（英文）4 5吨内燃平衡重式叉车使用说明书内页

User Manual of 4-5 Ton Diesel Balance Weight Forklift
Foreword
Firstly, thank you for using and understanding out products. To ensure the
correct, safe and efficient use of the forklift, please carefully read this
manual before using it.
This manual mainly focuses on the performance, structure, operation, repair
and maintenance of FD45/50/ series of forklifts so that the operators could
correctly use and maintain in a good state.
During the usage period, relevant operators and managers of the forklift
shall carefully execute the requirements and stipulations of this manual on
the use and maintenance of the forklift so that it could be always
maintained in a good state.
Zoomlion forklifts are subject to constant improvement so it is impracticable
for us to keep you updated with all of the improvements. We sincerely
appreciated for that!
Final interpretation of this manual will be owned by Zoomlion Anhui
Industrial Vehicle Co., Ltd.
Zoomlion Anhui Industrial Vehicle Co., Ltd.
January 2015
Content
I. Safety Precautions for Forklift Operation......................................................5
1. Safe operation procedures for forklift drivers.......................................... 5
2. Transport with forklift................................................................................6
3. Safekeeping and re-using...........................................................................6
3.1 Safekeeping of forklifts.........................................................................6
3.2 Reusing of the forklift........................................................................... 7
4. Preparation before usage.......................................................................... 7
5. Daily maintenance of the forklift...............................................................8
5.1 Matter of attentions in daily operation of the forklift.........................8
5.2 Attentions for using the cooling system.............................................. 8
5.3 Whole forklift lubrication..................................................................... 9
5.4 Hydraulic oil, grease and anti-freezing liquid used for the forklift......9
5.5 Lubrication system diagram............................................................... 10
6. Forklift operation..................................................................................... 11
6.1 Driving and instruments..................................................................... 11
6.2 Starting Operation.............................................................................. 11
6.3 Turning on and off the lights.............................................................. 12
6.4 Operation of the gear-changing handle.............................................13
6.5 Pedal operation...................................................................................13
6.6 Operation of multi-way valve.............................................................14
6.7 Steering wheel operation................................................................... 15
6.8 Parking brake handle.......................................................................... 15
6.9 Moving the forks.................................................................................16
6.10 Towing pin.........................................................................................17
6.11 Seat attachment............................................................................... 17
6.12 Hood Opening and Engine Stall........................................................18
6.13 Get on and get off forklift................................................................ 18
6.14 Protection during Work....................................................................19
II. Main Technical Parameters of Forklift....................................................... 20
III. Description of Main Forklift Parts..............................................................23

IV Structure, Principle, Adjustment................................................................ 23
1. Power System...........................................................................................23
1.1 Overview............................................................................................. 23
1.2 Engine..................................................................................................24
1.3 Fuel System......................................................................................... 24
1.4 Cooling System....................................................................................25
1.5 Inspection and Adjustment................................................................ 26
2. Electrical System...................................................................................... 30
2.1 Overview............................................................................................. 30
2.2 Brief Manipulation Description.......................................................... 31
2.3 Storage Battery................................................................................... 32
2.4 Wiring Harness....................................................................................32
3. Transmission Device................................................................................ 34
3.1 Torque converter................................................................................ 34
3.2 Oil feed pump..................................................................................... 35
3.3 Gearbox...............................................................................................36
4. Drive axle..................................................................................................38
4.1 Overview............................................................................................. 38
4.2 Maintenance....................................................................................... 39
5. Brake system............................................................................................ 39
5.1 Overview............................................................................................. 39
5.2 Service brake mechanism...................................................................40
5.3 Brake................................................................................................... 41
5.4 Parking brake mechanism.................................................................. 45
6. Steering system........................................................................................46
6.1 Overview............................................................................................. 46
6.2 Steering gear.......................................................................................48
6.3 Inspection of steering system after reassembly................................54
6.4 Removal of steering system fault.......................................................56
6.5 Steering axle assembly....................................................................... 57
7. Hydraulic system......................................................................................59
7.1 Overview............................................................................................. 59
7.2 Multi-way valve...................................................................................61
7.3 Multi-way control device....................................................................65
8. Lifting Cylinders and Tilt Cylinders.......................................................... 68
8.1 Lifting oil cylinder................................................................................68
8.2 Block valve.......................................................................................... 69
8.3 Governor valve....................................................................................70
8.4 Inclined oil cylinder.............................................................................72
9. Lifting system........................................................................................... 73
9.1 Overview............................................................................................. 73
9.2 Inner portal frame.............................................................................. 74
9.3 Fork support........................................................................................75
9.4 Adjustment of lifting system.............................................................. 75
I. Safety Precautions for Forklift Operation
1. Safe operation procedures for forklift drivers
1.1 A person could not drive a forklift until he/she accepts training, passes
examination and holds a forklift driver license;
1.2 A forklift driver must wear specifically designed shoes, hats, clothes and
gloves for safety purposes while working on a forklift;
1.3 Each control and alarm device must be inspected before driving a forklift.
DO NOT operate until any damages or defects are corrected;
1.4 Adjust the location of the seat and the angle of the back rest to a proper
position as per the adjustment signs on the
1.5 DO NOT try lifting an object with a load exceeding the upper limit. Insert
the full length of the forks into under the object the weight of which shall be
distributed onto the forks evenly. DO NOT use a single fork to lift the object.
1.6 Start, turn, drive, brake and stop the forklift smoothly. Slow down when
turning directions in damp or slippery roads;
1.7 Lower down the object as much as possible on loaded drive and
maintain the mast in a back inclining position;
1.8 Use care when driving on a slope. When driving on a 10% slope, drive
forward when climbing up a slope and backward when descending down
the slope; DO NOT turn directions when driving up and down the slope;
when the forklift goes down a slope, DO NOT load an object;
1.9 Mind walking people, barriers and rough road surface when driving the
forklift;
1.10 DO NOT allow any person to stand on the forks or in the driving cab;
1.11 DO NOT allow any person to stand or walk under the fork;
1.12 Trying to operate the forklift or attachments from a place other than
the driver seat is prohibited;
1.13 When lifting a forklift with a 3m high lift range, mind the falling object
and take necessary protection measures if necessary;
1.14 Try to maintain the mast in a back inclining position as much as
possible when operating a high lift range forklift; the loading and unloading
practices shall be conducted in forward leaning state to the minimum
extent;
1.15 Use additional care when driving on a wharf or temporarily laid plates
and drive slowly;
1.16 The driver shall turn off the engine and leave the forklift when filling
fuel. DO NOT fire the forklift up when checking the battery or the liquid level
in the fuel tank;
1.17 Drive an unloaded forklift with attachments in the same manner as if it
were a loaded forklift;

1.18 When handling unfastened or loosely packed objects, use care when it
comes to those with large sizes;
1.19 When leaving the forklift, land the forks on the ground and place the
gear in neutral position. Turn off the engine or cut off the power source.
When stopping on a slope, set the stop and braking system in place. Use
wedge blocks to secure the wheels when the stop would take a long time;
1.20 DO NOT open the water tank cover too casually when the engine is hot;
1.21 Before being shipped out of the factory, the forklift’s multi-way values
and safety vales have been well adjusted and should not be casually
adjusted by users later so as not to make a too high pressure, causing
damages to the whole hydraulic system and hydraulic components;
1.22 The air inflation pressure in the tires shall follow the values specified on
the tag of “tire pressure”;
1.23 The external noise level of the forklift is not more than 89 dB(A), as
tested in the procedure of JB/T3300;
1.24 Get familiar with and pay attention to the indicating function of various
labels on the forklift;
1.25 When leaving the forklift, tightly pull stop and braking system and place
the gear in neutral position.
2. Transport with forklift
Pay attention to following matters when loading the forklift:

2.1 Pull the manual parking brake handle in place;
2.2 The mask and the balance weight shall be secured with steel wires on
both the front and the back; use wedge blocks to well and safely cushion
corresponding positions of the front and rear tires;
2.3 When lifting objects, follow the positions marked on the “lifting tag” of
the forklift.
3. Safekeeping and re-using
3.1 Safekeeping of forklifts
If a forklift is expected to be idle for more than 2 months, conduct following

procedures before safekeeping it:
1) Check and make sure the tire pressure meets specified requirements;
2) Erect the mast and land the forks on the ground;

3) Apply rust resisting oil or lubricant oil to chains and exposed plunger rod
of the oil cylinder;
4) Remove the battery enclosures and the battery
5) Tighten the manual brake handle;
6) Release the cooling liquid in the engine and the water tank;
7) Add auxiliary support wood block under the rear bridge;
3.2 Reusing of the forklift
Before reusing a forklift that has been put into storage for a long time,
conduct following inspections:
1) Check and make sure the tire pressure meets specified requirements;
2) Check the diesel and hydraulic oil and replace them, if necessary;
3) Add cooling liquid; check the electrolytic solution in the battery and make
replenishment when the liquid level is low;
4) Tighten connection bolts as per specified torques;
5) Conduct unloaded forklift test firstly after re-starting; do not operate until
all moves are proven to be normal.
4. Preparation before usage
1. DO NOT check fuel level, hydraulic oil level and electric instruments. DO
NOT add fuel when the forklift is in operation;
2. Check the tire pressure;
3. The gear handle shall be in neutral position (Gear 0);
4. DO NOT smoke when operating and checking the fuel system and the
battery;
5. Check the conditions of each handle and the pedal;
6. Make good preparation before starting the forklift;

7. Release the parking brake device;
8. Try moving up and down the mast, inclining forward and backward,
steering and braking.
5. Daily maintenance of the forklift
5.1 Matter of attentions in daily operation of the forklift
1) The level of the hydraulic oil shall be in the middle of the scale of the oil
level gauge;
2) Check if the engine oil amount of the forklift engine meets requirements;
3) Check if the cooling liquid of the engine is enough;
4) Check if the pipes, connectors, pumps and valves have leakage and
damages;
5) Check the parking brake:
a) The idle stroke of the brake pedal should be 40mm;
b) The clearance between the front bottom plate and the pedal shall be
more than 20mm.
6) Check and ensure decent performance of the traveling system and the
parking brake system. When the manual brake handle is pulled to the
bottom, the forklift shall be reliably stopped by brake on a 20% slope (rated
load).
7) Instruments and lamps, etc: check if the instruments, lighting lamps,
connectors, switches and electric lines work normally.
8) Check the effectiveness, reliability and flexibility of the steering gear.
9) Discharge the sediment in the engine oil cleaner and clear off the
deposited dusts in the air cleaner.
10) Clean the floating dusts, soil and dirt on the forklift. Key areas are the
fork holder and the mast slide. Remove foreign objects like gravels that may
be embedded into the tires.
5.2 Attentions for using the cooling system
Attention!
When using the forklift, if the heat radiator “boils” or the cooling liquid
temperature is too high, DO NOT uncover the heat radiator immediately. If
the uncovering is necessary, slow down the engine to medium speed and
slowly rotate the heat radiator cover. Wait until the after temperature drops
before removing the radiator cover to prevent the cooling liquid from
splashing out and burning the operators. When tightening the radiator cover,
tighten it to the proper location; otherwise the specified pressure system
could hardly be maintained.
5.3 Whole forklift lubrication
Within the first two weeks of using a new forklift or a forklift that is reused
after long-term stop, use new lubricant oil to squeeze out old lubricant oil
when lubricating the bearings and such procedure shall be repeated more
than two times. Meanwhile, pay attention to following points:
1) Before lubrication, remove the dirt on the surface of the cover, oil plug
and oil nozzle so that the dirt would not fall inside the mechanism.
2) When injecting the lubricant with grease gun, it shall be conducted to
such an extent that lubricant is squeezed out of the junctions of the
components.
3) Change the lubricant (engine oil, etc) seasonally in summer or winter.
5.4 Hydraulic oil, grease and anti-freezing liquid used for the forklift
Name Original Brand, code and usage temperature

oil
Diesel Code of light 0 -10# -20# -35#
diesel
Usage 4 -5 -5~-14 -14~-29
temperature(C)
Diesel The Great Viscosity grade 5W/30 10W/30 15W/40 20W/50
engine oil Wall Usage -30~+30 -25~+30 -20~+40 -15~+50
temperature(C)
Hydraulic oil The Great Viscosity grade L-HM32 L-Hv32
Wall anti-wear low-temperatur
hydraulic oil e anti-wear
hydraulic oil
Usage temperature(C) -5 -20 (outdoor in
cold region)
Hydraulic
transmission Sea 8# hydraulic transmission fluid
fluid
Brake fluid Chongqing DOT3 synthetic fluid
Yiping
Lubrication The Great 3# general lithium lubricating grease (-20C ~+120C)
grease Wall
Gear oil for Viscosity grade 85W/90GL-5 85W/90GL-5
heavy load Sea Usage -15~+49 -25~+49
vehicles temperature(C)
Anti-freezin Jinbai Code FD-1 FD-2 FD-2A FD-3
g liquid Usage
temperature(C) -25 -35 -45 -50
5.5 Lubrication system diagram
Lubrication system diagram

6. Forklift operation
6.1 Driving and instruments
Graph: Forklift driving control

1. Timing chart; 2. Water temperature gauge; 3. Fuel gauge; 4. Parking brake
handle; 5. Gear-change handle; 6. Steering wheel; 7. Inching pedal; 8. Brake
pedal; 9. Fuel pedal; 10. Lifting handle; 11. Inclining handle; 12. Starting
switch;13. Steering indicator switch; 14. Trumpet button
6.2 Starting Operation

OFF- the stop position of the key, where it could be inserted in or pulled
out.
ON-the working position of the engine, whereupon the instruments and
indicators of the forklift will be displayed.
START-starting position of the engine; it would automatically go back to
ON after starting and when the key is released.
Attention:
Before starting, the driver shall be seated properly; check and make sure
the gear-changing handle is in neutral position; otherwise the forklift could
not be started properly.
DO NOT allow the starting motor to start for over 10 seconds; if the
starting fails, turn the key back to the OFF position and wait for 30 seconds
for re-start.
When the engine starts, DO NOT turn the starting switch back to the
starting position; otherwise the starting motor may be damaged.
6.3 Turning on and off the lights
(1) Turn left (2) Turn right
Front light and turning light control handles

When the starting switch is in ON, lift up the switch handle and the front
light will be turned on.
Attentions: if the front light is not needed, please turn it off. Turning on
the front light for a long time would lead to over-discharge of the battery
and affect the starting capacity of the engine.
Whether the starting switch is in On or OFF, pushing forward or pulling
back the light switch will be able to turn on the left and right turning switch
to flash the turning lights.

Pushing forward—the left turning light will be turned on;
Pulling back-the right turning light would be turned on.
6.4 Operation of the gear-changing handle
The handle that controls the driving direction and speed of the forklift
This forklift has three gears in total: two forward gears and one backward
gear. When the handle is pushed forward, it will be pushed forward under
the first gear and then under the second gear. When the handle is pulled
backward, it will be under the backward gear. Between the first forward
gear and the backward gear there is the neutral gear.
Attention: before starting, the handle shall be placed in the neutral
position; otherwise the forklift would not be able to be started.
6.5 Pedal operation

(1) Inching pedal (2) Brake pedal (3) Acceleration pedal
Inching pedal (1)

When treading down this pedal, the forklift could move slowly to realize
required inching movement; when this pedal is floored, it could also serve
as a brake.
Brake pedal (2)
When treading down this pedal, the forklift could be slowed down or
stopped and the brake light would be turned on.
(3) Acceleration pedal
Treading down the acceleration pedal could increase the rotation speed of
the engine, increasing the forklift’s movement speed and lifting speed.
When releasing the pedal, the engine would run at the idle speed.
6.6 Operation of multi-way valve
(1) Lower down (2) Lift up
Lift handle
Used to lift up and lower down the forks
Lift up-pulling back
Lower down-pushing forward
Inclining handle
Used to lean forward and backward the forks
Lean forward—pulling back
Lean backward—pushing forward
6.7 Steering wheel operation
The steering wheel is used to control the travelling direction of the

forklift to the left or the right. The operator may also hold the ball handle of
the steering wheel with the left hand only to realize such functions.
The central cover of the steering wheel is the trumpet button. Pressing
down the button would blow the trumpet, even if the starting switch is
turned off.
6.8 Parking brake handle
When the forklift stops, before the driver leaves, he/she shall firmly hold
and draw the handle toward him/her as shown in Position (1) in the graph.
Floor the brake pedal before such operation.
When releasing the parking brake, hold the handle firmly and push it back
to Position (2).
Attention: when the forklift would be parked on a slope for a long time, in
addition to pulling the handle in place, triangle wedges should be wedged
under the wheels.
The forklift would be damaged if it is started without releasing the parking
brake.
6.9 Moving the forks
(1) Fork brake
Before moving the forks, lift up the stopper handle, rotate it so that the
block pin would be placed onto the end surface of the round sling, when the
forks could be moved to the left or the right. After adjustment is over,
reinstate the stopper handle to the original position.
Attention: before handling an object, please check and make sure that
the locating pin of the forks has been secured!
6.10 Towing pin
The towing pin is inside the hole of the balance weight in the rear of the
forklift used to tow other attached vehicles, or allow the forklift to be towed
by other vehicles when the forklift is unable to work, or attach the sling to
lift up the forklift.
Attention: before towing the fork lift with other vehicles, dismantle the
two half axles from the driving bridge; otherwise the forklift will be
damaged!
6.11 Seat attachment
(1) Seat sliding rod

(2) Safety tie
When the seat sliding rod (1) is pulled up, the seat’s forward or
backward position could be adjusted. After adjustment, gently shake it to
secure the seat is locked in position.
Pull the safety belt out of the retractor and insert the projecting tongue
into the fixing base. When a click is heard, it means the buckle is secured
already.
Attention: remember to fasten the safety belt before operation! In

case the forklift overturns, the safety belt would greatly reduce the chance
of injury or death.
6.12 Hood Opening and Engine Stall
Hood opening and engine stall are achieved by flexible shaft and link
mechanism
When sitting on the seat, the driver pulls the handle, (1) the hood hook
is unconnected to the suspension loop. After the driver leaves the seat, the
hood will automatically open under the effect of gas spring.
When stalling the engine, the driver pulls the handle (2) until the engine
is totally stopped.
6.13 Get on and get off forklift
At the left side of the forklift, hold the handle and step on the safety
tread on the step to get on and get off the forklift
•Note:
When getting on and off the forklift, do not grasp the steering wheel or
control lever
Do not jump on or off the forklift. It is very dangerous
6.14 Protection during Work
During work, it is required to wear work clothes, helmet as well as

necessary articles for labor protection such as anti-skid gloves, and eye
protection equipment and necessary tools.
•Note:
The forklift shall only operate in the specified or allowed workplace. The
forklift is not allowed to run on road or in unauthorized places, as well as
flammable, explosive and other dangerous areas.
II. Main Technical Parameters of Forklift
No. Item Unit FD45 FD50L
1 Rated load kg 4500 5000
2 Load Center Distance mm 500
3 ,Maximum lifting height mm 3000
4 Free lifting height mm 140
5 Fork size mm 1070 X150X55
0
6 Frame angle 6/12
7 Minimum ground clearance mm 160
8 Minimum turning radius mm 2760 2800
9 Running speed, Forward km/h 9/19/9

I/Forward II/Back
10 Lifting Full load mm/s 410

speed
11 No load mm/s 430
12 Falling Full load mm/s 380

speed
13 No load mm/s 340
14 Maximum Full load kN 22

traction
15 No load kN 18
16 Maximum full-load climbing % 20 18

gradient
17 Domensio Length mm 4170 4215

n
18 Fork length wihtout mm 3060 3105
load
19 Width mm 1480
20 Height of overhead mm 2350

guard
21 Height of gantry mm 2245
when not lifting
22 Minimum right angle aisle mm 2740 2800

width; rightangle aisle width
23 Axle base mm 2000
24 Tread front wheel/rear wheel mm 1180/1190
25 Adjustment distance of fork mm 300-1340
26 Braking distance (no load) mm ^6(19Km/h)

Moving distance (no load)
27 Tire Front wheel 300-15-18PR
28 Rear wheel 7.00-12-12PR
29 Engine Model LR4B3G
30 Cylinder bore X mm 108X125

stroke
31 Total displacement cc 4580
32 Compression ratio 17:1
33 Power/rotary speed kw/rp 57/2200

m
34 Maximum Nm/rp 285/1300-1500
torque/rotary speed m
35 front overhang mm 570

36 Dead weight kg 6380 6600
Forklift Outline and Structure Size

III. Description of Main Forklift Parts
For main forklift parts, see the following table

No. Name Content
1 Power Include engine installation, fuel, exhaust and cooling system
system
2 Electrical Include lamps, batteries, instrumentation, wiring harness and
system other electrical components
3 Drive Include torque converter, gear box, differential mechanism,
system drive shaft, variable speed control
4 Drive axle Include axle case, axle shaft, brake and front wheel
5 Braking Include running brake and stopping brake
system
6 Steering Include steering wheel, fully hydraulic steering system
system
7 Steering Include steering axle, steering cylinder and rear wheel
axle
8 Lifting Include doorframe, fork, fork arm carrier, backrest, tilt cylinder,
system lifting cylinder, lifting chain, gantry sprocket, roller and so on
9 Body Include frame, instrument stand, internal combustion engine
system hoop, water tank cover plate, balancing weight, base board,
and seat
10 Operating Include (1) running brake and tender motion (2) stopping brake
system (3) accelerator manipulation
11 Hydraulic Include pump, valve, high and low pressure pipes, joints
system
12 Overhead Overhead guard (optional part in driver’s cab)
guard
IV Structure, Principle, Adjustment
1. Power System
1.1 Overview
Power system mainly includes engine, fuel system, cooling system and
exhaust system. The engine is mounted to the frame through cushion
rubber to reduce vibration. Engine and torque converter, gearbox, drive axle,
water tank and pump are combined together, shown in Figure 1.1.
Figure 1.1 Power system

1. Drive axle; 2. Gearbox; 3. Torque converter; 4. Engine; 5. Water tank;
6. Drive unit of pump
1.2 Engine
This series of forklifts is mainly equipped with Luoyang YTO Diesel

engine. The specific parameters are shown in Table 1.1. For detailed
description of engine, please see the engine manual in the attached
documents.
Table 1.1 Main Parameters of Engine
Engine Model LR4B3G
Type In-line water-cooling four-stroke,
direct injection
Cylinde Number of cylinder-cylinder bore 4—108x125

r X stroke 4.581
Total displacement 18-20
Rated power/rated rotary speed 57KW / 2200rpm
Maximum torque/ rotary speed at the 285N.m/ 1300~1500rpm
maximum torque ≤800±30rpm
Idle speed ≤235g/kw.h
Minimum fuel consumption Anticlockwise
Cranksaft rotation direction 410kg
Net weight 1—3—4—2
Work sequence of cylinder Forced water cooling cycle
Cooling system Pressure and splash
Lubrication system
1.3 Fuel System
Fuel system consists of fuel tank, filter and fuel sensor

1.3.1 Fuel Tank

Fuel tank is in a welding structure, which is connected to frame, and
put at the left side of the frame. Behind it, there are refueling pipes; above it,
there is a tank cover plate, which is equipped with fuel sensor, shown in
Figure 1.2.
1.3.2 Fuel Sensor
The function of fuel sensor is to convert the remained fuel volume into
current through up and down motion of float, and finally reflect it to the
fuel meter on the instrument board, to display intuitive remained fuel
volume, shown in Figure 1.3
Figure 1.2 Fuel Tank Figure 1.3 Fuel

Sensor
1.3.3 Fuel Filter
Fuel filter is used to filter fuel supplied to the engine, and it can supply
fuel to the engine.
1.4 Cooling System
The cooling system consists of pump, fan and tank. The pimp is
installed on the engine and driven by the crankshaft through V-shaped belt.
When the pump woks for 50-60 hours, it is necessary to check and adjust
the tightness of fan V-shaped belt. Too loose or too light will affect cooling
effect and shorten service life of V-shaped belt. During check, press
V-shaped belt between pump and engine with a force of 30-50N. The
pressure distance shall be 10-15mm. When changing V-shaped belt, it is
required to change both of them. It is not allowed to use one old and one
new belts or belts from different manufacturers.
Below the pump, there are weep holes, shown in Figure 1.4. It is not
allowed to block it in order to prevent leaked water from flowing into pump
bearing, which results in rapid bearing wear. In the outlet pipe of pump,
there is a thermostat, which ensures first small cycle of cooling water after
the diesel engine coldly starts. Until reaching the set temperature, the
thermostat will open for major cycle. The opening temperature of
temperature controller is 82 ± 2 ° C and the opening stroke of value is
8-10mm.
Note: During use, it is not allowed to freely remove thermostat;
otherwise, it will affect the normal operation of the engine as well as its
service life.
The cooling liquid added to the tank shall be clean water. If
anti-freezing solution is not used, at the outside temperature below 5 ° C,
when the diesel engine stops, it is necessary to open the water outlet
switches on cylinder block, radiator and oil cooler to release the cooling
water in the cooling system in order to avoid sudden temperature drop and
cracking of cylinder block, water tank, oil coolers and other components.
Figure 1.4 Pump Figure 1.5

Thermostat installation
1. Oil cup; 2. Water seal; 3. Bearing; 4. Weep hole 1. Stud; 2. Cover; 3.
Gasket; 4. Thermostat; 5. Housing; 6. Small water pipe
1.5 Inspection and Adjustment
To keep the engine in good working condition, it is necessary to regularly

inspect and maintain the engine. The essentials are as follows:
1.5.1 Air Filter
Structure is shown in Figure 1.6
(1) Remove filter element
(2) Check whether there is dust on the filter element or it is damaged.

Blow the low-pressure air from inside to outside to clean the filter element.
If it is seriously blocked and it is difficult to clean or it has been damaged, it
is necessary to change it.
(3)Clean dust in the cover
Figure 1.6 Air Filter
1.5.2 Fuel Filter

(1) Use special wrench to remove the filter. If it is damaged or blocked,
it is necessary to change it.
(2) Before installation, add several drops of fuel around the seal ring of
the filter. After the seal ring contacts the filter body, then tighten it 2/3
circles
Figure 1.7 Fuel Filter
1.5.3 Oil Filter

(1) Use special wrench to remove the filter and change it
(2) Add several drops of lubrication oil around the seal ring of the filter.
After the seal ring contacts the filter body, then tighten it 2/3 circles
(3) Change cooling liquid
Figure 1.8 Oil Filter
1.5.4 Fastening of Cylinder Head Screw

The diesel engine uses special cylinder head screws. When tightening
the cylinder head screws, it is necessary to follow the rule of crossing
symmetry, from inside to outside, and layer by layer. The order is shown in
Figure 1.9. At the first time, tighten with 80Nm of torque; at the second
time, tighten with 181Nm of torque
Figure 1.9 Tightening order of cylinder head screw
1.5.5 Adjustment of Valve Clearance

The intake valve clearance of diesel engine is 0.3-0.4mm and the
exhaust valve clearance is 0.4-0.5mm. Rotate the crankshaft to oil supply
TDC of 1st cylinder. From the front end, adjust 1, 2, 3, 6 valve clearances,
namely from front to back is “intake, exhaust, intake, exhaust”. Then rotate
crankshaft for one cycle to oil supply TDC of 4th cylinder. Adjust 4, 5, 7, 8
valve clearances, namely from back to front is “exhaust, intake, intake,
exhaust”. See Figure .10
Figure 1.10 Adjustment order of valve clearance

1.5.6 Installation of Timing Gear
There are strict requirements for the opening and closing time of intake
and exhaust valves of diesel engine as well as the fuel injection time of fuel
injection pump relative to movement location of the crankshaft. There is a
certain angular position relationship among camshaft gear wheel, gear of
fuel injection pump and crankshaft gear. The marks of gear of fuel injection
pump and crankshaft gear are aligned, as shown in Figure 1.11; otherwise,
the diesel engine cannot start or is damaged.
Figure 1.11 Timing gear chamber

1. Spare gear; 2. Camshaft gear wheel; 3. Idle gear; 4. Gear of fuel injection
pump; 5. Oil pump gear; 6. Crankshaft gear; 7. Hydraulic pump gear
2. Electrical System
2.1 Overview
Electrical system is the one-wire-system circuit with negative earth,

responsible for execution of forklift control order, light signal display and
power supply for all electrical elements. The electrical system mainly
consists of the following systems
2.1.1 Charging System
It consists of generator, battery and charging indicator, responsible for
power supply for electrical equipment. Voltage: DC24V
2/1/2 Start System
It mainly consists of preheating system, starting switch, starting
protection circuit and starter. Its main function is to start the engine.
2.1.3 Instrument System
It mainly consists of hour meter, fuel gauge, water temperature gauge
and the charge indicator, oil pressure indicator, neutral indicator, air filter
clogging warning light, and water precipitation (oil-water separator) light. It
is the inspection equipment on the forklift.
Figure 2.1 Electrical schematic diagram
2.1.4 Illumination Signal Equipment

Include various illuminations, signal lights and trumpet as well as buzzer
Headlamp: 70w
Front combination lamp (steering/width display): 21w/8w
Rear combination lamp (steering/width display/ head back/brake: 21w
(yellow) / 8w (yellow) / 10w (white) / 21w (Red)
Warning light (optional part): 21w
Rear lamp (optional part): 70w
License plate light (optional part): 10w
2.2 Brief Manipulation Description
2.2.1 Start
Before starting the engine, it is necessary to put the gearshift lever in
neutral (neutral indicator light is on), otherwise the engine will not start.
The start-up protection circuit is designed with safe start protection function
in order to prevent accidents. Rotate the starting switch clockwise to second
gear (startup gear), then the engine can start.
It is necessary to warm up when starting the engine in the cold regions.
Rotate the starting switch counterclockwise to the H-gear (warm-up gear).
The resistance wire of warm-up indicator gradually turns bed. At this point,
the intake air of the engine is heated to facilitate start. Rotate the stating
switch clockwise to 1 gear (power gear). The instrument is connected to the
power supply. The gear of starting switch is shown in Figure 2.2.
2.2.2 Light Switch
Pull out first gear. The front and rear width display lights are on. Pull to
second gear. The headlamp is on. At this point, the width display light is still
on.
2.2.3 Steering switch
Pull back the steering switch. The front combination light and rear
combination light at the right side of forklift are on. Pull the steering switch
forward. The front combination light and rear combination light at the light
side of forklift are on.
2.2.4 Brake Switch
The brake switch is installed under the brake pedal. When the brake
pedal is stepped, the rear combination light-brake light (red) is on.
2.2.5 Back-up Switch
The back-up switch is installed on the control valve of gearbox. When
the gear shift lever is pulled back to back-up gear, the rear combination
light-back-up light (white) is on, and the back-up buzzer is sounding.
2.2.6 Charging indicator
Before starting the engine, rotate the starting switch clockwise to first
gear (ON). At this point, the charging indicator is on. After starting the
engine, then flame out. If the engine is in a working state, the charting
indicator is on, indicating that there is fault in the charging circuit. It is
necessary to stop the forklift and check.
2.2.7 Oil Pressure Indicator
Before starting the engine, rotate the starting switch clockwise to first
gear (ON). At this point, the charging indicator is on. After starting the
engine, then flame out. If the engine is in a working state, the oil pressure
indicator is on, indicating that the oil pressure is too low. It is necessary to
stop the forklift and check.
2.2.8 Fuel meter: represent fuel storage volume in the oil tank
2.2.9 Water temperature meter: display the temperature of cooling
liquid of engine
2.2.10 Hour meter: accumulate working hours of engine
Figure 2.2 Starting switch Figure 2.3

Combination meter
2.3 Storage Battery
The storage battery consists of two 6-QW-90 maintenance-free

batteries in series. During use, there is no need of adding liquid. Note that
improper use of battery will generate inflammable gas and there is a danger
of explosion. Therefore, it is necessary to avoid short circuit as well as spark.
Fire is forbidden.
2.4 Wiring Harness
The wiring harness of forklift mainly consists of wiring harness of

instrument and wiring harness of engine, detailed in Figure 2.4 and 2.5.
Wire numbers and meanings are shown in 2.1

Table 2.1 Wire color letter
B R G Y L W Br Lg P V
black red green yellow blue white brown light pink violet
green
GY, GR, GW, WB, YR, RY, RB, LB represent bi-color wires. Number before
bi-color wire represents nominal cross section area of wire. For instance,
5BR represents black and red wires with the nominal cross section area of
5mm2.
Figure 2.4 Wiring harness of instrument

Figure 2.5 Wiring harness of engine
3. Transmission Device
3.1 Torque converter
The hydraulic torque converter is the impulse welding type and

indecomposable. It mainly consists of pump impeller, turbine and guide
roller.
The pump impeller is connected to the motor flywheel through spring
coupling disc. The mechanical energy of motor is transferred into kinetic
energy of fluids to make the fluid flow into turbine at high speed and drive
the rotation of turbine, then is output by turbine shaft and deliver the
rotating speed and torque to gearbox. After outflow from turbine, the liquid
flow enters the guide roller. When the load of torque converter is great and
the turbine rotating speed is at the stage of lower torque, the guide roller is
wedged and cannot rotate, the liquid flow acts on guide roller and the
torque reacts on turbine, and it causes the torque in turbine equal to the
addition of torque of pump impeller and guide roller, thus the output torque
is bigger than input torque, the bending moment occurs automatically. The
structure is as shown in figure 3.2.
Figure 3.2 Torque converter

1. Input plate 2. Bearing 3. Turbine 4. Pump impeller 5. Overrunning clutch
6. Impeller 7. Bearing 8. O ring
3.2 Oil feed pump
For the structure of oil feed pump, please refer to figure 3.3.
Figure 3.3
The oil feed pump consists of drive cylindrical gear, passive internal
gear, shell and cover, and it is installed in the upper part of torque converter.
The drive gear in oil feed pump is driven by pump impeller of torque
converter through neutral gear and oil pump gear. The oil liquid in the lower
part of the gearbox is supplied to torque converter for refilling by the oil
feed pump, and supplied to control valves to control shift gears and
switching.
3.3 Gearbox
3.2.1 Structure and Operating Principle of gearbox

The gearbox in this series of forklift is liquid drive gear box, and consists
of gearbox, main reducer. The gearbox includes two-directional clutch
assembly, one-directional clutch assembly, idler shaft, output gear, control
valve assembly, etc. There are two forwards gears and one reverse gear,
driven by power. For the structure, please refer to figure 3.4.
Figure 3.4 hydrodynamic transmission

1. Flexible connecting disc 2. Oil pump 3. Reverse gear 4. Reverse clutch 5.
Two-directional clutch 6. The first forward gear clutch 7. Control vale 8.
The first forward gear 9. Bearing block 10. Differential support 11. Drive
cone gear 12. Bearing cap 13. Passive cone gear 14. Adjusting nut 15.
Differential mechanism 16. Box 17. Suction pipe 18. Idler shaft 19.
Output gear 20. Torque converter shell 21. The second forward gear
clutch 22. The second forward gear 23. One-directional clutch 24.
Hydraulic torque converter 25. Turbine shaft 26. Oil filter 27. Overflow
valve 28. Pressure regulating valve
The two-directional clutch controls the switching of the first forward

gear and reverse gear, while the one-directional clutch controls the
switching of the second forward gear. Both of them are controlled by control
vale. The oil pump 2 is the internal gearing gear pump, and driven by the
motor through pump wheel. The oil pump system supplies pressure oil for
the system. The oil after the operation of hydraulic torque converter flows
into the radiator of the vehicle and then the gearbox to lubricate the friction
piece, bearing and gear after passing the oil filter. For the principle that the
gearbox controls the oil route, please refer to figure 3.5.
Figure 3.5 The principle that the gearbox controls the oil route
1. Oil tank 2. Coarse oil filter 3. Oil pump 4. Major pressure valve 5. Inlet
overflow valve 6. Torque converter 7. Cooler 8. Fine filter 9. Trimmer
valve 10. Change-over valve 11. Inching valve 12. Operating valve
3.2.2 Removal of drive system fault

Sheet 3.2 Reasons and removal method for drive system fault
Common fault Reasons Removal method
Effect decreases and the 1. The friction piece is 1. Replace friction piece
oil temperature is too high blocked or worn, 2. Repair or replace oil
uneven contacting or pump
bending 3. Replace bearing

2. Insufficient oil supply 4. Smoothen oil channel
for torque converter 5. Replace torque
3. Bearing is broken converter
4. The lubricating oil
channel is blocked
5. The one-directional
wheel of the torque
converter is blocked
Oil leakage 1. The seal gasket is 1. Replace sealing
broken gasket
2. The rubber parts is old 2. Replace rubber parts
or broken 3. Replace parts
3. The parts are broken
or cracked
The clutch pressure is low 1. Oil level is too low 1. Fill the oil volume to
and the swing is big 2. The rotating sealing of normal position
clutch shaft and piston 2. Replace rotating
is broken sealing
3. The oil pump is broken 3. Replace oil pump
4. The filter screen of the 4. Clean or replace oil
oil filter is blocked filter
4. Drive axle
4.1 Overview
The drive axle consists of axle case, brake, brake drum, hub and axle
shaft, etc. The axle case is the casting structure wholly, and integrated to the
gearbox with flange. For the details, please refer to figure 4.1. The power
passes main reducer (differential mechanism) and axle shaft to the hub to
drive the rotation of wheel.
The brake drum and rim are fixed on the wheel shell with bolts and
nuts. The hub is supported on the drive body by two cone roller bearings.
The brake is fixed on the drive case and installed inside the brake drum. The
quality of the front axle in the forklift is borne by the hub and axle. The axle
shaft only bears the torque instead of bending moment, so it is called
full-floating type.
Figure 4.1 Drive axle

1. Axle case 2. Brake drum 3. Hub 4. Outer oil seal 5. Axle shaft 6. Round
nut 7. Outer bearing 8. Inner bearing 9. Inner oil seal 10. Brake
4.2 Maintenance
For the specifications of the tyre and rim of the drive axle and tyre
pressure, please refer to the sheet shown as follows:
Sheet 4.1 Parameter of drive axle
Specifications of the front tyre 300-15-18PR
Air pressure of the front tyre MPa 0.8
Specifications of front rim 8.0-15
Tightening torque of tyre bolt Nm 480-560
Tightening torque of axle shaft bolt 100-120
Nm
The drive axle connects to the gearbox inside. It can be fueled through
the oil filling port on gearbox or drive axle. The oil volume and mark should
conform to the specifications in The Oil Sheet in the first part of this manual.
There is an air hole in the upper part of drive axle to diffuse heat, and the
shield hole should keep smooth.
5. Brake system
5.1 Overview
The brake system consists of service brake, parking brake and brake
driving mechanism. The service brake adopts dynamic braking type, and the
parking brake adopts mechanical leverage power structure. For the major
parameters of brake system, please refer to sheet 5.1:
Sheet 5.1 Major parameter of brake system

Brake Brake type Internal expanding lining,
non-balanced
Inner diameter of brake 317.5
drum
Inner diameter of wheel
cylinder
Lining dimension
Brake Diameter of master
valve cylinder
Rated pressure Mpa 16
Rated flow 1/min 20
5.2 Service brake mechanism
The service brake mechanism in this series of forklift uses the hydraulic
pressure system built in the forklift to provide a certain flow of pressure oil
source for brake valve through mono-stable divider valve; the brake valve is
controlled by foot plate, thus realizing power brake. The brake operation is
safe, reliable and energy saving, and can ensure the reliable brake when the
forklift does not have power oil source in coasting mode. For the service
brake structure, please refer to figure 5.1.
Lead to multiple unit valve
Figure 5.1 Service brake mechanism

1. Brake 2. Brake valve 3. Brake pedal 4. Divider valve 5. Oil pump
2. 6. Fuel tank
The brake pedal and inching pedal are installed on the left of frame
through a supporting plate, as is shown in figure 5.2. The brake pedal on the
right drives the piston assembly of brake valve through connecting rod. The
pressure oil is controlled by pedal. The inching pedal on the left and brake
pedal on the right play a role of linkage, and can control brake valve as well
as the inching valve of gearbox.
The brake pedal and idle stroke and pedal travel should conform to the
requirement in figure 5.2. In maintenance, adjust it as required and ensure
the sealing of each part of the pipeline.
Figure 5.2 Service brake pedal device
5.3 Brake
5.3.1 Brake structure

The service brake is non-balanced drum brake and consists of brake
shoe, spring, wheel cylinder, regulator and baseplate. For the details of
structure, please refer to figure 5.3. Two brakes are installed on both ends of
drive axle and the brake drum is installed in drive axle case. One end of
brake shoe is connected to the supporting pin and gap regulator, and pulled
to the plunger of wheel cylinder by spring or compressed spring pull pod.
The master brake shoe is equipped with hand braking pull rod, and the
auxiliary brake shoe is equipped with adjusting pull rod of gap regulator.
Notes: because this brake is drive by liquid oil, the leather cup of
brake master pump and wheel cylinder is the oil-proof rubber, which
cannot be replaced by general rubber in replacement.
Figure 5.3 Brake

1. Pin roll 2. Brake cylinder 3. Leather cup 4. Piston 5. Ejector rod 6. Support
7. Return spring
5.3.2 Adjustment of brake

The brake in this series of forklift has the mechanism of automatic gap
adjustment. When the brake shoe is worn, the brake will be backward, and
the adjusting steel rope will move adjusting pawl to adjust brake gap within
0.25-0.4mm.
In case of manually adjusting the gap after replacing the shoes or repair,
firstly take away the rubber cover in the regulator installed in the brake base
plate, stir and rotate the gear of the regulator with screwdriver from the
inner side to outer side until the friction piece contacts the inner wall of
brake drum, and then rotate the regulator tooth 5-6 tooth space backwards
(please refer to figure 5.4). Finally install the rubber cover after adjustment.
Expanding direction
Figure 5.4 Brake gap adjustment
5.3.3 Overhaul of brake
Check whether the braking performance of the brake is effective or
reliable. In case of bad or loss of braking performance, check whether the
gap between brake shoe and brake drum is between 0.25 mm and 0.4 mm.
in case above gap or good braking performance cannot be reached, the
brake shall be disassembled and repaired by specialists.
Check whether all the parts are worn or broken. In case of
disqualification, please replace or repair it.
1) Check whether the surface inside the heel cylinder or cylindrical surface
of piston rust; then measure the gap between the piston and cylinder.
The specified value: 0.03-0.10mm
Limit value: 0.15mm
2) Visually check whether the leather cup of wheel cylinder is broken or
deformed. If so, please replace it;
3) Check the free length of the cylinder spring. In case of unsuitable, please
replace it.
4) Check the thickness of friction piece. In case of excessive wearing, please
replace it.
The allowable minimum thickness: 10mm
5) Check the diameter of inner surface of brake drum. In case of excessive
wearing, please replace it.
Specified value: 317.5mm
Allowable maximum value: 319.5 mm
6) Measure the free length and installation load of return spring of the
brake shoe. In case of non-conforming to the requirement, please
replace it.
7) Check whether the regulator is broken and its operating conditions;
check the contacting point of the adjusting leverage is sound, and
whether the adjustment by pawl is effective. In case of damage, please

clean the inner surface before installation.
8) Check whether inside the brake drum is oil sludge, and please clean the
inner surface before installation.
5.3.4 Removal of brake fault

Sheet 5.2 Removal of common fault of brake
Fault Reason Removal method
Braking forceis not The braking liquid is leaked in Repair
sufficient brake system
The gap between friction piece is Adjust
adjusted improperly
Brake is overheated Check whether it is slip
Bad contact between brake drum Adjust
and friction piece
Impurities adhere to the surface Repair or replace
of friction shoe
The flow volume in divider valve Repair or replace
is not sufficient
The brake pedal is adjusted Adjust
improperly
Noise in brake operation The surface of friction shoe Repair or replace
hardens or impurities adhere to
it.
Connecting bolt is loose or the Repair or replace
baseplate is deformed
The friction shoe is deformed Repair or replace
after assembly or improper
assembly
Wearing of friction piece Replace
Wearing of wheel bearing Replace
Fault Reason Removal method
Uneven brake Impurities adhere to friction shoe Repair or replace
Improper action by wheel Repair or replace
cylinder
Off-center of brake drum Repair or replace
Gap of friction piece is adjusted Adjust
improperly
Inflation pressure of tyre is Adjust
improper
Pedal is soft without Leakage in brake system Repair
power Gap of friction piece is adjusted Adjust and repair
improperly
Air is in brake system Venting
Pedal is adjusted improperly Readjust
5.3.5 Brake valve

The power brake valve includes control valve, brake pump, master
cylinder and divider valve. The function of the control valve is to transfer the
pedal force into hydraulic power, as is shown in figure 5.5. then the brake is
realized by the power of hydraulic pressure oil.
When the brake pedal is stepped, the action of the pedal will pass to
piston, and then the inner cavity of the piston “A” is narrowed, while the oil
pressure in “B” increases, pushing the piston move towards left. At the same
time, “A” is open and the oil pressure in “B” increases, and the piston stops
moving.
The movement of input piston drives the movement of driving piston,
then the hydraulic pressure oil flows into the brake cylinder, enlarging the
operating force and completing brake function. The pressure in “B” will give
the piston an reacting force, and thus the drive can also feel the realization
of brake.
Figure 5.5 Brake vale

1. Valve body 2. Leather cup 3. Divider valve 4. Spring 5. Check valve 6. Plug
7.stop dog 8. Piston 9. Power piston 10. Control valve 11. Valve base 12.
Reacting piston 13 Push rod
5.4 Parking brake mechanism
The parking brake mechanism include parking brake handle and brake
steel rope, as is shown in figure 5.6.
The foot brake and it share the brake shoe and brake drum. The brake
handle is the knuckle type, and has the function of leverage power
increasing. The brake power is regulated by adjusting the screw on the top
of the handle. Rotate towards the right, the brake power increases,
otherwise, the brake power decreases.

When the forklift makes the parking brake in the slope with specified
gradient under standard load, measure the moving force in B point by
dynamometer, and the operating force of handle shall not be more than
300N.
Brake position
Adjust this place with screwdriver
Removal position
Brake stay rope Decrease
Increase
Brake
Figure 5.6 Parking brake mechanism
6. Steering system
6.1 Overview
For the major parameter of the steering system, please refer to sheet
6.1. The steering system consists of steering wheel, steering column
(including steering shaft and locking handle), cardan joint assembly, steering
gear, steering axle and steering cylinder. For the steering operation device,
please refer to figure 6.1.
Sheet 6.1 The main parameter of steering system

Model FD 45 FD50
Item
Steering system type Full-hydraulic power rear-wheel
transverse oil cylinder steering
Steering wheel diameter mm Φ360
Steering Type BZZ series full-hydraulic steering gear
gear Displacement ml/min 200
Rated pressure MPa 16
Steering oil Type Transverse and double-action type
cylinder Cylinder diameter/rod Φ90/60
diameter mm
Stroke mm 2*123
Divider Set pressure MPa 12
valve Rated flow l/min 12
Steering Type Central supporting transverse oil cylinder
axle type
Steering angle 78.7/54.6°
Outer tyre/inner tyre
Rear wheel track mm 1190
Space of master pin of 1020
steering knuckle mm
Wheel Tyre 7.00-12-12PR
Rim 5.50-12
Air pressure MPa 0.8
The steering shaft and steering gear are connected by cardan joint. The
steering wheel drives the steering shaft and cardan joint to rotate the
steering gear, realizing hydraulic pressure steering. The steering column
supporting the steering shaft
Can be inclined for some angles to be adjusted to the suitable position and
meet the demand of drivers of different heights. For the full-hydraulic
steering system, please refer to figure 6.2.
Steering wheel
Locking handle
Steering gear
Cardan joint
Connecting
shaft assembly
Figure 6.1 Steering control device
Figure 6.2 Sketch map of steering system

1. Steering wheel and column 2. Oil pump 3. Metering valve 4. Steering
gear 5. Steering oil cylinder 6. Steering axle 7. Oil pipe
6.2 Steering gear
6.2.1 Structure of steering gear

The steering gear is cycloidal full-hydraulic type. It can deliver pressure
oil from divider valve to steering cylinder through oil pipe according to
rotation angle of steering wheel, thus realizing the steering of rear wheel.
When the motor is flameout, and the oil pump cannot supply the oil, the
steering can be made manually. For the structure of steering gear, please
refer to figure 6.3.
Figure 6.3 Cycloidal full-hydraulic steering gear

1. Limited block 2. Valve body 3. Valve core 4. Connecting shaft 5. Spring
piece 6. Connecting block 7. Rotor 8. Stator 9. Valve pocket 10. Pull pin
6.2.2 Operating principle of steering gear

The valve core, valve pocket and valve body in steering gear constitute
the servo disc valve, which controls the flow direction of the oil. The rotor
and stator constitute the cyclonical mesh pair and play the role of measuring
element in power steering to guarantee that the oil volume flown into the
oil cylinder is positive to the rotating angle of steering wheel. It also plays
the role of manual oil pumping manual steering, and the driving shaft plays
a role of transmitting torque.
In neutral position (i.e. steering wheel keeps still), the oil from oil pump
in open-center system will return oil tank through cavity of valve core. (in
figure 6.4)
In power steering, the oil from oil pump flows through cycloidal pin
wheel mesh pair to push the rotor to rotate with the direction. Besides, the
oil will flow into left or right cavity in hydraulic state, and pushes rotating
wheel to realize power rotation. The oil volume is positive to rotating
angle and the oil in the other cavity of the cylinder will return oil tank. (b, c
in figure 6.4)
When the motor is flameout, the steering wheel can be controlled
manually. The rotor will be driven by valve core, pull pi and driving shaft to
pressurize the oil in one cavity to the other cavity, thus pushing the rotating
wheel and realizing manual rotation (d in figure 6.4). the oil will be refilled
from oil tank through refilling check valve.
The BZZ1 steering gear in this series of forklift is open-center
non-feedback type, namely the external force acting on the rotating wheel
will not be delivered to steering wheel and the driver will not feel the road.
Neutral position Turn left
Turn manually
Turn right
Figure 6.4 Working principle of steering gear

6.2.3 Inspection and maintenance of steering gear

To make the steering system keep good operating condition, and
prevent from accident, please do inspect it regularly.
(1) Regularly check the water content of operating oil liquid, mechanical
impurities, and acid value. in case of more than that in original plate,
please replace new oil. it is not allowed to use second-hand waste oil
without filtering.
(2) When checking the steering system, the steering gear shall not be
disassembled randomly. When confirming the fault of steering gear,
remove it as required in “Notes for Assembly”.
(3) All the accessories that can be disassembled and installed shall be
cleaned. The field should be cleaned. All the accessories had better be
disassembled indoors.
(4) Notes for assembly
a. Before assembly, clean all the parts with gasoline and kerosene. In case
of the paint in contacting surface, clean it with acetone. Cotton yarn or
waste cloth is not allowed to clean the parts, other than hairbrush or silk.
If permitted, blow it by compressed air. The rubber ring is not allowed to
immerse the gasoline for a long time. After installing the steering gear,
50-100mlhydraulic pressure oil shall be added to oil inlet before
shipment. Rotate the valve core towards left or right, in case of no
abnormal phenomenon, make assembly and commissioning.
b. The contacting surface of valve body, partition disc and rear cover shall
be cleaned completely without scratching or hitting.
c. The screw cover must be lower than the level of valve body.
d. On one side of retaining collar and slide ring is a chamfer surface. The
chamfer surface of the retaining collar shall be toward the front cover
while the chamfer surface of the slide ring shall be toward the valve core.
e. In the end surface of rotator and driving shaft is point of compact, and
two points should be opposite in assembly.
f. The gasket of limit bolt (with pin) must be coper gasket or aluminum
gasket.
g. Tightening method of seven bolts in rear cover: screw it every other two
bolts in order, tighten them gradually instead of successively. The tightening
force is 30-40N.m
h. In installing the oil pipe, please pay attention to the mark of “inlet”,
“return”, “left” and “right” on valve body and the valve shall be connected
to the oil pipe correspondingly.
(5) Disassembly and assembly (please refer to figure 6.5)
a. Disassembly order: front cover-retaining collar-sliding ring-valve pocket,

etc.-(gasket-pull pin-valve core-spring piece)-rear cover-limit
post-stator-rotor-driving shaft-partition disc-swivel nut-steel ball-valve body
If disassembling it from the rear cover, firstly take the steel ball away before
taking away the valve core. Otherwise, the valve body will be broken.
Besides, when disassembling the front cover, do not hit or scratch the other
end surface of the valve body.
b. Assembly order: valve core-spring disc-valve pocket-pull pin-gasket-sliding
ring-retaining collar-front cover-steel ball- swivel nut-partition disc-driving
axle-rotor-stator-limit post-rear cover.
Figure 6.5 Disassembly and Assembly of Steering Gear
阀芯 Valve core 弹簧片 Spring piece

阀套 Valve pocket 滑环 Sliding ring
挡环 Retaining collar 阀体 Valve body
“O”型密封圈 “O”-type seal ring 前盖 Front cover
“X”型密封圈 “X”-type seal ring 弹簧垫圈 Spring gasket
螺钉 Screw 钢球 Steel ball
螺栓 Bolt 限位螺栓 Limit bolt
垫圈 Gasket 铜垫圈 Copper gasket
拔销 Pull pin 限位销 Limit pin
螺套 Swivel nut 后盖 Rear cover
转子定子组 Rotor and stator pair 限位栓 Limit bolt
联动轴 Driving shaft 隔盘 Partition disc
6.2.4 Fault of steering gear and its removal

Sheet 6.2 Common fault and removal method for steering gear
Fault Reason Phenomenon Removal method
Oil leakage Dirty in contacting surface
Oil leakage in Clean
The rubber ring in shaft contacting surface Replace rubber
diameter is broken of valve body, ring
partition
The gasket is uneven n limit disc, Polish or replace
bolt stator and rear gasket
cover
Hard steering The oil supply by oil pump The steering Check whether
is insufficient wheel is light the divider valve
when rotating in oil pump is
slowly, while it is normal.
heavy when
rotating rapidly
Air in steering system Bubble in oil; Remove the air in
irregular noise; the system and
the oil cylinder check inlet line
The oil tank is not filled will move Fuel to stipulated
sometimes when oil level
The viscosity of oil liquid is the steering wheel Use the oil liquid
too high rotates with
recommended
viscosity
The steel ball and check The steering In case of the loss
valve in valve body is wheel is heavy no of steel ball, install
ineffective matter when Φ8 steel ball. In
rotating slowly or case the dirt
rapidly, and no blocks the steel
pressure in ball, clean it.
steering
The pressure of divider Light steering in Adjust the
valve is lower than the empty load (or pressure of divider
working pressure or light load), hard valve or clean
blocked by dirt. steering after divider valve
increasing load
Steering The spring piece is broken The steering Replace broken
failure wheel fails to spring piece
return, the
pressure in
neutral position
increases
The pull pin is broken or The pressure Replace pull pin
deformed runout increases
clearly and even
cannot rotate
The opening of driving The pressure Replace driving
shaft is broken or runout increases shaft
deformed clearly and even
cannot rotate
The position of rotor and The oil Reassemble it as
driving shaft is wrong for distribution is in required in Notes
each other disorder, the for Assembly (E)
steering wheel
rotates
automatically or
swings
Failure of two-directional When the vehicle Clean
overload valve (the steel is in pass-line two-directional
ball is blocked by dirt or the deflection or overload valve
spring is ineffective) rotates the
steering wheel,
the oil cylinder
stay still (or acts
slowly)
Failure to Decentraction between The pressure drop Remove them
return rotating pipe column and increases in according to the
automatically valve core neutral position or fault causes
The steering pipe column the steering gear
blocks valve core in axial fails unloading
direction (vehicle is in
The steering resistance of pass-ling
rotating pipe column is too deviation) when
big steering wheel
The spring piece is broken stops rotating
No manual The gap between radial In power steering, Replace rotor or
steering clearance and axial the piston of the stator
clearance of the rotor and oil cylinder is in
stator is too big extreme position,
and the
destination feeling
of the driver is not
clear. In manual
steering, the
steering wheel
keep still, so does
the oil cylinder
6.3 Inspection of steering system after reassembly
(1) Check whether the layout of hydraulic pipeline and the steer are
correct.
(2) Rotate the steering wheel towards left or right to a finish, and
observe whether the force is even or stable.
(3) Support steering axle after assembly of steering system to make the
motor operate at an idle speed. Then, slowly rotate the steering wheel for
several times to remove the air in hydraulic pipeline and steering cylinder.
Lay down the steering wheels and rotate the steering wheel for several
times. Check whether the rotating sound is normal. In case of normal, it is
shown that the air has been removed completed. Finally, operate the motor
at high speed to increase the oil temperature.
(4) Measure steering operating force
Park the forklift on dry and flat road, and use parking brake to bound
the spring equalizing device to the edge of steering wheel and measure the
steering operating force. The force must be lower than 150N.
Pressure gage
Connecting divider valve pipe

Connecting steering gear
Block valve Pipe

Figure 6.6 Measure the pressure
(5) To measure the pressure, the pressure gage (15-20MPa), block valve
and tube are connected as is shown in figure 6.6.
Disassemble the pipe connecting divider valve to steering gear, connect
to the pipe with pressure gage on one side near divider valve and connect to
pipe with block valve on one side near steering gear, and then operate the
motor at idle speed.
When the steering wheel is in the free condition, the oil pressure is
about 0.5-2Mpa. If the pressure exceeds it, check whether the divider valve
and pipeline are blocked. If not abnormal phenomenon, increase the
rotating speed of motor to about 1500 circle/min. then slowly shut off the
block valve and note the increasing of pressure.
The highest pressure of divider valve is adjusted to 12 MPa, and
therefore, its adjusted pressure value will be shown in pressure gage when
the divider valve shuts off totally.

If the pressure is over 12 MPa, it is shown that the divider valve is out
of control. However, if the pressure is too low, it is shown that the oil pump
is out of control or the spring of divider valve is broken, and at this moment,
the stop time of the divider valve shall not be more than 15 seconds.
The pressure is used to drive cylinder while the flow is related to the
working speed of cylinder. Therefore, even if the pressure is normal,
reaching 12 MPa and the flow is not enough, the steering cylinder cannot
work normally, leading to hard steering. Therefore, when the divider valve
need disassembling and reassembling, appropriately adjust the flow valve
and safety valve according to the operating conditions of volume and
steering cylinder, and then print cooperation mark in adjustment position to
make reassembly. Or measure and adjust the distance between bolts.
6.4 Removal of steering system fault
Sheet 6.3 Removal method of common fault of steering system

Fault Reasons Removal method
In making a turn rapidly, Block of flow control valve rod Disassemble and repair
the steering wheel is it or replace it
blocked Wearing of flow control valve rod Replace
Oil pressure does not rise Safety valve is open all the time Replace
(cannot be closed)
Oil pressure is higher than Safety valve is close all the time Replace
adjusted pressure of safety (cannot be open)
valve
Noise in safety valve Vibration of safety valve Clean or replace
Oil temperature is too high Safety valve is close all the time Clean or replace
(cannot be open)
Hard steering when motor Safety valve is open all the time Clean or replace
is at idle speed (cannot be closed)
Block of flow control valve rod Disassemble and repair
it or replace it
Wearing of flow control valve rod Replace
Change in steering force Vibration of safety valve Clean or replace
it or replace it
Hard steering Safety valve is open all the time Replace
(cannot be closed)
it or replace it
6.5 Steering axle assembly
6.5.1 Steering axle

The steering axle mainly consists of steering axle body, left and right
knuckle assembly, connecting rod assembly, steering cylinder assembly,
wheel shell and wheel rim, etc. For the structures, please refer to figure 6.7.
Steering axle
1. Steering axle body 2. Connecting rod 3. Steering oil cylinder 4. Mounting

base 5. Lining 6. Left steering knuckle 7. Bearing 8. Needle bearing 9.
Master pin 10. Tyre 11. Oil seal 12. Inner bearing 13. Outer bearing 14.
Hub cover 15. Hub 16. Hub bolt 17. Hub nut 18/ oil seal 19. O ring 20.
Lining 21. Dust ring 22. Right
The steering axle body is welded. The supporting shaft, axle sleeve and
bearing base in the front and reverse of the middle of axle body are fixed on
the frame. The axle body can swing for some angle through supporting shaft.
The left and right steering knuckle assembly is supported by axle body. The
wheel shell is installed in steering knuckle through thrust bearing. Oil seal is
installed in wheel shell to prevent the lubricating grease from overflowing,
and the wheel is mounted in the wheel shell. The plane thrust bearing is
mounted between steering knuckle and steering axle and the steering gap
will be adjusted by gasket under below. In the inner hole of upper and
below boss is steering master pin, which is supported by upper and below
needle bearing. The steering knuckle assembly and master pin are tightened
by locking pin. The tightening torque of bearing base and frame connecting
bolt is 416-624Nm.
6.5.2 Steering cylinder

The steering cylinder is double-acting type (figure 6.8), and is laid in the
middle of axle. Both ends of piston rod connect to the connecting rod
assembly. The power will drive the connecting rod through piston of
steering cylinder to drive the steering knuckle arm, thus rotating the
steering wheel. The tightening torque of connecting bolt of steering cylinder
and steering axle is 150-200 Nm.
防尘圈：dust ring 密封圈：seal ring 挡片：block pieces O 型圈：o ring 支

撑环：supporting ring 钢背轴承：steel-backed bearing 导向套：guide
sleeve
6.5.3 Steering wheel

The steering wheel consists of tyre and rim. The rim is fixed on the
wheel shell with bolt. For the structure, please refer to figure 6.9.
Adjustment for load of steering wheel bearing under pretension:
(1) As is shown in figure 6.9, fill 1/2-1/3 space of inner cavity of inner and
outer bearing and wheel shell cover with lubricating grease, and paint
some lubricating grease on lip of oil seal.
(2) Mount the outer ring of bearing on wheel shell, and mount the wheel
shell on steering knuckle.
(3) Mount flat washer and tighten inner round nut (tightening torque is
70-110N), screw the round nut for 1/6 until the wheel shell can be
moved freely by people. Mount the thrust washer and outer round nut
after stable rotation, the tightening torque is 110-160N. Finally, lock
locking washer and mount hub cover.
(4) The tightening torque of connecting bolt of steering wheel rim and shell
is 480-560Nm.
Inner round nut

Lock washer
Outer round nut
Inject lubricating grease
Wheel shell
Bearing
Figure 6.9 Steering wheel
7. Hydraulic system
7.1 Overview
The hydraulic system mainly consists of gear oil pump, mono-stable

divider valve, Multi-way valve, oil filer, high and low-pressure oil pipe,
connecting joint and oil tank, etc. For the technical parameters, please refer
to sheet 7.1.
Sheet 7.1 Main technical parameter of hydraulic system component
Main hydraulic component FD45 FD50L
Gear oil pump Model CBFT/G425ACK,-A/CBF7-G425ALK,X-A
Driving type Driven by gearbox
Rated pressure 20MPa
Displacement 1601/min
Multi-way Model CBD –F20-02
valve Type Double valve rod removable type (with safety
valve, divider valve and inclined self-locking
valve)
Rated pressure of 17.5Mpa 18Mpa
safety valve
Adjusted pressure 12MPa
of steering safety
valve
Lifting oil Type Single-action type
cylinder Cylinder diameter 70mm

Piston rod 50mm
diameter
Stroke (standard 1495mm
portal frame)
Inclined oil Type Double-action type
cylinder Cylinder diameter 90mm
Piston rod 45mm
diameter
Stroke (the front 202.5mm
and rear dip angle
is 6°/12°)
The oil pump is axle dual gear pump and driven by bent axle of motor.
When the motor operates, it will drive oil pump to extract oil from oil tank
and deliver it to Multi-way valve. One of the oil pumps will distribute oil
liquid for brake valve through divider valve. Certain volume (12L/min) of
hydraulic oil will be distributed to steering through Multi-way valve by
divider valve. The rest will be supplied to lifting and inclined oil cylinder. The
master safety valve in Multi-way valve is used to keep the oil pressure in
lifting and inclined cylinder within specified value while the steering safety
valve is used to keep the oil pressure of steering cylinder within specified
value. The action of lifting oil cylinder and inclined oil cylinder is made by
operating valve rod. For the schematic diagram of hydraulic system, please
Lifting oil cylinder Block valve Inclined oil cylinder
Governor valve
Multi-way valve
Steering oil cylinder
Steering gear
Divider valve
Oil filter
Front pump Brake pump
Oil filter
Oil filter Rear pump Connect wheel cylinder
Figure 7.1 Schematic diagram of hydraulic system
7.2 Multi-way valve
The Multi-way valve is combined type, and consists of inlet, outlet,

divider valve, safety valve, slide valve and valve body. For the details, please
refer to figure 7.1. Control valve body can be added as required. In the inlet
part is a master safety valve to adjust the oil pressure in oil line. The divider
valve distributes a part of flow for power steering, and the steering safety
valve is used to adjust the oil pressure in power steering oil line.
The slide valve is used to control lifting and inclined oil cylinder. It
controls lifting, declining, forward leaning and backward leaning by
operating lifting and inclined valve rod. To ensure the safety in operation, in
inclined slide valve mounts inclined self-locking valve to avoid flameout of
motor. When pushing control lever by mistake, the forklift will not be
forward leaned and make goods falling.
Lifting slide valve
Master safety
valve Inclined slide
valve
Outlet
Oil intake pump (inlet)
Return oil tank
Steering safety valve
Figure 7.2 Multi-way valve
7.2.1 Working process of Multi-way valve

(1) Neutral position (please refer to figure 7.3)
The oil discharged from master pump returns oil tank through middle
channel. At this time, the port A and B of oil cylinder are in the closed state.
Check valve
Parallel oil supply port

Oil cylinder port “B”
Oil cylinder port “A”
Valve body
Return spring
Slide valve
Low-pressure oil duct

Neutral-position oil duct
Figure 7.3 Neutral-potion

(2) Push on slide valve
At this time, the middle channel is in the closed state (blocked up). The
oil from oil inlet pushes (load) check valve and flows the port B of oil
cylinder. The returned oil discharged from port A of oil cylinder returns oil
tank through low-pressure channel. After loosening the control rod, the
slide valve can return the neutral position with the help of return spring.
Figure 7.4 Push on slide valve Figure 7.5 Pull out slide
valve
(3) Pull out slide valve (please refer to figure 7.5)
At this time, the neutral gear channel is also in the closed state. The oil
from oil inlet pushes (load) check valve and flows the port A of oil cylinder.
The returned oil discharged from port B of oil cylinder returns oil tank
through low-pressure channel. After loosening the control rod, the slide
valve can return the neutral position with the help of return spring.
7.2.2 Master safety valve

(1) The master safety valve is mounted between high-pressure port HP and
low-pressure channel LP of oil cylinder and is the pilot-operated valve. The
oil through valve core C acts on level A and B of different diameters, and
therefore the valve core K of check valve and valve core D of master safety
valve are tightly in valve base. (Please refer to figure 7.6)
Figure 7.6 Figure 7.7

低压：Low pressure
高压：High pressure
(2) When the oil pressure in high-pressure port exceeds the pressure
adjusted by spring force in cylinder, the guidance valve core “E” is open to
let the oil flow into the hole and then flow into low-pressure channel.
(Please refer to figure 7.7)
(3) When the guidance valve core E is open, the pressure behind valve core
C decreases and therefore, valve core C moves towards right and is located
in guidance valve core E. As a result, the oil channel behind safety valve core
D is cut off and thus its inner pressure decreases as well. (Please refer to
figure 7.8)
(4) Compared with port HP of oil cylinder, the inner pressure becomes
unbalanced leading to safety valve open. In this way, the oil in high-pressure
side will directly flow into “LP” in low-pressure channel. (Please refer to 7.9)

低压：Low pressure
高压：High pressure
7.2.3 Inclined self-locking valve

The inclined self-locking valve is used to prevent the portal frame from
vibration (caused by negative pressure may be caused in inclined cylinder).
Meanwhile, it also prevents the portal frame from inclination by
malfunction (crashing the inclined control rod) occasionally when the motor
is flameout. In traditional structure, even if the motor stops, the portal
frame will lean forward for crashing the inclined control rod. However, this
new type of inclined self-locking valve part will not lead to the forward
leaning of portal frame under above situations. Even if the inclined control
rod is pushed by force, the portal frame will not lean forward. For the
structure of inclined self-locking valve, please refer to figure 7.10. In the
figure, port A connects to the front side of inclined cylinder and port B
connects to the back side of inclined cylinder. When pulling inclined control
rod (pulling out slide valve), the oil from oil pump flows into port A while the
oil in port B returns oil tank. Therefore, the portal frame leans backwards.
When pushing inclined control rod (pushing on slide valve), the oil from oil
pump flows into port B to make the self-locking valve action in inclined slide
valve with the help of high-pressure oil and port A connect to low-pressure
circuit, thus making the portal frame lean forward. However, when the
motor shut off, there is no high-pressure oil to make self-locking valve action
and port A not connect to low-pressure circuit, and thus the portal frame
will not lean forward and the inclined cylinder will not cause negative
pressure inside.
Inclined oil cylinder
Spring Valve core
Slide valve
Lead to oil tank Lead to oil pump Lead to inclined oil

Figure 7.10 Inclined self-locking valve
7.3 Multi-way control device
Each slide valve of Multi-way control device is operated by control

handle. The control rod is mounted in the same axle and the axle is
mounted in the support of front instrument stand. The action of each
control rod is delivered to each slide valve of Multi-way valve through
connecting rod. Please refer to figure 7.10.
Attachment lever
Incline
Lift
Connecting rod
Multi-way valve
Part B
Figure 7.10 Control device of Multi-way valve
7.3.1 Control of Multi-way valve

The valve rod on the left of Multi-way valve controls the lifting of
forklift and the valve rod on the right controls the inclination of portal frame.
The mark is shown in the end of handle sleeve as is shown in figure 11.
符号：Mark
序号：No.
名称：Name
升降：Lifting
倾斜：Inclination
7.3.2 Disassembly of Multi-way valve

Disassemble Multi-way valve from forklift and clean its external part.
(1) Disassemble the connecting bolt and separate each piece of Multi-way
valve. But keep the spring on check valve and junction surface.
(2) Disassemble the screw on the side of head of slide valve and hexagonal
grooved bolt on cover side, as well as disassemble the slide valve
including leather cup, O seal ring and seal plate from valve body.
(3) Put slide valve on bench clamp and disassemble covered connecting bolt.
Then disassemble spring and spring base as well as the spring and valve
core inside the inclined self-locking valve in inclined slide valve with
inclined self-locking valve.
7.3.3 Reassembly of Multi-way valve

Clean all disassembled parts with mineral oil and check whether there
is burr or nick. In case of serious damage, replace it timely. The valve body,
slide valve and valve core shall be packed after assembly. In case of
replacement, replace them in whole.
(1) Clamp the slide valve with bench vice, and then mount valve core and
spring. Please pay attention to the direction of valve core.
(2) Install O seal ring, leather cup, seal plate, spring and spring base into the
end of slide valve in order. Cover them and tighten covered connecting
bolt by 25-32Nm torque.
(3) Insert the assembled slide valve assembly (a piece of valve) to the valve
body and cover it with shell and connect it with hexagon bolt (the
tightening torque of bolt is 9-22 Nm).
(4) Fix O seal ring and leather cup to the head of slide valve and tighten seal
plate with bolt. The tightening torque is 4.6-5.8Nm.
(5) After assembly, install a check valve, spring and O seal ring in every piece
of valve, and then tighten them with three connecting bolts as stipulated.
(one bolt is 103 Nm and the other bolt is 66Nm)
7.3.4 Notes
The pressure of each safety valve in Multi-way valve has been adjusted
before shipment, please do not adjust it randomly in case of leading to
damage of hydraulic system and components by excessive pressure. Modify
each safety valve as required in manual after maintenance.
8. Lifting oil cylinder and inclined oil cylinder
Sheet 8.1 Parameter of lifting oil cylinder and inclined oil cylinder
Model FD45 FD50L
Item
Lifting Type Single-action piston type
cylinder Inner diameter of oil cylinder mm Φ70
Outer diameter of piston rod Φ50
Stroke of oil cylinder 1495
Inclined Type Double-action piston type
cylinder Inner diameter of oil cylinder mm Φ90
Outer diameter of piston rod Φ45
Stroke of oil cylinder (6/12°) 202.5
8. Lifting Cylinders and Tilt Cylinders
8.1 Lifting oil cylinder
Two single-action lifting cylinders are respectively fixed behind both

sides of outer portal frame, and the cylinder bottom is fixed on the base of
oil cylinder of outer portal frame. The piston rod on the top of cylinder and
the beam on inner portal frame are connected with bolt. The piston stroke
of two lifting cylinders should be adjusted consistently to synchronize these
two cylinders. In case of not synchronization, adjust them with bolt. Please
The lifting cylinder mainly consists of cylinder body, piston, piston rod
and cylinder cover. Under the cylinder body is an oil inlet and from it
high-pressure oil flows. On the tope of cylinder body and under the Yx seal
ring of piston seal is an oil outlet connecting to oil return pipe.
The piston and piston rod are fixed with grooved nut, cotter pin and O
seal ring. On the outer annulus mounts Yx seal ring, check ring and support
ring. Because of high-pressure oil, piston moves upwards along the internal
surface of cylinder body. On cylinder cover mounts dust ring and
steel-backed bearing, and the cylinder cover is screwed into cylinder body
with thread. The steel-backed bearing is used to support piston rod while
dust ring is used to prevent dust from entering the cylinder. On the top of
cylinder, the top end of piston rod and beam on inner portal frame are fixed
by bolt.
When lifting control rod are pulled backwards, the high-pressure oil
inputs cylinder through oil inlet of lifting cylinder, push piston rod and beam
on inner portal frame upward and passes chain to lift forklift. When the
inner portal frame rises at the beginning, the height from ground to forklift
is called free lifting height, within which the portal height will not change.
When lifting control rod push forwards, the piston declines for dead
weight of piston rod, forklift frame, load backrest and forklift, then the oil
under piston is discharged from cylinder. The discharged oil from oil cylinder
is controlled by governor valve and returns oil tank by Multi-way valve.
1. Washer 2. Dust ring 3. YX seal ring 4. Cylinder cover 5. Steel-backed

bearing 6. O seal ring 7. Cylinder body 8. Piston rod 9. Ring 10.
Supporting ring 11. YX seal ring 12. Piston 13. Lifting chain 14. Chain
wheel 15. Ball bearing 16. Flexible ring 17. Spring 18. Block valve 19.
Beam on inner portal frame
Figure 8.1 Lifting oil cylinders
8.2 Block valve
On the bottom of two cylinders are block valve, as is shown in figure

8.1 No. 18. When high-pressure rubber pipe is broken suddenly, it can
prevent goods from falling down sharply. For the structure of block valve,
please refer to figure 8.2. The returned oil from lifting cylinder passes block
valve. The oil hole surrounding slide valve will make two cavities cause
pressure difference. When the pressure difference is less than spring force,
the slide valve will not act. If the high-pressure rubber pipe breaks suddenly,
the block valve compresses spring to move left rapidly and close the oil
leading hole in the direction of valve body. At this time, only the less
number of oil flows into small hole on slide valve end, and therefore, the
forklift falls slowly.
Connecting joint
Spring
Slide valve
In normal condition In shut-off condition
8.3 Governor valve
The governor valve (throttle valve) is mounted on oil line between

Multi-way valve and high-pressure oil port of two lifting cylinders, and near
left lifting cylinder as is shown in figure 8.3. The governor valve is used to
limit the descent velocity of forklift in heavy load. For its structure, please
Lifting oil cylinder (right)
Lifting oil cylinder (left)
From Multi-way valve
To oil tank
Governor valve
Figure 8.3 Assembly position of governor valve
Figure 8.4 Governor valve

1. Spring 2. Valve pocket 3. Spring 4. Nylon ball 5. Valve core 6. Choke block
7. Check ring 8. Valve body 9. Spring 10. Connecting joint
The function of governor valve is shown as follows:

As is shown in figure 8.4, when the forklift lifts, high-pressure oil from
Multi-way valve flows into Cavity A and drives valve pocket to move left,
thus opening port G. Then, high-pressure oil flows along two lines
(A-B-G-D-E and A-B-C-D-E) into lifting cylinder. In this instance, the oil flow is
free of adjustment and limit. When forklift starts declining, the returned oil
from lifting cylinder flows into Cavity E and drives valve pocket to move right
until valve pocket and connecting joint contact, thus closing port G.
Therefore, the returned oil passing E, D, H, C, B and A must pass choke block
to return oil tank. If the oil return volume discharged from lifting cylinder
increase sharply, the pressure in Cavity F increases and drives valve core
(No.5 in figure 8.4) to overcome spring force and move towards right, thus
making port H narrow. In this way, the oil from Cavity D to Cavity C reduces,
namely the descent velocity of forklift decreases.
8.4 Inclined oil cylinder
Two double-action inclined cylinders are mounted behind both sides of

portal frame and the earrings in front of inclined cylinder connect to portal
frame. The cylinder base connects to portal frame with pins. The inclined
cylinder assembly mainly consists of cylinder body, guide sleeve, piston and
piston rod, as is shown in figure 8.5.
The piston is welded in piston rod. On outer annulus surface of piston,
two Yx seal rings and a support ring are mounted. Under the function of
hydraulic oil pressure, piston moves inside cylinder. In inner hole of guide
sleeve (cylinder cover), it matches steel-backed bearing and Yx seal sing and
dust ring. The seal ring and dust ring are used to prevent from oil leakage
and dust (between piston rod and guide sleeve). On outer annulus surface
of piston, O ring is mounted and the guide sleeve is screwed into cylinder.
When inclined control rod moves forward, high-pressure oil flows into
back cavity of piston from cylinder bottom to make piston move forward,
thus the portal frame leans forward. When inclined control rod pulls
backward, high-pressure oil flows into front cavity of oil cylinder from front
oil inlet to make piston move backward, thus the portal frame leans
backward.
Figure 8.5 Inclined cylinder

1. Earrings 2. Gasket 3. Adjusting axle sleeve 4. Dust ring 5. Check ring 6. Yx
seal ring 7. Guide sleeve (cylinder cover) 8. O ring 9. Steel-backed bearing
10. Cylinder body 11. Yx seal ring 12. Support ring 13. Piston 14. Piston
rod 15. Screw 17. Check ring 18. Check ring 19. Cylinder base
9. Lifting system
9.1 Overview
The lifting system is mainly used to realize operations of goods, such as

fork taking, loading and unloading, lifting and stacking. It mainly consists of
fork, fork arm carrier, inner portal frame, outer portal frame and lifting chain.
For its major technical parameters, please refer to sheet 9.1; for its structure,
please refer to figure 9.1.
Sheet 9.1 Main technical parameter
Item Parameter
Type of portal frame Rolling type, welded portal frame with
free lifting, level-two stretching type
Lifting height (standard portal frame) mm 3000
Front and rear dip angle (standard state) 6/12°
Rolling Outer diameter of main roller Φ123
wheel mm
Outer diameter of side roller of Φ102
fork mm
Outer diameter of side roller of Φ58
fork (fork frame and inner portal
frame) mm
Lifting chain (plate chain) LH 1634 3*4
Fork lifting method Hydraulic type
Inclination method of portal frame Hydraulic type
Adjusting method of fork space Manual type
Figure 9.1 Lifting system

1. Lifting oil cylinder 2. Inclined oil cylinder 3. Outer portal frame 4. Inner
portal frame 5. Lifting chain 6. Fork arm carrier 7. Fork
9.2 Inner portal frame
This portal frame is level-two CJ rolling retractable type. The inner and
outer portal frames are welding structure. The portal frame is welded under
the outer portal frame to make the portal frame support on drive axle and
rotate around drive axle; in the middle part, it is welded with base
connecting inclined oil cylinder. The inclined piston rod stretches to drive
the portal frame lean forward and backward. At the bottom, it is welded
with lifting cylinder base to support lifting cylinder; on the top, it is installed
with main roller and side roller unit as the support and guidance in lifting of
inner portal frame. On both sides under the inner portal frame, it is installed
with main roller pair and side roller. When the inner portal frame lifts, the
main roller contacts two guidance plates of channel steel in outer portal
frame and the side roller contacts the web of outer portal frame. Their gap
is 0.5-1.0 mm (single side), thus ensuring the prevention of longitudinal and
horizontal inclination when inner portal frame lifts and declines. The gap is
adjusted by gasket.
9.3 Fork support
Two pairs of main roller and side roller are installed in upper and below
part of left and right riser in fork support. The main roller contacts the guide
plate of inner portal frame and downside roller contacts side of guide plate
of inner portal frame. The upper roller contacts web of inner portal frame.
The main roller bears longitudinal load and roller on upper and below side
bears horizontal load.
The gap between roller and guide plate and web of inner portal frame is
respectively 0.5-1.0mm (single side), and the gap is adjusted by gasket.
The upper and below beam of fork support conforms to international
standard (ISO standard), can be equipped with various different accessories.
Two forks are made from alloy steel and processed with heat treatment. So
it has good strength and rigidity.
9.4 Adjustment of lifting system
9.4.1 Adjustment of stroke of lifting oil cylinder

a) The lifting cylinder is installed in the beam of inner portal frame as is
shown in figure 4-2 (gasket will not be adjusted now).
b) Slowly arise the portal frame to maximum stroke and check whether two
cylinders are synchronous.
c) In case of not synchronization, measure the difference and decline the
portal frame. Add adjusting gasket between the top end of piston of oil
cylinder and beam of inner portal frame, and the thickness of adjusting
gasket is 0.5mm. (Please refer to figure 9.2)
9.4.2 Elevation adjustment of fork support

a) Park the forklift on level ground and make the portal frame vertical.
b) Make the bottom of fork contact the ground, adjust the adjusting nut of
end connector in the upper part of chain to make the main roller under the
fork support expose 1/3 of radius of main roller. (Figure 9.3)
c) Lift the fork to the highest point and confirm whether the gap of limited
block between fork support and portal frame B is 5-10mm. (Figure 9.4)
d) Drop the fork to the ground and lean it backward in place. Adjust the
adjusting nut of end connector in the upper part of chain. Install two pieces
of chain in the middle of chain and the tensioning degree of these two
chains must be same.
Tyre
Adjusting gasket
Inner portal frame
Upper beam of inner
portal frame
Main roller of fork support
Fork
Limited block of inner portal frame
Lifting oil cylinder

Limited block of inner portal frame
Chain
End connector
Limited block of fork support
Adjusting nut
Side end connector of portal
frame Locking nut
9.4.3 Adjustment of roller gap

There are three types of rollers in lifting system, namely main roller,
side roller and side roller train. They are respectively installed in inner frame,
outer frame and fork support, as is shown in figure 9.6. The main roller
bears longitudinal load and cannot be adjusted generally. The side roller
bears lateral (horizontal) load and the gap (gap is 0.5mm) on left or right
side can be adjusted by gasket, to make the inner portal frame and fork
support move freely and reduce the moving resistance of portal frame and
working noise.
Figure 9.6 Installation drawing of roller

1. Limited slide block 2. Main roller 3. Adjusting nut 4. Side roller 5. Side
roller train.
Note

（英文）4 5吨内燃平衡重式叉车使用说明书内页

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

（英文）4 5吨内燃平衡重式叉车使用说明书内页

Uploaded by

Copyright:

Available Formats

User Manual of 4-5 Ton Diesel Balance Weight Forklift

manual before using it.

This manual mainly focuses on the performance, structure, operation, repair

and maintenance of FD45/50/ series of forklifts so that the operators could

correctly use and maintain in a good state.

shall carefully execute the requirements and stipulations of this manual on

the use and maintenance of the forklift so that it could be always

maintained in a good state.

Zoomlion forklifts are subject to constant improvement so it is impracticable

for us to keep you updated with all of the improvements. We sincerely

appreciated for that!

Final interpretation of this manual will be owned by Zoomlion Anhui

Industrial Vehicle Co., Ltd.

Zoomlion Anhui Industrial Vehicle Co., Ltd.

III. Description of Main Forklift Parts..............................................................23

I. Safety Precautions for Forklift Operation

1. Safe operation procedures for forklift drivers

were a loaded forklift;

2. Transport with forklift

Pay attention to following matters when loading the forklift:

3. Safekeeping and re-using

3.1 Safekeeping of forklifts

If a forklift is expected to be idle for more than 2 months, conduct following

2) Erect the mast and land the forks on the ground;

3.2 Reusing of the forklift

4. Preparation before usage

6. Make good preparation before starting the forklift;

5. Daily maintenance of the forklift

5.1 Matter of attentions in daily operation of the forklift

5.2 Attentions for using the cooling system

5.3 Whole forklift lubrication

Name Original Brand, code and usage temperature

5.5 Lubrication system diagram

Lubrication system diagram

6.1 Driving and instruments

Graph: Forklift driving control

6.2 Starting Operation

6.3 Turning on and off the lights

(1) Turn left (2) Turn right

Front light and turning light control handles

to flash the turning lights.

6.4 Operation of the gear-changing handle

6.5 Pedal operation

(1) Inching pedal (2) Brake pedal (3) Acceleration pedal

Inching pedal (1)

6.6 Operation of multi-way valve

(1) Lower down (2) Lift up

6.7 Steering wheel operation

The steering wheel is used to control the travelling direction of the

6.8 Parking brake handle

6.9 Moving the forks

(1) Fork brake

6.10 Towing pin

6.11 Seat attachment

(1) Seat sliding rod

Attention: remember to fasten the safety belt before operation! In

6.12 Hood Opening and Engine Stall

6.13 Get on and get off forklift

6.14 Protection during Work

During work, it is required to wear work clothes, helmet as well as

II. Main Technical Parameters of Forklift

No. Item Unit FD45 FD50L