Two part: Inspection and adjusting for main parts

一、 Engine：see engine manual

Transmission system maintain: Loosen the lifting cylinder’s crew, then support the floor of
cabin,you will see and adjust the transmission system
二、Braking system：
Using Pneumatic clamp type brake system, Full brake pedal travel 160mm,free
travel8-10mm.need inspection when the brake pedal is too low.
(1)Air compressor do not work well, air cylinder pressure is low or no gas
(2)Data of pressure control valve is improper, air pressure is not enough, which lead in the
braking force weakened.
(3)piping break or loose connection, lead in air pressure shot,Braking torque to reduce
(4Brake valve film or Brake chamber diaphragm braking
(5)free travel is too long
(6)the gap between Friction and brake drum is too large, or frinction is dirty
Every 200 working hours,check the ware of the brake shoe.the gap between brake shoe and
drum should be adjusted when the pedal travel is too large. As following:
(1)Support the wheel
1 start engine,check the air manometer in instrument panel, if the data is “0”,step the brake
shoe,the loosen sound like exhaust, that means air manometer is brake,should change
it. If there is no sound deflated, check the air compressor belt and circumstances from an air
compressor to pump reservoir section of the trachea. After the inspection, in good condition,
such as a low pressure gauge indicates the number, the fault in the air compressor, you
should check the exhaust valve or cylinder internal technical condition, be repaired. Such as
the barometer indicated pressure values up to standard, you can press the pedal, the brake
to check whether the leak between the wheels of the Department. If there is no leakage of the
Department, then check pedal free travel and adjust the gap between the brake shoe lining
and brake drum.
(2)(Wheel brake) found on the back plate of the eccentric bolt brake, turn the eccentric bolt
until the shoe in contact with the drum, and then relax eccentric bolts until the free rotation of
the hub and the shoe when no friction.
Note: When you are not allowed to adjust the rotation and remove the brake shoe support
pin
三、 transmission shaft:

There are four needle bearing universal joints, universal joint cross shaft has a grease nipple,
every 150 hours of work should inject grease.
四、driving axles：
Passive gear according to the contact area has been the standard matching. Therefore,
long-term use are not adjusted, only replace the damaged parts or parts due to wear and
when to move. Parties need to be adjusted for the original bridge. Adjustments should pay
attention to the following:
(1)Drive gear bearing clearance should be no gap can rotate freely inside the pedestal
bearing inner race behind the initiative to adjust the gear change after adjustment.
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(2)Active and passive gear backlash, when measured by the driving gear flange around a
radius of 45mm displacement (arc length) should be between 0.2-0.6mm.
(3)After every 100 hours driving, drive axle oil level check, correct oil level is not lower than
the lower edge of the oil filler 10mm, add if necessary. After every 300 hours driving, you
should replace the gear shaft, the machine should be added on the 18 type hypoid gear oil
(4)each with 100 hours, should be replaced every round shell bearing grease, bearing
preload adjustment degrees to the right so far.
五、Hydraulic system
Hydraulic system consists of a gear pump, multiple commutation Court, diverter valve,
cylinder, work tank and piping components.
Pressure oil from the gear pump through the multi-valve, through the manipulation of the
corresponding slide valve to the oil transported to the cylinder. When working device does not
work, mostly through oil valve intermediate oil path back to the tank.

Three part: electric system

Electrical system uses AC voltage 24 V, negative ground system。

1\ battery, 2\fuse box,3\fuse, 4\electric starter, 5\starter relay, 6\ammeter, 7\starter switch,

8\turn lights,9\ steering switches 10-11\front and rear headlights,12-13\front headlight switch,

14\fan switch, 15\fan, 16\speakers ,17\horn button, 18\regulator ,19\generators, 20\water

tanks fan switch ,21\the fan, 22\the total power knife

一、Battery
Battery model N100-12V, its function is that when the engine is started, the power supply to
the starter. when the normal operation, if the voltage of the generator is higher than the
voltage of the battery, the power generator to charge the battery to store part of the
Please notes:

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1、 Keep the electric state. Such as the long-term need. Should be charged at least once a
month.
2、Always check the electrolyte fluid level. Level should be higher than 10-15 mm plates, add
distilled water is low, such as to ascertain the electrolyte leakage spill losses. You should add
a specific gravity of the electrolyte l.28.
3 、 Battery should always vent is blocked, remove external dirt and booties, wipe spilled
electrolyte and the electrode coated with a thin layer of calcium-based grease to prevent
corrosion.
4、Not overuse starter.
5、Battery should be tightened to protect against shock and damage
二、Generator and regulator
1、Alternator：
Generator has labeled "magnetic" armature "" word and a two terminals labeled "ground"
on the ground nail. They should be marked on the relay regulator same text terminal
connection, "ground" "ground" screw with the relay is connected to the screw on the
regulator.Generators at both ends with the bracket bolted to the generator; otherwise a
generator brace, used to adjust the V-belt tension.
2、Relay regulator：
Relay regulator by the closure, voltage regulators, flow restrictors composed of three devices.
The relay regulator labeled "armature", "magnetic", where two terminals and a grounding
screw. "Armature", "magnetic" and the base side of the grounding screw terminal should be
connected to the appropriate terminals on the power and grounding screw. "Battery" ammeter
connected terminal "-" sign posts, ammeter "+" sign and the battery terminal "-" sign pole pile
connected. After the discovery regulator is not working properly, or 100 hours of use, the need
for skilled electricians to adjust
三 、Starter:
Its purpose is to: supply power from the battery to start the engine. Mobile electromagnetic
starter gear is driven, with a one-way roller clutch, the starter can be prevented after the start
of the armature with the high-speed rotation of the engine being damaged.

四、others:
1, Fuse box:
When the circuit fails, the current overload, can automatically fuse blows, thus ensuring

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complete electrical equipment work. There is a fuse inside the fuse box assembly fourth gear,
and the operating current of each file uses the following table:

level 1 2 3 4

purpose Charging Headlights, Turning

Total Fuse
circuit taillights lights

Working current
30 20 6 6
(amps)
If you find that the circuit has not normal circumstances, you should immediately check the
fuse box corresponding fuse is blown, blown fuse according to another file, check the
protected elements. After troubleshooting, disconnect the fuse panel, pull start loading head,
the upper end of the fuse board with insurance fuse removed about 60 mm, between the fixed
installation in tight around the head, then pull back to move the head mounted, and then
install the fuse panel into the fuse box original position.
2, Voltmeter：
Ammeter to indicate battery charge and discharge current, when the generator to charge the
battery, the pointer bias "+"; on the contrary, for the "-" and no current flows through it means
zero.

3, Power locks:
Electric lock control the entire electrical system, after the key into the keyhole, right dial, all
electrical power is turned on; dial to the left, all electrical power except the electric starter is
turned on.

Four part: Driving operation

Before driving with job action, should be familiar with the structure, technical maintenance,
operation methods loaders, in order to ensure safe driving into work, increased life
expectancy and productivity loader.
When driving with a job during the operation note the following safety precautions:
1, The driver must go through to learn traffic rules, the mechanical structure, methods of
operation, etc., and read the instructions.
2, Expect driver, anywhere allowed no occupant.
3, Pay attention to the reactions of the various instruments work status。

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4, When operation, strictly prohibited to walk in the door frame and the tines down.
5, Immediately turn off the engine when parking to avoid steering failure caused the accident.
一、Car go together
Use units in the car, you must be operated without the commissioning of a new car may not
be the official job.
Commissioning friction parts of the machine to make adjustments, and avoid failure, thus
ensuring reliable operation loaders, prolong life.
The same applies to after overhaul loaders.

二、Empty commissioning (about 8h)

1、steps：
(1) according to the method prescribed starting diesel engines, after starting the first 5min to
speed idle (not in gear). Then gradually accelerate to maximum speed, running 10min.
(2) Operating working device lifting and tipping lever joystick, so Fork lifting, lowering, tilting
mast and recovery, were approximately 10 min.
(3) hang up before the file after the reverse, empty exercise. High-speed, every uniform
arrangement after the first low-speed gear.

2、Check items:
(1) comprehensive inspection ministries bolts, nuts fastening. Especially the cylinder head
bolts, the exhaust pipe and the front and rear axle bolt bolts, nuts rim, drive shaft connecting
bolts.
(2) engine, transmission, drive bridges part has no unusual sounds
(3) hydraulic system, transmission, engine lubrication systems, brake systems, engine
cooling system, such as whether the oil spills, leaking.
(4) The meter readings are normal.
(5) the steering is flexible. Braking is sensitive and reliable.
(6) whether the course of action working device stuck phenomenon.
(7) Check the electrical work.
三、Test run operation (about 20h)

1, job by job manipulation methods, loading quantity should be gradually increased.

2, work commissioning process, in addition to checking the empty commissioning inspection
items, but also the ability to observe the loader work in different tooling.
3, walk together during loading and unloading load shall not exceed the usual load of 70%.
4, in the period to go together with a fork mounted flat materials appropriate action may not
receive too much too fast
四、 Working Notes
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（一）require:
l, add diesel to be pure, diesel label shall comply with the quality requirements.
2, hydraulic system using hydraulic oil must be clean.
3, according to the provisions for regular maintenance and lubrication.
4, after the engine is started, empty running 2-3 minutes and then start driving, winter or cold
climates may be appropriate to increase the warm-up time.
5, when the steering fork and bucket reaches desired position, it should be placed in the
middle position of the joystick.
6, may not be elevated to the highest position the fork material transport, carrying the material
should be kept off the ground underside fork 300mm. In order to maintain stable running
(二)Empty travel
1、starting:
Carried out of the bus before the examination, confirmation ministries are normal after
starting the engine. Should be placed before starting each lever neutral position, and then
insert the key switches, and a clockwise position, power, depress the throttle, and then start
the engine. In case of low temperatures in winter, when cold water should be released, plus
hot or boiling water to start. When starting, engine oil pressure should observe proper throttle
control to prevent bush-burning engine.
one start time of 5-10s, if beyond the time must stop. Wait one minute, then make a second
start. More than three times as still can not start, you should check the reason, then start
troubleshooting.
2、Start with traveling
After start the eingine,should warm up the machine with middle speed throttle, and pay
close attention to the oil pressure gauge instructions.
Also check the diesel engine and other systems are all normal. Ministries are normal, it will
rise to the transport position forks, hang forward gear, slowly depress the accelerator pedal,
the loader can be moving forward, and then depending on the speed of its roads and jobs
where necessary, to select the appropriate file throttle position and into travel and jobs.
3、Parking and flameout
Before engine shutdown, should idling 2 to 3min, so that uniform cooling ministries.
Parking should be promptly after the winter unscrew the drain valve engine, put the net all the
water cooling system to prevent mechanical cracking. When the water temperature to a 20 ℃
-30 ℃, the battery should be removed, moved Nuanshi avoid cracking.
Also, pay attention to the flat on the ground before stopping the fork, turn off the power.
(三)working operation

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 Manipulation and operational work of the relevant driver proficiency, proficiency different
drivers have different work methods of operation, for reference purposes only. The use of the
machine can be master of their own comrades in the practice of job operations, continuous
improvement and summary methods of operation in order to improve the life of the production
and machine loading and unloading. Should clean up before the job site, filling pits,
elimination of sharp stones and other damage to the tire barrier and hinder job

1. Fork working：
(1) I stall speed is on the forward cargo, fork bottom section parallel to the ground plane
(which can also forward edge side down fork).
(2) at a distance of about 1-1.5mm goods at the fork down, flip the door frame, so that the
front edge of the fork ground, cargo and ground plane tines 3-7 degree angle cut into the
cargo.
(3) make the fork full throttle cut into the stockpile, and intermittently operated door frame and
fork lifting the bucket until the forks into fork until all goods.
(4) When all the forks into the cargo fork turn back door frame, the forks raised to the proper
height, then let the lever back to the middle position.

2、steering operation:
(1) point towards the cargo storage or transport vehicles. Ruoyin pavement is too soft or
without flat space, can not help with the truck or due to transport distance in less than 500mm,
when you need to rotate on their own, while towards the discharge point, the fork into the
transport position, in order to ensure that transport safe and smooth.
(2) After the installed goods, release the throttle the engine speed is reduced, hang reverse
gear, then slowly increase the throttle, will exit the cargo loaders.

Five part: Maintaining

Operating conditions working environment loader more severe, often uneven

construction site and work with various parts vulnerable to strong vibration or collision, loose

or damaged parts of the machine, so as to ensure good performance loaders, normal

operation prolong life, in addition to the machine must be familiar with the various parts of the

outer structure, but also require periodic inspection of the machine according to the state of

technology and technical maintenance seriously. This chapter describes the exception of

some of the technology outside of the engine maintenance, engine technology engine

maintenance instructions for reference.

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 一、 Loaders oil and lubrication Notes
1, injection of fuel, hydraulic oil, lubricating oil and grease should be oiling tools, containers,

and oiling parts cleaned to prevent water, mud, debris and oil into being.

2, filling a variety of oils, it is necessary to make the machine in a horizontal position, except

with the oil level indicating device can be observed, in general, are the oil plug overflows,

gearbox, oil dipstick cover the shift.

3, add oil, dirty oil should put the net, cleaning the oil injection oil level to the original work,

under no-load conditions, the engine running a few minutes, stop running, put the net

cleaning oil, then add clean the new oil, such as the viscosity of the oil may advance a little

too warm after dilution were filling.

4, at low or high temperatures for different operating conditions, the basis of the actual

situation and requirements, the type of work to replace all the oil lubricant.

二、 loaders oil types (shown in Table 5-l)

Table 5-1 oil types

model
YC50
items

fuel tank(diesel) summer（up10℃）0#，winter（down 10℃）-10#

 oil pan summer（up10℃）CC40，winter CC30

Transmission/axle 18# hypoid gear oil

Hydrauli oil tank winter46、summer 68antiwear hydraulic oil

Composite calcium base lubricating oil
Zerk

Brake oil “912”synthetic brake fluid

三、 lubrication
Proper lubrication can greatly reduce the frictional resistance and wear of machine parts, thus
extending the life of the machine.
Please note that the above precautions when oil lubrication, please use lubricants specified in
Table 5-1. Engine lubrication Follow the instructions provided by the engine
四、 regular servicing
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 Routine maintenance work in front of the class, and after the operation carried out much of its
content, time is short, but the normal operation and the reduction of accidents is extremely
important. The main work is :

1, before work, after the exposed parts of the machine to keep clean.

2. Check for loose and missing fasteners, and be tightened and filled.

3, various parts of the mechanical damage

4. Check the lubrication at whether to add a little oil.

5. Check all tanks (fuel tank, fuel tank work, brake master cylinder), you must add a little bit of

oil.

6, the engine cooling water is to add a little.

7, check the electrical system without loose wire connectors, battery power is adequate.

8, check the meter, the lamp is complete, good.

9, check the steering is flexible, and reliable.

10, after starting to check for holes, leaks, there are no unusual sounds.

11, the test is reliable braking, steering is flexible.

五、scheduled maintenance
（一）、every day maintain:
1. Check for oil, water, gas leaks and mechanical overheating;
2. Check the engine oil, coolant and hydraulic oil level;
3. Check the tire pressure and damage;
4. Check the instrumentation and lighting;
5. The hinge point pressure injection butter.
（二）、every week maintain（after 50 working hours）
1. Check the foot brake pedal stroke compliance requirements, such discrepancies are to be
adjusted.
2, before fastening, the rear propeller shaft connecting bolts, drive axle bolts, wheel nuts.
3, check the battery power, such as insufficient to be charged.
4, injection nozzle pressure injection of calcium based grease. (Front frame 13 pins, two
upper and lower hinge pin, two pin swing frame engines, pumps a total of 18 lubrication
points.
（三）every month maintain（after 200 working hours）
1, measuring tire pressure. If there is insufficient and should be qi.
2, clean fuel, hydraulic oil filter.
3. Check the brake system for leakage or damage.
4. Check and tighten the wheel bolts, brake discs and bearing cap bolts.

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 （四）、every quarter（about 600 working hours）
1. Check the multi-valve, fuel tank leakage various circumstances, if a serious decline in the
phenomenon of the working device, you should repair excluded.
2. Check the brake master cylinder for damage.
3. Adjust wheel bearing clearance, and outside the brake disc runout less than 0.2mm。
（五）、half year maintain〔about 1200 working hours〕。
1, replace all fuel and oil system oil, hydraulic system oil, transmission, brake oil, gear oil, and
front and rear axles. And the pipeline, oil shell, filters and other clean, purified and then
injected into the new oil
2, washable brake master cylinder, check the brake effect.
3, check the front and rear axles, the main drive gear meshing, if the main gear driven bevel
gear gap is too large, it should be adjusted to within 0.2-0.34mm
4, inspection equipment and racks, with or without modification, weld breakage.

Six part: General failure and cause analysis

parts failures reasons fixing

engine See engine manul
1, the pedal free travel is 1, re-adjust
too small
2, the pressure of the spring 2. Replace the pressure
Engagement slip weakness spring
3, the friction surface with 3. Cleaning
oil 4. Replace the friction
4, friction and wear overdue plate
1, spline wear too much 1, replacing the clutch
clutch 2, the fastening bolts loose or sleeve
Engagement 3, the friction surfaces with 2, fastening
trembling grease 3. Cleaning
4, the release lever to 4. re-adjust
adjust unevenness
1、 1, the pedal free 1\re-adjust
Clutch not be easily travel is too large
separated 2、 the separation 2\re-adjust
lever to adjust properly

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 1, gear wear overdue backlash tooth is 1, the replacement
too big gear
2, bearing wear overdue 2. Replace the
3, the fastening bolts loose bearings
Fat sound 3, fastening
4, the lack of lubricant
4, add lubricant
5, the gear and shaft splines wear
5, replace the gear or
excessive wear shaft
transmissi
on
1、 1, fork shaft positioning spring
1, replace the spring
weak or exchange effect 2. Replace the fork
Hop gear 2、 fork shaft positioning groove wear
shaft
overstress 3, replace the gear or
3、 internal and external spline wear
shaft
Shift is not Repair or replace the
1, the gear end collision hair
flexible gear deburring
1、 1, the main gear meshing point 1, adjust or replace
with a bad wheel the bevel gear
noise driving 2、 bearing wear or loose overstress 2. Replace the
3、 gear wear overstress bearings or adjust
3, replace gear
1, the brake plate bending 1. Repair or replace
Noise braking 2, brake linings loose rivets 2. Repair
3, brake drum damage 3, replace
Axles
1, the brake shoe surface oil 1, cleaning
Vehicle 2, improper gap adjustment 2, re-adjust
deviation 3, sub-standard tire pressure 3, the air pressure is
consistent
1, the brake drum and brake shoe 1, re-adjust
Braking not clearance adjustment inappropriate 2, cleaning
work 2, there is oil 3, replace
3, brake lining wear overstress
steering 1, the worm axial movement Readjust
steering wheel 2, worm and rolling engagement gap is Re-adjust or replace
to rotate freely too large
volume surge 3, the ball joint wear and tear or Replace
rupture overstress
Steering not 1, poor lubrication Lubricating
well 2, each ball joint to adjust properly Readjust

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 1, low system pressure relief valve 1, according to the
improperly adjusted specified value to
2, suction pipe and filter clogging adjust the system
3, oil pump, fuel tanks, pipeline leak operating pressure
4, multi-valve excessive wear, and 2, clean oil change
Inadequate
valve stem with the gap exceeds the 3, the replacement of
lifting force or
limited the pump, according
power steering
to the natural
settlement check the
system for leaks
4. Replace the
multi-way valve
1, the working oil deterioration 1,replace oil
2, blockage or damage 2, cleaning the oil
Reduced 3, the filter is clogged or damaged system and fuel tank
Hydraulic system 4, air in the system 3, clean or replace
system performance or 4. Check whether the
unstable leak into the oil
Braking
system
system 1, in the lift cylinder leak
Fork auto 1. overhaul cylinder, replace the
2, multi-valve stem
down after clearance is too large seals
lifting 2, overhaul or replacement

1, heavy-duty long working 1, rest stop or reduce the load

High oil
hours 2. Come to the provisions of the
temperature
2, fuel shortage oil level
1, in the steering return
1, replace the spring piece
shrapnel damage
Keep turning
overhaul
2,Stuck between the sleeve
after steering
2, open the steering repair
and the body with oil or with
wheel back to
oil between the sleeve and
the bit
the shaft with oil

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 1, air compressor belt too 1, Tighten or replace the belt
loose or broken 2. Replace the exhaust valve
2, compressor discharge repair
valve leak 3, adjust the pressure
3, the pressure control valve 4, tighten fittings, replace the
Foot braking
improperly adjusted tubing
force is
4, pipeline rupture or loose 5, alignment trip
insufficient
joints 6, replacement of brake pads
5, the pedal stroke
adjustment inappropriate
6, brake pad wear to the
limit
1, battery plate curing
The battery is 1, desulfurization process or
2, the generator belt is too
not charging or loose or damaged replace plates
charging low 3, the wiring is bad is not 2, re-adjust or replace
strong
with normal 4 regulator improperly 3,Check and eliminate it
engine adjusted or damaged... 4, re-adjust or repair
1,electrolyte specific gravity
1, re-adjust the specific gravity
or low level
Electric 2, short circuit between the of the electrolyte or to add
System plates 2, the elimination of the
Insufficient 3, plate curing
battery 4, the wire is bad precipitate, electrolyte
capacity 5, plate active material replacement desulfurization
shedding
3, or replaced plates
4. Check and eliminate it
5. Replace the plate

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 1, the residual magnetism
According to the original
disappears
2, the magnetic coil circuit polarity generators, batteries
fault connected to both ends of the
3, the commutator is bad
Generator not 4, brush stuck inflexible field coil and universal access
work 5, turn short circuit between number 0 or 00 sanded
the armature
Correction brush size, adjust
the spring pressure
Check and repair

Users known
1/ the user at the time of purchase to receive instructions, the machine certificate, warranty
certificate.
2/ the driver before operating the machine, you must read the detailed manual, shall be
specified in the requirements for operation, commissioning and maintenance.
3/ the hydraulic system of the machine are not allowed to freely adjust the pressure.
4/ the date of user purchase date, the warranty due to manufacturing quality problems, no
product certification, warranty certificate, electrical parts, wearing parts, tires and failures due
to improper use is not covered under warranty.
5/ the machine has a mechanical problem, the user immediately to the machine model
number, serial number, date of purchase by the warranty certificate phone informed me
company.

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