Use and Maintenance Manual & Part Manual MAXLIFT

Use and Maintenance Manual & Part Manual
for 1-3.5T Internal Combustion Forklift

Use and Maintenance Manual for 1-3.5T Internal Combustion Forklift
Preface
This Use Manual specifies the major components of 1-3.5t forklift and relevant main
points for maintenance. The users are encouraged to carefully read and use this
Manual when maintenance.
As the components and devices are being improved continually, the contents of this
Manual will be modified correspondingly without prior notice, please understand.
ZOOMLION ANHUI INDUSTRIAL VEHICLE CO., LTD

Table of Contents
I. Driving, operation and daily maintenance of forklift .............................................................................. 1

1. Transportation of forklift ......................................................................................................................... 1
2. Storage of forklift .................................................................................................................................... 1
3. Preparations before using ........................................................................................................................ 1
4. Operation of forklift ................................................................................................................................ 1
5. Precautions for cooling system ............................................................................................................... 3
6. Oil for forklift .......................................................................................................................................... 4
7. Lubrication system drawing .................................................................................................................... 5
II. Main technical parameters of forklift ...................................................................................................... 6
III. Structure, principle, adjustment and maintenance of forklift .................................................................. 9
1. Power system .......................................................................................................................................... 9
1.2 Matter complied with for installation and operation of Nissan gasoline engine (applicable to K21 and
K25) ...................................................................................................................................................... 11
1.3 Check and adjustment of engine ........................................................................................................... 12
1.3.1 Air filter ........................................................................................................................................ 12
1.3.2 Oil filter ........................................................................................................................................ 12
1.3.3 Water tank and attached water tank ............................................................................................. 13
1.3.4 Exhaust ......................................................................................................................................... 14
1.3.5 Adjustment of engine speed ......................................................................................................... 14
1.4 Fuel system............................................................................................................................................ 16
1.4.1 Fuel tank ....................................................................................................................................... 16
1.4.2 Fuel quantity sensor ..................................................................................................................... 16
1.4.3 Maintenance of fuel system.......................................................................................................... 17
1.5 Accelerator pedal ........................................................................................................................ 18
2. Electric System...................................................................................................................................... 18
2.1 General ........................................................................................................................................ 18
2.2 Operation brief description.................................................................................................................... 20
3. Clutch device ......................................................................................................................................... 26
3.1 General ........................................................................................................................................ 26
3.2 Maintenance ................................................................................................................................ 30
4. Mechanical drive unit ............................................................................................................................ 32
4.1 General ........................................................................................................................................ 32
5. Hydrodynamic drive unit ......................................................................................................................... 42
5.1 General ........................................................................................................................................ 42
5.2 Torque converter ......................................................................................................................... 44
5.3 Hydraulic clutch (Figure 5-3) ..................................................................................................... 45

5.4 Control valve, overflow valve and inching value ....................................................................... 46
5.5 Transmission housing ................................................................................................................. 48
5.6 Oil feed pump ............................................................................................................................. 48
5.7 Hydraulic circuit (hydraulic transmission) Figure 5-7 ................................................................ 48
5.8 Traction of the forklift to be repaired.......................................................................................... 49
5.9 Measurement of oil port connector position, oil pressure and temperature (Figure 5-8) ............ 50
6. Drive axle .............................................................................................................................................. 50
6.1 General ........................................................................................................................................ 50
6.2 Installation procedure of wheel hub ............................................................................................ 52
7. Steering system ..................................................................................................................................... 53
7.1 General ........................................................................................................................................ 53
7.2 Cycloidal hydraulic steering gear ............................................................................................... 54
7.3 Check after the steering system reassembly................................................................................ 55
7.4 Troubleshooting for steering system ........................................................................................... 55
8. Steering axle .......................................................................................................................................... 55
8.1 General ........................................................................................................................................ 55
8.2 Steering knuckle and steering king pin ....................................................................................... 57
8.3 Wheel .......................................................................................................................................... 57
8.4 Steering oil cylinder .................................................................................................................... 57
8.5 Adjustment of the preload of steering wheel bearing ................................................................. 58
9. Brake system ......................................................................................................................................... 59
9.1 General ........................................................................................................................................ 60
9.2 Maintenance ................................................................................................................................ 68
10. Hydraulic system ................................................................................................................................... 75
10.1 General .......................................................................................................................................... 76
10.2 Main pump .................................................................................................................................... 76
10.3 Multi-way valve and bypass valve .............................................................................................. 77
10.4 Hydraulic system oil way (Main oil way) (Figure 10-8） .......................................................... 80
10.5 Operation of the multi-way valve ............................................................................................... 82
10.6 Hoisting oil cylinder ................................................................................................................... 82
10.7 Speed limit valve......................................................................................................................... 84
10.8 Tilting oil cylinder (Figure 10-13) .............................................................................................. 85
10.9 Hydraulic oil tank ....................................................................................................................... 86
10.10 Maintenance of the main oil pump .............................................................................................. 89
10.11 Commissioning............................................................................................................................ 92
10.12 Troubleshooting guideline........................................................................................................... 92
11. Lifting system........................................................................................................................................ 94
11.1 General .......................................................................................................................................... 96
11.2 Inner and outer mast ...................................................................................................................... 96
11.3 Fork arm carrier ............................................................................................................................. 96

11.4 Roller position ............................................................................................................................... 96
11.5 Repair ............................................................................................................................................ 97
I. Driving, operation and daily maintenance of forklift
The forklift drivers and managers must remember the principle of “Safety First” and conduct safe and
standard operation in accordance with the Use and Maintenance Manual for forklift and the Driver
Handbook.
1. Transportation of forklift
Pay attention to the following matters when using containers or automobiles to ship forklifts;
(1) Hold on the parking brake
(2) The front and rear part of the mast and balance weight shall be fixed with steel wires; the front and rear
tires shall be fixed with wedge blocks at corresponding position.
(3) Lifting is conducted according to the position indicated on the “Lifting Label”.
2. Storage of forklift
(1) Drain off the fuel oil (the cooling water is a kind of anti-rust and antifreeze solution, so it shall not be
drained off);
(2) Coat the surface of unpainted parts with anti-rust oil; coat the lifting chain with lubricating oil;
(3) Lower the mast to the lowest position;
(4) Hold on the parking brake
(5) Fix the front and rear tires with wedge blocks well.
3. Preparations before using

(1) Do not check the fuel oil, oil leakage, oil level, as well as the electric instruments where there is an open
fire; do not add fuel oil when the forklift is running;
(2) Check air pressure of tire;
(3) Place the forward gear/backward gear handle in the middle position (neutral position);
(4) Don't smoke when fuel system is working and checking the storage battery;
(5) Check the handles and pedals;
(6) Prepare properly before starting;
(7) Release the parking brake;
(8) Try to lift, tilt forward and backward, rotate and brake the mast;
(9) The degree of pollution of the hydraulic oil shall not be more than Level 12.
4. Operation of forklift
(1) Only the trained driver with a driving license is allowed to drive;
(2) When operating, the operator shall wear shoes, hat, clothes and gloves using as safety protection;
1
(3) Before driving, each control and alarm device shall be checked, and they shall be repaired before the
operation in case damages or defects are found;
(4) When handling, the load shall not exceed the specified value; the fork shall be inserted under the goods
fully and the goods shall be placed on the fork evenly; it is not allowed to lift the goods with a single
fork tip.
(5) Starting, steering, driving, braking and stopping shall be conducted smoothly; when steering on wet or
smooth pavement, the speed shall be reduced;
(6) When driving with goods, the goods shall be placed as low as possible, and the mast shall be tilted
backwards.
(7) Be careful when driving on a ramp. When driving on a ramp more than 1/10, drive forward on an uphill
and backward on a downhill. Avoid steering on uphill or downhill. When driving a forklift on a
downhill, the loading and unloading shall not be allowed.
(8) When driving, the attention shall be paid to the pedestrian, barriers and potholes pavements, as well as
to the space above the forklift;
(9) People are not allowed to stand on the forks and it is prohibited for the forklift to load people.
(10) People are not allowed to stand or walk under the forks;
(11) It is prohibited to operate the forklift and its attachments at the position other than the cab seat;
(12) For high-lift forklift with a lifting height of more than 3m, the attention shall be paid to falling goods
and protective measures shall be taken when necessary;
(13) When high-lift forklift is working, the mast shall be tilted backwards as far as possible, and when
loading and unloading, it shall be tilted back and forth within the minimum range;
(14) Special attention shall be paid when driving in a wharf or a temporary auxiliary board, and the speed
shall be slow.
(15) When adding fuel oil, the driver shall get off the forklift and shut down the engine; when checking the
storage battery or the level in fuel tank, the fire shall not be ignited.
(16) On-load operation shall be conducted when the forklift with attachments is running without load.
(17) The unfixed or loosely-stacked goods shall not be moved; the goods with large size shall be moved
carefully;
(18) When leaving the forklift, the forklift shall be declined to the ground, the gear handle shall be placed at
the neutral position, the engine shall be shut down or the power shall be disconnected. When stopping
on a ramp, the parking brake device shall be pulled in proper position; if it needs to stop for a long time,
the wheels shall be fixed with wedge blocks;
(19) In case the engine is extremely hot, the water tank cap shall not be opened easily;
(20) Before delivery, the pressure of the multi-way valve and safety valve of the forklift have been adjusted
and the user shall not adjust randomly when using, so as to avoid damaging the whole hydraulic system
and hydraulic components due to excessively high pressure;
2
(21) The tires shall be inflated based on the air pressure specified on the label “Air Pressure of Tire”.
(22) The maximum noise value outside the forklift is not more than 89dB (A)and the test method shall base
on JB/T3300.
(23) To meet the needs of handling ultra-wide goods, the users select “extended forks”, but the following
shall be noted: The loading capacity of extended forks shall be in strict accordance with the load curve
requirements. Within the specified load center, the loading capacity of extended forks is the same as that
of standard forks; if the load center moves forward, the load must be reduced. However, it is prohibited
to lift or hit the goods using fork tip; be careful when driving or turning.
(24) During using the chain, it shall be checked regularly, ensuring good lubricating condition between chain
links and consistent elastic of right and left chain; In case the chain is worn when using, and the chain
pitch change exceeds 2% of standard value, the chain must be replaced to ensure safe loading.
5. Precautions for cooling system

(1) When the forklift is running, if the radiator “boiling” or high temperature of coolant occurs, the radiator
cap shall be opened immediately as far as possible. If it is necessary to open the cap in order to find out
the boiling reasons and to check the level, the engine shall be reduced to medium speed and rotate the
radiator cap slowly, and the radiator cap shall be removed after a while, so as to avoid coolant
splashing and hurting operators.
When tightening the radiator cap, it must be tightened in place, or it is difficult to establish the specified
pressure system,
(2) For the radiator which uses clean water as coolant, when the forklift is not used, only cold weather
occurs and there is a risk of freezing, the water in the radiator can be discharged. After the radiator has
been worked for a period of time, the radiator shall be removed and put in boiling soda solution for
cleaning, so as to remove the incrustation or precipitates formed on the inner surfaces of the radiator.
(3) For the radiator which uses long-acting anti-rust and antifreeze solution (FD-2 type, -35°C)as coolant, it
is strictly prohibited to add water and different types of antifreeze solution. In case of antifreeze solution
leakage or evaporation, the same type of anti-rust and antifreeze solution shall be added.
Same antifreeze solution will be used in summer and winter, not being changed at all seasons. In general,
after antifreeze solution is used for one year, it shall be discharged for filtration and purification
treatment, and then it can be used again.
(4) According to different working conditions, the smudginess on the outer surface of the radiator shall be
removed regularly by means of immersion cleaning using scouring agent or flushing using compressed
air or high pressure water (the pressure shall not more than 4kg/cm2).
3
6. Oil for forklift
Name Trade mark / code (Domestic) Trade mark / code (Abroad)
Gasoline RQ-85 JISK2202, 2#
Select according to the Diesel Engine Use and JISK2204, 2#

Maintenance Manual or the requirements of GB252-94 ( General region)
Light Diesel Oil:
Diesel
In summer 0#, in winter -10 ~ 35#
JISK2204, 3# (Cold region)
In summer 0#, in winter -10# at general regions
Northeast China region-25#, Guangdong region -10#
Select according to the Engine Use and Maintenance SAE10W (In winter)
Manual, or the standard provisions of gasoline engine
Lubricating oil
GB485-84 and diesel engine: GB11122-89, and its strict SAE30 (In summer)
degree of the working condition.
Hydraulic oil L-HV32# or L-HM46# ISOVG30
Hydrodynamic drive
8 # hydraulic drive oil SAE10W
oil
Gear oil GL-5 (80w/90) SAE90/SAE80W
Brake fluid DOT3 Synthetic brake fluid JISK-2233
Lubricating oil 3#lubricating oil170 JISK-2220, 1#, 2#
4
7. Lubrication system drawing
5
II. Main technical parameters of forklift
6
Main technical parameters
Unit: mm
FD10M FD18M FD20M FD25M FD30M FD35M

Model
S/N Symbols FD10H FD18H FD20H FD25H FD30H FD35H
Item
FD10Y FD18Y FD20Y FD25Y FD30Y FD35Y
1 A Maximum lifting height 3000
Interval adjustment of
2 C 240-1100 240-1100 240-1100 240-1100 260-1100 260-1100
fork
3 D Length of folk 920 1070
4 E Inclination of mast 6°~12°
5 F Total length 3125 3205 3595 3652 3765 3870
6 G Total width (single tire) 1070 1200 1230 1280
Height of the mast from

7 H the ground when it is 1985 2045 2055 2090
lowered
Height of the overhead

8 B 2040 2040 2090 2170
guard from the ground
Height of the top

carriage from the
9 J 4030 4256 4256
ground when the mast
is lifted
10 K Front track (single tire) 890 960 1000 1000
11 L Rear track 920 970 980
12 M Wheel base 920 1600 1700 1750
13 N Front overhang 420 425 472 477 483 505
14 O Rear overhang 425 430 430 500 520 550
Minimum ground
100 100 150 150 175 175
clearance (under frame)
15 P
Minimum ground
100 100 120 120 120 120
clearance (under mast)
7
Main technical parameters
Model FD10M FD18M FD20M FD25M FD30M FD35M
Item FD10H/Y FD18H/Y FD20H/Y FD25H/Y FD30H/Y FD35H/Y
Rated lifting capacity/ load center distance

1000/500 1800/500 2000/500 2500/500 3000/500 3500/500
(kg/mm)
Standard maximum lifting height (mm) 3000

Operational
capability
Lifting speed at full load (mm/s) 1.656 1.746 1.476
Descending speed at load (mm/s) 0.052 0.068 0.068
Mast tilt angle (back and forth)(degree) 6-12
Forward (km/h) 0-18 0-20 0-20

Operating speed
Backward (km/h) 0-18 0-20 0-20
Minimum turning radius (mm) 1980 2060 2240 2280 2420 2520
Minimum right angle

Single tire (mm) 1785 1865 1900 2000 2150 2300
channel width
Walking
Gradeability capacity % ≥20
capacity
Specification of front wheel
6.50-10-10PR 7.00-12-12PR 28x9-15-14PR
Air pressure (Kg / cm2)
Specification of rear wheel

5.00-8-10PR 6.00-9-10PR 6.50-10-10PR
Air pressure (Kg / cm2)
Total weight(Kg) 2280 2890 3420 3780 4380 4650
Front axle load, no-load (Kg) 890 1256 1430 1390 1730 1800
Axle load
Rear axle load, no-load (Kg) 1350 1600 1990 2390 2550 2850
8
III. Structure, principle, adjustment and maintenance of forklift
1. Power system
1.1 The series contains gasoline type and diesel type, the engine and transmission gear are integrated in one piece,
and the engine support reduces vibration by connecting the frame via rubber blanket.
Main parameters of gasoline engine
Model
K21 K25
Parameters
Type: Four-stroke, water cooling, straight and preset air valve
Number of cylinders – diameter of cylinder X

4-75.5X83.3 4-87.2X83.0
stroke
Total displacement 1.486 1.982
Compression ratio 9.0 8.7
Rated power/revolution speed kw(ps)/rpm 25(34)/2400 32.4(44)/2300
Rated torque / revolution speed N. m(kg. m)/rpm 113(11.5)/1600 142(14.5)/1600
No-load minimum revolution speed rpm 800 800
Minimum specific fuel consumption g/ps. h 215 210
Length X width X height mm 688.2X561X677 708.2X561X677
Weight Kg 159 160
Direction of rotation Clockwise direction from the scenery end
Cooling system Forced circulating water cooling
Lubrication system Forced lubrication
Battery Voltage V / capacity Ah 12/90
Lubricating oil 3.8
Cooling water 3.5
9
Main parameters of the diesel engine
Model
NB485BPG C240PKJ 4TNE98 A490BPG A495BPG
Parameters
Four-stroke, water cooling, straight and preset air valve swirl chamber Straight, water cooling, four-stroke, direct
Type:
type injection ω combustion chamber
Number of cylinders – diameter of cylinder X
4X85X100 4.86X102 4-954X107 4-90X100 4-95X105
stroke
Total displacement 2.270 2.369 3.095 2.54 2.977
Compression ratio 18 21.3 20.25 18 18.5
Rated power/revolution speed kw(ps)/rpm 30/2600 34.5(47)2500 44.9(60)/2450 37/2650 47.8/2650
Rated torque / revolution speed N. m(kg. m)/rpm 131/1800 139(14.2)/1800 186.3(19)1600-1800 148/1800~1900 180.2/2000~2200
No-load minimum revolution speed rpm 750±30 700±25 700±25 800±25 800±25
Minimum specific fuel consumption g/ps. h ≤244 ≤215 215 ≤238 ≤238
Length X width X height mm 709X560X636 698X561X667 715X544.5X732.5 751X565X704 696X541X696
Weight Kg 220 252 252 260 260
Direction of rotation Clockwise direction from the fan end
Cooling system Water cooling
Lubrication system Forced lubrication
Voltage of battery 12/90
Lubricating oil 3.8
Cooling water 4.6
See respective engine’s operation and maintenance instructions for parameters and structures of domestic engine used by 2-3.5t forklift.
10
1.2 Matter complied with for installation and operation of Nissan gasoline engine(applicable
to K21 and K25)
(1) Matters that shall be complied with for installation of Nissan gasoline engine
Matters that shall be complied with for

Requirements Note
forklift assembly
Allowance
80°C in common use, 110°C maximum:
temperature of To prevent engine overheat
(water temperature at outlet)
cooling water
Cooling system
Radiator cap pressure 88.3 kPa(0.9kg/cm2) in common use Standard value
Air shall be exhausted from the small tap
Exhaust
when injecting cooling water
Lubrication Allowable The maximum temperature of oil in the
system temperature oil receiver shall be 120°C
(2) Matters that shall be complied with for operation of Nissan gasoline engine
Matters that shall be complied with

Requirements Note
for forklift assembly
It is required to use net type narrow air
filter element which shall be replaced
Suction negative after 6 months operating for 1200 hours
pressure (the inlet generally; for three-shift system and
6.18kPa maximum, and below
Cooling system negative pressure at poor environment circumstances, it shall
0.98Kpa in common use.
the air suction be replaced as soon as possible
horn) otherwise it may result in air cylinder
and piston abrasions and discharging
black smoke containing CO.
Exhaust pressure
13.3kPa in common use, (less If exceeds, adverse impacts on engine
Exhaust system (exhaust port outlet
than 100mmHg) power and noise may occur.
pressure)
H15KA4GR00:6.2kgm/3480rpm
Power output Allowable load of If exceeds, adverse impacts on engine
P.T.D system oil pump power and noise may occur.
Electrical Standard and
Capacity of battery Commonly used in -15°C - +35°C
system Regulation:12V-90Ah
Environment Standard conditions:
temperature -15°C~-35°C
Operational
environment When used at areas of over 1000m,
Standard conditions: The
Area altitude hybrid compensator to fit the altitude
elevation is below 1000m
shall be made to the gasoline engine.
(3) Fuel oil, lubricating oil and other requirements for Nissan gasoline engine
11
Item Requirements Note
Use lead-free regular gasoline If used leaded gasoline, it

may result in abrasions in
Fuel Octant value of 89
gasoline engine and cause
Equivalent to No. JISK2202-1988 - 2 environment pollution.
Usage specifications: Above level API: SD
(equivalent to level above in China) SAE: for general
Lubricating oil areas:20W
Cold area10W
Replace after operation for 200 hours or a month
Equivalent to No. JISK2202-1988 - 2 Refer to the requirements
LLC concentration: Standard area(above -15°C) 30% for antifreeze solution used
Cold area (above -35°C) 50% in China. Long-acting
Antifreeze solution (LLC)
Generally, it shall be replaced every 2400 hours or 12 rust-proof anti-freezing
months but changes may be made as appropriate as solution (FD-2 type,
per different operation environments and conditions. -35°C) is recommended
Use authentic Nissan products

Fuel filter
Replace every 2400 hours or 12 months
Spare parts Oil filter
Air filter
Note: The replacement period stated in the table refers to the general condition (8 hours / day),
replacement shall be made ahead of time in case of three-shift system or poor operation conditions.
1.3 Check and adjustment of engine
1.3.1 Air filter
(1) Take off the filter element;
(2) Check the filter element for dust or damage conditions, if dirty, use low-pressure air to blast from the
inside towards the outside; If damage, replace it with a new one;
(3) Clean the dust collecting box cover;
(4) For the changing time, see Table 1.2.
1.3.2 Oil filter
▲ Gasoline engine
(1) Remove and change the filter with a filter wrench;
(2) Inject several drops of oil around the seal ring of the new filter and further screw 2/3 circle upon contact
of the seal ring and engine body.
12
▲ Diesel engine
(1) Remove and change the filter with a filter wrench;
(2) Inject several drops of engine oil around the seal ring of the new filter and further screw 2/3 circle upon
contact of the seal ring and engine body;
(3) For the changing time, see Table 1.2.
1.3.3 Water tank and attached water tank

Cap
(1) Check the cooling level of fluid in attached water tank
Check the level of fluid in attached water tank, if the level

is lower than the “Low” scale, more antifreeze solution as
per the concentration of antifreeze solution (LLC) in High
Section 1.2 shall be added to the stipulated level;
The level of fluid is higher than the “High” scale during

heat engine and at 2/3 of capacity during cold engine.
Low
Figure 1-1 Attached water tank
(2) Replace the antifreeze solution
(a) Stop engine and wait for 30 min;
(b) Move the water tank cap and loosen the water outlet switch on the water tank,
(c) Loosen the water outlet switch on the engine and drain out coolant;
(d) Tighten up the two said water outlet switch;
(e) Add antifreeze solution as per concentration requirements specified in Section 1.2 into the water
tank at a speed of less than 2L/min;
(f) Start the engine and idling for a while after full injection, check the level of fluid in the attached
water tank, if lower, continue to add to the stipulated level;
(g) Tighten the water tank cap and add antifreeze solution at any time to keep it above 2/3 of capacity.
(3) Adjust the tightness of the fan belt.
(a) Unscrew the installation bolts of engine;
(b) Move the location of engine to adjust the tightness of belt and press the belt with finger with a
force of 10 kg that 10mm shall be pressed down at the largest site.
13
1.3.4 Exhaust
▲ Diesel engine
(1) Press the manual pump to pump the oil into the injection pump;
(2) Press additional 5 - 10 times if felt heavy.
1.3.5 Adjustment of engine speed
(1) Idling
(a) Warm the engine until the temperature of cooling water of engine reaches 85°C;
(b) Furnish a revolution meter to the engine and use the idling adjusting screw of carburetor to adjust
the revolution speed of engine to the stipulated value at 700rpm.
(c) Adjust the minimum opening stop screw of air valve as per the direction of increasing engine
speed;
(d) Use the idling adjusting screw of carburetor to adjust a stable speed of engine at 700rpm.
(2) Maximum revolution speed (gasoline engine)
An adjuster is used to adjust the maximum revolution speed of engine. Attention shall be paid that
change too fast may cause cylinder knocking.
Adjustment section Width 2.55MM
Air pipe
Cable assembly
Width 12MM
To the carburetor
To the distributor
Cam spring Rocker arm

Idem
Figure 1-2 Adjuster
▲ Maximum no-load revolution speed adjustment
Remove the rubber cap and rotate the adjusting part to reach the stipulated maximum no-load revolution
speed. Clockwise rotation of the adjusting part will increase speed and otherwise reduce speed.
▲ Maximum loaded revolution speed adjustment (the overflow valve works)
(a) Rotate the adjusting screw to adjust the maximum loaded revolution speed and it may also adjust
the maximum no-load revolution speed (the screw for maximum no-load revolution speed
adjustment is in the adjusting part and the adjustment direction is the same with the direction of
14
adjusting screw for maximum loaded revolution speed adjustment)
(b) If adjusting screw operation fails to reach the maximum loaded revolution speed, cam adjustment
can be used but superb skills are needed for cam adjustment because even fine adjustment may
cause cylinder knocking.
Model
FG20Y(K21) FG25Y(K25)
Parameters
Maximum no-load Instantaneous value 2990〜3150 3050〜3250

revolution speed rpm Stable value 2820〜3080 2900〜3100
▲ Check and adjustment of cylinder knocking
Cylinder knocking is the phenomenon of extreme unstable state of engine revolution speed and special
attention must be paid to it regardless of maximum no-load revolution speed adjustment or maximum
loaded revolution speed adjustment.
Inspection
• Close the hydraulic pressure system and place in neutral gear position to check cylinder knocking
by slowly pressing the accelerator pedal during idle running.
Adjustment
If more than three times of cylinder knocking occur, adjustment shall be made as follows:
• Clockwise rotate the adjusting screw and adjust the Maximum no-load revolution speed
simultaneously;
• If cylinder knocking cannot be eliminated by the above adjustment, adjust the cam gear screw.
Fault Causes Solution

Engine wheel speed cannot be
• Cam cable breakage
increased under the no-load Replace cable components
• Spring damage or breakage
condition
Travel speed cannot be
increased • Improper adjustment of cam spring Adjust
Cylinder knocking (no cylinder • Balance piston jam Clean or replace governor assembly
knocking during raising)
Travel speed cannot be
increased • Improper adjustment of cam spring Adjust
Lifting slowly • Spring damage Replace cable components
Lifting slowly (normal travel • Improper adjustment of cam spring Adjust
speed)
• Improper adjustment of cam spring Adjust
Increase of travel speed is too
• Balance live valve jam Clean or replace governor assembly
fast
• Adjuster valve shaft jam Re-install
• Improper adjustment of cam spring Adjust
More than three times of
• Balance piston jam Clean or replace governor assembly
cylinder knocking occur
• Adjuster valve shaft jam Re-install
15
See respective engine operation and maintenance instructions for adjustments of other parts of engine.
1.4 Fuel system

The fuel system is composed of fuel tank, fuel filter, fuel quantity sensor and fuel gauge indicating oil level.
1.4.1 Fuel tank
The fuel tank is welled and integrated to the frame on the left side into one piece. The tank flap is located at
the upper place of the tank and is equipped with the fuel sensor monitoring oil quantity. The structures of
gasoline vehicle and diesel vehicle are the same but only the former uses an oil sucking pipe while the latter
uses an oil return pipe.
1.4.2 Fuel quantity sensor
The function of fuel quantity sensor is to translate stored fuel quantity into current value, see Figure 1-5.
Figure 1-5 Digital instrument board
A rheostat with nickel alloy wire is adopted and there is one sliding element connected to the floater. With the
up and down movements of floater, the resistance changes thus current passing the rheostat changes
simultaneously.
The fuel gauge is bimetallic strip type that the moving amplitude of pointer depends on the current value
passing the heating element of bimetallic strip. When the floater is at the top position, the resistance of fuel
sensor device is about 9.5 to 11 so that the larger the current, the more bend the bimetallic strip causing the
pointer of fuel gauge pointing at the full position “F”. On the contrary, with the decline of oil level, the
floater goes down, the resistance increase, the current weakens, which causes the pointer pointing at the
empty side “E”.
The fuel gauge is solid columnar display type, the more rightward the light pillar, the more fuel in the fuel
tank. On the contrary, the leftward the light pillar, the less fuel in the fuel tank. Buzzer warns when the fuel
oil is too few to the limit reminding the drive of oil injection in the fuel tank.
16
To the fuel gauge
A-direction section views
1.4.3 Maintenance of fuel system
One maintenance shall be made for the fuel system as per the following methods every 100 hours’ operation
and the fuel tank shall be cleaned every 600 hours’ operation.
(1) Fuel filter
The filter fitted to the fuel pump (gasoline engine) or the fuel tank (diesel engine) is used to filter the
fuel supplied to the engine clean and the oil filter of diesel engine also separate water from fuel.
Spring
Pump
Filter
element
Housing
Fuel level switch

Discharge switch
Gasoline engine type Diesel engine type
▲ Gasoline engine
(a) The entire filter shall be replaced every 300 hours’ operation;
17
(b) Loosen the swiveling wheel and move the cover;
(c) Unscrew the nut and remove the filter element;
(d) Clean or replace the filter element;
(e) After completion of replacement, start the engine to inject gasoline into the oil cup of filter to
check for leakage.
▲ Diesel engine
(a) The entire filter shall be replaced every 600 hours’ operation;
(b) Inject several drops of fuel around the seal ring of the new filter and install. Further screw 2/3
circle upon contact of the seal ring and engine body.
(c) When the warning lamp of filter is on, loosen the water outlet switch to drain out water.
(2) Clean of fuel tank
The fuel tank shall be cleaned every 600 hours’ operation. For gasoline forklift, special attention shall
be paid to prevent fire.
1.5 Accelerator pedal
As shown in the figure, the accelerator pedal fitted to the base plate is used to control the revolution speed of
engine and is connected to the engine via connecting rods and cable.
2. Electric System
2.1 General
The electrical system is single wire system circuit with negative pole connected to the car body and is mainly
composed of the following systems:
(1) Charging system
It is composed of generator, battery and charging indicator light, etc. to supply power for electric
equipment of forklift, voltage: DC12V.
(2) Starting system
It is mainly composed of automatic preheating system (only applicable to diesel engine), starting switch,
starting protection circuit, and starter, etc. the function of starting system is starting the engine.
(3) Electro-hydraulic reversing control system
① Electrical schematic diagram
② Main parts
18
Starting switch“C”
Starting relay
Backup lamp
Direction
switch
Control box
Control
valves
Electro-hydraulic control valve
Direction switch
Control box
③ General
Electro-hydraulic control valve is designed and developed on the basis of the original control valve
(see Section 5.4).
(a) Similarities with the control valve
• Performance
• The size of connecting parts with the transmission
• Orientations and sizes of oil ports (oil inlet, inching valve oil port, torque converter oil port,
forward gear oil port and backward gear oil port)
• Differences between performance parameters (b) of normal valve, overflow valve and
adjusting valve and that of control valve.
• The slide valves of major reversing valves are in different controlled ways that the slide valve
of control valve is controlled by machinery control and the reversing of electro-hydraulic
control valve is controlled by electromagnetic pilot operated valve. That is to say, the former
is machinery control and the latter is electric control.
(4) Instrument system
It is mainly composed of chronograph, fuel gauge, water thermometer and indicator light and is the
checkout equipment on forklift.
19
The combined instrument is assembled with US Curtis internal combustion engine instrument
movement. The fuel gauge and water thermometer of Curtis internal combustion engine instrument is
solid ten-section color LED display and the chronograph is solid digital backlight display.
(5) Illumination sign equipment
It includes various illuminations, indicator lights and horns and buzzers, etc.
Front headlight:55W
Front combination lamp (turning / clearance lamp) 21W/5W
Back combination lamp (turning / clearance lamp / backup lamp):21W (red)/5W(red/10W(white)
Warning lamp(optional part) 21W
2.2 Operation brief description

(1) Start
The direction switch shall be in zero position prior to starting the engine. Otherwise the engine shall not
be started. This is because of the protection function designed for the purpose of forklift safety in the
control box.
Clockwise rotate the starting switch to the first gear - power on gear, the instrument and ignition power
is on, for diesel engine, it will start to preheat, the preheat indicator light is on and will automatically go
off after 3.5 seconds and the preheating time will end at 13.5 second controlled by the time relay (also
known as timer).
Clockwise rotate the starting switch to the second gear – starting gear to start the engine.
After starting the engine, push forwards the direction switch, that is the forward gear, step on the
accelerator and the forklift will travel at a high speed or operate at a high speed;
Pull backwards the direction switch, that is the backward gear, the backup lamp is on and the backup
buzzer rings.
(2) Light switch: Pull to the first gear and the front and back clearance lamps are on; Pull to the second gear,
the front headlamp is on and the clearance lamp is still on at this point.
(3) Turning signal: Pull backwards the turning lamp switch, the left turning signal lamps of the front
combination lamp and back combination lamp of forklift will flash; Pull forwards the turning lamp
switch, the right turning signal lamps of the front combination lamp and back combination lamp of
forklift will flash.
(4) Brake signal: If the forklift needs brake, step on the brake pedal with the foot and the brake lamp (red)
of the back combination lamp is on.
(5) Backup signal: If the forklift needs backup, pull backwards the direction switch, at this point, the
transmission will be placed in the backward gear, the backup lamp (white) of back combination lamp is
on and the backup buzzer rings.
(6) Signal indication for not charging: Prior to starting the engine, switch the starting switch to the
power-on position, the charging indicator lamp is on and will automatically go off after the engine is
started; If the engine is in an operating condition and the charging indicator lamp is on, it indicates that
the charging circuit is out of order and does not charge. Then it needs to stop the vehicle and check.
(7) Engine oil pressure signal: Prior to starting the engine, switch the starting switch to the power-on
20
position, the oil pressure indicator lamp is on and will automatically go off after the engine is started; If
the engine is in an operating condition and the oil pressure indicator lamp is on, it indicates that the oil
pressure of engine is too low and has poor lubrication, then it needs to stop the vehicle and check.
(8) Signal display for oil-water separator: Prior to starting the engine, switch the starting switch to the
power-on position, the oil-water separator signal lamp is on and will automatically go off after the
engine is started; If this lamp is on during the operating process of engine, it indicates that the water
accumulation in the oil-water separator had exceeded the warning level, then it needs to press the
compression bar on the oil-water separator to drain the accumulated water. The indicator lamp goes off
after drainage.
(9) Fuel gauge: Shows the storage volume of fuel in tank. When the fuel gauge indicator shows less than 2
pillars, the warning buzzer will ring to indicate the fuel storage has been too few and remind the driver
of fuel injection to the tank.
(10) Water thermometer: Indicate operating hours of engine.
(11) Chronograph: Indicate accumulated operating hours of engine.
Attached: Electrical schematic diagram
21
22
Light powerred-blue1.5
Adaptive to FD25-FD30MA Xingchang 490engine, which can be used in

common by mechanical and manual hydraulic vehicles
Lamp power: red-blue 1.5
23
Left turn Key Turn signals Direction Lighting switch
Width signal switch switch switch
Headlamp lamp light Power Power
Right steering
Width lamp
Headlamp
Left steering Forward
Water
Oil
Left turn
Neutral position
Oil-water
Right turn
indication
Instrument
Oil pressure
Preheat
Recharging
Oil quantity
temperature
temperature
Position 2 Width lamp (lamplet)
Start position Right steering Backward Headlight
Oil temperature
Horn switch sensor
Horn Oil quantity

sensor
Water temperature
Preheating sensor
indication
white-yellow Oil-water separation
alarm switch
Time Relay
Ignition coil Oil pressure alarm

Red switch
Time Relay Preheating
Red output Preheater
Electrical yellow
Starting coil
white-black
control
box Starter
White
Fusible wire
Horn purple
24
Fuel shutoff valve
Instrument
power yellow Distributor
Reverse switch
blue
Accumulator cell
Generator
Flasher
green
adjuster
Electronic
Ground
black
Starter
Neutral Position Switch
Reversing solenoid valve

Brake light
switch Back-up buzzer
Left Clearance Stop Right Backup

steering lamp steering lamp Electric Schematic Diagram
Adaptive to FG25YB-FG35YB Nissan engine

Indicator
ph
Preheating Preheating
timer relay
Starting
Chronogra
switch
Water
Oil-water
thermometer
gauge
Oil quantity
Preheat
separation
Oil
pressure
Recharging
Adaptive to FD25YB-FD36YB Lamp switch
C240 engine and electronic
commutation
Width Headla
lamp mp
Clearance
Steering
Headlamp
Turn signals lamp
Horn
Horn
switch
Flasher Turn signals
switch
25
Oil-water
separator
Fuse box
Oil quantity
sensor
Starter
Generator
Fuel shutoff
valve
Idling preheating
Accumulator switch
cell
Oil pressure
switch
Water temperature
sensor
Rear combination lamp Neutral position Rear combination
switch lamp
switch
Stop lamp
Reversing
Turn signals lamp

lamp switch
Steering
Width lamp
Clearance
Stop lamp Preheating
plug Brake
Backup lamp Back-up
Reverse
buzzer
3. Clutch device
Type Monolithic dry type

Type of operation Foot pedal type
External diameter size of friction plate 275mm
Inner diameter 175mm
Thickness 8.9+0.3mm
Surface area 354cm2
Weight 12.5kg
3.1 General
The clutch device is composed of clutch housing, friction plate, brake cylinder, brake master cylinder and
platen assembly with functions of transmitting and disconnecting power from engine to the transmission.
3.1.1 Platen shell and friction plate
The platen shell is installed on the flywheel of the engine, its structure as shown in Figure 3-1, and the
friction plate is between the platen and the flywheel, installed on the drive shaft of the transmission through
the spline. When release sleeve moves forward and release lever is pushed forward, the platen leaves the
friction plate, thus the power from the engine is cut off.
26
Platen shell
Platen
Release lever
A - A section view
Transmission
Engine end
Figure 3-1 Clutch housing and friction plate
27
Release bearing Platen shell
Release sleeve
Friction plate Release fork
Release lever
28
Filling upon Base lubricant
installation
Figure 3-2 Clutch refueling points

Sleeve
Filling above 80% grease

Filling molybdenum-based
upon installation
grease upon installation
3.1.2 Brake slave cylinder
Brake slave cylinder structure as shown in Figure 3-3, installed on the left of the transmission. The brake
slave cylinder consists of by piston, spring and push rod. Push the push rod will pass the movement to the
release lever.
① Oil drain valve ④ Cylinder body ⑦ Spring

② Peel ⑤ Piston ⑧ Push rod
③ Dust cover ⑥ Lock nut ⑨ Connecting rod
Figure 3-3 Brake cylinder
3.1.3 Brake master cylinder
The master cylinder is shown in Figure 3-4, installed on the clutch pedal. The master cylinder is composed of
piston, spring, oil cup and push rod, and the movement of pedal is passed to the piston by the push rod,
which transforming the pedal force into hydraulic pressure
① Connecting
rod
② Push rod
③ Dust cover
④ Collar
Self-storage oil cup
⑤ Stop plate
To clutch slave cylinder ⑥ Piston
⑦ Peel
⑧ Spring
⑨ Valve rod
A section
A section vi
view ⑩Spring
○ Peel
11
○ Cylinder
12
body
Figure 3-4 Brake master cylinder
3.1.4 Clutch pedal
29
Clutch pedal and brake pedal are installed on the same bracket, which is installed on the top of the
transmission, and when the movement of the pedal is passed to the master cylinder and the pedal force will
be transformed into hydraulic pressure, the hydraulic pressure will drive the push rod of brake cylinder and
pass the movement to release fork.
Pedal
Bush Spring
Axle
Clutch master
cylinder
Connected with Clutch slave

the oil cup cylinder
Figure 3-5 Clutch pedal
3.2 Maintenance
Height Free travel
3.2.1 The adjustment of clutch pedal
(1) Remove the bottom plate;
(2) Loosen the catch bolt and lock nut;
(3) Turn the catch bolt Left and right to adjust the
height of the pedal;
(4) Tighten the lock nut, and install the bottom plate
30
Figure 3-6 Height of the clutch pedal
3.2.2 Friction plate replacement
(1) Remove the cover plate of the clutch housing; Platen shell
(2) Depress the clutch pedal, and withdraw the platen
with pull-out bolt; Platen Pull-out bolt
(3) Turn the slide bolts left to let the drive shaft enter the
transmission;
(4) Remove the fixed bolt of the platen cover, and take
down the friction plate;
(5) Install the new friction plate with the longer spline
end toward the transmission; Notice: Make sure the
drive shaft spline set into the spline groove of friction
Figure 3-7 Pull-out bolt
plate
(6) Slide the bolt and tighten the torque: 10.9 - 12.1kg.m
(7) Install the platen shell on the flywheel;
(8) Depress the pedal and remove the pull-out bolt;
(9) Check the free travel of the pedal and adjust if

necessary;(free travel:10mm)
(10) Keep the release rocker 14 mm away from the catch

bolt.
Figure 3-8 Clutch slave adjustment
31
4. Mechanical drive unit
Mechanical transmission Manual gearshift, sliding type synchromesh

Type: Forward and backward for 2 each
Gears number
Speed ratio Forward gear 1 / gear 2 3.253/1.407

Backward gear 1 / gear 2 3.204/1.386
Reducer Spiral bevel gear
Reduction gears 2.5(l-1.8t)
Reduction ratio 2.1(2-3t)
Differential Spur gear
Reduction gears 5.7(1-1.8t)
Reduction ratio 6.182(2-3t)
Common bevel gear
Oil quantity 8L
Weight (without oil) 136kg(1-1.8t),165kg(2-3t)
4.1 General
Mechanical drive unit is composed of transmission with synchronizer and differential.
32
Figure 4-1 Transmission with the synchronizer
33
① Retaining ring ○ O-ring

13 2○5 "Forward" gear 3○7 Tapered roller bearing
② Retaining ring
③ Ball bearing ○ Slide bolt
14 2○6 Needle bearing 3○8 Shift level
④ Space ring
○ Bearing holding rack
15 2○7 Counter gear 3○9 Shift lever
⑤ Ball bearing
⑥Drive gear ○ Drive shaft
16 2○8 Clutch 4○0 Zero switch
⑦ Needle bearing
○ O-ring
17 2○9 Space ring 4○1 Shift lever
⑧ Built-up gear
⑨ Needle bearing 1○8Drive gear 3○0 Needle bearing 4○2 Backup lamp switch
⑩ Space ring
1○9 Lock nut 3○1 Shaft 4○3O-ring
○ Ball bearing
11
2○0 Adjusting nut 3○2 "Backward" gear 4○4O-ring
○ Oil seal
12
2○1 Tapered roller bearing 3○3 "Low Speed" gear 4○5 Shaft collar
2○2Ball bearing 3○4Clutch
2○3 Bearing holding rack 3○5"High Speed" gear

2○4Steel frame 3○6Ball bearing
4.1.1 Transmission with the synchronizer
(1) Power transmission of the transmission
Mechanical transmission is mainly composed of a drive shaft, an output shaft, a main shaft and an idler
shaft (for backup) and each shaft has one or several gears of different tooth number. These gear shifts by
using the gearshift handle through the shift-sleeve type synchronizer on the main shaft, passing the
power of the engine to the driving wheels by the output shaft through the low speed gear and the
differential.
High gear position (median position) power from the drive shaft① pass to the high speed gear ④ and
low-speed gear ⑥ through the meshing input gear ② and the dual gear ③, but as the gear shift
sleeve that controls speed and direction is at the neutral gear position, the main shaft output gear and the
output shaft will not rotate, thus no power passing out.
Shift position, when changing the gear shift lever, the shifting fork drives the shift sleeve to move and
make all gears mesh through the synchronizer. The procedure of power transmission is as follows: Drive
shaft → input gear→ dual gear→ high or low speed gear → synchronizer→ main shaft → synchronizer,
reverse gear or forward gear →output gear→ output shaft outputs power.
The power transmission procedure of forward first gear:
○ →⑩→⑧→⑨→12
①→②→③→④→11 ○ →16
○ →15
○ →17
○ →18
○ →⑤→㉑
The power transmission procedure of forward second gear:
○ →16
①→②→③→⑥→⑦→⑧→⑨→12 ○ →15
○ →17
○ →18
○ →⑤→㉑
The power transmission procedure of backward first gear:
○ →⑩→⑧→⑨→12
①→②→③→④→11 ○ →16
○ →15
○ →14
○ →13
○ →19
○ →20
○ →⑤→㉑
The power transmission procedure of forward second gear:
○ →16
①→②→③→⑥→⑦→⑧→⑨→12 ○ →15
○ →14
○ →13
○ →19
○ →20
○ →⑤→㉑
34
①Drive shaft
②Input gear
③ Dual gear
④ Dual gear
⑤ Output gear
⑥ High speed gear
⑦ Synchronizer cone
⑧ Shift sleeve
⑨ Clutch driven plate
⑩ Synchronizer cone
○ Low speed gear
11
○ Main shaft
12
○ Backward gear
13
○ Synchronizer cone
14
○ Shift sleeve
15
○ Clutch driven plate

16
○ Synchronizer cone
17
Figure 4-2 Power transmission ○ Backward gear
18
○ Forward gear
19
○ Backward gear
20
㉑ Output shaft
(2) Synchronizer
The synchronizer makes the meshed gear rotate synchronously, avoiding collision while shifting,
especially in front and back reversing, and make the shift smooth.
35
① Synchronizer ring spline teeth

② Synchronizer ring
③ Spline teeth of the gear
④ Synchronizer cone
⑤ Shift sleeve
⑥ Spline of the shift sleeve
⑦ Insert blocks
⑧ Spring
⑨ Clutch driven plate
⑩ Shifting fork
○ Constant mesh gear

11
○ Teeth of gear
12
○ Constant mesh gear

13
○ Teeth of gear
14
Figure 4-3 Synchronizer
The synchronizer is mainly composed of synchronizer cone (a), synchronizer ring (b) and insert blocks
(c).
○ (or 13
(a) Synchronizer cone: Gear 11 ○ ) with involute spline of a shaft cone (synchronizer cone)
combine with synchronizer ring ② and shift sleeve ⑤ respectively through the friction surface
and spline tooth of this cone surface.
(b) Synchronizer ring: Synchronizer ring has one orifice cone, and cooperate with the synchronizer
cone through the friction surface of this cone surface. Synchronizer ring has three uniformly
distributed grooves along the circumference, which align with the dobby chain of the shift sleeve
and spline of synchronizer ring correspondingly to push it to synchronize direction half through
spline of the shift sleeve ⑥.
(c) Insert block: Install the middle bulge of the three insert blocks in the spline groove of the shift
sleeve ⑤, insert their sides into the three corresponding grooves of the synchronizer ring
respectively, and push the insert blocks to the top of the spline groove ⑥ with the two springs⑧,
the outward spring force aligned with dobby chain teeth of synchronizer ring.
36
Synchromesh operation, from neutral position to

the meshing completed, is divided into the
following six steps, and in this process, taking
the gear in Figure 4-3 as an example of the
synchronization process.
Step I:
The forces on the gear lever while gear shifting

transmit to the shift sleeve ⑤ through the
shifting fork, and the shift sleeve ⑤ and insert
block ⑦ move a distance X1 and X2 to the gear
respectively along the gear □, at the same time,
the middle budge of insert block ⑦ is still in
the inner groove of the shift sleeve.
Figure 4-4
Step II:
When gap X1 and X2 are eliminated, forces are

added to the friction surface of insert block ⑦,
synchronizer ring ② and synchronizer cone ④,
which offset the spring force and make the insert
blocks form an angle, forming the angle contact
as shown in the figure and the shift sleeve moves
for distance Z under this force.
Figure 4-5
Step III:
Friction torque is produced on the friction

surface of synchronizer cone through the force of
insert blocks ⑦ that acts on the synchronizer
ring, and makes the synchronizer ring turn an
angle. When one side of the synchronizer ring
groove contacts with the side of the insert block,
aligning the shift sleeve with and synchronizer
ring.
Figure 4-6
37
Step IV: 3. Mechanical transmission device
After the third step is completed, the synchronizer

shift sleeve has moved for distance Z to make the
position spline tooth of the synchronizer ring ①
contact with the chamfering part of the shift sleeve
spline ⑥ , meanwhile the synchronizer cone
surface gradually achieves the required friction
torque Tc, and the original inertia moment Ti of
gear reduces gradually, namely Ti < Tc, meshing
process started to be synchronizer.
Step V:
Figure 4-7
When the relative speed difference of the
synchronized constant mesh gear □ and shift
sleeve ⑤ is 0, the inertia moment Ti = 0, i.e.
friction torque offsets the inertia moment to make
the speed of gear equal to that of main shaft so as
to complete the synchronization. At this time due
to the continuous effect of axial force,
synchronizer ring turns an angle in the
circumferential direction to make the shift sleeve
teeth locate between ③ , meanwhile turns to
floating state under the external force of
synchronizer ring so that the shift sleeve can go
through the synchronizer rings smoothly.
Figure 4-8
Step VI:
The shift sleeve moves for distance Y1 after passing the synchronizer ring (see Figure 4-7) so that the
chamfering part of the shift sleeve spline tooth ⑥ start to contact with the chamfering part of spline tooth
③ of the gear edge (see Figure 4-9). Because the contact of this chamfer, torque TG is added on the teeth ③
through the shift sleeve spline tooth, which makes the gear □ turn an angle along the circumferential
direction relative to the shift sleeve, thus making the shift sleeve spline pass through the spline teeth ③ at
the gear edge and the synchronization process is completed. The forces pass through the dynamic platen hub,
shift sleeve and the spline teeth ③ of gear □ through the main shaft clutch, and the synchronization process
is complete. The forces pass out from the dynamic platen hub, shift sleeve and the gear □ through the main
shaft clutch thus realizing the gear shift process.
38
Figure 4-9
4.1.2 Reducer and differential
Reducer part locates in the front of the transmission, which reduces the rotate speed from the transmission
output shaft and increases the torque from the output shaft, then transmit the torque to the differential;
Reducer is mainly composed of the small spiral bevel gear on the output shaft, a big spiral bevel gear and a
small gear shaft. The large spiral bevel gear is installed on the small gear shaft through the spline, and both
ends of the small gear shaft are supported by cone roller bearing with gasket to adjust the side clearance.
Differential is installed on the front half shell with bearing base through the ball bearing of both ends, and the
front end connects with the axle housing and the shell of differential is left-right split type with two half shaft
gears and four planetary gears. Thrust washer is installed between the shell of differential and gear and leave
clearance between gears. Planetary gear is supported by gear shaft I, II, and gear shaft I is fixed to the shell of
differential with straight pin, and gear ring ① is fixed on the shell of differential with hinge bolt.
The forces from the transmission produce differential drive by the differential after speed reduction, and pass
to the gear through half shaft gear and axle shaft.
39
① Gear ring
② Pin
③ Ball pin bearing
④ Side gear
⑤ Gasket
⑥ O-ring
⑦Bearing cover
⑧Conical roller bearing
⑨ Adjustment gasket
⑩ Gear
○ Spacer bushing
11
○ Terminal helical shaft

12
○ Straight pin
13
○ Planetary gear
14
○ Gasket
15
○ Gear shaft
16
Figure 4-10 Reducer and differential
40
41
5. Hydrodynamic drive unit
Torque converter
Catalog Three-element, single stage, two phase type
Torque ratio 3
Setting pressure 0.5~0.68MPa
Oil feed pump
Type: Internal meshing gear type
Water Flow 27L/min(2000rpm,1.5MPa)
Hydrodynamic transmission
Category Power shift
Forward 1.35
Speed ratio Backward 1.35
Hydraulic clutch
Friction plate: outer diameter X, inner diameter X, 125X81X2.7mm
thickness 71cm2
Area of friction surface of friction plate 1.1〜1.4MPa
Setting pressure
Weight 165kg
Oil capacity 7L
Categories of used oil Engine oil SAE10W
Domestic 6# hydraulic drive oil
5.1 General
The hydraulic transmission forklift is equipped with the drive unit made of the torque converter and power
shift transmission (see Figure 5-1) and has the following advantages:
(1) The inching valve can make the forklift carry out the inching operation as the engine runs at the low
speed or high speed;
(2) The hydraulic clutch is equipped with four pairs of paper friction plates and steel plates upon special
treatment that improve the abrasive resistance of the friction pairs.
42
Figure 5-1 Hydrodynamic drive unit
① Forward clutch 1○4 Control valve ○ Circlip for hole

27 ○ O-ring
40
② Oil filter
assembly
③ Reverse clutch ○ Single-row
28 ○ Scraper ring
41
④ Single-row ○ Piston
15
centripetal ball
○ Single-row conical
42
bearing
centripetal ball ○ Spring
16
roller bearing
bearing ○ Single-row
29
⑤ Sealing ring (A) ○ Oil filler cover
17 ○ Output shaft
43
centripetal ball
⑥ O-ring
⑦ Oil feed pump
○ Safety valve cover
18 bearing ○ Bearing pad
44
assembly ○ Hexagonal socket

19 ○ O-ring
30
○ Single-row
45
⑧ Oil seal head plug ○ Check ring
31 centripetal ball
⑨ Pump impeller bearing
⑩ Guide roller ○ Plug
20
○ O-ring
32
○ Hexagonal socket
46
○ Turbine
11 ○ Flexible straight pin
21
○
33 Idlers head plug
1○2 Elastic plate ○ Shifting arm
22
○ Oil filter (I)
34 ○ Housing lid
47
assembly ○ Housing lid
23
○ Output gear
35 ○ Fixed bolt
48
1○3 Inching valve
○ Shifting arm shaft
24
○ Idler shaft
36 ○ Back light switch
49
assembly
○ O-ring
25
○ Single-row
37 ○ Oil drain plug
50
○ Woodruff key
26 centripetal ball
43
bearing
○ Bearing nut
38
○ Single-row conical
39
roller bearing
(3) The one-way overrun clutch installed in the torque converter improves the power transmission
efficiency;
(4) The superior filter in the oil circuit of the torque converter improves the life of torque converter.
5.2 Torque converter
The torque converter mainly consists of pump impeller, turbine and guide roller.
The pump impeller is driven by input shaft, and the fluid substantially flows (the mechanical energy is
converted into kinetic energy now) to the blade grid of the turbine along the blade grid of pump impeller
under t the action of centrifugal force to transmit the torque to output shaft, and the fluid that flows away
from the turbine is redirected under the action of guide roller so that part of the fluid flows back to pump
impeller at a certain angle, now the counter torque to push the guide roller is generated, so that the output
torque is the sum of the input and counter torques. When the rotate speed of the turbine increases and
approaches to input speed, the change of the angle of the fluid starts to reduce, and the torque of output shaft
lowers. Finally, the fluid flows to the guide blade grid at the reverse direction to make the original counter
torque acts backward. So, the torque of output shaft is less than torque of input shaft. To prevent this situation,
the overrun clutch installed in the guide roller makes the guide roller acts backward under the action of the
counter torque and rotate freely.
This torque conversion mode can ensure that the torque converter operates efficiently and stably.
The torque converter of transmission device is connected with the engine flywheel with the elastic plate and
rotates along with the rotation of engine. And it is filled with the torque converter oil inside. The main gear is
connected with the pump impeller with two claws to drive the oil feed pump to feed oil to the torque
converter and hydraulic shift transmission. The turbine is connected to turbine shaft with the spline and the
power is transmitted to power shift transmission by the turbine shaft.
44
Turbine
Elastic plate
Pump impeller
Guide roller
To clutch
Overrunning clutch
Figure 5-2 Torque converter
5.3 Hydraulic clutch (Figure 5-3)
The wet multi-plate type hydraulic clutch is installed on the input shaft of the hydraulic shift transmission
and distributes the pressure oil to the forward or reverse clutch by the control valve to realize the shift
between forward gear and backward gear. All gears in the transmission are constant mesh gears. Each clutch
consists of four spacers (No. 24) and four friction plates (No. 25) assembled separately, and one piston. The
inside and outside circles of the piston are equipped with sealing rings to ensure the leakproofness when it
works. At the time of the neutral position, the piston does not work and the spacers and friction plates are in
separated condition; At the time of the gear shift, the piston, spacers and frication plates compress mutually
under the action of oil pressure to form a contact maker by the friction force to transmit the power from the
torque converter to drive gear (frontward gear ④ or reverse gear □)
Procedures of power transmission from the torque converter to hydraulic transmission are as follows:
Turbine → input shaft assembly → spacer → friction plate → forward gear or reverse gear → output shaft
45
Pressure oil of forward clutch

Pressure oil of backward clutch
Connection with the

Lubricating Oil
torque converter
Figure 5-3 Hydraulic clutch
① Sealing ring (A) ⑧ O sealing ring ○ Sealing ring (A)

15 ○ Check ball
22
② Bearing ⑨ Input shaft assembly
③ Thrust shaft collar (B) ⑩ Sealing ring (B) ○ Sealing ring (A)
16 ○ Piston assembly
23
④ Forward gear ○ End plate
11 ○ Sealing ring (A)
17 ○ Spacer
24
⑤ Snap ring
⑥ Circlip ○ Collar (A)
12 ○ Thrust shaft collar (B)
18 ○ Friction plate
25
⑦ Spring seat
○ Reverse gear
13 ○ Needle bearing
19 ○ Return spring
26
○ Bearing
14 ○ Collar (A)
20 ○ Needle bearing
27
○ Circlip
21
5.4 Control valve, overflow valve and inching value
5.4.1 The control valve is installed inside the transmission housing lid and consists of the control slide valve,
constant pressure valve and adjusting valve: (Figure 5-4)
5.4.2 The constant pressure valve is used to control the oil pressure of the hydraulic clutch within 1.1-1.7MP&
and deliver oil to overflow valve for inputting the torque converter;
5.4.3 Adjusting valve: It is located between the inching valve and control slide valve, and it starts to work when
the control slide valve opens fully in order to reduce the impact at the time of the contact of hydraulic clutch;
5.4.4 Overflow valve: The overflow valve connected with the transmission housing makes the oil pressure of the
torque converter maintain within 0.5-0.7MPa to prevent the lock erosion;
5.4.5 Inching valve: The inching valve is installed outside of the transmission, its reel is connected to the inching
46
pedal linkage, and when stepping on the inching pedal, the reel moves towards the right, which lowers the oil
pressure of hydraulic clutch in a short time to makes the forklift achieve the inching effect (Figure 5-5)
Locating valve
Adjusting
valve
Control slide valve
Spring
Steel ball
Figure 5-4 Control valve
① Circlip
② O ring
③ Inching valve:
④ Elastic check ring
⑤ Spring
⑥ Valve core
⑦ Reel
⑧ Valve body
⑨ Spring
⑩ O ring
○ Cap
11
○ Oil seal
12
Figure 5-5 Inching valve
47
5.5 Transmission housing
The transmission housing is equipped with the input and output shafts and other mechanism, besides, it plays
the role as the oil tank, the oil filter I (filter screen with 150 meshes) for filtering the oil inhaled by the oil
feed pump is on its bottom, and the oil filter II in the pipeline, filler cap and oil filter cleaner are installed on
the housing cover.
5.6 Oil feed pump
The oil feed pump is installed between the torque converter and input shaft and delivers oil to the torque
converter and hydraulic transmission by using pump impeller to drive the gear pump composed of a pair of
inner mesh gears.
Oil drain hole
Driven gear
Drive gear
Oil seal Oil feed hole
Pump body Cap
O-ring
Oil inlet of the torque converter
Figure 5-5 Inching valve
5.7 Hydraulic circuit (hydraulic transmission) Figure 5-7
After the engine starts up, the oil feed pump pumps oil passing through the oil filter from the oil tank (i.e.,
the transmission housing bottom), and the pressure oil is divided into two parts through the control valve:
they are supplied to the hydraulic clutch and torque converter respectively.
The oil necessary for the operation of hydraulic clutch flows into the constant pressure valve (adjusting the
pressure to 1.1-1.4MPa), then on one hand, the oil from it flows further into the inching valve and control
slide valve, on the other hand, it passes through the overflow valve (the pressure adjusted to 0.5-0.7MPa) and
is supplied to the torque converter wheel, then the oil from it is cooled by the oil cooler, lubricates the
hydraulic clutch, and returns to the oil tank eventually.
At the time of the neutral position, the oil circuit from the control slide valve to clutch is closed, at that time
the constant pressure valve is opened to make oil totally pass through the overflow valve to be delivered to
the torque converter; when the control slide valve is in forward or backward position, the oil circuit from the
48
slide valve to forward clutch or reverse clutch is connected to make the clutches act respectively; When one
clutch acts, the spacers and friction plates of other clutches are separated and lubricated with the cooling oil
bringing off heat; when the inching pedal operates the inching valve, part or most of the oil in the clutch is
discharged to oil tank, and the oil circulation of the torque converter is the same to that of neutral position.
Switch
Constant
pressure valve
Inching valve
Backward - neutral
Control slide valve
position - forward
Adjusting valve
Oil filter
Oil feed pump
Torque converter
Oil filter
Reverse clutch
Overflow
valve Oil radiator
Forward or
reverse clutch
Figure 5-7 Hydraulic circuit
5.8 Traction of the forklift to be repaired
After the hydraulic transmission forklift is damaged and needs to be pulled by other vehicles, please notice
that:
(1) Take down the half shaft from front wheel;
(2) The shift lever shall be in neutral position.
49
5.9 Measurement of oil port connector position, oil pressure and temperature (Figure 5-8)
Side pressure hole of

High temperature oil
hydraulic clutch
port to the oil radiator
Low temperature oil
port to the oil radiator
Hole of oil temperature gauge Back light switch

Oil drain plug Neutral position switch
Filter
Inching valve
Figure 5-8 Measurement of oil temperature and pressure
6. Drive axle
Type: Front-wheel drive, axle body fixed with the frame, and full-floating type
1〜1.8t 2t, 2.5t 3t-3.5t
Forklift tonnage
Single tire Single tire Double tire Single tire Double tire
Tire size 2X6.5-10-10PR 2X7.00-12-12PR 4X7.00-12-12PR 2X28X9-15-12PR 4X28X9-15-12PR
wheel size 5.00F-10DT 5.00S-12D 5.00S-12D 7.00WFB-15 7.00WFB-15
Tire pressure 0.7MPa
6.1 General
The drive axle consists of the axle housing, wheel hub, half shaft and brake, the axle housing is the whole
cast structure, the tire and wheel hub are fitted together through the rim with studs and nuts, the power is
transmitted to half shaft by the differential, the front wheel rotates driving by the wheel hub eventually, each
wheel hub is installed on the axle housing with two tapered roller bearings, so the half shaft only bears the
torque transmitted to the wheel hub, and the wheel hub is equipped with oil seal to prevent the water and dust
from entering or oil leakage.
50
① Axle housing
② Half shaft
③ Wheel side brake
④ Brake drum
⑤ Oil seal
⑥ Tapered roller
bearing
Tightening torque
Tightening torque
⑦ Hub
⑧ Conical roller
bearing
⑨ Oil seal
⑩ Tire
○ Rim
11
○ Adjusting nut
12
○ Lock nut
13
B view
grease of 50%
A is filled with
B view
Torque of bolt with *
Figure 6-1 Drive axle
51
6.2 Installation procedure of wheel hub
(1) Fill 100cc grease into the wheel hub and

install it on the axle.
(2) Tighten the adjusting nut using around 1kg.m

torque and turn it back 1/2 round.
(3) Hang the spring scale on the bolt to measure

the starting torque of the wheel hub, and after
it reaches the specified value, slowly tighten Adjusting nut
the nut. Locking plate
Starting torque:5-15kg.m Locknut
Figure 6-2 Filling grease

(4) Install the locking plate and lock nut, and
make the locking plate lock for fastening.
(5) Tire assembly
Install the air intake lever and cap on the tire,

assemble the rim, and please notice the
following situations:
Note:(a) the valve stem is in the opening in

the rim outward;
Starting torque
(b) The rim bolt shall be installed with the
head facing outward.
Figure 6-3 Measurement of staring torque
Rim bolt structure
1. Tire 4. Inner wheel

2. Valve stem 5. Outer wheel
3. Cap 6. Rim bolt
Figure 6-4 wheel assembly
52
7. Steering system
Model
1~1.8t 2t, 2.5t 3t
Item
Type: Rear-wheel power steering
Steering gear type Cycloidal hydraulic steering gear
Steering gear model BZZ1II-125
Type: Double-acting piston
Steering oil Bore mm ɸ70

cylinder Diameter of piston rod mm ɸ50
Stroke mm 160
Rated pressure Mpa 7 9
Orient diameter mm ɸ300
Tire size 5.00-8-8PR 6.00-9-10PR 6.50-10-10PR
Tire pressure 0.7Mpa
7.1 General
The steering system mainly consists of the steering wheel, steering axle and steering gear, and the steering
column can tilt forward and backward to the appropriate position. (Figure 7-1)
Figure 7-1 Steering control device
53
7.2 Cycloidal hydraulic steering gear
The full hydraulic steering gear (Figure 7-2) can metrically deliver the pressure oil from the diverter valve to
the steering cylinder by the pipeline according to the rotation angle of steering wheel. When the engine stalls
and the oil pump is unable to supply oil, carry out the manual steering.
Figure 7-2 Cycloidal hydraulic steering gear
1. Limited post 4. Universal drive shaft 7. Rotor

2. Valve body 5. Leaf spring 8. Stator
3. Valve element 6. Link block 9. Valve sleeve
54
7.3 Check after the steering system reassembly
(1) Turn the steering wheel to the left and right as far as possible to check whether it is uniformly applied
force and rotary balance;
(2) Check whether the oil piping layout is correct and the left and right steering pipes are installed
conversely;
(3) Jack up the rear-wheel and slowly turn the steering wheel to the left and right for several times to
exhaust the air in the hydraulic pipeline and oil cylinder.
7.4 Troubleshooting for steering system
Problems Analysis of causes Troubleshooting

Oil pump is damaged or fails Replace
The steering wheel does The diverter valve is blocked or damaged Clean or replace it
not work
Rubber hose or connector is damaged or the pipe
Replace or clean
is blocked
The pressure of diverter valve is too low Adjust the pressure
Air exists in the oil line Exhaust the air
Weight of steering The reset of steering gear doesn’t work and the
wheel locating leaf spring is broken or weak in Replace the leaf spring
elasticity
Excessive inner leakage of steering cylinder Check the piston sealing
The forklift snakes or The steering wheel moves too much Adjust the flow of the diverter valve
shakes The spring is broken or inelastic Replace
The working noise is oil level in oil tank is low Refuel

loud The suction pipe or oil filter is clogged Clean or replace it
The guide sleeve sealing of steering cylinder,
Oil leakage Replace
the pipeline or connector is damaged.
8. Steering axle
8.1 General
The steering axle is the welding structure with box section (Figure 8-1) and consists of the axle body,
steering cylinder, connecting rod, steering knuckle and steering wheel. The steering trapezium uses the slider
crank mechanism. The pressure oil pushes the steering knuckle to redirect by the piston linkage of the oil
cylinder to make the steering wheel deflect and realize the steering. The steering axle is connected to the rear
tailstock of the frame with the buffer seat.
55
Figure 8-1 Steering axle
1. Steering axle body 9. King pin of steering knuckle 17. Wheel hub nut
2. Connecting rod 10. Tire 18. Oil seal
3. Steering oil cylinder 11. Oil seal 19. O-ring
4. Rear axle support 12. Tapered roller bearing 20. Sleeve
5. Sleeve 13. Tapered roller bearing 21. Dust cover
6. Right steering knuckle assembly 14 Wheel hub cover 22. Left steering knuckle assembly
7. Thrust bearing 15 Hub
8. Needle bearing 16. Rim bolt
56
8.2 Steering knuckle and steering king pin
The steering knuckle is installed on two ends of the steering axle body up and down with the king pin, cone
bearing, dust cover and “O” ring; the upper and lower sides of king pin are fixed to the axle body with the
stop pin and the nut respectively; and the cone bearing pressed on the axle body is used to support the
steering knuckle.
Oil seal
Conical bearing
Steering
Thrust bearing
knuckle
Steering knuckle
Fixing pin
Sleeve
Steering king pin
Figure 8-2 Steering knuckle
8.3 Wheel
The wheel hub is installed on the steering knuckle axle with two cone roller bearings, the wheel and wheel
hub are fitted together through the rim, the oil seal is installed inside the bearing to make the grease stay in
the wheel hub and steering knuckle cavity, and the nut is used to adjust the bearing tightness.
8.4 Steering oil cylinder
The oil cylinder is the double-acting piston cylinder; the sealing of the piston uses the bearing ring and
O-ring combined sealing, the cylinder cover and piston rod are axially sealed with YX-ring; the oil cylinder
is fixed on the steering axle by cylinder covers on its both sides.
57
Figure 8-2 Steering cylinder
1. Piston rod assembly 2. Cylinder head 3. Dust ring 50X72 4. YX-ring 50X65X9
5. O-ring 65X3.55 6. O-ring 60X3.55 7. Support ring 8. Cylinder sleeve
8.5 Adjustment of the preload of steering wheel
bearing
(1) As shown in Figure 8-4, apply the grease

to the inner and outer bearings and wheel
hub cover chamber, as well as the oil seal
lip;
(2) Fix the bearing outer ring to the wheel

hub and install the wheel hub on the
steering knuckle axle;
Fill grease
(3) Install the flat washer and tighten the
slotted nut with the moment of force of
206-235N.m(21-24kgm), loosen the
slotted nut, and the re-tighten the slotted
nut with the moment of force of
9.8N.m(1kgm);
(4) Tap the wheel hub with the wood

hammer, and turn it 3 or 4 rounds to Figure 8-4 Preload adjustment
ensure that the rim is tightened up;
(5) Tighten the slotted nut to make the slot

align to the split pin hole in the steering
knuckle;
(6) Tap the wheel hub with the wood

hammer again, and turn it by hand 3 or 4
58
rounds to ensure that it rotates steadily,

and measure the moment of rotation of
the wheel hub, which is
2.94-7.8N.m(0.3-0.8kgm);
(7) When the moment of rotation is higher

than specified value, turn it back 1/6
round, and measure the moment of
rotation.
(8) When it reaches to the specified moment

of rotation, lock the slotted nut with the
split pin.
9. Brake system
Type: Double front wheels brake, internal expanding and hydraulic type
Lever ratio of the pedal 5.66
Master cylinder diameter 19.05mm
wheel cylinder brake 1〜1.8t 2t, 2.5t 3t-3.5t
Type: Double servo type with parking brake
Branch cylinder diameter 22.22mm 28.58mm
Size of friction plate (Length X
279X48.5X5mm 324X60X7mm 348X76X8mm
width X thickness)
Area of friction plate 135.3cm2X4 194.4cm2X4 264cm2X4
Inner diameter of brake drum 254mm 310mm 314mm
Parking brake Double front wheels brake, internal expanding and hydraulic type
59
9.1 General
Pedal
The brake system is double front wheels brake Sleeve
system and consists of the brake master cylinder, Spring
Oil reservoir
brake and brake pedal mechanism. Bush
9.1.1 Brake pedal
The brake pedal device is shown in Figure 9-1 and

installed on the transmission by the bracket. The
pedal movement pushes the push rod to make the
piston move to increase the oil pressure. Main pump
Axle
Figure 9-1 Brake pedal (mechanical type)
Axle Brake pedal

Inching pedal
Spring Spring
Bush
Bush
Main
pump
Bush
Bush
Front To wheel brake
Inching valve (Reel)
Figure 9-2 Brake pedal (hydraulic type)
9.1.2 Master cylinder
The master cylinder includes a valve seat, a check valve, a return valve and leather cup, piston and
auxiliary leather cup. Its ends are fixed with the lock washer and locking steel wire, the rubber dust cover is
used for protection outside, and the master cylinder acts by operating the brake pedal and push rod. When
stepping on the pedal, the push rod pushes the piston forward, the brake fluid in pump flows back to oil
storage tank through the return port until the primary cup blocks the return port, after that, the brake fluid in
the front chamber of master cylinder is compressed to open the one-way valve and flows into the wheel
cylinder through the brake pipeline, hence, the piston of each wheel cylinder reaches out to make the brake
60
shoe lining and brake drum contact in order to slow down and brake, and now the rear chamber of the piston
is filled with the brake fluid from return port and oil inlet. After the brake pedal is released, the piston is
pressed by the reset spring, and at the same time, the brake fluid in each brake slave cylinder is compressed
by the return valve of brake shoe, which brings the brake fluid back to the master cylinder through the
check valve (front cavity of piston) and resets the piston. The brake fluid in the master cylinder flows back to
the oil tank through the return opening. Check the valve pressure and adjust it to a proportion with the
residual pressure in the brake pipeline and sub-pump of brake, making the leather cup of slave cylinder
be correctly positioned to prevent the oil leakage, and eliminate the air resistance possibly occurred in case
of emergency brake.
① Connecting rod
From oil storage tank ② Push rod
③ Dust cover
④ Elastic check ring
⑤ Auxiliary leather cup
⑥ Piston
⑦ Primary cup
⑧ Spring
To wheel brake ⑨ Check valve
Figure 9-3 Brake master cylinder
9.1.3 Wheel brake
The wheel brake is internal expanding and hydraulic type and consists of the brake shoe, spring, wheel
cylinder, adjuster and base plate. Two brakes are respectively installed on two ends of the front axle. Both
ends of the brake shoe are respectively connected with the support pin and the clearance adjuster and pressed
toward the base plate with the spring and compressed spring lever; the leading shoe is equipped with the
hand brake lever and the auxiliary brake shoe is equipped with the automatic clearance adjuster lever. See
Figures 9-4,9-5.
61
① Spring
② Cup
③ Piston
④ Cylinder body
⑤ Piston ejector rob
⑥ Return spring
⑦ Ejector rob
⑧ Return spring
⑨ Adjustment lever
⑩ Auxiliary brake shoe
○ Clearance adjuster
11
○ Spring
12
○ Brake cable wire assembly

13
○ Compressed spring cup

14
○ Compressed spring pull rod

15
○ Hand brake lever

16

17
E-shaped retainer ring
○ Brake cylinder assembly
18
○ Return spring
19
○ Primary brake shoe

20
Figure 9-4 2t and 2.5t wheel brake
① Brake cylinder assembly

② Spring
③ Cup Bolt tightening torque
④ Piston
⑤ Branch cylinder cover
⑥ Piston ejector rob
⑦Brake shoe return spring
⑧ Spring
⑨ Hand brake lever
⑩ Spring wire device
○ Compressed spring lever
11
○ brake shoe
12
○ Compressed spring seat

13
○ Compressed spring lever

14
○ Compressed spring
15
○ Spring
16
○ Pawl
17
○ Spring
18
62
○ Clearance adjuster assembly

19
○ Pin
20
○ Base plate
21
○ Brake shoe return spring

22

23
○ Brake cable wire assembly

24
Figure 9-53t and 3.5t wheel brake
Figure 9-6 1-1.8t wheel brake (left)
① Ejector rob of wheel ⑧ Brake shoe return ○ Return spring

15 ○ Compressed spring
22
cylinder piston spring
seat
② Shield ⑨ Spring ○ Pawl
16
③ Piston ⑩ Hand brake lever ○ Hand brake lever
23
○ Spring
17
④ Spring ○ Spring wire device
11 ○ Primary brake shoe
24
63
⑤ Cup ○ Compressed spring

12 ○ Clearance adjuster
18 ○ Return spring
25
⑥ Wheel cylinder
pull rod
⑦ Auxiliary brake shoe ○ “E” retainer ring
19
13
○ Parking brake wire
20
seat
rope
○ Spring
14
21
lever
(1) Brake action
The action of the brake during the process of running forward is shown as follows (Figure 9-7). Operate
the wheel cylinder, primary brake shoe and auxiliary brake shoe respectively under the action of two
equal and opposite forces to make the friction plate and brake hub contact, and leading shoe press
toward the adjuster by means of the friction force between the friction plate and brake hub. Thus, the
clearance adjuster generates a force larger than that for operating the wheel cylinder to force the upper
end of the auxiliary brake shoe to press toward the support pin under the action of strong force, so that
the larger brake force is generated. In the other direction, the brake acts in the opposite direction during
the process of running backward, while the brake force is the same as that during the process of running
forward.
Support pin
Rotation
direction of
Working force
brake drum
Working force
Leading Auxiliary
shoe brake shoe Leading Auxiliary
shoe brake shoe
Adjuster
Figure 9-7 Brake forward action Figure 9-8 Brake backward action
(2) Parking brake
Parking brake is a mechanical and inner expansion type brake which is internally installed in wheel
brake. Parking brake shares brake shoe and brake hub with foot brake. When you pull parking brake
handle, the brake handle drives hand brake pull rod through brake cable, and the pull rod pushes the
hand brake push rod towards the right with the help of pin acting as spindle to enable brake shoe to
press down on the brake hub.
Auxiliary
brake shoe
64
Pin
Pull rod Jackstay
Leading
shoe
Figure 9-9 Parking brake device
(3) Clearance self-adjusting mechanism
Clearance self-adjusting mechanism enables a certain clearance between friction plate and brake drum.
See Figures 9-10 and 9-11 for the structure. Clearance self-adjusting mechanism only acts in case of
reverse driving. There are two different kinds of self-adjusting mechanisms due to different types of
vehicles.
Pull cable
Spring
Guide
plate
Spring
Pawl
Adjuster
Adjuster
Hand brake lever
Figure 9-102-2.5t forklift Figure 9-1110-1.8t.3t.3.5t forklift
65
▲ Clearance self-adjusting mechanism
(a) 2-2.5t clearance self-adjusting mechanism of

forklift
It only acts when the forklift travels in reverse

direction. Auxiliary brake shoe shall connect
with and rotate together with brake shoe.
Therefore, pull rod shall rotate around point A
towards the right, as shown in Figure 9-10, and
point B is lifted. After brake is released, pull
rod rotates towards the left under the spring
force and point B descends.
When the clearance between friction plate and

brake drum is increased, vertical rotating
distance of point B pawl is increased, and
when the clearance is over 0.4mm, adjuster
moves for one toothed gear, adjustment lever
elongated and thus the clearance is shortened.
Adjustment range of gap: Within 0.4-0.45mm

Elongation along this direction
(b) 1-1.8t.3t clearance self-adjusting mechanism
of forklift, when forklift applies the brake in
reverse direction, auxiliary brake shoe shall Figure 9-12 Clearance self-adjusting mechanism
connect with and rotate together with brake （2-2.5t）
drum. Therefore, pull rod rotates around point
A towards the right and point B pawl
accordingly moves for one toothed gear of the
adjuster.
66
After brake is released, brake shoe returns

back to its original position, pull rod rotates
around point A towards the left and point B
descends. Thus, when clearance becomes
larger, adjuster will move for another toothed
gear.
Adjustment range: Within 0.25-0.4mm
9.1.4 Parking brake handle
Parking brake handle is kind of cam-style and

adjuster at the end of brake handle can be used to
adjust braking force.
Adjustment of braking force:
Clockwise rotate the adjuster to increase the

braking force; anti-clockwise rotate the adjuster to
reduce the braking force.
Traction: 20-30kg
Note:2-2.5t forklift, rotate bolt inside the adjuster

for adjustment.
Elongation along this

direction
Figure 9-12 Clearance self-adjusting mechanism

(2-2.5t)
9.1.5 Adjustment of brake pedal
(1) Shorten the push rod;
(2) Adjust the lock bolt like the pedal height as

adjusted in Figure4 -15;
(3) Slam on the brake pedal to elongate the push Left-side cable
rod until the front end of push rod is connected
Left-side cable
with piston of master brake cylinder;
(4) Tighten the lock nut of push rod.
Figure 9-12 Clearance self-adjusting mechanism

(2-2.5t)
67
Unit: mm
Type: Free travel

Height
Engine Tonnage Brake Micro-motion
CL 105 30 *
K21 1〜1.8t
TC 100 50 0
Height CL 118 10 *
K25 2〜3t
TC 121 30 0
2〜3t CL 120 10 *
K25
Pressurized TC 124 30 0
CL 118 10 *
NB485 1〜1.8t
TC 121 30 0
1〜1.8t CL 105 30 *
C240
CL 110 10 *
2〜3t
TC 116 30 0
2〜3t CL 116 10 *
4TNE98
CL: Mechanical forklift TC: Hydraulic forklift
Figure 9-15 Pedal height adjustment
▲ Adjustment of brake switch
(a) After the height of brake pedal has been

well adjusted, loosen the lock nut of brake
switch;
(b) Unplug the plug to disconnect the lead; Brake switch

(c) Brake switch, enable clearance A=1mm;
(d) Confirm that the brake light is On when

the brake pedal is depressed. Locknut
9.2 Maintenance
The chapter includes brake disassembly,

re-installation and adjustment as well as adjustment
for brake pedal, which is applicable to 1-1.8t.3t.3.5t
forklift brakes. Although 2-2.5 brakes differ in
structure of adjuster, their maintenance methods are
same.
9.2.1 Wheel edge brake disassembly
(1) Disassemble fixing pin, adjusting rod, adjuster Figure 9-16

and spring;
68
(2) Disassemble shoe return spring;
Figure 9-17
(3) Disassemble return spring of the brake shoe
Figure 9-18
(4) Disassemble primary shoe, auxiliary shoe and

spring of adjuster;
Figure 9-19
(5) Disassemble brake pipe and then mounting

bolt from wheel cylinder to separate wheel
cylinder and base plate;
Figure 9-20
69
(6) Disassemble the E-type check ring which

fixes brake cable with base plate,
disassemble mounting bolt from base plate
and then disassemble base plate from the
axle;
Figure 9-21
(7) Disassemble dust cover of wheel cylinder

and push all components out of the cylinder.
Figure 9-22
9.2.2 Check wheel brake
Check whether all components are worn or

damaged, and in case they are unqualified,
repairing and replacement are required.
(1) Check internal surface of wheel cylinder and

surface of cylindrical piston are rusted and
then measure clearance between piston and
cylinder body;
Specified value:.0.03-0.10mm
Limit value:0.15mm
Figure 9-23
(2) Visually inspect whether leather cup of
wheel cylinder is damaged or deformed and
unqualified one shall be replaced.
(3) Check spring of wheel cylinder for its free

length and unqualified one shall be replaced.
(4) Check the friction plate for its thickness and

the excessively worn one shall be replaced.
70
Unit: mm
1-1.8t 2-2.5t 3t
Standard
4.87 7.2 8
dimension
Limit 5.0 6
Figure 9-24
(5) Check brake drum for its internal surface

and the damaged or excessively worn one shall
be repaired or replaced.
Unit: mm
1-1.8t 2-2.5t 3t
Standard
254 310 314
dimension
Limit 256 312 316
Figure 9-25
9.2.3 Reassembly of wheel brake
(1) Leather cup of wheel cylinder and

piston shall be immersed in brake fluid
and spring, leather cup, piston and
shield shall be in assembled in proper
order.
(2) Wheel cylinder shall be installed on

base plate with tightening torque.
1~1.8t: 8〜12N.m
2〜2.5t:14.7〜19.6N.m
3t〜3.5t:17.6〜26.5N.m
(3) Base plate shall be installed on front

axle with tightening torque
20.6-22.5N.m
(4) Add lubricating oil as per the Figure 9-26

lubricating point as shown in Figure
71
9-26
(a) Supporting surface of base plate
(b) Fulcrum post
(c) Contact surface of shoe plate and

compressed spring plate
(d) Support pin of hand brake pull rod
(e) Adjuster thread and other

rotational components
Figure 9-27
(5) Brake cable assembly shall be installed
on base plate by using E-type check
ring
(6) Brake shoe shall be installed on base

plate by using fixed spring g.
(7) Compressed spring shall be installed

on hand brake push rod and push rod
shall then be installed on brake shoe..
(8) Brake shoe’s guide plate shall be

installed on support pin and then return
spring shall be installed. First install
main brake shoe before installation of
auxiliary brake shoe.
Figure 9-28
(9) Install adjuster, adjuster’s spring,

ejector rod and return spring of ejector
rod.
The following points shall be paid

attention to:
(a) Adjuster’s screw thread direction

and installation direction;
(b) Direction of adjuster’s spring

(Adjuster’s tooth is not allowed to
connect with spring); Figure 9-29
(c) Direction of return spring of

ejector rod (At the end of support
pin, spring hook shall be fixed on
opposite side of the ejector rod);
72
(d) When adjusting the lower end of

lever, it must connect with tooth
of adjuster.
(10) Brake pipe shall be connected with

wheel cylinder.
(11) Measure internal diameter, external

diameter of brake drum, adjust the
adjuster so that the difference between Figure 9-30
internal diameter of brake drum and
external diameter of friction plate of
brake shoe is 1mm.
9.2.4 Operational test for automatic clearanceadjuster
(1) Firstly, diameter of brake shoe shall be close to the installation dimension as specified, pull the
adjustment lever with hand to rotate the adjuster, when you loosen your hand, adjustment lever returns
to its original position and adjuster’s gear remains unchanged.
Notice: Even if you loosen your hand, adjuster’s gear can return together with adjustment lever and
adjuster can still be back to its normal work after being loaded.
(2) If you pull adjustment lever, adjuster cannot perform the above mentioned actions, the following items
shall be checked.
(a) Firmly install the adjustment lever, ejector rod, spring of ejector rod and compressed spring plate;
(b) Check whether return spring of ejector rod and spring of adjuster are damaged, check whether gear
of the adjuster is rotated properly and check whether meshing part is excessively worn or damaged.
Check whether lever and gear are connected. Replace damaged parts.
73
Expansion direction
Figure 9-31
9.2.5 Trouble shooting

1. The brake system has oil leakage Repair
2 Clearance of brake shoe is not properly adjusted Adjust adjuster
3. Over-heated brake Check for slide
Poor braking 4 Brake drum and friction plate are not properly connected Readjust
5 Impurities are attached to the friction plate. Repair or replace
6 Impurities are mixed in brake fluid. Checking the brake fluid
7 Brake pedal (inching valve) is improperly adjusted Adjust
1 Surface of friction plate is hardened or attached with impurities Repair or replace
2. The baseboard is deflected or the bolt is loose Repair or replace
The brake is
3. The brake shoe is deflected or incorrectly mounted Repair or replace
noisy
4 The friction plate is worn Replace
5. The wheel bearing is loose Repair
1 Surface of friction plate is contaminated with oil Repair or replace
Brake is not 2 Clearance of brake shoe is not properly adjusted Adjust adjuster
uneven 3 Failure of wheel cylinder Repair or replace
4 brake shoe return spring is damaged Replace
74

5 Deflection of brake drum Repair or replace
Brake fails 1. The brake system has oil leakage Repair or replace
2 Clearance of brake shoe is not properly adjusted Adjust adjuster
3 Air is mixed in the brake system Blow off the air
4 Adjustment of brake pedal is wrong readjustments
10. Hydraulic system

1〜1.8t 1〜1.8t 3t
Forklift type 2〜2.5t 2〜2.5t 3t
Gasoline Diesel Gasoline
Item Gasoline engine Diesel engine Diesel engine
engine engine engine
Engine model K21 NB485 K25 4JG2 C240PKJ K25 4TNE98 C240PKJ
Type Gear pump
CBT-
Main CBD-F32 CBD-F32
Model CBHZ-F23-ALO F428.2 CBD-F32LS CBT-F32LS-BB
pump LSL-BB LSL-BB
-AL
Displacement 23ml/r 28.2ml/r 31.5ml/r
Type Parallel slide valve, with relief valve, by-pass valve and self-locking tilt valve
Adjusting
Multi-way 17.5MPa
pressure
valve
Bypass pressure 7MPa 9MPa
Bypass flow 11L/min 13L/min
Type Single action piston with stop valve
Hoisting Cylinder
45 50 56
cylinder diameter
Stroke 1495mm (lifted for 3m)
Type Double-acting piston
Tilting Cylinder
70
cylinder diameter
Stroke 167mm
Fuel tank capacity 18L 32L
75
10.1 General
Hydraulic system is composed of main oil pump, multi-way valve, hoisting cylinder, tilting cylinder and
pipelines. Oil supply tank is on the right side of vehicle body.
10.2 Main pump
Main pump is a kind of gear pump which is directly driven by power takeoff unit of engine and oil in the oil
tank is piped to multi-way valve through main pump.
Main pump is composed of pump body, a pair of gears, liner plate and check ring. Pressure balanced bearing
and special lubricating method can be applied to minimize the gear backlash. Pressure balanced method is
used to make liner plate press down on side surface of gear due to oil extraction between liner plate and
pump body.
① Pump body
② Drive gear
③ Driven gear
④ Front housing
⑤ Rear end cover
⑥ Lining board
⑦ Seal ring
⑧ Check ring
⑨ Oil seal
⑩ Circlip
B-B direction A-A direction
Figure 10-1 Main pump
76
10.3 Multi-way valve and bypass valve
Two-chip multi-way valve is composed of 4 valves, 2 slide valves, 1 safety relief valve and 1 bypass valve. 4
valves are combined together by using 3 studs and nuts. Tilt slide valve is equipped with tilt self-locking
valve.
Main overflow valve

Lifting valve rod
Tilting valve rod
Oil return tank
Figure 10-2 Multi-way valve
77
10.3.1 Operation of slide valve (take tilt slide valve

for instance)
(1) Neutral position (Figure 10-3)
At this time, high pressure oil discharged One-way fuel charging valve
Cylinder
from oil pump shall return to oil tank by Main oil inlet
interface B Cylinder interface A
passing neutral position.
Return spring
Slide valve
Middle passage Low-pressure passage
Figure 10-3
(2) Push in the slide valve (Figure 10-4）
At this time, middle passage shall be

closed and oil from the oil inlet opens the
one-way valve to flow towards oil
cylinder interface B, and oil from
cylinder interface B shall flow into oil
tank via the low pressure passage and the
slide valve can return back to the neutral
position depending on return spring.
Figure 10-4
(3) Push in the slide valve (Figure 10-5)
At this time, middle passage shall be

closed and oil from the oil inlet opens the
one-way valve to flow towards oil
cylinder interface B, and oil from
cylinder interface B shall flow into oil
tank via the low pressure passage and the
slide valve can return back to the neutral
position depending on return spring.
Figure 10-5
10.3.2 Main safety relief valve and safety bypass valve (Figure 10-6)
Main safety relief valve is composed of main valve A and pilot valve B. When multi-way valve begins to
reverse, cavity Q is connected with high pressure oil in operating mechanism (such as hoisting cylinder and
tilting cylinder), pressure oil flows through fixed orifices D and E and has an effect on pilot valve B. When
system pressure is larger than the set pressure of the system, pilot valve B opens to reduce the pressure inside
the cavity F. Whole main valve core A moves towards the right to enable pressure oil directly flow into low
78
pressure passage G and the cavity Q is loaded to ensure stabilization of system pressure. Bolt H can be
adjusted for the purpose of adjusting stable pressure value of the system
The diverter safety valve has simple structure， which is direct-acting overflow type. It obtains the stable
pressure value of the steering system by means of the principle of direct balance between fluid pressure and
spring force. When operating the steering wheel, the oil chamber M is connected with the high-pressure oil
way and the system pressure exceeds the spring pressure, the valve element N will move rightwards, the
pressure oil will be connected to the low-pressure oil way via chamber T to unload chamber M so as to
ensure the stability of steering system pressure and adjustment of screw K may be used to adjust the stable
pressure value of the system.
Valve L is a balance valve. It changes the opening of R and S by shuffling the slide valve L via constant
change of flow and pressure so as to ensure the automatic balance of flow to the working chamber Q and
from outlet PS to the hydraulic steering gear as well as stable diverting in proportion: a refers to a fixed
orifice.
Connected to the
steering gear Oil inlet
Figure 10-6
79
10.3.3 Motions of the tilt self-locking valve Tilting cylinder

The tilt slide valve is equipped with a
self-locking valve mainly used to prevent
possible vibrations caused by internal negative
pressure of tilting cylinder and prevent from
severe consequences caused by malfunctions.
For general traditional structure, it is operable
to bend the slide valve forwards after stalling of
engine, but by using this kind of tilt
self-locking valve, the mast will not be bent
forwards even the control lever is pushed after Valve
stalling of engine, see Figure 10-7 for its Spring element Slide valve
structure.
Figure 10-7
The ports “A” and “B” of valve body are connected to the front and back chambers of the tilting cylinder’s
piston respectively. When the slide valve is pulled out, the high-pressure oil (P) will be connected to the port
“A” and the oil in the back chamber will return to the oil tank (T) via “B”, at this point, the mast is in a
backward bending state.
When pushing the tilt slide valve, the high-pressure oil will enter port “B”, to make a self-locking motion of
the slide valve by means of the high-pressure oil, “A” is connected to low-pressure, at the time of stalling or
stop of engine, since there is no high-pressure oil to make the self-locking motion of the slide valve, the port
“A” cannot be connected to low-pressure, the mast will not be bent forwards and no negative pressure will be
formed in the tilting cylinder.
10.4 Hydraulic system oil way (Main oil way) (Figure 10-8）
The high-pressure oil from the main oil pump reaches the multi-way valve and is divided into two sections
by the multi-way valve and through the diverter valve: One section is that the high-pressure oil is diverted to
the hoisting cylinder or tilting cylinder and the other section is that the high-pressure oil is diverted to the
steering gear at a constant flow to control the steering oil cylinder. When the hoisting and tilt slide valves are
in the neutral position, the high-pressure oil will return to the oil tank via the access. When the hoisting slide
valve is pulled, the high-pressure oil passes the throttling valve and then the lower part of hoisting piston will
push upwards the piston rod. When pushing the hoisting slide valve, the lower part of the hoisting cylinder
piston will be connected to the low-pressure and the piston rod is declined by dead load and cargo load, at
this point, the oil from the hoisting cylinder will control the declining speed via the throttling valve. When
operating the tilt slide valve, the high-pressure oil can flow into the front chamber of tilting cylinder and the
other end will be connected to the low-pressure so that the mast can complete forward and backward bending
motions.
80
Figure 10-8 Hydraulic system oil way
81
10.5 Operation of the multi-way valve
The multi-way valve is controlled by control levers. All control levers are installed on a connecting shaft
which is fixed to the instrument panel by a holder. The control lever controls the slide valve via connecting
rods.
Tilt control lever Attachment control lever

Hoisting control level
Multi-way
valve
Figure 10-9 Multi-way valve control
10.6 Hoisting oil cylinder
The hoisting oil cylinder is sing-action piston type and is composed of cylinder body, piston rod, piston and
cylinder head, etc. The bottom of hoisting oil cylinder is fixed to the support of hoisting oil cylinder of outer
mast with pins and bolts while the top of oil cylinder (e.g., the top of piston rod) is connected to the upper
beam of outer mast.
The piston is fixed to piston rod with flexible steel wires and oil seal and support ring are installed around the
piston.
The bottom of the cylinder is equipped with one stop valve which can provide protection in case the
high-pressure pipe is broken suddenly when the mast is raised.
Steel-backed bearing and oil seal are fitted to the cylinder hear to support the piston and prevent introduction
of dust.
82
① Top rail
② Adjustable pad
③ Dust ring
④ Oil seal
⑤ Guide sleeve
⑥ O-ring
⑦ Cylinder head
⑧ Steel-backed bearing
⑨ Cylinder body
⑩ Piston rod
○ Piston
11
○ Cylinder body
12
○ Oil seal
13
○ Race
14
○ Elastic baffle ring

15
○ Stop valve
16
○ Spring retainer
17
○ Split pin
18
○ Lock nut
19
○ Adjusting nut
20
○ End joint
21
○ Chain
22
○ Chain wheel
23
Figure 10-10 Hoisting oil cylinder
83
There is a stop valve at the bottom of hoisting cylinder (see Figure 10-11) which can prevent sharp decline of
cargoes in case the high-pressure rubber hose is broken suddenly. The oil from the hoisting cylinder passes
the slide valve of stop valve, the oil holes around the slide valve will create a pressure difference between the
two chambers, when this pressure difference is less than the spring force, the slide valve will not make any
motion; if the high-pressure rubber hose is broken to create a large pressure difference and cause the slide
valve’s motion to blocking the surrounding oil holes that only a few oil can pass the small holes at the end of
slide valve so as to make the cargo fork decline slowly.
Under normal Upon stop

circumstances
Figure 10-11
10.7 Speed limit valve
The speed limit valve (e.g. throttling valve) is fitted in the oil-way of hoisting oil cylinder so as to limit the
declining rate of cargo fork in case of heavy load. See Figure 10-12 for basic structure. When the slide valve
of multiway valve is placed at the position "Lifting", the high pressure oil from the multiway valve passes
through A, B, the holes C, D, E, F and the cavity G, and flows into the hoisting cylinder without subject of
throttle. When the multiway valve is at the position "Lowering", the oil from the hoisting cylinder will flow
the whole valve through the cavity G, the holes F, E, D, C and B, A. Now the pressure difference will
produce between the cavities A and B and draw up the ball valve. When the difference of pressure is more
than the elastic force of spring, the valve element will move to the right resulting in the reduction of oil mass
with the decrease of the holes D and C, as well as the flow through the throttle hole.
84
Normal flow
direction
Constant flow
direction
Hoisting cylinder Multiway valve side

side
1. Connector 3. O ring 5. Throttling plate 7. Valve element 9. Spring

2. Spring 4.Check ring 6. Valve sleeve 8. Nylon ball 10. Valve body
Figure 10-12 Speed limit valve
10.8 Tilting oil cylinder (Figure 10-13)
The tilting oil cylinder is double-acting type and is fitted to both sides of the mast. Its piston rod end is
connected to the mast and the cylinder bottom is connected to the frame.
The tilting oil cylinder assembly is mainly composed of piston, piston rod, cylinder body, cylinder bottom,
guide sleeve and sealing part. The piston and piston rod adopt welding structure that a support ring and two
Yx seal rings are fitted at the outer edge of piton; the press-fit with shaft sleeve as well as Yx seal ring, seal
ring, baffle ring and dust ring are fitted at the inner hole of guide sleeve; this shaft sleeve supports the piston
rod; the seal ring, baffle ring and dust ring can prevent oil leakage and dust and are screwed to the cylinder
body along with the O-ring.
1. Lug 5. O-ring 9. Piston rod 13. Piston

2. Dust ring 6. Guide sleeve 10. Cylinder block 14.Yx seal ring
3. Baffle ring 7. Bushing 11. Yx seal ring
4. Yx seal ring 8. O-ring 12. Support ring
Figure 10-13 Tilting oil cylinder
85
When the tilt slide valve is pushed forwards, the high-pressure oil will enter via the cylinder bottom to push
the piston to make forward bend 6 of the mast; when the slide valve is pushed backwards, the high-pressure
oil will enter via the front of the cylinder to push the piston backwards until backward bend 12 of the mast.
10.9 Hydraulic oil tank
As a component of the frame, the hydraulic oil tank is at the right tank body, and there are no absorbed oil
and return oil filtering to screen foreign matters in the oil tank.
Vent plug
Hydraulic oil dipstick
Oil return of the

multi-way valve
To the main
pump
Oil return of the

steering gear
Return oil filter Oil absorbing Drain plug

filter
Figure 10-14 Hydraulic oil tank
86
Tilting oil cylinder (right)
Oil tank
Multi-way
87
valve
To hoisting oil
Tilting oil
cylinder
cylinder (left)
Figure 10-15 Hydraulic pipeline (1-1.8t)

Main pump
Steering gear
For K21 and
NB485BPG Engine
Steering cylinder
Tilting oil cylinder (right)
Oil tank
Multi-way valve
Oil pressure testing
88
screw plug
Tilting oil cylinder
To lifting oil cylinder
(left)
Main pump
Figure 10-16 Hydraulic pipeline(2-3t)

Steering gear
For H20, H25
and 4JG2
Steering cylinder engine For C240 engine
10.10 Maintenance of the main oil pump
(1) Disassembly
Before disassembly, rinse thoroughly. Place the removed parts on clean paper or cloth. Be careful, do
not contaminate or operate the parts.
(a) Clamp the flange part of the pump on the vice bench.
(b) Remove the connecting bolt (11), pump cover ⑤ and pump tank ①.
(c) Remove the lining board ⑥, driving wheel ② and driven gear ③.
(d) Remove the seal ring ⑦ and the baffle ring ⑧ from the front and rear end cap
Notice: If there is no need to replace the seal ring, do not remove it from the front end cap.
(2) Checking
Check the disassembled parts and rinse them by gasoline (except for rubber parts)
(a) Pump body checking
If the length of the pump body inner

chamber contacting with the gear is
larger than 1/2 of the perimeter, replace
the pump body.
Figure 10-17
(b) Lining board checking Lining board

Oil inlet
Check the contact surface of the lining
board If the lining board surface is
damaged or the thickness of it is less
than the specified value, replace the
lining board.
Specified value of lining board

thickness: 4.94mm
Oil outlet
Figure 10-18
89
(c) Front and rear pump cover
If the color change (brown) of the inner

surface lining exceeds 150, replace it.
(d) Check the drive gear and the driven gear

in front and at back. If it is worn
seriously, replace a pair. If the size is
less than the specified value, replace
them in pairs.
D=20.961mm
Figure 10-19
(D) Replace the seal ring, lining sealing

elements, baffle ring, oil seal and spring
baffle ring as required.
Figure 10-21
(3) Assembly Root

Baffle ring
Sealing ring
(a) Install a new seal ring and a new baffle Bush
ring on the front end cap of the pump. Bottom surface of
the pump body inner
chamber
Figure 10-21 Bush sealing elements
(b) Install the lining board in the groove on

Oil suction side Trench
the front end cap. Be careful not to
confuse the oil suction and the oil drain.
(c) Install the drive gear and driven gear on

the front end cap.
(d) Install the lining board on the gear side,

Oil drain side
align the groove with the gear point. Be
careful not to confuse the oil suction
Figure 10-22 Lining board
side and the oil drain side.
(e) Install a new seal ring and a new baffle ring on the rear end cap of the trench. (See Figure 10-21)
(f) Install the rear cover on the pump body, be careful not to confuse the oil suction and the oil drain.
90
(g) After all of them are installed, tighten the connecting bolt to the required torque of 9-10kg.m.
① Pump body ⑦ Seal ring

② Drive gear ⑧ Check ring
③ Driven gear ⑨ Oil seal
④ Front housing ⑩ Circlip
⑤ Rear end cover ○ Bolt
11
⑥ Lining board
○ Washer
12
Figure 10-23 Gear pump
91
10.11 Commissioning
The commissioning make the oil pump run in; check whether the running is normal. It is the best choice to
carry out oil pump test on the test stand. The test can also be conducted on the forklift according to the
following steps:
(If the oil pump is disassembled and repaired because it is worn seriously or stuck due to the hydraulic oil,
the hydraulic oil and the filter shall be replaced during commissioning on the forklift)
(a) Load the pump on the forklift and install the pressure gauge at the pressure testing port on the multi-way
valve.
(b) Loosen the overflow valve adjusting screw and make the pump run at the speed of 500-1000rpm for
about 10 min. Make sure the oil pressure is lower than 10kg/cm
(c) Maintain the pump rotate speed of 1500-2000rpm and increase the pressure by 20 - 30kg/cm2 each time,
running for 5 min, until it reaches up to 175kg/cm, and then make the oil-ways work for 5 min before
replacing the return oil filter.
When increasing the oil pressure, pay attention to testing the oil temperature, the surface temperature of
the pump and the running sound. If the oil temperature and the surface temperature of the pump rise
excessively, reduce the load to lower the oil temperature and then continue the test.
(e) After the test, make the overflow pressure be 175kg/ cm2 and then measure the flow. The oil volume
may be measured through the lifting speed.
10.12 Troubleshooting guideline
If there is a fault in the hydraulic system, the causes should be identified according to the following table and
repair as necessary.
(1) Multiway valve
Fault Causes Repair method

Slide valve blockage Rinse and change oil after
disassembly
The pressure of the steering oil-way Sliding surface damage Replace the slide valve
cannot be increased to the required
Broken spring Replace the spring
oil volume.
Oil hole is clogged Clean after disassembly
Improperly adjusted overflow valve Adjust the overflow valve
The pressure of lifting oil line cannot The slide valve is stuck Clean after disassembly
increase Oil hole is clogged Clean after disassembly
The slide valve is stuck Clean after disassembly
The shock pressure increases slowly
Insufficient exhaust Adequately exhaust
The pressure of steering oil line is The slide valve is stuck Clean after disassembly
more than the specified value Oil hole is clogged Clean after disassembly
92

Failed to reach the specified oil Improperly adjusted overflow valve Adjust
amount
Improperly adjusted overflow valve Adjust
Noise
The sliding face is worn Replace the relief valve
Oil leakage (external) Aging or damaging of O-ring Replace the O-ring
Spring ring Replace the spring
Low setting pressure
Broken valve seat face Adjust or replace the relief valve
Oil leakage (internal) The surface of valve seat is damaged Amend the surface of valve seat
High setting pressure The valve is stuck Clean after disassembly
(2) Main pump

Low level in the oil tank Add oil to the specified value
Few oil discharge
Oil pipe or filter is clogged Clean or replace as needed
The lining board is damaged
The support is damaged
Replace
The seal ring, bushing seals or check ring are
in poor condition.
A pressure gauge should be used to
The pump pressure is low The relief valve is improperly adjusted adjust the relief valve pressure to the
specified value
• Re-tighten the oil pipe on the oil
suction side
There is air in the system
• Refuel
• Change oil seal of oil pump
The oil suction pipe is damage or oil filter is Check the pipes or maintain the oil
clogged filter.
The oil suction side is loose and leaks Fasten the loose part
Noise when running Replace with the oil whose viscosity

The oil viscosity is too high is compatible with the running
temperature of pump.
Find out the reasons for the bubbles
There are bubbles in oil
and take measures
The oil seal or seal ring of pump is damaged Replace
The pump has oil leakage
The pump is damaged Replace
93
11. Lifting system
1-1.8 Buried type Roller type, J-shaped inner mast, C-shaped

outer mast with a free-lifting and secondary
retractable mast
Inner mast section
Outer mast section
Roller:
Roller ɸ112.3mm
Limit roller ɸ80mm
Side roller ɸ91.5mm
Side roller ɸ40mm
Hoisting:
Lifting chain LH1223
Pallet fork and mast hoisting device hydraulic type
Mast tilting device hydraulic type
Pallet fork space adjusting device manual type
94
2-3.5t Type Roller type, J-shaped inner mast, C-shaped outer mast
with a free-lifting and secondary retractable mast
Inner mast section
Outer mast section

Taper
Roller:
Main roller 1 ɸ 120.5
Optional roller 1 ɸ 119.5
Optional roller 2 ɸ 118.5
Lifting (ISO) Lh1623 (2〜3t)
Lh1634 (3.5t)
Taper
Pallet fork and mast hoisting system hydraulic type
Pallet fork space adjusting device manual type
95
11.1 General
The hoisting system is a secondary roller type and vertically retractable system, which is composed by inner
and outer mast and fork arm carrier.
11.2 Inner and outer mast
The inner and outer masts are welding parts. The bearing used at the bottom of the outer mast is installed on
the drive axle.
The middle part of the outer mast is connected to the frame through the tilting cylinder and it can be tilted
back and forth under the action of tilting cylinder.
11.3 Fork arm carrier
The pallet fork bracket is rolling inside the inner mast through the main roller. The main roller is fitted on the
main roller shaft and clamped with the circlip. The main roller shaft is welded on the pallet fork bracket. The
side roller is fixed by the bolt on the pallet fork bracket. Rolling along the flange of the inner mast, which can
be adjusted with an adjustable pad.
11.4 Roller position
The rollers are installed on the outer mast, inner mast and the fork arm carrier, respectively.
Outer mast Inner mast Roller Carriage Sliding plate
Notice:(a) Adjust the side roller clearance to be 0.5MM;
(b) Add grease on the surface of main roller and contact area of mast
Figure 11-1 Roller location
96
Beam on the inner mast Adjusting pad

11.5 Repair
11.5.1 Hoisting cylinder adjustment
When disassembling and replacing the hoisting

cylinder, inner mast or outer mast, it is required
to readjust the stroke of the hoisting cylinder.
The adjusting methods are as follows:
(1) Install the piston rod head (without an

adjustable pad) in the beam on the inner
mast.
Hoisting cylinder
Figure 11-2
(2) Lift the mast slowly until the maximum

stretching stroke of the oil cylinder is
reached, and then check whether the two
oil cylinders are synchronous.
(3) Stop to add an adjustable pad between the

piston rod head of the oil cylinder and the
beam on the inner mast before motion.
The thickness of the adjustable pad is
0.2mm and 0.5mm.
(4) Adjust the degree of tension of the chain
11.5.2 Adjust the height of fork arm carrier

Tire
(1) Stop the forklift on the level ground and
make the mast be vertical.
Inner mast
(2) Make the pallet fork bottom surface touch Pallet fork bracket
the ground, adjust the adjusting nut at the Main roller
upper end joint of the chain to form a
distance A between the main roller and the Pallet fork
fork arm carrier.
Types of forklift Amm

1〜1.8t 36-41 Figure 11-3
1~2.5t 24-29
3t~3.5t 19-24
97
(3) Lower the pallet fork on the ground and tilt it

backward; adjust the upper end joint of the Chain
chain and the nut to make the degree of
tension of the two chains identical.
11.5.3 Replace the fork arm carrier roller

End joint
(1) Place a tray on the pallet fork and stop the
forklift on the level ground.
(2) Lower the pallet fork and the tray on the

Adjusting nut
ground.
Disassemble the upper end joint of the chain

Locknut
and remove the chain from the chain wheel.
(4) Hoist the inner mast (① in Figure 11-5) Figure 11-4
(5) Drive the forklift backward after confirming

the fork arm carrier has been removed from
the outer mast. (② in Figure 11-5)
(6) Replace the main roller
Remove all the spring baffle rings and

remove the main roller by drawing tools, be
careful to maintain the adjustable pad.
② Make sure that the new roller is the same

as the replaced one. Install the new roller in
the fork arm carrier and fixed with the elastic
baffle ring.
11.5.4 Replace the mast roller
Use the same methods specified in 11.5.3 Figure 11-5

“Replace the fork arm carrier roller” to remove the
fork arm carrier from the inner mast.
Drive the forklift to a level ground and underlay

the front wheels by 250-300mm.
Pull up hand brake and chock the rear wheels.
(4) Remove the hoisting cylinder and the inner

mast fixed bolts. Lift the inner mast, be
careful not to lose the adjustable pad at the
piston rod head.
(5) Remove the connecting bolts at the bottom of

the hoisting cylinder and outer mast. Remove
the hoisting cylinder and oil pipe between the
two cylinders. Don't loosen the oil pipe joint. Figure 11-6
(6) Lower the inner mast and remove the main

roller at the bottom of the inner mast. The
98
main roller at the top of the outer mast may

be exposed at the top of the inner mast.
(7) Replace the main roller.
Remove the upper main roller by drawing

tools, not losing the adjustable pad.
(b) Install the new roller together with the

adjustable pad which is removed in step
(a).
(8) Lift the inner mast until all rollers enter into
the mast.
(9) Reassemble the hoisting cylinder and the fork

arm carrier according to the reverse
disassembling steps.
99
Note
100
E王系列3.0t-3.8t内燃平衡重式叉车零件目录手册
本零件目录汇集了E王系列3.0 t -3.8t内燃平衡重式叉车的零部件
叉车型号说明：
F D 30 —X6
发动机代码
3吨
D:柴油 G :汽油
平衡重式叉车
Forklift truck type description:
F D 30 —X6
Engine Code
3 toncapacity
D:Diesel G:Gasoline
Forklift truck
1
本零件目录汇集了E王系列3.0 t -3.8t内燃平衡重式叉车的零部件
具体车型与发动机的对应关系：
FD30—W2配五十铃C240PKJ-30发动机 FD35,38—Dc1配大柴CA498-97发动机
FD30,35—W3配五十铃4JG2PE-01发动机 FD30,35—Qc2配全柴QCA490G发动机
FD30,35-N2配江铃 JX493G发动机
FD35—Qc1配全柴QCA495G发动机
FD30,35— Ym2配洋马 4TNE98发动机
FG30,35-K2配尼桑K25发动机
The following trucks are provided with corresponding engine
FD30—W2 /C240PKJ-30 engine FD35,38—Dc1/CA498-97 engine

FD30,35—W3 /4JG2PE-01 engine FD30,35—Qc2/QCA490G engine
FD35 —Qc1/QCA495G engine FD30.35—N2/JX493G engine
FD30,35—YM2/4TNE98 engine
FG30,35-K2/K25 engine
2
E王系列3.0t-3.8t内燃平衡重式叉车零件手册目录
1、发动机(柴油机) / E N G I E N ( D I E S E L ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
2、发动机(汽油机)/ENGIEN(GASOLINE)---------------------------------------------2
3、发动机(柴油机)/ENGIEN(DIESEL)-----------------------------------------------3
4、发动机(汽油机)/ENGIEN(GASOLINE)---------------------------------------------4
5、排气系统/EXHAUST SYSTEM-----------------------------------------------------5
6、排气系统/EXHAUST SYSTEM-----------------------------------------------------6
7、空滤器安装/AIR CLEANER ASS'Y------------------------------------------------7
8、空滤器安装/AIR CLEANER ASS'Y-------------------------------------------------8
9、空滤器安装/AIR CLEANER ASS'Y-------------------------------------------------9
10、空滤器安装/AIR CLEANER ASS'Y-----------------------------------------------10
11、冷却系统/COOLING SYSTEM----------------------------------------------------11
12、冷却系统/COOLING SYSTEM----------------------------------------------------12
13、变矩器油冷系统/TOR-CON OIL COOLING SYSTEM-----------------------------------13
14、燃油系统/FUEL SYSTEM-------------------------------------------------------14
15、燃油系统/FUEL SYSTEM-------------------------------------------------------15
16、燃油系统/FUEL SYSTEM------------------------------------------------------16
17、燃油系统/FUEL SYSTEM------------------------------------------------------17
18、油门操纵/ACCELERATOR PEDAL-------------------------------------------------18
19、油门操纵/ACCELERATOR PEDAL-------------------------------------------------19
20、变速箱变速操纵/TRANSMISSION CONTROL LINKAGE(TOR-CON TYPE)-------------------20
3
21、停车制动/BRAKE LEVER------------------------------------------------------21
22、行车制动与离合操纵/BRAKE AND CLUTCH CONTROL---------------------------------22
23、行车制动与离合操纵/BRAKE AND CLUTCH CONTROL---------------------------------23
2 4 、行车制动与微动操纵 / B R A K E A N D I N C H I N G C O N T R O L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 4
2 5 、行车制动与微动操纵 / B R A K E A N D I N C H I N G C O N T R O L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 5
26、驱动桥/DRIVE AXLE----------------------------------------------- ---------26
27、驱动桥/DRIVE AXLE----------------------------------------------- ---------27
28、驱动轮/DRIVE WHEEL--------------------------------------------------------28
29、驱动轮/DRIVE WHEEL--------------------------------------------------------29
30、转向轮/STEERING WHEEL-----------------------------------------------------30
3 1 、轮式制动器/ W H E E L B R A K E - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 1
3 2 、轮式制动器/ W H E E L B R A K E - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 2
33、传动装置安装(液力式)/DRIVE UNIT MOUNT------------------------------------37
34、传动装置安装(机械式)/DRIVE UNIT MOUNT-----------------------------------38
35、变速箱/TRANSMISSION---------------------------------------------------39
36、变速箱/TRANSMISSION-----------------------------------------------------40
37、变速箱/TRANSMISSION-------------------------------------------------41
38、传动装置(盖和微动阀)DRIVE UNIT(COVER&INCHING VALVE)--------------------42
39、传动装置(盖和微动阀)DRIVE UNIT(COVER&INCHING VALVE)--------------------43
40、液力离合器/HYDRAULC CLUTCH(TOR-CON TYPE)------------------------------44
4
41、控制阀CONTROL VALVE (TOR-CON TYPE)-----------------------------------45

4 2 、微动阀I N C H I N G V A L V E ( T O R - C O N T Y P E ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 6
43、供油泵/CHARGING PUMP-------------------------------------------------47
44、差速器总成/DIFFERENTIAL----------------------------------------------48
45、差速器总成/DIFFERENTIAL----------------------------------------------49
4 6 、车架与平衡重 / F R A M E A N D C O U N T E R W E I G H T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5 0
4 7 、车架与平衡重 / F R A M E A N D C O U N T E R W E I G H T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5 1
48、转向桥/STEERING AXLE-------------------------------------------------52
49、转向桥/STEERING AXLE-------------------------------------------------53
5 0 、转向油缸 / S T E E R I N G C Y L I N D E R - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 4
51、转向系统/STEERING SYSTEM---------------------------------------------55
5 2、转向系统 / S T E E R I N G S Y S T E M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 6
53、操纵杆总成(两片)VALVE CONTROL LINKAGE(TWO-THROW)------------------------------57
54、操纵杆总成(三片)VALVE CONTROL LINKAGE(THREE-THROW)----------------------------57
55、操纵杆总成(四片)VALVE CONTROL LINKAGE(FOUR-THROW)--------------------- --------58
56、液压系统/HYDRAULIC SYSTEM-------------------------------------------- --------59
57、液压系统/HYDRAULIC SYSTEM--------------------------------------------------60
58、液压油箱/OIL T ANK---------------------------------------------------------------63
59、护顶架/OVERHEAD G UARD----------------------------------------------------------64
60、组合仪表/COMBINATION M /T,TYPE--------------------------------------------------65
5
6 1、机罩底板及座椅HOOD,FLOOR B OARD A ND S EAT------------------------------------------66

6 2、机罩底板及座椅HOOD,FLOOR B OARD A ND S EAT------------------------------------------67
6 3、电气系统/ELECTRIC S YSTEM--------------------------------------------------------68
64、电气系统/ELECTRIC S YSTEM--------------------------------------------------------69
6 7、电气系统 / E L E C T R I C S Y S T EM------------------------------------ - - - - - - - - - - - - - - - - - - - 7 1
6 8 、门架管路系统（基本型）H Y D R A U L I C S Y S T E M M A S T ( N O R M A L M A S T M ) - - - - - - - - - - - - - - - - - - - - - 7 2
6 9 、门架管路系统（基本型）H Y D R A U L I C S Y S T E M M A S T ( N O R M A L M A S T M ) - - - - - - - - - - - - - - - - - - - - 7 3
7 0 、门架管路系统（二级全自由）H Y D R A U L I C S Y S T E M M A S T ( F U L L F R E E 2 - S T A G E M A S T Z M ) - - - - - 7 4
7 1 、门架管路系统（二级全自由）H Y D R A U L I C S Y S T E M M A S T ( F U L L F R E E 2 - S T A G E M A S T Z M ) - - - - 7 7
7 2 、货叉总成（基本及二级全自由）F O R K ( N O R M A L & F U L L F R E E 2 - S T A G E M A S T M & Z M ) - - - - - - - - -7 8
7 3 、货叉总成（基本及二级全自由）F O R K ( N O R M A L & F U L L F R E E 2 - S T A G E M A S T M & Z M ) - - - - - - - - - - -7 9
7 4 、货叉架总成（基本及二级全自由）L I F T B R A C K E T ( N O R M A L & F U L L F R E E 2 - S T A G E M A S T M & Z M ) - -8 0
7 5、门架（基本型）M A S T ( N O R M A L M A S T M ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 1
7 6 、门架（基本型）M A S T ( N O R M A L M A S T M ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 2
7 7、门架（基本型）M A S T ( N O R MAL MAST M)---------------------------- - - - - - - - - - - - - - - - - - - 8 3
7 8 、门架（二级全自由）M A S T ( F U L L F R E E 2 - S T A G E M A S T Z M ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 4
7 9 、门架（二级全自由）M A S T ( F U L L F R E E 2 - S T A G E M A S T Z M ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 5
8 0 、起升油缸（基本型）L I F T C Y L I N D E R ( N O R M A L M A S T M ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 6
6
LPG转换装置系统/LPG CONVERTER SYSTEM 103

CNG&LNG转换装置系统/CNG&LNG CONVERTER SYSTEM 104
7
发动机（柴油机）/ENGINE(DIESEL)
序号图号零部件名称件数备注
Item No Part No Description Q'ty Remark FD30,35 ,38 — Q C 2 , Q C 1
F D 3 0—W 2
01 FD30HB-D2000 Engine C240PKJ-30发动机 1 W2 FD30,35—W3
- FD35HC-D2000 Engine 4JG2PE-01发动机 1 W3
- FD30HL-D1100 Engine JX493G发动机 1 N2
- FD30MA-D8000 E n g i n e 全柴4 9 0 G P 1 Qc2
- FD38HAC-D1000 E n g i n e 全柴4 9 5 G P 1 Qc1
02 GB/T5783-10x110 Bolt 螺栓M10x110 2 GB/T5782-2000
03 FD30MA-D0004 Plate 垫片 2
04 FD30MA-D0003 Coller 套管 2
05 FD30MA-D0001 Rubber 橡胶垫 2
07 FD30MA-D0005 Washer 垫圈 2
08 GB/T6184-10 Nut 螺母M10 2 GB/T6184-2000
8
7
6
5
1
4
3
1
发动机（汽油机）/ENGINE(GASOLINE)
FD35,38—Dc1 Item No Part No Description Q'ty Remark
01 FD35HD-D2000 Engine CA498-97发动机 1 Dc1
03 FD30MA-D0004 Plate 垫片 2
08 G B / T 6 1 8 4 - 1 0 Nut 螺母M10 2 GB/T6184-2000
8
7
6
5
1
4
3
2
发动机（柴油机）/ENGINE(DIESEL)
Item No Part No Description Q'ty Remark FD30,35-YM2
01 FD30MK-D2000 Engine 发动机(4TNE98) 1 Ym2
02 GB/T5782-10X110 Bolt 螺栓M10x110 2 GB/T5782-2000
03 FD30MA-D0004 Washer 垫片 2

08 GB/T6184-10 Nut 螺母M10 2 GB/T6184-2000
09 FD30MK-D3000 Engine support 发动机支脚 2 Ym2 12

10 FD30HM-D2200 Packet R.H. 发动机托架（右） 1 Jb1
11 GB/T5783-10x30 Bolt 螺栓M10x30 8 Ym2

8
12 GB/T93-10 Washer 垫圈10 8 Ym1,Ym2
11 7
6
10
1 9 4
3
3
发动机（汽油机）/ENGINE(GASOLINE)
FG30,35-K2 Item No Part No Description Q'ty Remark
01 FG30HC-D1100 Engine 尼桑K25发动机 1 K2
03 FD30MA-D0004 Washer 垫片 2
08 GB/T6184-10 Nut 螺母M 10 2 GB/T6184-2000
09 FG30HC-D1200 Packet L.H. 发动机托架（左） 1

12 10 FG30HC-D1300 Packet R.H. 发动机托架（右） 1
11 GB/T5782- 10x40 Bolt 螺栓M10x1.5x40 8 GB/T5782-2000

11
8 12 GB/T93-10 Washer 垫圈10 8 GB/T93-1987
7
10 6
5
9
4
1 3
2
4
排气系统/EXHAUST SYSTEM
Item No Part No Description Q'ty FD30,35,38-QC1,QC2
Remark FD30-N2
01 FD30HLC-P1000 Pipe ass'y 排气管总成 1 N2
FD35-W3
- FD30YCC-P1000 Pipe ass'y 排气管总成 1 W3
- FD30MAC-P1000 Pipe ass'y 排气管总成 1 Qc1,Qc2
02 FD30MAJ-P1000 Muffler 消声器总成 1

03 GB /T 57 83 -1 0x 35 Bolt 螺栓M10x 35 4 GB/T5783-2000
04 GB/T93-10 Washer 4 GB/T93-1987

垫圈10
05 GB/T95-10 Washer 垫圈10 4 GB/T95-2000
06 FD30MAJ-P0001 Gasket 垫片 2
07 FD30MA-P0002 Bolt 消声器安装螺栓 2
08 FD30MA-P0003 Shim 垫片 2
09 FD30MA-P0001 Rubber 消声器安装橡胶垫 4
10 GB/T93-10 Washer 垫圈10 2 GB/T93-1987
11 GB/T6184-8 Nut 螺母M8 2 GB/T6184-2000
12 FD30MA-P0004 Clip 消声器固定管卡 1

14 FD30MAJ-P3000 Tu b e 排气尾管 1 3吨
- FD30MAJ-P4000 Tu b e 排气尾管 1 3.5吨
5
排气系统/EXHAUST SYSTEM
Item No Part No Description Q'ty Remark
FD30-W2
FD30,35-YM2, 01
FG30,35-K2 FD30YBC-P2000 Pipe ass'y 排气管总成 1 W2
FD38-DC1 FL35YCC-P1000 Pipe ass'y 排气管总成 1 K2

-
- FD30YKC-P1000 Pipe ass'y 排气管总成 1 Ym2
- FD38HDC-P1000 Pipe ass'y 排气管总成 1 Dc1
02 FD30YBJ-P1000 M u f f l e r 消声器总成 1
03 FD30MA-P0002 Bolt 消声器安装螺栓 4
04 FD30MA-P0003 Packing 垫片 2
05 FD30MA-P0001 Rubber 消声器橡胶垫 4
06 GB/T93-10 Washer 垫圈10 2 GB/T93-1987
07 GB/T6170-8 Nut 螺母8 2 GB/T6170-2 000
08 GB/T5783-10x30 Bolt 螺栓M10x 30 4 GB/T5783-2000
09 FD 30 MA -P 00 04 Clip 消声器固定卡 1
10 GB/T5783-10x35 Bolt 螺栓M 10 x 35 4 GB /T 57 83 -2 00 0
11 GB/T93-10 Washer 垫圈10 4 GB/T93-198 7
12 GB/T95-10 Washer 垫圈10 4
13 FD30MAJ-P0001 Gasket 垫片 2
14 FD30YBJ-P3000 T u b e 排气尾管 1
6
空滤器安装/AIR CLEANER ASS'Y

Item No Part No Description Q'ty Remark FD30,35-N2,QC1,QC2,YM2
FD35,38-DC1
01 FD30MA-J1000 Air cleaner ass'y 空气滤清器 1 N2,YM2,QC2,QC1
- FD35HD-J1000 Air cleaner ass'y 空气滤清器 1 Dc1
02 FD30MK-J0001 Duct I 进气管I 1 Ym2
- FD35HD-J0002 Duct II 进气管II 1 Dc1
- FD30MA-J0001 Duct I 进气管I 1 Qc1,Qc2 1
- FD30HL-J0001 Duct I 进气管I N2

1 4
03 FD30MA-J0001 Duct I 进气管I 1
2
04 JB/T8870-6080 Clip 双钢丝卡箍φ60-80 4 JB/T8870-1999
05 GB/T6170-8 Nut 螺母M8 2 GB/T6170-2000
06 GB/T93-8 Washer 垫圈8 2 GB/T93-1987
07 GB/T95-8 Washer 垫圈8 2 GB/T97.1-2000

N2,X4,X5,X7,X9
08 FD30MA-J1001 Filter element 空气滤芯 1 S2,YM2,YM1,QC2
- FD35HD-J1001 Filter element 空气滤芯 1 Dc1

7
6
7

FD30,35-W3
01 FD30MA-J1000 Air cleaner ass'y 空气滤清器 1
02 FD35HC-J0001 Duct I 进气管I 1
03 FD30MA-J0002 Duct I 进气管II 1
04 JB/T8870-6080 Clip 双钢丝卡箍φ60-φ80 2 JB/T8870-1999
05 JB/T8870-4060 Clip 双钢丝卡箍φ40-φ60 2 JB/T8870-1999
06 GB/T6170-8 Nut 螺母M8 2 GB/T6170-2000
1 07 GB/T93-8 Washer 垫圈8 2 GB/T93-1987

5 2 08 GB/T95-8 Washer 垫圈8 2 GB/T95-2002
09 FD30MA-J1001 F i l t e r e l ement 空气滤芯 1
8
7
6
4
8

Item No Part No Description Q'ty Remark FD30-W2
01 FD30MA-J1000 Air cleaner ass'y 空气滤清器 1

02 FD30HB-J0001 Duct 进气管 1 C240
03 FD30YBJ-J0001 Duct I 进气管I 1
04 JB/T8870-6080 Clip 双钢丝卡箍 φ6 0 - 8 0 2 JB/T8870-1999
05 JB/T8870-7089 Clip 双钢丝卡箍 φ7 0 - 8 9 2 JB/T8870-1999
06 GB/T6170-8 Nut 螺母M 8 2 GB/T6170-2000
07 GB/T93-8 Washer 垫圈8 2 GB/T93-1987
08 GB/T95-8 Washer 垫圈8 2 GB/T95-2002 1 5

09 FD30MA-J1001 Filter element 空气滤芯 1
2
8
7
4
6
3
9
9

FG30,35-K2
01 FG30HC-J1000 Air cleaner ass'y 空气滤清器 1
02 FG30HC-J0001 DuctI 进气管I 1
03 FD30MA-J0002 DuctI 进气管II 1
A 04 JB/T8870-6080 Clip 双钢丝卡箍φ60-80 4 JB/T8870-1999
05 GB/T6170-8 Nut 螺母M8 2 GB/T6170-2000
06 GB/T93-8 Washer 垫圈8 2 GB/T93-1987

4 07 GB/T97.1-8 Washer 垫圈8 2 GB/T97.1-1985
08 FG30HC-J1001 F i l t e r e l ement 空气滤芯 1

1
10
10
冷却系统/ COOLING SYSTEM

Item No Part No Description Q'ty Remark FD30-W2
FD30,35-W3,YM2
FG30,35-K2
01 FD30HBC-D1100 Radiator 散热器总成 1 W 2液力
- FD30YKC-D1100 Radiator 散热器总成 1 YM1,YM2液力
- FD30HCC-D1100 Radiator 散热器总成 1 W 3液力
- FG30HCC-D1100 Radiator 散热器总成 1 K2液力
02 FD30MA-D2001 Rubber II 橡胶垫I I 2
1 3 4
03 FD30MA-D2002 Shim 垫片 2 2
04 FD30MA-D2003 Bolt 螺栓 2 9
05 GB/T96.2-8 Washer 垫圈8 2 GB/T96.2-2002
14
06 GB/T6184-8 Nut 螺母M 8 2 GB/T6184-2000
07 FD30MA-D2004 Rubber I 橡胶垫I 2
08 FD30HB-D1200 Tank 副水箱总成 1
09 FD30HB-D1003 Hose 胶管φ1 2 xφ8 x L 1
11
10 JB/T8870-1016 Two-wire clamp 双钢丝卡箍 φ1 0 - 1 6 2 JB/T8870-1999
11 JB/T8870-3444 Two-wire clamp 双钢丝卡箍 φ3 4 - 4 4 2 Ym2

6 5
- JB/T8870-5060 Two-wire clamp 双钢丝卡箍 φ5 0 - 6 0 2 Ym2
13
- JB/T8870-3551 Two-wire clamp 双钢丝卡箍 φ3 5 - 5 1 4 K2
12 7
15
- JB/T8870-45 Two-wire clamp 双钢丝卡箍 φ4 5 4 W2,W3,
8
12 GB/T5783-6x15 Bolt 螺栓M 6 x 1 5 2 GB/T5783-2000
10
13 GB/T93-6 Washer 垫圈6 2 GB/T93-1987
14 FD30MK-D1002 Hose,lower 上水管 1 Ym2
- FD35HC-D1001 Hose,lower 上水管 1 W3
- FG30HC-D2002 Hose,lower 上水管 1 K2
FD30HB-D1001 Hose,lower 上水管 1 W2

-
15 FD30MK-D1003 Hose,lower 下水管 1 Ym2
- FD35HC-D1002 Hose,lower 下水管 1 W3
- FG30HC-D2001 Hose,lower 下水管 1 K2
- FD30HB-D1002 Hose,lower 下水管 1 W2

11
11
冷却系统/COOLING SYSTEM
FD30,35-N2,QC1,QC2 Item No
FD35,38-DC1 Part No Description Q'ty Remark
01 FD30MAC-D2100 Air cleaner ass'y 散热器总成 1 3tQC2机械
- FD30HAC-D1100 Air cleaner ass'y 散热器总成 1 QC1,QC2液力
- FD30HLC-D2100 Air cleaner ass'y 散热器总成 1 N2液力
FD38MAC-D2100 Air cleaner ass'y 散热器总成 1 3.5-3.8tQC2机械
- FD38HDC-D1001 Air cleaner ass'y 散热器总成 1 3.8tDc1机械
- FD35HD-D1100 Air cleaner ass'y 散热器总成 1 3.5tDc1液力
- FD35MD-D1100 Air cleaner ass'y 散热器总成 1 3.5tDc1机械
- FD38HDC-D1100 Air cleaner ass'y 散热器总成 1 3.8tDc1液力
02 FD30MA-D2001 Rubber pad 橡胶垫II 2

5
1 3 03 FD30MA-D2002 Gasket 垫片 2
7
04 GB/T96.2-8 Washer 垫圈8 2 GB/T96.2-2002
05 FD30MA-D2003 Bolt 螺栓 2
8
06 GB/T6170-8 Nut 螺母M8 2 GB/T6170-2000
10 07 FD30MA-D2004 Rubber pad 橡胶垫I 2

X4,X5,X7,X9,
08 FD30MA-D2005 On the water 上水管 1 QC2
10 9
10 - FD30HL-D2002 On the water 上水管 1 N2
4 - FD30HN-D1002 On the water 上水管 1 S2

6 - FD35HD-D1001 On the water 上水管 1 DC1
- FD30YOJ-D1001 On the water 上水管 1 Jb2

X4,X5,X7,X9,
09 FD30MA-D2006 Downcomer 下水管 1 QC2
2
- FD30HL-D2001 Downcomer 下水管 1 N2
- FD30HN-D1003 Downcomer 下水管 1 S2
- FD35HD-D1002 Downcomer 下水管 1 DC1
- FD30YOJ-D1002 Downcomer 下水管 1 Jb2
X4,X5,X7,X9,
10 JB / T 8870-3444 Worm clamp 蜗杆卡箍φ34-φ44 4 QC2,N2
- JB/T8870-4434 Worm clamp 蜗杆卡箍φ34-φ44 2 S2,Jb2
- JB/T8870-5560 Worm clamp 蜗杆卡箍φ55-φ60 2 S2,Jb2

12
12
变矩器油冷系统/TOR-CON OIL COOLING SYSTEM

序号图号零部件名称件数备注 F D 3 0 , 3 5, 3 8
01 GB/T8870-1619 Two-wire clamp 双钢丝卡箍φ16-19 4 JB/T8870-1999
02 FD30HA-D1002 Oil cooling pipe 油冷却管φ10x2600 1

- FD30HB-D1004 High Pressure Hose 高压胶管 1 仅W2用
03 FD30HA-D1003 Oil cooling pipe 油冷却管φ10x2400 1

- FD30HB-D1004 High Pressure Hose 高压胶管 1 仅W2用
04 FD30HA-D1001 Oil cooling connector 油冷却接头 2 A

- FD30HB-D1007 Transition joints 过渡接头 2 仅W2用
05 JB/T982-14 Combination washer 组合垫圈14 2 JB/T982-1977
3
2
4
5
13
13
燃油系统/FUEL SYSTEM
FD30,35-QC1,QC2 Item No Part No Description Q'ty Remark
FD30,35-YM2
01 FD30MA-D1100 Plate 燃油箱盖板总成 1
02 FD30MA-D1001 Packing 盖板垫 1
03 FD30MA-D1002 Packing 传感器橡胶垫 1
10 04 FD30MA-D1200 Oil，sensor 燃油传感器 1
7 11 05 GB/T5783-8x20 Bolt 螺栓M8x20 8 GB5783-1986
5
06 GB/T93-8 washer 垫圈8 8 GB/T93-1987
3 6
8 07 GB/T8870-1619 Clip 双钢丝卡箍φ16-19 4 JB/T8870-1999
4
9 08 FD30MA-D1005 Tube 胶管φ18xφ10 xL2 1 现场裁剪
14 09 FD30MA-D1006 Tube 胶管φ18xφ10 xL1 1 现场裁剪

1
11 GB/T93-5 washer 垫圈5 5 GB/T93-1987

2
12 FD30MA-D1007 Plug，drain 放油螺塞 1
13 JB/T982-20 washer 组合垫圈20 1 JB/T982-1977
15 14 FD30MA-D1300 Cap 燃油盖总成 1

15 FD30MA-D1400 Oil filter 滤油器 1
13
12
14
14
Item No Part No Description Q'ty Remark FG30,35-K2
01 FG30HC-D3100 Plate 燃油箱盖板总成 1

04 FD30MA-D1200 Oil，sensor 燃油传感器 1 10
15
11 B
06 GB/T93-8 washer 垫圈8 8 GB/T93-1987

7
08 GB/T93-5 washer 垫圈5 5 GB/T93-1987 5
8
09 FD30MA-D1400 Oil，filter 滤油器 1 3 4
10 GB/T8870-1619 Clip 双钢丝卡箍φ16-19 4 JB/T8870-1999
1 6
11 FG30HC-D3001 Tube 燃油管φ16xφ8xL 2 现场裁剪
12
12 FD30MA-D1300 Cap 燃油盖总成 1
2
13 FD30MA-D1007 Plug 放油螺塞 1
14 GB/T982-20 washer 组合垫圈20 1 JB/T982-1977
9
15 FG30HC-D3200 Sedimentor 汽油滤清器 1
14
13
15
15
FD35,38-DC1 Item No Part No Description Q'ty Remark
6 04 FD30MA-D1200 Oil，sensor 燃油传感器 1
8 7 05 FD30MA-D1300 Cap 燃油盖总成 1

9 11
06 GB /T 57 83 -8 x2 0 Bolt 螺栓M8x20 8 GB5783-2000
3 12
17 07 GB/T93-8 washer 垫圈8 8 GB/T93-1987
4
20 08 JB/T8870-1619 Clip 双钢丝卡箍φ16-19 6 JB/T8870-1999
1
21 09 FD35HD-D3002 Tube 胶管φ16xφ8xL 2
10
5 10 FD35HD-D3001 Tube 胶管φ14xφ6xL 1
18
19 11 GB/T5783-5x12 Bolt 螺栓M5x12 5 GB/T5783-1986
2
12 GB/T93-5 washer 垫圈5 5 GB/T93-1987
13 FD30MA-D1007 Plug，drain 放油螺塞 1

15 14 JB/T982-20 washer 组合垫圈20 1 JB/T982-1977
15 FD30MA-D1400 Cap 滤油器 1

16 16 FD35HD-D3100 Sedimentor 油水分离器 1 Dc1
18 GB/T93-8 washer 垫圈8 2 GB/T93-1987
19 FD35HD-D3003 Bracket 支架 1
14 21 GB/T93-8 washer 垫圈8 2 GB/T93-1987
13
16
16
Item No Part No Description Q'ty Remark FD30-W2,N2
FD30,35-W3
04 FD30MA-D1200 Oil，sensor 燃油传感器 1
3 10
05 FD30MA-D1300 Cap 燃油盖总成 1
06 GB/ T57 83- 8x2 0 Bolt 螺栓M8x20 8 GB5783-1986
6 11 8
07 GB/T93-8 washer 垫圈8 8 GB/T93-1987
7
08 JB /T 88 70 -1 61 9 Clip 双钢丝卡箍φ16-19 6 JB/T8870-1999
1
09 FD30HB-D3001 Tube 胶管φ16xφ10xL 3
9
10 GB/T5783-5x12 Bolt 螺栓M5x12 5 GB/T5783-1986 4
11 GB/T93-5 washer 垫圈5 5 GB/T93-1987
2
12 FD30MA-D1007 Plug，drain 放油螺塞 1 5
13 JB/T982-20 washer 组合垫圈20 1 JB/T982-1977
14
14 FD30MA-D1400 Cap 滤油器 1
17 16
15 FD30HB-D3100 Sedimentor 油水分离器 1 W2
- FD30HL-D3100 Sedimentor 油水分离器 1 N2
17 GB/T93-8 washer 垫圈8 2 GB/T93-1987
15
13
12
17
17
油门操纵/ACCELERATOR PEDAL
FD30,35-QC 1 , Q C 2电液序号图号零部件名称件数备注
FD 3 5,3 8 -Dc 1液力 Item No Part No Description Q'ty Remark
FD 3 0 , 3 5 - S 2 , N 2 01 FD30MA-L3100 Accelerator pedal 油门踏板 1
FD 3 0 - W 2 ,
FD 3 0 , 3 5 - Y M 2 , W 3 02 FD30MA-L3002 Sheave 滚轮 1
FG 3 0 , 3 5 - K 2
03 GB/T93-6 Washer 垫圈6 3 GB/T93-1987
04 GB/T91-2x20 Pin 开口销2x20 3 GB/T91-2000
05 GB/T5783-12x75 Bolt 限位螺栓M8x75 1

1 06 GB/T6170-12 Nut 螺母M12x1.25 1 GB/T6171-2000
7 07 GB/T5783-620 Bolt 螺栓M6x20 2 GB/T5783-2000
08 GB/T6170-6 Nut 螺母M6 2 GB/T6170-2000
5 09 GB/T95-6 Washer 垫圈6 2 GB/T95-2002
6 10 FD30YBJ-L3150 Link，ass'y 连接轴总成 1

11 FD30MA-L3004 Spring 弹簧 1
12 GB/T95-10 Washer 垫圈10 1 GB/T95-2002
13 GB/T91-3x12 Pin 销3x12 1 GB/T91-2000
14 FD30YBJ-L3160 Bracket 支架 1
15 GB/T882-10x45 Pin,axle 销轴10x45 2 GB/T882-86
15 16 GB/T5783-8x16 Bolt 螺栓M8x16 2 GB/T5783-2000

9 3 17 GB/T93-8 Washer 垫圈8 2
17 8 4
GB/T93-1987
14 16 2 18 FG30HC-L1100 Soft shaft 油门拉索总成 1 K2

34
18 - FD35HD-L1100 S o f t s h a f t 油门拉索总成 1 W2
11
3 - FD30HB-L1100 Soft shaft 油门拉索总成 1 其余
15 4
10
12
13
18
18
油门操纵/ACCELERATOR PEDAL
Item No Part No Description Q'ty FD30,35-QC1,QC2(机械，手液）
Remark
01 FD30MA-L3100 Accelerator pedal 油门踏板 1
02 FD30MA-L3002 Sh e a v e 滚轮 1
03 GB/T93-6 Wa s h e r 垫圈6 3 GB/T93-1987
04 GB/T91-2x12 Pi n 开口销2 x 1 2 3 GB/T91-2000
05 FD30MA-L3001 Bo l t 限位螺栓 1
06 GB/T6171-12 Nu t 螺母M 1 2 x 1 . 2 5 1 GB/T6171-2000 1
07 GB/T5783-6x20 Bo l t 螺栓M 6 x 2 0 2 GB/T5783-2000
08 GB/T95-6 Nu t 螺母M 6 4 GB/T95-2002
7
09 GB/T93-8 Wa s h e r 垫圈6 2 GB/T93-1987
10 FD30MA-L3200 Li n k，as s ' y 连接轴总成 1 机械 5

- FD30YBJ-L3150 L i n k，a s s ' y 连接轴总成 1 手液 6
11 FD30MA-L3004 Sp r i n g 弹簧 1
12 GB/T93-10 Wa s h e r 垫圈1 0 1 GB/T93-1987
13 GB/T91-3x12 Pi n 销3 x 1 2 1 GB/T91 -2000
14 FD30MAJ-L2150 Br a c k e t 支架 1 机械
- FD30YBJ-L3160 B r a c k e t 支架 1 手液 8
9
15 FD30MAJ-L2001 Li n k 拉杆 1 8 18
16 GB/T5783-8x16 Bo l t 螺栓M 8 x 1 6 2
17 4 2
GB/T5783-2000
16 3 15
17 GB/T93-8 Wa s h e r 垫圈8 2 GB/T93-198 7
14 3
18 FD30MA-L3006 Yo k e 支耳 1 11
10
12
13
19
19
变速箱变速操纵(液力式)/TRANSMISSION CONTROL LINKAGE(TOR-CON TYPE)

FD30,35 Item No Part No Description Q'ty Remark
01 FD30HA-L2003 Knob 换向手柄 1
02 GB/T6170-10 Nut 螺母M10 x 1.5 1 GB/T6170-2000
03 FD30HA-L2200 Lever 操纵杆总成 1

04 FD30HA-L2002 Bracket 支架 1
06 GB/T93-8 Washer 垫圈8 7 GB/T93-1987
08 GB/T93-6 Washer 垫圈6 2 GB/T93-1987
09 FD30HA-L2500 Shaft 销轴总成 2

10 FD30HA-L2100 Link 连杆 1
11 GB/T882-8x18 Pin 销轴8x18 2 GB/T882-2000
12 GB/T91-3.2x20 Pin 开口销3.2x20 2 GB/T91-1986
13 GB/T97.1-8 Washer 垫圈8 2 GB /T 97 .1 -2 00 0
14 FD30HAJ-L2002 Bracket 支架 1
15 FD30HAJ-L2200 Boss 摇臂总成 1
16 FD30HA-L2004 Link 连杆 1
17 GB/T6172-8 Nut(left) 螺母M8(左) 1 GB /T 61 72 -2 00 0
18 FD30HA-L2006 Bearing 弯杆型球头杆端关节轴承 1

19 GB/T6170-8 Nut 螺母M8 4 GB /T 61 70 -2 00 0
22 20 FD30HA-L2400 Link 连杆 1
21 GB/T5783-8x35 Bolt 螺栓M8x35 1 GB /T 57 83 -2 00 0
22 FD30HA-L2005 Bearing 弯杆型球头杆端关节轴承 1
20
20
停车制动/BRAKE LEVER
Item No Part No Description Q'ty FD30,35
Remark
01 FD30MA-L2001 Brake lever 调节杆 1
02 FD30MA-L2002 Over head 手柄头 1
03 GB/T80-4x3.7 Screw 内六角凹端紧定螺钉M4x3.7 1 GB/T80-1985
04 FD30MA-L2003 Screw rod 螺杆 1 1

05 GB/T39-8 Nut 方螺母M8 1 GB/T39-1988
2
06 GB/T96-8 Washer 大垫圈8 1 GB/T96-1985
07 FD30MA-L2004 Spring 弹簧1x5.5x10.8 1 3

6
08 FD30MA-L2005 Ball 钢球φ6 1 5
9
09 FD30MA-L2006 Seat 手柄座 1 7
10 FD30MA-L2007 lever 闸把体 1
8
11 FD30MA-L2008 Rod 拉杆体 1 10 4
19
12 GB/T882-8x35 Pin 平头销B8X35 1 12 11
GB/T882-1986
13
13 FD 30 MA -L 20 09 Stopper 限位块 1
21
14 FD30MA-L2100 Brcket 支架总成 1 23 18
24
15 GB/T923-10 Nut 组合式盖形螺母M10 1 GB/T923-1988
22
16 FD30MA-L2011 Brcket 拉线架 1
20
17 GB/T882-8x45 Pin 平头销B8X45 1 GB/T882-1986
21 17
18 FD30MA-L2012 Washer 垫圈II 1
25 17
19 FD30MA-L2200 Plate 支撑板总成 1
14
21 GB/T93-10 Washer 垫圈10 3 GB/T93-1987
22 FD30MA-L2300 link 拉板总成 1

23 GB/T896-8 Washer 垫圈8 3 GB/T896-1986
24 GB/T97.1-8 Washer 垫圈8 6 GB/T97.1-1985
21
21
行车制动与离合操纵(机械式）/BRAKE AND CLUTCH CONTROL(CLUTCH TYPE)

FD20,25,30,35 Item No Part No Description Q'ty Remark
01 GB/T5783-8x20 Bolt 螺栓M8X20 2 GB/T5783-2000
02 GB/T95-8 Washer 垫圈8 2 GB/T95-2002
03 GB/T93-6 Washer 垫圈8 2 GB/T93-1987
04 GB/T5783-10x35 Bolt 螺栓M10X35 1 GB/T5783-2000
05 FD30MA-L1131 Tank，reserve 储油罐 1

06 GB/T93-10 Washer 垫圈10 4 GB/T93-1987
07 FD30MA-L1111 Bushing 钢背轴承2525 1

08 FD30HA-L1180 Master，cylinder 制动泵总成 1
09 FD30YBJ-L1300 Hose 制动油管总成（右） 1 3t,3.5t
- FD25MA-L1100 Hose 制动油管总成（右） 1 2t,2.5t
10 FD30MA-L1002 Clip 管夹II 1

11 FD30MA-L1200 Hose 制动油管总成（左） 1 3t,3.5t
- FD25MA-L1200 Hose 制动油管总成（左） 1 2t,2.5t
12 FD30MA-L1001 Clip 管夹I 1

13 FD30MA-L1200 Clutch pedal 离合踏板总成 1
14 GB/T91-2.5x30 Snap pin 销2.5x30 1 GB/T91-1986
15 GB/T95-10 Washer 垫圈10 1 GB/T95-2002

8
16 FD30MA-L1160 Rod 分离杆总成 1
18 FD30MA-L1103 Spring 弹簧 1
19 FD30MA-L1113 Nut 球螺母 1
20 GB/T6170-12 Nut 螺母M12 1 GB/T6170-2000
21 FD30MA-L1114 Rubber 橡皮顶轴 1

22 FD30MA-L1140 Pin,clevis 油轴总成 1
23 FD30MA-L1110 Brake pedal 制动踏板总成 1
24 FD30HA-L1102 Spring 制动拉簧 2
25 FD30MA-L1115 Fitting 油杯90° M10x1 1
22
22
行车制动与离合操纵(机械式）/BRAKE AND CLUTCH CONTROL(CLUTCH TYPE)

Item No Part No Description Q'ty Remark FD20,25,30,35
FG20,25,30,35
26 FD30MA-L1150 Bracket 底板总成 1
27 FD30HA-L1101 Head cover 脚踏套 1
28 GB/T91-2.5x16 Pin,snap 销2.5x16 1 GB/T91-1986
29 FD30MA-L1111 Bushing 钢背轴承2525 2

30 GB/T882-10x26 Pin,clevis 销G10x26 1 GB/T882-1986
31 GB/T5783- 10x30 Bolt 螺栓M10x30 2 GB/T5783-2000
32 GB/T6170-10 Nut 螺母M10 4 GB/T6170-2000
5
6
23
23
行车制动与微动操纵(液力式）/BRAKE AND INCHING CONTROL(TOR-CON TYPE)

FD20,25,30,35 Item No Part No Description Q'ty
FG20,25,30,35 Remark
01 FD30MA-L1131 Tank，reserve 储油罐 1
02 FD30HA-L1160 Shaft 油轴总成 1
03 GB/T93-8 Washer 垫圈8 1 GB/T93-1987
05 FD30HA-L1101 Head cover 踏板垫 2

06 FD30MA-L1111 Bushing 钢背轴承25x25 2
07 FD30HA-L1201 Bushing 钢背轴承16x25 1
08 FD30HA-L1200 Hose 制动油管（右） 1 3t,3.5t
- FD25HA-L1100 Hose 制动油管（右） 1 2t,2.5t
09 FD30MA-L1002 Clip 管夹II 1

10 FD30HA-L1300 Hose 制动油管（左） 1 3t,3.5t
- FD25HA-L1200 Hose 制动油管（左） 1 2t,2.5t
11 FD30MA-L1001 Clip 管夹I 1

1
12 FD30HA-L1001 Clip 管夹 1
13 FD30HA-L1002 Clip 管夹 1
14 FD30HA-L1140 Clutch pedal 微动踏板总成 1
15 FD30HA-L1150 Clutch pedal 制动踏板总成 1
17 GB/T93-10 Washer 垫圈10 2 GB/T93-1987
18 GB/T882-8x30 Pin clevis 销B8x30 3 GB/T882-1986
19 GB/T91-2.5x16 Pin 销2.5x16 5 GB/T91-1986
20 FD30HA-L1202 Rubber 橡皮顶轴 1

21 FD30HA-L1173 Link 连接杆 1
22 GB/T97.1-16 Washer 垫圈16 1 GB/T97.1-2002
23 GB/T91-4x26 Pin 销4x26 1 GB/T91-1986
24 GB/T882-8x30 Pin,clevis 销轴8x30 1 GB/T882-1986

24
24
行车制动与微动操纵(液力式）/BRAKE AND INCHING CONTROL(TOR-CON TYPE)

Item No FD20,25,30,35
Part No Description Q'ty Remark FG20,25,30,35
26 FD30HA-L1190 Bracket 基座 1
28 GB/T6170-10 Nut 螺母M10 4 GB/T6170-2000
29 FD30HA-L1180 Master，cylinder 制动总泵 1

30 FD30HA-L1170 Link 摇臂 1
31 FD30HA-L1171 Clevis 支耳M10-6H(左旋) 1
32 GB/T6170-10 Nut 螺母M10(左旋） 1 GB/T6170-2000
33 FD30HA-L1172 Rod 螺杆 1
35 FD30HA-L1102 Spring 拉簧 2
36 FD30MA-L1115 Fitting 油杯90° M10x1 1
25
25
驱动桥/DRIVE AXLE
FD20,25,30,35 Item No Part No Description Q'ty
FG20,25,30,35 Remark
01 FB25DA-C2001 Housing,axle 桥壳 1 2t,2.5t
- FD25MA-C1001 Housing,axle 桥壳 1 3t
- FD35MA-C1001 Housing,axle 桥壳 1 3.5,3.8t
02 FD30MA-C1002 Retainer，oil seal 油封挡圈 2

03 FD30MA-C1003 Seal，oil U型密封圈FG100x125x12D 2
04 FD30MA-C1004 Retainer 挡油圈 2
34
25 05 FD30MA-C1005 Washer 备用垫 2
31 06 Z-30214E Bearing 轴承30214E 2 GB/T297-1994

18 30 33 07 GB/T119-10x30 Pin 销G10x30 1 GB/T119-1986
17 08 FB25DA-C2001 Drum，brake 制动鼓 2 2t,2.5t

单胎Single tire
1 32 - FB25DA-C2002 Drum，brake 制动鼓 2 2t,2.5t
双胎Double tire
28
24 - FD30MA-C1006 Drum，brake 制动鼓 2 3t,3.5t
18 20 09 FB25DA-C2003 Hub，front 轮毂 2
2t,2.5t
单胎Single tire
21 FB25DA-C2004 Hub，front 轮毂 2 2t,2.5t
7 2 63 - 双胎Double tire
5 4 - FD30MA-C1007 Hub，front 轮毂 2 3t,3.5t

22 10 FD30MA-C1100 2
23 轴承油封总成
8 13 11 FD30MA-C1008 Packing 垫 2
9
12 GB/T810-60 Nut 螺母M60x2 4 GB/T810-1988
10 11
14 13 GB/T858-60 Washer 垫圈60 2 GB/T858-1988
12
15 14 FB25DA-C2005 Shaft，drive 半轴 2 2t,2.5t
27
25 - FD30MA-C1009 Shaft，drive 半轴 2 3t,3.5t
26 16
15 FD30MA-C1010 Packing 半轴垫 2
16 FD30MA-C1011 Bolt 螺栓 24
17 FD30MA-C1012 Breather,air 通气塞 1
18 FD30MA-C1013 Flug 堵塞 3
26
26
驱动桥/DRIVE AXLE
Item No FD20,25,30,35
Part No Description Q'ty Remark FG20,25,30,35
21 GB/T6171-20 Nut 螺母M20x1.5 12 GB/T6171-1986
2t,2.5t
22 FB25DA-C2006 Bolt 螺栓柱 12 单胎Single tire
3t,3.5t
- FD30MA-C1016 Bolt 螺栓柱 12 单胎Single tire
2t,2.5t
23 FD30MA-C1017 Nut 球螺母 12 单胎Single tire
3t,3.5t
- FB25DA-C2007 Nut 球螺母 12 单胎Single tire
24 FB25DA-C2100 Wheel brake 制动器总成 1 2t,2.5t
- FD30MA-C1200 Wheel brake 制动器总成 1 3t,3.5t 34

2t,2.5t
25
25 FB25DA-C2008 Nut，hub 柱螺母 12 双胎Double tire
3t,3.5t
31
- FD30MA-C1018 Nut，hub 柱螺母 12 双胎Double tire 18 30 33
2t,2.5t
26 FB25DA-C2009 Nut，hub 双胎球螺母 12 双胎Double tire
17
3t,3.5t
- FD30MA-C1019 Nut，hub 双胎球螺母 12 双胎Double tire 1 32
27 FB25DA-C2010 Nut，hub 双胎螺栓柱 12
2t,2.5t
双胎Double tire 28
3t,3.5t
24
- FD30MA-C1020 Nut，hub 双胎螺栓柱 12 双胎Double tire 18 20
2t,2.5t
28 FD25MA-R0003 Fender 挡板左 1 双胎Double tire 21
- FD30MA-R0003 Fender 挡板左 1 3t,3.5t 7 2 63
双胎Double tire
GB/T5783-1988 5 4
29 GB/T5783-10x35 Bolt 螺栓M10x35 4 双胎Double tire 22
GB/T95-1986 23
30 GB/T95-10 Washer 垫圈10 8 双胎Double tire
8 13
31 GB/T93-10 Washer lock 垫圈10 8 GB/T93-1985
双胎Double tire
9
32 GB/T6140-10 Nut 螺母M10 4 GB/T6170-1987 10 11
33 GB/T5783-10x20 Bolt 螺栓M10x1.25x20 4 GB/T5783-1986 12
2t,2.5t
34 FD25MA-R0004 Fender 挡板右 1 双胎Double tire 27
3t,3.5t
25
- FD30MA-R0004 Fender 挡板右 1 双胎Double tire 26 16
27
27
驱动轮/DRIVE WHEEL(2.0t,2.5t SINGLE TIRE)

FD20,25
FG20,25 Item No Part No Description Q'ty Remark
01 FB25DA-Q0001 Rim,outside 外轮圈 2
02 FB25DA-Q0002 Rim,inside 内轮辋 2

03 GB/T6170-16 Nut 螺母M16 12 GB/T6170-2000
04 GB/T93-16 Washer,lock 垫圈16 12 GB/T93-1987
05 FB25DA-Q0003 Bolt 轮辋螺栓 12

06 FD45HA-B3000 Tire 轮胎7.00-12-13PR 2 GB/T2982-1982
6
5
1
4
3
28
28
驱动轮/DRIVE WHEEL(3t,3.5,3.8t SINGLE TIRE)

Item No Part No FD30,35
Description Q'ty Remark FG30,35
01 FD30MA-Q0001 Tire 轮胎28x9-15 2 GB/T2982-2001
02 FD30MA-Q0001 Rim assembly 轮辋总成 2

03 FD30MA-Q0002 Snap ring 挡圈7.00-15 2
29
29
转向轮/STEERING WHEEL
FD20,25,30,35
FG20,25,30,35 Item No Part No Description Q'ty Remark
01 FD30MA-B0001 Rim,inside 内轮辋 2 3.0t,3.5t
- FD25MA-B0002 Rim,inside 内轮辋 2 2.0t,2.5t
02 FD30MA-B0002 Tire 轮胎6.50-10-10PR 2 3.0t,3.5t
- FD25MA-B0001 Tire 轮胎6.00-9-10PR 2 2.0t,2.5t
03 FD30MA-B0003 Rim,outside 外轮辋 2 3.0t,3.5t
- FD25MA-B0003 Rim,outside 外轮辋 2 2.0t,2.5t
04 FD30MA-B0005 Nut 轮辋螺栓 16

1
05 GB/T6170-12 Nut 螺母M12 16 GB/T6170-2000
2
06 GB/T93-12 Washer 垫圈12 16 GB/T93-1987
5 6 3
30
30
轮式制动器/ WHEEL BRAKE(3t,3.5,3.8t )

Item No Part No FD30,35,38
Description Q'ty Remark
A FD30MA-C1200a Wheel brake ass'y(L.H) 制动器总成(左) 1
- FD30MA-C1200b Wheel brake ass'y(R.H) 制动器总成(右) 1
01 FD30MA-C1201 Cylinder 制动分泵缸 1
02 FD30MA-C1202 Piston 分泵活塞 2
03 FD30MA-C1203 Cup,piston 分泵皮碗 2
33
04 FD30MA-C1204 Spring 分泵弹簧 1 10
13 9
05 FD30MA-C1205 Cover,dust 分泵护罩 2 35 16
FD30MA-C1206 Rod,piston
6
06 分泵活塞顶杆 2 8 5
7
07 FD30MA-C1207 Plug 制动分泵油塞 1
34 2 3
4
08 FD30MA-C1208 Shroud 螺纹防护罩 1 19 3
09 FD30MA-C1209 Screw,breather 分泵放气螺钉 1
2
1
10 FD30MA-C1210 Cap,screw 分泵放气螺钉帽 1 36
11 FD30MA-C1211 Pin,shoe&lining ass'y 制动蹄带摩擦片总成(前) 1 16
12 FD30MA-C1212 Pin,shoe&lining ass'y 制动蹄带摩擦片总成(后) 1 5
13 FD30MA-C1213 Back plate 底板总成 1 左右对称各一
37 6
Left&right types 12 3 7
14 FD30MA-C1214 Adjuster cover 间隙调整套 1 左右旋螺纹各一 11
Left&right threads 21
15 FD30MA-C1215 Spring&Fitting ass'y 弹簧拉线装置 1 23
16 FD30MA-C1216 Pin,shoe hold down 压簧拉杆 2
15 22
17 FD30MA-C1217 Cup,shoe hold down 压簧座 4 31 32
18 FD30MA-C1218 Spring,shoe hold down 压簧 2 20 28
19 FD30MA-C1219 Cover,adjudsting hole 胶堵 1 29
26
20 FD30MA-C1220 Spring shoe 回位弹簧 1
40 27
21 FD30MA-C1221 Gudie plate 导向板 1
39
22 FD30MA-C1222 Retrun spring,brake shoe 制动蹄回位弹簧 2 17 38 25 24
18 14
23 FD30MA-C1223 Guide,cable 导向块 1 17
左右对称各一
24 FD30MA-C1224 Spring 弹簧 1 Left&right types
左右对称各一
25 FD30MA-C1225 Lever 棘爪 1 Left&right types
31
31
轮式制动器/ WHEEL BRAKE(3t,3.5,3.8t )

FD30,35,38 Item No Part No Description Q'ty Remark
26 FD30MA-C1226 Pin 销钉 1
左右对称各一
27 FD30MA-C1227 Rod 手制动推杆 1 Left&right types
28 FD30MA-C1228 Spring 弹簧 1
左右对称各一
29 FD30MA-C1229 Rod 手制动拉杆 1 Left&right types
33
10 30 FD30MA-C1230 Pin 销钉 1
13 9 31 FD30MA-C1231 Washer,spring 弹性垫片 1
35 16 6 32 FD30MA-C1232 Snap,rign,pin axle 杆销挡圈 1
8 5
7 33 制动钢索总成(左) 1
2 3
FD30MA-C1233 Cable L.H
34 4 - FD30MA-C1234 Cable R.H 制动钢索总成(右) 1
19 3
2 34 GB/T93-8 Washer,lock 垫圈8 2 GB/T93-1987
1
36 35 GB/T5783-8x20 Bolt 螺栓M8x20 1 GB/ T57 83- 200 0
36 FD30MA-C1235 Pin 支承销 2

16
5 37 FD30MA-C1236 Rivet 沉头铆钉 1
37 6 38 FD30MA-C1237 Adjuster bolt 间隙调螺丝 1 左右旋螺纹各一

12 37 Left&right threads
11 39 GB/T93-10 Washer 垫圈10 1 GB/T93-1987

21
40 FD30MA-C1238 Adjuster staff 间隙调整杆 1
23
15 22
31 32
20 28
29
26
40 27
39
17 38 25 24
18 14
17
32
32
传动装置安装（液力式）/DRIVE UNIT MOUNT(TOR-CON TYPE)

Item No Part No Description Q'ty FD30-QC2,N2
Remark FD30,35-W3,YM2
01 FD30HA-C1000 Drive unit 变速箱总成 1
Qc2 FD30-W2,
(手液) FG30,35-K2
_ Qc2 FD38-QC1,DC1
FD30YA-C1000 Drive unit 变速箱总成 1 (电液)
_
FD35HD-C1000 Drive unit 变速箱总成 1 3.5tDc1手液
_ FD35YD-C1000 Drive unit 变速箱总成 1 3.5tDc1电液
_ FG30HC-C1000 Drive unit 变速箱总成 1 K2手液
_ FG30YC-C1000 Drive unit 变速箱总成 1 K2电液
Qc1,3.8tDC1
FD40HA-C2000 Drive unit 变速箱总成 1 手液 4 5
_ W2,W3,YM2,N2,
FD30HB-C1000 Drive unit 变速箱总成 1 (手液)
_ FD30HB-C2000 Drive unit 变速箱总成 1
W2,W3,YM2,N2,
(电液)
04 GB /T 57 83 -1 2x 40 Bolt 螺栓M12x1.25x40 12 GB/T5783-2000
05 GB/T5782-10x35Bolt 螺栓M10x35 9 GB/T5782-2000
06 FD30MA-C0003 Packing 垫片 1
6
5 4
1
3
2
33
33
传动装置安装（机械式）/DRIVE UNIT MOUNT(CLUTCH TYPE)

FD30,35-QC2 Item No
FD35,38-DC1 Part No Description Q'ty Remark
FD38-QC1 01 FD30MA-C2000 机械变速箱总成 1 Qc2
- FD35MD-C1000 机械变速箱总成 1 Dc1
- FD38MAC-C1000 机械变速箱总成 1 Qc1
02 GB/T5783-12x40 螺栓M12x1.25x40 12 GB/T5783-2000
03 GB/T93-12 垫圈12 12 GB/T93-1987

24
04 FD30MA-C0003 垫片 1
9 05 GB/T119-8x30 销B8x30 1 GB/T119-1986
8 16
06 FD30MA-C3000 变速操纵杆总成 1
25 17
22 07 FD30MA-C4000 Levery,directi onchang 换向杆操纵杆总成 1
21 08 FD30MA-C0002 换向手柄 1
23 20
09 FD30MA-C0001 变速手柄 1
6
10 GB/T41-8 螺母M8 2 GB/T41-1986
7
19 12 11 GB/T5782-8x35 螺栓M8x35 2 GB/T5782-2000
12 11
18 12 GB/T93-8 垫圈8 10 GB/T93-1987
13 10 13 GB/T6170-8 螺母M8 2 GB/T6170-2000
14 GB/T5782-10x35 螺栓M10x35 9 GB/T5782-2000
15 GB/T93-10 垫圈10 9 GB/T93-1987
16 FD30MA-C2100 离合器摩擦片总成 1
1 15
17 FD30MA-C2200 离合器压盘及盖总成 1
2 14
18 GB/T5782-8x20 螺栓M8x20 6 GB/T5782-2000
5 3
19 GB/T95-8 垫圈8 1 GB/T95-2002
4
20 FD30MA-C0004 分离轴承套筒 6
21 FD30MA-C2300 分离轴承 1
22 FD30MA-C0005 支撑螺栓 1
23 GB/T6171-10 螺母M12x1.25 1 GB/T6171-2000
24 FD30MA-C0006 分离叉 1
25 FD30MA-C0007 弹簧挡圈 1
34
34
变速箱/TRANSMISSION
序号图号零部件名称件数备注 FD30,35
01 FD30HA-C2001 Case,tor-con 变矩器壳体 1
02 FD30HA-C2002 Cup 加油口盖
03 FD30HA-C2003 Pipe oil fill 加油管
04 y
FD30HA-C2004 Tor-con ass’ 液力变矩器 1
05 y
FD30HA-C2007 Charging pump ass’ 供油泵总成 1 60 61
24
06 FD30HA-C2008 Casket 垫片 1 2
07 FD30HA-C2009 Bolt 螺栓 2
3
53 20
08 FD30HA-C2010 Bolt 螺栓 4 51 52 58
28
29
54 59
27
09 FD30HA-C2011 Combinatorial gasket 组合密封垫圈 6
55
56
10 FD30HA-C2012 Plugs 螺塞 3 17
30
11 FD30HA-C2013 Plugs 螺塞 5 11
12 FD30HA-C2014 Shim 垫片 1
13 FD30HA-C2015 Bolt 螺栓 4 35
36
FD30HA-C2016 Bolt 41 37
14 螺栓 1 40
21 38 39
42 34 36
15 FD30HA-C2017 Bolt 螺栓 3 23
22 47 32
31 48
16 FD30HA-C2018 Bolt 螺栓 1 46 44 63 17
45 43
17 FD30HA-C2019 Spring washer 弹簧垫圈 20 50 5 98
13 6
16
18 FD30HA-C2020 Cylindrical pin 圆柱销 2
19 FD30HA-C2021 O-ring O形密封圈 2
23 15 7
12 17 4
20 FD30HA-C2022 Case 壳体 1
14
21 FD30HA-C2024 Bearing 轴承座 2 17
23 FD30HA-C2027 Locking pieces 锁片 2 18 11
24 FD30HA-C2029 Clutch,hydraulic 离合器总成 1

25 FD30HA-C2031 Shaft,idler 惰轮轴 1
26 FD30HA-C2032 Deep groove ball bearings 深沟球轴承 1
27 FD30HA-C2033 Gear,kdler 惰轮 2
35
35
28 FD30HA-C2034 Hole with elastic stalls circle 孔用弹性档圈 2
29 FD30HA-C2035 Hole with elastic stalls circle 深沟球轴承 2
30 FD30HA-C2036 Gear,output 输出齿轮 1
31 FD30HA-C2037 Shaft,output 输出轴 1
32 FD30HA-C2040 Bearing 圆锥滚子轴承 1
60 61
33 FD30HA-C2041 Bearing 圆锥滚子轴承 1
24
2 1
34 FD30HA-C2042 Oil seal cage 油封保持架
35 FD30HA-C2043 O-ring O形密封圈 1
3
53 20
58 29
51 52
54 59 28 36 FD30HA-C2044 Oil seal 油封 1
27
55 37 FD30HA-C2045 Nut 螺母 1
56
17
30 38 FD30HA-C2046 Gasket 垫 3
11 FD30HA-C2047
39 Gasket 垫 3
40 FD30HA-C2048 Gasket 垫 3
35 41 FD30HA-C2043 Collar 轴环 1
36
41 37
40 42 FD30HA-C2044 Gasket 垫片 3
21 38 39
42 34 36
23
22 47 32 43 FD30HA-C2045 Gasket 垫片 3
31 48
46 44 63 17 44 FD30HA-C2046 Gasket 垫片 3
45 43
50 5 98 45 FD30HA-C2047 Supporting piece 支承片 1
13 6
16
46 GB/ T57 83- 8x2 0 Bolt 螺栓 4
23 15 7 47 GB/T93-8 Spring Lock Washer 弹簧垫圈 4

12 17 4
48 GB/T5786-M10x1.25x20 Bolt 螺栓 6
14
17 49 FD30HA-C2048 Window hoods 窗盖 1
50 GB/T818-8X10 Screws 螺钉 2
18 11 GB/T70.1-10x30 Screws
51 螺钉 5
52 FD30HA-C2049 Oil filter seat 油滤座 1
53 FD30HA-C2050 Pad of paper 纸垫 1
54 FD30HA-C2051 Filter components 滤网组件 1
36
36
55 FD30HA-C2052 Screw 螺杆 1
56 GB/T6181-12 Nut 螺母 1
57 GB/T91-3.2X30 Pin 销 1
58 FD30HA-C2053 Block 堵塞 1
59 FD30HA-C2054 Combinatorial gasket 组合密封垫圈 1 60 61
24
60 FD30HA-C2055 Combinatorial gasket 标牌 1 2
61 GB/T827-2X5 Signs 标牌铆钉 4

3
GB/T6658-24x2.4 O-ring 53 20
62 O形密封圈 1 51 52 58
28
29
54 59
27
63 FD30HA-C2056 Washer 垫圈 1
55
56
17
30
11
35
36
41 37
40
21 38 39
42 34 36
23
22 47 32
31 48
46 44 63 17
45 43
50 5 98
13 6
16
23 15 7
12 17 4
14
17
18 11
37
37
传动装置(盖和微动阀)/DRIVE UNIT(COVER&INCHING VALVE )

FD30,35 序号图号零部件名称件数备注
01 FD30HA-C2101 C o v e r，C a s e 壳体盖 1
02 FD30HA-C2102 S h i f t Arm 变速臂 1
13
03 GB/T879-6x32 pin,lock 销6x32 1 GB/T879-1976
30 10 04 FD30HA-C2103 Shaft of Shift Arm 变速臂轴 1

17 11 12
7 05 GB/T1235-20x2.4 O-Ring O形密封圈20x2.4 1 GB/T1235-1976
16 8 36
18 06 GB/T1099-5x19 Key,Woodruff 半圆键5 x19 1 GB/T1099-1979
29
15 9 07 FD30HA-C2104 Set Bolt 固定螺栓 1
1 19
14 08 FD30HA-C2105 Shim 衬垫 7
20 4
27 6 09 FD30HA-C2106 Plug 塞子 1
5 10 FD30HA-C2107 Switch 倒车灯开关 2
2
11 FD30HA-C2108 Shim 垫片 2
3
37 12 FD30HA-C2109 Nipple 管接头 1
22 13 FD30HA-C2110 Filter,Oil 滤油器 1
31
21 35 14 GB/T879-4x25 Pin,lock 弹性圆柱销4 x25 1 GB/T879-1976
15 FD30HA-C2111 Piston 活塞 1
26
16 FD30HA-C2112 Spring 弹簧 1
23
24 17 FD30HA-C2113 Cup 安全阀盖 1
28
18 FD30HA-C2114 Packing ,copper 衬垫 1
19 FD30HA-C2115 Plug 螺塞 6
32 20 FD30HA-C2116 Plug 螺塞 4
26 21 FD30HA-C2117 Control ass'y 控制阀总成 1
33 34 22 FD30HA-C2118 Electric-controller 电液控件阀 1
hydraulic valve
23 FD30HA-C2119 Gasker 垫片 1
26 25 24 GB/T5782-8x35 Bolt 螺栓M8x35 2 GB/T5782-2000
27 GB/T93-8 Shim 垫圈8 11 GB/T93-1987

38
38
传动装置(盖和微动阀)/DRIVE UNIT(COVER&INCHING VALVE)

序号图号零部件名称件数备注 FD30,35
28 FD30HA-C2120 Washer,lock 垫片 1
29 GB/T1235-9x1.9 O-ring O形圈9x1.9 2 GB/T1235-1976
30 GB/T93-10 Gasket 垫圈10 8 GB/T93-1987

13
31 GB/T5782-10x55 Bolt 螺栓M10x1.25x55 2 GB/T5782-2000 30 10
17 11 12
32 FD30HA-C2121 lnching value ass'y 微动阀总成 1 7
33 GB/T95-8 Shim 垫圈8 2 GB/T95-2002 16 8 36
18 29
34 FD30HA-C2122 Shim 衬垫 1 15 9
1 19
14 20 4
36 FD30HA-C2123 Cover,tor-con 变矩器盖 1 27 6
37 GB/T5785-10x40 Bolt 螺栓M10x1.25x40 6 GB/T5785-2000 5
2
3
37
22
31
21 35
26
23
24
28
32
26
33 34
26 25
39
39
液力离合器(液力式)/HYDRAULC CLUTCH(TOR-CON TYPE)

A FD30HA-C2200 Clutch,hydraulic 离合器总成 1
01 FD30HA-C2201 Shift,input 输入轴总成 1
02 FD30HA-C2202 Gear,revease 倒车档齿轮 1
03 FD30HA-C2203 Gear,forward 前进档齿轮 1
04 FD30HA-C2204 Plate,end 端板 2
4
05 FD30HA-C2205 Spring,return 回程弹簧 2
17
5 06 FD30HA-C2206 Seat,spring 弹簧座 2
20 6
07 FD30HA-C2207 Ring,thrust 止推环A 2
3 7 08 FD30HA-C2208 Ring,thrust 止推环B 2
19
18 8 15
9 09 FD30HA-C2209 Piston 活塞 1
14 11 10 FD30HA-C2210 Plug 塞 1
10
11 FD30HA-C2211 Ball,steel 钢球 1
16 21 12 FD30HA-C2212 Plate,friction 摩擦片 8

10 FD30HA-C2213 Plate,separator
11 1 13 隔片 8
15
14 FD30HA-C2214 Ring,seal 密封环A 4
9
12 15 FD30HA-C2215 Ring,seal 密封环B 2
13 14
16 FD30HA-C2216 O-ring O形圈 2
20 18
8 17 FD30HA-C2217 Snap,ring 卡环 2
19
2 18 FD30HA-C2218 Bearing 轴承 2
7
6 19 FD30HA-C2219 Bearing,needle 滚珠轴承 2
5 20 GB/T894-40 Snap,ring 挡圈40 2 GB/T894-2000
17 21 GB/T78-8x8 Plug 螺钉M8x8 2 GB/T78-1985

4
40
40
控制阀(液力式)/CONTROL VALVE(TOR-CON TYPE)

Item No Part No Description Q'ty Remark FD30,35
A FD30HA-C2300 Control valve ass’y 控制阀总成 1

01 FD30HA-C2301 Body,valve 阀体 1
02 FD30HA-C2302 Selector 滑阀 1
03 FD30HA-C2303 Plug 油塞 1
05 FD30HA-C2305 Ball 钢球 1 15
10 3
06 FD30HA-C2306 Piston 活塞 1
4
09 FD30HA-C2309 Plug 塞 1
10 FD30HA-C2310 Pin,lock 弹性圆柱销 1
5
11 FD30HA-C2311 Spool 卷轴 1
12 FD30HA-C2312 Spring 弹簧 1 6
13 FD30HA-C2313 Spring 弹簧 1 8
14 FD30HA-C2314 Plug 塞 1
15 FD30HA-C2315 Pin,lock 弹性圆柱销 1 7
1
9
2
13
12
14
41
41
微动阀(液力式)/INCHING VALVE(TOR-CON TYPE)

01 FD30HA-C2400 Body,Inching Valve 微动阀体 1
02 FD30HA-C2401 Spool 微动阀杆 1
03 FD30HA-C2402 Oil Seal 油封 1
04 FD30HA-C2403 Plate 垫块 1
05 FD30HA-C2404 O-Ring O型密封圈 1
06 FD30HA-C2405 Circlips For Holes 孔用弹性挡圈 1
3 07 FD30HA-C2406 Spring 弹簧 1
13
4 08 FD30HA-C2407 Spring 弹簧 1
7 09 FD30HA-C2408 Plug 堵塞 1
10 FD30HA-C2409 Pluger 微动滑阀 1
2
11 12 11 FD30HA-C2410 Plug 节流螺塞 1
13 FD30HA-C2412 Circlips For Holes 孔用弹性挡圈 1
12
10
9 8
6 5
42
42
供油泵/CHARGING PUMP
01 FD30HA-C2500 Case,Pump 泵壳 1
02 FD30HA-C2501 Bushing 衬套 1
04 FD30HA-C2503 Oil,Seal 油封 1
05 FD30HA-C2504 O-Ring O型密封圈 1
06 FD30HA-C2505 Stator Seat 导轮座 1
07 FD30HA-C2506 Parallel Pins 圆柱销 2
08 FD30HA-C2507 Driving Gear 主动齿轮 1
10
09 FD30HA-C2508 Bushing 衬套 1
10 FD30HA-C2509 Driven Gear 被动齿轮 1
8 9
11 12
13 FD30HA-C2512 Combined Sealing Washer 组合密封垫圈 2 13
6
7
1
2 3
1
43
43
差速器总成/DIFFERENTIAL
FD30,35 序号图号零部件名称件数备注
01 FD30MA-C2601 Shaft,Final Pinion 齿轴 1
02 FD30MA-C2602 Spiral Bevel Gear 螺旋伞齿轮 1
03 FD30MA-C2603 Bushing 衬套 1
04 FD30MA-C2604 Tapered Roller Bearing 圆锥滚子轴承 2
05 FD30MA-C2605 Cover,Bearing 轴承盖 2
06 FD30MA-C2606 O-Ring O形密封圈 2
5 6 07 FD30MA-C2607 Bolt 螺栓 8
11
10 9 08 FD30MA-C2608 Spring Lock Washer 弹簧垫圈 8
4 09 FD30MA-C2609 Shim 垫片 1
7
8 10 FD30MA-C2610 Shim 垫片 1
11 FD30MA-C2611 Shim 垫片 1
1 32 12 FD30MA-C2612 Gear Ring 齿圈 1
4 910
13 13 FD30MA-C2613 Bolt 螺栓 16
28 11
29 6 5 14 B5050-00001 Nut 螺母 16
15 15 FD30MA-C2614 Washer Lock 锁片 8
14
16 FD30MA-C2615 Case.R.H,Differential Gear 右差速器壳 1
28 17 FD30MA-C2616 Case.L.H,Differential Gear 左差速器壳 1
12 25 6 7
19 18 FD30MA-C2617 Pinion Shaft 齿轮轴(Ⅰ) 1
16 24 25 27 19 FD30MA-C2618 Pinion Shaft 齿轮轴(Ⅱ) 1
26 20 FD30MA-C2619 Paraller Pins 圆柱销 1
18 21 22
23 21 FD30MA-C2620 Cear Side 半轴齿轮 2
24
17 22 FD30MA-C2621 Shim 垫圈 2
30
23 FD30MA-C2622 Shim 垫圈 2
24 FD30MA-C2623 Shim 垫圈 2
25 FD30MA-C2624 Planetary Pinion 行星齿轮 4
26 FD30MA-C2625 Washer,Thrust 止推垫圈 4
44
44
差速器总成/DIFFERENTIAL
Item No Part No Description Q'ty Remark FD30,35
28 FD30MA-C2628 Bolt 螺母 12
29 FD30MA-C2627 Washer,Lock 锁紧垫片 6
30 FD30MA-C2628 Deep Groove Ball Bearings 深沟球轴承 2
5 6
11
10 9
4
7
8
1 32
4 91 0
13
28 11
29 6 5
15
14
28
12 25 6 7
19
16 24 25 27
26
18 21 2 2
23
24
17
30
45
45
车架与平衡重(3.8t)/FRAME AND COUNTER WEIGHT(3.8t)

FD38-DC1,QC1 Item No Part No Description Q'ty Remark
01 FD38HDC-A1000 Frame 车架 1 Dc1
- FD38HAC-A1000 Frame 车架 1 Qc1
02 FD38HAC-A5001 Counter weight 平衡重 1

03 FD30MA-A5003 Cap 平衡重盖 2
04 FD30YBJ-A5100 Pin 牵引销总成 1
05 FD30MA-A5004 Bolt 平衡重螺栓 2
07 FD30MA-A5002 Washer 加厚平垫 2

08 FD30MA-K0001 Cap,frontaxlesupport 支座盖 2
46
46
车架与平衡重(3t,3.5t)/FRAME AND COUNTER WEIGHT(3t,3.5t)

Item No FD30,35
Part No Description Q'ty Remark
01 FD30MAC-A1000 Frame 车架 1 Qc2
- FD30HBC-A1000 Frame 车架 1 W2
- FD35HDC-A1000 Frame 车架 1 3.5tDc1
- FG30HCC-A1000 Frame 车架 1 K2
- FD30HLC-A1000 Frame 车架 1 N2
- FD30HCC-A1000 Frame 车架 1 W3
- FD30YKC-A1000 Frame 车架 1 Ym2
02 FD30MAC-A5001 Counter weight 平衡重 1 3 .0t
- FD35MAC-A5001 Counter weight 平衡重 1 3 .5t
03 FD30MA-A5003 Cap 平衡重盖 2

04 FD30YBJ-A5100 Pin 牵引销总成 1
05 FD30MA-A5004 Bolt 螺栓 2
07 FD30MA-A5002 Washer 加厚平垫 2
08 FD30MA-K0001 Cap,frontaxlesupport 支座盖 2

47
47
转向桥/STEERING AXLE
01 FD30MA-G1001 Axle ass'y 桥体 1 3.0t,3.5t
- FD25MA-G1001 Axle ass'y 桥体 1 2.0t,2.5t
02 FD30MA-G1003 Link 连杆 2
36
03 FD30MA-G1100 Power cylinder 转向缸 1
38 37
39 27 04 FD30MA-B0004 Rubber 减震块 2
2 2
05 FD30MA-A1304 Bracket 转向桥支架
40
33 3 06 FD30MA-G1300 Knuckle R.H.ass'y 转向节（右） 1
6 41 5 07 GB/T310--51208 Bearing 推力轴承51208 2 GB/T310-1993
4 08 GB/T290-943/32 Bearing 滚针轴承943/32 4 GB/T290-1989
09 FD30MA-G1002 Pin,king 销轴 2
10 GB/T119-10x20 Pin 销G10x20 2 GB/T119-1986
4 11 11 FD30MA-B0005 Shim 调整垫 4

35
25 15 12 GB/T9877.1-85x110x12 U-ring U型密封圈B85x110x12D 2 GB/T9877.1-1988
8
7 26 13 FD30MA-B0006 Shim 转向节调整垫 2
5
28 14 GB/T6172-12 Nut 螺母M12 18 GB/T6172-1986
42 15 FD30MA-B0007 Cap 防尘罩 2

31 23
8 44 16 GB/T297-7211E Bearing 轴承7211E 2 GB/T297-1984
32
43 9 24 17 GB/T297-7207E Bearing 轴承7207E 2 GB/T297-1984
18 FD30MA-B0008 Nut 螺母M30x2 2

13
12 19 GB/T97.1-30 Washer 垫圈30 2 GB/T97.1-1985
16 18 20 GB/T92-6.3x55 Pin 销6.3x55 2

22 GB/T92-1986
17 21 FD30MA-G1005 Cap 轮毂盖 2

19
20 22 FD30MA-G1004 Hub 轮毂 2
21 23 FD30MA-B0009 Pin 紧固销 2
24 GB/T6171-10 Nut 螺母M10x1.25 2 GB/T6171-1986
25 GB/T6170-16 Nut 螺母M16 4 GB/T6170-1986
26 FD30MA-B0010 Bushing 衬套 2
48
48
转向桥/STEERING AXLE
序号图号零部件名称件数备注 FD30,35,38
27 FD30MA-G1100 Fitting grease 直通式滑脂嘴M6 4
28 FD30MA-G1200 Knuckle R.H.ass'y 转向节（左） 1
30 GB/T93-14 Washer 垫圈14 4 GB/T93-1987

36
31 FD30MA-B0012 O-ring O形圈 2
38 37
32 FD30MA-B0013 Seal,oil 油封 2 39 27
2
33 FD30MA-B0014 Bushing 衬套 4
40
34 GB/T5782-12x30 Bolt 螺栓M12x30 2 GB/T5782-1986 33 3
35 ZBT33001.1-Z1/8 Fitting grease 弯颈式滑嘴Z1/8” 2 ZBT33001.1-1988
6 41 5
36 GB/T5780-8x18 Bolt 螺栓M8x18 4 GB/T5780-1986 4
37 GB/T93-8 Washer 垫圈8 4 GB/T93-1987
38 FD30MA-B0015 Baffle 挡板 2
39 FD30MA-G1451 Pin 连杆销 4 4 11
35
40 FD30MA-B0016 Bearing Es型向心关节轴承 4 25 8 15
41 FD30MA-B0017 Shim 调整垫 4 5 7
42 GB/T93-16 Washer 垫圈 4 GB/T93-1987 28
43 GB /T 57 82 -1 6x 55 Bolt 螺栓M16x55 4 GB/T5782-1986 42 31 23
8 44
44 GB/T97.1-10 Bolt 垫圈 2 GB/T97.1-1985
32
43 9 24
13
12
16 18
22
17
19
20
21
49
49
转向油缸/STEERING CYLINDER
01 FD30MA-G1101 Piston rod ass'y 活塞杆总成 1
02 FD30MA-G1102 Cap 缸盖 2
03 FD30MA-G1103 Seal,dust 防尘圈 1
04 FD30MA-G1104 U-ring U密封圈50x60x8 2
05 GB/T3452.1-63x3.55 O-ring O形圈63x3.55 2 GB/T3452.1-1982
06 GB/T3452.1-63x3.55 O-ring O形圈63x3.55 1 GB/T3452.1-1982

3
10 11 07 FD30MA-G1105 Seal,slipper 支撑环 1
12 4 08 FD30MA-G1106 Body,power steering 缸筒总成 1
2
5 09 FD30MA-G1107 Bearing 钢背轴承5030 2
9 10 GB/T93.1-72 Snap ring 挡圈72 2 GB/T93.1-1986
8 11 FD30MA-G1108 Ring 挡环 2
12 FD30MA-G1109 Snap shim 挡片50x60x3 2
7
6
1
9
5
2 4 3
50
50
转向系统/STEERING SYSTEM
Item No Part No Description Q'ty FD30,35,38
Remark
33
28
32 26 27
16
31 23 5
14 4
1 15
17
36 21
18 24 7
25 22
19 6
23
29 2 20 8
30
29
3
13
34
9
10 35
11
12
26 GB/T93-8 Washer 垫圈8 1 GB/T93-1987
51
转向系统/STEERING SYSTEM
28 FD30MA-M7000 Handle Shaft Ass'y 方向盘总成Φ300 1
29 FD30MA-M0016 Snapring 弹簧挡圈20 2
30 Z-61904-2Z Bearing 轴承61904-2Z 1
E
GB/T276-94
33 31 FD30MA-M3002 Spacer Ass'y 衬套 1

32 FD30MA-M3001 Shaft 转向轴 1
28 33 GB/T6173-16 Nut 螺母M16x1.5 1 GB/T6173-865
34 FD30MAC-M6000 Orbitrol 转向器（125ml/r） 1

35 FD30MA-M0021 Flange 连接法兰 1
36 FD30MA-M0017 Grommet 喇叭线套 1
32 26 27
16
31 23 5
14 4
1 15
17
36 21
18 24 7
25 22
19 6
23
29 2 20 8
30
29
3
13
34
9
10 35
11
12
52
52
操纵杆总成（两片）/VALVE CONTROL LINKAGE(TOW-THROW)

Remark
01 FD30MA-Y9006 Knob,lift 升降手柄 1
02 FD30MA-Y3300 Lever,lift 升降阀杆 1
03 FD30MA-Y3001 Bracket,valvelever 阀杆支架 1
04 FD30MA-Y3002 Bushing 衬套 2
05 GB/T5782-8X20 Bolt 螺栓M8x20 4 GB/T5782-1986 21
06 GB/T93-8 Wsher 垫圈8 4 GB/T93-1987
07 GB/T97.1-8 Wsher 垫圈8 4 GB/T97.1-1985

20 1
08 FD30MA-Y3003 Shim 垫片 2
09 GB/T5783-10X3 5 Bolt 螺栓M10x1.25x35 3 GB/T5783-1986
10 FD30MA-Y3006 Pin 销钉 4 2
4
11 GB/T93-6 Washer 垫圈6 4 GB/T93-1976
8
12 GB/T91-2X12 Pin,cotter 开口销φ2x12 4 GB/T91-1986 4
12
13 GB/T67-6X12 Bolt 螺钉M6x12 4 GB/T67-1985
13
11 10
14 FD30MA-Y3200 Shaft,valve 连接轴 1
15 FD30MA-Y3004 Joint 连接杆 2 14

16 FD30MA-Y3100 Contrl ass'y 多路阀总成 1 6
17 FD30MA-Y3008 Coller 套管 3
7 3
18 FD30MA-Y3007 Rubber 减振垫 6 5 1 21 1
19 GB/T96-10 Washer 大垫圈10 3 GB/T96-1985
10
20 FD30MA-Y3400 Lever,tilt 倾斜阀杆 1 18
21 FD30MA-Y9007 Knob,tilt 倾斜手柄 1 17
19 18
9 16
53
53
操纵杆总成（三片）/VALVE CONTROL LINKAGE(THREE-THROW)

06 GB/T93-8 Wsher 垫圈8 4 GB/T93-1987

24
22 07 GB/T97.1-8 Washer 垫圈8 4 GB/T97.1-1985
23
08 FD30MA-Y3003 Shim 垫片 4
1
21 09 GB/T57 83-10X 35 Bolt 螺栓M10x1.25x35 3 GB/T5783-1986
20 10 FD30MA-Y3006 Pin 销钉 6
4 2 11 GB/T93-9 Washer 垫圈6 6
84 GB/T93-1976
12 GB/T91-10X35 Pin,cotter 开口销φ2x12 6 GB/T91-1986

12 84
13 13 GB/T67-6X12 Bolt 螺钉M6x12 1 GB/T67-1985
11 10 14 FD30MA-Y3200 Shaft,valve 连接轴 1
14 15 FD30MA-Y3004 Joint 连接杆 3
6 15 16 FD30MA-Y3100 Contrl ass'y 多路阀总成 1
7 3 12
5 11 18 FD30MA-Y3007 Rubber 减振垫 6
10 19 GB/T96-10 Washer 大垫圈10 3 GB/T96-1985
18
19 20 FD30MA-Y3012 Coller 调节套 1
21 FD30MA-Y3400 Lever,tilt 倾斜阀杆 1
17 18 22 FD30MA-Y9007 Knob,tilt 1
16 倾斜手柄
9
23 FD30MA-Y3500 Lever,third 第三片阀杆 1
24 FD30MA-Y9006 Knob 手柄 1
54
54
操纵杆总成（四片）/VALVE CONTROL LINKAGE(FOUR-THROW)

Remark
06 GB/T93-8 Wsher 垫圈8 4 GB/T93-1987 23

23
07 GB/T97.1-8 Washer 垫圈8 4 GB/T97.1-1985
FD30MA-Y3003 Shim 垫片 21
08 6 25
09 GB/T5783-10X35 Bolt 螺栓M10x1.25x35 3 GB/T5783-1986 24 1
10 FD30MA-Y3006 Pin 销钉 6 20
4
11 B5050-00008 Washer 垫圈6 6 GB/T93-1976 84 2
12 B3011-02012 Pin,cotter 开口销φ2x12 6 GB/T91-1986 84
12 84
13 GB/T-6X12 Bolt 螺钉M6x12 1 GB/T67-1985
11
14 FD30MA-Y3200 Shaft,valve 连接轴 1 10
15 FD30MA-Y3004 Joint 连接杆 3
15
16 FD30MA-Y3100 Contrl ass'y 多路阀总成 1
12 11
18 FD30MA-Y3007 Rubber 减振垫 6 10
GB/T96-10 Washer 大垫圈10 3
18
19 GB/T96-1985
17
20 FD30MA-Y3400 Lever,tilt 倾斜阀杆 1
21 FD30MA-Y9007 Knob,tilt 倾斜手柄 1 18
19
22 FD30MA-Y3500 Lever,third 第三片阀杆 1
9
23 FD30MA-Y9006 Knob 手柄 2
24 FD30MA-Y3600 Lever,fourth 第四片阀杆 1
55
55
液压系统/HYDRAULIC SYSTEM
FD30,35,38-QC1,QC2,N2 序号图号零部件名称件数备注
FD30,35,38-DC1,W3,YM2 Item No Part No Description Q'ty Remark
FD30-YM1,W2, FD30MA-Y3000 Valve contgol linkeg 操纵阀杆总成
FG30,35-K2 01 1
02 FD30MA-Y2000 Vteel pipe ass'y 倾斜钢管总成 1
03 TGLBI-06030 Hose H.P 高压胶管 2
04 TGIBL-06034 Hose H.P 高压胶管 2
05 TGIBI-08200 Hose H.P 高压胶管 1
06 TGIBI-08210 Hose H.P 高压胶管 1

1 07 TGIBII-13117 Hose H.P 高压胶管05 1
18 19 08 GJT-001-00 Elbow 油泵接头 1

20
09 GJT-002-00 Elbow 直角接头 1
17
10 FD30MA-Y0001 Hose 油管01 1
16 11
2 11 FD30MA-Y1000 Cover plate ass'y 液压油箱盖板总成 1
3 21 12 12 FD30MA-D1001 Cover gasket 盖板垫 1
4 9
13 FD30MA-Y0002 Hose 油管02 1 QC1,QC2,K2
13
10 - FD30HB-Y0001 Hose 吸油管 1 W2,YM2
14 15 - FD35HD-Y0001 Hose 吸油管 1 DC1
- FD30HL-Y0001 Hose 吸油管 1 N2
- FD35HC-Y0001 Hose 吸油管 1 W3
14 GJT-010-00 Nipple 直通接头 1

7 8
15 FD30MA-Y8000 Pump 齿轮油泵 1 Qc2
- FD30HB-Y1000 Pump 齿轮油泵 1 W2,YM1,YM2
- FG30HC-Y1000 Pump 齿轮油泵 1 K2,W3,N2
- FG30HC-Y1000 Pump 齿轮油泵 1 3.5tDc1
5 6 - F D 4 0 H C - Y 1 0 0 0 Pump 齿轮油泵 1 3.8tDc1
- F D 4 0 H A - Y 1 0 0 0 Pump 齿轮油泵 1 QC1
16 GB/T8870-1619 Clip 双钢丝卡箍 φ16-19 2 GB/T8870-1999
17 FD30MA-Y0005 Hose 胶管φ12x100 1

18 FD30MA-Y7000 Breather 呼吸器 1
56
56
液压系统/HYDRAULIC SYSTEM
Item No Part No Description Q'ty FD30,35,38-QC1,QC2,N2
Remark FD30,35,38-DC1,W3,YM2
FD30-YM1,W2,
FG30,35-K2
20 GB/T93-8 Spacer 垫圈8 8 GB/T93-1987
Oiling cap
G
21 FD30MA-Y6000 加油盖 1
18 19
20
17
16 11
2
3 21 12
4 9
13
10
14 15
7 8
5 6
57
57
液压油箱/OIL TANK
FG30,35
01 FD30MA-Y6000 Oiliing cap 加油盖 1
02 FD30MA-Y1000 Cover plate ass'y 液压油箱盖板总成 1
03 FD30MA-D1001 Cover gasket 盖板垫 1
10
04 GB/T5783-8X20 Bilt 螺栓M8x20 1 GB/T5783-1985
4 12 GB/T93-8
05 Washer 垫圈8 8 GB/T93-1987
5 11 06 FD30MA-Y5000 Strainer 回油滤清器 8
12
07 FD30MA-Y4000 Strainer 吸油滤清器 1
2
08 JB/T982-18 Washer 组合垫圈18 1 JB/T982-1977
3 09 FD30MA-D1007 Drain plug 放油螺塞 1

10 FD30MA-Y7000 Breather 呼吸器 1
7 11 FD30MA-Y0005 Hose 胶管φ12x10 1
1
12 GB/T8870-1619 Clip 涡轮蜗杆卡箍φ16-19 2 GB/T8870-1999
8
9
58
58
护顶架/OVERHEAD GUARD
Remark FG30,35
01 FD30MA-H1000 Overhead guard 顶棚总成 1
02 GB/T17880.1-6 Flat head rivet nuts M6 平头铆螺母M6 8 GB/T17880.1-1999
03 FD30MA-H1455 Before the lighthouse 前灯架 2
04 GB/T95-6 Washer 垫圈6 6 GB/T95-2002
05 GB/T93-6 Washer 垫圈6 8 GB/T93-1987 13

06 GB/T5783-6X20 Bolt 螺栓M6X20 8 GB/T5783-2000
1
07 FD30MA-H0001 Outlet apron 出线胶圈 36 4
08 FD30MA-H0003 Side mirror 倒车镜 2
09 FD30MA-H0002 Side mirror bracket 倒车镜支架 2

10 FD30MA-H0004 Handle 把手 1
11 FD30MA-H0005 Into the hood 进气罩 1 11
5 8 12
12 FD30MA-H0006 Outlet apron 出线胶圈 25 2 8 9 3
13 FD30MA-H0007 Ceiling plastic cover 顶棚塑料罩 5 25 5 52
6 5
14 GB/T95-16 Washer 垫圈16 4 GB/T95-2002
2 2
15 GB/T93-16 Washer 垫圈16 4 GB/T93-1987
9 6
GB/T5783-16X40 Bolt 4
10
16 螺栓M16x40 GB/T5783-2000
24 23
17 GB/T95-12 Washer 垫圈12 4 GB/T95-2002 22
18 GB/T93-12 Washer 垫圈12 4 GB/T93-1987 7 21
23
19 GB/T6170-12 Nut 螺母M12 4 GB/T6170-2000
15
20 FD30MA-H0009 Left rear support baffle 左后支撑挡板 1
22 17 7
21 FD30MA-H0008 Right rear support baffle 右后支撑挡板 1 18 16
22 4
20
GB/T818-6X16 Screw 螺钉M6x16 GB/T818-2000
19 14
23 FD30MA-H0011 Front outrigger rubber pad 前支腿橡胶垫 2
24 FD30MAC-H3000 Right rear support 右后支撑 1
25 FD30MAC-H2000 Left rear support 左后支撑 1
59
59
组合仪表/COMBINATION M/T,TYPE
FG30,35
01 FD30MA-E1001 Left turn signal 左转向指示灯 1
02 FD30MA-E1002 Oil-water separator indicator 油水分离指示灯 1
03 FD30MA-E1003 Oil pressure indicator 油压指示灯 1
04 FD30MA-E1004 Charge indicator 充电指示灯 1
05 FD30MA-E1005 Neutral indicator light 空档指示灯 1
1 2 34 5 6 78 06 FD30MA-E1006 Preheat indicator 预热指示灯 1
07 FD30MA-E1007 Air filter indicator 空气滤清指示灯 1
08 FD30MA-E1008 Right turn indicator 右转向指示灯 1
N
09 FD30MA-E1009 Fuel dial 油量表盘 1
75
工作正常
1/2
10 FD30MA-E1010 Water temperature dial 水温表盘 1
110
C H E F
11 FD30MA-E1011 LCD monitors 液晶显示器 1
10 11 9
A图
16 12 8 4
15 11 7 3
14 10 6 2
13 9 5 1
B图
60
60
机罩底板及座椅/HOOD,FLOOR BOARD AND SEAT

Remark FG30,35
01 FD30MA-A7100 Bracket 支架总成 1
02 GB/T96-8 Washer 垫圈8 10 GB/T96-1985

13
H
05 FD30MA-A7001 Hinge 机罩铰链 2
06 ZCZ20-1020 Bearing 钢背轴承1020（δ2） 2
15 20
07 FD30MA-A7002 Bolt 铰链螺栓 2 17 21
08 GB/T6170-8 Nut 螺母M8 2 GB/T6170-1986
16
09 FD30MA-A7200 Shock,absorber 气弹簧640x270x750N 1
10 FD30MA-A7300 Floor board 前底板总成 1 机械 2 4
- FD30HA-A1000 Floor board 前底板总成 1 液力
14
11 GB/T818-8X16 Bolt 螺钉M8x16 2 GB/T818-1985
3
12 FD30MA-A7400 Floor board 后底板总成 1 机械 1
- FD30HA-A2000 Floor board 后底板总成 1 液力
6
- FG30HA-A1000 Floor board 后底板总成 1 仅B1液力用 18 7
19
13 FD30MA-A7500 Seat 座椅总成 1 23 11 5
27 29
14 FD30MA-A7600 Bonnet 机罩总成 1 26
22 8
15 GB/T95-10 Washer 垫圈10 4 GB/T95-1985
25
16 GB/T93-10 Washer,lock 垫圈10 4 GB/T93-1987 9
24 28
10
18 FD30MA-A7700 Bracket 电瓶支架总成 1
12
31
- FD30HB-A7100 Bracket 电瓶支架总成 1 带副水箱用
19 FD30MA-A7003 Box 工具盒 1 30

20 FD30MA-A7006 Cover 水箱盖板 1
21 FD30MA-A7007 Scerew 水箱盖板螺钉M8 2
22 FD30MA-A7008 Cushion 前底板隔音垫 1
23 FD30MA-A7009 Cushion 后底板隔音垫 1
61
61
机罩底板及座椅/HOOD,FLOOR BOARD AND SEAT

FG30,35
24 FD30MA-A7800 Catch 机罩下挂钩总成 1
26 FD30MA-A7900 Catch 机罩上挂钩总成 1
13
H
28 FD30MA-A7011 Box 挂钩盒 1

15 20 29 FD30MA-A7702 Rubber 橡胶垫I 1
17 21 30 FD30MA-A7004 Pedal 踏板(左) 1
16
31 FD30MA-A7005 Pedal 踏板(右) 1
2 4
14
3
1
6
18 7
19
23 11 5
27 29
26
22 8
25
9
24 28
10
12
31
30
62
62
电气系统/ELECTRIC SYSTEM
Item No Part No Description Q'ty FD30,35-QC2
Remark
01 FD30MA-E0003 Head lamp ass`y 前照灯 2
02 FD30MA-E0004 Front combination lamp ass`y 双面前小灯 2
03 FD30MA-E4000 Harness 护顶架线束 2
04 FD30MA-E0001 Combination M/T 组合仪表 1 机械
L
05 FD30MA-E3000 Cabinet harness 仪表架线束 1 机械
06 FD30MA-E0005 Rear combination lamp 后尾灯 1

07 FD30MA-E0006 Horn 喇叭 1
08 FD30MA-E0007 Brake switch 刹车灯开关 1
09 FD30MA-E2000 Engine harness 发动机线束 1
10 FD30MA-E7000 Cable 正极电瓶引线 1
11 FD30MA-E6000 Electrical control box 电器控制盒 1
12 FD30MA-E8000 Cable 负极电瓶引线 1
13 FD30MA-E0008 Back buzzer 倒车蜂鸣器 1
14 FD30MA-E0002 Fuse 易熔丝 1
15 FD30MA-E0009 Water temp sensor 水温传感器 1

16 FD30MA-E0011 Switch,turn signal 转向灯开关 1
17 FD30MA-E9000 Battery 蓄电池 1
63
63
FD30,35-QC2 Item No Part No Description Q'ty Remark
04 FD30HA-E0001 Combination M/T 组合仪表 1
05 FD30HA-E3000 Cabinet harness 仪表架线束 1 手液
- FD30YA-E3000 Cabinet harness 仪表架线束 1 电液

09 FD30MA-E2000 Engine harness 发动机线束 1 手液
- FD30YA-E2000 Engine harness 发动机线束 1 电液

15 FD30MA-E0011 Switch,turn signal 转向灯开关 1 手液
- FD30YA-E0011 Switch,turn signal 组合开关 1 电液
16 FD30HA-E0013 Oil temp sensor 油温传感器 1
64
Item No Part No Description Q'ty FD30,35-N2
Remark FD30,35-YM2
01 FD30MA-E0003 Head lamp ass`y 前照灯 2 FD30,35-W2
FG30,35-K2
- FD30HA-E0001 Combination M/T 组合仪表 1 手液，电液
05 FD30YA-E3000 Cabinet harness 仪表架线束 1

09 FD30HB-E2000 Engine harness 发动机线束 1 W2
- FD30MK-E2000 Engine harness 发动机线束 1 YM1,YM2
- FG30HC-E2000 Engine harness 发动机线束 1 K1,K2
- FD30HL-E2000 Engine harness 发动机线束 1 N2
10 FD30HB-E7000 Cable 正极电瓶引线 1

15 FDA0YD-E0009 Water temp sensor 水温传感器 1 W2,K1,K2,N2
- FD30MK-E0009 Water temp sensor 水温传感器 1 YM1,YM2
16 FD30MA-E0011 Switch,turn signal 转向灯开关 1 机械,手液
17 FD30HA-E0013 Oil temp sensor 油温传感器 1 手液，电液
65
65
FD30,35-W3 Item No Part No Description Q'ty Remark
05 FD30YA-E3000 Cabinet harness 仪表架线束 1

09 FG30HA-E2000 Engine harness 发动机线束 1 B1
- FD30HM-E2000 Engine harness 发动机线束 1 Jb1
- FD25YC-E2000 Engine harness 发动机线束 1 W3
- FD30HN-E2000 Engine harness 发动机线束 1 S2

15 FD30HN-E0009 Water temp sensor 水温传感器 1 S2
- FDAOYD-E0009 Water temp sensor 水温传感器 1 W3
16 FD30MA-E0011 Switch,turn signal 转向灯开关 1 机械,手液

66
66
Item No Part No Description Q'ty FD30,35-DC1
Remark
03 FD30MA-E4000 Right right harness 护顶架线束 2
05 FD30MA-E3000 Cabinet harness 仪表架线束 1 机械
- FD30HA-E3000 Cabinet harness 仪表架线束 1 手液
FD30YA-E3000 Cabinet harness 仪表架线束 1 电液

09 FD35MD-E1000 Engine harness 发动机线束 1 机械，手液
- FD35YD-E1000 Engine harness 发动机线束 1 电液

15 FD30MA-E0011 Switch,turn signal 转向灯开关 1 机械，手液
16 FD35YD-E0001 Water temp sensor 水温传感器 1

67
67
门架管路系统（基本型）/HYDRAULIC SYSTEM MAST(NORMAL MAST M)

FG20,25,30,35
A FD20MA-K4000 Mast hydraulic system 门架管路系统 1 2t,2.5t
- FD30YBJ-K2000 Mast hydraulic system 门架管路系统 1 3t
- FD35MA-K6000 Mast hydraulic system 门架管路系统 1 3.5t
01 GB/T8870-1016 Clip 双钢丝夹箍10-16 6 JB/T8870-1999
02 FD20MA-K4001 Rubber hose 塑料管d12xL 2 2t,2.5t
- FD30MA-K5001 Rubber hose 塑料管d12xL 2 3t
- FD35MA-K6001 Rubber hose 塑料管d12xL 2 3.5t
03 JB/T22344-8x35 Band 扎带8x35 4 JB/T22344-2008
04 FD30MA-K5003 Three way 回油接头 1

1
05 FD30MA-K5004 Rubber hose 塑料管d12x1100 1
2 06 TGIBII-13054GS Hose H.P. 高压胶管 1
3 07 FD20MA-K4100 Flow regulator 限速阀 1 2t,2.5t
- FD30MA-K5100 Flow regulator 限速阀 1 3t
- FD35MA-K6100 Flow regulator 限速阀 1 3.5t
08 GB/T982-22x2.7 Washer 组合垫圈22x2.7 1 GB/T982-1977
09 GJT-101-00 Three way 三通接头总成 1

5
10 TGIBII-13036 Hose H.P. 高压胶管 1 2t,2.5t
4
- TGIBII-13037 Hose H.P. 高压胶管 1 3t
- TGIBII-13037 Hose H.P. 高压胶管 1 3.5t
7 6 11 FD30MA-K5300 Valve 切断阀 1

8
9 11
10
68
68
门架管路系统（基本型）/HYDRAULIC SYSTEM MAST(NORMAL MAST M)

FD20,25,30,35
管路系统选用件 FG20,25,30,35
Mast Piping Optional Parts
件2塑料管长度
Plastic Hose
起升高度备注
Ifting 图号图号图号长度 Remark
Height Part No Part No Part No length
FD20MA FD30MA FD35MA 1050
2000 -K4001*k -K5001*k -K6001*k
2500 -K4001*l -K5001*l -K6001*l 1250
2700 -K4001*m -K5001*m -K6001*m 1350
3000 -K4001 -K5001 -K6001 1450 标准（S T D）
3300 -K4001*a -K5001*a -K6001*a 1650

-K4001*b -K5001*b -K6001*b
1
3500 1750
3700 -K4001*c -K5001*c -K6001*c 1850 2
4000 -K4001*d -K5001*d -K6001*d 2050 3
4250 -K4001*e -K5001*e -K6001*e 2150
4500 -K4001*f -K5001*f -K6001*f 2350
4750 -K4001*g -K5001*g -K6001*g 2450
5000 -K4001*h -K5001*h -K6001*h 2550
5
5500 -K4001*I -K5001*I -K6001*i 2850 4
6000 -K4001*j -K5001*j -K6001*j 3150
7 6
8
9 11
10
69
69
门架管路系统（二级全自由）/HYDRAULIC SYSTEM MAST(FULL FREE 2-STAGE MAST ZM)

FG20,25,30,35
A FD25MAJ-Z3000 Mast hydraulic system 门架管路系统 1 2t,2.5t
- FD30YBJ-Z4000 Mast hydraulic system 门架管路系统 1 3t
- FD 35 MA J- Z4 00 0 M a s t h y d r a ulic system 门架管路系统 1 3.5t

7
01 GJT-105-00 Elbow 直通接头 1
14
04 FD30YBJ-Z4100 Steel pipe ass'y 钢管总成 1 2t,2.5t

2
5 3
05 TGIAII-13*** Hose H.P. 高压胶管 1
08 TGIBII-13038 Hose H.P. 高压胶管 1
09 GJT-101-00 Three way 三通接头总成 1
4 10 FD20MA-K4100 Flow regulator 限速阀 1 2t,2.5t
- FD30MA-K5100 Flow regulator 限速阀 1 3t
- FD35MA-K6100 F l o w r e g u l ator 限速阀 1 3.5t
11 JB/T982-22 Washer 组合垫圈 1 JB/T982-1977

12
12 TGIBII-13054GS Hose H.P. 高压胶管 1
13 13 GB/T1235-18x2.4 O-ring seal. O型圈18x2.4 1 GB/T1235-1976
1
14 GB/T1235-17x2.65 O-ring seal. O型圈17x2.65 1 GB/T3452-2005
10
11
6
8
9
70
70
门架管路系统（二级全自由）/HYDRAULIC SYSTEM MAST(FULL FREE 2-STAGE MAST ZM)

FD20,25,30,35
管路系统选用件 Mast Piping Optional Parts FL20,25,30,35
二级全自由门架FULL FREE 2-STAGE MAST ZM
门架管理系统件5高压胶管代号
起升高度 HYDRAULIC SYSTEM HOSE H.P. 备注
Ifting Height Remark
2t, 2 . 5 t 3t,3.5t 2t,2.5t 3t,3.5t
7
2000 FD25MAJ-Z3000*k FD3 0YB J-Z 4200 *k TGIAII-13034 TGIAII-13041
2500 FD25MAJ-Z3000*l FD3 0YB J-Z 4200 *l TGIAII-13064 TGIAII-13071 14
2700 FD25MAJ-Z3000*m FD3 0YB J-Z 4200 *m TGIAII-13074 TGIAII-13081

3000 FD25MAJ-Z30 00 FD3 0YB J-Z 4200 TGIAII-13089 TGIAII-13096 标准（S T D） 2
5 3
3300 FD25MAJ-Z3000*a FD3 0YB J-Z 4200 *a TGIAII-13104 TGIAII-13111
3500 FD25MAJ-Z3000*b FD3 0YB J-Z 4200 *b TGIAII-13114 TGIAII-13121
3700 FD25MAJ-Z3000*c FD 30 YB J- Z4 20 0* c TGIAII-13124 TGIAII-13131
4000 FD25MAJ-Z3000*d FD 30 YB J- Z4 20 0* d TGIAII-13144 TGIAII-13151
4250 FD25MAJ-Z3000*e FD 30 YB J- Z4 20 0* e TGIAII-13156 TGIAII-13163 4
4500 FD25MAJ-Z3000*f FD 30 YB J- Z4 20 0* f TGIAII-13169 TGIAII-13176

4750 FD25MAJ-Z3000*g FD 30 YB J- Z4 20 0* g TGIAII-13181 TGIAII-13188
12
5000 FD25MAJ-Z3000*h FD 30 YB J- Z4 20 0* h TGIAII-13194 TGIAII-13201
5500 FD25MAJ-Z3000*I FD 30 YB J- Z4 20 0* I TGIAII-13224 TGIAII-13231 13
1
6000 FD25MAJ-Z3000*j FD 30 YB J- Z4 20 0* j TGIAII-13249 TGIAII-13256
10
11
6
8
9
71
71
货叉(基本及二级全自由)/FORK(NORMAL&FULL FREE 2-STAGE MAST M &ZM)

FD20,25,30,35,38 Item No Part No Description Q'ty Remark
FG20,25,30,35
01 FD20MA-K1000 Fork ass’y 货叉总成 2 2t,2,5t
- FD30MA-K2000 Fork ass’y 货叉总成 2 3t
- FD35MA-K2000 Fork ass’y 货叉总成 2 3.5t
- FD45HA-K7000 Fork ass’y 货叉总成 2 3.8t
02 FD30MA-K2001 Positioning pin 定位销 2

03 FD30MA-K2002 Spring 弹簧 2
04 FD30MA-K2003 Handle 把手 2
1
4
3
1
2
72
72
货叉(基本及二级全自由)/FORK(NORMAL&FULL FREE 2-STAGE MAST M &ZM)

FD20,25,30,35,38
货叉架选用件表 FG20,25,30,35
Fork Optional Parts
货叉总成代号
RART NO 长度备注
length Remark
3 .8 t 3t 3.5t
FD45HA-K7000*a FD 30 MA -K2000*a FD 35 MA -K2000*a 920
-K7000*b -K2000*b -K2000*b 1070 标准( S T D )
-K7000*c -K2000*c -K2000*c 1220
-K7000*d -K2000*d -K2000*d 1370
-K7000*e -K2000*e -K2000*e 1520
-K7000*f -K2000*f -K2000*f 1670

4
-K7000*g -K2000*g -K2000*g 1820 1
-K7000*h -K2000*h -K2000*h 1970
-K7000*I -K2000*I -K2000*I 2120
-K7000*j -K2000*j -K2000*j 900
-K7000*k -K2000*k -K2000*k 1000
3
-K7000*l -K2000*l -K2000*l 1100
-K7000*m -K2000*m -K2000*m 1200 2
1
-K7000*n -K2000*n -K2000*n 1300
-K7000*o -K2000*o -K2000*o 1400
-K7000*p -K2000*p -K2000*p 1500
-K7000*q -K2000*q -K2000*q 1600
-K7000*r -K2000*r -K2000*r 1700
-K7000*s -K2000*s -K2000*s 1800
-K7000*t -K2000*t -K2000*t 1900
-K7000*u -K2000*u -K2000*u 2000
73
73
货叉架（基本及二级全自由）/LIFT BRACKET(NORMAL&FULL FREE 2-STAGE MAST M &ZM)

FG20,25,30,35
01 GB/T5782-14x25 Bolt 螺栓M14x25 4 GB5782-2000
02 GB/T5782-14x30 Bolt 螺栓M14x30 4 GB5782-2000

H
GB/T93-1987
04 FD20MA-K2400 Backrest 挡货架总成 1 2t,2.5t
- FD30MA-K1400 Backrest 挡货架总成 1 3t,3.5,3.8t
05 FD30MA-K7200 End roller 主滚轮 6

06 FD30MA-K7001 Shim 调整垫圈按需
07 B6150-00055 Snap ring 挡圈55 6

08 GB/T5785-12x55 Bolt 螺栓M12x1.25x55 4 GB5785-2000
09 GB/T93-12 Washer 垫圈12 4 GB/T93-1987
10 FD30MA-K7300 Shaft 侧滚轮组 2

12 FD30MA-K7002 Spacer 垫块 4
基本型
13 FD20MA-K2300 Lift bracket 货叉架总成 1 2t,2.5t
- FD30MA-K1300 Lift bracket 货叉架总成 1 基本型 3t
- FD35MA-K1300 Lift bracket 货叉架总成 1 基本型 3.5t
- F D 4 5 H A - K 7 0 0 0 Lift bracket 货叉架总成 1 基本型 3. 8t
二级全自由
- FD20MA-Z1300 Lift bracket 货叉架总成 1 2t,2.5t
二级全自由
- FD30MA-Z1300 Lift bracket 货叉架总成 1 3t
二级全自由
- FD35MA-Z1300 Lift bracket 货叉架总成 1 3.5t
二级全自由
- FD38C-Z1300 Lift bracket 货叉架总成 1 3.8t
14 FD20MA-K1000 Fork 货叉总成 2 2t,2.5t
- FD30MA-K2000 Fork 货叉总成 2 3t
- FD35MA-K2000 Fork 货叉总成 2 3.5t
FD45HA-K7000 Fork 货叉总成 2 3.8t
15 GB/T77-12x20 Bolt 内六角拧紧螺钉M12x20 1 GB/T77-2000
16 GB/T93-12 Washer 垫圈12 1 GB/T93-1987

74
74
门架(基本型)/MAST(NORMAL MAST M)
Item No Part No Description Q'ty FD20,25,30,35,38
Remark FG30,35
01 GB/T894.1-55 Snap ring 挡圈55 4 GB/T894.1-1986

限位轴
6 7 8
2
H
03 FD30MA-K7012 Shaft 9 10
5
04 GB/T77-10X45 Screw 螺钉M10x45 2 GB/T77-2000 4 11
螺母M10
12
05 GB/T6170-10 Nut 2 GB/T6170-2000
06 FD30MA-K7007 Slipper 限位滑块 2 3

2
07 FD30MA-K7008 Shim 调整垫片按需 1
08 FD30MA-K7002 Spacer 垫块 4

侧滚轮组
13 14
10 FD30MA-K7300 Shaft 2
11 GB/T93-12 Washer 垫圈12 4 GB/T93-1987
12 GB/T5785-12X40 Bolt 螺栓M12x1.25x40 4 GB5785-2000

16
13 FD20MA-K2100 Outer mast 外门架总成 1 2t,2.5t
15
- FD30AA-K1100 Outer mast 外门架总成 1 3t 17 18
- FD35MA-K1100 Outer mast 外门架总成 1 3.5t 24 21
25
- FD38C-K1100 Outer mast 外门架总成 1 3.8t
20
14 FD30MA-K8000 Pin 销轴总成 2 23 19
15 GB/T93-10 Washer 垫圈10 2 GB/T93-1987
2
26
17 JB/T7940.1-10 Fitting 弯颈式润滑脂嘴M 10 x1.0 JB/T7940.1-1995
18 FD30MA-K0002 Bushing 轴衬 2
2
22
19 FD30MA-K0001 Cap 支座盖 2
20 GB/T93-16 Washer 垫圈16 4 GB/T93-1987
1

23 FD30MA-K0003 Shield 护板 1
75
75
门架(基本型)/MAST(NORMAL MAST M)
FD20,25,30,35,38 Item No Part No Description Q'ty Remark
FG30,35
24 GB/T93-6 Washer 垫圈6 2 GB/T93-1987

6 7 8
内门架总成
9 10 26 FD20MA-K2200 Inner mast 1 2t,2.5t
5
4 11 - FD30AA-K1200 Inner mast 内门架总成 1 3t
12 FD35MA-K1200 Inner mast 内门架总成 1
- 3.5t
3 - FD38C-K1200 Inner mast 内门架总成 1 3.8t

2
1
13 14
16
15
17 18
24 21
25
20
19
23
26
22
2
1
76
76
门架（基本型）/MAST(NORMAL MAST)
FD30,35,38
门架选用件表 Mast Optional Parts FG30,35
外门架总成内门架总成
Outer Mast Inner Mast 备注
起升高度
Ifting Height Remar k
6 7 8
3.8t 3t 3.5t 3.8t 3t 3.5t 9 10
FD38C FD30AA FD35C FD38C FD30AA FD35C 5
2000 -K1100*k -K1100*k -K2200*k
-K1100*k -K1100*k -K1200*k -K1200*k -K1200*k 4 11
2500 -K1100*l -K1100*l -K1100*l -K1200*l -K1200*l -K1200*l 12
2700 -K1100*m -K1100*m -K1100*m -K1200*m -K1200*m -K1200*m 3
2
3000 -K1100 -K1100 -K1100 -K1200 -K1200 -K1200 标准STD
1
3300 -K1100*a -K1100*a -K1100*a -K1200*a -K1200*a -K1200*a
3500 -K1100*b -K1100*b -K1100*b -K1200*b -K1200*b -K1200*b
3700 -K1100*c -K1100*c -K1100*c -K1200*c -K1200*c -K1200*c
13 14
4000 -K1100*d -K1100*d -K1100*d -K1200*d -K1200*d -K1200*d
4250 -K1100*e -K1100*e -K1100*e -K1200*e -K1200*e -K1200*e
16
4500 -K1100*f -K1100*f -K1100*f -K1200*f -K1200*f -K1200*f
15
4750 -K1100*g -K1100*g -K1100*g -K1200*g -K1200*g -K1200*g 17 18
5000 -K1100*h -K1100*h -K1100*h -K1200*h -K1200*h -K1200*h 24 21
-K1100*I -K1100*I -K1100*I -K1200*I
25
5500 -K1200*I -K1200*i
20
6000 -K1100*j -K1100*j -K1100*j -K1200*j -K1200*j -K1200*j 19
23
26
22
2
1
77
77
门架（二级全自由）/MAST(FULL FREE 2-STAGE MAST ZM)

FG30,35
01 FD30MA-K7007 Slipper 限位滑块 2
02 FD30MA-K7008 Shim 调整垫片按需
1 04 GB/T894.1-55 Snap ring 挡圈55 4 GB/T894.1-1986
2 10 05 FD30MA-K7002 Spacer 垫块 4
07 FD30MA-K7300 Shaft 侧滚轮组 2 GB/T77-2000
19 08 GB/T5785-12X40 Bolt 螺栓M12x1.25x40 4 GB5785-2000
09 GB/T93-12 Washer 垫圈12 4 GB/T93-1987

3
4 10 FD20C-Z1200 Outer mast 外门架总成 1 2t,2.5t
9 - FD30AA-Z1200 Outer mast 外门架总成 1 3t

5
6 - FD35C-Z1100 Outer mast 外门架总成 1 3.5t
7
8 - FD38C-Z1100 Outer mast 外门架总成 1 3.8t
11 FD30MA-K8000 Pin 销轴总成 2

12 12 GB/T93-10 Washer 垫圈10 2 GB/T93-1987
11 13
14 JB/T7940.1-10 Fitting 弯颈式润滑脂嘴M 10 x1.0 2 JB/T7940.1-1995

14
15 16 15 GB/T93-16 Washer 垫圈16 4 GB/T93-1987
17 FD30MA-K0002 Bushing 轴衬 2
17 18 18 FD30MA-K0001 Cap 支座盖 2
4
19 FD20C-Z1200 Inner mast 内门架总成 1 2t,2.5t
3
- FD30AA-Z1200 Inner mast 内门架总成 1 3t
- FD35C-Z1200 Inner mast 内门架总成 1 3.5t
- FD38C-Z1200 Inner mast 内门架总成 1 3.8t
78
78
门架（二级全自由）/MAST(FULL FREE 2-STAGE MAST ZM)

FD20,25,30,35
门架选用件表 Mast Optional Parts FG20,25,30,35
外门架总成内门架总成
Outer Mast Inner Mast 备注
起升高度
Ifting Height Remar k
3.8t 3t 3.5t 3.8t 3t 3.5t 1
2000 FD38C FD30AA
-Z1100*k -Z1100*k
FD35C
-Z1100*k
FD38C
-Z1200*k
FD30AA FD35MA 2 10
-Z1200*k -Z1200*k
2500 -Z1100*l -Z1100*l -Z1100*l -Z1200*l -Z1200*l -Z1200*l
2700 -Z1100*m -Z1100*m -Z1100*m -Z1200*m -Z1200*m -Z1200*m
3000 -Z1100 -Z1100 -Z1100 -Z1200 -Z1200 -Z1200 标准STD 19
3300 -Z1100*a -Z1100*a -Z1100*a -Z1200*a -Z1200*a -Z1200*a
3500 -Z1100*b -Z1100*b -Z1100*b -Z1200*b -Z1200*b -Z1200*b 3
4
3700 -Z1100*c -Z1100*c -Z1100*c -Z1200*c -Z1200*c -Z1200*c 9
-Z1100*d -Z1100*d -Z1100*d -Z1200*d -Z1200*d -Z1200*d 5
4000 6
-Z1100*e -Z1100*e -Z1100*e -Z1200*e 7
4250 -Z1200*e -Z1200*e 8
4500 -Z1100*f -Z1100*f -Z1100*f -Z1200*f -Z1200*f -Z1200*f
4750 -Z1100*g -Z1100*g -Z1100*g -Z1200*g -Z1200*g -Z1200*g 12
11 13
5000 -Z1100*h -Z1100*h -Z1100*h -Z1200*h -Z1200*h -Z1200*h
5500 -Z1100*I -Z1100*I -Z1100*I -Z1200*I -Z1200*I -Z1200*I
6000 -Z1100*j -Z1100*j -Z1100*j -Z1200*j -Z1200*j -Z1200*j 14

15 16
17 18
4
3
79
79
起升油缸（2.0t-3.0t基本型）/LIFT CYLINDER(NORMAL MAST M)

FG20,25,30
A FD20C-K3000 Lift cylinder 起升油缸安装 1
- FD30AA-K3000 Lift cylinder 起升油缸安装 1
2 5 01 Sheave 链轮
H 1
6 02
FD30MA-K3400
GB/T894.1-40 Snap ring 挡圈40
2
2 GB/T894.1-1986
7 03 FD20MA-K3100 Chain ass＇y 链条总成 2 2t,2.5t
- FD30MA-K3200 Chain ass＇y 链条总成 2 3t

8
04 FD20MA-K3200 Lift cylinder L.H. 2t,2.5t
1
9 10 12 - Lift cylinder L.H.
11 FD30MA-K3100 1 3t
05 GB/T5786-16X40 Bolt 螺栓M16x1.5x40 2

GB/T5786-2000
13
06 GB/T93-16 Washer 垫圈16 GB/T93-1987
3 2
07 FD30MA-K3006 Shim 调整垫圈
按需
14
15 08 FD30MA-K3004 U-bolt U型螺栓
2
09 FD30MA-K3002 Robber 调整块 2
10 FD30MA-K3003 Support 油缸支撑块 2
11 GB/T97.1-10 Washer 垫圈10 GB/T97.1-2002
4
12 GB/T93-10 Washer 垫圈10 GB/T93-1987
4
13 GB/T6173-10 Nut 螺母M10x1.25 GB/T6173-2000
4
14 GB/T5786-12X50 Bolt 螺栓M12x1.25-50 GB/T5786-2000
2
15 GB/T6171-12 Nut 螺母M12x1.25 GB/T6171-2000
16 2
16 FD20MA-K3300 Lift cylinder R.H. 起升油缸（右） 2t,2.5t
1
- FD30MA-K3300 Lift cylinder R.H. 起升油缸（右） 1 3t
4
17 FD30MA-K3005 Bolt 台阶螺栓 2
18 GB/T119-10X26 Pin 销轴 GB/T119-2000
2
17 18
80
80
起升油缸（2.0t-3.0t基本型）/LIFT CYLINDER(NORMAL MAST M)

FD20,25,30
起升油缸选用件表 FG20,25,30
Lift cylinder Optional Parts
2.0t,2.5t 3.0t
2 5
起升高度
左起升缸右起升缸
Ifting Height lift cylinder lift cylinder
链条总成
Chain
左起升缸右起升缸
lift cylinder lift cylinder
链条总成
Chain
1
6
H
L.H. R.H. ass＇y L.H. R.H. ass＇y 7
FD20MA FD20MA FD20MA FD30MA FD30MA FD30MA
2000 -K3200HC*k -K3300HC*k -K3100*k -K3100HC*k -K3300HC*k -K3200*k
2500 -K3200HC*l-K3300HC*l -K3100*l -K3100HC*l -K3300HC*l -K3200*l 8
2700 -K3200HC*m-K3300HC*m -K3100*m -K3100HC*m -K3300HC*m -K3200*m 9 10 12
11
3000 -K3200HC -K3300HC -K3100 -K3100HC -K33000HC -K3200
3300 -K3200HC*a-K3300HC*a -K3100*a -K3100HC*a -K3300HC*a -K3200*a 13

3500 -K3200HC*b-K3300HC*b -K3100*b -K3100HC*b -K3300HC*b -K3200*b 3
3700 -K3200HC*c-K3300HC*c -K3100*c -K3100HC*c -K3300HC*c -K3200*c 14
15
4000 -K3200HC*d-K3300HC*d -K3100*d -K3100HC*d -K3300HC*d -K3200*d
4250 -K3200HC*e-K3300HC*e -K3100*e -K3100HC*e -K3300HC*e -K3200*e
4500 -K3200HC*f-K3300HC*f -K3100*f -K3100HC*f -K3300HC*f -K3200*f
4750 -K3200HC*g-K3300HC*g -K3100*g -K3100HC*g -K3300HC*g -K3200*g

5000 -K3200HC*h-K3300HC*h -K3100*h -K3100HC*h -K3300HC*h -K3200*h
5500 -K3200HC*i-K3300HC*I -K3100*I -K3100HC*I -K3300HC*i -K3200*I
6000 -K3200HC*j-K3300HC*j -K3100*j -K3100HC*j -K3300HC*j -K3200*j
16
17 18
81
81
起升油缸（3.5,3.8t基本型）/LIFT CYLINDER(NORMAL MAST M)

FD35 Item No Part No Description Q'ty Remark
FG35
A FD35C-K2000 Lift cylinder 起升油缸安装图 1
01 FD35MA-K3400 Sheave 链轮 2
2 5 02 GB/T894.1-45 Snap ring 挡圈45 2
H 1 GB/T894.1-1986
6 03 FD35MA-K3200 Chain ass＇y 链条总成 2

7
04 FD35MA-K3100HC Lift cylinder L.H. 起升油缸（左） 1
8 05 GB/T5786-16X40 Bolt 螺栓M16x1.5x40 2 GB/T5786-2000
06 GB/T93-16 Washer 垫圈16 2 GB/T93-1987

9 10 12
11 07 FD30MA-K3006 Shim 调整垫圈按需
13 08 FD35MA-K3001 U-bolt U型螺栓 2
3 09 FD30MA-K3002 Robber 调整块 2
14 10 FD30MA-K3003 Support 油缸支撑块 2

15
11 GB/T97.1-10 Washer 垫圈10 4 GB/T97.1-2002
12 GB/T93-10 Washer 垫圈10 4 GB/T93-1987
13 GB/T6173-10 Nut 螺母M10x1.25 4 GB/T6173-2000
14 GB/T5786-12X50 Bolt 螺栓M12x1.25-50 2 GB/T5786-2000
15 GB/T6171-12 Nut 螺母M12x1.25 2 GB/T6171-2000
16 FD35MA-K3300HC Lift cylinder R.H. 起升油缸（右） 1

17 FD30MA-K3005 Bolt 台阶螺栓 2
16 18 GB/T119-10X26 Pin 销轴 2 GB/T119-2000
17 18
82
起升油缸（3.5t基本型）/LIFT CYLINDER(NORMAL MAST M)

FD35
起升油缸选用件表 FG35
Lift cylinder Optional Parts
3.5t
起升高度
2 5
左起升缸右起升缸链条总成备注 1
Lifting Height lift cylinder lift cylinder Chain 6
L.H. R.H. ass＇y Remark
FD35MA FD35MA FD35MA
7
2000 -K3100HC*k -K3300HC*k -K3200*k
2500 -K3100HC*l -K3300HC*l -K3200*l 8
2700 -K3100HC*m -K3300HC*m -K3200*m 9 10 12
11
3000 -K31000HC -K33000HC -K3200 标准STD
3300 -K3100HC*a -K3300HC*a -K3200*a 13

3500 -K3100HC*b -K3300HC*b -K3200*b 3
3700 -K3100HC*c -K3300HC*c -K3200*c 14
15
4000 -K3100HC*d -K3300HC*d -K3200*d
4250 -K3100HC*e -K3300HC*e -K3200*e
4500 -K3100HC*f -K3300HC*f -K3200*f
4750 -K3100HC*g -K3300HC*g -K3200*g
5000 -K3100HC*h -K3300HC*h -K3200*h
5500 -K3100HC*I -K3300HC*I -K3200*i
6000 -K3100HC*j -K3300HC*j -K3200*j
16
17 18
83
83
前起升油缸（二级全自由）/FRONT LIFT CYLINDER(FULL FREE 2-STAGE MAST ZM)

FG20,25,30,35
A FD20C-Z3100 Lift cylinder(front) 前起升油缸总成 1 2t,2.5t
- FD30C-Z3100 Lift cylinder(front) 前起升油缸总成 1 3t

1 - FD35C-Z3100 Lift cylinder(front) 前起升油缸总成 1 3.5t
2 01 GB/T5782-16X70 Bolt 螺栓M16x70 1 GB/T5782-2000
3 02 GB/T93-16 Washer 垫圈16 1 GB/T93-1987
03 FD30MA-Z3001 Stopper,chain 护链板 1 2t,2.5t,3t
4 - FD35MA-Z3001 Stopper,chain 护链板 1 3.5t

5
04 FD30MA-Z3005 Sheave seat 前缸座 1 2t,2.5t,3t
8 6 - FD35MA-Z3002 Sheave seat 前缸座 1 3.5t
05 FD30MA-K3400 Sheave 链轮 2 2t,2.5t,3t

9
- FD35MA-K3400 Sheave 链轮 2 3.5t
10 7
06 GB/T8941-40 Snap ring 挡圈40 2 GB/T8941-1986
07 FD20C-Z3300 Chain ass'y 链条总成 2 2t,2.5t

11
- FD30C-Z3300 Chain ass'y 链条总成 2 3t
12
- FD35C-Z3200 Chain ass'y 链条总成 2 3.5t
13
08 FD20MA-Z3101 Dust ring 防尘圈 1 2t,2.5t
14 - FD30MA-Z3101 Dust ring 防尘圈 1 3t
- FD35MA-Z3101 Dust ring 防尘圈 1 3.5t

20
09 FD20MA-Z3102 Snap ring 挡圈 1 2t,2.5t
19
18 - FD30MA-Z3102 Snap ring 挡圈 1 3t
15 17 - FD35MA-Z3102 Snap ring 挡圈 1 3.5t
16 10 FD20MA-Z3103 Yx-ring seal Yx密封圈 1 2t,2.5t
21 - FD30MA-Z3103 Yx-ring seal Yx密封圈 1 3t
- FD35MA-Z3103 Yx-ring seal Yx密封圈 1 3.5t

22
11 FD20MA-Z3104 Cap,lift cylinder 前缸盖 1 2t,2.5t
- FD20MA-Z3104 Cap,lift cylinder 前缸盖 1 3t
- FD20MA-Z3104 Cap,lift cylinder 前缸盖 1 3.5t

84
84

Item No Part No Description Q'ty FD20,25,30,35
Remark FG20,25,30,35
12 FD20MA-Z3105 Bushing 钢背轴承 1 2t,2.5t
- FD30MA-Z3105 Bushing 钢背轴承 1 3t
- FD35MA-Z3105 Bushing 钢背轴承 1 3.5t

1
13 FD20MA-Z3106 Snap ring 挡圈 1 2t,2.5t 2
- FD30MA-Z3106 Snap ring 挡圈 1 3t
3
- FD35MA-Z3106 Snap ring 挡圈 1 3.5t
14 FD20MA-Z3107 Piston rod ass'y 柱赛杆总成 1 2t,2.5t 4

5
- FD30MA-Z3107 Piston rod ass'y 柱赛杆总成 1 3t
- FD35MA-Z3107 Piston rod ass'y 柱赛杆总成 1 3.5t 8 6

15 FD20MA-Z3108 Wearing 支撑环 1 2t,2.5t
9
- FD20MA-Z3108 Wearing 支撑环 1 3t
10 7
- FD20MA-Z3108 Wearing 支撑环 1 3.5t
16 FD20MA-Z3109 Seal ring 密封环 1 2t,2.5t

11
- FD30MA-Z3109 Seal ring 密封环 1 3t
12
- FD35MA-Z3109 Seal ring 密封环 1 3.5t
13
17 FD20MA-Z3110 Cylinder body(front) 前缸体 1 2t,2.5t
- FD30MA-Z3110 Cylinder body(front) 前缸体 1 3t 14

- FD35MA-Z3110 Cylinder body(front) 前缸体 1 3.5t
20
18 GB/T5786--10X20 Bolt 螺栓M12x1.25x20 2 GB/T5786-2000
19
19 GB/T93-10 Washer 垫圈10 2 GB/T93-1987 18
20 FD20C-Z3001 Support 固定卡 1 2t,2.5t 15 17
- FD30MA-Z2002T Support 固定卡 1 3t 16
- FD35C-Z3003 Support 固定卡 1 3.5t
21
21 FD30MA-Z3004 Spacer 隔套 1
22
22 GB/T5786-12X30 Bolt 螺栓M12x1.25x30 1 GB/T5786-2000
85
85

FD20,25,30,35
FG20,25,30,35 前起升油缸（二级全自由）
FRONT LIFT CYLINDER(FULL FREE 2-STAGE MAST ZM)
1 前起升缸总成代号链条总成 (节数)

起升高度 Lift cylinder Chain ass'y 备注
2 Ifting Height Remark
2t,2.5t 3t 3.5t 2t,2.5t 3t 3.5t
3 2000
FD20MA FD30MA FD35MA
-Z3100*k -Z3100*k -Z3100*k 57 43 47
2500 -Z3100*l -Z3100*l -Z3100*l 69 53 57
4
5 2700 -Z3100*m -Z3100*m -Z3100*m 75 57 61
标准
8 6 3000 -Z3100 -Z3100 -Z3100 83 63 67 (STD)
3300 -Z3100*a -Z3100*a -Z3100*a 91 69 73

9 3500 -Z3100*b -Z3100*b -Z3100*b 95 73 77
10 7 3700 -Z3100*c -Z3100*c -Z3100*c 101 77 81
4000 -Z3100*d -Z3100*d -Z3100*d 111 85 89
11 4250 -Z3100*e -Z3100*e -Z3100*e 117 89 94
12 4500 -Z3100*f -Z3100*f -Z3100*f 123 95 97
13 4750 -Z3100*g -Z3100*g -Z3100*g 131 99 103
14 5000 -Z3100*h -Z3100*h -Z3100*h 137 105 107

5500 -Z3100*I -Z3100*I -Z3100*I 153 117 119
20 6000 -Z3100*j -Z3100*j -Z3100*j 165 127 129
19
18
15 17
16
21
22
86
86
后起升油缸（二级全自由）/FRONT LIFT CYLINDER(FULL FREE 2-STAGE MAST ZM)

Item No Part No Description Q'ty FD20,25,30,35
Remark FG20,25,30,35
01 GB/T5780-16X40 Stopper,chain 螺栓M16x1.5x40 2 GB/T5780-2000
02 GB/T93-16 Washer 垫圈16 2 GB/T93-1987
3-1 FD30MA-Z4101 Joint rod 连接杆 1

3-2 FD30MA-Z4102 O-ring seal O型密封圈 1
3-3 FD30MA-Z4103 Dust ring 防尘圈 1 1
2
3-4 FD30MA-Z4104 Snap ring 挡圈 1
3-5 FD30MA-Z4105 O-ring seal 密封圈 1
3-6 FD30MA-Z4106 Cap,cylinder 缸盖 1
3-7 FD30MA-Z4107 Plug 螺塞 1 3-1
3- 2
3-8 FD30MA-Z4108 Bushing 钢背轴承 1 3-3
3-9 FD30MA-Z4109 Screw 螺钉M6x10 1 3- 4
3-5
3-10 FD30MA-Z4110 O-ring seal 密封圈 1 3- 6
3-7 3-9 13-1
3-8 13-2
3-12 FD30MA-Z4112 Cylinder body 缸体 1 3-10 13-3
3-12
3-13 FD30MA-Z4113 Piston rod ass'y L,H 右柱塞杆 1 3-11 13-4
3-14 FD30MA-Z4114 Pin 销10x25 1 13-5
3-15 FD30MA-Z4115 Wearing 支承环 1 3-13 13-6
11 10
04 FD30MA-K3005 Bolt 台阶螺栓 2 9
12 5
05 FD30MA-K3004 Bolt U型螺栓 2 3-15
13-7
06 GB/T5783-10 Nut 螺母M10x1.25 4 GB/T5783-2000 6 78
07 GB/T93-10 Washer 垫圈10 4 GB/T93-1987 13-6
08 GB/T97.1-10 Washer 垫圈10 4 GB/T97.1-2002
09 FD30MA-K3003 Support 油缸支撑块 2

10 FD30MA-K3002 Rubber 调整块 2
12 GB/T5783-12 Bolt 螺栓M12x1.25 2 GB/T5783-2000
13-1 FD30MA-Z4201 Dust ring 防尘圈 1

87
87
后起升油缸（二级全自由）/REAR LIFT CYLINDER(FULL FREE 2-STAGE MAST ZM)

FG20,25,30,35
13-3 FD30MA-Z4203 Seal 密封圈 1
13-4 FD30MA-Z4204 1
H Plug 螺塞
13-5 FD30MA-Z4205 Bushing 钢背轴承 1
1 13-6 FD30MA-Z4206 Seal 密封圈 1
2 FD30MA-Z4207 Piston rod ass’y l.h 1
13-7 左柱塞杆
13-8 FD30MA-Z4208 Wearing 支承环 1
3-1
3-2
3-3
3-4
3-5
3-6
3-7 3-9 13-1
3-8 13-2
3 -10 13-3
3-12
3-11 13-4
13-5
3-13 13-6
11 10
9
12 5
3-15
13-7
6 78
13-6
88
88
后起升油缸（二级全自由）/REAR LIFT CYLINDER(FULL FREE 2-STAGE MAST ZM)

FD20,25,30,35
后起升油缸（二级全自由） FG20,25,30,35
FRONT LIFT CYLINDER(FULL FREE 2-STAGE MAST ZM)
起升高度钢管总成代号 L L1 L2 备注
Ifting Height HOSE Remark
2000 FD30MA-Z4100*k 1277 955

FD30MA-Z4100*l 1527 1205 1
2500
2
2700 FD30MA-Z4100*m 1627 1305
3000 FD30MA-Z4100 1777 1455 标准
3300 FD30MA-Z4100*a 1927 1605
3500 FD30MA-Z4100*b 2027 1705 3-1

3- 2
3700 FD30MA-Z4100*c 2127 1805 3-3
50
3- 4
4000 FD30MA-Z4100*d 2327 1955 3-5
3- 6
4250 FD30MA-Z4100*e 2452 2080 50 3-7 3-9 13-1
4500 FD30MA-Z4100*f 2577 2205 50
3-8 13-2
2702 3-10 13-3
4750 FD30MA-Z4100*g 2330 50 3-12
2827
3-11 13-4
5000 FD30MA-Z4100*h 2455 50
5500 FD30MA-Z4100*I 3127 2705 100 13-5

3-13 13-6
6000 FD30MA-Z4100*j 3377 2955 100 11 10
9
12 5
3-15
13-7
6 78
13-6
89
89
倾斜油缸/TILT CYLINDER
FG20,25,30
01 FD30MA-K4100 Ear ring 耳环 2
02 FD30MA-K4002 Shim 垫片 12
03 FD30MA-K4003 Plug 塞子 2
04 GB/T80-10X10 Screw 螺钉M10x10 2 GB/T80-2000
05 FD30MA-K4001 Spacer 调整轴套 2

12
8 06 FD30MA-K4004 Seal,dust 防尘圈 2
11 07 GB/T893.1-52 Ring,snap 挡圈52 2 GB/T893.1-1986
10
08 FD30MA-K4005 Guide sleeve 导向套 2
9
7 16 09 FD30MA-K4006 Ring,snap 挡圈 2
6
5 17 10 FD30MA-K4007 Shim 挡片 2
22
2 16 11 FD30MA-K4008 U-ring U型密封圈 2
21 14
12 GB/T1235-70X3 O-ring O型密封圈70x3.1 2 GB/T1235-1976
3 13 FD30MA-K4009 Bushing 轴套 2
24 4 14 FD30MA-K4200 Body,piston ass＇y 活塞体总成 2
19 23 15 FD30MA-K4300 Tube,cylinder R.H. 缸筒（右） 1

18 - FD30MA-K6100 Tube,cylinder L.H. 缸筒（左） 1
20
16 FD30MA-K4010 Yx-ring Yx密封圈 4
13
25 17 FD30MA-K4011 Wearing 支撑环 2
26
15 18 FD30MA-K4012 Bushing 轴套 2
27
19 JB/T7940.1-10X1 Fitting grease 油杯M10x1 2 JB/T7940.1-1995
20 FD30MA-K4013 Ring,snap 挡圈 2
21 FD30MA-K4400 Bushing 关节轴承 2
22 GB/T5782--14X55 Bolt 螺栓M14x55 2 GB/T5782-2000
23 GB/T6170-14 Nut 螺母M14 2 GB/T6170-2000
24 GB/T93-10X20 Washer,lock 垫圈14 2 GB/T93-1987
90
90
Remark FG20,25,30
25 FD30MA-K8000 Pin 销轴总成 2
12
8
11
10
9
7 16
6
5 17
22
2 16
21 14
3
24 4
19 23
18
20
13
25
26
15
27
91
91
FD20,25,30
FG20,25,30
倾斜油缸选用件表 Tilt cylinder Optional Parts
前/后倾角倾斜油缸(左）倾斜油缸(右）调整套

Tilt angle Tilt cylinder L.H. Tilt cylinder R.H. Spacer
12 6°～12° FD30MA-K4000*a FD30MA-K6000*a FD30MA-K4001*a

8
6°～6° FD30MA-K4000*b FD30MA-K6000*b FD30MA-K4001*b
11
10 3°～6° FD30MA-K4000*c FD30MA-K6000*c FD30MA-K4001*c
9 3°～3° FD30MA-K4000*d FD30MA-K6000*d FD30MA-K4001*d
7 16
6 3°～10° FD30MA-K4000*e FD30MA-K6000*e FD30MA-K4001*e
5 17
22
2 16
21 14
3
24 4
19 23
18
20
13
25
26
15
27
92
92
倾斜油缸/TILT CYLINDER H28

Item No Part No Description Q'ty Remark FD35
FG35
01 FD35MA-K5000 Ear ring 耳环 2
02 FD35MA-K5001 Shim 垫片 2
03 FD35MA-K5002 Plug 塞子 12
04 FD35MA-K5003 Screw 螺钉M10x10 2
12
05 FD35MA-K5004 Spacer 调整轴套 2 8
06 FD35MA-K5005 Seal,dust 防尘圈 2 11
07 FD35MA-K5006 Ring,back-up 挡圈 4 10
08 FD35MA-K5007 Guide sleeve 导向套 2
5 6 16
09 FD35MA-K5008 Washer,lock 垫圈10 2 22
10 FD35MA-K5009 Ring,back-up 挡圈 2
17 7
11 FD35MA-K5010 U-ring U型密封圈35x45x10 2
21 16 7
14
12 FD35MA-K5011 O-ring O型密封圈80x3.1 2
3
13 FD35MA-K5012 Bushing 钢背轴承3530 2
24 4
14 FD35MA-K5013 Body,piston 活塞体 2 23
Tube,cylinder R.H
19
15 FD35MA-K5014 缸体(右) 1
13
- FD35MA-K5015 Tube,cylinder L.H 缸体(左) 1 20 18
16 FD35MA-K5016 U-ring U型密封圈 4 1
17 FD35MA-K5017 Wearing 支承环 2 15 25
18 FD35MA-K5018 Bushing 轴套 2
9
26
19 FD35MA-K5019 Fitting grease 直通式滑脂嘴 2
20 FD35MA-K5020 Ring,snap 挡圈47 2
21 FD35MA-K5021 Bushing 关节轴承 2
22 FD35MA-K5022 Bolt 螺栓M14x55 2
23 FD35MA-K5023 Nut 螺母M14 2
24 FD35MA-K5024 Washer,lock 垫圈14 2
25 FD35MA-K5025 Pin 倾斜缸销轴 2
26 FD35MA-K5026 Bolt 螺栓M10x1.25x10 2
93
FD35
FG35
倾斜油缸选用件表 Tilt cylinder Optional Parts
前/后倾角倾斜油缸(左）倾斜油缸(右）调整套

Tilt angle Tilt cylinder L.H. Tilt cylinder R.H. Spacer
6°～12° FD35MA-K4000*a FD35MA-K5000*a FD30MA-K4001*a

12 6°～6° FD30MA-K4001*b
FD35MA-K4000*b FD35MA-K5000*b
8
3°～6° FD35MA-K4000*c FD35MA-K5000*c FD30MA-K4001*c
11
10 3°～3° FD35MA-K4000*d FD35MA-K5000*d FD30MA-K4001*d
3°～10° FD35MA-K4000*e FD35MA-K5000*e FD30MA-K4001*e

5 6 16
22
17 7
21 16 7
14
3
24 4
23
19
13
20 18
1
15 25
9
26
94
94
95
96
97
98
E王系列3.0t-3.8t内燃平衡重式叉车零部件目录手册
ＬＰＧ转换装置系统／ＬＰＧ　ＣＯＮＶＥＲＴＥＲ　ＳＹＳＴＥＭ
０１　ＦＬ３０ＹＣ－１１０００　ＬＰＧ　ｃｙｌｉｎｄｅｒ　　ＬＰＧ钢瓶（５０Ｌ）　１

０２　ＦＬ３０ＹＣ－１２０００　Ｃｙｌｉｎｄｅｒ　ｂｒａｃｋｅｔ　钢瓶支架　１
０３　ＦＬ３０ＹＣ－１０００１　Ｈｏｓｅ　Ｈ．Ｐ．　高压胶管Ⅰ　１
０４　ＦＬ３０ＹＣ－１０００２　Ｔｈｒｅｅ　ｗａｙ　三通接头　１
０５　ＦＬ３０ＹＣ－１０００３　Ｈｏｓｅ　Ｈ．Ｐ．　高压胶管Ⅱ　１
０６　ＦＬ３０ＹＣ－１０００４　Ｓｈｕｔ　ｏｆｆ　ｖａｌｖｅ　真空切断阀　１
０７　ＦＬ３０ＹＣ－１０００５　Ｓｏｌｅｎｏｉｄ　ｖａｌｖｅ　电磁阀　１
０８　ＦＬ３０ＹＣ－１０００６　Ｐｒｅｓｓｕｒｅ　ｒｅｌｉｅｆ　ｖａｌｖｅ　减压阀　１
０９　ＦＬ３０ＹＣ－１０００７　Ｓｗｉｔｃｈ　转换开关　１
１０　ＦＬ３０ＹＣ－１０００８　Ｍｉｘｅｒ　混合器　１
99
E王系列3.0t-3.8t内燃平衡重式叉车零部件目录手册
ＣＮＧ＆ＬＮＧ转换装置系统／ＣＮＧ＆ＬＮＧ　ＣＯＮＶＥＲＴＥＲ　ＳＹＳＴＥＭ
０１　ＦＮ３０ＹＡＨ－１２１００　ＣＮＧ　ｃｙｌｉｎｄｅｒ　　ＣＮＧ钢瓶（９０Ｌ）　１

０２　ＦＮ３０ＹＡＨ－１２２００　Ｃｙｌｉｎｄｅｒ　ｂｒａｃｋｅｔ　ＣＮＧ钢瓶支架　１
０３　ＦＮ３０ＹＡＨ－１２００１　Ｐｒｅｓｓｕｒｅ　ｒｅｌｉｅｆ　ｖａｌｖｅ　高压减压阀　１
０４　ＦＮ３０ＹＡＨ－１２００２　Ｈｏｓｅ　Ｈ．Ｐ．　高压胶管Ⅰ　１
０５　ＦＮ３０ＹＡＨ－１２００３　Ｔｈｒｅｅ　ｗａｙ　三通接头　１
０６　ＦＮ３０ＹＡＨ－１２００４　Ａｔｍｏｓｐｈｅｒｉｃ　ｖａｌｖｅ　泄压阀　１
０７　ＦＮ３０ＹＡＨ－１２００５　Ｈｏｓｅ　Ｈ．Ｐ．　高压胶管Ⅱ　１
０８　ＦＮ３０ＹＡＨ－１２００６　Ｐｒｅｓｓｕｒｅ　ｒｅｌｉｅｆ　ｖａｌｖｅ　中压减压阀　１
０９　ＦＮ３０ＹＡＨ－１２００７　Ｍｉｘｅｒ　混合器　１
１０　ＦＮ３０ＹＡＨ－１３１００　ＬＮＧ　ｃｙｌｉｎｄｅｒ　ＬＮＧ钢瓶（１５０Ｌ）　１
１１　ＦＮ３０ＹＡＨ－１３２００　Ｃｙｌｉｎｄｅｒ　ｂｒａｃｋｅｔ　ＬＮＧ钢瓶支架　１
１２　ＦＮ３０ＹＡＨ－１３００１　ＬＮＧ　ｅｖａｐｏｒａｔｏｒ　ＬＮＧ蒸发器　１
100

Use and Maintenance Manual &amp; Part Manual MAXLIFT

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Use and Maintenance Manual &amp; Part Manual MAXLIFT

Uploaded by

Copyright:

Available Formats

Use and Maintenance Manual & Part Manual

for 1-3.5T Internal Combustion Forklift

Manual when maintenance.

Manual will be modified correspondingly without prior notice, please understand.

ZOOMLION ANHUI INDUSTRIAL VEHICLE CO., LTD

I. Driving, operation and daily maintenance of forklift .............................................................................. 1

5.3 Hydraulic clutch (Figure 5-3) ..................................................................................................... 45

11.3 Fork arm carrier ............................................................................................................................. 96

I. Driving, operation and daily maintenance of forklift

(1) Hold on the parking brake

(3) Lower the mast to the lowest position;

(4) Hold on the parking brake

3. Preparations before using

(2) Check air pressure of tire;

(5) Check the handles and pedals;

(6) Prepare properly before starting;

(7) Release the parking brake;

5. Precautions for cooling system

6. Oil for forklift

Name Trade mark / code (Domestic) Trade mark / code (Abroad)

Gasoline RQ-85 JISK2202, 2#

Select according to the Diesel Engine Use and JISK2204, 2#

Hydraulic oil L-HV32# or L-HM46# ISOVG30

Gear oil GL-5 (80w/90) SAE90/SAE80W

Brake fluid DOT3 Synthetic brake fluid JISK-2233

Lubricating oil 3#lubricating oil170 JISK-2220, 1#, 2#

7. Lubrication system drawing

II. Main technical parameters of forklift

Main technical parameters

FD10M FD18M FD20M FD25M FD30M FD35M

1 A Maximum lifting height 3000

3 D Length of folk 920 1070

4 E Inclination of mast 6°~12°

5 F Total length 3125 3205 3595 3652 3765 3870

6 G Total width (single tire) 1070 1200 1230 1280

Height of the mast from

Height of the overhead

Height of the top

10 K Front track (single tire) 890 960 1000 1000

11 L Rear track 920 970 980

12 M Wheel base 920 1600 1700 1750

13 N Front overhang 420 425 472 477 483 505

14 O Rear overhang 425 430 430 500 520 550

Main technical parameters

Model FD10M FD18M FD20M FD25M FD30M FD35M

Item FD10H/Y FD18H/Y FD20H/Y FD25H/Y FD30H/Y FD35H/Y

Rated lifting capacity/ load center distance

Standard maximum lifting height (mm) 3000

Descending speed at load (mm/s) 0.052 0.068 0.068

Mast tilt angle (back and forth)(degree) 6-12

Forward (km/h) 0-18 0-20 0-20

Minimum right angle

Specification of rear wheel

Total weight(Kg) 2280 2890 3420 3780 4380 4650

III. Structure, principle, adjustment and maintenance of forklift

Main parameters of gasoline engine

Type: Four-stroke, water cooling, straight and preset air valve

Number of cylinders – diameter of cylinder X

Total displacement 1.486 1.982

Compression ratio 9.0 8.7

Rated power/revolution speed kw(ps)/rpm 25(34)/2400 32.4(44)/2300

Rated torque / revolution speed N. m(kg. m)/rpm 113(11.5)/1600 142(14.5)/1600

No-load minimum revolution speed rpm 800 800

Minimum specific fuel consumption g/ps. h 215 210

Use and Maintenance Manual & Part Manual MAXLIFT

Use and Maintenance Manual & Part Manual MAXLIFT