Download PDF: Service Manual for UTILEV 2.0T-3.5T Internal Combustion Counterbalanced Forklift Truck

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2.0T-3.5T Internal Combustion Counterbalanced Forklift Truck SERVICE MANUAL

September 2018

Original Instruction

PART NO. 76002089(R5) US Engines

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized UTILEV® distributor. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

Foreword This manual describes the structure and working principles of the 2.0-3.5T internal combustion forklift truck and provides instructions for servicing and maintenance.

To ensure safety and get the best out of your forklift, the relevant operators, equipment managers and maintenance personnel should carefully read this manual.

Only trained and qualified personnel are permitted to carry out servicing and repairs on the forklift truck.

Models and Configuration Series

2.0T & 2.5T

3.0T & 3.5T

Model

Engine

Transmission

UT25P

YANMAR 2.6L (4TNE92) DSL

YQXD25-2

UT25P

MAZDA 2.2L DUAL

YQXD25-5

UT25P

MAZDA 2.2L LPG

YQXD25-5

UT25P

PSI 2.4L DUAL

YQXD25-2

UT25P

PSI 2.4L LPG

YQXD25-2

UT25C

MAZDA 2.2L LPG

YQXCD25C-5

UT25C

PSI 2.4L LPG

YQXCD25C-5

UT30P

YANMAR 3.3L (4TNE98) DSL

YQXD30

UT30P

MAZDA 2.2L DUAL

YQXD30-5

UT30P

MAZDA 2.2L LPG

YQXD30-5

UT30P

PSI 2.4L DUAL

YQXD30

UT30P

PSI 2.4L LPG

YQXD30

UT30C

MAZDA 2.2L LPG

YQXCD30G1-5

UT30C

PSI 2.4L LPG

YQXCD30G1-5

NOTE: DUAL designates DUAL FUEL or BI-FUEL

Contents 1. Powertrain .................................................................................................................................................................... 6 1. 1.1 Engines ............................................................................................................................................................. 6 2. 1.2 Mazda 2.2L ....................................................................................................................................................... 7 3. 1.3 PSI 2.4L ............................................................................................................................................................. 8 4. 1.4 4TNE92/4TNE98 Diesel..................................................................................................................................... 9 2 Transmission and Torque Converter ........................................................................................................................... 12 5. 2.1 Data ................................................................................................................................................................ 12 6. 2.2. Summary: Transmission Overview ................................................................................................................ 13 7. 2.3. Principles of Operation ................................................................................................................................... 14 8. 2.4. Torque Converter (Fig 2-4) ............................................................................................................................ 19 9. 2.5. Two-Way Clutch (Fig 2-5) .............................................................................................................................. 20 10. 2.6. Charging Pump (Fig. 2-6) ............................................................................................................................... 21 11. 2.7. Inching Valve (Fig. 2-7) .................................................................................................................................. 22 12. 2.8. Transmission Housing ................................................................................................................................... 22 13. 2.9. Cover and Control Valve (Fig. 2-8) ................................................................................................................. 23 14. 2.10. Reducer Gear & Differential ........................................................................................................................ 24 3. Drive Axle.................................................................................................................................................................... 26 15. 3.1. Data ............................................................................................................................................................... 26 16. 3.2. Fault Diagnoses and Corrections .................................................................................................................... 26 17. 3.3. Drive Axle Components ................................................................................................................................. 27 18. 3.4. Assembly and Disassembly of Drive Axle ....................................................................................................... 29 19. 3.5. Axle Shaft and Wheel Hub ............................................................................................................................. 30 20. 3.6. Bearing Adjusting .......................................................................................................................................... 31 4. Steering Axle ............................................................................................................................................................... 32 21. 4.1. General Specifications ................................................................................................................................... 32 22. 4.2. Fault Diagnoses Corrections ........................................................................................................................... 32 23. 4.3. Steering Axle.................................................................................................................................................. 34 24. 4.4. Steering Kingpin and Steering Spindle ........................................................................................................... 34 25. 4.5. Wheel Bearing Adjustment ........................................................................................................................... 34 5. Steering System .......................................................................................................................................................... 36 26. 5.1. Data ............................................................................................................................................................... 36 27. 5.2. Trouble Shooting ............................................................................................................................................... 36

28. 5.3. Summary ....................................................................................................................................................... 37 29. 5.4. Install Steering System .................................................................................................................................. 39 6. Brake System .............................................................................................................................................................. 40 30. 6.1. Fault Diagnoses and Corrections .................................................................................................................... 40 31. 6.2. Summary ....................................................................................................................................................... 41 7. Hydraulic System ........................................................................................................................................................ 47 32. 7.1. Data ............................................................................................................................................................... 47 33. 7.2. Fault Diagnoses and Corrections .................................................................................................................. 48 34. 7.3. Main Pump .................................................................................................................................................... 50 35. 7.4. Hydraulic Control Valve (Fig. 7-2) .................................................................................................................. 51 36. 7.5. Hydraulic Schematic...................................................................................................................................... 54 8. Lifting System.............................................................................................................................................................. 57 37. 8.1. Assemble Data ............................................................................................................................................... 57 38. 8.2. Fault Diagnoses and Corrections................................................................................................................... 58 39. 8.3. Summary ....................................................................................................................................................... 59 40. 8.4. Removal and Adjustment .............................................................................................................................. 65 41. 8.5. Detaching and Installing the Lift Cylinders ............................................................................................... 69 42. 8.6. Disassembly and Installation of Tilt Cylinder ................................................................................................. 70 43. 8.7. Debugging Precautions Following Forklift Assembly .................................................................................... 71 44. 8.8 Counterbalance weight ................................................................................................................................ 72 9. Electrical System ......................................................................................................................................................... 73 45. 9.1 Schematics ..................................................................................................................................................... 82

Sensing System is the Operator Presence on the Electrical Schematics

1. Powertrain 1.1 Engines Yanmar Diesel

Engine Parameter Rated Output Rated Rotate Speed Max. Torque N·M/ Speed 206 Kg Forklift Truck Model

4tne92-Hrj

4tne98-Bqflc

32.8 Kw 2450 RPM 149.4/1600 RPM 194 Kg Ut20/25p (4tne92)

42.1 Kw 2300 RPM 186nm/1700 RPM 194 Kg Ut30/35p (4tne98)

Mazda

Engine Parameter Rated Output Rated Rotate Speed Max. Torque N·M/ Speed Service Weight

Forklift Truck Model

2.2L LPG

2.2L Dual

37 Kw 2700 RPM 135N·M / 1900 RPM 158 Kg UT20P UT25P UT30P UT35P UT25C UT30C

37 Kw 2700 RPM 135N·M / 1900 RPM 161 Kg UT20P UT25P UT30P UT35P UT25C UT30C

PSI

Engine Parameter

2.4l Lpg

2.4l Dual

Rated Output Rated Rotate Speed Max. Torque N·M/ Speed

47.1 Kw 2600 RPM 168.0 N-M / 1600 RPM

49.8 Kw 2600 RPM 169.7 N-M / 2400 RPM

Service Weight

206 Kg

206 Kg

Ut20p Ut25p Ut30p Ut35p Ut20c Ut25c Ut30c Ut32c

Ut20p Ut25p Ut30p Ut35p

Forklift Truck Model

See the chart below for the powertrain configuration of the 2-3.5T forklift trucks. For detailed information on technical parameters, structure, and specific maintenance services for the engine, see the engine maintenance or service manuals After the engine has been serviced, emissions values should be checked. Emission values should comply with the corresponding stipulations. See the table below for exhaust emissions values

Engine Power (kW)

CO (g/kW •h)

HC (g/kW •h)

NO2 (g/kW•h)

18≦P<37 37≦P<75

5.5 5

1.5 1.3

8 7

6

PT Particles (g/kWh) 0.8 0.4

1.2 Mazda 2.2L 1.2.1 Specifications Item

Model

Lpg

Dual Fuel

Type

In-Line, Four Cylinders

No. Of Cylinders: Cylinder Bore X Stroke 4-86 Mm (3.39 In.) X 94 Mm (3.70 In.) 4-86 Mm (3.39 In.) X 94 Mm (3.70 In.)

Piston Displacement

2184 Cm 3 (133.2 In. 3)

2184 Cm 3 (133.2 In. 3)

720 RPM ± 25 RPM

Direction Of Rotation

Clockwise, Cooling Fan

Firing Order

1-3-4-2

Cooling System

Water-Cooled With Fd-2 Antifreeze

Lubrication System

Forced Lubrication

Oil Pressure @ 2400 Rpm

226 To 362 Kpa (33 To 53 psi)

Main Components

Min. Rotate Speed Under No Load

Injection Nozzles

Throttle Type

Air Cleaner

Paper Element

Generator Starter

Voltage/Current

12v/60a

Voltage

12 V

Output Power

2.3 Kw

Oil Volume Min./Max Dimensions: Lxwxh

7.2/9.2 L 632x498x676

Valve Clearance Injection Initial

632x498x711 0.45 Mm

Pressure

120 Kg/Cm Btdc9°

Injection Timing

7

2

1.3 PSI 2.4L 1.3.1 Specifications Item

Model

Lpg

Dual

In-Line Ohv, Sohc Four Cylinder

Type No. Of Cylinders: Cylinder Bore X Stroke

4-86.5x100mm

4-86.5x100mm

Piston Displacement

2351 Cm 3 (133.2 In. 3)

2351 Cm 3 (133.2 In. 3)

750 RPM ± 25 RPM

Direction Of Rotation

Clockwise, Cooling Fan

Firing Order

1-3-4-2

Cooling System

Water-Cooled Use Coolant Meeting Specification Gm6277m

Lubrication System

Pressure Feed, Full-Flow Filtration

Idling Speed : Engine Oil Pressure

90 Kpa (13 psi) [Low Light @ 55 Kpa (8 psi)]

Loaded Speed: Engine Oil Pressure

340 Kpa (49 psi)

Main Components

Min. Rotate Speed Under No Load

Injection Nozzles

Throttle Type

Air Cleaner

Paper Type

Voltage/Current Generator Part Number Part Number Starter

Voltage Output Power

Oil Volume Min./Max Dimensions: Lxwxh Valve Clearance Fuel Rail Pressure Injection Timing

12v/65a 1 2 9 See Parts Manual 9 3 12v 0 1.7kw 7 7 4.7 L (5 Qts) 2 16 625.6mm X 628.7mm X 741.6mm 625.6mm X 628.7mm X 741.6mm 23 2 Self-Adjusting x 4 310-414 Kpa (45-60 psi) 9 8 Variable Controlled By Ecu x 7 1 1 See Parts Manual

8

1.4 4TNE92/4TNE98 Diesel 1.4.1 Specifications Item

Model

4tne92

4tne98

Water-Cooled, Four-Cycle, In-Line Overhead Valve, Swirl Chamber Type

Type No. Of Cylinders: Cylinder Bore X Stroke

4-92 X 100mm

4-98 X 110mm

Piston Displacement

2.659 L

3.319 L 850 Rpm± 25 Rpm

Direction Of Rotation

Clockwise, Cooling Fan

Firing Order

1-3-4-2

Cooling System

Water-Cooled With Fd-2 Antifreeze

Lubrication System

Forced Lubrication

Idling Speed : Engine Oil Pressure

0.13 Mpa

Normal Speed: Engine Oil Pressure

0.29-0.39 Mpa

Main Components

Min. Rotate Speed Under No Load

Injection Nozzles

Throttle Type

Air Cleaner

Paper Element

Voltage/Current

12v/60a

Part Number

See Parts Manual

Part Number

See Parts Manual

Voltage

12 V (3.1hp)

Output Power

2.3 Kw

Generator

Starter

Oil Volume Min./Max Dimensions: Lxwxh

7.2/9.2 L 632x498x676

Valve Clearance Injection Initial

719x496x717 0.45 Mm

Pressure

120 Kg/Cm Btdc9°

Injection Timing

9

2

1.4.2 The Maintenance of 4TNE92/98 Diesel Diesel fuel requires high quality maintenance of the air cleaner and fuel filter.

1.3.2.1 Changing the Air Cleaner Dry paper model Change the filter according to the maintenance schedule. If operating in a dusty environment, the air cleaner should be changed more frequently.

1.3.2.2 Check the Oil Filter Check and change the oil filter （1）Remove the head of the sensor from the oil filter. （2）Loosen the valve to drain the fuel. （3）Remove the sensor from the oil filter or draining valve. （4）Remove the oil filter. （5）Connect the oil sensor to the new oil filter. （6）Install the new oil filter.

The oil filter should only be tightened manually. （7）Connect the sensor head. （8）Remove air from the system.

Follow same procedure as described in Step 2.2.4 Drain water （1）Water should be drained according to the maintenance schedule, or when an alarm signals there is a problem. （2）Remove air from the system. （3）Make sure there is a container under the oil filter.

1.3.2.3 Filter the Diesel Oil Used diesel oil should be filtered before it is added to the oil container.

1.3.2.4 Bleed the Fuel of Air All air must be bled from the fuel. To avoid splashing oil, the bottom of the motor and pump should be wrapped by a piece of cloth.

If the motor still doesn’t run after bleeding the air, loosen the ejection pipe; shake the start-up motor until fuel flows out of ejection pipe. Tighten the nut of the ejection pipe.

If the motor operates erratically, run two or three times at high speed.

10

Without Air Vent Screw Method A: Move priming pump up and down until you can feel a sudden release of pressure.

Method B: (1) Loosen injection pump bleeder screw or disconnect return hose and priming (2) Make sure fuel overflows at bleeder screw/tube end, then tighten and connect hose With Air Vent Screw Method A: (1) Loosen the air vent screw (2)Move the priming pump up and down until no air comes out of the air vent screw.

(3)Tighten the air vent screw (4)Move the priming pump up and down until there is a sudden increase in resistance.

Method B: (1) Loosen the air vent screw (2)Move the priming pump up and down until no air comes out of the air vent screw (3)Tighten the air vent screw (4) Loosen injection pump bleeder screw or disconnect return hose and priming (5)Make sure fuel overflows at bleeder screw/tube end, then tighten and connect hose. Check Priming Pump Before checking priming pump, make sure fuel filter is filled with fuel (1)Disconnect fuel return hose. Place a suitable container under return hose (2)Pump priming pump and check that fuel flows out of hose end. If it does not, replace priming pump

11

2 Transmission and Torque Converter 2.1 Data Models

Hydrodynamic Torque Converter

Transmission Gear Ratio

Hydrodynamic Power Clutch

Reduction Transmission

Differential

2.0-2.5T

3.0-3.5T

Type

Single Stage, Two-Phase, Three-Element

Model

See Part Manual For P/N

Max. Torque Converter Ratio Ko

3

Diameter Of Circulating Chamber D(Mm)

265

Max Efficiency Ηmax

0.79

Forward

15.3652

17.4972

Reverse

15.3652

17.4972

Clutch Disc Diameter(Out)Diameter(In)X Thickness

125 X 81 X 2.7 Mm

Clutch Disc Area

71 Cm

Adjusted Pressure

1.1-1.4 Mpa (159.5-203 psi)

Reduction Gear

Helical Bevel Gear

Reduction Ratio

2

2

2.1

Reduction Gear

Straight Bevel Gear

Differential Gear

Straight Bevel Gear

Reduction Ratio Mass(Kg)

5.7

6.182

165

185

Oil Capability(L)

7

Using Oil Types

DEXRON III Or MERLON III

Dimensions (L X W X G)Mm

740 X 470 X 450

12

830 X 470 X 450

2.2. Summary: Transmission Overview The hydraulic transmission is composed of a hydraulic torque converter and power shift transmission having two gears one forward and one reverse).(Fig.2-1) It has the advantages described below: (1) The hydraulic torque converter endows this hydraulic transmission with automatically adaptive hydraulic transmission output. It can change its output torque and rotating speed in accordance with changes in the external load.

(2) It can absorb and eliminate impact vibrations from the engine and external loads that would otherwise affect the transmission system.

(3) The inching valve enables the forklift truck engine to carry out inching operations at low speeds or high speeds, making operation simple and convenient and starting smooth. It enables the operator to work with much less effort.

1. GEAR SHAFT

2. TAPERED ROLLER BEARINGS

3. TORQUE CONVERTER HOUSING

4. OIL-SUPPLY ASSEMBLY

5. COVER & CONTROL VALVE ASSEMBLY

6. CLUTCH ASSEMBLY

7. SUPPORT PLATE

8. HOUSING

9. IDLER SHAFT

10. OUTPUT SHAFT

11. IDLER

12. OUTPUT GEAR

13. HYDRAULIC TORQUE CONVERTER

14. INCHING VALVE ASSEMBLY

15. DIFFERENTIAL ASSEMBLY

16. SPIRAL BEVEL GEAR

Fig. 2-1 Transmission Details

13

2.3. Principles of Operation 2.3.1 Transmission of Power (Fig 2-2) The torque converter is driven by the engine through an Flex plate. It rotates the Pump wheel (#4), in this way, the fluid flows at high speed into the turbine wheel (#2) and rotates the turbine wheel. Guide wheel make the torque converter effective, through turbine shaft (#5), it transmits the torque to input shaft assembly (#11).

When in forward gear ratio, reverse clutch at idle motion, transmit order is 11→7→20→19→17→12→13, drives the differential (#15) to output the torque. When in reverse gear ratio, onward clutch at idle motion, transmit order is 11→ 10→ 18→ 21→ 20→19→ 17→ 12→ 13, drives the differential (#15) to output the torque. Onward and reverse clutch are controlled by a shift control valve. Oil pump (#6) is inner-mesh gear pump, it is driven by the engine through Pump wheel, the oil pump supplies the oil for the system, after hydrodynamic torque converter operates, the oil flows into the radiator, then into the gear-box-lubrication clutch disc, bearings and gears.

1. FLEX PLATE 5. TURBINE SHAFT 9. SEPTA 13. GEAR RING

2. TURBINE WHEEL 3. GUIDE WHEEL 6. OIL PUMP 7. GEAR (FORWARD GEAR RATIO) 10. GEAR (REVERSE GEAR RATIO) 11. INPUT SHAFT ASSEMBLY 14. HALF-AXLE GEAR 15. DIFFERENTIAL ASSEMBLY

17. HELICAL BEVEL GEAR 18. IDLER SHAFT 21. IDLER WHEEL

19. OUTPUT SHAFT

Fig. 2-2 Transmission Sketch

14

4. PUMP WHEEL 8. CLUTCH DISC 12. GEAR SHAFT 16. PLANET GEAR 20. OUTPUT GEAR

2.3.2 Fluid Circuit Principles (Fig 2-3) After the engine is started, the oil supply pump suctions fluid from the fluid reservoir (i.e., the base of the transmission housing) through the fluid filter. It flows through the control valve, where the hydraulic fluid is divided into two parts: One part is supplied to the clutch; the other part is supplied to the torque converter The oil for the hydrodynamic power clutch flows into the main-pressure valve (pressure at 1.1MPa 1.4MPa), then separates into two parts, one part going to the inching valve and shift-control valve, the other part going to the overflow valve (pressure at 0.5MPa-0.7MPa) and torque convertor The oil from the torque converter is cooled when passing through the radiator, then lubricates the hydrodynamic power clutch, and finally, returns to the tank.

When at idle motion, the oil route from the shift-control valve to the clutch is closed. At this time, the main-pressure valve is opened, the oil flows into the torque converter through the overflow valve. When the shift control valve is in forward or reverse gear oil flows from the slide valve to onward clutch or the reverse clutch; when one clutch works, the other clutch’s disc and septa are separated, the cooling oil lubricates it and removes heat. When the inching pedal is depressed operating the inching valve, some or a majority of oil, from the clutch, returns to the tank through the inching valve lever, and the oil circle of the torque converter is the same as at idle motion.

1.OIL STRAINER 5.BUFFER VALVE 9.COOLING DEVICE

2.OIL PUMP 6.SHIFT-CONTROL VALVE

3.MAIN-ADJUSTMENT-PRESSURE VALVE 7.RELIEF VALVE

Fig.2-3 Transmission Fluid Circuit

15

4.INCHING VALVE 8.OIL STRAINER

2.3.3 Transmission Oil Pressure Measurement Procedure

Measurement procedure: Use gauge rated for 2.5MPa 1. Vehicles parked on a solid level surface, pull the parking brake lever, gear position in the neutral position, the mast tilt, fork dropped to the ground, vehicle turned off; 2 Remove the front floor plate. Pressure meter should be rated for 2.5MPa Clutch Pressure Measurement 1： （1）With Allen wrench unscrew oil drain plug； （2）Connect the oil pressure gauge, the interface is Rc 1/8 (adapter 76502624), and tighten；(Quick disconnect 76502623) （3）Open the key switch, observe the pressure gauge readings, Normal pressure: 0.3MPa; ( Forward/Reverse Clutch Pressure 1.1-1.4Mpa) （4）Turn off Engine, loosen the pressure gauge connector: （5）Replace the drain plug。 Main oil pressure measurement 2： （1）With Allen wrench unscrew oil drain plug; （2）Connect the oil pressure gauge, the interface is Rc ¼ (adapter 76502700) and tighten （3）Open the key switch, observe the pressure gauge readings, Normal pressure：1.1-1.4MPa;(159-203 psi) （4）Turn off Engine, loosen the pressure gauge connector: （5）Replace the drain plug。 Torque converter oil inlet pressure measurement 3： （1）With Allen wrench unscrew oil drain plug;； （2）Connect the oil pressure gauge, the interface is Rc ¼ (adapter 76502700) and tighten （3）Open the key switch, observe the pressure gauge readings, Normal pressure：：0.5-0.7MPa; (72-101 psi) （4）Turn off Engine, loosen the pressure gauge connector: （5）Replace the drain plug 3.Replace the front floor plate

16

DISASSEMBLY PROCESS FOR TRANSMISSION 1. Remove XMSN from truck. Remove Oil Drain and drain oil.

2. Open the locking plate on the bearing bracket, open the bolts, then remove bearing bracket(note: before you remove the bearing bracket , you need to do sign to avoid to mix the bearing bracket position). After you remove the differential assembly, then install the bearing bracket back to transmission

3. Remove the torque converter assembly (fig. 2-4)

4. Remove the Oil Pump (fig. 2-6) 5. Remove the Torque converter Housing, 3X ORings & Gasket.

6. Remove control valve assembly, 2 xO-ring and the gasket (fig. 2-8) and remove the oil filter, gasket and dipstick

7. Remove the inching valve and the gasket (fig. 2-7)

8. Remove clutch assembly and idle shaft and remove the filter, gasket & dipstick.

17

9. Remove the two side bearing cover and adjusting pad(note: after you removed the bearing cover, you need to do sign to avoid to mix the left and right side covers). Knock on the axis where close to the spiral bevel gear side, the remove the axis, two sides bearings, bush and spiral bevel gear.

10. Remove the support chip and shaft collar (note: for the adjusting shims, you need to install the same number of the shims when you install them back to the transmission). Then remove the output shaft (note: for the rear adjusting shims, you also need to all of them back to original position when you assemble the transmission)

11. Remove the output shaft and idle gear from torque converter housing (Note: the two gears position)

12. Remove the differential & gear ring (Note: Half shaft gear & Planetary when you disassemble, place thrust washer/gear in pairs to avoid mix)

13. Disassemble the clutch pack (Note: place friction plate, spacer & bearing plate in pairs) (fig. 2-5)

14. Disassemble the output shaft (Note 2 bearing assemble sequence & direction)

18

2.4. Torque Converter (Fig 2-4) The torque converter consists of the Pump wheel, turbine wheel, and Guide wheel.

The Pump wheel is driven by an input shaft, fluid turns the blades of the turbine wheel along with blades of the Pump wheel through centrifugal force(mechanical energy converted into fluid kinetic energy), transmits torque to the output shaft., Fluid flows out of the turbine, changes direction by the effect of the Guide wheel, so a portion of the fluid returns to the Pump wheel at a definite angle. At this time, there is a conversed-effect torque to drive the Guide wheel, so as to make the output torque greater than the input torque. When the rotation speed is increasing and near the input rotation speed, the fluid’s flow angle begins to decrease; and the torque of the input shaft decreases. Finally, fluid flows into the blades of the Guide wheel on the conversed direction, making the original conversed torque have a conversed effect, hence, the output torque is less than the input torque, for preventing this to happen, the clutch in the Guide can rotate freely when the things described above happen.

This kind of converted torque mode can ensure high-efficiency, steady operation.

The torque converter in the transmission device connects to the fly wheel of the engine through an Flex (flexible) plate, which follows the rotation of the engine. The inner torque converter is full of oil, driving gears connect to the Pump wheel by using the spline, so as to drive the oil-supply pump to supply oil for the torque converter and hydrodynamic power transmission. The turbine wheel connects to the turbine shaft by using the spline and transmits the power to the transmission through the turbine shaft.

1. FLUID DRAIN PLUG

2. FLEX PLATE

3. TURBINE

4. GUIDE WHEEL

5. THRUST BEARING

6. BALL BEARINGS

7. RETAINER RING

8. TURBINE SHAFT

9. ONE-WAY CLUTCH

10. PUMP WHEEL

Fig.2-4 Torque Converter

19

2.5. Two-Way Clutch (Fig 2-5) 2.5.1 Summary Overview A wet, multi-disc two-way clutch is mounted on the input shaft of the hydraulic transmission. The one-way clutch is mounted on another shaft. The two clutch drums engage by means of the outer gear rings of the drums.

The two-way clutch’s forward I and reverse clutches are each composed of six mutually assembled active friction discs (i.e., outer friction discs) and passive friction discs (i.e., inner friction discs) and one piston. Installed on the piston outer ring is a seal. Mounted on the input shaft is an O-ring to ensure a seal for operation of the piston. When in neutral gear, the piston does not move, and the friction discs and the separator plates are apart.

When gears are shifted, hydraulic pressure acts on the piston, causing the friction discs and the separator plates to press tightly against each other. Relying on the frictional force, they transmit power from the torque converter to the forward I gear or to the reverse gear (See Figure 2-5).

1. CLUTCH DRUM ASSY

2. CLUTCH PISTON

3. REVERSE GEAR

4. FORWARD I GEAR

5. SPRING

6. SPRING SEAT

7. SNAP-RING

8. RETAINER RING

9. RETAINER RING

10. THRUST WASHER

11. FRICTION DISC

12. FRICTION DISC

13. END PLATE

14. O-RING

15. SEAL

16. SEAL

17. SNAP-RING

18. SEAL-RING

19. SNAP-RING

20. BEARING-NEEDLE

21. BEARING

22. BEARING

23. SCREW PLUG

24. PLUG

25. STEEL BALL

Fig 2-5 Two-Way Clutch 20

2.5.2 Disassembly and Assembly-Two-Way Clutch • Detach the left and right-end bearings.

• Separately remove the forward I gear, the reverse gear, the active friction discs, and the separator plates.

• Compress the spring at each of the two ends; remove the retainer rings, detach the piston, and the springs.

The assembly sequence is the opposite of the dismantling sequence.

Dismantling and assembly of one-way clutches is similar to two-way clutches.      

Caution: Flush the piston cavity of the input shaft assembly, oil route, and clean all other parts except the disc.

Replace the ring (A), (B) if they are damaged.

Replace the snap-ring.

Replace the disc if it is overly worn or bent.

Restraining ring (A), (B) should face to gears.

After assembly, rotate the gears, they should rotate freely.

2.6. Charging Pump (Fig. 2-6) The charging pump is installed on the torque convertor body. The drive gear (#8) is connected to the Pump wheel. Driven by the engine, it drives the driven gear (#10) and supplies oil to the torque convertor and hydraulic transmission.

1. HOUSING 5. BOLT M8X25 9. BUSHING

2. BUSHING 6. BOLT M8X35 10. DRIVEN GEAR

3. OIL SEAL 7. GASKET 11. PIN

Fig.2-6 Charge Pump

21

4. O-RING 8. DRIVE GEAR 12. IDLER PULLEY SEAT

2.7. Inching Valve (Fig. 2-7) The inching valve is installed on the transmission cover. Inching valve: The inching valve stem (6) is connected to the inching pedal connecting rod. When one steps down on the inching pedal, the inching valve stem is pulled out. This temporarily lowers clutch hydraulic pressure and, by means of the sliding of the clutch friction discs, produces an inching effect on the forklift truck. To check pressure, measure at Item (13) location. Output pressure: 1.1-1.4MPa

1. HOUSING 5. SPRING

2. OIL SEAL 6. SPOOL-INCHING VALVE STEM

3. SNAP-RING 7. SNAP-RING

4.SPACER 8. PLUG

9. O-RING 13. SCREW PLUG

10. SPRING

11. PLUNGER

12. PLUG

Fig. 2-7 Inching Valve 2.8. Transmission Housing The transmission housing plays the same role as the tank besides housing the input and output shafts.

The oil strainer in the bottom of it filters the oil flowing to the oil-supply pump, pipe oil strainer, and the oil-add cover and oil leveler on the top of the housing- cover.

22

2.9. Cover and Control Valve (Fig. 2-8) The cover and control valve are installed on the inside of the transmission housing, and consists of the housing (#1) and control valve (#22). Speed shift arm (#12) and oil input relief valve of torque converter (#20) are installed in the transmission housing, they keep the pressure of the torque converter within 0.5MPa-0.7MPa.

1. HOUSING 5. SCREW PIPE CONNECTOR 9. SPRING 13. CONSTANT PRESSURE VALVE-SMALL SPRING 17. ADJUST VALVE PLUG 21. BOLT

2. CONICAL BORE SOCKETS BOLT 6. ELECTROMAGNETIC DIRECTION SHIFT VALVE 10. COMPOUND GASKET 14. CONSTANT PRESSURE VALVE-BIG SPRING 18. ADJUST PLUG VALVE BIG SPRING 22. CONTROL VALVE BODY

3. PIN

4. PAPER GASKET

7. PIN

8. SMALL PISTON

11. SAFETY VALVE COVER

12. PISTON 16. CONSTANT PRESSURE VALVE PLUG

15. ELASTIC COLUMN PIN 19. ADJUST VALVE SMALL SPRING

20. REEL

23. WASHER

24. CONICAL PIPE SOCKETS BOLT

Fig. 2-8 Covers and Control Valve The control valve consists of the main pressure valve (#2), buffer valve (#7), shift-control valve (#7) and so on.

1. VALVE HOUSING 5. PLUG

2. PISTON 6. LOCK PIN 4X35

3. SPRING 7. SPOOL

9. SPRING

10. PLUG

11. LOCK PIN 4X40

Fig. 2-9 Control Valve 23

4. SPRING 8. SPRING

Main pressure valve: also called the fixed pressure valve, the oil pressure for controlling the hydrodynamic clutch is at 1.1-1.4MPa, sends the oil to the relief valve, then to the torque convertor.

Buffer valve: also called the adjustment valve, between the inching valve and the shift-control valve. When the control valve is fully open, the buffer valve works to reduce the impact when the hydrodynamic clutch is connecting.

Shift-control valve: sends the pressure oil to the forward or reverse clutch, in order to make the transmission change gears.

2.10. Reducer Gear & Differential

1. BOLT M10X25 5. GASKET 9. FINAL PINION 17. GEAR-SIDE 21. PLANETARY PINION

2. WASHER 10 6. BEARING 10. GEAR RING 18. PINION SHAFT 22. THRUST WASHER

3. BEARING COVER 7. SPIRAL BEVEL GEAR 13. BOLT 19. PINION SHAFT 23. BEARING

4. O-RING 75X3.1 8. BUSHING 16. GASKET 20. PIN, PARALLEL 24. BOLT

Fig.2-10 Reducer Gear & Differential 2.10.1 Reducer Gear The reducer gear is in the front of transmission, and works to reduce the speed of the output shaft of the transmission and increase the torque from the output shaft to the differential. The reduction gear consists of a small helical bevel gear on the output shaft, a big helical bevel gear and a small gear shaft. The big helical bevel gear is fixed in a small gear shaft through a spline, the two ends of the small gear shaft are all held by a taper roller bearing and adjusted gap by shim.

2.10.2 Differential The differential is installed on the front hull by a bearing holder through a ball bearing on both ends, with the front end connected with the axle carriage. The differential carriage is divided into left and right halves, which are

24

composed of two semi-axle gears and four planetary gears. The thrust ring is placed between the differential carriage and the gears in order to have a clearance between pairs of gears. The planetary gear is held by the gear shafts I, II. Gear shaft I is secured to the differential carriage by a columnar pin, and gear loop 1 is secured to the differential carriage by a ream bolt.

The power from the transmission is transmitted to the wheel through the semi-axle gear and semi-axle when it is reduced to come into differential driving by differential.

2.10.3 Remove Differential （1）Remove bolts securing bearing seat of differential. （2）Remove the section of differential from transmission. （3）Loosen and remove bolt and column (#20), detach differential left hull from right hull. （4）Remove thrust washer (#22), gear (#18), planetary gear (#21), semi-axle gear (#17), washer, (#16) gear shaft (#19) etc.

Caution:  Be sure to lay down adjustment shims individually and to not mix them up

2.10.4 Remove Reducer Gear （1）Loosen and remove the fixing bolts from the two ends of bearing cover (#3). （2）Gently tap the front of pinion (#9) near helical bevel gear. （3）Remove bearing (#6), pinion (#9), helical bevel gear (#7)

Caution:  Be sure to lay down adjustment shims individually and to not mix them up

2.10.5 Assembly For assembly, reverse the order of removal, observing the following: （1）Prevent each fixing connecting face and gear tooth surface from knocking together （2）Coat working surfaces of parts such as bearing, gear, seal ring and moving parts with a little gear oil. （3）Each part should be assembled correctly. （4）Each part should be running smoothly to prevent it from getting stuck. （5）Be sure to tighten firmly each joint bolt.

Reduction transmission and differentials The reduction transmission and differential for hydrodynamic power transmission truck is the same as the mechanical transmission truck (see 3, 5, 6 paragraph).

Structure of auto shift valve (auto shift truck)

Auto Shift Control Hydraulic Transmission

Features

2T-2.5T

3T-3.5T

YQXD25-2 YQXD25-5 YQXD25C-5 Connected Shell, Different; The Others Are Same

YQXD30 YQXD30-5 YQXD30G1-5 Connected Shell, Different; The Others Are Same

Auto Shift Control Valve: Electrical

25

3. Drive Axle 3.1. Data Full Floating, Axle And Truck Body Direct Install, Front Wheel Driving

Drive Axle Type

(7±0.2)X105pa

Tire Pressure Wheel Hub Rotation Starting Torque At Hub Bolt Nm

10-29

Axial Play Of Wheel Bearing Mm

Less 0.08

3.2. Fault Diagnoses and Corrections Condition

Abnormal Noises

Unstable Driving

Oil Leakage

Probable Cause

Corrective Action



Loose Driving Axle and Body Connecting Bolts.

Tighten



Loose Wheel Nut

Tighten



Worn Or Damaged Wheel Hub Bearing.

Replace



Wheel Hub Bearing Not Properly Adjusted.

Adjust



Worn Axle Shaft Spline.

Replace



Insufficient Lubrication

Lubricate



Loose Wheel Nut.

Tighten



Deformed Wheel.

Replace



Worn Or Damaged Wheel Hub Bearing.

Replace



Tighten



Loose Driving Axle and Body Connecting Bolts.

Wheel Hub Bearing Not Properly Adjusted.



Improper Tire Pressure

Adjust



Worn Or Damaged Axle Shaft Oil Seal.

Replace



Final Drive Improperly Installed.



Loose Drain Plug.

Adjust

Replace Gasket Tighten

26

3.3. Drive Axle Components

1.WHEEL RIM 5.HUB BOLT 9.BOLT 13.OIL SEAL 17.PIN 21.SUPPORT SLEEVE

2.BRAKE DRUM 6.NUT 10.DIFFERENTIAL SIDE SHAFT BOLT 14.TAPERED ROLLER BEARING 18.PAPER GASKET 22.WASHER

3.HUB 7.BRAKE DEVICE 11.DIFFERENTIAL SIDE SHAFT 15.ADJUST NUT 19.OIL SEAL 23.NUT

4.WHEEL NUT 8.WASHER 12.BOLT 16.LOCK NUT 20.AXLE HOUSING 24.BOLT

Fig. 3-1 (2 pc Hub & Drum) Drive Axle < 02-01-2014 Tightening torque: N.m Item #

2T-3.5T

Support Plate Fixing Nut (#23)

324-373

Brake Drum Retaining Nut (#6)

324-373

Brake Negatives Bolt (#9)

118-147

Wheel Nuts (#4)

363-490

Axle Bolt (#10)

58-78

27

Remarks

Conical Surface On Wheel Hub Nut Doesn’t Require Grease

1. PLATE 6. BOLTS 11. TIRE ASSY 15. PAPER GASKET 19. LOCK 23. BEARING 7815

3. PLATE 7. BRAKE ASSY 12. SEAL 16. LOCKNUT 20. AXLE 24. AXLE BOLTS

4. WASHER 9. BOLTS (BRAKE) 13. BEARING 17. WASHER 21. SEAL 25. WHEEL BOLTS

5. NUT 10. WASHER 14. WHEEL 18. BOLT 22. SEAL SEAT 26. WHEEL NUTS

Fig. 3-2 (1 pc Hub & Drum) 2.0-3.5T Drive Axle > 02-01-2014 Tighten torque：N.m 2T-3.5T

Hub Fixing Nut Support Plate Fixed Nut（#5）

324-373

Bolt, Brake Plate Assy（#9）

190-210

Wheel Hub Nut（#26）

363-490

Half Shaft Bolt（#24）

90-120

28

Remark

Conical Surface On Wheel Hub Nut Doesn’t Require Grease

3.4. Assembly and Disassembly of Drive Axle Warning:  Be careful when removing and installing the drive axle as it is heavy. （1）Raise front end of forklift truck and support frame with wooden blocks. （2）Remove mast assembles. （3）Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and transmission case. （4）After placing a pan under axle case, loosen oil plug, drain oil from axle case. （5）Disconnect brake nuts from left and right cylinders.(see fig.3-3)。 Caution:  Plug brake tube openings to prevent oil from flowing out. （6）Disconnect brake cable at hand brake lever. （7）Remove front wheels. （8）Remove axle shaft. （9）Support driving axle with Steel cable or chain and lifting device. （10）Remove bolts securing axle mounting bracket to frame.(see fig.3-4). （11）Remove nuts securing axle case to differential gear carrier.(see fig.3-5). （12）Remove driving axle assemble.

Fig. 3-3

Fig.3-4

Fig.3-5

（13）Remove brake drum then remove wheel hub. （14）Remove axle mounting bracket and brake component from axle tube. （15）Remove oil seal from axle tube. （16）To install driving axle assemble in the reverse order of removal. Observe the following: ① When installing axle mounting bracket and brake component, apply a coat of calcium grease to axle tube. ② Apply 1/3-2/3 of volume of calcium grease to wheel hub then install them on axle tube. ③ Install oil seal with its part number facing to the inside of forklift truck. ④ Install drain plug after cleaning it and covering it with seal tape (PVC, white). ⑤ Replenish axle case with gear oil. Tighten vent plug after clearing.

Gear Oil GL-585W/90 (L)

3.2

2.0T-3.5T hydro-transmission forklift except RW15A

Vent plug should clear instantly to prevent pressure buildup inside wheel hub.

29

3.5. Axle Shaft and Wheel Hub Remove （1）Raise the front end of forklift truck and support frame with wooden blocks. （2）Remove front wheel and axle shaft. （3）Remove lock nuts, lock washers, snap-ring, felt ring, and adjusting nut. Use special tools. （4）Remove brake drum (refer to Fig.3-6)； If brake drum is difficult to remove, remove adjusting rubber plug. Then with flat-blade screwdriver extend adjusting hole, turn adjusting ratchet wheel by 10 notches. To retract brake shoe lining (refer to Fig.3-7), evenly tap on brake drum with rubber mallet.

Fig.3-6

Fig.3-7

（5） Remove wheel hub, be careful not to drop bearing inner race. （6） Remove oil seal and inner bearing as an assembly. To do this, evenly tap on periphery of seal with a rubber mallet. （7） Remove bearing outer race from wheel hub by evenly tapping on its periphery with a rubber mallet.

Caution: 

Be careful not to damage oil seal and outer race.

Inspection 

Stepped wear or cracks on axle shaft splines

Replace



Seized, scratched, noisy or rusted bearing or improper rotation of rollers

Replace



Cracked or damaged wheel hub

Replace



Damaged oil seal.

Replace

Installation For assembly, reverse order for removal.

30

3.6. Bearing Adjusting （1）Lubricate taper roller bearing. （2）Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one hand. （3）From that position, turn back lock nut approx. 60°. （4）Turn back wheel hub two or three rotations so that bearing settles down. （5）Again tighten lock nut until it can no longer be rotated with one hand; then turn back approx.600. （6）Install snap-ring and attach felt ring, install lock washer so it’s hole in the pin of snap-ring.

Screw lock nut. （7）Turn wheel hub back and forth two or three rotations to see if rotation starting torque is within specifications. Rotation starting force：2.0T-3.5T is 10-29N, (refer to Fig.3-8); （8）Measure axial play of wheel hub to see if it is within specification. Axial play should be less than 0.10mm (refer to Fig.3-9).

Fig.3-8

Fig.3-9

31

4. Steering Axle 4.1. General Specifications Axle body type

Center-pivoted, turn around type

Turning angle

Inside turning angle Outside turning angle

2-3.5T

Vertical Play (mm)

0-0.5

77.8° Shims for end shaft of axle

2-3.5T

See Parts Manual

54.3° Thickness (mm)

Tire pressure

0.6, 1.0, 2.0

0.7MPa

Kingpin

Wheel Hub Bearing

Kingpin axial play(mm)

Less than 0.20 Pre-tighten

Kingpin adjusting washer thickness(mm)

Part No.

0.10,0.30,0.70

66000434

Axial play(mm)

Tighten steering spindle nut until drive wheel hub no longer rotates with one hand.

Then loosen 1/8-1/6 rotations.

Or wheel hub bolt force is 1029.8Nm Less than 0.10

4.2. Fault Diagnoses Corrections Condition

Unstable driving

Noises

Probable cause

Corrective action



loose wheel nut

Tighten



wheel bearing out of adjustment

Adjust



improperly adjusted shims

Adjust



faulty steering system

Refer to turning system section



insufficient lubrication

Apply calcium grease



loose bolts and nut

Tighten



improperly adjusting shim for axle end shaft

Adjust



damaged joint bearing at two ends of rod

Replace

32

Fig. 4-1 Steer Axle

33

4.3. Steering Axle Remove wheel hub （1）Raise forklift truck body and support with wooden blocks. （2）Remove tire. （3）Remove hubcap. （4）Remove steering spindle nut. （5）Pull off hub assembles. （6）Remove bearing inner race.

Caution.

Do not drop bearing inner race.

Do not damage oil seal.

4.4. Steering Kingpin and Steering Spindle （1）Remove rod.

Figure 4-2 （2）Loosen lock bolts(see Fig.4-2). （3）Remove grease fittings on kingpin. （4）Remove kingpin.

Caution: Hold kingpin to prevent it from dropping. (See Fig.4-3). （5）Take off spindle, thrust bearing and shim.

Inspection: （1）Replace spindle if cracked. （2）Replace bearing if its rollers or roller surfaces are rusted or nicked. （3）Replace steel sleeve if it is distorted, out of round, or cracked. （4）Replace thrust bearing and dust cap if they are damaged.

Installation： Figure 4-3 For assembly, reverse the order of removal. Carefully observe the following: （1）Always insert kingpin from the lower side. （2）Install thrust bearing, set the tightening-ring below the support and loosening-ring. Pack all grease between dust proof inside, loosening-ring, and tightening-ring. （3）Adjust axial play to specification with shims. Axial play should be less than 0.15mm. （4）The character of seal tape faces outside. Apply grease to roller of roller bearing, also apply grease between lip and groove of seal tape. （5）Pack all grease fittings with a sufficient amount of grease.4.5. Wheel bearing adjustment （1）Slowly rotate hub. Tighten steering spindle nut until it can no longer be rotated with one hand. （2）From that position, turn back steering spindle nut 1/6-1/4 rotation. Measure hub bolt force is 2N-10Nm. （3）Make sure that hub rotates smoothly and that its axial play is within specifications. Axial play should be less than 0.12mm.

4.5. Wheel Bearing Adjustment （1）Slowly rotate hub. Tighten steering spindle nut until it can no longer be rotated with one hand. （2）From that position, turn back steering spindle nut 1/6-1/4 rotation. Measure hub bolt force is 2N-10Nm. （3）Make sure that hub rotates smoothly and that its axial play is within specifications. Axial play should be less than 0.12mm.

34

Fig 4-4 Torque values for Steer Axle Components

35

5. Steering System 5.1. Data Steering system type

Change direction rear wheel with power steering 2T, 2.5T, 3T, 3.5T

Model hydraulic steering control unit

530-1322

Displacement ml/r

100

Type of connection

Inner spline

Features

Steering cylinder

Open center, low torque

Cylinder diameter (mm)

Ø65

Piston diameter (mm)

Ø40

Stroke (mm)

195

Wheel diameter (mm)

Ø360

5.2. Trouble Shooting Condition

Probable cause Damaged or trouble of oil pump

Failure to rotate steering wheel

Clean or replace

Damaged hose or connector, blocked lines

Replace or clean

Divide value pressure too low.

Adjust pressure Remove air

The steering fails to turn to its natural position, broken lock spring or insufficient spring pressure Too much internal leakage in steering cylinder.

Track travel zigzag or wobbly

Replace

Divide value is clogged or damaged.

Air in oil lines.

Difficult to steer

Corrective action

Too much oil flow to steering cylinder.

Replace spring flat Check piston for sealing Adjust divide value

Oil is not sufficient in oil tank.

Add oil.

Suction piping or filter clogged.

Clean or replace

Abnormal noise

Leakage

Damaged sealing of oriented bush of steering cylinder or hose or connector.

36

Replace

5.3. Summary The steering system is composed of the hydraulic steering control unit and the steering cylinder.

5.3.1 Hydraulic Steering Control unit assembly (Fig.5-1) The hydraulic steering control unit assembly includes the cyclical full hydrostatic power steering gear, steering column and steering wheel. The steering column and steering wheel can be adjusted 8°back or forth to accommodate all operators.

When the engine stops running, rotate steering wheel with 1kg force slightly in any direction, steering wheel should be return 10° after leaving hands automatically.

Fig. 5-1 Steering Column Assy

37

5.3.2 Hydraulic Steering Control Unit (Fig.5-2) When power steering is active, pressure oil flows from valve disk and valve sleeve pair to the rotary-stator valve pair, then drives rotary to rotate following the turning direction of the steering wheel, and drive oil enters the left or right cavity of the cylinder, and causes the steering tire to turn by the piston rod.

When the engine stops running, the pump does not supply oil, and the steering action must be accomplished manually by turning the steering wheel to move the valve spool, valve guide, coupling block, and to actuate the rotor to feed oil into the steering cylinder. The case, rotor and stator act as a hand pump, making manual steering possible. .

1. CONNECTED BLOCK 5. O-RING 9. SLIP RING 13. REAR COVER 17. VALVE DISK VALVE SLEEVE PAIR

2. FRONT COVER 6. X-RING 10. O-RING 14. BOLT 18. HOUSING

3. SCREW 7. STOP RING 11. DIAPHRAGM 15. STOP BLOCK 19. STEEL BALL

Fig. 5-2 H ydraulic Steering Control Unit

38

4. SPRING 8. THRUST BEARING 12 ROTARY-STATOR PAIR 16. COUPLE AXLE 20. STOP BOLT

5.3.3 Steering Cylinder (Fig.5-3) The steering cylinder is of double-acting piston type. The two ends of the piston are connected with the steering spindle through a rod. The oil from hydraulic steering control unit makes piston rod move left and right so as to turn truck lift and right.

1. CONNECTOR 5. ROD WIPER 9. O-RING 13. HOUSING

2. SNAP RING 6. O-RING 10. GUIDE SLEEVE 14. CYLINDER

3. BUSHING 7. SEAL RING 11. O-RING 15. PISTON ROD

4. SNAP-RING 8. ROD WIPER 12. PISTON SEAL

Fig. 5-3 Steering Cylinder 5.4. Install Steering System Carefully observe the following: （1）Hydraulic tie-in, bolts and piping must be clean before installing. （2）Check oil lines arrangement for properness, whether it is reverse order of steering direction or not, refer to steering system. （3）Turn wheel completely to the left and right to make sure turning force is even throughout. （4）Raise rear wheel and turn steering wheel slowly to the left and right and repeat it to bleed air from hydraulic lines and cylinder.

39

6. Brake System 6.1. Fault Diagnoses and Corrections Condition

Insufficient brake force

Unequal braking (forklift truck veers to one side)

Brake dragging

Brake noise.

Probable cause     

Corrective action Correct and replenish.

Bleed air.

Clean or replace.

Replace.

Correct or replace



Oil leakage in brake lines.

Air in brake lines.

Water or oil on linings.

Uneven wear or contact of brake linings Improper functioning of master cylinder or wheel cylinder.

Clogged oil lines.

             

Uneven tire pressure.

Brake out of adjustment.

Water or oil on brake linings.

Foreign particles in brake drum.

Deteriorated lining surface.

Improper contact of linings.

Worn lining.

Worn, warped, rusted or damaged brake drums.

Improper operation of wheel cylinder.

Improper sliding shoes.

Loose back plate blots.

Warped back plates.

Improperly adjusted wheel bearing.

Clogged oil lines.

Adjust.

Adjust.

Clean or replace.

Clean.

Replace.

Correct.

Replace.

Correct or replace.

Correct or replace Adjust.

Tighten or replace.

Replace.

Adjust or replace.

Clean.



No free play of brake pedal.

Adjust.



Improper shoe sliding.

Adjust



Improper operation of wheel cylinder.

Adjust or replace.



Faulty piston cup.

Replace.



Weak or broken return springs.

Replace.



Clogged master cylinder returns port.

Clean



Clogged oil lines.

Clean.



Wheel bearing out of adjusting.

Adjust or replace.



Lining surface harden or foreign particles on it.

Repair or replace.



Warped back plates or loosed blots.

Repair or replace.



Brake shoes warped or improper install.

Repair or replace.



Worn linings.

Replace



Loose wheel bearing.

Repair

40

Clean

6.2. Summary The brake system is the front two-wheel braking type consisting of a master cylinder, brakes and brake pedal.

6.2.1 Master Cylinder (Fig. 6-1) The 2-3.5T master cylinder contains a valve seat, check valve, return spring, primary cup, piston and secondary cup, which are kept in place with a stop washer and stop wire. The exterior of the cylinder is protected from dust by means of a rubber dust cover. The piston is actuated through the push rod by operation of the brake pedal. First, as the brake pedal is depressed, the push rod pushes the piston forward. The brake fluid in the cylinder flows back to the reserve tank through the return port until the primary cup fills up the return port. After the primary cup passes the return port, the brake fluid in the cylinder is pressurized and opens the check valve, flowing through the brake lines to the wheel cylinders. Thus, each wheel cylinder piston is forced outwards. This brings the brake shoes into contact with the wheel drums and slows or stops the lift truck. Meanwhile, the cavity created behind the piston is filled with brake fluid led through the return port and inlet port to lubricate the pistons.

When the brake pedal is released, the piston is forced back by the return spring. At the same time, the brake fluid in each wheel cylinder is pressurized by the force of the brake shoe return spring, thus returning to the master cylinder through the check valve. With the piston in its original position, the fluid in the cylinder flows into the reserve tank through the return port. The brake fluid in the brake lines and wheel cylinders has a residual pressure proportioned (about 0.04MPa) to the set pressure of the check valve, which makes each wheel cylinder piston cup securely seated to prevent oil leakage and eliminates the possibility of vapor lock developing when the lift truck is sharply braked.

Brake principle of brake master cylinder of 1-1.8t forklift is similar to that for 2-3.5T forklift.

1. LOCK NUT 5. GASKET RING 9. RAFFINATE VALVE

2. ROD 6. PISTON 10. VALVE SEAT

3. BOOT 7. PRIMARY CUP 11. CYLINDER HOUSING

Fig. 6-1 Master Cylinder

41

4. LIGHT SPRING 8. SPRING

6.2.2 Brake (Fig. 6-2 & Fig. 6-3) 2.0T-3.5T forklift right-hand structure, see fig. 6-2, structure of forklift hand brake is similar to 2.0T-3.5T.

1.BRAKEPLATE 5. BRAKE LEVER 9. LINK ACTUATOR 13. WASHER 17. WASHER 21. PLUG 25. HOUSING, WHEEL-CYLINDER 29. CUP, PISTON 33. CAP, SCREW 37. HOUSING-ADJUSTER

2.PIN 6. SPRING, SHOE RETURN 10. STRUT 14. SPRING 18. PIN SHOE HOLD 22. CABLE, CONTROL 26. COVER, DUST 30. SPRING 34. CAP, DUST 38. BOLT ADJUSTER

3. BRAKE SHOE 7. TOGGLE SHOE GUIDE 11. SPRING 15. WASHER, CUP 19. PIN LEVER 23. BOLT 27. ROD, PISTON 31. SEAT TUBE 35. RIVET 39. WASHER

Fig. 6-2 2.0T-3.5T Brake RH < 12-31-2013

42

4. WASHER 8. LINK, PAWL LEVER 12. LEVER PAWL 16. SPRING 20. WASHER 24. WASHER 28. PISTON 32. SCREW BLEEDER 36. PLATE 40. ADJUST STAFF

1.BRAKE PLATE ASSY 5. PIN 9. RETURN SPRING 13. PIN-LEVER 17. SPRING 21. CYLINDER ASSY 23. WASHER

2. BRAKE SHOE 6. WASHER-CUP 10. ADJUSTER 14. SPRING 18. SPRING 21-1. CUP-PISTON 24. CABLE-CONTROL

3. PLUG 7. SPRING 11. LEVER 15. LINK-LEVER 19. STRUT 21-2. COVER

Fig. 6-3 2.0T-3.5T Brake RH > 12-31-2013

43

4. LEVER 8. WASHER-CUP 12. SHIM CLIP 16. WASHER-CUP 20. TOGGLE-SHOE GUIDE 22. BOLT

6.2.3 Brake Adjustment: 1. Follow the Gap adjustment procedure items 1-8 in the Replacing brake shoe section item (9).

Note: Adjuster nut (wheel) adjustment step is very important, if ratchet adjustment is over tighten, it can cause the brake drum to heat up and cause premature wear on the brake drum.

2. Get back in the seat, start in forklift, tilt the mast forward, lifting forklift drive wheels off the surface. Using both hands turn the drive wheels both forward and backwards to check for rotation, wheel should turn freely. Otherwise, need to re-adjust nut (wheel) until it meets the requirements.

6.2.4 Replace Brake Shoe: Method of replacing brake shoes: 1) Park the forklift truck on a level concrete surface.

2) Start the engine and raise the fork approximately 100 mm.

3) Stick wheel chocks behind the rear wheels to prevent the forklift truck from moving back.

4) Loosen each wheel nut 2 to 3 turns.

5) Tilt the mast all the way back, and place a solid wood block under each side of the mast.

Warning: DO NOT allow wooden blocks do not come into contact with the front tires.

6) Tilt the mast forward until the tires leave the ground.

7) To support the forklift truck, add wood blocks on both sides of the front of the truck frame.

8) Turn off the engine.

9) Remove the wheel nuts and brake drum.

10) Replace with new brake shoe.

11) Reinstall the brake drum.

12) Adjust the gap between the shoe and the drum. The method is: ① Remove the rubber plug from the adjustment hole under the brake base plate. ② Insert a flat-bladed screwdriver into the adjustment hole. Turn the teeth on the adjustment ratchet downward, causing the brake shoe to open. At the same time, turn the wheel hub by hand until it can no longer turn. ③ Then turn the ratchet up 2 or 3 tooth positions. At this point, the wheel hub should turn freely, but allow there to be slight friction between the brake and the brake shoe. ④ Insert the rubber plug. ⑤ Install the wheel. ⑥ Adjust the pedal so that it has the correct travel distance. ⑦ Remove all the blocks. ⑧ After confirming that there are no people or obstacles near the forklift truck, back up the forklift truck at a speed of 2 km/h to 3 km/h. Step down on the brake pedal 2 or 3 times. If necessary, repeat steps until brakes function correctly 6.2.5 Park Brake (Fig. 6-4, Fig. 6-5 & Fig. 6-6) The parking brake uses the service brake shoes. Additional linkage pushes the shoes apart when the hand lever pulls the cables. Together with the foot brake, it shares the use of the shoe-type braking device that acts on the front wheels. Only use the parking brake when parking the forklift. If while driving the forklift truck you discover that the service foot brake is malfunctioning, you may also use the parking brake to bring the forklift truck to a stop.

The pulling force required for the parking brake lever is adjusted through the flat-bladed screw on the head of the lever. Turn the screw clockwise to increase the pulling force. Turning the screw counterclockwise will decrease the pulling force. Keep the pulling force in the 100N - 300N range.

44

Fig. 6-4 Park Brake

Fig. 6-5 Park Brake with OPS Switch 1.MICRO SWITCH

2. CAPSCREW M4X25

45

3 & 4. GASKET

5. WIRE HARNESS

Verify Drive System is working normally before adjusting Hand Brake.

1. Turn Nut B until length 68mm is obtained, then lock Nut B. 2. Turn Nut A to adjust Hand Brake Pull Force. Pull Force range 147N-196N at point P in the Q direction.

3. After adjusting Hand Brake Pull Force, Release Park Brake and verify brakes are released.

4. Set and release Hand Brake to check that adjustment are working properly.

Note: Use Lithium lubricating grease on guide rail C routinely.

Fig. 6-6 Park Brake Adjustment

46

7. Hydraulic System 7.1. Data Main Pump 2.0T-3.5T Model

Yanmar

Mazda/PSI

Type

Gear

Driving

Engine power take off type: gear

Displacement( ml/r)

26.5

30

Speed(RPM)

2450-2700

Output pressure (Rated/Max.) MPa

20/25

Hydraulic Control Valve 2.0T-3.5T Model

See Parts Manual

Type

Double-slide valve, with overflow divided valve and tilt-lock valve

Adjusting pressure MPa

18.5(can lift 110% of rated load, cannot lift 125% rated load)

Rated flow rate L/min

65

Pressure MPa

8.8±0.25

Flow rate L/min

12±1

Divide valve

47

7.2. Fault Diagnoses and Corrections 7.2.1 Main Pump Fault

No oil from oil pump

Probable cause

Corrective action

Low oil level in tank.



Add oil to specified level.

Clogged suction pipe or strainer.



Clean oil line and tank. If oil is dirty, change.

Worn bearing, damaged backup ring and O-ring.



Replace faulty parts.



Readjust to specified pressure using pressure gauge.



Retighten suction side pipe. Add oil in oil tank.



Check pumps oil seal.



Do not operate pump until bubbles in tank disappear.

Cavitation due to crushed suction hose or clogged strainer.



Adjust or replace crushed hose and clean strainer.

Air being sucked from loose suction side joint.



Retighten each joint.



Replace with new oil having proper viscosity for temperature at which pump is to be operated.



Operate when oil temperature is normal.



Determine cause of bubbles and remedy.



Replace faulty parts.

Maladjusted relief valve.

Low discharge pressure on oil pump.

Air in oil pump.

Noisy oil pump Cavitation due to too high oil viscosity.

Bubbles in hydraulic oil.

Faulty oil seal on pump, faulty Oil leaking from oil pump O-ring or worn sliding surfaces on pump.

48

7.2.2 Control Valve Fault

Pressure of relief valve is not steady or too low.

Fork tilt forward when control lever is used while engine is off.

Mast is unstable when tilting forward.

Lowering distance of mast is big when spool valve is in the center.

Spool valve is not return neutral position.

Leakage

Probable Cause

Corrective Action



Loose pressure-adjust screw.



Distorted or damaged pressureReplace. adjust spring.



Worn or blocked relief valve core.

Replace or clean.



Pump abated.

Examine and repair pump.



Worn or damaged tilt lock valve.

Replace valve core and tilt lock valve as an assembly.



Broken tilt locks spring.

Replace spring.



Damaged tilt valve plunger Oring.

Replace O-ring.



Malfunctioning tilt relief valve.

Replace tilt relief valve assembly.



Valve body and spool valve is worn and clearance between them is too great.

Replace spool valve with specified clearance.



Spool valve is not in center.

Keep spool in the center.



Cylinder seal abated.

Examine and repair cylinder.



Taper valve is worn or blocked by dirt.

Replace or clean taper valve.



Damaged or distorted repositionReplace spring. spring.



Dirt exists between valve body and spool valve.

Clean.



Blocked control device.

Adjusted.



Not coaxial parts at reposition

Reinstall be coaxial



Damaged O-ring.

Replace.



Faulty seal of joint.

Check and retighten.



Loose seal plate.

Clean seal plate and retighten blots.



Loosed lock-nut of relief valve and Tighten. connect-nut between plate and plate.

49

Readjusted and retighten.

7.3. Main Pump 7.3.1 2-3.5T Main Pump (Fig 7-1) The main oil pump is a gear pump. It is primarily composed of a pump housing, a pump cover, a pair of gears, a bearing, and seal rings. The main oil pump employs a load-balancing bearing and a special lubrication method which minimizes the gap at the gear ends.

Because the pump housing and pump cover are made from aluminum, they are light and sturdy. The active gear and the passive gear each have two shafts that are individually installed on pump housing bearings. These bearings are made of a special material. On the one hand, they bear the radial load of the gear. On the other hand, they serve as seats for the gear ends.

On the drive shaft side, a fluid seal is installed on the pump housing. To ensure sealing capabilities, the seal between the pump housing and the cover rely on a specially-shaped seal ring.

1. SNAP-RING 5. 3-SHAPE BACKING PLATE 9. DRIVE GEAR 13. MOUNTING BOLT

2. OIL SEAL 6. PRESSURE PLATE 10. GEAR PLATE

3. MOUNTING FLANGE 7. BUSH 11. END COVER

Fig.7-1 Gear Pump

50

4. SEAL PLATE 8. DRIVEN GEAR 12. WASHER

7.4. Hydraulic Control Valve (Fig. 7-2) The two lever type control valve consists of a four-spool valve housing, two plungers, a relief valve and a divided valve. The four spool valve housing is assembled with three bolts and nuts. The tilting plunger is fitted by tilting the lock-self valve. According to the requirements of the work device, it is capable of adding combined lock valve and rotating valve.

Fig.7-2 2 Lever Hyd. Control Valve for 2-3.5T Forklift Truck 7.4.1 Main Relief Valve and Flow Dividing Valve (Fig. 7-3) The main relief valve is a pilot valve; used for limiting the maximum pressure of the system. The main relief valve disk is not open under normal operating conditions. When the truck works at overload condition, or hydraulic system faults come, the system pressure is up to the set value of main relief valve, the pilot valve disk firstly opens, and then control valve disk opens to make system pressure not increase continuously, thus ensuring the system stays safe.

The steering relief valve is a directly operated type valve. Its set value is lower than the main relief valve.

When steering system malfunctions or the load is too big, pressure is up to set value by spring, and pressure overcome spring and friction force to open relief valve, thus ensuring the steering system stays safe.

One end of the pilot valve disk connects with the oil inlet of steering valve, and the other end connects with the steering valve outlet (signal port), keeping the pressure difference invariable, the pilot valve supplies proper oil flow according to the rotated speed of steering wheel by operator.

Extra oil flows to supply other working devices via a control valve. This device can improve system efficiency, reduce oil temperature, and improve experimental environment of the system.

51

Fig. 7-3 Main Relief Spool 7.4.2 Main Relief Pressure Adjustment The pressure of the main relieve valve is already adjusted at the factory, and it generally cannot be adjusted.

The following example of a 3T truck specifies how to adjust the pressure. （1）Put 125 percent of the rated load (3750kg) on the forklift stable. （2）Depress the accelerator all the way, operate the lift pole, if the forklift can be raised to a height of 0-300mm, the main relieve valve is all right. Otherwise, adjust it as per step (3). （3）If the forklift doesn’t work, enhance the pressure main relieve valve, remove the front soleplate, loosen the tightening nut of the main relief valve, turn the adjusting nut clockwise to enhance the pressure of the main relieve valve. If the height of lift is higher than 300mm, screw the adjust nut counterclockwise to reduce the pressure. （4）Depress the accelerator all the way to raise the forklift to a height between 0-300mm.

Otherwise, adjust it as step (3). （5）Retighten the tightening nut, and fix it on the front soleplate.

Warning:  

The load should be stable.

Don’t adjust if the pressure is already adjusted correctly.

52

Hydraulic Valve Pressures are pre-set at factoring and shouldn’t need to be adjusted.

Use the following to check hydraulic pressures at the valve.

1. Park truck on flat solid smooth surface. Set Park brake and place truck in neutral. Tilt mast all the way back. Place fork on surface. Turn off truck.

2. Remove floor plate, remove plug from hose/tube assemble (set aside), Capture any fluids.

3. Install adapter (76502624) torque (20-22Nm) and quick disconnect (76502623).

Connect the pressure gauge (should be larger than 20Mpa) 4. Start the engine, tilt mast forward until mast channel is 90° to floor and forks are 300mm from surface.

5. Check Pressure: 2.0t-3.5T: 18.5MPa± 0.25MPa 6. To Adjust Pressure: turn Adjusting bolt clockwise to increase, counterclockwise to decrease.

7. Wait for Pressure to stabilize, remove the gauge, replace plug, torque to 20-22Nm. Drop mast to surface, tilt mast back.

8. Retighten the adjusting nut.

Replace floor plate.

53

7.4.3 Operation of Tilt Lock Valve The tilt lock valve is fitted by a lock-self valve to prevent vibration owing to back pressure inside the tilt cylinder and to avoid injuries due to a malfunction. According to common structure, it can operate the tilt spool to tilt forward after the engine is off, but using the tilt lock valve, when engine is off, it cannot tilt mast forward even push the lever of operation valve, the structure is shown as Fig. 7-4.

The connector of valve body “A” & “B” connects separately with front and rear housing of the tilt cylinder piston. When pulling out the spool, high pressure oil (P) enters connector “A”, oil in rear housing returns to oil tank (T), during this time the mast is in tilting backward.

When pulling the tilting spool, high pressure oil enters connector “B”, by high pressure oil, lock valve in spool works to make “A” to connect with low pressure. When the engine is off or stopped, the lock valve in the spool cannot work without high pressure oil, so that connector “A” cannot connect the low pressure line and the mast cannot tilt forward, also there is no back pressure in tilt cylinder.

Fig. 7-4 Tilting Spool 7.5. Hydraulic Schematic The high pressure oil from the main pump goes to the control valve and divides into two parts by a priority valve inside the control valve: one of them goes to the steering gear control steering cylinder, with the remaining part going to the lift cylinder or tilt cylinder. When the lift and tilt spool is in neutral, high pressure oil returns to the oil tank directly from pass way. When pulling the lifting spool, high pressure oil goes by throttle valve and then pushes the piston rod under the lift cylinder piston. When pushing the lift spool, it is that bottom of the lift cylinder piston that connects with a low pressure line and then the piston rod drops by deadweight and weight of cargo.

During this time, oil from the lift cylinder goes by the unidirectional speed limiting valve so as to control the falling speed. When operating the tilt spool, high pressure oil goes to the front housing of the tilt cylinder and another connects with a low pressure line in order to make the mast tilt forward or backward.

The cutoff valve is located under the right lift cylinder and its function is to prevent goods from falling suddenly when an oil pipe bursts.

54

Fig. 7-5 (a) Hydraulic Schematic with Labeling

55

Fig. 7-5 (b) Hydraulic Schematic without Labeling

56

8. Lifting System 8.1. Assemble Data 2 Stg FFL Mast and 3 Stg FFL Mast Standard type and lifting height of 2-4 meters

Lifting height >4-5 meters

Lifting height > 5-6 meters

Forward

6°

6°

3°

Backward

12°

6°

6°

Mast type Mast tilt angle Fork arm carrier roller

Adopt combination roller and side roller if rated capacity is less than 3.5T.

Inspection and Adjustment Place Mast to lift roller Shims Mast to back up metal Shims

Assembly clearance (mm) Repair clearance(mm) 0.1-0.8 0.2-1 0.5, 1.0, 2.0 0.1-0.8 0.2-1 0.5, 1.0, 2.0

Inner mast to carriage side roller

0.1-0.6

Shims Lift chain deflection

0.2-1 0.5, 1.0, 1.5 25-30 mm

Tightening Torque Place

Model or Lifting capacity

N·m

Lift chain lock nut

2.0T-3.5T

245-314(M20)

Mast support cap bolt

2.0T-3.5T

176-216(M18)

Tilt cylinder lock nut

2.0T-3.5T

89-118(M14)

Lift cylinder bolt (top)

2.0T-3.5T

76-107(M12)

Lift cylinder bolt (bottom)

2.0T-3.5T

44-58(M10)

Lift cylinder fixing bolt (cylinder light bolt)

2.0T-3.5T

76-107(M12)

Basic model Mast Weight Model (truck)

2T

2.5T

3T

3.5T

Weight (mast) kg

575

644

721

820

57

8.2. Fault Diagnoses and Corrections Condition Carriage or mast tilts by itself.

The Carriage moves up and down sluggishly.

     

Fork lifting movement not smooth.

 

Carriage sides unevenly

  

Lift roller do not rotate    Excessive mast noise  

   Lifting weak or cannot lift.

  



Probable Cause Corrective action Replace piston ring tilt cylinder.

Tilt cylinder and ring abraded excessively The hydraulic control valve spring is Replace. inoperative.

Caused by piston jamming or bent piston Replace the faulty parts. rod.

Too much dirt is accumulated in the cylinder. Strip it down and clean.

Adjust clearance with thrust metal Carriage bracket assembly out of and carriage side roller. adjustment.

Insufficient clearance between inner and Adjust clearance with rollers. outer masts or rollers and mast.

Biting foreign backing materials between Remove foreign backing materials. moving parts.

Apply grease on contact surfaces of Insufficient lubrication. sliding parts.

Repair or replace.

Bent carriage bracket assembly.

Adjust lift chains.

Lift chains out of adjustment.

Grease stiffened or dirt accumulated on lift Clean and lubricate lift rollers. roller and mast sliding surfaces.

Adjust.

Improperly adjusted lift roller.

Lubricate.

Insufficient lubrication.

Improperly adjusted lift roller, side roller Adjust. and back-up metal.

By adjusting shims and rubber pad, piston rod is in touch with bottom Rubber pad on lower of outer mast is of cylinder body after inner mast is useless for container fork lift truck. in touch with rubber pad.

Excessive wear occurs between the oil Replace the worn parts or the oil pump body and gears, causing too much pump. clearance.

The lifting jack piston Yx-ring is worn, Replace Yx-ring. resulting in excessive inner leaks.

Springs of the multiple control valves and Replace. its relief valve are inoperative oil leaks.

Excessive wear on the hydraulic control Replace. valve, resulting in excessive oil leaks.

Dismantle for regrinding the joint Oil leaks occur between the hydraulic surfaces and reassemble the valve. control valve sections.

Tighten the joint nuts and inspect Leakage occurs in the hydraulic pipe. the seal for damage.

Change the wrong hydraulic oil or The hydraulic oil temperature is too high. stop operation for reducing the oil temperature. Find out the reasons Oil viscosity is too low and the rate is for high oil temperature and insufficient. eliminate the problem.

The load carried is beyond the designed Observe the lifting capacity limit. capacity.

58

8.3. Summary The forklift truck lift system is composed of the mast, fork carriage, fork, backrest, lift chain, rollers, lift cylinder, and tilt cylinder. Together with the fluid circuit and hydraulic system, it constitutes an operating unit of the forklift truck. It is the mechanism whereby the forklift truck performs loading and unloading operations. Generally, it is classified according to the type of mast structure. An ordinary mast is classified as one-stage, two-stage, or threestage. The forklift trucks manufactured by our company are equipped with three types: two-stage limited free lift masts, two-stage full free lift masts (including container masts), and three-stage full free lift masts.

8.3.1 2 Stg LFL Mast (fig. 8-1) The two-stage mast is composed of an outer mast that can neither rise nor drop and the inner most that can be retracted or extended vertically. The bottom of the lift cylinders are mounted on the lower cross-bar of the outer mast and are secured by U-bolts. The piston rod end and the inner mast upper cross-bar assembly connect. Generally, lift cylinders have a free lift range of 150 mm. Two main lift cylinders are positioned behind the mast (on the outside of the mast in some small-ton forklift trucks) in order to achieve a wide field of vision.

The fork is hung on the fork carriage using hanging hooks. There are vertical rollers and side rollers installed on the fork carriage. There are vertical rollers and side rollers installed on the lower end of the inner mast.

Hydraulic fluid from the hydraulic control valve passes through the speed-limiting valve into the lift cylinder, pushing up on the piston and piston rod and thus driving the inner mast to lift. At the same time, one end of the chain installed on the inner mast chain wheel is secured immovably to the outer mast. One end is connected to the fork carriage. As the inner mast rises and pulls the fork carriage, the fork is lifted, thus realizing the load lifting objective.

The basic type supplied by our company is forklift trucks that lift 3 meters. Other lifting heights (3.3 m - 4.5 m) are special ordered.

8.3.2 2 Stg FFL Mast (Fig. 8-2) The 2 Stage full free lift mast is also composed of an inner mast, outer mast, fork arm carrier, and etc., and is also a high visibility mast. It is different from the common standard type mast in that two postpose long lifting jacks are both pole stopper type cylinder. One piston rod is hollow, the hole of piston rod is used for hydraulic pressure oil flowing into free lifting jack. The end of the piston rod in two long lifting jacks is joined with upper branch of the inner mast. Besides, the short lifting jack that is installed middle of inner mast is named as free lifting jack. The free lifting jack is also pole stopper type cylinder.

The fork arm can rise or fall when the height goes beyond 1400mm, because the inner mast doesn’t rise when the free lifting jack is rising or falling. There are different specifications in this series of height, 2.5m, 2.7 m, 3 m, 3.3m, 4 m. Free lifting height is commonly about 1050-2100mm.

When the lowest height of mast ≥2200mm, lift height is 3m, full free lift height is about 1500mm. It can work inside container, mast which includes side-shift is named container fork lift truck mast (see Fig. 8-3).

Side shift cylinder of container fork lift truck mast can be side shifting only when goods are not placed appropriately. Normally, the side cylinder should set center.

For the structure of the left and right lifting cylinders of more than or equal to 3 t, see fig.8-6, fig.8-7; For the structure of the left and right lifting cylinders of less than or equal to 2.5 t, see fig.8-8, fig.8-9.

8.3.3 3 Stg FFL Mast (Fig. 8-3) The 3 Stage full free lift (FFL) mast consists of an inner mast, intermediate mast (inter), outer mast, and fork carriage. The inter and inner masts are telescopic and the main lift cylinders use piston-type cylinders for the rear-mounted long-stroke lift cylinders, and the relatively complex oil system. This series is available with lift heights from 4.5 - 5.5 m. The main differences compared with Simplex LFL masts are the additional intermediate mast and the center mounted short-stroke free lift cylinder which is situated within the inner mast.

This cylinder is a ram-type cylinder. Since the mast does not extend when the free lift cylinder rises, the forklift truck is able to work within the free lift height.

The mast enables the forklift to operate inside containers at its lowest height of 2200 mm and can also be equipped with a side shifter so that the forks can move sideways. The side shifter can be used to reach inaccessible locations when stacking or loading goods. At other times the side shifter should be reset to the middle position.

The free lift cylinder is equipped with chains. The left and right chains of the forklift truck should be kept the same length.

59

1.OUTER MAST 5. FORK ARMS 9. TILTING CYLINDER

2.INNER MAST 6. CHAIN 10. ROLLER

3.LOAD-BACKREST 7. LEFT LIFTING CYLINDER

4.FORK ARM CARRIER 8. RIGHT LIFTING CYLINDER

Fig. 8-1 2 Stage LFL Mast

1. OUTER MAST 5. FORK ARM CARRIER 9. LOAD BACKREST

2. INNER MAST 6. FORK ARMS 10. TILTING CYLINDER

3. CHAIN 7. LEFT LIFTING CYLINDER

Fig.8-2 2 Stage FFL Mast

60

4. FREE LIFTING CYLINDER 8. RIGHT LIFTING CYLINDER

1. OUTER MAST 5. FREE LIFTING CYLINDER 9. LEFT LIFTING CYLINDER

2. MIDDLE MAST 3. INNER MAST 6. FORK ARM CARRIER 7. FORK ARMS 10. RIGHT LIFTING CYLINDER 11. LOAD BACKREST Fig.8-3 3 Stage FFL Mast

61

4. FRONT CYLINDER CHAIN 8 CHAIN 12. TILTING CYLINDER

1. PISTON

2. DUSTPROOF RING

1. DUSTPROOF RING

2. CYLINDER COVER

3. GASKET RING 5. GUIDE SLEEVE 7. PISTON 9. PROTECT RING 11. OIL NOZZLE ASSY. (WITHOUT LEFT LIFT CYLINDER)

4. O-RING 6. CYLINDER 8. SUPPORT RING 10. GASKET RING 12. O-RING

3. PROTECT RING 5. O-RING 7. O-RING 9. PISTON ROD 11. WR WEAR RING

4. ISI RING 6. COMPOUND BUSHING 8. BOLT 10. CYLINDER 12. PISTON

Fig.8-4 Main Cylinder(Used in fig.8-1, 8-3) Fig. 8-5 Free lift Cylinder (Used in fig. 8-3) 2 Stg LFL & 3 Stg FFL

62

1. DUSTPROOF RING 3. GUIDE SLEEVE 5. STOP PIECE 7. SUPPORT RING 9. CHECK RING 11. ISI RING

2. CYLINDER COVER 4. O-RING 6. PLUNGER ROD ASSY 8. PISTON 1O. CYLINDER 12. O-RING

1. DUSTPROOF RING 3. GUIDE SLEEVE 5. O-RING 7. O-RING 9. PISTON ROD 11. SUPPORT RING

Fig.8-6 Main Cylinder (left) (used in fig.8-2)

2. CYLINDER COVER 4. O-RING 6. SEAL RING 8. DEFLATION PLUG 10. CYLINDER

Fig. 8-7 Free Lift Cylinder (used in 8-2)

2 Stg FFL 3T-3.5T Cylinder

63

1.CYLINDER COVER 3. ADJUSTING WASHER 5. ISI RING 7. COMPOUND SLEEVE 9. PISTON RING 11. SUPPORT RING

2. DUSTPROOF RING 4. GUIDE SLEEVE 6. O-RING 8. CYLINDER 10. PISTON 12. OSI RING

1. DUSTPROOF RING 3. GUIDE SLEEVE 5. O-RING 7. DEFLATION PLUG 9. CYLINDER ASSY 11. SUPPORT RING

Fig.8-8 Lifting Cylinder (left) (used in fig.8-2)

2. CYLINDER COVER 4. O-RING 6. SEAL RING 8. O-RING 10. PLUNGER ROD

Fig. 8-9 Free Lifting Cylinder (used in 8-2)

2 Stg FFL 2.0-2.5T Cylinder

64

6) Remove the high-pressure lift hose and the low-pressure fluid return hose.

8.4. Removal and Adjustment 

Warning： The fork, fork carriage, and mast are heavy components. Be particularly careful when dismantling or installing them

8.4.1 Remove Forks and Mast Assembly 1) Pull out the fork lock pin. Move the fork to the notch in the middle of the fork carriage.

2) Pull the lower part of the fork. Remove the fork from the slide piece under the fork.

Warning: 



7) Suspend the inner and outer mast assemblies using steel cable or slings.

Keep hands and feet away from the fork. Be careful when removing or installing! Do not allow hands or feet to enter between the fork and the fork carriage or below the fork Do not remove the fork from the fork top end! Keep the fork from dropping and causing crushing injuries.

8) Pull out the tilt cylinder front end, the positioning bolts, and the hinge pin.

3) Attach a steel cable or chain to the carriage assembly. Hoist it using hoisting equipment.

4) Unscrew the nuts at the end of the chain, and remove the chain from under the carriage assembly.

9) Unscrew the bolts for the lower bearing cover of the outer mast.

5) Remove the carriage assembly from the inner frame

65

10) Remove the mast assembly.

11) The installation sequence is the opposite of the dismantling sequence

8.4.2 Disassembly Warning： The mast is very heavy. Be extra careful when detaching it.

Detaching the lift cylinder 1) Place the mast flat on the ground. Remove the bolts from the lift cylinder piston rod and the Ushaped bolts and fastening screws from the outer mast.

Testing 1) Inspect the rollers, the roller seats, and other associated parts for wear or damage.

2) Replace damaged parts as needed 8.3.3 Assembly and Adjustment

8.4.3 Assembly and Adjustment Warning： The inner and outer masts are heavy.

Be extra careful when assembling them.

Inserting the rollers

Lift Roller Slide inner mast into outer mast and securely attach lift rollers.

2) Slide the inner mast; detach the lift cylinder.

Remove Roller 1) Extend the inner mast downward. Take out the main rollers and the lateral small rollers.

2) If you are for the moment without a removing device, you need to carefully pry them out (i.e., strike evenly and symmetrically from the top, the bottom, and the left and right). Otherwise, you will break the rollers.

Adjusting the Gap Between the Rollers and the Mast Channel 1) Set the roller distance between the inner mast and the outer mast to “L.” Then perform adjustment as at the factory Dimension “L” Unit：mm Model 2.0T-2.5T 3T Max lift height (mm) 2500-3300

328

368

Detaching the Inner Mast

3600

348

388

Tie a steel cable or sling to the middle of the inner mast, and roll it out with hoisting equipment.

4000

378

418

4500

403

443

66

（2）It is recommended that clearance of roller and outer mast is about 0.8-1.0mm. Clearance cannot be adjusted. Replace roller if roller wear is excessive. （3）Apply lubrication to interface of inner mast and outer mast, interface of roller and mast. Be careful when applying lubrication in areas with a lot of wind or sand.

Clearance of Back Up metal and Mast Steel Adjust clearance “B” to 0.1-0.8mm with shims, if needed. Thickness of shim is 0.5mm or1.0mm.

(1) Adjustable range “A” with shims: a. Dimension:0.1mm-0.6mm.(≤2 t)

Apply a layer of lubricating grease onto the guide plate. Install the mast and lift cylinder on the forklift truck. Connect the return hydraulic hose and the highpressure hose.

b. Dimension:0-0.5mm (2.5T-3T). One or two may not have rubber pad; Dimension: 0.1mm-0.6mm without rubber pad.

Orientation pin ensures that side roller is vertical to inner mast track.

8.4.4 Installing Left and Right Hydraulic Lift Cylinders and Making Preliminary Adjustments to Cylinder Positions （1）Install left and right lifting jack on mast, pin must be installed into orientation hole of outer mast lower cross beam. （2）Install upper of piston rod on inner mast.

Inner mast lay evenly in the direction of left, right, upper and lower. If it is not even, adjust by putting washer between hole of cylinder support and upper end of piston rod. （3）Install U-bolt onto cylinder, hand-tighten nuts and lock it with two tightening nuts. Screws down tighten bolt and nuts to avoiding them becoming loose.

67

2) Separately measure the left-right distances B, B’ and B” between the side rollers and the lateral rollers that are part of combination rolling.

3) Separately calculate the differences A-B, A-B’, and A-B”. The value of each set is the gap value between each level of roller and the inner mast channel.

Uniformly adjust the shim for each left and right side roller. Cause the gaps between the smallest part of the inner mast channel and the fork carriage side rollers to be as follows: adjust the set projecting at the top to 0.2 mm-1.0 mm; adjust the two sets (combination rolling) to 0.1 mm to 0.8 mm gaps.

A-B = 0.2 mm - 1.0 mm A-B′= 0.1mm - 0.8mm A-B″= 0.1mm - 0.8mm

8.4.5 Adjusting the Lift Chain After the carriage is installed in the inner mast, also install the chain. Tighten two nuts at each of the two ends. Stand the mast upright, with it fully descended. Adjust the nuts at the lower end of the chain so that the distance between the lower fork plate of the carriage and the ground is 74-76 mm

To adjust the chain tension, first lower the lift cylinder until the fork comes into contact with the ground. Then adjust the chain regulating nuts (three nuts at each end) until the length “C” attains the specified value when you press down on the middle of the chain with your fingers.

Dimension C: 25mm-30mm

Shims 0.5 mm, 1.0mm a. When using the adjusting shims, the numbers of adjusting shims on the left and on the right must be equal. b. After gap adjustment is completed, push and pull the fork carriage assembly on the inner mast, causing it to go up and down. Check whether it moves correctly.

8.4.6 Adjusting Gaps Between Fork Carriage Assembly Rollers 1) Measure the distance “A” between the two channel guide rails of the inner mast. Take separate measurements at the top, middle, inner mast middle cross-bar (cross-shaped frame) and the base.

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8.5. Detaching and Installing the Lift Cylinders 

Warning： Keep your body away from equipment

1) Turn off the engine. Put the cylinder in the fully lowered position (with the piston lowered to the cylinder bottom). All the fluid should be returned to the reservoir.

2) Unscrew the cylinder support seat bolts from the left and right cylinder piston rods and the mast.

3) Disconnect the lift cylinder tube. Remove the lower speed-limiting valve fluid inflow high-pressure hose and the high-pressure hoses connecting to the two cylinders.

4) Remove the U-bolts from the outer mast mounting plate and the fastening screws on the other side.

5) Remove the chain from the outer mast.

6) Hoist out the left and right lift cylinders from the inner mast using a steel cable



Caution：

Do not re-use dust gasket ring, O-ring or Y-ring.  Replace with new. （3）Draw out piston rod , remove Y-ring on end of piston.

8.5.2 Install and Replace Faulty Parts.

1) Wash each part with clean fluid prior to assembly.

2) Then wash the guide sleeve and piston using the same brand and specification number as in the operating fluid reservoir.

3) Be sure not to let dust or dirt fall into the lift cylinders.

4) The assembly procedure is the opposite of the breakdown procedure described above.

5) Install the Y Seal Ring.

6) Place the piston rod assembly (including the piston rod, the piston, the support ring, and the Y Seal Ring) into the cylinder drum which has been thoroughly washed.



8.5.1 Breakdown of Cylinders Rated capacity is less than 2.5 t Remove cylinder head and guiding bush. Rated capacity is more than 3 t Remove tighten skew and nylon stopper, then remove cylinder head. （1）Remove dust gasket ring. （2）Remove Y-ring with screwdriver.

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Caution： Make the cylinder drum opening has burrs, it must be polished thoroughly. Carefully aim and insert the parts; keep the Y Seal Ring from becoming scratched or broken.

7) Install the new replacement dust ring and Y Seal Ring onto the guide sleeve and cylinder cover



Caution： The guide sleeve with the installed Seal Ring needs to be lubricated with hydraulic fluid having the same brand and specification number as in the operating fluid reservoir.

8.5.1 Breakdown Parts 1) Grip the cylinder with pliers. With the cylinder inlet and outlet ports open, pull the piston rod back and forth, causing excess fluid to drain from inside the cylinder.

2) Loosen the clevis bolt (#17); unscrew the clevis (#21).

3) Remove the cylinder cover lock bolt (#15) and the nylon plug (#23).

4) Remove the cylinder cover (#14) and the guide sleeve (#12).

5) Remove the piston rod assembly (#25) (see figure below).

8) Pass the piston rod through the cylinder cover; tighten the cylinder housing

8.6. Disassembly and Installation of Tilt Cylinder Warning: When detaching a cylinder used for tilting, pay attention to the following:  Secure the outer mast with a steel cable or chain from a crane to prevent the mast from falling down after the cylinder is detached.  Keep your housing as far away as possible from the equipment. Do not stand on a fork carriage that is equipped with a fork.

1) Completely release the fork carriage.

2) Remove the bolts from the left and right supports of the outer mast, and extract the hinge pin.

3) Remove the fluid tube from the tilt cylinder inlet port.

4) Remove the bolts from the truck frame support; pull out the hinge pin, and detach the rollover cylinder.

5) The installation sequence is the opposite of the dismantling sequence.

6) Remove all visible dust rings, O-Rings, & Y Seal Rings.

7) Remove the cylinder cover’s dust ring. The method is the same as for detaching the dust ring from the lift cylinder cover. (See the lift cylinder disassembly figure above.)

8) Remove the O-ring from the guide sleeve outer ring.

9) Remove the O-ring and the Y-Seal Ring from the hole in the guide sleeve. (See the lift cylinder disassembly figure above.)

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2) Re-adjusting the installation positions of the left and right lift cylinders a. Observe, while the two cylinders are rising and falling, whether their exterior shapes synchronously vary as to height. Adjust the shims between the piston rod and the inner mast support seat. b. Loosen the two nuts for the U-shaped mounting bolt. Then repeatedly move the mast several times up and down, positioning the U-shaped bolt properly relative to the cylinders. Then tighten the two nuts on the U-shaped bolt, and tighten the fastening screws on the other side. This is the only way to lengthen the life of the lift cylinders and reduce wear on the piston rod.

3) For the tightening forces for the bolts and screws, see the table above. For the rest, please use the screw diameters to consult the ordinary bolt tightening torques specified by our company. (See the operating and maintenance handbook that complements these.)

Caution：  Throw away and do not re-use the dust ring and the Y Seal Ring 8.6.2 Assembly Following Replacement of Seal Rings The assembly procedure is the opposite of the dismantling procedure, but pay attention to the following: 1) Use clean hydraulic fluid to lubricate each part.

2) Prevent dust and grease from falling into the cylinder.

3) Avoid scratching the end of the cylinder tube and the oil inlet and outlet.

4) Carefully align and push the piston rod into the cylinder drum. Be especially careful to keep the Y Seal Ring from becoming scratched or broken.

5) Before inserting the guide sleeve, first lubricate with hydraulic oil of the same brand and specification number as the operating oil.

6) During insertion, be careful not to scratch or break the O-ring on the outer ring.

7) After the cylinder cover has been screwed on, do not forget to install the nylon plug and fastening screws.

8.7. Debugging Precautions Following Forklift Assembly 1) Adjusting the forward and backward tilt of the mast Park the forklift truck on a flat surface. Operate the hydraulic control valve control lever, causing the forklift truck mast to tilt fully forward and fully backward. In accordance with assembly debugging data (see above) requirements, adjust the length of the thread for joining the tilt cylinder front-end piston rod and the clevis until the backward tilt data angle is met. Then lock the clevis at the end of the tilt cylinder.

(See the table above for the M10 bolt tightening torque.)

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8.8 Counterbalance weight

Counter weight Bolt (6) - Required torque specification is 490~620N.m Model of truck

2t

2.5 t

3.0 t

3.5 t

Counterbalance weight

1192 kg

1534 kg

1780 kg

2100 kg

Torque Specifications Bolt Diameter mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

4.6 4-5 10-12 20-25 36-45 55-70 90-110 120-150 170-210 230-290 300-377 450-530 540-680 670-880 900-1100 928-1237

Unit：N•m Bolt Strength Grade 5.6 6.8 8.8 5-7 7-9 9-12 12-15 17-23 22-30 25-32 33-45 45-59 45-55 58-78 78-104 70-90 93-124 124-165 110-140 145-193 193-257 150-190 199-264 264-354 210-270 282-376 376-502 290-350 384-512 512-683 370-450 488-650 651-868 550-700 714-952 952-1269 680-850 969-1293 1293-1723 825-1100 1319-1759 1759-2345 1120-1400 1694-2259 2259-3012 1160-1546 1559-2079 2923-3898

ATTENTION:  Use grade 8.8 bolts and screws for all important connections.

Grade marked on head. Unmarked bolts are grade 8.8.

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9. Electrical System Warning： 

Before inspecting any electrical component, please, to avoid short circuits, take off jewelry and other electrically conductive objects, and turn off the start switch and disconnect the ground wire.

Description: To facilitate differentiation, there are various, different colors on the outsides of wires. The colors are expressed with one or two characters on wiring diagrams.

Before performing any electrical maintenance, be sure to disconnect wires connected to the battery.

Wire Colors： The wire colors are expressed with one or two characters.

B: Black, R: Brown, G: Green U: Blue, O: Orange, R: Red W: White, Y: Yellow, S: Grey, P: Purple The main wiring harnesses generally use single-color wires. Others are indicated with double colors: B/W: Black-and-white wire G/Y: Green-yellow wire

Testing： Referring to the wiring diagram, inspect all circuits. Use a conventional testing light or a multimeter to conduct connectivity or short-circuit tests. Prior to testing, confirm the following: 1． Each electrical part or each electrical wire is secured to its binding post/connector.

2． Each connector is firmly connected in its original position and is free of rust or dirt.

3． The surface layer of each wire is free of cracks, aging, or other damage.

4． Each connector maintains a safe distance from adjacent metal components.

5． Each wire is secured to the correct binding post or connector.

6． Wiring is isolated from components with sharp edges.

7． Wiring is isolated from all rotating or moving components.

8． The length of wire from a fixed part to a moving part should be sufficient to withstand vibrations.

9． Wiring should be kept a safe distance from the exhaust pipe and other high-temperature objects.

Fuse Box Assembly Fuses Dismantling 1. Turn the key switch to “OFF.” 2. Push down the latch on the fuse box cover, and then open the cover.

3. Remove the fuse from the box.

Description: If fuse has failed, replace with new one. Refer to figure as follows: ① If the fuse has failed, be sure to determine the cause before installing a new fuse. ② Do not use fuses that are higher than the design value. ③ Check the fixed bracket of fuse. If rust and dirt appears, polish with crocus paper or emery cloth until the fixed bracket and interface look new. Fuse fixed bracket contacted abnormally can increase pressure drop and heat; or make the circuit work abnormally.

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Fuse Positions Fuse Chart Location

Capacity

Component

1

Lighting

20A

Headlight, width light

2

Horn

10A

Horn

3

Brake light

10A

Brake light

4

Reverse light and flasher

10A

Steering light and reverse light

5

Meter

10A

Meter and indicator light

6

Fuel cut off

10A

Fuel cut off switch and preheat controller

7

Standby

10A

For alarm light

8

Standby

20A

For cab

Fusible lines A fused fusible line can very easily be observed and felt with the fingers. If you cannot determine whether it is broken, then you may test it with a multimeter or light bulb

Warning： ① If a fusible line is burned out, the cause may be a short circuit (excessive power supply or current). No matter what the cause, Carefully determine and eliminate the fault. ② Fusible lines will emit heat. Do not wrap them in tape. Finally, do not lay fusible lines close to other wiring or rubber or other such components.

Lighting System Bulb Specifications Light

Watts

Headlight

12V-55W

Small headlight Steering light Width light

12V-21W 12V-10W

Combined back light Brake and width light Steering light Reverse light

12V-21W/5W 12V-21W 12V-10W

Combined meter Floodlight Caution light

12V-2W 12V-2W

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Location of Lights

Light Switch Dismantling 1. Remove assembly.

2. Remove knobs, nuts, and spacers.

3. Disconnect wire connectors

Connector Location

1

O (off)

X

I (small light)

X

II (big light)

X

2

4

X

X X

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5

X

Turn Signal Light Switch Dismantling

1. Remove assembly.

2. Remove the screws, and disconnect the wiring connectors.

3. The installation sequence is the opposite of the dismantling sequence.

After installing the turn signal switch, make sure that the distance between the turn signal switch and the steering column top is 42 mm.

Inspection Use a multimeter (set to ohms scale) to check whether the positions under the turn signal switch are conducting: L, N, R. Location of switch

Junction point

L

1-3

N

No continuity

R

1-2

Headlight- Style 1 Removal and installation 1. Remove the headlight mounting nuts.

2. Disconnect the wire connectors.

3. Remove the screws and the diffusion glass. Replace the bulbs.

4. Installation is the opposite of removal.

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Headlight- Style 2 LED Cannot be Disassembled, replace assembly

Front Combination Light- Style 1 & 2 Removal and installation Style 1 1. Remove the support mounting screws.

2. Disconnect the wire connectors.

3. Remove the light cover mounting screws; and replace the bulbs.

4. Installation is the opposite of removal.

Front Combination Light- Style 2 Cannot be disassembled, replace assembly

Rear Combination Lights-Std Removal and installation 1. Remove the rear combination lamp mounting screws.

2. Disconnect the wire connectors.

3. Remove the diffusion glass mounting screws, and replace the bulbs.

4. Installation is the opposite of removal.

Instruments, Sensors, and Relays Check whether the relay circuits are conducting. Use a suitable voltage (battery supplied) to connect to a coil or disconnect. Then, with a multimeter (set to ohms scale), check whether contact loops are conducting.

Removal and Installation Dash Display 1. Remove the dash display fastening bolts.

2. Open the dash display (see figure below); disconnect the connectors for the light, instrument, and key switching wiring.

After a dash display has been connected to the electrical system, it cannot be washed with water or steam.

3. Installation is the opposite of removal.

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1. Fastening bolt of Display Housing

2. Turn Signal Lever

3. Rear work light switch

Fuel Gauge, Temperature Gauge, Hour Meter, and Warning Lights 1. Remove the fastening bolts from the dash display. Then separate the dash display and the dash display housing.

2. Remove the front protective cover fastening bolts. Then separate the front protective cover and the dash display.

3. Remove the dash display.

4. Remove the dash display fastening bolts from the PC board. Then remove the gages.

5. Unscrew the warning lights from the PC board. (All warning lights can be individually removed from the composite instruments.)

6. Installation is the opposite of removal.

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1. HOUR METER

2. WATER TEMP.GUAGE

3. FUEL GAUGE A. BATTERY CHARGE

B. OIL C. GLOW PRESSURE INDICATOR ALERT LIGHT G. RIGHT TURN H. LOW BRAKE PRESSURE SIGNAL WARNING LIGHT (8-10T ONLY)

D. SEDIMENT INDICATOR

E. TORQUE CONVERTER TEMP

F. LEFT TURN SIGNAL

Dash Display Instrument Inspection Graduation Range

Normal Range

Engine cool water temperature

40℃-55℃ yellow 55℃-110℃ green 110℃-120℃ red

Green zone

Cease and check when point is near red zone

4. Fuel Gauge

Engine fuel capacity

0-1/10 1/10-1

Green zone

Adding fuel when point is near red zone

1. Hour Meter

Accumulative total engine operate time

4 integers, 1 decimal fraction

E.Torque Converter Temp.

Gear-box oil temperature

45℃-60℃ yellow 60℃-120℃ green 120℃-140℃green

Green zone

Cease and check when point is near red zone

B. Oil Pressure

Engine grease pressure

0-0.2-0.4-0.8MPa

≥0.1 MPa

< 0.1 MPa cease and check< 0.1 MPa

Name

Purpose

3. Water temp.guage

red green

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Remark

Function

Warning Light

Light blank (normal)

Remarks

Charge warning Light

Indicate the alternator voltage up to its rate, whether charge battery or not.

The alternator doesn’t generate electricity or voltage is lower without charging.

The alternator is at normal condition

When running at idle speed, the light turns off because voltage is high.

Brake warning Light

It indicates the accumulator’s oil pressure

The oil pressure of accumulator is low.

Description

When light turns on, you should check the oil level.

Key (Start) Switch

1. Remove assembly.

2. Disconnect the wire connectors.

3. Remove the nuts, washers, spacers, and dash display.

4. Installation is the opposite of removal.

When installing, adjust the protruding portion of the switch to a suitable length.

Inspection With the multimeter (set to ohms scale), check whether each position of the key switch is conducting.

Switch Position OFF ON/ON/RUN START Switch position

Terminal Does not conduct B2-Acc conducts B2-Acc-C-R2 conducts

OFF

OR

START

O O

O O O O

Terminal

1（B2） 2（Acc） 3（C） 4（R2）

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Backup Alarm Removal and installation 1. Disconnect the wiring conductor; then remove the bolt.

2. Installation is the opposite of removal.

Horn Removal and installation 1. Remove the connector for the horn connecting wire.

2. Remove the bolt and the horn.

3. Installation is the opposite of removal

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9.1 Schematics

82

83

84

85

86

87

88

89

UTILEV TECHNICAL PUBLICATIONS “UTILEV is a registered trademark. THE UTILITY LIFT TRUCK and UTILITY YOU CAN TRUST are trademarks in the United States and certain other jurisdictions.

P/N 76002089

04/2017

(11/2015)