Maintenance Manual 1T-4T (LPG) - EN 英语

Operation &
Maintenance Manual
Internal Combustion Counterbalanced Forklift Trucks

Preface
This Manual describes the main parts of 1-4T (LPG) forklift trucks and related maintenance
essentials. You’d better carefully read this Manual before maintenance.
The content herein is subject to change without notice in accordance with the improvement
of parts and equipment.
March 2009
Shanghai Shangli Forklift Co., Ltd.
Table of Contents
System Description and Operating Principle ............................................................................................. 1
Installation of LPG System ......................................................................................................................... 5
Service and Maintenance of LPG Forklift Truck......................................................................................... 7
Troubleshooting of LPG System .............................................................................................................. 14
I. Driving, Operation and Routine Maintenance................................................................................... 23
1. Transportation ............................................................................................................................ 23
2. Storage ....................................................................................................................................... 23
3. Preparations before use ............................................................................................................ 23
4. Operation ................................................................................................................................... 23
5. Precautions for using cooling system ........................................................................................ 25
6. Oil ............................................................................................................................................... 25
7. Lubrication system diagram ....................................................................................................... 27
II. Main Technical Parameters ............................................................................................................... 28
III. Structure, Principle, Adjustment and Maintenance.................................................................... 31
1. Power system ............................................................................................................................ 31
1.1 Engine overview.............................................................................................................. 31
1.2 Precautions for installation and operation of gasoline engine (for 4G64 and GM3.0) ... 32
1.3 Engine check and adjustment ........................................................................................ 34
1.4 Fuel system..................................................................................................................... 37
1.5 Accelerator pedal ............................................................................................................ 39
2. Electrical System ....................................................................................................................... 39
2.1 General ........................................................................................................................... 40
2.2 Operation descriptions .................................................................................................... 46
3 Clutch ......................................................................................................................................... 49
3.1 General ........................................................................................................................... 49
3.2 Maintenance ................................................................................................................... 53
4. Hydraulic driving device ............................................................................................................. 55
4.1 General ........................................................................................................................... 55
4.2 Torque converter ............................................................................................................. 57
4.3 Hydraulic clutch (Fig. 4-3) ............................................................................................... 58
4.4 Control valve, overflow valve and inching valve ............................................................. 59
4.5 Gear-box housing ........................................................................................................... 60
4.6 Oil pump .......................................................................................................................... 61
4.7 Hydraulic oil circuit (hydraulic transmission) Fig. 4-7 ..................................................... 61
4.8 Towing the forklift truck to be repaired ............................................................................ 62
4.9 Oil port connector position and oil pressure and temperature measurement (Fig. 4-8) 63
5. Driving axle ................................................................................................................................ 63
5.1 General ........................................................................................................................... 64
5.2 Hub installation procedures ............................................................................................ 66
6. Steering system ......................................................................................................................... 67
6.1 General ........................................................................................................................... 67
6.2 Cycloidal full hydraulic steering gear .............................................................................. 68
6.3 Check of reassembled steering system ......................................................................... 70
6.4 Troubleshooting of steering system ................................................................................ 70
7. Steering axle .............................................................................................................................. 71
7.1 General ........................................................................................................................... 71
7.2 Steering knuckle and steering king pin ........................................................................... 72
7.3 Hub.................................................................................................................................. 72
7.4 Steering cylinder ............................................................................................................. 72
7.5 Adjustment of pretension load on steering wheel bearing ............................................. 73
8. Braking system .......................................................................................................................... 74
8.1 General ........................................................................................................................... 74
8.2 Maintenance ................................................................................................................... 82
9. Hydraulic system........................................................................................................................ 90
9.1 General ........................................................................................................................... 91
9.2 Main pump ...................................................................................................................... 91
9.3 Multi-way valve and diverter valve.................................................................................. 92
9.4 Oil circuit of hydraulic system (main oil circuit) (Fig. 9-8) ............................................... 96
9.5 Control of multi-way valve............................................................................................... 97
9.6 Lifting cylinder ................................................................................................................. 97
9.7 Speed limit valve ............................................................................................................. 99
9.8 Tilting cylinder (Fig. 9-13) ............................................................................................. 100
9.9 Hydraulic oil tank........................................................................................................... 101
9.10 Maintenance of main oil pump ...................................................................................... 102
9.11 Test run ......................................................................................................................... 106
9.12 Troubleshooting ............................................................................................................ 107
10. Lifting system ....................................................................................................................... 109
10.1 General ..........................................................................................................................112
10.2 Inner and outer masts ....................................................................................................112
10.3 Fork carriage ..................................................................................................................112
10.4 Load backrest ................................................................................................................112
10.5 Contact roller position ....................................................................................................112
10.6 Maintenance ..................................................................................................................115
11. Routine Maintenance and Regular Check .................................................................................119
12.Compulsory Check, Maintenance and Lubrication .................................................................... 123
System Description and Operating Principle
1. On a LPG forklift truck, a conversion device is equipped on the original gasoline engine to enable it
to burn LPG. Generally, there are two retrofit modes:
(1) Double-fuel system: For the retrofitted forklift truck, the original gasoline engine system remains
on the vehicle and two kinds of fuel are available. A cut-off switch is set in the conversion device,
so the operator can select one kind of fuel for use.
(2) Single-fuel system: For the retrofitted forklift truck, the carburetor and gasoline pump of the
original gasoline engine system have been removed and a LPG mixer is installed, so only LPG
can be used.
2. The two fuel systems above have basically identical conversion devices but slightly different retrofit
processes:
(1) For the double-fuel system, the gasoline is still used as fuel, so the parameters (such as idle
speed and ignition timing) of the original gasoline engine shall not be changed. However, the
basic characteristics of LPG are different from those of gasoline (e.g. air-fuel ratio, combustion
rate, thermal energy, etc.), so the LPG cannot produce the most possible efficiency. As a result,
the output power at the maximum speed of such internal combustion engine is slightly less than
that of original gasoline engine (approx. 90-95%). Nevertheless, if adjusted well, no difference
can be sensed.
(2) For the single-fuel system, as gasoline is not used any more, the ignition timing can be
advanced slightly by an angle of several degrees to bring the LPG into full play.
3. Principles and descriptions of main parts on LPG conversion device
(1) Cylinder (storage tank):
The cylinder is welded by steel plates. Its design, manufacture and test comply with
DOT-4BA240. The test pressure is up to 33.8 kg/cm2 (480 psig). The filling volume is 15 kg
(80% of its capacity).
The standard parts include:
(a) Filling valve: It is provided with an internal double check valve (ACME 1.75″ male thread; a
special gas filling gun is needed).
(b) Overflow valve: It is provided with an internal excess flow valve. When lots of LPG leaks
out due to damage of external pipe, this valve will quickly close automatically to stop LPG
leakage. In addition, a manual switch and a quick connector are provided on this valve.
(c) Filler opening (80%): Screw off the filler plug manually to fill LPG. When LPG occupies
80% of the cylinder capacity and there is white vaporific LPG out from this opening, screw
down the filler plug and stop filling. (To prevent excessive heat expansion of LPG in the
cylinder, the maximum filling volume shall not exceed 80% of the cylinder capacity for
safety purpose.)
(d) Safety relief valve: Its set pressure is 26.4 kg/cm2 (375 psig).
(e) Float level gauge: It indicates the LPG quantity in the cylinder.
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Filler opening (80%)
Safety relief valve
Float level gauge Gas tank

Liquid tank
Overflow valve
LPG Cylinder Structure
(2) Pipeline relief valve: There is residual liquid in the LPG pipeline. To prevent pipeline burst due
to heat expansion of LPG and ensure safety, this valve is necessary. It will open automatically
to release pressure when the internal pressure reaches 26.4 kg/cm2 (375 psig).
(3) Filter/vacuum cut-off valve (VFF30)
Functions: The filter screen filters the impurities in LPG and protects the downstream gasifier
against blockage;
When the internal combustion engine is stopped, the vacuum signal from the carburetor
disappears and the internal valve closes immediately to cut off the LPG supply to the gasoline
engine.
The filter chamber is set at the upper part of the device, in which a filter screen is provided to
prevent foreign objects from entering the fuel system. Excessive foreign objects on the filter
screen will affect the gas emission, so it shall be inspected regularly. If necessary, clean or
replace it. When the engine is stopped, the vacuum cut-off valve is closed under the pressure
from the spring above it and the liquid LPG cannot pass it through. When the engine is started,
the vacuum signal is sent to the diaphragm chamber set at the lower part of the device through
the hose and the diaphragm is lifted to push the top lever to open the valve, and the liquid LPG
can pass through the valve at this time. Only when the vacuum signal reaches 50 mmH2O, can
the valve be opened. When the engine is stopped, the vacuum signal disappears and the valve
closes automatically to cut off LPG supply. Therefore, it is a safety device.
(4) Gasifier/pressure regulator (model J converter)
Functions: In this device, the liquid LPG is heated and converted into gas LPG, so it is also
called converter; the LPG pressure satisfies the requirement of the gasoline engine after two
pressure reduction stages. However, the valve in this device is under normally closed state and
only opens when the vacuum suction (negative pressure) produced by engine running reaches
38 mmH2O. The LPG absorbs lots of ambient heat during gasification, so the hot water pipe of
the engine shall be connected into the housing for heating to prevent internal malfunction due
to icing.
See the profile of gasifier/pressure regulator for the structure. The structure of this device
includes two parts: primary chamber and secondary chamber. In the primary chamber, the
pressure drops to 10 kPa; in the secondary chamber, the pressure drops to -38 mmH2O
(vacuum).
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Function of the first pressure reduction stage: When there is no LPG under the primary
chamber diaphragm ①, the diaphragm is pressed down by the pressure from the spring ②
above it, which makes the primary chamber valve ③ under normally closed state through the
transverse lever. When the liquid LPG is introduced into this device and passes through the
valve ③, it quickly expands and gasifies to fill the primary chamber. At this time, the gas LPG
pressure overcomes the pressure from the spring ② to push the diaphragm ① up to close the
valve ③. The two operations above repeat continuously and alternately to keep the gas LPG
pressure in the primary chamber about 10 kPa. The liquid LPG absorbs lots of ambient heat
during gasification and icing may occur in the device. To keep stable LPG supply, it is
necessary to introduce the circulating hot water of the engine into the hot water chamber for
indirect heating so as to prevent icing.
Secondary chamber Gas LPG outlet to

Transverse lever Spring mixer
diaphragm
Secondary
Manual valve chamber
Breather hole
Secondary
chamber valve
Primary Hot water

Liquid LPG inlet chamber
Primary Primary chamber
chamber chamber Spring
valve diaphragm
Profile of Gasifier/Pressure Regulator (Model J Converter)
Function of the second pressure reduction stage: When the secondary chamber diaphragm ④
and the spring ⑤ are under balanced state, the secondary chamber valve ⑥ is under normally
closed state. When the engine is started, the vacuum suction is transmitted to the area below
the diaphragm ④ through the LPG mixer, which makes the diaphragm move down and open
the valve ⑥ through the transverse lever ⑦. At this time, the gas LPG below the valve ⑥
quickly flows into the secondary chamber. Then, the gas LPG pressure pushes the diaphragm
④ up to close the valve ⑥ again. The two operations above repeat continuously and alternately
to keep the pressure in the secondary chamber at -38 mmH2O (vacuum). The opening time of
the valve ⑥ is in direct proportion to the vacuum suction of the engine. Therefore, according to
the engine demand, accurate quantity of LPG can be introduced into the LPG mixer and then
mixed with the air to reach the optimal air-fuel ratio. The manual valve is used to press the
diaphragm ④ down to open the valve ⑥ to introduce gas LPG into the secondary chamber
when necessary.
(5) Temperature controller
It is used to keep the hot water temperature within such a specific range that the LPG will not be
pyrolyzed in hot days but can still gasify in cold days.
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(6) Mixer (CA55)
The air and LPG are mixed in this device to form combustible gas. After retrofitting, the idle
mixture ratio and the power mixture ratio shall be adjusted.
Structure, function and principle: Normally, the LPG metering valve is closed and no LPG flows
into this device. When the engine is started, the airflow compresses the spring through the
central floating venturi. Then, the venturi moves down to open the LPG metering valve, so the
LPG can flow into this device and mix with the air. The larger the engine suction is, the larger
the LPG metering valve opening will be and the more the inflowing LPG will be. The LPG flow
can be adjusted by the power adjusting knob. Turn this knot to R (rich) to increase the flow; turn
it to L (lean) to reduce the flow. The idle adjusting knob is used to control the air inflow to the
lower area of the mixer. Thus, screw in this knob and the air-fuel ratio reduces; otherwise, the
ratio increases.
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Installation of LPG System
1. Safety
(1) Work site:
• Good ventilation, and fan when necessary to blow away possible leaking LPG;
• No smoke/fire, heat source or any other device possibly generating spark such as grinding
machine and abrasive machine around the work site;
• No depression nearby such as ditch where LPG may accumulate;
• Necessary fire fighting apparatus such as fire extinguisher and water source;
• Emergency evacuation plan;
(2) Working personnel
• The working personnel shall wear necessary protective clothes, glasses, gloves, etc. and
take off the ring.
• Only the trained and qualified personnel can carry out retrofitting.
• Work in pairs for mutual assistance.
• When the LPG is filled into the system, pay special attention to leakage.
(3) Treatment of accidents
• If some one inhales too much LPG, he/she will get dizzy, have a headache or feel faint due
to hypoxia. In this case, it is best to move the patient to a well ventilated place, and then
take him/her to hospital if necessary.
• Liquid LPG may cause frostbite by skin contact. If accidental skin exposure occurs,
immerse the skin immediately into cold water and go to hospital if necessary.
• If you smell the odor of LPG, immediately stop the vehicle, shut down the engine and close
the manual valve on the cylinder, and then carefully find out the leaking part and do
troubleshooting.
• If the forklift truck is on fire, immediately close the manual valve on the cylinder if possible,
and then pour cold water onto the cylinder to prevent explosion resulting from heat
expansion. If the cylinder is also on fire, quickly evacuate the persons around and inform
the fire department.
2. Install the LPG system as approved by IMPCO in terms of installation procedure, method and
position. If the installation position shall be changed, inform our company immediately.
3. Other precautions for installation:
(1) Stop the forklift truck stably, lower the forks to the largest extent and wedge the front and rear
wheels with block stops.
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(2) Shut down the engine and disconnect the negative cable of battery.
(3) Install the additional pipes, especially the high-pressure LPG hose, far away from the fan,
vibration sources and heat sources (e.g. exhaust pipe) and tightly fasten them with the string or
line supplied with the retrofit kit.
(4) After retrofitting, be sure to carry out leak test. Especially for the connections installed
additionally on site, test them with suds. A portable leak detector will be preferable.
(5) Below are the special precautions for single-fuel system:
a) Before removing the carburetor, drain the radiator to prevent the coolant from entering the
intake manifold. After retrofitting, fill the radiator with coolant.
b) When removing the carburetor, never affect the speed limiter below it; otherwise, the
gasket under it shall be replaced.
c) The gasoline will not be used any more, so drain the gasoline tank, fill it with liquid that is
noncombustible and not easy to freeze, and seal it with the cover.
d) Remove the original carburetor and gasoline pump and keep them properly as spare parts.
(6) Any part of the LPG cylinder (storage tank) at the installation position shall not be beyond the
range of the counterweight.
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Service and Maintenance of LPG Forklift Truck
1. The LPG conversion device is installed on the original gasoline engine, so only the fuel supply
system is changed but the ignition system, cooling system, and intake & exhaust system of the
original gasoline engine and the basic structure and mechanical performance of the internal
combustion engine are not changed.
2. The recommended regular maintenance cycles special for LPG system are shown in Attached Table
I, including the minimum maintenance cycles and inspection items. The actual maintenance cycles
can be adjusted according to the local conditions:
(1) Local weather conditions: In cold regions or winter, the LPG gasifies slowly, which will affect the
function of the LPG system more or less. In this case, it is suggested to increase the propane
content in the fuel. Moreover, when the vehicle is started, perform warm-up for several minutes
at first to make the coolant become hot and flow into the mixer to accelerate the LPG
gasification.
(2) Local LPG quality and composition: In case of excessive impurities and tar in the LPG, shorten
the maintenance cycles to ensure normal operation of the forklift truck.
(3) Operating conditions of the forklift truck
(4) Driver’s operating habits and so on
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Attached Table I: Regular Maintenance Cycles for LPG System
Service Time After Retrofitting Retrofit 1 M/150
6 M/1000 h 18 M/2500 h 36 M/5000 h
Item Date h
1. Cylinder, check:
 Cylinder appearance
√ √ √ √ √
 Cylinder fittings
 Quick connectors
2. High-pressure system, check and leak
detection:
Between cylinder outlet and gasifier/pressure
regulator √ √ √ √ √
 High-pressure LPG hose
 Pipeline relief valve
 Connectors
3. Low-pressure system, check and leak
detection:
Between gasifier/pressure regulator outlet and
√ √ √ √ √
mixer
 Low-pressure LPG hose
 Connectors
4. Vacuum signal pipe and gasifier hot water
√ √ √ √ √
pipe, check
5. Filter/vacuum cut-off valve:
 Function check (adjustment of idle mixture √ √ √ √ √
ratio and power mixture ratio)
 Disassembly, cleaning and replacement of √ √ √
filter screen
 Rebuilding
6. Gasifier/pressure regulator:
 Function check (pressure check of √ √ √
primary and secondary chambers)
 Disassembly, cleaning and internal √ √ √
inspection
 Rebuilding
7. Mixer:
 Function check √ √ √
 Disassembly, cleaning and internal √ √ √
inspection
 Rebuilding
8. Intake system, air tightness test: √ √ √
9. Ignition system, check: √ √
3. All regular maintenance and service shall be recorded for future reference.
Notes:
(1) The cylinder is generally checked visually. Firstly, check the cylinder body for obvious dents,
8
scratches and rust; secondly, check the valve parts for failures, obvious damage and gas
leakage and check whether the safety relief valve is covered by a blue plastic cap and whether
the outlet is unblocked.
* If the cylinder is damaged seriously, never use it or fill it with oxygen. It shall be replaced
with a new one. The damaged cylinder, especially the cylinder with residual LPG, shall be
repaired by a specialized technician or a qualified manufacturer to ensure safety.
* If any valve part fails, replace the whole valve and contact us to obtain the replacement.
Caution: There is residual high-pressure gas in the cylinder, so try to discharge the gas
safely before removing any part.
* As a cut-off device is set in the quick connector, no leakage shall occur when the two ends
of the connector are separated. If there is any leak, carry out adjustment. If the leak still
exists, replace the leaking end.
(2) The pipes and fittings here are exposed to liquid LPG, so they are under the internal expansion
pressure (about 10 kg when the ambient temperature is 27℃). When performing leak detection,
be careful.
* Check whether the LPG hose is hardened, aged, distorted excessively or cracked, whether
the hose is tightly cling to the vehicle body, whether the connectors at both ends are tight,
and whether there is any heat or vibration source nearby.
* Check whether the pipeline relief valve is installed properly, whether the valve outlet is far
away from the driver, whether the plastic cap remains, and whether the outlet is blocked by
foreign objects.
* Check the threads of all connection fittings for leakage.
* Check for leakage with suds. A portable leak detector will be preferable.
(3) After the LPG gasifies, the pressure drops substantially, so the parts behind the
gasifier/pressure regulator are collectively called low-pressure system.
* Check whether the LPG hose at the gasifier outlet is hardened, aged, distorted or cracked
and whether the connectors at both ends are tight. When necessary, remove them to
check whether there are foreign objects or tar deposits in the hose.
* Check the threads of all connection fittings for damage and leakage.
* Check the connectors between the mixer and intake hoses at both ends for tightness.
(4) Check whether the hoses are hardened, aged, distorted or cracked and check the connectors
at both ends for looseness, gas and water leakage.
(5) Explain the basic functions of the filter/vacuum cut-off valve (refer to the profile):
(a) Filter: Too many foreign objects in the filter will block it and affect the LPG supply. In this
case, you will first find that the internal combustion engine runs unstably and the
horsepower reduces obviously. In case of serious blockage, there will be a pressure
difference in the filter, which will cause the LPG to gasify here. (Note: Normally, the LPG
passing through the filter shall be under liquid state and the LPG only gasifies when
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reaching the downstream gasifier.) In this case, much heat around will be absorbed,
resulting in a cold filter housing or even frost under operating condition with load. This is an
obvious symptom caused by internal blockage. (If the liquid fuel pipe is blocked, the same
consequence will be caused.)
(b) Vacuum cut-off valve: When the internal combustion engine is stopped, the internal valve
is closed. Only when the engine runs, can the valve be opened by the vacuum suction from
the mixer to allow LPG supply. (The vacuum suction for opening the valve is just -50
mmH2O. Generally, the vacuum suction from the mixer is about 100-150 mmH2O, which
can be measured with a multimeter.)
There are three methods for checking the valve function:
Method I: Stop the LPG forklift truck stably and idle the engine. At this time, if the vacuum
signal pipe at the mixer is removed (the vacuum suction disappears), the cut-off valve shall
be closed fully to block LPG supply. When the fuel in the system is exhausted, if the
internal combustion engine is stopped, it means that the vacuum cut-off valve functions
normally; if the engine runs continuously, it means that the valve is not closed fully, which
indicates that valve fails and shall be removed for check and repair.
Method II: Stop the LPG forklift truck stably. Disconnect the low-pressure hose at the mixer
outlet at first and then remove the vacuum signal pipe. Suck air with mouth to simulate a
vacuum suction to open the cut-off valve. Additionally, press the manual valve above the
gasifier by hand. At this time, the sound of fuel flowing out of the gasifier shall be heard and
the odor of LPG flowing out from the low-pressure hose shall be smelt. However, when the
mouth stops air suction, the LPG supply shall be stopped immediately; otherwise, the valve
fails.
Method III: Close the manual valve on the cylinder and then start the internal combustion
engine to exhaust the fuel remaining in the system until the engine is stopped. After that,
try to start the engine several times to verify that the fuel is used up indeed. Open the
cylinder valve to supply fuel. After about 5 min, if the cut-off valve is normal, it shall be
closed fully to block fuel supply with the internal combustion engine not started (without
vacuum signal). At this time, if you press the manual valve above the gasifier, no sound of
oxygen flowing out shall be heard or there shall be fuel flowing out from the low-pressure
hose; otherwise, the valve fails.
(6) Generally, this device shall be replaced completely only when it is damaged severely; otherwise,
just use the repair kit for part replacement or rebuilding. In the repair kit, there are various
wearing parts and consumables for replacement. To use the repair kit, please specify:
* VFF30 repair kit for filter/vacuum cut-off valve
* MODEL J repair kit for gasifier/pressure regulator
* CA55 repair kit for mixer
Note: For both the single-fuel system and double-fuel system, IMPCO Ca55 design is
adopted for their hearts, so the repair kits are interchangeable.
(7) Explain the basic functions of the gasifier/pressure regulator (refer to the profile):
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(a) Normally, when the internal combustion engine is stopped, the primary chamber valve shall
be under normally open state and the secondary chamber valve shall be under normally
closed state; otherwise, they are abnormal.
(b) Normally, the pressure in the primary chamber shall be 1.5-2.5 psi (pound/square inch)
and the pressure in the secondary chamber shall be about -1.5 W.G. (inch H2O vacuum);
otherwise, they are abnormal.
(c) Refer to "Pressure check of gasifier/pressure regulator" for the method and procedure.
During the check, IMPCO “ITK-1” pressure gauge shall be used. This pressure gauge is a
very effective tool for trouble diagnosis of LPG system.
(d) Method for preliminary function check:
* Stop the LPG forklift truck stably and shut down the engine. At this time, there shall be
residual fuel in the LPG system. Carefully remove the low-pressure hose at the outlet
of gasifier/pressure regulator. There will be a little fuel flowing out, but the engine will
flame out automatically soon later. This is because the secondary chamber valve will
be closed automatically when there is no vacuum suction from the internal combustion
engine.
* At this time, if you lightly press the manual valve of the secondary chamber to open
the valve manually, there shall be fuel flowing out. (Note: The primary chamber valve
is open all along) The residual fuel deposited between the gasifier and filter/vacuum
cut-off valve will gradually flow out completely. However, as the internal combustion
engine does not run and the vacuum cut-off valve is closed, the fuel will not flow out
continuously. After a while, the engine will automatically flame out again. This is
normal, indicating the gasifier/pressure regulator and the filter/vacuum cut-off valve
function normally. Otherwise, one of them fails and needs to be removed for repair.
(8) Refer to the illustration in the “Installation Manual of IMPCO J Gasifier/Pressure Regulator” in
the appendix for the procedures of removal, disassembly, replacement and reassembly.
(a) After disassembly, first check whether there is too much tar in it. If yes,
* Inform the user to use high-purity LPG with low content of impurities and tar.
* Or suggest him to shorten the maintenance cycle and clean the inside frequently to
keep normal operation.
* Further check whether the tar enters the downstream outlet hose or mixer. If yes,
clean them as well.
(b) Clean it with warm suds (without any solvent) and then check the inside for damage and
abnormalities.
* Check the diaphragms with bright light for small holes and cracks. In addition, check
whether they are elastic, aged and hardened.
* Check the middle gasket for damage.
* Check the primary chamber valve for impurities, distortion and tightness.
* Check the secondary chamber valve for impurities, distortion and tightness.
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* Check the secondary chamber valve lever for distortion. (Refer to “gasifier/pressure
regulator – pressure test method and procedure” in the appendix for the adjustment
method of lever height.)
* Check the breather for blockage and check whether the copper shield still exists.
(9) In case of difficult starting, unstable idling or insufficient power output, adjust the idle and power
mixture ratios again.
Next, check whether there is enough vacuum suction transmitted to the mixer (100-150
mmH2O “vacuum”) to make the venturi fluctuate.
• If the vacuum suction is normal but the venturi does not fluctuate, it means that the venturi
is seized. You shall remove it and check the inside.
• If the venturi does not fluctuate due to insufficient vacuum suction, it indicates that a leak
exists between the intake manifold and the mixer. You shall carefully check the
connections for tightness.
(10) Refer to the illustration in the “Installation Manual of IMPCO 50 Mixer” in the appendix for the
procedures of removal, disassembly, replacement and reassembly.
(a) Check the mixer for tar deposits. If any, clean them away with suds.
(b) Check the inside for cracks and burns due to backfire of internal combustion engine.
(c) Check the LPG metering valve for wear and foreign objects.
(d) Check whether the venturi can fluctuate freely.
(11) Refer to the attached diagram “Intake System of Internal Combustion Engine” for the possible
leaking parts.
* Start the internal combustion engine and spray carburetor cleaning agent or other similar
products to a possible leaking part. If the engine runs more quickly, it indicates that this part
is leaking and you shall repair it.
Caution: If the vacuum suction generated by the intake system of the internal combustion
engine is insufficient, it will directly affect the normal operation of the LPG system. This
problem will not happen to a new retrofitted vehicle but will be obvious for an old retrofitted
vehicle.
* There is a check hole on the LPG mixer. You can connect it with a vacuum pressure gauge
to measure the vacuum suction at this point from the internal combustion engine. Normally,
the vacuum suction shall be 100-150 mmH2O (vacuum).
(12) Note: LPG is a kind of gas fuel and gasoline is a kind of liquid fuel, so comparatively speaking,
the LPG is “dry” and the LPG-air mixture is “lean”. Consequently, the LPG requires a high
voltage to cross the spark plug gap to generate spark and finally achieve explosion in the
engine cylinder. (Generally, the gasoline only requires a voltage of 15,000-20,000 V, but the
LPG requires a voltage of 28,000-32,000 V.) If the ignition system of the gasoline engine
performs normally, it can output sufficient voltage for LPG without any adjustment. However, the
engines that have been used for a period or the old engines, especially the engines with little
maintenance, always cannot output sufficient voltage for LPG due to bad conditions. (For
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double-fuel system, if the engine can operate normally with gasoline, it indicates that the
voltage can satisfy the requirement of gasoline but not the requirement of LPG.)
Hence, if the starter motor can run but the internal combustion engine cannot be started
successfully, you shall first check whether the spark plug can generate spark and then
gradually check the LPG supply system.
(a) Ignition coil:
* Check for cracks and “electric shock”.
* If possible, measure the output voltage (20,000 V at least) with an oscilloscope or a

spark plug tester.
* In case of low voltage, use an ohmmeter to measure whether the resistances of

high-pressure and low-pressure coils are in accordance with the specification of the
original gasoline engine. If not, replace the coil.
(b) Spark plug:
* Maintain the gap for the original gasoline engine. You do not need to adjust it for LPG.
* Check the spark plug once every 2,500 working hours. Replace it when necessary.
(c) High-tension wire:
* Check it for damage and check the insulating layer for cracks and burns.
* Check both ends for good contact.
* Check whether the resistance is still in accordance with the specification of the original
gasoline engine.
(d) Distribution panel
* Check the cover for damage.
* Check the distribution panel rotor arm for damage.
* Check the inside for cracks, carbon deposits and “electric shock”.
(e) Ignition timing and advance
* Check that they are in accordance with the specification of the original gasoline
engine.
* For double-fuel system, both of them shall not be changed. For single-fuel system, the
ignition timing can be advanced slightly by an angle of several degrees to offset the
low combustion speed of LPG and ensure the complete combustion of LPG in the
cylinder and the maximum efficiency.
13
Troubleshooting of LPG System
1. When sending the LPG forklift truck for repair, the owner or the driver shall describe the symptoms
because they may be caused by their unfamiliarity with the LPG system or improper operation. In
this case, an experienced technician shall give correct demonstration and explanation, and when
necessary, operate the forklift truck personally to identify the causes.
2. When the LPG forklift truck goes wrong, the source is not necessarily the LPG conversion device.
Contrarily, the problem is always caused by the ignition system, intake system or cooling system of
the original gasoline engine. Therefore, before diagnosing the LPG system, it is necessary to
confirm the devices and performances of the original gasoline engine are normal. (If the LPG forklift
truck with double-fuel system goes wrong, you can use gasoline as fuel and operate the forklift truck
to see whether the problem still exists. Then, you can determine whether the problem is caused by
the original gasoline engine.)
3. Preparations before diagnosing the LPG system:
(1) Check whether the LPG quantity in the cylinder is enough.
(2) Check whether the manual switch of the overflow valve on the cylinder is set at the position for
full opening of the valve.
(3) Check whether the LPG pipe and LPG conversion device are cold or frost up.
(4) Check the high-pressure and low-pressure LPG pipes for deformation, twist, looseness and
leakage.
(5) Check the vacuum signal pipe for deformation, twist, looseness and leakage.
(6) Check the coolant pipe connected to gasifier/pressure regulator for deformation, twist,
looseness and leakage.
(7) Check whether the ignition system is normal (remove a spark plug and check the spark).
(8) Check whether the LPG conversion device is modified.
4. Take care! There is residual LPG in the LPG system. If it is unavoidable to remove any part for repair,
follow the method described in “Correct removal procedure of LPG system”.
Three other parts that may malfunction:
Diaphragm (damage): If the diaphragm is damaged, the vacuum chamber at the lower part of the
vacuum cut-off valve is connected with the atmosphere chamber. Check method: Disconnect the
vacuum signal pipe at the mixer and suck air with mouth to simulate a vacuum suction (-50 mmH2O).
When the mouth stops air suction, the vacuum negative pressure shall keep unchanged. If the
vacuum negative pressure drops and disappears, it means that the diaphragm is damaged and
needs to be replaced.
Valve stem and seal ring (leakage): In case of leakage of valve stem or seal ring, the LPG will flow
into the lower vacuum chamber and gasify quickly. Then, the gas LPG will flow reversely into the
mixer through the vacuum signal pipe and then into the internal combustion engine. At this time, you
14
can see two abnormal phenomena: 1. the vacuum cut-off valve is cold (heat absorption for
gasification); 2. the engine runs unstably because the leaking LPG does not flow into the engine
through the normal pipeline and rich fuel mixture is formed. Check method: Disconnect the vacuum
signal pipe at the mixer and use a vacuum pump to simulate a vacuum suction (never use your
mouth). Next, start the internal combustion engine and check whether it runs normally. (The leaking
LPG does not flow into the mixer but is sucked by the vacuum pump.)
Breather hole (blockage): If the breather hole is blocked, the vacuum suction cannot operate the
internal diaphragm and lever normally. (Note: If necessary, manually push up the diaphragm
through this hole to open the valve.)
5. Removal, disassembly, part replacement and reassembly.
(a) If the filter screen is not too dirty, use compressed air to blow it in the opposite direction to
remove the impurities. If it is too dirty or has been used for 2500 h, replace it. Never clean the
filter screen with any solvent. To use a used filter screen, install it with the dirty side toward to
the LPG inlet.
(b) In case of impurity or tar deposits, you’d better clean them away with suds (never use any
solvent). After cleaning, check the inside for damage and abnormities. Check the diaphragms
with bright light for small holes and cracks. In addition, check whether they are elastic, aged
and hardened.
(c) The filter screen of a newly retrofitted forklift truck may be blocked soon. There are two causes:
The LPG contains two many impurities. The residual scrap iron or rust in the new cylinder flows
out of the cylinder and flows to the filter screen.
Below is another abnormal phenomenon. The tar in the LPG dissolves in the liquid fuel and
penetrates the filter screen. However, the tar is separated during the gasification in the
downstream gasifier and deposits in the gasifier to cause malfunction.
15
Troubleshooting of LPG Forklift Truck
Malfunction: A. Failure to start the engine with LPG
Malfunction Sources Possible Causes Solutions
1. No or unsmooth LPG supply (A) Insufficient LPG in cylinder Add LPG.
to internal combustion engine (B) Manual overflow valve on Open it slowly.
cylinder not opened fully
(C) Excess flow valve in overflow See ① in the troubleshooting
valve on cylinder closed method table below.
accidentally
(D) Blockage of high-pressure ②
LPG pipe
(E) Too dirty filter/vacuum cut-off ③
valve
(F) Insufficient gas from ④
gasifier/pressure regulator or
insufficient gas output pressure
(G) Damage, distortion or Repair or replace
leakage of low-pressure LPG
pipe
(H) LPG electromagnetic valve Turn the changeover switch to
not opened (double-fuel system) LPG position and check the
lines.
2. Poor operation of (A) Unsmooth coolant flow for ⑤

gasifier/pressure regulator (first heating resulting in poor
check the gas output pressures gasification and affecting normal
of primary and secondary operation (cold feeling/frost)
chambers, see ④) (B) Damage of internal parts ⑥
(C) Low-quality fuel containing ⑦
too mach tar
3. Poor operation of LPG mixer (A) The internal floating venturi ⑧

cannot fluctuate freely (impurity
or tar deposits).
4. Too lean idle mixture (A) Improperly adjusted idle ⑨

mixture ratio
(B) Damage, distortion or Repair or replace
leakage of low-pressure LPG
pipe
(C) The floating venturi in mixer ⑧
cannot fluctuate freely.
(D) Hardened diaphragm in ⑥
gasifier/pressure regulator
16
5. Insufficient vacuum suction (A) Too low engine starting
from intake system speed
(B) Poor engine conditions: Check cylinder pressure. When
Untight engine valve necessary, rebuild it,
Untight piston ring
(C) Leakage between mixer and Tighten
engine
(D) Untight connections at both Repair or replace
ends of mixer
6. Vacuum signal transmitted to (A) Loose or damaged vacuum

filter/vacuum cut-off valve, signal pipe
resulting in valve closure (B) Insufficient vacuum suction ⑧
from intake system
(C) Blockage in mixer (impurity
or tar deposits)
Malfunction: B. Difficult starting

1. Unsmooth LPG supply (Refer to malfunction source A1)
2. Insufficient vacuum suction (Refer to malfunction source A5)
from intake system
3. Poor operation of (Refer to malfunction source A2)
4. Too lean idle mixture (Refer to malfunction source A4)
Malfunction: C. Available starting but failed continuous running or unstable running

1. Too dirty filter ③
2. Too low idle speed Adjust it in accordance with the
3. Too lean or rich idle mixture (Refer to malfunction source A4) specification of original gasoline
4. Poor operation of (Refer to malfunction source A2) engine
5. Insufficient gas from ④
gasifier/pressure regulator or
insufficient gas output pressure
17
Malfunction: D. Unstable idling or even flameout
1. Too low idle speed Adjust it in accordance with the
specification of original gasoline
engine
2. Incorrect idle mixture ratio ⑨
3. Insufficient vacuum suction (Refer to malfunction source A5) Remove inside tar or impurities
from intake system
4. Unsmooth oxygen supply for Blocked pipeline between Replace damaged hose or
LPG gasifier/pressure regulator and tighten connectors.
mixer or untight connectors at
both ends

6. Too much fuel (double-fuel Gasoline electromagnetic cut-off ⑩
system) valve not closed completely,
resulting in gasoline leakage into
engine
Malfunction: E. Too high idle speed

1. Incorrect engine idle speed (A) Poor operation of throttle Adjust it in accordance with the
valve outer pull rod or cable specification of original gasoline
engine
2. Failed complete closure of (A) Seizure or misalignment of Check and repair
engine throttle valve throttle valve internal valve plate Check and repair
Malfunction: F. Too high idle speed

1. Malfunction of ignition system Poor connection or looseness Check and repair
2. Poor operation of LPG (a) Poor connection or looseness Check and repair
electromagnetic cut-off valve (b) Internal malfunction
3. Unsmooth air flow into engine Too dirty air filter Check and repair or replace
4. Unsmooth oxygen supply for (Refer to malfunction source A1) Clean or replace
LPG
18
Malfunction: G. Backfire of engine
1. Malfunction of ignition system (A) Old spark plug, abnormal gap Adjust it in accordance with the
original specification
(B) Incorrect ignition timing As above

(C) Incorrect ignition advance of As above
distribution panel
(D) Damaged high-tension wire As above
(E) Defective ignition coil As above
2. Untight engine valve Check cylinder pressure. When
necessary, rebuild it,
3. Damage, distortion or leakage Check and repair or replace
of low-pressure LPG pipe
4. Incorrect idle mixture ratio (Refer to malfunction source A4)
Malfunction: H. Poor acceleration

1. Accidental closure of excess ①
flow valve
2. Impossible full opening of (A) Poor operation of engine Check and repair or replace
engine valve or delayed opening speed limit valve when necessary
(B) Poor operation of throttle As above
valve outer pull rod or cable
(C) Seizure or misalignment of As above
throttle valve internal valve plate
4. Incorrect idle mixture ratio (Refer to malfunction source A4)
Malfunction: I. Poor performance or insufficient power during high-speed running

1. Too dirty filter ③
2. Too dirty air filter Replace filter core
3. Blocked exhaust system Check and repair
5. Incorrect power mixture ratio Readjust
19
Malfunction: J. Frosting of LPG system
1. Frosting of gasifier/pressure (A) Insufficient circulating hot Add coolant into radiator
regulator during normal water
operation (B) Bubbles in gasifier/pressure Dismount hot water pipe outlet of
regulator or blockage by foreign gasifier/pressure regulator and
objects remove bubbles.
(C) Gasifier/pressure regulator Reinstall gasifier/pressure
higher than radiator regulator at a lower position.
(D) Blocked hot water pipe
(E) Failed hot water pump Do not accelerate engine before
(F) Failed temperature controller complete warm-up.
2. Frosting of gasifier/pressure (a) Insufficient water temperature Cover radiator in cold days to
regulator before complete rise quicken temperature rise.
warm-up Do not start engine. No smoking!
Fully turn off the manual switch
3. Frosting of gasifier/pressure Abnormal leakage of whole LPG on cylinder and immediately find
regulator before engine starting system; obvious odor out leaking part and cause.
4. Frosting of pipeline
5. Frost on cylinder surface Pipeline blockage Unblock the pipe.
Breakage of internal suction pipe Replace cylinder.
Malfunction: K. Cylinder-related problems

1. Failure to fill cylinder with LPG (A) Incorrect method Refer to Operator’s Manual for
or failure to add LPG into (B) Malfunction of filling valve on filling method.
cylinder cylinder Replace part or cylinder.
2. Automatic opening of safety (A) Saturated cylinder
relief valve
3. Leakage after quick connector (a) Overfilling Never fill LPG to exceed 80% of
is separated cylinder capacity.
(b) Too high cylinder temperature Drive vehicle to a cool place and
spray water to cylinder when
necessary.
4. Leakage at the thread (c) Internal malfunction of safety
connecting cylinder valve and relief valve
cylinder block
5. Malfunction or leakage of (a) Internal deposit of foreign Replace part or cylinder; clean
cylinder valve objects
(b) Malfunction of internal part Replace part or cylinder
Warning: As there is LPG in the cylinder, part replacement shall be carried out by a qualified and
experienced technician. Only after the residual LPG is discharged safely, can part repair be performed.
20
Troubleshooting Method
Item Description
① Fully close the manual overflow valve at the cylinder outlet. Wait about 5 s and then you will hear
a soft click sound. After that, slowly open the manual valve.
Note: An excess flow valve is set in the overflow valve. It is a safety device and cannot be seen
outside the cylinder. It can automatically return to open state when a serious leak occurs due to
breakage of any pipe or part in the LPG system. As the spring in the excess flow valve is very
sensitive, it may be closed accidentally if the manual valve is opened too quickly. Therefore, it is
necessary to take the above measure to open it again.
② There are two causes for blockage: 1. Deposit of foreign objects in pipe (especially for newly
retrofitted vehicle); 2. Excessive bending or deformation of pipe.
Method for removing foreign objects in pipe: 1. Refer to “Correct removal procedure of LPG
system”. Be careful! No smoking! 2. Fully close the manual valve at the cylinder outlet. 3.
Dismount the connector at the LPG inlet of filter/vacuum cut-off valve. 4. Open the manual valve
of the cylinder and allow 2-3 times of LPG ejection to blow away the foreign objects. 5. If the pipe
is still blocked, replace the pipe.
③ Remove the filter/vacuum cut-off valve according to “Correct removal procedure of LPG system”
and then disassemble, check and repair it in accordance with IMPCO VEF30 Maintenance
Manual. When necessary, use the IMPCO repair kit for part replacement.
Note: A too dirty filter core will render a pressure difference to the flowing LPG and consequently
lead to partial LPG gasification at this position. In this case, the filter will be cold or even frost up.
When serious, this will affect the LPG supply, resulting in engine power reduction or even
flameout.
④ Check the LPG output pressures of the primary and secondary chambers in accordance with the
method and procedure in “Pressure check of IMPCO J gasifier/pressure regulator”. (During the
check, IMPCO “ITK-1” pressure gauge shall be used,)
⑤ Check and repair: 1. Low coolant level in radiator; 2. Loose or broken fan belt; 3. Leakage of
cooling system; 4. Malfunction of cooling water pump; 5. Malfunction of temperature controller.
⑥ Remove the gasifier/pressure regulator according to “Correct removal procedure of LPG system”
and then disassemble and check it in accordance with IMPCO J Gasifier Maintenance Manual. 1.
Clean each part with suds, including diaphragm; 2. Check the dried diaphragms with bright light
for small holes, cracks, etc. In addition, check whether they are elastic, aged and hardened; 3.
Check the secondary chamber valve for tightness and leakage; 4. When necessary, use the
IMPCO repair kit for part replacement.
⑦ Check the inside for tar deposits. If any, clean it with warm suds. It is recommended to use
high-quality LPG.
⑧ (A) Before removing the mixer, check whether the internal floating venturi operates normally with
the following method:
(1) Dismount the hose connecting the front end of mixer and the air filter.
(2) Start and idle the engine.
(1) Check the floating venturi in the mixer. It shall move slightly when the engine is started and
move obviously when the engine accelerates.
(2) If it almost does not move when the engine accelerates, it means that the engine suction at
the mixer is insufficient and a leak exists between the mixer and engine (the vacuum suction at
the mixer shall be at least 100-150 mmH2O “vacuum”).
21
(3) In case of no leakage, further dismount and disassemble the mixer to check the inside.
(B) Clean the mixer inside with warm suds and then dry it. Next, check the inside for foreign
objects, obvious scratches and burns caused by backfire of engine; check the valve seat for
damage and deformation. When necessary, use the IMPCO Ca55 repair kit for mixer for part
replacement.
⑨ Readjust it in accordance with the method and procedure in “Adjustment of LPG system” in this
manual.
⑩ If a little gasoline leaks into the engine, it may be nothing during high-speed running, but when the
engine returns to idling, it may result in unstable idling or even flameout.
(A) Carefully remove the end of gasoline electromagnetic valve close to the gasifier and then start
the engine to check for leakage.
(B) Check whether the line of electromagnetic valve is correct and tight.
22
I. Driving, Operation and Routine Maintenance
The driver and management shall perform safe and standard operation in accordance with the
Operation & Service Manual and Operator’s Manual. Safety must be foremost in their minds at all
times.
1. Transportation
Observe the following precautions for forklift truck transportation by containers or vehicles:
(1) Apply the parking brake;
(2) Fix the front and rear parts of the mast and counterweight with steel wires. Wedge the front and
rear wheels firmly with wedge blocks;
(3) Lift the forklift truck from the point stated on the “Lifting Label”.
2. Storage
(1) Drain the fuel (the coolant is for rust and ice prevention, so do not drain it);
(2) Coat the uncoated surfaces with antirust oil. Lubricate the lifting chain;
(3) Lower the mast to the lowest position;
(4) Apply the parking brake;
(5) Wedge the front and rear wheels with wedge blocks.
3. Preparations before use

(1) Do not check the fuel, oil leakage, oil level or any electrical instrument near an open flame. Do
not add fuel when the forklift truck is in operation;
(2) Check the tyre pressure;
(3) Set the gear lever at neutral position (“0”);
(4) Do not smoke when the fuel system works or when checking the battery;
(5) Check all handles and pedals;
(6) Complete the preparation work before startup;
(7) Release the parking brake;
(8) Test the mast movements including lifting, falling, forward/backward tilting, steering and
braking;
(9) Ensure the pollution degree of hydraulic oil is not higher than class 12.
4. Operation
(1) Only the trained and certified driver can drive the forklift truck;
(2) The operator shall wear safety shoes, helmet, clothes and gloves during operation;
23
(3) Check all control and alarm devices before driving. In case of any damage or defect, conduct
repair before operation;
(4) Never overload the forklift truck. Set the forks under the goods fully and make the goods on the
forks evenly. It’s forbidden to pick up goods with a single fork tip;
(5) Perform startup, steering, travel, braking and stop smoothly. Decelerate during steering on wet
or slippery road;
(6) During travel with load, lower the load as low as possible and tilt the mast backwards;
(7) Take care when driving up/down a slope. For the slope with a gradient over 1/10, drive forwards
to climb up the slope and reverse to climb it down. Steering is forbidden when driving up/down a
slope. Loading/unloading is forbidden when driving down a slope;
(8) During driving, pay attention to pedestrians, obstacles and potholed roads and observe the
clearance above the forklift truck;
(9) No person shall stand on the fork. It’s forbidden to carry persons with the forklift truck;
(10) No person shall stand or walk under the fork;
(11) Never operate the forklift truck or attachments from the positions other than the driver’s seat;
(12) For the high-lift forklift truck with a lift height over 3m, goods falling shall be avoided. Take
protective measures when necessary;
(13) When the high-lift forklift truck works, try to tilt the mast backwards. Handling shall be done
within the minimum area by means of forward/backward tilting;
(14) Be careful to drive slowly on wharf or temporary planking;
(15) The driver shall stop the engine and leave the forklift truck when adding fuel. Ignition is
forbidden during battery or oil tank check;
(16) Operate the forklift truck with attachments but no load as a loaded forklift truck;
(17) Do not transport unfixed or loose goods. Take care to transport large-size goods;
(18)Before leaving the forklift truck, lower the goods on ground, set the gear lever at neutral position,
and stop the engine or cut off the power supply. To park the forklift truck on a slope, apply the
parking brake, and for long-time stop, wedge the wheels;
(19) If the engine is very hot, do not open the radiator cover;
(20) The pressures of multi-way valve and safety valve have been adjusted well before delivery. Do
not adjust them at will. If the pressure adjusted is too high, the whole hydraulic system and the
hydraulic elements will be damaged;
(21) Inflate the tyres in accordance with the “Tyre Pressure” label;
(22) Make sure the noise outside the forklift truck is not louder than 89dB (A). Test the noise in
accordance with JB/T3300;
(23) To carry extra wide goods, you can select "lengthened forks". It is to be noted that the
lengthened forks shall carry load in strict accordance with the requirements of load curve.
24
Within the specified load center, their carrying capacity is the same as that of standard forks.
However, when the load center shifts forwards, it is necessary to reduce load. It is forbidden to
pick up or knock the goods. Ensure safety during traveling and steering;
(24) Regularly check the chains. Ensure the chain joints are lubricated properly, and the left and
right chains are of same tension. If the pitch variation exceeds 2% of the standard value due to
wear, replace the chains to ensure safety.
5. Precautions for using cooling system

(1) In case of boiling radiator or high coolant temperature, try best not to open the radiator cover. If
it is necessary to open the radiator cover for cause identification and coolant level check,
reduce the engine speed to medium and then unscrew the cover slowly. Wait for a moment
before taking down the cover. This is to prevent the coolant from jetting out to scald the
operator;
The radiator cover shall be tightened completely. Otherwise, it is difficult to set up the specified
pressure system.
(2) For the radiator using clean water, drain the water for forklift truck storage only in cold weather
with the danger of icing. After working for a period, the radiator shall be dismounted and
washed by boiled soda solution to clear the scale or deposits on its surface;
(3) For the radiator using long-acting antifreeze fluid (FD-2, -35℃), it's forbidden to add water or
antifreeze fluid of a different model. Add the antifreeze fluid of the same model to compensate
for leakage or evaporation;
The antifreeze fluid is applicable for all seasons. It needs no change but filtration and
purification after a year generally. Then it can be used again.
(4) Regularly remove the dirt on the radiator surface with detergent, compressed air or
high-pressure water (pressure not higher than 4kg/cm2) according to different working
conditions.
6. Oil
Name Grade/Code (In China) Grade/Code (Overseas)
Gasoline RQ-85 JISK2202, 2#
Select lubricating oil in accordance with Engine SAE10W (winter)

User’s Guide or GB485-84 (gasoline engine),
Lubricating oil
GB11122-89 (diesel engine) and the working SAE30 (summer)
conditions.
Hydraulic oil N32# or N46# ISOVG30
Hydraulic
transmission 6# SAE10W
oil
Gear oil 85W/90 SAE90/SAE80W
Brake fluid 4604 synthetic brake fluid JISK-2233
Lubricating oil 3# lubricating oil 170 JISK-2220, 1#, 2#
25
Countermeasures against coldness and hotness
Oil
Use the oil suitable for the ambient temperature.
Coolant
The cooling system is provided with long-acting antifreeze fluid occupying 50% of its capacity. The
solidifying point is -35℃.
In hot weather, to obtain good cooling effect, pay more attention to the radiator and cooling system. Park
the forklift truck in a cool place.
26
7. Lubrication system diagram
27
II. Main Technical Parameters
Outside View
28
Main Technical Parameters
Unit: mm
No. Code Item\Model CPQYD10/15-SA CPQYD20/25-SA CPQYD30/35-SA CPYD40-SA
Max. lift
1 A 3000
height
Fork
2 C spacing 200-990 244-1022 250-1100/260-1105 260-1105
range
3 D Fork length 920 1070
4 Mast tilt 6º/12º
Overall
5 F 2242 2525/2582 2675 2800/2905
length
Overall
6 G width 1070 1200 1280
(single tyre)
7 H Mast height 2060 2090 2100
Overhead
8 B guard 2040 2140 2170
height
Max. sliding
rack height
9 J 3450 4020 4060 4180
with mast
extended
Wheel
10 K track, front 885 960 1000 1034
(single tyre)
Wheel
11 L 908 980
track, rear
12 M Wheelbase 1400 1625 1625 1750/1900
Front
13 N 472/477 505 505
suspension
Rear
14 545 545
suspension
Min. ground
15 P clearance 100 120 120 140
under mast
Min. turning
16 R 1990 2240/2280 2400/2500 2700
radius
29
Main Technical Parameters
Model CPQYD10/ CPQYD20/ CPQYD30/

CPYD40-SA
Item 15-SA 25-SA 35-SA
Rated lifting capacity/load 1000/1500 2000/2500 3000/3500

center (kg/mm) 4000/1500
500 500 500
Standard maximum lift

height (mm)
Working
capacity Lifting speed, with full
385 450 430 430/400
load (mm/s)
Lowering speed, with full

530 530 530 530
load (mm/s)
Mast tilt (forward-back) (°) 6-12
Forward
20 20 23
(km/h)
Traveling
speed
Backward
20 20 23
(km/h)
Gradeability % 20
Traveling
Tyre size, front 6.50-10-10P 7.00-12-12 28×9-15-12
capacity 250-15-16PR
Pressure (kg/cm2) R PR PR
0.7
0.7 0.7 0.7
5.00-8-8 6.0-9-10
Tyre size, rear 6.50-10-10PR
PR PR
Pressure (kg/cm2) 0.7
0.7 0.7
Gross weight (kg) 2700 3500/3800 4400/4650 4850
Front axle load, with no

Axle load load (kg)
Rear axle load, with no

load (kg)
30
III. Structure, Principle, Adjustment and Maintenance
1. Power system
1.1 Engine overview
This series of forklift trucks are equipped with gasoline engines. The engine and the driving device
are connected as a whole. The engine support is connected with the frame through the rubber pad
to reduce vibration.
Main Parameters of Gasoline Engine
Model
4G64 GM3.0
Parameter
Type 4-stroke, water-cooled, in-line, overhead valve
Number of cylinders-bore x stroke mm 4-86.5×100 4-101.6×91.44
Displacement L 2.35 2.967
Compression ratio 8.6 8.2
Rated power/speed kW(ps)/rpm 34.2/2200 65/3000
Rated torque/speed N.m (kg.m)/rpm 159/1600 128/1800
Min. speed without load rpm
Min. fuel consumption g/ps.h
Length x Width x Height mm
Weight kg
Rotation direction Clockwise viewed from the fan end
Cooling system Forced circulating water cooling
Lubrication system Forced lubrication
Battery voltage V/capacity Ah 12/100
Lubricating oil 3.8
Coolant 3.5
31
1.2 Precautions for installation and operation of gasoline engine (for 4G64 and GM3.0)
(1) Precautions for installation of gasoline engine
Item Requirement Remark
Cooling system Allowable coolant Normally 80 ℃ ; max. To prevent engine

temperature 110 ℃ (outlet overheat
temperature)
Radiator cap pressure Normally 88.3 kPa (0.9 Standard value

kg/cm2)
Air discharge Discharge air from the

petcock when adding
coolant.
Lubrication system Allowable temperature The temperature of oil

in the oil pan is 120℃
at most.
(2) Precautions for operation of gasoline engine
Cooling system Intake negative Max. 6.18 kPa; Use a screen type narrow air filter core.
pressure (negative Normally below Replace it every 6 months or 1200 hours. In
pressure at flared 0.98 kPa case of three-shift system or severe
air intake port) condition, replace it early. Otherwise, it may
lead to cylinder and piston wear and
emission of black smoke containing CO.
Exhaust system Exhaust pressure Normally 13.3 If too high, it may adversely affect the engine
(pressure at kPa (below 100 power and increase noise.
exhaust port) mmHg)
Power-take-out Allowable oil pump 4G64: kgm/rpm If too high, it may adversely affect the engine
(P.T.O) system load GM3.0: kgm/rpm power and increase noise.
Electrical Battery capacity Standard: 12 Generally for -15℃ ~ -35℃

system V-50 Ah
Service Ambient Standard: -15 ℃

condition temperature ~ -35℃
Altitude Standard: below In case of service above 1000 m, perform

1000 m mixture compensation for such height.
(elevation)
32
(3) Fuel, lubricating oil and others for gasoline engine
Fuel Common unleaded gasoline The leaded gasoline

will wear the
Octane number 89
gasoline engine part
Equivalent to JISK2202-1988 2# and pollute the
environment.
Lubricating oil Grade: API: SD or above (equivalent to Chinese QD

above)
SAE: General regions: 20W
Cold regions: 10W
Replacement interval: 200 hours or one month
Anti-freeze coolant Equivalent to JISK2234-1988 2# For Chinese

(LLC) anti-freeze coolant,
LLC concentration: General regions (above -15℃) 30%
observe the left
Cold regions (above -35℃) 50% requirements. It is
recommended to use
Replacement interval: 2400 hours or 12 months generally.
long-acting anti-rust
The replacement interval can be changed according to
coolant (FD-2 type,
actual service and operating conditions.
-35℃).
Spare Fuel filter Genuine Japanese product

parts
Replacement interval: 2400 hours or 12 months generally
Engine oil Genuine Japanese product

filter
Air filter Genuine Japanese product
Note: The replacement intervals in the table above are applicable to general conditions (8 h/day). In
case of three-shift system or severe condition, shorten the replacement intervals.
33
1.3 Engine check and adjustment
1.3.1 Air filter
(1) Take down the filter core;
(2) Check the filter core for dust and damage. If it is very dirty, blow low-pressure air from inside to
outside. If it is damaged, replace it with a new one;
(3) Clean the dust collection box cover;
(4) See the table in 1.2 for the replacement interval.
1.3.2 Engine oil filter
 Gasoline engine
(1) Remove the oil filter with a special spanner. Replace it with a new one;
(2) Apply a little of engine oil around the new oil filter seal ring. Then install it. Tighten it for another
2/3 circle after it contacts the filter body;
1.3.3 Radiator and expansion tank
(1) Checking the coolant level in the expansion tank
Check the coolant level in the expansion tank. If the level is lower than the mark LOW, add
antifreeze fluid (with the same concentration as that of antifreeze fluid LLC in 1.2) to the
specified level;
When the engine is hot, the level is higher than the mark HIGH. When it is cold, the level is at
the position of 2/3 of the radiator capacity.
Cover
HIGH
LOW
Fig. 1-1 Expansion Tank
(2) Changing the coolant
(a) Stop the engine. Wait for 30min;
(b) Remove the radiator cover and open the drain cock on it;
34
(c) Open the drain cock on the engine and drain the coolant;
(d) Tighten the two drain cocks;
(e) Add the antifreeze fluid into the radiator according to the concentration requirement in 1.2.
The adding speed shall be lower than 2L/min;
(f) After filling the radiator, start and idle the engine for a while. Check the level in the
expansion tank. If insufficient, continue to add antifreeze fluid to the specified level;
(g) Tighten the radiator cover. Always keep the level above the position of 2/3 of the radiator
capacity by adding antifreeze fluid.
(3) Adjusting the tightness of fan belt
(a) Loosen the generator mounting bolts;
(b) Move the generator to adjust the belt tightness. Press the belt by fingers with a force of
10kg. Press the belt down for 10mm at most.
1.3.4 Engine speed adjustment
(1) Idle speed
(a) Warm up the engine until the coolant temperature reaches 85℃;
(b) Install a tachometer on the engine. Adjust the engine speed to the specified value 700rpm
with the idle speed adjusting screw on carburetor;
(c) Adjust the limit screw for the minimum valve opening in the direction for engine speed
increase;
(d) Rotate the idle speed adjusting screw on carburetor until the engine speed keeps at
700rpm.
(2) Maximum speed
The maximum engine speed is adjusted through the governor. It is to be noted that too quick
speed change will cause knock.
Adjustment part Width
Gas pipe
Cable assembly
Width
To carburetor
To distribution panel
Cam spring Rocker arm

As above
Fig. 1-2 Speed Governor
Maximum speed adjustment with no load
35
Remove the rubber cover. Rotate the adjusting part to make the engine speed reach the
specified maximum speed with no load. Clockwise rotation will increase the speed.
Anticlockwise rotation will decrease the speed.
Maximum speed adjustment with load (the overflow valve works)
(a) Rotate the adjusting screw to adjust the maximum speed with load. In addition, the
maximum speed with no load can also be adjusted (the adjusting screw for the
maximum speed with no load is in the adjusting part; the rotation direction is the same
as that for the maximum speed with load).
(b) If the maximum speed with load cannot be reached by the adjusting screw, use the
cam. However, the cam adjustment needs high level of skill. Fine adjustment may also
cause knock.
Model
4G64 GM3.0
Parameter
Max. speed Instantaneous value 2890~3090 2990~3150

with no load
Stable value 2820~2900 2820~3080
rpm
Knock check and adjustment
Knock indicates unstable engine speed. Always check for knock during the adjustment of
maximum speed with load or no load.
Check
• Shut down the hydraulic system and engage the neutral gear. During idling,
depress the accelerator pedal slowly to check for knock.
Adjustment
In case of more than three times of knock, operate according to the following procedures
for adjustment:
• Rotate the adjusting screw clockwise and adjust the maximum speed with no
load;
• If the above operation cannot eliminate the knock, adjust the cam screw.
36
Malfunction Cause Solution
Failed engine speed increase • Broken cam cable

Replace cable assembly.
under no-load condition • Damaged or broken spring
• Improperly adjusted cam Adjust

Failed traveling speed increase
spring Clean or replace speed
Knock (no knock when lifting)
• Seized balance piston governor assembly.
• Improperly adjusted cam

Failed traveling speed increase
spring Adjust
Slow lifting
• Damaged spring Replace cable assembly.
Slow lifting (normal traveling
speed)
spring

Fast increase of traveling speed
• Seized governor valve shaft Reassemble

More than three times of knock
• Seized governor valve shaft Reassemble
For the adjustment of other parts of the engine, refer to the Engine User’s Guide.
1.4 Fuel system
The fuel system consists of fuel tank, fuel filter, fuel level sensor and fuel gauge.
1.4.1 Fuel tank
The fuel tank is a welding part. It is connected with the frame and located at the left side of the frame.
The fuel tank cover plate is on the upper plane. A fuel level sensor for monitoring the fuel level and a
fuel suction pipe are installed on the cover plate.
1.4.2 Fuel level sensor
The fuel level sensor is used to transform the fuel volume value into current value. See Fig. 1-5.
37
Fuel level indicator
(option)
Fuel gauge
Fig. 1-3 Digital Instrument Panel
A rheostat with nickel alloy wires is adopted. A sliding element is connected with the float. The
resistance changes with the up-and-down movement of the float. The current of the rheostat
changes accordingly.
The fuel gauge is of bimetallic strip type. The hand movement depends on the current passing
through the bimetallic strip heating element. When the float is at the highest position, the resistance
of the fuel level sensor is about 9.5-11. The larger the current is, the severer the bimetallic strip
bends. In this case, the fuel gauge hand will deflect to “F” (Full). Contrarily, when the level lowers,
the float will lower accordingly, the resistance will increase and the current will decrease. In this case,
the fuel gauge hand will deflect to “E” (Empty).
The fuel gauge indicates fuel volume by means of solid column. The closer the light column is to the
right end, the more the fuel is. Contrarily, the closer the light column is to the left end, the less the
fuel is. When the lower limit is exceeded, the buzzer will sound to remind the driver to add fuel.
To fuel gauge
To fuel level indicator lamp
View A
Fuel gauge
Fuel level switch
Fuel level sensor Connection diagram

Float
38
1.4.3 Maintenance of fuel system
Maintain the fuel system once every 100 working hours. Clean the fuel tank once every 600 working
hours.
(1) Fuel filter
The filter installed on the fuel pump is used to filter the fuel to the engine.
Spring
Pump
Filter core
Housing
Fuel level switch
Drain cock
Petrol engine Diesel engine
 Gasoline engine
(a) Replace the whole filter every after 300 working hours;
(b) Loosen the rotating wheel and remove the cover;
(c) Loosen the nut and dismount the filter core;
(d) Clean or replace the filter core;
(e) Reinstall the filter core, and then start the engine to fill gasoline into the filter oil cup.
Check it for oil leakage.
1.5 Accelerator pedal
The accelerator pedal on the back plate is used to control the engine speed. It is connected with the
engine through the connecting rod and cable.
2. Electrical System
! Warning: Before working on any electrical part, always set the starting switch at position OFF and
then disconnect the positive cable of the battery.
Test
Test all circuits according to the circuit diagram. Use a conventional test lamp or a universal meter to
test the continuity or short circuit. Before test, make sure:
1. Each electrical part or each wire is fixed on its connected terminal connector.
39
2. Each connector is connected firmly and free of dust and dirt.
3. Each wire surface is free of breakage, aging and other damages.
4. There is a safety distance between each connector and each adjacent metal part.
5. Each wire is fixed to the correct terminal or connector.
6. The wiring is separated from sharp edges.
7. The wiring is separated from all rotating and moving parts.
8. The wire between the fixed part and moving part is long enough to stand vibration and shock.
9. There is a safety distance between the wiring and the hot objects such as exhaust pipe.
2.1 General
The electrical system applies single-wire-system circuit with minus earth. It includes the following
systems:
(1) Charging system
It consists of generator, battery and charging indicator lamp. It is used to supply power to the
electric equipment of the forklift truck. The voltage is DC12V.
(a) Basic parameters of battery:
Battery model and quantity 6-QA-100C
Voltage 12V
Battery capacity (based on 20h) 100Ah
Overall dimension (L X W X H), mm 402x171x233
Net weight without electrolyte 20
(b) Charging state
i. Always keeping full battery power is the best method to extend the service life of
battery.
ii. The charging state can be determined according to the specific gravity of electrolyte. A
specific gravity between 1.260-1.280 indicates full battery power. The charging state
can also be determined according to the speed of electrolyte reduction. If the
electrolyte reduces to expose the polar plate within one month, the battery may be
charged excessively. If the electrolyte only reduces slightly within more than 3 months,
the battery may be charged insufficiently. The electrolyte level shall be kept 10mm
above the polar plate.
iii. Low-speed running of forklift truck is the cause for insufficient battery power. In this
case, the driver shall increase the speed and save power. In addition, you can also
increase the voltage of regulator by 0.05V-0.1V.
(c) Precautions for using alternator charging system
40
i. When the starting switch is closed, the terminal voltage of battery is added between
the regulator magnetic field terminal/live wire terminal/alternator armature terminal
and the ground. You shall remember this.
ii. The battery terminal polarity shall be the same as the polarity of ground of the
alternator. Never connect them wrongly, In case of reverse connection, the alternator
diode will blow out immediately. The relevant electrical wiring will also be damaged to
disable the electrical system.
iii. To charge the battery with a charger, remove the leads from the battery terminals at
first. Perform boost charge with the alternator connected with the battery will damage
the silicon diode of the alternator.
iv. Never check whether the alternator generates electricity by shorting the charger
armature terminal and the shell for spark. Never short the “armature” terminal and the
“magnetic field” terminal. This will damage the alternator. Never ground the “magnetic
field” terminal. This will damage the regulator.
v. Correctly judge whether the alternator charging system works normally. Normally, the
charging indicator lamp is on before (the switch has been turned on) and at the time of
engine startup; it is off after the engine runs normally. Otherwise, the charging system
malfunctions. You shall carry out check and troubleshooting. If the low alternator
output voltage is caused by regulator malfunction, replace or adjust the regulator. If
regulator adjustment is necessary (contact or arm), it is necessary to open the ignition
switch at first. Close the ignition switch when checking voltage after adjustment.
Otherwise, it is easy to damage the regulator contact or relevant electric equipment.
vi. If the alternator fails in generation or charging, find out the cause and clear the
malfunction in time. Do not continue running for a long time. Or else, the alternator will
be damaged. When checking the insulation of each part of the alternator, do not use
AC220V or megameter.
Countermeasures against coldness and hotness
Battery
• In cold seasons
The solidifying point of electrolyte under normal charging condition is -35℃.
Always charge the battery under good conditions. The solidified electrolyte will damage the
battery case. To avoid solidification, charge the battery to 75% of its capacity at least.
The best method is to keep a specific gravity of 1.260. However, do not exceed this value.
• In hot seasons
As the water in electrolyte is easy to volatilize, replenish distilled water frequently.
Check the electrolyte once every week. Replenish distilled water if insufficient.
In case of high ambient temperature, lower the specific gravity to 1.220±0.01.
As the efficiency of battery is high in hot days, no other maintenance is needed.
41
! Danger
The gas produced by the battery will explode. Never smoke or use an open flame. Never generate any
electric arc or spark around the battery. In case of battery storage or charging in a closed space, ensure
good ventilation. The sulfuric acid in the battery will cause burn. Keep it away from your eyes, skin and
clothes. In case of contact with sulfuric acid, use clean water for washing immediately. If the sulfuric acid
splashes into eyes, go to hospital.
42
Malfunction analysis:
Malfunction Possible Cause
1. Grounding or open circuit of stator winding
2. Open circuit of rotor winding
3. Failed excitation of alternator because the carbon brush is seized

in the carbon brush bracket
4. Short circuit between the magnetic field terminal and grounding

Alternator terminal
5. Short circuit between the armature terminal and magnetic field

terminal
6. Breakdown of silicon diode
7. Loose drive belt
8. Improper grounding of alternator
1. Open circuit or poor contact between the starting switch and the
Fast reduction live wire terminal of regulator
of battery Circuit
2. Open circuit or poor contact between the magnetic field terminal of
capacity
regulator and the magnetic field terminal of alternator
1. Insufficient electrolyte or incorrect specific gravity of electrolyte
2. Short circuit between polar plates

Battery 3. Vulcanization of polar plate
4. Poor contact between terminal and battery connector due to

corrosion
No overload if in accordance with standard electric load

Overload
Or too large additional load
1. Low adjusted voltage

Transistor
2. Poor contact of regulator connector
regulator
3. Damaged electronic element of regulator
43
Malfunction Possible Cause
1. Poor contact of regulator
Circuit 2. Loose connector in charging circuit
Excess battery 3. Short circuit in battery

charge
1. High regulator voltage
Regulator
2. Failed regulator control
Drive belt Loose drive belt
Unstable Ignition switch Poor contact in the start preheating switch

charging
indicator lamp 1. Open circuit or poor contact between the battery and the
under normal Circuit engine “armature” terminal
running state 2. Loose connector
Regulator Poor contact of regulator
1. Damaged bearing
Abnormal noise
Alternator 2. Breakdown of silicone diode
from alternator
3. Grounding of stator winding or turn-to-turn short circuit
Circuit Grounding of circuit behind fuse box
Alternator Breakdown of silicone diode
Blown fuse Regulator High regulated voltage
Battery Wrong connection of battery polarity
Overload Circuit load larger than fuse capacity
44
(2) Starting system
It mainly comprises automatic preheating system (only for diesel engine), starting switch, start
protection circuit and starter. It is used to start the engine.
(3) Electro-hydraulic reversing control system
① Electrical diagram
② Main parts
Electro-hydraulic control valve
Direction control lever
Control box
③ General
The electro-hydraulic control valve is designed and developed based on the original
control valve (see 5.4).
(a) Similarities with control valve
• Performance
• Dimension for connection with gear-box
• Directions and dimensions of oil ports (oil-in port, inching valve oil port, torque
converter oil port, forward gear oil port, and reverse gear oil port)
• Performance parameters of normal valve, overflow valve and regulating valve
(b) Differences from control valve
• The slide valves of main change valves have different control modes. The slide
valve of control valve is controlled mechanically. The reversing of
electro-hydraulic control valve is controlled by the electromagnetic leading valve.
That is to say, the former is under mechanical control, and the latter is under
electrical control.
45
Starting switch “C”
Reversing lamp
Starter relay
Direction control
Control box
Control
valve
(4) Instrument system
The instrument system mainly includes hour meter, fuel gauge, coolant temperature gauge and
indicator lamps. They are detection equipment of forklift truck.
The forklift truck applies CURTIS instruments. For the fuel gauge and coolant temperature
gauge, solid ten-section color LED display is used. For the hour meter, solid digital backlit
display is adopted.
(5) Lighting signal equipment
The lighting signal equipment includes various lighting lamps, signal lamps, horns and buzzers.
Headlamp: 55W
Front combined lamp (turn /width): 21W/8W
Rear combined lamp (turn /width/reversing): 21W
Warning lamp (option):21W
2.2 Operation descriptions
(1) Startup
Before engine startup, set the direction control lever at neutral position. Otherwise, the engine
cannot be started. This is because the control box is designed with safety start protection.
Rotate the starting switch clockwise to position “I” to connect the power supply for instruments
and ignition. At this time, the preheating of diesel engine starts automatically and the preheating
indicator lamp is lit up. After 3.5s, the lamp will go out automatically. The preheating time is
controlled by the time relay (also called timer). The preheating time is 13.5s at most.
Rotate the starting switch clockwise to position “II” to start the engine.
After engine startup, push the direction control lever forwards to forward gear. Depress the
46
accelerator pedal. The forklift truck will travel or work quickly.
When pulling the direction control lever backwards to reverse gear, the reversing lamp will be lit
on and the reversing alarm buzzer will sound.
(2) Lamp switch: The front and rear width lamps are lit up when this switch is set at position “I”.
When this switch is set at position “II”, the headlamps will be lit up and the width lamps will still
be on.
(3) Turn signal: Pull the turn lamp switch backwards and the left turn lamps of front and rear
combined lamps flash. Push the turn lamp switch forwards and the right turn lamps of front and
rear combined lamps flash
(4) Braking signal: To brake the forklift truck, depress the brake pedal and the brake lamp of rear
combined lamp is lit up.
(5) Reversing signal: To reverse the forklift truck, pull the direction control lever backwards. At this
time, the gear-box is set at reverse gear. The reversing lamp of rear combined lamp will be lit
up and the reversing alarm buzzer will sound.
(6) No-charging signal indication: Before engine startup, set the starting switch to position “Power
on”. At this time, the charging indicator lamp is lit up. After engine startup, this lamp goes out
automatically. If this lamp is on during engine operation, it indicates that the charging circuit fails
in charging due to malfunction. You shall stop the forklift truck for check.
(7) Engine oil pressure signal: Before engine startup, set the starting switch to position “Power on”.
At this time, the oil pressure indicator lamp is lit up. After engine startup, this lamp goes out
automatically. If this lamp is on during engine operation, it indicates poor lubrication due to low
engine oil pressure. You shall stop the forklift truck for check.
(8) Fuel water separator signal indication: Before engine startup, set the starting switch to position
“Power on”. At this time, the fuel water separator indicator lamp is lit up. After engine startup,
this lamp goes out automatically. If this lamp is on during engine operation, it indicates that the
water in fuel water separator has exceeded the alarm level. You shall operate the pressure rod
on the fuel water separator to drain the water. Afterwards, the indicator lamp will go out.
(9) Fuel gauge: It indicates the fuel volume in fuel tank. When the fuel volume is less than two
columns, the alarm buzzer will sound. It means that the fuel level is too low and you shall add
fuel.
(10) Coolant temperature gauge: It indicates the engine coolant temperature.
(11) Hour meter: It indicates the accumulative working hours of engine.
Attachment: Electrical Diagram
47
48
Lamp Switch Instrument combination
Starting Switch ON/OFF Table

ON/OFF Table
Terminal\ Hour Fuel Coolant Fuel
position meter gauge temperatu temperature
Terminal
re gauge gauge
\position
Fuel water separator
Preheating indicator lamp
Left turn indicator lamp

Right turn indicator lamp
Oil pressure indicator lamp
Charging indicator lamp
Turn lamp
switch
Headla Width Turn

mp lamp lamp Turn Width Headlamp
lamp lamp
Horn switch
Flasher Fuel level Coolant Fuel

sensor temperature temperature
sensor sensor
Neutral position Fuel Fuel water

switch pressure separator switch
Starter relay Brake lamp Starter
switch Reversing
lamp switch switch
Fuse box
Fusible wire
Electronic fuel
pump switch
Battery
Thermal relay
Generator
Time relay Turn lamp

Turn lamp Width lamp
Width lamp Brake lamp
Brake lamp Reversing
Reversing lamp
lamp Preheater
Buzzer
3 Clutch
Type Single-disc dry type
Operation mode Pedal
Facing outer
275mm
diameter
Inner diameter 175mm
Thickness 8.9±0.3mm
Surface area 354cm2
Weight 12.5kg
3.1 General
The clutch comprises clutch housing, facing, clutch slave cylinder, clutch master cylinder and
pressure plate assembly. It is used to control the power transmission from engine to gear-box.
3.1.1 Pressure plate cover and facing
The pressure plate cover is installed on the engine flywheel. See the structure in Fig. 3-1. The facing
is located between the pressure plate and the flywheel. It is installed on the gear-box driving shaft
through spline. The release sleeve moves forwards and the release lever is pushed to make the
pressure plate leave the facing. In this way, the power from the engine is cut off.
49
Pressure plate cover
Pressure plate
Release lever
Section A-A
Transmission
Engine end
Fig. 3-1 Clutch Housing and Facing
50
3.1.2
Release bearing Pressure plate cover
Clutch slave cylinder

Release sleeve
Facing Release fork
Release lever
To be coated with molybdenum-base

lubricating grease for installation
Fig. 3-2 Lubrication Points of Clutch

Bushing
Add grease to 80% of its
spring and push rod. Pushing the push rod can drive the release lever to move.
capacity at least for installation To be coated with molybdenum-base
lubricating grease for installation
See the clutch slave cylinder in Fig. 3-3. It is installed at the left side of gear-box. It comprises piston,
51
1. Oil-drain valve 4. Cylinder block 7. Spring
2. Cup 5. Piston 8. Push rod
3. Dust cover 6. Locking nut 9. Connecting rod
Fig. 3-3 Clutch Slave Cylinder
3.1.3 Clutch master cylinder
See Fig. 3-4 for the structure of clutch master cylinder. It is installed on the clutch pedal. It comprises
piston, spring, oil cup and push rod. The pedal movement is transmitted to the piston through the
push rod. Then, the acting force of pedal is transformed into hydraulic force.
1. Connecting rod
2. Push rod
From oil cup 3. Dust cover
To clutch slave cylinder 4. Snap ring
5. Stop plate
Section A-A 6. Piston
7. Cup
8. Spring
9. Valve stem
10. Spring
11. Cup
12. Cylinder block
Fig. 3-4 Clutch Master Cylinder
3.1.4 Clutch pedal
The clutch pedal and brake pedal are installed on the same support. The support is installed on the
gear-box body. The pedal movement is transmitted to the master cylinder. Then, the acting force of
52
pedal is transformed into hydraulic force. The hydraulic force pushes the push rod of clutch slave
cylinder to transmit the movement to the release fork.
Pedal
Bushing Spring
Shaft
Clutch master cylinder
Connected with oil cup Clutch slave cylinder
Fig. 3-5 Clutch Pedal
3.2 Maintenance
3.2.1 Clutch pedal adjustment
(1) Remove the back plate;
(2) Loosen the locking nut of catch bolt;
(3) Rotate the catch bolt left/right to adjust the pedal height;
(4) Tighten the locking nut and install the back plate.
Fig. 3-6 Clutch Pedal Height
3.2.2 Facing replacement
(1) Remove the clutch housing cover plate;
(2) Depress the clutch pedal and withdraw the pressure plate with a pull bolt;
53
(3) Rotate the slide bolt left to make the driving shaft enter the gear-box;
(4) Remove the fixing bolt of pressure plate cover and take down the facing;
(5) Install the new facing, with the end with long spline towards the gear-box; Notice: Make sure
the driving shaft spline is fitted in the facing spline groove.
(6) Tighten the slide bolt to 10.9-12.1kg.m;
(7) Mount the pressure plate cover on the flywheel;
(8) Depress the pedal and take down the pull bolt;
(9) Check the free play of the pedal. Adjust it when necessary; (free play: 10mm)
(10) Keep a spacing of 14mm between the release rocker arm and catch bolt.
Pressure plate cover
Pressure plate Pull bolt
Fig. 3-7 Pull Bolt
Fig. 3-8 Clutch Slave Cylinder Adjustment
54
4. Hydraulic driving device
Torque converter
Type 3-element, single stage, double phase
Torque ratio 3
Set pressure 0.5~0.68MPa
Oil pump
Type Inside engaged gear type
Output 27L/min (2000, 1.5MPa)
Hydraulic gear-box
Type Power shift
Forward 1.35
Speed ratio
Backward 1.35
Hydraulic clutch
Facing OD X ID X thickness 125x81x2.7mm
Facing friction surface area 71cm2
Set pressure 1.1~1.4MPa
Weight 165kg
Oil capacity 7L
Engine oil SAE10W

Oil type
Domestic 6# hydraulic transmission oil
4.1 General
The hydraulic transmission forklift truck is equipped with the driving device composed of torque
converter and power shift gear-box. See Fig. 4-1. It has the following advantages:
(1) The inching valve can make the forklift truck perform inching operation with the engine running
at a low or high speed;
(2) The hydraulic clutch is provided with 4 pairs of specially treated paper facings and steel plates.
The resistance of friction pair to wear is improved.
55
Fig. 4-1 Hydraulic Driving Device
27. Elastic retainer ring for

1. Forward clutch 14. Control valve assembly 40. O-ring
hole
28. Single-row radial ball
2. Oil filter 15 Piston 41. Oil ring
bearing
29. Single-row radial ball 42. Single-row taper roller
3. Reverse clutch 16. Spring
bearing bearing
17. Oil filler cap 30. O-ring 43. Output shaft
bearing
5. Seal ring (A) 18. Safety valve cover 31. Retainer ring 44. Bearing plate
19. Hexagon socket head 45. Single-row radial ball
6. O-ring 32. O-ring
cap plug bearing
46. Hexagon socket head
7. Oil pump assembly 20. Plug 33. Idler gear
cap plug
8. Oil seal 21. Elastic cylindrical pin 34. Oil filter (I) 47. Housing cover
9. Pump impeller 22. Shifting arm 35. Output gear 48. Fixing bolt
10. Guide wheel 23. Housing cover 36. Idler shaft 49. Reversing lamp switch
11. Turbine 24. Shaft of shifting arm 50. Oil-drain plug
bearing
12. Spring plate assembly 25. O-ring 38. Bearing nut
39. Single-row taper roller
13. Inching valve assembly 26. Woodruff key
bearing
56
(3) The unidirectional overrunning clutch installed in the torque converter improves the power
transmission efficiency.
(4) The filter in the oil circuit of torque converter is of good quality and can extend the service life of
torque converter.
4.2 Torque converter
The torque converter mainly comprises pump impeller, turbine and guide wheel.
The pump impeller is driven by the input shaft. The fluid is sprayed along the blade grid of pump
impeller (the mechanical energy is transformed into kinetic power) to the blade grid of turbine under
the action of centrifugal force. The torque is transmitted to the output shaft. The direction of the fluid
away from the turbine is changed under the effect of guide wheel. Therefore, partial fluid returns to
the pump impeller at a certain angle. At this moment, a reacting torque propelling the guide wheel is
produced. Consequently, the output torque equals to the sum of the input torque and the reacting
torque. When the turbine speed increases and approaches the input speed, the variation of flow
angle decreases and the torque of output shaft decreases. Finally, the fluid flows into the blade grid
of guide wheel in the opposite direction. This makes the original reacting torque act reversely.
Consequently, the torque of output shaft is smaller than that of input shaft. To prevent this, the
overrunning clutch in the guide wheel enables the guide wheel to rotate freely when the reacting
torque acts reversely.
This type of torque conversion can guarantee efficient and stable operation.
The torque converter is connected with the engine flywheel through the elastic plate. It rotates with
the engine rotation. The torque converter is filled with torque converter oil. The main gear is
connected with the pump impeller with two claws to drive the oil pump. Then the oil pump supplies
oil to the torque converter and hydraulic shift gear-box. The turbine is connected with the turbine
shaft through spline. The power is transmitted to the power shift gear-box through the turbine shaft.
57
Turbine
Elastic plate
Pump impeller
Guide wheel
To clutch
Unidirectional clutch
Fig. 4-2 Torque Converter
4.3 Hydraulic clutch (Fig. 4-3)
The wet multi-plate hydraulic clutch is installed on the input shaft of hydraulic gear-box. It distributes
the hydraulic oil to the forward or reverse clutch through the control valve to realize gear shift. All
gears in the gear-box are normally engaged gears. Each clutch consists of four separators (24), 4
facings (25) and one piston. They are assembled alternately. The inner and outer annuluses of the
piston are provided with seal rings to ensure sealing for working. In case of neutral gear, the piston
does not act, and the separator and facing are separated. For gear shift, the oil pressure acts on the
piston, and the separator and facing press onto each other tightly. A shifting coupling is formed
relying on the friction force to transmit the power from torque converter to the driving gear (forward
gear 4 or counter gear opening).
The process of power transmission from the torque converter to hydraulic gear-box is as follows:
Turbine → input shaft assembly → separator → facing → forward gear or counter gear → output
shaft
58
Forward clutch pressure oil
Reverse clutch pressure oil
Connected with Lubricating oil

torque converter
Fig. 4-3 Hydraulic Clutch
1. Seal ring (A) 8. O-ring 15. Seal ring (A) 22. Check ball
2. Bearing 9. Input shaft assembly 16. Seal ring (A) 23. Piston assembly
3. Thrust shaft collar (B) 10. Seal ring (B) 17. Seal ring (A) 24. Separator
18. Thrust shaft collar

4. Forward gear 11. End plate 25. Facing
(B)
5. Clamp ring 12. Shaft collar (A) 19. Needle bearing 26. Return spring
6. Elastic retainer ring 13. Counter gear 20. Shaft collar (A) 27. Needle bearing
7. Spring seat 14. Bearing 21. Elastic retainer ring
4.4 Control valve, overflow valve and inching valve
4.4.1 Control valve: It is installed on the inside of gear-box housing cover. It includes control slide valve,
constant pressure valve and adjusting valve. See Fig. 4-4.
4.4.2 Constant pressure valve: It is used to control the hydraulic clutch oil pressure between
1.1-1.17MPa. The oil is distributed to the overflow valve and then to the torque converter through
this valve.
4.4.3 Adjusting valve: It is located between the inching valve and control slide valve. When the control
valve is opened fully, this valve works to reduce the impact at the time of engagement of hydraulic
clutch.
4.4.4 Overflow valve: It is connected with the gear-box housing body. It keeps the oil pressure of torque
converter between 0.5-0.7MPa to avoid damage.
4.4.5 Inching valve: It is installed outside the gear-box. Its spool is connected to the connecting rod of
inching pedal. When the inching pedal is depressed, this spool moves rightwards. The oil
59
pressure of hydraulic clutch is reduced for a short time. Thus, the inching of forklift truck is
realized. See Fig. 4-5.
Constant pressure valve
Adjusting valve
Control slide valve
Spring
Steel ball
Fig. 4-4 Control Valve
1. Elastic retainer ring

2. O-ring
3. Inching valve stem
5. Spring
6. Valve core
7. Spool
8. Valve body
9. Spring
10. O-ring
11. Cover
12. Oil seal
Fig. 4-5 Inching Valve
4.5 Gear-box housing
The gear-box housing is installed with input shaft and output shaft. In addition, it also acts as an oil
tank. The oil filter I is set at the bottom (150-mesh screen) to filter the oil entering the oil pump. The
pipeline oil filter II, oil filler cap and oil filter are installed above the housing cover.
60
4.6 Oil pump
The oil pump is installed between the torque converter and input shaft. The pump impeller shaft
drives the gear pump composed of a pair of inside engaged gears to supply oil to the torque
converter and hydraulic gear-box.
Drain hole
Driven gear
Driving gear
Oil seal Oil inlet

Pump body Cover
O-ring
Oil inlet of torque converter
Fig. 4-6 Oil Pump
4.7 Hydraulic oil circuit (hydraulic transmission) Fig. 4-7
After engine startup, the oil pump sucks oil from the oil tank (i.e., gear-box housing bottom). The oil
is filtered by an oil filter and then passes through the control valve. In the valve, the pressure oil is
divided into two parts. One part is used for the hydraulic clutch and the other part is used for the
torque converter.
The oil required for the hydraulic clutch flows through the constant pressure valve (the pressure of
this valve is adjusted to 1.1-1.4MPa). One part of the oil from the constant pressure valve further
flows to the inching valve and control slide valve. The other part flows into the torque converter
impeller via the overflow valve (the pressure is adjusted to 0.5-0.7MPa). The oil from the torque
converter is cooled by the oil cooler at first, then lubricates the hydraulic clutch, and at last, returns
to the oil tank.
At neutral gear, the oil circuit from the control slide valve to clutch is closed. At this time, the constant
pressure valve opens to make the oil pass through the overflow valve and then flow to the torque
converter fully. When the control slide valve is at forward or reverse position, the oil circuit from slide
valve to forward clutch or reverse clutch is connected. Therefore, each clutch can act separately.
When one clutch acts, the separator and facing of the other one are disengaged. The cold oil
performs lubrication and cooling. When the inching pedal operates the inching valve, part or most of
the oil introduced into the clutch is drained into the oil tank through the inching valve stem. At this
time, the oil circuit circulation of the torque converter is the same as that at neutral gear.
61
ON OFF
Constant pressure valve
Inching valve
Control slide Reverse – neutral - forward
valve
Adjusting valve
Oil filter
Oil pump
Torque converter
Oil filter
Reverse clutch
Overflow
valve
Oil cooler
Forward clutch
Fig. 4-7 Hydraulic Oil Circuit
4.8 Towing the forklift truck to be repaired
When the forklift truck malfunctions and needs to be towed by a vehicle, you shall
(1) Take down the half axle from the front wheel;
(2) Set the gear lever at neutral position.
62
4.9 Oil port connector position and oil pressure and temperature measurement (Fig. 4-8)
To the high-temperature oil port From the Side pressure hole of hydraulic
of oil cooler low-temperature clutch
oil port of oil
cooler
Hole for oil temperature gauge

Reversing lamp switch
Drain plug Neutral position switch
Filter
Inching valve
Fig. 4-8 Oil Temperature and Oil Pressure Measurement
5. Driving axle
Type Front wheel drive, rigidly connected axle body and frame, full floating
1-1.8t 2t-2.5t 3t-3.5t

Tonnage
Single tyre Single tyre Double tyres Single tyre Double tyres
Tyre size 2x6.5-10-10PR 2x7.00-12-12PR 4x7.00-12-12PR 2x28X9-15-12PR 4x28X9-15-12PR
Rim size 5.00F-10 500S-12 500S-12 7.00T-15 7.00T-15
Tyre
pressure 0.7MPa
63
Type Front wheel drive, rigidly connected axle body and frame, full floating
4t
Tonnage
Single tyre Double tyres
Tyre size 2x250-15-16PR 4x250-15-16PR
Rim size 7.5V-15 7.5V-15
Tyre
pressure 0.7MPa
5.1 General
The driving axle mainly consists of axle housing, hub, half axle and brake. The axle housing is an
integral cast structure. The tyre is fitted on the hub by studs and nuts through rim. The power is
transmitted to the half axle through the differential. At last, the hubs drive the front wheels to rotate.
Each hub is mounted on the axle housing through two taper roller bearings. Therefore, the half axle
only bears the torque transmitted to the hub. An oil seal is set in the hub to prevent water and dust
ingression and oil leakage.
Malfunction diagnosis and troubleshooting
Malfunction Possible Cause Solution

• Loose connecting bolt between driving axle supporting sleeve Tighten
and frame
• Loose wheel nut Tighten
Abnormal
• Worn or damaged bearing in hub Replace
noise
• Improperly adjusted bearing in hub Adjust
• Worn spline of axle shaft Replace
• Poor lubrication Lubricate
• Loose wheel nut Tighten
• Distorted wheel Replace
• Worn or damaged bearing in hub Replace
Unstable
• Loose connecting bolt between driving axle supporting sleeve Tighten
traveling
and frame
• Improperly adjusted bearing in hub Adjust
• Incorrect tyre pressure Adjust
• Worn or damaged axle shaft oil seal Replace
• Incorrectly installed main driving device Replace paper
Oil leakage
washer
• Loose drain plug Tighten
64
Axle housing
Half axle
Wheel brake
Brake drum
Oil seal
Taper roller bearing
Tightening
Tightening
Hub
torque:
torque:
Taper roller bearing
Oil seal
Tyre
Rim
Adjusting nut
Locking nut
View B
A 50% lubricating grease

Tightening torque for bolt with *
View B
Fig. 5-1 Driving Axle
65
5.2 Hub installation procedures
(1) Add 100cc lubricating grease into the

hub. Then, install the hub onto the shaft.
(2) Tighten the adjusting nut to the torque

1kg.m. Then rotate it back for 1/2 circle.
(3) Hang a spring balance on the bolt to

measure the starting torque of the hub.
When the specified value is reached, lock Adjusting nut
the nut slowly. Locking plate
Locking nut
Starting torque: 5-15kg.m
Fig. 5-2 Adding Lubricating Grease
(4) Install the locking plate and locking nut.

Pull up the locking plate to lock it.
(5) Assemble the tyre.
Install the valve stem and nut cap onto

Starting torque
the tyre. Assemble the rim. Pay attention
to the following points:
Fig. 5-3 Measuring Starting Torque
Note:
(a) The valve stem shall be located at

the rim notch outwards.
(b) The rim bolt head shall face towards

the outside.
66
Rim bolt structure
1. Tyre 4. Inner wheel

2. Valve stem 5. Outer wheel
3. Nut cap 6. Rim bolt
Fig. 5-4 Wheel Assembly
6. Steering system
Vehicle type
1-1.8T 2-2.5T 3-4T
Item
Type Rear wheel power steering
Steering gear type Cycloidal full hydraulic steering gear
Steering gear model BZZ1-100AA BZZ1-125AA
Type Double-acting piston type
Steering Bore Φ70mm

cylinder Piston rod diameter Φ50mm
Stroke 160mm
Rated pressure 7MPa 9MPa
Diameter Φ360mm Φ420mm
Tyre size 5.00-8-10PR 6.00-9-10PR 6.50-10-10PR
Tyre pressure 0.7MPa
6.1 General
The steering system mainly consists of steering wheel, steering shaft and steering gear. The
steering column is connected with the steering gear through the universal joint. The steering shaft is
connected with the steering wheel through the universal joint. The steering column can tilt forwards
or backwards properly. See Fig. 6-1.
The steering system applies a cycloidal full hydraulic steering gear. The steering wheel and steering
column control the full hydraulic steering gear. Then, the pressure oil from the steering gear drives
the steering cylinder to result in the rotation of steering knuckle and direction change of steering
wheels. In this way, the traveling direction of forklift truck is changed.
67
Fig. 6-1 Steering Control Device
6.2 Cycloidal full hydraulic steering gear
The cycloidal full hydraulic steering gear (Fig. 6-2) can quantificationally deliver the pressure oil
from the diverter valve to the steering cylinder through pipeline according to the rotation angle of
steering wheel. When the engine stops, the oil pump cannot supply oil. In this case, steering can be
done manually.
68
Fig. 6-2 Cycloidal Full Hydraulic Steering Gear
1. Limit stop 4. Universal driving shaft 7. Rotor
2. Valve body 5. Spring piece 8. Stator
3. Valve core 6. Connecting block 9. Valve sleeve
69
6.3 Check of reassembled steering system
(1) Turn the steering wheel to left and right limit positions. Check whether the forces are uniform
and whether the rotation is balanced;
(2) Check whether the oil pressure pipeline is installed correctly and whether the left steering and
right steering are set reversely;
(3) Jack up the rear wheels and slowly turn the steering wheel repeatedly to release the air out of
the hydraulic pipeline and oil cylinder.
6.4 Troubleshooting of steering system
Damaged or failed oil pump Replace

Failure to
rotate
Blocked or damaged diverter valve Clean or replace
steering
wheel
Damaged rubber hose or connector or blocked pipeline Replace or clean
Low pressure of diverter valve Adjust pressure
Difficult Air in oil circuit Release air

rotation of
steering Failed resetting of steering gear, broken or weak
Replace spring piece
wheel retaining spring
Severe internal leakage of steering cylinder Check piston seal
Adjust the flow from diverter

Crawl or Too large steering oil flow
valve
swing of
forklift truck
Broken or weak spring Replace
Low oil level in oil tank Add oil

Loud working
noise
Blocked suction pipe or oil filter Clean or replace
Damaged guide sleeve seal of steering cylinder,

Oil leakage Replace
pipeline or connector
70
7. Steering axle
7.1 General
The steering axle is a welding structure with box section. See Fig. 7-1. It comprises steering axle
body, steering cylinder, connecting rod, steering knuckle and steering wheel. The ackerman steering
applies slider-crank mechanism. The steering cylinder piston rod drives the steering knuckle
through the connecting rod under the action of pressure oil to make the steering wheels deflect. In
this way, steering is realized. The steering axle is connected to the tail frame through a buffer seat.
Fig. 7-1 Steering Axle
1. Steering axle body 9. King pin of steering knuckle 17. Hub nut
2. Connecting rod 10. Tyre 18. Oil seal
3. Steering cylinder 11. Oil seal 19. O-ring
4. Rear axle bearer 12. Taper roller bearing 20. Bushing
5. Bushing 13. Taper roller bearing 21. Dust cover
6. Right steering knuckle 14. Hub cover 22. Left steering knuckle
assembly assembly
7. Thrust bearing 15. Hub
8. Needle bearing 16. Hub bolt
71
7.2 Steering knuckle and steering king pin
The steering knuckle is installed between the upper and lower parts at both ends of steering axle
body by the steering king pin, taper bearing, dust cover and O-ring. The upper and lower ends of the
king pin are fixed on the axle body with a retainer pin and a nut split pin respectively. The bearing is
supported by the taper bearing pressed on the axle body.
Oil seal
Taper bearing
Thrust bearing Steering knuckle

Steering knuckle
Retainer pin
Bushing
Steering king pin
Fig. 7-2 Steering Knuckle
7.3 Hub
The hub is installed on the steering knuckle shaft by two taper roller bearings. The wheel is fitted
onto the hub through the rim. The bearing inside is provided with an oil seal to keep the lubricating
grease in the hub and steering knuckle chamber. The nut is used to adjust the tightness of bearing.
7.4 Steering cylinder
The steering cylinder is of double-acting piston type. The piston seal is a combined seal composed
of supporting ring and O-ring. A YX-type seal ring is set between the cylinder head and piston rod.
The cylinder is fixed on the steering axle through the cylinder head at both sides.
72
Fig. 7-3 Steering Cylinder (2~3.5t)
1. Piston rod assembly 2. Cylinder head 3. Dust ring 50 x 72 4. YX-type seal ring 50x65x9
5. O-ring 65x3.55 6. O-ring 65x3.55 7. Supporting ring 8. Cylinder block
7.5 Adjustment of pretension load on steering wheel bearing
(1) Lubricate the hub, inner and outer

bearings, internal chamber of hub
cover, and oil seal lip. See Fig. 7-4.
(2) Fix the bearing cup on the hub. Install

the hub onto the steering knuckle shaft.
(3) Install the plain washer and tighten the

slotted nut to a torque between 206N.m
and 235N.m (21-24kg.m). Loosen the
slotted nut and then tighten this nut to
9.8N.m (1kg.m). Adding lubricating gr
ease
(4) Beat the hub lightly with a wood
hammer to rotate the hub for 3-4
circles. Make sure the rim is not loose.
(5) Tighten the slotted nut and align the

slot with the split pin hole on the
steering knuckle.
Fig. 7-4 Adjustment of Pretension Load
(6) Beat the hub lightly again with the wood
hammer. Rotate the hub for 3-4 circles
by hands to ensure stable rotation.
Measure the rotating torque of the hub.
It shall be 2.94-7.8N.m (0.3-0.8kg.m).
(7) When the rotating torque exceeds the

specified value, rotate the hub back for
1/6 circle. Measure the torque again.
(8) When the specified torque is reached,

lock the slotted nut with the split pin.
73
8. Braking system
Type Front wheel brake, internal expanding, hydraulic
Pedal lever ratio 5.66
Master cylinder bore 19.05mm
Wheel brake 1-1.8t 2-2.5t 3-4t
Type: Dual servo type with parking brake
Wheel cylinder bore 22.22mm 28.58mm
Friction plate size

279x48.5x5mm 324x60x7mm 348x76x8mm
(LXWXH)
Friction plate area 135.3cm2 x4 194.4cm2 x4 264cm2 x4
Brake drum ID 254mm 310mm 314mm
Parking brake: Front wheel brake, internal expanding, hydraulic
8.1 General
The braking system is of front wheel brake type. It consists of brake master cylinder, brake and
brake pedal mechanism.
8.1.1 Brake pedal
See the brake pedal in Fig. 8-1. It is installed on the gear-box through a support. When the pedal
moves, it pushes the tappet to drive the piston to run. Consequently, the oil circuit pressure is
increased.
Shaft Brake pedal

Inching pedal
Spring Spring
Bushing G
Bushing
Master cylinder
Bushing
Bushing
Front To wheel brake
Inching valve (spool)
Fig. 8-1 Brake Pedal
8.1.2 Master cylinder
The master cylinder includes one valve seat, one one-way valve, one return spring, cup, piston and
74
auxiliary cup. The end is fixed with a stop washer and retaining wires. The exterior is protected by a
rubber dust cover. The master cylinder piston operates through the push rod by controlling the brake
pedal. When the brake pedal is depressed, the push rod pushes the piston forwards. The brake fluid
in the cylinder returns to the oil tank via the oil return port until the main cup blocks the oil return port.
After the main cup passes through the oil return port, the brake fluid in the front chamber of master
cylinder is compressed and opens the one-way valve. Thus, the brake fluid flows to the wheel
cylinder through the brake pipeline. In this way, each wheel cylinder piston extends outwards. This
makes the brake shoe lining touch the brake drum. Afterwards, deceleration or braking is achieved.
At this time, the rear chamber of piston is filled with the brake fluid from the oil return port and oil
inlet. When the brake pedal is released, the piston is pressed backwards by the return spring and
the brake fluid in each brake wheel cylinder is pressed by the brake shoe return spring. Then, the
brake fluid returns to the master cylinder (front chamber of piston) via the one-way valve and the
piston returns to its original position. The brake fluid in the master cylinder returns to the oil tank
through the oil return port. The pressure of the one-way valve is adjusted to be in proportion to the
rest pressure in the brake pipeline and brake wheel cylinder. This ensures correct position of wheel
cylinder cup, so as to prevent oil leakage and vapor lock that may occur during emergency braking.
1. Connecting rod
From oil tank 2. Push rod

3. Dust cover
5. Auxiliary cup
6. Piston
To wheel brake 7. Main cup
8. Spring
9. One-way valve
Fig. 8-2 Brake Master Cylinder
8.1.3 Wheel brake
The wheel brake is an internal expanding and hydraulic brake. It consists of brake shoe, spring,
wheel cylinder, adjuster and back plate. Two brakes are installed at both ends of the front axle
respectively. One end of the brake shoe is connected with the supporting pin. The other end is
connected with the clearance adjuster and pressed to the back plate by the spring and pressure
spring pull rod. The main brake shoe is provided with a hand brake pull rod. The auxiliary brake
shoe is provided with the adjusting lever of the automatic clearance adjuster. See Fig. 8-3 and Fig.
8-4.
75
1. Spring
2. Cup
3. Piston
4. Cylinder block
5. Piston top rod
6. Return spring
7. Ram
8. Return spring
9. Adjusting lever
10. Auxiliary brake shoe
11. Clearance adjuster
12. Spring
13. Brake cable assembly
14. Pressure spring cover
15. Pressure spring pull rod
16. Hand brake pull rod E-type retainer ring
17. Hand brake push rod

18. Brake wheel cylinder assembly Fig. 8-3 2-2.5t Wheel Brake
19. Return spring
20. Main brake shoe
76
1. Brake wheel cylinder assembly
2. Spring Bolt tightening torque
3. Cup
4. Piston
5. Wheel cylinder protective cover
6. Piston top rod
7. Brake shoe return spring
8. Spring
9. Hand brake pull rod
10. Spring cable
12. Brake shoe
13. Pressure spring seat
15. Pressure spring
16. Spring
17. Pawl
18. Spring Fig. 8-4 3-4t Wheel Brake
19. Clearance adjuster assembly
20. Pin
21. Back plate
22. Brake shoe return spring
23. Hand brake pull rod
24. Brake cable assembly
77
Fig. 8-5 1-1.8t Wheel Brake (Left)
1. Wheel cylinder 8. Brake shoe return 15. Return spring 22. Pressure ring seat
piston top rod spring
2. Protective cover 9. Spring 16. Pawl 23. Hand brake pull rod
3. Piston 10. Hand brake pull rod 17. Spring 24. Main brake shoe
4. Spring 11. Spring cable 18. Clearance adjuster 25. Return spring
5. Cup 12. Pressure spring pull 19. E-type retainer ring

rod
6. Wheel cylinder 13. Pressure spring 20. Parking brake cable

seat
7. Auxiliary brake 14. Spring 21. Pressure spring pull

shoe rod
(1) Brake action
The brake action during forward traveling is as follows. See Fig. 8-6. After the brake wheel
cylinder is operated, the main brake shoe and auxiliary brake shoe are under the action of two
equal and opposite forces. This results in contact between the friction plate and brake drum.
The main brake shoe is pressed onto the adjuster under the effect of friction between the
78
friction plate and brake drum. Accordingly, the clearance adjuster produces a force to push the
auxiliary brake shoe. This force is larger than that for operating the wheel cylinder and compels
the upper end of auxiliary brake shoe to press to the supporting pin with a large force. Thus, a
large braking force can be obtained. For the brake action during reversing, the direction is
opposite but the braking force is the same compared with that during forward traveling.
Rotation direction of brake drum
Supporting pin
Working force Working force
Main brake shoe Auxiliary brake shoe Main brake shoe Auxiliary brake shoe
Adjuster
Fig. 8-6 Brake Action During Forward Traveling Fig. 8-7 Brake Action During Reversing
(2) Parking brake
The parking brake is a mechanical and internal expanding brake. It is located in the wheel
brake. It shares the brake shoe and brake drum with the foot brake. When pulling the parking
brake handle, the brake handle drives the hand brake pull rod through the brake cable. With the
assistance of the pin acting as a rotating shaft, the pull rod pushes the hand brake push rod
rightwards to press the brake shoe to the brake drum.
Pin Auxiliary brake shoe
Pull rod Supporting rod
Main brake shoe
Fig. 8-8 Parking Brake
(3) Automatic clearance adjusting mechanism
The automatic clearance adjusting mechanism can keep a proper clearance between the
friction plate and brake drum. See the structure in Fig. 8-9 and Fig. 8-10. It acts only during
reversing. There are two automatic adjusting mechanisms of different structures depending on
the vehicle type.
79
Cable
Spring
Guide plate
Spring
Pawl
Adjuster
Adjuster
Hand brake pull rod
Fig. 8-9 2-5t Forklift Truck Fig. 8-10 1-1.8t/3-4t Forklift Truck
Automatic clearance adjusting

mechanism
(A) For 2-2.5t forklift trucks
The automatic clearance adjusting

mechanism can act only during
reversing. The auxiliary and main
brake shoes contact and rotate
together. Consequently, the pull rod
rotates rightwards around point A.
See Fig. 8-9. Accordingly, point B is
raised. After brake release, the pull
rod rotates leftwards under the action
of spring force and point B is lowered.
When the clearance between the

friction plate and brake drum
Elongating along this
increases, the vertical distance for direction
pawl rotation at point B increases as
well. When the clearance exceeds
0.4mm, the adjuster gear will be Fig. 8-11 Automatic clearance adjusting mechanism
moved by one tooth. Consequently, (2-2.5t)
the adjuster rod elongates and the
clearance becomes small.
Clearance range: 0.4-0.45mm
(b) For 1-1.8t~3-4t forklift trucks
During reversing, the auxiliary and

main brake shoes contact and rotate
together. Consequently, the pull rod
rotates rightwards around point A.
Then, the pawl at point B moves the
80
adjuster gear.
After brake release, the brake shoe

returns its original position, the pull
rod rotates leftwards around point A
and point B is lowered. In this way,
when the clearance increases, the
adjuster gear will be moved by one
tooth.
Clearance range: 0.25-0.4mm
8.1.4 Parking brake handle
The parking brake handle is of cam

type. The braking force can be
adjusted by the adjuster at the end of
brake handle.
Adjustment of braking force:

Elongating along this
Rotate the adjuster clockwise and the direction
braking force increases. Rotate the
adjuster anticlockwise and the
Fig. 8-12 Automatic Clearance Adjusting Mechanism
braking force decreases.
(1-1.8t, 3-4t)
Pull force: 20-30kg
Note: For 2-2.5t forklift trucks, adjust

the braking force by rotating the
screw in the adjuster.
8.1.5 Adjustment of brake pedal
(1) Shorten the push rod;
(2) Adjust the catch bolt to adjust the

pedal height. See Fig. 8-14.
(3) Depress the brake pedal to elongate Right cable

the push rod until the front end of Left cable
push rod touches the master cylinder
piston.
(4) Tighten the locking nut of push rod.
Fig. 8-13 Parking Brake Handle
81
Unit: mm
Engine Free Play

Heigh
Tonnage
Height t Brakin Inchin
Type g g
4G64 1-1.8T
T
Turbocharge 100 50 0
C
d
2~3.5T
T
116 30 0
C
Fig. 8-14 Pedal Height Adjustment GM3. 4T

0 T
Turbocharge 119 30 0
C
d
TC: Torque converter type forklift truck

Adjustment of brake switch
(a) After adjusting the brake pedal

height, loosen the locking nut of
brake switch.
(b) Pull out he connector to Brake switch
disconnect the wire.
(c) Adjust the brake switch to make

Locking nut
the clearance A = 1mm.
(d) Make sure the brake lamp is lit up

when depressing the brake
pedal.
8.2 Maintenance
This section introduces the

disassembly, reassembly and
adjustment of brake and the
adjustment of brake pedal. It is Fig. 8-15
applicable to the brakes of 1-1.8t and
3-4t forklift trucks. For the brakes of
2-2.5t forklift trucks, although the
adjuster structure is different, the
maintenance method is basically the
same.
82
8.2.1 Disassembly of wheel brake
(1) Remove the retainer pin,

adjusting lever, adjuster and
spring from the auxiliary brake
shoe.
(2) Remove the return spring of

brake shoe.
Fig. 8-16
(3) Remove the retainer spring of

main brake shoe.
Fig. 8-17
(4) Remove the main brake shoe,

auxiliary brake shoe and adjuster
spring.
Fig. 8-18
(5) Remove the brake pipeline from

the wheel cylinder, and then
remove the mounting bolt of
wheel cylinder to separate the
wheel cylinder from the back
plate.
Fig. 8-19
83
(6) Remove the E-type retainer ring
fixing the brake cable to the back
plate. Remove the mounting bolt
of back plate and take down the
back plate from the axle.
Fig. 8-20
(7) Remove the wheel cylinder dust

cover and push all parts out of
the cylinder.
8.2.2 Wheel brake check
Check all parts for wear and damage.

In case of any unacceptable part,
repair or replace it.
(1) Check the inner surface of wheel

Fig. 8-21
cylinder block and the cylindrical
surface of piston for rust.
Measure the clearance between
the piston and cylinder block.
Specified value: 0.03-0.10mm
Limit: 0.15mm
(2) Visually check the cup for

damage and distortion. If any,
replace it.
Fig. 8-22
(3) Check the free length of the
cylinder spring. If unacceptable,
replace it.
(4) Check the thickness of friction

plate. In case of excessive wear,
replace it.
Unit: mm
1~1.8t 2~2.5t 3~4t
Standard 4.87 7.2 8

Fig. 8-23
Limit 5.0 6
(5) Check the inner surface of the
84
brake drum. In case of damage
or excessive wear, repair or
replace it.
Unit: mm
1~1.8t 2~2.5t 3~4t
Standard 254 310 314
Limit 256 312 316
8.2.3 Reassembly of wheel brake

Fig. 8-24
(1) Dip the wheel cylinder cup and
piston in brake fluid. Then,
sub-assemble the spring, cup,
piston and protective cover.
(2) Install the wheel cylinder on the

back plate. Tightening torque:
1~1.8t: 8~12N.m
2~2.5t: 14.7~19.6N.m
3~4t: 17.6~26.5N.m
(3) Install the back plate onto the

front axle.
Tightening torque:
20.6~22.5N.m Fig. 8-25

(4) Add lubricating oil to the
lubrication points shown in Fig.
8-25.
(a) Supporting surface of back

plate
(b) Supporting pin
(c) Contact surfaces between

the brake shoe and pressure
spring seat
(d) Supporting pin of hand Fig. 8-26

brake pull rod
(e) Adjuster thread and other

rotating parts
(5) Install the brake cable assembly

onto the back plate with the
85
E-type retainer ring.
(6) Install the brake shoe onto the

back plate with the retaining
spring.
(7) Install the pressure spring onto

the hand brake push rod, and
then install the push rod onto the
brake shoe.
(8) Install the guide plate of brake

shoe onto the supporting pin, and
then install the return spring of
brake shoe. Install the main
brake shoe at first, and then
install the auxiliary brake shoe.
Fig. 8-27
(9) Install the adjuster, adjuster

spring, ram and ram return
spring.
Pay attention to the following

points:
(a) The thread direction and

installation direction of the
adjuster
(b) The direction of adjuster

spring (the adjuster gear
cannot touch the spring).
Fig. 8-28
(c) The direction of ram return
spring (the spring hook at the
supporting pin end shall be
fixed at the opposite side of
ram).
(d) The lower end of adjusting

lever shall touch the adjuster
gear.
(10) Connect the brake pipe to the

wheel cylinder.
86
(11) Measure the inner diameter of
brake drum and outer diameter of
brake shoe. Operate the adjuster
to make the diameter difference
be 1mm.
Fig. 8-29
8.2.4 Operation test of automatic clearance adjuster
(1) Make the diameter of the brake shoe close to the specified installation dimension. Pull the
adjusting lever by hands to rotate the adjuster. When it is released, the adjusting lever returns
to its original position while the adjuster gear does not rotate.
Notice: Even the adjuster gear and adjusting lever return together after the lever is released,
the adjuster can still work normally after installation.
(2) If the adjuster cannot act as mentioned above when the adjusting lever is pulled, carry out the
following check.
(a) Check whether the adjusting lever, ram, ram spring and pressure spring seat are installed
firmly.
(b) Check the ram return spring and adjuster spring for damage. Check the rotation of adjuster
gear and check the meshing parts for excessive wear and damage. Check whether the
lever touches the gear. Replace the damaged parts.
Expansion direction
Fig. 8-30
87
8.2.5 Troubleshooting
1 Oil leakage of braking system Repair
2 Improper clearance of brake shoe Adjust adjuster
3 Overheating of brake Check for sliding

Poor braking
4 Poor contact between brake drum and friction plate Adjust again
effect
5 Impurities on friction plate Repair or replace
6 Impurities in brake fluid Check brake fluid
7 Improperly adjusted brake pedal (inching valve) Adjust
1 Hardening of friction plate surface or impurities on it Repair or replace
2 Distorted back plate or loose bolt Repair or replace

Noise from
3 Distorted brake shoe or incorrect installation Repair or replace
brake
4 Worn friction plate Replace
5 Loose wheel bearing Repair
1 Oil dirt on friction plate surface Repair or replace
Uneven braking 3 Failed wheel cylinder Repair or replace
4 Damaged return spring of brake shoe Replace
5 Deflected brake drum Repair or replace
1 Oil leakage of braking system Repair or replace

Weak braking
3 Air in braking system Release air
4 Improperly adjusted brake pedal Adjust again
88
8.2.6 ! Warning
Safe parking
(1) Park the forklift truck on level ground. Spacious places are the best. If it is unavoidable to park
the forklift truck on a slope, set it on the slope transversely and wedge the wheels with wedge
blocks to prevent sliding.
(2) Park the forklift truck at the specified place or at a place not blocking the driveway. If necessary,
set a sign or a signal lamp.
(3) Park the forklift truck on hard ground instead of soft, muddy or slippery road.
(4) If the lifting system is damaged and the forks cannot fall to the ground, hang a warning flag at
the fork end and park the forklift truck at a place not blocking the driveway.
! Warning
(1) Check whether the pedal for climbing and the bottom plate are slippery.
(2) Never get up or down the forklift truck during traveling.
(3) Never jump off the forklift truck.
Ground conditions
The performance of the forklift truck depends on the ground conditions. The traveling speed shall be
adjusted properly. Take special care when operating the forklift truck on a slope or rough road
surface.
Road covered with snow or ice
When driving on a road covered with snow or ice, use tyre chains. Never perform sudden
acceleration or turn. Control the traveling speed through the accelerator pedal effort.
89
9. Hydraulic system
Model 1~1.8t 2~2.5t 3~3.5t 4t
Item Gasoline Engine Gasoline Engine Gasoline Engine Gasoline Engine
Engine model 4G64 4G64 4G64 GM3.0
Type Gear pump
Main
Model CBD-F32F1H6L-CC
pump
Output 32ml/r
Double slide valve type, with overflow valve, diverter valve and tilting self-locking
Type
valve
Adjusted
17.5MPa
pressure
Multi-way
valve
Diverting
7MPa 9MPa
pressure
Diverting
11L/min 13L/min
flow
Type Single-acting piston, with cut-off valve
Lifting
Bore Φ45 Φ50 Φ56
cylinder
Stroke 1495mm (lift height of 3m)
Type Double-acting piston
Tilting
Bore Φ70
cylinder
Stroke 167mm
Oil tank capacity 18L 32L
90
Structural diagram of hydraulic system
Multi-way valve
Steering gear
Multi-way change
Lifting cylinder
valve
Workflow diagram of hydraulic system
Multi-way change
valve
Tilting cylinder
Working oil tank
Oil pump
Diverter valve
Working oil tank

Steering cylinder
Full hydraulic
steering gear
Full hydraulic
steering gear
9.1 General
The hydraulic system consists of main oil pump, multi-way valve, lifting cylinder, tilting cylinder and
pipeline. The oil tank is installed at the right side of body.
9.2 Main pump
The main pump is a gear pump. It is driven directly by the engine power output device. The oil from
oil tank is delivered to the multi-way valve through the main pump.
91
The main pump comprises pump body, a pair of gears, liner plate and retainer ring. The pressure
balanced bearing and special lubrication mode result in extremely small gear backlash. For the
pressure balanced method, the oil drain between the liner plate and pump body presses the liner
plate to the gear side.
(1) Precautions for use
(a) The full-open pressure of the safety valve cannot exceed the highest pressure of the oil
pump.
(b) The hydraulic oil shall be of the specified grade. The highest oil temperature shall be 20℃
-60℃.
(c) If the oil pump is to be idled for a long time, disconnect the oil pump from the engine. When
using the oil pump again, run it with no load for 10min at least.
(d) During use, frequently check the oil pump for oil leakage, abnormal noise and impact. In
case of any problem, do troubleshooting in time.
1. Pump body
2. Driving gear
3. Driven gear
4. Front end cover
5. Rear end cover
6. Liner plate
7. Seal ring
8. Retainer ring
9. Oil seal
View B-B View A-A
Fig. 9.1 Main Pump
9.3 Multi-way valve and diverter valve
The two-throw multi-way valve consists of 4 valve bodies, 2 slide valves, one safety overflow valve
and one diverter valve. The 4 valve bodies are assembled together by 3 stud bolts and nuts. The
92
tilting slide valve is provided with a tilting self-locking valve.
Main overflow valve

Lifting valve stem
Tilting valve stem
To oil tank
Fig. 9-2 Multi-way Valve
93
9.3.1 Operation of slide valve (take the tilting
slide valve as the example)
(1) Neutral position (Fig. 9-3)

Oil-in one-way valve
The high-pressure oil from the oil Main oil inlet
Cylinder connector B
pump returns to the oil tank via the Cylinder connector A
neutral position. Return spring
(2) Pushing into the slide valve (Fig. 9-4)
The middle passage is closed. The oil

from the oil inlet opens the one-way Slide valve
valve and flows to oil cylinder Middle passage Low-pressure passage
connector B. The oil from oil cylinder
connector A flows into the oil tank via
Fig. 9-3
the low-pressure passage. With the
assistance of return spring, the slide
valve can return to the neutral
position.
(3) Pulling out the slide valve (Fig. 9-5)
The neutral position is closed. The oil

from the oil inlet opens the one-way
valve and flows to oil cylinder
Fig. 9-4
connector A. The oil from oil cylinder
connector B flows into the oil tank via
the low-pressure passage. With the
assistance of return spring, the slide
valve can return to the neutral
position.
Fig. 9-5
9.3.2 Main safety overflow valve and diverter safety valve (Fig. 9-6)
The main safety overflow valve includes main valve A and leading valve B. When the multi-way
valve reverses, the high-pressure oil of chamber Q and that of working mechanism (such as lifting
cylinder and tilting cylinder) are connected. The pressure oil acts on leading valve B through fixed
throttle holes D and E. When the system pressure exceeds the setting pressure, leading valve B
opens to lower the pressure in chamber F. Then, the whole main valve core A moves rightwards.
Consequently, the pressure oil flows through low-pressure passage G and chamber Q is unloaded.
This guarantees stable system pressure. Adjusting screw H can be used to adjust the stable
pressure of the system.
The diverter safety valve is a direct-acting overflow valve. The structure is simple. The stable
94
pressure of the steering system is obtained based on the principle that the fluid pressure directly
equals to the spring force. When the steering wheel is operated, oil chamber M is connected with
the high-pressure oil circuit. When the system pressure exceeds the spring pressure, valve core N
moves rightwards. The pressure oil flows to the low-pressure oil circuit from chamber T to unload
chamber M. This guarantees stable system pressure. Adjusting screw K can be used to adjust the
stable pressure of the system.
Valve L is a balance valve. The variation of flow and pressure makes slide valve L move left or right
to change the opening at R and S. This is to guarantee the automatic balance between the flow to
working chamber Q/outlet PS and the flow to full hydraulic steering gear and proportionally stable
diversion. a refers to the fixed throttle hole.
To steering gear Oil inlet
Fig. 9-6
9.3.3 Operation of tilting self-locking valve

Tilting cylinder
The tilting slide valve is provided with a
self-locking valve. It is mainly used to
prevent the possible vibration caused by
the negative pressure in the tilting cylinder
and the severe consequences due to
misoperation. For general conventional
structure, the tilting slide valve can be
operated for forward tilting after engine Valve
Spring core Slide valve
stop. However, for the tilting self-locking
valve, after engine stop, even the control
lever is pushed forcefully, the mast will not Fig. 9-7
be tilted. See its structure in Fig. 9-7.
Cylinder connectors A and B are connected to the front and rear chambers of tilting cylinder piston
95
respectively. When pulling out the slide valve, the high-pressure oil (P) flows into connector A. The
oil in the rear chamber returns to the oil tank (T) via connector B. At this time, the mast tilts
backwards.
When pushing the tilting slide valve, the high-pressure oil flows into connector B. Under the action of
the high-pressure oil, the self-locking valve in the slide valve acts. Connector A is connected to low
pressure. When the engine stalls or stops, no high-pressure oil is used to make the self-locking
valve in the slide valve act, so connector A cannot be connected to low pressure. Consequently, the
mast will not tilt forwards and negative pressure cannot be set up in the tilting cylinder.
9.4 Oil circuit of hydraulic system (main oil circuit) (Fig. 9-8)
The high-pressure oil from the main oil pump reaches the multi-way valve and then is divided into
two parts by the diverter valve. One part is delivered to the lifting cylinder or tilting cylinder. The
other part is delivered to the steering gear with a constant flow to control the steering cylinder. When
the lifting slide valve and tilting slide valve are at neutral position, the high-pressure oil directly
returns to the oil tank. When the lifting slide valve is pulled, the high-pressure oil passes through the
throttle valve. Then, the lifting cylinder piston pushes up the piston rod. When the lifting slide valve is
pushed, the lower part of lifting cylinder piston is connected to low pressure. The piston rod falls
relying on its dead weight and goods weight. At this time, the oil from the lifting cylinder flows
through the throttle valve to control the falling speed. When the tilting slide valve is operated, the
high-pressure oil flows into the front chamber of tilting cylinder. The other side is connected with low
pressure to make the mast tilt backwards or forwards.
Fig. 9-8 Oil Circuit of Hydraulic System

96
9.5 Control of multi-way valve
The multi-way valve is controlled by control levers. All control levers are installed on one connecting
shaft. The shaft is fixed on the instrument panel through a support. The control levers control the
slide valve through the connecting rod.
Lifting control lever: For lifting or lowering the mast
Tilting control lever: For tilting the mast forwards or backwards
Attachment control lever: For attachment installation (one triple valve and two quadruple valves)
Tilting control lever Attachment control lever Symbol for lowering control lever
(option)
Lifting control lever Symbol for lifting control lever
Symbol for forward tilt control lever
Symbol for backward tilt control lever
Multi-way valve
Fig. 9-9 Control of Multi-way Valve
9.6 Lifting cylinder
The lifting cylinder is a single-acting piston type cylinder. It consists of cylinder block, piston rod,
piston and cylinder head. The bottom of the lifting cylinder is fixed to the lifting cylinder seat of outer
mast by pins and bolts. The top of the lifting cylinder (namely the piston rod top) is connected with
the upper cross beam of outer mast.
The piston is fixed on the piston rod with elastic steel wires. The piston outer ring is provided with an
oil seal and a supporting ring.
A cut-off valve is installed at the cylinder bottom. It can provide protection in case of sudden mast
lifting or sudden burst of high-pressure hose.
The cylinder head is equipped with a steel-backed bearing and an oil seal to support the piston and
prevent dust.
97
1. Upper cross beam
2. Adjusting gasket
3. Dust ring
4. Oil seal
5. Guide sleeve
6. O-ring
7. Cylinder head
8. Steel-backed bearing
9. Cylinder block
10. Piston rod
11. Piston
12. Cylinder block
13. Oil seal
14. Seat ring
16. Cut-off valve
17. Elastic locking ring
18. Split pin
19. Locking nut
20. Adjusting nut
21. End connector
22. Chain
23. Sprocket wheel
Fig. 9-10 Lifting Cylinder
A cut-off valve is installed at the cylinder bottom. See Fig. 9-11. It is used to prevent the goods from
falling quickly in case of sudden burst of high-pressure hose. The oil from the lifting cylinder passes
through the cut-off valve slide valve. The oil holes around the slide valve produce a pressure
difference between the two chambers. When this pressure difference is smaller than the spring
force, the slide valve does not act. If the high-pressure hose bursts, a large pressure difference will
be produced. Consequently, the slide valve will move to block the surrounding oil holes and only a
little of oil will flow through the hole at the slide valve end. In this case, the forks will fall slowly.
98
Normal Cut-off
Fig. 9-11
9.7 Speed limit valve
The speed limit valve (namely throttle valve) is installed in the oil circuit of lifting cylinder. It is used to
limit the falling speed of laden forks. See Fig. 9-12 for its structure. When the multi-way valve slide
valve is at “Lift” position, the high-pressure oil from the multi-way valve passes through chambers A
and B, holes C, D, E and F, and chamber G without throttling, and then flows into the lifting cylinder.
When the multi-way valve slide valve is at “Fall” position, the oil from the life cylinder passes through
chamber G, holes F, E, D and C, and chambers B and A. It flows through the whole valve. Then, a
pressure difference between chambers A and B is produced and the ball valve (part 8) is opened.
When the pressure difference exceeds the spring force of spring 2, valve core 7 moves rightwards
to make the oil flow lessen due to narrowed holes D and C. Accordingly, the oil flowing through the
orifice also reduces.
99
Normal flow direction
Frequent flow direction
Lifting cylinder side Multi-way valve side
1. Connector 3. O-ring 5. Throttle plate 7. Valve core 9. Spring
2. Spring 4. Retainer ring 6. Valve sleeve 8. Nylon ball 10. Valve body
Fig. 9-12 Speed Limit Valve
9.8 Tilting cylinder (Fig. 9-13)
The tilting cylinder is a double-acting cylinder. It is installed at both sides of the mast. Its piston rod
end is connected with the mast. The tilting cylinder bottom is connected with the frame with pins.
The tilting cylinder assembly consists of piston, piston rod, cylinder block, cylinder bottom, guide
sleeve and seal. The piston and piston rod are of welding structure. The piston outer ring is provided
with a supporting ring and two Yx-type seal rings. The inner hole of guide sleeve is equipped with a
shaft sleeve, a Yx-type seal ring, a retainer ring and a dust ring. The shaft sleeve supports the piston
rod. The seal ring, retainer ring and dust ring can prevent oil leakage and dust ingression. They are
fitted onto the cylinder block together with the O-ring.
1. Eye ring 5. O-ring 9. Piston rod 13. Piston

2. Dust ring 6. Guide sleeve 10. Cylinder block 14. Yx-type seal ring
3. Retainer ring 7. Shaft sleeve 11. Yx-type seal ring
4. Yx-type seal ring 8. O-ring 12. Supporting ring
Fig. 9-13 Tilting Cylinder
100
When the tilting cylinder slide valve is pushed forwards, the high-pressure oil enters the cylinder
from the bottom and pushes the piston forwards to tilt the mast forwards for 6°. When the slide valve
is pulled backwards, the high-pressure oil enters the cylinder from the front end of cylinder block
and pushes the piston backwards until the mast tilts backwards for 12°.
9.9 Hydraulic oil tank
The hydraulic oil tank is a member of the frame. It is installed on the right box body. An oil suction
filter and an oil return filter are set in the tank to filtrate foreign objects.
Vent plug
Hydraulic oil dipstick
Oil return of multi-way valve
To main pump
Oil return of steering gear
Drain plug
Oil return filter Oil suction filter
Fig. 9-14 Hydraulic Oil Tank
101
Oil tank
Tilting cylinder (RH)
Hydraulic pressure
To lifting cylinder
Main pump
detection plug
Steering cylinder
Multi-way valve
Steering gear
Tilting cylinder
(LH)
Fig. 9-15 Hydraulic Pipeline (1-4t)
9.10 Maintenance of main oil pump
(1) Disassembly
Before disassembly, clean the main oil pump thoroughly. Place the removed parts on a piece of
clean paper or cloth. Do not spot or operate any part.
(a) Clamp the flange of pump on the vice bench.
(b) Remove the connecting bolt 11, pump cover 5 and pump box 1.
(c) Remove the liner plate 6, driving gear 2 and driven gear 3.
(d) Remove the seal ring 7 and retainer ring 8 from the front and rear end covers.
Notice: If the seal ring will not be replaced, do not remove it from the front end.
102
(2) Check
Check the disassembled parts. Clean

them with gasoline (except the rubber
parts).
(a) Pump body
If the contact length between the

internal chamber of pump body and
the gear exceeds 1/2 of the
circumference, replace the pump
body. Fig. 9-16
Liner plate
Oil inlet
(b) Liner plate
Check the contact surface of the liner

plate. If the surface is damaged or
the liner plate thickness is less than
the specified value, replace the liner
plate.
Oil outlet
Fig. 9-17
(c) Front and rear pump covers
If the inner surface bushing discolors

(brown) for more than 150°, replace
it.
Fig. 9-18
103
(d) Check the driving and driven gears
from front and rear. In case of
excessive wear, replace a pair. If the
size is smaller than the specified
value, replace them in pairs.
D = 20.961mm
(e) Replace the seal ring, bushing seal,

retainer ring, oil seal and elastic
retainer ring as required.
(3) Assembly
Fig. 9-19
(a) Install a new seal ring and a new
retainer ring on the front end cover of
the pump.
(b) Install the liner plate in the groove of

front end cover. Do not confuse the Root
Retainer ring
Seal ring
oil suction port and oil drain port. Bushing
Bottom side of pump body
(c) Install the driving and driven gears internal chamber
on the front end cover.
(d) Install the liner plate at the side of

Fig. 9-20 Bushing Seal
gear, with the groove aligned with the
gear point. Do not confuse the oil
suction port side and oil drain port
side.
Oil suction port side Groove
(e) Install a new seal ring and a new
retainer ring in the groove of rear end
cover. (see Fig. 9-20)
(f) Install the rear end cover on the Oil drain port side
pump body. Do not confuse the oil
suction port and oil drain port. Fig. 9-21 Liner Plate
(g) After all parts are installed, tighten

the connecting bolts to the specified
torque of 9-10kg.m.
104
1. Pump body 7. Seal ring
2. Driving gear 8. Retainer ring
3. Driven gear 9. Oil seal
4. Front end cover 10. Elastic retainer ring
5. Rear end cover 11. Bolt
6. Liner plate 12. Washer
Fig. 9-22 Gear Pump
105
9.11 Test run
Perform a test run for running-in of oil pump. Check whether the running is normal. It would be the
best to test the oil pump on a bench. However, you can also test it on the forklift truck according to
the following procedures:
(If the oil pump is disassembled and repaired for its excessive wear or seizure caused by hydraulic
oil, change the hydraulic oil and replace the filter before the test run on forklift truck.)
(a) Install the pump onto the forklift truck. Install a pressure gauge at the upper pressure detection
port of the multi-way valve.
(b) Loosen the adjusting screw of the overflow valve to run the pump at a speed of 500-1000rpm
for about 10min. Keep the oil pressure lower than 10kg/cm2.
(c) Keep the pump speed of 1500-2000rpm and increase the pressure by 20-30kg/cm2 at a time.
Run the pump for 5min until the pressure reaches 175kg/cm2. Put each oil circuit into operation
for 5min. Then, replace the oil return filter.
(d) When increasing the oil pressure, check the oil temperature, pump surface temperature and
operation sound. In case of too high oil temperature or pump surface temperature, reduce load
to lower the oil temperature and then continue the test.
(e) After test, keep the overflow pressure at 175kg/cm2. Measure the flow by using the lifting
speed.
106
9.12 Troubleshooting
If the hydraulic system malfunctions, find out the cause and do troubleshooting based on the
following table.
(1) Multi-way valve
Disassemble and clean, change

Seized slide valve
oil
Failure to increase the Damaged sliding surface Replace slide valve

steering oil circuit
pressure and to reach Broken spring Replace spring
the specified oil volume
Blocked oil hole Disassemble and clean
Improperly adjusted overflow valve Adjust overflow valve
Seized slide valve Disassemble and clean

Failure to increase the
lifting oil circuit pressure
Blocked oil hole Disassemble and clean
Vibration Seized slide valve Disassemble and clean

Slow increase of
pressure Insufficient air bleeding Bleed sufficiently
Steering oil circuit Seized slide valve Disassemble and clean

pressure exceeding the
specified value Blocked oil hole Disassemble and clean
Failure to reach the

Improperly adjusted overflow valve Adjust
specified oil volume
Improperly adjusted overflow valve Adjust

Noise
Worn sliding surface Replace overflow valve
Oil leakage (external) Aged or damaged O-ring Replace O-ring
Damaged spring Replace spring

Low set pressure
Damaged valve seat surface Adjust or replace overflow valve
Oil leakage (internal) Damaged valve seat surface Repair valve seat surface
High set pressure Seized valve Disassemble and clean
107
(2) Main pump
Low oil level in tank Add oil to specified level

Less oil output
Blocked oil pipe or oil filter Clean or replace as required
• Damaged liner plate
• Damaged bearing
Replace
• Defective seal ring, bushing seal or
retainer ring
Adjust the pressure of overflow

Low pump pressure Improperly adjusted overflow valve valve to specified value with a
pressure gauge.
• Re-tighten the oil pipe at oil

suction side
Air in system
• Add oil
• Replace pump oil seal
Damaged oil suction pipe or blocked oil

Check pipe or repair oil filter
filter
Looseness and air leakage at oil suction

Tighten
side
Noise during operation
Change oil (suitable for the
High oil viscosity
pump operating temperature)
Find out cause and take

Air bubble in oil
measures
Damaged pump oil seal or seal ring Replace

Oil leakage of pump
Damaged pump Replace
108
10. Lifting system
1-1.8t: Type Contact roller type, C-shaped inner and outer

masts with free lift, and two-stage telescopic mast
Section of inner mast:
Section of outer mast:
Contact roller:
Contact roller: φ112.3mm
Limit contact roller: φ80mm
Side contact roller: φ91.5mm
Side contact roller: φ40mm
Lifting:
Lifting chain LH1223
Fork & mast lifting device Hydraulic
Mast tilting device Hydraulic
Fork spacing adjusting device Manual
109
2-4t: Type Contact roller type, C-shaped inner and outer
masts with free lift, and two-stage telescopic mast
Section of inner mast:
Conical
degree
Section of outer mast:
Conical
degree
Contact roller:
Main contact roller 1: φ120.5
Optional contact roller 1: φ119.5
Optional contact roller 2: φ118.5
Lifting chain (ISO) LH1623 (2-3t)
LH1634 (3.5-4t)
Fork & mast lifting system Hydraulic
Fork spacing adjusting device Manual
110
Malfunction analysis
Insufficient oil in oil tank

No lifting, Overflow valve malfunction
forward tilting or 1. Blocked oil return valve
backward tilting 2. Broken valve spring
of mast Pump malfunction
Overflow valve malfunction

1. Decreased set pressure of overflow val
ve
Failure to lift 2. Too large fitting clearance between liftin
rated weight g valve slide valve and valve hole
3. Damaged multi-way valve spring
4. Broken valve seat seal ring
Pump malfunction
Hydraulic system
Low engine speed

Low lifting speed Loose control lever and insufficient slide va
lve stroke
Blocked oil tank screen
Insufficient pump output
Internal leakage of multi-way valve
Damaged piston seal ring
Natural falling of
lifting cylinder Obvious scratch on the sliding surfaces bet
ween cylinder block and piston
Damaged or distorted piston rod surface
Internal leakage of multi-way valve

Natural tilt of Damaged piston seal ring
tilting cylinder
Foreign objects in packing
Damaged piston rod
Other abnormal distortion
Oil leakage from Foreign objects in oil seal or dust ring
cylinder head Damaged inner or outer diameter of oil se
al or dust ring
Damaged seal ring
Abnormal distortion
Viscous drag: The oxidization of hydraulic oil can produce dirt sediment. The ingression of metal
scraps and cotton fiber is easy to cause viscous drag.
111
10.1 General
The lifting system is of two-stage contact roller type. It performs vertical lifting. The lifting system is
composed of inner mast, outer mast and fork carriage.
10.2 Inner and outer masts
The inner and outer masts are welding parts. The bottom of outer mast is installed on the driving
axle with bearings.
The middle of outer mast is connected with the frame through the tilting cylinder. Under the effect of
tilting cylinder, the outer mast can tilt forwards/backwards.
10.3 Fork carriage
The fork carriage rolls in the inner mast through the main contact roller. The main contact roller is
installed on the main contact roller shaft and clamped by an elastic retainer ring. The main contact
roller shaft is welded on the fork carriage. The side contact rollers are fixed on the fork carriage with
bolts. They roll along the wing of inner mast. They can be adjusted with adjusting gaskets.
10.4 Load backrest
The load backrest is installed on the fork carriage by fixing the both sides with bolts. It can prevent
goods falling when the mast tilts backwards.
10.5 Contact roller position
There are two types of contact rollers: main contact roller and side contact rollers. They are installed
on the outer mast, inner mast and fork carriage respectively. The main contact roller bears the front
and rear load and the side contact rollers bear the side loads to ensure free motion of inner mast
and fork carriage.
112
Outer mast Inner mast Roller Load backrest Fork carriage
Notice:
(a) Adjust the side contact roller clearance to 0.5mm.
(b) Coat the surface of main contact roller and the contact surface of mast with grease.
Fig. 10-1 Contact Roller Position
113
Malfunction analysis
Seizure of sliding rack Too small clearance between sliding rack

and mast and side roller
Improperly adjusted clearance between slid
Unstable lifting and e valve and side roller
falling Unsmooth rotation of main roller
Poor up-and-down sliding of sprocket whee
l support and guide rod
Too large side roller clearance
Mast and forks
Tilted sliding rack

Uneven left and right chain tensions
Improperly adjusted roller clearance

Distorted mast
Working under heavier load or overload
Unsmooth rotation of roller

Noise from mast
Poor buffering of mast limiter
Distorted wings of sliding rack

Different fork tips Bent forks
Heavier load
114
10.6 Maintenance
10.6.1 Lifting cylinder adjustment
When replacing the lifting cylinder, inner

mast or outer mast, adjust the stroke of Adjusting gasket
Upper cross beam of
lifting cylinder in accordance with the inner mast
following method:
(1) Install the piston rod head into the

upper cross beam of inner mast without
any adjusting gasket.
(2) Lift the mast slowly to the maximum

stroke of the cylinder. Check whether
the two cylinders synchronize.
Lifting cylinder
(3) Set adjusting gaskets between the
piston rod head of the cylinder that
stops first and the upper cross beam of Fig. 10-2
inner mast. The adjusting gasket
thicknesses are 0.2mm and 0.5mm.
(4) Adjust the chain tension. Tyre
Inner mast
10.6.2 Fork carriage height adjustment Fork carriage
(1) Park the forklift truck on level ground Main contact roller
and make the mast vertical. Fork
(2) Make the fork bottoms touch the

ground. Adjust the adjusting nut at the
upper end connector of chain until a Fig. 10-3
distance A between the main contact
roller and fork carriage is produced.
Forklift truck
A mm
type
1~1.8t 36-41
1~2.5t 24-29
3t~4t 19-24
115
(3) Lower the forks to ground and tilt the
mast to the backmost position. Adjust Chain
the adjusting nut at the upper end
connector of chain to make the two
chains have the same tension. End connector
10.6.3 Replacement of fork carriage contact

roller
Adjusting nut
(1) Pick up a pallet and park the forklift
truck on level ground. Locking nut
(2) Lower the forks and pallet to ground.

Fig. 10-4
(3) Remove the upper end connectors of
the chains and take down the chains
from the sprocket wheel.
(4) Lift the inner mast (① in Fig. 10-5).
(5) Reverse the forklift truck after

confirming the fork carriage is
separated from the outer mast (② in
Fig. 10-5).
(6) Replace the main contact roller.
(a) Remove all elastic retainer rings.

Take down the main contact roller
with a pulling tool. Retain the
adjusting gaskets.
Fig. 10-5
(b) Make sure the new contact roller is
the same as the contact roller to be
replaced. Install the new contact
roller into the fork carriage and
clamp it with elastic retainer rings.
10.6.4 Replacement of mast contact roller
(1) Remove the fork carriage from the inner

mast with the same method for
replacement of fork carriage contact
roller in 10.6.3.
(2) Drive the forklift truck onto level ground

and put blocks under the front wheels to
raise them for 250-300mm.
Fig. 11-6
(3) Apply hand brake and wedge the rear
wheels with wedge blocks.
(4) Remove the bolts fixing the lifting
116
cylinder and inner mast. Lift the inner
mast. Do not lose the adjusting gaskets
set at the piston rod head.
(5) Remove the connecting bolts between

the lifting cylinder and outer mast
bottom. Remove the lifting cylinders
and the oil pipe between them. Do not
loosen the oil pipe connector.
(6) Lower the inner mast. Remove the main

contact roller at the bottom of inner
mast. In addition, the main contact roller
at the upper part of outer mast can also
appear from the inner mast top.
(7) Replace the main contact roller.
(a) Remove the main contact roller at the

upper part with a pulling tool. Do not
lose the adjusting gaskets.
(b) Install the new contact roller and the

adjusting gaskets removed in step (a).
(8) Lift the inner mast to make all contact

rollers enter the mast.
(9) Install the lifting cylinders and fork

carriage in the reverse order of
disassembly.
10.6.4 Loading
(1) Adjust the fork spacing to balance the goods.
(2) Align the forklift truck with the goods to facilitate loading.
(3) Place the pallet on forks symmetrically.
(4) Try to reach into the pallet.
(5) Lift the goods.
a. Lift the goods to 5-10cm above the ground. Make sure the goods are stable.
b. Then, tilt the mast backwards properly and lift the goods to 15-20cm above the ground.
Afterwards, start driving.
(6) The large-size goods will block the driver’s view, so reverse the forklift truck except slope
climbing.
10.6.5 Stacking
(1) When approaching the target location, decelerate.
117
(2) Park the forklift truck just in front of the location.
(3) Check the condition of the location.
(4) Tilt the mast forwards until the forks are horizontal. Lift the forks to the position slightly above
the unloading position.
(5) Travel forwards and place the goods above the unloading position. Next, stop the forklift truck.
(6) Make sure the good is above the unloading position. Then slowly lower the forks and confirm
the goods are placed at the destination safely.
(7) Perform necessary lifting and tilting operation. Reverse the forklift truck to withdraw the forks.
(8) After confirming the fork tips leave the goods, lower the forks to 15-20cm above the ground.
(9) Tilt the mast backwards properly.
! Warning:
• When the load is lifted for over 2m, never tilt the mast.
• When the load is high above the ground, never get down or leave the forklift truck.
10.6.6 Unstacking
(1) When approaching the target location, decelerate.
(2) Park the forklift truck just in front of the goods, with a distance of 30cm between the goods and
fork tips.
(3) Check the goods condition.
(4) Tilt the mast forwards until the forks are horizontal. Lift the forks to the pallet or sleeper.
(5) Make sure the forks are aligned with the pallet and then travel forwards slowly. Try to reach into
the pallet and then stop the forklift truck.
(6) Lift the forks to leave the stack for 5-10cm.
(7) Observe the surrounding area. In case of no obstacle, reverse slowly.
(8) Lower the forks to 15-20cm above the ground and tilt the mast backwards properly. Then,
transport the goods to the destination.
118
11. Routine Maintenance and Regular Check
○: Check/clear △: Replace/adjust
New Forklift Trucks Regular Check
Daily Every Every Every Every
Parts and Items Requirements 1 2 3 Every 3 Remarks
Check 1 half a 1 2
month months months months
month year year years
Oil leakage ○ ○ ○ ○ ○ ○ ○ ○ ○
Steering
Smooth ○ ○ ○ ○ ○ ○ ○ ○ ○
flexibility
Broken
Full Replace ○ ○ ○
spring piece
hydraulic
Manual
steering
steering ○ ○ ○
gear
operation
Air in
steering ○ ○ ○ ○ ○ ○ ○ ○ ○
system
Installation
position, Tighten ○ ○ ○ ○ ○
damage
Installation
state and
wear of Remove ○ ○ ○ ○
Levers connecting
Steering pieces
system Crack and
installation
state of ○ ○
steering
knuckle
Installation
○
state
Installation
King pin state of king
○
pin steering
knuckle
Crack ○
Wheel
○
alignment
Wheel Left and right
rotation ○
angles
Joint
Wear ○
bearing
Play of pedal
and the gap
between the
○ ○ ○ ○ ○ ○ ○ ○ ○
depressed
Brake pedal and
pedal floor
Operating
conditions of
○ ○ ○ ○ ○ ○ ○ ○ ○
braking
system
Installation
states of all
Hand brake ○ ○ ○ ○ ○ ○ ○ ○ ○
hand brake
parts
Lever and Installation
steel wire position and ○ ○ ○ ○ ○
rope state; wear
Brake
master Oil quantity ○ ○ ○ ○ ○ ○ ○ ○ ○
cylinder
Functions,
wear and
Brake Brake
damage of Disassemble,
system wheel ○ ○
master and check and test
cylinder
wheel
cylinders
Clearance
between
Adjust ○ ○ ○ ○
drum and
Brake drum shoe
and brake Wear of
○ ○
shoe brake shoe
Wear and
damage of ○ ○
brake drum
Installation
Metal brake and working
○ ○
shoe state on
chassis
Damage of
steel wire ○ ○
Automatic
rope
adjustment
Wear and
device
damage of ○ ○
ratchet
119
Daily Every Every Every Every Every
Parts and Items Requirements Remarks
1 2 3 Check 1 3 half a 1 2
month months months
month months year year years
Torque Oil quantity and

○ ○ ○ ○ ○ ○ △ △ △
converter leakage
Automatic
control ○ ○ ○ ○ ○
mechanism
Inching ○ ○ ○ ○ ○ ○ ○ ○ ○
Driving
device Disengagement
Gear-box and
○ ○ ○ ○ ○ ○ ○ ○ ○
engagement of
clutch
Oil pressure
Damage of
elastic plate
Oil quantity and

○ ○ ○ ○ ○ ○ ○ ○ ○
pollution
Oil tank Filter ○ ○ ○ ○
Pollution of oil
○ ○ ○
return filter
Oil leakage ○ ○ ○ ○ ○ ○ ○ ○ ○
Consumption of
○ ○ ○ ○
spline oil
Oil pump
Looseness of
bolt connecting
○ ○ ○
universal joint
and generator
Oil leakage ○ ○ ○ ○ ○ ○ ○ ○ ○
Diverter
valve Oil pressure of
○ ○ ○ ○ ○
steering system
Oil leakage ○ ○ ○ ○ ○ ○ ○ ○ ○
Total pressure
Multi-way of overflow ○ ○ ○ ○ ○ ○ ○ ○
valve valve
Flexibility of
○ ○ ○ ○ ○
control levers
Hydraulic
system Crack, damage
○ ○ ○ ○ ○
and distortion
Lifting function, wear

○ ○ ○ ○ ○ ○ ○ ○ ○
cylinder and oil leakage
Looseness of
○ ○ ○ ○ ○ ○ ○ ○ ○
mounting bolt
Leakage ○ ○ ○ ○ ○ ○ ○ ○ ○
Speed
limit Abnormal
valve speed ○ ○ ○ ○ ○ ○ ○ ○ ○
reduction
Crack, damage
○ ○ ○ ○ ○
and distortion
Tilting function, wear

○ ○ ○ ○ ○ ○ ○ ○ ○
cylinder and oil leakage
Installation
○ ○ ○ ○ ○ ○ ○ ○ ○
state
Leakage ○ ○ ○ ○ ○ ○ ○ ○ ○
Damage of
○ ○ ○ ○ ○ ○ ○ ○
hose
Pipeline
Connection of
bent hose and ○ ○ ○ ○ ○ ○ ○
connector
120
Daily Every Every Every Every Every
Parts and Items Requirements 1 2 3 Remarks
Check 1 3 half a 1 2
month months months
month months year year years
Front axle Crack and
○ ○
body distortion
Oil quantity
○ ○ ○ ○ ○ ○ △ △ △
Differential and leakage
and shaft Damage of
○ ○
shaft
Installation
state of
Rear axle supporting ○ ○ ○
shaft in
bushing
Front and rear
operation ○ ○ ○
Rear axle statuses
body Crack,
damage and ○ ○
distortion
Tyre pressure ○ ○ ○ ○ ○ ○ ○ ○ ○
Tyre crack
Front ○ ○ ○ ○ ○ ○
and damage
and
rear
Abnormal loss
axles
of outer wheel ○ ○ ○ ○ ○ ○
groove depth
Gravel, metal
scrap and
other foreign
○ ○ ○ ○ ○
objects
between tyre
treads
Looseness of
Wheel
rim bolt and Tighten ○ ○ ○ ○ ○ ○ ○ ○ ○
nut
Rim damage ○ ○ ○ ○ ○ ○ ○ ○ ○
Installation
state of
○ ○
bearings on
front wheels
Installation
state of
○ ○
bearings on
rear wheels
Crack,
distortion and ○ ○ ○ ○ ○ ○ ○ ○ ○
damage
Operation
condition of ○ ○ ○ ○ ○ ○ ○ ○
Mast and
mast support
sliding rack
Operation
condition and
damage of ○ ○ ○ ○ ○ ○ ○ ○ ○
side contact
rollers
Extension and
tension of ○ ○ ○ ○ ○ ○ ○ ○ ○
chain
Damage, rust
and distortion ○ ○ ○ ○ ○ ○ ○ ○ ○
of chain
Wear,
Chain and damage and ○ ○ ○ ○
sprocket distortion of
Working wheel sprocket
device wheel
Installation
state of
○ ○ ○ ○
sprocket
wheel bearing
Damage of
○ ○ ○ ○ ○ ○ ○ ○
hinge bolt
Wear,
damage and
○ ○ ○ ○ ○ ○ ○ ○ ○
distortion of
forks
Damage and
distortion of
Forks and ○ ○ ○ ○ ○ ○
fork locking
load
pin
backrest
Installation
state of load ○ ○ ○ ○ ○ ○ ○ ○ ○
backrest
Damage and
distortion of ○ ○ ○ ○ ○ ○ ○ ○ ○
load backrest
Lighting
Safety Effect ○ ○ ○ ○ ○ ○ ○ ○ ○
equipment
device
Horn Effect ○ ○ ○ ○ ○ ○ ○ ○ ○
121
Turn signal Effect ○ ○ ○ ○ ○ ○ ○ ○ ○
Instruments Effect ○ ○ ○ ○ ○ ○ ○ ○ ○
Installation
Overhead
state and ○ ○ ○ ○ ○ ○ ○ ○ ○
guard
damage
Damage and
looseness of ○ ○
parts
Installation
state and
○ ○ ○
damage of
Body and
Others driver’s seat
chassis
Lubrication
○ ○ ○ ○ ○ ○ ○ ○
points
According
to
Oil change
lubrication
chart
122
123
Compulsory Check, Maintenance and Lubrication

Check, Maintenance and Lubrication
Compulsory
Check and Repair Replace Lubricate

Every day or every 10h Oil
Every a week or 50h
Engine oil level Filters
Mast bearer
Coolant level Every month or every 200h
Every one month or 200h
Hydraulic oil level Engine oil
Rolling surface of upper roller
Steering fluid level Engine oil filter
of mast (left and right)
Brake fluid level Side roller of lifting bracket
Tyre pressure Every 6 months or 1200h
(left and right)
Hub nut, rim bolt and nut, clutch Gear-box differential fluid
Lifting chain (left and right)
pedal play (clutch type)
Tilt bearer (left and right)
(clutch type) Torque converter fluid level
Guide rod (left and right)
Brake pedal (torque converter type)
Front axle bearer (left and
Forks and mast Differential fluid level
right)
(torque converter type)
Tilting cylinder bearer (left
Hydraulic oil return filter
and right)
Every week or every 50h Torque converter fluid filter
Brake pedal
Battery electrolyte level (torque converter type)
Clutch fork shaft (left and
Air filter core (clean) right)
Bolts and nuts (looseness) Fuel filter
King pin (left and right)
Generator belt tension Air filter core
Steering cylinder bearer (left
and right)
Every 12 months or 2400h
Connecting rod (left and
Every month or every 200h Hydraulic oil
right)
Differential fluid level Brake fluid
Torque converter fluid level
(torque converter type)
Perform check, replacement and lubrication earlier in case of bad operating conditions
SHANGHAI SHAGNLI FORKLIFT CO., LTD.
Address: No. 2611 Bao’an Highway, Shanghai, China

Tel: +86-21-69156666
Fax: +86-21-69156000
Postal Code: 201801
Website: http://www.salcn.com

Maintenance Manual 1T-4T (LPG) - EN 英语

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Maintenance Manual 1T-4T (LPG) - EN 英语

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Operation &

Internal Combustion Counterbalanced Forklift Trucks

3. Principles and descriptions of main parts on LPG conversion device

(1) Cylinder (storage tank):

The standard parts include:

Float level gauge Gas tank

LPG Cylinder Structure

(3) Filter/vacuum cut-off valve (VFF30)

(4) Gasifier/pressure regulator (model J converter)

Secondary chamber Gas LPG outlet to

Primary Hot water

Profile of Gasifier/Pressure Regulator (Model J Converter)

(5) Temperature controller

(1) Work site:

• No depression nearby such as ditch where LPG may accumulate;

• Emergency evacuation plan;

(2) Working personnel

• Work in pairs for mutual assistance.

(3) Treatment of accidents

3. Other precautions for installation:

(5) Below are the special precautions for single-fuel system:

(3) Operating conditions of the forklift truck

(4) Driver’s operating habits and so on

* Check the threads of all connection fittings for leakage.

There are three methods for checking the valve function:

* VFF30 repair kit for filter/vacuum cut-off valve

* MODEL J repair kit for gasifier/pressure regulator

* CA55 repair kit for mixer

(d) Method for preliminary function check:

* Check the middle gasket for damage.

(d) Check whether the venturi can fluctuate freely.

(a) Ignition coil:

* Check for cracks and “electric shock”.

* If possible, measure the output voltage (20,000 V at least) with an oscilloscope or a

* In case of low voltage, use an ohmmeter to measure whether the resistances of

(b) Spark plug:

(c) High-tension wire:

* Check both ends for good contact.

(d) Distribution panel

* Check the cover for damage.

* Check the distribution panel rotor arm for damage.

(e) Ignition timing and advance

3. Preparations before diagnosing the LPG system:

(1) Check whether the LPG quantity in the cylinder is enough.

(8) Check whether the LPG conversion device is modified.

Three other parts that may malfunction:

5. Removal, disassembly, part replacement and reassembly.

2. Poor operation of (A) Unsmooth coolant flow for ⑤

3. Poor operation of LPG mixer (A) The internal floating venturi ⑧

4. Too lean idle mixture (A) Improperly adjusted idle ⑨

6. Vacuum signal transmitted to (A) Loose or damaged vacuum

Malfunction: B. Difficult starting

Malfunction: C. Available starting but failed continuous running or unstable running

5. Poor operation of (Refer to malfunction source A2)

Malfunction: E. Too high idle speed

Malfunction: F. Too high idle speed

(B) Incorrect ignition timing As above

Malfunction: H. Poor acceleration

Malfunction: I. Poor performance or insufficient power during high-speed running

Malfunction: K. Cylinder-related problems

(1) Apply the parking brake;

(3) Lower the mast to the lowest position;

(4) Apply the parking brake;