HELI H2000 Series Manual Download Page 32

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Fig.2.1 Electric principle

Battery

Starter

Fuse

Preheat

plug

Starter sw.

Relay

Hour

meter

Relay

Neutral sw.

Neutral

indicating

Backup sw.

Backup lamp

Turning lamp

Turning lamp sw.

Generator

Voltage adjuster

Charging

indication

Lamp sw.

Horn button

Horn

Water temp. meter

Fuel meter

Fuel meter sensor

Oil pressure signal

Air cleaner signal

Water deposit signal

Water deposit sw.

Front lamp

Width lamp

Backup lamp

Starter sw. table

Lamp sw. table

-28-

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Summary of Contents for H2000 Series

Page 1: ...t accord with requires in this manual our If any operation or maintenance does t accord with requires in this manual our related promises is inefficacy related promises is inefficacy Due to continuous improvements in design it is possible that the latest description Due to continuous improvements in design it is possible that the latest description contained herein may differ slightly from the tru...

Page 2: ... of the ignition time of oil injectio 1 3 7 Confirmation of the ignition time of oil injectio 1 3 8 Adjustment of ignition time of oil injection 1 3 8 Adjustment of ignition time of oil injection 1 3 9 Measurement of the compression pressure 1 3 9 Measurement of the compression pressure 1 3 10 Exhaust air of oil injection pump 1 3 10 Exhaust air of oil injection pump 2 Electric System 2 Electric S...

Page 3: ... brake 5 4 Travel brake 5 4 1 Travel brake 5 7t forklift truck 5 4 1 Travel brake 5 7t forklift truck 5 4 2 Travel brake 8 10t forklift truck 5 4 2 Travel brake 8 10t forklift truck 5 5 Stop brake 5 5 Stop brake 5 6 Trouble shooting 5 6 Trouble shooting 6 Steering System 6 Steering System 6 1 Steering unit 6 1 Steering unit 6 2 Checking after mounti 6 2 Checking after mounting on the ng on the mac...

Page 4: ... 4 9 Hoist System 9 Hoist System 9 1 General description 9 1 General description 9 2 Outer inner mast 9 2 Outer inner mast 9 3 Lift bracket 9 3 Lift bracket 9 4 Adjustment of hoist system 9 4 Adjustment of hoist system 9 4 1 Adjustment of shims of lift cylinder 9 4 1 Adjustment of shims of lift cylinder 9 4 2 Carriage adjustment 9 4 2 Carriage adjustment 9 5 Roller position of mounting 9 5 Roller ...

Page 5: ...mast to the lowest position 3 Lowing the mast to the lowest position 4 Apply the parking brake 4 Apply the parking brake 5 Wedged up the wheels 5 Wedged up the wheels 1 Don t check fuel leakage and lever or instruments at the place there is open 1 Don t check fuel leakage and lever or instruments at the place there is open flame Never fill the fuel tank with the engine running flame Never fill the...

Page 6: ...taken if necessary sary 13 Tilt the mast of the high lift forklift truck as backward as possible while the truck 13 Tilt the mast of the high lift forklift truck as backward as possible while the truck working working Use minimum forward tilt angle and Min reverse tilt when loading and unloading Use minimum forward tilt angle and Min reverse tilt when loading and unloading 14 Be careful and slowly...

Page 7: ...Horn button 7 Horn button 8 Turn signal switch 8 Turn signal switch 9 Steering handwheel 9 Steering handwheel 13 Lift lever 13 Lift lever 14 Tilt lever 14 Tilt lever 15 Parking brake lever 15 Parking brake lever 16 Forward reverse lever 16 Forward reverse lever 17 Inching pedal 17 Inching pedal 20 Brake pedal 20 Brake pedal 21 Accelerator pedal 21 Accelerator pedal 22 Cable of cover 22 Cable of co...

Page 8: ...Name Gasoline Gasoline Diesel Diesel Gear oil Gear oil gasoline SF gasoline SF Electric Electric injection SG injection SG Gear oil Gear oil diesel CD diesel CD Hydraulic oil Hydraulic oil Torque Torque converter oil converter oil Brake fluid Brake fluid Lubricating oil Lubricating oil Gear oil of Gear oil of heavy laden heavy laden vehicle vehicle Antifreeze fluid Antifreeze fluid Brand and temp ...

Page 9: ...cannot be formed be formed 2 There is a compensation can on the left of engine The letter FULL and 2 There is a compensation can on the left of engine The letter FULL and LOW are marked on the upper and lower of LOW are marked on the upper and lower of the can wall Correct antifreeze agent level the can wall Correct antifreeze agent level should be between letters Antifreeze liquid of same type sh...

Page 10: ...6 4 6 4 Lubrication Lubrication system system table table 6 6 https www besttruckmanuals com ...

Page 11: ...g V Ah V Ah 5t 5t 6t 6t 7t 7t 8 8t t 1 10 0t t 5 50 00 00 0 6 60 00 00 0 7 70 00 00 0 8 80 00 00 0 1 10 00 00 00 0 600 600 3000 3000 1 19 95 5 2 20 00 0 205 205 2 20 00 0 2 21 10 0 6 12 6 12 3250 3250 3 33 30 00 0 3 33 37 70 0 3 37 70 00 0 3 39 90 00 0 2 29 96 60 0 3 30 00 00 0 3 30 04 40 0 3 33 31 10 0 3 35 54 40 0 200 200 2 25 50 0 2 24 45 5 2 22 25 50 0 2 25 50 00 0 2800 2800 1 14 47 70 0 1 17 ...

Page 12: ...ling speed laden unladen laden unladen Laden Laden Unladen Unladen Laden Laden Unladen Unladen Gradeability laden Gradeability laden Front 4 Front 4 Tread Tread Overall Overall height height Lift speed Lift speed Max traction Max traction force force Tyre Tyre 5 50 00 00 0 6 60 00 00 0 7000 7000 5 50 00 00 0 6 60 00 00 0 60 600 0 3000 3000 20 205 5 6 6 1 12 2 2250 2250 1470 1470 1700 1700 7980 798...

Page 13: ...Max traction force force Tyre Tyre Rear 2 Rear 2 CCPP CC DD 55 00 CC UU 11 CCPP CC DD 66 00 CC UU 11 CCPP CC DD 77 00 CC UU 11 CCPP CC DD 88 00 CC UU CCPP CC DD 11 00 00 CC UU 5 50 00 00 0 6 60 00 00 0 7 70 00 00 0 8 80 00 00 0 1 10 00 00 00 0 60 600 0 3000 3000 20 205 5 6 6 1 12 2 2 22 25 50 0 2 25 50 00 0 2800 2800 1470 1470 1600 1600 1 17 70 00 0 1 17 70 00 0 7980 7980 8 86 64 40 0 9 93 35 50 0...

Page 14: ...BG 6102BG Komatsu diesel Komatsu diesel S4D95LE S4D95LE Weifang Weifang diesel diesel R4105G32 R4105G32 6 6 1 10 05 5 1 12 256 56 1 10 02 2 1 11 18 8 4 4 9 95 5 1 11 15 5 4 4 1 10 05 5 1 12 25 5 8 82 2 3 3 2 20 00 00 8 0 81 1 2 25 50 00 0 6 61 1 2 24 40 00 0 5 59 9 2 24 40 00 0 416 416 1400 1600 1400 1600 3 35 53 3 1 16 65 50 0 2 29 91 1 1 16 60 00 0 270 270 1400 1600 1400 1600 2 23 33 3 2 23 31 1...

Page 15: ...m m G G kw kwh h mm s mm s Km h Km h kn kn EE nn gg iinn ee CC PP CCDD 88 00 WW 44 CC PP CCDD 11 00 00 WW 44 CC PP CCDD 88 00 CC 33 CC PP CCDD 11 00 00 CC 33 ISUZU diesel ISUZU diesel A 6BG1QC A 6BG1QC Chaoyang Chaoyang diesel diesel 6102BG 6102BG 6 6 1 10 05 5 1 12 25 5 4 4 1 10 02 2 1 11 18 8 8 82 2 3 3 2 20 00 00 0 8 81 1 2 25 50 00 0 4 41 16 6 1 14 40 00 0 1 16 60 00 0 3 35 53 3 1 16 65 50 0 2...

Page 16: ... l l R min R min kw kw Nm rpm Nm rpm rpm rpm rpm rpm G kwh G kwh CPCD50 70 WX CPCD50 70 WX CA4110 CA4110 In line 4 cylinder In line 4 cylinder 4 cycle water cooled 4 cycle water cooled direct injection direct injection 4 110 125 4 110 125 4 752 4 752 17 1 17 1 2300 2300 64 64 305 1400 1600 305 1400 1600 2530 2530 700 700 230 230 CPCD50 60 C10 CPCD50 60 C10 6102GB A6B 6102GB A6B In line 6 cylinder ...

Page 17: ...inn ee Unit Unit mm mm l l R min R min kw kw Nm rpm Nm rpm rpm rpm rpm rpm G kwh G kwh CP CPCD CD50 50 7 70 0 CU CU1 1 CP CPCD CD80 80 1 100 00 C CU U B B3 3 3 3 C C8 80 0 4 4B BT TA AA A3 3 9 9 C C1 11 10 0 In line In line 4 cylinder 4 cyc 4 cylinder 4 cycle water cooled direct le water cooled direct injection injection 4 4 9 95 5 1 11 15 5 4 4 1 10 02 2 1 12 20 0 3 26 3 26 3 9 3 9 17 5 1 17 5 1 ...

Page 18: ...duction brake front wheel etc hub reduction brake front wheel etc Includes powered steering unit redirector etc Includes powered steering unit redirector etc Includes axle box steering cylinder rear wheel etc Includes axle box steering cylinder rear wheel etc Includes outer inner mast lift bracket backrest fork Includes outer inner mast lift bracket backrest fork tilt cylinder lift cylinder end ro...

Page 19: ...ne mounted 2 The engine and its 2 The engine and its accesso accessories ries Th The e po powe wer r of of 5 5 7t 7t fo fork rkli lift ft tr truc uck k is is pr prov ovid ided ed by by di dies esel el en engi gine ne IS ISUZ UZU U 6BG1 KOMATSU S4D95LE imported from Japan The homeland diesel engine includes 6BG1 KOMATSU S4D95LE imported from Japan The homeland diesel engine includes Chaoyang 6102GB...

Page 20: ...d speed rpm Rated output kw Rated output kw Max torque N m rpm Max torque N m rpm Full load fuel rate g kwh Full load fuel rate g kwh Idle rpm Idle rpm Weight kg Weight kg Measure mm Measure mm Ignition order Ignition order Rotating direction Rotating direction A6BG1QC A6BG1QC 6 6 10 105m 5mm m 12 125m 5mm m 6 494 6 494 17 17 2000 2000 82 3 82 3 416 1400 1600 416 1400 1600 23 233 3 70 700 0 45 450...

Page 21: ...or Start motor Type Type Voltage Voltage Output Output Flameout device Flameout device Preheating device Preheating device Charging generator Charging generator Type Type Overhead Overhead Boshing Boshing 9 9 5m 5mm m 8m 8mm m Porous type Porous type Plunger piston type Plunger piston type Paper filter core Paper filter core Centrifugal all speed control Centrifugal all speed control Forced lubric...

Page 22: ...kg cm 200rpm 2 2 2 2 1 3 Fuel system 1 3 Fuel system The fuel system is composed of fuel tank filter and fuel sensor The fuel system is composed of fuel tank filter and fuel sensor 1 3 1 Fuel tank 1 3 1 Fuel tank The fuel tank of welding structure is connect The fuel tank of welding structure is connected into one body with frame and placed at ed into one body with frame and placed at the left sid...

Page 23: ...ap cap Full Full Empty Empty Flowing Flowing to injection pump to injection pump Fig 1 3 Fuel box Fig 1 3 Fuel box Fig 1 4 Fuel sensor unit Fig 1 4 Fuel sensor unit Fuel meter Fuel meter to fuel meter to fuel meter 19 19 https www besttruckmanuals com ...

Page 24: ... to make regular In order to keep the engine in good working state it is necessary to make regular check and adjustment and the main points are as follows check and adjustment and the main points are as follows 1 5 1 For air filter plea 1 5 1 For air filter please See Fig 1 5 se See Fig 1 5 1 Take out filter element 1 Take out filter element 2 Check the dust and damage state of the filter element ...

Page 25: ...contacts with the main body of the fuel filter body of the fuel filter 1 5 3 For the machine oil filter See 1 5 3 For the machine oil filter See Fig 1 7 Fig 1 7 1 1 Dis Disman mantle tle it it wit with h a a sp spann anner er speciall specially used for fuel filter and change it y used for fuel filter and change it 2 Mount it after applying a few drops 2 Mount it after applying a few drops of lubr...

Page 26: ...osened Refer to Fig 1 9 Refer to Fig 1 9 Loosen the fixed bolt B and C of Loosen the fixed bolt B and C of the generator move it towards outside press the generator move it towards outside press down the belt at place A down the belt at place A with finger with 10kg with finger with 10kg force Its flexibility is about 10 mm and then force Its flexibility is about 10 mm and then tighten the B and C...

Page 27: ... 5 5 Tightening the cylinder head bolts 1 5 5 Tightening the cylinder head bolts of engine of engine 1 Tighten the 1 Tighten the cylin cylinder head der head bolts one bolts one by one with 68 by one with 68 Nm moment accord Nm moment according to the ing to the order shown in Fig 1 10 order shown in Fig 1 10 2 Incre 2 Increase the tightening momen ase the tightening moment to 93 t to 93 Nm and ti...

Page 28: ...from th m this p is posi ositio tion n See Fig 1 15 See Fig 1 15 For the concrete adjustm For the concrete adjustment table refer to Table 1 2 ent table refer to Table 1 2 Table 1 2 Table 1 2 Air cylinder Air cylinder Sequence No Sequence No Valve sequence No Valve sequence No I Suction valve I Suction valve E Exhaust valve E Exhaust valve Dead point at Dead point at compression stroke compression...

Page 29: ...ection far away from the engine in case of the engine in case of Ahead of time and adjust in the Ahead of time and adjust in the directi direction close to the engine in on close to the engine in case of delay case of delay 4 After adjustment screw tight all the assembly bolts of oil injection pump and 4 After adjustment screw tight all the assembly bolts of oil injection pump and confirm again th...

Page 30: ...of oil injection pump 1 Loosen the exhaust plug of oil injection pump 2 Opera 2 Operate slowly the manual pump till no air bulbs te slowly the manual pump till no air bulbs come from the exhaust plug come from the exhaust plug 3 Then tighte 3 Then tighten the air n the air exhaust plug exhaust plug Fig 1 19 Fig 1 19 26 26 https www besttruckmanuals com ...

Page 31: ...i consists of sts of key switch f key switch flameou lameout t and automatic and automatic flameout device Stop system use for IVECO and KOMATSU diesel engine consists of flameout device Stop system use for IVECO and KOMATSU diesel engine consists of key key switch and shut off fuel valve switch and shut off fuel valve 2 1 4 Instruments 2 1 4 Instruments It mainly consists of hour meter fuel meter...

Page 32: ...Generator Generator Voltageadjuster Voltageadjuster Charging Charging indication indication Lamp sw Lamp sw Horn button Horn button Horn Horn Water temp meter Water temp meter Fuel meter Fuel meter Fuel meter sensor Fuel meter sensor Oil pressure signal Oil pressure signal Air cleaner signal Air cleaner signal Water deposit signal Water deposit signal Water deposit sw Water deposit sw Front lamp F...

Page 33: ...n forward shifts then After engine starting push the shiftlever forward that is in forward shifts then pedal accele pedal accelerator shift the forklift truck runs faster and you can begin to work When pull rator shift the forklift truck runs faster and you can begin to work When pull the shiftlever backward that is in reverse shifts the back lamp is on and the buzzer the shiftlever backward that ...

Page 34: ... it indicates low lubricating oil pres s low lubricating oil pressure and you must stop working and check the sure and you must stop working and check the lubricating system as soon as possible lubricating system as soon as possible 2 2 7 Water deposit water and oil segregator indicator Before you start the engine 2 2 7 Water deposit water and oil segregator indicator Before you start the engine p...

Page 35: ... immediately While eye touches it flush with water and see a doctor immediately with water and see a doctor immediately r r 1 The wire harness colour corresponding table 1 The wire harness colour corresponding table The GY GR GW The GY GR GW WB YR RY RB WB YR RY RB LB etc means two LB etc means two color colors line the s line the former former s s quantity occupies quantity occupies 2 3 and the l...

Page 36: ... Attachment wiring harness show in Fig 2 4 Fig 2 13 Type Type Name Name Cabinet Cabinet cable cable Engine Engine cable cable Head guard Head guard cable cable 50 70 W 50 70 W 80 100 W 80 100 W 50 50 70 70 C C 80 80 1 100 00 C C 50 50 6 60 0 WF WF 50 50 7 70 0 Xs Xs All one page All one page 32 32 https www besttruckmanuals com ...

Page 37: ...n iinn gg llaamm pp ssww EE nn ggiinn ee ccaabb llee EE nn ggiinn ee ccaabb llee EE nn ggiinn ee ccaabb llee EE nn ggiinn ee ccaabb llee SSttaarr tt ssww iittcchh LL aamm pp ssww iittcchh SS oocckk eett BB SS oocckk eett AA OO vveerrhh eeaadd gguu aarrdd ccaabb llee HH oorrnn Fig 2 4 Cabinet wire harness Fig 2 4 Cabinet wire harness 33 33 https www besttruckmanuals com ...

Page 38: ... eellaa yy RR ee llaa yy RR ee llaa yy AA iirr cc llee aa nn ee rr BB aa cc kk uu pp bb uuzzzz eerr WW aa ttee rr ttee mm pp sseenn ssoorr WW aa rrnn iinn gg PP rree hh eeaa tt pp lluu gg OO iill pp rree ssssuurr ee ssww GG eenn ee rraa ttoorr WW oorrkk iinn gg llaa mmpp SS ttaa rrttoo rr LL iicceenn ssee pp llaa ttee llaamm pp BB rraa kk ee llaamm pp ssww CC aauu ttiioonn llaamm pp CC oo mm bb ii...

Page 39: ... uu ssee FF llaa sshh ee rr OO iill llee vv ee ll sseenn ssoo rr FF uu ssee RR ee llaayy RR ee llaa yy RR ee llaayy AA iirr cc llee aann ee rr BB aa cc kk uu ppbbuu zzzzee rr WW aa ttee rr tteemm pp sseenn ssoo rr WW aarrnn iinn gg PP rreehh ee aatt pp lluu gg OO iill pp rreessssuu rree ssww GG ee nn ee rraa ttoorr WW oorrkk iinn gg llaa mm pp SS ttaa rrttoorr LL iicc eenn ssee pp llaa ttee llaa m...

Page 40: ...ccoonn ttrrooll TT uu rrnniinngg llaamm pp ssww CC aabb sstt dd bb yy bb aatttteerryy aann OO vveerrhh eeaadd gguuaarr dd ccaabb llee SS oocckk eett BB SS oocckk eett AA EE nn ggiinnee ttaabb llee EE nn ggiinnee ccaabb llee OO vveerrhh eeaadd gguu aarrdd ccaabb llee HHoo rrnn EE nn ggiinn ee ccaabb llee 36 36 https www besttruckmanuals com ...

Page 41: ... FF llaasshh eerr RR eellaayy GG rroouu nn dd SS ttaarrttoorr VV aaccuuuu mm ww aarrnn iinn gg VV aaccuu uu aamm ssww CC oomm bb iinn aattiioonn llaamm pp LL iicc ee nn ss ee pp llaa ttee llaa mm pp WW aa rrkk iinn gg llaa mm pp EE nn ggiinn ee FFuu ssee BB rraakk ee llaamm pp ssww WW aatteerr tteemm pp sseenn ssoorr CC oomm bb iinn aattiioo nn llaamm pp BB aacckkuupp bb uu zzzzeerr AA iirr ccllee...

Page 42: ...r FF llaasshh eerr RR eellaayy GG rroouu nn dd SS ttaarrttoorr VV aaccuuuu mm ww aarrnn iinn gg VV aaccuu uu aamm ssww CC oomm bb iinn aattiioonn llaamm pp LL iicc ee nn ss ee pp llaa ttee llaa mm pp WW oo rrkk iinn gg llaa mm pp EE nn ggiinn ee FF uussee BB rraakk ee llaamm pp ssww WW aatteerr tteemm pp sseenn ssoorr CC oomm bb iinn aattiioo nn llaamm pp BB aacckkuupp bb uu zzzzeerr AA iirr cclle...

Page 43: ... llaasshh eerr RR eellaayy GG rroouu nn dd SS ttaarrttoorr CC oomm bbiinn aattiioonn llaamm pp LL iicc ee nn ss ee pp llaa ttee llaa mm pp WW aa rrkk iinn gg llaa mm pp EE nn ggiinn ee FF uu ssee BB rraa kk ee llaa mm pp ss ww WW aatteerr tteemm pp sseennss oorr CC oomm bb iinn aattiioonn llaamm pp VV aaccuu uu aamm ww aarrnn iinn gg VV aaccuu uu aamm ssww RR eevveerrssee bb uu zzzzeerr RR eellaay...

Page 44: ... aa ttoo rr HHoo uu rr mm ee ttee rr cc oo nn ttrroo ll TTuu rrnn iinn gg ssww CC aa bb ssttaa nn dd bb yy bb aa ttttee rryy OO vv ee rrhh ee aa dd gg uu aa rrdd cc aa bb llee EE nn gg iinn ee cc aa bb llee OO vv ee rrhh ee aa dd gg uu aa rrddcc aa bb llee HH oo rrnn EE nn gg iinn ee cc aa bb llee EE nn gg iinn eecc aa bb llee EE nn gg iinn ee cc aa bb llee 40 40 https www besttruckmanuals com ...

Page 45: ... RR eevveerrssee bb uuzzzzee rr CC oomm bb iinn aattiioonn llaamm pp GG rr oo uu nn dd PP aa rr kk ii nn gg SS ttaarrtteerr FF uu ssee RR eesseerrvvooiirr BB rraakk ee llaamm pp ssww PP rreehh eeaatt pp lluu gg LL iicc ee nn ss ee PP llaa ttee rr llaamm pp WW oorrkk iinn gg llaamm pp WW aarrnn iinngg OO iill pp rreessssuu rree GG eenn eerraattoorr OO iill aann dd ww aatteerr sseeggrreeggaattoorr W...

Page 46: ...ine wire harness Fig 2 13 Engine wire harness FF rroonn tt cc oo mm bb iinn aa ttiioo nn llaa mm pp FF rroo nn tt hh ee aa dd llaa mm pp TT oo cc aa bb iinn ee tt cc aa bb llee 42 42 https www besttruckmanuals com ...

Page 47: ...t 20 About 20 Model SAE10W engine oil or Model SAE10W engine oil or No 6 torque converter oil made No 6 torque converter oil made in China in China Item Item Torque Torque converter converter Type Type Circular Dia stall torque ratio Circular Dia stall torque ratio P Pr re es ss su ur re e s se et tt ti in ng g M MP Pa a Charging Charging pump pump D Di is sc ch ha ar rg ge e i i m mi in n Torque ...

Page 48: ... 10 0 S St tr ra ai in ne er r 1 11 1 O Oi il l s se ea al l 1 12 2 G Ge ea ar r 3 32 2T T 1 13 3 B Ba al ll l b be ea ar ri in ng g 1 14 4 S Sh ha af ft t 1 15 5 B Be ea ar ri in ng g c ca ag ge e 1 16 6 O Ou ut tp pu ut t s sh ha af ft t 1 17 7 O Oi il l s se ea al l 1 18 8 B Ba al ll l b be ea ar ri in ng g 1 19 9 G Ge ea ar r 4 47 7T T 2 20 0 R Re ev ve er rs se e c cl lu ut tc ch h p pa ac ck...

Page 49: ...rbine wheel is changed by the stator output shaft The direction of thr fluid leaving the turbine wheel is changed by the stator wheel so that it flows into the pump wheel at the best angle At this time a wheel so that it flows into the pump wheel at the best angle At this time a reaction torque reaction torque pushing the stator is generated as a result of pushing the stator is generated as a resu...

Page 50: ...e charging pump pump to drive the charging pump The turbine wheel is spline jointed to the main shaft It serves to transmit power to The turbine wheel is spline jointed to the main shaft It serves to transmit power to the wet type multidisk clutch the wet type multidisk clutch The construction of the torque converter see fig 3 2 The construction of the torque converter see fig 3 2 Fig 3 2 Torque c...

Page 51: ...eriphery and inner periphery of the piston is ensured with Oiltightness of outer periphery and inner periphery of the piston is ensured with the the slipper seal and O ring respectively when it operates In the neutral state the coil slipper seal and O ring respectively when it operates In the neutral state the coil spring acts to disengage the multidisk clutch The clutch surface is always spring a...

Page 52: ...aring Bearing Bearing Gear Gear Washer Washer Friction plate Friction plate Spacer Spacer Papilionaceous Papilionaceous plate plate O ring O ring Return spring Return spring 2 Shift gear 2 Shift gear Washer Washer Oil pressure Oil pressure Oil pressure Oil pressure Sleeve Sleeve Bearing Bearing 1 Shift gear 1 Shift gear Washer Washer Clip Clip Seal ring Seal ring Piston Piston Washer Washer End pl...

Page 53: ...that hydraulic pressure of clutch is lowered temporarily depressed the spool is forced in so that hydraulic pressure of clutch is lowered temporarily to disengage the clutch to disengage the clutch When the engine is started and the charging pump is put into operation the torque When the engine is started and the charging pump is put into operation the torque converter fluid in the oil converter f...

Page 54: ...tion fluid flows into the When the selector spool is set to the forward or reverse position fluid flows into the accumulator due to action of modulate valve so that pressure rises gradually During this accumulator due to action of modulate valve so that pressure rises gradually During this time the clutch starts to engage time the clutch starts to engage When the accumulator is filled with When th...

Page 55: ...smission e transmission 2 2 Set the Set the change l change lever in ever in neutral p neutral position osition Sin Since ce the the tor torque que con conver verter ter pum pump p doe does s not not ope operat rate n e norm ormal al lub lubric ricati ation on is is not not perfo performed rmed Ther Therefore efore if if rotat rotation ion is is trans transmitted from mitted from the the front whe...

Page 56: ...ssemble and check Disassemble and check Check spring tension Check spring tension Disassemble Disassemble check check and and measure measure Drain a small quantity of oil Drain a small quantity of oil and check for presence of and check for presence of foreign matter foreign matter Check Check Check joints and pipes Check joints and pipes Measurepressure Measurepressure Measure pressure Measure p...

Page 57: ...ir or replace replace Repair or Repair or replace replace Replace clutch plates Replace clutch plates Replace Replace Possible Causes Possible Causes 1 input plate broken 1 input plate broken 2 Bearings damaged or worn 2 Bearings damaged or worn 3 Gears broken 3 Gears broken 4 Spline worn 4 Spline worn 5 Noisy gear pump 5 Noisy gear pump 6 Loose bolts 6 Loose bolts 1 Bearings worn or seized 1 Bear...

Page 58: ...d check Disassemble and check Disassemble and check Remedy Remedy Replace Replace Add oil Add oil Replace Replace Replace Replace Replace Replace Add oil Add oil Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Clean or replace Clean or replace Replace Replace TT oorrqq uu ee CC oonn vveerrttee rr TT rraann ssmm iissssiioo nn Possible Causes Possible Causes 1 Damaged...

Page 59: ...tted to the spider being in mesh with each another The drive pinions supported by two taper roller bearings are installed in the bearing cage fitted to the supported by two taper roller bearings are installed in the bearing cage fitted to the differential carrier through shims and packings The ring gear is of the spiral bevel gear differential carrier through shims and packings The ring gear is of...

Page 60: ... 8 T Ta ap pe er r r ro ol ll le er r b be ea ar ri in ng g 9 9 A Ad dj ju us st t n nu ut t 1 10 0 L Lo oc ck k n nu ut t 1 11 1 P Pl la an ne et t c ca ar rr ri ie er r 1 12 2 T Th hr ru us st t c ca ap p 1 13 3 S Sh ha af ft t 1 14 4 S St te ee el l b ba al ll l 1 15 5 P Pl la an ne et t g ge ea ar r 1 16 6 G Ge ea ar r 1 17 7 S Su un n g ge ea ar r Tightening torque Tightening torque Tightenin...

Page 61: ...l l b br ra ak ke e 4 4 B Br ra ak ke e d dr ru um m 5 5 O Oi il l s se ea al l 6 6 T Ta ap pe er r r ro ol ll le er r b be ea ar ri in ng g 7 7 H Hu ub b 8 8 T Ta ap pe er r r ro ol ll le er r b be ea ar ri in ng g 9 9 A Ad dj ju us st t n nu ut t 1 10 0 L Lo oc ck k n nu ut t 11 P 11 Planet lanet carrie carrier r 12 T 12 Thrus hrust t cap cap Tightening torque Tightening torque Tightening torque...

Page 62: ...ar 1 13 3 T Th hr ru us st t w wa as sh he er r 1 14 4 N Ne ee ed dl le e b be ea ar ri in ng g 1 15 5 M Ma ai in n r re ed du uc ct ti io on n h ho ou us se e 1 16 6 L Lo oc ck k n nu ut t 1 17 7 A Ad dj ju us st t n nu ut t 1 18 8 D Dr ri iv vi in ng g p pi in ni io on n 1 19 9 T Ta ap pe er r r ro ol ll le er r b be ea ar ri in ng g 2 20 0 B Be ea ar ri in ng g c ca ag ge e 2 21 1 O O r ri in n...

Page 63: ...axle spindle through hub ough hub The princip The principle le of of power transm power transmissi ission on is as is as follo follows se ws see e fig 4 fig 4 4 When 4 When the sun the sun gear gear turns the rotation is transmitted to the pinion gears turns the rotation is transmitted to the pinion gears and ring gear However since the ring and ring gear However since the ring gear is gear is fix...

Page 64: ...spline part of companion flange and drive pinion e and drive pinion Backlash of drive pinion and ring gear Backlash of drive pinion and ring gear Preload of drive pinion N m Preload of drive pinion N m Back swing of ring gear Back swing of ring gear Tightenin Tightening torque of ring gear set g torque of ring gear set bolt N m bolt N m Tightening torque of cross case set bolt N m Tightening torqu...

Page 65: ... vale safetyvalve vale safetyvalve Move model Move model Intake flux Intake flux Max working oil pressure Max working oil pressure Type Type C Ca ap pa ac ci it ty y c cc c Piston I D Stroke mm Piston I D Stroke mm Oil pressure Oil pressure Max Working time MPa Max Working time MPa Relief oil pressure Relief oil pressure Vaccum assistant Vaccum assistant Front wheel internal expansion type lining ...

Page 66: ...lve and the sub pump of brake to produce braking while the other sub pump of brake to produce braking while the other way of oil enters into way of oil enters into accumulator accumulator to store energy for spare use Both ways of to store energy for spare use Both ways of the oil are the oil are contr controlled by the stroke of olled by the stroke of brak brake e pedal pedal 5 2 1 Brake pedal de...

Page 67: ...Fig 5 2 Brake pedal unit Fig 5 2 Brake pedal unit Brake sw Brake sw Brake pedal Brake pedal Inching pedal Inching pedal Brake Brake valve valve Reservoir Reservoir 63 63 https www besttruckmanuals com ...

Page 68: ...t NO 5 and this pushing force is in balance with pedal force pushing force is in balance with pedal force D D When the maxi When the maximum pedal forc mum pedal force is input in the right end of pisto e is input in the right end of piston and in order that n and in order that the oil the oil press pressure of ure of D chamber will not D chamber will not exceed the maximum adjust exceed the maxim...

Page 69: ... bac ack k pi pist ston on se seat at 5 5 Bo Bou unc nce e ba back ck p pis isto ton n 6 6 R Ret etur urn n sp spri rin ng g 7 7 Va Valv lve e s sle leev eve e 8 8 Sp Spri rin ng g 9 Oil seal 10 Piston ass y 9 Oil seal 10 Piston ass y Fig 5 3 Brake valve Fig 5 3 Brake valve Fig 5 4 Reservior Fig 5 4 Reservior RRee ssee rrvv oo iirr OO iillpp uu mm pp OO iill ttaa nn kk Brake Brake Steering Steerin...

Page 70: ...safety maximum energy at this time and the oil pressure is 13 MPa which is controlled by safety valve valve 5 3 Vacuum servo brake 5 3 Vacuum servo brake 5 7t forklift that 5 7t forklift that match matched ed with domestic machine adopts vacuum servo with domestic machine adopts vacuum servo brake brake i e i e vacuum booster and main brake cylinde vacuum booster and main brake cylinder main pump ...

Page 71: ...ng position while control air valve 4 while control air valve 4 is pressed tightly against work piece 5 by is pressed tightly against work piece 5 by small cone spring thus small cone spring thus closing the air valve port The two cavities of air cell of booster are interconnected through closing the air valve port The two cavities of air cell of booster are interconnected through chann channel A ...

Page 72: ...ilm hull 8 Rear film hull 9 Rear film 9 Rear film 10 Feedback tray 10 Feedback tray 11 Front film hull 11 Front film hull 12 Front flim 12 Front flim 13 Cylinder push rod 13 Cylinder push rod 14 Returnspring 14 Returnspring 15 joint 15 joint Fig 5 6 Vacuum booster and main brake cylinder constructure Fig 5 6 Vacuum booster and main brake cylinder constructure FF rroo nn tt iinn ffllaa ttiinngg cc ...

Page 73: ...n the brake pedal the A In the course of stepping on the brake pedal the push rod of control valve moves push rod of control valve moves forward forwards the air through the air valve port opened constantly ente s the air through the air valve port opened constantly enters into the front and rear rs into the front and rear cavities of air cell of booster and control valve body constantly moves for...

Page 74: ...3 5 4 Travel brake 5 4 Travel brake Travel brake is an internal expanding and shoe brake There is one symmetrically Travel brake is an internal expanding and shoe brake There is one symmetrically on on the left and right each which the left and right each which are mounted respectively in the two driving wheels Brake are mounted respectively in the two driving wheels Brake is is composed of a pair...

Page 75: ...rklift brake brakes for s for rever reversal i e when the sal i e when the adju adjusting lever has a sting lever has a large cleara large clearance the gear nce the gear on the on the automatic adjuster turns a tooth and makes the clearance after adjustment remain at 0 4 to automatic adjuster turns a tooth and makes the clearance after adjustment remain at 0 4 to 0 6mm For the adjustment of rotat...

Page 76: ...condary shoe 8 Returning spring 8 Returning spring 9 Securin 9 Securing pin for g pin for shoe shoe 10 Compression spring 10 Compression spring 11 Self adjusterspring 11 Self adjusterspring 12 Adjuster lever 12 Adjuster lever 13 Adjuster 13 Adjuster 14 Return spring 14 Return spring Fig 5 8 Brake 5 7t Fig 5 8 Brake 5 7t 72 72 https www besttruckmanuals com ...

Page 77: ...d 3 Push rod 4 Piston 4 Piston 5 Spring 5 Spring 6 Boot 6 Boot 7 Dust hood 7 Dust hood 8 Secondary shoe 8 Secondary shoe 9 Return spring 9 Return spring 10 Brake floor 10 Brake floor Fig 5 9 Brake 8 10t Fig 5 9 Brake 8 10t 73 73 https www besttruckmanuals com ...

Page 78: ...and the tooth of the adjuster is rotated from inside location on the bottom plate of the brake and the tooth of the adjuster is rotated from inside to outside with screwdriver until the friction disc contacts with the inner wall of braking to outside with screwdriver until the friction disc contacts with the inner wall of braking drum Then the tooth of the adjuster is back rota drum Then the tooth...

Page 79: ...f stop brake is shown in Fig 5 11 When the forklift is under the standard loading state and stop brake is made on the slope the manual operating force standard loading state and stop brake is made on the slope the manual operating force should be not bigger than 300N The pulling force is adjusted according to the direction should be not bigger than 300N The pulling force is adjusted according to t...

Page 80: ...g brake Fig 5 12 Parking brake 7 Return spring 7 Return spring 8 Adjuster 8 Adjuster 9 Adjuster spring 9 Adjuster spring 10 Pin 10 Pin 11 Spring seat 11 Spring seat 12 Lever 12 Lever 13 Support plate 13 Support plate 14 Pin 14 Pin 15 U ring 15 U ring 16 Plug 16 Plug 17 Parking brake cable 17 Parking brake cable 76 76 https www besttruckmanuals com ...

Page 81: ...ring to pad surface Auxiliary pump act improper Auxiliary pump act improper Drum eccentricity Drum eccentricity Improper clearance of pads Improper clearance of pads Improper tire pressure Improper tire pressure Brake fluid leakage from brake system Brake fluid leakage from brake system Improper clearance of pads Improper clearance of pads Air mixed in brake system Air mixed in brake system Incorr...

Page 82: ...g pin interval King pin interval Gimbal swivel radius Gimbal swivel radius Tire Tire Rim Rim Inflation pressure Inflation pressure Steering Steering unit unit Steering Steering cylinder cylinder Flow Flow divider divider Steering Steering axle axle Steering Steering wheels wheels 5 7t 5 7t 8 8t t 1 10 0t t Rear wheel steering powered Rear wheel steering powered 360 360 BZZ series powered steering ...

Page 83: ...g axle and steering cylinder Steering control unit see fig 6 1 steering unit steering axle and steering cylinder Steering control unit see fig 6 1 Fig 6 1 Steering control unit Fig 6 1 Steering control unit Steering hand wheel Steering hand wheel Steering unit Steering unit Lock handle Lock handle Gimal Gimal Linkage shaft ass y Linkage shaft ass y 79 79 https www besttruckmanuals com ...

Page 84: ...smit the pressure oil The steering unit is a full hydraulic steering unit and can transmit the pressure oil from the flow divider to steering cylinder through the oil pipe by metering The oil volume from the flow divider to steering cylinder through the oil pipe by metering The oil volume changes as the rotation angle of the handwheel When the engine goes out and the oil pump changes as the rotati...

Page 85: ... a flat Stop the machine on a flat dry paved rod and apply its parking brake Attach a spring dry paved rod and apply its parking brake Attach a spring balancer to the steering wheel rim to measure the steering power The steering power must balancer to the steering wheel rim to measure the steering power The steering power must be less than approx 150N be less than approx 150N 5 5 To To measu measu...

Page 86: ...wer steering it is necessary put the match mark in the set position or measure the distance to the screw head if disassembly of valve is needed measure the distance to the screw head if disassembly of valve is needed 6 3 Troubleshooting Guide 6 3 Troubleshooting Guide Possible cause Possible cause Flow control valve spool stuck Flow control valve spool stuck Flow control valve spool worn Flow cont...

Page 87: ...steering knuckle and the upper and lower bosses of steering axle body under which a gasket can be used body under which a gasket can be used to regulate the rotati to regulate the rotation clearance In the inner hole on clearance In the inner hole of upper and lower bosses the steering stub is mounted and is supported by the upper and of upper and lower bosses the steering stub is mounted and is s...

Page 88: ...Fig 6 4 Steering axle Fig 6 4 Steering axle Steering axle seat Steering axle seat Sleeve Sleeve Steering Steering cylinder cylinder 84 84 https www besttruckmanuals com ...

Page 89: ...Linkage Oil seal Oil seal Needle bushing Needle bushing Hu Hub b Turning knurl Turning knurl Nut outer Nut outer Nut inner Nut inner Pushing bushing Pushing bushing King pin King pin Needle bushing Needle bushing Dust ring Dust ring Seal ring Seal ring Snap ring Snap ring O ring O ring Wearing Wearing O ring O ring Bushing Bushing Guide cap Guide cap Cylinder Cylinder Piston Piston rad rad 85 85 h...

Page 90: ... P T O Transmission P T O 25Mpa 25Mpa A45E7 10202 A45E7 10202 36R 4R Double 36R 4R Double gear pump gear pump A05E7 10202 A05E7 10202 32R 3 5 Double 32R 3 5 Double gear pump gear pump A05E7 10202 A05E7 10202 32R 3 5 Double 32R 3 5 Double gear pump gear pump A45E7 10301 A45E7 10301 36L 36L A05E7 10301 A05E7 10301 32L 32L A05E7 10301 A05E7 10301 32L 32L H09E7 10202 H09E7 10202 32R 32R H09E7 10202 H0...

Page 91: ...h contains the two gears and other components The drive gear is in mesh with the driven contains the two gears and other components The drive gear is in mesh with the driven gear gear 7 3 Control valve See fig 7 1 7 3 Control valve See fig 7 1 Fig 7 1 Control valve Fig 7 1 Control valve The control valve is a sectional type consisting of the inlet section plunger section The control valve is a sec...

Page 92: ...rt B The returning oil from the cylinder port A flows through the low pressure passage to the port A flows through the low pressure passage to the tank The plunger is restored to tank The plunger is restored to the neutral positio the neutral position by n by thr return spring thr return spring 7 7 Drawing out Drawing out of of plunger See plunger See fig 7 4 fig 7 4 With the neutral passage close...

Page 93: ... As the pilot poppet E is opened the preeure behind the poppet C 3 As the pilot poppet E is opened the preeure behind the poppet C drops due to which the poppet C is moved to seat on the pilot poppet E As a drops due to which the poppet C is moved to seat on the pilot poppet E As a result of this the oil flowing behind the relief valve poppet D is shut off and the result of this the oil flowing be...

Page 94: ...of the plunger housing is led to the front side of the tilt cylinder and the port B side to its rear side When the tilt lever is pulled plunger cylinder and the port B side to its rear side When the tilt lever is pulled plunger drawn out the oil from the pump flows into the port A while the port B side oil drawn out the oil from the pump flows into the port A while the port B side oil returns to t...

Page 95: ...r unit Fig 7 10 Control valve lever unit Tilt lever Tilt lever Attachment lever Attachment lever option option Lift lever Lift lever Linkage Linkage Control valve Control valve Section Section 91 91 https www besttruckmanuals com ...

Page 96: ...pump Oil filter Front pump Oil filter Rear pump Oil filter Rear pump Fitting oil cap oil mark Fitting oil cap oil mark Self brake circuit Self brake circuit Breather Breather Steering cylinder Steering cylinder Lift cylinder Lift cylinder Fig 7 11 Oil tank Fig 7 11 Oil tank 92 92 https www besttruckmanuals com ...

Page 97: ...of 10 ton forklift trucks see fig 7 13 ation system of 10 ton forklift trucks see fig 7 13 Fig 7 12 Hydraulic system Fig 7 12 Hydraulic system Lift cylinder Lift cylinder Cut off valve Cut off valve Regulator Regulator Tilt cylinder Tilt cylinder Control valve Control valve Main relief valve Main relief valve Steering cylinder Steering cylinder Steering unit Steering unit Turning securing valve Tu...

Page 98: ...linder R Tilt cylinder R Tilt cylinder L Tilt cylinder L To lift cylinder To lift cylinder Control valve Control valve To lift cylinder To lift cylinder Rear pump Rear pump Front pump Front pump Steering unit Steering unit Steering Steering cylinder cylinder 94 94 https www besttruckmanuals com ...

Page 99: ...e side of the piston to push it The oil pushed by the piston returns to the oil tank through the control valve returns to the oil tank through the control valve 7 8 maintenance 7 8 maintenance 7 8 1 Disassembly of control valve 7 8 1 Disassembly of control valve Dismount the control valv Dismount the control valve from the machine and clean exterior of it e from the machine and clean exterior of i...

Page 100: ...y piston pis body piston piston rod and ton rod and cylinder cap At the lower part of the cylinder body is arranged an inlet for high pressure cylinder cap At the lower part of the cylinder body is arranged an inlet for high pressure oil and at the upper part there is an outlet for low pressure oil above the piston oil and at the upper part there is an outlet for low pressure oil above the piston ...

Page 101: ...ht does not vary With the lift lever tilted forward the pistons of the lift cylinders descend by the weights of the piston rods lift tilted forward the pistons of the lift cylinders descend by the weights of the piston rods lift bracket finger bar and forks causing oil under the piston to bracket finger bar and forks causing oil under the piston to flow out of the flow out of the cylinders The cyl...

Page 102: ...ton rod 9 Ring 9 Ring 10 Wearing 10 Wearing 11 Yx ring 11 Yx ring 12 Piston 12 Piston 13 Lift chain 13 Lift chain 14 Sheave 14 Sheave 15 Ball bushing 15 Ball bushing 16 Snap ring 16 Snap ring 17 Spring 17 Spring 18 Cut off valve 18 Cut off valve 19 Active beam 19 Active beam Fig 8 2 Lift cylinder 10t truck Fig 8 2 Lift cylinder 10t truck 98 98 https www besttruckmanuals com ...

Page 103: ...valve 8 3 Flow regulator 8 3 Flow regulator The flow regulator valve is located between the control valve and the high pressure The flow regulator valve is located between the control valve and the high pressure ports of the two lift cylinders near the left cylinder See fig 8 4 The structure of the flow ports of the two lift cylinders near the left cylinder See fig 8 4 The structure of the flow re...

Page 104: ...ipple This closes the opening G so that oil flows shifts the sleeve until it contacts the nipple This closes the opening G so that oil flows through E D H C B and A to the tank If the amount of oil discharged from the lift through E D H C B and A to the tank If the amount of oil discharged from the lift cylinders is rapidly increased the pressure in the chamber F rises cylinders is rapidly increas...

Page 105: ...l le e 8 Valve body 8 Valve body 9 Spring 9 Spring 1 Earring 1 Earring 2 Washer 2 Washer 3 Adjuster sleeve 3 Adjuster sleeve 4 Dust ring 4 Dust ring 5 Snap ring 5 Snap ring Fig 8 6 Tilt cylinder Fig 8 6 Tilt cylinder 6 Yx ring 6 Yx ring 7 Guide cylinder cap 7 Guide cylinder cap 8 O ring 8 O ring 9 Bushing 9 Bushing 10 Cylinder body 10 Cylinder body 11 Yx ring 11 Yx ring 12 Wearing 12 Wearing 13 Pi...

Page 106: ...ted bushing pack press fitted bushing packing and dust ing and dust seal to keep oil tightnes seal to keep oil tightness between the piston rod and the inside of the cylinde s between the piston rod and the inside of the cylinder cap r cap The cap fitte The cap fitted with an O ring on d with an O ring on the outer peripher the outer periphery is screwed into the cylinder body y is screwed into th...

Page 107: ...e cket t mm mm Lift chain Lift chain Fork lifting method Fork lifting method Mast tilting method Mast tilting method Fork spacing adjustment Fork spacing adjustment Forward tilt S T D Forward tilt S T D 5 7t 5 7t 8 8t t 1 10 0t t Rolling type welded mast with free lift Rolling type welded mast with free lift 2 stage telescopic mast 2 stage telescopic mast 3000mm 3000mm 6 6 12 12 Φ Φ1 15 51 1 5 5 Φ...

Page 108: ...r side rollers are located to sustain transverse load With the aid of these rollers the inner side rollers are located to sustain transverse load With the aid of these rollers the inner mast can smoothly operates mast can smoothly operates 9 3 Lift bracket 9 3 Lift bracket At the lift brackets end rolers that roll along the inside of he inner mast frames are At the lift brackets end rolers that ro...

Page 109: ...h the e ho hori rizo zont ntal al gr grou ound nd an and d ma make ke th the e ma mast st vertical vertical 2 Let the bottom of the fork contact 2 Let the bottom of the fork contact with the ground Adjust the adjusting nut with the ground Adjust the adjusting nut for the end nipple of the upper chain and for the end nipple of the upper chain and make a distance A between the main roller make a dis...

Page 110: ...s sustain the side loads Usual can adjust clearance in right and left side direction with shims so as to outer mast inner mast and bracket can move left side direction with shims so as to outer mast inner mast and bracket can move freely freely up and down up and down Fig 9 5 Roller lay for 5 7t truck Fig 9 5 Roller lay for 5 7t truck 4 Make the fork down to 4 Make the fork down to the ground and ...

Page 111: ...r Washer Stopper Stopper Lower Lower Upper Upper Lift bracket Lift bracket Inner Inner mast mast Outer Outer mast mast Side roller Side roller End roller End roller Chain Chain Lift cylinder Lift cylinder Washer Washer Stopper Stopper Fig 9 6 Roller lay for 8t truck Fig 9 6 Roller lay for 8t truck Fig 9 7 Roller lay for 10t truck Fig 9 7 Roller lay for 10t truck 107 107 https www besttruckmanuals ...

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