S63-5-2013 G Series 1-3.5t IC Forklift Operation and Maintenance Manual

FOREWORD
This manual accounts for “HELI” Forklift Truck of G series, includes its performance,
structure, safe operation and regular preventive maintenance, so that operators, mechanics and
supervisors of Forklift Truck correctly operate and prevent maintenance.
Read and understand this manual before operating your lift truck! This manual is your
guide to safe operation and regular preventive maintenance. So as to let the Forklift Truck keep
good working conditions.
If any operation or maintenance doesn’t accord with requires in this manual, our related
promises is inefficacy.
Due to continuous improvements in design, it is possible that the latest description
contained herein may differ slightly from the truck delivered to you. Moreover, the
specification of the forklift truck may be changed insignificantly depending on its destination.
CONTENTS
Ι. Safety Rules for Operation and Daily Maintenance of Forklift Truck 1

1.Delivery of Forklift Truck 1
2.Storage of Forklift Truck 1
3.Precautions Before Operation 1
4. Operation of Forklift Truck 1
5. Fuel and Lubricants Used for Forklift Truck 4
Ⅱ. Main Specifications of Forklift Truck 5
Ⅲ. Primary Assembly of Forklift Truck 21
Ⅵ. The Construction, Principle, Adjustment and Maintenance of Forklift Truck 22
1. Power System 22
1.1General Description of Engine 22
1.2Inspection and Adjustment of Engine 25
1.3Fuel System 29
1.4Accelerator Pedal 32
2. Electric System 32
2.1 General Description 32
2.2 Brief Explanation for Operation 34
2.3 Battery 37
2.4 Diagrams of Electric System 37
3. Hydrodynamic Drive Unit 41
3.2 Torque Converter 43
3.3 Hydraulic Clutch 44
3.4 Control Valve, Relief Valve and Inching Valve 45
3.5 Transmission Case 47
3.6 Charging Pump 47
3.7 Hydraulic Circuit (Hydrodynamic Transmission Type Drive Unit) 47
3.8 Towing Disabled Truck 50
3.9 Position of Connection Ports for Hydraulic Oil 50
3.10 Reduction and Differential 50
4. Drive Axle 51
4.2 Procedure for Hubs Remounted 55
5. Steering System 56
5.2 Cycloid Gear Type Powered Steering Unit 57
5.3 Inspection on Reassembly of Steering System 58
5.4 Steering System Troubleshooting 59
6. Steering Axle 60
6.2 Steering Knuckles and King Pin 61
6.3 Wheel Hub 61
6.4 Steering Cylinder 62
6.5 Rear Wheel Bearing Pre-load Adjustment 62
7. Braking System 64
7.2 Maintenance of the Brake 74
8. Hydraulic System 82
8.2 Maintenance of the Main Parts 86
8.3 Maintenance of Main Pump 98
8.4 Maintenance, Trouble Analysis and Trouble Shooting of the Hydraulic
System 106
9. Load System 110
9.2 Inner and Outer Masts 112
9.3 Carriage 112
9.4 Roller Adjustment 112
9.5 Maintenance 117
Ι.Safety Rules for Operation and Daily Maintenance of Forklift Truck
It is important that driver and manager for forklift trucks remember the principle of the
“first safety” and ensure the safety operation as the description in 《 OPERATION &
MAINTENANCE MANUAL》 and 《OPERATOR'S MANUAL》.
1.Delivery of Forklift Truck
It must be pay attention to the following items when you deliver forklift trucks with
container or trucks.
(1)Apply the parking brake.
(2)Fix the mast and the balance weight with steel wire. Wedge up all wheels.
(3)Sling points should be always at the positions specified in sling index plate when
hoisting up the forklift truck.
2.Storage of Forklift Truck
(1)Drain off fuel completely. Don’t drain off the cooling water containing antifreeze and
rustproof agent.
(2)Apply antirust to the surface of the parts not painted. Apply lubrication oil to the lift
chain.
(3)Lowing the mast to the lowest position.
(4)Apply the parking brake.
(5)Wedged up the wheels.
3.Precautions Before Operation
(1)Don’t check fuel leakage and lever or instruments at the place there is open flame.
Never fill the fuel tank with the engine running.
(2)Check the tire inflation pressure.
(3)The forward-reverse lever should be in neutral.
(4)Never smoke while the fuel system is under working or the
battery is inspected.
(5)Check all the levers and pedals.
(6)Complete the provisions before starting.
(7)Release the parking lever.
(8)Make trying operation of the mast for lifting, lowing and
Fwd/Bwd tilting and the truck for steering and braking.
4. Operation of Forklift Truck
(1)Only trained and authorized operator shall be permitted to
operate the truck.
-1-
(2)Wear all the safety guards, such as shoes, helmet, clothing and gloves while operating
the truck.
(3)Check all the control and warning devices before starting the truck. If any damages or
defects are found, operate it after repairing.
(4)At the rated loading center, either overload or overload operation is strictly prohibited.
If the goods is placed at non-rated loading center, the capacity is decided according to load
curve graph. The center of goods should be in line with the frame center, not out of the line.
The fork should insert completely under the goods and make the goods placed on it evenly. Do
not raise an object with one fork end.
(5)The starting, turning, driving, braking and stopping operation of the truck should be
done smoothly. When steering on the humid or low friction road, the truck should be
decelerated.
(6)Travel with loads as low as possible and tilted backward.
(7)Be careful when traveling on a slope. When climbing grades with a slope of more than
10%, the truck should forward travel, and when descending so grades, backward travel. Never
turning on a slope. Avoid loading and unloading operation when descending.
(8)Pay attention to pedestrian, obstacle and bumpy road when driving. Pay attention to
the clearance over forklift truck.
(9)Never allow any persons to stand on the forks or the truck to carry persons.
(10)Never permit anyone to stand or walk under upraised forks.
(11)Don’t operate truck and attachment of it at any position out of the drive seat.
(12)On the high lift forklift truck, when the lift high more than 3m, it is noted that the
goods on it should not fall down or the protection measures must
be taken if necessary.
(13)Tilt the mast of the high lift forklift truck as backward as
possible while the truck working. Use minimum forward tilt angle
and Min. reverse tilt when loading and unloading.
(14)Be careful and slowly driving over a dock board or
bridge-plate.
(15)Shut down the engine and don’t stay on the truck when
filling fuel. Don’t ignite the engine while checking battery or fuel
lever.
(16)The unloaded forklift truck with attachments should be
operated as a loaded truck.
-2-
(17)Don’t handle unfixed stacked goods. Be careful to bulky goods to be handled.
(18)If leaving the truck, lower the forks on the ground and let the shift lever to neutral,
shut down the engine or cut down electric supply. If parking on a slope is unavoidable, apply
the parking brake and block the wheels.
(19)Don’t open the radiator cap when the engine is warm.
(20)Don’t adjust the control valve and relief valve at all to prevent the damage of
hydraulic system and its components because of excessive pressure passing them.
(21)Tyres should be inflated according to the pressure valve specified in the mark plate of
“Tyre Pressure”.
(22)According to the measure method specified in JB/T 3300, max. noise at the outboard
of the truck should be not more than 89 dB(A).
(23)Be familiar with and pay attention to the functions of the decals that on the truck.
★During use and maintenance of the forklift, the operator must pay attention to the
narrow space around such mobile parts as at both sides of the tilt cylinder, outer mast
and so on to avoid being hurt due to clipping.
-3-
5. Fuel and Lubricants Used for Forklift Truck
Brand Recommended
General Standard Temperature GREAT WALL MOBIL SHELL ESSO
Product
SF Abolished Shell X100 Esso Extra Motor Oil
API SG SG Abolished Shell Helix
API SJ Assess SJ Mobil super S Esso Superflo
“Viscosity Shell Rimula C
Grade” CD Abolished Essolube XT ID
Engine Oils Diesel Engine Oil
according to
environment Mobil Delvac
API CF-4 CF-4 Essolube XT2
temperature Super 1300
Shell Rimula X
API CH-4 CH-4 Mobil Delvac MX Essolube XT5
Diesel Engine Oil
ISO 6743/4 L-HM Antiwear Hydraulic
Mobil DTE24 Shell Tellus Oil 32 Nuto H32
DIN 51524 Ⅱ Fluid L-HM32
Low Temperature Antiwear
Hydraulic Fluids ISO 6743/4 L-HV ≥-20℃ Shell Tellus Oil 32 Univis N32
Hydraulic Fluid L-HV32
-4-
Low Pour Point Antiwear
ISO 6743/4 L-HS ≥-40℃ Hydraulic Fluid L-HS32
Mobil DTE 13M Shell Tellus T32
Automatic
GM Dexron Ⅲ ATF-Ⅲ Mobil ATF Shell ATF Ⅲ Esso ATF
Transmission Fluid
Mobil Super Heavy Esso Brake Fluid
Break Fluid FMVSS 116-DOT3 JG-3 Shell Donax B
Duty Break Fluid (DOT-4)
3# General Lithium Esso Multipurpose
-20℃～+120℃ Mobil grease Shell Retinax Grease
Grease Grease H
Greases
MoS2 EP Lithium Mobil grease Shell Alvania HDX2
-20℃～+120℃ XHP 222 Special
Grease Grease
≥-25℃ FD-Ⅱ
Coolant Fluid ≥-35℃ FD-2A Mobil Coolant Shell Freeze Guard Esso Coolant
≥-40℃ FD-Ⅲ
Automotive API GL-5 or Heavy Duty Automotive Mobil HD Shell Spirax A Gear Esso Gear oil Gx
-15℃～+49℃
Gear oils MIL-L-2105D Gear Oil 85W/90GL-5 85W/90GL-5 Oil 85W/90GL-5
Ⅱ.Main Specifications of Forklift Truck
Outline Drawing of Forklift Truck
-5-
Main Specifications
Table 1
Model
CPCD10-KU1G CPCD15-KU1G CPCD18-KU1G
Item
Rated Capacity (kg) 1000 1500 1750
Load Center (mm) 500 500 500
Max. Lifting Height (mm) 3000 3000 3000
Free Lift (mm) 151 155 158
Mast Tilt Angle (Fwd/Bwd) (°) 6/12 6/12 6/12
Lifting Speed Unloaded 620 620 620

(mm/s) 590 590 590
Loaded
Traveling Speed Loaded 17 17 17

(km/h) 18 18 18
Unloaded
Max. Drawbar Pull (kN) Loaded 17.8 17.8 17.8
Gradeability Unloaded 25 19 18
(%) 42 32 28
Loaded
Overall Length (without fork) (mm) 2166 2230 2273
Overall Width (mm) 1075 1075 1090
Overall Height Mast 1995 1995 1995

(mm) 2140 2140 2140
Overhead Guard
Wheelbase (mm) 1410 1410 1410
Front 890 890 920

Tread(mm)
Rear 920 920 920
Min. Underclearance (mm) 114 114 114
Front Overhang (mm) 401 405 408
Rear Overhang (mm) 355 415 455
Min. Turning Radius (mm) 1870 1950 1980
Min. Intersecting Aisle (mm) 1845 1925 1955
Weight (unloaded) (kg) 2220 2660 2660
-6-
Main Specifications
Table 2
Model
Item
Free Lift (mm) 151 155 158

(mm/s) 590 590 590
Loaded

(km/h) 18 18 18
Unloaded
(%) 42 40 36
Loaded

(mm) 2140 2140 2140
Overhead Guard
Wheelbase (mm) 1410 1410 1410
Front 890 890 920

Tread(mm)
Rear 920 920 920
-7-
Main Specifications
Table 3
Model
CPCD10-RC2G CPCD15-RC2G CPCD18-RC2G
Item
Free Lift (mm) 131 135 138

(mm/s) 590 590 560
Loaded

(km/h) 17 17 17
Unloaded
Max. Drawbar Pull (kN) Loaded 16.6 17.1 17
(%) 25 19 20
Loaded

(mm) 2140 2140 2140
Overhead Guard
Wheelbase (mm) 1410 1410 1410
Front 900 900 930

Tread(mm)
Rear 930 930 930
-8-
Main Specifications
Table 4
Model
CPCD10-RC3G CPCD15-RC3G CPCD18-RC3G
Item
Free Lift (mm) 131 135 138

(mm/s) 520 520 490
Loaded

(km/h) 17 17 17
Unloaded
(%) 25 19 20
Loaded

(mm) 2140 2140 2140
Overhead Guard
Wheelbase (mm) 1410 1410 1410
Front 900 900 930

Tread(mm)
Rear 930 930 930
-9-
Main Specifications
Table 5
Model
CPCD10-WS3G CPCD15-WS3G CPCD18-WS3G
Item
Free Lift (mm) 131 135 138

(mm/s) 520 520 520
Loaded

(km/h) 19 19 19
Unloaded
Max. Drawbar Pull (kN) Loaded 16 16 16
(%) 23 18 18
Loaded

(mm) 2140 2140 2140
Overhead Guard
Wheelbase (mm) 1410 1410 1410
Front 900 900 930

Tread(mm)
Rear 930 930 930
-10-
Main Specifications
Table 6
CPCD35-W10G
Model
CPCD20-W10G
CPCD25-W10G
CPCD30-W10G
Item
Rated Capacity (kg) 2000 2500 3000 3500
Load Center (mm) 500 500 500 500
Max. Lifting Height (mm) 3000 3000 3000 3000
Free Lift (mm) 150 150 155 160
Mast Tilt Angle (Fwd/Bwd) (°) 6/12 6/12 6/12 6/12
Lifting Speed Unloaded 600 600 550 480

(mm/s) Loaded 550 550 500 450
Traveling Speed Loaded 19 19 19 19

(km/h) Unloaded 17 17 18 19
Max. Drawbar Pull (kN) Loaded 18.5 18.5 16.5 19
Gradeability Unloaded 18 16 17 20
(%) Loaded 25 23 20 21
Overall Length (without fork) (mm) 2510 2580 2700 2770
Overall Width (mm) 1150 1150 1225 1285
Overall Height Mast 2000 2000 2075 2180

(mm) Overhead Guard 2140 2140 2170 2170
Wheelbase (mm) 1600 1600 1700 1700
Front 970 970 1000 1060
Tread(mm)
Rear 970 970 970 970
Min. Underclearance (mm) 110 110 135 135
Front Overhang (mm) 470 470 475 485
Rear Overhang (mm) 440 510 525 585
Min. Turning Radius (mm) 2170 2240 2400 2420
Min. Intersecting Aisle (mm) 2200 2280 2380 2400
Weight (unloaded) (kg) 3480 3800 4400 5000
-11-
Main Specifications
Table 7
Model
CPCD20-HJ1G
CPCD25-HJ1G
CPCD30-HJ1G
CPCD35-HJ1G
Item
Load Center (mm) 500 500 500 500
Free Lift (mm) 150 150 155 160

(mm/s) Loaded 550 550 500 450

(%) Loaded 25 23 20 21
Overall Width (mm) 1150 1150 1225 1285

Wheelbase (mm) 1600 1600 1700 1700
Front 970 970 1000 1060
Tread(mm)
Rear 970 970 970 970
-12-
Main Specifications
Table 8
CPQD20-RC2G
CPQD25-RC2G
CPQD30-RC2G
CPQD35-RC2G
Model
Item
Load Center (mm) 500 500 500 500
Free Lift (mm) 150 150 155 160

(mm/s) Loaded 550 550 500 355

(%) Loaded 26 24 23 14
Overall Width (mm) 1150 1150 1225 1285

Wheelbase (mm) 1600 1600 1700 1700
Front 970 970 1000 1060
Tread(mm)
Rear 970 970 970 970
-13-
Main Specifications
Table 9
CPQD20-RC3G
CPQD25-RC3G
CPQD30-RC3G
CPQD35-RC3G
Model
Item
Load Center (mm) 500 500 500 500
Free Lift (mm) 150 150 155 160

(mm/s) Loaded 550 550 500 450

Max. Drawbar Pull (kN) Loaded 21 21 19 16.5
(%) Loaded 34 29 21 20
Overall Width (mm) 1150 1150 1225 1285

Wheelbase (mm) 1600 1600 1700 1700
Front 970 970 1000 1060
Tread(mm)
Rear 970 970 970 970
-14-
Main Specifications
Table 10
Model
CPCD20-D1G
CPCD25-D1G
CPCD30-D1G
CPCD35-D1G
Item
Load Center (mm) 500 500 500 500
Free Lift (mm) 150 150 155 160

(mm/s) Loaded 550 550 470 430
Traveling Speed Loaded 16.5 16.5 20 17.5

(km/h) Unloaded 15 15 19 16.5
Max. Drawbar Pull (kN) Loaded 24 24 20 21
(%) Loaded 40 37 19 20
Overall Width (mm) 1150 1150 1225 1285

Wheelbase (mm) 1600 1600 1700 1700
Front 970 970 1000 1060
Tread(mm)
Rear 970 970 970 970
-15-
Main Specifications
Table 11
CPCD20-WS3G
CPCD25-WS3G
C PCD30-WS3G
Model
CPCD20-WSG
CPCD25-WSG
CPCD30-WSG
CPCD35-WSG
Item
Load Center (mm) 500 500 500 500
Free Lift (mm) 150 150 155 160

(mm/s) Loaded 550 550 500 380

Max. Drawbar Pull (kN) Loaded 16.6 16.6 15 16
(%) Loaded 27 23 24 16
Overall Width (mm) 1150 1150 1225 1285

Wheelbase (mm) 1600 1600 1700 1700
Front 970 970 1000 1060
Tread(mm)
Rear 970 970 970 970
-16-
Main Specifications
Table 12
Model
Item
Free Lift (mm) 150 150 155

(mm/s)
Loaded 550 550 500

(km/h) 17 17 18
Unloaded
(%) 28 25 23
Loaded

(mm) 2140 2140 2170
Overhead Guard
Wheelbase (mm) 1600 1600 1700
Front 970 970 1000

Tread(mm)
Rear 970 970 970
-17-
Main Specifications
Table 13
CPCD20-KU10G
CPCD25-KU10G
CPCD30-KU10G
CPCD35-KU10G
Model
Item
Load Center (mm) 500 500 500 500
Free Lift (mm) 150 150 155 160

(mm/s) Loaded 540 540 470 430
Traveling Speed Loaded 16.5 16.5 20 17.5

(km/h) Unloaded 15 15 19 16.5
Max. Drawbar Pull (kN) Loaded 24 24 20 21
(%) Loaded 40 37 19 20
Overall Width (mm) 1150 1150 1225 1285

Wheelbase (mm) 1600 1600 1700 1700
Front 970 970 1000 1060
Tread(mm)
Rear 970 970 970 970
-18-
Main Specifications
Table 14
Model
Item
Free Lift (mm) 150 150 155

(mm/s)
Loaded 528 528 430

(km/h) 17 17 16
Unloaded
(%) 25 23 18
Loaded

(mm) 2140 2140 2170
Overhead Guard
Wheelbase (mm) 1600 1600 1700
Front 970 970 1000

Tread(mm)
Rear 970 970 970
-19-
Size & Weight of Removal Parts
Table 15
Size
No. Description Length×Width×Height(mm) Weight(kg)
480×724×1935 674
1 Mast (without fork arms) (without fork arms)
2 Balance Weight 713×1150×1015 1820
3 Overhead Guard 1456×1085×1440 87.6
-20-
Ⅲ. Primary Assembly of Forklift Truck
No. Name Contents

Includes engine mounting, fuel system, exhaust system and
1 Power System cooling system (includes torque-converter oil cooling
system)
Includes torque-converter, transmission, transmission shaft
2 Transmission System
and control linkage
Includes axle housing, drive shaft, differential, wheel
3 Drive Axle
reducer, brake and front wheels
4 Steering System Includes steering handwheel and powered steering unit
5 Steering Axle Includes steering axle, steering cylinder and rear wheels
Includes masts, forks, lift bracket, backrest, tilt cylinder, lift
6 Hoist System
cylinder, lift chain, sheaves and rollers
Includes frame, cabinet, hood, tank cover, counterweight,
7 Frame System
floor board and seat
Includes brake & inching control, brake lever and accelerator
8 Control System
pedal
9 Hydraulic System Includes pump, valve, H.P. & L.P. hose and connector
10 Electric System Includes lamps, battery, instrument and harness
11 Overhead Guard Overhead guard (cab is option)
-21-
Ⅳ.The Construction, Principle, Adjustment and Maintenance of Forklift Truck
1.Power System
1.1General Description of Engine
The engine is connected with the drive unit and the bracket of the engine is connected
with the frame by rubber cushion to avoid vibration.
Main Specifications of KUBOTA Engine Table 1
Model
CPCD10-18-Ku1G
CPCD30-Ku8G CPCD20-35-Ku10G
CPCD20-25-Ku8G
V2403 (IDI) V2403 (IDI) V3600

Specifications
Type In-line 4-cylinder, 4-cycle, water-cooled
Cyl. Number-Bor×Stroke (mm) 4-87×102.4 4 - 98×120
Total Displacement (L) 2.434 3.62
Compression Ratio 23.2:1 22.6:1
Rated Output /Speed (kW /rpm) 34.1 /2400 36.6/2600 46.9/2400
Rated Torque/Speed (N.m/rpm) 155.9/1600 158.6/1600 209.8/1600
Lowest Speed without Load (rpm) 800
Min. Fuel Consumption (g/kw.h) 225 240
Length×Width×Height (mm) 726×507×683 759×540×746
Weight (kg) 184 270
Rotation Direction Clockwise as viewed from fan
Cooling System Water type
Lubrication System Forced lubrication
Battery Voltage V / Capacity Ah 12/80
Lubricating Oil (L) 9.5 13.2
-22-
Main Specifications of ISUZU Engine
Table 2
Model CPCD20～35-
CPCD20～35- WSG CPCD10～35-
W10G CPCD10～18- WS3 G
WS4G
4JG2PE-01 C240PKJ-30 C240PKJ-32

Specifications
Type 4-cylinder,water-cooled,in-line,overhead valve,

whirl chamber
Cyl.Number - Bore×Stroke (mm) 4-95.4×107 4-86x102
Compression Ratio 20.25 21.3
Rated Output /Speed (kW /rpm) 44.9/2450 34.5/2500
Rated Torque/Speed (N.m/rpm) 186.3/1600～1800 137.7/1800
Lowest Speed without Load (rpm) 700±25
Min. Fuel Consumption (g/kw.h) ≤215 292.3
Length×Width×Height (mm) 715×544.5×732.5 693×550.5×689 693×550.5×720
Weight (kg) 252
Rotation Direction Clockwise as viewed from fan
Cooling System Water type
Lubrication System Forced lubrication
Battery Voltage V / Capacity Ah 12/100
Lubricating Oil (L) 3.8
Cooling Water (L) 4.6
-23-
Main Specifications of Engine
Table 3
Model CPCD20～35-D1G CPCD20～35-HJ1G
Specifications DACHAI CA498-12 JIANGLING HJ493

In-line 4-cylinder, 4-cycle, water-cooled,
Type direct injection
Cyl.Number - Bore×Stroke (mm) 4-98×105 4-93×102
Compression Ratio 17 18.2
Rated Speed (rpm) 2500 2500
Rated Output (kW) 45 39
Max.Torque/Speed (N.m/rpm) 175/1600～1800 165/1800
Highest Speed without Load (rpm) 2750 2850
Lowest Speed without Load (rpm) 50 750

Table 4
Model CPQD10～35-Rc2G CPQD10～35-Rc3G
Specifications NISSAN K21 NISSAN K25
Type 4-cylinder, water-cooled
Cyl.Number - Bore×Stroke (mm) 4-89×83 4-89×100
Compression Ratio 8.7 8.7
Rated Speed (rpm) 2250 2400
Rated Output (kW) 31.2 37.6
Max.Torque/Speed (N.m/rpm) 143.7 176.5
Highest Speed without Load (rpm) 3100 3100
Lowest Speed without Load (rpm) 800 800
-24-
Table 5
Model CPCD10～18-KU11G CPCD20～30-KU11G
Specifications V2403-M-Z3B-AHFT-2
Type 4-cylinder, water-cooled
Cyl.Number - Bore×Stroke (mm) 4-87×102.4
Total Displacement (L) 2.434
Compression Ratio 23.2:1
Rated Speed (rpm) 2400
Rated Output (kW) 34.1
Max.Torque/Speed (N.m/rpm) 155.9/1600
Highest Speed without Load (rpm) 2600
Lowest Speed without Load (rpm) 800
1.2 Inspection and Adjustment of Engine

1.2.1 Air Cleaner
(1) Remove element.
(2) Check the element. If it is dirty, it should be blown with low pressure from inner to
outer; if it is damaged, it should be replaced with a new one.
(3) Clean up the cap of dust-collector.
1.2.2 Oil Filter
★Be sure that the engine has stopped before changing the oil filter.
(1) Remove the filter element with the spanner specially used for the filter.
(2) Apply a thin layer of machine oil on the washer of the renewed filter element.
(3) Please screw on the new filter element by hand because undue screwing may deform
the rubber washer.
(4) After the filter element is changed, the level of machine oil will usually drop a little.
So, please check if the oil leakage comes from the sealing place and be sure to affirm the oil
level with relevant rule and then feed the oil to the stated mark.
1.2.3 Cautions on Cooling System
Cooling system which is filled with HELI exclusive coolant free from maintenance
normally before leaving the factory is used to cool engine and hydraulic powered transmission
-25-
unit (hydraulic powered type forklift truck). The coolant filled in the truck can not only protect
against freezing above -35℃, but also protect the cooling system from corrosion, scale-
forming and increase the coolant boiling point remarkable. So the coolant concentration will
not be reduced even in the warm season or area because of water replenishing. If greater anti-
freezing protection is needed considering climate, please contact with local HELI sales
network for HELI exclusive coolant with greater anti-freezing ability.
(1) If the radiator appears “boiling” or excessive coolant temperature, it is prohibited
strictly to open the radiator cover immediately. Do as the following:
(a) Park the truck at a safe area;
(b) Keep the engine idling and open the engine hood to keep good ventilation;
(c) Shut off the engine when the water temperature indicator points to the normal range;
(d) Check the following points when the engine is cool completely:
● Check if the coolant lever is correct;
● Check if the fan belt is loose;
● Check the engine oil quality and oil level;
● Check if the radiator is clogged;
● Check if the thermostat can open normally;
(2) Use HELI exclusive coolant in order to keep the engine and cooling system in good
condition. Change it once a year. If the coolant is bad in less than one year, change it when
necessary. When changing the coolant, clean the interior of the cooling system. The freezing
point of the coolant should be 10℃ lower than the lowest environment temperature. Cautions
on replacing the coolant:
(a) Wait 30 minutes after shutting off the engine.
(b) Remove the cap and loosen the draining switch of the radiator.
(c) Loosen the draining switch of the engine and drain all the
coolant.
(d) Tighten the above two draining switches.
(e) The speed of the adding is lower than 2l/min.
(f) Let the engine running in idle speed for a while after
topping up and assure the water level of tank stays its correct
position.
(3) Check the cooling water level of the tank, if the water
level is lower than the mark “low”, it should be added the correct
coolant according to the following demand to the correct level. The
water level should be higher than the mark “high” when the engine
is warm, and the level should stay the position of 2/3 of whole
height when the engine is cold.
Fig.1-1 Tank
-26-
(a) Replenish the coolant with HELI exclusive one only when the engine is cool when
necessary avoiding engine damage.
(b) If there is no HELI exclusive coolant in an emergency, never add any additives. Add
water only and contact with local HELI sales network for proper mixture as possible.
(c) Use new HELI exclusive coolant when replenishing. It is prohibited to add hard water
such as tap water, mineral water, river water, well water to the cooling system avoiding
radiator corrosion or scale forming which will reduce radiator performance and service life.
(4) Adjust the fan belt tension:
(a) Loosen the fixing bolts of the generator.
(b) Adjust the fan belt tension by moving the generator. Press the fan belt by applying
10kg pressure with fingers, the specified belt flexibility is about 10mm.
(5) It is prohibited to contact the radiator core directly with sharp hard objects such as if
the core is dirty. Clean it with water flow or air flow with the following set pressure value.
Keep the mouth against the radiator core.
Water flow pressure: no higher than 0.49MPa (5kgf/cm²)；
Air flow pressure: no higher than 0.98MPa (10kgf/cm²).
(6) Coolant storage notes:
(a) Avoid direct contact with the coolant which is bad for health;
(b) Store the coolant in proper sealed container because the coolant steam is harmful.
Make sure to keep it out of the reach of children because there is a danger of poisoning;
(c) Once the coolant goes to eyes, please wash with water and see a doctor;
(d) See a doctor immediately once the coolant is drank carelessly;
(e) Never use the coolant drained from the truck again. Place the coolant drained from the
truck in a special container and deal with environmental rules.　　　　　　　
1.2.4 Bleeding
▲Diesel Engine
(1) Fill the injection pump chamber with diesel fuel by moving the hand pump up and
down.
(2) Press 5-10 times again when the feeling of pressing is heavy.
1.2.5 Maintenance of the Engine
The details of the adjustments and maintenance of the engine refer to the each operation
and service manual.
-27-
Check List for Maintenance of the Engine KUBOTA V2403
Time interval for maintenance
Item Per
50h 100h 200h 400h 500h 1 or 2 months 1 year 800h 1500h 3000h 2 year
Check fuel hose and its clip ☆
Change the oil inside the oil bottom shell ★ ☆
Clean air filter element (to be changed after six times of cleaning) ☆
Clean fuel filter (filter element type) ☆
Check the level of electrolyte of battery ☆
Check the tension of the fan belt and damage to it
Change the oil filter element ★ ☆
Check the hose of radiator and its clip ☆
Check air inlet pipeline ☆
Change the fuel filter cartridge ☆
-28-
Clean water pipe sheath and the inside of the radiator ☆
Change fan belt ☆
Change air filter element ☆
Check the clearance of throttle valve ☆
Check the injecting pressure of the nozzle ☆
Check turbo ☆
Check the injecting pump ☆
Change air inlet pipeline ☆
Change the hose of radiator and its clip ☆
Change fuel hose and its clip ☆
Change cooling liquid of the radiator ☆
Change battery ☆
★ After the engine operates for the initial 50 hours, please change the oil and the oil filter element.
1.3 Fuel System
The fuel system is composed a tank, fuel filter, fuel sensor and fuel meter. (see Fig.1-2)
1.3.1 Fuel Tank
The fuel tank is a welded construction integrated with the truck frame. It is located on the
left side of the truck frame. The tank cover with a fuel sensor is located on the top surface of
the tank.
Fuel filter To engine(oil inlet)
Oil-water separator Cap
Pump
Driving axle center
Three way
To engine(oil return)
Bracket
Pump Hose
Hose inlet
Fuel sensor
Fig.1-2 Fuel System
-29-
1.3.2 Fuel Sensor
The fuel sensor is designed to convert the remaining amount of fuel into electric current.
Fig.1-3 Fuel Sensor
The rheostat made of alloy steel wire is linked with a float. As the float moves up and
down, the electric current is changed by the resistance’s changes.
The fuel meter of G series truck is double sheets metal construction, the range of the
meter finger is determined by the current scale which get across the
heat element of the double sheets metal. The current value is the
biggest when the float is in the highest position, (The resistance
value is about 9.5 to 11 at this time), and the fuel meter’s finger
refers to the “F” which means the fuel level is full. On the other
hand, the “E” means the fuel level is empty.
1.3.3 Maintenance of the Fuel System
Maintenance should be conducted once for the fuel system
according to the following method after it works 100 hours and it
should be also cleaned once every 600 working hours.
(1) Oil-water separator fixed on the fuel tank is used to filter
the fuel supplied to the engine. The diesel filter also plays the role
-30-
of separating water from oil.
(a) The whole oil-water separator should be changed after it works 600 hours.
(b) Inject drops of fuel around the seal ring of new filter and put it on. After the ring
touches the filter, screw it on 2/3 circle further.
(c) As the filter alarm light is turned on, loosen the draining switch to drain all the water.
Note:Be sure to shut the draining switch after water is drained completely.
Fig.1-4 Oil-water Separator
(2) The fuel filter element of the engine should be changed after it works 400 hours.
(a) Close the fuel switch (3).
(b) Screw off positioning ring (6) and remove the filter cup
and then clean the inside with kerosene.
(c) Change the filter element (4).
(d) Re-fix the fuel filter and keep it off dust and dirt.
(e) Bleed air to the fuel system.
-31-
1.4 Accelerator Pedal
As shown in Fig.1-6, the accelerator pedal fixed on the bottom is used to control the
rotational speed of the engine. It is connected with the engine through a linkage and soft shaft.
The height of limit bolt at the accelerator pedal is adjusted within the range 30-34mm.
Limit bolt
Fig.1-6 Accelerator Pedal
2. Electric System
2.1 General Description
The electric system for this forklift truck is of the single-pole type, in which the frame of
the truck provides the return path for the electricity. The electric system seems like the nerve
system of the truck and it mainly consists of the following systems.
2.1.1 Charging System
This system contains generator, battery, charging indicator, etc. It supplies current for all
the electric appliances. Voltage: 12V.
2.1.2 Starting System
This system mainly consists of automatic pre-heating unit
(only diesel engine), key switch, starting protection circuit, starting
motor, etc. The function of this system is starting the engine.
2.1.3 Electro-hydraulic Gearshift System
This system mainly consists of electro-hydraulic control
valve, direction switch and control box etc.
Working principle: To start up the forklift, direction switch
(shown in Fig.2-1, part 1) must be shifted to “OFF”, at this time,
the circuit safeguarding the start-up circuit is switched on in
control box (part 5). If the direction switch is not at “OFF”, the
-32-
control box turns off the start-up circuit and the engine cannot be initiated. It is because of the
design of a protective circuit for safe start-up. Push the direction switch forward and the
electromagnetic valve (part 3) in control valve is thus energized and then the valve spool
operates opening up the oil circuit in advancing direction. As the forward clutch works, the
drive gears engage and the power is outputted to drive the forklift forward. If the direction
switch is pulled backward, the electromagnetic valve (part 4) in control valve is accordingly
energized and then the valve spool reacts in reverse direction opening up the oil circuit for
backing. As the reverse clutch works, relevant reversing shaft gears engage and the power is
outputted to drive the forklift backward. At the meantime, the light and buzzer for backing are
turned on through the control box (part 5).
Fig.2-1 Electric Diagrammatic Layout

(1)Direction switch (2)Control valve (3) Winding of
electromagnetic valve I
(4) Winding of electromagnetic valveⅡ (5)Control box
2.1.4 Instrument System

The module of the instrument is a stepper motor with
indicator pointers and LCD. It has hour meter, water temperature
meter and fuel meter as well as indicator lamps to show charging
state, oil pressure, neutral, pre-heating, oil-water separation, air
-33-
filter obstruction, leftward turning, rightward turning, over-high motor temperature, over-high
temperature of cooling liquid, too low level of fuel, over-high temperature of torque converter
and too low braking pressure etc.
2.1.5 Lighting and Signal Devices
They include all kinds of illuminating lamps, signal lamps, horn and buzzer, etc.
Head lamp: 55W
Front combination lamp(turning/front): 21W/8W
Rear combination lamp(turning/rear/backing): 21W(red)/8W(red)/10W(white) Warning
lamp: 21W
2.2 Brief Explanation for Operation

2.2.1 Starting
There is a starting protection circuit in the control box for the forklift truck. You have to
shift the direction switch in neutral before you start the engine. Otherwise, you can’t start the
engine.
Turn the key switch clockwise to the first “on” position, the instrument circuit and the
firing circuit are ready for work. For diesel engine, the automatic pre-heater begins to work
and the pre-heating indicator lights. The pre-heating indicator automatically stops lighting after
3.5 seconds and the pre-heater automatically stops working after 13.5 seconds. The pre-heating
time is controlled by a time relay.
Turn the key switch clockwise to the second “on” position (starting position), then start
the engine.
After engine starting, push the direction switch forward (that
is in forward gearshift), then pedal accelerator, the forklift truck
runs faster and you can begin to work. When pull the direction
switch backward (that is in reverse gearshift), the backing lamp is
on and the buzzer sounds.
2.2.2 Switch of combination lamps
(a) Turn the knob at the end of right handle one span
clockwise, the width indictor lamps both in the front and rear will
shine.
(b) Turn the knob at the end of right handle clockwise to span
2 and the head lamps in the front will shine, at the same time, the
width indicator lamps will be still shining.
-34-
(c) Pull the right handle backward, the right-handed combination lamps in the front and
rear including turning signal lamp on the instrument panel will flash; push the right handle
forward, the left-handed combination lamps in the front and rear including turning signal lamp
on the instrument panel will flash.
2.2.3 Brake Signal
When you pedal brake, the brake lamps (red) in the rear combination lamps are on.
2.2.4 Backing Signal
When you need to reverse the forklift truck, pull the direction switch backward and the
transmission is in reverse gear. Then the backing lamps (white) in the rear combination lamps
are on and the buzzer sounds.
2.2.5 Charging Signal
Before you start the engine, put the key switch to the first “on” position and the charging
lamp is on. After engine starting, the charging lamp is automatically off. If the charging lamp
becomes on while the engine is working, it means something is wrong with the charging circuit
and you must stop working and check the charging circuit as soon as possible.
2.2.6 Oil Pressure Signal
Before you start the engine, put the key switch to the first “on” position and the oil
pressure alarm lamp is on. After engine starting, the oil pressure alarm lamp is automatically
off. If this lamp becomes on while the engine is working, it indicates low lubricating oil
pressure and you must stop working and check the lubricating system as soon as possible.
2.2.7 Oil-water Separator Signal
Before you start the engine, put the key switch to the first “on” position and the oil-water
separator alarm lamp is on. After engine starting, the oil-water
separator alarm lamp is automatically off. If this lamp becomes on
while the engine is working, it means too much water has been
accumulated in the oil-water separator. You should push the handle
in the oil-water separator to get rid of the water. After eliminating
the water, this lamp becomes off.
2.2.8 Fuel Meter
It indicates how much fuel is left in the fuel tank. If it displays
fewer than two bars, it means little fuel is left in the fuel tank and
the buzzer sounds. You should replenish the fuel tank as soon as
possible.
2.2.9 Water Temperature Meter
-35-
It indicates the temperature of the coolant for the engine.
2.2.10 Hour Meter
It indicates how many hours the engine has worked.
2.2.11 “Neutral” indicator lamp
As direction switch is shifted to “neutral”, relevant indicator lamp on the instrument panel
will be turned on; as the direction switch is positioned at the gear “forward” or “reverse”, the
indicator lamp will be turned off.
2.2.12 Pre-heating indicator lamp
As the key switch is turned to span 1 (electrifying span) clockwise, the instrument and
ignition power source will be switched on and the pre-heating indicator lamp will shine. The
engine (only diesel engine) is thus preheated automatically, the pre-heating indicator lamp will
be turned off automatically 3.5 seconds later, and the time of pre-heating will be under control
of time relay (also called timer) and lasts to 13.5 seconds.
2.2.13 Oil-water separation indicator lamp
As the precipitating water in oil-water separator reaches the warning line, the indicator
lamp on the instrument panel will be turned on. After the water is released, the indicator lamp
will die out.
2.2.14 Air filter obstruction indicator lamp
The indicator lamp shines on the instrument panel, showing that the air filter is full of
dust. It is time to take out the filter element, clean it and re-fix it again or change it.
2.2.15 Leftward and rightward turning-light indicator lamps
Turn on the leftward turning light, relevant indicator lamp on the instrument panel will
shine; turn on the rightward turning light, relevant indicator lamp
on the instrument panel will shine as well.
2.2.16 Over-high engine temperature indicator lamp
The engine should be turned off and checked as the indicator
lamp shines on the instrument panel.
2.2.17 Indicator lamp for over-high temperature of cooling
liquid
The engine should be turned off with its radiator and cooling
liquid being checked as the indicator lamp shines on the instrument
panel.
2.2.18 Indicator lamp for too low fuel level
Oil should be fed as soon as possible as the indicator lamp
-36-
shines on the instrument panel.
2.2.19 Indicator lamp for over-high temperature of torque converter
The engine should be turned off for checking as the indicator lamp shines on the
instrument panel.
2.2.20 Indicator lamp for too low braking pressure
The engine should be turned off with its braking system being checked as the indicator
lamp shines on the instrument panel.
2.2.21 Engine stops
Turn the key switch to the position “OFF”, the engine will stop working automatically.
2.2.22 Automatic monitoring system for the engine
The instrument has the function of automatically monitoring the engine. Electronic
monitoring system located inside the instrument can monitor the operation conditions of the
whole engine at any time and achieve data acquisition and processing based on input signals
from meters, sensors and pressure switches etc. As a datum reaches relevant limit, the alarm
unit will be initiated for grade 1 lighting warning or grade 2 acoustic-optic warning, reminding
the driver of stopping working for checking.
Grade 1 warning: Grade 1 warning signal will be given and relevant indicator lamp will
shine in case of one of following conditions:
(a) Over-high engine temperature;
(b) Over-high temperature of cooling liquid;
(c) Too low fuel level;
(d) Over-high temperature for torque converter.
If the grade 1 warning is not relieved, the monitoring system
will compulsively stop working of the engine 600s later.
Grade 2 warning: Grade 2 warning signal will be given and
relevant indicator lamp will shine and buzzer rings in case of one
of following conditions:
(a) Too low oil pressure for the engine;
(b) Breakdown in braking system.
The monitoring system will compulsively stop working of the
engine if the prompted issues remain unresolved 180s after the
grade 2 warning is given.
The engine can be started up again after being stopped by the
monitoring system. However, if the trouble is not eliminated,
-37-
Hour meter
Water temp.
meter
Indicator
Fuel meter
Warning lamp
Fig.2-2 Combined Instrument
-38-
Air fitter warning
warning switch
Over-head guard harness Water temp sensor
right
Electromagnetic value
Oil pressure switch Generator
Spare power To relay
Warning lamp switch

Electro-hydraulic
Oil capacity sensor
control box Electric choke
Brake lamp
switch Combine instrument Pre-heating indicator
Oil-water separator Buzzer
-39-
Groud
Starting switch
Fig.2-3 Diagram of Harness

Fuse Warning lamp. Rear lamp
To direction To cambined
switch lamp switch
Control hour meter Horn Starter
Center control box

To hand
brake switch
To center control box

left
Over-head guard harness
Fig.2-4 Diagram of Circuitry
-40-
3.Hydrodynamic Drive Unit
Torque Converter
Type T h ree elements, single stage, two phases
Torque Ratio 3.02
Set Pressure 0.5～0.68MPa
Charging Pump
Type Inner-mesh gear type
Flow Rate 27l/min(2000rpm, 1.5MPa)
Hydraulic Transmission
Type Power shifted
Forward 1.35
Speed Ratio
Backward 1.35
Hydraulic Clutch
Friction piece : O.D.×I.D.×T. 125×81×2.7
Friction area 71cm
2
Set Pressure 1.1～1.4MPa

Weight 165kg
Oil Amount 7L
Model SAE10W engine oil
Oil Type No.6 Torque converter oil made in China

Hydrodynamic transmission type forklift trucks are provided
with a drive unit including a torque converter and a hydraulic
transmission (See Fig.3-1). They feature the followings:
(1)With an inching valve, the inching operation can be done
under the conditions that the engine runs at both high and low
speeds.
-41-
Fig.3-1 Hydrodynamic Drive Unit
(1)Forward clutch (16)Spring (31)Clip ring (43)Output shaft

(2)Oil filterⅡ (17)Oil inlet cover (32)O-ring seal (44)Supporting piece
(3)Backward clutch (18)Safety valve cover (33)Idler (45)Single-row radial ball bearing
(4)Single-row radial ball bearing (34) Oil filter I (46)Inner-hexagoned plug
(5)Seal ring (A) (19)Inner-hexagoned plug (47)Transmission case cover
(6)O-ring seal (20)Plug (35)Output gear (48)Mounting bolt
(7)Charging pump (21)Spring pin (36)Idler shaft (49)Reverse lamp switch
(8)Oil seal (22)Shift arm (37)Single-row radial ball bearing
(9)Impeller (23)Transmission case cover (50)Oil drain plug
(10)Stator (24)Shift arm shaft (38)Nut for bearing
(11)Turbine (25)O-ring seal (39)Single-row tapered roll bearing
(12)Spring plate (26)Half-round key (40)O-ring seal
(13)Inching valve (27)Clip ring for hole (41)Oil seal
(14)Control valve (28)&(29)Single-row radial ball bearing
(15)Piston (30)O-ring seal (42)Single-row tapered roll bearing
-42-
(2) Each of two hydraulic clutches is provided with four pairs of steel plates and paper
friction pieces specially-treated, so as to improve the durability of friction pair.
(3) Both one-way overrun clutches in the torque converter are used to increase the
efficiency for power transmission.
(4) High quality of oil filters is helpful to increasing the life of the torque converter.
3.2 Torque Converter
The torque converter mainly consists of an impeller, a turbine and a stator.
The liquid, from the impeller driven by an input shaft, is jetted along its leaves to leaves
of the turbine to transmit the torque to the output shaft (i.e. Mechanical energy is changed into
kinetic one). And the flowing direction of the liquid from the turbine wheel is changed by the
stator to cause a part of the liquid return to the impeller at an angle and produce so large
reaction torque driving the stator that the value of output torque is more than that of input
torque by the value of the reaction torque. When the turbine speed keeps on increasing up to
near speed of the impeller, the change rate of the flow angle slows down and the value of the
output torque keeps on decreasing until the liquid flows into the leaves of the stator in opposite
direction. When original reaction torque acts in the opposite direction, the torque value of the
output shaft is less than that of the input shaft. To prevent this, a one-way overrun clutch is
fitted in the stator, causing the stator freely rotate in this case.
The way of torque-converting can be used to ensure efficient and smooth work of the
torque converter.
The torque converter, filled up with the torque converter oil, in the drive unit is driven by
an engine through a spring plate and flywheel on the engine. A charging pump is driven by a
driving gear which is splined to the impeller. The oil for the torque
converter and the transmission is supplied by the pump. The power
is transmitted to the transmission through a turbine shaft splined to
the turbine.
-43-
Fig.3-2 Torque Converter
(1)Spring plate (2)Turbine (3)Impeller (4)Stator (5)One-way overrun clutch
3.3 Hydraulic Clutch (Fig.3-3)

Both hydraulic multi-piece clutches of wet type are fixed on the input shaft of the
transmission. The pressure oil is supplied to the forward or the backward clutch through a
control valve to achieve the forward or the backward travel of the
truck. All of gears in the transmission are normally meshed. Every
clutch consists of four spacers (part 10) and four friction pieces
(part 9) assembled alternately and a piston. On the inner and the
outer circles of the piston are seal rings for sealing the piston. In
the neutral, the piston is still and the spacers and the friction pieces
are disengaged each other. When shifting, the oil pressure acts on
the piston and the spacers and the friction pieces are engaged each
other to form an integral so that the power from the torque
converter is transmitted to the forward driving gear (part 3) or the
backward driving gear (part 4).
The power from the torque converter is transmitted to the
-44-
Fig.3-3 Hydraulic Clutch
(1)Input shaft (2)Piston ass’y (3)Forward driving gear

(4)Backward driving gear (5)Return spring (6)Spring seat
(7)Thrust ring(A) (8)Thrust ring(B) (9)Friction piece
(10)Spacer (11)Seal ring(A) (12)Seal ring(B)
(13)Bearing (14)Needle bearing (15)O-ring seal
(16)End plate (17)Check valve ball
(18)Thrust ring(B)
(19)Thrust ring(A) (20)Snap ring
(21)Snap ring
(22)Snap ring (23)Needle bearing
(24)Bearing
(25) Seal ring(A) (26) Seal ring(A)
(27) Seal ring(A)
3.4 Control Valve, Relief Valve and Inching Valve

3.4.1 Control Valve
The control valve positioned at the inside of the transmission
-45-
Fig.3-4 Control Valve
(1)Pressure valve (2)Adjusting valve (3)Operation slide valve (4)Spring (5)Ball
3.4.3 Adjusting Valve

It is positioned between the inching valve and the operation slide valve. The adjusting
valve comes to work as soon as the operation slide valve is opened, so as to reduce the shock
from the engagement of either clutch.
3.4.4 Relief Valve
The relief valve connected with the transmission case keeps
the oil pressure in the torque converter within 0.5-0.7MPa to
prevent air corrosion.
3.4.5 Inching Valve
It is fixed in the outside of the transmission. Its spool is
connected with a connection rod of the inching pedal. When the
pedal is stressed, the spool moves to right, and the oil pressure in
the clutches is lowered temporarily to get the inching of the truck
(Fig.3-5).
-46-
(1)Snap ring (2)O-ring seal
(3)Inching valve rod
(4)Snap ring (5)Spring
(6)Valve core (7)Spool
(8)Valve body (9)Spring
(10)O-ring seal (11)Cover
(12)Oil seal
Fig.3-5 Inching Valve
3.5 Transmission Case

It is used to contain the input shaft, the output shaft, etc. and serve as an oil tank. There is
an oil filter (I) of 150 meshes in specification at the bottom of the case to filter the oil from the
charging pump. The oil filter (Ⅱ) for the pipeline, the oil inlet cover and the dip stick are all
fixed at the top of the case cover.
3.6 Charging Pump (See Fig.3-6)
The charging pump between the torque converter and the
input shaft of the transmission is a gear pump driven by the turbine
shaft concluding a pair of inner meshed gears for the purpose of
feeding the oil to the torque converter and the transmission.
3.7 Hydraulic Circuit (Hydrodynamic Transmission Type
Drive Unit) (SeeFig.3-7)
After the engine is started, the charging pump inhales the oil
from the oil tank (i.e. transmission case). The pressure oil from the
pump serves two parts for hydraulic clutches and torque converter.
The oil necessary to operate the hydraulic clutches is divided
into two circuits through the pressure valve (set pressure of 1.1-
1.4MPa):one circuit flowing to the torque converter via. a relief
-47-
Fig.3-6 Charging Pump
(1)O-ring seal (2)Driven gear (3)Driving gear (4)Cover (5)Pump body (6)Oil seal
Fig.3-7 Hydraulic Circuit

(1)Charging pump (2)Oil filter (3)Relief valve (4)Oil
filter (5)Pressure valve
(6)Oil radiator (7)Torque converter (8)Adjusting valve
-48-
In the neutral, the circuit from the operation slide valve to the clutches is intermitted, and
the pressure valve is opened to let the oil only flow into the torque converter. When the
operation slide valve lies at its forward or backward position, the circuit from the operation
slide valve to either the forward clutch or the backward clutch is closed accordingly, thus
causing corresponding clutch come to work. When a clutch is at work, another must stop
working, i.e. its spacers and friction pieces must be disengaged each other and be lubricated
and cooled. When the inching valve is operated through stressing the inching pedal, a part or
most of the oil in the clutches flows into the oil tank through the inching valve rod. The oil
circulation for the torque converter then is the same as that in the neutral.
3.8 Towing Disabled Truck
The followings should be done when the torque converter type truck to be repaired is
towed by other truck:
(1) Remove the half-shaft from the front wheel.
(2) Shift lever should be placed in the neutral.
3.9 Position of Connection Ports for Hydraulic Oil (See Fig.3-8)
Fig.3-8 Measure of Oil Temperature & Oil Pressure

(1)High temp. oil port (to radiator) (2)Low
temp. oil port (from radiator)
(3)Oil temp. meter port (4)Oil drain plug (5)Side
-49-
3.10 Reduction and Differential
The reduction gear located in the front of the transmission is used to reduce the speed and
increase the torque from the output shaft of the transmission and impart them to the
differential. It consists primarily of a small spiral bevel gear on the output shaft and a pinion
shaft splined with a big spiral bevel gear. Both ends of the pinion shaft are supported by
tapered roller bearing. Several shims are installed between the case and bearing covers to
adjust the clearances between them.
The differential is housed in the front portion of the case of the differential the front end
of which is connected with the axle housing. The differential case is of spliting type. The
differential includes two half shaft gears and four planet gears. The thrust washers are installed
between the differential case and each gear and between gear pairs to keep a proper clearances
between them. The planet gears are supported by planet gear shaft I and Ⅱ. The shaft I and
ring gear (1) are fixed to the differential case respectively with knock pin and bolt.
The power from the transmission is transmitted through the reduction gear, differential,
half shaft gear and half shaft to driving wheels.
(1)Gear ging
(2)Pin
(3)Ball bearing
(4)Side gear
(5)Shim
(6)O-ring seal
(7)Bearing cover
(8)Tapered roller bearing
(9)Adjusting shim
(10)Gear
(11)Spacer
(12)Pinion shaft
(13)Pin
(14)Planet gear
(15)Shim
(16)Gear shaft
Fig.3-9 Reduction and Differential
-50-
4. Drive Axle
Front wheel drive type truck, axle body rigidly connected to truck frame,
Type
fully floated half shaft
Model Wheel T yre size R im size Tyre pressure

1～1.8t Single wheel 2×6.5-10-10PR 5.00F-10DT 790kPa
Single wheel 2×7.00-12-12PR
2t,2.5t 5.00S-12D 860kPa
Double wheel 4×7.00-12-12PR
Single wheel 2×28×9-15-12PR
3t 7.00WFB-15 830kPa
Double wheel 4×28×9-15-12PR
Single wheel 2×28×9-15
3.5t 7.00-WFB-15
Double wheel 4×28×9-15-12PR 830kPa

The drive axel mainly consists of the housing, the wheel hubs, the half shafts and the
brakes. The housing is an integrally casted. The tyre with the rim is fixed to the hub with studs
and nuts. The power is transmitted to the half shafts through the differential and drives the
front wheels through the hubs. Each hub is fixed on the housing with two tapered roll bearings,
so that the half shafts bear only the torque transmitted to the hubs, In the inside of the hub are
oil seals to prevent water and dust from entering and oil leakage.
-51-
Torque
96.1～110.8 N.m(980～1130kgf.cm)
Torque
147.1～171.6 N.m(1500～1750kgf.cm)
-52-
Torque
117.7～137.3 N.m(1200～1400kgf.cm)
Fig.4-1 Drive Axle(1-1.8t)

A: 50% Full of grease
1.Housing 6.Tapered roller bearing 11.Rim

2.Half-shaft 7.Wheel hub 12.Adjustment nut
3.Brake 8.Tapered roller bearing 13.Lock nut
4.Brake drum 9.Oil seal
5.Oil seal 10.Tyre
Torque
Torque 96.1～110.8 N.m(980～1130kgf.cm)
205.9～225.6 N.m
(2100～2300kgf.cm)
B Torque
470.7～549.2 N.m(4800～5600kgf.cm)
-53-
Fig.4-2 Drive Axle(2-2.5t)

B

5.Oil seal 10.Tyre
Torque
205.9～225.6 N.m
(2100～2300kgf.cm) Torque
B 96.1～110.8 N.m(980～1130kgf.cm)
-54-
B
Torque
470.7～549.2 N.m(4800～5600kgf.cm)
Fig.4-3 Drive Axle(3t)


5.Oil seal 10.Tyre
4.2 Procedure for Hubs Remounted
(1)Grease the hubs for 100CC grease, then
install it on the shaft.
(2)Screw down the adjusting nut with a
torque for about 1 kg.m and then screw it out for
1/2 turn.
Fig.4-4 Add Grease
(3)Put the spring balance up on the bolt to

measure the hubs’ starting torque. When the
starting torque arrive to the specified value, lock
the nuts slowly.
Starting torque: 5 to 15 kg.m.
(4)Install the lock plates and lock nuts, after
that pull the lock plates up to lock the bolts. Fig.4-5 Measure Starting Torque
(5) Wheel assembly

Install the air valve rod and cap on the tyre and assemble the outside rim and inside rim.
Pay attention to the following condition:
(a) Put the air valve rod in the notch of the rim and make it face outside.
(b) Make the tops of the rim bolts face outside.
Fig.4-6 Wheel Assembly

(1)Tyre (2)Air valve rod (3)Cap (4)Inside rim
-55-
5. Steering System
Model
1～1.8t 2t,2.5t 3t,3.5t
Item
Type Rear wheel steering powered
Steering Ass’y Type Cycloid gear type powered steering unit
Steering Ass’y Model BZZ1-100 (sealed by taper O-rings)
Type Double-action piston type
Steering Bore (mm) Φ56 Φ70
Cylinder
Dia. of Piston Rod (mm) Φ40 Φ50
Stroke (mm) 91 99
Rated Pressure (MPa) 9
Radius of Steering Handwheel (mm) Φ300
Tyre Size 5.00-8-10PR 6.00-9-10PR 6.50-10-10PR
Tyre Pressure (kPa) 1000 860 790

The steering system mainly consists of steering handwheel, steering frame, driving shaft
and steering unit. The steering handwheel is connected with steering unit through the driving
shaft. The steering frame can tilt forward or backward to a suitable position ensuring the
driver’s easy control of the steering handwheel. Load-sensing powered steering system has a
priority valve fixed on its circuit ensuring the priority being given to it in sharing the flow for
adequate oil supply on any working conditions. As the steering unit
is maintained in middle position, less flow will pass the unit, thus
saving energy for the system.
-56-
Fig.5-1 Steering and Operating Device
5.2 Cycloid Gear Type Powered Steering Unit

(1) The powered steering unit (Fig.5-2) can transmit the
pressure oil from the flow-divider by pipes to the steering cylinder
in terms of the rotating angle of the handwheel. When the engine
stop running, the charging pump will not work, in this case a man-
powered steering should be adopted.
(2) Load-sensing steering system consists of pump, priority
valve, load-sensing steering unit, steering overflow valve and
system overflow valve. Steering circuit and other working circuits
do not interfere with each other. Priority is given to steering circuit
-57-
Fig.5-2 Cycloid Gear Type Powered Steering Unit
(1)Spacing sleeve (2)Valve body (3)Valve core (4)Interlock
shaft (5)Spring piece (6)Joint sleeve (7)Rotor
(8)Stator (9)Valve sleeve
5.3 Inspection on Reassembly of Steering System

(1) Check the forces necessary to turn the steering handwheel
to right and left until it can’t be turned any more to see if they are
identical each other and check the operation of the steering
handwheel for smoothness during above operation.
(2) Check the arrangement of hydraulic pipeline and turning
direction of the truck for correctness.
-58-
5.4 Steering System Troubleshooting
Problem Analyses of Trouble Remedies
Pump damaged or breaking down Replace

Fail to Turn
Flow-divider blocked or damaged Clean or replace
Handwheel
Hose or joint damaged or pipeline blocked Clean or replace
Too low oil pressure from flow-divider Adjust pressure
Air in steering oil circuit Exhaust air

Difficult to Turn
Steering unit fail to recover due to spring
Handwheel Replace spring piece
piece damaged or elasticity-insufficient
Excessive inner-leakage in steering cyl. Check piston seals
Adjust flow-divider for

Excessive flow rate for steering
Truck’s
Snacking or flow rate
Moving with Spring piece damaged or elasticity-insuffi-
Oscillation Replace
cient
Excessive Too low oil level in oil tank Refill oil

Noise Suction pipeline or oil filter block Clean or replace
Seals of guide sleeve, pipeline or joint

Oil Leakage Replace
damaged
-59-
6. Steering Axle
The steering axle is of section-boxed welded construction type (Fig.6-1). It includes axle
body, steering cylinder, tie rod, knuckles and steering wheels. The steering trapezium is made
of cranks and blocks. When pressure oil move the cylinder piston rod, the tie rod revolve the
knuckles, then the truck may be steered. The steering axle is bolted to the rear frame by the
buffer.
Fig.6-1 Steering Axle

(1)Axle body (2)Tie rod (3)Steering
cylinder (4)Rear trestle
(5)Bush (6)Right knuckle ass’y (7)Thrust
bearing (8)Needle bearing
(9)King pin (10)Tyre (11)Oil seal
(12)Tapered roller bearing
-60-
6.2 Steering Knuckles and King Pin
Both steering knuckles are fitted between the upper and the lower bushes through tow
king pins, tapered bearings, dust sleeves and O-ring seals. The upper extreme of the king pin is
locked on the axle body with a lock pin, the lower extreme of the king pin with a nut and a
split pin. Both ends of the king pin are supported by the tapered bearings which are pressed
into the axle body.
Steering cylinder
Bearing
Bracket
Bushing Steering knuckle
Rubber
Steering king pin
Fig.6-2 Steering Knuckles and King Pin

6.3 Wheel Hub
The rear wheel hubs are fitted to the knuckle shafts through two tapered roller bearings,
the wheels with rims are bolted on the hubs. There are oil seals keeping the grease in the hubs
and the chambers of the knuckles between the outside of the two
tapered roller bearings. The degree of the bearing tightness is
adjusted by the nut.
Steering wheel ass'y
Bearing
Steering knuckle
King pin
Washer
Nut
Pin
Grease fitting Wheel hub

U-type seal
Wheel hub cap
-61-
6.4 Steering Cylinder
The steering cylinder is of double-action piston type. The seal unit is consist of the
supporting ring and o-ring seal, Yx-ring seal is adopted between the cylinder cover and the
piston rod. The cylinder is fitted to the steering axle body through brackets.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 16
Fig.6-4 Steering Cylinder

(1)Piston rod (2)Dust ring (3)Snap ring (4)Bushing
(5)Snap ring (6)O-ring seal (7)Snap shim (8)O-ring seal
(9)O-ring seal (10)Cylinder head (11)Piston (12)Steel ball
(13)Retainer (14)Retainer (15)O-ring seal (16)Cylinder tube ass’y
6.5 Rear Wheel Bearing Pre-load Adjustment

(1) As shown in Fig.6-5, with lubricating grease, fill up the chamber formed by wheel
hubs, wheel hub bearings and wheel hub covers and coat the lips of the oil seals.
80% Fill of grease
80% Fill of grease
Fig.6-5 Fill Up Grease and Pre-load Adjustment
-62-
(2) Press the hub bearings into the hub and fit the hub on the knuckle shaft.
(3) Fit a flat washer and tighten a castle nut to a torque of 206-235Nm(21-24kgm) and
loosen it and then tighten it again to a torque of 9.8N.m(1kgm).
(4) To ensure firm installation of the hub, slightly knock at it with a wooden hammer and
in the meantime, rotate the hub for 3-4 turns.
(5) Tighten the castle nut and align one of its notches with a cotter pin hole drilled in the
steering knuckle.
(6) Again slightly knock at the hub with a wooden hammer and in this time, rotate
manually the hub for 3-4 turns to ensure its smooth rotation with a specified torque of 2.94-7.8
N.m (0.3-0.8kgm).
(7) If the torque value necessary to rotate the hub is more than the specified one above-
mentioned, screw out the castle nut for 1/6 turn and measure the torque value then.
(8) When the torque value measured is up to the specified one, lock the castle nut with a
cotter pin.
-63-
7. Braking System
Type: Front two-wheel braking, internal expansion, hydraulic type
Pedal Ratio 6.24 (Dynamic braking) 5.12 (Manual braking)
Master Cylinder Bore 19.05mm
Wheel Brake 1～1.8t 2t,2.5t 3t,3.5t
Type Duo-servo type with parking brake
Operating Cylinder Bore 22.22mm 28.58mm
Lining Size (L×W×T) 279×48.5×5mm 324×60×7mm 348×76×8mm
Friction Area 135.3 cm ×4

2
194.4 cm 2×4 264 cm 2×4
Inner Dia.of Brake Drum 254mm 310mm 314mm
Parking Brake: Front two-wheel braking, internal expansion, mechanical type

The braking system is the front two-wheel braking type consists of a master cylinder,
wheel brakes and braking pedal mechanism. It is classified into the dynamic and the manual
due to the difference in power source for braking. Dynamic braking has its power sourced from
high-pressure oil produced by gear pump and manual braking is powered from the operator’s
treading force.
-64-
Fig.7-1 Dynamic Braking System
Fig.7-2 Manual Braking System

7.1.1 Braking Pedal
The braking pedal unit is mounted on the front panel through
bracket as shown in Fig.7-1 and Fig.7-2. When the pedal moves, it
push the rod to course the piston moves and the pressure of the oil
circuit increased.
7.1.2 Master Cylinder
-65-
To oil inlet of brake
Oil inlet To oil tank
to flow-divide inlet of steering unit
Fig.7-3 Master Cylinder of Dynamic Braking System
The master cylinder of dynamic braking mechanism stores high-pressure oil sourced from
gear pump inside its body and the excessive pressure oil returns to the oil tank through oil-
return mouth. As the steering unit of the truck begins to work, the pressure oil flows from the
pump to it, reducing the oil-return flow. As the operator steps on the braking pedal, the braking
valve inside the pump is pushed open and some of pressure oil flows to the brake, at this time,
the flow toward steering unit reduces and the operator will feel a slight increment in turning
force. If there exists damage to the engine or gear pump, the operator still can tread the pedal
for braking because the hydraulic oil stored in the pump body is pushed into the brake by the
piston, thus stopping the running truck awaiting repair.
(2) Master cylinder of manual braking system
The cylinder contains valve seat, check valve, return spring, primary cup, piston and
secondary cup, which are all kept in place with a stop washer and a
stop wire. The exterior of the cylinder is protected from dust by
means of a rubber dust cover. The piston is actuated through the
push rod by operation of the braking pedal. As the braking pedal is
pressed, the push rod pushes the piston forwards. The brake fluid in
the cylinder flows back to the reserve tank through the return port
until the primary cup blocks up the return port. After the primary
cup passes through the return port, the brake fluid in the cylinder is
pressurized and opens the check valve, flowing through the brake
pipeline to the operating cylinder. Thus, each operating cylinder
piston is forced outwards. This brings the friction pieces on the
brake shoes into contact with the brake drum and slows or stops the
-66-
truck. Meanwhile, the cavity caused behind the piston is filled with brake fluid led through the
return port and inlet port. When the brake pedal is released, the piston is forced back by the
return spring. At the same time, the brake fluid in each operating cylinder is pressurized by the
return spring, returning into the master cylinder through the check valve. With the piston in its
original position, the fluid in the master cylinder flows into the reserve tank through the return
port. The brake fluid in the brake pipelines and operating cylinders has a residual pressure
proportioned to the set pressure of the check valve, which makes each operating cylinder
piston cup securely seated to prevent oil leakage and eliminates a possibility of air locking
when the truck is sharply braked.
Fig.7-4 Master cylinder of manual braking system

(1)Link rod (2)Push rod (3)Dust cover (4)Snap ring (5)Secondary cup (6)Piston
(7)Primary (8)Spring (9)Check valve
7.1.3 Wheel Brake

The wheel brake is the internal expansion hydraulic type
consisting of brake shoes, springs, operating cylinder, adjuster, and
backing plates. Two wheel brakes are provided on each end of the
front axle. The brake shoe, one end of it being connected to the
anchor pin and the other to the adjuster, is stressed on the backing
plate by the spring and spring pull rod. The primary shoe is
provided with the parking pull rod while the secondary shoe with
the adjusting lever of the clearance self-adjuster.
-67-
C-C
D-D
D-D
A-A
B-B
1.Pull rod 8.Pin 15.Dust couer

2.Secondary shoe 9.Primary shoe 16.Cylinder body
3.E-type retainer 10.Spring 17.Piston
4.Operating cylinder 11.Adjusting lever 18.Spring
5.Return spring 12.Adjuster 19.Cup
6.Push rod 13.Spring
7.Spring 14.Push rod
Fig.7-5 Wheel Brake(1-1.8t)
-68-
C-C
A-A
B-B
1.Push rod 8.Push rod 15.Rod
2.Piston 9.Pull rod 16.Push rod
3.Cup 10.Secondary shoe 17.Operating cylinder
4.Spring 11.Backing plate 18.Pin
5.Cylinder body 12.Adjuster 19.Spring
6.Spring 13.Spring 20.Primary shoe
7.Spring 14.Cable
-69-
C-C
D-D
D-D
A-A
B-B
1.Operating cylinder 8.Spring 15.Push rod

2.Spring 9.Adjusting lever 16.Pis ton
3.Cable 10.Adjuster 17.Cup
4.Secondary shoe 11.Spring 18.Spring
5.Backing plate 12.Pull rod 19.Cylinder body
6.Push rod 13.Primary shoe
7.Pin 14.Spring
-70-
(1) Braking operation
The braking operation in the truck’s forward travel is as follows: see Fig.7-6. The primary
and secondary shoes are respectively forced by a force equal in value and contrary in direction
each other, by operation of the operating cylinder to bring the friction piece in contact with the
brake drum. The primary shoe forces the adjuster with the aid of friction force between the
friction piece and the drum. Due to this, the adjuster pushes the secondary shoe by the larger
force than that offered by operation of the operating cylinder. The secondary shoe upper end is
forced strongly against the anchor pin, providing large braking force. On the other hand, the
braking operation in the truck’s reverse travel is performed in reverse order, but the braking
force is the same as that in the case of the truck’s forward travel.
Forward Travel Backward Travel

Fig.7-8 Braking Operation
(2) Parking brake

The parking brake is of mechanical, internal expansion type
and built in the wheel brake. It shares the brake shoes and brake
drum with the foot brake. As the parking
brake lever is pulled, the parking pull rod is
actuated through the brake cables. The
parking pull rod pushes, in turn, the parking
push rod to the right with the aid of the pin
as a fulcrum, forcing the secondary shoe
against the brake drum.
Fig.7-9 Parking Brake
-71-
(3) Clearance self-adjuster
The clearance self-adjuster keeps suitable clearance between the friction piece and drum
by itself. The construction is shown in Fig.7-10 and 7-11. This adjuster, however, actuates only
when the truck in reverse travel is braked. There are two different clearance self-adjusters.
(a) Clearance self-adjuster for 2 and 2.5 ton trucks
The adjuster actuates only when the truck in reverse travel is braked. The secondary shoe
come into contact with the brake drum and rotate together. As a result of this, the parking pull
rod turns right around the point A so that the point B of the rod raises. After releases the brake
pedal, the parking pull rod turns left with the spring force so that the point B of the rod lowers.
As the clearance between the friction piece and the brake drum increases, the rotating
vertical distance of the pawl by point B increases too. When the clearance is more than 0.4mm,
the adjuster is dialed a teeth and the adjusting lever becomes longer, so that the clearance
decreases.
Clearance adjusting range: within 0.4 to 0.45mm.
(b) Clearance self-adjuster for 1 to 1.8 ton and 3 to 3.5 ton trucks
The adjuster actuates only when the truck in reverse travel is braked. The secondary shoe
come into contact with the brake drum and rotate together. As a result of this, the parking pull
rod turns right around the point A so that the point B of the pawl dials the teeth of the adjuster.
After releases the brake pedal, the brake shoe return to the original position and the parking
pull rod turns left around the point A so that the point B of the rod lowers. When the clearance
increases, the adjuster is dialed another teeth.
Clearance adjusting range: within 0.25 to 0.4mm.
Fig.7-10 2 and 2.5 Ton Trucks Fig.7-11 1 to 1.8 Ton and 3 to

3.5 Ton Trucks
-72-
Fig.7-12 Clearance Self-adjuster
7.1.4 Parking Brake Lever
Release button Release button
Cable R.
Cable L.
Fig.7-13 Parking Brake Lever
Adjustment of tension of the lever:

(1)Lever at the release position.
(2)Adjusted to mark B and exerted with a tension of 200-
300N, the lever is movable. If the tension is a little bit bigger, part
A rotates rightward, if smaller, leftward.
-73-
Height
Front bot ton

plate
Fig.7-14 Height of the Brake Pedal
Free play of the inching pedal is 0mm. Adjust the initial height between the inching pedal
and the front floor. When it reaches 85mm, press the inching pedal for 20mm. At this time, the
inching pedal move with the brake pedal. Adjust the initial height of the brake pedal, then
tighten the stopper bolt of the brake pedal. Adjust the free play of the brake pedal for 20mm.
Free play adjustment of the brake pedal:
(1) Shortening the push rod of the master cylinder.
(2) Adjust the push rod of the master cylinder until the brake pedal be pressed for 20mm.
(3) Tighten the locking nut on the push rod.
▲Brake Switch Adjustment
(a) After you adjust the height of the brake pedal, loose the
lock nut of the brake switch.

(b) Pull the plug out to let the lead separate.
(c) Turn the switch to make the clearance
about 1mm.
(d) Make sure that when you press the brake
pedal the brake lamp light at the same time.
7.2 Maintenance of the Brake
This paragraph covers the disassembly,
reassembly and adjustment of the brake.
-74-
7.2.1 Wheel Brake Disassembly
(1) Remove the lock pin, adjust lever,
adjuster and spring of secondary shoe. (Fig.7-15)
Fig.7-15
(2)Remove shoe return springs. (Fig.7-16)
Fig.7-16
(3)Remove the lock pin of primary shoe.
(Fig.7-17)
Fig.7-17
(4)Remove the primary and secondary

shoes. (Fig.7-18)
Fig.7-18
-75-
(5) Remove the braking oil pipe from
the operating cylinder, remove operating
cylinder mounting bolts and detach the
operating cylinder from the backing plate.
(Fig.7-19)
Fig.7-19
(6) Remove the E-retainer for securing
the parking brake cable to the backing plate.
Remover the backing plate mounting bolts
and detach the backing plate from the drive
axle body. (Fig.7-20)
Fig.7-20
(7) Remove the operating cylinder boot

Top rod seal ring Seal ring Spring
and push all parts out of the cylinder. (Fig.7- Piston
Pump body
21)
Deflation screw
Fig.7-21
7.2.2 Inspection of Wheel Brake

Inspect all parts to make sure if there's any worn or damaged
part. If necessary, repair or replace with new one.
(1) Check the operating cylinder body's inner surface and the
piston periphery surface for rusting. Then, measure the clearance
between the piston and cylinder body.
Specified clearance: 0.03～0.10mm
Maximum clearance:0.15mm
(2) Visually check the piston cup of the operating cylinder for
damage or deformation. If necessary, replace it.
-76-
(4) Check the friction piece for thickness
to see if it is excessively worn. If necessary,
replace it.
Unit: mm
1-1.8t 2-2.5t 3-3.5t

Standard 4.87 7.2 8
Max. 2.5 5.0 6
Fig.7-22
(5) Check the inner surface of brake drum

for damage and excessive worn. If necessary,
repair or replace it.
Unit: mm
1-1.8t 2-2.5t 3-3.5t
Standard 254 310 314
Max. 256 312 316
Fig.7-23
7.2.3 Wheel Brake Remounting

(1) Apply brake fluid to the piston and piston cup and reinstall spring, cup, piston and
dust cover in this order.
(2) Install the operating cylinder on the backing plate.
Torque moment for bolts:
1-1.8t: 8-12 N.m
2-2.5t:14.7-19.6 N.m
3-3.5t:17.6-26.5N.m
(3) Install the backing plate on the front axle.
Torque moment for bolts:120-140N.m
-77-
(4) Apply lubricating oil on the a, b, c, d and
e points indicated in Fig.7-20.
(a) Contact surfaces between backing plate
and brake shoe
(b) Anchor pin
(c) Contact surfaces between shoe and
spring seat
(d) Anchor pin, parking puller
(e) Screws of the adjuster and other rotating Fig.7-24
part
(5) Install the brake cable assembly on the
backing plate with an E-retainer.
(6)Install shoes on the backing plate with
hold-down springs.
Fig.7-25
(7) Put the spring on the parking push rod
and then install the rod on the shoe.
(8) Install the shoe guide plate on the anchor
pin, and install the shoe return spring.
(9)Install the clearance self-adjuster,

adjuster spring, push rod and its return spring.
★Pay attention to the following points: Fig.7-26
(a)Adjuster thread direction and its
mounting direction.
(b)Adjuster spring direction. (Do not allow
the adjuster gear teeth to contact with the spring)
(c)Return spring direction of the push rod.
(Spring hook at anchor pin side should be located
at the opposite side to push rod)
(d) Make sure that the adjusting lever lower
end is in contact with the adjuster gear teeth.
Fig.7-27
-78-
(10) Install the braking oil pipe on the
operating cylinder.
(11) Measure the inner diameter of
drum and the outer diameter of shoe. Adjust
the adjuster to obtain the difference needed
between the drum inner diameter and the
friction piece outer diameter.
Specified difference: 1mm
Fig.7-28
7.2.4 Operation Test to Clearance Self-adjuster
(1) Make the brake shoe diameter approach the specified mounting size, and pull the
adjusting lever with your finger along the arrow marks to turn the adjuster gear. When
removing off your finger, the adjusting lever should return to its original position without
rotation of the adjuster gear.
Note: Even if the adjuster gear turn back along with the adjusting lever motion when
removing your finger, the adjuster will still operate normally after it is built in the machine.
(2) If the adjuster fail to do the above operation when the adjusting lever is pulled,
proceed with the following inspection.
(a) Make sure that the adjusting lever, push rod, return spring for push rod are securely
installed.
(b) Check the push rod return spring and adjuster spring for deterioration, and also check
the adjuster gear for rotating condition and undue wear or damage of the meshing section. Also
check if the adjusting lever is in contact with the gear.
Fig.7-29
-79-
7.2.5 Wheel Brake Troubleshooting
Problem Probable Cause Remedy
(1)Fluid leaks from brake system. Repair
(2)Maladjustment of brake shoe clearance. Adjust the adjuster
(3)Brake overheating. Check for dragging
(4)Poor contact between brake drum and Readjust

Poor Braking friction piece.
(5)Foreign matter adhered on friction piece. Repair or replace
(6)Foreign matter mixed in brake fluid. Check brake fluid
(7)Maladjustment of brake pedal (inching Adjust
valve).
(1)Hardened friction piece surface or Repair or replace
foreign matter adhered thereto.
(2)Deformed backing plate or loose bolts. Repair or replace

Noisy Brake
(3)Deformed shoe or incorrect installation. Repair or replace
(4)Worn friction piece. Replace
(5)Loose wheel bearing. Repair
(1)Oil-contaminated friction piece. Repair or replace
(2)Maladjustment of brake shoe clearance. Adjust the adjuster
Uneven Braking (3)Malfunctioning operating cylinder. Repair or replace
(4)Shoe return spring deteriorated. Replace
(5)Deflected drum. Repair or replace
(1)Brake fluid leaks from system. Repair
Soft or Spongy (2)Maladjustment of brake shoe clearance. Adjust the adjuster
Brake (3)Air mixed in brake system. Bleed air
(4)Maladjustment of brake pedal. Readjust
-80-
8. Hydraulic System
Table 1
Truck Model 1-1.5t 1.8t 2-2.5t 3t 2-3t 3.5t
Diesel Diesel Diesel Diesel Diesel Diesel
Item Engine Engine Engine Engine Engine Engine
Engine Model KUBOTA V2403 KUBOTA V3600
Type Gear pump
Main Pump
CBHZ-F28.2 CBHZ-F31.5
Model CBTDGZ-F420-ALΦ CBHZ-F23- ALΦ
- ALΦL - ALΦL
Displacement 20ml/r 23ml/r 28.2ml/r 31.5ml/r

Type Two-pool type with relief valve, flow divider and tilt valve
Control Valve
Setting Pre. 17.5MPa 21MPa

Dividing Pre. 9 MPa
Flow Rate 11 l/min
Type Single-action piston type with cut-off valve
Lift Cyl.
Bore Dia. Φ40 Φ45 Φ50 Φ45/Φ50 Φ56

Stroke 1495mm(Only for lift height of 3m)

Tilt Cyl.
Bore Dia. Φ63 Φ80
Stroke 114mm 129mm 165mm

Oil Amount 43L 65L
-81-
Table 2
Truck Model 2-2.5t 3t 3.5t 2-3t 3.5t 2-3t
Engine Model ISUZU 4JG2PE-01 HJ493 CA498
Type Gear pump
Main Pump
CBHZ-F23 CBHZ-F25 CBHZ-F28.2 CBHZ-F26.5 CBHZ-F28.2 CBHZ-F23-

Model
-ALΦ -ALΦ -ALΦ -ALΦ -ALΦL ALΦL
Displacement 23ml/r 25ml/r 28.2ml/r 26.5 ml/r 28.2ml/r 23ml/r

Control Valve
Setting Pre. 21MPa

Dividing Pre. 9 MPa
Flow Rate 11 l/min 13 l/min
Lift Cyl.
Bore Dia. Φ45 Φ50 Φ56 Φ45/Φ50 Φ56 Φ45/Φ50


Tilt Cyl.
Bore Dia. Φ80
Stroke 129mm 165mm 129mm 165mm 129mm

Oil Amount 65L
-82-
Table 3
Truck Model 3.5t 2-2.5t 3t 3.5t 2-2.5t 3t
Engine Model CA498 ISUZU C240PKJ-30 ISUZU C240PKJ-32
Type Gear pump
Main Pump
CBHZ-F26.5 CBHZ-F26.5 CBHZ-F28.2 CBHZ-F31.5 CBHZ-F26.5 CBHZ-F28.2

Model
-ALΦ -ALΦL -ALΦL -ALΦL -ALΦL -ALΦL
Displacement 26.5ml/r 26.5ml/r 28.2ml/r 31.5ml/r 26.5ml/r 28.2ml/r

Control Valve
Setting Pre. 21MPa

Dividing Pre. 9MPa
Flow Rate 11 l/min 13 l/min
Lift Cyl.
Bore Dia. Φ56 Φ45 Φ50 Φ56 Φ45 Φ50


Tilt Cyl.
Bore Dia. Φ80
Stroke 165mm 129mm 165mm 129mm

Oil Amount 65L
-83-
Table 4
Truck Model 2-3t 3.5t 2-3t 3.5t
Gasoline Gasoline Gasoline Gasoline
Item Engine Engine Engine Engine
Engine Model NISSAN K21 NISSAN K25
Type Gear pump
Main Pump
CBHZ-F28.2 CBHZ-F31.5 CBHZ-F28.2 CBHZ-F31.5

Model
-ALΦ -ALΦ -ALΦ -ALΦ
Displacement 28.2ml/r 31.5ml/r 28.2ml/r 31.5 ml/r

Control Valve
Setting Pre. 21MPa

Dividing Pre. 9MPa
Flow Rate 11 l/min
Lift Cyl.
Bore Dia. Φ45 Φ56 Φ45/Φ50 Φ56


Tilt Cyl.
Bore Dia. Φ80
Stroke 129mm 165mm 129mm 165mm

Oil Amount 65L
-84-
Lift cyl. Cut valve Tilt cyl.
Relif valve
Control valve
Steering cyl.
Steering box
Divide
Oil filter
Gear pump
Fig.8-1 Working Principle of the Hydraulic System(Manual Braking)

Lift cyl. Cut valve Tilt cyl.
Relif valve
Control valve
Steering cyl.
To brake
Brake valve
Steering box
Divide
Gear pump Oil filter
Fig.8-2 Working Principle of the Hydraulic System(Dynamic Braking)
-85-
The hydraulic system is mainly composed of dynamic mechanism, actuating mechanism,
operating mechanism and auxiliary unit. High-pressure oil flows out of the main pump
entering control valve and is herein divided into two parts by flow divider: one part is sent to
lifting or tilting cylinder and the other at a constant flow to the braking valve and steering unit
for dynamic braking and controlling steering cylinder. As the lifting and tilting spool valves
stay at the neutral position, high-pressure oil directly returns to the oil tank through the
passage. As the lifting spool valve is pulled, high-pressure oil passes through throttle valve to
the lifting cylinder to push forward the plunger rod. As the lifting spool valve is pushed, the
lower part of plunger of the lifting cylinder links to low pressure descending the plunger rod
by its own weight or goods weight. At this time, oil flowing out of the lifting cylinder passes
through the throttle valve having control of the descending speed. As the tilting spool valve is
operated, high-pressure oil flows into the front chamber of the tilting cylinder and the other
side links to low pressure making the mast fulfill backward or forward tilting action. The
working principle of the hydraulic system is as shown in Fig.8-1(manual braking) and Fig.8-
2(dynamic braking).
8.2 Maintenance of the Main Parts
8.2.1 Main Pump
The gear pump used for the forklift has a pair of external-engagement gears and the
working principle is as shown in Fig.8-3. A pair of engaged involute gears is fixed inside the
housing of the pump with the two end faces of the gears being sealed up. The gears divide the
housing into two airtight oil chambers - sucking chamber and draining chamber. When the gear
rotates arrow-wise as shown in the figure, the volume increases on
the right forming vacuum there, under the
air pressure, the tank oil passes through
the oil suction pipe of the pump into the
sucking chamber, filling in the inter-tooth
space. With the rotation of gears, the
inter-tooth space of each gear brings oil Press oil Suction oil
from right to the left chamber, increasing

the oil pressure in the left and the oil is
outputted from the oil press opening. As
the gear wheels rotate continuously, the
pump will keep sucking and draining oil Fig.8-3 Working Principle of the Gear Pump
-86-
The main pump consists mainly of a pump body, a pair of gears, lining plates and snap
rings. This pump uses pressure-balance type bearings and a special lubrication method so as to
minimum the clearance of the gear face.
Fig.8-4 Main Pump

(1)Pump body (2)Driving gear (3)Driven gear
(4)Front cover (5)Rear cover
(6)Lining plate (7)Ring (8)Snap ring (9)Oil
seal (10)Snap ring
8.2.2 Control Valve

The control valve (2 spool type) consists of four valve
housings, two spools, one relief valve and one flow divider. The
four valve housings are assembled together with three stud bolts
and nuts. The tilt spool valve consists a tilt lock valve.
-87-
Fig.8-5 The 2 Spool Type Control Valve
(1)Lift spool valve

(a)Neutral position
The high pressure oil discharged
from the pump returns to the oil tank
through the mid-passage.
(b)Pushing-in of Spool (Fig.8-7)

In this time, the spool is pushed Fig.8-6 Neutral Position
in to close the mid-passage. This
causes the oil from the main oil inlet
to push up the inlet check valve and to
flow into the port “B”. The return oil
from the port “A” flows through the
low-pressure passage to the oil tank
and the spool is restored to its neutral
position by the return spring. Fig.8-7 Pushing-in Position
-88-
(c) Drawing-out of Spool (Fig.8-8)
With the mid-passage closed, the oil
from the main oil-inlet pushes up the
check valve and flows into the port “A”.
The return oil from the port “B” flows
through the low-pressure passage to the
oil tank. The spool can be restored to its
neutral position by return spring.
Fig.8-8 Drawing-out Position
(2) Tilt-lock valve
Tilt spool valve housing contains a tilt lock valve. The tilt lock valve is intended to
prevent vibrations of the mast resulting from the negative pressure in the tilt cylinder and also
to avoid danger incurred from mishandling of the spool. On the conventional model, even if
the engine is not running, the mast can’t be tilted forward by actuating the tilt lever. But this
newly adopted tilt-lock valve does not allow the mast to tilt forward when the engine is at rest,
even if the tilt lever is pushed with a full load.
(a) Pull-out state of the spool valve Morin inlet volue
Single-woy volue Port B
Port A
is the same as shown in Fig.8-7 and the
neutral position state as shown in Fig. 8-9.
Spring
Spool valve Low-pressure possage Middle possage
(b) Push-in state of the spool valve

(of the pump at work) (Fig. 8-10) Fig.8-9 Neutral Position
As the spool valve is pushed in, oil
coming from the pump enters into
cylinder through relevant interface “B”.
Additionally, oil returning from the
cylinder enters into the spool hole “A”
and the follow-up valve works. So, the
returning cylinder oil passes through valve
spool holes “A” and “B” backs into
cylinder along the low-pressure passage. Fig.8-10 Tilt Forward
-89-
(c) Push-in state of the spool
valve (of the pump not at work) (Fig.8-
11)
As the pump stops working, spool
valve is pushed in, there is no oil
flowing into the cylinder interface “B”
and pressure at part “B” does not rise.
Consequently, the follow-up valve
does not work; oil at the cylinder
interface “A” cannot go back to Fig.8-11 Tilt Backward
cylinder and the cylinder is inactive.
(3) Relief valve and flow divider (See Fig.8-12)

The relief valve consists of main valve and proceeding valve. When the spool of the
control valve is operated, chamber linked with the operating cylinder is filled with high-
pressure oil. The high-pressure oil affects proceeding valve through throttle hole. If the system
pressure is higher than the setting pressure, the proceeding valve will be opened to make the
pressure lower and thus causes the main valve to move right, then the oil may directly flow to
low-pressure passage and reduce the pressure of the high-pressure chamber. In this way, the
system pressure may keep unvaried. The setting pressure may be adjusted by adjusting the
screw of the relief valve.
The construction of the flow divider is quite simple. It is of direct overflow type, and
ensures the constant pressure of the power steering system by
balancing the oil pressure with fixed spring force. When turning,
gets through with the high-pressure passage. If the oil pressure is
higher than the spring force, the poppet moves right, causing the
high-pressure oil to flow directly to the low-pressure passage and
keeping the pressure of the power steering system unvaried. The
setting pressure is adjusted by the adjusting screw.
Poppet is a balance type spool valve and may move right of
left according to the variety of the Oil flow and pressure passing
through it to change the opening of two chambers and ensures the
-90-
Poppet of flow divider
Throttle b Oil inlet
Throttle role a
Spring Value body
Throttle c
Plug of flow divide Balance value
Flow divide
Relif value
Fig.8-12 Relief Valve and Flow Divider
(4) Setting pressure

Do not adjust the pressure of the main relief valve at will. If necessary, you first loose the
lock nut, and then adjust the adjustive screw. When you turn the screw left, the pressure goes
down. When you turn the screw right, the pressure goes up. After you get the pressure that you
need, screw down the lock nut.
8.2.3 Operating of the Control Valve
As shown in Fig.8-13, all the spool valves of the control valve
are operated through levers that are mounted on a connecting shaft
fixed on the support plate via bracket. The bracket is mounted at
the right side of the forklift frame and the action of the lever is
transmitted to the spool valve via a connecting rod.
-91-
Fig.8-13 Operating of the Control Valve
(1)Handle (2)LeverⅠ (3)LeverⅡ (4)Shim plate
ass'y (5)Pin
(6)Washer (7)Pin (8)Bracket ass'y (9)Bolt M10
(10)Washer 10
(11)Washer 10 (12)Bolt M8 (13)Washer 8 (14)Washer 8
(15)Connecting shaft
(16)Screw M8 (17)Bolt M10 (18)Cushion (19)Sleeve
(20)Washer 10
(21)LeverⅢ (22)LeverⅣ (23)Nut M12
Cautions for the installation and operation of control valve:
-92-
(a) Before the mounting the control valve, the cushion and sleeve must be mounted inside
the plate hole of the bracket.
(b) When the control valve is mounted, the bolt must be screwed tight in order to prevent
the damage to the safety valve and joint etc.
(c) The cushion assembly shall be firstly mounted before the lever is mounted, after that
the operating levers pass through the slot holes on cushion assembly in turn from left to right
(the operating levers are mounted in turn from up to down), fix the operating levers onto the
valve rod of the control valve, then mounted it with the connecting shaft and get it fixed.
(d) The first and second pieces of handle mounted are used for lifting and tilting
respectively, the third and fourth for attachments and the corresponding handles should be
mounted according to the attachments. When mounting each handle, adjust well each height
and then use nut to screw tight.
8.2.4 Lifting Cylinder
The lifting cylinder is of plunger type, which consists of cylinder body, plunger &
plunger rod, cylinder cover, cut-off valve and sealing parts etc., (refer to Fig. 8-14) The
cylinder cover is equipped with bushing and oil seal to support plunger rod and prevent the
dust from entering. When the lifting spool valve of the control valve is put at the rising
position, the hydraulic oil shall move from flow divider to control valve and enter into the
cylinder. The oil liquid shall push the plunger rod to rise through pressure difference and thus
the goods is then lifted. When the lifting spool valve of the control valve is put at descending
position, the combined functions of the self-weight of goods, mast, lift bracket and plunger
will cause the plunger rod to descend and the hydraulic oil is pressed back to the oil tank. As
there is cut-off valve being mounted at the cylinder bottom (refer to
Fig.8-15), if the mast is lifted, the breaking of high-pressure pipe
can play the role of protection.
-93-
Fig.8-14 Lifting Cylinder
(1)Plunger rod (2)Dust ring (3)Cylinder cover (4)U-ring
seal (5)Bushing
(6)Plug (7)O-ring seal (8)Snap ring
(9)Cylinder body(L.) (10)Retainer
-94-
Cut-off Normal
Fig.8-15 Cut-off Valve
▲Working Principle of the Cut-off Valve

When moving back to oil tank the pressure oil in the lifting cylinder will pass through
holes A hole and B on the valve spool. If the flow velocity of the oil that passes the hole is less
than the set value of the valve, the pressure difference between the front and back of the valve
spool shall be less than the spring force. At this moment the valve spool stands still and the
slide valve does not act.
If the flow velocity that passes the valve spool exceeds the set value due to the breaking
of high-pressure pipe or other reasons, the pressure difference between the front and back of
the valve spool will be bigger than the spring force and cause the valve spool to move
leftward. Thus A hole closes, small amount of oil flows out from B
hole and the goods descends slowly.
▲Flow Regulator Valve
The flow regulator valve, located in the lift cylinder circuit to
limit the descending speed of loaded forks, has the construction as
shown in Fig.8-15. When the lift spool is placed in the “lift”
position, the oil from the control valve flows through the oil
chambers A and B, oil holes C, D, E and F, and the chamber G to
the lift cylinder without any regulator. When the lift spool is placed
in the “down” position, the oil flows in the reverse direction. When
the oil passes the orifice plate (5) and a pressure difference
generates between the chambers A and B, the pressure difference
-95-
Fig.8-16 Flow Regulator Valve
(1)Nipple (2)Spring (3)O-ring seal (4)Snap ring (5)Orifice plate
(6)Sleeve (7)Valve core (8)Ball (9)Spring (10)Valve body
8.2.5 Tilt Cylinder (Fig.8-17)

The tilt cylinder is of double-acing type. Each truck has two tilt cylinders which are
installed on two side of the mast assembly with pin while their piston rod ends are connected
with the outer mast channels. The tilt cylinder assembly consists primarily of piston, piston
rod, cylinder body, cylinder base, guide sleeve and seals. The piston, welded to the piston rod,
is fitted with two Yx-rings and one wear ring on its circumference. A bushing press-fitted to
the inner side of the guide sleeve supports the piston rod. The guide
sleeve is fitted with dust seal, snap ring, Yx-ring and O-ring to
prevent oil leakage and keep dust off. Fitted with them, the guide
sleeve is screwed into the cylinder body.
When the tilt lever is pushed forward, the high-pressure oil
enters into the cylinder body from the cylinder tail, moving the
piston forward and causing the mast assembly to tilt forward until 6
degrees. When the tilt lever is pulled backward, high-pressure oil
enters into the cylinder body from the guide sleeve and moves the
piston backward, tilting the mast backward until 12 degrees.
-96-
Fig.8-17 Tilt Cylinder
(1)Joint (2)Dust ring (3)Snap ring (4)Yx-ring seal (5)O-ring seal
(6)Guide sleeve (7)Bushing (8)O-ring seal (9)Piston rod (10)Cylinder body
(11)Yx-ring seal (12)Wear ring (13)Piston (14)Yx-ring seal
8.2.6 Oil Tank

The oil tank is a part of the frame located on the right box body. There are a inlet filter
and a return filter in the oil tank.
To main pump
1.Bolt
2.Washer
3.Breather
4.Cap
5.Drain Plug
6.Washer
7.Inlet filter
return oil from control value 8.Return filter
return oil from stearing unit 9.Coverplate assy
Fig.8-18 Oil Tank 10.Cover gasket
-97-
8.3 Maintenance of Main Pump
8.3.1 Make-up of the Main Pump
The main components consist of pump body, front-end cover, back-end cover, driving and
driven gear and oil seal etc, the basic structure of which is shown as Fig. 8-18.
Fig.8-19 Main Pump

(1)Pump body (2)Driving gear (3)Driven gear (4)Front
cover (5)Rear cover
(6)Lining plate (7)Seal ring (8)Ring (9)Oil seal
(10)Snap ring
-98-
8.3.2 Disassembly
▲Cautions:
(a) Before disassembly, make sure if there exits oil leakage at the joint interface between
oil seal, pump body, pump cover and on other parts.
(b) Before disassembly, through washing should be done. The components already
disassembled should be placed on clean paper or cloth, be careful not to get dirty or damage
the components.
(c) To avoid wrong installation, proper marking should be made according to the
“disassembly sequence”.
(d) Get the sealing parts, sealing ring and oil seals ready before disassembly.
(e) Prepare the special tools such as torque spanner and spring chuck clamp etc. for
disassembly.
(1)Clamp the flange part of the pump
onto the clamp table and fixed well as
shown in Fig.8-19. Note: for easy
installation, use oily pen to make marking
at the rear-end cover, front-end cover and
the driving gear of the pump body.
Fig.8-20
(2)Remove four connecting bolts. (as

shown in Fig.8-21)
Fig.8-21
-99-
(3)Use copper rod or wood hammer to
slightly knock the side of pump body and
remove the rear-end cover. (as shown in
Fig.8-22)
Fig.8-22
(4) Take down the pump body. When

the sealing ring is left at pump-body side,
move it to the side of rear-end cover. (as
shown in Fig.8-23)
Fig.8-23
(5) Remove the lining plate. Note:

make marking at the driving gear side on
lining plate of the rear-end cover. (as shown
in Fig.8-24)
(6) Dismantle the driving gear. Note: Fig.8-24

make marking on bearing side of the
driving gear. (as shown in Fig.8-25)
Fig.8-25
-100-
(7) Press down the front-end lining
plate to dismantle the driving gear. (as
shown in Fig.8-26)
Fig.8-26
(8) Remove the lining plate. Note:
make marking on the driving gear side on
the front lining plate. (as shown in Fig.8-27)
Fig.8-27
(9) Reserve and then fix the front-end

cover, take out the spring gasket. (as shown
in Fig.8-28)
(10)Take out oil seal. (as shown in

Fig.8-28
Fig.8-29)
Fig.8-29
-101-
8.3.3 Inspection
The disassembled parts except rubber
parts should be washed with light oil.
(1) Pump body inspection
If the scraping trace is up to 1/2 long
of the inner periphery, it indicates that the
Fig.8-30
bearing and gear shaft are subject to
excessive wear, replace the pump body.
(2) Inspect the contact surface of the

lining plate. If the surface is worn or its
thickness in smaller than the specified
value, replace the lining plate.
Specified thickness: 4.94mm
Fig.8-31
(3)If the inner surface of bushings of

the front and rear cover discolored, replace
it.
Fig.8-32
(4) Inspect the driving gear and the

driven gear. If they are worn, replace them.
If the dimension D is smaller than the
specified value, replace a pair.
D=20.961mm
Fig.8-33
-102-
(5) Replace seal rings, bushings, rings,
oil seals and snap rings as require.
8.3.4 Installation
(1) As shown in Fig.8-34, fix the front-
end cover on the clamp table.
Fig.8-34
(2) Fix a new sealing ring onto the

pump front-end cover. Note: do not twist.
Fig.8-35
(3) Install a new snap ring onto the

pump front-end cover with mounting
direction as shown in Fig.8-36.
Fig.8-36
(4) Put the pump body into the front-
end cover, be careful of direction of the
pump body.
Fig.8-37
-103-
(5) Mount the lining plate at groove
place of the front-end cover, be careful not
to mistake the oil-suction port with the oil-
discharging port and note direction of the
lining plate.
(6) Mount the driving gear into the

Fig.8-38
pump body with its spline side pointing
down.
Fig.8-39
(7) The driven gear is mounted into the
pump body with mounting direction shown
in Fig. 8-40.
Fig.8-40
(8) Fix the back lining plate into the
pump body, mount the lining plate at gear
side to make the groove in alignment with
the gear point. Take care not to mistake the
oil-suction port side with the oil-
discharging port side.
Fig.8-41
-104-
(9) Mount the sealing ring and snap
ring into the groove of back-end cover and
at the same time apply lubrication grease at
place of the sealing ring.
(10) Make the sealing ring of back-end Fig.8-42
cover pointing down and mount it into the

pump body. Take care not to mistake the
oil-suction port with the oil-discharging
port.
Fig.8-43
(11) Mount and tighten the connection

bolt to required torque at 9～10kg.m.
Fig.8-44
(12) Take off the pump from the clamp
table, put the lubrication grease on outer
ring and lip of the oil seal, then fix the
pump into the front-end cover by means of
mould.
Fig.8-45
-105-
(13) Mount the spring check ring by
chuck clamp and fix the oil seal.
Fig.8-46
8.3.5 Trial Run
After installing the gear pump in the truck, check it reassembled for specified
performance and do the running-in for it. If the pump’s gears are seized or internal parts worn
excessively, you should renew the hydraulic oil and filters or strainers or clean them. The trial
run procedures are as follows:
(a) Install the gear pump in the truck. Then install a pressure gauge in the pressure
inspection port of the control valve.
(b) Loosen the adjustment screw of the relief valve and run the pump at 500 to 1000rpm
for ten minutes. The oil pressure should be lower than 10 kg/cm2.
(c) Increase the speed of the pump to 1500 to 2000 rpm for ten minutes.
2
(d) Without the charge of the speed in step (c), increase the pressure to 20～ 30 kg/cm
2
and run the pump for five minutes. Then increase the pressure to 210 kg/cm . Each circuit
works for five minutes and then renew the return filter. During the increase of the pressure,
observe the change of oil temperature and pump body surface temperature and working voice.
If the oil temperature or pump body surface temperature is excessively high, discharge the
pump to adjust the temperature.
(e) After the trial run, measure the flow amount through lift
speed with the pressure of 210kg/cm2 of the relief valve.
8.4 Maintenance, Trouble Analysis and Trouble Shooting
of the Hydraulic System
8.4.1 Maintenance
Check whether there exits seepage or serious oil leaking
phenomenon on the pipe joint, lifting cylinder, tilting cylinder, oil
pump, full-hydraulic steering unit and steering cylinder of the
transmission system before and after the work shift. Check whether
there is enough operation oil inside the operation oil tank. Check
and clean the filter screen of the oil filter inside the operation oil
-106-
8.4.2 Trouble Analysis and Troubleshooting
Trouble Cause Trouble shooting
(1)Excessive wearing between the (1)Replace the wearable parts or oil

oil pump gear and pump body and pump.
wider-than-normal gap.
(2)Wearing and wider-than-normal (2)Replace with new piston sealing
gap of the piston sealing part in the ring.
lifting cylinder, excessive inner
leakage.
(3)Failure of safety valve spring of (3)Replace with new spring.
control valve.
(4)Excessive oil leakage due to (4)Chromium plating the valve rod
Insufficient
wearing between the control valve to couple with the hole with the gap
Lifting
rod of control valve and valve body. at 0.01～0.02.
Capacity
(5)Oil leakage among valve bodies (5)Change the sealing ring, screw
or Unable
of the control valve . tight the screw in sequence.
to Lift
(6)Oil leakage in hydraulic pipe. (6)Check to see whether there is
damage to the sealing ring or
connecting nut and screw tight the
pipe joint.
(7)Higher-than-normal temperature (7)Replace the unqualified hydraulic
of hydraulic oil (should be ≤80℃), oil, stop
e x c e s s i v e o i l d i l u t i o n a n d operation
insufficient flow. to lower
(8)Excessive load. o i l
temperatu
(1)Leakage inside the piston YX- re and try
Excessive ring seal of the lifting cylinder. to find the
Downwards (2)Inner leakage of A type spool cause of
Sliding for valve of the control valve. over high
Piston Rod of (3) Oil leakage of the lifting portion. o i l
the Lifting temperatu
Cylinder re.
-107-
(1)Oil leakage due to wearing of (1)Replace the ring seal.

ring seal at fasteners.
(2)Hydraulic oil is contaminated (2)Discharge air and add hydraulic
with air to form foam, air leakage at oil.
oil suction pipe-work, insuffi-cient
hydraulic oil.
Insufficient (3)Damaged ring seal inside the (3)Replace.
Pressure of pump cover groove.
Oil Pump (4)Wearing of the end face of (4)Replace.
bearing sleeve.
(5)Oil pump gear wears. (5)Replace the oil pump.
(6)Wrong rotation direction of oil (6)Correct.
pump.
(1)Inner leakage of control valve. (1)Replace O-ring seal, repair valve

rod and reassign the coupling gap
between valve rod and hole to
0.01～0.02.
(2)Inner leakage due to the damaged (2)Replace.
O-ring seal of piston rod of the
tilting cylinder.
Excessive (3)Oil leakage due to the damaged (3)Replac
Self Tilting YX-ring seal and O-ring seal in the e.
of the Tilting pilot sleeve.
Cylinder
-108-
(1)Insufficient oil supply of oil (1)Select appropriate oil pump or

pump, the slow-steering hand wheel check to see if the oil pump is
feels relatively light and the fast- normal.
steering hand wheel heavy.
(2)Air in the steering system, foam (2)Discharge air in the system and
in oil, making irregular noise, the check the oil suction pipe-work.
hand wheel can rotate while the oil
cylinder can not keep continuous
motion.
(3)Failure of the steel ball one-way (3)Check if the steel ball exists and
Heavy valve in the valve body, both the fast if there is dirty stuff blocking the
Steering and slow steering hand wheels are steel balls.

heavy, also no pressure at steering.
(4)Pressure of the overflow valve is (4)Adjust pressure of the overflow
lower than working pressure or the valve or clean it.
overflow valve is blocked by dirty
stuff, light steering in case of light or
no load, heavy steering when adding
load.
(5)Excessive viscosity of the oil (5)Use oil liquid with recommend-
liquid d e d
viscosity.
-109-
9. Load System
1-1.8t:
Type: Rolling type, L-shaped inner mast, C-shaped outer mast with free lift, 2-stage
telescopic mast.
Cross section of inner mast: Cross section of outer mast:
Fig.9-1 Fig.9-2
Roller:
Roller Φ112.3mm
Retaining roller Φ80mm
Side roller Φ91.5mm
Side roller Φ40mm
Lift:
Lifting chain LH1223
Fork, mast lifting system Hydraulic
Mast tilting device Hydraulic
Fork spacing adjustment Manual
-110-
2-3.5t:
Type: Rolling type, L-shaped inner mast, C-shaped outer mast with free lift, 2-stage
telescopic mast.
Cross section of inner mast: Cross section of outer mast:
Fig.9-3 Fig.9-4
Roller:
Roller Φ119.2mm
Retaining roller Φ109.7mm
Side roller Φ58mm
Lift:
Lifting chain LH1623
Fork, mast lifting system Hydraulic
Mast tilting device Hydraulic
Fork spacing adjustment Manual
-111-
The loading system is of the two-stage, rolling telescopic mast type and consists of inner
mast, outer mast and carriage.
9.2 Inner and Outer Masts
The inner and outer masts are welded parts. The bottom of outer mast is connected with
the frame support through supporting. At the outside middle of outer mast, there are tilt
cylinder connected with the frame. The mast assembly can be tilt forward and backward by
operating the tilt cylinder. The outer mast has C-shaped cross section and there are roller and
side roller on the upper part of it.
The inner mast has L-shaped cross section and there is only roller at the bottom of it. The
main roller can not only bear radial force but also lateral force through adjusting its gap.
The maintenance of the main rollers and side rollers belongs to exalted maintenance.
Please be careful.
9.3 Carriage
The carriage moves up and down smoothly along the channel of the inner mast with main
rollers. The uppermost main rollers mounted on the main roller shafts and blocked by snap
rings. The other main rollers are not blocked by snap rings and will bear the lateral force
through adjusting with gasket the gap between the channel steel plate and the main roller. The
main roller shafts are welded on the carriage and the side rollers at the very top of vertical
column plate are fixed on the carriage by bolts. The longitudinal load is born by the main
rollers and the rollers above appear from the top of mast when the fork rises to the top. The
transverse load is jointly born by the side rollers and the main rollers at bottom end.
9.4 Roller Adjustment
(1) 1-1.8t
There are eight main rollers. They are separately mounted on
the upper end of the outer mast(2), lower end of the inner mast(2)
and two sides of the carriage(4). There are four side rollers. They
are separately mounted on the upper end of the outer mast(2),
upper end of the carriage(2).
The main rollers of the upper end of the outer mast and the
upper end of the carriage sustain the loads from front and rear
direction, the other main rollers sustain the loads from front and
rear direction and the side loads. The side rollers sustain the side
loads from left and right direction. The main rollers and side rollers
-112-
Inner mast Carriage
Side roller
(upside of carriage)
Underside shim adjustrment Upside
Main roller
(upside of outer mast)
No adjustmert
Main roller
(Underside of inner mast) Limiting shim
Shim adjustment
Shim adjustment
Lift cylinder
Fig.9-5 Roller Position
Side roller(upside of
carriage)0-0.5mm Shim Bosseyed contact
Main roller Shim
(underside of inner mast)
Shim adjustment
Main roller
(underside of carriage
Shim adjustment) Main roller
No adjustment
PlateA Bosseyed contact
Clearance:0-0.5mm
Fig.9-6 Roller Adjustment
-113-
Clearance 0-0.5mm
Bosseyed contact
Plate B Upper roller of carriage Plate B
Shim Shim
Fig.9-7 Adjustment of Main Rollers of the Carriage
Clearance between plate

B of inner mast

A of inner mast
Fig.9-8 Adjustment of Rollers of the Carriage
-114-
(2) 2-3.5t
There are ten main rollers. They are separately mounted on the upper end of the outer
mast(2), lower end of the inner mast(2) and two sides of the carriage(6). There are four side
rollers. They are separately mounted on the upper end of the outer mast(2), upper end of the
carriage(2).
The main rollers of the upper end of the outer mast and the upper end of the carriage
sustain the loads from front and rear direction, the other main rollers sustain the loads from
front and rear direction and the side loads. The side rollers sustain the side loads from left and
right direction. The main rollers and side rollers are coordinately used so that the inner mast
and carriage can move freely.
Inner mast Carriage

Side roller
(upside of carriage)
Underside Shim adjustment Upside
Main roller
No adjustment
Main roller
(Underside of inner mast) Limiting shim
Shim adjustment
Shim adjustment
Lift cylinder
Fig.9-9 Roller Position
-115-
Side roller(upside of
carriage)0-0.5mm Shim Bosseyed contact
Main roller Shim
(underside of inner mast)
Shim adjustment
Main roller
(under side of carriage
Shim adjustment) Main roller
No adjustment
PlateA Bosseyed contct
Clearance:0-0.5mm
Fig.9-10 Roller Adjustment
Clearance 0-0.5mm
Plate B Bosseyed contact

The second roller of carriage Plate B
Shim Shim
Fig.9-11 Adjustment of Main Rollers of the Carriage
-116-
No adjustment

B of inner mast

A of inner mast
Fig.9-12 Adjustment of Rollers of the Carriage
9.5 Maintenance
9.5.1 Adjustment of Lift Cylinder
When replace the lift cylinder, inner mast or outer mast, we shall readjust the stroke of the
lift cylinder as following.
(1)Install the piston rod in the upper beam of the inner mast without shims.
(2)Lift the mast slowly to the max. stroke of the cylinder and check the two cylinders
synchronize or not. If the movement stop not at the same time
which means different strokes of left and right cylinders. Adjust the
cylinder cover of left and right cylinder to get
their strokes synchronous.
(3)Then slowly lower the inner mast,
observe if the upper beam of the inner mast is
horizontal when reaching the bottom. Install
shims between the piston rod head of lower end
and the upper beam of the inner mast. The shims
are 0.2mm or 0.5mm thick.
(4)Adjust the tightness of lift chains. The
adjustment of the lift cylinder also belongs to Fig.9-13
-117-
9.5.2 Rust Protection and Maintenance of the Lift Cylinder
The moisture content of the atmosphere and salt fog will go into the cylinder through the oil
return pipe and the clearance between the sealing parts and other parts if the cylinder is not used
for a long time. And thus the piston rod and inside of the cylinder barrel will be corroded and the
exterior of the cylinder will become rusty. Once the cylinder gets rusty, it will be no longer
serviceable.
Rust protection and maintenance measures:
(1) Rust protection of the piston rod exposed outside: wipe the surface of the piston rod with
oil cloth evenly every one or two week in sunny days so as to form oil firm. If it is humid weather,
do as above every 3-5days.
(2) Rust protection of the interior of the cylinder: lift and lower the mast several times in
sunny days every 3-5 days to make the interior of the cylinder be fully oil lubricated; do the
above every 2-3 days in humid weather.
9.5.3 Carriage Adjustment
(1) Let the truck parking on the horizontal ground and make the mast vertical.
(2) Let the bottom of the fork contact with the ground. Adjust the adjusting nut for the
end nipple of the upper chain and make a distance A(19mm～20mm) between the main roller
and the carriage.
(3) Make the fork down to the ground and tilt backward fully. Adjust the adjusting nut for
the end nipple of the upper chain and make the two chains’ tightness equal.
Fig.9-14
9.5.4 Carriage Rollers Replacement

(1) Fork a tray on the fork and let the truck parking on the
horizontal ground.
-118-
(2) Make the fork and the tray down to the ground.
(3) Disassemble the end nipple of the upper chain
and take the chain down from the sheave. (Fig.9-15)
(4) Lift the inner mast.
(5) Make the truck back up if the carriage is fully
separated from the outer mast.
(6) Replace the main rollers.
(a) Disassemble all the snap rings and take the main
rollers down with a drawing tool and remain the shims.
(b) Ensure the new rollers are equal to the replaced Fig.9-15
ones. Install the new rollers inside the carriage and block.
9.5.5 Mast Roller Replace

(1) Use the same way as 9.5.3 to disassemble the carriage from the inner mast.
(2) Let the truck parking on the horizontal ground and wedge up the front wheels for 250
to 300mm.
(3) Apply the parking brake and wedge up the rear wheels.
(4) Disassemble the fitted bolts for the lift cylinder and the inner mast. Hang up the inner
mast not to loose the shims for the top of the piston rod.
(5) Disassemble the connecting bolts for the lift cylinder and the bottom of the outer
mast. Disassemble the lift cylinders and the oil pipes between the two cylinders without loosen
the oil pipe joints.
(6) Put down the inner mast. Disassemble the main rollers under the bottom of the inner
mast.
(7) Replace the main rollers.
(a) Disassemble the upper main rollers with a drawing tool, don’t loose the shims.
(b) Install the new rollers and the shims disassemble in step (a).
(8) Hang up the inner mast to let all the rollers go into the mast.
(9) Reassemble the lift cylinder and the carriage.
-119-
S63-5:2013

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FOREWORD

Ι. Safety Rules for Operation and Daily Maintenance of Forklift Truck 1

Outline Drawing of Forklift Truck

Rated Capacity (kg) 1000 1500 1750

Load Center (mm) 500 500 500

Max. Lifting Height (mm) 3000 3000 3000

Free Lift (mm) 151 155 158

Mast Tilt Angle (Fwd/Bwd) (°) 6/12 6/12 6/12

Lifting Speed Unloaded 620 620 620

Traveling Speed Loaded 17 17 17

Max. Drawbar Pull (kN) Loaded 17.8 17.8 17.8

Overall Length (without fork) (mm) 2166 2230 2273

Overall Width (mm) 1075 1075 1090

Overall Height Mast 1995 1995 1995

Wheelbase (mm) 1410 1410 1410

Front 890 890 920

Min. Underclearance (mm) 114 114 114

Front Overhang (mm) 401 405 408

Rear Overhang (mm) 355 415 455

Min. Turning Radius (mm) 1870 1950 1980

Min. Intersecting Aisle (mm) 1845 1925 1955

Weight (unloaded) (kg) 2220 2660 2660

Rated Capacity (kg) 1000 1500 1750

Load Center (mm) 500 500 500

Max. Lifting Height (mm) 3000 3000 3000

Free Lift (mm) 151 155 158

Mast Tilt Angle (Fwd/Bwd) (°) 6/12 6/12 6/12

Lifting Speed Unloaded 620 620 620

Traveling Speed Loaded 17 17 17

Max. Drawbar Pull (kN) Loaded 17.8 17.8 17.8

Overall Length (without fork) (mm) 2166 2230 2273

Overall Width (mm) 1075 1075 1090

Overall Height Mast 1995 1995 1995

Wheelbase (mm) 1410 1410 1410

Front 890 890 920

Min. Underclearance (mm) 114 114 114

Front Overhang (mm) 401 405 408

Rear Overhang (mm) 355 415 455

Min. Turning Radius (mm) 1870 1950 1980

Min. Intersecting Aisle (mm) 1845 1925 1955

Weight (unloaded) (kg) 2220 2660 2660

Rated Capacity (kg) 1000 1500 1750

Load Center (mm) 500 500 500

Max. Lifting Height (mm) 3000 3000 3000

Free Lift (mm) 131 135 138

Mast Tilt Angle (Fwd/Bwd) (°) 5/10 5/10 5/10

Lifting Speed Unloaded 660 660 650

Traveling Speed Loaded 16 16 16

Max. Drawbar Pull (kN) Loaded 16.6 17.1 17

Overall Length (without fork) (mm) 2936 3150 3193

Overall Width (mm) 1075 1075 1090

Overall Height Mast 1995 1995 1995

Wheelbase (mm) 1410 1410 1410

Front 900 900 930

Min. Underclearance (mm) 114 114 114

Front Overhang (mm) 401 405 408

Rear Overhang (mm) 355 415 455