H-Series Forklift Manual

FOREWORD
H-series CPCD40,CPCD45, CPCD50, CPQD40, CPQD45, CPQD50, CPYD40,
CPYD45, CPYD50 and CPQYD40, CPQYD45, CPQYD50 internal combustion

counterbalanced forklift trucks-material handling machines that are driven by front axle, and
steered by rear axle. Trucks are used for materials handling, loading and discharging, and
piling piece cargo at the goods yard, station, port, building site and plant, also used to
transport in short distance.
For such features: Luxury exterior, fine streamline, low noise and pollution, flexible
operation, wide view mast, safety and reliability, shock absorption, dustproof, fine tractate and
traveling ability, fine riding comfort, trucks are regarded as ideal equipments to accomplish
the mechanization of loading and unloading.
There will have a wider use if trucks are fitted with all kinds of the attachments (such as
side shift, rotator, paper roll clamps, fork petitioners and so on).
This manual describes the performance, construction, operation and maintained of the
above trucks. Before putting the forklift trucks into use, please read the manual carefully in
order to ensure the proper operation of the forklift trucks.
To improve our forklift trucks, absorb your valuable suggestion, please send to us
suggestion content.
We also ask your understanding for the fact that, due to on-going improvement of parts
and equipment, the numerical values given in the manual are subject to change without notice.
CONTENT
FOREWORD
I.FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
II.EXTERNAL VIEW AND MAIN PERFORMANCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.EXTERNAL VIEW OF THE INTERNAL MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.MAIN PERFORMANCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III.CONSTRUCTION AND PERFORMANCE OF MAIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2. TORQUE CONVERTER TYPE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-2 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-3 CLUTCH GROUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-4 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2-5 OIL CIRCULATION ROUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2-6 CHARGING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-7 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-8 DIFFERENTIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3. FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-2 AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-3 FRONT WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4. BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-2 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-3 WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-4 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4-5 AUTOMATIC CLEARANCE ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4-6 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4-7.MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4-8. TROUBLE SHOOTING OF THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5. STEERING SYSTEM (ORBITROL TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5-1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5-2. STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5-3. STEERING WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5-4. ORBITRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5-5.STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5-6. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6-1. HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6-2. FLOW DIVIDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6-3. CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6-4.LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6-5.FLOW REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6-6.TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6-7.TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7. LOAD HANDLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7-1.MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7-2.CARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7-3.LIFT CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8. ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8-1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8-2 SIGNAL AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8-3. WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
IV. OPERATION, SAFETY INSTRUCTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 68
1. OPERATION AND INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2. BEFORE USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3. START ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4. SAFETY NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5. NOTES IN THE DURING BRAKE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6. QUANTITY OF OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7. ROUTINE CHECK BEFORE DAILY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8. REGULARLY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9. CASUAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10. TABLE OF LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PRODUCT IMPROVE SUGGESTION SHEET (FEEDBACK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
I.FEATURES
H-series CPCD40, CPCD45, CPCD50, CPQD40, CPQD45, CPQD50, CPYD40,
CPYD45, CPYD50 and CPQYD40, CPQYD45, CPQYD50 forklift truck adopt the drive way:
engine- hydraulic torque converter-gearbox-driving axle. Features are showed on the
following:
(1) Because of adopting hydraulic drive, guard against engine stopping under the
overload condition. If load capacity are increased sharply, meanwhile, accomplish smooth
shifting operation. For the trucks, such as stopping and starting regularly, shifting frequently,
raise working efficiency, simplify operation, reduce a driver’s labors intensity, cut down the
requirements of a driver’s operating skilled.
(2) Adopt full hydraulic steering device, transverse steering axle, small turning radius,
flexible steering, safety and reliability.
(3) Brake systems adopt power oil brake, smooth operating, and reliable brake.
(4) Adopt 2-stage CJ model telescoping mast, high strength, wide view, series designing,
mast with different lift height can be chosen.
(5) Integral machine has these features: Luxury exterior, fine streamline, low noise,
vibration damping, dustproof comfortable operating, safety and reliability.
(6) The series trucks can be fitted with 2-stage of 3-stage full free mast, even all kinds of
the attachments according to the demands of customers.
(7) The overhead guard and driver’s cab can be chosen according to different demands of
customer.
It is an ideal choice for customer to use the series trucks.
-1-
II.EXTERNAL VIEW AND MAIN PERFORMANCE TABLE
1. EXTERNAL VIEW OF THE INTERNAL MACHINE
2275
Series L L1 L2 R
4t 4145 555 520 2720
4.
5t 4165 555 540 2740
5t 4209 555 584 2800
-2-
2.MAIN PERFORMANCE TABLE OF H SERIES 4～5T FORKLIFT TRUCK:
2-1 CPCD40～50-WX5
Model CPCD40-WX5 CPCD45-WX5 CPCD50-WX5
1 Rated load kg 4000 4500 5000
2 Lord center mm 500
3 Max. Lift height mm 3000
4 Free Lift height mm 150
5 Tilt angle FWD/BWD ° 6/12
6 Max Lift speed Loaded/Unloaded mm/s 460/520
7 Traveling speed FWD/BWD km/h 16/24/18
8 Drawbar pull Loaded/Unloaded N 21560/17800
9 Grade ability Loaded/Unloaded % 20/20 19/
20
10Wheel base Front/Rear mm 2000
11Tread mm 1180/1190
12Clearance mm 165
13Min. turning radius of outer wheel mm 2720 2740 2800
14Min. intersecting aise mm 2480 2500 2550
L mm 4145 4165 4209

Dimension
15 W mm 1480
H mm 2275
Loaded kg 9010 9750 10500

Front Axle
Axle load
Unloaded kg 2750 2710 2680

16
Loaded kg 1590 1550 1600
Rear Axle
Unloaded kg 3850 4090 4420
17Front overhang mm 555
18Rear overhang mm 520 540 584
19Service weight kg 6600 6800 7100
20Distance between both forks mm 300～1340
21Brake distance (Unloaded) m ≤6
-3-
Model CPCD40-WX5 CPCD45-WX5 CPCD50-WX5
Model CA4110/125-HY20
Type 4-cylinder, water-cooled Diesel Engine

Engine
22 Total Displacement mL 4752
Rated Power/speed kW/rpm 61/2200
Max. torque/speed Nm/rpm 305/1400-1600
Rated pressure MPa 19

Hydraulic System
Pump Model CBKa-G425-ATφL CBKa-G425-ATφ
valve mode mL/r 25×2

23
Control valve model CDB-F20U
Diameter×Stroke(lift) mm 70×1495
Diameter×Stroke(tilt) mm 90×188
Front wheel 8.
25-15-14PR 300-15-20PR
5
Pneumatic Pa 8.3×10
Tyre
24
Rear wheel 2-7.00-12-14PR
5
Model BZZ1-160
Steering
25
Valve Displacement mL/r 160
Steering angle
(inner wheel) 78°42′
Steering
26 Steering angle
Axle 54°36′
(outer wheel)
-4-
2-2 CPCD40～50-WF6
Model CPCD40-WF6 CPCD45-WF6 CPCD50-WF6

1 Rated load kg 4000 4500 5000
20
11Tread mm 1180/1190
12Clearance mm 165
L mm 4145 4165 4209

Dimension
15 W mm 1480
H mm 2275
Loaded kg 9010 9750 10500

Front Axle
Axle load
Unloaded kg 2750 2710 2680

16
Loaded kg 1590 1550 1600
Rear Axle
Unloaded kg 3850 4090 4420

-5-
Model CPCD40-WF6 CPCD45-WF6 CPCD50-WF6
Model 4RMG25-1

Engine
Max. torque/speed Nm/rpm 280/1600-1800

Hydraulic System

23
Front wheel 8.
25-15-14PR 300-15-20PR
5
Tyre
24
5
Model BZZ1-160
Steering
25
Steering angle
Steering
26 Steering angle
Axle 54°36′
(outer wheel)
-6-
2-3 CPCD40～50-M2
Model CPCD40-M2 CPCD45-M2 CPCD50-M2

1 Rated load kg 4000 4500 5000
20
11Tread mm 1180/1190
12Clearance mm 165
L mm 4145 4165 4209

Dimension
15 W mm 1480
H mm 2275
Loaded kg 9010 9750 10500

Front Axle
Axle load
Unloaded kg 2750 2710 2680

16
Loaded kg 1590 1550 1600
Rear Axle
Unloaded kg 3850 4090 4420
-7-
Model CPCD40-M2 CPCD45-M2 CPCD50-M2
Model S6S

Engine
Max. torque/speed Nm/rpm 248/1700

Hydraulic System

23
Front wheel 8.
25-15-14PR 300-15-20PR
5
Tyre
24
5
Model BZZ1-160
Steering
25
Steering angle
Steering
26 Steering angle
Axle 54°36′
(outer wheel)
-8-
2-4 CPCD40～50-VM1
Model CPCD40-VM1 CPCD45-VM1 CPCD50-VM1

1 Rated load kg 4000 4500 5000
20
11Tread mm 1180/1190
12Clearance mm 165
L mm 4145 4165 4209

Dimension
15 W mm 1480
H mm 2275
Loaded kg 9010 9750 10500

Front Axle
Axle load
Unloaded kg 2750 2710 2680

16
Loaded kg 1590 1550 1600
Rear Axle
Unloaded kg 3850 4090 4420

-9-
Model CPCD40-VM1 CPCD45-VM1 CPCD50-VM1
Model VMR754ISE4

Engine
Rated Power/speed kW/rpm 54.

5/2
300

Hydraulic System

23
Front wheel 8.
25-15-14PR 300-15-20PR
Tyre
24
Model BZZ1-160
Steering
25
Steering angle
Steering (inner wheel) 78°42′
26 Steering angle
Axle
(outer wheel) 54°36′
-10-
2-5 CPQ(Y)D 40～50-TY5
Model CPQ(Y)D40-TY5 CPQ(Y)D45-TY5 CPQ(Y)D50-TY5

1 Rated load kg 4000 4500 5000
6 Max Lift speed Loaded/Unloaded mm/s 460/
520
20
11Tread mm 1180/1190
12Clearance mm 165
L mm 4145 4165 42
09
Dimension
15 W mm 1480
H mm 2
275
Loaded kg 9010 9750 10500
Front Axle
Axle load
Unloaded kg 2750 2710 2680

16
Loaded kg 1590 1550 1600
Rear Axle
Unloaded kg 3850 4090 4420

-11-
Model GM4.3L Non-certified
Type 6-cylinder, water-cooled Bi-fuel Engine

Engine

Hydraulic System

23
Front wheel 8.
25-15-14PR 300-15-20PR
Tyre
24
Model BZZ1-160
Steering
25
Steering angle
Steering
26 Steering angle
Axle 54°36′
(outer wheel)
-12-
2-6 CPQ(Y)D 40～50-TY6

1 Rated load kg 4000 4500 5000
6 Max Lift speed Loaded/Unloaded mm/s 460/
520
20
11Tread mm 1180/1190
12Clearance mm 165
L mm 4145 4165 42
09
Dimension
15 W mm 1480
H mm 2
275
Loaded kg 9010 9750 10500
Front Axle
Axle load
Unloaded kg 2750 2710 2680

16
Loaded kg 1590 1550 1600
Rear Axle
Unloaded kg 3850 4090 4420

-13-
Model GM4. c
3L ertified
Type 6-cylinder, water-cooled Bi-fuel Engine

Engine

Hydraulic System

23
Front wheel 8.
25-15-14PR 300-15-20PR
5
Tyre
24
5
Model BZZ1-160
Steering
25
Steering angle
Steering (inner wheel) 78°42′
26 Steering angle
Axle
(outer wheel) 54°36′
-14-
III.CONSTRUCTION AND PERFORMANCE OF MAIN PARTS
1. ENGINE:
Table No.1
Engine model DIESEL DIESEL DIESEL DIESEL
Main
performance CA4110/125-HY20 4RMG25-1 S6S R754ISE4
Rated Output(KW) 61 59 52 54.5
Rated speed (rpm) 2200 2400 2300 2300
Max. Torque(Nm/rpm) 305 280 248 284
For trucks model 0
CPCD40～5-WX5 CPCD40～50-WF6 CPCD40～5
0 0
-M2 CPCD40～5VM1
Table No.2
Engine model GASOLINE(LPG、 BI-FUEL) GASOLINE(LPG、 BI-FUEL)
Main performance GM4.3L Non-certified GM4.3L certified
Rated Output(KW) 70 70
Rated speed (rpm) 2300 2300
Max. Torque((Nm/rpm) 287 287
For trucks model CPQ(Y)D40~50-TY5 CPQ(Y)D40~50-TY6
Engine models and parameters are shown in Table 1 to table 2. The construction of the
engine refer to the ENGINE OPERATION MANUAL.
The power of the engine is transferred to the front axle to satisfied the needs of traveling
though the torque converter and the torque converter type transmission, is transferred to the
operation pump to meet the needs of the hydraulic system and the load handing system
through the pulley and drive shaft.
2. TORQUE CONVERTER TYPE TRANSMISSION
Torque Converter
Type: 3-element, 1-stage, 2-phase type
Stall Torque Ratio: 3
Pressure Setting(Out pressure): 0.5-0.7Mpa
Charging Pump
Type: Built-in gear type
Discharge: 25mLl/r
Transmission
Type: Power-shift constant mesh
-15-
Gear Ratio: fwd 3.232/2.143 rev 2.727
Clutch
Clutch facing size (mm): 134×90×2.8
Surface area: 7740(mm)×12
Pressure setting: 12-15kg/cm2
Oil to be used: Torque converter oil 20L
Differential
Reduction Ratio: 6.333
Weigh: 184kg
Oil to be used: Torque converter oil 7L
2-1 GENERAL DESCRIPTION
The power-shift transmission mounted on this series forklift truck is designed and made
in our HELI CORPORATION on the basis of incorporation the advanced experience of the
home and abroad, it has excellent features as follows:
(1)An inching vale provides the machine with improved inching performance. Due to
this vale, the lift truck is allowed to perform inching operation regardless of whether the
engine is at low RPM or at high RPM, and when the truck is started up.
(2)As clutch plates, three steel plates and the same number of composite plates subjected
to special treatment are provided so that improved durability can be ensured.
(3)A free wheel installed in the torque converter improves transmission efficiency.
(4)The torque converter circuit is given an inline filter to improve its durability.
-16-
Fig.2-1 Torque Converter Type Transmission
1.
Converter inlet relief valve 2. Converter outlet relief valve 3.
Turbine shaft
4. Torque converter 5. Ball bearing 6.
Output gear
7. Counter gear 8.Main speed reducer
9.
FWD 2nd speed clutch 10. Hydraulic clutch 11. Control valve
12.
Charging pump 13.Gear pump drive
2-2 TORQUE CONVERTER
The torque converter consists primarily of a pump wheel connected to the input shaft, a
turbine wheel connected to the output shaft, and a stator wheel fixed to the housing.
The pump wheel is rotated by the drive shaft and fluid is strongly ejected along the row
of pump wheel vanes under centrifugal force. (In this state mechanical energy is converted
into kinetic energy.) The ejected fluid flows in the row of turbine wheel are changed by the
stator wheel so that it flows into the pump wheel at proper angle. At this time reaction torque
pushing the stator is created so that the output torque exceeds the input torque by this reaction
torque. As the rotational speed of the turbine wheel increases and gets close to the input
rotational speed, angle change of the fluid is reduced and the output shaft torque is decreased.
Finally fluid flows into the row of stator vanes in the reverse direction, causing reverse
-17-
reaction torque. As a result of this the output shaft torque becomes smaller than the input shaft
torque. To prevent this condition, a free wheel (one –way clutch) is provided at the stator
section to allow the stator wheel to rotate freely when reaction torque acts in the reverse
direction.
The output torque is kept equal to the input torque so that highly effective operation is
ensured. Since the phase of torque transmission is converted by the mechanical means
(clutch), this type of torque conversion.
The torque converter section of the torque converter transmission is connected through
the flex plate to the engine flywheel and designed to rotate as the engine rotates. Inside the
torque converter case are turbine wheel, pump wheel, and stator wheel. The inner space is
filled with torque converter oil. The drive gear is splinted to the pump wheel to drive the
charging pump. The turbine wheel is splinted to the main shaft to transmit the power to the
hydraulic clutch.
Fig.2-2 Torque Converter

1. Input plate 2. Ball bearing 3. Turbine wheel 4. Stator wheel
5. One-way clutch 6. Impeller wheel 7. Ball bearing 8. “O”-ring
2-3 CLUTCH GROUS
The torque converter type transmission is provide with the forward clutch group and
reverse clutch group, each of which consists of 6 clutch disks and 6 steel plates assembled
alternately a piston, and an end plate. The piston is provided with piston rings on its inner and
-18-
outer circumferences encase to insure oil sealing during operation. The piston has a check ball
to prevent dragging.
The clutch surface and gear bushings are always lubricated with oil to prevent seizure.
When replacement of any clutch disk is needed, the mating steel plate should also be changed.
Fig.2-3 Clutch group

1. Seal ring 2. Seal ring 3. Ball bearing 4. Seal ring
5. Return spring 6. Piston 7. Seal ring 8. Conical plate
9. clutch plate 10. Steel plate 11. End plate 12. Snap ring
13. Thrust washer 14. Gear 15. Needle bearing 16. Thrust washer
17. Ball bearing
2-4 CONTROL VALVE
The control valve consists primarily of the directional selector valve, regulator valve,
accumulator piston , directional selector electromagnetic valve, Speed electromagnetic valve
and including valve. The accumulator piston, interlocked with the directional selector valve. Is
actuated by the operation of the directional selector spool.
The oil picked up by the gear pump flows into the control valve and flow regulated by
the orifice while its pressure is regulated to the specified pressure(12～15kg/cm2).
When the directional selector electromagnetic valve is placed in the forward or reverse
position, the pressure regulated oil is sent to the forward or reverse clutch pack by the
directional selector valve, while the accumulator piston is moved by the oil so that the shock
induced by clutch engagement is alleviated by operation of the accumulator along with the
orifice.
-19-
B C
ACCUMU. ATOR
活塞
A A
B C
Cross B-
sectional
viewB
剖面图 B-B
MODULATE SPOOL
调节阀杆
INCHING SPOOL
微动阀杆
OIL SEAL
油封
DETENT BALL
定位球
STOPPER
固定镙钉
Cross C-
sectional
viewC
剖面图 C-C
Cross
sectional
view
A-A
剖面图 A-A
Fig.2-4 Control Valve

1. Valve 2. Bolt 3. Washer
4. Directional selector electromagnetic valve 5. Speed electromagnetic valve
2-5 OIL CIRCULATION ROUTE
When the engine is stared and the charging pump is driven by the pump drive gear fitted
to the pump wheel boss, torque converter oil drawn from the oil tank (transmission case)
through the strainer by the pump and is routed under pressure to the main regulator valve and
the control valve in the converter housing. The oil necessary for clutch operation is set to the
specified pressure by the main regulator valve.
The oil which flows to the control valve is flow controlled by orifice and pressure
-20-
controlled by the pressure control mechanism to the specified pressure.
When the change lever is put in forward or in reverse, the oil is sent from the control
valve through the forward/reverse selector valve to the pressurization chamber of the forward
or the reverse clutch. Also some of the oil from the control valve flows into the accumulator
piston to help insure a smooth elevation of the clutch oil pressure.
The oil which flows to 2nd main regulator valve is pressure regulated by the conver inlet
relief valve to 5~7kg/cm and makes its way to converter wheels. The oil regulated by the
outlet relief valve flows through the oil cooler to the clutch groups and lubricates and cools
them before returning to the oil tank.
While the forward or the reverse clutch group is operating, the other clutch group is
rotating between the clutch disks and their mating plates. This area is thus lubricated with oil
from the oil cooler to prevent the plates from being seized.
When the brake pedal is pressed, the inching valve operates to drain most of the oil
flowing to the clutch from the inching valve into the transmission case.
TORQUE
CONVER
TER OIL
COOLER
变矩器油冷却器
LINE
FILTER
滤油器
CONVERTER
INLET
RELIFEF
VALVE
2
变矩器调节阀 5kg/cm ACCUMLATOR
(71psi) 蓄能器
2
MODULATE
VALVE
12～15kg/cm 调节器
(171～213psi)
MODULATE
VALVE INCHING
VALVE
CHOKE
调节器微动阀
节流孔
SELECTOR
VALVE
CHARGING PUMP 操纵阀
供油泵
STRAINER FWD2ND
CLUTCH
滤油器前进2档离合器
FWD1SD
CLUTCHRWV 1SD
CLUTCH
前进1档离合器后退1档离合器
Fig.2-5 Oil Circulation Route
-21-
2-6 CHARGING PUMP
The charging pump is a gear type and is installed in the torque converter housing, It
feeds oil to the torque converter, hydraulic clutches and transmission to lubricate them.
The charging pump consists of the drive gear, driven gear, case and cover, see Fig.2-6.
Fig.2-6 Charging Pump

2-7 DIFFERENTIAL
The differential is fitted to the rear case (reduction gear case) by ball bearings with
bearing caps and covered with the axle housing.
The cross case of the differential is of the split type containing two side gears and four-
pinion gears. The thrust plate is installed between the cross case and each gear according to
the backlash.
The pinion gear is supported by the pinion shaft, which is secured to the cross case with
a knock pin. The ring gear is installed on the circumference of the cross case with reamer
bolts.
The rotation sent from the transmission through the reduction gear is further reduced and
differentiated by this device to drive the drive shaft.
-22-
Fig. 2-7 Differential
1.Ring gear 2. Thrust washer 3.Side gear 4. Cross case
5. Pinion shaft 6. Pinion gear 7. Thrust washer 8. Drive pinion gear
9. Adjust nut 10. Tapered roller bearing 11. “O”-ring 12.Oil seal
13.Bearing case 14. “O”-ring 15. Tapered roller bearing 16. Adjust screw
17 Lock nut 18. “O”-ring 19. Carrier 20. Roller bearing
21. Tapered roller bearing 22. Adjust nut 23. Bearing cap 24. Stopper
2-8 DIFFERENTIAL MAINTENANCE
Reassemble the differential in the sequence opposite to disassembly, observing the
following conditions:
(1)Adjust the backlash between the side gear and pinion to the specified value.
Specified backlash: 0.23~0.33 mm
Adjustment should be made by changing the spacers at the side gear side. Use spacers of
the same thickness at each side.
Spacers: 1.8, 1.9, 2.0, 2.2, 2.3, 2.6 mm
(2)Tighten the cross case assembling bolts to the specified torque and make sure the side
gears are rotating without inference.
Tightening torque: 130~195N.m
(3)Tighten the ring gear fitting bolts to the specified torque.
(4)Adjust the preload of the drive pinion to the specified value.
-23-
Adjustment should be made by using the shims between the tapered roller bearing and
spacer
Shims: 0.1, 0.15, 0.2, 0.5, 2.3, 2.6 mm
(5)Adjust the backlash between the drive pinion and ring gear to the specified torque.
Backlash: 0.23~0.33mm
Adjustment should be made by using the shims between the bearing case and the carrer.
Adjust the engagement either.
(6)Tighten the bearing cap fitting bolts to the specified torque.
3.FRONT AXLE
Type Front two-wheel drive, full-floating
Tire Size 8.25-15-14PR 300-15-20PR
Rim Size 8.00V-15
Air Pressure 0.83MPa

The front axle is a full-floating type and cast into one piece construction consisting of the
axle housing, wheel hub, brake drums and wheel brakes, as shown is Fig.3-1. It is installed at
the front of the frame.
-24-
Tightening Torque:98-113Nm
Lithium Erease:240mL
Albany Erease:240lM
Fig.3-1 Front Axle

1. Oil seal 2. Brake drum 3. Hub 4.Dual tire ball nut 5.Ball nut
6. Tapered roller bearing 7. Oil seal 8. Axle shaft 9. Tapered roller bearing
10. Wheel assembly
-25-
3-2 AXLE HOUSING
The axle housing is a one –piece construction consisting of a banjo-shaped differential
housing and spindle and is secured to the frame with ban sector.
3-3 FRONT WHEEL HUB
The front wheel hub receives the power from the differential through the drive shaft and
drives the front wheels. The brake drum and rim are fitted to the front wheel hub with hub
bolts and nuts. The hub is installed on the axle housing by two tapered roller bearings. The
back-up plate is secured to the axle housing and house inside the brake drum.
The total weight of the truck is sustained by the hub and axle housing, and thus the drive
shaft only drives the wheels.
Inside the hub are inner and outer oil seals to prevent oil leaks.
3-4 MAINTENANCE
3-4-1 PRELOAD ADJUSTMENT
(1)Tighten the bearing nut and then turn back 1/8 circle.
(2)Tighten the bearing nut gradually while measuring the preload.
(3)When the preload is reached locks the nut with the lock nut and lock washer.
3-4-2 WHEEL INSTALLATION PROCEDURE
(1)Installing single wheel
[1]Align the wheel fitting holes and the hub stud bolts and install the wheel.
[2]Hand tightens 6 wheel nuts in a diagonal order.
[3]Tighten 6 wheel nuts evenly in several stages in a diagonal order.
[4]Tighten all wheel nuts to the specified torque.
(2) Installing double wheel
[1]Align the wheel fitting holes with the hub stud bolts and install the inner wheel.
[2]Tighten 6 inner wheel nuts by hand.
[
3]Tighten 6 inner wheel nuts evenly in several stages in a diagonal order.
[4]Tighten all inner wheel nuts to the specified torque.
[5]Align the outer wheel fitting holes with both the inner wheel position and the air valve
passing hole and install the outer wheel.
[
6]Tighten 6 outer wheel nuts by hand.
[3]Tighten 6 outer wheel nuts evenly in several stages in a diagonal order.
-26-
[
4]Tighten all outer wheel nuts to the specified torque.
Notes: If remove sand or any other contamination on the mating surfaces of the rim and
the hub and on the thread of the nuts or stud bolts.
4. BRAKE SYSTEM
Type Front-wheel braking, internal expansion hydraulic type
Type Hydraulic type

Booster
Pressure setting 50 kg/ cm2
Servo ratio 4.5
Type Dou-serve type
Pedal ratio 5.0

Wheel brake
Wheel cylinder bore 31.75mm
Brake drum inner diameter 317mm
Lining size 330×63×10mm
Surface area 416cm2
Parking brake Type Front two-wheel braking internal expansion, hydraulic type

The brake system consists of a brake pedal, wheel brakes and brake drums, a booster,
pipes and so on.
4-2. BRAKE PEDAL
The brake pedal is installed on the transmission as shown in Fig.4-1. The push rod
connected to the brake pedal pushes the booster reaction piston and its force is converted into
oil pressure and transmitted to the wheel cylinders.
The un-lubricated bearing is mounted between the brake pedal and shaft, so the
lubrication is not to be needed.
-27-
Fig.4-1 Brake pedal (Torque Converter Model)
4-3 WHEEL BRAKE (Fig.4-2)
The wheel brake is the internal expansion hydraulic type consisting of brake shoes,
springs, a wheel cylinder, an adjuster and backing plates. Two wheel brakes are provided on
each end or the front axle. The brake shoe, its one end being connected to the anchor pin and
the other end to the adjuster, is forced against the backing plate with a hold spring and pin.
The primary shoe is provided with the parking brake lever and the secondary shoe with the
actuator lever of the automatic clearance adjuster.
-28-
Fig.4-2 Wheel Brake
1. Retainer 2. Wheel Cylinder 3. Cup 4. Piston 5. Push rod
6. Strut 7. Return spring 8. Brake shoe 9. Hold-down pin
10. Cap 11. Spring 12. Spring 13. Adjuster lever 14. Adjuster
The braking operation in forward travel is as follows: (see Fig.4-3) the primary and
secondary shoes are forced by an equal force, by operation of the wheel cylinder to bring the
lining in contact with the brake drum. The primary shoe forces the adjuster with the aid of
lining to drum friction force. Due to this, the adjuster pushes the adjuster end of the secondary
shoe by a large force than that offered by the wheel cylinder operation. The secondary shoe
anchor end is forced strongly against the anchor pin, providing large braking force. On the
other hand, the braking operation in reverse travel is performed in the reverse direction, but
the braking force is the same as in the case of the forward travel. (Fig.4-4)
-29-
nim
Anchor pin
of d
n
ctio
dire
Working force
aing
Working force
Secondary
Secondary
Rot
ary
ary
Prim
Prim
Adjusrer
Fig.4-3BRAKE
4-4 PARKING In Forward Fig.4-4 In Reverse
The parking brake consists of the parking brake lever and cable as shown in Fig.4-5. The
brake shoes and brake drum are commonly used with the wheel brake system. The brake lever
is a toggle type which allows the adjustment of braking force with the adjuster at the tip or the
lever.
Push in adjuster with a scewdriver

and turn it for to agjust
Fig.4-5 Parking Brake

4-5 AUTOMATIC CLEARANCE ADJUSTER
-30-
The automatic clearance adjuster keeps a lining to break drum clearance of 0.4~0.6mm
automatically. This adjuster, however, actuates only when the truck is braked in reverse travel.
When the break pedal is pressed in reverse travel, the brake shoes are expanded. As a result of
this, the secondary and primary shoes come into contact with the brake drum and rotate
together until the upper end of the primary shoe comes into contact with the anchor pin.
On the other hand, as the secondary shoe leaves the anchor pin, the section (A) of the
actuator lever is relatively pulled. Therefore, the actuator lever turns around the section (B) so
that the section (C) of the actuator lever lowers carsing the section (D) of the adjuster to turn
to the left. As the brake pedal is further pressed, compression force applied on the adjuster
becomes larger. This result in increased resistance on the thread so that the actuator lever force
can not turn the section (D).
4-6 POWER BRAKE BOOSTER
The power brake booster consists of the control valve which converts pedal pressing
force into hydraulic pressure, and the master cylinder and the flow divider, as shown in Fig.4-
6.It makes uses of the power steering hydraulic pressure for its operation.
When the brake pedal is pressed, the depression of the brake pedal is transmitted
through the push rod to the control vale input piston, narrowing the part “A”. This in creases
the oil pressure at the part “B”,
moving the input piston to the left while opening the part “A”, so that the oil pressure at
the part “B” ceases to rise and the input piston stops.
The action of the input piston pushes the master cylinder piston, increasing the oil
pressure inside the wheel cylinder.
Some of the pressure at the part “B” acts on the input piston as a reaction force so that
it is felt by the driver as steering feel.
-31-
Fig.4-6 Power Break Booster
1. Body 2. Cup 3. Flow divider 4. Spring 5. check valve
6. Plug 7. Stopper 8. Piston 9. Power piston 10. Control valve
11. Seat 12. Reaction piston 13. Push rod
4-7 MAINTENANCE
This paragraph covers the procedures for disassembling, reassembling and adjusting the
wheel brake, and the procedure for adjusting the brake pedal. Some sketches may be different
from the actual unit. But the maintenance procedure is the same.
4-7-1 WHEEL BRAKE DISASSEMBLY
(1) Remove the secondary shoe hold-down spring, adjuster ever, adjuster and return
spring.
Fig.4-7
-32-
(2) Remove the shoe return spring.
Fig.4-8
(3) Remove the primary shoe hold-down spring.
Fig.4-9
(4) Remove the primary and secondary shoes along with the adjuster and adjuster spring.
Fig.4-10
-33-
(5) Remove the brake pipe from the wheel cylinder. Remove the wheel cylinder
mounting bolts and take the wheel cylinder off the backing plate.
Fig.4-11
(6) Remove the "E" retainer securing the parking brake cable to the backing plate.
Remove the backing plate fitting bolts and detach the backing plate from the axle.
Fig.4-12
(7) Remove the boot, and push the piston into the cylinder from one side while removing
the parts at the other side. Then push out the remaining parts from the opposite side.
Fig.4
-13
4-7-2 INSPECTION
Inspect all the parts for wear and damage. Repair or replace any defective parts with new
ones.
-34-
(1)Inspect the wheel cylinder’s inner surface and piston’s outer surface for sign of rust.
Measure the clearance between the piston and cylinder. Specified value: 0.03-0.10mm
Limit: 0.15 mm
(2)Visually check the piston cup for damage or deformation and replace it, if defective,
with a new one.
(3)Measure the free length of the wheel cylinder spring. If unsatisfactory, replace.
Fig.4-14
(4)Measure the brake lining thickness and if worn beyond the limit. Replace it with a
new one.
Specified value: 10.0 mm
Fig.4-15
(5)Visually check the brake drum inner surface for scratches, nicks or uneven wear, and
if found, repair by grinding. If the surface is badly scratched or worn, replace.
Standard size: 317.5 mm
Limit: 319.5 mm
Fig.4-16
-35-
(6)Measure the free length and setting load of the anchor side shoe return spring.
(7)Check the adjuster for damage and operation, and the contact area between the pole
lever and the gear for defect. Replace if necessary.
4-7-3 WHEEL BRAKE REASSEMBLY
(1)Apply brake fluid to the wheel cylinder cup and piston, and reinstall the spring, piston
cup, piston and boot in that order.
(2)Install the wheel cylinder to the backing plate. Note: Make sure each of the parts is
located on the right position.
Tightening torque: 18-27N.m
(3)Install the backing plate to the front axle.
Tightening torque: 120-140N.m
(4)Apply heat-resisting grease on the points indicated in Fig.4-17. Using caution so as
not to allow the lining to be contaminated with grease.
(a)Backing plate shoe ledge surface.
(b)Anchor pin
(c)Cable guide surface on which adjuster cable is to contact.
(d)Parking brake lever pin.
(e)Adjuster thread and its rotating part.
Fig.4-17
(5)Install the parking brake cable with “E” retainer.
(6)Install the shoes with the hold-down spring.
-36-
Fig.4-18
(7)Put the anti-rattle spring in the strut and install them on the shoe.
(8)Install the shoe guide pin on the anchorpin. Install the shoe return spring. For this
procedure, start with the primary shoe and then proceed with the secondary one.
Fig.4-19
(9)Install the spring, adjuster, adjuster spring and adjuster lever, observing the following
points:
[1]The left-side brake unit has a left threaded adjuster and the right-side brake unit has a
right threaded one.
[2]The adjuster teeth do not contact the spring.
[3]The adjuster shoe return spring is installed with the longer hook going to the adjuster
lever.
[4]After reassembly, make sure the adjuster lever end is in contact with the adjuster teeth.
-37-
Fig.4-20
(10) Install the brake pipe on the wheel cylinder.
(11) Measure the brake drum inner diameter and the shoe outer diameter. Adjust the
adjuster so that the brake shoe outer diameter is drum inner diameter-1.0mm.
Fig.4-21
4-7-4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER
(1) Make the brake shoe diameter nearly to the specified setting size, and pull the
adjuster lever by your hand to turn the adjuster gear. When removing off your hand, the
adjuster lever returns to the original position.
Note: the adjuster gear may turn back slightly along with the adjuster lever when
removing your hand, but the adjuster will operate normally when it is put back on the truck.
(2) If the adjuster fails to do normal operation when pushing the adjuster lever, tack the
following steps:
(a) Make sure the adjuster lever, adjuster, adjuster spring, adjuster cable and shoe return
spring is securely installed.
(b) Check the shoe return spring and adjuster spring for deterioration. Also check
whether the adjuster is rotating properly, its teeth are free from damage and wear.
-38-
Fig.4-22
4-7-5 BRAKE PEDAL ADJUSTMENT
(1) Shorten the master cylinder push rod properly.
(2) Adjust the pedal height with the stopper bolt as shown in Fig.4-23.
(3) Keeping the pedal pressed 30mm, extend the push rod so that the its end contact the
master cylinder piston.
(4) Tighten the push rod lock nut.
Fig.4-23
-39-
4-7-6 BRAKE SWITCH ADJUSTMENT
(1) After making sure that the brake pedal height is as indicated in Fig.4-23, loose the
brake switch lock nut.
(2) Remove the brake switch lead wire from the connector.
(3) Turn the switch so that the size at “A” is 1mm.
(4) Make sure the brake lamps turn on when the brake pedal is pressed 30mm.
4-7-7 AIR BLEEDING
(1) Place the truck on a level surface and apply the parking brake securely.
(2) Shift the transmission in neutral and shut off the engine.
(3) Connect a vinyl tube to the bleeder plug of the wheel cylinder and put the open end
of the hose in a pan.
(4) Start the engine.
(5) Press the brake pedal and hold it. Loosen the bleeder plug.
(6) When no air bubbles are observed in the oil coming from the bleeder plug, tighten the
bleeder plug.
(7) Use the same procedure for the other side of the brake unit.
-40-
4-8 TROUBLE SHOOTING OF THE BRAKE SYSTEM
Problem Probable cause Remedy
1.Fluid leaks from brake system Repair
2.Maladjustment of brake shoe clearance Check and adjust adjuster

Poor braking
3.Overheated brake Check for dragging
4.Poor contact between brake drum and lining Adjust contact
5.Foreign matter adhered to lining Repair or replace
6.Foreign matter mixed in brake fluid Check brake fluid level
7.Maladjustment of brake pedal Adjust
1.Hardened lining surface or foreign matter adhered Repair or replace

Noisy brake
2.Deformed backing plate or defective bolts Repair or replace
3.Deformed or improperly installed shoe Repair or replace
4.Uneven wear of lining Replace
5.Defective wheel bearing Replace
1.Contaminated lining Repair or replace
2.Maladjustment of brake shoe clearance Check and adjust adjuster

Uneven braking
3.Malfunctioning wheel cylinder Repair or replace
4.Defective shoe return spring Replace
5.Run out of drum Repair or replace
6.Improper in pressure of tire Adjust
1.Brake fluid leaks from system Repair

Soft or spongy
2. Maladjustment of brake shoe clearance Check and adjust adjuster
3.Air mixed in brake system Bleed air out of system

brake
4. Maladjustment of brake pedal Adjust
-41-
5.STEERING SYSTEM (ORBITROL TYPE)
Type Center-pin supported
King pin spacing 1020mm
King pin angle 0°

Steering axle
Ton-in 0°
Camber 1°
Caster 0°
Inner wheel 78°42′

Steering axle
Outer wheel 54°36′
Type Open-entered, no-load reaction type
Redirector Discharge 160ml/r
Pressure 12.5MPa
Type Double-acting piston type
Cylinder bore 90mm

Steering cylinder
Piston rod diameter 60mm
stroke 226mm

The steering system consists primarily of a steering wheel, orbitrol flow regulator valve,
steering axle, and steering cylinder. When the steering wheel is turned, the movement is
transmitted to the orbitrol. The oil passages in the orbitrol are changed over to direct the hydraulic
pressure from the flow regulator valve to the steering cylinder which extends or contracts
depending on the hydraulic pressure, thereby steering the truck. The oil can not be supplied from
the pump while the engine stops. The truck is steered by the manpower, but it is too difficult.
The steering cylinder is double acting type. Two sides of piston rod are connected with the
knuckle by the push rod. The pressure oil from the orbitrol is transmitted to the steering cylinder,
and pushes the piston rod to rotate. So the truck is steered.
-42-
5-2 STEERING AXLE
The steering axle is of steel-welded construction with a box shaped cross section,
incorporating a steering cylinder inside it. See Fig.5-1. The steering cylinder is housed in the axle
to protect it from being damaged by obstacles on the road surface. The axle is installed onto the
truck frame through a center pin with bushing and cap, and it cradles around this center pin.
Trghtening torque:1500-2000Kg.cm
Fig.5-1 Steering axle
5-3 STEERING WHEEL ASSEMBLY

The steering wheel assembly is arranged as shown in Fig.5-2.The orbitrol is located at the
bottom of the assembly. At the center of the wheel is the horn button.
The steering shaft is connected through the universal joint to the drive shaft of the orbitrol so
that the steering wheel can be moved to a certain extent back and forth to suit the driver's
physique.
-43-
Fig.5-2 Steering Wheel Assembly
5-4 ORBITRON
The orbitrol of model BZZ cycloidal type is open-centered, no-load reaction device (Fig.5-3).
The rotor and the stator is a pair of cycloidal pin gear internal mesh gears. It is serried between the
flow dividing valve and the steering cylinder during normal operation, it operated as an oil motor.
The turning angle is direct proportion with the oil which flows to or from the steering cylinder
because the oil must flows through the oil motor.
The steering wheel is connected with the valve core by the retainer 1, and moves the sleeve 6
by the spring 4. The sleeve 6 is connected with the rotor 9 by the shift arm 5 and the drive shaft 8.
The rotor 9 does not move because the oil route is not connected. When the steering wheel is
turned, the rotor 9 moves between the valve core and the sleeve. So the oil is sent to the steering
cylinder through the oil motor. When the steering wheel is not turned, the valve core and the sleeve
is located in neutral position by the spring 4 to shut off the oil route.
In an emergency, the sagety valve 14 is opened by vacuum to from return route within the
valve. The oil motor can be used as hand pump to send the oil from one chambers of the steering
cylinder to another, so the manpower turning is accomplished.
-44-
Fig.5-3 Orbitrol
1. Retainer 2. Head cap 3. Valve 4. Spring 5. Shift arm
6. Sleeve 7. Valve core 8. Drive shaft 9. Rotor 10. End cap
11. Spacer 12. Stator 13. “O”-ring 14. Steel ball 15. “O”-ring
16. “X”-ring 17. “O”-ring
(1) Operation of orbitrol
(a) In “Neutral”
While the steering wheel is in straight position, the oil from the pump flows through oil
passage (1) to oil groove (2). The sleeve has 24 oil holes (3) which are now in line with the
holes (4) in the spool so that the oil that flowed into groove (2) passes through oil holes (3)
and (4) to space (5) between the spool and drive shaft. Then the oil flows through spool
groove (6) and sleeve groove (7) back to the oil tank.
Since cylinder ports (20) and (21) are respectively open to oil holes (18) and (17) in the
sleeve but not to groove (16) nor (19) in the spool, the oil in the cylinder does not go any
where.
Oil passage (15) that leads to the hydraulic motor is open to oil hole (14) in the sleeve
which is used as the inlet and outlet for the hydraulic motor, but not to grooves (13) nor (16)
in the spool and thus the oil remain unmoved.
-45-
L R
20 21 15
6 14 13 23 12
5
6 16 4
3 4
7 3
8 2
10 11
9
1 15
L R
20 21 15
14
3 15 12
6
7 17
22 23
8
10 11 16
9 15
1
Fig.5-4
(b) When steering wheel is turned counter-clockwise
As the steering wheel is turned counter-clockwise, the grooves in the spool shift to the
left in relation with the holes and grooves in the sleeve so that holes (4) in the spool get out of
line with holes (3) in the sleeve. The oil that has flowed into groove (2) thus far begins to flow
into hole (12) in the sleeve, passing through grooves (23) and (13) in the spool, hole (14) in
the sleeve, and oil passage (15) in the housing, to the hydraulic motor.
The hydraulic motor thus rotates in the counter-clockwise direction and the oil
discharged from the hydraulic motor flows through oil hole (14) in the sleeve, groove (16) in
the spool, and oil hole (18) in the sleeve to the cylinder port L and thus actuates the steering
cylinder.
-46-
The returning oil from the steering cylinder flows, assign through the cylinder port R,
groove (11) in the valve housing, oil hole (17) in the sleeve, groove (19) in the spool, oil hole
(22) in the sleeve, and groove (8) in the valve housing, back to the oil tank.
L R
20 21 15
8 16
18
22 10 14
19 15 23 12 3
22 8 17 11 14
2
9
1
L R
20 21 15
10 11 14
8 9
17
6 16 16 4
15 12
7
23
22
2
9
12
1
Fig.5-5
(c) When steering wheel is turned clockwise
As the steering wheel is turned clockwise, the grooves in the spool shift to the right in
relation to the oil holes and grooves in the sleeve so that oil holes (4) in the spool get out of
with holes (3) in the sleeve. The oil that has flowed into groove (2) thus far begins to flow into
hole (12) in the sleeve and then flows through grooves (23) and (13) in the spool, oil hole (14)
in the sleeve, and oil passage (15) in the valve housing to the hydraulic motor. The hydraulic
motor thus rotates in the clockwise direction and the oil discharged from the hydraulic motor
flows through oil hole (14) in the sleeve, groove (16) in the spool, and oil hole (17) in the
sleeve to the cylinder port R in the housing and thus actuates the steering the steering cylinder.
-47-
The returning oil from the steering cylinder flows, passing through the cylinder port L,
groove (10) in the housing, oil hole (18) in the sleeve, groove (19) in the spool, oil hole (22)
in the sleeve and groove (9) in the housing back to the oil tank.
L R
20 21
22 8 18
10
19 14 13 23 12
16 3
9 17 11 14 2
15
1
L R
20 21 15
8 10 11 14
3
22 19 18
17 16 4
7 13 12
6 23
9 2
15
1
Fig.5-6
(2) Relationship between rotating speed and operation force of steering wheel
In principle, the force required to operate the orbitrol is only the force to change over the
valve, the force of compressing the centering spring is 0.3kg.m. In other words, since there are
no mechanical connections between the steering wheel and the tires and only the spring
compressing force is required, constant steering force is kept even at increased rotational
speed. The discharge of oil supplied from the rotor of the orbitrol to the cylinder is 160ml/r.
(3) Neutral feedback of orbitrol
-48-
The neutral feedback of the orbitrol is performed by changing-over in oil passages of the
valve, due to the reactions force of centering spring. (When the steering wheel is turned and
then released with the engine at rest, the steering wheel returns to the initial position.) Unless
the nevtral feedback is completely performed, the steering wheel may be turned, even through
the operator does not turn the steering wheel.
(4) Steering with defective pump
When the pump fails to supply hydraulic oil the orbitrol serves as an emergency hand
steering device. When the steering wheel is turned, the spool rotates. When turned by about
8°, the spool contacts the cross pin, which rotates the drive shaft, which in turn rotates the
rotor. Thus, the metering device serves as a hand pump to supply oil to the cylinder. In this
case the check valve provided between the return port and the suction port opens, so that oil
flows from the cylinder to the suction side, thereby effecting an emergency steering.
5-5 STEERING CYLINDER (Fig.5-7)
The steering cylinder is installed in the rear axle and is operated by oil from the orbitrol.
The cylinder body is secured to the axle, with both rod ends connected to the knuckle with
joints.
Fig.5-7 Steering Cylinder

5-6 TROUBLE SHOOTING
-49-
6.HYDRAULIC SYSTEM
Problem Possible cause Remedy

Defective or damaged pump Replace
Steering wheel
Relief vale stuck or damaged Clean or replace
won't operate
Control valve stuck, damaged, or worn Replace or repair
Damaged hose joint or clogged oil line Replace or clean
Low oil level in oil tank Add oil
Hard steering Insufficient air bleeding Air bleeding
wheel Low oil pressure See previous item
Control valve stuck or damaged Clean or replace
Loose control valve spool Retighten lock nut
Truck wanders
Damaged control valve Replace
or vibrates
Broken or deteriorated spring Replace
Low oil level in oil tank Add oil
Clogged suction pipe or filter Clean or replace
Noisy operation
Control valve stuck or damaged Replace
Improperly-installed or damaged “O”-ring or Replace
Oil leaks
oil seal for piping or control valve
-50-
Model CBKa-G425-ATφL/ CBKa-G425-ATφ
Type Gear type

Main pump Drive Speed box PTO
Discharge 50ml/r
Loaded pressure 20MPa
Model CBD-F20U
Spool sliding type, with relief valve, tilt lock valve, and
Control valve Type
flow divider.
Pressure setting 19MPa
Type Single acting piston with flow regulator.
Cylinder bore 85mm

Lift cylinder
Rod diameter 70mm
Stroke 1495mm
Type Double acting type
Cylinder bore 90mm

Tilt cylinder
Rod diameter 45mm
Stroke 193mm
The machine adopts double pumps hydraulic system (Fig.6-1). The pressure oil within
the main pump is driven by the P.T.O. fixed on the pump wheel bed of the torque converter, to
flow through the flow dividing valve into the brake system to brake. The other way into the
control valve, through the flow dividing valve within the control valve can be supplied to the
orbitrol, and then is transmitted through pipe into the steering cylinders acconding to steering
condition. The control valve controls the lift and tilt cylinders.
6-1 HYDRAULIC PUMP
The model of the hydraulic pump is CBKa-G425-AT￠/L type high-pressure gear pump.
Its displacement is (25×2)ml/r. The pump is double gear pump type, consists of the driving
gear, driven gear and pump body.
-51-
Tilt Cylinder
Steering Cylinder
Steering Capacity:12L/min
Lift Cylinder
To Break Pump Break Valve
Lood Sensor
Redirector
Fig.6-1 Hydraulic System Principle Diagram

6-2 FLOW DIVIDING VALVE (Fig.6-2)
The model of the flow-dividing valve is 21730-40667 type (the home type is 1WFL-
F15L-6). Its function supplying hydraulic oil to the loading system (except lift and tilt
cylinder). In addition supplying part oil to the brake system to complete power brake.
-52-
Relief valve Outlet Parallel feeder
Parallel feeder Lift valve Tilt valve
Flow dividing
valve
Fig.6-2 Flow Dividing Valve

6-3 CONTROL VALVE
The model of the control valve is CBDF-F20U, unit combination type. Add control
valves if needs. The valve's function is carrying respectively high pressure oil came from oil
pump to each hydraulic cylinder, making back oil returning to the tank, and changing the flow
direction by operating control lever.(Fig.6-3)
The control valve consists of an inlet section. Two plunger sections and an outlet section
which are assembled with three bolts. The control valve is slice type. On the inlet section has
a main relief valve. Under it has a steering valve, which regulates the main and steering circuit
oil pressures respectively.
The two plunger sections are used for lift and tilt circuits, separately. The oil flow is
changed by operating lift and tilt valve stems to control the cylinders.
The tilt plunger has a tilt lock valve. The oil from the cylinder returns through the tilt
lock valve to the tank. Every slice of the valves is sealed by the O-ring. There is a load check
valve on the high-pressure passage.
-53-
LOAD CHECK VALVE
PARALLEL FEEDER
CYLINDER PORT B
CYLINDER PORTA
RETURN SPRING
PLUNGER
NEUTRAL PASSAGE LOW-PRESSURE PASSAGE
Fig.6-3 Control Valve

(1)Plunger operation
(a)In neutral state(Fig.6-4)
The oil disc harged from the pump flows through the neutral passage back to the oil tank.
The ports “A” and “B” are closed.
Fig.6-4
(b)When plunger is pushed in(Fig.6-5) the neutral passage is closed by the plunger and
the oil flows through the parallel feeder, pushing up the load check valveinto the cylinder port
“B”. The returning oil from the cylinder port “A” flows through the low-pressure passage to
the tank. The plunger is restored to neutral position by the return spring.
-54-
Fig.6-5
(c)When plunger is drawn out (Fig.6-6) with the neutral passage closed, the oil pushes up
the load check valve, passing through the parallel feeder, and flows into the cylinder port “A”.
The returning oil from the cylinder port “B” flows through the low-pressure passage to the
tank. The plunger is restored to and B, thus seating the poppet “D” neutral position by the
return spring.
Fig.6-6
(1)Port relief valve operation
(a)The relief valve is located between the high-pressure passage “HP” and the low-
pressure passage “LP”. The oil flows through the hole in the piston “C” and affects two
different areas A and B, thus seating the poppet “D” securely.(Fig.6-7)
Fig.6-7
(b)When the pressure in the high-pressure passage “HP” reaches the set pressure of the
pilot spring, the pilot poppet “E” opens. Allowing the oil to flow around the pilot poppet, past
the drilled hole, to the low-pressure passage “LP”(Fig.6-8)
-55-
Fig.6-8
(c)As the pilot poppet “E” opens. The pressure behind the poppet “D” drops. The inside
pressure becomes imbalanced against the pressure at the high-pressure passage side “HP” so
that the popper “D” is opened to this pressure differential. Thus allowing the oil to flow
directly to the low-pressure passage “LP” (Fig6-9).
Fig.6-9
(d)When the pressure in the high-pressure passage “HP” is lower than the pressure in the
low-pressure passage “LP” , the poppet “D” opens due to the difference in diameter between
the areas A and B. Thus allowing the oil to flow from the low-pressure oil passage “LP” to the
high-pressure oil passage “HP”.(Fig.6-10)
TILT CYLINDER
SPRING
POPPET PLUNGER
Fig.6-10
-56-
(3)Tilt lock valve operation
The control valve in the tilt cylinder circuit has a spool incorporating a tilt lock valve to
prevent the mast from vibrating due to possible creation of negative pressure in the tilt
cylinder and also to avoid danger incurred from mishandling of the tilt lever. (Fig.6-11)
PORT A PORT B
PLUNGER
POPPET
Fig.6-11
(a)When the plunger is drawn out, the oil flows in the same manner as in Fig.6-5.
(b)When plunger is pushed in
The oil from the main pump flows through the port “B” into the tilt cylinders. The
returning oil from the cylinders flows through the oil hole “A” to actuate the poppet. This
allows the oil to pass through the plunger holes “A” and “B” to the low-pressure passage and
back to the tank.(Fig.6-12)
(c)When plunger is pushed in with engine at rest
When the plunger is pushed in with the engine shut off, the oil does not flow to the
cylinder port “B” and the pressure at the area “P” does not rise as well, because the pump is at
rest. Since the poppet does not move the oil at the cylinder port “A” won’t return to the tank,
and thus the cylinders stand still. (Fig.6-13)
PORT A PORT B PORT A PORT B
PLUNGER PLUNGER
POPPET POPPET
Fig.6-12 Fig.6-13
-57-
6-4 LIFT CYLINDER
The lift cylinders are the single-acting type and are located behind the outer mast frame.
The bottom of each cylinder is supported by the mast support of outer mast frame with knock
pin and bolts. The piston head is held by the inner mast piston head guide.
The lift cylinder assembly consists primarily of a cylinder body, piston, piston rod,
cylinder cap, and piston head. A cut-off valve is installed on the right-hand side of the cylinder
body. At the lower part of the cylinder body is provided a high-pressure oil inlet, the upper
part is provided with a low-pressure oil outlet to which a return pipe is connected.(Fig.6-14)
The piston is fastened to the piston rod with a lock ring and has a wear ring and a
packing on its circumference and slides along the inside of cylinder by high-pressure oil. It
slides in the cylinder by high-pressure oil.
The cylinder cap is fitted with a bushing and an oil seal and is screwed into the cylinder
body. The bushing supports the piston rod, and the oil seal prevents dirt from entering the
cylinder. The right and left piston rods are connected with a connecting member with snap
rings.
When the lift lever is pulled toward the operator, the high-pressure oil flows into the
lower part of each lift cylinder so that both the piston rod and piston is raised. This lifts the
forks through the lift chains. On the other hand, when the lift lever is pushed forward, the
piston descends by the weights of the piston rod, piston head, lift bracket, finger bar and forks,
causing the oil under the piston to flow out of the cylinder. The oil discharged from the
cylinders is regulated by the flow regulator and returns through the control valve to the oil
tank, the upper part of the cylinder is filled with the air from the oil thank.
Since the flow rate of the returning oil from the lift cylinders is usually regulated by the
flow regulator, the pressure differential generated by the oil passing through the oil hole in the
piston's circumference is smaller than the spring force, and thus the piston won't move. If the
hose piston's circumference, therefore, the forks drops at a low speed as the oil in the lift
cylinders flows out of the piston head hole in a small amount.
-58-
Fig.6-14 Lift Cylinder
1. Piston Rod 2. Dust Seal 3. Cylinder Cap 4. Seal Ring 5. Bushing
6. O-ring 7. Cylinder Body 8.Shim 9. Piston 10. Bushing
11. Seal Ring 12. Seal Ring 13. Valve 14. Spring
6-5 FLOW REGULATOR VALVE

The flow regulator valve controls the fork descending speed and servers as a safety
device if the rubber hose ruptures between the control valve and the lift cylinders. It is
installed in the high-pressure oil port at the lower part of the lift cylinders.
The flow regulator valve operation is shown in Fig.6-15. When the forks are descended,
the returning oil from the lift cylinders flows into the chamber (G). The oil then flows through
the parts (F), (E), (D) and (C) to the chamber (B). The oil which left the chamber (B) flows,
passing through the oil hole in the piston (7) and the chamber (A), into the lift cylinders.
The piston (7) moves to the right depending upon the flow rate of oil which passes the oil
hole in the piston (7), and thus the hole (C) narrowed, restricting the flow rate of oil passing
the hole (C). this way, the fork lowering speed is controlled.
When the forks are raised, the high-pressure oil from the control valve enters through the
chamber (A) into the chamber (B). The oil then flows through the areas (C), (D), (E), (F),(G),
and into the lift cylinders.
-59-
Lift Cylinder side Control valve side
Fig.6-15 Flow Regulator Valve

1. nipple 2. Spring 3. “O”-ring 4. Snap Ring 5. Orifice
6. Sleeve 7. Piston 8. Ball 9. Spring 10. Casel
6-6 TILT CYLINDER (Fig.6-16)
The tilt cylinder is a double-acting type, and its piston rod end is supported by the mast
and the cylinder tail is connected to the frame with a pin. This is provided with two tilt
cylinders on both sides of its front.
The tilt cylinder assembly consists primarily of a cylinder body, cylinder cap, piston and
piston rod. The piston is welded to the piston rod and has two packing and one wear ring on
the circumference and moves along the inner surface of the cylinder by the force of hydraulic
oil.
Inside the cylinder cap a bushing are pressed fitted together with a packing and dust seal
to provide oil tight-ness for the piston rod and the cylinder cap. This bushing also supports the
piston rod. The cap is fitted with an “O”-ring on the outer periphery and is screwed into the
cylinder body and fastened with a lock ring.
When the tilt lever in the drive's room is tilted forward, the high-pressure oil enters the
cylinder tail, moving the piston forward. This causes the mast to tilt forward 6 degrees. When
the tilt lever is tilted backward, high-pressure oil enters the cylinder cap side and moves the
piston backward, tilting the mast 12degrees backward.
Fig.6-16 Tilt Cylinder
-60-
6-7 TROUBLE SHOOTING
Problem Cause Remedy

The pump does not The oil within the cylinder is not enough Add oil to the specified lever.
operate The pipe or the filter is struck. Clean, change oil if necessary.
The bearing in the pump is worn. Replace
The pressure of the relief is not right. Readjust
The pressure of the Retighten the joint.
high pressure oil is Add oil in the cylinder.
not enough. There is air within the pump. Check the oil seal.
Drive the pump until there is not
air bubble within the cylinder.
The side joints have loosened make air in. Retighten every joint.
From the free chamber because the oil Replace the right viscosity oil.
viscosity is too high. The pump is driven when the oil
Noisy operation of
the gear pump. temperature returns to normal.
Not concentric. Readjust and make them
There are air bubbles within the concentric.
hydraulic oil. Check and repair.
The oil within the The oil seal of the pump is damaged. Replace
hydraulic pump
leaks. The sliding area is worn. (internal) Replace
Hydraulic pump gear is damaged or oil Renew gear or replace pump.
leaks.
The oil seal of lift cylinder is damaged. Replace oil seal.
Lifting is weak or
The relief valve of control valve is out Repair
can not lift
of order.
Hydraulic oil temperature is too high, oil Change oil, check.
has gone thin, and oil flow is reduced.
The control valve has oil leakage. Repair
The oil seal of the lift cylinder is Replace oil seal.
The lower slippage
the forks are too damaged.
large and the mast The return spring of control valve is Replace return spring.
tilts automatically.
damaged. The sleeve is not in right
position.
-61-
7.LOAD HANDLING SYSTEM
Only for 2-stage standard mast.
Rolling type 2-stage telescopic mast with free lift(J-

Type
shaped inner rail and C-shaped outer rail)
O.D. of end roller Φ1230

-0.
15
O.D. of side roller Φ67
O.D. of retaining roller Φ55×Φ135×Φ148.
5
Lift chain LH1634,3×4
Upper roller 80308
Fork lifting system Hydraulic
Mast tilting system Hydraulic
Fork spacing adjustment Manual
Loading system is used forking, loading and unloading piling, and so on, consisting of
forks, mast, lift chain, lift cylinder and tilt cylinder. There are masts from 3m to 6m can be
chosen (Fig .7-1).
7-1 MAST
The mast is of the two-stage, CJ type rolling telescopic mast. The outer mast and the
inner mast are frame type welded construction. The support is welded to the under of the outer
mast, make the mast to connect with the driving axle body, to support loading system, and
return around the axle body. The support, which connects with the tilt cylinder, is welded in
the middle of the outer mast, the loading system returns around the driving axle center to
complete tilting forward or backward when the piston rod in the tilt cylinder telescopes. The
support, which supports the lift cylinder, is welded to the bottom of the outer mast. Each set of
rollers are located at the top outside and inside of each outer mast, are used to guide which the
inner mast is lifting in the outer mast. A sideward roller is installed at the lower outside of the
each inner mast. The end rollers connecting clearance of single side is from 0.5 to 1.0 mm
.The side ward rollers connect with the outer mast channel steel web plate to avoid the inner
mast tilting in crosswise. The clearance is from 0.5 to 1.0mm .The clearance is adjusted by
adding or reducing shims.
7-2 CARRIAGE
An end roller and a sideward roller are installed to the carriage. The way that to adjust
the clearance between bracket and flange plate of the outer or inner mast, or bracket and web
-62-
plate of mast is same as that above about inner and outer mast. Fork and bracket can run up or
down in the inner mast. The distance between two forks can be adjusted according to needs;
its range is from 300mm to 1340mm
7-3 LIFT CHAIN
The lift chain is flat type chain. Each of the ends of two chain is connected with the fork
bracket. and the other is connected with the top of outer mast after chain run round the chain
wheel.
Fig.7-1 Loading System

1. Lift Cylinder 2.Tilt Cylinder 3.Outer Mast 4. Inner Mast 5.Lift Chain
6.Fork Bracket 7. Fork
8. ELECTRIC SYSTEM
The electric system is composed of a starter circuit, charging circuit, lighting circuit,
controlling circuit and safe ting circuit which are respectively activated by one 12-volt battery
connected in series. The wring used for each circuit is classified by color and given sufficient
current capacities. The main part to the starter circuit is the starter, of the charging circuit is
the generator, of the lighting circuit is the different function lights, of the controlling circuit is
the ECU, electric accelerator pedal, oxygen sensor and different function sensors, of the safe
ting circuit is the control, seat switch and hand control switch.
-63-
In addition the wiring is further divided into meter panel wiring, frame wiring, overhead
guard wiring, rear lamp wiring and engine wiring, each connected with couplers.
8-2 SIGNAL AND OPERATION
(1)Starter switch:
a. Turn to right 1st to connect the meter and equipments supplied by power.
b. Turn to right 2nd to start the engine.
(2)Pre-heat indicator:
When zhe indicator shows light red,the pre-heat has finished while the stater switch is
turned to left 1st.
(3)Light switch:
Put the light switch to the forward 1st position, the clearance lamps are turned on. To the
forward 2nd, the head lamp and the clearance lamps are turned on.
(4)Turn switch:
Push the switch forward, the left turned lamps both in front and back and left turn
indicator are turned on, at this time the truck can be turned to left.
Pull the switch backward, the right turned lamps both in front and right turn indicator are
turned on, at this time the truck can be turned to right.
(5)Brake indicator:
Press the brake pedal, and the back brake lamp is turned on when the emergency braking
is needed.
(6)Back-up indicator:
Put the shelves switch in back-up gear position when the forklift truck is needed to
reverse, the back-up lamp is turned on, and the back-up buzzer makes voice.
(7)Oil pressure warning indicator:
Turn the key switch to right 1st, the indicator is turned on, and it is turned off after
twinkling times. Should stop the forklift truck to check if the indicator is turned on while it is
running.
(8)Charging indicator:
Turn the key switch to right 1st, the charging indicator is turned on. It is turned off after
the engine is driven, it shows charging. Should stop the truck to check if the indicator is
turned on while it is running.
(9)Fuel meter:
The fuel meter consists of the fuel indicator and the fuel sensor. It shows oil capacity
-64-
within the fuel tank.
(10)Water temperature meter:
It shows the temperature of cooling water. The indicator pan is classified by three colors
to show three ranges of the temperature. The engine can be operated under normal conditions
when the hand is between green ranges.
(11)Hour meter:
It works when the truck is driven, and shows the working times of the truck.
To sum up, general description of operating the forklift truck is shown as follows:
Put the shelves switch in idle gear position. Press the accelerator pedal, turn the key
switch to right 1st, and this time the indicators on the medal are turned on. When the key
switch is turned to right 2nd, the starter is driven to rotate the engine, charge of this indicators
are turned off when the engine is driven, and the forklift truck can be used.
Note: Re-driven the engine after two minutes if is not driven within five seconds.
Should not to operate the starter continuously more than 15 seconds.
-65-
8-3 WIRING DIAGRAMS
8-3-1 Diesel engine wiring diagrams
Fig.8-1 Diesel engine wiring diagrams

1.Overhead line 2.Combination Instrument 3. Combination switch
4.Electric wire plan 5.Vehicle line 6.Integrated electrical box
7.Storage battery 8.Controlling apparatus 9.Rear combination lamp line
10.Alarm lamp 11.Starter relay
-66-
8-3-2 Gasoline engine wiring diagrams
Fig.8-2 Gasoline engine wiring diagrams
-67-
IV. OPERATION, SAFETY INSTRUCTION AND MAINTENANCE
1. OPERATION AND INSTRUMENT
Operation and instruments of the forklift truck refer to the drawings.
OPERATION AND INSTRUMENT

1.Parking brake lever 2.Lamp switch 3.Steering wheel
4.Flameout pull button 5.Inching pedal 6.Start switch
7.Steering wheel adjust lever 8.Brake pedal 9.Accelerator pedal
10.Shift lever 11.Tilt lever 12.Lift lever
13.Steering signal lever 14.Horn button
-68-
Functions and used states are showed on the following table:
No. Description Function Used state

Parking brake Operate parking brake Pull the lever back ward, the front wheels are
1
lever braked.
Control the lamps on or Position 1st , clearance lamps light. Position
2 Lamp switch off 2nd ,both clearance lamps and head lamp all
light.
Control direction Turned to left, truck steers to left; turn to right
3 Steering wheel
,truck steers to right.
4 Flameout pull button Cut off the engine Pull the button out to cut off the engine.
Operate the inching; Press the pedal, control oil pressure and oil
make the truck to travel capacity of the shift clutch in gearbox,
5 Inching pedal
slowly. accomplish the inching, press the pedal
completely, the brake pedal is taken to active.
Turn on the power and Turn to left to preheat, turn to right to start. It
start engine automatic ally returns to “ON” or “OFF”
6 Start switch position, when hand is away from the key.
(the start switch is also the cut off switch of
the import engine. )
Adjust the steering Push forward to fix, pull backward to loose,
Steering wheel
7 wheels forward or adjust the steering wheel’s position.
adjust lever
backward position.
Slow down and stop When the brake pedal is pressed, the truck is
8 Brake pedal slowed down, until is braked. Meanwhile, the
brake indicator lights.
Control the supplied Stepped stroke is more, fuel supplied capacity
9 Accelerator pedal
capacity of engine. is more, and speed is faster.
Control truck forward Push the lever forward, is forward speed 1st
10 Shift lever or reverse. ,forward further is forward speed 2nd .Pull
the lever backward, is reverse gear.
Control the mast tilting Pulling the lever backward will tilt the mast
backward, reversibly the mast tilt forward.
11 Tilt lever
The tilt speed is controlled by tilt angle of the
lever and accelerator pedal effort.
Control the forks to The fork can be raised or down by pulling
raise or lower. backward or pushing forward the lever. The
lift speed is controlled by tilt angle of the
12 Lift lever
lever and accelerator pedal effort. The
lowering speed can be controlled by the tilt
angle of the lever.
Steering signal Control the steering Operate the lever, lamps flash. Backward-
13
lever indicating lamps right turn N-neutral gear forward-left turn.
Make voice to bring Put down the rubber cap in the middle of the
14 Horn button pedestrian’s attention steering wheel, the horn makes voice at once.
-69-
2.BEFORE USE
Please pay attention to the followings in order to make the truck working with high
efficiency and lengthen is service life.
A. Adopt the home or import engine, when use and maintenance. please read the
manual carefully(accompanied with the machine).
B. Check on the pneumatic of tires, if doesn't enough, should pump air in time.
C. Top up each oil tank, grease each lubricating places(See oil tank capacity and
lubricating please)
D. Check electric system for the appearances of defective contact or short-circuited.
E. Check brake system, keep brake flexibility and reliability .
Check the radiator, and add antifreeze if necessary.
3.START ENGINE
A. Put the shift lever at the neutral position, and put the paring brake lever at the brake
position.
B. When starting, put the key into the start switch, turn it in the counter-clock-wise,
preheat 15-20seconds, then turn it in the clock-wise to “START” so the starter works. When
hand is away from the key, it automatically retunes to “ON” by spring force. Every starting
time shouldn't more than 5 seconds. Restarting should be after 2 minutes. As the engine
doesn't work after some times starting, should check and fix the fault, do not keep the starter
engaged for a ling time.
C. The engine is run about 5 minutes after starting, when the temperature of water raises
to about 60, so is allowed working with full load. At the end of each workday, should be race
rotated the machine 5 minutes then cut off the engine.
Note:
a.Do not keep the start switch at the “ON” position while the engine is shut down. This
will result in battery discharge.
b.While the engine running, do not turn the start switch to “START” position, since there
is a danger of damage to the starter motor.
4.SAFETY NOTES
A.Check the pointer of the instruments whether within the working ranges when the
engine running. Otherwise, should stop the engine to check at once.
B.Operating in overload is forbidden. Lift capacity and load center should be within the
operating range. (See the load chart plate)
-70-
C.Keep the machine traveling into cargo slowly, at the same time, pay attention to if
there are sharp and hard things nearby the cargo, in order to avoid tires stabbed.
D.Operating with single fork is forbidden, machine, keep the forks together, in the
middle of the machine, and in the center of the cargo.
E.When operating, load on the two forks should be same as much as possible, avoid the
cargo inclining to one side.
F.Mast should be placed at vertical position, and the machine is braked when operating.
G.When operating, press the accelerator pedal according to the cargo weight, and then
operate the lift lever.
H.Falling the cargo is decided on the gravity of its, so keep the engine in idle speed when
falling. Push the lever slowly, and keep the cargo falling slowly, avoid down suddenly .
I.Before tilting, the truck should be braked. The accelerator should be reduced when
tilting forward, avoid the cargo sliding away the forks suddenly.
J.Under clearance should be 300-500mm, and the mast be tilted backward when the
machine is traveling.
K.Changing direction is not allowed (e.g. from forward to reverse or reverse to
forward).In order to avoid the parts are damaged before the machine does not slow down or
stop completely.
L.The engine can not stop, or it will take a lot of effort to brake and steer when the truck
is traveling.
Never stand under an upraised mast.
5.NOTES IN THE DURING BRAKE-IN
we recommend to operate the machine under the light load, low speed condition for the
first stage of operation of 100hours. Avoid suddenly speeding and brake. Renew the oil in
engine oil pan transmission, driven axle and hydraulic oil tank after 200 operation hours.
-71-
6. QUANTITY OF OIL
Time(Hours)
No. Position Type of oil O'ty
50 1005001000
AN32 or AN46 type About
1 Hydraulic oil tank +
hydraulic oil 110L
-10 type diesel or 90 About
2 Fuel tank type gasoline
Daily check
110L
Transmission
3 (torque converter) 6 type hydraulic drive oil About 20L +
Accord with the demands

4 Engine oil pan About 15L
of engine
5 Driving axle Gear oil 85W/90 +
6 Radiator Antifreeze FD-2type-35℃ About 15L Daily check
7.ROUTINE CHECK BEFORE DAILY OPERATION

A. Check fuel.
B. Check oil pipe, water hose, exhaust pipe and hydraulic component for the leakage.
C. Check hydraulic oil.
D. Check bolts of wheels and transmission.
E. Check tires air pressure.
F. Check steering and transmission for flexibility and reliability.
G. Check the condition of electric circuit, inserts, lamp and instruments.
8. REGULARLY CHECK
A. Check the seal and reliability of the hydraulic system.
B. Check the reliability of the steering and brake system.
C. Check the specific gravity and lever of the electrolyze of battery. Keep the height of
12mm from the lever to the top. Add distilled water if needs.
D. Check the reliability of mast, driving axle and steering axle connecting with the
frame.
E. Check wheels for tight degree .
F. Change oil within the transmission(torque converter)after 500 operating hours.
G. Renew oil within the hydraulic oil tank, after 1000 operating hours.
9. CASUAL CHECK
-72-
A. Check the reliability of mast, frame and so on welding joints.
B. Check the reliability of steering cylinder, tie rod, driving axle knuckle and so on
connecting joints.
C. Check all pipes and hoses for the leakage and the condition.
D. Check wheel brake and parking brake.
10. TABLE OF LUBRICATION SYSTEM
Time(Hours)
No. Position Grease point Type
50 1005001000
1 Support of steering device 2 Lime grease +
The two end joints of
2 steering cylinder 2 Lime grease +
3 Bearing of knuckle 4 Lime grease +
4 Bearing seat of steering axle 2 Lime grease +
5 Pin of tilt cylinder 2 Lime grease +
6 Lever head of tilt cylinder 2 Lime grease +
7 Support bushing of mast 2 Lime grease +
8 Lift roller of fork bracket 8 Lime grease +

Note :About lubrication of the engine, refer to the ENGINE OPERATION MANUAL.
-73-
Product Improve Suggestion Sheet (Feedback)
Product name
Produce lot
Factory number number
Leave factory Start use date
date
Use company
Suggestion content:
To improve our forklift trucks, absorb your valuable suggestion, please send to us suggestion
content.
We also ask your understanding for the fact that due to on-going improvement of parts and
equipment, the numerical values given in the manual are subject to change without notice.
-74-

H-Series Forklift Manual

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H-Series Forklift Manual

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FOREWORD

H-series CPCD40,CPCD45, CPCD50, CPQD40, CPQD45, CPQD50, CPYD40,

CPYD45, CPYD50 and CPQYD40, CPQYD45, CPQYD50 internal combustion

5t 4209 555 584 2800

14Min. intersecting aise mm 2480 2500 2550

L mm 4145 4165 4209

Loaded kg 9010 9750 10500

Unloaded kg 2750 2710 2680

17Front overhang mm 555

18Rear overhang mm 520 540 584

19Service weight kg 6600 6800 7100

20Distance between both forks mm 300～1340

21Brake distance (Unloaded) m ≤6

Type 4-cylinder, water-cooled Diesel Engine

22 Total Displacement mL 4752

Rated Power/speed kW/rpm 61/2200

Max. torque/speed Nm/rpm 305/1400-1600

Rated pressure MPa 19

Pump Model CBKa-G425-ATφL CBKa-G425-ATφ

valve mode mL/r 25×2

Model CPCD40-WF6 CPCD45-WF6 CPCD50-WF6

14Min. intersecting aise mm 2480 2500 2550

L mm 4145 4165 4209

Loaded kg 9010 9750 10500

Unloaded kg 2750 2710 2680

17Front overhang mm 555

18Rear overhang mm 520 540 584

19Service weight kg 6600 6800 7100

20Distance between both forks mm 300～1340

21Brake distance (Unloaded) m ≤6

Type 4-cylinder, water-cooled Diesel Engine

22 Total Displacement mL 4329

Rated Power/speed kW/rpm 59/2400

Max. torque/speed Nm/rpm 280/1600-1800

Rated pressure MPa 19

Pump Model CBKa-G425-ATφL CBKa-G425-ATφ

valve mode mL/r 25×2

Model CPCD40-M2 CPCD45-M2 CPCD50-M2

14Min. intersecting aise mm 2480 2500 2550

L mm 4145 4165 4209

Loaded kg 9010 9750 10500

Unloaded kg 2750 2710 2680

17Front overhang mm 555

18Rear overhang mm 520 540 584

19Service weight kg 6600 6800 7100

20Distance between both forks mm 300～1340

21Brake distance (Unloaded) m ≤6

Type 6-cylinder, water-cooled Diesel Engine

22 Total Displacement mL 4966

Rated Power/speed kW/rpm 52/2300

Max. torque/speed Nm/rpm 248/1700

Rated pressure MPa 19

Pump Model CBKa-G425-ATφL CBKa-G425-ATφ

valve mode mL/r 25×2

Model CPCD40-VM1 CPCD45-VM1 CPCD50-VM1

14Min. intersecting aise mm 2480 2500 2550

L mm 4145 4165 4209

Loaded kg 9010 9750 10500

Unloaded kg 2750 2710 2680

17Front overhang mm 555

18Rear overhang mm 520 540 584

19Service weight kg 6600 6800 7100

20Distance between both forks mm 300～1340