Professional Documents
Culture Documents
Preface
The Manual is mainly about performance, structure, operation and maintenance of LG50DT to
LG100DT forklift trucks. It is convenient for operators and managers to learn the
configuration as well performance so as to operate or maintain the truck accurately.
In order to keep the truck running in good condition, operators and managers should seriously
carry out the safety operation regulations and daily maintenance requirement.
The content will be a little different from the products owing to design improvement of our
products. We are sorry about the change without notice.
Contents
Chapter 1 Safety regulations of driving and operation.................................................................. 1
1. Notification........................................................................................................................1
2. Transportation....................................................................................................................1
3. Storage............................................................................................................................... 1
4. Preparation before operation..............................................................................................1
5. Operation........................................................................................................................... 1
6. Sketch map of gauges and controls' layout........................................................................3
7. Daily Maintenance.............................................................................................................3
Chapter 2 Specification..................................................................................................................7
Chapter 3 Introduction of main components................................................................................. 9
Chapter 4 Forklift structure, principle, adjustment and maintenance.......................................... 10
1. Power system...................................................................................................................10
1.1 General...................................................................................................................10
1.2 Engine configure....................................................................................................11
1.3 Fuel system............................................................................................................ 14
1.4 Cooling system...................................................................................................... 15
1.5 Check and adjustment............................................................................................15
2. Gearing............................................................................................................................ 22
2.1 General...................................................................................................................24
2.2 Torque converter.................................................................................................... 24
2.3 Charging pump...................................................................................................... 25
2.4 Hydraulic clutch.....................................................................................................26
2.5 Control valve and inching valve............................................................................ 26
2.6 Oil piping system of torque converter................................................................... 28
2.7 Warnings when forklift is in trouble...................................................................... 29
2.8 Troubleshooting..................................................................................................... 29
3. Drive axle........................................................................................................................ 33
3.1 General...................................................................................................................33
3.2 Main reducing mechanism and differential........................................................... 33
3.3 Final drive..............................................................................................................37
3.4 Troubleshooting..................................................................................................... 37
3.5 Service data............................................................................................................38
4. Steering system................................................................................................................39
4.1 Steering gear.......................................................................................................... 41
4.2 Check after reassembling the steering system....................................................... 49
4.3 Troubleshooting of steering system....................................................................... 50
4.4 Steering axle.......................................................................................................... 51
5. Brake system....................................................................................................................53
5.1 General...................................................................................................................54
5.2 Drive boosted braking............................................................................................54
5.3 Vacuum boosted braking........................................................................................57
5.4 Service brake......................................................................................................... 62
5.5 Parking brake......................................................................................................... 66
5.5 Troubleshooting..................................................................................................... 68
6. Lifting system.................................................................................................................. 69
6.1 General...................................................................................................................69
6.2 Inner and outer masts.............................................................................................69
6.3 Fork carrier............................................................................................................ 70
6.4 Adjustment of lift system.......................................................................................70
6.5 Mounting positions of rollers.................................................................................72
6.6 Lift cylinder and tilt cylinder......................................................................................... 73
6.6.1 Lift cylinder........................................................................................................ 73
6.6.2 Cutoff valve........................................................................................................ 76
6.6.3 Speed limiting valve........................................................................................... 76
6.6.4 Tilt cylinder.........................................................................................................77
7. Hydraulic system............................................................................................................. 79
7.1 General................................................................................................................79
7.2 Oil pump................................................................................................................ 79
7.3 Multi-way valve.....................................................................................................79
7.4 Operation of multi-way valve................................................................................ 81
7.5 Operation of main safety valve.............................................................................. 81
7.6 Operation of tilt self -lock valve............................................................................ 82
7.7 Control device of multi-way valve..................................................................... 83
7.8 Oil tank.................................................................................................................. 84
7.9 Oil pipeline of hydraulic system............................................................................ 84
7.10 Repair...................................................................................................................87
8. Electrical system..............................................................................................................88
8.1 General...................................................................................................................88
8.2 Brief introduction of operation.............................................................................. 90
8.3 Battery................................................................................................................... 92
8.4 Wiring harness....................................................................................................... 93
2. Transportation
Pay attention when transporting forklifts as follows:
(1) Apply the parking brake.
(2) Fasten mast and counterweight with steel wire. Fill in the relevant position of the front
and rear tires with wedges firmly.
(3) Lift at the right place with lift label when lifting.
3. Storage
(1)
(2)
(3)
(4)
(5)
Release fuel and coolant (but dont release if the coolant is anti-rust or anti-freeze).
Spread anti-rust oil on the non-lacquered parts, spread lube on the lift chain.
Put mast down to the lowest position.
Apply the parking brake.
Fill in wedges under front wheels and rear wheels.
5. Operation
1)
2)
3)
4)
Only the trained operator with license can drive the forklift.
Wear fatigue dress for safety when operating.
Check each control device and warning device, if it is damaged or defective please
mend it before operation.
When transporting, the weight of load should not go beyond the rated value and the
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
fork must be inserted wholly under the load. Make sure the cargo be put on the fork
evenly. Never lift the cargo with a single tine.
Start, turn, run, brake and stop the vehicle smoothly. Speed down the forklift when
turning on dank or slick road.
When driving with cargo, put it as low as possible and tilt the mast backward.
Be careful when traveling on a slope. If the inclination of slope exceeds one tenth,
drive forward when going uphill and backward when going downhill. Never turning
on a slope and dont load or unload when the truck is going down hill.
Pay attention to passengers, barriers and the road condition as well as the overhead
clearance when driving.
People are not allowed to stand on the fork or to be carried on the truck.
Never stand or walk beneath the fork.
Dont operate the truck and the attachment unless you are on the seat.
Prevent the cargo from falling when driving a forklift with high travel mast over 3
meters. Protection measures could be taken if it is necessary.
For the forklift with high travel mast, tilt back as possible as it can, and tilt within the
permitted minimum range when loading or unloading. Pay especial attention to the
clearance above the vehicle.
Be careful and drive slowly when the forklift is running temporary road or gangplank
at dock.
When refueling please shut off the engine and never stay on the truck. Dont ignite
when checking battery or oil level.
When attachment is equipped with the forklift, operate the empty forklift in the same
way as with load.
Dont load loose cargo. Carry big cargo carefully.
Lower the fork to ground, shift in neutral position, and turn off the engine or power
switch before leaving the forklift. Apply the parking brake when stopping on a slope,
fill wedges under the wheels if stopping for a long time.
Dont open the radiator cover randomly when the water temperature is on the high
side.
Safety valve pressure of the directional control valve has been adjusted before the
forklift leaving factory so never adjust it arbitrarily lest high pressure damages the
hydraulic system and elements.
The air pressure of tires should be accord with the prescribed tire Pressure.
The noise number should be less than 89.8dbA exterior the forklift truck, and do
the test following the standard PrEN 12053. If running on the coarse and irregular
road, the noise number will be higher.
Do the test following the standard PrEN 13059At the maximal running speed on
the unloading condition, the vibration number is 2.04m/s.
Pay attention to and be familiar with the function of labels on forklift truck.
8. Ignition switch
2. Hour meter
3. Indicator light
4. Fuel meter
5. Horn button
6. Lamp switch
7. Daily Maintenance
1. Daily Checking
1 . Amount of hydraulic oil: The oil level should be at the middle position of the scale on
the dipstick.
2 . Check if pipes, joints, pumps and valves leak or be damaged.
3 . Check service brake system:
4 . Check the parking brake system: Forklift without load can be parked at 20% slope
normally.
2. Oil, grease and antifreeze
Description
Diesel oil
Diesel engine
oil (CD)
0#
-10#
-20#
-35#
Use temperature
-5
-5-14
-14-29
Code name
5W/30
10W/30
15W/40
20W/50
Use temperature
-30+30
-25+30
-20+40
-15+50
Code name
L-HM32 wearable
hydraulic oil
L-HV32 low
temperature hydraulic
oil
Use temperature
-5
Hydraulic oil
Hydraulic
drive oil
Brake fluid
Grease
Gear oil of
heavy load
vehicle
Code name
85W/90GL-5
80W/90GL-5
Use temperature
-15+49
-25+49
Code
FD-1
FD-2
FD-2A
FD-3
Use temperature
-25
-35
-45
-50
Antifreeze
Recommendation of our company: use Great Wall series of oil or grease first.
3. Cooling system precaution
1 . If the radiator is boiled or the coolant temperature is too high when operating the truck,
dont open the radiator cover immediately. If the radiator must be opened in order to find
out the cause, you should first slow down the engine to middle speed, then screw the
cover of radiator and take off the cover after a while less the coolant bursting out and
scalding the operator.
When screwing down the cover, please screw to the limit, otherwise the pressure could
not be accord with the prescription.
2 . The there is a tank reserve at the left side of engine with FULL and LOW
graduations, the level of antifreeze should between the two marks. Fill the same type of
antifreeze & antirust if there is any leakage or evaporation. Dont change antifreeze with
seasons. After a year use, filtrate and purify the antifreeze and then use continually.
3 . Clear the smudge on the surface of radiator regularly according to different conditions.
Scour, compressed air or high pressure water (the pressure should be no more than
4kg/cm2) are all available.
4 Chart of lubricating system
Chapter 2 Specification
Model
LG50DT
Diesel /
Power type
hydraulic
Diesel hydraulic
General
mechanic
Rated capacity
kg
J Load center
mm
S Front track
mm
P Rear track
mm
1700
mm
3000
mm
Fork
L5 Length
Size
WT Width thickness
5000
6000
1470
10000
1600
200
mm
205
1220
15060
15065
Size
deg
L3 Front overhang
mm
L4 Rear overhang
mm
L2Wheel base
mm
mm
W1 Overall width
mm
2000
mm
2500
mm
2464
mm
mm
Capacity
8000
600
7000
210
1500
1520
17570
17585
706
716
6/12
590
595
645
695
780
2250
4705
4755
3415
3400
4760
2800
5486
5520
2230
2595
2845
2650
3415
5400
Km/
2500
3680
4000
5600
5960
310/350
330/410
10500
13000
27/27
h
mm
330/450
/s
Max. gradability
Self weight
kg
mm
216
240
mm
248
300
90
110
150
170
mm
20
8082
8537
903
8981
903
1075
Description
Contents
Power System
Power Train
Steering System
Accelerator pedal
Flameout control
unit
Brake lever
Bodywork
Lifting System
10
Accessory
11
multi-way valve
12
Hydraulic System
pumps, valves, high & low pressure hoses, joints, lift cylinder
steel tube, etc.
13
Overhead Guard
14
Electrical System
15
Decal
flameout cable,rod,etc
foot brake & inching setting,etc
Control handle
Figure 1.2
Main performance parameters, structure and configuration of Yuchai 6BG1 are as Table below:
Name
A- 6BG1QC
Type
Cylinder number-cylinder
diameterstroke
6-105mm125mm
6.494
compression ratio
17
performance
Rated rotation speed (rpm)
2000
82.3
416/1400-1600
233
700
Weight (kg)
450
Sizemm
1129.5672.0860.0
Order of ignition
1-5-3-6-2-4
Rotation direction
valve device
Overhead device
fuel device
Fuel injection pump
dip cooling
9.5mm8mm
Jet burner
spongy
piston
Fuel filter
Speed regulator
Speed adjustment mode
Lubricating way
Compelling cycle
Lubricant device
Pumping
Gearing
Drive mode
Camshaft drive
Piston, spring
switch0.3kg/cm2
Filter mode
Cooler
Cooling installation
Cooling mode
Water cooler
Fan cooler
Drive mode
Belt transmission
Pump mode
Eddy-current
Drive mode
Belt transmission
82
95
Start engine
Mode
Voltage
24V
Output power
4.5KW
Choke
Preheating device
Charge engine
Mode
Voltage
24V
Output
25A
Drive mode
Belt transmission
Charge auto-regulator
Reference parameter
Oil disc capacity
Max13Min10
12
Valve clearance
Espirating valve
Exhausting valve
Espirating valve(off)
Exhausting valve(on)
Exhausting valve(off)
Injection period
Injection pressure
185kg/cm2
Compression pressure
31kg/cm2200rpm
2.
3.
4.
5.
Check the fuel level per shift, and avoid filling fuel after it's used up;
The fuel tank shall be filled after each shift ends, to prevent the air entering fuel system, if
the air enters, it shall be removed.
Check whether the fuel tank leaks.
Check the sealing condition of fuel tank cap and whether it leaks air.
After 250h operation, replace the fuel purifier and remove the system water.
After 1500h operation or a year, clean the fuel tank and remove all the impurities and
water in the fuel tank.
1.3.
2 Fuel sensor device
1.3.2
The fuel sensor device (shown in Fig. 1.4) is to convert the up and down movement of the
floater which is caused by the amount of fuel into electric current. The current then reflects on
the fuel meter which tells people the amount of the fuel intuitively.
Fuel filter
The fuel filter which connects with a intake fuel pipe on the engine filtrates the fuel supplied
to the engine. There is a bypass valve in the filter, which is used to serve the engine when the
filter should clog or plug.
1.4 Cooling system
The cooling system is made up of a water pump, a fan, a radiator and a tank reserve. The water
pump which attaches to the engine is driven by the crankshaft through a V-type belt.
1.5 Check and adjustment
To keep the engine in a good working trim, regular check and adjustment should be taken. The
main points are shown as follows:
Figure
2)
D. Inject prescriptive coolant. Start the engine in idle speed then check if the level of the
coolant in the tank reserve is at the 2/3 scale.
(3) Adjust fan belt
Tension the fan belt if it goes slack. See Fig.1.9.
Process: Remove the fixed bolts
B and
C on the generator and move the generator to the
A using
outside in order to get about 10mm flexibility when the fingers press on the belt
10kg force. Then screw down bolts
B and
C in order.
Figure 1.9
1.5.5 Fastening of the cylinder head bolts on the engine
(1) Screw down the bolts under 68 Nm
torque orderly as Fig. 1.10 shows.
(2) Increase the torque to 93 Nm to screw
down the bolts.
(3) Turn 90of the bolts to fasten it.
Fig. 1.10
Fig. 1.11
Fig. 1.12
Fig. 1.13
1
I
2
E
3
E
4
E
5
E
6
E
Fig. 1.14
Fig. 1.16
Fig. 1.15
Fig. 1.17
Figure 1.18
1.5.10 Exhaust of injection pump (Figure 1.19)
(1) Unclench the exhaust plug.
(2) Operate the hand pump slowly until no air bubble comes out of the plug.
(3) Then fix the plug tightly.
Figure 1.19
2. Gearing
The gearing mainly includes two parts, torque converter and transmission.
Table 2.1 shows the basic parameters and Fig. 2.1 shows the structure of gearing.
Table 2.1
Items
Units
Type
Torque
converter
0.50.7
Internal gear pump; Transmission
power output
Type
Oil pump
Flow
l/min
Type
Power-Shift
Gears
Transmission
1.621/0.526
Friction
plates
mm
Friction area
cm
77.4
Set pressure
MPa
1.21.5
Mass
kg
About 295
Oil capacity
About 20
Hydraulic
Clutch
Oil type
9. Parking brake
2. Charging pump
10. Filter
3. Ball bearing
19. Gear
4. Shaft
12. Gear
5. Ball bearing
6. Torque converter
14. Shaft
7. Ball bearing
8. Gear
2.1 General
The hydraulic transmission used in the forklift consists of the torque converter and the
power-shift transmission. It has the advantages below:
1) The inching valve assembled improves inching performance. So it can keep the
performance either starting the truck or at any rotate speed.
2) The friction plates of the hydraulic clutch contain seven steel plates and seven papery
friction plates. Thus it has good durability.
3) There is a unilateral clutch in torque converter to improve the gearing efficiency.
4) A filter is mounted in the torque converter oil piping system, therefore the cleanness is
improved and the life-span of torque converter is increased.
2.2 Torque converter
Torque converter of single-turbo, triple-element usually consists of a impeller wheel fixed on
the input shaft, a turbine wheel fixed on the output shaft and a stator wheel fixed on the torque
converter housing.
The impeller wheel is powered by elastic board which connects with the flywheel. It rotates
when the engine runs. The fluid in the impeller wheel is injected through the impeller wheel
blades as a result of centrifugal effect. At this moment the kinetic energy converts into
hydrodynamic energy.
Therefore the fluid comes into the blades of the turbine wheel and routes the torque to the
output shaft .The leaving direction of the fluid from the turbine wheel changes because of the
action of the stator wheel .Thus the fluid flows into the impeller wheel from the perfect angle
and produces a countertorque that impels the stator wheel. As a result, the output torque is one
countertorque larger than the input torque.
When the speed of turbine wheel increasing and approaching to the input speed, the change of
the fluid angle reduces and the output torque decreases as well. Finally, the fluid flows into the
stator wheel blades in the contrary direction and thus the countertorque acts reversely. In this
case, the output torque is smaller than the input torque. In order to prevent such case from
occurring, a unilateral clutch is installed inside the stator wheel. When the countertorque acts
reversely, the stator wheel runs freely. In such working condition, the input torque equals to
the output. Thus it ensures the torque converter run in high efficiency.
The torque converter changes the transfer of torque by means of mechanical method (clutch).
It plays both parts of coupling and converter, so it is called two-phase. Its characteristics are
smooth operation and high efficiency.
There is a unilateral clutch, a turbine wheel, an impeller wheel and a stator wheel inside the
torque converter which is full of hydraulic oil.
In the front of impeller wheel is a gear that meshes with the drive gear of charging pump
driven by the engagement.
The turbine wheel moving over the splines of the input shaft of the transmission transmits
Figure 2.5
Reverse clutch
Figure 2.7
The oil pressure of clutches in transmission is adjusted to 1.2-1.5MPa by its pressure control
valve and the oil of torque converter is adjusted to 0.5-0.7MPa by the torque converter
pressure control valve. Then the pressure oil gets to the torque converter blades. After the
pressure oil is cooled by the cooler it flows out to lubricate the clutches. Finally, the oil
returns to the reservoir. It circulates in such a way like this.
When the lever of the shift control valve setting in the neutral place (idle gear) the oil from
the shift sliding valve to the clutches will be cut off and the fluid will all come into the
torque converter.
When the lever of the shift control valve set in the forward or reverse place, oil will flow
into the clutch hydraulic chamber and act on the piston by the action of pressure control
valve. So the oil pressure will increase continuously in the period of clutches starting action
to being completely engaged.
When the hydraulic chamber is full of pressure oil, the pressure will increase acutely and
the hydraulic clutches will be in thorough engagement. If one kind of forward or reverse
clutches run and the other are out of mesh, the clutches will be lubricated and cooled by oil
from the cooler, which prevents conglutination of plates.
Inching valve acts when inching pedal is stepped on. Most of the oil in clutches loses
pressure through the inching valve and returns to the reservoir (called the oil pan). The oil
passages are the same as that of the idle gear.
2.7 Warnings when forklift is in trouble
When the forklift is in trouble and can not move by itself, however we want to drag it by
other facilities, attentions must be paid to the requirements blow:
1)
2)
Place the shift lever in the neutral position (called idle gear).
If the charging pump doesnt work there wont be good lubrication. Conglutination will
appear if the rotation of drive wheels is transmitted to the transmission gears and clutches.
So the transaxle must be disassembled.
2.8 Troubleshooting
(1) Deficiency of power: see Table 2.2.
(2) Abnormal rising of oil temperature: see Table 2.3.
(3) Loud noises of transmission: see Table 2.4.
(4) Low transmission efficiency: see Table 2.5.
(5) Oil leakage: see Table 2.6.
Causes of malfunctions
Checking methods
Solutions
Add oil
Refasten
connections and
replace seals
Clean or Replace
(4)Insufficiency of charging
pump displacement
Replace
Torque converter
Replace
Replace
B. Flywheel damages or
collides with other parts
Replace
Check
Screw down
connections or
replace
Adjust the
pressure
Adjust the
pressure
Replace
Replace
C. Incorrect position of
inching linkage and shift
lever
Engine
Transmission
B. Slide of clutch
Adjust
Torque converter
Parts
Causes of malfunctions
Checking methods
Add oil
Clean or Replace
(4)Air is sucked
Repair or Replace
Solutions
(1)Slide of clutch
Repair or Replace
Replace
Transmission
Torque converter
Parts
Causes of malfunctions
Checking methods
Solutions
Replace
(3)Breakage of gear
Replace
(4)Abrasion of spline
Replace
Repair or Replace
Replace
(2)Breakage of gear
Replace
(3)Abrasion of spline
Replace
(4)Loosening of bolts
Causes of malfunctions
Transmission
Torque converter
Checking methods
Solutions
Replace
(4)Breakage of shaft
Replace
(1)Deficiency or overabundance
Check the oil level
of oil
Replace
(4)Breakage of shaft
Replace
Replace
Replace
Replace
Causes of malfunctions
Checking methods
Solutions
Discharge the
redundant oil
3. Drive axle
Basic parameters of drive axle can be seen in Table 3.1.
Tonnage
Items
Type of drive axle
5 7t
Type
Main
reducing
mechanism
10t
Reduction ratio
Type
6.33
Planet gear type
Final drive
Reduction ratio
Total reduction
Oil
capacity
4.25
3.67
20.72
22.66
10L
Final drive
8.25-15-14PR
9.00-20-14PR
Rim
6.50-15
7.00T-20
wheels
Pressure
kPa
800
3.1 General
The drive axle shown in Fig.3.1 and Fig 3.2 consists of main reducing mechanism, differential,
final drive, service brake and parking brake (forklift with YQX5 transmission), etc. It is fixed
on the sector board of the frame and the mast is mounted on the drive axle housing.
3.2 Main reducing mechanism and differential
The final drive and the differential are basically composed of the left and right differential
case, the ring gear (the spiral bevel gear) and the drive pinion, etc. These parts which are all
assembled in the final drive housing, as the figure 3.3 shown, they are fixed on the drive axle
housing through washers.
The housing of the differential adopts the two-piece housing. Left and right housing are
connected with bolts. The interior of the housing contains the axle shaft gear and planetary
gear which is fixed on the spider. These two kinds of gears are meshed with each other.
The shaft of the drive pinion is supported by two tapered roller bearings, which is mounted in
bearing support. The bearing support is fixed on the main differential housing through gaskets.
The ring gear adopts the spiral bevel gear type, it is connected to the right differential housing
by bolts. The power from the transmission is decelerated through the pinion shaft and the ring
gear.
7.Hub
13.Shaft
2.Axle shaft
14.Steel ball
3.Brake
9.Adjusting nut
4.Brake drum
10.Locknut
16.Ring gear
5.Oil seal
17.Sun gear
12.End cover
7.Hub
13.Steel ball
2.Axle shaft
14.Shaft
3.Brake
9.Adjust nut
15.Sun gear
4.Brake drum
10.Locknut
16.End cover
5.Oil seal
17.Ring gear
12.Planetary gear
2.Bearing cover
3.Lock plate
7. Planetary gear
9.Spider
14.Roller bearing
16. Locknut
17.Adjusting bolt
20.Bearing support
21.O-ring
22. Lining
26.Oil seal
27.Flange
28. O-ring
29.gasket
30.Locknut
Cause of malfunction
Loud noises of
differential
Solution
Screw down or replace
Clean or replace
Replace
Replace
Replace
Adjust
Replace
Differential
Parts
Items
mm
0.10.20.5
69.95-70
0.036-0.067
0.20-0.30
2.5-3.5N.m
0.25-0.38
100-150N.m
100-150N.m
1.526-1.613
The spline teeth clearance used for connecting the axle shaft gear
and the axle shaft.
Bolt tightening force used for fixing the axle housing and the final
drive housing.
The fit diameter of the small bearing(figure 3.1, the serial number is
Axle housing
Standard values
0.038-0.130
100-175N.m
89.66-89.88
109.913-110
630-946N.m
280-330N.m
Hub
axle housing.
The fit diameter of the axle housing and the mast
189.2-190
The fit diameter of the wheel hub and the small bearing
159.32-159.72
The fit diameter of the wheel hub and the large bearing
179.32-179.72
The fit diameter of the wheel hub and the oil seal
164.6-165
The bolt tightening torque for fixing the brake drum and the wheel
hub
The bolt tightening torque for fixing the wheel hub and the planetary
gear carrier
The tightening torque of the wheel nut
280-330N.m
98-113N.m
480-560N.m
4. Steering system
See the table 4.1 for the main specifications.
Tonnage of forklift
5-7T
8-10T
Items
Type of the steering system
350
Model
Steering
gear
Displacement
ml/r
280
Rated pressure
MPa
16
Type
Steering
cylinder
Flow
divider
mm
2128
2130
Adjusting pressure
MPa
12.3
12
Rated flow
l/min
25
24
Type
Steering
axle
115/85
76/50
1700
1500
wheel
42
Tire
8.25-15-14PR
9.00-20-14PR
Rim
6.50-15
7.00T-20
Pressure
kPa
800
The steering system is made up of the steering wheel, the steering column (contains steering
shaft and the lock handle), the universal joint assembly, the steering gear, the steering axle
and the steering cylinder. See the figure 4.1 for the steering control device.
The universal joint connects the steering shaft to the steering gear. The steering wheel drives
the steering shaft and the universal joint to make the steering gear work and realize the
hydraulic steering. The steering column supporting the steering shaft can slanted to the
certain degree and can be adjusted to the proper position to meet different drivers needs.
1.Steering wheel
2. Universal joint
5. Drive axle
Figure 4.2
Figure
4.3
7.Rotor
2.Valve body
5.Spring plate
8.Stator
3.Valve core
6.Connecting block
9.Valve housing
steering system is in good working trim under all kinds of running conditions. If the
steering is heavy or failed, please carefully find the causes and dont force steering wheel
to run. Moreover, dont disassemble the parts of redirector arbitrarily lest the parts should
be damaged.
Check if the pressure of the system accords with the prescription when the piston rod of
cylinder reaches limit positions.
(7) Maintenance
Check whether or not there is oil leakage and check the oil level of oil tank as well as
working condition everyday. Replace filter elements and fluid regularly by prescription.
Put a drop of oil on a piece of blotting paper to check the hydraulic oil. If there is a black
center of oil mark, the oil can not be used anymore. If abnormal situation happens, find out
the cause carefully. Turning steering wheel simultaneously by two individuals is strictly
forbidden.
4.1.4 Check and repair of steering control unit
In order to keep steering system running in good condition and avoid accidents, please
check regularly.
1) Check water capacity, mechanical impurity and acid number of working fluid termly. If it
exceeds the prescription of original trademark, replace the fluid with new oil. Oil that
has been used but isnt filtered is forbidden.
2) Dont disassemble the steering unit arbitrarily in the checking of steering system. After
having made sure the redirector malfunctioned, disassemble it according to assemble
warnings.
3) All the tools used to disassemble the parts should be clean, the ground should be tidy. It is
better to work indoors.
4) Assemble warnings
a. Clean all the parts with gasoline or kerosene before assembling. If there is any paint on
joint surface, wipe it with acetone. Dont wipe the parts with cotton yarn or tatter, use
brush or silk. Compressed air can be used to if condition permits. Rubber ring must not
be soaked in gasoline too long. After the steering gear being assembled, add 50-100ml
hydraulic oil to the inlet port before fixing on forklift, then turn the valve core left and
right. Fix it on the truck if no abnormal phenomenon happens.
b. Joint surfaces of valve body, separation disc, stator and back cover should be kept in
highly cleanness. Be careful not to impact or nick the surfaces.
c. Pay attention to that the screw joint must below the valve body flat.
d. Both snap ring and slip ring have one of the sides chamfered. The chamfered side of
snap ring should face front cover and the chamfered side of slip ring should face valve
core.
e. There are punched point marks on the surfaces of rotor and link rotational shaft ends.
The two points should be placed opposite to each other in assembling.
f. The washers of position restricted bolts with pins should be made of copper or
aluminum.
g. Fastening method of the seven bolts on the back cover: screw the bolts every three ones
and dont screw down at one time. Fasten them gradually. The fastening force is
30-40N.m.
h. Pay attention to the inlet, return, left, right marks on valve body when installing
hoses. The marked ports should be matched with the hoses rightly.
5) Disassembling and assembling (see Fig. 4.5)
a. Disassembling sequence: front coversnap ringslip ringvalve housing, etc
(washer dial pinvalve corespring plate)back coverposition restricted column
stator rotorlink shaftseparation discscrew jointsteel ballvalve body.
If back cover is first removed, steel ball must be taken out first before valve core and
valve housing being taken out, or else valve body will get stuck and be damaged. Be
careful not to impact or nick the other end surface of valve body in removing front
cover.
b. Assembling sequence: valve corespring platevalve housingdial pin washer
valve body slip ringsnap ringfront coversteel ballscrew jointseparation
disc link shaftrotorstatorposition restricted columnback cover.
Cause
Dunghill exists on joint
surfaces
Oil
leakage
Heavy
steering
Phenomenon
Oil leaking from joint
surfaces of valve body,
separation disc, stator and
back cover.
Solution
Clean the accessories
again
Unsmooth surface of
washer on position
restricted bolt
Rubdown or replacing
Trouble
Steering
failed
Steering
Wheel cant
Return to
Middle
position
automatically
No
Manpowered
steering
Cause
Phenomenon
Solution
Replace
damaged
spring plate.
Replace dial
pin
Replace link
shaft
Assemble
again
according to
assembling
warnings.
Bidirectional shockproof
valve fails (steel ball gets
stuck or spring fails)
Clean
bidirectional
shockproof
valve.
Eliminate
troubles
according to
causes
Replace
rotor and
stator
4)
5)
Check if pipe lines are rightly laid and the left and right hoses for steering are changed
with each other.
Turn the steering wheel left and right to limit position. Check if the power of turning left
is equal to that of turning right and if the turning is smooth.
After the steering system being assembled, first raise steering cartwheels and run the
engine in idle speed, then turn steering wheel left and right slowly several times to get rid
of the air in hydraulic pipe lines and steering cylinder. Put down steering cartwheels then
turn steering wheel several times. Check if the noise is normal when turning. If there is
no abnormal noise, it means the air has been driven out. Finally set the engine running in
idle speed to raise oil temperature.
Measure operating force for steering:
Stop forklift on dry and smooth road and apply parking brake. Attach spring balanced
device to the brim of steering wheel to measure the operating force for steering which
must below 150N.
Adopt pressure gauge with a range of 15-20MPa to test the pressure. Connect flow
breaker with hose like which is shown in Fig. 4.6.
Warnings: oil pump supplies pressure oil to drive steering cylinder. There are two aspects of
its running to take into account, thats rated pressure and rated flow.
Pressure is used to drive cylinder while flow relates to working speed of cylinder. Therefore,
even if pressure is normal and reaches 12MPa but flow is deficient, the steering cylinder
will still run abnormally and it will cause heavy steering. So adjust flow valve and safety
valve properly according to capacity and working condition of steering cylinder when flow
divider requires disassembling and reassembling. Make a matching mark on the adjusted
position for reassembling or measure the distance of adjusting bolts.
4.3 Troubleshooting of steering system
Troubles and solutions of steering system caused by flow divider are shown in Table 4.3.
Troubles
Steering wheel is obstructed
when turning quickly.
Causes
Flow control valve lever gets stuck.
Solutions
Disassemble and repair
or replace.
Figure 4.7
Steering axle
1.Axle
11.Adjusted shim
21.Nut,hub
31.Bracket, axle
2.Power cylinder
12.Oil seal
22.Hub
32.Plate
13.Bushing
23.Snap ring
33.Seal shim
4.Pin
14.Pin,king
24.Bearing
34.Bearing
5.Bearing
15.Cap,hub
25.Oil seal
35.Fitting, grease
6.Bearing
16.Cap,hub
26.Locking pin
36.Steel bearing
7.Bearing,needle
17.Fitting, grease
27.Nut
37.Shim
8.Spacer
18.Fitting, grease
28.Washer
38.Shim
9.Knuckle (right)
19.Nut
29.Cap,hub
39.Shim
10.Knuckle (left)
20.Bolt,hub
30.Pin
40.Link assembly
(left)
5. Brake system
For basic parameters, see Table 5.1.
Model
5-7T
Domestic
engine
Items
8-10T
Import
engine
Type of braking
Vacuum servo
Type of brake
Drive boosted
317.5
438.15
31.75
47.62
32410010
48910012.7
4324
4489
Type
Parking Inner diameter of brake drum mm
brake Dimensions of friction lining on shoe
brake lengthwidth thickness
mm
Area of friction lining
c
Brake cylinder
mm
140363.5
50.4
31.75
9"/10"
Type of wide-open/type of
closed-end
Type of spring
27
10.5
Type of spring
cc
66.7
mm
50 34
MPa
7.2/4.9
MPa
13
MPa
Type
Storage Cubage
storage Piston dia. journey
Tank Oil pressure: max/working
160
5.1 General
The brake system consists of two parts, service brake which is assembled in the drive axle and
parking which is connected with the middle shaft at the back of transmission or the input shaft
of drive axle.
The method of the service brake is drive boosted.
5.2 Drive boosted braking
Dynamic service brake system is composed of brake pedal, brake valve, accumulator and
brake.
Dynamic brake is available by pressure oil which is exclusive for forklift hydraulic system and
transferred by the small gear pump. There are two oil ways, one is into Brake Valve and then
to brake transfer pump to create brake; the other is into accumulator for standby. Both of oil
ways are controlled by Brake pedal stroke.
Figure 5.2
Brake pedal
No brake
In the state of no brake, because brake valve port is open, pump port links with steering gear,
steering works. When brake pedal is not stepped and steering control doesnt produce brake, oil
D chamber doesnt rise, because port
D is closed.
pressure of control oil in
bushing 7 and recoil piston 5 is pressed toward left by spring group 8, at the same time, return
Spring 6 presses toward left.
B
A is closed, port
D disconnects with oil return
Owing to Part 7s movement, port
B is open, making port
D link to pump port.
tank. Port
At this moment, Valve Bushing 7 moves toward left again. Owing to the pressure on
C , oil pressure in pump port and chamber
D rises. i.e., oil pressure through
port
D pushes Recoil Piston 5,
brake transfer pump also rises. High pressure oil in chamber
3)
When right end of piston inputs max. pedal force, position is limited by bolt and pedal
D is over max adjustable oil pressure.
bracket to avoid oil pressure in chamber
When foot is moved away from pedal, valve bushing 7 is reposition by the reverse force
of Recoil Piston and part 6, 8 spring reverse force, and then brake process is completed.
Accumulators working process
When Oil Pump stops working (Owing to engine flameout) or is damaged, accumulator
would be in working.
A Step the brake pedal again, valve bushing 7, recoil piston 5 and check valve contact pin
D
3 move toward left. Contact Pin opens ball, at this moment, chamber
and
accumulator port link. Pressure oil in accumulator is available for brake branch pump.
B Foot moves away from pedal. valve bushing, recoil piston and contact pin move toward
right at the same time. Under the spring force, ball of check valve joint again with valve
seat, (check valve is closed) contact pin stop at this position.
C
4.piston bracket
7.valve cover
2.valve bracket
5.piston
8.spring
3.valve pin
6.spring
9.oil seal
10.piston
5.2.3 Accumulator
When engine stops work or oil pump fails, accumulator can be used as extraordinary energy for
brake. Power is accumulated by spring way. It is very dangerous of making maintenance when
the accumulator is accumulated. When engine is stopped, the pressure of the accumulator can be
completely released by continuously operating the brake pedal up and down several times, then
do the maintenance.
Illustration is under the no accumulation state. Alarm switch buzzer is under the constant sound
state.
When controlling brake pedal and oil pressure is over 3.9 MPa, check valve opens, accumulator,
oil flows in and push piston moves toward left and spring group is compressed, so that oil
pressure is generated.
At the same time, piston moves toward left, and makes the switch control lever of alarm switch
move toward left under the pressure of spring. Switch valve core is in the switch control levers
groove and the alarm switch is under the silence state.
With the rise of oil pressure of pump, position limiter in the middle of spring limits the left
stroke of piston. At this moment, accumulator has the max. energy; oil pressure is 13 MPa,
which is controlled by safety valve.
Figure 5.4
Units
Numerical Value
Max
mm
263
Min
mm
236
mm
39
Brake master
cylinder
Diameter
mm
31.75
mm
38
ml
15.8
ml
14.2
mm
272
Size of plate
mm
60804-M8
Size of outlet
mm
2-M101
Dead weight
kg
5.3
Figure 5.6 Structural diagram of vacuum booster and brake master cylinder
1.Control valve push rod
10.Feedback disc
4.Control valve
14.Return spring
1) Nonworking condition
When the vacuum booster doesn't work,big conical spiral spring 3 will push control valve push
rod 1 with control valve piston 5 to the back terminal point. Air control valve would be tightly
depressed on piton 5 by small conical spiral spring 6 therefore the inlet of air valve is closed. At
this moment,the two front and back cavities of force adding chamber are connected through
passage, control valve of chamber and passage B and separated from the atmosphere. There
would be some degree of vacuum in both the front and back chambers when the engine and
vacuum pump are running.
2) Braking condition
a. As soon as the brake pedal on, the force applied would be magnified by lever and acts on
control valve rod 1 and depresses element 3 to move forward with element 5. By the
actions of feedback disc 10 and master cylinder push rod 13,some pressure which is sent
to wheel brake cylinder (wheel pump) inside the brake wheel comes into being in the
interior of brake master cylinder. At the same time,air control valve 4 is pushed forward
with element 5 by the small conical spiral spring 6. It contacts with the inlet of vacuum
valve and closes it. Therefore, the front and back cavities of force adding air chamber are
separated,that is to say the back cavity of force adding air chamber is separated from
vacuum source.
b. With the continue moving of control valve push rod, control valve piston 5 leaves element
4 and the outside atmosphere goes through air filter bed 2, control valve chamber as well
as passage B and is charged into the back cavity of force adding air chamber. In this way,
a small part of the forward force, which is produced by the pressure difference of the two
cavities of force adding air chamber,is used to balance the force of big conical spiral
spring and the rest large part acts on the feedback disc through control valve body 7 and
then is transited to the master cylinder. So it plays the part of booster.
3) End of braking and getting back to nonworking condition
a. In the process of stepping on brake pedal that is to say in the forward moving of control
valve push rod, the air continuously comes into the front and back cavities of force adding
chamber through the open inlet of air valve and the control valve body also moves forward
continuously. When the brake pedal stops at the position where it closes the inlet of air
valve. The vacuum inlet and air valve inlet both close up at this time and the booster is in
balance of three forces: air pressure difference of force adding chamber's front and back
cavities, oil pressure of brake master cylinder and thrust of control valve push rod. In the
end, the wheel brake is in braking.
b. As soon as the pedal is released, return spring 14 and big conical spiral spring 3 push
control valve rod 1 and piston 5 backward and then control air valve 4 leaves the inlet of
vacuum valve, where upon the braking comes into an and the assembly returns to
nonworking condition.
5.3.2 Mounting method of vacuum booster and brake master assembly
1Fix the installation bracket with for M8 bolts to the forklift frame and then connect the
adjustable fork at the end of booster with brake pedal linkage. Finally, screw down the
bolts witch four M8 nuts. The tightening moment is 12N.m-18 N.m
2Connect vacuum hose with vacuum hose fitting. Ensure a sealed assembly.
3Connect the brake oil tubes witch two M10*1 outlets of brake master cylinder. The
tightening torque is12 N.m-16 N.m
4Open the cover of reservoir and inject brake fluid with no dust or impurity to expel all the
air in the whole brake system.
5When replace the brake master cylinder or vacuum booster separately, the tightening
torque of the connecting nut between them is 12N.m-16N.m
6Don't arbitrarily adjust the push rod head on the mating surface of vacuum booster and
brake master cylinder.
5.3.3 Warnings for consumers
1Certified brake fluid must be used in our products.
2When brake fluid is injected in the assembly, air should be emptied in the piping.
3After the air is expelled, observe the level of fluid in the reservoir which should be in the
middle position.
4If troubles listed in table 5.3 occur,the vehicle must be repaired by qualified professionals.
Customers must not venture to disassemble it.
5.3.4 Malfunction and analysis of causes
Malfunction and phenomenon
Analysis of causes
in
master
Pressure of output oil is not high & force 1.Vacuum leakage of booster
applied to the pedal becomes heavy
2.Vacuum piping leakage of engine
5.
4 Service brake
5.4
The service brake is an internal expanding, shoe brake. There are two service brakes mounted
symmetrically on the drive wheels which are at the two ends of drive axle. The brake consists of
a pair of brake shoe assemblies (include a primary brake shoe and a secondary brake shoe),
brake cylinder (5-7T has one wheel,8-10T has two wheel), a clearance regulator, three or four
return springs and a brake soleplate. Glued or riveted to the outside of each shoe is a brake
lining. The clearance between brake shoe lining and brake drum internal surface is adjusted by
the regulator.
5.4.1 Service brake (5-7T) (Fig 5.8)
There is only one wheel brake cylinder in each service brake of 5-7t forklift. The two ends of
the cylinder piston rod contact respectively with the tops of primary and secondary brake shoes.
The bottoms of brake shoes touch with the two ends of clearance regulator and are depressed on
the brake soleplate by spring pull rod.
The automatic clearance adjusting device usually works when backing a forklift and applying
the brake. The adjusting lever turns the regulator gear over one tooth if the clearance becomes
large. The adjusted clearance value would between 0.4-0.6mm. (Fig 5.7 shows the rotation
direction of regulator gear in the adjusting)
For the 5-7t Forklift service brake has two
forms of braking system, the cups of the
brake wheel cylinder are made of oil resistant
rubber. The vacuum booster cups are made of
leather or synthetic leather. More attention
should be paid when relace the parts.
Figure 5.7
6.Push rod
11.Regulator spring
2.Return spring
12.Adjustment lever
3.Dust ring
8.Return spring
13.Regulator
4.Leather cup
14.Return spring
5.Piston
10.Preload spring
Figure 5.10
6. Leather cup
2. Regulator
7. Dustproof ring
3. Push rod
4. Piston
9. Return spring
5. spring
5 Parking brake
5.
5.5
The parking brake which is an internal expanding, shoe brake is mounted on the output end of
middle shaft shown in Fig. 3.1, item 9 at the back of transmission. The detailed structure can
be seen in Fig. 5.12.
Figure 5.11 shows the operation of parking brake. The operation force applied by hand cant
exceed 300N when forklift is parked on a slope with rated load. Please adjust the pull in the
direction shown in picture. B is the force measuring point.
7.Return spring
13.Bracket
2.Brake shoe
8.Regulator
14.Pin
3.Fixed bol
9.Regulator spring
15.U-keeping ring
4.Nut
10.Pin
16.Piston
5.Spring washer
17.Brake cable
6.Washer
12.Rod
5.5 Troubleshooting
Table 5.4
Troubles
Solutions
Repair
Adjust
Overheating of brake
Poor Brake
Poor contact of bake drum and friction plate
force
Impurity adheres to the surface of shoe brake
Check if sliding
Adjust
Repair or Replace
Adjust
Uneven
braking
Repair or Replace
Replace
Replace
Repair or Replace
Repair or Replace
Repair or Replace
Adjust
Adjust
Repair
AdjustRepair
Expel
Adjust again
6. Lifting system
Main specifications are shown in Table 6.1.
5-7t
8-10t
Type of mast
3000mm
3500mm
Roller
6/12
mm
151.5
203.5
mm
82
64
102
119
LH2044 Chain
pitch 31.75
LH3234
Chain pitch 55
Hydraulic
Hydraulic
Manual
Hydraulic
6.1 General
The basic mode of lifting system which adopts rolling type is duplex telescopic mast. The
section of inner mast and the outer mast is in the shape of a J . Masts are all free lifting type.
6.2 Inner and outer masts
Mast is duplex telescopic type with free lifting. It consists of inner mast and outer mast and is
supported by mast support. Mast support which is welded at the bottom of outer mast extends
to axle housing and connects with it. Therefore, the weight of mast is supported by axle
housing. Tilt cylinder support which is connected with the front end of cylinder (called end of
piston rod) by pin shaft is also on the outer mast. Mast is tilted by tilt cylinder, 6 for forward
Figure 6.1
Figure. 6.2
Figure 6.3
Figure 6.4
7t
mm
80
90
100
60
70
70
Stroke of cylinder
1495
Type
Tilt
cylinder
Cylinder bore
Outer diameter of piston rod
Stroke of cylinder6/12
8-10t
5-6t
115
50
mm
227
242
8. Plug
2. Adjusted shim
9. Screw
16. U-ring
3. Dust ring
10. Elbow
17. Piston
4. U-ring
11. Body,cylinder
18. Nut
5. Cover,cylinder
12. Spacer
19. Pin
6. Plug ZG3/8"
13. O-ring
20. Piston
7.O-ring
14.Wearing
21.Spring
8.Cap
2.Seal,dust
9.Plug
16.Snap ring
3.U-ring
10.Screw
17.U-ring
4.Bearing
11.Cylinder body
18.Spring
5.Plug ZG3/8"
12.Sleeve,adjusted
19.Piston
6.Elbow
13.Piston
20.Gasket,adjusted
7.O-ring
14.Wearing
.2 Cutoff valve
6.6
6.6.2
Cutoff valves are mounted at the bottom of both lift
cylinders. They can avoid the cargo falling off
suddenly when the high pressure hose bursts
suddenly. The structure of cutoff valve is shown in
the figure 6.9. Return oil from lift cylinder passes
through cutoff valve and pressure difference happens
because of the oil orifices around the slide valve.
When the pressure is less than the spring force, the
slide valve When the pressure difference is less than
the spring force, the slide valve does not act. If high
pressure hose suddenly bursts, only a little oil will
flow through small openings on the end of slide
valve. Therefore, the fork will fall down slowly.
which makes the pressure oil flows along two passages(A-B-G-D-E and A-B-C- D -E), both
passages oil flows into the lift cylinder . Under this condition, flow rate of oil can not be
regulated and limited. When the fork begins to fall down. The return oil discharged from lift
cylinder comes into the E chamber and push the valve stem to move right, until the valve
stem begins to contact the connector, it means that the opening G is close, therefore, the
return oil should get back to the oil tank through the throttle plate. If the oil return quantity
increase sharply, pressure in Fchamber goes up, which drives the valve core (No 5 in the
figure 6.11) to overcome the spring force and moves right, which makes the opening H
becomes narrow, so that the flow rate which flows into the C chamber from Dchamber
decreases, namely the falling speed of fork is limited ( the speed reduces).
5. Valve core
9. Spring
2. Valve housing
6. Throttle plate
10. Connector
3. Disk spring
7. Snap ring
4. Nylon ball
8. Valve body
O ring is mounted.
When tilt control lever is pushed forward, high pressure oil flows from the bottom of cylinder to
the interior of cylinder, therefore, the piston begins to move forward and mast inclines forward
(can reach 6). When tilt control lever is pulled backward, high pressure oil flows from the front
guide sleeve to the interior of cylinder, therefore the piston begins to move backward and mast
inclines backward (can reach 12).
8. Guide sleeve
2. Bearing 5058
9. Snap ring
16. Spacer
3. Washer
10. U-ring
17. Wearing
4. Spacer
5. Dust seal
19. Plug
6. Snap ring 72
13. Bearing5030
20. Screw
7. Snap ring
14.Tube,cylinder
7. Hydraulic system
See the table 7.1 for the main technical parameters
Tonnage
Item
5-7T
Vacuum servo
brake
Brake type
8-10T
Power brake
Power brake
Drive type
Rated pressure
25 MPa
Main oil
pump
CDB-F20-02
36R/4R
duplex
pump
CBHYA-G36/F3.5AT
CBKa-G436-ATL
CDB-F20-04c
7.1 General
Hydraulic system mainly contains oil pump, multi-way valve (the distribution valve is
mounted with multi-way valve together), high and low pressure hoses, connectors and so on.
Oil pump which is a gear pump and it is mounted on the side of transmission. When the engine
is running, it drives oil pump to suck oil from oil tank and send the oil to multi-way valve.
The safety valve in multi-way valve is used to keep the oil pressure in oil passage within the
specified value. While through control of valve rod, oil passages in the multi-way valve
changes in order to control the cylinder. Through the distribution valve, oil flows to the
steering gear is used to control the action of steering cylinder.
7.2 Oil pump
Oil pumps consist of the front and the rear pump. The front pump is the main pump, which is
used to control steering, lifting and tilting operations. The rear pump only controls the lift and
tilt movements
Oil pump, which is a gear pump, is made up of drive gear, driven gear and pump body, that is
to say, the oil pump includes two gears and other components. The drive gear meshes with the
driven gear.
7.3 Multi-way valve
Multi-way valve is a split valve. It is divided into three parts: inlet (distribution valve is
mounted at the inlet), outlet and slide valve. The three parts are mounted together by three
bolts. The distribution valve ( inlet) is mounted with multi-way valve together, which keep the
2)
Main safety valve is mounted between high pressure port HP and low pressure passage
LP. Oil that flows through valve core C acts on two faces (A and B) with different
diameters. Therefore, both check valve core C and main safety valve core D fall into
valve seats firmly. See Figure 7.5.
When oil pressure of high pressure cylinder port exceeds the pressure regulated by spring
force, the pilot valve core E opens and oil flows around valve core and into the hole, then
the oil flows into the low pressure passages. See Figure 7.6.
Figure 7.5
3)
4)
Figure 7.6
Figure 7.7
Figure 7.8
When the pilot valve core E is open, Oil pressure behind valve core D drops when pilot
valve is open, therefore, valve core moves right and sits on pre-guide valve core E. As a
result, oil passage behind safety valve core D is cut off and the oil pressure inside falls as
well. See the figure 7.7.
Compared with cylinder port HP, the pressure inside becomes unbalanced, which results
in the opening of safety valve core D. In this way, oil at the high pressure side flows
directly into low pressure passage LP. See figure 7.8.
Figure. 7.10
Figure 7.13
7.10 Repair
7.10.1 Disassembly of multi-way valve
Remove multi-way valve from forklift and clean its exterior face.
(1) Remove the connecting bolt to separate the pieces of multi-way valve. Be careful not to
lose check valve and seal rings on joint face.
(2) Remove screws on one head side of slide valve and inner hexagon bolts on side cover.
Disassemble the slide valve included leather cup, O seal ring and seal plate from valve
body.
(3) Put the slide valve on bench vice. Remove connecting bolts fixed on cover and take
down spring and spring seat. On the tilt slide valve with tilt self lock valve, remove the
spring and valve core in the tilt self lock valve.
7.10.2 Reassembling of directional control valve
Clean all the parts that have been removed with mineral oil. Check if there is any burr or
nick. Replace the parts if necessary. After assembly, valve body and slide valve, the slide
valve and valve core should be well packed, if there is need to replace the part, replace the
whole unit.
(1) Clamp the slide valve with bench vice, then mount valve core and spring. Pay attention
to the direction of valve core.
(2) Mount O-ring, leather cup, seal plate, spring and spring seat to the end of slide valve in
order. After mounting them with covers, screw down connecting bolts of cover with a
torque of 25-32N.m.
(3) Insert the assembled slide valve assembly (one piece valve) into valve body and mount
the cover with inner hexagon bolts. The tightening torque of bolt is 9-11N.m.
(4) Fix O-ring and leather cup on the head of sliding valve and fasten the seal plate with
bolts. The tightening torque is 4.6-5.8N.m.
(5) After assembly, mount check valve, spring and O-ring on each piece of valve. Then
fasten the valve with three connecting bolts with specified torque. (The tightening
torque of one bolt is 103N.m, the other two is 66N.m.)
7.10.3
Precautions
The pressure in each safety valves in multi-way valve has been set before leaving factory.
Users should not adjust them privately during the use in order to avoid too high pressure
adjusted damaging the hydraulic system and elements. Adjust the pressure of each safety valve
correctly according to requirement of manual. During the assembly or disassembly, do not
damage the joint face of slide valve when clamping the slide valve with bench vice.
8. Electrical system
8.1 General
The electrical system is a one wire circuit with negative earth, it is the nerve system of the
truck.. The electrical system are mainly made up of the following systems. Plan of wiring for
electrical system: shown as the figure 8.1 (5-7T) , Figure 8.2 (8-10T):
1) Charging system
The charging system consists of generator, battery, charging indicator lamp, which supplies the
forklift electro-equipment with power supply.
2) Starting system
The starting system is mainly made up of (only for isuzu engine), start switch, start protective
circuit, starter, etc. It is used to start the engine.
3Stop control systemYUCHAI
The stop operating system of YUCHAI is composed of switch, choke relay and auto choke.
4) Instrument system
The instrument system mainly consists of hour meter, oil capacity, water temperature gauge
and charging indicator lamp, oil pressure indicator lamp, neutral indicator lamp, air cleaner
clogging alarm, etc, it is the detecting device of forklift.
5) Lighting signal equipment
It includes various lightings, signal lamps, horn, buzzer, etc.
Headlight (upper beam/dipped): 20W/35W
Front combination lamp (steering/width): 21W/4W
Rear combination lamp (steering /width /backup/stop): 21W (red ) / 5W (red) / 10W
(white) / 21W (yellow)
Warning lamp (optional): 21W
Rear headlamp (optional): 70W
Registration plate light (optional): 10W
8.2 Brief introduction of operation
1Starting
Shift the shift control lever in neutral position
before starting the engine(at this time the
neutral shift indicator lamp is on). Otherwise,
the engine will not be started, since safe
starting protective function for forklift is
designed in the starting protective circuit.
Turn the start switch clockwise to gear I
(electrifying gear), then the power supply of
instrument system will be switched on. Gear
schematic diagram of start switch is shown in
figure 8.3
Turn the start switch clockwise to gear(starting gear) , the engine will be started up.
After startup the engine, push the shift control lever forward, namely in the forward gear,
accelerate the throttle, the forklift will travel fast or work quickly. If pull backward the speed
rod, namely in the reverse gear, at this time, the backup lamp will be on, and the backup
buzzer will sound alarm.
2Lamp switches: Shift in gear I, front and rear width is on. Shift in gear II, front
headlamp and width lamp will be on. Shift in gear , the upper beam and width lamp
headlamps will be on.
3Steering signal: When pulling backward the steering lamp switch, steering signal lamps
of front and rear combination lamps on the left of forklift will flash. Push the steering
lamp switch forward, steering signal lamps of front and rear combination lamps on the
right side of forklift will flash.
4Brake signal: When there is need to brake the forklift, step the brake pedal, rear
combination lamp brake lamp will be on (red).
5Reverse signal: When there is need to reverse the forklift, pull the speed rod backward,
at this time the speed rod in in the reverse gear, rear combination lamp reverse lamp will
be on (white), the backup buzzer sounds alarm.
6Non-charging signal: before starting up the engine, turn the starting switch clockwise to
the gear I ( electrifying gear ), at this time the charging indicating lamp will be on. After
starting up the engine, the lamp will be off automatically. If the engine is under the
working state, the charging lamp is on, which indicates the charging circuit is out of
order and can not work, stop the forklift and perform the inspection.
7Engine oil pressure signal: Before starting up the engine, rotate the starting switch
clockwise to the gear I ( electrifying gear), at this time, the oil pressure indicator lamp
will be on. After starting up the engine, it be off automatically. If the engine is under the
working state, the oil pressure is on, which indicates that the oil pressure of engine is too
low and lubrication is poor, stop the forklift to perform the insection.
8 Water sediment ( oil and water separator) signal display: before starting up the engine,
rotate the starting switch clockwise to the gear I (electrifying gear), at this time, water
sediments signal indicator lamp will be on, after starting up the engine, the signal lamp
will be off automatically. During the operation of engine, if this warning lamp is on, it
means that the seeper in the oil and water separator exceeds the warning level, drain the
seeper, then the signal lamp will be off automatically.
9Fuel meter: indicates the oil capacity of oil in fuel tank.
8.3 Battery
Precautions during the use of battery:
1) The battery can produce combustible gas, which may cause explosion. Therefore short
circuit and sparks should be avoided, fireworks are strictly prohibited.
2) The electrolyte is dilute sulfuric acid, it is very dangerous (burning, blindness) to contact
the skin or the eye. When the electrolyte is splashed on the skin, flush them with water
immediately. And if it is splashed into the eye, flush them with water and see the doctor
in time.
black
red
green
yellow
blue
white
brown
purple
1.0
1.5
2.5
3.0
4.0
5.0
6.0
Carrying capacityA
11
14
20
22
25
25
35
5-7T
8-10T
Name