HELI CPC 20 Manual
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HELI CPC 20 Manual

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The performance, structure, operation and maintenance and other aspects of the K
series 2-3.8t forklift truck are described in this manual in order to guide the operators
to use and maintain the truck properly.
The rules and notices in the manual should be abided seriously by all of relative
person to enable trucks in optimized working state for long period and bring the
highest efficiency.
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Summary of Contents for HELI CPC 20

  • Page 1 FORWARD The performance, structure, operation and maintenance and other aspects of the K series 2-3.8t forklift truck are described in this manual in order to guide the operators to use and maintain the truck properly. The rules and notices in the manual should be abided seriously by all of relative person to enable trucks in optimized working state for long period and bring the highest efficiency.

  • Page 2: Table Of Contents

    CONTENTS FORWARD I.Driving Operation and Daily Maintenance of Forklift Truck 1. Transport of forklift truck 2. Storage of forklift truck 3. Precautions before operation 4. Operation of forklift truck 5.Cautions on cooling system 6. Oil for forklift truck 7. Lubrication chart II.Specifications of Forklift Truck III.Description of Main Parts of Forklift truck IV.Construction, Principle, Adjustment and Maintenance of Forklift Truck...

  • Page 3: I.driving Operation And Daily Maintenance Of Forklift Truck

    I.Driving Operation and Daily Maintenance of Forklift Truck It is important that driving and managing persons for forklift trucks remember the principle of the“first safety”and ensure the safety operation as the description of 《Operation and Service Manual》. 1. Transport of Forklift Truck Pay attention to the following items when you transport forklift trucks with container or trucks: (1)Apply the parking brake.

  • Page 4: Operation Of Forklift Truck

    (7)Release the parking brake. (8)Make trial of the mast for lifting, lowing and forward and backward tilting and the truck for steering and braking. (9)The contamination level of the hydraulic oil should be lower than 12 as described in NAS 1638. 4.

  • Page 5: Cautions On Cooling System

    89dB(A). 5. Cautions on Cooling System　　　 Cooling system which is filled with HELI exclusive coolant free from maintenance normally before leaving the factory is used to cool engine and hydraulic powered transmission unit (hydraulic powered type forklift truck). The coolant filled in the truck can not only protect the truck against freezing above -35℃, but also...
  • Page 6 ● Check if the thermostat can open normally; (2) Use HELI exclusive coolant in order to keep the engine and cooling system in good condition. Change it once a year. If the coolant is bad in less than one year, change it when necessary.

  • Page 7: Oil For Forklift Truck

    value. Keep the mouth against the radiator core. Water flow pressure: no higher than 0.49MPa (5kgf/cm²); Air flow pressure: no higher than 0.98MPa (10kgf/cm²). (5) Coolant storage notes: (a) Avoid direct contact with the coolant which is bad for health; (b) Store the coolant in proper sealed container because the coolant steam is harmful.

  • Page 8: Lubrication Chart

    7.Lubrication Chart...

  • Page 9: Ii.specifications Of Forklift Truck

    II.Specifications of Forklift Trucks (See Table 1) External View of Forklift Trucks...
  • Page 10 Specifications of Forklift Trucks Table 1 Model Parameters Rated Capacity 2000 2500 3000 3500 3800 Load Center Standard Lift Height 3000 Free Lift Height 6°/12° Mast Tilt Angle Fwd/Rwd Unloaded Lifting Speed mm/s Loaded Unloaded Loaded Unloaded Loaded 11.7 Unloaded Max.
  • Page 11 Specifications of Forklift Trucks Table 1 Model Parameters 3646 3752 3763 3962 Overall Length 3422 1150 1225 1225 1225 Overall Width 1150 2070 2090 2090 2090 Overall Height 2070 4030 4250 4250 4265 Overall Height(extended mast) 4030 1600 1700 1700 1900 1600 Wheelbase...

  • Page 12: Iii.description Of Main Parts Of Forklift Truck

    III.Description of Main Parts of Forklift Truck Clutch — Mechanical Transmission Power System — Transmission System — Torque Converter — Hydraulic Transmission Reduction Gear & Differential — Drive Axle — Steering System — Steering Axle — Lifting System — Operation of Brake and Clutch Pedals (Clutch type truck) Operation of Brake and Inching Pedals (Torque converter type truck) Operating System —...

  • Page 13: Iv.construction, Principle, Adjustment And Maintenance Of Forklift Truck

    IV.Construction, Principle, Adjustment and Maintenance of Forklift Trucks We herein explain the construction, basic principle, adjustment, disassembly and assembly, repair, troubleshooting and other contents of forklift trucks made by us for the operators to use, maintain and repair them more successfully. 1.
  • Page 14 1.2.1 Fuel tank The fuel tank is a welded construction integrated with the truck frame. It is located on the left side of the truck frame and has a capacity of 52l for 2-3.8 ton trucks. The fuel volume sensor is installed on the tank cover to detect the fuel level. 1.2.2 Fuel volume sensor The highest lever 2-3.8 (ton)
  • Page 15 (1) Fuel filter The fuel filter is for clearing the fuel of the dust and impurity. It is installed between the feed pump and injection pump. The filter is of cartridge type. Generally it can not be disassembled. Replace the filter assembly when required.

  • Page 16: Clutch And Clutch Pedal

    2.Clutch and Clutch Pedal Table 2 Truck Model CPC20、25、30、35、38 Parameters Type Single plate, dry Outer dia. Dimensions of Friction Inner dia. Piece Thickness when pressed Friction Surface Area about 10 Weight Operation Mode Foot operated 2.1 General Description The clutch consists primarily of pressure plate, friction piece and clutch yoke. The pressure plate is bolted to the engine flywheel.
  • Page 17 Fig.2-1 Clutch (1) Pressure plate case (2) Friction piece (3) Pressure plate (4) Pressure spring (5) Hub (6) Bearing (7) Driving shaft (8) Coil spring (9) Release lever (10) Release bearing (11) Release bearing block (12) Bolt (13) Lock nut (14) Release yoke (15) Cover After making certain that the driving shaft end has entered the middle...
  • Page 18 (8) Press the clutch pedal and remove the three spacers. (9) Adjust the travel of the clutch pedal. (See Fig.2-2) 2.3 Clutch Pedal The clutch pedal and the brake pedal are fitted on the same bracket. The clutch pedal is secured on the transmission. 2.4 Adjustment of Clutch Pedal Travel (See Fig.2-2) (1) Loosen clutch pedal stopper bolt (a).

  • Page 19: Transmission, Reduction Gear And Differential

    3.Transmission, Reduction Gear and Differential Transmission Type Manual-shift, slide type synchromesh mechanism Gears number FWD:2 BWD:2 Gear ratio FWD 1st/2nd 3.253/1.407 BWD 1st/2nd 3.204/1.386 Reduction gear Gear Spiral bevel gear Reduction ratio Differential Gear Spur gear Reduction ratio 6.182 Differential gear Bevel gear Oil amount Dry weight (no oil)
  • Page 20 Driving shaft’s end toward the clutch is held by the ball bearing located in flywheel, another end fitted with input gear is held in transmission case by the ball bearing and its middle portion is held in the bearing retainer which is fixed in transmission case with the slide lead screw.
  • Page 21 Fig. 3-1 Drive unit (1) Shift rod (15) Driving shaft (29) Idler gear (42) Lock nut (2) Shift arm (16) Input gear (30) Needle bearing (43) Tapered roller (3) Shift arm (17) Ball bearing (31) Idler shaft bearing (4) Shaft arm (18) Spacer (32) Ball (44) Ventilator duct...
  • Page 22 Shift fork Synchromesh Block ring Mesh sleeve Fig.3-2 Gearshifting mechanism 3.2.6 Synchromesh mechanism (See Fig. 3-3) (1)Block ring spline (2) Block ring (3) Spline of gear (11) (4) Synchromesh cone (5)Mesh sleeve (6) Mesh sleeve spline (7) Inserter (8) Spring (9) Clutch hub (10)Shift arm (11) Constant-mesh gear...
  • Page 23 The synchromesh mechanism consists primarily of synchromesh cones, block rings and inserts. (1) Synchromesh cone The gear (11) or (13) has a male cone, i.e. synchromesh cone mating with the block ring (2) through respective cone friction surface, and an involute spline (3) engaged with mesh sleeve spline (6).
  • Page 24 2nd Step (See Fig.3-5) After the elimination of the clearance X and X , the force above acts on the inserters (7) and synchromesh cone (4) through respective friction surface and makes the inserters inclined by an angle against the spring force to contact with synchromesh cone.
  • Page 25 5th Step (See Fig.3-8) When the relative speed between the gear (11) and the mesh sleeve (5) becomes zero, the inertial torque Ti becomes zero too and the speed of the gear (11) is equal to the main shaft’s. At this time, the block ring shifts in peripheral direction to allow every mesh sleeve spline tooth to place between the spline teeth of the gear (11)
  • Page 26 Power flow (1) Driving shaft (13) Reverse gear Driving shaft (2) Input gear (14) Synchronizing cone (3) Cluster gear (15) Mesh sleeve (4) Cluster gear (16) Clutch hub Output shaft (5) Output gear (17) Synchronizing cone (6) High speed gear (18) Forward gear (7) Synchronizing cone (8) Mesh sleeve...
  • Page 27 1-2-3-4-11-10-8-9-12-16-15-14-13-19-20-5-21 Power flow in reverse 2nd speed gear position: 1-2-3-6-7-8-9-12-16-15-14-13-19-20-5-21 3.3 Reduction Gear (See Fig.3-12) The reduction gear located in the front of the transmission is used to reduce the speed and increase the torque from the output shaft of the transmission and impart them to the differential.
  • Page 28 3.4 Differential (See Fig.3-12) The differential is housed in the front portion of the case of the differential the front end of which is connected with the axle housing. The differential case is of splitting type. The differential includes two half shaft gears and four planet gears. The thrust washers are installed between the differential case and each gear and between gear pairs to keep a proper clearances between them.
  • Page 29 (3)Remove the mounting bolts on the transmission case cover (Fig. 3-15). Fig. 3-15 (4)Speedly shift the speed gear from forward gear to backward gear or vide versa to let the front end of the shift rod leave the transmission housing (Fig.3-16).
  • Page 30 (7)Knock at the end of the rotating rod slightly but not heavily and remove the rod (See Fig. 3-19). Fig. 3-19 (8)Remove the shift forks together with the shift rod. Note: Take down the position of the shift forks then. (See Fig.3-20) Fig.
  • Page 31 ● The steel ball in the shift fork should fall into relative midchannel of the shift lever. Fig. 3-21 b) Align the shift forks with the channel of mesh sleeve and put the shift forks and the direction shift lever into the transmission.
  • Page 32 e) After the front end of the shift lever is put into the transmission, tighten the stop bolt to a torque of 7.8-17.6N.m (0.8-1.8kgm) and the lock nut to a torque of 3.7- 23.5N.m (1.4-2.4kgm) (See Fig.3-26, Fig.3-27). Fig. 3-26 Fig.

  • Page 33: Hydraulic-Powered Transmission & Torque Converter

    4.Hydraulic-powered Transmission & Torque Converter Torque converter Type Three elements, single stage, two phases Torque ratio Set pressure 0.5-0.68MPa Charging pump Type Inner-mesh gear type Flow rate 27l/min (2000rpm, 1.5MPa) Transmission Type Power shifted Speed ratio FWD/BWD 1.35/1.35 Hydraulic clutch Friction piece O.D.×I.D.×T.
  • Page 34 Fig. 4-1 Hydrodynamic transmission type drive unit (1) Forward clutch (17) Oil inlet cover (33) Idler (46) Inner-hexagoned plug (2) Oil filter (Ⅱ) (18) Safety valve cover (34) Oil filter (Ⅰ) (47) Transmission case cover (3)Backward clutch (19) Inner-hexagoned plug (48) Mounting bolt (4) Single-row radial ball bearing (35) Output gear...
  • Page 35 4.2Torque Converter The torque converter mainly consists of an impeller, a turbine and a stator. The liquid, from the impeller driven by an input shaft, is jetted along its leaves to leaves of the turbine to transmit the torque to the output shaft (i.e. Mechanical energy is changed into kinetic one).
  • Page 36 The way of torque-converting can be used to ensure efficient and smooth work of the torque converter. The torque converter, filled up with the torque converter oil, in the drive unit is driven by an engine through a spring plate and flywheel on the engine. A charging pump is driven by a driving gear which is splined to the impeller.
  • Page 37 Forward clutch pressure oil Backward clutch pressure oil Connected to Lubrication oil torque converter Fig.4-3 Hydraulic clutch (8) O-ring (15) Seal ring (A) (21) Snap ring (1)Seal ring (A) (2) Bearing (9) Input shaft (16) Seal ring (A) (22) Check valve ball (3) Thrust ring (B) (10) Seal ring (B) (17) Seal ring (A)
  • Page 38 Pressure valve Adjusting valve Operation slide valve Spring Steel ball Fig.4-4 Control valve 4.4.2 Pressure valve It is used to keep the oil pressure within 1.1-1.4MPa. Through the valve and the relief valve, the pressure oil is sent to the torque converter. 4.4.3 Adjusting valve It is positioned between the inching valve and the operation slide valve.
  • Page 39 (1)Snap ring (2) O-ring (3) Inching valve rod (4) Snap ring (5) Spring (6) Valve core (7) Spool (8) Valve body (9) Spring (10) O-ring (11) Cover (12) Oil seal Fig. 4-5 Inching valve 4.5 Transmission Case It is used to contain the input shaft, the output shaft, etc. and serve as an oil tank. There is an oil filter (I) of 150 meshes in specification at the bottom of the case to filter the oil from the charging pump.
  • Page 40 Oil discharging hole Driven gear Driving gear Oil sealing Oil inlet hole Pump body O-ring Torque converter oil inlet hole Fig.4-6 Charging pump 4.7 Hydraulic Circuit(Hydrodynamic Transmission Type Drive Unit)(See Fig.4-7) After the engine is started, the charging pump inhales the oil from the oil tank (i.e.
  • Page 41 inching valve and the operation slide valve. The oil out of the torque converter is cooled by and oil radiator and used to lubricate the hydraulic clutches and finally returns to the oil tank. In the neutral, the circuit from the operation slide valve to the clutches is intermitted, and the pressure valve is opened to let the oil only flow into the torque converter.
  • Page 42 The reduction gear and differential for torque converter type truck is the same as those for clutch type truck in construction (See 3.3 & 3.4). 4.9 Towing Disabled Truck The followings should be done when the torque converter type truck to be repaired is towed by other truck: (1) Remove the half -shaft from the front wheel.

  • Page 43: Drive Axle

    5. Drive Axle Type Front wheel drive type truck, axle body rigidly connected to truck frame, fully floated halfshaft 2 t、2 .5t 3.5t 3.8t 3-3.8t Truck capacity Single wheel type Twin wheel type Single wheel type Single wheel type Single wheel type Twin wheel type 2×7.00-12-12PR 4×7.00-12-12PR 2×28×9-15-14PR 2×28×9-15-14PR 2×250-15-16PR 4×28×9-15-14PR...
  • Page 44 The drive axle mainly consists of the housing, the wheel hubs, the half-shafts and the brakes. The housing is an integrally casted. The tyre with the rim is fixed to the hub with studs and nuts. The power is transmitted to the half-shafts through the differential and drives the front wheels through the hubs.
  • Page 45 nut is tightened, to let the wheel hub be able to be rotated freely. (3) Screw down the nut for the half-shaft to a torque of 96-111N.m (9.8- 11.3kgm). (4) Screw down the wheel nut to a torque of 470-550N.m. (5) Screw down the nut for the brake drum to a torque of 206-225N.m.

  • Page 46: Steering System

    6.Steering System Steering system type Rear wheel steering powered 2t、2.5t、3t、3.5t 、3.8 Truck capacity BZZ1-125 Cycloid gear type powered steering unit Φ70 Bore Steering Φ50 Dia. of piston rod cylinder Stroke Φ415 Dia. of steering handwheel 6.1 General Description The steering system principally consists of a powered steering ass'y and a steering cylinder.
  • Page 47 When the engine stops running, the charging pump will not work. In this time a manpowered steering should be adopted. Fig.6-2 Cycloid gear type powered steering unit (1) Spacing sleeve (2) Valve body (3) Valve core (4) Interlock axle (5) Spring piece (6) Joint sleeve (7) Rotor (8) Stator (9) Valve sleeve (2) Steering cylinder (See Fig.6-3) The steering cylinder is of double-action piston type.
  • Page 48 Fig.6-3 Steering cylinder (1) Piston rod (2) Cylinder cover (3) Cylinder body (4) O-ring (7) O-ring (8)Sleeve (5) Bearing ring (6) Sleeve (9) Yx-ring (10) Gasket (11) Dust ring (12) Bushing (13) Clip ring 6.2 Inspection on Reassembly of Steering System (1) Check the forces necessary to turn the steering handwheel to right and left until it can’t be turned any more to see if they are identical each other and check the operation of the steering handwheel for smoothness during above operation.
  • Page 49 6.3 Steering System Troubleshooting Analyses of Trouble Problem Remedies Replace Pump damaged or breaking down. Clean or replace Flow-divider blocked or damaged. Fail to turn handwheel Hose or joint damaged or Clean or replace pipeline blocked. Adjust pressure Too low oil pressure from flowdivider. Exhaust air Air in steering oil circuit.

  • Page 50: Steering Axle With Lateral Positional Cylinder

    7.Steering Axle with Lateral Positioned Cylinder Truck capacity 2t、2.5t 3t、3.5t 、3.8 Axle body type Center-pivoted supporting Inside wheel 78° Turning angle Outside wheel 54° Distance between pin axes 810mm King pin In-tilting angle 0° Out-tilting angle of wheel 1° 2×6.00-9-10PR(J) 2×6.50-10-10PR(J) Size of tyre 4.00E-9DT...
  • Page 51 7.1General Description Fig.7-1 Steering axle (1) Oil seal (2) Needle bearing (3) Thrust bearing (4) Oil seal (5) Hub nut (6) Tapered roll bearing (7) Tapered roll bearing (8) Lock nut (9) Hub cap (10) Steer hub (11) Stop pin (12) Shim (13) Needle bearing (14) Oil seal...
  • Page 52 the axle body be able to oscillate around the axles. Left and right knuckles are positioned at two sides of the steering axle respectively. The rear wheel hubs are fitted to the knuckle shafts through tapered roll bearings with oil seals keeping the grease in the chambers of the hubs and the knuckles.
  • Page 53 seals. (2) Press the hub bearings into the hub and fit the hub on the knuckle shaft. (3) Fit a flat washer and tighten a castle nut to a torque of 206-235N.m (21- 24kgm) and loosen it and then tighten it again to a torque of 9.8N.m (1kgm). (4) To ensure firm installation of the hub, slightly knock at it with a wooden hammer and in the meantime, rotate the hub for 3-4 turns.

  • Page 54: Brake System

    with a cotter pin. 2t,2.5t 3t,3.5t ,3.8 Truck capacity Brake system type Front two-wheel braking internal expansion, hydraulic type Pedal ratio 5.66 Master cyl. bore 19.05mm Wheel brake type Duo-servo type with parking brake Operating cyl. bore 28.58mm 324×60×7mm 348×76×8mm Lining size (LxWxT) 264cm ×4 194.4cm ×4...
  • Page 55 8.1 General Description The brake system is the front two-wheel braking type consisting of a master cylinder, wheel brakes and brake pedal mechanism. 8.2 Master Cylinder The cylinder contains valve seat, check valve, return spring, primary cup, piston and secondary cup, which are all kept in place with a stop washer and a stop wire. The exterior of the cylinder is protected from dust by means of a rubber dust cover.
  • Page 56 Fig.8-1 Master cylinder (1) Supporting ear (2) Lock nut (3) Push rod (4) Dust cover (5) Stop wire (6) Stop ring (7) Secondary cup (8) Piston (9) Primary cup (10) Spring (11) Check valve (12) Valve seat (13) Cylinder body 8.3 Wheel Brake The wheel brake is the internal expansion hydraulic type consisting of brake shoes, springs, operating cylinder and adjuster and backing plates.
  • Page 57 E type snap ring Fig.8-2 Wheel brake for 2 and 2.5 ton trucks (1) Spring (8) Return spring (15) Spring pull rod (2) Cup (9) Adjusting lever (16) Parking pull rod (3) Piston (10) Secondary shoe (17) Parking push rod (4) Cylinder body (11) Clearance self-adjuster (18) Operating cylinder...
  • Page 58 Torque T o r q u e Fig.8-3 Wheel brake for 3-3.8 ton trucks (1) Operating cylinder ass'y (9) Spring (17) Ratchet pawl (2) Spring (10) Parking push rod (18) Spring (3) Cup (11) Spring pull wire (19) Clearance self-adjuster (4) Piston (12) Brake shoe (20) Pin...
  • Page 59 adjuster pushes the secondary shoe by the larger force than that offered by operation of the operating cylinder. The secondary shoe upper end is forced strongly against the anchor pin, providing large braking force. On the other hand, the braking operation in the truck's reverse travel is performed in reverse order, but the braking force is the same as that in the case of the truck's forward travel.
  • Page 60 pressed, compression force applied on two ends of the adjuster becomes larger. This results in increasing of the rotating resistance of the thread and then causing the force from the adjuster lever don't be able to rotate the section (D) of the adjuster. 8.5 Parking Brake Parking brake lever Handle...
  • Page 61 8.6 Brake Pedal Adjustment (Truck with clutch) (See Fig.8-7) (1) Make the push rod short. (2) Adjust the pedal to the height of 111mm. (3) With the brake pedal pressed by the idle stroke of 30-40mm, pull the push rod out until its front end comes into contact with the master cylinder piston. (4) Tighten the push rod lock nut.
  • Page 62 8.7 Brake Pedal Adjustment (Truck with torque converter) (See Fig.8-8) (2-3.8t) Fig.8-8 Brake pedal adjustment (truck with torque converter) (1)Pedal 2)Linking bolt (3)Connecting shaft (4)Oil tank (5)Free travel stoke (6)Stop bolt (7)Screw stem (8)Inching valve (9)Brake master cylinder (1) Loosen the push rod and interlocking bolt. (2) Adjust the pedal to the height of 111mm with the stopper bolt.
  • Page 63 connection axle and lock the bolt. 8.8 Maintenance This paragraph covers the disassembly, reassembly and adjustment of the brake. (The description here is mainly for 2 ton truck’s brake, the 3-3.8 ton trucks brake is similar to it in general.) 8.8.1 Wheel brake disassembly (1) Remove the hold-down spring of secondary shoe, the...
  • Page 64 (4)Remove the primary and secondary shoes, at the same time, remove adjuster spring. (See Fig.8-12) Fig. 8-12 (5) Remove the braking oil pipe from the operating cylinder, remove operating cylinder mounting bolts and detach the operating cylinder from the backing plate. (See Fig.8-13) Fig.
  • Page 65 8.8.2 Inspection of wheel brake Inspect all parts to make sure if there's any worn or damaged part. If necessary, repair or replace with new one. (1) Check the operating cylinder body's inner surface and the piston periphery surface for rusting. Then, measure the clearance between the piston and cylinder body. Specified clearance: 0.065mm-0.150mm;...
  • Page 66 (7) Check push rod return spring for free length and setting load (See Fig.8- 17 and part No.8 on Fig.8-2, part No. 9 on Fig. 8-16 Fig.8-3). Free length: L=124.5mm; Setting length: L=130mm; Setting load: 245N. (8) Check the adjuster spring for (2-3.8t) free length and setting load (See Fig.8-18 Fig.
  • Page 67 8.8.3 Wheel brake remounting (1) Apply brake fluid to the piston and piston cup and reinstall spring, cup, piston and dust cover in this order. (2) Install the operating cylinder on the backing plate. CAUTION: Make sure each component is in position when in stalling it. Bolts should be torqued to 14.7-19.6N.m for 2 ton trucks and 17.6-26.5N.m for ton trucks.
  • Page 68 (5) Install the brake cable assembly on the backing plate with and E-retainer. (6) Install shoes on the backing plate with hold-down springs. However, hold-down spring at the secondary shoe lower part should be Fig. 8-23 fitted only after the spring seat and adjusting lever are properly mounted.
  • Page 69 hand thread for left-side brake and left-hand thread for right-side brake. In 3-3.8 trucks, right-hand thread for right-side brake, and left-hand thread for left-side brake.) b) Adjuster spring direction. (Do not allow the adjuster gear teeth to contact with the spring.) c) Return spring direction of the push rod.
  • Page 70 Fig. 8-26 (2) If the adjuster fail to do the above operation when the adjusting lever is pulled, proceed with the following inspection: a) Make sure that the adjusting lever, push rod, return spring for push rod are securely installed. b) Check to see if the adjusting lever and adjuster gear are correctly arranged.
  • Page 71 8.10 Wheel Brake Troubleshooting Remedy Problem Probable cause 1)Fluid leaks from brake system. Repair 2)Maladjustment of brake shoe Adjust the adjuster clearance. 3)Brake overheating. Check for dragging 4)Poor contact between brake drum and Readjust Poor braking friction piece. 5)Foreign matter adhered on friction Repair or replace piece.

  • Page 72: Hydraulic System

    9.Hydraulic System 2t,2.5t 3.5t,3.8t Truck model φ φ Model -F28.2-AL -F28.2(F31.5)-AL Main Type Gear type pump Displacement 28.2ml/r 28.2 ml/r (31.5ml/r) Model CDB-F15 Twin-pool type with relief valve, flow divider and Type tilt valve Control valve Setting pressure 17.5MPa Pressure 10 MPa Flow divider Flow rate...
  • Page 73 lubrication method so as to minimum the clearance of the gear face. Since the pump body and cover are made of aluminum alloy, they are light and rigid. The driving gear and driven gear are integrated with their respective shafts which are held in bushings.
  • Page 74 9.3.1Spool operation Take the tilt spool valve for example. (1) Neutral position (See Fig.9-2) The high pressure oil discharged from the pump returns to the tank through the mid-passage. Inlet check valve Main oil inlet Port"B" Port"A" Return spring Spool Mid-passage Low-pressure passage Fig.9-2...
  • Page 75 (3)Drawing-out of spool (See Fig.9-4) With the mid-passage closed, the oil from the main oil-inlet pushes up the check valve and flows into the port “A”. The return oil from the port “B” flows through the low-pressure passage to the tank. The spool can be restored to its neutral position by return spring.
  • Page 76 The relief valve consists of main valve A and proceeding valve B. When the spool of the control valve is operated, chamber C linked with the operating cylinder is filled with high pressure oil. The high pressure oil affects proceeding valve B through throttle hole D and E.
  • Page 77 forward when the engine is at rest, even if the tilt lever is pushed with a full load. The construction of the tilt-lock valve. (See Fig.9-6) Tilt cylinder Valve core Spring Spool Fig.9-6 The port A and B are connected respectively to the front and the rear chambers in the tilt cylinder.
  • Page 78 spool, the circuit between the lower part of the lift cylinder and the oil tank is connected and the piston begins to descend due to the weight of the load and all of lifting parts. In this case, the oil flow returning to the control valve is regulated by the flow regulator valve and the fork descent speed is controlled.
  • Page 79 channels and the bottoms of the cylinders are connected with the cylinder supporter of the outer mast by bolts and pins, while their tops (i.e. piston rod heads) are held by the inner mast piston head guide. Two piston rods should be synchronous during the lifting or lowering.
  • Page 80 Fig.9-8 Lift cylinder (1) Piston head guide (9) Piston (17) Flow regulator valve spool (25) Chain wheel (2) Dust seal (10) Packing (18) Spring (26) Plug (3) Bushing (11) Snap ring (19) Nipple (27) Stop plate (4) Cylinder cap (12) Yx-ring (20) O-ring (28) Set screw (5) O-ring...
  • Page 81 the spring force so that the cut-off valve spool won’t move. If the high-pressure hose bursts, the pressure difference will be big enough to overcome the spring force, causing the spool to move until the holes on the circumference on thee spool are blocked up and allowing only a small amount of oil to flow through the holes at the spool end to let the forks descend at low speed.
  • Page 82 difference overcomes the force of the spring(2) and moves the valve core(7) right, thus the oil flow being decreased by narrowing of the hole D and C, and reduces the oil flow passing through the orifice plate(5). Normal flow direction Orifice direction Control valve Lift cylinder...
  • Page 83 backward, tilting the mast backward until 12 degrees. Fig.9-11 Tilt cylinder (1) Joint (2) Dust seal (3) Snap ring (4) Yx-ring (5) O-ring (6) Guide sleeve (7) Bushing (8) O-ring (9) Piston rod (10) Cylinder body (11) Yx-ring (12) Wear ring (13) Piston (14) Yx-ring 9.8 Maintenance of Main Pump 9.8.1 Disassembly (See Fig.9-18 &...
  • Page 84 body and the gear circumference will surely get scraping traces. The normal scraping trace is not more than 1/3 long of the inner periphery of the pump body. If the scraping trace is up to 1/2 long of the inner periphery, it indicates that the bearing and gear shaft are subject to excessive wear.
  • Page 85 if your nail catches. b) Flaws can be found on the face of the bushing and gets very rough to the feel if your nail catches. c) The inner sliding surface and face have foreign matters sticked. In most case, above troubles on the bushing are caused by contamination of hydraulic oil.
  • Page 86 Oil seal(14) is a combined seal. The seal lip toward the pump shaft provides oil tightness and the seal lip outward mainly prevents enterance of dust (See Fig.9-16). Inspect the seal for flaw, wear or deformation and also its rubber to see if it has sufficient elasticity.
  • Page 87 (5) Turn the pump body over. Put driving gear(5) and driven gear(6) in the pump body so that the same teeth may be engaged as they were meshed before disassembly. (6) With the same procedure as step(4), install bushings(3) and (4) toward the front cover side.
  • Page 88 ports worn excessively, you should renew the hydraulic oil and filters or strainers or clean them. The trial run procedures are as follows: (1) Install a pressure gauge in the pressure pipeline as near to the pump as possible. (2) Place the control valve in its neutral position and run the pump at 500 to 1000rpm.
  • Page 89 Oil tank Main pump Steering cylinder To flow regulator Control valve Steering unit Tilt cylinder (left) Fig.9-18 Hydraulic pipeline sketch -87-...
  • Page 90 9.8.5 Trouble shooting Remedies Problem Possible cause Add oil up to specified oil level. Lower oil level in oil tank. Oil can t be pumped out Blocked suction pipeline or oil Clean it or replace oil if the oil ilter. iscontaminated.

  • Page 91: Lifting System

    10.Lifting System For 2 to 3.8t trucks Type: rolling type, J shaped inner mast, C shaped outer mast with free lift. 2 stage telescopic mast. Cross section of inner mast: 2-3.5t 3.8t Cross section of outer mast: Roller: Main roller 1 Φ...
  • Page 92 10.1 General Description The loading system is of the two-stage, rolling telescopic mast type. The inner mast has J-shaped cross section and the outer mast has C-shaped cross section. Forks and lift brackets both are designed according to international standard. The loading system has a free lift of 300mm.
  • Page 93 is within the range of 15-20mm. (2) Make the mast assembly tilt backward, adjust the pulling force of lift chains and let the tightness of lift chains be equal at b point (See Fig.10-1). (3) The travels of two lift cylinders should be equal. The travels may be adjusted by using the cylinder cap(4) (See Fig.9-8).

  • Page 94: Electric System

    11.Electric System 11.1 General Description The electric system is a system with single wire circuit connecting the negative pole with truck frame. It consists of following subsystems: (1) Charging subsystem This subsystem includes a generator, a set of battery, a charging indicating light and etc.
  • Page 95 starting circuit and the starter can not be started. (2) Light switch The switch is put out to 1st step to turn on the front and rear width indicators and to 2nd step to turn on the front big lamp. (3) Signaling for left turning Pull back the turning lamp switch and the left turning lamp in the front combination lamp lights up.
  • Page 96 (10) Water temperature meter It indicates the temperature of cooling water in engine. The white area in scale is used to indicate 60℃to 80℃, the green area to indicate 80℃to 110℃(normal working temperature of the engine) and the red area to indicate 110℃to 145℃.When the meter pointer reach at the red area, stop the truck until it returns to the green area.
  • Page 97 Fig. 11-1 Electric system -95-...
  • Page 98 -96-...

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