Service Manual Fuoristrada

2.5-3.
5T Rough terrain forklift truck
SERVICE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.

06/2020
HANGCHA GROUP CO. , LTD.
■ Address For: OVERSEAS USERS

■ Address: 666 Xiangfu Road, Lin'an,Hangzhou, Zhejiang, China
■ Fax: 0086-571-88926789 0086-571-88132890 ■ ZIP:311305
■ Web: http://www.hcforklift.com ■ E-mail: sales@hcforklift.com
Foreword
2.5-3.5T Rough terrain forklift truck is a new developed forklift of Hangcha
Group.
It owns characteristics as High vehicle capacity, novel structure and superior
performance.
The manual is the introduction of structure, working principle and serving of
forklift truck.
For safety and performance of truck, all in charge of operation, maintenance
and management must read and comprehend this manual well.
The manual also applies to container fork-lift trucks.
It is forbidden anybody without training and qualification to maintain.
Only in the event that the truck manufacturer is no longer in business and
there is no successor in the interest to the business, the user may arrange for a
modification or alteration to a powered industrial truck provided, however, that the
user shall:
a) Arrange for the modification or alteration to be designed, tested and
implemented by an engineer(s) expert in industrial trucks and their safety;
b) Maintain a permanent record of the design, test(s) and implementation of
the modification or alteration;
c) Approve and make appropriate changes to the capacity plate(s), decals,
tags and instruction handbook;
d) Affix a permanent and readily visible label to the truck stating the manner
in which the truck has been modified or altered together with the date of the
modification or alteration, and the name and address of theorganisation that
accomplished the tasks.
© 06/2020 HANGCHA GROUP CO., LTD.

CONTENT
Foreword
Foreword ............................................................................................................................................. 4
Ⅰ. Power System ................................................................................................................................... 6
1.Engine for Forklift ....................................................................................................................... 6
Ⅱ.Drive system .................................................................................................................................... 11
1. Summarize ................................................................................................................................ 11
2. Hydrodynamic power transmission gear-box ........................................................................... 13
3. Driving axle ................................................................................................................................ 1
Ⅲ Steering system ................................................................................................................................ 16
1 Structure introduction .......................................................................................................... 16
2 Technical parameters .......................................................................................................... 20
3 Steering system installation notes ..................................................................................... 20
4 Fault diagnoses and corrections ....................................................................................... 22
5 Hydraulic steering gear ....................................................................................................... 22
6 Steering axle......................................................................................................................... 26
7.Steering axle(four-wheel drive rough terrain forklift truck)................................................ 29
8 Steering cylinder .................................................................................................................. 33
Ⅳ.Brake system ................................................................................................................................... 35
1 Summary............................................................................................................................... 35
2 Data ....................................................................................................................................... 36
3 Brake inching pedal adjustment ............................................................................................. 37
4 Parking brake adjustment ....................................................................................................... 38
5 Brake ..................................................................................................................................... 39
6 Master cylinder ..................................................................................................................... 41
7 Fault diagnoses and corrections ....................................................................................... 43
8 Brake schematic ................................................................................................................ 44
Ⅴ.Hydraulic system ............................................................................................................................. 44
1.Data ........................................................................................................................................... 44
2.Trouble diagnoses and corrections ............................................................................................ 45
3.Main pump ................................................................................................................................ 47
4. Control valve ............................................................................................................................ 49
5. Hydraulic piping ....................................................................................................................... 52
Ⅵ. Lifting system ................................................................................................................................. 56
1. Assemble debugging data ......................................................................................................... 56
2.Trouble diagnoses and corrections ............................................................................................ 57
3. Summary .................................................................................................................................. 60
4. Removal and adjustment .......................................................................................................... 65
5. Disassembly and installation of lifting jack.............................................................................. 70
6.Disassembly and installation of tilting cylinder ........................................................................ 71
7. Noticing proceeding of debugging ........................................................................................... 72
Ⅶ. Interactive instrument ..................................................................................................................... 74
7.1 Engine fault information display page.................................................................................... 74
7.2 Forklift operation parameters and interface switching between Chinese and English ........... 74
7.3 Settings page........................................................................................................................... 75
7.4 Disassembly and installation .................................................................................................. 79
Ⅷ.Electrical system ........................................................................................................................... 81
1 Control box assembly ............................................................................................................. 82
2 Instrument,sensor and relay .................................................................................................... 93
3 Lighting system .................................................................................................................... 97
Ⅰ. Power System
1.Engine for Forklift
Engine Diesel
Parameter QSF2.8T3NA49 (Cummins)
Rated power kw 36.5
Rated rotate
2500
r/min
Max Torque
186/1500
N·m/speed r/min
Service weight
248
kg
CPCD25-XW43E-RT
Forklift truck CPCD30/35-XW43E-RT
model CPCD25-XW43C-RT4
CPCD30/35-XW43C-RT4
Engine Diesel
Parameter 4TNE98
(Yanmar)
Rated power kw 42.1
Rated rotate
2300
r/min
Max Torque
186/1700
N·m/speed r/min
Service weight
194
kg
CPCD25-XW33E-RT
Forklift truck CPCD30/35-XW33E-RT
CPCD30/35-XW33C-RT4
6
Engine Diesel
Parameter V2607-CR-TE5B
(Kubota)
Rated power kw 47.3kW/2400 r/min
Max Torque
221.7N·m/1500 r/min
N·m/speed r/min
Service weight
272
kg
CPCD30/35-XW98E-RT2
Forklift truck CPCD30/35-XW98C-RT4
CPCD25-XW98E-RT2
Specifications, structure and maintenance methods :

4TNE92/98, Yanmar engine see ENGINE MAINTENANCE MANUAL.
QSF2.8 Cummins engine see ENGINE OWNERS MANUAL.

Engine power CO HC NOX HC+ NOX PM(granule)
(Pmax) (kW) (g/kW•h) (g/kW•h) (g/kW•h) (g/kW•h) (g/kW•h)
37≤Pmax <75 5.0 — — 4.7 0.40
18≤Pmax <37 5.5 — — 7.5 0.60
7
1.1 DPF every 6000 service hours（only Kubota engine）
◆ Cleaning of DPF
The longer the DPF runs, the more ash (burnt residue) is collected in the filter. Too
much ash build-up adversely affects the DPF performance.
Equipped with the DPF cleaning alarm system, clean the DPF in case of an
alarm or every 6000 operating hours.
Consult your local HANGCHA Dealer for this service or agents.
◆ DPF regeneration
DPF: Diesel Particulate Filter
Working state
Regeneration method 特点
regeneration type
Passive regeneration Normal operation of the forklift Obvious effect, no feeling
occurs naturally of users
Driving The forklift keeps regenerating
Easy to use, fuel saving
Active regeneration while working normally
regeneration Parking Forklift parking, idle running Warning to avoid DPF
regeneration regeneration damage
Repair status regeneration Engine Fault code

Processing method
type flashes
Connect to diagnostic
Service regeneration SPN: 3701 FMI: 16
equipment
DPF service maintenance SPN: 3701 FMI: 00 Need to be disassembled
 The DPF is designed to burn (DPF-regenerate) trapped particulate
matters in an automatic way.Depending on operating conditions,
however, the regeneration may fail to go through and these matters may build
up in the DPF. If the DPF warning lamp lights up and the manual
DPF regenerating switch indicator starts blinking, turn on the manual
DPF regenerating switch.
 Manual DPF regeneration may be required depending on the engine
operating situation. The manual regenerating procedure is referred to in the
operator’s manual of the connected machine.
 During manual DPF regeneration, the exhaust gas becomes hotter than
usual and its quantity increases.Check to see if there is nothing flammable around
and the place is well ventilated. Refer to the operator’s manual of the
connected machine.
 When the interval of DPF regeneration has become 5 hours or shorter routinely,
change the 2/5000 diesel oil fule for new one.
If this condition continues even after an oil change, Consult your local
HANGCHA Dealer for this service or agents.
8
1.2 Air inlet system
Also a monthly inspection should be taken on the tightness and seals for intake pipe
10 as well as other air intake pipes, retighten the clamp and bolts if necessary.
Quarter-yearly inspect pipe 6, replace in case of breakage and decay .
About maintenance for air filter, please refer to Operating and Maintenance manual.
1.3 Exhaust system
Frequently inspect the connection between exhaust pipe 4 and engine as well as
DPF 7（Diesel Particulate Filter）, retighten the bolts if any looseness. Timely replace the
muffler if any air leakage.
Check fastenning condition of high exhaust pipe 3 mounting bolts 3 and clip 6 if any
9
looseness.
If there is any abnormal sound heard from the exhaust system while truck operating
or after starting the engine, please stop and check whether exhaust systems loose, then
to retighten to solve the problem.
10
Ⅱ.Drive system
1. Summarize
1. Bolt 2. Nut 3. Washer 4. Tire assembly 5. Drive axle

6. Bolt 7. Washer 8. Hydraulic transmission box 9. Bolt 10. Washer
11. Bolt 12. Washer 13. Nut 14. Bolt 15. Cooling oil pipe
Fig. 2-1 Drive system（Two-wheel drive）
11
2
6 5 3
12 11 10 9 8 7 17 4 1
13 6 14 15 16 17 18 19 20 21 6 22 23
23
6
25
26
6
14
27
1. Wheel assy. 2. Bolt 3. Nut 4. Washer 5. Bolt 6. Right gearbox

seat
7. Right gearbox 8. Bolt 9. Coupling 10. Left gearbox 11. Left gearbox 12. Drive axle assy.
seat assy. seat seat
13. Spacer 14. Bolt 15. Pin 16. Nut 17. Gearbox assy. 18. Bolt
19. Washer 20. Nut 21. Bolt 22. Bolt 23. Cooling oil 24. Rear drive shaft
pipe assy. assy.
25. Bolt 26. Nut 27. Washer 28. Shock pad
Fig. 2-2 Drive system（Four-wheel drive）
12
2. Hydrodynamic power transmission gear-box
1.Domestic hydrodynamic power transmission gear-box：
1.1summary
Hydraulic transmission gearbox is composed of torque converter and power gearshift gearbox
that owns two forward gears and one reverse gear.
Torque converter: hydraulic torque converter is a combination torque converter with single
stage two phase three running wheel. Hydraulic torque converter makes the hydraulic
transmission gearbox own automatic adaptability of hydraulic transmission output, change its
output torque and speed correspondingly as change of the variation of the external load, and can
absorb and remove impact vibration to the transmission system from the engine and external
load .
Power from engine, with torque effect of torque converter, transfers to the input shaft
assembly of gear box(forward clutch) through spline coupling by torque converter turbine.
Transmission gear box includes input shaft assembly(forward clutch), intermediate shaft(reverse
clutch), output gear, output flange, electro-hydraulic control valve assembly, supply pump etc.
Through electro-hydraulic control valve, pass the coupling by forward 1 gear or forward 2 gear
clutch or reverse gear clutch.
The adopted shift gear way to hydraulic transmission gear box is electromagnetic control
power shift and owns inching valve and cushion valve, which makes operation simple, easy, start
stable and ease operator’s labor intensity.
This transmission gearbox is without final drive assembly, and the final drive is installed on the
drive axle. Universal coupling connects final drive assembly of drive axles, transfers the power to
differential assembly, then acted on tires through differential axle shaft gear and axle shaft.
Transmission gear box can also play as oil reservoir.
13
1.2technical parameters list
Technical parameters list see Fig.1
Fig. 1 technical parameters of hydraulic transmission gearbox
Item FYQXD30Ⅲ
rated power of matched engine
kW 37～44
rated speed of matched engine
2200～2650
r/min
Forward F1 2.89
Transmission
Forward F2 1.595
ration
Reverse gears R1 2.367
Master pressure MPa 1.1～1.4
Electric device(voltage/power) DC12V/ 2.4A
Input pressure of torque converter
0.4～0.6
MPa
Valid diameter mm 265
Hydraulic torque converter
torque ratio at 0 speed

3.0±0.15
Max efficiency ≥0.80
pump impeller at 0 speed
31.65-33.5
Nominal moment N·m
Max efficiency
265
Nominal moment of pump
impeller N·m
Rotation direction(facing input) Clockwise
Oil Gear-box 6#、8# hydraulic transmission oil
reduction gearbox GL-5 85W-90 deadweight load truck gear oil
70-95,
Maximum working oil temperature does not
Temperature for work ℃
exceed 120 ℃ and the duration of no more than
5 minutes.
14
1.5. Notice about installation and usage
1.5.1 Before installation, first clean oil of oil seal on surface of hydraulic gearbox, to avoid leaking
when working, no disassemble freely hydraulic gearbox.
1.5.2 To avoid affecting precision of installation and usage must prevent every installation surfaces,
torque converter and out gear knocking.
1.5.3 Guarantee no more than 0.15mm run out for installation hole of engine flywheel, no more
than 0.1mm for flywheel end surface, no more than 0.2mm for installation end surface of flywheel,
no more than or equal to Ф0.1mm for location position of 2 location pins on installation surface.
1.5.4 Truck control mechanism must guarantee correct stroke of inching valve lever, and secure
location. Inching valve lever can return its initial location when operator loosens pedal. Inching
valve characteristic graph,
, inching valve lever can move together with brake pedal, must guarantee cut off the oil to clutch
before braking ,and the stroke of inching valve lever is equal to or more than 12mm(less than
20mm) ,when shifting, close inching valve first ,and then shift. When the brakes, you must turn off
the micro-valve, then brakes to prevent damage to the clutch or brake failure.
1.5.5 When hoisting, keep level, ensure gearbox and reduction gearbox calm, and avoid torque
converter sliding out.
1.5.6 Prohibit changing oil system of the gearbox. To ensure gearbox work regularly, lubricate
well, the circular oil of gearbox can not be used for other purpose, and the oil should accord with
required trademark.
1.5.7 Keep work oil clean and no other impurity, After the first use of the new machine in normal oil
temperature for 100 hours working oil should be replaced, and after every 1000 hours,or reuse
after long depositing.
1.5.8 Fill in work oil, run at neutral shift for5 minutes, then check oil height, and the height should
be within the specified range.
1.5.9 New hydraulic gearbox should breaking in 50 hours after it is installed,and the load is no
more than 70% in breaking in process, note oil temperature ,oil pressure and bolts loosen or not
usually, replace new oil after breaking in .
15
1.6. Cause and solutions
Item Cause Solutions
①lack oil Fill oil
Disassemble, check, replace
②efficiency of pump falls
if necessary
Insufficient power ③gasket ring wears Disassemble, replace
and over high ④bearing damage Disassemble, replace
oil temperature ⑤ filter jams Check and clean or replace
⑥pipe or connector damage Disassemble, replace
⑦inching valve lever reposit
Check,adjust
non-freely
① seal damage or hurt Disassemble, replace
② seal backing board damage Disassemble, replace
Oil leak ③rubber stiffen or distort Disassemble, replace
④bolt loosen, joint surface leak Screw down
⑤surface damage Disassemble, replace
①gear damage Disassemble, replace
②input elastic plate loosen or distort Screw down or replace
③bearing damage Disassemble, replace
④bolt loosen Screw down or replace
Abnormal noise
⑤spline damage Disassemble, replace
⑥air suction because of oil pipe
Check ,replace
leaking
⑦ air pocket because of oil lacking Fill oil
16
Domestic hydraulic transmission gear-box: pressure tap , lubrication connector, oil drain
hole ,see following.
17
2. 4F35S Hydraulic transmission gearbox (four-wheel drive)：
2.1 Generalization
In order to improve the working efficiency, we optimize the 4F35 hydraulic transmission
gearbox, and the optimized model is 4F35s hydraulic transmission gearbox.4F35S hydraulic
transmission gearbox is a new type gearbox for four-wheel drive rough terrain forklift truck, with
total 4 shifts (three forward and one reverse), and time sharing four-wheel drive can be realized
based on the actual requirement.
Torque converter for 4F35S hydraulic transmission gearbox is comprehensive with signal
stage two phase and three working wheel, thus it owns automatic adaptability of hydraulic
transmission output, which can change its output torque and speed as the change of external load,
and absorb and remove the shock vibration from engine and external load to the drive system; the
adopted electronic-hydraulic shift with inching valve and cushion valve makes operation simple,
easy and smooth starting, and greatly reduces the fatigue strength of the operation.
Axle disengaging mechanism is controlled by solenoid valve, and conversion between
two-wheel drive and four-wheel drive through hydraulic clutch can be carried out at any time
according to the condition of the road, thereby greatly improves the cross-country capacity of the
forklift
The 4F35s hydraulic transmission gearbox and 4F35 hydraulic transmission gearbox have
the same components except for the different transmission ratio.
2.2 Main technical parameters
Main technical parameters refer to table 2

Table 2 Main technical parameters of hydraulic transmission gearbox
Product model 4F35 4F35S
Rated output of matched engine Kw 40~48
Rated speed of matched engine r/min 2000~2650
Direction of rotation（face input end） Clockwise
F1 gear 3.3153 3.2657
Drive ratio on F2 gear 1.6318 1.6346

front axle F3 gear 0.8276 0.8276
R gear 1.3947 2.6942
F1 gear 2.8430 2.8004
Drive ratio on F2 gear 1.3993 1.4017

rear axle F3 gear 0.7097 0.7097
R gear 1.1960 2.3103
18
Torque converter model YJH265
L-TSA32GB11120 turbine oil or 6#,
Work oil temperature of gearbox
8# hydraulic transmission oil
2.3 Installment and use notice

2.3.1 When installing the hydraulic gearbox, firstly clean sealing oil on its surface. In order to
avoid oil leakage, it is not allowed to dismantle and disassemble the product.
2.3.2 Avoid knocking and collision on each mounting surface, torque converter and exposed
gear so as not to influence installment and use precision.
2.3.3 Check the run out of engine flywheel center mounting hole is not larger than 0.15mm,
flywheel end face run out is not larger than 0.1mm; flywheel casing installing end face run out is
not larger than 0.2mm, location degree of two locating pins is not larger than Ф0.1mm on the
mounting surface.
2.3.4 When the vehicle need shift, first close inching valve and then shift. When braking, first
close inching valve, and then brake to avoid damage clutch or brake malfunction.
2.3.5 When hoisting the gear box, try to keep level to avoid torque converter slip off.
2.3.6 It is prohibited to change the oil line system of the gearbox. In order to make sure
gearbox work normal and lubricate well, cycling oil of the gear box should not be used for other
purpose. Working oil mark should meet the requirement.
2.3.7 Working oil should keep clean, have no other impurity. Replace oil after being used for
100 hours for the first time, and then replace oil per 1000hours or use after stopping for a long
time.
2.3.8 Main oil pressure of gear box is 1.0MPa~1.3 MPa, inlet pressure of torque converter is
0.4MPa~0.6 MPa, and return pressure 0.1MPa~0.3 MPa.
2.3.9 Normal working oil temperature is 70℃～95℃, maximum working oil temperature
should not exceed 120℃ or last over 5 minutes.
2.3.10 Check the working oil level in the gearbox after the engine starts for 3 minutes, and the
oil level should be within the dipstick regulated scale.
2.4 Fault reason and corrections

Item Fault reason and corrections
1 Friction lining stuck or damage. Check if friction lining has gluing,

uneven contact or warpage;
Efficiency 2 Insufficient torque converter oil supply. Check if oil pump wear or
decline and
oil level is in normal position;
over high oil
temperature 3 Bearing failure. Replace bearing;
4 Check if lubricating oil line blocks;
5 Torque converter one-way wheel stuck.
19
1 Sealing gasket damage; Replace sealing gasket;
Oil leakage 2 Rubber parts age or damage; Replace parts;
3 Parts damage. Replace.
1 Low oil level. Check oil level and add oil to normal oil level;
Low clutch 2 Input shaft assembly and piston sealing ring wear or the joint is
pressure or wedged when assembling. Replace sealing ring or be careful when
over large assembling.
swing 3 Oil pump wear; Replace oil pump.
4 Inching valve rod not reset.
4F35 Hydraulic transmission gearbox： Refer to the following figure for per
pressure port, lubricating oil port and oil drain hole.
20
3. Driving axle
Drive axle of two-wheel drive rough terrain forklift truck
1). Data
Driving axle type Full floating, axle and truck body direct install, front wheel driving
Wheel hub rotation starting torque at
10～29
hub blot N
Axial gap of wheel bearing mm less than 0.08
2). Trouble diagnoses and corrections
condition Probable cause Corrective action
·loose driving axle and body connecting blots. Tighten.

·loose wheel nut Tighten.
·worn or damaged wheel hub bearing. Replace.
Abnormal noises
·wheel hub bearing not properly adjusted. Adjust.
·worn axle shaft spline. Replace.
·insufficient lubrication Lubricate.
·loose wheel nut. Tighten.
·deformed wheel. Replace.
·worn or damaged wheel hub bearing. Replace.
Unstable driving
·loose driving axle and body connecting blots. Tighten.
·wheel hub bearing not properly adjusted. Adjust.
·improper tire pressure. Adjust.
·worn or damaged axle shaft oil seal. Replace
Oil leakage ·final drive improperly installed. Replace gasket.
·loose drain plug. Tighten.
Fig. 2-4 Drive axles
1
Tighten torque：N·m
1. Half shaft bolt 110-130
2. Wheel hub nut 324-373
3. Brake base plate bolt 260-300
3). Driving axle assemble removal and installation

！ WARNING
Be careful when removal and installation driving axle as it is heavy.
1) Raise front end of forklift truck and support frame with wooden blocks.
2) Remove mast assembles.
3) Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and transmission case.
4) After placing a pan under axle case, loose oil plug, drain oil from axle case.
5) Disconnect brake nuts from left and right cylinders.(see fig.2-5）。
CAUTION：Plug brake tube openings to prevent oil from flowing out.
6) Disconnect brake cable at hand brake lever.
7) Remove front wheels.
8) Remove axle shaft.
9) Support driving axle with wire ropes and lifting device.
10) Remove bolts securing axle mounting bracket to frame.（see fig.2-6）.
11) Remove nuts securing axle case to differential gear carrier.（see fig.2-7）.
12) Remove driving axle assemble.
Fig.2-5 Fig.2-6 Fig.2-7

13) Remove locknut and lock sheet.
14) Remove wheel hub（together with brake drum ）.
15) Remove axle mounting bracket and brake component from axle tube.
16）Remove oil seal from axle tube.
17）To install driving axle assemble in the reverse order of removal. Observe the following:
① When installing axle mounting bracket and brake component, apply a coat of calcium grease to axle tube.
② Apply 1/3～2/3 of volume of calcium grease to wheel hub，then install them on axle tube.
③ Install oil seal with its part number facing to the inside of forklift truck.
④ attach seal tape （PVC, white）to drain plug then installed after cleaned it.
2
⑤ Replenish axle case with gear oil. Tighten vent plug after clearing.
⑥ Fabrication mill finish directs to bearing when installing locknut.
⑦ When installing component 17, please smear LOCTITE 222 mucilage (or 242 mucilage ) at screw thread
position(above 2/3) and then loosen.
Ton Models
2t-3.5t Remark
Fill in drive axle（L）
Vehicle gear oil GL-5 5．8L /

85W/90
Vent plug should clear instantly to prevent pressure inside of wheel hub from rising.
4). Axle shaft and wheel hub

Remove
1） Raise the front end of forklift truck and support frame with wooden blocks.
2） Remove front wheel and axle shaft.
3） Remove lock nuts, lock washers, snap ring, felt ring, adjusting nut. Use special tools.
4） Remove brake drum（refer to Fig.2-8）；
If brake drum is difficult to remove: a. Remove adjusting hole plug. Then with flat-blade screwdriver extend
adjusting hole, turn adjusting ratchet wheel by 10 notches. To contract brake shoe lining（refer to Fig.2-9）.
b.Evenly tapping on brake drum with brass bar or wooden mallet.
Fig.2-8 Fig.2-9
5） Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with a wooden
mallet and brass bar.
6） Remove bearing outer race from wheel hub by evenly tapping on its periphery with a wooden mallet.
CAUTION：Be careful not to damage oil seal and outer race.
Inspection
Stepped wear or cracks on axle shaft splines Replace
Seized, scratched, noisy or rusted bearing or improper rotation of Replace
rollers
Cracked or damage wheel hub Replace
Damaged oil seal felt ring. Replace
3
Installation
Install reverse order of removal.
5). Bearing adjusting
1） Lubricate on taper roller bearing.
2） Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one hand.
3） From that position, turn back lock nut approx. 600.
4） Turn back wheel hub two or three rotations so that bearing settles down.
5） Again tighten lock nut until it can no longer be rotated with one hand; then turn back approx.600.
6） Install snap ring and settles down felt ring, install lock washer so as to set its hole in the pin of snap ring.
Screw lock nut.
7） Turn wheel hub back and forth two or three rotations to see if rotation starting torque is within specifications.
Rotation starting force：10N～29N（refer to Fig.2-10）；
8） Measure axial play of wheel hub to see if it is within specification. Axial play is less than 0.08mm （refer to
Fig.2-11）.
Fig.2-10 Fig.2-11
4
Drive axle of four-wheel drive rough terrain forklift truck
1. Data
Drive axle model Wet brake drive axle, axle body is directly connected with chassis
Total reduction ratio 18.63
Reduction ratio Main reduction ratio 4.11

Reduction ratio of wheel planetary 4.533
gear drive
Max. braking torque 13000 N·m
Max. pressure 4.8MPa

Brake
Hand braking force 900N
Whole axle braking torque 12000N·m
Type Mobil 424 hydraulic

transmission oil
Lubricating oil The lower limit of oil level is

Oil quantity
8mm below the oil orifices
Weight 398kg
2. Fault diagnosis and corrections
Condition Possible reason Corrections
·Drive axle bearing plate and chassis

Tightening
connecting bolt loose
Tightening
·Wheel nut loose
Replace
Abnormal noise ·Hub bearing damage or wear
Adjust
·Incorrect hub bearing adjustment
Replace
·Half axle spline wear
Add lubricating grease
·Insufficient lubrication
5
·Wheel nut loosen
Tightening
·Wheel deformation.
Replace
·Hub bearing wear or damage.
Replace
Unstable move ·Drive axle supporting sleeve and chassis
Tightening.
connected bolt loosen.
Adjust
·Incorrect hub bearing adjustment
Adjust
·Incorrect tyre pressure
·Axle oil sealing wear or damage Replace

Oil leakage ·Incorrect main drive device installation Replace paper gasket
·Oil drain plug loose Tightening
3. Replace gear oil

Replace gear oil after the new truck has worked for 100h during breaking-in. Replace gear oil every a half year or
1000h (whichever comes first) afterwards.
Model Mobil 424 hydraulic transmission oil
Gear oil The lower limit of oil level is 8mm

Volume
below the oil orifices
6
Oil filler plug on left and right
Drive axle oil level hole
wheel of drive axle
Oil inlet plug on left and right
Drive axle drain plug
brake of drive axle
Drain plug on left and right wheel
of drive axle
Notice：
1) Discharge the lubricating oil to a proper container, dispose according to local laws and do not dump at will.
2) Check if there are too many metal particles on the oil level plug or drain plug, clean or replace oil plug.
3) After draining the lubricating oil, re-screw down the drain plug to designated torque.
4) Add oil to the oil level, and a few overflow is allowed. After adding gear oil, re-screw down all oil plugs to
designated torque.
4. Disassembly and assembly of the drive axle

Remove the drive axle from the forklift when disassembling and assembling the drive axle. Detailed operating procedures
are as follows:
After correctly hoisting the drive axle with facility, disconnect all its connecting lines. Disassemble the connecting bolts
from the forklift, remove the whole drive axle from the forklift and then place it on a flat surface.
Exhaust all gear oil in the drive axle.
Caution：
As parts are very heavy, please operate with proper hoisting equipment and (or) lifting system.
Disassembly of the final drive

1 Remove 13 pieces of full thread hexagon bolt②and
standard spring washer ③, bring down final drive
assembly①(with cylindrical spiral gear reducer and
hand brake)
Caution：
First remove linear actuator assembly.
When installing full thread hexagon bolt ③ , apply
Loctite 222 glue to the thread part.
Align with location pinhole when installing the
final drive.
7
2 Dismantle the following parts from the final drive ①
(with cylindrical spiral gear reducer and hand
brake) in sequence：
Hand brake component④
Input flanged shaft⑤
Flange face hex nut M24×2⑥
Hand brake disc⑦
3 Dismantle the following parts(with cylindrical spiral

gear reducer and hand brake) from the final drive ①
in sequence：
Oil seal FB85×110×12⑧
Single-row tapered roller bearing 32212⑨
Hexagon socket cap screws ⑩
Hand brake bracket(11)
Bearing seat (12)
Caution：
 Be careful not to damage O-ring or oil seal.
When mounting the oil seal, get the font
surface towards the inner drive axle, and
prevent oil seal scratch.
8
4 Dismantle the following parts from the final drive
① in sequence：
Pad （13）
Single-row tapered roller bearing 31309 (14)
Driving spiral bevel gear （15）
Adjusting shim（16）
Full thread hexagon bolt M6×30 （17）
Flatted wire snap ring for shaft 25 （18）
Block （19）
Cylindrical roller bearing CG532505UEY
（20）
Nut m6 （21）
Adjusting shim （22）
Final drive housing （23）
Single-row tapered roller bearing 29590/29522
（24）
Reducer bearing cap （25）
Reducer adjusting nut （26）
Standard spring washer 14 （27）
Bearing cap bolt （28）
Lock plate （29）
Full thread hexagon bolt M8×20 （31）
9
5 Dismantle the following parts from the differential
assembly in sequence：
Hexagon flange face bolt M10×1.25×55 （32）
Right differential case （34）
Half axle gear spacer （35）
Half axle gear （36）
Cross （37）
Planetary gear（38）
Planetary gear spacer（39）
Driven spiral bevel gear（40）
Left differential case （41）
Bolt M12×1.25×27（42）
Caution：
When installing hexagon cap screw（32）, tightening
torque is 60N·m~75N·m. When installing bolt（42）,
apply Loctite 262 glue to the thread part,
tightening torque is 105N·m~115N·m.
10
Disassembly of left/right wheel reducer
Note: When removing the front axle wheel reducer or right long axle shaft, be sure to ensure
that the front axle differential lock is active; (ie, when the vehicle is powered on, the button
is in the position shown.)
11
1 Remove 12 pieces of hexagon socket cap screws①,
bring down wheel assembly②(with planetary reducer
and outer half axle).
Caution：
When installing hexagon socket cap screws①,
apply Loctite 222 glue to the thread part.
2 Dismantle the following parts from the wheel

assembly②(with planetary reducer and outer half axle)
in sequence：
Planet carrier component
Sun gear④
Hexagon socket cap screws M14×1.5×35⑤
Gear ring⑥
Caution：
When installing hexagon socket cap screws⑤,
apply Loctite 262 glue to the thread part,
tightening torque is 170N·m~190N·m.
Make sure the assembled planet gear run smoothly,
steadily and no stuck phenomenon.
12
assembly ② in sequence：
Combined seal washer 20⑦
Hexagonal socket head plug M20×1.5⑧
Housing⑨
Oil seal seat ⑩
Oil seal FB160×190×15（11）
Single-row tapered roller bearing 32021（12）
Caution：
 Wrap sealant when installing the screws.
 Apply a little lithium base grease to the lip
when installing the oil seal.

Half axle bolts M12×1.25×40（13）
External half axle（14）
Type A circlip for shaft 52（15）
Full thread hexagon boltM6×12（16）
Spring washer 6 （17）
Lock sheet（18）
Locknut M90×2（19）
Single-row tapered roller bearing 33018（20）
Hub（21）
Hub bolt（22）
Caution：
 Hub bolts have been pressed in the hub. Please
do not disassemble them without any special
conditions
 Apply Loctite 598 to the joint of external half
axle and hub for sealing.
 When installing half axle bolts, apply Loctite
262 glue to the thread part, tightening torque
is 105N·m~115N·m.
 Pre-load of wheel bearing: Turn the wheel hub
and tighten the locknut until the wheel is
hardly turned. Then back the lock nut until
the starting torque of the hub reaches
3.5N·m~6.3N·m(apply a 30N-55N tangential
force at the hub bolt to turn the hub), and the
hole of lock sheet is aligned with the thread
hole of the locknut.
13
Hexagon socket cap screws M8×25（23）
Pressure plate（24）
Planet carrier（25）
Planet gear pad（26）
Planet gear（27）
Roller pin（28）
Planet shaft（29）
Steel ball（30）
Planet carrier（31）
Caution：
 When installing bolts, apply Loctite 262 glue
to the thread part, tightening torque is
28N·m~32N·m.
14
Disassembly of brake part
1 Dismantle the following parts from the brake
assembly in sequence：
Cylinder body①
Roller pin 5×15.8②
Rectangle seal ring161.97×3.53×3.53③
Rectangle seal ring 187.52×3.53×3.53④
Piston⑤
Friction plate assembly⑥
Drive gear⑦
Caution：
 Be careful when disassembling or
assembling O-rings, do not scratch or
damage.
2 Dismantle the following parts from the friction

plate assembly⑥ in sequence：
Hexagon bolt M5×28①
HW6011 Belleville spring ②
Braking steel disc③
Friction plate④
Type I full metal hexagon lock nut M5 ⑤
Caution：
 Install two pieces of HW6011 belleville
spring between per steel disc and friction
plate.
15
Ⅲ Steering system
1 Structure introduction
Steering system is mainly composed of steering device and steering axle, refer to fig. 3-1.
Steering device consists of steering wheel, steering column device, locking handle, full hydraulic
steering gear, refer to fig.3-1. Steering wheel and steering column is adjustable, and the adjusting
angle is 6°to adapt different drivers’ needs.
Steering axle assembly is mainly composed of steering axle, knuckle, steering hub, steering wheel
and steering cylinder etc., refer to fig.3-3.
Steering device
Steering axle assy
Fig.3-1 Steering system drawing
16
Steering device structure
2
1
3
4
8
7
6
5
10 9
11
12
13
14
13 15 15
12 14
16
1.Steering wheel assembly 2. Steering wheel nut 3.Washer 4. Steering pipe device
5.Locking handle 6.Snap spring 7.Locking shaft 8.Locking shaft sleeve I
9. Locking shaft sleeve II 10.Bolt 11. Washer 12.Nut
13. Washer 14. Bolt 15.Bush 16.Hydraulic steering gear
Fig.3-2 Steering device structure
17
Steering axle assembly structure（two-wheel drive）
1.Bolt 2. Washer 3. Dust ring 4.Base plate 5.Steering bumper block

6.Shaft sleeve 7.Adjusting shim 8. Bolt 9. Washer 10.Steering axle
11.Steering cylinder 12.Oil cup 13.Hinge pin 14.Upper joining beam 15.Snap ring
16. Bearing 17.Down joining beam 18. Nut 19.Pin 20. Bolt
21. Washer 22.Cover plate 23.Kingpin end cover gasket 24.Oil seal 25.Bearing
26.Hub bolt 27.Steering hub 28. Nut 29.Wheel assembly 30. Bearing
31. Washer 32.Nut 33. Washer 34.Hub end cover 35.Stop bolt
36.Nut 37.Oil cup 38.Seal ring 39. Bearing 40. Steel bushing Ⅱ
41. Bearing 42.Kingpin 43. Adjusting shim 44..Left knuckle 45.Right knuckle
46.Washer 47.Screw 48. Bearing 49.Steel bushing Ⅰ
Fig.3-3 Steering axle structure
18
Steering axle assembly structure（four-wheel drive）
Fig.3-4 Four-wheel drive steering axle structure

3. Spherical plain
radial bearing with
1. Axis pin 2. Circlip for hole 4. Link assy. 5. Slot nut M18x1.5
single fractured outer
ring
9. Hexagon socket 10. Swinging base
6. Cotter pin 7.Oil cup 8. Cylinder assy.
screw assy.
14. Swinging base
11. Final drive assy. 12. Screw plug 13.Wheel assy. 15. Stopper
assy.
17. Left/right axle
16. Hexagon bolt 18. Spring washer 19. Bolt 20.Breather assy.
body assy.
19
2 Technical parameters
two-wheel drive rough terrain forklift truck
Steering axle
Axle type Center bearing, rotary type Axial clearance（F/R） 0mm / ≤1.0mm
Inner max. steering 68.4° End axle Adjusting 0.5,1.0,1.6,3.0 mm
Steering angle shim thickness
angle Outer max. steering 48.6° Part No. R450-220013-000
angle
Kingpin Hub bearing
Axial clearance of kingpin ≤0.20mm Tighten the knuckle nut until

the hub cannot be turned by
Adjusting shim of kingpin hand, and then release 1/6
Pre-tension ring. Or the initial turning
Part No. force for hub connecting bolt
Thickness（mm）
is 7.8N～23.6N.
0.1,0.5,0.7,1.0 R450-220008-000 Axial 0mm

clearance
four-wheel drive rough terrain forklift truck
Main technical parameter Max. oil filling in the ml 660

steering cylinder
Overall speed 18.5 Action area of Cm2 26.50
ratio steering cylinder
Center speed 3.08 Steering cylinder mm 105×2
ratio stroke
Wheel speed 6 Steering cylinder MPa 9
ratio pressure
Max. Output KNm 20 Axle load KN 107.8（static load）
torque
Outer wheel 41.3° Axle load KN 53.9（dynamic
turn angle load）
Inner wheel 55° Weight Kg 300
turn angle
Thread mm 1207 Single axle length mm 1440
3 Steering system installation notes

– Hydraulic tie-in, blots and piping must be cleaned while installing;
– Check oil lines arrangement for properness, whether it is reverse order of steering direction or
not;
– Turn the steer wheel to end and to make sure whether it is equably of steering force on left
and right, and steering is smooth.
– Jack up rear wheel and turn the steering wheel left and right slowly, repeat for several times.
20
Bleed air of hydraulic lines and cylinder.
– When engine stops running, rotate steering wheel with 1kg force slightly, after releasing
hands, steering wheel should return 10°automatically..
21
4 Fault diagnoses and corrections
Damage or trouble of oil pump Replace

Failure to rotate Priority valve(multi-way valve) is clogged or
steering wheel damaged. Clean or replace
Damaged hose or connector, block lines Replace or clean
Steering overflow value pressure too low. Adjust pressure.
Air in oil lines. Exhaust air
Laborious Control oil pipe is blocked Clean or replace

operation for
steering Priority valve(multi-way valve) fault Check or replace
The steering fails to turn to its natural position,
broken lock spring or insufficient spring pressure Replace spring flat
Too much internal leakage in steering cylinder. Check piston for sealing
Oil is not sufficient in oil tank. Add oil.

Abnormal noise
Suction piping or filter clogged. Clean or replace.
Damaged guide sleeve sealing of steering
Oil leakage cylinder or hose or connector. Replace
5 Hydraulic steering gear

This hydraulic steering gear is load sensing type. There is a LS mouth in the steering gear
connected to priority valve that makes steering load pressure signal transmit to priority valve
through oil pipe, which controls the oil quantity supplied to the steering gear.
In the load sensing type steering system, whatever load pressure or steering wheel speed, it can
prioritize corresponding flow according to oil line requirement, and guarantees the steering reliable,
sensitive and light.
Besides the needed oil pump output flow to the steering system, the rest one is supplied to
working oil line, thus eliminates power loss from over oil supply to steering oil line, and improves
system efficiency.
When the power steering is working, pressure oil flows into rotor and stator pair through valve
element and valve pocket pair, and to drive rotor to rotate along with steering wheel, and push oil
into left and right chamber of steering cylinder, and piston rod pushes steering tires to steer.
When the engine stops running, the pump does not supply oil, and the steering action will be
realized manually by turning the steering wheel to move valve element, valve pocket, coupling,
and to actuate the rotor to feed oil into steering cylinder, in this case, rotor and stator act as a oil
pump.
22
Displacement：125mL/r
Max. inlet pressure：16Mpa
Oil port sealing type：taper port sealing
Fig.3-4 Hydraulic steering gear schematic diagram

Assemble notice
– When assembling the steering gear, make sure in the same axle with steering column, and
there should be axial clearance. Check if steering wheel returns flexibly after assemble.
Assemble should follow the following: “P”—connect muti-way valve Ps mouth; “T”—connect
hydraulic oil tank; “A”—connect steering cylinder left chamber; “B”—connect steering cylinder
right chamber; “Ls”—connect muti-way valve Ls mouth.
–
– A, B, P, T mouth connect thread M20×1.5，T=50N·m～60N·m；LS mouth connect thread
M12×1.5，T=30N·m～36N·m
– Make sure the oil clean to avoid dirt block steering gear inner part and cause steering
malfunction. Thus it needs check filter element of filter and oil work condition, replace if
necessary.
– If there occurs to heavy steering or malfunction during steering gear use, find out the reason
firstly, it cannot wrench the steering wheel hard, or dismantle the steering gear, otherwise it
may damage the parts. It is prohibited to rotate the steering wheel by two persons.
23
wiper scraper seal
screw spring washer Cover O-ring 50×3.1
25.8×2.65
combination sealing 1 combination sealing 2 Snap ring needle bearing slip ring
Valve Spool &
Spring pull pin valve block screw
valve pocket
O-ring valve body O-ring 77.5×2.65 Plate Shaft
Ball Pin Stator&Rotor Shaft Downside cover
Bolt Keeper
Fig.3-5 Hydraulic steering gear structure
24
Fault diagnosis and corrections
Fault Probable reason Phenomenon Corrective action
Combined part bolt

Screw down bolt
loosen
Combine face or
Oil
journal sealing ring Replace sealing ring
leakage
damage
Gasket damage Replace gasket
Insufficient oil supply Turn steering wheel slowly is Check if oil pump works
to oil pump light and fast is heavy.. normal
Foam in the oil and give out

irregular noise, rotate the Eliminate air in the system
Air in the steering
steering wheel but the and check if oil suction pipe
system
cylinder works sometimes leaks
and stop for a while.
Oil level is lower than

Add oil to specified height
Hard specified position
steering
Oil viscosity is too big Use specified oil
Steering wheel is heavy If steer ball losses, install the

Ball check valve
when fast steer or slow steer, ball; if steel ball is blocked
invalid.
and no steering pressure by dirt, clean it.
Steering system Check out the reason,

No load or light load steering
pressure is lower recover or improve system
is light, but much load
than working pressure(not exceed
steering is heavy.
pressure 16Mpa)
Steering wheel cannot

Spring leaf break off Replace spring leaf
automatically return in middle
Pin or universal No obvious pressure runout Replace pin or universal
Steering driving shaft open
failure or cannot turn driving shaft
break or deformation
Tooth space engagement
Rotor or universal
Steering wheel cannot rotate between compact point teeth
driving shaft open
or move from side to side on universal driving shaft
break or deformation
and on the rotor
No Overlarge stator Steer after misfire, steering

human radial clearance or wheel turns but the cylinder Replace stator
steering axial clearance keep still.
25
6 Steering axle
（ four-wheel drive rough terrain forklift
truck）
6.1 Dismantle and assemble

Hub dismantle
– Jack-up the forklift and support with
blocks;
– Dismantle wheel assembly（29）;
Caution
– Dismantle hub cover（34）;
 Push steering king pin to avoid drop.
– Dismantle knuckle locknut, thrust washer
and adjusting nut;
– Take down the whole set of knuckle
– Pull out hub assembly;
(including thrust bearing, dustproof shell,
– Dismantle inner ring of the bearing
shim)
Caution Inspect：
 Do not drop taper bearing.
– Replace knuckle if cracked;
 Be caution not damage the seal
– Replace bearing if its rollers or roller
element.
surfaces are rusted or nicked;
Steering king pin and knuckle – Replace needle bearing if it damaged;
– Dismantle nut(18) in the joint of knuckle – Replace thrust bearing and dust cap if
and draw bar device, disassemble draw they damaged.
bar device; Installation：
– Loose the fixed screw（47）; To install, reverse the order of removal. Careful
observes the following:
– Always insert kingpin from lower side;
– Install thrust bearing, set the tighten-ring
below the support and loosen-ring. Adjust
axial clearance to specification with shims.
Axial clearance is less than 0.2mm.
Caution
– Dismantle oil cup of steering king pin;  Thrust ball bearing is installed on the
（37）; upper knuckle, and the adjusting
– Dismantle steering king pin（42）; shim is installed on the down
knuckle.
– Apply grease between inner dust proof,
loosen-ring, and tighten-ring.
– Do not apply grease to the of needle
bearing outer ring and knuckle faying
26
surface
– Apple grease to roller of roller bearing and
ball of thrust bearing;
– Apply sufficient grease into the oil cup.
Hub bearing installation and adjustment
explanation
– Apply rust preventive oil on contact area
of nut (32) and bearing (30);
– Slowly rotate hub(27) with one hand.
Tighten locknut with the other hand until it
is hard to rotate steering hub(27), and
then rotate the nut(32) about 60°in
reverse direction;
– Rotate steering hub(27) 2～3 cycles, and
rotate the bearing roller in place;
– Rotate the steering hub(27) with one hand,
and screw down the nut(32) with the other
hand, rotation initial torque: T=0.88N·m～
2.65N·m.
– Place the protruding part of washer (31)
into the knuckle groove, adjust the outer
nut (32), align the notch at the outer
protruding part of washer (31), then put
the protruding part of washer (31) into the
nut notch.
– Rotate the steering hub(27) for 2 cycles,
measure the rotation initial force（7.8N～
23.6N）and if axial clearance(no clearance
in axial direction) meets stand, and adjust
if necessary.
27
6.2 Fault diagnoses and corrections
Wheel nuts loosens Tighten
Wheel bearing exceeds adjusting

Adjust
Unstable travel scope
Incorrect installation of end axle
Adjust
adjusting shim
Refer to the “steering system trouble
Steering system failure
diagnoses and corrections”
Insufficient lubrication Apply and fill lithium base grease
Bolt or nut loosens Tighten

Noise
Incorrect adjustment of end axle
Adjust
adjusting shim
Knuckle bearing on two ends of
Replace
connecting rod damaged
Steering axle
A：Insert proper 0.1mm gasket between 2 thick gasket to make axial clearance less than 0.2mm.
Tightening torque： Tightening torque：

N·m N·m
1. Nut 157-176 2. Bolt M6×12 3.7-5
3 screw 25-35 4. Bolt M16×1.5×45 193-257
28
7.Steering axle(four-wheel drive rough terrain forklift truck)
7.1 Assembly of steering axle
Rim nut is M18×1.5, tightening torque is 336 N·m, apply Loctite 242 to one group of rim nuts
symmetrically and evenly before the rim nuts are tightened. Often check if the nut is loosened
in normal use, tighten in time, nut end should match with rim ball socket, and make sure they
are compacted and reliably connected.
7.2 Oil filling method to steering axle

First open the oil level hole plug on the tank, and then open the oil filling hole plug at the left
and right hubs, make the oil filling hole and oil level hole at the the left and right hubs are
respectively positioned in the horizontal position.
（1）As to the wheel oil filling, first fill gear oil through the oil filling hole of the hub slowly, stop
until the oil overflows from the oil level hole of the end cap, repeat the above procedures in ten
minutes, and repeat again in ten minutes, totals for three times.
（2）Slowly fill gear oil from the oil level hole of the tank, stop until the oil overflows from the oil
level hole, shown as the below picture.
GL-5 85W/90 heavy load gear oil is generally used, and the standard code is GB12895-92.
29
7.3 Hoisting and storage
7.3.1 When hoisting the drive axle, hoist with the lifting rope getting through the position
indicated by the arrow in the picture, shovel still through the position indicated by the arrow in
the picture when transporting by shovel. Bump or drop is strictly prohibited whether hoisting or
shoveling.
Drive axle is in naked package, place separator between axles during transportation to avoid
collision, wrap the final drive flange plate with water proof paper to avoid corrosion.
7.3.2 Drive axle storage
Put in the warehouse, but not in open area. Drive axle should not be stored over one year,
or replace the easily damaged parts.
7.4 Steering axle maintenance

7.4.1 Grade I technical maintenance (about work 50 hours)
①If it is a new truck running-in, replace gear oil. (Note: When replacing oil, first drive truck
warming, release oil, and then wash with carbon oil. After that, add oil to specified position.)
②Check each drive parts move condition, abnormal noise is not allowed.
③Check if hub reduction gear, main driver and wet brake outer fastener loosen and screw
down. Tightening torque should meet the requirement of Table IX.
Tightening
No. Specification torque Remark
(Unit：N.m)
1 M16x1.5x75 301 Axle body connecting bolt

（10.9 grade）
2 M18x1.5 336 Rim nut
30
3 M18x1.5 299 Slot nut
4 M12x1.5x40 119 Crownwheel connecting bolt
④Check each part oil leak condition and repair in time. All sealing elements are not
allowed to reuse once dismantle.
7.4.2 Grade II technical maintenance (working time about 1200hours)
①Check and adjust bearing and crwonwheel clearance.
② Replace gear oil according to season or major repair requirement. When replacing oil,
first drive truck warming, release oil, and then wash with carbon oil. After that, add oil to
specified position.
③Check and fasten external fastener. If any loosen, apply Letai 242 anti-loose glue and screw
down.
7.4.3 Grade III technical maintenance (about work 2400hours)
①Carry out disassembling inspection to front/ rear axle wheel reducers and main driver,
repair or replace damaged parts. When assembling, clean the sealant part with solvent, apply
SD-314 silica gel after dry. All fastener bolts should also be cleaned and apply Loctite 262 after
dry, retighten, and the tightening torque should meet the requirement in table IX.
②Adjust main driver and wheel reducer.
③Axial clearance of driving spiral bevel gear bearing is 0.06mm～0.10mm, then the gear
should be flexible, and the axial clearance of the bearing should be adjusted with shims.
④Adjust the mounting distance of spiral bevel gear to correct position, and make sure the
correct meshing mark and clearance. It can be adjusted by nut and shim. The axial clearance
of the bearing is 0.05mm~0.10mm, backlash of driving/driven spiral bevel gear is
0.18mm~0.30mm, meshing mark is checked by staining method, and the correct driven spiral
bevel gear is listed as figure 5. Contact spots along the tooth height, tooth length are not less
than 50%, and the adjustment method of incorrect mark refers to table VI.
⑤Minimum meshing clearance between differential half axle gear and planet gear is
0.1mm, adjust with friction plate, and make sure it can be light rotated without being stuck after
assemble.
⑥Repair and replace wheel reducer gear, contact spots are checked by staining method,
more than 45% along tooth height and more than 50% along tooth length. After the wheel is
mounted, it will be turned by hand so that the bearing is in the correct position, the round nut
will be tightened tightly until the wheel can barely rotate, and then the round nut is returned
1/10 turn, and the wheel rotates freely and has no axial movement and swing phenomenon,
and finally fix with a round nut, so that the axial clearance is controlled within 0.1mm.
⑦If you replace the wheel planetary gear needle, group all needles and then select, so
that the diameter difference within the same group of no more than 0.005mm, needle cylinder
is 0.003mm, the radial clearance between needle, gear hole and pin is 0.02 ~ 0.03 mm
31
7.4.4 Incorrect mark and adjustment way to driven spiral bevel gear
Driven gear contact area Adjustment way Adjustment direction
First reduce the adjusting

shim thickness of the bearing
sleeve, get driving bevel gear
close driven bevel gear, if the
backlash is too small, move
driven bevel gear outward.
First increase the adjusting

sleeve, deviate driving bevel
gear from driven bevel gear, if
the backlash is too big, move
driven bevel gear inward.
First reduce the adjusting

sleeve, get driving bevel gear
close driven bevel gear, if the
backlash is too small, move
driven bevel gear outward.
First increase the adjusting

sleeve, deviate driving bevel
gear from driven bevel gear, if
the backlash is too big, move
driven bevel gear inward.
32
7.5 Common faults and corrections
No. Fault Reason Correction
1. Take apart to repair or

1. Parts friction
replace parts
I Abnormal noise 2. Bad gear meshing
2. Reassemble and adjust
3. Bad lubrication
3. Improve lubrication
1. Oil seal burning loss 1. Replace oil seal

and aging 2. Tighten the bolt
II Oil leakage 2. Bolt looseness 3. Improve lubrication
3. Bad lubrication 4. Drain oil to the specified
4. Oil level is too high position
1. Bad lubrication 1. Improve lubrication

Over high axle
III 2. Improper assemble 2. Adjust according to the
temperature
of gear and bearing drawing
8 Steering cylinder
Steering cylinder is of double-acting piston type. The two end of piston is connected with
knuckle through rod. The pressure oil from hydraulic steering gear makes piston rod to move
left and right so as to turn truck left and right. Refer to 3-6.
33
1.LBH Dust ring 2.Guard circle 3.ISI Sealing ring 4. Composite bush 5.Right guide sleeve
6.O-ring 7.Cylinder barrel 8. Glyd ring 9.Left guide sleeve 10.Piston rod
11.Bearing 12.Check ring 13.Nut 14.Screw
Fig.3-6 Steering cylinder structure
Disassembly procedures：
– Loosen nut(13), and remove screw(14);
– Dismantle left guide sleeve(9) and right two sides of guide sleeve(6);
– Dismantle LBH dust ring(1), guard circle(2), ISI sealing ring(3), composite bush(4).
O-ring(6) sequently;
– Dismantle piston rod(10) and Glyd ring(8).
– Check: replace if component damaged.
To install, reverse removal procedure.
Attentions to dismantle steering cylinder：
– Lubricate each part with clean hydraulic oil.

– Prevent dust and oil coming into the cylinder.
– Avoid scraping on cylinder mouth, inlet and outlet.
– ISI sealing ring lip is inward; LBH dust ring inlet is outward.
– Do not damage O-ring on the outer ring when installing.
– Be careful to centering, push the guide sleeve into cylinder barrel, avoid to damage O-ring
on the outer ring and sealing ring on inner ring.
– Apply the same brand grease with working oil between sealing ring.
34
Ⅳ.Brake system
1 Summary
Brake system is composed of service brake system and parking brake system. Service brake is
front dual wheels hydraulic boosting brake and park brake is mechanical barrows brake, both
woks on the shoe brakes which are installed on left and right front wheels. Refer to fig. 4-1.
Service brake realizes truck braking through foot steping and hydraulic boosting. This mechanism
is mainly composed of brake inching bracket, brake inching pedal mechanism, hydraulic boosted
braking assembly, brake line, brake oiler, left/right shoe brake etc.. Hydraulic boosting brake
assembly is composed by the joint of hydraulic boosted brake and brake master cylinder, makes
foot stepping easier and comfort, thus reduce operater’s fatigue. Even in the event that the
hydraulic boosting is invalid, it can use hydraulic braking to brake.
Parking brake mechanism is mainly composed of parking brake, left/right brake cable and brake
etc. Only when the truck stopped can apply the parking brake. If service brake fails during
travelling, use the parking brake to stop the truck.
1
6 2
5 10
3
4 11 15
14
9 To transmission
inching valve
13
1. Brake inching
2.Brake pedal 3.Inching pedal 4. Brake Pump 5.Rubber pipe
bracket
7.Left brake oil 8.Right brake oil
6.Brake oiler 9. Left brake 10.Right brake
pipe pipe
11. Inching stay wire 13. Left brake 14. Right brake cable 15.Parking
assembly cable assembly assembly brake
Fig.4-1 Brake system
35
2 Data
Free travel 5mm～15 mm
Brake pedal
Height that the pedal is away from front base

145mm±5mm
plate
Stepping height when brake light switch on 10mm～20 mm
Height that the pedal is away from front base
145mm±5mm
Inching
pedal
plate
Joint clearance with brake pedal 2mm～2.5mm
Full travel of brake piston 28mm±1mm

Brake master
cylinder
Highest work oil pressure 10MPa

Two-wheel drive：DOT3 or DOT4 or
equivalent oil
Brake fluid
Four-wheel drive：SAE10 Hydraulic oil or
which was not worse than it.
Oil pressure, internal expanding
Type
front-wheel mechanical brake
Brake
Clearance between friction plate and drum

0.4～0.6 mm
brake
Wear limit of friction plate(to the rivet head) Larger than 0.5 mm
Less than 80 mm
Parking brake Travel （With 147N tension force, at hand brake
handle）
36
3 Brake inching pedal adjustment
Brake pedal adjustment：
– Adjust brake pedal stop bolt at A, make the pedal pad point P 145±5mm from the front base
plate and screw down the bolt nut.
– Adjust Brake Pump push rod length, and make the spare travel of the point P to point Q is
5mm～15mm(just as1mm～3mm spare travel of push rod) , and lock the nut;
– When step the brake pedal 10mm～20mm gradually, the brake light switch is completely
connected, and release the foot to this state, brake light switch should disconnect.
Inching pedal adjustment：
– Adjust inching pedal stop bolt at C, make the pedal pad point P 145mm±5mm from the front
base plate and screw down the bolt nut.
– After adjusting the brake pedal, adjust the bolt at B and make the joint clearance between
inching pedal and brake pedal 2.0mm～2.5mm, then tighten.
Join
t cl e
ara
nce
8m C B A
m
T=20～23N.m
P
145±5
Fig.4-2 Brake inching pedal adjustment
37
4 Parking brake adjustment
When it is found out that the free travel of parking brake handle is too large or brake effect is worse
after it is used for some time, please adjust it in time. Adjusting way is as follows:
– Before adjusting parking brake, check and adjust the shoe brakes on both sides of driving
wheel;
– Tighten nut B;
– Adjust nut A until handle force(P on Q direction) is 15kg～20kg when locking handle.
– Release pull rod of parking brake, and make sure wheel brake is completely released.
Note: Apply proper lithium base grease to guide rail, and keep applying frequently.
Fig.4-3 Parking brake adjustment
38
5 Brake
Adopted shoe brake is mainly composed of brake pad, brake shoe, brake cylinder and brake
pad adjusting mechanism.
When brake connects with drive axle, according to marks (left, right) on brake, bleeder screw is on
the slight upper, oil line should be cleaned before connecting.
When brake shoe does not work and lies in original position, there should be proper clearance
between friction plate and drum brake, and adjust the brake clearance to 0.25mm～0.5mm.
Adjust clearance in time after friction plate wears. If friction plate wears severely, (distance
between rivet head and friction plate is less than 0.5mm) replace it in pairs.
1 2 3 4 5 6 78 9 11
10
35 12
13
14
34
15
33
16
17 18
32
20
29 28 19
30 27 26
25 24
31 23
22 21
1.Housing 2.Bolt 3.Spring washer 4. Brake bottom plate
6. Brake shoe with
5.Brake cylinder 7.Return spring pin 8.Pin
friction plate assembly
9.Pin 10. Upper pull rod 11.Return spring 12.Rocker pin
15.Spring riveting
13.Rocker 14.Cotter pin 16.Torsional spring pin
device
17. Lower tension
18.Pawl 19. Torsional spring 20.Adjuster assembly
spring
21 Pressure spring 23. Pressure spring
22. Pressure spring 24.Check ring
pedestal pull rod
27.Hand brake
25. Resilient pad 26.Bush 28.Pushrod pin
pushrod
29. Pull rod pin 30. Hand brake lever 31.Pin 32.Hand brake cable
33. Spring washer 34.Bolt 35.Rubber plug
Fig.4-4 Brake
39
Replace brake shoe
– Place the forklift truck on level concrete.

– Start engine and raise forks about 100mm.
– Place chocks behind rear wheels to prevent movement of forklift truck.
– Loosen wheel nuts two or three turns each.
– Tilt mast fully backward, and place a wooden block under each side of outer mast.
Warning
 Do not allow wooden blocks to touch
front tires.
– Tilt mast forward until front tires are raised from ground.
Warning
 Do not unscrew the wheel nut before
the wheel rise from the ground.
– Support forklift truck by putting additional wooden blocks under each side of front-end
frame.
– Stop engine.
– Remove wheel tire nuts and brake drum. Remove axle shaft, lock nut, and lock sheet.
– Remove wheel hub and brake drum.
– Replace brake shoes with new ones.
– Reinstall hub, brake drum, locknut and lock sheet. Adjust bearing clearance.
– Adjust shoe to drum clearance: rotate wheel counterclockwise and at the time press down
brake pedal several times.
– Take out every padding block：take out according to reverse procedures when inserting.
– Make sure no person or obstacle is around forklift, then operate forklift in reverse at 2
km/h to 3 km/h, set foot on brake pedal 2～3 times.
40
6 Master cylinder
The 2t-3.5t master cylinder contains a valve seat, check valve, return spring, primary cup, piston
and secondary cup, which are kept in place with stop washer and 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 brake pedal. First, as the brake pedal, 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 the return port, the brake
fluid in the cylinder is pressurized and opens the check valve, flowing through the brake lines to
the wheel cylinder. Thus, each wheel cylinder piston is forced outwards. This brings the brake
shoes into contact with the wheel drum and slows or stops the lift truck.. Meanwhile, the cavity
caused behind the piston is filled with brake fluid led through the return port and inlet port to
lubricate the piston. When the brake pedal is released, the piston is forced back by the return
spring. At the same time, the brake fluid in each wheel cylinder is pressurized by the force of the
brake shoe return spring, thus returning into the master through the check valve. With the piston in
its original position, the fluid in the cylinder flows into the reserve tank through the return port. The
brake fluid in the brake lines and wheel cylinders has a residual pressure proportioned(about
0.04MPa) to the set pressure of the check valve, which makes each wheel cylinder piston cup
securely seated to prevent oil leakage and eliminates of vapor lock developing when the lift truck is
sharply braked.
1. Lock nut 2. Rod 3. Duct cover 4. Clamp spring 5. Gasket ring 6. Piston
7. Primary cup 8. Spring 9. Raffinate valve 10. Valve seat 11. Cylinder
Fig.4-8 Brake master cylinder structure
41
Brake master cylinder disassembly
– Separate brake master cylinder and brake pedal.
– Take down snap ring, remove piston, insulation pad, spring seat and return spring.
Check
Clean all parts in the brake fluid and check their condition.
Serial No. Check condition Corrective action

Obvious scratch or wear on moving surface of
1 Replace
cylinder and piston
Clearance between cylinder body and piston
2 Replace
should not exceed 0.15mm.
Weak and damaged auxiliary leather collar
3 Replace
and pressure leather collar
4 Weak and damaged spring Replace
Caution
 Throw away the removed leather collar, and replace with new one.
 Remove the parts in clean ground and place them in sequence neatly.
 Do not use other cleaning agent to clean parts.
42
7 Fault diagnoses and corrections
Fault Probable cause Corrective action
Oil leakage in brake lines Correct and replenish

Air in brake lines Bleed air
Insufficient brake Water or oil on linings Clean or replace
force Uneven wear or contact of linings Grind or replace
Improper functioning of brake valve Correct or replace.
Clogged oil lines Clean
Uneven tire pressure. Adjust
Improper brake adjustment Adjust
Water or oil on brake linings Wipe or replace
Foreign pieces in brake drum Clean
Damage on friction lining Grind or replace
Improper contact of friction linings Grind or correct
Unequal braking Worn friction lining Replace
(forklift truck veers Worn, warped, rusted or damaged brake Correct or replace
to one side) drums
Improper operation of brake cylinder Correct or replace
Incorrect brake shoe sliding Adjust
Guard plate bolt looseness Tighten or replace
Guard plate warp Replace
Improperly adjusted wheel bearing Adjust or replace
Clogged oil lines Clean
No free play of brake pedal. Adjust
Incorrect brake shoe sliding Adjust
Incorrect brake cylinder operation Adjust or replace
Damage piston cup Replace
Brake dragging Weak or broken return springs Replace
Back-flow hole of brake master cylinder Clean
blockage
Clogged oil lines. Clean
Incorrect wheel bearing adjustment Adjust or replace
Lining surface harden or foreign pieces Repair or replace
on it.
Warped back plates or loosed blots. Repair or replace
Brake noise
Brake shoes warped or improper install. Repair or replace
Worn linings. Replace
Loose wheel bearing. Repair
43
8 Brake schematic
Fig.4-9 Brake schematic （Two-wheel drive）
Fig.4-10 Brake schematic （Four-wheel drive）
Ⅴ.Hydraulic system
1.Data
Main pump
2t-3.5t
Model CBHZG-F28.2-ALΦ L
44
type Gear
driving Engine power take off type: gear
displacement（ml/r） 28.2
speed（r/min） 600～3500
Output pressure
20/25
（rated/Max.）MPa
Control valve
1t-3.5t
Double-slide valve, with overflow divided valve and tilt-lock
type
valve
Adjusting pressure 18.5MPa
Rated flow rate L/min 65

Divide valve safe
10Mpa±0.5Mpa
pressure
2.Trouble diagnoses and corrections

Main pump
Trouble Probable cause Corrective action
Low oil level in tank. Add oil to specified level.
No oil from oil
Clogged suction pipe or Clean oil line and tank. If oil is dirty,
pump
strainer. change.
45
Worn bearing damaged
Replace faulty parts.
backup ring and O-ring.
Readjust to specified pressure using
Maladjusted relief valve.
Low discharge pressure gauge.
pressure on oil Retighten suction side pipe.
pump. Add oil in oil tank.
Air in oil pump. Check pumps oil seal.
Do not operate pump until bubbles in tank
disappear.
Cavitations due to crushed
Adjust or replace crushed hose and clean
suction hose or clogged
strainer.
strainer.
Air being sucked from loose
Retighten each joint.
suction side joint.
Noisy oil pump ·replace with new oil having proper
viscosity for temperature at which pump
Cavitations due to too high
is to be operate.
oil viscosity.
·to operate when oil temperature is
normal.
Bubbles in hydraulic oil. Determine cause of bubbles and remedy.
Faulty oil seal on pump,
Oil leaking
faulty O-ring or worn sliding Replace faulty parts.
from oil pump
surfaces on pump.
Control valve
Trouble Probable cause Corrective action

Loose of pressure-adjust screw. Readjusted and re-tighten.
Pressure of relief
Distorted or damaged pressure-adjust
valve is not Replace.
spring.
steady or too low.
Worn or blocked relief valve core. Replace or clean.
46
Pump abated. Examine and repair pump.
Fork tilt forward Replace valve core and tilt lock

Worn or damaged tilt lock valve.
when control valve as an assembly.
lever is used Broken tilting lock spring. Replace spring.
while engine is
off. Damaged tilt valve plunger O-ring. Replace O-ring.
Mast is unstable
Replace tilt relief valve
when tilting Malfunctioning tilt relief valve.
assembly.
forward.
Valve body and spool valve is worn
Replace spool valve with
and clearance between them is too
Lowering specified clearance.
great.
distance of mast
is big when spool Spool valve is not in centre. Keep being in the centre.
valve is in the
Cylinder seal abated. Examine and repair cylinder.
centre.
Taper valve is worn or blocked by dirt. Replace or clean taper valve.
Damaged or distorted
Replace spring.
reposition-spring.
Spool valve is not Dirt exist between valve body and
Clean.
return neutral spool valve.
position. Blocked control device. Adjusted.
Not coaxial parts at reposition Reinstall.，be coaxial
Damaged O-ring. Replace.
Faulty seal of joint. Check and retighten.

Leakage Clean seal plate and retighten
Loose seal plate.
blots.
Loosed lock-nut of relief valve and
Tighten.
connect-nut between plate and plate.
Valve disk of priority is blocked. Adjust.
Steering is heavy.
Signal port is jammed. Clean
3.Main pump
2-3.5t hydraulic system adopts CBHZG model gear pump. Gear pump CBHZG is an
external gear pump with axial interval self-compensation and radial hydraulic balance. By
using special structure, low noise comparing with those in symmetry. backing boarderials
used in the parts effectively improve the performance and make it reliable, i.g, DU sleeve
in bearing, double metal backing boarderial of side plate, AL. alloy die casting of front and
rear cover, extruding AL. alloy of middle section, etc.
CHBZG left rotation see fig. 6-1, right rotation see fig. 6-2.The difference of
47
counter-clockwise and clockwise pump is 3 shape backing plate. The direction of them is
different.
1. Snap ring 2. Oil seal 3. Mounting flange 4.Seal plate

5. 3 shape backing plate 6. Pressure plate 7. Bush
8. Driven gear 9. Drive gear 10. Gear plate 11. End cover
12. Washer 13. Mounting bolt
Fig. 6-1 CBHZG counterclockwise rotation gear pump (left)
48
4. Control valve
Two pieces type control valve consists of four pieces of valve body, two plungers, a
relief valve and a divided valve. Four pieces of valve body are assembled with three blots
and nuts. Tilting plunger is fitted by tilting lock-self valve. According to requirement of work
device, it is capable to add combined lock vale and rotating valve.
Fig.6-3 Control valve for 1t～3.5t forklift truck

4.1 Main relief valve and flow dividing valve
Main relief valve is a pilot valve; it is used for limiting the maximum pressure of
system. Main relief valve disk is not opened in normal condition. When the
truck works at overload condition, or hydraulic system faults come, the system
pressure is up to the set value of main relief valve ,the pilot valve disk firstly
opens, and then control valve disk opens to make system pressure not
increase continuously, so, it ensure system safe.
Steering relief valve is a directly operated type valve. Its set value is lower than main
relief valve, when steering system occurs faults or load is too big, pressure is up to set
value by spring, and pressure overcome spring and friction force to open relief valve. So it
ensure steering system safe.
One end of pilot valve disk connects with oil inlet of steering valve, and the other end
connects with steering valve outlet(signal port), so it make the pressure difference keep
invariableness, pilot valve supply proper oil flow according to the rotated speed of steering
wheel by driver.
Extra oil flows to supply other working devices via control valve. This device can
improve system efficiency, reduce oil temperature, improve experimental environment of
system
49
To redirector
Oil inlet
Pilot valve
Signal oil
port
Main relief
valve
Steering
relief valve
Fig. 6-4
4.2 Adjusting the pressure of the main safety valve
The main relieve valve has been adjusted before leaving the factory, , it is not allowed to
adjust at will in general condition. Adjusting way is as follows:
(1) Park the truck on solid and smooth road, place in neutral, pull up the hand brake
handle, tilt the mast backwards to the end, and drop the fork to the ground. The
engine stops.
(2) Open front soleplate, release the pressure mouth bolt of oil inlet pipeline in the
multi-way valve, and put in clean place. If hydraulic oil outflows, please protect the
environment.
(3) Connect the pressure gauge. Notice: a. Specification of gauge should be larger than
20Mpa. b. taper thread at pressure mouth matches: Rc1/8R1/8; c. tightening torque is
20N•m-22N•m.
(4) Start the engine, place the mast in vertical, and the fork is 300mm from the ground.
50
(5) Read out the indication in the pressure gauge, and judge is the main safety valve of
multi-way valve is in normal scope.
1.0t: 13MPa, 1.5t:15MPa, 1.8t:18.5MPa, 2.0t~3.5t:18.5MPa±0.25 MPa
(6) If the pressure is not in the normal scope, please release the main safety valve lock nut,
and adjust adjusting bolt.
If the indication is smaller than the normal scope, inner hexagon spanner the adjusting
bolt in clockwise (+) to increase main safety valve pressure.
If the indication is larger than normal scope, inner hexagon spanner the adjusting bolt
in counterclockwise (-) to decrease main safety valve pressure.
(7) Stable the pressure in normal scope for 30’s.
(8) Release pressure gauge, install the bolt, and the tightening torque is 20N•m-22N•m.
Drop the mast to the ground and tilt backward to end.
(9) Retighten the tightening nut, and fix it on the front soleplate.
4.3 Operation of tilt lock valve

Tilting lock valve is fitted by lock-self valve to prevent vibration owing to back
pressure inside tilt cylinder and avoid casualty because of miss-operation. According to
common structure, it can operate tilt spool to tilt forward after engine is off, but using the
tilt lock valve, when engine is off, it cannot tilt mast forward even push the lever of
operation valve, the structure is shown as Fig. 6-5.
Fig.6-5
Connector of valve body: “A”, “B” connects separately with frond and rear house of tilt
cylinder piston. When pulling out spool, high pressure oil (P) enters connector “A”, oil in
rear house returns to oil tank (T), in this time mast is in tilting backward.
When pulling tilting spool, high pressure oil enters connector “B”, by high pressure oil,
lock valve in spool works to make “A” to connect with low pressure. When engine is off or
stop, lock valve in spool cannot work without high pressure oil, so that connector “A” can
not connect low pressure line and mast cannot tilt forward, also there is not back pressure in
tilt cylinder.
51
5. Hydraulic piping
The high pressure oil from main pump goes to control valve and divide it to two parts
by priority valve inside control valve: one of them preferentially goes to steering gear
control steering cylinder, excess part goes to lifting cylinder or tilting cylinder. When lifting
and tilting spool is in neutral, high pressure oil return oil tank directly from pass way. When
pulling lifting spool, high pressure oil goes by throttle valve and then push piston rod under
lifting cylinder piston. When pushing lifting spool, it is that bottom of lifting cylinder piston
connects with low pressure line and then piston rod drops by deadweight and weight of
cargo. In this time, oil from lifting cylinder goes by unidirectional speed limiting valve so as
to control the falling speed. When operating tilting spool, high pressure oil goes to front
house of tilting cylinder and another connects with low pressure line so as to make mast
tilt forward or backward.
The cut off valve is used under right lifting cylinder, its function is to prevent goods
falling suddenly when oil pipe is busting.
52
Fig. 6-6 Hydraulic system principle diagram
53
Fig. 6-7 W98 Hydraulic system principle diagram（without OPS）
54
Fig. 6-8 W98 Hydraulic system principle diagram（with OPS）
55
Ⅵ. Lifting system
1. Assemble debugging data
Debugging data Double mast and triple mast
Standard type and
Lifting height Lifting height
Mast type lifting height of 2～4
>4～5 meter > 5～6 meter
meter
Mast For-ward 6° 6° 3°
tilt
Back-ward 12° 6° 6°
angle
Adopt combination roller and side roller if rated capacity is less than
Fork arm carrier roller
3 .5t.
Inspection and adjustment
Place Assembly clearance （mm） Repair clearance（mm）
Mast to lift roller 0.1～0.8 0.2～1
Shims 0.5,1.0,2.0
Mast to back up metal 0.1～0.8 0.2～1
Shims 0.5,1.0,2.0
Inner mast to carriage side

0.1～0.6 0.2～1
roller
Shims 0.5,1.0,1.5
Lift chain deflection 25～30

Tightening torque
Place Model or Lifting capacity N·m
1t-1.8t 193-257（M16）
Lift chain lock nut
2t～3.5t 245-314（M20）
1t-1.8t 124-165（M14）
Mast support cap blot
2t～3.5t 176-216（M18）
1t-1.8t
Tilt cylinder lock nut 89-118（M14）
2t～3.5t
1t-1.8t
Lift cylinder bolt(top) 76-107（M12）
2t～3.5t
1t-1.8t
Lift cylinder bolt(bottom) 22-30（M8）
2～3.5t
Lift cylinder fixing bolt 1t-1.8t

76-107（M12）
（cylinder clamp bolt） 2t～3.5t
56
Basic model mast weight
Model(truck) 1t-1.8t 2t-2.5t 3t 3.5t
Weight(mast) 515 652 731 836
2.Trouble diagnoses and corrections
Condition Probable cause Corrective action
Fork arm 1.Tilt cylinder and ring

Replace piston ring tilt cylinder.
carrier abraded excessively
or mast tilt by 2. The hydraulic control
itself. Replace it.
valve spring is inoperative.
The fork arms 1. Caused by piston
carrier moves Replace the faulty parts.
jamming or bent piston rod.
up
and down 2. Too much dirt is
Strip it down and clean.
sluggishly. accumulated in the cylinder.
1. Carriage bracket Adjust clearance with thrust metal and
assembly out of adjustment. carriage side roller.
2. Insufficient clearance
between inner and outer Adjust clearance with rollers.
masts or rollers and mast.
Forks are lifted 3. Biting foreign backing
or lowered boarderials between Remove foreign backing boarderials.
non-smoothly. moving part.
Apply grease on contact surfaces of
4. Insufficient lubrication.
sliding parts.（butter）
5. Bent carriage bracket
Repair or replace.
assembly.
Forks are lifted 1. Lift chains out of
Adjust lift chains.
unevenly adjustable.
1. Grease stiffened or dirt
accumulated on lift roller Clean and lubricate lift rollers.
Lift roller does and mast sliding surfaces.
not rotate
2. Improperly adjusted lift
Adjust.
roller.
1. Insufficient lubrication. Lubricate.

2. Improperly adjusted lift
Excessive mast roller, side roller and Adjust.
noise back-up metal.
By adjusting shims and rubber pad,
3. Rubber pad on lower of
piston rod is in touch with bottom of
outer mast is useless for
cylinder body after inner mast is in touch
container fork lift truck.
with rubber pad.
57
Condition Probable cause Corrective action
1. Excessive wear occurs

between the oil pump body
Replace the worn parts or the oil pump
and gears, causing too
much clearance.
2. The lifting jack piston
Yx-ring has worn, resulting in Replace Yx-ring.
excessive inner leaks.
3. Springs of the multiple
control valves and its relief
Replace.
valve are inoperative oil
leaks.
4. Excessive wear occurs
of the hydraulic control
Insufficient lift Replace.
valve, resulting in
power or no lift
excessive oil leaks.
movement.
5. Oil leaks occur between
Dismantle for regrinding the joint
the hydraulic control valve
surfaces and reassemble the valve.
sections.
6. Leakage occurs in the Tighten the joint nuts and inspect the
hydraulic pipe. seal for damage.
Change the wrong hydraulic oil or stop
7. The hydraulic oil
operation for reducing the oil
temperature is too high. Oil
temperature. Find out the reasons for
viscosity is too low and the
high oil temperature and eliminate the
rate is insufficient.
trouble.
8. The load carried is
beyond the designed Observe the lifting capacity limit.
capacity.
58
X25M300-000000-002 Lifting Mast assembly
—Tightening torque See foregoing table
59
3. Summary
The lifting system is composed of inner and outer mast, fork arm carrier, fork arm,
load backrest, chain, roller, lifting jack, and tilt cylinder, etc. Oil line system, hydraulic
pressure system and it compose fork lift truck work equipment. This equipment is
performing framework of load and unload. Commonly common mast has simple mast,
double mast and Triple mast class mast framework type. Fork lift truck what is made in our
company backing boardch Double high visibility mast, Double full free lift mast (including
container mast), Triple full free lift mast, mast framework adopted is CL model
juxtaposition roller type.
3.1 Double high visibility mast
Double mast is composed of outer mast which can’t lift and inner mast which can lift.
Lifting jack bottom is fixed on outer mast below cross beam, oriented with pin. Piston rod
extremity is joined with upper cross beam of inner mast; cylinder body is fixed on outer
mast fixation board with U-bolt. Commonly free lift range is 100 mm ~145mm, which is
difference with different tonnage. Two lifting jacks （fig.7-5 is right）are laid out back of
outer mast to realize high visibility; two lifting jacks are laid outside of outer mast.
Fork arm is hung on fork arm carrier by hook. Roller, combined roller (side roller is
installed middle of roller outside) and side roller (It is adopted combined roller in 1-1.8
tonnage fork lift truck) is installed on fork arm carrier. Combined roller is installed on below
of inner mast.
Pressure oil from hydraulic control valve is entered into lifting jack by unidirectional
speed limiting valve, forced piston and piston rod rising, thereby forced inner mast rising.
At the same time one end of lifting chain on inner mast is fixed on outer mast, the other is
joined with fork arm carrier. Fork arm carrier and fork arm is rising with inner mast rising to
realize aim of lifting goods.
It is basis model that our company offers forklift truck which lift 3 meter high. It is
especial model that our company offers forklift truck which lift height else (2m ~6 m).
3.2 Double full free lift mast (including container mast)
Double full free lift mast (Fig7-2) is also composed of inner mast, outer mast, fork arm
carrier, and etc, is also belong to high visibility mast. It is different from common standard
type mast that two postpose long lifting jacks are both pole stopper type cylinder. One
piston rod is hollow; hole of piston rod is bypassed for hydraulic pressure oil flowing into
free lifting jack. End of piston rod in two long lifting jacks is joined with upper branch of
inner mast. Besides, short lifting jack who is installed middle of inner mast is named as
60
free lifting jack. Free lifting jack is also pole stopper type cylinder.
Fork arm can rise or falling when height go beyond 1400mm, because inner mast
don’t rising when free lifting jack rising or falling. There are different specifications in this
series of height, 2.5m, 2.7 m, 3 m, 3.3m, 4 m and etc. Free lifting height is commonly
about 1050~2100mm.
When lowest height of mast ≥2200mm, lift height is 3m, full free lift height is about
1500mm. It can work inside container，mast which include side-shift is named container
fork lift truck mast (see Fig. 7-3). Side shift cylinder of container fork lift truck mast can be
side shifting only when goods don’t placed appropriate position. In another condition, side
cylinder should set center.
Left and right lifting cylinder structure see fig. 7-7.
3.3 Triple full free lift mast

Triple full free lift mast is composed of outer mast, middle mast, and inner mast,
middle mast and inner mast can flex. There are different specifications in this series of
height, 4m,4.3m, 4.5m, 4.8m, 5m, 5.5m, 6m,6.5m,7m ,etc. It is different from double full
free mast that mostly it includes middle mast, and its two postpone long lifting jacks are
both piston type cylinder(fig.7-5), and its oil system rather complex than oil system of
double full free mast. Free lift cylinder structure see fig.7-6.
Fig. 7-1 Double stage wide view mast

1.Outer mast 2. Inner mast 3. Load-backrest 4. Fork arm carrier 5. Fork arms
6.Chain 7.Left lifting cylinder 8.Right lifting cylinder 9. Tilting cylinder 10.Roller
61
Fig. 7-2 Double grade full free lifting mast
1.Outer mast 2. Inner mast 3. Chain 4. Free lifting cylinder 5. Fork arm
carrier 6. Fork arms 7.Left lifting cylinder 8.Right lifting cylinder 9. Load-backrest
10. Tilting cylinder
Fig. 7-3 Containers forklift mast

1.Outer mast 2. Inner mast 3. Chain 4. Free lifting cylinder
5. Fork arm carrier 6. Fork arms 7. Side move cylinder 8.Left lifting cylinder
9.Right lifting cylinder 10. Load-backrest 11. Tilting cylinder
62
Fig. 7-4 3 grade full free lifting mast
1.Outer mast 2. Middle mast 3. Inner mast 4. Front cylinder chain

5. Free lifting cylinder 6. Fork arm carrier 7. Fork arms 8. Chain
9.Left lifting cylinder 10.Right lifting cylinder 11. Load-backrest
12. Tilting cylinder
63
Fig. 7-5 lifting cylinder Fig. 7-6 Free lifting cylinder
(Used in fig.7-1, 7-4) (Used in fig. 7-2, 7-3, 7-4)
1. Piston 2. Dust ring 3. Gasket ring 1. Dust ring 2. Cylinder cover
4．O-ring 5.Guide sleeve 6.Cylinder 3. Protect ring 4. ISI ring 5.O-ring
7. Piston 8.Support ring 9.Protect ring 6. Compound bushing 7.O-ring
10.gasket ring 8. Bolt 9. Piston rod 10. Cylinder
11.Oil nozzle assembly(without left lifting 11. WR Wearing ring 12. Piston
cylinder)12 .O-ring
64
4. Removal and adjustment
！ WARNING
Be careful when removing and
installing the forks, carriage and mast as
they are heavy.
4.1 Remove forks and mast assembly
1） Unlock fork lock pins by pulling them
and move forks to cutout portion in the
middle of carriage bracket assembly.
2） Pull lower portion of fork to remove its
lower jaw and lift it out.
！ WARNING
a. Keep hands and feet away from forks.
When removing and installing forks
carefully, keep feet and hands clear.
b. Do not remove forks from the end of
the fork bar. Severe injury can result
if the fork is dropped.
Fig. 7-7 lifting cylinder (left)

（used in fig.7-2,7-3）
1.Dust ring 2.Cylinder cover
3. Guide sleeve 4.O-ring
5. Stop piece 6. Plunger rod
assembly
7. Support ring 8. Piston
9. Check ring 10. Cylinder 11. ISI ring 1）Remove the bolt 1 from the side of
the Load-backrest.
2） Remove the bolt 1 from The front of
the fork.
3）Remove block shelves from carriage
bracket assembly.
65
6） Pull out tilt cylinder pivot pin.
1） Attach wire ropes to carriage bracket
assembly and lift carriage bracket
assembly up with a lifting device.
2） Remove chain attaching nuts, and
detach chains from carriage bracket
assembly.
7） Remove mast support caps.
3） Remove carriage bracket assembly

8） Remove mast assembly.
from inner mast. 9） To install mast assembly, reverse
order of removal.
4） Detach high pressure hose, lift hose 4.2 Disassembly
and low pressure hose. ！ WARNING
Be careful when disassembling the masts
as they are heavy.
Remove lifting jack
1） Place mast flat on ground. Remove
lifting jack attaching bolts-bolts and
tighten screw.
5） Support mast assembly with wire

ropes.
66
INSPECTION
1） Check lift rollers, roller shafts, and
associated parts for wear or damage.
2） Replace damaged parts as required.
2） Slide inner mast, then remove lifting
4.3 Assembly and adjustment
cylinders.
Remove roller ！ WARNING
1）Slide inner mast out until rollers are Be careful when assembling the masts
exposed and remove little rollers with as they are heavy.

Lift roller
bearing puller. Make two pieces of
Slide inner mast into outer mast and
round board about 10mm thick and their
securely attach lift rollers.
diameter are Ф53 and Ф58, covered on
the seat of roller. Then remove the
compound roller and main roller with
bearing puller.
2）Unclench rollers carefully if no bearing
puller or rollers would be smashed.
Lift roller-to-mast clearance adjustment

1） Set roller pitch of inner and outer
masts to “L” dimension. Then proceed
with the following adjustment.
Dimension “L” unit：mm
Model or
Remove inner mast tonnage Ⅲ grade Ⅱgrade
Attach wire rope to middle of inner Max.lift 3t 2t～2.5t
height (mm)
mast and slide it out with a lifting device.
2500～3300 368 328
3600 388 348
67
4000 418 378
4500 443 403
2） Adjustable range “A” with shims:

a. Dimension:0.1mm～0.6mm.(≤2 t)
3） It is suitable that clearance of roller

and outer mast is about 0.8mm ～
1mm.Clearance can’t adjustable.
Replace it if roller wears too much.
4） Apply lubrication (butter) to interface of
b. Dimension:0mm ～ 0.5mm (2.5t ～ 3 inner mast and outer mast, interface of
t).One or two may not using rubber pad; roller and mast. To prevent sand from
Dimension:0.1mm ～ 0.6mm if no rubber entering, it is decided whether to apply
pad. lubrication or not in the area where
Orientation pin ensure that side roller is sand blown by wind heavily.
vertical to inner mast track. Clearance of back up metal and mast steel
Adjust clearance “B” to 0.1mm ～
0.8mm with shims, which may not use.
Thickness of shim is 0.5mm or 1mm.
68
Apply a coat of grease to back-up
metals. Install mast and lifting jack on
forklift truck. Connect circle tube and
high-pressure tube.
4.4 Left and right cylinder height
adjustment.
1）Install left and right lifting jack on mast,
pin must be installed into orientation hole
of outer mast lower cross beam.
2）Install upper of piston rod on inner mast.
Inner mast lay evenly in the direction of To adjust tension of lift chain, lower
left, right, upper and lower. If it is not lifting jack until fork is on the ground ,and
even, please adjust by putting washer adjust chain adjusting nut (three every
between hole of cylinder support and side) so that dimension C will be as listed
upper end of piston rod.
below when the middle portion of chain is
3） Installs U-bolt onto cylinder,
pressed by a finger.
hand-tighten nuts and lock it with two
Dimension C: 25 mm ~30 mm
tighten nuts. Screws down tighten bolt
and nuts to avoiding loosing.
4.5 Lifting chain adjustment

Installs fork arm carrier on inner mast,
and install lifting chain, then install two nuts
on end of every side. With mast set straight
up, lower carriage completely. Temporarily
adjust clearance of carriage to 74mm
-76mm above ground. If necessary, adjust
with chain adjusting nut. 4.6 Clearance of fork arm carrier
assembly and rollers adjustment
1） Measure inside width “A” between
inner masts. Make measurements at
the top, bottom and center (cross
beam) sections.
2） Measure right and left pitches,B,B’,B”
of carriage side roller, carriage roller
69
and thrust metal. 5. Disassembly and
3） Calculate A-B,A-Bˊand A- B".Each installation of lifting jack
result shows clearances between each
！ WARNING
roller and inner mast. Adjust shims of
Keep body away from equipment
each roller evenly on the left and right
1） Turn out engine, then make lifting jack
and make clearances, between
smallest part of inner mast and falling into lowest condition that lower of
carriage side roller. piton rod is touched bottom of cylinder
A- B = 0.2mm～1 mm body so as to oil flowing back tank
A-B′= 0.1mm～0.8 mm completely.
A- B" = 0.1mm～0.8 mm 2） Unscrew piston rod and bolt.
3） Disconnect circle oil pipe, remove
high pressure tubes.
4） Remove U-bolt of outer mast fixation
board and tighten skew of other side.
5） Remove chain of outer mast.
6）Attach wire rope to inner mast and remove
left and right lifting jack with a lifting device.
Shims
0.5 mm 1 mm
a. Number of shims must be the same on
the right and left sides, when using
shims.
b. After clearance adjustment, push
carriage assembly to see if it operates
properly.
5.1 Disassembly
Rated capacity is less than 2.5 t
Remove cylinder head and guiding
bush
70
Rated capacity is more than 3 t set center, avoid scratching Y-ring.
Removes tighten skew and nylon 7） Install replacing dust gasket ring and
stopper, then remove cylinder head. Y-ring in guiding bush and cylinder
1） Remove dust gasket ring. head.
2） Remove Y-ring with screwdriver. NOTICE：Apply hydraulic pressure grease
which trademark is the same as tank on
guide sleeve installed gasket ring
8） Rip cylinder head into piston rod,
screw down cylinder body.
6.Disassembly and
installation of tilting
cylinder
！ WARNING
Notices proceedings when removing
cylinders.
·Attach wire rope to outer mast, avoiding
mast fall down after removing tilting
cylinder.
·Keep body away from equipment, no
standing under the fork arm carrier.
CAUTION：Please not use dust gasket 1） Lay down fork arm carrier completely.
2） Remove bolt on the left and right
ring removed, O-ring, Y-ring again,
bracket of outer mast, moreover pull axis
must replace.
out.
3） Draw out piston rod , remove Y-ring
3） Remove oil pipe to the inlet of tilting
on end of piston.
cylinder.
5.2 Install and replace faulty parts. 4） Remove bolt on the bracket of
1） Cleanup parts with clean oil before Chassis, and pull pin out, then move tilting
installation. cylinder.
2） Then cleanup guiding bush and 5） The order of installation is reverse the
piston with hydraulic pressure oil the order of disassembly.
same as oil box trademark.
3） Dust or dunghill doesn’t drop into
lifting jack.
4） The order of installation is reverse the
order of disassembly.
5） Install Y-ring on piston.
6） Install piston rod assembly into clean
cylinder body.
CAUTION：The end of cylinder body

mast slick and clean, installation must
71
6.1 Disassembly of parts
1） Squeeze tilting cylinder with pliers,
then pull piston rod come-and-go as 8) Remove O-ring and Y-ring in the inner
opening of inlet and outlet on the tilting hole of guiding bush (see Fig. disassembly
cylinder, so remaining oil is discharged and installation of lifting jack).
tilting cylinder. CAUTION：No using dust gasket ring and
2） Screw earring bolts 2 loosely, and Y-ring removed.
screw earring 1 out. 6.2 Install tilting cylinder after replacing
3） Remove cylinder head guiding bush ring
3; The order of installation is reverse to the
4） Draw out piston rod assembly 4 (see order of disassembly, but should notice
as follows). follow proceedings：
1） Lubricate parts with clean hydraulic
pressure oil.
2） Avoid dust and oil dirty dropping into
tilting cylinder.
3） Avoid scratching the end of cylinder
body, and inlet and outlet for oil.
4） Push piston rod to cylinder body when
setting center, especially avoid scratching
5) Remove all dust gasket rings, O-ring Y-ring.
and Y-ring. 5） Before installing guiding bush, wipe
6）Remove dust gasket ring in the cylinder hydraulic pressure oil backing boardched
head. Means is the same as discharging with employment oil trademark in the
of dust gasket ring in the cylinder head of middle of O-ring and Y-ring in the inner
lifting jack (see disassembly and hole of guiding bush.
installation of lifting jack). 6） Don’t scratch O-ring outside in the
7）Remove O-ring outside in the guiding guiding bush when installing.
bush. 7） Remember install nylon stopper and
tighten screw after screw cylinder head.
7. Noticing proceeding of
debugging
1） Adjust Forward and Backward of the
mast
Place fork lift truck on the level ground,
72
operate control lever to realize that mast
inclined forward or backward extremely.
As assembly debugging data required,
adjust combined screw thread length till
according with data of Backward. Then
lock earring ring close. （ please see
foregoing table if you want know tightening
torque of M10 bolt）
2） Adjust installation position of left and
right lifting jack again
a. Adjust washer in the middle of piston
rod and inner mast bracket if one lifting
jack is not synchronization with the others
when rising or falling, and if one lifting jack
is different height from the others.
b. Loose two nuts on the U-bolt. Mast is
not rise and lower until relative position of
U-bolt and lifting jack is suitable. Then
screw down nuts and tightening screw on
the U-bolt. Thus lifting jack can be used
longer and wear of piston rod can be
reduced.
3） Please see foregoing table if you want
know tightening force of bolt or screw.
Please refer to common bolt tightening
torque prescribed in our company if you
want know other tightening force of bolt or
screw.（refer to OPERATION AND MAINTAIN
MANUAL backing boardched with it）.
73
Ⅶ. Interactive instrument
Key 4
Key 3
Key 2
Key 1
KUBOTA / XINCHAI Diesel engine, Main page
7.1 Engine fault information display page

KUBOTA diesel engine
No fault Fault
上一个
下一个
返回返回
Prev
Next
Back Back
①Enter the engine fault information display page: Main page=》Key 4

②Fault query page turning: press key 2 or key 3 to page turning (page turning key is not
displayed when there is no fault at present)
③Return to main page: press key 1 to return to main page
7.2 Forklift operation parameters and interface switching between Chinese and English
①Enter the engine information display page: Main page=》key 2 or key 3
②Language switch: press key 3 to switch language (Chinese / English)
74
③Return to main page: press key 1 to return to main page
Battary Engine Oil Load @

蓄电池电压发动机转速机油压力转速负载 Voltage Speed Pressure RPM
VDC r/min Bar % VDC r/min Bar %
Ash SOOT Intake Air Vehicle

Ash 负载 SOOT 负载进气温度行驶速度 Load Load Temperature Speed
% % ℃ km/h % % ℃ km/h
KUBOTA diesel engine

7.3 Settings page
7.3.1 Set page actions
高级设置 Setting
保养提醒
返回 Back
 Enter the setting page: Main page=》Key 1

 Enter advanced setting page (7.3.2): Main page=》Key 1=》Key 4, to enter advanced
setting password input page
 Enter the Emissions setting page(7.3.3): Main page=》Key 1=》Key 3, to enter the
emissions setting page
 Enter the maintenance page(7.3.4): Main page= 》 Key 1= 》 Key 2, to enter the
maintenance page
 Return to main page: press key 1 to return to main page
7.3.2 Advanced settings page
移位 Move
+ 增加 + Add
确定 Enter
返回 Back
To enter the advanced settings page, you need to enter the password first
①Shift: press key 4 to shift between four password input bits
②Digital input: press key 3 for digital input, and add 1 for each press from 0
③Password confirmation: press key 2 to confirm the currently entered password
④Return to main page operation: press key 1 to return to main page
75
Caution：default setting password: 4264
Enter the advanced setting page after the password is entered correctly
维保设置
Engine
车速设置 Speed
返回 Back
①Eter maintenance setting page (7.3.2.1): press key 4 to enter maintenance setting page
②Enter engine setting page: press key 3 to enter engine setting page (Kubota engine
invalid)
③Speed limit setting page (7.3.2.3): press key 2 to enter the speed limit setting page
④Return to the setting page operation : press the key 1 to return to the setting page
7.3.2.1 Maintenance reminders page
保存 Save
+ 增加 + Add
- 减少 - Sub
小时 Hours
返回 Back
①Save settings: press key 4 to save the current settings

②Add maintenance cycle setting: press key 3 once to add 50 hours of maintenance cycle
setting
③Reduce the maintenance cycle setting: press key 2 once to reduce the maintenance
cycle setting by 50 hours
④Return to advanced settings page: press key 1 to return to advanced settings page.
Note： The default maintenance interval is 100 hours.
7.3.2.3 Speed limit setting page（KUBOTA engine）
76
速度标定 l
限速设置
返回 Back
①Speed limit start / stop setting: press key 4 to set.

②Speed calibration setting: press key 3 to enter the speed calibration page.
( KUBOTA engine : Optional speed sensor )
③Speed limit setting: press key 2 to enter the speed limit setting page
④Return to advanced settings page: press key 1 to return to advanced settings page
Caution：default setting of vehicle speed limit control: disabled. After pressing key 4, it
will change to enable.
Speed calibration page (set the number of pulses per 10 meters)
保存 Save
+ 增加 + Add
- 减少 - Sub
返回 Back
Save settings: press key 4 to save the current settings

Pulse value increase setting: each time the key is pressed 3 times, the pulse value increases
1
Pulse value reduction setting: each time you press the key 2, the number of pulses decreases
by 1
Return to speed limit setting page: press key 1 to return to speed limit setting page
Caution：the default setting value of data is 500, and the setting range is 0-9999.
Speed setting page (set maximum speed limit value)
77
保存 Save
+ 增加 + Add
- 减少 - Sub
返回 Back
Save settings: press key 4 to save the current settings

Pulse value increase setting: press the key 3 once, the maximum speed limit value
increases by 1km / h
Pulse value reduction setting: the maximum speed limit is reduced by 1km / h every time
the key is pressed twice
Return to speed limit setting page: press key 1 to return to speed limit setting page
Caution：The maximum speed limit is 25km / h by default, and the setting
range is 3-50km/h.
7.3.3 DPF Emissions function setting page (Diesel engine)
取消禁止
禁止再生 Inhibit
请求再生 Regen
返回 Back
Cancel inhibit: press the key 4,The DPF is to burn (DPF-regenerate) trapped particulate
matters in an automatic way.
Inhibit: press key 3，DPF-regenerate function of off
Regen: press key 2 ,to turn on the manual DPF-regenerate function.
Return to the setting page: press key 1 to return to the setting page
7.3.4 Maintenance reminder maintenance page
(1) Remaining hours query page
78
重置 Reset
返回 Back
Reset: press the key 2 to jump to the maintenance time reset page to reset the remaining
hours of maintenance to the Set the initial value (maintenance interval).
Back: press key 1 to return to the setting page
(2) Maintenance time reset page
确定 Confirm
返回 Back
Confirm：press the key 2 to confirm the reset. After the confirmation, it will automatically return
to the maintenance query page.
Back: press key 1 to return to the setup page.
7.4 Disassembly and installation

Combination meter assembly
1.Remove 4 fixed bolt from meter crust. Notice that when installing and
removing ,please make instrument surface tilt an angle to avoid damaging the
screw thread of fixed parts on truck.
2.Take out wiring harness from sleeve, and then instrument can be brought
out.
3.There is transparent plastic cover to cover, so it can prevent dust and water,
and it is fixed by 6 plastic clip buckle, please press down plastic buckles lightly
to take out plastic cover when removing.
4.To install, reverse removal procedures.
79
CAN Bus Instrument
80
Ⅷ.Electrical system
Warning
 Before checking any parts of electrical system, remove rings and jewelry to prevent
short circuit, and turn off ignition switch and then disconnect battery ground cable.
 Before doing any electrical maintenance, make sure battery cable has been
disconnected.
Description
Cables are covered with color-coded vinyl for easy identification. In the wiring diagram, colors are
indicated by one or two alphabetical letters. Their meanings are as follows:
Letter B N G U O R W Y S P B/W G/Y
Black Green
Meaning Black Brown Green Blue Orange Red White Yellow Grey Purple
white yellow
Inspect
Inspect all electrical circuit, referring to wiring diagrams. Circuits should be tested for continuity or
short circuit with a conventional test lamp or circuit tester. Before inspecting circuit, ensure that：
– Each electrical component part or cable is securely fastened to its connector or terminal.
– Each connection is firmly in place and free from rust and dirt.
– No cable covering shows any evidence of cracks, deterioration or other damage.
– Each terminal is a safe distance away from any adjacent mental parts.
– Each cable is fastened to its proper connector or terminal.
– Wiring is kept away from any adjacent parts with sharp edges.
– Wiring is kept away from any rotating or moving parts.
– Cables between fixed portions and moving parts are long enough to withstand shocks and
vibrations.
– The wiring keeps a safety distance with the high temperature thing such as the vent-pipe.
81
1 Control box assembly
Component removal
– Turn key switch "OFF";
– Press lock buckle on control box and open the cover;
– Remove fuse and relay from box.
Explanation
If fuse or relay is broken, replace with new one.
①If fuse is damaged, be sure to eliminate cause of problem before installing new fuses.
②Never use fuse higher than specified rating.
82
CPCD25/30/35-XW33E-RT
K1—Starter relay K2—Head lamp relay K3—Neutral relay K4—Forward relay
K5—Reverse relay K6—Charging relay K7—Reverse handrail button relay
K8—High low speed relay SG—Flasher
Fuse identification
Position Capacity Application parts
R1 Light 15A Head Lamp
R2 Horn 10A Horn
R3 Signal lamp 10A Signal lamp
R4 Direction switch 15A Direction switch, control power
R5 Instrument 15A Instrument, indicator lamp power
R6 Engine 10A Alternator
R7 Cab 10A Cab power
R9 Backup power（1） 15A
R10 Backup power（1） 20A
83
CPCD25/30/35-XW33E-RT（OPS system）
1—Starter relay 2—Head lamp relay 3—Start control relay 4—Forward relay
8—Reverse armrest
5—Reverse relay 6—Flasher 7—Charging relay
horn button relay
10—Multi-way valve
9—High low speed relay
relay
Fuse identification
R2 Horn 10A Horn
R3 Signal lamp 10A braking light switch
R4 Direction switch 15A Direction switch, control power
R7 Signal lamp 10A Rear headlamp
R8 Controller 20A Controller
R9 Cab 15A Cab power supply 1
84
CPCD25/30/35-XW43E-RT
K1—Starter relay K2—Head lamp relay K3—Neutral relay K4—Forward relay
K5—Reverse relay K6— K7—Reverse handrail button relay
K8—High low speed relay K9—Alarm buzzer relay K10—Parking brake relay
K11—Fault alarm relay SG—Flasher

Fuse identification
R2 Horn 10A Horn
R4 Gearbox 20A High and low speed solenoid valve

Engine electronic control:
R5 Engine 5A
ECU Switch Power

Engine fault detection:
R11 Engine 15A
1939 Bus Power
R12 Engine 30A
ECU power
85
CPCD25/30/35-XW43E-RT（OPS system）
1 2 3 4 5 6
7 8 9 10 11
1—Ignition relay 2—Start relay 3—Headlight relay 4—Neutral

5—Forward relay 6—Back relay 7—Flasher 8—Multi-way valve relay
10—High and low speed
9—Start control relay 11—Horn button relay
relay
Fuse identification
R2 Horn 10A Horn
R4 Combination Switch 15A Combination Switch Power

R5 Engine 10A
ECU Switch Power
R8 Engine 30A ECU94 pin power supply

Engine fault detection:
R9 Engine 10A
1939 Bus Power
R10 Seat 10A Seat Switch power
R11 Cab 20A Cab power supply
R12 Cab 20A Cab power supply
86
CPCD25/35-XW33C-RT4
K1—Starter relay K2—Headlamp relay K3—Neutral relay K4—Start control relay

K5—Reverse gear relay K6—Charging relay K7—Reverse armrest horn button relay
K9—Second gear K10—Third gear
K8—First gear relay SG—Flasher
relay relay
Fuse list
Position Capacity Application component
R1 Light 15A Light switch power supply

R2 Horn 10A Horn
Rear headlamp, alarm lamp, braking

R3 Signal lamp 20A
light switch
R4 Combination switch 10A Combination switch
R5 Engine 15A ECU switch power supply
Instrument and indicator lamp power

R6 Instrument 15A
supply
R7 Engine 10A Generator

R11 Engine 10A J1939 Bus power supply
87
CPCD25/30/35-XW33C-RT4（OPS system）
2 3 4 5 6 7 8 9
1 11 10
1—Starter relay 2—Headlamp relay 3—Neutral relay 4—Forward relay

5—Reverse gear relay 6—armrest horn button relay 7—Multi-way valve relay
8—First gear relay 9—Second gear relay 10—Third gear relay 11—Flasher
Fuse list

R2 Horn 10A Horn
R3 Signal lamp 10A Braking light switch

R6 Instrument 10A
supply

R9 30A Reserved power
R11 Seat 10A OPS power
88
CPCD25/30/35-XW43C-RT4
K1—Starter relay K2—Headlamp relay K3—Neutral relay K4—Start control relay

K5—Reverse gear relay K6—Charging relay K7—Reverse armrest horn button relay
K9—Second gear K10—Third gear
K8—First gear relay SG—Flasher
relay relay
Fuse list

R2 Horn 10A Horn
Rear headlamp, alarm lamp, braking

R3 Signal lamp 10A
light switch

R6 Instrument 10A
supply

R12 Engine 30A ECU power supply
89
CPCD25/30/35-XW43C-RT4（OPS system）
2 3 4 5 6 7 8 9
1 12 11 10
1—Starter relay 2—Headlamp relay 3—Neutral relay 4—Start control relay

5—Reverse gear relay 6—Reverse armrest horn button relay 7—Forward relay
8—First gear relay 9—Second gear relay 10—Third gear relay 11—Multi-way valve relay
12—Flasher
Fuse list

R2 Horn 10A Horn
Rear headlamp, alarm lamp, braking light

R3 Signal lamp 10A
switch

R6 Instrument 10A Instrument and indicator lamp power
supply
R10 Seat 10A Seat Switch power
R12 Engine 30A ECU power supply
90
CPCD25/30/35-XW98C-RT4
1—Start relay 2—Headlight relay 3—Electric control relay 4—Neutral relay

5—Reverse relay 6—Horn button relay 7—Third gear relay 8—First gear relay
9—Second gear relay 10—Preheat relay 11—Flasher
Fuse list
R1 lighting 15A Light switch power supply

R2 horn 10A Horn power supply
Power supply of rear headlamp,
R3 Signal lamp 15A
alarm lamp and brake lamp
R4 Solenoid valve 15A Third gear solenoid valve
Power supply of instrument and
R5 Meter 10A
indicator light
R6 Engine 10A ECU start power
R7 Engine 20A Electric control relay
R8 Engine 5A ECU power R2
R9 Cab 10A Cab power 1
91
CPCD25/30/35-XW98E-RT2
1—Start relay 2—Headlight relay 3—Electric control relay 4—Neutral relay

8—High and low
5—Reverse relay 6—Horn button relay 7—Forward relay
speed relay
9—Preheat relay 10—Flasher
Fuse list
R1 lighting 15A Light switch power supply

R2 horn 10A Horn power supply
Power supply of rear headlamp,
R3 Signal lamp 15A
alarm lamp and brake lamp
R4 Solenoid valve 15A Direction switch (power supply)
Power supply of instrument and
R5 Meter 10A
indicator light
R6 Engine 10A ECU start power
R7 Engine 20A Electric control relay
R8 Engine 5A ECU power R2
92
2 Instrument,sensor and relay
Combination instrument assembly
– Remove 4 fixed bolts from meter case. Notice that when installing and removing, please make
instrument surface tilt an angle to avoid damaging the screw thread of fixed parts on truck.
– Take out wiring harness from sleeve, and then instrument can be brought out.
– There is transparent plastic cover to cover, so it can prevent dust and water, and it is fixed by 6
plastic clip buckles, please press down plastic buckles lightly to take out plastic cover when
removing.
– To install, reverse removal procedures.
Two wheel drive：
93
Four wheel drive：
94
Temperature display Temperature display
temperature starting point temperature starting point
Display effect Display effect
range Sensor resistance (Ω) range Sensor resistance (Ω)
Comparison table of water temperature parameters

Note: when the water temperature reaches 110 ℃, the water temperature symbol will flash and
the buzzer will give an alarm of 1Hz.
Comparison table of oil quantity parameters
Oil volume
Sensor resistance (Ω)
Display effect
95
Key (start) switch
Disassemble and install
– Remove combination meter.
– Disconnect connector of wring.
– Remove nuts, washers, spacers and instrument plate.
To install, reverse removal procedures.
Adjust ledge of switch to proper length when installing.
Inspect
Use multimeter (with ohm) to check key switch whether it is on at each position.
Switch position Terminal
OFF OFF
ON B1-B2-Acc on
START B1-B2-Acc-C-R2 on
Principle diagram of preheat start switch

Connection point
Position B1 B2 Acc C R1 R2
Preheat O O O
Close O O
Run O O O
Start O O O O
Backup buzzer disassemble and install

– Remove the wiring terminal, then unscrew the bolt.
To install, reverse removal procedure
Horn disassemble and install

– Disconnect horn harness connector.
– Remove bolt and horn.
To install, reverse removal procedure.
96
3 Lighting system
specification
Lamp Specification
Headlight
Front lighting
Steering lamp 12V-24V
Width lamp
Combined back lamp（LED）

Brake and width lamp (3.2V-20mA)×15
Steering lamp (3.2V-20mA)×15
Reverse lamp (3.2V-20mA)×15
Combination instrument
Lighting lamp
12V-2W
Caution lamp
12V-2W
Disassembly and installation for head lamp
– Remove the front lamp fixing nut.
– Disconnect the wiring connector.
– Remove the LED headlight.
– Installation is the reverse of removal
97
Disassembly and installation of rear combination lamp
– Take down rear combination lamp from overhead guard;

– Bring the whole rear combination lamp to maintain location, remove rear lamp cover,
and remove 4 bolts from back of cover;
– Remove LED penal , loosen 2 bolts from fixed connector, disconnect connector,
replace new LED panel
– To install, reverse removal procedures.
Direction switch（two-wheel drive）

Disassemble
1.Remove combined switch
2. Unscrew the screws, and disconnect
the wiring connector.
To install, reverse the order of removal.
F1—Forward 1 gear
F2—Forward 2 gears
R—Reverse gear
98
Direction switch（four-wheel drive）
Disassemble
1.Remove combined switch
2. Unscrew the screws, and disconnect
the wiring connector.
To install, reverse the order of removal.
1— 1 gear
2— 2 gears
3 —3 gears
F—Forward gear
R—Reverse gear
Direction switch check
– Disconnect switch connector clip, and check if each point is connected.
– Use multimeter (with ohm) to inspect whether each position is connected: F1, F2, N,
R.
（two-wheel drive）
Position Contact
F1 2—6
F2 3—6
N 1—6
R 4—6
99
（four-wheel drive)
Position Contact
F1 4—8
F2 4—8
F3 4—8
F 1—2
N 不导通
R 2—3
Light switch Turn signal switch

Dismantle
29. Dismantle combination instrument.
30. Unscrew screw, disconnect wiring
connector
To install, reverse removal procedure
Power
Turn light check
– Use multimeter(with ohm) to inspect whether it is on when turn light switch is on these
positions: left turn, N, right turn.
100
Position Contact
Left turn 1-2
N OFF
Right left 1-3
Inspect lighting switch
– Disconnect switch connector, and check whether each connection point is on.
– Use multimeter (with ohm) to inspect whether it is on when lighting switch is on these
positions: head lamp, width lamp, OFF.
Position Contact
Head lamp 4-6
Width lamp 4-5
OFF OFF
101
120 Ω
Preheat relay coil

ground terminal
Preheat relay coil

control terminal
Starter lock control

terminal inal 120 Ω
Pin sheath
Severe fault warning indicator light(Red)
Fault indicator light (Yellow)

Fault page on selection
Preheat start indicator light(White)
signal terminal
Fault page down selection

signal terminal
Common control terminal
Fault detection signal terminal

Accelerator pedal positive
power terminal
Accelerator pedal signal
feedback terminal
Accelerator pedal ground terminal
Accelerator pedal switch normally

closed terminal
Accelerator pedal switch
ground terminal

open terminal
start and preheat are short

working,automatically
return.
Note: "O" means ON.
Fig.1 CPCD25/30/35-XW43E-RT Electrical system diagram

Battery 12V DC
Alternator
Starter start and preheat are short

return.
Note: "O" means ON.

Glow plug
Preheat relay coil

ground terminal
Preheating relay
coil control terminal
Fuel water filter
terminalinal
Charge indicator lamp signal terminal
Oil pressure indicator lamp Fuel water filter
ground terminal
Oil temperature indicator lamp
Water temp
Oil gauge
Timer Severe fault warning indicator light(Red)
Preheat start indicator light(White) Fault page on selection

signal terminal
neutral indicator
Parking indicator Fault page down selection
signal terminal
Common control terminal
Fault detection signal terminal

Buzzer Accelerator pedal positive
power terminal
Working device solenoid valve feedback terminal

closed terminal
High speed solenoid valve Accelerator pedal switch
ground terminal
Forward solenoid valve open terminal
Rear headlight
Turn left indicator lamp
Left turn signal lamp-Front
Left turn signal lamp-Rear
Right turn signal lamp-Front
Right turn signal lamp-Rear
Turn right indicator lamp
Warning lamp
Left brake lamp
Right brake lamp
Horn
Reverse handrail button
Rear-left width lamp

Rear-right width lamp
Front-left width lamp
Front-right width lamp
Left head lamp
Right head lamp
Fig.1-1 CPCD25/30/35-XW43E-RT Electrical system diagram(OPS system)
103
return.
Fig.2 CPCD25/30/35-XW33E-RT Electrical system diagram
104
return.
Note: "O" means ON.
Fig.2-1 CPCD25/30/35-XW33E-RT Electrical system diagram(OPS system)
105
Battery 12V DC
Alternator
Starter
Preheat plug
Water temperature sensor
Oil return solenoid valve
Preheat indicator lamp

Charge indicator lamp
Oil pressure indicator lamp
Oil-water separator indicator lamp
Water temp
Oil temp
Timer
Parking indicator lamp
Mid-position indicator lamp
Forward solenoid valve

Reverse solenoid valve
Left reversing lamp
Right reversing lamp
Reverse warner
Fuel cut off solenoid valve
Forward first gear solenoid valve
Forward second gear solenoid valve
Forward third gear solenoid valve

4WD
Differential lock
Rear headlamps
Warning lamp
Left brake lamp
Right brake lamp
Horn

Left head lamp
Right head lamp
Fig.3 CPCD25/35-XW33C-RT4 Electrical system diagram
106
Battery 12V DC
Alternator
Starter
Glow plug start and preheat are short

working,automatically return.
Water temperature sensor
Oil return solenoid valve
Preheat indicator
Charge indicator lamp
Oil pressure indicator lamp
Oil water separation warning light
Water temp
Oil gauge
Timer
Seat belt indicator
OPS Fault indicator
Parking brake lamp
Buzzer
Working device solenoid valve
Fuel cut solenoid valve

First gear relay
Second gear relay
Third gear relay

4WD
Differential lock
Rear headlight
Warning lamp
Left brake lamp
Right brake lamp
Horn

Left head lamp
Right head lamp
Fig.3-1 CPCD25/35-XW33C-RT4 Electrical system diagram（OPS system）
107
Battery 12V DC
Alternator
Starter
Preheat plug
Preheat relay coil end
Charge indicator lamp Starter lock control terminal Fuel water filter
signal end
Oil pressure indicator lamp The source of the fuel

water filter
Water temp
Oil temp
Timer
Parking indicator lamp

Left reversing lamp
Right reversing lamp
Reverse warner
Forward first gear solenoid valve
Forward second gear solenoid valve
Forward third gear solenoid valve
4WD
Differential lock
Rear head lamp
Warning lamp
Left brake lamp
Right brake lamp
Horn
Reversing handrail horn switch

Left head lamp
Right head lamp
Fig.4 CPCD25/35-XW43C-RT4 Electrical system diagram
108
Battery 12V DC
Alternator
Starter

return.
Glow plug
Preheat relay coil

ground terminal
Note: "O" means ON.
Preheat relay coil
control terminal
terminalinal Fuel water filter
Charge indicator lamp signal terminal
Oil pressure indicator lamp Fuel water filter

ground terminal
Water temp
Oil gauge
Timer Severe fault warning indicator light(Red)
Preheat start indicator light(White)

Parking brake lamp
Buzzer
Accelerator pedal positive
power terminal
Working device solenoid valve feedback terminal

closed terminal
Accelerator pedal switch
ground terminal
Forward solenoid valve Accelerator pedal switch normally
open terminal
First gear relay
Second gear relay
Third gear relay
Differential lock
Rear headlight
Warning lamp
Left brake lamp
Right brake lamp
Horn

Left head lamp
Right head lamp
Fig.4-1 CPCD25/30/35-XW43C-RT4 Electrical system diagram(OPS system)
109
Fig.5 CPCD25/30/35-XW98C-RT4 Electrical system diagram
110
Fig.5-1 CPCD25/30/35-XW98C-RT4 Electrical system diagram(OPS system)
111
Fig.6 CPCD25/30/35-XW98E-RT2 Electrical system diagram
112
Fig.6-1 CPCD25/30/35-XW98E-RT2 Electrical system diagram(OPS system)
113

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2.5-3.

5T Rough terrain forklift truck

HANGCHA GROUP CO., LTD.

■ Address For: OVERSEAS USERS

© 06/2020 HANGCHA GROUP CO., LTD.

Parameter QSF2.8T3NA49 (Cummins)

Rated power kw 36.5

Rated power kw 42.1

Rated power kw 47.3kW/2400 r/min

Specifications, structure and maintenance methods :

QSF2.8 Cummins engine see ENGINE OWNERS MANUAL.

Repair status regeneration Engine Fault code

1. Bolt 2. Nut 3. Washer 4. Tire assembly 5. Drive axle

Fig. 2-1 Drive system（Two-wheel drive）

1. Wheel assy. 2. Bolt 3. Nut 4. Washer 5. Bolt 6. Right gearbox

Fig. 2-2 Drive system（Four-wheel drive）

torque ratio at 0 speed

2.2 Main technical parameters

Main technical parameters refer to table 2

F1 gear 3.3153 3.2657

Drive ratio on F2 gear 1.6318 1.6346

Drive ratio on F2 gear 1.3993 1.4017

2.3 Installment and use notice

2.4 Fault reason and corrections

1 Friction lining stuck or damage. Check if friction lining has gluing,

pressure port, lubricating oil port and oil drain hole.

2). Trouble diagnoses and corrections

condition Probable cause Corrective action

·loose driving axle and body connecting blots. Tighten.

Fig. 2-4 Drive axles

1. Half shaft bolt 110-130

2. Wheel hub nut 324-373

3. Brake base plate bolt 260-300

3). Driving axle assemble removal and installation

Fig.2-5 Fig.2-6 Fig.2-7

⑥ Fabrication mill finish directs to bearing when installing locknut.

Vehicle gear oil GL-5 5．8L /

4). Axle shaft and wheel hub

Total reduction ratio 18.63

Reduction ratio Main reduction ratio 4.11

Max. pressure 4.8MPa

Whole axle braking torque 12000N·m

Type Mobil 424 hydraulic

Lubricating oil The lower limit of oil level is

2. Fault diagnosis and corrections

Condition Possible reason Corrections

·Drive axle bearing plate and chassis

·Axle oil sealing wear or damage Replace

3. Replace gear oil

Gear oil The lower limit of oil level is 8mm

4. Disassembly and assembly of the drive axle

Disassembly of the final drive

3 Dismantle the following parts(with cylindrical spiral

2 Dismantle the following parts from the wheel

4 Dismantle the following parts from the wheel

2 Dismantle the following parts from the friction

Steering axle assy

Fig.3-1 Steering system drawing

Fig.3-2 Steering device structure

1.Bolt 2. Washer 3. Dust ring 4.Base plate 5.Steering bumper block

Fig.3-3 Steering axle structure

Fig.3-4 Four-wheel drive steering axle structure

two-wheel drive rough terrain forklift truck