HELI H2000 Series Manual

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This manual accounts for "HELI" Forklift Truck in H2000 series from 5t to 10t,

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Due to continuous improvements in design, it is possible that the latest description

contained herein may differ slightly from the truck delivered to you. Moreover, the

specification of the forklift truck may be changed insignificantly depending on its

destination.

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nameplates and quaulifying licenses.Designations in the CATALOGUE include engine

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https://www.besttruckmanuals.com/

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Summary of Contents for HELI H2000 Series

Page 1 FOREWORD FOREWORD This manual accounts for “HELI” Forklift Truck in H2000 series from 5t to 10t, This manual accounts for “HELI” Forklift Truck in H2000 series from 5t to 10t, includ ludes perfor forman mance, constr struct ucture...
Page 2: Table Of Contents
CONTENTS CONTENTS Ⅰ. Ⅰ. Safe Operation Rules and Daily Mainten Safe Operation Rules and Daily Mainten ance for Forklift ance for Forklift Ⅱ. Ⅱ. Primary Techni Primary Techni c Parameter of Forklift c Parameter of Forklift Ⅲ. Ⅲ. Primary Assembl Primary Assembl y Introduce of Forklift...
Page 3 3.8 Trouble shooting 3.8 Trouble shooting 4. Drive Axle 4. Drive Axle 4.1 General description 4.1 General description 4.2 Differential 4.2 Differential 4.3 Hub reduction gear 4.3 Hub reduction gear 4.4 Trouble shooting 4.4 Trouble shooting 4.5 Data use for service 4.5 Data use for service 5.
Page 4 7.5 Operation of relief valve 7.5 Operation of relief valve 7.6 Operation of tilt lock valve 7.6 Operation of tilt lock valve 7.7 Operation unit of the control valve 7.7 Operation unit of the control valve 7.8 Oil tank 7.8 Oil tank 8.
Page 5 Ⅰ. Safety rules for Operation and Daily Maintenance of Forklift Truck Ⅰ. Safety rules for Operation and Daily Maintenance of Forklift Truck It is important that driver and manager for forklift trucks remember the principle of It is important that driver and manager for forklift trucks remember the principle of the “first safety”...
Page 6 completely under the cargo and make the cargo placed on it evenly. Do not raise an object completely under the cargo and make the cargo placed on it evenly. Do not raise an object with one fork end. with one fork end.
Page 7 5. Arrangement sketch of instruments and controls 5. Arrangement sketch of instruments and controls 1. Fuel gauge 1. Fuel gauge 13. Lift lever 13. Lift lever 2. Monitor 2. Monitor 14. Tilt lever 14. Tilt lever 3. Water temp.meter 3.
Page 8 6. Daily maintenance of forklift truck 6. Daily maintenance of forklift truck 6.1 Caution for starting 6.1 Caution for starting (1) The amount of hydraulic oil:The oil level should be at the middle position between (1) The amount of hydraulic oil:The oil level should be at the middle position between the upper and lower scale marks of oil level meter.
Page 9 Cautions Cautions on cooling on cooling system system (1) During operation, if the radiator of forklift “boils” or the (1) During operation, if the radiator of forklift “boils” or the temperature of cooling temperature of cooling liquid is too high, do not open the cover of liquid is too high, do not open the cover of radiator immediately.
Page 10 Lubrication Lubrication system system table table https://www.besttruckmanuals.com/...
Page 11: Ⅱ. Primary Technic Parameter Of Forklift
Ⅱ. Primary Technic Parameter of Forklift Ⅱ. Primary Technic Parameter of Forklift Rated load Rated load Load center Load center Max.lift height(STD.)B Max.lift height(STD.)B 3000 3000 Free lift height(STD.)E Free lift height(STD.)E ...
Page 12 0 0 0 0 X X X X X X 1 1 1 1 W W W W W W C C C C - - - - - - -...
Page 13 1 1 1 1 1 1 U U U U U U U U U U C C C C C C C ...
Page 14 2 2 2 2 F F s s 6 6 Model Model W W C C X X W W - - - - - - - - 0 0 0 0 0 0 0...
Page 15 Model Model 4 4 3 3 4 4 3 3 W W C C W W C C - - - - - - 0 0 - - 0 0 0 0 0...
Page 16 Specification Specification Unit Unit CPCD50~70-WX CPCD50~70-WX CPCD50~60-C10 CPCD50~60-C10 Model Model CA4110 CA4110 6102GB-A6B 6102GB-A6B In line 4-cylinder, In line 4-cylinder, In line 6-cylinder, In line 6-cylinder, Type Type 4-cycle, water-cooled, 4-cycle, water-cooled, 4-cycle,water-cooled, 4-cycle,water-cooled, direct injection direct injection direct injection direct injection Cyl.N...
Page 17 Specification Specification Unit Unit CPCD CD50 50~7 ~70- 0-CU CPCD CD80 80~1 ~100 00-C Model Model In line In line 4-cylinder,4-cyc 4-cylinder,4-cycle,water-cooled, direct le,water-cooled, direct Type Type injection injection Cyl.N Cyl.Number umber-Bore -Bore Strok Stroke Total displacement Total displacement 3.26 3.26 ...
Page 18 Ⅲ. Ⅲ. Primary Assembly of Forklift Truck Primary Assembly of Forklift Truck Primary Assembly of Forklift Truck Primary Assembly of Forklift Truck Contents Contents No No. Name Name Includes engine mounting,fuel system,exhaust system, Includes engine mounting,fuel system,exhaust system, Engine System Engine System cooling system(torque converter pipelines)etc.
Page 19: Ⅳ. The Structure, Principle, Adjustment And Maintenance Of Forklift
Ⅳ. The structure, principle, adjustment and maintenance of forklift Ⅳ. The structure, principle, adjustment and maintenance of forklift 1. Dynamic system 1. Dynamic system (1) Brief introduction (1) Brief introduction The dynamic system includes the engine, air inlet system, cooling system and exhaust The dynamic system includes the engine, air inlet system, cooling system and exhaust system, etc.
Page 20 Generator Generator Fuel filter Fuel filter Oil injection hole Oil injection hole Grease fdter Grease fdter Start motor Start motor Grease Grease compress SW. compress SW. Fig.1.2 A-6BG1QC diesel engine Fig.1.2 A-6BG1QC diesel engine Name Name A6BG1QC A6BG1QC 4-cycle,water-cooled, in line,overhead...
Page 21 Valve device Valve device Overhead Overhead Fuel device Fuel device Injection pump Injection pump Boshing Boshing Plun Plunger pist piston radiu radiu strok stroke 9. 9.5m Injection nozzle Injection nozzle Porous type Porous type Oil pump Oil pump Plunger piston type Plunger piston type Fuel filter ...
Page 22: Fuel System
Voltage Voltage 24 24V Output Output 25 25V Driving method Driving method Belt driving Belt driving Automatic charging regulator Automatic charging regulator IC type(inside engine) IC type(inside engine) Referrence data Referrence data Oil disc oil quantity Oil disc oil quantity Max:12l,Min:10l Max:12l,Min:10l Cooling water ...
Page 23: Fuel Sender
Filling Filling Fuel sensor Fuel sensor Full Full Empty Empty Flowing Flowing to injection pump to injection pump Fig.1.3 Fuel box Fig.1.3 Fuel box Fuel meter Fuel meter to fuel meter to fuel meter Fig.1.4 Fuel sensor unit Fig.1.4 Fuel sensor unit -19- -19-...
Page 24: Fuel Filter
1.3.3 Fuel filter 1.3.3 Fuel filter The fuel filter is mounted on the fuel-f The fuel filter is mounted on the fuel-f eeding manif eeding manif old of engine and used to filter the old of engine and used to filter the fuel supplied to engine.
Page 25 1.5.2 For fuel filter, See Fig. 1.6. 1.5.2 For fuel filter, See Fig. 1.6. Side passage valve Side passage valve (1 (1) Di Dism sman antl tle wi with th the sp span anne ner r specially used for filter and change it if it specially used for filter and change it if it is damaged and obstructed.
Page 26: Cooling System
1.5.4 Cooling system 1.5.4 Cooling system (1) Check the cooling liquid of auxiliary wate (1) Check the cooling liquid of auxiliary wate r tank r tank For auxiliary water tank, refer to 1.8. When the cooling liquid is lower than making For auxiliary water tank, refer to 1.8.
Page 27: Tightening The Cylinder Head Bolts Of Engine
1.5.5 Tightening the cylinder head bolts 1.5.5 Tightening the cylinder head bolts Smearing grease Smearing grease of engine of engine (1) Tighten the (1) Tighten the cylin cylinder head der head bolts one bolts one by one with 68 by one with 68 Nm moment accord Nm moment...
Page 28: Confirmation Of The Ignition Time Of Oil Injectio
For the concrete adjustm For the concrete adjustment table, refer to Table 1.2. ent table, refer to Table 1.2. Table 1.2 Table 1.2 Air cylinder Air cylinder Sequence No. Sequence No. Valve sequence No. Valve sequence No.
Page 29: Adjustment Of Ignition Time Of Oil Injection
(3) Loosen the oil injection pipe of the first (3) Loosen the oil injection pipe of the first cylinder; dismantle the spring of dump valve cylinder; dismantle the spring of dump valve bracket and the valve. Mount the dump valve bracket and the valve.
Page 30 Fig. 1.18 Fig. 1.18 1.5.10 Air exhaust of oil injection pump (See Fig.1.19) 1.5.10 Air exhaust of oil injection pump (See Fig.1.19) (1) Loosen the exhaust plug of oil injection pump (1) Loosen the exhaust plug of oil injection pump (2)Opera (2)Opera te slowly the manual pump till no air bulbs...
Page 31 2. Eectric System 2. Eectric System 2.1 General 2.1 General The electric system for this forkli The electric system for this forkli ft truck is of the ft truck is of the single-po single-po le type, in which the frame le type, in which the frame of the truck provides the return path for the electricity.
Page 32 Battery Battery Starter Starter Preheat Preheat plug plug Fuse Fuse Starter sw. table Starter sw. table Starter sw. Starter sw. Relay Relay Hour Hour meter meter Relay Relay Neutral sw. Neutral sw. Neutral Neutral indicating...
Page 33 (2) Brief Explanation for operation (2) Brief Explanation for operation 2.1 Starting 2.1 Starting There is a starting protection circuit in the shiftlever the forklift truck. you have to There is a starting protection circuit in the shiftlever the forklift truck. you have to shift the shiftlever in neutral before you start the engine.
Page 34 2.2.4 Reverse signal：When you need to reverse the forklift truck ,pull the shiftlever 2.2.4 Reverse signal：When you need to reverse the forklift truck ,pull the shiftlever backward and the transmission is in reverse shift. Then the reverse lamps (white) in the backward and the transmission is in reverse shift.
Page 35: Battery
Fig.2.3-2 H2001 type combination meter Fig.2.3-2 H2001 type combination meter 1.Fuel meter 1.Fuel meter 2.Water temp. meter 2.Water temp. meter 3.Hour meter 4 3.Hour meter 4.Air cleaner ind .Air cleaner indicator icator 5.indicator 5.indicator 6.Charging indicator 7.Oil pressure indicator 8 Water temp. indicator 6.Charging indicator 7.Oil pressure indicator 8 Water temp.
Page 36 3) Forklift truck type and wire harness 3) Forklift truck type and wire harness Type Type 50~70-W 50~70-W 80~100-W 80~100-W 50~ 50~70 70-C 80 80~1 ~100 00-C 50 50~6 ~60- 0-WF 50 50~7 ~70- 0-Xs Name Name Cabinet...
Page 37 e e l l b b a a c c e e n n i i g g e e l l n n b b E E a...
Page 38 p p m m a a l l p p n n o o m m i i a a t t ...
Page 39 p p m m a a l l n n o o i i t t a a n n i i b b ...
Page 40 e e l l e e b b l l a a b b c c a a t t d d a a r r n n e ...
Page 41 r r p p e e z z m m z z a a u u l l b b n n i i t t o o u...
Page 42 r r p p e e z z m m z z a a u u l l b b n n i i t t o o u...
Page 43 p p m m a a . . l l w w n n s s o o p p e e i i t ...
Page 44 e e e e l l l l b b b b a a a a d d c c e e c c r r y ...
Page 45 p p m m a a l l n n o o i i t t a a n n i i r r b b m m z z z z e ...
Page 46 e e l l b b a a c c t t e e n n i i b b a a c c o o T T p ...
Page 47: Torque Converter
3. Transmission system 3. Transmission system trans nsmis missio sion system consis sists torque conver verter transm nsmiss ission & & torque converter. converter. The main specificat The main specificat ions of the system see table3.1 ions of the system see table3.1 Item Item Specifications...
Page 48 Fig.3-1 HydraulicTransmission Fig.3-1 HydraulicTransmission r r -44- -44- https://www.besttruckmanuals.com/...
Page 49 3.1 General description 3.1 General description The transmission adopted in this machine is a rational combination of torque The transmission adopted in this machine is a rational combination of torque converter with power-shift type transmission.It has the following features. converter with power-shift type transmission.It has the following features.
Page 50 Inside torqu que conver verter mounte nted torque conver verter case,t e,turb urbine wheel,pump wheel,and stator wheel,The inside of torque converter is filled with torque wheel,pump wheel,and stator wheel,The inside of torque converter is filled with torque converter fluid. converter fluid.
Page 51 Outlet Outlet Shuck Shuck Driving gear Driving gear O-ring O-ring Inner gear Inner gear Inlet Inlet Fig.3.3 Oil pump Fig.3.3 Oil pump Chargi rging pump consis sists drivin ving gear,i r,inne nner gear(d r(dive iven gear), r),shu shuck cover,mounted on the upper end of the tor-con housing.Driving gear is driven by pump cover,mounted on the upper end of the tor-con housing.Driving gear is driven by pump...
Page 52 or reverse gear→Output shaft. or reverse gear→Output shaft. 3.5 Control valve and Inching valve 3.5 Control valve and Inching valve The control valve see Fig.3-5. The control valve see Fig.3-5. Friction plate Friction plate 2-Shift gear 2-Shift gear Gear ...
Page 53 Spring Spring Piston Piston Bushing Bushing Oil seal Oil seal Inching spool Inching spool Oil seal Oil seal Selector spool Selector spool Stopper Stopper Fig.3.6 Control valve Fig.3.6 Control valve The control valve is provided on the upper part of transmission case.The change spool The control valve is provided on the upper part of transmission case.The change spool and inching spool are incorpora and inching spool are incorpora...
Page 54: Oil Pump
Tor-con Tor-con cooler cooler Filter Filter Tor-con relief valve Tor-con relief valve Lubrication Lubrication Accumulator Accumulator Main relief valve Main relief valve Inching vlave Inching vlave Oil pump Oil pump Selector Selector spool spool Strainer Strainer Fig.3.7 Tor-con hydraulic system Fig.3.7 Tor-con hydraulic system Pressur of the fluid for clutch is adjusted to 1.2 to 1.5 MPa with the relief valve.And...
Page 55 hydraulic oil supplied to the clutch is drained from the inching valve and returns to the hydraulic oil supplied to the clutch is drained from the inching valve and returns to the transmission case.The fluid for the torque converter circulates in the same manner as in transmission case.The fluid for the torque converter circulates in the same manner as in neutral state.
Page 56 Possible causes Possible causes Checking method Checking method Remedy Remedy A.Oil pressure too low A.Oil pressure too low (1) Low oil level (1) Low oil level Check oil level Check oil level Add oil Add oil (2) Air sucked from suction (2) Air sucked from suction Check joints and pipe Check joints and pipe...
Page 57 Possible Causes Possible Causes Checking Method Checking Method Remedy Remedy 1.Low oil level 1.Low oil level Check oil level Check oil level Add oil Add oil 2.Clogged oil filter 2.Clogged oil filter Disassemble and check Disassemble and check Clean or replace Clean or replace 3.Flywheel is in contact with...
Page 58 Possible Causes Possible Causes Checking Method Checking Method Remedy Remedy (1) Input plate broken (1) Input plate broken Check rotational sound at low Check rotational sound at low Replace Replace rmp and check whether front rmp and check whether front cover rotates cover rotates r...
Page 59 4.Front Axle 4.Front Axle The main specificat The main specificat ions of the front axle see Tale ions of the front axle see Tale 4-1. 4-1. 8-10t 8-10t 5-7t 5-7t Type Type Cast-steel,full-flo Cast-steel,full-floating ating type type Type Type Spiral bevel pinion type Spiral bevel pinion type...
Page 60 Tightening torque: Tightening torque: Tightening torque: Tightening torque: Tightening torque: Tightening torque: Fig.4-1 Front axle(5-7t truck) Fig.4-1 Front axle(5-7t truck) r r -56- -56- https://www.besttruckmanuals.com/...
Page 61 Tightening torque: Tightening torque: Tightening torque: Tightening torque: Tightening torque: Tightening torque: Fig.4-2 Front axle(8-10t truck) Fig.4-2 Front axle(8-10t truck) 11.P 11.Planet lanet carrie carrier 12.T 12.Thrus hrust r r -57- -57- https://www.besttruckmanuals.com/...
Page 62 Fig.4-3 Main Fig.4-3 Main reduction,differential reduction,differential 4. 4.Ta Tapp pper ro roll ller be bear arin ing 5. 5.Di Diff ffer eren enti tial ho hous use 6. 6.Ha Half lf-s -sha haft ge gear ar r r ...
Page 63 4.3 Hub reduction 4.3 Hub reduction The hub reduction is of the planet The hub reduction is of the planet gear type consisting of a gear type consisting of a sun gear,planetary gears sun gear,planetary gears and an internal gear.Two hub reduction are installed on each end of and an internal gear.Two hub reduction are installed on each end of the axle housing.The the axle housing.The...
Page 64 4.4 Troubleshooting Guide 4.4 Troubleshooting Guide See Table 4-2 See Table 4-2 Cause Cause Trouble Trouble Correction Correction Loose bolt or broken gasket of differential carrier. Loose bolt or broken gasket of differential carrier. Replace or retighten. Replace or retighten.
Page 65 5.Brake System 5.Brake System The main specificat The main specificat ions of the brake system See Table 5-1. ions of the brake system See Table 5-1. CPCD50,60,70 CPCD50,60,70 CPCD80,100 CPCD80,100 Homeland engine Homeland engine Import engine Import engine Brake type Brake type Power brake...
Page 66 5.1 General description 5.1 General description The braking system consists of traveling and stopping brakes. The traveling brake is The braking system consists of traveling and stopping brakes. The traveling brake is mounted inside the driving wheel, while the mounted inside the driving wheel, while the stopping brake is mounted on a stopping brake is mounted on a...
Page 67 Brake sw. Brake sw. Brake pedal Brake pedal Reservoir Reservoir Inching pedal Inching pedal Brake Brake valve valve Fig.5.2 Brake pedal unit Fig.5.2 Brake pedal unit -63- -63- https://www.besttruckmanuals.com/...
Page 68 5.2.2 Brake valve (See Fig. 5.3) 5.2.2 Brake valve (See Fig. 5.3) (1) Non-brake status (1) Non-brake status In case of not-braking state and due to opening of port A of brake valve , the pump In case of not-braking state and due to opening of port A of brake valve , the pump interface and the steering interface are interlinked and the steering works normally.
Page 69 C. The backflush piston moves to the right and C. The backflush piston moves to the right and C open to make C open to make the oil of brake sub- the oil of brake sub- pump of brake return to the fuel tank throug pump of brake return to the fuel tank throug h chamber D.
Page 70 5.2.3 Accumulator (See fig. 5.4) 5.2.3 Accumulator (See fig. 5.4) When the engine stops working or there is trouble on the oil pump, the accumulator When the engine stops working or there is trouble on the oil pump, the accumulator can be used as the abnormal (extra can be used as the abnormal (extra ) energy to meet the needs of braking.
Page 71 5.3.1 Vacuum booster and main brake cylinder assembly 5.3.1 Vacuum booster and main brake cylinder assembly The outline dimension of The outline dimension of 9″+10″dual-diap 9″+10″dual-diaphragm vacuum booster and hragm vacuum booster and main brake main brake cylinder assembly used for the forklift 5-7t is shown in cylinder assembly used for the forklift 5-7t is shown in Fig.
Page 72 1.Control valve push rod 1.Control valve push rod 2.Air cleaner 2.Air cleaner 3.Big cone spring 3.Big cone spring 4. Control air valve 4. Control air valve 5.Piston of control valve 5.Piston of control valve 6.Small cone spring 6.Small cone spring 7.Control valve body 7.Control valve body 8.Rear film hull...
Page 73 (2) Working conditions of braking (2) Working conditions of braking A 、As soon as the brake pedal is stepped on, th A 、As soon as the brake pedal is stepped on, th e pedal acts on the cont e pedal acts on the cont rol valve ro rol valve ro...
Page 74 (3 (3) Con Conne nect th the bra brake oi oil pi pipe wi with t the 2 -M10 1 th thre read at o ad at oil ou outl tlet of m et of mai ain cylinder of brake. The tightening moment is 12N.m-16N.m. cylinder of brake.
Page 75 and internal wall of braking drum. and internal wall of braking drum. Self-correcting indirection Self-correcting indirection Fig, 5.7 Fig, 5.7 5.4.1 Travel brake (5-7t forklif 5.4.1 Travel brake (5-7t forklif t truck) (See Fig. 5.8) t truck) (See Fig. 5.8) There is only one brake sub-pump on travel brake of 5-7t forklift and the two ends of ...
Page 76 1.Brake shoe 1.Brake shoe 6.Push rod 6.Push rod 11.Self-adjuster spring 11.Self-adjuster spring 2.Return spring 2.Return spring 7.Secondary shoe 7.Secondary shoe 12.Adjuster lever 12.Adjuster lever 3.Dust ring 3.Dust ring 8.Returning spring 8.Returning spring 13.Adjuster 13.Adjuster 4.Boot 4.Boot 9.Securin 9.Securin g pin for g pin for shoe...
Page 77 1.Brake shoe 1.Brake shoe 6.Boot 6.Boot 2.Adjuster 2.Adjuster 7.Dust hood 7.Dust hood 3.Push rod 3.Push rod 8.Secondary shoe 8.Secondary shoe 4.Piston 4.Piston 9.Return spring 9.Return spring 10.Brake floor 10.Brake floor 5.Spring 5.Spring Fig.5.9 Brake(8-10t) Fig.5.9 Brake(8-10t) -73- -73- https://www.besttruckmanuals.com/...
Page 78 5.4.2 Travel brake (8-10t forklif 5.4.2 Travel brake (8-10t forklif t truck) (See Fig. 5.9) t truck) (See Fig. 5.9) There are two brake sub- pumps for travel brake of 8-10t forklift. The upper and There are two brake sub- pumps for travel brake of 8-10t forklift. The upper and lower ones contact with two ends of primary and secondary braking shoes and the lower ones contact with two ends of primary and secondary braking shoes and the clearan...
Page 79 5.5 Stop brake 5.5 Stop brake Stop brake is an internal expanding and shoe type brake and is installed on the output Stop brake is an internal expanding and shoe type brake and is installed on the output end of one intermediary shaft at the rear side of the gearbox.
Page 80 1.Floor 1.Floor 7.Return spring 7.Return spring 13.Support plate 13.Support plate 2.Brake shoe 2.Brake shoe 8.Adjuster 8.Adjuster 14.Pin 14.Pin 3.Securing bolt 3.Securing bolt 9.Adjuster spring 9.Adjuster spring 15.U-ring 15.U-ring 10.Pin 10.Pin 4.Nut 4.Nut 16.Plug 16.Plug 11.Spring seat 11.Spring seat 5.Washer,lock 5.Washer,lock 17.Parking brake cable...
Page 81 5.6 Troubleshooting Guide (See Table 5-3). 5.6 Troubleshooting Guide (See Table 5-3). Problem Problem Possible cause Possible cause Remedy Remedy Fluid leakage from brake system Fluid leakage from brake system Repair Repair Improper clearance of pads Improper clearance of pads Adjust Adjust e ...
Page 82 6.Steering system 6.Steering system The main specificat The main specificat ions of the steering system see table 6-1 ions of the steering system see table 6-1 Item Item 5-7t 5-7t Type Type Rear wheel steering powered Rear wheel steering powered Dia.
Page 83 Steering system consists of a steering handwheel, a Steering system consists of a steering handwheel, a steering column,gimal assembly, steering column,gimal assembly, steering unit, steering axle and steering cylinder. Steering control unit see fig.6-1. steering unit, steering axle and steering cylinder. Steering control unit see fig.6-1. Steering hand wheel Steering hand wheel Lock handle...
Page 84 The steering shaft connects the steering unit with a gimbal,the steering handwheel The steering shaft connects the steering unit with a gimbal,the steering handwheel turns with the steering turns with the steering shaft and steering column,realizes hydraulic steering. The shaft and steering column,realizes hydraulic steering.
Page 85 6.2 Checking after mounti 6.2 Checking after mounti ng on the ng on the machine machine (1) Check the arrangement of hydraulic pipeline and turing direction (1) Check the arrangement of hydraulic pipeline and turing direction of the truck for of the truck for ...
Page 86 The limit pressure of relief valve has been set to 12MPa.Therefore,when the stop The limit pressure of relief valve has been set to 12MPa.Therefore,when the stop valve is completely closed,the preeure gauge indicates its setting preesure. valve is completely closed,the preeure gauge indicates its setting preesure. hydrau raulic pressu...
Page 87 6.4 Steering axle 6.4 Steering axle 5-10t forklift entirely adopts transverse steering oil cylinder. The front and rear of 5-10t forklift entirely adopts transverse steering oil cylinder. The front and rear of the center are supported by two supporting axle through sleeve on the steering axle the center are supported by two supporting axle through sleeve on the steering axle base, base,...
Page 88 Steering axle seat Steering axle seat Sleeve Sleeve Steering Steering cylinder cylinder Fig.6.4 Steering axle Fig.6.4 Steering axle -84- -84- https://www.besttruckmanuals.com/...
Page 89 Pushing Pushing Bushing Bushing Lock pin Lock pin Needle bushing Needle bushing Turning knurl Turning knurl Nut(outer) Nut(outer) Nut(inner) Nut(inner) Pushing bushing Pushing bushing Steering cylinder Steering cylinder King pin King pin Steering axle body Steering axle body Linkage Linkage Needle bushing...
Page 90 7. Hydraulic system 7. Hydraulic system 5-7t 5-7t 8-10t 8-10t Vacuum Vacuum Power brake Power brake assistant assistant Power Power brake brake Drive type Drive type Transmission P.T.O. Transmission P.T.O. Rated pressure Rated pressure 25Mpa 25Mpa...
Page 91 7.1 General Description 7.1 General Description hydrau raulic system mainly consis sists main pump,c p,cont ontrol valve, ve,hig high & & pressure oil pipes and joints.The main pump is a gear type and installed on the top of the pressure oil pipes and joints.The main pump is a gear type and installed on the top of the transmission.This pump is fitted to a gear to which the transmission.This pump is fitted to a gear to which the...
Page 92 section.Earch section is sealed with O-ring,and the oil passage at the high pressure side is section.Earch section is sealed with O-ring,and the oil passage at the high pressure side is given a check valve. given a check valve. 7.4 Operation of control valve 7.4 Operation of control valve (1) Neutral position (See fig.7-2)
Page 93 7.5 Operation of relief valve 7.5 Operation of relief valve (1) The relief valve is mounted between the cylinder port “HP” and the low- (1) The relief valve is mounted between the cylinder port “HP” and the low- pressure passage “LP”,The oil flows through the poppet”C”...
Page 94 7.6 Operation of tilt lock valve 7.6 Operation of tilt lock valve The tilt—lock valves are intended to prevent vibrations of the mast due to possible The tilt—lock valves are intended to prevent vibrations of the mast due to possible creation of internal negative pressure in the tilt cylinder and also to creation of internal negative pressure in the tilt cylinder and also to avoid a danger of the...
Page 95 Attachment lever Attachment lever (option) (option) Tilt lever Tilt lever Lift lever Lift lever Linkage Linkage Control valve Control valve Section Section Fig.7.10 Control valve lever unit Fig.7.10 Control valve lever unit https://www.besttruckmanuals.com/ -91- -91-...
Page 96 Steering cylinder Steering cylinder To Rear pump To Rear pump To front pump To front pump Lift cylinder Lift cylinder From control valve From control valve Oil filter (Front pump) Oil filter (Front pump) Oil filter (Rear pump) Oil filter (Rear pump) Fitting oil cap(oil mark) Fitting oil cap(oil mark)
Page 97 7.7 Hydraulic circulation system(Main circuit) 7.7 Hydraulic circulation system(Main circuit) The hydraulic system sketch see following: The hydraulic system sketch see following: The hydraulic circul The hydraulic circul ation system of 5 to 8 ation system of 5 to 8 ton forklift truck ton forklift truck s see fig.7-12.
Page 98 Tilt cylinder(R) Tilt cylinder(R) Tilt cylinder(L) Tilt cylinder(L) To lift cylinder To lift cylinder Control valve Control valve Rear pump Rear pump To lift cylinder To lift cylinder Front pump Front pump Steering Steering cylinder cylinder Steering unit Steering unit Fig.7.13 Hydraulic circuit(for 5-10t truck)
Page 99 The hydraulic circulation system of the main circuit is complicated with the hydraulic The hydraulic circulation system of the main circuit is complicated with the hydraulic circu circuit for power for power steer steering.T ing.The hydra hydraulic piping is ulic piping is O-rin O-ring...
Page 100 with hex groove.(Tightening torque:9 to 11 N.m) with hex groove.(Tightening torque:9 to 11 N.m) Fasten the O-ring and wip Fasten the O-ring and wiper to the plunger head side and er to the plunger head side and tighten the seal plate tighten the seal plate with screw to the torque of 4.6 to 5.8 N.m.
Page 101 seal prevents dust from entering the cylinder.The upper end of the piston rod is locked seal prevents dust from entering the cylinder.The upper end of the piston rod is locked with piston head set bolts. with piston head set bolts. When the lift lever is When the lift lever is tilted backward,high oil pressure is sent into the lift...
Page 102 1.Washer 1.Washer 2.Dust 2.Dust 3.Yx-ring 3.Yx-ring 4.Guide cap 4.Guide cap 5.Ball bushing 5.Ball bushing 6.O-ring 6.O-ring 7.Cylinder body 7.Cylinder body 8.Piston rod 8.Piston rod 9.Ring 9.Ring 10.Wearing 10.Wearing 11.Yx-ring 11.Yx-ring 12.Piston 12.Piston 13.Lift chain 13.Lift chain 14.Sheave 14.Sheave 15.Ball bushing 15.Ball bushing 16.Snap ring...
Page 103 8.2 Cut—off valve 8.2 Cut—off valve At the bottom of the two lift cylinders are two cut—off valves(See fig.8-1 No.19 or At the bottom of the two lift cylinders are two cut—off valves(See fig.8-1 No.19 or fig.8-2 No.18) which operate when the high—pressure hose bursts for any reason to fig.8-2 No.18) which operate when the high—pressure hose bursts for any reason to prevent the load from dropping down abruptly.The oil from prevent the load from dropping down abruptly.The oil from...
Page 104 See fig.8-5.With the forks upraised,high pressure oil led from the control See fig.8-5.With the forks upraised,high pressure oil led from the control valve flows valve flows into the chamber (A) and shifts the sleev into the chamber (A) and shifts the sleev e (2) to the left.This opens the opening (G) to allow e (2) to the left.This opens the opening (G) to allow the high pressure oil to flow along the two routes(A—B—G—D—E and A—B—C—D) and...
Page 105 control control valve valve To lift cylinder To lift cylinder 1.Spring 1.Spring 4.Nylon ball 4.Nylon ball 2.Valve sleeve 2.Valve sleeve 5.Valve core 5.Valve core 8.Valve body 8.Valve body 3.Spring 3.Spring 6.Regulator plate 6.Regulator plate 9.Spring 9.Spring Fig.8.5 Regulator(5-7t truck) Fig.8.5 Regulator(5-7t truck) 8.4 Tilt cylinder ...
Page 106 Two tilt cylinders of double acting type are provided at each side of the frame.The Two tilt cylinders of double acting type are provided at each side of the frame.The front end of the piston rod is installed on the mast and the cylinder tail is on the frame with front end of the piston rod is installed on the mast and the cylinder tail is on the frame with pins.
Page 107 9. Hoist system 9. Hoist system The main specifications see table 9-1. The main specifications see table 9-1. 5-7t 5-7t Rolling type,welded mast with free lift, Rolling type,welded mast with free lift, Type Type 2-stage telescopic mast 2-stage telescopic mast Cross section of inner mast Cross section of inner mast...
Page 108 9.1 General 9.1 General The hoist system is of the two—stage,rolling telescopic mast type.The inner mast The hoist system is of the two—stage,rolling telescopic mast type.The inner mast frames have J—shaped section.The outer mast frames have J—shaped section of 10 ton frames have J—shaped section.The outer mast frames have J—shaped section of 10 ton forklift trucks and have C—shaped section of 5 to 8 ton forklift trucks.The masts of 5 to 10 forklift trucks and have C—shaped section of 5 to 8 ton forklift trucks.The masts of 5 to 10...
Page 109 (1 (1) In Inst stal all th the pi pist ston ro rod th the upper beam the inner mast the inner mast withou hout Upper beam of Upper beam of Spacer Spacer inner master inner master shims.
Page 110 Chain Chain (4) Make the fork down to (4) Make the fork down to the ground and tilt the ground and tilt backward fully. Adjust the adjusting nut for the end backward fully. Adjust the adjusting nut for the end End joint End joint nipple of the upper chain and make the two chains'...
Page 111 Outer mast Outer mast Side roller Side roller Washer Washer Stopper Stopper End roller End roller Chain Chain Lift cylinder Lift cylinder Upper Upper Lower Lower Fig.9.6 Roller lay(for 8t truck) Fig.9.6 Roller lay(for 8t truck) Inner Inner mast...

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