FOREWORD

This manual states the performance, structure, safe operation and regular
maintenance of the “HELI” H2000 series forklift truck from 5t-10t so as to help the
operators, mechanics and supervisors of forklift truck operate correctly and attain the
highest function. It is necessary to read over the manual before operating.
If any operation or maintenance does’t accord with requires in this manual, our
related promises is inefficacy.
Due to continuous improvements in design, it is possible that the latest description
contained herein may differ slightly from the truck delivered to you. Moreover, the
specification of the forklift truck may be changed insignificantly depending on its
destination.
NOTE: The"Model" in this MANUAL is different from the "Model" on the name plate
and the certificate of quality. The "Model" in this MANUAL includes "Model" and
"Configuration No." on the name plate and the certificate of quality.

CPCD50 - W2

Configuration No.

Model
 CONTENTS

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

Ⅱ. Primary Technic Parameter of Forklift 7
Ⅲ. Primary Assembly Introduce of Forklift 22
Ⅳ. The Structure, Principle, Adjustment and Maintenance of Forklift 23
1. Dynamic System 23
1.1 Fuel system 26
1.1.1 Fuel tank 26
1.1.2 Fuel sender 26
1.1.3 Fuel filter 28
1.2 Cooling system 28
1.3 Inspection and adjustment 28
1.3.1 Air cleaner 28
1.3.2 Oil filter(fuel) 29
1.3.3 Oil filter(machine oil) 29
1.3.4 Cooling system 30
1.3.5 Tightening the cylinder head bolts of engine 31
1.3.6 Adjustment of clearance of air gate 31
1.3.7 Confirmation of the ignition time of oil injectio 32
1.3.8 Adjustment of ignition time of oil injection 33
1.3.9 Measurement of the compression pressure 33
1.3.10 Exhaust air of oil injection pump 34
2. Electric System 35
2.1 General 37
2.2 Lamp switch 37
2.3 Battery 39
2.4 Wire harness 38
3. Transmission System 72
3.1 General description 74
3.2 Torque converter 74
3.3 Oil pump 75
3.4 Hydraulic clutch group 76
3.5 Control valve & inching valve 77
3.6 Hydraulic circulation system in tor-con 78
3.7 Cautions when the forklift truck trouble occurs 80
3.8 Trouble shooting 80
4. Drive Axle 84
4.1 General description 84
4.2 Differential 84
4.3 Hub reduction gear 88
4.4 Trouble shooting 89
4.5 Data use for service 89
5. Brake System 90
5.1 General description 91
5.2 Power brake 91
5.2.1 Brake pedal device 91
5.2.2 Brake valve 93
5.2.3 Accumulator 95
5.3 Vacuum servo brake 95
5.3.1 Vacuum booster and main brake cylinder assembly 96
5.3.2 Installation method for vacuum booster and main brake cylinder assembly 98
5.3.3 Points of attention for users 99
5.3.4 Trouble shooting and cause analysis 99
5.4 Travel brake 99
5.4.1 Travel brake(5-7t forklift truck) 100
5.4.2 Travel brake(8-10t forklift truck) 103
5.5 Stop brake 104
5.6 Trouble shooting 106
6. Steering System 107
6.1 Steering unit 109
6.2 Checking after mounting on the machine 110
6.3 Troubleshooting guide 111
6.4 Steering axle 112
6.4.1 Steering axle body 112
6.4.2 Left and right steering knuckle assembly 112
6.4.3 Wheel hub 112
6.4.4 Steering oil cylinder 112
7. Hydraulic System 115
7.1 General description 116
7.2 Main pump 116
7.3 Control valve 116
7.4 Operation of control valve 117
7.5 Operation of relief valve 118
7.6 Operation of tilt lock valve 119
7.7 Operation unit of the control valve 120
7.8 Oil tank 121
7.9 Hydraulic circulation system 122
7.10 Maintenance 122
8. Lift Cylinder & tilt cylinder 125
8.1 Lift cylinder 125
8.2 Cut-off valve 128
8.3 Flow regulator 128
8.4 Tilt cylinder 130
9. Hoist System 132
9.1 General description 133
9.2 Outer & inner mast 133
9.3 Lift bracket 133
9.4 Adjustment of hoist system 133
9.4.1 Adjustment of shims of lift cylinder 133
9.4.2 Carriage adjustment 134
9.5 Roller position of mounting 135
 Ⅰ. Safety Rules for Operation and Daily Maintenance of Forklift Truck
It is important that driver and manager for forklift trucks remember the principle of
the “first safety” and ensure the safety operation as the description in 《OPERATION
AND SERVICE MANUAL》.
1. Delivery of Forklift Truck
Pay attention to the following items when you deliver forklift trucks with container or
truck.
(1) Apply the parking brake.
(2) Fix the mast and the balanceweight with steel [Link] up all wheels.
(3) Sling points should be always at the positions specified in sling index plate when
hoisting up the forklift truck.
2. Storage of Forklift Truck
(1) Drain off fuel completely. Don’t drain off the cooling water containing antifreeze
and rustproof agent.
(2) Apply antirust to the surface of the parts not painted. Apply lubrication oil to the
lift chain.
(3) Lower the mast to the lowest position.
(4) Apply the parking brake.
(5) Wedged up the wheels.
3. Precautions Before Operation
(1) Don’ t check fuel leakage and lever or instruments at the place where there is
open flame. Never fill the fuel tank with the engine running.
(2) Check the tire inflation pressure.
(3) The forward-reverse lever should be in neutral.
(4) Never smoke while the fuel system is under working or the battery is inspected.
(5) Check all the levers and pedals.
(6) Complete the provisions before starting.
(7) Release the parking lever.
(8) Make trying opteration of the mast for lifting, lowing and Fwd/Bwd tilting and the
truck for steering and braking.
4. Operation of Forklift Truck
(1) Only trained and authorized operator shall be permitted to operate the truck.
(2) Wear all the safety guards, such as shoes, helmet, clothing and gloves while
operating the truck.
(3) Check all the control and warning devices before starting the truck. If any
damages or defects are found, operate it after repairing.
(4) Overload or overload operation is strictly prohibited. The fork should insert

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completely under the cargo and make the cargo placed on it evenly. Do not raise an object
with one fork end.
(5) The starting, turning, driving, braking and stopping operation of the truck should
be done smoothly. When steering on the humid or low friction road, the truck should be
decelerated.
(6) Travel with loads as low as possible and tilted backward.
(7) Be careful when traveling on a slope. When climbing grades with a slope more than
10%, the truck should forward travel, and when descending so grades, backward travel.
Never turning on a slope. Avoid loading and unloading operation when decending.
(8) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay attention
to the clearance over forklift truck.
(9) Never allow any persons to stand on the forks or the truck to carry persons.
(10) Never permit anyone to stand or walk under upraised forks.
(11) Don’t operate truck and attachment of it at any position out of the drive seat.
(12) If the goods are lifted more than 3m, be careful that the goods on it should not fall
down or the protection measures must be taken if necessary.
(13) Tilt the mast of the high lift forklift truck as backward as possible while the truck
working. Use minimum forward tilt angle and Min. reverse tilt angle when loading and
unloading.
(14) Drive slowly and carefully over a dockboard or bridge plate.
(15) Shut down the engine and don’t stay on the truck when filling fuel. Don’t ignite
the engine while checking battery or fuel lever.
(16) The unloaded forklift truck with attachments should be operated as a loaded
truck.
(17) Don’t handle unfixed stacked goods. Be careful with bulky goods to be handled.
(18) If leaving the truck, lower the forks to the ground and let the shift lever to neutral,
shut down the engine or cut down electric supply. If parking on a slope is unavoidable,
apply the parking brake and block the wheels.
(19) Don’t open the radiator cap when the engine is worm.
(20) Don’t adjust the control valve and relief valve at will to prevent the damage of
hydraulic system and its components because of excessive pressure passing them.
(21) The test for the maximum radiation noise outside the body of the forklift shall be
carried out according to the noise standard of EN 12053.
(22) Notice and be familiar with all kinds of decals’ function.

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5. Arrangement Sketch of Instruments and Controls

1 3 2 4 7 6 8

12
5

17
13
10
18
11
9

14 15 16

1. Fuel gauge 10. Lift lever

2. Monitor 11. Tilt lever
3. Water [Link] 12. Parking brake lever
4. Hour meter 13. Forward-reverse lever
5. Ignition switch 14. Inching pedal
6. Lamp switch 15. Brake pedal
7. Horn button 16. Acceleration pedal
8. Turn signal switch 17. Cable of cover
9. Steering handwheel 18. Cable of extinguish

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 6. Daily Maintenance of Forklift Truck
6.1 Caution for starting
(1) The amount of hydraulic oil:The oil level should be at the middle position between
the upper and lower scale marks of oil level meter.
(2) Check if there is any leak or damage on the piping joints, pumps and valves.
(3) Check the travelling brakes:
a）The free travel of brake pedal should be within the range of 40mm.
b）The clearance between the front floor and the pedal should be bigger than 20mm.
(4) Often check the parking [Link] laden truck can park on the 20% grade
ramp,when the parking lever is pulled to the bottom.
(5) Check the meters,lights,switches and electric wirings to see if they are properly in
operation.
6.2 Fuel and lubrication used in forklift truck.

Name Brand and temp. of using

Gasoline 93# or 97#

Brand(diesel) 0# -10# -20# -35#

Diesel
Temp. of using ≥4 ≥-5 ≥-5~-14 ≥-14~-29
Gear oil Sticky grade 5W/30 10W/40 10W/30 15W/40
(gasoline,SF) Chang cheng
Electric
injection(SG) Temp. of using -30～+30 -25~+40 -25~+30 -20~+40

Sticky grade 5W/30 10W/30 15W/40 20W/50

Gear oil
Chang cheng
(diesel,CD)
[Link] using -30～+30 -25~+30 -20~+40 -15~+50

Sticky grade L-HM32 wearable L-HV32 low temp.

hydraulic oil wearable oil
Hydraulic oil Chang cheng
Temp. of using ≥-5 ≥-20(cold region)
Torque Hai pai 6# Tor-con oil
converter oil
Chong qing 4604 compound brake fluid GB12981 HZY4
Brake fluid yi ping
Lubricating oil Hai pai 3# lithium base grease(-20℃~+120℃)

Gear oil of Sticky grade 85W/90GL-5 80W/90GL-5

heavy-laden Hai pai
vehicle Temp. of using -15～+49 -25~+49

Number FD-1 FD-2 FD-2A FD-3

Antifreeze fluid Jin bai
Temp. of using ≥-25 ≥-35 ≥-45 ≥-50

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 6.3 Cautions on cooling system
(1) During operation, if the radiator of forklift “boils” or the temperature of cooling
liquid is too high, do not open the cover of radiator immediately. If the cover needs to be
removed to find out the cause for it, reduce the rotational speed of engine to the moderate,
slowly rotate the cover and not remove it very soon so as to prevent operators from being
scalded by the splashing liquid. When recovering the radiator, it must be screwed tightly,
otherwise, the system may not be well enclosed and the system pressure stipulated cannot
be formed.
(2) There is a compensation can on the left of [Link] letter”FULL”and
“LOW”are marked on the upper and lower end of the can [Link] antifreeze agent
level should be between marked lever. Antifreeze liquid of same type should be
replenished after the liquid leaks or evaporates, which is not changed around the year,
regardless of summer or winter. Generally, after being used for one year, it should be let
out for filtration and purification and then use again.
(3) Based on different working conditions, regularly clean the outer surface of the
2
radiator with detergent, compressed air or high-pressure water (no high than 4kg/cm ).

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6.4 Lubrication system table

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 Ⅱ. Primary Technic Parameter of Forklift

Table 1

CPCD100-WX
CPCD50-WX

CPCD60-WX

CPCD70-WX

CPCD80-WX
Item Unit

Rated capacity kg 5000 6000 7000 8000 10000

Load center mm 600
[Link] height mm 3000
Free lift height mm 205
Tilt angle (Fwd/Bwd) deg 6/12
Wheelbase mm 2250 2500 2800
Front mm 1470 1600
Tread
Rear mm 1700
Weight kg 7980 8640 9350 10960 12510
Overall width mm 1995 2165 2245
Overall height (At mast) mm 2500 2625 2700 2850
Overall length mm 4660 4735 4800 5160 5480
Min. under clearance mm 200 245
Min. turning radius mm 3250 3300 3370 3700 3900
Max. traveling speed(loaded/unloaded) km/h 29/32 26/30

Lifting Loaded mm/s 400 300 400 330

speed Unloaded mm/s 410 410 430 350
Max. drawbar pull (Loaded) kN 42 41 63.2 61
Loaded % 25 22 20 21 15
Gradeability
Unloaded % 19 21 20
Front 4 8.25-15-14PR 9.00-20-14PR
Tyre
Rear 2 8.25-15-14PR 9.00-20-14PR

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 Table 2

CPCD50-WX3

CPCD60-WX3

CPCD70-WX3

CPCD50-C8

CPCD60-C8

CPCD70-C8
Item Unit

Rated capacity kg 5000 6000 7000 5000 6000 7000

Load center mm 600
[Link] height mm 3000
Free lift height mm 205
Tilt angle (Fwd/Bwd) deg 6/12
Wheelbase mm 2250 2250
Front mm 1470 1470
Tread
Rear mm 1700
Weight kg 7980 8640 9350 7980 8640 9350
Overall width mm 1995 1995
Overall height (At mast) mm 2500 2625 2500 2625
Overall length mm 4660 4735 4800 4660 4735 4800
Min. under clearance mm 200 200
Min. turning radius mm 3250 3300 3370 3250 3300 3370
Max. traveling speed(loaded/unloaded) km/h 26/30 30/34

Lifting Loaded mm/s 510 500 390 325

speed Unloaded mm/s 530 520 450 380
Max. drawbar pull (Loaded) kN 63 62 53 52
Loaded % 38 35 32 15
Gradeability
Unloaded % 19 20
Front 4 8.25-15-14PR 8.25-15-14PR
Tyre
Rear 2 8.25-15-14PR 8.25-15-14PR

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 Table 3

CPCD100-W5
CPCD50-W2

CPCD60-W2

CPCD70-W2

CPCD80-W5
Item Unit

Rated capacity kg 5000 6000 7000 8000 10000

Load center mm 600
[Link] height mm 3000
Free lift height mm 205
Tilt angle (Fwd/Bwd) deg 6/12
Wheelbase mm 2250 2500 2800
Front mm 1470 1600
Tread
Rear mm 1700
Weight kg 7980 8640 9350 10960 12510
Overall width mm 1995 2165 2245
Overall height (At mast) mm 2500 2625 2700 2850
Overall length mm 4660 4735 4800 5160 5480
Min. under clearance mm 200 245
Min. turning radius mm 3250 3300 3370 3700 3900
Max. traveling speed(loaded/unloaded) km/h 26/28 26/30

Lifting Loaded mm/s 430 350 380 310

speed Unloaded mm/s 500 380 410 350
Max. drawbar pull (Loaded) kN 54 63.2 58
Loaded % 15 21 15
Gradeability
Unloaded % 20 21 20
Front 4 8.25-15-14PR 9.00-20-14PR
Tyre
Rear 2 8.25-15-14PR 9.00-20-14PR

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 Table 4

CPCD100-C3
CPCD50-C6

CPCD60-C6

CPCD70-C6

CPCD80-C3
Item Unit

Rated capacity kg 5000 6000 7000 8000 10000

Load center mm 600
[Link] height mm 3000
Free lift height mm 205
Tilt angle (Fwd/Bwd) deg 6/12
Wheelbase mm 2250 2500 2800
Front mm 1470 1600
Tread
Rear mm 1700
Weight kg 7980 8640 9350 10960 12510
Overall width mm 1995 2165 2245
Overall height (At mast) mm 2500 2625 2700 2850
Overall length mm 4660 4735 4800 5160 5480
Min. under clearance mm 200 245
Min. turning radius mm 3250 3300 3370 3700 3900
Max. traveling speed(loaded/unloaded) km/h 26/28 26/30

Lifting Loaded mm/s 390 325 360 260

speed Unloaded mm/s 450 380 400 320
Max. drawbar pull (Loaded) kN 53 52 51 57
Loaded % 15 21 15
Gradeability
Unloaded % 20 21 20
Front 4 8.25-15-14PR 9.00-20-14PR
Tyre
Rear 2 8.25-15-14PR 9.00-20-14PR

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 Table 5

CPCD50-WF2

CPCD60-WF2
CPCD50-C10

CPCD60-C10
Item Unit

Rated capacity kg 5000 6000 5000 6000

Load center mm 600
[Link] height mm 3000
Free lift height mm 205
Tilt angle (Fwd/Bwd) deg 6/12
Wheelbase mm 2250
Front mm 1470
Tread
Rear mm 1700
Weight kg 8640 7980 8640
Overall width mm 1995
Overall height (At mast) mm 2500
Overall length mm 4802 4660 4735
Min. under clearance mm 200
Min. turning radius mm 3250 3250 3300
Max. traveling speed(loaded/unloaded) km/h 26/28 26/30

Lifting Loaded mm/s 430 330

speed Unloaded mm/s 500 480
Max. drawbar pull (Loaded) kN 54 41.5
Loaded % 15 26 22
Gradeability
Unloaded % 20 23 20
Front 4 8.25-20-14PR 8.25-15-14PR
Tyre
Rear 2 8.25-15-14PR

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 Table 6

CPCD100-CU1
CPCD50-CU3

CPCD60-CU3

CPCD70-CU3

CPCD80-CU1
Item Unit

Rated capacity kg 5000 6000 7000 8000 10000

Load center mm 600
[Link] height mm 3000
Free lift height mm 205
Tilt angle (Fwd/Bwd) deg 6/12
Wheelbase mm 2250 2500 2800
Front mm 1470 1600
Tread
Rear mm 1700
Weight kg 7980 8640 9350 10960 12510
Overall width mm 1995 2245
Overall height (At mast) mm 2500 2700 2850
Overall length mm 4660 4735 4800 5160 5480
Min. under clearance mm 200 245
Min. turning radius mm 3250 3300 3370 3700 3900
Max. traveling speed(loaded/unloaded) km/h 26/28 26/30

Lifting Loaded mm/s 490 480 440 350

speed Unloaded mm/s 510 500 470 370
Max. drawbar pull (Loaded) kN 57 60 58
Loaded % 19 27 21
Gradeability
Unloaded % 21 19 20
Front 4 8.25-15-14PR 9.00-20-14PR
Tyre
Rear 2 8.25-15-14PR 9.00-20-14PR

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 Table 7

CPCD50-P1

CPCD60-P1

CPCD70-P1

CPCD100-P
Item Unit

CPCD80-P
Rated capacity kg 5000 6000 7000 8000 10000
Load center mm 600
[Link] height mm 3000
Free lift height mm 205
Tilt angle (Fwd/Bwd) deg 6/12
Wheelbase mm 2250 2500 2800
Front mm 1470 1600
Tread
Rear mm 1700
Weight kg 7980 8640 9350 10960 12510
Overall width mm 1995 2245
Overall height (At mast) mm 2500 2700 2850
Overall length mm 4660 4735 4800 5160 5480
Min. under clearance mm 200 245
Min. turning radius mm 3250 3300 3370 3700 3900
Max. traveling speed(loaded/unloaded) km/h 24/29 26/30

Lifting Loaded mm/s 530 510 400 360

speed Unloaded mm/s 550 540 440 380
Max. drawbar pull (Loaded) kN 60 60 58
Loaded % 34 31 29 25 21
Gradeability
Unloaded % 19 20 20
Front 4 8.25-15-14PR 9.00-20-14PR
Tyre
Rear 2 8.25-15-14PR 9.00-20-14PR

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 Table 8

CPCD50-M1

CPCD60-M1

CPCD70-M1
Item Unit

Rated capacity kg 5000 6000 7000

Load center mm 600
[Link] height mm 3000
Free lift height mm 205
Tilt angle (Fwd/Bwd) deg 6/12
Wheelbase mm 2250
Front mm 1470
Tread
Rear mm 1700
Weight kg 7980 8640 9350
Overall width mm 1995
Overall height (At mast) mm 2500
Overall length mm 4660 4735 4800
Min. under clearance mm 200
Min. turning radius mm 3250 3300 3370
Max. traveling speed(loaded/unloaded) km/h 26/30

Lifting Loaded mm/s 450 440 410

speed Unloaded mm/s 460 460 450
Max. drawbar pull (Loaded) kN 42 40 40
Loaded % 23 20 20
Gradeability
Unloaded % 19
Front 4 8.25-15-14PR
Tyre
Rear 2 8.25-15-14PR

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 Table 9

CP(Q)YD50-TY1

CP(Q)YD60-TY1

CP(Q)YD70-TY1
Item Unit

Capacity kg 5000 6000 7000

Load center mm 600 600 600
Max. lift height mm 3000 3000 3000
Free lift (without backrest) mm 205 205 205
Mast tilt angle (Fwd/Bwd) ° 6/12 6/12 6/12
Max. lifting speed (Loaded/unloaded) mm/s 350/355 350/355 340/350
Max. traveling speed (Loaded/unloaded) km/h 28/31 28/31 23/31
Gradeability (Load) ％ 24 21 18
Max. drawbar pull (Loaded) kN 44 44 44
Wheelbase mm 2250 2250 2800
Tread (F/R) mm 1470/1700 1470/1700 1470/1700
Overhang (F/R) mm 590/600 590/675 590/740
Length (with fork) mm 4660 4735 4800
Width mm 1995 1995 1995
Height (at mast) mm 2450 2450 2450
Height from seat to overhead guard mm 1120 1120 1120
Min. Turning radius mm 3250 3300 3370
Min. Underclearance (at drive axle) mm 200 200 200
Weight 7980 8640 9350
Front 8.25-15-14PR 8.25-15-14PR 8.25-15-14PR
Tire
Rear 8.25-15-14PR 8.25-15-14PR 8.25-15-14PR
Engine type GM4.3
Rated output/Speed kW/rpm 70/2300
Rated torque/Speed Nm/rpm 287/1700

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 Specifications Unit CPCD50～70-C8
Model Chaoyang 6102BG-6A
Type In-line 6-cylinder, 4-cycle,water-cooled, direct injection

[Link]-bore×stroke mm 6-102×118
Total displacement l 5.785
Compression ratio 17.5:1
Rated speed r/min 2500
Rated output kW 81
[Link]/speed Nm 353/1650rpm
Highest speed without load rpm 2800
Lowest speed without load rpm 750
Min. fuel consumption g/kWh 220

CPCD50～70-WX3
Specifications Unit CPCD50～70-WX CPCD80,100-WX
Model Wuxi CA4110 Wuxi CA6110/125-HL10

In-line 4-cylinder, 4-cycle, In-line 6-cylinder, 4-cycle,

Type water-cooed, direct injection water-cooled, direct injection

[Link]-bore×stroke mm 4-110×125 6-110×125

Total displacement l 4.752 7.127
Compression ratio 17:1 17:1
Rated speed r/min 2300 2000
Rated output kW 64 83
[Link]/speed Nm 305/1400～1600rpm 450/1400～1500rpm
Highest speed without load rpm 2530 2200
Lowest speed without load rpm 700 750
Min. fuel consumption g/kWh 230 220

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 Specifications Unit CPCD50～70-W2 CPCD80,100-W5
Model ISUZU A-6BG1QC-02
Type In-line 6-cylinder, 4-cycle,water-cooled, direct injection

[Link]-bore×stroke mm 6-105×125
Total displacement l 6.494
Compression ratio 17.5:1
Rated speed r/min 2000
Rated output kW 82.3
[Link]/speed Nm 416/1400～1600rpm
Highest speed without load rpm 2270
Lowest speed without load rpm 720
Min. fuel consumption g/kWh 222

Specifications Unit CPCD50～70-C6 CPCD80,100-C3

Model Chaoyang 6102BG
Type In-line 6-cylinder, 4-cycle,water-cooled, direct injection

[Link]-bore×stroke mm 6-102×118
Total displacement l 5.785
Compression ratio 17.5:1
Rated speed r/min 2500
Rated output kW 81
[Link]/speed Nm 353/1650rpm
Highest speed without load rpm 2800
Lowest speed without load rpm 750
Min. fuel consumption g/kWh 220

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 Specifications Unit CPCD50,60-WF2 CPCD50,60-C10
Model Weifang R4105G32 Chaoyang 6102GB-A6B

In-line 6-cylinder, 4-cycle,

Type water-cooled, direct injection

[Link]-bore×stroke mm 4-105×125 6-102×118

Total displacement l 6.494
Compression ratio 17:1
Rated speed r/min 2400 2200
Rated output kW 59 73
[Link]/speed Nm 270/1400～1600rpm 353/1650rpm
Highest speed without load rpm 2464
Lowest speed without load rpm 750
Min. fuel consumption g/kWh 243 220

Specifications Unit CPCD50～70-CU3 CPCD80,100-CU1

Model Cummins QSB4.5-C110
Type In-line 4-cylinder, 4-cycle,water-cooled, direct injection

[Link]-bore×stroke mm 4-110×120
Total displacement l 4.5
Compression ratio 17.2:1
Rated speed r/min 2200
Rated output kW 82
[Link]/speed Nm 488/1500rpm
Highest speed without load rpm 2350
Lowest speed without load rpm 750
Min. fuel consumption g/kWh 235

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 Specifications Unit CPCD50～70-P1 CPCD80,100-P
Model Perkins 1104D-44TA
Type In line 4-cylinder, 4-cycle, water cooled
[Link]-bore×stroke mm 4-105×127
Total displacement l 4.4
Compression ratio 18.2:1
Rated speed r/min 2200
Rated output kW 83
[Link]/speed Nm 418/1400rpm
Highest speed without load rpm 2400
Lowest speed without load rpm 900
Min. fuel consumption g/kWh 196

Specifications Unit CPCD50～70-M1

Model Mitsubishi S6S-T
Type In line 6-cylinder, 4-cycle, water cooled
[Link]-bore×stroke mm 6-94×120
Total displacement l 4.996
Compression ratio 22:1
Rated speed r/min 2300
Rated output kW 63.9
[Link]/speed Nm 285/1700rpm
Highest speed without load rpm 2570
Lowest speed without load rpm 800
Min. fuel consumption g/kWh 250

The supplementary of Cummins QSB4.5:

[Link] on Cummins QSB4.5
(1) It is not recommended to weld on the parts of the whole machine. If it is necessary,
pull out the connectors of the ECM and the cables of both positive pole and negative pole
from the battery. When connecting the grounded cable of the welding machine, keep the
cable more than 0.16m away from the welding parts. It is strictly forbidden to connect the
grounded cable to the ECM.
(2) The ECM will make a systematic examination on the whole engine and record

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certain data after the turning off of the engine. So turn off the supplying power which is
power switch after 30 seconds of the turning off of the key switch. If the turning off of the
power is too early, the ECM will display faults. The power of the engine will be reduced as
well.
(3) Fill up the oil filter with oil first before the installation of remote oil filter. Connect
the pipeline first, and then install the whole part.
(4) It is not allowed to flush the engine with water in case of ECM short circuit causing
by the entering of water into the electrical system.
(5) Please connect with the local Cummins dealers in time when a fault of the engine
is displayed. It is strictly prohibit from detaching the high pressure pipeline because the
maximize pressure in the high pressure chamber is up to 160MPa.
(6) Before loading, keep the machine in an idle mood 3-5 minutes after the starting of
the engine. Before turning off the key switch, keep the machine in an idle mood 3-5
minutes after full loading.
(7) It is recommended not to start the engine before the finding out of the fault code. It
is strictly prohibit from running whit high speed or load after starting.
(8) In order to protect the turbocharger, it is not allowed to start the engine without air
cleaner.
(9) 6-wire electronic throttle replaces the mechanical lever throttle, so there is no
connection between the throttle and engine operation. The reflection of throttle operation
thus becomes more sensitive.
[Link] automatic diagnostic system
Cummins QSB4.5 has a function of automatic diagnosis and alarming. If there is
something wrong with the whole machine, both the yellow warning light and the red
warning light on the instrument will flash indicating that it is need to check the whole
machine. And also fault code can be read through the red warning light flashing frequency.
Fault indications with two different colors are used according to the severity of
failure.
[ ] yellow warning light: the yellow warning light is on indicating that it needs to
troubleshoot as soon as possible.
[ ● ] red stop signal: the red light is on indicating that it needs to stop the engine and
troubleshoot as soon as possible. Do not start the engine before troubleshooting.
Check whether the current fault code exists or not .turn the key switch to "OFF"
position, and the diagnostic switch to the “ON" position, then the key switch to the "ON"
position.
If there is no record of the current fault code, the yellow warning light and red stop
signal will be on at the same time, and will be always on.

-20-
 If there is current fault code record, the yellow warning light and red stop lights will
turn on instantly, and then start flashing recorded fault code.
Fault codes will flash in the following order:
The yellow warning light lights up. After 1 to 2 seconds’ pause, the red signal begins
to flash the fault code with 1 to 2 seconds between each number.
The yellow light lights up again after the red signal finishes its flashing. And then red
signal repeats flashing the fault code.
When the whole machine is more than one fault, use the fault diagnosis switch for
page turning.
Flip the "idling adjustment switch" to the (+) position to check the next fault code;
Flip the "idling adjustment switch" to the (-) position to check the fault code before. If
there is only one fault code, the fault signal will display the one constantly in either (+)
position or (-) position.
Disconnect the diagnosis switch when the diagnostic system is not in use. If the
diagnosis switch is not turned off, ECM will not record some of the fault code.
If the diagnosis switch is not turned off after the starting of the engine, when adjusting
"idling adjustment switch", the idling of the engine will be adjusted. The idling will be
increased or decreased by 25r/min in each page up or page down .

-21-
 Ⅲ. Primary Assembly of Forklift Truck
Primary Assembly of Forklift Truck

No. Name Contents

Includes engine mounting,fuel system,exhaust system,

01 Engine System cooling system(torque converter pipelines)etc.

Includes transmission, tor-con, transmission shaft

02 Transmission System control linkages etc.

Includes axle house, half shafts, differential,

03 Drive Axle hub reduction, brake, front wheel etc.

04 Steering System Includes powered steering unit, redirector etc.

05 Steering Axle Includes axle box, steering cylinder,rear wheel etc.

Includes outer & inner mast, lift bracket, backrest, fork,

06 Hoist System tilt cylinder, lift cylinder, end roller, side roller, sheave,
chain etc.

Includes frame, cabinet,tank in frame, hood, floor,

07 Frame System counterweight, seat,cover of radiator etc.

Includes operation series of brake & inching control,

08 Operation system parking brake and accelerator etc.

Includes pump,valve,high & low pressure oil pipe,

09 Hydraulic system connecter,etc.

10 Electric system Includes lights,battery,instruments harness,meter etc.

11 Overhead guard Overhead guard(cab is option)

-22-
 Ⅳ. The Structure, Principle, Adjustment and Maintenance of Forklift
1. Dynamic System
(1) Brief introduction
The dynamic system includes the engine, air inlet system, cooling system and exhaust
system, etc. The engine is linked to transmission device. The holder of engine is connected
with the frame of the forklift through a rubber cushion to reduce vibration. The engine is
connected to the tor-con,the transmission,transmission shaft and drive axle,see following
figure:

Transmission shaft

Transmission

Drive axle

Fig.1.1 Engine mounted

(2) The engine and its accessories

The power of 5-7t forklift truck is provided by diesel engine ISUZU(6BG1),
CUMMINS(B3.3,QSB4.5), PERKINS(1104D), MITSUBISHI(S6S-T). The homeland diesel
engine includes Chaoyang(6102BG),Weifang(R4105G32), Wuxi(CA4110).
The power of 8-10t forklift truck is provided by diesel engine ISUZU (6BG1),
CUMMINS(4BTAA3.9, QSB4.5), PERKINS(1104D). The homeland diesel engine includes
Chaoyang(6102BG), Wuxi(CA6110).
Refer to relevant manual for the details of operation and maintenances for the engine.
The structure figure of ISUZU(6BG1) engine as following:

-23-
 Fuel filter Generator

Oil injection hole

Grease fdter
Grease Start motor
compress SW.

Fig.1.2 A-6BG1QC diesel engine

Name A6BG1QC
4-cycle,water-cooled, in line,overhead
Type valve system
[Link]-bore×stroke 6-105mm×125mm
Total displacement (L) 6.494
Compression ratio 17
Performance
Rated speed (rpm) 2000
Rated output (kW) 82.3
[Link] (Nm/rpm) 416/1400-1600
Full-load fuel rate (g/kWh) 233
Idle(rpm) 700
Weight(kg) 450
Measure(mm) 1129.5×672.0×860.0
Ignition order 1-5-3-6-2-4
Rotating direction Clockwise

-24-
Valve device Overhead
Fuel device
Injection pump Boshing
Plunger piston radiu×stroke 9.5mm×8mm
Injection nozzle Porous type
Oil pump Plunger piston type
Fuel filter Paper filter core
Governor
Governing method Centrifugal,all-speed control
Lubricating method Forced lubrication
Lubricating device
Pump type Gear pump
Driving method Camshaft drive
Hydraulic regulator Piston spring type
Oil pressure indicator Switch type
Filting method Full-fluid,filter-paper
Radiator Water cooling,inner store type
Cooling device
Cooling method Water cooling
Cooling fan Outside radiu 550mm,7-blade,pusher type
Drive method Belt driving
Pump type Vortex type
Driving method Belt driving
Water [Link] Wax pellet type
Water [Link],open temp. 82℃
Water [Link],full-open temp. 95℃
Start motor
Type Engage magnet type
Voltage 24V
Output 4.5kW
Flameout device Fuel cut-off
Preheating device provided
Charging generator
Type AC,diode commutated generator

-25-
 Voltage 24V
Output 25V
Driving method Belt driving
Automatic charging regulator IC type(inside engine)
Referrence data
Oil disc oil quantity Max:12l,Min:10l
Cooling water 12l
Valve clearance
Suction valve 0.4mm(cold)
Exhaust valve 0.4mm(cold)
Valve opening and closing timing
Suction valve opening 19°before T.D.C.
Suction valve closing 47°after B.D.C.
Exhaust valve opening 57°before B.D.C.
Exhaust valve closing 15°after T.D.C.
Injection timing 14°before T.D.C.
Injection starting pressure 185kg/cm 2
Compression pressure 31kg/cm 2(200rpm)

1.1 Fuel system

The fuel system is composed of fuel tank, filter and fuel sensor.
1.1.1 Fuel tank
The fuel tank of welding structure is connected into one body with frame and placed at
the left side of frame. There is an oil tank cap plate on which the fuel sensor is mounted.
Refer to Fig. 1.3.
1.1.2 Fuel sensor
The function of fuel sensor is to convert the oil stored in the fuel tank into current
through up and down movement of float, which will be finally displayed on the fuel meter
on the instrument panel so that people can directly know the quantity of oil inside the fuel
tank. Refer to Fig. 1.4.

-26-
 Filling oil cap
Fuel sensor

Full

Empty

Flowing
to injection pump

Fig.1.3 Fuel box

Fuel meter

to fuel meter

Fig.1.4 Fuel sensor unit

-27-
 1.1.3 Fuel filter
The fuel filter is mounted on the fuel-feeding manifold of engine and used to filter the
fuel supplied to engine. The bypass valve is mounted inside filter , which can supply fuel
to engine in case of obstruction of filter element.
1.2 Cooling system
The cooling system is made up of water pump, fan, water tank and auxiliary water
tank. The water pump is mounted on the engine and crankshaft drives the work of water
pump through V-shaped rubber tape.
1.3 Check and adjustment
In order to keep the engine in good working state, it is necessary to make regular
check and adjustment and the main points are as follows:
1.3.1 For air filter, please See Fig. 1.5.
(1)Take out filter element
(2)Check the dust and damage state of the filter element. The lower pressure air is
used to blow from inside to outside for purging and replace the filter element with a new
one if it can’t be cleaned due to serious obstruction or damaged.
(3)Clean off the dust inside the cap.

Intake air
Core
Tache

to engine

Indicator
Body Cap

Fig.1.5 Air cleaner

-28-
 1.3.2 For fuel filter, See Fig. 1.6.
(1) Dismantle it with the spanner Side passage valve
specially used for filter and change it if it
is damaged and obstructed.
(2) Mount it after applying a few drops
of fuel oil around the sealing ring of the
new fuel filter and screw in 2/3 turns after
the sealing ring contacts with the main
body of the fuel filter.

Core

Fig. 1.6

1.3.3 For the machine oil filter, See

Fig. 1.7.
(1)Dismantle it with a spanner Core
specially used for fuel filter and change it.
(2)Mount it after applying a few drops
of lubricating oil around the sealing ring of
the new filter and screw in 2/3 turns after
the sealing ring contacts with the machine
body.

Fig. 1.7

-29-
 1.3.4 Cooling system
(1) Check the cooling liquid of auxiliary water tank
For auxiliary water tank, refer to 1.8. When the cooling liquid is lower than making
line of “ LOW”, it indicates that the supplementation amount in the water tank is small
and the cooling liquid needs to be added. The cooling liquid should be added to the 2/3
graduation of upper and lower marking lines during cooling down.
(2) Replacing cooling liquid
a) Open the water tank cover after cooling
when the machine stops for over half an hour
and loosen the water drainage valve at the
lower part of water tank.
b) Loosen the water drainage valve of
engine and thoroughly drain dry the cooling
liquid.
c) The above two water drainage valves
should be tightened after drainage.
d) Fill in the specified cooling liquid and
check if the level of auxiliary water tank is at
2/3 of the upper and lower graduation lines
after running at slow speed. Fig. 1.8

(3) Adjust the belt of fan and tighten if it is

loosened. Refer to Fig. 1.9.
Steps： Loosen the fixed bolt B and C of
the generator, move it towards outside, press
down the belt at place A with finger with 10kg
force. Its flexibility is about 10 mm and then
tighten the B and C bolts in proper order.

Fig. 1.9
-30-
 1.3.5 Tightening the cylinder head bolts Smearing grease
of engine
(1) Tighten the cylinder head bolts one
by one with 68 Nm moment according to the
order shown in Fig. 1.10. Front
side

Fig. 1.10
(2)Increase the tightening moment to 93 Nm and tighten the bolts one by one.
(3) Then turn each bolt 90°and screw tightly.
1.3.6 Adjustment of clearance of air gate
(1) Turn the crankshaft clockwise and make the “TC” mark of belt wheel shock
absorber coincide with the needle.
(2) Open the manhole cover and confirm the mark of the bottom plate and position of
the needle. If the mark of the bottom plate
coincides with the needle position, it
indicates the upper dead point on the
compression stroke of the first cylinder, Pointer

adjust the clearances of the air gate with

“△ ” and “ ※ ” as well. The clearance
value of the air gate： 0.4mm (When it is
under cooling state, the air suction and
exhaustion are of the same value.)For details,
please refer to Figs 1.11,1.12,1.13 Fig. 1.11

Pointer

Floor mark

Fig. 1.12 Fig. 1.13

-31-
 For the concrete adjustment table, refer to Table 1.2.
Table 1.2
Air cylinder
Sequence No. 1 2 3 4 5 6

Valve sequence No.

I: Suction valve I E I E I E I E I E I E
E: Exhaust valve
Dead point at
compression stroke △ △ △ △ △ △
of the 1st cylinder
Dead point at
compression stroke ※ ※ ※ ※ ※ ※
of the 6th cylinder

1.3.7 Confirmation of the ignition time of

oil injection
Flange bracket
(1) First make sure if the“assembly
marks”on the flange of oil injection pump are Cap bracket
in conformity with each other, See Fig. 1.14.

Countermark

Fig. 1.14

(2)Place the first cylinder at the dead

point position of compression stroke and turn
the crankshaft about 30 °from this position.
See Fig. 1.15. Turn left

Fig. 1.15

-32-
 (3) Loosen the oil injection pipe of the first
cylinder; dismantle the spring of dump valve
bracket and the valve. Mount the dump valve
bracket on the oil injection pump. See Fig.1.16. Relief valve support

Fig. 1.16

Pointer
(4)While the fuel is compressed and
delivered by oil supply pump, turn slowly the
Mark
crankshaft clockwise as shown in Fig.1.16 and Ignition
time mark
stop turning it when the oil level of dump valve
base raises to the position it stops. See Fig.
1.17 to confirm the marks of the needle.
1.3.8 Adjustment of ignition time of oil
injection Fig. 1.17

(1) Dismantle the pipes mounted on the oil injection pump (fuel and lubrication oil)
(2) Loosen the mounting bolts of oil injection pump.
(3) While making sure the ignition time according to the main points of 1.6.7, adjust it
in the direction far away from the engine in case of “ Ahead of time” and adjust in the
direction close to the engine in case of “delay”.
(4) After adjustment, screw tight all the assembly bolts of oil injection pump and
confirm again the ignition time.
(5) Assemble the oil discharge valve used for the first cylinder and mount each pipe
on their original and respective positions.
1.3.9 Measurement of the compression pressure (See Fig.1.18)
(1) Dismantle completely the heat spark plug and oil injection pipes.
(2) Mount the manometer on the assembly positions of the heat spark plug of the first
2
cylinder. ( The nominal valve is 500N/cm )；
(3) Start the device with battery of sufficient electrical power and measure the
pressure at this time.
(4)Measurement is made with the same method to the 6th cylinder, over twice for each,
then calculate their respective average values: Compressed pressure： 304N/cm 2
2
(Limiting value 255N/cm ) .

-33-
 Fig. 1.18

1.3.10 Air exhaust of oil injection pump (See Fig.1.19)

(1) Loosen the exhaust plug of oil injection pump.
(2)Operate slowly the manual pump till no air bulbs come from the exhaust plug.
(3)Then tighten the air exhaust plug.

Fig. 1.19

-34-
 2. Electric System
2.1 General
The electric system for this forklift truck is of the single-pole type, in which the frame
of the truck provides the return path for the electricity. The electric system seems like
“the nerve centre” of the truck and it mainly consists of the following :
2.1.1 Charging devices
This devices contains generator, battery,charging indicator, etc. It supplies electric
energy for all the electric devices.
Voltage: 24V
2.1.2 Start system
This system mainly consists of automatic pre-heating unit, key switch, start
protection circuit, start motor, etc. The function of this system is starting the engine.
2.1.3 Stop system(use for ISUZU,CUMMINS, PERKINS and MITSUBISHI diesel
engine)
Stop system(use for ISUZU engine) consists of key switch,flameout and automatic
flameout [Link] system(use for CUMMINS, PERKINS and MITSUBISHI diesel
engine) consists of key switch and shut-off fuel valve.
2.1.4 Instruments
It mainly consists of hour meter, fuel meter, water temperature meter, charging
indicator, oil pressure indicator, neutral indicator, warning lamp of air cleaner etc. They
are all checking instruments of the forklift truck.
2.1.5 Lighting and signal instruments
They include all kinds of illuminating lamps, signal lamp, horn and buzzer, etc.
Headlight: 35W
Front lamp: 70W
Front combination lamp(turning/front): 21W/8W
Rear combination lamp:(turning/rear/reverse/braking):21W(red)/8W(red)/10W
(white)/21W(red)
Warning lamp:(optional)21W
Rear lamp:(optional)70W
Licenese lamp:(optional)10W

-35-
 Battery

Starter
Preheat plug
Fuse Starter sw. table
Starter sw.

Relay Hour meter

Relay
Neutral sw. Neutral indicating
Backup sw.
Backup lamp

Turning lamp
Generator Lamp sw. table
Turning lamp sw.

Water temp. meter

Charging
Voltage adjuster indication

Fuel meter
Fuel meter sensor

Oil pressure signal

Air cleaner signal
Water deposit sw. Water deposit signal
Lamp sw.
Front lamp

Width lamp

Backup lamp

Horn button Horn

Fig.2.1 Electric principle

-36-
 2.1.6 Starting
There is a starting protection circuit in the shiftlever of the forklift truck. You have to
shift the shiftlever in neutral before you start the engine. Otherwise，you can not start the
engine.
Turn the key switch anti-clockwise to the “H”position (pre-heating position),the
air of the engine is heated to benefit for starting. Turn the key switch clockwise to the
first“ on” position， the instrument circuit and the ignition circuit are ready for work.
The key switch as follows:

Fig.2.2 Key switch

Turn the key switch clockwise to the second “on”position(starting position), then
start the engine.
Release the brake switch before starting, Otherwise， the forklift truck can not step
because the drive unit is cut off.
After engine starting， push the shiftlever forward (that is in forward shifts)， then
pedal accelerator shift，the forklift truck runs faster and you can begin to work. When pull
the shiftlever backward(that is in reverse shifts)， the back lamp is on and the buzzer
sounds.
2.2 Lamp switch
2.2.1 Turn the lamp switch clockwise to the first “on” position, the front and rear
width lamps turn on; turn the lamp switch to the second “on: position, the headlight turns
on and the front and rear lamps keep on.
2.2.2 Push the turning switch backward, the left turning lamps on the front
combination lamp and the rear combination lamp flash，Pull the turning switch forward,
the right turning lamps on the front combination lamp and the rear combination lamp flash.
2.2.3 Brake signal：When you step on the brake pedal, the brake lamps (red) in the
rear combination lamp are on.

-37-
 2.2.4 Reverse signal：When you need to reverse the forklift truck ,pull the shiftlever
backward and the transmission is in reverse shift. Then the reverse lamps (white) in the
rear combination lamps are on and the buzzer sounds.
2.2.5 Charging signal： Before you start the engine, put the key switch to the first
“ on” position and the charging lamp is on. After engine starting, the charging lamp is
automatically off. If the charging lamp becomes on while the engine is working , it means
something is wrong with the charging circuit and you must stop working and check the
charging circuit as soon as possible.
2.2.6 Oil pressure signal： Before you start the engine, put the key switch to the
first“ on” position and the oil pressure alarm lamp is on， After engine starting, the oil
pressure alarm lamp is automatically off. If this lamp becomes on while the engine is
working , it indicates low lubricating oil pressure and you must stop working and check the
lubricating system as soon as possible.
2.2.7 Fuel meter：It indicates how much fuel is left in tank.
2.2.8 Water temperature meter：It indicates the temperature of the engine coolant.
2.2.9 Hour meter：It indicates how many hours the engine has worked .

6 3 5 4
7
2 1

1 234 5 .6

23:20

Fig.2.3-1 908 type combination meter

[Link] meter [Link] temp. meter [Link] meter [Link] cleaner indicator
[Link] gear indicator [Link] indicator [Link] pressure indicator

-38-
 Fig.2.3-2 H2001 type combination meter
[Link] meter [Link] temp. meter [Link] meter [Link] cleaner indicator
[Link] gear indicator [Link] indicator [Link] pressure indicator

2.3 Battery
▲Notice
(1) The battery will produce combustible air which has a danger of explosion. Avoid
short circuit and the produced spark. Firework should be kept away from the battery.
(2) The electrolyte is a sparse vitriol，it is dangerous if skin or eye touches it. If skin
touches electrolyte,it must be flush with the water immediately, While eye touches it, flush
with water and see a doctor immediately.
2.4 Wire harness
(1) The wire harness colour corresponding table:

B R G Y L W Br Lg P V
green yellow Light pink
black red blue white brown green violet

The GY, GR, GW, WB, YR, RY, RB, LB etc. means two colors line, the former’s
quantity occupies 2/3, and the latter’s quantity occupies 1/[Link] number before the two
colour means section area.
(2) Laden current of low pressure wire harness allowing
Section
2 0.5 0.8 1.0 1.5 2.5 3.0 4.0 5.0 6.0
area(mm )
Laden
current(A) 11 14 20 22 25 25 35

-39-
 3) Forklift truck type and wire harness
2.5 Operator presence system(OPS)
Operator presence system(OPS) has two functions:
(1)Lock the transmission
When the OPS detects the driver leaving the seat for five seconds, it will disengage
the transmission to cut off the power; when driver seats back and the seat switch is closed,
the direction lever is shifted to neutral position, then the lock status can be released.
(2)Warning indication
When the OPS detects the driver leaving the seat for one second, the OPS alarm will
make a warning sound as "BEE", in the mean time the warning light will show on the dash
display; the warning light will be always on during the driver absence, it means the forklift
is locked on the transmission. When the driver seats back the forklift will be still locked if
the direction lever is not put into neutral position, in that case the OPS alarm will make a
continuing warning sound as "BEE...."
Attachment：wiring harness show in Fig.2.4-Fig.2.34:

-40-
 Fig. 2.4 Cabinet wire harness
(CPCD50～100-W,CPCD50～70-WX for normal control valve)

-41-
 Fig. 2.5 Cabinet wire harness
(CPCD50～100-W for electric-hydraulic valve)

-42-
 Fig. 2.6 Engine wire harness
(CPCD50～70-W for normal control valve)

-43-
 Fig. 2.7 Engine wire harness
(CPCD50～70-W for electric-hydraulic valve)

-44-
 Fig. 2.8 Engine wire harness
(CPCD80,100-W for normal control valve)

-45-
 Fig. 2.9 Engine wire harness
(CPCD80,100-W for electric-hydraulic valve)

-46-
 Fig. 2.10 Cabinet wire harness
(CPCD50～100-C for normal control valve)

-47-
 Fig. 2.11 Cabinet wire harness
(CPCD50～100-C for electric-hydraulic valve)

-48-
 Fig. 2.12 Engine wire harness
(CPCD50～70-C for normal control valve)

-49-
 Fig. 2.13 Engine wire harness
(CPCD50～70-C for electric-hydraulic valve)

-50-
 Fig. 2.1 4 Engine wire harness
(CPCD80,100-C for normal control valve)

-51-
 Fig. 2.1 5 Engine wire harness
(CPCD80,100-C for electric-hydraulic valve)

-52-
 Fig. 2.1 6 Cabinet wire harness
(CPCD50～100-CU for electric-hydraulic valve)

-53-
 Fig. 2.1 7 Engine wire harness
(CPCD50～70-CU3 for electric-hydraulic valve)

-54-
 Fig. 2.1 8 Engine wire harness
(CPCD80,100-CU1 for electric-hydraulic valve)

-55-
 Fig. 2.1 9 Cabinet wire harness
(CPCD50～100-P for electric-hydraulic valve)

-56-
 Fig. 2. 20 Engine wire harness
(CPCD50～70-P1 for electric-hydraulic valve)

-57-
 Fig. 2. 2 1 Engine wire harness
(CPCD80,100-P for electric-hydraulic valve)

-58-
 Fig. 2. 22 Cabinet wire harness
(CPCD50～70-M1 for normal control valve)

-59-
 Fig. 2. 23 Cabinet wire harness
(CPCD50～70-M1 for electric-hydraulic valve)

-60-
 Fig. 2.24 Engine wire harness
(CPCD50～70-M1 for normal control valve)

-61-
 Fig. 2. 25 Engine wire harness
(CPCD50～70-M1 for electric-hydraulic valve)

-62-
 Fig. 2. 26 Cabinet wire harness
(CPCD80,100-WX for normal control valve)

-63-
 Fig. 2.27 Engine wire harness
(CPCD50～70-WX for normal control valve)

-64-
 Fig. 2. 28 Engine wire harness
(CPCD80,100-WX for normal control valve)

-65-
Fig. 2. 29 Cabinet wire harness (CPQD50～70-TY1)

-66-
Fig. 2. 30 Cabinet wire harness (CPQYD50～70-TY1)

-67-
Fig. 2. 31 Cabinet wire harness (CPYD50～70-TY1)

-68-
Fig. 2. 32 Engine wire harness (CPQD50～70-TY1)

-69-
Fig. 2. 33 Engine wire harness (CPYD50～70-TY1)

-70-
Fig. 2. 34 Engine wire harness(CPQYD50～70-TY1)

-71-
 3. Transmission System
The transmission system consists of torque converter transmission & torque
converter.
The main specifications of the system see table3.1

Item Specifications

Type 3-element,1-stage,2-phase
Torque Circular Dia.& stall torque ratio Dia.12.5”(φ315),stall torque
converter ratio 3:1
Pressure setting MPa 0.5~0.7

Type Crescent type,gear pump,

Charging transmission output
pump
Discharge r/min 40(2000rpm,2MPa)

Power shift type

1st(forward and backward) 1.621

Gear ratio
2nd(forward and backward) 0.526

Torque Clutch outer dia. mm 134

Converter
Transmission Clutch inner dia. mm 90

Hydraulic Clutch Clutch thickness mm 2.8

Clutch surface area cm2 77.4(6 faces)

Pressure setting MPa 1.2~1.50

Weight kg About 295

Oil amount l About 30

Model SAE10W engine oil or
Oil type No. 6 torque converter oil made
in China

-72-
 Fig.3.1 Hydraulic transmission

[Link] valve [Link] pump [Link] bearing

[Link] shaft [Link] bearing [Link] converter
[Link] bearing [Link](30T) [Link] brake
[Link] [Link] seal [Link](32T)
[Link] bearing [Link] [Link] cage
[Link] shaft [Link] seal [Link] bearing
[Link](47T) [Link] clutch pack [Link] clutch pack
[Link] plate [Link] output shaft

-73-
 3.1 General description
The transmission adopted in this machine is a rational combination of torque
converter with power-shift type [Link] has the following features.
(1) The inching valve is provided so as to improve the inching [Link],the
inching performance can be maintained when starting and at any rotational speed of
engine.
(2) The clutch has 7 steel plates and 7 specially treated paper [Link]
excellent durability is ensured.
(3) The torque converter is provided with the free wheel so as to enhance the
transmission efficiency(3-element,1-stage,2-phase type).
(4) The line filter is provided in the torque converter circuit so as to improve the
durability.
3.2 Torque converter
Generally,the torque converter consists of pump wheel fitted to the input
shaft,turbine wheel fitted to the output shaft,and stator wheel fixed to the housing(3-
element,1-stage type).
The pump wheel is rotated by the drive shaft,so that the fluid in the pump forced out
by the centrifugal force along the vanes of pump wheel.(At this time mechanical energy is
converted to kinetic energy).
Thereby the fluid flows into the impeller of turbine wheel,transmitting torque to the
output [Link] direction of the fluid leaving the turbine wheel is changed by the stator
wheel so that it flows into the pump wheel at the best [Link] this time a reaction torque
pushing the stator is generated,as a result of which the output torque becomes larger than
the input torque by the valve equal to the reaction torque.
As the rotational speed of turbine wheel increases,approaching to the input rotational
speed,the change of fluid flow angle reduces,and the output shaft torque also [Link]
finally the fluid begins to flow contrary to the direction of stator vanes,as a result of which
the reaction torque beings to affect in the reverse direction.
In this case the output shaft torque becomes smaller than the input shaft [Link] as
to prevent this phenomenon,a free wheel(one-way clutch) is provided on the stator. When
the reaction torque acts in the reverse direction,the stator wheel rotates [Link] this state
the input torque becomes equal to the output torque so that high performance is ensured.
As the phase of torque transmission is changed by the mechanical means (clutch),the
torque converter is called the 2-phase [Link] features smooth operation and enhanced
efficiency.
The torque converter is fixed to the flywheel through the flex plate so that it rotates
always together with the engine.

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 The torque converter case, turbine wheel, pump wheel and stator wheel are mounted
inside the torque converter. The inside of the torque converter is filled with torque
converter fluid. The inside of torque converter is filled with torque converter fluid.
The pump wheel has gear at its end which is engaged with the drive gear of charging
pump to drive the charging pump.
The turbine wheel is spline-jointed to the main [Link] serves to transmit power to
the wet type multidisk clutch.
The construction of the torque converter see Fig.3.2.

Turbine wheel
Input plate
Pump wheel

Stator wheel
Stator support

One-way clutch

Fig.3.2 Torque converter

3.3 Charging pump

The construct of charging pump See Fig.3.3.

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 Outlet Cap
Shuck

Driving gear
O-ring
Inner gear
Inlet

Fig.3.3 Oil pump

Charging pump consists of driving gear,inner gear(diven gear),shuck and

cover,mounted on the upper end of the tor-con [Link] gear is driven by pump
wheel,idle gear and oil pump driven gear ,the oil pump supply oil in lower half of the
transmission for every area of the transmission.
3.4 The hydraulic clutch group
The hydraulic wet type multidisk clutch group is provided at the transmission
[Link] drive gear of forward clutch side is engaged with the driven gear whereas the
counter drive gear of reverse clutch side is engaged with the counter shaft gear.
Inside one clutch group the 6 clutch disks(sintered plates) and the 7 clutch steel
disks (steel plates) are alternately and assembled together with the piston.
Oiltightness of outer periphery and inner periphery of the piston is ensured with the
slipper seal and “O”-ring,respectively,when it [Link] the neutral state the coil
spring acts to disengage the multidisk [Link] clutch surface is always lubricated with
the oil returned from the oil cooler so that seizure and wear of the clutch surface are
prevented.
When hydraulic pressure affects the piston,the alternately arranged sintered plates
and steel plates are depressed so that the clutch group is made integral and transmits
power from the torque converter to the drive gear.
Accordingly,power transmission route from the Tor-Co-Matic transmission is as
follows:Turbine wheel→Main shaft→Clutch drum→Steel plate→Sintered plate→Forward

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or reverse gear→Output shaft.
3.5 Control valve and inching valve
The control valve see Fig.3.5.

Friction plate 2-Shift gear

Gear Spacer Return spring
Papilionaceous
Washer plate
O-ring
Washer

Oil pressure
Oil pressure
Bearing Bearing
Sleeve Sleeve
Bearing End plate
Piston Bearing
1-Shift gear Clip
Washer
Washer Seal ring

Fig.3.4 Forward clutch

Friction plate Return spring

Gear Spacer
Papilionaceous 2-Shift gear
Washer plate
O-ring
Washer
Seal ring

Oil pressure
Oil pressure
Bearing
Bearing
Sleeve Sleeve
Bearing End plate Piston
1-Shift gear Clip Bearing
Seal ring Washer
Washer

Fig.3.5 Reverse clutch

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 Spring Piston
Bushing
Oil seal

Inching spool

Oil seal

Selector spool
Stopper

Fig.3.6 Control valve

The control valve is provided on the upper part of transmission [Link] change spool
and inching spool are incorporated in the valve body.
The clutch relief valve is designated to adjust the hydraulic pressure of the
transmission [Link] converter relief valve serves to adjust the hydraulic pressures of
fluid which fills the converter.
The inching spool is connected to the link of brake [Link] the brake pedal is
depressed,the spool is forced in,so that hydraulic pressure of clutch is lowered temporarily
to disengage the clutch.
3.6 Hydraulic circulation system(See Fig.3.7)
When the engine is started and the charging pump is put into operation,the torque
converter fluid in the oil tank (transmission case) is forcibly sent to the control valve from
the pump through the strainer.
The fluid sent from the charging pump is divided to two directions in the torque
converter case,one for torque converter and the other for transmission.

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 Tor-con Oil cooler
Filter
Tor-con relief valve
Lubrication
Accumulator

Main relief valve

Inching vlave

Oil pump
Selector
spool

Strainer

Fig.3.7 Tor-con hydraulic system

Pressure of the fluid for clutch is adjusted to 1.2 to 1.5 MPa with the relief [Link]
then it is supplied to the control [Link] of the fluid divided for the converter is
adjusted to 0.5 to 0.7 MPa with the converter relief [Link] that this fluid reaches the
wheel of torque [Link] it is cooled by the oil cooler,it lubricates the clutch group
and then returns to the oil tank through the filter.
When the selector valve is in neutral position,the circuit from the selector valve to the
clutch is [Link] the fluid is joined with the torque converter filling fluid.
When the selector spool is set to the forward or reverse position,fluid flows into the
accumulator due to action of modulate valve,so that pressure rises gradually,During this
time the clutch starts to engage.
When the accumulator is filled with fluid,hydraulic preesure rises intensively so that
the hydraulic clutch is completely engaged.
While the forward or reverse clutch is operating,another clutch is rotating between
the sintered plates and the steel [Link] this part is lubricated with oil sent from
the oil cooler to prevent seizure of plates.
When the brake pedal is depressed and the inching valve is actuated,most of

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hydraulic oil supplied to the clutch is drained from the inching valve and returns to the
transmission [Link] fluid for the torque converter circulates in the same manner as in
neutral state.
3.7 Cautions when the machine trouble occurs
When the machine with Tor-Co-Matic transmission cannot run by itself due to
trouble and it must be dragged with another machine,be sure to observe the following
requirements.
(1) Remove the propeller shaft between the differential and the transmission.
(2) Set the change lever in neutral position.
Since the torque converter pump does not operate,normal lubrication is not
[Link],if rotation is transmitted from the front wheel to the transmission
gear and clutch disk,seizure may occur.
3.8 Troubleshooting Guide
(1) Low power:see Table 3.2
(2) Abnormal rise of oil temperature:See Table 3.3
(3) Noisy transmission:see Table 3.4
(4) No power transmission:See Table 3.5
(5) Oil leakage:See table 3.6

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 Table 3.2
Possible causes Checking method Remedy
[Link] pressure too low
(1) Low oil level Check oil level Add oil
(2) Air sucked from suction Check joints and pipe Retighten and replace packing
side.
(3) Clogged oil filter Disassemble and check Clean or replace
Torque Converter

(4) Insufficient discharge of Disassemble and check Replace

pump
(5) Main relief valve coil Check spring tension Replace
spring deteriorated
(6) Seal ring or O-ring Disassemble,check and Replace
damaged or worn. measure.
[Link] damaged or in Drain a small quantity of oil Replace
contact with other parts and check for presence of
foreign matter.
[Link] oil is used or Check
bubbles are foamed.
(1) Air sucked from suction Check joints and pipes Retighten or replace
side.
(2) Torque converter oil Measure pressure. Adjust pressure
pressure is too low and
bubbles are foamed.
[Link] slips
(1) Low oil pressure Measure pressure Adjust pressure
Transmission

(2) Seal ring worn Disassemble,check and

measure Replace
(3) Clutch piston ring worn Disassemble and check Replace
(4) Clutch disks are burned Disassemble and check,Start Replace
and plates deformed. engine and place direction
control lever in forward,
reverse and neutral respec-
[Link] runs with the
lever in neutral but not in
[Link] bwd.
C. Link lever between brake Check and measure. Adjust
shift and valve spool is
improperly positioned.
Engine power drops Check STALL [Link] Adjust or repair engine
Engine

working sound of enginge.

Check maximum rmp of
engine with gears in neutral.
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 Table 3.3
Possible Causes Checking Method Remedy
(1)Low oil level Check oil level Add oil
(2)Clogged oil filter Disassemble and check Clean or replace
(3)Flywheel is in contact with Drain oil from oil filter or oil Replace
Torque Converter

other parts tank and check for foreign

matter.
(4)Air is sucked Check joints and piping at Retighten or replace gasket
suction side
(5)Water mixed in oil Drain and check oil Replace oil
(6)Low flow rate of oil Check piping for damage or Repair or replace
bending
(7) Bearings worn or seized Disassemble and check Repair or replace
(1)Clutch drags Check whether the truck runs Replace clutch plates
Transmi-

with gears in neutral.

ssion

(2)Bearings worn or seized Disassemble and check Replace

Table 3.4
Possible Causes Checking Method Remedy
(1) input plate broken Check rotational sound at low Replace input plate
rmp.
Torque converter

(2) Bearings damaged or worn Disassemble and check. Replace

(3) Gears broken Disassemble and check. Replace
(4) Spline worn Disassemble and check. Replace
(5) Noisy gear pump Disassemble and check. Repair or replace
(6) Loose bolts Disassemble and check. Retighten or replace
(1) Bearings worn or seized Disassemble and check. Replace
Transmission

(2) Gears broken Disassemble and check. Replace

(3) Spline worn Disassemble and check. Replace
(4) Loose bolts Disassemble and check. Retighten or replace

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 Table 3.5
Possible Causes Checking Method Remedy
(1) Input plate broken Check rotational sound at low Replace
rmp and check whether front
cover rotates
Torque Converter

(2) lack of oil Check oil level Add oil

(3) Driving system of oil pump Disassemble and check Replace
malfunctioning
(4) Shaft is broken Disassemble and check Replace
(5) Oil pressure is too low Check whether suction Replace
pressure generates at inlet
side of pump
(1) Lack of oil Check oil level Add oil
(2) Damaged seal ring Disassemble and check Replace
(3) Clutch plates seized Check clutch oil pressure Replace
(4) Shaft is broken Disassemble and check Replace
Transmission

(5) Clutch cover broken Disassemble and check Replace

(6) Snap ring for clutch cover Disassemble and check Replace
is broken.
(7) Foreign material in clutch Disassemble and check Clean or replace
oil tank
(8) Spline part of shaft is [Link] and check Replace

Table 3.6
Possible Causes Checking method Remedy
(1) Damaged oil seal Disassemble and [Link] Replace oil seal
seal lip or its mating sliding
Torque Converter and transmission

part is worn.
(2) Case connected improperly. Check Retighten or replace gasket.
(3) Loose joints and piping Check Repair or replace gasket.
(4) loose drain plug Check Retighten or replace gasket
(5) Oil is ejected from breather Drain oil and check for Replace oil. Retighten or
mixing of water. Check replace packing. Repair
whether air is sucked from
suction joint. Check air hole
of air breather.
(6) Excessive oil Check oil level. Remove excess oil.

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 [Link] Axle
The main specifications of the front axle see Tale 4.1.
Tale 4.1
5-7t 8-10t
Type Cast-steel,full-floating type

Main Type Spiral bevel pinion type

reduction Reduction ratio 4.75 6.33

Hub Type Planetary gear type

reduction Reduction ratio 4.25 3.75
Total reduction ratio 20.19 23.75
Main reduction,differential 10L
Oil amount
Hub reduction Left and right each 8L Left and right each 10L
Tire(left and right each 2) 8.25-15-14PR 9.00-20-14PR
Driving
Rim 6.50-15 7.0-20
wheel
Air pressure kPa 830 760

4.1 General description

The front axle that consists of a main reduction,differential,hub reduction and brakes
as shown in Fig.4.1 and Fig.4.2 is bolted to the front side of the [Link] masts are
installed on the axle housing.
4.2 Main reduction and differential
The main reduction and differential consists primarily of a cross case,ring gear and
drive pinions,which are all assembled on the differential carrier as shown in Fig.4.3,and is
fitted to the axle housing through packings.
The cross case is of the split [Link] cross case,assembled with bolts,contains side
gears and pinions fitted to the spider,being in mesh with each [Link] drive pinions
supported by two taper roller bearings are installed in the bearing cage fitted to the
differential carrier through shims and [Link] ring gear is of the spiral bevel gear
[Link] is bolted to the cross [Link] from the transmission is reduced by the
combination of the ring gear and drive pinions.

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 Tightening torque:
Tightening torque:

Tightening torque:

Fig.4.1 Front axle(5-7t truck)

[Link] house 2. Half-shaft 3. Wheel brake [Link] drum

[Link] seal [Link] roller bearing [Link]
8. Taper roller bearing [Link] nut [Link] nut
[Link] carrier [Link] cap [Link] [Link] ball
15. Planet gear [Link] [Link] gear

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 Tightening torque:
Tightening torque:

Tightening torque:

Fig.4.2 Front axle(8-10t truck)

[Link] house 2. Half-shaft 3. Wheel brake [Link] drum

[Link] seal [Link] roller bearing [Link]
8. Taper roller bearing [Link] nut [Link] nut
[Link] carrier [Link] cap [Link] ball [Link]
15 Sun gear [Link] cap [Link]

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 Fig.4.3 Main reduction,differential

[Link] nut [Link] cap [Link] plate

[Link] roller bearing [Link] house [Link]-shaft gear
[Link] gear 8 .Gear [Link]
[Link] washer [Link] house(right) [Link]-shaft gear
[Link] washer [Link] bearing [Link] reduction house
[Link] nut [Link] nut [Link] pinion
[Link] roller bearing [Link] cage 21.O-ring
[Link] [Link] [Link] roller bearing
[Link] seal carrier [Link] seal [Link]
28.O-ring [Link] [Link] nut

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 4.3 Hub reduction
The hub reduction is of the planet gear type consisting of a sun gear,planetary gears
and an internal [Link] hub reduction are installed on each end of the axle [Link]
sun gear is splined to the axle shaft and locked with snap [Link] planetary gears are
installed onto the shafts in the planet carrier which is fixed to the wheel [Link] internal
gear is splined to the axle spindle through hub.
The principle of power transmission is followed (see Fig.4.4): When the sun gear
turns,the rotation is transmitted to the pinion gears and ring [Link],since the ring
gear is fixed to the spindle,the pinion gears revolve around the sun gear while spining
[Link] pinion gears are installed to the carrier which is fixed to the wheel
hub,therefore,power of the drive shaft causes the wheel to turn.

Inner gear
Sun gear
Half-shaft

Pinion

Fig.4.4 Hub reduction

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 4.4 Troubleshooting guide
See Table 4.2
Cause Trouble Correction

(1)Oil leaks from Loose bolt or broken gasket of differential carrier. Replace or retighten.
differential carrier Breather is clogged. Clean or replace.
Oil seal is worn or damage. Replace.
(2)Noisy Gear is worn,damaged or broken. Replace.
differential
Bearing is worn,damaged or broken. Replace.
Improper backlash Adjust.
Loose spline fitness of side gear to propeller shaft Replace parts.
Insufficient gear oil Add as necessary.

4.5 The remedy specifications

See Table 4.3
Part Item STD Value
Thickness of bearing cage shim 0.1,0.2,0.5
O.D. of oil seal sliding part of companion flange 69.95-70
Backlash of spline part of companion flange and drive pinion. 0.036-0.067
Backlash of drive pinion and ring gear 0.20-0.30
Differential

Preload of drive pinion(N.m) 2.5-3.5

Back swing of ring gear. 0.25-0.38
Tightening torque of ring gear set bolt (N.m) 100-150
Tightening torque of cross case set bolt(N.m) 100-150
Thickness of pinion washers 1.562-1.613
Backlash of spline of side gear and drive shaft 0.038-0.130
Tightening torque of the set bolt for axle housing and differential 150-175
carrier(N.m)
Axle housing

O.D. of hub bearing fitting part of spindle 89.66-89.88

O.D. of spindle oil seal sliding part 109.913-110
Tightening torque set bolt securing axle housing to frame(N.m) 630-946
Tightening torque set bolt securing brake floor to axle housing 280-330
O.D. of mast support part(N.m) 189.2-190
I.D. of hub bearing fitting part (Inside) 159.32-159.72
I.D. of hub bearing fitting part (Outside) 179.32-179.72
I.D. of hub Oil seal fitting part 164.6-165
Hub

Tightening torque of set bolt securing brake drum to hub(N.m) 280-330

Tightening torque of set bolt securing planet carrier to hub(N.m) 98-113
Tightening torque of hub nut (N.m) 480-560

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 [Link] System
The main specifications of the brake system See Table 5.1.
Table 5.1
CPCD50,60,70
CPCD80,100
Homeland engine Import engine

Brake type Vaccum assistant Power brake

Brake model Front wheel,internal expansion type,lining brake

Wheel brake

I.D. of brake drum Φ317.5 Φ438.15

Wheel cylinder drum Φ31.75 Φ47.62

Lining size 324×100×10 489×100×12.7

Surface area of lining cm2 4×324 4×489

Type Transmission middle shaft-mounted,internal

expansion mechanical type
Parking brake

I.D. of brake drum Φ160

Disk size 140×36×3.5

2
Surface area of disk cm 50.4

Brake cylinder mm Φ31.75

I.D. of Vaccum assistant
Brake pump & valve

Fwd/bwd Φ9”/Φ10”

Type:main vale/safety valve Open core type/Close core type

Brake valve

Move model Spring type

Intake flux 27

[Link] oil pressure 10.5

Type Spring type

Capacity cc 66.7
Reserver

Piston:I.D.×Stroke mm Φ50×34
Oil pressure:
Max./Working time MPa 7.2/4.9

Relief oil pressure 13

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 5.1 General description
The braking system consists of traveling and parking brakes. The traveling brake is
mounted inside the driving wheel, while the parking brake is mounted on a intermediate
shaft at the rear side of the gear box. The traveling brake has two modes of power brake
and vacuum brake.
5.2 Power brake (For the schematic diagram of the system, refer to 5.1)
The traveling braking system that adopts the power brake mode consists of brake
pedal, brake valve, energy storage and brake.
The power brake is to make use of the pressure oil transferred by pinion pump set
specially for the hydraulic system of forklift, one way of oil enters into brake valve and the
sub-pump of brake to produce braking, while the other way of oil enters into accumulator
to store energy for spare use. Both ways of the oil are controlled by the stroke of brake
pedal.
5.2.1 Brake pedal device (See Fig. 5.2)
Brake pedal and inching pedal are mounted at the left side of the frame through a
bracket. The brake pedal at the right side pushes forward the piston assembly of brake
valve through connecting bar and makes the pedal control the pressure oil. The inching
pedal at the left side and brake pedal at the right side play the role of linkage and can
manipulate the brake valve and the inching valve of gearbox as well.
Brake valve Steering hand wheel

Brake pedal
Reservoir

Pump

Steering cylinder

Brake Fig.5.1 Brake system

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 Brake sw.

Brake pedal

Inching pedal Brake valve Reservoir

Fig.5.2 Brake pedal unit

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 5.2.2 Brake valve (See Fig. 5.3)
(1) Non-brake status
In case of not-braking state and due to opening of port A of brake valve , the pump
interface and the steering interface are interlinked and the steering works normally. When
the brake pedal is not stepped on, even if the steering operation will not produce braking,
the oil pressure of control oil pressure chamber D will not rise as the port B is closed at this
time.
(2)Starting and finishing of the braking
a)When the brake pedal is stepped on, the piston assembly (part NO.10) moves to the
left , the valve sleeve (part NO.7) and backflush piston (part NO.5) are pressed to the left
side by the spring set (part NO.8) and meanwhile the return spring (part NO.6) is
compressed to the left side .
b)The movement of work piece (part NO.7) closes the place A, breaks the interface of
D and oil return tank. B opens correspondingly and makes D chamber and pump interface
connect.
c)At this time, the valve sleeve (part NO.7) moves to the left and the oil pressure that
leads to the sub-pump of brake rises along with the increase of oil pressure of pump
interface and chamber D due to compression. Meanwhile, the relatively higher oil pressure
in chamber D moves to the right and push the backflush piston (part NO.5) and this
pushing force is in balance with pedal force.
d)When the maximum pedal force is input in the right end of piston and in order that
the oil pressure of D chamber will not exceed the maximum adjusting oil pressure, the
bolts and pedal brackets are used for position limitation.
e)When your foot leaves off the pedal , the counterforce of backflush piston and the
spring counterforce of work pieces (part NO.6) and (part NO.8) return the valve sleeve
(part NO.7) to the original position and the braking process is finished.
(3)The working process of accumulator
When the oil pump stops working, ( due to engine stops) or is damaged, the
accumulator needs to enter into working state.
a)When the brake pedal is further stepped on, valve sleeve (part NO.7), back flush
piston (part NO.5) and contact pin of check valve move together towards left, the contact
pin will prop open the ball and chamber D and accumulator are interlinked at this time and
the pressure oil of accumulator is utilized to play the braking role for brake sub-pump.
b)When your foot leaves off the pedal, the valve sleeve , back flush piston and contact
pin move to the right at the same time. The ball of the check valve restores joining with
valve seat under the action of spring force (check valve closes) and the contact pin stops at
this position correspondingly.

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 c)The backflush piston moves to the right and C open to make the oil of brake sub-
pump of brake return to the fuel tank through chamber D.

Reservoir

Oil tank
Oil pump

Brake Steering unit

[Link] 2.1-way valve seat 3.1-way valve pin [Link]-back piston seat
5. Bounce-back piston 6. Return spring 7. Valve sleeve [Link]
[Link] seal [Link] ass’y
Fig.5.3 Brake valve

Spring O-ring Snap ring Safety valve 1-way valve

O-ring

Piston Warning sw.

Fig.5.4 Reservior

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 5.2.3 Accumulator (See Fig. 5.4)
When the engine stops working or there is trouble on the oil pump, the accumulator
can be used as the abnormal (extra) energy to meet the needs of braking.
The accumulating mode is of spring type.
The Fig. Shows the non-accumulating state and the buzzer of alarming switch is in
normal sounding state.
When the brake pedal is operated and the oil pressure reaches over 3.9 MPa, the
check valve opens and feeds the oil to the accumulator so as to push forward the piston.
Move to the left and compress the combined spring to set up oil pressure.
Meanwhile, the piston moves towards left and makes the switch control lever at
alarming switch move towards left under the action of spring pressure and the switch valve
spool drop into recess of switch control lever. Now the alarm is in the silence state.
With the increase of oil pressure of the pump, the left moving stroke of the piston is
restricted by the stop tube in the middle of combined spring. The accumulator stores the
maximum energy at this time and the oil pressure is 13 MPa, which is controlled by safety
valve.
5.3 Vacuum servo brake
5-7t forklift that matched with domestic machine adopts vacuum servo brake, i.e.
vacuum booster and main brake cylinder (main pump) assembly to realize the servo brake.
The vacuum booster is to use vacuum (negative pressure) as dynamic force (use the
pressure difference between vacuum pressure and atmosphere) to obtain the higher oil
pressure of sub-cylinder (sub-pump) of brake under the action of light brake pedal force
of operator and play the role of boosting and force saving, thus alleviating the working
strength of drivers and improving the safety of traveling brake.
For main technical performances, See Table 5.2
Name Metering unit Value
Effective diameter of vacuum Maximum mm Φ 263
cylinder Minimum mm Φ 236
Maximum stroke of vacuum servo brake mm 39
Servo ratio 7
Diameter mm Φ 31.75
Main brake Maximum stroke mm 38
cylinder Front cavity displacement ml 15.8
Rear cavity displacement ml 14.2
Maximum outside diameter of the assembly mm Φ 272
Dimension of mounting plate mm 60 × 80，4-M8 hole
Oil outlet dimension mm 2-M10 × 1
Dead weight kg 5.3
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 5.3.1 Vacuum booster and main brake cylinder assembly
The outline dimension of 9″+10″dual-diaphragm vacuum booster and main brake
cylinder assembly used for the forklift 5-7t is shown in Fig. 5.5 and the internal structure
is in the Fig. 5.6. The working status of the assembly is briefed as follows:
(1) Non-working status
When the vacuum booster does not work, the big cone spring 3 pushes the push rod 1
of control valve together with piston 5 of control valve to the rear end limiting position,
while control air valve 4 is pressed tightly against work piece 5 by small cone spring, thus
closing the air valve port. The two cavities of air cell of booster are interconnected through
channel A， control valve cavity and channel B and are isolated with the atmosphere.
When the engine and vacuum pump are working, there is a certain vacuum degree in both
front and rear cavities of the air cell of the booster.

Brake cylinder Push pole fork

Push pole, control pole

Push pole

Vacuuam assistant

Vacuuam jointer

Dust ring

Fig.5.5 Vacuum assistant and brake cylinder

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 [Link] valve push rod
[Link] cleaner
[Link] cone spring
4. Control air valve
[Link] of control valve
[Link] cone spring
[Link] valve body
[Link] film hull
[Link] film
[Link] tray
[Link] film hull
[Link] flim
[Link] push rod
[Link] spring
[Link]

Rear inflating cavity

Front inflating cavity

Fig.5.6 Vacuum booster and main brake cylinder constructure

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 (2) Working conditions of braking
a)As soon as the brake pedal is stepped on, the pedal acts on the control valve rod 1
after the pedal force being amplified by lever and compresses the work piece 3 and moves
forward with work piece 5. Certain pressure will be produced inside main brake cylinder
through the actions of feed back disc 10 and push rod 13 of main cylinder and transmitted
to the sub-cylinder (sub-pump) of brake inside the braking wheel 5. Meanwhile, the
control air valve 4 moves forward together with work piece 5 under the action of small cone
spring 6, contacts with vacuum valve port on control valve body 7 and closes it, thus
isolating the front and rear cavities of the air cell of booster. (i.e. the rear cavity of air cell
of booster disconnects with vacuum source.
b)With the continuous moving forward of the push rod 1 of the control valve , the
piston 5 of control valve leaves work piece 4, the outside atmosphere fills into the rear
cavity of air-cell of booster through air filter pad 2 , control valve cavity and channel B.
Thus, most of the acting force caused by the two cavities of air cell of booster, except a
small part of it is used to balance the acting force of big cone spring 3, acts on the feed
back disc through control valve body 7 and is transmitted to the main brake cylinder, thus
playing the boosting role.
(3)The braking process terminates and the non-working state resumes
a)In the course of stepping on the brake pedal( the push rod of control valve moves
forwards), the air through the air valve port opened constantly enters into the front and rear
cavities of air cell of booster and control valve body constantly moves forward. When the
brake pedal stops being stepped on and stays at a position, the control valve body moves
forward with it and stops at the position that can close the air valve port. Now, the vacuum
valve port and air valve port are closed and the booster is in the balanced state, i.e. the air
pressure difference of the front and rear cavities of the air cell of the booster remains
balanced with the oil pressure of the oil in main brake cylinder and pushing force of push
rod of control valve and the wheel brake is under the braking state.
b)When the brake pedal is released, the push rod 1 and piston 5 of the control valve
are pushed backward at once under the action of return spring 14 and big cone spring 3 and
make the control air valve 4 separate with vacuum valve port, thus a braking process is
finished and the original non-working state restored.
5.3.2 Installation method for vacuum booster and main brake cylinder assembly
(1)Connect the 4-M8 bolt of booster with mounting bracket, then mount it on the
frame of forklift, connect the adjusting fork at the end of booster with connecting bar of
brake pedal, then tightened 4-M8 bolts. The tightening moment is 12N.m-18N.m.
(2)Connect the vacuum host to the vacuum pipe connector of booster and keep it
sealed.

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 (3)Connect the brake oil pipe with the 2-M10 × 1 thread at oil outlet of main cylinder
of brake. The tightening moment is 12N.m-16N.m.
(4)Open the screwed cover of liquid storage tank, fill in the brake liquid (the dust or
impurities are not allowed to enter) and drain off the air inside the entire braking system.
(5)When the main cylinder of brake or vacuum booster is independently changed, the
tightening moment of the connecting nut between the two is 12 N.m-18N.m.
(6)Please do not easily adjust the vacuum booster and push-rod head of main brake
cylinder matching surface.
5.3.3 Points of attention for users
(1)The product must use the braking liquid stipulated in the instruction.
(2)The air in the pipes must be drained completely after the assembly is added with
braking liquid.
(3)Observe if the liquid level of storage tank is in the middle position after exhaust.
(4)The troubles listed in Table 5.3 must be repaired by the professional personnel
with qualification and the users are not allowed to dismantle it without authorization.
5.3.4 Trouble shooting and cause analysis (See Table 5.3)

Trouble and phenomenon Analysis

No oil pressure set up in two cavities or in (1) The leather ring of main cylinder wears.
one of them of the main cylinder, which is (2) The oil outlet pipe is damaged.
reflected by: Pedal stroke becomes bigger

The output oil pressure is not big and (1) The vacuum of booster leaks.
pedal force becomes heavy. (2) The vacuum pipe of engine leaks

The oil storage tank often lacks oil. (1) The joint at oil cylinder leaks.
(2) The leather ring of the first piston wears.

The brake pedal is low and soft. (1) There is air in the oil circuit system
(2) The clearance between push rod of
booster and piston of main cylinder is too
big.

5.4 Travel brake

Travel brake is an internal expanding and shoe brake. There is one symmetrically on
the left and right each, which are mounted respectively in the two driving wheels. Brake is
composed of a pair of braking shoes (one primary and one secondary), brake sub-pump
(one for 5-7t truck and two for 8-10t truck), a clearance adjuster, three or four return
springs and bottom plate of brake. A friction disc is riveted on the outside of braking shoe.
Clearance adjuster is used to adjust the clearance between friction disc of braking shoe

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and internal wall of braking drum.

Self-correcting indirection

Fig, 5.7

5.4.1 Travel brake (5-7t forklift truck) (See Fig. 5.8)

There is only one brake sub-pump on travel brake of 5-7t forklift and the two ends of
its piston rod contact with the upper end of primary and secondary braking shoes
respectively. The lower end of primary and secondary braking shoes contact with the both
ends of clearance adjuster and are pressed against the bottom plate of brake by spring and
rod for setting lever spring.
The automatic clearance adjusting device generally plays the role when the forklift
brakes for reversal i.e. when the adjusting lever has a large clearance, the gear on the
automatic adjuster turns a tooth and makes the clearance after adjustment remain at 0.4 to
0.6mm. For the adjustment of rotation direction of the gear, See Fig. 5.7.
Because the braking of 5-7t forklift has two open-types, there are two kinds of
material used for leather bowl of brake sub-pump, i.e. the leather bowl of dynamic braking
type uses oil-resistant rubber and the leather bowl of vacuum assisted type is made up of
leather or synthetic leather. More attention should be paid in changing parts and fittings.

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[Link] shoe [Link] rod [Link]-adjuster spring
[Link] spring [Link] shoe [Link] lever
[Link] ring [Link] spring [Link]
[Link] [Link] pin for shoe [Link] spring
[Link] [Link] spring

Fig.5.8 Brake(5-7t)

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[Link] shoe [Link]
[Link] [Link] hood
[Link] rod [Link] shoe
[Link] [Link] spring
[Link] [Link] floor

Fig.5.9 Brake(8-10t)

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 5.4.2 Travel brake (8-10t forklift truck) (See Fig. 5.9)
There are two brake sub- pumps for travel brake of 8-10t forklift. The upper and
lower ones contact with two ends of primary and secondary braking shoes and the
clearance adjuster is next to the brake sub-pump.
When the clearance is adjusted, remove the rubber cover installed at the adjuster
location on the bottom plate of the brake and the tooth of the adjuster is rotated from inside
to outside with screwdriver until the friction disc contacts with the inner wall of braking
drum. Then the tooth of the adjuster is back rotated about 5 or 6 splines. (See Fig. 5.10)
8-10t forklift adopts dynamic braking and the material used for leather bowl of brake
sub-pump is oil-resistant rubber. More attention should be paid in the replacement.

Rubber cap

Expand

Fig.5.10

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 5.5 Parking brake
Parking brake is an internal expanding and shoe type brake and is installed on the
output end of one intermediary shaft at the rear side of the gearbox. (See No. 9 of Fig. 3.1)
For detailed structure, See Fig. 5.12.
The operation of stop brake is shown in Fig. 5.11. When the forklift is under the
standard loading state and stop brake is made on the slope, the manual operating force
should be not bigger than 300N. The pulling force is adjusted according to the direction
shown in the Fig and B is the force measurement point.

Release position
Brake position

Reduce

Augment

Parking brake

Fig.5.11 Parking brake unit

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[Link] [Link] spring [Link] plate
[Link] shoe [Link] [Link]
[Link] bolt [Link] spring 15.U-ring
[Link] [Link] [Link]
[Link],lock [Link] seat [Link] brake cable
[Link] [Link]

Fig.5.12 Parking brake

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5.6 Troubleshooting guide (See Table 5.3).

Problem Possible cause Remedy

Fluid leakage from brake system Repair

Improper clearance of pads Adjust

Poor braking force

Overheat of brake Checking if it sliding

Improper cantact of rotor and pads Adjust

Foreign material adhering to pad surface Repair or replace

Foreign material mixed in brake fluid Change fluid

Incorrect adjustment of pedal(inching valve) Adjust

Hardened pad surface foreign material adhered to it Repair or replace

Noisy braking operation

Loose carrier mounting bolts,floor distortion Repair or replace

Deformed or incorrectly installed pad Repair or replace

Worn pad Replace

Loose ball bearing Replace

Bearing of wheel improper Repair

Foreign material adhering to pad surface Repair or replace

Uneven braking

Auxiliary pump act improper Repair or replace

Drum eccentricity Repair or replace

Improper clearance of pads Adjust

Improper tire pressure Adjust

Soft or spongey pedal

Brake fluid leakage from brake system Repair

Improper clearance of pads Repair or replace

Air mixed in brake system Bleed air

Incorrect pedal adjustment Readjust

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 [Link] System
The main specifications of the steering system see table 6.1.

Item 5-7t 8t 10t

Type Rear wheel steering powered

Dia. Of steering handwheel mm 360
Type BZZ series powered steering unit
Steering
Delivery rate ml/min 280
unit
Rated pressure MPa 16
Bore mm Landscape，double function
Steering
Dia. Of cyl./Dia. Of piston rod mm Φ115/Φ85
cylinder
Stroke 2×216 2×260
Setting pressure MPa 12.3
Flow-
divider Rated flow l/min 25 27
Type Center pin supported,landscape cylinder
Steering angle:Inner/Outer wheel 79°
/50°
Steering
axle Rear wheel:tread 1700
King pin:interval 1500
Gimbal swivel radius Φ42
Tire 8.25-15-14PR 9.00-20-14PR
Steering Rim
6.50-15 7.0-20
wheels
Inflation pressure 830 760

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 Steering system consists of a steering handwheel, a steering column,gimal assembly,
steering unit, steering axle and steering cylinder. Steering control unit see Fig.6.1.

Steering hand wheel

Lock handle

Steering unit
Gimal
Linkage shaft ass'y

Fig.6.1 Steering control unit

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 The steering shaft connects the steering unit with a gimbal,the steering handwheel
turns with the steering shaft and steering column, realizing hydraulic steering. The
steering column supporting steering shaft changes some tilt angle forward and backward to
adjust to a proper position ,so as to satisfy the driver's need.
6.1 Steering unit
The steering unit is a full-hydraulic steering unit,and can transmit the pressure oil
from the flow-divider to steering cylinder through the oil pipe by [Link] oil volume
changes with the rotation angle of the [Link] the engine goes out and the oil
pump can not supply oil,the steering shall be done by manpower.

Fig.6.2 Full-hydraulic steering system

[Link] and steering shaft [Link] cylinder

[Link] [Link] axle
[Link]-divider [Link]
[Link] steering unit

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 6.2 Checking after mounting on the machine
(1) Check the arrangement of hydraulic pipeline and turing direction of the truck for
correctness.
(2) Check the forces necessary to turn the steering handwheel to right and left until it
can’t be turned any more to see if they are identical with each other and check the
operation of the steering handwheel for smoothness during above operation.
(3) After mounting on the machine,jack up the rear wheels,run the engine idly,and
steer the steering wheel several times to discharge air from the piping and power steering
[Link] down the rear wheels,steer the steering wheel several times to check for
abnormal [Link] abnormal sound is not heard,this indicates that air has been completely
[Link] set the engine in idling state to raise oil temperature.
(4) Measurement of steering power
Stop the machine on a flat dry paved road, and apply its parking brake. Attach a
spring balancer to the steering wheel rim to measure the steering [Link] steering
power must be less than approx.150N.
(5) To measure hydraulic pressure,use the pressure gauge(15-20MPa),stop valve
and hoses connected as shown in fig.6.3.

Pressure meter

To flow-divider
Hose
To steering unit

Stop valve Hose

Fig.6.3 Measure pressure

Disconnect the hose which has been connected from the flow valve to the power
steering,connect the hose provided with the stop valve to the power steering side,and run
the engine idly.
When the steering wheel is kept in free state,the hydraulic pressure is about 0.5 to
[Link] the hydraulic pressure exceeds this value,check for clogging of the control valve
and [Link] no abnormality is found,raise the rotational speed of engine up to about
1500rpm,and slowly close the stop valve,paying attention to preesure rise.

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 The limit pressure of relief valve has been set to [Link],when the stop
valve is completely closed,the preeure gauge indicates its setting preesure.
If the hydraulic pressure exceeds 12MPa,this indicates that the relief valve
[Link] the hydraulic pressure is too low,this indicates that the oil pump
malfunctions or the relief valve spring has been [Link] this case be careful not to keep
the stop valve closed for more than 15 seconds.
Caution:The pump supplies the hydraulic oil to actuate the power [Link] work
must be considered from two different aspects,namely pressure and flow rate.
Pressure is designated to give thrust to the cylinder whereas flow rate relates to the
kinetic speed of the cylinder.
Therefore,even when the hydraulic pressure is normal,say 12MPa,the power steering
cannot work normally if flow rate is [Link] results in heavy [Link] the
flow valve and relief valve have been properly adjusted according to capacity and use
conditions of the power steering,it is necessary put the match mark in the set position or
measure the distance to the screw head if disassembly of valve is needed.
6.3 Troubleshooting guide

Problem Possible cause Remedy

Steering wheel is caught Flow control valve spool stuck Disassemble,repair or replace
when rapidly turned
Flow control valve spool worn Replace as assembly
Oil pressure does not rise Relief valve stuck open Replace as assembly
Oil pressure higher than Relief valve stuck closed Replace as assembly
relief set pressure
Noisy relief valve Relief valve vibrating Replace as assembly

Too high oil temperature Relief valve stuck closed Replace as assembly

Relief valve stuck open Replace as assembly

Hard steering operation
Flow control valve spool stuck Disassemble and repair or replace
while idling
Flow control valve spool worn Replace as assembly

Relief valve vibrating Replace as assembly

Varying steering force Flow control valve spool stuck

Flow control valve spool worn Replace as assembly

Relief valve stuck open Replace as assembly

Hard steering operation Flow control valve spool stuck Disassemble and repair or replace

Flow control valve spool worn Replace as assembly

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 6.4 Steering axle
5-10t forklift entirely adopts transverse steering oil cylinder. The front and rear of
the center are supported by two supporting axle through sleeve on the steering axle base,
the later is fixed on the forklift frame. The two supporting axle can sway a certain angle to
the right and left. The structures of steering axle of 5-10t forklifts are the same in the most
parts and the main structure is presented in the Fig. 6.3 and Fig. 6.4.
Steering axle is mainly made up of steering axle body, left and right steering knuckle
assembly, connecting rod assembly, wheel, wheel hub and steering oil cylinder
6.4.1 Steering axle body
Steering axle body is a steel plate with welding structure. On its two ends there are
upper and lower bosses (holes) that connect the left and right steering knuckle assembly
with the axle body by using the steering stub. The opening size of the boss for 5-8t forklift
is small while that for 10t is large.
6.4.2 Left and right steering knuckle assembly
Left and right steering knuckle assembly is supported on the wheel hub through two
thrust bearings and the wheel is mounted on the wheel hub. Oil seal is provided on the
wheel hub in order to prevent grease from overflowing. The plane thrust bearing is
mounted between the steering knuckle and the upper and lower bosses of steering axle
body, under which a gasket can be used to regulate the rotation clearance. In the inner hole
of upper and lower bosses, the steering stub is mounted and is supported by the upper and
lower needle bearings, under which the oil seal is used. An oil nozzle is mounted on the
upper extreme cover in order to lubricate all the bearings through the inner hole of stub.
Users should fill in the grease on time. The locking pin is used for fixture between the
steering stubs of steering knuckle assembly.
6.4.3 Wheel hub
Wheel hub is spherical iron. As the tires of 8-10t forklifts are different from those of
5-7t, the wheel hubs are also different.
6.4.4 Steering ram (oil cylinder)
The steering ram horizontally set in the middle of the axle body is of double-action
type. The piston rods on two ends are connected with connecting bar assembly; the other
end of the later can propel the steering knuckle arm to make the wheel change direction.
On the two ends of the oil cylinder are the pilot sleeves and the steel-backed bearing ，
baffle plate ，sealing ring and anti-dust ring are installed in the inner holes of the sleeve，
which contact with piston rod. Outside the sleeve are the supporting ring and O-shaped
ring, which contact with the inner wall of the cylinder. The oil cylinder of 5-8t forklift is
for general use. For the structure, refer to Fig. 6.6.

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Steering axle seat Sleeve Steering cylinder

Fig.6.4 Steering axle

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 Pushing

Bushing

Lock pin Needle bushing

Hub

Turning knurl

Nut(outer)
Nut(inner)

Pushing bushing
Steering cylinder
King pin
Steering axle body
Linkage
Needle bushing
Oil seal

Fig.6.5 Steering axle

Snap ring Wearing Guide cap

Seal ring O-ring Bushing
Dust ring O-ring

Cylinder Piston rad

Fig.6.6 Steering cylinder

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 7. Hydraulic System

5-7t 8-10t

Vacuum
Power brake Power brake
assistant

Drive type Transmission P.T.O.

Rated pressure 25MPa

A45E7-10202
Match Japan 6BG1 36R/4R Double-
gear pump A45E7-10202
36R/4R Double-
Front pump NO.

A05E7-10202 gear pump

Match Chaochai 32R/3.5 Double- H09E7-10202
6102BG gear pump 32R
A05E7-10202
Match Komatsu 32R/3.5 Double-
Oil pump

S4D95LE-2 gear pump

Match Weifang H09E7-10202
R4105G32 32R(5-6t truck)

Match Japan 6BG1 A45E7-10301

36L
A45E7-10301
36L
Rear pump NO.

Match Chaochai A05E7-10301 A05E7-10301

6102BG 32L 32L

Match Komatsu A05E7-10301

S4D95LE-2 32L

Match Weifang A05E7-10301

R4105G32 32L(5-6t truck)

Type Two-spool sliding type(with relief

valve and tilt-lock valve)

Setting pressure 20MPa

Control valve

Two-throw 25787-30202G 25907-30201G

Part NO.

Three-throw 25787-30212G 25907-30301G

Four-throw 25787-30222G 25907-30401G

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 7.1 General description
The hydraulic system mainly consists of main pump,control valve,high & low
pressure oil pipes and [Link] main pump is a gear type and installed on the top of the
[Link] pump is fitted to a gear to which the charging pump is also [Link] the
engine runs,the main pump is driven to draw up oil from the tank and send it to the control
[Link] control valve,provided with a relief valve to keep the circuit pressure within the
specified one,controls the cylinders by changing over the oil passages inside the valve
body with the spools.
7.2 Main pump
The main pump consists primarily of a drive gear,driven gear and pump body which
contains the two gears and other [Link] drive gear is in mesh with the driven
gear.
7.3 Control valve(See Fig.7.1)

Lift slide valve

Tilt slide valve
Main relief valve

Outlet
To pump

Tank port

Flow-divider

Turning Relief valve

Fig.7.1 Control valve

The control valve is a sectional type consisting of the inlet section,plunger section
and outlet section which are assembled with three bolts.
At the inlet section is a cartridge type relief valve to set the oil pressure in the
[Link] plunger section controls the hydraulic cylinders by changing over the flow of
oil from the relief valve with [Link] tilt cylinder plunger section is equipped with a
tilt lock [Link] returned from the cylinders is returned to the tank through the outlet

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section. Each section is sealed with O-ring,and the oil passage at the high pressure side is
given a check valve.
7.4 Operation of control valve
(1) Neutral position (See Fig.7-2)

One-way valve
Parallel feeder
Cylinder port "B" Cylinder port "A"

Return sping

Core
Neutral passage Low pressure passage

Fig.7.2 Neutral position

The oil discharged from the pump returns to the tank through the neutral [Link]
cylinder ports “A” and “B” are kept closed.
(2)Pushing-in of plunger (See Fig.7.3)
The neutral passage is closed,and the oil pushes up the load check valve from the
parallel feeder and flows to the cylinder port “B”. The returning oil from the cylinder
port“A” flows through the low-pressure passage to the [Link] plunger is restored to
the neutral position by thr return spring.
(3)Drawing-out of plunger(See Fig.7.4)
With the neutral passage closed,the oil pushes up the load check valve from paralled
feeder and flows to the cylinder port “A”. The returning oil from the cylinder port “B”
flows through the low-pressure passage to the tank. The plunger is restored to the neutral
position by the return spring.

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 Fig.7.3 Push slide valve Fig.7.4 Pull slide valve

7.5 Operation of relief valve

(1) The relief valve is mounted between the cylinder port “HP” and the low-
pressure passage “LP”,The oil flows through the poppet“C” and affects the two areas
“A” and “B” differently in diameter,so that the check valve poppet “K” and the
relief valve poppet “D” are securely seated.(See Fig.7.5)
(2) When the pressure in the cylinder port “HP” reaches the set pressure of the
pilot poppet spring force,the pilot poppet “E” [Link] oil passes around the
poppet,flowing through the drilled hole to the low pressure side “LP”.(See Fig.7.6)
(3) As the pilot poppet “E” is opened,the preeure behind the poppet “C”
drops,due to which the poppet “C” is moved to seat on the pilot poppet “E”.As a
result of this,the oil flowing behind the relief valve poppet,”D” is shut off and the
pressure at the inner side is reduced.(See Fig.7.7)
(4) Compared to the pressure at the cylinder port “HP” side,the inner pressure
becomes unbalanced,causing the relief valve poppet “D” to open and thereby sending
the oil directly to the low-pressure passage “LP”.(See Fig.7.8)
Low pressure
Low pressure
High
pressure
High
pressure

Low pressure Low pressure

Fig.7.5 Fig.7.6
Low pressure Low pressure

High High
pressure pressure

Low pressure Low pressure

Fig.7.7 Fig.7.8

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 7.6 Operation of tilt lock valve
The tilt—lock valves are intended to prevent vibrations of the mast due to possible
creation of internal negative pressure in the tilt cylinder and also to avoid a danger of the
mast tilting due to accidental lever action when the engine is at [Link] the conventional
model,even if the engine is kept at rest,the mast can be tilted forward by actuating the
[Link] this newly adopted tilt—lock valves does not allow the mast to tilt forward as
far as the engine is at rest,even if the tilt lever is pushed with the full [Link] to fig.7-9
for the construction of the tilt—lock valve.
The port “A” side of the plunger housing is led to the front side of the tilt
cylinder,and the port “B” side to its rear [Link] the tilt lever is pulled(plunger
drawn out),the oil from the pump flows into the port “A” while the port “B” side oil
returns to the tank,due to which the mast is tilted backward by the tilt cylinders.
When the tilt lever is pushed (plunger pressed),the oil from the pump flows into the
port “B”.But the port “A” side oil does not return to the tank unless the poppet
installed in the plunger is moved,nor does the mast tilt [Link],while the engine is
being shut down,the mast never tilts forward nor does the internal pressure in the tilt
cylinders get negative.

Tilt cylinder

Spring
Plunger
Poppet

T: To tank P: To oil pump A、B: To tilt cylinder

Fig.7.9 Tilt lock valve

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 7.7 Operation unit of the control valve (refer to the fig. 7.10)
The control valve is operated with the valve levers are assembled together with a shaft
and the shaft is assembled on the bracket of the cabinet. The valve levers operate the
control valve with the joints.

Attachment lever
(option)
Tilt lever
Lift lever

Linkage

Control valve

Section

Fig.7.10 Control valve lever unit

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 7.8 Oil tank (refer to the fig. 7.11)
The hydraulic oil tank is on the right side of the frame. Oil filter of the front and rear
oil pump, the oil cap with a oil meter and brake return oil pipe used when powered braking
are assembled on the tank’s plate.

Steering cylinder To Rear pump

To front pump

Lift cylinder

From control valve

Oil filter (Front pump)

Oil filter (Rear pump)

Fitting oil cap(oil mark)

Self-brake circuit

Breather

Fig.7.11 Oil tank

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 7.9 Hydraulic circulation system(Main circuit)
The hydraulic system sketch see following:
The hydraulic circulation system of 5 to 8 ton forklift trucks see Fig.7.12.
The hydraulic circulation system of 10 ton forklift trucks see Fig.7.13

Tilt cylinder
Lift cylinder
Control valve

Cut-off valve

Regulator

Main relief valve

Front pump
Steering cylinder
Rear pump
Flow-divider

Oil filter Double-pump

Turning securing valve Steering unit

Fig.7.12 Hydraulic system

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 Tilt cylinder(R)
Tilt cylinder(L)

To lift cylinder

Control valve
Rear pump

To lift cylin der

Front pump

Steering cylinder
Steering unit

Fig.7.13 Hydraulic circuit(for 5-10t truck)

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 The hydraulic circulation system of the main circuit becomes complicated because of
the application of the hydraulic circuit for power [Link] hydraulic piping is of O-
ring fitting type with excellent sealing performance,providing secure oil tightness.
The hydraulic oil sent from the rear main pump flows directly to the control
valve,while the hydraulic oil sent from the front main pump is divided by the flow divider
valve in two portions for steering and load handling operation.
The hydraulic oil for load handling flows into the control valve and mingles with the
hydraulic oil from the rear main [Link] the control valve in neutral position,the oil
returns to the oil tank,passing through the valve.
When the lift lever is pulled,the hydraulic oil from the control valve flows through the
flow regulator valve and reaches the lower part of the lift cylinder piston to push up the
piston [Link] the lift lever is pushed,the circuit between the lower part of the lift
cylinder piston and the oil tank is opened,and the piston begins to descend due to the
weight of the piston rod,lift bracket,forks,[Link] this case,the oil returning to the control
valve is regulated by the flow [Link] the tilt lever is operated,the hydraulic oil
from the main pump reaches one side of the piston to push [Link] oil pushed by the piston
returns to the oil tank through the control valve.
7.10 maintenance
7.10.1 Disassembly of control valve
Dismount the control valve from the machine and clean the exterior of it.
(1)Remove the fitting bolts and separate the control valve into each [Link]’t
lose the check valves and springs arranged at the joint sections.
(2)Remove the screws at the plunger head side and the bolts with [Link] at the
cap side,and remove the wiper,O-ring and seal plate from the valve housing together with
plunger.
(3)Put the plunger on the vice and remove the cap [Link] then remove the springs
and spring [Link] the plunger provided with a tilt lock,remove also the spring and
poppet in the plunger.
7.10.2 Reassembly of control valve
Using mineral oil,clean all the disassembled [Link] them for burrs or nicks,and
replace as [Link] valve housing and plunger,and the plunger and poppet are
assembled by [Link] replacement is needed,replace the assembly.
(1) Fasten the plunger with vice,and install the poppet and spring in the
plunger,observing the direction of poppet.
(2) Install the O-ring,wiper,seal plate,spring seat,spring and spring seat in this
order to the plunger end side,and tighten them with cap screw to the torque of 25 to 32N.m.
(3) Insert the assembled plunger into the valve housing and fit the cap by the bolt

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with hex groove.(Tightening torque:9 to 11 N.m)
(4) Fasten the O-ring and wiper to the plunger head side and tighten the seal plate
with screw to the torque of 4.6 to 5.8 N.m.
(5) After assembling,install the check valve,spring and O-ring in each section and
tighten them to the specified torques with three bolts.(one bolt:103N.m;the others:66N.m)
7.10.3 Note
The pressures of the safe valves inside the control valve are adjusted before leaving
the factory. They can not be adjusted as will by users avoiding the damaged of the
hydraulic system and hydraulic units because of over high pressures. Regulate the
pressures of the safe valves according to the manual after repair.

8. Lift Cylinder & Tilt Cylinder

The main specification see Table 8.1.
Table 8.1

5-7t 8t 10t
Type Single-acting piston type
Lift cylinder

Cylinder bore Φ80 Φ90 Φ100

O.D. of piston rod mm Φ60 Φ70
Stroke 1495
Type Double-acting piston type
Tilt cylinder

Cylinder bore Φ115

O.D. of piston rod mm Φ50
Stroke 227 242
8.1 Lift Cylinder
The two lift cylinders of single acting type are used and located behind each outer
mast [Link] bottoms of the cylinders are sustained by the mast support of the outer
mast while the tops of them,or the piston rod ends are inserted into the one body
construction piston head.
The lift cylinder assembly consists primarily of a cylinder body,piston,piston rod and
cylinder [Link] the lower part of the cylinder body is arranged an inlet for high-pressure
oil,and at the upper part there is an outlet for low-pressure oil above the piston packing,to
which a return pipe is [Link] piston is fastened to the piston rod with castle nut
and cotter pin together with an O-ring.A wear ring,packing and back-up ring are attached
to the outside periphery of the piston which is moved along the inner surface of the
cylinder by high-pressure [Link] oil seal and bushing are installed on the cylinder cap
which is screwed into the cylinder [Link] bushing supports the piston rod,and oil seal

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prevents dust from entering the [Link] upper end of the piston rod is locked with
piston head set bolts.
When the lift lever is tilted backward,high oil pressure is sent into the lift cylinders
through their inlets to push up the piston rods and active beam causing the forks to rise
through [Link] height from the ground to the fork position at which the inner mast
frame connecting member begins to be lifted is called “Free Lift” [Link] this
range,the mast height does not [Link] the lift lever tilted forward,the pistons of the lift
cylinders descend by the weights of the piston rods,lift bracket,finger bar and
forks,causing oil under the piston to flow out of the [Link] oil discharged from the
cylinders is regulated by the flow regulator and returns through the control valve to the oil
tank.
[Link]
[Link]
[Link]-ring
[Link] cap
[Link] bushing
6.O-ring
[Link] body
[Link] rod
9.O-ring
[Link]
[Link]-ring
[Link] nut
[Link] pin
[Link] chain
[Link]
[Link] bushing
[Link] ring
[Link]
[Link]-off valve
[Link] beam

Fig.8.1 Lift cylinder(5-8t truck)

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 [Link]
[Link]
[Link]-ring
[Link] cap
[Link] bushing
6.O-ring
[Link] body
[Link] rod
[Link]
[Link]
[Link]-ring
[Link]
[Link] chain
[Link]
[Link] bushing
[Link] ring
[Link]
[Link]-off valve
[Link] beam

Fig.8.2 Lift cylinder(10t truck)

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 8.2 Cut-off valve
At the bottom of the two lift cylinders are two cut-off valves(See Fig.8.1 No.19 or
Fig.8.2 No.18) which operate when the high-pressure hose bursts for any reason to prevent
the load from dropping down [Link] oil from the lift cylinder flows through small
holes in the circumference of the cut-off piston and produce a pressure difference between
two chambers. As the pressure difference as result of passing the holes is smaller than the
spring force so that the cut-off spool won't [Link] the high-pressure hose bursts, it allows
only a small amount of oil to flow through the holes in the spool head to let the forks
descend at low speed.

Natural conditions Cut-off conditions

Fig.8.3 Cut-off valve

8.3 Flow regulator

The flow regulator valve is located between the control valve and the high pressure
ports of the two lift cylinders,near the left cylinder (See Fig.8.4).The structure of the flow
regulator valve is shown in Fig.8.5. The structures of 8 ton and 10 ton forklift trucks are
almost the same as 5 to 7 ton forklift [Link].3 in Fig.8.5 is taper helical spring for 8 ton
forklift trucks and is coil spring for 10 ton forklift trucks.
The flow regulator valve serves both as a flow regulating valve while forks are
lowering and a safety device if rubber hoses between the control valve and lift cylinders
are damaged due to any reason.
The operation of the flow regulator valve is given below.

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 See [Link] the forks upraised,high pressure oil led from the control valve flows
into the chamber (A) and shifts the sleeve (2) to the [Link] opens the opening (G) to allow
the high pressure oil to flow along the two routes(A-B-G-D-E and A-B-C-D) and both
flows of oil lead to the lift [Link] this case,the flows of oil is not [Link] the
forks begin to lower,oil discharged from the lift cylinders enters the chamber (E) and shifts
the sleeve until it contacts the [Link] closes the opening (G) so that oil flows through
(E),(D),(H),(C),(B) and (A) to the [Link] the amount of oil discharged from the lift
cylinders is rapidly increased,the pressure in the chamber (F) rises and moves the piston
(5) to the right in spite of the spring force,narrowing the opening (H).So the flow of oil from
the chamber (D) to the chamber (C) is decreased so that the descending speed of the forks
is controlled.

Lift cylinder(R)

Lift cylinder(L)

From control valve

To oil tank

Regulator

Fig.8.4 Regulator mounting position

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To lift cylinder To control valve

[Link] [Link] ball [Link] ring [Link]

[Link] sleeve [Link] core [Link] body
[Link] [Link] plate [Link]

Fig.8.5 Regulator(5-7t truck)

8.4 Tilt cylinder

[Link] [Link]-ring [Link]-ring [Link]

[Link] [Link](cylinder cap) [Link] [Link] ring
[Link] sleeve 8.O-ring [Link] [Link] ring
[Link] ring [Link] [Link] rod
[Link] ring [Link] body [Link]

Fig.8.6 Tilt cylinder

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 Two tilt cylinders of double acting type are provided at each side of the [Link]
front end of the piston rod is installed on the mast and the cylinder tail is on the frame with
pins.
The tilt cylinder assembly aonsists primarily of a cylinder body,cylinder cap,piston
and piston [Link] piston is welded to the piston [Link] piston,of which the outside
periphery is given two packings and a wear ring,slides inside the cylinder by hydraulic
[Link] inside periphery of the cylinder cap has a press—fitted bushing,packing and dust
seal to keep oil tightness between the piston rod and the inside of the cylinder cap.
The cap,fitted with an O-ring on the outer periphery,is screwed into the cylinder body
and fastened with a lock ring.
When the tilt lever in the drive's room is tilted forward,high pressure oil enters from
the cylinder tail side to shifts the piston forward,tilting the mast forward 6 [Link]
the tilt lever tilted backward,high pressure oil enters from the cylinder cap [Link] shifts
the piston to the rear,causing the mast to tilt backward 12 degrees.

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 9. Hoist System
The main specifications see table 9.1.

5-7t 8t 10t

Type Rolling type,welded mast with free lift,

2-stage telescopic mast

Cross section of inner mast

Cross section of outer mast

Max. Lift Height (S.T.D.) 3000mm

Forward tilt (S.T.D.) 6°

Backward tilt (S.T.D.) 12°

O.D. of end rollers mm Φ151.5 Φ183.5

Rollers

O.D. of side rollers mm Φ82

O.D. of retaining
(on bracket) mm Φ102 Φ109.7 Φ119
LH2044,4×4， LH2444,4×4， LH2844,4×4,
Lift chain
P=31.75 P=38.1 P=44.5
Fork lifting method Hydraulic

Mast tilting method Hydraulic

Fork spacing adjustment Manual

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 9.1 General
The hoist system is of the two-stage,rolling telescopic mast type. The inner mast
frames have J-shaped section. The outer mast frames have J-shaped section of 10 ton
forklift trucks and have C-shaped section of 5 to 8 ton forklift trucks. The masts of 5 to 10
ton forklift trucks all contain a free lift range.
9.2 Outer & inner mast
The mast assembly is of the free lift range-contained two stage telescopic type
consisting of the inner and outer mast,and is sustained by mast [Link] mast supports
are welded to the bottom of the outer mast,being extended from the axle housing. The outer
masts are provided with brackets for lock pins of tilt cylinder connecting [Link]
mast is tilted by operation of the tilt cylinders,forward 6°and backward 12°.
The inner mast is composed of right and left mast frames which are connected with
each other by upper and lower connecting [Link] the upper inside of each outer mast
frame an end roller is installed on the end roller shaft welded to the frame,with a snap
[Link] addition,the outer mast frames are fitted with side rollers to sustain the inner mast
[Link] the lower outside of each inner mast frame an end roller is installed on the end
roller shaft with snap ring,which is welded to the inner [Link] the end rollers other
side rollers are located to sustain transverse [Link] the aid of these rollers,the inner
mast can smoothly operates.
9.3 Lift bracket
At the lift brackets,end rolers that roll along the inside of the inner mast frames are
installed on the end roller shafts with snap [Link] end roller shafts are welded to the lift
[Link] side rollers that roll along the inside of the inner mast frames are bolt
fitted,being shim [Link] prevent the tolling of the finger bar,two retaining rollers are
used,which roll along the outside of inner mast [Link] lingitudinal load is sustained
by the end rollers of which the upper ones emerge from the mast top when the forks reaches
the maximum lift [Link] transverse load is sustained by upper retaining rollers and
lower side [Link] we mentioned above,the mast assembly and lift brackets are designed
with rigidity,stability and smooth operation in [Link],the finger bar and lift
brackets are made into one body construction using high tension steel to improve the
[Link] meets the ISO Standards.
The two forks installed on the finger bar are made of special alloy steel which has
been subjected to heat treatment.
9.4 Adjustment of hoist system
9.4.1 Adjustment of lift cylinder
When replace the lift cylinder,inner mast or outer mast,we shall readjust the stroke of
the lift cylinder as following steps.
(1)Install the piston rod in the upper beam of the inner mast without shims.
(2)Lift the mast slowly to the max. stroke of the cylinder and check whether the two
cylinders synchronize or not.
(3)Install shims between the top of the piston rod of the cylinder which stop first and
the upper beam of the inner [Link] shim are 0.2mm or 0.5mm thick.
(4)Adjust the tightness of lift chains.

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 The adjustment of the lift cylinder also belongs to exalted maintenance. Please be
careful.
Upper beam of
inner master Spacer

Lift cylinder

Fig.9.1

9.4.2 Rust protection and maintenance of the lift cylinder

The moisture content of the atmosphere and salt fog will go into the cylinder
through the oil return pipe and the clearance between the sealing parts and other parts if
the cylinder is not used for a long time. And thus the piston rod and inside of the cylinder
barrel will be corroded and the exterior of the cylinder will become rusty. Once the
cylinder gets rusty, it will be no longer serviceable.
Rust protection and maintenance measures:
(1) Rust protection of the piston rod exposed outside: wipe the surface of the piston
rod with oil cloth evenly every one or two week in sunny days so as to form oil firm. If it is
humid weather, do as above every 3-5days.
(2) Rust protection of the interior of the cylinder: lift and lower the mast several
times in sunny days every 3-5 days to make the interior of the cylinder be fully oil
lubricated; do the above every 2-3 days in humid weather.
9.4.3 Carriage adjustment
(1)Let the truck parking on the horizontal ground and make the mast vertical.
(2)Let the bottom of the fork contact with the [Link] the adjusting nut for the

Stopper of inner mast

Tire

Inner mast

End roller Stopper of bracket

Fork
Side end joint of mast

Fig.9.2 Fig.9.3
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end nipple of the upper chain and make a distance A
Chain
between the main roller and the carriage A. The A's
value equals the 1/4-1/3 value of the main roller's
radiu.
(3)Lift the fork to the max. height to ensure the
End joint
clearance B between the stopper of bracket and the
stopper of inner mast is 5-10mm.
(4) Make the fork down to the ground and tilt
Adjust nut
backward fully. Adjust the adjusting nut for the end
nipple of the upper chain and make the two chains' Lock nut
tightness equal.

Fig.9.4

9.5 Roller disposal

There are three kinds of rollers in the hoist system,main roller,side roller group,side
[Link] are separately mounted on the outer mast,inner mast and carriage. Roller
disposal of the trucks of 5-10t is almost [Link] main rollers sustain the loads from
front and rear direction, and generally can not be [Link] side rollers sustain the side
loads. Clearance in right and left side direction can be adjusted with shims so that outer
mast, inner mast and bracket can move freely up and down.

Lift bracket Inner mast

Outer mast

Washer Side roller

Stopper
End roller

Chain
Lift cylinder

Upper Lower

Fig.9.5 Roller lay(for 5-7t truck)

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 Lift bracket Inner mast
Outer mast

Washer Side roller

Stopper

End roller

Chain
Lift cylinder

Upper Lower

Fig.9.6 Roller lay(for 8t truck)

Inner mast Outer mast

Lift bracket

Washer
Side roller

Stopper

End roller

Chain
Lift cylinder
Upper Lower

Fig.9.7 Roller lay(for 10t truck)

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地址：安徽 合肥 经开区方兴大道668号
电话：0551 63689000
传真：0551 63689666

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S66-6:2013