Baoli CPCD 80, CPCD 100 Operating And Servicing Manual

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OPERATION & SERVICE

MANUAL

8-10t Internal Combustion

Counterbalanced Forklift Truck

KION Baoli (Jiangsu) Forklift Co., Ltd.

PREFACE

Thank you for selecting BAOLI forklift truck! Your trust is a great honor to us!

8-10 ton internal combustion counterbalanced forklift trucks adopt hydraulic transmission with advanced TCM continuous speed control and integral drive axle with wheel reducer, so they have a lot of advantages such as good traction and travel performance, easy operation, reliable brake, wide visibility and safe performance. These trucks are all suit for handling and stacking packed goods in stations, ports, goods yards and warehouses and used widely in food processing, light and textile, mining industries and other factories, with some of attachments fitted, the trucks can be applied more and more.

This manual states the trucks’ specifications, operation, maintenance, service,

main assemblies’ constructions and working principles so as to be completely familiar

with the truck to get the most of it, and to help the operators to use the trucks correctly and attain the highest functions. It is necessary to read over the manual before they operate the trucks or service personnel serve these trucks.

Besides this Operation and Service Manual, there is Operator’s Manual, which

includes important information of safety driving and periodic maintenance. And, the manual of some important parts is provided.

We suggest you to give the manual a proper storage. If there is something in the manual you do not understand, ask the distributor to explain it to you. Suggestion and criticisms are welcome.

This manual content might not correspond with the actual condition because of the improving of our products. Our products are subject to improvements and changes without notice.

We heartily wish you keep everything running smoothly during operation of BAOLI forklift truck!

CONTENTS

Ⅰ. About the forklift truck..........…….………………………................................1

1. External view and specification……………………………………………………1

2. Characteristic of forklift truck………………………………………………………3

Ⅱ. Safety instruction and operation of forklift truck………………………5

1. Handling a new forklift truck………………………………………………………5

2. Inspection before operation………………………………………………………5

3. Start and stop of the engine………………………………...................................6

4. Shipping, loading and unloading, slinging and towing of forklift truck…………7

5. Parking and storing…. . ……………………………………………………………8

6. Information of safety operation…. …………………………...... ………………10

7. Operation device and meter………………………………………………………16

8. Caution plate……………………………………………………..........................18

Ⅲ. Periodic inspection and servicing…………………………………………23

1. General rules on inspection and maintenance…………………………………23

2. Essentials of servicing..............…………………………..............................24

3. Recommended oil...........................……………………............................25

4. Lubrication system..................................………………………..................25

5. Routine check before daily operation...........……………............................27

6. Precautions of cooling system……………………………………………………27

7. Notes during brake-in...........................…………………….............................27

Ⅳ. Construction, principle, adjustment and maintenance of forklift truck…28

1. Power system………………………………………………………………………..28

1.1 General description…………………………………………………………….28

1.2 Engine disposition………………………………………………………………..29

1.3 Inspection and adjustment of engine…………………………………………..31

1.4 Fuel system……………………………………………………………………..31

1.5 Coolant system…………………………………………………………………..33

1.6 Check and adjustment………………………………………………………….33

1.7 Precautions of cooling system…………………………………………………..38

2. Drive unit……………………………………………………………………………39

2.1 General description…………………………………………………………….39

2.2 Torque converter…………………………………………………………………41

2.3 Charging pump……………………………………………………………………42

2.4 Hydraulic clutch…………………………………………………………………..43

2.5 Control valve and inching valve…………………………………………………43

2.6 Hydraulic circulation system…………………………………………………….45

2.7 Principle……………………………………………………………………………46

2.8 Caution when the trouble occurs………………………………………………46

2.9 Trouble shooting…………………………………………………………………47

3. Front axle……………………………………………………………………………50

3.1 General description…………………………………………………………….50

3.2 Main reduction gear & differential……………………………………………….50

3.3 Final reduction gear………………………………………………………………50

3.4 Troubleshooting…………………………………………………………………53

3.5 Service data……………………………………………………………………….53

4. Brake system……………………………………………………………………...54

4.1 General description…………………………………………………………….54

4.2 Power brake……………………………………………………………………..54

4.3 Parking brake……………………………………………………………………58

4.4 Wheel brake……………………………………………………………………..58

4.5 Troubleshooting………………………………………………………………….60

5. Steering system…………………………………………………………………….61

5.1 General description…………………………………………………………….61

5.2 Hand wheel……………………………………………………………………….60

5.3 Cycloid gear type powered steering unit……………………………………..62

5.4 Steering system troubleshooting……………………………………………...70

5.5 Rear axle…………………………………………………………………………..71

6. Hydraulic system…………………………………………………………………..73

6.1 General description………………………………………………………………73

6.2 Main pump……………………………………………………………………….73

6.3 Control valve…………………………………………………………………….73

6.4 Control valve operation………………………………………………………….74

6.5 Main safety valve operation……………………………………………………..76

6.6 Tilt lock valve operation…………………………………………………………77

6.7 Hydraulic circulation system (Main circuit)……………………………………..78

6.8 Troubleshooting………………………………………………………………….79

6.9 Maintenance……………………………………………………………………...80

7. Lift Cylinder & tilt Cylinder……………………………………………………….81

7.1 Lift cylinder……………………………………………………………………….81

7.2 Flow regulator…………………………………………………………………….83

7.3 Tilt cylinder……………………………………………………………………….84

8. Lifting system……………………………………………………………………….85

8.1 General description…………………………………………………………….85

8.2 Inner & outer mast………………………………………………………………..85

8.3 Lift bracket………………………………………………………………………..85

8.4 Roller position…………………………………………………………………..86

8.5 Adjustment of lifting system………………………………………………...88

8.6 Maintenance and adjustment…………………………………………………...88

9. Electric system………………………………………………………………………91

9.1 General description……………………………………………………………. 91

9.2 Brief explanation for operation…………………………………………………..95

9.3 Precautions when using the battery……………………………………………97

9.4 Harness…………………………………………………………………………...97

Product improve suggestion sheet…………………………………………………102

NOTE……………………………………………………………………………………10 3

EC DECLARATION OF CONFORMITY………………………………………………104

Ⅰ. About the forklift truck

1. External view and specification

External view of internal forklift truck

Main specification

General

Model

CPCD80

-C

CPCD80-W

CPCD100

-C

CPCD100-W

CPCD80-CU1

CPCD100-CU1

Power type

Diesel

Operating way

Sitting

Rated capacity

8000

10000

Load center

600

Dimensions

Lift height

3000

Free lift height

205

210

Fork size L×W×T

1500×160×75

1500×160×80

Fork outside spread (Min./Max.)

320/2015

420/2144

Mast tilt angle

α/β

deg

6/12

Front overhang

700

733

Overall

dimensions

Length to fork face

3940

4258

Overall width

2245

Mast lowered height

2695

2845

Mast extended height

4445

4307

Overhead guard height

2565

Turning radius

3700

3900

Performance

No load/full load Travel speed

km/h

28 / 24

28 / 22

Lift speed

mm/sec

480/350

410/350

390/280

390/300

Max. gradeability

Self weight

11080

12860

Chassis

Tyre Front

9.00-20-14PR

Rear

9.00-20-14PR

Tread Front

1600

Rear

1700

Wheelbase

2500

2800

Min. mast ground clearance (no load/full load)

Mast

245/205

Frame

343/323

Drive units &

control

Battery

V/AH

2×12/100

2. Characteristic of forklift truck

The forklift truck has advantages as follows:

1. The hydraulic steering device makes steering flexible and the double ladder like

steering bridge makes the turning radius minor.

2. The braking system employs oil brake, makes it possible to manipulate

conveniently and brake reliably.

3. Employed wide-vision extension type mast, the truck is high intensity.

4. Hydraulic transmission type forklift trucks are provided with a drive unit including

a torque converter and a hydraulic transmission. They feature the following:

a. Hydraulic torque converter can change the speed automatically with no limitation

and output torque makes the forklift truck have good performance of drawing.

b. The slight travel device makes it easy for the drivers to aim the truck to the

position of cargo.

c. At work, for the forklift truck that need starting and shifting frequently, achievement of smooth gear shifting control can raise working efficiency, simplify operation, reduce the driver’s labor intensity and reduce requirement of the driver’s operation skill.

5. The trucks’ braking system employs oil brake, make it possible to manipulate

conveniently and brake reliably.

6. Employed wide-vision type mast, and it’s frame is two stage CJ extension type mast. The truck is high intensity and has wide vision. The mast adopts series design, having different lifting height according to the needs of the client.

7. Specific outline adopts streamline design, it has advantages such as low noise, small libration, comfortable operation, safety and reliability.

Main parts of forklift truck:

No.

Name

Contents

Power system

engine mounting, system of fuel, exhaust and coolant etc.

Transmission

torque converter, transmission, transmission shaft, etc.

Drive axle

housing, half shaft, differential, wheel reducer, brake, front wheel etc.

Brake system

wheel brake and parking brake

Steering system

steering wheel, steering shaft, cycloid gear type powered steering unit and steering axle assy etc.

Hydraulic system

pump, valve, HP oil pipe, LP oil pipe, connectors etc.

Electric system

lamps and lanterns, battery, meter, harness etc.

Load system

mast, fork, carriage, load backrest, tilt cylinder, lift cylinder, lift chain, mast roller etc.

Weight of the main parts that can be disassembled

Model Specification

10T

Balance

weight

Slinging capacity

(kg)

>4500

>5000

Overhead

guard

Slinging capacity

(kg)

>150

Mast

Slinging capacity

(kg)

>2000

>2100

Carriage

Slinging capacity

(kg)

>1000

>1200

Fork

Slinging capacity

(kg)

>220

>250

Ⅱ. Safety instruction and operation of forklift truck

It is important for drivers and managers to remember the principle of “first safety”

and ensure the safety operation as the description of Operation & Service Manual. Please read this manual thoroughly. This will give you a complete understanding of Baoli forklift truck and you will operate them correctly and safely.

1. Handling a new forklift truck

The performance and service life of the forklift truck depends heavily upon the way you handle it during the break-in period. Drive with special caution while becoming familiar with a new forklift truck. (1) Always warm up your vehicle before putting it to work irrespective of season. Don’t run engine at high rpm without load needlessly. Operate the vehicle under the light load, avoid sudden speeding and braking.

(2) Replace gear oil in the differential and reducer after the new forklift truck

working for 100 hours.

(3) Renew the oil in engine oil pan, transmission, driving axle and hydraulic oil tank; check and readjust the clearance of the driving and driven gear in the reducer after the new forklift truck working for 200 hours.

2. Inspection before operation

Please pay attention to the following items in order to make the vehicle working with high efficiency and lengthen its service life.

(1) The forklift truck adopts the home or imported engine, please read the manual accompanied with the engine carefully when using and maintenance.

(2) Check the tyre inflation pressure, if doesn’t enough, charge air in time. Check the bolts of all wheels for tightness.

(3) Check the amount of oil in the working oil tank for sufficiency, the position of lubrication should be lubricated. The oil level should be at the middle position between the upper and lower scale marks of oil level meter. The contamination level of the hydraulic oil should be lower than Grade 12.

(4) Check the radiator, and add antifreeze if necessary.

(5) Check hydraulic oil and brake fluid for leakage. Check if any leak or damage found on the oil pipes, water hoses, vent-pipes and the piping joints, pumps and valves

etc.

(6) Check for all the terminals and plugs in normal state. Check the meters, lamps, switches and electric circuit if they are running properly.

(7) Check every pedal for free stroke and the levers for looseness and smooth operation. Check lifting system, actuate the lifting and tilting levers to be certain that the lift bracket moves up and down properly and the mast can be tilted smoothly. Check brake system and steering system for flexibility and reliability.

(8) Check the wheel brake: the free stroke of brake pedal is 4-8 mm, when achieving effective brake, the clearance between the front floor and the pedal should be more than 20mm.

(9) Check the parking brake: the unload forklift truck can park on 20% slope, when the parking brake is locked.

(10) Check all connectors and fasteners for looseness.

3. Start and stop of the engine

(1) Start of the engine

(a) First set the shift lever at the neutral position and the parking brake at the braking position.

(b) When starting, put the key into the start switch, turn it in the counter clockwise, preheat 15-20 seconds, and then turn it in the clockwise to “START” so the starting motor works. When your hand is away from the key, it automatically returns to “ON” by

spring force. Every starting time shouldn’t morn than 15 seconds. Restarting should be

after 30 seconds. As the engine doesn’t work after some times starting, should check

and remove the trouble, do not keep the starting motor engaged for a long time.

for five minutes. Full load operation can’t be started until water temperature of the

engine rises above 60℃.

When the engine is on idle running, you must check water thermometer, oil manometer, ammeter, fuel measurer, and so on for the data, whether to meet the specification, and check each pedal for free stoke, braking performance for its reliability, steering operation for its flexibility, tyre pressure for its conformance to the standard. If there is no trouble, operation may be allowed.

(2) Stop the engine

First set the engine on idle running for five minutes, so as to cool the engine gradually, and then turn off the ignition switch, so the engine is stopped to work.

Notice：

．While the engine running, does not turn the start switch to “START” position, or it

will damage the starting motor.

．Do not keep the start switch at the “ON” position while the engine is shut down.

This will result in battery discharge.

4. Shipping, loading and unloading, slinging and towing of forklift truck

(1) Ship the forklift truck

(a) Apply the parking brake when shipping the forklift trucks by container or freight car.

(b) Fix the mast and the balance weight with steel wire and use jacks to prevent the forklift trucks from moving in the cabin.

(c) Pay attention to the overall length, width, height when loading, unloading and shipping and conforming the regulations is necessary.

(d) Single transporting if necessary after disassembling the mast and balance weight.

Model

Mast

Balance weight

Dimension(mm)

Weight(kg)

Dimension(mm)

Weight(kg)

2450×2175×850

2423

1980×1166×1325

4193

10T

Mast

2600×1201×695

1864

1980×1610×1169

4826

Carriage

2238×1330×435

1330

Notice:

Dismantling and slinging the component shall not be performed without the approval of our company. Under special circumstances, the appointed sling position should be used. The balance weight, fork and mast of the forklift truck all have their appointed sling position. The above-mentioned data is only for a reference, which may be adjusted because of configuration or technology optimization.

(2) Load and unload the forklift truck

(a) Use the plate with enough length, width and strength.

(b) Pull the parking brake and use jacks to stop the wheel.

(d) The left and right height of the plate must be equal to make the loading and unloading smooth.

(e) Don’t change the direction on the plate to prevent the danger.

(f) Reverse the forklift truck slowly when loading it on the freight car.

(3) Sling the forklift truck

(a) Only the specially trained personnel can sling the truck.

(b) Sling points should be always at the positions specified in sling nameplate.

(d) Disassembled parts of forklift truck must be slung in the appointed position.

(4) Towing of forklift truck

(a) The towing pin is installed below the counter weight. When towing the forklift truck, first extract the pin and fasten a steel wire, then install the pin back.

(b) When towing the forklift truck, release the hand brake lever.

(c) The towing pin only used for following situation, while the forklift truck can’t move or while transporting the forklift truck.

(d) Fasten the towing steel wire at the appointed position.

(e) Don’t apply capacity abruptly when towing the forklift truck.

(5) Repair the broken-down forklift truck

If the forklift truck broken-down suddenly during using, drag it away and repair in time to avoid hindering other vehicles or workers.

5. Parking and storing

(1) Safe parking

(a) Park your forklift truck on a level ground preferably in a wide area. If parking on a slope is unavoidable, pull the parking brake device and block the wheels to prevent

accidental roll. The forklift truck is forbidden parking on a steep slope.

(b) Park your forklift truck in the area where designated or traffic conditions permit. If necessary, put a signpost or signal lights around the truck.

(d) If you can not lower the forks on the ground due to break-down of the lifting system, put a warning flag to the fork end and park in the traffic conditions permitting.

(2) Storing

·Before storing

Before storing your forklift truck, clean it thoroughly and perform inspection using the following procedures.

(a) Wipe away grease, oil, etc. adhering to the body of the truck with waste cloth and water, if needed.

(b) While washing the body of the truck, check general condition of the truck.

Especially check the truck’s body for recess or damage and tyres for wear and nails or

stones in the tread.

(d) Check for leakage of hydraulic oil, engine oil, fuel or coolant.

(e) Apply grease where needed.

(f) Check for looseness of hub nuts and cylinder piston rod joints. Check the surface of piston rod for damage.

(g) Check mast rollers to see that they rotate smoothly.

(h) Full oil into the lift cylinders by lifting the lift cylinders at the full stroke.

(i) In cold weather, don’t draw off long antifreeze, if there is cooling water, run it

away.

·Daily storage

(a) Park the forklift truck at a specified place and block the wheels.

(b) Place the shift lever in the neutral position and pull the parking brake lever.

the control valve several times and release the residual pressure of the cylinder or pipes.

(d) Remove the key and keep it in a secure place.

·Long time storage

Perform the following service and checks in addition to the “Daily storage” service:

(a) Taking the rainy season into consideration, park the truck at a higher and hard ground.

(b) Apply antirust oil to the exposed parts such as piston rods and shafts which tends to rust.

(d) The truck should be operated at least once a week. Fill the cooling system, if cooling water is discharged. Remove grease from the piston rods and shafts. Start the engine and warm up thoroughly. Move the truck slowly forwards and backwards. Operate the hydraulic controls several times.

(e) Avoid parking on soft grounds such as asphalted road in summer.

·Operate the forklift truck after long time storage

(a) Remove antirust oil from the exposed parts.

(b) Discharge the engine oil in crankshaft case of the engine, discharge the gear oil or hydraulic transmission oil in differential and gear box, after cleaning up then renew oil.

(d) Remove the cylinder cap, the valves and the rocker shafts, check for the clearance in normal data.

(e) Add cooling fluid to specified level.

(f) Perform pre-operation checks carefully.

(g) Warm up the engine before operation.

Warning:

If at any time your forklift truck is found to be in need of repair, defective, or in any way unsafe, the condition should be reported to the supervisor, and the truck should be taken out of service until it has been restored to safe operating condition.

6. Information of safety operation

(1) The forklift truck belongs to special equipment. Only trained and authorized operator shall be permitted to operate and service the truck.

(2) Wear the safety guards, such as clothing, shoes, helmet and gloves while operating the truck.

(3) When operating the truck, observe and follow all nameplates stuck on the truck. The nameplates must be replaced if lost or damaged.

(4) Daily maintenance should be done before or after using the truck. Anytime you find that the truck is not functioning normally, operation of the truck should be halted and check or repair at once.

(5) When the distance between the gravity center of loads and the fork arms is 600mm, the max. capacity is the rated capacity. When the distance exceeds 600mm, the capacity shall be reduced according to the load chart. Overloading is strictly prohibited.

(6) Operate your forklift truck on a hard ground. Operate on other ground, the lift capacity and travel speed must be decreased. Wipe off the oil and grease from the floor.

(7) If the forklift truck is equipped with attachment, its usage sphere will be wider, but its allowable load and stability is reduced. The attachment and special device is not

to be diverted to any other purpose. It’s very dangerous to rebuild the attachment.

Please read the additional instruction we supplied and operate the truck following it strictly.

(8) Users select “Lengthening fork” in order to carry widening loads. Pay much

attention not to overload and observe the allowable load and the capacity chart stuck on the truck. Careful driving should be taken when traveling and turning.

(9) The unloaded forklift truck with attachment should be operated as a loaded truck.

(10) Connect the power and turn on the key switch, select the position of direction switch, check the truck for normal operation by turning steering wheel, depress the speed-adjusting pedal softly to keep proper acceleration.

(11) During operation, pay attention to the performance and condition of the system of machinery, hydraulic, electric and speed-adjuster etc.

(12) When operate one lever, pay attention not to shift another lever. Don’t operate

the lever at any position out of the driver’s seat.

(13) The shift distance of control valve lever can control the speed of the lifting or descending of the goods. When the goods are lifted or descended, the initial speed shouldn’t be too fast in either case.

(14) When tilting the mast forward or backward to the limit or lifting the fork to the maximum height, return the directional lever to neutral.

(15) The starting, turning, driving, braking and stopping of the truck should be done smoothly. When turning on the humid or slippery road, the truck should be decelerated.

(16) Because the forklift truck turns by the rear wheels, the end counterweight may swing widely when turning. Use care in narrow aisles and other workplaces.

(17) Operate the forklift truck smoothly, don’t jerk the steering wheel. Avoid sudden stop, acceleration, stop or turn. In the case of improper operation, the truck will turn over.

In case of this, the driver must keep calm, don’t jump off the truck. The driver must hold

tightly the control wheel with two hands; meanwhile, his body must incline in opposite direction of truck’s turning over.

(18) Turning, lateral or deflective traveling shall not be taken on a slope. It could cause overturning of the truck, it is very dangerous. On a slope, drive the truck with load forward to ascend and backward to descend. When the truck goes down on a slope, drive slowly with the brakes on. Make sure that the engine should not be shut down when traveling on a slope.

(19) The stability of the truck is influenced by the wind-force during outside operation, you must notice specially.

(20) Be careful and slow driving over a dock or temporary paving slab.

(21) Insert forks deeply under goods. Adjust fork’s distance according to the

dimension of goods. Make the loads distribute on the forks evenly to avoid tilt and slide of goods.

(22) Don’t pick the loads with single fork. Fork can not be used to pull out any

embedded goods, if necessary, the pulling force should be estimated.

(23) Don’t handle unfixed or loose goods. Be careful to handle bulky goods. To prevent the collapse of stacked goods, tighten them. Forbid loading loose or little volume goods without pallet.

(24) When loading the goods, lower the forks to the floor. After the fork inserting stacked goods, the fork arms should be in contact with the goods. Drive the truck with mast tilting back for stabilizing the load. Before traveling, raise the forks for 200mm-300mm from the floor.

(25) When handling bulky loads which block your view, operate the forklift truck in reverse or have a guide.

(26) While mast’s lifting and lowering, anyone is absolutely prohibited from standing

under the lift bracket or being lifted with forks. Never permit anyone to stand or walk

under upraised forks.

(27) When lifting the load, according to the weight of the load, accelerate properly and then pull the lifting lever.

(28) The load descends for the gravity, at this time, the engine must be in idle position, and the lever must be pulled slowly to prevent the load from sudden falling.

(29) When loading and unloading goods, keep the mast vertical and the truck is in braking state.

(30) Load should cling to the load backrest. Do not handle the load which exceeds height of the backrest, or else there is a danger of load’s falling against operator.

(31) When travel with load, don’t tilt mast forward, don’t do handling. Don’t brake abruptly to prevent goods from slipping off the forks.

(32) It is necessary to brake before tilting the mast forward or backward. It’s also

necessary to decelerate and tilt forward slowly so as to prevent the goods from slipping off the forks.

(33) Don’t make a sudden braking when the truck traveling with loads.

(34) Drive the forklift truck to the stacked goods at a low speed, at the same time, pay much attention to sharp and hard objects near the goods, otherwise, the tyres will be pricked.

(35) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay attention to the clearance over the forklift truck.

(36) Keep your head, hands, arms, feet and legs within the confines of the cab. Never allow other persons on the forklift truck.

(37) Tilt the mast of the high lift forklift truck as backward as possible when operating the truck. Use minimum forward and backward tilt when loading and unloading. It is dangerous to travel or turn when lifting the goods at high levels.

(38) It is noted that the goods will fall down when the forks of the truck with lifting height more than 3m lift, take the protection measures if necessary.

(39) Before the truck decelerating and stopping, don’t change gear to reverse shift, so as to ensure the safe loading.

(40) When the truck stops and the engine is on idle position, the mast must be tilted backward. You shouldn’t leave the truck with idling engine or hanged goods unattended.

(41) When adding fuel, make the driver leave the truck and the engine flameout. Don’t ignite when checking the level of fuel tank.

(42) Don’t open the radiator cap when the engine is very hot.

(43) After one day’s working, the fuel tank should be added oil to prevent the

humidity in the fuel tank from becoming the blob and then interfusing the fluid.

(44) When leaving, engage the hand brake, lower the forks on the ground and let the shift lever to neutral, make the engine flameout or cut down the electric supply. If parking on a slope with smaller gradient, apply the parking brake and block the wheels. The truck is forbidden parking on a slope with bigger gradient.

(45) Don’t adjust the control valve and relief valve at will to prevent the damage of

hydraulic system and its components because of excessive pressure passing them.

(46) Tyres should be inflated according to the pressure value specified in the nameplate of “Tyre Pressure”.

(47) Check the chains periodically to make sure that good lubrication condition exists between the chain elements, the degree of tightness between left and right chain is identical. If the variation value of the chain pitch exceeds 2% standard value, it indicates that the chains have been worn excessively, replace it immediately.

(48) The overhead guard is main part which is strong enough to meet safety

standard, and protect the operator from falling materials. It’s very dangerous to

dismantle or rebuild the overhead guard, because these conditions could lead to an accident.

(49) A load backrest shall be used as protection against back falling objects on the

fork. It’s very dangerous to dismantle or rebuild the load backrest, because these

conditions could lead to an accident.

(50) You can’t change or add other working equipments on the truck without our company’s permission, or the rated capacity and safety operation will be affected.

(51) Keep safety when serving on high position.

(52) The forklift truck must be operated under the following environment: below an elevation of 1000 meters and temperature between -20℃and 40℃, relative humidity is 95%. Careful operation must observe under other adverse circumstances.

(53) Because of the danger for the people, the forklift is forbidden operating in airtight space, or you may be choked by the tail gas. The tail gas’s exhausting standard shouldn’t be lower than the no-load mechanical vehicle exhaust standard ruled by the nation that users are in. If in Europe nation, the adopted tail gas’s exhausting index should be applied Europe StageⅢA standard.

(54) According to the Directive 2000/14/EC and based on EN12053 standard，the noise pressure level at the operator’s position and the measured sound power level and the guaranteed sound power level is referred to the following table. But the noise of the forklift truck may fluctuate due to different operation and the influence of the external environment.

(55) The driver feels the vibration of the forklift truck when operating and traveling the forklift truck.. According to ISO3691 and based on EN13059 standard. The vibration of the forklift truck fluctuates according to environment condition. In normal working condition, the vertical direction acceleration mean value from the seat to the operator by testing is in the following table. But the vibration frequency felt by the driver depends on the working condition (etc. road, operation method), so the actual vibration frequency must be determined according to environment condition when necessary.

(56) To prevent the fire, accident or other unpredictable event, prepare the fire extinguishers in advance and operate them according to the instructions.

(57) Preventive maintenance services should be done before or after using the truck. Anytime you find that the truck is not functioning properly, operation of the truck should be halted and check or repair the trouble.

(58) When operating the machine, observe and follow all markings on the machine. If the marking is lost, please stick it in time.

Model

The noise pressure

level at the

operator’s position

The measured

sound power level

The

guaranteed

sound power

level

The vertical

direction

acceleration

mean value from

the seat to the

operator

EN12053

2000/14/EC

CPCD80

87 dB(A)

110 dB(A)

111 dB(A)

0.92 (m/s2)

CPCD100

86 dB(A)

109 dB(A)

111 dB(A)

1.06 (m/s2)

7. Operation device and meter

Inching pedal

11.

Air filter indicator (option)

Button for stopping engine

12.

Water temp. gauge

Brake pedal

13.

Sedimentor indicator (option)

Parking brake lever

14.

Hour meter

Hand wheel adjusting lever

15.

Horn button

Shift lever

16.

Turn signal lever

Oil pressure indicator

17.

Accelerator pedal

Fuel gauge

18.

Lift lever

Charge signal

19.

Tilt lever

10.

Neutral signal

The function and use method of operation device and meter is listed as follows:

No.

Name

Function

Use method

Inching pedal

Couple or uncouple the transmission.

When the pedal is pressed, the transmission is uncoupled.

Button for stopping engine

Stop the engine.

Pull the button to stop the engine.

Brake pedal

Brake the truck.

Depress the pedal to brake the truck.

Parking brake lever

Park the truck.

Pull the lever backward fully.

Hand wheel adjusting lever

Adjust the angle of steering wheel.

Shift lever

Change the travel direction.

Pull the lever forward, the truck travels forward.

Oil pressure indicator

Indicate the pressure of engine oil.

Pressure is insufficient, it lights up.

Fuel gauge

Indicate the fuel capacity.

Ignition switch is set at on.

Charge signal

Indicate the battery condition of charge.

Lamp comes on when the ignition switch is set at on.

Neutral signal

Indicate the neutral position.

Shift lever is in neutral position, it lights up.

Air filter indicator (option)

It will warn when the air filter is blocked.

Exceed standard resistance, it flashes.

Water temp. gauge

Indicate the temperature of engine coolant.

Ignition switch is set at on.

Sedimentor indicator (option)

Indicate water amount in sedimentor.

Water reaches to a certain level, it lights up

Hour meter

Shift lever is in neutral position.

Ignition switch is set at on.

Horn button

Control the horn.

Press it to sound horn.

Turn signal lever

Indicate the turning direction.

Pull the lever, the turn signal light blinks.

Accelerator pedal

Increase the engine speed

Depress the pedal to increase the speed.

Lift lever

Control lift cylinder.

Pull backward to lift, pull forward to decline.

Tilt lever

Control tilt cylinder.

Pull the lever backward to tilt the mast backward.

8. Caution plate

The caution plates attached on the vehicle indicates the operating method and instructions. Before driving it, please be sure to read them thoroughly. If the caution plate drops, stick it again. When maintaining, check if the caution plate is complete and the writing is legible, if necessary, please replace them.

(1) Safety mark (People are forbidden to stand on or down the fork.)

(2) General information when operating

(3) Nameplate of forklift truck

(4) Lubrication system

(5) Capacity chart

(6) Inspections before starting

(7) Adjust parking brake

(8) Add hydraulic oil

(9) Add fuel

(10) Add antifreeze

(11) Tyre safety decal (charging tyre)

(12) Tyre pressure decal (charging tyre)

(13) Cautions for high voltage

(14) Sling point indication

(15) Sling decal

(16) Forbid entering into the space behind the mast

(17) Forbid conveying person

(18) Hand caution decal

(19) Fan hurting hands

(20) Hood crushing hands

Energy accumulator decal

Belt pulley thumb hand decal

Ⅲ. Periodic inspection and servicing

During operating the forklift truck, it is necessary to operate carefully, service and

maintain periodically to make the forklift truck keep in good condition.

1. General rules on inspection and maintenance

(1) Only use genuine parts provided by our company. (2) Only use genuine or recommended oil when replacing or adding. (3) Clean oil fillers and grease fittings with a brush or waste cloth before adding oil

or grease.

(4) Checking oil level and adding oil should be made with the truck parked on a

level ground.

(5) Preventive maintenance should be done in an orderly manner and due care

taken not to injure yourself.

(6) If any damage or fault is found, stop the truck and report the condition to the

manager. Do not operate the truck until it has been repaired completely.

．Regular inspection

(1) Check the seal and the reliability of the hydraulic system. (2) Check the reliability of the steering and braking system. (3) Check the reliability of mast, driving axle and steering axle connecting with the

frame.

(4) Check all wheels for tightness.

．Irregular inspection

(1) Check the reliability of each welding joints of the mast, frame and so on. (2) Check the reliability of connecting joints of steering cylinder, joint plate and

gimbals etc.

(3) Check all pipes and hoses for any leakage and breakage. (4) Check the performance of the traveling brake and the parking brake.

Caution:

．Only trained and authorized serviceman shall be permitted to service and

repair the truck.

．When checking and maintaining the forklift truck, do not use the mast or the load backrest instead of a ladder, these actions will lead to a dangerous condition unexpectedly.

2. Essentials of servicing

(1) Some critical components must be replaced according to demands periodically. Use genuine parts only.

(2) Use the same model oil only when replacing or adding.

(3) If any damage or fault is found, stop the truck and report the condition to the manager. Do not operate the truck until it has been repaired completely.

Periodic service and maintenance must be done according to the following list after using the forklift truck.

No.

Item

Contents

Period (hrs.)

Remark

Bearing, steering wheel

Replace grease

1000

Bearing, drive wheel

Replace grease

1000

Steering link lever

Replace grease

1000

Parking brake lever

Add grease

200

Pin, foot brake

Add grease

200

Drive axle body

Replace gear oil

2400

Braking oil

Add

Whenever necessary

Pin, tilting cylinder

Add lubricating grease

400

King pin, knuckle

Replace grease

1000

Hydraulic tank and filter

Clean

1000

Hydraulic oil

Replace

1000

Lift chain

Replace

3000

If damaged,

replace it.

H. P. hose

Replace

3000

Switch, hydraulic motor

Clean photoelectric coupler

200

Brush, traction motor

Check

1000

Brush, hydraulic motor

Check

1000

Brush, steering motor

Check

1000

Notice:

When serving and checking the truck, do not use the mast or the load backrest instead of a ladder, these actions will lead to a dangerous condition unexpectedly.9. Periodic servicing

3. Recommended oil

Name

Brand or code

Quantity

Domestic

Overseas

Diesel

Refer to diesel engine manual

select GB252-81 light

diesel:

Winter―10～―35#

Summer0#

JISK2204/2#

(general region)

JISK2204/3# (cold region)

140L

Lubricant oil

Select refer to engine manual

or working condition

diesel:GB5323-85

SAE10W (Winter)

SAE30 (Summer)

Hydraulic oil

N32# or N46#

ISOVG30

90L

Torque

converter oil

6# Torque converter oil

SAE10W

20L

Gear oil

85W/90

SAE85W/90

18L

Brake fluid

DOT3 Compound brake fluid

1.5L

Lubricant

grease

3# Lithium base grease

(drop point 170)

JISK2220/2#

Coolant

Water or―35℃ Long Life Coolant (FD-2)

Filled

Adding oil, grease and coolant should follow relevant automobile standard. The waster of the forklift truck must be reclaimed obeying the relevant laws and regulations. Incorrect treatment will pollute water, soil and atmosphere etc.

Wear a helmet, safety shoes and working clothes to avoid contacting with body when adding oil, grease and coolant.

4. Lubrication system

NO.

Position

Grease

point

Type

Time(hours)

100

500

1000

Support of steering

Lime grease

The two end joints of steering cylinder

Lime grease

Bearing of knuckle

Lime grease

+ 4

Bracket of foot control

Lime grease

+ 5

Pin of tilt cylinder

Lime grease

+ 6

Lever head of tilt cylinder

Lime grease

Support bushing of mast

Lime grease

Lift roller of fork bracket

Lime grease

Note: About lubrication of the engine, refer to the ENGINE OPERATION MANUAL.

Lubrication diagram

5. Routine check before daily operation

(1) Check the storage of fuel.

(2) Check if any leak or damage found on the oil pipe, water hose, vent-pipe and hydraulic parts.

(3) Check whether the hydraulic hose storage attain to the regular capacity, the oil level should be at the middle position between the upper and lower scale marks of oil level meter.

(4) Check if fix or loose found on the wheel bolt and transmission bolt.

(5) Check tires air pressure.

(6) Check steering and transmission for flexibility and reliability.

(7) Check the traveling brakes: The free travel of brake pedal is 40mm, the clearance between the front floor and the pedal should be bigger than 20mm.

(8) Check the parking brake: The unload truck can park on the 20% grade ramp, when the parking level is pulled to the bottom.

(9) Check the electric system to see whether connect, the connector whether loose, the lights, meter whether work normally.

6. Precautions of cooling system

(1) Use extreme care when removing the radiator pressure cap. In pressure system, the sudden release of pressure can cause a steam flash which would cause a serious personal injury. Loosen cap slowly to allow steam to escape. After that, tighten cap securely.

(2) Check the radiator coolant reservoir fluid level. It should between FULL and LOW mark. Add the same type coolant to specified level if necessary. The coolant can be used all the year round.

(3) Put the coolant on a safe place and mark “Dangerous Matter” for its poisonous. If swallowed by accident, take the emergency first aid and consult a physician immediately.

(4) According to variety working condition, periodic wiping away the dirt adhering to the surface of the radiator is necessary.

7. Notes during brake-in

Operating the machine under the light load, low speed condition for the first stage of operation of 100 hours. Avoid suddenly speeding and brake. Renew the oil in engine oil pan, transmission, driving axle and hydraulic oil tank after 200 operation hours.

Ⅳ. Construction, principle, adjustment and maintenance of forklift truck

In order to keep good condition of your truck, you must have an intimate understanding of the construction, principle, adjustment and maintenance of the forklift truck. When find damage or a fault at the truck, stop operating the truck and inform a

professional serviceman. Use genuine parts of our company for replacement.

1. Power system

1.1 General description

Power system consists of the engine, fuel system, cooling system and exhaust system. The engine is connected with the frame by rubber cushion to avoid vibration (Fig.1.1).

For the construction and adjustment of engine, please refer to the operation and maintenance manual of engine.

Fig. 1.1 Installation of engine

1.2 Engine disposition

The engine used for 8-10t forklift truck includes the import engine 6BG1 (ISUZU), the home engine 6102BG6 (Zhaoyang).

Engine model

6102BG6A

A-6BG1QC

QSB4.5

Place of production

Zhaocai

Japan(ISUZU)

Cummins,Inc.

Rated output / Speed kw/rpm

80.9/2500

82.3/2000

82/2200

Rated torque / Speed N.m/rpm

353/1600

416/1400-1600

488/1500

Cylinder number

6 6 4

Bore×Stroke mm

102×118

105×125

102×137

Total displacement L

5.785

6.494

4.5

Appropriate truck model

CPCD80-CY

CPCD100-CY

CPCD80

CPCD100

CPCD80-CU1

CPCD100-CU1

Parallel table for engine and forklift model which is coincidence and stuck with CE label:

Engine model

The guaranteed

sound power level

LwA(dB)

2000/14/EC

Exhausting

2004/26/EC

CONFORMITY

2006/42/EC

Truck model

Diesel

engine

Cummins,Inc.

QSB4.5

111

StageⅢA

yes

CPCD80-CU1

CPCD100-CU1

Note: The sound power level L

according to 2000/14/EC standard, the

exhausting according to 2004/26/EC standard.

Here we give a brief description of the construction, parameter and disposition about model 6BG1 imported engine. For the construction and specifications of other engines, see their respective operation instruction. Refer to Fig 1.2 and attached list about the construction and specifications of 6BG1.

Fig.1.2 A-6BG1QC diesel engine

Main performance and disposition of A-6BG1QC

Model

A-6BG1QC

Type

4-cycle,water-cooled,overhead valve

No. of cylinder—bore×stroke

6-105mm×125mm

Total displacement (L)

6.494

Compression ratio

Performance

Rated speed

rpm

2000

Rated output

82.3

Max. torque (N.m/rpm)

416/1400-1600

Full-load fuel consumption

g/kwh

233

No-load Min. speed

rpm

700

Weight

450

Dimension

1129.5×672.0×860.0

Injection start pressure

kg/cm2

Compress pressure

kg/cm2

1.3 Inspection and adjustment of engine

In order to keep good condition of your truck, you must carry out periodic inspection and adjustment of power system.

(1) Regularly clear the dust of air cleaner.

(2) Regularly replace oil filter and fuel filter.

(3) Check and apply the coolant periodically.

(4) Periodic inspection of throttle valve and injection pump.

(5) Check fan belt for tension and all fasteners.

Note:

Always check the exhaust gas of the engine during using the forklift truck. Especially

after maintaining the engine, it’s necessary to verify the discharge indicator ensure that

discharge value is fit for the national standard, so as to minimum damage to the person and environment.

1.4 Fuel system

The fuel system composed with the fuel tank, filter, fuel sensor.

1.4.1 Fuel tank

The fuel tank is a welded construction integrated with the truck frame. It is located on the left side of the truck frame. The tank cover with a fuel sensor is located on the top surface of the tank. Once every 600 hours operation, it is required to clean the fuel tank.

Fig.1.3 Fuel tank

1.4.2 Fuel sensor

The function of the fuel sensor is to change the oil in the oil tank to the electric through the bobber up and down sport, in the end transfer to the fuel chart in the dashboard, let others to know the oil quantity directly. See Fig.1.4.

(a) Once every 600 hours operation, it is required to replace the filter assembly.

(b) Apply several drops of fuel to the around of the new filter’s seal before

installation, it should be screwed 2/3 circles again when the filter’s seal touches the

body of engine.

Note: Turn off the draining switch after draining water.

Fig.1.4 Fuel filter

1.4.3 Fuel filter

The fuel filter was installed in the engine enters hose, used to filtrate the fuel supply to the engine. There also have other through valve inside of the filter, when the filter jammed, it also can supply the oil to the engine. See Fig.1.5.

Fig.1.5 Fuel sensor

1.5 Coolant system

The coolant system composed with water pump, fan, radiator and the ancillary radiator, the water pump installed in the engine, the crank through the V-series tape to drive the water pump work.

1.6 Check and adjustment

To have a good work state, it needs to check and research on the engine termly. The main point is as following:

1.6.1 Cleaning of the air condition (Fig.1.6)

(1) Take out the filter.

(2) Check the dust and the damage of the filter, fist puff away from inside to outside to clean with low pressure air, if it’s jammed and can’t clean or has been damage, change a new one.

(3) Clean the dust in the cover.

Fig.1.6 Air condition

1.6.2 Replacement of fuel filter (Fig.1.7)

(1) Use the filter specially spanner disassemble, if damage or block, need to change.

(2) Along with the around of the new filter seal O-ring, add little lube then install, when it contact the filter, screw 2/3 circle.

Fig.1.7

1.6.3 Replacement of oil filter (Fig.1.8)

(1) Use the filter specially spanner disassemble and change.

(2) Along with the around of the new oil filter seal o-ring, add little lube then install, when it contact the filter, screw 2/3 circle.

Fig.1.8

1.6.4 Vice radiator (Fig.1.9)

(1) Check the coolant in the vice radiator

The ancillary radiator as Fig.1.8, when the antifreeze under the “LOW” scale, it means need to add coolant, add to the 2/3 scale of the up and down scale.

(2) Change the coolant

a. Stop working more than half an hour, wait it cooling, then open the radiator cover, and loose the water outlet valve under the radiator.

b. Loose the engine water outlet valve, release all the coolant.

c. After releasing, screw down those two valve which mentioned in the above.

d. Add the regular coolant, after idle work few time, check the ancillary radiator, it should be in the 2/3 scale.

Fig.1.9 Fig.1.10

1.6.5 Adjust the fan belt

If the fan belt is loose, tighten it. See Fig.1.10.

Step: loosen the fixed bolt B and C of generator, move the generator out. Press the A section of belt with the force of 10kg strength, the flexible degree is about 10mm, then tighten the bolt B,C orderly.

1.6.6 Tighten the bolt of the engine cylinder end

(1) Tighten the bolt with 68Nm twisting moment by the order of Fig 1.11. (2) Tighten the twisting moment to 93Nm, then tighten the bolt orderly.

(3) Turn the bolt 90 degree and tighten them.

Fig.1.11

1.6.7 Valve clearance adjustment

(1) Turn the crank shaft clockwise, make the "TC" mark on shock absorber of belt

coincide with the pointer.

(2) Inspect the hole cover, affirm the position of soleplate mark and pointer. If the soleplate mark coincide with hand position, show the 1st cylinder. TDC, adjust

the valve clearance with "△" mark. And adjust the valve clearance with "※"mark.

Valve clearance value: 0.4mm. (the same to absorb and exhaust, cooling state) Refer to Fig1.12, 1.13, 1.14.

Fig.1.12

Fig.1.13 Fig.1.14

The material adjustment see Table 3.2.

Cylinder NO.

1 2 3 4 5

I:inspiration valve E: exhaust valve

I E I E I E I E I E I

1st cyl. in TDC

△ △ △ △ △ △

6th cyl. in TDC

※ ※ ※ ※ ※

※

1.6.8 Fuel injection ignition time affirmation

(1) Affirm if the "assemble countermark" is in conformity with the place of injection

pump flange. See Fig1.15.

(2) Put the 1st cylinder to the TDC position, turn the crank shaft about 30°

counterclockwise, See Fig1.16.

Fig.1.15 Fig.1.16

(3) Loosen the 1st cylinder injection pipe, dismantle the spring on drain valve bracket and drain valve, then install the drain valve bracket on injection pump. See Fig1.17.

Fig.1.17

4) While charging pump transmit fuel, it turn the crank shaft clockwise , when the fuel lever of drain valve bracket up to the stop position, stop turning the crank shaft. Affirm the hand sign. See Fig 1.18.

Fig.1.18

1.6.9 Fuel injection ignition time adjustment

(1) Dismantle pipe installed on injection pump. (2) Loosen installed bolt of injection pump. (3) While affirm the ignition time according 1.5.7 gist, turn it over engine under

advance condition , turn it to engine under "delay" condition.

(4) After adjustment, tighten all the bolt of injection pump, affirm the ignition time

again.

(5) Assemble the drain valve used in the 1st cylinder, and install each bolt on each

position.

1.6.10 Measurement of compression pressure (Fig 1.19)

Fig.1.19 (1) Dismantle heat spark plug and fuel injection pipe. (2) Install manometer on the heat spark plug of 1st cylinder, the demarcate value of

the manometer is 500N/ cm2.

(3) Running the starting device by plenty battery, meter the pressure at this time. (4) Measure the other 5 cylinder by the same way, and measure 2 times, then

figure out each average value; compression pressure: 304N/cm2 (limit value 255N/cm2)

1.6.11 Exhaust of injection pump ( Fig 1.20)

(1) Loosen core vent of injection pump. (2) Operate hand pump slowly till the core vent doesn't bubbling. (3) Tighten the core vent.

Fig.1.20

1.7 Precautions of cooling system

(1) During using the forklift truck, if the temperature of the radiator or coolant is too

high, don’t open the cap of the radiator immediately. To find the reason for boiling, use

extreme care when removing the cap, the sudden release of pressure can cause a steam flash which would cause a serious personal injury. Lower the running speed of the engine to moderate speed, after the cooling system cooled then turn to idle speed, loosen cap slowly to allow steam to escape, the cap can be removed. After that, make sure the cap is tightened securely.

(2) Check the radiator coolant reservoir fluid level. It should between FULL and

LOW mark. Add the same type coolant to specified level if necessary. The coolant can be used all the year round.

(3) Put the coolant on a safe place and mark “Dangerous Matter” for its toxicity. If

swallowed by accident, take the emergency first aid and consult a physician immediately.

(4) According to variety working condition, periodic wiping away the dirt adhering to

the surface of the radiator with detergent, compressed air or high pressure water (pressure less than 4kg/cm2) is necessary.

2. Drive unit

Drive unit consists of torque converter and a hydraulic transmission. The structure

of the hydraulic transmission refers to Fig.2-1, the structure of the torque converter refers to Fig.2-2.

Main technical parameter

Item

Parameter

Torque converter

Type

3-element,1-stage,2-phase type

Torque converter ratio

12.5″(Φ315) ratio 3.1

Pressure setting

Mpa

0.5~0.7

Charging pump

Type

Inner-mesh gear type

Flow rate (l/min)

40 (2000rpm, 2Mpa)

Transmission

Type

Power-shift constant mesh

Shift NO.

Apiece 2 Fwd/Bwd

Gear ration

Ⅰ:1.621 / Ⅱ:0.526

Clutch Friction piece

O.D.Φ134 / I.D.Φ90 / T.2.8

Surface area

cm2

77.4

Pressure

Mpa

1.2~1.5

Weight (kg)

295

Oil amount (l)

Oil type

NO.6 torque converter oil/ SAE10W

2.1 General description

The power-shift transmission mounted on the forklift truck has excellent features as

follows:

(1) An inching valve provides the machine with improved inching performance. Due

to this valve, the lift truck is allowed to perform inching operation regardless of whether the engine is at low RPM or at high RPM, and when the truck is started up.

(2) As clutch plates, seven steel plates and the same number of composite plates

subjected to special treatment are provided so that improved durability can be ensured.

(3) Both one-way overrun clutches in the torque converter are used to increase the

efficiency for power transmission.

(4) High quality of oil filters is helpful to increasing the life of the torque converter.

Fig.2.1 Torque converter transmission

Control valve

Parking brake

17.

Oil seal

Charging pump

10.

Strainer

18.

Ball bearing

11.

Oil seal

19.

Gear

Drive shaft

12.

Gear

20.

Reverse clutch pack

Ball bearing

13.

Ball bearing

21.

Forward clutch pack

Torque converter

14.

Shaft

22.

Input plate

Ball bearing

15.

Bearing cover

23.

Transmission output shaft

Gear

16.

Output shaft

2.2 Torque converter

The torque converter consists of pump wheel installed on input shaft, a turbine

wheel installed on output shaft and stator wheel fixed on torque converter body.

Pump rotor is driven by elastic plate, the elastic plate is connected with flywheel,

the pump rotor start turning while the engine is running. The liquid in pump rotor eject along blade lattice. The mechanical energy changes to kinetic energy.

So the liquid feed into vane of turbo, and transfer the moment to output shaft, the

direction that the liquid leave turbo change under the action of idler pulley, and the liquid flow into pump rotor with the best angle, it produce counterforce moment to push the idler pulley and the output shaft add a moment which is equal to the counterforce moment When the turbo rotate speed increase and near to input rotate speed, the change of liquid angle reduce, the moment of output reduce to it, finally, the liquid flow into idler pulley in the reverse direction, and then the above counterforce moment act backward. Under the circumstance, the torque from output shaft is less than the input shaft's. To prevent the phenomenal, there is a unilateralism clutch installed in idler pulley, when the counterforce moment act backward, the idler pulley running freely, under the circumstance, the input torque is equal to output torque, and ensure work efficiently.

The torque converter changes the transfer of moment by mechanic method, and

has coupling mechanism and torque converter function, so it' is two phase, operate swiftly and raise efficiency.

There are unilateralism clutch, turbo, pump rotor and idler pulley installed in torque

converter. The torque converter is full of oil.

On pump wheel end, there is a gear engaged with the drive gear of charging pump

to drive changing pump.

The turbine wheel is connected with input shaft by spine, transfer power to

hydraulic clutch. The structure of the torque converter refers to Fig.2-2.

Fig.2.2 Torque conv

Fig 2.2 Torque converter

2.3 Charging pump

Fig 2.3 shows the structure of charging pump. The charging pump consists of drive gear, driven gear, case and cover. They are

fixed on the head of torque converter housing. The drive gear is driven by pump wheel, driven gear and drive gear, the charging pump feeds oil in the under part of transmission to each part of it.

Fig.2.3 Charging pump

2.4 Hydraulic clutch

Fwd clutch see Fig 2.4, reverse clutch see Fig.2.5. There is a hydraulic clutch fixed on transmission, the drive gear on the side of clutch is engaged with the corresponding driven gear, the drive gear on the side of reverse clutch is engaged with the opposite gear. The clutch is consists of 6 clutch disks and 7 steel plates. They are installed alternately and assembled with piston. The piston is provided with sliding type oil seal on its inner and outer circumferences to insure oil sealing during operation. When out the action, the dish-shaped return spring comes away the hydraulic clutch, the surface of clutch is lubricated by the oil from oil condenser, to prevent conglutination and abrasion on clutch surface. When pressure oil acts to piston, the clutch and steel plate which fitted together are pressed, so the clutch transfer the power to drive gear from torque converter. The transfer flow of power from torque to transmission is as follows:

Turbine wheel-input shaft-clutch drum-steel plate-clutch disk-forward or reverse

gear-output shaft.

2.5 Control valve and inching valve

The control valve see Fig.2.6. The control valve is installed on the top of transmission housing, reverse valve and

inching valve are installed in it.

Hydraulic clutch relief valve adjusts the oil pressure of clutch in transmission, the

torque converter relief valve adjusts the pressure of oil feed into torque converter.

The inching valve pole is connected with inching pedal, when press inching pedal,

the inching pedal press in , the oil pressure of clutch depress for a while, the clutch loosen.

Fig.2.4 Forward shift clutch

Fig.2.5 Reverse shift clutch

Fig.2.6 Control valve

2.6 Hydraulic circulation system (see Fig. 2.7)

When the engine is started and the charging pump is put into operation, the torque

converter fluid in the oil tank (transmission case) is forcibly sent to the control valve from the pump through the strainer.

The fluid sent from the charging pump is divided to two directions in the torque

converter case, one for torque converter and the other for transmission.

Pressure of the fluid for clutch is adjusted to 1.2 to 1.5 MPa with the relief valve.

And then it is supplied to the control valve. Pressure of the fluid divided for the converter is adjusted to 0.5 to 0.7 MPa with the converter relief valve. After that this fluid reaches the wheel of torque converter. After it is cooled by the oil cooler, it lubricates the clutch group and then returns to the oil tank through the filter.

When the selector valve is in neutral position, the circuit from the selector valve to the clutch is closed. Therefore the fluid is joined with the torque converter filling fluid. When the selector spool is set to the forward or reverse position, fluid flows into the accumulator due to action of modulate valve, so that pressure rises gradually. During this time the clutch starts to engage. When the accumulator is filled with fluid, hydraulic pressure rises intensively so that the hydraulic clutch is completely engage. While the forward or reverse clutch is operating, another clutch is rotating between the sintered plates and the steel plates. Therefore this part is lubricated with oil sent from the oil cooler to prevent seizure of plates. When the brake pedal is depressed and the inching valve is actuated, most of hydraulic oil supplied to the clutch is drained from the inching valve and returns to the transmission case. The fluid for the torque converter circulates in the same manner as in neutral state.

Fig. 2.7 Hydraulic circulation system

2.7 Principle

The torque converter consists primarily of a pump wheel connected to the input

shaft, a turbine wheel connected to the output shaft, and a stator wheel fixed to the housing.

The transmission consists of charging pump, hydraulic clutch, the forward gear and

reverse gear.

Power transmission route from the torque converter to the transmission is as follows: Turbine wheel — main shaft — clutch drum — steel plate — clutch plate—forward or reverse gear—output shaft.

2.8 Caution when the trouble occurs When the truck cannot run by itself due to trouble and it must be dragged with

another machine, be sure to observe the following requirements.

(1) Remove the propeller shaft between the transmission and the differential.

(2) Set the shift lever in neutral position. When the charging pump does not operate, normal lubrication is not performed.

Therefore, if rotation is transmitted from the front wheel to the transmission gear and clutch disk, seizure may occur.

2.9 Trouble shooting (1) Insufficient power

Parts

Problem

Possible cause and remedy

Torque

converter

A. Too low oil pressure

1. Lower oil level

Check oil level and add oil.

2. Air entering in resulting from loose connectors.

Check connectors or oil pipes. Retighten each connectors or replace seals.

3. Blocked oil filter

Check, clean or replace

4. Oil can not be pumped out.

Check and replace.

5. Deformed spring of relief valve.

Check tension of spring

6. Seal ring or O-ring seal damaged

Check and replace. B. Fly wheel damaged

Check oil, if have dirt, replace it.

Gear

box

A .Unsuitable oil or air bubble

Check oil

1. Air entering in resulting

from loose connections.

Check connectors or oil pipes. Retighten each connector or replace seals.

2. Too lower oil pressure or air bubble in oil

Measure and adjust pressure. B. Slipped clutch

1. Oil pressure lower

Measure and adjust pressure.

2. Seal ring damaged

Check and replace

3. Piston ring of the clutch

damaged

Check and replace

4. Worn friction piece or

deformed steel piece

Replace

C. Incorrect position between

inching rod and shift rod.

Check and adjust.

Engine

Insufficient engine power

Adjust or repair engine

(2) Too higher oil temperature

Parts

Problem

Possible cause and remedy

Torque

converter

1. Lower oil level

Check oil level and add oil.

2. Blocked oil filter

Check, clean or replace.

3. Fly wheel bump against other

parts.

Check oil, if have dirt, replace it.

4. Air entering in resulting

from loose connectors.

Check connectors or oil pipes. Retighten each connector or replace seals.

5. Water mixed into oil

Check and replace oil.

6. Low oil flow

Check pipes and replace.

7. Worn bearing

Check and replace.

Gear

box

1. Slipped clutch

Replace friction piece of clutch.

2. Worn bearing

Check and replace.

(3) Noisy gear box

Parts

Problem

Possible cause and remedy

Torque

converter

1. Elasticity plate is broken.

Check noise and replace elasticity plate.

2. Damaged or worn bearing.

Check or replace

3. Gear is broken.

Check or replace

4. Spline is worn

Check or replace

5. Noisy main pump

Check or replace

6. Loosen bolt

Check, tighten or replace

Gear

box

1. Bearing is worn

Check or replace

2. Gear is broken

Check or replace

3. Spline is worn

Check or replace

4. Loosen bolt

Check, tighten or replace

(4) Too lower transmission efficiency

Parts

Problem

Possible cause and remedy

Torque

converter

1. Elasticity plate is broken.

Check turn noise and replace.

2. Lower oil amount.

Check oil level and add oil.

3. Driving system of oil pump is ineffective.

Check and replace.

4. Shaft is broken.

Check and replace.

5. Too lower oil pressure.

Check oil pump for suction pipe.

Gear box

1. Lower oil amount.

Check oil level and add oil.

2. Seal ring is worn.

Check and replace.

3. Slipped clutch.

Check oil pressure of the clutch.

4. Shaft is broken.

Check and replace.

5. Clutch cap is broken.

Check and replace.

6. Retainer ring of clutch cap

is broken.

Check and replace.

7. Foreign matters mixed in oil tank of clutch.

Check, clean or replace.

8. Spline of shaft is worn.

Check and replace.

(5) Oil leakage

Parts

Problem

Possible cause and remedy

Torque

Converter

or Gear

Box

1. Worn seal ring

Check and replace seal ring.

2. Incorrect connection of case.

Check, tighten or replace.

3. Loose connector and oil pipe.

Check, tighten or replace.

4. Loose drain plug.

Check, tighten or replace.

5. Oil spray from air hole.

Check connectors, air holes or replace pipes.

6. Much oil.

Check oil level and drain surplus oil.

3. Front axle

The main specifications of the front axle:

Type

Full-floating type, integral shaped

Main reduction gear Type

Spiral bevel pinion type

Reduction ratio

6.33

Final reduction gear Type

Planetary gear type

Reduction ratio

3.58

Total reduction ratio

22.66

Amount of oil Main reduction gear

10 L

Final reduction gear

8 L (left and right)

Driving wheel Tire

9.00-20-14PR

Rim

7.00-20

Air pressure

760

3.1 General description

The front axle consists of the main reduction gear, the differential, the final reduction gear and brakes. (see Fig. 3.1) The front axle is bolted to the front side of the frame. The mast is installed on the axle housing.

3.2 Main reduction gear & differential

The main reduction gear & differential consists primarily of a cross case, ring gear (spiral bevel pinion) and drive pinions, which are all assembled on the main reduction gear carrier as shown in Fig. 3.2, and is fitted to the axle housing through packing.

3.3 Final reduction gear

The final reduction gear is of the planet gear type consisting of a sun gear, planetary gears and an internal gear. Two final reduction gears are installed on each end of the axle housing. The sun gear is splined to the axle shaft and locked with snap ring. The planetary gears are installed onto the shafts in the planet carrier which is fixed to the wheel hub. The internal gear is splined to the axle spindle through hub.

The principle of power transmission is as follows (see Fig. 3.3).

When the sun gear turns, the rotation is transmitted to the pinion gears and ring gear. However, since the ring gear is fixed to the spindle, the pinion gears revolve around the sun gear while spinning themselves. The pinion gears are installed to the carrier which is fixed to the wheel hub, therefore, power of the drive shaft causes the wheel to turn.

Fig.3.1 Front axle

Breaking dial

Lock nut(in)

15.

Roller bearing

Wheel assembly

Prevent-loosen gasket

16.

Steel ball

Tyre

10.

Lock nut(out)

17.

Pinion gear shaft

Oil seal

11.

Inner-gear seat

18.

Thrust washer

Taper roller bearing

12.

Braking plate and shell assembly

19.

Half-bearing cover

Wheel assembly

13.

Inner gear ring

20.

Pinion gear bracket

Taper roller bearing

14.

Pinion gear

21.

Clamp brake

Fig. 3.2 Reducer & differential

Adjust nut

11.

Flange half

21.

O-ring

Cap

12.

Side gear

22.

Spacer

Lock plate

13.

Thrust washer

23.

Shim

Taper roller bearing

14.

Roller bearing

24.

Taper roller bearing

Plain half

15.

Carrier

25.

Seal retainer

Side gear

16.

Lock nut

26.

Oil seal

Pinion gear

17.

Adjust bolt

27.

Flange

Spiral bevel pinion

18.

Drive pinion

28.

O-ring

Spider

19.

Taper roller bearing

29.

Washer

10.

Thrust washer

20.

Bearing cage

30.

Lock nut

Fig. 3.3 Final reduction gear

3.4 Troubleshooting

Trouble

Cause

Correction

Oil leaks from

differential carrier.

Loose bolt or broken gasket of differential carrier.

Retighten or replace.

Breather is clogged.

Clean or replace.

Oil seal is worn or damaged.

Replace.

Noisy differential

Gear is worn, damaged or broken.

Replace.

Bearing is worn, damaged or broken.

Replace.

Improper backlash.

Adjust

Loose spline fitness of side gear to propeller shaft.

Replace parts.

Insufficient gear oil.

Add as necessary.

3.5 Service data

Parts

Item

Standard value

(mm)

Differential

Tightening torque of ring gear set bolt

140-160(N.m)

Tightening torque of cross case set bolt

140-160(N.m)

Thickness of pinion washers

1.562-1.613

Axle housing

Tightening torque of the set bolt for axle housing and differential carrier.

150-175(N.m)

Tightening torque set bolt securing axle housing to frame.

630-946(N.m)

Tightening torque set bolt brake board to axle housing.

280-330(N.m)

Hub

I.D. of hub oil seal fitting part

164.6-165

Tightening torque of set bolt securing brake drum to hub.

280-330(N.m)

Tightening torque of set bolt securing planet carrier to hub.

98-113(N.m)

Tightening torque of hub nut.

480-560(N.m)

4. Brake system

4.1 General description

The brake system consists of two wheel brakes installed on the front axle and parking brake on the propeller shaft.

4.2 Power brake (see Fig.4.1)

The wheel brake system consists of brake pedal, brake valve, power accumulator and brake. The power brake works by making use of pressure oil provided by gear pump of hydraulic system, the pressure oil is divided to two directions, one for the brake valve, and the other for the energy reservoir. They are controlled by the stroke of the brake pedal.

4.2.1 Position of brake pedal (Fig. 4.2)

The brake pedal and the inching pedal are mounted on the left side of the frame by a bracket. The piston of the brake valve is actuated through the push rod by the operation of the brake pedal. The inching pedal also can control the brake valve by linkage with the brake pedal, in the meantime, can control the inching valve in the transmission.

Fig. 4.1 Brake system

Fig. 4.2 Position of brake pedal

4.2.2 Brake valve (Fig. 4.3)

(1) Non-brake state Since the brake valve A port is open, the nozzle of the pump and powered steering is interlinked, the operation of steering is normal in the state of non-brake. When the brake pedal isn’t been pressed, the oil pressure in the chamber D won’t go up in that the port B is close. (2) Brake state A. When pressing the brake pedal, the piston 10 shifts to the left, valve sleeve 7 and recoil piston 5 are pressed to the left by the spring group 8, in the meantime, the return spring 6 is compressed to the left. B. A port is closed owing to the shift of the part 7, and chamber D disconnects with the port of the return oil tank, and the chamber D connects with the port of pump in that the port B is closed. C. Now the valve sleeve 7 shifts to the left, the oil pressure of the pump port and the chamber D rises in that the C is compressed, in the meantime, the recoil piston 5 is pushed by higher oil pressure in the chamber D . D. When the max. pedal force acts on the right end of the piston, the bolt and the pedal bracket can limit the position in order to make the oil pressure in the chamber D lower the max. adjusting oil pressure. E. When your foot releases the pedal, the valve sleeve 7 returning to the original position relies on the opposite force, the process of the brake ends.

(3) Reservoir working performance When the oil pump stops working (engine flameout) or damage, the reservoir is on

working performance.

A. Press the brake pedal, valve sleeve 7, backswing piston 5, check valve pin 3 will be shifted left, the pin tips the ball over, at the same time, chamber D is connected with reservoir connector, acts on the brake cylinder with reservoir pressure. B. Leaves the pedal, valve sleeve, backswing piston and pin moves left, the ball of check valve is connected with valve seat (check valve closed) acting by spring force, the pin stops in the corresponding position.

C. Backswing moves right, chamber C opens, the oil of brake cylinder goes back to the oil tank through chamber D.

4.2.3 Energy reservoir (Fig.4.4)

The energy reservoir can supply energy when the engine stops working or the oil pump is in trouble. The type of the energy storage is spring type. The buzzer of the warning switch sounds continuously when the reservoir doesn’t storage energy. When pressing the brake pedal, the oil pressure exceeds 3.9MPa, the check valve

opens and oil flows to the energy reservoir. Now the piston shifts to the left, the warning switch doesn’t ring. The reservoir storages the maximum energy along with the oil pressure rises constantly, the oil pressure is 13 MPa, this value is controlled by the safety valve. The energy reservoir storages the pressure energy, there are safety valve and pressure alarm switch inside it. Preventive maintenance should be done by authorized serviceman. Failure to use will cause crack. Depressurization treatment should be done when the truck parking or preventive maintenance. The method to decrease the pressure: After the engine is flameout, press the brake pedal for 5 to 8 times, then the pressure of reservoir in brake system can be decreased.

Fig. 4.3 Brake valve

Plug

Recoil piston

Oil seal

One-way valve base

Return spring

Piston assy

One-way valve pin

Valve sleeve

Piston guide base

Spring group

Fig. 4.4 Energy reservoir

4.3 Parking brake The parking brake is of internal expansion and lining type, and built in the output shaft of the torque converter transmission. The operation of the parking brake is shown in Fig.4.5. When the forklift truck parks on a slope with standard capacity, the hand operation force should below 300N. Adjust the pull force by diagrammatic direction.

4.4 Wheel brake (Fig. 4.6)

Wheel brake is clamp brake, installing symmetry around. Clamp brake consists of clamp body, operating cylinder (four by one couple), rub pieces (two by one couple), brake plate. The structure is seen in the picture. The wheel brake is consisting of a pair of brake shoes, operating cylinder, a adjuster, 3-4 return springs and backing plates. Two wheel brakes are provided on each end of the front axle. The adjuster adjusts the clearance between the brake shoes and the inner surface of brake drum.

Fig. 4.5 Parking brake device

Fig.4.6 clamp brake

clamp body

dustproof cover

deflate spile

rectangle ring seal

O-ring seal

deflate seat

rub piece assy

bolt

nut

below crock cover

above crock cover

bolt

pump plunger

pin shaft

4.5 Troubleshooting

Problem

Possible cause

Remedy

Poor

braking

force

Fluid leakage from brake system

Repair

Maladjustment of brake shoe clearance

Adjust

Brake overheating

Check for dragging

Poor contact between brake drum and friction piece

Adjust Foreign matter adhered on friction piece

Repair or replace

Foreign matter mixed in brake fluid

Replace

Maladjustment of brake pedal

Adjust

Noisy brake

Hardened friction piece surface or foreign matter adhered thereto

Repair or replace Deformed backing plate or loose bolts

Repair or replace

Deformed shoe or incorrect installation

Repair or replace

Worn friction piece

Replace

Loose wheel bearing

Replace

Uneven

braking

Oil-contaminated friction piece

Repair or replace

Malfunction operating cylinder

Repair or replace

Eccentric brake drum

Repair or replace

Maladjustment clearance of friction piece

Adjust

Improper tire pressure

Adjust

Soft or

spongy

brake

Brake fluid leaks from system

Repair

Maladjustment clearance of friction piece

Adjust and repair

Air mixed in brake system

Exhaust air

Maladjustment of brake pedal

Readjust

5. Steering system

5.1 General description

Steering system contains mainly a steering hand wheel, a steering column, a cardan joint, a powered steering unit, a steering axle and a steering cylinder.

The steering shaft is connected with the steering unit and steering hand wheel by the joint. The steering column may be tilted properly forward or backward. Turn the hand wheel clockwise, the forklift truck will turn to the right, on the contrary, the truck will turn to the left. Main parameter and structure of the steering system sees below:

Item

Parameter & structure

Type

Rear wheel steering powered

Diameter of steering hand wheel

360

Steering unit

Type

BZZ powered steering unit

Displacement

min

280

Rated pressure

MPa

Steering cylinder

Type

Double-action type

Cylinder dia. / Rod dia.

Φ115/Φ85

Stroke

2×216

Divider Setting pressure

MPa

12.5

Rated displacement

Steering axle Type

Transverse cylinder type

Steering angle(outside/inside)

76°/54°

Rear tread

1700

Interval of knuckle spindle

1500

Diameter of cardan joint

Φ42

Wheel Tire

9.00-20-14PR

Rim

7.00-20

Pressure

KPa

760

5.2 Hand wheel

Hand wheel is operated in normal way, that is to say, when turning the hand wheel right, the truck will turn right. When turning the hand wheel left, the truck will turn left. The rear wheels of the forklift truck are steering wheels, which make the tail section of the truck swing out when turning. The turning method can be mastered easily through practice.

5.3 Cycloid gear type powered steering unit

The steering unit can transmit the pressure oil from the flow divider by pipes to the steering cylinder in terms of the rotating angle of the hand wheel. When the engine stop running, the charging pump will not work, in this case a man-powered steering should be adopted. The sketch map of powered steering system is shown as Fig.5.1. The structure of the steering unit is shown as Fig.5.2.

Fig. 5.1 Hydraulic steering system

Hand wheel and steer shaft

Steering cylinder

Oil pump

Steering axle

Flow control valve

Hose

Hydraulic steering unit

5.3.1 Steering unit assy

Fig.5.2 Cycloid gear type powered steering unit

Spacing sleeve

Joint sleeve

Valve body

Rotor

Valve core

Stator

Interlock shaft

Valve sleeve

Spring piece

5.3.2 Work principle

Valve bore, valve sleeve, valve body in the redirector makes up of along valve, having an effect of controlling the direction of the oil flow. Rotor and stator makes up of cycloid mesh, having an effect of measure element when turning, to make sure that the oil quantity in oil crock and corner of steering wheel makes direct ratio; having an effect of hand moving oil pump when turning by manpower; and linkage shaft having an effect of transferring wrest rules. Middle position (steering wheel isn’t running), in the opening ring system, the oil from oil pump passes through the lumen of valve bore to oil box.(Fig.5.2 a)

When turning by power, oil from oil pump pass through the along valve to cycloid pin wheel mesh, force rotor running following steering wheel, and press the ration oil to the left or the right of crock, force turning wheel to turn by power, and oil in the other cylinder flows back to oil box.(Fig.5.2 b, c)

When engine comes out flameout, the steering wheel will be operated by manpower, with valve bore, melt, interlock shaft, driving rotor to press oil in one cylinder to the other one, then force turning wheel, to carry out turning by manpower (Fig.5.2 d). Filling oil by oil box when passing through filling unilateralism valve.

Fig5.3 Oil circuit of steering unit

5.3.3 Usage of the steering unit

(1) Install the steering unit When installing the steering unit, it must ensure concentric with the connecting shaft, axial clearance can avoid propping by valve core, checking the hand wheel if it can return to the neutral position flexibly after installing. The allowable flow rate of the inlet oil pipe is 1-1.5m/s, the allowable flow rate of the outlet oil pipe is 4-5m/s. The experimental pressure of the high pressure tube must high than 1.5 times as much as the maximum working pressure. For the safety and convenient repair, it is suggested that a connector should be installed at the inlet port of the steering unit for a pressure gauge.

(2) Oil temperature range:-20℃~+80℃

Normal oil temperature:+30℃~+60℃

(3) Choose oil: N46 or N32 hydraulic oil

(4) Filter oil: The accuracy of oil inputted into the steering unit is 30 micron.

0.2-0.3MPa Back pressure of outlet oil of the steering unit can prevent the oil from flowing into the oil for the manpower turning.

(5) Cleaning pipes of the system and closed oil tank can reduce the oil pollution.

(6) Trial run: Clean the oil tank and add oil to the top level before trial run. Loose the bolt connector of the steering cylinder and bleed air at the low speed of the oil pump.

Disassemble the piston rod and steering wheel, turn the hand wheel, make the

piston at the limit left or right position, then add oil into the oil tank to the top level.

Tighten all bolt connectors and connect the piston rod, check the steering system for the good condition. If the hand wheel can’t be operated flexibly, it’s necessary to find possible cause and remedy it.

Check the system pressure when the piston of the steering cylinder reaches the limit position.

(7) Maintenance: Check the condition of the leakage, oil level of the oil tank

everyday. Regularly replace the oil filter and oil. During operation abnormal condition is

found, it’s necessary to find possible cause and remedy it. Don’t turn the hand wheel by

two men at the same time.

5.3.4 Check and maintenance of the steering unit

In order to keep the steering system in good working condition and avoid accidents, it is necessary to check the steering system regularly. The structure of steering unit is referred to Fig5.4. (1) Regularly check water, foreign matter and acid number of the working oil, if necessary, replace it with new oil. (2) When checking the steering system, don’t disassembly the steering unit readily, if the steering unit is in trouble, please ask professional service men to repair it. (3) Dismounting tool used and repair site must be clean. It would be the best adopting indoor operations. (4) Notes of assembling

a. Wash all parties clearly with gasoline or kerosene before assembling, for there is

paint on the connection surface, it must be washed with acetone. You can’t wash the

parties with cotton yarn or cloth, but with brush, even clear away with compress air if

possible. Shouldn’t immerse the rubber in the gasoline for a long time. After assembling

the steering, join 50-100ml pressure oil in the orifice, turn the valve bore to right and left, then install and practice the truck if they are not abnormal.

b. Valve body, block plate, stator, rotor and the connection surface of the back

cover must be kept clean, and they can’t be hurt.

c. Notice that the whorl cover most be lower than the surface of the valve body. d. Block ring and slip ring have an inverse surface, the surface of block ring should

face the front cover, while the slip ring faces the valve bore.

e. There is mark on the surface of the rotor and interlock shaft, the mark must be

face to face when assembling.

f. The gasket of the bolt (with pin) must be cuprum or aluminum. g. The method of riveting the seven bolt in the back cover: screw one by two in

order, not in turn but gradually, with the power of 30-40N.m.

h. When assembling the oil pipe, notice the mark “in”, “back”, “left”, “right” on the

valve body, they must be connected with the right oil pipe.

(5) Disassembly and assembly

a. Order of disassembly: front cover-block ring-slip ring-valve sleeve- (shim- shift arm-valve core-spring piece)-back cover-spacing sleeve- stator-rotor- interlock shaft-block plate-pin cover-steel ball-valve body.

b. Order of assembly

valve core-spring piece-valve sleeve-shift arm-shim-valve body-slip ring-block ringfront cover-steel ball-screw cover-block plate-interlock shaft -rotor-stator

-spacing sleeve-back cover.

Fig5.4 Structure of steering unit

5.3.5 Inspection on reassembly of steering system

(1) Check the arrangement of the hydraulic pipeline and the turning direction for correctness.

(2) Check the force necessary to turn the steering handwheel to right and left until it

can’t be turned any more to see if they are identical each other and check the operation

if the steering handwheel for smoothness during above operation.

(3) After assembling a steering system, put up the turning wheel, make the engine to run at a slack speed, then turn the steering wheel slowly, and do it times and times, to exhaust the air in the hydraulic pipeline and cylinder. Check whether voice for it to turns is normal or not. If abnormal voice can’t be heard, it says that the air has been exhausted absolutely. Then make the engine run at a slack speed, to go up the oil temperature.

(4) Measure the operation of steering

Place the truck on the dry and flat road. Attach the spring equilibrator to the verge

of the steering wheel with the parking detent, to measure the operation of steering, which must be under 150N.

(5) Measure the pressure with pressure meter (15-20MPa), cutoff valve and soft tube in Fig. 5.4.

Remove the split-flow valve to the line of the turning implement, engage a line with pressure meter on the side of diffluent valve, engage a line with breaking valve on the side of turning implement, then make the engine run at a slack speed.

When the steering wheel is at a free state, the oil pressure is about 0.5-2MPa. If the pressure is higher than it, check whether the diffluent valve and line is stopped or not. If there is no abnormal thing, speed up the engine to about 1500r/min. Then close the parking valve slowly and notice that the temperature of pressure is improved.

Move the highest pressure of the diffluent valve to 12MPa, so, when the parking valve is closed, the pressure meter will show its pressure. If the pressure is over 12MPa, it shows that the diffluent valve has malfunction. But if the pressure is too low, it shows that the oil pump has malfunction or the spring of the diffluent valve has rupture. In this circumstance, the time of the closed of the parking valve can’t be over 15 seconds.

Notice: The oil pump provides pressure oil to make the cylinder run, so its task must be thought in two ways, demarcate pressure and rating flux.

The pressure is to force the cylinder while the flux is relation to the speed of the cylinder. It says that, even though the pressure is normal, to 12MPa, if the flux is lack,

the cylinder can’t run normally, resulting in that the steering is too heavy to operate. So

when the diffluent valve needs to be disassembled and be assembled again, adjust the flux valve and safety valve properly according to the capacity and the operation of the cylinder, then mark in the proper position to assemble again or measure the distance of the bolt.

Fig5.5 Measure the pressure

5.3.6 Steering unit troubleshooting

Problem

Possible cause

Remedy

Oil

leakage

Oil leaks from the connection surface of valve body, stator and rear cap due to the dirty.

Clean. The rubber ring is worn.

Replace rubber ring.

The washer of limit bolt is uneven.

Grind or replace washer.

Hard

steering

operation

Oil pump can’t supply insufficient fuel.

Select appropriate oil pump or check the divider.

Air mixed in steering system.

Vent air and check oil pipes.

Oil tank isn’t full.

Add oil to specified level.

Oil is too sticky.

Use recommended viscosity oil.

The ball check valve inside the valve body malfunctioning.

If the ball is lost, fit a Φ8 ball. If the ball is blocked by the dirty, clean it.

Oil pressure of the divider is lower than the working pressure or the divider is blocked by the dirty.

Adjust the pressure of the divider or clean it.

Steering

malfunction

Spring piece is broken off. The hand

wheel can’t return to neutral position

automatically.

Replace the spring piece. Shift arm is broken off or deformed.

Replace the shift arm.

Drive shaft is broken off or deformed

Replace the drive shaft.

Mutual position between the rotor and the drive shaft is disorder.

Reassemble the rotor and the drive shaft.

Bilateral overload valve is out of order. (the steel ball is seized up by the dirty )

Clean the valve.

Handwheel

can’t return

to neutral

position.

1. Valve core and the column is decentraction.

2. Valve core is propped by the column.

3. Hard to steer the column.

4. Broken spring piece

Readjust or replace.

No hand

steering

device

Radial and axial clearance between the rotor and stator is improper.

Replace rotor and stator.

5.4 Steering system troubleshooting

5.4.1 Inspection after reassembling the steering system

(1) Check the force when turning the steering handwheel to right and left until it

can’t be turned any more to see if they are identical each other and check the operation

if the steering handwheel for smoothness during above operation.

(2) Check the arrangement of the hydraulic pipeline and the turning direction for correctness.

(3) Lift up the rear wheels and slowly turn the handwheel over several times to exhaust the air in the hydraulic pipelines and the cylinder.

5.4.2 The troubleshooting of the steering system for the distributor valve is the following table:

Problem

Possible cause

Remedy

Steering wheel is caught when rapidly turned.

Flow control valve spool blocked

Disassemble, repair or replace

Flow control valve spool worn

Replace as assembly

Oil pressure does not rise.

Relief valve stuck open

Replace as assembly

Oil pressure higher than relief set pressure.

Relief valve stuck closed

Replace as assembly Noisy relief valve

Relief valve vibrating.

Replace as assembly

Too high oil temperature.

Relief valve stuck closed

Replace as assembly

Hard steering operation while idling.

Relief valve stuck open

Replace as assembly

Flow control valve spool blocked

Disassemble, repair or replace

Flow control valve spool worn

Replace as assembly

Varying steering force.

Relief valve vibrating.

Replace as assembly

Flow control valve spool blocked

Disassemble, repair or replace

Flow control valve spool worn

Replace as assembly

Hard steering operation.

Relief valve stuck open

Replace as assembly

Flow control valve spool blocked

Disassemble, repair or replace

Flow control valve spool worn

Replace as assembly

5.5 Rear axle

The rear axle is primarily composed of an axle body, right and left knuckles, tie rods, wheels, hubs and steering cylinder. The steering axle is of cranks and slider mechanism. The cylinder piston rod pushes the knuckle steering through tie rod, causing wheel’s

deflection and truck’s steering. The steering axle is bolted to the rear frame by the

buffer.

(1) Rear axle body

The rear axle body is of the steel plate weld construction type and has boss holes for knuckles at both ends.

(2) Right and left knuckles

On the knuckle, a hub for installing a wheel thereon is installed by two bearings. The hub is provided with an oil seal for grease. The knuckle is installed between two bosses with bearings through which a king pin is inserted. Lubricate all bearings by a nozzle installed on the top cover, users must add lubricant in time.

(3) Steering cylinder

The steering cylinder is of double-action piston type. The seal unit consists of the supporting ring and O-ring seal. The construction of the steering cylinder is shown as Fig. 5.6.

Fig. 5.6 Steering cylinder

Dust ring

Back-up ring

Bushing

Seal ring

O-ring

10.

Piston rod

Snap ring

Back-up ring

11.

Cylinder body

O-ring

Bearing

(4) Rear wheel bearing pre-load adjustment

a. As shown in Fig5.7, fill up the chamber formed by wheel hubs, wheel hub bearing and wheel hub covers with lubricating grease. Coat the lips of the oil seals with lubricating grease.

b. Press the hub bearing into the hub and fit the hub on the knuckle shaft.

c. Fit a flat washer and tighten a castle nut with torque of 206～235N.m and loosen it and then tighten it again with torque of 9.8N.m.

d. To ensure firm installation of the hub, slightly knock at it with a wooden hammer and in the meantime, rotate the hub for 3～4 turns.

e. Tighten the castle nut and align one of its notches with a hole drilled in the steering knuckle.

f. Again slightly knock at the hub with a wooden hammer and in this time, rotate manually the hub for 3～4 turns to ensure its smooth rotation with a specified torque of

2.94～7.8N.m.

g. If the torque value necessary to rotate the hub is more than the specified one above-mentioned, screw out the castle nut for 1/6 turn and measure the torque value then.

h. When the torque value measured is up to the specified one, lock the castle nut with a cotter pin.

Fig5.7 Pre-load adjustment

6. Hydraulic system

Hydraulic

oil pump

Type

Gear pump

Displacement

32 ml/r 36 ml/r

Control

valve

Type

Two-pool type with relief valve, flow divider

and tilt self-locking valve

Setting pressure

19 MPa

Dividing pressure

12 MPa

Flow rate

25 L/min

6.1 General description

The hydraulic system mainly consists of main pump, control valve, high & low pressure oil pipes and joints. The main pump is a gear type and installed on the side of the transmission. As the engine runs, the main pump is driven to draw up oil from the tank and send it to the control valve. The control valve, provided with a relief valve to keep the circuit pressure within the specified one, controls the cylinders by changing over the oil passages inside the valve body with the spools.

6.2 Main pump

The main pump consists primarily of a drive gear, driven gear and pump body which contain the two gears and other components. The drive gear is in mesh with the driven gear.

6.3 Control valve (See Fig.6.1)

The control valve is a sectional type consisting of the inlet section, plunger section and outlet section which are assembled with three bolts.

At the inlet section there is a cartridge type relief valve to set the oil pressure in the circuit. The steering relief valve is used for adjusting the oil pressure in the steering oil circuit. Twist them clockwise, raise the oil pressure, on the contrary, reduce the oil pressure. The plunger section controls the hydraulic cylinders by changing over the flow of oil from the relief valve with plungers. The tilt cylinder plunger section is equipped with a tilt lock valve. Oil returned from the cylinders is returned to the tank through the

outlet section. Each section is sealed with O-ring, and the oil passage at the high pressure side is given a check valve.

Caution: Don’t adjust the pressure of the main relief valve at will. If the pressure is

too high, the hydraulic system and hydraulic component may be damaged. When

maintaining or using, if oil pressure isn’t the same as the standard value, on the basis of

JB/TT3300 test way, the professional serviceman should adjust the pressure according to the following procedures:

(a) Screw the plug screw off the inlet port of the control valve, install a 25MPa oil pressure gauge.

(b) Operate the tilt lever, measure the pressure when the oil pressure stroke to the end.

(c) When the oil pressure isn’t the same as the standard value, twist the adjusting nut, twist it clockwise, raise oil pressure, on the contrary, reduce oil pressure.

(d) After adjusting, tighten the nut.

Fig.6.1 Control valve

6.4 Control valve operation

(1) Middle position (See Fig.6.2)

The oil that is expelled from the main pump will pass the middle passage and be back to fuel tank. This moment, the cylinder port A & B must be off.

Fig.6.2 Middle position

(2) Push slide valve (See Fig.6.3)

At that time, the middle passage is off. The oil that is come from the oil enter will push out the one-way valve, and inflood cylinder port B. The oil that is expelled from the cylinder port A will pass the low-pressure passage and be back to fuel tank. The slide valve will replace to the middle position recur to the replacement spring.

(3) Pull slide valve (See Fig.6.4)

This moment, the middle position passage is off. The oil that is come from the oil enter port will push out the one-way valve, and inflood cylinder port A, the oil that is expelled from the cylinder port B will pass the low-pressure passage and be back to fuel tank. The slide valve will replace to the middle position recur to the replacement spring.

Fig.6.3 push slide valve Fig.6.4 pull slide valve

6.5 Main safety valve operation

(1)The main safety valve must be installed between the cylinder HP port and LP passage. The oil that pass through the valve core will be acting on the different diameter surface A & B, so the core K of the one-way valve and the core D of the main safety valve will be firmly fall into the valve base. (See Fig.6.5) (2)When the oil pressure of the cylinder HP port is overrun the spring limit pressure, the precursor valve core E will be open, and the oil will inflood the hole via the valve core circumference, then reach the LP passage. (See Fig.6.6)

(3)Once the precursor valve core E is open, the back pressure of the core C will be reduced, so the core C will be shift to the right direction, then be on the core E. As a result, the back oil route of the core D will be cut off, the inside pressure will be also reduced. (See Fig.6.7) (4)Compared with the cylinder port HP, the inside pressure is imbalance, then the safety valve core will be open, so the oil of the HP side will reach LP passage directly. (See Fig.6.8)

Fig.6.5 Fig.6.6

Fig.6.7 Fig.6.8

6.6 Tilt lock valve operation

Tilt lock valve is used for preventing the shaking of the mast (because the tilt cylinder maybe cause the inside negative pressure), at the same time, it can avoid the danger that the mast will be tilted due to the wrong operation (hit the tilt operation staff) when the engine is off. In traditional structure, even if the engine is off, the mast will be pitch if someone hit the tilt operation staff. But using this new-style tilt lock valve, in spite of the strength that push the tilt operation staff, this complexion will be not occurred. Tilt lock valve structure, see Fig.6.9. In the picture, the port A is connect with the front of the tilt cylinder and the port B is with the behind. When pull the tilt operation staff ( pull slide valve), the oil that is come from the oil pump will be inpour A, and the oil that is come from B port will be back to Oil tank. As a result, the mast will be retroverted. On the other hand, push the tilt operation staff (push slide valve), the oil that is come from oil pump will be inpour B, recur to the HP oil, the lock valve begin to work, then Port A can connect with LP, the mast will be pitch. But when the engine is off, that is, have no HP oil make the lock valve work, so Port A cannot connect with LP, and the mast will not be pitch, at the last, the tilt cylinder will not be cause the negative pressure.

Fig. 6.9 Tilt lock valve

T: to oil tank P: to oil pump A,B: to tilt cylinder

6.7 Hydraulic circulation system (Main circuit) The hydraulic system sketch sees Fig. 6.10. The hydraulic circulation system of the main circuit is complicated with the hydraulic for power steering. The hydraulic piping is of O-ring fitting type with excellent sealing performance, providing secure oil tightness. The hydraulic oil sent from the rear main pump flows directly to the control valve, while the hydraulic oil sent from the front main pump is divided by the flow divider valve in two portions for steering and load handling operation. The hydraulic oil for load handling flows into the control valve and mingles with the hydraulic oil from the rear main pump. With the control valve in neutral position, the oil returns to the oil tank, passing through the valve. When the lift lever is pulled, the hydraulic oil from the control valve flows through the flow regulator valve and reaches the lower part of the lift cylinder piston to push up the piston rod. When the lift lever is pushed, the circuit between the lower part of the lift cylinder piston and the oil tank is opened, and the piston begins to descend due to the weight of the piston rod, lift bracket, forks, etc. In this case, the oil returning to the control valve is regulated by the flow regulator. When the tilt lever is operated, the hydraulic oil from the main pump reaches one side of the piston to push it. The oil pushed by the piston returns to the oil tank through the control valve.

Fig.6.10 Hydraulic system

Ton

t 8 10

Flow of control valve Q1

L/min

160

Flow of steering unit Q2

L/min

Pressure of primary safety valve P1

MPa

Pressure of steering safety valve P2

MPa

12.3

6.8 Troubleshooting

Problem

Possible cause

Remedies

Gear pump can not be pressurized.

Parts worn.

Disassembly, repair or replace parts.

Blocked oil pipe.

Make the oil pipe through.

Blocked oil tank or filter.

Clean dirty or replace oil.

Too high oil stickiness or oil temperature.

Use recommended oil.

Noisy or undulate pressure.

Blocked oil filter.

Clean dirty.

Lower oil level.

Add oil up to specified oil level.

Air entering in resulting from loose suction connections.

Retighten each connection.

Gear precision is reduced.

Replace gear or shave.

Control valve leaks.

O-ring seal (ends of valve body) broken down.

Replace O- ring seal.

O-ring seal (connections of valve body) broken down.

Replace O- ring seal.

Spool can not be reset.

Return spring become deformed.

Replace return spring.

There is dirty between valve body and spool valve.

Clean.

Valve body deformed with the too tight coupling bolt.

Retighten coupling bolt.

The pressure of the relief valve is not right.

Pressure regulating spring deformed.

Replace pressure regulating spring.

Cone valve is worn.

Replace cone valve.

Lock nut is loosen.

Tighten and lock.

Outlet port is block up.

Clean.

The lower slippage of the mast is too large.

The clearance between valve body and spool becomes large.

Repair or renew spool.

The spool isn’t in neutral position.

Make the spool in neutral position.

Cone valve is worn or seized by dirt.

Replace cone valve or clean dirty.

6.9 Maintenance

6.9.1 Detaching of multi-way valve

Detach the valve from forklift and clean it.

(1) Loose bolts and separate each part ,please note that 1-way valve or spring on contact surface shall be kept well.

(2) Loose the bolts at a side of slide valve end as well as at cover side, and then detach them together with valve leather, o-ring and sealing washer.

(3) Place slide valve onto table vice, loose bolts and dismantle spring and its base, spring and valve rod shall be taken out in the case of tilt slide valve with self-locking tilt valve.

6.9.2 Reassembly of multi-way valve

Clean all parts with mineral oil and check if there is any burrs or scars, replace it if necessary. valve body ,slide valve and valve rod shall be in good order, replace complete part if necessary.

(1) Clamp the slice valve with table vice, and then assemble valve rod and spring in right direction.

(2) Put O-ring, valve leather, sealing washer, spring and its base in good order into end of slide valve, and then cover it and tighten the bolts at 25～32N.m.

(3) Insert slide valve (1 piece)assembly into valve body and cover it, tighten the bolts with hex at hexagon slot (torque9~11N.m).

(4) Fix O-ring and valve leather onto the head of slide valve and screw the bolts with 4.6～5.8N.m.

(5) After the above assembly, 1-way valve ,spring and o-ring shall be inserted into every slide valve, tighten it with 3 bolts (torque 103N.m for large bolts, 66N.m for small ones).

7. Lift cylinder & tilt cylinder

Lift

cylinder

Type

Single-action piston type, with cut-off valve

Bore diameter

Φ100

Stroke

1495mm (Only for 3m lift height)

Tilt

cylinder

Type

Double-action piston type

Bore diameter

Φ115

Stroke

242mm

7.1 Lift cylinder

The two lift cylinders of single acting type are used and located behind each outer mast frame. The bottoms of the cylinders are sustained by the mast support of the outer mast while the tops of cylinders, or the piston rod tops are inserted into the upper beam of the inner mast. The lift cylinder assembly consists primarily of a cylinder body, piston, piston rod and cylinder cap. At the lower part of the cylinder body is arranged an inlet for high-pressure oil, and at the upper part there is an outlet for low-pressure oil above the piston packing, to which a return pipe is connected. The piston is fastened to the piston rod with a steel clamp. A wear ring, packing and back-up ring are attached to the outside periphery of the piston which is moved along the inner surface of the cylinder by high-pressure oil. An oil seal and bushing are installed on the cylinder cap which is screwed into the cylinder body. The bushing supports the piston rod, and the oil seal prevents dust from entering the cylinder. The upper end of the piston rod and inner mast upper beam is locked with bolts. When the lift lever is tilted backward, high oil pressure is sent into the lift cylinders through their inlets to push up the piston rods and the piston head, causing the forks to rise through chains. The height from the ground to the fork upper position when the inner mast channel beam upper ends exceed the outer mast upper ends is called “Free lift” . Within this range, the mast height does not vary. With the lift lever tilted forward, the piston rods of the lift cylinders descend by the weights of the piston rods, inner mast, lift bracket, finger bar and forks, causing oil under the piston to flow out of the cylinders. The oil discharged from the cylinders is regulated by the flow regulator and returns through the control valve to the oil tank. The structure of the lift cylinder is shown in Fig. 7.1.

Note: Please pay more regard to safety when adjusting the lift cylinder.

Fig.7.1 Lift cylinder

1. Adjusting pacer

2. Dust ring

3. Yx ring

4. Cylinder cap

5. Bushing

6. O-seal ring

7. Cylinder body

8. Piston rod

9. Snap ring, steel

10. Wear ring

11. Yx ring

12. Piston

13. Lift chain

14. Chain wheel

15. Ball bearing

16. Snap ring

17. Spring

18. Cut-off valve

19. Upper beam

7.2 Flow regulator

The flow regulator is located between the control valve and the high pressure ports of the two lift cylinders, near the left lift cylinder. The structure of the flow regulator valve is shown in Fig7.2. When the lift spool valve is placed in the “lift” position, the oil from the control valve flows through the oil chambers A and B, C, oil holes H, G, D, E, and the chamber I to the lift cylinder without any regulation. When the control valve is placed in the “down” position, the oil flows through chamber I, oil holes E, D, G, H, and chambers C, B, A to the valve. Then there is pressure difference between chamber A and C. Turn on the ball valve (4), a pressure difference overcomes the force of the spring (9) and moves the valve core (5) right, thus the oil flow being decreased by narrowing of the hole G and H, and reduces the oil flow passing through the throttle plate. The flow regulator valve serving both as a flow regulating valve while forks are being lowering and a safety device if rubber hoses between the control valve and lift cylinders are damaged due to any reason.

Fig.7.2 Flow regulator

1. Spring

4. Nylon ball

7. Snap ring

10. Joint

2. Valve sleeve

5. Valve core

8. Valve body

3. Spring

6. Throttle plate

9. Spring

7.3 Tilt cylinder

Two tilt cylinders of double acting type are provided at each side of the frame. The front end of the piston rod is installed on the mast and the cylinder tail is on the frame with pins. The tilt cylinder assembly consists primarily of a cylinder body, cylinder cap, piston and piston rod. The structure of the tilt cylinder is shown as Fig7.3. When the tilt lever in the driver’s room is tilted forward, high pressure oil enters from the cylinder tail to shift the piston forward, tilting the mast forward 6°. With the tilt lever tilted, high pressure oil enters from the cylinder cap side. This shifts the piston to the rear, causing the mast to tilt backward 12°.

Fig7.3 Tilt cylinder

Ear ring

Guide sleeve

13.

Piston

Dust ring

O-ring

14.

Piston rod

Adjusting sleeve

Bearing

15.

Plug

Dust ring

10.

Cylinder body

16.

Screw

Snap ring

11.

Yx-ring

17.

Snap ring

Yx-ring

12.

Retainer ring

18.

Snap ring

8. Lifting system

8.1 General description

The lifting system is of two-stage, rolling telescopic mast type. The inner mast frames have J-shaped section. The outer mast frames have C-shaped section. The masts of forklift trucks all contain a free lift range. The structure of the mast sees Fig. 8.1 and Fig8.2.

Fig8.1 Mast (8t)

1. Fork

2. Lift bracket

3. Lift chain

4. Inner mast

5. Outer mast

6. Tilt cylinder

7. Lift cylinder

Fig8.2 Mast (10t)

1. Fork

2. Lift bracket

3. Lift chain

4. Inner mast

5. Outer mast

6. Tilt cylinder

7. Lift cylinder

8.2 Inner & outer mast

The mast assembly is of the free lift range-contained two stage telescopic type consisting of the inner and outer mast, and is sustained by mast supports. The mast supports are welded to the bottom of the outer mast, being extended from the axle housing. The outer masts are provided with brackets for lock pins of tilt cylinder connecting hardware. The mast is tilted by operation of the tilt cylinders. The inner mast is composed of right and left mast frames which are connected with each other by upper and lower connecting members. At the upper inside of each outer mast frame an end roller is installed on the end roller shaft welded to the frame, with a snap ring. In addition, the outer mast frames are fitted with side rollers to sustain the inner mast frames. At the lower outside of each inner mast frame an end roller is installed on the end roller shaft with snap ring, which is welded to the inner mast. Under the end rollers other side rollers are located to sustain transverse load. With the aid of these rollers, the inner mast can smoothly operate. Notice: Please pay more regard to safety when maintaining the main rollers and side rollers on the upper of outer mast.

8.3 Lift bracket

At the lift brackets, end rollers that roll along the inside of the inner mast frames are installed on the end roller shafts with snap rings. The end roller shafts are welded to the lift brackets. The side rollers that roll along on the inside of the inner mast frames are bolt fitted, being shim adjusted. To prevent the rolling of the finger bar, two retaining rollers are used, which roll along on the outside of inner mast frames. The longitudinal load is sustained by the end rollers of which the upper ones emerge from the top mast when the forks reach the maximum lift height. The transverse load is sustained by upper retaining rollers and lower side rollers. As we mentioned above, the mast assembly and lift brackets are designed with rigidity, stability and smooth operation in mind. Furthermore, the finger bar and lift brackets are made into one body construction using high tension steel to improve the durability. This meets the ISO Standards. The two forks installed on the finger bar are made of special alloy steel which has been subjected to heat treatment. The fork pin fastens the fork on the definite position. When adjusting the clearance

of the fork, pull the fork pin turn 1/4 circle, the fork clearance must be adjusted according to the loaded goods.

8.4 Roller position

There are three kinds of rollers, main roller, side roller group and side roller. They are separately mounted on the inner mast, outer mast and lift bracket. The main rollers sustain the main loads from front, which can’t be adjusted, and rear direction and the side rollers sustain the side loads with the left and right side clearance adjusted by the gasket group, this will make the inner mast and lift bracket move freely. See Fig8.3, Fig8.4.

Fig8.3 Roller mounting (8t forklift)

Fig8.4 Roller mounting (10t forklift)

8.5 Adjustment of lifting system

a. The clearance between the inner mast and the guide plate of the outer mast is

0.5-1.0mm, which is adjusted by the spacer of the guide plate. The clearance between the side roller and the channel beam is 0.3-0.8mm, which is adjusted by the axial bolt inner the roller.

b. Make the forks descend to the ground, adjust the lifting chain to assure the distance between the center of lift bracket lower rollers and the bottom of inner mast is smaller than 25mm. c. Make the mast assembly tilts backward, adjust the pulling force of lift chains and let the tightness of lift chains be equal. d. Make use of the spacer of the lift cylinder to adjust the error occurred between the right and left cylinders in height.

8.6 Maintenance and adjustment

8.6.1 Adjustment of lift cylinder (Fig8.5)

When replace the lift cylinder, inner mast or outer mast, we shall readjust the stroke of the lift cylinder as following:

(1) Install the piston rod in the upper beam of the inner mast without shims.

(2) Lift the mast slowly to the max. stroke of the cylinder and check the two cylinders synchronize or not.

(3) Install shims between the top of the piston rod of the cylinder which stop first and the upper beam of the inner mast. The thickness of the shim is

0.2mm or 0.5mm.

(4) Adjust the tightness of lift chains. Fig8.5

Notice: Please pay more regard to safety when adjusting the lift cylinder at an elevated height.

8.6.2 Carriage adjustment

(1) Park forklift on horizontal place and let mast vertical.

(2) Put the bottom of fork onto ground, screw the adjustable nut at the end of joint and let main idler wheel come out l/4-l/3 of its radius. See Fig8.6.

Fig.8.6

(3) Lift fork to Max. height, and ensure gap B between limit blocks of fork and of inner mast shall be 5-10mm. See Fig8.7.

Fig.8.7

(4) Put down the fork and tilt to specified position, adjust the nut at chain upside and tensility of two chains should be same. See Fug8.8.

Fig.8.8

8.6.3 Replace rollers of the lift bracket

(1) Place a pallet on the forks and let the truck parking on the horizontal ground.

(2) Make the forks and the pallet down to the ground.

(3) Disassemble the end nipple of the upper chain and take the chain down from the sheave.

(4) Lift the inner mast (See Fig8.9 ①).

(5) Make the truck back-up if the lift bracket is fully separated from the outer mast. (See Fig8.9 ②)

(6) Replace the main rollers.

·Disassemble all the snap rings and take out the main rollers with a drawing tool

except the adjusting shims.

·Ensure the new rollers have the same types as the replaced rollers. Install the new

rollers inside the lift bracket and fasten them with snap rings.

8.6.4 Replace rollers (Fig8.10)

(1) Use the same way as 8.5 to disassemble the lift bracket from the inner mast.

(2) Let the truck parking on the horizontal ground and wedge up the front wheels for 250mm to 300mm.

(3) Apply the parking brake and wedge up the rear wheels.

(4) Disassemble the bolts which fasten the lift cylinder and the inner mast. Hang up the inner mast not to loose the shims of the piston rod heads.

(5) Disassemble the connecting bolts for the lift cylinder and the bottom of the outer mast. Disassemble the lift cylinders and the oil pipes between the two cylinders without loosen the oil pipe joints.

(6) Main rollers on the upper outer mast will be showed on the top of the inner mast as soon as main rollers were taken apart from bottom of the inner mast after laying down the inner mast.

(7) Replace the main rollers.

·Disassemble the upper main rollers with a drawing tool, don’t loose the adjust

shims.

·Install the new rollers and the shims disassembled before.

(8) Hang up the inner mast to let all the rollers in the mast.

(9) Reassemble the lift cylinder and the lift bracket.

Fig8.9 Fig8.10

9. Electric system

9.1 General description

The electric system for this forklift truck is of the single-pole type. It mainly consists of the following systems (See the principle diagram in Fig9.1, Fig9.2):

(1) Charge system

This system contains generator, battery, charging indictor, etc. It supplies current for all the electric appliances.

Voltage: DC24V

Dealing with the waste and worn batteries according to relevant laws and regulations.

(2) Starting system This system mainly consists of mid-relay, starting relay (only ISUZU diesel engine), key switch, starting protection circuit, starting motor, etc. This system is used for starting the engine.

(3) Parking control system (ISUZU diesel engine) This system consists of the key switch, relay for stopping engine and automatic device for stopping engine. For the truck equipped with a homemade engine, this system is controlled by a cable for stopping engine.

(4) Instruments It mainly consists of hour meter, fuel meter, water temperature meter, charge signal, oil pressure indicator, neutral signal, air filter indicator and sedimentor indicator. They are all performance checking instruments for the forklift truck.

The instrument panel adopts Curtis internal-combustion engine meter core. The fuel meter and water temperature meter are ten solid state bars of multicolor LED display. The hour meter in the BAOLI instrument panel is solid state digital display with back lamp.

Notice for operation of instrument:

a. Working circumstance: Elevation is lower than 1200 meters, working temperature -25℃～+40℃, relative humidity is not larger than 95%.

b. Forbid wetting the meter. When washing the truck, don’t let water into the meter,

if it happens, clean it with dry cloth.

c. Don’t pull the plug of the meter and harness for the connection.

d. Forbid impacting or scratching the meter strongly.

e. When the meter works abnormally, contact with our company for maintenance.

(5) Lighting and signal device They include all kinds of illuminating lamps, signal lamps, horn and buzzer, etc. Headlight:55W Front combination lamp (turning/front):21W/5W Rear combination lamp (turning/rear/brake/backing) (up):

21W(yellow)/5W(red)/21W(red)/10W(white) Rear combination lamp (down): 55W (yellow) Warning lamp (optional):21W Rear lamp (optional): 70W Decal lamp (optional): 10W

Fig.9.1 Principle diagram of electric system (domestic) CPCD80-100CY

Fig.9.2 Principle diagram of electric system (imported) CPCD80-100W

Baoli CPCD 80, CPCD 100 Operating And Servicing Manual

Specifications and Main Features

Frequently Asked Questions

User Manual