Manual de Servicio y Mantenimiento Serie M Térmica FD200-320T - en

M Series FD200-320T Internal Combustion
Counterbalanced Forklift truck
Operation and Maintenance Manual
Zhejiang Maximal Forklift Co., Ltd

M Series FD200-320T Internal Combustion Counterbalanced Forklift truck Operation and Maintenance Manual
FOREWORD
This manual mainly introduces the performance, structure, operation and

maintenance and other contents of FD200-320T forklift truck, in order that users or
operators are able to use and maintain it properly.
While users are in the use process, relevant operators and equipment
management personnel should conscientiously implement the relevant requirements
and regulations of this manual for use and maintenance, to make the forklift often
keep good state of use.
If any operation or maintenance doesn’t accord with requires in this manual, our
related promises is inefficacy, please pay attention.
Because of continuous improvement in parts and devices, the content of the
manual will change, without prior notice, please users understand.
I
Contents
I．Safety rules for Operation and Daily Maintenance of Forklift Truck ................. - 1 -
Ⅱ. Primary Parameter of Forklift Truck................................................................. - 18 -
Ⅲ. Primary Assembly of Forklift Truck ................................................................. - 21 -
IV. The structure, principle, adjustment and maintenance of forklift ..................... - 22 -
1. Dynamic system .................................................................................................. - 22 -
2. Transmission device ............................................................................................ - 23 -
3. Drive axle ............................................................................................................ - 30 -
4. Steering system ................................................................................................... - 34 -
5. Steering Axle ....................................................................................................... - 40 -
6. Brake System ...................................................................................................... - 43 -
7. Electric system .................................................................................................... - 48 -
8. Hydraulic System ................................................................................................ - 56 -
9. Hoist system ........................................................................................................ - 65 -
II
I．Safety rules for Operation and Daily Maintenance of Forklift Truck

It is important that driver and manager for forklift trucks remember the principle
of the “first safety” and ensure the safety operation and standard operation as the
description in OPERATION AND SERVICE MANUAL.
1. Delivery of Forklift Truck
It must be pay attention to the following items when you deliver forklift trucks:
(1) Apply the parking brake.
(2) Fix the mast and the balance weight with steel wire. Wedge up all wheels.
(3) Sling points should be always at the positions specified in sling index plate
when hoisting up the forklift truck.
2. Storage of Forklift Truck
(1) Drain off fuel completely.
(2) Apply antirust to the surface of the parts not painted. Apply lubrication oil to
the lift chain.
(3) Descend the mast to the lowest position.
(4) Apply the parking brake.
(5) Wedged up the front and rear tyre.
3. Precaution before Operation
(1) Don’t check fuel leakage and lever or instruments at the place where there is
open flame. Never fill the fuel tank with the engine running.
(2) Check the tire inflation pressure.
(3) The forward-reverse lever should be in neutral.
(4) Never smoke while the fuel system is under working or the battery is
inspected.
(5) Check all the levers and pedals.
(6) Complete the provisions before starting.
(7) Release the parking brake.
(8) Make trying operation of the mast for lifting, descend and Fwd/Bwd tilting
and the truck for steering and braking.
(9) The contamination level of the hydraulic oil should be lower than 12.
-1-
4. Safety operation rules of Forklift Truck

Sound power level of this truck is equal or less than 106dB. Sound pressure level
of cab is equal or less than 80dB. On condition that no-load truck is running at the
maximum speed, the integrated vibration acceleration of person on the seat is equal or
less than 5.8 m/s2. For sake of safety and efficiency, driver must observe the following
instructions:
(1) Only trained and driving license authorized operator shall be permitted to
operate the truck.
(2) Wear all the safety guards, such as shoes, helmet, clothing and gloves while
operating the truck.
(3) The truck is forbidden to be used in explosive environment stacked with LPG
bottle, timber, paper and chemicals.
(4) Check all the control and warning devices before starting the truck. If any
damages or defects are found, operate it after repairing.
(5) At the rated loading center, either overload or overload operation is strictly
prohibited. If the cargo is placed at non-rated loading center, the capacity is decided
according to load curve graph. The center of cargo should be in line with the frame
center, not but of the line. The fork should insert completely under the cargo and make
the cargo placed on it evenly. Do not raise an object with single fork.
(6) The starting, turning, driving, braking and stopping operation of the truck
should be done smoothly. When steering on the humid or low friction road, the truck
should be decelerated.
(7) Travel with loads as low as possible and tilted the mast backward.
(8) Be careful when traveling on a slope. When the climbing grades with a slope
of more than 10%, the truck should forward travel, and when descend so grades,
backward travel. Never turning on a slope. Avoid loading and unloading operation
when descending.
(9) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay
attention to the clearance over forklift truck.
(10) Never allow any persons to stand on/under the forks. Never permit anyone
-2-
to walk under upraised forks or the truck to carry persons.

(11) Don’t operate truck and attachment of it at any position out of the drive seat.
(12) Don't handle the stacked goods unsecured or loose, and handle the goods in
large size carefully.
(13) On the high forklift truck, when the lift height more than 3m, it is noted that
the goods on it should not fall down or the protection measures must be taken if
necessary.
(14) Tilt the mast of the high lift forklift truck as backward as possible while the
truck working. Use minimum for forward tilt angle and min. reverse tilt when loading
and unloading.
(15) Be careful and slowly driving over a dock board or temporary bed plank.
(16) Shut down the engine and don’t stay on the truck when filling fuel. Don’t
ignite the engine while checking battery or fuel lever.
(17) The unloaded forklift truck with attachments should be operated as a loaded
truck.
(18) If leaving the truck, lower the forks on the ground and let the shift lever to
neutral, shut down the engine or cut down electric supply. If parking on the slope, the
parking brake device is connected, and the wheels need to be padded with wedge
when parking for a long time.
(19) Don’t open the radiator cap when the engine is very hot.
(20) The pressure of the multi-way valve and relief valve has been adjusted
before the fork starts, and users do not adjust in the process of using, so as to avoid
excessive pressure damaging the whole hydraulic system and hydraulic components
(21) During loading and unloading operations, adjustment of parts, overhauling
or maintenance is strictly forbidden.
(22) It is strictly forbidden the fork in the running process turns at a high speed.
(23) Tyres are inflated according to the pressure value regulated on the “tyre air
pressure” sign.
(24) When mast leans forward, cargo lifting and driving lifting with fork are
strictly forbidden.
-3-
5. Installation and connection diagram of cab flip lifting device

The forklift truck is equipped with a cab tilting mechanism (as shown in Figure
1-1). The forklift cab is mounted on the tilting rack. When tilting the cab is required,
simply shake the hand pump manually, and pull down the support bar after the cab is
tilted to a reasonable height (the hand pump with self-locking function).
Warning: when tilting the cab, the working device must be ensured in a vertical
position.
Flip rack Support bar
Mounting base
Oil cylinder
Rocker Hand pump
Support frame
Figure 1-1 Cab Tilting Mechanism
-4-
(1) Connection diagram of tipping cylinder oil line
Single cylinder oil line connection diagram Ⅰ
Intake and exhaust plug

Hand rocker arm
Reversing handle
Oil cylinder
Fuel pump
Outlet A connection of oil cylinder

Outlet A of oil cylinder
Outlet B connection of oil cylinder
Outlet B of oil cylinder
Reversing handle diagram II

Hand rocker arm
Reversing handle
Cab rising Cab decline
(2) Manual pump refueling diagram

Refueling port
Refueling are flush with the plunger
Filling the rocker arm must be in the down position
B pipe joint
A pipe joint Manual pump reversing handle
-5-
(3) Exhausting procedures for cab flip lifting cylinder and oil pump
1) Connect a rubber oil pipe to the port A and port B of the oil pump as required,
then put the reversing handle of the hand pump to the vertical position (Cab in the
rollover state) and then shake the rocker arm of the oil pump from up to down, and
visually check that there is hydraulic oil to flow out of the other end of the rubber oil
pipe.
2) Then, connect the rubber oil pipe and the port A and port B of the oil cylinder,
flip the gravity of the cab normally to the upper end point, release the port B
connector connecting the oil cylinder, discharge the air in the cavity B of the oil
cylinder, and then twist tightly the pipe connector; next, put the oil pump handle to
the level state (the cab in the dropped state), shake the rocker arm of the oil pump
from up to down, and make the cab fall; at this time, the air in the cavity A of the oil
cylinder is automatically discharged.
3) Repeat operations for 2-3 times following the method above.
(4) Notes in use
1) When whole vehicles are assembled at the host factory, after the oil cylinder
and oil pump are installed to the specified locations, before connecting the oil pipe
and lifting the controller, please note that hydraulic oil must be first added to the fuel
tank (YLC-0001 shock absorber oil is used in the environment below -10℃; 46#
anti-grinding hydraulic oil is used in the environment above -10℃) before refueling,
above 200 meshes of stainless steel filter screen is used to filter the oil. Connect the
oil pipe according to the operating regulation of flipping and lifting the oil cylinder in
the cab and of fuel pump exhaust.
2) The intake and exhaust plug of the oil tank has such functions as automatic
suction and exhaust and removal of excess oil. Therefore, there is oil discharged out
of the intake and exhaust plug, which does not belong to oil leakage.
3) When the oil pump is operated to climb over the gravity of the cab, or when
there is a reliable support at the bottom of the cab, operators can begin to repair.
-6-
4) Make sure before driving to confirm that the oil pump reversing handle is at
the downward dead center position, otherwise it will lose the cabin’s floating
function.
5) When the cab is turned over the center of gravity, the hand pump should slow
down the pump speed to guarantee that no air is sucked in the system.
6) When the cab flip lifting device is used in the general environment, the cab is
flipped at least once a week; when it is used in a bad condition, the cab is flipped at
least once a day. Under the unfavourable environmental conditions, the dirt on the oil
pump assembly, oil cylinder assembly surface, and especially the intake and exhaust
plug O-ring must be manually cleaned each day to ensure that the exhaust vent of the
exhaust plug in the oil pump assembly is smooth.
7) The hydraulic oil used in the system should be replaced once every 6 months
or every 30,000 miles; according to the requirements: YLC-0001 shock absorber oil is
used in the environment below -10℃ and 46# anti-grinding hydraulic oil is used in
the environment above -10 ℃.
8) When the cab flip lifting device is used, the vehicle should stop on a level
ground surface. Start the parking controller, change the gear into the neutral, and fix
the items in the cab.
9) When repairing the engine, please be careful not to damage the oil pipe and
wires of the cab flip system.
10) Different brands of oil tank and oil pump assembly products are not mixed,
so as to avoid security accidents.
11) At the time for trial assembly of the fuel pump and oil cylinder for the first
time, the vehicle manufacturer should cooperate or if the gravity of the cabin is not
determined in the process of preparation, the cab should be hung with a crane before it
is flipped to prevent too frequent cab flips or damage.
-7-
5) Common fault and elimination methods
Trouble Cause for trouble Remedy

The reversing handle is Place the reversing handle onto
not rising in the cab the rising position of the cab
Oil pump works normally,
and the cab does not rise Intake and exhaust vents
and drop Clean the intake and exhaust
in the tank are clogged
vents
by dirt
Drop the cab in situ and
remove the intake and exhaust
plugs in the oil tank; lay a filler
The hand pump starts to
screen at the filling port of the
work after the cab rises up
Lack of oil in the oil tank oil tank, and refuel to the place
in half, but the cab stops
flushing with the upper surface
rising
of the piston (when the rocker
arm should be down), as
shown in the filling diagram.
The hydraulic system
inside has been
Clean the oil pool, oil pipe and
contaminated, and the
Cab continues falling hydraulic system, and replace
hydraulic control
the hydraulic oil
one-way valve ball of the
oil cylinder is not sealed
The intake and exhaust
Clean the intake and exhaust
vents in the tank are
vents
blocked by debris
Take down the collar nut of the
cylinder pipe A, and drain oil
using a hand pump to the
The hydraulic oil is outside;
When the oil pump is
working properly, the cab contaminated, and the Or take down the joint screws
flips up or down slowly; holes and connecting oil and connecting oil piles of the
or does not rise or drop
piles in the oil pump cylinder pipe A, clean and
system or oil cylinder blow with air the debris in the
joint screws are blocked hole and connecting pipe of the
by debris pipe joint screw and, if
necessary, replace the
hydraulic oil
-8-

Put the reversing handle of the
The parking time is too
pump to the "up" position,
long after flipping the
press it for a few times, and
cab, and the cylinder
make the limit pawl of the
limit pawl is locked (for
cylinder out of the pawl slot;
this symptom that the
then, reverse the oil pump
cylinders with limit pawl
handle to "down" position, and
cannot decrease)
the cab drops by pressing
When the cab drops, there After completion of the system
are bubbles and oil at the exhaust, check the oil level,
intake and exhaust plugs, and refuel to the place flushing
Too much hydraulic oil
there is oil leaked at the with the upper surface of the
in the tank
connection of the oil pump piston (the rocker should be
and oil tank, and the oil down) as shown in the fuel
pool is burst. diagram
Clean the system and replace
Cab drops not in place Dirty oil
the hydraulic oil
Hydraulic latch
Tank intake and exhaust Pull the cab in place
interference
plug "leak" oil, and when
The intake and exhaust plug
the cab is approaching to Normal
drop in place, it automatically leak oil
automatically drops
Normal Floating function
6. Points for attention on use of cooling system

(1) The cooling medium used for the radiator of the forklift of our company is
generally long-lasting antirust and antifreeze liquid (FD-2 type-35℃), w hich is not
changed around the year, regardless of summer or winter. Generally, after being used
for one year, it should be let out for filtration and purification and then put to use
again. The cooling system, is furnished with an auxiliary water tank, on the wall of
which are marked with “FULL” and ”LOW”, between which the level of antifreeze
liquid should stay when the system is in use.
(2) Regularly check the sealing performance of the cooling system and the level
of cooling liquid and shoot the trouble as early as possible, otherwise, the auxiliary
water tank will lose its function, give wrong indication of level and finally shorten the
lifetime of the engine.
(3) When antifreeze liquid is used as cooling medium, it is strictly forbidden to
-9-
add water and different type of antifreeze liquid at will. Antifreeze liquid of same type
should be replenished after the liquid leaks or evaporates.
(4) If water is used as cooling medium, it probably freezes in cold winter when
the machine is at the time of parking. In this case, the water should be discharged
from the radiator. After the radiator works for a period of time, it should be
dismantled and put into boiling soda solution for cleaning the scale or sediment
accumulated on the inner surface of it.
(5) During operation, if the radiator of forklift “boils” or the temperature of
cooling liquid is too high, do not open the cover of radiator immediately. If the cover
needs to be removed to find out the cause for it, reduce the rotational speed of engine
to the moderate, slowly rotate the cover and not remove it very soon so as to prevent
operators from being scalded by the splashing liquid.
When the radiator cap is tightened, it must be tightened in place; otherwise the
system is not sealed, which is difficult to establish the provided system pressure.
(6) Based on different working conditions, regularly clean the outer surface of
the radiator with detergent, or wash it with compressed air or high-pressure water (no
less than 4kg/cm2).
7. Anti-tilting Safety Attention
- 10 -
8. Packaging and Transport
Lifting Forklift Truck
·The lifting holes at both ends of outer upright mounting beam are fastened with the
counterweight hook by the wire rope, and then the forklift truck will be lifted by using
- 11 -
lifting equipment.
Warning:
• When lifting the forklift truck, be sure not to wind the wire rope and the overhead
guard together.
• The wire rope and lifting device shall be very strong to safely support the forklift
truck (forklift truck is extremely heavy.)
• Do not use the cab (overhead guard) to lift the forklift truck.
• When lifting forklift truck, do not enter the forklift truck bottom.
Handling:
• The forklift truck is generally used for loading and unloading and short-distance
transport and not suitable for long-distance transport. If the forklift truck is used for
long-distance transport, the ship, train, or more than 36T load-carrying automobile
and other load-carrying vehicles are needed for handling. The wheel is padded with a
wedge, and the vehicle body is tied securely to prevent slippage of vehicle in transit.
9. Nameplate & warning label

Usage and precaution on the label are for the sake of you and truck. Please
- 12 -
operate the truck conforming to instructions. If the label drops please replace it with a
new one.
(1) Nameplate
(1) Fork lift nameplate
(2) Safety label
Standing on or under the fork is prohibited, in
case personal security is threatened by rising or
falling of the fork.
(3) No standing behind the mast please.
Standing behind the mast is forbidden against
potential safety hazard.

Warning
- 13 -
(4) For goods only!
Warning: Carriage of person is forbidden. Forbid Hitching People
(5) Tyre safety label
Warning: it needs to be aware of when installing and
inflating the tyres.
(6) No hoisting!
Lifting with the two holes is prohibited to prevent confusion
with the two holes below for hoisting.
(7) Caution! The rolling fan!
The label warns of potential hazard to be caught and

Waring
hurt by the fan.
(8) Caution! Hot!
Warning: High temperature hidden trouble exists
in exhaust pipes, in order to prevent hands being
scalded.
- 14 -
(9) Antifreeze added already.
The label warns that antifreeze has been added
already.
(10) Caution! The clamping mast!
The label warns of potential danger during the
rising and falling of mast, in case that the moving
mast clamps hand.
(11) Alert to tipping over please.
The label warns of potential danger rising out
of tipping over.
(12) Danger! Electricity!
The label warns of potential danger of electric shock.
(13) No flushing.
No flushing for fear of water penetration into
air filter.
- 15 -
10. Oil Used for Forklift Truck

Name Brand Code (Homeland) Brand Code (Export)
No.0 in summer;
Fuel (Diesel)
No.-10 in winter
Lubricant for Gear GL-5 85W/90
Hydraulic Oil L-HM32
Hydraulic Drive Oil SG/CF-4 15W-40
Brake Oil GL-5 85W/90
Lubricant for Engine SG/CF-4 15W-40

No.3 Lithium Base Grease
Grease
(drop point 170)
- 16 -
11. The Chart of Lubrication System
Inspection every 1200 hours


Steering cylinder
Radiator
Wheel bearing
Crankcase Steering center pin
Oil tank
Torcon oil
(hydraulic type)
Tilting cylinder pin
Transmission
(machanic type)
Braking fluid
Differential
Wheel bearing
Mast Tilter
cylinder pin
Free lift plate
Lifting chain Mast bracket lid
Oil types
Lubricant Engine oil Brake oil
Wheel bearing Gear lubricant Torcon oil
Lubricant
Operating tank oil Water Supply Exchange
- 17 -
Ⅱ.P rim ary Param eter of Forklift Truck

Technical parameter table 1 for
FD200-320T diesel hydraulic forklift
No. Parameter name Unit FD200T FD230T FD250T
1 Rated lifting capacity kg 20000 23000 25000

2 Load centre distance mm 1220 1220 1220
3 Lift height mm 4000 4000 4000
4 Mast tilt angle Deg 6°/12° 6°/12° 6°/12°
Lifting speed
5 mm/sec 350/380 350/380 350/380
(Full load/No load)
Max.Travelling speed
6 km/h 30 30 30
(No load)
7 Max.Gradeability (With load)) % 25 25 25
8 Max.Drawbar pull (With load) kN 160 160 160
9 Wheel base mm 4500 4500 4500
10 Front mm 2200 2200 2200
Tread
11 Rear mm 2300 2300 2300
12 Front mm 1200 1200 1200
Overhang
13 Rear mm 1100 1100 1100
Fork
14 L×W×T mm 2440×300×105 2440×300×110 2440×300×110
dimension
Lateral fork adjustment
15 mm
(Outside of fork) 1040-2660 1040-2660 1040-2660
Min.ground clearance
16 mm 320 320 320
(Bottom of mast)
17 Min.turning radius (Outside) mm 6100 6100 6100
18 Length mm 9240 9240 9240
19 Shape Width mm 3020 3020 3020
dimensions Height
20 mm 4250 4250 4250
(Mast)
Cummins Cummins Cummins
21 Model
QSC8.3-C240-L QSC8.3-C240-L QSC8.3-C240-L
22 Rated output/rpm. kW 179/2200 179/2200 179/2200
23 Engine Rated torque/rpm. N·m 1085/1500 1085/1500 1085/1500
24 Cylinder No. 6 6 6
25 Diameter× Distance mm 117×135 117×135 117×135
26 Displacement L 8.3 8.3 8.3
27 Model ZF3WG211 ZF3WG211 ZF3WG211
Transmission
28 Stage (FWD/RVS) 3/3 3/3 3/3
- 18 -
29 Driving wheel 4 14.00-24-24PR 14.00-24-28PR 14.00-24-28PR

Tire
30 Steering wheel 2 14.00-24-24PR 14.00-24-28PR 14.00-24-28PR
31 Gravity (including oily water) kg 34600 35000 36000
Technical parameter table 2 for

FD200-320T diesel hydraulic forklift
No. Parameter name Unit FD280T FD300T FD320T
1 Rated lifting capacity kg 28000 30000 32000
2 Load centre distance mm 1220 1220 1220
3 Lift height mm 4000 4000 4000
4 Mast tilt angle Deg 6°/12° 6°/12° 6°/12°
Lifting speed
5 mm/sec 270/310 270310 260/310
(Full load/No load)
Max.Travelling speed
6 km/h 26 26 26
(No load)
7 Max.Gradeability (With load)) % 20 20 20
8 Max.Drawbar pull (With load) kN 250 250 250
9 Wheel base mm 4800 4800 4800
10 Front mm 2490 2490 2490

Tread
11 Rear mm 2450 2450 2450
12 Front mm 1260 1260 1260

Overhang
13 Rear mm 1200 1200 1200
Fork
14 L×W×T mm 2440×300×110 2440×320×110 2440×320×110
dimension
Lateral fork adjustment
15 mm
(Outside of fork) 1500-3120 1500-3120 1500-3120
Min.ground clearance
16 mm 300 300 300
(Bottom of mast)
17 Min.turning radius (Outside) mm 6500 6500 6500
18 Length mm 9740 9740 9740
19 Shape Width mm 3420 3420 3420

dimensions Height
20 mm 4290 4290 4290
(Mast)
Cummins Cummins Cummins
21 Model
QSC8.3-C260-L QSC8.3-C260-L QSC8.3-C260-L
Rated
22 Engine kW 194/2200 194/2200 194/2200
output/rpm.
Rated
23 N·m 1180/1500 1180/1500 1180/1500
torque/rpm.
- 19 -
24 Cylinder No. 6 6 6
Diameter×
25 mm 117×135 117×135 117×135
Distance
26 Displacement L 8.3 8.3 8.3
27 Model ZF3WG211 ZF3WG211 ZF3WG211

Transmission Stage
28 3/3 3/3 3/3
(FWD/RVS)
29 Driving wheel 4 16.00-25-32PR 16.00-25-32PR 16.00-25-36PR
Tire
30 Steering wheel 2 16.00-25-32PR 16.00-25-32PR 16.00-25-36PR
31 Gravity (including oily water) kg 41500 42000 42800
- 20 -
Ⅲ.P rim ary A ssem bly of Forklift T ruck
No. Name Contents
1 Engine mounting Includes engine, air cleaner
2 Cooling System Mainly including the radiator, water pipe and auxiliary water tank
3 Exhaust System Mainly including muffler, exhaust hose and telescopic hose
Oil Cooling System

4 Mainly including torque converter oil radiator and cooling oil pipe
of torque converter
Transmission Mainly including transmission assembly, torque converter, drive

5
System shaft assembly and variable speed control
Includes axle house, half shafts, differential, hub reduction,

6 Drive axle assembly
wet-type brake
Mainly including brake valve, parking brake valve, brake oil

7 Brake System
pump, filling valve, brake tube and accumulator
Mainly including steering axle, steering king pin, steering knuckle
8 Steering Axle assembly, wheel hub, connecting rod assembly and steering
cylinder
9 Steering System Mainly including full hydraulic steering gear and redirector
10 Wheel Includes front tyre, & rim, rear tyre & rim
11 Frame System Includes frame, tank in frame, hood, floor, counterweight, seat
Includes outer & inner mast, lift bracket, cylinder positioner, fork,
12 Lifting system
lift cylinder, end roller, side roller, sheave, chain
13 Tilting Cylinder Includes cylinder body, piston assembly, cylinder cover, oil seal
14 Hydraulic System Includes control valve, oil pump, oil filter, cover plate
15 Electric System Includes air-conditions, combination meter, lamp, battery
- 21 -
IV. The structure, principle, adjustment and maintenance of forklift

1. Dynamic system
(1) Introduction
The dynamic system includes the installation of the engine, air inlet system,
cooling system and exhaust system, etc. The engine is linked to transmission device.
The holder of engine is connected with the frame of the forklift through a rubber
cushion to reduce vibration. The power of engine is transferred to the driving system
by a flywheel through a torque converter.
The power of forklift FD200-320T is provided by diesel engine Cummins
QSC8.3 imported from USA. The accessories of the engine such as air filter and
silencer are all from the supplier of Cummins equipments to ensure normal operation
and maintenances for the engine. Operation and maintenance of the engine refer to the
Engine Operation and Maintenance Manual.
(2) Primary Parameter of Cummins QSC8.3 Engine
Parameter Cummins QSC8.3-C240-L
Four-stroke, increase Pressure and Mid-cooling
Type
in-line
Cylinders No.-Bore× Stroke 6-117×135
Total output 8.3 L
Compression Ratio 17.5
Rated Power / Speed 179 kW / 2200rpm
Rated Torque / Speed 1085N·m/1500rpm
Idle Speed 800rpm
Min. Fuel Consume 226 g / kW·h
Max. Dimensions of Outline 1128×872×1154
Net Weight 720kg
Turning Direction Clockwise direction
Lubricant 25 L
- 22 -
Parameter Cummins QSC8.3-C260-L

Four-stroke, increase Pressure and Mid-cooling
Type
in-line
Cylinders No.-Bore× Stroke 6-117×135
Total output 8.3 L
Compression Ratio 17.5
Rated Power / Speed 194kW / 2200rpm
Rated Torque / Speed 1180N·m/1500rpm
Idle Speed 800rpm
Min. Fuel Consume 226 g / kW·h
Max. Dimensions of Outline 1128×872×1154
Net Weight 720kg
Turning Direction Clockwise direction
Lubricant 25 L
2. Transmission device
(1) Introduction
The transmission device is imported from ZF Company of Germany. It consists
of hydraulic torque converter, dynamic shifting gearbox, hydraulic system and
electrical system and has the following advantages:
1.1 Compact structure design and built-in oil circuit.
1.2 High-tooth and high-coefficient helical tooth engagement, both reducing
noise and improving bearing capacity.
1.3 Proportional electromagnetic valve facilitating automatic manipulation and
control unit integrating diversified control programs, i.e. EST-37A are adopted.
1.4 The inching of electronic controlled program is used and the function is
realized by EST-37A control element, so that the micro control accuracy of the
driving and heavy load of the forklift can be realized more easily.
1.5 The hydraulic clutch is furnished with specially treated paper friction lining
and steel sheet to improve its abrasion, the oil circuit of hydraulic torque converter is
- 23 -
fixed with a good filter to improve the purity of oil and elongate the service life of the
torque converter.
(2) Base Structure and Performance of Forklift Truck
Structure and Performance of Transmission

Item Unit FD200-320T
Type
Circular
Torque Diameter mm 340
Convertor Torque Ratio 1.773

Setting
Pressure MPa
Oil pump flow L/min

Type
Hydraulic 1 (FWD/RVS) 4.579/4.062

Speed
transmission box 2 (FWD/RVS) 2.304/2.044
ratio
3 (FWD/RVS) 0.963/0.854
Net Weight ㎏ 490
Oil Capacity L 13
Oil Type SG/CF-4 15W-40
2.1 Hydraulic torque converter
2.1.1 Function of hydraulic torque converter
The main functions of the hydraulic torque converter are: realizing stepless
variable speed, increasing traction, improving engine performance, and preventing
engine flameout when working; improving the shift quality of gearbox, and benefiting
power shift.
2.1.2 Structure of hydraulic torque converter
The hydraulic torque converter consists mainly of pump wheel, turbine and guide
wheel. The pump wheel is fixed on input shaft, turbine wheel installed on the output
shaft and connected with the input shaft of gearbox through a spline, playing the role
of transferring power to hydraulic gearbox. The guide wheel is fixed on the shell of
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torque converter.
2.1.3 The working principle of Torque Convertor
Liquid under the action of centrifugal force is sprayed to the blade grid of turbine
wheel along the pump impeller blade grid, torque is passed to the output shaft, and the
turbine liquid under the action of guide roller changes direction, making it flow into
the pump wheel with the best angle; at this time, a reaction torque is produced to push
the wheel, so that the output torque is larger than the input torque by a torque
equivalent to the reaction torque.
As the rotational speed of turbine increases, approaching to the input rotational
speed, the change of flow angle reduces. And the output shaft torque also reduces.
And finally the fluid begins to flow contrary to the direction of stator vanes and blade
grid, as a result of which the reaction torque beings to affect in the reverse direction.
In this case the output shaft torque becomes smaller than the input shaft torque. So as
to prevent this phenomenon, a free wheel (one-way clutch) is provided on the stator
wheel. When the reaction torque acts in the reverse direction, the stator wheel rotates
idly. In this state the input torque becomes equal to the output torque so that high
performance is ensured.
In order to avoid cavitation, the torque converter is always full of pressure oil,
which is completed by the torque converter control valve.
2.2 Dynamic shifting gearbox
Its main functions include: changing transmission ratio, satisfying the need of the
traveling forklift under different working conditions and realizing shifting gears
without power interruption.
2.3 Hydraulic system
The main functions of the hydraulic system are to provide hydraulic torque
converter with a transmission medium – oil, to keep the circulating cooling of
hydraulic torque converter, to provide the hydraulic clutch of power shift gearbox
with pressure oil, to control the shift and to provide the power shift transmission gear
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with lubricant oil.
2.4 Electrical system
Its main functions are receiving gear-shifting signal, controlling gear-shifting
logic and manipulating electromagnetic valve. Based on sensor’s signal, it also can
control blocking, achieve automatic shifting, prevent over speed of the engine and
control interlocking etc.
3. Use of Manipulation
3.1 Before starting the vehicle, the driver must switch the shifting lever of
gearbox to neutral position. It would be best not to loosen the parking brake to ensure
safety.
3.2 The parking brake should be released when the gearbox is put into gear and
the vehicle is ready to go.
3.3 When the vehicle is driving, the gearbox should be made up and down
operation in turn and out of turn operation is not allowed. As for torque converter’s
structure is backward trailer and one-way clutch, to prevent the engine overspeeding,
only when the vehicle speed reaches the speed which is the limit one of lower
adjacent gear, the shifting to lower gear should be performed. If necessary, pedal
brake can be used to slow down the vehicle before changing to low gear.
3.4 When the vehicle is coasting along a slope, the rotational speed of engine
should not be lower than 1200 rpm, otherwise, the gear in gearbox and friction lining
will be damaged.
3.5 When inverse manipulation is needed for the vehicle (from advancing gear
directly to reverse gear, or reverse gear directly to advance gear), the driver should
lower the rotational speed of engine and driving speed of the vehicle and the highest
speed of direction control is not allowed to exceed 10km/h.
3.6 When the vehicle stops moving, the engine cannot perform a function as
brake due to torque converter, so when the vehicle stops on a slope, the stopper should
be placed under the wheel to prevent the vehicle from coasting down.
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3.7 When the vehicle travels reversely, the driver should lower the rotational
speed of engine and the driving at speed 1 or speed 2 is suggested.
3.8 When the vehicle is in trouble and needs to be dragged off, the towing speed
should be no more than 10km/h and the longest distance no more than 10km. If more
distance of towing is required, the transmission shaft between the output end of the
gearbox and the axle should be removed or the vehicle should be shipped.
3.9 If the vehicle pulls up and the engine and gearbox linked to it are still
running, the engine stalling is not allowed.
4. Maintenance and repair
4.1 Oil filling
The proper amount of oil stipulated should be filled before the gearbox is used.
For the first filling the oil storage volume of the external components such as filter, oil
pipe and cooler etc should be considered. So the oil filled this time should be a bit
more than that for future.
The engine should be kept at idle speed state when filling in oil, or the oil of the
higher components such as torque converter and cooler etc will flow into gearbox, the
oil level will be higher than the normal one and the height of oil level is not easy to be
controlled.
The oil level height must be controlled according to the scale of oil gauge.
When the oil temperature is about 40℃,the oil level should be at the low er scale
of the oil gauge and when the oil temperature is about 80 ℃, the oil level sh
the upper scale of the oil gauge.
4.2 Oil temperature control
When the forklift is in operation, the driver should pay attention to the oil
temperature of the gearbox. The oil temperature of gearbox for normal working is
usually between 80 ℃ to 110℃ and
temperature exceeds 120 ℃, stop it to check
1200-1500rpm and put the gearbox at idle position. The temperature should decrease
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to the normal value within 2-3 minutes under the normal condition. Otherwise, it
indicates that there are problems in the system and it can only be used again after the
troubles are eliminated.
4.3 Oil pressure control
The pressure of the gearbox should be controlled by pressure control valve, the
normally manipulated oil pressure is 15-17bar and the main oil pressure will be
decreased at the moment of shifting, which is resulted from the oil filling in oil
cylinder of clutch. The oil pressure should return to the normal value after shifting
and if the oil pressure is lower than the value stipulated, it will result in the slippage
and heating of friction lining of clutch, finally burning and damaged. Therefore, the
forklift must be stopped for examination and used again after the trouble is
eliminated.
4.4 Oil changing
The oil in the gearbox should be changed at regular intervals, after 100 hours of
working for the first use, then change once every 100 hours. But change at least once
a year, and the oil level is controlled oil according to the method in section 5.1 of this
article when refueling.
Every time while changing the oil, the filter or filter element must be replaced,
and the mesh hole of the filter element is 0.025mm in size, the minimum filtration
area 5100cm and the flow of the oil filter is about 100dm/min.
4.5 Electric welding
When the forklift needs welding, all the electrical elements of gearbox must be
unplugged and disconnected with the electrical system of it, or it will lead to the
damage of the electrical elements of gearbox.
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5. General trouble shooting
5.1 Abnormal noise

Cause for trouble Check method Remedy
Check the sound of rotation under Replace elastic
Fracture of elastic plate
the low speed plate
Bearing damaged or
Disassemble and check Replace
worn
Fracture of gear Disassemble and check Replace
Spline worn Disassemble and check Replace

Big noise of oil supply
Disassemble and check Repair or replace
pump
Loose bolt Disassemble and check Tighten or replace
Fill the oil as
Oil level is too high Check the scale of oil gauge
specified
Obstruction of oil
Check the oil suction filter Clean or replace
suction filter
5.2 Fail to put into gear or the engine can’t be started up

Cause for
Check method Remedy
trouble
Circuit fuse Replace the fuse after trouble is
Disassemble and check
burnt eliminated
Loose cable Disassemble and check each Tighten the connecting cable
plug connecting part socket at each part
5.3 Oil temperature too high

Cause for trouble Check method Remedy
Parking brake has not been Check the working
Loosen parking brake
completely loosened condition of brake
Obstruction of oil suction
Disassemble and check Clean or replace
filter
Oil level is too low Check the oil level Fill the oil as specified
Re-control the height
Oil level is too high Check the oil level
of oil level
Obstruction of oil cooler Disassemble and check Cleaning
Replace the friction
Slippage of clutch
lining of clutch
Bearing worn or blocked Disassemble and check Replace
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3. Drive axle
1. Introduction
Kessler drive axle with advanced technology used by the truck is basically
adopted for large-tonnage forklift trucks at home and abroad, and the drive axle is
composed of differential mechanism, hub reduction gear and wet-type driving brake
and has the following characteristics.
1.1 The driving brake of the drive axle adopts multi-plate and fully-enclosed wet
type brake, which is portable and convenient in operation and the axle-load has good
dust and water resistant ability and free from maintenance.
1.2 Big braking torque, safe and reliable.
1.3 Equipped with caliper disc type parking brake.
2. Structure introduction
1. Main Speed Reducer Shell 2. Bolt 3. Main Drive Gear Pair 4. Rolling Bearing 5. Bolt
6. Nut 7. Bevel Gear Differential Assembly 8. Bevel Gear Differential Left Shell
9. Bevel Gear Differential Right Shell 10. Axle Shaft Gear Pad 11. Axle Shaft Gear, Cross
Shaft, Differential Gear 12. Bearing 13. Bearing Adjustment Nut 14. Stop plate 15. Bolt
16. Bearing Block Assembly 17. Bearing Block 18. Bearing 19. Sleeve, Adjusting Pad
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20. Bearing 21. Adjustment Pad 22. Bearing Gland 23. Paper Pad 24. Oil seal assembly
25. Seal Ring 26. Input Flange Assembly 27. Flange 28. Dust Cover 29. Lock Nut, Washer
30. Bolt 31. Washer 32. Bolt 33. Spring Washer
Figure 3-1 Main Speed Reducer Assembly
2.1 Differential and hub reduction gear
The differential mechanism is mainly made of differential case, drive bevel gear,
driven bevel gear, half shaft gear and bearing etc. Tapered roller bearing is mounted at
the both ends of differential for mounting driven bevel gear, tow tapered roller
bearings are mounted at the rear axle part of drive bevel gear to bear the forward and
backward thrust force and a bearing is mounted at the head of gear to bear the radial
force.
The hub reduction gear is made of a central gear, a set of planetary gear and an
internal gear. The central gear is engaged with planetary gear, which is mounted on
the shaft of planet carrier and engaged with the internal gear.
The power is transmitted from driving gear to the driven gear, driving the
planetary gear of differential, then transmitted to half axle gear to drive the central
gear, which drives the planetary gear and then transmitted to the planet carrier of the
driving wheel.
2.2 Wet-type driving brake
Wet-type brake is made of brake case, parting slip, friction lining and piston etc.
The parting slip and brake case are connected with splines and the friction lining is
mounted on the brake case. When the brake is stepped on, oil pressure produced by
hydraulic oil will push the piston, which compresses tightly the parting slip, thus
reducing the speed of the friction lining in rotation and finally resulting in the speed
reduction of brake case to its stop.
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3. Primary Parameter of Drive Axle
Type Box-shaped full floating bridge welding
Tire 14.00-24-28PR
Driving wheel Rim 10.00-24

Air Pressure 0.91MPa
Type Spiral bevel gear type
Differential Speed Reduction
Ratio 2.92
Type Planetary gear type

Hub Reduction
gear Speed Reduction
Ratio 6.0
Differential 28.5L
Oil Capacity
Hub Reduction gear 3.2×2L
Total Speed Reduction Ratio 19.8
Oil Type LS90
4. Maintenance and Trouble-shooting
4.1 Check the oil level of main drive, hub reduction gear and brake oil tank of
drive axle for every 100 hours and fill the gear oil of the same type if necessary.
Check the working state of ventilation plug and clean it if necessary.
4.2 Check the tightening state of connecting bolt of drive axle every 400 hours
and tighten the bolt based on the tightening torque of 2000 N·m.
4.3 Replace the oil of drive gear, hub reduction gear and brake oil tank every
1000 hours with the oil of same type and specification and check if there is any
impurities such as metal in these two parts.
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4.4 Trouble shooting
The cause for troubles and remedies are as follows:

The connecting bolt of main reduction
Tighten or
gearbox is loose or the gasket
replace
Oil leakage from the damaged.
main reduction gearbox
Obstruction of ventilation hole Clean or replace
Oil seal worn or damaged Replace
Noise of differential is Gear worn, damaged or broken Replace

Bearing worn ,damaged or broken Replace
too big
Improper gear backlash Adjust
The spline fit connecting half axle gear
Replace the parts
is loose
Fill in oil
Insufficient gear oil according to the
need
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4. Steering system
1. Introduction
A steering system is mainly composed of a full hydraulic steering gear with low
torque load and a steering wheel assembly, and the structure of the steering gear is
shown in Figure 4-1. The full hydraulic steering gear is located at the lower end of the
steering wheel assembly, and the center of the steering wheel is a horn button. The
steering shaft through a universal joint is connected onto the drive shaft of the
hydraulic steering gear, and the steering wheel can be adjusted according to the needs
of the driver; when the steering gear is rotated, its movement is passed to the full
hydraulic steering gear, and the full hydraulic steering gear according to the turning
angle of the steering wheel passes the pressure oil from the shunt valve through
pipeline to the steering cylinder by means of measurement; when the engine stops, the
oil pump can not supply oil, but manual steering can still be realized, but it is
laborsome.
Figure 4-1 Steering System
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2. The main specification of the steering system:
Item FD200-320T
Rear wheel with steering

Type of steering system
powered
Type BZZ5-E400B
Full hydraulic steering Emission Capacity (ml/r) 400

Max pressure of intake (bar) 160
gear
Max pressure of working
back (bar) 16
Diameter of steering wheel (mm) 365
3. Full Hydraulic Steering Gear
3.1 Working Principle

The cycloid-style full hydraulic steering gear is an open center non-reaction full
hydraulic steering gear, as shown in Figure 4-2. The rotor and the stator are a pair of
cyclical pinwheel inside engaged gears, during the normal work (power steering),
they are in series between the shunt valve and the steering cylinder through the servo
valve (play the role of metering motor). Because the oil for in-out steering has to pass
through the metering motor, the rotation angle is in direct proportion to the in-out
flow of steering cylinder. The steering wheel is connected with the spool valve via
connection block 1, and then the valve bush 6 is driven via positioning spring 4. The
valve bush 6 passes through the pin roll 5, and the connector 8 is connected with the
rotor 9. Because oil way is obstructed, the rotor 9 is fixed. When turning the steering
wheel, the rotor 9 will rotate relatively between a pair of rotary valves (valve core,
valve sleeve) used for oil distribution. The rotation makes the circuit connected so that
the oil pumped in goes to the steering cylinder for steering through the motor. When
the steering wheel is fixed, the valve core and valve sleeve are in the center under the
interaction of the positioning spring 4 to close the oil way.
In the case of oil pump without oil supply, the safety valve 14 is opened by the
vacuum to form intra-valve circuit. At this moment, the motor is equivalent to a hand
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pump, which presses the oil from one chamber of the steering cylinder to another to
achieve manual steering.
Figure 4-2 Full Hydraulic Steering Gear

1. Cross-Connection Block 2. Front Cover 3. Valve Body 4. Leaf Spring 5. Pin Roll
6. Valve Sleeve 7. Valve Core 8. Driving Shaft 9. Rotor 10. Back Cover
11. Separation Disc 12. Stator 13.O-ring 14. Steel Ball 15.O-ring
16.X-ring 17.O-ring
3.2 Operation Requirements
3.2.1 Installation
During the installation of steering gear, ensure that the steering gear is concentric
with the steering column, and there should be axial clearance to avoid the dieback of
the valve core. Check whether the steering wheel can rotate flexibly or not after
installation.
In piping installation, the steering gear joint marked with “P” shall be connected
to the fuel inlet pipe of oil pump; the joint marked with “T” is connected to the oil
tank; the joints marked with “A” and “B” are connected to the left and right chambers
of steering cylinder respectively; and the joint marked with “Ls” is connected to Ls
port of the preferential valve.
Suction pipe allows a flow rate of 1-1.5m/s, pressure pipe and oil return pipe
allow a flow rate of 4-5m/s, and high-pressure hose test pressure shall not be less than
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3 times the maximum working pressure. The oil pipe joint of steering cylinder should
face up for easy deflation.
3.2.2 Oil Temperature Range: -20 ～+80℃
℃
Normal Oil Temperature: +30℃～+60℃
3.2.3 Oil Selection: The oil viscosity is 17-23 centisthene, and it is
recommended to use low-freezing hydraulic oil.
3.2.4 Filtration: The filtration precision of oil into the steering gear is 30 micron,
and it is ensured that oil return of steering gear has 0.2-0.3Mpa backpressure to
prevent the oil flowing back into the oil tank during the manual steering.
3.2.5 Commissioning: Before running, wash the oil tank and then inject the oil
to the highest oil level. Release the steering cylinder nipple to make the oil pimp
running at low speed for deflation until the oil coming out does not contain foam.
Tighten up all threaded connections, and check whether the steering system is
working properly under various conditions. If hard or failed steering is discovered, the
causes should be carefully found out. Do not turn the steering wheel hard, and do not
easily disassemble steering gear to prevent the damages of parts of the steering gear.
Check whether the system pressure meets the specified value when the steering
cylinder piston reaches the limit position.
3.2.6 Operation Maintenance
Daily check oil leak, oil level of oil tank and working conditions. Regularly
replace filter element and oil as required. For hydraulic oil, it can be checked by
dripping a drop of oil to the blotter; if the oil stains have a black center, then it must
be replaced.
If unusual situation is found during the use, the causes should be carefully found
out, and it is strictly prohibited that two persons turn the steering wheel
simultaneously.
In order to maintain a good working status of the steering system to prevent
accidents, the water, mechanical impurities and acid value of the oil must be regularly
checked. If exceeding the requirements of the original label plate, it should be
replaced with new oil. It is absolutely prohibited to use the waste oil which has been
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used without the filtration.

Do not easily open the steering gear when check the steering system. If the
steering gear is confirmed to have failures, it must be dealt with according to relevant
requirements.
All the dismantling devices should be clean, the site should be clean, and the
dismantling is preferably completed indoors.
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4. Steering system troubleshooting
Trouble Cause for trouble Remedies
Pump damaged or breaking down Replace

Fail to turn
Preferential valve jammed or damaged Clean or replace
handwheel
Hose or joint damaged or pipeline blocked Clean or replace
Preferential valve pressure too low Adjust pressure
Air in oil circuit of steering system Exhaust air

Hard to turn Steering unit fail to reposition due to spring Replace spring
handwheel plate damaged or elasticity-insufficient plate
Excessive inner-leakage in steering cylinder Check piston seals
Excessive low level in oil tank Refill oil
Adjust the
Forklift
Excessive flow as steering preferential valve
crawling/swing
flow
Excessively low level of oil in tank Refill oil
Abnormal noise
Suction pipeline or oil filter blocked Clean or replace
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5. Steering Axle
1. Introduction
Steering axle, with a welded structure of box-shaped cross section (see figure 5-1)
is composed of steering bridge axle body, steering cylinder, connecting rod and
steering wheel; the steering trapezoid has a slider-crank mechanism, and the steering
knuckle is driven to turn by the cylinder piston rod through the connecting rod, so that
the deflecting wheel deflects, so as to realize steering. The steering axle is connected
to the vehicle tail frame with front and rear hinge pin, to make the axle able to swing
around the hinge pin; there are a left and right steering knuckle at the left and right
side of the steering axle respectively, the rear wheel hub is installed with two tapered
roller bearings onto the steering shaft, the wheels through the wheel rim are pried to
the hub, and a oil seal is arranged inside the bearing, to keep the grease inside the hub
and steering knuckle cavity.
Figure 5-1 Steering Axle
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The main parameter of the steering axle:
Model FD200-320T
Central supporting shaft

Type
bearing
Maximum Inner wheel 74°
deflection
Outer wheel 54°
angle
Steering
King pin center distance 1980mm
axle Steering king
Inner obliquity 0°
pin
Outer obliquity of wheel 1°
Mass 1600kg
Tire 14.00-24-28PR
Steering
Wheel rim 10.00-24
wheel
Inflation pressure 0.88Mpa
2. Steering Knuckles and King Pin
Steering knuckle is positioned between the upper and lower bushings at both
ends of the steering axle by use of a steering knuckle king pin, thrust bearing and
adjusting shim, the middle part of the king pin is locked with a locking pin on the
steering knuckle, the two ends of the king pin are supported by the needle roller
bearing, oil seals are arranged on both ends of the bearing, and a grease nipple is
installed on the upper part of the king pin.
3. Steering (rear) wheel bearing pre-load adjustment
3.1 The wheel hub, tapered roller bearing, wheel hub cover cavity and oil seal lip are
refueled with grease at the location shown in Figure 5-2.
3.2 Press the hub bearings into the hub and fit the hub on the knuckle shaft.
3.3 Fit a flat washer and tighten a castle nut to a torque of 206-235N·m and loosen it
and then tighten it again to a torque of 9.8 N·m.
3.4 Slightly knock at it with wooden hammer and in the meantime, rotate the nut for
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3-4 turns, to ensure that the hub is not loose.

3.5 Tighten the castle nut to make the slot aligned to the cotter pin of the steering
knuckle.
3.6 Again slightly knock at the hub with a wooden hammer and in this time, rotate
manually the hub for 3-4 turns to ensure its smooth rotation with a specified torque of
2.94-7.8N·m.
3.7 When the torque value measured is up to the specified one, lock the castle nut
with a cotter pin.
Tighten torque 580-680Nm
Daub sealant GY-340
Fill lubricant
Figure 5-2 Pre-tightening load adjustment
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6. Brake System
When the vehicle travels, the braking system make the vehicle reduce speed or
stop, or make the vehicle park for a long time on flat or slope.
This machine is braked by hydraulic power.
This machine’s braking system is divided into two parts:
1. Walking brake system
It’s usually used to control the vehicle’s speed and to make it stop. In the vehicle,
it adopts hydraulic power braking. This has many advantages such as braking equable,
response time little, reacting sensitiveness, operating portable, safety reliable, and the
braking performance is not affected by work environment, etc.
2. Parking braking system
The parking brake is a disc brake owned by the drive axle. It is a spring-loaded
brake system used for brake after parking, and can also be used for emergency
braking, and it is controlled by manual brake valve. The spring force of the brake oil
cylinder is offset by the hydraulic pressure before parking and canceling the brake.
The brake cylinder and brake caliper assembly are combined into a whole. The
parking brake can be realized by manipulating the parking brake valve of the cab.
Emergency parking brake will cause serious abrasion on the parking brake friction
plate, so the parking brake friction plate must be replaced after two emergency brakes.
The parking brake configuration is as follows:
Figure 6-1 Configuration of Parking Brake
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梭阀
Shuttle valve
盘式制
Disc 动器
brake 单路制动阀 brake valve
Single-way
Accumulator
蓄能器
油散
Oil pipe
Press
接手制动 manual brake
button
按钮开关 switch
ACC1
ACC2
Cool
PBM
PB
TA
ACCM
多路阀
Multi-way valve
35 Bar
PA
1 65B ar
滤清
Filter T
220 Bar
FG
17 5Ba r
M
M 14CC LSM O LS O
PM P
T P1
Figure 6-2 Working Principle of Brake System

This system is a fully hydraulic power braking system (the principle is shown in
Figure 6-2). It consists of oil pump, accumulator, single-way brake valve, multi-way
valve, caliper disc brake, shuttle valve, manual brake button, oil cooler, pressure
switch and pipeline and other components. When the accumulator in the braking
system reaches 16.5Mpa, the multi-way valve stops oil supply to the accumulator, and
oil flows to the drive axle cooling system. When the oil pressure of the accumulator
drops below 13Mpa, the multi-way valve supplies oil to the accumulator.
The pressure from the oil pump through the multi-way valve is filled to the accu
mulator of the driving brake and parking brake circuit. The system has two single-way
brake valves, and the high pressure oil outlet of the brake valve is connected with a
shuttle valve to guarantee that the two brake valves do not interfere mutually: the left
brake valve is not cut off with power, and is mainly used for uphill braking; the
engine still has power output in the braking situation, thereby guaranteeing the
security in the course of uphill braking; the right brake valve is cut off with power,
and is mainly used for plane and downhill braking. The engine has no power output in
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the braking situation. When stepping on pedal, the high pressure oil which is stored in
accumulators goes into power braking, passing through brake valve, then make
wheels stop running. When the pedal is released, the braking is unlocked. The oil in
the power brake goes through brake valve and returns to oil tank. The oil pressure
from the walking brake valve is direct ratio with the force which is on the pedal. A
very little power to make the pressure run to 13.8Mpa which walking brake system
demands. The stop valve is connected with vehicle braking circuit and parking brake
circuit, which can guarantee that when one loop is damaged, the other loop can still
play a role.
Shortly after the engine start up, the low-pressure warning lamp is bright for a
little time because of the oil pressure in the accumulator lower than warning pressure
(10Mpa). When the oil pressure in the accumulator is above the alarm pressure, the
alarm will automatically stop. After the alarm stops, the parking brake handle can be
released. In the course of operation, if the system fails, when the oil pressure in the
accumulator of the brake circuit drops below 10Mpa, the accumulator’s low-pressure
alarm light is on, and at this time the machine should stop operating for checking.
Parking brake consists of a brake disc, a brake cylinder mounted at the front axle
input shaft and a brake switch mounted on the control panel of the pilot valve. The
power spring of the cylinder applies pressure to the disc to brake. The parking brake
can also start as an emergency brake, the brake pad is worn seriously under
emergency braking, and the brake pad needs to be replaced during secondary
emergency braking. When driving, close the manual brake switch, and the valve is
open when the parking brake valve is relaxed; the high pressure oil in the accumulator
is pressed into the cylinder (min 10Mpa) to offset the strong spring force, so that the
parking brake is released; at the time of parking, open the manual brake switch, pull
the parking brake valve, and the accumulator’s oil cannot flow into the oil cylinder.
The high pressure oil in the oil cylinder through the brake valve unloading flows to
the fuel tank, when the strong spring in the oil cylinder brakes the brake disc.
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In order to ensure that the drive axle brake oil temperature is in the right context
and that the braking effect gets bad not because of too high brake oil temperature, the
braking system can cool brake oil. The drive axle on this forklift has an oil cooling
channel, cooling oil is from the multi-way valve by shunt, and an oil disperser is
arranged at the drive axle cooling oil outlet; after the temperature rises, the
temperature sensor sends out a signal, and the electric fan of the oil disperser is open
to help the braking system to cool.
Walking brake is oil immersion wetness multiple disc brake. The friction discs
and rotating are assembled crosswise on the drive axle hubs. The power pressure oil
compresses the unit and it produces brake force. The system’s excellences are no
adjusting, force no run down and wearing fairly little. In addition, for the system is
immerses in obstruction in oil tank, the water and dirty can’t go into the brake. The
system has many advantages such as large braking torque, long service life, antiaging,
dirt resistance, no servicing and so on.
The accumulator both in walking braking system and in parking braking system
are sack-lift structure. It’s only charged nitrogen gas, not aerated in oxygen,
compressed air or any other gas which is combustible. The gas is aerated by special
tools. It’s necessary as the accumulator’s accessory. It can be filled gas, be relieved,
check atmospheric pressure and revise the pressure. The pressure in accumulator’s
bath in walking braking circuit and in parking braking circuit is 6 Mpa. The pressure
in the accumulator is checked regularly so that it ensures the vehicle is safety.
(1) Pedal eight continuous after stopping and push and pull the manual control
valve more than five times. So the oil of high pressure in the accumulator is
discharged.
(2) Connect one end of the special tool which has a pressure gauge to the
accumulator, the other connected to nitrogen steel bottle.
(3) Switch on the nitrogen cylinder switch, and after the pressure gauge is stable,
open the switch on the pneumatic tool, that is, open the single-way valve inside the
- 46 -
accumulator to fill with air.
(4) Pressure may run to parameter designed instantly. Close the nitrogen steel
bottle’s switch, and check the indication after the pressure gauge’s hand being stable.
If being lack, charge again.
(5) When the demanding pressure realized, close the bottle’s switch, then close
the special tool’s switch, finally move the tool away.
(6) If the accumulator leakages (smear its head with engine oil, and it leaks if
there is bubble), tap the single-way valve inside the accumulator with a hammer or
small screwdriver, make it down first, and then return quickly, so that the sealing
surface has complete contact.
The gas in the tube can effect brake capability. Deflate gas after dismantling and
checking or replacing parts. A bleed screw is arranged inside two wheel hubs of this
machine’s front axle. Open the bleed screw to deflate, and step down the brake pedal
to let oil flow out until there is no bubble; in the case of the pedal treaded down,
tighten the bleed screw. The inside of the drive axle hub is shown in Figure 6-3.
Exhaust port
Brake oil inlet
Cooling oil outlet

Cooling oil inlet
Oil pointer port
Figure 6-3 Inside of drive axle hub
- 47 -
7. Electric system
1. Introduction
Electric system is a single wire circuit with cathode iron, and it is like the
nervous system of the forklift. The electric system mainly consists of the following:
Electrical schematic diagram as shown in Figure 7-4.
1.1 Integrated electrical board
Integrated electrical board consists of relays and fuses. These relays used to
amplify the switches’ capability, and the fuses protect the wirings and the electrical
equipment.
1.2 Charging system
It consists of generator, battery, charging indicator light and other components,
and is used to provide the electrical equipment of the forklift with power supply.
Voltage: 24V.
1.3 Starting system
It mainly consists of preheating system, starting switch, starting protection line,
starting machine and other components, and its function is to start the engine.
1.4 Parking control system
It consists of a starting switch, automatic flameout device and other components.
1.5 Instrument system
It mainly includes hourmeter, oil gauge, water temperature gauge, voltmeter,
generator tachometers, torque converter oil temperature gauge, speedometer, charging
indicator light, oil pressure indicator light, left turn indicator light, right turn indicator
light, neutral indicator light, brake indicator light, fuel filter clogging alarm light,
too-low brake pressure alarm light, air filter clogging alarm light and so on, and it
provides operators with a variety of information.
1.6 Lighting and Signal devices
These devices include all kinds of illuminating lamps, signal lamps, horn and
buzzer, etc.
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Work lamp: 70W
Double side yellow light: 21W/8W
Front combination light (distance light/passing light, turning and width):
75W/70W, 21W, 8W
Rear combination light (shift/width/reverse/brake): 21W (yellow)/ 8W (yellow)/
10W (white)/ 21W (red)
Warning light: 11W
1.7 Cab electrical system
Including wiper, cabin dome light, washer pump and other auxiliary electrical
equipment.
1.8 Air-condition
It can adjust temperature; make the cab warm or cool if it is demanded.
2. Brief explanation for operation
2.1 Start
Before you start the engine, you should move the gearshift lever to neutral (at
this time, the neutral indicator light is on); otherwise the engine will not start. This is
because the start circuit has safety protection.
Turn the starting switch clockwise to the first gear (power-on), and connect the
power supply of all electrical systems. The diagram of the starting switch gear is
shown in Figure 7-1.
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Figure 7-1 Starting switch gear diagram
Turn the starting switch clockwise to the second gear (starting gear) to start the
engine.
Before driving, release the manual brake switch; otherwise the gearbox power is
cut off, and the forklift will be unable to run.
After the engine starts, push the gearshift lever forward, namely to the forward
gear; step on the throttle, and the forklift moves forward; if the gearshift lever is
pulled back, that is, the backward gear, the reversing light is on and the reversing
buzzer and rear view system work; the forklift move backward if stepping on the
throttle at this time. There are 3 forward and backward gears, the larger numbers of
the gear, the higher speed.
Note: when the forklift is not used for a long term, the main power switch should
be turned off.
2.2 Combination switch
2.2.1 Light switch: turn one gear counterclockwise backward, and the front and
rear width lights are on. Switch to the second gear, and the head light is on, while the
width light is still on. Switch to the third gear, and the work light is on and both the
head light and width lamp are on.
2.2.2 Turn signal: pull the turn signal switch backward, and the front
combination light on the right of the forklift and the turn signal lamp of the rear
combination light are shining; push the turn signal switch forward, and the front
combination light on the left of the forklift and the turn signal lamp of the rear
combination light are shining.
2.2.3 Braking signal: when the forklift needs to be braked, step on the brake
pedal, and the rear combination light’s brake light (red) is on.
2.2.4 Reversing signal: when the forklift needs to be reversed, pull the gearshift
lever backward; at this time, the gearbox is in the state of reverse gear, the rear
combination light’s reversing light (white) is on, the reversing buzzer calls and the
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rear view system begins to work.
2.2.5 Non-charging signal indication: before starting the engine, turn the starting
switch clockwise to the first gear (power on). The charging light is on at this time, and
after the engine starts, it will automatically turn off; if the engine is in the working
condition, when the charging indicator light is on, the charging circuit is faulty and it
does not charge, so the machine should be stopped for checking.
2.2.6 Engine oil pressure signal: before starting the engine, turn the starting
switch clockwise to the first gear (power on), and the oil pressure indicator light is on;
after the engine starts, it will automatically turn off; if the engine is in the working
condition, when the oil pressure indicator light is on, the engine oil pressure is too low
and the lubricating effect is not good, so the machine should be stopped for checking.
2.2.7 Too low brake pressure warning light: before starting the engine, turn the
starting switch clockwise to the first gear (power on), and at the time, the warning
light is on if the brake pressure is too low; after the engine has started for a period of
time, the light will automatically go out; if the engine is working, when the indicator
light is on, the brake system pressure is insufficient, so the machine should
immediately be stopped for checking; or else, the brake failure will be dangerous.
2.2.8 Fuel gauge: indicates the storage volume of fuel in the fuel tank.
2.2.9 Water temperature gauge: indicates the temperature of the engine coolant.
2.2.10 Hour gauge: accumulates the operating hours of the engine.
2.2.11 Voltage gauge: indicates the system supply voltage.
2.2.12 Speedometer: indicates the traveling speed of the forklift (km/h).
2.2.15 Torque converter oil temperature: indicates the working oil temperature of
the torque converter.
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Instrument diagram as shown in Figure 7-2

1. Water temperature gauge
2. Engine oil pressure gauge (not used)
3. Voltage gauge
4. Tachometer
5. Speedometer
6. Hour gauge
7. Fuel gauge
8. Transmission oil pressure gauge (not used)
9. Transmission oil temperature gauge
10. Water temperature alarm lamp
11. Transmission oil pressure alarm lamp
12. Braking oil pressure alarm lamp
13. Charging signal
14. Parking brake signal
15. Air filter pressure alarm lamp
16. Neutral indication
17. Low engine oil pressure alarm lamp
18. Fault light
19. Engine parking indicator
20. Pre-heating signal
21. Oil/water separation indicator (not used)
- 52 -
22. Low brake oil pressure alarm lamp

23. Multivalve oil jam alarm lamp
24. Left turning lamp
25. Right turning lamp
2.3 Air-condition operation
A cooling switch is arranged on the right side of the control panel, and you need
to select whether to cool according to need. When the switch is opened, the air
conditioner starts refrigerating, and the cooling intensity can be adjusted; when the
switch is closed and the coolant valve located under the cab is opened, the air
conditioner starts heating. The turning switch on the left of control panel is wind
speed adjust switch. L means the low speed, M means the middle speed, and H means
the high speed. The faster the wind speeds, the louder the noise of air-condition.
Instrument diagram as in Figure 7-3
2.4 With regard to the electrical components and related operations of the engine
and gearbox, please refer to the relevant specifications.
3. Battery
6-QW-120 quick-start maintenance-free battery is used in this series forklift
truck, and the following several points need to be paid attention to in use and
maintenance:
(1) At the time of installation and maintenance, do not touch the battery conductor,
which can cause severe burns.
- 53 -
(2) When charging the battery, do not connect the positive and negative
incorrectly, or else it will result in high temperature, fire, smoke or explosion.
(3) When the battery is maintained, the operator should ware goggles, rubber
gloves and rubber boots.
(4) The battery can produce flammable gases, and there is a danger of explosion,
so it should be avoided short circuit and sparks. Smoking is strictly prohibited.
(5) It is strictly prohibited to dismantle the battery, because the battery’s
electrolyte is dilute sulfuric acid. When it is exposed to the skin, rinse with water
immediately, and when it gets to eye, wash with water immediately and see a doctor
in time.
▲Notes when using the battery:
(1) The battery can produce flammable gases, and there is a danger of explosion,
so it should be avoided short circuit and sparks. Smoking is strictly prohibited.
(2) The electrolyte is dilute sulfuric acid, so contact with skin or eye is very
dangerous (burns, blindness). When the electrolyte comes into contact with the skin,
wash with water immediately. When it gets into the eye, wash with water immediately
and see a doctor in time.
- 54 -
Figure 7- 4 Electric Principle Diagram
- 55 -
8. Hydraulic System
Primary Parameter of Hydraulic System
Type of Forklift Truck FD200-300T
Type PGP365B178EWAB15-1HWAB12-1
Double
Output 89/74mL/rpm
pump
Drive Type Power Output of Transmission
Hydraulic Pump
Type CBTZ-F14-AGΦ9-01
Single
Output 14 mL/rpm
pump
Drive Type Power Output of Engine
Multi-way valve Type FV-3638
1. Introduction
The hydraulic system of this forklift is a load-sensing control system; the system
includes hydraulic pump, multi-way valve, steering gear, pilot valve, flow regulator,
piping accessories and fuel tank and so on. When the engine is running, the double
pump driven through the gearbox sucks out oil from the fuel tank, The front and rear
pump send directly oil to the multi-way valve. The front pump transmits oil to the
multi-way valve for rising joint, mainly to provide pressure oil to the working device
to rise; the rear pump sends oil to the integrated valve block of the multi-way valve,
and after the oil for the steering gear is guaranteed, the remaining part is sent to the
second, third and fourth joint; when the second, third and fourth joint manipulations
are not done for the multi-way valve, the hydraulic oil will return to the rising joint
to combine with the front pump, so that the working device has enough rising speed.
The single pump sends oil to the integrated valve block of the multi-way valve to
provide the braking system and pilot valve control with pressure oil. The safety valve
in the multi-way valve is used to keep hydraulic pressure of the oil line within the
provided range; the forklift driver controls the direction and size of the multi-way
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valve through manipulating the pilot control handle, thereby controlling the
movement and speed of the actuating mechanism. The hydraulic oil is assigned in
priority by the integrated valve block to the load sensing steering gear to control the
steering cylinder to work. Other accessories in the hydraulic system such as
anti-explosion valve, flow regulator, balancing valve and others provide safe and
reliable operation of the system with a guarantee.
2. The principle of hydraulic system
- 57 -
Figure 8-1 Hydraulic Schematic Diagram
One double gear pump and one single pump are selected as the oil pump for the
hydraulic system (the principle as shown in Figure 8-1), the pressure oil discharged
- 58 -
from the double pump is sent by two ways to the multi-way valve, and one-way oil is
directly send to the lifting part; the other-way oil is sent to the integrated valve block
of the multi-way valve, first guaranteeing the oil supply to the steering oil line, while
the remaining part is sent to other joints of the multi-way valve; when the other joints
do not work, the system will send the oil to the lifting joint of the multi-way valve.
After the secondary pump outputs oil, the oil is sent to the integrated valve block of
the multi-way valve, and then it is diverted into the pilot valve; the oil is supplied to
the pilot control handle, to reverse the multi-way valve, and the valve block has a
pilot relief valve to ensure that the pilot valve works properly; the rest flows to every
part of the braking system.
The integrated valve block of the multi-way valve together with the hydraulic
steering gear forms a load-sensing hydraulic steering system. In the case of a change
in steering wheel speed, the multi-way valve can give priority to ensure that the flow
access to the oil port of the steering gear is always necessary for the steering gear.
When steering in use, the system’s flow is in priority supplied to the steering gear;
when not steering in use, most of the system’s flow is supplied to the main oil line,
which can reduce the discharge capacity of the primary pump and the flow loss to
achieve the energy-saving effect.
The mode of hydraulic proportional pilot control is adopted, that is, the
movement of the multi-way valve’s main spool is controlled by the pilot oil line; the
pressure area of the pilot spool is small and its output control oil pressure is low, so
the force acting on the control handle is very small, easy manipulation, labor-saving
and comfortable, with good safety performance. With this system, handling cargo is
controlled with four pilot handles, which control lift, tilt, lateral displacement and
distance adjustment respectively. When the lift is pulled with a handle, the oil flow
out of the multi-way reaches the lower part of the lift cylinder piston through the flow
regulator to push the piston rod. When driving the lift to move, the oil line between
the lower part of the lift cylinder and the fuel tank is connected; due to the self
- 59 -
weights of the piston rod, forklift fork and lift bracket, the piston begins to decline; in
this case, the return speed of the oil from the multi-way valve back to the tank is
adjusted by the flow regulator. When manipulating the tilter, the hydraulic oil from
the pump reaches a side of the tilting cylinder and pushes the piston to move, the oil
in the other side is pushed out by the piston, and flows back to the fuel tank via the
multi-way valve. Manipulate the other two handles to achieve lateral displacement
and distance adjustment of the lift bracket.
3. Hydraulic pump
Hydraulic pump has such features as low noise, compact, reliable and long
service life. Double pump is mounted on the curvature port of the gearbox, and the
front and rear pump are combined in a multi-way valve; oil controlled by the valve is
assigned to the lifting cylinder, tilting cylinder, pitch cylinder, and steering cylinder.
Single pump is mounted on the curvature port of the engine, and hydraulic oil is
distributed by the multi-way valve and is provided to the pilot valve steering and
braking system.
4. Multi-way valve
4.1 Working principle and structure of multi-way valve
Figure 8-2 Schematic diagram of multi-way valve

A hydraulically controlled multi-way valve is used as the hydraulic main valve in
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the working device. The multi-way valve is an integrated valve, the system supplies
oil to the multi-way valve, and the multi-way valve distributes pressure oil to the
working device, steering gear and braking system, thus saving the space of
arrangement for hydraulic parts significantly. A fixed differential pressure relief valve
is added at the inlet of the valve each, and this differential pressure relief valve
ensures that each valve’s flow is concerned only with the spool opening of the valve
and is independent of the load pressure of the actuating mechanism. In this way, if
insufficient flow occurs within the system, that is, the oil pump does not supply
enough flow to meet the flow for multiple actuating mechanisms that work at the
same time, the actuating mechanisms will decrease in lateral speed, and there will be
no actuating mechanisms to stop working.
Working principle of multi-way valve as Figure 8-2:
When the main spool is positioned in the middle, the load holding valve and
pressure compensator are closed, the connection between the pump and actuating
mechanism is cut off by the main spool being obscured.
When the hydraulic oil from the pilot control valve acts on the main spool, the
displacement of the main spool will be proportional to the size of the pressure. Move
the main spool, open the inlet throttling flowmeter tank, connect the main pump oil
port P to the inlet of the pressure compensator, and thus open the pressure
compensator and finally act on the load holding valve.
The pressure Pc on the actuator element at the port A enables the left load to
keep closed through the flow inside the control valve. When the pressure P increases
and is beyond Pc, the load holding valve is open. Connect the oil line from the pump
to the actuating mechanism, and the actuating mechanism begins to move. The return
oil of the actuating mechanism flows from B back into the tank via the outlet T. The
larger valve opening, the more flow, and the faster actuating mechanism. As long as
the pressure of the actuator element is higher than that Pc on the secondary overflow
port A, the left load is enabled to be closed through the flow line in the control valve
- 61 -
element. When P pressure increases and is beyond Pc, the load holding valve is open.
The oil line of the pump actuator is switched on, and the of the actuator begins to
work. The valve is opened to restrict the maximum pressure; if the actuating
mechanism sucks air, the main cone valve element of the secondary relief valve is
open to the direction of oil suction (A), and oil is supplemented from the tank pressure
channel in the valve. It becomes a load-independent flow distribution valve. The
pressure and flow of each valve can be set according to the actuating mechanism, so
as to provide different flows within the scope of the same main valve elements, thus
improving the speed control accuracy of the low flow actuating mechanisms. The
actuating mechanism’s speed is not affected by the working pressure and it can
smoothly run.
5. BZZ5 Load sensing full hydraulic steering gear
Figure 8-4 Schematic diagram of steering gear

BZZ5-load sensing full hydraulic steering gear consists of a pair of rotary valve
combinations and a pair of rotor and stator meshing pairs. The steering gear is
attached to the vehicle’s steering wheel through a steering column; when the steering
wheel rotates, the oil from the steering system oil feed pump flows to the block or
- 62 -
right chamber of the cylinder through the rotary valve rotor and stator pairs
(depending on the steering direction).
The oil from the rotor and stator pairs is proportional to the angle of the steering
wheel. If too little oil is from the steering system oil feed pump, the steering gear can
be viewed as a manual pump.
To guarantee the security of the steering gear, we have added a steering
combination valve block (that is, safety valve block), and it is directly installed on the
steering gear. The valve block is composed of integrated one-way valve,
bi-directional buffer valve, oil filling valve and overflow valve. The bi-directional
buffer valve in the valve block enables the oil line between the steering gear and fuel
tank to be free from the shock of overload pressure; the oil filling valve is used to
prevent cavitation erosion resulting from its system; the one-way valve is used to
prevent backflow of the load oil pressure oil; the overflow valve is used to prevent oil
pump overload.
6. Hydraulic proportional pilot valve
Figure 8-5 Schematic diagram of pilot valve
This forklift in the operating course is controlled with hydraulic pilot by use of
ergonomic (principle is shown in Figure 8-5), dual-axis operating handle, and the
handle has the features, namely sensitive control, small operating force and
comfortable operation. It can realize remote control.
Hydraulic pilot control, first of all, follows the pressure of the pilot handle output
is proportional to the handle displacement, and the pressure acts on the main spool
movement; the displacement of the main spool is proportional to the handle
- 63 -
displacement, and the flow and speed of the actuating mechanism is controlled using
the handle.
There are 4 handles, which control lift, tilt, lateral displacement and distance
adjustment respectively four main actions. When pushing the handle to deviate from
the center, the actuating mechanism starts moving at a low speed; if the driver would
like to increase the speed, continue to push the handle.
7. Return oil filter
Figure 8-7 Schematic diagram of filter

To guarantee clean oil liquid, we have increased an oil return filter on the
multi-way valve return line; the filter can filter mechanical impurities mixed in the
hydraulic oil and the colloid, asphalt, carbon slag and so on produced by chemical
changes from hydraulic oil itself, thereby preventing the hydraulic valve element from
being blocked, the throttle small hole gap and damping hole from being jammed and
hydraulic pieces from being fast worn. This filter has a differential pressure signaling
device, and when the filter pollution is blocked until the oil pressure is 0.35Mpa, it
emits a switch signal; the filter element needs to be replaced at this time in order to
achieve the objective of system security.
The filter is made of glass fiber filter material in accordance with ISO standards,
with high-precision filtration, big oil through capability, small original pressure loss,
large quantity of pollutants and so on.
- 64 -
9. Hoist system
The main parameters of the hoist system
Model FD200-300XT
Rolling type, welding basic mast, secondary

Mast type
retractable
Cross section of inner mast
Cross section of outer mast
Max. Lift height (S.T.D) 4000 ㎜ (standard)- 6500 ㎜
Forward/Backward Tilt (S.T.D) 6°/12°
Φ250
Rollers
O.D. of end rollers mm
O.D. of side rollers mm Φ90
Lift chain (leaf chain) LH3266, 6×6 Pitch P=50.8 (LH3288，8×8)
Fork lifting method Hydraulic
Mast tilting method Hydraulic
Fork spacing adjustment Hydraulic
- 65 -
1. Introduction
The hoist system is adopted the two-stage, rolling telescopic mast type. The inner mast
and outer mast frame have C-shape section. (as shown in Figure 9-1)
Outer mast
Inner mast
Mobile rack
Slide block
Figure 9-1 Mast diagram

2. Outer & Inner mast
The inner mast make up of top beam assembly, left section steel and right section steel,
roll shaft, crossbeam etc. The left and right mast channel steel are connected through cap
beam and beam, and the girder ear outside the mast and the vehicle body are connected
together through the pin shaft; there is a tilting cylinder bearing outside the mast, and the
front end of the tilting cylinder is connected using a pin shaft with the bearing. The mast tilts
forward by 6° and backward by 12° under the effect of tilting cylinder.
- 66 -
3. Lift bracket
At the lift brackets welded roll shaft, end rollers that roll along the inside of the inner
mast frames are installed on the end roller shafts with snap rings. The side rollers that roll
along on the inside of the inner mast frames are bolted, being adjusted by shims. In order to
prevent the lift bracket beam (lift bracket plate, or upper beam) being shaking, two groups of
limit rollers are set, and the limit rollers roll along the outer side of the inner mast. The main
roller bears a vertical load; when the lift bracket reaches the maximum lifting height, the
lateral load is borne by the above limit roller and the side roller below. Enough rigidity and
strength of the mast assembly and lift bracket are considered in the design, coupled with
operating stability.
4. Adjustment of hoist system
4.1 Make the forks or suspenders to descend to the ground, adjust the lift chain to
assure the distance of the center line of lower rollers on the lift bracket is equal to the
bottom line of inner mast.
4.2 Make the mast tilt backward, adjust the pulling force of lift chains and let the
strain of each lift chain be equal.
4.3 Travelling distance of two lift cylinders should be equal, travelling distance may
be adjusted by adjusting the top bolt.
4.4 The adjusting gasket at the upper end of the lifting cylinder is used to adjust the
left and right lifting cylinder in synchronization.
5. Lifting device
Lifting device is composed of lifting cylinder, chain assembly, sprocket assembly,
etc.
Each lift cylinder is located behind each side of outer mast, cylinder bottom fixed
upon the cylinder bracket of outer mast, the upper end of the piston rod is connected
with beam set bolts. The travel distance of two lift cylinders should be equal to
in-phase. Otherwise, it is adjusted through the bolt. (connected to the walking beam
and piston rod)
The lift cylinder assembly consists primarily of a cylinder body, piston, piston
rod and cylinder cap. At the lower part of the cylinder body is arranged an inlet for
- 67 -
high-pressure oil, and at the upper part there is an outlet for low-pressure oil above the
piston packing to which a return pipe is connected.
The piston and piston rod key, retainer ring and O ring are fixed together; the
outer cycle of the piston is equipped with a rectangular sealing ring and supporting
ring. The cylinder head is screwed into the cylinder body via thread, and the
supporting ring is used for supporting the piston rod, and the scraper seal is to prevent
dust flying into the cylinder. The upper part of the cylinder with the end of the piston
rod are fixed with the walking beam by bolts.
When the lift lever is pulled backward, high-pressure oil is sent into the lift
cylinders through their inlets to push up the piston rods, the piston head and beam,
rising the forks and side suspenders by chains. As the lift lever pushed forward, the
pistons of the lift cylinders descend by the weights of the piston rods, lift bracket and
forks pushing oil under the piston to flow out of the cylinders. The oil discharged off
the cylinders is regulated by the flow regulator (throttle valve) and returns through the
multi-way valve to the oil tank.
The structure of FD200-320T forklift lifting cylinder is shown in Figure 9-2
1. Rod piston 2. Seal dust 3. Snap ring 4. U-ring 5. O- ring

6. Cylinder body 7. Sleeve adjusted 8. Snap spring 9.Piston 10. Snap ring
11.U-ring 12. Slide valve 13. Spring 14.Supporting ring 15.Bolt 16. Washer
17. Nut 18.Steel-backed bearing 19. Cylinder cover
Figure 9－2 Lifting cylinder
6. Flow regulator
- 68 -
Flow regulator (throttle valve) is located between the control valve and the high
pressure ports of the two lift cylinders, near the lift cylinder. Flow regulator is used to
limit the fall speed of forks and side suspenders when over loading, the structure of
the flow regulator as shown in Figure 9-3.
To lifting cylinder
1. Union 2. Spring 3. O-ring 4. Snap ring 5. Pore plate

6. Sleeve 7. Valve core 8. Nylon 9.Spring 10. Valve body
Figure 9-2 Drop flow regulator
The flow regulator serving both as a flow regulating valve while forks are being
lowering and a safety device if hoses between the control valve and lift cylinders are
damaged due to any reason, At this time, the flow regulator plays the role of a safety
device (to prevent goods dropping suddenly, causing a danger).
The operation of the flow regulator is given below.
As shown in figure 9-3: the flow regulator is installed at the high pressure oil
mouth at the bottom of the lifting cylinder, in order to limit the falling speed when the
lift bracket is overloaded; at the same time when the rubber hose between the multiple
directional control valve and the lifting cylinder bursts, the governor valve can be
used as a safety device.
Its action is as shown in Figure 9-2. When the multi-way valve is at the “down”
position, the oil from the lifting cylinder flows into C cavity, and then into the cavity
B through the oil holes F, E, D and C, and enters the lifting oil cylinder through the
- 69 -
valve core (7) and the cavity A.

The valve core (7) moves to the right and left as driven by the oil hole in the
valve core (7) to make the hole C become narrow, and the volume of oil through the
hole C lowers down, so that the lift bracket’s down speed is controlled. When the
multi-way valve is at the “lifting” position, the high pressure oil from the multi-way
valve flows into the cavity B through the cavity A, and then into the lifting cylinder
through the oil holes C, D, E, F and G.
7. Tilting cylinder
1. Ear ring 2. Round nut 3. Seal dust 4. Snap ring 5. Sealing ring for shaft 6. O-ring
7. Wearing 8. Guide sleeve 9. Buffering ring 10. Snap ring 11. O-ring 12. Piston 13.
Cylinder body 14. SPGO 5. HBTS
Figure 9-4 Tilting cylinder
Two tilting cylinders of double acting type are mounted on each side of the mast.
The front end of the piston rod is connected to the mast and the cylinder tail is on the
frame by pins. The tilting cylinder assembly consists primarily of a cylinder body,
guide sleeve, piston and piston rod.
The piston is welded to the piston rod. The piston, of which the outside periphery
is given two YX seal diagram and a dust seal. Rings and dust seal is used for
preventing leak and dust (between piston rod and guide sleeve). The guide sleeve,
fitted with an O-ring on the outer periphery, is screwed into the cylinder body.
When the tilt lever is pushed forward, high pressure oil enters from the cylinder
tail side to shifts the piston forward. Tilting the mast forward 6 degrees. As the tilt
lever pulled backward, high pressure oil enters the cylinder from guide sleeve. This
shifts the piston to the rear, causing the mast to tilt backward 12 degrees.
- 70 -
Sino-American Zhejiang Maximal Forklift Co., Ltd.

Address: No.1 Jinxin Road, Lushan Street, Fuyang, Zhejiang
Tel: 0571-63160118/63486999
Fax: 0571-63160107
Website: www.maxforklift.cn
E-mail:mks@maxforklift.com
Zhejiang Maximal Forklift Co., Ltd. reserves the right and power of interpretation, modification and deletion of
the content of this manual. In case of any doubt, please contact company promptly.
- 71 -

Manual de Servicio y Mantenimiento Serie M Térmica FD200-320T - en

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Manual de Servicio y Mantenimiento Serie M Térmica FD200-320T - en

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M Series FD200-320T Internal Combustion

Counterbalanced Forklift truck

Operation and Maintenance Manual

Zhejiang Maximal Forklift Co., Ltd

This manual mainly introduces the performance, structure, operation and

I．Safety rules for Operation and Daily Maintenance of Forklift Truck

4. Safety operation rules of Forklift Truck

to walk under upraised forks or the truck to carry persons.

5. Installation and connection diagram of cab flip lifting device

tilted to a reasonable height (the hand pump with self-locking function).

Flip rack Support bar

Rocker Hand pump

Figure 1-1 Cab Tilting Mechanism

(1) Connection diagram of tipping cylinder oil line

Single cylinder oil line connection diagram Ⅰ

Intake and exhaust plug

Outlet A connection of oil cylinder

Reversing handle diagram II

Cab rising Cab decline

(2) Manual pump refueling diagram

Refueling are flush with the plunger

Filling the rocker arm must be in the down position

A pipe joint Manual pump reversing handle

cylinder is automatically discharged.

3) Repeat operations for 2-3 times following the method above.

(4) Notes in use

the cab and of fuel pump exhaust.

exhaust plug in the oil pump assembly is smooth.

the environment above -10 ℃.

the items in the cab.

wires of the cab flip system.

so as to avoid security accidents.

is flipped to prevent too frequent cab flips or damage.

5) Common fault and elimination methods

Trouble Cause for trouble Remedy

Trouble Cause for trouble Remedy

6. Points for attention on use of cooling system

8. Packaging and Transport

Lifting Forklift Truck

truck (forklift truck is extremely heavy.)

9. Nameplate & warning label

(2) Safety label

Standing on or under the fork is prohibited, in

case personal security is threatened by rising or

falling of the fork.

(3) No standing behind the mast please.

Standing behind the mast is forbidden against

potential safety hazard.

(4) For goods only!

Warning: Carriage of person is forbidden. Forbid Hitching People

(5) Tyre safety label

Warning: it needs to be aware of when installing and

inflating the tyres.

Lifting with the two holes is prohibited to prevent confusion

with the two holes below for hoisting.

(7) Caution! The rolling fan!

The label warns of potential hazard to be caught and

hurt by the fan.

(8) Caution! Hot!

Warning: High temperature hidden trouble exists

in exhaust pipes, in order to prevent hands being

(9) Antifreeze added already.