pump and the interface of the steering gear are interlinked, and
the steering gear works normally. When the brake pedal is not pressed
down, even if the operator steers, it will not brake. In this situation,
because B is closed, controlling hydraulic housing D will not cause the oil
pressure to go up.
(2) Start and End of Braking Status
A. When the brake pedal is presses down, piston assembly 10 moves
left. Consequently, valve bush 7 and recoil piston 5 are pressed left by
spring group 8. At the same time, return spring 6 is pressed left.
Chart
5.2
Brake
Pedal
Device
B. Because of the movement of 7, close 0 and cut off its connection with
the interface of the oil return tank. Then open B and connect 0 with
the interface of the pump.
C. At this time, valve bush 7 moves left again. Because of the
compression of 0, the oil pressure of the interface of the pump and 0
goes up. Accordingly, the pressure of the oil going to the brake pump
goes up. At the same time, the high oil pressure of 0 pushes right
recoil piston 5. This thrust counterbalances the pedal power.
D. When the right side of the piston receives a maximum pedal power,
in order to keep the oil pressure of 0 below the maximum value, limit
it with screw bolts and pedal brackets.

E. When the operator’s foot leaves the pedal, valve bush 7 returns to
the original position by the reverse thrust of the recoil piston and the
reverse thrust of spring 6 and spring 8. The braking process ends.
(3) Working procedure of the accumulator
When the oil pump stops working (the status of coasting after the
engine burns out) or is damaged, the accumulator starts working.
A. When the brake pedal is pressed down further, valve bush 7, recoil
piston 5 and retaining valve contact pin 3 move left together. The
pushes the ball away. Consequently, 0 is connected with the interface
of the accumulator, using the oil in the accumulator to brake the
brake pump.
B. When the operator’s foot leaves the pedal, the valve bush, recoil
piston and the contact pin move right simultaneously. The ball of the
retaining valve reconnects with the valve seat (the retaining valve is
closed) under the spring’s force. The contact pin stops in the position
accordingly.
C. The recoil piston moves right, and g is open, allowing the oil in the
brake pump to go back into the oil tank.
5.3 Brake valve

1. Screw plug
2. Retaining valve seat
3. Retaining valve contact pin

4. Recoil piston guide
5. Recoil piston
6. Return spring
7. Valve bush
8. Spring group
9. Oil seal
10.Piston assembly
5.2.3 Accumulator
The accumulator is of spring-piston style. When the engine stops
working or the oil pump breaks down, it can be used as non-
conventional energy. It satisfies the need of braking and it works
sensitively and reliably. And it has the low pressure security alerting
function. It is shown in Chart 5.4.
In the chart, it is in a non-accumulating state. The buzz of the
alert switch is in working condition.
When the brake pedal is pressed down, the oil pressure goes up
to over 3.9MPa. The retaining valve is open, allowing the oil to go into
the accumulator. Accordingly, the piston is pushed left and
compresses the spring group to form oil pressure.
At the same time, the piston moves left. In this way, it makes the
control rod of the alert switch move left under the spring’s force and
makes the valve key right in the groove of the control rod. The alert
switch is in off-working condition.
With the rising of the oil pressure in the pump, the piston’s left
stroke is limited by the stop pipe in the middle of the spring group. At
this time, the accumulator has the largest energy with an oil pressure
of 13MPa. The value is controlled by the safety valve.
Chart 5.4 Accumulator
5.3 Vacuum dynamic braking
5-7 ton forklifts with domestic engine currently use vacuum assisted
brake, namely, using vacuum booster with brake master cylinder
assembly to realize energy assisted braking.
The vacuum booster uses vacuum (negative pressure) as motive
power (namely, using pressure difference between vacuum and
atmospheric pressure), allowing the operator to acquire high braking
pump pressure in an assistant and labor-saving way under weak brake
pedal power. It reduces the driver’s labor intensity and increases the
security of service braking.
The major performance parameters are shown in Chart 5.2.

Item Unit Value
Vacuum cylinder Maximum mm φ263
valid diameter Minimum mm φ236
Vacuum booster maximum stroke mm 39

Impetus ratio 7
Brake master Diameter mm φ31.75
cylinder Maximum stroke mm 38
Front chamber ml 15.8
emission
Back chamber ml 14.2
emission
Assembly maximum outside mm φ272
diameter
Installation plate size mm 60*80, 4-M8
hole
Oil port size mm 2-M10*1
Dead weight kg 5.3

5.3.1 Vacuum booster and brake master cylinder assembly
The outline drawing of the double diaphragm vacuum booster and
the brake master cylinder assembly used in 5-7 ton forklifts is shown in
Chart 5.5. The internal structure is shown in Chart 5.6. The working
conditions of the assembly are simply shown as follows:
Chart 5.5 Outline of the vacuum booster and the brake master
cylinder
(1) off-working condition
When the vacuum booster is not in working condition, big cone
spring 3 pushes rod 1 and piston 5 of the control valve to an

extremely back position. Air control valve 4 is pushed onto 5 by small
cone spring 6. Consequently, the air valve is closed. At this time, the
front chamber and the back chamber of the thrust chamber are
connected through the passageway, the air control valve and
passageway B and they are disconnected with the atmosphere. When
the engine and the vacuum pump are in working condition, both the
front chamber and the back chamber of the thrust chamber have
specific vacuum.
(2) Braking condition
A. As soon as the brake pedal is pressed down, the pedal power goes to
pod 1 of the control valve after being amplified by the lever and
compresses 3. Then both 3 and 5 move forward. After the work of
reaction plate 10 and push rod 13 of the master cylinder, there is
specific pressure in the brake master cylinder and it passes to the
brake pump in the brake wheel. At the same time, air control valve 4
move forward with 5 under the work of small cone spring 6, and
contacts with the interface of the vacuum valve on control valve 7
and force it to close. Accordingly, the front chamber and the back
chamber of the thrust chamber separate with each other (namely,
the back chamber of the thrust chamber separates with the vacuum
source).
B. With push rod 1 of the control valve continues moving forward,
control valve piston 4 separates with 4. While the atmosphere goes
into the back chamber of the thrust chamber through air filter 2 and
valve chamber and passageway B. In this way, the force formed by the
pressure difference between the two chambers of the thrust chamber
is mainly used to work on reaction plate through control valve 7,
while a small part of it is used to balance the force of big cone spring
3 and passed to brake master cylinder, performing the function of
booster.
(3) End of braking condition and return to off-working condition
A. In the process of pressing down the brake pedal (namely, the push
rod of the control valve moving forward), air goes into the front
chamber and the back chamber of the thrust chamber continuously
through the open air valve, and the control valve moves forward
continuously. When the brake pedal stops and remains in a specific
position, the control valve accordingly moves to a position to close
the air valve and stops. At this time, the vacuum valve port and the
air valve port are both closed. The booster is in a balanced condition,
namely, the pressure difference between the front chamber and the
back chamber, oil pressure of the brake master cylinder, and the
thrust of the push pod of the control valve keep balanced. The wheel
brake is in braking state.
B. When the brake pedal is released, push rod 1 and piston 5 of the
control valve are immediately pushed backward under the work of
return spring 14 and big cone spring 3, making air control valve 4
separate with vacuum valve port. Then a procedure of braking ends
and it goes back to off-working condition.
Chart 5.6 Vacuum booster and brake master cylinder structure

drawing
1. Push rod of control valve
2. Air filter
3. Big cone spring
4. Air control valve
5. Control valve piston
6. Small cone spring
7. Control valve
8. Back coating shell
9. Back coating
10.Reaction plate
11.Front coating shell
12.Front coating
13.Push rod of brake master cylinder
14.Return spring
15.Joint of vacuum tube
5.3.2 Installation instructions of vacuum booster and brake master
cylinder assembly
(1) Install booster 4-M8 screw bolt and installation bracket on the
frame of the forklift. Connect the adjusting fork of the booster
terminal with the rod of the brake pedal. Then tighten 4-M8 screw
nut. The moment of force should be 12Nm- 18Nm.
(2) Connect the vacuum hose with vacuum joint of the booster and
keep sealed.
(3) Connect the brake oil tube with screw thread 2-M10xl of the oil
port of the brake master cylinder. The moment of force should be
12Nm- 16Nm.
(4) Open the lid of the reservoir and pour in brake fluid (do not mix in
dust or impurities) to drain all the air in the braking system.
(5) When change the brake master cylinder or the vacuum booster
separately, the moment of force of the connecting screw nut between
the two should be 12Nm- 18Nm.
(6) Please do not adjust rashly the push rod on the matching surface
of the vacuum booster and the brake master cylinder.
5.3.3 Cautions for users
(1) This product must use the brake fluid provided in this manual.
(2) After pouring the brake fluid in the assembly, the air should be
drained completely.
(3) After the air is drained, the fluid level should be in the middle of
the reservoir.
(4) When breakdown occurs as in Chart 5.3, it should be fixed by
qualified professionals. The user should not disassemble it rashly.
5.3.4 Breakdown and cause analysis
Chart 5.3 Common breakdown and causes of vacuum assisted brake
Breakdown and symptoms Cause analysis
Master cylinder chamber two or 1. Master cylinder rubber collar is
any other chamber no air damaged
pressure, pedal stroke soaring 2. Oil port tube is damaged
Output oil pressure not high, 1.Booster vacuum leaks
pedal force becoming large 2.Engine vacuum tube leaks
suddenly
Oil storage tank always in short of 1.Oil tank joint leaks
oil 2.Master cylinder piston one
rubber collar is damaged
Brake pedal low and soft Air in oil passageway
Clearance between the booster
push rod and the master cylinder
piston is too large
5.4 Service brakes
The service brake consists of an internal expanding brake and a

shoe brake, installed symmetrically on the left and right driving
wheels. The brake consists of a pair of brake shoe assemblies (one
primary brake shoe and one secondary brake shoe), a brake pump
(one for 5-7 ton and two for 8-10 ton), a clearance adjuster, 3-4
return springs and a brake backing plate. A friction disc is pivoted
outside the brake shoe. The clearance adjuster is used to adjust the
clearance between the friction disc of the brake shoe and the inner
wall of the brake drum.
Chart 5.7
5.4.1 The
service
brake (5-
7 t
forklifts)
A 5-7 t
service
brake has
only one
brake
pump
and the
two ends
of the
piston
rod are
connected separately to the upper ends of the primary brake shoe

and the secondary brake shoe. The bottoms of the primary brake
shoe and the secondary brake shoe are connected to the two ends of
the clearance adjuster and they are pushed down onto the brake
backing plate by springs and pressure spring rods. It is shown in Chart
5.8.
The automatic clearance adjuster is used when the forklift brakes
backward. That is to say, when the adjustment lever has large

clearance, it adjusts the gear wheel of the adjuster automatically to
turn one tooth to keep the clearance between 0.4mm and 0.6mm.
The turning direction of the gear wheel is shown in Chart 5.7.
There are two kinds of service brake for 5-7 t forklifts. Thus, there
are two kinds of rubber cup material in the brake pump, namely, oil
resisting rubber for rubber cup in dynamic braking and leather or
synthetic leather for rubber cup in vacuum assisted brake. It should
be paid special attention to when replacing parts.
Chart 5.8 Brake

1. Primary brake shoe

2. Return spring
3. Dust ring
4. Rubber cup
5. Piston
6. Push rod
7. Secondary brake shoe
8. Return spring
9. Shoe fixing pin
10.Spring with pretightening force
11.Adjuster spring
12.Adjustment lever
13.Adjuster
14.Return spring
5.4.2 Service brake (8-10 t forklifts)
It is shown in Chart 5.9
An 8-10 t service brake has two brake pumps, separately connected to
the two ends of the primary brake shoe and the secondary brake shoe.
The clearance adjuster is beside the brake pump.
When adjusting the clearance, first take off the rubber lid of the adjuster
on the brake backing plate, then turn the gear wheel of the adjuster
outward with a screwdriver until the contact of the friction disc and the
inner wall of the brake drum is stable. Next, turn the gear wheel of the
adjuster back for 5-6 teeth (shown in Chart 5.10).
An 8-10 t forklift uses dynamic braking and the material of the rubber
cup of the service brake pump is oil resisting rubber. It should be paid
special attention to when replacing parts.
Chart 5.9 Brake (8-10 t)

1. Primary brake shoe
2. Adjuster
3. Push rod
4. Piston
5. Spring
6. Rubber cup
7. Dust cover
8. Secondary brake shoe
9. Return spring
10.Brake backing plate
Chart 5.10 Drawing of partial enlargement of the brake

5.5 Parking brakes
Chart 5.11 Parking brake control device

Operation of the parking brake is shown in chart 5.11. When acting
parking brake in the standard load state on a ramp, the operation force
of the hand should not be more than 300N. The force should be adjusted
in the direction as in the chart. B is the force measuring point.
The parking brake is an internal expanding one, installed on the
intermediate shaft output terminal at the back end of the transmission

(shown in Chart 3.1, Serial number 9). Detailed structure is shown in
Chart 5.12.
Chart 5.12 Parking brake

1. Backing plate
2. Brake shoe
3. Fixing screw bolt
4. Screw nut
5. Spring washer
6. Washer
7. Return spring
8. Adjuster
9. Adjuster spring
10.Pin
11.Spring installation bracket
12.Rod
13.supporting plate
14.pin
15.U-shaped retainer
16.Plunger
17.Soft brake cable
5.6 Trouble Shooting
Please check the cause and shooting methods of common trouble in

Table 5.4.
Table 5.4 the cause and shooting methods of common trouble
Trouble Cause of trouble Shooting method
Insufficient braking force Leakage of braking fluid in Repair it
breaking system
Misalignment of gap in Adjust it
friction plate
Overheating of the brake Check the slippage
Unsatisfactory contact Adjust it
between brake drum and
friction plate
Existing oil caused by the Change it
invalidation of sealing ring
Impurity in braking fluid Change the braking fluid
Inappropriate adjustment Adjust it
of brake pedal
Noises in braking Surface hardening or Repair or change it
procedure adhesion of impurities of
friction shoe lining
connecting bolt being Repair or change it
loose and deformation of

bottom plate
Deformation of friction Repair or change it
shoe lining after assembly
or incorrect assembly
Abrasion of friction plate Change it
Wide worn clearance of Change it
wheel bearing
Uneven braking Adhesion of impurities in Repair or change it
friction shoe lining
Rough wheel cylinder Repair or change it
action
Brake drum being off Repair or change it
center
Misalignment of gap in Adjust it
friction plate
Inappropriate air charging Adjust it
pressure of the wheel
Pedal being soft and weak Leakage of braking fluid in Repair it
breaking system
Misalignment of gap in Adjust and repair it
friction plate
Air being mixed into Exhaust air
breaking system
Inappropriate adjustment Readjust it
of pedal
6. steering system
Please check the main parameter of steering system in Table 6.1.

Table 6.1 basic parameter of steering system
Parameter, structure
5-7t 8t 10t
Steering system pattern Rear wheel steering carrying power
steering
Steering wheel diameter φ360
Steering model BZZ orbitrol steering gear
gear Delivery capacity ml/rpm 280
Rated pressure MPa 16
Steering pattern Horizontal type, Double acting type
cylinder Cylinder diameter / Rod φ115/φ85
diameter mm
Stroke mm 2x216 2x260
Flow divider Pressure setting MPa 12.3
valve Rated flow l/min 25 27
Steering Type The central supporting shaft
bridge bearing, exhaust cylinder type

Steering angle 79°/50°
Outer gear/ internal gear
rear wheel distance mm 1700
Steering knuckle in residence 1500
spacing mm
Universal joint swing mm φ42
Wheels Tire 8.25-15-14PR 9.00-20-14PR
Tire rim 6.50-15 7.0-20
Pressure KPa 800 760
The steering system is consist of steering wheel, steering
column(including steering axle and locking handle), universal joint,
steering gear, steering bridge and steering cylinder. Please check steering
operating gear in Table6.1.
Steering axle and steering gear are connected by universal joint.
Steering wheel steering axle and drive universal joint to make steering
gear shift. It would realize fluid-link steering. Steering column that
supports steering axle could lean back for certain angle to adjust to a
appropriate position. It could satisfy the need of drivers in different
height and make them feel comfortable and portable.
6.1 Steering gear
6.1.1 Introduction
The steering gear is cycloidal hydraulic steering gear and is
composed of rotary valve group, the rotor pump, valve block, etc.
According to the turning angle of plate size measurement, it could
transport the pressure obtained by diverter valve flow from oil tubing to
steering cylinder. Through it the driver can use small operating force to
control the hydraulic oil into the steering cylinder and realize a large
force to make the rear wheels, the vibration of the steering wheel
caused by uneven non-pavement, safe and reliable performance and
convenient and flexible operation.
The steering gear also have emergency steering function. When the
engine flameout and oil pump can not supply oil, if someone turn the
steering wheel, the rotor pump oil could achieve supply functions. It
would realize human steering. Full hydraulic steering system diagram is
shown in figure 6.2. Steering structure is shown in figure 6.3.
Figure 6.1 steering operating gear

方向盘：steering wheel
锁紧手柄：locking handle
转向器：steering gear
万向节：universal joint
连接轴总成： connecting shaft assembly
Figure6.2 full hydraulic steering system diagram

1. steering wheel and steering axle 2. Oil pump 3. Flow control valves
4. hydraulic steering gear 5. steering cylinder 6. Steering bridge 7.
Flexible pipe
Figure6.3 cycloidal orbitrol steering gear

1. baffle ring 2. valve body 3. rotary valve 4. universal driving shaft 5.
valve plug 6. front cover 7. Rotor 8.stator 9. valve barrel
6.1.2 Working principle
The valve core, valve sleeve and body in steering gear composed
regulated valve, in the role of controlling the flow of oil. The rotor and
stator make up wire mesh, in the role of the measuring element when
the power steering starts, so as to ensure the flow of the oil cylinder is
proportional to the steering wheel angle. When the human manual oil
pump, it works as joint shaft torque. It’s shown in figure 6.4.
Middle position (i.e., the steering wheel won’t rotate), in the opening-
core system, the oil in the oil pump is back to the tank through the valve
core chamber.( in figure 6.4a) .
When the power steering start, the oil in pump to servo valve into the
cycloidal meshing pair, push the rotor rotate with the steering wheel,
and push quantitative oil into the left or right side of the cavity. It would
promote the steering wheel to achieve power steering. Another
chamber of the oil cylinder would be back to the tank.(Figure. 6.4 b, c).
When the engine flame out, it would rely on human power to
manipulate the steering wheel. Through the valve core, dial pin, linkage
drive shaft rotor will shift the oil in one of the cavity pressure into
another cavity, promote the steering wheel and realize human power
steering (Figure. 6.4 d).Through oil compensating valve, oil would be
added by oil tank.
This forklift truck adopts BZZ1 type redirector which is opening-core
non-reactive type, namely the external forces acting on the steering
wheel being unable to be transferred onto steering wheel on. The driver
wouldn’t feel like on the road.
Figure6.4
Drawing of
Steering Gear’s
Oil Circuti
中间位置：
position in the
middle
左转向：
left steering
右转向：
right steering
人力转向：
human power
steering
6.1.3 The
using
requirements
(1) Installing
When installing the steering gear, make sure that it is always

concentric with the connecting shaft assembly under the universal joint,
and there are axial intervals to avoid the valve plug stopped. After
installation, check if the steering wheel is flexible.
The pipes should connect with the oil outlet pipes of the oil pump
according to the “in” mark of the steering gear, the “out” mark
connected with the oil tank, the “left” and “right” marks respectively
connected with the left and right side of the oil tank.
(2) Range of oil temperature: From -20℃ to +80℃
Normal oil temperature: From +30℃ to +60℃
(3) Choice of oil: N46 or N32 hydraulic oil
(4) Filtering: the filtration accuracy is 30μm for oil entering the
steering gear
(5) All the pipes of the system should be cleaned up, and the fuel tank
should be sealed to reduce pollution of the oil.
6.1.4 The inspection and repairing of the steering gear
The regular inspection is needed to maintain the good working state
of the steering system and avoid accidents.
(1) Regularly inspect the water in the working oil, the mechanical
admixture and the acid number. When they are over the number of the
original grade requirements, the new oil should replace, and the used
unfiltered oil is absolutely forbidden.
(2) When checking the steering system, the steering gear should not
be rashly opened. When the steering gear breaks down, it should be
disassembled according to the “ Assembling Cautions”.
(3) All the tools used to assemble and disassemble should be clean as
well as the working place, which had better be indoor.
(4) Assembling Cautions:
a. Before assembling, all the components should be washed by
gasoline or coal oil, and the oil paint on the contact surface should be
cleaned with acetone. Cotton and rags are forbidden in cleaning the
components, which should be replaced by brush or silk. The compressed
air is permitted if available. The rubber ring cannot be dipped in the
gasoline for too long. When the steering gear assembling is done, 50 to
100ml hydraulic oil should be added to the fuel inlet before assembling
the car. Until there are no abnormalities when turning the valve plug, the
car can be assembled.
b. The contact face of the valve body, separation disc, stator and the
back cover should be extraordinarily clean without bruises or scratches.
c. The screw cover should be under the level of the valve body.
d. The baffle ring and the slip-ring both have a chamfered surface. The
baffle ring’s should face the front cover, and the slip-ring’s should face
the valve plug.
e. The ends of the rotor and the the universal driving shaft have red
point marks, which should coincide with each other when assembling.
f. The stop bolt(with feather)’s washer should be made of copper or
aluminum.
g. The way to tighten the 7 screws of the back cover is to wring one
every two screws in order and gradually tighten them, instead of one by
one. The tightening force is 30-40Nm.
h. When installing the oil pipes, pay attention to the marks of “in”,
“out”, “left” and “right” of the valve body, which should be accordingly
linked with the oil pipes.
(5) Disassembling and assembling(shown in Picture 6.5)
a. The order of disassembling:front cover-baffle ring-slip ring-valve
barrel etc.-(gasket-pin-valve plug-spring leaf)-back cover-stop column-
stator-rotor-universal driving shaft-separation disc-screw cover-steel ball-
valve body.
If starting from removing the back cover, before taking out the valve
core and valve set and so on, you must remove the ball first, or it will
ruin the valve body. On the demolition of the front cover, you must be
careful not to bruise or scratch the other body of the valve.
b. Assembly sequence: valve core---spring piece---valve set---dial pin---
gasket---valve body---slip ring---retaining ring---front cover---steel ball---
screw set---separation plate---linkage shaft---rotor---stator---limit
column---back cover.
Figure 6.5 the

removing and
assembling
diagram of
steering gear
6.1.5 The
trouble and
elimination methods of steering gear
Diagram 6.2 the common troubles and elimination methods of
steering gear
Trouble Causes Phenomenon Elimination methods

Oil leakage There is dirt on There is oil Re-cleansing.
the combing leakage on the
surface. valve body,
separation plate,
stator and back
cover.
Oil leakage Rubber gasket
caused by the shaft replacement.
neck and rubber
gasket damage.
Oil leakage Smooth or replace the
caused by uneven gasket.
gasket on the limit
bolt.
Hard steering The shortage of When turning Choose the right pump
pump oil. slowly, the steering or check whether the
wheel is light, pump diverter valve is
when turning normal.
quickly, the
steering wheel is
heavy.
There is air in There is bubble Eliminate the air in the
the steering in oil; the irregular system and check the
system. sound; when turn suction line.
the steering wheel,
the oil cylinder
sometimes moves
sometimes doesn’t
move.
Oil tank is not Fill the oil to the
full. specified oil level.
Oil viscosity is Use the recommended
too thick. viscosity oil.
Steel ball one- Steering wheel is If the steel ball loses,

way valve in the heavy whether then load the φ8 ball, if
body valve loses turning fast or there is dirt sticking the
efficacy. slow, and without wheel ball, then it should
pressure. be washed.
Diverter valve When it is empty Adjust the diverter
pressure is lower load (or light load), valve pressure or cleaning
than the working the turning is light, the diverter valve.
pressure or it is when increase the
stuck by dirt. load, the turning is
heavy.
6.2 Checking after the steering system reload
(1) Check whether the hydraulic piping layout is correct, whether it is

installed backwards when turning left or right.
(2) Turn the steering wheel to the left or right, and turn to the end,
and see whether the strength is even or the rotation is smooth.
(3) After assembling the steering system, jacking up the directive
wheel, and idle running the engine, and then slowing turn the steering
wheel to the left or right and repeat for several times in order to exclude
the air in the hydraulic line and steering cylinder. Put down the directive
wheel, then turn the steering wheel several times to check whether the
sound is normal. If you can’t hear the unusual sound, it means that the
air has been completely drained. Then fix the engine at high speed to
increase the oil temperature.
(4) Measure the steering operation force
Park the forklift truck on dry flat road. Apply the parking brake, tie the
spring balancing device to the edge of the steering wheel, if it measures
the steering operation force, the force must be less than 150N.
Figure 6.6
Measuring
pressure
(5) In
order to
measure
pressure,
using the pressure gauge (15-20MPa), the block valve and hose as shown
in figure 6.6.
Remove the tube from the diverter valve to the steering gear, by the
side of diverter valve, connect the tube with the pressure gauge, by the
side of steering gear, connect the tube with the shut-off valve, and then
let the engine idle running.
When the steering wheel is in a free state, the oil pressure is about
0.5-2MPa, if the pressure exceeds this valve, it is necessary to check
whether the diverter valve and pipeline are blocked. If there is no
abnormal situation, increase the engine speed to 1500rev/min or so.
Then slowly close the shut-off valve and pay attention to the pressure.
Adjust maximum pressure of the diverter valve to 12MPa, therefore,
when the shut-off valve is fully closed, there is the set pressure on the
pressure gauge.
If the pressure exceeds 12MPa, it means that the diverter valve is out
of order. But if the pressure is too low, it means that the pump is out of
order or the rupture of the diverter valve spring. In this situation, it
should pay attention that doesn’t let the diverter valve close for longer
than 15 seconds.
Attention: the oil pump provides the pressure oil to make the steering
cylinder move; its work must be considered from two aspects, namely
the calibration pressure and rated flow.
Pressure is used to push the oil cylinder, and the flow is related to the
rate of the cylinder operation. Therefore, the pressure should be
reaching 12MPa.
And if the flow rate is insufficient, the steering cylinder is still not
working normally, it will causing heavy steering. Therefore, when the
diverter valve requires disassembled and re-assembled, it should adjust
the flow valve and safety valve according to the capacity and using
condition of the steering cylinder, and mark on the settling position, in
order to reload or measure, and adjust the bolt distance.
6.3 Steering system troubleshooting
The steering system trouble caused by diverter valve and its trouble
clearing see table6.3
Table6.3
Trouble The reason for trouble Methods for
troubleshooting
Steering wheel getting Flow control valve stem Removing and repairing or
stuck when turning quickly blocks replacing
Flow control valve stem Replacing the whole
blocks wears
Oil pressure can’t rise high Safety valve normally Replacing the whole
opens(cannot close )
Oil pressure is higher than Safety valve normally Replacing the whole
the set pressure of the closes(cannot open )
relief valve
Safety valve has noise Safety valve shakes Replacing the whole
Oil pressure is too high Safety valve normally Replacing the whole
closes(cannot open )
Turning operation is Safety valve normally Replacing the whole
difficult when engine opens(cannot close )
idling Flow control valve stem Removing and repairing or
blocks replacing
blocks wears
Steering force has change Safety valve shakes Replacing the whole
Flow control valve stem Removing and repairing or
blocks replacing
blocks wears
Turning operation is Safety valve normally Replacing the whole
difficult opens(cannot close )
Flow control valve stem Removing and repairing or
blocks replacing
blocks wears
6.4 Steering axle
5-10t forklift all use horizontal type steering cylinder, the front and back
of center are supported on the steering axle base through two bearing
axles, the latter is separately fixed on the frame, two bearing axles can
swing some angle. 5-10t forklift Steering axle structure is basically same;
the main structure representing graphs see table 6.7 and table 6.8.
The steering axle is mainly consist of steering axle frame, left and right
steering assembly, connecting rod assembly, wheel, wheel hub, fulcrum
bearing, connecting bolt and steering cylinder etc..
6.4.1 Steering axle frame
The steering axle frame is welded intensity beam structure, good rigidity,
high bearing capacity, the each end of the bridge has a convex sets, a
king pin is equipped in the convex holes and connects the left and right
steering assembly with frame. The convex opening size of 5-8t forklift is
small, 10t is big.
6.4.2 Left and right steering assembly
The left and right steering assembly is supported on the wheel hub
through two thrust bearing, wheels are installed on the wheel hub; there
is oil seal on the wheel hub to avoid grease overflowing. Thrust bearing
assembly installed between the up and down convex of steering knuckle
and steering frame. The underneath can be adjusted running clearance
by the gasket, the steering king pin installed in the holes of up and down
convex , supported by up and down needle roller bearings, the
underneath is sealed with oil seal. The upper end cover equipped with
oil nozzle which through the kingpin hole for all bearing lubrication,
users need to fill lubricating grease on time. There is locking pin between
the king pin lock of the steering knuckle assembly to fix it.
6.4.3 Wheel hub
Wheel hub is ductile iron parts; it is also different due to 8-10t forklift
tires different from 5-7t.
Table 6.7 Steering axle frame

1. Steering axle frame 2.Connecting rod 3.Steering cylinder 4.Rear axle
bearing 5.Bushing 6.Right steering assembly 7.Thrust bearing 8. Needle
bearing 9.Kingpin
10. Tire 11.Oil seal 12.Conical roller bearing 13.Conical roller bearing
14.Wheel hub cover 15.Wheel hub16.Hub bolt17.Wheel hub nut 18.Oil
seal 19. O rings 20.Bushing 21. Dirt-proof boot 22.Left steering assembly
6.4.4 .Steering cylinder
The steering cylinder is double-acting which placed horizontally in the
middle of steering axle frame, the piston rod on both ends connect rod
assembly, the another end of the latter can promote the steering knuckle
arm to turn the wheel. The both ends of the cylinder are the guide
sleeve, the inner hole is equipped with steel bearings, block slice, sealing
ring back and shield to contact with the piston rod, the outer hole has
bearing ring, o type ring contacting the cylinder wall, cylinder can be
employed universally in 5-8t forklift. The structure see table 6.8.
Table 6.8 Steering cylinder
7. Hydraulic system
The main technical parameters of hydraulic system see table 7.1

Table 7.1 the main technical parameters of hydraulic system
Forklift model FD50、60、70 FD80、100
Project
Brake type Dynam Vacuum assisted Dynamic braking
ic braking
brakin
g
The Driving mode Transmission power output
main oil Nominal pressure 25MPa
pump the forth 6BG1QC-02 36R/4 36R/4R double
tooth Wheel of Japan R pump
pump double
pump
6102BG of 32R/3. 32R
Chao chai 5
double
pump
S4D95LE-2 32R/3. /
of Xiao song 5
double
pump
R4105G32 of 32R（5-6t） /
Weifang
the back 6BG1-02 of 36L 36L
tooth Wheel Japan
pump 6102BG of 32L 32L
Chao chai
S4D95LE-2 32L /
of Xiao song
R4105G32 of 32L（5-6t ） /
Weifang
Multitan Type Double slide valve stem (with safety valve, shunt valve
dem and tilting self-locking valve)
valve set pressure 20MPa
figure Two pieces CDB-F20-02a
number of valve
Three pieces CDB-F20-03b
of valve
Four pieces CDB-F20-04c
of valve
7.1 Overview
Hydraulic system mainly consists of the oil pump with front pump and rear
pump, multitandem valve ( installing with shunt valve together ), high pressure
tubing, low pressure tubing, fittings and so on. The oil pump is a gear pump,
mounted on the side of gearbox. When the engine is running, it drives the oil pump
to suck out oil from the oil tank and deliver oil to the multitandem valve. The safety
valve inside multitandem valve is used to keep the oil way and oil pressure within a
specified range through the manipulation of the multitandem valve’s valve rod,
which can change the flow direction of hydraulic oil, so as to control the oil cylinder
of working device and realize the loading and unloading operation. The oil flowing to
the steering gear through the shunt valve can be used to control the diversion of oil
cylinder.
7.2 The Oil Pump

The oil pump is composed of a front pump and a rear pump, and they are both
the gear pump constituted by a driving gear, a driven gear and the pump body. In
other words, the oil pump includes two gears and other components. The driving
gear meshes with the driven gear. For dynamic braking forklifts, the front pump is a
double pump, and the small tandem pumps are used to supply oil for dynamic
braking.
7.3 The Multitandem Valve

The appearance of multitandem valve is shown in Figure 7.1.
The multitandem valve is in split form and consists of three parts—entrance

(with shunt valve installed in the entrance section ), exit and guiding valve, which
are installed together by three screw bolts. The shunt valve (in the entrance
section ) is installed with multitandem valve, which makes the structure compact
and pipeline simple.
In the entrance section, there is a main safety valve with the form of threaded
cartridge valve to adjust the oil pressure in oil ways and a diversion safety valve
used to adjust the oil pressure in power-steering oil ways.
The guiding valve is used to control the lifting and tilting cylinder. It controls the
opening size of lifting and tilting valve core through the movement of operating
lever to manipulate the change of oil flow volume, so as to control the movement
speed of oil cylinder. Installing the tilt self-locking valve on tilt valve spool can avoid
the situation that the forks of forklift truck lean forwards at its downtime because of
misperation, which can ensure the operation safety. The return oil from the oil
cylinder goes through the exit section and return to the oil tank. Each valve is sealed
with O shaped seal ring, and meanwhile, the oil ways in high pressure side are
installed with non-return valve.
7.4 The Operation of Multitandem Valve

(1). The Median Position (See Figure 7.2 )
The oil discharged from the main pump returns to the oil tank through the
middle channel. As this time, the interface A and B of oil cylinder are in the closed
state.
(2). Push-in Guiding Valve ( See Figure 7.3 )
At this time, the middle channel is in the closed state ( impassible ). The oil from
the oil inlet pushes away ( loading ) non-return valve and flows into the interface B
of oil cylinder, while the return oil discharged from interface A of oil cylinder returns
to the oil tank. With the action of a returning spring, the guiding valve can go back
to the median position.
(3).Pull-out Guiding Valve ( See Figure 7.4 )
At this time, the median shift channel is also in the closed state. The oil from the
oil inlet pushes away ( loading ) non-return valve and flows into the interface A of
oil cylinder, while the return oil discharged from interface B of oil cylinder returns to
the oil tank. With the action of a returning spring, the guiding valve can go back to
the median position.
7.5 The Operation of Main Safety Valve

(1). The main safety valve is installed between the high pressure interface HP
and the low pressure channel LP. The oil going through the valve core C performs
its function on the two surfaces with different diameters –surface A and surface B.
Therefore, the valve core K of non-return valve and the valve core D of main safety
valve are pressed in the valve seat. ( See Figure 7.5 )
(2). When the oil pressure in the high pressure interface of oil cylinder
exceeds the setting pressure of spring force, the pilot valve core “E” opens,
and the oil going through the periphery of valve core flows into the holes
and then into the low pressure channel. ( See Figure 7.6 )
(3). When the pilot valve core E is opened, the pressure behind the valve
core C falls. Thus, the valve core C moves rightwards and locates in the pilot
valve core E. As a result, the oil ways behind the safety valve core D are cut
off, which also leads to the reduction of their inner pressure. ( See Figure 7.7
)
(4). Compared with the interface “HP” of oil cylinder, the unbalance of
inner pressure leads to the open of safety valve core D. In this way, the oil in
high pressure side directly flows into the low pressure channel “LP”. ( See
Figure 7.8 )
7.6 The Operation of Tilt Self-locking Valve

The tilt self-locking valve can not only prevent the door frame from
vibration (because of the negative pressure probably produced in the tilt
cylinder) but also avoid the dangerous situation that when the engine shuts
down, the accidental misoperation ( like touching the tilt lever ) makes the
door frame tilt. As for the old forklifts, even if the engine has been shut
down, its door frame can also leans forwards due to the accidental collision
of the tilt operating lever. But if the new type tilt self-locking valve is put into
use, under the same circumstance, the door frame will not lean forwards,
and even if you push the tilt operating lever hard, it will not lean forwards.
The structure of tilt self-locking valve is shown in Figure 7.9. In the Figure,
the interface A is positioned in front of the tilt cylinder, while the interface B
behind it. When the tilt operating lever is pulled to move ( the guiding valve
pulling out ), the oil from oil pump flows into the interface A, while the oil in
interface B returns back to oil tank. Consequently, the door frame leans
backwards. When the tilt operating lever is pushed to move ( the guiding
valve feeding in ), the oil from the oil cylinder flows into the interface B,
which, with the action of high pressure oil, makes the self-locking valve in
the tilt guiding valve begin to operate and connect the interface A to low
pressure. Consequently, the door frame leans forwards. However, under the
condition of closing the engine, if there is no high pressure oil to operate the
self-locking valve, the interface A will not connect to low pressure, so the
door frame will not lean forwards and the negative pressure will not be
produced in the tilt cylinder.

Tilt
Spring /Valve Core /Guiding Valve

T: Working as Oil Tank P: Connecting to Oil Pump A、B：Connecting
to Tilt Cylinder
7.7 The Operating Device of Multitandem Valve

Each guiding valve of multitandem valve is manipulated by a control
handle, and the steering direction of general operating levers can be found
in the identification on the handle with details. The meaning represented by
figure is shown in Figure 7.10.

Each operating lever is installed on the same shaft, and the shaft is
mounted on the bracket of the frt instrument stand. Each operating lever
transmit to each guiding valve of multitandem valve through the connecting
rods. The forklifts with standard configuration only have the lifting-drop and
tilt two operating valve rods, while the forklifts with accessories can be
installed no more than five operating valve rods according to the number of
movement. ( See Figure 7.11 )
7.8 Oil Tank

The hydraulic oil tank is on the right side of car frame, and the oil suction
filter with front and rear pump is installed on the oil tank cap. The fuel cap
with oil scale and the braking return oil pipe that is used while dynamic
force braking happens are shown in Figure 7.12.
7.9 The
Oil Way
of
Hydraulic
System
(the Main Oil Way )
The schematic diagram of the hydraulic system is shown in Figure 7.13.
The oil way diagram of 5-10t forklifts’ hydraulic system is shown in Figure
7.14.
The main oil way of hydraulic system adopts the double pumps and
confluence oil supply to achieve the functions like loading and unloading
operation, diversion and braking. The fittings of oil pipe are sealed with O-
shaped seal ring which has great sealing to ensure the oil seal.
The hydraulic oil discharged from the rear pump can be directly delivered
to the multitandem valve, while the hydraulic oil discharged from the front
pump ( the main pump ) is divided into two parts by multitandem valve to
fulfill the diversion and goods loading-unloading work.
The hydraulic oil, used to conduct the good loading and unloading work,
flows into the multitandem valve and combine with the hydraulic oil,
discharged from the rear pump, to perform the function of goods loading –
unloading and tilt work together. When the multitandem valve is in the
median state, these hydraulic oils go through the multitandem valve and
return back to the oil tank.
When the lifting lever is pulled to move, the oil from multitandem valve
goes through the governor valve and reaches the bottom of lifting cylinder
piston to push the piston rod. When the lifting lever is pushed to move, the
oil way between the bottom of lifting cylinder piston and oil tank is
connected, and the piston begins to descend due to the self-weight of
piston rod, pallet fork carrier and pallet fork, etc. Under this circumstance,
the oil-return speed from multitandem valve to oil tank is adjusted by the
governor valve.
When the tilt lever is manipulated, the hydraulic oil from the front pump
reaches one side of tilt cylinder piston and pushes the piston to operate,
while the oil in the other side is pushed out, going through the multitandem
valve and returning back to the oil tank.
The Tilt Oil Cylinder
7.10 Maintenance
7.10.1 The Disassembly of Multitandem Valve
Remove the multitandem valve from forklifts and clean its outer part.
(1). Remove the connecting bolts to separate the multitandem valve, but
do not lose the spring of non-return valve and adjoining plane.
(2). Remove the bolts in one side of the guiding valve head and the
hexagon bolts in the sides of guiding valve cap, and remove the guiding
valve with the seal cup, 0-shaped seal ring and seal plate from the valve
body.
(3). Put the guiding valve on a bench clamp, remove the connecting bolts
from its cap and then remove the spring and spring seat. As for the tilt
guiding valve with tilt self-locking valve, the spring and valve core of tilt self-
locking valve need removing.
7.10.2 The Reassembly of Multitandem Valve
Clean all removed components with mineral oil, check whether there are
any burrs or scores on them and replace those that require replacement.
After assembling the valve body and guiding valve, the guiding valve and
valve core, they need to be packed well. If they need replacing, it’s
necessary to replace the whole part.
(1). Use the bench clamp to vise the guiding valve, enclose the valve core
and spring into it and pay attention to the enclosing direction of valve core.
(2). Enclose O-shaped seal ring, seal cup, seal plate, spring and spring
seat into the bottom of guiding valve in an orderly manner. After the
installment of them and cap, use the torque with 25-32 Nm to tighten the
connecting bolts of the guiding valve cap.
(3). Put the assembled guiding valve assembly (a valve ) into the valve
body, install the cap and connect it with hexagon bolts ( the tightening
torque of bolts is 9-11Nm ).
(4). Fix the O-shaped seal ring and seal cup to the head of guiding valve,
tighten the seal plate with bolts and the tightening torque is 4.6-5.8 Nm.
(5). After the assembly, install the non-return valve, spring and O-shaped
bolts into each valve, tighten it with 3 connecting bolts according to the
specified torque ( one bolt is 103 Nm, the other 66 Nm ).
7.10.3 Matters Needing Attention
Before forklifts leave the factory, the pressure of each safety valve in
multitandem valve has been adjusted well, so the users should not adjust it
when using them, in order to avoid regulating the pressure excessively, for
this will lead to the damage of hydraulic system and hydraulic components.
If the pressure must be adjusted, it should be adjusted by professionals in
accordance with the specified pressure in the instrument book.
8. The Lifting Oil Cylinder and the Tilt Oil Cylinder

The main parameter is shown in Figure 8.1.
8.1 Lifting Oil Cylinder

The two single functional lifting cylinders are respectively fixed on the
rear of both sides of outer door frame, and the cylinder bottom are fixed on
the oil cylinder seat of the outer door frame. As for the top of cylinder, or to
say, the rear of piston rod and the beam of inner door frame are connected
by bolts. The pistons of two lifting cylinders should be consistent, so as to
make the two cylinders in synchronism, and if they are not , adjusting the
bolts can synchronize them. ( See Figure 8.1 )
The lifting oil cylinder consists of the cylinder body, a piston, a piston rod
and a cylinder cap, and there is an oil inlet in the bottom of cylinder body,
which is the entrance for high pressure oil. On the top of cylinder body,
there is an oil outlet under the Yx-shaped piston seal ring, which is the exit
for low pressure oil. (The oil outlet and the oil-return pipe are connected ).
The piston and piston rod are fixed together by castle nut, cotter pin and
O-shaped seal ring, and there are Yx seal ring, retainer ring and back-up ring
fixed on the outer circumference of the piston. With the action of high
pressure oil, the piston moves upwards along with the surface of cylinder
body. The dust ring and steel-backed bearing are fixed on the cylinder cap
that relies on the threaded cylinder body and steel-backed bearing to
support the piston rod, and the dust ring is used to prevent the duct from
entering the cylinder. On the top of cylinder, the rear of piston rod and the
beam of inner door frame are fixed by bolts.
When the lifting operating lever is pulled to move backwards, the high
pressure oil flows into the cylinder through the oil inlet of lifting cylinder to
uplift the piston rod and the beam of inner door frame, which lift the pallet
fork by chains. When the upper part of inner door frame does not exceed
the outer door frame, the height from ground to the upper surface of pallet
fork is called by the free lifting height. Within this range, the height of door
frame does not change.
When the lifting operating lever is pushed to move forwards, the self-
weight of piston rod, pallet fork carrier, load backrest and pallet fork makes
the piston fall and discharges the oil under the piston out of the cylinder
body. The oil discharged from the cylinder body has governor valve ( throttle
valve ) control its speed and returns back to the oil tank through
multitandem valve.
The structure of 5-8t forklifts lifting cylinder is shown in Figure 8.1.
The structure of 10t forklifts lifting cylinder is shown in Figure 8.2.
8.2 Stop Valve

There is a stop valve installed on the bottom of lifting cylinder. ( See
Figure 8.1 Number 19 or Figure 8.2 Number 18). When the high-pressure
rubber hose bursts suddenly, the stop valve can prevent the sharp drop of
goods. The structure of the stop valve is shown in Figure 8.3. The return oil
from the lifting cylinder makes the two chambers produce pressure
difference by the stop valve and oil holes around the guiding valve. When
the pressure difference is smaller than the spring force, the guiding valve
does not operate. If the high-pressure rubber hose bursts suddenly, there is
only a little oil flowing through the small holes of guiding valve’s end face.
Thus, the drop of pallet forks lows down.
1. Spacer
2. Dust
Ring
3. Yx-
shaped
Seal
Ring
4.
Cylinder Cap
5. Steel-backed Bearing 6. “O”-shaped Seal Ring 7. Cylinder Body 8.
Piston Rod 9. “O”-shaped Seal Ring 10. Back-up Ring 11. Yx-shaped
Seal Ring 12. Castle Nut 13. Cotter Pin 14. Lifting Chain 15. Chain
Wheel 16. Ball Bearing
17. Snap Ring 18. Spring 19. Stop Valve 20. Beam of Inner Door Frame
1.Spacer 2. Dust
Ring 3. Yx-shaped
Seal Ring 4. Cylinder
Cap 5. Steel-backed
Bearing
6. “O”-shaped Seal
Ring 7. Cylinder Body
8. Piston Rod 9. Ring
10. Back-up Ring
11. Yx-shaped Seal
Ring 12. Piston 13.
Lifting Chain 14.
Chain Wheel 15. Ball
Bearing
16. Snap Ring 17.
Spring 18. Stop
Valve 19. Beam of
Inner Door Frame
8.3
Governor Valve
The governor valve ( the throttle valve) is installed on the oil way
between the multitandem valve and the high-pressure oil port of two lifting
cylinder, whose position is close to the left lifting cylinder. See Figure 8.4.
The governor valve is used to limit the dropping speed of pallet fork when
the pallet fork is overloaded. The governor valve of 5-7t forklifts is basically
similar with that of 8-10t forklifts. In Figure 8.4 No.2 spring, the 5-7t forklifts
use the conical spiral spring, while the 8-10t forklifts use the Bellville spring.
1.Fitting 2. Spring 3. Retainer Ring 4. Choke Block 5. Valve Pocket 6.

Valve Core 7. Nylon Ball 8. Spring 9. Spring 10. Valve Body.
In addition to control the dropping speed of goods, the governor valve

still plays the role as a safety device. Due to some reasons, the rubber hose
between multitandem valve and lifting cylinder gets damaged. Under this
condition, the governor valve can ensure the safety. ( By avoiding the danger
of the goods’ fast fall ).
The operation of governor valve is as follows.
See Figure 8.4. When the pallet fork raises, the high pressure oil from the
multitandem valve flows into the “A” chamber and pushes the valve pocket
to move leftwards. Consequently, it unfolds the opening “G” , which makes
the high pressure oil flow along the two routes ( A-B-G-D-E and A-B-C-D-E).
Following the routes, the high pressure oil flows into the lifting cylinder.
Under this situation, the oil flow is not be adjusted and limited. When the
pallet fork begins to go down, the return oil discharged from the lifting
cylinder enters the “E” chamber and pushes the valve pocket to move
rightwards until the valve pocket contacts the fitting, which closes the
opening “G”. Therefore, the return oil, flowing the routes—E.D.H.C.B and A,
must goes through the choke block to return back to the oil tank. If the
volume of return oil discharged from the lifting cylinder is increasing
dramatically, the pressure in “F” chamber rises, which pushes the valve core
( See Figure 8.5 No.5 ) to overcome the spring force to move to rightwards
and narrows the opening “H”, so the oil flow from the “D” chamber to “C”
chamber reduces, which means the falling speed of pallet fork is restricted
( the speed slowing down ).
8.4 Tilt Oil Cylinder

Two double functional tilt oil cylinders are installed on the both sides of
the door frame, and the front piston rod of tilt cylinder connects with the
door frame. The cylinder bottom pin in the rear of tilt cylinder connects with
the car frame, and the assembly of tile cylinder is mainly composed of the
cylinder body, a guide sleeve, a piston and a piston rod.
The piston is welded on the piston rod. On the outer circumferential
surface of the piston, two Yx-shaped seal rings and a back-up ring are
installed. Under the action of hydraulic oil pressure, the piston moves in the
cylinder body.
In the inner hole of the guide sleeve ( the cylinder cap), there are a press-
fit steel-back bearing, a Yx-shaped seal ring and a dust ring. The seal ring and
the dust ring can be used to prevent the oil leak and dust ( between the
piston and the guide sleeve). An O-shaped ring is mounted on the outer
circumferential surface of the guide sleeve, and the guide sleeve is screwed
into the cylinder body.
When the tilt operating lever moves forwards, the high pressure oil
enters into the cylinder from its bottom and makes the piston moves
forwards. Consequently, the door frame leans forwards ( up to 6 degrees).
When the tilt operating lever is pulled back, the high pressure oil enters the
cylinder from the front of guide sleeve side and makes the piston moves
backwards. Thus, the door frame leans backwards ( up to 12 degrees).
1. Earring 2. Dust Ring 3. Shield Ring 4. Yx-shaped Seal Ring 5. O-shaped

Ring 6. Guide Sleeve 7. Bearing 8. O-shaped Ring 9. Piston Rod 10.

Cylinder Body 11. Yx-shaped Seal Ring 12. Back-up Ring 13. Piston 14.
Yx-shaped Seal Ring
9. Lifting System
The main parameter is shown in Figure 9.1.
9.1 Overview
The lifting system adopts the rolling type, whose basic type is the
secondary telescopic door frame type. Its inner door frame is a J-shaped
cross section, and except for the 10t forklifts whose outer door frame is J-
shaped cross section, other 5-8t forklifts use the door frame with C-shaped
cross section. The door frame of 5-10t forklifts all has the free ascending
function.
9.2 Inner and Outer Door Frame
The assembly of door frame is the free-lift secondary telescopic type,

which consists of the inner door frame and the outer door frame that are
supported by the door frame seat. The door frame seat is welded on the
bottom of outer door frame, extending to the axle case and connecting with
it. That is to say the self-weight of door frame is supported by the axle case.
There is still a tilt cylinder seat on the outer door frame. The front of tilt
cylinder ( the piston rod end) is connected with this seat by axis pin. Under
the action of tilt cylinder, the door frame can leans 6 degrees forwards and
12 degrees backwards.
The inner door frame consists of the left and right door frame channel
steels that are connected by the top and bottom beams. Similarly, the outer
door frame consists of the left and right door frame channel steels that are
connected by the top, middle and bottom beams. There are roller shafts on
the top of the left and right door frame channel steels, which are welded on
the inner surface of outer door frame channel steel to install the main roller
and its snap ring. In addition, the side rollers are mounted on the outer door
frame to support the inner door frame in its side direction. In the bottom of
the left and right door frame channel steels, the roller shaft is welded
outside them, while the main roller and its snap ring are installed on the
roller shaft. Under the main roller, the side roller is also equipped to support
the horizontal load. With the help of these rollers, the inner door frame can
work smoothly.
9.3 Pallet Fork Carrier
The roller shaft is welded on the pallet fork carrier, and the main roller
rolling along the inner surface of the inner door frame and its snap ring are
mounted on the roller shaft. As for the side roller rolling along the inner side
of the inner door frame, it is installed on the inner door frame by bolts
through the side roller shaft and is adjusted by spacer shim. In order to
prevent the shaking of fork beam ( the pallet fork plate, or the top beam ),
two limiting rollers are installed, which roll along the outer side of the inner
door frame. The main roller bears the vertical load. When the pallet fork is
hoisted to its maximum lifting height, the main roller on it is exposed (a part)
from the top of door frame, while the horizontal load is bore by the limiting
roller above and the side roller below. The design of door frame assembly
and pallet fork carrier takes enough rigidity, strength as well as steady
operation into account.
In addition, the top and bottom beams of the pallet fork carrier are made
of the high-strength steel. The pallet fork carrier forms the whole structure
to guarantee its durability, and it accords with the standard of ISO ( the
international standard).
Two pallet forks, made of alloy steel after heat treatment, are installed
on the pallet fork carrier.
9.4 The Adjustment of Lifting System

9.4.1 The Adjustment of Spacer in the Cylinder End of Lifting Oil Cylinder
When the lifting oil cylinder, the inner or outer door frame need to be
disassembled and replaced, the stroke of lifting oil cylinder requires the
readjustment.
The readjusting methods are as follows.
(1). Leave the head of piston rod with no adjusting spacer, and then
install the piston rod on the top beam of inner door frame.
(2). Rise the door frame slowly to the maximum stroke of oil cylinder, and
then check whether the two cylinders are synchronous or not.
(3). Add the adjusting spacer between the piston rod head of the oil
cylinder that first stops moving and the top beam of inner door frame. The
thickness of adjusting spacer is from 0.2mm—0.5mm.
(4). Adjust the stretch degree of chains.
See Figure 9.1.
9.4.2 The Height Adjustment of Pallet Fork Carrier
(1). Park the car on a lever ground and make the door frame vertical.
(2). Make the bottom of pallet fork touch the ground, adjust the joint
adjusting nuts on the upper part of the chains to make the main roller under
the pallet fork carrier exposed about the 1 /4-1 / 3 of the main roller’s radius
A. ( See Figure 9.2)
(3). Raise the pallet fork to the highest point, and make sure the space B
between the limit bloke of pallet fork carrier and that of inner door frame is
within 5—10mm. ( See Figure 9.3)
(4). Make the pallet fork carrier land and lean backwards in right
position, adjust the joint adjusting nuts on the upper part of the chains to
make the stretch degree of the two chains remain same. ( See Figure 9.4)
9.5 The
Installation Position of Rollers

The rollers of lifting system have three kinds, namely the main roller, the
side roller set and the side roller, which are installed on the inner and outer
door frames and the pallet fork carrier. The installation of 5-10t rollers is
basically same, which is shown respectively in Figure 9.5, Figure 9.6 and
Figure 9.7. The main roller bears the main load in the anteroposterior
direction of forklifts, which generally can not be adjusted. The side roller
bears the side load, which generally can be adjusted the side space by
spacer unit to make the inner door frame and pallet fork carrier move up
and down freely.

Operation and Maintenace Manual (5-10T)

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Operation and Maintenace Manual (5-10T)

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User Manual of 5-10 Ton Diesel Balance Weight Forklift

4.2 Main Reducer and Differential Mechanism...........................43

8. The Lifting Oil Cylinder and the Tilt Oil Cylinder.................................99

I. The Main Technical Parameters of Forklift

RASA: right angle stacking channel width a: gap b: Payload Length

II. Introduction to the Main Parts of Forklift

Forklift main components are as follows:

III. Structure, Principle, Adjustment and Maintenance of Forklift

1. The Power System

Power system includes an engine installation, fuel system, cooling

Compression ratio 17.5 17 17

the fuel gauge pointer instrument panel.You can have an intuitive

1.5.4 Cooling system

(2) Change the

1.5.5 Fastening of bolts in the cylinder head of the engine

The upper limit of the

1.5.7 Affordance of the ignition time of the injection

1.5.10 Exhaust of fuel pump

(3) Then tighten the vent plug.

Electrical system is negative-ground single-line circuit, which is

2) After the engine starts, for electronic liquid, return it into

black red green yellow blue white brown Light purple

black red green yellow blue white brown Light purple

(2) The load-permissible current nominal value in the low-voltage wire

The gearing mainly includes torque converter and transmission. Its

Flow 40 (when reaching

The hydraulic transmission of the forklift is composed of torque

3.2 torque converter

Torque Converter is the integrated hydraulic converter who is single-

1. Control valve 2. supply pump 3. Radical bearing 4. Shaft 5. Radical

Diagram 3.2 Torque Converter

When turbine rotation speed increases and approaching to input

Torque converter is installed with one-way clutch, turbine, pump

3.3 Oil Feed Pump

Refer to Diagram 3.3 for the structure of oil feed pump.

Diagram 3.3 Oil Feed Pump

3.4 Hydraulic Clutch

Diagram 3.4 Forward Gear Clutch

Diagram 3.5 Reverse Gear Clutch

3.5 Operating Valve and Inching Valve

Diagram 3.6 Operating Valve

3.6 Torque Converter Oil Way

Diagram 3.7 Torque Converter Oil System

Oil pressure of gear box clutch is adjusted to 1.2 to 1.5MPa by pressure

3.7 Notes When Forklift Failure

3.8 Trouble Shooting

1. Oil temperature increase to an abnormal level: refer to table 3.2

Table 3.2 Oil Temperature Increase to An Abnormal Level

Table 3.3 Power Shortage

Part Cause of Failure Check Method Trouble Shooting

Extract bit oil and

Check joint and oil Tighten the joint or

Table 3.4 Gear Box Noise Increase

Table 3.5 Low Transmission Efficiency

Table 3.6 Oil Leakage

is any wearing on oil sealing lip

Refer to table 4.1 for main parameters of the driving axle.

Table 4.1 Driving Axle Parameter

Driving axle is consist with main reducer, differential mechanism, hub

4.2 Main Reducer and Differential Mechanism

4.3 Hub Reduction Gear

Diagram 4.1 Driving Axle (5~7 tons Forklift)

1. Driving Axle Shell 7. Hub 13. Shaft

Diagram 4.2 Driving Axle (8~10 tons Forklift)