IC4 0-Mini5 0

4-5t Internal Combustion Counterbalance Forklift Truck
Operation & Maintenance Manual
Introduction
M series of FD40T, FD45T and FD50Tinternal combustion counterbalance forklift trucks is
the front-wheel driving and rear-wheel steering lifting and conveyance machine, and it is
applicable to loading-unloading, stacking, and short-distance conveyance of the formed
cargos at freight yard, station, port, and dock, as well as general factories and mines. This
forklift truck is characterized by novel appearance, nice CBU streamline, low noise, few
pollution, easy and flexible operation, broad visual field, strong shock-absorption and
anti-dust functions, and good comfort, safe and reliable, typical of good drawbar and
driving performance, as ideal equipment for achieving loading-unloading mechanization.
The scope of its operation will become wider if various attachements (such as traversing
device, bucket, clamping and holding device, and hoist cable, etc) are fitted.
This manual has mainly introduced the performance, and structure of main parts, as well as
maintenance and service etc for the above forklift truck. Users are kindly expected to read
this manual carefully, prior to use, and use and maintain the forklift truck following the
procedures and requirements as indicated in the manual, for the forklift truck to be
frequently maintained under its good technical condition.
In order to improve product quality, users are kindly expected to timely feedback the issues
found during the process of operation to our factory, so that we will be able to make
improvement on the product. The forklift truck is subject to partial alterations such as
machine structures and parameters, etc without prior notices.
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Table of Contents
1
I. Features of the Forklift Truck ................................................................................................................. 4
II. CBU Outside Drawing and Table of Performance Parameters.............................................................. 5
1. CBU Outside Drawing ........................................................................................................................... 5
2. Table of Performance Parameters .......................................................................................................... 5
III. Structure and Performance of Main Parts ............................................................................................ 8
1. Power System......................................................................................................................................... 8
2. Hydraulic Transmission Case, Torque Converter and Differential ........................................................ 8
2.1 Overview.............................................................................................................................................. 9
2.2 Torque Converter ................................................................................................................................11
2.3 Hydraulic Clutch Unit ........................................................................................................................ 12
2.4 Control Valve ..................................................................................................................................... 13
2.5 Hydraulic Oil Circuit ......................................................................................................................... 15
2.6 Charging Pump .................................................................................................................................. 16
2.7 Differential ......................................................................................................................................... 16
2.8 Maintenance of Differential ............................................................................................................... 16
3. Drive Axle ............................................................................................................................................ 18
3.1 Overview............................................................................................................................................ 18
3.2 Axle Housing...................................................................................................................................... 19
3.3 Front Wheel Hub................................................................................................................................ 19
3.4 Maintenance ....................................................................................................................................... 19
3.4.1 Adjustment of Pre-tightening Force ................................................................................................ 19
3.4.2 Wheel Mounting Sequence ............................................................................................................. 19
3.4.2.1 Tyre Installation ........................................................................................................................... 19
3.4.2.2 Installation of Double Tyre .......................................................................................................... 19
4. Brake System ....................................................................................................................................... 20
4.1 Overview............................................................................................................................................ 20
4.2 Brake Pedal ........................................................................................................................................ 20
4.3 Wheel Brake Drum ............................................................................................................................ 22
4.4 Parking Brake..................................................................................................................................... 23
4.5 Clearance Automatic Regulator ......................................................................................................... 24
4.6 Brake Valve ........................................................................................................................................ 25
4.7 Maintenance ....................................................................................................................................... 26
4.8 Common Failures and Remedies for Brake System........................................................................... 32
5. Steering System (Full Hydraulic Steering Model) ............................................................................... 33
5.1 Overview............................................................................................................................................ 33
5.2 Cross-setting Cyliner Steering Axle ................................................................................................... 33
5.3 Steering Device .................................................................................................................................. 34
5.4 Full Hydraulic Steering Unit .............................................................................................................. 35
5.5 Steering Cylinder ............................................................................................................................... 40
5.6 Failure Removal for Steering System ................................................................................................ 41
6. Hydraulic System................................................................................................................................. 42
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6.1 Operating Oil Pump ........................................................................................................................... 43
6.2 Bypass Valve ...................................................................................................................................... 44
6.3 Multi-way Valve................................................................................................................................. 45
6.4 Lifting Cylinder.................................................................................................................................. 49
6.5 Cut-off Valve ...................................................................................................................................... 50
6.6 Tilting Cylinder .................................................................................................................................. 51
6.7 Common Failures and Remedies for Hydraulic System .................................................................... 53
7. Working Device ................................................................................................................................... 54
7.1 Mast.................................................................................................................................................... 54
7.2 Carriage.............................................................................................................................................. 54
7.3 Lifting chain....................................................................................................................................... 55
8. Electrical System.................................................................................................................................. 56
8.1 Overview............................................................................................................................................ 56
8.2 Instrument Signal and Operation Instructions.................................................................................... 56
8.3 Battery................................................................................................................................................ 58
8.4 Schematic Diagram for Electrical System ......................................................................................... 59
IV. Safety Drive, Operation, and Routine Maintenance and Service of Forklift Truck ........................... 62
1. The functions and Application Status of Respective Operating Mechanisms are listed in the following
table:......................................................................................................................................................... 62
2. Notices Prior to Use ............................................................................................................................. 64
3. Start of Engine ..................................................................................................................................... 64
4. Notices for Safety Operation................................................................................................................ 64
5. Notices for Prevention from Tip-over .................................................................................................. 66
6. Notices for Running-in of New Forklift Truck .................................................................................... 67
7. Oils Used for Forklift Truck................................................................................................................. 67
8. Examination Prior to Truck Dispatch for Each Working Shift............................................................. 68
9. Regular Examination............................................................................................................................ 68
10. Irregular Examination ........................................................................................................................ 68
11．Regular Maintenance........................................................................................................................ 68
12. Lubricating System Table................................................................................................................... 84
13. Data Plate and Warning Signs ............................................................................................................ 84
14. Package and Conveyance................................................................................................................... 86
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I. Features of the Forklift Truck
The driving way of engine – hydraulic torque converter – power gear-shift transmission – drive axle is
applied to M series of FD40T, FD45T and FD50T forklift trucks, and this forklift truck is characterized
by following main advantages:
1. As hydraulic transmission is applied, it is able to protect engine from overloaded flameout, when load
is suddenly increased, and at the same time, a stable gear-shift control is achieved in operation, which
has increased operating efficiency, simplified operation, alleviated driver labor intensity, and lowered the
requirement of driver operation skill, speaking from a forklift truck for frequent parking and starting as
well as frequent gear shifting during operation.
2. Full hydraulic steering device is used for this forklift truck, and the steering axle is a cross-setting
cyliner steering axle, with small turning radius as well as simple and flexible steering, safe and reliable.
3. Hydraulic power brake is applied to the brake system of the forklift truck, typical of simple and labor
saving, with a reliable braking performance.
4. Mast with broad visual field is used for the forklift truck, and its structure is a 2-stage CJ-shaped
telescopic masts, with high strength of mast and wide driver visual field. The masts are designed in
series, and masts of different lift heights are available for user selection.
5. The CBU apparent modeling is unique, featuring a good streamline, low noise, shock absorption,
dustproof, and other advantages.
6. This series of forklift trucks can be matched with 2-stage and 3-stage full free lifting masts, and can
also be fitted with various attachements, according to user demands.
7. Overhead guard or cab of different heights can be selected for this series of forklift trucks, based on
in-container operation or off-container operation.
8. According to the standard EN12053, the noise of this forklift truck is lower than 109dB(A), and
according to the standard EN13059, the integrated vibration acceleration of human body is m / s2
under the condition of maximum no-load running speed, and that at the maximum full-load lifting speed
is m / s2 .
This series of forklift truck products is the most ideal choice to numerous users.
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II. CBU Outside Drawing and Table of Performance Parameters
1. CBU Outside Drawing
Capacity L L2 R T
4t 4210 550 2740 590
4.5 t 4230 570 2760 595

5.0 t 4274 614 2820 595
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2. Table of Performance Parameters
MODEL
ITEM FD40T-M FD45T-M FD50T-M FD40T-M FD45T-M FD50T-M FD40T- FD45T- FD50T-MG
WG3 WG3 WG3 WI3 WI3 WI3 MGG3 MGG3 G3
Serial Number
Diesel Diesel Diesel Diesel Diesel Diesel Diesel
Power Diesel Fuel Diesel Fuel
Fuel Fuel Fuel Fuel Fuel Fuel Fuel
Standard Load
500 500 500 500 500 500 500 500 500
Center (mm)
Lowest Position of
Cargo Fork
0 0 0 0 0 0 0 0 0
Ground Clearance
(mm)
6-QW-8
Battery Model 6-QW-80 6-QW-80 6-QW-80 6-QW-80 6-QW-80 6-QW-80 6-QW-80 6-QW-80
0
Battery Voltage 2×12V/ 2×12V/80 2×12V/80A
2×12v/80A 2×12V/80 2×12v/80 2×12v/80 2×12V/80 2×12V/80
(V)
h Ah Ah Ah Ah Ah 80Ah Ah h
Capacity (Ah)
Battery Dead
Weight/ Gross
2 ×22Kg 2×22Kg 2×22Kg 2×22Kg 2×22Kg 2×22Kg 2×22Kg 2×22Kg 2×22Kg
Weight with
Container (kg)
Engine Yituo Yituo Yituo
Perkins Perkins Perkins Mitsubishi Mitsubishi Mitsubishi
Manufacturer Factory Factory Factory
LR4B3- LR4B3-G
Engine Model 1104D-44 1104D-44 1104D-44 S6S S6S S6S LR4B3-G98
G98 98
Engine Rated
Power (kW)
56/2200 56/2200 56/2200 52/2300 52/2300 52/2300 57/2200 57/2200 57/2200
/Rated Speed
(rpm)
Max Torque (Nm) 260 260 260 250 250 250 285 285 285
Engine Emission
Euro III Euro III Euro III Euro III Euro III China II China II China II China II
Level
Max Drawbar
(kN)
22/20 22/20 22/20 21/19 21/19 21/19 23/21 23/21 23/21
Full Load/ No
Load
Front Wheel 300-15 300-15- 300-15
300-15-18P 300-15-18 300-15-18 300-15-18 300-15-18 300-15
Model/Outer -18PR/84 18PR/8 -18PR/84
R/840 PR/840 PR/840 PR/840 PR/840 -18PR/840
Diameter (mm) 0 40 0
Front Wheel
Charging Air 830 830 830 830 830 830 830 830 830
Pressure (kPa)
Rear Wheel 7.00-12-
7.00-12-12 7.00-12-1 7.00-12-1 7.00-12-1 7.00-12-1 7.00-12-1 7.00-12-1 7.00-12
Model/Outer 12PR/6
PR/676 2PR/676 2PR/676 2PR/676 2PR/676 2PR/676 2PR/676 -12PR/676
Diameter (mm) 76
- - 6
Rear Wheel
Charging Air 860 860 860 860 860 860 860 860 860
Pressure (kPa)
Mast Tilt Angle
6°/12° 6°/12° 6°/12° 6°/12° 6°/12° 6°/12° 6°/12° 6°/12° 6°/12°
Front/ Back
1070×1
Cargo Fork 1070×150× 1070×150 1070×150 1070×150 1070×150 1070×150 1070×150 1070×150
50×55/9
Dimension/Weight 50/90 ×55/98 ×55/98 ×50/90 ×55/98 ×50/90 ×55/98 ×55/98
0
Rated
4000 4500 5000 4000 4500 5000 4500 4500 5000
Capacity(kg)
Max Lift Height
3000 3000 3000 3000 3000 3000 3000 3000 3000
(mm)
Load at Max Lift
4000 4500 5000 4000 4500 5000 4500 4500 5000
Height(kg)
Operation Pressure
of Hydraulic 19 19 19 19 19 19 19 19 19
System (MPa)
Max Travel Speed
at Rated 18 18 18 18 18 18 18 18 18
CapacityvQ (km/h)
Max Travel Speed
at No Load v 20 20 20 20 20 20 20 20 20
(km/h)
Gradeability i(%)
Full Load/ No 19/17 19/17 19/17 18/17 18/17 18/17 19/17 19/17 19/17
Load
Min Turning
2740 2760 2820 2740 2760 2820 2740 2760 2820
Radius (mm)
Loaded Lifting
Speed (mm/s) Full 450/500 450/500 450/500 470/530 470/530 470/530 450/500 450/500 450/500
Load/No Load
Loaded Lowering
Speed (mm/s) Full 500/450 500/450 500/450 500/450 500/450 500/450 500/450 500/450 500/450
Load/ No Load
External 4210×1
4210×1480 4230×148 4274×148 4210×148 4230×148 4274×148 4230×148 4274×1480×
Dimension 480×23
×2385 0×2385 0×2385 0×2385 0×2385 0×2385 0×2385 2385
(L×W×H) (mm) 85
Forklift Truck
6600 6800 7000 6600 6800 7000 6600 6800 7000
Gross Weight (kg)
Wheelbase (mm) 2000 2000 2000 2000 2000 2000 2000 2000 2000
Tread(mm) Front/ 1180/11 1180/119

1180/1190 1180/1190 1180/1190 1180/1190 1180/1190 1180/1190 1180/1190
Rear 90 0
Balance Weight
2080 2290 2500 2080 2290 2500 2080 2290 2500
(kg)
Manufacturer and
Specification of
/ / / / / / / / /
Electric Control
System
Seat Model YH-23 YH-23 YH-23 YH-23 YH-23 YH-23 YH-23 YH-23 YH-23
Note: LR4B3-G89 engine used domestically
- - 7
III. Structure and Performance of Main Parts
1. Power System
Table 1
Engine Model Diesel Engine
Main Parameters LR4B3-G89
Rated Power(kw) 57
Rated Speed rpm 2200
Max Torque N.m/rpm 285/1500
Used for Truck Model
Table 2
Engine Model Diesel Engine Diesel Engine
Main Parameters
1104D-44 S6S
Rated Power(kw) 56 52
Rated Speed rpm 2200 2300
Max Torque N.m/rpm 260/1650 250/1700
Used for Truck Model
Refer to Table 1 for Chinese engines currently used for forklift trucks, and refer to Table 2 for imported
engines currently used for forklift trucks.
Refer to Engine Operation Manual separately for introduction about engine structure.
Power of engine is transmitted by flywheel through torque converter, and hydraulic transmission case to
drive axle, to meet the running requirement, and to satisfy the demands of hydraulic system and working
device, through operating oil pump driven by transmission case.
2. Hydraulic Transmission Case, Torque Converter and Differential
Torque Converter:
Type: Three-Element, Single-Stage, and Two-Phase Type
Torque Ratio: 3
Adjusting Pressure: 0.5-0.7MPa
Charging Pump:
Type: Internal-Meshing Gear Type
- - 8
Flow: 26ml/r
Hydraulic Transmission Case:
Friction Plate Outer Diameter × Inner Diameter × Thickness 134×90×2.8
Friction Plate Frictional Surface Area: 7740mm×12
Adjusting Pressure: 12～15kg/cm2
Oil Capacity: Hydraulic Torque Converter Oil 20L
Differential:
Speed Reducing Ratio: 6.333
Weight: 184kg
Oil Supply: Hydraulic Oil 7L
2.1 Overview
The power gear-shift transmission case of forklift trucks in this series is designed and manufactured
based on assimilating domestic and foreign advanced technology and manufacturing experience, typical
of undermentioned advantages:
(1) The inching valve enables the forklift truck to perform inching operation during work at both low
RPM and high RPM of engine.
(2) The hydraulic clutch is fitted with 3 groups of specially treated steel plates for paper friction plate,
which has improved the wear resistance of its friction surface.
(3) The one-way overrunning clutch is fitted in the torque converter, which has improved power
efficiency.
(4) Quality filter is fitted in the oil circuit of torque converter, which as increased the service life of
torque converter.
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Fig 2.1 Hydraulic Torque Converter and Transmission Assembly
- - 10
2.2 Torque Converter
The torque converter is mainly composed of the pump impeller connected onto the input shaft, the
turbine connected onto the output shaft, and the guide wheel mounted on the torque converter housing.
The pump impeller is driven by input shaft, and the oil flows onto the blade of turbine along the blade of
pump impeller at high RPM (mechanical energy transformed into kinetic energy) under the action of
centrifugal force, for torque to be transmitted to output shaft. The oil leaving turbine changes direction
under the effect of guide wheel, thus one part of oil begins to reduce according to the change in angle of
liquid flow, while the torque of output shaft is reduced. Finally, the liquid flows into the blades of guide
pulley in a reverse direction, for the original reactive torque to act reversely. On this account, the torque
of output shaft is smaller than that of the input shaft. To prevent such situation, the overrunning clutch
mounted inside the guide pulley allows the guide pulley to be able for free rotation, when reactive torque
acts reversely.
When input torque and output torque are equivalent to each other, it is only able to ensure a high-speed
stable operation of the forklift truck. As the torque of transmission case is converted in mechanical way,
the torque converter in this form is called the 2-phase type.
The part of the torque converter for the transmission device is connected with the flywheel of engine
through elastic plate, and turns along with the rotation of engine, with oil for torque converter to be
filled up inside the torque converter. The driving gear is connected with pump impeller using spline, to
actuate charging pump, to feed the oil to the torque converter and the hydraulic shifting transmission
case. The turbine is connected onto the turbine shaft using spline, and the power is transmitted to power
gear-shift transmission case through turbine shaft.
Fig 2.2 Hydraulic Torque Converter
1. Input plate 2. Ball Bearing 3. Turbine 4. Guide Pulley

5. Overruning Clutch 6. Impeller 7. Ball Bearing 8. O-Ring
- - 11
2.3 Hydraulic Clutch Unit
The wet multiple disc hydraulic clutch achieves forward/backward gear shift, through forward and
backward clutches. Each unit of clutch contains 6 friction plates and 6 steel plates alternately assembled,
as well as one piston and one end plate. Both inner and outer rings of piston are fitted with seal rings, to
ensure the seal of piston during work. One test ball is also available on the piston to prevent self
movement.
The surface of clutch and the bushing of gear shall be frequently lubricated, to prevent them from being
blocked. When any friction plate is replaced, the mated steel plate shall also be replaced along with.
Fig 2.3 Clutch Unit
1.2. Seal Ring 3. Ball Bearing 4.Seal Ring 5. Return Spring
6. Piston 7.Seal Ring 8. Tapered Plate 9.Spacer
10. Steel Plate 11. End Plate 12. Snap Ring 13.Thrust Washer
14. Gear 15.Needle Roller Bearing 16.Thrust Washer 17. Ball Bearing
- - 12
2.4 Control Valve
The control valve is mainly comprised of reversing valve, adjusting valve, energy accumulator, and
inching valve. The energy accumulator connected with reversing valve moves under the action of
reversing valve lever.
The oil pumped out from the gear oil pump flows into the control valve, and its pressure is adjusted to
the specified pressure (12～15kg/cm2) , while the flow is adjusted by pore plate.
When reversing lever is pushed forward or backward, the adjusted pressure oil is sent to forward or
backward clutch under the action of reversing valve, and at this point, the energy accumulator moves
pushed by part of the oil, thus the vibration aroused by clutch engagement is relieved.
- - 13
Fig. 2.4 Control Valve
- - 14
2.5 Hydraulic Oil Circuit
After engine is started, the pump driving gear mounted on pump impeller hub drives the oil pump, and
the charging pump sucks out oil from oil tank (namely the transmission oil pan) through oil filter, to
flow through the main adjusting valve and the control valve under the action of pressure. The oil
required for operation of hydraulic clutch may be adjusted to proper pressure through main adjusting
valve.
The flow of oil flowing to control valve is controlled by pore plate, and the oil can be adjusted to proper
pressure through main adjusting valve.
When gear-shift lever is pushed forward or backward, one channel of oil from the control valve flows to
the supercharging cavity of forward/backward clutch through reversing valve, while another channel of
oil from the control valve flows into the energy accumulator, to ensure that a stable pressure will be
formed for oil pressure of clutch.
The pressure of oil flowing to the main adjusting valve is adjusted to 5～7kg/cm2 by internal overflow
valve, and the oil flows to the torque converter. The oil flowing out through external overflow valve
flows to oil cooler, to be cooled down before it returns to oil tank.
When forward or backward clutch is acting, the other clutch keeps racing between the friction plate and
the spacer, and is lubricated by the oil from the oil cooler.
When inching pedal is pushed down, most oil flows to clutch from inching valve, and then enters into
the transmission oil pan.
Fig 2.5 Oil Circuit Diagram for Hydraulic Transmission Case
- - 15
2.6 Charging Pump
Gear charging pump is installed inside the torque converter housing, and it is responsible for supplying
oil to torque converter, hydraulic clutch, and transmission case, for them to be lubricated. The charging
pump mainly consists of driving gear, driven gear, pump body, and pressure plate.
Fig 2.6 Charging pump

2.7 Differential
The differential is mounted on the differential case using bearing seat through ball bearings on both ends,
and the differential case can be connected with axle housing.
The case support for differential is in a left-right symmetrical type, fitted with two half shaft gears and
four planetary gears, and thrust washer is mounted between the case body of differential and the gear,
with clearances retained between respective gears.
The planetary gear is supported with gear shaft, and the gear shaft is fixed onto the differential case
using cylindrical pin, while the gear ring is fastened onto the differential case using hinged bolt.
Power passes through transmission case, for differential to generate differential speed, and the driving
half shaft enables wheels to turn.
2.8 Maintenance of Differential
The procedure for reassembling differential is contrary to that for disassembly, but attention must be
paid to the several points as follows:
(1) Adjust the clearance between half-shaft gear and planetary gear to 0.23～0.33mm, and the clearance
can be adjusted by replacing the washer on the side face of half-shaft gear. Washers of the same
thickness shall be used on both sides during replacement. Washer thicknesses: 1.8, 1.9, 2.0, 2.2, and
2.6mm.
- - 16
(2) Fasten the bolts on differential case, and ensure that the half-shaft gear is able to rotate flexibly.
Tightening Torque: 130～195N.m
(3) Fasten the bolts on gear ring.
Tightening Torque: 130～195 N.m
(4) Adjust the preload of driving planetary gear to the specified value.
It can be adjusted by replacing the spacer between tapered roller bearing and the spacer ring.
Spacer Thicknesses: 0.1, 0.15, 0.2, 0.5, 2.3, 2.6mm
(5) Adjust the clearance between driving planetary gear and gear ring.
Adjusting Clearance: 0.23～0.33mm
The clearance can be adjusted through adjusting the spacer between bearing bracket and bearer.
(6) Fasten the bolts on bearing seat.
Tightening Torque: 222～232 N.m
Fig 2.7 Differential
- - 17
3. Drive Axle
FD40T、/ FD45T Model Forklift Truck
Type Front Wheel Drive, Housing Fixed with Frame, and Fully Floating Type
Tyre Type 300-15-18PR
Rim 8.00V-15(M4543002000)
Tyre Pressure 0.83MPa
3.1 Overview
The full-floating drive axle is an integrated cast structure, mainly composed of axle housing, wheel hub,
brake drum, and brake, etc, as indicated in Fig 3.1, mounted in the front part of truck frame.
Fig 3.1 Drive Axle

1. Adjusting Nut 2. Half Shaft 3. Lock Nut 4. Oil Seal 5. Bearing
6. Wheel Hub 7. Brake Drum 8. Bearing 9. Oil Seal 10. Brake Air Pump
- - 18
3.2 Axle Housing
The axle housing is an integrated cast structure, fixed on truck frame with differential and half shaft,
through bushing cap.
3.3 Front Wheel Hub
Power is passed through the differential, for half shaft to transmit to the front wheel hub, and the wheel
hub drives the tyre to run. The brake drum and the wheel hub are fixed on the front wheel hub using
bolts and nuts for wheel hub. The wheel hub is connected with the axle housing through two tapered
roller bearings, while the brake is fixed on the axle housing, and embedded inside the brake drum.
The wheel hub and the axle housing bear the weight of front axle for the forklift truck, thus, the half
shaft only bears torque while not subject to torque conversion, called full-floating type.
Inner and outer oil seals are available inside the wheel hub, to prevent oil leak.
3.4 Maintenance
3.4.1 Adjustment of Pre-tightening Force
(1) Tighten the bearing nuts, and then turn backwards by 1/8 circle.
(2) Measure the preload while gradually tightening the bearing nuts.
(3) When preload is reached, lock up the bearing nuts using lock nuts and lock washer.
3.4.2 Wheel Mounting Sequence
3.4.2.1 Tyre Installation
1) Align the mounting holes of rim with the stud bolts of wheel hub, and mount the wheel.
2) Tighten 6 hub nuts using hand sequentially in diagonal direction.
3) Screw down the 6 nuts uniformly and sequentially in diagonal direction.
4) Screw down all the nuts.
3.4.2.2 Installation of Double Tyre
1) Align the mounting holes of inner rim with the bolts of wheel hub, and mount the inner wheel.
2) Tighten 6 inner stud nuts using hand.
3) Screw down the 6 inner stud nuts uniformly and sequentially in diagonal direction.
4) Screw down all the stud nuts.
5) Align the mounting holes of outer rim with the stub nuts and the valve core.
6) Tighten 6 nuts using hand.
7) Screw down the 6 nuts uniformly and sequentially in diagonal direction.
8) Screw down all the nuts.
- - 19
Attention: It is not allowed for any extraneous substance to be present on the surfaces of rim and
wheel hub, as well as the thread surfaces of nuts and stud bolts.
4. Brake System
Type: Front Wheel Brake, Hydraulic
Brake Valve
Type: Hydraulic
Pressure: 50kg/cm2
Servo Ratio: 4.5
Brake
Type: Double Servo Type with Parking Brake
Pedal Ratio: 5.0
Wheel Cylinder Diameter: 31.75mm
Brake Drum Inner Diameter: 317mm
Friction Plate Dimension: 330X×63×10mm
Friction Area: 416cm2
Parking Brake
Type: Front-wheel Brake, Internal Expanding, and Hydraulic
4.1 Overview
The brake system is composed of brake pedal, brake and brake drum, as well as oil pipe, etc.
4.2 Brake Pedal
Brake pedal is mounted on transmission case, as indicated in Fig 4.1. The push rod connected with brake
pedal pushes the piston of brake valve, and oil pressure will then be transmitted to the brake wheel
cylinder.
Lubrication-free bearing is assembled between brake pedal and shaft, and lubrication is not required
generally.
- - 20
Fig. 4.1 Brake System
- - 21
4.3 Wheel Brake Drum (Fig 4.2)
The wheel bake drum is of internal expanding and hydraulic type, and it is composed of brake shoe,
spring, wheel cylinder, regulator, and bottom plate, with two brakes respectively located on the two ends
of the front axle. One end of the brake shoe is connected with the support pin, and the other end is
connected with clearance regulator, borne down on the bottom plate by spring and pressure spring rod.
Handbrake rod is mounted on the primary brake shoe, while the adjusting rod for automatic clearance
regulators is installed on the secondary brake shoe.
The action of forward brake is indicated as in Fig 4.3, and through operating brake wheel cylinder, the
primary brake shoe and the secondary brake shoe are respectively effected by two forces of the same
degree but in reverse directions, for friction plate and brake drum to get into touch with each other. The
primary shoe bears down on the regulator by virtue of frictional force between friction plate and brake
drum, and thereby the clearance regulator generates a larger force than that when the wheel cylinder is
originally operated to push the secondary brake shoe, to force the upper end of the secondary brake shoe
to bear down on the support pin with a strong force, thus to get relatively large braking force. The action
of reversing brake is shown as in Fig 4.4. The braking action during backward movement is taken in a
reverse direction, but the braking force is the same as that for forward movement.
Fig 4.2 Brake

1. Pin 2. Brake Air Pump 3. Rubber Cup 4.Piston 5. Knockout Pin
6. Brace 7. Return Spring 8. Brake Shoe 9. Pressing Pin 10. Cover
11.Spring 12.Spring 13. Lever 14. Clearance Regulator
- - 22
Fig 4.3 Forward Direction
Fig 4.4 Reversing Direction
4.4 Parking Brake
The parking brake includes parking brake handle and brake cable, as indicated in Fig 4-5, and it shares
the brake shoe and the brake drum with foot brake. The brake handle is of elbow type, thus for regulator
to facilitate the adjustment of braking force at the top of handle.
- - 23
Adjust this place using screwdriver
Fig 4.5 Parking Brake
4.5 Clearance Automatic Regulator
The clearance automatic regulator enables the clearance between friction plate and brake drum to be
automatically maintained between 0.4～0.6 mm, but this regulator will only act during reverse brake.
During backward movement, the brake shoe will disengaged once the brake pedal is pushed down, and
thereby the secondary brake shoe and the primary brake shoe get into contact with brake drum and turn
together, until the upper end of primary brake shoe begins getting into contact with the support pin.
Meanwhile, when secondary brake shoe leaves the support pin, the Part A of adjusting lever is relatively
pulled, thus for the adjusting lever to rotate around the Part B, so as to drop the Part C. The Part D of the
regulator takes left-hand rotation, to achieve the purpose for automatic adjustment. When brake shoe is
further pushed down, the pressure applied to the both ends of regulator will turn to be higher, thus to
increase the resistance to thread rotation, so that the force of adjusting lever is unable for Part D to
rotate.
- - 24
4.6 Brake Valve
The power brake valve includes brake valve, brake master cylinder, and bypass valve. The function of
control valve is to transform the pedal pressure into hydraulic pressure, as indicated in Fig 4.6, and then
the power brake is fulfilled by hydraulic oil.
When brake pedal is pushed down, the stroke of pedal is transmitted to the input piston of control valve
by push rod, and then the place “A” turns to be narrow and the oil pressure in the place “B” rises, to
push the piston to move leftwards. At the same time when the place “A” is opened and the oil pressure
in the place “B” stops going up, the input piston will stop movement as well.
The moving brake master cylinder piston of input piston allows hydraulic oil to flow into the brake
wheel cylinder, to fulfill the braking function.
The pressure in the place “B” gives piston a reactive force, and thus the driver can feel a feedback force.
Fig 4.6 Brake Valve
1. Valve Body 2. Rubber Cup 3. Bypass Valve 4. Spring 5. Check Valve
6. Plug 7. Retainer 8.Piston 9. Power piston 10. Control Valve
11. Valve Seat 12. Reactive Piston 13. Push Rod
- - 25
4.7 Maintenance
This section covers the process for disassembly, reassembly, and adjustment of brake. The following
sketches may possibly vary from the actual devices, but its maintenance process is the same.
4.7.1 Disassembly of Brake
(1) Remove the fixed spring, and take off the adjusting
lever, the knockout pin, and the return spring of knockout
pin.
Fig 4.7
(2) Remove the return spring for brake shoe.
Fig 4.8
(3) Remove the other 3 fixed springs.
Fig 4.9
(4) Detach the primary brake shoe and the secondary
brake shoe, and at the same time, remove the spring
for regulator.
Fig 4.10
- - 26
(5) Dismount the brake oil pipe from on the wheel
cylinder, and then loosen off the mounting bolts for
wheel cylinder
Fig 4.11
(6) Detach the E-shaped retainer ring that fastens the
brake cable on the bottom plate, then loosen off the
mounting bolts on the bottom plate, and detach the
bottom plate.
Fig 4.12
(7) Demount the wheel cylinder cover, push the piston
into one end of the cylinder, and at the same time push
out all the parts on the other end.
Fig 4.13
4.7.2 Examination of Brake
Examine whether or not all the parts are worn out or
damaged, and they shall be repaired or replaced, if
incompliant.
(1) Examine whether or not the inner surface of the wheel
cylinder body and the surface of piston column are rusted,
and then measure the clearance between piston and cylinder
body.
Specified Value: 0.03～0.10mm
Fig 4.14
Max Value: 0.15mm
- - 27
(2) Visually examine whether or not the rubber cup of
wheel cylinder is damaged or distorted.
(3) Examine the free length of spring for wheel cylinder,
and it shall be replaced, if incompliant.
(4) Examine the thickness of friction plate, and it shall be
replaced, if found to be over-worn.
Specified Value: 10.0mm
Fig 4.15
(5) Examine the inner surface status of the brake drum, and
it shall be rehabilitated or replaced, of found to be damaged
or over-worn.
Standard Value: 318mm
Max Value after Rehabilitation: 319.5mm
Fig 4.16
(6) Measure the free length and mounted load for return spring of brake shoe.
(7) Examine whether or not the adjusting mechanism is damaged, how the operating status is, and
additionally examine whether or not the contact of adjusting lever is out of order. It is to be replaced,
when necessary.
4.7.3 Reassembly of Brake
(1) Firstly dip the wheel cylinder rubber cup and piston with hydraulic oil, and then assemble spring,
rubber cup, piston, and shield in turn.
(2) Mount the wheel cylinder on the bottom plate.
Attention: Ensure that respective parts are all at the correct position, during assembly.
Bolt Tightening Torque: 18～27N.m
(3) Mount the bottom plate on the front axle.
(4) As indicated in Fig 4.17, add heat-resisting lubricating grease into respective lubricating points of a,
b, c, and d, and pay attention that it is absolutely not allowed to stick grease on friction plate.
- - 28
a. Bottom Plate Bearing Surface
b. Support Pin
c. Contact Surface of Brake Shoe and Pressure
Spring Seat
d. Support Pin for Handbrake Rod
e. Regulator Thread and other Turning Parts
Fig 4.17
(5) Mount the brake cable assembly onto the bottom

plate using E-shaped retainer ring.
(6) Mount the brake shoe on the bottom plate using
fixed spring.
F
ig 4.18
(7) Mount the compression spring onto the handbrake
pull rod, and then fit the push rod onto the brake shoe.
(8) Mount the brake shoe guide plate onto the support
pin, and fit the return spring for brake shoe. Pay
attention that primary brake shoe shall be assembled before the secondary brake shoe.
Fig 4.19
(9) Mount spring, regulator, regulator spring, and
adjusting lever. Attention shall be paid to the several
points as follows:
a. The left brake has a left-hand thread regulator, and
the right brake has a right-hand thread regulator.
b. It is not allowed for the regulator tooth part and the
spring to get into contact with each other.
c. The spring hook at the end of support pin shall be fastened on the side opposite to knockout pin.
Fig 4.20
- - 29
d. After reassembly, make sure that the lower end of
adjusting lever and the regulator tooth part must be in
contact with each other.
(10) Connect the brake oil pipe onto the wheel cylinder.
(11) Measure the inner diameter of brake drum and
outer diameter of brake shoe. Adjust the regulator, for
the difference between the outer diameter of brake shoe
and the inner diameter of brake drum to be 1.0mm.
Fig 4.21
4.7.4 Operation and Inspection of Clearance Automatic Regulator

(1) Firstly allow the diameter of brake shoe to approach the specified size. Pull the adjusting lever using
hand for the regulator to turn, and the adjusting lever will return to its original place, when hand is
released, while the gear of regulator remains not turning.
Attention: Even when hand is released, the regulator gear and the adjusting lever will return together,
and the regulator is still able to work normally after it is assembled to the truck.
(2) In the case when adjusting lever is pushed, the regulator fails to do the abovementioned action, the
following examination shall be performed.
a. Fit firmly the adjusting lever, the regulator, the regulator spring, the regulator steel cable, and the
return spring for brake shoe.
b. Examine whether or not the return spring for brake shoe and the spring for regulator are damaged, and
then examine the rotating status of regulator gear and whether or not the engaged part is over-worn or
damaged.
Fig 4.22
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4.7.5 Adjustment of Brake Pedal
(1) Shorten the push rod of brake master cylinder.
(2) Adjust the height of pedal through adjusting the catch bolt, as indicated in Fig 4-23.
(3) Push down the brake pedal by 30mm, and lengthen the push rod, until the front end of push rod
begins to get into contact with the master cylinder piston.
(4) Tighten the lock nut for push rod.
4.7.6 Adjustment of Brake Switch
(1) Ensure that the height of brake pedal is as indicated in Fig 4-23, and loosen the lock nut for brake
switch.
(2) Remove the lead wire for brake switch from the connector.
(3) Turn on the switch and the size in the place “A” is 1mm.
(4) Ensure that the brake light turns on, when the pedal is pushed down by 30mm.
Fig 4.23
- - 31
4.8 Common Failures and Remedies for Brake System
Issue Causes Remedy
1. Oil leak with brake system To be repaired
2. Clearance of brake shoe not properly adjusted Regulator to be adjusted
3. Brake overheated Whether or not skidding to be

Poor Brake
examined
4. Poor contact between brake drum and friction plate To be readjusted
5. Impurity attached on friction plate To be repaired or replaced
6. Impurity blended into brake fluid Brake fluid to be examined
7. Improper adjustment of brake pedal To be adjusted
1. Surface of friction plate hardened or impurity To be repaired or replaced

Nose with Brake
attached on it
2. Bottom plate distorted or bolt loosened To be repaired or replaced
3. Brake shoe distorted or improperly mounted To be repaired or replaced
4. Friction plate worn out To be replaced
5. Bearing loosened To be repaired
1. Oil stain present on the surface of friction plate To be repaired or replaced

Un-uniform Brake
3. Wheel cylinder out of order To be repaired or replaced
4. Return spring of brake shoe damaged To be replaced
5. Brake drum deviated To be repaired or replaced
6. Tyre air pressure incompliant with requirement To be adjusted
1. Oil leak with brake system To be repaired or replaced

Bad Brake
3. Air blended into brake system Air to be released
4. Incorrect adjustment of brake pedal To be readjusted
- - 32
5. Steering System (Full Hydraulic Steering Model)
Type Center Pin Supporting
King Pin Spacing 1030mm
King Pin Angle 0°
Steering Axle
Inward Angle 0°
Kingpin Outward Angle 1°
Kingpin Backward Angle 0°
Inside Wheel 78.42°
Steering Angle
Outside Wheel 54.36°
Type BZZ-280
Full Hydraulic Steering Unit Displacement 280ml/r
Operating Pressure 17.2MPa
Type Double Acting Piston
Cylinder Diameter 90mm
Steering Cylinder
Piston Rod Diameter 60mm
Stroke 226mm
5.1Overview
The steering system main consists of steering wheel, full hydraulic steering unit, adjusting valve,
cross-setting cyliner steering axle, steering axle cylinder, and pipeline, etc. The steering wheel can be
adjusted forward and backward according to different drivers. When steering wheel turns, the movement
is transmitted to full hydraulic steering unit, and the full hydraulic steering unit is able transmit the
pressure oil from bypass valve in a measuring way according to the size of angle for rotation of steering
wheel to the steering cylinder through pipeline. When engine is flamed out, oil pump cannot supply oil,
while manual steering is still achievable, but it is relatively tiresome.
The steering cylinder is of a double-action through type. The two ends of piston rod are connected with
steering knuckle through connecting rod, and the pressure oil from the full hydraulic steering unit
enables the leftward/rightward movement of the piston rod, thus to achieve the left-hand/right-hand
turning.
5.2 Cross-setting Cyliner Steering Axle
The cross-setting cyliner steering axle is in a box section welded structure, in which one steering
cylinder is installed, as indicated in Fig 5-1. The steering cylinder is embedded inside the axle housing,
able to effectively prevent injury aroused by ground barriers. The steering axle is mounted on the truck
frame through shaft sleeve and shaft cover used for king pin, able to swing around the center pin.
- - 33
Fig 5.1 Steering Axle
5.3 Steering Device
The structure of steering device is indicated as in Fig 5.2. The full hydraulic steering unit is located on
the lower end of the steering wheel assembly, and the center of the steering wheel is the horn button. The
steering shaft passes through a universal joint and is connected onto the driving shaft of the full
hydraulic steering unit, and the steering wheel can be adjusted forward or backward according to the
demands of drivers.
- - 34
Fig 5.2 Steering Device

5.4 Full Hydraulic Steering Unit
BZZ-model cycloid full-hydraulic steering unit is an open-center irresponsive full hydraulic steering
device, as indicated in Fig 5.3. The rotor and the stator are a pair of cycloidal internal meshing pin gears,
connected in series between bypass valve and steering cylinder through servo valve (playing the
function of measuring motor) during normal work (power steering). As oil both incoming and outgoing
through the steering cylinder must pass through the measuring motor, the turning angle and the flow and
the flow incoming and outgoing through steering cylinder are directly proportional. The steering wheel
is connected with valve core through Link Block 1, then to actuate Valve Sleeve 6 through Fixed Spring
4. The Valve Sleeve 6 is connected with Rotor 9 through Pin Shaft 5 and Connector 8. Rotor 9 remains
motionless, as oil circuit is obstructed. When steering wheel is turned, it is relatively turned between one
pair of rotary valves (valve core and valve sleeve) used for oil distribution. Such turning puts through
the oil circuit, for the oil from the pump to pass through oil motor to steering cylinder to perform
steering. When steering steel remains unturned, the valve core and the valve sleeve are located at center
position under the action of Fixed Spring 4, for oil circuit to be closed.
Under the condition when oil pump does not supply oil, the Safety Valve 14 is turned on under the effect
of vacuum, to form a loop inside the valve. At this point motor is equivalent to a hand pump, to press the
oil from one cavity of the steering cylinder into the other cavity, so as to achieve manual steering.
- - 35
Fig 5.3 Full Hydraulic Steering Unit
1. Cross Shaped Connector 2. Front Cover 3. Valve Body 4. Leaf Spring 5. Pin Shaft 6. Valve
Sleeve 7. Valve Core 8. Universal Driving Shaft 9. Rotor 10. Rear Cover 11. Spacer 12.
Stator 13.O-Ring 14. Steel Ball 15. O-Ring 16. X-Ring 17. O-Ring
(1) Operation of Full Hydraulic Steering Unit
(2) Neutral Position
a. At the time when steering wheel remains unturned
When steering wheel remains unturned, the oil from oil pump flows through Oil Circuit (1) into Groove
(2). The valve sleeve has 24 Holes (3), with Hole (4) standing upright inside the slide valve. The oil
flows into the Groove (2), passes through the Holes (3) and Hole (4), flows into the gap between slide
valve and transmission shaft, and afterwards flows through the Slide Valve Groove (6) and Valve Sleeve
(7), and returns into oil tank.
Though the Cylinder Joints (20) and (21) are mutually through to the Oil Holes (18) and (17) inside the
valve sleeve, but they are not mutually through to the Grooves (16) and (19) inside the slide valve, and
the oil in the cylinder will not flow to any place.
The Oil Hole (14) inside the valve sleeve behind Channel (15) is mutually through, able to be used as
the oil inlet port for the hydraulic motor, but it does not lead to the Grooves (13) and (16) inside the slide
valve, thus the cylinder will remain still.
- - 36
Fig 5.4
b. At the time when the steering wheel is rotating in counterclockwise direction
When steering wheel rotates in counterclockwise direction, the groove inside the slide valve will move
leftwards, to maintain consistent to the hole and the groove inside the valve sleeve, and then the Hole (4)
and the Hole (3) of the valve sleeve will be staggered. The oil will flow into Groove (2), flow into Hole
(12), flow through Groove (23) and Hole (13) inside the slide valve, Hole (14) of the valve sleeve, and
the Oil Circuit (15) inside the housing, and flow out from the steering unit.
When the steering unit runs in counterclockwise direction, the oil drained from the steering unit flows
through the Oil Hole (14) of the valve sleeve, the Groove (16) of the slide valve, and the Oil Hole (18)
of the valve sleeve, into the “L” tray in the cylinder, for steering cylinder to work.
The return oil from the steering cylinder, flows through the Point “R” of the cylinder, the Groove (11) of
the valve housing, the Oil Hole (17) inside the valve sleeve, the Groove (19) inside the slide valve, the
Oil Hole (22) inside the valve sleeve, and the Groove (8) inside the valve housing, and returns to the oil
tank.
- - 37
Fig 5.5
c. At the time when steering wheel rotates in clockwise direction
When steering wheel rotates in clockwise direction, the groove inside the slide valve moves rightward,
to be through to the oil hole and the groove inside the valve sleeve, and then the Oil Hole (4) inside the
slide valve and the Oil Hole (8) inside the valve sleeve are staggered. The oil flows into Groove (2), the
Oil Hole (14) inside the valve sleeve, and the oil inside the valve sleeve flows out from the steering unit
through (15). The steering unit runs in clockwise direction, and the oil drained therefrom flows through
the Oil Hole (14) inside the valve sleeve, the Groove (16) inside the slide valve, and the Oil Hole (17)
inside the valve sleeve, into the Point “R” of cylinder, for the steering cylinder to work.
The oil returning from the steering cylinder, flows through the Point “L” of the cylinder, the Groove (10)
inside the housing, the Oil Hole (18) inside the valve sleeve, the Groove (19) inside the slide valve, the
Oil Hole (22) inside the valve sleeve, and the Groove (9) inside the housing, and returns to the oil tank.
- - 38
Fig 5.6
(2) Relationship between Steering Wheel Running Speed and Operating Force
In principle, the force required for operating the full hydraulic steering unit is only a force to push the
reversing valve, and the force of compression center spring is 0.3kgm. In addition, though there is no
touch between steering wheel and tyre, the force of compression spring is really needed, for steering
force to be still maintained when rotating speed is increased. The displacement of steering unit is
280ml/r.
(1) Neutral Feedback of Full Hydraulic Steering Unit
The neutral feedback of full hydraulic steering unit is formed with oil circuit closed by the reactive force
of the fixed spring (when steering wheel stops turning, or when engine is flamed out, and the steering
wheel is released, the steering wheel returns to the initial position), while the steering wheel can rotate
only after the neutral feedback is formed, and otherwise, the operator is unable to turn the steering
wheel.
(4) When oil pump is unable to feed oil, the full hydraulic steering unit will serve as a manual pump,
able to achieve manual steering.
- - 39
5.5 Steering Cylinder
The steering cylinder is assembled on the steering axle, to be operated by full hydraulic steering unit.
The cylinder body is fixed on the axle, and the push rods on both ends are connected with steering
knuckle using link plate, as indicated in Fig 5.7.
Fig 5.7 Steering Cylinder
1. Dust Sealing Ring 2. Retainer Ring 3. Lock Washer 4.Seal Ring 5.Cylinder Cover
6. Cylinder Body 7.Seal Ring 8. Piston Rod 9. O-Ring 10.Shaft Sleeve 11. Support Ring
- - 40
5.6 Failure Removal for Steering System
Issue Causes Remedy
Failure of Oil level of oil tank low Oil to be added
Steering
Suction pipe or oil filter blocked To be cleaned or replaced
Wheel to
Turn Control valve blocked or damaged To be replaced
Oil level of oil tank low Oil to be added
Steering
Air present in oil circuit Air to be released
Operation
Oil pressure low Pressure to be adjusted
Tiresome
Control valve blocked or damaged To be cleaned or replaced
Locking nut to be
Forklift Control valve slot loosened
re-tightened
Truck
Control valve damaged To be replaced
Hunting or
Swinging
Leaf spring broken or elasticity insufficient To be replaced
Oil pump damaged or out of order To be replaced
Abnormal Bypass valve blocked or damaged To be cleaned or replaced
Noise Control valve blocked, worn, or damaged To be replaced or repaired
Hose or joint damaged or pipeline blocked To be replaced or repaired
Seal of guide sleeve for steering cylinder damaged or piping

Oil Leak To be replaced
joint damaged
- - 41
Model LR4B3-G89 and/or 1104D-44 Fitted with

CBKa-G32-ATΦL/ CBKa-G32-ATΦR
S6S Fitted with CBKa-G25-ATΦL/ CBKa-G25-ATΦR
Oil Pump Type Gear Type
Drive Transmission Driven
Displacement 32×2ml/r / 25×2ml/r
Pressure (Rated Pressure) 20MPa
Model 1WFL-F25L-25
Bypass Valve Shunt Capacity 25L/min

Shunt Pressure 16MPa
Model CBD-F20D
Multi-way Double Slide Valve Type, with overflow valve, tilt

Type
Valve auto-locking valve, without bypass valve
Pressure (System Pressure) 19MPa
Type Single Acting Type
Lifting Cylinder Diameter 70mm

Cylinder Rod Diameter 50mm
Stroke 1495mm
Type Double Acting Type
Cylinder Diameter 90mm

Tilting Cylinder
Rod Diameter 45mm
Stroke 202mm
6. Hydraulic System
This machine uses dual-pump double-circuit hydraulic system (as in Fig 6.1), and the front and rear gear
pumps are driven by transmission case for the operating oil pump. One circuit of pressure oil enters into
brake valve through bypass valve, to meet the brake requirement, and at the same time is distributed to
the full hydraulic gear by brake valve, while the other circuit interflows into the multi-way valve. The
steering unit sends the pressure oil into the steering cylinder through oil pipe according to steering work
condition, and the milti-way valve controls the lifting cylinder and the tilting cylinder.
- - 42
6.1 Operating Oil Pump
CBKa-G32-ATΦL/ CBKa-G32-ATΦR model HP gear pump is used for LR4B3-G89/1104D-44
operating oil pump, and the nominal displacement is 32×2 ml/r, while CBKa-G25-ATΦL
/CBKa-G25-ATΦR model HP gear pump is used for S6S operating oil pump, and the nominal
displacement is 25×2ml/r. The gear pumps on the transmission case are the front and rear gear pumps,
mainly composed of driving gear, driven gear, and pump body.
- - 43
Fig 6.1 Schematic Diagram for Hydraulic System

6.2 Bypass Valve (Fig 6.2)
1WFL-F25L-25 bypass valve is used for bypass valve, and its function is to supply one part of oil to
brake system, to be used by power brake and steering system, in addition to feeding the oil to the
operating system.
- - 44
Fig 6.2 Bypass Valve
6.3 Multi-way Valve
This machine adopts CBD-F20D-model milti-way valve, and this valve is of a unit combination type,
able to be added with control valve block as per requirements. Its function is to distribute the HP oil
from oil pump to respective operating cylinders of the forklift truck, and for oil to flow back to the oil
tank. The flow direction is changed through control handle. The milti-way valve is indicated as in Fig
6.3.
This multi-way valve is in the cut type, and it is composed of three main parts including oil inlet port, oil
outlet port, and slide valve, with these three parts sub-assembled together using three bolts. A cylinder
main safety valve is available on the top of oil inlet port, used to adjust oil pressure in oil circuit.
The slide valve is used to control the lifting and tilting cylinders. It achieves the purpose for controlling
cylinders through control over lifting and tilting valve levers to change the oil flow.
Tilt auto-lock valve is mounted on the tilt slide valve, and the return oil from the cylinder returns to oil
tank through this valve. Each valve plate is sealed using R-ring, and at the same time, one one-way
valve is fitted in the oil circuit at the high pressure side.
- - 45
Lifting/Lowering Valve Block

Main Safety Valve Tilting Valve Block
Return Oil Inlet

Oil Inlet
Bypass Valve Oil Inlet
Steering Safety Valve
Fig 6.3 Multi-way Valve
(1) Operation of Multi-way Valve
a. Neutral Position (Fig 6.4)
The oil drained from the main pump returns to oil
tank through the neutral passage. At this point,
both Port A and Port B are in the closed status.
Fig 6.4
b. Push-in Slide Valve (Fig 6.5)
When slide valve is pushed in, the neutral passage is
in the close status, and the oil from the oil port
pushes open the one-way valve, and flows into
cylinder Port B, while the oil drained from cylinder
Port A returns to oil tank through LP oil passage. It is
able for slide valve to return to neutral position, by
virtue of return spring. Fig 6.5
- - 46
c. Pull-out Slide Valve (Fig 6.6)
When slide valve is pulled out, the neutral passage
is also under the closed status, and the oil
incoming from the oil inlet port pushes open the
one-way valve, and flows into the cylinder Port A,
while the return oil drained from the cylinder Port
B returns to oil tank through LP passage. It is able
for slide valve to return to neutral position, by virtue of return spring.

Fig 6.6
(2) Work of Main Safety Valve
a. The main safety valve is mounted between the HP
joint HP and the LP passage LP. The oil flowing
through the Valve Core C acts on the Valve Cores A
and B of different diameters, thus the Valve Core K
of one-way valve and the Valve Core D of the main
safety valve are both firmly fallen into the valve seat,
as indicated in Fig 6.7. Fig 6.7
b. When oil pressure in HP passage exceeds the
pressure adjusted by priority valve core and spring
force, the Priority Valve Core E is opened. The oil
passes through the holes around the valve core, and
then flows into the LP passage LP, as indicated in Fig
6.8.
Fig 6.8
c. When Priority Valve Core E is opened, the pressure
after the Valve Core D drops, and therefore the Valve
Core D moves rightwards, thus the oil circuit after
the Valve Core D is cut off, and thereby its internal
pressure drops, as indicated in Fig 6.9.
Fig 6.9
- - 47
d. When oil pressure of HP oil passage HP is lower

than the oil pressure of LP oil passage, as the area
difference of the two valve cores opens the Valve
Core D, thus the HP passage is directly through to
the LP passage, and oil can directly flow into the LP
oil passage LP, as indicted in Fig 6.10.
Fig 6.10
(3) Work of Tilt Auto-locking Valve

Tilt auto-locking valve is used to prevent the shake of
mast caused by possibly generated negative pressure
inside tilting cylinder, and at the same time it has
avoided the danger of mast tilt due to misoperation
when engine is flamed out, as indicated in Fig 6.11.
a. When slide valve is pulled out, oil flow status is
indicated as in Fig 6.5.
Fig 6.11
b. At the time when slide valve is pushed in
The oil from the main pump enters into tilting
cylinder through Oil Port B, and the return oil after
passing through Oil Port A, as indicated in Fig 6.12,
returns ultimately to the oil tank after entering into
the LP oil circuit through Holes A and B on the slide
valve.
Fig 6.12
c. Slide valve pushed in when engine is flamed out
When engine is flamed out, there is no output of
pressure oil, as oil pump is not working. So
pressure cannot be generated on the Section P, and
valve core does not act, there is no oil flow at Port
B, and return oil cannot return to oil tank through
Port A, thus the tilting cylinder is locked, as
indicated in Fig 6.13. Fig 6.13
- - 48
6.4 Lifting Cylinder
Two single-acting lifting cylinders are fixed on the rear sides of the channel beams for the outer mast,
and the bottom of cylinder is fixed onto the bracket for lifting cylinder of outer mast using pins and bolts,
while the top of the cylinder (namely the top of the piston rod) is connected with the upper crossbeam of
inner mast.
The lifting cylinder assembly mainly consists of cylinder body, piston, piston rod, cylinder head, and
piston head. One pipe burst safety valve is mounted on the right side of cylinder body. The HP oil inlet
port is located in the lower part, while return oil port connected with return oil pipe is located in the
upper part of the cylinder, as indicated in Fig 6.14.
The piston is pushed by the piston rod with lock ring, and one support ring and one seal ring are
available on the surface of piston. This piston slides along the inner surface of cylinder body under the
action of HP oil.
Shaft sleeve and dustproof ring are fitted in the inner hole of cylinder head, and this shaft sleeve
supports the piston rod and the dustproof ring, able for the cylinder body to resist dust. The left and right
piston rods are connected on the upper end of inner mast on their top, and fastened with bolts. The
sprocket wheel is installed on the two ends in the upper part of inner mast.
When slide valve of multi-way valve is pulled backward, the HP oil enters through the bottom of lifting
cylinder, to push the piston and the piston rod, for cargo fork and inner mast to rise by virtue of lifting
chain. When lifting slide valve is pushed forward, the piston falls under the action of piston rod, carriage,
cargo fork, and cargo weight, so that the oil under the piston flows out from the bottom of cylinder. The
oil drained from the lifting cylinder is controlled by throttle vale, and returns to oil tank through
multi-way valve. Hydraulic oil in the oil tank is sucked into the upper part of the cylinder, to lubricate
the piston rod.
One pipe burst safety valve is available at the bottom of lifting cylinder, to prevent abrupt drop of cargo,
when HP rubber hose is suddenly cracked. The oil from the lifting cylinder allows a pressure difference
to be generated for the two cavities through the oil holes around the slide valve of pipe burst safety valve,
and the slide valve remains still when is pressure difference is smaller than the spring force. If HP rubber
hose is cracked, a huge pressure difference is formed, for the slide valve to move and block up the oil
holes around it, while only a small quantity of oil is allowed to flow though the pores in the end part of
slide valve, for cargo fork to fall slowly.
- - 49
Fig 6.14 Lifting Cylinder
1. Piston Rod 2. Dustproof ring 3.Cylinder Head 4.Seal Ring 5. O-Ring 6. Bearing 7.
Bushing 8. Cylinder body 9. Adjusting Spacer 10. Retainer Ring 11. Support Ring 12. Snap
ring 13.Seal Ring 14.Piston 15. Spring 16. Slide Valve 17. Pin
6.5 Cut-off Valve
The limiting valve is mounted in the place of HP oil port at the bottom of lifting cylinder, to limit the
lowering speed when cargo fork is loaded with weight, and at the same time when the rubber hose
between the multi-way reversing vale and the lifting cylinder is cracked, the limiting valve can serve as
a safety device.
Its action is shown as in Fig 6.15. When slide valve of multi-way valve is at the “Falling” position, the
oil returning from the lifting cylinder flows into the Cavity C, then into the Cavity B, through oil holes
F.E.D.C, and further then pass through the Valve Core (7) and the Cavity A, into the lifting cylinder.
The Valve Core (7) moves rightwards under the push of oil in oil hole of Valve Core (7), for the Hole C
to turn narrow, so that the oil volume through the Hole C is reduced, thus to achieve the control over the
lowering speed of cargo fork. When slide valve of multi-way valve is at “Rising” position, the HP oil
from the multi-way valve passes through Cavity A and enters into Cavity B, and then flows through oil
holes C.D.E.F.G, into the listing cylinder.
- - 50
Connected to Lifting Cylinder
Fig 6.15 Cut-off Valve
1. Joint 2. Spring 3. O-Ring 4. Retainer Ring 5. Pore Plate
6. Valve Sleeve 7. Valve Core 8. Nylon Ball 9. Spring 10. Valve Body
6.6 Tilting Cylinder (Figure 6.16)
The tilting cylinder is of double-action type, mounted on the two sides of mast. Its piston rod end is
connected with mast, and the bottom of tilting cylinder is connected with truck frame using pins.
The tilting cylinder assembly mainly consists of cylinder body, cylinder head, piston, and piston rod.
Piston and piston rod are in welded structure, and one support ring and two seal rings are fitted on the
outer edge of piston, to move along the inner surface of the cylinder body under the action of hydraulic
oil.
Shaft sleeve is pressed and fitted in the inner hole of guide sleeve, with real ring and dustproof ring
loaded, able to prevent oil leak and dust. The shaft sleeve supports the piston rod, and is screwed onto
the cylinder body together with O-ring.
When tilt slide valve is pushed forward, the high pressure oil enters from the front end of cylinder body,
to push backward the piston, until the mast tips back by 12°.
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Fig 6.16 Tilting Cylinder
1. Oil Cup 2. Ear Cup 3. Retainer Ring 4. Knuckle Bearing
5. Limiting Sleeve 6. Piston Assembly 7. Dustproof ring 8. Retainer Ring
9.Cylinder Cover 10. O-Ring 11. Support Ring 12.Seal Ring
13. Bushing 14. Cylinder body 15. Shaft Lining 16.Seal Ring
17. Snap Ring 18. Retainer Ring
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6.7 Common Failures and Removal Methods for Hydraulic System
Issue Possible Cause Remedy

Oil level in oil tank to the low end Oil to be added to the specified oil
Failure of Oil
level
Pump for Oil to
Oil filter of suction pipeline blocked To be cleaned, and oil to be replaced
Come
if it is dirty
Bearing inside oil pump worn out, and sealing
To be replaced
filler damaged
Pressure adjustment for overflow valve To be readjusted
improper
Insufficient
(1) Loosened joint at the side of
Pressure for HP
suction pipe to be re-tightened
Oil
(2) Oil to be added into oil tank
Air blended into pump
(3) Oil seal of pump to be examined
(4) Pump to be only turned on until
there is no more air bubble in oil tank
Joint at the side of suction pipe loosened,
Each joint to be re-tightened
leading to air indraft
(1) Oil of proper viscosity to be used
Big Noise with Oil viscosity too high, giving rise to empty
(2) Work to be started only when oil
Gear Pump cavity
temperature is normal
Air bubble present in hydraulic oil Cause for generation of air bubble to
be examined, and to be repaired
(1) Oil seal and seal ring of pump at fault
Oil Leak with
(2) Sliding surface worn out (internal leak To be replaced
Pump
aggravated)
(1) Gear of oil pump damaged or internal leak (1) Damaged parts to be replaced or
Slack Lift of severe the pump to be replaced
Working Device (2) Oil seal of lifting cylinder damaged (2) Oil seal to be replaced
or Failure of (3) Safety valve of milti-way valve failed (3) To be examined and repaired
Working Device (4) Deteriorated oil to be replaced
to Rise (4) Oil temperature too high and the cause for too high oil
temperature to be examined
(1) Internal leak of multi-way valve serious (1) To be disassembled for
Considerable
examination, and to be rehabilitated
Downslide of
(2) Oil seal of cylinder damaged (2) To be replaced
Cargo Fork and
(3) Return spring of multi-way valve
Automatic Tilt of
damaged, and slide valve not in the middle (3) Return spring to be replaced
Mast
position
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7. Working Device
Only 2-stage standard mast is introduced in this manual.

Type Mobile Type, 2-stage Automatic Telescopic Mast (“J”-shaped
Inner Mast and “C”-shaped Outer Mast)
Main Roller Φ123
Side Roller for Inside Frame Φ67
Side Roller for Sliding Carriage 1480707KT Φ102
Sprocket Wheel Φ55×Φ135×Φ148.5
Lifting Chain LH1634, 3×4 Combination
Upper Roller for Outside Frame CN-16 Φ87
Carriage Lifting System Hydraulic
Cargo Fork Spacing Adjusting Device Manual/Hydraulic
The working device is mainly used to fulfill fork taking, loading-unloading, lifting, and stacking, etc. It
is mainly composed of cargo fork, mast, lifting chain, lifting cylinder, and tilting cylinder, etc. This
device has 3m~6m lift heights for user selection. Its structure is indicated as in Fig 7.1.
7.1 Mast
This is a 2-stage CJ-shaped telescopic mast, and its inner mast and outer mast are both in framework
welded and pulled structure. Mast bracket is welded in the lower part of the outer mast, for the mast to
be connected onto the drive axle used for supporting working device, and able to rotate around the
casing. A bracket connected with tilting cylinder is welded in the middle part of the outer mast, and
when the piston rod of tilting cylinder stretches or retracts, the working device rotates around the drive
center, to achieve forward and backward tilt. The lifting cylinder bracket is welded at the bottom of
outer mast to support the lifting cylinder. One group of rollers are respectively fitted on the inner and
outer sides on the upper end of outer mast, used for top guide of inner mast when outer mast is lifted.
Two groups of rollers are mounted on the two sides in the lower part of inner mast. The vertical roller
touches the 2 wing plates for the channel beam of mast, able to prevent vertical deflection of inner mast,
for its movement to be balanced, and for rollers to turn freely. The side roller touches the web plate for
the channel beam of outer mast, able to prevent horizontal deflection, and its single-side contact is
0.5~1.0mm, while this clearance may be adjusted by the method through increase or decrease in
adjusting shims.
7.2 Carriage
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Vertical roller and side roller are mounted on the vertical plate of carriage, and the clearance
adjustment between it and the wing plate and the web plate of inner mast is the same as the above
mentioned inner and outer masts. The cargo fork and the carriage roll and lift in the inner mast, and the
spacing of the two cargo forks may be adjusted according to work status, ranging 300~1380mm.
7.3 Lifting chain
The lifting chain is a plate chain. The lower-end joints of the two chains are respectively connected with
fork carriage, and the other end is connected with the upper end of the outer mast, after the chain is
winded through sprocket.
Fig 7.1 Working Device

1. Lifting Cylinder 2. Tilting Cylinder 3. Outer Mast 4. Inner Mast
5. Lifting Chain 6. Carriage 7. Cargo Fork
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8. Electrical System
8.1 Overview
The electrical system of the forklift truck is composed of starting system, charging system, and lighting
and signal equipment, and negative earth is applied to CBU, with two groups of 12V batteries to supply
power. The lead wires for different circuits are differentiated by colors. The main part of starting system
includes starter, and the charging system mainly has generator and voltage regulator, while lighting and
signal equipment is composed of truck lights and buzzer typical of various functions.
The CBU wire harness is divided into generator harness, overhead guard harness, and taillight holder
harness, and the wire harnesses for respective parts are connected using plug-in connectors, able to
considerably facilitate installation and maintenance.
8.2 Instrument Signal and Operation Instructions
(1) Preheating Start Switch:
a) Right-hand turn 1st gear to switch on instrument and ignition power supply, and to
automatically preheat
b) Right-hand turn 2nd gear to start engine
c) Recovery to original position, to flame out the engine (1104D-44)
Note:
a. It is required to start the engine only when the gear shift is placed on neutral position, and
otherwise engine is unable to work.
b. Preheating is required for S6S and 1104D-44 engines, while preheating is not required for
4108, as it is a direct injection engine.
(2) Preheating Indication: When switch is turned rightward to 1st gear, it switches on the instrument and
the ignition power supply. The preheating indicator light turns on, indicating that engine is preheating,
and the preheating circuit is automatically powered on for preheating: After a period of time (12±5S),
the preheating indicator light turns off, indicating preheating is completed. The preheating circuit will
automatically cut off power supply to stop preheating.
(3) Light Switch: Turn forward the switch for one gear, the width light turns on, while turn forward the
switch for two gears, the front headlight will turn on.
(4) Turn Signal Switch: Push forward the turn signal switch, the left turn signal light turns on, and the
left-hand steering indicator light on instrument panel turns on, indicating that the forklift truck turn left.
Pull backward the turn signal switch, the right turn signal light turns on, and the right-hand steering
indicator light on instrument panel turns on, indicating that the forklift truck turns right.
(5) Running Signal: When emergency brake is required for the forklift truck, push down the brake pedal,
and the brake light will turn on.
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(6) Direction Control and Signal: Pushing forward the direction switch for one gear indicates Forward
1st Gear, and pushing it forward for two gears indicates Forward 2nd Gear. When direction switch is
placed in the middle, it indicates neutral gear, and at this point the neutral gear indicator light on
instrument turns on, indicating that engine can be started, while engine is unable to work otherwise.
Pulling backward the direction switch for one gear indicates Backward 1st Gear, and pulling it backward
for two gears indicates Backward 2nd Gear. When direction switch is at the position of backward gear,
reversing light and caution light turn on, and reversing buzzer sounds.
(7) Oil Pressure Alarm Display: Turn the key switch rightward for one gear, the engine oil indicator light
turns on, and the indicator light turns off after the engine is running. It is the oil pressure alarm display if
this indicator light turns on during working process of the forklift truck, and shutdown for examination
is required.
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(8) Charging Alarm Display: Turn the key switch rightward for one gear, the charging indicator light
turns on, and it indicates charging when this light turns off after engine is running. It then indicates that
failure exists with charging system, if this light turns on during the working process of the forklift truck,
and shutdown for examination is required.
(9) Oil-Water Separator Indicator Light: If this indicator light turns on alone, it indicates that water is
already full in the oil-water separator, and it is required to drain water from the oil-water separator.
(10) Fuel Gage: It indicates the fuel storage status, and is composed with fuel sensor and fuel gage as
components, to display the volume of fuel tank.
(11) Water Temperature Gauge: It displays the temperature of engine cooling water, composed with
water temperature sensor and water temperature gauge as components. The dial scale is differentiated by
two colors, and it indicates that engine is able to work normally when pointer is in the green area.
(12) Torque Converter Oil Temperature: The torque converter oil temperature is displayed in digital
form on the LCD screen in the middle of instrument.
(13) Time Meter: It begins time keeping after engine is started, to accumulate engine running time, and
the display form is the same as that for torque converter oil temperature.
(14) Instrument Indication: (as in Fig 8.1) To sum up the abovementioned, the forklift truck operating
rules are briefly described as follows:
Place the turn signal switch on neutral position. Push down the throttle pedal using right foot. Turn the
key switch rightward for one gear, and at this point, the oil pressure alarm light, the charging indicator
light, the oil-water separator indicator light, and the neutral gear indicator light turn on, and automatic
preheating begins. Observe the preheating indicator light, and it indicates preheating is completed when
the preheating indicator light turns off. After preheating is completed, turn the key switch rightward for
two gears, to switch on the start motor and drive the engine to run. If oil pressure alarm light, charging
indicator light, oil-water separator indicator light turn off after engine is started, the forklift truck is now
able to work. Attention must be paid if engine fails to be started with 5 seconds, restart is required after
waiting for 2 minutes. It is not advisable for the continuous working time of starter to exceed 15 seconds,
and otherwise it is liable to cause starter damage.
8.3 Battery
6-QW-80×2-model XUNQI battery is used for this series of forklift trucks, and attention shall be paid to
the several points as follows during use and maintenance:
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(1) Avoid touching the conductor of the battery during installation and maintenance, as this may
give rise to severe burn injury.
(2) The positive and negative poles cannot be reversely connected during battery charge, and
otherwise it will cause high temperature, burning, smoke, or explosion.
(3) It is required to wear goggles, rubber gloves, and rubber shoes, when battery is maintained.
(4) Battery may generate inflammable gas and has the danger for incidence of explosion.
Therefore, generation of short circuit and sparks shall be avoided, and firework is strictly
prohibited.
(5) It is forbidden to disassemble the battery. The battery electrolyte is dilute sulfuric acid, and it
must be flushed with water immediately when skin is touched. Water shall be used for flushing
and doctor shall be timely visited if it splashes into the eye.
Fig 8.1 Combination Instrument
1. Left Turn Signal Indicator Light 2. Fuel Indicator Light 3. Oil Pressure Warning Indicator Light
4. Charging Indicator Light 5. Neutral Gear Indicator Light 6. Preheating Indicator Light 7. Neutral
Gear Indicator Light 8. Right Turn Signal Indicator Light 9. Water Temperature Gauge 10. Fuel
Gage 11. LCD
8.4 Schematic Diagram for Electrical System
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- - 60
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IV. Safety Drive, Operation, and Routine Maintenance and Service of Forklift
Truck
1. The functions and Application Status of Respective Operating Mechanisms are listed in the following
table:
S/N Name Function Operating Status
To achieve parking brake Pull the handle to perform brake to the front wheel
1 Hand Brake Handle
for forklift truck of forklift truck
To control Push the handle forward is Forward Gear I, further
2 Gear-Shift Handle forward/backward push the handle forward is Forward Gear II, and
movement of forklift truck pull the handle backward is Backward Gear.
3 Hood Pull Button To open engine hood Pull backward to open the hood.
Pull out one gear, for front and rear width lights to
To control the switch for
4 Light Switch turn on, and pull out two gears, for the front
truck lights
headlight to turn on.
To control the driving Left-hand rotation for forklift truck to turn left, and
5 Steering Wheel
direction of forklift truck right-hand rotation for forklift truck to turn right
Flameout Pull Button
6 (Used for Chinese To turn off the engine Pull out the pull button is to turn off the engine.
engines)
Push down the inching pedal, to control the oil
To achieve inching
pressure and oil volume of shift clutch, to achieve
movement of forklift truck,
7 Inching Pedal inching movement of forklift truck, and pushing
for the truck to move
down the inching pedal completely actuates the
slowly
brake pedal to play the braking function
Left-hand turn is Preheating Status, right-hand turn
is Starting Status, while it will automatically turn
To switch on power supply,
8 Start Switch back to running status or flameout status, after key
to start engine
is loosened (The flameout switch for imported
mainframe is also this switch.)
Steering Wheel To adjust the front/rear Push forward to be fixed, and adjust the position of
9
Adjusting Rod position of steering wheel steering wheel after pulled backward to be released
Push down the brake pedal, to slow down the
running speed of forklift truck, until it is parked,
10 Brake Pedal To decelerate for parking
and at the same time, the brake indicator light will
turn on.
To control the engine fuel The longer the pushed stroke is, the more the
11 Throttle Pedal supply, and to control the engine fuel supply will be, and the faster the speed
engine speed will be.
To control the forward/ Turn backward for mast to tilt backward, while
12 Tilting Handle backward tilting position turn forward for mast to tilt forward. Tilting speed
of mast depends on the tilt angle and the opening size of
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throttle.
Turn the handle backward for cargo fork to rise,
To control rise and fall of while turn the handle forward for cargo fork to fall.
13 Lifting Handle
cargo fork The cargo fork lifting speed depends on the size of
tilt angle and the opening size of throttle.
Operate this lever, and the turn signal indicator
Turn Signal Light To control the turning
14 light will flash – Forward – Left-hand Turn Signal
Switch Light indication for forklift truck
and Backward – Right-hand Turn Signal
To give out sound, to
Press the rubber cover in the center of steering
15 Horn Button arouse the attention of the
wheel, the horn will give out sound.
surrounding pedestrians
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2. Notices Prior to Use
In order to secure a high-efficiency work and prolong the service life of the forklift truck, pay attention
to the following points prior to use:
(1) This forklift truck is installed with homemade or imported engine, and please carefully read this
manual (carryover with the machine) for use and maintenance.
(2) Examine the tyre air pressure according to specification, and it shall be timely charged when
requirement is not met.
(3) Oil tanks shall be filled up with various oils as per requirement, and enough lubricating oil shall be
added at the lubricating parts (Refer to Filling Volumes and Lubricating Points for forklift truck.).
(4) Examine the electrical system, as to whether or not poor contact or short circuit exists.
(5) Examine the brake system, to secure a flexible and reliable brake.
(6) Examine the heat radiator, and fill anti-freeze fluid based on requirement.
3. Start of Engine
(1) Place the gear-shift handle at the neutral gear position, and put the handbrake handle at the brake
position.
(2) During startup, insert the key into the preheating start switch, and turn it in counterclockwise
direction. Firstly preheat for 15~ 20 seconds, and then turn to the “Start” position in clockwise direction,
the start motor can then begin startup. When hand is released from the key, the key will automatically
return to “Run” position under the action of spring force. The starting time shall not exceed 5 seconds
for each time, and restart may proceed after an interval of 2 minutes. When engine still fails to work
after startup for a number of times, the failure shall be examined and removed. It is never allowed to
continuously start the engine for a long time.
(3) Race the engine for about 5 minutes after it is started, full-load operation is only allowable, until the
temperature engine cooling water has risen to about 60°. The forklift truck shall be cooled down for 5
minutes, and then be shut down.
Notices:
a. When engine is turned off, the preheating start switch shall not be at the “Run” position, and
otherwise it will give rise to battery discharging effect.
b. When engine is running, it is not allowed to turn the preheating start switch to “Start” position, and
otherwise it may damage start motor.
4. Notices for Safety Operation
(1) Only trained and approved operators are allowed to operate the forklift truck.
(2) It is strictly prohibited for this forklift truck to be used under the environments with potential
explosive hazard (liquefied gas tank, timber, paper, and chemical substances).
- - 64
(3) When engine is racing after being started, examine whether or not the readings of respective
instruments are within the range of application, and otherwise, immediate shutdown for examination is
required.
(4) Overloaded use is prohibited, and the load-lifting capacity and load center shall be within the
specified ranges (Refer to data plate for load curves.).
(5) The forklift truck shall drive slowly into cargo stacks,
and at the same time pay attention as to whether or not
protruding hard objects are present around the cargo
stack, to avoid stab of tyres.
(6) It is prohibited to pick up the cargo using one single
fork, and the cargo forks shall be combined, for the two
forks to be located in the middle and placed in the center
of cargo, when cargo is to be picked up.
(7) During operation of forklift truck, the loads borne by
two cargo forks shall be the same as much as possible,
to avoid offset load.
(8) When cargo is lifted, the mast shall be placed at a vertical position, and the forklift truck shall be
under the braked status.
(9) When cargo is lifted, the throttle shall be properly increased according to the cargo weight and size,
before the lifting control lever is turned.
(10) Drop of cargo depends on the gravity action of cargo, and on this account engine shall be put under
idling condition when cargo is falling. Slowly turn the handle, for cargo to drop slowly, to prevent a
sudden fall of cargo.
(11) Before mast is tilted forward or backward, the forklift truck shall be braked. Throttle shall be
decreased for a slow tilt during tip forward, to prevent sudden cargo slide-out.
(12) When forklift truck is running, the cargo forks shall be lifted in a place of 300~500mm ground
clearance, and the mast shall tip back.
(13) It is not allowed to reverse direction, when forklift truck
has not yet been fully decelerated and parked (such as
forward to backward, or backward to forward), to prevent
damage of parts.
(14) Engine shall not be turned off, when forklift truck is
running, and otherwise it will cause braking and steering to
be tiresome.
(15) It is strictly prohibited for anyone to be under the fork
carriage, after cargo fork is lifted.
- - 65
5. Notices for Prevention from Tip-over
- - 66
6. Notices for Running-in of New Forklift Truck

New truck shall run at low load and low RPM during the initial use for 100 hours, and abrupt
acceleration and brake shall be avoided. The lubricating oil in diesel engine oil pan, transmission, and
drive axle and the operating oil in operating oil tank shall be replaced, after use for 200 hours.
7. Oils Used for Forklift Truck
Filling Time (Hour)

S/N Filling Position Oil Brand Oil Volume
50 100 500 1000
1 Operating Oil Tank AN32/N46 # Hydraulic Oil About 90L +
-10 # Diesel Fuel/0 #
2 Fuel Tank About 90L To be examined every day
Gasoline
Transmission Case 6# Hydraulic Transmission
3 About 20L +
(Torque Converter) Fluid
As per engine
4 Engine Oil Pan About 15L
requirement
Gear Lubricating Oil
5 Drive Axle +
85W/90
Anti-freeze Fluid Model
6 Radiator About 15L To be examined every day
FD-2 Type -35℃
- - 67
8. Examination Prior to Truck Dispatch for Each Working Shift
(1) Examine the fuel storage volume.
(2) Examine whether or not leakage exists with oil pipe, water pipe, exhaust pipe, and hydraulic parts.
(3) Examine whether or not the storage volume of hydraulic oil tank has reached the specified capacity.
(4) Examine the fastening degrees for wheel bolts and whether or not the bolts for drive system are
loosened.
(5) Examine whether or not the air pressure of tyre has reached the specified value.
(6) Examine whether or not the steering and drive systems are flexible and reliable.
(7) Examine whether or not the electrical circuit is earthed, whether or not the joint is loosened, and
whether or not various light fittings and instruments are working normally.
9. Regular Examination
(1) Examine the sealing property and working reliability of hydraulic system.
(2) Examine the working reliability of steering and brake system.
(3) Examine the specific weight and level height of battery electrolyte, and it is required to ensure that
the distance of level height to the top end is 12mm. Add distilled water when required.
(4) Examine the reliability for connection between mast, drive axle, and steering axle with truck frame.
(5) Examine whether or not the fastening degree of wheels is reliable.
(6) Transmission oil (torque converter oil) shall be replaced after forklift truck has worked for 500
hours.
(7) Oils for operating oil tank and drive axle shall be replaced with new ones, after forklift truck has
worked for 1000 hours.
10. Irregular Examination
(1) Examine the reliability for respective welded places of mast and truck frame.
(2) Examine whether or not the connecting places for steering cylinder, connecting plate, and universal
joint, etc are firm and reliable.
(3) Examine whether or not oil leakage and oil seepage exist with all the oil pipelines, and whether or
not damage exists with all the hoses.
(4) Examine whether or not running brake and parking brake performances are compliant with the
standards.
11．Regular Maintenance
Attention:
·It is required for forklift truck to be regularly examined and maintained, for it to be under a good
performance status.
·Examination and maintenance are liable to be neglected very often, and problems shall be found as
early as possible and solved timely.
·Use authentic Maximal accessories.
·Avoid using oil of different model, when oil is to be replaced or filled.
- - 68
·The replaced scrap oil and battery shall be subject to recovery treatment according to the requirements
of the local environmental laws and regulations, and they shall not be dumped and abandoned at
discretion, in order to prevent environmental pollution.
·It is forbidden to repair the forklift without being trained.
This timetable is set based on standard working hours and operating conditions. Please perform
maintenance in advance, if forklift truck works under atrocious conditions (“●” indicating replacement).
Engine
Monthly Quarterly Semianually Annually
Daily (8
Item Examination Item Tool (200 (600 (1200 (2400
Hours)
Hours) Hours) Hours) Hours)
Visually
examining engine ○ ○ ○ ○ ○
running status
Sound of engine ○ ○ ○ ○ ○
Exhaust color ○ ○ ○ ○ ○
Cleaning or
replacing air filter ○ ○ ● ●
core
Examining
○
crankcase and ○ ○
cleaning scale
Engine Examining and Thick Feeler
adjusting valve Gage ○ ○
clearance
Tightening Torque ○
cylinder head bolt Wrench Only for
○ C240
Diesel
Engine
Examining Pressure
cylinder Gauge
○
compression
pressure
- - 69
Examining the
Crankshaft
blocked or
Ventilation ○ ○
damaged status of
Device
valve and pipe
Speed Examining the Tachometer
Governor maximum
○
or Injection rotational speed at
Pump no load
Whether or not oil
○ ○ ○ ○ ○
leak with engine
Examining oil
volume and ○ ○ ○ ○ ○
cleanliness
Replacing engine ●
Lubrication
oil 50 Hours
System ● ● ●
for First
Time
Replacing engine ●
oil filter core 50 Hours
● ● ●
for First
Time
Visually
examining whether
Fuel
or not oil leak with ○ ○ ○ ○ ○
System
oil pipe, oil pump,
and oil tank
Examining
whether or not fuel ○ ○ ○
filter is blocked
Cleaning fuel filter
○ ○ ●
(gasoline engine)
Replacing fuel
filter (diesel ● ● ●
engine)
Examining nozzle, Injection test
and adjusting machine
○ ○
pressure status
(diesel engine)
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Examining
loosening status
for the connecting
○ ○ ○
mechanism and
cleanliness of
carburetor
Ignition moment Time Meter
○ ○ ○
(diesel engine
Jet moment (diesel
○
engine)
Water discharge
○ ○ ○
for fuel tank
Cleaning fuel tank ○ ○
Examining fuel
○ ○ ○ ○ ○
volume
Coolant volume ○ ○ ○ ○ ○
Leaking status ○ ○ ○ ○ ○
Rubber hose
○ ○ ○
ageing status
Performance and
Cooling installation status ○ ○ ○ ○
System of radiator cover

Cleaning or
● ● ●
replacing coolant
Examining
tensioning force
○ ○ ○ ○ ○
and damage status
for belt of fan
- - 71
Power Transmission
Daily Monthly Quarterly Semianually Annually
Item Examination Item Tool (8 (200 (600 (1200 (2400
Hours) Hours) Hours) Hours) Hours)
Examining idle stroke Dividing
of clutch pedal and Ruler
clearance between
○ ○ ○ ○ ○
pedal surface and
bottom plate when
Clutch
clutch is disengaged
Sound and operating
○ ○ ○ ○ ○
status
Slide and engagement
○ ○ ○ ○ ○
status
Operating status of
gear-shift lever and
Mechanical ○ ○ ○ ○
whether or not
Transmission
loosened
Case
Examining leakage ○ ○ ○ ○ ○
Replacing oil ● ●
Examining oil volume
○ ○ ● ●
and replacing oil
Operating and
loosening status of ○ ○ ○ ○
gear-shift lever
Performance of
control valve and ○ ○ ○ ○ ○
Hydraulic hydraulic clutch
Transmission Performance of
Case ○ ○ ○ ○ ○
inching valve
Idle stroke and
movement status of ○ ○ ○ ○ ○
inching pedal
Replacing oil suction ●
filter core 200
Hours ● ●
for First
Time
Leaking examination ○ ○ ○ ○ ○
Front Axle Replacing oil ● ●

Loosening status of Detection
○ ○ ○ ○
mounting bolt Hammer
- - 72
Wheel
Daily Monthly Quarterly Annually
Examination Semianually
Item Tool (8 (200 (600 (2400
Item (1200 Hours)
Air
Charging
Pressure ○ ○ ○ ○ ○
pressure
Gauge
Crack or injury ○ ○ ○ ○ ○
Wearing status
for ground ○ ○ ○ ○
touchdown
Tyre
Abnormal Depth
○ ○ ○ ○ ○
wearing status gauge
Whether or not
nail, stone, or
other extraneous ○ ○ ○ ○
substance is
present on tyre
Examining Detection
whether or not Hammer ○ ○ ○ ○ ○
Tyre
bolt is loosened
Installation
Examining
○ ○ ○ ○ ○
injury status
Injury status of
Rim
rim, wheel
Wheel ○ ○ ○ ○ ○
spoke, and disc
Spoke
wheel
Examining
looseness and ○ ○ ○ ○
Axle noise
Bearing Wiping up and
refill lubricating ● ●
oil
Examining
distortion,
Axle crack, or injury ○ ○ ○ ○
status of axle
body
- - 73
Steering System
Examination Semianually
Item Tool (8 (200 (600 (2400
Item (1200 Hours)
Examining
○ ○ ○ ○ ○
clearance
Examining axial
○ ○ ○ ○ ○
Steering looseness
Wheel Examining
○ ○ ○ ○ ○
radial looseness
Examining
○ ○ ○ ○ ○
operating status
Examining
Steering whether or not
○ ○ ○ ○
Unit mounting bolt is
loosened
Examining
whether or not
king pin is ○ ○ ○ ○
loosened or
injured
Rear Axle
Examining
Steering
bend, distortion,
Knuckle ○ ○ ○ ○
crack or injury
status
Examining
Detection
installation ○ ○ ○ ○
Hammer
status
Examining
○ ○ ○ ○ ○
operating status
Examining
whether or not ○ ○ ○ ○ ○
Steering leakage exists
Cylinder Examining
whether or not
loosened during ○ ○ ○ ○
assembly and
articulation
- - 74
Brake System
Semianually
(1200 Hours)
Idle stroke ○ ○ ○ ○ ○
Dividing
Pedal stroke ○ ○ ○ ○ ○
Brake Ruler
Pedal Operating status ○ ○ ○ ○ ○
Whether or not air
○ ○ ○ ○ ○
exists in brake pipe
Whether or not
brake is safe and
reliable, and
Parking ○ ○ ○ ○ ○
whether or not
Brake
there is enough
Control
stroke
Control
○ ○ ○ ○ ○
performance
Control
○ ○ ○ ○ ○
performance
Rod and
Whether or not
Cable, etc
connection is ○ ○ ○ ○ ○
loosened
Injury, leakage,
○ ○ ○ ○
and crack
Pipeline Loosening status
of connecting and ○ ○ ○ ○
clamping parts
Brake Leaking status ○ ○ ○ ○
Master Examining oil
Cylinder level and replacing ○ ○ ○ ● ●
and oil
Wheel Action status of
Cylinder master cylinder ○
and wheel cylinder
- - 75
Leakage and injury
status of master
○
cylinder and wheel
cylinder
Leakage and injury
status of master
●
cylinder and wheel
cylinder
Whether or not the
mounting parts for Detection
○ ○ ○ ○
brake drum are Hammer
loosened
Wearing status of Vernier
○
friction plate Scale
Action status of
○
brake shoe
Whether or not
Brake ○
fixed pin is rusted
Drum and
Damage status of Dividing
Brake ○
return spring Ruler
Shoe
Examining
whether or not
clearance is proper
○
during operation of
automatic
adjusting device
Wear and injury
status of brake ○
drum
Whether or not
bottom plate is ○
distorted
Bottom
Whether or not
Plate of ○
cracked
Brake
Whether or not
loosened during ○
assembly
- - 76
Lifting System
Semianually
(1200 Hours)
Injury, distortion,
and wear status of ○ ○ ○ ○ ○
cargo fork
Injury or wear
status of ○ ○ ○
Cargo Fork positioning pin
Crack and wear
status of welding
part for the hook ○ ○ ○ ○
at the rootage of
cargo fork
Whether or not
the welding parts
for the upper and
Mast and
cross beams of ○ ○ ○ ○
Carriage
inner mast and
outer mast are
cracked or injured
Whether or not
the welding part
of tilting cylinder
bracket and mast ○ ○ ○ ○
is badly welded,
cracked, or
injured.
Whether or not
inner-outer masts
are badly welded, ○ ○ ○ ○
cracked, or
injured
Whether or not
carriage is badly
○ ○ ○ ○
welded, cracked,
or injured
Whether or not
○ ○ ○ ○
roller is loosened
- - 77
Wear and injury
status of mast
○
support bearing
bush
Whether or not
bolt for mast
○ ○ ○
support co9ver is
loosened
Whether or not
bolt on the bottom
of lifting cylinder,
bolt on the head
of piston rod, ○ ○ ○
U-bolt, and bolt
for guide rail of
walking beam are
loosened
Crack and injury
status of roller,
○ ○ ○ ○
roller shaft, and
welded part
Examining chain
tensioning status,
Chain and
and whether or ○ ○ ○ ○ ○
Sprocket
not distorted,
Wheel injured, or rusted
Filling oil to chain ○ ○ ○ ○
Riveted pin and
○ ○ ○ ○
loosening status
Distortion and
Chain and
injury status of ○ ○ ○ ○
Sprocket
sprocket wheel
Wheel
Whether or not
sprocket bearing ○ ○ ○ ○
is loosened
Examining
whether or not
Attachement ○ ○ ○ ○
under normal
status
- - 78
Status as to
whether or not
piston rod, piston
Lifting rod thread, and Detection
○ ○ ○ ○ ○
Cylinder connection are Hammer
loosened,
distorted, or
injured
Operating status ○ ○ ○ ○ ○
Wear and injury
status of pin and
steel-backed ○ ○ ○ ○
bearing for
Hydraulic cylinder
Pump Whether or not oil
leak or noise
○ ○ ○ ○ ○
exists in hydraulic
pump
Wearing status of
driving gear for ○ ○ ○ ○
hydraulic pump
- - 79
Hydraulic System
Semianually
(1200 Hours)
Examining oil
volume, and ○ ○ ○ ○ ○
replacing oil
Hydraulic Cleaning core of
○ ○
Oil Tank suction filter
Removing
extraneous ○ ○
substance
Return Oil Replacing return oil
● ●
Filter filter
Whether or not
Control connection is ○ ○ ○ ○ ○
Valve Lever loosened
Operating status ○ ○ ○ ○ ○
Oil leak ○ ○ ○ ○ ○
Operating status of
safety valve and tilt ○ ○ ○ ○
Multi-way
auto-locking valve
Valve
Oil
Measuring pressure
Pressure ○ ○
of safety valve
Gauge
Leakage, looseness,
crack, distortion, ○ ○ ○ ○ ○
Piping Joint and injury status
●
Replacing pipe 1-2 Years
- - 80
Electrical System
Semianually
(1200 Hours)
Whether or not
distributor cap is ○ ○ ○
cracked
Whether or not
spark plug is ○
burned out
Adjusting the
Feeler
clearance of spark ○ ○ ○
Gage
plug
Cleaning the
Ignition clearance of spark ○ ○ ○
Device plug
(Gasoline Mounting status of
○
cover and HP wire
Engine)
Whether or not
distributor is ○
burned out
Wear and injury
status of center part ○
for distributor
Filling lubricating
○ ○ ○
oil to rotating shaft
HP wire breakage Test
○
status Meter
Start Pinion meshing
○ ○ ○
Motor status
Electrolyte volume
○ ○ ○ ○
and cleaning
Battery Examining specific
weight of ○ ○ ○
electrolyte
Wire harness injury
and loosening ○ ○ ○ ○
Electric status
Wire Loosening status of
connection for ○ ○ ○
electric circuit
- - 81
Safety Devices and Accessories
Semianually
(1200 Hours)
Examining whether
Seat or not bolts are ○ ○
injured or loosened
Whether or not
truck frame and
○
crossbeam are
injured and cracked
Whether or not
Detection
rivet and bolt are ○
Hammer
Truck Body loosened
Examining the ○ ○ ○ ○
parts that have
○
been once repaired,
if required
Overall
○
examination
Examining the ○ ○ ○ ○
Addition of
lubricating status of Grease
Lubricating ○
chassis after Gun
Grease or
cleaning
Replacement
Examining oil in
of Oil ○
oil tank
Key Safety Parts for Regular Replacement
It is difficult for some parts to be found injured or damaged through regular maintenance, and please
replace the parts given in the following table on a regular basis, in order to ensure a safety use of the
truck.
These parts shall be replaced immediately, if they have become abnormal though the replacement time is
not mature.
Name of Key Safety Parts Service Life (Year)
Brake Hose or Hard Tube 1~2
Hydraulic Rubber Hose for Lifting System 1~2
Lifting Chain 2~4
HP Rubber Hose and Hose for Hydraulic System 2
Brake Fluid Oil Cup 2~4
Fuel Hose 2
Inner Sealing Parts and Rubber Parts of Hydraulic
2
System
- - 82
List of Wearing Parts
Under normal operating condition, some parts are easily damaged, and they are listed as follows:
起升油缸 Lifting Cylinder
序号数量备注
S/N 代号 Code 名称 Name QTY Remarks
01 LBH 50×58×5/6.5 Dustproof ring 防尘圈 2
02 ISI 50×60×6 Shaft Seal 轴封 2
03 GB/T1235-1876 O-ring Seal 80×3.1 O 形圈密封 80×3.1 2
04 D70×8×2.5 Hole Support Ring 孔用支承环 2
05 OSI 70×60×6 Hole Seal 孔封 2
倾斜油缸 Tilting Cylinder
序号数量备注
01 LBH 45×53×5/6.5 Dustproof ring 防尘圈 2
转向油缸 Steering Cylinder
序号数量备注
01 LBH60×68×5/6.5 Dustproof ring 防尘圈 2
- - 83
12. Lubricating System Table
Filling Filling Time (Hour)
S/N Filling Position Places Oil Brand
50 100 500 1000
(Points)
Calcium Base
1 Steering Device Bracket 2 +
Grease
Joint for Two Ends of Calcium Base
2 2 +
Steering Cylinder Grease
Calcium Base
3 Steering Knuckle Bearing 4 +
Grease
Calcium Base
4 Steering Axle Bearing Seat 2 +
Grease
Calcium Base
5 Tilting Cylinder Stud 2 +
Grease
Calcium Base
6 Tilting Cylinder Rod Head 2 +
Grease
Mast Support Bearing Calcium Base
7 2 +
Bush Grease
Mast Bracket Lifting Calcium Base
8 8 +
Roller Grease
Note: Refer to Engine Operating Manual for details about engine lubrication.
13. Data Plate and Warning Signs
The data plate pasted on the truck is used to indicate the vehicle application methods and notices. This is
to consider you while taking the vehicle into consideration as well. Please re-affix the data plate
immediately after it is dropped out.
(1) Forklift Truck Data Plate
- - 84
(2) Safety Identification
It is prohibited to stand on and under the cargo fork, to
prevent cargo fork existing safety hidden danger to
human body.
(3) Identification for Prohibiting People from Standing
behind Mast
Forbid standing behind mast, to prevent mast existing hidden danger
to human body.
(4) Identification for Strictly Prohibiting
Carrying People
Caution to driver to forbid carrying people
(5) Tyre Safety Identification
Caution for required points of concern during tyre installation
(6) Identification for Prohibiting Lifting
Forbid using these two holes for lifting, to prevent confusion with the two lifting holes aback.
(7) Fan Caution Identification
Caution for fan existing safety hidden danger, to prevent hand crush injury
- - 85
(8) Identification for Prevention from Hand Burn
Caution for fan existing safety hidden danger, to prevent hand
burn
(9) Identification Indicating Anti-freeze Fluid has been Added
Caution indicating that anti-freeze fluid has been added, and
it is no more needed to add it.
(10) Identification for Hand Crush Injury by Mast
Caution for safety hidden danger existing when mast is lifted,
to prevent hand crush injury during the mast lifting process.
(11) Identification for Prevention from Tip over
Caution indicating that rolling of machine may possibly cause
personal hazard
(12) Safety Identification for Prevention from Electric Shock
Caution for battery existing safety hidden danger, to prevent
electric shock
(13) Identification for Strictly Prohibiting Flushing
Caution that the intake window shall not be flushed, to prevent
water entry into air filter.
14. Package and Conveyance

Hoist the Forklift Truck
·Tie firmly the cable wire in the lifting holes at both ends of the crossbeam on outer mast and the
counterweight hook, and then hoist the forklift truck using lifting device.
Warning:
·Make sure not to wind the cable wire and the overhead guard together, when forklift truck is hoisted.
- - 86
·The cable wire and the lifting device shall be very firm, safe enough to support the forklift truck (The
forklift truck is extremely heavy.).
·Never use cab (overhead guard) to lift up the forklift truck.
·Never enter into under the forklift truck, when forklift truck is lifted.
Conveyance
·Forklift truck is generally used for loading-unloading and short-distance conveyance, not suitable for
long-distance transportation. In the case when forklift truck is to be conveyed for a long distance, it shall
be conveyed using ship, train, or truck with a carrying capacity larger than 5T, and other load-carrying
vehicles. Use wedges to block up wheels firmly, and at the same time bind the vehicle body firmly and
reliably, to prevent glide of vehicle on the way of transportation.
- - 87
中美合资-浙江美科斯叉车有限公司
Sino-American Zhejiang Maximal Forklift Co., Ltd
地址: 浙江省富阳市鹿山街道金鑫路 1 号
Address: #1, Jinxin Road, Lushan Subdistrict, Fuyang, Zhejiang Province
电话: 0571-63160118/63486999
Tel: 0571-63160118/63486999
传真: 0571-63160107
Fax: 0571-63160107
网址: www.maxforklift.cn
Web: www.maxforklift.cn
E-mail:mks@maxforklift.com
浙江美科斯叉车有限公司保留对该手册内容的修改、删除及解释权。如有疑问，请及时联系本公
司。
Zhejiang Maximal Forklift Truck Co., Ltd reserves the right to modify, delete, and interpret the content
of this manual. Please contact our Company timely, should you have any query.
- - 88

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4-5t Internal Combustion Counterbalance Forklift Truck

Operation & Maintenance Manual

M series of FD40T, FD45T and FD50Tinternal combustion counterbalance forklift trucks is

applicable to loading-unloading, stacking, and short-distance conveyance of the formed

driving performance, as ideal equipment for achieving loading-unloading mechanization.

frequently maintained under its good technical condition.

machine structures and parameters, etc without prior notices.

by following main advantages:

well as frequent gear shifting during operation.

saving, with a reliable braking performance.

dustproof, and other advantages.

also be fitted with various attachements, according to user demands.

in-container operation or off-container operation.

4t 4210 550 2740 590

4.5 t 4230 570 2760 595

Tread(mm) Front/ 1180/11 1180/119

Engine Model Diesel Engine

Main Parameters LR4B3-G89

Rated Speed rpm 2200

Max Torque N.m/rpm 285/1500

Used for Truck Model

Engine Model Diesel Engine Diesel Engine

Rated Speed rpm 2200 2300

Max Torque N.m/rpm 260/1650 250/1700

Used for Truck Model

engines currently used for forklift trucks.

device, through operating oil pump driven by transmission case.

2. Hydraulic Transmission Case, Torque Converter and Differential

Type: Three-Element, Single-Stage, and Two-Phase Type

Adjusting Pressure: 0.5-0.7MPa

Type: Internal-Meshing Gear Type

Hydraulic Transmission Case:

Friction Plate Outer Diameter × Inner Diameter × Thickness 134×90×2.8

Friction Plate Frictional Surface Area: 7740mm×12

Adjusting Pressure: 12～15kg/cm2

Oil Capacity: Hydraulic Torque Converter Oil 20L

Speed Reducing Ratio: 6.333

Oil Supply: Hydraulic Oil 7L

RPM and high RPM of engine.

which has improved the wear resistance of its friction surface.

Fig 2.1 Hydraulic Torque Converter and Transmission Assembly

Fig 2.2 Hydraulic Torque Converter

1. Input plate 2. Ball Bearing 3. Turbine 4. Guide Pulley

Fig 2.3 Clutch Unit

1.2. Seal Ring 3. Ball Bearing 4.Seal Ring 5. Return Spring

6. Piston 7.Seal Ring 8. Tapered Plate 9.Spacer

reversing valve lever.

Fig. 2.4 Control Valve

pressure through main adjusting valve.

formed for oil pressure of clutch.

flows to oil cooler, to be cooled down before it returns to oil tank.

the transmission oil pan.

Fig 2.5 Oil Circuit Diagram for Hydraulic Transmission Case

Fig 2.6 Charging pump

Tightening Torque: 130～195N.m

(3) Fasten the bolts on gear ring.

Tightening Torque: 130～195 N.m

Spacer Thicknesses: 0.1, 0.15, 0.2, 0.5, 2.3, 2.6mm

Adjusting Clearance: 0.23～0.33mm

(6) Fasten the bolts on bearing seat.

Tightening Torque: 222～232 N.m

Fig 2.7 Differential

FD40T、/ FD45T Model Forklift Truck