HELI Forklift Truck H2000 5-10t Service Repair Manual

FOREWORD This manual accounts for “HELI” Forklift Truck in H2000 series from 5t to 10t, includes its performance, constructure, safe operation and regular preventive maintenance, so that operators, mechanics and supervisors of Forklift Truck correctly operate and prevent maintenance. Read and understand this manual before operating your lift truck! This manual is your guide to safe operation and regular preventive maintenance. So as to let the Forklift Truck keep good working conditions. If any operation or maintenance does’t accord with requires in this manual, our related promises is inefficacy. 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. Notice:Designations in the CATALOGUE are difference from those in product nameplates and quaulifying licenses.Designations in the CATALOGUE include engine code and number of remodification. CPCD50 - W2 Engine code and number of remodification. Type.

CONTENTS Ⅰ. Safe Operation Rules and Daily Maintenance for Forklift Ⅱ. Primary Technic Parameter of Forklift Ⅲ. Primary Assembly Introduce of Forklift Ⅳ. The structure, principle, adjustment and maintenance of Forklift 1. Dynamic System 1.1 Fuel system 1.1.1 Fuel tank 1.1.2 Fuel sender 1.1.3 Fuel filter 1.2 Cooling system 1.3 Inspection and adjustment 1.3.1 Air cleaner 1.3.2 Oil filter(fuel) 1.3.3 Oil filter(machine oil) 1.3.4 Cooling system 1.3.5 Tightening the cylinder head bolts of engine 1.3.6 Adjustment of clearance of air gate 1.3.7 Confirmation of the ignition time of oil injectio 1.3.8 Adjustment of ignition time of oil injection 1.3.9 Measurement of the compression pressure 1.3.10 Exhaust air of oil injection pump 2. Electric System 2.1 General description 2.2 Brief explanation for operation 2.3 Battery 2.4 Wire harness 3. Transmission Device 3.1 General description 3.2 Torque converter 3.3 Oil pump 3.4 Hydraulic clutch group 3.5 Control valve & inching valve 3.6 Hydraulic circulation system in tor-con 3.7 Cautions when the forklift truck trouble occurs 1 7 14 15 15 18 18 18 20 20 20 20 21 21 22 23 23 24 25 25 26 27 29 29 31 31 43 45 45 46 47 48 49 51

3.8 Trouble shooting 4. Drive Axle 4.1 General description 4.2 Differential 4.3 Hub reduction gear 4.4 Trouble shooting 4.5 Data use for service 5. Brake System 5.1 General description 5.2 Power brake 5.2.1 Brake pedal device 5.2.2 Brake valve 5.2.3 Accumulator 5.3 Vacuum servo brake 5.3.1 Vacuum booster and main brake cylinder assembly 5.3.2 Installation method for vacuum booster and main brake cylinder assembly 5.3.3 Points of attention for users 5.3.4 Trouble shooting and cause analysis 5.4 Travel brake 5.4.1 Travel brake(5-7t forklift truck) 5.4.2 Travel brake(8-10t forklift truck) 5.5 Stop brake 5.6 Trouble shooting 6. Steering System 6.1 Steering unit 6.2 Checking after mounting on the machine 6.3 Troubleshooting guide 6.4 Steering axle 6.4.1 Steering axle body 6.4.2 Left and right steering knuckle assembly 6.4.3 Wheel hub 6.4.4 Steering oil cylinder 7. Hydraulic System 7.1 General description 7.2 Main pump 7.3 Control valve 7.4 Operation of control valve 51 55 55 55 59 60 60 61 62 62 62 64 66 66 67 69 70 70 70 71 74 75 77 78 80 81 82 83 83 83 83 83 86 87 87 87 88

7.5 Operation of relief valve 7.6 Operation of tilt lock valve 7.7 Operation unit of the control valve 7.8 Oil tank 8. Lift Cylinder & tilt cylinder 8.1 Lift cylinder 8.2 Cut-off valve 8.3 Flow regulator 8.4 9. Hoist System 9.1 General description 9.2 Outer & inner mast 9.3 Lift bracket 9.4 Adjustment of hoist system 9.4.1 Adjustment of shims of lift cylinder 9.4.2 Carriage adjustment 9.5 Roller position of mounting Tilt cylinder 89 90 93 95 96 96 99 99 101 103 104 104 104 104 104 105 106

-1- Ⅰ. Safety rules for Operation and Daily Maintenance of Forklift Truck 1. Delivery of Forklift Truck 2. Storage of Forklift Truck 3. Precautions Before Operation 4. Operation of Forklift Truck It is important that driver and manager for forklift trucks remember the principle of the “first safety” and ensure the safety operation as the description in 《OPERATION AND SERVICE MANUAL》. It must be pay attention to the following items when you delive forklift trucks with container or trucks. (1) Apply the parking brake. (2) Fix the mast and the balanceweight with steel wire.Wedge up all wheels. (3) Sling points should be always at the positions specified in sling index plate when hoisting up the forklift truck. (1) Drain off fuel completely. Don’t drain off the cooling water containing antifreeze and rustproof agent. (2) Apply antirust to the surface of the parts not painted. Apply lubrication oil to the lift chain. (3) Lowing the mast to the lowest position. (4) Apply the parking brake. (5) Wedged up the wheels. (1) Don’t check fuel leakage and lever or instruments at the place there is open flame. Never fill the fuel tank with the engine running. (2) Check the tire inflation pressure. (3) The forward-reverse lever should be in neutral. (4) Never smoke while the fuel system is under working or the battery is inspected. (5) Check all the levers and pedals. (6) Complete the provisions before starting. (7) Release the parking lever. (8) Make trying opteration of the mast for lifting, lowing and Fwd/Bwd tilting and the truck for steering and braking. (1) Only trained and authorized operator shall be permitted to operate the truck. (2) Wear all the safety guards, such as shoes, helmet, clothing and gloves while operating the truck. (3) Check all the control and warning devices before starting the truck. If any damages or defects are found, operate it after repairing. (4) Overload or overload operation is strictly prohibited. The fork should insert

completely under the cargo and make the cargo placed on it evenly. Do not raise an object with one fork end. (5) The starting, turning, driving, braking and stopping operation of the truck should be done smoothly. When steering on the humid or low friction road, the truck should be decelerated. (6) Travel with loads as low as possible and tilted backward. (7) Be careful when traveling on a slope. When climbing grades with a slope of more than 10%, the truck should forward travel, and when descending so grades, backward travel. Never turning on a slope. Avoid loading and unloading operation when decending. (8) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay attention to the clearance over forklift truck. (9) Never allow any persons to stand on the forks or the truck to carry persons. (10) Never permit anyone to stand or walk under upraised forks. (11) Don’t operate truck and attachment of it at any position out of the drive seat. (12) On the high lift forklift truck, when the lift high more than 3m, it is noted that the goods on it should not fall down or the protection measures must be taken if necessary. (13) Tilt the mast of the high lift forklift truck as backward as possible while the truck working. Use minimum forward tilt angle and Min. reverse tilt when loading and unloading. (14) Be careful and slowly driving over a dockboard or bridge-plate. (15) Shut down the engine and don’t stay on the truck when filling fuel. Don’t ignite the engine while checking battery or fuel lever. (16) The unloaded forklift truck with attachments should be operated as a loaded truck. (17) Don’t handle unfixed stacked goods.Be careful to bulky goods to be handled. (18) If leaving the truck, lower the forks on the ground and let the shift lever to neutral, shut down the engine or cut down electric supply. If parking on a slope is unavoidable, apply the parking brake and block the wheels. (19) Don’t open the radiator cap when the engine is worm. (20) Don’t adjust the control valve and relief valve at will to prevent the damage of hydraulic system and its components because of excessive pressure passing them. (21) According to the measure method specified in JB/T3300,max.noise at the outboard of the truck should be not more than 89dB(A). (22) Notice and be familiar with all kinds of decal’s function. -2-

5. Arrangement sketch of instruments and controls -3- 1. Fuel gauge 2. Monitor 3. Water temp.meter 4. Hour meter 5. Ignition switch 6. Lamp switch 7. Horn button 8. Turn signal switch 9. Steering handwheel 13. Lift lever 14. Tilt lever 15. Parking brake lever 16. Forward-reverse lever 17. Inching pedal 20. Brake pedal 21. Accelerator pedal 22. Cable of cover 23. Cable of extinguish

6. Daily maintenance of forklift truck 6.1 Caution for starting (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. (2) Check if any leak or damage found on the piping joints,pumps and valves. (3) Check the travelling brakes: A）The free travel of brake pedal should be within the range of 40mm. B）The clearance between the front floor and the pedal should be bigger than 20mm. (4) Often check the parking brake.The laden truck can park on the 20% grade ramp,when the parking lever is pulled to the bottom. (5) Check the meters,lights,switches and electric wirings to see if they are properly in operation or not. 6.2 Fuel and lubrication used in forklift truck. -4- Name Gasoline Diesel Gear oil (gasoline,SF) Electric injection(SG) Gear oil (diesel,CD) Hydraulic oil Torque converter oil Brake fluid Lubricating oil Gear oil of heavy-laden vehicle Antifreeze fluid Brand and temp. of using 93# or 97# Brand(diesel) Temp. of using Sticky grade Temp. of using Sticky grade Temp.of using Sticky grade Temp. of using 6# Tor-con oil 4604 compound brake fluid GB12981 HZY4 3# lithium base grease(-20℃~+120℃) Sticky grade Temp. of using Number Temp. of using Chang cheng Chang cheng Chang cheng Hai pai Chong qing yi ping Hai pai Hai pai Jin bai 0# ≥4 5W/30 -30～+30 5W/30 -30～+30 L-HM32 wearable hydraulic oil ≥-5 85W/90GL-5 -15～+49 FD-1 ≥-25 -10# ≥-5 10W/40 -25~+40 10W/30 -25~+30 FD-2 ≥-35 -20# ≥-5~-14 10W/30 -25~+30 15W/40 -20~+40 FD-2A ≥-45 -35# ≥-14~-29 15W/40 -20~+40 20W/50 -15~+50 FD-3 ≥-50 80W/90GL-5 -25~+49 L-HV32 low temp. wearable oil ≥-20(cold region)

6.3 Cautions on cooling system (1) During operation, if the radiator of forklift “boils” or the temperature of cooling liquid is too high, do not open the cover of radiator immediately. If the cover needs to be removed to find out the cause for it, reduce the rotational speed of engine to the moderate, slowly rotate the cover and not remove it very soon so as to prevent operators from being scalded by the splashing liquid. When recovering the radiator, it must be screwed tightly, otherwise, the system may not be well enclosed and the system pressure stipulated cannot be formed. (2) There is a compensation can on the left of engine.The letter”FULL”and “LOW”are marked on the upper and lower of the can wall.Correct antifreeze agent level should be between letters. Antifreeze liquid of same type should be replenished after the liquid leaks or evaporates. which is not changed around the year, regardless of summer or winter. Generally, after being used for one year, it should be let out for filtration and purification and then put to use again. (3) Based on different working conditions, regularly clean the outer surface of the radiator with detergent, compressed air or high-pressure water (no high than 4kg/cm ). 2 -5-

6.4 Lubrication system table -6-

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HELI Forklift Truck H2000 5-10t Service Repair Manual

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