Maintenance: Glp/Gdp20Ux, Glp/Gdp25Ux, Glp/Gdp30Ux, GLP/ Gdp35Ux

Maintenance
A7S1
SERVICE MANUAL
GLP/GDP20UX, GLP/GDP25UX, GLP/GDP30UX, GLP/
GDP35UX
PART NO. 550216372 8000 YRM 2199

INTRODUCTION
The Service Manuals are updated on a regular basis, but may not reflect the latest design changes to the product.
Updated technical service information may be available from your local authorized YALE® distributor. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and
experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.
FOREWORD
This manual describes the structure and working principles of the 2-3.5T internal combustion forklift truck and
provides instructions for servicing and maintenance.
To ensure safety and get the best out of your forklift, all operators, equipment managers and maintenance
personnel should carefully read this manual.
Only trained and qualified personnel are permitted to carry out servicing and repairs on the forklift truck.
Series Model Engine Transmission

GLP/GDP20-25UX NISSAN K21 LPG YQXD30H(PHF)
GLP/GDP20-25UX NISSAN K21 GAS YQXD30H(PHF)
GLP/GDP20-25UX NISSAN K21 DUAL YQXD30H(PHF)
2-2.5T
Series Model Engine Transmission
GLP/GDP20-25UX MITSUBISHI S4S-455 YQXD30(PHF)
GLP/GDP20-25UX PSI 4G64 2.4L YQXD30(PHF)
2-2.5T
GLP/GDP20-25UX XINCHAI 4D27G31 YQXD30A(PHF)
GLP/GDP20-25UX YANMAR 4TNE92 YQXD30(PHF)
GLP/GDP30-35UX MITSUBISHI S4S-455 YQXD30(PHF)
3-3.5T
GLP/GDP30-35UX PSI 4G64 2.4L YQXD30(PHF)
GLP/GDP30-35UX XINCHAI 4D27G31 YQXD30A(PHF)
NOTE: DUAL designates DUAL FUEL or BI-FUEL.

Table of Contents
TABLE OF CONTENTS
Forklift Truck Main Parts......................................................................................................................................... 1
Description of Forklift Truck Main Parts................................................................................................................1
Forklift Main Technical Parameters......................................................................................................................... 2
Main Technical Parameters.................................................................................................................................. 2
Power System......................................................................................................................................................... 5
Engine System......................................................................................................................................................5
Engine Overview................................................................................................................................................5
Fuel System....................................................................................................................................................... 6
Fuel Tank.........................................................................................................................................................7
Fuel Level Sensor............................................................................................................................................8
Maintenance of Fuel System...........................................................................................................................9
Fuel filter service...........................................................................................................................................9
Hydraulic Transmission Case and Torque Converter............................................................................................10
Overview.............................................................................................................................................................10
Torque Converter................................................................................................................................................ 11
Hydraulic Clutch..................................................................................................................................................12
Control Valve, Safety Valve, and Inching Valve.................................................................................................. 13
Transmission Case............................................................................................................................................. 15
Transmission Pump............................................................................................................................................ 15
Transmission hydraulic schematic .....................................................................................................................15
Speed Reducer and Speed Differential.............................................................................................................. 16
Speed Reducer................................................................................................................................................ 16
Speed Differential.............................................................................................................................................17
Towing the Lift Truck...........................................................................................................................................17
Oil Inlet/Outlet Connection Location................................................................................................................... 17
Drive Axle..............................................................................................................................................................18
Overview.............................................................................................................................................................18
Maintenance of Drive Axle..................................................................................................................................19
Steering System....................................................................................................................................................20
Steering System................................................................................................................................................. 20
Overview.......................................................................................................................................................... 20
Hydraulic Steering Gear Assembly................................................................................................................20
Steering Cylinder...........................................................................................................................................21
Inspection of Reassembled Steering System.................................................................................................. 22
Troubleshoot Steering System.........................................................................................................................23
Steering and Drive Axle Information..................................................................................................................... 24
Steering Axle...................................................................................................................................................... 24
Overview.......................................................................................................................................................... 24
Steering Knuckle and Steering King Pin.......................................................................................................... 25
Steering Wheel Bearing Pre-load Information..................................................................................................26
Brake System........................................................................................................................................................26
Overview.............................................................................................................................................................27
Brake Master Cylinder........................................................................................................................................ 27
Wheel Brake....................................................................................................................................................... 27
Automatic Brake Adjuster................................................................................................................................... 31
Manual Brake......................................................................................................................................................32
Adjustment of Brake Pedal................................................................................................................................. 32
Maintenance....................................................................................................................................................... 32
Disassemble, Wheel Brake..............................................................................................................................33
Examination of Wheel Brake............................................................................................................................35
Assemble, Wheel Brake...................................................................................................................................36
Operating Test Automatic Clearance Regulator...............................................................................................38
©2021 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)

Troubleshoot Wheel Brake...............................................................................................................................39
Hydraulic System.................................................................................................................................................. 41
Overview.............................................................................................................................................................41
Steering Control Unit.......................................................................................................................................... 42
Multi-way Valve and Priority spool ..................................................................................................................... 42
Operation of Spool Valve................................................................................................................................. 42
Neutral Position............................................................................................................................................. 42
Spool Valve (Pushed In):............................................................................................................................... 43
Spool Valve (Pulled out):............................................................................................................................... 43
Primary Relief Valve and Priority Spool........................................................................................................... 43
Inclined Auto-Lock Valve..................................................................................................................................44
Hydraulic System Main Oil Circuit ..................................................................................................................... 45
Lift Cylinder.........................................................................................................................................................47
Velocity Fuse...................................................................................................................................................... 49
Tilt Cylinder.........................................................................................................................................................50
Maintenance of Hydraulic Pump.........................................................................................................................51
Disassemble, Main Oil Pump...........................................................................................................................51
Inspection and Repair...................................................................................................................................... 51
Assemble, Main Oil Pump................................................................................................................................54
Test...................................................................................................................................................................55
Troubleshoot Hydraulic System..........................................................................................................................59
Lifting System........................................................................................................................................................60
Safety Procedures When Working Near Mast.................................................................................................... 60
Overview.............................................................................................................................................................62
Inside and Outside Masts................................................................................................................................... 62
Carriage..............................................................................................................................................................63
Adjustment of Lifting System.............................................................................................................................. 63
Electrical System...................................................................................................................................................64
Overview.............................................................................................................................................................64
Power supply system....................................................................................................................................... 64
Starting system................................................................................................................................................ 64
Ignition system (ICE forklift truck).................................................................................................................... 64
Preheating system (diesel forklift truck)........................................................................................................... 64
Dash Instrument Display System.....................................................................................................................65
Lighting, sound and alarm system................................................................................................................... 65
Electrical Box......................................................................................................................................................65
Battery................................................................................................................................................................ 65
Description and Summary of Basic Truck Operations........................................................................................ 65
Introduction to the Power Distribution Module (PDM)........................................................................................ 67
Electrical Schematics..........................................................................................................................................67
Troubleshoot Electrical System.......................................................................................................................... 81
Troubleshooting............................................................................................................................................... 81
Drive, Operation, and Routine Maintenance of Forklift Truck............................................................................... 82
Cooling System Troubleshooting and Service....................................................................................................82
Coolant level check..........................................................................................................................................82
Flushing the cooling system.............................................................................................................................82
Adding antifreeze/coolant.................................................................................................................................82
Cleaning the radiator........................................................................................................................................82
Oils Used for Forklift Truck................................................................................................................................. 83
Hydraulic Oil Gauge and Hydraulic Oil fill...........................................................................................................83
General inspection requirements..................................................................................................................... 83
Fill Level Requirements....................................................................................................................................83
ii
Table of Contents
TABLE OF CONTENTS (Continued)

Lubrication System............................................................................................................................................. 83
PDM Schematics...................................................................................................................................................85
iii
8000 YRM 2199 Forklift Truck Main Parts
Forklift Truck Main Parts

DESCRIPTION OF FORKLIFT TRUCK
MAIN PARTS
System Subassemblies
Power System Transmission System Torque Converter Hydraulic Speed Reducer or
Transmission Case Speed Differential
Drive Axle Steering System Steering Axle Lifting System
Brake and Inching
Control (Hydraulic
Truck)
Control System Parking Brake Hydraulic System
Throttle Control
Steering Control
Electrical System
1
Forklift Main Technical Parameters 8000 YRM 2199
Forklift Main Technical Parameters
MAIN TECHNICAL PARAMETERS
Figure 1. Outside Drawing of Forklift Truck(LPG/DUAL)
2
8000 YRM 2199 Forklift Main Technical Parameters
Figure 2. Outside Drawing of Forklift Truck (Diesel engine/gasoline engine)
NOTE: Truck with diesel engine is shown. Other are for standard configuration only. Always consult the
trucks are similar. The values in the parameter tables nameplate to see the values of a specific truck.
3
Forklift Main Technical Parameters 8000 YRM 2199
Table 1. Technical Parameters

Parameter Model
GLP/GDP20UX GLP/GDP25UX
Engine Model 4G64 2.4L 4G64 2.4L
Manufacturer PSI PSI
Power Source GAS/LPG GAS/LPG
Rated Capacity 2000 kg (4409.2 lb) 2500 kg (5511.6 lb)
Load Center 500 mm (19.7 in.) 500 mm (19.7 in.)
Lifting Height 3000 mm (118.1 in.) 3000 mm (118.1 in.)
Free Lift Height 160 mm (6.3 in.) 160 mm (6.3 in.)
Mast Tilt Angle Forward/Back 6/12° 6/12°
Max Lifting Speed No-Load 580 mm/s (1.9 ft/s) 580 mm/s (1.9 ft/s)
Full-Load 550 mm/s (1.8 ft/s) 550 mm/s (1.8 ft/s)
Running Speed Forward 20 kph (12.4 mph) 20 kph (12.4 mph)
Back 20 kph (12.4 mph) 20 kph (12.4 mph)
Max Traction Force No-Load 15000 N (3372.1 lbf) N 15000 N (3372.1 lbf)
( lbf)
Full-Load 17000 N (3821.8 lbf) 17000 N (3821.8 lbf)
Gradeability No-Load 20% 20%
Full-Load 20% 20%
Min Turning Radius 2290 mm (90.2 in.) 2350 mm (92.5 in.)
Minimum Turning Radius Width K 3966 mm (156.1 in.) 4026 mm (158.5 in.)
Total Length L （Without Fork） 2535 mm (99.8 in.) 2596 mm (102.2 in.)
Total Width W 1150 mm (45.3 in.) 1150 mm (45.3 in.)
Total Height D （Mast Retracted） 2010 mm (79.1 in.) 2010 mm (79.1 in.)
Total Height E （Mast Extended） 3990 mm (157.1 in.) 3990 mm (157.1 in.)
Wheelbase F 1600 mm (63 in.) 1600 mm (63 in.)
Track Width Front Q1 970 mm (38.2 in.) 970 mm (38.2 in.)
Front Q2 980 mm (38.6 in.) 980 mm (38.6 in.)
Front Overhang B 476 mm (18.7 in.) 476 mm (18.7 in.)
Rear Overhang C 484 mm (19.1 in.) 545 mm (21.5 in.)
Fork Dimension Length 1070 mm (42.1 in.) 1070 mm (42.1 in.)
Width 100 mm (3.9 in.) 100 mm (3.9 in.)
Height 40 mm (1.6 in.) 40 mm (1.6 in.)
Fork Spacing Adjustable Range 250-1000 mm 250-1000 mm
(9.8-39.4 in.) (9.8-39.4 in.)
Ground Clearance （Bottom Of Mast） 125 mm (4.9 in.) 125 mm (4.9 in.)
Total Weight 3390 kg (7474 lb) 3650 kg (8046.9 lb)
4
8000 YRM 2199 Power System
Power System
ENGINE SYSTEM
NOTE: Engine availability may be different in your
market. Contact your local Hyster dealer for more
information.
Engine Overview
Refer to Table 2 for the imported DUAL FUEL and
LPG used for 2.0-3.5t forklift trucks in A series.
Table 2. Gasoline Engine (2.4)

Model PSI 4G64-2.4L
Type 4-Stroke, Water-Cooling, Straight-Line, and Valve in Head
Number of Cylinders 4
Cylinder Diameter × Stroke 86.5 × 100 mm (3.41 × 3.94 in.)
Total Displacement I 2.35 liter (143.4 in.3)
Compression Ratio 9.5
48/2700（kw/rpm）
Gasoline Engine
Rated Power/ 64.4/2700（hp/rpm）
Speed kw(ps)/rpm 46/2700（kw/rpm）
LPG Engine
61.7/2700（hp/rpm）
170/2400（N.m/rpm）
Gasoline Engine
125.4/2400（lbf·ft/rpm）
Max Torque/Speed
168/1600（N.m/rpm）
LPG Engine
123.9/1600（lbf·ft/rpm）
No-Load Min Speed 750 rpm
Fuel Specific Consumption 290 g/psh (.096 g/hph)
677.4 × 543.6 × 711.0 mm
Total Length × Total Width × Total
Height
(26.7 × 21.4 × 28.0 in.)
Movement Direction In Clockwise Direction Looking from the End of Fan
Firing Order 1-3-4-2
5
Power System 8000 YRM 2199
Table 2. Gasoline Engine (2.4) (Continued)

Model PSI 4G64-2.4L
Inlet Valve Open
before Top Dead 8°
Center (BTDC)
Inlet Valve Close
after Bottom Dead 48°
Center (ABDC)
Valve Timing Exhaust Valve

Open before
31°
Bottom Dead
Center (BBDC)
Exhaust Valve
Close after Top
36°
Dead Center
(ATDC)
Timing belt change interval 6000 hrs
Cooling System Forced Circulation Water Cooling
Lubricating System Forced Lubrication
Gasoline Pump Membrane Type
Air Filter Paper Element Filter
Engine Oil Pump Gear Type
Oil Rough Filter Paper Filtration
Water Pump Centrifugal Type
Thermostat Wax Type
Voltage 12V
Generator
Current 70A
Voltage 12V
Starter
Output Power 1.2 kW (1.61 hp)
Voltage 12V
Battery
Capacity 60Ah
Referential Data
Lubricating Oil 4.5 liter (4.7 qt)
Engine 3.5 liter (3.7 qt)
Coolant
Radiator 3.5 liter (3.7 qt)
Refer to the engine operation and maintenance Fuel System

manuals for more information about engines used for
2-3.5t forklift trucks. Fuel system is composed of fuel tank, fuel quantity
sensor, and fuel quantity indicator. See Figure 5 and
Figure 6.
6
Fuel Tank 3-3.5t forklift trucks. The Fuel Level Sensor is fitted on
the tank cover of fuel tank to detect the fuel level. See
The fuel tank is a welded structure contained within Figure 3 or Figure 4.
the frame of the forklift truck. The capacity of fuel tank
for 2-2.5t is 59 liter (15.6 gal), and 65 liter (17.2 gal) for
1. PORT SEALED 3. FLOAT RISE 5. OIL INLET

2. FUEL LEVEL 4. FLOAT DROP 6. GAS FILTER
Figure 3. Fuel Tank (Gasoline Forklift Truck)
7
Power System 8000 YRM 2199
Figure 4. Fuel Tank (LPG Forklift Truck)
Fuel Level Sensor

The Fuel Level Sensor is used to convert the
remaining fuel quantity in fuel tank into voltage. This is
to monitor the amount of fuel currently in the fuel tank.
Refer to Figure 5. The value of resistance will change
when the float moves up and down, depending on the
fuel level. Resistance is controlled by using steel wire
that is fabricated into the slide. The fuel quantity inside
the fuel tank can be read on the instrument panel
through the electromagnetic fuel gauge.
1. FUEL LEVEL
2. FLOAT RISE
3. FLOAT DROP
Figure 5. Fuel Level Sensor
8
Fuel Position Resistance (Ω)

FULL 180±5
½ 95±5
EMPTY 10±½
Maintenance of Fuel System

The fuel system is to be maintained and serviced once
for every 100 work hours, with the following method.
The fuel tank must be cleaned once every 600 work
hours.
Fuel filter service

The fuel filter is used to remove dust and impurities in
fuel. The fuel filter is located between the fuel tank and
the gasoline pump (gasoline engine) or oil delivery
pump and oil injection pump (diesel engine).
1. STEEL TUBE CLAMP

2. FUEL FILTER
3. HIGH PRESSURE FUEL PUMP
4. FUEL PUMP FITTING AND GASKET
5. FUEL PUMP MANIFOLD
6. 6 STOR 5/16 SAE FITTING
7. 3 STOR 5/16 SAE FITTING
Figure 6. Fuel Filter (PSI 4G64-2.4L Engine)
The fuel filter must be changed every 400 hours or

every 6 months.
9
Hydraulic Transmission Case and Torque Converter 8000 YRM 2199
Hydraulic Transmission Case and Torque Converter
Type Three-Element, Single-Stage, and

Two-Phase Type
Torque Converter
Torque Ratio 2.8-3.0:1
Pressure Range 0.5-0.7 MPa (72.5-101.5 psi)
Type Internal Meshing Gear Type
Oil Feed Pump Flow Rate 27 l/min (1.5 MPa x 2000 rpm)
7.1 g/min (217.6 psi x 2000 rpm)

Type Power Gear Shift
Forward 17.5:1
Hydraulic Transmission Case Speed Ratio
Reverse 17.5:1
Pressure Range 1.2 to 1.5 MPa (174 to 218 psi)
Brake Shoes Outer Diameter x Inner 125 x 81 x 2.7 mm (4.9 x 3.2 x
Diameter x Thickness 0.1 in.)
Hydraulic Clutch
Brake Shoes Frictional Surface Area 71 cm2 (11 in2)
Pressure Range 1.1 to 1.4 MPa (160 to 203 psi)
Weight 165 kg (363.8 lb)
Transmission (Total) 8.6 liter (9.1 qt)
Oil Capacity Transmission (Drain and fill) 4.7 liter (5 qt)
Radiator 1 liter (1.1 qt)
Type of Oils Used Kinematic Viscosity 5-7 cSt at 212°F
(100℃ mm2/s）
CALTEX：Torque Fluid 175; RPM

torque fluid NO.5
ESSO:Torque Fluid 47
SHELL：Rotella 10w
Clean the oil filter（coarse strainer） Every 1000 hours
Replace the oil filter（fine filter） Every 250 hours
OVERVIEW 2. The hydraulic clutch is equipped with four pairs

of brake shoes and steel plates that have been
The transmission is mounted with a torque converter specially designed to be abrasion resistant.
and power gear-shift transmission case (see Figure 7).
3. The hydraulic clutch is mounted in the torque
The hydraulic transmission case and torque converter converter to improve the transmission power
provides the following advantages: and efficiency.
1. The inching valve allows the truck to perform 4. A filter is located in the hydraulic circuit, to
inching operations at both high and low engine screen impurities from the fluid/oil and help
speeds. keep the torque converter clean and functioning.
10
8000 YRM 2199 Hydraulic Transmission Case and Torque Converter
1. GEAR SHAFT 10. OUTPUT SHAFT

2. TAPERED ROLLER BEARING 11. IDLER GEAR
3. TORQUE CONVERTER HOUSING ASSEMBLY 12. OUTPUT GEAR
4. OIL PUMP ASSEMBLY 13. HYDRAULIC TOR-CON CONVERTER
5. COVER AND CONTROL VALVE ASSEMBLY 14. INCH VALVE ASSEMBLY
6. CLUTCH ASSEMBLY 15. DIFFERENTIAL ASSEMBLY
7. BEARING PLATE 16. SPIRAL BEVEL GEAR
8. HOUSING 17. BEARING CAP
9. IDLER SHAFT
Figure 7. Hydraulic Transmission Device
TORQUE CONVERTER This method of torque conversion ensures a high-

efficient and steady operation.
The torque converter is composed of three parts, a
pump impeller, turbine, and guide pulley. The torque converter for the transmission is connected
with the flywheel of engine through an elastic plate, it
Pump impeller is driven by the input shaft. The fluid is turns along with the rotation of the engine. Oil fills the
sprayed onto the blades of turbine and along the pump torque converter. The drive gear is connected to the
impeller blades by centrifugal force. Torque is then pump impeller by gear teeth, this controls the oil feed
provided to output shaft. The fluid exiting the turbine pump. The oil feed pump then supplies oil to the
changes direction to the guide pulley. Reactive torque torque converted and the hydraulic shifting
is then generated to push the guide pulley causing the transmission case. The turbine is connected to the
output torque to be greater than the input torque. If the turbine shaft with splines. Power is transmitted to the
fluid flows into the blades of guide pulley in reverse power gear-shift transmission case through the turbine
direction, it causes the reactive torque to act in shaft.
reverse. This causes the torque of output shaft to be
less than the input shaft torque. To prevent this, the
clutch mounted inside the guide pulley allows the
guide pulley to rotate freely when reactive torque is
reversed.
11
HYDRAULIC CLUTCH
Wet multi-disk hydraulic clutch is mounted on the input
shaft of hydraulic transmission case. It distributes oil
pressure to the forward or reverse clutch through the
control valve, this causes the forward and reverse gear
shift. All the gears in transmission case are normally-
engaged gears. Each clutch is composed of alternately
assembled, four spacers (item 18, Figure 9), four
brake shoes (item 19, Figure 9), and one piston (item
2, Figure 9). The internal and external surfaces of the
piston are fitted with seal rings to ensure a proper seal.
In NEUTRAL position, the piston does not interact with
the spacer and the brake shoe. While in gear, oil
pressure controls the piston. The spacer compresses
against the brake shoe, and an the adapter transmits
power from torque converter to the driving gears
(items 4 and 6, Figure 9).
The transmission of power from torque converter to
hydraulic transmission case is as follows:
Turbine → Input Shaft Assembly → Spacer →
Brake Shoe → Forward Gear or Reversing Gear →
1. OIL DRAIN PLUG 6. BALL BEARING Output Shaft
2. FLEX PLATE 7. RETAINER RING
3. TURBINE 8. TURBO SHAFT
4. GUIDE PULLEY 9. ONE-WAY CLUTCH
5. THRUST BEARING 10. PUMP IMPELLER
Figure 8. Torque Converter
12
1. END PLATE 9. INPUT SHAFT ASSEMBLY 17. SEAL RING (B)

2. PISTON 10. THRUST COLLAR (A) 18. SPACER
3. O-RING 11. NEEDLE BEARING 19. BRAKE SHOE
4. FORWARD GEAR 12. THRUST SHAFT COLLAR (B) 20. STOPPER
5. RETURNING SPRING 13. AXIS SNAP RING 21. DISC PLATE
6. REVERSING GEAR 14. SPRING SEAT 22. FORWARD OIL CIRCUIT
7. BEARING 15. STEEL BALL 23. REVERSE OIL CIRCUIT
8. SEAL RING (A) 16. PLUG
Figure 9. Forward/Reverse Clutch Pack
CONTROL VALVE, SAFETY VALVE, AND The Overflow Valve: The overflow valve is connected
INCHING VALVE to the transmission case and allows the oil pressure
from the torque converter to maintain within its
The Control Valve is mounted on the inner side of the operating range 0.5-0.7 MPa (72.5-101.5 psi). See
transmission case cover (see Figure 10). The control Figure 16
valve includes three components: controlling slide
valve, constant pressure valve, and adjusting valve. The Inching Valve The inching valve is installed on
the left side of transmission case. The spool is
• Controlling Slide Valve: Used to control connected to the linking rod of the inching pedal. This
forward and backward functions. spool will move forward when inching pedal is
• Constant Pressure Valve: Maintains the oil pressed. The oil pressure of the hydraulic clutch will be
pressure of the hydraulic clutch to be within the reduced, causing the truck to move slowly. See
range of 1.1-1.4 MPa (159.5-203.1 psi). Figure 11.
• Adjusting Valve: It is located between inching
valve and controlling slide valve. When
controlling slide valve is fully open, this valve
will start adjusting to reduce the impact of clutch
during engagement.
13
1. WOODRUFF KEY 3. PIN

2. O-RING SEAL
A. FORWARD C. REVERSE
B. NEURTRAL POSITION
Figure 10. Control Valve
14
1. DRIVING GEAR
1. SCREW PLUG 8. SPRING 2. GUIDING GEAR SEAT
2. SCREW PLUG 9. SNAP RING 3. DRIVEN GEAR
3. SNAP RING 10. OIL SEAL 4. PUMP SHELL
4. SPRING 11. PAD
5. SCREW PLUG 12. INCHING VALVE
6. O-RING BODY Figure 12. Oil Feed Pump
7. INCHING VALVE 13. INCHING SLIDE
SHAFT VALVE TRANSMISSION HYDRAULIC SCHEMATIC
Figure 11. Inching Valve After the engine is started, the oil feed pump draws out
oil from the oil tank (the bottom of transmission case)
TRANSMISSION CASE through the oil filler. The oil then flows through the
control valve in which the pressurized oil is divided into
The transmission case houses the input shaft, output two parts. One part is fed to the hydraulic clutch, and
shaft, other internal components, and also functions as the other part is fed to the torque converter.
an oil tank. An oil filter is available on the side of the
The oil necessary for operation of hydraulic clutch
case to filter the oil that is drawn into the oil pump.
flows into the constant pressure valve (the pressure of
While the pipeline filter/oil filler cap are mounted in the
this valve should be adjusted to
upper part of the case cover.
1.1-1.4 MPa (159.5-203.1 psi)). The oil from the
constant pressure valve then flows to inching valve, to
TRANSMISSION PUMP
the controlling slide valve. It is also directed from the
The transmission Pump is installed between the torque inching valve into the impeller of torque converter
converter and the input shaft. It feeds oil to torque through overflow valve (the pressure should be
converter and hydraulic transmission case by adjusted to 0.5-0.7 MPa (72.5-101.5 psi)). The oil
actuating a pair of gears through pump impeller. See coming out of the torque converter is cooled down
Figure 12. through transmission cooler. It then lubricates the
hydraulic clutch and returns to oil tank. See Oil Inlet/
Outlet Connection Location
When in neutral, the oil circuit from controlling slide
valve to clutch is turned off. The constant pressure
valve is turned on to make sure all the oil is
transmitted to torque converter through the overflow
valve. When controlling slide valve is in the forward or
reverse position, the oil circuit from slide valve to the
forward clutch or to reverse clutch is connected to
make each clutch engage. When one clutch is
15
engaged, the spacer and the brake shoes of the other or most of the oil flowing into clutch is drained to the oil
clutch are separated and are lubricated by cooling oil. tank through inching valve, of the oil to torque
When inching pedal operates the inching valve, part of converter is the same as in neutral position.
1. OVERFLOW PRESSURE BUFFER VALVE 10. TO LUBRICATING OIL CIRCUIT

2. BUFFER VALVE 11. ROUGH OIL FILTER
3. MAJOR OIL PRESSURE 12. OIL PUMP
4. MAJOR PRESSURE ADJUSTING VALVE 13. INCHING VALVE
5. OVERFLOW VALVE 14. CLUTCH PRESSURE REDUCTION FINISHES
6. OVERFLOW PRESSURE 15. CLUTCH PRESSURE REDUCTION STARTS
7. IMPELLER 16. ELECTROMAGNETIC REVERSING VALVE
8. GUIDE WHEEL 17. THROTTLE ORFICE
9. TURBINE 18. FINE OIL FILTER
Figure 13. Transmission Hydraulic Schematic
SPEED REDUCER AND SPEED with tapered roller bearing, and a gasket is used to
DIFFERENTIAL adjust the clearance.
Speed Reducer
The speed reducer is located on the front of the
transmission case (see Figure 14). This mechanism
reduces the rotating speed of output shaft and
increased the torque transmitted from the output shaft.
It sends this torque to the speed differential. The
speed reducer is composed of a small spiral bevel
gear on the output shaft, a large spiral bevel gear, and
a small gear shaft. The large spiral bevel gear is
mounted on the small gear shaft through spline while
the two ends of small gear shaft are both supported
16
cylindrical pink, and gear ring I is fixed onto the shell of

speed differential using articulated bolts. See
Figure 15.
A half shaft gear and half transmit power from the
transmission through the differential and to the wheels.
1. SPEED REDUCER ASSEMBLY

2. BEARING SEAT
3. SHELL
4. BEARING COVER
5. BEARING
6. GASKET
7. TERMINAL BEVEL GEAR SHAFT
8. DRIVING SPIRAL BEVEL GEAR 1. GEAR RING
9. RING SPIRAL BEVEL GEAR 2. BOLT
3. BEARING
Figure 14. Speed Reducer 4. COPPER PAD
5. CROSS AXLE
Speed Differential 6. SPEED DIFFERENTIAL SHELL
7. HALF-AXLE GEAR
The speed differential is mounted on the front of the 8. PLANETARY GEAR
shell by a bearing seat and ball bearings on the two
ends. The front is connected to the axle shell. The Figure 15. Speed Differential
shell of speed differential is made into a type of left
and right parts, with two half shaft gears and four TOWING THE LIFT TRUCK
planetary gears. The thrust washer is mounted When the forklift truck with hydraulic transmission is
between the shell of speed differential and gear and it damaged and must be towed by other vehicles.
is allowable for a clearance to be retained between
respective gear pairs. The planetary gears are • Remove the half shaft from the front wheel.
supported using gear shafts I and II, while gear shaft I • Place the gear-shift lever in the NEUTRAL
is fastened onto the body of speed differential using position.
17
Drive Axle 8000 YRM 2199
OIL INLET/OUTLET CONNECTION LOCATION
Figure 16. Oil Inlet/Outlet Connection Location
Drive Axle
Type Front Wheel Drive, Axle Body Fixed with Vehicle Chassis, and Fully Floating Type
Truck 2-2.5T 3-3.5T
Single Tire Double Tire Single Tire Double Tire
Capacity
Tire Model 7.00-12-12 PR 7.00-12-12 PR 28×9-15-14 PR 28×9-15-14 PR
Rim Size 5.00S-12 5.00S-12 7.00T-15 7.00T-15
Tire Pressure 860 kPa (124.7 psi) 970 kPa (140.7 psi)
OVERVIEW receives the torque transmitted by wheel hut. The oil

seal is fitted inside the wheel hub, to prevent entry of
The Drive axle is composed of the axle housing, wheel water and dust, or an oil leak.
hub, half shaft, and brake. The axle housing is a cast
structure. The tire is connected to the wheel hub by The 2-2.5t the wheel rim for a single tire is a partial
the wheel rim with stud bolts and nuts. The power is type, with the wide tire used for 3t and 3.5t. The 2-3.5t
transmitted to half shaft through the speed differential, forklift trucks may be equipped with a double tire. See
then to the front wheel, causing the wheel hub to Figure 17 and Figure 18.
rotate. Each wheel hub is mounted on axle housing by
two tapered roller bearings, so the half shaft only
18
8000 YRM 2199 Drive Axle
3. Tighten the half shaft mounting nut. Torque to

96-111 N•m (70.8-81.9 lbf ft).
4. Tighten the wheel mounting nut. Torque to

470-550 N•m (346.7-405.7 lbf ft).
5. Tighten the brake drum mounting. Torque to

206-225 N•m (151.9-166.0 lbf ft).
1. WHEEL RIM
2. WHEEL HUB
3. BRAKE DEVICE
4. AXLE HOUSING
5. HALF SHAFT
Figure 17. Single Wheel Drive Axle
MAINTENANCE OF DRIVE AXLE

To replace the drive axle wheel nut: Figure 18. Dual Wheel Drive Axle
1. Coat tapered roller bearing with lubricating

grease.
2. Tighten the lock nuts. Make sure that the rotating

torque of the wheel hub is
9.8-29.4 N•m (7.2-21.7 lbf ft).
19
Steering System 8000 YRM 2199
Steering System
STEERING SYSTEM
Type of Steering System Rear Wheel Steering with Power Steering

Forklift Truck Capacity 2T, 2.5T, 3T, 3.5T
Cycloid Full Hydraulic Steering Gear BZZ1-125BC-D
Cylinder Diameter 70 mm (2.8 in.)
Steering
Diameter of Piston Rod 50 mm (2 in.)
Cylinder
Stroke 99 mm (3.9 in.)
Diameter of Steering Wheel 300 mm (11.8 in.)
Overview
The steering system is composed of a hydraulic
steering gear, and steering cylinder.
Hydraulic Steering Gear Assembly

The steering system is composed of a fully hydraulic
steering gear and steering cylinder. See Figure 19
Item 2. The hydraulic steering gear transfers high
pressure hydraulic fluid from the bypass valve to the
steering cylinder. When engine is turned off, the pump
cannot feed hydraulic fluid, and steering may be
performed manually.
The steering column and steering wheel are designed
to tilt 4.5º forward and backward, for operator comfort.
See Figure 19 Item 1.
1. STEERING WHEEL 2. STEERING GEAR
Figure 19. Hydraulic Steering Gear and Steering

Wheel
20
8000 YRM 2199 Steering System
1. VALVE ELEMENT 16. SPRING SHIM

2. SLEEVE 17. JOINT SHAFT
3. NEEDLE BEARING 18. MIDDLE PLATE
4. SLEEVE 19. ROTOR
5. O-RING 20. STATOR
6. VALVE BODY 21. O-RING
7. O-RING 22. SLIP RING
8. X-TYPE SEAL 23. LIMIT RING
9. FRONT CAP 24. REAR CAP
10. O-RING 25. WASHER
11. SPRING WASHER 26. LIMIT BOLT 35-40 N•m (25.8-29.5 psi)
12. HEX SOCKET SCREW 20-30 N•m (14.8-22.1 psi) 27. HEX FLANGED SCREW 35-40 N•m (25.8-29.5 psi)
13. PIN 28. THREAD BUSHING
14. VALVE DRUM 29. STEEL BALLS
15. WASHER
Figure 20. Hydraulic Steering Gear
Steering Cylinder
The steering cylinder is a double acting cylinder. The fully hydraulic steering gear enables the piston rod to
two ends of piston rod are connected with a steering move left or right through steering cylinder, thus to
knuckle by connecting rod. Pressurized oil from the achieve proper steering.
21
Steering System 8000 YRM 2199
1. CYLINDER CASING 9. RETAINER

2. CIRCLIP 10. PISTON ROD
3. O-RING 11. SUPPORT RING
4. AXIAL SEAL RING 12. O-RING SEAL
5. FLAP 13. STEEL BALL
6. O-RING SEAL 14. PISTON
7. CYLINDER CAP 15. O-RING SEAL
8. DUST RING 16. SUPPORT RING
Figure 21. Steering Cylinder
Inspection of Reassembled Steering 3. Use a jack to lift the rear wheels. Slowly turn the
System steering wheel to the left and right. Repeat for
several times, to remove any air from the fluid line
1. Turn the steering wheel to the left and right, to and cylinder.
confirm both sides will turn to equally.
2. Inspect hydraulic oil lines and confirm they are

connected in the right direction and properly
routed.
22
8000 YRM 2199 Steering System
Troubleshoot Steering System
Problem Cause Solution

Oil pump damaged or malfunctioning Replace pump
Steering Wheel Not
Priority spool blocked or damaged Clean or replace
Turning
Rubber hose joint damaged or fluid line blocked Clean or replace
Adjust Steering relief
Steering relief valve pressure too low
valve
Air present in oil circuit Remove air
Hard Steering
Reset of steering gear out of operation, and
Replace leaf spring
positioning leaf spring broken
Excessive internal leak of steering cylinder Inspect sealing of piston
Adjust Steering relief
Excessive oil flow
Forklift Truck Swinging valve
walk Check physical
Warn or damaged steering components
components
Fluid tank level low Add hydraulic fluid
Abnormal Noise Clean or replace suction
Suction pipe or oil filter blocked
pipe or filter
Steering cylinder guide sleeve damaged or hoses or
Fluid Leak Replace
joint damaged
23
Steering and Drive Axle Information 8000 YRM 2199
Steering and Drive Axle Information

STEERING AXLE
Tonnage 2-3.5t
Type of Axle body Supported with Central Supporting Shaft
Steering angle Inner Side Wheel 78º
Outer Side Wheel 54º
King pin Center to Center of Kingpins 810mm (31.89 in)
Side Inclination Angle 0º
Wheel Camber Angle 1º
Wheel
Tonnage 2-2.5t 3-3.5t
Tire Drive 7.00-12-12 PR 28×9-15-14 PR
Steer 6.00-9-10 PR 6.50-10-10 PR
Rim Drive 5.00S-12 7.00T-15
Steer 4.00E-09 5.00F-10
Inflation Pressure Drive 860KPa (124.7 psi) 970KPa (140.7 psi)
Steer 860KPa (124.7 psi) 790KPa (114.6 psi)
Total Weight Around 115kg (253.5 lbs.) Around 140kg (308.6 lbs.)
Overview frame, swing bridge fitness around the pin axis, around
the steering axle were about to have a steering
The steering bridge is an open welded structure with knuckle, wheel hub with two tapered roller bearings
box cross-section (see Figure 22). It is composed of after loaded on the steering shaft, wheel by pry to the
the steering bridge body, the steering cylinder, the hub, rim inside of the bearing is equipped with oil seal,
connecting rod and the steering wheel. The steering keep the grease in the cavity between the wheel and
trapezoid adopts a crank slider mechanism. Before steering knuckle.
and after the steering axle by pry to the frame at the
back of the pin shaft through the bearing bolt tail
24
8000 YRM 2199 Steering and Drive Axle Information
1. LEFT UNIVERSAL JOINT 20. NUT M20X2

2. STEERING AXLE 21. WASHER 30
3. NUT M12 22. TAPERED ROLLER BEARING
4. NUT M12X40 23. BEARING 30211
5. WASHER 14 24. GREASE NIPPLE Z1/8
6. WASHER 14 25. OIL SEAL
7. BOLT M14X45 26. NEEDLE BEARING
8. KING PIN 27. O-RING
9. CYLINDRICAL PIN 10X20 28. ADJUSTING SHIM
10. BUSHING 29. LINK PIN
11. BEARING 198908K 30. LINK ROD
12. RIGHT UNIVERSAL JOINT 31. RETAINING PLATE
13. HEX NUT M12X30 32. WASHER 8
14. COTTER PIN 6.3X50 33. BOLT M8X16
15. OIL SEAL 34. KNUCKLE BEARING
16. WHEEL BOLT 35. NIPPLE M6
17. WHEEL 36. BUSHING
18. WHEEL NUT 37. STEERING CYLINDER
19. WHEEL CAP
Figure 22. Steering Axle
Steering Knuckle and Steering King Pin body using steering knuckle king pin, thrust bearing,
and gasket. The middle part of king pin is locked on
Steering knuckle is mounted between the upper and steering knuckle using grub screw, while the two ends
lower shaft sleeves on the two ends of steering axle
25
Brake System 8000 YRM 2199
of king pin are supported by needle roller bearings

pressed on the axle body. Oil seals are mounted on
the two ends of needle roller bearings, and oil cup is
fitted on the king pin.
Steering Wheel Bearing Pre-load

Information
1. Grease the hub, internal and external bearings
and the inner cavity of the hub cap and lip of oil
seal. See Figure 23.
2. Install the bearing outer ring onto the wheel hub,

and mount the wheel hub onto the shaft of
steering knuckle.
3. Mount the flat washer and tighten the slot nut.

Torque to 206-235 N•m (151.9-173.3 lbf ft).
4. Loosen the slot nut and then tighten the nut.

Torque to 9.8 N•m (7.2 lbf ft).
5. Tap the wheel hub gently using a hammer.

Manually turn the wheel hub 3-4 times to ensure
a steady rotation. Torque to
2.9-7.8 N•m (2.1-5.8 lbf ft).
6. When rotating torque is higher than the specified

1. SLOT NUT
value, loosen nut by 1/6 turn, then check torque 2. GREASING LOCATION
again.
Figure 23. Adjustment for Pre-loading
7. Lock the slot nut using cotter pin, when specified
rotating torque is reached.
Brake System
Type Front Twin Wheel Brake, Internal Expansion, Hydraulic

Pedal Lever Ratio 5.66
Master Cylinder Diameter 19.05 mm (0.75 in.)
Wheel Brake 2-2.5T 3-3.5T
Type Dual Servo Type with Parking Brake
Wheel Cylinder Diameter 28.6 mm (1.1 in.)
Size of Brake Shoe (L×W×T) 324×60×7 mm (12.8×2.4×0.28 in.) 348×76×8 mm (13.7×2.99×0.31 in.)
Area of Brake Shoe 194.4 cm2×4 264 cm2×4
Inner Diameter of Brake Drum 310 mm (12.2 in.) 314 mm (12.4 in.)
Parking Brake Front Twin Wheel Brake, Internal Expansion, and Hydraulic Type
26
8000 YRM 2199 Brake System
OVERVIEW compressed and opens the one-way valve. This allows

oil to flow to the wheel cylinder through the bypass
Brake system is in a front double-wheel brake type, pipeline. The pistons of the wheel cylinders extend
and it is composed of brake master cylinder, Dry outwards. This causes friction plate of brake shoes
Brakes (Drum and Shoes), and brake pedal. and the brake drum to contact each other, allowing the
forklift truck to deceleration and brake. The rear cavity
BRAKE MASTER CYLINDER of piston is supplied with the brake fluid from return oil
The brake master cylinder contains a valve seat, one- port and oil inlet port. When brake pedal is released,
way valve, return spring, primary cup, piston, and the piston is retracted by the return spring. Brake
secondary cup. It is held together using a thrust cylinders are likewise compressed by return spring of
washer and snap ring. The external part is protected brake shoes, causing the brake fluid to return to the
through a rubber dust cap. The master cylinder piston master cylinder (the front cavity of piston) through a
moves with a push rod that is operated by the brake one-way valve. The piston returns, and the brake fluid
pedal. When brake pedal is activated, the push rod in master cylinder flows back to oil tank through return
pushes the piston forward, and the brake fluid in the oil port. The pressure of the one-way valve adjusts to
cylinder body flows back to oil tank through return oil to the remaining pressure in brake cylinders. This
port, until the primary packing cup blocks the return oil causes the secondary packing cup of wheel cylinder to
hole. After primary packing cup blocked the return oil be correctly placed to prevent oil leaks, and to
port, the brake fluid in front cavity of master cylinder is eliminate air in the brake system.
1. TO OIL RESERVOIR 3. PRIMARY PACKING CUP

2. TO WHEEL SPEED REDUCER 4. SECONDARY PACKING CUP
Figure 24. Brake Master Cylinder
WHEEL BRAKE other end is connected to the brake adjuster, and

presses onto the bottom plate by spring and pull rod.
The wheel brake is a internal expansion, hydraulic The brake is mounted on primary brake shoe, while
type, composed of brake shoes, spring, wheel cylinder, adjustment pull rod for automatic clearance adjuster is
adjuster, and bottom plate. The two brake shoes are on secondary brake shoe. See Figure 25 and
mounted on the two ends of the front axle. One end of Figure 26.
brake shoe is connected with support pin, while the
27
Figure 25. 2-2.5T Wheel Brakes
28
Legend for Figure 25.
1. BOTTOM PLATE 14. SPRING 28. PISTON

2. ADJUSTING SLEEVE 15. SPRING CAP 29. BRAKE CYLINDER CUP
3. BRAKE SHOE 16. SPRING 30. BRAKE CYLINDER SPRING
4. ELASTIC GASKET 17. SPRING SEAT 31. OIL PLUG
5. PARK BRAKE PULL ROD 18. SPRING PULL ROD 32. DEFLATION SCREW
6. RETURN SPRING 19. SUPPORT PIN 33. DEFLATION SCREW COVER
7. SHIM 20. SHIM 34. DUST CAP
8. MANDREL 21. RUBBER PLUG 35. RIVET
9. PULL SPRING 22. BRAKE CABLE 36. CUSHION
10. PART BRAKE PUSH ROD 23. BOLT M8X16 37. SUPPORT PIN
11. COMPRESSED SPRING 24. WASHER 8 38. CLEARANCE-ADJUSTING BOLT
12. ADJUSTING LEVERAGE 25. BRAKE CYLINDER 39. WASHER 10
13. SPRING SEAT 26. COVER 40. CLEARANCE-ADJUSTING ROD
27. PISTON ROD
29
1. BRAKE CYLINDER 10. RUBBER PLUG 19. SPRING

2. CLUTCH DISCS WITH 11. PULL SPRING 20. PARK BRAKE PULL ROD
FRICTION PLATE ASSEMBLY 12. GUIDE PANEL 21. PIN
3. BOTTOM PLATE 13. GUIDE PLATE 22. ELASTIC GASKET
4. BRAKE ADJUSTER 14. RETURN SPRING (REAR) 23. ROD-PIN RETAINER
5. SPRING CABLE 15. TORSION SPRING 24. BRAKE CABLE
6. BRAKE SHOES WITH 16. PAWL 25. WASHER
FRICTION PLATE 17. PIN 26. BOLT
7. SPRING PULL ROD 18. LEFT BRAKE PUSH ROD 27. RETURN SPRING
8. SPRING SEAT
9. COMPRESSED SPRING
Figure 26. 3-3.5T Wheel Brake
The brake action in forward movement is as follows: Brake shoes and brake drum to get into contact with
(see Figure 27). Through operating brake wheel each other, while the primary Brake shoes is pressed
cylinder, the Brake shoes are effected by two forces of onto the adjuster with support of friction force between
equal size but reverse directions, respectively, for Brake shoes and brake drum, thereby for brake
30
adjuster to generate a larger force used to operate the

wheel cylinder to push the secondary Brake shoes,
and to force the upper end of secondary Brake shoes
to bear down on the support pin, thus to get a
relatively large brake force. In another connection, the
reversing brake action is performed in reverse
direction, but the brake force is the same as that
during forward movement.
1. POSITIONING PIN
2. BRAKE DIRECTION
3. FORCE
4. DRIVING BRAKE SHOE
Figure 28. Brake Actions during Reversing

Process
AUTOMATIC BRAKE ADJUSTER

1. BRAKE DIRECTION The automatic brake adjuster is able to automatically
2. POSITIONING PIN maintain the clearance between brake shoes and
3. FORCE
4. DRIVING BRAKE SHOE brake drum between 0.4-0.45 mm (0.016-0.018 in.) for
2-2.5 ton or 0.25-0.4 mm (0.01-0.016 in.) for 3-3.5 ton.
Figure 27. Brake Actions during Forward Running However this adjuster only acts during reversing
Process brake. During reverse movement, the brake shoes will
disengage once the brake pedal is activated, thereby,
the secondary and the primarily Brake shoes will begin
to get into contact with brake drum for rotation
together, until the upper end of primarily Brake shoes
begins to get into contact with support pin.
When the secondary brake shoes is released from the
support pin, the A part of adjusting level Figure 25).
When the brake pedal is released, point B of the rod is
lowered. As the clearance between the friction plate
and the brake drum is increased, the distance of point
B increases also. When the distance is more than
0.4mm, point B will contact the adjuster bolt (item 38,
Figure 25) and the clearance will decrease.
31
MANUAL BRAKE ADJUSTMENT OF BRAKE PEDAL

The manual brake uses a pull handle. With the foot 1. Adjust the limit bolts to the pedal location shown
brake, it employs an automatic power brake that stops in Figure 30. Confirm the distance between the
the front wheels. Only when the truck has been front floor and the brake pedal is 113 mm (4.4 in.)
parked, can the manual parking brake be used. and the pedal stroke is 20 mm (0.8 in.). Tighten
the limit bolts.
Before adjusting the parking brake, test to confirm the
drive axle braking system functions properly:
1. Adjust the lock nut (item 5, Figure 29) so the

length is equal to 68 mm (2.7 in.). Tighten the
lock nut.
2. Turn the nut (item 7, Figure 29) to adjust the

parking brake’s pulling force to
147-196 N•m (108.4-144.6 lbf ft).
3. After the manual brake lever is correctly adjusted,

release the lever to release the brake.
4. Ensure that the parking brake is functioning

properly.
NOTE: Coat appropriate amount of lithium base

grease onto the guide rail (item 6, Figure 29) and
apply regularly.
1. OIL TANK 4. INCHING VALVE

2. LIMIT BOLT 5. BRAKE MASTER
3. PEDAL PUMP
Figure 30. Adjustment of Brake Pedal
MAINTENANCE
This section covers brake disassembly, reassembly,
and adjustment. The following procedures describe
steps for servicing a 2-2.5T brake. Brakes for 3-3.5T
are similar.
1. BRAKE CABLE 5. LOCK NUT

2. BRAKING ROPE 6. GUIDE RAIL
3. DISPLAY 7. NUT
BRACKET
4. PARKING BRAKE
LEVER
Figure 29. Parking Brake
32
Disassemble, Wheel Brake

STEP 1.
Remove the spring of the secondary brake shoes,
and the adjusting lever, top lever, and the top
lever return spring.
STEP 2.
Remove the return springs for the two brake
shoes.
STEP 3.
Remove the other three fixed springs.
33
STEP 4.
Detach the primary brake shoes and the
secondary brake shoes, and remove the spring
for adjuster.
STEP 5.
Remove the brake fluid line from the wheel
cylinder. Remove the mounting bolts for the wheel
cylinder, and separate the wheel cylinder from the
bottom plate.
STEP 6.
Remove the E-shaped retainer ring that fastens
the brake cable onto the bottom plate, then
remove the mounting bolts on bottom plate, and
detach the bottom plate from the axle.
34
STEP 7.
Remove the shield for the wheel cylinder, remove
all the parts from inside the cylinder.
Examination of Wheel Brake 6. Measure the free length and installation load of
return spring for brake shoes. See Figure 31.
Examine all the parts for ware or damage. Replace
parts as necessary.
1. Examine the inner surface of the wheel cylinder

body and the surface of piston column for rust.
Measure the clearance between the piston and
cylinder body. Replace if necessary.
Specified Value:
0.065-0.150 mm (0.003-0.006 in.) (2-3.5T truck
only). Forklift Truck 2-2.5T 3-3.5T
Tonnage
2. Check if the rubber cup is damaged or distorted.
Measure the diameter of the rubber cup to 106 mm 115.1 mm
Free Length
confirm specified value of Φ30.1-0.2 (2-3.5T). (4.17 in.) (4.53 in.)
The standard value for interference of rubber cup 116 mm 122 mm
is Φ1.52, and the minimum value is Φ0.42 Installed Length
(4.57 in.) (4.80 in.)
(2-3.5T).
Maximum
246 N (55.3 lb) 225 N (50.58 lb)
3. Check the free lengths of the wheel cylinder working
spring. Replace if necessary.
Figure 31. Load return spring for brake shoe
Specified Value: 60 mm (2.4 in.) for 2-2.5T and
58 mm (2.3 in.) for 3-3.5T. 7. Measure the free length and installation load of
return spring for top rod. See Figure 32.
4. Check the thickness of the brake shoes. Replace
if excessively worn.
Specified Value: 4.5-7.2 mm (0.18-0.28 in.) for
2-2.5T and 5.0-8.8 mm (0.20-0.35 in.) for 3-3.5T.
5. Check the diameter of the inner surface of the

brake drum to confirm specified value. Replace or
restore if excessively worn.
Specified Value: 310-312 mm (12.20-12.28 in.) for
2-2.5T and 314-316 mm (12.36-12.44 in.) for
3-3.5T.
35
Forklift Truck Tonnage 2-3.5T

Free Length 124.5 mm (4.90 in.) Figure 34. Ratchet spring
Installation Length 130 mm (5.12 in.)
10. Check the adjusting spring for damage and
Installation Load 246 N (55.3 lb) confirm the adjusting lever is functioning properly.
Replace if necessary.
Figure 32. Load return spring for top rod
Assemble, Wheel Brake
8. Measure the free length and installation load of
adjuster spring. See Figure 33. 1. Coat the wheel cylinder rubber cup and piston
with brake fluid.
2. Assemble the spring, rubber cup, piston, and

shield.
3. Mount the wheel cylinder on bottom plate.
NOTE: Confirm that all parts are in correct position

during installation and bolts are torque to
14.7-19.6 N•m (10.84-14.46 lbf) for 2-2.5T and
17.6-26.5 N•m (12.98-19.55 lbf ft) for 3-3.5T.
Forklift Truck 2-2.5T 3-3.5T
Tonnage 4. Mount the bottom plate onto the front axle. Torque
121 mm to:120-140 N•m (88.50-103.26 lbf).
Free Length 86 mm (3.39 in.)
(4.76 in.)
5. Add lubricating grease at items 1, 2, 4 and 5 on
Installation 137 mm Figure 35. Be careful not to allow this grease to
97 mm (3.82 in.)
Length (5.39 in.) adhere to brake shoes.
Installation Load 152 N (34.17 lb) 71.5 N (16.1 lb)
Figure 33. Adjusting spring
9. Measure free length and installation load of

ratchet spring (see Figure 34). Installation Load:
14.7N (3-3.5t)
36
9. Mount the guide plate of brake shoes onto the

support pin. Install the return spring of brake
shoes.
1. SUPPORT FACE OF BOTTOM PLATE

2. SUPPORT PIN OF LEVER L H BRAKE
3. SUPPORT PIN 10. Install adjuster, adjuster spring, top rod, and
4. ADJUSTER THREAD AND OTHER ROTATING return spring for top rod.
PARTS
5. CONTACT FACE OF BRAKE SHOE AND Check the following:
WASHER CUP
• Adjuster thread direction and installation
Figure 35. For 2-3.5T Forklift Truck direction.
- For 2-2.5T trucks, right-hand thread is used
6. Mount the brake cable assembly onto the bottom for left brake, while the left-hand thread is
plate using E-shaped retainer ring. used for right brake.
- For 3-3.5T trucks, left-hand thread is used
7. Mount the brake shoes onto the bottom plate for left brake, while right-hand thread is
using the fixing spring. Install the washer, cup and used for right brake.
the adjusting lever. Mount the bottom part of the • Adjuster spring direction The tooth part of
secondary brakes shoe with fixing spring. Make adjuster must not contact the spring.
sure that the pressure seat is fitted in the holes of • Top rod return spring direction. The spring hook
brake shoes and adjusting lever. must be installed on the opposite side of the top
rod at the end of the support pin.
• Top rod and top rod return spring shall be fixed
inside the slot of support pin.
• Make sure that the lower end of adjusting lever
contacts the tooth of the adjuster.
8. Mount the compressed spring onto the hand

brake push rod. Install the push rod onto the
brake shoes.
37
Operating Test Automatic Clearance

Regulator
1. Allow the diameter of brake shoes to approach
the installation size. Pull the adjusting lever to
rotate. When the adjusting lever is released, it
returns to its original place. The adjuster gear will
not rotate.
NOTE: Even when hand brake is released, the

adjuster will still function properly after being
assembled.
2. If the adjuster does not return to original position,
inspect these items.
a. Mount the adjusting lever, the top rod, the top

11. Connect the brake fluid line onto the wheel rod spring, and the washer cup.
cylinder.
b. Examine whether or not the position of the
12. Measure the inner diameter of the brake drum. adjusting lever and adjusting gear is correct
Adjust the differences between the inner diameter (see Figure 36.) Replace the parts if
of brake drum and the friction plate of brake shoe necessary. Check if lever and gear are in
to: contact with each other.
• 0.8-0.9 mm (0.031-0.035 in.) for 2-2.5T trucks.
• 0.5-0.8 mm (0.019-0.031 in.) for 3-3.5T trucks.
38
1. TURN BRAKE ADJUSTER
Figure 36. Brake Adjuster
3. Check the return spring of top rod and the 4. Make sure the adjuster gear rotates. Confirm no
adjuster spring for damage. Confirm no wear or wear or damage.
damage.
39
Troubleshoot Wheel Brake

Fluid leak in brake system Repair
Clearance of brake shoes not properly adjusted Adjust adjuster gear
Brake too hot Check if skidding exists
Poor contact between brake drum and brake shoe Adjust brake adjuster
Brake Spongy
Repair or replace brake
Contamination on brake shoe shoe
Contamination in brake fluid Inspect brake fluid
Brake pedal (inching valve) improperly adjusted Adjust brake pedal
Surface of brake shoes hardened or dirty shoes
Bottom plate distorted or bolt loosened Repair or replace plate
Brake Noise
Brake shoes distorted or installation incorrect shoes
Brake shoes worn shoes
Loose wheel bearing Repair or replace
Brake fluid on brake shoes shoe
Brake Drum or Brake Shoe Clearance of brake shoes not properly adjusted Adjust brake adjuster
surfaces damaged or Wheel cylinder failure Repair or replace
distorted Brake shoe return spring damaged Replace
Brake drum failure drum
Fluid leak with brake system Repair leak
Clearance of brake shoes not properly adjusted Adjust brake adjuster
Braking Pressure Low
Air in brake system Bleed air
Adjustment of brake pedal incorrect Readjust
40
8000 YRM 2199 Hydraulic System
Hydraulic System
NOTE: If the forklift truck is kept without operating for times at least every 10 days for lubrication
a long time, it is required to lift the mast cylinder 2-3 maintenance.
GLP/ GLP/ GLP/ GLP/

Forklift Truck Tonnage
GDP20UX GDP25UX GDP30UX GDP35UX
Equipped Engine PSI 4G64 2.4L
Type Gear Type Gear Type Gear Type Gear Type
Driving Engine driven
Main Pump 72 liter/min 72 liter/min 72 liter/min 82 liter/min

Full load flow
(19 gal/min) (19 gal/min) (19 gal/min) (21.7 gal/min)
78 liter/min 78 liter/min 78 liter/min 88 liter/min
No load flow
(20.6 gal/min) (20.6 gal/min) (20.6 gal/min) (23.2 gal/min)
Model MFT04 MFT04 MFT04 MFT04
Double Spool Valve, with Overflow Valve, Bypass Valve, and
Type
Inclined Auto-locking Valve, pilot valve load feedback
18 MPa 18 MPa 18 MPa 18 MPa
Multi-way Adjusting Pressure
(2610.68 psi) (2610.68 psi) (2610.68 psi) (2610.68 psi)
Valve
11 MPa 11 MPa 11 MPa 11 MPa
Pressure
(1595.42 psi) (1595.42 psi) (1595.42 psi) (1595.42 psi)
Bypass Valve
12 liter/min 12 liter/min 12 liter/min 12 liter/min
Flow Rate
(3.2 gal/min) (3.2 gal/min) (3.2 gal/min) (3.2 gal/min)
Single Act Piston Type, with Shutoff Valve, one-way valve and
Type
lower buffer
Φ50 mm Φ50 mm Φ56 mm Φ63 mm
Lift Cylinder Cylinder Inner Diameter
(2.0 in.) (2.0 in.) (2.2 in.) (2.5 in.)
(2nd-grade Standard Mast at 3m Lifting Height) 1495mm
Stroke
(Varying along with Type of Mast and Lifting Height)
Double Acting Double Acting Double Acting Double Acting
Type
Cylinder Cylinder Cylinder Cylinder
Cylinder Inner Diameter
(2.8 in.) (2.8 in.) (3.1 in.) (3.1 in.)
Tilt Cylinder
Piston Rod Outer Diameter
(1.3 in.) (1.3 in.) (1.4 in.) (1.4 in.)
122 mm 122 mm 141 mm 141 mm
Stroke
(4.8 in.) (4.8 in.) (5.6 in.) (5.6 in.)
OVERVIEW Because the pump housing and pump cover are made
from aluminum, they are light and sturdy. The active
The hydraulic system is composed of a steering gear and the passive gear each have two shafts that
control unit, a multi-way valve, lift cylinders, tilt are individually installed on the pump housing
cylinders, and Hydraulic hoses and or Hydraulic bearings. These bearings are made of special
Tubes, The power-take-off (PTO) of the engine drives material, to bear the radial load of the gear and also
the steering control unit directly. serve as the baffle seats for the gear ends.
41
Hydraulic System 8000 YRM 2199
On the drive shaft side, a fluid seal is installed on the

pump housing. A seal between the pump housing and
the cover rely on a specially-shaped seal ring.
STEERING CONTROL UNIT

The steering control unit is a gear pump consisting of a
pump housing, pump cover, one pair of gears, a
bearing, and seal rings. The pump employs a load-
balancing bearing and a special lubrication method
which minimizes the gap at the gear ends.
Because the pump housing and pump cover are made
from aluminum, they are light and sturdy. The active
gear and the passive gear each have two shafts that
are individually installed on the pump housing
bearings. These bearings are made of special
material, to bear the radial load of the gear and also
serve as the baffle seats for the gear ends.
On the drive shaft side, a fluid seal is installed on the
pump housing. A seal between the pump housing and
the cover rely on a specially-shaped seal ring.
MULTI-WAY VALVE AND PRIORITY SPOOL

The 4-disk multi-way valve consists of a six-plate valve
body, four spool valves, one relief valve, and one
priority spool. The six-plate valve body is assembled
using three stub bolts and nuts. The tilt spool valves
are fitted with a tilt auto-locking valve.
1. SAFETY 5. PORT (OIL OUTLET)

OVERFLOW VALVE 6. BYPASS VALVE
2. LIFTING SPOOL (CONNECTED WITH
VALVE STEERING GEAR)
3. TILT SPOOL VALVE 7. PORT (OIL INLET)
4. AUX. SPOOL
VALVE
Figure 37. Multi-way Valve
Operation of Spool Valve

The Tilt Spool Valve is described below. All other spool
valves operate, and are repaired in a similar fashion.
Neutral Position
In the NEUTRAL position, the high-pressure fluid is
drained from the pump and returns to the fluid tank.
See Figure 38.
42
Spool Valve (Pulled out):

When neutral position is closed, the hydraulic oil from
the inlet port opens the one-way valve and flows to the
cylinder interface A, (item 2, Figure 40) while the oil
from cylinder interface B (item 1, Figure 40) flows to
the tank through low-pressure channel. A return spring
returns the valve to NEUTRAL position.
Figure 38. Spool Valve Neutral
Spool Valve (Pushed In): 1. FLUID TO CYLINDER INTERFACE B

When the valve is pushed in, the middle channel is 2. FLUID FROM TILT CYLINDER INTERFACE A
3. RETURNING TO FLUID TANK
closed while the fluid from the inlet port opens the one-
way valve. The fluid flows to the interface B of the Figure 40. Pull-out Spool Valve
cylinder (item 1, Figure 39), while the fluid from
cylinder interface A (item 2, Figure 39) flows to the Primary Relief Valve and Priority Spool
tank through low-pressure channel (item 3, Figure 39).
A return spring returns the valve to NEUTRAL position. Reference Figure 41
The primary relief valve is composed of the two parts,
a main valve and pilot valve. When multi-way valve is
reversed, the high-pressure oils in cavity (P) and
working mechanisms (such as lift cylinder and tilt
cylinder) are connected, the pressurized oil acts on the
pilot valve, through the fixed throttle holes. When
system pressure is larger than the system regulated
pressure, the pilot valve opens, The valve core of the
entire main valve (A) moves rightwards, for the
pressurized oil to be directly connected with low-
pressure channel (G), for cavity for the pressure in
cavity P to lower, in order to ensure the stability of
system pressure. Adjusting screw H on the primary
relief valve will increase or decrease the system
pressure.
1. FLUID FROM TILT CYLINDER INTERFACE B The priority spool is in a spool and spring set up. It is
2. FLUID TO TILT CYLINDER INTERFACE A used to divert oil to the Steering Control Unit (SCU)
3. RETURNING TO FLUID TANK
first and then actuates, to divert oil to provide hydraulic
Figure 39. Push-in Spool Valve oil to the hydraulic valve for Mast functions. When the
steering wheel is rotated, the oil cavity (M) is
connected with high-pressure oil circuit. When system
pressure is greater than spring pressure, the valve
43
core (N) moves right, and pressure oil is connected By changing the flow rate and pressure, the slide valve
with low-pressure oil circuit through cavity (T), for the L moves to the left and right to change the opening of
pressure in cavity (M) to lower, in order to ensure the (R) and (S), to ensure the automatic balance of the
stability for the pressure of steering system. Adjusting flow rate of the deworking chamber (Q) and PF orifice
screw K may be used to adjust the stable pressure and the full hydraulic steering gear, and the flow is
value of the system. divided stable in proportion
1. ONE WAY VALVE 4. OIL RETURN

2. CONNECTING ORBITROL 5. MAIN RELIEF VALVE
3. STEERING OVERFLOW VALVE
Figure 41. Primary Relief Valve and Priority Spool
Inclined Auto-Lock Valve spool valve can still be operated to tilt backward after
the engine is turned off. However, when this tilt auto-
The tilt spool valve is fitted with an auto-lock valve to lock valve is used, a forward tilt can not be performed
prevent vibration caused by back pressure inside the when the engine is turned off. See Figure 42 for tilt
tilt cylinder. It is designed to keep the mast of the lift auto-lock valve structure.
truck from "drifting" while a load is raised. The inclined
44
1. CONNECTING TILT CYLINDER INTERFACE B 2. CONNECTING TILT CYLINDER INTERFACE A
Figure 42. Tilt Auto-lock Valve
The interfaces “2” and “1” of valve body connect parts by the priority spool within the multi-way valve.
separately with front and rear housing of the tilt High pressure oil is divided to either go to the hydraulic
cylinder piston. When spool valve is pulled out, control valve or the SCU (Steering Control Unit). When
(control lever pulled back) the high-pressure fluid the lift or tilt spool valves are at the neutral position,
enters into interface “2” (item 2, Figure 42), while the the high-pressure oil returns to tank. When lift spool
oil in the rear cavity returns to the tank. In this case, valve is pulled, the high-pressure oil passes through
the mast is tilted backward. the velocity fuse, and then pushes the piston of the
lifting cylinder up. When lift spool valve is pushed, the
When the spool valve is pushed in (control lever is
lower part of lift cylinder piston is connected with low
pushed forward), high pressure oil enters connector
pressure, allowing the piston to drop, depending on
“1”, (item 1, Figure 42) by high pressure oil, and the
mast weight and cargo weight. The oil flowing out from
lock valve in spool works to make “2” connect with low
lift cylinder then passes through the velocity fuse for
pressure. When engine is off or stopped, there is no
the lowering speed to be controlled. When the tilt spool
high-pressure oil for auto-lock inside the spool valve to
valve is operated, the high-pressure oil may flow into
act. In this case the interface “2” cannot be connected
the front cavity of tilt cylinder, while the other side is
with low pressure, and the mast will not tip forward and
connected with low pressure. This causes the mast to
there is no back pressure in tilt cylinder.
tilt backward or forward.
HYDRAULIC SYSTEM MAIN OIL CIRCUIT
The high-pressure oil from the steering control unit is
routed to the multi-way pump, and is split into two
45
Figure 43. Oil Circuit of Hydraulic System
46
Figure 44. Oil Circuit of Hydraulic System (OPS)
LIFT CYLINDER parts. One port is located in the lower part of cylinder
body. A return pipe is mounted in the upper part of
Two single-acting lift cylinders are attached on the cylinder body for a small amount of leaked fluid to
back of the outer mast channel, and the bottom part of return to the tank. The piston is fastened onto the
cylinder is attached to the outer mast channel using piston rod using a nut and cotter pin, and one seal
pins and bolts. The top part of the cylinder (piston rod) ring, retainer ring and wear ring are fitted on the outer
is connected to the cross member of the outer mast surface of the piston (see Figure 45). The high-
channel. The piston strokes must be adjusted to be pressure fluid moves the piston along the cylinder
consistent, for the two cylinders to lift simultaneously. body. A shaft sleeve and dust ring are mounted in the
The lift cylinder is composed of cylinder body, piston, inner hold of cylinder cover, to support the piston rod,
piston rod, cylinder cover, cylinder bottom and sealing while resisting dust.
47
When the lift is commanded, the high-pressure fluid under the weight of the forks and cargo, and the inner
enters through the bottom part of lift cylinder, pushing mast will be lowered. The oil drained out from lift
up the piston attached to the mast and raising the cylinder is controlled by velocity fuse, and returns to
inner mast along with the lift chain. When lower is tank through multi-way valve.
commanded, the fluid under the piston will flow out
1. BEAM 12. SEAL RING

2. WIPER 13. RETAINER RING
3. SHAFT SEAL 14. LOCATER PIN
4. CYLINDER COVER 15. VELOCITY FUSE
5. O-RING 16. VALVE SLEEVE
6. CYLINDER ROD 17. CHECK VALVE
7. CYLINDER BODY 18. HOIST CHAIN
8. O-RING 19. RETAINER RING
9. PISTON 20. ROLLER SPROCKET
10. SUPPORT RING 21. SHIMS
11. RETAINER RING 22. BOLT
Figure 45. Lifting Cylinder
There is one velocity fuse on the bottom of the lift difference. When this pressure difference is smaller
cylinder (see Figure 46). It is designed to prevent load than the spring force, the spool valve will not act. If the
from sudden drop, in the event that a hose carrying high-pressure hose fails, a significant pressure
hydraulic oil should suddenly fail. The fluid from lift difference is formed collapsing the spring and blocks
cylinder passes through the velocity fuse, and the oil off most oil flow back to tank , helping to prevent an
holes around the spool valve generates pressure accident.
48
A. WHEN NORMAL B. WHEN DISCONNECTED
Figure 46. Velocity Fuse
VELOCITY FUSE In an emergency situation, caused by a significant

pressure drop in the system (ex. hydraulic hose burst),
A velocity fuse (throttle valve) is mounted within the oil the velocity fuse actuates. The hydraulic fluid moves
circuit of lift cylinder, to limit the dropping speed under quickly from points G through A causing the internal
a heavy load (see Figure 47). Under normal body of the velocity fuse to the move to the right,
conditions, the velocity fuse does not activate when closing off most oil flow. If this occurs the velocity fuse
hydraulic flow is generated from the lift function. Oil considerably reduces the flow of the hydraulic fluid
flows to the velocity fuse into cavities A, B, C, D, E, F leaving the cylinder, allowing the suspended load to
and G and into the lift cylinder. safely be lowered.
49
1. NORMAL FLOW 8. VALVE SLEEVE

2. THROTTLE FLOW 9. VALVE CORE
3. SIDE OF MULTI-WAY VALVE 10. NYLON BALL
4. VALVE BODY 11. SPRING
5. O-RING 12. CONNECTOR
6. SPRING 13. SIDE OF LIFT CYLINDER
7. THROTTLE PLATE
A. VALVE CAVITY E. VALVE CAVITY

B. VALVE CAVITY F. VALVE CAVITY
C. VALVE HOLE G. VALVE CAVITY
D. VALVE HOLE H. VALVE CAVITY
Figure 47. Limiting Valve
TILT CYLINDER together. One wear ring and two Yx seal rings are
mounted on the outer edge of piston. A Yx seal ring
The tilt cylinder is a double acting cylinder, mounted on and dust rings are pressed in the cylinder bore and
each side of the mast. matched with guide sleeve. The shaft sleeve supports
The tilt cylinder assembly consist of the piston, piston the piston rod, while the seal ring, and dust rings
rod, cylinder body, cylinder bottom, guide sleeve, and prevent oil leaks and dust.
sealing parts. The piston and piston rods are welded
50
1. CLEVIS 6. GUIDE SLEEVE 11. SEAL RING

2. DUST RING 7. BEARING 12. WEAR RING
3. BAFFLE RING 8. O-RING 13. PISTON
4. SEAL RING 9. PISTON ROD 14. SEAL RING
5. O-RING 10. CYLINDER BODY
Figure 48. Tilting Cylinder
When tilt spool valve is pushed forward, the high- 4. Remove bearings and gears (items 3-6) from
pressure fluid enters from the bottom of the cylinder, pump body. Bearings may be removed by
pushing the the piston forward and allowing the mast pressing the gears, if it is difficult to remove them.
to mast to tilt forward by 6°. When spool valve is pulled
backwards, the fluid enters from the front end of Inspection and Repair
cylinder body, to push the piston until the mast tips
Clean disassembled metal parts with hydraulic fluid.
backwards by 12°.
Inspect, repair, or replace according to following
procedure.
MAINTENANCE OF HYDRAULIC PUMP
Disassemble, Main Oil Pump Inspection of Pump Body
NOTE: For the following procedures refer to Figure 55 1. The gear pump is designed so the gear rotates
and Figure 56. along the inner surface of the pump body. Under
normal wear its wear area shall not exceed a
1. Clamp the pump gently on a vice stand after length 1/3 of the inner edge of the pump body. If it
cleaning. Remove the bolts (item 12). reads ½ length, it indicates that the bearing and
gear shaft are worn out. When size at "X"
2. Detach pump cover (item 1) and seal rings (items, exceeds 39.180 mm (1.542 in.), replace the pump
8, 9, 10, and 11). body. See Figure 49.
3. Remove the front-end cover (item 7) and seal

rings.
51
1. INLET 4. MAINTENANCE LIMIT SIZE

2. WEAR AREA 5. OUTLET SIDE
3. OUTLET
Figure 49. Main Oil Pump
Inspection of Bearing
2. Inspect that the inner surface of bearing is
smooth, and the contact surface is shown at the
position about ½ at the inlet side. See
Figure 50.The bearing must be replaced, if any of
the following cases occurs.
1. OUTLET
2. SCRATCH
3. INLET
4. GEAR SIDE
Figure 50. Inspection of bearing
52
a. The trace of contact appears on the entire slide failure has also occurred, and must be inspected.
inner surface, and roughness is felt when The limit size for the axial diameter of gear shaft
scraped with a finger nail. is 18.94 mm (.075 in.).
b. Crack appears around the face, and roughness

is felt when scraped with a finger nail.
c. Foreign matter is on the internal slide surface

or end face.
Most cases of failures are caused by dirty
hydraulic oil. The whole oil circuit may be
cleaned or the oil may be replaced. Some
individual cases are attributed to overloaded
safety valve, air corrosion, too high
temperature, or too low viscosity. In the case
when failures occur, leading to roughness or
severe wear on the gear shaft or the surface of
the gear, the gear and bearing shall be A. 18.94 mm (.075 in.)
replaced. The limit size for bearing
Figure 52. Gear Inspection
maintenance is:
Inner Diameter—19.12 mm (0.75 in.) Inspection of Oil Seal
Total Length—26.41 mm (1.04 in.) NOTE: For the following procedures refer to or .
a. Oil Seal (item 14) is a combination seal. The lip

on inner side of the pump shaft provides
sealing, while the lip at the outer side is for
dust resistance. Check if crack, wear, or
distortion exists on oil seal, and inspect
whether or not the rubber is elastic.
b. Replace seal rings (items 8-9) for bearing.
c. Inspect seal rings (items 10-11) for wear and

damage.
A. INNER DIAMETER
B. TOTAL LENGTH
Figure 51. Inner Bearing Inspection
Inspection of Gear
3. If clean hydraulic fluid is used, the gear shaft and
gear surface will not be damaged. If roughness is
felt on the surface, a crack occurs, or uneven
wear is present, replace the gear. When gear
surface is worn or discolored, it indicates that
53
1. DUST-PROOF LIP
2. PUMP OUTER SIDE
3. PUMP INNER SIDE
4. SEAL RING NOZZLE
Figure 53. Oil Seal Inspection
Assemble, Main Oil Pump 1. BEARING

2. DRIVING GEAR
NOTE: For the following procedures refer to Figure 55 3. INLET SIDE
or Figure 56. 4. CLEARANCE NOT ALLOWED
5. POSITIONING PIN (AT INLET SWITCH)
1. Clean the disassembled parts. 6. DRIVEN GEAR
2. Coat a thin layer of clean grease on the lips of oil Figure 54. Pump Body
seals.
5. Turn over the pump body. Put the driving and
3. Place the pump body and the pump cover on a driven gears (items 5-6) into the pump body, and
flat stand. Coat the inner surface of the pump allow the engaged teeth to be at the same
body with clean hydraulic oil. position as prior to disassembly.
4. Place bearings into the pump body, and pay 6. Mount the bearings (items 3-4) on one side of the
attention to put them in correct positions. Do not front end cover using the same method as in .
press it in forcibly. See Figure 54.
7. Mount the seal ring for pump body (item 8), the
seal ring for bearing (item 9), and seal rings
(items 10-11), and do not allow the seal rings to
overlap.
8. Assemble the front end cover (item 7), and wrap

the band around the end of driving gear to avoid
damage of oil ring lip. Remove the band after the
front end cover is mounted.
9. When pump body is turned over to mount end

cover, prevent seal rings from moving.
10. Mount seal rings (items 8-11), with the same

method as in Step 7.
11. Put on the end cover (item 11).
54
12. Mount spring washer (item 13) and bolt (item 12), gauge should read slightly lower than
and torque to 47 N•m (34.67 lbf). 1 MPa (145.04 psi). Keep pump running for 10
minutes.
13. Inspect the gear pump to confirm it is assembled
completely. Place the driving shaft into the vice 3. Increase rotating speed to 1500-2000rpm, and
stand, then turn pump and confirm it rotates allow to idle for 10 minutes.
easily.
4. Keep the rotating speed at 1500-2000rpm,
Before this pump is reinstalled, check a second
increase the pressure to
time to confirm it is assembled completely and the
2-3 MPa (290.08-435.11 psi) for 5 minutes.
rotating direction is correct.
Repeat until maximum pressure is reached. Use
overflow valve to increase the load to adjust
a. Check if the lower part is damaged or dirty.
pressure. Allow each fluid circuit to work for 5
b. Check if the flange surface is damaged or dirty. minutes, and replace or clean the filter core of
return filter. When pressure increases then,
c. Mount O-ring, after following the previous monitor fluid temperature of the pump body and
steps. overall proper functionality. If fluid temperature or
pump temperature are too high, flush the pump
Test immediately to lower the temperature, and repeat
the process.
Test the pump after assembly. Confirm the pump has
reached the specified performance after reassembly. 5. After testing is complete ,make sure to set the
Perform a test run after pump is installed into forklift hydraulic pressure back to required specs per the
truck. If pump is blocked or internal parts are capacity specifications Manual.
excessively worn out, fluid must be replaced and filter
NOTE: Unloading test must be performed, to ensure
must be replaced or cleaned.
that this device has a proper speed.
1. Install pressure gauge on high-pressure line near NOTE: See Figure 55 and Figure 56 for gear oil pump
the pump. structures in clockwise and counterclockwise rotations.
2. Place the transmission in the NEUTRAL position, See Figure 57 for a diagram of hydraulic pipeline.
for pump to run at a speed of 500-1000rpm. While
in the in the NEUTRAL position, the pressure
55
1. END COVER 6. DRIVEN GEAR 11. SEAL RING

2. PUMP BODY 7. FRONT END COVER 12. BOLT
3. BEARING 8. SEAL RING 13. LOCK WASHER
4. BEARING 9. SEAL RING 14. LOCKING COLLAR
5. DRIVING GEAR 10. SEAL RING 15. OIL SEAL
Figure 55. Clockwise Rotation of Gear Pump (2-3.5T Gasoline Forklift Trucks)
56
1. END COVER 6. DRIVEN GEAR 11. SEAL RING

2. PUMP BODY 7. FRONT END COVER 12. BOLT
3. BEARING 8. SEAL RING 13. LOCK WASHER
4. BEARING 9. SEAL RING 14. OIL SEAL
5. DRIVING GEAR 10. SEAL RING 15. LOCKING COLLAR
Figure 56. Counterclockwise Rotation of Gear Pump (2-3.5T Diesel Forklift Truck)
57
Figure 57. Hydraulic Schematic (Diesel and Gasoline Forklift Trucks)
58
1. HOSE CLAMP 18. HOOP D25 35. TILT CYLINDER CONNECTOR

2. PUMP SUCTION PIPE 19. ORBITAL PIPE CONNECTOR 36. 0-RING 16×2.4
3. PUMP SUCTION FITTING 20. ORBITAL CONNECTOR I 37. BOLT M6×25
4. 0-RING 35×3.5 21. ORBITAL CONNECTOR II 38. WASHER 6
5. GEAR PUMP 22. ORBITAL 39. WASHER 6
6. 0-RING 80×3.55 23. MULTI-CHANNEL VALVE- 40. NUT M6
7. WASHER 10 HOSE II 41. BOLT M6×12
8. WASHER 10 24. CONNECTOR 42. CLIP
9. BOLT M10×35 25. VALVE INLET CONNECTOR 43. BOLT M8×20
10. 0-RING 22×2.4 26. 0-RING 24×2.4 44. WASHER 8
11. PUMP OUTLET FITTING 27. MULTI-CHANNEL VALVE 45. NUT M8
12. VALVE H.P. HOSE 28. MULTI-CHANNEL VALVE-TILT 46. CLAMP PLATE
13. 0-RING 18×2.4 CYLINDER CONNECTOR 47. CLAMP
14. STEERING CYLINDER 29. RETURN OIL HOSE 48. CLIP
CONNECTOR 30. TILT CYLINDER PIPE I 49. CABLE TIE
15. STEERING CYLINDER H.P. 31. TILT CYLINDER PIPE II 50. DIVERTER CONNECTOR
HOSE I 32. CLIP I 51. DIVERTER CONNECTOR
16. STEERING CYLINDER H.P. 33. CLIP II
HOSE II 34. TILT CYLINDER HOSE
17. ORBITAL PIPE (FRONT)
TROUBLESHOOT HYDRAULIC SYSTEM

Fluid level in tank is at low end Fill fluid to the specified level
Fluid Level Low
Fluid suction side pipeline or filter blocked Clean or replace fluid if dirty
Bearings are worn, and bearing seal rings
are at fault. Replace
Overflow valve misadjusted Raise pressure gauge
Failure of Gear Pump Tighten joint at suction pipe side
for Supercharge Add fluid into tank
Air blended into pump Check pump seal
Run pump until there are no more air
bubbles in fuel tank
Fluid suction hose twisted, or cavity blocked
by filter Clean filter and adjust hose
Air pulled inside due to loosening of fluid
Noise of Gear Pump suction side joint Tighten each joint
Loud Use proper viscosity fluid
Excessive fluid viscosity Do not operate until fluid temperature is
normal
Air bubble present in hydraulic fluid Check for cause of air bubble
Seal and seal ring of pump at fault
Fluid Leak with Pump Sliding face worn (for internal leak to be Replace
increased)
59
Lifting System 8000 YRM 2199
Lifting System
SAFETY PROCEDURES WHEN WORKING • If parts of the mast must be in a raised position,
install a safety chain to restrain the moving parts
NEAR MAST of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
WARNING 1. Put mast in vertical position.
The following procedures MUST be used when
inspecting or working near the mast. Additional 2. Raise mast to align bottom crossmember of
precautions and procedures can be required when weldment that moves in the outer weldment with
repairing or removing the mast. See the correct a crossmember on the outer weldment. On the
Service Manual section for the specific mast being two-stage and free-lift mast, the moving part is
repaired. the inner weldment. On the three-stage mast, it is
the intermediate weldment. See Figure 58.
• Never put any part of the body into or under the
mast or carriage unless all parts are completely 3. Use a 3/8 inch minimum safety chain with a hook
lowered or a safety chain is installed. Also make to fasten the crossmembers together so the
sure that the power is off and the key is movable member cannot lower. Put the hook on
removed. Put a DO NOT OPERATE tag in the the back side of the mast. Make sure the hook is
operator's compartment. Disconnect the battery completely engaged with a link in the chain. Make
on electric lift trucks and put a tag or lock on the sure the safety chain does not touch lift chains or
battery connector. chain sheaves, tubes, hoses, fittings, or other
• Be careful of the forks. When the mast is raised, parts on the mast.
the forks can be at a height to cause an injury.
• DO NOT climb on the mast or lift truck at any 4. Lower mast until there is tension in the safety
time. Use a ladder or personnel lift to work on chain and the free-lift cylinder (three-stage) is
the mast. completely retracted. If running, stop the engine.
• DO NOT use blocks to support the mast Apply parking brake. Install a DO NOT REMOVE
weldments or to restrain their movement. tag on the safety chain(s).
• Mast repairs require disassembly and removal
of parts and can require removal of the mast or 5. Install another safety chain (3/8 inch minimum)
carriage. Follow the repair procedures in the between the top or bottom crossmember of the
correct Service Manual for the mast. carriage and a crossmember on the outer
weldment. See Figure 58.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely. Push NOTE: Apply parking brake. After lowering or
the lift/lower control lever forward and make restraining the mast, shut off power and remove key.
sure there is no movement in the mast. Make Put a DO NOT OPERATE tag in the operator's
sure that all parts of the mast that move are fully compartment. Disconnect battery on electric lift trucks
lowered. and put a tag or lock on battery connector.
OR
60
8000 YRM 2199 Lifting System
Figure 58. Two-Stage, Free-Lift, and Three-Stage Masts
61
Lifting System 8000 YRM 2199
A. TWO-STAGE MAST B. FREE-LIFT MAST C. THREE-STAGE MAST
1. OUTER WELDMENT 3. INTERMEDIATE WELDMENT 6. CROSSMEMBER

2. INNER WELDMENT 4. HOOK 7. CROSSMEMBER
5. FREE-LIFT CYLINDER
OVERVIEW
The lifting system is a two-stage rolling telescopic
mast, with the outside mast typical of a “C” shaped
end face, and the inside mast in a “J” shaped end
face. The fork and the bracket comply with the
international standard, with a free lift of about 150mm
150 mm (5.9 in.) during operation.
Measurement
A 55 mm (2.17 in.)
B 15 mm (0.59 in.)
C 120 mm (4.72 in.)
D 160 mm (6.30 in.)
Figure 60. End Face of Outer Mast

Measurement
A 54 mm (2.13 in.) INSIDE AND OUTSIDE MASTS
B 15 mm (0.59 in.) The mast assembly is composed of an inside, middle,
C 18 mm (0.71 in.) and outside masts (the middle masts is only for the
3FFL mast). The lower portion of the outside mast is
D 38 mm (1.50 in.) connected to the drive axle, with most of the weight
E 92 mm (3.62 in.) supported by the axle housing. The tilt cylinder is
connected to the frame of the truck and the outer mast
F 120 mm (4.72 in.)
channel. The mast is able to tip forward and reverse.
G 160 mm (6.30 in.)
Figure 59. End Face of Inner Mast
62
8000 YRM 2199 Lifting System
CARRIAGE
The carriage is made up of a series of welded
components that move up and down in the inner mast
channel, with the help of load and side rollers.
The Mast on the 2-3.5T 2FFL has a total of three
groups of composite load rollers and two groups of
standard load rollers. At the mast maximum height,
two standard load rollers will extend out of the top of
the inner channel.
The fork is locked inside the groove on the bracket
using lock pins, and the spacing of fork can be
adjusted manually
ADJUSTMENT OF LIFTING SYSTEM

1. Once carriage is placed into the inner channel of
the mast, set the carriage height by placing a
gauge block that is 76 mm (2.3 in.) high to set
carriage height.
Drop the fork to the ground, and adjust the nut on
the lift chain’s upper end to ensure that there is
the distance A between the load roller and the
inner mast. See Adjustment of Lifting System 1. OUTER MAST
2. COMBINATION ROLLER
Forklift Model A 3. INNER MAST
4. FORK CARRIAGE
2-2.5T 24-29 mm (.94-1.14 in.)
3-3.5T 19-24 mm (.75-.94 in.) 2. Lower the fork to the ground, adjust the
tensioning force of lift chain, to make sure the
tensioning degrees of both lift chains to be
equivalent.
1. LOCKNUT I
2. LOCKNUT II
3. END CONNECTOR
4. CHAIN
3. When lift cylinder, inner mast and outer mast

need to be disassembled or replaced, adjust the
assembly distance as follows:
a. Place the piston rod head onto the upper beam

of the inner mast without adjusting shims.
63
Electrical System 8000 YRM 2199
b. Raise the mast slowly until the maximum

stroke of the cylinder is reached, check
whether the two cylinders are synchronized.
c. Add adjusting shims between piston rod head

and the upper beam of the inner mast. Make
sure the washer is 02.-0.5 mm (0.008-0.02 in.)
thick.
NOTE: Safety precautions must be taken when

adjusting the cylinder.
d. Adjust the tension of the chains.
1. INNER MAST
2. LIFT CYLINDER
3. ADJUSTING WASHER
4. UPPER BEAM OF THE INNER MAST
Electrical System
OVERVIEW engine. After the key switch is turned on, the glow plug
heats up. The starting system has neutral protection
The electrical system in this model series is a single- function; the truck will only start if the shift lever is at
line electrical system that utilizes anode bonding in the the neutral position.
truck’s electrical circuitry to ensure that the forklift truck
works properly in various conditions. The electrical
Ignition system (ICE forklift truck)
equipment is composed of following systems:
Gasoline equipped forklifts do not have a preheating
Power supply system components as diesel forklift do. They have spark
plugs, and on some ICE engines a distributor and
The power supply system consists of battery, spark plug wires are present for the ignition system to
alternator, charging indicator light and other function.
components. It supplies power to the electric
equipment of the truck. The battery provides power
Preheating system (diesel forklift truck)
prior to starting the forklift. The alternator provides
power when the forklift runs, and at the same time The preheating system mainly consists of preheating
charges the battery. The charging indicator light is plug (glow plug), preheating relay and time relay. The
used to display the charging status. preheating time is set to 10-13seconds, but can be
adjusted through time relay. Diesel with ECU electric
Starting system control system is available. A temperature sensor is
equipped to detect whether the current temperature
The starting system is composed of glow plug (diesel needs to be preheated to increase the service life of
truck only), key switch, neutral switch, and starter components.
lamp. The function of the starting system is to start the
64
8000 YRM 2199 Electrical System
Dash Instrument Display System and displays it through the display. This allows the
operator to understand the status of the forklift .
The instrument display system is composed of a water
temperature sensor, oil temperature sensor, fuel
Lighting, sound and alarm system
sensor, oil pressure switch, (on Diesel equipped
forklifts), oil-water separators and other components. The system includes a variety of lighting equipment,
Its function is to detect the operation of the forklift truck signal lights, horn, buzzer, and other components.
Front Front Rear Warning

combinatio combinatio combinatio light
n lamp n lights n light
turning width width brake reverse turning
steering
Power (W) 27 10 10 5 21 21 10 21
ELECTRICAL BOX 3. When performing the battery routine

maintenance, wear goggles, rubber gloves and
The electrical box houses fuses and relays. The fuses rubber shoes.
are used to protect the circuits to prevent damage due
to short circuit. The relays are used to expand the 4. The battery will produce flammable gas, therefore
switch capacity, making the small-capacity switch able potential risk of explosion exists. It is necessary to
to control high-power electrical items. avoid short circuits, spark occurrence, and any
source of flame.
BATTERY
For truck with a maintenance-free battery, pay 5. Prohibit contact with the battery. The battery
attention to the following: electrolyte is dilute sulfuric acid. If contacted with
the skin, please immediately rinse affected area
1. When installing and maintaining, do not touch the with water. If contacted with the eyes, rinse
conductor of the battery. This may cause serious intensively with water and see a doctor as early
burns. as possible.
2. When charging the battery, the positive and

negative terminals can not be reversed. This will
cause high temperature, burning, fumes or
explosion.
65
DESCRIPTION AND SUMMARY OF BASIC TRUCK OPERATIONS
Item Description Function

1 left turn indicator indicating the work of the left turn
signal of forklift
2 right turn indicator indicating the right turn signal light of
forklift
3 oil-water separation indicator lamp indicating that the water content in
the oil-water separator is too high
and manual drainage is required
4 low oil pressure indicator lamp indicating low engine oil pressure
5 Engine Warning Indicator indicating the engine failure
6 Glow Plug Light indicating that the Glow Plug works
7 the handbrake indicator light indicates that the handbrake is in
pull state
8 charging indicator light indicates that the battery is not
charged by the motor
9 seat indicator light Indicates that an Operator is present
in seat
10 Hour indicator Shows the hours that the forklift has
operated since new
66
Item Description Function

11 indicates the temperature of the
engine
12 indicates the remaining fuel of
gasoline or diesel
13 Excessive Transmission Shows the temperature of the
Temperature Indicator transmission oil when it exceeds a
certain threshold
14 neutral gear light
15 Issue with Air Filter Monitor Air Flow Restriction
16 indicate the oil temperature of the shows the temperature of the
transmission transmission oil only
INTRODUCTION TO THE POWER The key controls the function of the main power
DISTRIBUTION MODULE (PDM) supply, such as the starting function, preheating
function, flasher, time relay, main power relay, starting
NOTE: Three spare fuses are located within the PDM. relay, headlamp relay, preheating relay, and various
The PDM is made up of flasher, fuses, and other other functions.
electrical components. It functions as the forklift truck
engine starting control, and protection circuit. It ELECTRICAL SCHEMATICS
contains the relays and fuses, making the vehicle The schematic drawing of different engines differ from
circuit maintenance more convenient. The see each other mainly on the starting system and on the
Figure 76 and/or Figure 77 for the ordinary and sensor. It is suggested to refer to the specific drawing
expanded PDM. and real condition of the truck first when carrying out
Application and function requirements of PDM: repair.
67
Figure 61. With NISSAN engine (K21, K25 Sheet 1 of 2)
68
Figure 62. With NISSAN engine (K21, K25 Sheet 2 of 2)
69
Figure 63. With PSI engine Sheet 1 of 2
70
Figure 64. With PSI engine Sheet 2 of 2
71
Figure 65. With Mitsubishi engine (S4S Sheet 1 of 2)
72
Figure 66. With Mitsubishi engine (S4S Sheet 2 of 2)
73
Figure 67. With Xinchai engine (Sheet 1 of 2)
74
Figure 68. With Xinchai engine (Sheet 2 of 2)
75
Figure 69. With Yanmar engine (92-98 Sheet 1 of 2)
76
Figure 70. With Yanmar engine (92-98 Sheet 2 of 2)
77
Figure 71. With Yanmar engine (94 Sheet 1 of 2)
78
Figure 72. With Yanmar engine (94 Sheet 2 of 2)
79
Figure 73. Optional Accessories
80
TROUBLESHOOT ELECTRICAL SYSTEM Example 2: The IC truck could be started but

could not move forward or reverse
• For manually controlled truck, the gear is
WARNING controlled by the lever.
When examining the electrical wires, the key • For the hydraulic controlled truck (With OPS
switch and battery grounding wire should be installed, make sure that the seat and seat belt
turned off and the wiring harness with the same switch are off and hand brake is on), check the
serial number should be connected. Check the gear switch’s input and output voltage to see if it
voltage of the electrical components. Avoid is 12V.
contact with conductive accessories to prevent 1. If there is no input, then check the power
short. Use the electric box wiring and schematic supply for the gear switch lever.
drawings as reference, and follow the steps below 2. If it is with input voltage but without output
to inspect the wiring harness of the truck. voltage, it means that the gear switch lever
is damaged
• No damage on each electrical part
3. If it is with both input and output voltage,
• Each plug should be connected properly with no then check the voltage at where the
rust and dirt directional valve is located.
• Each plug should maintain a safe distance of 4. If voltage exists, the valve or transmission
10 mm (0.40 in.)from its ambient metal part. is damaged. If there is no voltage, the
• The main wire shows no damage or decay wiring between the gear switch lever and
directional valve is disconnected.
• Each plug is labeled to avoid possible wrong
connection
Troubleshooting
• All wiring should be kept away from high
temperature objects like the exhaust system Truck will not start
• All wiring and fuel (gas) manifold should be kept 1. Check if the starting condition is met when the
away from high temperature objects like the operator sits on the seat (whether the seat
exhaust system switch is closed and grounded).
2. Check if the starting conditions are met and the
handbrake is pulled up (whether the handbrake
When the truck fails, first check the electric box to switch is closed and grounded).
inspect for damage to the time relay and fuse (the time
3. Check if the starting conditions are met. For
relay will smell burned, if it is damaged). The middle of Australian customers, if there is seat belt and
the fuse will be blown. Use a multimeter to check when seat starting sequence, whether the starting
these instances are not visible. Replace the damaged conditions are followed.
parts with new ones. The specification of the new fuse
Lift, Lowering and Tilt functions are not working
should not exceed that of the removed fuse.
1. Check if the seat switch is closed and grounded.
Example 1: The IC truck could not be started
2. Check if the solenoid valve is closed. When the
• Turn the key and listen to hear if the starting seat switch is closed and grounded, there
motor is working (engine will turn over). If should be 12V voltage input to the solenoid
starting motor is not functioning, perform the valve. When the seat switch is closed and
following. grounded, there should be 12V voltage at the
1. Check if the gear is at neutral position (with output end of the electrical box.
OPS installed, whether the seat, seat belt 3. Check if the and socket connections are tight or
and hand brake are in place). loose.
2. Check if the negative end of the wiring is 4. Confirm there is voltage input to the solenoid
connected. valve. If valve is not working, check the solenoid
3. Check the start system (key switch) to valve spool.
confirm it functions correctly. Forward and reverse functions are not working
4. Check for damage at the starting motor. If
1. Check if the seat switch is closed and not
the starting motor functions properly, check grounded.
if the oil supply system is working.
81
Drive, Operation, and Routine Maintenance of Forklift Truck 8000 YRM 2199
2. Check if the hand brake is pulled up. The hand 5. Check if the pin and socket connections are
brake switch should be disconnected and tight or loose.
ungrounded. 6. Confirm there is voltage input to the direction
3. Check if there is 12V voltage output when the valve. If the valve is not working, check the
combination switch is put into forward or reverse transmission direction valve.
gear.
4. Check if there is 12V voltage input in the
forward and reverse direction valve.
Drive, Operation, and Routine Maintenance of Forklift Truck

COOLING SYSTEM TROUBLESHOOTING 3. Install the radiator cap.
AND SERVICE
Flushing the cooling system
NOTE: Cleaning water used to flush the cooling
WARNING system must be completely drained, and replaced with
DO NOT operate a lift truck that needs repairs. approved coolant to avoid freezing.
Report the need for repairs immediately. If repair is
• Clean water can be used to flush to cooling
necessary, put a DO NOT OPERATE tag in the
system.
operators area. Remove the key from the key
switch. • Periodically the radiator must be removed and
cleaned in a 1% concentrated boiled soda
Safety labels are installed on the lift truck to give solution. This removes scale and sediment
information about operation and possible hazards. formed that has formed in the radiator.
It is important that all safety labels are installed on
the lift truck and can be read. Adding antifreeze/coolant
Coolant must be less than 40°C (104°F) before Add only approved type FD-2 -35°C (-31°F). Do not
draining the radiator or personal injury may occur add water or any other antifreeze/coolants to the
cooling system.
Coolant level check Filter or replace the antifreeze/coolant after a year of
use.
1. If radiator coolant is boiling or temperature is too
high, do not to open the radiator cap immediately.
Cleaning the radiator
If the forklift truck is running, bring the engine idle
down to low or medium speed. The exterior of the radiator should be cleaned
Periodically. Cleaning may be required more frequently
Loosen radiator cap slowly to relieve pressure. depending on working conditions.
Once there is no pressure, remove the radiator
cap. Use detergent, compressed air, or high-pressure water
to clean the radiator. Pressure used to clean the
2. Check coolant level. Add approved coolant as radiator should not exceed 4 kg/cm ( 56.9 psi).
needed.
NOTE: Radiator cap must be installed completely. If

the radiator cap is not tight, the cooling system can not
build adequate pressure.
82
8000 YRM 2199 Drive, Operation, and Routine Maintenance of Forklift Truck
OILS USED FOR FORKLIFT TRUCK
Name Brand or Code (Domestic)

Gasoline 87 number gasoline.
Engine Oil API rating of SM or newer
Hydraulic Oil Kinematic Viscosity 28.8-35.2 cSt @ 104F (40℃
mm2/s）
Kinematic Viscosity ≥5 cSt @ 212F (100℃ mm2/s)
Transmission Oil Kinematic Viscosity 5-7 cSt @ 212F (100℃ mm2/s）
Gear Oil API GL-5 85W-90
Brake Fluid DOT4 Synthetic Brake Fluid
Grease (steer axle) NLGI grade 2 lithium type complex grease (with
minimum of 3% molybedenum disulphide additive)
Grease (rest of truck) NLGI grade 2 lithium based grease
• H line indicates the maximum level of hydraulic

HYDRAULIC OIL GAUGE AND oil required. If the reading on the dipstick is
above this line, flush oil from the tank.
HYDRAULIC OIL FILL
General inspection requirements
1. Check the oil level of the hydraulic oil tank. Take
the oil level trace as a reference. The mast,
attachments, and steering system must be taken
in consideration in order to fill the hydraulic
system to the correct level.
2. Forklift must be parked for five minutes before oil

level can be checked.
3. The engine must be OFF, the forklift truck must

be on flat ground, the mast must be vertical state,
forks must be on the ground, and attachments
should be retracted. This ensures the hydraulic oil
is back in the tank.
Fill Level Requirements

NOTE: For items below, refer to Figure 74.
• L line indicates the lowest level of hydraulic oil
required to operate the mast up to 4 m (13.1 ft) A. FILL LEVEL REQUIRED FOR MAST ABOVE
in height (including the full free lift mast and 4 m (13.1 ft), WITH ATTACHMENTS.
mast with special attachment). B. FILL LEVEL REQUIRED FOR MAST BELOW
• M line indicates the lowest level of hydraulic oil 4 m (13.1 ft), WITH ATTACHMENTS.
required to operate the mast
ABOVE4 m (13.1 ft) in height (including the full Figure 74. Oil Fill Stick
free lift mast and mast with special attachment).
83
Drive, Operation, and Routine Maintenance of Forklift Truck 8000 YRM 2199
LUBRICATION SYSTEM
Figure 75. Lubricating System
84
8000 YRM 2199 PDM Schematics
PDM Schematics
85
8000 YRM 2199 Figure 76. PDM (Suitable For All Engines) 87/(88 blank)
8000 YRM 2199 Figure 77. PDM With OPS (Suitable For All Engines) 89/(90 blank)
8000 YRM 2199 1/21 (10/20)(11/19)(10/19)(5/19)

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Maintenance

PART NO. 550216372 8000 YRM 2199

Series Model Engine Transmission

NOTE: DUAL designates DUAL FUEL or BI-FUEL.

©2021 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

Forklift Truck Main Parts

Forklift Main Technical Parameters

MAIN TECHNICAL PARAMETERS

Figure 1. Outside Drawing of Forklift Truck(LPG/DUAL)

Figure 2. Outside Drawing of Forklift Truck (Diesel engine/gasoline engine)

Table 1. Technical Parameters

Table 2. Gasoline Engine (2.4)

Table 2. Gasoline Engine (2.4) (Continued)

Valve Timing Exhaust Valve

Refer to the engine operation and maintenance Fuel System

1. PORT SEALED 3. FLOAT RISE 5. OIL INLET

Figure 3. Fuel Tank (Gasoline Forklift Truck)

Figure 4. Fuel Tank (LPG Forklift Truck)

Fuel Level Sensor

Figure 5. Fuel Level Sensor

Fuel Position Resistance (Ω)

Maintenance of Fuel System

Fuel filter service

1. STEEL TUBE CLAMP

Figure 6. Fuel Filter (PSI 4G64-2.4L Engine)

The fuel filter must be changed every 400 hours or

Hydraulic Transmission Case and Torque Converter

Type Three-Element, Single-Stage, and

7.1 g/min (217.6 psi x 2000 rpm)

CALTEX：Torque Fluid 175; RPM

OVERVIEW 2. The hydraulic clutch is equipped with four pairs

1. GEAR SHAFT 10. OUTPUT SHAFT

Figure 7. Hydraulic Transmission Device

TORQUE CONVERTER This method of torque conversion ensures a high-

Figure 8. Torque Converter

1. END PLATE 9. INPUT SHAFT ASSEMBLY 17. SEAL RING (B)

Figure 9. Forward/Reverse Clutch Pack

1. WOODRUFF KEY 3. PIN

Figure 10. Control Valve

1. OVERFLOW PRESSURE BUFFER VALVE 10. TO LUBRICATING OIL CIRCUIT

Figure 13. Transmission Hydraulic Schematic

cylindrical pink, and gear ring I is fixed onto the shell of

1. SPEED REDUCER ASSEMBLY

OIL INLET/OUTLET CONNECTION LOCATION

Figure 16. Oil Inlet/Outlet Connection Location

OVERVIEW receives the torque transmitted by wheel hut. The oil

3. Tighten the half shaft mounting nut. Torque to

4. Tighten the wheel mounting nut. Torque to

5. Tighten the brake drum mounting. Torque to

Figure 17. Single Wheel Drive Axle

MAINTENANCE OF DRIVE AXLE

1. Coat tapered roller bearing with lubricating

2. Tighten the lock nuts. Make sure that the rotating

Type of Steering System Rear Wheel Steering with Power Steering

Hydraulic Steering Gear Assembly

1. STEERING WHEEL 2. STEERING GEAR

Figure 19. Hydraulic Steering Gear and Steering