Yale Forklift A7S5 (ERP16-20UXT) Service Manual - PDF DOWNLOAD

Maintenance

A7S5 ERP16-20UXT

PART NO. 550236284

8000 YRM 2354

INTRODUCTION The Service Manuals are updated on a regular basis, but may not reflect the latest design changes to the product.

Updated technical service information may be available from your local authorized YALE® distributor. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

Counterbalanced 3-Wheel Battery Forklift Truck is a new series of products developed and manufactured by our company to satisfy the market demands, based on assimilating domestic and foreign battery forklift trucks, in combination with foreign advanced technology introduced by our company. They are especially applicable to stations, ports, freight yards, and warehouses, as well as foods, light textile industry, and general factories and mines for loading and unloading, conveyance, stacking, and other operations.

This truck has a full hydraulic steering mechanism, automatic power brake, new-type stepless speed regulator, open overhead guard, and other advanced features are used for this forklift, and also equipped with quality motor, battery, MOSFET electric control, and large screen liquid crystal combination instrument, it is characterized by superior performance, easy operation, expanse visual field, flexible steering, small turning radius, reliable brake, good dynamic property, low noise, free pollution, nice outside appearance, etc.

This manual contains the technical parameters, structures of respective main parts, and operating principle as well as operation, maintenance, service, and other aspects of the counterbalanced 3-wheel Battery Forklift Trucks. It is able to help operators to rationally use the battery forklift truck, for the battery truck to play its maximum efficacy. It is hoped that operators and equipment management staff will seriously read the manual prior to operation of the battery forklift trucks.

The specifications and notices in this manual shall be strictly observed during operation, and elaborative use will allow your forklift truck to be under optical working status, so as to play higher efficacy.

As parts and devices are being continuously improved, the contents related in this manual will be subject to changes along with without separate notices. User’s understanding is kindly expected. This manual is also applicable to the forklift trucks assembled with affiliated attachments. The counterbalanced 3-wheel battery forklift trucks have been CE certified.

NOTE: It is strictly prohibited for users to privately refit the forklift truck without permission!

FOREWORD The Service Manuals are updated on a regular basis, but may not reflect the latest design changes to the product.

Updated technical service information may be available from your local authorized Yale distributor. Service manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

Series

Model ERP16UXT

1.6-2.0T

ERP18UXT ERP20UXT

Drive Controller ZAPI Drive Controller

Pump Controller ZAPI Pump Controller

ZAPI Pump ZAPI Drive Controller Controller

Rated Capacity (st)/ Load Center (mm) 1600 kg (4286 lb) / 500 mm (19.7 in.)

1800 kg (4822 lb) / 500 mm (19.7 in.)

2000 kg (5358 lb) / 500 mm (19.7 in.)

This manual describes the structure and working principles of the 1.6-2.0T 3-Wheel forklift truck and provides instructions for servicing and maintenance. To ensure safety and get the best out of your forklift, all operators, equipment managers and maintenance personnel should carefully read this manual. Only trained and qualified personnel are permitted to carry out servicing and repairs on the forklift truck.

Table of Contents

TABLE OF CONTENTS Forklift Truck Main Parts......................................................................................................................................... 1 Battery.................................................................................................................................................................. 1 Battery and Installation.......................................................................................................................................1 Overview..........................................................................................................................................................1 Structure of Battery..........................................................................................................................................1 Storage of Battery............................................................................................................................................1 Use of Battery..................................................................................................................................................1 Service of Battery............................................................................................................................................ 2 General Notices...............................................................................................................................................3 Common Failures and Disposal Methods of Battery....................................................................................... 3 Main Technical Specification of Forklift Truck......................................................................................................... 4 Driving Motor and Driving System...........................................................................................................................7 Overview...............................................................................................................................................................7 Transmission........................................................................................................................................................ 7 Driving Motor.......................................................................................................................................................11 Specification of Driving Motor...........................................................................................................................11 Conditions of Operating Environment.............................................................................................................. 11 Pump Motor and Installation..................................................................................................................................11 Electrical System...................................................................................................................................................12 Overview.............................................................................................................................................................12 AC Motor Controller............................................................................................................................................12 Instruments.........................................................................................................................................................15 Fault Codes........................................................................................................................................................ 17 Steering Device and Installation............................................................................................................................23 Overview.............................................................................................................................................................23 Examination of Steering System After Reassembly.........................................................................................23 Steering System Fault Diagnosis.....................................................................................................................24 Steering Axle and Installation................................................................................................................................25 Hand Brake Operation.......................................................................................................................................... 28 Overview.............................................................................................................................................................28 Parking Brake Operation Device........................................................................................................................ 28 Adjustment of Braking Force............................................................................................................................28 Fault Diagnosis................................................................................................................................................ 29 Foot Brake Operation............................................................................................................................................30 Overview.............................................................................................................................................................30 Foot Brake Pedal................................................................................................................................................30 Adjustment of Foot Pedal Brake...................................................................................................................... 30 Adjustment of Brake Switch...........................................................................................................................31 Brake Master Cylinder........................................................................................................................................ 31 Fault Diagnosis...................................................................................................................................................32 Working Oil Tank and Installation.......................................................................................................................... 33 Overview.............................................................................................................................................................33 Hydraulic Oil Tank...............................................................................................................................................33 Hydraulic System.................................................................................................................................................. 33 Overview.............................................................................................................................................................33 Gear Pump......................................................................................................................................................... 36 Maintenance of Gear Pump............................................................................................................................. 36 Fault Diagnosis................................................................................................................................................ 39 Multi-Way Valve.................................................................................................................................................. 40 Fault Diagnosis................................................................................................................................................ 46 Full Hydraulic Orbitrol......................................................................................................................................... 47 Speed Limit Valve............................................................................................................................................... 48

©2020 Yale Materials Handling Corp.

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Table of Contents

TABLE OF CONTENTS (Continued) Hydraulic Lines................................................................................................................................................... 49 Lifting System........................................................................................................................................................50 Safety Procedures when Working Near Mast.....................................................................................................50 Overview.............................................................................................................................................................50 Inner and Outer Mast..........................................................................................................................................50 Fork Carriage Assembly..................................................................................................................................... 51 Adjustment for Height of Fork Carriage............................................................................................................51 Roller Positions...................................................................................................................................................52 Replacement of Fork Backrest.........................................................................................................................52 Lifting Cylinder....................................................................................................................................................52 Working Status of Explosion Relieve Valve..................................................................................................... 54 Adjustment of Lifting Cylinder.......................................................................................................................... 54 Tilting Cylinder.................................................................................................................................................... 55 Installation of Mast..............................................................................................................................................55 Disassembly of Mast...........................................................................................................................................57 List of Wear Parts..................................................................................................................................................57

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8000 YRM 2354

Forklift Truck Main Parts

Forklift Truck Main Parts BATTERY

chemical action. The lead-acid chemicals store the electric energy until the electric energy is needed to operate an electric device.

Battery and Installation Overview A lead-acid battery converts chemical energy into electrical energy. Chemical changes within the battery give the electrical energy. When the chemical reaction has occurred so the battery will not give its rated voltage and current, the battery is discharged. A reverse chemical action must occur so the battery can be used again. The batteries described in this section can be charged again by an electric voltage and current from an outside source so there is a reverse

Structure of Battery A lead-acid battery is made from several lead-acid batteries called cells. Each cell has positive and negative plates with dielectric spacers between each plate. All of the plates are within a solution of electrolyte.

The Specifications of the Battery (standard configuration of Zibo) and charger are shown in Table 1.

Table 1. Structure of Battery Type

Model

Capacity

ERP16UXT

48V4PZS460

500Ah

ERP18UXT

48V4PZ460

500Ah

ERP20UXT

40-548V8PZB 600DB500H

625Ah

Voltage

Individual Qty

48V

24 pcs

The battery that is delivered from factory without charge shall be stored indoors clean and dry at a temperature of 5-45°C (41-113°F). The storage period beginning from the date when battery is delivered from the factory is two years, and the battery initial charging time shall be properly prolonged, if it has been stored more than two years.

For the battery that has been initially charged and delivered from the factory, its storage shall comply with the following aspects: a.

It shall be stored indoors clean and dry at a temperature of 5-45°C (41-113°F), and be ventilated regularly.

b.

Dust dropped on the battery cover and electrolyte dripped on the battery during measurement shall be timely wiped up using

C2B3E-65A/48V C2B3E-80A/48V

REMA 160

(5-10) % soda water solution or main water, to maintain the cleanliness and dryness for the outside surface of battery. c.

Direct sunlight shall be avoided, and the battery stored away from heat sources.

d.

A supplementary charge or an equalizing charge shall be performed to the battery every 30 days using the 2nd-phase current of normal charge.

e.

Extended long storage will affect the general service life of battery.

Storage of Battery

2.

Plug Specifications

C2B3E-65A/48V

NOTE: The brand model specifications of the battery, charger and plug are subject to change due to order requirements or other reasons and are not described in this manual.

1.

Charger Specifications

Use of Battery Battery Routine Charging Steps: 1.

Container cover and other coverings on battery box must be removed or opened before charge to ensure a full dispersion of flammable and combustible gas generated during charge, and steady 30 minutes when charge has been completed (only useable after 30 minutes when charge has been completed). Charging room shall be well ventilated and indoor charging house shall be installed with ventilating device.

1

Forklift Truck Main Parts 2.

Turn off the forklift truck's power supply first, and then open the battery power plug to disconnect the plug from the body end power plug.

3.

Open the liquid filling plug cover on each battery unit and measure the density of electrolyte. If the density of electrolyte is smaller than 1.13kg/l (Hawker) or 1.15kg/l (Zibo), it indicates that the battery has been over-discharged (discharging depth having exceeded 80%). Repeated overdischarging may shorten the service life of battery.

4.

Measure the temperature of electrolyte. If it is higher than 45°C (113°F), the following steps shall be continued after waiting for battery to cool down.

5.

Connect the plug between the battery and the charger cable.

6.

If Trak® air (air disturbance system) is equipped, confirm that the air pipeline has been connected.

7.

If battery is equipped with automatic water supply system, connect the water pipe plug.

8.

Turn on the charging switch of charger, and begin charge.

9.

After charge is completed, turn off the charger power supply, poke the cable plug connection for battery and charger and other supporting auxiliary system connections (such as automatic water supply, etc.).

10. If the battery automatic water supply system is not equipped, check the liquid level of the electrolyte after the battery is charged. If the liquid level is lower than the allowable height (below the minimum of the liquid filling plug or the buoy is not floating at all), it shall be supplemented with distilled water that meets the standard or battery replenishment water produced by a regular manufacturer (the lowest point of the filling plug is 1-2cm upwards or the buoy floats), but any acid cannot be added.

11. Water shall be added after charge, and water addition before charge may possibly give rise to overflow of acidic liquid.

12. Connect the battery cable plug.

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8000 YRM 2354 NOTE: The energy charger can adjust the charging curve according to the actual situation (new and old batteries, different brands of batteries). The method is to open the charger, find the three-gear switch on the internal circuit board of the charger. I-O-II can be chosen. The default is O shift. For the specific operation, refer to the Charger Manual.

Service of Battery Daily Service a.

Battery shall be charged immediately after discharge each time.

b.

Discharge each time shall not exceed 80% of the total battery capacity.

c.

Battery must be wiped up if any acidic liquid is overspilled, in order to avoid corrosion of the container and the battery leakage.

Weekly Service a.

If battery is not equipped with automatic liquid adding system, it is required to examine the height of electrolyte after charge. When it is lower than the allowable liquid level (below the lowest point of the liquid filling plug or the buoy is not floating at all), it is required to add qualified distilled water to the specified height.

When electrolyte is excessive, it shall be extracted to the specified height.

b.

Examine whether or not water is accumulated inside the battery container. The accumulated water must be sucked up immediately if it is found.

c.

Check if the positive and negative lead wires and the pole terminal fastening nuts are loose.

If looseness is found, tighten immediately to prevent the spark from burning the pole when used.

Monthly Service a.

Before charge is completed, examine the voltages of all the electrode units and the battery, and keep records.

8000 YRM 2354 b.

Forklift Truck Main Parts

After charge is completed, it is required to measure the density and temperature of each battery unit, and keep records. If a huge difference from the previous measurement value is found, a professional shall be contacted for examination.

Annual Service a.

b.

A professional shall examine the insulation resistance of forklift truck and the insulation resistance of battery once a year. The insulation resistance for battery is specified as 50Ω/V. The resistance to the entire battery (voltage to reach 20V) is 1000Ω.

General Notices 1.

Battery shall be maintained clean and dry, able to avoid generation of creeping current.

2.

Liquid must be sucked out immediately using suction pipe, if any in battery container.

3.

Damage of inside/outside paint or coating of battery shall be mended immediately, if any is found, and the outside container insulation shall be protected, free from corrosion.

4.

Replacement of battery unit shall be carried out by a professional.

Examine the charger once according to the instruction manual, to ensure that respective functions are under normal conditions.

Common Failures and Disposal Methods of Battery

Active Matter Excessive Dropout

Pole Plate Salinization

Effect

Failure Characteristic

Cause

Solution

Capacity dropped at normal discharge.

Specific gravity dropped lower than normal value.

Quick voltage drop at discharge.

Early generation of air bubble at charge.

PbSO4crystallization coarse and large.

Initial charge insufficient.

Discharging status, and placement time too long.

Long-term charge insufficient.

Electrolyte proportion high.

Liquid level receded, the top of plate exposed to air.

Electrolyte impure.

Internal short circuit.

Overcharging method.

Repeated charging method.

Hydropathy method.

Deposit found inside electric liquid, brown matter rises at charge.

Batter capacity reduced.

Drown deposit due to over-large charging current.

White deposit due to excessive discharge.

Contaminant present inside battery.

Dropout in bulk, plate quality issue.

The cast in paste status, due to long-time proportion or temperature to the high end.

Rubber shell battery, plate replaceable, and deposit removable.

To be charge with small current and electric liquid density and liquid level height to be adjusted.

3

Failure Characteristic

Cause

Internal Short Circuit

Voltage fairly low at charge.

Air bubble rather few at the end stage of charge.

Quick temperature rise at charge, no change in electrolyte proportion.

Discharge capacity low and voltage dropped.

Conductive substance dropped inside.

Plate bent, and separator damaged.

Lots of deposits.

Reversal

Effect

8000 YRM 2354

Batter capacity dropped.

Voltage obviously reduced.

Assembling issue.

Battery to be replaced.

Excessive discharge.

Reversal battery to be charged Insufficient charge, giving rise to separately. plate salinization.

Electrolyte Issue

Forklift Truck Main Parts

Excessive water addition or plate Proportion, capacity, and voltage salinization.

Density to be adjusted and to the low end.

Add electrolyte by mistake. salinization to be eliminated.

Proportion too high.

Contents of distilled water and Some electrolyte to be taken out Electrolyte impure, present with electrolyte contaminants and density to be adjusted. contaminant. exceeding the specified Electrolyte to be replaced. requirements.

WARNING The contents above related to battery are for reference. Please operate and maintain the battery according to the Battery Use and Maintenance Manual. If you have any questions, please contact a professional.

4

Solution

Conductive substance to be removed.

Pole plate to be replaced.

Separator to be replaced.

8000 YRM 2354

Main Technical Specification of Forklift Truck

Main Technical Specification of Forklift Truck

Figure 1. Forklift Truck Exterior

5

Main Technical Specification of Forklift Truck

Model

1

ERP16UXT

ERP18UXT

ERP20UXT

1600

1800

2000

Rated Capacity

kg

2

Load Centre

mm

3

500

Lifting Height

mm

4

3000

Free Lifting Height

mm

5

0

Fork Size

sxex1

mm

6

Mast Tilting Angle

a°/β°

Deg

7

Length (to forkface)

mm

8

1930

2045

Width A

mm

9

1085

1140

Height when mast

mm

10

1975

Height when mast

mm

11

4010

Height to Safeguard H

mm

12

2012

Min R

mm

13

1593

1708

mm

14

371

376

924/186

945/186

Overall Dimensions

Turning Radius

Front Overhang G

35 x 100 x 920

40 x 122 x 1070

6.5/6.5

Tread

Front Q/ Rear S

mm

15

Ground Clearance

Min H3

mm

16

mm

17

Min/Max

mm

18

800 x 1200 Horizontally

mm

19

3290

3410

1000 x 1200 Longitudinally

mm

20

3415

3535

Travel (Laden)

km/h

21

14

Travel (Unladed)

km/h

22

16

Lifting (Laden)

mm/s

23

Lifting (Unladed)

mm/s

24

520

Laden

%

25

15

Unladed

%

26

15

Include battery box

kg

27

Wheelbase F Fork Spread Working aisle width Pallets (Ast)

Speed

Gradeability Service Tyre Motor

Battery

6

8000 YRM 2354

96 1400

1515 200/890

360

350

3430

3270

Front x 2

28

18 x 7-8

Rear x 2

29

15 x 4.5-8

340

3220 200/50-10

Driving Motor x 2

kw

30

5

Pump Motor

kw

31

11

Standard

V/Ah

32

Optional (Capacity expansion)

V/Ah

33

48/500 HAWKER, ZIBO

48/625

8000 YRM 2354

Driving Motor and Driving System

Model Controller

1

ERP16UXT

ERP18UXT

Type

34

ACE2 2uC

Manufacturer

35

ZAPI

Operating Pressure

Mpa

36

14.5

ERP20UXT

17.5

NOTE: The standard configuration of the battery is TIANNENG and the option is HAWKER, ZIBO. Different battery brands have different capacities.

Driving Motor and Driving System OVERVIEW The three-wheel driving system is a double front driving system (one driving motor for left and right, respectively), the driving wheel on each side is directly actuated by driving motor, and the rotational speed of each motor is controlled by swing angle of rear wheel.

Driving motors on respective sides are all connected with the PMP ERP16/18/20-UTX ) transmission，and the two transmissions are both wet brake. Solid tyres and integrated wheel rims are applied in the driving system.

Refer to the following table for models of front wheel tyres and wheel rims: Forklift Truck Tonnage

1.6T, 1.8T

Tyre Wheel Rim

2.0T

Refer to Table of Specifications (Solid) 4.33R-8 (Whole)

6.50F-10 (Whole)

TRANSMISSION These transmissions are both typical of double speed reduction, of which the first reduction gear is a cylindrical spiral gear, while and other is the planetary gear, in a compact and small structure. The structures of the transmissions are shown in Figure 2.

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Driving Motor and Driving System

8000 YRM 2354

Figure 2. Axle Box

8

8000 YRM 2354

Driving Motor and Driving System Legend for Figure 2.

1. INPUT SHAFT 2. SNAP SPRING 3. HUB BOLT 4. COVER 5. BRAKE HOUSING 6. SPIRAL BEVEL GEAR 7. INTERNAL GEAR 8. FLEX GEAR 9. FRICTION PLATE 10. FRICTION PLATE 11. STEEL DISK 12. FRICTION PLATE 13. POSITIONING RING 14. NUT 15. WASHER 16. CONNECTING DISK 17. BRAKE LEVER 18. HUB 19. PIN 20. PIN 21. SPIRAL BEVEL GEAR 22. DRIVING GEAR 23. PISTON 24. GEAR CARRIER 25. SERVICE BRAKE CONNECTION 26. PLANET GEAR 27. HOUSING 28. SPACER 29. BLEEDER VALVE 30. BLIND VALVE 31. POSITIONING RING 32. SNAP RING

33. POSITIONING RING 34. POSITIONING RING 35. SNAP RING 36. NYLON RING 37. GLAND RING 38. O-RING 39. SEAL RING 40. SEAL RING 41. ROLLER BEARING 42. BEARING 43. BEARING 44. NEEDLE BEARING 45. BEARING 46. NEEDLE BEARING 47. KEY 48. KEY 49. SPRING SNAP RING 50. REED 51. SPRING 52. WASHER 53. POSITIONING PIN 54. POSITIONING PIN 55. POSITIONING PIN 56. ELASTIC PIN 57. BREATHER PLUG 58. SCREW PLUG 59. MAGNETIC SCREW PLUG 60. BOLT 61. BOLT 62. BOLT 63. BOLT

This truck has no driving axle, and the transmission plays the function of axle.

Brake is the maintenance-free wet disc brake.

Failure Effect

Possible Cause

Removal

Noise

Too large gear clearance Too large gear wear

To be adjusted To be replaced

Stay noise generated during running process

Low oil level in gear oil tank Too large gear clearance Too large gear wear

Gear oil to be filled and added To be adjusted To be replaced

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Driving Motor and Driving System

8000 YRM 2354

Hand Brake

Foot Brake

Table 2. Parameters of Transmission Item

PMS601 Parameter

Weight (not including oil)

38 kg

Oil Rate

0.55~0.65 L

Oil Type

SAE800/APOGL4/UTTO

Brake Fluid

DoT3

Control Pressure

60-80 bar

Normal Pressure (Max Continuous)

75 bar

Max Pressure

150 bar

Hydraulic Cylinder Brake Fluid Capacity (Under Normal Condition)

7.8 cm3

Hydraulic Cylinder Brake Fluid Capacity (Under Max Wearing Condition)

3.1 cm3

Hand Brake Handle Pull

100N

Stroke

5.3 mm

Wearing Limit Stroke

8 mm Legend for Figure 3.

1. AIR BLEED SCREW RING 2. HAND BRAKE GUIDE CABLE CONNECTING HEAD 3. BRAKE WHEEL CYLINDER OIL INLET PORT There is one hole on the brake rocker arm (brake wheel cylinder oil inlet port):

Figure 3. PMP Transmission

1.

Air Bleed Screw Plug – The air bleed screw plug shall be loosened after brake fluid is added, for air bleed.

2.

Hand Brake Guide Cable Connecting Head – The wearing limit of hand brake guy cable connecting head is 13mm, and it shall be replaced when the wear exceeds this limit.

3.

Brake Wheel Cylinder Oil Inlet Port – The brake wheel cylinder shall be replaced for leakage.

Please refer to the “PMS601 Maintenance Manual” for more details.

10

8000 YRM 2354

Pump Motor and Installation

DRIVING MOTOR Specification of Driving Motor Type

Item

Driving Motor Model

ERP16UXT ERP18UXT ERP20UXT

JHL AC

AHT5-4020B

Excitation Mode

Rated Power kw

Rated Voltage V

Rated Current A

Rated Speed r/min

5

AC33V

119

2932

Conditions of Operating Environment

2.

Motor shall be able to operate normally under the following environments:

Range of change in ambient air temperature -25°C (+40°F).

3.

Relative humidity up to 100%.

1.

Altitude not exceeding 1200 m.

Pump Motor and Installation Type

Item

Pump Motor Model

ERP16UXT ERP18UXT ERP20UXT

JHL AC

AST11-4012B

Excitation Mode

Rated Power kw

Rated Voltage V

Rated Current A

Rated Speed r/min

11

AC32

274

2107

11

Electrical System

8000 YRM 2354

Electrical System OVERVIEW Electrical system mainly includes battery, traction motor, oil pump motor, motor controller, instruments, and auxiliary electrical equipment (switch, light fitting, and message sound device, etc). ZAPI Controller and adaptive motor are applied.

As dual motor and motor controller driving are applied for running of 3-wheel forklift truck, different from the single motor driving that achieves different speeds of

inner wheel and outer wheel at turning using driving axle differential, angle potentiometer is utilized to detect the changes in wheel position angle of steering wheel, to achieve the electronic different speeds through controlling the rotational speed of the two motors, while as data of wheel position angle are introduced, the controller is also able to automatically reduce speed at vehicle turning, which has enhanced the driving safety.

AC MOTOR CONTROLLER

1.

2.

3.

4.

FUSE LEFT TRACTION CONTROLLER A SOCKET LEFT TRACTION MOTOR CONTROLLER CONNECTING END 5. D SOCKET 6. RIGHT TRACTION CONTROLLER 7. B SOCKET

8. RIGHT TRACTION MOTOR CONTROLLER CONNECTING END 9. D SOCKET 10. OIL PUMP CONTROLLER 11. C SOCKET 12. OIL PUMP MOTOR CONNECTING END 13. D SOCKET 14. MAIN CONTROLLER

Figure 4. Form and Characteristics of Controller

12

8000 YRM 2354 One set of AC2 2uC Motor Controller is used as oil pump controller on this series of trucks. Motor speed and temperature feedback model micro-processing control, regenerated brake, and CANBAUS communication interface are available to conduct precision control over the traction and oil pump of the vehicle, and also able to adjust the motor controller according to different work conditions of operating environments and load types of driving online through hand actuating unit or onboard instruments (authorization required), with a view to achieving the most perfect operating efficiency and performance representation. At the same time, the controller is also

Electrical System provided with comparatively self-contained fault self diagnosis function, able to give out fault coeds of common failures, to facilitate maintainers to analyze the position of failure, to remove failure within a shortest time, and to minimize the loss of working time aroused by vehicle failures.

Users are able to choose various driving modes from the dashboard in which there are S (super mode), P (power mode), E (economic mode) and T (turtle mode).

There are two AC2 controllers, one each for the right and left that are used as traction controllers.

13

Electrical System

8000 YRM 2354

Figure 5. Electrical System Principle Diagram (General Pedal)

14

8000 YRM 2354

Electrical System

Figure 6. Electrical System Principle Diagram (Monotrol Pedal)

15

Electrical System

8000 YRM 2354

INSTRUMENTS

Figure 7. Instruments SMARTDISPLAY display is smart instrument panel through CAN bus connection to the vehicle system.

This smart instrument provides diagnosis and setup of CBU system. The diagnosis and setup include: smart display itself, traction controller, lifting controller, and valve controller. The smart display menu enters into SMART instrument menu through 6 operating pushbuttons on the contact touch keyboard. The SMART display has 6 built-in red LBDs, able to provide operators with some simple information about

There is one LCD at the proper position in the center of the heading, to display electric rate, orientation of steering wheel, and running speed.

16

vehicle status. LCD is additionally able to provide fault codes, in the following figures such as the indicated failure generated with fault code as “60” at the Node “5) of the system and the failure with fault code as “66” generated at Node “2” of the system. The vehicle will normally shut down when “ALARM” failure is generated, while the failure grade of “WARNING” generated may be somewhat lower, the system will shut down sometimes and the output power will be reduced sometimes.

8000 YRM 2354

Electrical System

Three symbols tell operators the following acts: Sandglass Symbol (A) – Flash of this symbol indicates that hourmeter is working.

Battery Symbol (B) – Turn-on of light on this symbol indicate that electric level of battery is insufficient at the current displayed time.

Adjustable Wrench Symbol (C) – Flash of this symbol indicates maintenance requirement or the specified warning set by the program. Related code will be displayed under such circumstances.

WARNING Please stop operation at once when fault code appears, until failure is eliminated. When electric quantity is displayed less than 20, please stop operation immediately, and charge the battery timely.

17

Electrical System

8000 YRM 2354

FAULT CODES Table 3. Primary Controller Fault Codes

18

OPEN CAN CODE

MDI CODE

CAN CODE

ALARM

Main Contactor

0x0000

94

0

NONE

Closed

0x6010

8

8

WATCHDOG

Open

0xFF11

17

17

LOGIC FAILURE #3

Open

0xFF12

18

18

LOGIC FAILURE #2

Open

0x5114

19

19

LOGIC FAILURE #1

Open

0xFF1C

28

28

PUMP VMN LOW

Open

0xFF1D

29

29

PUMP VMN HIGH

Open

0x3120

30

30

VMN LOW

Open

0x3110

31

31

VMN HIGH

Open

0x5442

37

37

CONTACTOR CLOSED

0x5441

38

38

CONTACTOR OPEN

0x2312

52

52

PUMP I=0 EVER

Open

0x2311

53

53

STBY I HIGH

Open

0x3130

60

60

CAPACITOR CHARGE

Open

0x4210

62

62

TH. PROTECTION

Closed

0x4110

65

65

MOTOR TEMPERAT.

Closed

0xFF42

0

66

BATTERY LOW

Closed

0x3211

74

74

DRIVER SHORTED

Open

0x3221

75

75

CONTACTOR DRIVER

Open

0xFF4E

78

78

VACC NOT OK

Closed

0xFF4F

79

79

INCORRECT START

Closed

0xFF50

80

80

FORW + BACK

Closed

0xFF52

82

82

ENCODER ERROR

Open

0xFF56

86

86

PEDAL WIRE KO

0xFFB5

80

151

MONOTROL XX

0xFF98

82

152

SENSOR SUPPLY XX

0xFF99

3

153

OFFSET SPD.SENS.

0xFF9A

3

154

SIXSTEP ERROR

0xFF9B

45

155

WAIT MOTOR STILL

0xFF9D

4

157

FAULT DRV.POWER

0xFF9E

4

158

NOT RDY DRV.POW.

0xFF9F

5

159

HVIL FAIL

0xFFA0

0

160

SENS BAT TEMP KO

0xFFA1

0

161

RPM HIGH

8000 YRM 2354

Electrical System

Table 3. Primary Controller Fault Codes (Continued) OPEN CAN CODE

MDI CODE

CAN CODE

ALARM

Main Contactor

0xFFA2

0

162

BUMPER STOP

0xFFA3

7

163

ED SLIP MISMATCH

0xFFA4

6

164

PWM ACQ. ERROR

0xFFA8

3

168

SIN/COS D.ERR XX

0xFFA9

3

169

ENCODER D.ERR XX

0x3101

41

170

WRONG KEY VOLT.

0xFFAB

2

171

ACQUIRING A.S.

0xFFAC

2

172

ACQUIRE ABORT

0xFFAD

2

173

ACQUIRE END

0xFFAF

81

175

SPEED FB. ERROR

0xFFB0

3

176

HOME SENS.ERR XX

0xFFB1

76

177

COIL SHOR. EB.

Open

0xFFB2

65

178

MOTOR TEMP. STOP

Closed

0xFFB3

95

179

STEER SENSOR KO

Closed

0xFFB4

57

180

OVERLOAD

Open

0xFF51

83

181

WRONG ENC SET

Open

0xFFB9

64

185

TILLER ERROR

0xFFBA

45

186

WAIT MOT.P STILL

0xFFBB

49

187

LIFT+LOWER

Closed

0xFFBC

50

188

PUMP VACC NOT OK

Closed

0xFFBD

79

189

PUMP INC START

Closed

0xFFBE

33

190

PUMP VMN NOT OK

Closed

0xFFBF

56

191

PUMP I NO ZERO

Open

0xFFC0

90

192

PUMP VACC RANGE

Closed

0x3302

69

193

SMARTDRIVER KO

Open

0x5001

27

194

AUX BATT. SHORT.

Closed

0x3223

84

195

POS. EB. SHORTED

Open

0xFFC4

47

196

MOT.PHASE SH.

Open

0xFFC5

91

197

WRONG SLAVE VER.

Open

0xFFC6

97

198

M/S PAR CHK MISM

Closed

0xFFC7

93

199

PARAM TRANSFER

Closed

0xFFC8

88

200

VDC OFF SHORTED

Open

0xFFC9

98

201

TORQUE PROFILE

Closed

0xFFCA

77

202

VDC LINK OVERV.

Open

Open

19

Electrical System

8000 YRM 2354

Table 3. Primary Controller Fault Codes (Continued)

20

OPEN CAN CODE

MDI CODE

CAN CODE

ALARM

Main Contactor

0xFFCB

32

203

HW FAULT MC

Open

0xFFCC

63

204

BRAKE RUN OUT

0xFFCD

70

205

EPS RELAY OPEN

Closed

0x3111

31

206

INIT VMN HIGH

Open

0x3121

30

207

INIT VMN LOW

Open

0x3610

13

208

EEPROM KO

Closed

0x0000

14

209

PARAM RESTORE

Closed

0xFFD2

71

210

WRONG RAM MEM.

Open

0xFFD3

11

211

STALL ROTOR

Closed

0xFFD4

39

212

POWER MISMATCH

Open

0xFFD5

35

213

POSITIVE LC OPEN

Open

0x5002

9

214

EVP COIL OPEN

Closed

0x5003

9

215

EVP DRIV. SHORT.

Open

0xFFD8

43

216

EB. COIL OPEN

At keyon Opened after closed

0xFFDB

25

217

PEV NOT OK

Closed

0x4311

68

218

SENS MOT TEMP KO

Closed

0x5101

20

220

VKEY OFF SHORTED

Open

0xFFDD

46

221

HANDBRAKE

Closed

0xFFDE

15

222

SEAT MISMATCH

Open

0x2250

76

223

COIL SHOR. MC

Open

0x0000

0

224

WAITING FOR NODE

Open

0xFFE2

85

226

VACC OUT RANGE

Closed

0xFFE3

32

227

HW FAULT

Open

0x0000

51

228

TILLER OPEN

0xFFE5

34

229

HW FAULT EB.

Closed

0xFFE6

22

230

LC COIL OPEN

Open

0xFFE8

21

232

CONT. DRV. EV

Closed

0xFFE9

89

233

POWERMOS SHORTED

Open

0xFFF9

21

234

DRV. SHOR. EV

0x6302

92

236

CURRENT GAIN

Closed

0xFFFA

96

237

ANALOG INPUT

Open

0xFFEE

16

238

HW FAULT EV.

0xFFEF

12

239

CONTROLLER MISM.

Closed

0xFFF8

9

240

EVP DRIVER OPEN

Closed

8000 YRM 2354

Electrical System

Table 3. Primary Controller Fault Codes (Continued) OPEN CAN CODE

MDI CODE

CAN CODE

ALARM

Main Contactor

0xFFF2

21

242

OPEN COIL EV.

Closed

0xFFF3

48

243

THROTTLE PROG.

Closed

0xFF01

1

244

WARNING SLAVE

0xFFF5

24

245

IQ MISMATCHED

Open

0x3224

42

246

EB. DRIV.OPEN

Closed

0x0000

0

247

DATA ACQUISITION

Closed

0x8130

67

248

NO CAN MSG.

Open

0x0000

0

249

CHECK UP NEEDED

Closed

0x4211

61

250

THERMIC SENS. KO

Closed

0x3100

41

251

WRONG SET BAT.

Open

0x3201

58

252

WRONG ZERO

0xFFFD

36

253

FIELD ORIENT. KO

Open

0x3222

40

254

EB. DRIV.SHRT.

ACE4: Opened, other controllers: Closed

Table 4. Auxiliary Controller Fault Codes OPEN CAN CODE

MDI CODE

CAN CODE

ALARM

0x6010

8

8

WATCHDOG

0xFF11

17

17

LOGIC FAILURE #3

0x5114

19

19

LOGIC FAILURE #1

0xFFC7

0

199

BUMPER STOP

0xFFC3

95

200

STEER SENSOR KO

0xFF51

85

201

WRONG ENC SET

0xFFCA

77

202

VDC LINK OVERV.

0x3610

13

208

EEPROM KO

0x3611

14

209

PARAM RESTORE

0xFFD2

71

210

WRONG RAM MEM.

0xFFD4

59

212

W.SET. TG-EB XX

0xFFD5

58

213

INPUT MISMATCH

0xFFE3

16

227

OUT MISMATCH XX

0x8131

67

229

NO CAN WR MSG.XX

0xFFE6

0

230

SOFTWARE ERROR

0xFFFA

96

237

ANALOG INPUT

21

Electrical System

8000 YRM 2354

Table 4. Auxiliary Controller Fault Codes (Continued) OPEN CAN CODE

MDI CODE

CAN CODE

ALARM

0xFFEF

12

239

CONTROLLER MISM.

0xFFF0

20

240

OUT MISMATCH PU

0xFFF1

18

241

SP MISMATCH PUMP

0xFFF2

15

242

SP MISMATCH XX

0x8130

67

248

NO CAN MSG.

Table 5. Smart Display Fault Codes

22

CAN CODE

ALARM

13

EEPROM KO

18

LOGIC FAILURE #2

19

LOGIC FAILURE #1

76

COIL SHORTED

102

CAN BUS KO MAST

103

SERVICE REQUIRED

8000 YRM 2354

Steering Device and Installation

Steering Device and Installation OVERVIEW The steering mechanism comprises of steering wheel, steering column and column bracket. The steering column upper section is connected by nut to the steering wheel, the column lower section is connected by bolt to the Orbitrol, enabling the steering column adjustable towards either front or rear.

Steering device and installation structural composition are indicated in Figure 8.

Examination of Steering System After Reassembly 1.

Turn the steering wheel leftward and rightward and turn it thorough and thorough to find whether or not left and right force applications are uniform, and whether or not turning is stable.

2.

Examine whether or not the oil pressure piping layout is correct, and whether or not left/right steering is reversely installed.

3.

Jack up the rear wheel, slowly turn the steering wheel leftward and rightward, repeat it for several times, and remove the air in the hydraulic pipeline and the cylinder.

1. STEERING WHEEL 2. LOCKING HANDLE 3. ORBITROL CONTROL UNIT Figure 8. Steering Device

23

Steering Device and Installation

8000 YRM 2354

Steering System Fault Diagnosis Problem

Steering Wheel Fails to Turn

Steering Operation Strenuous

Analysis of Cause for Generation

Removal Method

Damage or failure of oil pump

To be replaced

Priority valve blocked or damaged

To be cleaned or replaced

Hose or joint damaged or pipeline blocked

To be cleaned or replaced

Pressure of bypass valve too low

Pressure to be adjusted

Air present in oil circuit

Air to be removed

Failure of steering gear reset, positioning spring broken or elasticity not enough

Spring leaf to be replaced

Internal leak of steering cylinder too large

Piston sealing to be examined

Oil level of oil tank low

Oil to be added

Shaft strip of steering gear damaged To be replaced Abnormal Noise

Oil Leak

Steering Angles of Left and Right Driving Wheels (Front Wheels) Not Matching Each Other

24

Wheel hub bearing or support bearing damaged

To be replaced

Lubrication insufficient

Lubricating grease to be added

Suction pipe or oil filter blocked

To be cleaned or replaced

Seal ring of steering cylinder damaged or pipe or joint damaged

To be replaced

Seal ring for wheel hub bearing or support bearing damaged

Seal ring to be replaced

Controller parameter incorrect

To be adjusted

8000 YRM 2354

Steering Device and Installation

1. LOCKING HANDLE 2. BUCKLE 3. SHAFT 4. CUSHION 5. STEERING COLUMN 6. STEERING WHEEL 7. LOCKING PIECE 8. BOLT 9. WASHER 10. BOLT 11. BUSHING 12. NUT 13. WASHER Figure 9. Steering Device and Installation

25

Steering Axle and Installation

8000 YRM 2354

Steering Axle and Installation

1. BOLT 2. WASHER 3. WASHER 4. STEER POTENTIOMETER SHAFT 5. NUT 6. STEER POTENTIOMETER BRACKET 7. STEERING AXLE 8. NUT 9. WASHER 10. BOLT Figure 10. Installation of Steering Axle

26

8000 YRM 2354

Steering Axle and Installation

Figure 11. Steering Axle

27

Hand Brake Operation

8000 YRM 2354 Legend for Figure 11.

1.

2.

3.

4.

5.

6.

7.

8.

CYLINDER BODY BRACKET NUT SPLINE SHAFT BUSHING SEAL RING BEARING BEARING

9. SEAL RING 10. SEAL RING 11. BEARING 12. SHAFT 13. BEARING 14. WASHER 15. NUT 16. PIN 17. CYLINDER CAP

18. HUB 19. SEAL RING 20. PLUG 21. POLE 22. PIN 23. WASHER 24. SEAL RING 25. PLUG

Hand Brake Operation OVERVIEW Hand pull flexible shaft mechanism is applied to the hand brake device, and it shares one automatic power block brake actuated to the front wheel with foot brake.

Hand brake is used only when the forklift truck is parked.

PARKING BRAKE OPERATION DEVICE The park brake is of ratchet type by which braking force could be adjustable with the adjuster located inside the brake handle.

Adjustment of Braking Force Turn the regulator clockwise, to increase the braking force and turn the regulator counterclockwise, to reduce the braking force.

Pull 200~300 N•m (45~67 lbf ft).

Installation of hand brake is indicated as in Figure 12.

1. HAND BRAKE ASSEMBLY 2. BOLT 3. WASHER 4. WASHER 5. BOLT M12X45 6. WASHER 7. WASHER 8. NUT 9. STAY CLIP 10. BRAKE STAY Figure 12. Installation of Hand Brake Operation

28

8000 YRM 2354

Hand Brake Operation

Fault Diagnosis Obstacle

Braking Force Insufficient

Brake Seized

Possible Cause

Corrective Action

Oil leak in brake pipeline

To be corrected and oil to be readded

Air present in brake pipeline

Air to be removed

Brake master cylinder function abnormal

To be corrected or replaced

Oil pipeline blocked

To be cleaned

Brake pedal without free stroke

To be adjusted

Piston cup damaged

To be replaced

Return spring weak or broken

To be replaced

Backflow hole of brake master cylinder blocked

To be cleaned

Oil pipe blocked

To be cleaned

29

Foot Brake Operation

8000 YRM 2354

Foot Brake Operation OVERVIEW

FOOT BRAKE PEDAL

Foot brake operation is composed of foot brake assembly, as well as left and right brake oil pipes.

The structure of foot brake pedal is shown in Figure 13, and the brake cover is welded to the instrument stand of frame.

1. COVER PLATE 2. PEDAL 3. BRAKE FLUID TANK

4. BRAKE PUMP 5. BRAKE LINE Figure 13. Foot Brake Operation

Adjustment of Foot Pedal Brake 1.

Adjust the push rod to be short.

2.

Adjust the catch bolt, to adjust the pedal height as indicated in Figure 13.

30

3.

Push down the brake pedal, and adjust the push rod to be long, until the front end of push rod contacts the master cylinder piston.

4.

Screw down the lock nut for the push rod.

8000 YRM 2354

Foot Brake Operation Legend for Figure 14.

1.

2.

3.

4.

5.

6.

7.

CATCH BOLT LOCK NUT LOCK NUT PUSH ROD PUSH ROD FREE STROKE EFFECTIVE STROKE FLOORMAT

Adjustment of Brake Switch 1.

Loosen the lock nut for brake switch, after the height of brake pedal has been properly adjusted.

2.

Pull off the plug and allow the lead wire to separate.

3.

Turn the switch, for Clearance A =1 mm.

4.

Confirm that the brake light shall be turned on when brake pedal is pushed down.

BRAKE MASTER CYLINDER

Figure 14. Adjustment of Foot Pedal Brake

The master cylinder includes a valve seat, an one-way valve, one and return spring, as well as cup, piston, and auxiliary cup. Its top part is fixed using stopping washer and stopping steel wire, and its outside part is protected through rubber dust cover. The master cylinder piston acts through push rod based on operation of brake pedal. When brake pedal is pushed down, the push rod pushes the piston forward, and the brake fluid in the cylinder body returns to the oils storage tank through return oil port, until the main cup blocks up the return oil hole. After the main cup has pushed the return oil port, the brake fluid in the front cavity of cylinder body is compressed and opens the one-way valve, thus flows to the wheel cylinders through brake pipeline, the way respective wheel cylinders extend outwards, for brake block friction plate and brake drum to contact each other, achieving the effect of speed reduction or brake. At this point, the rear cavity of piston is supplied with brake fluid from return oil port and oil inlet port. When brake pedal is loosened, the piston is pressed backward by return spring, and at the same time the brake fluid in respective brake wheel cylinders will also be compressed by brake block return spring, for the brake fluid to return to the master cylinder (the front cavity of piston) through one-way valve. The piston will return to its original position, the brake fluid in the master cylinder will return to the return oil tank through return oil port, and the pressure of one-way valve is adjusted to a certain proportion with the remaining pressure in brake pipeline and brake wheel cylinders, for the cup

31

Foot Brake Operation

8000 YRM 2354

of wheel cylinder to be correctly placed to prevent oil leak, as well as to eliminate air resistance possibly generated during emergency brake. The structure of brake master cylinder is indicated as in Figure 15.

A. SELF-ADJUSTING STORING TANK B. SELF-ADJUSTING WHEEL BRAKE Figure 15. Brake Master Cylinder

FAULT DIAGNOSIS Problem

Poor Brake

Analysis of Cause for Generation

Removal Method

Oil leak with brake system

To be repaired

Clearance of brake clearance not properly adjusted

Regulator to be adjusted

Brake overheated

Examine whether or not skidding exists

Poor contact of brake drum and friction plate

To be readjusted

Contaminant attached on friction plate

To be repaired or replaced

Contaminant blended into brake fluid Brake fluid to be examined Brake pedal (micro-valve) improperly adjusted

To be adjusted

Surface of friction plate hardened or To be repaired or replaced contaminant attached to it

Noise Present with Brake

32

Bottom plate distorted or bolt loosened

To be repaired or replaced

Brake block distorted or installation incorrect

To be repaired or replaced

Friction block worn out

To be replaced

Wheel bearing loosened

To be repaired

8000 YRM 2354

Problem

Un-Uniform Brake

Weak Brake

Working Oil Tank and Installation

Analysis of Cause for Generation

Removal Method

Oil stain present on friction plate

To be repaired or replaced

Brake clearance not properly adjusted

Regulator to be adjusted

Failure of wheel cylinder

To be repaired or replaced

Return spring of brake block damaged

To be replaced

Brake drum deflected

To be repaired or replaced

Oil leak with brake system

To be repaired or replaced

Clearance between brake blocks not Regulator to be adjusted properly adjusted Air blended into brake system

Air to be bled

Brake pedal wrongly adjusted

To be readjusted

Working Oil Tank and Installation OVERVIEW

HYDRAULIC OIL TANK

Working oil tank and installation are mainly composed of oil tank, oil tank cover plate, magnet, filter core, breather, oil tank cover, drain plug, and gasket, etc.

The hydraulic oil tank for three-wheel vehicle type is on the left tank body of vehicle chassis. Oil suction filter is fitted in the oil tank, to ensure a supply of clean oil.

Hydraulic System OVERVIEW The hydraulic system consists of oil pump, multi-way valve, orbitrol, oil hose and joints. When the high pressure oil from the main oil pump reaches the multiway valve, it will be divided into two paths: one path will direct the oil to lift or tilt cylinder, the other will flow to the Orbitrol to empower the steering cylinder. In the steering system with load sensor, there will be a Ls

port in the orbitrol connecting to that in the multi-way valve so that the steering load signal will be passed to the LS port in the valve to control the amount of oil supplied to the Orbitrol. When the load sensor indicates neutral, there will be a little oil flowing back to the oil tank which obviously is energy saving. See Figure 16.

33

Hydraulic System

8000 YRM 2354

Figure 16. Hydraulic Schematic Drawing (Sheet 1 of 2)

34

8000 YRM 2354

Hydraulic System

Figure 16. Hydraulic Schematic Drawing (Sheet 2 of 2)

35

Hydraulic System

8000 YRM 2354

GEAR PUMP Gear pump is driven by lifting motor. The structure of gear pump is indicated as in Figure 17.

Maintenance of Gear Pump Disassembly 1.

Before disassembly, it shall be thoroughly cleaned. The demounted parts shall be put on clean paper or cloth. Take care not to contaminate or injure the parts. a.

Clamp the flange part of pump on the clamp bench.

b.

Dismount the Connecting Bolt 11, Pump Cover 5, and Pump Housing 1.

c.

Detach the Lining Plate 6, the Driving Gear 2, and the Driven Gear 3.

d.

Demount the Seal Ring 7 and 3-Shape seal ring 8 from the front and rear end caps.

Legend for Figure 17.

1. PUMP BODY 2. DRIVING GEAR 3. DRIVEN GEAR 4. FRONT END CAP 5. REAR END CAP 6. LINING PLATE 7. SEAL RING 8. 3-SHAPE SEAL RING 9. OIL SEAL 10. SPRING RETAINER RING 11. BOLT 12. WASHER Examination 2.

Examine the disassembled parts, and clean them using gasoline (except rubber parts).

NOTE: Don’t demount the seal ring if it is not to be replaced.

Examination of Pump Body a.

The pump body shall be replaced, if the contact length of pump body internal cavity and the gear is larger than the circumference by ½.

Examination of Lining Plate b.

Examine the contact face of lining plate, and the lining place shall be replaced if the surface is damaged or the thickness of lining plate is smaller than the specified value.

The specified value for thickness of lining plate is 4.94 mm (.19 in.).

Figure 17. Gear Pump

36

8000 YRM 2354

A. INLET PORT B. LINING PLATE C. OUTLET PORT

Hydraulic System

3.

Assembly a.

Mount on a new seal ring and new retainer ring on the front end of the pump.

Figure 18. Gear Pump Facing Front and Rear Pump Caps c.

The inner surface lining shall be replaced, if lining color change (brown color)

d.

Examine the driving and driven gears from front and rear. A pair shall be replaced in the case of excessive wear, and they shall be replaced in pairs if side D as indicated in Fig. 10-6 is smaller than the specified value.

1.

2.

3.

4.

5.

RETAINER RING ROOTAGE SEAL RING PUMP BODY INTERNAL CAVITY UNDERSIDE LINING Figure 19. b.

e.

Mount on the lining plate in the groove part of front end cover, and take care not to mistake the oil suction port and oil drain port.

Replace seal ring, lining seal part, retainer ring, and spring retainer ring, as per requirements.

37

Hydraulic System

8000 YRM 2354 (If oil pump is disassembled for maintenance due to severe worn-out or block-up because of hydraulic oil, the hydraulic oil and the filter shall be replaced, prior to trial run on forklift truck.)

c.

Mount on the driving and driven gears on the front end cover.

d.

Mount on the lining plate on the side of gear for the groove to be aligned with gear point. Take care not to mistake the oil suction port side and the oil drain port side.

e.

Mount on a new seal ring and new retainer ring on the groove part of rear cap. Refer to the figure 10-7.

f.

Mount the rear cap on the pump body, and pay attention not to mistake the oil suction port and the oil drain port.

g.

Tighten the connecting bolts to the specified torque 9-10kg.m after everything has been properly assembled.

Trial Run 4.

38

Trial run is for oil pump to run in. Examine whether or not the pump moves normally, and it is best to test the oil pump on test bench, but it may also be tested on forklift truck in following steps:

a.

Mount the pump on the forklift truck, and mount on pressure gauge at the pressure test port of multi-way valve.

b.

Loosen the adjusting screw of overflow valve, for pump to run for about 10 minutes at 500～ 1000rpm, to ensure that the oil pressure is lower than 10kg/cm².

c.

Speed up the pump rotation to 1500～ 2000rpm, and run for about 10 minutes.

d.

Maintain the pump speed at 1500～2000rpm, and increase the pressure by 20～30kg/cm² each time, run for 5 minutes, until it reaches 175kg/cm².

CAUTION Pay attention to test the temperature of oil, the temperature of pump surface, and running sound, when oil pressure is increased, and reduce the load for oil temperature to drop if oil temperature or pump surface temperature too high, before test is continued. e.

After completing the above procedures, the overflow valve is re-adjusted to the original working condition, and the unloading test is carried out.

8000 YRM 2354

Hydraulic System

Fault Diagnosis Failure Oil Drainage Quantity Small

Pump Pressure Low

Cause

Repair Method

Oil level of oil tank low

Oil to be added to specified quantity

Oil pipe or oil filter blocked

To be cleaned or replaced as per requirement

Lining plate damaged Bearing damaged Seal ring, lining seal part or retainer ring under poor condition

To be replaced

Overflow valve misadjusted

Overflow valve to be adjusted to specified value using pressure gauge

Air present in system

Oil pipe at oil suction side to be refastened Oil to be added Oil seal of pump to be replaced

Oil suction pipe damaged or oil filter Pipe to be examined or oil filter to be blocked maintained Oil suction side loosened and air leak

Loosened area to be fastened

Oil viscosity too high

To be replaced with oil with viscosity adaptive to pump operating temperature

Air bubble present in oil

Cause of air bubble to be found out and actions to be taken

Pump oil seal or seal ring damaged

To be replaced

Pump damaged

To be replaced

Noise Present During Operation

Pump Oil leak

39

Hydraulic System

8000 YRM 2354

MULTI-WAY VALVE

of tilting cylinder, mainly used for preventing severe aftereffect caused by mis-operation of control rod under the condition when tilting cylinder has no pressure source. One-way valve is installed between the oil inlet port and the oil suction port of lifting valve as well as between the oil inlet port of lifting valve and the oil inlet port of tilting valve plate.

Two-piece and four-body type is applied to multi-way valve, and the hydraulic oil from hydraulic oil pump is controlled through multi-way valve stem, to distribute the high-pressure oil to lifting cylinder or tilting cylinder.

Safety valve and self-lock valve are available inside the multi-way valve. The safety valve is set on the oil inlet port of multi-way valve, able to control system pressure, while self-lock valve is set on the valve plate

1.

2.

3.

4.

LIFTING VALVE TILTING VALVE AUXILIARY VALVE AUXILIARY VALVE

The shape of multi-way valve is indicated as in Figure 20.

5.

6.

7.

8.

TO OIL TANK TO STEERING TO OIL PUMP SAFETY OVERFLOW VALVE

Figure 20. Multi-Way Valve

40

8000 YRM 2354

Hydraulic System

Operation of Tilting Valve (Tilting slide valve as example) a.

1.

2.

3.

4.

At this point the high-pressure oil drained from oil pump returns to oil tank through neutral position.

Neutral Position (Figure 21)

OIL INLET ONE-WAY VALVE MAIN OIL INLET PORT CYLINDER POINT A RESET SPRING

5.

6.

7.

8.

TILTING VALVE LOW PRESSURE PASSAGE MIDDLE PASSAGE CYLINDER POINT B

Figure 21. Tilting Slide Valve Push-in Tilting Valve b.

See Figure 22.

At this point, the middle passage is closed, and the oil from the oil inlet port opens the one-way valve and flows to cylinder interface B, while the oil from cylinder interface A flows to the oil tank through low-pressure passage, able for slide valve to return to neutral position, depending on the return spring.

Figure 22. Push-In Tilting Valve

41

Hydraulic System Pull-out Slide Valve c.

See Figure 23.

At this point the neutral position is closed, and the oil from the oil inlet port opens the one-way valve, and flows to cylinder interface A, while the oil from cylinder interface B flows to the oil tank through low-pressure passage, able for slide valve to return to the neutral position, depending on return spring.

8000 YRM 2354 The pressure set in the oil pump “HP” passage acts on the spring of guide valve, and the oneway valve “E” will open. Oil passes around the valve and flows into the low-pressure “LP” side via through hole, as indicated in .

Figure 25.

Figure 23. Pull-Out Slide Valve Action of Safety Overflow Valve 1.

Once the guide valve “E” is opened, the pressure of the inner side of valve “C” will drop, and valve “E” and valve “C” both drop on the valve seat.

The fluid flow in the back of flow valve “D” will be closed, for which the pressure of the inner-side part will drop, as indicated in .

Overflow valve is installed between the oil pump “HP” interface and low-pressure “LP” passage.

Through function of lifting valve “C” oil on the different areas of “A” and “B”, in this way the oneway valve “K” and the overflow lifting valve “D” both drop on the valve seat, as indicated in Figure 24.

Figure 26.

Figure 24. Safety Overflow Valve

42

The pressures on the oil pump “HP” passage side and the inner side are imbalanced, and the valve “D” will open under the action of pressure difference, for oil to directly flow into the low-pressure “LP” circuit, as indicated in .

8000 YRM 2354

Hydraulic System

Figure 27.

Action of Tilting Self-Lock Valve 2.

The tilting slide valve is equipped with a self-lock valve, which is mainly used to prevent vibration caused by the negative pressure inside the tilting cylinder and avoid serious consequences caused by the action. Generally, the conventional structure can also operate the tilting slide valve to make it tilt forward after the engine is turned off.

However, in case that this tilting self-lock valve is adopted, when the engine is flameout, the mast cannot be tilted forward even when the operating valve is pushed.

1. OIL PORT A 2. OIL PORT B 3. PRESSURE VALVE Figure 28. Valve Core Pushed In (Pump Working) b.

When valve core is pushed in (pump not working) Push in the valve core when oil pump is not working, no oil will enter into cylinder interface “B, and thus the pressure in the P part will not rise. On this account, piston will not move, the oil of cylinder interface “A” cannot return to oil tank, and the cylinder does not move.

The flow direction of oil is the same as indicated in Fig 10-12 when valve core is pulled out, and at this point the mast is in the tipping-back status.

The status when valve core is pushed in is described below. a.

When valve core is pushed in (pump working) The oil from the main pump passes interface “B” to the tilting cylinder, the oil returning from cylinder passes oil port A and acts on the piston, and the oil returns to the oil tank through the LP oil circuit holes A and B on valve core.

1. OIL PORT A 2. OIL PORT B 3. PRESSURE VALVE Figure 29. Valve Core Pushed In (Pump Not Working)

43

Hydraulic System

8000 YRM 2354

Multi-Way Valve Control

Figure 30. Multi-Way Valve Control 3.

Multi-way valve is controlled by control rod, and all the control rods are installed on one piece of connecting shaft. The shaft is fixed on instrument panel through bracket, and the control rods control slide valves through connecting rod.

1. LIFTING 2. TILTING Figure 31. Logo of Multi-Way Valve Control

44

8000 YRM 2354

Hydraulic System

According to what’s indicated in Figure 31, push forward and pull up backward the lifting handle, the mast will rise and drop, respectively. Push forward and pull backward the tilting handle, the mast will tip forward and backward, respectively.

Adjustment of Multi-way Valve Pressure d.

ERP16UXT ERP18UXT ERP20UXT Safety Valve Pressure Control Value

14.5Mpa

17.5Mpa

17.5Mpa

Orbitrol Pressure Setting

4.5Mpa

6.3Mpa

6.3Mpa

4.

Tighten the nut after it has been properly adjusted.

Pressure Adjusting Method for Safety Valve (Figure 32) The pressure of safety valve shall not be randomly adjusted, and please adjust the pressure in the following steps. a.

Screw off the measurement hole screw plug for the inlet part of multi-way valve, mount on the oil pressure gauge that is able to measure 20MPa.

b.

Operate the tilting handle, and measure the pressure when stroke of cylinder has moved to the end.

c.

When oil pressure and specified value are different, loosen the lock nut of overflow valve, and adjust the left/right turning adjusting screw to the specified value.

1.

2.

3.

4.

OIL INLET PORT LOCK NUT CAP PRESSURE VALVE

Figure 32. Pressure Adjustment Method for Safety Valve

45

Hydraulic System

8000 YRM 2354

Fault Diagnosis Failure

Cause

Pressure of Lifting Oil Circuit Fails to Valve blocked be Increased Oil hole blocked Slow Pressure Rise

Repair Method To be cleaned after disassembly

Valve blocked

To be cleaned after disassembly

Air Exhaust insufficient

Air to be fully exhausted

Pressure of Steering Oil Circuit Larger than Specified Value

Valve blocked and stagnant

Specified Oil Quantity Cannot Be Reached

Adjustment of overflow valve improper

To be adjusted

Noise Present

Adjustment of overflow valve improper

To be adjusted

Slide Surface Worn-out

Overflow valve to be replaced

O-ring aged or damaged

O-ring to be replaced

Spring broken

Spring to be replaced

Valve seat surface damaged

To be adjusted or overflow valve to be replaced

Oil Leak (Internal)

Valve seat surface damaged

Valve seat surface to be amended

Set Pressure High

Valve blocked and stagnant

To be cleaned after disassembly

Oil Leak (External) Set Pressure Low

46

Oil hole blocked

To be cleaned after disassembly

8000 YRM 2354

Hydraulic System

FULL HYDRAULIC ORBITROL Full hydraulic orbitrol (Figure 33) is able to measure the size of angle according to the rotation of steering

1.

2.

3.

4.

5.

6.

VALVE CORE SPRING LEAF VALVE SLEEVE PIN PULL-OUT LARGE RETAINING RING THRUST NEEDLE ROLLER BEARING 7. SMALL RETAINING RING 8. O-SEAL RING 77.5 X 2.65

wheel and transmit the pressure from oil pump to bypass valve through pipeline. When oil pump fails to supply oil, steering can be achieved manually.

9. STEEL BALL S Φ8 10. VALVE BODY 11. O-SEAL RING 50 X 3.1 12. X-SHAPE SEAL RING 13. O-SEAL RING 25.8 X 2.65 14. FRONT COVER 15. SPRING WASHER 8 16. INNER HEXAGON SCREW M8 X 20 17. HEXAGON HEAD BOLT M10 X 1.25 X 50

18. COMBINATION SEALING WASHER 19. PIN 4 X 32 20. REAR COVER 21. LIMITED POST 22. O-SEAL RING 79 X 2 23. ROTOR AND STATOR ACCESSORIES 24. UNIVERSAL DRIVING SHAFT 25. DIAPHRAGM PLATE

Figure 33. Full Hydraulic Orbitrol

47

Hydraulic System

8000 YRM 2354

SPEED LIMIT VALVE The speed limit valve (i.e., the throttle valve) is installed in the lifting cylinder oil circuit to limit the descent speed of the fork when it is under heavy load.

Refer to Figure 34 for working status of speed limit valve.

Return oil of lifting cylinder enters into the valve cavity G, and returns to multi-way valve through FEDCB and A.

When a large quantity of oil flows through the valve core hole C, the pressure difference generated in valve core enables the valve core to move rightward.

Thus the passage between the holes D and C turns narrow, the return oil quantity is reduced for it, and the dropping speed of fork turns slow.

If fork is to be lifted, the HP oil from multi-way valve enters into lifting cylinder through ABCDEF and G.

Figure 34. Speed Limit Valve

48

8000 YRM 2354

Hydraulic System

HYDRAULIC LINES Refer to Figure 35 for hydraulic oil pipeline of ERP16 ERP18UXT hydraulic system.

Figure 35. Hydraulic Lines

49

Lifting System

8000 YRM 2354

Lifting System SAFETY PROCEDURES WHEN WORKING NEAR MAST

2.

Raise mast to align bottom crossmember of weldment that moves in the outer weldment with a crossmember on the outer weldment. On the two-stage and free-lift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. See Figure 44.

3.

Use a 3/8 inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast.

4.

Lower mast until there is tension in the safety chain and the free-lift cylinder (three-stage) is completely retracted. If running, stop the engine.

Apply parking brake. Install a DO NOT REMOVE tag on the safety chain(s).

5.

Install another safety chain (3/8 inch minimum) between the top or bottom crossmember of the carriage and a crossmember on the outer weldment. See Figure 44.

WARNING The following procedures MUST be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

•

• •

• •

Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is off and the key is removed. Put a DO NOT OPERATE tag in the operator's compartment. Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector.

Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

DO NOT use blocks to support the mast weldments or to restrain their movement.

Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the Mast.

WHEN WORKING NEAR THE MAST ALWAYS: •

Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

OR •

1.

50

If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: Put mast in vertical position.

NOTE: Apply parking brake. After lowering or restraining the mast, shut off power and remove key.

Put a DO NOT OPERATE tag in the operator's compartment. Disconnect battery on electric lift trucks and put a tag or lock on battery connector.

OVERVIEW The lifting system is mainly composed of inner mast, outer mast, fork carriage, lifting cylinder, and tilting cylinder, etc.

INNER AND OUTER MAST The inner and outer masts are the welded parts. The bottom part of outer mast is installed on driving axle using support. See Figure 36.

The middle part of outer mast is connected together with vehicle chassis through tilting cylinder, and able to tip forward and backward under the function of tilting cylinder.

8000 YRM 2354

Lifting System

The channel steels for inner is J type and outer mast is C type, the main roller and side rollers are installed on the top of the outer mast, and the composition roller is mounted on the bottom of inner mast.

The maintenance and service of the composite rollers for the inner and outer mast are high-position service, and attention shall be paid to safety.

1.

2.

3.

4.

1.

2.

3.

4.

5.

6.

7.

ROLLER STOP PLATE OUTER MAST SHAFT PIN SUPPORT COVER BUSHING ROLLER Figure 36. Two-Stage Mast

FORK CARRIAGE ASSEMBLY Fork carriage is composed of fork carriage, composite roller, backrest, and fork. The fork rolls inside the inner mast through composite roller, Composite roller shaft head is directly welded on the carriage, and the rolling clearance is to be adjusted by traverse roller inside the composite roller. See Figure 37.

BACKREST ROLLER FORK CARRIAGE Figure 37. Fork Carriage Assembly

Adjustment for Height of Fork Carriage 1.

Park the vehicle on a level ground and keep the mast to be vertical.

2.

Allow the underside of fork to contact the ground, adjust the adjusting nut of the joint on the top end of chain for there to be a distance A between the combination roller and the inner36-41 mm mast.

51

Lifting System 3.

1.

2.

3.

4.

Allow the fork to drop to the ground and tilt backward in place. Adjust the joint on the top part of chain, and adjust the nuts for the tensioning degrees of the two chains to be the same.

LOCKNUT 1 LOCKNUT 2 END CONNECTOR CHAIN

8000 YRM 2354 Add grease on the surface of composite roller and the contact fact of mast.

Replacement of Fork Backrest 1.

Park the truck on a level ground, with one pallet on the fork.

2.

Drop the fork and the pallet on the ground.

3.

Detach the joint on the top end of chain, and take off the chain from sprocket wheel.

4.

Lift inner mast (1 in Figure 40).

5.

Reverse the fork, after it is confirmed that the fork carriage has been disengaged from the outer mast. (2 in Figure 40).

Figure 38. Chain LH1634

ROLLER POSITIONS Rollers are divided into composite roller and side roller, installed on outer mast, inner mast, and fork carriage, respectively. The composite roller bears the front/rear, and side loads, while the side rollers mainly bear the side loads, thus for the inner mast and the fork carriage to move freely. (Figure 39)

Figure 40. Replacement of Fork Backrest 1.

2.

3.

4.

5.

6.

7.

SIDE ROLLER INNER MAST ROLLER BACKREST TILTING CYLINDER LIFTING CYLINDER OUTER MAST Figure 39. Schematic Diagram of the Roller

NOTE: Adjust the side clearance of composite roller to be 0.5mm.

52

LIFTING CYLINDER Lifting cylinder is in a single-function piston type, composed of cylinder body, piston rod, piston, and cylinder head, etc. For this series of forklift trucks, two piece of lifting cylinders are installed behind the outer mast, and its bottom part is fixed using pins and bolts on the support of the lifting cylinder on outer mast, while the top part of the cylinder (namely the top part of piston rod) is connected with the upper crossbeam of the inner mast.

8000 YRM 2354

Lifting System

The piston is fixed on the piston rod using spring steel wire, and oil seal and support ring are installed on the outer ring of piston.

One explosion relieve valve is mounted on the bottom part of the cylinder, and it can play the safety

1. BOLT M12 X 1.25 X 25 2. CYLINDRICAL PIN B10 X 25 3. WASHER 12 4. CYLINDER BODY 5. O-RING 22 X 2.4 6. EXPLOSION RELIEF VALVE 7. HOOP 8. RUBBER SLEEVE 9. HOOP SEAT 10. WASHER 10 11. NUT M10 X 1.25 12. BOLT M12 X 1.25 X 30

protective function if HP pipe suddenly cracks when mast is lifted up. Steel-backed bearing and oil seal are installed on the cylinder cover, used to support piston rod and prevent dust entry. See Figure 41.

13. NUT M12 X 1.25 14. ROUNDWIRE SNAP RING 24 15. VALVE SLEEVE 16. HOLE SEAL 45 X 35 X 6 17. RETAINER RING 18. HOLE SUPPORT RING 19. PISTON 20. SPACER SLEEVE Φ35 X 50 21. PISTON ROD 22. LINING 23. O-RING 49.7 X 3.5 24. STEEL-BACKED BEARING Φ35 X Φ39 X 30 25. NYLON CUSHION Φ6 X 3

26. SCREW M8 X 8 27. CYLINDER HEAD 28. SHAFT SEAL 35 X 45 X 6 29. DUST RING 35 X 45 X 5/6.5 30. WASHER 14 31. BOLT M14 X 1.5 X 35 32. RETAINER RING 40 33. SPROCKET WHEEL 34. CHAIN 35. COTTER PIN B3.2 X 30 36. SPHERICAL NUT M14 X 1.5 37. NUT M14 X 1.5

Figure 41. Lifting Cylinder

53

Lifting System

8000 YRM 2354

Working Status of Explosion Relieve Valve One explosion relieve valve is available at the bottom part of lifting cylinder, and refer to Figure 42. It is used to prevent abrupt drop of cargo, when HP hose is suddenly cracked. The oil from the lifting cylinder passes the cutoff slide valve, and the oil holes around the slide valve allow the two cavities to generate pressure difference. At this point when differential

A. NORMAL

pressure is smaller than the spring force, the slide valve will not act. In the case if HP hose is cracked, a very big differential pressure is formed, for the slide valve to move and block up the oil holes around it, while only a small quantity of oil is allowed to flow through the pores at the top part of slide valve, for fork to drop slowly.

B. DISCONNECTED Figure 42. Working Status of Explosion Relief Valve

Adjustment of Lifting Cylinder

3.

When lifting cylinder, inner mast or outer mast is disassembled and replaced, it is required to re-adjust the stroke of lifting cylinder. The adjusting method is given as follows. Refer to Figure 43.

After movement is stopped, add adjusting shim between the head of piston and the upper crossbeam of mast. The thicknesses of adjusting shim are 0.2mm and 0.5mm.

4.

Adjust the tensioning degree of chain. The adjustment of lifting cylinder is also a highposition service, and attention shall be paid to safety.

1.

Mount the head part of piston into the upper crossbeam of inner mast without adding the adjusting shim.

2.

Slowly lift the mast to the maximum stretching range of cylinder, and examine whether or not the two lifting cylinders are synchronous.

54

NOTE: If the forklift truck is not used for up to 10 days, the oil cylinder shall be lifted to the top for 2 or 3 times for the lubrication and maintenance.

8000 YRM 2354

1.

2.

3.

4.

INNER MAST LIFTING CYLINDER ADJUSTING SHIM UPPER CROSSBEAM OF INNER MAST Figure 43. Adjustment of Lifting Cylinder

TILTING CYLINDER Tilting cylinder is in double function type, and its end part of piston rod is connected with mast through ear ring. The tilting cylinder bottom is connected with vehicle chassis using pins, and one piece of tilting cylinder is available on the two sides of forklift truck, respectively.

The tilting cylinder is mainly composed of piston, piston rod, cylinder body, cylinder cover, guide sleeve, and seal part, etc. Piston and piston rod are in the welded structure. One support ring and two Yx seal rings are mounted at the outer edge of piston, while shaft sleeve is press fitted for and Yx seal ring, retainer ring, and dust ring are mounted in the inner hole of guide sleeve. This shaft sleeve supports the piston rod, the seal ring, the retainer ring, and the dust ring, able to prevent oil leakage and dust, screwed onto the cylinder body together with O-ring, indicated as in Figure 44.

When tilting slide valve is pushed forward, HP oil enters from the cylinder bottom, thus to push the piston forward for the mast to tip forward. When the slide valve is pulled backward, HP oil enters from the front end of cylinder body, to push the piston backward, for the mast to tip backward.

Lifting System

1.

2.

3.

4.

5.

NUT M12 X 1.5 WASHER 12 OIL CUP M10 X 1 EAR RING KNUCKLE BEARING GE30ES 6. HOLE SPRING BLOCK D47 7. BOLT M12 X 1.5 X 40 8. DUST RING D30 X 38 X 5/6.5 9. RETAINER RING 10. SHAFT SEAL Φ30 X Φ40 X 6 11. STEEL-BACKED BEARING Φ30 X Φ34 X 30 12. GUIDE SLEEVE 13. RETAINER RING 14. O-RING 63 X 3.1

15. PISTON ROD 16. O-RING 22 X 2.4 17. SPACER SLEEVE I 18. HOLE SEAL 63 X 53 X 6 19. HOLE SUPPORT RING 20. PISTON 21. COTTER PIN 4 X 40 22. SLOTTED NUT M20 X 2 THICKNESS 20 23. CYLINDER SLEEVE II 24. CYLINDER BODY 25. PIN SHAFT 26. WASHER 10 27. BOLT M10 X 20

Figure 44. Tilting Cylinder

INSTALLATION OF MAST 1.

Set the part 1 the tilting cylinder liner on the part 4 of vehicle chassis tilting cylinder support. Refer to Figure 45.

2.

Pass the part 6 the tilting cylinder pin shaft (in the place of vehicle chassis) through the tilting cylinder and its support installation holes.

55

Lifting System

8000 YRM 2354

3.

Tighten the part 7 the tilting cylinder pin shaft fasteners (bolt and spring washer).

4.

The supporting seat of masts are placed on the mounting position of the upper mast of drive axle.

After the left and right clearance are adjusted, 9 supporting cover is also be covered, and the 8 support cover fastener (bolt, spring washer, flat washer) is tightened (one for the left, and one for the right).

5.

Set the part 1 the tilting cylinder liner into 4 the mast tilting cylinder support.

6.

Pass the part 9 the tilting cylinder pin shaft (in the place of mast) through the tilting cylinder and its support installation holes, and tighten the fastener (bolt, spring washer, and flat washer).

7.

Connect the part 10 the multi-way valve – speed limit valve hose.

8.

Set the part 3 the return oil pipe on the tee of the mast, and fix the return oil pipe fast, the return oil pipe collar clamp, and the assembly of the mast is now completed.

NOTE: DURING INSTALLATION OF MAST, SAFE HOISTING OF MAST SHALL BE ENSURED, AND THE INSTALLERS MUST BE RELEVANTLY TRAINED. 1.

2.

3.

4.

5.

TILT CYLINDER BRACKET FASTENER CYLINDER SUPPORT MAST CHANNEL

6. PIN SHAFT 7. FASTENER 8. FASTENER 9. SUPPORT COVER 10. SPEED LIMITER HOSE Figure 45. Mast

56

8000 YRM 2354

List of Wear Parts

DISASSEMBLY OF MAST 1.

Remove 10 the multi-way valve –speed limit valve hose. Refer to Figure 45.

2.

Detach the part 3 the fasteners.

3.

Remove fasteners 3

4.

Remove the fasteners (bolt, spring washer, and flat washer) on the part 9 the tilting cylinder pin shaft (in the place of mast), and then detach the part 9 the tilting cylinder pin shaft (in the place of mast).

NOTE: Safe hoisting of mast shall be ensured, during disassembly and assembly of mast, and the installers must be trained relevantly.

5.

Hoist out the mast and complete the disassembly of mast.

List of Wear Parts Table 6. Some Wearing Parts S/N

Name

Qty

Installed Position

1

Driving Wheel

2

Driving Axle

2

Steering Wheel

2

Steering Axle

3

Piston

1

Lifting Cylinder (Standard)

4

Piston

1

Tilting Cylinder

5

Instrument Left Cover Plate

1

Instrument Rack

6

Instrument Right Cover Plate

1

Instrument Rack

7

Various Hoses

Hydraulic System/Mast Piping System Table 7. Oil Seal

S/N

Standard

Model/Spec

Qty

Installed Position

1

NOK

Shaft Seal 35×45×6

2

Lifting Cylinder (Standard)

2

LBH

Dust Ring 35×45×5/6.5

2

Lifting Cylinder (Standard)

3

NOK

Hole Seal 45×35×6

2

Lifting Cylinder (Standard)

4

LBH

Dust Ring 30×38×5/6.5

1

Tilting Cylinder

5

NOK

Shaft Seal 30×40×6

1

Tilting Cylinder

6

NOK

Hole Seal D63×5.×6

2

Tilting Cylinder

Table 8. O-Ring S/N

Standard

Spec

Qty

Installed Position

1

GB1235-76

22×2.4

1

Lifting Cylinder (Standard)

2

GB1235-76

63×3.1

1

Tilting Cylinder

57

List of Wear Parts

8000 YRM 2354

Table 8. O-Ring (Continued) S/N

Standard

Spec

Qty

Installed Position

3

GB1235-76

22×2.4

1

Tilting Cylinder

4

GB1235-76

18×2.4

2

Hydraulic System

5

GB1235-76

35×3.5

1

Hydraulic System

6

GB/T3452.1-1992

11.2×2.4

13

Hydraulic System

7

GB1235-76

24.2.4

1

Hydraulic System

Table 9. Combination Seal Ring S/N

Standard

Spec

QTY

Installed Position

1

JB/T 982-1977

14

2

Hydraulic System

Table 10. Some Electric Appliance Components

58

S/N

Name

Model/Spec

Qty

Remarks

1

Fuse Box

BX2081

1

2

Microswitch

TM1308

1

Hand Brake

3

Microswitch

Z-15GW22-B

1

Multi-way Valve

8000 YRM 2354

6/20