FOREWORD

2 to 3.5 ton counterbalanced forklift truck with clutch/torque

converter of on the base of advantages of some trucks made by
domestic and foreign manufacturers and developed in introduced
technology from abroad.
This manual states the trucks' specifications, operation,
maintenance. service, main assemblies' constructions and working
principles so as to help operators to use the trucks correctly and attain
the highest functions. It is necessary to read over the manual before
they operate the trucks or service personnel serve these trucks.
The rules and notices in the manual should be abided seriously
by all of relative personnel to enable these trucks in optimized working
state for long period and bring the highest efficiency.
This manual content might not correspond with the actual
condition because of the improving of our products. Our products are
subj ect to improvements and charges without notice.
NOTE: The "Model" in this MANUAL is different from the
"Model" on the name plate and the certificate of quality. The "Model"
in this MANUAL includes the configuration number on the name plate
and the cretificate of quality.

For example:
CPCD30 – W2Y

Configuration N

Model

Model CPCD20,25,30,35-W2Y are assembled with ISUZU

GK-4JG2NKFC01 engine
Model CPCD20,25,30,35-W1Y are assembled with ISUZU
4JG2PE engine
Model CPCD20,25,30,35-KUY are assembled with KUBOTA
V2403-CR-TE5B engine

1
 CONTENTS
...............................................................................................错误！未定义书签。
FOREWORD.......................................................................................................... 1
Ⅰ.Safety Rules for Operation and Daily Maintenance of Forklift Truck..............3
It is important that driver and manager for forklift trucks remember the principle
of the "first safety" and ensure the safety operation as the description in
《 OPERATIONAND SERVICE MANUAL》 ................................................. 3
1. Delivery of Forklift Truck.........................................................................3
2. Storage of Forklift Truck.......................................................................... 3
3. Precautions Before Operation...................................................................3
4. Operation of Forklift Truck.......................................................................4
5. Spare parts.................................................................................................5
II . Specifications of Forklift Trucks....................................................................6
III. Construction, Principle, Adjustment and Maintenance of Forklift Trucks...... 8
l.Power System..............................................................................................8
2.Electric System Description.....................................................................21
3. Clutch Unit................................................................................................ 30
4.Mechanical Drive Unit...............................................................................36
5.Hydrodynamic Drive Unlt......................................................................... 44
6. Drive Axle................................................................................................. 54
7. Steering System.........................................................................................57
8. Steering Axle.............................................................................................61
9. Brake SY stem...........................................................................................65
10.Hydraulic System.....................................................................................80
11.Load System...........................................................................................102
IV.EURO V higher emission limits stage........................................................... 109
1.Instrument(for certain truck models )...................................................... 109
2. DPF maintenance(regeneration type,for certain truck models)..............111

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Ⅰ .Safety Rules for Operation and Daily Maintenance of Forklift

Truck

It is important that driver and manager for forklift trucks

remember the principle of the "first safety" and ensure the safety

operation as the description in 《 OPERATIONAND SERVICE

MANUAL》 .

1. Delivery of Forklift Truck

It must be pay attention to the following items when you delive
forklift trucks with container or trucks.
(l) Apply the parking brake.
(2) Fix the mast and the balanceweight with steel wire.Wedge up
all wheels.
(3) Sling points should be always at the positions specified in
sling index plate when hoisting up the forklift truck.
2. Storage of Forklift Truck
(l) Drain off fuel completely. Don't drain off the cooling water
containing antifreezeand rustproof agent.
(2) Apply antirust to the surface of the parts not painted. Apply
lubrication oil to the lift chain.
(3) Lowing the mast to the lowest position.
(4) Apply the parking brake.
(5) Wedged up the wheels.
3. Precautions Before Operation
(l) Don't check fuel leakage and lever or instruments at the place
there is open flame.Never fill the fuel tank with the engine running.
(2) Check the tire inflation pressure.
(3) The forward-reverse lever should be in neutral.
(4) Never smoke while the fuel system is under working or the
battery is inspected.
(5) Check all the levers and pedals.
(6) Complete the provisions before starting.

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 (7) Release the parking lever.
(8) Make trying opteration of the mast for lifting, lowing and
Fwd/ Bwd tilting and the truck for steering and braking.
4. Operation of Forklift Truck
(l) Only trained and authorized operator shall be permitted to
operate the truck.
(2) Wear all the safety guards. such as shoes. helmet. clothing
and gloves while operating the truck.
(3) Check all the control and warning devices before starting the
truck. If any
damages or defects are found, operate it after repairing.
(4) Overload or overload operation is strictly prohibited. The
fork should insert completely under the cargo and make the cargo
placed on it evenly. Do not raise an object with one fork end.
(5) The starting, turning, driving, braking and stopping operation
of the truck should be done smoothly. When steering on the humid or
low friction road. the truck should be decelerated.
(6) Travel with loads as low as possible and tilted backward.
(7) Be careful when traveling on a slope. When climbing grades
with a slope of more than l0%. the truck should forward travel. and
when descending so grades, backward travel. Never turning on a slope.
Avoid loading and unloading operation when decending.
(8) Pay attention to pedestrian. obstacle and bumpy road when
driving. Pay attention to the clearance over forklift truck.
(9) Never allow any persons to stand on the forks or the truck to
carry persons.
(10) Never permit anyone to stand or walk under upraised forks.
(11) Don't operate truck and attachment of it at any position out
of the drive seat.
(12) On the high lift forklift truck. when the lift high more than
3m. it is noted that the goods on it should not fall down or the
protection measures must be taken if necessary.
(13) Tilt the mast of the high lift forklift truck as backward as
possible while the truck working. Use minimum forward tilt angle and
min. reverse tilt when loading and unloading.
(14) Be careful and slowly driving over a dockboard or
bridge-plate.
(15) Shut down the engine and don't stay on the truck when
filling fuel. Don't ignite the engine while checking battery or fuel
lever.
(16) The unloaded forklift truck with attachments should be
operated as a loaded truck.

4
 (17) Don't handle unfixed stacked goods.Be careful to bulky
goods to be handled.
(18) If leaving the truck. lower the forks on the ground and let
the shift lever to neutral. shut down the engine or cut down electric
supply. If parking on a slope is
unavoidable, apply the parking brake and block the wheels.
(19) Don't open the radiator cap when the engine is warm.
(20) Don't adjust the control valve and relief valve at will to
prevent the damage of hydraulic system and its components because of
excessive pressure passing them.
(21) The test for the maximum radiation noise outside the body
of the forklift shall be carried out according to the noise standard of
EN 12053:2001. The noise label that indicates the noise value of the
truck shall be added on the truck. The vibration test of the forklift shall
be carried out according to the vibration standard of EN 13059:2002.
The vibration value of the whole body of the forklift is less than 0.5
m/s2.
(22) Notice and be familiar with all kinds ofdecal's function.
(23) The inflation pressure of tire should be based on the air
pressure value specified on the label of "Tire pressure". The
insufficient pressure of tire, rough or uneven work road and
deformation of tire will result in the increase of noise valve of the
whole truck.
(24) The standard configuration of the forklift is of open-type
overhead guard
structure. with the drive cab as option. The forklift equipped with drive
cab has left and right side doors.
5. Spare parts
Heli pure components and parts are requested to be used in
addition to the spare parts of original engine manufacturer.

5
II . Specifications of Forklift Trucks

External View of Forklift Trucks

Main Specifications
CPCD20

CPCD25

CPCD30

CPCD35

Item Unit

Rated Load kg 2000 2500 3000 3500

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Load Center mm 500

Max.Lift Height mm 3000

Free Lift Height mm 160

Mast Tilt Angle ° 10/12

Wheelbase mm 1900

Front mm 1160
Tread
Rear mm 1100

Weight(with oil and water) kg 4500 4700 4950 5150

Overall Width mm 1550

Overall Height mast mm 2325

Overall Length mm 4200

Min.Underclearance mm 270

Min.Turning Radius mm 3265

Max.Traveling Speed Fwd/Bwd km/s 20/20

Lift Speed Laden/Unladen mm/s 470/450

Max
Laden kN 15
Drawbar Pull
Laden % 20 18 16 14
Gradeability
Unladen % 20

Front 15-19.5TL 15-19.5TL

Tyre
Rear 10-16.5-8PR 10-16.5-8PR

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III. Construction, Principle, Adjustment and

Maintenance of Forklift Trucks

l.Power System
1.1. General Description
This K series forklift trucks consist of diesel type. The engine
is connected with the drive unit and the brake of the engine is
connected with the frame by rubber cushion to avoid vibration.

Specification Unit CPCD20/25/30/35-W1Y

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Specification Unit CPCD20/25/30/35-W2Y
Model ISUZU GK-4JG2NKFC01
Type 4-cylinder,water-cooled,
Total Displacement L 31.5
Rated Speed rpm 2450
Rated Output kw 36.5
Max.Torque/Speed Nm 170/1700

Specification Unit CPCD20/25/30/35-KUY

Model KUBOTA V2403-CR-TE5B
Type 4-cylinder,water-cooled,
Total Displacement L 2.43
Rated Speed rpm 2400

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Rated Output kw 42.6
Max.Torque/Speed Nm 195.6/1500

1.3 Inspection and Adjustment of Engine

1.3.1 Adir Cleaner
(I)Remove element.
(2)Check the element. If it is dirty, it should be blown with low
pressure from inner to
outer; if it is damaged, it should be replaced with a new one.
(3)Clean up the cap of dust-collector.
(4)The time to replace is to see the table of l.2.
1.3.2 0il Filter
▲Gasoline Engine
(I)Remove the oil filter with the special spanner and replace it
with a new one.
(2)Apply several drops of engine oil to the around of the new
filter's seal before installation and it should be screwed 2/3 circles
again when the filter's seal touches the body of engine.
▲Diesel Engine
(I)Remove the oil filter with the special spanner and replace it
with a new one.
(2)Apply several drops of engine oil to the around of the new
filter's seal before installation and it should be screwed 2/3 circles
again when the filter's seal touches the body of engine.
(3)The time to replace is to see the table of l.2
1.3.3 Cautions on Cooling System
Cooling system which is filled with HELI exclusive coolant free
from maintenance normally before leaving the factory is used to cool
engine and hydraulic powered transmission unit (hydraulic powered
type forklift truck). The coolant filled in the truck can not only protect
against freezing above -35 0C. but also protect the cooling system
from corrosion. scale-forming and increase the coolant boiling point
remarkable. So the coolant concentration will not be reduced even in
the warm season or area because of water replenishing. If greater
anti-freezing protection is need considering climate, please contact
with local HELI sales network for HELI exclusive coolant with greater
anti-freezing ability.
(l)lf the radiator appears "boiling" or excessive coolant
temperature, it is prohibited
strictly to open the radiator cover immediately. Do as the following:
(a) Park the truck at a safe area;
(b) Keep the engine idling and open the engine hood to keep

10
good ventilation;
(c) Shut off the engine when the water temperature indicator
points to the normal range;
(d) Check the following points when the engine is cool
completely:
● Check if the coolant lever is correct;
● Check if the fan belt is loose;
● Check the engine oil quality and oil level;
● Check if the radiator is clogged;
● Check if the thermostat can open normally;
(2)Use HELI exclusive coolant in order to keep the engine and
cooling system in good condition. Change it once a year. If the coolant
is bad in less than one year, change it when necessary. When changing
the coolant. clean the interior of the cooling system. The freezing point
of the coolant should be 10 0C lower than the lowest environment
temperature. Cautions on replacing the coolant:
(a) Wait 30 minutes after shutting off the engine.
(b) Remove the cap and loosen the draining switch of the radiator.
(c) Loosen the draining switch of the engine and drain all the
coolant
(d) Tighten the above two draining switches
(e) The speed of the adding is lower than 21/min
(f) Let the engine running in idle speed for a while
after topping up and assure the water level of tank stays
its correct position
(3)Check the cooling water level of the tank. if the
water level is lower than the mark "Iow". it should be
added the correct coolant according to the following
demand to the correct level. The water level should be
higher than the mark "high" when the engine is warm,
and the level should stay the position of 2/3 0f whole
height when the engine is cold
(a) Replenish the coolant with HELI exclusive one
only when the engine is cool when necessary avoiding
engine damage.
Fig.l-I Tank
(b) If there is no HELI exclusive coolant in an
emergency, never add any additives. Add water only and contact with
local HELI sales network for proper mixture as possible.
(c) Use new HELI exclusive coolant when replenishing. It is
prohibited to add hard water such as tap water, mineral water, river
water. well water to the cooling system avoiding radiator corrosion or

11
scale forming which will reduce radiator performance and
service life.
(4)Adjust the fan belt tension
(a) Loosen the fixing bolts of the generator
(b) Adjust the fan belt tension by moving the generator. Press the
fan belt by applying 10kg pressure with fingers, the specified belt
flexibility is about 10mm
(5)lt is prohibited to contact the radiator core directly with
sharp hard obj ects such as if the core is dirty. Clean it with water flow
or air flow with the following set pressure value. Keep the mouth
against the radiator core
Water flow pressure: no higher than 0.49MPa (5kgf/cm2);
Air flow pressure: no higher than 0.98MPa (lOkgf/cm2)
(6)Coolant storage notes
(a) Avoid direct contact with the coolant which is bad for
health;
(b) Store the coolant in proper sealed container because the
coolant steam is harmful
Make sure to keep it out of the reach of children because there is a
danger ofpoisoning;
(c)Once the coolant goes to eyes, please wash with water and
see a doctor;
(d) See a doctor immediately once the coolant is drank
carelessly;
(e) Never use the coolant drained from the truck again. Place
the coolant drained from the truck in a special container and deal with
environmental rules
1.3.4 Bleeding
▲Diesel Engine
(I)Fill the inj ection pump chamber with diesel fuel by moving
the hand pump up and down.
(2)Press 5-10 times again when the feeling ofpressing is heavy
1.3.5 Engine's Speed Adjustment
(l)ldle Speed
(a)Warm up the engine until the engine coolant temperature
reaches 85 0C
(b)lnstall a tachometer on the engine and use carburetor throttle
adjusting screw to set the engine speed t0 700rpm
(c)Turn the adjusting screw to minmum clearance of throttle
valve in the direction of engine speed increasing
(d)Set the engine steady speed t0 700rpm again with the
throttle adjusting screw

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 (2)Adjustment of Maximum Speed (for gasoline engine)
The maximum speed of engine is adjusted through regulator.lf
the change of speed is over fast. it will cause cylinder knocking

Fig.l-2 Regulator
▲Adjustment of No-Ioad Maximum Speed
Make the no-load maximum speed reaches the specified speed
by removing the rubber cap and rotating the adjusting part. The speed
is creasing while according to the direct. and it is reducing while in
another direction
▲ Adjustment of Full-Ioad Maximum Speed(overflow valve
works)
(a)Adjust the full-load maximum speed by turning the
adjusting bolts, this method can also adjust no-load maximum speed at
the same time.(The adjusting bolts of no-load maximum speed are in
the inner of the adjusting part. The adjusting direction of no-load speed
is same as the full-load)
(b)lf full-load speed can't reach the specified speed value. it
can be adjusted with cam. But adjust cam need good skill. and this
method may cause cylinder knocking
▲lnspection and Adjustment of Cylinder Knocking
Cylinder knocking happens when the the cylinder knocking
while adjusting the speed of engine is not steady.Pay attention too-load
or full-load speed.
Ispection
▲ After shutting off the hydraulic system and placing the
transmission in neutral position, we inspect the cylinder knocking by
pressing the accelerate pedal slowly while the engine is in idle speed

13
state.
Adjustment
Adjust the engine in the following manner if the cylinder
knocking occurs more than three times
● Turn the adjusting bolt in direct direction and adjust the
no-load maximum speed at the same time
●We should adjust the screw of cam unit if the above method
can not solve the problem.

Problem Analyses Trouble Remedies

Engine speed can't be enhanced Soft shaft of cam is broken Replace the soft
when there is no-load Spring is damaged or broken
Travel speed can't be enhanced Adjustment of cam spring is Adjust
not correct
Cylinder knocking(no Balanceable piston is blocked Clean or replace
cylinder the regulator
knocking occurs while lifting) assembly
Travel speed can't be enhanced Adjustment of cam spring is Adjust
not correct
Lift speed is slowly Spring is damaged Replace the soft
Lift speed is slowly while shaft assembly
travel Adjustment of cam spring is Adjust
speed is normal not correct
Travel speed enhances over Adjustment of cam spring is Adjust
fast not correct
Balanceable piston is blocked
Clean or replace
the regulator
Valve shaft of regulator is assembly
blocked Reassembly
Cylinder knocking occurs more Adjustment of cam spring is Adjust
than three times not correct
Balanceable valve is blocked Clean or replace
the regulator
Valve shaft of regulator is assembly
blocked Reassembly

The adjustments of engine other parts refer to the each

operation and service manual
1.4 Fuel System
The fuel system is composed a tank. fuel filter. fuel sensor

14
and fuel meter.

Fig.l-3 Fuel System (Gasoline Engine)

15
 Fig.l-4 Fuel System (Diesel Engine)
1.4.1 Fuel Tank
The fuel tank is a welded construction integrated with the truck
frame. It is located on the left side of the truck frame. The tank cover
with a fuel sensor is located on the top surface of the tank. The fuel
tank design is almost the same for the gasoline and diesel engine type
trucks. The difference is that the gasoline type is fitted with a inlet pipe
and the diesel type with a return pipe.
1.4.2 Fuel Sensor
The fuel sensor is designed to convert the remaining amount of
fuel into electric current. See Fig.l-5

16
 Fig.l-5
The theostat made of alloy steel wire is linked with a float. As
the float moves up and down. the electric current is changed by the
resistance's changes.
The K type fuel meter is double sheets metal construction. the
range of the meter finger is determined by the current scale which get
across the heat element of the double sheets metal. The current value is
the biggest when the float is in the highest position,(The resistance
value is about 9.5 to ll at this time), and the fuel meter's finger refers to
the "F" which means the fuel level is full. On the other hand. the "E"
means the fuel level is empty.
The K type fuel meter is solid column display construction. the
column moves to the right hand shows that the fuel level is full, and
the column moves to the left hand shows that the fuel level is empty.
When the fuel level reduces to the limit. the alarm will be given to the
operator.

17
 Fig.l-6 Fuel Sensor
1.4.3 Maintenance of the Fuel System
Once every 100 hours operation, it is required to maintain the
fuel system according to the methods as follows. Once every 600
hours operation, it is required to clean the fuel tank
(I)Fuel Filter
The fuel filter is used to clean the fuel applying to the engine. It is
installed in the fuel pump(for gasoline engine) or on the fuel tank (for
diesel engine). The fuel filter used in diesel engine can also separate
water from fuel

18
 Fig.l-7 Fuel Filter
▲Gasoline Engine
(a)Loosen the circle wheel and remove the cap.
(b)Loosen the nut and take the filter element out.
(c)Clean or replace the filter element.
(d)After reassembly of filter. start the engine to feed gasoline
into filter bowl and check for leaks.
▲Diesel Engine
(a)Once every 600 hours operation, it is required to replace the
filter assembly.
(b)Apply several drops of fuel to the around of the new filter's
seal before installation. it should be screwed 2/3 circles again when the
filter's seal touches the body of engine.
(c)When the warning lamp is on. drain all the water by loosing
the draining switch.
Note: Turn off the draining switch after draining water.
(2)The Cleaning of Fuel Tank
Once every 600 hours operation the fuel tank should be cleaned.
As for the gasoline
truck. it is required to take care of fire when cleaning.
1.5 Accelerator Pedal
The accelerator pedal is used to control the engine speed, and it
is connected with engine through the linkage and soft shaft. See Fig.l-8

19
 Engine Model Height
C240 49
4JG2 51

Fig.l-8 Accelerator Pedal

20
 2.Electric System Description
2.1 General
The electric system for this forklift truck is of the single-pole
type, in which the frame of the truck provides the return path for the
electricity. The electric system seems like the nerve system of the truck
and it mainly consists of the following systems.
(I)Charging System
This system contains generator. battery, charging indicator. etc.
It supplies current for all the electric appliances.
Voltage:12V
(2)Starting System
This system mainly consists of automatic pre-heating unit (only
diesel engine), key switch. starting protection circuit. starting motor.
etc. The function of this system is starting the engine.
(3)Electro-hydraulic Gearshift System
①Electric diagrammatic layout

②Main parts
electro-hydraulically operated valve
direction switch
control box

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 ③Summary
The electro-hydraulically operated valve develops from the
mechano-hydraulically operated valve.
(a)The same points as mechano-hydraulically operated valve
. same functions
. same dimensions mounting to the transmisson
. oil ports with same directions and same dimensions. The ports
include suction oil port, inching valve oil ports, torque converter oil
ports, forward gearshift oil ports. reversegearshift oil ports.
(b)hydraul
The difference between electro-hydraulically operated valve and
mechano-ically operated valve
The way to control the moving direction of the sliding valve in
the direction control valve is different. The sliding valve is
mechanically operated in the mechano-hydraulically operated valve.
while it is operated by pilot solenoid valve in the electro-
hydraulically operated valve
⑷Instruments
It mainly consists of hour meter. fuel meter. water temperature
meter and indicator lamps. They are all performance checking
instruments for the forklift truck
The meters in the K instrument panel are cross
magnetodynamic. Their pointers defect proportionally to their sensor's
parameters. The fuel meter and water temperature meter in theK
instrument panel are ten solid state bars of multicolor LED display
The hour meter in the K instrument panel is solid state digital display
with backlight
(5)Lighting and Signal Devices
They include all kinds of illuminating lamps, signal lamps, horn
and buzzer. etc
Headlight: 35W
Front combination lamp: 2IW/8W(turning/front)
Rear combination lamp : 2IW(red)/8W(red)/IOW(white)
(turning/rear/backing)
Warning lamp: 2IW(optional)
2.2 Brief Explanation for Operation
(I)Starting
There is a starting protection circuit in the control box for the
forklift truck. You have to shift the direction switch in neutral before
you start the engine. Otherwise, you can not
start the
Turn the key switch clockwise to the first "on" position. the

22
instrument circuit and firing circuit are ready for work. For diesel
engine. the automatic pre-heater begins to work and the pre-heating
indicator lights. The pre-heating indicator automatically lighting after
3.5 seconds and the pre-heater automaticallly stops working after 13.5
seconds. The pre-heating time is controlled by a time relay
Turn the key switch clockwise to the second "on" position
(starting position), then start the engine.
After engine starting, push the direction switch forward(that is in
forward gearshift),then pedal accelerator. the forklift truck runs faster
and you can begin to work.
When pull the direction switch backward (that is in reverse
gearshift), the backing lamp is on and the buzzer sounds
(2)Lamp Switch
Pull the lamp switch to the first "on" position. the front lamps
and rear lamps are on
Pull the lamp switch to the second "on" position. the headlights
are on while the front
lamps and rear lamps keep on
(3)Turning Signal
Pull the turning switch backward. the left turning lamps flash.
Push the turning switch forward. the right turning lamps flash
(4)Brake Signal
When you pedal brake. the brake lamps (red) in the rear
combination lamps are on
(5)Backing Signal
When you need to reverse the forklift truck, pull the direction
switch backward and the transmission is in reverse gear. Then the
backing lamps (white) in the rear combination lamps are on and the
buzzer sounds
(6)Charging Signal
Before you start the engine, put the key switch to the first "on"
charging lamp is on. After engine starting, the charging lamp is automa
position and the tically off. If the charging lamp becomes on while the
engine is working, it means something is wrong with the charging
circuit and you must stop working and check the charging circuit as
soon as possible.
(7)Oil Pressure Signal
Before you start the engine, put the key switch to the first "on"
position and the oil pressure alarm lamp is on. After engine starting,
the oil pressure alarm lamp is automatically off. If this lamp becomes
on while the engine is working, it indicates low lubricating oil pressure
and you must stop working and check the lubricating system as soon

23
as possible.
(8)Water Separator Signal
Before you start the engine, put the key switch to the first "on"
position and the water separator alarm lamp is on. After engine starting,
the water separator alarm lamp is automatically off. If this lamp
becomes on while the engine is working, it means too much water has
been accumulated in the water separator. You should push the handle
in the water separator to get rid of the water. After eliminating the
water. this lamp becomes off.
(9)Fuel Meter
It indicates how much fuel is left in the fuel tank. If it displays
fewer than two bars. It means little fuel is left in the fuel tank and the
buzzer sounds. You should replenish the fuel tank as soon as possible.
(10)Water Temperature Meter
It indicates the temperature of the coolant for the engine
(11)Hour Meter
It indicates how many hours the engine has worked
2.3 0perator Presence System
Operator Presence System (OPS) has tow functions
(I)Lock the Transmission
When the OPS detects the driver leaving the seat for five
seconds. it will disengage the transmission to cut off the power; when
driver seats back and the seat switch is closed. the direction lever is
shifted to neutral position. then the lock status can be released
(2) Warning Indication
When the OPS detects the driver leaving the seat for one second.
the OPS alarm will make a warning sound as "BEE", in the mean time
the warning light will show on the dash display; the warning light will
be always on during the driver absence. it means the forklift is locked
on the transmission. When the driver seats back the forklift will be still
locked if the direction lever is not put into neutral position. in that case
the OPS alarm will make acontinuing warning sound as "BEE……″

24
25
26
27
28
KUY

29
3. Clutch Unit

Type Dry single plate type

Operation Foot-pedal type
Facing Outer Dia 275mm
Facing Inner Dia. 175mm
Facing Thickness 8.9 士 0.3mm
Surface Area 354cm²
Weight 12.5kg
3.1 General Description
The clutch consists primarily of clutch housing, clutch disk.
clutch cylinder. Master cylinder and pressure plate ass'y. It transmits or
cuts off the power from the engine to the gear box.
3.1.1 Pressure Plate Case and Clutch Disk
The pressure plate case is installed on the flywheel as shown is
Fig.3-I.The clutch disk lies between the pressure plate and the
flywheel and is connected with the main shaft of the gear box by the
splines. When the release block moves forward. the release lever is
pushed forward. then the pressure plate can't contact with the clutch
disk. at the same time, the power from the engine is cut off.

30
Fig.3-1 Clutch Housing and Disk

31
Fig.3-2 Clutch Oil Site

32
 3.1.2 Clutch Cylinder
The clutch cylinder consists piston, spring and push-rod. It is
installed on the left side of the gear box as shown is Fig.3-3. When
pushing the push-rod, the release lever moves

Fig.3-3 Clutch Cylinder

3.1.3 Main Cylinder

The main cylinder consists piston, spring, oil chamber and
push-rod. It is installed on the clutch pedal as shown in Fig.3-4. The
movement of the pedal transmits to the piston through push-rod. Then
the power from the pedal turns into the hydraulic power.
Fig.3-4 Main Cylinder

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 3.1.4 Clutch Pedal
The clutch pedal is fitted on the
same bracket as the brake pedal and is
secured on the top of the transmission.
The movement of the pedal transmitted
to the main cylinder and turns the pedal
power into the hydraulic power. The
hydraulic power transmits the
movement to the clevis through the
push-rod of the clutch cylinder.
3.2 Maintenance
3.2.1 Adjustment of Clutch Pedal
(I)Move the floor board.
(2)Loose the lock-nut of the catch-
bolt. ④
(3)Turn the catch-bolt left or right
for adjusing the height of the clutch
pedal.
(4)Screw the lock-nut tightly and Fig.3-5 Clutch Pedal
fit the floor board.
Unit: mm
Engine Capacity Height Free Stroke
C240 1~1.8t 105 10
4JG2 3.0/3.5t 116 10

Fig.3-6 Clutch Pedal's Height

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 3.2.2 Replacement of Clutch Disk
(I)Remove the clutch cover.
(2)Press the clutch pedal and move
out the pressure plate with liftout bolt.
(3)Turn the slide bolt left to let the
drive shaft go into the transmission.
(4)Remove the clutch cover
mounting bolts and the clutch disk.
(5)Install a new clutch disk with
the longerspline boss pointing toward
the transmission.
(6)The tighten torque of the slide
bolt:10.9-12.lkg.m.
(7)Install the clutch cover on the
flywheel.
(8)Press the clutch pedal and
remove the liftout bolt.
(9)Check the free stroke of the
clutch pedal and adjust it if necessary.
(Free stroke:lOmm)
(10)The distance between the
seperating rocker arm and the catch-bolt
is 14mm.

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4.Mechanical Drive Unit

Transmission Mannal-shift. slide type synchromesh

Type mechanism
Steep No FWD 2 BWD 2
Gear Ratio FWD lst/2nd 3.253/1.407
BWD lst/2nd 3.204/1.386
Reduction
Reduction Gear Spiral bevel gear
Reduction Ratio 2.5 (1 to 1.8 ton trucks)
2.1 (2 to 3.5 ton trucks)
2.1 (3.8 ton trucks)
Differential
Reduction Gea Spur gear
Reduction Ratio 5.7 (1 to 1.8 ton trucks)
6.182 (2 to 3.5 ton trucks)
Differential Gear Bevel gear
Oil Amount 81
Weight (without oil) 136kg(l to 1.8 ton trucks)
165kg(2 to 3.5 ton trucks)
165kg(3.8 ton trucks)

4.1 General Description

The drive unit of clutch type truck is consist of transmission and
differential. The transmission is provided with a synchromesh
mechanism

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 4.1 . I Transmission with Synchromesh Mechanism
(I)Power Transmitted of the Transmission
The transmission consists mainly of a driving, output, main and
idler shafts. Each having gear(s) of different sizes on it. The gear(s)
can be shifted with the aid of the synchromesh mechanism installed on
the main shaft by operation of the shift handle. The power from the
output shaft is transmitted through the reduction gear, differential and
halfshafts to the drive shaft
In neutral position-
The power from the driving shaft I is transmitted through the
input gear. the cluster gear 2 & 4 to the high speed gear 6 0r low speed
gear. Due to the mesh sleeve is in the neutral position, the main shaft,
output gear and output shaft are not rotated so the power is not
transmitted to the high speed or low speed gear
Gear shifting-
When the shifting lever is operated. the shift fork move the mesh
sleeve to allow relative gears to mesh through the synchromesh
mechanism. Power is transmitted in the following order:
Driving shaft-lnput gear-Cluster gear-High(or low)speed
gear-Synchromesh mechanism-Main shaft-Synchromesh
mechanism-Reverse(or forward)gear-Output
gear-Output shaft
Power flow in forward lst speed gear position
I -2 - 3 -4 - ll - 10 - 8 - 9 - 12 - 16 - 15 - 17 -18 - 5 - 21
Power flow in forward 2nd speed gear position
I -2 - 3 -6 -7 - 8 - 9- 12 - 16 - 15 - 17 - 18 - 5 - 21
Power flow in reverse lst speed gear position
I -2 - 3 -4 - ll - 10 - 8 - 9 - 12 - 16 - 15 - 14 - 13 - 19 - 20 - 5 - 21
Power flow in reverse 2nd speed gear position
I -2 - 3 -6 -7 - 8 - 9- 12 - 16 - 15 - 14 - 13 - 19 - 20 - 5 -21

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 The synchromesh mechanism consists primarily of synchromesh
cones. block rings and inserters.
a)Synchromesh cone
The gear 11 0r 13 has a male cone, i.e. synchromesh cone
mating with the block ring 2 through respective cone friction surface.
and an involute spline 3 engaged with mesh sleeve spline 6.
b)Block ring
The block ring has a female cone friction surface mating with
the male cone's of the synchromesh cone and three notches on its
circumference to align the spline of mesh sleeve with block ring's so
that the mesh sleeve spline 6 is to be pressed toward the block ring
spline l.
c)lnserter
There are three inserters included. Their center projections are
fitted in the inner annular groove of the mesh sleeve spline, respective
two ends in three notches of the block ring. These inserters are pressed
against the top of mesh sleeve spline by two springs 8 to keep the
block ring in position.
The operation of sychromesh mechanism is
completed in six steps below (talk the gear ll
for example).
Ist Step (See Fig.4-4)
When the force is applied on the shift lever.
it is transmitted to the mesh sleeve 5 through the
shift fork and then makes the mesh sleeve 5 and
inserters 7 axially move toward the gear ll by
Xi and X2 respectively. In this time. the center
projections of inserters 7 are still in the groove
of mesh sleeve spline.
2nd Step (See Fig.4-5)
After the elimination of the clearance Xi
and X2. the force above acts on the inserters 7
and synchromesh cone 4 through respective
friction surface and makes the inserters inclined
by an angle against the spring force to contact
with synchromesh cone. At this time the mesh
sleeve moves by a distance of Z.

Fig.4-5

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5.Hydrodynamic Drive Unlt

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6. Drive Axle

Type Front whee drive type truck, axle body rigidly connected to
truck frame, floated halfshaft
Wheel Single
Arrangement wheel type
Whee Size 15-19.5-16PR
Rim size 19.5X11.75
Tyre 550kPa
Pressure

6.1 General Description

The drive axel mainly consists of the housing, the wheel hubs. the
halfshafts and the brakes. The housing is an integrally casted. The tyre
with the rim is fixed to the hub with studs and nuts. The power is
transmitted to the half-shafts through the differential and drives the
front wheels through the hubs. Each hub is fixed on the housing with
two tapered roll bearings, so that the half-shafts bear only the torque
transmitted to the hubs.In the inside of the hub are oil seals to prevent
water and dust from entering and oil leakage.

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7. Steering System

Model
2t-3.5t
Item
Type Rear wheel steering powered

Steering Ass'y Type Cycloid gear type powered steering

unit
SteeringAss'y Model BZZI-100 (sealed by taper o-rings)
Type Double-action piston type
Bore mm φ70
Steering
Cylinder Dia.of Piston Rod mm φ50
Stroke mm 160
Rated Pressure MPa 10
Radius of Steering Handwheel mm 386
Wheel Size 10-16.5-10PR
Tyre Pressure 520kPa

7.1 General Description

The steering system principally consists of a steering handwheel.
a steering shaft and a steering unit. The steering shaft is connected
with the steering unit and steering handwheel by the joint. The steering
column may be tilted properly forward or backward (See Fig.7-I)

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 Fig.7-I Steering and Operating Device
7.2 Cycloid Gear Type Powered Steering Unit
The powered steering unit can transmit the pressure oil from the
flow-divider by pipes to the steering cylinder in terms of the rotating
angle of the handwheel. When the engine stop running, the charging
pump will not work. in this case a man-powered steering should be
adopted.

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 Fig.7-2 Cycloid Gear Type Powered Steering Unit

l. Spacing sleeve 4. Interlock shaft 7. Rotor

2. Valve body 5. Spring piece 8. Stator
3. Valve core 6. Joint sleeve 9. Valve sleeve

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 7.3 Inspection on Reassembly of Steering System
(I)Check the forces necessary to turn the steering handwheel to
right and left until it can't be turned any more to see if they are
identical each other and check the operation of the steering handwheel
for smoothness during above operation.
(2)Check the arrangement of hydraulic pipeline and turning
direction of the truck for correctness.
(3)Put up the rear wheels and slowly turn the handwheel over
again to exhaust the air in the hydraulic pipelines and the cylinder.
7.4 Steering System Troubleshooting

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8. Steering Axle

8.1 General Description

The steering axle is of section-boxed welded construction type
(Fig.8-1). It includes axle body, steering cylinder. tie rod. knuckles and
steering wheels. The steering trapezium is made of cranks and blocks.
When pressure oil move the cylinder piston rod. the tie rod revole the
knuckles, then the truck may be steered. The steering axle is bolted to
the rear frame by the buffer.

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 8.2 Steering Knuckles and King Pin
Both steering knuckles are fitted between the upper and the
lower bushes through tow king pins, tapered bearings, dust sleeves and
O-ring seals. The upper extreme of the king pin is locked on the axle
body with a lock pin, the lower extreme of the king pin with a nut and
a split pin. Both ends of the king pin are supported by the tapered
bearings which are pressed into the axle body.

8.3 Wheel Hub

The rear wheel hubs are fitted to the knuckle shafts through two
tapered roller bearings, the wheels with rims are bolted on the hubs.
There are oil seals keeping the grease in the hubs and the chambers of
the knuckles between the outside of the two tapered roller bearings.
The degree of the bearing tightness is adjusted by the nut.
8.4 Steering Cylinder
The steering cylinder is of double-action piston type. The seal
unit is consist of the supporting ring and o-ring seal, Yx-ring seal is
adopted between the cylinder cover and the piston rod. The cylinder is
fitted to the steering axle through two cylinder covers.

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63
 (I)As shown in Fig.8-4, with lubricating grease, fill up the
chamber formed by wheel hubs. wheel hub bearings and wheel hub
covers and coat the lips of the oil seals
(2)Press the hub bearings into the hub and fit the hub on the
knuckle shaft
(3)Fit a flat washer and tighten a castle nut to a torque of
206-235Nm(21-24kgm) and loosen it and then tighten it again to a
torque of 9.8N.m(lkgm)
(4)To ensure firm installation of the hub, slightly knock at it with
a wooden hammer and in the meantime. rotate the hub for 3-4 turns
(5)Tighten the castle nut and align one of its notches with a cotter
pin hole drilled in the steering knuckle
(6)Again slightly knock at the hub with a wooden hammer and in
this time. Rotate manually the hub for 3-4 turns to ensure its smooth
rotation with a specified torque of
2.94-7.8 N.m (0.3-0.8kgm)
(7)If the torque value necessary to rotate the hub is more than the
specified one above-mentioned. screw out the castle nut for l/6 turn
and measure the torque value then
(8)When the torque value measured is up to the specified one.
lock the castle nut with a cotter pin.

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9. Brake SY stem

Type: Front two-wheel braking, internal expansion, hydraulic type

Pedal Ratio: 5.66
Master Cylinder Bore: 19.05mm
Wheel Brake 1~1.8t 2t.2.5t 3t.3.5t 3.8t
Type: Duo-servo type with parking brake
Operating 22.22mm 25.58mm 25.58mm
Cyl. Bore
Lining 279x48.5x5mm 324×76×8mm 348 × 76 ×
Size(LxWxT) 8mm
Friction Area 135.3cm²×4 194.4cm²×4 135.3cm‘×4
Inner Dia.of 254mm 310mm 314mm 314mm
Brake Drum
Parking Brake:Front two-wheel braking, internal expansion, hydraulic
type
9.1 General Deseription
The brake system is the front
two-wheel braking type consisting of
a master cylinder. wheel brakes and
brake pedal mechanism.
9.1.1 Brake Pedal
The brake pedal unit is mounted
on the transmission throuhg bracket
as shown in Fig.9-I. When the pedal
moves. it push the rod to course the
piston moves and the pressure of the
oil circuit increased.

Fig.9-I Brake Pedal (Clutch Type)

65
 Fig.9-2 Brake Pedal (Tor-con Type)
9.1.2 Master Cylinder
The cylinder contains valve seat. check valve. return spring,
primary cup, piston and secondary cup, which are all kept in place
with a stop washer and a stop wire. The exterior of the cylinder is
protected from dust by means of a rubber dust cover. The
piston is actuated through the push rod by operation of the brake pedal.
As the brake pedal is pressed, the push rod pushes the piston forwards.
The brake fluid in the cylinder flows back to the reserve tank through
the return port until the primary cup blocks up the return port. After the
primary cup passes through the return port. the brake fluid in the
cylinder is pressurized and opens the check valve. flowing through the
brake pipeline to the operating cylinder. Thus. each operating cylinder
piston is forced outwards. This brings the friction pieces on the brake
shoes into contact with the brake drum and slows or stops the truck..
Meanwhile. the cavity caused behind the piston is filled with brake
fluid led through the return port and inlet port. When the brake pedal is
released. the piston is forced back by the return spring. At the same
time. the brake fluid in each operating cylinder is pressurized by the
return spring, returning into the master cylinder through the check
valve. With the piston in its original position. the fluid in the master
cylinder flows into the reserve tank through the return port. The brake
fluid in the brake pipelines and operating cylinders has a residual
pressure proportioned to the set pressure of the check valve. which
makes each operating cylinder piston cup securely seated to prevent oil
leakage and eliminates a possibility of air locking when the truck is

66
sharply braked.

67
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10.Hydraulic System

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11.Load System

102
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 For 3.8 ton trucks
Type: Rolling type, J-shaped inner mast, C-shaped outer mast
with free lift.
2-stage telescopic mast

Cross section of inner mast

Cross section of outer mast

Roller:
Roller I φ123mm
Side roller assembly I φ80mm
Side roller assembly φ91.5mm
Lifting chain LH1634
Fork. mast lifting system Hydraulic
Fork spacing adjustment Manual

104
 11.1 General Description
The loading system is of the two-stage, rolling telescopic mast
type and consists of inner mast. outer mast and carriage.
11.2 Inner and Outer Masts
The inner and outer masts are welded parts. The bottom of outer
mast is connected with the drive axle through supporting. At the
outside middle of outer mast. there are tilt cylinder connected with the
frame. The mast assembly can be tilt forward and backward by
operating the tilt cylinder.
The outer mast has C-shaped cross section and there are roller
and side roller on the upper part of it.
The inner mast has J-shaped cross section and there are roller
and side raller at the bottom of it.
11.3 Carriage
The carriage moves up and down smoothly along the channel of
the inner mast with main rollers. The main rollers mounted on the
main roller shafts and blocked by snap rings. The main roller shafts are
welded on the carriage. The side rollers fitted on the carriage with
bolts. They roll along the flank plate of the inner mast and may adjust
with shims. Two fitted side rollers roll along the outside of the flank
plate of the inner mast to prevent the rolling clearance. The main
rollers sustain the longitudinal loads and the side rollers sustain the
transverse loads.
11.4 Roller Position
There are two kinds of rollers. main roller and side roller. They
are separately mounted on the outer mast. inner mast and carriage. The
main rollers sustain the loads from front and rear direction and the side
rollers sustain the side loads.

105
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IV.EURO V higher emission limits

stage

1.Instrument(for certain truck models )

18 Forklift run-well
27 Warning of high exhausting temperature
28 Parked regeneration request
29 Inhibit regeneration
23~26 DPF jammed volume is the volume that cannot be
processed by regeneration.

109
30 Air cleaner(optional)
Parked regeneration request
When the figure is displayed,it means that the truck needs to be parked
for regeneration

Warning of high exhausting temperature

When the truck is under regenerating,the instrument will give a
warning of high exhausting temperature when the exhausting
temperature reaches to a value.

Inhibit regeneration(for certain truck model)

When the inhibit regeneration switch is pressed,the figure will display
to suggest that the truck is under inhibit regeneration mode

110
 When the inhibit regeneration button is pressed,the active regeneration
mode will not be effective.After a period of time,it is easy to cause blockage of
post-treatment system.The maintenance cycle will be shortened.

Safety belt reminder

After the vehicle is started after 20s,if it is detected that the safety belt is not
fastened,and the instrument will give a buzzer alarm.

2. DPF maintenance(regeneration type,for

certain truck models)

111
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