1. Forklift engine system

  1. 1 General Description

The power of K series forklift trucks with 2 to 3.5 ton capacity is provided by diesel engine Xinchang A490BPG-76, Xinchang C490BPG-200 or Quanchai QC490GP. DachaiCA498-97,and 3.8 ton capacity is provided by diesel engine Xinchang A4965BPG, Quanchai QC495G or Dachai CA498-97.Refer to relevant manual for the details of operation and maintenances for the engine.

  1. 2 Fuel System

The fuel system is composed of a tank, fuel volume sensor and fuel meter (see Fig. 1-1)

Fig. 1-1 Fuel tank for 2-3.8 ton forklift trucks

  1. 21 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. 22 Fuel volume sensor

Fig. 1-2 Fuel volume sensor

The sensor is designed to convert the remaining amount of fuel into voltage. (See Fig.1-2) The sliding type resistor made of alloy steel wire is linked with float. As the float moves up and down, resistance is changed. With electro-magnetic fuel meter, the remaining amount of fuel in the fuel tank can be read off the meter panel.

  1. 23 Maintenance

Once every 100 working hours, it is required to maintain the fuel system according to the following methods. Once every 600 working hours, it is required to clean the fuel tank.

  • 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.

For maintenance of the filter, proceedings are as follows (See Fig.1-3):

  1. Once a 100 working hours, it is required to remove the cartridge cover by specific tools and then take out the filter element.
  2. Once a 600 hours operation, it is required to replace the filter
  3. After the re-fitment of filter, check it for
  4. Check overflow valve (1) for correct working.

forklift fuel filter

  • Cleaning of fuel tank

Once every 600 working hours, the fuel tank should be cleared.

2.Forklift clucth and clutch pedal

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. There is an inspection hole attached to the clutch cover. The clutch pedal pushes the clutch yoke by push rod in order to release the friction piece from flywheel which normally mesh together.

2.1 Replacement of Friction Piece

  • Press the clutch pedal and place three spacers between the pressure plate case and release lever to cause the friction piece apart.
  • Turn counter clockwise the slide lead screw in the upper of the transmission to let the driving shaft go into the transmission (See Fig.3-1).
  • Remove six mounting bolts on the pressure plate case to cause the flywheel apart and remove the old friction piece right
  • When a new friction piece is installed, notice the hub (See part 5 in Fig.2-1) with the longer spline boss being toward the transmission.
  • Turn the slide lead screw clockwise and pull out the driving shaft step by step and let its spline match with the hub spline.

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 bearing of the flywheel, tighten the slide lead screw to the torque of 107-119N.m (10.9-12.1kgm).
  • Install the pressure plate case on the flywheel.
  • Press the clutch pedal and remove the three spacers.
  • 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 2-2)

  • Loosen clutch pedal stopper bolt (a).
  • Using stopper bolt (a) to get a pedal height from the floor of Spare travel is 30-40mm.
  • Detach the spring at the end of the clutch pedal and loosen the nut (b).
  • Press the clutch pedal about 30 to 40mm. At this time, pull the release yoke When resistance is felt, turn spherical nut (b) until it comes into contact with release yoke and then lock with lock nut (c).
  • Install the pedal spring

Fig.2-2 Clutch pedal