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HELI G3 Series User Manual
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5
1.2.1 Disassembly and assembly of right reduction box assembl
y
Lift
and
erect
the
integrated
bridge
assembl
y
,
remove
the
connection
bolts
of
the
reduction
box
assembly
,
specification:
14
-M12*1.25.
When
installed,
the
bolt
torque
is
124-165N.m.
Remove the reduction box assembly and the primary
planetary reduction assembly
.
7
9
Table of Contents
Table of Contents
3
Main Specifications of Forklift Trucks
4
External View of the Truck
4
Main Parameters
5
Size and Weight of the Main Parts that Can be Disassembled
6
Transmission System
7
General Description
7
Construction, Principle, Adjustment and Maintenance of Forklift Trucks
7
Disassembly and Assembly of Right Reduction Box Assembly
8
Disassembly of Wet Friction Plate
9
Disassembly of Piston Assembly
10
Announcements in Daily Maintenance
11
Brake Lever, Fork Disassembly
11
Brake Maintenance
12
Fuel Quantity of Integrated Electrical Bridge
12
Vulnerable Parts of Integrated Electrical Bridge
12
Brake Pedal
13
Brake System
13
Principle Diagram of Service Brake
13
Brake Valve
14
Connection between Brake System and Drive Axle
14
Shape of the Brake Valve and the Position of each Interface
14
The Connection of Service Brake
14
Gas Exhausting of Brake System
15
The Connection of Parking Brake
15
Inspection and Maintenance of Brake System
16
Inspection of Parking Braking Performance
16
Maintenance and Adjusting of Brake System
16
Operation of Brake System
16
Adjustment of Brake Pedal
17
Adjustment of Brake Switch
17
Shortening Push Rod
17
Steering System
17
Steering Operation Device
18
Steering Wheel and Its Function
18
Duplex Pump
19
Oil Can for Steering
19
Full Hydraulic Steering Unit
20
Principle Diagram of the Hydraulic Steering System
20
Steering Axle
21
Steering Cylinder
23
Steering Knuckle
24
Adjusting and Fault Diagnosis
25
Connection between Steering Knuckle and Axle
25
Hub
25
Pre-Tightening Adjusting of Hub’s Bearing
25
Inspect after Reassembling the Steering System
26
Pre-Tightening Adjusting of Bearing
26
Electric System
27
Steering System Troubleshooting
27
Principle Diagram of Electric System
29
Instrument
31
Introduction of Panel Layout
31
Jiachen Color Screen Instrument
31
Panel Layout
31
Display Interface
32
Hour Meter
32
Instrument Interface Display Information Introduction
32
Instrument Interface-Fault Display
32
LED Lights
33
Steering Angle Indicator
33
Steering Wheel Angle Indicator
33
Travelling Mode
33
Instrument Panel Introduction
34
Battery Status
35
Functions and Applications
35
Milemeter
35
Travelling Speed
35
Control System
36
Introduction to Control System
36
Protection Functions of AC Motor Controller
36
Assembly of Control Device
37
ZAPI Control System Composition
37
Lithium Battery
38
Lithium Battery Specification
38
Motor
38
Motor Specification
38
Lithium Battery Maintenance
39
Lithium Battery Storage and Keep
39
Lithium Battery Usage
39
Daily Maintenance
40
Lithium Battery Error and Resolution
40
Diagnosis
41
Fault Diagnosis of INMOTION
41
General Instruction
41
Fault Diagnosis of ZAPI
45
Fault List of Main Pump, Main Traction
45
Hydraulic System
95
Main Pump
95
Principle Diagram of Hydraulic System
95
Multi-Way Control Valve
96
Auxiliary Piece of Multi-Way Control Valve
97
Lifting and Lowering Piece of Multi-Way Control Valve
97
Oil Inlet Piece of Multi-Way Control Valve
97
Tilting Piece of Multi-Way Control Valve
97
Lifting System
98
Inner and Outer Mast
99
Adjusting of Shims at the Lifting Cylinder’s Head
100
Fork Carrier
100
Repair and Maintenance
100
Adjustment of Fork Carrier’s Height
101
Replacing Rollers of Masts
102
Replacing Rollers of the Fork Carrier
102
Replacing Main Rollers
103
Lithium Battery Changing
104
Truck Selection for Lithium Battery Changing
104
General Description
104
Load Center C
105
Steps to Change the Lithium Battery
105
Disconnect the Lithium Battery Connections
106
Steps to Install the Lithium Battery
107
5
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HELI G3 Series Specifications
General
Brand
HELI
Model
G3 Series
Category
Trucks
Language
English
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