5t～10t XF series

Internal Combustion Counterbalanced Forklift Truck

SERVICE MANUAL

Original Instruction

HANGCHA GROUP CO., LTD.

Feb. 2020
 Foreword

XF series diesel fork truck is a new generation fork truck which adopted the latest
concept to design, it has these features: novel appearance, compact structure,
advanced function. The manual is the introduction of structure, working principle and
maintenance and so on.
For safety and performance of truck, all in charge of operation, maintenance and
management must read and comprehend this manual well.
The manual also applies to container fork-lift trucks.
It is forbidden anybody without training and qualification to maintain.

○
C Feb. 2020 HANGCHA GROUP CO.,LTD.
 Content
Ⅰ.Power system ............................................................................................................................... 1
1.Engine ............................................................................................................................................ 3
2.Air intake system ........................................................................................................................... 8
3.Exhaust system............................................................................................................................. 10
4.Cooling system............................................................................................................................. 11
Ⅱ.Transmission shaft ..................................................................................................................... 12
Ⅲ.Hydraulic transmission gear box................................................................................................ 14
1.Summarize ................................................................................................................................... 14
2.Main technical parameter ............................................................................................................. 16
3.Working principle ........................................................................................................................ 17
4.Structure introduction................................................................................................................... 19
5.Installment and use notice ............................................................................................................ 23
6. Fault reason and corrections ....................................................................................................... 24
Ⅳ. Drive axle assembly .................................................................................................................. 25
1. Drive axle basic structure and its working principle ................................................................... 25
2.Periodical technical maintenance ................................................................................................. 28
3.Drive axle oil adding way ............................................................................................................ 29
4. Drive axle hoisting ...................................................................................................................... 30
5. Driven spiral bevel gear engagement contact condition and adjustment .................................... 30
6. Fault diagnosis and corrections ................................................................................................... 32
7. Dismantle and assemble .............................................................................................................. 33
V. Steering system ........................................................................................................................... 40
1.Hydraulic steering gear ................................................................................................................ 40
2.Steering axle................................................................................................................................. 43
VI. Brake system ............................................................................................................................. 47
1.Data .............................................................................................................................................. 47
2.Fault diagnosis and corrections .................................................................................................... 50
3.Pedal height, free stroke ............................................................................................................... 51
4. Brake valve and accumulator ...................................................................................................... 52
5. Hand brake .................................................................................................................................. 54
6.Service brake（W65G/W75G/W95G） ...................................................................................... 57
7. Hydraulic brake malfunction diagnosis ...................................................................................... 60
8. Exhaust of air in the hydraulic system ........................................................................................ 60
VII. Hydraulic system ..................................................................................................................... 61
1.Oil pump ...................................................................................................................................... 61
2. Multiple directional control valve ............................................................................................... 64
3. Rotary type piping filter .............................................................................................................. 71
4. One-way governor valve ............................................................................................................. 72
5. Lifting cylinder ........................................................................................................................... 72
6. Tilting cylinder ............................................................................................................................ 73
7. Air exhaust in hydraulic system .................................................................................................. 73
8. Hydraulic system fault diagnosis and corrections ....................................................................... 74
9. Hydraulic system schematic diagram.......................................................................................... 75
VIII. Lifting system......................................................................................................................... 77
1. Assemble debugging data............................................................................................................ 78
2. Fault diagnosis and corrections ................................................................................................... 79
3. Summarize .................................................................................................................................. 80
4. Mast dismantle and install adjustment ........................................................................................ 82
5. Disassembly and installation of lifting cylinder .......................................................................... 86
6.Disassembly and installation of tilting cylinder ........................................................................... 87
7. Noticing proceeding of debugging .............................................................................................. 88
IX. Electrical system ....................................................................................................................... 89
Electrical plate assembly ................................................................................................................. 89
Key switch(start) ............................................................................................................................. 95
Combination instrument assembly(except W65G\W75G\W95G) .................................................. 96
Combination switch assembly ........................................................................................................ 99
Gear combination switch(except W65G\W75G\W95G) ................................................................ 99
Light combination switch.............................................................................................................. 100
Starter and generator repair ........................................................................................................... 103
Engine fault detection(Cummins）............................................................................................... 104
Electrical system diagram ............................................................................................................. 125
Ⅹ. Overhead guard disassembly and installation ......................................................................... 135
Ⅰ.Power system

Exhaust
muffler
Air filter Water bottle Intake muffler Engine
Fan Expansion Radiator
tank

Fig.1-1-1 Power system drawing

1
Fig.1-1-2 Power system drawing

2
 1.Engine

1.1 Power disposition

GM4.3L
(LPG non approved
Model QSB3.3（Cummins） QSB4.5（Cummins）
electronically controlled dual
fuel)
Displacement（L） 3.3 4.5 4.294

Rated power（kW） 74 82 74

Rated speed（r/min） 2200 2200 2300

Max. torque/rotate speed（N·m/rpm） 415/1600 488/1500 301/1700

Cylinder stator No.（piece） 4 4 6

Cylinder diameter×stroke（㎜） 95×115 107×124 101.6×88.4

Engine oil volume（L） 8～12 8～12 \

Coolant volume（L） 4.6 8.5 \

Air inlet way Supercharge Supercharge \

Dry weight（㎏） 275 371 197

QSB3.3 100 QSB4.5 110 GM4.3L

Model
（Cummins） （Cummins） (LPG non approved single fuel)

Displacement（L） 3.3 4.5 4.294

Rated power（kW） 75 82 74

Rated speed（r/min） 2200 2200 2300

Max. torque/rotate speed
414/1600 489/1500 323/1700
（N·m/rpm）
Cylinder stator No.（piece） 4 4 6

Cylinder diameter×stroke（㎜） 95×115 107×124 101.6×88.4

Engine oil volume（L） 8～12 8～12 \

Coolant volume（L） 4.6 8.5 \

Air inlet way Supercharge Supercharge \

Dry weight（㎏） 361 390 197

3
 GM4.3L LP
Model
(LPG approved single fuel）

Displacement（L） 4.294

Rated power（kW） 75

Rated speed（r/min） 2300

Max.torque/rotate speed（N·m/rpm） 324/1700

Cylinder stator No.（piece） 6

Cylinder diameter×stroke（㎜） 101.6×88.4

Engine oil volume（L） 4.9

Coolant volume（L） 7.3

Air inlet way \

Dry weight（㎏） 197

TCD3.6 L4(EU
TCD3.6 L4 TCD3.6 L4 f
Model Stage Ⅴ)
(DEUTZ) (DEUTZ)
（DEUTZ）
Displacement（L） 3.6 4.5 3.6

Rated power（kW） 55.4 82 55.4

Rated speed（r/min） 2300 2200 2300

Max. torque/rotate speed
390/1300 488/1500 405/1300
（N·m/rpm）
Cylinder stator No.（piece） 4 4 4

1.2 Use and maintenance of Cummins engine

1.2.1 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).

4
• 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.
◆ If the engine has the following condition, you should report it in time, such as fire
lack, vibration, abnormal noise, leakage, sudden water temperature or engine oil
pressure change, smoking, power coastdown, inability or fuel consumption increase.
◆ After engine run with full load:
• Idling for 3-5 minutes.
•When the engine misses, stay ON position for at least 10 seconds, and then cut the
power ( Electronic controlled engine).
•Do not wash the engine with water( Electronic controlled engine).

1.2.2 Daily maintenance requirement

Discharge water in oil-water separator daily
◆ 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
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.

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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,
vibration, abnormal noise, leakage, sudden change of water temperature and engine
oil pressure, smoking, power coastdown, inability, increase of engine oil and fuel oil
consumption.
◆ 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 must
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 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.

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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.
◆ 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 displacement after the maintenance or servicing, and
ensure that the exhaust gas is in accordance with relevant figure, see the following
table:
Engine
CO HC NOx HC+NOx PM
power
kW (g/Kw·h) (g/Kw·h) (g/Kw·h) (g/Kw·h) (g/Kw·h)

37≤P<56 5.0 — — 4.7 0.025

56≤P<75 5.0 0.19 3.3 — 0.025

75≤P<130 5.0 0.19 3.3 — 0.025

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2.Air intake system

Air

1. Intake muffler 2. Air filter 3. Turbocharger 4. Empty intercooler

Fig. 1-2 Intake system
Intake pipe maintenance
Before daily work, start the engine, keep in idling speed and check if the intake pipe
leaks. If air leaks, make sure the leakage position, shut down the engine and check the
air leakage reason. If air leakage caused by the T-type clamp in pipe joint looseness,
re-screw down T-type clamp; if it is caused by tube ageing, replace a new rubber tube.
Note: If intake pipe has ageing and delamination problem, replace aged tube as soon
as possible no mater leak or not.
Air filter
Air filter maintenance
Maintenance way(outer):
Lightly knock the filter element end cap and shake off the dust.
Blow clean the filter element along the bevel angle direction from inside to outside
with dry compressed air whose pressure is no larger than 500kpa.
Replace filter element
1. Outer filter element or maintenance reaches 5 times.
2. There is still maintenance signal after installing the maintained filter element.
Note: Inner filter element does not need maintain and replace when change the outer

8
filter element.
It is not suggested to clean, please replace it.
Air filter maintenance, main filter element, safety filter element and filter element
model refer to notice on the filter.
Air filter replace and maintain procedure

Open the six fasteners with thumb

as the right fig.

Lightly wave the

Hold the fasteners main filter element
and pull out the cover and pull out the main
as shown in the fig. filter element

Safety filter element needs Wipe both sides of the inner

no maintenance, if it needs shell pointed by the arrow in
replacement, wave the order not to influence
filter element to right and installation and sealing
left, slowly pull out it. effect

Check the safety Check the main filter

filter element and element and install
install into the shell into the shell

Put the cover and Lock the fasteners as

keep the anti-dust bag fig. shown place and
downward installation finish

Note: Maintenance notice and parts replace, you may contact Hangcha after-sales
service.

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3.Exhaust system

1. Turbocharger 2. Muffler 3 Exhaust tail pipe

Fig.1-3 Exhaust system flowchart

Exhaust pipe maintenance

Before daily starting the engine, clean the dirt on the muffler sunshade, check if the
exhaust pipe or muffler assembly damage, pipeline connected hoop loosen. Replace
exhaust pipe or muffler assembly, re-screw down clamp if necessary.

Muffler assembly replacement

(1) Turn the truck left to the end and shut down the engine;
(2) After engine exhaust pipe fully cool down, take down muffler sunshade;
(3) Disassemble hoop in the exhaust pipe entrance and exhaust connection;
(4) Disassemble fixed bolts between exhaust pipe two ear plates and chassis.
(5) Take out old exhaust pipe and replace a new one.
Disassembly order is opposite to the installation order.

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4.Cooling system

Cooling system is composed of fan, composite cooler and each cooling pipeline.
According to different cooling material, it divides into water cooling system, air
cooling system and hydraulic oil cooling system. All these three cooling systems
realize cooling through composite cooler.
Cooling system maintenance:
(1) Before start the engine, check the expansion water bottle liquid level and add
antifreeze solution in necessary.
(2) Before start the engine, check if the cooling pipe leaks.
(3) Replace antifreeze solution every two years or after long-time park.

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Ⅱ.Transmission shaft
Transmission shaft(refer to fig.2-1) is composed of flange yoke, universal joint pin,
bearing and center fork etc.. Universal joint pin is installed in the earhole of center
fork, needle bearing bush in four bearing block, universal joint pin with oil cup, and
the oil cup can be filed with lubricating oil and lubricate all bearings through the oil
line.
When there is too big clearance in the needle bearing, you should take apart flange
yoke, change bearing or universal joint pin according to condition, and the bearing
change should be in group. The two universal joint pin should be in the same side.
Transmission shaft needle bearing use MoS2 lubricating oil, and is prohibited to use
thick oil(Such lubricate with butter, cause the butter will stop the needle roller on the
universal joint pin rotate and speed the wear). When working with thick dust, you
should often fill lubricating.

Fig. 2-1 Transmission shaft

Universal joint pin damage and repair

(1) When universal joint pin surface has nick, dent and journal wear is larger than
0.04mm, it can repair with chroming or steeling. Or grind four journals into the
same size and equip with amplified kingpin, when the carbon bed is insufficient
after shortening the journal, it needs carburization and heat treatment. Journal
circular degree and cylindricity deviation after grinding should not be larger than
0.01mm; error of perpendicularity of two axis should not be larger than 0.1mm.
(2) During installation, fit clearance between journal and bearing is 02-0.09mm, and
the max. clearance should not be larger than 0.13mm.
(3) Universal joint bearing kingpins wear, fracture and groove should replace.
Check and repair of flange yoke and center fork
(1) If flange yoke or center fork fracture, replace it.
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(2) If kingpin bearing saddle bore wears, it can be repaired with bead weld, and then
bore a hole to match the size.
(3) Bearing cover plate thread should fix, snap ring groove match piston, there should
no looseness.

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Ⅲ.Hydraulic transmission gear box
Specifications, W28B、W48B ，W38B、W46B，structure and maintenance methods
for model power transmission gear-box and torque converter, please see
《Y53490Z、Y53500Z MODEL TORQUE CONVERTER MAINTENANCE MANUAL》.
W65G 、 W75G 、 W95G ， structure and maintenance methods for model power
transmission gear-box and torque converter, please see《3WG95 service manual》.

1.Summarize

Hydraulic transmission gear box is composed of stamping torque converter and power
gearshift gear-box that owns four gears as forward two gears, reverse 2 gears.
Hydraulic torque converter is a combination torque converter with single stage two
phase three running wheel.
Hydraulic torque converter is the hydraulic transmission gearbox output automatic
hydraulic transmission is adaptive, can with the variation of the external load and the
corresponding change its output torque and speed, and can absorb and remove from
the engine and external load on the transmission system of the buffer hydraulic
transmission gearbox to connection vibration flange output, the shift for power shift
and way with buffer valve, simple and convenient operation, start smoothly,
considerably reduce the labor intensity of the operator
Hydraulic torque converter make hydraulic transmission gearbox own automatic
adaptive to fluid drive output, it can change the output torque and speed as outer load
changes, and also can absorb and eliminate buffer vibration to the drive system from
engine and outer load. Hydraulic transmission gear box is through connecting flange
output, and the adopted shift gear way is power shift and owns cushion valve, which
makes operation simple, easy, start stable and ease operator‘s labor intensity.

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Fig. 3-1 Hydraulic transmission gear box outline drawing

15
 2.Main technical parameter

Item Main technical parameter

Forward 1 gear 1.852

Drive ratio

Forward 2 gears 0.526

Reverse 1 gear 1.852

Reverse 2 gears 0.526

Main oil pressure MPa 1.2～1.5

Torque converter oil inlet pressure MPa 0.5～0.7

Model YJH315

Circling round diameter D ㎜ 315

Transmission gear box

Zero-speed working condition torque

3.15±0.15
ratio
Peak efficiency ＞0.79

Zero-speed working condition

71±4
impeller rated torque N.m
Peak-efficient working condition
60±3
impeller rated torque N.m

）
Direction of rotation（Face input end） Clockwise

Work oil 6# hydraulic transmission oil

Work oil temperature℃ 70～95

Highest work oil temperature℃ 120（no more than 5min）

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 3.Working principle

3.1 Drive principle

Hydraulic transmission gear box drive diagram refers to fig. 3-2. Torque converter is
driven by engine through flexible coupling plate 2, drives the impeller 5 to rotate,
makes the fluid flow into the turbine 3 along the blade in high speed, and pushes
turbine rotate. Guide roller 4 makes torque converter generate torque change action,
transfer torque to hydraulic transmission gear box F-axle assembly 15 through turbine
shaft 1.

Input

1-Turbine shaft 2 Flexible coupling plate 3-Turbine 4-Guide roller 5-Impeller 6-Idler shaft
7-Idler 8-Pump drive gear 9- Oil pump assembly 10- Forward II gear 11- Internal friction lining 12- External friction lining
13-Dish plate 14-Platen 15- F- axle assembly 16- Forward I gear 17-Back gear 18-ReverseⅠgear
19-Reverse gear 20-R- axle assembly 21- Low speed gear 22-Adapting flange 23-Parking brake gear 24- Parking brake axle
25-Manipulator brake 26-High gear 27-Output shaft 28- Reverse Ⅱ gear
Fig 3-2 Hydraulic transmission gear box diagram
When hang to forward I gear, forward 1 gear and clutch works, forward 2 gear,
reverse 1 gear, reverse 2 gear clutch idles, and the delivery order is piece 1→ piece
15→piece 16→ piece 21 → piece 27 → piece 22.
When hang to forward II gear, forward 2 gears and clutch works, forward 1 gear,
reverse 1 gear, reverse 2 gear and clutch idles, and the delivery order is piece 1→

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 piece 15→piece 10→ piece 26 → piece 27 → piece 22.
When hang to reverse I gear, reverse 1 gear and clutch works, forward 1 gear, forward
2 gear, reverse 2 gear and clutch idles, and the delivery order is piece 1→ piece
15→piece 17→ piece 19 → piece 20 → piece 18→ piece 21 → piece 27→ piece 22.
When hang to reverse II gear, reverse 2 gears and clutch works, forward 1 gear,
forward 2 gear, reverse 1 gear, and clutch idles, and the delivery order is piece 1→
piece 15→piece 17→ piece 19 → piece 20 → piece 28 → piece 26 → piece 27 →
piece 22.
Forward and reverse clutch is controlled by pilot valve component. Oil pump
assembly is inner gearing gear pump, oil pump supply pressure oil to system, oil after
hydraulic torque converter works entered into truck radiator, and then enter gear box
lubrication friction lining, bearing and gear.
This gear box equips with parking brake.
1.2 Oil line principle
Oil line of hydraulic transmission gear box schematic refers to fig.3-3. In the fig., F1
shows forward I gear, F2 shows forward II gear, R1 shows reverse I gear, R2 shows
reverse II gear, N shows neutral gear.

Enter lubrication oil line

P1 Main oil pressure

P2 Clutch pressure
P3 Torque converter inlet pressure
P4 Torque converter oil return pressure

1-Oil filter 2-Oil pump 3-Main pressure regulator valve 4-Relief valve 5-Overflow valve
6-Accumulator valve 7-Switch valve 8-Inching valve 9-Shift governor valve 10-Pressure measure valve
Fig. 3-3 Hydraulic transmission gear box oil line diagram

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 4.Structure introduction

4.1Hydraulic transmission gear box

4.1.1 Structure introduction
Hydraulic transmission gear box structure diagram refers to fig. 3-4 and its working
principle is as previously mentioned. According to truck performance requirement, the
gear box is composed of torque converter and gear box. Engine power inputs to gear
box forward clutch 12 through torque converter‘s bending movement of torque
converter turboshaft spline joint. Gear box includes forward clutch 12, reverse clutch
15, idler 3, pump drive gear 4, oil pump assembly 5, control valve assembly 9, high
gear 16, low gear 17, adapting flange 18, output shaft 19, internal expanding
mechanical hand brake 20, park brake shaft 21, parking brake gear 22. Piece8 is
transmission case, and itself works as an oil tank.

1- Flexible terminal pad 2- Turbine shaft 3-Idler 4- Pump drive gear 5- Oil pump assembly 6- Forward II gear
7-Forward I gear 8-Transmission case 9-Control valve assembly 10-Reverse gear 11- Reverse II gear 12- Forward clutch
13- Reverse I gear 14-Reverse gear 15-Reverse clutch 16-High gear 17-Low gear 18-Adapting flange
19-Output shaft 20- internal expanding mechanical hand brake 21- parking brake shaft 22- parking brake gear
Fig. 3-4 YQXD100H type hydraulic transmission gear box structure diagram
4.1.2 Dismantle and assemble order
Dismantle the hydraulic gear box according to the following order
① Open drain plug and release oil;

19
② Take out torque converter;
③ Take out pin, nut, gasket, bolt that installs internal expanding mechanical hand
brake, then take out the internal expanding mechanical hand brake;
④ Dismantle oil suction assembly, case cover assembly, oil pump assembly, control
valve assembly, clutch F axle and clutch R axle successively;
⑤ Dismantle other spare parts.
Assemble order is opposite to dismantlement.
4.2 Torque converter
Torque converter structure refers to fig.3-5, and is mainly composed off turbine shaft1,
pumper impeller 2, guild roller 3, turbine 4, flexible coupling plate 5.
Pumper impeller 2 is connected to engine flywheel through flexible coupling plate 5.
Pumper impeller transfers the engine mechanical energy to working oil kinetic energy,
and makes oil flow into turbine 4 along blade in high speed, push turbine rotate, and
output from turbine shaft, and transfer the speed and torque to gear box. Oil outflows
from turbine enters guilder roller 3. When the torque converter is in heavy load and
low turbine speed torque changing stage, guilder roller 3 is wedged not to rotate by
one-way clutch, torque from liquid flow worked on guild roller reacts on liquid flow
by guild roller, liquid flow increases torque by action of guild roller, torque on the
turbine equals the sum of pump impeller and guide roller, thus the output torque is
larger than input torque and generates automatic torque change.
Torque converter is weld-type, and undecomposable.

1. Turbine shaft 2.Pump impeller 3.Guide roller 4.Turbine 5.Flexible coupling plate
Fig. 3-5 Torque converter structure
4.3 Oil pump assembly
Oil pump assembly structure refers to fig. 3-6. Oil pump assembly is mainly
composed of oil pump body 1, oil pump cover 2, oil pump driving gear 3 and oil
pump internal gear 4 etc. Oil pump body 1 is casting, with high pressure chamber and
low pressure chamber. Oil pump assembly is installed on torque converter shell, after
speed up of gear, idler and pump drive gear on the torque converter, transfers the
power to oil pump driving gear 3, drive the oil pump inner gear 4, and forms inner
gearing gear pump to offer system oil.

20
 1-Oil pump body 2-Oil pump cover 3-Oil pump driving gear 4-Oil pump inner gear
Fig. 3-6 Oil pump assembly structure
4.4. Main pressure adjusting valve and relief valve
Main pressure adjusting valve and relief valve structure diagram refers to fig.3-7, and
is mainly composed of main pressure adjusting spring, over flow spring, valve plug
and round pin. Main pressure adjusting valve controls clutch oil pressure between
1.2Mpa and 1.5Mpa, part oil enter control valve though inching valve to realize gear
shift, and the other part oil enter relief valve, and adjust oil pressure between 0.5Mpa
and 0.7 Mpa, and then work in the torque converter.

1-Spring 2- Spring 3-Valve plug 4-Round pin

Fig.3-7 Main pressure adjusting valve and relief valve structure diagram
4.5 Control valve assembly
Operating valve assembly structure refers to fig. 3-8, and is mainly composed of

21
inching valve 1, switch valve 2, operating valve 3, accumulator valve 4 and pressure
measure valve 5 etc. Inching valve rod is connected to inching pedal connecting rod,
when stepping the inching valve pedal, inching valve rod move inward, when inching
valve rod moves inward 4mm, clutch begins to reduce pressure, when the clutch
pressure reduces to certain pressure, friction lining slips, make trucks reach inching
effect; when inching valve rod move inward 10.5mm, clutch pressure reduces to 0,
clutch outer friction lining and inner friction lining cannot combine; when inching
valve rod moves inward 30mm, inching valve rod stop travel. Inching valve 2 and
accumulator valve 4 combines cushion valve to reduce impact between clutch
combine and separate. Pressure measure valve is used to measure vehicle pressure.

1-Inching valve 2-Switch valve 3-Operating valve 4-Energy storage valve 5-Pressure measure valve
Fig. 3-8 Operating valve assembly structure

4.6 Clutch
4.6.1 Structure introduction
This hydraulic transmission gear box owns two clutches, clutch I(forward clutch),
clutch II(reverse clutch), clutch structure refers to Fig. 3-9.
Clutch is composed of shaft assembly 12, inner friction lining 3, outer friction lining 2,
spring 26, shaped plate 17, sealing ring 18 and each gear. Left and right clutch is wet
multi-plate hydraulic clutch, the left clutch(low gear) installs seven inner friction
lining, six outer friction lining, one compression plate and one shaped plate, and the
right clutch installs seven inner friction lining, seven outer friction lining, clutch
housing is welded together with input shaft, pressure oil control valve enters into
forward 1 gear, forward 2 gear, reverse 1 gear, reverse 2 gear clutch respectively, thus
realizes gear shifting. Sealing ring 18 on piston circlip and sealing ring 25 on input
shaft guarantee the sealing during clutch working. When in neutral, no pressure oil
enter into the clutch, piston return on the force of spring 26, and the inner friction
lining is off from outer friction lining. When shifting gears, oil pressure works on the

22
 piston, inner friction lining and outer friction lining combines, and transmits the
torque converter power to each gear by friction force.

1-End plate 2-Outer friction lining 3-Inner friction lining 4- Spring base 5-Thrust ring 6-Space ring 7-ⅠGear
8-Thrust ring 9- Reverse gear 10-Ball bearing 11- Circlip 12-Axle assembly 13-Sealing ring 14-Screw
15-Needle bearing 16-Compression plate 17-Shaped plate 18-Sealing ring 19-Snap ring 20-Ⅱgear 21-Piston assembly
22-Ball bearing 23-Circlip 24-Space ring 25-Sealing ring 26-Spring
Fig.3-9 Clutch structure
4.6.2 Dismantle ad assemble order
Dismantle and disassemble clutch according to series order:
①Take out left and right bearing, gear, circlip for shaft, thrust ring, inner friction
lining, outer friction lining, snap ring and end plate.
② Compress ends spring 26 respectively, take out check ring 23, dismantle piston 21
and spring 26.
Assemble is opposite to dismantlement.

5.Installment and use notice

①When installing this product, firstly clean sealing oil on the product surface. In
order to avoid oil leakage, it is not allowed to dismantle and disassemble the product.
②Avoid knocking and collision on each mounting surface and torque converter so
that not influence mounting and use precision.
③Check the runout of engine flywheel center mounting hole is no larger than 0.15mm,
flywheel end face runout is no larger than 0.1mm; flywheel casing installing end face
runout is no larger than 0.2mm.
④Forklift control mechanism should guarantee operating valve rod and inching valve
rod travel precise and positioning reliable. Inching valve rod can reset after operator
23
 release pedal. Only make sure clutch pressure is larger than 1.2Mpa can proceed gear
shift operation.
⑤When hoisting this gear box, try to keep level to avoid torque converter slip off.
⑥It is prohibited to change gear box oil line system. In order to make sure gear box
work normal and lubricate well, cycling oil of the gear box should not use for other
purpose. Working oil mark should meet the requirement.
⑦Working oil should keep clean, have no other impurity. After first use for 50 hours,
use per 1000hours or use after stopping for a long time, it needs change new one.
⑧Fill working oil, drive for 5 minutes in neutral and then check oil level, which
should be in the specified scope. Filler cap is also used as vent cap.
⑨After filling new hydraulic oil, it needs 50-hour running-in, and the load should not
exceed 70% in the running-in device, pay attention to oil temperature, oil pressure and
bolt tightening condition, replace new oil after running-in finishes.

6. Fault reason and corrections

Item Fault reason Corrections

1. Check if friction lining has gluing, uneven

1. Friction lining blind or damage;
Efficiency contact or warpage;
decline and 2. Check if oil pump wear or oil level is in
2.Insufficient torque converter oil supply;
over high normal position;
3.Bearing damage;
oil 3. Replace bearing;
4. Check if lubricating oil line blocks;
temperature 4. Dredge oil line;
5.Torque converter one-way wheel blind;
5. Replace torque converter
5. Replace torque converter;
1.Sealing gasket damage; 1 Replace sealing gasket;
Oil leakage 2. Rubber parts age or damage; 2.Replace parts;
3.Parts damage; 3.Replace;

1. Low oil level; 1. Check oil level and add oil to normal oil level;
2. Rotation sealing ring on clutch shaft and 2. Replace rotation sealing ring;
Low clutch
piston wear;
pressure or
3. Oil pump wear; 3.Replace oil pump;
over large
4. Oil filter strainer is blocked by 4. Clean or replace oil filter;
swing
impurity ;
5. Inching valve rod not reset; 5. Reset the inching valve rod;

24
Ⅳ. Drive axle assembly

1. Drive axle basic structure and its working principle

1. 1 Basic structure and its working principle

Dive axle basic structure is shown as fig. 4-2. Fig. 4-3, it 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. 4-1: 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.4-1 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, refer to fig.4-2.
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. Refer to fig. 4-3 for details.
1.4 Drum brake structure
The adopted drum brake braking, mainly composed brake plate, brake cylinder and
support. Refer to brake system.

25
 1.5 Main technical parameter
5-7T 8-10T

Drive axle type Full floating, axle body and chassis directly install

Total reduction ratio 20.72 30.87

Main reduction ratio 4.875 6.333

Hub reduction ratio 4.25 4.874

Hub reduction gear Cylinder planetary gear type

Brake Drum brake

W65G\W75G\W95G 5-7T 8-10T

Drive axle type Full floating, axle body and chassis directly install

Total reduction ratio 11.82 22.029

Main reduction ratio 2.73 6.333

Hub reduction ratio 4.33 3.478

Hub reduction gear Cylinder planetary gear type

Brake Wet brake

26
1-Axle housing 2- Main reduction assy 3-Brake assy 4- Hexagonal socket head plug
5-Gear half shaft 6-Bearing plate 7-Spring washer 8-Retainer
9- Combination seal washer 10-Bolt 11-Bolt 12-Bolt
13-Adjusting brace 14-Breather plug 15- Breather plug base 16-Bolt
17-Spring washer 18-Bolt 19-Spring washer 20-End cap
21-Steel ball 22-Planet carrier 23-O-RING 24-Planetary axle
25-Pad 26-Spacer bush 27- Planetary gear 28-Gear rim
29-Hub 30-Nut 31-Nut 32-Double-end bolt
33-Spring washer 34-Nut 35-Bearing 36-Skeleton oil seal
37-Bearing 38-O-RING 39-Skeleton oil seal 40-Spring washer
41-Nut 42-Bolt 43-Spring washer 44-Spacer bush
45-Anti-loose block 46-Bolt 47-Brake drum
Fig.4-2 Drive axle structure

1. main reducing gear 2.relief plug 3.axle housing assy 4.wet brake

5.hub reduction gear assy 6.screw 7.half shift 8.washer

9. washer 10. bolt

Fig. 4-2-1 Wet drive axle structure

27
 Fig. 4-3 Main reducing gear structure

Fig. 4-3-1 Main reducing gear structure

2.Periodical technical maintenance

2.1 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.
28
 ④Check brake pad wear condition.
⑤Check each part oil leak condition and repair in time. All sealing elements are not
allowed to reuse once dismantle.
2.2 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.Drive axle oil adding way

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.

Breather plug

Oil level plug

Drain plug

Fig. 4-4

Lubricating part Lubricating oil type Oil capacity（L）

≈10 5-7T
Main reducing gear GL—5 85W/90 Gear oil
≈10 8-10T

≈1.5（One side） 5-7T

Hub reduction gear GL—5 85W/90 Gear oil
≈2.5（One side） 8-10T

29
 W65G\W75G\W95G:
Lubricating part Lubricating oil type Oil capacity（L）

Mobil 424 Hydraulic ≈5 5-7T

Main reducing gear
transmission oil ≈8 8-10T

Mobil 424 Hydraulic ≈1.5（One side） 5-7T

Hub reduction gear
transmission oil ≈2.5（One side） 8-10T

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.

Fig.4-5

5. 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

30
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.

31
 6. Fault diagnosis and corrections

Condition Possible reason Corrections

·Drive axle supporting cover and chassis
Tightening
connecting bolt loose
·Wheel nut loose Tightening

·Other installing parts loose Tightening

Abnormal noise
Before correction, make sure ·Hub bearing damage or wear Replace
noise is from half axle but not
Re-adjust
from hub reduction gear or ·Bad gear engagement
assemble
main reducing gear.
·Incorrect hub bearing adjustment Adjust

·Half shaft spline wear Replace

Add
·Insufficient lubrication
lubricating oil
·Wheel nut loosen Tightening

·Wheel deformation Replace

Unstable move ·Hub bearing wear or damage Replace

This diagnosis and corrections
·Drive axle supporting cover and chassis
is also apply to rear wheel Tightening
connected bolt loosen
·Incorrect hub Bearing adjustment Adjust

·Incorrect tyre pressure Adjust

·Axle oil sealing wear or damage Replace

Replace paper
·Incorrect main drive device installation
gasket

·Fill oil and oil plug loosen Tightening

Oil leakage
Improve
·Bad lubrication
lubrication
Add oil to
·Over high oil level specified
position

32
7. Dismantle and assemble

7.1 Dismantle and install of drive axle

assembly
Dismantle
(1) Pull the forklift end, and support the
carriage with block or safe
permanent seat.
(2) Dismantle mast
(3) Dismantle front wheel Fig.4-7
(4) Low container of the axle housing (7) Hoist drive axle with lifting gear and
will drain the gear oil in rear slop.
housing.
(5) Dismantle brake connecting nut
from the left & right brake pump.
Notice：
Plug rubber plug in the brake pipe
mouth to avoid brake fluid flowing.

Fig.4-8
(8) Dismantle supporting cover and
frame connected bolt.

Fig. 4-6
(6) Dismantle drive axle

Warning：
Be careful to avoid brake oil pipe and
other spare parts damage.

Fig.4-9
(9) Dismantle drive axle.

Assemble of drive axle assembly is

opposite to dismantlement.

33
7.2 Dismantle and assemble of hub Fig.4-12
reduction gear (7) Dismantle drum brake
Dismantle
(1) Dismantle pinion from drive axle
hub until discharge gear oil
completely.

Fig.4-13
(8) Rap along the bearing by stick
matted with soft cloth and dismantle
inner bearing.

Fig. 4-10 Assemble

(2) Pull out half shaft Assemble order is opposite to
dismantlement.
·Place hub outer bearing into hub stably.
Check if the deflation mouth of the
oil seal faces outside and assemble.
·Bearing adjustment
Adjust bearing according to planet
carrier, half shaft and gear ring.
1) Apply lubricating grease to the taped
roller bearing.
2) Screw down hub bearing lock nut
Fig. 4-11
until hub can not be turned by one
(3) Dismantle brake
hand.
(4) Dismantle locking ring and locking
3) Rotate lock nut 60° to opposite
nut.
direction according to above
(5) Dismantle wheel gear from hub.
position.
(6) Connect hub and brake to dismantle.
4) Turn hub 2-3 rings to opposite
direction to match bearing bracket.
5) Fasten lock nut again until hub can
not be turned by one hand. Then turn
nut 60°to opposite direction
7.3 Main reducing gear dismantle and
assemble
Dismantle drive axle and main reducer from
the truck.

34
(1) Support the rear wheel with wood. Fig.4-15
(2) Rise the front forklift, put a wood at Dismantle
under each supporting cover. Before dismantle, please fully check the
Warning：Be careful and put a wood flank clearance of drive and driven
under counterbalance weight. spiral bevel gear, check engage area
(3) Make sure the bearing cover safely among drive gear, driven gear and half
put on the block. axle gear, then diagnose the correct fault
(4) Dismantle mast and relevant parts. Dismantle differential carrier
(5) Drain oil in the drive axle housing. (1) Mark on left & right differential
(6) Dismantle half axle(the same as carrier and right ＆ left bearing
drive axle dismantle). bracket.
(7) Jack up the main drive housing. (2) Dismantle lock nut plate at the two
(8) Dismantle drive axle from the main sides of right＆left bearing bracket.
reduction gear.
(9) Dismantle brake oil pipe.
(10) Safely dismantle supporting cover
connected bolt
(11) Dismantle drive axle and main
reduction gear carefully.

Fig.4-16
(3) Release bearing bracket mounting
bolt slightly, and dismantle adjusting
nut.
Fig.4-14
(12) Dismantle main reducing gear
mounting bolt, and separate main
reducing gear.
Assemble order is opposite to
dismantlement.

Fig.4-17
(4) Dismantle bearing bracket mounting
bolt and right＆left bearing bracket.
(5) Hoist reducer assembly with
calabash or other way, be careful not
to damage outside bearing area.

35
 thrust washer of half axle
gear

Thrust washer

Half axle gear

Thrust washer

Fig.4-18 Planetary gear

(6) Dismantle the mounting bolt of Fig.4-21
spiral bevel gear, pre-apply Letai (9) Dismantle bearing from left & right
262 glue to bolt. Dismantle spiral differential carrier with bearing
bevel gear. puller.
Dismantle drive spiral bevel gear
(1) Dismantle snap ring and guiding
bear from drive spiral bevel gear with
bearing puller.

Fig.4-19
(7) Dismantle differential carrier
connecting bolt, disassemble
differential carrier. Pre-apply Letai
262 glue to bolt
Fig.4-22
(2) Dismantle bearing bracket and cover
connecting bolt.
(3) Dismantle flange locking round nut,
washer, flange, cover, oil seal and spacer
bush.
(4) Press the drive spiral bevel gear and
pull out bearing bracket.

Fig.4-20
(8) Dismantle planetary gear, thrust
washer, planetary gear shaft and

36
 Assemble
Tips:
·Use clean gear oil when re-assemble.
·When assembling differential conical
roller bearing and adjusting nut, left &
right spare parts should not be mistaken.
·Do not forget to assemble oil seal and
gasket.
· Confirm that the drive and driven
spiral bevel gear is in pair.
Make sure the above tips and do the
opposite order to dismantle and do
Fig.4-23 proper adjustment.
(5) Dismantle adjusting washer and Assemble drive spiral bevel gear
washer from drive spiral bevel gear. Pull (1) Press the out bearing to bearing
out conical roller bearing with bearing bracket.
puller.

Fig.4-26
(2) Press in guide bearing to the top of
Fig.4-24 drive spiral bevel gear and install
(6) Dismantle conical roller bearing snap ring.
from bearing bracket. (3) Press in conical roller bearing.

Fig.4-25 Fig.4-27

37
(4) Pre-adjust rive spiral bevel gear differential carrier.
assembly (3) Measure the backlash between half
① Install any adjusting washer and axle gear and planetary gear pair,
washer to drive spiral bevel gear (Teeth backlash: (0.19-0.25mm) If
the backlash is not in this scope, please
change planetary gear and half axle
gear.)

Notice：
Planetary gear shaft should not move
when measuring.
(4) Install half axle gear and thrust
washer

Fig.4-28

Notice：
To avoid over preload, choose some
thick adjusting washer firstly and
decrease thickness gradually until gain
proper preload.
②Install drive spiral bevel gear into
bearing bracket. Fig.4-29
③Place the up drive spiral bevel gear (5) Press half axle bearing surface into
axle to spacer bush, oil seal, bearing differential right shell.
bracket adjusting washer, cover (hand (6) Mark on the differential carrier
brake support) and flange. successively.
④Choose adjusting washer until locking (7) Assemble differential carrier.
nut arrives defined tightening torque Pre-apply Letai glue to connecting
343-441N.m, starting torque of drive bolt and tighten to specified torque
spiral bevel gear is 2.0-3.9N.m. 100N.m.
⑤After preload, exit flange and cover (8) Assemble spiral bevel gear.
(brake support). Pre-apply Letai glue to connecting
(5) Place oil seal applied with bolt and tighten to specified torque
lubricating grease into cover (brake 120N.m.
support).
(6) Install spacer bush and flange.
Install differential carrier
(1) Press the half shaft bearing surface
facing the differential carrier
(2) Install half axle gear and matched
planetary gear, gear shaft and
matched adjusting washer to
38
 Fig.4-30
Assemble reducer housing Fig.4-32
1) Install drive spiral bevel gear (3) Do measuring mark when observing
assembly into reducer housing. Add dismantle, pre-tighten bearing bracket
any adjusting washer, tighten bolt, and adjust with side lock nut.
connecting bolt to fixed torque (4) Pre-tighten lock nut and push the
45N.m. bearing to the end.
(5) Measure teeth backlash of drive and
driven spiral bevel gear, adjust the teeth
backlash to 02-0.35mm by lock nut.

Fig.4-31
·Drive spiral bevel gear needs to place
into reducer housing smoothly, if Fig.4-33
damage the snap ring, please change (6) Adjusting the teeth backlash to
it. 0.2-0.35mm by the above way, lock the
·When assembling washer, it needs nut completely and make the bearing pre
combined type with mono-sheet type. tightening force as 29-49 N.m.
(2) Put the roll bearing outer ring to (7) Screw down bearing bracket
mounting bolt tightening torque 170
differential assembly and then put into
N.m.
the differential housing.
(8) Mount locking plate and screw down
adjusting bolt 10-15 N.m.

39
V. Steering system
Steering system is mainly composed of steering device, priority valve, steering oil pipe and
steering axle.
Steering device consists of steering wheel, steering column and hydraulic steering gear.
Steering wheel and steering column is adjustable, and the adjusting angle is 6°to adapt
different drivers‘ needs. In the engine misfire condition, rotate the steering wheel with 1kg
power, after release the hand, the steering wheel can automatic return about 10°.

1.Hydraulic steering gear

1.1 Summarize
This hydraulic steering gear is load sensing type. There is a LS mouth in the steering gear
connected to priority valve that makes steering load pressure signal transmit to priority valve
through oil pipe, which controls the oil quantity supply to the steering gear.
In the load sensing type steering system, whatever load pressure or steering wheel speed, it
can prioritise corresponding flow according to oil line requirement, and guarantees the
steering reliable, sensitive and light.
Besides the needed oil pump output flow to the steering system, the rest one is supply to
working oil, thus eliminates power loss of over oil supply to steering oil line, and improves
system efficiency.

Fig.5-1 Steering device diagram

40
 Fig.5-2 Full hydraulic steering gear schematic diagram
1.2 Assemble notice
1) When assembling the steering gear, make sure in the same axle with steering column, and
there should be axial clearance. Check if steering wheel return flexible after assemble.
Assemble should follows the following: ―P‖—connect muti-way valve Ps mouth;
―T‖—connect hydraulic oil tank; ―A‖—connect steering cylinder lift chamber;
―B‖—connect steering cylinder right lift chamber; ―Ls‖—connect muti-way valve Ls
mouth.
2) Make sure the oil clean to avoid dirt block steering gear inner part and cause steering
malfunction. Thus it needs check filter element of filter and oil work condition, replace
when necessary.
3) If there occurs to heavy steering or malfunction during steering gear use, find out the
reason firstly, it cannot wrench the steering wheel hard, or dismantle the steering gear,
otherwise it may damage the parts. It is prohibited to rotate the steering wheel by two
persons.
1.3 Diagnosis and corrections

Fault Probable reason Phenomenon Corrective action

Combined part bolt Screw down bolt

loosen
Oil leakage

Combine face or
journal sealing ring Replace sealing ring
damage
Gasket damage Replace gasket

Insufficient oil Turn steering wheel slowly Check if oil pump works
supply to oil pump is light and fast is heavy.. normal
Hard steering

Foam in the oil and give out

Air in the steering irregular noise, rotate the Eliminate air in the system
steering wheel but the and check if oil suction pipe
system cylinder works sometimes leaks
and stop for a while.
Oil level is lower
than specified Add oil to specified height
position

41
 Oil viscosity is too
Use specified oil
big
Steering wheel is heavy If steer ball losses, install
Ball check valve when fast steer or slow the ball; if steel ball is
invalid. steer, and no steering blocked by dirt, clean it.
pressure
Steering system No load or light load Check out the reason,
pressure is lower steering is light, but much recover or improve system
than working load steering is heavy. pressure(not exceed 16Mpa)
pressure
Steering wheel cannot
Spring leaf break off automatically return in Replace spring leaf
middle
Steering failure

Dial pin or universal No obvious pressure runout Replace dial pin or

driving shaft open
or cannot turn universal driving shaft
break or deformation
Tooth space engagement
Rotor or universal Steering wheel cannot rotate between compact point teeth
driving shaft open or move from side to side on universal driving shaft
break or deformation and on the rotor
steering

Overlarge stator Steer after misfire, steering

human
No

radial clearance or wheel turns but the cylinder Replace stator

axial clearance keep still.

42
2.Steering axle

This end is no
clearance

Fill lubrication oil with Adjust the

oil cup M6, then remove clearance less
oil cup, put the dust than 0.2mm.
Add lubrication oil cover, full fill lubrication
oil and clamp the dust
cover.

1.Housing 2.Wheel 3.Steering cylinder 4.Stop bolt 5.Open nut

6. Draw bar device 7.Axis pin 8.Bearing 9. Steel cover 10.Bearing

11.Main pin 12. Right knuckle 13.Oil seal 14.Bearing 15.Hub
16.Nut 17. Tyre bolt 18.Tyre nut 19.Bearing 20. Thrust gasket
21.Lock nut 22. Hub cover 23.Bolt 24.Oil cup 25.Cover plate
Fig.5-3 Steering axle

43
2.1 Technical parameters
King pin inclination angle 0°
king pin caster angle 0°
Steering wheel camber angle 0°
Toe-in 0°
5-7T 80°
Max. inner wheel turn angle
8-10T 77°
Max. Outer wheel turn angle 53°

2.2 Steering axle dismantle, disassemble and assemble

Dismantle
(1) Support the front wheel with block and discharge forklift counterbalance.
(2) Jack-up the rear chassis, make the rear wheel 1cm off the ground, and support the chassis
with block;
(3) Dismantle steering wheel;
(4) Dismantle steering pipeline;
(5) Support the steering axle two ends with stand or jack up, and dismantle bearing support;
(6) Hoist the steering axle with hang truck.
Disassemble
Hub
(1) Jack-up the forklift and support with blocks;
(2) Dismantle tyre;
(3) Dismantle hub cover, locking nut and thrust gasket;
(4) Pull out hub assembly;
(5) Dismantle inner ring of the bearing
Notice: a. do not drop taper bearing
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: a. Push steering king pin to avoid drop.
b. Take down the whole set of knuckle (including thrust bearing, dustproof shell,
shim).
Steering cylinder
(1) Dismantle anti-dust cover, axis pin, snap ring and draw bar device that connected the
steering cylinder;
(2) Dismantle steering oil pipe;
(3) Dismantle steering cylinder and axle connected bolt.
(4) Take out steering cylinder from the axle.
Installation
Install order is opposite to the dismantling order, please be cautious:
(1) Install thrust ball bearing;
(2) End play is less than 0.2mm(End play gained from regulation shim);
44
(3) When assembling cylinder, pay attention not to crash the oil pipe connector or wipe the
cylinder piston rod;
(4) After assembling, piece 9 axis pin can rotate freely, cylinder and draw bar move stable;
(5) Apply lubricating grease to the installed oil cup and hub bearing

2.3 Steering axle check and adjustment

2.3.1 Knuckle check:
(1) Check if there is flaw with knuckle oil color inspection method or oil immersed
hammering method;
(2) Check fit clearance of knuckle king pin and steeling axle main pin hole;
(3) Check if there is wear in the needle bearing hole;
(4) Check if there is damage or chap on knuckle arm plate taper hole.
2.3.2 King pin tension check:
Check if there is wear, damage or erosion on king pin and bearing sliding surface. If wear
exceeds limit, replace together with its needle bearing.
2.3.3Check of the king pin and steel jacket clearance
(1) Adjust the hub bearing pre-tightening to specified scope;
(2) Hold the wheel and hub, push and pull, if there is obvious looseness, it means there is over
large clearance between steering knuckle and steel clearance.
2.3.4 Check and adjustment of end play of knuckle and steering axle
(1) Check if end play of knuckle and steering axle: hold the knuckle axle, shake up and down,
if there is obvious looseness, it means there is over large clearance between them;
(2) Adjustment of end play of knuckle and steering axle is adjusted through increasing or
reducing shim thickness.
2.3.5 Adjustment of hub bearing pretension load
(1) Apply lubrication grease to the hub and steering nut, and also to the oil seal lip;
(2) Fix bearing outer ring to the hub, and install the hub to the knuckle;
(3) Rotate the hub with one hand, and the other hand screw down the nut to the end, and then
return 1/6 circle in negative direction;
(4) Rotate the hub 2-3 circles and rotate the bearing roller in place;
(5) Repeat ③ action, then put the thrust gasket and locking nut;
(6) Rotate around 2-3 circles, measure initial torque end play, it need satisfy: end play ≤0.08
㎜, initial torque ≤25.5N(at hub bolt). Otherwise, repeatedly adjust to then requirement.
2.4 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. Refer to fig. 6-3.

45
1-Piston 2- Dustproof ring 3- Guiding sleeve 4-O-ring 5-Oil seal 6-Composite bush
7- Combined seal 8- O-ring 9- O-ring 10-Cylinder body 11-Bush
Fig.5-4 Steering cylinder

46
 VI. Brake system
Brake system is composed of service brake system and park brake system. Service brake is
front dual tyre hydraulic boosting brake and park brake is mechanical barrows brake.

1.Data
Hydraulic supercharge, oil pressure, internal expanding
Model
front wheel mechanical brake
Drive axle
brake

Clearance between friction lining and

0.25-0.5
brake drum ㎜
Friction lining wear limit（To rivet
Larger than 0.5
head）㎜
Model X700-640008-G00
Type With accumulator, pedal, central hydraulic brake valve
Total travel mm 12.5
Brake valve

Nominal flow rate L/min 25

Nominal pressure MPa 16
Brake pressure MPa 10.5±0.5
Relief valve adjusting pressure MPa 13
Allowed oil temperature ℃ -20～110
Oil type L-HM32 anti-brake oil
X700-640001-G00（5-7T）
Model
X1000-640001-G00（8-10T）
Alert pressure MPa 6.5
Overflow pressure MPa 13
Accumulator

Initial oil filling pressure MPa 5.2±0.2

Burst pressure MPa 28
No lower than GB/T 14039 18/16 leve or NAS 1638
Oil cleanness
10level
Oil type L-HM32 anti-brake oil
Max. volume ml 100
Effective volume ml 75
Internal expanding mechanical, work on double change
Model
brake
Hand

output shaft through parking brake gear.

Less than 80（With 147N tensile force, at the hand brake
Stroke mm
handle.）
Free stroke mm 5～7.5
Brake
pedal

Pedal height mm 145±5

Stepping height mm Larger than 60
Free stroke mm 145±5
Inchin
pedal
g

Pedal height mm 18

47
 CPCD50/60/70-XW65G、CPCD50/60/70-XW95G
Model X700-640008-G00
Type With accumulator, pedal, central hydraulic brake valve
Total travel mm 12.5
Brake valve

Nominal flow rate L/min 25

Nominal pressure MPa 16
Brake pressure MPa 10.5±0.5
Relief valve adjusting pressure MPa 13
Allowed oil temperature ℃ -20～110
Oil type L-HM32 anti-brake oil
Model X740-640002-G01

Alert pressure MPa 6

Overflow pressure MPa 13
Initial oil filling pressure MPa 5
Accumulator

No lower than GB/T 14039 18/16 leve or NAS 1638

Oil cleanness
10level
Oil type L-HM32 anti-brake oil
Alarm switch voltage V 12～48
Max. volume ml 276
Effective volume ml 178
Internal expanding mechanical, work on double change
Model
brake
Hand

output shaft through parking brake gear.

Less than 80（With 147N tensile force, at the hand brake
Stroke mm
handle.）
Free stroke mm 5～7.5
Brake
pedal

Pedal height mm 145±5

Stepping height mm Larger than 60
Free stroke mm 145±5
Inchin
pedal
g

Pedal height mm 18

48
 CPCD80/100-XW75G
Model X700-640008-G00
Type With accumulator, pedal, central hydraulic brake valve
Total travel mm 12.5
Brake valve

Nominal flow rate L/min 25

Nominal pressure MPa 16
Brake pressure MPa 10.5±0.5
Relief valve adjusting pressure MPa 13
Allowed oil temperature ℃ -20～110
Oil type L-HM32 anti-brake oil
Model XR1000-640400-G00

Alert pressure MPa 6.5

Overflow pressure MPa 13
Accumulator

No lower than GB/T 14039 18/16 leve or NAS 1638

Oil cleanness
10level
Oil type L-HM32 anti-brake oil
Alarm switch voltage V 48
Max. volume ml 300
Effective volume ml 130
Internal expanding mechanical, work on double change
Model
brake
Hand

output shaft through parking brake gear.

Less than 80（With 147N tensile force, at the hand brake
Stroke mm
handle.）
Free stroke mm 5～7.5
Brake
pedal

Pedal height mm 145±5

Stepping height mm Larger than 60
Free stroke mm 145±5
Inchin
pedal
g

Pedal height mm 18

49
2.Fault diagnosis and corrections

Main brake
Fault Probable cause Corrective action
Oil leakage in brake lines. Correct and replenish.
Air in brake lines. Bleed air.
Water or oil on linings. Clean or replace.
Insufficient Uneven wear or contact of brake Grind or replace.
brake linings.
force Improper functioning of brake valve Correct or replace.
Clogged oil lines. Clean.
Leakage of caliper disc brake piston Replace O-ring
cavity
Uneven tire pressure. Adjust.
Improper relief valve adjustment Adjust.
Water or oil on brake linings. Clean or replace.
Foreign pieces in brake drum. Clean.
Unequal braking Deteriorated lining surface. Grind or replace.
(forklift truck Improper contact of linings. Grind or correct.
veers to one Worn lining Replace.
side) Worn, warped, rusted or damaged Correct or replace.
brake drums.
Improper operation of wheel cylinder. Correct or replace.
Improperly adjusted wheel bearing. Adjust or replace.
Clogged oil lines. Clean.
No free play of brake pedal. Adjust.
Abnormal operate of caliper disc brake Adjust or replace.
Faulty piston cup. Replace.
Weak or broken return springs. Replace.
Brake dragging Blockage of hydraulic power brake Clean.
valve return hole.
Clogged oil lines. Clean.
Hydraulic brake valve out of adjusting. Adjust or replace.
Lining surface harden or foreign Repair or replace.
pieces on it.
Warped back plates or loosed blots. Repair or replace.
Brake noise Brake shoes warped or improper install. Repair or replace.
Worn linings. Replace.
Loose wheel bearing. Repair.

50
Hand brake
Fault Probable cause Corrective action
Friction lining wear
Replace.
Large travel of control rod
Adjust.
Insufficient Ratchet wear or damage
Replace.
brake Hand brake dragline lengthen
Replace.
Water or oil on linings
force Clean or replace.
Uneven wear or contact of friction
Grind or correct.
linings.

3.Pedal height, free stroke

Brake pedal adjustment:
(1) Adjust brake pedal stop bolt, make the pedal pad point P 145 ㎜±5 ㎜ from the front base
plate and screw down the bolt nut.
(2) Adjust hydraulic booster manipulator push rod length, and make the idle stroke of the
point P to point Q is 1 ㎜～3 ㎜, and lock the nut;
(3) When step the brake pedal 10 ㎜～20 ㎜ little by little, the brake light switch is completely
connected, and release the foot to this state, brake light switch should disconnect.
Inching pedal adjustment:
(1) Adjust R bolt, make the pedal pad point P 145 ㎜±5 ㎜ from the front base plate and
screw down the bolt nut.
(2) Adjust the brake pedal after adjustment.

Fig.6-1 Pedal adjustment

51
4. Brake valve and accumulator

4.1 Brake valve

Brake valve is composed of valve body, closed valve rod, responding piston, slide valve,
pushrod valve, check valve and spring. Refer to fig. 6-2.

Fig. 6-2 Brake valve

1.Bolt 2.Valve stand 3. Closed valve rod 4.Guide sleeve 5. Responding piston
6.Return spring 7.Slide valve 8. Spring 9. Cup 10. Push rod piston 11.Stop nut
12. check valve 13.Push rod
It realizes forklift brake through changing oil line direction. In general condition, from
reversing multi-way valve oil P mouth to BR mouth to push caliper disc brake piston generate
brake; accumulator oil (PA mouth) to BR mouth to push caliper disc brake piston generate
brake when parking. N mouth is to hydraulic steering gear oil port, steering oil line and brake
oil line can separately work, or united work. No interference when united work.
4.2 Accumulator
Combined spring O-ring Snap ring O-ring Relief valve Check valve

Piston Alarm switch

Fig. 6-3 Accumulator

When the engine stop work or the oil pump occurs to fault, accumulator can be used as
abnormal energy to satisfy brake need, and the energy storage is spring type.
The figure shows no energy storage state, and the alarm switch is in keep noise state.

52
When operating brake pedal, the oil pressure reaches above 5Mpa, the check valve open and
let oil enter into accumulator, so that push piston move left to compress the combined spring
and build up the oil pressure.
Meanwhile piston left shift makes the switch control lever at the alarm switch move left under
the spring force, and fall the spring valve spool down the switch control lever groove, then the
alarm switch is in no noise state.
With the pump oil pressure increasing, piston left shift stroke is limited by the stop tube in
middle of combined spring, at this time, the accumulator has max. energy, oil pressure is
10Mpa, and the value is limited by relief valve opening and closing characteristic.
Brake valve and power accumulator system schematic diagram. Refer to fig. 6-4

Fig. 6-4 Schematic diagram

Use notice：
·Brake pipeline should install after discharge air in the pipeline.
·Make cleanness of the hydraulic oil.
·Guarantee clearance between push rod and push rod piston is (0. 5～1) mm

△! Warning
Before repair hydraulic system, shut down the vehicle, step the brake pedal 5 to 10 times
continuously to release accumulator energy, otherwise the repairman may have major
accidents and endanger personal safety.
Set up the front axle, if the front wheel can be rotated, it mean fully released. Only after
fully release the energy can proceed to the next operation.

53
5. Hand brake

Hand brake is internal expanding mechanical hand brake, its brake base installed to the box,
brake drum is fixed to supporting flange, supporting flange is connected to parking brake
shaft through spline, parking brake gear on parking brake shaft often engaged with double
change output shaft. When truck moves, parking brake gear drives brake drum operate. When
pulling tight the brake handle, make brake shoe open through brake flexible shaft, enclasp the
brake drum, brake the gear on double change output shaft by the parking brake gear, thus
realize truck parking brake.
During use and maintenance, if any bad hand brake, check and adjust in time. When the hand
brake idle stroke increases but cannot reach the specified stopping requirement, adjust in time.
Friction plate and brake drum replace
1. Release brake drum clamp nut and release brake drum;
2. Take out parking brake shaft cotter and dismantle supporting flange;
3. Check friction lining, if wear is serious, replace new one in pairs.
4. Check brake drum surface, if rust or scratch, apply 120#-150# abrasive paper and sanding
to deal with friction lining contact surface; if abrasion seriously, replace new brake drum;
5. Installing order is to the opposite；
6. Check brake drum and brake shoe correct contact;
Adjust when the free stroke of hand brake handle is over large Firstly release the hand brake
control lever to limiting position, adjust handle head screw with screw driver, screw down in
clockwise, and unscrew in counterclockwise.

1.Output shaft 2.Gear 3. Parking brake shaft 4. Parking brake gear 5.Spacer bush
6. Internal expanding mechanical brake 7. Gasket 8.Bolt 9. Axis elastic gasket
10.Sealing ring 11.Supporting flange 12. Gasket 13.Bolt 14.Brake stand
15. Gasket 16.Nut 17.Pin 18.Paper pad
19. Gasket 20.Bolt 21.Gasket 22. Bolt
Fig. 6-5 Hand brake

54
 Internal expanding mechanical hand brake

Fig. 6-6.Parking brake system diagram

55
Instrument stand
5.1 Parking brake system fault diagnosis and corrections

Fault Probable cause Corrective action

Friction plate wear Replace

Large control rod stroke Adjust
Insufficient brake Ratchet wear or damage Replace
force Hand brake dragline lengthen Replace
Oil or water on friction lining Clean or replace
Uneven friction lining contact or wear Grind or replace

5.2 Hand brake control lever adjustment

Adjust when the free stroke of hand brake handle is over large. Firstly release the hand brake
control lever to limiting position, adjust handle head screw with screw driver, screw down in
clockwise, and unscrew in counterclockwise.
Adjusting main point: (1) Adjust internal mechanical hand brake before adjust the hand brake
control lever; (2) Mount brake dragline, fasten nut B; (3) Adjust nut A until the handle
force(point P) is no larger than 15 kg when locking the handle; (4) Apply sufficient lithium
base grease to guide rail C.
5.3 Internal expanding mechanical hand brake
Internal expanding mechanical hand brake lies in the bottom right of hydraulic transmission
gear box motor, its brake base installed to the box, brake drum is fixed to supporting flange,
supporting flange is connected to parking brake shaft through spline, parking brake gears on
parking brake shaft often engaged with gears on hydraulic transmission gear box output shaft.
When truck moves, parking brake gear drives brake drum operate. When pulling tight the
brake handle, make brake shoe open through brake flexible shaft, enclasp the brake drum,
brake the gear on double change output shaft by the parking brake gear, thus realize truck
parking brake.
During use and maintenance, if any bad hand brake, check and adjust in time. When the hand
brake idle stroke increases but cannot reach the specified stopping requirement, adjust in time.

56
 Output shaft

Gear

Parking
brake shaft

Parking
brake gear
Internal expanding mechanical
hand brake

Fig. 6-7

5.4 Friction plate and brake drum replace

(1) Release brake drum clamp nut and release brake drum;
(2) Take out parking brake shaft cotter and dismantle supporting flange;
(3) Check friction lining, if wear is serious, replace new one in pairs.
(4) Check brake drum surface, if rust or scratch, apply 120#-150# abrasive paper and sanding
to deal with friction lining contact surface; if abrasion seriously, replace new brake drum;
(5) Check brake drum and brake shoe correct contact;
Installing order is to the opposite；

6.Service brake（W65G/W75G/W95G）

The truck equipped with wet brakes. Wet brakes include friction plate assembly, brake pads,
piston, cylinder, brake housing and other components. When connecting the brake and the
drive axle, the oil must be cleaned before connecting.

57
 1.screw 2. brake shell 3.oil seal 4. piston 5.washer
6.cylinder 7. washer 8.plug 9.oil tube 10.plug
11.bolt 12.Washer brake pad 13.Friction disc assembly 14.tow way joint 15.oil tube
16. washer 17. bolt
Fig. 6-8-1 wet brake(5t-7t)

1. oil seal 2. brake shell 3.Pin shart 4. Washer brake pad 5.Friction disc assembly
6. o-ring 7. bolt 8. washer 9. piston 10. washer
11. cylinder 12.washer 13.plug 14.plug 15.washer
16.joint 17.bolt 18.bolt 19.bolt
Fig. 6-8-2 wet brake 1 (8t-10t)
Wet brake maintain：
1)Lubricating oil
Brake use Mobil 424 hydraulic transmission lubricants, single brake oil is about 2.5L,
regularly check the brake oil and change oil (first 500 hours, followed by 1000 hours or one
year).
58
2)Brake temperature
When normal operating the brake temperature not higher than 90℃, if the high strength brake
temperature anomalies, (greater than 130℃ for half an hour) should inspect the brake
disassembly.
3)Oil seal
The brakes have two oil seals, gaskets and rectangular ring combinations need to regularly
check the leak: a combination of seals seal brake oil, can observe the outer brake fluid to
determine whether there is leakage or not; rectangular ring seals on the high-pressure piston
oil leak judgment method: turn off the engine, slam the brake pedal to maintain five minutes
to see if there is a low pressure alarm sounded, if so, need to replace the rectangular ring.
4)Change splined hub
Splined hub which in wheel hub, when replacement note spline hub and wheel hub
combination flat top coat sealant Loctite 598, connecting bolt paint Loctite 262, bolt
tightening torque 90-110 N.m (Figure 6-9).
5) Change friction plate
When the friction plate grooves polished, need to replace them in pairs and dual steel friction
plate, friction plates and steel plates spaced alternately fitted into the brake housing, the first
piece and the last piece are steel and not installed backwards (Figure 6 -10).

Paint sealant surface

Fig.6-9

Fig.6-10

59
 oil level port

Fig.6-11

7. Hydraulic brake malfunction diagnosis

In the parking state, step the brake pedal, generate pressure in brake system, continue stress
force, if pedal gradually low down, leak on hydraulic system surface, check leakage and oil
spots, then you can find out detailed fault position, tighten, repair or replace.
Step the brake pedal, if it can be stepped to the end, it means insufficient brake fluid,
overlarge brake clearance, overlarge pedal free stroke or air in the system. Check the reason
further and eliminate it.
If continually step the pedal, its working stroke decreases, that is pedal height gradually
increases. Otherwise the master pump oil hole blocks and makes the oil in the pump cannot be
increased.

8. Exhaust of air in the hydraulic system

Park the truck on flat and solid road surface, shut down and pull up the hand brake. One
person continually step the brake pedal and generate enough pressure; another person under
the truck, releases bleed screw, exhausts air, and then screws the bleed screw. After repeat this
action several times until fully exhausts the air. After that, add enough brake fluid in time.

60
 VII. Hydraulic system

1.Oil pump
As to fig. 7-1, there is one left oil pump and one right oil pump, with the same structure and
opposite rotation. Gear pump axial is an external gear pump of balanced outer clearance
autocompensation and radial hydraulic. Its gears adopt asymmetric tooth profile special gears,
owns little volume and low noise compared with symmetrical tooth profile gears of the same
displacement.

Connect multi-valve P2 mouth Connect multi-valve P21 mouth

Engine side

Oil pump 2
Oil pump 1

Connect hydraulic oil tank

Connect hydraulic oil tank
Fig. 7-1-1 Oil pump schematic diagram(except W65G、W75G、W95G)

Fig. 7-1-2 Oil pump schematic diagram(W65G、W75G、W95G)

61
1.1 Performance parameter

5-7T(EXCEPT W65G\W95G)：
Item Oil pump1 Oil pump 2

Model CBK-G436-AFФ CBK-G423-AFФL

Rotation direction Right-handed rotation Left-handed rotation

Nominal displacement （ml/r） 36 23

Rated pressure （MPa） 25 25

Rated speed （r/min） 2500 2500

Volumetric efficiency[Rated
≥92 ≥92
speed]（%）

5-7T(W65G\W95G)：
Item Double gear pump

Model 7993002J

Rotation direction Left-handed rotation

Nominal displacement （ml/r） 34(Oil pump 1)/31(Oil pump 2)

Rated pressure （MPa） 28(Oil pump 1)/22(Oil pump 2)

Rated speed （r/min） 3000

8-10T(except W75G)：
Item Oil pump1 Oil pump 2

Model CBK-G436-AFФ CBK-G430-AFФL

Rotation direction Right-handed rotation Left-handed rotation

Nominal displacement （ml/r） 36 30

Rated pressure （MPa） 25 25

Rated speed （r/min） 2500 2500

Volumetric efficiency[Rated
≥92 ≥92
speed]（%）

62
8-10T(W75G)：
Item Double gear pump

Model 7993002K

Rotation direction Left-handed rotation

Nominal displacement （ml/r） 41(Oil pump 1)/34(Oil pump 2)

Rated pressure （MPa） 28(Oil pump 1)/21(Oil pump 2)

Rated speed （r/min） 3000

1.2 Common fault and corrections

Fault Probable cause Corrective action

1. Pump does not rotate or low speed; 1. Make sure if oil pump is normally connected
No oil from oil pump or insufficient

with prime motor;

2. Incorrect steering; 2. Change prime motor rotation or change to
opposite rotated gear pump;
3. Insufficient oil in oil tank; 3. Add oil to specified position;
4. Oil inlet and outlet reversed; 4. Correctly connect according to the nameplate;
5.Oil absorption pipeline or filter 5. Check pipeline, clean or replace oil filter;
blockage;
6. Intake duct leakage; 6. Check intake duct, seal and tighten;
7. Pump cover bolt loosen; 7. Screw down bolt;
8. Leakage in the system; 8. Check system and repair leakage point;
9. Over high or low of oil viscosity; 9. Use recommended oil;
10. Over low or high oil temperature; 10. Preheat or cool down, use recommended oil;

1. Overflow valve setting pressure 1. Check, adjust overflow valve pressure or replace
Low pressure

too low or not work; overflow valve;

2. Intake oil; 2. Check inlet line and eliminate suction condition;
3. Leakage in the system; 3. Check system and repair leak point;
4. Bubble in the oil; 4. Add oil or immerse fuel return port in the oil；
leakage

1. Sealing element ageing 1. Repair at repair station or factory;

Oil

2. Coupling screw or joint loosen; 2. Tighten screw or coupling;

63
 1. Inlet line or filter blockage; 1.Check pipeline, clean or replace oil filter;
Low noise or big vibration 2. Overlarge oil absorption height; 2. Reduce oil suction height;
3. Overlarge oil viscosity; 3. Use recommended oil;
4. Intake oil; 4. Check oil suction line, eliminate inspiration
5. Different axle of pump spindle and condition;
prime motor; 5. Reinstall, make axiality less then 0.05;
6. Bubble in the oil; 6. Replenish oil;
7. Over high pump speed; 7. Lower down speed;
8. Over high pump pressure; 8. Lower down hydraulic
overheating
Severe

1. Over small installing clearance; 1.Check and repair

2. Over little oil tank volume; 2. Enlarge oil tank volume;

2. Multiple directional control valve

2.1 Structure and principle
The multiple directional control valve is fraction model, which is made up of input, output
and slide valve.
Main relief valve is used to control the pressure of oil circuit. Main relief valve pressure has
also been adjusted in the factory, so please don‘t adjust it at will.
Steering relief valve is used to control the pressure of oil circuit.
Slide valve is used to control tilt hydro cylinder, lift hydro cylinder, side shift cylinder,
platform cylinder and jack. The cylinder control is realized by maneuvering the tilt valve stem,
elevating valve stem, fork valve stem. Tilting slide valve owns forward tilting latching 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 check valve in the high pressure oil line.

Note: Main relief valve of this multi-way valve is at the bottom, steering relief valve is on the
top, and is different to ordinary multi-way valve.

64
Note:
the 1st the 2nd

Steering relief valve

（behind LS valve）

Main relief valve

Valve 1

Diverter valve

Connect brake valve Booster

Connect steering gear

Priority valve

Fig. 7-2 Two through multiple directional control valve structure and oil line schematic diagram

65
 the 1st the 2nd the 3rd

Steering relief valve

（behind LS valve）

Main relief valve

Valve 1

Valve 2

Diverter valve

Connect brake valve Booster

Connect steering gear

Priority valve
Fig. 7-3 Three-through multiple directional control valve structure and oil line schematic diagram

66
 the 1st the 2nd the 3rd the 4th

Steering relief valve

（behind LS valve）

Main relief valve

Valve 2

Valve 2

Valve 1

Diverter valve

Connect brake valve Booster

Connect steering gear

Priority valve

Fig. 7-4 Four-through multiple directional control valve structure and oil line schematic diagram

67
 Steering relief valve
（behind LS valve） the 1st the 2nd the 3rd the 4th the 5th

Main relief valve

Valve 2

Valve 2

Valve 2

Valve 1

Diverter valve

Connect brake valve Booster

Connect steering gear

Priority valve

Fig. 7-5 Five-through multiple directional control valve structure and oil line schematic diagram

68
2.2 Performance parameter

Nominal pressure（MPa） 20

Nominal diameter（㎜） 20

Inlet flow（L/min） 180

Allow rate of back pressure（MPa） 1.5

Main relief valve Setting pressure（MPa） 19±0.25

Steering relief valve Setting pressure（MPa） 11±0.25

Valve1 15±0.25
Overload valve pressure adjusted
range（MPa）
Valve 2 5±0.25

Control pressure（MPa） 1.1

Priority valve Max. inlet pressure（MPa） 25

Inlet flow（L/min） 140

Forward tilting brake valve Control pressure（MPa） ≤2

Monostable diverter valve Shuntvolume（L/min） 5

2.3 Main relief valve pressure adjustment:

Main relief valve pressure has also been adjusted in the factory, so please don‘t adjust it at
will, adjusting way is as follows：
a) Unscrew the tube assembly measure hole screw of front pump(truck heading) to
multiway valve P1, mount the oil gauge than can measure 20Mpa.
b) Step accelerating pedal to the end, lift to the maximum, and measure the pressure when
the cylinder travel to the end.
c) When the oil pressure is different from the specified value, unscrew overflow valve
locking nut, rotate and adjust the screw to the specified value. When in high pressure, rotate to
the left; when in low pressure, rotate to the right.
d) Relock the locking nut.

△! Warn
It is not allowed to adjust pressure without pressure gauge.

69
2.4 Fault diagnosis and adjustment

Fault Probable cause Corrective action

Loose of pressure-adjust screw. Readjusted and retighten.

Pressure of relief Distorted or damaged pressure-adjust Replace.

valve is not spring.
steady or cannot Replace or clean for new
be adjusted. Worn or blocked relief valve core.
assembling.
Pump malfunction Examine and repair pump.

Replace valve core and tilt lock

Fork tilt forward Worn or damaged tilt lock valve.
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
Malfunction tilt relief valve.
when tilting assembly.
forward. Clearance between valve body and Replace valve rod with
Fork carriage valve rod is too large. specified clearance.
descends Valve rod is not in centre. Keep the lever be in the neutral
apparently when
the lifting lever is Cylinder seal abated. Examine and repair cylinder.
in neutral Overload valve is worn or blocked
Replace or clean taper valve.
by dirt.
Damaged or distorted
Replace spring.
reposition-spring.
Dirt exists between valve body and
Clean
Reset failure spool valve.
Blocked control device. Adjust

Not coaxial parts at reposition Reinstall, be coaxial

Damaged O-ring. Replace.

Check and retighten. of the
Leakage Faulty seal of joint.
relevant part
Clean seal plate and retighten
Loose seal plate.
blots.

70
 Loose of lock-nut of relief valve and
Tighten.
connect-nut between plate and plate.
Valve element of priority valve sticking Adjust
Heavy steering
Signal port blockage Clean

3. Rotary type piping filter

Multiple directional control valve

Hydraulic oil way

hydraulic oil tank

Return opening of
Rotary filter

Filter oil line principle

Fig. 7-6 Oil return line of hydraulic filter

3.1Data
Filter model SPB-10×10

Filter type model SPH-10

Filter element model SPBX-10×10

Max. working pressure 0.7Mpa

Bypass valve opening pressure 0.25Mpa

Burst pressure 2.0Mpa

Max oil return flow 320L/min

Filter precision 10um

3.2Filter installation
（1）Install with hands, firstly apply oil to the sealing gasket, rotate the thread on the filter
head and screw down.
（2）Check if oil leaks.
Notice: Hydraulic filter head must include bypass valve.
3.3 Filter replacement
There installs signal generator on the filter head to check filter use condition, when the
71
 indicator is in the red zone, it means the filter element blockage is severe, bypass valve on the
filter head is opened, and the filter does not have filtration, it must unscrew the filter drum and
replace new filter element.
Filter dosed not have to wholly replace, replace filter element is enough.
Replace procedure：
（1）During change the filter element, use special spanner to dismantle filter, take out the
filter element and replace it.
（2）Apply some lubrication oil along the filter sealing gasket, and then install the filter, after
contact the engine body, screw two thirds circles.

4. One-way governor valve

One-way governor valve is installed in the truck up and down return circuit, and lies in the
front of the lifting cylinder oil inlet. Actually it is a one-way throttle valve, and its structure
refers to fig. 7-7

Normal flow

Throttle direction

Lifting cylinder side Multiway valve side

1- Speed limiting valve body 2-Spool 4-Positioning nut

Fig. 7-7 One-way governor valve

When the valve fully open in lifting position, all oil flow into lit; when the valve in
descending position, the valve oil hole C,D hides some parts and forms throttling action, oil
flow reduces correspondingly, and slow the fork descending speed, that the goods descending
speed will not be too fast.

5. Lifting cylinder

Lifting cylinder is single-acting piston structure, composed of cylinder cover, piston rod,
cylinder body and piston. Notice to use:
1） Keep piston rod from being damaged, and keep good seal ability of the seal ring;
2）During daily usage, if there floats leakage oil on the piston rod surface, you should
check if there is galling phenomenon on the piston rod surface, and replace o-ring and piston.

72
 1- Snap ring 60 2-OSI Seal ring 3-Catch 4- Spacer bush 5- Support ring
6- Piston 7- Snap ring 8- Piston rod 9-Cylinder body 10-Joint
11-Guide sleeve 12-Composite bush 13-O-ring 14-ISI Seal ring 15-DKI Dust ring

Fig. 7-8 Lifting cylinder（Left）

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

1-Bearing 2-Draw head 3-Nut 4- Piston rod 5-LBH Dust ring 6-ISI Seal ring
7- O-ring 8- Guide sleeve 9-Stering seal 10- Snap ring 11- O-ring 12- Composite bush
13- Cylinder body14-OSI seal ring 15- O-ring 16-Support ring 17-Piston 18- Castle nut
19-Pin 20-Copper bush

Fig. 7-9 Tilting cylinder

7. Air exhaust in hydraulic system

（1）Add the recommended hydraulic oil to scale specified oil level, lift the lifting cylinder
when adding oil.;
（2）Make the truck load reach 1/10～1/8 of rated load, unscrew the bleed screw on the lifting
cylinder, lift or fall the fork carriage several times until there is no bubble at the bleed screw,
and then screw down the bleed screw;
（3）Tilt the tilting cylinder forward or backward to the maximum for several times, which
can exhaust air in it.
73
 8. Hydraulic system fault diagnosis and corrections

Fault Probable cause Corrective action

Insufficient oil supply Add oil to oil marking

Unable to lift or tilt Insufficient gear pump displacement or

Replace oil pump or spare parts
with no load large backlash
Multiple directional control valve
Dredge oil line
blockage
Insufficient oil in the system Add oil to the oil tank

Oil leak and oil pipe fracture caused by Add seal, screw down joint and
bad seal or loose oil pipe connecting. replace oil pipe.
Lifting cylinder Insufficient oil supply caused by oil
plunger move slow, pump malfunction Repair or replace oil pump
interruption or impact
Incorrect relief valve adjustment or
to lifting frame. Adjust or repair relief valve
damage
Replace hydraulic piping filter
Hydraulic piping filter blockage
element
Air in the hydraulic system Exhaust air
Over fast fork carriage One-way throttle valve block at opening Disassemble one-way throttle
descending speed place or reversely installed. valve and eliminate fault
Over large lifting
Too much reversing valve rod discharge Replace valve rod
cylinder gliding
Too large tilting Tilting cylinder piston seal ring invalid,
Replace real ring
cylinder angle inner leakage
Plunger rod or piston
Oil seal damage Replace oil seal
rod with oil
Noise in hydraulic
system or unstable oil Oil absorption fold or blockage Dredge oil piping
cylinder move
Filter, relief valve dirty, blockage,
Replace filter element, clean
Oil pipe cracking increase the oil pressure and make oil
relief valve
piping cracking.
Adjust tilting cylinder piston
rod, make end thread cross the
Tilting cylinder out of ear observation port, make
sync connection firm and adjust
piston rod to make two
cylinders work in step.

Air in the system Exhaust from air bleed hole

74
 Gear pump bearing wear or grind Replace bearing

Gear pump side plate wear Change side plate R

9. Hydraulic system schematic diagram

Fig. 7-10-1 Hydraulic system schematic diagram(EXCEPT W65G、W75G、W95G)

75
Fig. 7-10-2 Hydraulic system schematic diagram(W65G、W95G)

Fig. 7-10-3 Hydraulic system schematic diagram(W75G)

76
VIII. Lifting system

1. Outer mast 2. Inner mast 3.Lift cylinder 4. Chain 5. Tilt cylinder 6.Fork carriage 7.Fork

Fig. 8-1 Standard lifting assembly

77
1. Assemble debugging data

Debugging data Duplex mast and triplex mast

Standard type and Lifting height Lifting height
Mast type
lifting height of 2.5～4M > 4～5 M > 5～6 M

Mast tilting Forward 60 60 30

angle Backward 120 60 60
Fork carriage roller Adopt longitudinal roller and side roller.

Inspection and adjustment

Check Place Assembly clearance（mm） Repair clearance（mm）(Without

replacing spare part)
Mast to lift roller 0.3～1.25 0.4～1.4

Mast to bearing guide plate 0.2～1 0.3～1.2

Inner mast to fork carriage 0.3～1.25 0.4～1.4

side roller
Lift chain deflection 25～30 mm

Tightening torque

Place Unit：N.m

Lift chain lock nut 933-1244 (M27×2)

Tilt cylinder lock nut 245～314（M20×1.5）

Lift cylinder bolt 638-850（M24）

Lift cylinder fixing bolt（U type） 45-58(M10)

78
2. Fault diagnosis and corrections
Condition Probable cause Corrective action

Fork carriage or Tilt cylinder and ring abraded excessively Replace piston ring tilt cylinder.
mast tilt
automatically The hydraulic control valve spring is
Replace it.
inoperative.
The fork arms Caused by piston jamming or piston rod bent. Replace the faulty parts.
carrier moves up
and down
sluggishly. Too much dirt is accumulated in the cylinder. Clean

Adjust clearance with thrust metal and

Carriage bracket assembly out of adjustment.
carriage side roller.
Insufficient clearance between rollers and mast
Adjust roller clearance
channel.
Forks are lifted or
Biting foreign materials between moving part. Remove foreign materials.
lowered unsmooth.
Apply grease on contact surfaces of
Insufficient lubrication.
sliding parts.（butter）

Inner mast deflection or fork carriage bent Repair or replace.

Forks are lifted

Lift chains out of adjustable. Adjust lift chains.
unevenly

Lift roller does not Grease stiffened or dirt accumulated on lift roller Clean and lubricate lift rollers.
rotate
Improperly adjusted lift roller. Adjust.

Insufficient lubrication. Lubricate.

Excessive mast
noise Improperly adjusted lift roller, after extending
Adjust roller, side roller adjusting shim
mast, descend to bump with mast channel
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 Y-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
Insufficient lift valve, resulting in excessive oil leaks. Replace.
power or no lift Oil leaks occur between the hydraulic control Dismantle for regrinding the joint
movement.
valve sections. surfaces and reassemble the valve.
Tighten the joint nuts and inspect the
Leakage occurs in the hydraulic pipe.
seal for damage.
The hydraulic oil temperature is too high. Oil Change the wrong hydraulic oil or stop
operation for reducing the oil, find out
viscosity is too low and the rate is insufficient. the reasons for high oil temperature
The load carried is beyond the designed
Lift according to requirement.
capacity.

79
3. Summarize

3.1 Duplex wide view mast

Duplex mast (Fig.8-1) 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.
Treat forklift with 3 m lifting height as basic type. Other lifting height(2.5Mt to 6M) is for
special order.
3.2Duplex full free lift mast（Including railway container forklift mast）
Duplex full free lift mast (Fig8-2) 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.
When lowest height of mast≤22200mm, the truck can work inside the container. The truck
also can equip with side-shift device. Side shift cylinder of container fork lift truck mast can
be side shifting only when goods don‘t placed appropriate position. In another condition, side
cylinder should set center.
Free lifting cylinder equips with chain. Two chains with the same length are in both left and
right forklifts.

80
 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.8-2 Duplex full free lift mast

3.3 Triple full free lift mast
Triple full free lift mast (refer to fig. 8-3) 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. 8-3 Triple full free lift mast

81
4. Mast dismantle and install
adjustment

△! Warning
Be careful when removing and installing
Fig.8-5
the forks, carriage and mast as they are
heavy. （5）Support mast assembly with wire ropes.
4.1 Dismantle forks and mast assembly
Fork
（1）Dismantle adjusting cylinder(8t-10t)
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 Fig.8-6
or the bottom of forks. （6）Pull out tilt cylinder pivot pin.
b. Do not dismantle goods from top
（7）Remove mast support caps.
forks！To avoid crush from fork falling.
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.8-7
（8）Remove mast assembly.
To install mast assembly, reverse order of
removal.
4.2 Disassembly
△! Warning
Be careful when disassembling the masts
as they are heavy.
Remove lifting Cylinder
Fig.8-4 （1）Place mast flat on ground. Remove
（ 3 ） Remove carriage bracket assembly lifting cylinder attaching bolts, and U-type
from inner mast. screw tighten screw if it is high lifted mast.
（4）Detach high pressure hose, lift hose and （2）Slide inner mast, then remove lifting
low pressure hose. cylinders.
Remove roller
（1）Slide inner mast out until rollers are
exposed and remove little rollers and main
roller.

82
（2）Unclench rollers carefully if no bearing （2）It is suitable that clearance of roller and
puller or rollers would be smashed.(Up and outer mast is about 0.8mm -1mm. Clearance
down, left and right, knock symmetrically.) 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
entering, it is decided whether to apply
lubrication or not in the area where sand
blown by wind heavily.
Clearance of back up metal and mast
steel
Fig.8-8 Adjust clearance ―B‖ to 0.2mm ～ 1mm
Remove inner mast with shims, which may not use. Thickness
Attach wire rope to middle of inner mast and of shim is 0.2mm.
slide it out with a lifting device.

Fig.8-11
Fig.8-9 Apply a coat of grease to back-up metals.
Inspection Install mast and lifting cylinder on forklift
（1）Check lift rollers, roller shafts, and truck. Connect circle tube and high-pressure
associated parts for wear or damage. tube.
（2）Replace damaged parts as required. 4.4 Left and right cylinder height
4.3 Assembly and adjustment adjustment.
（1）Install left and right lifting cylinder on
△! Warning mast, pin must be installed into orientation
Be careful when assembling the masts as hole of outer mast lower cross beam.
they are heavy. （2）Install upper of piston rod on inner
Lift roller mast. Inner mast lay evenly in the direction
Slide inner mast into outer mast and of left, right, upper and lower. If it is not
securely attach lift rollers. 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.8-10
Lift roller-to-mast clearance adjustment
（1）Adjustable left and right ―A‖ with
shims, adjust to 0.5mm～1.2mm.
83
 Fig.8-12
4.5 Lifting chain adjustment
Installs fork arm carrier on inner mast, and
install lifting chain, then install two nuts on
end of every side. With mast set straight up,
lower carriage completely. Temporarily
Fig. 8-14
adjust clearance of carriage： 4.6 Clearance of fork carriage and rollers
5t-7t is 127mm； adjustment
8t-10t is 160mm. 5~6T clearance of fork carriage and rollers
adjustment
There equips with 4 main roller and 4 side
roller at the fork carriage, and the side roller
is installed to the inner and outer sides of
right upright steel flange. Outer side roller is
welded in place before leaving the factory,
so it cannot be adjusted, you can only adjust
the inner side roller adjusting shim to
Fig. 8-13 control clearance between two sides side
To adjust tension of lift chain, lower lifting roller and section steel.
cylinder until fork is on the ground, and a. When the fork carriage going up and
adjust chain adjusting nut (three every side) down along the fork carriage the clearance
so that dimension C will be as listed below between inner and outer side roller and
when the middle portion of chain is pressed section steel flange is 0.2mm～1mm.
by a finger. b. When going up and down, the inner
Dimension C: 25 mm ~30 mm roller rolls along the inner flange, and it
could not occur to both sides clamp.
c. If outer roller wears largely, replace
side roller, because it cannot be adjusted
with shims.

84
 Side
Lift roller rolle Lift roller
Spacer shim
r
Fork carriage Side roller
Spacer shim

Spacer shim
Fork carriage Spacer shim Side roller Side roller

Fig. 8-15 Fig. 8-16

7T truck fork carriage assembly roller Adjusting shim
0.5mm 1mm
clearance
a. Number of shims must be the same on the
There equips with 6 main rollers and 5 side
right and left sides, when using shims.
rollers in the 7T truck, 4 side rollers of them
b. After clearance adjustment, push carriage
can use spacer shim to adjust clearance with
assembly to see if it operates properly.
side roller and mast upright. One outer side
roller is welded in place before leaving the
4.7 Installing and dismantling way of load
factory, so it cannot be adjusted
backrest extension
（1）Measure inside width ―A‖ between
inner mast two U-bar guide rails. Make
measurements at the top, bottom and center
(cross beam) sections, meanwhile measure
inside width ―Aˊ‖ between inner 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 Load backrest dismantlement：
and right roller evenly and make clearances 1. Screw down 8 nuts, which installed at the load
between smallest part of inner mast U-bar backrest and fork carriage, and dismantle them;
and carriage side roller. 2. Dismantle load backrest.
A-B = 0.2mm～1mm Dismantlement is opposite to installment.
Aˊ-Bˊ= 0.2mm～1mm

85
5. Disassembly and installation
of lifting cylinder

△! Warning
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 Fig. 8-19
cylinder body so as to return oil flowing Caution：
back tank completely. Please not use dust gasket ring removed,
（2）Disconnect lifting cylinder oil return O-ring, Y-ring again, must replace.
pipe, dismantle bottom end governor valve （3）Draw out piston rod , remove sealing
oil inlet high pressure hose and two cylinder ring on end of piston.
connected high pressure hose. 5.2 Assemble and replace quick-wear part
（3）Remove U-bolt of outer mast fixation （1）Cleanup parts with clean oil before
board and tighten skew of other side. installation.
（4）Unscrew mounting screw on left and （2）Then cleanup guiding bush and piston
right cylinder piston rods and mast cylinder. with hydraulic pressure oil the same as oil
（5）Remove chain of outer mast and the box trademark.
bottom cylinder bolt. （3）Dust or dunghill doesn‘t drop into
（6）Attach wire rope to inner mast and lifting jack.
remove left and right lifting cylinder with a （4）The order of installation is reverse the
lifting device. 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：
If there is burr in the cylinder barrel, you
must clean smooth, place into the middle
carefully, to avoid Y-seal ring scrape.
（7）Install replacing dust gasket ring and
Fig. 8-17 sealing ring in guiding bush and cylinder
5.1 Disassembly head.
Removes tighten screw and nylon stopper,
Notice：Apply hydraulic pressure grease
then remove cylinder head.
which trademark is the same as tank on
（1）Remove dust gasket ring. guide sleeve installed gasket ring
（2）Remove sealing ring with screwdriver. （ 8）Rip cylinder head into piston rod,
screw down cylinder body.

Fig. 8-18
86
6.Disassembly and 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. Fig. 8-21
6.1Disassembly （7）Remove dust gasket ring in the cylinder
（1）Lay down the fork carriage completely. head. Means is the same as discharging of
（2）Dismantle oil pipe at the entrance of dust gasket ring in the cylinder head of
tilting cylinder. lifting cylinder (see disassembly and
（3）Remove bolt on the left and right installation of lifting cylinder).
bracket of outer mast, moreover pull axis （8）Remove O-ring outside in the guiding
out. bush..
（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. 8-22
（9）Remove O-ring and sealing ring in the
inner hole of guiding bush (see Fig.
disassembly and installation of lifting
cylinder).
Fig. 8-20 Notice：
6.2 Disassembly spare parts No using dust gasket ring and sealing
（1）Squeeze tilting cylinder with pliers, ring removed.
then pull piston rod come-and-go as opening 6.3 Assemble after real ring changing
of inlet and outlet on the tilting cylinder, so Assemble order is opposite to dismantle
remaining oil is discharged tilting cylinder. order, but you need to pay attention to the
（2）Screw earring 21. following item：
（ 3 ） Removes tighten screw and nylon （1）Lubricate each spare parts with clean
stopper. hydraulic oil.
（4）Remove cylinder head 14 and guiding （ 2 ） Prevent dust and oil dirt fall into
bush 12. cylinder.
（5）Draw out piston rod assembly 25（see （3）Prevent burr in the cylinder barrel
Fig. ）. mouth and entrance.
（6）Remove all dust gasket rings, O-ring （4）Centering carefully, push the piston rod
and sealing ring. to cylinder barrel, especially avoid scraping

87
the seal ring.
（ 5 ） Before placing guild sleeve, apply
hydraulic oil the same brand to work oil
between O-ring and seal ring.
（6）Do not scrape O-ring of the outer ring.
（7）Remember install nylon stopper and
tighten screw after screw cylinder head.

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.
Please see foregoing table if you want know
tightening force of bolt or screw. Please
refer to common bolt tightening torque
prescribed in our company if you want know
other tightening force of bolt or screw.（refer
to OPERATION AND MAINTAIN
MANUAL）.

88
IX. 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.
Note
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， N：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.

Electrical plate assembly

Electrical plate assembly is under the truck engine cover and near the left battery. It is
mainly composed of electrical plate, control box assembly, starter relay, pre-heat relay,
fault detection switch, fault detection up and down select switch etc.
Component dismantle：
89
 （1）Disconnect emergency disconnect switch and turn to OFF;
（2）Press down lock catch on the control box cover, and then open the cover or
unscrew fixed electrical cover plate screw, take down the electrical cover plate;
（3）Pull out or dismantle fuse or relay
Explanation：If the fuse or relay is damaged, replace a new one, refer to the following
figure;
①If a fuse is damaged, please be sure to eliminate cause of problem before
replace a new one；
②Never use fuse higher than specified rating.

90
 (W65G/W75G/W95G)
Fuse identification(excepe W65G/W75G/W95G)
Location Capacity Component
F3 15 A Headlight, width lamp
F4 10 A Horn
F5 30 A Engine ECU4 sheath power
F6 5A Engine bus power
F7 10 A Brake lamp, alarm lamp power
F8 10 A Steering lights
F9 10 A Instrument and indicator lamp power
F10 5A Switch power
Pre-heat start indicator light, fault indicator light, major failure
F11 5A
indicator light power
Solenoid valve, reversing light, back-up buzzer, parking brake
F12 15 A
indicator
F13 10 A Backup
F14 20A Backup

Control box fuse identification(W65G/W75G/W95G)

Location Capacity Component
F3 10 A Oil pump power
F4 30 A ECU power
F5 10 A ECU diagnostic power
F6 7.5 A Reversing power
F7 10 A TCU power
F8 10 A Instrument power
F9 10 A Headlamps power
F10 10 A Brake light/corner lamp power
F11 10 A Horn power
91
 F12 15 A Post-processing power 1
F13 5A Post-processing power 2
F14 30A Post-processing power 3
Fuse block identification(W65G/W75G/W95G)
Location Capacity Component
1 15 A Front wiper power
2 15 A Rear wiper power
3 10 A Reserve power
4 10 A Reserve power
5 15 A Reserve power
6 10 A Reserve power

92
93
Control box schematic diagram fuse block schematic diagram
(W65G/W75G/W95G)

94
Key switch(start)

(1)Remove the combination instrument.

(2)Disconnect the wiring connector.
(3)Dismantle nut, gasket, space ring
and instrument panel.
(4)To install reverse the order of
removal.
During installation, adjust switch
projection to proper length.

Direction A
Connect R2 Connect C
Start switch

Connect
Connect Acc B1

Check
Use multimeter (with ohm) to inspect whether it is on when lighting switch is on each
positions.
Preheat start switch schematic diagram

95
Combination instrument assembly(except
W65G\W75G\W95G)

Sheath

Instrument schematic diagram

96
 Disassembly and installation：
①Remove 4 fixed bolt from meter crust. Notice that when installing and removing,
please make instrument surface tilt an angle to avoid damaging the screw thread of
fixed parts on truck.
②Take out wiring harness from sleeve, and then instrument can be brought out.
③There is transparent plastic cover to cover, so it can prevent dust and water, and it is
fixed by 6 plastic clip buckle, please press down plastic buckles lightly to take out
plastic cover when removing.
To install, reverse removal procedures.
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.

Instrument schematic diagram

Light grey

Charging indicator Meso-position indicator

Engine oil pressure alarm indicator Fault indicator

Severe fault indicator
Parking brake indicator Filter alarm
Preheat indicator indicator Transmission gear box alarm indicator

97
Display map of each condition at instrument

98
 Combination switch assembly

Gear combination switch Light combination switch

Gear combination Light combination Horn switch

switch connector lug switch connector lug connector lug

Gear combination switch(except W65G\W75G\W95G)

Disassemble
（1）Remove the combination instrument and steering wheel.
（2）Unscrew the screws, and disconnect the wiring connector
（3）To install reverse the order of removal.
Gear switch check
Disconnect switch connect clip, and check if each point is connected.
Use multimeter (with ohm) to inspect whether each gear switch is connected.

99
 Gear combination switch
Gear circuit diagram （―O‖ means connected）

Hole
Forward 2 gears
Color Green Red White
Pink Brown Blue
yellow white brown
Power
Forward 1 gear Handle
position

Reverse 1 gear

Reverse 2 gears

Light combination switch

Gear circuit diagram （―O‖ means connected）

Light combination switch

Hole

Color Green Black Black

Blue white Green
Turn left white white blue
Power
Handle
position

Turn
left

In
neutral

Turn
right
Turn right

100
Turn light check
Turn left Use multimeter(with ohm) to inspect
whether it is on when lighting switch is on
these position: left turn, N, right turn
Switch position Connection point

Left turn 1-2

N OFF

Turn right Right left 1-3

Light switch check

Width lamp Disconnect switch connector, and check
whether each connection point is on.
Use multimeter (with ohm) to inspect
whether it is on when lighting switch is on
these positions: headlight, width lamp,
Overhead lamp
OFF

Switch position Connection point

Headlight 4-6
Width lamp 4-5
OFF OFF

101
 Headlamp assembly
Disassemble and installment：
① Dismantle decorating frame;
② Unscrew 4 bolts at the back of lamp housing, and
then open it;
③ Disconnect headlamp lead, release lock catch,
dismantle headlamp and replace new bulb and
install it;
④ Unscrew two fixed bolts of LED width lamp, take
out the width lamp, and check if it is damaged, if
damage, cut the outgoing line welding spot, replace
new panel, re-weld to the original place and install
it;
⑤ Rotate according to the arrows in the back of
steering light, take out steering light, replace new
bulb and install it;
⑥ Close light housing, screw bolt and fasten the
decorating frame

Rear combination light

Turn lamp Width lamp/Brake lamp Reversing lamp

Disassemble and installment：

① Dismantle rear combination light from overhead guard and be careful;
② Take the rear combination light to the service station, take out the lamp house, unscrew
the mounting screw at the back of lamp housing;
③Take out LED panel, unscrew fixed connector bolt, disconnect connector, and replace
new LED panel.
To install reverse the order of removal.

Bulb specification
Lamp Specification
Front combination lamp
Headlamp 24V-70W
Turn light 24V-21W
Width lamp 24V-5W
Rear combination lamp（LED）
Turn light (3.2V-20mA)×15
Brake lamp, width lamp (3.2V-20mA)×15
Reversing lamp (3.2V-20mA)×15

102
 Starter and generator repair

Starter

Phenomenon Reason Correction

Insufficient accumulator Replace battery or charge
capacity
Starter circuit Repair or replace wire, starter
disconnection relay
Replace or repair magnetic
Magnetic switch damaged switch
Starter does not rotate Bad pinion and wire-wound Replace or repair
gear engagement
Adjust brush position and clean
Bad brush contact the surface.
Brush wear Replace
Armature coil Replace armature coil
disconnection

Starter rotate but does not Bad pinion Replace

drive the engine Bad wire-wound gear shaft Repair
Generator
Phenomenon Reason Correction
Regulator damage Replace regulator
Magnetic field wiring Replace
damage
Unable to charge Diode damage Replace
Reed wire disconnection or Repair or replace
Charging indicator light is on

bad contact
Fuse damage Repair
Exciting coil damage Replace
Diode damage Replace
Little charge current Bad reed contact Repair or replace
Large electrical load Reduce load
Bad belt tension Adjust
Regulator damage Replace
Large charge current
Fastener looseness of
current output return circuit Repair
Battery liquid level Battery damage Replace and add liquid
drops

103
 Regulator damage Replace
Others

Abnormal generator Bad internal Repair or replace

noise contact(bearing, brush)
Bad driving belt tension Adjust

Engine fault detection(Cummins）

1. Engine detection port is under the overhead guard left beam(above the left truck
body);gear II is fault diagnosis switch, gear III is fault detection up and down
diagnosis switch.
2. Turn the fault detection switch to ―OFF ‖disconnect position, turn the diagnosis
switch to ―ON‖ position, and also turn the key switch to ―ON‖ position, if it does not
record current fault code, alarm indicator light and stop indicator light keep lighting
state; if it records current fault code, alarm indicator light and stop indicator light are
on, and flashes the recorded fault code.
Fault code flashes according to the following sequence:
Triangle with exclamation mark alarm indicator light is on for a while, and pause for
1-2 seconds.
Another triangle stop indicator light flashes the fault code, and pause 1-2 seconds
between each two figures.
After the triangle stop indicator light flashes the fault code, triangle with exclamation
mark alarm indicator light flashes again, and then triangle stop indicator light
repeatedly flashes fault code.
If you want to check the next fault code, pull the （+）position of fault diagnosis up
and down selection switch. If you want to check the previous fault code, pull the （-）
position of fault diagnosis up and down selection switch. If it only records one current
fault code, whether you pull to（+）position or （-）position, the fault indicator light
will show the same fault code.
Once you do not use the diagnosis system, disconnect the diagnosis switch; if
diagnosis switch does not disconnect, ECM will not record some fault code.

Note：After flameout power off switch can be switched off until 30s and flameout cannot
use power off switch,if not may detect fault code 1117. Remove this fault code needs to
normal operation(ignite-flameout-after 30s-switch off power off switch ) once.

104
 J1587
FAULT J1939
PID（P）
CODE SPN（S） REASON EFFECT
SID（S）
{LAMP} {FMI}
{FMI}
111 S254 629 Engine Control Module Critical Internal Possible no noticeable
{12} {12} Failure-Bad Intelligent Device or performance effects,
Component. Error internal to the ECM engine dying, or hard
related to memory hardware failures or starting.
internal ECM voltage supply circuits.
115 P190 612 Engine Magnetic Crankshaft Fueling to injectors is
{2} {2} Speed/Position lost both of two signals disabled and the engine
–Data Erratic, Intermittent, or Incorrect. can not be started
The ECM has detected that the primary
engine speed sensor and the backup
engine speed sensor signals are reversed.
122 P102 102 Intake Manifold 1 Pressure Sensor Engine power derate.
{3} {3} Circuit –Voltage Above Normal, or
Shorted to High source. High signal
voltage detected at the intake manifold
pressure circuit.
123 P102 102 Intake Manifold 1 Pressure Sensor Engine power derate.
{4} {4} Circuit —Voltage Below Normal, or
Shorted to Low source. Low signal
voltage or open circuit detected at the
intake manifold pressure circuit.
124 P102 102 Intake Manifold 1 Pressure Sensor Engine power derate.
{0} {16} Circuit — Data Valid but Above Normal
Operational Range-Moderately Severe
Level. Intake manifold pressure has
exceeded the maximum limit for the
given engine rating
131 P091 091 Accelerator Pedal or Lever Position Sever derate in power
{3} {3} Sensor 1 Circuit —Voltage Above output of the engine.
Normal, or Shorted to High source. High Limp home power
voltage detected at accelerator pedal only.
position circuit.
132 P091 091 Accelerator Pedal or Lever Position Sever derate in power
{4} {4} Sensor 1 Circuit —Voltage Below output of the engine.
Normal, or Shorted to Low source. Low Limp home power
voltage detected at accelerator pedal only.
position signal circuit.
133 P029 974 Remote Accelerator Pedal or Lever Remote accelerator will
{3} {3} Position Sensor 1 Circuit —Voltage not operator. Remote
Above Normal, or Shorted to High accelerator position
source. High voltage detected at remote will be set to zero
accelerator pedal position circuit. percent.
134 P029 974 Remote Accelerator Pedal or Lever Remote accelerator will
{4} {4} Position Sensor 1 Circuit — Voltage not operator. Remote
Below Normal, or Shorted to Low accelerator position
source. Low voltage detected at remote will be set to zero
accelerator pedal position signal circuit. percent.

105
 J1587
FAULT J1939
PID（P）
CODE SPN（S） REASON EFFECT
SID（S）
{LMAP} {FMI}
{FMI}
135 P100 100 Engine Oil Rifle Pressure 1 Sensor None on performance.
{3} {3} Circuit —Voltage Above Normal, or No engine protection
Shorted to High source. High signal for oil pressure.
voltage detected at the engine oil
pressure circuit.
141 P100 100 Engine Oil Rifle Pressure 1 Sensor None on performance.
{4} {4} Circuit —Voltage Below Normal, or No engine protection
Shorted to Low source. Low signal for oil pressure.
voltage detected at engine oil pressure
circuit.
143 P100 100 Engine Oil Rifle Pressure —Data None on performance.
{1} {18} Valid but Below Normal Operational
Range-. Moderate severe level
144 P110 110 Engine Coolant Temperature 1 Sensor Possible white smoke.
{3} {3} Circuit — Voltage Above Normal, or Fan will stay ON if
Shorted to High Source. High signal controlled by ECM. No
voltage or open circuit detected at engine protection for oil
engine coolant temperature circuit. pressure.
145 P110 110 Engine Coolant Temperature 1 Sensor Possible white smoke.
{4} {4} Circuit — Voltage Below Normal, or Fan will stay ON if
Shorted to Low Source. Low signal controlled by ECM. No
voltage at engine coolant temperature engine protection for oil
circuit. pressure.
146 P110 110 Engine Coolant Temperature — Data Progressive power
{0} {16} Valid but Above Normal Operational derate increasing in
Range — Moderately Severe Level. severity from time of
Engine Coolant Temperature signal alert.
indicates engine coolant temperature
is above engine protection warning
limit.
147 P091 091 Accelerator Pedal or Lever Position 1 Sever derate in power
{1} {1} Sensor Circuit Frequency — Data output of the engine.
Valid but Below Normal Operational Limp home power only.
Range — Most Severe Level. A
frequency of less than 100Hz has been
detected at the frequency throttle input
to the ECM.

106
 J1587
FAULT
PID（P） J1939
CODE REASON EFFECT
SID（S） SPN（S）
{LMAP}
{FMI} {FMI}
148 P091 091 Accelerator Pedal or Lever Position Sever derate in
{0} {0} Sensor 1 — Data Valid but Above power output of the
Normal Operational Range — Most engine. Limp home
Severe Level. A frequency of more than power only.
1500Hz has been detected at the
frequency throttle input to the ECM.
151 P110 110 Engine Coolant Temperature — Data Progressive power
{0} {0} Valid but Above Normal Operational derate increasing in
Range — Most Severe Level. Engine severity from time of
Coolant Temperature signal indicates alert. If Engine
engine coolant temperature above engine Protection Shutdown
protection critical limit. feature is enabled,
engine will shut
down 30 seconds
after Red Stop Lamp
stats flashing.
153 P105 105 Intake Manifold 1 Temperature Sensor Possible white
{3} {3} Circuit — Voltage Above Normal, or smoke. Fan will stay
Shorted to High Source. High Signal ON if controlled by
voltage detected at intake manifold air ECM. No engine
temperature circuit. protection for intake
manifold air
temperature.
154 P105 105 Intake Manifold 1 Temperature Sensor Possible white
{4} {4} Circuit — Voltage Below Normal, or smoke. Fan will stay
Shorted to Low Source. Low Signal ON if controlled by
voltage detected at intake manifold air ECM. No engine
temperature circuit. protection for intake
manifold air
temperature.
155 P105 105 Intake Manifold 1 Temperature — Data Progressive power
{0} {0} Valid but Above Normal Operational derate increasing in
Range — Most Severe Level. Intake severity from time of
manifold air temperature signal indicated alert. If Engine
intake manifold air temperature above Protection Shutdown
engine protection critical limit. feature in enabled,
engine will shut
down 30 seconds
after Red Stop Lamp
starts flashing.

107
FAULT J1587 REASON EFFECT
CODE PID（P） J1939
{LMAP} SID（S） SPN（S）
{FMI} {FMI}
187 S232 1080 Sensor Supply 2 circuit — Voltage Engine power
{4} {4} Below Normal, or Shorted to Low derate.
Source. Low voltage detected at the
Sensor Supply 2 circuit.
195 P111 111 Coolant Level Sensor 1 Circuit — None on
{3} {3} Voltage Above Normal, or Shorted to performance.
High Source. High signal voltage
detected at engine coolant level circuit.
196 P111 111 Coolant Level Sensor 1 Circuit — None on
{4} {4} Voltage Below Normal, or Shorted to performance.
Low Source. Low signal voltage
detected at engine coolant level circuit.
197 P111 111 Coolant Level — Data Valid but Below None on
{1} {18} Normal Operational Range — performance.
Moderately Severe Level. Low signal
voltage has been detected.
221 P108 108 Barometric Pressure Sensor Circuit — Engine power
{3} {3} Voltage Above Normal, or Shorted to derate.
High Source. High signal voltage
detected at barometric pressure circuit.
222 P108 108 Barometric Pressure Sensor Circuit — Engine power
{4} {4} Voltage Below Normal, or Shorted to derate.
Low Source. Low signal voltage
detected at barometric pressure circuit.
227 S232 1080 Sensor Supply 2 circuit — Voltage Engine power
{3} {3} Above Normal, or Shorted to High derate.
Source. High voltage detected at sensor
supply 2 circuit.
234 P190 190 Engine Crankshaft Speed/Position — Fuel injection
{0} {0} Data Valid but Above Normal disabled until engine
Operational Range — Most Severe speed fails below the
Level. Engine speed signal indicates overspeed limit.
engine speed above engine protection
limit.

108
 J1587
FAULT J1939
PID（P）
CODE SPN（S） REASON EFFECT
SID（S）
{LMAP} {FMI}
{FMI}
235 P111 111 Coolant Level — Data Valid but Below Progressive power
{1} {1} Normal Operational Range — Most derate increasing in
Severe Level. Low engine coolant level severity from time of
detected. alert. If Engine
Protection Shutdown
feature in enabled,
engine will shut
down 30 seconds
after Red Stop Lamp
starts flashing.
237 S030 644 External Speed Command Primary or
{2} {2} Input(Multiple Unit Synchronization)— secondary engines
Data Erratic, Intermittent, or Incorrect. may be shutdown.
The throttle input signal to the primary
or secondary engine for multiple unit
synchronization is less than three percent
or more than 97 percent.
238 S232 620 Sensor Supply 3 Circuit — Voltage Possible hard
{4} {4} Below Normal, or Shorted to Low starting and rough
Source. Low voltage detected on the +5 running.
VDC sensor supply circuit to the engine
speed sensor.
241 P084 084 Wheel-Based Vehicle Speed — Data Engine speed limited
{2} {2} Erratic, Intermittent, or Incorrect. The to Maximum Engine
ECM lost the vehicle speed signal. Speed without VSS
parameter value.
Cruise control,
geardown
protection, and road
speed governor will
not work.
242 P084 084 Wheel-Based Vehicle Speed Sensor Engine speed limited
{10} {10} Circuit Tampering has Benn Detected to Maximum Engine
— Abnormal Rate of Change. Signal Speed without VSS
indicates an intermittent connection of parameter value.
VSS tampering. Cruise control,
geardown
protection, and road
speed governor will
not work.

109
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
245 S033 647 Fan Control Circuit — Voltage Below The fan may stay on
{4} {4} Normal, or Shorted to Low Source. Low continuously or not
signal voltage detected at the fan control run at all.
circuit when commanded on.
268 P094 094 Fuel Delivery Pressure — Data Erratic, THE ECM WILL
{2} {2} Intermittent, or Incorrect. The ECM has ESTIMATE FUEL
detected that the fuel pressure signal is PRESSURE AND
not changing. POWER IS
REDUCED.
271 S126 1347 Fuel Pump Pressurizing Assembly 1 Engine will run
{4} {4} Circuit — Voltage Below Normal, or poorly at idle.
Shorted to Low Source. Low signal Engine will have
voltage detected at the fuel pump low power. Fuel
actuator circuit. pressure will be
higher than
commanded.
272 S126 1347 Fuel Pump Pressurizing Assembly 1 Engine will not run
{3} {3} Circuit — Voltage Above Normal, or or engine will run
Shorted to High Source. High signal poorly.
voltage or open circuit detected at the
fuel pump actuator circuit.
275 S127 1348 Fuel Pump Pressurizing Assembly 2 Engine will not run
{3} {3} Circuit — Voltage Above Normal, or or engine will run
Shorted to High Source. poorly.
281 S126 1347 Fuel Pump Pressurizing Assembly 1 — Engine will not run
{7} {7} Mechanical System Not Responding or engine will run
Properly or Out of Adjustment. A poorly.
pumping imbalance between the front
and rear pumping plungers has been
detected.
284 S126 1347 Fuel Pump Pressurizing Assembly 1 — Possible hard
{7} {7} Mechanical System Not Responding starting and rough
Properly or Out of Adjustment. Low running.
signal voltage detected on the ECM
voltage supply line to the engine speed
sensor.

110
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
285 S231 639 SAE J1939 Multiplexing PGN Timeout At least one
{9} {9} Error — Abnormal Update Rate. The multiplexed device
ECM expected information from a will not operate
multiplexed device by did not receive it properly.
soon enough or did not receive it at all
286 S231 639 SAE J1939 Multiplexing Configuration At least one
{13} {13} Error — Out of Calibration. The ECM multiplexed device
expected information from a multiplexed will not operate
device but only received a portion of the properly.
necessary information.
287 P091 091 SAE J1939 Multiplexed Accelerator Engine may only
{2} {19} Pedal or Lever Sensor System — idle or engine will
Received Network Data in Error. The not accelerate to full
OEM vehicle electronic control unit speed.
detected a fault with its accelerator
pedal.
288 P029 974 SAE J1939 Multiplexing Accelerator The engine will not
{2} {19} Pedal or Lever Position Sensor Circuit respond to the
— Received detected a Network Data in remote throttle.
Error. The OEM vehicle electronic Engine may only
control unit detected a fault with the idle. The primary or
remote accelerator. cab accelerator may
be able to be used.
292 P441 441 Auxiliary Temperature Sensor Input 1 — Possible engine
{14} {14} Special instructions. power derate.
293 P441 441 Auxiliary Temperature Sensor Input 1 None on
{3} {3} Circuit— Voltage Above Normal, or performance.
Shorted to High Source. High signal
voltage or open circuit detected at the
OEM auxiliary temperature circuit.
294 P441 441 Auxiliary Temperature Sensor Input 1 None on
{4} {4} Circuit— Voltage Below Normal, or performance.
Shorted to Low Source. Low signal
voltage detected at the OEM auxiliary
temperature circuit.
296 P223 1388 Auxiliary Pressure Sensor Input 1 — Possible engine
{14} {14} Special instructions. power derate.

111
 J1587
FAULT J1939
PID（P）
CODE SPN（S） REASON EFFECT
SID（S）
{LMAP} {FMI}
{FMI}
297 P223 1388 Auxiliary Pressure Sensor Input 1 None on
{3} {3} Circuit— Voltage Above Normal, or performance.
Shorted to High Source. High signal
voltage detected at the OEM pressure
circuit.
298 P223 1388 Auxiliary Pressure Sensor Input 1 circuit None on
{4} {4} — Voltage Below Normal, or Shorted to performance.
Low Source. Low signal voltage or open
circuit detected at the OEM pressure
circuit.
319 P251 251 Real Time Clock Power Interrupt — None on
{2} {2} Data Erratic, Intermittent, or Incorrect. performance. Data in
Real Time Clock lost power the ECM will not
have accurate time
and date
information.
322 S001 651 Injector Solenoid Driver Cylinder 1 Engine can possibly
{5} {5} Circuit — Current Below Normal, or misfire or run rough
Open Circuit. High resistance detected
on injector Number 1 circuit or no
current detected at Number 1 Injector
driver or return pin when the voltage
supply at the harness is on.
323 S006 655 Injector Solenoid Driver Cylinder 5 Engine can possibly
{5} {5} Circuit — Current Below Normal, or misfire or run rough
Open Circuit. High resistance detected
on injector Number 5 circuit or no
current detected at Number 5 Injector
driver or return pin when the voltage
supply at the harness is on.
324 S005 653 Injector Solenoid Driver Cylinder 3ircuit Engine can possibly
{5} {5} — Current Below Normal, or Open misfire or run rough
Circuit. High resistance detected on
injector Number 3 circuit or no current
detected at Number 3 Injector driver or
return pin when the voltage supply at the
harness is on.

112
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
325 S006 656 Injector Solenoid Driver Cylinder 6 Engine can possibly
{5} {5} Circuit — Current Below Normal, or misfire or run rough
Open Circuit. High resistance detected
on injector Number 6 circuit or no
current detected at Number 6 Injector
driver or return pin when the voltage
supply at the harness is on.
331 S002 652 Injector Solenoid Driver Cylinder 2 Engine can possibly
{5} {5} Circuit — Current Below Normal, or misfire or run rough
Open Circuit. High resistance detected
on injector Number 2 circuit or no
current detected at Number 2 Injector
driver or return pin when the voltage
supply at the harness is on.
332 S004 654 Injector Solenoid Driver Cylinder 4 Engine can possibly
{5} {5} Circuit — Current Below Normal, or misfire or run rough
Open Circuit. High resistance detected
on injector Number 4 circuit or no
current detected at Number 4 Injector
driver or return pin when the voltage
supply at the harness is on.
334 P110 110 Engine Coolant Temperature — Data ECM will estimate
{2} {2} Erratic, Intermittent, or Incorrect. Engine Engine Coolant
Coolant Temperature reading is not Temperature.
changing with engine operation
conditions.
342 S253 630 Electronic Calibration Code None on
{13} {13} Incompatibility — Out of Calibration. performance.
An incompatible calibration between the
primary and secondary OEM installed
ECM‘s has been detected.
343 S254 629 Engine Control Module Warning Internal No performance
{12} {12} Hardware Failure — Bad Intelligent effects or possible
Device or Component. Internal ECM severe power derate.
failure.

113
 J1587
FAULT J1939
PID（P）
CODE SPN（S） REASON EFFECT
SID（S）
{LMAP} {FMI}
{FMI}
351 S254 627 Injector Power Supply — Bad intelligent Possible smoke, low
{12} {12} Device or Component. The ECM power, engine
measured injector boost voltage is low. misfire, and/or
engine will not start.
352 S212 1079 Sensor Supply 1 Circuit — Voltage Engine power
{4} {4} Below Normal, or Shorted to Low derate.
Source. Low voltage detected at sensor
supply Number 1 circuit.
386 S212 1079 Sensor Supply 1 Circuit — Voltage Engine power
{3} {3} Above Normal, or Shorted to High derate.
Source. High voltage detected at sensor
supply Number 1 circuit.
387 S212 1079 Sensor Supply 1 Circuit — Voltage Engine will only
{3} {3} Above Normal, or Shorted to High idle.
Source. High voltage detected at sensor
supply circuit for the accelerator pedal
position sensor.
415 P100 100 Engine Oil Rifle Pressure — Data Valid Progressive power
{1} {1} but Below Normal Operational Range — derate increasing in
Most Severe Level. Oil pressure signal severity from time of
indicates oil pressure below the engine alert. If Engine
protection critical limit. Protection Shutdown
feature in enabled,
engine will shut
down 30 seconds
after Red Stop Lamp
starts flashing.
418 P097 097 Water in Fuel Indicator — Data Valid but Possible white
{0} {15} Above Normal Operational Range — smoke, loss of
Most Severe Level. Water has been power, or hard
detected in the fuel filter. starting.
427 S231 639 SAE J1939 Datalink — Abnormal Engine speed will
{9} {9} Update Rate. Communication between ramp down and
the electronic control module(ECM) and remain at idle.
another device on the SAE J1939
datalink has been lost.
428 P097 097 Water in Fuel Indicator Circuit — None on
{3} {3} Voltage Above Normal, or Shorted to performance. No
High Source. High voltage detected at water in fuel
the water in fuel circuit. warning available

114
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
429 P097 097 Water in Fuel Indicator Circuit — None on
{4} {4} Voltage Below Normal, or Shorted to performance. No
Low Source. Low voltage detected at the water in fuel
water in fuel circuit. warning available
431 S230 558 Accelerator Pedal or Lever Idle Engine will only
{2} {2} Validation Switch — Data Erratic, idle.
Intermittent, or Incorrect. Voltage
detected simultaneously on both idle
validation and off-idle validation
switched.
432 S230 558 Accelerator Pedal or Lever Idle Engine will only
{13} {13} Validation Circuit — Out of Calibration. idle.
Voltage at idle validation on-idle and
off-idle circuit down not match
accelerator pedal position.
434 S251 627 Power Supply Lost Without Ignition Off Possible no
{2} {2} — Data Erratic, Intermittent, or noticeable
Incorrect. Supply voltage to the ECM performance effects.
fell below 6.2 volts momentarily, or the Engine dying, or
ECM was not allowed to power down hard starting. Fault
correctly. information, trip
information, and
maintenance monitor
may be inaccurate.
435 P100 100 Engine Oil Rifle Pressure — Data None on
{2} {2} Erratic, Intermittent, or Incorrect. An performance. No
error in the engine oil pressure switch engine protection for
signal was detected by the ECM oil pressure.
441 P168 168 Battery 1 Voltage — Data Valid but Engine may stop
{1} {18} Below Normal Operational Range — running or be
Moderately Severe Level. ECM supply difficult to start.
voltage is below the minimum system
voltage level.
442 P168 168 Battery 1 Voltage — Data Valid but Possible electrical
{0} {16} Above Normal Operational Range — damage to all
Moderately Severe Level. ECM supply electrical
voltage is above the minimum system components.
voltage level.

115
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
443 P168 168 Battery 1 Voltage — Data Valid but Engine will only
{0} {16} Above Normal Operational Range — idle.
Moderately Severe Level. Low voltage
detected at sensor supply circuit to the
accelerator pedal position sensor.
449 P157 157 Injector Metering Rail 1 Pressure — None or possible
{0} {0} Data Valid but Above Normal engine noise
Operational Range — Most Severe associated with
Level. higher injection
pressures(especially
at idle or light load).
Engine power is
reduced.
451 P157 157 Metering Rail 1 Pressure Sensor Circuit Power and or speed
{3} {3} — Voltage Above Normal, or Shorted to derate.
High Source. High voltage detected at
the rail fuel pressure sensor circuit.
452 P157 157 Metering Rail 1 Pressure Sensor Circuit Power and or speed
{4} {4} — Voltage Below Normal, or Shorted to derate.
Low Source. Low signal voltage
detected at the detected at the rail fuel
pressure sensor circuit.
488 P105 105 Intake Manifold 1 Temperature — Data Progressive power
{0} {16} Valid but Above Normal Operational derate increasing in
Range — Moderately Severe Level. severity from time of
Intake manifold temperature signal alert.
indicates intake manifold air temperature
is above the engine protection warning
limit.
497 S114 1377 Multiple Unit Synchronization Switch Multi-unit
{2} {2} — Data Erratic, Intermittent, or synchronization
Incorrect. Multi-unit synchronization feature is disabled.
ON/OFF switch and Multi-unit
synchronization complimentary ON/OFF
switch have different values in the ECM.

116
 J1587
FAULT J1939
PID（P）
CODE SPN（S） REASON EFFECT
SID（S）
{LMAP} {FMI}
{FMI}
523 P089 611 Auxiliary Intermediate （ PTO ） Speed Intermediate speed
{2} {2} Switch Validation — Data Erratic, control switch may
Intermittent, or Incorrect. The position of not operate correctly.
intermediate speed control switch 1 does
not match the position of the
intermediate speed control validation
switch.
527 P154 702 Auxiliary Input/output 2 Circuit — None on
{3} {3} Voltage Above Normal, or Shorted to performance.
High Source. High signal voltage or
open circuit has been detected at the
auxiliary input/output 2 circuit.
528 P093 093 Auxiliary Alternate Torque Validation Torque curve setting
{2} {2} Switch — Data Erratic, Intermittent, or defaults to the
Incorrect. An error has been detected in default torque curve.
the alternate torque switch circuit.
529 S051 703 Auxiliary Input/output 3 Circuit — None on
{3} {3} Voltage Above Normal, or Shorted to performance.
High Source. High signal voltage or
open circuit has been detected at the
auxiliary input/output 3 circuit.
551 S230 558 Accelerator Pedal or Lever Idle Engine will only
{4} {4} Validation Switch1 — Voltage Below idle.
Normal, or Shorted to Low Source. No
voltage detected simultaneously on both
the idle validation off-idle and on-idle
circuits.
553 P157 157 Injector Metering Rail 1 Pressure— Data None or possible
{0} {16} Valid but Above Normal Operational engine noise
Range — Moderately Severe Level. The associated with
ECM has detected that fuel pressure is higher injection
higher than commanded pressure. pressures(especially
at idle or light load).
Engine power is
reduced.
554 P157 157 Injector Metering Rail 1 Pressure— Data THE ECM WILL
{2} {2} Erratic, Intermittent, or Incorrect. The ESTIMATE FUEL
ECM has detected that fuel pressure is PRESSURE AND
not changing. POWER IS
REDUCED.

117
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
559 P157 157 Injector Metering Rail 1 Pressure— Data Possible hard to
{1} {18} Valid but Above Normal Operational start, low power, or
Range — Moderately Severe Level. The engine smoke.
ECM has detected that fuel pressure is
lower than commanded pressure.
584 S039 677 Starter Relay Driver Circuit — Voltage Either the engine
{3} {3} Above Normal, or Shorted to High will not start or the
Source. High signal voltage or open engine will not have
circuit has been detected at the sensor starter lockout
lockout circuit. protection.
585 S039 677 Starter Relay Driver Circuit — Voltage The engine will not
{4} {4} Below Normal, or Shorted to Low have starter lockout
Source. Low voltage has been detected protection.
at the sensor lockout circuit.
596 P167 167 Electrical Charging System Voltage — Amber lamp will
{0} {16} Data Valid but Above Normal light until high
Operational Range — Moderately battery voltage
Severe Level. High battery voltage condition is
detected by the battery voltage monitor corrected.
feature.
597 P167 167 Electrical Charging System Voltage — Amber lamp will
{1} {18} Data Valid but Below Normal light until low
Operational Range — Moderately battery voltage
Severe Level. Low battery voltage condition is
detected by the battery voltage monitor corrected.
feature.
598 P167 167 Electrical Charging System Voltage — Red lamp will light
{1} {1} Data Valid but Below Normal until low battery
Operational Range — Most Severe voltage condition is
Level. Very low battery voltage detected corrected.
by the battery voltage monitor feature.
599 S025 640 Auxiliary Commanded Dual Output Engine will shut
{14} {14} Shutdown — Special instructions. The down.
engine protection limit has been
exceeded for the dual outputs calibrated
limits.

118
 J1587
FAULT J1939
PID（P）
CODE SPN（S） REASON EFFECT
SID（S）
{LMAP} {FMI}
{FMI}
649 S153 1378 Engine oil change interval — Condition None on
{11} {31} Exist. Change engine oil and filter performance,
maintenance
reminder only.
689 P190 190 Engine Crankshaft Speed/Position — Engine can run
{2} {2} Data Erratic, Intermittent, or Incorrect. rough. Possibly poor
Loss of signal from crankshaft sensor starting capability.
Engine runs using
backup speed sensor.
Engine power is
reduced.
691 none 1172 Turbocharger 1 Compressor Inlet Engine power
{3} {3} Temperature Circuit — Voltage Above derate.
Normal, or Shorted to High Source.
High signal voltage been detected at
turbocharger compressor inlet air
temperature Circuit.
692 none 1172 Turbocharger 1 Compressor Inlet Engine power
{4} {4} Temperature Circuit — Voltage Below derate.
Normal, or Shorted to Low Source.
Low signal voltage been detected at
turbocharger compressor inlet air
temperature Circuit
731 S064 723 Engine Speed/Position Camshaft and Engine will run
{7} {7} Crankshaft Misalignment —Mechanical detated. Excessive
System Not Responding Properly or Out black smoke, hard
of Adjustment. Mechanical start, and rough idle
misalignment between the crankshaft possible.
and camshaft engine speed sensors.
757 none 611 Electronic Control Module Data Lost — Possible no
{11} {31} Condition Exists. Severe loss of data noticeable
from the ECM. performance effects.
Engine dying, or
hard starting.
778 S064 723 Engine Camshaft Speed/Position Sensor Engine poor starting
{2} {2} — Data Erratic, Intermittent, or Engine power
Incorrect. The ECM has detected and derate.
error in the camshaft position sensor
signal.

119
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
779 S051 703 Auxiliary Equipment Sensor Input 3 — Possible engine
{11} {11} Root Cause Not Known power derate.
1117 S251 627 Power Supply Lost Without Ignition Off Possible no
{2} {2} — Data Erratic, Intermittent, or noticeable
Incorrect. Supply voltage to the ECM performance effects.
fell below 6.2 VDC momentarily, or the Engine dying, or
ECM was not allowed to power down hard starting. Fault
correctly (retain battery voltage for 30 information, trip
seconds after key OFF). information, and
maintenance monitor
may be inaccurate.
1139 S001 651 Injector Solenoid Driver Cylinder 1 — Engine will shut
{7} {7} Mechanical System Not Responding down.
Properly or Out of Adjustment.
Unintended fueling detected in cylinder
Number 1.
1141 S002 652 Injector Solenoid Driver Cylinder 2 — Engine will shut
{7} {7} Mechanical System Not Responding down.
Properly or Out of Adjustment.
Unintended fueling detected in cylinder
Number 2.
1142 S003 653 Injector Solenoid Driver Cylinder 3 — Engine will shut
{7} {7} Mechanical System Not Responding down.
Properly or Out of Adjustment.
Unintended fueling detected in cylinder
Number 3.
1143 S004 654 Injector Solenoid Driver Cylinder 4 — Engine will shut
{7} {7} Mechanical System Not Responding down.
Properly or Out of Adjustment.
Unintended fueling detected in cylinder
Number 4.
1144 S005 655 Injector Solenoid Driver Cylinder 4— Engine will shut
{7} {7} Mechanical System Not Responding down.
Properly or Out of Adjustment.
Unintended fueling detected in cylinder
Number 4.

120
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
1145 S006 656 Injector Solenoid Driver Cylinder 4 — Engine will shut
{7} {7} Mechanical System Not Responding down.
Properly or Out of Adjustment.
Unintended fueling detected in cylinder
Number 4.
2185 S232 620 Sensor Supply 4 Circuit — Voltage Engine will only
{3} {3} Above Normal, or Shorted to High idle.
Source.
2186 S232 648 Sensor Supply 4 Circuit — Voltage Engine will only
{4} {4} Below Normal, or Shorted to Low idle.
Source. High voltage detected at +5
VDC sensor supply circuit to the
accelerator pedal position sensor.
2215 P094 094 Fuel Pump Delivery Pressure — Data Possibly hard to
{1} {18} Valid but Below Normal Operational start, low power, or
Range — Moderately Severe Level. The engine smoke.
ECM has detected that fuel pressure is
lower than commanded pressure.
2216 P094 094 Fuel Pump Delivery Pressure — Data None or possible
{0} {16} Valid but Below Normal Operational engine noise
Range — Moderately Severe Level. The associated with
ECM has detected that fuel pressure is higher injection
higher than commanded pressure. pressures (especially
at idle or light load).
2217 S240 630 Engine Control Module Calibration Possible no
{11} {31} Program Memory（RAM）Corruption — noticeable
Condition Exists. Severe loss of data performance effects.
from the ECM. Engine dying, or
hard starting. Fault
information, trip
information, and
maintenance monitor
may be inaccurate.
2249 P157 157 Injector Metering Rail 1 Pressure — Possibly hard to
{1} {1} Data Valid but Below Normal start, low power, or
Operational Range — Most Severe engine smoke.
Level. The ECM has detected that fuel
pressure is lower than commanded
pressure.

121
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
2265 P073 1075 Electric Lift Pump for Engine Fuel Engine may be
{3} {3} Supply Circuit — Voltage Above difficult to start.
Normal, or Shorted to High Source.
High voltage or open detected at the fuel
lift pump signal circuit
2266 P073 1075 Electric Lift Pump for Engine Fuel Engine may be
{4} {4} Supply Circuit — Voltage Below difficult to start.
Normal, or Shorted to Low Source. Low
signal voltage detected at the fuel lift
pump signal circuit
2311 S018 633 Electronic Fuel Injection Con Fuel pump Possible low power
{11} {31} actuator circuit resistance too high or too
low.
2321 P190 190 Engine Crankshaft Speed/Position Engine may exhibit
{2} {2} Sensor — Data Erratic, Intermittent, or misfire as control
Incorrect. Crankshaft engine speed senor switches from the
intermittent synchronization. primary to the
backup speed sensor.
Engine power is
reduced while the
engine operates on
the backup speed
sensor.
2322 S064 723 Engine Camshaft Speed/Position Sensor Possible low power.
{2} {2} — Data Erratic, Intermittent, or
Incorrect. Camshaft engine speed senor
intermittent synchronization.
2346 none 2789 Turbocharger Turbine Inlet Engine power
{0} {15} Temperature(Calculated)— Most Severe derate.
Level. Turbocharger Turbine inlet
temperature has exceeded the engine
protection limit.
2347 S309 2790 Turbocharger Compressor Outlet Engine power
{0} {15} Temperature(Calculated)— Data Valid derate.
but Below Normal Operational Range —
Least Severe Level.

122
FAULT J1587 J1939 REASON EFFECT
CODE PID（P） SPN（S）
{LMAP} SID（S） {FMI}
{FMI}
2362 S028 1072 Engine Brake Actuator Circuit Number1 Engine brake on
{4} {4} —Voltage Below Normal, or Shorted to cylinder 1, 2, and
Low Source. Low voltage detected at the 3can not be activated
engine brake solenoid Number 1 signal or exhaust brake will
circuit. not operate.
2363 S029 1073 Engine Brake Actuator Circuit Number2 Engine brake on
{4} {4} —Voltage Below Normal, or Shorted to cylinder 4, 5, and
Low Source. Low voltage detected at the 6can not be
engine brake solenoid Number 2 signal activated.
circuit.
2366 S028 1072 Engine Brake Actuator Circuit Number1 Engine brake on
{3} {3} —Voltage Above Normal, or Shorted to cylinder 1, 2, and
High Source. High voltage detected at 3can not be activated
the engine brake solenoid Number 1 or exhaust brake will
signal circuit. not operate.
2367 S029 1073 Engine Brake Actuator Circuit Number Engine brake on
{3} {3} Driver Output2 — Voltage Above cylinder 4, 5, and
Normal, or Shorted to High Source. 6can not be
High voltage or open circuit detected at activated.
the engine brake solenoid Number 2
signal circuit.
2377 S033 647 Fan Control Circuit — Voltage Above The fan may stay on
{3} {3} Normal, or Shorted to High Source. continuously or not
High voltage or open circuit detected at run at all.
the fan control circuit.
2555 S070 729 Intake Air Heater 1 Circuit — Voltage The intake air
{3} {3} Above Normal, or Shorted to High heaters may be ON
Source. High voltage detected at the air or OFF all the time.
heater signal circuit.
2556 P070 729 Intake Air Heater 1 Circuit — Voltage The intake air
{4} {4} Below Normal, or Shorted to Low heaters may be ON
Source..Low voltage detected at the air or OFF all the time.
heater signal circuit.
2557 S057 697 Auxiliary Pulse Width Modulation Can not control
{3} {3} Driver 1 Circuit — Voltage Above transmission.
Normal, or Shorted to High Source.
High voltage detected at the analog
torque circuit.

123
 J1587
FAULT J1939
PID（P）
CODE SPN（S） REASON EFFECT
SID（S）
{LMAP} {FMI}
{FMI}
2558 S057 697 Auxiliary Pulse Width Modulation Can not control
{4} {4} Driver 1 Circuit— Voltage Below transmission.
Normal, or Shorted to Low Source. Low
voltage detected at the analog torque
circuit.
2963 P110 110 Engine Coolant Temperature — Data Power derate and
{0} {15} Valid but Above Normal Operational possible engine
Range — Least Severe Level. Engine shutdown if engine
coolant temperature signal indicates protection shutdown
engine coolant Temperature is above feature is enabled.
engine protection warning limit.
2964 P105 105 Intake Manifold 1 Temperature — Data Progressive power
{0} {15} Valid but Above Normal Operational derate increasing in
Range — Least Severe Level. Intake severity from time of
manifold temperature signal indicates alert.
intake manifold temperature is above
engine protection warning limit.
2973 P102 102 Intake Manifold 1Pressure — Data Engine power
{2} {2} Erratic, Intermittent, or Incorrect. The derate.
ECM has detected an intake manifold
pressure signal that is too high or low for
current engine operating condition.

124
Electrical system diagram

CPCD50/60/70-XW38/ XW38B Electrical system diagram（ CE）

125
CPCD50/60/70-XW46/ XW46B Electrical system diagram（ CE）

126
CPYD50/60/70-XW57 Electrical system diagram（ CE）

127
CPQYD50/60/70-XW57 Electrical system diagram（ CE）

128
CPCD80/100-XW28/XW28B Electrical system diagram（ CE）

129
CPCD80/100-XW48/ XW48B Electrical system diagram（ CE）

130
 start and preheat are short
working,automatically return.

CPYD50/60/70-XW68、CPYD50/60/70-XW24 Electrical system diagram

131
CPCD50/60/70-XW65GElectrical system diagram

132
CPCD80/100-XW75G Electrical system diagram

133
CPCD50/60/70-XW95G Electrical system diagram

134
 Ⅹ. Overhead guard disassembly and installation

Overhead guard disassembly way：

1. Right gasket 2、Washer 8（10piece） 3. Washer 8（10piece） 4. Bolt M8×35（2） 5. Sleeve

6. Cushion collar 7. Bolt M6×25（4piece） 8. Left gasket 9. Handle 10. Nut M10

15. Instrument stand

11. Washer10 12. Bolt M6×35（4 piece） 13. Beam assembly 14. Bolt M8×25（6 piece）
and overhead guard

16. Cover plate 17. Bolt M6×12（8 piece） 18. Washer6 (8 piece) 19. Inlet vent 20. Pipe clamp

21. Hose 22. Thrust ring 23. Bottom beam assembly 24. Washer10 25. Bolt M10×25

27. Rearview mirror

26. Nut M8 28. Mounting plate 29. Washer6（4 piece） 30. Washer6（4 piece）
assembly
Fig.10-1 Overhead guard

135
Dismantle way：
1. Park the truck on flat repair station, place the gear in neutral, pull up the hand
brake and the engine shut down.
2. Dismantle instrument stand connected left shield, right shield and rear shield.
(Note: push inward when the button is releastd)

Front shield

Right shield

Rear shield

Left shield

Fig.10-2
3. Dismantle pedal pad, rear base plate and front base plate.
4. Disconnect right shield connected fan, alarm light(optional) switch wire.
5. Dismantle 2 bolts of inner side of left and right landing leg.
6. Open the engine cover
7. Dismantle 2 bolts of inner side of left and right landing leg.(manual wrench)
8. Dismantle auxiliary water tank of rear right leg, and dismantle 2 fixed tightening
bolts.
9. Hoist the overhead guard lightly, and dismantle 4 landing leg wires.
10.Hoist lightly

Installation is opposite to dismantlement, tightening torque of 8 bolts in place 4 is

T=137 N ·m ~167 N ·m.

136
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■ ZIP:311305
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