Yale A7S1 Page 33 Service Manual Download

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1. LEFT UNIVERSAL JOINT

2. STEERING AXLE

3. NUT M12

4. NUT M12X40

5. WASHER 14

6. WASHER 14

7. BOLT M14X45

8. KING PIN

9. CYLINDRICAL PIN 10X20

10. BUSHING

11. BEARING 198908K

12. RIGHT UNIVERSAL JOINT

13. HEX NUT M12X30

14. COTTER PIN 6.3X50

15. OIL SEAL

16. WHEEL BOLT

17. WHEEL

18. WHEEL NUT

19. WHEEL CAP

20. NUT M20X2

21. WASHER 30

22. TAPERED ROLLER BEARING

23. BEARING 30211

24. GREASE NIPPLE Z1/8

25. OIL SEAL

26. NEEDLE BEARING

27. O-RING

28. ADJUSTING SHIM

29. LINK PIN

30. LINK ROD

31. RETAINING PLATE

32. WASHER 8

33. BOLT M8X16

34. KNUCKLE BEARING

35. NIPPLE M6

36. BUSHING

37. STEERING CYLINDER

Figure 22. Steering Axle

Steering Knuckle and Steering King Pin

Steering knuckle is mounted between the upper and
lower shaft sleeves on the two ends of steering axle

body using steering knuckle king pin, thrust bearing,
and gasket. The middle part of king pin is locked on
steering knuckle using grub screw, while the two ends

8000 YRM 2199

Steering and Drive Axle Information

Summary of Contents for A7S1

Page 1: ...Maintenance A7S1 SERVICE MANUAL GLP GDP20UX GLP GDP25UX GLP GDP30UX GLP GDP35UX PART NO 550216372 8000 YRM 2199 ...

Page 2: ...r death FOREWORD This manual describes the structure and working principles of the 2 3 5T internal combustion 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 servici...

Page 3: ...2 YQXD30 PHF 3 3 5T GLP GDP30 35UX NISSAN K25 LPG YQXD30H PHF GLP GDP30 35UX NISSAN K25 GAS YQXD30H PHF GLP GDP30 35UX NISSAN K25 DUAL YQXD30H PHF GLP GDP30 35UX MITSUBISHI S4S 455 YQXD30 PHF GLP GDP30 35UX PSI 4G64 2 4L YQXD30 PHF GLP GDP30 35UX XINCHAI 4D27G31 YQXD30A PHF GLP GDP30 35UX YANMAR 4TNE94 YQXD30 PHF GLP GDP30 35UX YANMAR 4TNE98 YQXD30 PHF NOTE DUAL designates DUAL FUEL or BI FUEL ...

Page 4: ......

Page 5: ... Speed Reducer 16 Speed Differential 17 Towing the Lift Truck 17 Oil Inlet Outlet Connection Location 17 Drive Axle 18 Overview 18 Maintenance of Drive Axle 19 Steering System 20 Steering System 20 Overview 20 Hydraulic Steering Gear Assembly 20 Steering Cylinder 21 Inspection of Reassembled Steering System 22 Troubleshoot Steering System 23 Steering and Drive Axle Information 24 Steering Axle 24 ...

Page 6: ...s 62 Carriage 63 Adjustment of Lifting System 63 Electrical System 64 Overview 64 Power supply system 64 Starting system 64 Ignition system ICE forklift truck 64 Preheating system diesel forklift truck 64 Dash Instrument Display System 65 Lighting sound and alarm system 65 Electrical Box 65 Battery 65 Description and Summary of Basic Truck Operations 65 Introduction to the Power Distribution Modul...

Page 7: ...TABLE OF CONTENTS Continued Lubrication System 83 PDM Schematics 85 Table of Contents iii ...

Page 8: ......

Page 9: ...m Torque Converter Hydraulic Transmission Case Speed Reducer or Speed Differential Drive Axle Steering System Steering Axle Lifting System Control System Brake and Inching Control Hydraulic Truck Hydraulic System Parking Brake Throttle Control Steering Control Electrical System 8000 YRM 2199 Forklift Truck Main Parts 1 ...

Page 10: ...Forklift Main Technical Parameters MAIN TECHNICAL PARAMETERS Figure 1 Outside Drawing of Forklift Truck LPG DUAL Forklift Main Technical Parameters 8000 YRM 2199 2 ...

Page 11: ...ine engine NOTE Truck with diesel engine is shown Other trucks are similar The values in the parameter tables are for standard configuration only Always consult the nameplate to see the values of a specific truck 8000 YRM 2199 Forklift Main Technical Parameters 3 ...

Page 12: ... 20 20 Min Turning Radius 2290 mm 90 2 in 2350 mm 92 5 in Minimum Turning Radius Width K 3966 mm 156 1 in 4026 mm 158 5 in Total Length L Without Fork 2535 mm 99 8 in 2596 mm 102 2 in Total Width W 1150 mm 45 3 in 1150 mm 45 3 in Total Height D Mast Retracted 2010 mm 79 1 in 2010 mm 79 1 in Total Height E Mast Extended 3990 mm 157 1 in 3990 mm 157 1 in Wheelbase F 1600 mm 63 in 1600 mm 63 in Track...

Page 13: ...roke 86 5 100 mm 3 41 3 94 in Total Displacement I 2 35 liter 143 4 in 3 Compression Ratio 9 5 Rated Power Speed kw ps rpm Gasoline Engine 48 2700 kw rpm 64 4 2700 hp rpm LPG Engine 46 2700 kw rpm 61 7 2700 hp rpm Max Torque Speed Gasoline Engine 170 2400 N m rpm 125 4 2400 lbf ft rpm LPG Engine 168 1600 N m rpm 123 9 1600 lbf ft rpm No Load Min Speed 750 rpm Fuel Specific Consumption 290 g psh 09...

Page 14: ...lter Paper Element Filter Engine Oil Pump Gear Type Oil Rough Filter Paper Filtration Water Pump Centrifugal Type Thermostat Wax Type Generator Voltage 12V Current 70A Starter Voltage 12V Output Power 1 2 kW 1 61 hp Battery Voltage 12V Capacity 60Ah Referential Data Lubricating Oil 4 5 liter 4 7 qt Coolant Engine 3 5 liter 3 7 qt Radiator 3 5 liter 3 7 qt Refer to the engine operation and maintena...

Page 15: ... is 59 liter 15 6 gal and 65 liter 17 2 gal for 3 3 5t forklift trucks The Fuel Level Sensor is fitted on the tank cover of fuel tank to detect the fuel level See Figure 3 or Figure 4 1 PORT SEALED 2 FUEL LEVEL 3 FLOAT RISE 4 FLOAT DROP 5 OIL INLET 6 GAS FILTER Figure 3 Fuel Tank Gasoline Forklift Truck 8000 YRM 2199 Power System 7 ...

Page 16: ...el tank Refer to Figure 5 The value of resistance will change when the float moves up and down depending on the fuel level Resistance is controlled by using steel wire that is fabricated into the slide The fuel quantity inside the fuel tank can be read on the instrument panel through the electromagnetic fuel gauge 1 FUEL LEVEL 2 FLOAT RISE 3 FLOAT DROP Figure 5 Fuel Level Sensor Power System 8000 ...

Page 17: ...d to remove dust and impurities in fuel The fuel filter is located between the fuel tank and the gasoline pump gasoline engine or oil delivery pump and oil injection pump diesel engine 1 STEEL TUBE CLAMP 2 FUEL FILTER 3 HIGH PRESSURE FUEL PUMP 4 FUEL PUMP FITTING AND GASKET 5 FUEL PUMP MANIFOLD 6 6 STOR 5 16 SAE FITTING 7 3 STOR 5 16 SAE FITTING Figure 6 Fuel Filter PSI 4G64 2 4L Engine The fuel f...

Page 18: ...Kinematic Viscosity 5 7 cSt at 212 F 100 mm2 s CALTEX Torque Fluid 175 RPM torque fluid NO 5 ESSO Torque Fluid 47 SHELL Rotella 10w Clean the oil filter coarse strainer Every 1000 hours Replace the oil filter fine filter Every 250 hours OVERVIEW The transmission is mounted with a torque converter and power gear shift transmission case see Figure 7 The hydraulic transmission case and torque convert...

Page 19: ...greater than the input torque If the fluid flows into the blades of guide pulley in reverse direction it causes the reactive torque to act in reverse This causes the torque of output shaft to be less than the input shaft torque To prevent this the clutch mounted inside the guide pulley allows the guide pulley to rotate freely when reactive torque is reversed This method of torque conversion ensure...

Page 20: ...mbled four spacers item 18 Figure 9 four brake shoes item 19 Figure 9 and one piston item 2 Figure 9 The internal and external surfaces of the piston are fitted with seal rings to ensure a proper seal In NEUTRAL position the piston does not interact with the spacer and the brake shoe While in gear oil pressure controls the piston The spacer compresses against the brake shoe and an the adapter tran...

Page 21: ...tant Pressure Valve Maintains the oil pressure of the hydraulic clutch to be within the range of 1 1 1 4 MPa 159 5 203 1 psi Adjusting Valve It is located between inching valve and controlling slide valve When controlling slide valve is fully open this valve will start adjusting to reduce the impact of clutch during engagement The Overflow Valve The overflow valve is connected to the transmission ...

Page 22: ...1 WOODRUFF KEY 2 O RING SEAL 3 PIN A FORWARD B NEURTRAL POSITION C REVERSE Figure 10 Control Valve Hydraulic Transmission Case and Torque Converter 8000 YRM 2199 14 ...

Page 23: ...ve in which the pressurized oil is divided into two parts One part is fed to the hydraulic clutch and the other part is fed to the torque converter The oil necessary for operation of hydraulic clutch flows into the constant pressure valve the pressure of this valve should be adjusted to 1 1 1 4 MPa 159 5 203 1 psi The oil from the constant pressure valve then flows to inching valve to the controll...

Page 24: ...DUCTION STARTS 16 ELECTROMAGNETIC REVERSING VALVE 17 THROTTLE ORFICE 18 FINE OIL FILTER Figure 13 Transmission Hydraulic Schematic SPEED REDUCER AND SPEED DIFFERENTIAL Speed Reducer The speed reducer is located on the front of the transmission case see Figure 14 This mechanism reduces the rotating speed of output shaft and increased the torque transmitted from the output shaft It sends this torque...

Page 25: ...d between respective gear pairs The planetary gears are supported using gear shafts I and II while gear shaft I is fastened onto the body of speed differential using cylindrical pink and gear ring I is fixed onto the shell of speed differential using articulated bolts See Figure 15 A half shaft gear and half transmit power from the transmission through the differential and to the wheels 1 GEAR RIN...

Page 26: ...rake The axle housing is a cast structure The tire is connected to the wheel hub by the wheel rim with stud bolts and nuts The power is transmitted to half shaft through the speed differential then to the front wheel causing the wheel hub to rotate Each wheel hub is mounted on axle housing by two tapered roller bearings so the half shaft only receives the torque transmitted by wheel hut The oil se...

Page 27: ...ating grease 2 Tighten the lock nuts Make sure that the rotating torque of the wheel hub is 9 8 29 4 N m 7 2 21 7 lbf ft 3 Tighten the half shaft mounting nut Torque to 96 111 N m 70 8 81 9 lbf ft 4 Tighten the wheel mounting nut Torque to 470 550 N m 346 7 405 7 lbf ft 5 Tighten the brake drum mounting Torque to 206 225 N m 151 9 166 0 lbf ft Figure 18 Dual Wheel Drive Axle 8000 YRM 2199 Drive Ax...

Page 28: ...cylinder Hydraulic Steering Gear Assembly The steering system is composed of a fully hydraulic steering gear and steering cylinder See Figure 19 Item 2 The hydraulic steering gear transfers high pressure hydraulic fluid from the bypass valve to the steering cylinder When engine is turned off the pump cannot feed hydraulic fluid and steering may be performed manually The steering column and steerin...

Page 29: ...24 REAR CAP 25 WASHER 26 LIMIT BOLT 35 40 N m 25 8 29 5 psi 27 HEX FLANGED SCREW 35 40 N m 25 8 29 5 psi 28 THREAD BUSHING 29 STEEL BALLS Figure 20 Hydraulic Steering Gear Steering Cylinder The steering cylinder is a double acting cylinder The two ends of piston rod are connected with a steering knuckle by connecting rod Pressurized oil from the fully hydraulic steering gear enables the piston rod...

Page 30: ...der Inspection of Reassembled Steering System 1 Turn the steering wheel to the left and right to confirm both sides will turn to equally 2 Inspect hydraulic oil lines and confirm they are connected in the right direction and properly routed 3 Use a jack to lift the rear wheels Slowly turn the steering wheel to the left and right Repeat for several times to remove any air from the fluid line and cy...

Page 31: ...e air Reset of steering gear out of operation and positioning leaf spring broken Replace leaf spring Excessive internal leak of steering cylinder Inspect sealing of piston Forklift Truck Swinging walk Excessive oil flow Adjust Steering relief valve Warn or damaged steering components Check physical components Abnormal Noise Fluid tank level low Add hydraulic fluid Suction pipe or oil filter blocke...

Page 32: ...nd 140kg 308 6 lbs Overview The steering bridge is an open welded structure with box cross section see Figure 22 It is composed of the steering bridge body the steering cylinder the connecting rod and the steering wheel The steering trapezoid adopts a crank slider mechanism Before and after the steering axle by pry to the frame at the back of the pin shaft through the bearing bolt tail frame swing...

Page 33: ...LE Z1 8 25 OIL SEAL 26 NEEDLE BEARING 27 O RING 28 ADJUSTING SHIM 29 LINK PIN 30 LINK ROD 31 RETAINING PLATE 32 WASHER 8 33 BOLT M8X16 34 KNUCKLE BEARING 35 NIPPLE M6 36 BUSHING 37 STEERING CYLINDER Figure 22 Steering Axle Steering Knuckle and Steering King Pin Steering knuckle is mounted between the upper and lower shaft sleeves on the two ends of steering axle body using steering knuckle king pi...

Page 34: ...rn the wheel hub 3 4 times to ensure a steady rotation Torque to 2 9 7 8 N m 2 1 5 8 lbf ft 6 When rotating torque is higher than the specified value loosen nut by 1 6 turn then check torque again 7 Lock the slot nut using cotter pin when specified rotating torque is reached 1 SLOT NUT 2 GREASING LOCATION Figure 23 Adjustment for Pre loading Brake System Type Front Twin Wheel Brake Internal Expans...

Page 35: ...pplied with the brake fluid from return oil port and oil inlet port When brake pedal is released the piston is retracted by the return spring Brake cylinders are likewise compressed by return spring of brake shoes causing the brake fluid to return to the master cylinder the front cavity of piston through a one way valve The piston returns and the brake fluid in master cylinder flows back to oil ta...

Page 36: ...Figure 25 2 2 5T Wheel Brakes Brake System 8000 YRM 2199 28 ...

Page 37: ...PRING 15 SPRING CAP 16 SPRING 17 SPRING SEAT 18 SPRING PULL ROD 19 SUPPORT PIN 20 SHIM 21 RUBBER PLUG 22 BRAKE CABLE 23 BOLT M8X16 24 WASHER 8 25 BRAKE CYLINDER 26 COVER 27 PISTON ROD 28 PISTON 29 BRAKE CYLINDER CUP 30 BRAKE CYLINDER SPRING 31 OIL PLUG 32 DEFLATION SCREW 33 DEFLATION SCREW COVER 34 DUST CAP 35 RIVET 36 CUSHION 37 SUPPORT PIN 38 CLEARANCE ADJUSTING BOLT 39 WASHER 10 40 CLEARANCE AD...

Page 38: ...OD 21 PIN 22 ELASTIC GASKET 23 ROD PIN RETAINER 24 BRAKE CABLE 25 WASHER 26 BOLT 27 RETURN SPRING Figure 26 3 3 5T Wheel Brake The brake action in forward movement is as follows see Figure 27 Through operating brake wheel cylinder the Brake shoes are effected by two forces of equal size but reverse directions respectively for Brake shoes and brake drum to get into contact with each other while the...

Page 39: ...etween brake shoes and brake drum between 0 4 0 45 mm 0 016 0 018 in for 2 2 5 ton or 0 25 0 4 mm 0 01 0 016 in for 3 3 5 ton However this adjuster only acts during reversing brake During reverse movement the brake shoes will disengage once the brake pedal is activated thereby the secondary and the primarily Brake shoes will begin to get into contact with brake drum for rotation together until the...

Page 40: ...at the parking brake is functioning properly NOTE Coat appropriate amount of lithium base grease onto the guide rail item 6 Figure 29 and apply regularly 1 BRAKE CABLE 2 BRAKING ROPE 3 DISPLAY BRACKET 4 PARKING BRAKE LEVER 5 LOCK NUT 6 GUIDE RAIL 7 NUT Figure 29 Parking Brake ADJUSTMENT OF BRAKE PEDAL 1 Adjust the limit bolts to the pedal location shown in Figure 30 Confirm the distance between th...

Page 41: ...e the spring of the secondary brake shoes and the adjusting lever top lever and the top lever return spring STEP 2 Remove the return springs for the two brake shoes STEP 3 Remove the other three fixed springs 8000 YRM 2199 Brake System 33 ...

Page 42: ... from the wheel cylinder Remove the mounting bolts for the wheel cylinder and separate the wheel cylinder from the bottom plate STEP 6 Remove the E shaped retainer ring that fastens the brake cable onto the bottom plate then remove the mounting bolts on bottom plate and detach the bottom plate from the axle Brake System 8000 YRM 2199 34 ...

Page 43: ...r spring Replace if necessary Specified Value 60 mm 2 4 in for 2 2 5T and 58 mm 2 3 in for 3 3 5T 4 Check the thickness of the brake shoes Replace if excessively worn Specified Value 4 5 7 2 mm 0 18 0 28 in for 2 2 5T and 5 0 8 8 mm 0 20 0 35 in for 3 3 5T 5 Check the diameter of the inner surface of the brake drum to confirm specified value Replace or restore if excessively worn Specified Value 3...

Page 44: ...N 3 3 5t Figure 34 Ratchet spring 10 Check the adjusting spring for damage and confirm the adjusting lever is functioning properly Replace if necessary Assemble Wheel Brake 1 Coat the wheel cylinder rubber cup and piston with brake fluid 2 Assemble the spring rubber cup piston and shield 3 Mount the wheel cylinder on bottom plate NOTE Confirm that all parts are in correct position during installat...

Page 45: ...Mount the guide plate of brake shoes onto the support pin Install the return spring of brake shoes 10 Install adjuster adjuster spring top rod and return spring for top rod Check the following Adjuster thread direction and installation direction For 2 2 5T trucks right hand thread is used for left brake while the left hand thread is used for right brake For 3 3 5T trucks left hand thread is used f...

Page 46: ...ull the adjusting lever to rotate When the adjusting lever is released it returns to its original place The adjuster gear will not rotate NOTE Even when hand brake is released the adjuster will still function properly after being assembled 2 If the adjuster does not return to original position inspect these items a Mount the adjusting lever the top rod the top rod spring and the washer cup b Exami...

Page 47: ...TER Figure 36 Brake Adjuster 3 Check the return spring of top rod and the adjuster spring for damage Confirm no wear or damage 4 Make sure the adjuster gear rotates Confirm no wear or damage 8000 YRM 2199 Brake System 39 ...

Page 48: ...or bolt loosened Repair or replace plate Brake shoes distorted or installation incorrect Repair or replace brake shoes Brake shoes worn Repair or replace brake shoes Loose wheel bearing Repair or replace Brake Drum or Brake Shoe surfaces damaged or distorted Brake fluid on brake shoes Repair or replace brake shoe Clearance of brake shoes not properly adjusted Adjust brake adjuster Wheel cylinder f...

Page 49: ...in 3 2 gal min Lift Cylinder Type Single Act Piston Type with Shutoff Valve one way valve and lower buffer Cylinder Inner Diameter Φ50 mm 2 0 in Φ50 mm 2 0 in Φ56 mm 2 2 in Φ63 mm 2 5 in Stroke 2nd grade Standard Mast at 3m Lifting Height 1495mm Varying along with Type of Mast and Lifting Height Tilt Cylinder Type Double Acting Cylinder Double Acting Cylinder Double Acting Cylinder Double Acting C...

Page 50: ...he gear ends On the drive shaft side a fluid seal is installed on the pump housing A seal between the pump housing and the cover rely on a specially shaped seal ring MULTI WAY VALVE AND PRIORITY SPOOL The 4 disk multi way valve consists of a six plate valve body four spool valves one relief valve and one priority spool The six plate valve body is assembled using three stub bolts and nuts The tilt ...

Page 51: ...ol Valve Primary Relief Valve and Priority Spool Reference Figure 41 The primary relief valve is composed of the two parts a main valve and pilot valve When multi way valve is reversed the high pressure oils in cavity P and working mechanisms such as lift cylinder and tilt cylinder are connected the pressurized oil acts on the pilot valve through the fixed throttle holes When system pressure is la...

Page 52: ... gear and the flow is divided stable in proportion 1 ONE WAY VALVE 2 CONNECTING ORBITROL 3 STEERING OVERFLOW VALVE 4 OIL RETURN 5 MAIN RELIEF VALVE Figure 41 Primary Relief Valve and Priority Spool Inclined Auto Lock Valve The tilt spool valve is fitted with an auto lock valve to prevent vibration caused by back pressure inside the tilt cylinder It is designed to keep the mast of the lift truck fr...

Page 53: ...ilt cylinder HYDRAULIC SYSTEM MAIN OIL CIRCUIT The high pressure oil from the steering control unit is routed to the multi way pump and is split into two parts by the priority spool within the multi way valve High pressure oil is divided to either go to the hydraulic control valve or the SCU Steering Control Unit When the lift or tilt spool valves are at the neutral position the high pressure oil ...

Page 54: ...Figure 43 Oil Circuit of Hydraulic System Hydraulic System 8000 YRM 2199 46 ...

Page 55: ...osed of cylinder body piston piston rod cylinder cover cylinder bottom and sealing parts One port is located in the lower part of cylinder body A return pipe is mounted in the upper part of cylinder body for a small amount of leaked fluid to return to the tank The piston is fastened onto the piston rod using a nut and cotter pin and one seal ring retainer ring and wear ring are fitted on the outer...

Page 56: ... 13 RETAINER RING 14 LOCATER PIN 15 VELOCITY FUSE 16 VALVE SLEEVE 17 CHECK VALVE 18 HOIST CHAIN 19 RETAINER RING 20 ROLLER SPROCKET 21 SHIMS 22 BOLT Figure 45 Lifting Cylinder There is one velocity fuse on the bottom of the lift cylinder see Figure 46 It is designed to prevent load from sudden drop in the event that a hose carrying hydraulic oil should suddenly fail The fluid from lift cylinder pa...

Page 57: ... velocity fuse into cavities A B C D E F and G and into the lift cylinder In an emergency situation caused by a significant pressure drop in the system ex hydraulic hose burst the velocity fuse actuates The hydraulic fluid moves quickly from points G through A causing the internal body of the velocity fuse to the move to the right closing off most oil flow If this occurs the velocity fuse consider...

Page 58: ...he tilt cylinder is a double acting cylinder mounted on each side of the mast The tilt cylinder assembly consist of the piston piston rod cylinder body cylinder bottom guide sleeve and sealing parts The piston and piston rods are welded together One wear ring and two Yx seal rings are mounted on the outer edge of piston A Yx seal ring and dust rings are pressed in the cylinder bore and matched wit...

Page 59: ...lamp the pump gently on a vice stand after cleaning Remove the bolts item 12 2 Detach pump cover item 1 and seal rings items 8 9 10 and 11 3 Remove the front end cover item 7 and seal rings 4 Remove bearings and gears items 3 6 from pump body Bearings may be removed by pressing the gears if it is difficult to remove them Inspection and Repair Clean disassembled metal parts with hydraulic fluid Ins...

Page 60: ...g 2 Inspect that the inner surface of bearing is smooth and the contact surface is shown at the position about at the inlet side See Figure 50 The bearing must be replaced if any of the following cases occurs 1 OUTLET 2 SCRATCH 3 INLET 4 GEAR SIDE Figure 50 Inspection of bearing Hydraulic System 8000 YRM 2199 52 ...

Page 61: ... mm 1 04 in A INNER DIAMETER B TOTAL LENGTH Figure 51 Inner Bearing Inspection Inspection of Gear 3 If clean hydraulic fluid is used the gear shaft and gear surface will not be damaged If roughness is felt on the surface a crack occurs or uneven wear is present replace the gear When gear surface is worn or discolored it indicates that failure has also occurred and must be inspected The limit size ...

Page 62: ...CH 6 DRIVEN GEAR Figure 54 Pump Body 5 Turn over the pump body Put the driving and driven gears items 5 6 into the pump body and allow the engaged teeth to be at the same position as prior to disassembly 6 Mount the bearings items 3 4 on one side of the front end cover using the same method as in 7 Mount the seal ring for pump body item 8 the seal ring for bearing item 9 and seal rings items 10 11...

Page 63: ...le in the in the NEUTRAL position the pressure gauge should read slightly lower than 1 MPa 145 04 psi Keep pump running for 10 minutes 3 Increase rotating speed to 1500 2000rpm and allow to idle for 10 minutes 4 Keep the rotating speed at 1500 2000rpm increase the pressure to 2 3 MPa 290 08 435 11 psi for 5 minutes Repeat until maximum pressure is reached Use overflow valve to increase the load to...

Page 64: ...ING GEAR 6 DRIVEN GEAR 7 FRONT END COVER 8 SEAL RING 9 SEAL RING 10 SEAL RING 11 SEAL RING 12 BOLT 13 LOCK WASHER 14 LOCKING COLLAR 15 OIL SEAL Figure 55 Clockwise Rotation of Gear Pump 2 3 5T Gasoline Forklift Trucks Hydraulic System 8000 YRM 2199 56 ...

Page 65: ...G GEAR 6 DRIVEN GEAR 7 FRONT END COVER 8 SEAL RING 9 SEAL RING 10 SEAL RING 11 SEAL RING 12 BOLT 13 LOCK WASHER 14 OIL SEAL 15 LOCKING COLLAR Figure 56 Counterclockwise Rotation of Gear Pump 2 3 5T Diesel Forklift Truck 8000 YRM 2199 Hydraulic System 57 ...

Page 66: ...Figure 57 Hydraulic Schematic Diesel and Gasoline Forklift Trucks Hydraulic System 8000 YRM 2199 58 ...

Page 67: ...P 48 CLIP 49 CABLE TIE 50 DIVERTER CONNECTOR 51 DIVERTER CONNECTOR TROUBLESHOOT HYDRAULIC SYSTEM Problem Cause Solution Fluid Level Low Fluid level in tank is at low end Fill fluid to the specified level Fluid suction side pipeline or filter blocked Clean or replace fluid if dirty Failure of Gear Pump for Supercharge Bearings are worn and bearing seal rings are at fault Replace Overflow valve misa...

Page 68: ...hat move are fully lowered OR 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 1 Put mast in vertical position 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 fr...

Page 69: ...Figure 58 Two Stage Free Lift and Three Stage Masts 8000 YRM 2199 Lifting System 61 ...

Page 70: ...urement A 54 mm 2 13 in B 15 mm 0 59 in C 18 mm 0 71 in D 38 mm 1 50 in E 92 mm 3 62 in F 120 mm 4 72 in G 160 mm 6 30 in Figure 59 End Face of Inner Mast Measurement A 55 mm 2 17 in B 15 mm 0 59 in C 120 mm 4 72 in D 160 mm 6 30 in Figure 60 End Face of Outer Mast INSIDE AND OUTSIDE MASTS The mast assembly is composed of an inside middle and outside masts the middle masts is only for the 3FFL mas...

Page 71: ...auge block that is 76 mm 2 3 in high to set carriage height Drop the fork to the ground and adjust the nut on the lift chain s upper end to ensure that there is the distance A between the load roller and the inner mast See Adjustment of Lifting System Forklift Model A 2 2 5T 24 29 mm 94 1 14 in 3 3 5T 19 24 mm 75 94 in 1 OUTER MAST 2 COMBINATION ROLLER 3 INNER MAST 4 FORK CARRIAGE 2 Lower the fork...

Page 72: ...s power when the forklift runs and at the same time charges the battery The charging indicator light is used to display the charging status Starting system The starting system is composed of glow plug diesel truck only key switch neutral switch and starter lamp The function of the starting system is to start the engine After the key switch is turned on the glow plug heats up The starting system ha...

Page 73: ...short circuit The relays are used to expand the switch capacity making the small capacity switch able to control high power electrical items BATTERY For truck with a maintenance free battery pay attention to the following 1 When installing and maintaining do not touch the conductor of the battery This may cause serious burns 2 When charging the battery the positive and negative terminals can not b...

Page 74: ...anual drainage is required 4 low oil pressure indicator lamp indicating low engine oil pressure 5 Engine Warning Indicator indicating the engine failure 6 Glow Plug Light indicating that the Glow Plug works 7 the handbrake indicator light indicates that the handbrake is in pull state 8 charging indicator light indicates that the battery is not charged by the motor 9 seat indicator light Indicates ...

Page 75: ...omponents It functions as the forklift truck engine starting control and protection circuit It contains the relays and fuses making the vehicle circuit maintenance more convenient The see Figure 76 and or Figure 77 for the ordinary and expanded PDM Application and function requirements of PDM The key controls the function of the main power supply such as the starting function preheating function f...

Page 76: ...Figure 61 With NISSAN engine K21 K25 Sheet 1 of 2 Electrical System 8000 YRM 2199 68 ...

Page 77: ...Figure 62 With NISSAN engine K21 K25 Sheet 2 of 2 8000 YRM 2199 Electrical System 69 ...

Page 78: ...Figure 63 With PSI engine Sheet 1 of 2 Electrical System 8000 YRM 2199 70 ...

Page 79: ...Figure 64 With PSI engine Sheet 2 of 2 8000 YRM 2199 Electrical System 71 ...

Page 80: ...Figure 65 With Mitsubishi engine S4S Sheet 1 of 2 Electrical System 8000 YRM 2199 72 ...

Page 81: ...Figure 66 With Mitsubishi engine S4S Sheet 2 of 2 8000 YRM 2199 Electrical System 73 ...

Page 82: ...Figure 67 With Xinchai engine Sheet 1 of 2 Electrical System 8000 YRM 2199 74 ...

Page 83: ...Figure 68 With Xinchai engine Sheet 2 of 2 8000 YRM 2199 Electrical System 75 ...

Page 84: ...Figure 69 With Yanmar engine 92 98 Sheet 1 of 2 Electrical System 8000 YRM 2199 76 ...

Page 85: ...Figure 70 With Yanmar engine 92 98 Sheet 2 of 2 8000 YRM 2199 Electrical System 77 ...

Page 86: ...Figure 71 With Yanmar engine 94 Sheet 1 of 2 Electrical System 8000 YRM 2199 78 ...

Page 87: ...Figure 72 With Yanmar engine 94 Sheet 2 of 2 8000 YRM 2199 Electrical System 79 ...

Page 88: ...Figure 73 Optional Accessories Electrical System 8000 YRM 2199 80 ...

Page 89: ...tarting motor functions properly check if the oil supply system is working Example 2 The IC truck could be started but could not move forward or reverse For manually controlled truck the gear is controlled by the lever For the hydraulic controlled truck With OPS installed make sure that the seat and seat belt switch are off and hand brake is on check the gear switch s input and output voltage to s...

Page 90: ...or cap immediately If the forklift truck is running bring the engine idle down to low or medium speed Loosen radiator cap slowly to relieve pressure Once there is no pressure remove the radiator cap 2 Check coolant level Add approved coolant as needed NOTE Radiator cap must be installed completely If the radiator cap is not tight the cooling system can not build adequate pressure 3 Install the rad...

Page 91: ...five minutes before oil level can be checked 3 The engine must be OFF the forklift truck must be on flat ground the mast must be vertical state forks must be on the ground and attachments should be retracted This ensures the hydraulic oil is back in the tank Fill Level Requirements NOTE For items below refer to Figure 74 L line indicates the lowest level of hydraulic oil required to operate the ma...

Page 92: ...LUBRICATION SYSTEM Figure 75 Lubricating System Drive Operation and Routine Maintenance of Forklift Truck 8000 YRM 2199 84 ...

Page 93: ...PDM Schematics 8000 YRM 2199 PDM Schematics 85 ...

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Page 95: ...8000 YRM 2199 Figure 76 PDM Suitable For All Engines 87 88 blank ...

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Page 97: ...8000 YRM 2199 Figure 77 PDM With OPS Suitable For All Engines 89 90 blank ...

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Page 100: ...8000 YRM 2199 1 21 10 20 11 19 10 19 5 19 ...

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