Baoli F 2-3.5T Series Operation And Service Manual
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Baoli F 2-3.5T Series Operation And Service Manual

Internal combustion counterbalanced forklift truck
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Summary of Contents for Baoli F 2-3.5T Series

  • Page 1         https://www.besttruckmanuals.com/...
  • Page 2 F-Series F-Series CPCD20/25/30/35F CPCD20/25/30/35F CPQ(Y)D20/25/30/35F CPQ(Y)D20/25/30/35F Internal Combustion Counterbalanced Forklift Truck Internal Combustion Counterbalanced Forklift Truck 2-3.5T 2-3.5T OPERATION & SERVICE MANUAL OPERATION & SERVICE MANUAL KION Baoli (Jiangsu) Forklift Co., Ltd. KION Baoli (Jiangsu) Forklift Co., Ltd.    https://www.besttruckmanuals.com/...
  • Page 3     PREFACE PREFACE F-series balance weight type forklift trucks with engine are designed on the base of F-series balance weight type forklift trucks with engine are designed on the base of the advanced features available from both local and foreign designs. These trucks are the advanced features available from both local and foreign designs.

  • Page 4: Table Of Contents

        CONTENTS CONTENTS     Ⅰ Ⅰ . About F-series forklift truck . About F-series forklift truck…………………………………………………………… ……………………………………………………………    1 1 1. External view and technical parameter………………………………………………… 1. External view and technical parameter…………………………………………………    1 1 2. Characteristic……………………………………………………………………………… 2. Characteristic………………………………………………………………………………    3 3 3.
  • Page 5     2.2 Reducer and differential………………………………………………………………… 2.2 Reducer and differential…………………………………………………………………    42 …………………………………………………………………………    43 2.3 Torque converter  2.3 Torque converter  … ………………………………………………………………………     2.4 Hydraulic circuit 2.4 Hydraulic circuit………………………………………………………………………… …………………………………………………………………………     44 2.5 Towing disabled truck 2.5 Towing disabled truck…………………………………………………………………… …………………………………………………………………… ...
  • Page 6     7. Lifting system 7. Lifting system…………………………………………………………………………… ……………………………………………………………………………    73 7.1 General description 7.1 General description……………………………………………………………………… ………………………………………………………………………    73 7.2 Maintenance and adjustment 7.2 Maintenance and adjustment…………………………………………………………… ……………………………………………………………    75 8. Electric system 8. Electric system…………………………………………………………………………… ……………………………………………………………………………    78 8.1 General description………………………………………………………………………...

  • Page 7: External View And Technical Parameter

        . Ab . About F-series out F-series forklift truck forklift truck     1. External view and technical parameter  1. External view and technical parameter  Fig1.1 External view Fig1.1 External view     https://www.besttruckmanuals.com/...
  • Page 8     Technical parameter Technical parameter Manufacturer Manufacturer KION Baoli KION Baoli CPCD20F CPCD20F CPCD25F CPCD25F CPCD30F CPCD30F CPCD35F CPCD35F    l    l Model Model   a   a CPQ(Y)D20F CPQ(Y)D20F CPQ(Y)D25F CPQ(Y)D25F CPQ(Y)D30F CPQ(Y)D30F CPQ(Y)D35F CPQ(Y)D35F   r   r   e   e   n   n   e...

  • Page 9: Characteristic

        2. 2. Characteristic Characteristic (1) The hydraulic steering device and transverse steering axle makes steering (1) The hydraulic steering device and transverse steering axle makes steering flexible and the flexible and the turning radius minor. turning radius minor. (2) The braking system employs hydraulic brake, makes it possible to manipulate (2) The braking system employs hydraulic brake, makes it possible to manipulate conveniently and brake reliably.

  • Page 10: Main Components

        4. Main components 4. Main components Fig1.2 Fig1.2 1. 1. Outer Outer mast mast 2. 2. Inner Inner mast mast 3. 3. Lift Lift chain chain 4. 4. Lift Lift cylinder cylinder 5. 5. Load Load backrest backrest 6.

  • Page 11: Operation Device And Instrument Panel

        5. Operation device and instrument panel 5. Operation device and instrument panel Fig1.3 Fig1.3 1. 1. Direction Direction control control lever lever 2. 2. Steering Steering wheel wheel 3. 3. Horn Horn button button 4. 4. Integrated Integrated light light and and turn turn signal...
  • Page 12     5.1 Switch (Fig.1.3) 5.1 Switch (Fig.1.3) Name Name Operation Operation and and attention attention O (OFF): O (OFF): Engine stop position. Key insertion and Engine stop position. Key insertion and withdraw withdraw Ignition Ignition switch switch are performed in this position. are performed in this position.
  • Page 13     5.2 Control 5.2 Control component components (Fig.1.3) s (Fig.1.3) Name Name Operation Operation and and attention attention Lever for shifting between forward and reverse. Lever for shifting between forward and reverse. Direction Direction control control lever lever Forward……………………Push forward Forward……………………Push forward ...
  • Page 14     1. The steering wheel position may be adjusted back and 1. The steering wheel position may be adjusted back and Steering Steering wheel wheel adjustment adjustment forth. forth. lever lever 2. Lowering the directional lever at the proper position 2.
  • Page 15     5.3 Body components (Fig. 1.2) 5.3 Body components (Fig. 1.2) Name Name Operation Operation and and attention attention     The operator’s seat and seat belt are provided for your The operator’s seat and seat belt are provided for your (Fig.

  • Page 16: Handling A New Forklift Truck

    Operation & Service Manual. Please read this manual thoroughly. This will give you a complete understanding of Baoli forklift read this manual thoroughly. This will give you a complete understanding of Baoli forklift...

  • Page 17: Start And Stop Of The Engine

        operation. Check lifting system, actuate the lifting and tilting levers to be certain that the operation. Check lifting system, actuate the lifting and tilting levers to be certain that the lift bracket moves up lift bracket moves up and down properly and and down properly and the mast can be the mast can be tilted smoothly tilted smoothly.

  • Page 18: Parking And Storing

        4. Parking and storing 4. Parking and storing (1) Safe parking (1) Safe parking (a) Park your forklift truck on a level ground preferably in a wide area. If parking on a (a) Park your forklift truck on a level ground preferably in a wide area. If parking on a slope is unavoidable, press down the parking brake device and block the wheels to slope is unavoidable, press down the parking brake device and block the wheels to prevent accidental roll.

  • Page 19: Shipping, Loading And Unloading, Slinging And Towing Of Forklift Truck

        Perform the following service and checks in addition to the Perform the following service and checks in addition to the “Daily storage” service “Daily storage” service: : (a) Taking the rainy season into consideration, park the truck at a higher and hard (a) Taking the rainy season into consideration, park the truck at a higher and hard ground.

  • Page 20: Information Of Safety Operation

        (a) Use the plate (a) Use the plate with enough length, width and strength. with enough length, width and strength. (b) Pull the parking brake and (b) Pull the parking brake and use jacks to stop the wheel. use jacks to stop the wheel.
  • Page 21     (4) Daily maintenance should be done before or after using the truck. Anytime you (4) Daily maintenance should be done before or after using the truck. Anytime you find that the truck is not functioning normally, operation of the truck should be halted and find that the truck is not functioning normally, operation of the truck should be halted and check or repair at once.
  • Page 22     tightly the control wheel with two hands; meanwhile, his body must incline in opposite tightly the control wheel with two hands; meanwhile, his body must incline in opposite direction of direction of truck’s turning over. truck’s turning over.    (18) Turning, lateral or deflective traveling shall not be taken on a slope.
  • Page 23     (31) W (31) When travel with load, don’t tilt mast forward, don’t do handling. Don’t brake hen travel with load, don’t tilt mast forward, don’t do handling. Don’t brake abruptly to prevent goods from slipping off the abruptly to prevent goods from slipping off the forks. forks.
  • Page 24     (47) Check the chains periodically to make sure that good lubrication condition exists (47) Check the chains periodically to make sure that good lubrication condition exists between the chain elements, the degree of tightness between left and right chain is between the chain elements, the degree of tightness between left and right chain is identical.

  • Page 25: Caution Plate

        The vertical The vertical The noise pressure The noise pressure The measured sound The measured sound The guaranteed The guaranteed direction direction level at the operator’s level at the operator’s power level power level sound power level sound power level Model Model acceleration mean...
  • Page 26     (3) Nameplate of forklift truck (3) Nameplate of forklift truck (4) Lubrication system (4) Lubrication system (5) Capacity chart (5) Capacity chart    (6) Inspections before (6) Inspections before starting starting (7) Adjust parking brake (7) Adjust parking brake  ...
  • Page 27     (8) Use parking brake (8) Use parking brake    (9) Add hydraulic oil (9) Add hydraulic oil    (10) Add fuel (gasoline) (10) Add fuel (gasoline)    (11) Add fuel (11) Add fuel (12) Add antifreeze (12) Add antifreeze    (13) Tyre safety (charging tyre) (13) Tyre safety (charging tyre)  ...
  • Page 28     (14) Tyre pressure decal (charging tyre) (14) Tyre pressure decal (charging tyre) 2-2.5t forklift truck 2-2.5t forklift truck 3-3.5t forklift truck 3-3.5t forklift truck (15) Sling point indication (15) Sling point indication    (16) Sling decal (16) Sling decal (17) Forbid entering into the space behind the mast (17) Forbid entering into the space behind the mast  ...
  • Page 29     (18) Forbid (18) Forbid conveying person conveying person (19) Hand caution (19) Hand caution (20) Fan hurting hand (20) Fan hurting hand (21) Hood crushing hand (21) Hood crushing hand (22) Belt pulley thumb hand decal (22) Belt pulley thumb hand decal  ...
  • Page 30     . Periodic inspection and servicing . Periodic inspection and servicing During operating the forklift truck, it is necessary to operate carefully, service and During operating the forklift truck, it is necessary to operate carefully, service and maintain periodically to make the forklift truck keep in maintain periodically to make the forklift truck keep in good condition.

  • Page 31: Inspection Content

        2. Inspection content 2. Inspection content Walk around inspection Walk around inspection    Vehicle uprightness Vehicle uprightness Does the vehicle lean to one side or the other? If it, check for a Does the vehicle lean to one side or the other? If it, check for a tyre puncture or a tyre puncture or a problem with the undercarriage.
  • Page 32     Engine compartment inspection Engine compartment inspection     Level check and supply of engine coolant shall be performed Level check and supply of engine coolant shall be performed Engine coolant level check and Engine coolant level check and while the coolant is cool.
  • Page 33     Engine oil inspection Engine oil inspection 1. Park the vehicle on a flat ground. If the vehicle is 1. Park the vehicle on a flat ground. If the vehicle is inclined, the inclined, the indicated level may be indicated level may be incorrect.
  • Page 34     1. Depress the brake pedal fully, and check the floor clearance 1. Depress the brake pedal fully, and check the floor clearance Brake pedal inspection Brake pedal inspection (clearance between the pedal and floor is not fewer than (clearance between the pedal and floor is not fewer than 110mm) 110mm)
  • Page 35     Start the engine and warm it up sufficiently. Start the engine and warm it up sufficiently. Engine inspection Engine inspection 1. Check each meter and warning lamp to see there is no 1. Check each meter and warning lamp to see there is no abnormality.

  • Page 36: Periodic Replacement Table

        Before garaging the vehicle Before garaging the vehicle     Remove dirt from all Remove dirt from all vehicle component vehicle components and s and then perform the following. then perform the following. 1. Inspect for oil or 1.

  • Page 37: Lubrication Chart

        4. Lubrication chart 4. Lubrication chart Chain Chain Inspect Inspect every every 8 8 hours hours (daily) (daily) Ⅰ Ⅰ 2. 2. Differential Differential gear gear Ⅱ Ⅱ Inspect Inspect every every 40 40 hours hours (weekly) (weekly) 3.

  • Page 38: Weekly Maintenance

        5. 5. Weekly maintenance Weekly maintenance Inspect the items below in addition to the preoperation items. Please inspect the Inspect the items below in addition to the preoperation items. Please inspect the vehicles thoroughly every week to insure safety and pleasant working conditions. vehicles thoroughly every week to insure safety and pleasant working conditions.
  • Page 39 2. Look for leak. 3. Touch possible leak. 3. Touch possible leak. See the nearest Baoli dealer upon finding leak and have See the nearest Baoli dealer upon finding leak and have them repair tank immediately. them repair tank immediately.

  • Page 40: Self Service

        6. Self service 6. Self service Prepare tools and jack necessary for replacing or repairing Prepare tools and jack necessary for replacing or repairing Replacing or repairing tyre Replacing or repairing tyre tyres. tyres. 1. Front wheel 1. Front wheel ．...
  • Page 41         If a lamp does not come on or an electrical device does not If a lamp does not come on or an electrical device does not Fuse replacement Fuse replacement function, the corresponding fuse may be function, the corresponding fuse may be blown.

  • Page 42: Recommended Oil And Grease

        Terminals Terminals ： ：         Maintaining the battery Maintaining the battery 1. A loose or corroding terminal causes failure in connection. 1. A loose or corroding terminal causes failure in connection. Eliminate white powder, if noticed on the terminal, by pouring Eliminate white powder, if noticed on the terminal, by pouring warm over it to disable and then grease the terminal.

  • Page 43: Truck

        Brand Brand Recommended Recommended General standard General standard Viscosity Viscosity Domestic Domestic Caltex Caltex Mobil Mobil Shell Shell Esso Esso Oil level level Product Product temperature temperature  Asses “Viscosity Grad  Asses “Viscosity Grade” e” Shell Shell X100 X100 Esso Esso extra extra motor...
  • Page 44 Rated Rated Rated Rated Cylinder number Cylinder number Total Total Weight Weight  Appropriate  Appropriate Engine model Engine model output /Speed output /Speed torque / Speed torque / Speed - - Bore×Stroke Bore×Stroke displacement displacement Remark Remark truck model truck model Kw / r.p.m Kw / r.p.m N.m / r.p.m...

  • Page 45: Inspection And Adjustment Of Engine

    1.3 Inspection and adjustment of engine 1.3 Inspection and adjustment of engine In order to keep good condition of your truck, you must carry out periodic inspection In order to keep good condition of your truck, you must carry out periodic inspection and adjustment of power system.

  • Page 46: General Description

    ～ ～ Set pressure pressure 0.68 MPa 0.68 MPa Type Type Inner-m Inner-mesh esh gear gear pump pump Charging pump Charging pump Flow Flow rate rate 27 L/min(2000rpm,1.5MP L/min(2000rpm,1.5MPa) a) Hydraulic Hydraulic Type Type Power Power shifted shifted transmission transmission Speed ration Speed ration 1.35/1.35...

  • Page 47: Reducer And Differential

    Fig2.1 Hydraulic drive unit Fig2.1 Hydraulic drive unit 1. 1. Forward Forward clutch clutch 18. Safety Safety valve valve cover cover 35. Output Output gear gear 2. 2. Oil Oil filter filter 19. Inner-hexa Inner-hexagon gon plug plug 36. Idler Idler shaft shaft 3.

  • Page 48: Reducer And Differential

    The power from the transmission is transmitted through the reduction gear, The power from the transmission is transmitted through the reduction gear, differential, halfshaft gear and halfshaft to driving wheels. differential, halfshaft gear and halfshaft to driving wheels. 1. 1. Gear Gear ring ring 2.

  • Page 49: Torque Converter

    smooth work of smooth work of the torque converter. the torque converter. The torque converter, filled up with the torque converter oil, in the drive unit is driven 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.

  • Page 50: Towing Disabled Truck

    the torque converter then is the same as that in the neutral. the torque converter then is the same as that in the neutral. 1. 1. Charging Charging pump pump 2. 2. Oil Oil filter filter 3. 3. Relief Relief valve valve 4.
  • Page 51 Gear Gear 1. 1. Oil Oil pressure pressure lower lower Measure Measure and and adjust adjust pressure pressure 2. 2. Seal Seal ring ring damaged damaged Check Check and and replace replace 3. 3. Piston Piston ring ring of of the the clutch clutch damaged damaged...

  • Page 52: Drive System

    2. 2. Lower Lower oil oil amount amount Check Check oil oil level level and and add add oil Torque Torque 3. Ineffective driving system of oil 3. Ineffective driving system of oil Check and replace Check and replace converter converter 4.

  • Page 53: Assembly Of Wheel Hub

    brake unit. (See Fig3.1) The housing is an integral casting body. The tyre with the rim is brake unit. (See Fig3.1) The housing is an integral casting body. The tyre with the rim is fixed to the hub with fixed to the hub with studs and nuts. The power is transmitted to the studs and nuts.
  • Page 54 Fig3.1 Drive axle Fig3.1 Drive axle 1. 1. Housing Housing 6. 6. T T apered apered roller roller bearing bearing 11. Rim 2. 2. Half-shaft Half-shaft 7. 7. Wheel Wheel hub 12. Adjusting Adjusting nut 3. 3. Wheel Wheel brake brake 8.

  • Page 55: Troubleshoot

    Structure of rim bolt Structure of rim bolt Fig3.4 Wheel Fig3.4 Wheel assembly assembly 1. 1. Tyre Tyre 4. 4. Inner Inner rim 7. 7. Spring Spring washer washer 2. 2. Air Air valve valve 5. 5. Outer Outer rim 8.
  • Page 56 Replace parts Replace parts half shaft gear and half shaft half shaft gear and half shaft Insufficient Insufficient gear gear oil Add oil         4. Brake system 4. Brake system Front two-wheel braking, Front two-wheel braking, internal expansion, internal expansion, Type of brake system Type of brake system...

  • Page 57: Master Cylinder

    4.1 General 4.1 General description description The brake system is the f The brake system is the front two-wheel braking type consisting of ront two-wheel braking type consisting of a master cylinder, a master cylinder, wheel brakes and brake wheel brakes and brake pedal mechanism. pedal mechanism.

  • Page 58: Master Cylinder

    Fig4.1 Master cylinder Fig4.1 Master cylinder 1. 1. Link Link rod 6. 6. Piston Piston 2. 2. Push Push rod 7. 7. Primary Primary cup 3. 3. Dust Dust cover cover Spring pring 4. 4. Snap Snap ring ring 9. 9. Check Check valve valve...

  • Page 59: Operating Device Of Parking Brake

    1. 1. Spring Spring 8. 8. Return Return spring spring 15. Spr Spring ing pull pull rod 2. 2. Cup 9. 9. Adjusting Adjusting lever lever 16. Parking Parking pull pull rod 3. 3. Piston Piston Second Secondary ary brake brake shoe shoe 17.

  • Page 60: Inspection Of Wheel Brake

    When you turn the adjuster clockwise, the f When you turn the adjuster clockwise, the force increases, otherwise, when you turn orce increases, otherwise, when you turn the adjuster counterclockwise, the force the adjuster counterclockwise, the force decreases. decreases. Press force: 50kg Press force: 50kg Operating method: Turn off the key, press the parking brake pedal with Operating method: Turn off the key, press the parking brake pedal with left foot, until...

  • Page 61: Troubleshoot

    Standard Standard thickness thickness Max. Max. thickness thickness (5) Check the inner surface of (5) Check the inner surface of brake drum for damage and excessively worn. If brake drum for damage and excessively worn. If necessary necessary, repair , repair or replace i or replace it.

  • Page 62: Steering System

    Noisy Noisy 3.Deformed 3.Deformed shoe shoe or or incorrect incorrect installation installation Repair Repair or or replace replace brake brake 4.Worn 4.Worn friction friction piece piece Replace Replace 5.Loose 5.Loose wheel wheel bearing bearing Repair Repair 1.Oil-contaminated 1.Oil-contaminated friction friction piece piece Repair Repair or or replace...

  • Page 63: Hand Wheel

    unit. The steering shaft is connected with the steering unit. The steering column can be unit. The steering shaft is connected with the steering unit. The steering column can be tilted forward or backward to sui tilted forward or backward to suitable position. (See Fig5.1) table position.
  • Page 64 Fig5.2 Cycloid gear type powered steering unit Fig5.2 Cycloid gear type powered steering unit 1. Spac 1. Spacing ing sleeve sleeve 4. Interlock 4. Interlock shaft shaft 7. Rotor 7. Rotor 2. 2. Va Valve lve body body 5. 5. Spring Spring piece piece 8.

  • Page 65: Steering Axle

    Fail to turn Fail to turn Flow-divider Flow-divider blocked blocked or or damaged damaged Clean Clean or or replace replace handwheel handwheel Hose Hose or or joint joint damaged damaged or or pipeline pipeline blocked blocked Clean Clean or or replace replace T T oo oo low...
  • Page 66 Fig5.3 Steering axle Fig5.3 Steering axle 1. 1. Axle Axle body body 9. 9. Ty Tyre re 17. Oil Oil seal seal 2. 2. Tie Tie rod 10. Oil Oil seal seal 18. O-ring O-ring 3. 3. Steering Steering cylinder cylinder 1 1 1.
  • Page 67 Fig5.4 Steering cylinder Fig5.4 Steering cylinder 1. 1. Piston Piston rod rod assy assy 4. 4. Yx-ring Yx-ring 7. 7. Supporting Supporting ring ring 2. 2. Cylinder Cylinder cover cover 5. 5. O-ring O-ring 8. 8. Cylinder Cylinder body body 3.

  • Page 68: Hydraulic System

    Fig5.5 Pre-load adjustment Fig5.5 Pre-load adjustment            6. Hydraulic system 6. Hydraulic system Hydraulic Hydraulic Type Type Gear Gear pump pump oil pump oil pump Displacement Displacement 32 ml/r ml/r Type Two-p Two-pool ool type type with with relief relief valve, valve, flow...
  • Page 69 6.1 General 6.1 General description description The hydraulic system consists of hydraulic pump, control valve, lift cylinder, tilt The hydraulic system consists of hydraulic pump, control valve, lift cylinder, tilt cylinder cylinder, and oil pipe-lines etc. The oi , and oil pipe-lines etc. The oil tank is installed on the ri l tank is installed on the right side of the truck.
  • Page 70     Fig6.1 Hydraulic pump Fig6.1 Hydraulic pump     Fig6.2 Control valve Fig6.2 Control valve         6.3.1 Relief valve and flow 6.3.1 Relief valve and flow divider (see Fig6.3) divider (see Fig6.3) The relief valve consists of main valve A and proceeding valve B. When the spool of The relief valve consists of main valve A and proceeding valve B.
  • Page 71 adjusted by adjusting the screw K. adjusted by adjusting the screw K. V V alve L is a balance spool valve, and alve L is a balance spool valve, and may move right or may move right or left according to the variety left according to the variety of the oil fl of the oil flow and pressure passing through it to change the opening of chamber R and S...
  • Page 72 Fig. 6.4 Setting pressure of the relief valve Fig. 6.4 Setting pressure of the relief valve         6.4 Hydraulic oil circuit (Fig6.5) 6.4 Hydraulic oil circuit (Fig6.5) The oil from the hydraulic pump comes to the control valve first and there is divided The oil from the hydraulic pump comes to the control valve first and there is divided by the flow divider into by the flow divider into two parts, one being sent to lift cylinder or...
  • Page 73 Flow,control Flow,control L/min L/min valve Q1 valve Q1 circuit circuit Flow,steering Flow,steering L/min L/min unit unit Primary Primary pressure, pressure, 17.5 17.5 hydraulic hydraulic system P1 system P1 Steering Steering 10.5 10.5 pressure P2 pressure P2 Fig6.5 Hydraulic oil Fig6.5 Hydraulic oil  ...
  • Page 74 5. 5. Guide Guide sleeve sleeve    6. O-ring 6. O-ring 7. 7. Cylinder Cylinder head head    8. Bushing 8. Bushing    9. 9. Cylinder Cylinder body body    10. Piston Piston rod rod    11. Piston 11. Piston    12.
  • Page 75 Fig6.7 Flow regulator valve Fig6.7 Flow regulator valve 1. 1. Joint Joint 5. 5. Throttle Throttle plate plate 9. 9. Spring Spring 2. 2. Spring Spring 6. 6. Valve Valve sleeve sleeve 10. Valve Valve body body 3. 3. O-ring O-ring 7.

  • Page 76: Troubleshoot

    backward until 11 degrees. backward until 11 degrees. Fig 6.8 Tilt cylinder Fig 6.8 Tilt cylinder 1. 1. Joint Joint 6. 6. Guide Guide sleeve sleeve 1 1 1. 1. Yx-ring Yx-ring 2. 2. Dust Dust ring ring 7. 7. Bearing Bearing 12.
  • Page 77 lifting oil circuit lifting oil circuit Oil hole hole is is blocked blocked Disassembly Disassembly and and clean clean Spool Spool is is held held up Disassembly Disassembly and and clean clean Vibrate and the oil Vibrate and the oil pressure rises slowly pressure rises slowly Exhaust...

  • Page 78: Lifting System

    suction pipe suction pipe  Air entering into the pump  Air entering into the pump  Add oil into oil tank  Add oil into oil tank Replace oil seal Replace oil seal Worn suction pipe or Worn suction pipe or blocked blocked Correct pipe or repair filter Correct pipe or repair filter oil filter...

  • Page 79: General Description

    Fig7.1 Mast Fig7.1 Mast 1. 1. Outer Outer mast mast 4. 4. Tilt Tilt cylinder cylinder 7. 7. Lift Lift bracket bracket 2. 2. Inner Inner mast mast 5. 5. Load Load backrest backrest 8. 8. Fork Fork 3. 3. Lift Lift cylinder cylinder 6.
  • Page 80 bracket with bolts. They roll along the flank plate of the inner mast and rolling clearance bracket with bolts. They roll along the flank plate of the inner mast and rolling clearance can be adjusted with shims. The main rollers sustain the longitudinal loads and the side can be adjusted with shims.
  • Page 81 7.2.1 Adjustment of lift cylinder (Fig7.3) 7.2.1 Adjustment of lift cylinder (Fig7.3) When replace the lift cylinder, inner mast or outer mast, we shall readjust the stroke When replace the lift cylinder, inner mast or outer mast, we shall readjust the stroke of the lift cylinder as following: of the lift cylinder as following: (1) Install the piston rod in the upper beam of the inner mast without shims.
  • Page 82 (3) Make the fork down to the ground and tilt backward fully. Adjust the adjusting nut (3) Make the fork down to the ground and tilt backward fully. Adjust the adjusting nut for the end nipple of for the end nipple of the upper chain and make the two chain’s tightness equal. the upper chain and make the two chain’s tightness equal. ...

  • Page 83: Electric System

    ·Disassemble the upper main rollers with a drawing tool, don’t ·Disassemble the upper main rollers with a drawing tool, don’t loose the adjust shims. loose the adjust shims.    · · Install the new rollers and the shims Install the new rollers and the shims disassembled before. disassembled before.

  • Page 84: Brief Explanation For Operation

    (3) Instrument (3) Instrument The numeric combination meter (Fig8.1) for internal combustion forklift truck adopts The numeric combination meter (Fig8.1) for internal combustion forklift truck adopts advanced electron technology, the input signal can be dealed with high-precision digital advanced electron technology, the input signal can be dealed with high-precision digital processing.
  • Page 85 switch backward (that is in reverse shift), the backing lamps light and the back buzzers switch backward (that is in reverse shift), the backing lamps light and the back buzzers sound. sound. (2) Turning handle switch (2) Turning handle switch Pull the turning handle switch to the Pull the turning handle switch to the Ⅰ...

  • Page 86: Instructions Of Meter Panel

    (2) When the meter (2) When the meter is during self-check, the LCD displays Baoli welcome. is during self-check, the LCD displays Baoli welcome. When running normally When running normally, the , the LCD displays running well.
  • Page 87 If the indicator does not go out or it lights during engine running, the preheating intake heater engine running, the preheating intake heater may be defective. Please ask a Baoli dealer for be defective. Please ask a Baoli dealer for inspection or repair.
  • Page 88 If lamp does not go out, the generation system If lamp does not go out, the generation system may be faulty. Please ask a Baoli dealer may be faulty. Please ask a Baoli dealer immediately for inspection and immediately for inspection and repair repair.
  • Page 89 be displayed in the upper left of LCD. be displayed in the upper left of LCD. converter oil (option) converter oil (option) Before starting the engine, put the key switch to Before starting the engine, put the key switch to （...

  • Page 90: Principle Diagram Of Electrical System

    Stop the operation lubrication system is faulty. Stop the operation engine oil pressure engine oil pressure immediately and ask a Baoli dealer for inspection immediately and ask a Baoli dealer for inspection and repair. and repair.
  • Page 91 Fig8.3-1 Diagram of harness (4JG2 engine) Fig8.3-1 Diagram of harness (4JG2 engine) Fig8.3-2 Diagram of harness (Dachai 498 engine) Fig8.3-2 Diagram of harness (Dachai 498 engine) Fig8.3-3 Diagram of harness (Xinchai 498 engine) Fig8.3-3 Diagram of harness (Xinchai 498 engine) Fig8.3-4 Diagram of Fig8.3-4 Diagram of harness (Y harness (Yanmar 4TNE98 engine)
  • Page 92 10 Preheating Preheating 12 Main Main power power 13 Preheating Preheating fuse fuse 14 Starter 14 Starter 15 Optional Optional power power 1 1 16 Optional Optional power power 2 2 17 Indicating, Indicating, neutral neutral 18 Generator Generator N N 19 Generator Generator F F 20 Charging...
  • Page 93 09 Power, Power, headlamp headlamp 10 Preheating Preheating indicating indicating 12 Main Main power power 13 Preheating Preheating fuse fuse 14 Starter 14 Starter 15 Optional Optional power power 1 1 16 Optional Optional power power 2 2 17 Indicating, Indicating, neutral neutral 18 Generator...
  • Page 94 10 Preheating Preheating indicating indicating 12 Main Main power power 13 Preheating Preheating fuse fuse 14 Starter 14 Starter 15 Optional Optional power power 1 1 16 Optional Optional power power 2 2 17 Indicating, Indicating, neutral neutral 18 Generator Generator N N 19 Generator Generator F F...
  • Page 95     Fig8.3-1 Diagram of harness (4JG2 engine) Fig8.3-1 Diagram of harness (4JG2 engine)         https://www.besttruckmanuals.com/...
  • Page 96 Fig8.3-2 Diagram of harness (Dachai 498 engine) Fig8.3-2 Diagram of harness (Dachai 498 engine)         https://www.besttruckmanuals.com/...
  • Page 97     Fig8.3-3 Diagram of Fig8.3-3 Diagram of harness (Xinchai 498engine) harness (Xinchai 498engine)         https://www.besttruckmanuals.com/...
  • Page 98     Fig8.3-4 Diagram of Fig8.3-4 Diagram of harness (Y harness (Yanmar 4TNE98 engine) anmar 4TNE98 engine)         NOTE NOTE https://www.besttruckmanuals.com/...
  • Page 99         https://www.besttruckmanuals.com/...
  • Page 100             https://www.besttruckmanuals.com/ KION Baoli (Jiangsu) KION Baoli (Jiangsu) Forklift Co., Ltd. Forklift Co., Ltd.
  • Page 101 · · · · www.baoli-mh.com www.baoli-mh.com * We reserve the right to make any * We reserve the right to make any changes or modifications of pictures and specifications in this changes or modifications of pictures and specifications in this manual without giving previous notice and without manual without giving previous notice and without incurring any obligation.
  • Page 102 https://www.besttruckmanuals.com/...

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