Original Instructions - Baoli

Original
Instructions
L

Preface
Thank you for selecting Baoli forklift truck! Your trust is a great honor for us!
4-5 ton internal combustion balance weight forklift trucks are driven by front axle,
and steered by rear axle. Trucks are used for materials handling, loading and
discharging, and piling piece cargo at the goods yard, station, port, building site and
plant, also used to transport in short distance. For such features: luxury exterior, fine
streamline, low noise and pollution, flexible operation, wide view mast, safety and
reliability, shock absorption, dustproof, fine traction travel ability, fine riding comfort,
trucks are regarded as ideal equipments to accomplish the mechanization of loading and
unloading. There will have a wider use if trucks are fitted with all kinds of the attachments
(such as side shift, bucket, clamp, sling and so on).
This manual describes the performance, construction, operation and maintenance
of the 4-5 ton forklift trucks. Before putting the forklift trucks into use, please read the
manual carefully in order to ensure the proper operation of the forklift trucks.
To improve our forklift trucks, absorb your valuable suggestion, please send to us
suggestion content.
We also ask your understanding for the fact that, due to on-going improvement of
parts and equipment, the numerical values given in the manual are subject to change
without notice.

Content
Ⅰ. Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1
Ⅱ. External view and main performance table . . . . . . . . . . . . . . . .. .. . . . . . . . . . 2
1. External view of the integral machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Main specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 3
Ⅲ. Operation, safety instruction and maintenance . . . . . . . .. . . . . . . . . . . . . . . . . . 4
1. Operation device and meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Handling a new forklift truck. . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . 6
3. Inspection before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 6
4. Start and stop of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 7
5. Shipping, loading and unloading, slinging and towing of forklift truck. . . . . . . . . 8
6. Parking and storing. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 10
7. Information of safety operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . 12
8. Caution plate . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 17
Ⅳ. Periodic inspection and servicing. . . . . . . .. . . . . . . . . . . . . . . . . . 22
1. General rules on inspection and maintenance. . . . . . . . . . . . . . . . . . . . 22
2. Essentials of servicing. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 23
3. Recommended oil, grease and coolant . . . . . . . . . . . . . . . .. . . . . . . . . . . 24
4. Lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Ⅴ. Construction and performance of main parts. . . . . . .. . . . . . . . . . . 26
1. Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2. Torque converter type transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Torque converter. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 28
2.3 Clutch groups. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4 Control valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 30
2.5 Oil circulation route. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Charging pump. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . 32
2.7 Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . 33
2.8 Differential maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.9 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3. Front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 General description. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 37

3.2 Axle housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3 Front wheel hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 38
3.5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 39
4. Brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 40
4.1 General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 40
4.2 Brake pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 40
4.3 Wheel brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Automatic clearance adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.5 Parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 44
4.6 Power brake booster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5. Steering system (cycloid gear steering type). . . . . . . . .. . . . . . . .. .. . . . . . . . . . . . . 52
5.1 General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 52
5.2 Steering axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3 Steering wheel assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.4 Cycloid gear type steering unit . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.5 Hand wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.6 Steering cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6. Hydraulic system. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 62
6.1 Hydraulic pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 63
6.2 Flow dividing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 64
6.3 Control valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.4 Lift cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.5 Flow regulator valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.6 Tilt cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.7 Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7. Load handling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.1 Mast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 74
7.2 Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 75
7.3 Lift chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . .. . . . . 75

8. Electric system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . .. . . . . . . . 76
8.1 General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.2 Signal and operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.3 Precautions when using the battery. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 78
8.4 Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 78
9. Import diesel engine (Isuzu). . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 86
9.2 General description. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 89
9.3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Product improve suggestion sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
NOTE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
EC DECLARATION OF CONFORMITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1

Ⅰ. Feature
4-5 Ton internal combustion counterbalanced forklift truck adopts the drive way:
engine-hydraulic torque converter-gearbox-driving axle. Features are showed on the
following:
(1) Hydraulic torque converter can change the speed automatically with no
limitation and output torque makes the forklift truck have good performance of
drawing.
(2) The slight travel device makes it easy for the drivers to aim the truck to the
position of cargo.
(3) Because of adopting hydraulic drive, guard against engine stopping under the
overload condition, if load capacity is increased sharply, meanwhile, accomplish
smooth shifting operation. For the trucks, such as stopping and starting regularly,
shifting frequently, raise working efficiency, simplify operation, reduce a driver‘s labor
intensity, cut down the requirements of a driver’s operating skilled.
(4) Adopt full hydraulic steering device, transverse steering axle, small turning
radius, flexible steering, safety and reliability.
(5) Brake system adopts power oil brake, smooth operating, reliable brake.
(6) Adopt 2-stage CJ model telescoping mast. high strength, wide view, series
designing, mast with different lift height can be chosen.
(7) Integral machine has these features: Luxury exterior, fine streamline, low
noise, vibration damping, dustproof, comfortable operating, safety and reliability.
(8) The series trucks can be fitted with 2-stage of 3-stage full free mast, even all
kinds of the attachments according to the demands of customers.
(9) The overhead guard and driver’s cab of the distinct height can be chosen
according to the operating into container or out container.
It is an ideal choice for customers to use the series trucks.
1

Ⅱ. External view and main specification
1. External view of the integral machine
External view
2

2. Main specification
General
Dimension
Performance
Chassis
Model CPCD40 CPCD45 CPCD50L
Power type Diesel
Rated capacity kg 4000 4500 5000
Load center mm 500
Lift height H mm 3000
Free lift height H4 mm 150 155
Fork size
W×T Fork outside spread
Mast tilt angle
Min./Max.
L×W×T
3
mm 1070×140×50 1070×140×55 1070×150×55
mm 280/1380 300/1380
deg x
6/12
α/β Front overhang .
X mm 562 567
Overall
dimension
Length to fork face L1 mm 3091 3091 3125
Overall width B1 mm 1485
Mast lowered height H1 mm 2390
Mast extended height H3 mm 4275
Overhead guard height H2 mm 2290
Turning radius R mm 2790 2830
No load/
full load
Travel
speed
Forward Ⅰ
15/14
Forward Ⅱ km/h
22/20
Backward Ⅰ 15/14
Lift speed mm/sec 480/450 480/430
Max. gradeability ≥20%
Max. drawbar pull KN >21
Self weight kg 6450 6770 7050
Tyre
Tread
Front 300-15-18PR
Rear 7.00-12-12PR
Front B2 mm 1180
Rear B3 mm 1190
Wheelbase Y mm 2000
Min.ground clearance
(no load/full load)
Mast M
175/145
mm
Frame F 190/180
Battery V/AH 2-12V/80AH

Ⅲ.Operation, safety instruction and maintenance
1. Operation device and meter
1. Inching pedal 11. Air filter indicator (option)
2. Button for stopping engine 12. Coolant temp. gauge
3. Brake pedal 13. Sedimentator indicator (option)
4. Parking brake lever 14. Hour meter
5. Hand wheel adjusting lever 15. Horn button
6. Shift lever 16. Turn signal lever
7. Oil pressure indicator 17. Accelerator pedal
8. Fuel gauge 18. Lift lever
9. Charge signal 19. Tilt lever
10. Neutral signal
4

The function and use method of operation device and meter is listed as follows:
No. Name Function Use method
1 Inching pedal
2
Flameout pull
button
Couple or uncouple the
transmission.
3 Brake pedal Brake the truck.
4
5
Parking brake
lever
Hand wheel
adjusting lever
5
When the pedal is pressed, the
transmission is uncoupled.
Stop the engine. Pull the button to stop the engine.
Depress the pedal to brake the
truck.
Park the truck. Pull the lever backward fully.
Adjust the angle of steering
wheel.
6 Shift lever Change the travel direction.
7
Oil pressure
indicator
Indicate the pressure of
engine oil.
Pull the lever forward, the truck
travels forward.
Pressure is insufficient, it lights up.
8 Fuel gauge Indicate the fuel capacity. Ignition switch is set at on.
9 Charge signal
Indicate the battery
condition of charge.
10 Neutral signal Indicate the neutral position.
11
12
13
Air filter indicator
(option)
Coolant temp.
gauge
Sedimentator
indicator (option)
14 Hour meter
It will warn when the air filter
is blocked.
Indicate the temperature of
engine coolant.
Indicate water amount in
sedimentator.
Shift lever is in neutral
position.
Lamp comes on when the ignition
switch is set at on.
Shift lever is in neutral position,
it lights up.
Exceed standard resistance,
it flashes.
Ignition switch is set at on.
Water reaches to a certain level, it
lights up
Ignition switch is set at on.
15 Horn button Control the horn. Press it to sound horn.
16 Turn signal lever
17
18
19
Accelerator
pedal
Indicate the turning
direction.
Increase the engine speed
Lift lever Control lift cylinder.
Tilt lever Control tilt cylinder.
Pull the lever, the turn signal light
blinks.
Depress the pedal to increase the
speed.
Pull backward to lift, pull forward
to decline.
Pull the lever backward to tilt the
mast backward.
It is important for drivers and managers to remember the principle of “first safety”

and ensure the safety operation as the description of Operation & Service Manual.
Please read this manual thoroughly. This will give you a complete understanding of
Baoli forklift truck and you will operate them correctly and safely.
2. Handling a new forklift truck
The performance and service life of the forklift truck depends heavily upon the
way you handle it during the break-in period. Drive with special caution while
becoming familiar with a new forklift truck.
(1) Always warm up your vehicle before putting it to work irrespective of season.
Don’t run engine at high rpm without load needlessly. Operate the vehicle under the
light load, avoid sudden speeding and braking.
(2) Replace gear oil in the differential and reducer after the new forklift truck
working for 100 hours.
(3) Renew the oil in engine oil pan, transmission, driving axle and hydraulic oil
tank; check and readjust the clearance of the driving and driven gear in the reducer
after the new forklift truck working for 200 hours.
3. Inspection before operation
Please pay attention to the following items in order to make the vehicle working
with high efficiency and lengthen its service life.
(1) The forklift truck adopts the home or imported engine, please read the manual
accompanied with the engine carefully when using and maintenance.
(2) Check the tyre inflation pressure, if doesn’t enough, charge air in time. Check
the bolts of all wheels for tightness.
(3) Check the amount of oil in the working oil tank for sufficiency, the position of
lubrication should be lubricated. The oil level should be at the middle position between
the upper and lower scale marks of oil level meter. The contamination level of the
hydraulic oil should be lower than Grade 12.
(4) Check the radiator, and add antifreeze if necessary.
(5) Check hydraulic oil and brake fluid for leakage. Check if any leak or damage
found on the oil pipes, water hoses, vent-pipes and the piping joints, pumps and
valves etc.
6

(6) Check for all the terminals and plugs in normal state. Check the meters, lamps,
switches and electric circuit if they are running properly.
(7) Check every pedal for free stroke and the levers for looseness and smooth
operation. Check lifting system, actuate the lifting and tilting levers to be certain that
the lift bracket moves up and down properly and the mast can be tilted smoothly.
Check brake system and steering system for flexibility and reliability.
(8) Check the wheel brake: the free stroke of brake pedal is 4-8 mm, when
achieving effective brake, the clearance between the front floor and the pedal should
be more than 20mm.
(9) Check the parking brake: the unload forklift truck can park on 20% slope,
when the parking brake is locked.
(10) Check all connectors and fasteners for looseness.
4. Start and stop of the engine
(1) Start of the engine
(a) First set the shift lever at the neutral position and the parking brake at the
braking position.
(b) When starting, put the key into the start switch, turn it in the counter clockwise,
preheat 15-20 seconds, and then turn it in the clockwise to “START” so the starting
motor works. When your hand is away from the key, it automatically returns to “ON” by
spring force. Every starting time shouldn’t morn than 15 seconds. Restarting should
be after 30 seconds. As the engine doesn’t work after some times starting, should
check and remove the trouble, do not keep the starting motor engaged for a long time.
(c) Following the start of the engine, it’s necessary to set the engine on idle
running for five minutes. Full load operation can’t be started until water temperature of
the engine rises above 60℃.
When the engine is on idle running, you must check water thermometer, oil
manometer, ammeter, fuel measurer, and so on for the data, whether to meet the
specification, and check each pedal for free stoke, braking performance for its reliability,
steering operation for its flexibility, tyre pressure for its conformance to the standard. If
there is no trouble, operation may be allowed.
(2) Stop the engine
7

First set the engine on idle running for five minutes, so as to cool the engine
gradually, and then turn off the ignition switch, so the engine is stopped to work.
Notice:
.While the engine running, does not turn the start switch to “START” position, or
it will damage the starting motor.
.Do not keep the start switch at the “ON” position while the engine is shut down.
This will result in battery discharge.
5. Shipping, loading and unloading, slinging and towing of forklift
truck
(1) Ship the forklift truck
car.
(a) Apply the parking brake when shipping the forklift trucks by container or freight
(b) Fix the mast and the balance weight with steel wire and use jacks to prevent
the forklift trucks from moving in the cabin.
(c) Pay attention to the overall length, width, height when loading, unloading
and shipping and conforming the regulations is necessary.
weight.
(d) Single transporting if necessary after disassembling the mast and balance
(2) Load and unload the forklift truck
plate.
(a) Use the plate with enough length, width and strength.
(b) Pull the parking brake and use jacks to stop the wheel.
(c) Fasten the plate on the center of the cabin, there must be no grease on the
(d) The left and right height of the plate must be equal to make the loading and
unloading smooth.
(e) Don’t change the direction on the plate to prevent the danger.
(f) Reverse the forklift truck slowly when loading it on the freight car.
(3) Sling the forklift truck
(a) Only the specially trained personnel can sling the truck.
(b) Sling points should be always at the positions specified in sling nameplate.
8

(c) The slinging cable must be enough to hang the forklift truck.
(d) Disassembled parts of forklift truck must be slung in the appointed position.
Model
Dimension
(mm)
Mast (normal type) Balance weight
Slinging capacity
(kg)
9
Dimension
(mm)
Slinging capacity
(kg)
4.0T 2215×1480×685 >2000 1115×1400×899 >2500
4.5T 2215×1480×685 >2000 1115×1400×899 >2500
5.0T 2215×1480×685 >2000 1115×1400×933 >3000
Notice:
Dismantling and slinging the component shall not be performed without the
approval of our company. Under special circumstances, the appointed sling
position should be used. The balance weight, fork and mast of the forklift truck all
have their appointed sling position. The above-mentioned data is only for a
reference, which may be adjusted because of configuration or technology
optimization.
(4) Towing of forklift truck
(a) The towing pin is installed below the counter weight. When towing the forklift
truck, first extract the pin and fasten a steel wire, then install the pin back.
(b) When towing the forklift truck, release the hand brake lever.
(c) The towing pin only used for following situation, while the forklift truck can’t
move or while transporting the forklift truck.
(d) Fasten the towing steel wire at the appointed position.
(e) Don’t apply capacity abruptly when towing the forklift truck.
(5) Repair the broken-down forklift truck
If the forklift truck broken-down suddenly during using, drag it away and repair in
time to avoid hindering other vehicles or workers.

6. Parking and storing
(1) Safe parking
(a) Park your forklift truck on a level ground preferably in a wide area. If parking
on a slope is unavoidable, pull the parking brake device and block the wheels to
prevent accidental roll. The forklift truck is forbidden parking on a steep slope.
(b) Park your forklift truck in the area where designated or traffic conditions permit.
If necessary, put a signpost or signal lights around the truck.
(c) Park your forklift truck on the solid ground. Avoid soft ground, deep mud or
slippery surfaces.
(d) If you can not lower the forks on the ground due to break-down of the lifting
system, put a warning flag to the fork end and park in the traffic conditions permitting.
(2) Storing
·Before storing
Before storing your forklift truck, clean it thoroughly and perform inspection using
the following procedures.
(a) Wipe away grease, oil, etc. adhering to the body of the truck with waste cloth
and water, if needed.
(b) While washing the body of the truck, check general condition of the truck.
Especially check the truck’s body for recess or damage and tyres for wear and nails or
stones in the tread.
(c) Fill the oil tank up with the appointed fuel.
(d) Check for leakage of hydraulic oil, engine oil, fuel or coolant.
(e) Apply grease where needed.
(f) Check for looseness of hub nuts and cylinder piston rod joints. Check the
surface of piston rod for damage.
away.
(g) Check mast rollers to see that they rotate smoothly.
(h) Full oil into the lift cylinders by lifting the lift cylinders at the full stroke.
(i) In cold weather, don’t draw off long antifreeze, if there is cooling water, run it
·Daily storage
(a) Park the forklift truck at a specified place and block the wheels.
(b) Place the shift lever in the neutral position and pull the parking brake lever.
10

(c) Put the key switch in “OFF” position and turn off the engine, operate the lever
of the control valve several times and release the residual pressure of the cylinder or
pipes.
(d) Remove the key and keep it in a secure place.
·Long time storage
service:
ground.
Perform the following service and checks in addition to the “Daily storage”
(a) Taking the rainy season into consideration, park the truck at a higher and hard
(b) Apply antirust oil to the exposed parts such as piston rods and shafts which
tends to rust.
(c) Cover components which may be caught with humidity.
(d) The truck should be operated at least once a week. Fill the cooling system, if
cooling water is discharged. Remove grease from the piston rods and shafts. Start the
engine and warm up thoroughly. Move the truck slowly forwards and backwards.
Operate the hydraulic controls several times.
(e) Avoid parking on soft grounds such as asphalted road in summer.
·Operate the forklift truck after long time storage
(a) Remove antirust oil from the exposed parts.
(b) Discharge the engine oil in crankshaft case of the engine, discharge the gear
oil or hydraulic transmission oil in differential and gear box, after cleaning up then
renew oil.
(c) Discharge foreign matter and water from the hydraulic reservoir and fuel tank.
(d) Remove the cylinder cap, the valves and the rocker shafts, check for the
clearance in normal data.
(e) Add cooling fluid to specified level.
(f) Perform pre-operation checks carefully.
(g) Warm up the engine before operation.
Warning:
If at any time your forklift truck is found to be in need of repair, defective, or in any
way unsafe, the condition should be reported to the supervisor, and the truck should
11

e taken out of service until it has been restored to safe operating condition.
7. Information of safety operation
(1) The forklift truck belongs to special equipment. Only trained and authorized
operator shall be permitted to operate and service the truck.
(2) Wear the safety guards, such as clothing, shoes, helmet and gloves while
operating the truck.
(3) When operating the truck, observe and follow all nameplates stuck on the
truck. The nameplates must be replaced if lost or damaged.
(4) Daily maintenance should be done before or after using the truck. Anytime
you find that the truck is not functioning normally, operation of the truck should be
halted and check or repair at once.
(5) When the distance between the gravity center of loads and the fork arms is
500mm, the max. capacity is the rated capacity. When the distance exceeds 500mm,
the capacity shall be reduced according to the load chart. Overloading is strictly
prohibited.
(6) Operate your forklift truck on a hard ground. Operate on other ground, the lift
capacity and travel speed must be decreased. Wipe off the oil and grease from the
floor.
(7) If the forklift truck is equipped with attachment, its usage sphere will be wider,
but its allowable load and stability is reduced. The attachment and special device is
not to be diverted to any other purpose. It’s very dangerous to rebuild the attachment.
Please read the additional instruction we supplied and operate the truck following it
strictly.
(8) Users select “Lengthening fork” in order to carry widening loads. Pay much
attention not to overload and observe the allowable load and the capacity chart stuck
on the truck. Careful driving should be taken when traveling and turning.
truck.
(9) The unloaded forklift truck with attachment should be operated as a loaded
(10) Connect the power and turn on the key switch, select the position of direction
switch, check the truck for normal operation by turning steering wheel, depress the
speed-adjusting pedal softly to keep proper acceleration.
12

(11) During operation, pay attention to the performance and condition of the
system of machinery, hydraulic, electric and speed-adjuster etc.
(12) When operate one lever, pay attention not to shift another lever. Don’t
operate the lever at any position out of the driver’s seat.
(13) The shift distance of control valve lever can control the speed of the lifting or
descending of the goods. When the goods are lifted or descended, the initial speed
shouldn’t be too fast in either case.
(14) When tilting the mast forward or backward to the limit or lifting the fork to the
maximum height, return the directional lever to neutral.
(15) The starting, turning, driving, braking and stopping of the truck should be
done smoothly. When turning on the humid or slippery road, the truck should be
decelerated.
(16) Because the forklift truck turns by the rear wheels, the end counterweight
may swing widely when turning. Use care in narrow aisles and other workplaces.
(17) Operate the forklift truck smoothly, don’t jerk the steering wheel. Avoid
sudden stop, acceleration, stop or turn. In the case of improper operation, the truck
will turn over. In case of this, the driver must keep calm, don’t jump off the truck. The
driver must hold tightly the control wheel with two hands; meanwhile, his body must
incline in opposite direction of truck’s turning over.
(18) Turning, lateral or deflective traveling shall not be taken on a slope. It could
cause overturning of the truck, it is very dangerous. On a slope, drive the truck with
load forward to ascend and backward to descend. When the truck goes down on a
slope, drive slowly with the brakes on. Make sure that the engine should not be shut
down when traveling on a slope.
(19) The stability of the truck is influenced by the wind-force during outside
operation, you must notice specially.
(20) Be careful and slow driving over a dock or temporary paving slab.
(21) Insert forks deeply under goods. Adjust fork’s distance according to the
dimension of goods. Make the loads distribute on the forks evenly to avoid tilt and
slide of goods.
(22) Don’t pick the loads with single fork. Fork can not be used to pull out any
embedded goods, if necessary, the pulling force should be estimated.
13

(23) Don’t handle unfixed or loose goods. Be careful to handle bulky goods. To
prevent the collapse of stacked goods, tighten them. Forbid loading loose or little
volume goods without pallet.
(24) When loading the goods, lower the forks to the floor. After the fork inserting
stacked goods, the fork arms should be in contact with the goods. Drive the truck with
mast tilting back for stabilizing the load. Before traveling, raise the forks for
200mm-300mm from the floor.
(25) When handling bulky loads which block your view, operate the forklift truck in
reverse or have a guide.
(26) While mast’s lifting and lowering, anyone is absolutely prohibited from
standing under the lift bracket or being lifted with forks. Never permit anyone to stand
or walk under upraised forks.
(27) When lifting the load, according to the weight of the load, accelerate properly
and then pull the lifting lever.
(28) The load descends for the gravity, at this time, the engine must be in idle
position, and the lever must be pulled slowly to prevent the load from sudden falling.
(29) When loading and unloading goods, keep the mast vertical and the truck is in
braking state.
(30) Load should cling to the load backrest. Do not handle the load which
exceeds height of the backrest, or else there is a danger of load’s falling against
operator.
(31) When travel with load, don’t tilt mast forward, don’t do handling. Don’t brake
abruptly to prevent goods from slipping off the forks.
(32) It is necessary to brake before tilting the mast forward or backward. It’s also
necessary to decelerate and tilt forward slowly so as to prevent the goods from
slipping off the forks.
(33) Don’t make a sudden braking when the truck traveling with loads.
(34) Drive the forklift truck to the stacked goods at a low speed, at the same time,
pay much attention to sharp and hard objects near the goods, otherwise, the tyres will
be pricked.
(35) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay
attention to the clearance over the forklift truck.
14

(36) Keep your head, hands, arms, feet and legs within the confines of the cab.
Never allow other persons on the forklift truck.
(37) Tilt the mast of the high lift forklift truck as backward as possible when
operating the truck. Use minimum forward and backward tilt when loading and
unloading. It is dangerous to travel or turn when lifting the goods at high levels.
(38) It is noted that the goods will fall down when the forks of the truck with lifting
height more than 3m lift, take the protection measures if necessary.
(39) Before the truck decelerating and stopping, don’t change gear to reverse
shift, so as to ensure the safe loading.
(40) When the truck stops and the engine is on idle position, the mast must be
tilted backward. You shouldn’t leave the truck with idling engine or hanged goods
unattended.
(41) When adding fuel, make the driver leave the truck and the engine flameout.
Don’t ignite when checking the level of fuel tank.
(42) Don’t open the radiator cap when the engine is very hot.
(43) After one day’s working, the fuel tank should be added oil to prevent the
humidity in the fuel tank from becoming the blob and then interfusing the fluid.
(44) When leaving, engage the hand brake, lower the forks on the ground and let
the shift lever to neutral, make the engine flameout or cut down the electric supply. If
parking on a slope with smaller gradient, apply the parking brake and block the wheels.
The truck is forbidden parking on a slope with bigger gradient.
(45) Don’t adjust the control valve and relief valve at will to prevent the damage of
hydraulic system and its components because of excessive pressure passing them.
(46) Tyres should be inflated according to the pressure value specified in the
nameplate of “Tyre Pressure”.
(47) Check the chains periodically to make sure that good lubrication condition
exists between the chain elements, the degree of tightness between left and right
chain is identical. If the variation value of the chain pitch exceeds 2% standard value,
it indicates that the chains have been worn excessively, replace it immediately.
(48) The overhead guard is main part which is strong enough to meet safety
standard, and protect the operator from falling materials. It’s very dangerous to
dismantle or rebuild the overhead guard, because these conditions could lead to an
accident.
15

(49) A load backrest shall be used as protection against back falling objects on
the fork. It’s very dangerous to dismantle or rebuild the load backrest, because these
conditions could lead to an accident.
(50) You can’t change or add other working equipments on the truck without our
company’s permission, or the rated capacity and safety operation will be affected.
(51) Keep safety when serving on high position.
(52) The forklift truck must be operated under the following environment: below
an elevation of 1000 meters and temperature between -20℃and 40℃, relative
humidity is 95%. Careful operation must observe under other adverse circumstances.
(53) Because of the danger for the people, the forklift is forbidden operating in
airtight space, or you may be choked by the tail gas. The tail gas’s exhausting
standard shouldn’t be lower than the no-load mechanical vehicle exhaust standard
ruled by the nation that users are in. If in Europe nation, the adopted tail gas’s
exhausting index should be applied Europe StageⅢA standard.
(54) According to the Directive 2000/14/EC and based on EN12053 standard,the
noise pressure level at the operator’s position and the measured sound power level
and the guaranteed sound power level is referred to the following table. But the noise
of the forklift truck may fluctuate due to different operation and the influence of the
external environment.
(55) The driver feels the vibration of the forklift truck when operating and traveling
the forklift truck. According to ISO3691 and based on EN13059 standard. The
vibration of the forklift truck fluctuates according to environment condition .In normal
working condition, the vertical direction acceleration mean value from the seat to the
operator by testing is in the following table. But the vibration frequency felt by the
driver depends on the working condition (etc. road, operation method), so the actual
vibration frequency must be determined according to environment condition when
necessary.
Model
The noise pressure
level at the operator’s
position
The measured sound
power level
16
The guaranteed
sound power level
EN12053 EN12053 2000/14/EC
The vertical direction
acceleration mean
value from the seat
to the operator
CPCD40 83 dB(A) 107 dB(A) 110dB(A) 0.94 (m/s 2 )
CPCD45 83 dB(A) 107 dB(A) 110dB(A) 0.88(m/s 2 )
CPCD50L 84 dB(A) 108 dB(A) 110 dB(A) 0.80(m/s 2 )

(56) To prevent the fire, accident or other unpredictable event, prepare the fire
extinguishers in advance and operate them according to the instructions.
8. Caution plate
The caution plates attached on the vehicle indicates the operating method and
instructions. Before driving it, please be sure to read them thoroughly. If the caution
plate drops, stick it again. When maintaining, check if the caution plate is complete
and the writing is legible, if necessary, please replace them.
(1) Safety mark (People are forbidden to stand on or down the fork)
(2) General information when operating
(3) Nameplate of forklift truck
17

(4) Lubrication system
(5) Capacity chart
(6) Inspections before starting
18

(7) Adjust parking brake
(8) Add hydraulic oil
(9) Add fuel
(10) Add antifreeze
(11) Tyre safety decal (charging tyre)
19

(12) Tyre pressure decal (charging tyre)
(13) Sling point indication
(14) Sling decal
(15) Forbid entering into the space behind the mast
(16) Forbid conveying person
20

(17) Hand caution decal
(18) Fan hurting hands
(19) Hood crushing hands
(20) Overturn caution decal
(21) Belt pulley thumb hand decal
21

Ⅳ. Periodic inspection and servicing
During operating the forklift truck, it is necessary to operate carefully, service and
maintain periodically to make the forklift truck keep in good condition.
1. General rules on inspection and maintenance
(1) Only use genuine parts provided by our company.
(2) Only use genuine or recommended oil when replacing or adding.
(3) Clean oil fillers and grease fittings with a brush or waste cloth before adding
oil or grease.
(4) Checking oil level and adding oil should be made with the truck parked on a
level ground.
(5) Preventive maintenance should be done in an orderly manner and due care
taken not to injure yourself.
(6) If any damage or fault is found, stop the truck and report the condition to the
manager. Do not operate the truck until it has been repaired completely.
frame.
.Regular inspection
(1) Check the seal and the reliability of the hydraulic system.
(2) Check the reliability of the steering and braking system.
(3) Check the reliability of mast, driving axle and steering axle connecting with the
(4) Check all wheels for tightness.
.Irregular inspection
(1) Check the reliability of each welding joints of the mast, frame and so on.
(2) Check the reliability of connecting joints of steering cylinder, joint plate and
gimbals etc.
(3) Check all pipes and hoses for any leakage and breakage.
(4) Check the performance of the traveling brake and the parking brake.
Caution:
.Only trained and authorized serviceman shall be permitted to service and
repair the truck.
.When checking and maintaining the forklift truck, do not use the mast or
the load backrest instead of a ladder, these actions will lead to a dangerous
condition unexpectedly.
22

2. Essentials of servicing
(1) Some critical components must be replaced according to demands
periodically. Use genuine parts only.
(2) Use the same model oil only when replacing or adding.
(3) If any damage or fault is found, stop the truck and report the condition to the
manager. Do not operate the truck until it has been repaired completely.
Periodic service and maintenance must be done according to the following list
after using the forklift truck.
No. Item Contents Period (hrs.) Remark
1 Bearing, steering wheel Replace grease 1000
2 Bearing, drive wheel Replace grease 1000
3 Steering link lever Replace grease 1000
4 Parking brake lever Add grease 200
5 Pin, foot brake Add grease 200
6 Drive axle body Replace gear oil 2400
7 Braking oil Add
23
Whenever
necessary
8 Pin, tilting cylinder Add lubricating grease 400
9 King pin, knuckle Replace grease 1000
10 Hydraulic tank and filter Clean 1000
11 Hydraulic oil Replace 1000
12 Lift chain Replace 3000 If damaged,
replace it.
13 H. P. hose Replace 3000
14 Switch, hydraulic motor
Clean photoelectric
coupler
200
15 Brush, traction motor Check 1000
16 Brush, hydraulic motor Check 1000
17 Brush, steering motor Check 1000
Notice:
When serving and checking the truck, do not use the mast or the load
backrest instead of a ladder, these actions will lead to a dangerous condition
unexpectedly.

3. Recommended oil, grease and coolant
No. Position Type of oil Quantity
1 Hydraulic oil tank
2 Fuel tank
3
Transmission
(torque converter)
AN32 or AN46
Hydraulic oil
-10 type diesel or 90
type gasoline
6 type Hydraulic
drive oil
24
About 90L +
About
90L
About
20L
Time (Hours)
50 100 500 1000
Daily check
4 Engine oil pan About 15L
Accord with the
demands
5 Driving axle Gear oil 85W/90
of the engine.
+
6 Radiator
Antifreeze
FD-2type-35℃
About
15L
+
Daily check
The oil quantity listed in above table is approximation, the detailed value when
operating is inspected according to the meter or corresponding gauge.
Adding oil, grease and coolant should follow relevant automobile standard. The
waster of the truck must be reclaimed obeying the relevant laws and regulations.
Incorrect treatment will pollute water, soil and atmosphere etc.
It is necessary to wear a helmet, safety shoes and working clothes to avoid
contacting with body when adding. Once the greasy dirt adhered on the skin, wash it
with clean water and soap, it is forbidden to wash with gasoline or kerosene.
4. Lubrication system
No. Position Point Brand
1 Support of steering device 2 Lime grease +
2
Both end joints of steering
cylinder
2 Lime grease +
3 Bearing of knuckle 4 Lime grease +
4 Bracket of foot control 1 Lime grease +
5 Pin of tilt cylinder 2 Lime grease +
6 Lever head of tilt cylinder 2 Lime grease +
7 Support bushing of mast 2 Lime grease +
8 Lift roller of fork bracket 8 Lime grease +
Time (hours)
50 100 500 1000
Note: About lubrication of the engine, refer to the ENGINE OPERATION MANUAL.

Ⅴ. Construction and performance of main parts
1. Engine
Engine model
Diesel engine
A-6BG1QC-05 R4105G Mitsubishi S6S Mitsubishi S6S-T
Rated output Kw 68 59 55.3 63.9
Rated speed r/min 2000 2300 2450 2300
Max. torque N.m/rpm 340/1600 280/1600 240/1600 285/1700
For truck model
CPCD40-LW
CPCD45-LW
CPCD50-LW
26
CPCD40-LF
CPCD45-LF
CPCD50-LF
CPCD40-LM1
CPCD45-LM1
CPCD50-LM1
CPCD40-LM2
CPCD45-LM2
CPCD50-LM2
Now the engine used for the forklift truck refers to the above table. The
construction of the engine refers to the Section Nine.
The construction of the domestic engine refers to the ENGINE OPERATION
MANUAL.
The power of the engine is transmissed to the front axle to satisfy the needs of
traveling through the torque converter type transmission, is transmissed to the
operation pump to meet the needs of the hydraulic system and the load handling
system through the pulley and the drive shaft.
Parallel table for engine and forklift model which is coincidence
and stuck with CE label:
Diesel
engine
Engine model
the guaranteed
sound power
level LwA(dB)
2000/14/EC
Exhausting
2004/26/EC
Mitsubishi S6S 110 StageⅢA Yes
Mitsubishi S6S-T 110 StageⅢA Yes
CE CONFORMITY
2006/42/EC
Truck model
CPCD40-LM1
CPCD45-LM1
CPCD50-LM1
CPCD40-LM2
CPCD45-LM2
CPCD50-LM2
Note: The sound power level LWA according to 2000/14/EC standard, the
exhausting according to 2004/26/EC standard.

2. Torque converter type transmission
Torque Converter:
Type: 3-element, 1-stage, 2-phase type
Stall Torque Ratio: 3
Pressure Setting (Out pressure): 0.5-0.7MPa
Charging Pump:
Type: Built-in gear type
Discharge: 26ml/r
Transmission:
Clutch:
Type: Power-shift constant mesh
Clutch facing size (mm): 134×90×2.8
Surface area: 7740mm×12
Pressure setting: 12-15kg/cm 2
Oil to be used: Torque converter oil 20L
Differential:
Reduction Ratio: 6.333
Weight: 184kg
Oil to be used: Torque converter oil 7.0L
2.1 General description
The power-shift transmission has excellent features as follows:
(1) An inching valve provides the machine with improved inching performance.
Due to this valve, the lift truck is allowed to perform inching operation regardless of
whether the engine is at low RPM or at high RPM, and when the truck is started up.
(2) As clutch plates, three steel plates and the same number of composite plates
subjected to special treatment are provided so that improved durability can be
ensured.
(3) A free wheel installed in the torque converter improves transmission
efficiency.
(4) The torque converter circuit is given a high quality filter to improve its
durability.
27

2.2 Torque converter
Fig2.1 Torque converter type transmission
The torque converter consists primarily of a pump wheel connected to the input
shaft, a turbine wheel connected to the output shaft, and a stator wheel fixed to the
housing.
The pump wheel is rotated by the drive shaft and fluid is strongly ejected along
the row of pump wheel vanes under centrifugal force, (In this state mechanical energy
is converted into kinetic energy). The ejected fluid flows in the row of turbine wheel
vanes to transmit torque to the output shaft. The direction of fluid leaving the turbine
wheel is changed by the stator wheel so that it floes into the pump wheel at proper
28

angle. At this time reaction torque pushing the stator is created so that the output
torque exceeds the input torque by this reaction torque. As the rotational speed of the
turbine wheel increases and gets close to the input rotational speed, angle change of
the fluid is reduced and the output shaft torque is decreased. Finally fluid flows into
the row of the stator vanes in the reverse direction, causing reverse reaction torque.
As a result of this the output shaft torque becomes smaller than the input shaft torque.
To prevent this condition, a free wheel (one-way clutch) is provided at the stator
section to aloe the stator wheel to rotate freely when reaction torque acts in the
reverse direction.
The output torque is kept equal to the input torque so that highly effective
operation is ensured. Since the phase of torque transmission is converted by the
mechanical means (clutch), this type of torque conversion is called 2-phase type,
which ensures smooth and effective operation.
The torque converter section of the torque converter transmission is connected
through the flex plate to the engine flywheel, and designed to rotate as the engine
rotates. Inside the torque converter case are turbine wheel pump wheel, and stator
wheel, and stator wheel. The inner space is filled with torque converter oil. The drive
gear is splined to the pump wheel to drive the charging pump. The turbine wheel is
splined to the main shaft to transmit the power to the hydraulic clutch.
Fig.2-2 Torque converter
29
1. Input plate
2. Ball bearing
3. Turbine wheel
4. Stator wheel
5. One-way clutch
6. Impeller wheel
7. Ball bearing
8. “O”-ring

2.3 Clutch groups
The torque converter type transmission is provided with the forward clutch group
and reverse clutch group, each of which consists of 6 clutch disks and 6 state plates
assembled alternately a piston, and an end plate. The piston is provided with piston
rings on its inner and outer circumference to insure oil sealing during operation. The
piston has a check ball to prevent dragging.
The clutch surface and gear bushings are always lubricated with oil to prevent
seizure. When replacement of any clutch disk is needed, the mating steel plate should
also be changed.
Fig.2.3 Clutch group
1. Seal ring 2.Seal ring 3.Ball bearing 4.Seal ring
5.Return spring 6.Piston 7. Seal ring 8. Conical plate
9.Clutch plate 10.Steel plate 11.End plate 12.Snap ring
13.Thrust washer 14.Gear (28T) 15.Needle bearing 16Thrust washer
17.Ball bearing
2.4 Control valve
The control valve consists primarily of the directional selector valve, regulator
valve, accumulator piston and inching valve. The accumulator piston, interlocked with
the directional selector valve, is actuated by the operation of the directional selector
spool.
The oil picked up by the gear pump flows into the control valve and floe regulated
by the orifice while its pressure is regulated to the specified pressure (12-15kg/cm 2 ).
When the directional control lever is in the forward or reverse position, the
pressure regulated oil is sent to the forward or reverse clutch pack by the directional
30

selector valve, while the accumulator piston is moved by some of the oil so that the
shock induced by clutch engagement is alleviated by operation of the accumulator
along with the orifice.
2.5 Oil circulation route
Fig.2.4 Control valve
When the engine is started and the charging pump is driven by the pump drive
gear fitted to the pump wheel boss, torque converter oil is drawn from the oil tank
(transmission case) through the strainer by the pump and is routed under pressure to
the main regulator valve and the control valve in the converter housing. The oil
necessary for clutch operation is set to the specified pressure by the main regulator
valve.
The oil which flows to the control valve is flow controlled by orifice and pressure
controlled by the pressure control mechanism to the specified pressure.
31

When the change lever is put in forward or in reverse, the oil is sent from the
control valve through the forward/reverse selector valve to the pressurization chamber
of the forward or the reverse clutch. Also some of the oil from the control valve flows
into the accumulator piston to help insure a smooth elevation of the clutch oil
pressure.
The oil which flows to the mail regulator valve is pressure regulated by the
converter inlet relief valve to 5-7kg/cm 2 and makes its way to torque converter wheels.
The oil regulated by the outlet relief valve flows through the oil cooler to the clutch
groups and lubricates and cools them before returning to the oil tank.
While the forward or the reverse clutch group is operating, the other clutch group
is rotating between the clutch disks and their mating plates. This area is thus
lubricated with oil from the oil cooler to prevent the plates from being seized.
When the brake pedal is pressed, the inching valve operates to drain most of the
oil flowing to the clutch from the inching valve into the transmission case.
2.6 Charging pump
Fig.2.5 Oil circulation route
The charging pump is a gear type and is installed in the torque converter housing.
It feeds oil to the torque converter, hydraulic clutches and transmission to lubricate
them.
Fig.2.6.
The charging pump consists of the drive gear, driven gear, case and cover. See
32

2.7 Differential
Fig.2.6 Charging pump
The differential is fitted to the rear case (reduction gear case) by ball bearings
with bearing caps and covered with the axle housing.
The cross case of the differential is of the split type containing two side gears and
four pinion gears. The thrust plate is installed between the cross case and each gear
according to the backlash.
The pinion is supported by the pinion shaft, which is secures to the cross case
with a knock pin. The ring gear is installed on the circumference of the cross case with
reamer bolts.
The rotation sent from the transmission through the reduction gear is further
reduced and differentiated by this device to drive the drive shaft.
2.8 Differential maintenance
Reassemble the differential in the sequence opposite to disassembly, observing
the following conditions:
(1) Adjust the backlash between the side gear and pinion to the specified valve.
Specified backlash: 0.23-0.33mm
Adjustment should be made by changing the spacers at the side gear side. Use
spacers of the same thickness at each side.
Spacers: 1.8, 1.9, 2.0, 2.2, 2.3, 2.6mm
(2)Tighten the cross case assembling bolts to the specified torque and make sure
the side gears are rotating without inference.
Tighten torque: 130-195N.m
33

(3) Tighten the ring gear fitting bolts to the specified torque.
Tighten torque: 130-195N.m
(4)Adjust the preload of the drive pinion to the specified valve.
Adjustment should be made by using the shims between the tapered roller
bearing and spacer.
torque.
Shim: 0.1, 0.15, 0.2, 0.5, 2.3, 2.6mm
(5) Adjust the backlash between the drive pinion and ring gear to the specified
Backlash: 0.23-0.33mm
Adjustment should be made by using the shims between the bearing case and
the carrer.
Adjust the engagement either.
(6)Tighten the bearing cap fitting bolts to the specified torque.
Tightening torque: 222-332N.m
1.Ring gear
2.9 Trouble shooting
2.Thrust washer 3.Side gear 4.Cross case 5.Pinionshaft
6.Pinion gear 7.Thrust washer 8.Drive pinion gear 9.Adjust nut
10.Tapered
roller bearing
11.”O”-ring 12.Oil seal 13.Bearing case 14.”O”-ring
15.Tapered
roller bearing
16.Adjust screw 17.Lock nut 18.”O”-ring 19. Carrier
20.Roller
bearing
21.Tapered roller
bearing
22.Adjust nut 23.Bearing
34

2.9 Troubleshooting
(1) Insufficient power
Parts Problem Possible cause and remedy
Torque
converter
Gear
box
A. Too low oil pressure
1. Lower oil level Check oil level and add oil.
2. Air entering in resulting from
loose connectors.
35
Check connector or oil pipe. Retighten
each connector or replace seals.
3. Blocked oil filter Check, clean or replace
4. Oil can not be pumped out. Check and replace.
5. Deformed spring of relief valve. Check tension of spring
6. Seal ring or O-ring seal damaged Check and replace.
B. Fly wheel damaged Check oil, if have dirt, replace it.
A .Unsuitable oil or air bubble in oil Check oil
1. Air entering in resulting
Check connector or oil pipe. Retighten
from loose connections.
each connector or replace seals.
2. Too lower oil pressure or air
bubble in oil
Measure and adjust pressure.
B. Slipped clutch
1. Oil pressure lower Measure and adjust pressure.
2. Seal ring damaged Check and replace
3. Piston ring of the clutch damaged Check and replace
4. Worn friction piece or deformed
steel piece
C. Incorrect position between
inching rod and shift rod.
Replace
Check and adjust.
Engine Insufficient engine power Adjust or repair engine
(2) Too high oil temperature
Parts Problem Possible cause and remedy
Torque
converter
Gear
box
1. Lower oil level Check oil level and add oil.
2. Blocked oil filter Check, clean or replace.
3. Fly wheel bump against other
parts.
Check oil, if have dirt, replace it.
4. Air entering in resulting
from loose connectors.
Check connectors or oil pipes.
Retighten each connector or replace
seals.
5. Water mixed into oil Check and replace oil.
6. Low oil flow Check pipes and replace.
7. Worn bearing Check and replace.
1. Slipped clutch Replace friction piece of clutch.
2. Worn bearing Check and replace.

(3) Noisy gear box
Parts Problem Possible cause and remedy
Torque
converter
Gear
box
1. Elasticity plate is broken Check noise and replace elasticity plate.
2. Damaged or worn bearing Check or replace
3. Gear is broken. Check or replace
4. Spline is worn Check or replace
5. Noisy main pump Check or replace
6. Loosen bolt Check, tighten or replace
1. Bearing is worn Check or replace
2. Gear is broken Check or replace
3. Spline is worn Check or replace
4. Loosen bolt Check, tighten or replace
(4) Too low transmission effiency
Parts Problem Possible cause and remedy
Torque
converter
Gear
box
(5) Oil leakage
1. Elasticity plate is broken. Check turn noise and replace.
2. Lower oil amount. Check oil level and add oil.
3. Driving system of oil pump is ineffective. Check and replace.
4. Shaft is broken. Check and replace.
5. Too lower oil pressure. Check oil pump for suction pipe.
1. Lower oil amount. Check oil level and add oil.
2. Seal ring is worn. Check and replace.
3. Slipped clutch. Check oil pressure of the clutch.
4. Shaft is broken. Check and replace.
5. Clutch cap is broken. Check and replace.
6. Retainer ring of clutch cap is broken. Check and replace.
7. Foreign matters mixed in oil tank of
clutch.
Check, clean or replace.
8. Spline of shaft is worn. Check and replace.
Parts Problem Possible cause and remedy
1. Worn seal ring. Check and replace seal ring.
Torque
converter
or gear
box
2. Incorrect connection of case. Check, tighten or replace.
3. Loose connector and oil pipe. Check, tighten or replace.
4. Loose drain plug. Check, tighten or replace.
5. Oil spray from air hole.
Check connectors, air holes or replace
pipes.
6. Much oil. Check oil level and drain surplus oil.
36

3. Front axle
CPCD40L,45L,50L CPCD40LF,45LF,50LF
Type Front two-wheel drive, full-floating
Tire Size 300-15-18PR
Rim Size 8.00V-15
Air Pressure 0.84Mpa
3.1 General description
The front axle is a full-floating type and cast into one piece construction
consisting of the axle housing, wheel hub, brake drums and wheel brakes as shown is
Fig.3-1. it is installed at the front of the frame.
Fig.3.1 Front-axle
1. Adjust nut 4.Oil seal 7.Brake drum 10.Wheel
2.Axle shaft 5. Tapered roller bearing 8. Tapered roller bearing
3.Lock nut 6.Hub 9.Oil ring
37
cylinder

3.2 Axle housing
The axle housing is a one-piece construction consisting of a banjo-shaped
differential housing and spindle and id secured to the frame with caps.
3.3 Front wheel hub
The front wheel hub receives the power from the drive shaft and drives the front
wheels. The brake drum and rim are fitted to the front wheel hub with hub bolts and
nuts. The hub is installed on the axle housing by two tapered roller bearing. The
back-up plate is secured to the axle housing and house inside the brake drum.
The total weight of the truck is sustained by the hub and axle housing, and thus
the drive shaft only drives the wheels.
Inside the hub are inner and outer oil seals to prevent oil leaks.
3.4 Maintenance
3.4.1 Preload adjustment
(1) Tighten the bearing nut and then turn back 1/8 circle.
(2) Tighten the bearing nut gradually while measuring the preload.
(3) When the preload is reached lock the nut with the lock nut and lock washer.
3.4.2 Wheel installation procedure
(1) Installing signal wheel
[1] Align the wheel fitting holes and the hub stub holes and install the wheel.
[2] Hand tighten 6 wheel nuts in a diagonal order.
[3] Tighten 6wheel nuts evenly in several stages in a diagonal order.
[4] Tighten all wheel nuts to the specified torque.
Tightening torque: 480-560N.m
(2) Installing double wheels
[1] Align the inner wheel fitting holes with the hub stub bolts and install the inner
wheel.
[2] Tighten 6 inner wheel nuts by hand.
[3] Tighten 6 inner wheel nuts evenly in several stages in a diagonal order.
[4] Tighten all inner wheel nuts to the specified torque.
38

Tightening torque: 480-560N.m
[5] Align the outer wheel fitting holes with both the inner wheel position and the air
valve passing hole and install the outer wheel.
[6] Tighten 6 outer wheel nuts by hand.
[7] Tighten 6 outer wheel nuts evenly in several stages in a diagonal order.
[8] Tighten all outer wheel nuts to the specified torque.
Tightening torque: 480-560N.m
NOTE: If remove stand or any other contamination on the mating surfaces of the rim
and the hub and on the thread of the nuts or stub bolts.
3.5 Troubleshooting
Trouble Cause Correction
Oil leaks from
differential
carrier.
Noisy
differential.
Loose bolt or broken gasket of differential
carrier.
Breather is clogged.
Oil seal is worn or damaged.
Gear is worn, damaged or broken.
Bearing is worn, damaged or broken.
Improper backlash.
Loose spline fitness of side gear to
propeller shaft.
Insufficient gear oil.
39
Retighten or replace.
Clean or replace.
Replace.
Replace.
Replace.
Adjust
Replace parts.
Add as necessary.

4. Brake system
Type:
Booster:
Type;
Pressure setting:
Servo ratio:
Wheel brake:
Type:
Pedal ratio:
Wheel cylinder bore:
Brake drum inner diameter:
Lining size:
Surface area:
Parking brake:
Type:
4.1 General description
Front-wheel braking, internal
Expansion hydraulic type
Hydraulic type
50kg/cm 2
4.5
Dou-servo type
5.0
31.75mm
317mm
330×63×10mm
416cm 2
Front two-wheel braking internal
expansion, hydraulic type
The brake system consists of a brake pedal, wheel brakes and rake drums, a
booster, pipes and so on.
4.2 Brake pedal
The brake pedal is installed on the transmission as shown in Fig.4.1. the push rod
connected to the brake pedal pushes the booster reaction piston and its force is
converted into oil pressure and transmitted to the wheel cylinder.
The unlubricated bearing is mounted between the brake pedal and shaft, so the
lubrication is not to be needed.
Fig.4.1 Brake pedal (Torque converter model)
40

4.3 Wheel brake (Fig.4.2)
The wheel brake is the internal expansion hydraulic type consisting of brake
shoes, springs, a wheel cylinder, an adjuster and backing plates. Two wheel brakes
are provided on each end of the front axle. The brake shoe, its one end being
connected to the anchor pin and the other end to the adjuster, is forced against the
backing plate with a hold spring and pin. The primary shoe is provided with the
parking brake lever and the secondary shoe with the actuator lever of the automatic
clearance adjuster.
Fig.4.2 Wheel brake
1. Retainer 2. Wheel cylinder 3. Cup 4. Piston
5. Push rod 6. Strut 7. Return spring 8. Brake shoe
9. Hold-down pin 10. Cap 11. Spring 12. Spring
13. Adjuster lever 14. Adjuster
41

The braking operation in forward travel is as follows: (See Fig.4.3) the primary
and secondary shoes are forced by an equal force, by operation of the wheel cylinder
to bring the lining in contact with the brake drum. The primary shoe forces the adjuster
with the aid of lining-to-drum friction force. Due to this, the adjuster end of the
secondary shoe by a large force than offered by the wheel cylinder operation. The
secondary shoe anchor end is forced strongly against the anchor pin providing large
braking force. On the other hand, the braking operation in reverse travel is performed
in the reverse direction, but the braking force is the same as in the case of the forward
travel. (Fig.4.4)
Fig.4.3 In forward
Fig.4.4 In reverse
42

4.4 Automatic clearance adjuster
The automatic clearance adjuster keeps a lining to brake drum clearance of
0.4-0.6mm automatically. This adjuster, however, actuates only when the truck is
baked in reverse travel. When the brake pedal is pressed in reverse travel, the brake
shoes are expanded. As a result of this, the secondary and primary shoes come into
contact with the brake drum and rotate together until the upper end of the primary
shoe comes into contact with the anchor pin.
On the other hand, as the secondary shoe leaves the anchor pin, the section (A)
of the actuator leaves relatively pulled. Therefore, the actuator lever turns around the
section (B) so that the section(C) of the actuator lever lowers, carsing the section (D)
of the adjuster to turn to the left. As the brake pedal is further pressed, compression
force applied on the adjuster becomes larger. This results in increased resistance on
the thread so that the actuator lever force can not turn the diction (D).
Fig.4.5 Parking brake
43

4.5 Parking brake
The parking brake consists of the parking brake lever and cable as shown in
Fig.4.5. The brake shoes and brake drum are commonly used with the wheel brake
system. The brake lever is a toggle type which allows the adjustment of braking force
with the adjuster at the tip of the lever.
4.6 Power brake booster
The power brake booster consists of the control valve which converts pedal
pressing force into hydraulic pressure and the master cylinder and the floe divider, as
shown in Fig.4.6. It makes use of the power steering hydraulic pressure for its
operation.
When the brake pedal is pressed, the depression of the brake pedal is transmitted
through the push rod to the control valve input piston, narrowing the part “A”. This in
creases the oil pressure at the part “B”, moving the input piston to the left while
opening the part “A”, so that the oil pressure at the part “B” ceases to rise and the
input piston stops.
The action of the input piston pushes the master cylinder piston increasing the oil
pressure inside the wheel cylinder.
Some of the pressure at the part “B” acts on the input piston as a reaction force
so that it is felt by the driver as steering feel.
Fig.4.6 Power brake booster
1.Body 2.Cup 3.Flow divider 4.Spring 5.Check valve
6.Plug 7.Stopper 8.Piston 9.Power piston 10.Control valve
11.Seat 12.Raction
piston
13.Push rod
44

4.7 Maintenance
This paragraph covers the procedures for disassembling, reassembling and
adjusting the wheel brake, and the procedure for adjusting the brake pedal. Some
sketches may be different from the actual unit, but the maintenance procedure is the
same.
4.7.1 Wheel brake disassembly
(1) Remove the secondary shoe hold-down
spring, adjuster lever, adjuster and return spring.
(2) Remove the shoe return spring.
(3) Remove the primary shoe hold-down spring.
(4) Remove the primary and secondary shoes
along with the adjuster and adjuster spring.
45
Fig.4.7
Fig.4.8
Fig.4.9
Fig.4.10

(5) Remove the brake pipe from the wheel cylinder. Remove the wheel cylinder
mounting bolts and take the wheel cylinder off the backing plate
(6) Remove the “E” retainer securing the parking brake cable to the backing plate.
Remove the backing plate fitting bolts and detach the backing plate from the axle.
(7) Remove the boot, and push the piston into the cylinder from one side while
removing the parts at the other side. Then push out the remaining parts from the
opposite side.
4.7.2 Inspection
Inspect all the parts for wear and damage. Repair or replace any defective parts
with new ones.
(1) Inspection the wheel cylinder’s inner surface and piston’s outer surface for
sign of rust.
Measure the clearance between the piston and cylinder.
Specified value: 0.03-0.10mm
Limit: 0.15mm
(2) Visually check the piston cup for damage or deformation, and replace it, if
defective, replace a new one.
(3) Measure the free length of the wheel cylinder spring. If unsatisfactory, replace.
(4) Measure the brake lining thickness, and if worn beyond the limit, replace it
with a new one.
Specified value:10.0mm
(5) Visually check the brake drum inner surface for scratches, nicks or uneven
wear, and if found, repair by grinding. If the surface is badly scratched or worn,
replace.
spring.
Standard size: 317.5mm
Limit: 319.5mm
(6) Measure the free length and setting load of the anchor side shoe return
(7) Check the adjuster for damage and operation, and the contact area between
the pole lever and the gear for delect. Replace if necessary.
46

4.7.3 Wheel brake reassembly
(1) Apply brake fluid to the wheel cylinder cup and piston, and reinstall the spring,
piston cup, piston and boot in that order.
(2) Install the wheel cylinder to the backing plate. Note: Make sure each of the
parts is located on the right position.
Tightening torque: 18-27N.m
(3) Install the backing plate to the front axle.
Tightening torque: 120-140N.m
(4) Apply heat-resisting grease on the points indicates in Fig.4-11, using caution
so as not to allow the lining to be contaminated
with grease.
(a) Backing plate shoe ledge surface
(b) Anchor pin
(c) Cable guide surface on which adjuster
cable is to contact.
(d) Parking brake lever pin
(e) Adjuster thread and its rotating part
(5) Install the parking brake cable with “E” retainer. Fig.4.11
(6) Install the shoes with the hold-down spring.
(7) Put the anti-rattle spring in the strut and
install them on the shoe.
(8) Install shoe guide pin on the anchor pin.
Install the shoe return spring. For this procedure,
start with the primary shoe and then proceed with
the secondary one. Fig.4.12
(9) Install the spring, adjuster, adjuster
following points:
[1] The left side brake unit has a left threaded
adjuster and the right side brake unit has a right
threaded one.
47
Fig.4.13

spring.
[2] The adjuster teeth do not contact the
[3] The adjuster shoe return spring is installed
with the long hook going to the adjuster lever.
[4] After reassembly, male sure the adjuster
lever end is in contact with the adjuster teeth.
cylinder.
(10) Install the brake pipe on the wheel
(11) Measure the brake drum inner diameter
and the shoe outer diameter. Adjust the adjuster
so that the brake shoe outer diameter is drum
inner diameter-1.0mm.
4.7.4 Operation test of automatic clearance
48
Fig.4.14
Fig.4.15
(1) Make the brake shoe diameter nearly to the specified setting size, and pull the
adjuster lever by your hand to turn the adjuster gear, when removing off your hand,
the adjuster lever returns to the original position.
Note: The adjuster gear may turn back slightly along with the adjuster lever when
removing your hand, but the adjuster will operate normally when it is put back on the
truck.
(2) If the adjuster fails to do normal operation when pushing the adjuster lever,
take the following steps.
(a) Make sure the adjuster lever, adjuster, adjuster spring, adjuster cable and
shoe return spring are securely installed.
(b) Check the shoe return spring and adjuster spring for deterioration. Also check
whether the adjuster is rotating properly, its teeth are free from damage and wear.

4.7.5 Brake pedal adjustment
Fig.4.16
(1) Shorten the master cylinder push rod properly.
(2) Adjust the pedal height with the stopper bolt as shown in Fig.4.17.
(3) Keeping the pedal pressed 30mm, extend the push rod so that its end contact
the master cylinder piston.
(4) Tighten the push rod lock nut.
4.7.6 Brake switch adjustment
(1) After making sure that the brake pedal height is as indicated in Fig.4.17,
loosen the brake switch lock nut.
(2) Remove making the brake switch lead wire from the connector.
(3) Turn the switch so that the size at “A” is 1mm.
(4) Make sure the brake lamps turn on when the brake pedal is pressed 30mm.
49

4.7.7 Air bleeding
Fig.4.17
(1) Place the truck on a level surface and apply the parking brakes securely.
(2) Shift the transmission in neutral and shut off the engine.
(3) Connect a vinyl tube to the bleeder plug of the wheel cylinder and put the
open end of the hose in a pan.
(4) Start the engine.
(5) Press the brake pedal and hold it. Loosen the bleeder plug.
(6) When no air bubbles are observed in the oil coming from the bleeder plug,
tighten the bleeder plug.
(7) Use the same procedure for the other side of the brake unit.
50

4.8 Troubleshooting
Problem Problem cause Remedy
Poor
braking
Noisy
brake
Uneven
braking
Soft or
spongy
brake
1.Fluid leaks from brake system Repair
2.Maladjustment of brake shoe clearance Check and adjust adjuster
3. Overheated brake Check for dragging
4. Poor contact between brake drum and lining Adjust contact
5. Foreign matter adhered to lining Repair or replace
6. Foreign matter mixed in brake fluid Check brake fluid level
7. Maladjustment of brake pedal Adjust
1. Hardened lining surface or foreign matter
adhered to thereto.
51
Repair or replace
2. Deformed backing plate or defective bolts Repair or replace
3. Deformed or improperly installed shoe Repair or replace
4. Uneven wear of lining Replace
5. Defective wheel bearing Replace
1. Contaminated lining Repair of replace
2. Maladjustment of brake shoe clearance Check and adjust adjuster
3. Maladjustment wheel cylinder Repair or replace
4. Defective shoe return spring Replace
5. Run out of drum Repair or replace
6. Improper inflation pressure of tire Adjust
1. Brake fluid leaks from system Repair
2. Maladjustment of brake shoe clearance Check and adjust adjuster
3. Air mixed in brake system Bleed air out of system
4. Maladjustment of brake pedal Adjust

5. Steering system (cycloid gear steering type)
Steering Axle:
Type:
King pin spacing:
King pin spacing:
Toe-in:
Camber:
Caster:
Steering angle
Inner wheel:
Outer wheel:
Cycloid gear type steering unit:
Type:
Discharge:
Pressure:
Steering cylinder:
Type:
Cylinder bore:
Piston rod diameter:
Stroke:
Rear wheel:
Tire type:
Rim type:
Pressure:
5.1 General description
Center-pin supported
1030mm
0°
0°
1°
0°
78.42°
54.36°
Open-central, no-load reaction type
160ml/r
12.5Mpa
Double-acting piston type
90mm
60mm
226mm
7.00-12-12PR
5.00S-12
0.84MPa
The steering system consists primarily of a steering wheel, cycloid gear type
steering unit flow regulator valve, steering axle, and steering cylinder. Turn the
steering wheel clockwise, the forklift truck will turn to the right, on the contrary, the
truck will turn to the left. When the steering wheel is turned, the rotation is transmitted
to the cycloid gear type steering unit. The oil passages in the steering unit are
changed over to direct the hydraulic pressure from the flow regulator valve to the
steering cylinder which extends or contracts depending on the hydraulic pressure,
thereby steering the truck. The oil can not be supplied from the pump while the engine
stops. The truck is steered by the manpowers, but it is too difficult.
The steering cylinder is double acting type. Two sides of piston rod is connected
with the knuckle by the push rod. The pressure oil from the steering unit is transmitted
to the steering cylinder, and pushes the piston rod to rotate. So the truck is steered.
52

5.2 Steering axle
The steering axle is of steel-welded construction with a box shaped cross section,
incorporation a steering cylinder inside it. See Fig5.1. The steering cylinder is housed
in the axle to protect it from being damaged by obstacles on the road surface. The
axle is installed onto the truck frame through a center pin with bushing and cap, and it
cradles around this center pin.
Fig.5.1 Steering axle
1.Cap 2.Bushing 3.Thrust bearing 4.Oil seal
5.Tapered roller bearing 6.Cap 7.Lock nut 8.Lock washer
9.Ajust nut 10.Hub 11.Tapered roller bearing 12.Lock pin
13.Oil seal 14.King pin 15.Shim 16.Seal ring
17.Knuckle 18. Joint
53

5.3 Steering wheel assembly
The steering wheel assembly is arranged as shown in Fig5.2. The steering unit is
located at the bottom of the assembly. At the center of the wheel is the horn button.
The steering shaft is connected through the universal joint to the drive shaft of the
steering unit so that the steering wheel can be moved to a certain extent back and
forth to suit the driver’s physique.
Fig.5.2 Steering wheel assembly
54

5.4 Cycloid gear type powered steering unit
The steering unit of model BZZ cycloidal type is open-centered, no-load reaction
device (Fig5.3). The rotor and the stator is a pair of cycloidal pin gear internal mesh
gears. It is serried between the flow dividing valve and the steering cylinder. During
normal operation, it operates as an oil motor. The turning angle is direct proportion
with flows to or from the steering cylinder because the oil must flows through the oil
motor.
The steering wheel is connected with the valve core by the retainer1, and moves
the sleeve 6 by the spring 4. The sleeve 6 is connected with the rotor 9 by the shift
arm 5 and the drive shaft8. the rotor 9 does not move because the oil route is not
connected, when the steering wheel is turned, the rotor 9 moves between the valve
core and the sleeves. So the oil is sent to the steering cylinder through the oil motor.
When the steering wheel is not turned, the valve core and the sleeve is located in
neutral position by the spring 4 to shut off the oil route.
In an emergency, the safety valve 14 is opened by vacuum to form return route
within the value. The oil motor can be used as hand pump to send the oil from one
chambers of the steering cylinder to another, so the manpower turning is
accomplished.
Fig.5.3 Cycloid gear type powered steering unit
1. Retainer 2. Head cap 3. Valve 4. Spring
5. Shift arm 6. Sleeve 7. Valve core 8. Drive shaft
9. Rotor 10. End cap 11. Spacer 12. Stator
13. ”O”-ring 14. Stewel ball 15. ”O”-ring 16. ”X”-ring
17. ”O”-ring
55

(1) Operation of steering unit
(a) In “neutral”
While the steering wheel is in straight position, the oil from the pump flows
through oil passage (1) to oil groove (2). The sleeve has 24oil holes (3)which are now
in line with the holes (4)in the spool so that the oil that flowed into groove (2) passes
through oil holes (3) and (4) to space (5) between the spool and drive shaft. Then the
oil flows through spool groove (6) and sleeve groove (7) back to the oil tank.
Since cylinder ports (20) and (21) are respectively open to oil holes (18) and (17)
in the sleeve but not to groove (16) nor (19) in the spool, the oil in the cylinder does
not go any where.
Oil passage (15) that leads to the hydraulic motor is opened to oil hole (14) in the
sleeve which is used as the inlet and outlet for the hydraulic motor, but not to grooves
(13) nor (16) in the spool and thus the oil remain unmoved.
Fig.5.4
56

(b) When steering wheel is turned counter-clockwise
As the steering wheel is turned counter-clockwise, the grooves in the spool shift
to the left in relation with the holes and grooves in the sleeve so that holes (4) in the
spool get out of line with holes (3) in the sleeve. The oil that has flowed into groove (2)
thus far begins to flows into hole (12) in the sleeve, passing through grooves (23) and
(13 ) in the spool, hole (14) in the sleeve, and oil passage (15) in the housing, to the
hydraulic motor.
The hydraulic motor thus rotates in the counter-clockwise direction and the oil
discharged from the hydraulic motor flows through oil hole (14) in the sleeve, groove
(16) in the spool and oil hole (18) in the sleeve to the cylinder port L and thus actuates
the steering cylinder.
The hydraulic oil from the steering cylinder flows, passing through the cylinder
port R, groove (11) in the valve housing, oil hole (17) in the sleeve, groove (19) in the
spool, oil hole (22) in the sleeve, and groove (8) in the valve housing, back to the oil
tank.
Fig.5.5
57

(c) When steering wheel is turned clockwise
As the steering wheel is turned clockwise, the grooves in the spool shift to the
right in relation to the oil holes and grooves in the sleeve so that oil holes (4) in the
spool get out of line with holes (3) in the sleeve, the oil that flowed into groove (2) thus
far begins to flow into hole (12) in the sleeve and then floes through grooves (23) and
(13) in the spool, oil hole (14) in the sleeve, and oil passage (15) in the valve housing
to the hydraulic motor. The hydraulic motor thus rotates in the clockwise direction and
the oil discharged from the hydraulic motor flows through oil hole (14) in the sleeve,
groove (16) in the spool, and oil hole (17) in the sleeve to the cylinder port R in the
housing and thus actuates the steering cylinder.
The returning oil from the steering cylinder flows, passing through the cylinder
port L, groove (10) in the housing, oil hole (18) in the sleeve, groove (19) in the spool,
oil hole (22) in the sleeve and groove (9) in the housing back to the oil tank.
Fig.5.6
58

(2) Relationship between rotating speed and operating force of steering wheel
In principle, the force required to operate the steering unit is only the force to
change over the valve, i.e. the force of compressing the centering spring is 0.3kgm. in
other words, since there are no mechanical connections between the steering wheel
and the tires and only the spring compressing force is required, constant steering
force is kept even at increased rotational speed. The discharge of oil supplied from
the rotor of the steering unit to the cylinder is 160ml/r.
(3) Neutral feedback of steering unit
The neutral feedback of the steering unit is performed by changing-over in oil
passage of the valve, due to the reaction force of centering spring. (When the steering
wheel is turned and then released with the engine at rest, the steering wheel returns
to the initial position.) Unless the neutral feedback is completely performed, the
steering wheel may be turned, even though the operator does not turn the steering
wheel.
(4) Steering with defective pump
When the pump fails to supply hydraulic oil the steering unit serves as an
emergency hand steering device. When the steering wheel is turned, the spool rotates.
When turned by about 8, the spool contacts the cross pin, which rotates the drive shaft,
which in turn rotates the rotor. Thus, the metering device serves as a hand pump to
supply oil to the cylinder. In this case the check valve provided between the return port
and the suction port opens, so that oil flows from the cylinder to the suction, thereby
effecting an emergency steering.
5.5 Hand wheel
Hand wheel is operated in normal way, that is to say,
when turning the hand wheel right, the truck will turn right.
When turning the hand wheel left, the truck will turn left. The
rear wheels of the forklift truck are steering wheels, which
make the tail section of the truck swing out when turning. The
turning method can be mastered easily through practice.
59

5.6 Steering cylinder (Fig.5.7)
The steering cylinder is installed in the rear axle and is operated by oil from the
steering unit. The cylinder body is secured to the axle, with both rod ends connected
to the knuckle with joints.
Fig.5.7 Steering cylinder
1. Wiper seal 2. Snap ring 3. Lock washer 4. Packing
5. Cylinder cap 6. Cylinder 7. Packing 8. Piston rod
9. ”O”-ring 10. Bushing 11. Back-up ring
60

5.7 Troubleshooting
Problem Possible cause Remedy
Steering wheel
won’t operate
Hard steering
wheel
Truck wanders
Or vibrates
Noisy operation
Oil leaks
Defective or damaged pump Replace
Relief valve stuck or damaged Clean or replace
Control valve stuck, damaged, or warn Replace or repair
Damaged hoes joint or clogged oil line Replace or clean
Low oil level in oil tank Add oil
Insufficient air bleeding Air bleeding
Low oil pressure See previous item
Control valve stuck or damaged Clean or replace
Loose control valve spool Retighten lock nut
Damaged control valve Replace
Broken or deteriorated spring Replace
Low oil level in oil tank Add oil
Clogged suction pipe of filter Clean or replace
Control valve stuck or damaged Replace
Improperly installed or damaged “o”-ring or
oil seal for piping or control valve.
61
Replace

6. Hydraulic system
Main pump
Model:
Type:
Drive:
Discharged:
Loaded pressure:
Flow dividing valve:
Model:
Discharged:
Pressure:
Control valve:
Model:
Type:
Pressure setting:
Lift cylinder:
Type:
Cylinder bore:
Rod diameter:
Stroke:
Tilt cylinder:
Type:
Cylinder bore:
Rod diameter:
Stroke:
62
CBQL-F532/F532-AFHL
Gear type
Crank shaft PTO
32×2ml/r
20MPa
1WFL-F15L-6
6L/min
19MPa
CBDF-F20U
Spool sliding type with
Relief valve, tilt lock valve, and flow divider
19MPa
Signal acting piston with flow regulator
70mm
50mm
1495mm
Double acting type
90mm
45mm
202mm
The machine adopts double pumps hydraulic system (Fig.6.1). The pressure oil
within the main pump is driven by the P.T.O. fixed on the pump wheel the torque
converter, to flow through the flow dividing valve into the brake system to brake, the
other way into the control valve, through the flow dividing valve within the control valve
can be supplied to the steering unit, then is transmitted through pipe into the steering
cylinder according to steering condition. The control valve controls the lift and tilt
cylinders.

6.1 Hydraulic pump
The model of the hydraulic pump is CBQL-F532/F532-AFHL type high-pressure
gear pump. Its displacement is (3×22) ml/r. The pump is double gear pump type,
consists of the driving gear, driven gear and pump body.
Flow,control valve Q1 L/min 160
Flow,steering unit Q2 L/min 18
Primary pressure, hydraulic system P1 Mpa 19
Steering pressure P2 Mpa 12.3
Fig.6.1 Hydraulic system principle diagram
63

6.2 Flow dividing valve (Fig.6.2)
The model of the flow-dividing valve is 1WFL-F15L-6. Its function is supplied
hydraulic oil to the loading system (except lift and tilt cylinder), in addition, supplying
part oil to the brake system to the brake system to complete power brake.
6.3 Control valve
Fig.6.2 Flow Dividing Valve
The model of the control vale is CBDF-F20U, unit combination. Add control
valves if needs. The valve’s function is carrying respectively high pressure oil came
from oil pump to each hydraulic cylinder, making back oil returning to the tank, and
changing the flow direction by operating control lever. (Fig.6.3)
The control valve consists of an inlet section, two plunger sections and an outlet
section which are assembled with three bolts. The control valve is slice type. On the
inlet section has a main relief valve under it has a steering valve, which regulates the
main and steering circuit oil pressure, respectively. Twist them clockwise, raise oil
pressure, on the contrary, reduce oil pressure.
The two plunger sections are used to lift and tilt circuits separately. The oil flow is
changed by operating lift and tilt valve stems to control the cylinders.
The tilt plunger has a tilt lock valve. The oil from the cylinder returns through the
oil lock valve to the tank. Every slice of the sealed by the O-ring. There is a load check
valve on the high-pressure passage.
64

Caution:
Don’t adjust the pressure of the main relief valve at will. If the pressure is too high,
the hydraulic system and hydraulic component may be damaged. When maintaining
or using, if oil pressure isn’t the same as the standard value, on the basis of
JB/TT3300 test way, the professional serviceman should adjust the pressure
according to the following procedures:
(a) Screw the plug screw off the inlet port of the control valve and install a 25MPa
oil pressure gauge.
the end.
(b) Operate the tilt lever, measure the pressure when the oil pressure stroke to
(c) When the oil pressure isn’t the same as the standard value, twist the adjusting
nut, twist it clockwise, raise oil pressure, on the contrary, reduce oil pressure.
(d) After adjusting, tighten the nut.
Fig.6.3 Control Valve
65

(1) Plunger operation
(a) In neutral state(Fig.6.4)
The oil discharged from the pump flow
through the neutral passage back to the oil
tank. The ports “A” and “B” are closed.
(b) When plunger is pushed in
(Fig.6.5), the neutral passage is closed by
the plunger and the oil flows through the
parallel feeder, pushing up the load check
valve into the cylinder port “B”. The
returning oil from the cylinder port “A”
flows through the low pressure to the tank.
66
Fig.6.4
The plunger is restored to neutral position Fig.6.5
by the return spring.
(c) When plunger is drawn out
(Fig.6.6), with the neutral passage closed,
the oil pushes up the load check valve,
passing through the parallel feeder, and
flow into the cylinder port “A”. The
returning oil from the cylinder port “B”
flows through the low-pressure passage to
the tank. The plunger is restored to neutral
position by the return spring. Fig.6.6

(2)Port relief valve operation
(a) The relief valve is located
between the high-pressure passage
“HP” and the low-pressure passage “LP”.
The oil flows the hole in the piston “C”
and affects two different areas A and B,
thus seating the poppet “D” securely.
(Fig.6.7)
(b) When the pressure in the
high-pressure passage “HP” reaches the
set pressure of the pilot spring, the pilot
poppet “E” opens, allowing the oil to flow
around the pilot poppet past the drilled
hole, to the low-pressure passage “LP”.
(Fig.6.8)
(c) As the pilot poppet “E” opens, the
pressure behind the poppet “D” drops. The
inside pressure becomes imbalanced
against the pressure at the high-pressure
passage side “HP”, so that the poppet “D”
is open due to this pressure differential,
thus allowing the oil to flow directly to the
low-pressure passage “LP”. (Fig.6.9)
Fig.6.9
67
Fig.6.7
Fig.6.8

(d) When the pressure in the
high-pressure passage “HP” is lower than
the pressure in the low-pressure passage
“LP” the poppet “D” opens due to the
difference in diameter between the areas A
and B, thus slowing the oil to flow from the
low-pressure oil passage “LP”
to the high-pressure oil passage oil passage Fig.6.10
“HP”. (Fig.6.10)
(3) Tilt lock valve operation
The control valve in the tilt cylinder circuit
has a spool incorporating a tilt lock valve to
prevent the mast from vibrating due to
possible creation of negative pressure in the
tilt cylinder and also to avoid danger incurred
from mishandling of the tilt lever. (Fig.6.11)
(a) When the plunger is drawn out, the oil
flows in the same matter as in Fig.6.5.
(b) When plunger is pushed in, the oil
from the main pump flows through the port “B”
into the tilt cylinders. The returning oil from the
cylinders flows through the oil hole “A” to
actuate the poppet. This allows the oil to pass
through the plunger holes “A” and
68
Fig.6.11
“B” to the low-pressure passage and back to Fig.6.12
the tank. (Fig.6.12)

(c) When plunger is pushed in with
engine at rest, When the plunger is
pushed in with the engine shut off, the oil
does not flow to the cylinder port “B” and
the pressure at the area “P” does not
rise as well, because the pump is at rest.
Since the poppet does not move the oil
at the cylinder port “A” won’t return to
the tank, and thus the cylinders stand Fig.6.13
still. (Fig 6.13).
6.4 Lift cylinder
The lift cylinders are the single-acting type and are located behind the outer mast
frame. The bottom of each cylinder is supported by the mast support of outer mast
frame with knock pin and bolts. The piston head is held by the inner mast piston head
guide.
The lift cylinder assembly consists primarily of a cylinder body, piston, piston rod,
cylinder cap, and piston head. A cut-off valve is installed on the right-hand side of the
cylinder body. At the low part of the cylinder body is provided a high-pressure oil inlet.
The upper part is provided with a low-pressure oil outlet to which a return pipe is
connected. (Fig.6.14)
Fig.6.14 Lift cylinder
1.Piston rod 2.Dust seal 3.Cylinder cap 4.Seal ring 5.O-ring
6.Bearing 7.Bushing 8.Cylinder body 9.Shim 10. Snap ring
11.Bushing 12.Seal ring 13.Seal ring 14.Piston 15. Spring
16.Valve 17.Pin 18.Snap ring
69

The piston is fastened to the piston rod with a lock ring and has a wear ring and a
packing on its circumference arid slides along the inside of cylinder by high-pressure
oil. It slides in the cylinder by high-pressure oil.
The cylinder cap is fitted with a bushing and an oil seal and is screwed into the
cylinder body. The bushing supports the piston, rod, and the oil seal prevents dirt from
entering the cylinder. The right and left piston rods are connected with a connecting
member at their top areas and fixed with bolts. Chain sheaves are installed at both
sides of the connecting member with snap rings.
When the lift lever is pulled toward the operator, the high-pressure oil flows into
the lower part of each lift cylinder so that both the piston rod and piston is raised. This
lifts the forks through the lift chains. On the other hand, when the lift lever is pushed
forward, the piston descends by the weight of the piston rod, piston head, lift bracket,
finger bar and forks, causing the oil under the piston to flow out of the cylinder. The oil
discharged from the cylinders is regulated by the flow regulator and returns the control
valve to the oil tank. The upper part of the cylinder is filled with the air from the oil tank.
Since the flow rate of the returning oil from the lift cylinders is usually regulated by
the flow regulator, the pressure differential generated by the oil passing through the oil
hole in the piston’s circumference is smaller than the spring force, and thus the piston
won’t move. If the hose ruptures and the returning oil increases, the piston moves to
the left, blocking the oil hole in the piston’s circumference. Therefore, the forks drops
at a low speed as the oil in the lift cylinders flows out of the piston head hole in a small
amount.
6.5 Flow regulator valve
The flow regulator valve controls the fork descending speed and serves as a
safety device if the rubber hose ruptures between the control valve and the lift
cylinders, it is installed in the high-pressure oil part at the lower part of the lift
cylinders.
The flow regulator valve operation is shown in Fig.6.15. When the forks are
descended, the returning oil from the lift cylinders flows into the chamber(G). The oil
then flows through the pats (F), (E), (D) and (C) to the chamber (B). The oil which left
the chamber (B) flows, passing through the oil hole in the piston (7) and the chamber
70

(A) into the lift cylinders.
The piston (7) moves to the right depending upon the flow rate of the oil which
passes the oil hole in the piston (7), and thus the hole (C) narrowed, restricting the
flow rate of oil passing the hole (C). This way, the fork lowering speed is controlled.
When the forks are raised, the high-pressure oil from the control valve enters
through the chamber (A) into the chamber (B). The oil then flows through the areas
(C), (D), (E), (F), (G), and into the lift cylinders.
Fig.6.15 Flow regulator valve
1.Nipple 2.Spring 3.”O”-ring 4.Snap ring 5.Orifice
6.Sleeve 7.Piston 8.Ball 9.Spring 10.Case
6.6 Tilt cylinder (Fig.6.16)
The tilt cylinder is a double-acting type, and its piston rod end is supported by the
mast and the cylinder tail is connected to the frame with a pin. This truck is provided
with two tilt cylinders on both sides of its front.
The tilt cylinder assembly consists primarily of a cylinder body, cylinder cap,
piston and piston rod. The piston is welded to the piston rod and has two packings
and one wear ring on the circumference and moves along the inner surface of the
cylinder by the force of hydraulic oil.
71

Inside the cylinder cap a bushing are pressed fitted together with a packing and
dust seal to provide oil tightness for the piston rod and the cylinder cap. This bushing
also supports the piston rod. The cap is fitted with an “O”-ring on the outer periphery
and is screwed into the cylinder body and fastened with a lock ring.
When the tilt lever in the driver’s room is tilted forward, the high-pressure oil
enters the cylinder tail moving the piston forward. This causes the mast to tilt forward
6 degrees. When the tilt lever is tilled backward, high-pressure oil enters the cylinder
cap side and moves the piston backward, tilting the mast 12 degrees backward.
Fig.6.16 Tilt cylinder
1.Grease nipple 2.Rod end 3.Snap ring 4.Bearing 5.Cover
6.Piston assembly 7.Dust ring 8. Snap ring 9.Cylinder cap 10.O-ring
11.Bushing 12.Seal ring 13.Bushing 14.Cylinder body 15.Bushing
16.Seal ring 17.Snap ring 18.Snap ring
72

6.7 Troubleshooting
Problem Cause Remedy
The pump does
not operate.
The pressure
of the high
pressure oil
is not enough.
Noisy operation
of the gear
pump.
The oil within the
hydraulic
pump leaks.
Lifting is
weak or can
not lift.
The lower
slippage of the
forks is too large
and the mast tilts
automatically.
1. The oil within the cylinder is not
enough.
2. The pipe or the filter is struck.
1. The bearing in the pump is worn.
2. The pressure of the relief is not right.
3. There is air within the pump.
1. The side joints have loosened make
air in.
2. Form the free chamber
Because the oil viscosity is too high.
3. Not concentric.
4. There are air bubbles within the
hydraulic oil.
1. The oil seal of the pump is damaged.
2. The sliding are
a is worn.(internal)
1. Hydraulic pump gear is damaged or
oil leaks.
2. The oil seal of lift cylinder is damaged.
3. The relief valve of control valve is out
of order.
4. Hydraulic oil temperature
is too high oil has gone thin, oil flow is
reduced.
1. The control valve has oil leakage.
2. The oil leak of the lift cylinder is
damaged.
3. The return spring of control valve is
damaged. The sleeve is not in right
position.
73
1. Add oil to the
specified level
2. Clean, change oil if
necessary.
1. Replace.
2. Readjust.
3. (1) Retighten the joint.
(2)Add oil in the cylinder.
(3)Check the oil seal.
(4)Drive the pump until
there is not air bubble
within the cylinder.
1. Retighten every joints.
2. (1) Replace the right
viscosity oil.
(2)The pump is driven
when the oil temperature
returns to normal.
3. Readjust and make
them concentric.
4.
1.
Check
Replace.
and repair.
2. Replace.
1. Renew gear or
replace pump.
2. Replace oil seal.
3. Repair.
4.Change oil, check.
1. Repair.
2. Replace oil seal.
3. Replace return spring.

7. Load handling system
It’s only for 2-stage standard mast.
Type
O.D. of end roller
O.D. of side roller
O.D. of retaining roller
Lift chain
Upper roller
Fork lifting system
Mast tilting system
Fork spacing adjustment
Rolling type 2-stage telescopic
mast with free lift
(J-shaped inner rail and C-shaped outer rail)
Φ123°-0.15
Φ67
Φ55×Φ135×Φ155
LH1634, 3×4
80308
Hydraulic
Hydraulic
Manual
Loading system is used forking, loading and unloading, pilling, and so on,
consisting of forks, mast, lift chain, lift cylinder and tilt cylinder. There are masts from
3m to 6m can be chosen. (Fig.7-1)
7.1 Mast
The mast is of the two-stage, CJ type rolling telescopic mast. The outer mast and
the inner mast are frame type welded construction. The Support is welded to the
under of the outer mast, make the mast to connect with the driving axle body, to
support loading system, and return around the axle body. The support, which
connects with the tilt cylinder, is welded in the middle of the outer mast, the loading
system returns around the driving axle center to complete tilting forward or backward
when the piston rod in the tilt cylinder telescopes. The support, which supports the lift
cylinder, is welded to the bottom of the outer mast. Each set of rollers are located at
the top outside and inside of each outer mast, are used to guide while the inner mast
is lifting in the outer mast. A sideward roller is installed at the lower outside of the each
inner mast. The end rollers connect with the mast channel steel flange plates to avoid
the inner mast tilting in lengthwise. The connecting clearance of single side is from 0.5
to 1.0mm. The sideward rollers connect with the outer mast channel steel web plate to
avoid the inner mast tilting in crosswise. The clearance is from 0.5 to 1.0mm. The
clearance is adjusted by adding or reducing shims.
74

7.2 Carriage
An end roller and a sideward roller are installed to the carriage. The way that to
adjust the clearance between bracket and flange plate of the outer or inner mast, or
bracket and web plate of mast is same as that above about inner and outer mast. Fork
and bracket can run up or down in the inner mast. The distance between forks can be
adjusted according to needs; its range is from 300mm to 1200mm.
7.3 Lift chain
The lift chain is of flat type chain. Each of the ends of two chains is connected
with the fork bracket and the other is connected with the top of outer mast after chain
run round the chain wheel.
Fig.7.11 Loading system
1.Lift cylinder 2.Tilt cylinder 3.Outer mast
4.Inner mast 5.Lift chain 6.Fork bracket
7.Fork
75

8. Electric system
8.1 General description
The electric system is composed of a starter circuit, charging circuit and lighting
circuit which are respectively activated by 12-volt batteries connected in series. The
wiring used for each circuit is classified by color and given sufficient current capacities.
The main of the starter circuit is the starter, of the charging circuit is the generator and
adjuster, of the lighting circuit is the different function lights.
In addition, the wiring is further divided into the engine wiring, meter panel wiring
and overhead guard wiring, each connected with couplers.
8.2 Signal and operation
(1) Pre-heat starter switch
a. Turn to left 1 st to pre-heat.
b. Turn to left 1 st to connect the meter and the ignition power supply.
c. Turn to right 2 nd to start the engine.
d. Keep the switch to the original position, to shut down the engine (6BG1).
Notes: a. Put the shift lever in idle gear to start.
b. The model of 6BG1 engine should be pre-heated. R4105G25 engines
should not be pre-heated because they are spray nozzle type engines.
(2) Pre-heat indicator (6BG1): When the indicator shows light red, the pre-heat
has finished while the starter switch is turned to left 1st.
(3) Light switch: Put the shift lever to the 1st position, the clearance lamps are
turned on to the 2 nd , the head lamp is turned on.
(4) Turn switch: Push the switch forward, the left small lamps both in front and at
the back of the truck and the left turn indicator are turned on. At this time the truck can
be turned to left.
Pull the switch backward, the right small lamps both in front and at the back of it
and the right turn indicator are turned on. So it can be turned to right.
(5) Brake indicator: Press the brake pedal and the back brake lamp is turned on
when the emergency braking is needed.
(6) Back-up indicator: Put the shift lever in back-up gear position when the forklift
truck is needed to reverse, the back-up lamp is turned on, and the back-up buzzer
makes voice.
76

(7) Oil pressure warning indicator: Turn the key switch to right 1st, the indicator is
turned on, and it is turned off when the engine is driven. Stop the forklift truck to check
if the indicator is turned on while it is running.
(8) Charging indicator: Turn the key switch to right 1st, the charging indicator is
turned on. It is turned off after the engine is driven, it shows charging. Stop the truck to
check if the indicator is turned on while it is running.
(9) Idle indicator: Put the shift lever in idle position, the indicator is turned on, the
starter can be driven, otherwise it is not driven.
(10) Warning indicator (when fuel is not enough): The indicator is turned on when
the fuel is not enough, should add oil.
(11) De-oiler: The water within the de-oiler is full, and should drain the water away
when the indicator is turned on.
(12) Fuel meter: The fuel meter consists of the fuel indicator and the fuel sensor.
It shows oil capacity within the fuel tank.
(13) Water temperature meter: It shows the temperature of cooling water. The
indicator pan is classified by three colors to show three ranges of the temperature.
The engine can be operated under normal conditions when the hand is between
green ranges.
(14) Oil temperature meter for torque converter: (selected)
Show the oil temperature of the torque converter. The principle is the same as the
water temperature meter.
(15) Hour meter: It works when the engine is driven and shows the working time
of the engine.
(16) Instrument: (Fig.8.1)
To sum up, general description of operating the forklift truck is shown as follows:
Put the shift lever in idle gear position, press the accelerator pedal, turn the key
switch to left 1st to preheat. When the preheat is finished, put the key switch to right
1st, at this time the oil pressure warning indicator and he charge indicator are turned
on. When the key switch is turned to right 2nd, the starter is driven to rotate the engine.
The oil pressure warning indicator and the charge indicator are turned off when the
engine is driven, and the forklift truck can be used.
77

Notes: Re-driven the engine after two minutes if it is not driven within five
seconds. Not operate the starter continuously more than 15 seconds.
Fig.8.1 LED Combined Instrument
1 Fuel meter 4 Oil pressure indicator 7 Filter indicator
2 Water temperature meter 5 Charge indicator 8 Water separator signal
3 Hour meter 6 Neutral indicator
8.3 Precautions when using the battery
(1) Avoid the short circuit, spark and smoking for the battery may cause
combustible gas which has danger of explosion.
(2) The electrolyte is dilute sulfuric acid which is dangerous when touching the
skin or eyes. If it is on the skin, wash it with water immediately. If in the eyes, please
go to hospital at once after cleaning the eyes with water.
(3) Dealing with the waste and worn batteries according to relevant laws and
regulations.
8.4 Diagrams
Fig.8.3.
See the principle diagram of electric system in Fig.8.2. diagram of harness in
78

8.2-1 Principle diagram of electric system (Weichai 4105G25 engine)
79

8.2-2 Principle diagram of electric system (ISUZU 6BG1 engine)
80

8.2-3 Principle diagram of electric system (Chaochai 6102BG-6A engine)
81

8.3-1 Diagram of main harness (domestic)
82

8.3-2 Diagram of meter harness (domestic)
83

8.3-3 Diagram of main harness (imported)
84

8.3-4 Diagram of meter harness (imported)
85

9. Import diesel engine (Isuzu)
9.1 Specifications
Model A-6 BG1QC-05 Isuzu motors
Type
86
4-cycle, water-cooled, overhead valve,
in line. direct injection type
No. of cylinder-bore×stroke: 6-105×125mm
Total displacement: 6494cc
Compression ratio: 17.5:1
Performance:
Rated Speed:
Rated output:
Maximum torque:
Full-load Maximum-Fuel Consumption:
(at rated speed)
No-load Maximum speed:
No-load Maximum Speed(at rated output):
2000rpm
68kw
340N.m/1400~1600rpm
185g/psh
Weight: 430kg
Dimensions:
o. a. length×o. a. width×o. a. height
2200±25rpm
700rpm+25rpm
1056×629×819mm
Order of ignition: 1-5-3-6-2-4
Rotational direction: Clockwise when viewed from fan side
Valve mechanism: Overhead valve type
Fuel system:
Injection Pump:
Plunger:
Injection Nozzle:
Fuel Injection Pump:
Fuel Filter:
Governor:
Governor:
Lubrication:
Lubrication system:
Lubrication oil pump:
Drive:
Oil pressure Regulator:
Oil pressure Indicator:
Plunger type
9.5×8mm
Perforated type
Plunger type
Paper filter
RSV centrifugal type all-speed control
Forced lubrication
Gear type
Cam shaft drive
Piston spring type
At oil check port

Lube oil filter:
Lube oil cooler:
Cooling system
Cooling method:
Cooling fan:
Drive:
Water pump:
Type:
Drive:
Water temperature regulator
Type:
Starting motor
Voltage:
Output:
87
Full-flow type
Water cooling, built-in type
Water cooling
Pusher type six-blade, O. D. of 430mm
Belt drive
Vortex type
Belt drive
Wax pellet
24V
4.5kw
Stopping device: Fuel shut-off, solenoid type
Charging generator:
Type:
Voltage:
Output:
Drive:
Automatic charging regulator:
Intake valve
Exhaust valve
AC generated diode rectification
24V
25A
Belt-drive
Transistor type(incorporated in charging
generator)
Valve clearance Open Closed
0.40mm
0.40mm
BTDC 18°
BBDC 48°
ABDC 46°
ATDC 16°
Injection timing: BTDC 16°
Injection start pressure: 185kg/cm
Water temperature regulator opening start temperature: 82°
Temperature at which stroke reaches 8 mm or more: 95°

Fig.9.1 Performance curve
88

9.2 General description
The engine delivers power to the traveling and load handling systems. It drives
both the water pump and the generator through the belt. It also drives the fan fitted to
the frame through the propeller shaft by means of a belt.
The engine is started and shut off with the key switch alone.
(1) Engine stopper
When the key switch is turned off the auto-stopper plunger pulls the fuel cut-off
lever of the injection pump to cut of the fuel, thus shutting off the engine.
When the key switch is turned on, the auto-stopper plunger pulls the fuel cut-off
lever to supply the fuel, thus starting the engine.
(2) Starter switch
Fig.9-2 shows the design of the starter switch. It has three positions: ON, START,
and PREHEAT. When the key is released at PREHEAT or START, it automatically
returns to the OFF or ON position. The key can be put in and off at the OFF position.
Fig.9.2 Starter switch
89

(3) Fuel system
The engine fuel system consists primarily of the charging pump, injection pump,
fuel filter and injection nozzle.
When the injection pump is driven by the engine, the fuel pump sends fuel from
the fuel tank to the fuel filter under pressure. The fuel is filtered through the filter and
led to the injection pump and send under pressure to the nozzle. The excess fuel not
injected into the cylinder returns through the filter overflow valve to the tank.
Fig.9.3 Fuel tank
90

(4) Lubrication system
The engine lubrication is performed with the gear pump which is driven by the
cam shaft. The oil is sent under pressure by the gear pump through the oil filter and
flows to the positions, shown in Fig.9.4 and returns to the oil pan.
The filter is a full-flow type which opens the by-pass valve if the element becomes
clogged so that the switch is turned on to let the oil flow directly to each part bypassing
the element.
Fig.9.4 Lubrication system
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(5) Cooling system
The engine is cooled by means of the water pump and the radiator. The cooling
medium is a 40% LLC (long life coolant)
The LLC cooled by the radiator is picked up from under the radiator into the water
pump, which in turn sends the LLC into the cylinder block for cooling.
The LLC which cooled each part enters the thermostat housing. It flows to the
radiator when the thermostat is opened and is directed to the cylinder block by the
water pump when it is closed.
Fig.9.5 Cooling system
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(6) Accelerator pedal
The accelerator pedal is installed as shown in Fig.9.6. The pedal movement is
sent through the wire cable to the injection pump control lever.
When the accelerator pedal is pressed, the lever next to the pedal pulls the wire
to move shift the control lever to the FULL side.
When the accelerator pedal is released, the pedal is returned to the original
position by spring force while the control lever returns to the IDL position.
Fig.9.6 Accelerator pedal
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9.3 Maintenance
(1) Cylinder head bolts
Tighten the cylinder head bolts in the
sequence indicated in Fig.9.7. Loosen them
in the reverse order of tightening.
Tightening torque:
95 N. m [New]
115 N. m [reuse]
Note: The cylinder head bolts should
not be reused more than twice. Fig.9.7
(2) Valve clearance adjustment
(a)Turn the crank shaft counter
clockwise to align the 0° marking with the
pointer. Make sure there is a clearance
between the rocket arm and the stem of the
exhaust valve and the intake valve of the
first or the sixth cylinder. (Fig.9.8)
(b) Put a thickness gauge between the
rocker arm and the valve stem and adjust with
the adjust screw. When the first cylinder is in
TDC on the compression stroke, make
adjustment on the cylinders marked “○”; when
the sixth cylinder in TDC on the compression
strokes, make adjustment on the cylinders
marked “●”. (Fig.9.9)
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Fig.9.8
Valve clearance: 0.4mm [cold] Fig.9.9

Cylinder No. 1 2 3 4 5 6
Valve arrangement I E I E I E I E I E I E
No.1 cylinder in TDC ○ ○ ○ ○ ○ ○
No.6 cylinder in TDC ● ● ● ● ● ●
(3) Compression pressure (Fig.9.10)
(a) Remove the glow plug and injection piping from each cylinder. At this time,
lock the injection pump control lever at the fuel cut-off position.
charged.
(b) Make sure the battery is fully
(c) Connect a pressure gauge to the
glow plug fitting part.
(d) Engage the starter 3 to 4 seconds
and measure the pressure.
(e) Repeat steps(c) and (d) more than
twice on all the cylinders and average the
measured values.
Compression pressure: 2.6-3.1 MPa/200rpm Fig.9.10
(4) Injection nozzle adjustment (Fig.9.11, 9.12)
(a) Install the injection nozzle on the nozzle tester.
(b) Operate the tester handle and measure the injection start pressure.
Injection start pressure: 18.5MPa
(c) If the measured value is out of he specified value, adjust with the adjust screw.
Fig.9.11 Fig.9.12
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(5) Air bleeding (Fig.9.13)
If air is mixed in the fuel system, perform air bleeding with the printing pump.
(a) Loosen the air bleeding with a screwdriver.
(b) Pushing in the pump handle, turn it counter-clock wise to unlock.
(c) Move the pump up and down to send fuel under pressure.
(d) After air bleeding, turn the handle clockwise pushing it in.
(e)Tighten the air bleeding with the screwdriver.
(6) Belt tension adjustment (Fig.9.14)
Fig.9.13
(a) Loosen the generator fitting bolt and move the generator away from the
engine to adjust the belt tension.
Belt tension: 10-15mm (When pressure is 10kg)
(b) After adjustment, tighten the generator fitting bolt.
Fig.9.14
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