Introduction

This manual main introduces the items in the aspects of performance, structure, and
operation, as well as maintenance and service, etc of the 2t-3.5t forklift trucks, so that the
operators are able for a correct use and maintenance.

During the user operating process, the operators and equipment management personal
involved shall carefully follow the relevant regulations of this manual, for the forklift truck to
maintain its good technical conditions.

1
 Table of Contents

Introduction ........................................................................................ 1
I. Forklift Truck Main Technical Parameters ................................................ 4

II. Description about Forklift Truck Main Parts .....8

III. Structure, Principle, Adjustment, and Maintenance of Forklift Truck .......... 10
1. Power System ................................................................................ 10
1.1 Engine Overview............................................................................. 10
1.2 Items to be Observed for Installation & Operation of Engine(LPG/Gasoline) ...... 13
1.3 Engine Adjustment .......................................................................... 15
1.4 Fuel System: ................................................................................. 16
2. Clutch and Its Pedal......................................................................... 21
2.1 Overview ...................................................................................... 24
2.2 Method for Replacement of Brake Shoe Assembly .................................... 24
3. Hydraulic Transmission Case and Torque Converter ............................... 26
3.1 Overview ...................................................................................... 26
3.2 Torque Converter ............................................................................ 28
3.3 Hydraulic Clutch ............................................................................. 29
3.4 Control Valve, Safety Valve, and Inching Valve ......................................... 30
3.5 Transmission Case .......................................................................... 31
3.6 Oil Feed Pump ............................................................................... 31
3.7 Hydraulic Oil Circuit (Hydraulic Transmission) .......................................... 32
3.8 Speed Reducer and Speed Differential .................................................. 33
3.9 Traction of Forklift Truck to be Repaired .................................................. 33
3.10 Oil Port Joint Positions .................................................................... 33
4. Drive Axle ...................................................................................... 34
4.1 Overview ...................................................................................... 34
4.2 Maintenance of Drive Axle ................................................................. 35
5. Steering System ............................................................................. 36
5.1 Overview ...................................................................................... 36
5.2 Examination after Reassembly of Steering System .................................... 38
5.3 Failure Removal for Steering System .................................................... 39
6. Cross Cylinder Drive Axle ................................................................. 40
6.1 Overview ...................................................................................... 40
6.2 Steering Knuckle and Steering King Pin ................................................. 42
6.3 Adjustment for Pre-Tightened Load of Steering Wheel Bearing ..................... 42
7. Brake System ................................................................................. 43
7.1 Overview ...................................................................................... 43
7.3 Wheel Brake .................................................................................. 44
7.4 Automatic Clearance Regulator ........................................................... 46
7.5 Parking Brake ................................................................................ 46
2
7.6 Adjustment of Brake Pedal (Mechanical Forklift Truck)................................. 46
7.7 Adjustment of Brake Pedal (Hydraulic Forklift Truck) ................................... 48
7.8 Maintenance ................................................................................... 48
7.9 Operating Test on Automatic Clearance Regulator ..................................... 54
7.10 Failure Removal for Wheel Brake......................................................... 55
8. Hydraulic System ............................................................................. 56
8.1 Overview ....................................................................................... 56
8.2 Main Oil Pump ................................................................................. 57
8.3 Multi-way Valve and Bypass Valve ......................................................... 57
8.3.1 Operation of Spool Valve .................................................................. 58
8.3.2 Main Safety Overflow Valve and Bypass Safety Valve ............................... 58
8.3.3 Action of Inclined Autolock Valve ......................................................... 59
8.4 Oil Circuit of Hydraulic System (Main Oil Circuit) ....................................... 60
8.5 Lifting Cylinder ................................................................................ 61
8.6 Limiting Valve .................................................................................. 62
8.7 Tilting Cylinder ................................................................................. 63
8.8 Maintenance of Main Oil Pump............................................................. 64
9. Lifting System ................................................................................. 72
9.1 Overview ....................................................................................... 73
9.2 Inside and Outside Masts ................................................................... 73
9.3 Bracket .......................................................................................... 73
9.4 Adjustment of Lifting System ............................................................... 73
10. Electrical System ............................................................................ 74
10.1 Overview ...................................................................................... 74
10.2 Operating Brief Description................................................................ 74

IV. Drive, Operation, and Routine Maintenance of Forklift Truck .......................... 75

1. Conveyance of Forklift Truck .................................................................. 76
2. Storage of Forklift Truck ....................................................................... 76
3. Preparation prior to Operation................................................................ 76
4. Operation of Forklift Truck ..................................................................... 76
5. Notices for application of Cooling System.................................................. 77
6. Oils Used for Forklift Truck .................................................................... 78
7. Lubricating System Table ..................................................................... 79

3
 I. Forklift Truck Main Technical Parameters (Refer Table Diesel F/L & LPG/Gasoline F/L)
Main Technical Parameters
Diesel F/L

Model 20D-7SA 25D-7SA 30D-7SA 35D-7SA

Parameter
Rated Load (KG) 2000 2500 3000 3500

Load Center (mm) 500

Lifting Height (mm) 3000

Free Lifting Height (mm) 160 165 170

Mast Tilt Angle (Front/Rear) 6/12

+Performance Parameter

Lifting
No-Load 550 550 440 350
Speed
(mm/s) Full-Load 530 530 425 335

Running
Speed Forward 20 20 19 18
(km/h)

Max No-Load (N) 15000 1700

Traction
Force Full-Load (N) 17000 1900

No-Load (%) 20 18
Gradeability
Full-Load (%) 20 18

Min Turning Radius R (mm) 2330 2330 2450 2510

Min Cross Passage Width K (mm) 1940 2010 2140 2160

4
 Main Technical Parameters
Diesel F/L Continued

Model 20D-7SA 25D-7SA 30D-7SA 35D-7SA

Parameter
Whole Length L (Without Fork) (mm)
2590 2590 2705 2790
Whole Width W (mm) 1150 1210
Whole Height D(Mast Retracted) (mm)
2010 2075 2150
Whole Height E(Mast Extended) (mm)
3990 4100
Wheelbase F (mm)
1600 1700
Front Q1 (mm)
Size Parameter

970 1000
Wheel
Base Rear Q2 (mm) 980
Front Clearance B (mm) 475 490 510
Rear Clearance C (mm) 515 515 580
Length (mm) 1070

Fork Dimension Width (mm) 122 125

Height (mm) 40 45 50
Fork Horizontal Adjustment Quantity (mm) 250-1040 250-1100 260-1110
Ground Clearance(in the Place of Mast) (mm) 125 140
Self weight (kg) 3400 3700 4380 4730

5
 Main Technical Parameters
LPG/Gasoline F/L

Model 20L-7SA 25L-7SA 30L-7SA 35L-7SA

Parameter
Rated Load (kg) 2000 2500 3000 3500

Load Center (mm) 500

Lifting Height (mm) 3000

FreeLifting Height (mm) 160 165 170

Mast Tilt Angle (Front/Rear) 6/12

Performance Parameter

No-Load 550 550 450 350

Lifting Speed
(mm/s) Full-Load 530 530 425 335
Running
Speed Forward 20 20 19 18
(km/h)

Max Traction No-Load (N) 15000

Force Full-Load (N) 17000

No-Load (%) 20 18
Gradeability
Full-Load (%) 20 18

Min Turning Radius R (mm) 2330 2330 2450 2510

Min. Cross Passage Width K (mm) 1940 2010 2140 2160

6
 Main Technical Parameters
LPG/Gasoline F/L Continued

Model 20L-7SA 25L-7SA 30L-7SA 35L-7SA

Parameter
Whole Length L (Without Fork) (mm)
2590 2590 2705 2790
Whole Width W (mm) 1150 1210
Whole Height D(Mast Retracted)(mm)
2010 2075 2150
Whole Height E(Mast Extended) (mm)
3990 4100
Wheelbase F (mm)
1600 1700
Front Q1 (mm)
970 1000
Size Parameter

Wheel
base Rear Q2 (mm) 980
Front Clearance B (mm)
475 490 510
Rear Clearance C (mm) 515 515 580
Length (mm) 1070
Dimension
Fork

Width (mm) 122 125

Height (mm) 40 45 50
Fork Horizontal Adjustment Q ty (mm) 250-1040 250-1100 260-1110
Ground Clearance( Mast) (mm) 125 140
Service Weight (kg) 3320 3620 4300 4650

7
II. Description about Forklift Truck Main Parts
Mechanical
Clutch Transmission
PowerSystem Transmission Speed Reducer or
Case
System Torque Hydraulic Speed Differential
Converter Transmission
Case

Drive Axle Steering System Steering Axle Lifting System

Brake and Clutch Control (Mechanical Truck)

Brake and Inching Control (Hydraulic Truck)
Control System Parking Brake Hydraulic System
Throttle Control/
Air Throttle Control

Electrical System

8
Outside Drawing of Forklift Truck

9
III. Structure, Principle, Adjustment, and Maintenance of Forklift Truck
In order for operators to use, service, and maintain the forklift truck in a better way, the items of such
aspects as the structure, principle, adjustment, disassembly and assembly, maintenance, and failure
removal, etc related to the forklift truck are now introduced one by one, respectively.

1. Power System
1.1 Engine Overview
Refer to Table 1 and Table 2 for the Diesel and LPG/Gasoline engines used at present for 2.0-3.5t forklift
trucks.

10
 Diesel Engine
Table 1
Main Technical Parameters Diesel Engine
Model Mitsubishi S4S
Type 4-Stroke, Water-Cooling, Straight-Line
and Valve in Head
Number of Cylinders Cylinder
4-94×120
Diameter x Stroke (mm)
Cylinder Total Displacement 3.331
Compression Ratio 22.1
Rated Power/Speed 35.3kw/22500rpm
Max Torque/Speed 182N.m/1800rpm
No-Load Min Speed (rpm) 770 20
Min Fuel Specific Consumption (g/ps.h) 265
Whole Length x Whole Width x Whole Height (mm) 781×567×717
Movement Direction Counterclockwise as viewed from flywheel side
Firing Order 1-3-4-2
Inlet Valve Open before Top Dead
30
Center(BTDC)
Inlet Valve Close after Bottom Dead
50
Center(ABDC)
Valve Timing

Exhaust Valve Open before Bottom

74
Dead Center(BBDC)
Exhaust Valve Close after Top Dead
30
Center(ATDC)
Valve Inlet Valve (Heat Engine) 0.25
Clearance
mm ExhaustValve(Heat Engine) 0.25
Cooling System Forced Circulation Water Cooling
Lubricating System Forced Circulation
Injection Pump Bosch A
Fuel Filter Catridge of Paper Element
Engine Oil Pump Trochoid
Oil Rough Filter Catridge of Paper Element
Water Pump Centrifugal Type
Main Part

Thermostat Wax Pellet Type

Voltage 12V
Generator
Current 50A
Voltage 12V
Starter
Output Power 2.2kw
Voltage 12V
Batter
y

Capacity 90Ah

Lubricating Oil Capacity 10 (Oil Pan : 9 , Filter : 1 )

Referential Data Cooling Water
5.5
(Engine Water Jacket)

11
 LPG/Gasoline ENGINE
Table 2
Main Technical Parameters LPG engine
Model Nissan K25
Type 4-Stroke, Water-Cooling, Straight-Line, and Valve
in Head
Number of Cylinders Cylinder
4-89×100
Diameter x Stroke (mm)
Cylinder Total Displacement 2.488
Compression Ratio 8.7
Rated Power/Speed 37.4kw/2300rpm
Max Torque/Speed 176.5N.m/1600rpm
No-Load Min Speed 850rpm
Min Fuel Specific Consumption 290g/kw.h
Whole Length x Whole Width x Whole Height 708.9×588.6×728mm
Movement Direction In Clockwise Direction Looking from the
End of Fan
Firing Order 1-3-4-2
Inlet Valve Open before Top Dead
14
Center(BTDC)
Inlet Valve Close after Bottom Dead
30
Center(ABDC)
Valve Timing

Exhaust Valve Open before Bottom

32
Dead Center(BBDC)
Exhaust Valve Close after Top Dead
12
Center(ATDC)
Valve Inlet Valve (Heat Engine) 0.38
Clearan
ce (mm) Exhaust Valve(Heat Engine) 0.38
Cooling System Forced Circulation Water Cooling
Lubricating System Forced Lubrication
Gasoline Pump Membrane Type
Air Filter Paper Element Filter
Engine Oil Pump Gear Type
Oil Rough Filter Paper Filtration
Water Pump Centrifugal Type
Main Part

Thermostat Wax Type

Voltage 12V
Generator
Current 50A
Voltage 12V
Starter
Output Power 1.2kw
Voltage 12V
Battery
Capacity 60Ah
Lubricating Oil 3.5
Referential Data
Cooling Water 3.5
Refer to their respective engine operation and maintenance manuals for the introduction about
homemade engines used for 2.0-3.5 forklift trucks. The power of engine is mainly transmitted to the
transmission system from flywheel through clutch or torque converter, and as engine itself carries
working oil pump, it is relatively convenient for engine to replace fan belt.

12
1.2 Items to be observed for Installation and Operation of LPG/Gasoline Engine
(1) Items to be observed for Installation of LPG/Gasoline Engine
Items to be Observed during Assembly
Requirement Remarks
of Forklift Truck
80 in Common Use and
Allowed Temperature for To prevent too heated
Cooling System

Max 110 (Outlet Water

Cooling Water engine
Temperature)
2
Pressure of Heat 88.3kPa(0.9kg/cm ) in
Standard Value
Radiator Cover Common Use
Exhaust shall be performed
Exhaust from the place of pet cock,
when cooling water is injected.
Lubricating 120 Max Oil Temperature
Allowed Temperature
System inside Oil Pan

(2)Items to be observed for Operation of LPG/Gasoline Engine

Items to be Observed during Operation Requirement Remarks
It is required to use wire
mesh air filter core, to be
replaced generally after
work for 1200 hours in 6
months, while it shall be
Air Suction Negative
Max 6.18kPa, and replaced as soon as
Pressure (Inlet Negative
Cooling System below 0.98kPa in possible for 3-shift
Pressure of Inlet Bell
Common Use system or for atrocious
Mouth)
environment, and
otherwise, the cylinder
and piston will be worn
out, and CO black smoke
will be discharged.
13.3kPa (below Adverse impact will arise
Exhaust Pressure
Exhaust System 100mmHg) in for engine power and
(Air Vent Outlet Pressure)
Common Use noise, if too high.
P.T.O Otherwise P.T.O. chain
(Power-Take-Off) Oil Pump Allowable Load 6.7kg mm/3215rpm will extend and break and
System engine will stall out.
Standard
Electrical Generally used for
Battery Capacity Specification:
System -15 +35
12V-60Ah

Standard Situation:
Ambient Temperature
-15 +35

When used at more than

Operating 1000m altitude, the
Environment Standard
mixed compensation
Specification:
Regional Altitude shall be performed for
Elevation below
gasoline engines in
1000m
combination with
altitudes.

13
 (2)Fuel, Lubricating Oil Used for LPG/Gasoline Engines and Other Requirements

Item Requirement Remarks

Equivalent to Chinese Standard
GB484-86RQ-90 Number gasoline,
and otherwise, the rotating speed will
be instable, it will fail to combust
Lead-free general gasoline at 89 octane
completely, if present with lead
Fuel rating to be used, equivalent to Number
gasoline, and will cause wear to parts
JIS K2202-1988 2
of gasoline engines, and give rise to
environmental pollution.
National engine use National
or above diesel

Application Specifications: API: Above SD

Grade (Equivalent to above Chinese QD
Grade)
Switched to CF-4 level or above from
Lubricating Oil SAE: For Normal Regions: 20W th
12 May, 2016
Clod Zones: 10W
To be replaced after use for 200 hours or
1 month

Equivalent to JIS K2234-1988, 2 Kinds

LLC Concentration:
Standard Zones (above -15 ) 30%
Anti-freezing Chinese anti-freezing fluids shall be
Fluid Cold Zones (above -35 ) 50% referred to for implementation, and it is
(LLC-Long Life To be replaced generally for every 2400 recommended to use long-acting
Coolant) hours or 12 months, but it is changeable antirust anti-freezing fluid (-35 )
by taking circumstances into
consideration, as operating environments
and conditions are different.

Authentic products to be used

Fuel
To be replaced for every 2400 hours or 12
Filter
months
Remark

Authentic products to be used

Engine
To be replaced for every 600 hours or 3
Oil Filter
months

Authentic products to be used

Air Filter To be replaced for every 1200 hours or 6
months

Note: The period for replacement in the table indicates general situation (8 hours/day), and it shall be
replaced earlier for 3-shift system or under atrocious operating conditions.

14
1.3 Engine Adjustment
It is required to adjust the rotating speed of engine as it produces influence over operating efficiency with
both running speed and lifting speed of forklift truck, and the rotating speed of engine shall be adjusted
according to the undermentioned methods, if it fails to reach the specified value.
(1) Adjusting idle speed (used for LPG/Gasoline Engine)
a) Warm up the engine until the temperature of engine cooling water reaches 85 .
b) Mount tachometer on engine, and use the idle speed adjusting screw of carburetor to adjust the
engine speed to 650r/min for 2-3.5t forklift trucks.
c) Adjust the limit screw for the minimum openness of air throttle, in the direction for engine speed to be
increased.
d) Use idle speed adjusting screw of carburetor, to adjust the engine for 2-3.5t to 650r/min.
e) Repeat the steps c) and d) until a stable rotating speed of 650r/min.

(2) Adjusting the no-load maximum rotating speed (used for LPG/Gasoline Engine)
a) Warm up the engine until the temperature of engine cooling water reaches 85 .
b) Shut down, and ensure that the accelerator pedal is pushed down to the bottom and the air throttle is
fully opened.
c) Start engine, and allow air throttle to be fully opened.
d) The adjusting screw for speed limiter may be turned until the specified speed is reached, if the rotating
speed of engine is higher or lower than specified value.
e) The maximum no-load rotating speed for 2-3.5t is 2800-3000r/min.

(3) Adjusting idle speed (Used for Diesel engine)

The speed of diesel engine is controlled by speed limiter of fuel injection pump, and the latter has been
properly adjusted on test bed in general, while it can no longer be adjusted after engine is mounted. The
steps for adjustment using test bed are given as follows (for reference):

Fig 1-1

a) Control the zero adjustment of gear rack, mount the control rack for measurement device onto the end
face of control rack for oil injection pump, and align the zero position of control rack for measurement
device with the zero position of graduated scale.
b) Fully tilt the control rod in the direction for fuel to be increased, and ensure that the control rack
extends by more than 15mm. Then fully tilt the control rod in the direction for fuel to be stopped, and
ensure that the control rack on the graduated scale is less than 1mm.
c) Adjust the oil injection timing and injection speed.

15
d) Adjust the pressure from the minimum negative pressure.

(4) Examining whether or not air leak exists, by making use of adjusting rack to adjust the negative
pressure of oil injection pump in reference to Fig 1-2
(5) Adjusting the limit of smoke by making use of adjusting screw for limit of smoke, while the operators
shall pay attention that please never adjust it for imported engines, when they are basically under normal
operating conditions.

Fig 1-2
1.4 Fuel System:
Fuel system is composed of fuel tank, oil quantity sensor, and oil quantity indicator (Fig 1-3 and Fig 1-4)

Full Level

Float to Rise to This Place

Float to Drop to This Place

Oil Drain Plug

16
 Oil-Water Separator

Fuel Tank

Fig 1-3 Fuel Tank (Diesel Forklift Truck)

Full Level
Float to Rise to This Place

Float to Drop to This Place

Resistance as 1

Oil Drain Plug Engine Oil Inlet

Gasoline Filter
Port Sealed up
Fuel Tank

Fig 1-4 Fuel Tank (LPG/Gasoline Forklift Truck)

17
1.4.1 Fuel Tank
Fuel tank is an integrated welded structure connected with vehicle chassis into a whole, located on the
left side of vehicle chassis. The capacity of fuel tank for 1-2.5t is 52L, 60L for 3-3.5t forklift trucks, and the
fuel quantity sensor is fitted on the tank cover of fuel tank to detect the fuel level.

1.4.2 Fuel Quantity Sensor

K Direction

K Direction

Full
Level

Float to Rise to This Place

Resistance as

Fig 1-6 LPG/Gasoline Filter

Fuel position Resistance as( ) (Specially Available for LPG/Gasoline Engines)

Float to Drop to
This Place
Resistance as 1

Fig 1-5 Fuel Quantity Sensor

The fuel quantity sensor is used to convert the remaining fuel quantity in fuel tank into voltage, and refer
to Fig 1-5. The value of resistance will change, when float moves upward and downward, by making use
of alloy steel wire to be fabricated into slide resistance connected with float, and the storage fuel quantity
inside fuel tank can be read out from the instrument panel through electromagnetic fuel gauge.
1.4.3 Maintenance of Fuel System
The fuel system is to be maintained and serviced once for every work of 100 hours with the following
method, and the fuel tank shall be cleaned once for every work of 600 hours.
(1) Fuel Filter
Fuel filter is used for remove dust and impurity in fuel, and this fuel filter is located between the fuel tank
and the LPG/Gasoline pump (LPG/Gasoline engine) or oil delivery pump and oil injection pump (diesel
engine).
Service of fuel filter for LPG/Gasoline engine: (including the two items of A) and B))

A) Fuel Filter I for LPG/Gasoline engine is in a through or cylindrical type and it shall be replaced
periodically (namely replacement by years). (Refer to Fig 1-6). It is peculiar, with one grade of fuel
filtration increased.
B) Fuel filter for LPG/Gasoline engine (Refer to Fig 1-7.)

18
a) Take off the oil drain plug (Refer to Fig 1-7) and drain the fuel in gas cup completely.
b) Loosen Nut 1, and detach Filter Core 4.
c) Clean or replace the filter core.
d) After reassembly is completed, start engine for Fuel to be filled into the gas cup of filter. Examine
whether or not gas leak exists, and Parts 8 and 5 seal rings may be replaced if leak exists.
(2) Service of Diesel Engine fuel filter
This filter is in cylindrical type, not detachable generally, and it shall be replaced in complete set if
required.
a) For every work of 100 hours, dismount the cylindrical shell using special tools, and take out the filter
core.
b) For every work of 600 hours, the entire filter shall be replaced.
c) It is required to pay attention to examining as to whether or not fuel leak exists after reassembly.
d) Pay attention to examining the working status of Part 1 overflow valve.

Fig 1-7 Fig 1-8

(3)Fuel-Water Separator (Sediment Bowl)

As VE oil injection pump is lubricated with fuel internally, water content in fuel must be separated, and
therefore sediment bowl is used. If indicator light of fuel-water separator turns on, water shall be drained.
(Fig 1-9)
a) Water Drain
Loosen off the fuel drain plug and allow fuel drain plug to drain water manually. Then tighten the fuel
drain pump and start the pump for multiple times. It shall be ensured that not fuel leak exists, engine is
started, and warning light is turned off. Firmly tighten the fuel drain plug

19
b) Air Exhaust
Loosen off the air exhaust plug (overflow valve) of oil injection pump, and press the main pump until no
air emits. It shall be ensured that no fuel leak exists.
(4) Cleaning of Fuel Tank
The fuel tank is to be cleaned once for every work of 600 hours, and attention shall be paid to fire control
for forklift trucks using gasoline engine during cleaning.

Manual Fuel Pump

Fuel Drain Plug

Fig 1-9

20
2. Clutch and Its Pedal

Truck
Model 20/25/30/35L-7SA 20/25/30/35D-7SA
Parameter
Type Single Disk Dry Type

Outer Diameter 275 275

Size of Brake Inner Diameter 175 180
Shoe (mm)
Thickness when
7.8 8.4
Compacted
2
Surface Area (cm ) 352 340

Weight (kg) About 10 About 10

Operation Foot Pedal Type

21
 Fig 2-1 Clutch (Used for 2-3.5t LPG/Gasoline Forklift Trucks)

1. Pressure Plate Shell 5. Damping Disc Spring 9. Declutching Lever 13. Nut
2. Clutch Brake Shoe 6. Disc Hub 10.Clutch Release Bearing 14. Release Fork
3. Pressure Disc 7. Driving Shaft 11. Disengaging Bearing Sleeve 15. Cover
4. Pressure Spring 8. Bearing 12. Support Bolt

22
 Fig 2-2 Clutch (Used for 2-3.5t Diesel Forklift Trucks)

1. Clutch 5. Disc Hub 9. Declutching Lever 13. Nut

2. Clutch Brake Shoe 6. Bearing 10.Clutch Release Bearing 14. Release Fork
3. Pressure Plate 7. Driving Shaft 11. Disengaging Bearing Sleeve 15. Cover
4. Pressure Spring 8. Damping Disc Spring 12. Lock Nut

23
2.1 Overview
Clutch is mainly composed of pressure plate assembly, brake shoe assembly, and release fork. Pressure
plate is fixed using bolts on the flywheel of engine. Slight hole is mounted on clutch housing. The clutch
pedal allows the normally engaged brake shoe and flywheel to disengage from each other using release
fork through link.
The clutches used for LPG/Gasoline forklift trucks and diesel forklift trucks are respectively indicated in
Figs 2-1, 2-2.
2.2 Method for Replacement of Brake Shoe Assembly
2.2.1 Push down the clutch pedal, and use three spacer sleeves between the shell of pressure plate and
the release fork to disengage the brake shoe.
2.2.2 Turn the slide screw stem on the upper end of transmission case counterclockwise (Refer to the Fig
3-1 to be followed) for the driving shaft to retreat into the transmission case.
2.2.3 Take off the 6 bolts for the shell of pressure plate, for it to de released from flywheel, and then
immediately take out the old brake shoe assembly.
2.2.4 It is required to pay attention to the disc hub of brake shoe, when new brake shoe assembly is to be
fitted in (Refer to Part 6 in Fig 2-1 and Part 5 in and 2-2) and the end with relatively long extension of
spline sleeve shall face the side of transmission case.
2.2.5 Turn the slide screw stem clockwise, and pull out the driving shaft gradually, for it to be inserted into
the spline hole of disc hub for brake shoe.
2.2.6 Once it is determined that the driving shaft has entered into the middle bearing of flywheel, it is
then to lock up the slide screw stem, with a tightening torque as 107-119N.m (10.9-12.1kgm).
2.2.7 Mount the shell of pressure plate on flywheel.
2.2.8 Step on the clutch pedal, and take off the three spacer sleeves.
2.2.9 Adjust the stroke of clutch pedal (Refer to Fig 2-1).
2.3 Clutch Pedal
Clutch pedal and brake pedal are mounted on the same bracket, and fixed on the drive device.
2.4 Adjustment for Stroke of Clutch Pedal (Refer to Fig 2-1.)
2.4.1 Loosen the limit bolt for clutch pedal.
2.4.2 Use limit bolt (a) to adjust the height of pedal to: 113mm for 2-3.5t LPG/Gasoline forklift trucks and
111mm for diesel forklift trucks, with an idle stroke as 3 - 40mm.
2.4.3 Remove the tension spring on one end of clutch pedal, and loosen the nut (b).
2.4.4 Push down the clutch pedal by about 3-40mm, and at this point, pull forward the release fork. When
hand feels resistance, tighten the spherical nut (b) until it gets into contact with release fork, and tighten
up the nut (c).
2.4.5 Mount the pedal tension spring properly.

24
 Idle Stroke
Pedal Height

Gasoline Forklift Truck 113mm

Diesel Forklift Truck 111mm

Catch Bolt (a)

Spherical Nut (b)

Clutch Pedal

Lock Nut (c)

Fig 2-3 Clutch Pedal (2t-3.5t)

25
3. Hydraulic Transmission Case and Torque Converter

Torque Converter
Type Three-Element, Single-Stage, and Two-Phase Type
Torque Ratio 3
Adjusting Pressure 0.5-0.68MPa
Oil Feed Pump
Type Internal-Meshing Gear Type
Flow Rate 27 l/min(2000rpm,1.5MPa)
Hydraulic Transmission Case
Type Power Gear Shift
Forward 1.35
Speed Ratio
Backward 1.35
Hydraulic Clutch
Brake Shoe Outer Diameter × Inner 125×81×2.7mm
Diameter × Thickness
2
Brake Shoe Frictional Surface Area 71cm
Adjusting Pressure 1.1-1.4MPa
Weight 165kg

Oil Capacity 7L
Type of Oils Used Engine Oil SF15W
6# Hydraulic Transmission Oil

3.1 Overview
The hydraulic transmission forklift truck is mounted with the driving device composed of torque converter
and power gear-shift transmission case (Refer to Fig 3-1), typical of undermentioned advantages:
(1) Inching valve is able to allow the forklift truck to be able for inching operations both at high speed and
low speed of engine.
(2) The hydraulic clutch is equipped with four pairs of paper brake shoes and steel plates that have been
specially treated, which has improved the resistance to wear of its friction pair.

26
 Fig 3-1 Hydraulic Transmission Device

1. Forward Clutch 14. ControlValve Assembly 27. Hole Elastic Snap Ring 40. O-Ring
2. Oil Filter (II) 15. Piston 28. Single Row Radial Ball 41. Oil Seal
3. Backward Clutch 16. Spring Bearing 42. Single Row Tapered
4. Single Row Radial Ball 17. Oil Filler Port Cap 29. Single Row Radial Ball Roller Bearing
Bearing 18. Safety Valve Cover Bearing 43. Output Shaft
5. Seal Ring (A) 19. Hexagonal Socket 30. O-Ring 44. Supporting Plate
6. O-Ring Head Plug 31. Retainer Ring 45. Single Row Radial
7. Oil Feed Pump 20. Plug 32. O-Ring Ball Bearing
Assembly 21. Elastic Cylindrical Pin 33. Idler Wheel 46. Hexagonal Socket
8. Oil Seal 22. Transmission Arm 34. Oil Filer I Head Plug
9. Pump Impeller 23. Shell Cover 35. Output Gear 47. Shell Cover
10. Guide Wheel 24. Transmission Arm 36. Idler Wheel Shaft 48. Fixed Bolt
11. Turbine Shaft 37. Single Row Radial Ball 49. Reversing Light
12. Elastic Plate Assembly 25. O-Ring Bearing Switch
13. Inching Valve 26. Woodruff Key 38. Bearing Nut 50. Oil Drain Plug
Assembly 39. Single Row Tapered
Roller Bearing

27
(3) The one-way over running clutch mounted in torque converter has changed the power transmission
efficiency.
(4) Relatively satisfactory filter is available in the oil circuit of torque converter, which has enhanced the
service life of the torque converter.
3.2 Torque Converter
Torque converter is mainly composed of three elements including pump impeller, turbine, and guide
pulley.
Pump impeller is driven by input shaft. The liquid is vigorously sprayed onto the blades of turbine along
the the pump impeller blades under the action of centrifugal force (at this point the mechanical energy is
transformed into kinetic energy.), for torque to be transmitted to output shaft. The liquid leaving from the
turbine changes the direction under the effect of guide pulley, thus for a part of liquid to flow back to the
pump impeller at certain angle, to generate a reactive torque to push the guide pulley at this point, so as
to allow the output torque to have a value larger by one reactive torque compared with input torque.
Finally, the liquid flows into the blades of guide pulley in a reverse direction, for the original reactive
torque to act reversely. On this account, the torque of output shaft is smaller than that of the input shaft.
To prevent such situation, the overrunning clutch mounted inside the guide pulley allows the guide pulley
to be able for free rotation, when reactive torque acts reversely.
This kind of torque conversion method is able to ensure a high-efficient and steady operation.
The part of the torque converter for the transmission device is connected with the flywheel of engine
through elastic plate, and turns along with the rotation of engine, with oil for torque converter to be filled
up inside the torque converter. The driving gear is connected with pump impeller using two claws, to
actuate oil feed pump, to feed the oil to the torque converted and the hydraulic shifting transmission case.
The turbine is connected onto the turbine shaft using spline, and the power is transmitted to power
gear-shift transmission case through turbine shaft.

1. Air Displacement
2. Elastic Plate
3. Turbine
4. Guide Pulley
5. Thrust Bearing
6. Ball Bearing
7. Retainer Ring
8. Turbo Shaft
9. One-way Clutch
10. Pump Impeller

C240 Diesel Engine LPG/Gasoline Engine

Fig 3-2 Torque Converter

28
 3.3 Hydraulic Clutch (Fig 3-3)

Wet multi-disk hydraulic clutch is mounted on the input shift of hydraulic transmission case, to distribute
pressure oil to forward or backward clutch through control valve, to achieve forward and backward gear
shift. All the gears in transmission case are normally engaged gears. Each clutch is composed of
alternately assembled four spacers (Part 24) and four brake shoes (Part 25) as well as one piston. Both
internal circle and external circle are fitted with seal rings, to ensure the sealing performance during work
of piston. The piston does not act at neutral gear, and the spacer and the brake shoe are under the
separate status. During gear shifting operation, oil pressure acts on the piston, the spacer and the brake
shoe are mutually compacted, for form an adapter depending on friction force, so as to transmit the
power from torque converted to the driving gear (forward gear 4 or reversing gear 13).
The power transmission procedure from torque converter to hydraulic transmission case is as follows:
Turbine Input Shaft Assembly Spacer Brake Shoe Forward Gear or Reversing Gear
Output Shaft

Forward Clutch Pressure Oil

Backward Clutch Pressure Oil
Connected with
Torque Converter Lubricating Oil

Fig 3-3 Hydraulic Clutch

1. Seal Ring (A) 8. O-Ring 15. Seal Ring (A) 22. Check Ball
2. Bearing 9. Input Shaft Assembly 16. Seal Ring (A) 23. Piston Assembly
3. Thrust Collar (B) 10. Seal Ring (B) 17. Seal Ring (A) 24. Spacer
4. Forward Gear 11. End Plate 18. Thrust Collar (B) 25. Brake Shoe
5. Snap Ring 12. Shaft Collar (A) 19. Needle Roller Bearing 26. Return Spring
6. Elastic Collar 13. Reverse Gear 20. Shaft Collar (A) 27. Needle Roller Bearing
7. Spring Seat 14. Bearing 21. Elastic collar

29
3.4 Control Valve, Safety Valve, and Inching Valve
3.4.1 Control valve is mounted on the inner side of transmission case cover, and the control valve
includes three parts such as control spool valve, constant pressure valve, and adjusting valve. (Fig 3-4)
3.4.2 Constant Pressure Valve: It is used to control the oil pressure of hydraulic clutch between 1.1 -
1.4MPa, and send the oil content through it to overflow valve to be transmitted to torque converter.
3.4.3 Adjuster: It is located between inching valve and control spool valve. When control spool valve is
fully opened, this valve will work, to reduce the impact of clutch during engagement.
3.4.4 Overflow Valve: The overflow valve connected together with transmission case allows the oil
pressure of torque converter to maintain between 0.5-0.7MPa.
3.4.5 Inching Valve: Inching valve is installed on the outer side of transmission case. The winding shaft of
valve is connected onto the link for inching pedal. This winding shaft will move rightwards, when inching
pedal is pushed down, which has reduced the oil pressure of hydraulic clutch for a short time, for the
forklift truck to achieve the inching effect (Fig 3-5).

Constant
Pressure Valve

Adjusting
Valve

Control Spool Valve

Spring
Steel Ball

Fig 3-4 Control Valve

30
 1. Spring Collar
2. O-Ring
3. Inching Valve Stem
4. Elastic Collar
5. Spring
6. Valve Core
7. Winding Shaft
8. Valve Body
9. Spring
10. O-Ring
11. Cover
12. Oil Seal
Fig 3-5 Inching Valve

3.5 Transmission Case

Except for installation of input shaft, output shaft, and other mechanisms, the transmission itself also
plays the function of oil tank. An oil filter I (of 150 mesh screen) is available on the bottom part of the case
to filter the oil sucked into oil feed pump, while the pipe line filter II, oil filler cap, and oil tappet are
mounted in the upper part of case cover.

3.6 Oil Feed Pump

Oil fee pump is installed between the torque converter and the input shaft, to feed oil to torque converter
and hydraulic transmission case, by actuating one pair of gear pumps composed of internal engaged
gears through pump impeller.

Oil Drain Outlet

Driven Gear
Driving Gear

Oil Seal Oil Feed Inlet

Cover
Pump Body O-Ring

Torque Converter Oil Inlet

Fig 3-6 Oil Feed Pump

31
3.7 Hydraulic Oil Circuit (Hydraulic Transmission) Fig 3-7
After engine is started, the oil feed pump sucks out oil from the oil tank (namely the bottom of
transmission case) through oil filler that flows through control valve, and the pressure oil is divided into
two parts in valve, one part to be fed and used by hydraulic clutch, and the other part to be fed to torque
converter.
The oil necessary for operation of hydraulic clutch flows into the constant pressure valve (the pressure of
this valve to be adjusted to 1.1-1.4MPa). The oil from the constant pressure valve further flows to inching
valve and control spool valve on one hand, and is fed into the impeller of torque converter on another
(pressure to be adjusted to 0.5-0.5MPa). The oil from torque converter is cooled down through oil heat
radiator, then lubricates the hydraulic clutch, and returns to oil tank afterwards.
At the time of neutral gear, the oil circuit from control spool valve to clutch is closed. At this point, the
constant pressure valve is turned on, for all the oil to pass the overflow valve transmitted to torque
converter. When control spool valve is at forward or backward position, the oil circuit from spool valve to
forward or backward clutch is connected for respective clutches to take separate actions. When one
clutch is taking action, the spacer and the brake shoe of another clutch are under separate status, and
lubricated by cooling oil and with heat taken away. When inching pedal operates inching valve, one part
or most of oil into clutch is drained to oil tank through inching valve lever, and at this point the circulation
for the oil circuit of torque converter is the same as it is at the neutral gear.

Switch

Constant Pressure Valve

Inching Valve

Control Spool Valve Backward Neutral Position Forward

Adjusting Valve
Oil Filter
Oil Feed
Pump
Torque Converter
Oil Filter Backward Clutch
Overflow Valve

Oil Heat Radiator

Forward Clutch

Fig 3-7 Hydraulic Oil Circuit

32
3.8 Speed Reducer and Speed Differential (Fig 3-8)
The part of speed reducer is located on the front part of transmission case. This mechanism has reduced
the rotating speed of output shaft from transmission case and increased the torque transmitted from the
output shaft, and then sends this torque to the speed differential. The speed reducer is mainly composed
of the small spiral bevel gear on the output shaft, one large spiral bevel gear, and one small gear shaft.
The large spiral bevel gear is mounted on the small gear shaft through spline, while the two ends of small
gear shaft are both supported with tapered roller bearing, and filled with gasket to adjust the side
clearance.
Speed differential is mounted on the front half shell using bearing seat through ball bearings on the two
ends, and the front end is connected with axle shell. The shell of speed differential is made into a type of
left and right parts, with two half shaft gears and four planetary gears. The thrust washer is mounted
between the shell of speed differential and gear and it is allowed for a clearance to be retained between
respective gear pairs. The planetary gears are supported using gear shafts I and II, while gear shaft I is
fastened onto the body of speed differential using cylindrical pink, and gear ring I is fixed onto the shell of
speed differential using articulated bolts.
The power from transmission is generated into differential speed by speed differential through speed
reduction transmitted onto the wheels through half shaft gear and half shaft.

3.9 Traction of Forklift Truck to be repaired

Attention shall be paid after the hydraulic transmission forklift track is damaged, and when traction by
other vehicles is required:
1 The half shaft shall be taken off from the front wheel.
2 The gear-shift lever shall be placed at neutral position.
3.10 Oil Port Joint Positions (Refer to 3-8)

Connected with Hydraulic Clutch Side Pressure Hole

Oil Head Radiator From Oil Heat
High Temperature Radiator Low
Oil Port Temperature
Oil Port

Oil Temperature Gauge Hole Backward Light Switch

Oil Drain Plug Neutral Gear Switch
Filter

Inching Valve

Fig 3-8 Speed Reducer and Speed Differential

33
4. Drive Axle
4.1 Overview

Type Front Wheel Drive, Axle Body Fixed with Vehicle Chassis, and Fully Floating Type

2t and 2.5t 3t and 3.5t

Forklift
Truck
Tonnage Single Tyre Double Tyre Single Tyre Double Tyre

Tyre Size 2×7.00-12-12 PR 4×7.00-12-12 PR 2×28×9-15-14 PR 4×28×9-15-14 PR

Rim Size 5.00S-12 5.00S-12 7.00T-15 7.00T-15

Tire
860 MPa 970 MPa
Pressure

Drive axel is mainly composed of axle housing, wheel hub, half shaft, and brake. The axle housing is in
an integrated cast structure. The tire is prized on wheel hub through wheel rim using stub bolt and nut.
The power is transmitted to half shaft through speed differential, and finally the front wheel is actuated by
wheel hub for rotation. Each wheel hub is mounted on axle housing through two tapered roller bearings,
so the half shaft only bears the torque transmitted by wheel hut. Oil seal is fitted inside the wheel hub, to
prevent entry of water and dust, or oil leak.
1-2.5t the wheel rim for single tire is in partial type, with wide tire used for 3t and 4t, while 2-4t forklift
trucks may be equipped with double tire (Refer to Fig 4-2.).

1. Conical Nut
2. Wheel Rim
3. Bolt Stud
4. Brake Drum
5. Wheel Hub
6. Brake Cylinder
7. Axle Housing
8. Oil Seal Retainer Ring
9. Oil Seal
10. Tapered Roller Bearing
11. Tapered Roller Bearing
12. Round Nut
13. Half Shaft

Fig 4-1 Drive Axle

34
4.2 Maintenance of Drive Axle
The wheel hut of drive axle shall be reassembled according to the following procedure:
1 Coat lubricating grease on the tapered roller bearing.
2 When the lock nuts for tapered roller bearing inside the wheel hub is tightened, attention shall be
paid that the rotating torque of wheel hub is 9.8-29.4N.m(1-3kg.m) after tightening (or return by
about 1/8 circles after tightening, for wheel hub to be able to rotate freely).
3 Tighten the half shaft mounting nut and its torque is 96-111N.m(9.8-11.3kg.m).
4 Tighten the wheel mounting nut and its torque is 470-550N.m for 2-3.5t.
5 Tighten the brake drum mounting nut and its torque is 206-225N for 2-3.5t.

Fig 4-2

35
5. Steering System

Type of Steering System Rear Wheel Steering with Power Steering

Power Steering

Forklift Truck Tonnage 2t, 2.5t, 3t, 3.5t

Cycloid Full Hydraulic Steering Gear BZZ1-E125BA

Cylinder
Steering

Cylinder Diameter mm 70

Diameter of Piston Rod mm 50

Stroke mm 198
Diameter of Steering Wheel
300
mm

5.1 Overview
Steering system is mainly composed of fully hydraulic steering gear, and steering cylinder.
(1)Fully Hydraulic Steering Gear Assembly (Fig 5-1)
It mainly includes cycloid fully hydraulic gear, (Refer to Fig 5-2), steering column, and steering wheel.
The steering column and the steering wheel are able for forward and backward rotation by 4.5 , to adapt
eds.
Fully hydraulic steering gear is able to transmit the pressure oil from bypass valve to steering cylinder
through pipeline according to the size measurement for the rotation of steering wheel. When engine is
turned off, oil pump cannot feed oil, and then steering may be achieved manually.
(2)Steering Cylinder (Fig 5-3)
Steering cylinder is in dual-action through type. The two ends of piston rod are connected with steering
knuckle through link. Pressure oil from fully hydraulic steering gear enables the piston rod to move
leftward or rightward through steering cylinder, thus to achieve leftward or rightward steering.

Fig 5-1

36
 Fig 5-2 Cycloid Fully Hydraulic Steering Gear

1. Limit Post 4. Universal Driving Shaft 7. Rotor

2. Valve Body 5. Leaf Spring 8. Stator
3. Valve Core 6. Connecting Block 9. Valve Sleeve

37
 Fig 5-3 Steering Cylinder

1. Piston Body 6. Shaft Sleeve 11. Dust Ring

2. Cylinder Cover 7. O-Ring 12. Lining
3. Cylinder Body 8. Shaft Sleeve 13. Block Film
4. O-Ring 9. YX Seal Ring
5. Wear Ring 10. Gasket

5.2 Examination after Reassembly of Steering System

(1) Turn the steering wheel leftward and rightward thoroughly to see whether or not left and right force
application are uniform, and whether or not rotation is steady.
(2) Examine whether or not oil pressure pipeline is correctly arranged, and whether or not the left and
right steering are reversely assembled.
(3) Jack up the rear wheels, and slowly turn the steering wheel leftward and rightward. Repeat it for
several times, and remove the air in the hydraulic pipeline and the cylinder.

38
5.3 Failure Removal for Steering System

Problem Analysis Cause of Generation Removal Method

Oil pump damaged or out of action To be replaced
Steering
Bypass valve blocked or damaged To be cleaned or replaced
Wheel Fixed
Rubber hose joint damaged or pipeline blocked. To be replaced or cleaned
Bypass valve pressure too low Pressure to be adjusted
Air present in oil circuit Air to be removed
Steering Reset of steering gear out of operation, and
Operation positioning leaf spring broken or elasticity Leaf spring to be replaced
Toilsome insufficient.
Sealing of piston to be
Excessive internal leak of steering cylinder
examined
Forklift Truck
Flow of bypass valve to be
Serpentine or Excessive steering flow
adjusted
Swinging

Abnormal Oil tank level low Oil to be added

Noise Suction pipe or oil filter blocked To be cleaned or replaced
Sealing of steering cylinder guide sleeve damaged
Oil Leak To be replaced
or pipe line or joint damaged.

39
6. Cross Cylinder Drive Axle

Tonnage 2t, 2.5t, 3t, 3.5t,

Type of Axle Body Supported with Central Supporting Shaft
Inner Side Wheel 78
Steering Angle
Outer Side Wheel 54
Center Distance of King Pin 810mm
King Pin
Sidewise Inclination Angle 0
Wheel Camber Angle 1

Wheel

Tonnage 2-2.5t 3-3.5t

Tyre 2×6.00-9-10 PR 2×6.50-10-10 PR
Wheel Rim 4.00E-9 5.00F-10
Charging Pressure 860KPa 790KPa
Total Weight About 155kg

6.1 Overview

Steering axle is in a type of welded structure of a box cross section (Fig 6-1), and it is composed of
steering axle body, steering cylinder, link, and steering wheel. Slider-crank mechanism is applied to
steering trapezium. The steering knuckle is actuated by cylinder piston rod through link for rotation, for
steering wheel to deflect, thus to achieve steering. Steering axle is prized on the tail bracket in the rear
part of truck frame using bolts through bearing seas via forward and backward pin shafts, for the axle
body is able to swing round the pin shaft. One left and right steering knuckle is available respectively on
left and right of steering axle. The rear wheel hub is mounted on the shaft of steering knuckle using two
tapered roller bearings. The wheel is prized on the wheel hub through wheel rim. Oil seal is fitted on the
inner side of bearing, for lubricating grease to be retained inside the wheel hub and the steering knuckle.

40
 Fig 6-1 Steering Axle

1. Oil Seal 7. Tapered Roller Bearing 13. Needle Roller Bearing 19. Link
2. Needle Roller Bearing 8. Lock Nut 14. Oil Seal 20. Pin Shaft
3. Thrust Bearing 9. Wheel Hub Cover 15. Steering Knuckle King Pin
4. Oil Seal 10. Steering Wheel Hub 16. Steering Knuckle
5. Wheel Hub Nut 11. Lock Pin 17. Steering Cylinder
6. Tapered Roller Bearing 12. Adjusting Washer 18. Steering Axle Body

41
6.2 Steering Knuckle and Steering King Pin
Steering knuckle is mounted between the upper and lower shaft sleeves on the two ends of steering axle
body using steering knuckle king pin, thrust bearing, and gasket. The middle part of king pin is locked on
steering knuckle using lock pin, while the two ends of king pin are supported by needle roller bearings
pressed on the axle body. Oil seals are mounted on the two ends of needle roller bearings, and oil cup is
fitted on the king pin.
6.3 Adjustment for Pre-tightened Load of Steering Wheel Bearing
(1) As indicated in Fig 6-2, the internal cavities of internal and external bearings as well as wheel hub
cover are added with lubricating grease, and at the same time some lubricating grease shall also be
coated on the lip of oil seal.
(2) Fix the bearing outer ring onto the wheel hub, and mount the wheel hub onto the shaft of steering
knuckle.
(3) Mount the flat washer and tighten the slot nut, and its torque is 06-235N.m(21-24kgm). Loosen the
slot nut and then tighten this nut, with its torque as 9.8N.m(1kgm).
(4) Knock at the wheel hub gently using wood hammer, turn the wheel hub manually by 3-4 circles, to
ensure a steady rotation, and measure the rotating torque, with its value as 2.94-7.8N.m(0.3-0.8kgm).
(7) When rotating torque is higher than the specified value, it may be returned by 1/6 circles, and then
measure its rotating torque.
(8) Lock up the slot nut using cotter pin, when specified rotating torque is reached.

Inject Lubricating
Grease

Fig 6-2 Adjustment for Pre-tightened Load

42
7. Brake System

Type Front Twin Wheel Brake, Internal Expansion, Hydraulic

Pedal Lever Ratio 5.66
Master Cylinder
19.05mm
Diameter
Wheel Brake 2-2.5t 3-3.5t
Type Dual Servo Type with Parking Brake
Wheel Cylinder
28.58
Diameter
Size of Brake Shoe
324×60×7mm 348×76×8mm
(L X W X T)
2 2
Area of Brake Shoe 194.4 cm ×4 264 cm ×4
Inner Diameter of
310mm 314mm
Brake Drum
Parking Brake Front Twin Wheel Brake, Internal Expansion, and Hydraulic Type

7.1 Overview
Brake system is in a front double-wheel brake type, and it is composed of brake master cylinder, brake,
and brake pedal mechanism.
7.2 Brake master cylinder includes one valve seat, one one-way valve, and one return spring, as well as
rubber cup, piston, and auxiliary rubber cup. The end part is fixed using thrust washer and stop steel wire,
while and external part is protected through rubber dust cap. The master cylinder piston acts through
push rod through operating brake pedal. When brake pedal is pushed down, the push rod pushes
forward the piston, and the brake fluid in the cylinder body flows back to oil tank through return oil port,
until the main rubber cup blocks the return oil hole. After main rubber cup has pushed the return oil port,
the brake fluid in front cavity of master cylinder is compressed and opens the one-way valve, thus to flow
to the wheel cylinder through bypass pipeline. In this way, the pistons of respective wheel cylinders
extend outwards, for the friction plate of brake shoe and the brake drum to get into contact with each
other, to achieve the effect of deceleration or brake. At this point, the rear cavity of piston is
supplemented with the brake fluid from return oil port and oil inlet port. When brake pedal is loosened,
the piston is pressed by return spring, and at the same time the brake fluid in respective brake cylinders
are likewise compressed by return spring of brake shoe, for brake fluid to return to the master cylinder
(the front cavity of piston) through one-way valve. The piston will return to original place, the brake fluid in
master cylinder will flow back to oil tank through return oil port, and the pressure of one-way valve is
adjusted to certain proportion to the remaining pressure in brake cylinders, so that the rubber cup of
wheel cylinder is correctly placed to prevent oil leak, and to eliminate the effect of choke that may
possibly arise during emergency brake.

43
 Fig 7-1 Brake Master Cylinder

1. Clevis 5. Stop Steel Wire 9. Main Cup 13. Pump Body

2. Lock Nut 6. Stop Washer 10. Spring
3. Push Rod 7. Auxiliary Cup 11. One-way Valve
4. Dust Cap 8. Piston 12. Valve Seat

7.3 Wheel Brake

Wheel brake is in an internal expansion and hydraulic type, and it is composed of brake shoe, spring,
wheel cylinder, adjuster, and bottom plate. The two brakes are respectively mounted on the two ends of
front axle. One end of brake shoe is connected with support pin, while the other end is connected with
clearance adjuster, and bears down onto the bottom plate by spring and tension spring pull rod. Lever L
H Brake is mounted on primary brake shoe, while adjustment pull rod for automatic clearance adjuster is
fitted on secondary brake shoe. Refer to Fig 7-2, Fig 7-3.

44
1. Spring
2. Rubber Cup
3. Piston
4. Cylinder Body
5. Piston Top Rod
6. Return Spring
7. Top Rod
8. Return Spring
9. Adjusting Lever
10. Auxiliary Brake Shoe
11. Clearance Adjuster
12. Spring
13. Brake Steel Cable Assembly
14. Pressure Spring Cap
15. Pin, shoe hold
16. Lever L H Brake E-Shaped Retainer Ring
17. Hand Brake Push Rod
18. Brake Cylinder Assembly
19. Return Spring
20. Primary Brake Shoe Fig 7-2 2t and 2.5t Wheel Brakes

1. Brake Cylinder Assembly

2. Spring
3. Rubber Cup
4. Piston Bolt Tightening Torque

5. Wheel Cylinder Shield

6. Piston Top Rod
7. Brake Shoe Return Spring
8. Brake Shoe
9. Spring
10. Hand Brake Push Rod Bolt Tightening
11. Spring Stay Wire Device Torque
12. Brake Shoe
13. Washer cup
14. Pin, shoe hold
15. Pressure Spring
16. Spring
17. Ratchet
18. Spring
19. Clearance Adjuster Assembly
20. Pin
21. Bottom Plate
22. Brake Shoe Return Spring
23. Lever L H Brake
24. Brake Steel Cable Assembly

Fig 7-3 3t and 3.5t Wheel Brakes

45
 The brake action in forward movement is as follows
Support Pin
(as indicated in Fig 7-4). Through operating brake
wheel cylinder, the primary brake shoe and the F
secondary brake shoe are effected by two forces of i Working Force

Shoe
Secondary
equal size but reverse directions, respectively, for g

Primary
Shoe
brake shoe and brake drum to get into contact with
8
each other, while the primary brake shoe is pressed
-
onto the adjuster with support of friction force 5
between brake shoe and brake drum, thereby for
clearance adjuster to generate a larger force used to Adjuster
operate the wheel cylinder to push the secondary
Fig 7-4 Brake Actions during Forward
brake shoe, and to force the upper end of secondary
Running Process
brake shoe to bear down on the support pin, thus to
get a relatively large brake force. In another
connection, the reversing brake action is performed in
reverse direction, but the brake force is the same as Working Force

Shoe
Secondary
that during forward movement.

Primary
Shoe
Fig 7-5 Brake Actions during
Reversing Process

7.4 Automatic Clearance Regulator (with 2t brake mainly described, and the action principle of 1-4t
brakes is the same as that of 2t)
The automatic clearance adjuster is able to automatically maintain the clearance between brake shoe
and brake drum between 0.4-0.45mm (0.25-0.4mm for 3, 3.5). However this adjuster only acts during
reversing brake. During reverse movement, the brake shoe will disengage once the brake pedal is
pushed down, thereby, the secondary and the primarily brake shoes will begin to get into contact with
brake drum for rotation together, until the upper end of primarily brake shoe begins to get into contact
with support pin. Meanwhile when secondary brake shoe is released from the support pin, the A part of
adjusting lever (Refer to Fig 7-2.) is relatively in tension, thus for adjusting lever to rotate around the B
part, for C part to lower, and the D part of adjuster to rotate leftward, so as to achieve the objective of
automatic adjustment. When brake pedal is further pushed down, the pressure applied to both ends of
adjust is larger, which has increased the resistance to thread rotation, for the force of adjusting lever to
be unable to actuate rotation of part B.
7.5 Parking Brake
Parking brake is in mechanical, internal expansion type and built-in on wheel brake, and it shares the
brake shoe and the brake drum with foot brake. When the handle of parking brake is pulled, the brake
handle actuates the manual pull rod through brake cable (Refer to Fig 7-2 E), and this cable pushes the
manual brake push rod rightwards with the support of pin that plays the function of rotating shaft, for the
brake shoe to step towards the brake drum.
7.6 Adjustment of Brake Pedal (Mechanical Forklift Truck) (Refer to Fig 7-7.)
(1)Adjust short the push rod.
(2)Adjust the catch bolt, for the heights of pedals for 2-4t diesel forklift truck and LPG/Gasoline forklift
truck to be respectively 111mm and 113mm.
(3)Push down the brake pedal by 30-40mmt, and adjust long the push rod until the front end of push rod
begins to contact the piston of master cylinder.
(4)Screw down the lock nuts for push rod.
46
 Parking Brake Handle
Brake Handle

Pin

Tension Plate

Brake Steel Cable

Fig 7-6 Parking Brake Device

Oil Tank

(Idle Stroke) (Idle Stroke)

Catch Bolt

Pedal

Fig 7-7 Adjustment of Brake Pedal (Mechanical Type)

47
7.7 Adjustment of Brake
Pedal (Hydraulic Forklift Oil Tank
Truck) (Inching Pedal)
(1)Loosen the push rod and (Brake Pedal)
the interlock bolt. (Idle Stroke)

(2)Adjust the catch bolt, for Idle Stroke

the heights of pedals for
2-3.5t diesel forklift truck
and LPG/Gasoline truck to
be respectively 111mm and
113mm.
Catch Bolt
(3)Adjust the screw stem, for
the left pedal (inching pedal) Pedal
to get a 2-10mm idle stroke. Screw stem
Interlock Bolt
(4)Push down the right Connecting
pedal for 2-4t forklift truck by Shaft
60mm and adjust the length
of screw stem until the front
end of push rod begins to
contact the piston of master Brake Master
cylinder. Then tighten the Inching Valve
Pump
lock nut.
(5)Adjust the interlock bolt,
until the head of bolt begins
to contact the connecting
shaft, and lock it up.

Fig 7-8 Adjustment of Brake Pedal (Hydraulic Trucks)

7.8 Maintenance
This section covers brake disassembly, reassembly, and
adjustment (with mainly 2t brake described, while the
brakes for 3t are similar. Attention: The following ones
with are only the part drawings for 3t brake.).
7.8.1 Disassembly of Wheel Brake
(1)Remove the fixed spring of secondary brake shoe,
and take off the adjusting lever, top lever, and the top
lever return spring (Fig 7-9).

Fig 7-9

48
(2) Remove the return springs for the two brake
shoes. (Fig 7-10)

Fig 7-10

(3) Remove the other three fixed springs. (Fig 7-11)

Fig 7-11

(4) Detach the primary brake shoe and the

secondary brake shoe, and at the same time remove
the spring for adjuster. (Fig 7-12)

Fig 7-12

(5) Demount the brake oil pip on the wheel Cylinder,

then remove the mounting bolts for wheel cylinder,
and separate the wheel cylinder from the bottom
plate. (Fig 7-13)

Fig 7-13
49
 (6) Remove the E-shaped retainer ring that fastens the
brake cable onto the bottom plate, then remove the
mounting bolts on bottom plate, and detach the bottom
plate from the axle. (Fig 7-14)

Fig 7-14

(7) Remove the shield for wheel cylinder, and push out
all the parts inside the cylinder. (Fig 7-15).

Fig 7-15

7.8.2 Examination of Wheel Brake

Examine all the parts as to whether or not any of them is worn or damaged, and it shall be repaired or
replace, if incompliant.
(1)Examine whether or not the inner surface of wheel cylinder body and the surface of piston column are
rusted, and then measure the clearance between piston and cylinder body.
Specified Value: 0.065mm-0.150mm(2-3.5t Forklift Truck) Maximum Value: 0.15
(2)Visually check whether or not the pump rubber cup is damaged or distorted, and replace it if
incompliant.
Outer Diameter of Rubber Cup: 30.1-0.2(2-3.5t)
The standard value for interference of rubber cup is 1.52, and the minimum value is 0.42 (2-3.5t).
(3)Examine the free length of wheel cylinder spring, and replace it is improper.
It is specified that the free lengths of wheel cylinder springs for 3t, and 3.5t forklift trucks as well as 2t
forklift truck are respectively 58mm and 60mm.
(4)Examine the thickness of brake shoe, and replace it if it is found to be excessively worn out.
Specified Thickness: 7.2mm (2t) 8.0mm (3t, 3.5t)
Minimum Thickness: 2.0mm (2t) 1.0mm (3t, 3.5t)

50
5) Examine the status of inner surface of brake drum, and it
shall be rehabilitated or replaced, if it is found to be
excessively worn out.
Standard Value: 310mm (2t, 2.5t), 314mm(3t, 3.5t)

Maximum Value after Rehabilitation: 312mm (2t, 2.5t), 316mm (3t, 3.5t) Fig 7-16

(6) Measure the free length and installation load of return

spring for brake shoe (Fig 7-16). Refer to Part 6 of Fig 7-2,
and Part 7 of Fig 7-3.)
Free Length: L= 106mm (2t, 2.5t), L=115.1mm (3t,3.5t)

Installation Length: 116mm (2t, 2.5t), 122mm (3, 3.5t)

Installation Load: 246N (2t, 2.5t), 225N (3t, 3.5t) Fig 7-17

(7) Measure the free length and installation load of return

spring for top rod (Fig 7-17). (Refer to Part 8 of Fig 7-2 and
Part 9 of Fig 7-3)

Fig 7-18
Free Length 124.5mm
Installation Length 130mm
Installation Load 245N
Forklift Truck Tonnage 2-3.5t

(8) Measure the free length and installation load of adjuster

spring (Fig 7-18 and Fig 7-19).
Free Length: 86mm (2t, 2.5t) 121mm (3t, 3.5t)

Installation Length: 97mm (2t, 2.5t) 137mm (3t, 3.5t)

Fig 7-19
Installation Load: 153N (2t, 2.5t) 71.5N (3t, 3.5t)

(9) Measure free length and installation load of ratchet spring

(Fig 7-20). Installation Load: 14.7N (3t, 3.5t)

Fig 7-20

51
(10) Examine whether or not the adjusting mechanism is damaged, how the operating status is, and also
examine whether or not the contact of adjusting lever is out of order, and replace it when necessary.

7.8.3 Reassembly of Wheel Brake

(1) Firstly dip the wheel cylinder rubber cup and the piston with brake fluid, and then assemble spring,
rubber cup, piston, and shield in turn.
(2) Mount the wheel cylinder on bottom plate.
Attention: Ensure that respective parts are all at the correct position during installation, and the bolt
tightening torques are 14.7-19.6N.m (2t), 17.6 - 26.5N.m(3t and 3.5t).
(3) Mount the bottom plate onto the front axle. Bolt Tightening Torque: 120-140N.m
(4) Add #2 calcium base lubricating grease at a, b, c, d respective lubricating pints as indicated in Fig
7-21 and Fig 7-22, and be careful not to allow this grease to be adhibited on brake shoe.
(a) Support Face of Bottom Plate (b) Support Pin of Lever L H Brake
(c) Support Pin (d) Adjuster Thread and Other Rotating Parts
(e) Contact Face of Brake Shoe and Washer, Cup

Fig 7-21. 2t, 2.5t Forklift Truck Fig 7-22. 3t, 3.5t Forklift Trucks

(5) Mount the brake cable assembly onto the bottom plate using E-shaped retainer ring.

52
(6) Mount the brake shoe onto the bottom plate using
fixing spring, but the bottom part of secondary brake
shoe shall be mounted with fixing spring after the
washer, cup and the adjusting lever have been properly
installed, to ensure that the pressure seat is fitted in the
holes of brake shoe and adjusting lever (Fig 7-23).

F
Fig 7-23

(7) Mount the compressed spring onto the hand brake

push rod, and then install the push rod onto the brake
shoe.
(8) Mount the guide plate of brake shoe onto the
support pin, and then install the return spring of brake
shoe (Fig 7-24).

Fig 7-24

(9) Install adjuster, adjuster spring, top rod, and return

spring for top rod (Fig 7-25).

Fig 7-25
Pay attention to the following respective items:
a) Adjuster Threat Direction and Its Installation Direction (In 2t, 2.5t forklift truck, right-hand threat is used
for left brake, while the left-hand thread is used for right brake. In 3t and 3.5t forklift trucks, left-hand
thread is used for left brake, while right-hand thread is used for right brake.)
b) Adjuster Spring Direction (It is not allowed for the tooth part of adjuster to contact the spring.
c) Top Rod Return Spring Direction (At the end of support pin, the spring hook shall be fixed on the
opposite side of top rod.)
d) Top rod and top rod return spring shall be fixed inside the sloth of support pin.
e) Make sure that the lower end of adjusting lever shall be in contact with the tooth part of adjuster.
(10) Connect the brake oil pip onto the wheel cylinder.
(11) Measure the inner diameter of brake drum, and adjust the adjuster for the differences between the
inner diameter of brake drum and the friction plate of brake shoe to be: 0.8-0.9mm (2t, 2.5t) , 0.5-0.8mm
(3t, 3.5t).

53
7.9 Operating Test on Automatic Clearance Regulator
(1) Firstly allow the diameter of brake shoe to approach the installation size, and pull the adjusting lever
with hand in the direction as indicated by the arrow in Fig 7-26 for adjust to rotate. When hand is released,
the adjusting lever returns to its original place, while the gear of adjuster will not rotate.
Attention: Even if when hand is released, and the adjuster gear and the adjusting lever return together,
the adjuster is still able for normal work after being assembled.
(2) In the case when adjusting lever is pulled, and the adjuster cannot do the abovementioned action, the
following items shall be examined:
a) Mount the adjusting lever, the top rod, the top rod spring, and the washer, cup firmly.
b) Examine whether or not the relationship in arrangement between adjusting lever and adjusting gear is
correct. Refer to Fig 7-26 (2t, 2.5t), Fig 7-27 (3t, 3.5t), and replace the parts if not satisfactory. In addition,
examine whether or not lever and gear are in contact with each other.

Fig 7-26

Fig 7-27

c) Examine whether or not the return spring of top rod and the spring for adjuster are damaged, and then
examine the rotating status of adjuster gear and whether or not its engaged part is excessively worn out
or damaged.

54
7.10 Failure Removal for Wheel Brake

Problem Analysis for Cause of Generation Removal Method

1. Oil leak with brake system To be repaired

Brake under Poor Condition

2. Clearance of brake shoe not properly Adjuster to be adjusted

adjusted
3. Brake too hot Examine whether or not
skidding exists
4. Contact between brake drum and brake shoe To be readjusted
under poor condition
5. Impurity attached on brake shoe To be repaired or replaced
6. Impurity blended into brake fluid Brake fluid to be examined
7. Brake pedal (inching valve) improperly To be adjusted
adjusted
1. Surface of brake shoe hardened or impurity To be repaired or replaced
Noise Present with Brake

attached on it
2. Bottom plate distorted or bolt loosened To be repaired or replaced
3. Brake shoe distorted or installation incorrect To be repaired or replaced
4. Brake shoe worn To be replaced
5. Bearing of wheel loosened To be repaired

1. Oil stain present on surface of brake shoe To be repaired or replaced

2. Clearance of brake shoe not properly Adjuster to be adjusted
Brake Un-uniform

adjusted
3. Wheel cylinder out of operation To be repaired or replaced
4. Brake shoe return spring damaged To be replaced
5. Brake drum deflected To be repaired or replaced

1. Oil leak with brake system To be repaired or replaced

2. Clearance of brake shoe not properly Adjuster to be adjusted
adjusted
Brake Weak

3. Air blended into brake system Air to be bled

4. Adjustment of brake pedal incorrect To be readjusted

55
8. Hydraulic System
Forklift Truck
2t-3.5t
Tonnage
Equipped Engine NISSAN K25 MITSUBISHI S4S-455

Model SGP1A28.2D2H9-R330C SGP1A28.2D2H1-L707D

Type Gear Type

Main Pump

Driving Driving with Engine Power Output Gear

Loaded 78 L/min
2 57L/min [2260 rpm]
Displacement [2650rpm/1715N(175kg/cm )]

No-load 79 L/min
2 63L/min [2385 rpm]
Displacement [2650rpm/196N(20kg/cm )]

Model CBD3 Haihong brand

Double Spool Valve, with Overflow Valve, Bypass Valve, and Inclined
Type
Autolocking Valve
Multi-way Valve

Adjusting
17.5MPa
Pressure

Pressure 10 MPa
Bypass
Valve

Flow
11 l/min
Rate

Type Single Act Piston Type, with Shutoff Valve and Speed Limiting Valve
Lift Cylinder

2-2.5t: 50mm
Cylinder Inner
3t: 56mm
Diameter
3.5t: 63mm

1495mm
nd
Stroke (At 2 -grade Standard Mast at 3m Lifting Height (Varying along with Type of
Mast and Lifting Height))

Type Double Act

Cylinder Inner 2-2.5t: 70mm

Diameter 3-3.5t: 80mm
Tilt Cylinder

Piston Rod
2-2.5t: 32mm
Outer
3-3.5t: 35mm
Diameter

2-2.5t: 122mm
Stroke
3-3.5t: 141mm

Note: When forklift idle for a long time, please do lubrication maintenance no more than every 10 days:
upgrade the cylinder to the top 2-3 times.

56
8.1 Overview
Hydraulic system is composed of main oil pump, multi-way valve, lift cylinder, tilt cylinder, and oil pipe line,
as well as the direct transmission oil pump of engine power-take-off (P.T.O).
8.2 Main Oil Pump
The main oil pump is a gear pump, mainly composed of pump body, pump cover, one pair of gears,
bearing, and seal ring. Load balanced bearing and special lubricating method are applied to main oil
pump, for the end face of gear to gain the minimum clearance.
As pump body and pump cover are light and firm, as they are made of alloy aluminum. The two shafts
respectively provided for driving gear and driven gear are separately installed on the bearing of pump
body. These bearings are made of special material, to bear the radial load of gear shaft on one hand, and
to serve as the baffle seat for the end face of gear on another.
On the side of drive shaft, one oil seal is pressed and fitted on the pump body, to ensure the sealing
property. The sealing between pump body and cover is ensured with seal ring in special shape mounted.
8.3 Multi-way Valve and Bypass Valve (Fig 8-1)
The 2-disk multi-way valve consists of four-plate valve body, two spool valves, one safety overflow valve,
and one bypass valve. The four-plate valve body is assembled using three stub bolts and nuts, and the
inclined spool valves are mounted with inclined autolocking valve.

Safety Overflow Valve Lifting Spool Valve Inclined Spool Valve

Connected
with Oil Pump Used for Connection
with Pressure Gauge

Leading to
Oil Tank

Bypass
Valve

Connected with Steering Gear

Fig 8-1 Multi-way Valve

57
8.3.1 Operation of Spool Valve (Taking inclined Spool
Valve as example)
(1)Neutral Position (Fig 8-2)
At this point the High-pressure oil drained from oil pump
returns to oil tank through neutral position. Oil Feed One-way Valve
Cylinder interface B Main Oil Feed Inlet
Cylinder interface A

Return Spring

Spool Valve
Middle Channel Low Pressure Channel

Fig 8-2

(2)Push-in Spool Valve (Fig 8-3):

At this point middle channel is closed the oil from oil
inlet port opens the one-way valve and flows to the
interface B of cylinder, while the oil from cylinder
interface A flows to oil tank through low-pressure
channel. By virtue of return spring, it may allow the
spool valve to return to neutral position.

Fig 8-3
(3)Pull-out Spool Valve (Fig 8-4)
At this point when neutral position is closed, the oil from
the oil inlet port opens the one-way valve and flows to
the cylinder interface A, while the oil from cylinder
interface B flows to the oil tank through low-pressure
channel.By virtue of return spring, it may allow the spool
valve to return to neutral position.

Fig 8-4
8.3.2 Main Safety Overflow Valve and Bypass Safety Valve (Fig 8-5)
The main safety overflow valve is composed of the two parts including main valve A and pilot valve B.
When multi-way valve is reserved, the high-pressure oils in cavity C and working mechanisms (such as
lift cylinder and tilt cylinder) are connected, the pressure oil acts on the pilot valve B, through the fixed
throttle holes D and E. When system pressure is larger than the system regulated pressure, the pilot
valve B is opens, for the pressure in cavity F to drop. The valve core of the entire main valve A moves
rightwards, for the pressure oil to be directly connected with low-pressure channel G, for cavity C to be
relieved, in order to ensure the stability of system pressure. Adjusting screw H may be used to adjust the
stable pressure value of the system.
The bypass safety valve is in a relatively simple structure, as a direct-acting type of overflow, to get a
stable pressure value for steering system by making use of the principle for direct balance of liquid
pressure with spring force. When operating wheel is operated, the oil cavity M is connected with
high-pressure oil circuit. When system pressure is larger than spring pressure, the valve core N moves
rightwards, and pressure oil is connected with low-pressure oil circuit through cavity T, for cavity M to be
relieved, in order to ensure the stability for the pressure of steering system. Adjusting screw K may be
58
used to adjust the stable pressure value of the system.
L valve is a balanced spool valve, and the spool valve L moves leftwards and rightwards through
continuous change in flow and pressure to change the openness in the two places of R and S, to ensure
that the flows to working cavity Q and outlet PS to fully hydraulic steering gear are automatically
balanced, and to be passed by steadily according to proportion. a, b, and c are the fixed throttle holes.

Oil Feed Inlet

Return Oil Port

Connected with
Steering Gear

Main Safety Valve

Bypass Safety Valve

Fig 8-5

8.3.3 Action of Inclined Autolock Valve

The inclined spool valve is mounted with autolock valve,
mainly used to prevent vibration possibly arisen from Tilting Cylinder
internal negative pressure of tilting cylinder, and avoid
severe aftereffect caused by misoperation. For general
conventional structure, the inclined spool valve can still be
operated for it to tip forward after engine is turned off.
However, when this tilt autolock valve is used, it cannot
make the mast tip forward, even if the valve is operate with
a big push, in the case when engine is turned off.
Refer to Fig 8-6 for its structure.
Valve Spool
Spring Core Valve

Fig 8-6

59
piston for tilting cylinder. When spool valve is pulled out, the high-
mast is under the
back-tip status.
When inclined spool valve is pushed, the high- , to allow the autolock
valve in spool valve to act by virtue of high-
engine turns off or stop rotation, there is no high-pressure oil for autolock inside the spool valve to act,
hence the interfa mast will not tip forward, and
negative pressure can neither be formed in tilt cylinder.
8.4 Oil Circuit of Hydraulic System (Main Oil Circuit) (Fig 8-7)
The high-pressure oil from the main oil pump reaches the multi-way pump, divided into two parts via
multi-way valve and through the bypass valve therein: One part for high-pressure oil to be divided into lift
cylinder or tilt cylinder, and the other part is divided at an invariable flow rate into steering gear, to control
the steering cylinder. When lift and tilt two spool valves are at the neutral position, the high-pressure oil
returns to oil tank directly through channel. When lift spool valve is pulled, the high-pressure oil passes
through the throttle valve, and then pushes the piston rod upwards from downward of lift cylinder piston.
When lift spool valve is pushed, the lower part of lift cylinder piston is connected with low pressure, for
piston rod to drop depending on self weight and cargo weight. AT this point the oil flowing out from lift
cylinder passes through the throttle valve for the dropping speed to be controlled. When tilt spool valve is
operated, the high-pressure oil may flow into the front cavity of tilt cylinder, while the other side is
connected with low pressure, for the door frame to achieve the back tip or front tip action.

Fig 8-7 Oil Circuit of Hydraulic System

60
8.5 Lifting Cylinder (Fig 8-8)
Two single-acting lifting cylinders are fixed on the rear side of channel steel for the outside mast, and the
bottom part of cylinder is fixed on the bracket of lift cylinder on the outside mast using pins and bolts,
while the top part of cylinder (namely the top part of piston rod) is connected with active beam. The
piston strokes for the two cylinders shall be adjusted to be consistent, for the two cylinders to lift
synchronously, and the parts 28 and 29 may be adjusted to achieve the synchronization, if they are still
not synchronized.
The lifting cylinder is mainly composed of cylinder body, piston, piston rod, cylinder cover, cylinder
bottom and sealing parts. One oil port is available in the lower part of cylinder body, while one return oil
pipe is mounted in the upper part of cylinder body for a small amount of leaked oil above the piston to
return to oil tank. The piston is fastened onto the piston rod using slot nut and cotter pine, and one YX
seal ring, retainer ring and wear ring are fitted on the outer edge of piston. This piston moves along the
inner surface of cylinder body under the action of high-pressure oil. Shaft sleeve and dust ring pressed
and matched are mounted in the inner hold of cylinder cover, and this shaft sleeve supports the piston
rod, while the dust ring is able for cylinder body to resist dust. The stroke of piston may be adjusted by
making use of cylinder cover.
When the lift spool valve of multi-way valve is pulled backwards, the high-pressure oil enters through the
bottom part of lift cylinder, to push the piston and the piston rod, for fork and inside mast to lift by virtue of
lift chain. When lift spool valve is pushed forward, the piston of lift cylinder drops under the effect of piston
rod, bracket, fork and cargo weight, for the oil under the piston to flow out. The oil drained out from lift
cylinder is controlled by throttle valve, and returns to oil tank through multi-way valve.

1. Active Beam 16. Pin

2. Dust Ring 17. Spool Valve
3. Shaft Cap 18. Spring
4. Cylinder Cover 19. Joint Fig 9-8 Lifting Cylinder

5. O-Ring 20. O-Ring

6. Piston Rod 21. Hosting Chain
7. Cylinder Body 22. Plug
8. O-Ring 23. Screw
9. Piston 24. Retainer Ring
10. Wear Ring 25. Sheave
11. Retainer Ring 26. Plug
12. Yx Seal Ring 27. Chuck Plate
13. Nut 28. Bolt
14. Cotter Pin 29. Screw Plug
15. Bolt

Fig 8-8

61
There is one shut-off valve on the bottom of lift cylinder (Refer to Fig 8-9), to prevent cargo from abrupt
drop, when high-pressure rubber hose is suddenly cracked. The oil from lift cylinder passes through the
spool valve of shut-off valve, and the oil holes around the spool valve allow the two rubber hoes to
generate pressure difference. When this pressure difference is smaller than the spring force, the spool
valve will not act. If the high-pressure rubber hose is cracked, a very huge pressure difference is formed,
for the spool valve to move and block up its surrounding oil holes, only to allow a small amount of oil to
flow through the pores on the end part of spool valve, for fork to slowly drop.

When Normal When Disconnected

Fig 8-9

8.6 Limiting Valve

Speed limiting valve (namely throttle valve) is mounted in the oil circuit of lift cylinder, to restrain the
dropping speed when fork carries a heavy load, and its structure is indicated as in Fig 8-10. When spool
valve of multi- -pressure oil from multi-way valve passes through
cavities A and B as well as holes C, D, E, and F, and cavity G under the condition when it is not throttled,
and then flows into the lift cylinder. When spool valve of multi-
from lift cylinder passes cavity G, oil holes F, E, D, and C, as well as cavities B and A thought the entire
valve. AT this point, pressure difference is generated between cavity A and cavity B, and opens the ball
valve (Part 8). When pressure difference exceeds the spring force of spring 2, the valve core 7 moves
rightwards, for the flow quantity of oil to drop for diminish of D and C holes, which has also reduced the
flow quantity through the throttle hole.

62
 Normal Flow
Direction
Throttle
Direction

Lifting Multi-way
Cylinder Side Valve Side

1. Joint 3. O-Ring 5. Throttle Plate 7. Valve Core 9. Spring

2. Spring 4. Retainer Ring 6. Valve Sleeve 8. Nylon Ball 10. Valve Body

Fig 8-10 Limiting Valve

8.7 Tilting Cylinder (Fig 8-11)

Tilting cylinder is in a double-acting type, mounted on the two sides of mast. Its end of piston rod is
connected with mast, and the bottom of tilt cylinder is connected with truck frame using pins.
The tilting cylinder assembly comprises of piston, piston rod, cylinder body, cylinder bottom, guide sleeve,
and sealing parts. Welded structure is applied to piston and piston rod. One wear ring and two Yx seal
rings are mounted on the outer edge of piston, while Yx seal ring, retainer ring, and dust ring are fitted in
the inner hold of guide sleeve, pressed and matched with shaft sleeve. This shaft sleeve supports the
piston rod, while the seal ring, retainer ring, and dust ring are able to prevent oil leak and dust, screwed
onto the cylinder body together with O-ring.

1. Clevis 4. Yx Seal Ring 7. Bearing 10. Cylinder Body 13. Piston

2. Dust Ring 5. O-Ring 8. O-Ring 11. Yx Seal Ring 14. Yx Seal Ring
3. Baffle Ring 6. Guide Sleeve 9. Piston Rod 12. Wear Ring

Fig 8-11 Tilting Cylinder

63
When tilt spool valve is pushed forward, the high-pressure oil enters from the bottom of cylinder, thus to
push forward the piston for mast to tip forward by 6 , and when spool valve is pulled backwards, the
high-pressure oil enters from the front end of cylinder body, to push backward the piston, until the mast
tips backwards by 12 .
8.8 Maintenance of Main Oil Pump
8.8.1 Disassembly (Refer to Fig 8-18 and 8-19 for Imported Main Oil Pump in combination.)
(1) Clamp the pump gently on the vice stand after cleaning, and firstly remove the bolt 12.
(2) Detach pump cover 1 and seal rings 8, 9, 10, and 11.
(3) Remove the front-end cover 7, and 8, 9, 10, and 11.
(4) Demount bearings 3 and 4, as well as gears 5 and 6 from pump body 2, and bearings may be
dismounted through pressing the gears, if it is difficult to disassemble them.
It is the best to make arrangement according to the sequences in Fig 8-18 and Fig 8-19, in order to
facilitate examination.
8.8.2 Examination and Repair
The parts that have been disassembled, except rubber, shall be cleaned firstly with oil, and examined,
repaired, or replaces according to following steps.
(1) Examination of Pump Body
High-efficiency gear pump is designed into that the crest of gear rotates along the inner surface of pump
body through slight press and touch, and the trace of scratch will be generated around the inner surface
of the crest and the pump body. Under normal situation, its trace shall not exceed a length 1/3 of the
inner edge of the pump body, and if it reaches 1/2 length, it indicates that the bearing and gear shaft are
severely worn out. In Fig 8-12, when size X exceeds 39.180mm, or the trace of scratch on inner edge
exceeds one half, it is required to replace the pump body.

Inlet Outlet

Scratch

Outlet Side

Maintenance Limit Size

Fig 8-12

(2) Examination of Bearing (Fig 8-13 and Fig 8-14)

The ideal situation is to require that the inner surface of bearing is not coarse, and the contact surface
with brightness is shown at the position about 1/2 at the inlet side. The bearing shall be replaced, if any
of the undermentioned cases occurs.

64
a) The trace of contact appears on the entire slide inner
surface, and a feeling of obvious coarseness exists when it is
Outlet
scraped with finger nail.
b) Crack appears around the end face, and a severe Scratch
coarseness is felt when it is scraped with finger nail.
c) The bonding trace with other extraneous substance
appears on the internal slide surface and the end face.
Gear Side
Most cases of abovementioned failures are aroused by
un-cleaned hydraulic oil. At this point the whole oil circuit may
be cleaned or the oil may be replaced. Some individual cases Inlet
are attributed to overloaded safety valve, air corrosion, or too
high temperature, or too low viscosity. In the case when the
abovementioned failures occur, leading to coarseness or
severe wear on the gear shaft or the end face of gear, the gear Fig 8-13
and bearing shall be replaced. The limit size for bearing
maintenance is:

Inner Diameter - 19.123mm (Fig 8-14)

Total Length - 26.411mm

(3)Examination of Gear
So long as clean hydraulic oil is used, generally speaking,
gear shaft and gear end face will not be damaged. In the case
when a coar seness to a certain degree is felt when it is
scraped with finger nail on the end face of bearing and gear,
or crack occurs on the gear end face, or severe un-uniform
wear is present on the gear end face, the gear shall be Fig 8-14
replaced at this point. When gear surface is worn or discolored,
it indicates that failure has also occurred with bearing or pump
body, and it shall be examined. The limit size for the axial
diameter of gear shaft is 18.935mm (as indicated in Fig 8-15).

(4)Examination of Oil Seal

a) Oil Seal 14: (Refer to Figs 8-18 and 8-19) Oil seal 14 is a
combination seal, and the lip at inner side of the pump shaft
plays the sealing function, while the lip at the outer side is
mainly for dust resistance (as in Fig 8-16). It is mainly required
to examine whether or not crack, wear, or distortion exists with
oil seal, and it is also required to examine whether or not the
elasticity of rubber is enough, and it shall be replaced once it Fig 8-15
is out of order.
b) Seal Rings 8 and 9;
Seal ring 8 for pump body and seal ring 9 for bearing shall be Dust-proof
replaced with new ones, when pump body is reassembled. Lip
c) Seal Rings 10 and 11: Examine whether or not they are
worn and damaged. Seal Ring
Nozzle

Pump Inner Side Pump Outer Side

F
Fig 8-16

65
8.8.3 Reassembly (Fig 8-17)
(1) Clean the disassembled parts.
(2) Coat a thin layer of clean grease on the lips of oil seals 8, 9, 10, 11, and 14.
(3) Place the pump body 2 and the pump cover 1 on a flat stand, and coat the inner surface of pump
body with clean hydraulic oil.
(4) Put bearings 3 and 4 into the pump body, and pay attention not to misplace their mutual positions.
Place the bearing at correct position, and it may be taken out for reassembly, in the case of difficulty. It is
never allowed to knock it gently or press it in forcibly.

Driving Gear
Bearing

Driven Gear

Positioning Pin
(at Inlet Side)
Inlet Side

Clearance not Allowed

Fig 8-17

(5) Turn over the pump body, put the driving and driven gears 5 and 6 into the pump body, and allow the
engaged teeth to be at the same engagement positions prior to disassembly.
(6) Mount the bearings 3 and 4 on one side of the front end cover using the same method as in Step (4).
(7) Mount the seal ring for pump body 8, the seal ring for bearing 9, and seal rings 10 and 11, and pay
attention not to allow the seal rings to be overlaid in the middle.
(8) Assemble the front end cover 7, and in this case, wrap the band around the end of driving gear, to
fter the front end cover is mounted.

66
(9) When pump body is turned over to mount end cover, pay attention to prevent the slide of seal rings
installed during step (7).
(10) Mount seal rings 8, 9, 10, and 11, with the same method as in step (7).
(11) Put on the end cover 1.
0.25 0.26
(12) Mount spring washer 13 and bolt 12, and tighten the bolt with a torque of 47 0 N.m (4.7 0· kgm).

Examine the gear pump as to whether or not it is assembled completely and properly. Place the driving
shaft into the vice stand, the turn this pump, and the rotation of this pump shall be quite light. It is
required to reexamine the pump, in the case when it is difficult to rotate.
Before this pump is assembled onto the machine, it is required to examine for a second time whether or
not the assembly of the hydraulic pump is correct, and whether or not the rotating direction is correct.
Attention shall be paid to the following items when the pump is assembled:
a) Examine whether or not the lower part based on centerline is damaged or present with dust.
b) Examine whether or not the flange face of pipeline is damaged or present with dirt.
Mount O-ring, after the abovementioned has been examined.
8.8.4 Test Run
Operation shall be carried out after assembly. Observe whether or not the pump has the specified
performance after reassembly, and do running-in. It is required for test run to be performed when pump is
assembled on forklift truck, and test run shall be conducted according to the following method. If pump is
blocked or its internal part is excessively worn out, oil shall be replaced and filter shall be replaced or
cleaned.
(1) Install pressure gauge on high-pressure pipeline near the pump.
(2) Place the control valve at neutral gear, for pump to run at a speed of 500-1000rpm. As this valve is at
neutral gear, the reading of pressure gauge shall be slightly lower than 1MPa (10kg/cm), and keep the
pump running for 10 minutes under such status.
(3) Increase its rotating speed to 1500-2000rpm, and allow it to be idle for 10 minutes.
(4) Keep the rotating speed at Step (3) unchanged, increase the pressure to 2-3MPa (20-30kg/cm) for a
further operation for 5 minutes, and repeat such operation until maximum pressure is reached. During
this process, use overflow valve to increase load so as to adjust pressure. Allow each oil circuit to work
for 5 minutes, and replace or clean the filter core of return oil filter. When pressure is boosted, attention
shall be paid to oil temperature, as well as the surface temperature and working sound of pump body. IF
oil temperature or pump temperature is too high, the pump shall be unloaded immediately to lower the
temperature, and then this process is to be repeated.
(5) After the above procedure is completed, readjust the overflow valve to the original working condition
and perform unloading test.
(6) No matter it is loading or not loaded, unloading test shall be made in either cases to ensure that this
device has a proper speed.
Fig 8-18 and Fig 8-19 respectively indicate the lateral views for structure of gear oil pump in clockwise
and counterclockwise rotations, and Fig 8-20 represents the schematic diagram of hydraulic pipeline, for
your information.

67
 Clockwise Rotation

1. End Cover 2. Pump Body 3. Bearing 4. Bearing 5. Driving Gear 6. Driven Gear
7. Front End Cover 8. Seal Ring 9. Seal Ring 10. Seal Ring 11. Seal Ring 12.Bolt
13. Lock Washer 14. Oil Seal 15. Locking Collar

Fig 8-18 Clockwise Rotation of Gear Pump

(2t-3.5t LPG Forklift Trucks)

68
1. End Cover
2. Pump Body
3. Bearing
4. Bearing
5. Driving Gear
6. Driven Gear
7. Front End Cover
8. Seal Ring
9. Seal Ring
10. Seal Ring
11. Seal Ring
12. Bolt
13. Lock Washer
14. Oil Seal
15. Locking Collar

Counterclockwise Rotation

Fig 8-19 Counterclockwise Rotation of Gear Pump

(2-3.5t Diesel Forklift Truck)
69
 Steering Gear

Multi-way Valve

Multi-way Valve Limiting

Valve Rubber Hose

Tilting Cylinder (Left)

Steering Cylinder

Working Oil Tank Device

Fixed Bolt
Pump

(Diesel and LPG/Gasoline Forklift Trucks)

Tilting Cylinder (Right)

Fig 8-20 Schematic Drawing of Hydraulic Pipeline

Paper Pad

70
8.8.5 Failure Removal

Problem Possible Cause Removal Method

Oil level in oil tank to the low end Oil to be filled to the specified oil level
Oil of Oil Pump
Staying away
To be cleaned, and oil to be replaced
Oil suction side pipeline or filter blocked
if it is dirty

Bearings 3 and 4 worn, and bearing

seal ring 9 or filler seal rings 10 and 11 To be replaced
at fault

Pressure to be raised based by virtue

Overflow valve misadjusted
of pressure gauge
Failure of Gear
Pump for
Supercharge (1) Loosene3d joint at suction pipe
side to be re-tightened
(2) Oil to be added into oil tank
Air blended into pump
(3) Oil seal of pump to b e examined
(4) Pump to be started only until there
is no more air bubble in oil tank

Oil suction side hose twisted, or cavity Oil filter to be cleaned and hose to be
aroused by blockage of oil filter adjusted

Air sucked inside due to loosening of oil

Each joint to be re-tightened
suction side joint

(1) Oil of proper viscosity to be used

Cavity aroused due to excessive
Noise of Gear (2) Work to be started only when oil
viscosity
Pump Loud temperature is normal

Non-concentric To be concentric

Cause for generation of air bubble to

Air bubble present in hydraulic oil
be examined and to be repaired

(1) Oil seal and seal ring 8 of

Oil Leak with pump at fault
To be replaced
Pump (2) Sliding face worn
(for internal leak to be increased)

71
9. Lifting System

2t-3.5t Type -shaped inside mast -shaped mast with free lifting, two-stage
telescopic mast

End Face of
Inside Mast:

Taper 1:10

End Face of
Outside Mast:

Taper 1:10

Rollers:
Main Roller I
Roller 2
Limit Roller
Side Roller Group I
Side Roller Group II
Side Roller Group
Lifting Chain (ISO)

Fork Mast Lifting System

Fork Mast Adjusting Device
Weight (Lifting Height at 3m)

72
9.1 Overview
Lifting system is a two-stage rolling telescopic mast, with the outside mast
face, and the inside mast bracket comply with the international
standard, with a free lift of about 300mm during operation.
9.2 Inside and Outside Masts
The mast assembly is composed of inside and outside masts. The lower part of the outside mast is
connected with drive axle, with weight mainly supported on axle housing. The bracket of tilt cylinder on
the outer side in the middle of outside mast is connected with piston rod of tilt cylinder. The mast is able
to tip forward for 6 and backward for 12 through operating the inclined spool valve of multi-way valve.
The inside and outside masts are welded parts, to bear the longitudinal and traverse loads through
rollers and side rollers, and to allow the inside mast to rise and fall steadily.
9.3 Bracket
The bracket is also in a structure of welded part, to allow the bracket to move upward and downward
steadily along the inner edges of the channel steel for the inside mast and to bear the longitudinal and
traverse loads through rollers and side rollers with clearance adjustable. There are three groups of main
rollers (Roller I) and two groups of side rollers on each side of the bracket for 2-4t forklift trucks, and
when the fork rises to the maximum height, one pair of main rollers on left and right on top will extend to
the upper edge of the inside mast.
The fork is locked inside the groove on the bracket using lock pins, and the spacing of fork may be
adjusted on the left or right manual. International standard (ISO) is applied to fork and bracket, to
facilitate common use and interchange.
9.4 Adjustment of Lifting System
(1) Drop the fork to the ground, and adjust the lift chain, to ensure that the distance between the lower
roller center of bracket and the lower edge of inside mast is 15-20mm.
(2) Tip back the mast and adjust the tensioning force of lift chain, for the tensioning degrees of lift chain
at places b to be equivalent (Fig 9-1).
(3) The strokes of left and right lift cylinders shall be equivalent, and their strokes may be adjusted using
cylinder cover 4 (Refer to Fig 8-8.).
(4) Adjust the error of position for the height of left and right lift cylinders by making use of the adjusting
bolt on the upper end of right lift cylinder as indicated in Fig 9-2.

Adjusting Bolt

Active Beam

Fig 9-1 Fig 9-2

73
10. Electrical System
10.1 Overview
The electrical system is a negative earthed signal-wire circuit. The electrical equipment is mainly
composed of following several systems:
(1) Charging System
It consists of engine, battery, charging indicator signal light, etc, belonging to a power supply for power
equipment used for forklift trucks, with a voltage: 12V.
(2) Starting System
It is mainly composed of starter, and start switch, and its purpose is to start engine.
(3) Ignition System (LPG/Gasoline Forklift Truck)
It mainly comprises of distribution block, ignition wire, and spark plug, etc, used for ignite burning mixture
in LPG/Gasoline engine.
(4) Instruments
They cover hour meter, oil gage, and water temperature gauge, etc, are the monitoring equipment on the
forklift truck.
(5) Lighting and Signal Equipment
It includes various lighting, and signal lights, as well as horn, and buzzer, etc.
Front Headlight: 55W
Front Combination Light (Steering/Width Light): 10W
Rear Combination Light (Width/Brake/Reversing/Steering): 5W/21W/21W/10W
10.2 Operating Brief Description
st
(1) Preheating Start Switch: Right-hand turn to 1 gear, the instrument and ignition power is connected,
to automatically start preheating for the diesel engine. The preheating indicator light turns on, and
nd
preheating will be completed after it has lasted for 12 seconds. It may be turned to the 2 gear to start
engine.
Attention: Place the transmission case lever must be placed on zero gear before it can be started for
hydraulic forklift truck, and otherwise, the zero-gear switch will be in open circuit, and the starter fails to
be started.
st nd
(2) Light Switch: Turn to the 1 gear, the front and rear width lights turn on, and turn to the 2 gear, for the
front headlight to turn on.
(3) Left-hand Turn Signal: Pull backward the switch for turn signal light, the left-hand turn signal light of
the front combination headlight flashes and turns on.
(4) Right-hand Turn Signal: Push forward the switch for turn signal light, the right-hand turn signal light of
the front combination light flashes and turns on.
(5) Brake Signal: When it is required to forklift truck to brake, push down the brake pedal with foot, the
brake light (red) of the rear combination light turns on
(6) Reversing Signal: When it is required for forklift truck to reverse, place the control rod at the reversing
gear, and at this point, the reversing light (white) turns on, and the reversing buzzer will hoot immediately.
st
(7) Charging Signal Display: Right-hand turn of start switch to the 1 gear, the charging indicator light
turns on, and it will automatically turn off at once after engine is started.
st
(8) Oil Pressure Signal Display: Right-hand turn of the start switch to 1 gear, the engine oil pressure
indicator light turns on, and it will automatically turn off after engine is started. If the light turns on in
running process, it then indicates that lubrication is not under satisfactory condition, and it shall be
parked for examination.
st
(9) Oil-Water Separator Indicator Signal Display: Right-hand turn of start switch to the 1 gear, the signal
light will turn on, and it will automatically turn off after engine is started. If the light turns on in running
process, it then indicates that water is accumulated in fuel-water separator. Press the compression bar
on oil-water separator for water to be then drained out, and the signal light will turn off after water is
drained (only used for diesel engine trucks).
74
(10) Fuel Gauge: Indicating the storage volume of fuel in fuel tank.
(11) Water Temperature Gauge: Indicating the temperature of engine cooling water. The white area on
the scale plate is 60-80 , the green area is 80-110 (normal working temperature of engine), and the
red area is 110-145 . When pointer is pointed to the red area, the forklift truck shall be stopped for use,
to be launched into work again when pointer returns to green area.
(12) Hour Meter: Cumulative total working hours of engine
10.3 For the engine control section, please read the engine manual
10.4 Battery
This series forklift with Xunqi battery, in the use of maintenance should note the following:
(1) When installing and maintaining, do not touch the conductor of the battery, which can cause serious
burns.
(2) When charge the battery, the positive and negative can not be reversed, otherwise it will cause high
temperature, burning, smoke or explosion.
(3) When do the battery maintenance, please wear goggles, rubber gloves, rubber shoes.
(4) The battery will produce flammable gas, there is a risk of explosion, it should avoid short circuit and
spark production, strictly prohibited fireworks.
(5) Prohibit the removal of the battery, the battery electrolyte is dilute sulfuric acid, when contact with the
skin, please immediately rinse with water, get the eyes rinse with water and see doctor in time.

Fig 10.1 Combination display National III display comes with fault indicator

1. Fuel gauge 2. Left turn indicator light 3. Neutral indicator 4. ECU failure(not use)

5. Sediment indicator light 6. E/G oil pressure alert light 7. Pre-heat indicator light

8. Battery Charging light 9. Seat belt light 10. T/M oil temp gauge 11. Air filter indicator light

12. Right turn indicator light 13. Water Temperature gauge 14. Houre meter

75
 IV. Drive, Operation, and Routine Maintenance of Forklift Truck
The forklift drivers and managemen
operation and standard operation according to the forklift truck operation and maintenance manual as
well as driver manual.
1. Conveyance of Forklift Truck
Attention must be paid to following items when container or motor vehicle is used to convey forklift trucks:
(1) Trigger the parking brake.
(2) It is required to fasten properly the front part and the rear part of the mast and the counter weight
using steel wire, and to wedge up properly the corresponding positions of front and rear wheels using
wedge blocks.
(3)
2. Storage of Forklift Truck
(1) Drain the fuel completely. (Cooling water is not to be drained if it is the antirust and anti-freezing fluid.)
(2) Coat antirust oil on the surface of un-painted parts, and coat lubricating oil on the lift chain.
(3) Drop the door to the lowest position.
(4) Trigger the parking brake.
(5) Fill the front and rear wheels properly using wedge blocks.
3. Preparation prior to Operation
(1) Avoid examining fuel, oil leak, and oil level as well as examining electrical instrument in the place with
open fire, and avoid adding fuel during operation.
(2) Examine air pressure of tyres.
(3) The handle for forward and reversing gear shall be placed at the middle position (the position of part).
(4) when fuel system is work and when battery is examined.
(5) Examine the status of respective handles and pedals.
(6) Get well prepared prior to start.
(7) Loosen the parking brake.
(8) Perform the test actions for lift and drop, forward and backward tip of mast as well as steering and
brake of forklift truck.
(9) The degree for contamination of hydraulic oil is larger than Grade 12, and the NAS1638

4. Operation of Forklift Truck

(1) The forklift truck shall be driven by drivers who have been trained and hold driving license.
(2) The operators shall wear shoes, helmet, clothes, and gloves usable for safety protection during
operation.
(3) Examine respective controls and warning devices before truck is driven, and it is required to operate
the truck after repair in the case when any damage or defect is found.
(4) Load shall not exceed the specified values during conveyance. Fork must be completely inserted
under the cargo, and cargo shall be uniformly placed on the fork. It is not allowed to pick up cargo
using single fork tip.
(5) Smoothly perform start, turning, driving, brake, and stop. Slow down at turning, on wet or smooth
pavements.
(6) It is required to place cargo as low as possible, and to keep the mast tilt backwards, when cargo is
load for driving.
76
(7) It is required to be careful during driving on a ramp. It is required to drive forward during upgrade and
drive reversely during downgrade, when the truck is driven on a ramp larger than 1/10. Turning shall be
avoided by all means, and please never perform loading-unloading operation when forklift truck is
running downgrade.
(8) It is required to pay attention to passengers, obstacles, and low-lying pavements, and pay attention to
the clearance above the forklift truck, during driving.
(9) It is not allowed for anyone to stand on fork and it is not allowed for anyone to be carried on truck.
(10) It is not allowed for anyone to stand under the fork, or to walk under the fork.
(11) It is not allowed to control the truck and spreaders at any position other than the driver seat.
(12) It is required to pay attention to the fall of cargo from above, for any high lift forklift trucks with a lifting
height larger than 3m, and protective measures must be taken, when necessary.
(13) Try as much as possible to tip backward the mast for high-lift forklift trucks during work, and it is
required to perform front or back tip within the minimum range during loading-unloading operation.
(14) It is required to take a doubled care, and to drive slowly, during running on dock or on temporary
planks.
(15) Driver shall not stay on the truck, when fuel is added, and the engine shall be turned off. Ignition is to
be avoided when battery or level of oil tank is examined.
(16) The forklift trucks with spreaders shall be operated as loaded forklift trucks during empty-load
operation.
(17) cargo, and take care when cargo of relatively large size is
conveyed.
(18) Drop the fork onto the ground, and put the handle for gear position to neutral gear, and turn off the
engine or disconnect the power supply when driver leaves the truck. Pull the parking brake device
properly when truck is parked on a ramp, while wedge blocks must be used to fill up the wheels when the
truck is to be parked there for a long time.
(19) It is not allowed to open water tank cover carelessly, under the condition when engine is very hot.
(20) The pressures of multi-way valve and safety valve have been properly adjusted before delivery of
forklift truck from factory, and users shall not adjust them at discretion during use, to avoid damage of
entire hydraulic system and hydraulic components due to excessively high adjustment.
(21) i
air charge.
(22) The maximum noise outside the forklift truck is not to be larger than 89dB (A), and JB/T3300 shall
be followed as test method.
5. Notices for application of Cooling System
(1) When forklift truck is being used, in the case when radiator is overheated or temperature of coolant is
excessively high, try as much as possible not to open the radiator cover immediately. Examine the liquid
level, in order to find the overheating cause. When cover has to be opened, it is required to drop engine
to medium speed. Turn the radiator cover slowly and loosen off the cover after waiting for a while, to
avoid scald of operator by splash of coolant.
Make sure to screw the radiator cover properly in place, when it is tightened up, and otherwise it is
difficult to build up a specified pressure system.
(2) Regarding the radiator with coolant used as cleaning water, the water in radiator shall be drained out,
only when truck is parked in cold weather and risk exists for water to be frozen. The radiator shall be
detached, after it has worked for a period of time, and shall be cleaned in the boiled soda solution, to
remove the scale or sediment formed on respective inner surfaces of radiator.
(3) Regarding radiator with long-acting antirust and anti-freezing fluid used for coolant, it is strictly
prohibited to randomly add water and anti-freezing fluid of different models. The antirust and
anti-freezing fluid of the same model shall be supplemented after anti-freezing fluid is leaked or
evaporated.
77
Anti-freezing fluid is generally used both in winter and summer, not changed for four seasons. It shall be
drained out for filtration and purification treatment after use for one year in general, to be then further
used.
(4) According to different work conditions, the smudge on the outer surface of radiator shall be
periodically cleaned and removed, either to be soak cleaned using detergent, or to be flushed using
compressed air or high-pressure water (pressure not larger than 4kg/cm).

6. Oils Used for Forklift Truck

* Refer to followed Operator s manual page 78.

78
7. Lubricating System Table

79