Yale A7S1 Service Manual
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Yale A7S1 Service Manual

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Maintenance
A7S1
SERVICE MANUAL
GLP/GDP20UX, GLP/GDP25UX, GLP/GDP30UX, GLP/
GDP35UX
PART NO. 550216372
8000 YRM 2199

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Summary of Contents for Yale A7S1

  • Page 1 Maintenance A7S1 SERVICE MANUAL GLP/GDP20UX, GLP/GDP25UX, GLP/GDP30UX, GLP/ GDP35UX PART NO. 550216372 8000 YRM 2199...
  • Page 2 The Service Manuals are updated on a regular basis, but may not reflect the latest design changes to the product. Updated technical service information may be available from your local authorized YALE® distributor. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians.
  • Page 3 Series Model Engine Transmission GLP/GDP20-25UX MITSUBISHI S4S-455 YQXD30(PHF) GLP/GDP20-25UX PSI 4G64 2.4L YQXD30(PHF) 2-2.5T GLP/GDP20-25UX XINCHAI 4D27G31 YQXD30A(PHF) GLP/GDP20-25UX YANMAR 4TNE92 YQXD30(PHF) 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) 3-3.5T GLP/GDP30-35UX...

  • Page 5: Table Of Contents

    Brake Master Cylinder............................27 Wheel Brake............................... 27 Automatic Brake Adjuster........................... 31 Manual Brake..............................32 Adjustment of Brake Pedal..........................32 Maintenance............................... 32 Disassemble, Wheel Brake..........................33 Examination of Wheel Brake..........................35 Assemble, Wheel Brake...........................36 Operating Test Automatic Clearance Regulator....................38 ©2021 Yale Materials Handling Corp.
  • Page 6 Table of Contents TABLE OF CONTENTS (Continued) Troubleshoot Wheel Brake..........................39 Hydraulic System..............................41 Overview................................41 Steering Control Unit............................42 Multi-way Valve and Priority spool ........................42 Operation of Spool Valve..........................42 Neutral Position............................. 42 Spool Valve (Pushed In):..........................43 Spool Valve (Pulled out):..........................43 Primary Relief Valve and Priority Spool......................
  • Page 7 Table of Contents TABLE OF CONTENTS (Continued) Lubrication System............................. 83 PDM Schematics..............................85...

  • Page 9: Forklift Truck Main Parts

    8000 YRM 2199 Forklift Truck Main Parts Forklift Truck Main Parts DESCRIPTION OF FORKLIFT TRUCK MAIN PARTS System Subassemblies Power System Transmission System Torque Converter Hydraulic Speed Reducer or Transmission Case Speed Differential Drive Axle Steering System Steering Axle Lifting System Brake and Inching Control (Hydraulic Truck)

  • Page 10: Forklift Main Technical Parameters

    Forklift Main Technical Parameters 8000 YRM 2199 Forklift Main Technical Parameters MAIN TECHNICAL PARAMETERS Figure 1. Outside Drawing of Forklift Truck(LPG/DUAL)
  • Page 11 8000 YRM 2199 Forklift Main Technical Parameters Figure 2. Outside Drawing of Forklift Truck (Diesel engine/gasoline engine) NOTE: Truck with diesel engine is shown. Other are for standard configuration only. Always consult the trucks are similar. The values in the parameter tables nameplate to see the values of a specific truck.
  • Page 12 Forklift Main Technical Parameters 8000 YRM 2199 Table 1. Technical Parameters Parameter Model GLP/GDP20UX GLP/GDP25UX Engine Model 4G64 2.4L 4G64 2.4L Manufacturer Power Source GAS/LPG GAS/LPG Rated Capacity 2000 kg (4409.2 lb) 2500 kg (5511.6 lb) Load Center 500 mm (19.7 in.) 500 mm (19.7 in.) Lifting Height 3000 mm (118.1 in.)

  • Page 13: Power System

    8000 YRM 2199 Power System Power System ENGINE SYSTEM NOTE: Engine availability may be different in your market. Contact your local Hyster dealer for more information. Engine Overview Refer to Table 2 for the imported DUAL FUEL and LPG used for 2.0-3.5t forklift trucks in A series. Table 2.

  • Page 14: Fuel System

    Power System 8000 YRM 2199 Table 2. Gasoline Engine (2.4) (Continued) Model PSI 4G64-2.4L Inlet Valve Open before Top Dead 8° Center (BTDC) Inlet Valve Close after Bottom Dead 48° Center (ABDC) Exhaust Valve Valve Timing Open before 31° Bottom Dead Center (BBDC) Exhaust Valve Close after Top...

  • Page 15: Fuel Tank

    8000 YRM 2199 Power System Fuel Tank 3-3.5t forklift trucks. The Fuel Level Sensor is fitted on the tank cover of fuel tank to detect the fuel level. See The fuel tank is a welded structure contained within Figure 3 or Figure 4. the frame of the forklift truck.

  • Page 16: Fuel Level Sensor

    Power System 8000 YRM 2199 Figure 4. Fuel Tank (LPG Forklift Truck) Fuel Level Sensor The Fuel Level Sensor is used to convert the remaining fuel quantity in fuel tank into voltage. This is to monitor the amount of fuel currently in the fuel tank. Refer to Figure 5.

  • Page 17: Maintenance Of Fuel System

    8000 YRM 2199 Power System Fuel Position Resistance (Ω) FULL 180±5 ½ 95±5 EMPTY 10±½ Maintenance of Fuel System The fuel system is to be maintained and serviced once for every 100 work hours, with the following method. The fuel tank must be cleaned once every 600 work hours.

  • Page 18: Hydraulic Transmission Case And Torque Converter

    Hydraulic Transmission Case and Torque Converter 8000 YRM 2199 Hydraulic Transmission Case and Torque Converter Type Three-Element, Single-Stage, and Two-Phase Type Torque Converter Torque Ratio 2.8-3.0:1 Pressure Range 0.5-0.7 MPa (72.5-101.5 psi) Type Internal Meshing Gear Type Flow Rate 27 l/min (1.5 MPa x 2000 rpm) Oil Feed Pump 7.1 g/min (217.6 psi x 2000 rpm) Type...

  • Page 19: Torque Converter

    8000 YRM 2199 Hydraulic Transmission Case and Torque Converter 1. GEAR SHAFT 10. OUTPUT SHAFT 2. TAPERED ROLLER BEARING 11. IDLER GEAR 3. TORQUE CONVERTER HOUSING ASSEMBLY 12. OUTPUT GEAR 4. OIL PUMP ASSEMBLY 13. HYDRAULIC TOR-CON CONVERTER 5. COVER AND CONTROL VALVE ASSEMBLY 14.

  • Page 20: Hydraulic Clutch

    Hydraulic Transmission Case and Torque Converter 8000 YRM 2199 HYDRAULIC CLUTCH Wet multi-disk hydraulic clutch is mounted on the input shaft of hydraulic transmission case. It distributes oil pressure to the forward or reverse clutch through the control valve, this causes the forward and reverse gear shift.

  • Page 21: Control Valve, Safety Valve, And Inching Valve

    8000 YRM 2199 Hydraulic Transmission Case and Torque Converter 1. END PLATE 9. INPUT SHAFT ASSEMBLY 17. SEAL RING (B) 2. PISTON 10. THRUST COLLAR (A) 18. SPACER 3. O-RING 11. NEEDLE BEARING 19. BRAKE SHOE 4. FORWARD GEAR 12. THRUST SHAFT COLLAR (B) 20.
  • Page 22 Hydraulic Transmission Case and Torque Converter 8000 YRM 2199 1. WOODRUFF KEY 3. PIN 2. O-RING SEAL A. FORWARD C. REVERSE B. NEURTRAL POSITION Figure 10. Control Valve...

  • Page 23: Transmission Case

    8000 YRM 2199 Hydraulic Transmission Case and Torque Converter 1. DRIVING GEAR 1. SCREW PLUG 8. SPRING 2. GUIDING GEAR SEAT 2. SCREW PLUG 9. SNAP RING 3. DRIVEN GEAR 3. SNAP RING 10. OIL SEAL 4. PUMP SHELL 4. SPRING 11.

  • Page 24: Speed Reducer And Speed Differential

    Hydraulic Transmission Case and Torque Converter 8000 YRM 2199 engaged, the spacer and the brake shoes of the other or most of the oil flowing into clutch is drained to the oil clutch are separated and are lubricated by cooling oil. tank through inching valve, of the oil to torque When inching pedal operates the inching valve, part of converter is the same as in neutral position.

  • Page 25: Speed Differential

    8000 YRM 2199 Hydraulic Transmission Case and Torque Converter 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.

  • Page 26: Oil Inlet/Outlet Connection Location

    Drive Axle 8000 YRM 2199 OIL INLET/OUTLET CONNECTION LOCATION Figure 16. Oil Inlet/Outlet Connection Location Drive Axle Type Front Wheel Drive, Axle Body Fixed with Vehicle Chassis, and Fully Floating Type Truck 2-2.5T 3-3.5T Single Tire Double Tire Single Tire Double Tire Capacity Tire Model...

  • Page 27: Maintenance Of Drive Axle

    8000 YRM 2199 Drive Axle Tighten the half shaft mounting nut. Torque to 96-111 N•m (70.8-81.9 lbf ft). Tighten the wheel mounting nut. Torque to 470-550 N•m (346.7-405.7 lbf ft). Tighten the brake drum mounting. Torque to 206-225 N•m (151.9-166.0 lbf ft). 1.

  • Page 28: Steering System

    Steering System 8000 YRM 2199 Steering System STEERING SYSTEM Type of Steering System Rear Wheel Steering with Power Steering Forklift Truck Capacity 2T, 2.5T, 3T, 3.5T Cycloid Full Hydraulic Steering Gear BZZ1-125BC-D Cylinder Diameter 70 mm (2.8 in.) Steering Diameter of Piston Rod 50 mm (2 in.) Cylinder Stroke...

  • Page 29: Steering Cylinder

    8000 YRM 2199 Steering System 1. VALVE ELEMENT 16. SPRING SHIM 2. SLEEVE 17. JOINT SHAFT 3. NEEDLE BEARING 18. MIDDLE PLATE 4. SLEEVE 19. ROTOR 5. O-RING 20. STATOR 6. VALVE BODY 21. O-RING 7. O-RING 22. SLIP RING 8.

  • Page 30: Inspection Of Reassembled Steering System

    Steering System 8000 YRM 2199 1. CYLINDER CASING 9. RETAINER 2. CIRCLIP 10. PISTON ROD 3. O-RING 11. SUPPORT RING 4. AXIAL SEAL RING 12. O-RING SEAL 5. FLAP 13. STEEL BALL 6. O-RING SEAL 14. PISTON 7. CYLINDER CAP 15.

  • Page 31: Troubleshoot Steering System

    8000 YRM 2199 Steering System Troubleshoot Steering System Problem Cause Solution Oil pump damaged or malfunctioning Replace pump Steering Wheel Not Priority spool blocked or damaged Clean or replace Turning Rubber hose joint damaged or fluid line blocked Clean or replace Adjust Steering relief Steering relief valve pressure too low valve...

  • Page 32: Steering And Drive Axle Information

    Steering and Drive Axle Information 8000 YRM 2199 Steering and Drive Axle Information STEERING AXLE Tonnage 2-3.5t Type of Axle body Supported with Central Supporting Shaft Steering angle Inner Side Wheel 78º Outer Side Wheel 54º King pin Center to Center of Kingpins 810mm (31.89 in) Side Inclination Angle 0º...

  • Page 33: Steering Knuckle And Steering King Pin

    8000 YRM 2199 Steering and Drive Axle Information 1. LEFT UNIVERSAL JOINT 20. NUT M20X2 2. STEERING AXLE 21. WASHER 30 3. NUT M12 22. TAPERED ROLLER BEARING 4. NUT M12X40 23. BEARING 30211 5. WASHER 14 24. GREASE NIPPLE Z1/8 6.

  • Page 34: Steering Wheel Bearing Pre-Load Information

    Brake System 8000 YRM 2199 of king pin are supported by needle roller bearings pressed on the axle body. Oil seals are mounted on the two ends of needle roller bearings, and oil cup is fitted on the king pin. Steering Wheel Bearing Pre-load Information Grease the hub, internal and external bearings...

  • Page 35: Overview

    8000 YRM 2199 Brake System OVERVIEW compressed and opens the one-way valve. This allows oil to flow to the wheel cylinder through the bypass Brake system is in a front double-wheel brake type, pipeline. The pistons of the wheel cylinders extend and it is composed of brake master cylinder, Dry outwards.
  • Page 36 Brake System 8000 YRM 2199 Figure 25. 2-2.5T Wheel Brakes...
  • Page 37 8000 YRM 2199 Brake System Legend for Figure 25. 1. BOTTOM PLATE 14. SPRING 28. PISTON 2. ADJUSTING SLEEVE 15. SPRING CAP 29. BRAKE CYLINDER CUP 3. BRAKE SHOE 16. SPRING 30. BRAKE CYLINDER SPRING 4. ELASTIC GASKET 17. SPRING SEAT 31.
  • Page 38 Brake System 8000 YRM 2199 1. BRAKE CYLINDER 10. RUBBER PLUG 19. SPRING 2. CLUTCH DISCS WITH 11. PULL SPRING 20. PARK BRAKE PULL ROD FRICTION PLATE ASSEMBLY 12. GUIDE PANEL 21. PIN 3. BOTTOM PLATE 13. GUIDE PLATE 22. ELASTIC GASKET 4.

  • Page 39: Automatic Brake Adjuster

    8000 YRM 2199 Brake System adjuster to generate a larger force used to operate the wheel cylinder to push the secondary Brake shoes, and to force the upper end of secondary Brake shoes to bear down on the support pin, thus to get a relatively large brake force.

  • Page 40: Manual Brake

    Brake System 8000 YRM 2199 MANUAL BRAKE ADJUSTMENT OF BRAKE PEDAL The manual brake uses a pull handle. With the foot Adjust the limit bolts to the pedal location shown brake, it employs an automatic power brake that stops in Figure 30. Confirm the distance between the the front wheels.

  • Page 41: Disassemble, Wheel Brake

    8000 YRM 2199 Brake System Disassemble, Wheel Brake STEP 1. Remove 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.
  • Page 42 Brake System 8000 YRM 2199 STEP 4. Detach the primary brake shoes and the secondary brake shoes, and remove the spring for adjuster. STEP 5. Remove the brake fluid line from the wheel cylinder. Remove the mounting bolts for the wheel cylinder, and separate the wheel cylinder from the bottom plate.

  • Page 43: Examination Of Wheel Brake

    8000 YRM 2199 Brake System STEP 7. Remove the shield for the wheel cylinder, remove all the parts from inside the cylinder. Examination of Wheel Brake Measure the free length and installation load of return spring for brake shoes. See Figure 31. Examine all the parts for ware or damage.

  • Page 44: Assemble, Wheel Brake

    Brake System 8000 YRM 2199 Forklift Truck Tonnage 2-3.5T Free Length 124.5 mm (4.90 in.) Figure 34. Ratchet spring Installation Length 130 mm (5.12 in.) 10. Check the adjusting spring for damage and Installation Load 246 N (55.3 lb) confirm the adjusting lever is functioning properly. Replace if necessary.
  • Page 45 8000 YRM 2199 Brake System Mount the guide plate of brake shoes onto the support pin. Install the return spring of brake shoes. 1. SUPPORT FACE OF BOTTOM PLATE 2. SUPPORT PIN OF LEVER L H BRAKE 3. SUPPORT PIN 10.

  • Page 46: Operating Test Automatic Clearance Regulator

    Brake System 8000 YRM 2199 Operating Test Automatic Clearance Regulator Allow the diameter of brake shoes to approach the installation size. Pull the adjusting lever to rotate. When the adjusting lever is released, it returns to its original place. The adjuster gear will not rotate.
  • Page 47 8000 YRM 2199 Brake System 1. TURN BRAKE ADJUSTER Figure 36. Brake Adjuster Check the return spring of top rod and the Make sure the adjuster gear rotates. Confirm no adjuster spring for damage. Confirm no wear or wear or damage. damage.

  • Page 48: Troubleshoot Wheel Brake

    Brake System 8000 YRM 2199 Troubleshoot Wheel Brake Problem Cause Solution Fluid leak in brake system Repair Clearance of brake shoes not properly adjusted Adjust adjuster gear Brake too hot Check if skidding exists Poor contact between brake drum and brake shoe Adjust brake adjuster Brake Spongy Repair or replace brake...

  • Page 49: Hydraulic System

    8000 YRM 2199 Hydraulic System Hydraulic System NOTE: If the forklift truck is kept without operating for times at least every 10 days for lubrication a long time, it is required to lift the mast cylinder 2-3 maintenance. GLP/ GLP/ GLP/ GLP/ Forklift Truck Tonnage...

  • Page 50: Steering Control Unit

    Hydraulic System 8000 YRM 2199 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. STEERING CONTROL UNIT The steering control unit is a gear pump consisting of a pump housing, pump cover, one pair of gears, a bearing, and seal rings.

  • Page 51: Spool Valve (Pushed In)

    8000 YRM 2199 Hydraulic System Spool Valve (Pulled out): When neutral position is closed, the hydraulic oil from the inlet port opens the one-way valve and flows to the cylinder interface A, (item 2, Figure 40) while the oil from cylinder interface B (item 1, Figure 40) flows to the tank through low-pressure channel.

  • Page 52: Inclined Auto-Lock Valve

    Hydraulic System 8000 YRM 2199 core (N) moves right, and pressure oil is connected By changing the flow rate and pressure, the slide valve with low-pressure oil circuit through cavity (T), for the L moves to the left and right to change the opening of pressure in cavity (M) to lower, in order to ensure the (R) and (S), to ensure the automatic balance of the stability for the pressure of steering system.

  • Page 53: Hydraulic System Main Oil Circuit

    8000 YRM 2199 Hydraulic System 1. CONNECTING TILT CYLINDER INTERFACE B 2. CONNECTING TILT CYLINDER INTERFACE A Figure 42. Tilt Auto-lock Valve The interfaces “2” and “1” of valve body connect parts by the priority spool within the multi-way valve. separately with front and rear housing of the tilt High pressure oil is divided to either go to the hydraulic cylinder piston.
  • Page 54 Hydraulic System 8000 YRM 2199 Figure 43. Oil Circuit of Hydraulic System...

  • Page 55: Lift Cylinder

    8000 YRM 2199 Hydraulic System Figure 44. Oil Circuit of Hydraulic System (OPS) LIFT CYLINDER parts. One port is located in the lower part of cylinder body. A return pipe is mounted in the upper part of Two single-acting lift cylinders are attached on the cylinder body for a small amount of leaked fluid to back of the outer mast channel, and the bottom part of return to the tank.
  • Page 56 Hydraulic System 8000 YRM 2199 When the lift is commanded, the high-pressure fluid under the weight of the forks and cargo, and the inner enters through the bottom part of lift cylinder, pushing mast will be lowered. The oil drained out from lift up the piston attached to the mast and raising the cylinder is controlled by velocity fuse, and returns to inner mast along with the lift chain.

  • Page 57: Velocity Fuse

    8000 YRM 2199 Hydraulic System A. WHEN NORMAL B. WHEN DISCONNECTED Figure 46. Velocity Fuse VELOCITY FUSE In an emergency situation, caused by a significant pressure drop in the system (ex. hydraulic hose burst), A velocity fuse (throttle valve) is mounted within the oil the velocity fuse actuates.

  • Page 58: Tilt Cylinder

    Hydraulic System 8000 YRM 2199 1. NORMAL FLOW 8. VALVE SLEEVE 2. THROTTLE FLOW 9. VALVE CORE 3. SIDE OF MULTI-WAY VALVE 10. NYLON BALL 4. VALVE BODY 11. SPRING 5. O-RING 12. CONNECTOR 6. SPRING 13. SIDE OF LIFT CYLINDER 7.

  • Page 59: Maintenance Of Hydraulic Pump

    8000 YRM 2199 Hydraulic System 1. CLEVIS 6. GUIDE SLEEVE 11. SEAL RING 2. DUST RING 7. BEARING 12. WEAR RING 3. BAFFLE RING 8. O-RING 13. PISTON 4. SEAL RING 9. PISTON ROD 14. SEAL RING 5. O-RING 10. CYLINDER BODY Figure 48.
  • Page 60 Hydraulic System 8000 YRM 2199 1. INLET 4. MAINTENANCE LIMIT SIZE 2. WEAR AREA 5. OUTLET SIDE 3. OUTLET Figure 49. Main Oil Pump Inspection of Bearing Inspect that the inner surface of bearing is smooth, and the contact surface is shown at the position about ½...
  • Page 61 8000 YRM 2199 Hydraulic System The trace of contact appears on the entire slide failure has also occurred, and must be inspected. inner surface, and roughness is felt when The limit size for the axial diameter of gear shaft scraped with a finger nail. is 18.94 mm (.075 in.).

  • Page 62: Assemble, Main Oil Pump

    Hydraulic System 8000 YRM 2199 1. DUST-PROOF LIP 2. PUMP OUTER SIDE 3. PUMP INNER SIDE 4. SEAL RING NOZZLE Figure 53. Oil Seal Inspection Assemble, Main Oil Pump 1. BEARING 2. DRIVING GEAR NOTE: For the following procedures refer to Figure 55 3.

  • Page 63: Test

    8000 YRM 2199 Hydraulic System 12. Mount spring washer (item 13) and bolt (item 12), gauge should read slightly lower than and torque to 47 N•m (34.67 lbf). 1 MPa (145.04 psi). Keep pump running for 10 minutes. 13. Inspect the gear pump to confirm it is assembled completely.
  • Page 64 Hydraulic System 8000 YRM 2199 1. END COVER 6. DRIVEN GEAR 11. SEAL RING 2. PUMP BODY 7. FRONT END COVER 12. BOLT 3. BEARING 8. SEAL RING 13. LOCK WASHER 4. BEARING 9. SEAL RING 14. LOCKING COLLAR 5. DRIVING GEAR 10.
  • Page 65 8000 YRM 2199 Hydraulic System 1. END COVER 6. DRIVEN GEAR 11. SEAL RING 2. PUMP BODY 7. FRONT END COVER 12. BOLT 3. BEARING 8. SEAL RING 13. LOCK WASHER 4. BEARING 9. SEAL RING 14. OIL SEAL 5. DRIVING GEAR 10.
  • Page 66 Hydraulic System 8000 YRM 2199 Figure 57. Hydraulic Schematic (Diesel and Gasoline Forklift Trucks)

  • Page 67: Troubleshoot Hydraulic System

    8000 YRM 2199 Hydraulic System Legend for Figure 57. 1. HOSE CLAMP 18. HOOP D25 35. TILT CYLINDER CONNECTOR 2. PUMP SUCTION PIPE 19. ORBITAL PIPE CONNECTOR 36. 0-RING 16×2.4 3. PUMP SUCTION FITTING 20. ORBITAL CONNECTOR I 37. BOLT M6×25 4.

  • Page 68: Lifting System

    Lifting System 8000 YRM 2199 Lifting System If parts of the mast must be in a raised position, SAFETY PROCEDURES WHEN WORKING • install a safety chain to restrain the moving parts NEAR MAST of the mast. Connect moving parts to a part that does not move.
  • Page 69 8000 YRM 2199 Lifting System Figure 58. Two-Stage, Free-Lift, and Three-Stage Masts...

  • Page 70: Overview

    Lifting System 8000 YRM 2199 Legend for Figure 58. A. TWO-STAGE MAST B. FREE-LIFT MAST C. THREE-STAGE MAST 1. OUTER WELDMENT 3. INTERMEDIATE WELDMENT 6. CROSSMEMBER 2. INNER WELDMENT 4. HOOK 7. CROSSMEMBER 5. FREE-LIFT CYLINDER OVERVIEW The lifting system is a two-stage rolling telescopic mast, with the outside mast typical of a “C”...

  • Page 71: Carriage

    8000 YRM 2199 Lifting System CARRIAGE The carriage is made up of a series of welded components that move up and down in the inner mast channel, with the help of load and side rollers. The Mast on the 2-3.5T 2FFL has a total of three groups of composite load rollers and two groups of standard load rollers.

  • Page 72: Electrical System

    Electrical System 8000 YRM 2199 Raise the mast slowly until the maximum stroke of the cylinder is reached, check whether the two cylinders are synchronized. Add adjusting shims between piston rod head and the upper beam of the inner mast. Make sure the washer is 02.-0.5 mm (0.008-0.02 in.) thick.

  • Page 73: Dash Instrument Display System

    8000 YRM 2199 Electrical System Dash Instrument Display System and displays it through the display. This allows the operator to understand the status of the forklift . The instrument display system is composed of a water temperature sensor, oil temperature sensor, fuel Lighting, sound and alarm system sensor, oil pressure switch, (on Diesel equipped The system includes a variety of lighting equipment,...

  • Page 74: Description And Summary Of Basic Truck Operations

    Electrical System 8000 YRM 2199 DESCRIPTION AND SUMMARY OF BASIC TRUCK OPERATIONS Item Description Function left turn indicator indicating the work of the left turn signal of forklift right turn indicator indicating the right turn signal light of forklift oil-water separation indicator lamp indicating that the water content in the oil-water separator is too high and manual drainage is required...

  • Page 75: Introduction To The Power Distribution Module (Pdm)

    8000 YRM 2199 Electrical System Item Description Function indicates the temperature of the engine indicates the remaining fuel of gasoline or diesel Excessive Transmission Shows the temperature of the Temperature Indicator transmission oil when it exceeds a certain threshold neutral gear light Issue with Air Filter Monitor Air Flow Restriction indicate the oil temperature of the...
  • Page 76 Electrical System 8000 YRM 2199 Figure 61. With NISSAN engine (K21, K25 Sheet 1 of 2)
  • Page 77 8000 YRM 2199 Electrical System Figure 62. With NISSAN engine (K21, K25 Sheet 2 of 2)
  • Page 78 Electrical System 8000 YRM 2199 Figure 63. With PSI engine Sheet 1 of 2...
  • Page 79 8000 YRM 2199 Electrical System Figure 64. With PSI engine Sheet 2 of 2...
  • Page 80 Electrical System 8000 YRM 2199 Figure 65. With Mitsubishi engine (S4S Sheet 1 of 2)
  • Page 81 8000 YRM 2199 Electrical System Figure 66. With Mitsubishi engine (S4S Sheet 2 of 2)
  • Page 82 Electrical System 8000 YRM 2199 Figure 67. With Xinchai engine (Sheet 1 of 2)
  • Page 83 8000 YRM 2199 Electrical System Figure 68. With Xinchai engine (Sheet 2 of 2)
  • Page 84 Electrical System 8000 YRM 2199 Figure 69. With Yanmar engine (92-98 Sheet 1 of 2)
  • Page 85 8000 YRM 2199 Electrical System Figure 70. With Yanmar engine (92-98 Sheet 2 of 2)
  • Page 86 Electrical System 8000 YRM 2199 Figure 71. With Yanmar engine (94 Sheet 1 of 2)
  • Page 87 8000 YRM 2199 Electrical System Figure 72. With Yanmar engine (94 Sheet 2 of 2)
  • Page 88 Electrical System 8000 YRM 2199 Figure 73. Optional Accessories...

  • Page 89: Troubleshoot Electrical System

    8000 YRM 2199 Electrical System TROUBLESHOOT ELECTRICAL SYSTEM Example 2: The IC truck could be started but could not move forward or reverse For manually controlled truck, the gear is • WARNING controlled by the lever. When examining the electrical wires, the key For the hydraulic controlled truck (With OPS •...

  • Page 90: Drive, Operation, And Routine Maintenance Of Forklift Truck

    Drive, Operation, and Routine Maintenance of Forklift Truck 8000 YRM 2199 2. Check if the hand brake is pulled up. The hand 5. Check if the pin and socket connections are brake switch should be disconnected and tight or loose. ungrounded.

  • Page 91: Oils Used For Forklift Truck

    8000 YRM 2199 Drive, Operation, and Routine Maintenance of Forklift Truck OILS USED FOR FORKLIFT TRUCK Name Brand or Code (Domestic) Gasoline 87 number gasoline. Engine Oil API rating of SM or newer Hydraulic Oil Kinematic Viscosity 28.8-35.2 cSt @ 104F (40℃ mm2/s）...
  • Page 92 Drive, Operation, and Routine Maintenance of Forklift Truck 8000 YRM 2199 LUBRICATION SYSTEM Figure 75. Lubricating System...
  • Page 93 8000 YRM 2199 PDM Schematics PDM Schematics...
  • Page 95 8000 YRM 2199 Figure 76. PDM (Suitable For All Engines) 87/(88 blank)
  • Page 97 8000 YRM 2199 Figure 77. PDM With OPS (Suitable For All Engines) 89/(90 blank)
  • Page 100 8000 YRM 2199 1/21 (10/20)(11/19)(10/19)(5/19)

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