26000lb-35000lb(12t-16t) Counterbalance Internal

Combustion Forklift Truck

SERVICE MANUAL

CPCD120/140/160-XW79

Original Instruction

HANGCHA GROUP CO., LTD.

Sep .201 9
HANGCHA GROUP CO. , LTD.

■ Address For: OVERSEAS USERS

■ Address: 666 Xiangfu Road ,Lin ’an,Hangzhou ,Zhejiang,China
■ ZIP:311305
■ Fax: 0086-571- 88926789 0086-571-88132890
■ Web: http://www.hcforklift.com ■ E-mail: sales@hcforklift.com
 Foreword

The manual is the introduction of structure, working principle and

serving .etc of 26000lb-35000lb( 12t-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.

© Sep.2019 HANGCHA GROUP CO.,LTD.

 Foreword
I. DRIVING SYSTEM ............................................................................................................................... 1
II. HYDRAULIC GEAR-BOX AND TORQUE CONVERTER ......................................................... 2
III. DRIVE AXLE AND CARRIER ASSEMBLY .................................................................................. 3
IV. STEERING AXLE..................................................................................................................................4
1. G ENERAL SPE CIFICATION ....................................................................................................................... 4
2. T ROUBLE DI AGNOS ES AND CORRECTION ............................................................................................. 4

3. S TEERING A XL E S TRUCTUR ................................................................................................................... 5

V. STEERING SYSTEM ........................................................................................................................... 8
1. T ROUBLE DI AGNOS ES AND CORRECTION ............................................................................................. 8
2. G ENERAL .................................................................................................................................................. 9
VI. BRAKE SYSTEM................................................................................................................................ 10
1 A IR DRYER ............................................................................................................................................... 11
2. S AF ETY VALVE ....................................................................................................................................... 12
3A UTOMATIC RELEAS E VALVE ................................................................................................................. 13
4.A IR BRAKE .............................................................................................................................................. 14
5.S HUT TLE VALVE ......................................................................................................................................15

6 RE LAY VALVE ...........................................................................................................................................16

7. H AND - CONTROL LED BRAKE .................................................................................................................17

8. Q UI CK RELEAS E VALVE ........................................................................................................................ 19

9 C OM BINATION BRAKE CHAMBE R ......................................................................................................... 21

10. P RESS URE SENS ORS , AL ARM LIGHTS SWITCH ................................................................................. 22
11. S HOE BRAKE ........................................................................................................................................ 23

VII. HYDRAULIC SYSTEM ...................................................................................................................... 25

1.D ATA ........................................................................................................................................................ 25
2.T ROUBL E DIAGNOS ES AND CORRE CTIONS .......................................................................................... 25
3. P UM P ....................................................................................................................................................... 27
4. C ONTROL VALVE .................................................................................................................................... 27

5. O NE - WAY CHECK VALVE ....................................................................................................................... 30

6. H YDR AULIC SYSTEM PRINCIP LE DI AGRAM ........................................................................................ 31

VIII.ELECTRICAL SYSTEM ................................................................................................................... 32

IX. LIFTING SYSTEM .............................................................................................................................. 42
1. A SSEM BLE DE BUGGING DATA ..............................................................................................................42
2. F AI LURE DI AGNOS E AND CORRE CTIONS ............................................................................................ 43
 I. Driving System
Power configure

Engine
Diesel
parameter

Type QSB6.7

Rated output
158( 118)
hp(kW )

Rated rpm r/min 2100

Max.torque
lbf · ft(N·m)/speed 643( 841)/1500
rpm
Forklift model CPCD120/140/160-XW79

Specification, structure and maintenance, please refer to ENGINE

MAINTENATION MANUAL.
There is need to check the exhaust quantity after the maintenance or servicing,
and ensure that the exhaust gas accord with the table:

发动机功率 CO HC NO X HC+NOx PM
hp(kW ) (g/kWh) (g/kWh) (g/kWh) (g/kWh) (g/kWh)
100.6 ≤ P＜ 174.3
5 - - 4.0 0.3
(75 ≦ P <130 )

1
II. Hydraulic gear-box and torque converter

Data

Model Y63270Z/X

Hydrodyna
Two stage, triphase ,four
mic torque Type
element
converter

Variety Electronic shift gear

Hydrodyna Forwarder gear Ⅰ 1.179

mic power
Transmission
gear-box Forwarder gear Ⅱ 0.645
gear ratio
Reverse gear Ⅰ 0.844
Shift gear oil pressure psi( MPa) 145.0-232.1( 1.0-1.6 )
Oil pressure Torque converter output oil pressure
≤72.5( 0.50 )
psi( MPa )

Mass lb (kg) 992( 450)

Approximate
Oil capacity ft 3 (L)
1.09-1.13( 31-32 )
Using oil type ATF DEXRON II（ Caltex ）

Specifications, structure and maintenance methods ,please see

《 Y63270Z/X Japan Okamura MODEL TORQUE CONVERTER
MAINTENANCE MANUAL 》 .

2
III. Drive axle and Carrier assembly
1. Data

One step carrier assembly and wheel-end reduction

Drive axle type
Full floating, direct frame mount, front-wheel drive
Carrier assembly One step helical bevel gear
Differential assembly. Straight tooth gear
Wheel-end reduction pinions

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

·Loose axle mounting bracket bolts. Tighten.
Unusual noise ·Loose wheel nuts. Tighten.
Before attempting a correct ·Other retaining parts loose. Tighten.
ion, make sure the noise is
coming from the drive shaft-not ·Worn or damaged wheel bearing. Replace.
from the final drive or wheel·Wheel bearing not properly adjusted Adjust.
reduction gear. ·Worn sun gear (drive shaft) splines. Replace.
·Insufficient lubrication. Lubricate
·Loose wheel nut. Tighten.
Unstable driving ·Deformed road wheel. Replace.
Also refer to the Trouble ·Worn or damaged wheel bearing. Replace.
Diagnoses and Corrections in ·Loose axle mounting bracket bolts. Tighten.
the RA section. ·Wheel bearing not properly adjusted. Adjust.
·Improper tire pressure. Adjust.
·Worn or damaged axle tube oil seal. Replace.
Oil leakage ·Final drive improperly installed. Replace gasket.
·Loose filler or drain plug. Tighten.

Specifications, structure and maintenance methods ,please see《MAINTENANCE

MANUAL And PARTS ITEM》.

3
IV. Steering axle

1. General specification axle center

Fore-aft 0~0.039(0～1)
Center support, wing
suspension type clearance (forward is no
type
in(mm) clearance)
Inner Fore-aft adjusting shim
77.6°
Max. Steering wheel
Thickness
angle Outer Part number
50° in(mm)
wheel
0.020,0.039,
Tire pressure 120.4psi(0.83MPa) 0.059 GX160-220005-000
(0.5，1.0，1.5）

Kingpin wheel bearing

Less than 0.008(0.2)
Axial play in(mm) Tighten bearing nut until
rotating resistance is felt,
Adjusting shim
from this position; back off
Pre-tightnes
bearing nut 1/8-1/6 turn. or
s wheel hub bolt initial
Thickness in(mm） Part number
force is less than
2.25lbf-6.52lbf(10N-29N).

0.004,0.028,0.039 Axle play

G160-220014-000 Less than 0.0031(0.08)
(0．1，0.7，1.0) in(mm)

2. Trouble diagnoses and correction

condition Probable cause Corrective action

·loose wheel nut tighten
Unstable ·wheel bearing out of adjusting adjust
driving ·improperly adjusted mount shims adjust
·faulty steering system refer to steering section
·insufficient lubrication Apply grease
Noises ·loose bolts and nuts tighten
·improperly adjusted mount shims adjust

4
3. Steering Axle Structur

5
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 bushing
41.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 assembly.
Caution： a. Be careful not to drop bearing cone.
6) Remove inner bearing cone.
Caution： b. Be careful not to damage grease seal.

 Kingpin and steering spindle

1) Remove ball stud nut and disconnect tie-rod from steering spindle.
2) Loosen lock nut and remove 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 the order of removal. Carefully observe the following.
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 place thrust bearing on upper side of spindle, and shims on lower
side.
3） Apply grease inside the dust-proof 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.

6
 Wheel bearing installation and adjustment
1) Apply grease or anti-rust oil on contact surface of bearings and 6 spindle nut.
2） Rotate hub slowly. Tighten 6 bearing nut until rotating resistance is felt; turn
bearing nut back off 1/6 to 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 25 bearing washer and tighten the other
6 bearing nut.
5 ） Rotate frontward and backward hub 2~3 turns, make sure its axle clearance is
less than 0.0031in( 0.08mm ), and rotated starting torque at hub bolt is less than
5.73lbf( 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 the order of removal. Carefully observe the following:
Add shims on both sides until fore-aft clearance between steering axle and frame is
less than 0.028in( 0.7mm ).

7
V. Steering system
rear wheel steering
Steering system type
with power steering
line mounted with
fully hydraulic redirector priority valve ,load
sensing
double-action
power cylinder
transfixed
1. Trouble diagnoses and correction
condition Probable cause Corrective action
Pump damaged or faulty Replace
Steering Flow priority valve blocked or damaged Clean or replace
wheel failure Pipes or connections damaged or
Clean or replace
passage blocked
Low oil pressure in the flow priority valve Adjust
Air in system Bleed air
Flow priority valve control pipe blocked Clean or replace
Hard steering Flow priority valve damaged Check or replace
Steering gear fails to reset, or
Replace elastic shim
orientation shim is broken or of failure
Power cylinder piston seal damaged Replace
Insufficient oil in tank Replenish
noises
Blocked in the passage or filter Clean or replace
Seal on the guide set, piping or
leakage Replace
connector is damaged

8
2. General
The steering system is mainly composed of cycloid fully hydraulic redirector and the
power cylinder.

2.1 Cycloid fully hydraulic redirector

It consists of cycloid steering gear, steering column and steering wheel. The
assembly position can be adjusted 8°aft-forth to satisfy drivers’ needs.
Turn the steering with 2.2lb(1kg) 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
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
piston rod move left and right to steer truck.

1. piston rod 2.LBI seal ring d80 3. bolt 4.O-ring seal 80X5.3
5.ISI seal ring d80 6. guide set 7.O-ring sea 100X5.3 8.cylinder body
9.glan-ring D110 10.steel ball 11.support ring 12.piston
Fig 5-1 steering cylinder

9
VI. Brake system
Brake system uses air pressure braking system, its supply devices and
gears are air pressure type. Its control devices are composed of brake pedal
framework, air- brake valve, hand brake valve, oil-water separator combination
valve, air tank, safety valve, brake air-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. 6-1 brake system diagram

10
1 Air dryer

Instructions to air dryer

Vent 1-Diaphragm 2- Pressure regulating valve assembly 3-O-ring 4- Exhaust valve 5-Exhaust piston

Fig.6-2 Air dryer

1.1 Usage
The air dryer is used in automobile and engineering vehicle braking system, because
the condensed water in the compressed air from air compressor is the main reason for
pipeline rust and the failure of lubricating film, if the environment temperature is lower,
there maybe the risk of pipeline frozen. All this will drop the system reliability, reduce
service life, or even generate brake failure. The air dryer, by means of oil water filter and
the molecular sieve, can effectively remove water and greasy dirt in the compressed air,
and then take molecular sieve regeneration, to purify compressed air.
1.2 Working principle
Compressed air from air compressor, enters cavity A through the air dryer intake
mouth 1, and enters the middle of the molecular sieve through shell, filter and dry the
compressed air by molecular sieve, and clean air will reach mouth C through mouth B,
after through air outlet mouth 21, inflate the air storage tank. When the air pressure of air
storage tank reaches opening pressure value, gas enters the lower diaphragm cavity,
overcomes the upper adjusting spring force, promote the diaphragm move up, airflow
enters the upper exhaust piston cavity, push down the exhaust piston, open the lower
exhaust valve, get the vent compressed air, water and impurity discharged into the
atmosphere through the vent, make the air compressor in the no-load running state; when
the air pressure of air storage tank drop to the closing pressure value, lower diaphragm
cavity pressure is not enough to overcome the adjusting spring force, diaphragm
assembly moves down, the vent valve moves up to shut the valve under the action of
spring, thus the valve continues to supply air storage tank gas. In the exhaust process, the
input compressed air of regeneration cylinder flow to drying cylinder through mouth B,
drive water staying around the drying cylinder top and drying shell flow into valve body
vent in opposite direction to inlet, and discharge to the atmosphere.
1.3 Technical parameter
1. Withstand voltage：188.5psi(1.3MPa)；
2. Opening pressure：113.7psi±2.9psi(784kPa±20kPa)；
3. Closing pressure：94.9psi~105psi(654kPa～724kPa)；
4.Heater voltage：24V，0.13hp(100W)；
5. Working temperature：-40℉~+149℉(－40℃～+65℃)。
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1.4 Installation and connection size
1.Installation size：3-M12×1.5－6H screwed hole（isosceles triangle），base space is
4.13in(105mm)，and height is 2.83in(72mm)··.
2. Connection size：air inlet M22×1.5-6g，air outlet M22×1.5-6H（connect gas holder）,
M12×1.5－6H（connect 5L regeneration gas holder）.
1.5 Easily damaged parts
No. Name Fig. No. Quantity
1 O-ring EQ153-3512028 1
2 Exhaust valve WSL-1109038 1
3 Diaphragm EQ153-3512032 1
Pressure regulating
4 EQ153-3512040 1
valve assembly
1.6 Common fault, fault diagnosis and corrections
No. Common fault Fault diagnosis Corrections
Exhaust valve
1 Air leakage in vent Replace exhaust valve
damage
Rotate the adjusting
screw downward
properly
Low opening Part wear as
2 Note: according to
pressure adjusting screw
vehicle pressure gage,
adjust product technical
parameter.

2. Safety valve
2.1 Structure and Principle
Compressed air flowed from inlet, when the inlet pressure is greater than
123.3psi(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
130.5psi(900kPa).
Safe working pressure: 123.3psi~130.5psi(850kPa~900kPa). Inlet M16 × 1.5-6g is
the connecting thread.

Adjust bolt

Exhaust port

inlet
Fig.6-3 safety valve
12
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 Rubber safety valve Replacement

leakage stem assembly damage safety valve assembly

Wearing parts

Name Figure No. No.

Safety valve
150-3511051A 1
stem assembly

3Automatic release valve

3.1Structure and Principle

Automatic release valve is used to pump air brake pipe reservoir of pool water,
through the pressure fluctuations in value (pressure drop 4.35psi~14.5psi
(0.03MPa~0.1MPa)) automatically from the exhaust water; achieve automatic deflation
function; while parking users also can manually operate button for fast water drainage.

Fig.6-4 Automatic release valve

Rated working pressure 116psi(800kPa)

Installation and connection dimension M22×1.5-6g

Exhaust down

13
 Wearing parts

Name Code No.

Membrane inlet assembly PY20-1305030 1

4.Air brake
4.1Structure and Principle

When pressing on the bake pedal 2, through push rod 3, the balance spring 4 is forced to
pull piston 6 down and open inlet valve 7, compressed air flows from inlet to outlet. When
loosing pedal 2, return spring 5 pushs pistons 6 up, inlet valve 7 returns back to close the
way between inlet and outlet, the residual gas emissions from the exhaust.

1.screw 2.pedal 3.push rod 4.balance spring

5.return spring 6.piston 7.inlet valve
Fig.6-5 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 0.02in(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
1)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 replaced, and ensure that the installation is in place, solid and
14
reliable, and may not damage other parts.
2）The movement location of air brake parts should be used grease for maintenance. If the
brake is failed or weak, it has to check the wearing parts of air brake valve and brake
system.
3）Replacement may not be installed without a qualified pilot.
4.3 Common faults, failure analysis and troubleshooting

Common faults failure analysis troubleshooting

Non-working state Rubber Parts Replace wearing parts or replace product
leakage damage assembly
Working state Rubber Parts replace wearing parts or replace product
leakage damage assembly
Piston stuck replacement product assembly
Manually re-adjust screw so that the pedal on
Pedal wheel does
Exhaust of sorts the mandrel wheel just contacts appropriate,
not adjust well with
(the pressure roller mandrills screw down
the mandrills
surplus amount of not more than 0.5mm)

5.Shuttle valve
5.1Structure and Principle
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 into the shuttle valve.
Shuttle valve only allows higher pressure compressed air to flow through outlet, through
relay valve to driving brake air chamber.

Fig.6-6 shuttle valve

Compressed air flows from the A mouth, the air pressure will push the piston D to the
B-side, because the both sides of pistons D are rubber, thus it can guarantee non-air leak
from outlet, so that pressure can outflow from the outlet C; Similarly, if the air flows into the
inlet B ,the pressure will outflow as the same way outflows from the outlet C. Rated
working pressure is 113.7psi(784kPa).
Maintenance should be to protect the interface thread.
5.2 Common faults, failure analysis and troubleshooting

15
 Common faults failure analysis troubleshooting

Valve port Replace the

Rubber plunger valve damage
leakage valve plunger

Wearing parts

Name Fig.No No.

Valve plunger SUSH-3527013 1

6 relay valve
6.1Structure and Principle
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.6-7 relay valve

1. Exhaust valve assembly 2.O-ring
Technical parameters
Rated working 113.7psi(784kPa)
pressure
Initial balance ≤7.25psi(50kPa)
pressure
Connection Outlet :2-M22 × 1.5-6H, inlet: M22 × 1.5-6H
dimension Control of air intake: M22 × 1.5-6H

16
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 be loosen.
2) Piping connections should be recognized inlet, outlet and control of air intake. Interface
marked "1" for air intake, interface marked "2" for the outlet, interface 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 replacing wearing parts, damaged fasteners(bolts, nuts) in the process of
replacement must be replaced, and ensure that the installation is in place, solid and
reliable, and may not damage other parts.
3) Replacement may not be installed without a qualified pilot.
6.3Common faults, fault analysis and troubleshooting
Common fault analysis troubleshooting
faults
Non-working O-ring wear replace wearing parts or replace
state leakage product assembly
Working state Intake valve assembly replace wearing parts or replace
leakage rubber parts damage product assembly
Wearing parts
Serial Name Fig. No No.
number
1 O-ring GB3452.1-92 1
2 O-ring HFC-3527033 1
3 Inlet valve assembly HFC-3527020 1

7. Hand-controlled brake
7.1 Structure and Principle
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.

17
 Fig.6-8 Hand-controlled brake

Its working state is braking deflated. Namely: When the system pressure is as low as
34.8psi~45.0psi(240kPa~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 113.7psi(784kPa)

Insurance pressure 34.8psi~45.0psi
(240kPa～310kPa)
Installation, connection Intake: Z1/8 "
dimension Outlet :2-Z1/4 "

7.2 Proper use and maintenance methods

(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.

18
(2) maintenance
1)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 replaced, and ensure that the installation is in place, solid and
reliable, and may not damage other parts.
Replacement may not be installed without a qualified pilot.
2)The movement location of emergency brake parts must be maintained with
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-working state
leakage Rubber parts Replace wearing parts or replace
wear product assembly
Working state leakage

Wearing parts
Serial
name Fig. No. No.
number
1 Mandrels ring CT-3526064 1

2 Valve base ring CT-3526061 1

Rubber valve
3 CT-3526050 1
assembly

8. Quick release valve

8.1 Structure and Principle
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 tympanic
membrane 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: 113.7psi(784kPa).
Connection Size: inlet M22 × 1.5-6g; outlet 2-M22 × 1.5-6g.

19
 Fig.6-9 quick release valve

8.2 Proper use and maintenance methods

(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 replacing wearing parts, damaged fasteners(bolts, nuts) in the process of
replacement must be replaced, and ensure that the installation is in place, solid and
reliable, and may not damage other parts.
3) Replacement may not be installed without a qualified pilot.

8.3 Common faults, failure analysis and troubleshooting

common faults failure analysis troubleshooting

Parts of the exhaust valve has

Clean pipe
dirt
Exhaust leak
Membrane damage Replace membrane

Interval between top

seal washers aging Replace washers
and bottom body leak

Wearing parts
Serial
Name Fig. No. No.
No.
1 tympanum JN441-3516012 1
2 Seal washer JN441-3516014 1

20
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
parking--emergency brake chamber, parking brake or emergency brake takes effect 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 deflated 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 spring energy.
Working pressure: 116psi(0.8MPa); work trip 2.17in(55mm)

Fig.6-10 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 tools 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
bolts from supplied state to work state;
21
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 87psi(600kPa), piston is push back, and then screw
adjustment bolts about 30mm. After releasing pressure, seal-plug can be removed with
special 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 to 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 slowly, prevent the spring hurting people. To ensure safety and
prevent spring hurting people, it is forbidden anybody to stand in direction 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
Name No.
number
1 membrane（item 9 in fig.7-9） 1

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
below 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 driver, pay
attention to the low pressure of the storage air chamber. At that time, the drivers should be
immediately stopped, and when the pressure value is higher than 0.4MPa and the alarm
light switch goes out, the drivers can continue travel.

22
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: 116psi(0.8MPa)
Braking torque: 15.9/12.5lbf·ft(21.5/17N·m) (line / in)
Available friction thickness: 0.35in(9mm)

1、friction plate 2、horseshoe 3、roller wheel 4、bottom bushing

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、jam 16、hanging spring pin 17、bolt
18、bolt 19、dust cap 20、shoe-axis 21、elastic column pin
Fig.6-11 Brake

23
Its working principle is that, taking use of spring and pressure 43.5psi~58.0psi
（0.3Mpa~0.4Mpa） of spring brake chamber to transfer the power to brake shoe 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 driving brake
chamber, 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 flows out the driving brake chamber, to ensure brake by pressure and
spring force.
Brake block working surface should be kept clean, if it is polluted slightly, 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 point the gap of brake shoe and brake hub is between 0.012in~0.028in
(0.3mm~0.7mm), and the gap of the two brakes may not be more than 0.020in(0.5mm).

24
VII. Hydraulic system
1.Data
Control valve
Lift truck type 12t~16t
CDB-F20HC12-03a（2 spools）
Model
CDB-F20HC12-05e（4 spools）
type Double-slide valve, with tilt-lock valve
Adjusting pressure 3046psi(21Mpa)（can lift 110% of rated load, can't lift 125% rated load）
Rated flow rate 9.18ft3/min(260L/min)

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 oil
Clogged suction pipe or
pump Clean oil line and tank. If oil is dirty, change.
strainer.
Worn bearing damaged
Replace faulty parts.
backup ring and O-ring.
Readjust to specified pressure using
Maladjusted relief valve.
Low deflate pressure gauge.
pressure on oil Retighten suction side pipe.
pump. Add oil in oil tank.
Air in oil pump. Check pumps oil seal.
Do not operate pump until bubbles in tank
disappear.
Cavitation due to crushed
Adjust or replace crushed hose and clean
suction hose or clogged
strainer.
strainer.
Air being sucked from loose
Retighten each joint.
suction side joint.
Noisy oil pump
Replace with new oil having proper viscosity
Cavitation due to too high oil for temperature at which pump is to be
viscosity. operated.
to operate when oil temperature is normal.
Bubbles in hydraulic oil. Determine cause of bubbles and remedy.
Faulty oil seal on pump, faulty
Oil leaking from
O-ring or worn sliding surfaces Replace faulty parts.
oil pump
on pump.

25
Control valve
Trouble Probable cause Corrective action
Loose of pressure-adjust screw. Readjusted and retighten.
Pressure of relief Distorted or damaged pressure-adjust
Replace.
valve is not spring.
steady or too low. Worn or blocked relief valve core. Replace or clean.
Pump abated. Examine and repair pump.
Fork tilt forward Replace valve core and tilt lock
Worn or damaged tilt lock valve.
when control valve as an assembly.
lever is used Broken tilting lock spring. Replace spring.
while engine is
Damaged tilt valve plunger O-ring. Replace O-ring.
off.
Mast is unstable
Replace tilt relief valve
when tilting Malfunctioning tilt relief valve.
assembly.
forward.
Valve body and spool valve is worn
Lowering Replace spool valve with
and clearance between them is too
distance of mast specified clearance.
great.
is big when spool
Spool valve is not in centre. Keep being in the centre.
valve is in the
Cylinder seal abated. Examine and repair cylinder.
centre.
Taper valve is worn or blocked by dirt. Replace or clean taper valve.
Damaged or distorted
Replace spring.
reposition-spring.
Spool valve is not Dirt exists between valve body and
return neutral Clean.
spool valve.
position.
Blocked control device. Adjusted.
Not coaxial parts at reposition Reinstall.，be coaxial
Damaged O-ring. Replace.
Faulty seal of joint. Check and retighten.
Clean seal plate and retighten
Leakage Loose seal plate.
blots.
Loosed lock-nut of relief valve and
Tighten.
connect-nut between plate and plate.

26
3. Pump

front pump rear pump

spline

Fig 7-1 double gear pump

The CBG-Fa2050/2040-216L double gear pump is used as main pump in the hydraulic
system of 26000lb(12t). The CBG-Fa2063/2050-216L double gear pump is used as main
pump in the hydraulic system of 30000lb-35000lb(14t-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 pressure, high reliability, high efficiency,
and little noise.

4. Control valve
The control valve is section model, which is made up of input, output and slide valve.
Flow valve is installed in the entrance with main relief valve.
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.
Slide valve is used to control tilt hydro cylinder and lift hydro cylinder, and it can
change the flux to control hydro cylinder by maneuvering the tilt and lift lever.
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 maneuver “O-ring. At the same time, there is a clappet valve.

27
 Fig.7-2 control valve,2sec

Fig.7-3 schematic diagram control valve,2sec

28
 Fig.7-4 control valve,4sec

Fig.7-5 schematic diagram control valve,4sec

Safety valve pressure adjustment:

1） Truck stay at level and solid ground, pull up handle brake button, and make
parking brake 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 3046psi(21MPa).

29
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
protect the circuit when lift circuit is explosion.

1. Valve body 2. Valve core 3. Spring4. Orientation nut

Fig. 7-6 Governed speed valve

30
6. Hydraulic system principle diagram

Fig.7-7 hydraulic system principle diagram

2 spools pump is the power source of hydraulic system, it supply high pressure
hydraulic oil to system by engine. Front pump make oil flow to control valve, rear pump
make oil flow to priority valve, distribute from priority valve to steering system , 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 bottom of lifting cylinder piston connects with
low pressure line and then piston rod drops by deadweight and weight of cargo. In this
time, oil from lifting cylinder goes by unidirectional speed limiting valve so as to control the
falling speed. When operating tilting spool, high pressure oil goes to front house of tilting
cylinder and another connects with low pressure line so as to make mast tilt forward or
backward.
31
VIII. 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 multimeter. 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 shows any evidence of cracks, deterioration or other damage.
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，please be sure to eliminate cause of problem, then replace it.
2 Never use fuse higher than specified rating.

32
Principle diagram

Fuse table
Location Capacity Application parts
1 Fuse 1 80A Start relay,brake light,horn
2 Fuse 2 80A key switch
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 of removal.
INSPECTION
Check the continuity the location in turn signal lamp and the combination switch of
lighting.

33
Shift handle

note：“○”means on。

Light combination switch handle

34
 note：“○”means on。

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

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.
3. To install, reverse the order of removal.
4. To install, reverse the order of removal.

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 bolt from PC
3． Remove the fixing bolt of instrument from PC, and remove the instrument.
4． Remove the caution light from the PC, (all of caution light can be removed from
the combinational instrument).
5． 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.
3. To install, reverse the order of removal.
4. To install, reverse the order of removal.
35
INSPECT
Check the continuity between terminals with multimeter.

Note: “○”means on.

REVERSE BUZZER
REMOVE & INSTALL
1. Disconnect the wiring connector, and then remove the bolt.
2. To install, reverse the order of removal

HORN
REMOVE & INSTALL
1. Remove the wiring connector of the horn
2. Remove the bolt and horn.
3. To install, reverse the order of removal.

36
Instrument inspect

name purpose Graduation arrange Normal remark

water 40℃-55℃ yellow Cease and check
Engine cool water
temperature 55℃-110℃ green Green zone when point is
meter temperature 110℃-120℃ red near red zone
0-1/10 red Adding oil when
oil capacity
Engine fuel capacity 1/10-1 green Green zone point is near red
meter
zone
4 integers, 1 decimal
timing Accumulative total engine fraction
operate time
meter
oil pressure Engine lubricate grease 0～0.2～0.4～ < 0.1 Mpa
≥0.1 MPa
meter pressure 0.8MPa cease and check

WARNING LAMP INSPECT

Light blank
Description Function Lamp light（warning） Remarks
(normal)

Indicate the When running at

The alternator doesn’t The
Charge alternator voltage up idle speed, the
generate electricity or alternator is
warning to its rate, whether light turns off
voltage is lower ， at normal
lamp charge battery or because voltage
without inflating. condition
not. is high.
Brake It indicates the When light turns
The oil pressure of on, you should
warning accumulator’s oil check the oil
accumulator is low.
lamp pressure pipe.

37
Repair of starter/dynamotor

starter
phenomenon reason settlement
Battery capacity is not
Change battery or charge
enough
Repair or change electrical
Electric circuit break
layout, starter delay and so on
Electromagnetism switch Change and repair
shatter electromagnetism switch
Not rotate
Pinion doesn’t joggle well
with line roll gear Change or repair
Adjust brush location, clean the
Brush doesn’t contract well
surface of brush
Brush abrasion change
Armature circuit break Change armature circuit
Starter rotates but the Pinion doesn’t work well change
engine can’t rotate line roll gear shaft isn’t good repair
Dynamotor

phenomenon reason settlement

Adjuster shatter Change shatter
Charge indicator shine

Magnetic field connection shatter change

Diode shatter change
Can’t charge Reed lead break or contact
Repair or change
badness
Repair
Fuse shatter

Surge magnet circuit shatter change

Diode shatter change
Charge current is
Reed lead contact badness Repair or change
small
Electricity load is too high Reduce electricity load
Strap strain badness Adjust
Adjuster shatter
Change current too Change
Current output circuit fastener
big Repair
loose
Battery liquid
Battery shatter Change or add liquid
surface descend
Adjuster shatter Change
others

Dynamotor sound
Bearing/brush don’t contact well Repair or change
abnormal
Strap strain badness Adjust

38
Fig 8-1 CPCD120/140/160-XW79 electrical system(Ⅰ)

39
Fig 8-2 CPCD120/140/160-XW79 electrical system(Ⅱ)

40
IX. Lifting system
1. Assemble debugging data

Debugging data Double mast

Standard type and

Lifting height Lifting height
Mast type lifting height of 3～
>4.5～5 meter > 5～6.5 meter
4.5 meter

Mast Forward 60 60 30
tilting
angle Backward 120 60 60

Fork arm carrier Adopt combination roller and side roller.

roller
Inspection and adjustment

Assembly clearance Repair clearance

Place
in（mm） in（mm）

Mast to lift roller 0.011~0.049(0.3～1.25) 0.016~0.055(0.4～1.4)

Mast to bearing board 0.008~0.039(0.2～1) 0.011~0.047(0.3～1.2)

Inner mast to carriage side 0.011~0.049(0.3～1.25) 0.016~0.055(0.4～1.4)

Lift chain deflection 0.98~1.18(25～30)

Tightening torque

Place Model or Lifting capacity lbf·ft(N·m)

Lift chain lock nut 2952~3173(4000～4300)(M45×3)

Mast support cap blot 42.8~57.6(58～78)（M12）

Small 35000lb(16t)
Lift cylinder bolt 470.8~627.3(638～850)（M24）
Lift cylinder fixing bolt
139.5~186.0(189～252)（M16）
（U type）

Mast dimension in×in×in Weight

(mm×mm×mm) lb（kg）
35000lb(16t) 119.3×93.3×35.2 10582(4800)
(3030×2370×895)
41
 2. Failure diagnose and corrections
Condition Probable cause Corrective action
Fork arm 1.Tilt cylinder and ring abraded excessively Replace piston ring tilt cylinder.
carrier or
2. The hydraulic control valve spring is
mast tilt by Replace it.
inoperative.
itself.
The fork arms 1. Caused by piston jamming or bent piston
carrier moves Replace the faulty parts.
rod.
up and down
sluggishly. 2. Too much dirt is accumulated in the cylinder. Strip it down and clean.
1. Carriage bracket assembly out of Adjust clearance with thrust metal
adjustment. and carriage side roller.
2. Insufficient clearance between inner and
Forks are outer masts or rollers and mast. Adjust clearance with rollers.
lifted or
3. Biting foreign materials between moving
lowered Remove foreign materials.
part.
unsmooth.
Apply grease on contact surfaces of
4. Insufficient lubrication.
sliding parts.（butter）
5. Bent carriage bracket assembly. Repair or replace.
Forks are
1. Lift chains out of adjustable. Adjust lift chains.
lifted unevenly
1. Grease stiffened or dirt accumulated on lift
Lift roller does Clean and lubricate lift rollers.
roller and mast sliding surfaces.
not rotate
2. Improperly adjusted lift roller. Adjust.
1. Insufficient lubrication. Lubricate.
Excessive
2. Improperly adjusted lift roller, side roller and
mast noise Adjust.
back-up metal.
1. Excessive wear occurs between the oil
Replace the worn parts or the oil
pump body and gears, causing too much
pump.
clearance.
2. The lifting jack piston Yx-ring has worn,
Replace Yx-ring.
resulting in excessive inner leaks.
3. Springs of the multiple control valves and its
Replace.
relief valve are inoperative oil leaks.
4. Excessive wear occurs of the hydraulic
control valve, resulting in excessive oil Replace.
Insufficient lift leaks.
power or no 5. Oil leaks occur between the hydraulic control Dismantle for regrinding the joint
lift movement. valve sections. surfaces and reassemble the valve.
Tighten the joint nuts and inspect the
6. Leakage occurs in the hydraulic pipe.
seal for damage.
Change the wrong hydraulic oil or
7. The hydraulic oil temperature is too high. Oil stop operation for reducing the oil
viscosity is too low and the rate is temperature. Find out the reasons
insufficient. for high oil temperature and
eliminate the trouble.
8. The load carried is beyond the designed
Observe the lifting capacity limit.
capacity.
1. The ring of Setting-up cylinder and ring
Forks does Replace ring
abraded excessively
not adjust
2 Fork’s shaft rust seriously Clean and lubricate
setting-up
3. Fork is turn back by foreign materials Clean

42
Double high visibility mast

Double mast is composed of outer mast which can’t lift and inner mast which can lift.
Lifting jack bottom is fixed on outer mast below cross beam, oriented with pin. Piston rod
extremity is joined with upper cross beam of inner mast; cylinder body is fixed on outer
mast fixation board with U-bolt. Commonly free lift range is 200mm, which is difference
with different tonnage. Two lifting jacks are laid out back of outer mast to realize high
visibility.
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
joined with fork arm carrier. Fork arm carrier and fork arm is rising with inner mast rising to
realize aim of lifting goods.

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

43
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.Piston rod 13.piston 14. Seal ring 15. Check ring
16.O-ring seal 17. Support ring 18. Slotted nut 19. Pin 20. Joint
Fig. 9-3 tilt cylinder

44
Load backrest extension

Load backrest extensions have height, width, and size openings sufficient to minimize the
possibility of the load falling toward the mast when the mast is in a position of maximum
rearward tilt.
The size of openings in the load backrest extension not exceed 5.91in(150mm) in one of
the two dimensions.
The installing holes of load backrest extension see the following fig.

Fig. 9-4 Load backrest extension

45