DOWNLOAD PDF Shangli CPCD50SA CPCD60SA CPCD 70SA Operation & Service Instruction Manual

OPERATION & SERVICE INSTRUCTION

CPCD50SA CPCD60SA CPCD70SA

Internal Combustion Balanced Forklift

Table of Contents Chapter 1 The General Parameters ................................................................................1 Chapter 2 The Driving System.....................................................................................10 Chapter 3 The Transmission of Torque Converter -.....................................................12 Chapter 4 The Driving Axle and Differential Mechanism...........................................30 Chapter 5 The Steering System....................................................................................40 Chapter 6 The Braking System ....................................................................................46 Chapter 7 The Steering Control System ......................................................................56 Chapter 8 The Hydraulic System .................................................................................62 Chapter 9 The Lifting System (Gantry Mounting and Fork) .......................................69 Chapter 10 The Cooling System ..................................................................................73 Chapter 11 The Fault Diagnosis...................................................................................74 Chapter 12 The Maintenance Standard ........................................................................83 Chapter 13 The Electrical System................................................................................98 Product Warranty

Note: Some of the specification parameters in this operation and maintenance instruction will be updated without prior notification due to the innovation. We are appreciated for your understanding.

Chapter 1

The General Parameters

(I) The scope of application This instruction is applicable to the operation and maintenance of the Internal Combustion Balanced Forklift of model CACD50SA/60SA. And the manual information will be updated without prior notification due to the innovation of design. We are appreciated for your understanding.

.1.

(II) The outside view and the main specification parameters

No.

Item

Model

CPCD50SA/60SA

1

The maximum lifting height

3000

2

The adjusting range of fork (outside)

300̚1600

3

The length of fork

1220

4

The tilting angle of gantry mounting (Forward/backward)

6°/12°

5

Total length

4810

6

1910

9

Total width The height between gantry mounting and floor after the fork is down The height between cargo fender and floor after the fork reaches to the maximum height The height between the roof of protection rack and floor

10

The wheel space of front

1400

11

The wheel space of rear

1534

12

The wheel base The minimum clearance from the floor (at the position of gantry mounting)

2300

7 8

13

.2.

2732 4380 2450

170

No.

Model Item

CPCD70SA

1

The maximum lifting height

3000

2

The adjusting range of fork (outside)

300̚1600

3

The length of fork

1220

4

The tilting angle of gantry mounting (Forward/backward)

6°/12°

5

Total length

4810

6

Total width

1910

7

2732 4380

9

The height between gantry mounting and floor after the fork is down The height between cargo fender and floor after the fork reaches to the maximum height The height between the roof of protection rack and floor

10

The wheel space of front

1400

11

The wheel space of rear

1534

12

The wheel base The minimum clearance from the floor (at the position of gantry mounting)

2300

8

13

2450

170

.3.

(III)

The main technical parameters

(Table 1.1) Model CPCD50SA/60SA

The moving capacity

The operation capacity

Item The rated lifting load/Load center

Kg/ mm

The rated maximum lifting height

mm

5000 / 600 6000 3000

The maximum lifting speed (full load/no load) The tilting angle of gantry mounting (forward/backward) FORWARD I

mm/s

284/300

Degree

6°/12°

FORWARD II

The operation speed

BACKWARD I

8

The minimum turning radius The passage width for square stacking

Tire

Size Air pressure

24 2900

% (tan)

>20% 8.25-15-12PR

Rear wheel

8.25-15-12PR

Front wheel (double) Rear wheel

700

KPa Kg

Model Engine

3300

mm

Front wheel (double)

Net weight

700 7900/8160 6BG1 Diesel

Total discharge capacity

L

6.494

The rated power

KW N•m (r/min)

82

The maximum torque Battery

8

BACKWARD II

The maximum climbing grade (full load)

.4.

22

Km/h

Model

275/1560 6-QA-75 (S) L

Voltage

V

24

Capacity

Ah

80

(III)

The main technical parameters

(Table 1.1) Model

The moving capacity

The operation capacity

Item The rated lifting load/Load center

Kg/mm

7000/600

The rated maximum lifting height

mm

3000

The maximum lifting speed (full load/no load) The tilting angle of gantry mounting (forward/backward) Gear I for forward

mm/s

284/300

Degree

6°/12°

Gear II for forward

The operation speed

Gear I for backward

8

The minimum turning radius The passage width for square stacking

Tire

Size

8 22 3300

mm

2900

% (tan)

>20%

Front wheel (double)

8.25-15-12PR

Rear wheel

8.25-15-12PR

Front wheel (double)

Air pressure

Rear wheel

Net weight

700

KPa

700

Kg

Model Engine

22

Km/h

Gear II for backward

The maximum climbing grade (full load)

8400 6BG1 Diesel

Total discharge capacity

L

6.494

The rated power

KW N•m (r/min)

82

The maximum torque Battery

CPCD70SA

Model

275/1560 6-QA-75 (S) L

Voltage

V

24

Capacity

Ah

80

.5.

(Continued Table 1.1) Model Item Type

Four components, single stage, three-phase

Model

Z420-3

Torque ratio

3.4

Operation mode

Hydraulic control

Driving system

Torque converter

Transmission

Gear ratio

FORWARD I

1.829

FORWARD II

0.65

BACKWARD I

1.829

BACKWARD II

0.65

Type

Spiral bevel gear

Gear ratio

4.875

Type

Planet gear

Gear ratio

4.25

Prime reduction Reduction gear Secondary reduction Differential mechanism Steering angle

Semi-axle gear

Straight tooth bevel gear (2)

Planet gear

Straight tooth bevel gear (4)

Inside

78°

Outside

52°40ƍ

Steering system

The diameter of steering wheel

.6.

mm

Type Cylinder diameter × Quantity Power steering

CPCD50SA/60SA

Cylinder stroke

The pressure of safety valve The flow capacity of diverter valve The camber angle of tire

320 Hydraulic power steering

mm

100×1 148.5

MPa

8.5

L/Min

22

Degree

1°

(Continued Table 1.1) Model

CPCD50SA/60SA

Item Type

Float shoe brake

The diameter of brake drum

Braking system

Foot brake

Accumulator Vacuum system

Handbrake

Hydraulic system

Oil pump

Control valve Diverter valve

The diameter of braking main pump The dimension of brake shoe (length × width × quantity) Amplification ratio

22.2

mm

343×90×2 3

Adjustment of pressure

The height of -500̚-700 mercury column (mm) Spring

Type

Mechanical – internal expanding

Vacuum

The diameter of brake drum The dimension of brake shoe (length × width × quantity) Type

203 mm

216×50×6.7×2 Gear

Model Discharge capacity

CBF-E80 mL/r

80.4

Drive

Torque converter

Model

ZSI-L25E-T-AO

The pressure of safety valve

MPa

Model Flow capacity Cylinder diameter

The oil cylinder for lifting

317.5

Stroke

1WFL-F25L L/Min

Cylinder diameter Stroke

Quantity The capacity of hydraulic oil tank

160 90

mm

Quantity The oil cylinder for tilting

14

1500 2 100

mm

217 2

L/Min

90

.7.

(Continued Table 1.1) Model

Operation devices

Item The type of gantry mounting The outside gantry The dimension of gantry mounting mounting (diameter of trolley × base plate × The inside gantry side plate) mounting Type The main trolley Diameter × width Side trolley Leaf jack chain

Pitch Breaking load Fork (length × width × height) The adjustment range of fork (outside)

.8.

Model of CI 130×20×25 mm 130×20×25 Ball bearing mm

Type Diameter × width

CPCD50SA/60SA

130×40 Needle roller

mm Kg mm

52×36 31.75 18600 1220×150×65 300̚1600

(IV)

The curve drawing of load

(Figure 1.1) The load curve drawing for the forklift of 5 ton

(Figure 1.2) The load curve drawing for the forklift of 6 ton

.9.

Chapter 2

The Driving System

(I) General: This chapter is used to introduce the disassembly step and maintenance of engine bus, torque converter and transmission.

(II) The disassembly of driving system: 1.

Disassembly :( Figure 2.1)

1. Roof of protection rack 2. Engine hood 3. Crossbeam 4. Base plate, crossbeam and accelerator pedal 5. Braking main pump, braking pedal and inching pedal 6. Air filter 7. Battery 8. Cooling rubber hose 9. Exhaust pipe 10. Hose for connecting gear pump 11. Driving shaft 12. Anchor bolt 13. The transmission of engine torque converter Figure 2.1

1.

The disassembly and assembly for the transmission of engine torque converter 13: (Refer to the Figure 2.2) As shown of figure 2.2, hang the transmission of engine torque converter out of the frame body.

2. Assembly Implement according to the reverse steps of disassembly. Hang it into the frame body when the transmission of engine torque converter is assembled as a whole body, and then maintenance according to the following steps. a. Fill the anti-rusting agent and anti-creaming agent recommended to the cooling system. b. Fill the correspondent oil to the torque converter, transmission and driving axle according to the regulation. c. Empty the air of braking system.

. 10 .

d. e.

Check the oil level of oil tank whether is accordance with the standard.

Start the engine and observe whether the operation is stable (adjustment of bolt is available).

Figure 2.2

(III) 1. a. b. c. d.

2. a. b.

The disassembly of engine:

Disassembly: Turn the crank of engine and disassemble the connecting bolts between connecting plate and flywheel.

Hang the transmission of engine torque converter out of the frame body.

Disassemble the connecting bolts between the shell of torque converter and the shell of engine flywheel.

Place the transmission of torque converter levelly and separate the engine and transmission of torque converter.

Assembly and maintenance Check the bearing operation of connecting flange whether is stable.

Fasten the connecting bolts between the shell of torque converter and the shell of engine flywheel, the connecting plate and the flywheel with the regulated tightening torque.

. 11 .

Chapter 3

The Transmission of Torque Converter -

(I) General (Figure 3.1)

BACKWARDĉ

BACKWARDĊ

Oil pump

Clutch assembly

Input shaft

FORWARDĉ FORWARDĊ

Output shaft

The power transmission line (The teeth of gear) Gear Speed ratio FORWARD I A (35) ĺF (64) 1.829 FORWARD II C (60) ĺH (39) 0.65 BACKWARD I B (62) ĺG (62) ĺD 1.829 (35) ĺF (64) BACKWARD B (62) ĺG (62) ĺE 0.65 II (60) ĺH (39)

FORWARD 1 FORWARD 2

BACKWARD1 BACKWARD 22

Figure 3.1 The Transmission of Torque Converter is single-stage, four-component and 3-phase. The transmission is connected with the torque converter integrally. There are 5 sets of multi-disc friction clutches, and the control oil circuit will drive the clutch to realize two speeds (forward/ backward) for the forklift.

. 12 .

1.

The sketch drawing of hydraulic oil circuit: (Figure 3.2) (Figure 3.3)

Figure 3.2

Figure 3.3

. 13 .

2 Torque converter (1) The sketch drawing of the structure (Figure 3.4)

1.

2.

3.

4.

5.

6.

7.

8.

Connecting flange Connecting plate The shell of torque converter Turbine Guider Impeller Hollow shaft Turbine shaft (driven shaft)

Figure 3.4

(2) The sketch drawing of oil circuit: (Figure 3.5)

Figure 3.5

. 14 .

3 Transmission (part sectioned view) (1) The sketch drawing of the structure (Figure 3.6)

1.

4.

7.

10.

Gear External friction disc Gear Bearing

2.

5.

8.

Figure 3.6 Platen Piston Piston

3.

6.

9.

Internal friction disc Clutch hub The spring base

(2) The sketch drawing of oil circuit: (Figure 3.7)

Figure 3.7

. 15 .

4.

Shift valve (Figure 3.3) (Figure 3.9)

1. Shift valve lever 2. Dust ring 3. Valve body 4. Adjusting screw 5. Spring 6. Steel ball 7. Inching valve lever 8. Piston 9. Block

Figure 3.8

Figure 3.9

The assembly of shift control valve is composed of shift control valve and inching valve. Five positions equipped in shift control valve to make the forklift forward and backward with two kinds of speed respectively and with neutral position. The gear stay at the neutral position when start the engine and the inching valve equipped with two positions of on and off, move the lever to make the forklift forward and backward with low speed.

(1) The pressure oil flow to the oil circuit of “BACKWARD I” to make the forklift backward with lower speed when the inching valve lever is on the position of “ON” and the shift control valve is on the position of “BACKWARD I”. (Fig. 3.10)

Figure 3.10

. 16 .

(2) The forklift will stop because of the pressure oil will not affect on the clutch even if move the shift control lever to any positions (means forward or backward) when the inching valve is on the position of “OFF” i.e. the pressure oil from the oil pump is switched off. (Figure 3.11)

Figure 3.11 5

Pressure adjusting valve: (Figure 3.12) 1

Lever of main pressure adjusting valve

2

Valve body

3

Spring base

4

Outer spring

5

Inter spring

6

Pressure adjusting valve lever of torque converter

7

Spring

8

Sealing gasket

9

Adjusting screw

Figure3.12 The pressure adjusting valve is composed of main pressure adjusting valve and pressure adjusting valve of torque converter. The oil from oil pump is supplied to the torque converter by passing main pressure adjusting valve. The hydraulic oil will maintain certain back pressure which from the torque converter by passing the main pressure adjusting valve of torque converter in order to guarantee the main torque converter operates normally.

(1) The hydraulic oil outlet from the oil pump will enter into the upper pressure adjusting valve by passing entrance 1 and be supplied to torque converter by passing entrance 3 in order to achieve the aim of pressure adjustment by changing the channel of valve body; the position of damping hole contained in the end of high pressure lever will be determined by the main pressure adjusting valve lever with the pressure difference of spring and two ends. (Figure 3.13) (2) The pressure difference on two ends of valve lever will overcome the spring force to make the valve lever move to the right and change the position of valve lever, then connect to the channel 4 of oil tank to outlet the hydraulic oil by channel 4 which add at the output of pump in case the pressure of the pressure oil that outlet from the oil pump increase. (Figure 3.14) (3) The oil from the torque converter will affect on the pressure adjusting valve lever to make it move forward along the arrow by pressure, and adjust the pressure according to the size of channel 3; the pressure adjusting valve lever will move to the right by the action of pressure and connect to the oil circuit of transmission clutch to make the oil flow to oil tank by passing clutch which come from torque converter. (Figure 3.15) . 17 .

(Figure 3.13)

(Figure 3.14)

(2) The disassembly of components: 1

Gear pump, oil filter and filter screen: (Figure 3.16)

1 Oil filter, cover and O-ring

2

Air filter, pipe and bolt

3 Oil gauge

4

Eyebolt

5 Oil pipe

6

Oil pipe

7 Assembly of oil filter screen

8

Oil pump

9 Drain plug

. 18 .

2 Torque converter (1) Disassembly: (Figure 3.17)

1

Drain plug

9

Guider, sleeve and roller

2

Connecting plate, connecting flange,

10

Impeller, O-ring and spring retainer ring11. Shell

gasket and O-ring 3

Retainer ring and cylindrical pin

11

Shell

4

Retainer ring

12

Clamp, locking gasket and bolt

5

Shell of driver and turbine

13

Medium shaft

6

Semi-cycle

14

Medium gear, bearing and springretainer

7

Turbine

8

shaft,

spring

retainer

ring

ring,

bearing and gasket

15

Hollow shaft and gasket

Round nut, thrust gasket

16

Bearing, gear shaft and O-ring

(Figure 3.17)

. 19 .

9 The disassembly of guider: (Figure 3.18) As the shown of figure, hold the guider by hands, lift the guider slightly while rotate the guider anticlockwise alone the joint surface of hollow shaft in order to avoid the falling of roller in it.

(2) Assembly: (Figure 3.19)

ķ

Turbine shaft and hollow shaft

ĸ

Medium shaft

Ĺ

Mpeller, turbine and guider (torque converter)

ĺ

Connecting flange and connecting plate

Ļ

Gear shaft

(Figure 3.19) (3) a b c d e

f

The assembly of torque converter: Assemble all the springs and spring bases into the eye of spring of overdrive clutch.

Assemble the sleeve of one-way wheel Assemble the roller with pressing the spring by sheet. (Figure 3.20) Guarantee the sleeve of one-way wheel rotates along only one direction after assembly.

Measure the connecting plate whether is deformation after the assembly of torque converter and replace the connecting plate if the jumpiness value is grater than 0.5mm (difference between the maximum depth and minimum depth). (Figure 3.21) Measure the depth between the joint surface of torque converter and connecting plate in order to guarantee the dimension of 10±0.4mm and the depth variation shall be less than 0.5mm.

(Figure 3.22)

Figure 3.20 . 20 .

Figure 3.21

Figure 3.22 4

Figure 3.23

The assembly of connecting flange

Guarantee the fitting signs of connecting flange and connecting plate are alignment.

3

Transmission

(1) Disassembly: a.

Output shaft: (Figure 3.24)

(Figure 3.24)

. 21 .

b.

Medium shaft: (Figure 3.25)

1

Gasket and the cap of medium bearing 7

Bearing and bush

2

Collar and anchor ring

8

Retainer ring, bearing and gear

3

Medium shaft

9

Retainer ring, anchor ring and spring

4

Round nut and locking nut

10

Retainer, baffler, inter frication disc and outer frication disc

5

Bearing and bush

11

Piston and piston ring

6

O-ring

12

Sealing ring and clutch hub

(Figure 3.25)

10 The disassembly of frication disc: Compress the spring by pressing the anchor ring with pressing machine; disassemble the collar in order to disassemble the frication disc. (Figure 3.26)

(Figure 3.26)

. 22 .

c.

Output shaft: (Figure 3.27)

1

Gasket, the cap of medium bearing

8

Retainer, anchor ring and spring

2

Round nut and locking nut

9

Retainer, baffle, inter frication disc and

3

Input shaft

outer frication disc

4

Shaft nut and bush

10

Piston and piston ring

5

Retainer and anchor ring

11

Sealing ring and clutch hub

6

Retainer ring

12

O-ring

7

Bearing, retainer ring and gear (Figure 3.27)

10

The disassembly of frication disc: (Figure 3.26)

(2) Assembly: (Figure 3.28) The assembly of clutch (frication disc): Press the anchor down by pressing machine. Compress the spring and install the retainer ring (Figure 3.29).

The quantity of frication disc and assembly shall be accordance with the requirements of drawing and replace the outer frication disc when the inter frication disc is damage. (Figure 3.30)

. 23 .

1 The assembly of clutch hub (input shaft) 2 Input shaft, collar and anchor ring 3 Retainer ring, bearing, round nut and locking plate 4 Gasket, the cap of input bearing 5 The assembly of clutch (medium shaft) 6 Medium shaft, bearing, anchor ring and collar 7 Bearing, bush, round nut and locking plate 8 The cap of medium bearing and sealing ring 9 Bearing, ratio gear of Gear I, ratio gear of Gear II 10 Output shaft, bearing, bush and retainer ring 11 Bearing, retainer, gasket and locking plate 12 Output flange, oil seal and cap of output bearing

(Figure 3.28)

(Figure 3.29)

. 24 .

(Figure 3.30)

4

Shift control valve: (Figure 3.31)

1 2 3

Positioning bolt, nut and spring ball Gasket and plug Dust ring and shift control valve lever

4 5 6

Pin, gasket and plug Dust ring and inching valve lever Gasket, plug (The switch of reversing lamp)

(Figure 3.31) 5

Pressure adjusting valve: (Figure 3.32)

1.

2.

Plug Spring base, outer spring and inter spring Gasket and plug The main pressure adjusting valve lever

3.

4.

5.

6.

7.

8.

Gasket and plug Pressure adjusting screw Gasket and plug The pressure adjusting lever of torque converter, gasket and spring (Figure 3.32)

. 25 .

(3) Check and adjustment: 1.

(1) a b c d (2) a b c d e f (3) a b c (4) a b c (5) a b c d (6) a

(7) a 2.

(1) a b c (2) a b (3) a b

. 26 .

Torque converter Impeller: (Figure 3.33) Whether the blades of impeller are crack or damaged.

Whether the connecting bolts between driver shells are fastened and the joint surface whether is oil leakage.

Whether the joint surface between the gear and oil seal and the oil seal are damaged.

Whether the joint surface between the gear and sealing ring, and the sealing ring are damaged.

Guider: (Figure 3.34) Whether the blades of guider are crack or damage.

Whether inter and outer sleeves of one-way wheel are abrasion or damaged.

Whether the spring base and spring are abrasion or crack.

Whether each roller is abrasion or deformation.

Whether the spline for inter and outer sleeve of one-way wheel are damaged.

Whether the gasket is abrasion or with other damage to affect its use.

Turbine: (Figure 3.35) Whether the blades of turbine are crack or damaged.

Whether the fitting of turbine and turbine hub are appropriate.

Whether the spline of turbine hub is damaged.

Turbine shaft: Check the each dimension of bearing whether is abrasion.

Whether the spline is abrasion.

Check the sealing ring groove whether is abrasion or damaged.

Hollow shaft Check the fitting of shaft and bearing.

Whether the spline is abrasion or damaged.

All oil circuit shall be clean, clear and without block.

Check the sealing ring groove whether is abrasion.

Connecting plate: Check the connecting plate whether is crack or damage and check its deformation whether is greater than the standard.

Connecting flange: Check the guiding end (assemble to the flywheel center of engine) whether is abrasion or damaged.

Transmission: Input shaft, medium shaft and output shaft: Whether the splines of each shaft are abrasion or damaged.

Whether each sealing groove is abrasion or damaged alone the direction of width.

All oil circuit shall be clean, clear and without block.

Gear: Check each gear.

Whether the fitting surface to bearing is abrasion or damaged.

Clutch hub: Check the sliding surface of frication disc whether is abrasion or damaged.

Check the sliding surface of piston whether is abrasion or damaged.

(Figure 3.33)

(Figure 3.34)

(Figure 3.35)

(4) Frication disc: (Figure 3.36)

(Figure 3.36)

(Figure 3.37)

a

Whether with the appearances of binding, contact unevenly or excessive abrasion. b Check the spline whether is abrasion or damaged.

(5) Piston: (Figure 3.37) a The piston can rotate and the ball on the piston can move freely.

Note: Do not disassemble the piston only if the piston with fault. b Check the sealing ring and the setting groove whether are abrasion or damaged.

(6) Bearing cap: a Check the joint surface whether is damaged.

(7) Filter screen: a Check it whether is blocked or crack.

(8) The measurement of backlash: (Figure 3.38) a Place a fuse on the engaging place of two tooth surfaces and rotate the gear to collapse the fuse. b Measure the collapsed fuse by micrometer in order to determine the backlash.

3. Shift control vale: a Whether each oil circuit is without block. b Whether valve lever is abrasion, damaged or binding. c Whether the lip of oil seal is damaged. d Whether the positioning ball and the surface of ball base of shift control valve are damaged. e Whether the throttle orifice of inching valve is clear.

4. Pressure adjusting valve: a Whether each oil circuit is clean and throttling. b Check the valve body and valve lever whether is abrasion or damaged. c Whether each spring is accordance with the requirement of design and is damaged.

5. Gear pump: a Check the clearance between the pump gear and the body. (Figure 3.39)

. 27 .

b c

Check the clearance between the ends of gear (axial clearance). (Figure 3.40) Check the backlash of gear.

6. a.

The measurement of oil pressure: (Figure 3.41) Connect the oil gauge (measuring range of 20Kg/cm2) to the pipe joint. b. Check the oil level in oil tank. c. Increase the temperature of oil to 60°C to 90°C. d. Start the engine.

Note: The rotation velocity standard n-1000 to 1500 r/min. Adjust the rotation velocity when it exceeds the range. e. Switch on the inching valve and move the shift control valve to each gear position and measure the oil pressure.

Unit: kg/ cm2 Item Standard value Limit value Upper limit:15 Main pressure 8̚13 Lower limit :8 The output pressure of torque Upper limit:3 2.5̚2.7 Lower limit :0.8 converter Note: The data sheet is measured in the circumstances of engine idle and oil temperature of transmission of 60°C to 90°C. 7. The measurement of stall: a Check the oil in the transmission whether is accordance with the regulated standard. b The oil temperature of transmission is 60°C to 90°C. c Brake the front and rear wheels and pull the handbrake. d Start the engine to the idle state.

. 28 .

e

Move the shift lever to the Forward I and trample the acceleration (accelerator) pedal gradually, and then measure the stall rotation velocity by tachometer.

Note: Do not trample the automatic pedal and do not make the engine continue to operate at the maximum rotation velocity, and the stall operation shall be limited within 30 second without long time in order to avoid the damage of torque converter components. f Measure the stall rotation velocity for other gear situations with the same methods.

Note: The allowable rotation velocity for stalling at any gear shall be with ±100 r/min. g The stall rotation velocity is less than the regulated value: I Check the acceleration (accelerator pedal).

II Check the main pressure and the output pressure of pressure adjusting valve of torque converter whether are accordance with the data sheet. h The overdrive clutch of torque converter is fault if the above requirements are accordance with that of sub-clause g. i The overdrive clutch is slipping if the stall rotation velocity is greater than the regulated value.

8 The measurement for the acceleration of 10 meters from start: a Engine with idle and move the shift lever to neutral gear. b Move the shift lever to the forward gear according to the order; meanwhile always trample the acceleration (accelerator) pedal. c Measure the time when drive to 10 meters.

9 Inching pedal (Figure 3.42) a Adjust the braking pedal correctly. b Adjust the height (relative to the base plate) A of inching pedal to the correct value by positioning screw 1 in order to guarantee the clearance B between the inching pedal and braking pedal is correct. c Adjust the length A of pull rod to the correct value and guarantee the stroke D (measure from the end of inching valve) of inching valve is correct. d Adjust the length C of pull rod if the stroke D is not correct. e Start the forklift, trample the inching pedal and guarantee the stroke E of inching valve is correct. f Adjust the clearance B of not greater than 1 mm with positioning screw 1 if the stroke E is not correct. g Adjust the wheel braking system (adjust the clearance between brake shoe and the brake drum) and then adjust according to the above steps of sub-clause a ~ f, if the value of A, B, C, D & E are still not correct after the correct adjustment. (Reference to the table 12.1 for A, B, C, D & E)

(Figure 3.42)

. 29 .

Chapter 4

The Driving Axle and Differential Mechanism

(1) General: (Figure 4.1)

1 2 3

Hub The shell of driving axle Semi-axis

Driving spiral bevel 6 The shell of reducer 7 Carriage gear 5 Driven spiral bevel gear Figure 4.1 The power will be transmitted to driving axle by passing transmission from engine to drive the driving wheel (front wheel), the driving axle contains two-stage reductions, first of driving spiral bevel gear and the other of wheel planet reducer.

The semi-axle is the type of full floating and is used to transmit the torque only; the driving spiral bevel gear that engage with the driven spiral bevel gear is support by two taper roller bearings and with a roller bearing at the front end; in the differential mechanism, four differential gears are installed on the joint spider respectively which engage with two semi-axle gears that installed on the semi-axle with connecting by spline.

The straight sun wheel (sun wheel integrate with semi-axle) installed outside of the semi-axle engage with three planet gears; and each planet gear is installed on its axle respectively, the shaft locked on the planet gear carrier with steel ball and the planet gear carrier connect with the hub by bolts as a integrality, the rim is installed on the hub.

Three planet gears engage with the annular gear that anchored on the driving axle by spline so that the annular gear can not rotate. The torque from the semi-axle is transmitted to the planet gear and then to planet gear carrier by passing sun wheel, finally to hub to accomplish the secondary reduction.

The hub is supported by two taper roller bearings on the driving axle and connects to the brake drum by bolts; the brake drum, hub, planet gear carrier and the rim connect as integrality.

There is a bush between the planet gear and shaft, the lubrication oil flow to the bush to form oil film by passing the oil channel in order to guarantee the lubrication of planet gear.

. 30 .

4

And there is a reservoir between the planet gear carrier and the end cover in order to avoid the oil leak and guarantee the lubrication of planet gear reduction mechanism.

(2) Disassembly: (Figure 4.2)

1 2

Fork frame Gantry mounting

3 4

Driving axle Brake oil pipe

5 6 7

Braking cable Driving shaft Driving axle

Figure 4.2

7 The driving axle: (Figure 4.3) Hang the front part of forklift and lay the wood under it, disassemble the connecting bolts between the support plates and the frame on both sides and then disassemble the driving axle.

Figure 4.3

. 31 .

(2) Disassembly: (Figure 4.2) 1. The driving axle: (1) Disassembly: (Figure 4.4)

1 2 3

Plug, gasket Bolt, gasket and end cover Steel ball, shaft, planet gear carrier, O-ring, planet gear, bush and retainer ring

4 5 6 7

Semi-axle, semi-axle gear Locking nut, locking plate and bolt Annular gear, retainer ring Brake drum and hub system

8

Bolt, diverting device, oil seal and brake drum 9 Bearing and hub 10 O-ring and guard ring of oil seal 11 Spacer

Figure 4.4 Note: Do not disassemble the whole driving axle when disassemble the hub and the components of planet reducer.

(2) Assembly: (Figure 4.5) 5 Brake drum and hub: As shown of the arrow in the figure, the hub shall align to the air drain groove on the brake drums.

(Figure 4.6) 7 The adjustment of hub bearing: (Figure 4.7) . 32 .

Figure 4.5 1 2 3 4

The shell of driving axle Braking system Guard ring of oil seal Bearing

Figure 4.6

5 6 7

Brake drum and hub assembly Shell of shaft Nut of annular gear

8 9

Semi-axle, planet gear and shaft End cover

Figure 4.7

2 Differential mechanism and main reducer: (1) Disassembly: (Figure 4.8) Note: Record the clearance between the driving and driven spiral bevel gear before disassembly in order to refer when re-assembly. It is not necessary when replace couple gears.

. 33 .

(2) Assembly: (Figure 4.9)

1 2 3 4 5 6 7 8

Thrust gasket, locking plate and bolt (Adjusting) nut Bearing cap, locking plate and bolt Carriage Bearing and shell of differential mechanism (Left) Gasket and semi-axle gear Joint spider, gasket and planet gear Gasket and semi-axle gear

9 10 11 12 13 14 15

Figure 4.8

. 34 .

Bearing, shell of differential mechanism (right) and driven spiral bevel gear Gasket, nut Brake drum Hub Oil seal, gasket, bearing, bearing seat and adjusting gasket Retainer ring, bearing driving spiral bevel gear Bearing and gasket

1

Driven spiral bevel gear and the shell of differential mechanism (right) 2 Joint spider, differential gear and semi-axle gear 3 Differential mechanism assembly 4 Bearing 5 Bearing seat, (adjusting) nut, blocking plate 6 Bolt and locking plate 7 Bearing, driving spiral bevel gear 8 Oil seal 9 Carriage and bearing seat 10 Bearing

Figure 4.9

3 a

Differential mechanism assembly: Place the differential mechanism assembly (includes two bearings and the driven spiral bevel gear anchored on the right shell of differential mechanism) on the carriage. b Temporarily anchor the left and right bearing cap and adjust the clearance between the driving spiral bevel gear and driven spiral bevel gear by (adjusting) nut.

Note: Assemble the bearing cap and carriage according to the method b and notice the sign, mark the new component when replace.

4 The adjustment of bearing: Adjust the pre-tightening load of bearing on both sides, the clearance between driving spiral bevel gear and driven spiral bevel gear until they are appropriate. a Hook the shell of differential mechanism by spring balance and fasten the left and right (adjusting) nut with the pre-tightening load of 2.6 to 3.5 Kg force. (Figure 4.10) b The pre-tightening load of left and right (adjusting) nut shall be the same and guarantee their pre-tightening load.

Measure the clearance between the driving spiral bevel gear and driven spiral bevel gear. Contact the big end of driven spiral bevel gear with the contact finger of dial gage, anchor the driving spiral bevel gear, then rotate the driven spiral bevel gear forward and backward, check the readings of pointer. (Figure 4.11) (Table 4.1)

. 35 .

Item Clearance between driving spiral bevel gear and driven spiral bevel gear

Table 4.1 Standard value

Limit value

0.25̚0.35

0.5

c Measure the end jumpiness of driven spiral bevel gear.

Contact the surface of maximum diameter at the back of driven spiral bevel gear with the contact finger of dial gage, it is necessary to fasten the bolts that connect to the shell of differential mechanism and driven spiral bevel gear if the jumpiness of gear is greater than 0.15mm when rotate.(Figure 4.12) (Table 4.2) Table 4.2 Item Standard value Limit value Clearance between driving spiral bevel 0.15 0.2 gear and driven spiral bevel gear

Figure 4.11

5

Adjustment for the contacting area of serration: a Paint some red lead on the serration of driven spiral bevel gear and rotate the gear pair to make the red lead distribute evenly on the serration in order to check the contacting area of serration(both surface of convex and concave). (Figure 4.13) The requirements for the contacting area shall be 50% to 70% along the direction of length and greater and 50% along the direction of height. The contacting area refers to the figure 4.14 and shall be without other formal defects. b. Adjustment: I. Move the driving spiral bevel gear along the direction B and the driven spiral bevel gear along the direction A until find an appropriate contacting area in order to guarantee the backlash if the contacting area is small and deflect to the big end.

(Figure 4.15) II. Move the driving spiral bevel gear along the direction B and the driven spiral bevel gear along the direction A until find an appropriate contacting area in order to guarantee the backlash if the contacting area is small and deflect to the small end.

(Figure 4.16)

. 36 .

Figure 4.12

6 a

The bolt of bearing seat: The tightening torque of bolt shall be 166N•m and lock the bolt by locking plate in order to avoid the looseness of bolt. b Check the pre-tightening load of bearing after the adjustment of contacting area; and lock the bolt by locking plate in order to avoid the looseness of bolt; anchor the blocking plate with bolt if the pre-tightening load is appropriate.

7 Measurement for the pre-tightening load of bearing: Disassemble the driving spiral bevel gear (include all the components of the assembly) and measure the pre-tightening load, the value shall be as 80% of the standard. (Figure 4.17) 8 Oil seal: This oil seal is the type of double lips. Apply the grease between double lips of oil seal, the side with spring near the bearing and the dust lip near one side of hub when assemble.(Figure 4.18)

Figure 4.17

Figure 4.18

9 Determination of adjusting gasket: Determine the thickness of adjusting gasket according to the data of X, Y and A. (Figure 4.19) X: The distance from the internal side of bearing seat to the external end of inner loop of bearing.

Y: The distance from the center of differential mechanism to the external end of bracket.

A: The distance from the center of differential mechanism to the big end of driving spiral bevel gear. a Measure the actual size of X and set the X to be the discrepancy if the nominal size is 0.2mm i.e. the discrepancy is 0.2mm.

. 37 .

b

We can get some data at the small end of driving spiral bevel gear. e.g. +0.2 means the actual size is greater than nominal size with 0.2mm.And set this discrepancy as a. (Figure 4.20) c Mark the actual discrepancy X on the edge of bracket flange with the unit of 1/100 mm. e.g. +10 means the actual size is greater than nominal size with 0.1mm.And set this discrepancy as y. d Minus the thickness of adjusting gasket. (Table 4.3) S=2.5+x-y+a Formula: Front side: x==0.2, y=0.1, a=0.2 Substitute the above data in the formula: S=2.5+0.2-0.1+0.2=2.8 Select one group gasket to meet the above size.

Item S (thickness of gasket) X Y A

Table 4.3 Nominal size 2.5 51 226.5 178

10 The application of viscose glue: a Clean the internal bore and external ring of bearing on the carriage with alcohol or other alkaline solutions with volatility and dry. (Do not clean them with fixed solutions such as gasoline, diesel and kerosene) b Paint some viscose glue evenly on the external ring of bearing bore on the carriage with brush or sponge (about 0.2mL). (Figure 4.21) c Install the bearing on the bearing bore immediately. d Place it for 30 minutes to 2 hours after the above treatments.

(4) Check and adjustment: 1 Semi-axle: a Check the abrasion of spline. (Figure 4.22) Install the semi-axle gear on the semi-axle and anchor the semi-axle, push the serration of semi-axle gear with contact finger of dial gage, rotate the semi-axle gear along the direction of forward and backward then check the readings on the dial gage. b Check the diameter jumpiness of semi-axle: (Figure 4.23) Place the semi-axle on two V iron blocks and check the diameter jumpiness on the surface of spline and the medium part of semi-axle in order to adjust.

. 38 .

Discrepancy x y a

Figure 4.22

2 a b c d e.

3 a

4 a b c d e

Figure 4.23

Driving axle: Check the abrasion and damage on the surface of guard ring of oil seal.

Check the abrasion and damage of oil seal.

Check the abrasion and damage on the fitting parts of driving axle connecting plate and gantry mounting bush, body connecting plate and gantry mounting bush.

Check the deformation and damage of whole axle shell especially the welding parts and repair immediately if there are cracks.

Check the abrasion and damage of the planet gear (joint spider) and annular gear.

Driven spiral bevel gear: Check the appearances such as surface abrasion, pitting and ablation. Abrade and repair for the slight damage parts with the tool of oilstone; and replace the driving spiral bevel gear pair and driven spiral bevel gear pair for the serious damage parts (the gear pair shall be selected).

Differential mechanism: Check the damage of the shell of differential mechanism especially the damage extent of the fitting part with bearing on both sides.

Check the loss and damage of sliding gaskets of semi-axle gear and planet gear. (Figure 4.24) Check the fitting clearance between the differential mechanism gear and semi-axle gear.

Check the fitting clearance between the joint spider and differential mechanism gear.

Assemble the differential mechanism and check the engaging clearance with dial gage or fuse.

Figure 4.24

. 39 .

Chapter 5

The Steering System

(1) General: (Figure 5.1)

1 2

Connecting rod Steering oil cylinder

3 4

Steering axle body Steering knuckle

5 6

Main pin Hub

Figure 5.1 The steering axle adopts the welding structure. The steering axle realizes the action of rotation with the connecting of shaft on both sides of axle body and the frame. The steering knuckle connects to the steering axle body by main pin and the bearing installed on the steering knuckle to support the hub.

(2) Disassembly: (Figure 5.2) 1 a b 2 a b 3 a b

. 40 .

Wheel: Pull the handbrake lever.

Push up the tail of forklift and lay the wood under it, and then disassemble wheels. (Figure 5.3) Balance weight: Disassemble the anchoring bolt of balance weight. Disassemble the wires of tail lamp from their relevant terminal.

Hang the balance weight out of the forklift. (Figure 5.4) Steering oil cylinder: Disassemble the oil pipe and bolt. (Figure 5.5) Disassemble the nut, pin.

5 a

The assembly of steering axle: Disassemble the bracket in order to disassemble the steering axle. (Figure 5.6)

Figure 5.2

(3) The disassembly of components:

Figure 5.3

Figure 5.5

Figure 5.4

Figure 5.6

. 41 .

1

Disassembly: (Figure 5.7)

1 2 3 4

Rim, locking nut and thrust gasket Hub, taper roller bearing, oil seal and hub bolt (use pulling tool) Split pin, notched nut Nipple, pin, gasket, linking rod and knuckle bearing (do not damage the bearing when disassemble the bearing) Fastening screw, nut, main pin and nipple Thrust bearing and steering knuckle (do not damage the bearing when disassemble the bearing) and roller bearing Bolt and spring gasket Steering cylinder

5 6 7 8

Figure 5.7

. 42 .

1

Disassembly of locking nut (Figure 5.8)

Figure 5.8

6. Disassembly of roller bearing: (Figure 5.10)

Figure 5.10

2.

1. a. b.

2. a. b. c.

3. a.

2

Disassembly of hub (Figure 5.9)

Figure 5.9

6. Disassembly of steering knuckle: (Figure 5.11)

Figure 5.11

Assembly: (Figure 5.12) Steering knuckle (Figure 5.13) Apply the grease before assemble the one-way ball bearing and thrust surface of each bearing shall face upward.

Fasten the fastening screw according to the regulated force.

Hub: Assemble the bearing internal ring and external ring of bearing on the steering knuckle with special tools. (Figure 5.14) Assemble the oil seal. (Figure 5.15) Fill the grease to the space of hub and apply the grease on the lip of oil seal and the holder of roller bearing. (Figure 5.16) The adjustment for the load of hub bearing: Adjust the pre-tightening load of inner nut to regulated value and fasten the outer nut according to the regulated torque, then check the pre-tightening load. The pre-tightening load can be 1/2 of the regulated value if the inner bearing of hub is used for long-term. (Figure 5.17)

. 43 .

1.

2.

Connecting rod Steering oil cylinder

3.

4.

Steering axle Steering knuckle

5.

6.

Main pin Hub

Figure 5.12

Figure 5.13

. 44 .

Figure 5.14

Figure 5.15

Figure 5.16

Figure 5.17

(4) Check and adjustment: 1. Main pin and pin axle: The surface of pin shall be without scratching and the contact surface of bearing shall be without the appearance of sectional abrasion.

Note: Replace the roller bearing when replace the main pin and pin axle.

2. Steering knuckle: Check the main pin bore of steering knuckle whether abrasion or damaged, whether the pin bore hold the ball pin and whether the tapered bore is crack.

. 45 .

Chapter 5

The Braking System

(1) General: 1.

Foot brake: (Figure 6.1)

1.

Vacuum intensifier Air filter

2.

3.

4.

Brake pedal Brake main pump

5.

6.

Braking fluid tank Vacuum pump

7.

8.

Vacuum case Foot brake

Figure 6.1 The foot brake adopts the brake of automatic and vacuum intensifier driven by hydraulic. It can adjust the clearance automatically after the abrasion of brake strap. The brake shoe adopts the distribution of symmetry in order to guarantee the same brake action when forward and backward and enhance the brake efficiency.

The brake pedal and inching pedal are installed on the same shaft.

The brake main pump is installed behind the bracket of brake pedal and connects with the brake pedal by push-rod.

The vacuum intensifier drives the vacuum pump and enhances the brake force by the pressure difference of vacuum and air pressure. The vacuum case installed in the braking system can make the brake operations for some times after flame out of engine.

2. Handbrake: (Figure 6.2) The handbrake adopts the inner expanding brake with mechanical driven. The handbrake is installed between the driving axle and transmission shaft and the handbrake lever act by the brake cable.

. 46 .

3.

1.

Handbrake lever

2.

Brake drum assembly

3.

Handbrake cable

Foot brake pedal, brake main pump: (Figure 6.3)

1. Brake plate 2. Push rod 6. Valve core 7. Baffle 11. Rubber gasket 12. Pump body

3. Dust case 8. Leather cup

4. Collar 9. Spring

5. Leather ring 10. One-way valve

Figure 6.3 3. Vacuum intensifier: (Figure 6.4) The vacuum intensifier is composed of three components such as pumping chamber, auxiliary oil cylinder and control valve.

. 47 .

1.

2.

3.

4.

5.

6.

Outlet joint Auxiliary oil cylinder Ball valve Piston of auxiliary oil cylinder Push rod Membrane of pumping chamber (valve core) 7. Vent pipe 8. Shell of pumping chamber 9. Piston of control valve 10. Body of control valve 11. Hose

Figure 6.4

5.

Foot brake: (Figure 6.5)

1.

2.

3.

Assembly of branch pump Assembly of brake shoe Spring

Figure 6.5 6.

Handbrake lever: (Figure 6.6)

1.

2.

3.

4.

5.

6.

Lever cap Screw rod Lever Screw rod Connecting plate Bracket

Figure 6.6

. 48 .

7. Handbrake: (Figure 6.7)

1.

2.

3.

4.

5.

6.

7.

8.

Shield Retracing spring Brake shoe Support plate Adjusting spring Adjusting screw Tie-rod Support plate for fastening pin

Figure 6.7

(2) The disassembly of components: 1.

Main brake pump: (Figure 6.8)

1.

Fork case, nut and push rod Dust case Collar Valve core, baffle,

2.

3.

4.

5.

6.

leather cup and leather ring Spring One-way valve and rubber gasket

7.

8.

Joint, sealing gasket and clip Pump body

Figure 6.8 a. b.

Clean all the metal components by volatile cleansing solution and dry after disassembly.

Paint a layer of rubber lubrication oil on the inner chamber of pump body and leather cup when assemble the main pump.

. 49 .

2. Vacuum intensifier: (1) Disassembly: (Figure 6.9) a. Clean the dust with solvent and alcohol. b. Keep the clean of components after cleaning.

1.

2.

3.

4.

5.

6.

Clip and bend pipe Pipe cap, collar and valve spring Control valve assembly Auxiliary oil cylinder assembly Push rod Auxiliary piston assembly

Figure 6.9

. 50 .

7.

8.

9.

10.

11.

Bolt and nut End cover assembly Joint Retracing spring and O-ring Membrane assembly of pumping chamber 12. Shell of pumping chamber

(2) Assembly: (Figure 6.10)

1.

2.

3.

4.

5.

6.

7.

Pumping chamber assembly Auxiliary oil cylinder assembly End cover and sealing ring Auxiliary piston assembly Pumping chamber assembly, auxiliary oil cylinder assembly and auxiliary piston assembly Shell of pumping chamber, bolt and nut Control valve assembly

Figure 6.10 7. a.

b.

Control valve assembly: Two piston rings shall be installed according to the position as the figure shown. (Figure 6.11) The distance between the vacuum valve and air valve can affect the performance of control valve directly, and the fastening screw shall be fastened when install the vacuum valve and air valve.

(Figure 6.12)

Figure 6.11

Figure 6.12

Figure 6.13

. 51 .

4.

Brake branch pump: (Figure 6.14)

1.

2.

3.

4.

5.

Push rod and dust case Piston, leather cup and spring seat Spring Drain nipple and cap Pump body

Figure 6.14 5.

Handbrake: (Figure 6.15)

1.

2.

3.

4.

Handbrake drum 5. Gasket and bolt Spring 6. Shaft, tie-rod and gasket Plate 7. Shield and support plate assembly Brake shoe assembly, adjusting case and spring Figure 6.15

(3) Check and adjustment: 1. a.

b. c. d.

2. a.

. 52 .

Main pump: Check the pump chamber whether is rust, corrosion and scratching. The oil inlet and overflow vent whether is clean, the thread whether is integrity, and the dust shield whether is damaged.

Replace the piston when there is any damage. And check the radial clearance of piston and pump chamber whether is within the regulated range.

Whether the piston leather cup and rubber gasket are damaged. Replace the inflated leather cup.

All the sealing components shall be not used repeatedly and be replaced for each year or major repair.

Vacuum intensifier: Check the spring of control valve and replace it if it is not accordance with the regulated standard.

b. c.

Check the retracing spring and replace it if it is not accordance with the regulated standard.

Check the inner surface of valve whether is rust, corrosion, crack and damage. The piston clearance of control valve shall be appropriate, replace it if the clearance is out of standard. d. Check the ball seat of auxiliary oil cylinder whether is damaged. e. Check the push rod whether is corrosion, rust and deformation. f. Check the clearance between the auxiliary piston and cylinder whether is appropriate and replace it if the clearance is out of standard.

3. Foot brake: (1) Chassis: a. Check the chassis whether is crack. b. Fasten the connecting bolts of chassis with the regulated torque.

(2) Brake shoe: a. Check the brake shoe whether is crack. b. Replace the brake shoe if the frication disc with oil dirty, burnout or abrasion. c. Replace the frication disc if the thickness of disc is out of standard. (Figure 6.16)

Figure 6.16

Figure 6.17

I. Disassembly: Drill the head of rivet on the shoe disc by bit then take the frication disc off. (Figure 6.17) II. Assembly: Install the new rivets and fasten them.

Note: Install the frication disc on the shoe disc and check the rivet whether is higher than the frication surface, remove it if exist.

(3) Brake drum: Check the abrasion of inner frication surface of brake drum whether is uniform or with scratching, replace it if exist.

4. Brake branch pump: a. Check the inner chamber whether is rust, abrasion or scratching, replace it if exist. b. Check the piston whether is rust and scratching. And the radial clearance between the piston and cylinder body whether is within the regulated range. (Figure 6.18) c. The leather cup of piston whether is damaged. Replace the expanded leather cup and replace it for each major Figure 6.18 repair or each year, and the leather cup of piston shall be good when assembling the branch pump. d. Replace the dust case if it is aging, damaged and with other defects.

5. Handbrake: a. Check the shoe disc and frication disc whether is crack. b. Replace the brake shoe if the frication disc with oil dirty, burnout or abrasion. c. Replace the frication disc if the thickness of disc is out of standard.

(1) Brake drum:

. 53 .

(2) Adjusting case of clearance: Check the tooth whether is rust, and turn the rotation part by hand in order to check whether the rotation is smooth. (Figure 6.19) (3) Handbrake lever: Check the support pin and the pin bore of lever whether are abrasion, and replace the handbrake hood if necessary. Replace the wire cable which with permanent state of full length, serious rusty and damage.

6. Brake pedal: a. Check the pedal whether is crack and the bush whether with abrasion. b. Replace the matting of pedal if it is serious abrasion or damage.

7. Air exhaustion in the oil circuit of brake: Exhaust the air when disassemble any component of braking system during maintenance.

Figure 6.19 a. Exhaust the air according to the following steps: Vacuum intensifier ĺ Right branch pump ĺ Left branch pump. b. Connect one side of hose with the outlet of vacuum intensifier; the other side connects to the container filled with brake oil. c. Move the brake pedal for some times and trample it down, release the drain plug; fasten the drain plug when there is no air bubble (observe from the container).Repeat the above steps until brake fluid flow to the container only. d. Implement the above steps for each brake.

Note: There shall be brake fluid in the oil tank during the whole process of exhausting air. Adopt the regulated brake fluid and not to use the brake fluid which mix with other kind of brake oil.

8. Adjustment for the clearance between the brake pedal and brake shoe: (Figure 6.20) a. Adjust the length (L) of push rod of main pump to the right value. b. Adjust the height (A) of pedal by positioning bolt (1) and lock the positioning bolt. c. Adjust the clearance of brake shoe according to the following steps.

Figure 6.20 The value of A and B refer to table 12.3

. 54 .

I.

Turn the clearance adjusting case of foot brake clockwise until the brake shoe contact the brake drum, and then turn 2 to 3 teeth in anticlockwise. (Figure 6.21) II. Check the clearance between the brake shoe and brake drum. d. Trample the pedal down and check the idle stroke (B) whether is right. e. Adjust the length (L) of push rod in order to get the right rod clearance (C) if the value (B) is not correct.

Note: Do not push the piston of main pump.

9. Clearance adjustment of handbrake shoe: a. Move the forklift in order to make the service hole on the brake drum align to right of the bottom medium about 30 mm. b. Release the handbrake lever. c. Take the rubber plug off the service hole; turn the clearance adjusting case until the brake shoe contact to the brake drum. Turn 8 teeth along the opposite direction to get the right clearance between the brake shoe and brake drum. (Figure 6.22) d. Take off the rubber plug from dust shield and measure with feeler gauge when check the clearance.

Figure 6.21

Figure 6.22

. 55 .

Chapter 6

The Steering Control System

(1) General: (Figure 7.1)

1.

2.

3.

Steering wheel Hydraulic oil tank Hydraulic steering gear

4.

5.

6.

Diverter valve Gear pump Steering oil cylinder

Figure 7.1

The steering control system adopts the method of full hydraulic control and the steering wheel and rear wheel without mechanical connecting. Turn the steering wheel to drive the hydraulic steering gear to inject the hydraulic oil to the relevant chamber of steering oil cylinder, then to make the rear wheel rotate.

The hydraulic oil from gear pump is distributed to two oil circuits by passing diverter valve. One to steering system and the other to lifting oil cylinder and tilt oil cylinder.

1. Diverter valve: (Figure 7.2) M: Main outlet (flow to lifting oil cylinder), S: Steering oil outlet P: Oil inlet (flow to gear pump), T: oil return outlet (flow to hydraulic oil tank) The diverter valve is used to distribute the oil to hydraulic steering gear according to the regulated value regardless of the fluid volume of gear pump. The safety valve (2) is opened in order to distribute the oil with high pressure to the oil circuit connected with hydraulic oil tank while the oil pressure increase in the steering oil circuit.

(Figure 7.3)

. 56 .

1. Valve core

2. Safety valve

Figure 7.2

3. One-way valve

Figure 7.3 2.

3.

Full hydraulic steering gear: (Figure 7.4) Steering oil cylinder: (Figure 7.5)

1.

2.

3.

4.

Front cover Valve body Separated dish Stator case

5.

6.

7.

8.

Rear cover Retainer Spring plate Pin

9.

10.

11.

12.

Linking shaft Valve core Valve case Rotator

13. Limiter 14. Steel ball

Figure 7.4

Figure 7.5

. 57 .

(2) Disassembly: (Figure 7.6)

1.

2.

3.

4.

5.

6.

7.

8.

Pedal and bolt Rubber hose for high pressure Pipe Clip and rubber gasket Steering rod Switch for steering signal Steering wheel Steering oil cylinder

Figure 7.6 8. Steering oil cylinder: Push up the tail of forklift by jack and lay wood under the body on left and right sides, and then disassemble the steering oil cylinder.

(3) Disassembly of components: 1. Full hydraulic steering gear (1) Disassembly: (Figure 7.7)

1.

2.

3.

4.

5.

6.

7.

8.

Figure 7.7

. 58 .

Bolt and gasket O-ring, rear cover, stator case, rotator, limiter, separated dish and linking shaft Screw, oil seal, front cover and O-ring Retainer Valve case, pin and spring plate Plug and O-ring Ball base Valve body

1 Disassembly of bolt: (Figure 7.8) 5 Disassembly of valve case: a. Disassemble the valve case by rotating carefully because of the clearance of valve case and valve body is small. (Figure 7.9) b. Take off the pin, pull out the valve core and remove the spring plate. (Figure 7.10) c. Disassemble the valve core by rotating carefully because of the clearance of valve case and valve core is small.

Figure 7.8

Figure 7.9

Figure 7.10

Figure 7.11

6. Disassembly of plug: (Figure 7.11) (1) Assembly: (Figure 7.12)

1.

2.

3.

4.

5.

6.

7.

Plug, steel ball, ball base and spring Spring plate, pin, valve case and valve core Retainer Front cover and dust shield Separated dish Linking shaft Rear cover and bolt

Figure 7.13

Figure 7.12 1 a. b.

Spring: Set the biggest diameter end of spring face downward and then rotate the steel ball. (Figure 7.13) Check the steel ball whether place on the smallest diameter end of spring.

. 59 .

2 a.

b. c.

Valve core and valve case Apply a layer of clean hydraulic on the valve core, and then install the valve core into the case by rotating carefully. Rotate the valve core by hand and the rotation shall be smooth.

(Figure 7.14) Install the dust shield and place the front cover on the spline end of valve core. (Figure 7.15) Check all the surface of valve body whether contact with front cover in order to avoid the block of retainer.

Figure 7.14 Figure 7.15 6 Linking shaft, rotator: (Figure 7.16) Install the rotator of linking shaft after the alignment of pin groove and root of rotator. (Figure 7.17)

2.

Figure 7.16 Diverter valve: (Figure 7.18)

1.

2.

Plug, O-ring, valve core and spring Plug, O-ring and spring

Figure 7.17

3.

4.

Figure 7.18

Valve core, steel ball, ball base, gasket and spring Valve body

(4) Check and adjustment: 1. Hydraulic steering gear (1) Check the movement of valve core in the valve body and case whether is smooth. a. Whether the movement of valve core in the components is smooth. b. Disassemble the hydraulic steering gear and check the sliding surface whether is abnormal abrasion, rust and damaged if the movement of valve core is tacky or exist other defects.

Replace all the control valve assembly if the situation of the sliding surface is serious.

(2) Check the torque of spring plate: a. Measure the torque with spring balance. Anchor the steering gear, and block all the inlet and outlet of steering gear, hang the spring balance on the lever (with the distance of 19 mm to center), pull the spring balance to make the steering wheel rotate until the center position of valve core contact to spring plate and valve case (spring coincide).Check the readings on the spring balance while the steering wheel is rotating and calculate the torque. The installation of spring balance is appropriate if the readings of spring balance between 1 to 1.5 Kg. (Figure 7.19) (Table 7.1)

. 60 .

Table 7.1 Assembly torque of spring plate Relevant reading of spring plate

2±0.5 N·m 1 ~ 1.5 Kg

b.

Check the spring plate and sliding surface and determine whether they will be replaced if the measured torque is out of the regulated range.

2. The floating gap of steering wheel: (Figure 7.20) Check at the idle of engine. The rotation stroke of valve core shall be the same with the top side displacement of steering wheel edge because the steering wheel and the hydraulic steering gear adopt the semi-suspended connecting.

3. Steering force: a. Parking and brake. Start the engine to heat the hydraulic oil with the temperature of 40 ~ 60ć. b. Hang the spring balance on the edge of steering wheel and turn the steering wheel, check the readings of spring balance at the beginning of turning steering wheel.

Figure 7.19

Figure 7.20

. 61 .

Chapter 7

The Hydraulic System

(1) General: (Figure 8.1)

1.

2.

3.

4.

Hydraulic oil cylinder Diverter valve Gear pump Steering oil cylinder

5.

6.

7.

Tilting oil cylinder Lifting oil cylinder Control valve (multi-loop valve)

8.

9.

Throttle valve Hydraulic steering gear

Figure 8.1 The hydraulic system refers to the figure 8.1, one of the oil from oil tank flow to steering oil cylinder and the other flow to lifting oil cylinder and titling oil cylinder. Hydraulic steering gear, steering oil cylinder and diverter valve refer to the relevant introduction in control system.

1. Hydraulic oil tank: (Figure 8.2)

1.

2.

3.

4.

5.

6.

Figure 8.2

. 62 .

Filter Cover Return oil filter Sucking oil filter Oil gauge Drain plug

Filter the particulate impurity of oil by filter when fill oil to the tank. There are two filters in the oil tank, one of sucking oil filter and the other is return oil filter with overflow valve. The return oil hose connect to lifting oil cylinder.

2.

Gear pump: (Figure 8.3)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Rear cover Sealing gasket Bush Pump body Input shaft Gear shaft Bush Sealing ring Sealing gasket Front cover

Figure 8.3

3.

Control valve (Multi-loop valve) (Figure 8.4)

1.

2.

3.

4.

5.

6.

7.

Bracket Safety valve Return outlet Fastening bolt Reversal valve Tilting valve lever Lifting valve lever

Figure 8.4 This valve is composed of some reversal valves and equipped with safety valve. The control lever connects with valve core by pin.

. 63 .

4.

1.

2.

Lifting oil cylinder and tilting oil cylinder: (Figure 8.5) The lifting oil cylinder is single acting oil cylinder and equipped with throttle valve at the inlet of base.

The tilting oil cylinder is double acting oil cylinder and equipped with earring at the end of piston rod and connect with outer gantry mounting. Two tilting oil cylinders can implement the same movements to gantry mounting because of the rotation of earring.

Lifting oil cylinder

Tilting oil cylinder Figure 8.5 3.

Throttle valve: (Figure 8.6)

Figure 8.6

The throttle valve is installed between the lifting oil cylinder and control valve which with the functions of controlling the falling velocity of fork and controlling the flow capacity of throttle valve according to the different load in order to guarantee the fork with stable falling velocity.

. 64 .

(2) Disassembly of components: 1.

Gear pump: (Figure 8.7)

1.

2.

3.

4.

5.

Clamp and rubber hose Pipe, gasket and bolt Hose for high pressure O-ring, output oil hose and bolt Gear pump assembly

Figure 8.7 2.

Control valve (Multi-loop reversal valve): (Figure 8.8)

1.

2.

3.

4.

5.

6.

7.

8.

Pedal Tie-rod, U pin and split pin Oil pipe Oil pipe of lifting Oil intake pipe Clamp and rubber hose Bolt and gasket Control valve assembly

Figure 8.8

. 65 .

3.

Lifting oil cylinder: (Figure 8.9)

1.

3.

5.

Fork frame Bracket, clamp and nut Bolt and gasket

2.

4.

6.

Oil pipe Pin, gasket and split pin Lifting oil cylinder (double)

Figure 8.9

4.

Tilting oil cylinder: (Figure 8.10)

1.

2.

3.

4.

Figure 8.10

. 66 .

Rubber hose for high pressure Pin, gasket and bolt Pin, gasket and bolt Tilting cylinder assembly

5.

Throttle valve: (Figure 8.11)

1.

2.

Retainer ring Piston

3.

4.

Gasket and spring Collar and spring

5.

6.

Valve Sleeve and O-ring

Figure 8.11

(3) Check and adjustment: 1.

1. a. b.

2 a. b. c.

3 a. b. c. d.

e. f.

Control valve (multi-loop reversal valve): Valve body, valve core and retracing spring: Check the valve body whether is damaged and check the bore surface and safety valve whether are abrasion and damaged.

Check the sliding surface of each valve core whether is burnout, scratching or other surface defects and deformation, and the inner control force of valve core and valve body shall be not greater than the regulated value.

Outside leakage: O-ring installed each component of valve.

Seal ring and O-ring.

Thread.

Adjustment of safety valve: Disassemble the nut and loosen the locking nut, remove the adjusting screw.

Start the pump with low rotation speed which can bear the load with the regulated pressure.

Pull the lifting lever and the fork will not lift because of the adjusting screw is disassembled; turn the adjusting screw gradually until the lift action of fork.

Control the tilting lever forward and backward until the oil cylinder reach the terminal of stroke; fasten the adjusting screw gradually while check the readings of pressure gauge(forward or backward) until the readings reach the regulated value.

Fasten the locking nut and anchor it.

Check the safety valve whether discharge at the regulated value after the above adjustments.

. 67 .

2. a. b.

3. a. b. c.

4. a. b.

5. a. b.

. 68 .

Oil cylinder: Check the wall of cylinder whether is abrasion, crack, scratching and rust.

Check the welding seam whether is crack.

Piston rod: Check each piston rod whether is bending. (Figure 8.12) Check the piston rod whether with surface defects such as crack, scratching, rust and abrasion.

Check the thread of piston rod whether is damaged.

Replace it when damage.

Sealing ring: Check the edge of sealing ring whether is damaged and Figure 8.12 deformation.

Check all the sealing rings whether is aging and damages.

Throttle valve: Check the spring whether is fatigue wear.

Check the valve body and piston whether is damaged, and check the sliding surface whether is binding; replace it when necessary.

Chapter 8

The Lifting System (Gantry Mounting and Fork)

(1) General: (Figure 9.1) The ideal operation mode for gantry mounting is the rolling surface contacts with the gantry mounting smoothly, but there is clearance between the trolley and gantry mounting in actual situation. We shall adjust the clearance to the smallest value as far as possible.

1.

2.

Inside gantry mounting Outside gantry mounting

3.

4.

5.

Chain Fork frame Bearing seat

6.

7.

Main trolley Side trolley

Figure 9.1

. 69 .

(2) Disassembly: 1.

Disassembly: (Figure 9.2)

1.

2.

3.

Inside gantry mounting Oil intake pipe of lifting oil cylinder Oil return pipe of lifting oil cylinder

4.

5.

Tilting oil cylinder assembly Bearing seat

Figure 9.2 5 a. b.

Bearing seat: Hang the gantry mounting by crane and notice do not make the forklift to suspend. (Figure 9.3) Loosen the fastening bolt of bearing seat and mark the relevant signs on each couple bearing seat. (Figure 9.4)

Figure 9.3

. 70 .

Figure 9.4

2.

Disassembly and assembly: (Figure 9.5)

1.

2.

3.

Chain, nut and split pin Fork frame Cargo fender

4.

5.

6.

Trolley Side trolley Bracket

7.

8.

9.

Trolley Inside gantry mounting Sprocket

Figure 9.2 2 Disassembly of fork frame: Loosen the connecting nut of chain, lift the inside gantry mounting and reverse, and then place the fork frame on the ground.

5 Disassembly of side trolley: The gasket is used to adjust the clearance of each side trolley, and the bracket is anchored on the fork frame by gasket and bolt. (Figure 9.6) 8 Disassembly of inside gantry mounting: Just make the top part of the inside gantry mounting slide from the outside gantry mounting.

(Figure 9.7)

Figure 9.6

Figure 9.7

(3) Check and adjustment: 1. Fork: The fork point of two forks shall be on the same horizontal plane and the deflection value shall be within the allowable range. Replace the fork which is with crack or serious deformation. (Figure 9.8)

. 71 .

2.

Fork frame:

Figure 9.8 a.

Figure 9.9

Check the rotation of main and side trolley whether is stable and each trolley whether with abrasion or crack; replace it when necessary. b. Check the welding part whether is crack. c. Check the top plate of fork rack whether is a straight line. (Figure 9.9) 3. Chain, sprocket and bracket: a. The length of two chains shall be the same and check the chains whether are abrasion and breakage; each chain element whether can rotate. b. Check the connecting pins of chain and bolt whether are with abrasion and the thread whether is damaged. c. Check the sprocket bracket and sprocket whether are with abrasion or breakage.

4. Gantry mounting a. Check the trolley whether is with abrasion or breakage. b. Check the tray of each trolley whether is abrasion, deformation or damaged. c. Check all the welding seams of gantry mounting whether are crack. d. Check the abrasion situation of bearing seat and bush of gantry mounting.

5. Adjustment of chain Figure 9.10 Adjust the chain according to the following steps in order to guarantee the right assembly. a. Place the forklift on the horizontal ground, decline the fork on the ground and check the lifting oil cylinder whether retract completely. b. Implement the following steps: assemble the connecting chain and the hinging bolt of fork (Figure 9.10), the dimension of fastening nut and locking nut shall be 70 mm. c. Adjust the tension of two chains; the chain is appropriate if the chain coil within the diameter of 20mm range by applying a force to the chain at the distance of 1 m.

Note: the chain will loosen when the titling of gantry mounting and the gantry mounting shall be vertical, and then check the Figure 9.11 tension of chain according to the above method.

6. Adjustment for the clearance of gantry mounting and trolley (Figure 9.11) a. There are three dimensions of trolley for gantry mounting and fork rack to be selected and select the trolley with the radial clearance less than 1mm. b. Control the lifting lever after gets the appropriate radial clearance; the movement of inside gantry mounting and fork frame shall be smooth.

. 72 .

Chapter 9

The Cooling System

Water tank (radiator) adopts the structure of pipe and belt. The cooling system adopts the air-cooled method and the oil cooling of torque converter adopts the water-cooled method which installed at the base of water tank. (Figure 10.1)

1. Water tank (radiator)

2. Fan shield

3. Cooler of torque converter oil

Figure 10.1

. 73 .

Chapter 10

The Fault Diagnosis

(1) Torque converter and transmission Fault

Reason Engine

Torque converter The torque output is inadequacy

Transmission

Tire

Torque converter

Without power output Transmission

Driving shaft

. 74 .

1. The torque output of engine is inadequacy.

2. The performance of engine is bad.

1. Too low of oil level.

2. Air in the suction inlet.

3. Fault of pressure adjusting valve channel.

4. The adjusting valve spring is aging.

5. Abrasion of pump gear and pump with low flow.

6. Block of oil filter.

7. Abrasion of sealing ring or O-ring.

8. Failure of overdrive clutch.

9. Damage or abrasion of blades of rotation components 1. Air in the suction inlet.

2. Outlet with foam cause by low pressure.

3. Water in oil.

4. The adjustment of pedal braking device has not been done.

5. Low of main pressure and sliding of clutch.

6. Abrasion of sealing ring or O-ring.

7. Damage of clutch piston.

8. Block or abrasion of frication disc.

1. High mechanical resistance 1. Abrasion of connecting plate.

2. Lack of oil.

3. Fault of oil pump driving mechanism.

4. Damage of turbine shaft.

5. Low of main pressure.

1. Lack of oil.

2. Failure of linking device of brake pedal.

3. The navigation of shift mechanism of clutch to connecting rod is wrong.

4. Normally open of clutch disc.

5. Abrasion of sealing ring of bearing cap.

6. Abrasion of O-ring.

7. Looseness of oil plug on shaft.

8. Block of clutch.

9. Damage of shaft and oil leak.

10. Damage of collar groove of clutch drum.

11. Damage of inner collar of clutch drum.

12. Block of clutch piston circuit.

13. Damage of spline.

1. Damage of components.

Fault

Reason

Torque converter

Transmission Sound abnormal Strong noise

Low noise

Oil leakage

Oil temperature is higher

1. Damage of connecting.

2. Damage of bearing 3. Damage of gear.

4. Abrasion of blades of rotation components.

5. Looseness of bolt.

6. Damage of spring.

7. Noise of oil pump.

1. Fault of clutch.

2. Block of bearing.

3. Damage of gear.

4. Looseness of bolt.

5. Damage of spring.

1. Block of oil filter at outlet.

2. Pipeline fault of pressure adjusting valve.

3. Block of oil pipe.

4. Low water temperature cause high viscosity of oil.

5. Failure of equipment (fault).

6. Oil category is not appropriate.

1. Block of oil filter.

2. Fault of oil pump.

3. Serious oil leakage.

4. Damage or aging of the spring of adjusting valve.

5. Pipeline fault of pressure adjusting valve.

6. Suction with air.

7. Low of the oil level.

1. Oil leakage of oil seal.

2. Oil leakage at the connecting place of shell.

3. Oil leakage at the joint of oil pipe or connecting position.

4. Oil leakage of drain plug.

5. Crack or air hole on the shell.

6. Oil injected off the transmission shell.

7. Too much oil.

1. High or low for the oil level.

2. Block of oil filter.

3. Abrasion of blades of the rotation components.

4. Fault of guider.

5. Suction with air.

6. Water in oil.

7. Block of oil pipe (cause the circulation to flow decline) 8. Damage of bearing.

9. Failure of equipment (fault) 1. Fault of clutch.

2. Damage of bearing.

3. Damage of control device.

. 75 .

Fault Oil temperature is high Main pressure is high

The main pressure is too low

Pressure of clutch is too low

Stall

. 76 .

Reason

Exclude power system

1. Inappropriate driving of forklift.

2. Fault of driving system or wheel.

3. Belt damage of cooling fan.

4. Block of oil cooler.

5. Failure of brake (can not separate) 1. Fault of pressure adjusting valve.

2. Block of oil pipe (cause the circulation to flow decline) 3. Low of temperature and high viscosity of oil.

4. Oil category is not appropriate.

1. Block of filter.

2. Damage of oil pump.

3. Spring damage for the pressure adjusting valve.

4. Unstable for the valve core movement of pressure adjusting valve.

5. Suction with air.

6. Lack of oil.

7. Damage of control device.

8. Fault of inching valve.

1. Block of filter.

2. Damage of oil pump or other faults.

3. Spring damage of pressure adjusting valve.

4. Unstable for the valve core movement of pressure adjusting valve.

5. Suction with air.

6. Lack of oil.

7. Damage of control device.

8. Fault of inching valve.

9. Oil seal break at the position of bearing cap.

10. Oil seal damage of clutch.

1. Inadequacy engine power cause lower driving speed.

2. Damage of overdrive clutch cause lowest driving speed.

3. Block of inching pedal device and clutch cause high speed.

(2) Driving axle: Fault Continue noise when drive with normal economic speed.

Irregular noise when drive with normal economic speed.

Abnormal when steering.

noise forklift

Reducer heat

is

over

Abnormal noise for planet reducer

Reason

Measure

1. Bad contact of gear or tooth damage of gear.

2. Inappropriate pre-tightening load or damage of bearing 3. Damage of hub bearing 4. Bad contact of side clearance 1. Damage of reducer or hub bearing.

2. Damage of differential mechanism.

3. Impurity in the shell of driving device.

4. Anchor the bolt of semi-axle and carriage.

1. The assembly of differential mechanism inside the shell is not accordance with the requirements because of abrasion.

2. Damage of differential gear or block of joint spider.

1. Damage of bearing and too high pre-tightening load of bearing.

2. Too small clearance between the driving and driven gear.

1. Low oil level or inappropriate oil mark.

2. Damage of planet gear.

3. Bearing damage of planet gear.

Re-adjust or replace Re-adjust or replace Replace Re-adjust Replace Replace Clean and replace oil Re-adjust Replace

Replace Replace and readjust Re-adjust Fill or replace Replace Replace

(3) Steering axle: Fault Strong steering force

Reason 1. Steering mechanism is lack of lubrication oil.

2. Low pressure of tire.

Deviation of tire

1. Different for the diameter of left and right tire.

2. Different for the air pressure of left and right tire.

Serpentuate (steering wheel oscillate around main shaft)

1. Large clearance between main pin and bearing.

2. Damage of hub bearing.

3. Fault of steering system.

Fast and uniform abrasion for the rear tire

1. The adjustment for tire has not done.

2. Equipped with different tires and with air pressure on left and right.

. 77 .

(4) Brake: Fault

Failure of brake

Brake system

Brake force is insufficient

Too long for the stroke of pedal

Return of brake pedal

Fault of brake

. 78 .

Reason 1. Bad contact of brake shoe and brake drum 2. Brake shoe with impurity 3. Use frequently to cause high temperature 4. Vacuum is insufficient. ķ Joint looseness of vacuum pipeline. ĸ Pipe crack or wrench of vacuum pump. Ĺ Vacuum hose crack or aging. ĺ The operation of vacuum pump is abnormal.

5. The vacuum intensifier can not maintain the vacuum. ķ Same to the clause ķĸĹ of item 4. ĸ Fault of vacuum intensifier. a. Sewage enters into the control valve. b. Dust enters into the air valve. c. Sewage enters into the vacuum valve. d. Damage of sealing gasket or membrane of piston.

6. Sewage block the air vent to cause the vacuum intensifier can operate normally.

1. Bad air tightness. ķ Fault of vacuum intensifier. a. Air leakage of air valve. b. Damage of sealing gasket or membrane of piston.

2. Block of air intake ķ Block of air filter.

1. Air in the oil.

2. Fault of brake main pump ķ Damage of piston leather cup ĸ Air in the brake oil tank Ĺ Too large of the clearance of push rod.

3. Oil leakage of vacuum intensifier. ķ Damage of cylinder leather cup. ĸ Membrane damage of control valve. Ĺ Plug nut looseness of the control valve joint and auxiliary oil cylinder.

The fault of control valve causes the brake oil return to the circuit of brake main pump from brake circuit.

1. Piston leather cup or seal gasket damage of the auxiliary oil cylinder.

2. Single-way ball or ball base damage of auxiliary oil cylinder.

1. The adjustment of brake pedal has not done. ķ The return outlet of brake main pump may be blocked.

2. The operation of brake main pump is abnormal. ķThe deformation of leather cup interfere the piston return to terminal.

3. The return force of pedal is insufficient. ķToo soft of the spring ĸDamage of pedal barrel or lack of oil 4. The operation of vacuum intensifier control valve is abnormal. ķThe bad leather cup causes the block of piston. ĸThe fitting clearance of valve core is inadequate or the screw looseness on the vacuum valve or air valve.

5. Block of turbo-piston. ķFill the lubrication oil. ĸThe guide sleeve is so tight.

Measure Adjust or repair Repair Cooling Fasten Replace Replace Repair or replace

Repair or replace Repair or replace Repair or replace Replace Replace

Repair or replace Replace Repair or replace

Replace the leather cup Fill brake fluid and empty the air Adjust Replace Replace Repair or replace Replace Repair or replace (change the oil meanwhile)

Replace cup

the

leather

Replace Replace and fill oil Repair or replace the leather cup Repair or fasten the screw.

Fault

Deviation of brake

Brake system

Brake with scream

Knocking from brake wheel

Pedal become soft after air release

Brake after engine start

Parking and brake system

No brake

Park and brake with noise when drive normally

The stroke of brake lever is inadequate

Reason 1. The clearance between the brake drum and brake shoe is inadequate.

2. Oil on the brake drum and brake shoe.

3. Looseness of brake drum or other components.

4. The tire pressure is inadequacy.

The fault of wheel brake: 1. Sliding of frication disc.

2. Damage of frication disc.

3. Brake chassis is looseness caused by bolt looseness.

4. Dirty of brake drum.

1. Brake shoe knocks the support pin.

2. Knocking sounds for each steering when driving. ķDamage of chassis ĸSerious damage of branch pump piston

Bad seal ability 1. Wrong position of branch pump leather cup.

2. Looseness of circuit joint.

The piston leather cup not act in main pump.

1. The binding of leather cup.

Measure Adjust Clean by solvent and repair the contact point.

Fasten or repair Adjust the tire pressure

Grind by abrasive cloth Replace the frication disc Fasten the bolt Clean This is not a fault Replace the chassis Replace the branch pump

Adjust the position of branch pump leather cup.

Re-fasten

Repair or replace the leather cup until the piston can return smoothly.

2. Wrong position of leather cup

Repair or replace

1. Too large clearance between the brake drum and brake shoe.

Adjust to appropriate clearance.

Replace

2. Serious abrasion of brake shoe.

1. Serious deformation of brake drum.

2. Looseness or brake of rivet.

3. The clearance between the brake drum and shoe disc is inadequate.

1. The clearance between the brake drum and shoe disc is inadequate.

Repair or replace (refer to the regulation of maintenance) Replace the damage rivet

Adjust

. 79 .

(5) Steering system:

Steering force becomes larger.

Fault

Diverter valve

Reason 1. The result of no steering oil. ķLack of channel ĸSoft of spring 2. Safety valve ķLow safety pressure ĸDamage of valve body ĹSoft of spring 3. The damage of O-ring seal of valve body to cause the pressure oil leakage of safety valve.

Measure Clean Replace Re-adjust Replace the assembly Replace and Re-adjust Replace

1. Block of gerotor pump.

2. Fault of gasket 3. Unstable movement of valve case

Clean or replace Clean or replace Clean or replace

1. Bending of piston rod.

2. Piston seal ring damage of steering oil cylinder.

Repair or replace Replace

Oil pipe or hose is blocked or damaged

Replace

Serpentuate

1. Oil pipe or hose is blocked or damaged 2. The piston seal of steering oil cylinder is damaged.

Replace Replace

Knock or noise

1. Circuit air intake.

2. Connecting looseness for the bracket of steering oil cylinder.

Exhaust the air Repair or replace

Fault of steering gear Fault of steering cylinder Others

. 80 .

(6) Hydraulic system: Fault

Reason

The gantry mounting can not lift or tilt.

1. The oil is inadequacy in the oil tank.

2. Failure of safety valve. ķBlock of valve rod. ĸDamage of spring.

3. Fault of oil pump.

The gantry mounting can not list with the rated load

1. Failure of safety valve. ķToo low for the safety pressure. ĸFault of the guide valve seat. ĹSpring damage of guide valve.

2. Damage of oil pump.

Low lifting speed

1. Oil leakage inside the control valve.

2. The sliding surface of lifting oil cylinder is scratching.

3. The action surface of lifting oil cylinder is damage.

4. The piston seal ring of lifting oil cylinder is damage or deformation.

Gantry mounting slide at the rated load

1. The inside of control valve is leakage.

2. The sliding surface of lifting oil cylinder is scratching.

3. The sliding surface of lifting oil cylinder is damaged.

4. The piston sealing ring of lifting is damaged or deformation.

The gantry mounting tilt forward automatically

1. Oil leakage inside the control valve.

2. Impurity.

3. The piston seal ring of tilting oil cylinder is damage.

4. The tilting oil cylinder is deformation.

Oil leakage of cylinder

1. The impurity enters into the sealing components such as O-ring and dust ring.

2. The O-ring and dust ring is damage.

3. The oil cylinder is deformation.

. 81 .

(7) Lifting system: Fault The fork lifts with the inside gantry mounting.

The movement of fork rack and inside gantry mounting is unstable.

The fork rack is askew

The gantry mounting make noise

Reason There is no clearance between the lifting trolley and side trolley.

1. The clearance between the lifting trolley and side trolley is inadequate.

2. The trolley and trolley shaft is blocked.

3. The sliding of sprocket is unstable.

1. The adjusting clearance of side trolley is large.

2. The tension extent of two lifting chain is different.

1. The rolling of trolley is unstable.

2. The cushion of gantry mounting is damage

The gantry mounting is deformation

1. The clearance between the lifting trolleys is inadequate.

2. The Load is greater than the rated load.

The heights of fork sharp are different

1. The cargo fender of fork is deformation.

2. The fork is deformation.

3. Operate inadequately.

(8) Lifting oil cylinder and tilting oil cylinder: Fault The lifting oil cylinder slides downward and the tilting oil cylinder tilts forward The lifting oil cylinder and tilting oil cylinder appear crawling situation at certain point.

Reason 1. The inner wall of cylinder is damage.

2. The oil pipe is leakage.

3. The oil leakage of control valve is serious.

4. The piston seal ring is abrasion, deformation or damage.

1. The inner surface of oil cylinder is serious damage.

2. The oil cylinder is deformation.

Oil cylinder knocks during operation

1. The piston rod is deformation.

2. Air enters into the oil circuit.

3. The oil tank is lack of oil.

The decline speed is too low

1. The valve case of throttle valve is blocked.

2. The throttle valve is blocked by impurity, and the oil pipe is damaged or blocked.

The movement of oil cylinder is too slow.

1. The discharge capacity of oil cylinder is inadequacy.

2. The piston seal ring is abrasion or damage.

The output power of oil cylinder is inadequacy

1. The pressure of safety valve is too low.

2. The piston seal ring is abrasion or damaged.

. 82 .

Chapter 11

The Maintenance Standard

(1) Torque converter and transmission: (Table 12.1)

Item

A: Standard value for assembly B: Limit value for maintenance Unit: mm CPCD50E/60E

Thickness of outer frication disc Thickness of inner frication disc Backlash of frication disc Clutch Width of piston ring

Width of piston ring groove Free length of retracing spring Width of seal ring groove of guider shaft

A

17±0.02

B

1.4

A

2.7±0.1

B

2.3

A

0.06̚0.26

A B

5 0.1 4.85

A

5+0.05

B

5.4

A

62

A

2.3 0.01 1.9

B Width of the seal ring of guider shaft

Inside diameter of the seal ring of guider shaft Transmission shaft, medium shaft and bearing cap

Width of piston seal ring of clutch

Width of piston seal ring groove of clutch Width of seal ring of bearing cap

Width of seal ring groove of bearing cap

Inside diameter at the seal ring of bearing cap Output shaft

Tightening torque for the connecting bolt of lock plate (kg.m) Backlash Side clearance of spline

A

0.05

0.06

0.05

B

2.5 0.01 2.9

A

65+0.03

B

65.3

A B

3.0 0.03 2.7

A

3.0+0.25

B

3.3

A

2.25+0.07

B

1.85

A B

2.5 0.05 2.9

A

30±0.021

B

30.4

A

1.7

A

0.07̚0.26

B

0.4

A

0.052̚0.148

B

0.3

0.01

0.20

. 83 .

Continued Item

CPCD50E/60E

Tightening torque (N•m) Bolt of oil pump cap 1

A

210±10

Bolt of retainer 2

A

120±50

Round nut 3

A

210±10

Bolt of connecting plate 4

A

210±10

Connecting bolt of pump impeller 5

A

210±10

Connecting bolt of oil pump shell 6

A

420±20

Connecting bolt of input bearing cap 7

A

420±20

Connecting bolt of input bearing cap 8

A

420±20

Connecting bolt of medium bearing cap 9

A

420±20

Height of the pedal to base plate 1

A

173

Distance between the brake pedal and inching pedal 2

A

0.1̚0.5

Stroke of inching valve core 3

A

75

Length of adjusting rod 3

A

108

Control dimension of inching pedal

. 84 .

Continued Item

A B A B A

0.19̚0.25 0.5 3±0.025 2.5 0.03̚0.07

A

0.35

A

26̚35

A

Max. 0.15

A

0.25̚0.35

Backlash of semi-axle spline 7

A

0.5

Fastening bolt of driven spiral bevel gear 8 Connecting bolt of differential mechanism shell 9 Fastening bolt of bearing cap 10

A

200

A

125

A

166

Fastening bolt of holder 11

A

84

Fastening bolt of thrusting gasket 12 Sleeve nut of driving spiral bevel gear bearing 13

A

35

A

68

Pre-tightening load of hub bearing (N·m) ķ

A B A

1 2 50̚500

Locking nut (outer nut) ĸ

A

18

Connecting bolt of cover Ĺ

A

41

Fastening bolt of planet gear carrier ĺ

A

99

Backlash between the differential gear and semi-axle gear 1 Thickness of thrusting gasket 2 Differential mechanism

CPCD50E/60E

Clearance between the differential gear and joint spider 3 Pre-tightening load for the bearing of differential mechanism (N·m) 4 End jumpiness of the driven spiral bevel gear 5 Backlash of driving and driven spiral bevel gear 6

Tightening torque (N·m)

Hub and wheel Buckling (bending) of front axle (1/2 in percentage)

. 85 .

Continued Item

Hub and wheel

Wheel reduction

Tightening torque (N·m)

CPCD50E/60E

Connecting bolt of the body support plate 5

A

551

Connecting bolt of hub and brake drum 6

A

287̚292

Nut of rim 7

A

411

Locking nut of hub

A

441

A

26 0.01 26.3

Inside diameter of planet gear bush (with gear) 1

B A

Axle pin diameter of planet gear 2

B A

Thrusting gasket thickness of planet gear (planet gear assembly) 3

B

0.10

0.009

26 0.001 25.9 0.1

2.3 0.2 1..8

(2) Steering axle: (Table 12.2) A: Standard value of assembly B: Limit value of maintenance Unit: mm Item

. 86 .

CPCD50E/60E

Toe-in

A

0

Angle of rake for main pin

A

0

Outside of wheel

A

1°

Rake angle of main pin

A

1°

Axial clearance of the center of steering axle 1

A

Max. 0.8

Fastening bolt of bracket 2 (tightening torque: N·m)

A

334

Continued Item

A

40-0.016

B

39.8

A B

0.2 0.07 1.4

A

0.5̚5

Locking nut of hub bearing (outer nut) 4

A

18

Nut of rim

A

411

Locking nut of positioning bolt

A

48

Axial clearance of main pin 2

Diameter of main pin 1 Pre-tightening load of hub bearing 3 (N•m) Tightening torque (N•m)

CPCD50E/60E

1.37

(2) Brake: (Table 12.2) A: Standard value of assembly B: Limit value of maintenance Unit: mm Item

Brake pedal

CPCD50E/60E

Height (from base plate to pedal center) 1

A

173

Pedal stroke (from the acting point of brake) 2

A

28̚43

A

0.02̚0.143

B

0.2

Assembly length of push rod 4

A

132

Clearance between piston and push rod 5

A

1

Idle stroke of pedal

A

10̚16

Clearance between the pedal pin axle and bush 3

. 87 .

Continued Item Brake pedal

Retracing spring

Foot brake

CPCD50E/60E Free length

A

170

Initial working length/test load (mm/kg)

A

250/ 25.7

A

317.5+0.2

B A B A

319.5

Inside diameter of brake drum 1 Thickness of frication disc 2 Clearance between brake drum and frication disc (One side) 3 Spring 4

Brake main pump

Free length

A

Initial working length/test load (mm/kg)

B

Tightening torque for the connecting bolt of chassis (N•m)

A

287̚292

Bore diameter of pump body 1

A

22.22+0.052

Diameter of piston 2

A

22.22

A

0.02̚0.105

B

0.2

A

Matching clearance between pump body and piston

Free length of spring 5

A

23.5±0.1 Replace annually 23.6̚0.4 Replace annually 85

Tightening torque for the mounting bolt of main pump (N•m)

A

34

Inside diameter of pump body 1

A

Outside diameter of piston 2

A

Diameter of leather cup (lip edge) 3

B A

Diameter of leather ring (lip edge) 4

Brake branch pump

. 88 .

0.2̚0.3

B

Continued Item

CPCD50E/60E

Fitting clearance between pump body and piston Brake branch pump

Diameter of leather cup (Lip edge) 3 Tightening torque (N•m)

A B A B

Mounting bolt of branch pump

A

117̚156

Plug for ventilation

A

6̚9

Initial pressure (KPa)

A

650

Free length

A

45.2

Initial operation length/test load (mm/kg) 1

A

27.6/1.3

Free length

A

395

Initial operation length/test load (mm/kg) 2

A

181/18

Fitting clearance between valve case and piston 3

A

0.05̚0.11

Fitting clearance between auxiliary cylinder piston and housing 4

A

0.045̚0.125

Push rod deflection 5

A

0.3

Position of handbrake lever 1

A

4°̚5°

Force of handbrake lever (kg) II

A

21̚30

A

203.2+0.3

B

205

Vacuum intensifier Spring Spring

Handbrake lever

Handbrake drum

The diameter of brake drum

. 89 .

Continued Item

CPCD50E/60E A

5.5

B

3.5

Clearance between brake drum and frication disc

A

0.4

Free length of spring

A

48

Tightening torque for mounting bolt (N•m)

A

32.5

Thickness of frication disc 2 Handbrake drum

(4) Steering system: (Table 12.4) A: Standard value of assembly B: Limit value of maintenance Unit: mm Item

Steering wheel

CPCD50E/60E

Control force (wheel edge) (N) Steering wheel turns from one dead center to another dead center with the speed of 1 rpm at the state of engine idle.

Internal steering angle Steering angle External steering angle

A

2 78° 52°40ƍ

The number of coil from the medium place to dead center

A

2.8

Tightening torque of mounting nut (N•m)

A

55̚60

Discharge capacity (mL/r)

A

2000

Measured oil pressure (MPa)

A

8.5

Flow capacity (L/min)

A

15

Mounting bolt of bracket 1

A

36

Mounting bolt of flange 2

A

23

Mounting bolt of end cover 3

A

33

Inside cylinder diameter

A

100

Diameter of piston rod

A

60

Deflection of piston rod

B

1

Center distance of holes on both sides (Standard value)

A

Full hydraulic steering gear

Tightening torque

Steering oil cylinder

. 90 .

Continued Item

CPCD50E/60E

Diverter valve Measured the flow capacity (L/min) Open pressure for one-way valve (MPa) Flow capacity (L/min) Flow capacity of Open pressure for safety valve main oil circuit (MPa) Suction flow capacity (L/min)

A

22

A

8.5±0.5

A

12̚13

A

14

A

34̚160

Plug of diverter valve 1

A

110

Nut of safety valve 2

A

12

Plug of safety valve 3

A

90

Safety bolt of diverter valve 4

A

35±5

Flow capacity of steering oil circuit

Tightening torque (N•m)

(5) Hydraulic system: (Table 12.5) A: Standard value of assembly B: Limit value of maintenance Unit: mm Item

CPCD50E/60E

Lifting speed (rated load/no load) (mm/s)

A

284/380

Falling speed (rated load) (mm/s)

A

460

Angle of tilt

A

6°

Caster angle

A

12°

Tilting time for forward (engine speed 2400 r/min) (s)

A

2.2

Tilting time for backward (engine speed 2400 r/min) (s)

A

2.0

Open pressure for safety valve (MPa)

A

14

Open pressure for steering one-way valve (MPa) Sliding displacement of lifting oil cylinder (cause by oil leakage inside) (rated load) Sliding displacement of tilting oil cylinder (cause by oil leakage inside) (rated load) Discharge capacity (2500 r/min) (L/min) Oil pump Tightening torque for the mounting bolt of pump (N•m)

A

8.5

A

20

A

14.8

A

200

A

80

A

Max. 360

A

61

Fork

Gantry mounting

Shift control valve

Control force of valve core (N) Tightening torque for the safety bolt of shift control valve (N•m)

. 91 .

Continued Item

CPCD50E/60E

Lifting oil cylinder

A

90

B

90.1

A

60

Cylinder head 3

A

500±60

Positioning blot of oil cylinder

A

297

A

100.0

B

100.14

Outside diameter of piston 2

A

40

Nut 3

A

60±5

Retaining nut of earring 4

A

662

Mounting bolt of oil cylinder

A

34

A

40

B

40.5

A

40

B

39.65

Internal diameter of housing 1 External diameter of piston rod 2 Tightening torque (N•m)

Inside diameter of housing 1 Tilting oil cylinder

Tightening torque (N•m)

Internal diameter of cylinder earring and cylinder head bush External diameter of pin

(6) Gantry mounting and fork: (Table 12.6) A: Standard value of assembly B: Limit value of maintenance Unit: mm Item

CPCD50E/60E

Height difference of fork point Tilting oil cylinder

. 92 .

Max. 5

A

635

B

647

Retaining nut of chain

A

393

Fastening bolt of chain bracket

A

99

A

52

Length of chain (each 20 pitch) Tightening torque (N•m)

Trolley

A

Internal diameter of side trolley

Item

CPCD50E/60E

Outside gantry mounting, inside gantry mounting

Maximum inner distance of outside gantry mounting Maximum outer distance of inside gantry mounting Clearance of outside gantry mounting and inside gantry mounting (at the maximum lifting height) Clearance between inside gantry mounting, outside gantry mounting and trolley (at the minimum lifting height) Maximum outer distance of fork frame Inside Clearance between trolley of fork frame and inside gantry gantry mounting (at the maximum lifting height) mounting Deflection of cross beam (on fork frame) and fork Tightening torque for the mounting blot of fork frame frame (N•m) Tightening torque for the connecting bolt of bearing cap on outside gantry mounting (N•m)

A A

802.0 684

A

0.1̚1

A

0.1̚1

A A

0.1̚1

A

Max. 5

A

214

A

497

(7) Maintenance regularly: (Table 12.7) ż: Check or clean Ɣ: Replace or adjust

Steering system

Engine The coolant whether is leakage.

Water level Cover of water tank Tension extent of fan belt Cooling system The valve core of water tank whether is blocked.

The fan whether is damage.

Rubber hose Idle stroke and jarring Steering The control whether is wheel free.

Lever Assembly Steering gear Oil leakage

Biennially

Twenty months

Six months

Three months

Monthly

Regular maintenance

Daily

Three months

Requirement

Two months

Check item

One month

Interval of new car

Refer to the operation and maintenance instruction of diesel ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż ż ż

ż ż ż

ż ż ż

ż ż ż

ż ż ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż ż

ż ż

ż ż

ż ż

ż ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

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. 93 .

Continued

Wheel

Braking system

Braking system

Steering oil cylinder Brake pedal Handbrake Hose Connecting rod Brake drum and brake shoe

Vacuum intensifier Connecting rod Chassis

Driving system

Driver and steering axle

Driver

. 94 .

Steering axle

Wheel

Torque converter and transmission

ż

ż

ż

ż

Biennially

ż

ż ż ż ż ż ż ż ż

ż ż ż ż ż ż

ż

ż

ż

ż

ż

ż ż ż ż

ż ż ż ż

ż ż ż

ż ż ż ż ż

Clearance Brake shoe Brake drum Pressure Air exhaust Air leakage Assembly and damage Assembly and adjust Crack and deformation Oil level and leakage Semi-axle End shaft Longitudinal clearance Crack and deformation Tire pressure Crack Abrasion Stone and iron scale on the tire Bolt and nut Rim Bearing of front wheel Bearing of rear wheel Oil level and leakage Jarring Inching pedal Engagement and separation of clutch Oil pressure

Twenty months

Monthly

Daily

Three months

ż

Six months

Steering knuckle

Assembly Bearing shim Gear Main pin Steering knuckle Crack Wheel calibration Steering angle (left and right) Oil leakage Assembly Idle stroke and height Brake performance Brake performance Oil leakage Assembly and damage

Regular maintenance Three months

Cooling system

Steering gear

Requirement

Two months

Check item

One month

Interval of new car

ż ż ż ż ż

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ż ż ż ż ż ż ż

ż ż ż ż ż ż ż

ż

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ż ż ż

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ż ż ż

ż ż ż

ż ż ż ż Ɣ ż ż ż ż ż ż ż

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Ɣ ż ż

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Continued Interval of new car

Hydraulic system

Throttle valve Pipe Pump

Gantry mounting and fork

Lifting chain Sprocket

Gantry mounting

Other

Safety device

Fork Cargo fender

Illumination Horn Lamp Reflection of light Instrument Roof of protection rack Exhaust pipe and suppressor Frame

ż

ż

ż

ż

ż

ż ż ż ż ż

ż ż ż ż ż

ż ż ż ż ż

ż ż ż ż ż

ż

ż

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ż

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ż ż ż ż

ż ż

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ż ż ż ż ż ż

ż ż ż ż ż ż

ż ż ż ż ż ż

ż

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ż

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ż

ż

ż

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ż

ż

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ż

ż

ż

ż

ż ż

ż ż ż

ż ż ż

ż ż ż

ż ż ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

Three months

Ɣ ż Ɣ ż

Monthly

ż

Ɣ ż Ɣ ż

Daily

Biennially

Lifting oil cylinder

Twenty months

Control valve

Six months

Hydraulic system

Diverter valve

ż ż Ɣ ż

Two months Three months

Oil pressure

Requirement

One month

Check item

Regular maintenance

ż

ż

ż ż

ż

ż

ż

ż

ż

ż

ż

ż

Oil level Filter Filter Oil leakage Oil pressure of steering system Oil leakage Oil pressure Pressure of safety valve Jarring of control lever Crack and deformation Performance and abrasion Bolt Oil leakage Throttle (reduction) Oil leakage Hose Rubber hose

ż

ż

ż

ż ż ż ż ż ż

ż ż ż ż ż ż

Oil leakage

ż

Chain Chain is abrasion and deformation Sprocket Sprocket bearing Chain bolt Deformation and abrasion Bearing seat for gantry mounting Side trolley Deformation and abrasion Positioning pin of fork Cargo fender Cargo fender is deformation and abrasion Control Control Control

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ż

ż

ż

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ż

ż

ż

ż

ż

ż

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ż

ż

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ż ż

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ż

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ż

ż

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ż ż ż

ż ż ż

ż ż ż

ż ż ż

ż ż ż

ż ż ż

ż ż ż

ż ż ż

Control

ż

ż

ż

ż

ż

ż

ż

ż

ż

Control

ż

ż

ż

ż

ż

ż

ż

ż

ż

Control

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż

ż ż

ż ż ż

ż ż ż

Assembly and damage Noise suppression function Looseness and abrasion Driver seat Oil hole

ż

ż

ż

ż

ż

(8) Regular replacement components: (Table 12.8) . 95 .

The components submitted in this table are important to the normal operation of forklift, so we shall replace these components regularly and this regulation also applies to the maintenance of forklift. ƿ: Important safety components Time Regular replacement components

One month after delivery

Monthly

Semiannually

Piston, dust ring and sealing ring of brake main pumpƿ Piston, dust ring and sealing ring of brake branch pumpƿ Rubber components of steering oil cylinder ƿ Fuel hoseƿ

Annually

Biennially

ż

ż

ż

ż

ż

ż

ż

ż

Filter core of engine oil

ż

ż

ż

ż

ż

Filter core of fuel

ż

ż

ż

ż

ż

Filter of hydraulic oil tank

ż

ż

ż

ż

ż

ż

ż

Core of air filter

ż

Clean Replace

ż

(9) Filling capacity: (Table 12.9) Unit: L Item

CPCD50E/60E

Fuel tank

110

Hydraulic oil tank

75

Torque converter and transmission

17

Differential mechanism

7

Planet gear reduction

2.3

Brake fluid (mL)

180

Vacuum intensifier (mL)

60

Engine

Cooler

. 96 .

Chassis

11

Fuel Filter

0.85

Total

11.85

Engine

6.5

Water tank

8

Total

14.5

(10) Lubrication table: (Figure 12.1)

Check and fill oil Replace oil Lubrication point on left and right

ATF: Torque converter fluid MPG: Multi-purpose grease GO: Gear oil EO: Engine oil BF: Brake fluid HO: Hydraulic oil Vo: Vacuum intensifier oil Figure 12.1

. 97 .

Chapter 12 The Electrical System The rated voltage of the electrical system for the forklift of model CPCD50E/60E is 24V, single-wire system and earth on negative electrode. This electrical system is composed of power circuit, startup circuit, instrument circuit and the circuit of lighting and signal device.

(1) Instruction for composite instrument: 1.

Instrument case: (Figure 13.1)

1.

2.

3.

4.

5.

6.

7.

8.

9.

Water temperature gauge of engine Oil temperature of torque converter Fuel gauge Chronograph Fuse box Check button Monitor Startup switch Light switch

I.

Monitor: (Figure 13.2)

Figure 13.1

Figure 13.2 No 1 2 3 4 5 6 7 8 9 10 11 12

. 98 .

Display of indicator Warning lamp for air filter Warning lamp for fuel Warning lamp for the cooling water level of engine Indicator lamp for system checking Warning lamp for brake fluid level Warning lamp for fuel filter Indicator lamp for the light change of headlight Warning lamp for clutch Warning lamp for liquefied petroleum gas (LPG) Warning lamp for oil pressure of engine Warning lamp for charge of generator Indicator lamp for preheating

OFF Normal Normal

ON Component block Shortage

Remark Option Option

Normal

Shortage

Option

Normal

Abnormal

Option

Normal

Shortage

Normal

Drain water

OFF

(ON)Turn

Pressure disc without abrasion

Pressure disc with abrasion

Option

Normal

Shortage

Option

Normal

Low oil pressure

Normal

Abnormal

Normal

Heat

Model of diesel

Model of diesel

2 How to check the bulb of warning lamp: Turn the startup switch to the position of “ON” and press the checking button. It is normal if all the warning lamps lit while press the checking button. And this situation is normal too: the warning lamps for oil pressure and charging lit while startup the engine and then blackout as the acceleration of engine.

II. The disassembly and assembly of instrument case: (Figure 13.3)

Figure 13.3 1. Disassembly: 1. Disassemble the wire connecting termination 1 and check the wire on the side of engine.

2. Disassemble the fastening screws 2 (4 pcs) and remove the cover.

3. Disassemble the bolts 3 (2 pcs) and remove the clip on the steering column.

4. Disassemble the nut 4 (2 pcs) and remove the instrument case.

5. Disassemble the fastening screws 5 (4 pcs) and separate the front and back plate.

6. Disassemble the fastening screws 6 (5 pcs) and remove the composite dashboard.

7. Disassemble the plug of each connecting termination.

2. Assembly: Assemble according to the reversal steps of disassembly.

. 99 .

III. Internal components of instrument case: (Figure 13.4)

1.

2.

3.

4.

Back plate Checking button Flash chopper Fuse box Startup switch

5.

6.

7.

8.

Front plate Instrument harness Time relay (diesel) Thermal relay (diesel) Relay harness

Figure 13.4 IV. The disassembly and assembly of composite dashboard: (Figure 13.5) 1. Disassembly: 1. Instrument panel 2. Instrument cover 3. Body 4. Printed circuit board 5. Bulb Note: Does not damage the printed circuit board while disassemble.

2. Assembly: Assemble according to the reversal steps of disassembly.

Figure 13.5

. 100 .

V. Replacement for the warning lamp and indicator lamp bulb: 1. Disassemble the back plate (Figure 13.6+) (1) Disassemble the screw (4 pcs) in order to separate the front plate and back plate from the dashboard.

(2) Turn the bulb anticlockwise on the printed circuit board, and then disassemble the relevant bulbs.

Figure 13.6 2.

Bulb arrangement (on the printed circuit board) (Figure 13.7)

1.

2.

3.

4.

5.

Warning lamp for brake fluid level Warning lamp for the fuel filter (diesel) Indicator lamp for preheating (diesel) Warning lamp for uncharged of engine Warning lamp for the oil pressure of engine Indicator lamp for the system checking Warning lamp for the air filter Warning lamp for fuel (option) Warning lamp for the cooling water of engine (option) Indicator lamp for the light change of headlight Warning lamp for the clutch (option) Instrument lamp Warning lamp for liquefied petroleum gas (LPG) (option)

6.

7.

8.

9.

10.

11.

12.

13.

Figure 13.7

(2) Ignition switch (Figure 13.8) This switch has the function of locking automatically. This locking mechanism can stop the operator turn the key to the position of “START” from the position of “ON” when the engine is running in order to avoid the damage of engine gear or meshing gear. Gasoline engine and diesel engine adopt the same startup switch, but equipped with different form of circuit wiring.

. 101 .

Figure 13.8 Continuity table of startup switch (gasoline engine) Terminal Key position

B

G2

M

S

OFF ON START Continuity table of startup switch (diesel engine) Terminal B Key position

M

S

OFF ON START

(3) Lighting switch (Figure 13.9)

Figure 13.9 Continuity table for the range position of lighting switch Terminal plug B T Switch position OFF 1 2

. 102 .

Turn Turn

H

F

P

(4) Fuse case: (Figure 13.10)

Figure 13.10

No.

Capacity

Circuit

A

10A

Reverse lamp and reverse buzzer

B

10A

Instrument of brake lamp and turn signal

C

20A

Spare (Driver cab)

D

20A

Lighting switch, headlight and lamp of front and rear

E

10A

Horn

F

10A

Spare

G

20A

Spare

H

10A

Spare

J

10A

Spare

(5) Battery and charge: 1. Basic parameters of battery Model and quantity 6QAˉ75(S)L×2 Rated voltage (V) 12 Rated capacity (AH) 75 Dimension (Length × Width × Height) mm 313×166×225 Net without electrolytic solution (kg) 19 2. Charge state of battery a. Check and measure the charge state of battery for forklift during daily use. The battery shall maintain the state of full electricity and this is the best maintenance method to extend the life of battery. b. Measure the density of electrolytic solution by hydrometer. Determine the charge state of battery according to the density of electrolytic solution. The battery is at the state of full electricity if the density of electrolytic solution within 1.26 to 1.28 in the room temperature.

Large quantity electricity has been consumed if the density of electrolytic solution decrease to 1.75, and then the battery shall be disassembled and charge.

The charge state of battery can be judged by the density decline speed of electrolytic solution.

That means the battery has been over-charged if the electrolytic solution of battery had decreased to expose the plate electrode within one month. That means the battery has been short-charged if the level of electrolytic solution almost had no change over three months. The level of electrolytic solution shall be higher than the plate electrode with 10 mm . 103 .

c.

3. a.

b.

c. d.

e.

f.

g.

Low operation velocity of forklift engine causes the short-charge of battery. We shall avoid making the engine stay at the state of low operation velocity for long term, increase the engine velocity and save in power meanwhile. Moreover we can adjust the voltage of adjust with increasing of 0.05 to 0.1 V. It will harm the life of battery if the voltage is too high.

Notice for the operation of AC generator and charge system We shall remember the terminal of adjuster magnetic field, the terminal of battery and terminal of generator magnetic field electrify while the switch on the startup switch and the terminal of generator armature always connect to battery (i.e. the same to the startup switch is off) for safety and economic. There is a voltage between above terminal which means the terminal voltage of battery; we shall notice this before operate.

The grounding polarity of battery shall be the same to that of generator when re-assemble the battery. Do not contact wrong. The silicon diodes of AC generator will burnout immediately and the relevant wires on forklift will burnout to cause the electrical system fault when contact wrong.

Disassemble the wire on the terminal of battery and then charge for battery by charger, otherwise the silicon diodes of AC generator will be damaged.

It is forbid to implement the method to check generator whether is operation by connecting the terminal of generator armature and shell with wires directly in order to avoid damaging the generator. And do not make the terminal of magnetic field shore-circuit in order to avoid burning the contact of adjuster.

There is fault on generator or charge system when the indicator lamp of charge is lit during the operation of forklift. Park the forklift and check otherwise the generator will be damaged and the capacity of battery will drop.

Cut off the power when adjust the adjuster (adjust the contact or arm) i.e. switch on the startup switch. Calibrate the voltage of voltage adjuster after adjustment, and then connect power otherwise the contact or other electrical components will be damaged.

Do not use the AC of 220V or megger when check the insulating property of each component of generator. Disassemble the generator and break all the connecting between the diode and other components if we use the AC of 220V or megger.

(6) Tools: Tools table for the forklift of model CPCD50SA/60SA Item

Rated volt. 24V (W), 24V(W)

Quantity

28

2

Front lamp

10

2

Turn signal lamp

21

2

Turn signal lamp

21

2

Rear lamp, brake lamp

8/21

2

Reverse lamp

10

2

Instrument illuminator

3.8

2

Indicator lamp of warning

3

12

Lamp category Headlight

Front composite lamp

Rear composite lamp

. 104 .

Type

Remark

(7) Fault diagnosis for electrical equipment Fault

Potential result

Circuit Overcharge for battery Adjuster

Generator

The capacity of battery drop rapidly.

Circuit

Assembly of generator

Battery

The capacity of battery drop rapidly.

Adjuster

Overload

The charge indicator lamp is flashing

The charge indicator lamp is dark in normal condition

Driving belt Startup switch Circuit Adjuster Startup switch Circuit Adjuster

1. Bad contact for the terminal E of adjuster.

2. The circuit between terminal N of engine and terminal N of adjuster is open or the contact is looseness.

3. The terminal F of adjust is short circuit or wrong wiring.

1. The circuit of voltage relay is open.

2. The terminal of low speed is fused or damaged.

3. Bad contact for the terminal of high speed.

4. The adjusting voltage is high.

5. The control of adjuster is failure.

1. The stator coil is short or open.

2. The rotator coil is open.

3. The carbon brush is blocked in the bracket of carbon brush and the generator without energization.

4. The circuit between the terminal of magnetic field and ground terminal is short.

5. The silicon diode has been penetrated.

1. The wires between startup switch and adjust is open or with bad contact.

2. The wires between the terminal of adjuster magnetic field and terminal of generator magnetic field is open or with bad contact.

3. Fuse is burnout or the wire contact is looseness.

1. The driving belt is looseness.

2. The ground contact of generator is bad.

1. The electrolytic solution is inadequacy or the density of electrolytic solution is not appropriate.

2. Short circuit between plate electrodes.

3. The plate electrode is sulfidization.

4. The terminal is corrosion and the battery terminal is with the bad contact.

1. The adjusting voltage is too low.

2. The contact of adjuster connector is bad or there is dirt on the contacting point.

3. The coil of magnetic field relay is open circuit.

There shall be without overload according to the electrical load standard, otherwise it is caused by the larger of additional load.

Loose of driving belt Bad contact for the inside startup switch Bad contact for the wire connecting Bad contact for the inside of signal relay Bad contact for the startup switch The resistance of circuit between the terminal of generator armature and charge indicator lamp by passing fuse is too high.

The control of signal relay is failure.

. 105 .

Continued Fault There is abnormal noise during the operation of generator.

The fuse of charge circuit always burn out.

Potential result

Generator

1. Damage of bearing 2. The silicon diode has been penetrated.

3. Rotator knocks stator.

4. There is dirt on the sliding ring.

Circuit

Include the grounding for armature loop of generator.

Generator

The silicon diode has been penetrated.

Adjuster

The adjusting voltage is too higher.

Battery

Wrong polar contact of battery.

Overload The load of circuit exceeds the capacity of fuse.

Note: The relevant results for difficult starting the engine refer to the instruction for the operation and maintenance of engine.

. 106 .

SHANGHAI SHANGLI FORKLIFT CO., LTD Address: 2611, Bao’an Highway, Shanghai, China Tel.: 86-21-69156666 Fax: 86-21-69156666 P.C.: 201801 Website: http://www.salcn.com E-mail: sal@salcn.com