PREFASE

M Series Reach Truck Operation and Maintenance Manual
PREFACE
Thanks for purchasing M-series 1-2t reach truck manufactured by Maximal forklift
Co., Ltd.
M-series reach truck adopts the best design. It characterizes the strong output of
torque, mast for wide view, the whole hydraulic steering and the forward and reverse
with hydraulic control, upon which, it owns the following advantages, such as
comfortable operation, flexible steering, easy charging, the tight grab of the drive wheel
on the accidented ground and so on.
FBR-10~20 series reach truck appears an attractive feature, low noise, power shift,
and advanced design. So it has been widely used in many industry fields, such as
merchandise, medicine, meat, water-producing machine and the materials handling in
freezing warehouse. So it is the best tool to improve the labor efficiency and to realize
the work for high place in a three-dimensional warehouse.
The performance index this manual offer is for the standard models. Now the
M-series reach truck equipped the high mast is specially fit in a high place and
three-dimensional warehouse. The maximal lifting height is 7.2 m, while we can offer
the models with the height that the customers request.
M-series truck will be improved with the market request and the customer’s
demand. So it will be some difference between what the manual said and the real
products and we will make a continuous revise and complements, but it will not be
informed for the improvement of the small part.
In order to help the operator get a knowledge of the working principle of the forklift,
the manual offer a brief instruction of performance and the structure, operation,
maintenance and so on. It is hoped that the forklift is operated according to the manual
and make sure the forklift work normally. It is necessary to obey the rules carefully when
concerning the safety of the people and the security of the forklift.
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CONTENT
1、M-Series Reach Truck Appearance Diagram………………………………………… 2

2、The Main Technical Characteristic …………………………………………… 4
（Ⅰ）Performance Parameter…………………………………………………………… 4
（Ⅱ）Dimension Parameter …………………………………………………………… 4
（Ⅲ）Weight Parameter………………………………………………………………… 4
（Ⅳ）Main Outside Fittings ………………………………………………………… 5
3、The Configuration of Reach Truck ………………………………………………… 5
（Ⅰ）Driving System ………………………………………………………………… 5
1、Summary ………………………………………………………………… 5
2、Gear Box ………………………………………………………………… 7
3、Wheel……………………………………………………………………… 9
（Ⅱ）Steering System………………………………………………………………… 11
（Ⅲ）Braking System………………………………………………………………… 13
（Ⅳ）Lifting System ……………………………………………………………… 15
（Ⅴ）Hydraulic System …………………………………………………………… 17
（Ⅵ）Electrical System……………………………………………………………… 23
（Ⅶ）Forward & Backward Device of Battery……………………………………… 27
4、Operation Introduction and Note Items…………………………………………… 27
5、Fault and Resolution ……………………………………………………………… 30
6、Maintenance………………………………………………………………………… 31
7、Specification Form of some Standard Parts & Wearing Parts …………………… 32

1、M series appearance of reach battery truck
Chart 1-1 FBR10～13 appearance of the reach truck

Chart 1-2 FBR15～20 appearance of the reach truck

2、The main technical characteristic

（Ⅰ）、Performance parameter
Parameter
Item FBR10 FBR13 FBR15 FBR18 FBR20
MC MJZ MC MJZ MC MJZ MC MJZ MC MJZ
Rated load
1000 1300 1500 1800 2000
capacity（kg）
Load center
500 500 500 500 500
（mm）
The max lifting
3000 3000 3000 3000 3000
height（mm）
Free Lift Height
330 330 330 330 330
（mm）
Max lifting speed
160 175 160 175 230 240 220 230 210 220
（㎜/s）
Travel speed
（full/no load） 7.7/8.0 8/8.5 7.5/7.8 8/8.5 9.5/10 8.8/9.3 9.2/10 8.5/9.3 8.5/9 9.1/9
（km/h）
The distance of
mast forward 550 600 500 550 600
movement（mm）
Mast forward 30 30 30 30 30
Tilt
Angle backward 50 50 50 50 50
Min turning
1430 1500 1580 1660 1700
radius（mm）
Max gradeability
12 12 12 12 10
（laden）%
System of speed
CurTis DC/ZAPI AC
control

（Ⅱ）、Dimension parameter
Parameter
Item
FBR10 FBR13 FBR15 FBR18 FBR20
Overall Length（mm） 1790 1870 2057 2107 2187
Overall width（mm） 1020 1020 1200 1200 1200
Height of overhead
2160 2160 2160 2160 2160
guard（mm）
Height of mast, lowered
2080 2080 2120 2120 2120
（mm）
（Ⅲ）、Weight parameter
Parameter
Item
FBR10 FBR13 FBR15 FBR18 FBR20
Service weight（kg） 1700 1800 2550 2650 2800
3、The Configuration of Reach Truck

(Ⅰ) Drive system
1. Summary
The drive system of FBR 10-20 series consists of drive motor (9), gear plate (3) and
gear box (1). It utilizes the hinge between higher & lower bracket(6、7)、pin(10、13), base
on the spring effect, the truck body’s weight transfer to the drive wheel, ensure the
maximal attraction, drive on the rough ground, the upside and downside brackets have
the effect which could auto regulated. At the end of the motor, loads the brake wheel (8),
according the foot brake, execute the whole truck braking. Between the gear plate and
the gear box, loads the plane bearing. We should ensure the weight loading, and the
drive wheel could rotate where it is.

1、gear Box 2、big steering gear 3、gear plate 4、higher spring 5、pin
6、lower bracket 7、higher bracket 8、brake wheel 9、drive motor 10、higher pin
11、hydraulic motor 12、steering box 13、lower pin 14、lower spring
Chart 2 Drive System

2. Gear box
The Configuration of gear box FBR10~20, illustrated in the figure 3-1, gear box
connect with the steering main axes bearing、big steering gear and cover, and ensure
the drive wheel rotates where it is. When the truck turns, the steering wheel could
accomplish the size adjustment of steering and turning radius, according to the gear
drives the gear axes circumrotating, and then drives the big steering gear
circumrotating, engaged with the small gear on the gear axes.
The gear box achieves duplicate decelerating through four gears. The power from
motor fan-out drives small gear through the spline joint cover; transfer to the bevel drive
gear through the big gear and pinion gear in the big gear. In the end, drive wheel
circumrotating through the drive axle. The reach truck forward and backward, speed
change, all achieved by the handle accelerator gives the speed signal through the
controller. Due to the drive wheel and steering wheel combines, and high precision
cylindrical helical gear transmission is laid on the high-level, bevel gear transmission is
laid on the low-level, so the transmission is special balanced, noise is greatly reduced,
the structure is very small.
The note of system maintenance:
(I)The bottom of the gear box, please infuse 3 liters gear oil (SY1103-62/HL-20),the
liquid level height should be standardized by the flooding plug floods when open it.
(II)The clearance adjustment of the gear box bevel gear pair achieves through the
gasket regulation, ensure there is no block when it joggles. When installing the bevel
drive gear, make use of regulating the gasket, ensure the center spacing size between
the bevel pinion gear and the bevel drive gear. And then, installing the bevel pinion gear,
make use of the bolt and gasket regulating, ensure the joggle point along the gear width
is not less than 70%, the joggle clearance is 0.13-0.31.after installing, each
transmission part should freely，no blocking and axial float. The easiest method is
exhausting over the gear oil in the transmission, remove the cover, fetch the pinion gear,
and then install the cover, infuse the gear oil. After half or one year using the truck,
customer should check the joggle clearance of bevel gear pair. If the clearance exceeds
0.25-0.3, you should adjust again. After adjust the clearance every time, the brake
should be loosened before the motor starts, use the hand turns the brake wheel 6
circles, there should not happen tighten at any position.

The configuration of FBR15-20 drive unit shows in the chart3-2, 4 gears in the drive
unit achieve duplicate deceleration. The power from motor fan-out transfers to the small
gear(1)， then drives the big gear(2) through the spline joint cover; Through the
pedestal of spline bevel drive gear (4), bevel pinion gear(5),in the end, drive wheel
circumrotating through the spline drive axle. The reach truck forward and backward,
speed change, all achieved by the handle accelerator gives the speed signal through
the controller.
An adjust nut installed on the spline drive axle in the gear box, which adjusts the
clearance between the bevel drive gear and the bevel pinion gear. According to screw
the adjust nut, two gears` clearance maintains in the range of 0.10-0.15, no tightened,
no looser clearance, screw the bevel drive gear, feel easy.
The gear box divides into upside & downside, inject 18# hyperbola gear oil into the
box. The oil level of box’s higher half should accord with the tow sides of gear plane, the
oil level of lower half should accord with oil flooding, after loosen the middle plug which
locates on the side cover of flooding box.
1、big steering gear 2、little gear 3、big gear 4、drive gear pedestal
5、drive gear 6、adjusting gasket 7、drive axle 8、pinion gear pedestal
9、pinion gear
Chart3-1 Gear Box
9

1、pinion gear 2、big gear 3、drive gear pedestal

4、bevel drive gear pedestal 5、bevel pinion gear
6、pinion gear pedestal 7、drive axle
8、adjustint nut 9、drive wheel
Chart3-2 Gear Box
3、Wheel
All wheels of Maximal reach truck are using the special broadside solid tire，this
kind of tire bears to whet, oil and low temperature，and it fits Maximal 4 wheel truck’s tire.
Due to the drive wheel designed and installing in one side of truck’s body, for guarantee
the body balance and the stability of complete truck, there should dispose a set of
balance wheel, this shows in the chart 4.The balance wheel and drive wheel play an
effect of complete truck’s balance according to the lever principle & spring. When the
truck runs on the bumpy and tilting ground, the balance wheel loading increasing, and
10

transmits the loading to the drive wheel which loading decreasing, this according to
spring as a result of lever principle. The drive wheel should have enough adhesive force
and to make the running truck no skid in any situation.
The Configuration of front wheel shows in the chart 5.The wheels fixed on the two
sides of the front part of truck’s body. Due to front wheel fixed by two bearing and axle, it
is flexible and reliable when it runs. When installing it, please note to hold the clearance
not less than 2mm between wheel and the plane of forward arm, if it is undersize, not
only accelerate the tire wearing, but also decrease the complete truck’s efficiency.
Flange links the drive wheel and transmission axle, easy to remove or maintain it.
1、bracket shaft 2、balance wheel 3、balance wheel bady

4、bracket 5、axle
Chart4 Balance Wheel
11

Chart5 Front Wheel
(Ⅱ) steering system (chart 6-1, 6-2)

1、 Drive wheel steering
The FBR10~13 series reach truck steering through the deflected steering wheel.
The front wheel is stationary type engaged wheel. When steering, the driver operates
the steering wheel (1) by single hand, it drives the input shaft (2) turning, through two
big gears (9) drive the output shaft, then through the gimbal joint (7) connects the spline
shaft (6) and coupling sleeve (4), the gear shaft (5), the big steering gear on the gear
box, the whole gear box & drive wheel deviated and realized the demand of steering.
Compared to the normal truck, the steering system and drive system of FBR10～
13 series truck is integrative. Due to the big steering gear is rigidity connecting with the
gear box, and drive axle as steering axle, only has one drive wheel, there is no travel
different of L&R wheel, so the compensating gear is not used when running and
steering, and make the configuration of gear box so simply.
The transmission from steering wheel to shaft is using the gear’s., it is accurate,
reliable, high efficiency, simply structure and easy operating, so decrease the driver’s
weariness greatly.
The simple cross gimbal joint with the output shaft and gear shaft & spline，overcome
two shaft centering owing to the inaccurate installing and frame distortion, not only easy
to install, but also make the up and down shafts running freely after joint it.
The instant steering centre loads the crossing point of front tyre line and truck’s
12

lengthways centre line，this insure the min. turning radius when the reach truck
forward 、backward and speed change, improves the truck’s flexibility. when the truck
go forward, the steering wheel’s turning direction is the same as the truck’s, namely, the
steering wheel turn tight, the truck turn right, the same as left( drive wheel max. left
turning angle is 77°46′,steering wheel turns right 3.3 circles, the max. right turning angle
is 102°13′,steering wheel turns left 4 circles.)
2、Entire hydraulic steering

The FBR10~13 series reach truck using the entire hydraulic steering、together
pumps technology, steering and lifting using the same motor, front wheel is stationary
type engaged wheel. When you operating, open the start switch, stamp the brake pedal,
pump motor starts to work, driver operates the steering wheel by single hand, when
steering, through the hydraulic redirector changes the direction of oil channel. Along
with the redirector’s oil channel changed, the drive motor turns L&R, the turning power
transmits to the drive gear(3) 、middle gear(10) ,through the spline to gear shaft(4),the
gig pinion gear(6) drive the gear box turn L&R 360°,to achieve dependable turning
efficiency.
Compared to the normal truck, the steering system and drive system of FBR15～20
series truck is integrative. Due to the big steering gear is rigidity connecting with the
gear box, and drive axle as steering axle, only has one drive wheel, there is no travel
different of L&R wheel, so the compensating gear is not used when running and
steering.
When the big steering gear turns, the upper extreme of left turn big gear installed the
special bearing inside band(8) 、bearing upper band(5) and bearing lower band(7),use
the cylindrical roller to make cross installing, big load capacity，reduce the gear box
steering load efficaciously. Due to the truck use the entire hydraulic steering, turning
transmission through the gear joggle. Steering accurately, high efficiency and flexibly.
The steering wheel、direct lever installed with hydraulic redirector on the same axial
lead. This overcomes two shaft centering owing to the inaccurate installing and frame
distortion, not only easy to install, but also make the up and down shafts running freely
after joint it. When the truck go forward, the steering wheel’s turning direction is the
same as the truck’s, namely, the steering wheel turn right, the truck turn right, the same
13

as left. Drive wheel max. left turning angle is 77°(steering wheel turns right 2.5 circles)
the max. right turning angle is 108°(steering wheel turns left 3.5 circles.)
1、steering wheel 2、input shaft 3、middle shaft 4、coupling sleeve 5、gear shaft
6、spline shaft 7、gimbal joint 8、output shaft 9、big gear
Chart6-1 Steering System
1、hydraulic motor 2、steering box 3、drive gear 4、gear shaft

5、bearing upper band 6、pinion gear 7、bearing lower band 8、bearing inside
band 9、gear box 10、control dial 11、connecting pedal 12、
redirector
14

Chart6-2 Steering System
(Ⅲ)Brake system (Chart 7)

The brake system is type of NC (normally closed) band, designed be integrative with
drive system. The system is made up of contracting brake、brake shoe(4)、brake
cam(3) 、pedal(1) and other levers. The brake shoe is directly installed on the drive
motor of drive system; the brake wheel is installed on the shaft tip of drive motor’s tail.
The motor has high speed and little torque, so need little brake torque, braking steadily,
reliability, operation easily.
When the truck stops, brake shoe clasps the brake wheel closely; and when need
the truck runs, driver stamps brake pedal, through one pair of lever, control the cam
circumrotating, expanding the contracting brake, brake shoe separates with the brake
wheel. At the time of brake shoe separated, the lever of brake system turn on the travel
switch on the drive motor, through the operating switch makes the drive motor electrifies
and circumrotating, then the whole truck runs. Oppositely, if you need brake urgently,
driver only need loose the foot pedal, due to the function of the spring in the brake
system, the lever returns and closes the travel switch, the drive motor lose the power. At
the same time, the truck brakes and stops rapidly due to the brake shoe returns.
The clearance adjustment of contracting brake and brake shoe has much to do with
the brake effect. When adjusting, loose the nuts of cam’s two sides, located the suitable
position, makes the brake shoe clasps brake wheel, then adjusts the pressure spring
nut, until the hand could not turn the brake wheel. When the truck has max speed and
fully loaded, the distance of urgent braking should not more than 3m, we can also
increase longer appropriately base on the customer’s requirement, to prevent unwound
goods slides when the truck braking urgently. The pressure spring should not adjust
closer, to prevent increasing unnecessary pedal pressure and raising the driver’s weary.
Brake shoe should change if the wearing capacity is more than 1.5mm.
15

1、brake pedal 2、pull rod 3、brake cam

4、brake shoe 5、rocking plate 6、link lever bolt
Chart7 Brake System
16

(Ⅳ) Lifting System (Chart 8)

The system is made up of inner & outer mast、fork bracket、fork、sheave、chain、
lifting cylinder、forward cylinder and tilting cylinder.
1、outer mast 2、inner mast 3、head plate 4、compound roller

5、lifting cylinder 6、lifting chain 7、fork bracket 8、fork bracket
Chart8 Lifting System
The forward cylinder’s extension makes the whole lifting system through the 4
rollers under the outside mast, along the truck’s lead rail forward or backward, travel
route is 500mm.There is a regulating spacer on the roller’s surface, contacts with the
inner surface of truck’s lead rail. You should note the lateral symmetry and suitable
tightness when installing it. If too tight, it’s easy to lock and cause exceptional sound, if
too loose, it’s make the mast falter. Please note the clearance size when use it and
regulate it in duty time. Through adjusting the bolt advance and retreat, then change the
clearance size.
The move roller of fork bracket and inner mast is the compound roller (chart 10), the
side roller (6) installed in the compound one, the side clearance adjustment between
17

compound roller and mast lead rail could achieve through changing the regulating
shim’s thickness in the compound roller. Please note injecting the lubrication in the mast
lead rail regularly in service; maintain the compound roller works flexibly. The two lifting
chains should have the same tightness，no distortion; the max length of chain should
adjust when the fork lifting on the highest position(as the lifting cylinder’s piston rod
rises on the top).After adjusting, the chain should not too tight, two sheaves should run
flexibly.
1、compound roller pedestal 2、adjusting bolt 3、inner roller 4、inner roller shaft
Chart9 Roller
1、roller shell 2、end cover 3、end cover 4、supporting pedestal

5、side roller 6、shaft 7、washer 8、snap ring
9、bearing 10、column pin 11、adjusting washer
Chart10 Compound Roller
18

The move roller of inner mast & ouster’s adopted two pairs of compound one. The
side ones all installed in the main roller. The compound one (chart 10) under the inner
mast has adjusted the clearance when assembling it. You can adjust it through
changing the regulating shim’s thickness if necessary. After assembling and in service,
the compound roller on the top of outer mast, you can adjust it through the tighten nut
base on the circs of mast swinging，make the mast more steadily.
The tilting cylinder effects the fork bracket directly, makes the fork moves forward or
backward. Please note the L&R cylinder be parallel、the same height、distance of piston
rod extending、etc., to prevent single cylinder got pressure. The distance between two
forks, you can adjust it base on the goods size.
(Ⅴ)Hydraulic System
1、Hydraulic System
The reach truck’s hydraulic system has two parts: hydraulic lifting、 forward、tilting &
hydraulic steering system. Hydraulic lifting、 forward、tilting system is made up of lifting
cylinder (1) 、lifting cylinder (2) 、tilting cylinder（3）、motor（5）、oil box (8) 、multi- unit
valve (9) 、percolator (10) 、percolator (7).The flow and theory show in the chart 11.
Oil box fixed under the seat’s right side, capacity is 25 L, and magnetic plug is fixed
on the bottom, and adsorbs the scrap iron. The oil screen in each oil filler hole and oil
inlet should clean at regular times.
The pipeline adopts rubber hose H.P and 60°pyramidal face hard hose joint by
standard JB1885-77, it has simple structure、good sealability、standing H.P、high
reliability、using stably and easy operating.
19

1、lifting cylinder 2、governor valve 3、tilting cylinder

4、forward cylinder 5、motor 6、pump
7、percolator 8、oil box 9、multi- unit valve
10、percolator
Chart11 Hydraulic System
2、main parts
A .pump & motor
The motor adopts XQD-8.2 AC ones, the gear pump adopts
DSG05A18F9H1-R004C, they connects directly with flange，installs on the truck’s
upside. When you need maintain it, remove the meter and do it.
B. Hydraulic motor ＆ redirector
the motor is BM-100H gerotor motor ,delivery capacity is 100ml/r,the redirector
adopts Eaton 403-7981-33,including the preferential valve, delivery capacity is 80ml/r.
Oil motor installs on the plate of drive system, open the door and you can disassemble
it, redirector and direct lever is cross connecting and installed under the direct lever.
20

C. multiple unit valve

The model is CDB2-F15DC; it is made up of oil injecting valve、reversing valve and
oil return valve, P is one point pressure oil inlet connects with oil pump outlet. O is one
point oil return port connects with the oil box’s ones, A joints the back cavity, B closed, C
& D joint the back cavity of tilting cylinder, E & F joint the back cavity of forward
cylinder, multi- unit valve’s spillover valve adjusted and achieves the 10% over loading
capacity, ensure the relevant rated capacity and lifting to 3 m. The multi- unit valve’s
pressure has fixed before leaving factory, do not maintain it on working.
D. Lifting cylinder (chart 13)
This model is single action piston’s structure, made up of piston lever(1)、guide
sleeve(6) 、body(7).In using, the piston internal leaking with the hydraulic oil of body’s
inner wall, oil returns from cylinder upside’s port to oil box. If the inner leaking is large,
the cylinder lifting pressure will go down, this time, change the Yx seal.
E. Forward Cylinder & Tilting Cylinder
Their model all is double action structure, show in (chart 14,15)
F. Single governor valve
The valve fixed on the oil inlet of lifting cylinder, the configuration shows in the chart
16. The valve makes use of pressure difference between the spring and valve hole,
controls the oil return, and achieves the purpose of limit the dropping speed.
3、Hydraulic oil
Choose the oil, mainly due to oil’s solidifying point. Whereas nowadays Chinese
oil’s fact and engineering machine’s test on the low temperature condition, the
solidifying point should better lower 30℃ than the using temperature, to prevent the oil
more sticky, and make operating difficultly. This series truck working ground is mainly
low temperature storage, the meal、aquatic product storage below 0℃ choose the
following standard hydraulic oil:
21

standard 13# machine oil（SYB1206-56）

12# voyage liquid
value Composed spindle oil SY1220-68
（SY1181-76）
character （GB442-64）
Movement con.（m 2/s） Not less than

（12-14）×10-6 12×10-6
-6
18×10
flash point℃（not less

163 160 100
than）
freezing point℃ （ not

-45 -40 -70
higher than）
Now series trucks of Maximal forklift use the SY1220-68 hydraulic oil.
Fruit storage chooses the 20-1 hydraulic oil (freezing point-30℃、50℃, movement
concentration is 12.5×10-6m2/S), normal storage can choose HJ-20 hydraulic oil or
spindle oil.
Different models of hydraulic oil could not be using combined, you must clear the
oil box when add the oil. For reduce oil system fault, must restrict the oil’s impurity
content exactly. You should replace the oil per 1500h and note clear the screen in
normally using.
22

1、holding valve 2、relief valve shell 3、relief valve

4、lifting slide valve 5、tilting slide valve 6、forward slide valve
7、oil return shell 8、forward valve shell 9、tilting valve shell
10、lifting valve shell
Chart12 Multiple Unit Valve
23

1
2
3
4
5
7
8
10
11
12
1、piston lever 2、wiper seal 3、O-ring seal 4、Yx ring seal

5、O-ring seal 6、guide sleeve 7、cylinder 8、pivot ring
9、Yx ring seal 10、spring 11、single spacer 12、iron ball
Chart13 Lifting Cylinder
24

1、cylinder body 2、piston 3、pivot ring 4、Yx-ring seal

5、piston lever 6、guide sleeve 7、O-ring seal 8、Y x- ring seal
9、wiper seal 10、O-ring seal
Chart14 Tilting Cylinder
1、piston lever 2、wiper seal 3、Yx -ring seal 4、O-ring seal

5、guide sleeve 6、cylinder body 7、piston 8、Yx-ring seal
9、pivot ring 10、cylinder pedestal 11、O-ring seal 12、bushing
Char15 Forward Cylinder
25

1、valve body 2、slide valve 3、spring 4、O-ring seal 5、joint
Chart16 Single Governor Valve
（Ⅵ）Electrical System
The electrical control system of reach forklift comprises the drawing controller,
pump controller, travel motor, oil pump motor, instrument accelerator, battery and
various of switches. The principle of electrical system is available in picture 17-1、17-2.
1、the preparation for operating
①、insert the pin of battery into the power and then put on the emergency cut-off
switch.
②、turn the key switch on and the instrument display the quantity of battery power
and the starting working state
2、the control of the driving motor

①、step down the brake pedal and put the motor braking switch, which is prepared
for the making a star
②、you can move forward or backward the accelerator handle to realize the travel
direction you want. the rate is depended on the degree of the accelerator handle
movement.
③、loosing the accelerator handle travel motor is made to stop by the controller
④、If emergency occurred , you can release the brake pedal and loose the
accelerator handle to make the forklift stop by mechanical and electromagnetic brake
controlled by braking switch and controller.
26

3、the pump motor controlling

The inching switch is cutting off when the hydraulic device is operated with the
control lever to realize the tile and lift and forward-reverse of the mast. And then
different movement signals are sent to by the controller cause the relevant voltages
which control the pump motor to realize the rate of lifting and tilting and forward-reverse.
The motor will be out of power and stop working when the control lever return neutral.
4、Battery
The sets of battery offer power for the forklift, it will make a great different
performance whether the forklift is operated and maintained in right way or not, so it is
necessary to maintain as required and you could find it detailedly in battery instruction
and related rules, the points as follow
①、check whether the battery is unbroken before charging, whether the line is in
good touch. Then clean the appearance and open the cover.
②、the temperature couldn’t surpass 45℃ when charging , or else you need to
decrease the source current and low the temperature with other methods.
③、the proportion of electrolyte should be 1:28 and stay the same in 2-3 hours
when the battery is fully charged. A lot of air bubble is produced.
④、please charge in time when voltage of one unit is decreased to 1.75V and the
proportion of electrolyte is below 1:15.
⑤、the height of electrolyte level is kept higher than plate when the battery work all
the time .
⑥、the first charging affect the battery life greatly, the charging will be operated by
special person when the first charging technology and equipment is not offered.
27

Chart17-1 FBR Series Forklift Electrical Principle (DC)
28

Chart 17-2 FBR Series Forklift Electrical Principle（AC）
29

(Ⅶ) Forward & Backward Device of Battery

FBR15~20 series of forklifts: the work principle introduction of battery exchange,
maintenance and charge:
There’re two groups of active vanes loading on a gate ledger. On the body
footboard is loaded with the active hook board. Before the operation you should turn
over the vane, and hang the battery onto the vane( make sure the hanging position
should be in the center). The operator should also move the forward cylinder backward,
because there is a hook plate equipped behind the battery box. When the battery is
backed to the right position, the body hook plate and active plate will be connected
automatically through the spring. Then move the forward cylinder to the front, the
battery will be fixed in the right position to the forklift automatically. And then just put
down the mast active plate, the forklift can work now. When charging, you should pull
out the battery. The principle for it is that: turn up the mast active plate, move the
forward cylinder back, then thanks to the slant plate under the battery box, when to the
right position, because of the active plate and the slant plate, the battery will be lifted
and fixed on the mast active plate. Then operator can step on the hook plate, move the
cylinder to the front, and the battery can be taken into charge, maintenance, clean and
replacement.
4、Operation Introduction and Note items
（Ⅰ）Familiar with the instruments and operating institutions position(Chart 18)

（Ⅱ）Preparation before starting:
1. Check whether the battery voltage is normal.
2. Check whether the electric contactor and line is normal
3. Check the adequacy of hydraulic oil
4. Check for any leaks in the pipeline connecting joints.
5. Check the brake reliability, and should not turn the walking motor rotation axis
when stop.
6. Check whether there’re loose bolts site, and make sure the gas between every
part is suitable.
30

（Ⅲ）、Starting
1. Before starting the forklift, you should finish the electrical system preparation as
follows:
2. When starting, push the electrical manipulation handle with the right hand to
push the accelerator handle slowly, and then accelerate after slowly-starting.
3. Test forklift without load: check the battery voltage and observe the instrument.
When the electricity down to the 20%, it means it has reached the lowest discharge
voltage. You should recharge at once and don’t use the forklift, or it’ll do damage to the
battery.
（Ⅳ）Running Notes:
1. During operation, whether backward or forward, the accelerator should be
pushed slowly to avoid the sudden acceleration, to avoid the sudden force.
2. When starting, the pump motor can rotate automatically to provide impetus. The
power switch should be shut down when it stop, and to check the fault.
3. Pay attention to position of the accelerator handle when forward and backward
during the moving.
4. In order to enable the good stability of the operation of the forklift, after shoveling
the goods, the mast should be back to near the bodywork, the fork should incline, and
fall down to the floor as lower as possible. Moving the forklifts with the cargo high-lifted
is forbidden to avoid the accident and loss.
5. In high-speed operation, it’s not allowed to toggle the inverted-switch handle
directly. The direction should be changed after stopping the forklift.
6. Adjust the distance between the two forks by the size of cargo to make the
weight evenly distributed in the two forks so as not to partial set.
7. Strictly comply with truck load capacity according to the load curve of the table.
Overload is forbidden. The load centre is 500 mm in the front of shelf. If the actual use
of the tray laden is larger than the size of 1000 × 1000, Load should be reduced in
accordance with requirements of load curves
8. in order to ensure traffic safety, abrupt lane, high-speed turns and brake slams
should be avoided in the operation to prevent releases of persons and goods,
especially not on the slopes. It should be low speed when downgrade with heavy-duty.
31

And backward operation is suggested.

9. In the operation, if any abnormal noises and smells came out, you should stop
the forklift immediately and do the troubleshooting.
10. The power should be cut off and the switch key should be unplugged when you
left the forklift.
1、lifting lever 2、tilting lever 3、forward lever

4、accelerating knob 5、advance and retreat pedal, battery
6、brake pedal 7、steering wheel
Chart18 Position of Instrument and Operating Assembly
32

Chart19 Transport Drawing
5、Fault and Resolution
No fault cause resolution

Instrument no re-shut the automatic switch
Automatic switch Released action
instruction and check the cause
Contactor not Do troubleshooting, replace
1 fuse broken
action the fuse
Bright lights do
Poor contact of battery power Recover the electrical plug
not work
The main circuit connections loose,

Contactor action
dynamic and static contact point is Restore connectors
2 Forklifts can not
bad
walk
Brush of motor contact poor Repair the motor
adjust the redirector
low pressure or damage of the
pressure or replace the
3 Heavy turning redirector
bearing spring
Damage of the transmission Replace the ball
33

turning bearing
Improper shoes gap adjustment Adjust the shoes gap
Brake
4 excessive worn of shoes replace the brake shoes
powerless
damage of brake pump replace the pump
Brake shoes Gas adjusted too tight Adjust the gas appropriately
5 separated
Return-spring valid Replace the spring
completely
noise of the rivets exposed of the shoes

6 replace the shoes
brake friction surface
Gear damage or surface adjust the gap of the bevel
spalling gear
Abnormal noise Gear gap too big Replace the gear
7
from the gear box Something-unknown in the box clean the box, fill oil
no oil in the box repair the oil-leak of the box
bearing broken replace the bearing
Pump motor fault Repair the motor
The oil pump gear and the pump
powerless lift body attrit excessively, the oversized Replace the attrition or oil pump
8
or lift inability gap creates seriously inner-leak
Up-down cylinder inner-leak Replace the Yx seal collar

multi-valve inner-leak repair the multi-valve
The hydraulic Inspect oil pipe connection seal
Oil suction pipe intake air
system and the situation, replace the seal
gate frame send hydraulic oil is in sufficient in

9 fill oil
out the abnormal the tank
sound Gate components worn out or the Exchanges gate components,
gap is too loose adjust the gap
34

6、Maintenance
(Ⅰ)Caution
1 、 Use the standard lube and hydraulic oil according to the environment
temperature and the various oil must not be mixed to used. The hydraulic oil must be
kept clean.
2、This series forklift must be used in adaptive temperature and the lube is required
to be the No. J-2 clay grease.
3、when the temperature stay all the same, the forklift should not be left in outdoors
all night along or in the freezing warehouse.
（Ⅱ）lubricated parts
Item Parts name lube filling time
Inside and outside
1 No.J-2 clay grease Twice a month
mast
2 Flexing transmit rail No.J-2 clay grease Twice a month
3 The mast bearing No.J-2 clay grease Once half a year
The direction chain
4 No.J-2 clay grease Twice a month
wheel
5 Steering axle gear No.J-2 clay grease Once a week
Twice a month（fill in the oil
6 Steering bearing 30#mechanical oil
hole）
supporting sleeve, U&D once a month（fill in the oil
7 No.J-2 clay grease
bracket hole，picture20）
Front wheel bearing
8 No.J-2 clay grease Spread when fixing
for balance roll
（Ⅲ）Maintenance
1、Daily maintenance
①you should clean the dirt and dust among the connecting leading after finishing
the work everyday.
②check whether the brake is normal.
③check whether the tightening parts in all the places and steering cross-axis
35

gimbal rivet is normal.

④check whether oil is leaked.
2、the first maintenance （once a week），the follow attention besides the daily
maintenance：
①add the lube as requested.
②adjust the roller of the inside and outside mast、transmit rail roller、the clearance
between the fork frame、tightening bolt so that make the cushion good performance.
3 、 the second maintenance （once a month ），attention more besides the first
maintenance：
①adjust clearance of the brake assembly, make sue it normal.
②add gear oil in the transmission box。
③adjust the degree of tightness of the lifting cylinder chain
④check the connecting points of the electrical system.
4、the third maintenance（once half a year），attention more besides the second
maintenance：
①change the oil in the oil system、clean the oil cleaner、oil tank、and change the seal
ring of cylinder.
②change the new tires（depend on the degree of wear）.
③check overall electric appliance and change the electric fitting when problem.
④change the lube of the bearing and chain roller as requested.
⑤clean the redirector appearance of drive motor and pump motor using air
compressor, be attention to the situation of the redirector and redirecting light，check
whether the carbon brush is blocked and broken ,change carbon brush if the height is
less than 16mm(not fit for AC motor).
7、Specification Form of some Standard Parts & Wearing Parts
（Ⅰ）Bearing
Item standard model quantity Fixing position
1 GB292-86 bearing207 2 input gear of gear box
2 GB292-86 bearing109 2 counter gear of gear box
3 GB297-84 bearing 7206 2 bevel gear of gear box
4 GB276-84 bearing 7211 2 drive shaft in gear box
36

5 GB276-82 bearing 107 2 drive gear
6 GB276-82 bearing 207 2 idle gear

7 GB276-82 bearing 208 2 the seat for mast chain roller
8 GB276-82 bearing 60309 4 Bearing in the outside mast
9 GB276-82 bearing 111 4 compound roller ,inner & outer mast
10 GB276-82 bearing 210 4 compound roller, fork
bearing 208、
11 GB276-82 each 2 Front wheel bearing
209
12 GB276-82 bearing 60206 2 Balance wheel bearing
wimble handle bearing of balance
13 GB297-82 bearing 7207 1
wheel
（Ⅱ）Snap Ring
Item standard Specification material quantity Fixing position
1 GB893.1-86 72 65Mn 2 middle shaft, steering box
2 GB894.1-86 32 65Mn 1 upside, middle shaft
3 GB894.1-86 28 65Mn 1 rear of driving motor
45 lower bearing of outside
4 GB894-76 65Mn 4
mast
55 shaft of inside or outside
5 GB894-76 65Mn 4
mast
90 shaft of inside or outside
6 GB894-76 65Mn 4
mast
50 shell of inside or outside
7 GB893-76 65Mn 4
mast
8 GB893-76 90 65Mn 4 shell of fork
9 GB894-76 35 65Mn 2 sheave shaft
10 GB894-76 80 65Mn 2 sheave shaft
(Ⅲ) Oil Seal
Item Standard Specification Quantity Fixing position
1 GB9877.1-88 Oil seal B30×52×7D 1 upper bevel drive gear
2 GB9877.1-88 Oil seal B45×65×8D 1 lower bevel drive gear
37

Oil seal
3 HG4-692-67 1 drive shaft
PD80×100×12
（Ⅳ）Yx Ring
Item Standard Specification Material Quantity Fixing position
D2(import) guide sleeve,
1 D32 polyurethane 1
forward cylinder
D1(import) piston, forward
cylinder
guide sleeve, lifting
cylinder
FH0613L0(import) piston, tilting

4 Osd50 polyurethane 1
cylinder
guide sleeve,
tilting cylinder
piston, tilting
cylinder
(（Ⅴ）Hose H.P.
Hydraulic system to front core of
1 DIN3863-1995 6I-220 2
L&R tilting cylinder
Hydraulic system to rear core of
2 DIN3863-1995 6I-115 2
L&R tilting cylinder
3 DIN3863-1995 6I-2282 2 Hydraulic system to L&R winding hose
The joint of hydraulic system with
4 DIN3863-1995 8I-1120 2
body（tilting cylinder outlet）
The tube for entry and return of
5 DIN3863-1995 8I-1120 2
lifting cylinder
The tube from hydraulic system to
6 DIN3863-1995 13I-1120 1
lifting cylinder
The tube from oil pump to multi-way
7 DIN3863-1995 13II-1020 1
valve
38


8 DIN3863-1995 8I-1850 2
forward cylinder
9 DIN3863-1995 8I-700 2
oil motor
（Ⅵ）O-ring Seal
1 NOK LBH32 1 Forward cylinder
2 NOK USI32 1 Forward cylinder
3 NOK OSI60 1 Forward cylinder
4 GB1235-76 70×3.5 2 Forward cylinder
5 NOK LBH35 1 Lifting cylinder
6 NOK ISI35 1 Lifting cylinder
7 NOK P50 1 Lifting cylinder
8 NOK OSI45 1 Lifting cylinder
9 NOK OSI63 2 Tilting cylinder
10 GB1235-76 22×2.4 1 Tilting cylinder
11 GB1235-76 63×3.1 1 Tilting cylinder
12 NOK ISI28 1 Tilting cylinder
13 NOK LBH28 1 Tilting cylinder
（Ⅶ）Part of Electric Fittings

Item Name Model Quantity Remark
1 fuse plug RP1-RD5 5
2 Inching switch WK2-WK3 3
The switch of
3 CK 1
electrical system
4 The pin of battery CZ 1
The switch of metal
5 K1\K3 2
handle
6 Brake switch WK5 1
39

（Ⅷ）Port of Wearing Parts

Item Picture number Name Quantity Fixing place
Input gear of transmission
1 M15D-110003 Small gear 1
box
2 M15D-110005 Big gear 1 Input pinion gear, gear box
secondary axle gear, gear
3 M1D11-00-19 bevel drive gear 1
box
secondary pinion gear, gear
4 M1D11-00-20 bevel pinion gear 1
box
Input splicing sleeve, gear
6 M15D-120003 splicing sleeve 1
box
Input gear of the redirecting
7 M15D-120010 drive gear 1
box
Parallels side Compound roller, fork bracket
11 M1D32-00-05 4
roller body
12 M15D-51001 brake strap 2 contracting brake body
Compound
13 M1D11-00-12 2 Driving system
roller body
14 M15D-900000 Front wheel 2 The shaft of front wheel
Balance roller
15 M15D-802000 2 Balance roller bracket
body
40

Little Gear
41

Big Gear
42

Bevel Drive Gear
43

Bevel Pinion Gear
44

导轨侧滚轮
45

连接套
46

石棉刹车带
47

Front Wheel
48

Balance Wheel Bady
49

Compound Roller
50

Drive Gear
51

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M Series Reach Truck Operation and Maintenance Manual

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1、M-Series Reach Truck Appearance Diagram………………………………………… 2

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1、M series appearance of reach battery truck

Chart 1-1 FBR10～13 appearance of the reach truck

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Chart 1-2 FBR15～20 appearance of the reach truck

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2、The main technical characteristic

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Overall Length（mm） 1790 1870 2057 2107 2187

Overall width（mm） 1020 1020 1200 1200 1200

3、The Configuration of Reach Truck

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Chart 2 Drive System

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1、pinion gear 2、big gear 3、drive gear pedestal

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1、bracket shaft 2、balance wheel 3、balance wheel bady

Chart4 Balance Wheel

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Chart5 Front Wheel

(Ⅱ) steering system (chart 6-1, 6-2)

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2、Entire hydraulic steering

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1、hydraulic motor 2、steering box 3、drive gear 4、gear shaft

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Chart6-2 Steering System

(Ⅲ)Brake system (Chart 7)

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1、brake pedal 2、pull rod 3、brake cam

Chart7 Brake System

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(Ⅳ) Lifting System (Chart 8)

1、outer mast 2、inner mast 3、head plate 4、compound roller

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1、roller shell 2、end cover 3、end cover 4、supporting pedestal

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1、lifting cylinder 2、governor valve 3、tilting cylinder

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C. multiple unit valve

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standard 13# machine oil（SYB1206-56）

Movement con.（m 2/s） Not less than

flash point℃（not less

freezing point℃ （ not

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1、holding valve 2、relief valve shell 3、relief valve

Chart12 Multiple Unit Valve

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1、piston lever 2、wiper seal 3、O-ring seal 4、Yx ring seal

Chart13 Lifting Cylinder

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1、cylinder body 2、piston 3、pivot ring 4、Yx-ring seal

Chart14 Tilting Cylinder

1、piston lever 2、wiper seal 3、Yx -ring seal 4、O-ring seal

Char15 Forward Cylinder

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1、valve body 2、slide valve 3、spring 4、O-ring seal 5、joint