Manual de Operação Emp. Xg Cpc160 - Inglês

8/17/2019 Manual de Operação Emp. Xg Cpc160 - Inglês

http://slidepdf.com/reader/full/manual-de-operacao-emp-xg-cpc160-ingles 1/100

CPCD120/140/160-XG35 Forklift Truck

OPERATION AND MAINTENANCE MANUAL

ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.

2008.08 1st

EDITION



Foreword

Thanks for your purchasing our forklift truck.

The 12-16t series diesel fork lift truck are new products that our company develops

recently. This operation manual is the explanations that how to use 12-16t R-series forklift truck

correctly. It will instruct you how to operate safety and precautionary maintenance. All that in

charge of operation, maintenance and management must read and comprehend this manual well.

Our products are updating and improving on and on, so this manual may not be the same as

the truck you have.

If you have any questions please keep touches with ZHEJIANG HANGCHA ENGINEERING

MACHINERY CO., LTD. sales department or let the agents know.

©2008.08 1st EDITION ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.



CONTENT

Foreword

GENERAL RULES--------------------------------------------------------------------------------------------------------1

NAME OF MAIN PARTS OR COMPONENT----------------------------------------------------------------------2

METERS AND OPERATION-----------------------------------------------------------------------------------2

CONTROL -----------------------------------------------------------------------------------------------------------5

OTHERS--------------------------------------------------------------------------------------------------------------7

SAFETY INSTRUCTIONS---------------------------------------------------------------------------------------10

8 HOUR (DAILY OR EVERY SHIFT) CHECK -----------------------------------------------------------15

STRUCTURE AND STABILITY OF TRUCK（ prevent truck tilting)-------------------------------------19

OPERATION -----------------------------------------------------------------------------------------------------21

DEPOSIT------------------------------------------------------------------------------------------------------------24

.MAINTENANCE TABLE---------------------------------------------------------------------------------------- 27

TABLE FOR BOLT’S TIGHT TORQUE---------------------------------------------------------------------37

REPLACE KEY PARTS AT REGULAR INTERVALS------------------------------------------------------37

TABLE FOR OIL USED IN THE TRUCK----------------------------------------------------------------------38

TRUCK’S CONVEY, LIFTING, TOWING-------------------------------------------------------------------39

FORKLIFT’S SPECIFICATION AND PARAMETER------------------------------------------------------40

THE SIZE AND WEIGHT OF IMPORTANT PARTS AND LIFTING SKETCH MAP-----------------41

MAINTENANCE RECORD --------------------------------------------------------------------------------------43



Address: 398 Shi Qiao Road,Hangzhou 310022,P.R.of China Post Code: 310022

Tel :0571-88130499 (switchboard number) 85191117

Fax :0571-85199348

Web site: http://www.hzforklift.com E-mail: [email protected]

ADD:398 Shi Qiao Road,Hangzhou 310022,P.R.of China ZIP:310022

TEL:+86-571-8813 5220 ,8813 0499(Ext.8116,8156,8200)

FAX:+86-571-8813 2890,8812 6379

E-mail:[email protected] [email protected]



浙江杭叉工程机械股份有限公司

1

General Rules

1. To make the truck and you safety, operator should obey these rules below:

2. Only trained and authorized operator shall be permitted to operate the truck;

3. Before start truck you should check all control and alarm device, if there are any damaged or

objection, you could not operate it until repaired it;

4. When carry the load, the weight should not much overload. The fork shall insert in the load

entirely and well proportioned. It is not permitted use only one fork to load;

5. You should operate the truck smoothly when start, turning, travel, brake and parking. On a

slick or wet road, you should decrease speed when turning;

6. Travel with load as low as possible and tilt back;

7. Be carefully when traveled a ramp. If the ramp angle is bigger than 10%, travel forward up

ramp and backward down ramp. Never turn sideways and stack load on an incline;

8. Notice the foot passenger, barrier, pothole and the clearance upside;9. It is prohibit picking up a man or standing on the fork ；

10. No permitted to stand or walk under the fork ；

11. No permitted to operate the truck and attachment on other position except the operator’s

seat；

12. Do not carry the unstable load. Be carefully to carry these goods with large size；

13. Notice the load not drop form the load bracket for those trucks that overall maximum lift

height is higher than 3 meters. If necessary, make some protective measure；

14. Tilt back the mast as more as possible when working for those high lift height trucks, and use

minimum forward and reverse tilt when stacking and unloading loads.

15. You should to drive carefully and slowly when driving over a dock-board or bridge-plate；

16. Make sure that there is no naked flame near the area, never smoke. The driver should not

remain seated when adding fuel.

17. The truck with attachments should be treated as a loaded truck ；

18. When leave the truck, you should let the fork down, make the shift lever neutral , pull-up the

hand brake button and cut the power. Parking on a grade, make sure to pull-up the hand brake

button . If necessary, use a block when parking on a grade for a long time.

19. If any trouble comes on at lifting or sloping, leaking of battery acid, hydraulic oil, break fluid.Please stop the truck and service the truck at once, and let the truck in a safety place. At the

same time, please inform the service or let the agent know.

20. Before lading, the fork can be moved around by using special implement(square core thimble)

the screw of the roll adjustment of the fork according to demand . In any event, the left and

right fork must keep symmetry. The fork can not be moved in order to prevent the damage of

the component and the imbalance of the fork when loding .

21. The components of the vehicles are very heavy, be sure to use the equipment which have

enough lifting ability when you demolition of assembly;Even if the small component, it may

more heavy than you want,so be sure to use the lifting tools in order to avoid anybody get

hurt.




2

Name of main parts or component

1．Fork 2. Fork pitch adjustment screw 3.The shelf off 4. Lifting cylinder 5. Inside Mast

6. Outside Mast 7. Overhead guard 8. Fuel reservoir cap 9. Counter balance

10. Rear wheel 11.The frame 12. Forward wheel 13. Tilting cylinder

(14. The screw sleeve location of the fork pitch adjustment)




3

Instruments and control

1. Steering wheel 2. Horn button 3. Key switch 4.Combination switch

5. Angle of inclination screw adjustment of the steering wheel 6. Gearshift perch

7. Inching pedal 8. Brake pedal 9. Accelerator pedal 10 Lift and lilt lever

11. Before and after tilt lever 12. Parking brake lever 13. Switch off

14.( Reserve tube of the brake system) Barometer

Instruments




4

Water temperature gauge[1]

It indicates the engine’s cooling water

temperature, normal conditions, the pointer

should be in the range of 55-115.

Caution:If the pointer enters the red range, this is the

position at which the key stop the operation

instantly and slow down engine speed to

cool the coolant and wait until the pointer

goes into the green area.

Oil temperature gauge[2]

It indicates the fluid power transmission oil

temperature, normal conditions, the pointer

should be in the range of 60-120.

Caution:

If the pointer enters the red range, this is the

position at which the key stop the operation

instantly and slow down engine speed to

cool the coolant and wait until the pointer

goes into the green area.

Timer [3]

Working one time, the timer revolution

be able to increase one number .The

stopwatch indicates running time of the

fork .This meter measures working time of

engine. Use meter to schedule checking,

maintain and service and maintenance

periods.

Fuel gauge [4]

The gauge indicates the fuel in the tank. If

the pointer points left empty; points 1/2

means that fuel has 1/2 of the maximum; point right means fuel full.

Caution:

Fill the fuel at the end of each workday (or

every shift). This practice will reduce the

condensation of moisture within the tank.

Indicator

The lamp indicates whether the device run

correctly. If they have any abnormal status,

the lamp lights.

Charger indicator (B)

This lamp indicates the battery condition of

charge. The lamp comes on when the

ignition switch is set at “ON”, but it goes out

as the engine starts and accelerator pedal is

pressed.

Caution:

If the light continues to stay lit or lights up

during operation, it shows charge

abnormality and should be checked

immediately.

Oil pressure alert lamp (C)

This lamp indicates the pressure

condition of engine lube oil. Although it

lights up when the engine switch is set at

“ON”, once the engine starts up and the

accelerator pedal is pressed, this lamp goes

out.

Caution

If this light continues to stay lit or

lights up during operation, the pressure is

lower than 0.05Mpa and should be checked

immediately.

Air-cleaner indicator (D)

This lamp lights up when the air-cleaner is

dirty, you must clean or replace the element.

Reserve tube pressure alert lamp (E)

To instruct the number for the reserve tube

pressur of the brake system, the normal

pressure is 0.4-0.8Mpa . This lamp lights up

means low pressure，you must check the

pipeline or components of the brake system.

Gearbox oil filter alert lamp（F）

Show the working Situation of gearbox

oil filter ，This lamp lights up means oil filter

plugged,you must clean the oil filter.

Gearsbox oil filter is on the right gearbox

of the forklift body.




5

CHG (G)

This lamp lights up when water in

sedimentor reaches to a certain level, while

the engine is running. In normal state, once

the starter is set to “ON” position, this lamp

lights up. After the engine is started up, it

goes out.

If this lamp continues to stay lit or

lights up during the engine running,

stopping the engine and discharge water

immediately.

Caution

If the truck is operated when thelamp continues to stay lit, the fuelinjection pump may be damaged.

Gear-box oil pressure indication (H)

This lamp bright indicates the gear-box

oil pressure low, should check gear-box.

Median start switch (I)

This lamp lights up means gearbox is free.

At this point you can start the forklift, or not

you couldn’t start.

Left light switch (J)

This lamp lights up when you turn left.

Right light switch (K)

This lamp lights up when you turn right.

Serious warning switch（L）（disuse）

Warm-up switch（M）

Put the switch to“ON”side the lights up for

a moment，when the lights turn off put the

switch to“START”side to start the forklift.

Barometer [14]

To instruct the outside pressureof the

brake system ， the normal pressure is

0.4-0.8Mpa.If the pressure lower

than0.4MPa,you must check the components

sealing of the brake system.

The total power switch

Under the seat on the left side, pull-out

this switch befor you start to put through the

power. When you work off,turn the switch

back to cut off the power.

Control

Steering wheel [1]

When the wheel is turn right, the truck

will turn to the right; when the wheel is turn

left, the truck will turn to the left. The steer

wheels are located at the rear of the truck.

These cause the rear of the truck to swing

out when a turn is made.

！ Warning

This truck is provided with the power

steering, so heavy hand-wheel operation is

caused when the steering motor comes to a

stall. To put the power steering in operation

again, restart the steering motor without

delay.

Horn button [2] Pressing the rubber cover at the center of

steering wheel will sound the horn, no

matter whether the starter key is on the

“OFF” position.

Key switch [3]

OFF Inserted or drawn outON The electric circuit is closed when

the starter switch at “ON”. After the engine

is started, key is at this position.

START As the key is placed in the “start”

position that it means that the fuel is the

starter motor is engaged. When removing

hand off key, it is automatically returned to

the “ON” position by spring force.




6

Caution:

1. Don’t keep the starter key in the “ON”

position while engine is shut down. This result

in a discharge battery.

2. While the engine running, don’t switchthe starter key into the “START” position,

otherwise it may damage the starter motor.

3. Don’t keep the motor running more than 5

seconds while starting up, and wait 2

minutes before another try.

4.Neutral start device is standard equipment.

When the gearlever is not on the neutral

position, you could not start the engine.

Combination light switch [4]

Turn indication

Use this level to indicate the turning

direction of the truck..When this level is

placed in a turn position, the turn signal light

blinks.

R — right turn

N— neutral

L— left turn

Turn forward—left turn lights up

Turn back—right turn lights up

Caution:

The turn signal lever does not automatically

return to the neutral position unlike general

the passenger cars. Reset it by hand. The

lever set right on the steering wheel.

Light switch

This light switch can be circumgyrate at two

steps.

0-small lamp light

1-small,big lamp light

Former dial - right turn light

Back dial- right turn light

Horn button is not sound

Gearshift lever [6]

That car change its dirction by electricity and

it has two go forward file and one

countermarches finle.

Before change to drive the direction, trample

brake predate pedal to make car is stop , then

press direction of request to place to go

forward the file of filesⅠ and go forward the

fileⅡ ,and retreating the file.Ⅰ

1 2

forward Forward Ⅰ Forward Ⅱ

Back dial Back Ⅰ Back Ⅱ

Attention:

1、Make sure the gearshift lever is in the

middle when you start.

2、

Turn toⅠ，

when start or climbing.

Inching pedal [7]

Pressing this pedal will decline the oil

pressure of the hydraulic clutch. Use this

pedal to jiggle the truck while decelerating,

approaching and loading goods. While

pressed more, this pedal serves as a brake.




7

！

Warning

Don’t press the inching pedal or press down

your foot on it long time, otherwise the oil in

the torque converter will be overheated and

the hydraulic clutch will skid.Brake pedal [8]

Press the brake pedal to slowdown or stop

the truck .The brake light is turned on at the

same time.

Accelerator pedal [9]

Press this pedal to increase the truck.. Loose

the pedal, the engine speed be able to slow.

Up and down control lever [10]

Control the fork to up and down

Forword——down Back——up

Lifting speed controled by handstick

back-inclination and accelerator

pedal.Falling speed controled by handstick

forward-inclination.

Inclination control lever [11]

Control the inclination angle of the mast.

Forward — forward inclination

Back dial——

backward inclination

Inclination speed controled by handstick

back-inclination and accelerator pedal

Attention:

Multi-valve have self-locking valve，you can

not make the Inclination control lever forward

inclination when the engine off.

Hand brake control button[12]

Pull up this button when parking brake ，the

brake chamber degassing controlled by hand

brake valve, the spring in the brake chamber

degassing energy release at the same time，

though the forklift parking brake.

The rated working pressure is 784kPa。

When the system pressure lower than 240～

310kPa or the piping broken， the hand

braking valve worked automatic to get an

emergency brake.Put down the button to lift the parking

brake.

The screw sleeve location of the fork pitch

adjustment

You can let the fork moving around by

adjusting lead screw. The left screw control

the left fork and the right too. Use the sleave

S20×20 and the shaft when modulating.

Warning:

You should according to goods, adjust the

position of fork before load .Under all

circumstances, the left or right fork should

keep symmetry.

Strictly forbid to operate adjustment handle or

adjust position when fork lode running,

otherwise adjustment organization of the fork

will damage. At the same time the fork will

loses the balance, having the side to turn over

the danger.




8

otherSeat and seat adjusting lever

Move the adjusting lever about, adjust the

seat to a position which is comfortable to sit

and easy to operate. Make sure the seatlocked securely before proceeding work

Safety belt

when you wearing the safety belt，the

human body should be close to the seat.

Check whether the seat belt fixed bolts

were loose frequently.Do not to tie belt

when use it. Do not let the belt down on the

hard seat or fragile objects，don’t friction

with sharp-edged friction also ,as not to

damage. Do not let the seat is too tilted ，

otherwise the safety belts will not be able to

correctly elongation。

Each part on the safety belt should not be

arbitrary demolition.The belt witch are

frequent used need appearance inspection

frequently,the belt can use 3~5 years, when

the belt off normal should early disposal.

Overhead guard

The overhead guard is strong enough tomeet safety standard, prevents the operator

from hurt by falling matter.

Hood [8]

The hood can be swung up fully; it is

convenient to maintaining service. With the

help of hood damper inside, you can open

the hood easily. To close the hood, just push

down the front of the hood.

Caution

Take care of your finger from being hurt

when shutting the hood.

Hydraulic fuel tank and oil scale

Hydraulic fuel tank at the right side of the

forklift, open it when to oil.

Outside hydraulic fuelset up an oil dial

gauge, hydraulic oil should between the

upper and lower scale,when lower oil up.

The hydraulic oil should be filtered by 10μ

filter, screw lid when the oil full.

Fuel reservoir cap

The fuel reservoir cap is located in the left

side of the forklift. Check to see the

blowhole in the cap is through every time

adding fuel, or the fuel system will get into

trouble.

Caution:

----Add fuel----

1. Stop the forklift, shut down the engine

and apply the parking brake securely.

Make sure there is no naked flamenearby. The driver should get off.

2. Lock the fuel reservoir cap securely

after finishing, any loose could cause

fuel leakage or fire hazard in the worst

case.

3. Clean up the fuel spilled out before

starting the engine.

4. Forbid flame when checking fuel level.

5. If fuel splash into eyes, please use water

wash your eyes, if necessary see doctor.

Radiator cover board and radiator cap

The cover board can be swung up fully.

There is the just position that the cover

board could be locked stable. To close it,

shut down the cover board carefully.

The radiator cap is located under the cover

board. To check the level or to add water, you

should open the cover board at first.

Warning!

1．Don’t remove the water cap abruptly

while the temperature of engine more than

700C.. Press the cap and turn it a little to the

left to relieve the pressure in the .

2．Don’t wear gloves to remove the cap.

Obliquity adjusting lever to steering

wheelTo satisfy the operator, the steering pole is




9

able to be tilt.

Pulling downward the adjusting lever that

site at the left side of the steering pole, the

steering is released; pushing upward the

adjusting lever, the steering pole is locked.

Warning:

1. Don’t attempt to adjust the tilt angle of

the steering wheel during operating;

only when the forklift is at rest allows

adjusting the tilt angle.

2. Adjusting finished, make sure the

steering pole is locked securely.

Headlight and turning signal lamp

Two headlights and turning signal lamp

are installed at the front side of the

safeguard. Take care of the lights, clean dust

often and replace any damaged lights

immediately.

Combined lights (rear)

Combined lights at the rear include turn

signal, taillight, stoplight and reversing light.

Take care of the lights, clean dust often andreplace any damaged lights immediately.

Brake light

Install a reversing light in the back and

middle of the balance weight. It is lighted

when the vehicle brakes.

Cab

A cab is collocated in the vehicle .there

are two doors with locks in it setting on its

two sides .there are Close the door before

driving without fail. Lock the door well after

leaving the vehicle.

The door glass can adjust to up and

down,please down the glass to ventilate

when the air is bad in the forklift.

Air condition

Turn on The forklift air-condition when the

air uncomfortable.

The cab tilting mechanism and tools

Usually the handle down at right side of the

cab ,back to the place after use.

Remove the two bolts on the two cushions at

right before you turn up the cab.

Hand pump

Open the hood can see a hand pump at the

right behand of the cab which can let the cab

slant. Need to add a shaft.

Tipping Check the piping and elements

under the cab before. Turn to “Work” side ,

shake the shaft again and again, the cab

should be tipped slowly.




10

Down turn to “Off ”，The cab should down

slowly by it’s weight.

Wiper switch and the cab forward light

button

Wipers are set on forward backward

windshield glass ,the top of the cab,turn onif rain.

Forward wiper

Left first button

Backward wiper

Left second button

Top wiper

Left third button

Cab forward light button

Left fourth button




11

Safety instructions1. Only trained and authorized operator shall

be permitted to operate the truck.

2. Inspect the truck at periodic intervals for

oil or water leak, deformation, lousiness, etc.

If neglected, short life of components will be

caused and in the worst case a fatal accident

would occur.

Make sure to replace the “key component”

in schedule maintenance.

Wipe off oil, grease or water from the floor

board and foot and hand controls, if any.Shut down the engine before inspecting the

engine and its allied components. Especially

use caution to the engine fan.

When inspecting the radiator or muffler,

exercise caution not to get burnt.

3. Any time you find that the trucks are not

functioning properly, operation of the truck

should be halted and the condition reported

to the supervisor.

When doing maintenance in the high place

(for example mast or front lamp), be care of

no sliding.

If any warning lamp comes on, move to a

safe place and check or repair the trouble.

The sign of defect should be put on the

defecting forklift truck.

4. Don’t use an open flame to check level, or

for leakage, of fuel, electrolyte or cooling

water.

Never smoke while inspecting the battery,

handling fuel or working on the fuel system.

There is a danger of explosion.

Never fill the fuel tank with the engine

running

5. Warm up and cool down the temperature

of the water 70 degree before and after

work.

If the temperature of the water tank higher

than 70 degree, never open the tank cap

6 .Waste gases is dangerous to your health.

When using your truck in an enclosed space,

make sure there is enough ventilation. It’s

forbidden to operate the truck where it is

explosive or flammability. If necessary, use

a ventilation fan.

7. Never mount or dismount the moving

truck. Use the safety step(s) and safety grip

facing the truck when mounting or

dismounting the truck.

8. Never attempt to work the controls unless

properly seated.

Before staring, adjusting the seat so you can

get easy access to all hand and foot control.

9. Before staring up, make sure that:

①Before staring, make sure no one is under,

on and close to the truck.②The forward-reverse lever is in neutral.

10. Park the truck on a level surface and

apply the parking brake securely. If parking

on a grade is unavoidable, be sure to block

the wheel.

Put the forks on the ground or floor and tilt

little forwards. Shut down the engine and

remove the key.

11. Operate the controls smoothly-don’t jerk

the steering wheel. Avoid sudden stops,

starts or turns.

12. Observe speed and traffic control signs.

When traveling on public roads or streets,

obey all local traffic regulations.

13. Pay attention to the route of the

truck, be sure to make a wide sight.




12

14. Never allow other person(s) to ride onthe forks, pallets or on the truck.

15. Before driving over a dock-board or

bridge-plate, be sure that it is properly

secured and strong enough to sustain the

weigh. Check the ground or floor conditionof working area in advance.

16. Keep your mind on your work. Learn to

anticipate danger before it arises.

17. Keep your head, hands, arms, feet and

legs within the confines of the operator’s

compartment. Never reach into upright for

any reason.

18.When handling bulky loads, which

restrict your vision, operate the machine in

reverse or have a guide.

19. Slow down and sound horn at cross

aisles and other locations where vision is

restricted.

20. Keep fluid cans, row cotton, paper or

chemicals away from the truck during

operation since there is a danger of their

firing or exploding due to exhaust gas from

the muffler.

21. Use head lamp and side lamp at night

and control travel speed.

22. Make sure to operate the truck on

concrete firmly enough or bituminous

macadam.

The weather of working condition is:

Air temperature -20~50

Wind speed: Less than 5m/s.

Air specific humidity: Less than 90%.

(Temp at 20 ).Inspect the surface overwhich you will run. Look for holes,




13

drop-offs, obstacles, and look for rough

spots. Look for anything that might cause

you to lose control, bog down or upset.

Clear away trash and debris. Pick up

anything that might puncture a tire or let the

load lose balance.

Slow down for wet and slippery roads.

Stay away from the edge of the road. If

unavoidable, use extreme caution.

Do not use the forklift truck on the

condition of bad weathers.

The noise of truck is less than 105dBA,

test method is use a decibel tester to record

the voice 7 meters far away from truck. The

decibel near operator’s ear is less than

93dBA.

23. When operating loaded truck, have

the rear end of your machine pointed

downhill. When climbing grades, use

forward gears, and when descending, use

reverse gears.

Never turn sideways on an incline.

There is danger of the truck turning over.

24. When running down on a grade, use

engine brake. While using engine brake,

don’t operate directional and speed control

levers. If the truck exceeds the gear range,

use the brake pedal.

25. It is dangerous to travel with forks

higher than appropriate position regardless

of whether loaded or not. Keep the good

traveling posture. (When traveling, the forksshould be 15 to 30 cm above the ground or

floor.)

Do not operate the side shift mechanism,

if equipped, when the forks are raised and

loaded, since this will cause the truck to be

unbalanced.

26． When the forks are raised and loaded,

mast should reclined to reduce the high of

goods




14

27. Avoid braking too sharply or descending

on a grade at a high speed. There is danger

of loads falling down or the truck turning

over.

28. Always brake to full stop before

reversing direction of travel.

29.Taking account of the shape and material

of loads to be handled, use a proper

attachment and tools.

Avoid hoisting the load, with wire rope hung

on the forks or attachment, since the wire

rope may slide off. If needed, a qualified

personnel for slinging operation should

perform, making use of a hook or crane arm

attachment.

Take care not to protrude the forks out of the

load. The protruded fork tips may damage or

turn over the adjacent load.

30. Know the rated capacity of your lift

truck and its attachment, if any, and neverexceed it.

Do not use a man as an additional

counterweight. It’s quite dangerous.

31. Hang Zhou forklift truck Co., ltd. offers

a variety of attachments, such as forks,

bucket, rotating roll clamp, load grab or

hinged forks. Don’t use such attachments

and special equipment for applications other

than specified.

32. Safeguard protect you do not be hurt by

the goods fallen. Load bracket protect you

load goods smoothly. It is forbidden to use

truck without safeguard or load bracket.

33. It is forbidden to walk down the fork or

the attachment.

·It is forbidden to walk up the fork or stand

on the fork.




15

34. It is forbidden to put your hands, arms

or head stretch between the mast and

safeguard.

·It is forbidden to put your hands in

inner and outer mast.

35. When load is to be retrieved from a pile,

enter the area squarely. Engage forks into

the pallet carefully.

36. Don’t enter into loads at a high speed.

Always make certain that your load is stable

before lifting the forks.

·Be sure to once stop in front of the load to

be lifted, and make certain that there is no

obstacle, then engage the load by driving

forwards.

37. Make certain that your load is well

stacked and evenly positioned across both

forks. Don’t attempt to lift a load with only

one fork.

·On the truck with an attachment such as a

load grab, make certain that the load is

securely and correctly grabbed, and pull the

loading control level to the full.

38. Never lift loads with the truck inclined.

Avoid loading work on a grade.

39. Don’t stack loads on forks in such a way

that the top of loads exceeds the load

backrest height. If unavoidable, make the

load stable securely. When handling bulky

loads that restrict your vision, operate the

truck in reverse or have a guide.

40. Use minimum forward and reverse tilt

when stacking and unloading loads. Never

tilt forward unless load is over stack or at

low lift height.

When stacking loads on a high place,

once make the mast vertical at a height of 15

to 20 cm above the ground and then lift the

load farther. Never attempt to tilt the mast

beyond vertical when the load is raised high.

To unloading loads from a high place,

insert forks into the pallet and drive

backwards, then lower the load. Tilt the mast

back after lowering. Never attempt to tilt the

mast with the load raised high.

41. Don’t tow the truck that it’s motor has

trouble or it’s steering system doesn’t work

correctly or it’s braking system has been

disabled.·Obey the communication rules on the road




16

when towing the truck.

42. Dress the overalls or other protective

uniforms, suck as safety helmet, safety shoes

etc. Don’t dress necktie or other

accouterments.

43. Markings on the machine describewarning and methods to operate the lift

truck. When operating the machine, observe

and follow all markings on the machine in

addition to this operator’s manual.

Inspection decals and replace damaged or

missing decals.




17

Before starting forklift (8 hour) check

Before starting your forklift truck, be

sure to inspect the following items for safety

sake and efficient productivity.

1. Check leaks of oil, fuel or water

Warning!

Don’t attempt to operate the truck if leaked

fuel is found through pre-operational check.

Correct the leak before starting engine.

Check if the engine, connector of hydraulic

pipe, radiator and driving system are leakage

or not. Do not use an open flame to check

level, or for leakage, of fuel, electrolyte or

cooling water.

2. Tire inflation pressure check

Turn the tire valve cap counter clock-wise

and move it. Using a tire pressure gauge,

measure the inflation pressure, and adjusting

it to the specified pressure, if needed. After

making sure there is no sir leakage from the

tire valve,reinstall the cap.

Check that each tire does not get damaged at

the tread surface or side face or bending at

the rim.

Warning!

Since the forklift truck needs tires that have

a high inflation pressure to carry heavy

loads, even a small bending of rims or

damage at the tread surface could cause an

accident.

When using an air compressor, first adjust

the air pressure of the compress-or. Failure

to do so will cause a serious accident, since

the compressor delivers the maximum

pressure.

Put the tyre in the safeguard case to protect

your safe.

Tire pressure

Front wheel Rear wheel

0.83Mpa

0.88Mpa

3. Hub nut torque check

Check hub nuts should be tightened to the

specified torque securely.

4Check water level in the radiator

When the water temperature of the engine

higher than 70 degree, please do not open

the pressure cap of the radiator.

Loosen cap slowly to allow steam to escape.

After that, tighten cap securely. It is good

practice to use thick waste cloth or the like

when removing the cap. Avoid putting on

gloves, since you may get burnt at your hand

if hot water splashes on it.

Warning:

Adding clean water to radiator. If you use

antifreeze, use the same brand of antifreeze.

Check the radiator coolant reservoir fluid

level. It should be between high and lowlevel marks. Add coolant if necessary.

engine oil level check.

5. Oil level inspect

Caution

When check the engine oil, should let the

forklift truck on the level ground.

When check the engine oil, it is exact when

the engine is cool.

Remove the dipstick, clean the rod and

reinstall. Pull it out again and check the oil

level. The level should be within the mark

on the dipstick.




18

6. Battery electrolyte check

The battery case is given upper and lower

level marks to allow the operator to see the

electrolyte level. The level should be

between the two marks. Otherwise, adding

clean water to the up level.

7. Hydraulic oil level

If the oil is too little, air will go into the

hydraulic tube; too much, the oil will go out

from the tank. The oil level should be in the

place between two slots. If slow the

level ,should add to oil and the oil should

pass the dross filter .

The oil level check should be done with

engine shut down, forks on the ground or

floor .The truck itself on a level ground.

8 Brake pedal, inching pedal and check

Press these pedal to make certain that each

pedal can be pressed smoothly and that is

also can restore without interference.

9. Parking brake lever

Make sure that the parking brake is securely

applied by operating the parking brake lever.

10 vFan belt tension check

First, stop the engine, then …

Check the fan belt for correct tension and

damage. The deflection of the belts when the

midway between the water pump pulley and

the generator pulley is as follows:

Engine

Drop

distance

(mm)

Force (N)

CY6108ZG 10-15 39

Warning!

If the belt has already been pulled long, cut

out or has no surplus, it should be changed.

11. Horn

Press the horn button to make certain the

horn sounds.

12．Hydraulic transmission oil level

screw off the oil scale , take out, checkwhether the oil lever is between the scale.

Change oil or the time to change oil:

The first time to change the oil is worked

100 hours, than change at every each 1000

hours ,less than 1 year, change the oil filter

together.

13 Drivers seat adjustment

Make sure the driver’s seat is properly

located. If not properly, shift the adjusting

lever to the right and move the driver’s seat

to a position which provides easy access to

all foot and hand controls.

14. Shift lever(s) check

Check the shift lever(s) for looseness and

operation for smooth.

15 Loading levers check

Check the loading levers (for lift, tilt and

optional attachment) for looseness andsmooth operation.




19

Start the engine…

Before starting the engine, make certain the

shift lever(s) is in neutral and parking brake

is securely applied.

16. Fuel lever check

The fuel level gauge is provided on the

indicator panel. Check that fuel level is

sufficient for the day’s work.

17. Turn signal check

Make sure that the turn signal operates

properly by moving the turn signal lever.

18. Instruments and sensors

Make sure that hour meter, water

temperature indicator, oil temperature

indicator and transmission fluid sensor etc.,

properly.

19. Mast

Actuate the lift and tilt levers to be certain

that the carriage moves up and down

properly and the mast can be tilted smoothly.

Pay attention to system operating sound.

20. Lift chain tension check

To check the tension, raised the fork about

10-15 cm above the ground.

Push the middle of the chain with the thumb.

Make certain the tension for the right and

left chains are even.

If uneven tension is found, loosen the lock

nut (1) and(3)of anchor pin and adjust the

chain, turning the adjusting nut (2) of the

chain anchor pin. Then tighten the nut(1)and(3).

Caution

Don’t use “Grease” but “Machine Oil (ex.

Hydraulic Oil)” only for lift chain

lubrication in order to prevent dirt attach on

the grease.21. Check steer

Fork need slowly run..

Steering wheel separate left 、right turn .

Observe left right steering whether or not

homology

22 Exhaust gas check

Check condition of exhaust gas after the

engine warm-up is finished.

Colorless or

bluish

Normal: complete combustion

BlackAbnormal:incomplete

combustion

WhiteAbnormal: water come in

the burnt house

Blue Abnormal: oil burns

23.

Inching pedal check

Press the inching pedal a little and check

whether the truck speed decreases.

24. Brake test

Run the truck slowly and press the brake

pedal to check the braking effect. When the

brake pedal is pressed, the stop lamp comes

on.

In normal, the air pressure of the brake

system should between 0.4-0.8Mpa.25. Back-up lamp check

The back-up lamp comes on and buzzer

sounds when the shift lever or directional

control lever is placed in reverse position.

27

Water discharge from sedimentor

jiggle check

① Stop the engine, loosen the drain plug by

turning 4 to 5 turns (A) and press the

priming pump (B). Continue pressing the

priming pump (B) until water is entirelydischarged through the sedimentor.




20

② Fasten the drain plug and press the

priming pump (B) several times to see that

there is no fuel leakage from the plug.

③ Start the engine to confirm that the

indicator does not light up.

When the sedimentor indicator lamp lights

up, it means need water discharge.




21

During brake-in

We recommend operating the

machine under light load

conditions for the first stage of

ration. Especially the

requirements given below should

be observed while the machine is

in a stage of 100 hours of

operation.

*Always warm up your machine

before putting it to work

irrespective of season.

*Perform specified preventive maintenance

services carefully and completely.

*Avoid sudden stop, starts or turns.

*Oil changes and lubrication are

recommended to do earlier than specified.

*Don’t run engine at high rpm without load

needless.




22

.Structure and stability of truck

It is very important for operator to know the truck’s structure and relationship between

load and stability.

Caution The structure of the truckThe basic structure of the truck is mast (include mast and

forks) and body (include tire).

The lift truck keeps the balance of weight between the

truck body and the load on the forks with the center of the front

wheels as a fulcrum when the rated capacity load is placed in

position.

Due care should be paid to the weight and the center of

gravity of loads to maintain the stability of the truck.

Caution Load center

There is difference because of the loads’ shape, gravity,

such as box, board and large roller. It is very important to

distinguish the difference and the gravity center of loads.

Warning!

If the truck will turn over, do not attempt to get out of the truck, because the speed

of overturn is much fast than you. You should hold the steering wheel handle, and this

practice will let you in the seats.

Caution Gravity and stability

The combined center that is composed of the barycenter

and the load center determine the stability of lift trucks.

When unloaded, the barycenter does not change;

When loaded, the barycenter is determined by the truck

and the load’s center.The barycenter is also determined by the tilting and

lifting of the mast.

The combined center is determined by these factors:

Load’s size, weight and shape.

The lifting height.

The tilting angle.

The pressure of the tire.

The radius of turning.

The road and grade’s angle.

The attachments.




23

Caution the stability zone of the bar center

In order to make the truck stable, the combined center must be in the

triangle which is made up of two points that the two front wheels

attach ground and the midpoint of the back driving axle.

If the combined center is in the front driving axle, the two front

wheels become two fulcrums, the truck will overturn. If the

combined center departures the triangle, the trucks shall overturn in

the corresponding direction.

Caution the max load

The distance between the load center and the front surface of

forklift or load bracket (select the min) on the forklift is called

LOAD CENTER DISTANCE. The max gravity that the truck can

load is called MAX LOAD on condition that the load is on the load

center distance. The relationship of MAX LOAD and LOAD CENTER

DISTANCE is specified on the load capability chart. If the load center

is moved near the front of forklift, the load should be cut down.

Caution The load capability chart

The chart given above shows the relation between the load

center and the weight of loads. Check whether the load and the

load center are in the permitted range. If the shape of the load is

complexity , take the heaviest part to the center between forks

and close to the load bracket.

Caution speed and acceleration

It is very dangerous to press the brake suddenly. It may result in capsizal or sliding down of the load

because of huge force to the front.

Centrifugal force will be formed during turning and its direction is from the turning center to the outer.

The force may result in the capsizal of truck. Right-and-left stable zone is very small, so the truck’s speed

must be reduced when turning to prevent capsizal. If the truck conveys the load which is on the high

location, feasibility of capsizal is very big.




24

operater

Warning!

Before operating the truck, check all controls and

warning devices for proper operation. If any damageof fault is found, don’t operate truck until corrected.

Star-up

Starting diesel engine

• Make sure that the shift lever(s) and loading levers

are in neutral and hold position.

• Turn the ignition switch to ON position after

turning the ignition switch to START position.

Caution

If you can not start the engine in 5 seconds, should

switch to OFF, after 2 minutes then start it again.

If you can not start the engine 3 times continuously

should check the truck to the core.

Caution

If the temperature lower than –5 degree, crank the

engine by turning the ignition key to “START”.

Release key when engine starts.

Caution

Start time less than 5 seconds and start interval less

than 2 minutes every time.

。After engine has started

• Warm up the engine (for about 5 minutes)

• Check the rotation (sound or gear) of the engine.

Caution

Diesel model

After starring up the engine, accelerate it’s speed to

the arrange of 1800-2000r/min, and warm it without

work.

·Check the combustion (or misfiring) sound.

·Check the condition (density) of exhaust.

·Make sure that all the warming lamps are off.

·After thoroughly warming up the engine, operate the

loading levers 2 to 3 times in their full stroke and

check their working conditions.

2. Traveling

Hold the knob on the steering wheel with your left

hand and get the right hand ready for loading working,

lightly putting it on the wheel.

Set the bottom of the fork 15 to 20 cm above the

ground and fully tilt back the upright.

·Check the safety around the machine and give a

signal when starting the engine.

·Depress brake pedal and engage the forward-reverse

lever.

·Release the parking brake lever.

·Release brake pedal and depress the accelerator pedal

to start the machine.

Gear shifting

·Always stop the truck before reversing the direction

of travel.

·Shift the shifting lever.

Slow down

Release accelerator pedal depression a little, and press

the brake pedal, if needed.

Steering

Unlike general passenger-cars, the steer wheels are

located at the rear of the truck. These cause the rear of

the truck to swing out when a turn is made.

Slow down the truck and move toward the side to

which you are turning. The steer hand wheel should be

turned a bit earlier than as with the front wheel

steering car.

Stopping or parking the truck.

1. Slow down and press the brake pedal to stop the

truck (in the case of clutch type machine, the

clutch pedal is used). Place the shift lever in




25

neutral.

2. Apply the parking brake by pulling up on the

parking brake lever.

3. Down the forks on the ground.

4. Place the key switch in “OFF” to shut down the

engine. In the case of the diesel truck, pull out the

engine stop button. Remove the key and keep it.

Caution

·Don’t dismount from the moving machine.

· Never jump off the machine.

3.Pick up

The forks should be adjusted sidewise to maintain

proper balance of load.

Place the machine right in front of the load to be

handled.

The pallet should be evenly positioned across bothforks.

Insert forks into the pallet as far as possible.

To raise loads from the ground:

① Once lift the forks 5 to 10 cm off the ground or

floor and make sure loads rest stable.

② Then, tilt the mast backwards fully and lift forks

up to 15 to 20 cm off ground then start running.

·When handling bulky loads which restrict your

vision, operate the truck in reverse except when

climbing grades.

4.Stacking load

·When approaching the deposit area slow down your

truck.

·Once stop the truck right in front of the area where

your load is to be deposited.

·Check the condition of the deposit position.

·Tilt the mast forward until forks become horizontal.

·Raise forks until they are a little higher than the

deposit position.

·Move forward to place the load directly over the

desired area and stop the truck.

·Make sure your load is just over the desired area.·Slowly lower the load into position. Make sure the

load is securely stacked.

·Disengaged forks from the load by using necessary

lift-tilt operation and then back away.

·After making sure the fork tips leave the load, lower

the forks to the basic position (15 to 20 cm off the

ground).

·Tilt the mast backwards.




26

Warning!

Never tilt the mast with loads upraised 2m or more.

Don’t leave or dismount from the truck when the load

is raising high.

5.Remove load·When approaching the area where the load is to be

retrieved, slow down your truck.

·Stop the truck in front of the load so that the distance

between the load and fork tips is about 30 cm.

·Check the condition of the load.

·Tilt the mast forward until forks become horizontal.

Elevate forks up to the position of the pallet or skid.

·Make sure forks are positioned properly for the pallet.

Move forward slowly to insert forks into the pallet as

far as possible and then stop the truck.

Caution

If the forks are hard to be fully inserted, use the

following procedure: move forward and insert 3/4 of

the forks. Raise the forks 5 to 10 cm and move

backward 10 to 20 cm with the pallet or skid on the

forks, then lower the pallet or skid on the stack. Move

forward again to insert the forks fully.

·Raise the forks 5 to 10 cm off the stack.·Check all around the truck to insure that the path of

travel is unobstructed and back away slowly.

·Lower forks to a height of 15 to 20 cm above the

ground. Tilt the mast backward fully and move to the

desired area.

6.Measures against cold and hot

weathersOil

Use the oil suitable for ambient temperature.

Battery

·

In cold weather

Under normal charged conditions, the freezing point

of electrolyte is about –35 degree.

Always keep the battery in a well-charged condition

since there is danger of damaging the battery jar if

electrolyte freezes. To prevent the freezing, charge at

least 75% of the whole capacity.

Also it is effective to keep the specified gravity up to

1.260, but not higher than this value.

·

In hot weather

As the water of electrolyte is especially likely to

evaporate in hot weather, replenish distilled water

from time to time.

In a region where the ambient temperature is intensely

hot, it is practicable to lower the specified gravity of a

completely charged battery down to 1.220±0.01.

·Antifreeze of radiator

Warning!

·Antifreeze is harmful to your health, do not eat it.

·Far away from children.

Your truck is generally shipped with the cooling

system filled with Long Life Coolant of 50%

volumetric mixture. The freezing point of the coolant

of such a mixing ratio is –36.5 degree. When the

coolant is not enough, you can add CALTEX

ELC6280 antifreeze in the tank.In hot weather: To

maintain good cooling effect, special care should be

paid to radiator and cooling system. Parking in the

shade is recommended.

Clean the radiator

Warning!

The dust will enter your eyes if you have not worn adust proof glass.

If the radiator has been jammed by dust, this may

cause the radiator over hot. So you should use

compress air, water or high pressure vapors to clean

the radiator.

Caution

When using compressed air or vapor to clean the

spreading-heat slices, put the ejecting mouse vertically

to the slices.




27

Check the fan belt tension

If the belt is loosening, adjust it.

When the engine is too hot, do not stop it immediately,

just do these things:

1. Run the engine at low speed

2. Open the hood in order to increase the fan speed.3. When the water temperature decreased, stop the

engine.

4. Check the radiator; add water or antifreeze if needed.

Air filter maintenance

Normal：

When the forklift working for 50~250

hours(4000~20000 km vehicles

) to maintain the air filter.

After six times later change it.

Caution：

If your car working in a bad condition,you

should change the air filter frequently.

If your car working in a more dust bad condition,you

should maintain the air filter for 8~50 hours, change

the between 100~300 hours.

maintenance method:① Open the air filter cover ；

② Filter out；

③ Blowing inside and outside the dust filter

net by compressed air.

Warning：

1、Dust will fly into your eyes， to wear protective

mirror before blowing。

2、 Not maintain and replacement the filter in time,

will lead to engine damage ahead.




28

Deposit

Deposit daily

Park your truck on a level ground-preferably in a

wide area. If parking on a slope is unavoidable,

position the truck so that it cross the slope and block

the wheels to prevent accidental roll.

Make sure the shift level on neutral position.

Pull the hand brake.

Shut down the engine and control the lift and tilt

level several times so that the inner pressure in the

hydraulic tube will decreased.

Take down the key and deposit it in a safe position.

Warning!

You should tell the manager if you find any failure

about the truck, then repair it immediately.

① Clean the oil and grease with cloth and water on

the truck body.

②Check the whole situation of truck, especially the

tyres.

③ Fill the oil tank with destined fuel.④ Check whether the hydraulic oil, the engine oil,

fuel and the cooling liquid are leakage.

⑤ Fill lubricate grease.

⑥ Check whether the junction plane between the nuts

of wheel boss and the piston of hydro cylinder is loose,

and whether the surface of piston has been pulled.

⑦ Check whether the wheels of mast roll stably.

⑧ Lift the lifting cylinder to the top and fill it with

oil.

⑨ In cold weather, it needn’t to discharge the

antifreeze, but the cold water should be removed

completely.

Deposit the truck for a long time

When deposit the truck foot a long time, you

should block the truck body and block under the counter

balance so as to reduce the load of the rear wheals.

Warning!

a. The block must be a single that is hard enough to

support the truck.

b. Do not use the block that is higher than 300mm

(11.81 inch).

c.

Hoist the truck just to be deposited on the block.d. Block the truck under both left and right body.

e. Sway the truck right and left, front and back after

the truck has been blocked to check weather it is

safety.

On the basic of the “deposit” you should do these

checks and maintain additional.

1. Take down the battery and recharge it once a week,

place it in the shade.

2. Brush antirust oil on those part which is exposed such

as piston rod and axle.

3. Put a cloth on vent-plug and air-cleaner.

4. Start the engine once a week. If the water has already

been let out, add water in the radiator. Then start the

fork lightly.

5. In summer, it is not recommendatory to park the fork

on asphaltum road.




29

Running after deposit for a long time

1. Get down the antirust oil on the exposed parts.

2. Adding new fuel and oil.

3. Get rid of the eyewink and water in the oil tank, fuel

tank.

4. Check the clearance of the valve, gas valve cap and

other parts on the engine.

5. Adding antifreeze or water.

6. Recharge the battery.

7. Check others carefully.

8. Warm-up your truck.

9. Check all the function of the truck as above describes.




30

Maintenance

Maintenance summarization

· The fork lift truck needs trebly inspection

and maintenance, make it in good working

condition.

· Inspection and maintenance are usually

ignored, you must find the problems and solve

it in time.

· Please dispose of old oil in locally

approved manner.

· Make a particular maintenance and repair

schedule.

· Take a complete note after maintenance and

repair.

· Don’t use different oil when changing or

adding oil.

· Forbid to repair the fork lift truck if you

haven’t been trained.

· After service maintenance, please record it.

· Take a complete note after maintenance andrepair.




31

Preventive maintenance schedule

— Check, revise, adjust

× — Replace

Maintenance

Item

Service

RequiredTools

Daily

(8 hrs)

Monthly

(200 hrs)

Semiannually

(1200 hrs)

Annually

(2400 hrs)

Visually inspect condition ofengine rotation (include ofVoice，color of exhaust gas)

Clean or replace the aircleanerelement

× × ×

Check crankcase for dirtand clean

Check the valve clearanceis correct

Thickness

gauge

Retighten cylinder head

bolt

Torque

wrench

Engine

Check cylinder for propercompressioncompression

Compre-ssiongauge

Crankshaft

Device

Check metering valve and pipe for clogging ordamage

Governor

or injection

Pump

Check no-load maximum

rpm

Tacho-

meter

Engine

Maintenance

ItemService required Tools

Daily

(8 hrs)

Monthly

(200hrs)

Semiannually

(1200 hrs)

Annually

(2400 hrs)

Check oil leakage for engine

Check engine for oil Level

and dirt

Replace engine oil × × ×

Lubricationsystem

Replace engine oil filter

cartridge× × ×

Visually check for fuel leak

from pipe, pump or tank

Check fuel filter for clogging

Fuel

system

Replace fuel filter cartridge

（diesel engine D） × ×




32

Check that injection nozzle

has correct inject press and

pattern（diesel engine）

Nozzle

tester

Check for injection

timing(diesel engine)

Drain off water from fuel

tank

Clean fuel tank

Check fuel quantity

Check for coolant level

Check for coolant leak

Clean and change coolant ×

× Use

antifreeze

for 3~5 years

Check fan belt for tension

and damage

Clean the exterior body of

radiator

Check the radiator cap for

condition and installation

Cooling

system

Check hoses for

deterioration

Driving System

Checking


Daily

(8hrs)

Monthly

(200hrs)

Semiannually

(1200 hrs)

Annually

(2400hrs)

Check clutch pedal for

free travel and clearance

between pedal surfaceand floor when clutch is

unlocked

×

First(200h)

×

Check for noise and

operation

Clutch

Check for slipping and

engagement

First

(200h) ×

Check change lever for

operation and looseness

Check for oil leaks Mechanical

Transmission

Change oil




33

Replace line filter

element

Check for oil leaks

Check for oil level ,or

change oilX X

Check inching pedal for

free travel and pedal

travel

Check for control valve

and hydraulic clutch for

proper operation

TorqueConverter

Transmission

Check inching valve for

Proper operation

Check wheel hub

bearing

for looseness，noise

Clean and repack grease

Check for leaks

Check the axle body for

deformation， crack or

damage

Check bolts which is

connected to the truck

body for looseness

Check wheel hub bolts

for retighten moment

Torque

wrench

Front Axle

Wheel reducing

mechanism

Wheels ( Front, Rear Wheels)

Checking


Daily

(8 hrs)

Monthly

(200hrs)

Semiannually

(1200 hrs)

Annually

(2400 hrs)

Check for inflation

pressureTire gauge

Check for abrasion ，

cracks or damage

Check for spikes ，

stones or foreign matter

Check the wheel hub for

damage

Tires

Check the split body

wheel hub-bolts for

looseness

Test

hammer




34

Steering System

Checking

Item

Service required Tools Daily

(8 hrs)

Monthly

(200hrs)

Semiannually

(1200 hrs)

Annually

(2400 hrs)

Check for peripheral

play

Check for sideways

looseness

Check for vertical

looseness

Steering

wheel

Check for proper

operation

Steering

Gear Box

Check mounting bolts

for looseness

Check king pins for

looseness or damage

Check for deflection,

deformation, cracks or

damage

Knuckle

Rear Axle

Check for mounting

condition

Test

hammer

Check for operation Steering

Cylinder Check for oil leaks

Brake system

Checking

Item

Service required ToolsDaily

(8 hrs)

Monthly

(200hrs)

Semiannually

(1200 hrs)

Annually

(2400 hrs)

Check for free travel Scale 〇〇〇〇

Check for pedal travel 〇〇〇〇Brake

pedal Check for proper

operation 〇〇〇〇

Check for lever is

securely locked 〇〇〇〇

Parking

Brake

Lever Check for proper

operation 〇〇〇〇

Hoses andCheck for damage,

leakage or collapse〇〇〇〇




35

PipesCheck for loose

connection or

clamping parts

〇〇〇

Check for the interface

is leaking 〇〇〇〇Air tank

Check for Whetherto install a solid 〇〇〇〇

Check for Whether the

leak〇〇〇〇

Check for

Automatically adjust

braking pressure on

the system's

performance

〇〇〇

Oil-water

separation

Combinati

on valve

Check for Oil, water

impurities automatic

discharge performance

〇〇〇


leak〇〇〇〇

Safety

valve Check for Brake

pressure control

system performa

〇〇〇


leak〇〇〇〇〇

Check for Auto

emissions function〇〇〇〇〇

Automatic

release

valve Check for when rescue

park operations

manual button fastwater

〇〇〇

Check for Pedal, the

valve is installed to

connect firmly

〇〇〇〇〇

Check for Valve

clearance is normal〇〇〇〇


leak〇〇〇〇〇

Gas system

Valve

action

Check for Campaign

site for the use of

grease mainte

〇〇〇

Checking

Item

Service required ToolsDaily

(8 hrs)

Monthly

(200hrs)

Semiannually

(1200 hrs)

Annually

(2400 hrs)


leak〇〇〇〇

shuttle

valveCheck for

performance is normal〇〇〇〇




36


leak〇〇〇〇

relay valveCheck for Braking is

lagging〇〇〇〇

Check for Whether theleak

〇〇〇〇

Check for Whether or

not to install a solid〇〇〇〇

Check for Campaign

site for the use of

grease maintenance

〇〇〇〇

Manual

brake

Check for

performance is normal〇〇〇〇

Check for whether the

rapid lifting of the

brake brake

〇〇〇〇Quick

release

valve


leak〇〇〇〇

Check drum mounting

part for looseness

Test

hamme

r

〇〇〇

Check clutch block s

ray

Slides

calipers 〇

Check clutch blocks

for proper operation 〇

Check anchor pin for

rust or distortion 〇

Check seal ring for

deterioration〇〇〇

Check automatic brake

disc for deterioration,

Check for cracks

Crack

detectio

n

〇

Check Adjust the arm

extended wear,damage

〇〇

Brake

Drum &

clutch

blocks

Check camshaft

、cam stent is installed

loose

,deformation,wear

Test

hamme

r

〇




37

Hydraulic System

Checking


Daily

(8 hrs)

Monthly

(200hrs)

Semiannually

(1200 hrs)

Annually

(2400hrs)

Check for oil level, Change oil

Clean suction strainer HydraulicReservoir

Drain for foreign matter

Check levers for looseness at

link

Control lever

Check for proper operation

Check for oil leaks

Check relief valve and tilt lock

valve for proper operation

Control valve

Measure relief pressureOil press

gauge

Check for oil leaks, looseness,

collapse, deformation and

damage

Hose, Piping

Hose Reel &

Swivel JointChange hoses 1-2 Years

Electrical system

Checking


Daily

(8 hrs)

Monthly

(200hrs)

Semiannually

(1200 hrs)

Annually

(2400hrs)

Starter

motor Pinion joggle

Check for electrolyte level and clean Battery

Check specific gravity of electrolyte

Check for wire harness for damage

and clamps for looseness

Wiring

Check connections for looseness

.Lifting system

Checkingitem

Service required Tools Daily(8 hrs)

Monthly(200hrs)

Semiannual

ly

(1200 hrs)

Annually(2400hrs)

Check chain for

tension, damage or rust〇〇〇〇

Lubrication of chains 〇〇〇

Check connection of

chain anchor pin and

chain for looseness

〇〇〇

Chains &

Sheave

Check sheaves for

deformation or damage 〇〇〇




38

Check sheave bearings

for looseness〇〇〇

Optional

Attachment

Perform general

inspection〇〇〇

Check piston rod, rodscrew and connection

for looseness

deformation or damage

Test

hammer 〇〇〇〇

Check cylinders for

proper operation〇〇〇〇

Check for oil leaks 〇〇〇〇

Lifting

cylinder

Check pins and

cylinder bushings for

wear or damage 〇〇〇

Check hydraulic pump

oil leak or have noise〇〇〇〇

hydraulic

pump

Check driving gear

of the hydraulic

pump worn condition

〇〇

Check forks for

damage, deformation

or wear

〇〇〇

Fork Check fork base and

hook welding for

defective cracks or

wear

〇〇〇

Check Screw state

inspection

,deformation, corrosion

damage

〇〇〇〇 Screw

Check screw fuel 〇〇〇

Check cross members

on outer and inner

masts for defective

weld, cracks or damage

〇〇〇

Check tilt cylinder

bracket and mast for

defective weld ,cracks

or damage

〇〇〇

Mast &

Lift

Bracket

Check outer and inner

masts for defectiveweld, cracks or damage

〇〇〇




39

Check for defective

weld, cracks or damage

of lift bracket

〇〇〇

Check roller bearings

for looseness

〇〇〇

Check mast support

bushings for wear or

damage

〇

Check mast support

cap bolts for looseness

Test

hammer

〇

(for 1st

time only）〇〇

Check lift cylinder tall

bolts, piston rod head

bolts, U-bolts, and

piston head guide boltsfor looseness

Test

hammer

〇

(for 1st

time only）

〇〇

Check rollers, roller

pins and welded parts

for cracks or damage

〇〇〇

Additional

Checking

itemService required Tools

Daily

(8 hrs)

Monthly

(200hrs)

Semiannua

lly

(1200 hrs)

Annually

(2400hrs)

Check for tight

installationTest

hammer 〇〇〇〇

Check cab Bearing

on the right side of

the pin installed in

place

〇〇〇〇

Check deformation,cracks, damage

〇〇〇〇

Check wiper work〇〇〇〇

Check the door

open to close〇〇〇〇

Check the

manually pump

work

〇〇〇〇

Cab

Check cab tipping

is normal〇〇〇〇




40

Turn signal Check for proper

operation and tight

installation

〇〇〇〇

Horn Check for proper

operation and tightinstallation

〇〇〇〇

Light &

Lamps

Check for proper

operation and tight

installation

〇〇〇〇

Buck-up

Buzzer

Check for proper

operation and tight

installation

〇〇〇〇

Meters Check meters for

proper operation〇〇〇〇




41

Replace the key safe parts termly

· Some parts should be checked termly to detect the damage , for improving the safety more,users should replace the parts termly which is listed in the table as follows .

· If the parts is abnormal before the replacing time is coming ,it should be replaced immediately .

KEY SAFE PART’S DESCRIPTION TERM OF USING (YEAR)

Brake hose or tube 1~2

Hydraulic hose for lifting system 1~2

Lifting chain 2~4

High-pressure hose ，hose for hydraulic system 2

Fuel oil hose 2

Inner hermetic，rubber matter 2

Table for bolt’s tight moment

Unit N·m

GradeBolt’s

diameter 4.6 5.6 6.6 8.8

6 4~5 5~7 6~8 9~12

8 10~12 12~15 14~18 22~29

10 20~25 25~31 29~39 44~58

12 35~44 44~54 49~64 76~107

14 54~69 69~88 83~98 121~162

16 88~108 108~137 127~157 189~252

18 118~147 147~186 176~216 260~347

20 167~206 206~265 245~314 369~492

22 225~284 284~343 343~431 502~669

24 294~370 370~441 441~539 638~850

27 441~519 539~686 637~784 933~1244

30 529~666 666~833 784~980 1267~1689

36 882~1078 1098~1372 1323~1677 2214~2952

47 4000-4300

Note:·Use entirely 8.8 grade bolt in the important joint position.

· Bolt’s grade can be found in the head of the table, if it can’t be found, the grade is 8.8.




42

Table for the oil used in the truck

Description Shop sign，Code name Capacity Remark

Diesel0#(summer)

-10#~-35#(winter)120

General season：CD grade 10

W/30 or according to service

manual of engine

冬季：CD级以上10W／30或

根据发动机维护说明书

Diesel engine oil

高寒环境：CD级以上5W/30

或CD级以上5W/40

11～13

General season: Anti-wear

hydraulic oil

L— HM32

Hydraulic oil Alpine Environment

:Wear low-temperature

hydraulic oil

L-HV32

110

Hydrodynamic

power

transmission oil

ATF DEXRON II（Caltex） 31-32 Tr ansmi ssi on by

Gear oil GL-5 85 W/90 14 Driving axle、wheel reduction

antifreeze -35 antifreeze，kunlun 28

Industrial

vaseline 2#

Electrode of Storage

battery

Lubrication

grease

Currency lithium group

lubricate grease

Note: · The Fork Lift Truck have been injected with the antirust antifreeze liquid according to

scale of 1:1, you may not let it out even in the severe winter. Usually it was changed

every 2-4 years.




43

Engine service technical parameter·Engine’s other parameters are listed in Engine Service Manual

Diesel engine 6BTA5.9-C18

Idlerpm

700-750

Max. Speed

rpm2530

Ignition order 1-5-3-6-2-4

advance angle

of fuel supply13±2

0

Injection open

pressure Mpa23~24

admis

sion

mm

0.4(Cold engine)valve

cleara

nce Exhau

st mm0.45(Cold engine)




44

Truck’s convey, lifting, towing

Convey

·The Fork Lift Truck is designed for material handling only, It is inappropriate for

long-distance transportation. The Fork Lift Truck must be transported by ship, train or lorry,

of 20T loading.

·Use a loading flat roof or lifting set loading and unloading truck.

·Lock hand brake and use chocks fix the wheel , use firmly cord fix body ,prevent slippage.

Hoist the truck

·Use the steel wire ropes to tie the holes in the two side of the outside mast’s beam and the

hook of the counter balance, then use the lifting device to hoist the truck.

！

Warning

·When hoist the truck, don’t coil the overhead guard with the steel wire.

·The steel wire ropes and the lifting device must be very firm to support the truck because the

truck is very heavy.

·Don’t lift the truck by hoist the overhead guard.

·When lifting the truck, don’t take yourself below the truck.




45

CPCD160-XG35 inner ignite fork technology parameter

model CPCD160-XG35

Power type Diesel

Rated capacity kg 16000

Load center mm 600

Lifting height mm 3000

Free lifting height mm 0

Fork size mm 1820×200×105

Fork distance(outside) mm 520-2200

Tilting angle deg 6/12

Length（not contain mm 4820

Width mm 2480

Overall

dimensio

n Height mm 3080mmGround

Clearan mm 270

Min turning radius mm 4450

Max lifting speed,laden mm/s 350

Max traveling speed km/h 34

Max Grade ability % (Laden),

≥2km/h% 20

peak traction kN 100

Service weight kg 18800

Front 12.00-20-20PR

Rear 12.00-20-20PRTire

Qty, 4/2

battery V/AH 2×12/120

Model YC6108ZG

Rated power / kw/rpm 115/2300

Max torque/ Nm/rpm 560/1500

Cylinder 6

Bore/stroke mm 108×120

Motor

Displacement l




46




47

Cab tipping rules

warning

·Vehicles will be parked at the level on the ground, the handle stalls on the free, fork fell to

ground, the gantry forward tilt, lay the parking brake, engine off and disconnect the power;

· Before cab tipping, remove non-fixed items, nobody in, nobody beside on the left when tipping;

·Rotating the pin which at the right side of the driver's seat bottom cushion to the direction of

opening slot and out , do not want to hold tipping, manually pump knob to "work" location;

·Cover fixed to prevent collisions, Shake the handle bar for tipping cab operation, stop when the

handle force increased , Cover to prevent the closure of misoperation;

·Before into the in-house maintenance repair operation, use items solidly supported or fixed the cab,

strictly prohibit loosing the fuel cab tipping tank and the connected pipeline joints and so on;

·Before the cab repositted ,must confirm there is no person in it, get rid of backstop or fixation, turn

the handle-pump konb to "short circuit" slowly and anticolockwise, then the cab re-posit calmly

with itself-weight.

·Make sure the cab repositted ,then assemble cushion and joint it with body carrier. Insert rotation pin

shaft, turn it's lower upright to notch, and the handle pump remain keep loosening.



2

- 6

tR

Series Forklift Truck

SERVICE MANUAL

CPCD120/140/160-XG35

HANGZHOU FORKLIFT TRUCK Co., Ltd2008.9 1st EDITION



Foreword

The manual is the introduction of structure, working principle and

serving .etc of 12-16t series diesel fork truck . For safety and performance

of truck, all in charge of operation, maintenance and management must read and

comprehend this manual well.

It is forbidden anybody without training and qualification to

maintain.



Foreword

I. Driving System .................................................................................................错误！未定义书签。

II. Hydraulic gear-box and torque converter.......................................................... 错误！未定义书签。

III. Drive axle and Carrier assembly........................................................................错误！未定义书签。

IV. Steering axle......................................................................................................错误！未定义书签。

V. Steering system .................................................................................................错误！未定义书签。

VI. Brake system..................................................................................................... 错误！未定义书签。

VII. Hydraulic system ...............................................................................................错误！未定义书签。

VIII. Electrical system................................................................................................ 错误！未定义书签。

IX. Lifting system ...................................................................................................错误！未定义书签。



1

Driving System

Power configure

DieselEngine

parameter CY6108ZG(Yuchai )

Rated output KW 115

Rated rpm r/min 2300

Max. torque

N·m/speed rpm560/1500

Forklift model CPCD120/140/160-XG35

Specification, structure and maintenance, please refer to ENGI NE MAINTENATIO N

MANU AL.

There is need to check the exhaust quantity after the maintenance or servicing, and ensure

that the exhaust gas accord with the table:

Engine power

KW

CO

(g/kwh)

HC

(g/kwh)

NO2

(g/kwh)

PT granule

(g/kwh)

75≦P <120 5 1.3 7 0.4



2

Hydraulic gear-box and torque converter

Data

Model YQXD100H1

Hydrodynamic

torque

converter

TypeTwo stage, three phase,

four-element

Variety Electrical shift

Forward I 1.179

Forward II 0.645Hydrodynamic

power ge ar-box

Transmissi

on gear

ratio Reverse I 0.844

Shift gear oil pressure

MPa1.0-1.6

Oil pressureTorque converter output oil p ressure

MPa<=0.50

Mass (kg) 450

Oil capacity (L) approximate31-32

Using oil type ATF DEXRON II（Caltex）

Specifications, structure and maintenance methods ,please see《Y63270ZJapan

Okamura MODEL TORQUE CONVERTER MAINTENANCE MANUAL》 .



3

Drive axle and Carrier assembly

Drive axle typeOne step carrier assembly and wheel-end reduction

Full floating, direct frame mount, front-wheel drive

Carrier assembly One step helical bevel gear

Differential assembly. Straight tooth gear

Wheel-end reduction pinions

Oil capacity in housing GL-5 85W/90 (L)

Oil capacity in wheel-end

reductionGL-5 85W/90 (L)

TROUBLE DIAGNOSES AND CORRECTIONS

Specifications, structure and maintenance methods ,please see《CPCD160-XG35

MODEL MAINTENANCE MANUAL And PARTS ITEM》 .

Condition Probable causeCorrective

action

·Loose axle mounting bracket bolts. Tighten.

·Loose wheel nuts. Tighten.

·Other retaining parts loose. Tighten.

·Worn or damaged wheel bearing. Replace.

·Wheel bearing not properly adjusted Adjust.

·Worn sun gear (drive shaft) splines. Replace.

Unusual noise

Before attempting a correct

ion, make sure the noise is

coming from the drive

shaft-not from the final drive

or wheel reduction gear.·Insufficient lubrication. Lubricate

·Loose wheel nut. Tighten.

·Deformed road wheel. Replace.

·Worn or damaged wheel bearing. Replace.

·Loose axle mounting bracket bolts. Tighten.

·Wheel bearing not properly adjusted. Adjust.

Unstable driving

Also refer to the Trouble

Diagnoses and Corrections in

the RA section.

·Improper tire pressure. Adjust.

·Worn or damaged axle tube oil seal. Replace.

·Final drive improperly installed. Replace gasket.Oil leakage

·Loose filler or drain plug. Tighten.



4

V Steering axle

1. General specification axle center

suspension type Center support, wing typeFore-aft

clearance（mm）

0～1(forward is no

clearance)

Fore-aft adjusting shimInner

wheel77.6°

Max. Steering angleOuter

wheel50°

Thickness

（mm） Part number

Tire pressure 0.83MPa 0.5，1.0，1.5 GX160-220005-000

Kingpin wheel bearing

Axial play（mm） Less than 0.2

Adjusting shim

Thickness（mm） Part number

Pre-tightness

Tighten bearing nut until rotating

resistance is felt, from this

position; back off bearing nut

1/8-1/6 turn. or wheel hub bolt

initial force is less than

10-29N

0．1，0.7，1.0 G160-220014-000 Axle play(mm) Less than 0.08

2. Trouble diagnoses and correction

condition Probable cause Corrective action

Unstable driving

·loose wheel nut

·wheel bearing out of adjusting·improperly adjusted mount shims

·faulty steering system

tighten

adjustadjust

refer to steering section

Noises

·insufficient lubrication

·loose bolts and nuts

·improperly adjusted mount shims

Apply grease

tighten

adjust



3. Steering Axle Structure



6

1.steering wheels assembly 2.ball nut 3.join nut 6.end cover

7. paper washer 8.left steering spindle 11. bearing 13. bearing 14.oil seal

15.cover plate 17.oil cup 18.O-ring seal 19.steel bushing 20.bearing

21.soldering cup 22.bolt 26.axis pin 27.mounting cap 28.bearing

29.connecting rod 34.right steering spindle 35.axis pin 36.mounting cap

37. steering axis 38.steering cylinder 39.dust ring 40.bearing bushing41.adjusting shim 44.king pin 45.bearing

Fig 4-1 steering axis

Removal

•

Steering wheel hub

1) Jack up and support truck body with safety stands.

2) Remove tire.

3) Remove hub cap.

4) Remove spindle nuts and bearing washer.

5)

Pull off hub ass embly.

Caution：

a. Be careful not to drop bearing cone.

6) Remove inner bearing cone.

Caution： b. Be ca re fu l not to damage grea se se al .

• Kingpin and steering spindle

1) Remove ball stud nut and disconnect tie-rod from steering spi ndle.

2) Loosen lock nut and re move set-screw.

3) Remove grease nipple.

4) Attach a pad to upper end of kingpin, and drive out kingpin.

Caution: hold kingpin to prevent it from dropping。

5) Take off spindle, including thrust bearings and shim as an assembly.

Inspection

1）．Replace spindle if cracked.

2）．Replace thrust bearing if its rollers or roller surfaces are rusted or nicked.

3）．Replace needle bearings if damaged.

4）．Replace bearings and dust-proof cover if damaged.

installation：

To install, reverse t he order of removal. Carefully observe the foll owing.

1）Always insert kingpin from lower side.

2） Install thrust bearing with its cover facing up, and adjust axial play less than 0.2mm with

shims.

caution：Always pl ac e th ru st be ar ing on uppe r si de of sp ind le, and sh ims on low er si de .

3）Apply grease inside the dust-proo f cover and between two rings of thrust bear.

5）Do not apply grease to spindle mating with bearing.

6）Apply grease on needles and balls of bearings.

7）Pack all grease nipples with a sufficient amount of grease.

• Wheel bearing installation and adjustment

1) Apply grease or anti-rust oil on contact surface of bearings and spindle nut.

2）Rotate hub slowly. Tighten bearing nut until rotating resistance is felt; turn bearing



7

nut back off 1/4turn from that position.

3）Rotate hub 2~3 turns, make the rollers stay in the right position.

4）Repeat the second step, and install bearing washer and tighten the other bearing nut.

5）Rotate frontward and backward hub 2~3 turns, make sure its axle clearance is less than

0.08mm, and rotated starting torque at hub bolt is less than 25.5N. Otherwise, return to the

second step.Axle center

Removal

1. Jack up and support truck body with safety stands.

2. Remove tire.

3. Disconnect ball joint at tie-rod.

4. Support axle center with a jack.

5. Disconnect piping connectors and remove mounting caps.

6. Remove axle center.

caution：Be careful not to slide jack out of place.

Installation

To install, reverse t he order of removal. Carefully observe the foll owing:

Add shims on both sides until fore-aft clearance between steering axle and frame is less than

0.7mm.



8

V Steering system

Steering system typerear wheel steering with

powe r st ee ring

fully hydraulic

redirector

line mounted with

pr ior it y va lve ,l oad

sensing

power cy lin de rdouble-action

transfixed

1. Trouble diagnoses and correction

condition Probable cause Corrective action

Pump damaged or faulty replace

Flow priority valve blocked or damaged Clean or replaceSteering wheel

failure Pipes or connections damaged or passage

bl ocke dClean or replace

Low oil pressure in the flow priority valve adjust

Air in system Bleed air

Steering gear fails to reset, or orientation

shim is broken or of failure

Replace elastic shimHard steering

Power cylinder piston seal damaged replace

Truck travels

like snake orGreat steering deflate adjust

Insufficient oil in tank replenishnoises

Blocked in the passage or filter Clean or replace

leakageSeal on the guide set, piping or connector is

damagedreplace

2. General

The steering system is mainly composed of cycloid fully hydraulic redirector and the

power cy lin de r.

2.1 Cycloid fully hydraulic redirector

It consists of cycloid steering gear, steering column and steering wheel. The assembly

posi tion ca n be ad jus ted 8°af t-forth to sa tis fy dr ive rs ’ nee ds .

Turn the steering with 1 KG power when the power is off, and it can return about

10°automatically after loosening.2.2 Fully hydraulic steering

With overflow valve, load sensing. Pressure oil enters stator-rotor set from valve disk and



9

sleeve valve set, then drives rotor turns following with steering wheel, and presses oil into

left and right chamber of steering cylinder, then cylinder piston rod forces steering wheel to

steer.

2.3 Steering oil cylinder

Steering cylinder is of double-action piston type; each end of piston rod is connected

to tie-rod and spindle in turn. Hydraulic oil from fully hydraulic steering gear makes the

pi st on rod move le ft and ri gh t to steer tr uc k.

1. piston rod 2.LBI seal ring d80 3. bolt 4.O-ring seal 80X5.35.ISI seal ring d80 6. guide set 7.O-ring sea 100X5.3 8. cylinder body9.glan-ring D110 10． steel ball 11.support ring 12.piston

Fig 5-1 steering cylinder



10

V Brake system

Brake system uses air pressure braking system, its supply devices and gears are air

pres su re type. It s contro l de vice s are composed of brake pe da l fr amew ork , ai r- brake va lve,

hand brake valve, oil-water separator combination valve, air tank, safety valve, brakeair-chamber, drain valve, shuttle valve, relay valve, quick lease valve, etc. Air compressor

feed in oil-water separator combination valve compressed air by engine, then the air flows

from check valve to air tank (with safety valve and hand water release valve), one way to

hand control valve, parking brake chamber to control parking brake; another way to air brake

valve, shuttle valve, relay valve, run brake air chamber to control run brake. The air circuit

has drain water and filter device to ensure air source is clean. Taking antirust treatment to

air brake system pipe and air tank.

Fig. 7-1brake system diagram

1 oil-water separator combination valve

1. 1Technical parameters

Opening pressure 784kPa±20kPa

Stop draining air pressure 685～750kPa

Joining dimension

Input M22×1.5-6g

Output M22×1.5-6H



11

1.2 Structure and Principle

Oil-water separator combination valve is used to adjust the pressure of brake system

automatically; it can deflate the filtered air and water. Because of safety device, it can

ensure the pressure of system is safe.

The pressure air from air compressor flows through inlet to valve, the filter filters waterand impurity which existed in air, the filtered air flows from check valve to outlet to charge

air tank. When the pressure of tank is up to the opening pressure, the air in top head chamber

pu ll s contro l pi ston assembly up , opens dra in va lve , then de fl at es the fi lt er ed wa ter and

impurity and compresses air from outl et to air, makes air compressor run without load, when

the pressure of tank reduces to the valve of stop draining , the pressure of top head chamber

does not overcome the force of pressure-adjust spring, control piston assembly move down,

the spring pulls drain valve up to close drain valve port, then conti nues to supply air.

Fig.7-2oil-water separator combination valve

1.3 correct use and maintenance

1）Product is installed at installation plate with 70 intervals, down the exhaust.

2）Before the factory, pressure adjustment screw, safety valve assemblies have been set, the

user will not be permitted to adjust, demolish.

3）The piping from air compressor shall not be less than two meters i n length in order to be

fully cooling hot air , condensing moistu re in air.

4）Wearing parts wear seriously or leak seriously , wearing parts should be immediately

replaced.

5）Please be in accordance with the corresponding replacement of wearing parts in kind when

replacing wearing parts, damaged fasteners(bolts, nuts) in the process of replacement must

be repl aced , and ensur e that the in st al lat ion is in pl ac e, so lid and re li ab le, and ma y no t

damage other parts.

6）Replacement without a qualified pilot shall not be used.



12

1.4Common faults, failure analysis and troubleshooting

Commonfaults

failure analysis troubleshooting

There are impurities at exhaustvalve. Clean pipeLeakage of

exhaust portexhaust valve damaged Change exhaust valve

diaphragm damaged change diaphragmLeakage of tophead exhaust

hole Control piston o-ring damagedChange control piston

o-ring

Wearing parts table

Serial

number

name Fig NO. NO.

1 o-ring seal SH380A-3511061 1

2 Control piston o-ring SH380A-3511071 1

3 diaphragm SH380A-3511078 1

4 Drain valve SH380A-3511038 1

2. Safety valve

2.1Structure and Principle

Compressed air flowed from inlet, when the inlet pressure is greater than 850kPa, the

safety valve A opens air on the air brake pipe from the role of security protection to ensure

that the inflating air brake pipe pressure does not exceed 900kPa.

Safe working pressure: 850 ~ 900kPa. Inlet M16 × 1.5-6g is the connecting thread.



13

Fig.7-3 safety valve

2.2caution when use

Before the factory, the adjustment bolts on safety valve assembly have been set , users are not

free to self-adjust, demolish.

2.3Common faults, failure analysis and troubleshooting

Common

faults

failure analysis

troubleshooting

Valve port

leakage

Rubber safety valve

stem assembly damage

Replacement

safety valve assembly

Wearing parts

Na me Figu re No . No.

Safety valvestem assembly

150-3511051A 1

3Automatic release valve


Automatic release valve is used to pump air brake pipe reservoir of pool water, through the

pres su re fl uctua ti ons in va lue (p re ssur e drop 0.03 ~ 0.1MPa ) au to mati ca lly from the exha us t

Ad ust bol t

Exhaust ort

inlet



14

water; achieve automatic deflation function; while parking users also can manually operate

bu tton fo r fa st wa ter dra inage.

`

Fig.7-4Automatic release valve

Rated working pressure 800kPa

Installation and connection dimension M22×1.5-6g

Exhaust down

Wearing parts

Na me Code No .

Membrane inlet assembly PY20-1305030 1

4．Air brake


When pressing on the bake pedal 2, through push rod 3, the balance spring 4 is forced to pull

pi st on 6 down and open in let va lve 7, compressed ai r flows from in let to ou tl et . When loosing

peda l 2, re tu rn sp ring 5 pushs pi stons 6 up , inl et va lv e 7 re tur ns ba ck to close the wa y

be tween in le t and ou tle t, the re sidua l ga s emiss ions fr om th e exha us t.

To air tank

Manual water

bu tton

Exhaust po rt



15

1、 screw 2、 peda l 3、 pu sh rod 4、 bal ance sp ring

5、 return spring piston 7、 inlet valve

Fig.7-5 air brake valve

4.2 Proper use and maintenance methods

4.2.1 Caution

1） Ensure that the pedal firmly connect with the valve body, screw-adjust valve clearance

should be adjusted well (to ensure that the pressure roller mandrills screw down surplus

amount of not more than 0.5mm), and tight nut.

2）M8 bolts through the 4-φ9 hole are firmly connected.

3）Piping connections should be recognized inlet, outlet. Interface marked "1" for the inlet,

interface marked "2" outlet, interface marked "3" exhaust.

4.2.2 Attention of maintenance

Please be in accordance with the corresponding replacement of wearing parts in kind when


be repl aced , and ensu re tha t the ins tal la ti on is in pl ac e, so lid and re li ab le, and may no t

damage other parts.

2）The movement location of air brake parts should be used grease for maintenance. If the

brake is fa il ed or weak , it ha s to check the wear in g pa rt s of ai r brake va lve and br ake sys te m.

3）Replacement may not be installed without a qualified pilot.

4.3 Common faults, failure analysis and troubleshooting

Common faults failure analysis troubleshooting



16

Non- workin g st at e

leakage

Rubber Parts

damage

Replace wearing parts or replace product

assembly

Working state

leakage

Rubber Parts

damage

replace wearing parts or replace product

assembly

Piston stuck replacement product assembly

Exhaust of sorts

Pedal wheel does

not adjust well

with the

mandrills

Manually re-adjust screw so that the pedal

on the mandrel wheel just contacts

appropriate, (the pressure roller mandrills

screw down surplus amount of not more

than 0.5mm)

5．Shuttle valve


Actually it is a special three-way valve. The output pressure of frontward and backward

cavity in dual-chamber may not be inconsistent, so they both pass int o the shuttle valve.

Shuttle valve only allows higher pressure compressed air to flow through outlet, th rough

relay valve to driving brake air chamber.

Compressed air flows from the A mouth, the air pressure will push the pi ston D to the B-sid e, because the bo th si de s of pi stons D are rubb er, thus it can guara ntee no n-ai r leak from out le t,

so that pressure can outflow from the outlet C; Similarly, if the air flows into the inlet B ,the

pres su re wi ll ou tflow as the sa me wa y ou tflow s from the ou tle t C. Rated work ing press ur e is

784kPa.

Maintenance should be to protect the interface thread.


Common

faults failure analysis troubleshooting



17

Valve portleakage

Rubber plunger valve damageReplace the

valve plunger

Wearing parts

Name Fig.No No.

Valve plunger SUSH-3527013 1

6 relay valve


Compressed air does not flow through the air brake but direct charges into the lane brake

chamber so as to shorten the supply route to reduce the braking time lag.

1） Brake

The pressure from control valve entering 4, pushes piston down, closes the valve,opens the intake valve so that air pressure from the reservoir pushed by pump opens intake

valve, flows from outlet 2 to brake air chamber, at the rated working pressure, the gas

outlet pressure is controlled by the air intake pressure with a direct proportion .

2) Loosening the brake: after loosening control intake4 air pressure, then the piston is

moving up, and exhaust is opening, brake pressure in the chamber will be deflated into the

atmosphere through the exhaust port.

Fig.7-6

1. Exhaust valve assembly 2.O-ring

Technical parameters

Rated working

pr essu re

784kPa



18

Initial balance

pr essu re

≤50kPa

Connection

dimension

Outlet :2-M22 × 1.5-6H, inlet: M22 × 1.5-6H

Control of air intake: M22 × 1.5-6H

6.2 Proper use, maintenance and Cautions

(1 ) Caution

1) Installed in the installation board with 74 × 74 interval, the exhaust outlet is down, then

tightens the 4-M8 nuts, and it shall not b e loosen.

2) Piping connections should be recognized inlet, outlet and control of air intake. Int erface

marked "1" for air intake, int erface marked "2" for the outlet, i nterface marked "3" for the

exhaust port, and interface marked "4" for the control of air intake.

(2 ) maintenance, maintenance of attention

1) When founding severe wear wearing parts, or leakage, grave wearing parts should be

immediately replaced.2)Please be in accordance with the corresponding replacement of wearing parts in kind when



damage other parts.

3) Replacement may not be installed without a qualified pilot.

6.3Common faults, fault analysis and troubleshooting

Common

faults

fault analysis troubleshooting

Non-wor king

state leakage

O-ring wear replace wearing parts or

replace product assembly

Working state

leakage

Intake valve assembly

rubber parts damage

replace wearing parts or

replace product assembly

Wearing parts

Serial

number

Name Fig. No No.

1 O-ring GB3452.1-92 1

2 O-ring HFC-3527033 13 Inlet valve assembly HFC-3527020 1

7. Hand-controlled brake


When parking or emergency brake, hand-controlled valve can be used to brake ---

emergency brake chamber is connected with atmospheric air chamber, so that parking brake

or emergency braking can take effect while exhausting and reducing pressure. When

loosening the brake the car can be paring--- emergency air chamber is connected with the

reservoir pump.



19

Fig.7-7Hand-controlled brake

Its working state is braking deflated. Namely: When the system pressure is as low as 240 ~

310kPa, or a pipeline is ruptured, manual brake can automatically be took off to release the

interior air brake pressure of spring energy storage system, the spring energy storage on the

drive shaft can implement effective emergency braking. When emergency or stopping

happens, the driver lifts the button at the same time which plays the role of the above, so that

the vehicle can safely stop. Because it belongs to a result of deflated brake, so it is safe and

reliable.

Rated working pressure 784kPa

Insurance pressure 240～310kPa

Installation, connection

dimension

Intake: Z1/8 "

Outlet :2-Z1/4 "


(1 ) Caution

1)When installing, after M22 × 1.5 thread seal nut is screwed off, then screwing sealed nut

and tightening through the installation of plate.

2)Recognizing each interface when connecting: Marked "1" for air intake; marked "2" for the

outlet, marked "3" for the exhaust port.

(2 ) maintenance

1)Please be in accordance with the corresponding replacement of wearing parts in kind when



damage other parts.

Replacement may not be installed without a qualified pilot.

2)The movement location of emergency brake parts must be maintained with



20

high-temperature resistant grease. If the brake is failed or weak, it has to check the brake

system and emergency brake of wearing parts.

7.3 Common Faults and fault analysis and troubleshooting

Common Faults fault analysis troubleshooting

Non- work in g st at e

leakage

Working state

leakage

Rubber parts

wear

Replace wearing parts or replace

product as sembl y

Wearing parts

Serialnumber

name Fig. No. No.

1 Mandrels ring CT-3526064 1

2 Valve base ring CT-3526061 1

3Rubber valve

assemblyCT-3526050 1

8. Quick release valve


The function of the quick release valve between the hand-controlled brake and brake

air chamber is :when releasing the manual brake button, the route of parking brake air

chamber and the time can be shorten, and ensure the front wheel brake is loosen rapidly. Air

flows from the air brake inlet to quick release valve, the pressure acts on the tympanicmembrane to close exhaust valve, so that it make the outer part of tympanic membrane bend

downward, after that, the air flows from outlet to brake chamber through the surrounding

clearance of membrane. Lifting the brake, the air pressure of inlet releases through air brake

valve, the pressure below tympanic membrane will be pushed. When closing the top intake

channel, and opening the exhaust channel of lower body, the braking pressure in the chamber

is deflated into the atmosphere through exhaust port.

Rated working pressure: 784kPa.

Connection Size: inlet M22 × 1.5-6g; outlet 2-M22 × 1.5-6 g.



21

Fig.7-8 quick release valve


(1) Caution

Connecting pipe with three thread interfaces, the exhaust is downward.

(2) Maintenance

1) When found leakage then should immediately replace the wearing parts.

2) Please be in accordance with the corresponding replacement of wearing parts in kind when


be repl aced , and ensur e that the in st al lat ion is in pl ac e, so lid and re li ab le, and ma y no t

damage other parts.

3) Replacement may not be installed without a qualified pilot.


common

faultsfailure analysis troubleshooting

Parts of the exhaust valve

has dirt Clean pipe

Exhaust leak

Membrane damage Replace

membrane



22

Interval between

top and bottom

body leak

seal washers aging Replace washers

Wearing parts

Serial No .

Name Fig. No . No .

1 tympanum JN441-3516012 1

2 Seal washer JN441-3516014 1

9 Combination brake chamber

Combination brake chamber is composed of front and rear air chambers which are

unattached .one is driving brake chamber, driving brake takes effect when inflating and

increasing pressure. It is also called as inflatable braking room. Another is

pa rk ing -- emerge ncy br ake chamber, pa rk in g brake or emerge ncy br ake ta ke s ef fect when

exhausting and reducing pressure. When it inflating and increasing pressure, it becomes

weak even it will loose brake, so it is called inflatable braking room.

Inflatable braking room is for driving brake, deflated spring brake chamber is for parking

and emergency brake.

9.1 Structure and working principle

There are both inflatable brake room and deflat ed brake chamber in it. It generate force for

the wheel brake by filling and deflating , inflatable braking chamber (11 cavity) is for the

driving brake, deflated brake chamber (cavity 12) is for parking and emergency braking, the

main features of spring brake chamber is that it can get a mechanical braking force by the

release of sprin g energy.

Working pressure: 0 .8MPa; work trip 55mm



23

Fig.7-9 brake chamber

9.2 Caution

Warning！：

Extremely dangerous

1、

For internal structure of combination brake chamber, demolition ,assembly,

adjustment and replacement of wearing parts, must be done by professional

manufacturers;

2、

Demolition and assembly must use special tool s to prevent the spring

wounding.

1)"11" inlet to driving brake chamber; "12" inlet to emergency brake chamber;

2) When Loading, the air flows into emergency brake chamber ,screwing the adjustment

bo lt s from suppl ie d st at e to work st at e;

3)Vehicle was moving locked when driving, should promptly screw adjustment bolts to lift

the brake state (that is, supply status)

4)When driving brake chamber leak a little, can screw bolts on hoop down by wrench ;

5)Prevent bump ,do not damage the exhaust pipe, exhaust pipe shall not be loaded, pull;

6)Do not take down without special equipments, that is to guard against the spring

wounding.

9.3 Description of demolition and repair

1)Please confirm whether the adjustment bolts is screwed back before demolition and repair,

which is lift brake state and supplied state. And remove nut of adjustment bolts.

2) Put the spring brake chamber lifted brake state on compactor and compact it, then can use

wrench to unscrew bolts on hoop to remove hoop. Remove clamping device, then can

replace wearing part 1 membrane.

3) When the pressure of inlet 12 is 600 kPa, piston is push back, and then screw adjustment

bo lt s abou t 30mm. Af te r re leasi ng pr es su re , se al -p lug can be re moved wi th spec ial wrench ,

then replace wearing parts 2(o-ring 19×2.4). Removing fastening bolts on connecting cover

with wrench, then can replace wearing parts 3 (o-ring)

4)Put the storage cylinder assembly on special compactor and compact it, then remove

adjustment bolts, take out storage piston t o replace wearing part 5(0-ring170×8.6） )

9.4 Safety precautions

1)It is important to have a special compacter with spring-proof device to disassemble spring

brake chamber slow ly, pr event th e sp ring hu rt ing pe op le . To ensu re safety and pr even t spr ing

hurting people, it is forbidden anybody to stand in di rection of spring ejecting.

2) When assembling compact storage spring with compacter, the adjustment bolts must be

screwed to specified depth (adjustment bolts showing 60mm outside), then pressure of

compacter can be released.

Wearing parts

Serial

numberName No.

1 membrane（ item 9 in fig.7-9） 1



24

2 O-ring19×2.4（ item 8 in fig.7-9） 1

3 O-ring33.7×5.1（ item7 in fig.7-9） 2

4 O-ring164×3.1（ item 6 in fig.7-9） 1

5 O-ring170×8.6（ item 5 in fig.7-9） 1

10 Pressure sensors, alarm lights switch

The reserve pump of the brake circuit is equipped with pressure sensors and alarm lights

switch, when the pressure of the reserve pump reduced to a certain pressure (pressure belo w

0.4MPa) due to several times consumption, the barometer installed in the right seat will be

displayed that the pressure value is less than 0.4MPa, alarm pressure switch on the panel in

front of the driver will be non-stop flashing lights to warn the d river, pay attention to the low

pr essur e of the sto rage ai r chamber. At that time , the drive rs should be immedia te ly st oppe d,

and when the pressure value is higher than 0.4MPa and the alarm light switch goes out, the

drivers can continue travel.

11. Shoe brake

Shoe brake is composed of brake hub, brake shoe, air chamber assembly and the cam bodies.

Structure Chart:

Chamber specifications: 32/30 inch (line / in)

Rated pressure: 0.8MPa

Braking torque: 21.5/17 (line / in)

Available friction t hickness: 9mm



25

1、 friction plate 2、horseshoe 3、 roller wheel 4、 bo tt om bu sh in g

5、camshaft 6、 return spring 7、 horseshoe rivet 8、 adjustment arm with

lengthening 9、 shim 10、check ring 11、washer 12、cam stent

13、O-ringφ49×φ40 14、shim 15、 ja m 16、hanging spring pin 17、 bo lt

18、 bo lt 19、dust cap 20、 shoe-axis 21、elastic column pin

Fig.7-10 Brake



26

Its working principle is that, taking use of spring and pressure（0.3~0.4Mpa） of spring brake

chamber to transfer the power to brake s hoe through adjusted arm, camshaft, to make brake

shoe tighten brake drum, so it can generate brake torque to brake wheels.

When parking, air is discharge all from driving brake chamber (12) and parking brake

chamber (11) to brake truck by spring force, when normal driving, air flows in drivin g brakechamber, and the air in parking brake chamber is discharged to overcome spring force, so

that it lifts brake shoe to ensure normal driving. When driving brake, air flows in parking

brake chamber, and fl ows out the dr iv ing br ake chamber, to ensu re brake by pr essur e and

spring force.

Brake block working surface should be kept clean, if it is polluted sli ghtly, acetone and

gauze can be used to remove, or it should be replaced with new pieces. If friction block

assembly wears to trench of friction material, friction block assemblies should be replaced.

Replacement of friction plates must be replaced in pairs.

Adjust description of brake assembly: after connecting the brake and air chamber adjust arm

with support pin, and then adjusting worm on adjust arm. At first, adjusting brake shoe to

tighten brake drum ,then adjusting backward till when hear the sound of three "click" ,at this

po in t the ga p of brake shoe and br ake hub is between 0.3 ~ 0.7mm, and the gap of the tw o

brakes may no t be more than 0.5mm.



27

V Hydraulic system

1．Data

Control valve

Lift truck type 12~16t

ModelDC32F4-AT·R03T-2（2 spools）

DC32F4-AT·R03T·033T·033T-2（4 spools）

type Double-slide valve, with tilt-lock valve

Adjusting pressure 20Mpa（can lift 110% of rated load, can't lift 125% rated load）

Rated flow rate L/min 280

2．

Trouble diagnoses and corrections

Main pump

Trouble Probable cause Corrective action

Low oil level in tank. Add oil to specified level. No oil from oi l

pumpClogged suction pipe or

strainer.

Clean oil line and tank. If oil is dirty,

change.

Worn bearing damaged

backup ring and O- ring.

Replace faulty parts.

Maladjusted relief valve.Readjust to specified pressure using

pr essu re gauge .Low deflate

pressure on oi l

pump.

Air in oil pump.

Retighten suction side pipe.

Add oil in oil tank.

Check pumps oil seal.

Do not operate pump until bubbles in tank

disappear.

Cavitation due to crushed

suction hose or clogged

strainer.

Adjust or replace crushed hose and clean

strainer.

Air being sucked from loose

suction side joint.Retighten each joint.

No isy oi l

pump

Cavitation due to too high

oil viscosity.

Replace with new oil having proper

viscosity for temperature at which pump

is to be operated.



28

to operate when oil temperature is

normal.

Bubbles in hydraulic oil. Determine cause of bubbles and remedy.

Oil leakingfrom oil pump

Faulty oil seal on pump,

faulty O-ring or worn sliding

surfaces on pump.

Replace faulty parts.

Control valve

Trouble Probable cause Corrective action

Loose of pressure-adjust screw. Readjusted and retighten.

Distorted or damaged

pr es su re -adjus t sp ring .Replace.

Worn or blocked relief valve core. Replace or clean.

Pressure of relief

valve is not

steady or too

low.

Pump abated. Examine and repair pump.

Worn or damaged tilt lock valve.Replace valve core and tilt lock

valve as an assembly.

Broken tilting lock spring. Replace spring.

Fork tilt forward

when control

lever is used

while engine is

off.Damaged tilt valve plunger O-ring. Replace O-ring.

Mast is unstable

when tilting

forward.

Malfunctioning tilt relief valve.Replace tilt relief valve

assembly.

Valve body and spool valve is worn

and clearance between them is too

great.

Replace spool valve with

specified clearance.

Spool valve is not in centre. Keep being in the centre.

Cylinder seal abated. Examine and repair cylinder.

Lowering

distance of mast

is big when

spool valve is in

the centre. Taper valve is worn or b locked by

dirt.Replace or clean taper valve.

Damaged or distorted

reposition-spring.Replace spring.

Spool valve is

not return

neutral position.Dirt exists between valve body and Clean.



29

spool valve.

Blocked control device. Adjusted.

No t coax ial pa rt s at repos iti on Reinstall.， be coaxial

Damaged O-ring. Replace.

Faulty seal of joint. Check and retighten.

Loose seal plate.Clean seal plate and retighten

blot s.

Leakage

Loosed lock-nut of relief valve and

connect-nut between plate and plate.Tighten.

3. Pump

Fig 7-1 2 spools pump

The CBG-Fa2063/2050-216L double gear pump is used as main pump in t he hydraulic system

of 12-16t. Front pump supply control valve oil directly; rear pump connects with priority

valve, ensure pump to supply steering system oil preferentially, excess flow is to control

valve. This pump is full cast part with high intension; it also uses axis clearance auto

compensation and radial hydraulic balance technique. It has following advantages, anti-high

pres su re , hi gh re lia bi lit y, high ef fi ci ency, and lit tl e no ise .

4. Control valve

The control valve CDB-F20 is section model, which is made up of input, output and slide

valve. Flow valve is installed in the entrance with main relief valve. See fig.7-2.

Main relief valve is used to control the pressure of oil circuit. Its pressure has also been

adjusted in the factory, so please don’t adjust it at will.

Steering relief valve is used to adjust the pressure of driving steering oil circuit.

Slide valve is used to control tilt hydro cylinder and lift hydro cylinder, and it can

splinefront pump rear pump



30

change the flux to control hydro cylinder by maneuvering the tilt and lift l ever.

Tilt slide valve is equipped with front-tilt self-lock valve.

Oil from hydro cylinder returns to oil box from output, and every piece of valve is sealed

by mane uver “O-r ing . At the sa me time , ther e is a cl appe t va lve .

Fig.7-2

Safety valve pressure adjustment:

1） Truck stay at level and solid ground, pull up handle brake button, and make parking

br ake work .

2） Connect pressure gauge with safety valve pressure hole.

3） Start engine, run idle 2-3min.

4） Adjust safety valve's pressure; stabilize its valve at 20MPa.

5. One-way check valve

To limit the descend speed of lift hydro cylinder, install one-way governed speed valve

to control the recycle oil flux, and this can limit the descend speed of hydro cylinder and

prote ct th e ci rc ui t when li ft ci rcui t is explosion .

1. Valve body 2. Valve core 3. Spring 4. Orientation nut

Safety valve

pres su re

hole

Tilt valve Lift valve Safety valve



31

Fig. 7-3 Governed speed valve

6.Hydraulic system principle diagram

Fig.7-4 hydraulic system principle diagram

2 spools pump is the power source of hydraulic system, it suppl y high pressure hydraulic oil

to system by engine. Front pump make oil flow to control valve, rear pump make oil flow to

pr ior it y valve , dis tri bu te fr om pr io ri ty va lve to st ee ring sy st em , by feedback from load ,

according to requirement of steering, give priority to supply steering oil. After supplying

steering enough flow, excess flow is distributed to control valve. When the lift and tilt valve

are on the middle location, high pressure oil flow back to oil tank directly; When pushing

lifting spool, it is that bott om of lifting cylinder piston connects with lo w pressure line and

then piston rod drops by deadweight and weight of cargo. In this time, oil from li fting

cylinder goes by unidirectional speed limiting valve so as to contro l the falling speed. When

operating tilting spool, high pressure oil goes t o front house of tilting cylinder and another

connects with low pressure line so as to make mast tilt forward or backward.

tilt lift

Speed

limited valve

steering

Control

valve

Priorityvalve

2

spools

pu mp



32

V Electrical system

CAUTION：

· To guard against a short circuit, take off jewelry ornaments and disconnect the ignition

switch and battery ground cable, before starting to check any part of electrical system.ACCOUNT

· The different colorful wire is chosen for the different part of the electrical system. To differ

from different colorful wire, color is denoted by one or two letter. Identify carefully that the

cable of accumulator has been disconnected before repairing the electrical system.

Cable color ：

B: black R: brown G: green U: blue

O: orange R: red W: white Y: yellow

S: gray P: purple

Main wiring harness use homochromatic wire. Other wire use double color.

B/W: black and white

G/Y: green and yellow

INSPECT

Inspect all electrical circuit according wiring diagram. You should make short circuit or open

circuit test with the test lamp or multi meter. Before inspection ,ensure that：

1． Each electrical component or cable is securely fastened its terminal.

2． Each terminal is firmly in place and free from rust and dirt.

3． No cable covering sh ow s any ev id ence of crac ks , det er io ra ti on or othe r da mage .

4．

Each terminal keeps a safety distance with adjacent metal parts.

5． Every cable is fastened to its proper connector or terminal.

6． The wiring is kept away from any adjacent parts with sharp edges.

7． The wiring disconnect to each rotating or moving parts.

8． The length of the wire linking the fixed part and unfixed part should

be enough to shake.

9． The wiring keeps a safety distance with the high temperature thing

such as the vent-pipe.

FUSE SYSTEM

FUSE

DISASSEMBLE

1. Turn key switch “OFF”.

2. Compact the nut on the cover of the fuse box , and open the cover.

3. Disconnect the fuse from the box.

Account

If the fuse is blown， replace with new one, refer to the figure.

①

If a fuse is blown， pl ea se be su re to el imina te cause of probl em, then repl ace it.

② Ne ver use fu se high er tha n spec ifi ed ra ti ng .



33

Principle diagram

location capacity Application part

1 flasher 10A Steering lights

2 preheating 10A preheating

3 meter 20A Meter, work light,

width lamp, reversing light

4 Shift control 15A Forward, backward relay

5 backup 20A

6 backup 20A

7 horn 10A horn

8 brake 10A Brake light

9 air-condition power 1 20A air-condition power


11 Front rain wiper 10A Front rain wiper

12 Rear rain wiper 10A Rear rain wiper

13 Top rain wiper 10A Top rain wiper


15 backup 10A

Fuse table

Location Capacit

y

Application parts

1 Fuse 1 80A Start relay,brake light,horn2 Fuse 2 80A key switch



34

LIGHTING SYSTEM

BULB SPE CIFICATIONS

Location wattage

Front big lamp 24V/35W

Front work lamp 24V/35W

Front and rear turn signal lamp 24V/10W/21W

Rear light/reverse lamp

Combination rear lamp

Turn light

Reverse light

Width light

24V/35W

24V/21W

24V/21W

24V/10W

Combination meterlighting

Alarm light

24V/2W

24V/2W

Combination switch:

Disassemble

1. Remove the combination instrument and steering wheel.

2. Wrest the screws, and disconnect the wiring connector

3. To install reverse the order o f removal.

INSPECTIONCheck the continuity the location in turn signal lamp and the combination switch of

lighting.

terminal 1 2 3 4 5 6 7 8

Location Wire

color

Purpl

e

yello

w

Yello

w

green

Blue

yello

w

red tan green grey Blac

k

yello

wneutral



35

neutra

l

Go forward

Go

backward

3shift

2shift

1shift

note：“”means on。

Light combination switch handle

terminal 1 2 3 4 5 6 7 8

Location Wire

color

w hi te g re en b lue Red

green

red black Red

yellow

Red

white

Turn left

Turn

right

Go straight

0

1

2

3

note：“”means on。

Work light: head big light, head small light, front work light, rear work light/reverselight, combination rear light.

REMOVAL & INSTALL

1. Remove securing nuts of the big lamp

2. Take apart the wiring connector

3. Remove bolt、 lens, then replace faulty bulb with new one.

4. To install, reverse the order of removal.

Meter, sensor and relay

Check whether relay circuit is on or not, connect or disconnect with ring as appropriate

voltage(supply by battery) ,then uses multimeter (Ω)to check whether contact loop is on or

not.



36

REMOVE & INSTALL

INSTRUMENT ASSEMBLY

1. Remove fixing bolt of instrument cover.

2. Open the instrument cover, see fig follow, disconnects the wiring connector of

instrument and key switch. Never wash the electrical system using water and water vapour

after you connect the instrument to the electrical system.


Oil pressure gauge、

water temp. gauge、

hour meter and warning lamp

1． Remove the fixing bolt of panel, and take apart panel form cover of panel.

2． Remove the fixing bolt of front cover, and take apart front cover and panel.

3． Remove the panel

4．

Remove the fixing bolt of instrument from PC, and remove the inst rument.

5． Remove the caution light from the PC, (all of caution light can be removed from the

combinational instrument).

6． To install, reverse the order of removal.

Key (start) switch

Remove the combinational instrument

1. Disconnect the wiring connector.

2. Remove the ring nut, washer, spacer, meter panel.


INSPECT

Check the continuity between terminals with

multimeter.

B ACC C R1 R2 BR

Pre-heat

ing

Operatio

n

Star-up

Star-up

Note: “”means on.

REVERSE BUZZER

REMOVE & INSTALL

1. Disconnect the wiring connector, and then remove th e bolt.

2. To install, reverse the order of removal



37

HORN

REMOVE & INSTALL

1. Remove the wiring connector of the horn

2. Remove the bolt and horn.

3. To install, reverse t he order of removal.

Instrument inspect

name purpose Graduation arrange No rm al remark

water

temperature

meter

Engine cool water

temperature

40-55 yellow

55-110 green

110-120 red

Green zone

Cease and check

when point is

near red zone

oil capacity

meterEngine fuel capacity

0-1/10 red

1/10-1

green

Green zone

Adding oil when

po in t is ne ar re d

zone

timing

meter

Accumulative total

engine operate time

4 integers, 1

decimal fraction

oil

temperature

meter

Gear-box oil temperature

45-60 yellow

60-120 green

12 0-140 green

Green zone

Cease and check

when point is

near red zone

oil pressure

meter

Engine lubricate grease

pr es sur e

0～0. 2～0. 4～

0.8MPa≥0.1 MPa

< 0.1 Mpa

cease and check



38

WARNING LAMP INSPECT

Descriptio

nFunction

Lamp light

（warning）

Light blank

(normal)Remarks

Charge

warning

lamp

Indicate the

alternator voltage

up to its rate,

whether charge

ba tt ery or no t.

The alternator

doesn’t generate

electricity or voltage

is lower ， without

inflating.

Thealternator is

at normal

condition

When running at

idle speed, the

light turns off

because voltage

is high.

Brake

warning

lamp

It indicates the

accumulator’s oil

pressure

The oil pressure of

accumulator is low.

When light

turns on, you

should check

the oil pipe.

Repair of starter/dynamotor

starter

phenomeno n reason se tt lement

Battery capacity is not

enoughChange battery or charge

Electric circuit breakRepair or change electrical

layout, starter delay and so on

Electromagnetism switch

shatter

Change and repairelectromagnetism switch

Pinion doesn’t joggle wellwith l ine roll gear Change or repair

Brush doesn’t contract

well

Adjust brush location, clean

the surface of brush

Brush abrasion change

Not ro tat e

Armature circuit break Change armature circuit

Pinion doesn’t work well changeStarter rotates but the

engine can’t rotatel ine roll gear shaft isn’t

good repair

Dynamotor

phenomeno n reason se tt lement

Adjuster shatter Change shatter

Magnetic field connection

shatterchange

Diode shatter change

Reed lead break or contact

badnes sRepair or change

C h a r g e

i n d i c a t or s h

i n e

Can’t charge

Fuse shatterRepair



39

Surge magnet circuit shatter change

Diode shatter change

Reed lead contact badness Repair or change

Electricity load is too high Reduce electricity load

Charge current is

small

Strap strain badness Adjust

Change current too

bi g

Adjuster shatterCurrent output circuit fastener

loose

Change

Repair

Battery liquid

surface descendBattery shatter Change or add liquid

Adjuster shatter Change

Bearing/brush don’t contact well Repair or change

o t h e r s

Dynamotor sound

abnormalStrap strain badness Adjust







42

X Lifting system

1. Assemble debugging data

Debugging data Double mast

Mast type

Standard type and

lifting height of 3～

4.5 meter

Lifting height

>4.5～

5 meter

Lifting height

> 5～

6.5 meter

Forward 60 6

0 3

0 Mast

tilting

angle Backward 120 6

0 6

0

Fork arm carrier Adopt combination roller and side roller.

Inspection and adjustment

Place Assembly clearance Repair clearance（mm）

Mast to lift roller 0.3～1.25 0.4～1.4

Mast to bearing board 0.2～1 0.3～1.2

Inner mast to carriage side 0.3～1.25 0.4～1.4

Lift chain deflection 25～30 mm

Tightening torque

PlaceModel or

Lifting N·M

Lift chain lock nut 4000-4300 (M45×3)

Mast support cap blot 58～78（M12）

Lift cylinder bolt 638-850（M24）

Lift cylinder fixing

bo lt（U type）

Small 16t

189～252（M16）

Mast dimension (mm×mm×mm) weight（Kg）

16t 3030×2370×895 4800



43

2. Failure diagnose and corrections

Condition Probable cause Corrective action

1.Tilt cylinder and ring abraded excessively Replace piston ring tilt cylinder.Fork arm

carrier or

mast tilt by

itself.

2. The hydraulic control valve spring is

inoperative.Replace it.

1. Caused by piston jamming or bent piston

rod.Replace the faulty parts.

The fork

arms carrier

moves up and

down

sluggishly.

2. Too much dirt is accumulated in the

cylinder.Strip it down and clean.

1. Carriage bracket assembly out of

adjustment.

Adjust clearance with thrust metal

and carriage side roll er.

2. Insufficient clearance between inner and

outer masts or rollers and mast.Adjust clearance with rollers.

3. Biting foreign materials between moving

pa rt .Remove foreign materials.

4. Insufficient lubrication.Apply grease on contact surfaces

of sliding parts.（ bu tte r ）

Forks are

lifted or

lowered

unsmooth.

5. Bent carriage bracket assembly. Repair or replace.

Forks are

lifted

unevenly

1. Lift chains out of adjustable. Adjust lift chains.

1. Grease stiffened or dirt accumulated on

lift roller and mast sliding surfaces.Clean and lubricate lift rollers.

Lift roller

does not

rotate 2. Improperly adjusted lift roller. Adjust.

1. Insufficient lubrication. Lubricate.Excessive

mast noise2. Improperly adjusted lift roller, side roller

and back-up metal.Adjust.

1. Excessive wear occurs between the oil

pump body and ge ar s, caus ing to o much

clearance.

Replace the worn parts or the oil

pump .

2. The lifting jack piston Yx-ring has worn,

resulting in excessive inner leaks.Replace Yx-ring.

3. Springs of the multiple control valves and

its relief valve are inoperative oil leaks.Replace.

4. Excessive wear occurs of the hydraulic

control valve, resulting in excessive oil

leaks.

Replace.

Insufficient

lift power or

no liftmovement.

5. Oil leaks occur between the hydraulic

control valve sections.

Dismantle for regrinding the joint

surfaces and reassemble the valve.



44

6. Leakage occurs in the hydraulic pipe.Tighten the joint nuts and inspect

the seal for damage.

7. The hydraulic oil temperature is too high.

Oil viscosity is too low and the rate is

insufficient.

Change the wrong hydraulic oil or

stop operation for reducing the oil

temperature. Find out the reasons

for high oil temperature and

eliminate the trouble.

8. The load carried is beyond the designed

capacity.Observe the lifting capacity limit.

1. The ring of Setting-up cylinder and ring

abraded excessivelyreplace ring

2 Fork’s shaft rust seriously Clean and lubricate

Forks does

not adjust

setting-up3. Fork is turn back by foreign materials Clean

Double high visibility mast

Double mast is composed of outer mast which can’t lift and inner mast which can lift. Lifting

ja ck bo tt om is fi xe d on ou ter mast be low cr os s be am, ori en te d wi th pin. Pi ston rod ex tre mi ty

is joined with upper cross beam of inner mast; cylinder body is fixed on o uter mast fixation

board wi th U- bo lt. Co mmonl y fr ee li ft range is 200mm, wh ic h is di fference wi th dif fe re nt

tonnage. Two lifting jacks are laid out back of outer mast to realize high vi sibility.

8-10t’s forks adjust its distance by changing the cylinder, but the changing cylinder can only

work when the fork is unloaded, fork loading is forbidden.

Fork arm is hung on fork arm carrier by hook. roller and side roller are installed on the

fork arm carrier. The roller and side roller are also installed on bottom of inner mast.

Pressure oil from hydraulic control valve is entered into lifting jack by unidirectional

speed limiting valve, forced piston and piston rod rising, thereby forced inner mast rising. At

the same time one end of lifting chain on inner mast is fixed on outer mast, the other is

jo ined wi th fo rk ar m ca rr ier. Fo rk ar m ca rr ie r and fo rk ar m is ri si ng wi th inne r ma st ri si ng to

realize aim of lifting goods.



45

1.Outer mast 2.Inner mast 3.Fork arm carrier 4.Tilt cylinder

5. Left lift cylinder 6.Right lift cylinder 7.Lift oil circuit 8. Chain

Fig 9-1 Double high visibility mast

Lift cylinder

Lift cylinder is single-action piston mode, and it composes of cylinder head, piston rod,cylinder block, piston etc. Caution when using:1,avoid damaging piston rod, and keep seal

ring seal well;2, if piston rod's surface has exudates oil when uses normally, please check

whether piston rod's surface has woolly grain or not, can change o-ring seal and piston.

1. Cylinder blocks 2. Piston 3. Seal ring 4. Catch 5. Support ring 6.Check ring

7. Separated sets 8. Piston rod 9. oil return pipe 10. Bearing block

11. Steel Backing bearing 12. O-ring seal 13.cylinder head 14.Seal ring

15. Dust ring 16.Bolt 17.Plug 18.Bush 19. Check ring

Fig.9-2 lift cylinder



Tilt cylinder

Tilt cylinder is double-action piston mode, when the rake angle of front and rear is not

accord with its requirement, or the cation of two cylinder piston do not move in the same

time, can adjust the nut location of piston rod to reach requirement, then lock the nut. The

caution is same with lift cylinder.

1. Tier rod 2.Thin nut 3.Dust ring 4. Seal ring 5. O-ring seal

6.Site seal 7.guide sleeve 8.check ring 9.O-ring seal 10. Steel back bearing

11.Cylinder block 12.Pi ston rod 13.pis ton 14. Seal ring 15. Check ring

16.O-ring seal 17. Support ring 18. Slotte d nut 19. Pin 20. Joint

Fig. 9-3 tilt cylinder

Documents

Manual de Operação Emp. Xg Cpc160 - Inglês