X SERIES 14t-18t

INTERNAL COMBUSTION TRUCK

SERVICE MANUAL

CPCD160-XRXG90B
CPCD120/140/160-XRXG57B
CPCD120/140/160-XRXW25B
CPCD160-XRMG57B
CPCD160-XRMW25B
CPCD120/140/160-XRXH13B
CPCD160-XRMH13B

HANGCHA GROUP CO.,LTD.

January. 2021
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: [email protected]
 Foreword

The manual is the introduction of structure, working principle and serving .etc

of X series internal combustion forklift.

In order for safety guarantee and make full performance of the truck you

bought, relevant operator, equipment manager and maintainer should read

and comprehend this manual well.

Anybody without training and qualification is not allowed to maintain the truck.

○
C January. 2021 HANGCHA GROUP CO.,LTD.
 Content

I. Power system.................................................................................................................................1
1. Power disposition................................................................................................................. 1
2. Use and maintenance of engine........................................................................................2
II.Hydraulic gear-box and torque convert..................................................................................... 8
III. Drive axle...................................................................................................................................... 1
1. Drive axle basic structure and its working principle.............................................................. 1
2.Use of drive axle...................................................................................................................... 2
3.Periodical technical maintenance.......................................................................................3
4. Driven spiral bevel gear engagement contact condition and adjustment.................. 5
5. Fault diagnosis and corrections...............................................................................................6
IV. Steering axle................................................................................................................................7
V. Steering system..........................................................................................................................10
VI. Brake system............................................................................................................................... 13
1.Operating hydraulic pipe line.............................................................................................14
2.Brake and inching control assembly................................................................................ 15
3.Brake valve.............................................................................................................................16
4.Accumulator........................................................................................................................... 17
5. Valve block assembly............................................................................................................18
6.Control valve assy.................................................................................................................. 19
7.Fault diagnosis and corrections（service brake）........................................................20
8.Fault diagnosis and corrections（parking brake）....................................................... 21
VII Hydraulic system...................................................................................................................... 22
1. Pump.................................................................................................................................... 22
2. Control valve......................................................................................................................... 24
3. One-way check valve........................................................................................................ 29
4. Lifting cylinder......................................................................................................................29
5. Tilting cylinder...................................................................................................................... 30
6. Hydraulic system schematic diagram.............................................................................31
VIII. Electrical system.....................................................................................................................32
IX. Lifting system............................................................................................................................ 50
1. Assemble debugging data......................................................................................................50
2. Failure diagnose and corrections...........................................................................................51
3.General................................................................................................................................... 52
4. Mast dismantle and install adjustment..................................................................................55
5. Disassembly and installation of lifting cylinder................................................................... 59
6.Disassembly and installation of tilting cylinder.................................................................... 60
7.Noticing proceeding of debugging....................................................................................62
I. Power system
1. Power disposition
Engine Diesel engine Diesel engine
Parameter
QSB6.7-173 YCA07160-T400
Rated output kW 129 118
Rated speed r/min 2200 2200
Max. torque N·m/rotate speed 799/1400 670/(1400~1700)
rpm
Displacement L 6.7 6.87
CPCD140-XRAW85G
CPCD140/160-XRW85
Forklift model CPCD160-XRXG90B
G
CPCD180-XRXW85G

Engine Diesel engine Diesel engine

Parameter
Cummins B6.7 Cummins B6.7
Rated output kW 149 116

Rated speed r/min 2200 2200

Max. torque N·m/rotate speed 990/1300 746/1300
rpm
Displacement L 6.7 6.7

CPCD120/ 140/160-XR
CPCD160-XRAH9G XH13B
Forklift model
CPCD180-XRH9G CPCD160-XRMH13B

1
2. Use and maintenance of engine
2.1 Basic operation requirement
◆ Before starting the engine, you should check the level of machine oil and coolant,
and seek:
• Leakage place
• Looseness place and damage article
• Any change of the appearance of the engine
◆ When starting:
• Do not place the hydraulic system operating grip and transmission gear box place in
neutral.
• Do not step on the accelerator (Electronic controlled engine).
• Switch the key to the connecting position “ON ”, wait for the “WAIT-TO-START ”
indicator going out, and then re-start the engine (Electronic controlled engine).
• Starting time of the motor should not exceed 30 seconds, and interval between two
starting should be 2 minutes.
• If there is current malfunction, you should deal with the problem and re-start the
engine (Electronic controlled engine).
• If you are unable to start the truck for 3 times, you should check the electrical control
and fuel system.
• If there is still no machine oil pressure for 15 seconds after starting the truck, you
should shut down the engine and check the lubricating system.
◆ After starting:
• Reload for idling at least 3-5 minutes to make sure the normal of lubricating oil.
• The engine is not allowed to run under low idling speed condition for overlong time
(exceed 10 minutes).
• It is not allowed to keep the engine accelerator open exceeding 30 seconds when it
is below motor linear torque rotate speed(refer to linear torque speed on the engine
nameplate), otherwise it may shorten engine heavy repair interval and damage the
engine badly.
• Engine speed is not allowed to over the max. speed of the engine, or it will cause
sever damage to the engine.
• During then engine running, if the temperature of engine coolant continually is over
or below the technical specified value given by the maintenance technical regulation.
2.2 Daily maintenance requirement
Let out water in oil-water separator
◆ Turning off the engine. Turn on the water discharging switch, let out water and
deposit in the oil-water separator until the clean oil flows out.
Notice: Water discharge switch should not screw too tightly, or it will make thread
invalid.
Check oil level of the machine oil daily
◆ When checking oil level of the machine oil, the engine should be placed in level,
and the measurement should carry out in 5 minutes since stop. Taking out oil gauge to

2
check oil level, which should be between “L” and “H” marked on the oil gauge.
Check fluid level of coolant daily
Caution: When the engine is still heat, do not take off the radiator cover! The
temperature should be below 50 ℃, then you can take off the pressure cover, let out
the pressure of the cooling system slowly.
◆ You should check fluid level of coolant daily and get the radiator full of coolant.
Coolant cover should work normally. Please apply the recommended Renewal interval
to replace the filter.
◆ You should report the following condition of the engine in time: lacking spark,
vibrate, abnormal noise, leakage, sudden change of water temperature and machine
oil pressure, smoking, power coastdown, inability, consumption of machine oil and
fuel oil.
◆ After full-loaded running of the engine
• Idling 3-5 minutes then stop the truck.
• When the engine shut down, stay the ‘ON ” position for at least 10 seconds, then cut
off the power (Electronic controlled engine).
• You are not allowed to clean the engine with water (Electronic controlled engine).
◆There must be certain DCA4 in the coolant to supply the best anticorrosion ability.
Notice: If adding coolant is needed, you must add the mixed coolant (intensive mixing
of 50% water and 50% antifreeze solution).
Check driving belt weekly
◆ Check the longitudinal crack of the belt. Transverse crack is acceptable, while
longitudinal crack intersecting with transverse crack is unacceptable. You mush
change the belt if there is any deformity or damage.
Check cooling fan weekly
◆ Check the crack of the cooling fan. Make sure the cooling fan firmly install and
change the damaged one.
Renewal interval of lubricating oil and filter
◆ Only use high-quality lubricating oil and fleetguard filter recognized by Cummins.
◆ Choose lubricating oil that suits local temperature. The max. Renewal interval of
lubricating oil and filter recommended is 250 hours or 3 months or 10,000 km(based
on the first arrival)
Notice: Do not get the dirty into the lubricating system when changing filter and
lubricating oil.
Adding fuel oil, the Renewal interval of fuel filter
◆ Cummins suggest to use diesel with high quality and proper viscosity and
fleetguard filter. Replace fuel filter every 250 hours and 10,000 km, or refer to the
recommended Renewal interval of the manual.
Notice:
• Never get the dirt into the fuel system when changing filter and adding oil to the oil
box.
• Clean oil box periodically.
• Never use low-quality and non-Cummins filter, otherwise it may cause severely early

3
wear of fuel pump.
Check air intake system and air filter weekly
◆ Check whether there is crack in the air intake pipe or the looseness in the pipe.
When the intake resistance reaching the specified max. intake resistance, you should
replace air filter or clean air filter according the manufactures’ requirement.
Notice: Even little dirt enter the engine, it will cause severe wear of piston ring and big
low exhausting. Make sure the clean and no air leakage of intake system.
Starting motor and battery
◆ Make sure the clean and no looseness of the battery wiring. Interval between two
continuous starting should exceed 2 minutes. Per starting time should not exceed 30
seconds. You should charge the battery periodically and pay attention to battery ’s
winter insulation.
Turbocharging and intercooling system
◆ The common turbocharging is waste gas supercharger, using the waste gas
exhausted from the engine to drive impeller to compress the fresh air thus increase
the air inflow.
◆ Air temperature increased after supercharging, first is air density of the cylinder
decreased(the higher temperature, the lower oxygen content) and the output power
decreased; second is causing engine detonation. As a result, cooling the air after
supercharging is beneficial to improve engine power, reduce fuel consumption, reduce
engine thermal load and lessen engine detonation trend. This is realized through the
intercooler at the back of the compressor.
Notice: You should check and adjust the intercooler intake pipe to avoid the air
leakage.
◆ After high-speed running for a long time, the engine should not shut down
immediately. The reason is that, after sudden stop, engine oil pressure drops to zero
rapidly, machine oil supply for lubricating and cooling suspend, meanwhile the rotor is
still in inertially high-speed rotation. Thus it cause the “seizure ” between the spindle
and shaft sleeve of the turbocharger and damage the spindle and shaft sleeve.
Moreover, after sudden shutdown of engine, temperature of exhaust manifold is very
high, it will boil the machine oil in the turbocharger into carbon deposit. If this carbon
deposit is accumulated much, it will lead to the oil lack of shaft sleeve and speed the
wear between spindle and shaft sleeve of the turbocharger.
Specification, structure and maintenance, please refer to ENGINE MAINTENATION

MANUAL.
You should check the exhaust quantity after the maintenance or servicing, and ensure
that the exhaust gas is in accordance with relevant figure .

phase III see the following table:

Engine power CO HC NO X HC+NOx PM
kW (g/kWh) (g/kWh) (g/kWh) (g/kWh) (g/kWh)

4
 37 ≦P <75 5.0 - - 4.7 0.4

75≦P <130 5 - - 4.0 0.3

Phase Ⅳ see the following table:

Engine power CO HC NO X HC+NOx PM
kW (g/kWh) (g/kWh) (g/kWh) (g/kWh) (g/kWh)

75≦P <130 5 0.19 3.3 - 0.025

5
1.Fuel 2.Bolt 3.Support 4.Air intake 5.Bolt
system system
6.Hoop 7.Engin 8.Exhaust 9.Engine mount 10.Cooling system
e system
Fig 1-1 Power system Drawing

6
1.Intercooler hose 2.Engine outlet 3.Coupling tube 4.Radiator and shroud
pipe 1 assy
5.Engine outlet 6.Hoop 7.Water supply pipe 8.Engine inlet pipe
pipe 2
9.Intercooler exit
pipe
Fig 1-2 Cooling system drawing

Fig 1-3 Exhaust system drawing

7
II.Hydraulic gear-box and torque convert
Data
Model Y63270Z/X

Hydrodynamic Two stage, triphase ,four

Type
torque element
converter

Variety Electronic shift gear

Hydrodynamic Forwarder gear Ⅰ 1.179

power Transmiss
0.645
gear-box ion gear Forwarder gear Ⅱ
ratio
0.844
Reverse gear Ⅰ
Shift gear oil pressure
1.0-1.6
MPa
Oil pressure
Torque converter output oil pressure
≤ 0.50
MPa

Mass (kg) 450

Oil capacity (L) approximate31-32
Using oil type ATF DEXRON II（ Caltex ）

Specifications, structure and maintenance methods ,please see

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

8
III. Drive axle
1. Drive axle basic structure and its working principle
1. 1 Basic structure and its working principle
Dive axle basic structure is mainly composed of axle housing, main reducing gear assembly,
half shaft, hub reduction gear and drum brake etc.
Its working principle is shown as fig. 3-1: driving torque inputs into main reducing gear, by
means of mutual vertically installed main axle drive bevel pinion and driven bevel pinion,
changes power direction, reduces speed, enlarges the transferred torque, and then transmits
power to the wheel by differential and haft shaft. After further slowing down by hub reduction
mechanism, transmit movement and torque to two drive axle.

Fig.3-1 Work principle diagram

1.2 Hub reduction gear and axle housing
Hub reduction gear is planetary reducing gear, mainly composed of planet carrier, inner gear,
planetary gear and central gear, internal gear is fixed to shaft, planet carrier fix together with
hub.
1.3 Main reduction gear assembly structure
Main reduction gear is composed of spiral bevel gear and differential. Differential is a
differential planet gear transmission gear, that is composed of two tapered straight tooth half
shaft gears, four tapered straight tooth planetary gears, differential carrier and universal joint
pin.
1.4 Wet brake structure
The adopted wet brake braking, mainly composed annular gear, cylinder block, piston, friction
slices, static friction silces, land, gear ring, floating seal seat.
1.5 Main technical parameter

Total reduction ratio 25.46 Output torque 105kN·m

Service brake torque 49kN·m Load per axle 320kN

Total length 2213mm Wheel track 1780mm

Total weight 1000kg Connecting hole center distance 810mm

1
2.Use of drive axle
2.1 Installation of drive bridge.
Rim large nuts, rim sleeves all right-handed, tightening torque is 850N ·m, a group of rim
nuts should be coated with 242 lotai glue before tightening, and must be symmetrical and
uniform. In normal use, it is necessary to check whether the nut is loose and fastened in time,
and the end of the nut ball should be consistent with the rim ball socket, and the contact
compaction should be made to make it connect firmly.

2.2Drive axle oil adding /drainage way and fuel-injection quantity

When adding oil, place the oil hole at left and right hub reduction gear to highest
place(lowest place when discharging oil), open the vent plug, oil level plug and oil plug at left
and right hub reduction gear, add lubrication oil to the left, right and middle position, until
overflow from the oil level, refer to the following fig.
Note: Specified injection of fuel is approximate, Prevail along the flush to the oil surface and
the filling hole.

2.3 Use of brakes.

The operating pressure of the brake is 12 MPa. Before the main machine is running,
please debug the foot brake brake to make the brake flexible and reliable. At the time of
debugging, first tighten the air release nozzle, and step on the foot brake plate continuously
until it feels hard to step forward. At this time, step on the foot brake plate, release the open air
nozzle, release the air bubbles, then tighten the air release nozzle and release the foot brake
plate; repeat the above steps until there is no air bubble to appear. Each secondary brake is
operated as per the above requirements. (the brake medium is hydraulic oil)

4. Drive axle hoisting

When hoisting the drive axle, hoist through rope according to the arrow listed place, if
shovel needed, shovel according to the arrow listed place. No matter hoist or shovel, collision
or obscission is prohibited.
The drive axle shall be bare. In the course of transportation, the partition shall be set
between the bridge and the bridge to avoid collision. The flange of the main reducer shall be
wrapped with moisture-proof paper so as not to rust, and the air vent of the bridge and the oil
outlet of the brake shall be blocked by the rubber plug.

2
3.Periodical technical maintenance
3.1 Grade I technical maintenance (about work 50 hours)
①If it is new truck running-in, replace gear oil.
Note: When replacing oil, first drive truck warming, release oil, and then wash with carbon oil.
After that, add oil to specified position.
②Check each drive parts move condition, abnormal noise is not allowed.
③Check if hub reduction gear, main driver and brake outer fastener loosen and screw down,
Tighten torque as required in the following table.
Tray bolt（M14×1.5×40） 140N·m
End cover bolt（M10×25） 47N·m
Hub nut（M22×1.5） 850N·m
Hun bolt（M22×1.5） 850N·m
Brake disc bolt（M16×1.5×60） 205N·m
Floating seal seat bolt（M8×20） 24N·m
Brake bolt（M14×1.5×45） 140N·m
④Check each part oil leak condition and repair in time. All sealing elements are not allowed to
reuse once dismantle.

3.2 Grade II technical maintenance (working time about 1200hours)

①Check and adjust bearing and basin tooth clearance.
②Replace gear oil according to season or major repair requirement. When replacing oil, first
drive truck warming, release oil, and then wash with carbon oil. After that, add oil to specified
position.
③Check and clean greasy dirt, soil and dust, especially breather plug on the axle housing
should keep smooth.
④Check and fasten external fastener. If any loosen, apply Letai 242 anti-loose glue and screw
down.

3.3 Grade Ⅲ technical maintenance (working time about 2400hours)

①Disintegrate inspection, repair and replace damaged parts of wheel edge reducer and main
driver. During assembly, apply solvent to clean the original part coated with sealant, dry, smear
SD-314 silica gel. All fastener bolts should also be cleaned, dry, coated with Letai 242
anti-loosening glue, and then tightened, tightening torque to meet the requirements of the
above table.
②Adjustment of the main and wheel-side reduction mechanisms.
1.When the axial clearance of the active spiral bevel gear bearing is (0.05~0.10) mm, the gear
should rotate flexibly, push the feeling of no axial movement by hand, and the axial clearance
of the bearing should be adjusted by gasket.
2.The installation distance of spiral bevel gear must be adjusted to the correct position to
ensure the correct meshing mark and clearance. Adjustable nuts, gaskets to achieve. The
axial clearance of the bearing is (0.05~0.10) mm, and the tooth side clearance of the passive
spiral bevel gear is (0.20~0.35) mm, meshing mark is examined by coloring method. The
correct mark of the driven spiral bevel gear is shown in Fig. 5. Contact spots along the tooth
height, tooth length direction is not less than 50%.

3
3.The minimum meshing gap between the half shaft gear and the planet gear of the differential
is 0.1 mm, and the supporting gasket is used to adjust it to ensure that after assembly, the
hand can be rotated lightly without sticking.
4.The gear edge deceleration gear should be repaired and replaced, and the contact spots
should be checked by coloring method. The tooth height should be more than 45% and the
tooth length should be more than 50%. After the hub is installed and rotated by hand, the
bearing is in the correct position, then the inner gear is installed, and the round nut is tightened
so that the pretightening force of the hub bearing is in the range of 18~23N.m, fixed with the
inner hexagonal bolt, and then installed on the planet frame assembly.
5.If the needle in the planetary gear in the wheel side is replaced, all the needle-rolling groups
must be selected so that the diameter difference in the same group is not more than 0.005mm,
the diameter difference of the needle-rolling cylinder is not more than 0.005mm, and the radial
clearance between the inner hole of the gear and the pin shaft is (0.02-0.03) mm.

4
4. Driven spiral bevel gear engagement contact condition and
adjustment
Ideal engagement contact condition of driven spiral bevel gear
Driven spiral bevel gear Driving spiral bevel gear

Driving Driven Driving

surface Driven
surface surface
surface

Incorrect imprinting and adjustment way to driven spiral bevel gear

Gear move
direction(first
Adjustment way adjust active line,
then adjust dotted
Backup
line)
Drive

Get driven gear close driving

gear, if the gear clearance is
too small, move driving gear
outward.

Move the driven gear out from

driving gear, if the gear
clearance is too big, move
driving gear inward.

Get driving gear close driven

gear, if the gear clearance is
too small, move driven gear
outward.

Get driving gear close driven

gear, if the gear clearance is
too big, move driven gear
inward.

5
5. Fault diagnosis and corrections
Condition Possible reason Corrections

Separate service or replace

Parts depreciation
The parts
Abnormal noise Bad gear engagement Re-adjust assemble

Insufficient lubrication Add lubricating oil

Axle oil sealing wear or

Replace
damage
Fill oil and oil plug loosen Tightening
Oil leakage
Bad lubrication Improve lubrication

Over high oil level Add oil to specified position

Bad lubrication Improve lubrication

Axle case
overtemperature Improper assemble of gears
Re-adjust assemble
and bearings.
Clean brake endo and
Brake piston jammed
Brake dragging piston
Brake oil circuit clogged Examine oil circuit

6
 IV. Steering axle
1. General date Steering axle frame
Axle type Center support, wing type
Axial clearance（mm） 0～1(forward is no clearance)
Inner angle 77.6°
Steering angle End axle adjusting shim
Outer angle 540
Thickness（mm） Part No.
Tire pressure 0.89MPa
1.0，2.0 GX160-220005-000

Steering king pin Wheel bearing

End play
Less than 0.2 Tighten bearing nut until rotating
clearance（mm）
resistance is felt, from this position; back
Steering king pin adjusting shim Pre-tightness
off bearing nut 1/8-1/6 turn. or wheel hub
Thickness（mm） Part No. 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. Diagnosis and correction

condition Probable cause Corrective action
·wheel nut looseness
tighten
·wheel bearing out of adjusting range
Unstable adjust
·improper installation of end axle adjusted
driving adjust
shims
refer to steering section
·steering system fault
·insufficient lubrication
Apply lithium base grease
·bolts and nuts looseness
Noises tighten
·improper installation of end axle adjusted
adjust
shims
3. Steering axle
Steering gear is composed of steering axle frame, steering cylinder, connecting rod and steering
wheel (fig 4-1), steering trapezium adopts slider-crank mechanism, push knuckle steering through
connecting rod by cylinder piston rod, which makes deflection of steering wheel and realize
steering. Steering axle use bolt to connect the back carriage from front and rear pin shaft through
bearing block, which makes the axle frame rotate along pin shaft. The left and right steering axle
has a knuckle separately, rear hub is installed to knuckle upper shaft by two tapered roller bearing,
wheel is connected to hub by rim, and there equips with oil seal inside the bearing to keep the
lubricating grease in the hub and knuckle intracavity.
Knuckles is knuckles kingpin, thrust bearings and gasket, installed in the steering shaft between
the upper and lower ends of bridge, Kingpin central locking with a pin on the steering knuckle, the
ends of the master pin is supported by the needle bearing pressed on the axle, needle bearings
have seals at both ends, while upper master pin equips with oil cup.

7
1.Ball nut 2.Bolt 3.Steering wheel hub 4.Nut M100×2 5.Washer 100
6.Left steering knuckle
7.End cap 8.Bearing 32022 9.Bearing 32026 10.Oil seal

11.Cover plate 12.Lubricating line 13.Bolt M10×25 14.Washer 10 15.Steel jacket

16.Bearing 51314 17.Pin 18.Adjusting shim 19.Steering axle 20.Steering cylinder

25.Bearing GE30ES-2RS
21.Bolt M10×20 22.Dirt-proof boot 23.Axis pin assy 24.Spacer bushⅡ
30.Bolt
26.Link rod 27.Axis pin assy 28.Spacer bushⅢ 29.Right steering knuckle

31.Washer 22 32.Bolt 33.Nut M16×1.5 34.Set screw 35.Washer 14

Fig. 4-1 Steering axle

8
Dismantle
Hub
1) Jack-up the forklift and support with blocks;
2) Dismantle tyre;
3) Dismantle hub cover;
4) Dismantle lock nut, thrust washer and adjusting nut of the knuckle;
5) Pull out hub assembly;
Notice: a. do not drop taper bearing
6) Dismantle inner ring of the bearing
Notice: b. Be caution not damage the seal element.
Steering king pin and knuckle
1) Dismantle nut in the joint of knuckle and draw bar device, disassemble draw bar device;
2) Loose the fixed screw;
3) Dismantle oil cup of steering king pin;
4) Dismantle steering king pin;
Notice: Push steering king pin to avoid drop.
5) Take down the whole set of knuckle (including thrust bearing, dustproof shell, shim).
Inspect:
1) Replace the knuckle if fracture;
2) Replace the bearing if there is rust or crack on the surface of thrust bearing roller;
3) Replace if the needle bearing damaged.
4) Replace if the thrust bearing and dustproof shell damaged.
Installation:
Install order is opposite to the dismantling order, please be cautious:
1) Insert knuckle king pin from the bottom to up;
2) Install thrust ball bearing with straining ring below, retainer and loose ring above. End play
gained from regulation shim. End play is less than 0.2mm;
Notice: Thrust bolt is installed at the upside of knuckle, and adjusting shim is installed at the
downside of knuckle;
3) Apply lubricating grease to the inner wall, loose ring and straining ring of dustproof shell;
4) Do not apply lubricating grease to faying face of needle bearing outer ring and knuckle;
5) Apply lubricating grease to roller needle of needle bearing and ball of thrust ball bearing;
6) Fill enough lubricating grease to all oil cups.
Installment and adjustment of hub bearing
1) Apply grease and antirust oil to bearing fitting face and article 6 knuckle nut flank.
2) Turn the hub with on hand, screw article 6 knuckle nut the other until you can’t screw it, and
turn in opposite direction 1/6～1/4 circle.
3) Turn hub 2-3 circles and rotate the bearing roller in place.
4) Repeat step2), put article 25 thrust washer, and install article 6 knuckle nut for lock;
5) Turn around 2-3 circles, measure rotate initial force and end play, should meet the following
requirement, otherwise, re-adjust until meeting the requirement. End play should be less than
0.08mm, rotate initial force should be less than 25.5N (Hub bolt).

Steering axle frame

Dismantle
1) Jack-up the forklift and support with blocks;
2) Dismantle tyre;
3) Dismantle castle nut on the draw bar device;
4) Jack-up the axle frame;
5) Dismantle steering oil pipe and bearing block;
6) Dismantle axle frame.
Notice: Support should be stable to avoid accident.
Installation
Install order is opposite to the dismantling order, please be cautious:
Adjust steering end axle adjusting shim to make the end play in specified value and should be less
than 0.7mm.

9
V. Steering system
1. Data
Rear wheel drive with
Steering system type
power steering
Hydraulic steering gear Xcel45-500
Bore mm Φ120
Steering Piston rod diameter mm Φ85
cylinder Working pressure Mpa 14
Rated flow L/min 40
Steering wheel diameter mm Φ360

2. Steering system fault and correction

Condition Probable cause Corrective action

Pump damaged or fault Replace
Steering wheel Flow priority valve blocked or damaged Clean or replace
failure Pipes or connections damaged or passage
Clean or replace
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 orientation
Replace spring strip
spring strip is broken or of failure
Inner leakage of steering cylinder Check piston seal
Insufficient oil in tank Replenish
Abnormal noises
Blocked in the passage or filter Clean or replace
Seal on the guide set, piping or connector is
leakage Replace
damaged
3. General
The steering system is mainly composed of hydraulic steering gear and steering cylinder.
3.1 Steering gear
It mainly includes full hydraulic steering gear, steering column and steering wheel. The steering
column and steering wheel can be adjusted forward and backward, with an adjustable angle of
8°to suit the needs of different drivers.

10
 1.Nut M16×1.5 2.Washer 16 3.Bolt M10×25 4.Washer 10
5.Washer 8
6.Bolt M8×40 7.Steering device 8.Screw M10×40
9.Washer 5 10.Screw M5×14 11.Washer 5 12.Screw M5×14
13.Upper end sheath 14.Sheath 15.Upper end sheath 16.Steering wheelassembly
17.Steering column
Fig 5-1 Steering gear
3.2 Hydraulic steering gear
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.
Hydraulic steering gear is pathless hydraulic steering device, stator and rotor is a pair of cycloid
pin gear inside engaged gear, serves as calculation servo valve, which is placed between flow
divider and steering cylinder in series, where the oil flowing in and out from steering cylinder
should go through. According to steering wheel turning angle, metrically transfer the pressure oil
from the flow divider to steering cylinder to realize steering. The pair of rotary valve linked with the
coupling is used for oil distribution, which makes the oil transportation and rotor change
synchronously.
When steering wheel do not rotate, under the action of spring strip, spool and valve bush are in
neutral position, cutting the hydraulic oil leaded to the steering cylinder, and hydraulic oil flows to
oil tank directly.
When engine misses, oil pump does not supply oil, through spool, valve bush, couple axle, driving
rotor, when rotor and stator equals a manual pump, steering wheel input oil to the steering cylinder
and realize manual steering. Refer to fig. 5-2.

Fig 5-2 Hydraulic steering gear

11
 Fig 5-3 Schematic diagram of hydraulic steering gear
3.3 Steering cylinder
Steering cylinder is of double-action piston type; each end of piston rod is connected to knuckle
and through the connecting rod. Hydraulic oil from hydraulic steering gear makes the piston rod
move left and right to steer truck. Thrust of cylinder is 5066kg, vertical force on the cylinder is
717kg, steering cylinder forms 227mm, rated working pressure is 14MPa, rated flow 40L/min. and
working oil temperature is -120~100℃. Refer to fig. 5-3.

1. Piston rod 2. Seal ring 3. Screw 4. O-ring 5. Seal ring 6. Guild sleeve
7. O-ring 8. Cylinder body 9. Glyd ring 10 Steel ball 11. Support ring
12. Piston 13. Spacer bush
Fig. 5-4 Steering cylinder

12
VI. Brake system
Brake system adopts hydraulic braking system, its supply devices and gears are hydraulic
type. Its control devices are composed of brake pedal framework, parking brake, hand brake,
hydraulic pump, control valve and energy accumulator etc. Pipeline and energy accumulator in the
hydraulic brake system deals with rustproof treatment.
Working principle: High pressure oil in the gear pump enters control valve and ennergy
accumulator, then diveide into two ways: one way to hand control valve, to central brake, when
starting hand brake, pressure oil push the central brake, and parking brake takes effect; another
way brake at the drive axle wheel through foot brake, when steping the foot brake pedal, pressure
oil push the brake cylinder and realize service brake. Charging valve pressure is defaulted in a
range, when the pressure is lower than the set value, pressure oil enters energy accumulato for oil
flling; when the pressure is higher than the set value, charging valve cut down the pressure oil and
stop filling.

Fig.6-1 brake system schematic diagram

13
1.Operating hydraulic pipe line

1.Cooling filtrating oil pipe 2.Brake oil pipe 4.Front axle hydraulic pipe 3.Accumulator oil pipe
Fig 6-2 Operating hydraulic pipe line

14
2.Brake and inching control assembly
2.1 structure and principle
When press brake pedal, the spring in brake valve suffer from force of mandril, which makes the
piston slide downwards and the inlet valve open. Thus the hydraulic oil flow from inlet port to outlet
port. When release the pedal, the reset spring push the piston slide upwards, and the inlet valve
closes. Thus the channel between the inlet port and outlet port close, and the rest oil discharge
from the oil drain.

1.Brake pedal assy 2.Shaft 3.Spring 4.Stop screw 5.Stop bolt

6.Pin shaft B10×32 7.Pin 3.2×18 8.Oil cup 9.Brake valve
Fig6-3 Brake and inching control assembly

2.2 Pedal angle adjusting

Adjust the 5 limit bolt so the bolt reaches out to 18mm, then tighten the nut M8 at a 45°angle
between the pedal and the front floor.
Adjust the 4 limit screws so that the screw reaches out to 36 mm, then tighten the nut M8 with a
31°angle to the front floor when the pedal is stepped down.

2.3 Points for attention of operation

1） ensure the connection between pedal and valve firm, adjust the clearance of valve by adjusting
the adjusting bolt(ensure the clearance from ilder wheel to mandril is less than 0.5mm), then
tighten the nut.
2）pin shaft 10×32 should be fastened by pin 3.2×18.
3）don’t confuse the inlet port and outlet port.

2.4 Points for attention of maintenance

1）When replace the vulnerable parts, replace it according to the practicality,and the fasteners
(such as retaining ring, bolt) should be replace as well. Make sure these parts fixed in position
reliable, and don’t mangle other parts.
2 ）the movement parts of brake valve should be maintained by using lubricating grease. If the
brake is invalid or not good enough, please check the vulnerable parts of brake valve and brake
system.
3）the parts after replacement can’t use to assemble before pass the experiment.

15
3.Brake valve
The brake valve is a direct operated 3-way pressure reducing valve.( the increase of pressure is
proportional to the operating force.) It owns the features as follow：
- Small installation dimensions
- Integrated maximum pressure limitation of the brake circuit
- The brake pressure is proportional to the operating force
- Low hysteresis

Fig.6-4 the outline of brake valve

Fig.6-5 hydraulic function diagram of brake valve

16
4.Accumulator
Accumulator is an indispensable and important part of hydraulic system, which can save
energy, stabilize pressure, reduce energy consumption and compensate leakage. Absorb oil
pressure pulse impact force and other functions.
The NXQ series skin bag accumulator is naturally divided into two parts: nitrogen in the
capsule and hydraulic oil outside the capsule. When the hydraulic oil enters the accumulator, the
skin is compressed and deformed, the volume of gas is reduced, and the hydraulic oil is stored. On
the contrary, the system needs to increase the hydraulic oil, then the gas expansion hydraulic oil is
discharged, so that the energy of the system can be compensated.
When the pipeline and components of the brake system need to be repaired and replaced, the
ball valve shall be opened in advance, and the oil of the energy accumulator shall be drained, so
as to avoid the oil injection accident.

Fig. 6-6 structure of accumulator

Accumulator parameters:
type Bag type accumulator
Working medium nitrogen
Nominal capacity 4.0 L
Nomial pressure 31.5 Mpa
Quality 18.5kg
Working temperature -20～120℃
Nitrogen pressure 8.5Mpa

Caution: There is a pressure release valve(ball valve) between accumulator and bank. It is close
when it is vertical, and it is open when it is level. The circuit pressure is high because it is
connected with the accumulator. It is necessary to open the ball valve to release the oil with high
pressue when repair the related hydraulic pipes, and close the ball valve after the repair work
finished.

17
5. Valve block assembly
The valve block assembly is fixed on the parking brake shell of drive axle through a bracket.
There are three port on the upper of valve, and they are connected separately to brake valve, oil
filter and the t-junction in oil return flange . There are three ports on each side of the valve, and
they are connected to inlet port, outlet port of cooling for wet disk brake on drive axle and parking
brake port. The surface of the valve is galvanized and passivated.

Fig.6-7 valve block assembly

18
6.Control valve assy
Control valve is mainly used to maintain the pressure of accumulator circuit within a certain limit
value (cut-off pressure, turn-on pressure). The switching pressure difference is about 18% of the
cut-off pressure. The valve is a normally open valve. It connects the pump's LS signal to the fuel
tank. It compares the accumulator pressure with its setting. If the accumulator pressure is too low,
it will turn off and the LS signal will start the pump to boost the accumulator. When the accumulator
pressure reaches the preset value, the filling valve will open.

Fig.6-8 Brake filling valve

Fig.6-9 Brake filling valve schematic diagram

19
7.Fault diagnosis and corrections（service brake）
Condition Possible reason Corrections

Vehicle does not

Hydraulic system damage Repair hydraulic system
move

Piston return spring damage Replace

Check piston seal and seal

Piston cannot return diaphragm for damage,
Brake dragging
replace if necessary

Cooling liquid(gear oil) or hydraulic oil Clean and use correct clean
error oil

Too low pressure Check pipeline or element

Brake Friction plate wear badly or damage Replace

performance
Cool or check, replace plate
reduction Seal and plate overheated.
and seal if necessary.

Cooling liquid(gear oil) or liquid oil is dirty Clean and use correct clean
oil
Oil leakage in brake lines Correct and replenish
Insufficient brake Air in brake lines Bleed air
force Uneven wear or contact of linings Grind or replace
Oil lines plugged Clean
Uneven tire pressure Adjust
Unequal braking Improper contact of linings Grind or correct
(forklift truck veers Worn lining Replace
to one side) Improper wheel bearing adjustment Adjust or replace
Clogged oil lines Clean
Worn linings Replace
Brake noise
Loose wheel bearing Repair
Wheel gear assembly seal damage Check out
Leakage Final drive assembly seal damage Check out
Deformation or loosening at each joint Check and tighten

20
 8.Fault diagnosis and corrections（parking brake）
Condition Possible reason Corrections

Check the hydraulic oil level,

whether there is air in the
Hydraulic oil is too low pipeline, whether it leaks, and
whether the seal is installed
Parking brake
reversely
cannot be released

Piston stuck Replace piston or shell

Check and repair electrical

No electrical signal
connector
Damaged spring in brake caliper Replace spring
Parking brake is not Check and repair electrical
Piston stuck
available connector
Snap ring stuck Adjust

Improper adjustment Adjust

Excessive wear of linings or brake discs Replace linings or brake discs

The brake cannot
clasp.
Oil or grease on the lining or brake disc Wipe off, and clean

Damaged spring in brake caliper Replace spring

21
VII Hydraulic system
Hydraulic system is composed of main oil pump, control valve, lifting cylinder, tilting
cylinder and oil pipeline. Engine power take-off (PTO) directly drives the pump.

1. Pump
Front pump Middle pump Rear pump

Fig. 7-1 Outside drawing of oil pump

The oil pump is the power source of the hydraulic system, which provides high
pressure hydraulic oil to the hydraulic system driven by the engine. The hydraulic oil
supplied by front pump flows directly to the multi-channel valve, and the hydraulic oil
supplied by middle pump flows to the priority valve, which is shunted through the priority
valve and supplied to the steering system with high pressure oil according to the steering
needs through hydraulic load feedback. With sufficient steering flow guaranteed, the
excess hydraulic oil is diverted to the multichannel valve. When the lifting and tilting
two-slide valve is in the neutral position, the high pressure oil is returned directly through
the passage to the oil tank; when the lift slide valve is pulled, the high pressure oil passes
through the throttle valve, and then the piston rod is pushed upward by the piston under
the lift cylinder. When When pushing the lifting slide valve, the lower part of the lifting
cylinder piston is connected with the low pressure, and the piston rod is lowered by the
weight and cargo weight. At this time, the oil flowing from the lifting cylinder is controlled
by the one-way speed limiting valve. When the tilting slide valve is operated, the high
pressure oil can flow into the front cavity of the tilting cylinder, and the other side is
connected with the low pressure so that the gantry can be tilted backward or forward.
Rear pump is used for circulating cooling of hydraulic oil.
Oil pump’s technical data is as follows:
Nomina displacement(front/middle/rear) ml/r 63/50/20
Rated pressure Mpa 20
Rated speed rpm 2500
Sense of rotation Ievorotation
Volumetric efficiency ≥93%
Hydraulic oil L-HM32 or equivalent oil
Operating temperature -40-100

22
 Fault diagnosis and adjustment:

Fault Probable cause Corrective action

Low oil level Fill to the specified oil level
No oil pumps
Blocking of oil suction pipe or Clean oil pipe and oil tank. If hydraulic oil
from the pump
strainer is dirty, please replace it.
Bearing worn; retainer, O-ring
Change the bad spare parts
damage
Adjustment failure of relieve
Adjust the pressure to correct value
Low oil valve
pressure of oil ·Screw the loose connector of the intake
pump output side
Air in the oil pump ·Fill hydraulic oil to the oil tank
·Check pump oil seal
·Use the pump after bubble vanishing
Distortion of soft tube of the oil
Adjust or replace soft tube and clean the
absorbing side or cavitation
strainer
arising from the strainer blocking
Suck the air from the loose
Re-screw each connector
connector at the intake side.
Noise of oil
·Replace new hydraulic oil, whose
pump
Cavity caused by the high viscosity suits pump running speed
viscosity of hydraulic oil ·Work only when the oil temperature is
normal
Check the reason for the bubble and
Bubble in the hydraulic oil
take measures
Damage of oil seal of the pump,
Oil leakage of
damage of O-ring or wear of the Change the bad spare parts
the pump
pump sliding surface.

23
2. Control valve
CDB-F20HC12-03a（2th）
Model CDB-F20HC12-04C(3th）
CDB-F20HC12-05e（4th）
Type Double slide valve, with tilting latching valve
21 MPa (be able to normally lift 110% rated load, and unable
Main relief valve pressure MPa
to lift 125% rated load)
Rated flow L/min 260
Nominal pressure Mpa 20

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.

24
Fig.7-2 control valve and schematic diagram,2sec

25
Fig.7-3 control valve and schematic diagram,3sec

26
Fig.7-4 control valve and schematic diagram,4sec

27
Fault diagnosis and corrections

Condition Possible reason Corrections

Loose of pressure-adjust screw Readjusted and retighten

Pressure of relief Distorted or damaged
Replace
valve is not pressure-adjust spring
steady or too
Worn or blocked relief valve element Replace or clean
low.
Pump abated Examine and repair pump

Mast tilt forward Worn or damaged tilt lock valve Replace valve core and tilt lock
when control valve as an assembly
lever is used Broken tilting lock spring Replace spring
while engine is
off. Damaged tilt valve plunger O-ring. Replace O-ring

Mast is unstable
Replace tilt relief valve
when tilting Malfunctioning of tilt relief valve
assembly
forward.
Valve body and spool valve lever is Replace spool valve with
The carriage is worn and their clearance is too great. specified clearance.
downward when Spool valve lever is not in centre. Keep being in the centre
the control lever
is in the neutral Cylinder seal abated. Examine and repair cylinder
position. Overload valve is worn or blocked by
Replace or clean taper valve
dirt.

Damaged or distorted reset spring. Replace spring.

Dirt exists between valve body and
Spool valve is Clean.
valve lever.
unable to return
neutral position. Blocked control device. Adjust

Not coaxial parts at reposition Reinstall, be coaxial

Damaged O-ring. Replace.

Faulty seal of joint. Check and retighten.

Leakage
Clean seal plate and retighten
Loose seal plate.
blots.
Loosed lock-nut of relief valve and
Tighten.
connect bolt between plate and plate.
Control valve
can’t move Control valve adjusting handle
Adjust
forward or interference
backward

28
 3. 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. Spring 4. Orientation nut

Fig. 7-5 Governed speed valve

4. Lifting cylinder
Lifting cylinder is single-acting piston structure, composed of piston rod, cylinder body and
piston. Be cautious when use: 1) protect piston rob from being damaged and keep the
good sealability of seal ring; 2) During normal use, if there floats leaking oil on the piston
rod surface, you should check whether there is brushing phenomenon, and replace O-ring
and replace.

1. Cylinder block 2. Piston 3. Seal ring 4. Catch 5. Support ring

6. Snap ring 7. Spacer bush 8. Piston rod 9. Oil return pipe 10. Bearing block
11.Steel-back bearing 12. O-ring 13.Cylinder cover 14. Seal fig 15.Dust ring
16. Screw 17.Sleeve 18.Lining 19. Snap ring
Fig 7-6 Lifting cylinder

29
 5. Tilting cylinder
Tilting cylinder is double-acting piston structure. When forward and backward tilting angle
do not meet the requirement or the action of two cylinders piston are out of step, you can
adjust the nut on the piston to meet the requirement, then screw down the nut. Notice and
the lifting cylinder are the same.

1. Head of rod 2. This nut 3. Steel snap ring 4. Dust ring 5. Cylinder cover
6. Snap ring 7. Seal ring 8. Screw 9. Nylon shim 10. O-ring
11. Guild sleeve 12. Steel-backed bearing 13. Cylinder body 14. Piston rod
15. Piston 16. Seal ring 17. Snap ring 18. O-ring 19. Support ring
20. Slotted nut 21. Pin 22. Stem
Fig 7-7 Tilting cylinder

30
6. Hydraulic system schematic diagram

1 2 T P 3 4

Fig 7-8 Schematic diagram of Controlling hydraulic oil way

31
VIII. Electrical system
Warn:
Before starting to check any fault of electrical system, take off jewelry ornaments to guard
against a short circuit, and disconnect the start switch and dismantle positive cable of
storage battery.
The different colorful wire is chosen for the different part of the electrical system. You
should recognize them before repair.
Power wire (+)R: Red Earth wire(-)B: Black

Explanation
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：
Cable color showed by 1 or 2 letters
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 block assembly

Fuse
Dismantle

32
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.
Explanation:
If the fuse is blown, replace with new one.
1. If a fuse is blown, please be sure to eliminate cause of problem, then replace it.
2. Use fuse with rated power. Never use fuse higher than specified rating.
3. Check fuse socket. If you find the socket is too loosen, or with bad contact, adjust it in
time.
Bad contact of fuse will cause low down or heat of voltage, as well as abnormal of circuit.
Fuse identification
location capacity Application part location capacity Application part
F3 15A Ignition F7 10A Shift switch
F4 30A ECU F9 10A Shift solenoid valve

F5 15A Diagnose port F10 10A Automatic shift

F6 25A Urea pump F12 10A Multitandem valve
F8 10A Perception system F14 10A Revr view system ACC+
F11 10A instrument F15 5A Lamp
F13 10A Revr view system B+ F16 10A Horn
F23 15A Compressor F17 10A Worklamp
F24 20A Condensate fan F18 10A Steering lamp
F26 5A Trouble lamp F19 10A Front wiper
F28 10A USB F20 10A Rear wiper
F31 30A Tip-over pimp F21 10A Top wiper
F22 20A Air conditioner F29 10A DC-DC
F25 10A Electronic pump F30 10A Megaphone
F27 10A Radio

33
 Combination switch:
Disassemble
1. Remove the combination instrument and steering wheel, open engine cover.
2. Wrest the screws, and disconnect the wiring connector
3. To install reverse the order of removal.
Inspection
Check with mulitmeter (switch to ohm gear) to see whether position below the steering
lamp and the lighting combination switch is connected.

Forward

Neutral

Backward

Fig 8-1 Shift gear handle

terminal 1 2 3 4 5 6 7 8
Location Wire Purple Yellow Blue Red Tan Gree Grey Black
color yellow green yellow n yellow
neutral ●
Forward ● ●
Backward ● ●
3 shift ● ● ●
2 shift ● ● ●
1 shift ● ● ●
Notice: “●”means on.

Turn left

Middle

Turn right

Fig 8-2 Light combination switch handle

34
Work light: headlight, front combination light, front work light, rear work
light/reverse light, combination rear light.
Removal and install
1. Remove securing nuts of the working 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 to ring with appropriate voltage(supply by
battery) or disconnect, then uses multimeter (Ω)to check whether contact loop is on or not.

Remove and Install

Key (start) switch
Remove the combinational instrument
1. Dismantle steering wheel and combination meter, open engine cover;
2. Disconnect the wiring connector.
3. Remove the ring nut, washer, spacer, meter panel.
4. To install, reverse the order of removal.
When installing, aim the bulge part of spacer
Switch on-off position（F05） to the hole on the meter plate

1 2 3
Junction
OFF O
ON O O
ST O O O 1. Ring nut
2. Washer
3. Spacer
4. Meter plate

Inspect
Check the continuity between terminals with multimeter.

B ACC C R1 R2 BR
Pre-heating ● ● ●
Operation ●
Star-up ● ● ●
Star-up ● ● ● ● ●
Note: “●”means on.

35
Backup buzzer
Removal and install
1. Disconnect the wiring connector, and then remove the bolt.
2. To install, reverse the order of removal

Horn
Horn fixed
Removal and install bolt
1. Remove the wiring connector of the horn
2. Remove the bolt and horn.
3. To install, reverse the order of removal.

36
Repair of starter and 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
damage 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 damage Change damage
Charge indicator shine

Magnetic field connection damage change

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

Surge magnet circuit damage change

Diode damage 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 damage
Change current too Change
Current output circuit fastener
big Repair
loose
Battery liquid
Battery damage Change or add liquid
surface descend
Adjuster damage Change
others

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

37
CPCD160-XRXG90B electrical schematic diagram（Ⅰ）

38
CPCD160-XRXG90B electrical schematic diagram（Ⅱ）

39
CPCD160-XRXG90B electrical schematic diagram（Ⅲ）

40
CPCD120/140/160-XRXG57B、CPCD160-XRMG57B electrical schematic diagram（1）

41
R2 5.1K R

新风电机

CPCD120/140/160-XRXG57B、CPCD160-XRMG57B electrical schematic diagram（2）

42
CPCD120/140/160-XRW25B、CPCD160-XRMW25B electrical schematic diagram（1）

43
CPCD120/140/160-XRW25B、CPCD160-XRMW25B electrical schematic diagram（2）

44
 R2 5 .1K
R

R1 5.1K
R

R1 5.1K
R

新风电机

CPCD120/140/160-XRW25B、CPCD160-XRMW25B electrical schematic diagram（3）

45
CPCD120/140/160-XRXH13B、CPCD160-XRMH13B electrical schematic diagram（1）

46
CPCD120/140/160-XRXH13B、CPCD160-XRMH13B electrical schematic diagram（2）

47
CPCD120/140/160-XRXH13B、CPCD160-XRMH13B electrical schematic diagram（3）

48
 R2 5.1K
R

R1 5.1K
R

R1 5.1K
R

CPCD120/140/160-XRXH13B、CPCD160-XRMH13B electrical schematic diagram（4）

49
 IX. Lifting system
1. Assemble debugging data

Debugging data Duplex 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 carriage roller Adopt longitudinal roller and side roller.

Inspection and adjustment

Assembly clearance Repair clearance（mm）(Without

Place
（mm） replacing spare part)

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 fork carriage side 0.3～1.25 0.4～1.4

Lift chain deflection 25～30 mm

Tightening torque

Model or
Place N·M
Lifting capacity

Lift chain lock nut 4000-4300 (M45×3)

Tile cylinder lock nut 58～78（M12）

Large 16t
Lift cylinder bolt 638-850（M24）

Lift cylinder fixing bolt

189～252（M16）
（U type）

50
 2. Failure diagnose and corrections
Condition Probable cause Corrective action
Fork carriage Tilt cylinder and ring abraded excessively Replace piston ring tilt cylinder.
or mast tilt by The hydraulic control valve spring is
Replace it.
itself. inoperative.
The fork arms
Caused by piston jamming or piston rod bent. Replace the faulty parts.
carrier moves
up and down
Too much dirt is accumulated in the cylinder. Strip it down and clean.
sluggishly.
Adjust clearance with thrust metal
Carriage bracket assembly out of adjustment.
and carriage side roller.
Forks are Insufficient clearance between rollers and mast
Adjust roller clearance
lifted or channel.
lowered Biting foreign materials between moving part. Remove foreign materials.
unsmooth. Apply grease on contact surfaces of
Insufficient lubrication.
sliding parts.（butter）
Inner mast deflection or fork carriage bent Repair or replace.
Forks are
Lift chains out of adjustable. Adjust lift chains.
lifted unevenly
Grease stiffened or dirt accumulated on lift
Lift roller does Clean and lubricate lift rollers.
roller and mast sliding surfaces.
not rotate
Improperly adjusted lift roller. Adjust.
Insufficient lubrication. Lubricate.
Excessive
Improperly adjusted lift roller, after extending Adjust roller, side roller adjusting
mast noise
mast, descend to bump with mast channel shim
Excessive wear occurs between the oil pump Replace the worn parts or the oil
body and gears, causing too much clearance. pump.
The lifting jack piston seal ring has worn, resulting
Replace Yx-ring.
in excessive inner leaks.
Springs of the multiple control valves and its
Replace new spring.
relief valve are inoperative.
Excessive wear occurs of the hydraulic control
Replace.
valve, resulting in excessive oil leaks.
Insufficient lift Oil leaks occur between the hydraulic control Dismantle for regrinding the joint
power or no valve sections. surfaces and reassemble the valve.
lift movement. Tighten the joint nuts and inspect the
Leakage occurs in the hydraulic pipe.
seal for damage.
Change the wrong hydraulic oil or
stop operation for reducing the oil
The hydraulic oil temperature is too high. Oil
temperature. Find out the reasons
viscosity is too low and the rate is insufficient.
for high oil temperature and
eliminate the trouble.
The load carried is beyond the designed
Lift according to requirement.
capacity.
Forks does Screw rod rust or have foreign materials Clean and lubricate
not adjust Fork’s shaft rust seriously Clean and lubricate
setting-up Fork is turn back by foreign materials Clean

51
 3.General

3.1 Duplex wide view mast

Duplex mast is composed of outer mast which can’t lift and inner mast which can lift.
Bottom of lifting cylinder is fixed down the cross beam of outer mast, oriented with pin.
Piston rod end is joined with upper cross beam of inner mast; cylinder body is fixed on
outer mast fixation board with bolt, and the chain wheel frame on the piston end and
connect with leader to realize free lifting. Rollers are laid out at the back of outer mast to
realize high visibility.
Fork arm is hung on fork carriage, where installs the tilting cylinder to realize tilting forward
and backward, which equips with roller and side roller. The bottom of inner mast also
equips with roller and side roller.
Pressure oil from control valve, entering into lifting cylinder through governor valve, force
piston and piston rod to rise, thereby force inner mast to rise. At the same time one end of
lifting chain on inner mast is fixed on outer mast, the other is joined with fork carriage. Fork
carriage and fork are rising with inner mast rising to realize goods lifting.

1-Outer mast 2-Inner mast 3-Fork rack 4-Tilting cylinder 5-Left lifting cylinder
6-Right lifting cylinder 7-;Lifting oil pipe 8-Chain

Fig.9-1

52
3.2 Duplex full free lift mast
Duplex full free lift mast) is also composed of inner mast, outer mast, fork arm carrier, and
etc, is also belong to high visibility mast. It is different from common standard type mast
that two postpose long lifting cylinders are both pole stopper type cylinder. One piston rod
is hollow; hole of piston rod is bypassed for hydraulic pressure oil flowing into free lifting
jack. End of piston rod in two long lifting jacks is joined with upper branch of inner mast.
Besides, short lifting cylinder which is installed middle of inner mast is named as free
lifting cylinder. Free lifting cylinder is also pole stopper type cylinder.
As inner mast do not rise when free lifting cylinder rising or falling, and forks can rise in
free lifting range.
Free lifting cylinder equips with chain. Two chains with the same length are in both left and
right forklifts.

1-Outer mast 2-Inner mast 3-Long lifting cylinder 4-Free lifting cylinder 5-Chain
6-Tilting cylinder 7-Load-backrest 8-Forks

Fig.9-2 Duplex full free lift mast

53
3.3 Triple full free lift mast
Triple full free lift mast is composed of outer mast, middle mast and inner mast, middle
mast and inner mast can flex. There are different specifications in this series of height,
4m,4.3m, 4.5m, 4.8m, 5m, 5.5m, 6m,6.5m,7m ,etc. It is different from duplex full free mast
that mostly it includes middle mast, and its two postpone long lifting cylinders are both
piston type cylinder, and its oil system rather complex than oil system of double full free
mast. Its middle is also free lifting cylinder and the structure is similar to the duplex full free
lifting mast.

1-Outer mast 2-Middle mast 3-Inner mast 4-Long lifting cylinder 5-Free lifting cylinder
6-Chain 7- Chain 8- Tilting cylinder 9-Load-backrest 10-Fork
Fig. 9-3 Triple full free lift mast

54
4. Mast dismantle and
install adjustment

△
! Warning
Be careful when removing and installing the
forks, carriage and mast as they are heavy.
Fig.9-5
4.1 Dismantle forks and mast assembly （5）Support mast assembly with wire
Fork ropes.
（ 1 ） Dismantle adjusting cylinder and
connecting tube;.
（2）Dismantle fork shaft stop, pull out fork
shaft and dismantle forks.

△
! Warning

a. Be careful! Hands and feet should not

approach between forks and fork carriage
or the bottom of forks. Fig.9-6
b. Do not dismantle goods from top forks！ （6）Pull out tilt cylinder pivot pin.
To avoid crush from fork falling.
（7）Remove mast support caps.
Fork carriage
（1）Attach wire ropes to carriage bracket
assembly and lift carriage bracket
assembly up with a lifting device.
（ 2 ） Remove chain attaching nuts, and
detach chains from carriage bracket
assembly.

Fig.9-7
（8）Remove mast assembly.
To install mast assembly, reverse order of
removal.
4.2 Disassembly

△
! Warning
Fig.9-4
Be careful when disassembling the masts
（3 ）Remove carriage bracket assembly
as they are heavy.
from inner mast.
Remove lifting Cylinder
（4）Detach high pressure hose, lift hose
（1）Place mast flat on ground. Remove
and low pressure hose.
lifting cylinder attaching bolts, and U-type
screw tighten screw if it is high lifted mast.

55
（2）Slide inner mast, then remove lifting
cylinders.
Remove roller
（1）Slide inner mast out until rollers are
exposed and remove little rollers and main
roller.
（2） Unclench rollers carefully if no bearing
puller or rollers would be smashed.(Up Fig.9-10
and down, left and right, knock Lift roller-to-mast clearance adjustment
symmetrically.) （ 1 ） Adjustable left and right “A” with
shims, adjust to 0.5mm～1.2mm.
（2）It is suitable that clearance of roller
and outer mast is about 0.8mm -1mm.
Clearance can’t adjustable. Replace it if
roller wears too much.
（3）Apply lubrication (butter) to interface
of inner mast and outer mast, interface of
roller and mast. To prevent sand from
Fig.9-8 entering, it is decided whether to apply
Remove inner mast lubrication or not in the area where sand
Attach wire rope to middle of inner mast blown by wind heavily.
and slide it out with a lifting device. Clearance of back up metal and mast
steel
Adjust clearance “B” to 0.2mm ～ 1mm
with shims, which may not use. Thickness
of shim is 0.2mm.

Fig.9-9
Inspection
（ 1 ） Check lift rollers, roller shafts, and
associated parts for wear or damage. Fig.9-11
（2）Replace damaged parts as required. Apply a coat of grease to back-up metals.
4.3 Assembly and adjustment Install mast and lifting cylinder on forklift

△
truck. Connect circle tube and
! Warning high-pressure tube.
Be careful when assembling the masts as
they are heavy.
Lift roller
Slide inner mast into outer mast and
securely attach lift rollers.

56
4.4 Left and right cylinder height below when the middle portion of chain is
adjustment. pressed by a finger.
（1）Install left and right lifting cylinder on Dimension C: 25 mm ~30 mm
mast, pin must be installed into orientation
hole of outer mast lower cross beam.
（ 2 ） Install upper of piston rod on inner
mast. Inner mast lay evenly in the direction
of left, right, upper and lower. If it is not
even, please adjust by putting washer
between hole of cylinder support and
upper end of piston rod.
（ 3 ） Installs U-bolt onto cylinder,
hand-tighten nuts and lock it with two
tighten nuts. Screws down tighten bolt and
nuts to avoiding loosing.

Fig. 9-14
4.6 Clearance of fork carriage and
rollers adjustment
There equips with 4 main rollers and 4
side rollers in the truck, you can adjust
the inner side roller adjusting shim to
control clearance between two sides side
Fig.9-12 roller and portal frame post.
4.5 Lifting chain adjustment （1）Measure inside width “A” between
Installs fork arm carrier on inner mast, and inner mast two U-bar guide rails. Make
install lifting chain, then install two nuts on measurements at the top, bottom and
end of every side. With mast set straight center (cross beam) sections, meanwhile
up, lower carriage completely. Temporarily measure inside width “Aˊ” between inner
adjust clearance of carriage： flange of inner mast two U-bar.
（2）Measure upside outer side roller on
fork carriage B, left and right distance Bˊof
bottom side roller.
（ 3 ） Calculate A-B,A-Bˊand A- B". Each
result shows clearances between each
roller and inner mast. Adjust shims of each
left and right roller evenly and make
clearances between smallest part of inner
Fig. 9-13 mast U-bar and carriage side roller.
To adjust tension of lift chain, lower lifting A-B = 0.2mm～1mm
cylinder until fork is on the ground, and Aˊ-Bˊ= 0.2mm～1mm
adjust chain adjusting nut (three every
side) so that dimension C will be as listed

57
 Fig. 9-15
Adjusting shim
0.5mm 1mm
a. Number of shims must be the same on
the right and left sides, when using shims.
b. After clearance adjustment, push
carriage assembly to see if it operates
properly.

58
5.Disassembly and
installation of lifting
cylinder

△
! Warning
Fig. 9-17

Keep body away from equipment

（ 1 ） Turn down the engine, then make

lifting cylinder falling into lowest condition
that lower of piton rod is touched bottom of
cylinder body so as to return oil flowing
back tank completely.
（ 2 ） Disconnect lifting cylinder oil return
pipe, dismantle bottom end governor valve Fig.9-18
oil inlet high pressure hose and two Caution：
cylinder connected high pressure hose. Please not use dust gasket ring removed,
（3）Remove U-bolt of outer mast fixation O-ring, Y-ring again, must replace.
board and tighten skew of other side. （3）Draw out piston rod , remove sealing
（4）Unscrew mounting screw on left and ring on end of piston.
right cylinder piston rods and mast 5.2 Assemble and replace quick-wear
cylinder. part
（5）Remove chain of outer mast and the （ 1 ） Cleanup parts with clean oil before
bottom cylinder bolt. installation.
（6 ）Attach wire rope to inner mast and （ 2 ） Then cleanup guiding bush and
remove left and right lifting cylinder with a piston with hydraulic pressure oil the same
lifting device. as oil box trademark.
（ 3 ） Dust or dunghill doesn’t drop into
lifting jack.
（4）The order of installation is reverse the
order of disassembly.
（5）Install sealing ring on piston.
（6）Install piston rod assembly into clean
cylinder body.(including piston rod, piston,
supporting ring and seal ring)
Caution：
Fig. 9-16 If there is burr in the cylinder barrel, you
5.1 Disassembly must clean smooth, place into the middle
Removes tighten screw and nylon stopper, carefully, to avoid Y-seal ring scrape.
then remove cylinder head. （7）Install replacing dust gasket ring and
（1）Remove dust gasket ring. sealing ring in guiding bush and cylinder
（ 2 ） Remove sealing ring with head.
screwdriver. Notice：Apply hydraulic pressure grease

59
which trademark is the same as tank on
guide sleeve installed gasket ring
6.Disassembly and
（8）Rip cylinder head into piston rod,
screw down cylinder body.
installation of tilting
cylinder

△
! Warning
·Attach wire rope to outer mast, avoiding
mast fall down after removing tilting
cylinder.
·Keep body away from equipment, no
standing under the fork arm carrier.

6.1Disassembly
（ 1 ） Lay down the fork carriage
completely.
（2）Dismantle oil pipe at the entrance of
tilting cylinder.
（ 3 ） Remove bolt on the left and right
bracket of outer mast, moreover pull axis
out.
（ 4 ） Remove bolt on the bracket of
chassis, and pull pin out, then move tilting
cylinder.
The order of installation is reverse the
order of disassembly.

Fig. 9-19

6.2 Disassembly spare parts

（ 1 ） Squeeze tilting cylinder with pliers,
then pull piston rod come-and-go as
opening of inlet and outlet on the tilting
cylinder, so remaining oil is discharged

60
tilting cylinder. Notice：
（2）Screw earring 21. No using dust gasket ring and sealing ring
（ 3 ） Removes tighten screw and nylon removed.
stopper.
（4）Remove cylinder head 14 and guiding 6.3 Assemble after real ring changing
bush 12. Assemble order is opposite to dismantle
（5）Draw out piston rod assembly 25（see order, but you need to pay attention to the
Fig8-21 ）. following item：
（6）Remove all dust gasket rings, O-ring （1）Lubricate each spare parts with clean
and sealing ring. hydraulic oil.
（ 2 ） Prevent dust and oil dirt fall into
cylinder.
（ 3 ） Prevent burr in the cylinder barrel
mouth and entrance.
（4 ）Centering carefully, push the piston
rod to cylinder barrel, especially avoid
scraping the seal ring.
（ 5 ） Before placing guild sleeve, apply
hydraulic oil the same brand to work oil
Fig. 9-20 between O-ring and seal ring.
（ 7 ） Remove dust gasket ring in the （6）Do not scrape O-ring of the outer ring.
cylinder head. Means is the same as （7）Remember install nylon stopper and
discharging of dust gasket ring in the tighten screw after screw cylinder head.
cylinder head of lifting cylinder (see
disassembly and installation of lifting
cylinder).
（8）Remove O-ring outside in the guiding
bush..

Fig. 9-21
（9）Remove O-ring and sealing ring in
the inner hole of guiding bush (see Fig.
disassembly and installation of lifting
cylinder).

61
7.Noticing proceeding of
debugging
（1）Adjust Forward and Backward of the
Mast:
Place fork lift truck on the level ground,
operate control lever to realize that mast
inclined forward or backward extremely.
As assembly debugging data required,
adjust combined screw thread length till
according with data of Backward. Then
lock earring ring close.
（2）Adjust installation position of left and
right lifting jack again
Adjust washer in the middle of piston rod
and inner mast bracket if one lifting
cylinder is not synchronization with the
others when rising or falling, and if one
lifting cylinder is different height from the
others.
Loose two nuts on the U-bolt. Mast is not
rise and lower until relative position of
U-bolt and lifting jack is suitable. Then
screw down nuts and tightening screw on
the U-bolt. Thus lifting jack can be used
longer and wear of piston rod can be
reduced.

62