Operacion y Mantenimiento LG50DT

Operators, equipment managers and technicians, please read the Manual!
Preface
The Manual is mainly about performance, structure, operation and maintenance of LG50DT to
LG100DT forklift trucks. It is convenient for operators and managers to learn the
configuration as well performance so as to operate or maintain the truck accurately.
In order to keep the truck running in good condition, operators and managers should seriously
carry out the safety operation regulations and daily maintenance requirement.
The content will be a little different from the products owing to design improvement of our
products. We are sorry about the change without notice.
China LONKING (Shanghai) Forklift Co., Ltd.

addNo. 196 Xinrun road, Xinqiao Town,
Songjiang Industrial Estate, Shanghai, PRC
http//www.lonking.cn
Contents
Chapter 1 Safety regulations of driving and operation.................................................................. 1
1. Notification........................................................................................................................1
2. Transportation....................................................................................................................1
3. Storage............................................................................................................................... 1
4. Preparation before operation..............................................................................................1
5. Operation........................................................................................................................... 1
6. Sketch map of gauges and controls' layout........................................................................3
7. Daily Maintenance.............................................................................................................3
Chapter 2 Specification..................................................................................................................7
Chapter 3 Introduction of main components................................................................................. 9
Chapter 4 Forklift structure, principle, adjustment and maintenance.......................................... 10
1. Power system...................................................................................................................10
1.1 General...................................................................................................................10
1.2 Engine configure....................................................................................................11
1.3 Fuel system............................................................................................................ 14
1.4 Cooling system...................................................................................................... 15
1.5 Check and adjustment............................................................................................15
2. Gearing............................................................................................................................ 22
2.1 General...................................................................................................................24
2.2 Torque converter.................................................................................................... 24
2.3 Charging pump...................................................................................................... 25
2.4 Hydraulic clutch.....................................................................................................26
2.5 Control valve and inching valve............................................................................ 26
2.6 Oil piping system of torque converter................................................................... 28
2.7 Warnings when forklift is in trouble...................................................................... 29
2.8 Troubleshooting..................................................................................................... 29
3. Drive axle........................................................................................................................ 33
3.1 General...................................................................................................................33
3.2 Main reducing mechanism and differential........................................................... 33
3.3 Final drive..............................................................................................................37
3.5 Service data............................................................................................................38
4. Steering system................................................................................................................39
4.1 Steering gear.......................................................................................................... 41
4.2 Check after reassembling the steering system....................................................... 49
4.3 Troubleshooting of steering system....................................................................... 50
4.4 Steering axle.......................................................................................................... 51
5. Brake system....................................................................................................................53
5.1 General...................................................................................................................54
5.2 Drive boosted braking............................................................................................54
5.3 Vacuum boosted braking........................................................................................57
5.4 Service brake......................................................................................................... 62
5.5 Parking brake......................................................................................................... 66
6. Lifting system.................................................................................................................. 69
6.1 General...................................................................................................................69
6.2 Inner and outer masts.............................................................................................69
6.3 Fork carrier............................................................................................................ 70
6.4 Adjustment of lift system.......................................................................................70
6.5 Mounting positions of rollers.................................................................................72
6.6 Lift cylinder and tilt cylinder......................................................................................... 73
6.6.1 Lift cylinder........................................................................................................ 73
6.6.2 Cutoff valve........................................................................................................ 76
6.6.3 Speed limiting valve........................................................................................... 76
6.6.4 Tilt cylinder.........................................................................................................77
7. Hydraulic system............................................................................................................. 79
7.1 General................................................................................................................79
7.2 Oil pump................................................................................................................ 79
7.3 Multi-way valve.....................................................................................................79
7.4 Operation of multi-way valve................................................................................ 81
7.5 Operation of main safety valve.............................................................................. 81
7.6 Operation of tilt self -lock valve............................................................................ 82
7.7 Control device of multi-way valve..................................................................... 83
7.8 Oil tank.................................................................................................................. 84
7.9 Oil pipeline of hydraulic system............................................................................ 84
7.10 Repair...................................................................................................................87
8. Electrical system..............................................................................................................88
8.1 General...................................................................................................................88
8.2 Brief introduction of operation.............................................................................. 90
8.3 Battery................................................................................................................... 92
8.4 Wiring harness....................................................................................................... 93
Chapter 1 Safety regulations of driving and operation

1. Notification
Drivers and managers should never forget Safety is the First and operate the truck
according to Manual of Operation and Maintenance and Driver Manual .
2. Transportation
Pay attention when transporting forklifts as follows:
(1) Apply the parking brake.
(2) Fasten mast and counterweight with steel wire. Fill in the relevant position of the front
and rear tires with wedges firmly.
(3) Lift at the right place with lift label when lifting.
3. Storage
(1)
(2)
(3)
(4)
(5)
Release fuel and coolant (but dont release if the coolant is anti-rust or anti-freeze).
Spread anti-rust oil on the non-lacquered parts, spread lube on the lift chain.
Put mast down to the lowest position.
Apply the parking brake.
Fill in wedges under front wheels and rear wheels.
4. Preparation before operation

(1) Never check the fuel, leakage or level as well as electrical meter and never refuel
when running.
(2) Check tire pressure.
(3) Make sure the shifting handle for forward or reverse in the no gear position.
(4) Turn on electrical source and check electrical elements and meters.
(5) Check if handles and pedals run normally.
(6) Start the engine.
(7) Lift and tilt the mast.
(8) Do not apply the parking brake.
(9) Turn around the vehicle and apply the brake.
5. Operation
1)
2)
3)
4)
Only the trained operator with license can drive the forklift.
Wear fatigue dress for safety when operating.
Check each control device and warning device, if it is damaged or defective please
mend it before operation.
When transporting, the weight of load should not go beyond the rated value and the
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
fork must be inserted wholly under the load. Make sure the cargo be put on the fork
evenly. Never lift the cargo with a single tine.
Start, turn, run, brake and stop the vehicle smoothly. Speed down the forklift when
turning on dank or slick road.
When driving with cargo, put it as low as possible and tilt the mast backward.
Be careful when traveling on a slope. If the inclination of slope exceeds one tenth,
drive forward when going uphill and backward when going downhill. Never turning
on a slope and dont load or unload when the truck is going down hill.
Pay attention to passengers, barriers and the road condition as well as the overhead
clearance when driving.
People are not allowed to stand on the fork or to be carried on the truck.
Never stand or walk beneath the fork.
Dont operate the truck and the attachment unless you are on the seat.
Prevent the cargo from falling when driving a forklift with high travel mast over 3
meters. Protection measures could be taken if it is necessary.
For the forklift with high travel mast, tilt back as possible as it can, and tilt within the
permitted minimum range when loading or unloading. Pay especial attention to the
clearance above the vehicle.
Be careful and drive slowly when the forklift is running temporary road or gangplank
at dock.
When refueling please shut off the engine and never stay on the truck. Dont ignite
when checking battery or oil level.
When attachment is equipped with the forklift, operate the empty forklift in the same
way as with load.
Dont load loose cargo. Carry big cargo carefully.
Lower the fork to ground, shift in neutral position, and turn off the engine or power
switch before leaving the forklift. Apply the parking brake when stopping on a slope,
fill wedges under the wheels if stopping for a long time.
Dont open the radiator cover randomly when the water temperature is on the high
side.
Safety valve pressure of the directional control valve has been adjusted before the
forklift leaving factory so never adjust it arbitrarily lest high pressure damages the
hydraulic system and elements.
The air pressure of tires should be accord with the prescribed tire Pressure.
The noise number should be less than 89.8dbA exterior the forklift truck, and do
the test following the standard PrEN 12053. If running on the coarse and irregular
road, the noise number will be higher.
Do the test following the standard PrEN 13059At the maximal running speed on
the unloading condition, the vibration number is 2.04m/s.
Pay attention to and be familiar with the function of labels on forklift truck.
6. Sketch map of gauges and controls

controls'' layout
1. Water temperature meter
8. Ignition switch
15. Steering wheel
2. Hour meter
9. Lift control lever
16. Extinguish cable
3. Indicator light
10. Tilt control lever
17. Shift handle
4. Fuel meter
11. Accelerator pedal
18. Motor cover cable
5. Horn button
12. Rubber floor
19.Parking brake handle
6. Lamp switch
13. Service brake pedal
7. Turn lamp switch
14. Inching pedal
7. Daily Maintenance
1. Daily Checking
1 . Amount of hydraulic oil: The oil level should be at the middle position of the scale on
the dipstick.
2 . Check if pipes, joints, pumps and valves leak or be damaged.
3 . Check service brake system:
a. The travel of brake pedal should be within 40mm.

b. The clearance between front soleplate and footplate should be over 20mm.
4 . Check the parking brake system: Forklift without load can be parked at 20% slope
when the parking brake handle is pulled to the limit.

5 . Meters and lights: Check if meters, lights, joints, switches and circuits can work
normally.
2. Oil, grease and antifreeze
Description
Diesel oil
Diesel engine
oil (CD)
Specification and Use temperature

Code name of light
diesel oil
0#
-10#
-20#
-35#
Use temperature
-5
-5-14
-14-29
Code name
5W/30
10W/30
15W/40
20W/50
Use temperature
-30+30
-25+30
-20+40
-15+50
Code name
L-HM32 wearable
hydraulic oil
L-HV32 low
temperature hydraulic
oil
Use temperature
-5
-20open cold area
Hydraulic oil
Hydraulic
drive oil
6# hydraulic drive oil
Brake fluid
L-HM32 wearable hydraulic oil
Grease
3# general lithium based grease-20+120
Gear oil of
heavy load
vehicle
Code name
85W/90GL-5
80W/90GL-5
Use temperature
-15+49
-25+49
Code
FD-1
FD-2
FD-2A
FD-3
Use temperature
-25
-35
-45
-50
Antifreeze
Recommendation of our company: use Great Wall series of oil or grease first.
3. Cooling system precaution
1 . If the radiator is boiled or the coolant temperature is too high when operating the truck,
dont open the radiator cover immediately. If the radiator must be opened in order to find
out the cause, you should first slow down the engine to middle speed, then screw the
cover of radiator and take off the cover after a while less the coolant bursting out and
scalding the operator.
When screwing down the cover, please screw to the limit, otherwise the pressure could
not be accord with the prescription.
2 . The there is a tank reserve at the left side of engine with FULL and LOW
graduations, the level of antifreeze should between the two marks. Fill the same type of
antifreeze & antirust if there is any leakage or evaporation. Dont change antifreeze with
seasons. After a year use, filtrate and purify the antifreeze and then use continually.
3 . Clear the smudge on the surface of radiator regularly according to different conditions.
Scour, compressed air or high pressure water (the pressure should be no more than
4kg/cm2) are all available.
4 Chart of lubricating system
Chapter 2 Specification
RASA: Width of right-angle aisle for stacking
a: Clearance b: Load length
Model
LG50DT
LG60DT LG70DT LG80DT LG100DT
Diesel /
Power type
hydraulic
Diesel hydraulic
General
mechanic
Rated capacity
kg
J Load center
mm
S Front track
mm
P Rear track
mm
1700
h1 Max lift height
mm
3000
h3 Free lift height
mm
Fork
L5 Length
Size
WT Width thickness
5000
6000
1470
10000
1600
200
mm
205
1220
15060
15065
Size
deg
L3 Front overhang
mm
L4 Rear overhang
mm
L2Wheel base
mm
L1 Overall lengthwith fork
mm
W1 Overall width
mm
2000
h2 Mast lowered height
mm
2500
h4 Overhead guard height
mm
2464
R1 Min. turning radius
mm
Ra Min. right angle aisle width
mm
Capacity
Max. lift speed(full load/unload)
8000
600
Mast tilt angle
Max. travel speed(full load/unload)
7000
210
1500
1520
17570
17585
706
716
6/12
590
595
645
695
780
2250
4705
4755
3415
3400
4760
2800
5486
5520
2230
2595
2845
2650
3415
5400
Km/
2500
3680
4000
5600
5960
310/350
330/410
10500
13000
27/27
h
mm
330/450
/s
Max. gradability
Self weight
kg
m2 Masts min. ground gap
mm
216
240
m1 Frames min. ground gap
mm
248
300
Working oil tank capacity
90
110
Fuel tank capacity
150
170
Distance from seat SIP to

overhead guard
mm
20
8082
8537
903
8981
903
1075
Chapter 3 Introduction of main components

The main components are listed in the table below
Item
Description
Contents
Power System
engine mount, fuel, exhaust air intake and cooling system

etc.
Power Train
Steering System
steering wheel, hydraulic steering control unit, steering axle,

steering control, steering cartwheels, etc.
Accelerator pedal
Accelerator pedal,soft shaft and bracket,etc
Flameout control
unit
Brake & inching

control
Brake lever
hand brake & rod,etc
Bodywork
frame, counter weight,drag pin,etc
Lifting System
mast, fork, Fork carrier , backresttilt cylinder, lift cylinder, lift

chain, mast sheave, roller, etc.
10
Accessory
instrument panel, engine cover, radiator cover, toolbox, floor

board, seat, etc.
11
multi-way valve
12
Hydraulic System
pumps, valves, high & low pressure hoses, joints, lift cylinder
steel tube, etc.
13
Overhead Guard
Overhead GuardCab is an optional unit
14
Electrical System
electrical elements such as horn ,lamps,switch, battery, gauges,

circuits, etc.
15
Decal
transmission, transaxle, shift control, etc.
flameout cable,rod,etc
foot brake & inching setting,etc
Control handle
Nameplate, capacity chart, lubrication chart, etc
Chapter 4 Forklift structure, principle, adjustment and maintenance

1. Power system
1.1 General
The power system basically consists of the diesel engine, fuel system, cooling systemair
intake system and exhaust system. The engine is mounted on the frame with some rubbers
which can absorb vibration. The engine, torque converter and the transmission connect
with the drive axle through the drive shaft in a single unit, which is shown in Fig. 1.1.
Figure 1.1 Engine Installation
1.2 Engine configure

5-10t forklifts principally employ CY6102BG engines from Chao yang Diesel Company. In
addition. And import diesel engine YUCHAI 6BG1.
The outer configuration picture of YUCHAI 6BG1 is as below
Figure 1.2
Diesel engine YUCHAI 6BG1
Main performance parameters, structure and configuration of Yuchai 6BG1 are as Table below:
Name
A- 6BG1QC
Type
Four stroke, water-cooling, line, top ventilator type
Cylinder number-cylinder
diameterstroke
6-105mm125mm
Total displacement (1)
6.494
compression ratio
17
performance
Rated rotation speed (rpm)
2000
Rate power (kw)
82.3
Max. torque (N-m/rpm)
416/1400-1600
Full load oil consumption (g/kwh)
233
Idle speed (rpm)
700
Weight (kg)
450
Sizemm
1129.5672.0860.0
Order of ignition
1-5-3-6-2-4
Rotation direction
the clockwise direction in the face of fan
valve device
Overhead device
fuel device
Fuel injection pump
dip cooling
Piston pump diameterstroke
9.5mm8mm
Jet burner
spongy
Fuel feed pump
piston
Fuel filter
paper filter element
Speed regulator
Speed adjustment mode
Centrifugal, full speed control
Lubricating way
Compelling cycle
Lubricant device
Pumping
Gearing
Drive mode
Camshaft drive
Oil pressure regulator
Piston, spring
Oil pressure indicator
switch0.3kg/cm2
Filter mode
full-flow filter, paper filter
Cooler
Inter water cooler
Cooling installation
Cooling mode
Water cooler
Fan cooler
Exhaust, seven-pieces fan, external diameter 550mm
Drive mode
Belt transmission
Pump mode
Eddy-current
Drive mode
Belt transmission
Water temperature adjuster

Mode
Waxen ball mode
Thermostat open temperature
82
Thermostat full opened temperature
95
Start engine
Mode
Magnet operating mode
Voltage
24V
Output power
4.5KW
Choke
Cut off fuel access
Preheating device
Charge engine
Mode
A.C generateddiode commutate
Voltage
24V
Output
25A
Drive mode
Belt transmission
Charge auto-regulator
IC typeinside the generator)
Reference parameter
Oil disc capacity
Max13Min10
Cooling water capacity
12
Valve clearance
Espirating valve
0.4mm (cooled state)
Exhausting valve
0.4mm (cooled state)
Valve switching time

Espirating valve(on)
Before top dead center 19
Espirating valve(off)
After bottom dead center 47
Exhausting valve(on)
Before bottom dead center 57
Exhausting valve(off)
After top dead center 15
Injection period
Before top dead center 14
Injection pressure
185kg/cm2
Compression pressure
31kg/cm2200rpm
1.3 Fuel system

The fuel system consists of a fuel tank, a filter and a fuel sensor device.
1.3.1 Fuel tank
The fuel tank (shown in Fig. 1.3) combines with the frame by welding as a unit. It lies on the
left of the frame and above it is a tank cover with a fuel sensor fixed on.
Figure 1.3 Fuel Tank
Routine maintenance of fuel tank

1.
2.
3.
4.
5.
Check the fuel level per shift, and avoid filling fuel after it's used up;
The fuel tank shall be filled after each shift ends, to prevent the air entering fuel system, if
the air enters, it shall be removed.
Check whether the fuel tank leaks.
Check the sealing condition of fuel tank cap and whether it leaks air.
After 250h operation, replace the fuel purifier and remove the system water.
After 1500h operation or a year, clean the fuel tank and remove all the impurities and
water in the fuel tank.
1.3.
2 Fuel sensor device
1.3.2
The fuel sensor device (shown in Fig. 1.4) is to convert the up and down movement of the
floater which is caused by the amount of fuel into electric current. The current then reflects on
the fuel meter which tells people the amount of the fuel intuitively.
Figure 1.4 Fuel Sensor Device

1.3.3
Fuel filter
The fuel filter which connects with a intake fuel pipe on the engine filtrates the fuel supplied
to the engine. There is a bypass valve in the filter, which is used to serve the engine when the
filter should clog or plug.
1.4 Cooling system
The cooling system is made up of a water pump, a fan, a radiator and a tank reserve. The water
pump which attaches to the engine is driven by the crankshaft through a V-type belt.
1.5 Check and adjustment
To keep the engine in a good working trim, regular check and adjustment should be taken. The
main points are shown as follows:
1.5.1 Air cleaner (Fig 1.5)

1) Take off the strainer core.
2) Check the dust and damage of the strainer core. Firstly use low pressure air to clean it
from inside to outside. Change the strainer core if the clogging is so serious that
cleaning cant be done or it has been damaged.
3) Clear the dust in the cover.
Figure
1.5 Air Cleaner
1.5.2 Fuel filter (Fig 1.6)

1)
Use a special wrench to take down the

filter, change it for a new one if it has
clogged or be damaged.
2)
Add several drops of fuel around the

seal then assemble the new filter. After
the seal coming into contact with the
filter body, screw in 2/3 circle to
retighten it.
Fig. 1.6 Fuel Filter
1.5.3 Engine oil filter

(1) Use a special wrench to take down the filter and change it.
(2) Add several drops of oil around the seal then assemble the new filter. After the seal
coming into contact with the filter body, screw in 2/3 circle to retighten it.
Fig. 1.7 Engine Oil Filter

1.5.4 Cooling system
(1) Check the coolant in the tank reserve (shown in Fig. 1.8).
If the coolant level is under the LOW mark, it means the supplement of the radiator
reduces. Add some coolant in this situation and add to the 2/3 scale when the engine is
cold.
Fig. 1.8 Tank Reserve

(2) Replacing of coolant
A. After the engine ceases over half an hour and becomes cold, take off the cover then
loosen the outlet valve below the radiator.
B. Loosen the outlet valve on the engine, release all the coolant.
C. Fasten the two valves mentioned above when the coolant all comes out.
D. Inject prescriptive coolant. Start the engine in idle speed then check if the level of the
coolant in the tank reserve is at the 2/3 scale.
(3) Adjust fan belt
Tension the fan belt if it goes slack. See Fig.1.9.
Process: Remove the fixed bolts
B and
C on the generator and move the generator to the
A using
outside in order to get about 10mm flexibility when the fingers press on the belt
10kg force. Then screw down bolts
B and
C in order.
Figure 1.9
1.5.5 Fastening of the cylinder head bolts on the engine
(1) Screw down the bolts under 68 Nm
torque orderly as Fig. 1.10 shows.
(2) Increase the torque to 93 Nm to screw
down the bolts.
(3) Turn 90of the bolts to fasten it.
Fig. 1.10
1.5.6 Adjustment of the valves clearance

(1) Rotate the crankshaft clockwise to make the TC mark on the belt wheel shock
absorber coincides with the pointer.
(2) Open the cap of check hole to make sure the positions of soleplate mark and pointer.
If the soleplate mark coincides with the pointer, the compression stroke of the first
cylinder will be at the top dead center. In this case, adjust the clearance of the valve
marked ,otherwise adjust the clearance of the valve marked .
Numerical value of valve clearance: 0.4mm (the same for the intake and exhaust valve
when the engine is cold).
See figure 1.11, 1.12, 1.13.
Fig. 1.11
Fig. 1.12
Fig. 1.13
Table 1.2 shows the detail:

cylinder serial number
valves serial number
Iintake valve
Eexhaust valve
1
I
2
E
3
E
the top dead center in the compression

stroke of the first cylinder
the top dead center in the compression
stroke of the sixth cylinder
4
E
5
E
6
E
1.5.7 Definition of inject and ignite time

(1) First make sure if the assembly time marks on the injection pump flange are consistent.
See Fig. 1.14.
(2) Make the first cylinder stay at the top dead center, then turn the crankshaft about 30 in
the counter-clockwise direction, shown in Fig. 1.15.
(3) Release the injection pipe on the first cylinder and remove the spring of the exhaust
valve seat as well as exhaust valve, then install the exhaust valve seat on the injection
pump. See Fig. 1.16.
(4) Rotate the crankshaft clockwise in low speed as while as the charging pump transports
fuel. Stop rotating the crankshaft when the fuel level in front of the exhaust valve ceases
rising at that position. Define signed mark on the pointer. See Fig. 1.17.
Fig. 1.14
Fig. 1.16
Fig. 1.15
Fig. 1.17
1.5.8 Adjustment of inject and ignition time

(1) Remove pipes assembled on the injection pump (fuel and oil).
(2) Unscrew the fixing bolts on the injection pump.
(3) Adjust far away from the engine in the case of advance and close to in the case of
delay while defining ignite time according to essentials in 1.5.7.
(4) In the end of the adjustment, screw down all the fixing bolts on the injection pump,
redefine the ignite time.
(5) Fix the outlet valve of the first cylinder and assemble the pipes in their primary
position.
1.5.9 Measurement of compress pressure (Figure 1.18)

(1) Take down all the fuel injectors.
(2) Install manometer on the assemble part of the first cylinders fuel injector (demarcated
pressure value is 500N/c ).
(3) Run the start device with full charged battery. Measure the pressure at this time.
(4) Measure the pressure in the same way until the sixth cylinder, two times for each, and
then calculate the average of each cylinder.
Figure 1.18
1.5.10 Exhaust of injection pump (Figure 1.19)
(1) Unclench the exhaust plug.
(2) Operate the hand pump slowly until no air bubble comes out of the plug.
(3) Then fix the plug tightly.
Figure 1.19
2. Gearing
The gearing mainly includes two parts, torque converter and transmission.
Table 2.1 shows the basic parameters and Fig. 2.1 shows the structure of gearing.
Table 2.1
Items
Units
Triple -Element, Single-Turbo &

Two-Phase
Type
Torque
converter
Structure characteristics and parameters
Diameter of cycle ring and

Torque ratio
Set offering pressure
12.5(315) Torque Ratio 3.1

MPa
0.50.7
Internal gear pump; Transmission
power output
Type
Oil pump
Flow
l/min
402000rpm,2MPa working state
Type
Power-Shift
Gears
Two gears for both forward and reverse
Transmission
Gear ratiosthe same for

forward and reverse
1.621/0.526
Friction
plates
mm
Outer diameter134 Inner

diameter90Thickness2.8
Friction area
cm
77.4
Set pressure
MPa
1.21.5
Mass
kg
About 295
Oil capacity
About 20
Hydraulic
Clutch
Oil type
6# hydraulic oilsimilar to SAE10W
Figure 2.1 Hydraulic Transmission

1.Control valve
9. Parking brake
17. Oil seal
2. Charging pump
10. Filter
18. Ball bearing
3. Ball bearing
11. Oil seal
19. Gear
4. Shaft
12. Gear
20. Reverse clutch
5. Ball bearing
13. Ball bearing
21. Forward clutch
6. Torque converter
14. Shaft
22. Elastic board (input board)
7. Ball bearing
15. Bearing cover
23. Transmission input shaft
8. Gear
16. Output shaft
2.1 General
The hydraulic transmission used in the forklift consists of the torque converter and the
power-shift transmission. It has the advantages below:
1) The inching valve assembled improves inching performance. So it can keep the
performance either starting the truck or at any rotate speed.
2) The friction plates of the hydraulic clutch contain seven steel plates and seven papery
friction plates. Thus it has good durability.
3) There is a unilateral clutch in torque converter to improve the gearing efficiency.
4) A filter is mounted in the torque converter oil piping system, therefore the cleanness is
improved and the life-span of torque converter is increased.
2.2 Torque converter
Torque converter of single-turbo, triple-element usually consists of a impeller wheel fixed on
the input shaft, a turbine wheel fixed on the output shaft and a stator wheel fixed on the torque
converter housing.
The impeller wheel is powered by elastic board which connects with the flywheel. It rotates
when the engine runs. The fluid in the impeller wheel is injected through the impeller wheel
blades as a result of centrifugal effect. At this moment the kinetic energy converts into
hydrodynamic energy.
Therefore the fluid comes into the blades of the turbine wheel and routes the torque to the
output shaft .The leaving direction of the fluid from the turbine wheel changes because of the
action of the stator wheel .Thus the fluid flows into the impeller wheel from the perfect angle
and produces a countertorque that impels the stator wheel. As a result, the output torque is one
countertorque larger than the input torque.
When the speed of turbine wheel increasing and approaching to the input speed, the change of
the fluid angle reduces and the output torque decreases as well. Finally, the fluid flows into the
stator wheel blades in the contrary direction and thus the countertorque acts reversely. In this
case, the output torque is smaller than the input torque. In order to prevent such case from
occurring, a unilateral clutch is installed inside the stator wheel. When the countertorque acts
reversely, the stator wheel runs freely. In such working condition, the input torque equals to
the output. Thus it ensures the torque converter run in high efficiency.
The torque converter changes the transfer of torque by means of mechanical method (clutch).
It plays both parts of coupling and converter, so it is called two-phase. Its characteristics are
smooth operation and high efficiency.
There is a unilateral clutch, a turbine wheel, an impeller wheel and a stator wheel inside the
torque converter which is full of hydraulic oil.
In the front of impeller wheel is a gear that meshes with the drive gear of charging pump
driven by the engagement.
The turbine wheel moving over the splines of the input shaft of the transmission transmits
power to the hydraulic clutch.

The structure of torque converter is shown in Fig.2.2.
Figure 2.2 Torque converter

2.3 Charging pump
The structure of charging pump can be seen in Fig.2.3.
The charging pump which is mounted on the top of torque converter housing consists of a
drive gear, an inner-tooth gear (driven gear), housing and cover. The drive gear is driven by
the impeller wheel, idle gear and the pump drive gear. Oil in the underside of transmission is
supplied to each part of transmission by the charging pump.
Figure 2.3 Charging pump
2.4 Hydraulic clutch

Forward clutch is shown in Fig.2.4 and reverse clutch is shown in Fig.2.5.
The hydraulic clutch which is wet, multi-plate is assembled inside the transmission and the
drive gear on one side of it meshes with the corresponding drive gear. There are six sintered
friction plates and seven steel plates in one set of clutches. The plates are alternately fixed and
attached to the piston.
When the clutch working, the seal of pistons outer and inner surface is guaranteed by the
sliding seal and O ring. When the clutch is not working, it is released by the return disc spring
and the surface of clutch is always lubricated by the oil comes from oil cooler. Therefore the
clutch surface is kept from conglutination and wear abrasion.
When the pressure oil acts on the piston, the alternately fixed sintered friction plates and steel
plates are pressed therefore the set of clutches rotates as a whole and carries the power from
torque converter to drive gear.
The power transmission flow from torque converter to transmission is shown below:
Turbine wheelInput shaftClutch drumSteel platesSintered platesForward &
Reverse gearsOutput shaft.
2.5 Control valve and inching valve
Control valve is shown in Figure 2.6.
Figure 2.4 Forward clutch
Figure 2.5
Reverse clutch
Figure 2.6 Control valve

The control valve is installed on the top of transmission. Shift sliding valve and inching sliding
valve are both fixed inside the valve.
Oil pressure of the clutches in the transmission is adjusted by a pressure control valve and the
control valve of torque converter controls the pressure of oil that flows into torque converter.
The inching valve lever connects with the inching pedal linkage. When the operator steps on
the inching pedal, the inching valve lever is depressed in. So the oil pressure of clutch reduces
temporarily and the clutch is disengaged or half-engaged.
2.6 Oil piping system of torque converter

The charging pump runs when the engine is started. It sucks torque converter oil from the
reservoir (called the oil pan) through a filter and pushes it into control valve.
The torque converter oil flowing out of charging pump is divided into two lines. One is for
torque converter and the other is for transmission.
Figure 2.7
Oil piping system of torque converter
The oil pressure of clutches in transmission is adjusted to 1.2-1.5MPa by its pressure control
valve and the oil of torque converter is adjusted to 0.5-0.7MPa by the torque converter
pressure control valve. Then the pressure oil gets to the torque converter blades. After the
pressure oil is cooled by the cooler it flows out to lubricate the clutches. Finally, the oil
returns to the reservoir. It circulates in such a way like this.
When the lever of the shift control valve setting in the neutral place (idle gear) the oil from
the shift sliding valve to the clutches will be cut off and the fluid will all come into the
torque converter.
When the lever of the shift control valve set in the forward or reverse place, oil will flow
into the clutch hydraulic chamber and act on the piston by the action of pressure control
valve. So the oil pressure will increase continuously in the period of clutches starting action
to being completely engaged.
When the hydraulic chamber is full of pressure oil, the pressure will increase acutely and
the hydraulic clutches will be in thorough engagement. If one kind of forward or reverse
clutches run and the other are out of mesh, the clutches will be lubricated and cooled by oil
from the cooler, which prevents conglutination of plates.
Inching valve acts when inching pedal is stepped on. Most of the oil in clutches loses
pressure through the inching valve and returns to the reservoir (called the oil pan). The oil
passages are the same as that of the idle gear.
2.7 Warnings when forklift is in trouble
When the forklift is in trouble and can not move by itself, however we want to drag it by
other facilities, attentions must be paid to the requirements blow:
1)
Disassemble the transaxle between transmission and drive axle.
2)
Place the shift lever in the neutral position (called idle gear).
If the charging pump doesnt work there wont be good lubrication. Conglutination will
appear if the rotation of drive wheels is transmitted to the transmission gears and clutches.
So the transaxle must be disassembled.
2.8 Troubleshooting
(1) Deficiency of power: see Table 2.2.
(2) Abnormal rising of oil temperature: see Table 2.3.
(3) Loud noises of transmission: see Table 2.4.
(4) Low transmission efficiency: see Table 2.5.
(5) Oil leakage: see Table 2.6.
Table2.2 Deficiency of power

Parts
Causes of malfunctions
Checking methods
Solutions
(1)Low oil level
Check the oil level
Add oil
(2)Air gets into oil suction

pipe
Check connections and pipes
(3)Oil filter is blocked.
Disassemble and check
Refasten
connections and
replace seals
Clean or Replace
(4)Insufficiency of charging
pump displacement
Replace
Torque converter
A. Oil pressure is too low
(5)Twist of spring on dominant

Check spring tension
pressure relief valve disc
Replace
(6)Damage or abrasion of the

seal ring or o-ring
Replace
B. Flywheel damages or
collides with other parts
Get some oil to check if impurity

exists
Replace
A. Improper use of oil or

bubbling
Check
(1) Air gets into oil suction

pipe
Check connections and oil pipes
Screw down
connections or
replace
(2) The pressure of torque

converter oil is too low or
bubbling
Test the pressure
Adjust the
pressure
(1) Low oil pressure
Test the pressure
Adjust the
pressure
(2)Abrasion of seal ring
Disassemble, check and test
Replace
(3)Abrasion of clutch piston

ring
Replace
(4)Abrasion of friction plates

or distortion of steel plates
Disassemble and check. Start the

engine and place shift lever in forward,
reverse or idle gear respectively.
Replace
Forklift runs at idle gear and doesnt
run at forward gear or reverse gear
C. Incorrect position of
inching linkage and shift
lever
Check and test
Decrease of engine power
Check speed when the engine losing

speed,check noises of engine when
Adjust or repair
running and check the maximum
the engine
speed of engine at middle position(idle
gear)
Engine
Transmission
B. Slide of clutch
Adjust
Table2.3 Abnormal rising of oil temperature
Torque converter
Parts
Checking methods
(1)Low oil level
Check the oil level
Add oil
(2)Oil filter is blocked.
Clean or Replace
(3)Flywheel collides with other

parts
Drain the oil in oil filter or

oil tank and check if there Replace
are any outer components
(4)Air is sucked
Check connections and

Screw down connections
pipes of air suction piping or replace gaskets
(5)Water is mixed into oil
Drain the oil and check
Replace the oil
(6)Little flow of oil
Check if pipes damaged

or bent
Repair or Replace
(7)Abrasion or clipping of bearing Disassemble and check

Transmission
Solutions
(1)Slide of clutch
Repair or Replace
Put shift lever in idle gear

Replace friction plates of
position and check if
the clutch
forklift runs
Replace
Table 2.4 Loud noises of transmission
Transmission
Torque converter
Parts
Checking methods
Solutions
(1)Breakage of elastic board
Check rotate sound at low

speed
Replace elastic board
(2)Damage or abrasion of bearing
Replace
(3)Breakage of gear
Replace
(4)Abrasion of spline
Replace
(5)Loud noise of charging pump
Repair or Replace
(6) Loosening of bolts
Screw down or Replace
Replace
(2)Breakage of gear
Replace
(3)Abrasion of spline
Replace
(4)Loosening of bolts
Screw down or Replace
Table 2.5 Low transmission efficiency

Parts
Transmission
Torque converter
(1) Breakage of elastic board
Checking methods
Solutions
Check rotate sound at low speed

Replace
and check if the front cover runs
(2) Deficiency or overabundance

Check the oil level
of oil
Charge or discharge oil
(3)Failure of drive system of

charging pump
Replace
(4)Breakage of shaft
Replace
(5)Oil pressure is too low
Check if there is oil suction

pressure in the oil intake pipe of Replace
charging pump
(1)Deficiency or overabundance
Check the oil level
of oil
Charge or discharge oil
(2)Damage of seal ring
Replace
(3)Slide of clutch plates
Check the oil pressure of clutch Replace
(4)Breakage of shaft
Replace
(5)Breakage of clutch cover
Replace
(6)Breakage of clip ring of

clutch cover
Replace
(7)Odds and ends exist in the

clutch oil tank
Clean and Replace
(8)Abrasion of the part of spline

on shaft
Replace
Table 2.6 Oil leakage

Parts
Checking methods
Solutions
Disassemble and check if there is

abrasion of the lip of oil seal or
Replace the oil seal
other slipping mating parts
(2)Incorrect connection of
Screw down or
Check
housings
replace washers
(3)Loosening of connections
Screw down or
Check
and pipes
replace pipes
Screw down or
(4)Loosening of oil drain plug Check
replace
Drain the oil and check whether
Change the oil
there is any water mixed in, check
(5)Oil spurts from venthole
Screw or change the
whether there is air in oil suction
oil pipe and repair
connector, check the vent hole
Torque converter and transmission
(1)Damage of oil seal
(6)The oil charged is too much Check the oil level
Discharge the
redundant oil
3. Drive axle
Basic parameters of drive axle can be seen in Table 3.1.
Tonnage
Items
Type of drive axle
5 7t
full-floating, cast steel axle
Type
Main
reducing
mechanism
10t
Reduction ratio
spiral bevel gear

4.875
Type
6.33
Planet gear type
Final drive
Reduction ratio
Total reduction
Oil
capacity
4.25
3.67
20.72
22.66
Main reducing mechanism and

Differential
10L
Final drive
8L (left and right)
tires (two for both left and right
8.25-15-14PR
9.00-20-14PR
Rim
6.50-15
7.00T-20
wheels
Pressure
kPa
800
3.1 General
The drive axle shown in Fig.3.1 and Fig 3.2 consists of main reducing mechanism, differential,
final drive, service brake and parking brake (forklift with YQX5 transmission), etc. It is fixed
on the sector board of the frame and the mast is mounted on the drive axle housing.
3.2 Main reducing mechanism and differential
The final drive and the differential are basically composed of the left and right differential
case, the ring gear (the spiral bevel gear) and the drive pinion, etc. These parts which are all
assembled in the final drive housing, as the figure 3.3 shown, they are fixed on the drive axle
housing through washers.
The housing of the differential adopts the two-piece housing. Left and right housing are
connected with bolts. The interior of the housing contains the axle shaft gear and planetary
gear which is fixed on the spider. These two kinds of gears are meshed with each other.
The shaft of the drive pinion is supported by two tapered roller bearings, which is mounted in
bearing support. The bearing support is fixed on the main differential housing through gaskets.
The ring gear adopts the spiral bevel gear type, it is connected to the right differential housing
by bolts. The power from the transmission is decelerated through the pinion shaft and the ring
gear.
Figure 3.1 Drive axle (5-7T)

1.Axle housing
7.Hub
13.Shaft
2.Axle shaft
8.Tapered roller bearing
14.Steel ball
3.Brake
9.Adjusting nut
15. Planetary gear
4.Brake drum
10.Locknut
16.Ring gear
5.Oil seal
11. Planetary gear carrier
17.Sun gear
6. tapered roller bearing
12.End cover
Figure 3.2 Drive axle(8-10T)

1. Axle housing
7.Hub
13.Steel ball
2.Axle shaft
8.Tapered roller bearing
14.Shaft
3.Brake
9.Adjust nut
15.Sun gear
4.Brake drum
10.Locknut
16.End cover
5.Oil seal
11. Planetary gear carrier
17.Ring gear
6. Tapered roller bearing
12.Planetary gear
Figure 3.3 Main reducing mechanism and Differential

1. Adjust nut
2.Bearing cover
3.Lock plate
5.Differential housing (left)
6.Axle shaft gear
7. Planetary gear
8.Spiral bevel gear
9.Spider
10. Thrust gasket
11.Differential housing (right)
12. Axle shaft gear
13. Thrust gasket
14.Roller bearing
15.Final drive housing
16. Locknut
17.Adjusting bolt
18. Shaft of drive gear
20.Bearing support
21.O-ring
22. Lining
23. Adjusting gasket
24. Tapered roller bearing
25. Oil seal bracket
26.Oil seal
27.Flange
28. O-ring
29.gasket
30.Locknut
3.3 Final drive

The final drive contains a sun gear, a group of planetary gear and an inner ring gear. Two sets
of wheel hub reduction gear devices are mounted on both ends of the drive axle housing. The
sun gear is installed on the axle shaft with the spline, and is kept off by the spring sprag. The
planetary carrier is mounted on the wheel housing. A group of planetary gears are separately
mounted on the a group of planetary gear shafts which are inside of the planetary carrier. The
inner ring gear (or through the inner ring gear seat) is mounted on the drive axle housing with
the spline.
When the sun gear rotates, that is to say the axle shaft runs, the rotation will be transferred to
the planetary gear and the inner ring gear. However, the inner ring gear is fixed on the both
ends of the drive axle housing, therefore the planetary gear will move around the sun gear, at
the same time, it will rotate on the gear shaft. The planetary gear is mounted on the planetary
gear carrier and the gear carrier is connected to the wheel hub. The wheel rim is connected to
the wheel hub.
See the figure 3.4 for the principle of power transmission.
Figure 3.4 Final Drive

3.4 Troubleshooting
Malfunction
Cause of malfunction
Loose of connection bolts of final drive or

Oil leaks from the damage of the gasket.
Venthole is jammed
final drive housing
Loud noises of
differential
Solution
Screw down or replace
Clean or replace
Abrasion and damage of the oil seal
Replace
Abrasion, damage or fracture of the gear
Replace
Abrasion, damage or fracture of the bearing
Replace
Improper clearance of gear teeth
Adjust
The spline fit connect the axle shaft gear and

the axle shaft is loose.
Replace
The gear oil is insufficient
Add oil according to need
3.5 Service data

See the table 3.3
Differential
Parts
Items
mm
Gasket thickness of bearing support.
0.10.20.5
The fit diameter of the flange and the oil seal
69.95-70
Spline teeth clearance of flange and drive pinion (shaft)
0.036-0.067
Clearance of gear ring and the drive pinion
0.20-0.30
Preload of the drive pinion
2.5-3.5N.m
Backswing of the ring gear
0.25-0.38
The bolt tightening fore of the fixed ring gear
100-150N.m
The bolt tightening fore of the fixed differential
100-150N.m
Gasket thickness of the planetary gear
1.526-1.613
The spline teeth clearance used for connecting the axle shaft gear
and the axle shaft.
Bolt tightening force used for fixing the axle housing and the final
drive housing.
The fit diameter of the small bearing(figure 3.1, the serial number is
Axle housing
Standard values
6) at both ends of the axle and the axle housing.

The fit diameter of the oil seal at both ends of the axle housing and
the axle housing.
The bolt tightening torque of the fixed axle housing and the frame.
The bolt tightening torque of the bottom plate of the brake and the
0.038-0.130
100-175N.m
89.66-89.88
109.913-110
630-946N.m
280-330N.m
Hub
axle housing.
The fit diameter of the axle housing and the mast
189.2-190
The fit diameter of the wheel hub and the small bearing
159.32-159.72
The fit diameter of the wheel hub and the large bearing
179.32-179.72
The fit diameter of the wheel hub and the oil seal
164.6-165
The bolt tightening torque for fixing the brake drum and the wheel
hub
The bolt tightening torque for fixing the wheel hub and the planetary
gear carrier
The tightening torque of the wheel nut
280-330N.m
98-113N.m
480-560N.m
4. Steering system
See the table 4.1 for the main specifications.
Tonnage of forklift
5-7T
8-10T
Items
Type of the steering system
rear wheel steering with hydraulic

steering
Diameter of steering wheel (mm)
350
Model
Steering
gear
BZZ series of full hydraulic steering gear
Displacement
ml/r
280
Rated pressure
MPa
16
Type
Steering
cylinder
Flow
divider
horizontal disposed, double-acting
Diameter of cylinder / Diameter of

rod
mm
Stroke
mm
2128
2130
Adjusting pressure
MPa
12.3
12
Rated flow
l/min
25
24
central axis supporting and horizontal

disposition cylinder
Type
Steering
axle
115/85
Steering angles of outside wheel

and inside wheel
76/50
Tread of rear wheels mm
1700
Distance of king pins of steering

knuckles mm
1500
Return diameter of universal joint assembly

mm
wheel
42
Tire
8.25-15-14PR
9.00-20-14PR
Rim
6.50-15
7.00T-20
Pressure
kPa
800
The steering system is made up of the steering wheel, the steering column (contains steering
shaft and the lock handle), the universal joint assembly, the steering gear, the steering axle
and the steering cylinder. See the figure 4.1 for the steering control device.
The universal joint connects the steering shaft to the steering gear. The steering wheel drives
the steering shaft and the universal joint to make the steering gear work and realize the
hydraulic steering. The steering column supporting the steering shaft can slanted to the
certain degree and can be adjusted to the proper position to meet different drivers needs.
Figure. 4.1 Steering control mechanism
1.Steering wheel
4.Steering control unit
2. Universal joint
5. Drive axle
3. Connecting shaft assembly
4.1 Steering gear

4.1.1 General
The steering gear is a cycloid full hydraulic steering gear, it can send the pressure oil from the
distribution valve to the steering cylinder through the oil pipe, and realize the rear wheel
steering. When the engine is shuted down, the oil pump can not supply the oil, at this moment,
perform the steering operation artificially. The full hydraulic steering system schematic
diagram is shown as the figure 4.2. The structure diagram of the steering gear is shown as the
figure 4.3.
Figure 4.2
Schematic diagram of full hydraulic steering system
1. Steering wheel assembly

2. Oil pump
3. Flow control valve (accessory of multi-way valve)
4. Hydraulic converter
5. Steering cylinder
6. Steering axle
7. Hose
Figure
4.3
Cycloid full hydraulic steering gear
1. Limit position column
4.Universal driving shaft
7.Rotor
2.Valve body
5.Spring plate
8.Stator
3.Valve core
6.Connecting block
9.Valve housing
4.1.2 Operation principles

See the figure 4.4.
Fig. 4.4 Oil channels of steering gear

The servo valve is made up of the valve core, the valve housing and the valve body. It
can control the direction of the oil flow. The rotor and the stator constitutes of the cycloid
meshing pair, it measures the element when the machine turns, which assures the flow coming
into the oil cylinder is in direct proportion to the steering angle of the steering wheel. The
cycloid meshing pair can be used as the hand pump when perform the steering operation
artificially. The universal driving shaft can transfer the torque.
When the servo valve is in the middle position, that is to say the steering sheel does not rotate,
the oil from oil pump returns to the oil tank through the valve core in the open-center system.
(a in the figure 4.4)
When the forklift turns, the oil from pump comes into the cycloid needle gear meshing pair.
The oil can impel the rotor to rotate following the steering wheel and to press the constant oil
into the left or right cylinder of the cylinder. The constant oil can drive the steering wheel to
realize the power steering. The oil in the other chamber returns to the oil tank.
See b and c in the figure 4.4.

When shut down the engine, operate the steering wheel artificially, press the oil in one
chamber of the steering cylinder into the other chamber with the steering wheel through the
valve core, the pull pin, the drive rotor of the universal driving shaft.drive the steering wheel
to realize the steering operation artificially (see the d in the figure 4.4). Refill the oil with the
oil tank through the one-way valve
The forklift adopts BZZ1steering gear, it is an open- center and non-reaction steering gear. It
means that the outside force acted on the steering wheel is not transferred to the steering
wheel.
4.1.3 Use requirements
(1) Installation
After installing the steering gear, make sure that it has a common center with the link shaft
below universal joint and there is clearance in axial direction to avoid the valve core being
withstood. After installing, check whether the steering wheel can return flexibly.
When assemble pipelines, according to the inletmarked at the connector of the steering gear,
connect the connector to the inlet oil pipe of the oil pump. As the return marked, connect the
connector to the oil tank. As the left and the right marked, connect the port to left and
right chambers of the cylinder separately.
Allowable flow speed of intake pipe is 1-1.5m/s, the allowable flow speeds of press pipe and
return pipe are 4-5m/s and the test pressure of high pressure hose should not be below 1.5
times of the maximum working pressure.
The position of oil tank should be commonly higher than the position where the steering gear
is fixed. Oil return pipe should be put underneath the oi surface so that it can complement oil
when steering by manpower and avoid air mixing with oil.
(2) Oil temperature range: -20+80
Normal temperature range: +30+60
(3) Oil selection: L-HM32 or L-HV32 antiwear hydraulic oil
(4) Filtration: The filter fineness of oil coming into steering gear is 30m. The oil filter also
guarantees 0.2-0.3Mpa back pressure of oil that returns to the redirector lest the fluid
might flow back to oil tank.
(5) All the pipelines of hydraulic system must be kept clean and the oil tank should be closed
in order to reduce oil pollution.
(6) Test run: Cleanout oil tank and transfuse oil to maximum level before running. Loosen
the screw joints of steering cylinder then run the oil pump in low speed to expel the air
until there is no bubble in the oil coming out.
Disconnect piston rods and steering cartwheels and then turn the steering wheel to drive
the piston rod to the leftmost or rightmost position (Dont stop at the two limit positions).
Recharge oil tank with oil to the maximum level.
Fasten all the screw connectors with no pressure then connect piston rod. Check if the
steering system is in good working trim under all kinds of running conditions. If the
steering is heavy or failed, please carefully find the causes and dont force steering wheel
to run. Moreover, dont disassemble the parts of redirector arbitrarily lest the parts should
be damaged.
Check if the pressure of the system accords with the prescription when the piston rod of
cylinder reaches limit positions.
(7) Maintenance
Check whether or not there is oil leakage and check the oil level of oil tank as well as
working condition everyday. Replace filter elements and fluid regularly by prescription.
Put a drop of oil on a piece of blotting paper to check the hydraulic oil. If there is a black
center of oil mark, the oil can not be used anymore. If abnormal situation happens, find out
the cause carefully. Turning steering wheel simultaneously by two individuals is strictly
forbidden.
4.1.4 Check and repair of steering control unit
In order to keep steering system running in good condition and avoid accidents, please
check regularly.
1) Check water capacity, mechanical impurity and acid number of working fluid termly. If it
exceeds the prescription of original trademark, replace the fluid with new oil. Oil that
has been used but isnt filtered is forbidden.
2) Dont disassemble the steering unit arbitrarily in the checking of steering system. After
having made sure the redirector malfunctioned, disassemble it according to assemble
warnings.
3) All the tools used to disassemble the parts should be clean, the ground should be tidy. It is
better to work indoors.
4) Assemble warnings
a. Clean all the parts with gasoline or kerosene before assembling. If there is any paint on
joint surface, wipe it with acetone. Dont wipe the parts with cotton yarn or tatter, use
brush or silk. Compressed air can be used to if condition permits. Rubber ring must not
be soaked in gasoline too long. After the steering gear being assembled, add 50-100ml
hydraulic oil to the inlet port before fixing on forklift, then turn the valve core left and
right. Fix it on the truck if no abnormal phenomenon happens.
b. Joint surfaces of valve body, separation disc, stator and back cover should be kept in
highly cleanness. Be careful not to impact or nick the surfaces.
c. Pay attention to that the screw joint must below the valve body flat.
d. Both snap ring and slip ring have one of the sides chamfered. The chamfered side of
snap ring should face front cover and the chamfered side of slip ring should face valve
core.
e. There are punched point marks on the surfaces of rotor and link rotational shaft ends.
The two points should be placed opposite to each other in assembling.
f. The washers of position restricted bolts with pins should be made of copper or
aluminum.
g. Fastening method of the seven bolts on the back cover: screw the bolts every three ones
and dont screw down at one time. Fasten them gradually. The fastening force is
30-40N.m.
h. Pay attention to the inlet, return, left, right marks on valve body when installing
hoses. The marked ports should be matched with the hoses rightly.
5) Disassembling and assembling (see Fig. 4.5)
a. Disassembling sequence: front coversnap ringslip ringvalve housing, etc
(washer dial pinvalve corespring plate)back coverposition restricted column
stator rotorlink shaftseparation discscrew jointsteel ballvalve body.
If back cover is first removed, steel ball must be taken out first before valve core and
valve housing being taken out, or else valve body will get stuck and be damaged. Be
careful not to impact or nick the other end surface of valve body in removing front
cover.
b. Assembling sequence: valve corespring platevalve housingdial pin washer
valve body slip ringsnap ringfront coversteel ballscrew jointseparation
disc link shaftrotorstatorposition restricted columnback cover.
Fig. 4.5 Disassembling and assembling diagram of steering control unit
4.1.5 Troubles and solutions of steering control unit

See Table 4.2.
Trouble
Cause
Dunghill exists on joint
surfaces
Oil
leakage
Heavy
steering
Phenomenon
Oil leaking from joint
surfaces of valve body,
separation disc, stator and
back cover.
Solution
Clean the accessories
again
Damage of rubber ring on

axle journal
Replace the rubber

ring
Unsmooth surface of
washer on position
restricted bolt
Rubdown or replacing
Insufficient oil supplied by

oil pump
Its light to turn steering

wheel in low speed but
heavy in high speed.
Choose right oil pump

or check if flow
divider runs normally.
Air exists in steering

system.
Foam exists in oil; irregular

noise emitted; when turning
steering wheel, the cylinder
some times moves and some
times not.
Get rid of the air and

check the intake pipes.
Not enough fluid in oil

tank
Fill oil to the

prescribed level
Oil viscosity is too high
Use oil with

recommended
viscosity
Steel ball check valve in

valve body failed
Pressure of flow divider is

lower than working
pressure or the flow divider
gets stuck by dunghill.
Its heavy to turn steering

wheel not only in high speed
but also in low speed.
Besides there is no pressure
when steering.
Its light to steer with no
load or light load but heavy
to steer when adding load.
If steel ball is lost,

mount one whose
diameter is 8mm and
if it gets stuck by
dunghill, cleaning
must be done.
Adjust pressure of
flow divider or clean
the flow divider
Trouble
Steering
failed
Steering
Wheel cant
Return to
Middle
position
automatically
No
Manpowered
steering
Cause
Phenomenon
Solution
Spring plate is broken off.
Steering wheel cant return to

middle position
automatically. Pressure
difference of middle position
increases.
Replace
damaged
spring plate.
Dial pin is broken off or is

distorted.
Pressure vibration aggravates

obviously and steering wheel
even can not be driven.
Replace dial
pin
Clearance becomes large for

abrasion of spline on link
shaft
Pressure vibration aggravates

obviously and steering wheel
even can not be driven.
Replace link
shaft
Mistake assembling rotor and

link shaft for each other
Oil matching is in disorder.

Steering wheel runs by itself
or moves left and right.
Assemble
again
according to
assembling
warnings.
Bidirectional shockproof
valve fails (steel ball gets
stuck or spring fails)
Vehicle runs to one side or

cylinder dose not move or
moves slowly when turning
steering wheel.
Clean
bidirectional
shockproof
valve.
(1)Steering column doesnt

have a common center with
valve core.
(2)Valve core is sustained by
steering column shaft and
can not move.
(3)Rotating resistance of
steering column is too
large.
(4)Spring plate is broken off.
Pressure difference of middle

position increases or
redirector doesnt unload
when steering wheel stops
running (vehicle runs to one
side).
Eliminate
troubles
according to
causes
Radial and axial clearances of

rotor and stator are both too
large.
Drivers sense of terminal

isnt obvious when steering
by power and the cylinder
piton reaches limit position.
When steering by manpower,
steering wheel runs but
cylinder does not move.
Replace
rotor and
stator
4.2 Check after reassembling the steering system

1)
2)
3)
4)
5)
Check if pipe lines are rightly laid and the left and right hoses for steering are changed
with each other.
Turn the steering wheel left and right to limit position. Check if the power of turning left
is equal to that of turning right and if the turning is smooth.
After the steering system being assembled, first raise steering cartwheels and run the
engine in idle speed, then turn steering wheel left and right slowly several times to get rid
of the air in hydraulic pipe lines and steering cylinder. Put down steering cartwheels then
turn steering wheel several times. Check if the noise is normal when turning. If there is
no abnormal noise, it means the air has been driven out. Finally set the engine running in
idle speed to raise oil temperature.
Measure operating force for steering:
Stop forklift on dry and smooth road and apply parking brake. Attach spring balanced
device to the brim of steering wheel to measure the operating force for steering which
must below 150N.
Adopt pressure gauge with a range of 15-20MPa to test the pressure. Connect flow
breaker with hose like which is shown in Fig. 4.6.
Figure 4.6 Pressure test

Remove the hose which connects flow divider and steering control unit. Connect hose with
pressure gauge to the side of flow divider and connect hose with flow breaker to the side of
steering control unit. Then run the engine in idle speed.
The oil pressure is about 0.5-2MPa when steering wheel in natural position. If pressure
exceeds the range, check whether or not flow divider or hoses are in jam. Increase engine
speed to about 1500r/min if there is no abnormal instance. Then turn off flow breaker
slowly and pay attention to the increasing pressure.
The highest adjusted pressure of flow divider is 12MPa, so when flow breaker is turned off
completely, the pressure gauge reveals the adjusted pressure.
If the pressure exceeds 12MPa, it means flow divider is failed. But if the pressure is too low,
it means the oil pump is failed or spring of flow divider is broken off. In this case, be careful
not to make the time when flow breaker is turned off exceed 15 seconds.
Warnings: oil pump supplies pressure oil to drive steering cylinder. There are two aspects of
its running to take into account, thats rated pressure and rated flow.
Pressure is used to drive cylinder while flow relates to working speed of cylinder. Therefore,
even if pressure is normal and reaches 12MPa but flow is deficient, the steering cylinder
will still run abnormally and it will cause heavy steering. So adjust flow valve and safety
valve properly according to capacity and working condition of steering cylinder when flow
divider requires disassembling and reassembling. Make a matching mark on the adjusted
position for reassembling or measure the distance of adjusting bolts.
4.3 Troubleshooting of steering system
Troubles and solutions of steering system caused by flow divider are shown in Table 4.3.
Troubles
Steering wheel is obstructed
when turning quickly.
Causes
Flow control valve lever gets stuck.
Solutions
Disassemble and repair
or replace.
Abrasion of flow control valve lever Replace the whole

Oil pressure can not rise high.
Safety valve is always open (can not

Replace the whole
close)
Oil pressure is higher than

Safety valve is always close (can not
Replace the whole
adjusted pressure of safety valve open)
There is noise of safety valve.
Safety valve shakes
Replace the whole
Oil temperature is too high.
Safety valve is always close (can not

Replace the whole
open)
Replace the whole
close)
Its difficult to steer when engine

running in idle speed.

or replace.
Steering force changes.
Safety valve shakes
Replace the whole

or replace.

Replace the whole
close)
Its difficult to steer.

or replace.
4.4 Steering axle

Forklift adopts horizontal disposed steering axle with steering cylinder. The front and back of
centrality are supported on axle carriers by two supporting shafts through bushes and the axle
carriers are fixed on frame respectively. The two supporting shafts can swing to a certain angle.
The main structure can be seen at Fig 4.7 .
Steering axle mainly consists of steering axle body, left and right steering knuckle assemblies,
linkage assembly, cartwheels, hubs and steering cylinder.
4.4.1 Steering axle body
The steering axle body is a welded structure of steel plates. There are two up and down
protruding supports or holes for steering king pins to connect left and right steering knuckle
assemblies with axle body.
4.4.2 Left and right steering knuckle assemblies
Left and right steering knuckle assemblies are supported by two thrust bearings on hubs on
which cart wheels are mounted. Oil seals are fixed on hubs to prevent lubricating grease from
leaking. Plane thrust bearings are mounted between steering knuckles and up and down
protruding supports. The rotating clearance can be adjusted by gasket underside. Inside the
holes of up and down protruding supports are steering king pins which are supported by needle
bearings. There are oil seals to seal up the underside. Grease nipples are fixed on upside cover
to lubricate all the bearings through inside hole of king pin. Users should inject lubricating
grease on time. King pins of steering knuckle assemblies are fixed by lock pins.
4.4.3 Hubs
Hubs are elements of ball iron.
4.4.4 Steering cylinder
The steering cylinder horizontal disposed in the middle of steering axle body is double-acting.
Cylinder rods at the two ends connect with linkage assembly. The other end of linkage
assembly drives steering knuckle arm to turn cartwheels. Inside the guide sleeves on the two
ends of cylinder are steel bushing bearings, snap rings, seal rings and dustproof rings, which
all contact with piston rod. Outside the guide sleeves are supporting rings, O-rings, both of
which contact with the inside of cylinder barrel. Fig. 4.8 shows the structure.
Figure 4.8 Steering cylinder
Figure 4.7
Steering axle
1.Axle
11.Adjusted shim
21.Nut,hub
31.Bracket, axle
2.Power cylinder
12.Oil seal
22.Hub
32.Plate
3.Link assembly (right)
13.Bushing
23.Snap ring
33.Seal shim
4.Pin
14.Pin,king
24.Bearing
34.Bearing
5.Bearing
15.Cap,hub
25.Oil seal
35.Fitting, grease
6.Bearing
16.Cap,hub
26.Locking pin
36.Steel bearing
7.Bearing,needle
17.Fitting, grease
27.Nut
37.Shim
8.Spacer
18.Fitting, grease
28.Washer
38.Shim
9.Knuckle (right)
19.Nut
29.Cap,hub
39.Shim
10.Knuckle (left)
20.Bolt,hub
30.Pin
40.Link assembly
(left)
5. Brake system
For basic parameters, see Table 5.1.
Model
5-7T
Domestic
engine
Items
8-10T
Import
engine
Type of braking
Vacuum servo
Type of brake
Internal expanding, shoe brake on front wheel
Service Inner diameter of brake drum mm

brake Inner diameter of the wheel cylinder
Dimensions of friction lining on shoe
brakelengthwidth thicknessmm
Area of friction lining
Drive boosted
317.5
438.15
31.75
47.62
32410010
48910012.7
4324
4489
mechanical, internal expanding brake fixed on

the middle shaft of transmission or drive axle
Type
Parking Inner diameter of brake drum mm
brake Dimensions of friction lining on shoe
brake lengthwidth thickness
mm
Area of friction lining
c
Brake cylinder
mm
Diameter of the vacuum booster

front housing/rear housing
Brake
Type:mian valve/safety valve
pump,
valve Brake
Type of move
valve
Entry flux
l/min
Max oil pressure
Overfall oil pressure
140363.5
50.4
31.75
9"/10"
Type of wide-open/type of
closed-end
Type of spring
27
10.5
Type of spring
cc
66.7
mm
50 34
MPa
7.2/4.9
MPa
13
MPa
Type
Storage Cubage
storage Piston dia. journey
Tank Oil pressure: max/working
160
5.1 General
The brake system consists of two parts, service brake which is assembled in the drive axle and
parking which is connected with the middle shaft at the back of transmission or the input shaft
of drive axle.
The method of the service brake is drive boosted.
5.2 Drive boosted braking
Dynamic service brake system is composed of brake pedal, brake valve, accumulator and
brake.
Dynamic brake is available by pressure oil which is exclusive for forklift hydraulic system and
transferred by the small gear pump. There are two oil ways, one is into Brake Valve and then
to brake transfer pump to create brake; the other is into accumulator for standby. Both of oil
ways are controlled by Brake pedal stroke.
5.1 The brake system

5.2.1 Brake pedal
Brake pedal and microdrive pedal is fixed on the left of frame by bracket. Brake pedal, on the
right, pushes piston assembly of brake valve through connecting rod, in order to control the
pressure oil. Microdrive pedal, on the left, links with brake pedal, so it also can control the
brake valve as well as the microdrive valve of transmission.
Figure 5.2
Brake pedal
5.2.2 Brake Valve

1)
No brake
In the state of no brake, because brake valve port is open, pump port links with steering gear,
steering works. When brake pedal is not stepped and steering control doesnt produce brake, oil
D chamber doesnt rise, because port
D is closed.
pressure of control oil in
2) Brake start and complete

A, When brake pedal is stepped, Piston Assembly 10 moves toward left and then valve
bushing 7 and recoil piston 5 is pressed toward left by spring group 8, at the same time, return
Spring 6 presses toward left.
B
A is closed, port
D disconnects with oil return
Owing to Part 7s movement, port
B is open, making port
D link to pump port.
tank. Port
At this moment, Valve Bushing 7 moves toward left again. Owing to the pressure on
C , oil pressure in pump port and chamber
D rises. i.e., oil pressure through
port
D pushes Recoil Piston 5,
brake transfer pump also rises. High pressure oil in chamber
its force balances with pedal force.
3)
When right end of piston inputs max. pedal force, position is limited by bolt and pedal
D is over max adjustable oil pressure.
bracket to avoid oil pressure in chamber
When foot is moved away from pedal, valve bushing 7 is reposition by the reverse force
of Recoil Piston and part 6, 8 spring reverse force, and then brake process is completed.
Accumulators working process
When Oil Pump stops working (Owing to engine flameout) or is damaged, accumulator
would be in working.
A Step the brake pedal again, valve bushing 7, recoil piston 5 and check valve contact pin
D
3 move toward left. Contact Pin opens ball, at this moment, chamber
and
accumulator port link. Pressure oil in accumulator is available for brake branch pump.
B Foot moves away from pedal. valve bushing, recoil piston and contact pin move toward
right at the same time. Under the spring force, ball of check valve joint again with valve
seat, (check valve is closed) contact pin stop at this position.
C
C is open, so that oil in brake transfer

Recoil Piston moves toward right. Chamber
D.
pump returns to oil tank through chamber
Figure 5.3 brake valve

1.plug
4.piston bracket
7.valve cover
2.valve bracket
5.piston
8.spring
3.valve pin
6.spring
9.oil seal
10.piston
5.2.3 Accumulator
When engine stops work or oil pump fails, accumulator can be used as extraordinary energy for
brake. Power is accumulated by spring way. It is very dangerous of making maintenance when
the accumulator is accumulated. When engine is stopped, the pressure of the accumulator can be
completely released by continuously operating the brake pedal up and down several times, then
do the maintenance.
Illustration is under the no accumulation state. Alarm switch buzzer is under the constant sound
state.
When controlling brake pedal and oil pressure is over 3.9 MPa, check valve opens, accumulator,
oil flows in and push piston moves toward left and spring group is compressed, so that oil
pressure is generated.
At the same time, piston moves toward left, and makes the switch control lever of alarm switch
move toward left under the pressure of spring. Switch valve core is in the switch control levers
groove and the alarm switch is under the silence state.
With the rise of oil pressure of pump, position limiter in the middle of spring limits the left
stroke of piston. At this moment, accumulator has the max. energy; oil pressure is 13 MPa,
which is controlled by safety valve.
Figure 5.4
Energy storage top
5.3 Vacuum boosted braking

5-7T forklift employ vacuum boosted brake which adopt vacuum booster to drive brake master
cylinder (called master pump) so as to realize the boosted braking.
The vacuum booster makes use of vacuum degree (called minus pressure) as power, that is to
say use the difference of vacuum pressure and atmospheric pressure to reduce the force applied
by driver to the brake pedal so as to obtain higher pressure of wheel brake cylinders (wheel
pumps). It reduces and assists the force applied, eases the working intensity of driver as well as
enhances the security of service braking.
Table 5.2 show the main specifications

Description
Valid dimension of vacuum
cylinder
Units
Numerical Value
Max
mm
263
Min
mm
236
mm
39
The longest stroke of vacuum booster

Ratio of booster
Brake master
cylinder
Diameter
mm
31.75
The longest stroke
mm
38
Displacement of front chamber
ml
15.8
Displacement of rear chamber
ml
14.2
Max outer diameter
mm
272
Size of plate
mm
60804-M8
Size of outlet
mm
2-M101
Dead weight
kg
5.3
5.3.1Assembly of vacuum booster and brake master cylinder

The figure of "9+10" double film vacuum booster used in 5-7T forklift is shown in fig 5.5. And
the inner structure appears in figure 5.6. The working status of the assembly simply introduced
as follows:
Figure 5.5 Diagram of vacuum booster and brake master cylinder
Figure 5.6 Structural diagram of vacuum booster and brake master cylinder
1.Control valve push rod
9.Rear leather film
2.Air filter bed
10.Feedback disc
3.Big conical spiral spring
11.Front leather film cover
4.Control valve
12.Front leather film
5.Control valve piston
13.Brake master cylinder push rod
6.Small conical spiral spring
14.Return spring
7.Control valve body
15.Vacuum hose fitting
8.Rear leather film cover
1) Nonworking condition
When the vacuum booster doesn't work,big conical spiral spring 3 will push control valve push
rod 1 with control valve piston 5 to the back terminal point. Air control valve would be tightly
depressed on piton 5 by small conical spiral spring 6 therefore the inlet of air valve is closed. At
this moment,the two front and back cavities of force adding chamber are connected through
passage, control valve of chamber and passage B and separated from the atmosphere. There
would be some degree of vacuum in both the front and back chambers when the engine and
vacuum pump are running.
2) Braking condition
a. As soon as the brake pedal on, the force applied would be magnified by lever and acts on
control valve rod 1 and depresses element 3 to move forward with element 5. By the
actions of feedback disc 10 and master cylinder push rod 13,some pressure which is sent
to wheel brake cylinder (wheel pump) inside the brake wheel comes into being in the
interior of brake master cylinder. At the same time,air control valve 4 is pushed forward
with element 5 by the small conical spiral spring 6. It contacts with the inlet of vacuum
valve and closes it. Therefore, the front and back cavities of force adding air chamber are
separated,that is to say the back cavity of force adding air chamber is separated from
vacuum source.
b. With the continue moving of control valve push rod, control valve piston 5 leaves element
4 and the outside atmosphere goes through air filter bed 2, control valve chamber as well
as passage B and is charged into the back cavity of force adding air chamber. In this way,
a small part of the forward force, which is produced by the pressure difference of the two
cavities of force adding air chamber,is used to balance the force of big conical spiral
spring and the rest large part acts on the feedback disc through control valve body 7 and
then is transited to the master cylinder. So it plays the part of booster.
3) End of braking and getting back to nonworking condition
a. In the process of stepping on brake pedal that is to say in the forward moving of control
valve push rod, the air continuously comes into the front and back cavities of force adding
chamber through the open inlet of air valve and the control valve body also moves forward
continuously. When the brake pedal stops at the position where it closes the inlet of air
valve. The vacuum inlet and air valve inlet both close up at this time and the booster is in
balance of three forces: air pressure difference of force adding chamber's front and back
cavities, oil pressure of brake master cylinder and thrust of control valve push rod. In the
end, the wheel brake is in braking.
b. As soon as the pedal is released, return spring 14 and big conical spiral spring 3 push
control valve rod 1 and piston 5 backward and then control air valve 4 leaves the inlet of
vacuum valve, where upon the braking comes into an and the assembly returns to
nonworking condition.
5.3.2 Mounting method of vacuum booster and brake master assembly
1Fix the installation bracket with for M8 bolts to the forklift frame and then connect the
adjustable fork at the end of booster with brake pedal linkage. Finally, screw down the
bolts witch four M8 nuts. The tightening moment is 12N.m-18 N.m
2Connect vacuum hose with vacuum hose fitting. Ensure a sealed assembly.
3Connect the brake oil tubes witch two M10*1 outlets of brake master cylinder. The
tightening torque is12 N.m-16 N.m
4Open the cover of reservoir and inject brake fluid with no dust or impurity to expel all the
air in the whole brake system.
5When replace the brake master cylinder or vacuum booster separately, the tightening
torque of the connecting nut between them is 12N.m-16N.m
6Don't arbitrarily adjust the push rod head on the mating surface of vacuum booster and
brake master cylinder.
5.3.3 Warnings for consumers
1Certified brake fluid must be used in our products.
2When brake fluid is injected in the assembly, air should be emptied in the piping.
3After the air is expelled, observe the level of fluid in the reservoir which should be in the
middle position.
4If troubles listed in table 5.3 occur,the vehicle must be repaired by qualified professionals.
Customers must not venture to disassemble it.
5.3.4 Malfunction and analysis of causes
Malfunction and phenomenon
Analysis of causes
No pressure is built up in the two cavities of 1.Abrasion of rubber ring

master cylinder or one of the cavities, it is cylinder;
showing at the sudden increase of pedal travel
2.Damage of output piping
in
master
Pressure of output oil is not high & force 1.Vacuum leakage of booster
applied to the pedal becomes heavy
2.Vacuum piping leakage of engine
Frequent lack of oil in the reservoir
1.Joints leakage of cylinder

2.Abrasion of rubber ring of first piston in
master cylinder
1.Air exists in oil piping

Sense of lowness and softness when stepping
2.Overlarge clearance between booster push
on the brake pedal
rod and master cylinder piston
5.
4 Service brake
5.4
The service brake is an internal expanding, shoe brake. There are two service brakes mounted
symmetrically on the drive wheels which are at the two ends of drive axle. The brake consists of
a pair of brake shoe assemblies (include a primary brake shoe and a secondary brake shoe),
brake cylinder (5-7T has one wheel,8-10T has two wheel), a clearance regulator, three or four
return springs and a brake soleplate. Glued or riveted to the outside of each shoe is a brake
lining. The clearance between brake shoe lining and brake drum internal surface is adjusted by
the regulator.
5.4.1 Service brake (5-7T) (Fig 5.8)
There is only one wheel brake cylinder in each service brake of 5-7t forklift. The two ends of
the cylinder piston rod contact respectively with the tops of primary and secondary brake shoes.
The bottoms of brake shoes touch with the two ends of clearance regulator and are depressed on
the brake soleplate by spring pull rod.
The automatic clearance adjusting device usually works when backing a forklift and applying
the brake. The adjusting lever turns the regulator gear over one tooth if the clearance becomes
large. The adjusted clearance value would between 0.4-0.6mm. (Fig 5.7 shows the rotation
direction of regulator gear in the adjusting)
For the 5-7t Forklift service brake has two
forms of braking system, the cups of the
brake wheel cylinder are made of oil resistant
rubber. The vacuum booster cups are made of
leather or synthetic leather. More attention
should be paid when relace the parts.
Figure 5.7
Figure 5.8 Brake (5-7T)

1.Primary brake shoe
6.Push rod
11.Regulator spring
2.Return spring
7.Secondary brake shoe
12.Adjustment lever
3.Dust ring
8.Return spring
13.Regulator
4.Leather cup
9.Shoe fixed pin
14.Return spring
5.Piston
10.Preload spring
5.4.2 Service brake (8-10T) (Fig 5.9)

8-10 Ton Forklift Brake has two brake transfer pumps, one is in the upper position, and the
other is in the lower position. Both link to two ends of main and auxiliary brake shoes.
Clearance regulator is on the side of brake transfer pump.
During adjustment of clearance, uninstall rubber lid of regulator which is fixed on brakes
bottom plate. Move and rotate teeth of regulator from inner toward outer by screwdriver until
the clearance between friction disc and brake drum wall is nearly zero. And then rotate the
regulator in the opposite direction 5-6 alveolus. (See figure 5.10)
8-10 Ton Forklift is with dynamic brake. Leather cup of brake transfer pump of service brake
service brake and its material is oil proof rubber, please pay attention when replacing.
\
Figure 5.10
5.9 Brake (8-10T)

1. Primary brake shoe
6. Leather cup
2. Regulator
7. Dustproof ring
3. Push rod
8. Secondary brake shoe
4. Piston
9. Return spring
5. spring
10. brake soleplate
5 Parking brake
5.
5.5
The parking brake which is an internal expanding, shoe brake is mounted on the output end of
middle shaft shown in Fig. 3.1, item 9 at the back of transmission. The detailed structure can
be seen in Fig. 5.12.
Figure 5.11 shows the operation of parking brake. The operation force applied by hand cant
exceed 300N when forklift is parked on a slope with rated load. Please adjust the pull in the
direction shown in picture. B is the force measuring point.
Figure. 5.11 Operation device of parking brake
Figure 5.12 Parking Brake

1.Soleplate
7.Return spring
13.Bracket
2.Brake shoe
8.Regulator
14.Pin
3.Fixed bol
9.Regulator spring
15.U-keeping ring
4.Nut
10.Pin
16.Piston
5.Spring washer
11.Spring fixing bracket
17.Brake cable
6.Washer
12.Rod
5.5 Troubleshooting
Table 5.4
Troubles
Causes of the troubles
Solutions
Fluid leakage of brake system
Repair
Improper clearance of friction plates
Adjust
Overheating of brake
Poor Brake
Poor contact of bake drum and friction plate
force
Impurity adheres to the surface of shoe brake
Check if sliding
Adjust
Repair or Replace
Impurity interfuses in brake fluid
Replace the brake fluid
Improper adjustment of brake pedal
Adjust
Hardening of shoe brake surface or impurity adheres to it Repair or Replace

Distortion of soleplate or loosening of bolts
Noises in
braking
Uneven
braking
Repair or Replace
Distortion of shoe brake or improper assembling of shoe

Repair or Replace
brake
Partial wear abrasion of friction plates
Replace
Bad wheel bearing
Replace
Impurity adheres to the surface of shoe brake
Repair or Replace
Malfunction of wheel pump
Repair or Replace
Eccentricity of brake drum
Repair or Replace
Improper clearance of friction plates
Adjust
Improper tire pressure
Adjust
Fluid leakage of brake system
Repair
Inability of Improper clearance of friction plates

brake pedal Air is mixed in brake system
Improper adjustment of brake pedal
AdjustRepair
Expel
Adjust again
6. Lifting system
Main specifications are shown in Table 6.1.
5-7t
8-10t
Rolling, welded mast with free

lifting, duplex telescopic mast
Type of mast
Section shape of inner mast
Section shape of outer mast
Max lift heightstandard mast
3000mm
3500mm
Front or back tilt anglestandard condition
Roller
6/12
Outer diameter of main roller
mm
151.5
203.5
Outer diameter of side roller
mm
82
64
102
119
Outer diameter of side roller on Fork carrier

mm
Lift chain (plate link chain)
LH2044 Chain
pitch 31.75
LH3234
Chain pitch 55
Lifting method of fork
Hydraulic
Tilting method of mast
Hydraulic
Adjusting method of distance between forks
Manual
Hydraulic
6.1 General
The basic mode of lifting system which adopts rolling type is duplex telescopic mast. The
section of inner mast and the outer mast is in the shape of a J . Masts are all free lifting type.
6.2 Inner and outer masts
Mast is duplex telescopic type with free lifting. It consists of inner mast and outer mast and is
supported by mast support. Mast support which is welded at the bottom of outer mast extends
to axle housing and connects with it. Therefore, the weight of mast is supported by axle
housing. Tilt cylinder support which is connected with the front end of cylinder (called end of
piston rod) by pin shaft is also on the outer mast. Mast is tilted by tilt cylinder, 6 for forward
tilting and 12 for backward tilting.

Inner mast is composed of left and right mast channel steels which are connected by up and
down crossbeams. Outer mast is also composed of left and right mast channel steels which are
connected by up, middle and down crossbeams. Roller shafts on which mount main rollers and
their clip rings are welded on the inside and upside of outer mast left and right channel steels.
In addition, side rollers which support inner mast in lateral direction are mounted on outer
mast. At the lower part of inner mast left and right channel steels, the roller shaft is welded
outside of the inner mast, main roller and its spring sprag is mounted on the roller shaft. Under
the main roller, the side roller is mounted and it is used to bear the lateral load. By means of
these rollers, the inner mast can work stably.
6.3 Fork carrier
Roller shaft is welded on fork carrier. Main roller which moves along the inside of inner mast
and its spring sprag are both mounted on the roller shaft. Side roller which moves along the
inside of inner mast is assembled on upright board of fork carrier and adjusted by shims. In
order to prevent fork beam (called fork supporting board or up crossbeam) from shaking, two
limit rollers which moves along the external lateral face of inner mast are mounted. Main
rollers bear the lengthwise load. When the fork is lifted to the maximum height, main rollers
mounted on the upper part exposes ( a part )from the top of mast and the lateral load is bore by
limit rollers upper and side rollers at the lower part. In the design of mast assembly and fork
carrier, we have taken adequate rigidity and strength as well smooth operation into account.
Besides, Fork carrier whose up and down crossbeams are made of high strength steel is an
integral structure which ensures its durability. It accords with ISO standard (international
standard).
Two forks which are mounted on fork carrier are made of alloy steel and have been heat treated.
6.4 Adjustment of lift system
6.4.1 Adjustment of gasket on the end of lift cylinder
See Fig. 6.1.
The stroke of lift cylinder should be readjusted if lift
cylinder, inner mast or outer mast is disassembled or
replaced.The adjusting method is as follows:
1. Fix the head of piston rod into the upper beam of
inner mast without no gasket.
2. Lift the mast slowly to the maximum stroke of
cylinder and check whether the two cylinders are
synchronic.
3. Before movement, stop adding adjustment gasket
between piston rod head of cylinder and upper beam
of inner mast firstly.
The thickness range of adjust gasket is 0.2-0.5mm.
Figure 6.1
4. Tension adjustment of chain.

6.4.2 Height adjustment of fork carrier
1) Stop the truck on horizontal ground and
keep the mast vertical.
2) Make the bottom of fork contact ground
and regulate the adjustment nut on the
upper connection of chain in order to
make the exposed part of main roller
Figure. 6.2
achieve a quarter or a third of radius of

main roller.
3) Lift the fork to the highest position and
B between
make sure that the clearance
the stopper of fork carrier and inner mast
is with the range of 5-10mm.
See Fig. 6.3
Figure 6.3
4) Lower fork carrier to the ground and tilt it

backward to the limit position. Regulate
the adjustment adjustment nut of
connector at the upper end of chain, so
that tension degrees of chains are the
same. See the figure 6.4.
Figure 6.4
6.5 Mounting positions of rollers

Rollers of lift system can be classified into tree categories, namely main roller, side roller
group and side roller, which are separately mounted on inner and outer mast as well fork
carrier. Layout of 5-10T forklifts are large identical with slight difference, shown as the fig.6.5
and figure 6.6 respectively. Main roller bears main load in forward and backward direction of
forklift and it can not be adjusted. Side roller bears the lateral load, it can be generally adjusted
by gasket group to regulate the left and right lateral clearances so that the inner mast and fork
carrier can move up and down freely.
Figure 6.5 Roller installation (5-7T)
Fig.6.6 Roller installation (8-10T)
6.6 Lift cylinder and tilt cylinder

Table 6.2 shows the main specifications
Tonnage
Item
Type
Lift
cylinder
7t
mm
80
90
100
60
70
70
Stroke of cylinder
1495
Type
Tilt
cylinder
Double acting, piston type
Cylinder bore
Outer diameter of piston rod
Stroke of cylinder6/12
8-10t
Single action, piston type
Cylinder inner diameter

Outer diameter of piston rod
5-6t
115
50
mm
227
242
6.6.1 Lift cylinder

Two single action lift cylinders are mounted separately on the backside of outer masts two
sides. The bottom of cylinder is fastened by bolts on cylinder support of outer mast, while the
top of cylinder, which can be also called the tail of piston rod is connected with upper beam of
inner mast by bolts. Piston strokes of the two lift cylinders should be adjusted in consistency
in order to synchronize the two cylinders. If they dont work synchronously, adjust them by
bolts. (see the figure 6.7)
Lift cylinder is mainly made up of cylinder block, piston, piston rod and cylinder cover. At
the bottom of cylinder, there is an inlet, where the high pressure oil come into the cylinder.On
the upper part of cylinder, there is outlet under the an piston seal Yx seal ring block, where the
low pressure oil is discharged. (The outlet is connected with return hose.)
Piston and piston rod are fixed together by castle nut, cotter pin and O-ring. Yx seal ring, snap
ring and support ring are mounted around the outer surface of piston. Piston moves up along
the inner surface of cylinder block by high pressure oil. Dust ring and steel bushing bearing
are mounted on cylinder cover, which is connected with cylinder by screw thread.
Steel-backed bearing is used to support the piston rod while dust ring prevents dust from
coming into cylinder.
When pull backward the control joystick, the high pressure oil flows into cylinder through the
lift cylinder in order to push the piston rod and inner mast up, through the chain, the fork
carrier and fork can be lifted. When the inner mast begins to lift the same level as the top of
outer mast, height from the ground to fork position is called free lift height, within the range,
mast height does not change.
When move forward the lift control handle, because of the piston rod, fork carrier, load
backrest and the service weight of fork, the piston falls down, and the oil under under piston is
discharged to the cylinder. Oil discharged from the cylinder is controlled by the throttle valve
and returns to oil tank through multi-way valve.

Figure 6.7 shows the structure of lift cylinder of 5-7t forklifts
Figure 6.7 Lift cylinder(5-7T)

1. Bearing 6035
8. Plug
15. Snap ring
2. Adjusted shim
9. Screw
16. U-ring
3. Dust ring
10. Elbow
17. Piston
4. U-ring
11. Body,cylinder
18. Nut
5. Cover,cylinder
12. Spacer
19. Pin
6. Plug ZG3/8"
13. O-ring
20. Piston
7.O-ring
14.Wearing
21.Spring
Figure 6.8 shows the structure of lift cylinder of 8-10t forklift
Fig. 6.8 Lift cylinder (8-10T)

1.Rod,piston
8.Cap
15.Stop ring,steel wire
2.Seal,dust
9.Plug
16.Snap ring
3.U-ring
10.Screw
17.U-ring
4.Bearing
11.Cylinder body
18.Spring
5.Plug ZG3/8"
12.Sleeve,adjusted
19.Piston
6.Elbow
13.Piston
20.Gasket,adjusted
7.O-ring
14.Wearing
.2 Cutoff valve
6.6
6.6.2
Cutoff valves are mounted at the bottom of both lift
cylinders. They can avoid the cargo falling off
suddenly when the high pressure hose bursts
suddenly. The structure of cutoff valve is shown in
the figure 6.9. Return oil from lift cylinder passes
through cutoff valve and pressure difference happens
because of the oil orifices around the slide valve.
When the pressure is less than the spring force, the
slide valve When the pressure difference is less than
the spring force, the slide valve does not act. If high
pressure hose suddenly bursts, only a little oil will
flow through small openings on the end of slide
valve. Therefore, the fork will fall down slowly.
Figure 6.9 cutoff valve
6.6.3 Speed limiting valve

Speed limiting valve (called throttle valve) is mounted in oil pipeline between directional
control valve and high pressure oil ports of two lift cylinders. It is near to the left lift cylinder.
(See Fig. 6.10). Speed limiting valve is used to limit the falling speed of fork when it loads
heavily. The structure is shown in Fig. 6.11.
Figure 6.10 Assembly position of speed limiting valve

Working of the speed limiting valve is described as follow:
See the figure 6.11, when lift the fork, the pressure oil from multi-way valve flows into the
A chamber and drives the valve stem to move left, therefore the opening G is opened,
which makes the pressure oil flows along two passages(A-B-G-D-E and A-B-C- D -E), both
passages oil flows into the lift cylinder . Under this condition, flow rate of oil can not be
regulated and limited. When the fork begins to fall down. The return oil discharged from lift
cylinder comes into the E chamber and push the valve stem to move right, until the valve
stem begins to contact the connector, it means that the opening G is close, therefore, the
return oil should get back to the oil tank through the throttle plate. If the oil return quantity
increase sharply, pressure in Fchamber goes up, which drives the valve core (No 5 in the
figure 6.11) to overcome the spring force and moves right, which makes the opening H
becomes narrow, so that the flow rate which flows into the C chamber from Dchamber
decreases, namely the falling speed of fork is limited ( the speed reduces).
Figure 6.11 Speed limiting valve

1. Spring
5. Valve core
9. Spring
2. Valve housing
6. Throttle plate
10. Connector
3. Disk spring
7. Snap ring
4. Nylon ball
8. Valve body
6.6.4 Tilt cylinder

Two double action tilt cylinders are mounted on the two sides of mast. Piston rod end in the front
of cylinder is connected with mast and the rear end of tilt cylinder is connected to chassis with
the pin.Tilt cylinder mainly consists of cylinder, guide sleeve, piston and piston rod.
On the outer circle of piston, there are two Yx seal rings and a pivot ring. Unde the action of
hydraulic oil, the piston moves inside the cylinder.
Two Yx seal rings and a support ring is mounted around the outer surface of piston which
moves along cylinder body by hydraulic oil.
In the internal orifice of guide sleeve, a steel- backed bearing is pressed, besides a yx seal ring
and a dust ring is mounted. The seal ring and dust ring is used to avoid oil leakage and dust
( between piston rod and guide sleeve). On the surface of the circle surface for guide sleeve, an
O ring is mounted.
When tilt control lever is pushed forward, high pressure oil flows from the bottom of cylinder to
the interior of cylinder, therefore, the piston begins to move forward and mast inclines forward
(can reach 6). When tilt control lever is pulled backward, high pressure oil flows from the front
guide sleeve to the interior of cylinder, therefore the piston begins to move backward and mast
inclines backward (can reach 12).
Figure 6.12 Tilt cylinder

1. Ear ring
8. Guide sleeve
15. Body, piston
2. Bearing 5058
9. Snap ring
16. Spacer
3. Washer
10. U-ring
17. Wearing
4. Spacer
11. O seal ring
18. Seal ring
5. Dust seal
12. Snap ring
19. Plug
6. Snap ring 72
13. Bearing5030
20. Screw
7. Snap ring
14.Tube,cylinder
7. Hydraulic system
See the table 7.1 for the main technical parameters
Tonnage
Item
5-7T
Vacuum servo
brake
Brake type
8-10T
Power brake
Power brake
Drive type
Transmission power output
Rated pressure
25 MPa
Main oil
pump
Model of front 36R/32R

CBKc-G432-AT
gear pump
duplex
Type of front fear
CBKc-G432-ATL
pump
pump
Double valve rod, slid type (
Type
valve, tilt self-lock valve
multi-way
valve
Setting pressure 20 MPa
model
CDB-F20-02
36R/4R
duplex
pump
CBHYA-G36/F3.5AT
CBKa-G436-ATL
with safety valve, distribution
CDB-F20-04c
7.1 General
Hydraulic system mainly contains oil pump, multi-way valve (the distribution valve is
mounted with multi-way valve together), high and low pressure hoses, connectors and so on.
Oil pump which is a gear pump and it is mounted on the side of transmission. When the engine
is running, it drives oil pump to suck oil from oil tank and send the oil to multi-way valve.
The safety valve in multi-way valve is used to keep the oil pressure in oil passage within the
specified value. While through control of valve rod, oil passages in the multi-way valve
changes in order to control the cylinder. Through the distribution valve, oil flows to the
steering gear is used to control the action of steering cylinder.
7.2 Oil pump
Oil pumps consist of the front and the rear pump. The front pump is the main pump, which is
used to control steering, lifting and tilting operations. The rear pump only controls the lift and
tilt movements
Oil pump, which is a gear pump, is made up of drive gear, driven gear and pump body, that is
to say, the oil pump includes two gears and other components. The drive gear meshes with the
driven gear.
7.3 Multi-way valve
Multi-way valve is a split valve. It is divided into three parts: inlet (distribution valve is
mounted at the inlet), outlet and slide valve. The three parts are mounted together by three
bolts. The distribution valve ( inlet) is mounted with multi-way valve together, which keep the
structure compact and pipeline clean.

There is a cylinder safety sleeve valve in the inlet, which is used to adjust oil pressure in the
oil passage. There is also a steering safety valve, which is used to adjust oil pressure in the
steering oil passages.
The slide valves controls lift and tilt cylinders. Through operation of lift and tilt control levers,
the oil flow changes to control the oil cylinder.
A tilt self-lock valve is mounted on the tilt slide valve, return oil from the oil cylinder gets
back to oil tank through the outlet. Each piece of valve is sealed with O seal ring, meanwhile,
a check valve in the oil passages at the pressure side.
Figure 7.1 Multi-way valve
7.4 Operation of multi-way valve

1) Middle position: (see Figure 7.2)
Oil that is discharged from main
pump gets back to oil tank through
middle passage . At this time, cylinder
ports A and B are both close.
Figure 7.2 Middle position

2) Pushing slide valve in: (see figure 7.3)
Here the middle passage is close (obstructed), oil from inlet port pushes (load) check valve
open and flows into cylinder port B. Oil discharged from cylinder port A returns to oil tank
through low pressure passages. The slide valve can get back to middle position by the
return spring.
3) Pulling slide valve out: (see Fig. 7.4)
At this time, passages in the middle position is also close. Oil from inlet port pushes (load)
check valve open and flows into cylinder port A first and oil discharged from cylinder port B
returns to oil tank through low pressure passages. The slide valve can get back to middle
position by return spring.
Figure 7.3 Pushing sliding valve in
Figure 7.4 Pulling sliding valve out
7.5 Operation of main safety valve

1)
2)
Main safety valve is mounted between high pressure port HP and low pressure passage
LP. Oil that flows through valve core C acts on two faces (A and B) with different
diameters. Therefore, both check valve core C and main safety valve core D fall into
valve seats firmly. See Figure 7.5.
When oil pressure of high pressure cylinder port exceeds the pressure regulated by spring
force, the pilot valve core E opens and oil flows around valve core and into the hole, then
the oil flows into the low pressure passages. See Figure 7.6.
Figure 7.5
3)
4)
Figure 7.6
Figure 7.7
Figure 7.8
When the pilot valve core E is open, Oil pressure behind valve core D drops when pilot
valve is open, therefore, valve core moves right and sits on pre-guide valve core E. As a
result, oil passage behind safety valve core D is cut off and the oil pressure inside falls as
well. See the figure 7.7.
Compared with cylinder port HP, the pressure inside becomes unbalanced, which results
in the opening of safety valve core D. In this way, oil at the high pressure side flows
directly into low pressure passage LP. See figure 7.8.
7.6 Operation of tilt self -lock valve

Tilt self -lock valve is used to avoid ( caused by the internal possible minus pressure in the tilt
cylinder) the the mast vibrating meanwhile, it avoids the danger of mast tilting produced by
misoperation(hit the tilt control lever) when the engine is shuted down. In the traditional
structure, although the engine stops running, mast will still incline forward for hitting the tilt
control lever. However, adopt this new type self lock valve part, mast wont incline forward in
the above situation even if push the tilt control lever roughly. See the figure 7.9 for the
structure of tilt self-lock valve. In the picture, A port is connected to the front of tilt cylinder
while B port is connected to the rear side of tilt cylinder. When pulling tilt control
lever(pulling sliding valve out), oil from oil pump flows into port A and oil at port B will
return to oil tank. Therefore mast will incline backward. When pushing the tilt control lever
( pushing sliding valve in), oil from oil pump flows into port , by means of the pressure oil,
self lock valve in the tilt slide valve acts, the port A is connected to low pressure, therefore, the
mast will incline forward. However, when the engine is shuted down, no pressure oil to make
the self-lock valve act, the port A is not connected to low pressure, the mast wont incline
forward and there is no minor pressure in the tilt cylinder.
Figure 7.9 Tilt self lock valve

T : connected to oil tank
P : connected to oil pump
A, B: connected to tilt cylinder
7.7 Control device of multi-way valve
Each slide valve of multi-way valve is controlled by each control handle. All of the control
handles are mounted on the same shaft, which is mounted on the bracket of front instrument
panel. Movement of each handle above are sent to each slide valve of multi-way valve through
the linkage.
Figure. 7.10
7.8 Oil tank

Hydraulic oil tank is on the right side of chassis. The oil suction filter of the oil pump, oil filler
with the oil dipstick are mounted on oil tank cover. See the figure 7.11.
Figure 7.11 Oil tank
7.9 Oil pipeline of hydraulic system

The schematic diagram of hydraulic system is shown in the figure 7.12.
Oil pipeline of hydraulic system is shown in Figure 7.13.
Figure 7.12 Schematic diagram of hydraulic system

The main line becomes complicated for the applying of double pumps and steering pipeline
Fittings and high pressure hoses adopt soft sealed structure of 24cone O-ring seal which has
very good seal ability and can guarantee the sealing.
Hydraulic oil discharged from the rear pump flows directly to multi-way valve, while
hydraulic oil discharged from the front pump (called master pump ) is divided into two lines
by the distribution valve for steering and loading or unloading the cargo.
The hydraulic oil for loading or unloading the cargo above flows into multi-way valve, and is
supplied for lift and tilt operation with the oil discharged from the rear pump. When the
multi-way valve is at the middle position, these hydraulic oil returns to the oil tank through
multi-way valve.
When lift control lever is pulled, oil from multi-way valve flows through speed limiting valve
and reaches the bottom of lift cylinder piston to push the piston rod. When push lift control
lever, oil pipeline between the bottom of lift cylinder piston and oil tank is put through. The
piston begins to decline for the weight of piston rod, fork carrier, fork, etc. In such situation,
oil return speed of oil which passes through the multi-way valve and returns to the oil tank
When operating tilt control lever, hydraulic oil from oil pump reaches one side of tilt cylinder
rod and drives piston to move. Oil of the other side is pushed out by piston and then it passes
through multi-way valve and gets back to oil tank.
Figure 7.13
Oil pipeline diagram of hydraulic system
7.10 Repair
7.10.1 Disassembly of multi-way valve
Remove multi-way valve from forklift and clean its exterior face.
(1) Remove the connecting bolt to separate the pieces of multi-way valve. Be careful not to
lose check valve and seal rings on joint face.
(2) Remove screws on one head side of slide valve and inner hexagon bolts on side cover.
Disassemble the slide valve included leather cup, O seal ring and seal plate from valve
body.
(3) Put the slide valve on bench vice. Remove connecting bolts fixed on cover and take
down spring and spring seat. On the tilt slide valve with tilt self lock valve, remove the
spring and valve core in the tilt self lock valve.
7.10.2 Reassembling of directional control valve
Clean all the parts that have been removed with mineral oil. Check if there is any burr or
nick. Replace the parts if necessary. After assembly, valve body and slide valve, the slide
valve and valve core should be well packed, if there is need to replace the part, replace the
whole unit.
(1) Clamp the slide valve with bench vice, then mount valve core and spring. Pay attention
to the direction of valve core.
(2) Mount O-ring, leather cup, seal plate, spring and spring seat to the end of slide valve in
order. After mounting them with covers, screw down connecting bolts of cover with a
torque of 25-32N.m.
(3) Insert the assembled slide valve assembly (one piece valve) into valve body and mount
the cover with inner hexagon bolts. The tightening torque of bolt is 9-11N.m.
(4) Fix O-ring and leather cup on the head of sliding valve and fasten the seal plate with
bolts. The tightening torque is 4.6-5.8N.m.
(5) After assembly, mount check valve, spring and O-ring on each piece of valve. Then
fasten the valve with three connecting bolts with specified torque. (The tightening
torque of one bolt is 103N.m, the other two is 66N.m.)
7.10.3
Precautions
The pressure in each safety valves in multi-way valve has been set before leaving factory.
Users should not adjust them privately during the use in order to avoid too high pressure
adjusted damaging the hydraulic system and elements. Adjust the pressure of each safety valve
correctly according to requirement of manual. During the assembly or disassembly, do not
damage the joint face of slide valve when clamping the slide valve with bench vice.
8. Electrical system
8.1 General
The electrical system is a one wire circuit with negative earth, it is the nerve system of the
truck.. The electrical system are mainly made up of the following systems. Plan of wiring for
electrical system: shown as the figure 8.1 (5-7T) , Figure 8.2 (8-10T):
Figure 8.1 Plan of wiring for electrical system (5-7T)
Figure 8.2 Plan of wiring for electrical system (8-10T)
1) Charging system
The charging system consists of generator, battery, charging indicator lamp, which supplies the
forklift electro-equipment with power supply.
2) Starting system
The starting system is mainly made up of (only for isuzu engine), start switch, start protective
circuit, starter, etc. It is used to start the engine.
3Stop control systemYUCHAI
The stop operating system of YUCHAI is composed of switch, choke relay and auto choke.
4) Instrument system
The instrument system mainly consists of hour meter, oil capacity, water temperature gauge
and charging indicator lamp, oil pressure indicator lamp, neutral indicator lamp, air cleaner
clogging alarm, etc, it is the detecting device of forklift.
5) Lighting signal equipment
It includes various lightings, signal lamps, horn, buzzer, etc.
Headlight (upper beam/dipped): 20W/35W
Front combination lamp (steering/width): 21W/4W
Rear combination lamp (steering /width /backup/stop): 21W (red ) / 5W (red) / 10W
(white) / 21W (yellow)
Warning lamp (optional): 21W
Rear headlamp (optional): 70W
Registration plate light (optional): 10W
8.2 Brief introduction of operation
1Starting
Shift the shift control lever in neutral position
before starting the engine(at this time the
neutral shift indicator lamp is on). Otherwise,
the engine will not be started, since safe
starting protective function for forklift is
designed in the starting protective circuit.
Turn the start switch clockwise to gear I
(electrifying gear), then the power supply of
instrument system will be switched on. Gear
schematic diagram of start switch is shown in
figure 8.3
Figure. 8.3 Gear schematic diagram

of start switch
Turn the start switch clockwise to gear(starting gear) , the engine will be started up.
After startup the engine, push the shift control lever forward, namely in the forward gear,
accelerate the throttle, the forklift will travel fast or work quickly. If pull backward the speed
rod, namely in the reverse gear, at this time, the backup lamp will be on, and the backup
buzzer will sound alarm.
2Lamp switches: Shift in gear I, front and rear width is on. Shift in gear II, front
headlamp and width lamp will be on. Shift in gear , the upper beam and width lamp
headlamps will be on.
3Steering signal: When pulling backward the steering lamp switch, steering signal lamps
of front and rear combination lamps on the left of forklift will flash. Push the steering
lamp switch forward, steering signal lamps of front and rear combination lamps on the
right side of forklift will flash.
4Brake signal: When there is need to brake the forklift, step the brake pedal, rear
combination lamp brake lamp will be on (red).
5Reverse signal: When there is need to reverse the forklift, pull the speed rod backward,
at this time the speed rod in in the reverse gear, rear combination lamp reverse lamp will
be on (white), the backup buzzer sounds alarm.
6Non-charging signal: before starting up the engine, turn the starting switch clockwise to
the gear I ( electrifying gear ), at this time the charging indicating lamp will be on. After
starting up the engine, the lamp will be off automatically. If the engine is under the
working state, the charging lamp is on, which indicates the charging circuit is out of
order and can not work, stop the forklift and perform the inspection.
7Engine oil pressure signal: Before starting up the engine, rotate the starting switch
clockwise to the gear I ( electrifying gear), at this time, the oil pressure indicator lamp
will be on. After starting up the engine, it be off automatically. If the engine is under the
working state, the oil pressure is on, which indicates that the oil pressure of engine is too
low and lubrication is poor, stop the forklift to perform the insection.
8 Water sediment ( oil and water separator) signal display: before starting up the engine,
rotate the starting switch clockwise to the gear I (electrifying gear), at this time, water
sediments signal indicator lamp will be on, after starting up the engine, the signal lamp
will be off automatically. During the operation of engine, if this warning lamp is on, it
means that the seeper in the oil and water separator exceeds the warning level, drain the
seeper, then the signal lamp will be off automatically.
9Fuel meter: indicates the oil capacity of oil in fuel tank.
10Water temperature meter: It shows the temperature of engine coolant.

11Hour meter: It accumulates the engines working hours.
Schematic diagram of instrument is shown in Figure 8.4.
Fig. 8.4 Combined instruments

1.Water temperature gauge
5. Charging indicator lamp
9.Right steering indicator
2. Left steering indicator lamp
6. Neutral indicator lamp
10. Fuel meter
3. Oil and water separator
7. Preheat indicator lamp
11. Hour meter
4. Oil pressure indicator lamp
8. Air filter indicator lamp
8.3 Battery
Precautions during the use of battery:
1) The battery can produce combustible gas, which may cause explosion. Therefore short
circuit and sparks should be avoided, fireworks are strictly prohibited.
2) The electrolyte is dilute sulfuric acid, it is very dangerous (burning, blindness) to contact
the skin or the eye. When the electrolyte is splashed on the skin, flush them with water
immediately. And if it is splashed into the eye, flush them with water and see the doctor
in time.
8.4 Wiring harness

8.4.1 Comparison table of wire color
B
black
red
green
yellow
blue
white
brown
purple
GYGRGWWBYRRYRBUBdenote double color wire. The former occupies

two thirds and the later occupies one third. The Arabic number in front of the double color
code represents the rated section area of wire, for example 5BR shows the wires rated
section area is5mm2.
8.4.2 Allowable current value with load of low pressure wire rated section
Sectionm
1.0
1.5
2.5
3.0
4.0
5.0
6.0
Carrying capacityA
11
14
20
22
25
25
35
8.4.3 Model and wiring harness

Model
5-7T
8-10T
Wiring harness of instrument
Wiring harness of engine
Wiring harness of overhead guard
Name
Wiring harness of vehicle body
Wiring harness of front lamp
Wiring harness of electrical element
See figure 8.5-8..12
8.5 Wiring harness of instrument (5-7T)
8.6 Wiring harness of instrument (8-10T)
8.7 Wiring Harness of engine (5-7T)
8.8 Wiring harness of front overhead guard (5-7T)
8.9 Wiring harness of front overhead guard (8-10T)
Figure 8.10 Wiring harness of bodywork (8-10T)
Figure 8.11 Wiring harness of front light (8-10T)
Figure 8.12 Wiring harness of electric organ (8-10T)

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Operators, equipment managers and technicians, please read the Manual!

China LONKING (Shanghai) Forklift Co., Ltd.

Chapter 1 Safety regulations of driving and operation

4. Preparation before operation

6. Sketch map of gauges and controls

1. Water temperature meter

15. Steering wheel

9. Lift control lever

16. Extinguish cable

10. Tilt control lever

17. Shift handle

11. Accelerator pedal

18. Motor cover cable

12. Rubber floor

19.Parking brake handle

13. Service brake pedal

7. Turn lamp switch

14. Inching pedal

a. The travel of brake pedal should be within 40mm.

when the parking brake handle is pulled to the limit.

Specification and Use temperature

-20open cold area

6# hydraulic drive oil

L-HM32 wearable hydraulic oil

3# general lithium based grease-20+120

RASA: Width of right-angle aisle for stacking

a: Clearance b: Load length

LG60DT LG70DT LG80DT LG100DT

h1 Max lift height

h3 Free lift height

L1 Overall lengthwith fork

h2 Mast lowered height

h4 Overhead guard height

R1 Min. turning radius

Ra Min. right angle aisle width

Max. lift speed(full load/unload)

Mast tilt angle

Max. travel speed(full load/unload)

m2 Masts min. ground gap

m1 Frames min. ground gap

Working oil tank capacity

Fuel tank capacity

Distance from seat SIP to

Chapter 3 Introduction of main components

engine mount, fuel, exhaust air intake and cooling system

steering wheel, hydraulic steering control unit, steering axle,

Accelerator pedal,soft shaft and bracket,etc

Brake & inching

hand brake & rod,etc

frame, counter weight,drag pin,etc

mast, fork, Fork carrier , backresttilt cylinder, lift cylinder, lift

instrument panel, engine cover, radiator cover, toolbox, floor

Overhead GuardCab is an optional unit

electrical elements such as horn ,lamps,switch, battery, gauges,

transmission, transaxle, shift control, etc.

Nameplate, capacity chart, lubrication chart, etc

Chapter 4 Forklift structure, principle, adjustment and maintenance

Figure 1.1 Engine Installation

1.2 Engine configure

Diesel engine YUCHAI 6BG1

Four stroke, water-cooling, line, top ventilator type

Total displacement (1)

Rate power (kw)

Max. torque (N-m/rpm)