HELI CPD15 Operation & Service Manual Download Page 3

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CONTENTS

I. Safety Rules for Opeartion and Daily Maintenance of Forklift Truck ....................... 2

II. Main Specifications of Forklift Truck ....................................................................... 7

III. Construction, Priciple, Adjustment and Maintenance of Forklift Truck ................ 10

1. Transmission System ....................................................................................... 10

2. Brake System ................................................................................................... 16

3. Steering System ............................................................................................... 18

4. Electric System ................................................................................................ 24

5. Hydraulic System ............................................................................................. 75

6. Lifting System .................................................................................................. 96

Summary of Contents for CPD15

Page 1: ......

Page 2: ...c controller and liquid crystal combined meter with large screen so they have a lot of advantages such as good performance easy operation wide visibility of operator flexible steering reliable braking powerful and smooth power low noise no contamination to environment and beautiful contour This manual states the trucks specifications operation maintenance service main assemblies constructions and ...

Page 3: ...of Forklift Truck 2 II Main Specifications of Forklift Truck 7 III Construction Priciple Adjustment and Maintenance of Forklift Truck 10 1 Transmission System 10 2 Brake System 16 3 Steering System 18 4 Electric System 24 5 Hydraulic System 75 6 Lifting System 96 ...

Page 4: ...s should be always at the positions specified in sling index plate when hoisting up the forklift truck 2 Storage of Forklift Truck 1 Drain off fuel completely Don t drain off the cooling water containing antifreeze and rustproof agent 2 Apply antirust to the surface of the parts not painted Apply lubrication oil to the lift chain 3 Lowing the mast to the lowest position 4 Apply the parking brake 5...

Page 5: ...turning driving braking and stopping operation of the truck should be done smoothly When steering on the humid or low friction road the truck should be decelerated 6 Travel with loads as low as possible and tilted backward 7 Be careful when traveling on a slope When climbing grades with a slope of more than 10 the truck should forward travel and when descending so grades backward travel Never turn...

Page 6: ... down electric supply If parking on a slope is unavoidable apply the parking brake and block the wheels 19 Don t adjust the control valve and relief valve at will to prevent the damage of hydraulic system and its components because of excessive pressure passing them 20 Inflate a tyre according to it s stated air pressure Never over inflate a tyre 21 According to the measure method specified in JB ...

Page 7: ...iring to see if they work normally or not 2 Oil used for forklift trucks Name Recommended brand Brand and temperature of using Hydraulic oil Chang cheng Sticky grade L HM32 wearable hydraulic oil L HV32 low temp wearable hydraulic oil Temp of using 5 20 cold region Lubricating grease Chang cheng 3 lithium base grease 20 120 Gear oil of heavy laden truck Hai pai Sticky grade 85W 90GL 5 80W 90GL 5 T...

Page 8: ...6 3 Lubrication chart Note for the truck without brake liquid it is not necessary to refer to the chart for relative operation ...

Page 9: ...7 Ⅱ Main Specifications of Forklift Truck Enternal view of forklift trucks ...

Page 10: ...ck body 90 at mast 100 in the middle of truck body Minimum steering radius Wa mm 1487 1487 1595 1595 Travelling speed unloaded loaded km h 16 16 Lifting speed unloaded loaded mm s 600 380 600 430 600 400 Lower speed unloaded loaded mm s 400 500 Gradeability unloaded loaded 30 20 Service weight kg 2990 3250 3350 3600 Axle load unloaded front rear kg 1420 1570 1490 1760 1620 1730 1640 1960 Axle load...

Page 11: ... 1060 775 455 1060 775 Weight kg 750 945 1068 Assistant counterweight Max overall size mm 980 190 522 980 190 522 980 190 630 980 190 630 Weight kg 471 658 516 791 Overhead guard Max overall size mm 1238 1030 1541 1292 1030 1541 1400 1030 1541 Weight kg 65 75 90 Mast lifting height 3300mm Max overall size mm 1267 1010 2075 1267 1086 2075 Weight kg 577 604 ...

Page 12: ... sensor installed on rear wheel sends information to drive motor controller on right and left front wheel after receiving different information right and left front wheel give out different speed and thus steering of the truck is realized The steering of the three wheeled truck is realized through electric differential The system has no bevel gear which thus not only improves working efficiency bu...

Page 13: ...se 6 drive nut and remove drive wheel Then loose the 7 bolts on frame hexagon socket bolts and remove transmission box connected with travelling motor from frame Refer to figure 1 1 Figure 1 1 1 2 2 Removal of travelling motor Refer to figure 1 2 to remove the bolts fixing travelling motor one is M8 x50 and two are M8 x75 ...

Page 14: ...ng motor Before assembling clean the contacting face between transmission box and motor with cleanser for example loctite 706 or alcohol then make it dry Check if the contactor is damaged if there is slight damage remove it with oil stone Refer to figure 1 3 Note cleansers can not come into contact with the skin they must not be swallowed and their vapors must not be inhaled Always use protective ...

Page 15: ...le installing the motor This can cause knocking noise 6 Turn motor to coincide bore pattern of transmission with bore pattern of motor 7 Screw motor to transmission with three hexagon bolts parts1 and 2 1 M8 50 and 2 M8 75 Tightening torque 23 Nm Figure 1 3 1 3 2 Mounting the transmission unit to the truck frame Check the frame surface for damage and irregularities The maximum admissible irregular...

Page 16: ...ing to the first reached time replace gear oil in differential and main reducer 1 Unscrew fluid filling plug part 3 with sealing ring part1 and let the gear oil out completely Before screw fluid filling plug again remove the dust on the plug It is necessary to replace the sealing ring if it is damaged 2 Unscrew fluid filling plug part 4 with sealing ring part 2 3 Add gear oil to transmission box D...

Page 17: ... 21666 or DONAXTG PLUSD 22543 or DONAXTG D 21126 ESSO TYPESUFFIXA or ATF D 21065 or ATF D 21611 or ATF D 22079 6 Screw fluid filling plug part 1 with the sealing ring part 2 Tightening torque 22Nm Refer to figure 1 5 Figure 1 5 ...

Page 18: ...he service brake principle diagram and the structure of brake pedal During travelling releasing the accelerating pedal slowly or quickly can reduce truck speed quickly and achieve brake effect Brake effect in normal condition can be realized During travelling Step the brake pedal 2 can achieve brake effect flexibly Different brake effect can be achieved 减速箱车轮定子转子驱动电机旋转方向制动力矩M Reducer box Whe...

Page 19: ...g brake When truck is stopped on a slope the truck keep stopping through electric method ant then parking brake is started And thus the truck is stopped with parking brake When operating direction switch and stepping on accelerating pedal at the same time the electromagnetic parking brake is loosed automatically and truck can be operated normally 2 Power off parking brake When key switch is turned...

Page 20: ...18 Danger Except under emergency case it is prohibited to start electromagnetic parking brake through power off parking brake When electromagnetic parking brake is applied do not tow the truck ...

Page 21: ...all force As requested by the working characteristic of the forklifts the operation site and driving pass are relatively narrow changing over is frequent and the minimum radius turnings are often needed therefore the steering system is required to be reliable and light in operation Since the load of steering axle occupies about 60 of the vehicle weight in case of idling G2 series three wheel lithi...

Page 22: ...g bracket as shown in Figure 3 1 They are fixed on the dashboard by mounting bracket the steering wheel steering column and coupling shaft are connected together the steering unit is fixed at the lower end of the coupling shaft and the rotation of steering wheel will drive the rotation of steering unit The steering wheel can be adjusted to the comfortable position by adjusting the handle 2 Torque ...

Page 23: ...is driven by the steering motor When the driver operates the steering wheel the angle signal is provided to the controller which gives the control signal to the steering motor The steering motor outputs a steering torque through the mechanical structure to control the truck steering The wheel is pried to the rear wheel hub through the wheel rim and the rear wheel hub is installed on the steering w...

Page 24: ...grease 2 Press the hub bearing into the hub and fit the hub on the knuckle shaft 3 Fit a flat washer and tighten a castle nut to a torque of 206 235Nm 21 24kgm and loosen it and then tighten it again to a torque of 9 8Nm 1kgm 4 To ensure firm installation of the hub slightly knock at it with a wooden hammer and in the meantime rotate the hub for 3 4turns 5 Tighten the castle nut and align one of i...

Page 25: ... the specified one lock the castle nut with a cotter pin Fig 3 3 Fill lubricating grease and pre load adjustment 3 5 2 Inspect after reassembling the steering system 1 Turning the steering wheel right and left inspect whether the steering power is smooth 2 Inspect connection of the electric harness whether is correct by turning the steering hand wheel ring and left 3 Lift up the rear wheels and sl...

Page 26: ...g motor Check the harness or replace No working of steering controller Check the harness or replace Large noise when steering Large clearance between gears Adjust Over wear of gear Replace Rigid steering operation Uneven rotation of steering wheel Make the steering wheel to be concentric with steering axle ...

Page 27: ...he traction control system is made up of direction switch acceleration pedal brake pedal electromagnetic brake traction motor and traction controller Lifting control system is made up of valve control switch lifting motor and lifting controller EPS electric steering control system is composed of feedback device of steering wheel operation force steering controller steering axle and so on Notice Ou...

Page 28: ...26 Figure 4 1 Electric system principle diagram CPD15SQ 20SQ GB2Li 1M1 2M1 μ ú é è ...

Page 29: ...on SMART DISPLAY is an intelligent dashboard connected to the truck system by CANBUS line This dashboard provides the diagnostic and set up of the whole truck system Connecting the ZAPI handset or PCWIN tool to SMART DISPLAY it is possible to read and modify the setting of all the modules present on the CANBUS net The display implements an interface to the operator through a main page and a number...

Page 30: ...ng mode display the driver can choose the mode through the switch except under hand console mode When indicator turns on the truck is travel with medium speed when indicator turns on the truck travels with slow speed when both and are off the truck travels with high speed d Fault code display If fault appears is often on and refer to Table 4 2 for the fault code the first line displayed in the WIN...

Page 31: ...Italy so it has advantages of advanced technology of high frequency MOS tube superior speed regulating performance good safety flexibility and first class protection etc The controller assembly includes motor controller contactor relay set fuse OPS warning buzzer and the related harness 4 3 2 Control device ...

Page 32: ...30 Figure 4 5 CPD15SQ GB2Li control device assembly ...

Page 33: ...31 Figure 4 6 CPD16SQ GB2Li control device assembly ...

Page 34: ...32 Figure 4 7 CPD18 20SQ GB2Li control device assembly ...

Page 35: ...Model Item CPD15 16SQ GB2Li CPD18 20SQ GB2Li Model of traction motor Rated power Rated voltage Rated current Rated speed JXQ 5 4 HL 5 4kW 32 V 134 6A 1777 r min Model of lifting motor Rated power Rated voltage Rated current Rated speed YDB11 4 6191 11kW 32V 307A 1780 r min YDB11 4 6193 11kW 32V 307A 1780 r min Model of steering motor Rated power Rated voltage Rated current Rated speed C38215A 0 4 ...

Page 36: ...ce and service life of battery therefore the users must make maintenance and service by contrast with the actual condition and according to the maintenance instruction provided by manufacturer For any questions please contact the engineers and after sales service of HELI 1 Battery safety notes 1 Keep the battery away from dangerous goods or environment such as conductive dust particles corrosive c...

Page 37: ...he battery pole pressing bolt and the conductive belt contacting the positive and negative poles of the battery which may cause personal injury or property loss 6 It is forbidden to expose the battery or put it in the environment above 55 for a long time It is forbidden to try to heat or put the battery into the fire This operation may cause personal injury or property loss 7 It is forbidden to ch...

Page 38: ...mmediately after using under the temperature environment below 0 2 The range of discharge temperature is 25 50 and the discharge capacity at low temperature 25 0 may be lower than that at normal temperature which is a normal phenomenon the battery can be used at 40 50 but if the ambient temperature of the battery is too high especially in the high temperature environment for a long time it will ac...

Page 39: ...ouch it in case of inadvertent contact wash it with a large amount of water in case of eye contact wash it with a large amount of boric acid solution and get medical treatment quickly 10 When the truck or battery is on fire leave the truck quickly to a safe dare Please use yellow sand and dry powder fire extinguisher for treatment It is strictly forbidden to use water or incorrect fire extinguishe...

Page 40: ...y charged and discharged at least once a month 4 5 3 Charger model Table 4 4 Charger model No Item Notes 1 D80V 200A Li quick charger 80V 48V compatible 2 D80V 200A Li 423 quick charger 80V 48V compatible 3 D48V 200A Li quick charger 48V 4 D48V 200A Li 423 quick charger 48V 4 5 4 Charger usage notes 1 Please charge in a safe environment and be away from dust fire corrosion and other environments 2...

Page 41: ...d personal injury 7 After charging please close the protection cover and door of the truck charging port to prevent foreign matters from entering the charging port during the truck operation as this will cause damage to the charging port 8 In order to avoid damage to the charging equipment please pay attention to the following a Do not close the door of charging port when the protection cover of c...

Page 42: ...k it every three months 5 Check the mechanical moving of the contactor every three months if there is any damage or condition affecting the safety contact with ZAPI dealer Notice After the controller is installed the wheels of the truck shall be lifted off the ground for test so that even if there is a connection error there will be no danger After the battery switch is disconnected there is a cer...

Page 43: ...aused by the user s unauthorized maintenance 4 7 Hand brake switch When the truck is stopped and driver is away from the seat apply parking brake manually At this time only hand brake light on the meter turns on all the time and truck can not travel When restarting the truck release the parking brake manually at this time the brake light on the meter turns off The track can travel again Figure 4 8...

Page 44: ...ower off switch in the following three cases 1 When the forklift is not used for more than 72 hours for a long time please press the emergency power off switch when ensuring that the power of lithium battery meets the storage requirements see the operation and maintenance manual of lithium power battery for details 2 In the process of truck transportation please press the emergency power off switc...

Page 45: ...d held display information and code displayed by the instrument 4 9 1 AC2 ACE2 controller 1 Common fault of travelling system The second line of instrument indicates ON NODE 2 Table 4 5 Common fault of travelling system of AC2 ACE2 Fault Code Implication Note Measures 13 EEPROM KO EEPROM damaged The fault is in the internal memory for storing and regulating parameters When the fault appears the ma...

Page 46: ...f motor is incorrect or there is circuit problem in motor Check if three phase connection of motor is correct if there is any leakage of electricity on ground and circuit break of motor coil 2 If actuation of main contactor is rigid and if there is any wearing on contact 3 Change the controller 31 VMN HIGH High VMN Cause During startup the low end voltage of MOS tube is 10 higher than that of norm...

Page 47: ...MAXIMUM CURRENT 70 92 MAXIMUM CURRENT 80 90 MAXIMUM CURRENT 90 88 MAXIMUM CURRENT 100 86 Now the max current of controller decreases with the increase of the max current temperature When the temperature is 105 the current of controller decreases to zero The fault appears if chopper is in the cold state 1 Temperature calibration parameter of logic card is incorrect check parameters 2 The internal t...

Page 48: ...rrect wire joining 4 If the trouble still can not be eliminated change the controller 80 FORW BACK Forward and backward signals exist at the same time adhesion of direction switch The machine will keep on detecting But when there are signals requesting operation from two directions at the same time alarm is given Possible causes 1 The wire is damaged 2 Direction switch fault 3 Improper operation 4...

Page 49: ...g circuit is activated before software is started The watchdog signal is invalid alarm state in case of standby or operation state Fault analysis The hardware circuit of watchdog or output of micro controller is damaged The above two cases has nothing to do with external parts so change the controller 228 TILLER OPEN TILLE off When tiller input switch is off about 30S later the main contactor will...

Page 50: ...ge the controller 235 HANDBRAKE Fault of handbrake switch Handbrake input signal is valid when the running instruction is issued Resolution Possible causes for the fault 1 Handbrake switch is damaged or wiring is wrong 2 Handbrake switch works normally In TESTER menu handbrake is always ON This is a logic fault so change the controller 236 CURRENT GAIN Fault of current gain The maximum current gai...

Page 51: ... controller if periphery is normal 243 SENS MOT TEMP KO Fault of temperature sensor Phenomenon The output signal of temperature sensor of motor exceeds the scope Solution Check the value of sensor and connection of wires and the fault is inside the controller in case of no problem found 244 SOFTWARE ERROR Software error During software testing there are many reasons for such fault such as CAN comm...

Page 52: ... software 208 NO CAN MSG BMS01 Sudden break off of 0X2F0 ID sent by battery BMS The battery management System BMS inside the lithium battery is sending 0x2f0 ID normally The controller can receive the ID normally and work but the ID is suddenly interrupted Check the message sent by BMS through CAN analysis software 211 BMS 01 High battery voltage Check if the voltage of the battery is correct 212 ...

Page 53: ...ystem such as DC DC and brake coils etc or if the input power supply contact of controller is good 2 If the battery voltage is excessively low or high 3 Check B and B and see if the power cable on the wiring terminal of contactor etc is tightly fixed 4 If the voltage calibration parameter of controller is in consistent with actual voltage 5 There is circuit fault of overvoltage protection hardware...

Page 54: ...Their corresponding relations are as follows Parameter set alarm temperature MAXIMUM CURRENT 50 96 MAXIMUM CURRENT 60 94 MAXIMUM CURRENT 70 92 MAXIMUM CURRENT 80 90 MAXIMUM CURRENT 90 88 MAXIMUM CURRENT 100 86 Now the max current of controller decreases with the increase of the max current temperature When the temperature is 105 the current of controller decreases to zero The fault appears if chop...

Page 55: ...t change the controller 221 SEAT MISMATCH Seat switch signal fault If the parameter of the SAFE OUT CONFIG is 1 the fault may occur If the traction seat switch signal is different from the pump controller sear switch signal the fault may occur Check the seat switch connecting 222 WAITING FOR NODE Waiting for node signal In CAN communication network a controller receives a signal that the other con...

Page 56: ...rise to BATT If the change of phase voltage value does not conform to the instruction this fault signal is produced Change the controller 237 ANALOG INPUT Fault of Analog Input The fault signal is produced when A D of all analog signals is converted into a fixed value and delay exceeds 400 millisecond This function is used to check the fault of A D converter or analog signal conversion Fault analy...

Page 57: ... parameter of DEBUG MODE the value must be OFF 245 WRONG RAM MEMORY Dynamic memory fault Wrong contents are found when testing the main memory The registration address is DIRTY and the fault will restrict the operability of vehicle Fault analysis Switch on the key after switching it off and change the controller if the trouble still exists 247 DATA ACQUISITION Data acquisition The fault will be hi...

Page 58: ...en standby 30 VMN LOW The voltage is low 49 CURRENT ALWAYS EQUAL 0 The current is 0 33 FULL CONDUCTION KO It is not completely conducted 78 VACC NO OK Fault of speed adjusting sensor 62 THERMIC SENSOR KO Fault of temperature sensor 66 BATTERY LOW Insufficient of battery electric quantity 79 INCORRECT START Protection of starting order 7 CHOPPER NOT CONFIG Fault of logic data storage unit 242 BATTE...

Page 59: ...ible causes The current sensor is faulty Replace the power unit e WATCH DOG The test is made in both running and standby It is a self diagnosis test within the logic If an alarm should occur replace the logic f COIL SHORTED Cause This alarm occurs when there is a short circuit of LC coil connected to driver output of the HP CAN After the overload condition has been removed the alarm exits automati...

Page 60: ... connections ohmic continuity Motor power cables connections If the motor connection are OK the problem is inside the controller If the problem occurs after closing the LC the LC closed and then opens back again check Motor connections If motor windings cables have leakages towards truck frame If no problem is found on the motors the problem is inside the controller If the alarm occurs during moto...

Page 61: ...ices CAN BUS nodes Troubleshooting This alarm could be caused by a can bus malfunctioning which blinds communication Otherwise it is an internal fault of the controller which must be replaced 3 Common fault for ZAPI instrument system The second line of instrument indicates ON NODE 16 Table 4 8 Common fault for instrument system Fault Code Implication Note Measures 13 EEPROM KO EEPROM damaged Troub...

Page 62: ...strument because the instrument can not receive any message So suggest to check the wiring and connection of CAN or the CAN interface fault of other modules will appear in the CAN network 103 SERVICE REQUIRED Maintenance is Needed It is the time for maintenance service 104 HYDRAULIC OIL The input of hydraulic oil level is valid during startup Trouble Diagnosis Check if the related digital input on...

Page 63: ...ump 1 Oil suction cavity 2 Oil pressing cavity A pair of meshed involute gear is mounted inside the housing the two end face seals of gear and gear separate the pump housing into two sealing oil cavities as shown 1 and 2 in the Fig When the gear of gear pump rotates in the direction shown in the Fig the volume of space shown by 1 engaging part for gear disengagement changes from small to big and f...

Page 64: ...raulic energy so the oil pump is the actuating unit of hydraulic system of the forklift The main pump consists mainly of a pump body a pair of gears lining plates and oil seals This pump uses pressure balance type bearings and a special lubrication method so as to minimum the clearance of the gear face See Fig 5 2 Fig 5 2 Gear pump 1 Pump body 2 Driving gear 3 Driven gear 4 Front cover 5 Rear cove...

Page 65: ...lt locking valves inside the control valve The safety relief valve is at the top of oil inlet of control valve to control the pressure of the system The tilt locking valve is on the tilt valve block and is mainly used to prevent the serious consequence due to wrong operation of control rod when the tilt cylinder has no pressure source The check valve is mounted between oil inlet and inlet port of ...

Page 66: ... up the inlet check valve and to flow into the port B The return oil from the port A flows through the low pressure passage to the tank and the spool is restored to its neutral position by the return spring Fig 5 5 Push in spool c Drawing out of spool See Fig 5 6 With the mid passage closed the oil from the main oil inlet pushes up the check valve and flows into the port A The return oil from the ...

Page 67: ...alve the check valve E will open The oil flows into LP side through holes around the valve as shown in Fig 5 8 Fig 5 7 Fig 5 8 Once the pilot valve E opens the pressure inside valve C will drop valve E and valve C are on the valve seat The liquid flowing to the rear of the valve D will be closed so the pressure inside will be decreased See Fig 5 9 The HP passage pressure and inside pressure of oil...

Page 68: ...n See Fig 5 12 when the lift motor stops a The spool is pushed in The pressure oil flows through the port B to tilt cylinder and moves the tilt lock valve to let the port A connect with the low pressure tank The tilt cylinder and the mast is tilted forward Fig 5 11 b The spool is pushed in when the lift motor stops When the lift motor stops no pressure oil flows to the tilt lock valve The port A c...

Page 69: ...he joints See Fig 5 13 Figure 5 13 Control valve As you see in Fig 5 14 the mast lift up when you push the lift lever forward the mast fall down when you pull the lift lever backward The mast tilt forward when you push the tilt lever forward the mast tilt backward when you pull the tilt lever backward Fig 5 14 The symbol on the operation lever ...

Page 70: ...If the oil pressure is different with the specified value loosen the locking nut of the relief valve and turn the adjusting screw left and right until the pressure reaching the specified value Turn left when the pressure is high and turn right when the pressure is low d Tighten the nut after adjusting Fig 5 15 5 1 3 Lift cylinder The lift cylinder is of single acting piston type It consists of cyl...

Page 71: ...acket and piston itself the hydraulic oil is pressed back to oil tank If the cut off valve is mounted at the bottom of cylinder See Fig 5 17 it can play the role of protection if the mast rises when high pressure pipe cracks 1 upper beam 2 Adjusting shim 3 Dust proof ring 4 Oil seal 5 Guide sleeve 6 O ring 7 Cylinder head 8 Bearing 9 Cylinder body 10 Piston rod 11 Piston 12 Piston oil seal 13 oil ...

Page 72: ...tting value due to high pressure pipe cracking or other reasons the pressure difference before and after spool will be larger than the spring force and move the spool to the left In this way hole A is closed only small amount of oil flows out from the small clearance of spool and valve bush and the goods descends slowly When flow is lower than set value when flow is higher than set value Figure 5 ...

Page 73: ...d at both sides of mast with its piston rod end connecting with mast The bottom of tilt cylinder is connected through dowel with connecting end of frame and mast and the forward and backward tilting of the mast are fulfilled by the motion of tilt cylinder The tilt cylinder consists primarily of piston piston rod cylinder body cylinder base guide sleeve and seals The piston welded to the piston rod...

Page 74: ... sleeve and moves the piston backward tilting the mast assembly backward Fig 5 19 Tilt cylinder 1 Ear ring 2 Dust ring 3 Snap ring 4 Yx ring 5 O ring 6 Guide sleeve 7 Bushing 8 O ring 9 Piston rod 10 Cylinder body 11 Yx ring 12 Wearing 13 Piston 14 Yx ring 5 1 7 Oil tank Oil suction filter is fixed in the oil tank while the return oil filter is fixed in the oil returning pipelines to make sure the...

Page 75: ...g 5 20 Hydraulic system principle diagram 1 Oil tank 2 Oil suction filter 3 Pump motor 4 Gear pump 5 Control valve 6 Flow regulator valve 7 Cut off valve 8 Lift cylinder 11 Tilt cylinder 12 Return oil filter ...

Page 76: ...st cylinder tilt cylinder oil pump before and after each shift Check if the working oil inside work oil tank is sufficient and check and clean the strainer mesh of oil filter mounted in the work oil tank once every week Normally change the oil in the work oil tank once every 1200 1500 hours of work and mixed use of oils of different brands is not allowed 5 2 2 Maintenance of lift pump 1 Disassembl...

Page 77: ...mp cover 5 pump body 1 c Remove lining plate 6 drive gear2 driven gear 3 d Remove the seal ring 7 and ring 8 from front cover or rear cover Notice Don t remove the seal ring and ring from the front cover and rear cover if the seal ring and ring needn t be replaced Fig 5 22 Gear pump 1 Pump body 2 Drive gear 3 Driven gear 4 Front cover 5 Rear cover 6 Lining plate 7 Seal ring 8 Ring 9 Oil seal 10 Sn...

Page 78: ...tact surface of the lining plate If the surface is worn or its thickness is smaller than the specified value replace the lining plate The specified thickness of the lining plate 4 94mm Fig 5 24 c Front and rear pump cover If the color changed range of the inner surface of the bushing exceed 150 replace the bushing Fig 5 25 d Inspect the drive gear and the driven gear from front and rear If they ar...

Page 79: ...the pump Notice Don t twist Fig 5 29 c Install a new ring on the front cover of the pump The direction of the installation see Fig 5 30 Fig 5 30 d Install the pump body on the front cover Pay attention to the direction of the pump body Fig 5 31 e Install the lining plate on the groove of the front cover don t confuse the inlet oil port and the outlet oil port Pay attention to the direction of the ...

Page 80: ... h Install the lining plate on the side of the gear don t confuse the inlet oil port and the outlet oil port Fig 5 35 i Install a new seal ring and a new ring on the groove of the rear cover Apply lubricating grease on the seal ring Fig 5 36 j Install the rear cover on the pump body with it s seal ring downward don t confuse the inlet oil port and the outlet oil port Fig 5 37 ...

Page 81: ...nning of the pump is normal Test the oil pump on the test station And also the test can be done on the forklift truck according to the following procedures If the oil pump needs maintenance because of serious wear or its being stuck caused by the hydraulic oil change the hydraulic oil or filter before carrying out the test run on the forklift truck a Install the pump onto the truck and the pressur...

Page 82: ...the oil filter Inspect the temperature of the oil the temperature of the surface of the pump and the running noise when increasing the oil pressure If the oil temperature or the temperature of the pump s surface increases to a over high degree reduce the load and lower the oil temperature And then go on carrying on the trail e Make the relieving pressure at 210kg cm2 after the test and measure the...

Page 83: ... see whether there is damage to the sealing ring or connecting nut and screw tight the pipe joint 7 Replace the unqualified hydraulic oil stop operation to lower oil temperature and try to find the cause of over high oil temperature 8 Lift load according to requirements Insufficient pressure of oil pump 1 Oil leakage due to wearing of ring seal at fasteners 2 Hydraulic oil is contaminated with air...

Page 84: ...inder and it can tilt forward and backward under the action of tilting cylinder The steel channel of outer mast is of C type There is one pair of combined roller on top of the end The steel channel of inner mast is of H type and there is one pair of combined roller at the lower end The inner mast keeps a fixed ralative position between inner mast and outer mast during moving through main roller an...

Page 85: ...er comes out form the mast upper end The transverse load is beared by side roller Figure 6 2 Fork brakcet 6 4 Roller adjusting method There are 10 main rollers which are installed on outer mast upper end 2 inner mast lower end 2 and two sides of forkbracket upright plate 6 respectively There are 8 combined rollers which are installed on outer mast upper end 2 inner mast lower end 2 and fork bracke...

Page 86: ...ing method is followed 1 Install piston rod head into inner mast top beam without adjusting shim 2 Lift the mast slowly to cylinder max stroke Check if two cylinders are synchronous If the two cylinders do not stop at the same time it means the cylinder stokes are not the same Adjust the stoke to be the same through asjuting shim 0 2mm Combined roller main roller Side roller inner mast outer mast ...

Page 87: ...uld be stopped on horizontal ground And ensure the masts erect 2 Lower the forks on the ground adjust the set nut of tie in on the upper of chains to make the distance A between main rollers and the lift bracket 3 Make the mast assembly tilt backward when forks descended to the ground adjust the pulling force of lift chains and let the tightness of lift chains be equal Truck type A mm 1 1 8t 36 41...

Page 88: ...ound 3 Take down tie in on top of the chains And take out chains from sheave See Fig 6 7 4 Make the inner mast rise 5 The forklift can be reversed when the lift bracket disengaged from the outer mast 6 Replacing main rollers a Take apart all of snap ring from the lift bracket and take out main rollers b Fit the new main roller the same type as the old one on the lift bracket and fastened with snap...

Page 89: ...eads carefully 5 Take apart bolts which jointed lift cylinders and the bottom of outer mast and take apart the oil pipe between two lift cylinders without loosing the nipple 6 Let down the inner mast and dismantle inner mast lower end main roller 7 Main rollers on the upper outer mast will be showed on the top of the inner mast then main roller can be removed 8 Replacing main rollers a Take apart ...

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