CPCD120/140/160-XG35

Forklift Truck

OPERATION AND MAINTENANCE MANUAL

ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.

2008.08

1st EDITION

Foreword
Thanks for your purchasing our forklift truck.
The 12-16t series

diesel fork lift truck are new products that our company develops

recently. This operation manual is the explanations that how to use 12-16t R-series forklift truck
correctly. It will instruct you how to operate safety and precautionary maintenance. All that in
charge of operation, maintenance and management must read and comprehend this manual well.
Our products are updating and improving on and on, so this manual may not be the same as
the truck you have.
If you have any questions please keep touches with ZHEJIANG HANGCHA ENGINEERING
MACHINERY CO., LTD. sales department or let the agents know.

2008.08

1st EDITION ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.

CONTENT
Foreword
GENERAL RULES--------------------------------------------------------------------------------------------------------1
NAME OF MAIN PARTS OR COMPONENT----------------------------------------------------------------------2

METERS AND

OPERATION-----------------------------------------------------------------------------------2

CONTROL -----------------------------------------------------------------------------------------------------------5
OTHERS--------------------------------------------------------------------------------------------------------------7
SAFETY INSTRUCTIONS---------------------------------------------------------------------------------------10
8 HOUR (DAILY OR EVERY SHIFT) CHECK

-----------------------------------------------------------15

STRUCTURE AND STABILITY OF TRUCKprevent truck tilting)-------------------------------------19

OPERATION

-----------------------------------------------------------------------------------------------------21

DEPOSIT------------------------------------------------------------------------------------------------------------24
.MAINTENANCE TABLE---------------------------------------------------------------------------------------- 27
TABLE FOR BOLTS TIGHT TORQUE---------------------------------------------------------------------37
REPLACE KEY PARTS AT REGULAR INTERVALS------------------------------------------------------37
TABLE FOR OIL USED IN THE TRUCK----------------------------------------------------------------------38
TRUCKS CONVEY, LIFTING, TOWING-------------------------------------------------------------------39
FORKLIFTS SPECIFICATION AND PARAMETER------------------------------------------------------40
THE SIZE AND WEIGHT OF IMPORTANT PARTS AND LIFTING SKETCH MAP-----------------41
MAINTENANCE RECORD --------------------------------------------------------------------------------------43

Address: 398 Shi Qiao Road,Hangzhou 310022,P.R.of China

Tel :0571-88130499 (switchboard number)

Post Code: 310022

85191117

Fax :0571-85199348
Web site: http://www.hzforklift.com

E-mail: hcpub@mail.hz.zj.cn

ADD:398 Shi Qiao Road,Hangzhou 310022,P.R.of China

TEL:+86-571-8813 5220 ,8813 0499(Ext.8116,8156,8200)
FAX:+86-571-8813 2890,8812 6379
E-mail:sales@hcforklift.com

hangcha@mail.hz.zj.cn

ZIP:310022

General

Rules

1.

To make the truck and you safety, operator should obey these rules below:

2.

Only trained and authorized operator shall be permitted to operate the truck;

3.

Before start truck you should check all control and alarm device, if there are any damaged or
objection, you could not operate it until repaired it;

4.

When carry the load, the weight should not much overload. The fork shall insert in the load
entirely and well proportioned. It is not permitted use only one fork to load;

5.

You should operate the truck smoothly when start, turning, travel, brake and parking. On a
slick or wet road, you should decrease speed when turning;

6.

Travel with load as low as possible and tilt back;

7.

Be carefully when traveled a ramp. If the ramp angle is bigger than 10%, travel forward up
ramp and backward down ramp. Never turn sideways and stack load on an incline;

8.

Notice the foot passenger, barrier, pothole and the clearance upside;

9.

It is prohibit picking up a man or standing on the fork

10. No permitted to stand or walk under the fork

11. No permitted to operate the truck and attachment on other position except the operators
seat
12. Do not carry the unstable load. Be carefully to carry these goods with large size
13. Notice the load not drop form the load bracket for those trucks that overall maximum lift
height is higher than 3 meters. If necessary, make some protective measure
14. Tilt back the mast as more as possible when working for those high lift height trucks, and use
minimum forward and reverse tilt when stacking and unloading loads.
15. You should to drive carefully and slowly when driving over a dock-board or bridge-plate
16. Make sure that there is no naked flame near the area, never smoke. The driver should not
remain seated when adding fuel.
17. The truck with attachments should be treated as a loaded truck
18. When leave the truck, you should let the fork down, make the shift lever neutral , pull-up the
hand brake button and cut the power. Parking on a grade, make sure to pull-up the hand brake
button . If necessary, use a block when parking on a grade for a long time.
19. If any trouble comes on at lifting or sloping, leaking of battery acid, hydraulic oil, break fluid.
Please stop the truck and service the truck at once, and let the truck in a safety place. At the
same time, please inform the service or let the agent know.
20. Before lading, the fork can be moved around by using special implement(square core thimble)
the screw of the roll adjustment of the fork according to demand . In any event, the left and
right fork must keep symmetry. The fork can not be moved in order to prevent the damage of
the component and the imbalance of the fork when loding .
21. The components of the vehicles are very heavy, be sure to use the equipment which have
enough lifting ability when you demolition of assembly;Even if the small component, it may
more heavy than you want,so be sure to use the lifting tools in order to avoid anybody get
hurt.
1

Name of main parts or component

1Fork

2. Fork pitch adjustment screw 3.The shelf off

6. Outside Mast
10. Rear wheel

7. Overhead guard
11.The frame

4. Lifting cylinder

8. Fuel reservoir cap

12. Forward wheel

(14. The screw sleeve location of the fork pitch adjustment)

5. Inside Mast

9. Counter balance
13. Tilting cylinder

Instruments and control

1.

Steering wheel

2. Horn button

3. Key switch

5. Angle of inclination screw adjustment of the

7. Inching pedal

8. Brake pedal

11. Before and after tilt lever

steering wheel

9. Accelerator pedal

12. Parking brake lever

14.( Reserve tube of the brake system) Barometer

Instruments

4.Combination switch
6. Gearshift perch
10 Lift and lilt lever

13. Switch off

Charger indicator (B)

This lamp indicates the battery condition of
charge. The lamp comes on when the
ignition switch is set at ON, but it goes out
as the engine starts and accelerator pedal is
pressed.

Water temperature gauge[1]

It indicates the engines cooling water
temperature, normal conditions, the pointer
should be in the range of 55-115.
Caution:
If the pointer enters the red range, this is the
position at which the key stop the operation
instantly and slow down engine speed to
cool the coolant and wait until the pointer
goes into the green area.

Caution:
If the light continues to stay lit or lights up
during operation, it shows charge
abnormality and should be checked
immediately.

Oil temperature gauge[2]

It indicates the fluid power transmission oil
temperature, normal conditions, the pointer
should be in the range of 60-120.

Oil pressure alert lamp (C)

This lamp indicates the pressure
condition of engine lube oil. Although it
lights up when the engine switch is set at
ON, once the engine starts up and the
accelerator pedal is pressed, this lamp goes
out.

Caution:
If the pointer enters the red range, this is the
position at which the key stop the operation
instantly and slow down engine speed to
cool the coolant and wait until the pointer
goes into the green area.

Caution
Timer [3]

If this light continues to stay lit or

lights up during operation, the pressure is
lower than 0.05Mpa and should be checked
immediately.

Working one time, the timer revolution

be able to increase one number .The
stopwatch indicates running time of the
fork .This meter measures working time of
engine. Use meter to schedule checking,
maintain and service and maintenance
periods.
Fuel gauge [4]
The gauge indicates the fuel in the tank. If
the pointer points left empty; points 1/2
means that fuel has 1/2 of the maximum;
point right means fuel full.

Air-cleaner indicator (D)

This lamp lights up when the air-cleaner is
dirty, you must clean or replace the element.
Reserve tube pressure alert lamp (E)
To instruct the number for the reserve tube
pressur of the brake system, the normal
pressure is 0.4-0.8Mpa . This lamp lights up
means low pressureyou must check the
pipeline or components of the brake system.

Caution:
Fill the fuel at the end of each workday (or
every shift). This practice will reduce the
condensation of moisture within the tank.

Gearbox oil filter alert lampF

Show the working Situation of gearbox
oil filterThis lamp lights up means oil filter
plugged,you must
clean the oil filter.
Gearsbox oil filter is on the right gearbox
of the forklift body.

Indicator
The lamp indicates whether the device run
correctly. If they have any abnormal status,

the lamp lights.

4

than0.4MPa,you must check the components

sealing of the brake system.
The total power switch
Under the seat on the left side, pull-out
this switch befor you start to put through the
power. When you work off,turn the switch
back to cut off the power.

CHG (G)
This lamp lights up when water in
sedimentor reaches to a certain level, while
the engine is running. In normal state, once
the starter is set to ON position, this lamp
lights up. After the engine is started up, it
goes out.
If this lamp continues to stay lit or
lights up during the engine running,
stopping the engine and discharge water
immediately.

Control
Steering wheel [1]
When the wheel is turn right, the truck
will turn to the right; when the wheel is turn
left, the truck will turn to the left. The steer
wheels are located at the rear of the truck.
These cause the rear of the truck to swing
out when a turn is made.

Caution
If the truck is operated when the
lamp continues to stay lit, the fuel
injection pump may be damaged.
Gear-box oil pressure indication (H)

Warning
This truck is provided with the power
steering, so heavy hand-wheel operation is
caused when the steering motor comes to a
stall. To put the power steering in operation
again, restart the steering motor without
delay.

This lamp bright indicates the gear-box

oil pressure low, should check gear-box.
Median start switch (I)
This lamp lights up means gearbox is free.
At this point you can start the forklift, or not
you couldnt start.

Horn button [2]

Pressing the rubber cover at the center of
steering wheel will sound the horn, no
matter whether the starter key is on the
OFF position.

Left light switch (J)

This lamp lights up when you turn left.

Right light switch (K)
This lamp lights up when you turn right.

Key switch [3]

OFF
Inserted or drawn out
ON
The electric circuit is closed when
the starter switch at ON. After the engine
is started, key is at this position.

Serious warning switchLdisuse

Warm-up switchM
Put the switch to ONside the lights up for
a momentwhen the lights turn off put the

START As the key is placed in the start

switch toSTARTside to start the forklift.

position that it means that the fuel is the

starter motor is engaged. When removing
Barometer [14]
To instruct the outside pressureof the
brake system the normal pressure is
0.4-0.8Mpa.If
the
pressure
lower

hand off key, it is automatically returned to

the ON position by spring force.

Caution:
1. Dont keep the starter key in the ON
position while engine is shut down. This result
in a discharge battery.
2. While the engine running, dont switch
the starter key into the START position,
otherwise it may damage the starter motor.
3. Dont keep the motor running more than 5

Gearshift lever [6]

That car change its dirction by electricity and
it has two go forward file and one
countermarches finle.
Before change to drive the direction, trample
brake predate pedal to make car is stop , then
press direction of request to place to go
forward the file of files and go forward the
file ,and retreating the file.

seconds while starting up, and wait 2

minutes before another try.
4.Neutral start device is standard equipment.
When the gearlever is not on the neutral
position, you could not start the engine.
Combination light switch [4]
Turn indication
Use this level to indicate the turning
direction of the truck..When this level is
placed in a turn position, the turn signal light
blinks.
R right turn
N neutral
L left turn

Turn forwardleft turn lights up

Turn backright turn lights up

forward

Forward

Forward

Caution:

Back dial

Back

Back

The turn signal lever does not automatically

return to the neutral position unlike general
the passenger cars. Reset it by hand. The
lever set right on the steering wheel.

Attention:
1Make sure the gearshift lever is in the
middle when you start.
2Turn to when start or climbing.

Light switch
This light switch can be circumgyrate at two
steps.

Inching pedal [7]

Pressing this pedal will decline the oil
pressure of the hydraulic clutch. Use this
pedal to jiggle the truck while decelerating,
approaching and loading goods. While
pressed more, this pedal serves as a brake.

0-small lamp light

1-small,big lamp light
Former dial - right turn light
Back dial- right turn light
Horn button is not sound

Warning
Dont press the inching pedal or press down
your foot on it long time, otherwise the oil in
the torque converter will be overheated and
the hydraulic clutch will skid.

brake.
The screw sleeve location of the fork pitch
adjustment
You can let the fork moving around by
adjusting lead screw. The left screw control
the left fork and the right too. Use the sleave
S2020 and the shaft when modulating.

Brake pedal [8]

Press the brake pedal to slowdown or stop
the truck .The brake light is turned on at the
same time.

Warning:
You should according to goods, adjust the
position of fork before load .Under all
circumstances, the left or right fork should
keep symmetry.
Strictly forbid to operate adjustment handle or
adjust position when fork lode running,
otherwise adjustment organization of the fork
will damage. At the same time the fork will
loses the balance, having the side to turn over
the danger.

Accelerator pedal [9]

Press this pedal to increase the truck.. Loose
the pedal, the engine speed be able to slow.
Up and down control lever [10]
Control the fork to up and down
Forworddown
Backup
Lifting speed controled by handstick
back-inclination
and
accelerator
pedal.Falling speed controled by handstick
forward-inclination.
Inclination control lever [11]
Control the inclination angle of the mast.
Forward

forward

inclination

Back dialbackward inclination

Inclination speed controled by handstick
back-inclination and accelerator pedal
Attention:
Multi-valve have self-locking valveyou can
not make the Inclination control lever forward
inclination when the engine off.
Hand brake control button[12]
Pull up this button when parking brake the
brake chamber degassing controlled by hand
brake valve, the spring in the brake chamber
degassing energy release at the same time
though the forklift parking brake.
The rated working pressure is 784kPa
When the system pressure lower than 240
310kPa or the piping broken the hand
braking valve worked automatic to get an
emergency brake.
Put down the button to lift the parking
7

other

The hydraulic oil should be filtered by 10

Seat and seat adjusting lever

Move the adjusting lever about, adjust the
seat to a position which is comfortable to sit
and easy to operate. Make sure the seat
locked securely before proceeding work
Safety belt
when you wearing the safety beltthe
human body should be close to the seat.
Check whether the seat belt fixed bolts
were loose frequently.Do not to tie belt
when use it. Do not let the belt down on the
hard seat or fragile objectsdont friction
with sharp-edged friction also ,as not to
damage. Do not let the seat is too tilted
otherwise the safety belts will not be able to
correctly elongation
Each part on the safety belt should not be
arbitrary demolition.The belt witch are
frequent used need appearance inspection
frequently,the belt can use 3~5 years, when
the belt off normal should early disposal.
Overhead guard
The overhead guard is strong enough to
meet safety standard, prevents the operator
from hurt by falling matter.
Hood [8]
The hood can be swung up fully; it is
convenient to maintaining service. With the
help of hood damper inside, you can open
the hood easily. To close the hood, just push
down the front of the hood.

filter, screw lid when the oil full.

Fuel reservoir cap
The fuel reservoir cap is located in the left
side of the forklift. Check to see the
blowhole in the cap is through every time
adding fuel, or the fuel system will get into
trouble.
Caution:
----Add fuel---1. Stop the forklift, shut down the engine
and apply the parking brake securely.
Make sure there is no naked flame
nearby. The driver should get off.
2. Lock the fuel reservoir cap securely
after finishing, any loose could cause
fuel leakage or fire hazard in the worst
case.
3. Clean up the fuel spilled out before
starting the engine.
4. Forbid flame when checking fuel level.
5. If fuel splash into eyes, please use water
wash your eyes, if necessary see doctor.

Radiator cover board and radiator cap

The cover board can be swung up fully.
There is the just position that the cover
board could be locked stable. To close it,
shut down the cover board carefully.
The radiator cap is located under the cover
board. To check the level or to add water, you
should open the cover board at first.

Caution
Take care of your finger from being hurt
when shutting the hood.

Warning!
1Dont remove the water cap abruptly
while the temperature of engine more than
700C.. Press the cap and turn it a little to the
left to relieve the pressure in the
.
2Dont wear gloves to remove the cap.

Hydraulic fuel tank and oil scale

Hydraulic fuel tank at the right side of the
forklift, open it when to oil.
Outside hydraulic fuelset up an oil dial

Obliquity adjusting lever to steering

wheel
To satisfy the operator, the steering pole is

gauge, hydraulic oil should between the

upper and lower scale,when lower oil up.
8

The door glass can adjust to up and

down,please down the glass to ventilate
when the air is bad in the forklift.

able to be tilt.
Pulling downward the adjusting lever that
site at the left side of the steering pole, the
steering is released; pushing upward the
adjusting lever, the steering pole is locked.
Warning:
1. Dont attempt to adjust the tilt angle of
the steering wheel during operating;
only when the forklift is at rest allows
adjusting the tilt angle.
2. Adjusting finished, make sure the
steering pole is locked securely.

Air condition
Turn on The forklift air-condition when the
air uncomfortable.
The cab tilting mechanism and tools

Headlight and turning signal lamp

Two headlights and turning signal lamp
are installed at the front side of the
safeguard. Take care of the lights, clean dust
often and replace any damaged lights
immediately.
Combined lights (rear)
Combined lights at the rear include turn
signal, taillight, stoplight and reversing light.
Take care of the lights, clean dust often and
replace any damaged lights immediately.
Brake light
Install a reversing light in the back and
middle of the balance weight. It is lighted
when the vehicle brakes.
Cab
A cab is collocated in the vehicle .there
are two doors with locks in it setting on its
two sides .there are Close the door before
driving without fail. Lock the door well after
leaving the vehicle.

Usually the handle down at right side of the

cab ,back to the place after use.

Remove the two bolts on the two cushions at

right before you

turn up the cab.

Hand pump
Open the hood

can see a hand pump at the

right behand of the cab which can let the cab

slant. Need to add a shaft.
Tipping

Check the piping and elements

under the cab before. Turn to Work side ,

shake the shaft again and again, the cab
should be tipped slowly.
9

Down turn to OffThe cab should down

slowly by its weight.

Wiper switch and the cab forward light

button
Wipers are set on forward backward
windshield glass ,the top of the cab,turn on
if rain.

Forward wiper
Left first button
Backward wiper
Left second button
Top wiper
Left third button
Cab forward light button
Left fourth button

10

Safety instructions

of the water 70 degree before and after

1. Only trained and authorized operator shall

If the temperature of the water tank higher

be permitted to operate the truck.

than 70 degree, never open the tank cap

2. Inspect the truck at periodic intervals for

6 .Waste gases is dangerous to your health.

oil or water leak, deformation, lousiness, etc.

When using your truck in an enclosed space,

If neglected, short life of components will be

make sure there is enough ventilation. Its

caused and in the worst case a fatal accident

forbidden to operate the truck where it is

would occur.

explosive or flammability. If necessary, use

Make sure to replace the key component

a ventilation fan.

in schedule maintenance.

7. Never mount or dismount the moving

Wipe off oil, grease or water from the floor

truck. Use the safety step(s) and safety grip

board and foot and hand controls, if any.

facing

Shut down the engine before inspecting the

dismounting the truck.

engine and its allied components. Especially

8. Never attempt to work the controls unless

use caution to the engine fan.

properly seated.

When inspecting the radiator or muffler,

Before staring, adjusting the seat so you can

exercise caution not to get burnt.

get easy access to all hand and foot control.

3. Any time you find that the trucks are not

9. Before staring up, make sure that:

functioning properly, operation of the truck

Before staring, make sure no one is under,

should be halted and the condition reported

on and close to the truck.

to the supervisor.

The forward-reverse lever is in neutral.

When doing maintenance in the high place

10. Park the truck on a level surface and

(for example mast or front lamp), be care of

apply the parking brake securely. If parking

no sliding.

on a grade is unavoidable, be sure to block

If any warning lamp comes on, move to a

the wheel.

safe place and check or repair the trouble.

Put the forks on the ground or floor and tilt

The sign of defect should be put on the

little forwards. Shut down the engine and

defecting forklift truck.

remove the key.

4. Dont use an open flame to check level, or

11. Operate the controls smoothly-dont jerk

for leakage, of fuel, electrolyte or cooling

the steering wheel. Avoid sudden stops,

water.

starts or turns.

Never smoke while inspecting the battery,

12. Observe speed and traffic control signs.

handling fuel or working on the fuel system.

When traveling on public roads or streets,

There is a danger of explosion.

obey all local traffic regulations.

work.

the

truck

when

mounting

or

13. Pay attention to the route of the

truck, be sure to make a wide sight.

Never fill the fuel tank with the engine

running
5. Warm up and cool down the temperature
11

14. Never allow other person(s) to ride on

the forks, pallets or on the truck.

18.When handling bulky loads, which

restrict your vision, operate the machine in
reverse or have a guide.
19. Slow down and sound horn at cross
aisles and other locations where vision is
restricted.

15. Before driving over a

bridge-plate, be sure that
secured and strong enough
weigh. Check the ground or
of working area in advance.

dock-board or
it is properly
to sustain the
floor condition

20. Keep fluid cans, row cotton, paper or

chemicals away from the truck during
operation since there is a danger of their
firing or exploding due to exhaust gas from
the muffler.
21. Use head lamp and side lamp at night
16. Keep your mind on your work. Learn to

and control travel speed.

anticipate danger before it arises.

22. Make sure to operate the truck on

17. Keep your head, hands, arms, feet and

concrete firmly enough or bituminous

legs within the confines of the operators

macadam.

compartment. Never reach into upright for

The weather of working condition is:

any reason.

Air temperature -20~50

Wind speed: Less than 5m/s.
Air specific humidity: Less than 90%.
(Temp at 20).Inspect the surface over
which you will run. Look for holes,
12

drop-offs, obstacles, and look for rough

spots. Look for anything that might cause
you to lose control, bog down or upset.
Clear away trash and debris. Pick up
anything that might puncture a tire or let the
load lose balance.
Slow down for wet and slippery roads.
Stay away from the edge of the road. If
unavoidable, use extreme caution.
Do not use the forklift truck on the
condition of bad weathers.
The noise of truck is less than 105dBA,
test method is use a decibel tester to record

24. When running down on a grade, use

the voice 7 meters far away from truck. The

engine brake. While using engine brake,

decibel near operators ear is less than

dont operate directional and speed control

93dBA.

levers. If the truck exceeds the gear range,

use the brake pedal.
25. It is dangerous to travel with forks
higher than appropriate position regardless
of whether loaded or not. Keep the good
traveling posture. (When traveling, the forks
should be 15 to 30 cm above the ground or
floor.)
Do not operate the side shift mechanism,
if equipped, when the forks are raised and
loaded, since this will cause the truck to be
unbalanced.

23. When operating loaded truck, have

the rear end of your machine pointed
downhill.

When

climbing

grades,

use

forward gears, and when descending, use

reverse gears.
Never turn sideways on an incline.
There is danger of the truck turning over.
26 When the forks are raised and loaded,
mast should reclined to reduce the high of
goods

13

Do not use a man as an additional

counterweight. Its quite dangerous.

27. Avoid braking too sharply or descending

on a grade at a high speed. There is danger

31. Hang Zhou forklift truck Co., ltd. offers

of loads falling down or the truck turning

a variety of attachments, such as forks,

over.

bucket, rotating roll clamp, load grab or

hinged forks. Dont use such attachments
and special equipment for applications other
than specified.
32. Safeguard protect you do not be hurt by
the goods fallen. Load bracket protect you
load goods smoothly. It is forbidden to use
truck without safeguard or load bracket.
33. It is forbidden to walk down the fork or
the attachment.

28. Always brake to full stop before

It is forbidden to walk up the fork or stand

reversing direction of travel.

on the fork.

29.Taking account of the shape and material

of loads to be handled, use a proper
attachment and tools.
Avoid hoisting the load, with wire rope hung
on the forks or attachment, since the wire
rope may slide off. If needed, a qualified
personnel for slinging operation should
perform, making use of a hook or crane arm
attachment.
Take care not to protrude the forks out of the
load. The protruded fork tips may damage or
turn over the adjacent load.
30. Know the rated capacity of your lift
truck and its attachment, if any, and never
exceed it.
14

stacked and evenly positioned across both

forks. Dont attempt to lift a load with only
one fork.
On the truck with an attachment such as a
load grab, make certain that the load is
securely and correctly grabbed, and pull the
loading control level to the full.
38. Never lift loads with the truck inclined.
Avoid loading work on a grade.
39. Dont stack loads on forks in such a way
that the top of loads exceeds the load
backrest height. If unavoidable, make the
load stable securely. When handling bulky
loads that restrict your vision, operate the
truck in reverse or have a guide.

34. It is forbidden to put your hands, arms

or head stretch between the mast and
safeguard.
It is forbidden to put your hands in
inner and outer mast.

35. When load is to be retrieved from a pile,

enter the area squarely. Engage forks into
the pallet carefully.

40. Use minimum forward and reverse tilt

when stacking and unloading loads. Never
tilt forward unless load is over stack or at
low lift height.
When stacking loads on a high place,
once make the mast vertical at a height of 15
to 20 cm above the ground and then lift the
load farther. Never attempt to tilt the mast
beyond vertical when the load is raised high.
To unloading loads from a high place,
insert forks into the pallet and drive
backwards, then lower the load. Tilt the mast
back after lowering. Never attempt to tilt the
mast with the load raised high.
41. Dont tow the truck that its motor has
trouble or its steering system doesnt work
correctly or its braking system has been
disabled.
Obey the communication rules on the road

36. Dont enter into loads at a high speed.

Always make certain that your load is stable
before lifting the forks.
Be sure to once stop in front of the load to
be lifted, and make certain that there is no
obstacle, then engage the load by driving
forwards.

37. Make certain that your load is well

15

when towing the truck.

42. Dress the overalls or other protective
uniforms, suck as safety helmet, safety shoes
etc. Dont dress necktie or other
accouterments.
43. Markings on the machine describe
warning and methods to operate the lift
truck. When operating the machine, observe
and follow all markings on the machine in
addition to this operators manual.
Inspection decals and replace damaged or
missing decals.

16

Before starting forklift (8 hour) check

Before starting your forklift truck, be
sure to inspect the following items for safety
sake and efficient productivity.
1. Check leaks of oil, fuel or water

Tire pressure
Front wheel

Rear wheel

0.83Mpa

0.88Mpa

3. Hub nut torque check

Check hub nuts should be tightened to the
specified torque securely.
4Check water level in the radiator
When the water temperature of the engine
higher than 70 degree, please do not open
the pressure cap of the radiator.
Loosen cap slowly to allow steam to escape.
After that, tighten cap securely. It is good
practice to use thick waste cloth or the like
when removing the cap. Avoid putting on
gloves, since you may get burnt at your hand
if hot water splashes on it.

Warning!
Dont attempt to operate the truck if leaked
fuel is found through pre-operational check.
Correct the leak before starting engine.
Check if the engine, connector of hydraulic
pipe, radiator and driving system are leakage
or not. Do not use an open flame to check
level, or for leakage, of fuel, electrolyte or
cooling water.
2. Tire inflation pressure check
Turn the tire valve cap counter clock-wise
and move it. Using a tire pressure gauge,
measure the inflation pressure, and adjusting
it to the specified pressure, if needed. After
making sure there is no sir leakage from the
tire valve,
reinstall the cap.
Check that each tire does not get damaged at
the tread surface or side face or bending at
the rim.

Warning:
Adding clean water to radiator. If you use
antifreeze, use the same brand of antifreeze.
Check the radiator coolant reservoir fluid
level. It should be between high and low
level marks. Add coolant if necessary.
engine oil level check.

5. Oil level inspect

Warning!
Since the forklift truck needs tires that have
a high inflation pressure to carry heavy
loads, even a small bending of rims or
damage at the tread surface could cause an
accident.
When using an air compressor, first adjust
the air pressure of the compress-or. Failure
to do so will cause a serious accident, since
the compressor delivers the maximum
pressure.
Put the tyre in the safeguard case to protect
your safe.

Caution
When check the engine oil, should let the
forklift truck on the level ground.
When check the engine oil, it is exact when
the engine is cool.
Remove the dipstick, clean the rod and
reinstall. Pull it out again and check the oil
level. The level should be within the mark
on the dipstick.

17

midway between the water pump pulley and

the generator pulley is as follows:

6. Battery electrolyte check

The battery case is given upper and lower
level marks to allow the operator to see the
electrolyte level. The level should be
between the two marks. Otherwise, adding
clean water to the up level.

Engine

Drop
distance
(mm)

Force (N)

CY6108ZG

10-15

39

Warning!
If the belt has already been pulled long, cut
out or has no surplus, it should be changed.
11. Horn
Press the horn button to make certain the
horn sounds.
12Hydraulic transmission oil level
7. Hydraulic oil level
If the oil is too little, air will go into the
hydraulic tube; too much, the oil will go out
from the tank. The oil level should be in the
place between two slots. If slow the
level ,should add to oil and the oil should
pass the dross filter .
The oil level check should be done with
engine shut down, forks on the ground or
floor .The truck itself on a level ground.
8
Brake pedal, inching pedal and check
Press these pedal to make certain that each
pedal can be pressed smoothly and that is
also can restore without interference.
9. Parking brake lever
Make sure that the parking brake is securely
applied by operating the parking brake lever.
10 vFan belt tension check
First, stop the engine, then
Check the fan belt for correct tension and
damage. The deflection of the belts when the

screw off the oil scale , take out, check

whether the oil lever is between the scale.
Change oil or the time to change oil:
The first time to change the oil is worked
100 hours, than change at every each 1000
hours ,less than 1 year, change the oil filter
together.
13 Drivers seat adjustment
Make sure the drivers seat is properly
located. If not properly, shift the adjusting
lever to the right and move the drivers seat
to a position which provides easy access to
all foot and hand controls.
14. Shift lever(s) check
Check the shift lever(s) for looseness and
operation for smooth.
15 Loading levers check
Check the loading levers (for lift, tilt and
optional attachment) for looseness and
smooth operation.
18

Start the engine

Before starting the engine, make certain the
shift lever(s) is in neutral and parking brake
is securely applied.
16. Fuel lever check
The fuel level gauge is provided on the
indicator panel. Check that fuel level is
sufficient for the days work.
17. Turn signal check
Make sure that the turn signal operates
properly by moving the turn signal lever.
18. Instruments and sensors
Make sure that hour meter, water
temperature indicator, oil temperature
indicator and transmission fluid sensor etc.,
properly.
19. Mast

Caution
Dont use Grease but Machine Oil (ex.
Hydraulic Oil) only for lift chain
lubrication in order to prevent dirt attach on
the grease.

21. Check steer

Fork need slowly run..
Steering wheel separate left right turn .
Observe left right steering whether or not
homology
22 Exhaust gas check
Check condition of exhaust gas after the
engine warm-up is finished.
Colorless or
bluish

Actuate the lift and tilt levers to be certain

that the carriage moves up and down
properly and the mast can be tilted smoothly.
Pay attention to system operating sound.

Normal: complete combustion

Black

Abnormal:incomplete
combustion

White

Abnormal: water come in

the burnt house

Blue

Abnormal: oil burns

20. Lift chain tension check

23. Inching pedal check
Press the inching pedal a little and check
whether the truck speed decreases.
24. Brake test
Run the truck slowly and press the brake
pedal to check the braking effect. When the
brake pedal is pressed, the stop lamp comes
on.

To check the tension, raised the fork about

10-15 cm above the ground.
Push the middle of the chain with the thumb.
Make certain the tension for the right and
left chains are even.
If uneven tension is found, loosen the lock
nut (1) and(3)of anchor pin and adjust the
chain, turning the adjusting nut (2) of the

In normal, the air pressure of the brake

system should between 0.4-0.8Mpa.
25. Back-up lamp check
The back-up lamp comes on and buzzer
sounds when the shift lever or directional
control lever is placed in reverse position.
27. Water discharge from sedimentor
jiggle check
Stop the engine, loosen the drain plug by
turning 4 to 5 turns (A) and press the
priming pump (B). Continue pressing the
priming pump (B) until water is entirely
discharged through the sedimentor.

chain anchor pin. Then tighten the nut

(1)and(3).

19

Fasten the drain plug and press the

priming pump (B) several times to see that
there is no fuel leakage from the plug.
Start the engine to confirm that the
indicator does not light up.
When the sedimentor indicator lamp lights
up, it means need water discharge.

20

During brake-in

We recommend operating the

machine

under

light

load

conditions for the first stage of

ration.

Especially

the

requirements given below should

be observed while the machine is
in a stage of 100 hours of
operation.
*Always warm up your machine
before

putting

it

to

work

irrespective of season.
*Perform specified preventive maintenance
services carefully and completely.
*Avoid sudden stop, starts or turns.
*Oil
changes
and
lubrication are
recommended to do earlier than specified.
*Dont run engine at high rpm without load
needless.

21

.Structure and stability of truck

It is very important for operator to know the trucks structure and relationship between
load and stability.
Caution
The structure of the truck
The basic structure of the truck is mast (include mast and
forks) and body (include tire).
The lift truck keeps the balance of weight between the
truck body and the load on the forks with the center of the front
wheels as a fulcrum when the rated capacity load is placed in
position.
Due care should be paid to the weight and the center of
gravity of loads to maintain the stability of the truck.
Caution
Load center
There is difference because of the loads shape, gravity,
such as box, board and large roller. It is very important to
distinguish the difference and the gravity center of loads.
Warning!
If the truck will turn over, do not attempt to get out of the truck, because the speed
of overturn is much fast than you. You should hold the steering wheel handle, and this
practice will let you in the seats.

Caution
Gravity and stability
The combined center that is composed of the barycenter
and the load center determine the stability of lift trucks.
When unloaded, the barycenter does not change;
When loaded, the barycenter is determined by the truck
and the loads center.
The barycenter is also determined by the tilting and
lifting of the mast.
The combined center is determined by these factors:
Loads size, weight and shape.
The lifting height.
The tilting angle.
The pressure of the tire.
The radius of turning.
The road and grades angle.
The attachments.

22

Caution

the stability zone of the bar center

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

Caution

the max load

The distance between the load center and the front surface of
forklift or load bracket (select the min) on the forklift is called
LOAD CENTER DISTANCE. The max gravity that the truck can
load is called MAX LOAD on condition that the load is on the load
center distance. The relationship of MAX LOAD and LOAD CENTER
DISTANCE is specified on the load capability chart. If the load center
is moved near the front of forklift, the load should be cut down.

Caution

The load capability chart

The chart given above shows the relation between the load
center and the weight of loads. Check whether the load and the
load center are in the permitted range. If the shape of the load is
complexity , take the heaviest part to the center between forks
and close to the load bracket.

Caution

speed and acceleration

It is very dangerous to press the brake suddenly. It may result in capsizal or sliding down of the load
because of huge force to the front.
Centrifugal force will be formed during turning and its direction is from the turning center to the outer.
The force may result in the capsizal of truck. Right-and-left stable zone is very small, so the trucks speed
must be reduced when turning to prevent capsizal. If the truck conveys the load which is on the high
location, feasibility of capsizal is very big.

23

check their working conditions.

operater

2.

Warning!
Before operating the truck, check all controls and
warning devices for proper operation. If any damage
of fault is found, dont operate truck until corrected.

Traveling

Hold the knob on the steering wheel with your left

hand and get the right hand ready for loading working,
lightly putting it on the wheel.
Set the bottom of the fork 15 to 20 cm above the
ground and fully tilt back the upright.

Star-up
Starting diesel engine
Make sure that the shift lever(s) and loading levers
are in neutral and hold position.
Turn the ignition switch to ON position after
turning the ignition switch to START position.
Caution
If you can not start the engine in 5 seconds, should
switch to OFF, after 2 minutes then start it again.
If you can not start the engine 3 times continuously
should check the truck to the core.

Check the safety around the machine and give a

signal when starting the engine.
Depress brake pedal and engage the forward-reverse
lever.
Release the parking brake lever.
Release brake pedal and depress the accelerator pedal
to start the machine.

Caution
If the temperature lower than 5 degree, crank the
engine by turning the ignition key to START.
Release key when engine starts.

Gear shifting
Always stop the truck before reversing the direction
of travel.
Shift the shifting lever.
Slow down
Release accelerator pedal depression a little, and press
the brake pedal, if needed.
Steering
Unlike general passenger-cars, the steer wheels are
located at the rear of the truck. These cause the rear of
the truck to swing out when a turn is made.
Slow down the truck and move toward the side to
which you are turning. The steer hand wheel should be
turned a bit earlier than as with the front wheel
steering car.
Stopping or parking the truck.
1. Slow down and press the brake pedal to stop the
truck (in the case of clutch type machine, the
clutch pedal is used). Place the shift lever in

Caution
Start time less than 5 seconds and start interval less
than 2 minutes every time.
After engine has started
Warm up the engine (for about 5 minutes)
Check the rotation (sound or gear) of the engine.
Caution
Diesel model
After starring up the engine, accelerate its speed to
the arrange of 1800-2000r/min, and warm it without
work.
Check the combustion (or misfiring) sound.
Check the condition (density) of exhaust.
Make sure that all the warming lamps are off.
After thoroughly warming up the engine, operate the
loading levers 2 to 3 times in their full stroke and
24

neutral.
2. Apply the parking brake by pulling up on the
parking brake lever.
3. Down the forks on the ground.
4. Place the key switch in OFF to shut down the
engine. In the case of the diesel truck, pull out the
engine stop button. Remove the key and keep it.
Caution
Dont dismount from the moving machine.
Never jump off the machine.

3.Pick up
The forks should be adjusted sidewise to maintain
proper balance of load.
Place the machine right in front of the load to be
handled.
The pallet should be evenly positioned across both
forks.
Insert forks into the pallet as far as possible.
To raise loads from the ground:
Once lift the forks 5 to 10 cm off the ground or
floor and make sure loads rest stable.
Then, tilt the mast backwards fully and lift forks
up to 15 to 20 cm off ground then start running.
When handling bulky loads which restrict your
vision, operate the truck in reverse except when
climbing grades.

4.Stacking load
When approaching the deposit area slow down your
truck.
Once stop the truck right in front of the area where
your load is to be deposited.
Check the condition of the deposit position.
Tilt the mast forward until forks become horizontal.
Raise forks until they are a little higher than the
deposit position.
Move forward to place the load directly over the
desired area and stop the truck.
Make sure your load is just over the desired area.
Slowly lower the load into position. Make sure the
load is securely stacked.
Disengaged forks from the load by using necessary
lift-tilt operation and then back away.
After making sure the fork tips leave the load, lower
the forks to the basic position (15 to 20 cm off the
ground).
Tilt the mast backwards.

25

1.260, but not higher than this value.

In hot weather
As the water of electrolyte is especially likely to
evaporate in hot weather, replenish distilled water
from time to time.
In a region where the ambient temperature is intensely
hot, it is practicable to lower the specified gravity of a
completely charged battery down to 1.2200.01.
Antifreeze of radiator

Warning!
Never tilt the mast with loads upraised 2m or more.
Dont leave or dismount from the truck when the load
is raising high.
5.Remove load
When approaching the area where the load is to be
retrieved, slow down your truck.
Stop the truck in front of the load so that the distance
between the load and fork tips is about 30 cm.
Check the condition of the load.
Tilt the mast forward until forks become horizontal.
Elevate forks up to the position of the pallet or skid.
Make sure forks are positioned properly for the pallet.
Move forward slowly to insert forks into the pallet as
far as possible and then stop the truck.

Warning!
Antifreeze is harmful to your health, do not eat it.
Far away from children.
Your truck is generally shipped with the cooling
system filled with Long Life Coolant of 50%
volumetric mixture. The freezing point of the coolant
of such a mixing ratio is 36.5 degree. When the
coolant is not enough, you can add CALTEX
ELC6280 antifreeze in the tank.In hot weather: To
maintain good cooling effect, special care should be
paid to radiator and cooling system. Parking in the
shade is recommended.
Clean the radiator

Caution
If the forks are hard to be fully inserted, use the
following procedure: move forward and insert 3/4 of
the forks. Raise the forks 5 to 10 cm and move
backward 10 to 20 cm with the pallet or skid on the
forks, then lower the pallet or skid on the stack. Move
forward again to insert the forks fully.

Warning!
The dust will enter your eyes if you have not worn a
dust proof glass.

Raise the forks 5 to 10 cm off the stack.

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

If the radiator has been jammed by dust, this may

cause the radiator over hot. So you should use
compress air, water or high pressure vapors to clean
the radiator.
Caution
When using compressed air or vapor to clean the
spreading-heat slices, put the ejecting mouse vertically
to the slices.

6.Measures against cold and hot

weathers
Oil
Use the oil suitable for ambient temperature.
Battery
In cold weather
Under normal charged conditions, the freezing point
of electrolyte is about 35 degree.
Always keep the battery in a well-charged condition
since there is danger of damaging the battery jar if
electrolyte freezes. To prevent the freezing, charge at
least 75% of the whole capacity.
Also it is effective to keep the specified gravity up to
26

Warning
1Dust will fly into your eyes to wear protective
mirror before blowing
2Not maintain and replacement the filter in time,
will lead to engine damage ahead.

Check the fan belt tension

If the belt is loosening, adjust it.
When the engine is too hot, do not stop it immediately,
just do these things:
1. Run the engine at low speed
2. Open the hood in order to increase the fan speed.
3. When the water temperature decreased, stop the
engine.
4. Check the radiator; add water or antifreeze if needed.
Air filter maintenance

Normal
When
the
forklift
working
hours(4000~20000 km vehicles
) to maintain the air filter.
After six times later change it.

for

50~250

Caution
If your car working in a bad condition,you
should change the air filter frequently.
If your car working in a more dust bad condition,you
should maintain the air filter for 8~50 hours, change
the between 100~300 hours.

maintenance method:
Open the air filter cover
Filter out
Blowing inside and outside the dust filter
net by compressed air.

27

support the truck.

Deposit

b. Do not use the block that is higher than 300mm

Deposit daily

(11.81 inch).

Park your truck on a level ground-preferably in a

wide area. If parking on a slope is unavoidable,
position the truck so that it cross the slope and block
the wheels to prevent accidental roll.
Make sure the shift level on neutral position.
Pull the hand brake.
Shut down the engine and control the lift and tilt
level several times so that the inner pressure in the
hydraulic tube will decreased.
Take down the key and deposit it in a safe position.

c.

Hoist the truck just to be deposited on the block.

d. Block the truck under both left and right body.

e.

Sway the truck right and left, front and back after
the truck has been blocked to check weather it is
safety.

Warning!
You should tell the manager if you find any failure
about the truck, then repair it immediately.
Clean the oil and grease with cloth and water on
the truck body.
Check the whole situation of truck, especially the
tyres.
Fill the oil tank with destined fuel.
Check whether the hydraulic oil, the engine oil,
fuel and the cooling liquid are leakage.
Fill lubricate grease.
Check whether the junction plane between the nuts
of wheel boss and the piston of hydro cylinder is loose,
and whether the surface of piston has been pulled.
Check whether the wheels of mast roll stably.
Lift the lifting cylinder to the top and fill it with
oil.
In cold weather, it neednt to discharge the
antifreeze, but the cold water should be removed
completely.

On the basic of the deposit you should do these

checks and maintain additional.
1. Take down the battery and recharge it once a week,
place it in the shade.
2. Brush antirust oil on those part which is exposed such
as piston rod and axle.
3. Put a cloth on vent-plug and air-cleaner.

Deposit the truck for a long time

4. Start the engine once a week. If the water has already

When deposit the truck foot a long time, you

should block the truck body and block under the counter
balance so as to reduce the load of the rear wheals.

fork lightly.
5. In summer, it is not recommendatory to park the fork
on asphaltum road.

Warning!
a.

been let out, add water in the radiator. Then start the

The block must be a single that is hard enough to

28

Running after deposit for a long time

1. Get down the antirust oil on the exposed parts.
2. Adding new fuel and oil.
3. Get rid of the eyewink and water in the oil tank, fuel
tank.
4. Check the clearance of the valve, gas valve cap and
other parts on the engine.
5. Adding antifreeze or water.
6. Recharge the battery.
7. Check others carefully.
8. Warm-up your truck.
9. Check all the function of the truck as above describes.

29

Maintenance

Maintenance summarization
The fork lift truck needs trebly inspection
and maintenance, make it in good working
condition.
Inspection and maintenance are usually
ignored, you must find the problems and solve
it in time.
Please dispose of old oil in locally
approved manner.
Make a particular maintenance and repair
schedule.
Take a complete note after maintenance and
repair.
Dont use different oil when changing or
adding oil.
Forbid to repair the fork lift truck if you
havent been trained.
After service maintenance, please record it.
Take a complete note after maintenance and
repair.

30

Preventive maintenance schedule

Check, revise, adjust
Replace
Maintenance
Item

Engine

Crankshaft
Device

Service
Required

Tools

Monthly

(8 hrs)

(200 hrs)

Visually inspect condition of

engine rotation (include of
Voicecolor of exhaust gas)
Clean or replace the air
cleaner
element
Check crankcase for dirt
and clean
Check the valve clearance Thickness
is correct
gauge

Retighten cylinder head

Torque
bolt
wrench
Check cylinder for proper Comprecompression
ssion
compression
gauge
Check metering valve and
pipe for clogging or
damage

Governor
Check no-load maximum
or injection
rpm
Pump

Semiannu
ally

Daily

(1200 hrs)

Annually
(2400 hrs)

Tachometer

Engine
Daily
(8 hrs)

Monthly
(200hrs)

Semiannually
(1200 hrs)

Annually
(2400 hrs)

Check oil leakage for engine

Check engine for oil Level

Lubrication and dirt
system
Replace engine oil

Check fuel filter for clogging

Replace fuel filter cartridge

diesel engine D

Maintenance
Item

Fuel
system

Service required

Replace engine oil filter

cartridge
Visually check for fuel leak
from pipe, pump or tank

Tools

31

Check that injection nozzle

Nozzle
has correct inject press and
tester
patterndiesel engine
Check
for
injection
timing(diesel engine)
Drain off water from fuel
tank

Clean fuel tank

Check for coolant level

Check for coolant leak

Use
antifreeze
for 3~5 years

Check

fuel quantity

Clean and change coolant

Cooling
system

Check fan belt for tension

and damage
Clean the exterior body of
radiator
Check the radiator cap for
condition and installation
Check
hoses
for
deterioration

Driving System
Checking
Item

Clutch

Service required
Check clutch pedal for
free travel and clearance
between pedal surface
and floor when clutch is
unlocked
Check for noise and
operation
Check for slipping and
engagement
Check change lever for
operation and looseness

Mechanical
Transmission Check for oil leaks
Change oil

Daily
Tools (8hrs)

Monthly
(200hrs)

Semiannually
(1200 hrs)

Annually
(2400hrs)

First
(200h)

First
(200h)

32

Replace
element

line

filter

Check for oil leaks

Check for oil level ,or
change oil
Torque
Check inching pedal for
Converter
free travel and pedal
Transmission
travel
Check for control valve
and hydraulic clutch for
proper operation
Check inching valve for
Proper operation
Check
wheel
hub
bearing
for loosenessnoise

Clean and repack grease

Front Axle

Check the axle body for

deformation crack or
damage
Check bolts which is
connected to the truck
body for looseness
Check wheel hub bolts Torque
for retighten moment
wrench

Wheel
mechanism

Check for leaks

reducing

Wheels ( Front, Rear Wheels)

Checking
Item

Service required
Check for
pressure

inflation

Tools

Daily
(8 hrs)

Monthly
(200hrs)

Tire gauge

Check for abrasion

cracks or damage
Tires

Check for spikes

stones or foreign matter

Semiannually Annually
(1200 hrs)
(2400 hrs)

Check the wheel hub for

damage

Check the split body

Test
wheel hub-bolts for
hammer
looseness

33

Steering System
Checking
Item

Service required

Daily
(8 hrs)

Monthly
(200hrs)

Check mounting bolts

for looseness

Check king pins for

looseness or damage

Check for deflection,

deformation, cracks or
damage

Check for
condition

Check
play
Steering
wheel

Steering
Gear Box

Knuckle
Rear Axle

Steering
Cylinder

for

peripheral

Check for
looseness

sideways

Check
for
looseness

vertical

Check
for
operation

proper

Tools

mounting Test
hammer

Semiannually Annually
(1200 hrs) (2400 hrs)

Check for operation

Check for oil leaks

Brake system
Checking
Service required

Tools

Item
Check for free travel
Brake

Check for pedal travel

pedal

Check

Parking
Brake

for

Daily
(8 hrs)

Monthly
(200hrs)

Semiannually
(1200 hrs)

Annually
(2400 hrs)

Scale

proper

operation
Check for lever is
securely locked
Check

for

proper

Lever
operation
Hoses and

Check for damage,

leakage or collapse

34

Pipes

Air tank

Oil-water
separation
Combinati
on valve

Safety
valve

Automatic
release
valve

Gas system
Valve
action

Check
for
loose
connection
or
clamping parts
Check for the interface
is leaking
Check for Whether
to install a solid
Check for Whether the
leak
Check for
Automatically adjust
braking pressure on
the system's
performance
Check for Oil, water
impurities automatic
discharge performance
Check for Whether the
leak
Check
for
Brake
pressure
control
system performa
Check for Whether the
leak
Check
for
Auto
emissions function
Check for when rescue
park operations
manual button fast
water
Check for Pedal, the
valve is installed to
connect firmly
Check for Valve
clearance is normal
Check for Whether the
leak
Check for Campaign
site for the use of
grease mainte

Daily
(8 hrs)

Monthly
(200hrs)

Semiannually
(1200 hrs)

Annually
(2400 hrs)

Check for Whether the

leak

Check for
performance is normal

Service required
Item

valve

Checking

shuttle

Tools

35

relay valve

Manual
brake

Quick
release
valve

Check for Whether the

leak

Check for Braking is

lagging

Check for Whether the

leak

Check for Whether or

not to install a solid

Check for Campaign

site for the use of
grease maintenance

Check for
performance is normal

Check for whether the

rapid lifting of the
brake brake
Check for Whether the

leak

Brake
Drum &
clutch
blocks

Check drum mounting

part for looseness

Test
hamme
r

Check clutch block s

ray

Slides

Check clutch blocks

for proper operation
Check anchor pin for
rust or distortion
Check seal ring for
deterioration
Check automatic brake
disc for deterioration,
Check for cracks
Check Adjust the arm
extended wear,
damage
Check camshaft
cam stent is installed
loose
,deformation,wear

calipers

Crack
detectio
n

Test

hamme
r

36

Hydraulic System
Checking
Item
Hydraulic
Reservoir

Service required

Daily
(8 hrs)

Tools

Check for oil level, Change oil

Clean suction strainer

Monthly Semiannually Annually

(200hrs) (1200 hrs) (2400hrs)

Drain for foreign matter

Check levers for looseness at

Control lever link
Check for proper operation
Check for oil leaks

Check relief valve and tilt lock

Control valve valve for proper operation
Oil press
gauge

Measure relief pressure

Check for oil leaks, looseness,

Hose, Piping collapse,
deformation
and
Hose Reel &
damage
Swivel Joint
Change hoses

1-2 Years

Electrical system
Checking
Service required
Item
Starter
Pinion joggle
motor
Check for electrolyte level and clean
Battery
Check specific gravity of electrolyte
Check for wire harness for damage
Wiring and clamps for looseness
Check connections for looseness

Tools

Daily
(8 hrs)

Monthly
(200hrs)

Semiannually Annually
(1200 hrs) (2400hrs)

.Lifting system
Daily
(8 hrs)

Monthly
(200hrs)

Semiannual
ly
(1200 hrs)

Annually
(2400hrs)

Lubrication of chains

Check connection of
chain anchor pin and
chain for looseness

Check sheaves for

deformation or damage

Checking
item

Service required

Chains &
Sheave

Check
chain
for
tension, damage or rust

Tools

37

Optional
Attachment

Check sheave bearings

for looseness

Perform
inspection

Check screw fuel

Check cross members

on outer and inner
masts for defective
weld, cracks or damage

Check tilt cylinder

bracket and mast for
defective weld ,cracks
or damage

Check outer and inner

masts for defective
weld, cracks or damage

general

Check piston rod, rod

screw and connection
for
looseness
deformation or damage
Lifting
cylinder

Check cylinders
proper operation

for

Check for oil leaks

Test
hammer

Check
pins
and
cylinder bushings for
wear or damage
hydraulic
pump

Check hydraulic pump

oil leak or have noise

Check
driving gear
of the
hydraulic
pump worn condition
Check
damage,
or wear
Fork

Screw

Mast &
Lift
Bracket

forks
for
deformation

Check fork base and

hook
welding
for
defective cracks or
wear
Check Screw state
inspection
,deformation, corrosion
damage

38

Check for defective

weld, cracks or damage
of lift bracket

Check roller bearings

for looseness

Check mast support

bushings for wear or
damage

Check mast support

cap bolts for looseness

Test
hammer

(for
1st
time only

Check lift cylinder tall

bolts, piston rod head
bolts, U-bolts, and
piston head guide bolts
for looseness

Test
hammer

(for
1st
time only

Check rollers, roller

pins and welded parts
for cracks or damage

Additional
Semiannua
Checking

Daily
Service required

Monthly

Tools

item

lly
(8 hrs)

(200hrs)

Annually
(2400hrs)

(1200 hrs)
Cab

Check for
installation

tight

Test

Check cab Bearing

on the right side of
the pin installed in
place

Check deformation,
cracks, damage

Check the door

open to close

Check the
manually pump
work

Check cab tipping

is normal

hammer

Check wiper work

39

Turn signal

Check for proper

operation and tight
installation

Check for proper

operation and tight
installation

Check for proper

operation and tight
installation

Buck-up
Buzzer

Check for proper

operation and tight
installation

Meters

Check meters for

proper operation

Horn

Light
Lamps

&

40

Replace the key safe parts termly

Some parts should be checked termly to detect the damage , for improving the safety more,
users should replace the parts termly which is listed in the table as follows .
If the parts is abnormal before the replacing time is coming ,it should be replaced immediately .
KEY SAFE PARTS DESCRIPTION

TERM OF USING (YEAR)

Brake hose or tube

1~2

Hydraulic hose for lifting system

1~2

Lifting

2~4

chain

High-pressure hose hose for hydraulic system

Fuel oil hose

Inner hermeticrubber matter

Table for bolts tight moment

Unit

Nm

Grade

Bolts
diameter

4.6

5.6

6.6

8.8

4~5

5~7

6~8

9~12

10~12

12~15

14~18

22~29

10

20~25

25~31

29~39

44~58

12

35~44

44~54

49~64

76~107

14

54~69

69~88

83~98

121~162

16

88~108

108~137

127~157

189~252

18

118~147

147~186

176~216

260~347

20

167~206

206~265

245~314

369~492

22

225~284

284~343

343~431

502~669

24

294~370

370~441

441~539

638~850

27

441~519

539~686

637~784

933~1244

30

529~666

666~833

784~980

1267~1689

36

882~1078

1098~1372

1323~1677

2214~2952

47

4000-4300

Note:Use entirely 8.8 grade bolt in the important joint position.

Bolts grade can be found in the head of the table, if it cant be found, the grade is 8.8.

41

Table for the oil used in the truck

Description
Diesel

Shop signCode name

0#(summer)
-10#~-35#(winter)

Capacity

Remark

120

General seasonCD grade 10

W/30 or according to service
manual of engine
Diesel engine oil

CD10W30

1113

CD5W/30
CD5W/40
General season:
hydraulic oil
L HM32
Hydraulic oil

Anti-wear

Alpine Environment
:Wear
low-temperature
hydraulic oil
L-HV32

110

Hydrodynamic
power

ATF DEXRON IICaltex

31-32

Transmission by

transmission oil
Gear oil

GL-5

85 W/90

14

antifreeze

-35 antifreezekunlun

28

Industrial
vaseline
Lubrication
grease

Electrode of Storage
battery

2#
Currency
lithium
lubricate grease

Driving axlewheel reduction

unit

group

Note: The Fork Lift Truck have been injected with the antirust antifreeze liquid according to
scale of 1:1, you may not let it out even in the severe winter. Usually it was changed
every 2-4 years.

42

Engine service technical parameter

Engines other parameters are listed in Engine Service Manual
Diesel engine
Idle
rpm
Max. Speed
rpm
Ignition order
advance angle
of fuel supply
Injection open
pressure Mpa
admis
valve
sion
cleara
mm
nce
Exhau
st mm

6BTA5.9-C18
700-750
2530
1-5-3-6-2-4
132 0
23~24

0.4(Cold engine)

0.45(Cold engine)

43

Trucks convey, lifting, towing

Convey
The Fork Lift Truck is designed for material handling only, It is inappropriate for
long-distance transportation. The Fork Lift Truck must be transported by ship, train or lorry,
of 20T loading.
Use a loading flat roof or lifting set loading and unloading truck.
Lock hand brake and use chocks fix the wheel , use firmly cord fix body ,prevent slippage.

Hoist the truck

Use the steel wire ropes to tie the holes in the two side of the outside masts beam and the
hook of the counter balance, then use the lifting device to hoist the truck.
Warning
When hoist the truck, dont coil the overhead guard with the steel wire.
The steel wire ropes and the lifting device must be very firm to support the truck because the
truck is very heavy.
Dont lift the truck by hoist the overhead guard.
When lifting the truck, dont take yourself below the truck.

44

CPCD160-XG35 inner ignite fork technology parameter

model
Power type

CPCD160-XG35
Diesel

Rated capacity

kg

16000

Load center

mm

600

Lifting height

mm

3000

Free lifting height

mm

Fork size

mm

1820200105

Fork distance(outside)

mm

520-2200

Tilting angle
Overall Lengthnot contain

dimensio Width

deg

6/12

mm

4820

mm

2480

mm

3080

n
Ground
Clearan

Height

mm
mm

270

mm

4450

Max lifting speed,laden

mm/s

350

Max traveling speed

km/h

34

20

kN
kg

100
18800

Min turning radius

Max Grade ability % (Laden),

2km/h
peak traction
Service weight
Tire

Front

12.00-20-20PR

Rear
Qty,

12.00-20-20PR
4/2

battery

Motor

V/AH

212/120

Model
Rated power /

kw/rpm

115/2300

Max

Nm/rpm

560/1500

torque/

YC6108ZG

Cylinder
Bore/stroke
Displacement

6
mm

108120

45

46

Cab tipping rules

warning
Vehicles will be parked at the level on the ground, the handle stalls on the free, fork fell to
ground, the gantry forward tilt, lay the parking brake, engine off and disconnect the power;
Before cab tipping, remove non-fixed items, nobody in, nobody beside on the left when tipping;
Rotating the pin which at the right side of the driver's seat bottom cushion to

the direction of

opening slot and out , do not want to hold tipping, manually pump knob to "work" location;

Cover fixed to prevent collisions, Shake the handle bar for tipping cab operation, stop when
handle force increased , Cover to prevent the closure of misoperation;

the

Before into the in-house maintenance repair operation, use items solidly supported or fixed the cab,
strictly prohibit loosing the fuel cab tipping tank and the connected pipeline joints and so on;
Before the cab repositted ,must confirm there is no person in it, get rid of backstop or fixation, turn
the handle-pump konb to "short circuit" slowly and anticolockwise, then the cab re-posit calmly
with itself-weight.
Make sure the cab repositted ,then assemble cushion and joint it with body carrier. Insert rotation pin
shaft, turn it's lower upright to notch, and the handle pump remain keep loosening.

47

12-16t R Series Forklift Truck

SERVICE MANUAL

CPCD120/140/160-XG35

HANGZHOU FORKLIFT TRUCK Co., Ltd

2008.9 1st EDITION

Foreword

The manual is the introduction of structure, working principle and

serving .etc of 12-16t series diesel fork truck.

For safety and performance

of truck, all in charge of operation, maintenance and management must read and
comprehend this manual well.
It is forbidden anybody without training and qualification to
maintain.

Foreword
I.
Driving System .................................................................................................
II.
Hydraulic gear-box and torque converter..........................................................
III. Drive axle and Carrier assembly........................................................................
IV.
Steering axle......................................................................................................
V.
Steering system .................................................................................................
VI.
Brake system .....................................................................................................
VII. Hydraulic system ...............................................................................................
VIII. Electrical system................................................................................................
IX.
Lifting system ...................................................................................................

I. Driving System
Power configure
Diesel
Engine
CY6108ZG(Yuchai )

parameter
Rated output KW

115

Rated rpm r/min

2300

Max. torque

560/1500

Nm/speed rpm
Forklift model

CPCD120/140/160-XG35

Specification, structure and maintenance, please refer to ENGINE MAINTENATION

MANUAL.
There is need to check the exhaust quantity after the maintenance or servicing, and ensure
that the exhaust gas accord with the table:
Engine power

CO

HC

NO2

PT granule

KW

(g/kwh)

(g/kwh)

(g/kwh)

(g/kwh)

75 P <120

1.3

0.4

II. Hydraulic gear-box and torque converter

Data
Model
Hydrodynamic

YQXD100H1

Type

torque

Two stage, three phase,

four-element

converter
Variety
Hydrodynamic

Transmissi

power gear-box

on gear

Forward I

1.179

Forward II

0.645

Reverse I

0.844

ratio

Shift gear oil pressure

Oil pressure

Electrical shift

MPa
Torque converter output oil pressure
MPa

1.0-1.6
<=0.50

Mass (kg)

450

Oil capacity (L)

approximate31-32

Using oil type

ATF DEXRON II Caltex

Specifications, structure and maintenance methods ,please see Y63270ZJapan

Okamura

MODEL TORQUE CONVERTER MAINTENANCE MANUAL .

III. Drive axle and Carrier assembly

One step carrier assembly and wheel-end reduction

Drive axle type

Full floating, direct frame mount, front-wheel drive

Carrier assembly

One step helical bevel gear

Differential assembly.

Straight tooth gear

Wheel-end reduction

pinions

Oil capacity in housing

Oil capacity in wheel-end
reduction

GL-5

85W/90

(L)

GL-5

85W/90

(L)

TROUBLE DIAGNOSES AND CORRECTIONS

Condition

Probable cause

Unusual noise
Before attempting a correct
ion, make sure the noise is
coming

from

the

drive

shaft-not from the final drive

or wheel reduction gear.

Corrective
action

Loose axle mounting bracket bolts.

Tighten.

Loose wheel nuts.

Tighten.

Other retaining parts loose.

Tighten.

Worn or damaged wheel bearing.

Replace.

Wheel bearing not properly adjusted

Adjust.

Worn sun gear (drive shaft) splines.

Replace.

Insufficient lubrication.

Lubricate

Loose wheel nut.

Tighten.

Unstable driving

Deformed road wheel.

Replace.

Also refer to the Trouble

Worn or damaged wheel bearing.

Replace.

Diagnoses and Corrections in

Loose axle mounting bracket bolts.

Tighten.

the RA section.

Wheel bearing not properly adjusted.

Adjust.

Improper tire pressure.

Adjust.

Worn or damaged axle tube oil seal.

Oil leakage

Final drive improperly installed.

Loose filler or drain plug.

Replace.
Replace gasket.
Tighten.

Specifications, structure and maintenance methods ,please see CPCD160-XG35

MODEL

MAINTENANCE MANUAL And PARTS ITEM .

IV. Steering axle

1. General specification

suspension type

axle center

Center support, wing type

Inner

Max. Steering angle

77.6

wheel

01(forward is no

clearancemm

clearance)

Fore-aft adjusting shim

Thickness

Outer

50

wheel
Tire pressure

Fore-aft

0.83MPa

Kingpin

Part number

mm
0.51.01.5

GX160-220005-000

wheel bearing

Axial playmm

Pre-tightness

Tighten bearing nut until rotating

resistance is felt, from this
position; back off bearing nut
1/8-1/6 turn. or wheel hub bolt
initial force is less than
10-29N

Axle play(mm)

Less than 0.08

Less than 0.2

Adjusting shim
Thicknessmm

Part number

010.71.0

G160-220014-000

2. Trouble diagnoses and correction

condition

Unstable driving

Noises

Probable cause

Corrective action

loose wheel nut

tighten

wheel bearing out of adjusting

adjust

improperly adjusted mount shims

adjust

faulty steering system

refer to steering section

insufficient lubrication

Apply grease

loose bolts and nuts

tighten

improperly adjusted mount shims

adjust

3. Steering Axle Structure

Ground

1.steering wheels assembly

7. paper washer
15.cover plate

2.ball nut

3.join nut

6.end cover

8.left steering spindle 11. bearing

17.oil cup

18.O-ring seal

21.soldering cup

22.bolt

29.connecting rod

34.right steering spindle

37. steering axis

41.adjusting shim

19.steel bushing

26.axis pin

27.mounting cap
35.axis pin

38.steering cylinder
44.king pin

13. bearing

14.oil seal

20.bearing
28.bearing

36.mounting cap

39.dust ring

40.bearing bushing

45.bearing
Fig 4-1 steering axis

Removal

Steering wheel hub

1)

Jack up and support truck body with safety stands.

2)

Remove tire.

3)

Remove hub cap.

4)

Remove spindle nuts and bearing washer.

5)

Pull off hub assembly.

Caution a.
6)

Remove inner bearing cone.

Caution b.

Be careful not to drop bearing cone.

Be careful not to damage grease seal.

Kingpin and steering spindle

1)

Remove ball stud nut and disconnect tie-rod from steering spindle.

2)

Loosen lock nut and remove set-screw.

3)

Remove grease nipple.

4)

Attach a pad to upper end of kingpin, and drive out kingpin.

Caution: hold kingpin to prevent it from dropping

5)

Take off spindle, including thrust bearings and shim as an assembly.

Inspection
1 Replace spindle if cracked.
2 Replace thrust bearing if its rollers or roller surfaces are rusted or nicked.
3 Replace needle bearings if damaged.
4 Replace bearings and dust-proof cover if damaged.
installation
To install, reverse the order of removal. Carefully observe the following.
1 Always insert kingpin from lower side.
2 Install thrust bearing with its cover facing up, and adjust axial play less than 0.2mm with
shims.
caution Always place thrust bearing on upper side of spindle, and shims on lower side.
3 Apply grease inside the dust-proof cover and between two rings of thrust bear.
5 Do not apply grease to spindle mating with bearing.
6 Apply grease on needles and balls of bearings.
7 Pack all grease nipples with a sufficient amount of grease.

Wheel bearing installation and adjustment

1) Apply grease or anti-rust oil on contact surface of bearings and spindle nut.
2 Rotate hub slowly. Tighten bearing nut until rotating resistance is felt; turn bearing
6

nut back off 1/4turn from that position.

3Rotate hub 2~3 turns, make the rollers stay in the right position.
4Repeat the second step, and install bearing washer and tighten the other bearing nut.
5 Rotate frontward and backward hub 2~3 turns, make sure its axle clearance is less than
0.08mm, and rotated starting torque at hub bolt is less than 25.5N. Otherwise, return to the
second step.

Axle center
Removal
1. Jack up and support truck body with safety stands.
2. Remove tire.
3. Disconnect ball joint at tie-rod.
4. Support axle center with a jack.
5. Disconnect piping connectors and remove mounting caps.
6. Remove axle center.
caution Be careful not to slide jack out of place.

Installation
To install, reverse the order of removal. Carefully observe the following:
Add shims on both sides until fore-aft clearance between steering axle and frame is less than
0.7mm.

V. Steering system
Steering system type
fully

rear wheel steering with

hydraulic

redirector

power steering
line mounted

with

priority valve ,load

sensing

power cylinder

double-action
transfixed

1. Trouble diagnoses and correction

condition
Steering wheel
failure

Probable cause
Pump damaged or faulty

replace

Flow priority valve blocked or damaged

Clean or replace

Pipes or connections damaged or passage

blocked

Hard steering

like snake or
noises

leakage

Clean or replace

Low oil pressure in the flow priority valve

adjust

Air in system

Bleed air

Steering gear fails to reset, or orientation

shim is broken or of failure

Truck travels

Corrective action

Replace elastic shim

Power cylinder piston seal damaged

replace

Great steering deflate

adjust

Insufficient oil in tank

replenish

Blocked in the passage or filter

Clean or replace

Seal on the guide set, piping or connector is

damaged

replace

2. General
The steering system is mainly composed of cycloid fully hydraulic redirector and the
power cylinder.
2.1 Cycloid fully hydraulic redirector
It consists of cycloid steering gear, steering column and steering wheel. The assembly
position can be adjusted 8aft-forth to satisfy drivers needs.
Turn the steering with 1 KG power when the power is off, and it can return about
10automatically after loosening.
2.2 Fully hydraulic steering
With overflow valve, load sensing. Pressure oil enters stator-rotor set from valve disk and
8

sleeve valve set, then drives rotor turns following with steering wheel, and presses oil into
left and right chamber of steering cylinder, then cylinder piston rod forces steering wheel to
steer.
2.3 Steering oil cylinder
Steering cylinder is of double-action piston type; each end of piston rod is connected
to tie-rod and spindle in turn. Hydraulic oil from fully hydraulic steering gear makes the
piston rod move left and right to steer truck.

1. piston rod
2.LBI seal ring d80
3. bolt
4.O-ring seal 80X5.3
5.ISI seal ring d80
6. guide set
7.O-ring sea 100X5.3
8. cylinder body
9.glan-ring D110
10 steel ball
11.support ring 12.piston

Fig 5-1 steering cylinder

VI. Brake system

Brake system uses air pressure braking system, its supply devices and gears are air
pressure type. Its control devices are composed of

brake pedal framework, air- brake valve,

hand brake valve, oil-water separator combination valve, air tank, safety valve, brake
air-chamber,

drain valve, shuttle valve, relay valve, quick lease valve, etc. Air compressor

feed in oil-water separator combination valve compressed air by engine, then the air flows
from check valve to air tank (with safety valve and hand water release valve), one way to
hand control valve, parking brake chamber to control parking brake; another way to air brake
valve, shuttle valve, relay valve, run brake air chamber to control run brake. The air circuit
has drain water and filter device to ensure air source is clean.

Taking antirust treatment to

air brake system pipe and air tank.

Fig. 7-1brake system diagram

1 oil-water separator combination valve

1.1Technical parameters
Opening pressure

784kPa20kPa

Stop draining air pressure

685 750kPa

Joining dimension

Input M221.5-6g
Output M221.5-6H

10

1.2 Structure and Principle

Oil-water separator combination valve is used to adjust the pressure of brake system
automatically; it can deflate the filtered air and water. Because of safety device, it can
ensure the pressure of system is safe.
The pressure air from air compressor flows through inlet to valve, the filter filters water
and impurity which existed in air, the filtered air flows from check valve to outlet to charge
air tank. When the pressure of tank is up to the opening pressure, the air in top head chamber
pulls control piston assembly up, opens drain valve, then deflates the filtered water and
impurity and compresses air from outlet to air, makes air compressor run without load, when
the pressure of tank reduces to the valve of stop draining , the pressure of top head chamber
does not overcome the force of pressure-adjust spring, control piston assembly move down,
the spring pulls drain valve up to close drain valve port, then continues to supply air.

Fig.7-2oil-water separator combination valve

1.3 correct use and maintenance
1 Product is installed at installation plate with 70 intervals, down the exhaust.
2 Before the factory, pressure adjustment screw, safety valve assemblies have been set, the
user will not be permitted to adjust, demolish.
3 The piping from air compressor shall not be less than two meters in length in order to be
fully cooling hot air , condensing moisture in air.
4 Wearing parts wear seriously or leak seriously , wearing parts should be immediately
replaced.
5Please be in accordance with the corresponding replacement of wearing parts in kind when
replacing wearing parts,

damaged fasteners(bolts, nuts) in the process of replacement must

be replaced, and ensure that the installation

is in place, solid and reliable, and may not

damage other parts.

6 Replacement without a qualified pilot shall not be used.

11

1.4Common faults, failure analysis and troubleshooting

Common
faults
Leakage of
exhaust port
Leakage of top
head exhaust
hole

failure analysis

troubleshooting

There are impurities at exhaust

valve.

Clean pipe

exhaust valve damaged

Change exhaust valve

diaphragm damaged

change diaphragm

Control piston o-ring

damaged

Change control piston

o-ring

Wearing parts table

Serial
number
1
2
3
4

name

Fig NO.

NO.

o-ring seal
Control piston o-ring
diaphragm
Drain valve

SH380A-3511061
SH380A-3511071
SH380A-3511078
SH380A-3511038

1
1
1
1

2. Safety valve
2.1Structure and Principle
Compressed air flowed from inlet, when the inlet pressure is greater than 850kPa, the
safety valve A opens air on the air brake pipe from the role of security protection to ensure
that the inflating air brake pipe pressure does not exceed 900kPa.
Safe working pressure: 850 ~ 900kPa. Inlet M16 1.5-6g is the connecting thread.

12

Adjust bolt

Exhaust port

inlet

Fig.7-3 safety valve

2.2caution when use
Before the factory, the adjustment bolts on safety valve assembly have been set, users are not
free to self-adjust, demolish.
2.3Common faults, failure analysis and troubleshooting
Common

troubleshooting
failure analysis

faults
Valve port
leakage

Rubber safety valve

Replacement

stem assembly damage

safety valve assembly

Wearing parts
Name

Figure No.

No.

Safety valve
stem assembly

150-3511051A

3Automatic release valve

3.1Structure and Principle
Automatic release valve is used to pump air brake pipe reservoir of pool water, through the
pressure fluctuations in value (pressure drop 0.03 ~ 0.1MPa) automatically from the exhaust
13

water; achieve automatic deflation function; while parking users also can
button for fast water drainage.

manually operate

To air tank

Manual water

button
Exhaust
port
Fig.7-4Automatic release valve

Rated working pressure

800kPa

Installation and connection dimension

M221.5-6g
Exhaust down

Wearing parts
Name

Code

No.

Membrane inlet assembly

PY20-1305030

4Air brake
4.1Structure and Principle
When pressing on the bake pedal 2, through push rod 3, the balance spring 4 is forced to pull
piston 6 down and open inlet valve 7, compressed air flows from inlet to outlet. When loosing
pedal 2, return spring 5 pushs pistons 6 up, inlet valve 7 returns back to close the way
between inlet and outlet, the residual gas emissions from the exhaust.

14

1 screw

2 pedal

5 return spring

3 push rod
piston

4 balance spring

7 inlet valve

Fig.7-5 air brake valve

4.2 Proper use and maintenance methods

4.2.1 Caution
1 Ensure that the pedal firmly connect with the valve body, screw-adjust valve clearance
should be adjusted well (to ensure that the pressure roller mandrills screw down surplus
amount of not more than 0.5mm), and tight nut.
2 M8 bolts through the 4-9 hole are firmly connected.
3Piping connections should be recognized

inlet, outlet. Interface marked "1" for the inlet,

interface marked "2" outlet, interface marked "3" exhaust.

4.2.2 Attention of maintenance
Please be in accordance with the corresponding replacement of wearing parts in kind when
replacing wearing parts,

damaged fasteners(bolts, nuts) in the process of replacement must

be replaced, and ensure that the installation

is in place, solid and reliable, and may not

damage other parts.

2 The movement location of air brake parts should be used grease for maintenance. If the
brake is failed or weak, it has to check the wearing parts of air brake valve and brake system.
3 Replacement may not be installed without a qualified pilot.
4.3 Common faults, failure analysis and troubleshooting
Common faults

failure analysis

troubleshooting

15

Non-working state

Rubber

leakage

damage

Working state

Rubber

leakage

damage

Parts
Parts

replace wearing parts or replace product

assembly
replacement product assembly

Pedal wheel does

not

product

assembly

Piston stuck

Exhaust of sorts

Replace wearing parts or replace

adjust

with

well
the

mandrills

Manually re-adjust screw so that the pedal

on

the

mandrel

wheel

just

contacts

appropriate, (the pressure roller mandrills

screw down surplus amount of not more
than 0.5mm)

5Shuttle valve
5.1Structure and Principle
Actually it is a special three-way valve. The output pressure of frontward and backward
cavity in dual-chamber may not be inconsistent, so they both pass into the shuttle valve.
Shuttle valve only allows higher pressure compressed air to flow through outlet, through
relay valve to driving brake air chamber.

Compressed air flows from the A mouth, the air pressure will push the piston D to the B-side,
because the both sides of pistons D are rubber, thus it can guarantee non-air leak from outlet,
so that pressure can outflow from the outlet C; Similarly, if the air flows into the inlet B ,the
pressure will outflow as the same way outflows from the outlet C. Rated working pressure is
784kPa.
Maintenance should be to protect the interface thread.
5.2 Common faults, failure analysis and troubleshooting

Common
faults

failure analysis

troubleshooting

16

Valve port
leakage

Rubber plunger valve damage

Replace the
valve plunger

Wearing parts

Name

Fig.No

No.

Valve plunger

SUSH-3527013

6 relay valve
6.1Structure and Principle
Compressed air does not flow through the air brake but direct charges into the lane brake
chamber so as to shorten the supply route to reduce the braking time lag.
1 Brake
The pressure from control valve entering 4, pushes piston down, closes the valve,
opens the intake valve so that air pressure from the reservoir pushed by pump opens intake
valve, flows from outlet 2 to brake air chamber, at the rated working pressure, the gas
outlet pressure is controlled by the air intake pressure with a direct proportion .
2) Loosening the brake: after loosening control intake4 air pressure, then the piston is
moving up, and exhaust is opening, brake pressure in the chamber will be deflated into the
atmosphere through the exhaust port.

Fig.7-6
1. Exhaust valve assembly

2.O-ring

Technical parameters
Rated
pressure

working

784kPa
17

Initial
pressure
Connection
dimension

balance

50kPa
Outlet :2-M22 1.5-6H, inlet: M22 1.5-6H
Control of air intake: M22 1.5-6H

6.2 Proper use, maintenance and Cautions

(1) Caution
1) Installed in the installation board with 74 74 interval, the exhaust outlet is down, then
tightens the 4-M8 nuts, and it shall not be loosen.
2) Piping connections should be recognized inlet, outlet and control of air intake. Interface
marked "1" for air intake, interface marked "2" for the outlet, interface marked "3" for the
exhaust port, and interface marked "4" for the control of air intake.
(2) maintenance, maintenance of attention
1) When founding severe wear wearing parts, or leakage, grave wearing parts should be
immediately replaced.
2)Please be in accordance with the corresponding replacement of wearing parts in kind when
replacing wearing parts, damaged fasteners(bolts, nuts) in the process of replacement must
be replaced, and ensure that the installation is in place, solid and reliable, and may not
damage other parts.
3) Replacement may not be installed without a qualified pilot.
6.3Common faults, fault analysis and troubleshooting
Common
faults
Non-working
state leakage
Working state
leakage

fault analysis

troubleshooting

O-ring wear

replace
wearing
parts
replace product assembly
replace
wearing
parts
replace product assembly

Intake
valve
assembly
rubber parts damage

or
or

Wearing parts
Serial
number
1

Name

Fig. No

No.

O-ring

GB3452.1-92

O-ring

HFC-3527033

Inlet valve assembly

HFC-3527020

7. Hand-controlled brake
7.1 Structure and Principle
When parking or emergency brake, hand-controlled valve can be used to brake --emergency brake chamber is connected with atmospheric air chamber, so that parking brake
or emergency braking can take effect while exhausting and reducing pressure. When
loosening the brake the car can be paring--- emergency air chamber is connected with the
reservoir pump.

18

Fig.7-7Hand-controlled brake
Its working state is braking deflated. Namely: When the system pressure is as low as 240 ~
310kPa, or a pipeline is ruptured, manual brake can automatically be took off to release the
interior air brake pressure of spring energy storage system, the spring energy storage on the
drive shaft can implement effective emergency braking. When emergency or stopping
happens, the driver lifts the button at the same time which plays the role of the above, so that
the vehicle can safely stop. Because it belongs to a result of deflated brake, so it is safe and
reliable.
Rated working pressure

784kPa

Insurance pressure

240 310kPa

Installation,

Intake: Z1/8 "

connection

dimension

Outlet :2-Z1/4 "

7.2 Proper use and maintenance methods

(1) Caution
1)When installing, after M22 1.5 thread seal nut is screwed off, then screwing sealed nut
and tightening through the installation of plate.
2)Recognizing each interface when connecting: Marked "1" for air intake; marked "2" for the
outlet, marked "3" for the exhaust port.
(2) maintenance
1)Please be in accordance with the corresponding replacement of wearing parts in kind when
replacing wearing parts,

damaged fasteners(bolts, nuts) in the process of replacement must

be replaced, and ensure that the installation

is in place, solid and reliable, and may not

damage other parts.

Replacement may not be installed without a qualified pilot.
2)The

movement

location

of

emergency

brake

parts

must

be

maintained

with
19

high-temperature resistant grease. If the brake is failed or weak, it has to check the brake
system and emergency brake of wearing parts.
7.3 Common Faults and fault analysis and troubleshooting
Common Faults
Non-working

fault analysis

state

leakage
Working

troubleshooting

Rubber
state

wear

parts

Replace wearing parts or replace

product assembly

leakage
Wearing parts
Serial
number

name

Fig. No.

No.

Mandrels ring

CT-3526064

Valve base ring

CT-3526061

Rubber valve
assembly

CT-3526050

8. Quick release valve

8.1 Structure and Principle
The function of the quick release valve between the hand-controlled brake and brake
air chamber is :when releasing the manual brake button, the route of parking brake air
chamber and the time can be shorten, and ensure the front wheel brake is loosen rapidly. Air
flows from the air brake inlet to quick release valve, the pressure acts on the tympanic
membrane to close exhaust valve, so that it make the outer part of tympanic membrane bend
downward, after that, the air flows from outlet to brake chamber through the surrounding
clearance of membrane. Lifting the brake, the air pressure of inlet releases through air brake
valve, the pressure below tympanic membrane will be pushed. When closing the top intake
channel, and opening the exhaust channel of lower body, the braking pressure in the chamber
is deflated into the atmosphere through exhaust port.
Rated working pressure: 784kPa.
Connection Size: inlet M22 1.5-6g; outlet 2-M22 1.5-6g.

20

Fig.7-8

quick release valve

8.2 Proper use and maintenance methods

(1) Caution
Connecting pipe with three thread interfaces, the exhaust is downward.
(2) Maintenance
1) When found leakage then should immediately replace the wearing parts.
2) Please be in accordance with the corresponding replacement of wearing parts in kind when
replacing wearing parts,

damaged fasteners(bolts, nuts) in the process of replacement must

be replaced, and ensure that the installation

is in place, solid and reliable, and may not

damage other parts.

3) Replacement may not be installed without a qualified pilot.

8.3 Common faults, failure analysis and troubleshooting

common
faults

failure analysis
Parts of the exhaust valve

Exhaust leak

has dirt
Membrane damage

troubleshooting
Clean pipe
Replace
membrane

21

Interval
top

between

and

bottom

seal washers

aging

Replace washers

body leak
Wearing parts
Serial

Name

Fig. No.

No.

tympanum

JN441-3516012

Seal washer

JN441-3516014

No.

9 Combination brake chamber

Combination brake chamber is composed of front and rear air chambers which are
unattached .one is driving brake chamber, driving brake takes effect when inflating and
increasing

pressure.

It

is

also

called

as

inflatable

braking

room.

Another

is

parking--emergency brake chamber, parking brake or emergency brake takes effect when
exhausting and reducing pressure. When it inflating and increasing pressure, it becomes
weak even it will loose brake, so it is called inflatable braking room.
Inflatable braking room is for driving brake, deflated spring brake chamber is for parking
and emergency brake.
9.1 Structure and working principle
There are both inflatable brake room and deflated brake chamber in it. It generate force for
the wheel brake by filling and deflating , inflatable braking chamber (11 cavity) is for the
driving brake, deflated brake chamber (cavity 12) is for parking and emergency braking, the
main features of spring brake chamber is that it can get a mechanical braking force by the
release of spring energy.
Working pressure: 0.8MPa; work trip 55mm

22

Fig.7-9 brake chamber

9.2 Caution
Warning Extremely dangerous
1 For internal structure of combination brake chamber, demolition

,assembly,

adjustment and replacement of wearing parts, must be done by professional

manufacturers;
2 Demolition and assembly must use special tools to prevent the spring
wounding.
1)"11" inlet to driving brake chamber; "12" inlet to emergency brake chamber;
2) When Loading,
bolts from

the air flows into emergency brake chamber ,screwing the adjustment

supplied state

to work state;

3)Vehicle was moving locked when driving, should promptly screw adjustment bolts

to lift

the brake state (that is, supply status)

4)When driving brake chamber leak a little, can

screw bolts on

hoop down by wrench ;

5)Prevent bump ,do not damage the exhaust pipe, exhaust pipe shall not be loaded, pull;
6)Do not take down without special equipments, that is to guard against the spring
wounding.
9.3 Description of demolition and repair
1)Please confirm whether the adjustment bolts is screwed back before demolition and repair,
which is lift brake state and supplied state. And remove nut of adjustment bolts.
2) Put the spring brake chamber lifted brake state on compactor and compact it, then can use
wrench to unscrew bolts on hoop to remove hoop. Remove clamping device, then can
replace wearing part 1 membrane.
3) When the pressure of inlet 12 is 600 kPa, piston is push back, and then screw adjustment
bolts about 30mm. After releasing pressure, seal-plug can be removed with special wrench,
then replace wearing parts 2(o-ring 192.4). Removing fastening bolts

on connecting cover

with wrench, then can replace wearing parts 3(o-ring)

4)Put the storage cylinder assembly on special compactor and compact it, then remove
adjustment bolts, take out storage piston to replace wearing part 5(0-ring1708.6 )
9.4 Safety precautions
1)It is important to have a special compacter with spring-proof device to disassemble spring
brake chamber slowly, prevent the spring hurting people. To ensure safety and prevent spring
hurting people, it is forbidden anybody to stand in direction of spring ejecting.
2) When assembling compact storage spring with compacter, the adjustment bolts must be
screwed to specified depth (adjustment bolts showing 60mm outside), then pressure of
compacter can be released.
Wearing parts
Serial
number
1

Name
membrane item 9 in fig.7-9

No.
1
23

O-ring192.4 item 8 in fig.7-9

O-ring33.75.1 item7 in fig.7-9

O-ring1643.1 item 6 in fig.7-9

O-ring1708.6 item 5 in fig.7-9

10 Pressure sensors, alarm lights switch

The reserve pump of the brake circuit is equipped with pressure sensors and alarm lights
switch, when the pressure of the reserve pump reduced to a certain pressure (pressure below
0.4MPa) due to several times consumption, the barometer installed in the right seat will be
displayed that the pressure value is less than 0.4MPa, alarm pressure switch on the panel in
front of the driver will be non-stop flashing lights to warn the driver, pay attention to the low
pressure of the storage air chamber. At that time, the drivers should be immediately stopped,
and when the pressure value is higher than 0.4MPa and the alarm light switch goes out, the
drivers can continue travel.

11. Shoe brake

Shoe brake is composed of brake hub, brake shoe, air chamber assembly and the cam bodies.
Structure Chart:
Chamber specifications: 32/30 inch (line / in)
Rated pressure: 0.8MPa
Braking torque: 21.5/17 (line / in)
Available friction thickness: 9mm

24

1 friction plate

2 horseshoe

5 camshaft

6 return spring

lengthening

9 shim

13 O-ring4940
18 bolt

4 bottom bushing

7 horseshoe rivet

10 check ring

14 shim

19 dust cap

3 roller wheel

15 jam

20 shoe-axis

11 washer

8 adjustment arm with

12 cam stent

16 hanging spring pin

17 bolt

21 elastic column pin

Fig.7-10 Brake

25

Its working principle is that, taking use of spring and pressure 0.3~0.4Mpa of spring brake
chamber to transfer the power to brake shoe through adjusted arm, camshaft, to make brake
shoe tighten brake drum, so it can generate brake torque to brake wheels.
When parking, air is discharge all from driving brake chamber (12) and parking brake
chamber (11) to brake truck by spring force, when normal driving, air flows in driving brake
chamber, and the air in parking brake chamber is discharged to overcome spring force, so
that it lifts brake shoe to ensure normal driving. When driving brake, air flows in parking
brake chamber, and flows out the driving brake chamber, to ensure brake by pressure and
spring force.
Brake block working surface should be kept clean, if it is polluted slightly, acetone and
gauze can be used to remove, or it should be replaced with new pieces. If friction block
assembly wears to trench of friction material, friction block assemblies should be replaced.
Replacement of friction plates must be replaced in pairs.
Adjust description of brake assembly: after connecting the brake and air chamber adjust arm
with support pin, and then adjusting worm on adjust arm. At first, adjusting brake shoe to
tighten brake drum ,then adjusting backward till when hear the sound of three "click" ,at this
point the gap of brake shoe and brake hub is between 0.3 ~ 0.7mm, and the gap of the two
brakes may not be more than 0.5mm.

26

VII. Hydraulic system

1Data
Control valve
12~16t

Lift truck type

DC32F4-ATR03T-2 2 spools

Model

DC32F4-ATR03T033T033T-2 4 spools

type

Double-slide valve, with tilt-lock valve

Adjusting pressure

20Mpa can lift 110% of rated load, can't lift 125% rated load

Rated flow rate L/min

280

2Trouble diagnoses and corrections

Main pump
Trouble
No oil from oil
pump

Probable cause

Corrective action

Low oil level in tank.

Clogged

suction

pipe

Add oil to specified level.

or

strainer.
Worn

Clean oil line and tank. If oil is dirty,

change.

bearing

damaged

Replace faulty parts.

backup ring and O-ring.

Low deflate

Maladjusted relief valve.

pressure on oil

Readjust

to

specified

pressure

using

pressure gauge.
Retighten suction side pipe.

pump.

Add oil in oil tank.

Air in oil pump.

Check pumps oil seal.

Do not operate pump until bubbles in tank
disappear.

Noisy oil
pump

Cavitation due to crushed

suction

hose

or

clogged

strainer.
Air being sucked from loose
suction side joint.

Adjust or replace crushed hose and clean

strainer.

Retighten each joint.

Cavitation due to too high

Replace with new oil having proper

oil viscosity.

viscosity for temperature at which pump

is to be operated.

27

to

operate

when

oil

temperature

is

normal.
Bubbles in hydraulic oil.
Oil leaking
from oil pump

Determine cause of bubbles and remedy.

Faulty oil seal on pump,

faulty O-ring or worn sliding

Replace faulty parts.

surfaces on pump.

Control valve
Trouble

Probable cause
Loose of pressure-adjust screw.

Pressure of relief
valve is not

Distorted or damaged
pressure-adjust spring.

Corrective action
Readjusted and retighten.
Replace.

steady or too
low.
Fork tilt forward
when control
lever is used

Worn or blocked relief valve core.

Replace or clean.

Pump abated.

Examine and repair pump.

Worn or damaged tilt lock valve.

Replace valve core and tilt lock

valve as an assembly.

Broken tilting lock spring.

Replace spring.

Damaged tilt valve plunger O-ring.

Replace O-ring.

while engine is
off.
Mast is unstable
when tilting

Malfunctioning tilt relief valve.

forward.
Valve body and spool valve is worn

Replace tilt relief valve

assembly.

Replace spool valve with

Lowering

and clearance between them is too

distance of mast

great.

is big when

Spool valve is not in centre.

Keep being in the centre.

spool valve is in

Cylinder seal abated.

Examine and repair cylinder.

the centre.

Taper valve is worn or blocked by

dirt.

Spool valve is
not return

Damaged or distorted
reposition-spring.

specified clearance.

Replace or clean taper valve.

Replace spring.

neutral position.
Dirt exists between valve body and

Clean.
28

spool valve.
Blocked control device.

Adjusted.

Not coaxial parts at reposition

Reinstall. be coaxial

Damaged O-ring.

Replace.

Faulty seal of joint.

Check and retighten.

Leakage

Clean seal plate and retighten

Loose seal plate.

blots.
Loosed lock-nut of relief valve and
connect-nut between plate and plate.

Tighten.

3. Pump
spline

front pump

rear pump

Fig 7-1 2 spools pump

The CBG-Fa2063/2050-216L double gear pump is used as main pump in the hydraulic system
of 12-16t. Front pump supply control valve oil directly; rear pump connects with priority
valve, ensure pump to supply steering system oil preferentially, excess flow is to control
valve. This pump is full cast part with high intension; it also uses axis clearance auto
compensation and radial hydraulic balance technique. It has following advantages, anti-high
pressure, high reliability, high efficiency, and little noise.

4. Control valve
The control valve CDB-F20 is section model, which is made up of input, output and slide
valve. Flow valve is installed in the entrance with main relief valve. See fig.7-2.
Main relief valve is used to control the pressure of oil circuit. Its pressure has also been
adjusted in the factory, so please dont adjust it at will.
Steering relief valve is used to adjust the pressure of driving steering oil circuit.
Slide valve is used to control tilt hydro cylinder and lift hydro cylinder, and it can
29

change the flux to control hydro cylinder by maneuvering the tilt and lift lever.
Tilt slide valve is equipped with front-tilt self-lock valve.
Oil from hydro cylinder returns to oil box from output, and every piece of valve is sealed
by maneuver O-ring. At the same time, there is a clappet valve.

Tilt valve Lift valve

Safety valve

Safety valve
pressure
hole
Fig.7-2
Safety valve pressure adjustment:
1 Truck stay at level and solid ground, pull up handle brake button, and make parking
brake work.
2 Connect pressure gauge with safety valve pressure hole.
3 Start engine, run idle 2-3min.
4 Adjust safety valve's pressure; stabilize its valve at 20MPa.

5. One-way check valve

To limit the descend speed of lift hydro cylinder, install one-way governed speed valve
to control the recycle oil flux, and this can limit the descend speed of hydro cylinder and
protect the circuit when lift circuit is explosion.

1. Valve body

2. Valve core 3. Spring

4. Orientation nut
30

Fig. 7-3 Governed speed valve

6.Hydraulic system principle diagram

tilt

lift

steering

Speed
limited valve

Priority
valve

2
spools
Control

pump

valve

Fig.7-4 hydraulic system principle diagram

2 spools pump is the power source of hydraulic system, it supply high pressure hydraulic oil
to system by engine. Front pump make oil flow to control valve, rear pump make oil flow to
priority valve,

distribute from priority valve to steering system , by feedback from load,

according to requirement of steering, give priority to supply steering oil. After supplying
steering enough flow, excess flow is distributed to control valve. When the lift and tilt valve
are on the middle location, high pressure oil flow back to oil tank directly; When pushing
lifting spool, it is that bottom of lifting cylinder piston connects with low pressure line and
then piston rod drops by deadweight and weight of cargo. In this time, oil from lifting
cylinder goes by unidirectional speed limiting valve so as to control the falling speed. When
operating tilting spool, high pressure oil goes to front house of tilting cylinder and another
connects with low pressure line so as to make mast tilt forward or backward.

31

VIII. Electrical system

CAUTION
To guard against a short circuit, take off jewelry ornaments and disconnect the ignition
switch and battery ground cable, before starting to check any part of electrical system.
ACCOUNT
The different colorful wire is chosen for the different part of the electrical system. To differ
from different colorful wire, color is denoted by one or two letter. Identify carefully that the
cable of accumulator has been disconnected before repairing the electrical system.
Cable color
B: black

R: brown

G: green

U: blue

O: orange

R: red

W: white

Y: yellow

S: gray

P: purple

Main wiring harness use homochromatic wire. Other wire use double color.
B/W:

black and white

G/Y:

green and yellow

INSPECT
Inspect all electrical circuit according wiring diagram. You should make short circuit or open
circuit test with the test lamp or multimeter. Before inspection ,ensure that
1 Each electrical component or cable is securely fastened its terminal.
2 Each terminal is firmly in place and free from rust and dirt.
3 No cable covering shows any evidence of cracks, deterioration or other damage.
4 Each terminal keeps a safety distance with adjacent metal parts.
5 Every cable is fastened to its proper connector or terminal.
6 The wiring is kept away from any adjacent parts with sharp edges.
7 The wiring disconnect to each rotating or moving parts.
8 The length of the wire linking the fixed part and unfixed part should
be enough to shake.
9 The wiring keeps a safety distance with the high temperature thing
such as the vent-pipe.
FUSE SYSTEM
FUSE
DISASSEMBLE
1. Turn key switch OFF.
2. Compact the nut on the cover of the fuse box, and open the cover.
3. Disconnect the fuse from the box.
Account
If the fuse is blown replace with new one, refer to the figure.
If a fuse is blown please be sure to eliminate cause of problem, then replace it.
Never use fuse higher than specified rating.
32

Principle diagram

location

capacity

Application part

flasher

10A

Steering lights

preheating

10A

preheating

meter

20A

Meter, work light,

width lamp, reversing light

Shift control

15A

Forward, backward relay

backup

20A

backup

20A

horn

10A

horn

brake

10A

Brake light

air-condition power 1

20A

air-condition power

10

air-condition power 2

20A

air-condition power

11

Front rain wiper

10A

Front rain wiper

12

Rear rain wiper

10A

Rear rain wiper

13

Top

rain wiper

10A

Top

14

air-condition power 3

20A

air-condition power

15

backup

10A

rain wiper

Fuse table
Location

Capacit

Application parts

y
1

Fuse 1

80A

Start relay,brake light,horn

Fuse 2

80A

key switch
33

LIGHTING SYSTEM
BULB SPECIFICATIONS
Location

wattage

Front big lamp

24V/35W

Front work lamp

24V/35W

Front and rear turn signal lamp

24V/10W/21W

Rear light/reverse lamp

24V/35W

Combination rear lamp

Turn light

24V/21W

Reverse light

24V/21W

Width light

24V/10W

Combination meter
lighting

24V/2W

Alarm light

24V/2W

Combination switch:
Disassemble
1. Remove the combination instrument and steering wheel.
2. Wrest the screws, and disconnect the wiring connector
3. To install reverse the order of removal.
INSPECTION
Check the continuity the location in turn signal lamp and the combination

switch of

lighting.

Location

terminal

Wire

Purpl

Yello

Blue

red

tan

green

grey

Blac

color

yello

yello

green

yello
w

w
neutral

34

neutra
l
Go forward

Go

backward
3shift

2shift

1shift

note means on
Light combination switch handle

Location

terminal

Wire

white

green

blue

Red

red

black

Red

Red

yellow

white

color

green

Turn left
Turn

right
Go straight

0
1

note means on
Work light: head big light, head small light, front work light, rear work light/reverse
light, combination rear light.
REMOVAL & INSTALL
1. Remove securing nuts of the big lamp
2. Take apart the wiring connector
3. Remove bolt lens, then replace faulty bulb with new one.
4. To install, reverse the order of removal.
Meter, sensor and relay
Check whether relay circuit is on or not, connect or disconnect with

ring as appropriate

voltage(supply by battery) ,then uses multimeter ()to check whether contact loop is on or
not.
35

REMOVE & INSTALL

INSTRUMENT ASSEMBLY
1.

Remove fixing bolt of instrument cover.

2.

Open the instrument cover, see fig follow, disconnects the wiring connector of

instrument and key switch. Never wash the electrical system using water and water vapour
after you connect the instrument to the electrical system.
3. To install, reverse the order of removal.
Oil pressure gauge water temp. gauge hour meter and warning lamp
1 Remove the fixing bolt of panel, and take apart panel form cover of panel.
2 Remove the fixing bolt of front cover, and take apart front cover and panel.
3 Remove the panel
4 Remove the fixing bolt of instrument from PC, and remove the instrument.
5 Remove the caution light from the PC, (all of caution light can be removed from the
combinational instrument).
6 To install, reverse the order of removal.
Key (start) switch
Remove the combinational instrument
1.

Disconnect the wiring connector.

2.

Remove the ring nut, washer, spacer, meter panel.

3.

To install, reverse the order of removal.

INSPECT
Check

the

continuity

between

terminals

ACC

with

multimeter.

Pre-heat
ing
Operatio
n
Star-up
Star-up

R1

R2

BR

Note: means on.

REVERSE BUZZER
REMOVE & INSTALL
1. Disconnect the wiring connector, and then remove the bolt.
2. To install, reverse the order of removal

36

HORN
REMOVE & INSTALL
1. Remove the wiring connector of the horn
2. Remove the bolt and horn.
3. To install, reverse the order of removal.

Instrument inspect
name
water
temperature
meter
oil capacity
meter
timing
meter
oil
temperature
meter
oil pressure
meter

purpose
Engine cool water
temperature
Engine fuel capacity

Accumulative total

Graduation arrange

Normal

remark

40-55 yellow
55-110 green
110-120 red

Green zone

Cease and check

when point is
near red zone

Green zone

Adding oil when

point is near red
zone

45-60 yellow
60-120 green
120-140 green

Green zone

Cease and check

when point is
near red zone

0 0.2 0.4
0.8MPa

0.1 MPa

< 0.1 Mpa

cease and check

0-1/10
red
1/10-1
green
4 integers, 1
decimal fraction

engine operate time

Gear-box oil temperature
Engine lubricate grease
pressure

37

WARNING LAMP INSPECT

Descriptio
n

Indicate
the
alternator
voltage
up to its rate,
whether
charge
battery or not.

Charge
warning
lamp

Lamp light

Light blank

warning

(normal)

The
alternator
doesnt
generate
electricity or voltage
is lower without
inflating.

The
alternator is
at normal
condition

Function

Brake

It

indicates

the

warning

accumulators

oil

lamp

pressure

Remarks
When running at
idle speed, the
light turns off
because voltage
is high.
When

light

The oil pressure of

turns on, you

accumulator is low.

should

check

the oil pipe.

Repair of starter/dynamotor
starter
phenomenon

reason
Battery

capacity

settlement
is

not

enough

Repair or change

Electric circuit break

Electromagnetism
Not rotate

Starter rotates but the

engine cant rotate

Change battery or charge

electrical

layout, starter delay and so on

switch

shatter
Pinion doesnt joggle well
with line roll gear
Brush doesnt contract

Change
and
repair
electromagnetism switch
Change or repair
Adjust brush location, clean

well

the surface of brush

Brush abrasion

change

Armature circuit break

Change armature circuit

Pinion doesnt work well

change

line roll gear shaft isnt

good

repair

Dynamotor
phenomenon

reason

settlement

Charge indicator shine

Adjuster shatter
Magnetic

field

Change shatter
connection

shatter
Cant charge

Diode shatter
Reed

lead

badness
Fuse shatter

change
change

break

or

contact

Repair or change
Repair

38

Charge current is
small

Change current too

big
Battery liquid
surface descend
others

Dynamotor
abnormal

sound

Surge magnet circuit shatter

change

Diode shatter

change

Reed lead contact badness

Repair or change

Electricity load is too high

Reduce electricity load

Strap strain badness

Adjuster shatter
Current output circuit fastener
loose

Adjust
Change
Repair

Battery shatter

Change or add liquid

Adjuster shatter

Change

Bearing/brush dont contact well

Repair or change

Strap strain badness

Adjust

39

40

41

IX. Lifting system

1. Assemble debugging data
Double mast

Debugging data

Standard type and

Mast type

lifting height of 3
4.5 meter

Mast

Lifting height

Lifting height

>4.5 5 meter

> 5 6.5 meter

Forward

60

60

30

Backward

12 0

60

60

tilting
angle

Fork arm carrier

Adopt combination roller and side roller.

ll

Inspection and adjustment

Place

Assembly clearance

Repair clearance mm

0.3 1.25

0.4 1.4

0.2 1

0.3 1.2

0.3 1.25

0.4 1.4

Mast to lift roller

Mast to bearing board
Inner mast to carriage side
Lift chain deflection

25 30 mm

Tightening torque
Place

Model or

NM

Lifting

Lift chain lock nut

4000-4300 (M453)

Mast support cap blot

58 78 M12
Small 16t

Lift cylinder bolt

638-850 M24

Lift cylinder fixing

bolt U type

189 252 M16

16t

Mast dimension (mmmmmm)

weight Kg

30302370895

4800

42

2. Failure diagnose and corrections

Condition
Fork

arm

carrier

or

mast tilt by
itself.
The
arms

fork
carrier

moves up and
down

Probable cause

Corrective action

1.Tilt cylinder and ring abraded excessively

2. The hydraulic control valve spring is
inoperative.
1. Caused by piston jamming or bent piston
rod.
2. Too much dirt is accumulated in the
cylinder.

sluggishly.

1.

Carriage

bracket

assembly

out

of

adjustment.
Forks

are

lifted

or

lowered

2. Insufficient clearance between inner and

outer masts or rollers and mast.
3. Biting foreign materials between moving
part.

unsmooth.

4. Insufficient lubrication.

Forks

Replace piston ring tilt cylinder.

Replace it.

Replace the faulty parts.

Strip it down and clean.

Adjust clearance with thrust metal
and carriage side roller.
Adjust clearance with rollers.
Remove foreign materials.
Apply grease on contact surfaces
of sliding parts. butter

5. Bent carriage bracket assembly.

Repair or replace.

1. Lift chains out of adjustable.

Adjust lift chains.

are

lifted
unevenly
Lift

roller

does

not

rotate
Excessive

1. Grease stiffened or dirt accumulated on

lift roller and mast sliding surfaces.
2. Improperly adjusted lift roller.

Adjust.

1. Insufficient lubrication.

Lubricate.

2. Improperly adjusted lift roller, side roller

mast noise

and back-up metal.

Insufficient

1. Excessive wear occurs between the oil

lift power or

pump body and gears, causing too much

no

clearance.

lift

movement.

Clean and lubricate lift rollers.

2. The lifting jack piston Yx-ring has worn,

resulting in excessive inner leaks.
3. Springs of the multiple control valves and
its relief valve are inoperative oil leaks.

Adjust.
Replace the worn parts or the oil
pump.
Replace Yx-ring.
Replace.

4. Excessive wear occurs of the hydraulic

control valve, resulting in excessive oil

Replace.

leaks.
5. Oil leaks occur between the hydraulic

Dismantle for regrinding the joint

control valve sections.

surfaces and reassemble the valve.

43

6. Leakage occurs in the hydraulic pipe.

Tighten the joint nuts and inspect

the seal for damage.
Change the wrong hydraulic oil or

7. The hydraulic oil temperature is too high.

stop operation for reducing the oil

Oil viscosity is too low and the rate is

temperature. Find out the reasons

insufficient.

for

high

oil

temperature

and

eliminate the trouble.

8. The load carried is beyond the designed
capacity.
Forks does
not adjust
setting-up

1. The ring of Setting-up cylinder and ring

abraded excessively

Observe the lifting capacity limit.

replace ring

2 Forks shaft rust seriously

Clean and lubricate

3. Fork is turn back by foreign materials

Clean

Double high visibility mast

Double mast is composed of outer mast which cant lift and inner mast which can lift. Lifting
jack bottom is fixed on outer mast below cross beam, oriented with pin. Piston rod extremity
is joined with upper cross beam of inner mast; cylinder body is fixed on outer mast fixation
board with U-bolt. Commonly free lift range is 200mm, which is difference with different
tonnage. Two lifting jacks are laid out back of outer mast to realize high visibility.
8-10ts forks adjust its distance by changing the cylinder, but the changing cylinder can only
work when the fork is unloaded, fork loading is forbidden.
Fork arm is hung on fork arm carrier by hook. roller and side roller are installed on the
fork arm carrier. The roller and side roller are also installed on bottom of inner mast.
Pressure oil from hydraulic control valve is entered into lifting jack by unidirectional
speed limiting valve, forced piston and piston rod rising, thereby forced inner mast rising. At
the same time one end of lifting chain on inner mast is fixed on outer mast, the other is
joined with fork arm carrier. Fork arm carrier and fork arm is rising with inner mast rising to
realize aim of lifting goods.

44

1.Outer mast

2.Inner mast

5. Left lift cylinder

3.Fork arm carrier

6.Right lift cylinder

4.Tilt cylinder

7.Lift oil circuit

8. Chain

Fig 9-1 Double high visibility mast

Lift cylinder
Lift cylinder is single-action piston mode, and it composes of cylinder head, piston rod,
cylinder block, piston etc. Caution when using:1,avoid damaging piston rod, and keep seal
ring seal well;2, if piston rod's surface has exudates oil when uses normally, please check
whether piston rod's surface has woolly grain or not, can change o-ring seal and piston.

1. Cylinder blocks
7. Separated sets

2. Piston
8. Piston rod

3. Seal ring

9. oil return pipe

11. Steel Backing bearing 12. O-ring seal

15. Dust ring

16.Bolt

4. Catch

17.Plug

5. Support ring
10. Bearing block

13.cylinder head

18.Bush

6.Check ring

14.Seal ring

19. Check ring

Fig.9-2 lift cylinder

45

Tilt cylinder
Tilt cylinder is double-action piston mode, when the rake angle of front and rear is not
accord with its requirement, or the cation of two cylinder piston do not move in the same
time, can adjust the nut location of piston rod to reach requirement, then lock the nut. The
caution is same with lift cylinder.

1. Tier rod
6.Site seal

2.Thin nut
7.guide sleeve

11.Cylinder block
16.O-ring seal

3.Dust ring
8.check ring

12.Piston rod 13.piston

17. Support ring

4. Seal ring
9.O-ring seal
14. Seal ring

18. Slotted nut

Fig. 9-3

19. Pin

5. O-ring seal

10. Steel back bearing

15. Check ring
20. Joint

tilt cylinder

46