Operator's Manual (SWFD50-70)

SWFD50H~70H Operator’s Manual
TABLE OF CONTENTS
1. SAFETY RULES AND OTHER SAFETY INSTRUCTIONS.................................................2

1.1. GENERAL INSTRUCTIONS .................................................................................................2
1.2. SAFETY INSTRUCTIONS FOR OPERATION......................................................................2
1.2.1. General safety instructions ..............................................................................................2
1.2.2. In emergency situation.....................................................................................................2
1.2.3. Inspect before start-up .....................................................................................................2
1.2.4. Know about your forklift.................................................................................................3
1.2.5. Operate qualification .......................................................................................................3
1.2.6. Periodic check ................................................................................................................. 3
1.2.7. Dispose when failure happened .......................................................................................3
1.2.8. Protect yourself................................................................................................................3
1.2.9. Environment ....................................................................................................................4
1.2.10. Enter and leave safety......................................................................................................4
1.2.11. Operate after sit down .....................................................................................................4
1.2.12. Start-up safety..................................................................................................................4
1.2.13. Park machine correctly ....................................................................................................4
1.2.14. Do not play “chase” game ...............................................................................................4
1.2.15. Follow traffic rules ..........................................................................................................5
1.2.16. Do not extend any part of body outside forklift...............................................................5
1.2.17. Inspect the working area..................................................................................................5
1.2.18. Know about the loading...................................................................................................5
1.2.19. Know about the loading cargo.........................................................................................5
1.2.20. Attention to the traveling direction..................................................................................5
1.2.21. No passengers in forklift..................................................................................................5
1.2.22. Keep a certain distance from roadside and platform .......................................................6
1.2.23. Passing boat plate or bridge plate ....................................................................................6
1.2.24. Carry super-large and over length cargo..........................................................................6
1.2.25. Attention to the jobsite ....................................................................................................6
1.2.26. Travel slowly in corner....................................................................................................6
1.2.27. Attention to other object ..................................................................................................7
1.2.28. Travel slowly ...................................................................................................................7
1.2.29. Load cargo in front face...................................................................................................7
1.2.30. Load back inclination ......................................................................................................7
1.2.31. Load stably ......................................................................................................................7
1.2.32. Lower the cargo before load ............................................................................................7
1.2.33. Do not load the cargo too high ........................................................................................7
1.2.34. Forbid lifts unstable cargo ...............................................................................................8
1.2.35. Forbid incline gentry when cargo lifted...........................................................................8
1.2.36. Forbid push and pull suddenly when gantry lifted ..........................................................8
1.2.37. Forbid lifting cargo above ...............................................................................................8
1.2.38. Avoid brake suddenly ......................................................................................................8
1.2.39. Shift smoothly .................................................................................................................8
1.2.40. Attention to traveling direction when in slope.................................................................9
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1.2.41. Avoid working in slope....................................................................................................9

1.2.42. Others ..............................................................................................................................9
1.3. OTHER SAFETY INSTRUCTIONS AND EXPLANATION ...............................................10
1.3.1. Safety mark....................................................................................................................10
1.3.2. Safety labels ..................................................................................................................10
1.3.3. Mark in gantry ...............................................................................................................10
1.3.4. Mark in machine............................................................................................................ 11
1.3.5. Trade mark..................................................................................................................... 11
1.3.6. Warning label................................................................................................................. 11
1.3.7. Seat belt label ................................................................................................................ 12
1.3.8. Maintenance label..........................................................................................................12
1.3.9. Waterproof label ............................................................................................................12
1.3.10. Lowest temperature label...............................................................................................13
1.3.11. Lift off sketch map ........................................................................................................13
1.3.12. Fuel label .......................................................................................................................13
1.3.13. Loading curve label .......................................................................................................14
1.3.14. Safety label ....................................................................................................................14
1.3.15. Lift position label ..........................................................................................................14
1.3.16. Prevent nip your hand label ...........................................................................................15
1.3.17. Prevent hurt by engine fan label ....................................................................................15
1.3.18. Hydraulic oil label .........................................................................................................16
1.3.19. No passengers label .......................................................................................................16
1.3.20. Prevent step label...........................................................................................................17
1.3.21. Tire pressure label .........................................................................................................17
1.3.22. Prevent wash label.........................................................................................................18
1.3.23. Nameplate......................................................................................................................18
1.3.24. Noise claim....................................................................................................................18
2. TRANSPORTATION AND STORAGE ................................................................................19
2.1. PORTAGE OF FORKLIFT....................................................................................................19
2.2. LIFT UP FORKLIFT .............................................................................................................19
2.3. STORAGE .............................................................................................................................19
2.3.1. Daily storage..................................................................................................................19
2.3.2. Long term storage..........................................................................................................19
2.3.3. Operate after long term storage .....................................................................................20
2.4. TOW THE VEHICLE ............................................................................................................20
3. MAIN TECHNICAL DATA OF FORKLIFT TRUCK ...........................................................21
3.1. DIMENTION OF FORKLIFT TRUCK .................................................................................21
3.2. TECHNICAL DATA..............................................................................................................22
3.3. MODEL CODE AND ITS EXPLANATION .........................................................................23
3.4. OPERATE ENVIRONMENT................................................................................................23
4. OPERATION INSTRUCTIONS ..........................................................................................24
4.1. ADJUST SEAT ......................................................................................................................24
4.2. OPERATION PROCEDURE.................................................................................................24
4.2.1. Start-up forklift..............................................................................................................24
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4.2.2. Operation .......................................................................................................................25

4.2.3. Turning ..........................................................................................................................25
4.2.4. Park................................................................................................................................25
4.2.5. Loading..........................................................................................................................26
4.2.6. Stack ..............................................................................................................................26
4.2.7. Load in stack .................................................................................................................26
4.2.8. Inspect after operation ...................................................................................................27
5. MAINTENANCE ..................................................................................................................28
5.1. RUNNING-IN .......................................................................................................................28
5.2. DAILY MAINTENANCE .....................................................................................................28
5.2.1. Routine maintain ...........................................................................................................28
5.2.1. Maintenance level 1 (Every 250 working hours)...........................................................31
5.2.2. Maintenance level 2 (Every 1500 working hours).........................................................32
5.3. LUBRICATION.....................................................................................................................33
6. STRUCTURE, THEORY, ADJUST AND MAINTENANCE................................................35
6.1. POWER SYSTEM.................................................................................................................35
6.1.1. Summarization of engine...............................................................................................35
6.1.2. Inspect and adjust engine...............................................................................................37
6.1.3. Cooling system ..............................................................................................................42
6.1.4. Fuel system.................................................................................................................... 43
6.2. ELECTRICAL SYSTEM.......................................................................................................45
6.2.1. General ..........................................................................................................................45
6.2.2. General instructions for operation .................................................................................45
6.3. TRANSMISSION DEVICE...................................................................................................47
6.3.1. General ..........................................................................................................................47
6.3.2. Torque converter............................................................................................................49
6.3.3. Oil inject pump ..............................................................................................................49
6.3.4. Clutch ............................................................................................................................50
6.3.5. Control valve, flooding valve and jiggle valve..............................................................51
6.3.6. Hydraulic circuitry in torque converter .........................................................................52
6.4. BRAKING SYSTEM.............................................................................................................53
6.4.1. General ..........................................................................................................................53
6.4.2. Vacuum auxiliary brake .................................................................................................53
6.4.3. Moving brake device .....................................................................................................55
6.4.4. Parking brake device .....................................................................................................56
6.5. DRIVING AXLE ...................................................................................................................57
6.5.1. General ..........................................................................................................................57
6.5.2. Main reducer and speed controller ................................................................................58
6.5.3. Wheel side reducer ........................................................................................................59
6.5.4. Trouble shooting............................................................................................................59
6.6. STEERING SYSTEM............................................................................................................60
6.6.1. General ..........................................................................................................................60
6.6.2. Cycloid hydraulic steering system.................................................................................61
6.6.3. Inspect after re-install steering system ..........................................................................62
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6.6.4. Trouble shooting for steering system.............................................................................62

6.6.5. Steering axle ..................................................................................................................63
6.7. HYDRAULIC SYSTEM .......................................................................................................65
6.7.1. General ..........................................................................................................................65
6.7.3. Pump..............................................................................................................................66
6.7.4. Distributor and its control device ..................................................................................66
6.7.5. Lift cylinder...................................................................................................................70
6.7.6. Security valve ................................................................................................................72
6.7.7. Speed limiting valve ......................................................................................................72
6.7.8. Tilt cylinder ...................................................................................................................73
6.7.9. Hydraulic tank ...............................................................................................................74
6.7.10. Trouble shooting............................................................................................................75
6.8. LIFT AND DECLINE SYSTEM .....................................................................................................77
6.8.1. General ..........................................................................................................................77
6.8.2. Inner and outer mask .....................................................................................................77
6.8.3. Fork block......................................................................................................................77
6.8.4. Install location for roller ................................................................................................78
6.8.5. Repair ............................................................................................................................78
7. ATTACHMENTS ..................................................................................................................81
8. MANUFACTURER DATA....................................................................................................84
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Foreword
This manual introduces the performance, structure, operation and maintenance of

SWFD series 5-7T forklift truck, will help users operate and maintain the forklift
correctly.
During operation, operator and administer should execute as per the request in manual,
to keep machine in good condition.
The manual should be regarded as the permanent part of forklift and kept in the cab
for consultation at any time. And the manual should be attached when the forklift is
transferred or sold.
Position definition: RIGHT and LEFT always mean the left and right of an operator
seated correctly in the forklift. The forklift drive wheel is in front.
Please write your forklift number in the manual “machine number”, write down all
numbers correctly will be convenient for searching in the future. When you order
spare parts, the dealer also need these numbers; if the manual is put in forklift, please
make sure to prepare a copy of these numbers in safety archiving.
For best forklift performance, all instructions given in this manual should be complied
with strictly. Possible warranty claims may be considered only provided that all
operations are made by qualified operator and scheduled inspections are made at the
specified times by qualified technician. Warranty claims will not be considered
provided the forklift is abused, overloaded, or if there are changes to the original
functions of forklift.
Regarding SAFETY in particular, we recommend carefully reading the SAFETY
RULES in this manual and complying with all the safety rules.
The equipment covered by this manual meets the applicable technical specifications
effective as of its date of issue. The manufacturer SUNWARD reserves the right to
make from time to time and without prior notice any modification or amendment of
any nature, deemed useful or necessary, to any forklift component, without any
obligation to amend the content of this manual accordingly. Pictures and data
contained in this manual are not binding. Consequently, no claim raised in this respect
will be considered.
Hunan Sunward Intelligent Machinery Co., Ltd.
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1. SAFETY RULES AND OTHER SAFETY INSTRUCTIONS
1.1. GENERAL INSTRUCTIONS
The safety rules is standard forklift basic safety rules and attention, which is also available to
special forklift and related vehicle. Please read the manual seriously and fully know your
vehicle to prevent accident and make sure your safe.
This “SAFETY RULES” just refers to the basic safety instructions of forklift, not all possible
dangerous are covered. If there is any problem, please inform your superior before operation
and maintenance.
Safe is your responsibility and obligation which will bring profit and happiness to you!
1.2. SAFETY INSTRUCTIONS FOR OPERATION
1.2.1. General safety instructions
(1) Please read all the safety labels and its security instructions in forklift, and relevant
information in this manual carefully.
(2) Maintain the machine daily, displace safety labels when necessary. If safety labels or manual
damaged or lost, please order from our dealer as same as order spare parts. Inform the dealer
with model at the same time.
(3) Only trained personnel who gets the qualification allows operating. Maintain the machine as
per manual to keep it in good condition.
(4) Do not make any modification without consent, modification may effects the function, life
time to machine and even causes bodily injury.
1.2.2. In emergency situation
Operator and relevant personnel should beware of

accident all the time. Prepare first-aid kit and fire
extinguisher near the machine (as the right figure);
place the phone number of hospital and fire department
near telephone.
1.2.3. Inspect before start-up
Every day or shift, check the machine carefully. The inspect range see to “Correct maintain and
inspect procedure”.
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1.2.4. Know about your forklift
Forklift is a professional vehicle for cargo loading and unloading, stack-building and short
distance transportation. So it is different from other vehicle in structure, pay attention：
(1) Forklift is set lifting system within gantry, front field vision is limited.
(2) Forklift is driven by front wheel and rear wheel turning. Vehicle rear part is rotating outward
when turning.
(3) Forklift is heavy because of its hard structure design. When loading, all load is in front
wheel, gravity center move forward, so its stability is a little worse.
(4) During normal operation, the shake effects in seat will less than 1m/s2 without load, and less
than 0.7m/s2 with full load, the shake is not harmful to human body.
(5) Read “Operator’s Manual” and nameplate, warning mark in forklift; familiar with and
control vehicle status and operation rule, if there is any question please contact with
administrator.
1.2.5. Operate qualification
Only trained personnel who passed the test allow operating forklift
1.2.6. Periodic check
(1) Check forklift action, water and oil sealing, parts connection, assembly parts distortion and
lubrication status periodically. Ignoring check will shorten vehicle lifetime，even will lead to
accident.
(2) Make sure to replace “safe parts” in periodic check.
(3) Wipe oil, grease and water cleanly in base board, foot pedal and control bar.
1.2.7. Dispose when failure happened
(1) Once failure happened, stop forklift immediately, hang the label of “failure” or “danger” in
forklift and take the key, report to manager at the same time.
(2) Only after failure solved, forklift could be used again.
1.2.8. Protect yourself
Operator must wear helmet, work shoes and work clothes.
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1.2.9. Environment
(1) Prevent explosion. Forbid any kind of naked flame approach to battery.
(2)Forbid tool touches battery two poles to prevent flame or short circuit.
(2)Well ventilated. When forklift is working in close circumstance, make sure enough ventilators
or assembling fan in necessary.
1.2.10. Enter and leave safety
(1) Use safe pedal and handle when enter and leave forklift.
(2) Never enter or leave forklift when it is working.
1.2.11. Operate after sit down
(1)Before starting forklift, adjust seat according to operator status to proper location. See to
relevant section in chapter 4.
(2) Only start up machine after operator sit down.
1.2.12. Start-up safety
Please make sure the following points before start-up:

(1) Braking lever has unlocked.
(2) Steering lever in neutral.
(3) There is nobody around machine.
(4) Do not operate gantry before start-up.
1.2.13. Park machine correctly
(1) Forklift should be parked on flat ground and brake; if it is necessary to park forklift in
ramp way, it must fasten the wheel by wedge block..
(2) Fork should be landed on ground, gantry little inclining forward; close key switch and take out
the key.
(3)Parking location should be far away from fire.
1.2.14. Do not play “chase” game
(1)Don’t use forklift to play “chase” games.

(2)Before starting the forklift, please press horn to alarm surrounding person.
(3)Operation should be stable and correct, do not turn steering wheel suddenly, avoiding
emergency stop, start and turning.
(4)Incorrect operation may cause roll over. When roll over, operator should stay in seat and hold
steering wheel firmly, because the machine falls much faster than you jump out.
4
1.2.15. Follow traffic rules
(1)Control vehicle speed and follow traffic signal；

(2)Follow traffic rules when drive in highway or road；
(3)When traveling in narrow pathway or ramp way, unload vehicle should give way to loading
vehicle.
1.2.16. Do not extend any part of body outside forklift
Operator’s head, arm, hand, leg and foot should be in the cabin, don’t extend to outside of
vehicle in any time.
1.2.17. Inspect the working area
(1) Check work area road surface, opening, steep, slope, obstacle, raised point and any road status
which maybe lead to out of control, thrashing accidents.
(2) Clean trash, chippings and any impurity which maybe pierce tire, to avoid lose balance.
1.2.18. Know about the loading
(1) Know forklift and its accessary loading curve, forbiding overload;
(2) Don’t use person as counter balance, it is very dangerous.
1.2.19. Know about the loading cargo
(1) According to loading cargo shape and material, choose suitable accessary and tool;
(2) Don’t use cord to hang fork and accessary to lift cargo, because cord maybe slide; if real
necessary, it should ask qualified person to adopt lifting hook or arm to do;
(3) Don’t make fork contacting ground in travelling, to avoid to damage fork teeth or road surface.
1.2.20. Attention to the traveling direction
Because of its special structure and purpose, please attention to the traveling direction, and keep a
good visibility. Especially when backing up.
1.2.21. No passengers in forklift
Nobody allowed to sit in fork, pallet or forklift.
5
1.2.22. Keep a certain distance from roadside and platform
(1) Pay attention to keep certain distance

with road side or platform when forklift
is working.
(2) Travel slowly in wet-skidding road
surface; don’t travel in road edge, if
necessary, it should pay much attention
to safe.
1.2.23. Passing boat plate or bridge plate
When forklift pass through boat plate or bridge plate, check road surface in work site at first, the
most important is to check boat plate or bridge plate is fixed correctly and stably or not; whether
could bear forklift weight and its loading.
1.2.24. Carry super-large and over length cargo
(1) When transport super large and limit field of vision, please backing-up running or leading by
guide. When lead by guide, operator must understand the guide hand signal, flag, whistle or
other signal;
(2) When transport long cargo such as timber, pipe and ling shape cargo or operate forklift with
extending accessory, traveling in narrow pathway or turning, it must pay fully attention to
front, left- right side and other people.
1.2.25. Attention to the jobsite
Pay attention to observe turnout, card,

entrance-exit and suspension when working.
1.2.26. Travel slowly in corner
When pass through cross pathway, corner or

bad vision road, it should deceleration and
press horn.
6
1.2.27. Attention to other object
(1) When backing-up and turning, it should be careful to avoid fork teeth touch other goods;
(2) Because forklift is rear wheel turning, vehicle rear part is rotating outward when turning. So
it should be careful in turning;
(3) Make sure that cargo is flat locating in two forks and packed ok, travel carefully in rough
road surface.
1.2.28. Travel slowly
(1) When work in long distance or in rough road, it will happen misplay easily; So it must pay
attention to control speed and make sure safe braking;
(2) When work at night, please use head light and width light.
1.2.29. Load cargo in front face
(1) Taking cargo from front face, put fork into pallet carefully;
(2) Cargo and pallet gravity center should be located between two forks center.
(3) Forbid to load cargo with single fork.
1.2.30. Load back inclination
After forklift loading, gantry should be back inclination and fall down cargo; especially steel pallet,
it must make sure gantry back inclination to avoid sliding.
1.2.31. Load stably
(1) Forbid loading cargo at high speed. Before fork lifting, it must make sure that cargo is fixed
stably;
(2) Before lifting cargo, please stop for a moment to make sure no obstacle around.
1.2.32. Lower the cargo before load
No matter in unload or loading status, it is dangerous to travel with gantry lifted, it should keep
standard status when traveling (distance between fork and ground is 15~30cm);
1.2.33. Do not load the cargo too high
(1) Do not load the cargo over block shelf, if necessary, please fasten the cargo.
(2) When carry with super-large cargo which affected the visibility, please drive backwards.
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1.2.34. Forbid lifts unstable cargo
(1) Making sure cargo packed stably and flat put in fork, forbid adopting single fork to lift cargo.
(2) Forklift with accessory such as flat plate clip should make sure cargo packed stably and
clamped, then gantry fully back inclination.
(3) Forklift with side shifter or accessory which is used to load long cargo should pay much
attention to loading center distance in operation, loading center should near fork bracket.
1.2.35. Forbid incline gentry when cargo lifted
(1) When stack and discharge cargo, it should minimize the forward inclination angle; if cargo is
little higher than stack floor or in low level, it can forward incline gantry;
(2) If it need to stack in high level, it should vertical gantry near ground 15~20cm, then lifting,
and don’t let gantry inclination at the same time;
(3) When take cargo in high location, fork should be inserted into pallet completely and lifting
slowly, after receding stack then falling down, gantry back inclination. Never incline gantry
when cargo is in high level.
1.2.36. Forbid push and pull suddenly when gantry lifted
Because gantry forward and back ward inclination will lead to cargo and vehicle overturn or
damage, so don’t allow sudden push pull work in gantry lifted status.
1.2.37. Forbid lifting cargo above
Forbid stand or walk under lifting fork, if necessary, it should in safe place and support fork or
accessory by wood block to prevent accident.
1.2.38. Avoid brake suddenly
Avoid brake suddenly and fast downgrade to prevent cargo falling down, roll over.
1.2.39. Shift smoothly
(1) When forklift need to travel backwards, it should stop forklift at first then backing-up;
(2) Forklift speed adjusting and shifting should be smoothly, pull control lever to neutral position
at first then push to related gear.
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1.2.40. Attention to traveling direction when in slope
(1) In loading, backing-up travel when falling and forward travel when climbing;
(2) In unload, backing-up travel when climbing and forward travel when downwards;
(3) Don’t turn in slope to prevent roll over；
1.2.41. Avoid working in slope
Do not lift cargo in gradient ground, and avoid working in slope.
1.2.42. Others
Use suitable accessory

Our company supply special accessory with multi-function to customer, such as flat plate clip,
rotated clamp, side-shifter, lifting arm, strand bar and bucket etc, customer could choose their
needed accessory.
Use suitable pallet
Pallet should have enough strength to bear cargo weigh, forbid to use damaged or distorted pallet.
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1.3. OTHER SAFETY INSTRUCTIONS AND EXPLANATION
The labels in machine contents warning signs and operation measures, please read and follow this
“Operation and maintenance manual” and labels in machine. Displace labels when labels damaged
or lost.
1.3.1. Safety mark
The figure to the right is a safety reminder.

When you see this mark on the forklift or in
the manual, it indicates that you may be in
danger of injury.
1.3.2. Safety labels
There are various labels at various places on

the forklift indicating various risks, such as
Danger, Warning, Attention, etc (As right
figure), they have the following meaning:
Danger---Direct danger. It will cause death
or grievous bodily harm (GBH) if accident
occurs.
Warning---Potential danger. It may cause
death or GBH if accident occurs.
Attention---Potential danger. It may cause
flesh or moderate wound.
Danger, Warning safety labels are placed at

given locations of the drill rig in the possible
dangerous area. General attentions are listed
on the “Attention” safety label. In this
manual, “Attention” is also used to remind
of safety instruction.
1.3.3. Mark in gantry
Mark in gantry (As the figure 1.6) indicates the English logo of Hunan Sunward Machinery Co.,
LTD: SUNWARD.
Figure 1.6 Mark in gantry
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1.3.4. Mark in machine
Mark in machine (As the figure 1.7) indicates the business code, for example SWFD 50H.
Figure 1.7 Mark in machine
1.3.5. Trade mark
The following logo is from the manufacturer, as figure 1.8 indicates
Figure 1.8 Trade mark
1.3.6. Warning label
Warning label as the figure 1.9 indicates. It reminds operator read the relevant instructions before
operation.
Figure 1.9 Warning label
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1.3.7. Seat belt label
Use the seat belt as figure 1.10 indicates. The label reminds operator use the seat belt correctly and
how to deal with roll over.
Figure 1.10 Seat belt label
1.3.8. Maintenance label
Maintenance label as figure 1.11 indicates. This label listed with daily maintenance instructions.
Figure 1.11 Maintenance label
1.3.9. Waterproof label
Waterproof label as the figure 1.12 indicates. It reminds operator protect the relevant part to avoid
water leak in.
Figure 1.12 Waterproof label
12
1.3.10. Lowest temperature label
Lowest temperature label as the figure 1.13 indicates. It shows the lowest temperature fits for
working normally.
Figure 1.13 Lowest temperature label
1.3.11. Lift off sketch map
Lift off sketch map as the figure 1.14; it indicates how to lift off the forklift.
Figure 1.14 Lift-off sketch map
1.3.12. Fuel label
Fuel label as the figure 1.15, it indicates the location of fuel inlet point.
Figure 1.15 Fuel label
13
1.3.13. Loading curve label
Loading curve label as the figure 1.16 shows. It indicates the load ability of forklift.
Figure 1.16 Loading curve label
1.3.14. Safety label
As figure 1.17 shows, it warns people forbid stand in or under gantry.
Figure 1.17 Forbid stand in or under gantry
1.3.15. Lift position label
Lift position label as the figure 1.18 shows. It indicates the place where to put the lift tools.
Figure 1.18 Lift position label
14
1.3.16. Prevent nip your hand label
Prevent nip your hand label as the figure 1.19 shows. The label placed in mask indicate forbid
extend your hand between inner and outer mask, to prevent nip your hand.
Figure 1.19 Prevent nip your hand
1.3.17. Prevent hurt by engine fan label
Prevent hurt by engine fan label as the figure 1.20 shows. It reminds people beware of running fan,
to avoid injury.
Figure 1.20 Prevent hurt by engine fan label
15
1.3.18. Hydraulic oil label
Hydraulic oil label as figure 1.21 shows. It indicates the hydraulic oil inlet position.
Figure 1.21 Hydraulic oil label
1.3.19. No passengers label
No passengers label as the figure 1.22 shows. It reminds operator do not allow other person stay in
machine when working, it is dangerous!
Figure 1.22 No passengers label
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1.3.20. Prevent step label
Prevent step label as the figure 1.23 shows. It reminds operator to protect the place where marked
with prevent step label.
Figure 1.23 Prevent step label
1.3.21. Tire pressure label
Tire pressure label as the figure 1.24 shows. It indicates the theory value when the tire is fully
permeated.
Figure 1.24 Tire pressure label
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1.3.22. Prevent wash label
Prevent wash label as the figure 1.25 shows. It indicates the position where should prevent wash
with water, reminds the user.
Figure 1.25 Prevent wash label
1.3.23. Nameplate
Nameplate as the figure 1.26 shows. It marked with main technical data, numbers etc.
Figure 1.26 Nameplate
1.3.24. Noise claim
SWFD series 5-7T forklift truck test based on EN12053:2000 standard, the MAX noise volume in
operator’s position: LpA=84.9dB, MAX noise volume: LW<100dB.
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2. TRANSPORTATION AND STORAGE
2.1. PORTAGE OF FORKLIFT
Forklift generally use for the purpose like load/unload and short distance transportation. Forklift
do not fits for long distance transportation, please use steamboat, train or truck which over 10t to
load forklift and follow the instructions below:
(1) Lock parking brake.
(2) Fasten the gantry and counter weight, use block to fix wheels.
(3) Lift up the forklift from where marked with “Lift position label”.
2.2. LIFT UP FORKLIFT
Fasten steel rope to lift position in mask and counter weight (fasten the hook to the hole), then lift
the forklift with lifting device. Please follow the following instructions:
(1) Lift machine according to lift off sketch map (See to former chapter figure 1.15)
(2) Do not let steel rope and top guard wrap together.
(3) Make sure steel rope and lifting device has enough carrying capacity to lift forklift.
(4) Forbid fasten the steel rope to top guard to lift the machine.
(5) No body allows to stay below the forklift when lifting.
2.3. STORAGE
2.3.1. Daily storage
(1) Store forklift in appointed position and

cushion in wheel.
(2) Set shifting handle in neutral position.
(3) Pull hand brake handle.
(4) Close key switch, operate multi-valve
handle several times to release residual
pressure in cylinder and pipeline.
(5) Take down the key for safe keep.
2.3.2. Long term storage
Maintain and check following instructions

based on “Daily Storage”:
(1) Coating oil to exposed parts, such as
piston bar and shaft.
(2) Cover riser vent etc. where wet air goes in easily.
(3) Cover whole forklift by hood.
(4) Coating oil or grease in lubricating points.
19
(5) Cushion vehicle body and balancing weight by block to reduce loading in two rear wheels (As
figure 2.1).
(6) Running forklift weekly. Lift fork to max height several times.
(7) Check electrolyte proportion and liquid level monthly.
(8) Equalizing charge one time monthly.
Attention: Wood block must be single-block and very firm to support forklift weight. Don’t use
wood block which is higher than 300mm (11.81feet). Lift forklift to position where could just put
in the support wood block. Put same volume wood blocks in two sides of frame (As the figure 2.1).
After supporting forklift by wood block, swing forklift to check safety.
2.3.3. Operate after long term storage
(1) Dispose the oil in piston bar and shaft.

(2) Vent out engine oil inside crankcase, vent out transmission oil in gear box, and vent out gear
oil in driving axle, clean all the mentioned parts and fill in fresh oil.
(3) Clean hydraulic oil tank and fuel tank.
(4) Disassemble cylinder plug, valve, axis and inspect all the distant in valve whether acceptable.
(5) Fill up coolant to specific need.
(6) Charge accumulator, and connect to forklift.
(7) Inspect forklift carefully before start-up, then inspect start-up, forward, backward, steer, lift,
decline, etc functions.
(8) Preheat forklift.
2.4. TOW THE VEHICLE
When forklift can not travel, please tow the machine with towing pin (under the counter weight) to
safe place (As the figure 2.2). Release the brake and follow traffic rules when towing, and place a
signal on machine. Forbid connect towing tool (E.g. steel rope) to any part of machine except the
towing pin. Do not bear the towing tool with load.
Figure 2.2 Tow the vehicle
20
3. MAIN TECHNICAL DATA OF FORKLIFT TRUCK
3.1. DIMENTION OF FORKLIFT TRUCK
21
3.2. TECHNICAL DATA
Forklift truck technical data

Model SWFD50H SWFD60H SWFD70H
Rated lift capacity kg 5000 6000 7000
Load center L1 mm 600
Transmission mode Diesel Hydraulic Diesel Hydraulic Diesel Hydraulic
Operation mode Sitting Sitting Sitting
Tire Pneumatic Pneumatic Pneumatic
Max lift high B 3000 3000 3000
mm
Free lift high E 160 160 160
Tilting angle α/β ° 6/12 6/12 6/12
Min turning radius R 3300 3300 3300
Min intersecting aisle X 3050 3050 3150
Min distance to ground G 200 200 200
Wheel base L 2300 2300 2300
Wheel track S/T 1510/1535 1510/1535 1510/1535
Suspending distance Front/Rear K/M 612/650 612/650 612/650
Total length (Including fork) H mm 4782 4782 4882
Total width Q 2005 2005 2005
Gantry C 2534 2534 2534
High
Top guard bar P 2500 2500 2500
Fork lift high (including fork block) A 4380 4380 4380
Length J 1220 1220 1220
Fork Width U× Thickness F 150×60 150×60 150×65
Fork adjust range (out side of fork) W
300~1630 300~1630 300~1630
Total weight kg 8000 8300 8950
Front 4 8.25–20–14PR 8.25–20–14PR 8.25–20–14PR
Tire
Rear 2 8.25–15–14PR 8.25–15–14PR 8.25–15–14PR
Accumulator Voltage /Capacity V/Ah 24/2×80 24/2×80 24/2×80
Max traveling speed Full load/Unload km/h 32/28 32/28 30/26
Max lift speed Full load mm/s 480 480 400
Max decline speed full load mm/s ≤600 ≤600 ≤600
Hook traction KN 53 53 52
Max grade ability full load/unload % 20/32 20/32 20/30
Model CY6102BG CY6102BG YC6105G
Kw/rp
Rated power 81/2500 81/2500 85/2300
m
Engine
Nm/rp
Max torque 353/1700 353/1700 390/1500
m
Displacement L 5.785 5.785 6.494
Pedal brake Vacuum auxiliary brake––pedal (Dynamical brake is optional)
Manual brake Dynamical––manual brake
22
3.3. MODEL CODE AND ITS EXPLANATION
The following is explanation of SUNWARD forklift model code, take SWFD50H for example.
SWFD50H,
SW: SUNWARD
FD: Forklift with diesel engine.
50: Rated loading capacity, SWFD50H rated loading capacity is 5000KG.
H: Hydraulic transmission.
3.4. OPERATE ENVIRONMENT
This series of forklift truck designed for the following environment: temperature between
-20℃~40℃, wind speed ≤5m/s, relative humidity≤90% (When temperature is 25℃).
The forklift should working in flat and firm cement road, asphalt road or concrete road. Please
inspect the working area first, and inspect the entrance, escarpment, roadblock or everything may
cause out of control and jolt. When in sandstorm, snow, thunder, rainstorm, strong wind etc, please
do not use forklift truck. Forbid operate in explosive atmosphere. Forbid operate forklift in
freezing temperature over half hour.
23
4. OPERATION INSTRUCTIONS
4.1. ADJUST SEAT
Before operate, the operator should adjust

seat according or his/her need, make sure
when back lean against backrest, feet still
control pedal freely. When adjusting, bear
the seat adjusting rod left, and then adjust
seat to proper position. Bear seat adjusting
rod to lock the rod. Adjust seat as the figure
4.2. OPERATION PROCEDURE
4.2.1. Start-up forklift
When forklift start up, please follow the following steps, as the figure 4.2 and 4.3:
(1) Set all control levers into neutral position.
(2) Hold the steering wheel with left hand; turn on key switch with right hand.
(3) Gantry back inclination, operating lifting control lever, lift fork to the height of 150~200mm.
Operate inclination control lever to make gantry backward dump.
(4) Operate the control lever.
(5) Release manual brake. Stamp jiggle pedal, push forward hand brake control bar .hold steering
wheel handle by left hand, put right hand in steering wheel lightly.
Figure 4.2 Figure 4.3
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4.2.2. Operation
Forklift change speed and direction frequently, thus whether operate correctly decide the life time
of gear box even the life time of machine. Please change speed as per the following instructions:
(1) Speed up (from 1 position to 2 position). In this condition, please change directly. Release
accelerator, change shift lever from 1 into 2, increase accelerator.
(2) Slow down (from 2 position to 1 position). Please do not change directly, because thus change
will cause harmful strike to gear box. Please stamp jiggle pedal to cut off oil loop, then set the
shift lever from 2 into neutral. Set shift lever into 1 position when forklift almost stop.
(3) Change direction
Please follow the instructions below:
Release accelerator, stamp jiggle pedal to cut off oil loop. If continue this step will decelerate and
brake. Set the shift lever to reversal position after machine stopped (or from reversal to forward),
release jiggle pedal and stamp accelerator. Please keep the machine in idle speed after release
jiggle pedal, and stamp accelerator after start up or may cause damage to gear box. Stamp jiggle
pedal and brake pedal at same time to stop machine immediately.
Anyhow, when change speed from fast into slow or change direction, please stamp jiggle pedal to
cut off oil loop, or it is harmful to gear box.
(4) Decelerate under the following situations:
a. When steering;
b. When approaching goods or pallet;
c. When approaching stack area;
d. In confined passage;
e. When the road or ground is not so good.
Please notice: Do not start up or brake suddenly to avoid goods drop down.
4.2.3. Turning
Forklift is different from common vehicle which is rear wheel turning; when turning, rear balance
weight rotate to outside. Before turning, reduce the speed at first, rotate the steering wheel to
turning direction, steering wheel should be rotated earlier than front wheel turning vehicle.
4.2.4. Park
(1) Reduce speed and stamp brake pedal for parking. Please do not brake suddenly.
(2) Set the shift lever into neutral.
(3) Set manual brake into lock position.
(4) Incline the gantry to front as possible, decline the fork to ground.
(5) Shut down engine, turn the key switch into “OFF” position and then take out.
Please notice: Do not park forklift in road. When park in slope, please place block under wheels.
Vent out cooling water after operation in winter to avoid damage.
25
4.2.5. Loading
(1) Adjusting forks space according to cargo volume to make cargo keep balance.
(2)Vehicle positive alignment cargo, travel slowly, insert fork into pallet completely.
(3) Pallet should be set in two forks symmetrically.
(4) Fork should insert into pallet completely.
(5) Lift cargo.
① At first, lift cargo 5~10cm to confirm cargo is safe and firm.
② Gantry incline backwards, lift cargo to 15~20cm, then travel.
(5) Carry large volume cargo will affect field of vision, expect climbing.
4.2.6. Stack
(1) Check cargo area status.

(2) When close to cargo area, it should reduce the speed.
(3) Vehicle should park in the front of cargo area.
(4) Gantry forward dump to fork level, lift fork to the location which is little higher than
discharging position.
(5) Go forward, locate cargo under discharging position, then stop.
(6) After confirming discharging position, fall forklift down slowly then check cargo is
discharged safely or not.
(7) Do necessary lift and incline operation, backward forklift to make fork exit from cargo.
(8) After confirming fork top departed from cargo, hold fork in 15~20cm position.
(9) Gantry inclines backwards.
4.2.7. Load in stack
(1) When forklift is close to cargo getting area, it should reduce the speed.
(2) Stop forklift when near cargo 30cm.
(3) Check cargo status.
(4) Gantry incline forward to fork level, fork lifting to pallet or crosstie position.
(5) Confirm fork aim at pallet, travel slowly to make fork insert into pallet completely then park.
(6) Fork is lifted to stack 5~l0cm.
(7) Look around vehicle to confirm no obstacle, run backward slowly.
(8) Fork fall down to ground clearance 15~20cm, gantry backward incline then carry cargo to
destination.
26
4.2.8. Inspect after operation
After using, it should clean forklift and do following inspection:

(1) Have damage or oil leakage or not.
(2) Filling lubricating oil according to real status.
(3) Check inner tire is damaged or inserted into impurity or not.
(4) Check side-ring nuts are loose or not.
(5) Check electrolyte liquid level.
(6) If there have not lifted fork to max height in daily operation, it should lift fork to max
height 2-3 times after operation.
Please notice: If find out failure, it should be repaired in the day. Never use the forklift again
before it is repaired completely.
27
5. MAINTENANCE
5.1. RUNNING-IN
We adjust the forklift carefully in our factory. The first running-in period is very important to the
forklift’s performance and life time. Please make sure the forklift is working with low load during
the running-in period, and notice the following instructions:
(1) Before operation, please inspect all the exposed connector and fastening components.
(2) Inspect the hydraulic system, fuel tank and tire.
(3) Inspect lubricating oil in engine, gear box, and driving axle. Inspect the water level in radiator
and whether oil/water leak out exist.
(4) Set engine racing to preheat engine, only operate machine after the water temperature over
40℃.
(5) During operation, please avoid working long time with fully load, suddenly start up, suddenly
accelerator, and suddenly brake.
(6) After running-in period, please displace engine oil, gear box , lubricating oil and hydraulic oil.
(7) This period usually is 100~200 working hours.
5.2. DAILY MAINTENANCE
5.2.1. Routine maintain
In order to make sure the security and efficiency please finish the following inspect points after
daily work.
(1) Inspect the leakage: Inspect hydraulic oil, braking oil and water. Touch the corresponding
cylinder, connector of hydraulic pipe, water tank and driving system with hand, forbid use
naked flame.
(2) Inspect the level of cooling water in engine
Inspect the level of cooling water in auxiliary water tank, when engine is cooled down. If lower
than “LOW” mark please fill the tank to “FULL” mark. If there is no cooling water in auxiliary
water tank, please inspect the cooling water in water tank. Fill the water tank when there is not
enough cooling water inside, and fill up the auxiliary water tank to “FULL” mark.
Please notice: Fill the tank only when the cooling system cools down. Do not open the water tank
when its temperature over 70℃ to avoid scalding.
(3) Inspect gantry
Operate hydraulic joystick to inspect its function.
(4) Inspect the intensity chain belt
Inspect and adjust method:
a. Set the gantry vertically and rise fork 50~100mm;
b. Press the middle of two chain belts and inspect the two belts whether in same intensity.
c. Adjust the intensity if necessary (as the figure 5.1):
Loosen off nut 1 and nut 2, use nut 2 to adjust the chain belt. Fasten nut 1 and nut 2 after
adjustment.
28
(5) Inspect the fork and block shelf

Inspect the fork whether distorted or chapped, and the status of fix pin; inspect the fasten bolt,
fasten the bolt if necessary.
(6) Inspect the tire and its pressure
Loosen off the cover in tire, measure its pressure with barometer. Fill up when the pressure lower
than specific need, and fasten the cover.
Inspect the tire whether exist leakage or damage.
The specific pressure in tire (same pressure in front and rear): 0.83±0.02Mpa
Figure 5.2 Inspect pressure
Please notice when inspecting: It is necessary to keep a high pressure in tire to bear the weight of
forklift, any distorted in side-ring or leakage in tire may cause accident. When operate air
compressor fill the tire, please adjust the pressure first, because the Max output pressure of air
compressor is much higher than specific pressure in tire. After assemble tire and side-ring, torque
all bolt as per specific need, and then fasten the cover. The pressure in tire can not exceed specific
need.
Please put the tire in protective case to ensure the security.
(7)The torque of bolt in wheel hub
Inspect the fasten torque in wheel hub whether meet specific need.
The fasten torque please see to annex 2 torque table.
29
1. Nut 2.Semiaxis bolt 3. Side-ring bolt 4. Nut

Figure 5.3
(8) Inspect brake pedal (As the figure 5.4)

Brake pedal and jiggle pedal installed in left side of mainframe, the brake pedal (at right side)
connects brake valve with rod to control hydraulic oil; the jiggle pedal connects brake pedal to
control brake valve and jiggle valve in gear box.
Stamp brake pedal to inspect its movement, its movement should be stable, and flexible. The move
range of brake pedal is 110~130mm, free range is 30~40mm. Braking distance when without load
should less than 6m.
Figure 5.4 Inspect brake pedal

(9) Inspect manual brake device (As the figure 5.5)
Operate manual brake to inspect stability of relevant parts, their function, and whether the pulling
distance suitable. The effect force in manual brake should less than 300N. Adjust the screw in top
to adjust effect force: turn clockwise to increase effect force; anticlockwise to decrease.
30
Figure 5.5 Inspect manual brake device
(10) Inspect steering wheel (As the figure 5.6)

Turn the steering clockwise and
anticlockwise lightly, to check its rebound
ability. The rebound distance normally is
50~100mm. the angle of steering wheel is
adjustable, ±7º from the original place.
(11) Inspect turning Figure 5.6
Drive the machine slowly; turn steering wheel 3 rounds to left and 3 rounds to right. The steering
force to left and right should almost the same. Inspect other abnormal situation.
(12) Adjust seat
Turn the adjust lever to left, and then adjust seat forwards/backwards to comfortable place, turn
the lever back to lock seat. See to relevant part in Operate instruction chapter for more
information.
(13) Inspect meters and lighting system (electrical voltage, fault)
Inspect meters, lighting system, connector, switch and wires.
(14) Inspect level of braking liquid
Open the braking liquid inlet in meter panel to inspect braking liquid, fill up braking liquid if
necessary; please inspect pipeline to avoid leakage and prevent air goes inside. When filling
braking liquid, do not let dust, water, etc mix into braking liquid.
(15) Inspect level of hydraulic oil
Park the machine on a flat ground; decline fork to ground. Insert a clean wire into fuel tank to
inspect its level. The level should between 3/5 and 4/5 of tank.
5.2.1. Maintenance level 1 (Every 250 working hours)
a. Inspect the seal ability and stability of all sealing parts in hydraulic system.
b. Inspect the stability of all parts in steering system and braking system.
c. Inspect the specific gravity and level of electrolyte. Make sure the level is 15~20mm higher
than pole plate. Fill distilled water when necessary; do not fill oil of vitriol or electrolyte.
d. Inspect the stability of driving axle and steering axle.
e. Inspect the chain belt for damage or excursion.
31
5.2.2. Maintenance level 2 (Every 1500 working hours)
a. Displace gear box, lubricant in driving axle and braking liquid. Clean hydraulic oil tank and fuel
tank.
b. Inspect manual brake device for linkage and fasten status. Adjust the operate range of manual
brake and pedal.
c. Clean water tank and water pump.
d. Inspect gantry. Make sure there is no distortion or crack in gantry.
e. Disassemble and inspect steering cylinder, lifting cylinder and tilting cylinder, displace
component which is worn-out.
32
5.3. LUBRICATION
Lubricate machine correctly will extend its life time. User should lubricate machine as per
lubricate schedule. The lubricate schedule as the figure 5.7 shows. Dispose the dust around before
grease; and clean the inject point after grease. Please use antirust to protect exposed part, when
storage.
33
Oil schedule for forklift truck

Dosage for
Item Brand Application unit
each unit
Engine oil Delo Silver SAE 15W-40 18L Engine 16 L
Gear oil Thuban GL-5 EP SAE 80W-90 18L Shell 15 L
Hydraulic oil Rando HD46 200L Hydraulic tank 120 L
Lubricant Multifak EP2 Working attachment 1 KG
Antifreeze Antifreeze:Soft water =50:50 Water tank 10 L
Diesel 0# Fuel tank 100 L
Torque converter oil
8# Transmission oil Gear box 12 L
Brake oil JG3/DOT3 Brake system 1 L
34
6. STRUCTURE, THEORY, ADJUST AND MAINTENANCE
6.1. POWER SYSTEM
6.1.1. Summarization of engine
This series of Sunward forklift truck is drive by diesel engine. Engine, torque converter,
transmission axis and driving axle connect together. The power system mounted with rubber mat
to mainframe, the rubber mat uses for absorb shake in operation. See to figure 6.1
Figure 6.1 Engine assembly
5-7 ton forklift truck equipped with Chinese diesel engine CY6102BG and YC6105G. The main
technical data please see Table 6.1 and Table 6.2.
Table 6.1 Main technical data for CY6102BG
Model CY6102BG
Type 4 stroke, water-cooled
Cylinder– Bore × Stroke mm 6–102×118
Displacement L 5.785
Rated power Kw/rpm 73/2200–81/2500
Rated torsion Nm/rpm 353/1600–353/1700
Dimension: length × Width× High 1122.6×662×846.2
Stable timing rate ≤10%
Min RPM without load r/min ≤650
Cylinder work sequence 1—5—3—6—2—4
Rotate direction (from flywheel side) Anticlockwise
Start method Electrical
Stop method Cut up oil
Lubricant method Coerce splash
Weight kg 480
35
Table 6.2 Main technical data for YC6105G

Model CY6105G
Type 4 stroke, water-cooled
Cylinder– Bore × Stroke mm 6–105×125
Displacement L 6.494
Rated power Kw/rpm 63/1500–118/2800
Rated torsion Nm/rpm 390/1400–560/1600
Dimension: length × Width× High 1122.6×662×846.2
Min RPM without load r/min 700~750
Cylinder work sequence 1—5—3—6—2—4
Rotate direction (from flywheel side) Anticlockwise
Start method Electrical
Stop method Cut up oil
Lubricant method Press splash Composite
Weight kg 600±50
The dimension of CY6102BG as the figure 6.2 shows
Figure 6.2 CY6102BG engine
36
6.1.2. Inspect and adjust engine
In order to keep forklift in good condition and extend its life time, please inspect and adjust engine
regularly as per following instructions.
6.1.2.1 Air filter

(1) Take out inner filter.
(2) Inspect the dust inside filter, blow from inside to outside with low pressure air. If the filter
damaged or can not clean, please displace it.
(3) Clean the dust inside cover.
Air filter as figure 6.3 shows
Figure 6.3 Air filter
6.1.2.2 Fuel filter

(1) Disassemble with specific wrench;
displace filter if damaged or jam-up.
(2) Drop little fuel to sealing ring in new
filter. Assemble 2/3 round after filter touches
the main bracket.
Fuel filter as the figure 6.4
6.1.2.3 Engine oil filter

(1) Disassemble with specific wrench;
displace filter if damaged or jam-up.
(2) Drop little fuel to sealing ring in new
filter. Assemble 2/3 round after filter touches
the main bracket.
Engine oil filter as the figure 6.5
37
Figure 6.5 Engine oil filter
6.1.2.4 Exhaust
(1) Release exhaust plug in oil inject pump.
(2) Press manual pump slowly to inject oil into oil inject pump, till there is no air bubble in
exhaust plug.
(3) Fasten exhaust plug.
6.1.2.5 Fasten the bolt in engine cylinder head

(1) Follow the order in figure 6.6 shown; torque each bolt in 68 Nm one by one;
(2) Torque each bolt in 93 Nm one by one..
(3) Fasten each bolt 90º to right.
Figure 6.6
38
6.1.2.6 Adjust distance in valve

Turn the crank to let the dead center reticle (Later reticle in clockwise direction) superpose with
finger in gear box; now 1, 6 cylinders in upper side, then decide which locals in upper side
depends on the movement of crank, when 1 cylinder in upper side please adjust “0” marked valve
in table 2.2, when 6 cylinder in upper side please adjust “▲”marked valve.
The average distance in inlet valve is 0.4mm.
Please see to figure 6.7, 6.8, 6.9 and table 6.3 for more information.
39
Table 6.3
Sequence 1 2 3 4 5 6
Valve I: Air intake valve
I E I E I E I E I E I E
order E: Exhaust valve
Cylinder 1 0 0 0 0 0 0
Cylinder 6 ▲ ▲ ▲ ▲ ▲ ▲
6.1.2.7 Time confirmation of oil injects and ignites

(1) At first please confirm the “Assemble mark” whether the same in flange, as the figure 6.10.
(2) Place 1 cylinder in the upper side, at this position turns crank anticlockwise 30º, as the figure
6.11.
(3) Release oil inject pipe in 1 cylinder, disassemble spring in release valve bracket and release
valve, and then assemble release valve bracket in oil inject pump, as the figure 6.12.
(4) When oil inject pump transmission oil, turn crank clockwise slowly, when the front oil level in
release valve stopped increase, please stop turning the crank. Confirm the mark of finger. As the
figure 6.13
40
6.1.2.8 Adjust of oil injects and ignites

(1) Disassemble all pipes in oil inject valve (fuel and lubricant);
(2) Release the mounting bolt in oil inject pump;
(3) Following step 6.1.2.7 to confirm the ignite time. Adjust to the direction away from engine to
advance; adjust to the direction close with engine to delay.
(4) After adjustment, please fasten all the mounting bolts, and then confirm the time of ignite.
(5) Assemble the oil vent valve for 1 cylinder, and install back all the hoses.
6.1.2.9 Test the pressure force

(1) Disassemble all the spark plug and oil inject pipe;
(2) Assemble pressure gauge instead of spark plug in cylinder 1 (Demarcate valve 500 N/cm2);
(3) Test the pressure when equipped with well-charged accumulator;
(4) Test from cylinder 1 to cylinder 6 with same method, test twice each cylinder, and then count
average value; the test pressure force should be 304 N/cm2 (Limitation: 255 N/cm2).
Test the pressure force as per figure 6.14
Figure 6.14
41
6.1.3. Cooling system
Cooling system including water pump, fan, water tank and auxiliary water tank; the water pump
mounting in engine, drives by v belt via crank.
Inspect and adjust the cooling system as following:
(1) Inspect coolant in auxiliary water tank
Auxiliary water tank show as the figure 6.15,
when the level of coolant below “LOW”
means coolant is not enough, fill coolant to
2/3 position between “FULL” and “LOW”
when machine cooled down.
(2) Displace coolant
(a) Shut down engine and wait at least 30
minutes.
(b) Open the cover board of water tank,
release outlet valve;
(c) Release outlet valve in auxiliary water
tank vent out all coolant;
(d) Fasten the mentioned valve after
venting;
(e) Fill in specific coolant, and make sure
the level of coolant at 2/3 position
between “FULL” and “LOW” after
operate idly.
(3) Adjust fan belt
Fan belt may get loose after long time working, if fan belt is loose, please adjust as the figure 6.16
Figure 6.16
42
Adjust steps:
Release bolt 2 and 3, move engine towards outside. Press point 1 with 10KG force, the acceptable
displacement is about 10mm. Fasten bolt 2 and 3.
6.1.4. Fuel system
Fuel system including fuel tank, filter and level sensor device.
6.1.4.1 Fuel tank

Fuel tank locates in left side of mainframe and combined with mainframe. The cover board placed
on fuel tank and equipped with level sensor device.
6.1.4.2 Oil level sensor

Oil level sensor (As the figure 6.17) measures the level of oil by floater and display the level in
fuel meter; to inform operator.
Figure 6.17 Oil level sensor device
43
6.1.4.3 Fuel filter

Fuel filter installed in engine inlet pipeline, to filtrate fuel. There is a collateral valve inside filter
to provide fuel even inner filter jammed.
44
6.2. ELECTRICAL SYSTEM
6.2.1. General
This series of Sunward forklift truck equipped with single-track circuit. The theory drawing please
check attachment in this chapter. The electrical system including the following system:
(1) Charge system
This system including generator, accumulator, and indicate light, the working voltage is 24 V.
(2) Start-up system
This system including start switch, protective circuit, start device, the function of this system is
start generator.
(3) Meter system
HZB261-W-ZN type numerical meter is the standard model, refers to pic 6.18. The SUNWARD
model meter is the optional one. It includes the hour meter, fuel gauge, water temperature meter
and oil temperature meter ( it only for hydraulic trucks ,there is no such function for the
mechanical type trucks, and charge indicating light, oil pressure indicating light, neutral indicating
light and air filter block warning light is tools for testing , SUNWARD model numerical meter
do not provide those elements .
(4) Lighting and signal equipment
Including all lighting device, indicate light, horn and buzzer.
6.2.2. General instructions for operation
(1) Start-up
Before start-up forklift, please set the direction switch into neutral position, or engine can not start
up because of the security function designed in control box.
Turn start switch into 1 position—electrify position, meter and ignition connects to power supply.
The machine begins to preheat, preheat indicator lights on, 3.5 seconds later, the indicator lights
out. Preheat procedure controlled by time relay (timer) least for 13.5 seconds.
Turn start switch into 2 position—start up, to start up engine.
Push direction switch forwards after the engine started, means push direction switch from Low
speed mode into High speed model; Stamp accelerator to speed up. If pull the switch backwards,
it is back off low speed and indicators horn activated; pull backwards again to back off high
speed.
(2) Light switch: into position 1, the front/rear width indicator activated; into 2 position, activate
the front light, meantime width indicator still working.
(3) Steering signal: Pull backwards turning indicator switch to activate left-front and left-back
indicate light; push switch forwards to activate right-front and right-back indicate light.
(4) Braking signal: Stamp brake pedal when brake needed, rear braking indicator will activate
(red).
(5) Back off signal: Pull direction switch backwards when needed, rear indicator and horn
activated (white).
(6) Non charge signal: Turn start up switch into electrifies position before start up engine,
meantime, charge indicator lights on and out when engine started; if this indicator still lights on
45
when engine working, means the circuit is fault, please stop machine and inspect.
(7) Engine oil pressure signal: Turn start up switch into electrifies position before start up engine,
engine oil indicator lights on and out when engine started; if this indicator still lights on when
engine working, means pressure is too low or engine is not well lubricated, please stop machine
and inspect.
(8) Separator signal display: Turn start up switch into electrifies position before start up engine,
separator indicator lights on and out when engine started; if this indicator still lights on when
engine working, means the liquid level inside is too high, please pull the rod in separator to
release pressure. The indicator lights out when liquid level inside backs to normal value.
(9) Fuel meter: Display the fuel storage inside fuel tank, when fuel meter displays fuel less than 2
columniations the buzzer will activates to warn low fuel.
(10) Water temperature: Display the temperature of coolant.
(11) Hours meter: Add up total working hours.
Meters as the figure 6.18
Electrical system diagram , wire harness layout and the drawing please refers to the appx.
46
6.3. TRANSMISSION DEVICE
6.3.1. General
Transmission device generally including torque converter and gear box.

The specific technical data see table 6.4
Table 6.4 Transmission data
Transmission device Unit Structure features and data
Form monopole
Torque converter
Effective diameter mm 315
Torque coefficient 3.15±0.15
Max efficiency ＞0.79
Moment at 0 speed Nm 71±4
Moment at Max speed Nm 60±3
Main pressure Mpa 1.2～1.5
Pressure in torque converter Mpa 0.5～0.7
Forward I 1.8519
Transmission rate
Forward II 0.6415
Backward I 1.8519
Backward II 0.6415
Rotate direction (face to input side) Clockwise

L-TSA32GB11120 Engine oil or6# 8#
Oil
Transmission oil
Operating temperature °C 70~95
Highest operating temperature °C 120 (Within 5 minutes)
Dimension Length × Width × Height mm 20
Weight kg 320
Gear box shown as figure 6.19. Specific structure see its operation instructions.
Transmission device generally including torque converter and gear box, its characteristic as the
following:
(1) Equipped jiggle valve in gear box, it is enable the jiggle ability of forklift when started or
traveling in any speed.
(2) The friction plate inside clutch including 7 steel plates and 7 special paper plates ensured its
good wear ability.
47
(3) Equipped single way clutch inside torque converter to improve its efficiency.
(4) Filter inside torque converter extend its life time.
2
Figure 6.19 Gear box
1 Change speed by force 2 Change speed by electrical-hydraulic
48
6.3.2. Torque converter
Torque converter including pump wheel, turbine and oriented wheel.

Pump wheel drives by input axis, liquid inject form pump wheel to turbine (mechanical energy
transfer into kinetic energy), transfer torque to output axis, the liquid leave turbine change its
direction by oriented wheel, and part of them back to pump wheel; thus a torque to push oriented
wheel formed, and output a torque lager than input.
When the speed of turbine increase and approaching to input speed, the angle of flow decreases,
torque in output axis decrease as well, at last flow inflow into oriented wheel severally. In this
case, the torque in input axis is lager than torque in output axis. Equipped with single way clutch
in oriented wheel to prevent mentioned above.
The structure of torque converter as the figure 6.20
Figure 6.20 Torque converter
6.3.3. Oil inject pump
Oil inject pump including initiative gear, inner gear (passiveness gear) and shell. Oil inject pump
installed in top of torque converter. Initiative gear drives by torque converter, neutral gear and
driving wheel; oil inject pump transfer all oil in bottom of gear box to all parts in gear box.
The structure of oil inject pump as the figure 6.21
49
Figure 6.21 Oil inject pump
6.3.4. Clutch
Gear box clutch divides into forward clutch and backward clutch.
Initiative gear at side of forward clutch meshes the corresponding passiveness gear; initiative gear
at side of backward clutch meshes the corresponding passiveness gear.
One set of clutch including 6 pieces of friction plates and 7 pieces of steel spacers. They installed
alternately and assembled with piston.
When working, the outer circle and inner circle sealed with slip sealing and O-ring respectively.
After work, the circles get away form clutch by spring.
When pressure oil effects in piston, the friction plates and steel spacers pressured as well, clutch
transfer force from torque converter to initiative gear.
The transfer procedure as the following:
Turbine—input axis—separator—steel spacer—friction plate—gear –output axis
The structure of forward clutch as figure 6.22, the structure of backward clutch as figure 6.23
50
6.3.5. Control valve, flooding valve and jiggle valve
Control valve installed in top of gear box, shift valve and jiggle valve installed inside valve body.
Clutch flooding valve uses to adjust pressure in clutch, torque converter flooding valve uses to
adjust pressure towards torque converter.
Jiggle valve rod connects to jiggle pedal, when stamp jiggle pedal, valve rod press in, the pressure
inside clutch will reduce temporarily, clutch released.
Control valve as the figure 6.24
Figure 6.24 Control valve
51
6.3.6. Hydraulic circuitry in torque converter
After engine started, oil inject pump suck oil from fuel tank (bottom of gear box), divide oil into
two part in control valve: one part for clutch, the other for torque converter.
The oil in clutch must via pressure adjust valve (pressure between 1.2~1.5MPa) and pressure
adjust valve provides oil to jiggle valve and control valve, on the other hand provide oil to torque
converter via flooding valve (adjust the pressure to 0.5~0.7MPa), oil return from torque converter
cool down in radiator, lubricate clutch and then back to tank.
When in neutral position, the circuitry from control valve to clutch is closed, turn on adjust valve
release oil to torque converter via flooding valve; when control valve in forward or backward
position, circuitry from slip valve to forward clutch or backward clutch close respectively enable
clutch moves respectively; when one clutch is working, the other clutch’s spacer and friction plate
is not closed, coolant lubricate and cool it down, stamp jiggle pedal or jiggle valve, most or part of
oil in clutch will vent to tank, this time the circuitry in torque converter as same as neutral.
52
6.4. BRAKING SYSTEM
6.4.1. General
The braking system of this series forklift truck divides into moving brake and parking brake,
moving brake system contented in wheel, and parking brake installed in gear box.
There are two methods of moving brake: dynamical brake and vacuum auxiliary brake. This series
of forklift uses the later brake system, dynamical brake is optional.
6.4.2. Vacuum auxiliary brake
Vacuum auxiliary brake uses vacuum auxiliary force drive brake cylinder (main pump) to realize
auxiliary brake.
Vacuum auxiliary brake drives by vacuum, the operator just need to stamp brake pedal to gain a
high brake pressure.
Table 6.5 list out the relevant information
Table 6.5
Item unit Value
Effective Max mm Ф263
diameter Min mm Ф236
Max stroke of vacuum
mm 39
auxiliary brake
Auxiliary rate 7
Diameter mm Ф31.75
Max stroke mm 38
Brake Front
ml 15.8
cylinder displacement
Rear
ml 14.2
displacement
Max outer diameter mm Ф272
Oil outlet diameter mm 2–M10×1
Weight Kg 5.3
The structure of vacuum auxiliary device and brake main cylinder as figure 6.25.
The following is their working status:
1. Non working status
Spring 3 controls rod 1 and piston 5 push them backwards to limiting position, air controls valve 4
fixed to component 5 by spring 6, thus closed air valve, meantime pressure air room cut off form
atmosphere and connects to control valve and passage B; air room formed certain power when
working.
2. Working status
(1) When stamp brake pedal, the force works in control valve rod 1 after zoom in and press
spring 3 move forwards with control piston 5, effects with plate 10 and cylinder rod 13 to
form a certain pressure and transfer to brake cylinder (pump) in brake wheel, control air valve
4 and spring 6 control piston 5 move forwards contact to vacuum valve, close it.
53
1.Control lever 2.Filter valve 3.Spring 4. Control valve 5.Control valve piston
6. Spring 7.Body of control valve 8.Rear shell 9. Rear membrane 10.Feedback plate
11.Front shell 12.Front membrane 13.Brake cylinder rod 14.Rebound spring
15. Vacuum pipe connector
(2) With control valve rod 1 move forwards, control piston 5 leave air valve 4, air go through air
mat 2, control valve and passage B enter cylinder, and then formed a forward pressure.
3. After brake procedure back to non working status.
(1) When stamp brake pedal, air get into cylinder via air valve, control valve moves forwards.
When brake pedal stopped at a certain place, control valve body will stop at where air valve
closed, meantime vacuum valve and air valve are closed, cylinder at balance status.
(2) After release brake pedal, spring 14 and spring 3 will control valve rod 1 and piston 5 move
backwards; let control air valve away form vacuum valve, and then brake procedure is over.
54
6.4.3. Moving brake device
Moving brake device including inflexed brake device, installed symmetrically in driving wheel.
Brake device contents one pair of brake device assembly, brake pump, distant adjust device,
spring and brake pedal. One friction plate was welded in brake device. The cylinder rod of brake
pump connects to main auxiliary brake device.
Distant adjust device work when forklift move backwards, if distant between adjust lever is too
large, adjust device will control the distant within 0.4~0.6mm.
Brake device as figure 6.26.
1. Brake device 8.Rebound spring

2. Rebound spring 9.Fixing pin
3. dustproof ring 10.Spring
4. Skin 11.Adjust spring
5. piston 12.Adjsut lever
6. Push rod 13.Adjust device
7. Auxiliary brake device 14. Rebound spring
55
6.4.4. Parking brake device
The structure of parking brake device as the figure 6.27
1.Bottom plate 2.Brake device 3.Fixing bolt 4.Bolt 5.Spring mat

6.Mat 7.Rebound spring 8.Adjust device 9.Adjust device spring 10.Shaft
11.Spring bracket 12.Lever 13.Mounting plate 14.Shaft 15.U-ring
Figure 6.27
The operation force to brake in slope with full load should less than 300 N.
56
6.5. DRIVING AXLE
6.5.1. General
This series of Sunward forklift uses float and steel driving axle. Driving axle including main
reducer, speed controller, wheel side reducer and moving brake. Driving axle fixed to mainframe
by bolt. The shell of driving axle is cast component, tire fixed in wheel hub by bolt and nut, power
passes to axis via speed controller and drives front wheel. There is sealing in side wheel hub to
prevent water and dust.
The structure of driving axle as the figure 6.28
Figure 6.28
1.Shell 2.Semi axis 3.Brake 4.Brake drum 5.Sealing

6.Roller bearing 7.Wheel hub 8.Roller bearing
9.Adjust bolt 10.Gear 11.Planet gear bracket 12.Side cover
13.Planet gear 14.Axis 15.Sun gear 16.Fasten nut
57
6.5.2. Main reducer and speed controller
Main reducer and speed controller installed in the shell of main reducer, including left and right
speed controller, helix gear and initiative gear.
left and right speed controller shell connected with bolt, inside of reducer there are 2 semi axis
gears and 4 planet gears.
Initiative gear supported by 2 roller bearings. Helix gear fixed to speed controller shell, force from
gear box reduce by gear and helix gear.
The structure of main reducer and speed controller as the figure 6.29
1.Adjust bolt 11.Speed control (Right) 21.O-ring

2.Side plate 12.Semi axis gear 22.Sleeve
3.Locking plate 13.Washer 23.Adjsut mat
4.Roller bearing 14.Roller bearing 24.Roller bearing
5.Speed control (Left) 15.Main gear box shell 25.Sealing bracket
6.Semi axis gear 16.Locking nut 26.Sealing
7.Planet gear 17. Adjust bolt 27.Flange
8.Gear 18. Initiative gear 28.O-ring
9.Axis 19.Roller bearing 29.Washer
10.Washer 20.Bearing bracket 30.Locking nut
58
6.5.3. Wheel side reducer
Wheel side reducer including one sun gear, one unit (3 pieces) planet gear and one inner gear.
Symmetrically assembled in both side of driving axle.
Structure of wheel side reducer as figure 6.30
The transmission theory of wheel side reducer is as following:

Sun gear turns around semi axis, drives planet gear and inner gear. Because inner gear fixed in
both side of driving axle, so planet gear turns around the sun gear. Planet gear installed in bracket,
this bracket connects to wheel hub, wheel hub connects to side-ring. Thus, power in semi axis
transfer to wheel, and drives wheel.
6.5.4. Trouble shooting
Problem about driving axle and its solution as the table 6.6
Fault Reason Solution
Bolt is loose Fasten or displace
Washer damaged Fasten or displace
Leakage in main gear box
Vent hole jammed Clean or displace
Sealing damaged Displace
Gear damaged Displace
Bearing worn-out or damaged Displace
Noisy Incorrect distance between gears Adjust
Semi axis gear is loose Displace
Not enough gear oil Fill gear oil
59
6.6. STEERING SYSTEM
6.6.1. General
Steering system including steering wheel, direction pole, gimbals assemble, steering device,
steering axle and steering cylinder, steering device as the figure 6.31.
Steering axis connects with steering device by gimbals, they drives by steering wheel. The angle
of direction pole is adjustable according to the operator.
1.Steering wheel 2.Direction pole 3.Gimbals assemble 4.Steering device
60
6.6.2. Cycloid hydraulic steering system
Cycloid hydraulic steering system (as figure 6.32) transfer the oil to steering cylinder depends on
the steering angle, thus to realize turning with rear wheel. After engine shut down, the steering
controlled by manual.
This series of forklift uses BZZI steering device. The force in wheel won’t effects to steering
wheel.
1.Limiting pole 4.Join axis 7. Rotor

2.Valve body 5.Spring plate 8. Stator
3.Valve core 6.Connecting block 9.Sleeve
61
6.6.3. Inspect after re-install steering system
(1) Turn steering wheel to left and right, inspect the resistance;
(2) inspect the circuitry whether assembled correctly;
(3) Lift up the rear wheel and turn left and right slowly to vent out air inside.
6.6.4. Trouble shooting for steering system
Table 6.7 Trouble shooting for steering system
Oil pump damaged or fault Displace

Steering wheel Clean or
Shunt valve jammed or damaged
jammed displace
Clean or
Hose or connector damaged or pipeline jammed
displace
Low pressure in shunt valve Adjust pressure
Steering wheel is Air exist in circuitry Vent out air

too heavy
Rebound spring damaged Displace
Leakage in steering cylinder Inspect sealing
High pressure in steering Adjust

Travel waveringly
Spring damaged or low bounce forcr Displace
Low level in tank Fill up

Noisy
Clean or
Oil sucking pipe or filter jammed
displace
Leakage Pipeline or connector damaged Displace
62
6.6.5. Steering axle
Steering axle including steering axle, left/right redirector, connect rod assembly, wheel, wheel hub
and steering cylinder.
This series of Sunward forklift truck uses horizontal steering cylinder, front and rear bearing in
center connects to steering axle via sleeve, the front and rear bearing allow to swing at a certain
angle; steering axle installed in mainframe. The structure of steering axle as the figure 6.33
1.Nut 2.Roller bearing 3.Gimbal 4.Wheel hub

2.Roller bearing 6.Sealing ring 7.Bearing 8.Grease nozzle
9.Steering shaft 10.Push bearing 11.Steering axle
12.Steering cylinder
63
6.6.5.1 Main body of steering axle

Main body of steering axle is joint component; there are fix point at two sides to link steering axle
and left/right redirector by steering shaft.
6.6.5.2 Left/right redirector assembly

Left/right redirector assembly fixed to wheel hub by two thrust bearing, horizontal thrust bearing
installed between redirector and fix point, bottom of redirector is adjustable by washer, to adjust
its clearance, steering shaft installed in fix point and support by bearing. Grease nozzle in the top
cover board can lubricate all bearings.
6.6.5.3 Wheel hub

Wheel hub is cast iron component, installed in redirector axis by two roller axis, wheel assembled
in side-ring and side-ring assembled in wheel hub, there is sealing in inner side to keep lubricant
in wheel hub and redirector, please adjust nut to fasten/ loose bearings.
6.6.5.4 Steering cylinder

Horizontal steering cylinder is works in both sides, piston rod in both sides link with connect rod.
The connect rod link to steering device. There are oriented sleeves in both side of cylinder; it
contents bearing, shield plate, sealing and dustproof ring contacts to piston rod, out of sleeves
there are supporting ring and o-ring contact to cylinder. The structure as the figure 6.34
64
6.7. HYDRAULIC SYSTEM
6.7.1. General
Hydraulic system including hydraulic oil tank, main pump, distributor, lift cylinder, tilt cylinder
and hydraulic pipelines, fuel tank locates in right side of mainframe. Main pump is gear pump
installed in flank, drives by engine. Main pump sucks hydraulic oil from hydraulic oil tank
transfer to distributor. Operator control distributor to change circuitry inside distributor, and then
cylinders will work follow these changes.
6.7.2. Hydraulic system circuitry

Hydraulic system theory drawing as the figure 6.35
1.Front pump 2.Rear pump 3.Distributor 4.Shunt valve 5.Steering security valve
6.Steering device 7.Steering cylinder 8.Main security valve 9.Lift cylinder
10.Limiting valve 11.Security valve
Figure 6.35
Compared the hydraulic system with forklift 2~3t, forklift 5~7t uses double pump and turning
circuitry, it is more complex. The hydraulic oil from rear pump transfer to distributor 3. And
hydraulic oil from front pump 1 divides into 2 circuitries, for steering and loading/unloading.
Hydraulic oil for loading comes from distributor and rear pump, to activate cylinder related to
lift/decline and tilt. When distributor in middle position; the hydraulic oil will back to tank via
distributor.
When pull lift valve, the hydraulic oil from distributor via valve 10, press the lift cylinder. When
push lift valve, the piston in lift cylinder connects to tank, effects by weight and gravity, the piston
rod declines, hydraulic oil from lift cylinder transfer to valve 10, so the decline speed is
controllable. When operate tilt valve, hydraulic oil from front valve transfer into certain side of tilt
cylinder and press piston, another side connects to tank, thus realized tilt forwards or backwards.
65
6.7.3. Pump
Pump including front pump and rear pump, the front pump is main pump, uses to control steering,
lift/decline and tilt of gantry, rear pump uses to control lift/decline and tilt of gantry.
The pump in forklift is gear pump, including initiative gear, passive gear and main body.
6.7.4. Distributor and its control device
6.7.4.1 Distributor
Two plate-distributor including four pieces of valve body, two slip valve, one security flooding
valve and one shunt valve. Four pieces of valve body assembled together by there double-bolts
and nuts, tilt valve equipped with self-lock device. Besides, there is steering security valve to
adjust pressure in steering circuitry. Slip valve uses to control lift/decline and tilt cylinder. It
controls valve rod of lift/decline and tilt to change the pressure and then realized its function.
The distributor as the figure 6.36
Figure 6.36
66
6.7.4.2 Operate instructions for slip valve in distributor

(1) Middle position
Hydraulic oil from front pump does not pass through cylinder transfer to tank directly. Now
connector A and connector B closed.
Middle position as the figure 6.37
Figure 6.37
(2) Push-in slip valve
In this status, center passage is closed, hydraulic oil from inlet unfold one way valve and transfer
to connector B; hydraulic oil from connector A back to tank via low-pressure passage. With the
help from rebound spring, slip valve will back to middle position.
Figure 6.38
(3) Pull-out slip valve (See figure 6.39)
In this status, center passage is closed, hydraulic oil from inlet unfold one way valve and transfer
to connector A, hydraulic oil from connector B back to tank via low-pressure passage. With the
help from rebound spring, slip valve will back to middle position.
67
Figure 6.39
6.7.4.3 Main security valve
Working theory of main security valve is as following (As figure 6.40: 1—2—3—4)
(1) Main security valve connects to high pressure connector HP and low pressure passage. The
hydraulic oil passes through its core effects in side A and side B, the diameter of A and B is
different. So core of one way valve K and core of main security valve D installed in valve
bracket firmly.
(2) When the pressure in high pressure connector lager than spring adjustment, turn on core of
pilot “E”, hydraulic oil transfer to hole and then into low pressure passage.
(3) Turn on core of pilot valve E, the pressure behind valve core C decrease, leads valve core C
moves rightwards till touch to pilot valve core E, thus the circuitry behind security valve core
is cut up, the pressure falls down.
(4) The pressure inside security valve falls down, can not meet the balance with cylinder
connector HP, thus leads to security valve core D unfolded, high pressure connector HP
connects to low pressure passage.
68
6.7.4.4 Tilt self-lock valve

Tilt self-lock valve is designed fore avoid shake in gantry. Meantime it is uses for prevent gantry
tilt caused in control incorrectly after engine shun down. The structure of tilt self-lock valve is as
the figure 7.7. Connector A locates in front of tilt cylinder, connector B locates in rear of tilt
cylinder. When pull out tilt slip valve, high pressure hydraulic oil get in connector A, hydraulic oil
in connector B transfer to tank, gantry tilt backwards. When pull in tilt slip valve, hydraulic oil get
in connector B, enable self-lock moves, connector A connects to tank, gantry tilt forwards. When
engine flames out, because there is no hydraulic oil activate self-lock, connector A will not
connects to tank, and gantry will not move.
6.7.4.5 Control device for distributor

Distributor controlled by control lever, all of control levers are mounted in one connecting bar,
and this axis fixed in meter panel, control lever controls slip valve via connecting bar.
Control device for distributor as the figure 6.42. The figure shows is standard configuration, it is
control lever just has lift join and tilt join. Attachment control lever is optional (The third join, the
fourth join).
69
Figure 6.42
1.Lift control lever 2.Tilt control lever 3.Distributor rod 4.Distributor
6.7.5. Lift cylinder
There are totally two lift cylinder (As the figure 6.43), installed in outer gantry symmetrically. It is
including main body of cylinder, piston, piston rod and cover board. There is oil inlet point at
bottom, hydraulic oil transfer into cylinder from this point. And there is oil outlet point below Yx
sealing ring, low pressure hydraulic oil vent out from this point.
Piston and piston rod fix together by nut, pin and o-ring, outer of piston are Yx sealing ring, shield
ring and supporting ring. With the pressure of hydraulic oil, piston moves upwards. In cover board
mounting dustproof ring and bearing, cover connects to body by screw thread, bearing uses to
support piston rod.
In order to lift goods stably, two lift cylinders should work together. If two cylinders work
inordinately, please adjust the related bolt.
70
Figure 6.43
1.Washer 2.Dustproof ring 3.Yx sealing ring 4.Cover board 5.Bearing 6.O-ring
7.Main body of cylinder 8.Piston rod 9.O-ring 10.Supporting ring
11.Yx sealing ring 12.Nut 13.Pin 14.Lift chain belt 15.Chain wheel
16.Roller bearing 17.Shield ring 18.Spring 19.Cut valve 20. Crossbeam in inner mask
71
6.7.6. Security valve
Security valve uses to prevent rapid decline cased by hose outbursts when lifting. It installed in
the bottom of lift cylinder. The oil return from lift cylinder passes through security valve, holes
around slip valve causing different pressure in two cavities; slip valve won’t move when the
different value less than the force from spring. If outburst happened, only few oil passes through
holes, thus the decline speed is much slower.
6.7.7. Speed limiting valve
Speed limiting valve (Structure as the figure 6.44) uses to limit the decline speed of fork. It
installed between distributor and lift cylinder, closer to the left lift cylinder.
Working theory of speed limiting valve is as following:
When fork lifted, oil from distributor get in cavity A and push sleeve move to left, now the G
unfolded, hydraulic oil transfer along A—B—G—D—E and A—B—C—D—E to enter lift
cylinder. In this status, speed limiting valve will not control its flux. When declining fork, the
return oil from lift cylinder get in cavity E and push sleeve move to right, till contact to connector,
now G closed. Return oil travels E—D—H—C—B—A has to pass through speed limiting valve
then back to tank. When return oil increase suddenly, the pressure in cavity F increase and push
valve core 5 to right, make H more confined, thus the flux from D to C decrease, to decrease the
falling speed of fork.
1.Spring 4.Nylon ball 7.Shield ring 10.Connector

2.Valve sleeve 5.Valve core 8.Body of valve
3.Spring 6. Throttle plate 9.Spring
72
6.7.8. Tilt cylinder
Tilt cylinder (As the figure 6.45) including main body, oriented sleeve, piston and piston rod, it is
installed in both side of gantry. It connects gantry with front side and connects mainframe with
rear side.
Piston and piston rod welded together. Around the outer side of piston, installed two Yx sealing
ring and one supporting ring, with the pressure of hydraulic oil, piston moves alone the cylinder.
In the inner hole of cover board installed a steel bearing, a Yx sealing rind and dustproof ring.
Sealing ring and dustproof ring uses to prevent oil and dust. Around the surface of cylinder, there
is an o-ring.
When pull out slip valve, high pressure hydraulic oil get in cylinder, push piston move forwards,
the gantry tilt forwards (6°Maximum); when pull in slip valve, high pressure hydraulic oil get in
cylinder from the side of cover board, push piston move backwards, the gantry tilt backwards
(12°Maximum).
1.Ring 6.Yx sealing ring 11.Yx sealing ring 16.Screw

2.Washer 7.Oriented sleeve (Cover board) 12.Supporting ring 17.Shield ring
3.Adjust sleeve 8.O-ring 13.Piston 18.Shield ring
4.Dustproof ring 9.Bearing 14.Piston rod
5.Shield ring 10.Body of cylinder 15.Plug
73
6.7.9. Hydraulic tank
Hydraulic tank locates in right side of mainframe; in its cover board installed the filter for front
pump/rear pump and cover with level measure rule
74
6.7.10. Trouble shooting
6.7.10.1 Trouble shooting for distributor
Please check Table 6.8
Table 6.8
Slip valve jammed Clean after disassemble
Slip surface damaged Displace slip valve
Low pressure in steering
Spring damaged Displace spring
circuitry
Hole jammed Clean after disassemble
Flooding valve adjust incorrectly Adjust again
Low pressure in lift circuitry
Hole jammed Clean after disassemble
Shake, pressure increase Slip valve jammed Clean after disassemble
slowly Exhaust not well Exhaust fully
High pressure in steering Slip valve jammed Clean after disassemble
circuitry Hole jammed Clean after disassemble
Flooding valve adjust incorrectly Adjust again
Noisy
Slip surface damaged Displace slip valve
Leakage (Outside) O-ring damaged or worn-out Displace
Spring damaged Displace spring
Low pressure
Leakage (Inside) Valve bracket damaged Fix damage
High pressure Slip valve jammed Clean after disassemble
75
6.7.10.2 Trouble shooting for oil pump
Please check Table 6.9

Table 6.9
Oil level is low Fill up oil
Low displacement
Pipeline or filter jammed Clean or displace
Scale board damaged
Cutch damaged Displace
Sealing component damaged
Low presser in Flooding valve adjust
Adjust again
pump incorrectly
Fasten oil sucking pipe again
Air inside system Fill up oil
Displace sealing
Oil sucking pipe jammed or
Displace oil sucking pipe or filter
filter jammed
Noisy when
Pipeline is loose Fasten the loose place
working
Oil is too ropy Displace hydraulic oil
Air bubbles in oil Take relevant measure
Sealing damaged Displace
Leakage
Pump damaged Displace
76
6.8. Lift and decline system
6.8.1. General
The gantry uses telescopic mast, including inner mask, outer mask and side pulley. Side-glance of
inner mask is J shape; the outer mask is C shape.
6.8.2. Inner and outer mask
Gantry including inner mask and outer mask. The masks are jointing component. Bottom of outer
mask installed in driving axle by bearing, middle of outer mask connects to mainframe by tilt
cylinder, and the angle of mask is changeable because of tilt cylinder. Inner mask connects to
outer mask by lift cylinder; there are main roller and side roller in both mask, enable inner mask
lift and decline alone outer mask.
Maintenance for main roller and side roller in masks please take care.
Side-glance of inner mask and outer mask as the figure 6.47
6.8.3. Fork block
Fork block connects to outer mask by chain belt. Fork block installed with main roller and side
roller, enable forklift move alone inner mask. To prevent unstable shake in fork block, two fasten
roller installed in fork block. Main roller supports the portrait load; horizontal load supported by
fasten roller and side roller.
77
6.8.4. Install location for roller
In lift and decline system of forklift including main roller, side roller and fasten roller. Main roller
supports portrait load, usually not adjust its position; side roller supports horizontal load, usually
adjust their position by washer, ensure the side rollers move smoothly in inner mask and fork
block.
Roller assembly as the figure 6.48
6.8.5. Repair
6.8.5.1 Adjust lift cylinder

After disassemble or displace lift cylinder, inner mask and outer mask, please adjust lift cylinders.
The adjust method is as following:
(1) Install piston rod to crossbeam in inner mask without adjust mat;
(2) Lift two cylinders to the highest position slowly, check whether them lift in same speed;
(3) Add adjust mat to the cylinder which moves faster, there are 0.2mm mat and 0.5mm mat
optional.
(4) Adjust the tension of chain belt.
This maintenance procedure is executing in high position, please take care.
Adjust gantry as the figure 6.49
78
Figure 6.49
6.8.5.2 Adjust the high of fork block
(1) Park the machine in flat ground and set gantry vertically.
(2) Let the bottom of fork block contact to ground, adjust the fasten nut 2 in lift chain belt, form a
distant A between main roller and forklift block, the distant A should be 1/3~1/4 of the semi
diameter of main roller.
(3) lift the forklift block to the highest position, conform the distant B between limiting block of
forklift block and limiting block of inner mask, the distant should be 5~10mm.
(4) Decline the forklift to ground and tilt backwards, adjust the fasten nut 2 in lift chain belt, to
make sure the both chain belt in same tensile force.
Adjust forklift block as the figures 6.50, 6.51 and 6.52
79
80
7. ATTACHMENTS
Attachment 1 Accessories list

5~7t forklift accessories including one tool bag, one grease gun (Model JC-LG14K) and one tool
box. The accessories in tool bag are as following:
Attachment 1 Accessories list
Item Specification Num
Wrench for driving axle 38/20 1
Hammer 1.5P 1
Screwdriver 75×5 1
Screwdriver 200×8×1.2 GB10639 1
Curving rod 12.5 Square toes 1
Short rod Square toes, Square 12.5×12.5 1
Sleeve wrench 30mm 1
Double-edged wrench 27-30 1
81
Attachment 2 Torque table

Unit: N ·m
Grade
Diameter
8.8 10.9 12.9
6 10±1 13.2±1.4
8 20±2 31±3
10 49±5 66±7 74±7
12 88±9 113±10 127±12
14 137±14 177±19
16 205±20 270±30 317±30
18 294±30 382±39
20 392±40 549±59 620±62
22 539±54 745±83
24 686±70 927±103 1070±100
27 1029±100 1320±140
30 1421±140 1720±190 2150±200
82
Attachment 3 SWFD50-70H forklift electrical system diagram

Diagram for forklift equipped domestic engine
Diagram for forklift equipped ISUZU engine.
83
8. MANUFACTURER DATA
Company: Hunan Sunward Intelligent Machinery Co., LTD
Tread mark:
Address: Lixiang road No 16, Xingsha, Changsha, Hunan
Tel: +86-0741-3572634
Dealer:
Information of dealer
Name:
Add:
Tel:
FAX:
Email:
Contactor:
Remark
84

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SWFD50H~70H Operator’s Manual

1. SAFETY RULES AND OTHER SAFETY INSTRUCTIONS.................................................2

1.2.41. Avoid working in slope....................................................................................................9

4.2.2. Operation .......................................................................................................................25

6.6.4. Trouble shooting for steering system.............................................................................62

This manual introduces the performance, structure, operation and maintenance of

Hunan Sunward Intelligent Machinery Co., Ltd.

1. SAFETY RULES AND OTHER SAFETY INSTRUCTIONS

1.1. GENERAL INSTRUCTIONS

1.2. SAFETY INSTRUCTIONS FOR OPERATION

1.2.1. General safety instructions

1.2.2. In emergency situation

Operator and relevant personnel should beware of

1.2.3. Inspect before start-up

1.2.4. Know about your forklift

1.2.5. Operate qualification

1.2.6. Periodic check

1.2.7. Dispose when failure happened

1.2.8. Protect yourself

Operator must wear helmet, work shoes and work clothes.

1.2.10. Enter and leave safety

1.2.11. Operate after sit down

1.2.12. Start-up safety

Please make sure the following points before start-up:

1.2.13. Park machine correctly

1.2.14. Do not play “chase” game

(1)Don’t use forklift to play “chase” games.

1.2.15. Follow traffic rules

(1)Control vehicle speed and follow traffic signal；

1.2.16. Do not extend any part of body outside forklift

1.2.17. Inspect the working area

1.2.18. Know about the loading

1.2.19. Know about the loading cargo

1.2.20. Attention to the traveling direction

1.2.21. No passengers in forklift

Nobody allowed to sit in fork, pallet or forklift.

1.2.22. Keep a certain distance from roadside and platform

(1) Pay attention to keep certain distance

1.2.23. Passing boat plate or bridge plate

1.2.24. Carry super-large and over length cargo

1.2.25. Attention to the jobsite

Pay attention to observe turnout, card,

1.2.26. Travel slowly in corner

When pass through cross pathway, corner or

1.2.27. Attention to other object

1.2.28. Travel slowly

1.2.29. Load cargo in front face

1.2.30. Load back inclination

1.2.31. Load stably

1.2.32. Lower the cargo before load

1.2.33. Do not load the cargo too high

1.2.34. Forbid lifts unstable cargo

1.2.35. Forbid incline gentry when cargo lifted

1.2.36. Forbid push and pull suddenly when gantry lifted

1.2.37. Forbid lifting cargo above

1.2.38. Avoid brake suddenly

1.2.39. Shift smoothly

1.2.40. Attention to traveling direction when in slope

1.2.41. Avoid working in slope

Do not lift cargo in gradient ground, and avoid working in slope.

Use suitable accessory

1.3. OTHER SAFETY INSTRUCTIONS AND EXPLANATION