5-10ton R Series Forklift Truck

SERVICE MANUAL

CPCD50/60/70/80/100-RG16
CPCD50/60/70/80/100-RW28
CPCD80/100-RG17
CPCD50/60/70-RG24
CPCD80/100-RG25
CPCD50/60/70/80/100-RW14
CPCD50/60/70-RW14B
CPCD50/60/70-RW19A
CPCD50/60/70-RW18A
CPQD50/60/70-RW17-Y

E-P Equipment Co., Ltd.

2007.08 2st EDITION
 FOREWORD

This manual instructs you the structure, principle and servicing methods on 5~10t

R series forklift truck for Hang Zhou Forklift Truck Co., Ltd.

To ensure safety and exert the truck’s potential, all the personnel that in charge of

operation, maintenance and management must read this manual thoroughly before

starting work with the forklift.

This manual is also applicable to the container forklift truck.

Forbid repairing the truck if you haven’t been trained.

 Contents
Contents.............................................................................................................................. 1

1.Driving System................................................................................................................. 1

2. Hydraulic gear-box and torque converter........................................................................ 2

3. Transmission Axle........................................................................................................... 3

5. Steering axle................................................................................................................. 16

6. Steering system.............................................................................................................20

7. Break system................................................................................................................. 23

8. Hydraulic system........................................................................................................... 36

9．Electrical system.......................................................................................................... 42

10. Lifting system.............................................................................................................. 50

Appendix A........................................................................................................................ 64

Appendix B........................................................................................................................ 71
1.Driving System
Power configure
Diesel
Engine
Parameter CY6102BG-2 QSB4.5(USA)
LR4108G10Y
(Chaochai)

Rated Output/KW 81 85 65
Rated rpm/min 2500 2200 2400
Max. torque
253/1650 435/1600-1700 300/1400-1600
N·m/speed rpm
CPCD50/60/70-
CPCD50/60/70-RG16
Forklift model RW28 CPCD50/60/70-RG24
CPCD80/100-RG16
CPCD80/100-RW28

Engine Diesel
Parameter
LR6108G62 6BG1QP
Rated Ouptput 85 84．6
Rated rpm r/min 2200 2200
Max. torque
4300/160-1700 411/1600
N·m/speed rpm
CPCD50/60/70-RW14
Forklift model CPCD80/100-RG25 CPCD80/100-RW14
CPCD50/60/70-RW14B

Engine Diesel Engine Gasoline Engine

Parameter GM4.3L
TD42 FE6
Rated Output KW 62.5 88 74

Rated rpm r/min 2300 2100 2300

Max. torque 301/1600

274.4/1600 412/1600
N·m/speed rpm
CPCD50/60/70- CPCD50/60/70- CPQD50/60/70-
Forklift Model RW17-Y
RW19A RW18A

Engine’s specification,construction and maintenance shown in ENGINE MAINTENATION

MANUAL.
After maintaining the engine,you should measure the displacement,the value should accord with
the correlative standard. Exhaust gas value shown in the below table.

1
 Engine Power CO HC NO2 PT granule
KW (g/kwh) (g/kwh) (g/kwh) (g/kwh)

75≦P <110 5 1.3 7 0.4

2. Hydraulic gear-box and torque converter

．Data
1．

Model YQXD100H1
torque converter

Type Single stage, two phase, three-element

Hydrodynamic

Diameter of circulating chamber D

(mm) 315

Type Electrical shift

power gear-box
Hydrodynamic

ForwardⅠ 1.8519
Speed Scale

F 0.533
ForwardⅡ 0.6415
/
1.8519
ReverseⅠ
R 1.829
ReverseⅡ 0.6415
/
Type
Oil Supply
Pump

Position Out pump

Displacement ml/r 21
32
Oil Pressure

Shift gear oil pressure 1.2-1.5

Torque Conver Input Pressure MPa 0.5-0.7

Torque Conver Output Pressure MPa 0.39

Mass（Kg） 320
306
Oil Capacity（l） 25
11
Using oil type 6# or8# Hydrodynamic power transmission oil
Specifications,structure and maintenance methods for CPCD50/60/70-RW19A 、
CPCD50/60/70-RW18A power transmission gear-box and torque converter,please
see 《 NISSAN IMPORTED COMPONENT （ power transmission gear-box ） MAINTENANCE
MANUAL》.
Specifications,structure and maintenance methods for CPCD50/60/70-RW14B power
transmission gear-box and torque converter,please see《Y63180Z-00（power transmission gear-

2
box）MAINTENANCE MANUAL》.
The other specifications, structure and maintenance methods for YQXD100H1 power
transmission gear-box and torque converter, please see 《 YQXD100H1 MODEL TORQUE
CONVERTER MAINTENANCE MANUAL》.

3. Transmission Axle
The transmission axle is consisting of universal joint sliding yoke, universal cross axle,
bearing, center yoke and such etc. The universal cross is mounted in the hole of the center yoke.
Needle bearing is mounted in the support ring of bearing bracket. There is a grease nipple on
the universal cross axle; you can lubricate the needle bearing by this nipple. When the
clearance between needle bearings and universal cross axle is too much, you should detach
the universal joint sliding yoke and see which parts is over-wearing and decide to replace
bearings or universal cross axle. When replace bearings, you should replace a pair of bearing,
do not replace one by one. Two grease nipples must be to the same side.
Using lubricant oil MoS2 for needle bearing, absolutely forbid to use stiff oil (as the
lubricating grease, because it prevent needle to roll on the journal face that accelerate wear
and tear. At the dust occasion it must be frequently oil.

Fig 3-1 Transmission Axle

4. Driving axle and Final drive

1.Data

One step redactor and wheel-end reduction

Type Of Dring Axle
Full floating, direct frame mount, front-wheel drive

Final drive Single spiral bevel gear

Reduction ratio 6．33
Differential Straight tooth gear
Wheel reductor Planetary
Speed ratio 3．63
Total reduction ratio 22．98

3
 Standard
Item Remark
Parameter

Spider wheel lining inside diameter 45mm

Spider shaft diameter 86mm

Luck nut back off after

Wheel-end reduction

Pre-load to hub gear 50N.m

tight
Lock bolt fasten torque 50N.m
Wheel-end reduction hull to brake hull fasten
50N.m
torque
Rim nut fasten torque 500N.m
Wheel-end reduction hull fasten torque 500N.m
Wheel-end reduction hull to brake hull fasten
100N.m
torque
Backlash between the side gear and pinion 0.19-0.25mm Limit 0.5mm
shaft
Gear set backlash 0.2-0.35mm Limit 0.5mm
Ring gear skip
Drive and differential carrier

0.15mm Limit 0.2mm

Side gear thrust washer thickness 1．6mm

The same degree of

Taper roller bearing pre-load 26-35N.m
tightness

Ring gear fasten torque 120N.m Paint Loctite262

Left and right diff, case fasten torque 130N.m Paint Loctite262
Bearing sleeve mounting bolt fasten torque 250N.m Paint Loctite262
Carrier to housing mounting bolt fasten torque 100N.m Paint Loctite262
Adjusting nut fasten torque 35N.m Paint Loctite262

Oil capacity in housing GL-5 85W/90 9．5 L

Oil capacity in wheel-end

GL-5 85W/90 4．5 L
reduction

2. TROUBLE DIAGNOSES AND CORRECTIONS

Status Probable cause Corrective action
Unusual noise Loose axle mounting bracket bolts. Fasten
Before attempting a correct Loose wheel nuts. Fasten
ion, make sure the noise is
Other retaining parts loose. Fasten
coming from the drive shaft-
not from the final drive or Worn or damaged wheel bearing. Replace
wheel reduction gear. Wheel bearing not properly adjusted Adjust

4
 Worn sun gear(drive shaft) splines. Replace

Insufficient lubrication. Inject lubricating oil

Loose wheel nut. Fasten

Deformed road wheel. Replace
Unstable driving
Also refer to the Trouble Worn or damaged wheel bearing. Replace
Diagnoses and Corrections in Loose axle mounting bracket bolts. Fasten
the RA section.
Wheel bearing not properly adjusted. Adjust
Improper tire pressure. Adjust
Worn or damaged axle tube oil seal. Replace

Oil leakage Final drive improperly installed. Replace gasket.

Loose filler or drain plug. Fasten

3. Drive axle structure
PR60·23 composed of axle housing, Final drive,Wheel redactor,Caliper disc brake and so
on.（Shown figure 4-1）.

Fig 4-1A Drive axle（8-10t）

1. Main reduction 2. Driving axle housing 3. Brake clamp 4. Half axle 5. Wheel-end reduction

5
 1. Wheel 2. Rim 3. Wheel-end reduction 4. Shaft
5. Foot brake 6. Carrier 7. Hand brake 8. Housing
Fig 4-1B Drive axle（5-7t）

Tightening torque: N•m

Support bush to truck frame fasten torque 550 N.m

Universal joint to flange yoke fasten torque 150 N.m

Brake assembly fasten torque 189-252 N.m

Rim bolts fasten torque 411 N.m

4. REMOVE AND INSTALLATION

1). Raise front end of lift truck and support
frame with a block or safely stand.
2). Remove mast assembly and related parts.
3). Remove front road wheels.
4). Drain oil from differential carrier.
5). Disconnect brake flare nuts from right and
left wheel cylinders.

Fig.4-2
Note: Plug brake tube openings with
rubber caps to prevent oil from flowing 6). Separate universal joint from differential
out.
carrier

6
 10). To install axle assembly, reverse the order
removal

5. DISASSEMBLY AND ASSEMBLY

DISASSEMBLY
1). Remove pinion gear carrier from axle hub,
and drain oil
completely.

Fig.4-3
7) Support axle assembly with lifting device
and wire ropes.

Fig.4-6
2).Pull out half axle.

Fig. 4-4
8). Remove bolts securing axle mounting
bracket to frame.

Fig.4-7
3). Remove the brake clamp (Here we take
8～10 ton series forklift for example).

Fig.4-5
9). Remove axle assembly.
CAUTION:
Be careful not to damage brake tubes
and other parts during lifting.
Fig.4-8

7
4). Remove bearing washer and bearing nut.
5). Remove ring gear from axle hub.
6). Remove drive axle hub with brake drum
assembly.

Fig.4-10
8) Remove dust seal and inner bearing as an
assembly by tapping evenly along periphery of
Fig.4-9 bearing with a wooden mallet through a soft
7). Separate drive wheel hub from brake drum pad.
assembly.

INSPECTION
Stepped wear or cracks on axle shaft splines. Replace
Seized, nicked, noisy or rusted wheel bearing or improper Replace
rotation of rollers.
Cracked or damaged drive wheel hub. Replace
Damaged oil seal, dust seal or O-ring. Replace
Cracked or damaged axle housing or axle tube assembly. Replace

ASSEMBLY
Assemble drive axle in the reverse order of disassembly.
·Drive outer races of wheel bearings evenly into drive wheel hub.
Check that protruded mark that indicates the position of air bleeding slit faces
upward. Then install securely.
·Bearing adjustment
Adjust wheel bearing with pinion gear carrier, axle shaft and road wheel removed.
1). Apply a coat of multi-purpose grease to threaded areas of wheel bearing nut and bearing
contact surface.
2). Tighten wheel bearing nut until drive wheel hub can no longer be rotated with one hand.
3). From that position, turn back wheel bearing nut approximately 60°.
4). With wheel bearing nut held in that position, turn drive wheel hub two or three rotations so that
bearing settles down.
5). Again tighten wheel bearing nut until drive wheel hub no longer rotates with one hand, then
turn back approximately 60°.

8
6. REMOVAL AND ASSEMBLY FOR DIFFERENTIAL CARRIER
：
6.1.Explored view for differential carrier：

Fig.4-11 Differential carrier

1. Carrier 2.Bolt 3.Gear-set 4.Bearing 5.Bolt 6.Nut

7.Diff ass 8.Diff case 9.Bolt 10.Nut 11-1.Shim 11-2.Side gear
11-3.Cross 11-4.Planet
11-5.Shim 12.Bearing 13.Diff nut 14.Lock plate
shaft gear
16.Bearing 17.Bearing
15.Bolt 18.Bearing 19．Shim 19-1.Washer
cage ass cage
27.Flange
20.Bearing 21.Washer 22.Flange 24.Oil seal 25.O-ring
yoke
28.Dust
29.Washer 30.Lock nut 33.Bolt 34.Washer
cover

6.2 REMOVAL AND INSTALLATION

Remove Axle Shaft and Differential Carrier
from the truck.
1).Block rear wheel with chocks. Shaft for removal.
2).Jack up front of truck, and place wood 7).Support differential carrier with the jack.
blocks under each side of frame. 8).Separate universal joint from differential
WARNING: carrier.
To insure safety, also place wood blocks 9).Remove brake tube from back plate.
under counterweight.
10).Remove bolts securing axle mounting
bracket.
3).Make sure frame is secured on wood
11).Carefully removes front axle assembly and
blocks.
differential carrier as a unit.
4). Remove mast assembly and related parts.
(Fig.4-12)
5).Drain oil from differential carrier.
12).Remove bolts securing gear carrier, and
6).Remove drive axle shaft. Refer to Axle

9
detach differential carrier. (Fig.4-13)
To install, reverse order of removal

Fig.4-12 Fig.4-14
3). Loosen the side bearing cap mounting bolt
slightly and remove the adjusting nut.

Fig.4-13
DISASSEMBLY
Before disassembly, thoroughly check ring
gear and drive pinion for tooth contact and
backlash, drive pinion for pre-load, and ring
gear and differential gear for smooth rotation; Fig.4-15
and correctly diagnose the cause of 4).Remove the side bearing cap mounting bolt
malfunction. and remove the left and right bearing caps.
DIFFERENTIAL CASE 5). Remove the differential case assembly
1). Place matching marks on the left and right using a hoist, etc. Be careful that the outer
side bearing caps and carrier. race of the bearing doesn’t fall out.
2). Loosen the bolts and remove the lock plate
locking the adjusting nut from the left and right
side bearing caps.

Fig.4-16
6). Loosen the bolts mounting the ring gear to
the differential case and remove the ring gear.
The bolts are coated with loctite262.

10
 washer from the drive pinion, using a bearing
puller.

Fig.4-17
7).Loosen the differential case bolts and
separates the case. The bolts are coated with Fig.4-20
loctite262. 2). Loosen the bearing sleeve mounting bolts
before remove the hand brake.
3). Remove the lock nuts, plate washers,
flange yoke, oil seal, dust cover, and
companion flange.
4). Remove the bearing sleeve by pushing the
drive pinion with a press.

Fig.4-18
8).Remove the pinion gear, thrust washer,
pinion shaft, side gear, and side thrust washer.

Fig.4-21
5). Remove the bearing spacer and shim from
the drive pinion. Remove the taper roller
bearing and oil seal from the bearing sleeve.

Fig.4-19
9). Remove the bearing from the differential
case (right and left sides), using a bearing
puller.
REM0VA DRIVEN PINION
1).Remove the polite bearing and plate Fig.4-22

11
6). Remove the taper roller bearing outer race ring to the end of the pinion.
from the bearing sleeve. 3).Press-fit the taper roller bearing to the drive
pinion with a press.

Fig.4-23 Fig.4-25
ASSEMBLY 4).Adjust pre-load of drive pinion assembly.
Notes on reassembling: ①Insert an adjusting shim of any thickness
·Be sure to apply clean gear oil to each and spacer onto the drive pinion.
bearing when reassembling.
·Use care not to confuse R.H. and L.H. side
parts when assembling side bearings,
adjusting nuts and side bearings.
·Use care not to misassemble spacers and
washers.
·Be sure to use ring gear and drive pinion as a
matched set.
Observe the above listed cautionary
instructions. Assemble parts in the reverse
order of disassembly procedure after marking Fig.4-26
necessary inspection and adjustment on each NOTICE:
part. In order to avoid application of excessive pre-
DRIVE PINION ASSEMBLY load to bearing, first select a thick adjusting
1). Press-fit outer and inner bearing races to shim, and gradually reduce its thickness until
the sleeve with a press. specified pre-load is obtained.
②Insert drive pinion into sleeve.
③Install dust cover, oil seal, bearing sleeve
adjusting shim, companion flange and flange
yoke.
④Select adjusting shim so that drive pinion
starting torque is 2.0 to 3.9N•m when drive
pinion lock nut is tightened to specified torque
343-441N•m.
⑤After adjusting pre-load, remove
companion flange.
Fig.4-24 5).After packing the oil seal with grease, drive
2).Press fit the pilot bearing and fit the snap onto the sleeve using an insertion tool.

12
6).Install the companion flange.

DIFFERENTIAL CASE
1).Press-fit side bearing inner race to
differential case (L.H.).
2).Install side gear, pinion mate gear and
pinion mate shaft together with their thrust
washers on one side of differential case.
3).Measure backlash between side gear and
pinion mate gear. Use dial gauge as shown.

NOTICE: Fig.4-28
Do not allow pinion mate shaft to move during
measurement. DIFFERENTIAL CARRIER
1).Install drive pinion assembly to the
Backlash: 0.15-0.4mm. If backlash is not differential carrier through an arbitrary
within the specified value, replace pinion gear thickness adjusting shim, and then tighter the
and side gear. sleeve mounting bolts to the specified torque
45 N•m.
4). Install side gear and thrust washer.

Fig.4-27
Fig.4-29
5).Press-fit side bearing inner race into
·When installing the drive pinion assembly to
differential case (R.H.).
the carrier, confirm that the pilot bearing enters
6).Align to matching mark on differential case.
the carrier smoothly. If the pilot bearing is
7).Coat differential case mounting bolts with
forced into the carrier, the side plate of the
loctite and then tightens to specified torque.
pilot bearing may be separated.
100 N·m
·Install the unit type adjusting shim at the
8).Install ring gear to differential case coat
differential carrier side and sandwich thin
drive gear mounting bolts with loctite and then
shims between thick shims.
tightens to the specified torque. 120 N·m.
2).Install the bearing outer race to the
differential case assembly and place onto the
carrier.

13
 6). After setting the backlash in 5 above,
tighten the left and right adjusting nuts equally
and adjust so that the bearing pre-load is 29 to
49 N by starting force of the ring gear
mounting bolt.
7). Securely tighten the bearing cap mounting
bolt 170Nm.
8). Install the lock plate and fasten with the
adjusting nut 10-15 Nm.

Fig.4-30
3).Match the matching marks made at the time
of disassembly and temporarily tighten the
bearing cap and then match with the pitch of
the adjusting nut mounting screw.
4).Install the adjusting nut and tighten up to
the end of the bearing.
5).Measure the drive pinion and ring gear
backlash with a dial gauge, and adjust with
the adjusting nut so that the dial gauge
reads 0.2 to 0.35mm.

Fig.4-31

INSPERCTION
Thoroughly clean and check each disassembled part. Repair or replace any damaged or
unserviceable part.
Part name Condition and corrective action
Ring gear and drive ·If tooth contact is incorrect, check the cause, and adjust to contact
pinion properly when reassembling.
·If damage to teeth is very slight, repair by using oil stone.
·If worn excessively, or if readjustment is impossible replace the gears
as a set.
·If cracks, damage, or seizure is found on tooth face , replace the gea

14
 rs as a set.
Side gears and pinion ·If damage to tooth surface is very slight, repair by using oil stone.
gears ·If cracks or damage is found on tooth face, replace with new one.
·If wear or seizure is found on thrust washer contacting surface,
replace with new one.
Bearings ·Replace if seizure, flaking, wear, rust, or binding or noise in rotation
is found.
Thrust washers ·Replace if seizure, damage, or uneven wear is noted.
Oil seals ·Replace if fatigue, damage, or uneven wear is found.
·Do not reuse any oil seal that has been removed once.
Gear carrier ·If wear or damage is noted on the bearing fitting surface replace with
new one.
Differential case ·Replace the case if wear or crack is found on sliding portion.

ADJUSTMENT
Gear teeth mesh and adjustment

Move ring gear to pinion, move

pinion external if backlash small.

Leave ring gear from pinion, move

pinion external if backlash is big.

Move pinion to ring gear, move

ring gear external if backlash is
small.

Leave pinion from ring gear, move

ring gear internal if backlash is
small.

Correct tooth contact.

15
5. Steering axle
1. General specification Axle center
Fore-aft
suspension type Center support, wing type 0～0.7
clearance（mm）
5~7T 75° Fore-aft adjusting shim
Inner
8~10
Max. Steering wheel 77°
T
angle
Outer
53° thickness （mm） Part number
wheel
Tire pressure 0.86MPa 0.6，1.0，2.0 50W-410011

Kingpin wheel bearing

Less than 0.2
Axial play（mm） Tighten bearing nut until
Adjusting shim rotating resistance is felt,
Pre-tightness from this position; back off
bearing nut 1/8-1/6 turn.
Thickness（mm） Part number

5~7T 50W-410008
0.8，1.0，1.2，1.4 Axle play(mm) Less than 0.08
8~10T 80DH-410004

2. Trouble diagnoses and correction

condition Probable cause Corrective action
·loose wheel nut tighten
Unstable ·wheel bearing out of adjusting adjust
driving ·improperly adjusted mount shims adjust
·faulty steering system refer to steering section
·insufficient lubrication Apply grease
Noises ·loose bolts and nuts tighten
·improperly adjusted mount shims adjust

16
3. Steering Axle Structure

screw moment N·m

8-10t
A 343～392

B 441～588

C 196～245
D 490~588

E 121～162

1. Tire 2. Rim 3. Tire bolt 4. Steering wheel hub 5. Outer wheel bearing 6. Spindle
nut 7. Steering spindle 8. Baffle 9. Kingpin 10. Axle center 11.Thrust bearing 12.
Tie-rod 13. Steering cylinder 14. Fore-aft adjusting shim 15. Needle bearing 16. Grease
seal 17. Inner wheel bearing 18.shim 19. Bolts 20. Mounting cap 21. Mounting bushing
22. Set-screw 23. Hub cap 24. Grease nipple 25. Gearing washer

Fig 5-1 Steering axle

17
Removal

• Steering wheel hub

1) Jack up and support truck body with safety stands.
2) Remove tire.
3) Remove hub cap.
4) Remove spindle nuts and bearing washer.
5) Pull off hub assembly.
：a. Be careful not to drop bearing cone.
Caution：
6) Remove inner bearing cone.
：b. Be careful not to damage grease seal.
Caution：
Fig.5-2

• Kingpin and steering spindle

1) Remove ball stud nut and disconnect tie-rod from steering spindle.
2) Loosen lock nut and remove set-screw（see fig 5-2）.
3) Remove grease nipple.
4) Attach a pad to upper end of kingpin, and drive out kingpin.
Caution: hold kingpin to prevent it from dropping（see fig 5-3）。
5) Take off spindle, including thrust bearings and shim as an assembly.

Inspection
1）．Replace spindle if cracked.
2）．Replace thrust bearing if its rollers or roller surfaces
are rusted or nicked.
3）．Replace needle bearings if damaged.
4）．Replace bearings and dust-proof cover if damaged.

installation：
To install, reverse the order of removal. Carefully observe the following. Fig. 5-3
1）Always insert kingpin from lower side.
2）Install thrust bearing with its cover facing up, and adjust axial play less than 0.2mm with shims.
：Always place thrust bearing on upper side of spindle, and shims on lower side.
caution：
3）Apply grease inside the dust-proof cover and between two rings of thrust bear.
5）Do not apply grease to spindle mating with bearing.
6）Apply grease on needles and balls of bearings.
7）Pack all grease nipples with a sufficient amount of grease.
• Wheel bearing installation and adjustment
1) Apply grease or anti-rust oil on contact surface of bearings and spindle nut.
2）Slowing rotate hub. Tighten bearing nut until rotating resistance is felt. From that position,
back off bearing nut 1/4turn.
3）Rotate hub 2~3 turns, make the rollers staying in the right position.
4）Repeat the second step, and install bearing washer and tighten the other bearing nut.
5）Rotate hub 2~3 turns, make sure its axle play is less than 0.08mm, rotation starting torque at

18
hub bolt less than 25.5N. Otherwise, return to the second step.
Axle center
Removal
1. Jack up and support truck body with safety stands.
2. Remove tire.
3. Disconnect ball joint at tie-rod.
4. Support axle center with a jack.
5. Disconnect piping connectors and remove mounting caps.
6. Remove axle center.
caution：Be careful not to slide jack out of place.
Installation
To install, reverse the order of removal. Carefully observe the following:
Add shims on both sides until fore-aft play between steering axle and frame is less than 0.7mm.

19
6. Steering system
1. Trouble diagnoses and correction

condition Probable cause Corrective action

Pump damaged or faulty replace
Steering wheel Flow priority valve blocked or damaged Clean or replace
failure Pipes or connections damaged or passage
Clean or replace
blocked
Low oil pressure in the flow priority valve adjust
Air in system Bleed air
Hard steering Steering gear fails to reset, or orientation shim
Replace elastic shim
is broken or of failure
Power cylinder piston seal damaged replace
Truck travels like
Great steering discharge adjust
snake or swing

Insufficient oil in tank replenish

noises
Blocked in the passage or filter Clean or replace
Seal on the guide set, piping or connector is
leakage replace
damaged

2. General
The steering system is mainly composed of cycloid fully hydraulic redirector and the power
cylinder.
2.1 Cycloid fully hydraulic redirector（see fig 6-1）
It consists of cycloid steering gear, steering column and steering wheel. The assembly
position can be adjusted 8°aft-forth to satisfy drivers’ ne eds.
Turn the steering with 1 KG power when the power is off, and it can return about
10°automatically after loosening .

20
 Fig.6-1 Steering device

2.2 Fully hydraulic steering (shown as Fig 7-2)

The hydraulic steering gear with cycloid rotor valve is a fully hydraulic steering device
insensitive to road condition, shown as Fig 7-2. The rotor (9) and stator (10) are a pair of
cycloid needle gears (internally engaged), which act as a dispensing and servo valve in the
case of power steering. It is series-mounted between the priority dividing valve and the
steering cylinder. The hydraulic oil passing in and out of the steering cylinder must flow past
the dispensing and servo valve. Hydraulic oil from the priority-dividing valve is transferred to
the steering cylinder in proportion to the angle the steering wheel is turning. A pair of rotary
valves (the valve spool 4and the valve guide 11) is connected to the coupling block (8),
exporting hydraulic oil in step with the rotating rotor.
When the steering wheel is not turning, the valve spool (4) and the valve guide (11) are in
neutral position under the action of the spring shim (5), hydraulic oil to the steering cylinder is
shut off. By the time, hydraulic oil returns to oil tank directly.
When the engine stops running, the oil pump does not supply oil, the steering action will
be realized manually，that is, to turn the steering wheel ,along with valve spool (4), valve guide
(11) , and coupling block (2) to drive the rotor(9) to feed oil into steering cylinder. On this

21
occasion, rotor (9) and stator (10) act as a hand pump.

1. Baffle 2. Coupling block 3. Valve body 4. Valve spool 5. Spring shim

6. O-ring 7. Y ring 8. Coupling block 9. Rotor 10. Stator 11. Valve guide
Fig 6-2 hydraulic steering gear with cycloid rotor valve

2.3 Steering oil cylinder

Steering cylinder is of double-action piston type, each end of the piston rod is connected
to tie-rod and spindle in turn, shown as Fig 6-3. Hydraulic oil from fully hydraulic steering gear
makes the piston rod move left and right so as to steer truck.

1. Piston 2. Wiper ring 3. Guide set 4. O ring 5.Seal 6. Bushing

7. Combination seal 8. O ring 9. O -ring 10.Tube 11.Bush 12.Secure bolt

Fig 6-3 steering system

22
7. Break system
1. General specification
5-7T
Drive axle brake（service brake）CPCD70HS

type Hydraulic, brake clamp with auto-adjuster

Driving Clearance between lining and

axle 0.25-0.5
drum（mm）
brake
Wear limit of brake lining（to rivet
more than 0.5
head）（mm）
Type
Brake
Stroke at control lever （mm） 35
master
Oil tank capacity (cm3) 150
pump
Braking oil TCM
Type Hydraulic operation
Piston diameter （mm） 40
Brake Operation pole diameter （mm） 20
master Power multiple 4
cylinder Safety pressure (Mpa) 4.9
Length of output pole out of brake
pump assembly installation 9.9~10
surface Mechanical, operated on transmission output
Type F05W50-70、F05V50-70
Hand shaft
brake Less than 80
Stroke at control lever （mm）
（at pulling force 147N）
Pedal play （mm） 5-7.5
Brake
Pedal height （mm） 142
pedal
Depressed height （mm） More than 60
Inching Pedal height （mm） 142
brake
pedal Pedal play （mm） 18

23
8-10T

type Hydraulic, duo-servo drum with auto-adjuster

Driving Clearance between lining and

axle 0.1-0.2
drum（mm）
brake
Wear limit of brake lining（to rivet
To bottom of slot
head）（mm）
Model OBV-L25E
Type With accumulator, Hydraulically operated
Rated flow flux L/min 25
Brake Nominal Pressure Mpa 16
booster Operate Pressure Mpa 10
Safety relief valve pressure 13
Mpa
Oil type L-HM32 hydraulic oil
Volume kg 1.9
Type HXQ-00
Warning Lamp Voltage V 12-48
Not less than GB/T 14039-93 18/16 class
Accum Oil cleanliness
or NAS 1638 10 class
ulator Oil type L-HM32 hydraulic oil
Volume ml 70
Capacity kg 12.1
Mechanical, operated on transmission output
Model
shaft
Hand Type ZY3507
brake
Less than 80
Stroke at control lever （mm）
（at pulling force 147N）
Pedal play （mm） 5-7.5
Brake
Pedal height （mm） 142
pedal
Depressed height （mm） More than 60
Inching Pedal height （mm） 142
brake
pedal Pedal play （mm） 18

2. Trouble diagnoses and correction

Service brake

5-7T
condition Probable cause Corrective action
Oil leakage in brake lines Correct and replenish
Insufficient Air in brake lines Bleed air
braking force Water or oil on linings Clean or replace
Uneven wear or contract of brake linings Grind or replace
Improper functioning of master cylinder or whe Correct or replace

24
 el cylinder
clogged oil lines clean
improper functioning of brake booster, correct or replace
hydraulic oil bump or flow priority valve
Uneven tire pressure adjust
Brakes out of adjustment adjust
Water or oil on linings clean or replace
Foreign particles in brake drum clean
Deteriorated lining surfaces grind or replace
Improper contact of lining grind or correct
Unequal braking Worn lining replace
（truck veers to one Worn or warped, rusted or damaged brake correct or replace
drums correct or replace
side）
Improper operation of wheel cylinder adjust
Improper sliding of shoes tighten or replace
Loose back plate bolts replace
Warped back plate adjust or replace
Improperly adjusted wheel bearing clean
Clogged oil lines
No free play of brake pedal adjust
Improper shoe sliding adjust
Improper operation of wheel cylinder adjust or replace
Faulty piston cup replace
Brake dragging Weak or broken return spring replace
Clogged master cylinder return port clean
Clogged oil lines clean
Wheel bearing out of adjustment adjust or replace
Improper functioning of brake booster correct or replace
Rough or foreign particles on frictional Repair or replace
surfaces Repair or replace
Warped back plates or loose its bolts Repair or replace
Brake noise
Warped or improper installed brake shoes replace
Worn linings repair
Loose wheel bearing

8-10T
condition Probable cause Corrective action
Oil leakage in brake lines Correct and replenish
Air in brake lines Bleed air
Insufficient Water or oil on linings Clean or replace
braking force Uneven wear or contract of brake linings Grind or replace
Improper functioning of fully hydraulic valve Correct or replace
clogged oil lines clean
leakage in caliper brake cylinder replace the O-ring
Unequal braking Uneven tire pressure adjust
Safety valve out of adjustment adjust
（truck veers to one
Water or oil on caliper brake clean or replace
side） Foreign particles in brake drum clean

25
 Deteriorated lining surfaces grind or replace
Improper contact of lining grind or correct
Worn lining replace
Worn or warped, rusted or damaged brake correct or replace
drums correct or replace
Improper operation of wheel cylinder adjust or replace
Improperly adjusted wheel bearing clean
Clogged oil lines
No free play of brake pedal adjustt
Improper operation of wheel cylinder adjust or replace
Faulty piston cup replace
Brake dragging Weak or broken return spring replace
Clogged master cylinder return port clean
Clogged oil lines clean
Improper functioning of brake booster correct or replace
Rough or foreign particles on frictional Repair or replace
surfaces Repair or replace
Warped back plates or loose its bolts Repair or replace
Brake noise
Warped or improper installed brake shoes replace
Worn linings repair
Loose wheel bearing

Hand brake
condition Probable cause Corrective action
Worn lining replace
Large control stem stroke adjust
Insufficient worn or damaged control ratchet replace
braking force open or elongated wire replace
water or oil on lining clean or replace
uneven wear or contact of brake linings grind or replace
3. Brake pedal and inching brake pedal
Brake pedal adjustment ：
① Adjust pedal height up to 170mm using pedal stopper, and tighten lock nut securely.
② Adjust push rod length of brake booster until pedal play is with 4.5-6mm, and tighten lock
nut securely.
③ Check “depressed” height more than 60mm, if it is not as specified, check brake system.
④ Depress and release pedal several times to see if it travels smoothly.
⑤ Depress brake pedal 7-18mm to ensure that stop lamp switch comes on; release pedal
from that position to ensure that switch goes off. Repeat this check 2-3 times.
4. Service brake (5~7T)
The brake system consists of foot brake system and parking brake system. And it is the
front two-wheel braking type consisting of a master cylinder, brake booster and brake pedal.
Brake and hand brake device of the mechanical engine are similar with hydrodynamic truck,
the other contents of brake system refer to clutch.
Remove

26
 1) Take apart brake master cylinder and brake booster.
2) Take apart snap ring, piston, stop washer, spring bracket and spring.
Caution:
·Through away the primary cup and replace a new one.
·Keep the work plane clean

Fig. 7-1 Brake master cylinder

Inspection
Check the master cylinder’s parts in brake fluid for damage and deformation.
Caution: You can’t use other fluid or oil but brake fluid.
No Condition Corrective action

1 Scratched or worn sliding surfaces of cylinder and replace

piston
2 Cylinder-to-piston clearance exceeding 0.15mm replace

3 Weak, worn or damaged primary and/or secondary replace

4 Weak, or deformed return spring replace

5 Deformed or damaged reservoir tank replace

Reassembly
To install, reverse the order of removal.
Caution:
1) Clean the parts in brake fluid.
2) Daub brake fluid on the frictional surface of piston and cylinder.
3) It is forbidden to cut and damage the surface of the piston.
4) The position of the piston cup and spring bracket must be correct (refer to fig.7-2)

27
 Fig. 7-2 Cup、spring bracket position
5. Service brake (5~7T)

Fig. 7-3 Brake boosters

Remove
1. Remove the joint and input rod.
2. Remove the nut on the brake pedal, which mount brake booster.
3. Remove the pipe between brake master cylinder and brake booster.
4. Remove the booster and master cylinder.
5. Detach the booster and master cylinder.
6. To install, reverse the order of removal.
Caution:
When detach pipe on the master cylinder and booster, keep them clean and prevent dirt from
entering the pip
Detach the booster
1. Remove the anti-dust cover and input rod.

28
2. Remove the output rod. Refer to fig. 7-4.
3. Detach the O-ring, piston spring and washer.
4. Remove the piston guide. Refer to fig.7-5.
5. Remove the piston and working rod. Refer to fig. 7-6.

Fig 7-4

Fig 7-5 Fig 7-6

6. Remove the snap ring and pull out the slide bar, spring and stopper. Refer to fig.7-7
7. Remove the relief valve assemble and spring, be careful the relief valve assy. can’t be
detached. Refer to fig.7-8.

Fig 7-7 Fig 7-8

Inspection
1. Inspect the wearing of the seal, if broken, replace it.
2. Replace the broken seal o-ring.
3. Inspect cylinder body, piston, slide rod, working rod, output rod, guide rod, relief valve assy.
and piston guide to see there is any wearing or cut on the surface of them, if necessary
replace it.

29
 Reassemble
To install, reverse the order of removal.
Caution:
1. Use light oil to clean the parts, do not use gasoline.
2. Do not let sundries in inner surface of these parts.
3. Paint hydraulic oil on the kinetic parts before assemble.
4. Be notice the assemble direction of the relief valve assy. and slide rod.
5. Do not assemble wrong direction of the stopper.
6. Make sure the snap ring is on the right position.
7. When inserting piston and operating rod into body, make sure piston groove direction
shown as fig. 7-9. As viewed form mounting location of the master cylinder, and tighten piston
guide. And the piston guide tighten torque is 26-36 Nm.
8. Install rod guide with air vent groove facing downward.
9. Install anti-dust cover with air vent hole facing downward.
10. When body, piston, output rod or rod guide is replaced, use shims to adjust amount of
output rod’s protrusion to 9.9-10mm. Refer to fig. 7-10.

Fig 7-9 Fig 7-10

Brake booster trouble diagnoses and correction
Condition Probable cause Correction
·oil leakage at or around oil lines ·repair or add oil
·oil pumps or priority valve
·repair or add oil
Brake does not work damage
efficiently ·foreign matter in spool valve ·clean or replace
·foreign matter in relief valve ·clean or replace
·oil leakage due to worn seal ·replace
Brake works too
Spool valve failure ·replace
sharply
Brake drags (oil Foreign matter in spool valve ·clean or replace
pressure will not be zer

30
 o even when pedal is Foreign matter attached to output
·clean or replace
free) rod
If the Clearance between brake lining and rivet head less than 0.5mm , replace the brake
lining.
6. Brake and wheel cylinder（5-7T）
6.1 The Front wheel brake
The wheel brake is the internal expansion hydraulic type consisting of brake shoes, spring,
wheel cylinder, and adjuster and backing plates. Comply with the symbol on the brake when
connect it to the driving axle (left , right) and keep the bleed screw up toward .Clean the oil
lines before connecting .
There should be proper clearance between brake lining and brake drum when brake
shoes at original position and clearance of this brake should be adjusted to 0.25 ～ 0.5mm
,adjust in time to keep the clearance. If the abrasion is serious (the distance between brake
lining and rivet head less than 0.5mm),replace both of brake lining.

Fig.7-11 Forklift right brake

1.return spring 2.lining assemble 3.back plate 4.brake cylinder 5.pin 6.up pull rod
7.return spring 8.spring 9.ratchet 10.plug 11.adjuster assembly
12.spring
6.2 brake cylinder
Brake cylinder is secured to back plate by bolts. There are double pistons in the cylinder,
and spring keeps two cups respectively on the pistons. Seal capacity of cups is important to
brake performance. Check piston cup and cylinder and repair or replace them if damaged
when there is found oil leakage in the brake drum. Be careful not to leak oil in the drum during
reparation. Do not apply mineral oil but brake fluid when cup installation.

31
 Fig 7-19 brake cylinder
1.protrusion rod 2.cylinder 3.vent screw 4.cover 5.connector
6.spring 7.spring seat 8.cylinder cup 9.piston 10.dust cove
7. Service brake booster valve and accumulator（8-10T）
The service brake booster valve is consist of valve seat, closed valve rod, service piston,
pushing rod piston, cone way valve and spring such etc. Please see fig.7-13.

Fig 7-13 Master cylinder

1. Drain Plug 2.Valve Seat 3.Closed Valve rod 4.Guide 5.Service Piston 6.Sping
7.Slide Valve 8. Spring 9.Rubber cap 10.Pushing rod Piston 11.Position Nut12.
Cone way valve 13. Pushing Rod
It makes the truck brake through change the oil direction. In general, oil comes from
control valve’s input plug (P plug) to BR plug, and this makes the brake clamp’s pushing rod
move to make service brake. When parking or the truck does not move, the accumulator afford
oil pressure to make the oil comes from PA plug to BR plug, and this make the brake clamp
action to clamp the brake disk. N plug is the oil pug which oil comes to steering gears. The
steering hydraulic system can work solely, and can work associated with brake oil system,
they does not interference.
The hydraulic system principle diagram, please see fig.7-14.

32
 Fig 7-14
Caution:
1). After bleed off the air in the oil pipe can be mounted on the brake system.
2). Keep the brake fluid clean.
3). Make sure the clearance between pushing rod and the pushing piston 0.5-1mm.
8. Brake Clamp(8-10T)
8.1 Structure and Principle of Brake Clamp
The Brake Clamp mainly consists of Clamp body, Brake disk, Piston and Clutch blocks
and etc. Please refer to fig. 7-7. The brake disk is mounted on the wheel hub and the clamp
body is mounted on the Driving axle. The working principle is when you press the brake pedal,
the hydraulic brake booster make the high pressure oil comes into the cylinder in the brake
clamp, and the piston moves, it makes the brake clamp seized the brake disk. Brake torque
comes out by this way.
When you do not press the pedal, the distance between clutch blocks and the brake disk
is about 0.1-0.2mm, so the brake booster’s stroke is very small. The rubber ring 6 and the
piston has a closing running fit, so the brake piston has no relative slide to rubber ring, and it
makes the rubber ring deformed. When the oil pressure decreased, the seal rubber ring
recovers its origin aspect, the brake piston and clutch blocks restored. If the clutch blocks are
wearing too much, the clearance between clutch blocks and brake disks are exceed the
wearing limit. It may cause the brake stoke is too long; there is a relative slide between piston
and seal rubber ring, the friction force decrease. When brake action is over, the seal rubber
ring restore to origin position because of spring force. (Equal to origin value setting.) So the
clutch block has the function of self-compensatory

33
 Fig.7-15
1. Clamp Body 2.Screw 3.Nut 4.Pin 5.Dust cover 6.O ring 7.Piston 8.Clutch block
9. Bleed plug 10.Combined seal ring 11.Connector bolt 12.Connector13.Lower cylinder cover
14. Upper cylinder cover 15.Bolt 16.Washer 17.O ring

8.2. Replace the clutch blocks

You should make sure the surface of clutch blocks is clean. If they were polluted by dirty,
please use gauze cleans it by acetone. If the clutch blocks are wearing to the bottom of the slot,
you should replace a new one. Replace method: (1). Remove the brake clamp body from the
driving axle; (2). Loosen the screw 2 and remove the pin 4. (3). Remove the clutch block assy.
(4). Replace a new one. (5) Observe the following, and reassemble parts in the reverse order
of disassembly.
8.3 Air bleed from the oil pipe
Keep the hydraulic pipe, hydraulic oil clean. You’d better bleed the air in pipe on schedule.
The method is: (1) Tighten the air bleed screw plug. (2) Depress the brake pedal for several
times when you feel the resistance force is big enough. (3) Press the pedal and at this time
loosen the air bleed screw plug 9. (4). Tighten the screw and loosen the brake pedal. (5)
Repeat the steps above for several times till there is no air bleeding.
8.4 Replace the seal rubber ring
If the hydraulic oil is leaking from the piston body, maybe the seal rubber ring is damaged.
Please replace it as followed: (1) Remove the brake clamp from the driving axle. (2). Loosen
the screw 2, remove the pin4 and clutch blocks. (3). Remove the upper cylinder cover 14 and
lower cylinder cover 13. (4). Push the piston to center and take it out. (5). For left side piston,
you should make a M10*15 screw rod, the length is about 200-300mm. Use this rod push the
left side piston to center and take it out. (6). Clean the piston by light oil, and then use hydraulic
oil clean them. (7).Take out the seal rubber ring. (8). Replace a new one.

34
 Observe the following, and reassemble parts in the reverse order of disassembly.
9. Parking brake
The parking brake used in 5-10T forklift truck model is ZY3507 which install near the
output shaft of torque converter. The brake drum connect to the flange which connect to the
parking brake shaft, and the parking brake gear engage with the gear on the output shaft of
torque converter. The brake drum turn with the parking brake gear when the truck is running.
Pull the handle to make the lining and drum clapping tightly, according the parking rake gear to
stop the gear on the output shaft, and then make the truck stop.
Check and adjust in time when you find the parking brake not work well after service and
during maintenance. If free stroke is so large that the truck cannot park on the specified slope,
Check and adjust hand brake in time
The replacement of lining and brake drum: 1. loose the nut, remove the brake drum;
2.take out the pin at the head of the parking brake shaft, remove the flange; 3.check the lining,
if it worn, replace both of them.4.****5.***

1. Output shaft 2.Gear 3.Packing brake shaft 4.Parking brake gear 5. Washer
6. Mechanical parking brake 7.Washer 8.Bolt 9.Clip ring for axle10.Seal ring
11.Flange 12.Washer 13. Bolt 14.Bracket of parking brake 15.Washer
16.Bolt 17. Pin 18.Paper shim 19. Washer 20.Bolt 21.Waher 22.Bolt

Fig. 7-16 Parking Brake

35
8. Hydraulic system
1．Data

Control valve
Truck type 5-7T 8-10T
CDB-F20H-02c(Two-way)
CDB-F20H-02d(Two-way)
Model CDB-F20H-03（Three-way）
CDB-F20H-03d（Three-way）
CDB-F20H-04c(Four-way）
Type Double-slide valve, with overflow divided valve and tilt-lock valve
Main relief valve pressure 18.5 MPa （ can lift 110% of rated load, cannot lift 125% rated
MPa load）
Displacement L/min 160
Pressure
Flow 9.8
MPa
valve
Flux L/min 22±1

2. Trouble diagnoses and corrections

Pump
Trouble Probable cause Correction action
Low oil level in tank. Add oil to specified level.
No oil form oil
pump Clogged suction pipe or
Clean oil line and tank. If oil is dirty, change.
strainer.

Worn bearing, damaged

Replace faulty parts.
backup ring and O-ring.

Readjust to specified pressure using pressure

Low Maladjusted relief valve.
gauge.
discharge
pressure on
Retighten suction side pipe.
oil pump.
Add oil in oil tank.
Air in oil pump. Check pump oil seal.
Do not operate pump until bubbles in tank
disappear.
Cavitation due to crushed
Adjust or replace crushed hose and clean
suction hose or clogged
strainer.
strainer
Air being sucked from loose
Retighten each joint.
suction side joint.
Noisy oil ·replace with new oil having proper viscosity
pump Cavitation due to too high oil for temperature at which pump is to be
viscosity. operate.
·to operate when oil temperature is normal.

Bubbles in hydraulic oil. Determine cause of bubbles and remedy.

Oil leaking Faulty oil seal on pump, faulty

from oil O-ring or worn sliding Replace faulty parts.
pump surfaces on pump.

36
Control valve

Trouble Probable cause Corrective action

Loose of pressure-adjust screw. Readjusted and retighten.
Distorted or damaged pressure-adjust
Pressure of relief Replace.
spring.
valve is not
steady or too low. Worn or blocked relief valve core. Replace or clean.

Pump abated. Examine and repair pump.

Fork tilt forward Replace valve core and tilt lock

Worn or damaged tilt lock valve.
when control valve as an assemble.
lever is used Broken tilt lock spring. Replace spring.
while engine is off. Damaged tilt valve plunger O-ring. Replace O-ring.
Mast is unstable
when tilting Malfunctioning tilt relief valve. Replace tilt relief valve assembly.
forward.
Valve body and spool valve is worn
Replace spool valve with
and clearance between them is too
Lowering specified clearance.
great.
distance of mast
is big when spool Spool valve is not in center. Keep being in the center.
valve is in the
center. Cylinder seal abated. Examine and repair cylinder.

Taper valve is worn or blocked by dirt. Replace or clean taper valve.

Damaged or distorted reposition-
Replace spring.
spring.
Spool valve is not Dirt exist between valve body and
Clean.
return neutral spool valve.
position. Blocked control device. Adjusted.

Not coaxial parts at reposition Reinstall.，be coaxial

Damaged O-ring. Replace.

Faulty seal of joint. Check and retighten.

Leakage Clean seal plate and retighten

Loose seal plate.
blots.

Loosed lock-nut of relief valve and

Tighten.
connect-nut between plate and plate.

3. Pump
The truck’s working pump for 5-7t is Model: CBHZA-F30-AFФ、CBHZA-F30-AFФL. The
gear pump is working pump. For 8-10, the working pump is model: SGP1-30A1H1-L,SGP1-
30A1H1-R. The two gear pump is split flow pump, the rotate direction, one is clockwise, and
the other is anti-clockwise. The two pumps’ structures are the same.
4. Control valve
The control valve CDB-F20 is section model, which is made up of input, output and slide
valve. Flow valve is installed in the entrance with main relief valve. See fig.8-2 and fig.8-3
Main relief valve is used to control the pressure of oil circuit. Its pressure has also been
adjusted in the factory, so please don’t adjust it at will.

37
 Steering relief valve is used to adjust the pressure of driving steering oil circuit.
Slide valve is used to control tilt hydro cylinder and lift hydro cylinder, and it can change the
flux to control hydro cylinder by maneuvering the tilt and lift lever.
Tilt slide valve is equipped with front-tilt self-lock valve.
Oil from hydro cylinder returns to oil box from output, and every piece of valve is sealed by
maneuver “O”ring. At the same time, there is a clappet valve.

Fig.8-2 5-7 tons Control Valve

Fig.8-3 8-10 tons Control Valve

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

38
 1. Valve body 2. Valve core 3. Spring4. Orientation nut
Fig. 8-4 Governed speed valve
6. Lifting cylinder
Lifting cylinder is single-function piston structure which consists of cover, piston lever,
body, and piston and so on. Caution in using:1）Keep the piston from being attainted; Assure of
the leakproofness of seal ring; 2）If you find a cover of leakage oil on the surface of piston,
check the piston surface, and replace the o ring and piston. Refer to fig.8-5.

1. cylinder 2. piston 3. YX seal ring 4. block slice 5. bearing loop

6.steel 7.piston lever 8. bearing seat 9.steel-back 10.O ring
retainer ring bearing
11.tie-in 12.Yx seal ring 13.cover 14.dustproof 15. plug screw
ring
16.bolt 17.plug 18.adjust washer 19.bush（lift height>4m）

Fig.8-5 Lifting cylinder

7. Tilting cylinder
Tilting cylinder is double-function piston structure. If the front and the rear obliquity don’t
cater to the request or the movement of both cylinder piston don’t operate in same step, adjust
the location of nut on the adjust piston lever, then screw the nut tightly. Caution is same with
lifting cylinder.

39
1.Joint bearing 2．Oil cup 3．Lever head 4．nut 5．Piston lever 6．Dustproof ring
7．O ring 8．Adjust washer 9．cover 10．bolt 11．Nylon washer 12．O-ring
13．YXseal ring 14．Guide set 15 ． Composite 16．bush（lift height>4m） 17．body
bush
18．Piston 19．
O ring 20．Bearing loop 21．
YXseal ring 22．Slot nut 23．Hatch pin
24. Bronze bush
Fig.8-6 Tilting cylinder

8. Hydraulic system principle diagram

Fig.8-7 5-7 tons forklift truck’s hydraulic system principle diagram

40
Fig. 8-8 8-10 tons forklift truck’s hydraulic system principle diagram

Fig.8-8 8-10 tons forklift truck’s hydraulic system principle diagram

41
 ．Electrical system
9．
CAUTION：
· To guard against a short circuit, take off jewelry ornaments and disconnect the ignition switch
and battery ground cable, before starting to check any part of electrical system.

ACCOUNT
· The different colorful wire is chosen for the different part of the electrical system. To differ
from different colorful wire, color is denoted by one or two letter. Identify carefully that the cable
of accumulator has been disconnected before repairing the electrical system.
Cable color：
B: black Br: brown G: green Bl: blue
O: orange R: red W: white Y: yellow
S: gray P: purple
Main wiring harness use homochromatic wire. Other wire use double color.
B/W: black and white
G/Y: green and yellow

INSPECT
Inspect all electrical circuit according wiring diagram. You should make short circuit or open
circuit test with the test lamp or multimeter. Before inspection ,ensure that：
1． Each electrical component or cable is securely fastened its terminal.
2． Each terminal is firmly in place and free from rust and dirt.
3． No cable covering shows any evidence of cracks, deterioration or other damage.
4． Each terminal keeps a safety distance with adjacent metal parts.
5． Every cable is fastened to its proper connector or terminal.
6． The wiring is kept away from any adjacent parts with sharp edges.
7． The wiring disconnect to each rotating or moving parts.
8． The length of the wire linking the fixed part and unfixed part should be enough to
shake.
9． The wiring keeps a safety distance with the high temperature thing such as the vent-
pipe.

FUSE SYSTEM
FUSE
DISASSEMBLE
1. Turn key switch “OFF”.
2. Press the nut on the cover of the fuse box, and open the
cover.
3. Disconnect the fuse from the box.

Account
If the fuse is blown，replace with ting.new one, refer to the right figure.
① If a fuse is blown ， please be sure to eliminate cause of

42
 problem, then replace it.
② Never use fuse higher than specified ra

Principle diagram

Fuse location
FUSE IDENTIFICATION
LOCATION FUSE RATING APPLICABLE PART
1 FLASHER 15A Front big lamp、Side Lamp
2 HORN 10A horn
3 BRAKE 10A Brake signal lamp
4 REVERSE/FLASHER 10A Turn signal lamp 、 reverse signal
SINGAL lamp
5 INSTRUMENT 10A Instrument、indicator light
6 Fuel SWITCH OFF 10A Fuel switch off、warm-up controller
7 STANDBY 10A Using alarm lamp
8 STANDBY 20A Using illuminator
FUSIBLE WIRES
It very easy to observe a fused wire,and very easy to feel it with hand. If you can not sure
whether it is blown, you should test it with multimeter or bulb.
CAUTION:
1. If the fuse is blown, Probable cause is short circuit.No matter what causes, please
inspect it carefully and be sure to eliminate cause of problem.
2. Never wrap the fusible wires with adhesive tape, because of the fusible will heat easily.
Finally don not close the fuse to other wirings and rubber etc.
LIGHTING SYSTEM
BULB SPECIFICATIONS
Item wattage
Front big lamp 24V/35W
Front little lamp
turn signal lamp 24V/21W
Side Lamp 24V/10W
rear combination lamp
Side Lamp brake signal lamp 24V/21W/5W
43
turn signal lamp 24V/21W
reverse lamp 24V/10W
combination instrument
head lamp 24V/2W
alarm lamp 24V/2W

Combination switch:
Disassemble
1. Remove the combination instrument.
2. Wrest the screws, and disconnect the wiring connector
3. To install reverse the order of removal.
After setting Combination switch complete,ensure the distance between Turn Signal Lamp and
the top of Steering Column is 42mm.

INSPECTION
Check the continuity the location in turn signal lamp and the combinational switch of lighting.

Sheathing NO. (“O”---connect, “×”---

LOCATION disconnect)
Sheathing end view
1 2 3 4 5 6
L（turn left） O O × × × ×
N（neutral） O × × × × ×
R（turn right） O × O × × ×
Side Lamp × × × O O ×
Big lamp × × × O × O

Sheathing NO. (“O”---connect, “×”---

disconnect)
LOCATION Sheathing end view
A sheathing B sheathing
1 2 3 1 2 3
F（forward） O × O
N（neutral） × × O
R（backward） × O O
Low speed O × ×
High speed O O ×

44
Head Big Lamp
Removal & Install
1. Remove securing nuts of the big lamp
2. Take apart the wiring connector
3. Remove bolt、lens, then replace faulty bulb with new one.
4. To install, reverse the order of removal.

Head Combination Lamp

Removal & Install
1. Remove fixing bolt of bracker.
2. Disconnect the wiring connector
3. Remove bolt, astigmatism glass, then replace faulty bulb with new one.

Rear Combination Lamp

Removal & Install
1. Remove fixing bolt of bracket.
2. Disconnect the wiring connector.

45
 3. Remove bolt、astigmatism glass, then replace faulty bulb with new one.
4. To install, reverse the order of removal.
Instrument Assembly
1. Remove fixing bolt of instrument cover.
2. Open the instrument cover, see fig follow, disconnects the wiring connector of
instrument and key switch. Never wash the electrical system using water and water vapour
after you connect the instrument to the electrical system.
3. To install, reverse the order of removal.

Oil pressure gauge 、water temp. gauge、 、hour meter and warning lamp
1． Remove the fixing bolt of panel, and take apart panel form cover of panel.
2． Remove the fixing bolt of front cover, and take apart front cover and panel.
3． Remove the panel
4． Remove the fixing bolt of instrument from PC, and remove the instrument.
5． Remove the caution light from the PC, (all of caution light can be removed from the
combinational instrument).
6． To install, reverse the order of removal.

46
Key (start) switch
Remove the combinational instrument
1. Disconnect the wiring connector.
2. Remove the ring nut, washer, spacer, meter panel.
3. To install, reverse the order of removal.
Inspect
Check the continuity between terminals with multimeter.

B ACC C R1 R2 BR
Pre- O
O O
heating
Operatio O
n
Star-up O O O
Star-up O O O O O

Reverse Buzzer
Remove & Install
1. Disconnect the wiring connector, then remove the bolt .
2. To install, reverse the order of removal

Horn
Remove & Install
a) Remove the wiring connector of the horn
b) Remove the bolt and horn.
c) To install, reverse the order of removal.

47
Instrument inspect
name purpose Graduation arrange Normal remark
water 40℃-55℃ yellow Cease and check
Engine cool water
temperature 55℃-110℃ green Green zone when point is
meter temperature 110℃-120℃ red near red zone
0-1/10 red Adding oil when
oil capacity
Engine fuel capacity 1/10-1 green Green zone point is near red
meter
zone
4 integers, 1 decimal
timing Accumulative total engine fraction
operate time
meter
oil 45℃-60℃ yellow Cease and check
temperature Gear-box oil temperature 60℃-120℃ green Green zone when point is
meter 120℃-140℃green near red zone
oil pressure Engine lubricate grease 0～0.2～0.4～ < 0.1 Mpa
≥0.1 MPa
meter pressure 0.8MPa cease and check

WARNING LAMP INSPECT

Light blank
Description Function Lamp light（warning） Remarks
(normal)

When running at
Indicate the The alternator doesn’t The
Charge idle speed, the
alternator voltage up generate electricity or alternator is
warning light turns off
to its rate, whether voltage is lower ， at normal
lamp charge battery or not. without charging. condition because voltage
is high.
Brake It indicates the When light turns
The oil pressure of on, you should
warning accumulator’s oil check the oil
accumulator is low.
lamp pressure pipe.

48
Repair of starter/dynamotor
starter
phenomenon reason settlement
Battery capacity is not
Change battery or charge
enough
Repair or change electrical
Electric circuit break
layout, starter delay and so on
Electromagnetism switch Change and repair
shatter electromagnetism switch
Not rotate
Pinion doesn’t joggle well
with line roll gear Change or repair
Adjust brush location, clean the
Brush doesn’t contract well
surface of brush
Brush abrasion change
Armature circuit break Change armature circuit
Starter rotates but the Pinion doesn’t work well change
engine can’t rotate line roll gear shaft isn’t good repair
Dynamotor
phenomenon reason settlement
Adjuster shatter Change shatter
Charge indicator shine

Magnetic field connection shatter change

Diode shatter change
Can’t charge
Reed lead break or contact
Repair or change
badness
Fuse shatter repair
Surge magnet circuit shatter change
Diode shatter change
Charge current is
Reed lead contact badness Repair or change
small
Electricity load is too high Reduce electricity load
Strap strain badness Adjust
Adjuster shatter
Change current too Change
Current output circuit fastener
big Repair
loose
Battery liquid surface
Battery shatter Change or add liquid
descend
Adjuster shatter Change
others

Dynamotor sound
Bearing/brush don’t contact well Repair or change
abnormal
Strap strain badness Adjust

49
50
10. Lifting system
1. Assemble debugging data
Debugging data Double mast and triple mast
Standard type and
Lifting height Lifting height
Mast type ～4
lifting height of 2～
>4～～5 meter > 5～～6 meter
meter

Mast Forward 6° 6° 3°
tilting
angle
Backward 12° 6° 6°

Fork arm carrier

Adopt combination roller and side roller.
roller

Inspection and adjustment

Assembly
Place Repair clearance（mm）
clearance （mm）
Mast to lift roller 0.3～1.25 0.4～1.4

Mast to bearing board 0.2～1 0.3～1.2

Inner mast to carriage side
0.3～1.25 0.4～1.4
roller
Lift chain deflection 25～30 mm

Tightening torque
Model or Lifting
Place capacity capacity N·M
capacity capacity

5-6t 638-850 (M24×2)

7t 933-1244 (M27×2)
Lift chain lock nut
8t 969～1293(M30×2)

10t 1319～1759(M33×2)
5～10t
Mast support cap blot 245～314（M20×1.5）

Lift cylinder bolt 638-850（M24）

Lift cylinder fixing bolt 5-7t 45-58(M10)

（U type）
8-10t 58～78（M12）

Mast dimension (mm×mm×mm) weight（Kg）

5-6t 2300×1660×770 1670
7t 2300×1600×780 1780
8t 2450×1900×920 2200
10t 2600×1900×940 2720

51
 2. Failure diagnose and corrections
Condition Probable cause Corrective action
Fork arm 1.Tilt cylinder and ring abraded excessively Replace piston ring tilt cylinder.
carrier or
2. The hydraulic control valve spring is
mast tilt by Replace it.
inoperative.
itself.
The fork arms 1. Caused by piston jamming or bent piston
carrier moves rod. Replace the faulty parts.
up and down
sluggishly. 2. Too much dirt is accumulated in the cylinder. Strip it down and clean.
1. Carriage bracket assembly out of Adjust clearance with thrust metal
adjustment. and carriage side roller.
Forks are 2. Insufficient clearance between inner and
Adjust clearance with rollers.
lifted or outer masts or rollers and mast.
lowered 3. Biting foreign materials between moving part. Remove foreign materials.
unsmooth. Apply grease on contact surfaces of
4. Insufficient lubrication.
sliding parts.（butter）
5. Bent carriage bracket assembly. Repair or replace.
Forks are
lifted 1. Lift chains out of adjustable. Adjust lift chains.
unevenly
1. Grease stiffened or dirt accumulated on lift
Lift roller does Clean and lubricate lift rollers.
roller and mast sliding surfaces.
not rotate
2. Improperly adjusted lift roller. Adjust.
1. Insufficient lubrication. Lubricate.
Excessive
2. Improperly adjusted lift roller, side roller and
mast noise Adjust.
back-up metal.
1. Excessive wear occurs between the oil
Replace the worn parts or the oil
pump body and gears, causing too much
pump.
clearance.
2. The lifting jack piston Yx-ring has worn,
Replace Yx-ring.
resulting in excessive inner leaks.
3. Springs of the multiple control valves and its
Replace.
relief valve are inoperative oil leaks.
4. Excessive wear occurs of the hydraulic
control valve, resulting in excessive oil Replace.
Insufficient lift leaks.
power or no 5. Oil leaks occur between the hydraulic Dismantle for regrinding the joint
lift movement. control valve sections. surfaces and reassemble the valve.
Tighten the joint nuts and inspect
6. Leakage occurs in the hydraulic pipe.
the seal for damage.
Change the wrong hydraulic oil or
7. The hydraulic oil temperature is too high. Oil stop operation for reducing the oil
viscosity is too low and the rate is temperature. Find out the reasons
insufficient. for high oil temperature and
eliminate the trouble.
8. The load carried is beyond the designed
Observe the lifting capacity limit.
capacity.
Forks does 1. The ring of Setting-up cylinder and ring
replace ring
not adjust abraded excessively
setting-up (for 2 Fork’s shaft rust.seriously Clean and lubricate
8-10 tons) 3. Fork is turn back by foreign materials Clean
3. General
3.1 Double high visibility mast
Double mast(see Fig 10-1 and 10-2) is composed of outer mast which can’t lift and inner
52
mast which can lift. Lifting jack bottom is fixed on outer mast below cross beam, oriented with
pin. Piston rod extremity is joined with upper cross beam of inner mast; cylinder body is fixed
on outer mast fixation board with U-bolt. Commonly free lift range is 200mm, which is
difference with different tonnage. Two lifting jacks are laid out back of outer mast to realize high
visibility.
8-10t’s forks adjust its distance by changing the cylinder,but the chaning cylinder can only
work when the fork is unloaden,fork loading s forbidden.
Fork arm is hung on fork arm carrier by hook. roller and side roller are installed on the
fork arm carrier. The roller and side roller are also installed on bottom of inner mast.
Pressure oil from hydraulic control valve is entered into lifting jack by unidirectional speed
limiting valve, forced piston and piston rod rising, thereby forced inner mast rising. At the same
time one end of lifting chain on inner mast is fixed on outer mast, the other is joined with fork
arm carrier. Fork arm carrier and fork arm is rising with inner mast rising to realize aim of lifting
goods.
It is basis model that our company offers forklift truck which lift 3 meter high. It is especial
model that our company offers forklift truck which lift height else (2.5~6.0 m).

（5-7 tons ）
3.2 Double full free lift mast (including container mast)（
Double full free lift mast (Fig10-3) is also composed of inner mast, outer mast, fork arm
carrier, and etc, is also belong to high visibility mast. It is different from common standard type
mast that two postpose long lifting jacks are both pole stopper type cylinder. One piston rod is
hollow; hole of piston rod is bypass for hydraulic pressure oil flowing into free lifting jack. End
of piston rod in two long lifting jacks is joined with upper branch of inner mast. Besides, short
lifting jack who is installed middle of inner mast is named as free lifting jack. Free lifting jack is
also pole stopper type cylinder.
Because inner mast doesn’t rise when free lifting jack rising or falling, fork arm just can work
below the lifting height.
When lowest height of mast ≤2200mm, it can work inside standard container，mast which
include side-shift is named container fork lift truck mast. Side shift cylinder of container forklift
truck mast can be side shifting only when goods don’t placed appropriate position. In another
condition, side cylinder should set center.
Free lifting jack is equipped with two chains laid in right and left respectively, and the two
chains should be maintained same tension in free lifting jack.

3.3 Triple full free lift mast (5-7 tons)

Triple full free lift mast is composed of outer mast, middle mast (fig.10-4), and inner mast,
middle mast and inner mast can flex. There are different specifications in this series of height,
4.3~7 meter. It is different from double full free mast that mostly it includes middle mast, and its
53
two postpose long lifting jacks are both piston type cylinder, and its oil system rather complex
than oil system of double full free mast. The center is full free lift cylinder, and its structure is as
same as double full free lift cylinder.

1.outer mast 2.inner mast 3.lift jack 4.chain

5 tilt cylinder 6.fork arm carrier 7 fork arms
Fig.10-1 5-7tons lift mast

54
1. outer mast 2. inner mast 3. lift jack 4. chain 5 tilt cylinder
6 fork arm carrier 7. fork arm 8. adjusting cylinder
Fig.10-2 8~10 tons lift mast

55
 1. outer mast 2. inner mast 3. long lift cylinder 4. free lift cylinder 5. chains
6.tilt cylinder 7. fork arm carrier 8. fork arms
（5-7tons）
Fig.10-3 double free lift mast（ ）

1. Outer mast 2.neutral mast 3. Inner mast 4.long lift jack 5. Free lift jack
6. chain 7.chain 8. Tilt cylinder 9. Fork arm carrier 10. Fork arm
Fig.10-4 triangle free lift mast(8-10tons)
4. Removal and adjustment
！ WARNING
Be careful when removing and installing the forks, carriage and mast as they are heavy.
4.1 Remove forks and mast assembly
56
1） Unlock fork lock pins by pulling them and move forks to cutout portion in the middle of
carriage bracket assembly.
2） Pull lower portion of fork to remove its lower jaw and lift it out.
！ WARNING
a. Keep hands and feet away from forks. When removing and installing forks carefully, keep
feet and hands clear.
b. Do not remove forks from the end of the fork bar. Severe injury can result if the fork is
dropped

1) Attach wire ropes to carriage bracket assembly and lift carriage bracket assembly up with a
lifting device.

2) Remove chain attaching nuts, and detach chains from carriage bracket assembly.

6) Pull out tilt cylinder pivot pin.

3) Remove carriage bracket assembly from 7) Remove mast support caps.

inner mast.

4) Detach high pressure hose, lift hose and

low pressure hose.

8) Remove mast assembly.

9) To install mast assembly, reverse order

of removal.
5) Support mast assembly with wire ropes. 4.2 Disassembly
！ WARNING
Be careful when disassembling the masts as
they are heavy.

57
Remove lifting jack securely attach lift rollers.
1） Place mast flat on ground. Remove
lifting jack attaching bolts-bolts and
tighten screw.
2） Slide inner mast, and then remove lifting
cylinders.
Remove roller
1）Slide inner mast out until rollers are
exposed and remove little rollers and
main rollers with bearing puller.
2）Unclench rollers carefully if no bearing puller
or rollers would be smashed.
Lift roller-to-mast clearance adjustment
1） Adjustable range “A” with shims:
Dimension:0.5～1.2mm.
2） It is suitable that clearance of roller and
outer mast is about 0.8 ～1mm.Clearance
can’t adjustable. Replace it if roller wears
too much.
3） Apply lubrication (butter) to interface of
Remove inner mast
inner mast and outer mast, interface of
Attach wire rope to middle of inner mast
roller and mast. To prevent sand from
and slide it out with a lifting device.
entering, it is decided whether to apply
lubrication or not in the area where sand
blown by wind heavily.
The clearance of guide board and box
iron of mast.
Adjust the clearance “B”of guide board
and inner mast pole to 0.2-1mm with clout,
INSPECTION
and the clout can be selected according to
1） Check lift rollers, roller shafts, and
necessary and the thickness of clout is
associated parts for wear or damage.
0.2mm.
2） Replace damaged parts as required.
4.3 Assembly and adjustment
！ WARNING
Be careful when assembling the inner
masts and outer masts as they are heavy.
Assemble Lift roller
Slide inner mast into outer mast and

58
 Daub layer grease (butter) on the guide
board, and install the mast and lifting
cylinder on the truck, then connect the return
hose and high-pressure hose.
4.4 Left and right cylinder height
adjustment.
1） Install left and right lifting jack on mast,
To adjust tension of lift chain, lower
pin must be installed into orientation hole
lifting jack until fork is on the ground ,and
of outer mast lower cross beam.
2） Install upper of piston rod on inner mast. adjust chain adjusting nut (three every side)

Inner mast lay evenly in the direction of so that dimension C will be as listed below
left, right, upper and lower. If it is not when the middle portion of chain is pressed
even, please adjust by putting washer by a finger.
between hole of cylinder support and Dimension C: 25~30 mm
upper end of piston rod.
3） Installs U-bolt onto cylinder, hand-
tighten nuts and lock it with two tighten
nuts. Screws down tighten bolt and nuts
to avoiding loosing.

4.5 Lifting chain adjustment

Installs fork arm carrier on inner mast,
and install lifting chain, then install two nuts
4.6 Clearance of fork arm carrier
on end of every side. With mast set straight assembly and rollers adjustment
up, lower carriage completely. Clearance of 5-6t fork arm carrier
assembly and rollers
adjust with chain adjusting nut, so as to adjustment
get the clearance of fork arm lower to follow There are 4 main rollers and 4 side- rollers
dimension above ground. on the fork barrier, and side-rollers are
5-7T, 127mm installed inner and outer side of right stand
8-10T, 160mm pole steel wing. Outer side-roller had been
welded on the right location, so they can’t be
adjusted. You can control the clearance of

59
both sides roller and profiled bar only by between each roller and inner mast.
adjusting the washers: Adjust shims of each roller evenly on the
a) The clearance of both sides rollers and left and right and make clearances, between
profiled bar is 0.2-1mm when the fork smallest part of inner mast and carriage side
barrier lifts along inner mast. roller.
b) When lifting, the inner roller rolls along A-B = 0.2 ～1mm
wing, and check post should not be Aˊ-Bˊ= 0.2 ～1mm
found.
c) The side-roller should be replaced if the
outer roller abrase very hard, because it
can’t be adjusted by washer.

shims 0.5mm 1mm

a. Number of shims must be the same on
the right and left sides, when using shims.
b. After clearance adjustment, push
carriage assembly to see if it operates
properly.
Clearance of 7t fork arm carrier
assembly and rollers
Clearance of 8-10t fork arm carrier
adjustment
assembly and rollers
There are 6 main rollers and 5 side-
adjustment
rollers on the fork barrier of 7 tons truck.
There are 4 main rollers and 6 side-
There are 4 side-rollers that can control the
rollers on the fork barrier of 8 tons truck.
clearance of both side roller and stand pole
Control the clearance of both side roller and
steel wing by adjusting the washers. One
stand pole steel wing by adjusting the
outer side-roller had been welded on the
washers.
right location, so they can’t be adjusted.
There are 6 main rollers and 6 side-
1） Measure inside width “A” between inner
rollers on the fork barrier of 7 tons truck.
masts. Make measurements at the top,
There are 4 side-rollers that can control the
bottom and center (cross beam) sections.
Measure the distance Aˊ of the two box clearance of both side roller and stand pole
iron inside of inner mast. steel wing by adjusting the washers. Two
2） Measure right and left pitches, B, B’ of outer side-roller had been welded on the
upside roller, downside roller. right location, so they can’t be adjusted.
3） Calculate the minus of A-Band Aˊ- 4） Measure inside width “A” between inner
Bˊ.Each result shows clearances masts. Make measurements at the top,
60
bottom and center (cross beam) sections.
Measure the distance Aˊ of the two box iron
inside of inner mast.
5） Measure right and left pitches, B, B’ of
upside roller, downside roller.
6） Calculate the minus of A-Band Aˊ-
Bˊ.Each result shows clearances
between each roller and inner mast.
Adjust shims of each roller evenly on the
left and right and make clearances, between
smallest part of inner mast and carriage side
roller. shims 0.5mm 1mm
A-B = 0.2 ～1mm c. Number of shims must be the same on
Aˊ-Bˊ= 0.2 ～1mm
the right and left sides, when using shims.
d. After clearance adjustment, push
carriage assembly to see if it operates

61
 properly.

5. Disassembly and installation of lifting cylinder

！ WARNING
Keep body away from equipment.
1) Turn out engine, then make lifting jack
falling into lowest condition that lower of
piton rod is touched bottom of cylinder
body so as to oil flowing back tank
completely.
2) Unscrew piston rod and bolt.
3) Disconnect circle oil pipe, remove high
pressure tubes.
4) Remove U-bolt of outer mast fixation
board and tighten skew of other side.
5) Remove chain of outer mast., and
remove the bolt at the bottom of jack.
6) Attach wire rope to inner mast and
remove left and right lifting jack with a
lifting device Caution Please not use dust seal ring
removed, O-ring, Y-ring again, must
replace.
3) Draw out piston rod; remove Y-ring on
end of piston.
5.2 Install and replace faulty parts
1） Cleanup parts with clean oil before
installation.
2） Then cleanup guiding bush and piston
with hydraulic pressure oil the same as
oil box trademark.
3） Dust or dunghill doesn’t drop into lifting
jack.
4） The order of installation is reverse the
5.1 Disassembly of parts order of disassembly.
Remove the cover tighten nuts and 5） Install Y-ring on piston.
nylon plug, the remove the cylinder cover. 6） Install piston rod assembly(including
1） Remove dustproof ring. piston lever, piston, bearing ring, y-ring)
2） Remove the y-ring with screwdriver. into clean cylinder body.。
：The end of cylinder body mast
CAUTION：
62
slick and clean, installation must set
center, avoid scratching Y-ring. 6.2 Disassembly of parts
7） Install replacing dust seal ring and Y-ring 1） Squeeze tilting cylinder with pliers, then
in guiding bush and cylinder head. pull piston rod come-and-go as opening
of inlet and outlet on the tilting cylinder,
NOTICE ： Apply hydraulic pressure grease
so remaining oil is discharged tilting
which trademark is the same as tank on
cylinder.
guide sleeve installed seal ring
2） Screw earring 21 out.
8） Rip cylinder head into piston rod, screw 3） Remove bolt and nylon stopper.
down cylinder body. 4） Remove cylinder head 14 and guiding
6. Disassembly and installation of tilting bush 12.
cylinder 5） Draw out piston rod assembly 25 (see
as follows).
！ WARNING
6） Remove all dust seal rings, O-ring and
Noticing proceedings when removing Y-ring.
cylinders.
·Attach wire rope to outer mast, avoiding
mast fall down after removing tilting cylinder.
·Keep body away from equipment, no
standing under the fork arm carrier.
6.1 Remove
1) Lay down fork arm carrier completely.
2) Remove oil pipe to the inlet of tilting
cylinder.
3) Remove bolt on the left and right bracket
7 ） Remove dust seal ring in the cylinder
of outer mast, moreover pull axis out.
head. Means is the same as discharging
4) Remove bolt on the bracket of Chassis,
of dust seal ring in the cylinder head of
and pull pin out, then move tilting
cylinder. lifting jack (see disassembly and

5) The order of installation is reverse the installation of lifting jack).

order of disassembly. 8 ） Remove O-ring outside in the guiding
bush.

9） Remove O-ring and Y-ring in the inner

63
 hole of guiding bush (See Fig. 4) Detach the adjusting cylinder.
disassembly and installation of lifting 5) Assembly is in the reserve order of
jack). disassembly.
CAUTION ： No using dust seal ring and Y- 8. Noticing proceeding of debugging
ring removed. Replace a new one. 1. Adjust Forward and Backward of the
6.3 Install tilting cylinder after replacing mast
ring
Place fork lift truck on the level ground,
The order of installation is reverse to the
operate control lever to realize that mast
order of disassembly, but should notice
inclined forward or backward extremely. As
follow proceedings：
assembly debugging data required, adjust
1） Lubricate parts with clean hydraulic
combined screw thread length till according
pressure oil.
with data of Backward. Then lock earring
2） Avoid dust and oil dirty dropping into
ring close.（please see foregoing table if you
tilting cylinder.
want know tightening torque of M10 bolt.）
3） Avoid scratching the end of cylinder
2. Adjust installation position of left and
body, and inlet and outlet for oil.
right lifting jack again.
4） Push piston rod to cylinder body when
a) Adjust washer in the middle of piston
setting center, especially avoid scratching
rod and inner mast bracket if one lifting
Y-ring.
jack is not synchronization with the
5） Before installing guiding bush, wipe
others when rising or falling, and if one
hydraulic pressure oil matched with
lifting jack is different height from the
employment oil trademark in the middle
others.
of O-ring and Y-ring in the inner hole of
b) Loose two nuts on the U-bolt. Mast is
guiding bush.
not rise and lower until relative position
6） Don’t scratch O-ring outside in the
of U-bolt and lifting jack is suitable. Then
guiding bush when installing.
screw down nuts and tightening screw
7） Remember install nylon stopper and
on the U-bolt. Thus lifting jack can be
tighten screw after screw cylinder head.
used longer and wear of piston rod can
7. Adjusting the distance of fork spread
be reduced.
(8-10 tons)
Please see foregoing table if you want
1) Lower the fork to the ground.
know tightening force of bolt or screw.
2) Detach the oil tube on the adjusting
Please refer to common bolt tightening
distance cylinder.
torque prescribed in our company if you want
3) Detach the two fixing bolts at the side of
know other tightening force of bolt or screw.
cylinder, and pull out the pin.
（ Refer to OPERATION AND MAINTAIN MANUAL

64
matched with it）

Appendix A
（QSB4.5 /QSB6.7/QSC/QSL ）Fault Code Information
CPCD50/60/70/80/100-RW28（

(zhs06-fc111) Engine Control Module Critical Internal Failure-Bad Intelligent

Device or Component.Error internal to the ECM related to memory hardware
failures or internal EcMVoltage supply circuits.
(zhs06-fc115) Engine Magnetic Crankshaft Speed/Position lost both of two
signals-Data Erratic,Intermittent,or Incorrect.The ECM has detected that the
primary engine speed sensor and the backup engine speed sensor signals are
reversed.
(zhs06-fc122) Intake Manifold Pressure Sensor Circuit-Voltage Above Normal,or
Shorted to High source.High signal voltage etected at the intake manifold
pressure circuit.
(zhs06-fc123) Intake Manifold 1 Pressure Sensor Circuit-Voltage Below Normal,or
Shorted to Low source.Low signal voltage or open circuit detected at the intake
manifold pressure circuit.
(zhs06-fc124) Intake Manifold1 Pressure-Data Valid but Above Normal
Operational Range-Moderately Severe Level.Intake manifold pressure has
exceeded the maximum limit for the given engine rating.
(zhs06-fc131) Accelerator Pedal or Lever Position Sensor1 Circuit-Shorted to High
Source.High voltage detected at accelerator pedal position circuit.
65
(zhs06-fc132) Accelerator Pedal or Lever Position Sensor1 Circuit-Voltage Below
Normal,or Shorted to Low Source.Low voltage detected at accelerator pedal
position signal circuit.
(zhs06-fc133) Remote Accelerator Pedal or Lever Position Sensor1Circuit-
Voltage Above Normal,or Shorted to High Source.High voltage detected at remote
accelerator pedal position circuit.
(zhs06-fc134) Remote Accelerator Pedal or Lever Position Sensor1Circuit-
Voltage Below Normal,or Shorted to Low Source.Low voltage detected at remote
accelerator pedal position signal circuit.
(zhs06-fc135) Engine Oil Rifle Pressure1 sensor-Voltage Above Normal,or
Shorted to High Source Highh signal voltage detected at the engine oil pressure
circuit.
(zhs06-fc141) Engine Oil Pressure sensor Circuit-Voltage Below Normal,or
Shorted to Low Source.Low signal voltage etected at engine oil pressure circuit.
(zhs06-fc143) Engine Oil Rifle Pressure –Data Valid but Below Normal
Operational Range-Moderately Severe Level.
(zhs06-fc144) Engine coolant Temperature1 Sensor Circuit-Voltage Above
Normal,or Shorted to High Source.High signal voltage or open circuit detected at
engine coolant temperature circuit.
(zhs06-fc145) Engine Coolant Temperature1 Sensor Circuit-Voltage Below
Normal,or Shorted to Low Source.Low signal voltage detected at engine coolant
temperature circuit.
(zhs06-fc146)Engine Coolant Temperature-Data Valid but Above Normal
Operational Range -Moderately Severe Level.Engine coolant temperature signal
indicates engine coolant temperature is above engine protection warning limit.
(zhs06-fc147) Accelerator Pedal or Lever Position1 Sensor Circuit Frequency-data
Valid but Below Normal Operational Range-Most Severe Level.Afrequecyof less
than 100Hz has been detected at the frequency throttle input to the ECM.
(zhs06-fc148) Accelerator Pedal or Lever Position1 Sensor-data Valid but Above
Normal Operational Range-Most Severe Leve.A frequency throttle input to the
ECM.
(zhs06-fc151) Engine coolant Temperature –Data Valid but Above Normal
Operational Range-Most Severe Level.Engine coolant temperature signal
indicates engine coolant temperature above engine protection critical limit.
(zhs06-fc153) Intake Manifold1 Temperature Sensor Circuit-Voltage Above
Normal,or Shorted to High Source.High Signal voltage detected at intake manifold
air temperature circuit.
(zhs06-fc154) Intake Manifold1 Temperature Sensor Circuit-Voltage Below
Normal,or Shorted to Low Source.Low signal voltage detected at intake manifold
air temperature circuit.
(zhs06-fc155) Intake Manifold 1 Temperture-Data Valid but Above Normal
Operational Range-Most Severe Level.Intake manifold air temperature signal
indicated intake manifold air temperature above engine protection critical limit.
(zhs06-fc187) Sensor Supply 2 Circuit -Voltage Below Normal,or Shorted to Low
Source.Low voltage detected at the sensor supply Number2circuit..
(zhs06-fc195) Coolant Level Sensor1 Circuit-Voltage Above Normal,or Shorted to
High Source. High signal voltage detected at engine coolant level circuit.
(zhs06-fc196) Coolant Level Sensor1 Circuit-Voltage Below Normal,or Shorted to
Low Source.Low signal voltage detected at engine coolant level circuit.
(zhs06-fc197) Coolant Level-Data Valid but Below Normal Operational Range-
Moderately Severe Level.Low coolant level has been detected.
(zhs06-fc221) Barometric Pressure Sensor Circuit-Voltage Above Normal,or
Shorted to High Source.High signal voltage detected at barometric pressure
circuit.
(zhs06-fc222) Barometric Pressure sensor Circuit-Voltage Below Normal,or Short
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ed to Low Source.Low signal voltage detected at barometric pressure circuit.
(zhs06-fc227) Sensor Supply2 circuit-Voltage Above Normal,or Shorted to High
Source.High voltage detected at sensor supply Number2 circuit.
(zhs06-fc234) Engine Crankshaft Speed/Position-Data Valid but Above Normal
Operational Range-Most Severe Level.Engine speed signal indicates engine
speed above engine protection limit.
(zhs06-fc235) Coolant Level-Data Valid but Below Normal Operational Range-
Most Severe Level.Low engine coolant level detected.
(zhs06-fc237) External Speed Command Input(Multiple Unit Synchronization)-
data Erratric,Intermittent,or Incorrect.The throttle input signal to the primary tor
secondary engine for multiple unit synchronization si less than three percent or
more than 97 percent.
(zhs06-fc238) Sensor Supply3 Circuit –Voltage Below Normal,or Shorted to Low
Source.Low voltage detected on the +5VDC sensor supply circuit to the engine
speed sensor.
(zhs06-fc241) Wheel-Based Vehicle Speed-Data Erratic,Interimttent,or
Incorrect.The ECMlost the vehicle speed signal.
(zhs06-fc242) Wheel-Based Vehicle Speed Sensor Circuit Tampering has Been
Detected- Abnormal Rate of Change.Signal indicates an intermittent connection of
VSS tampering.
(zhs06-fc245) Fan control Circuit-Voltage Below Normal,or Shorted to Low
Source.Low signal voltage detected at the fan control circuit when commanded on.
(zhs06-fc268) Fuel Delivery Pressure-Data Erratic,Intermitten,or Incorrect.The
ECMhs detecte tha the fuel pressure signal is not changing.
(zhs06-fc271)Fuel Pump Pressurizing Assembly 1 Circuit-Voltage Below Normal
,or Shorted to Low Source.Low signal voltage detected at the fuel pump actuator
circuit.
(zhs06-fc272) Fuel Pump Pressuring Assembly 1Circuit-Voltage High Normal ,or
Shorted to High Source.High signal voltage or open circuit detected at the fuel
pump actuator circuit.
(zhs06-fc275) Fuel Pump Pressuring Assembly 2 Circuit –Voltage Above
Normal,or Shortedto High Source.
(zhs06-fc281) Fuel Pump Pressurizing Assembly 1- Mechanical System No
Responding Properly or Out of Adjustment .Apumping imbalance between the
front and rear pumping plungers has been detected.
(zhs06-fc284) Fuel Pump Pressurizing Assembly 1- Mechanical System No
Responding Properly or Out of Adjustment .Low voltage detected on the
ECMvoltage supply line to the engine speed sensor.
(zhs06-fc285) SAE J1939 Multiplexing PGN Timeout Error-Abnormal Update
Rate.The ECM expecte information form a multiplexed device but olly received a
portion of the necessary information.
(zhs06-fc286) SAE J1939 Multiplexing Configuration Error-Out of Calibration.The
OEMvehicle electronic control unit detected a fault with the remote accelerator.
(zhs06-fc287) SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System-
Received Network Data In Error.The OEM vehicle electronic control unit detected
a fault with its accelerator pedal.
(zhs06-fc288) SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data
Error-Received Network Data In Error.The OEM vehicle electronic control unit
detected a fault with the remote accelerator.
(zhs06-fc292) Auxiliary Temperature Sensor Input1-Special Instructions
(zhs06-fc293) Auxiliary Temperature Sensor Input1 Circuit-Voltage Above
Normal,or Shorted to High Source.High signal voltage or open circuit detected at
the OEMauxiliary temperature circuit.
(zhs06-fc294) Auxiliary Pressure Sensor1 Input Circuit-Voltage Below Normal,or
Shorted to Low Source.Low signal voltage detected at the OEMauxiliary temperat
67
ure circuit.
(zhs06-fc296) Auxiliary Pressure Sensor Input1-Special Instructions
(zhs06-fc297) Auxiliary Pressure Sensor Input1 Circuit-Voltage Above Normal,or
Shorted to High Source.High signal voltage detected at the OEM pressure circuit.
(zhs06-fc298) Auxiliary Pressure Sensor Input1 Circuit-Voltage Below Normal,or
Shorted to Low Source. Low signal voltage detected at the OEM pressure circuit.
(zhs06-fc319) Real Time Clock Power Interrupt-Data Erratic,Intermittent,or
Incorrect.Real Time Clock lost power.
(zhs06-fc322) Injector Solenoid Driver Cylinder 1 Circuit-current Below Normal,or
Open Circuit.High resistance detected on injector Number 1 circuit or no current
detected at Number 1 Injector Number 1 Injector driver or returen pin when the
voltage supply at the harness is on.
(zhs06-fc323) Injector Solenoid Driver Cylinder 5 Circuit-current Below Normal,or
Open Circuit.High resistance detected on injector Number 5 circuit or no current
detected at Number 5 injector driveror return pin when the voltage supply at he
harness is on.
(zhs06-fc324) Injector Solenoid Driver Cylinder 3 Circuit-current Below Normal,or
Open Circuit.High resistance detected on injector Number 3 circuit or no current
detected at Number 3 injector driver or returen pin when the voltage supply at the
harness is on
(zhs06-fc325) Injector Solenoid Driver Cylinder 6 Circuit-current Below Normal,or
Open Circuit.High resistance detected on injector Number 6 circuit or no current
detected at Number 6 injector driver or return pin when the voltage supply at the
harness is on.
(zhs06-fc331) Injector Solenoid Driver Cylinder 2 Circuit-current Below Normal,or
Open Circuit.High resistance detected on injector Number 2 circuit or no current
detected at Number 2 injector drive or return pin when the voltage supply at the
harness is on.
(zhs06-fc332) Injector Solenoid Driver Cylinder 4 Circuit-current Below Normal,or
Open Circuit.High resistance detected on injector Number 4 circuit or no current
detected at Number 4 injector driver or return pin when the voltage supply at the
harness is on.
(zhs06-fc334) Engine Coolant Temperature-Data Erraticf,Intermitent,or
Incorrect.The engine coolant temperature reading is not changing with engine
operation conditions.
(zhs06-fc342) Electronic Calibration Code Incompatibility-Out of Calibration.An
incompatible calibraton between the primary and secondary OEM installed ECM’s
has been detected.
(zhs06-fc343) Engine control Module Warning Internal Hardware Failure.Bad
Intelligent Device or Component .Internal ECM failure.
(zhs06-fc351) Injector Power Supply- Bad Intelligent Device or Component.The
ECM measured injector boost voltage is low.
(zhs06-fc352) Sensor Supply1 circuit –Voltage Below Normal,or Shorted to Low
Source.Low voltage detected at sensor supply Number 1 circuit.
(zhs06-fc386) Sensor Supply1 circuit –Voltage High Normal,or Shorted to High
Source.High voltage detected at sensor supply Number 1 circuit.
(zhs06-fc387) Sensor Supply 1 circuit –Voltage Above Normal,or Shorted to High
Source.High Voltage detected at sensor supply circiuit for the accelerator pedal
position sensor.
(zhs06-fc415) Engine Oil Rifle Pressure-Data Valid but Below Normal Operational
Range-Most Severe Level.Oil pressure signal indicates oil pressure below the
engine protection critical limit.
(zhs06-fc418) Water in Fuel Indicator-data Valid but Above Normal Operational
range-Least Severe Level.Water has been detected in the fuel filter.
(zhs06-fc427) SAE J1939 datalink-Abnormal Update rate.Communicationbetween
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the electronic control module(ECM)and another device on the SAE J1939 datalink
has been lost.
(zhs06-fc428) Water in fuel Indicator Sensor circuit-Voltage Above Normal,or
shorted to High Source.Low voltage detected at the water in fuel circuit
(zhs06-fc429) Water in fuel Indicator Sensor circuit-Voltage Below Normal,or
shorted to Low Source.Low voltage detected at the water in fuel circuit.
(zhs06-fc431) Accelerator Pedal or Lever Idle VAlidationi Switch-Data
Erratic,Intermittent,or Incorrect.Voltage detected Simultaneously on both idle
validation and off-idle validation switches.
(zhs06-fc432) Accelerator Pedal or Lever Idle Validation circuit-Out of
Calibration.Voltage at idle validation on-idle and off –idle circuit down not match
accelerator pedal position.
(zhs06-fc434) Power Supply Lost Without Ignition Off-Data Erratic,Intermittent,or
Incorrect.Supply voltage to the ECM fell belw 6.2 volts momentarily ,or the ECM
was not allowed to power down correctly.
(zhs06-fc435) Engine Oil Pressure Switch Sensor Circit-Data
Erratic,Intermittent,or Incorrect.An error in the engine oil pressure switch signal
was detected by the ECM.
(zhs06-fc441) Battery 1 Voltage-Data Valid but Below Normal Operational Range-
Moderately Severe Level.ECM supply voltage is below the minimum system
voltage level.
(zhs06-fc442) Battery 1 Voltage-Data Valid but Below Normal Operational Range-
Moderately Severe Level.ECM supply voltage is above the maximum system
voltage level.
(zhs06-fc443) Battery 1 Voltage-Data Valid but Above Normal Operational Range
–Moderately Severe Level.Low voltage detected at sensor supply circuit to the
accelerator pedal position sensor.
(zhs06-fc451) Injector Metering Rail1 Pressure Sensor circuit-Voltage Above
Normal,or Shorted to High Source.High signal voltage detected at the rail fuel
pressure sensor circuit.
(zhs06-fc452) Injector Metering Rail1 Pressure Sensor circuit-Voltage Below
Normal,or Shorted to Low Source.Low signal voltage detected at the rail fuel
pressure sensor circuit.
(zhs06-fc488) Intake Manifold 1 Temperature Data Valid but Above Normal
Operational Range-Mooderately Severe Level.Intake manifold air temperature
signal indicates intake manifold air temperature signal indicates intake manifold
air temperature is above the engine protection warning limit.
(zhs06-fc497) Multiple Unit Synchronization Switch-Data Erratic,Intermittent,or
IncorrectMulti-unit synchronous ON/OFF switch and Multi-unit synchronous
complimentary ON/OFF switch have different values in the ECM.
(zhs06-fc523) Auxiliary Intermediate(PTO)Speed Switch Validation-Data
erratic,Intermittent,or Incorrect.The position of the intermittent,or Incorrect.The
position of the intermediate speed control switch 1 does not match the position of
the intermediate speed control validation switch.
(zhs06-fc527) Auxiliary Input/Output 2 Circut-Voltage Above Normal,or Shorted to
High Source.High signal voltage or ope circuit has been detected at the auxiliary
input/output 2 circuit
(zhs06-fc528) Auxiliary Alternate Torque Validation Switch-Data
Erratic,Intermittent,or Incorrect.An error has been detected in the alternate torque
switch circuit.
(zhs06-fc529) Auxiliary Input/Output 2 Circut-Voltage Above Normal,or Shorted to
High Source.High signal voltage or open circuit has been detected at the auxiliary
input/output 3 circuit.
(zhs06-fc551) Accelerator Pedal or Lever Idle Validation Circuit-Voltage Below
Normal,or Shorted to Low Source.No voltage detected simultaneously on both the

69
idle validation off-idle and on-idle circuits.
(zhs06-fc553) Injector Metering Rail1 Pressure-Data Valid but Above Normal
Operational Range-Moderately Severe Level.The ECM has detected tha fuel
pressure is higher than commanded pressure.
(zhs06-fc554) Injector Metering Rail1 Pressure-Data Erratic,Intermittent,or
Incorrect.The ECM has detected tha fuel pressure is higher than commanded
pressure.
(zhs06-fc559) Fuel Pump Oil Pressure Low-Data Valid but Below Normal-
Moderately Severe Level.The ECM has detected that fuel pressure is lower than
commanded pressure.
(zhs06-fc584) Starter Relay Driver Circuit-Voltage Above Normal,or Shorted to
High Source.Open circuit or high voltage detected at starter lockout circuit.
(zhs06-fc585) Starter Relay Driver Circuit-Voltage Below Normal,or Shorted to
Low Source.Low voltage detected at starter lockout circuit.
(zhs06-fc596) Elecrical Charging System Voltage High-Data Valid but Above
Normal Operational Range-Moderately Severe Level.High battery voltage
detected by the battery voltage monitor feature.
(zhs06-fc597) Elecrical Charging System Voltage Low-Data Valid but Below
Normal Operational Range-Moderately Severe LevelLow battery voltage detected
by the battery voltage monitor feature.
(zhs06-fc598) Elecrical Charging System Voltage Low-Data Valid but Below
Normal Operational Range-Most Severe Level.Very low battery voltage detected
by the battery voltgage monitor feature.
(zhs06-fc599) Auxiliary Commanded Dual Output Shutdown-Special
Instructions.The engine protection limit has been exeeeded for the dual outputs
calibrated limits.
(zhs06-fc649)Engine Oil Change Interval-Condition Exists.Change engine oil and
filter.
(zhs06-fc689) Engine Crankshaft Speed/Position-Data Erratic,Intermittent,or
Incorredt.Loss of signal from crankshaft sensor.
(zhs06-fc691) Turbocharger1 Compressor Inlet Temperature Circuit-Voltage
Below Normal,or Shorted to Low Source.High signal voltage detected at
turbocharger compressor inlet air temperature circuit.
(zhs06-fc692) Turbocharger1 Compressor Inlet Temperature Circuit-Voltage
Below Normal,or Shorted to Low Source.Low signal voltage detectdat turbocharge
compressor inlet air temperature circuit.
(zhs06-fc731) Engine Speed Sensor/Position Camshaft and Crankshaft
Misalignment-Mechanical System Nor Responding Properly or Out of
Adjustment.Mechanical misalignmentg between the crankshaft and camshaft
engine speed sensor.
(zhs06-fc757) Electronic Control Module Data Lost-Condition Exists.Severe loss
of data from the ECM.
(zhs06-fc778) Engine camshaft Speed/Position Sensor-Data Erratic,Intermittent,
or Incorrect.The ECM has detected an error in the camshaft position sensor signal.
(zhs06-fc779) 3 Auxiliary equipment Sensor Input3-Root Cause Not Known
(zhs06-fc1117) Power Supply Lost With Ignition On-Data Erratic,Intermittent,or
Incorrect.Supply voltageto the ECM fell belw 6.2 VDC momentarily ,or the
ECMwas not allowed to power down correctly (retain battery voltage for 30
seconds after key OFF)
(zhs06-fc1139) Injector Solennoid Driver Cylinder 1-Mechanical System Not
Responding Properly or Out of Adjustment.Unintended fueling detected in cylinder
Number 1.
(zhs06-fc1141) Injector Solennoid Driver Cylinder 2-Mechanical System Not
Responding Properly or Out of Adjustment.Unintended fueling detected in cylinder
Number2.
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(zhs06-fc1142) Injector Solennoid Driver Cylinder 3-Mechanical System Not
Responding Properly or Out of Adjustment
(zhs06-fc1143) Injector Solennoid Driver Cylinder 4-Mechanical System Not
Responding Properly or Out of Adjustment. Unintended fueling detected in
cylinder Number3.
(zhs06-fc1144) Injector Solennoid Driver Cylinder 5-Mechanical System Not
Responding Properly or Out of Adjustment
(zhs06-fc1145) Injector Solennoid Driver Cylinder 6-Mechanical System Not
Responding Properly or Out of Adjustmen. Unintended fueling detected in cylinder
Number6.
(zhs06-fc2185) Sensor Supply 4 Circuit-Voltage Above Normal,or Shorted to High
Source.High voltage detected at +5VDC sensor supply circuit to the accelerator
pedal position sensor.
(zhs06-fc2186) Sensor Supply 4 Circuit-Voltage Below Normal,or Shorted to Low
Source.Low voltage detected at +5VDC volt sensor supply circuit to the
accelerator pedal position sensor.
(zhs06-fc2215) Fuel Pump Delivery Pressure –Data Valid but Below Normal
Operational Range –Moderately Severe Level .The ECM has detected that fuel
pressure is higher than commanded pressure.
(zhs06-fc2216) Fuel Pump Delivery Pressure High-Data Valid but Above Normal
Operational Range-Moderately Severe Level .The ECM has detected that fuel
pressure is higher than commanded pressure.
(zhs06-fc2217) Engine Control Module CalibrationProgram Memory(RAM)
corruption-Condition Exists.Severe loss of data from the ECM.
(zhs06-fc2249) Injector Metering Rail 1 Pressure-Data Valid but Below Normal
Operational Range-Most Severe Level.The ECM has detected that fuel pressure
is lower than commanded pressure.
(zhs06-fc2265)Electric Lift Pump for Engine Fuel Supply Circuit-Voltage Above
Normal,or Shorted to High Source.High voltage or oen detected at the fuel lift
pump signal circuit.
(zhs06-fc2266) Electric Lift Pump for Engine Fuel Supply Circuit-Voltage Below
Normal,or Shorted to Low Source.Low signal voltage detected at the fuel lift pump
circuit.
(zhs06-fc2311) Electronic Fuel Injection Control Valve 1 Circuit –Conditioni
Exists.Fuel pump actuator circuit resistance too high or too low.
(zhs06-fc2321) Engine Crankshaft Speed/Position Sensor-Data
Erratic,Intermittent,or Incorrect.Crankshaft engine speed sensor intermitetent
synchronization.
(zhs06-fc2322) Engine Crankshaft Speed/Position Sensor2-Data
Erratic,Intermittent,or Incorrect.Camshaft engine speed sensor intermittent
synchronization.
(zhs06-fc2346) Turbocharge Turbine LInlet Temperature (Calculated)-Least
Severe Level.Turebocharger turbine inlet temperature has exceeded the engine
protection limit.
(zhs06-fc2347cl) Turbocharger Compressor Outlet Temperature (Calculated)-Data
Valid but Above Normal Operational Range -Least Severe Level
(zhs06-fc2362) Engine Brake Actuator Circuit Number 1-Voltage Above Normal,or
Shorted to High Source.Low voltage detected at the engine brake solenod
Number 1 signal circuit.
(zhs06-fc2363) Engine Brake Actuator Circuit Number 2-Voltage Below Normal,or
Shorted to Low Source. Low voltage detected at the engine brake solenod
Number 2 signal circuit.
(zhs06-fc2366) Engine Brake Actuator Circuit Number 1-Voltage Above Normal,or
Shorted to High Source.Open circuit or high voltage detected at the engine brake
solenoid Number 1 signal circuit.

71
(zhs06-fc2367) Engine Brake Actuator Circuit Number 2-Voltage Above Normal,or
Shorted to High Source.Open circuit or high voltage detected at the engine brake
solenoid Number 2 signal circuit.
(zhs06-fc2377) Fan Control Circuit-Voltage Above Normal,or Shorted to High
Source.Open circuit or high voltage detected at the fan control circuit.
(zhs06-fc2555) Intake Air Heater 1 circuit- Voltage Above Normal,or Shorted to
High Source.High voltage detected at the intake air heater signal circuit.
(zhs06-fc2557) Auxiliary Pulse Width Modulatioin Driver 1 Circuit –Voltage Above
Normal,or Shorted to High Source.High signal voltage detected at the analog
torque circuit.
(zhs06-fc2558) Auxiliary Pulse Width Modulatioin Driver 1 Circuit –Voltage Below
Normal,or Shorted to Low Source.Low signal voltage detected detected at the
analog torque circuit.
(zhs06-fc2963) Engine Coolant Temperature High-Data Valid but Above Normal
Operational Range-Least Severe Levl.Engine coolant temperature signal
indicates engine coolant temperature is above engine protection warning limit.
(zhs06-fc2964) Intake Manifold 1 Temperature High-Data Valid but Above Normal
Operational Range-Least Severe Level.Intake manifold air temperature signal
indicates intake manifold air temperature is above the engine protection warning
limit
(zhs06-fc2973) Intake Manifold 1 Pressure –Data Erratic,Intermittent,or
Incorrect.The ECM has detected an intake manifold pressure signal that is too
high or low for current engine operating conditions.

72
Appendix B

Fig 9-1 CPCD50/60/70/80/100-RG16 Electrical Principal diagram

73
Fig. 9-2 CPCD50/60/70/80/100-RG16 Electrical Wiring Systems Diagram

74
Fig 9-3 CPCD50/60/70/80/100-RW28 Electrical Principal diagram

75
Fig. 9-4 CPCD50/60/70/80/100-RW28 Electrical Wiring Systems Diagram

76
Fig 9-5 CPCD80/100-RG17 Electrical Principal diagram

77
Fig. 9-6 CPCD80/100-RG17 Electrical Wiring Systems Diagram

78
Fig 9-7 CPCD50-RG24 Electrical Principal diagram

79
Fig. 9-8 CPCD50-RG24 Electrical Wiring Systems Diagram

80
Fig 9-9 CPCD80/100-RG25 Electrical Principal diagram

81
Fig. 9-10 CPCD80/100-RG25 Electrical Wiring Systems Diagram

82
Fig 9-11 CPCD50/60/70/80/100-RW24 Electrical Principal diagram

83
Fig. 9-12 CPCD50/60/70/80/100-RW24 Electrical Wiring Systems Diagram

84
Fig 9-13 CPCD50/60/70-RW14B Electrical Principal diagram

85
Fig 9-14 CPCD50/60/70-RW14B Electrical Wiring Systems Diagram

86
Fig 9-15 CPCD50/60/70—RW19AElectrical Principal diagram

87
Fig 9-16 CPCD50/60/70—RW19A Electrical Wiring Systems Diagram

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E-P Equipment Co., Ltd.

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