PREFACE The new type BAOLI forklift truck is of internal combustion balance weight type, which adopts advanced TCM transmission, wide vision mast system, cycloid gear type powered steering unit, and other advanced technique and equipment. So it is characterized by high performance, convenient operation, wide vision, flexible steering, reliable braking, low noise and attractive appearance. It is suitable for loading and transportation of kinds goods in goods station, port, airport, factory and store house.
CONTENTS Ⅰ. About forklift truck……………………………………………………………… 1 1. External view and technical parameter………………………………………… 1 2. Characteristic……………………………………………………………………… 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.
3.3 Hydraulic circuit…………………………………………………………………… 38 3.4 Towing disabled truck…………………………………………………………… 39 3.5 Troubleshoot……………………………………………………………………… 39 4. Drive system…………………………………………………………………………… 42 4.1 General description……………………………………………………………… 42 4.2 Procedure for hubs remounted………………………………………………… 42 4.3 Troubleshoot……………………………………………………………………… 45 5. Brake system…………………………………………………………………………… 46 5.1 General description……………………………………………………………… 46 5.
8. Lifting system………………………………………………………………………… 69 8.1 Inner and outer mast…………………………………………………………… 69 8.2 Lift bracket………………………………………………………………………… 70 8.3 Fork………………………………………………………………………………… 70 8.4 Roller position…………………………………………………………………… 70 8.5 Maintenance and adjustment…………………………………………………… 71 9. Electrical system……………………………………………………………………… 74 9.1 General description……………………………………………………………… 74 9.2 Brief explanation for operation………………………………………………… 75 9.
Ⅰ. About forklift truck 1.
Technical parameter General Manufacturer KION Baoli CPC(D)20 CPC(D)25 CPC(D)30 CPC(D)35 CPQ(Y)D20 CPQ(Y)D25 CPQ(Y)D30 CPQ(Y)D35 Model Power type Diesel / Gasoline/ LPG Rated capacity kg Load center 3000 mm 500 3000 3500 H mm Free lift height H4 mm L×W×T mm 1070×120×40 1070×120×45 1070×125×45 1075×130×45 α/β deg 6/12 X mm 484 489 494 500 Length to fork face L1 mm 2510 2580 2720 2775 Overall width B1 mm 1150 Mast lowered height H1 mm 2050 Mast extended height H3
2. Characteristic The forklift truck has advantages as follows: 1. The hydraulic steering device makes steering flexible and the double ladder like steering axle makes the turning radius minor. 2. The braking system employs oil pressure brake, makes it possible to manipulate conveniently and brake reliably. 3. Employed wide-vision extension type mast, the forklift truck is high intensity.
Main system of forklift truck No. Name Content engine mounting, system of fuel, exhaust 1 Power system and cooling (inc. torque converter oil cooler) clutch, transmission with synchromesh Mechanical drive 2 mechanism, differential etc. Transmission system torque converter, power shifted Hydraulic drive 3 Drive axle 4 Brake system transmission, differential, gearshift etc. axle housing, half shaft, wheel hub, brake, and front wheel etc. brake cylinder, brake unit, brake pedal etc.
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.
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.
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.
(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. (c) The slinging cable must be enough to hang the forklift truck. (d) Disassembled parts of forklift truck must be slung in the appointed position. Mast (normal type) Model Balance weight Dimension Slinging capacity Dimension Slinging capacity (mm) (kg) (mm) (kg) 2.0T 1890×1040×470 >7800 1135×543×950 >1200 2.
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. (c) Park your forklift truck on the solid ground.
(c) Put the key switch in “OFF” position and turn off the engine, operate the lever of 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.
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.
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.
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.
(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.
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.
(2) General information when operating (3) Nameplate of forklift truck (4) Lubrication system (5) Capacity chart 16
(6) Inspections before starting (7) Adjust parking brake (8) Add hydraulic oil (9) Add fuel (gasoline) (10) Add fuel 17
(11) Add antifreeze (12) Tyre safety decal (charging tyre) (13) Tyre pressure decal (charging tyre) 2-2.5t forklift truck 3-3.
(15) Sling decal (16) Forbid entering into the space behind the mast (17) Forbid conveying person (18) Hand caution decal (19) Fan hurting hands 19
(20) Hood crushing hands (21)Belt pulley thumb hand decal (21) Overturn caution decal 20
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.
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.
3.
Ⅳ. Construction, principle, adjustment and maintenance of forklift truck In order to keep good condition of your forklift truck, you must have an intimate understanding of the construction, principle, adjustment and maintenance of the forklift truck. When finding damage or fault with the truck, stop operating the truck and inform a professional serviceman. Use genuine parts of our company for replacement. 1. Power system 1.
Parallel table for engine and forklift model which is coincidence and stuck with CE label: The guaranteed Sound power level LwA(dB) 2000/14/EC Exhausting 2004/26/EC CE CONFORMITY 2006/42/EC C240PKJ 106 StageⅢA yes 4TNE92 107 StageⅢA yes 4TNE98 107 StageⅢA yes 4G64 -31ZG 105 yes K21 105 yes K25 105 yes Gasoline engine Diesel engine Engine model ISUZU Yanmar Mitsubishi Nissan Truck model CPCD 20/25/30-W1 CPCD 20/25-Y1 CPCD 25/30/35-Y2 CPQD 20/25/30-H1 CPQD 20/25-H2 CPQD 20/25/30/
diesel engine type trucks. The difference is that the gasoline type is fitted with oil suction pipe and the diesel type with oil return pipe. 1.4.1 Fuel sensor The fuel sensor is designed to convert the remaining amount of fuel electric current. See Fig1.1. Fig1.1 Fuel sensor 1.4.2 Maintenance of the fuel system Once every 100 hours operation, it is required to maintain the fuel system according to the methods as follows. Once every 600 hours operation, it is required to clean the fuel tank.
(b) Loosen the circle wheel and remove the cap. (c) Loosen the nut and take the filter element out. (d) Clean or replace the filter element. (e) After reassembly of filter, start the engine to feed gasoline into filter bowl and check for leaks. ▲ Diesel engine (a) Once every 600 hours operation, it is required to replace the filter assembly.
2. Mechanical drive system 2.1 Clutch Type Dry single plate type Operation Foot-pedal type Friction piece outer diameter 275mm Friction piece inner diameter 175mm Friction piece thickness 8.9±0.3mm Surface area 354cm2 Weight 12.5kg 2.1.1 General description The clutch consists primarily of clutch housing, friction pieces, jib and pressure plate assy. It transmits or cuts off the power from the engine to the gear box. The structure of clutch is referred to Fig2.1. 1. Housing 2.
2.1.2 Maintenance A. Adjustment of clutch pedal (1) Remove the floor board. (2) Loose the lock-nut of the stopper bolt. (3) Turn the stopper bolt left and right to adjust the height of the clutch pedal. (4) Screw the lock nut tightly and fit the floor board. B. Replacement of friction pieces (1) Remove the clutch cover. (2) Press the clutch pedal and move out the pressure plate with liftout bolt. (See Fig 2.2) (3) Turn the slide bolt left to let the drive shaft go into the transmission.
2.2 Mechanical drive unit Manual-shift, slide type synchromesh mechanism FWD 2 BWD 2 Type Transmission Shift No. Gear Ratio Reducer Differential FWD 1st/2nd 3.253/1.407 BWD 1st/2nd 3.204/1.386 Reduction gear Spiral bevel gear Reduction ratio 2.1 Reduction gear Spur gear Reduction ratio 6.182 Differential gear Bevel gear Oil amount 8L Weight (without oil) 165kg 2.2.1 General description The drive unit of clutch type truck consists of transmission and differential.
1. Snap ring Fig 2.3 Transmission 13. O-ring seal 25. Forward gear 2. Snap ring 14. Slide bolt 26. Needle bearing 38. Shift lever 3. Ball bearing 15. Retainer, bearing 27. Reverse gear 39. Shift fork 4. Spacer 16. Drive shaft 28. Clutch hub 40. Switch, neutral 5. Ball bearing 17. O-ring seal 29. Spacer 41. Shift fork 6. Drive gear 18. Drive gear 30. Needle bearing 42. Switch, reverse lamp back-upseal lamp 31. Shaft 43. O-ring 7. Needle bearing 19. Lock nut 37. Tapered roller bearing 8.
Fig 2.4 Reducer and differential 1. Gear ring 5. Shim 9. 2. Pin 6. O-ring seal 10. Gear 14. Planet gear 3. Ball bearing 7. Bearing cover 11. Spacer 15. Shim 4. Side gear 12. Pinion shaft 16. Gear shaft 8. Tapered roller bearing 32 Adjusting shim 13.
3. Hydraulic drive unit Type Torque converter Charging pump Three elements, single stage, two phases Torque ratio 3 Set pressure 0.5～0.68 MPa Type Inner-mesh gear pump Flow rate Hydraulic transmission 27 L/min(2000rpm,1.5MPa) Type Power shifted Speed ration 1.35/1.35 (FWD/BWD) Friction piece: Ф125×Ф80×2.7 (mm) Hydraulic O.D.×I.D.×T. clutch Friction area 71cm2 Set pressure 1.1～1.4 MPa Weight 165kg Oil amount 7L Oil type 6# or 8# Torque converter oil 3.
Fig3.1 Hydraulic drive unit 1. Forward clutch 18. Safety valve cover 35. Output gear 2. Oil filter 19. Inner-hexagon plug 36. Idler shaft 3. Backward clutch 20. Plug 37. Single-row radial ball bearing 4. Single-row radial ball bearing 21. Spring pin 38. Bearing nut 5. Seal ring 22. Shift arm 39. Single-row tapered roller bearing 6. O-ring 23. Transmission case cover 40. O-ring 7. Charging pump 24. Shift shaft 41. Oil seal 8. Oil seal 25. O-ring 42. Single-row tapered roller bearing 9.
3.2 Torque converter (Fig 3.2) The torque converter mainly consists of an impeller, a turbine and a guide wheel. The liquid, from the impeller driven by an input shaft, is jetted along its leaves to leaves of the turbine to transmit the torque to the output shaft (Mechanical energy is changed into kinetic one).
3.3 Hydraulic circuit (See Fig3.3) After the engine is started, the charging pump inhales the oil from the oil tank. The pressure oil from the pump serves two parts for hydraulic clutches and torque converter. The oil necessary to operate the hydraulic clutches is divided into two circuits through the pressure valve (set pressure of 1.1-1.4MPa): one circuit flowing to the torque converter via. a relief valve (set pressure of 0.5-0.7MPa) and another to the inching valve and the slide valve.
3.4 Towing disabled truck Pay attention to the following items when the forklift truck to be repaired is towed by other truck: (1) Remove the drive shaft between the transmission case and differential. (only for the truck with drive shaft) (2) The half shaft should be took off from the front wheel. (3) Shift lever should be placed in the neutral. The lubrication can’t be achieved if the charging pump is out of work.
(2) Higher oil temperature Parts Problem Possible cause and remedy 1. Lower oil level Check oil level and add oil 2. Blocked oil filter Check, clean or replace. 3. Fly wheel bump against Check oil, if have dirt, replace it. other arts Torque converter 4. Air entering in resulting from Check connection or oil pipe. Retighten loose connections each connection or replace seal. 5. Water mixed into oil Check and replace oil 6. Lower oil flow Check pipe and replace 7.
(4) Too low transmission efficiency Parts Torque converter Gear box Problem Possible cause and remedy 1. Elasticity plate is broken Check noise and replace 2. Lower oil amount Check oil level and add oil 3. Ineffective driving system of oil pump Check and replace 4. Shaft is broken Check and replace 5. Too low oil pressure Check oil pump for suction pipe 1. Lower oil amount Check oil level and add oil 2. Seal ring is worn Check and replace 3.
4. Drive system Type Front wheel drive, axle body and frame fastened together, fully floating type 2t, 2.5t Forklift truck 3t Single tyre (2) Tyre size 7.00-12-12PR Rim size 5.00S-12D Tyre pressure 0.84MPa 3.5t Double tyres (4) Dual28×9-15-12PR tyre 7.00WFB-15 28×9-15-14PR 7.00WFB-15 0.80MPa Notice: For the difference of manufacturers’ standard, please charge the tyre according to the pressure specification of actual tyres. 4.
and inner rim. Pay attention to the following points: (a) Put the air valve rod in the notch of the rim and make it face outside. (b) Make the tops of the rim mounting bolts face outside. (c) Don’t stand near the tyre when inflating air. (d) When the tyre pressure reaches 98KPa (1kgf/cm2), knock the tyre lightly to make the inner tyre and gasket into the rim. Fig4.1 Drive axle 1. Housing 6. Tapered roller bearing 11. Rim 2. Half-shaft 7. Wheel hub 12. Adjusting nut 3. Wheel brake 8.
Fig4.2 Add grease Fig4.3 Measure starting torque Structure of rim bolt Fig4.4 Wheel assembly 1.Tyre 4.Inner rim 7.Spring washer 2.Air valve core 5.Outer rim 8.Nut, rim 3.Bushing 6.
4.
5. Brake system Type of brake system Front two-wheel braking, internal expansion, hydraulic type Pedal ratio 5.66 Master cylinder bore 19.05mm Wheel brake 2t, 2.5t Type Duo-servo type with parking brake Operating cylinder bore Size, friction pieces (L×W×T) 28.58mm 324×60×7 (mm) 2 Area, friction pieces Inner diameter of brake drum Parking brake 3t, 3.5t 348×76×8 (mm) 194.4cm ×4 264cm2×4 310mm 314mm Front two-wheel braking, internal expansion, hydraulic type 5.
At the same time, the brake fluid in each operating cylinder is pressurized by the return spring, returning into the master cylinder through the check valve. With the piston in its original position, the brake fluid in the master cylinder flows into the reserve tank through the return port.
Fig5.2 Wheel brake 1. Spring 8. Return spring 15. Spring pull rod 2. Cup 9. Adjusting lever 16. Parking pull rod 3. Piston 10. Secondary brake shoe 17. Parking push rod 4. Cylinder body 11. Clearance adjuster 18. Operating cylinder 5. Push rod, piston 12. Spring 19. Return spring 6. Return spring 13. Parking cable assy 20. Primary brake unit 7. Push rod 14.
Fig5.3 Clearance self-adjuster 5.4 Parking brake lever (Fig5.4) The parking brake lever is of a cam type. The brake force can be adjusted with the screw in the adjuster which is on the end of the brake lever. Brake force adjustment: When you turn the adjuster clockwise, the force increases, otherwise, when you turn the adjuster counterclockwise, the force decreases. Pull force: 20 to 30kg. Fig5.
5.5 Inspection of wheel brake Inspect all parts to make sure if there’re any worn or damaged parts. If necessary, repair or replace with new one. (1) Check the operating cylinder body’s inner surface and the piston periphery surface for rusting. Then, measure the clearance between the piston and cylinder body: Specified clearance: 0.03 to 0.10 mm Maximum clearance: 0.15mm (2) Visually check the piston cup of the operating cylinder for damage or deformation. If necessary, replace it.
5.6 Troubleshoot Problem Poor braking Probable cause 1.Fluid leaks from brake system Repair 2.Maladjustment of brake shoe clearance Adjust the adjuster 3.Brake overheating Check for dragging 4.Poor contact between brake drum and friction Readjust piece 5.Foreign matter adhered on friction piece Repair or replace 6.Foreign matter mixed in brake fluid Check brake fluid 7.Maladjustment of brake pedal (inching valve) Adjust 1.
6. Steering system 2t, 2.5t Steering system 3t 3.5t Rear wheel powered steering Type of steering unit Cycloid gear type powered steering unit Model of steering unit BZZ1-100 (sealed by taper ring) Type Double-action piston type Steering Cylinder bore mm Ф70 cylinder Diameter of piston rod mm Ф50 Stroke mm 160 Rated pressure Mpa Diameter of handwheel mm Pressure of steering wheel Mpa 7 9 10.5 Ф380 0.84 0.76 6.
6.2 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. 6.3 Cycloid gear type powered steering unit The powered steering unit (Fig6.
6.4 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.
6.6 Steering axle The steering axle is of section-boxed welded construction type (Fig6.3). It includes axle body, steering cylinder, tie rod, steering knuckles and steering wheels. 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. Fig6.3 Steering axle assy 1. Axle body 9. Tyre 17. Oil seal 2. Tie rod 10. Oil seal 18.
6.6.1 Steering cylinder (Fig6.4) The steering cylinder is of double-action piston type. The seal unit consists of the supporting ring and O-ring, Yx-ring seal is adopted between the cylinder cover and the piston rod. The cylinder is fitted on the steering axle through two sides cylinder covers. Fig6.4 Steering cylinder 1. Piston rod assy 4. Yx-ring 7. Supporting ring 2. Cylinder cover 5. O-ring 8. Cylinder body 3. Dust ring 6. O-ring 6.6.
(6) Again slightly knock at the hub with a wooden hammer and in this time, rotate manually the hub for 3～4 turns to ensure its smooth rotation with a specified torque of 2.94～7.8N.m. (7) 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. (8) When the torque value measured is up to the specified one, lock the castle nut with a cotter pin. Fig6.
7. Hydraulic system Hydraulic Type Gear pump oil pump Displacement 31.5 ml/r Type Control valve Tilt cylinder 17.5MPa pressure Dividing Flow rate cylinder and tilt self-locking valve Setting pressure Lift Two-pool type with relief valve, flow divider 7 MPa (2, 2.5t) / 9 MPa (3t) / 10.5 Mpa (3.5t) 11L/min (2t, 2.5t) 13L/min (3t, 3.
1. Pump body 2. Driving gear 3. Driven gear 4. Front cover 5. Rear cover 6. Lining plate 7. Seal ring 8. Ring 9. Oil seal 10. Snap ring Fig7.1 Hydraulic oil pump Fig7.
Relief valve and flow divider (see Fig7.3) The relief valve consists of main valve A and proceeding valve B. When the spool of the control valve is operated, chamber Q linked with the operating cylinder is filled with high pressure oil. The high pressure oil affects proceeding valve B through throttle hole D and E.
▲Setting pressure of the relief valve (Fig7.4) The pressure of the relief valve has been set before delivery. Don’t adjust the pressure at will, for it will bring danger for system and safety. If the oil pressure is different with standard value, according to the measure method specified in JB/T3300, specialized servicemen adjust the pressure as follows: (a) Screw out the measured hole plug from the inlet port of control valve and install the oil-pressure gauge (20MPa) on it.
7.4 Hydraulic oil circuit (Fig7.5) The oil from the hydraulic pump comes to the control valve first and there is divided by the flow divider into two parts, one being sent to lift cylinder or tilt cylinder, and another to the power steering unit in constant flow rate to operate the steering cylinder. With the spools of the lift and tilt spool valves in neutral position, the oil from the pump directly returns to the tank through the passage in the control valve.
7.5 Lift cylinder (Fig7.6) The lift cylinder is of single-action piston type. It consists of cylinder body, piston rod, piston and cylinder head etc. The bottom of the cylinder is connected with the cylinder supporter of the outer mast by bolts and pins, while its top (i.e. piston rod head) is connected with the upper beam of the outer mast. The piston, fastened to the piston rod with spring wire is fitted with oil seals and wearing on its outer periphery.
7.6 Flow regulator valve (Fig7.7) The flow regulator valve, located in the lift cylinder circuit to limiting the descending speed of loaded forks, has the construction as shown in Fig7.7. 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, oil holes C, D, E and F, and the chamber G to the lift cylinder without any regulation. When the lift spool valve is placed in the “down” position, the oil flows in the reverse position.
7.7 Tilt cylinder (Fig7.8) The tilt cylinder is of double-acting type. Each truck has two cylinders which are installed on two sides of the mast, their cylinder base are connected with frame with pins while their piston rod ends are connected with the outer mast channels. The tilt cylinder assembly consists of piston, piston rod, cylinder body, cylinder base, guide sleeve and seals. The piston, welded to the piston rod, is fitted with two Yx-rings and one wear ring on its circumference.
7.8 Hydraulic pipe-line Fig7.
7.9 Troubleshoot If the hydraulic system occurs trouble, find out the possible cause according to the following tables and repair it.
(2) Hydraulic oil pump Problem Oil can not be pumped out Possible cause Remedy Lower oil level in oil tank Add oil up to specified oil level Blocked pipe-line or oil filter Clean or replace oil if necessary Lining plate broken down Wearing broken down Replace Seal ring, bushing or snap ring broken down Oil pump can not be pressurized Misadjusted relief valve Adjust pressure to specified value Retighten loose connections for suction pipe Air entering into the pump Add oil into oil tank Repla
8. Lifting system The lifting system is the type of lifting and descending vertically with the two-stage rollers. It consists of the inner mast, the outer mast and the lift bracket. Fig8.1 Mast 1.Outer mast 4.Tilt cylinder 7.Carriage 2.Inner mast 5.Load backrest 8.Fork 3.Lift cylinder 6.Lift chain 8.1 Inner and outer mast The inner and outer masts are welded parts. The bottom of outer mast is connected with the drive axle through supporting.
8.2 Lift bracket The lift bracket moves up and down smoothly along the channel of the inner mast by the main rollers. The main rollers mounted on the main roller shafts and blocked by snap rings. The main roller shafts are welded on the lift bracket. The side rollers fitted on the lift bracket with bolts. They roll along the flank plate of the inner mast and rolling clearance can be adjusted with shims. The main rollers sustain the longitudinal loads and the side rollers sustain the transverse loads. 8.
8.5 Maintenance and adjustment 8.5.1 Adjustment of lift cylinder (Fig8.3) 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.
(3) Make the fork down to the ground and tilt backward fully. Adjust the adjusting nut for the end nipple of the upper chain and make the two chain’s tightness equal. 8.5.3 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 Fig8.5 ①).
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. Fig8.5 Fig8.
9. Electrical system 9.1 General description The electric system for this forklift truck is single wire system with minus earth. It mainly consists of the following systems: (1) Charge system This system contains generator, battery, charging indicator, etc. It supplies current for all the electric appliances. Voltage: 12V (DC) (2) Starting system This system mainly consists of automatic pre-heating unit (only diesel engine), key switch, starting protection circuit, starting motor, etc.
9.2 Brief explanation for operation (1) Starting There is a starting protection circuit in the control box for the forklift truck. You have to shift the direction switch in neutral before you start the engine. Otherwise, you can not start the engine. Turn the key switch clockwise to the first “on” position, the instrument circuit and the firing circuit is ready for work. For diesel engine, the automatic pre-heater begins to work and the pre-heating indicator lights.
combination lamps are on and the buzzer sounds. (6) Charging signal Before you start the engine, put the key switch to the first “on” position and the charging lamp is on. After engine starting, the charging lamp is automatically off. If the charging lamp becomes on while the engine is working, it means something is wrong with the charging circuit and you must stop working and check the charging circuit as soon as possible.
(11) Hour meter It indicates the temperature of the coolant for the engine. 9.3 Precautions when using the battery (1) Avoid the short circuit, spark and smoking for the battery may cause combustible gas which has danger of explosion. (2) The electrolyte is dilute sulfuric acid which is dangerous when touching the skin or eyes. If it is on the skin, wash it with water immediately. If in the eyes, please go to hospital at once after cleaning the eyes with water.
Central control box 00 Power(-) 01 Power, horn 02 Power, lamp 03 Power, meter 04 Power, switch 05 Switch, turning lamp 06 Power, ignition switch 07 Switch, light 08 Switch, start 09 Power, headlamp 10 Preheating indicating 12 Main power 13 Preheating fuse 14 Starter 15 Optional power 1 16 Optional power 2 17 Indicating, neutral 18 Generator N 19 Generator F 20 Charging indicating 21 Switch, forward 22 Switch, reverse 23 Lamp, reverse Fig9.
Central control box 00 Power(-) 01 Power, horn 02 Power, lamp 03 Power, meter 04 Power, switch 05 Switch, turning lamp 06 Power, ignition switch 07 Switch, light 08 Switch, start 09 Power, headlamp 10 Preheating indicating 12 Main power 13 Preheating fuse 14 Starter 15 Optional power 1 16 Optional power 2 17 Indicating, neutral 18 Generator N 19 Generator F 20 Charging indicating 21 Switch, forward 22 Switch, reverse 23 Lamp, reverse Fig9.
Central control box 00 Power(-) 01 Power, horn 02 Power, lamp 03 Power, meter 04 Power, switch 05 Switch, turning lamp 06 Power, ignition switch 07 Switch, light 08 Switch, start 09 Power, headlamp 10 Preheating indicating 12 Main power 13 Preheating fuse 14 Starter 15 Optional power 1 16 Optional power 2 17 Indicating, neutral 18 Generator N 19 Generator F 20 Charging indicating 21 Switch, forward 22 Switch, reverse 23 Lamp, reverse Fig9.
Fig9.
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Fig9.
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