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HELI CPCD140 Manual
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HELI CPCD140 Manual

Forklift truck
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This manual accounts for "HELI" Forklift Truck of CPCD140～160 type,
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 doesn'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.
FOREWORD

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Summary of Contents for HELI CPCD140

  • Page 1 FOREWORD This manual accounts for “HELI” Forklift Truck of CPCD140～160 type, 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.

  • Page 2: Table Of Contents

    CONTENTS Ⅰ . Safe Operation Rules and Daily Maintenance for Forklift………………….2 . Primary Technic Parameter of Forklift………………………………………8 Ⅱ Ⅲ. Primary Assembly Introduce of Forklift……………………………………..11 Ⅳ. The structure, principle, adjustment and maintenance of Forklift………..12 1. Dynamic System……………………………………………………………..12 2. Transmission Device…………………………………………………………13 3.

  • Page 3: Ⅰ . Safe Operation Rules And Daily Maintenance For Forklift

    Ι. Safety rules for Operation and Daily Maintenance 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》. 1.
  • Page 4 (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. (9) The contamination level of the hydraulic oil should be lower than 12 as described in NAS1683.
  • Page 5 (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.
  • Page 6 generally long-lasting antirust and antifreeze liquid (FD-2 type-35-degree), 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.
  • Page 7 6. Oil Used for Forklift Truck Name Brand（homeland） Brand（Export） No.0 in summer， Fuel（Diesel） No.10 in winter Lubricant for Gears Titan gear LS90（85W-90） Hydraulic Oil L-HM46 Tor-con Oil SG/CF-4 15W-40 Brake Oil Titan gear Hydra ZF20W-40 Lubricant for engine SG/CF-4 15W-40 No.3 Lithium Base Grease Grease (drop point 170)
  • Page 8 7. The Table of Lubrication System...

  • Page 9: Ⅱ . Primary Technic Parameter Of Forklift

    Ⅱ. Primary Parameter of Forklift Truck Primary Parameter of Forklift Truck Item Unit CPCD140 CPCD150 CPCD160-CU2 CPCD160-CU1 Rated Load 14000 15000 16000 Load Centre 1200 Standard Lift Height 3000 Mast Tilt (fwd/bwd) 6/12 Wheelbase 3650 4000 Tread (fwd/bwd) 1885/2100 Overhang (fwd/bwd）...
  • Page 10 Item Unit CPCD160-CU3 CPCD160-CU4 Rated Load 16000 16000 Load Centre 1200 Standard Lift Height 3000 Mast Tilt (fwd/bwd) 6/12 Wheelbase 3650 4000 Tread (fwd/bwd) 1885/2120 Overhang (fwd/bwd） 1040/900 Overall Width 2560 Overall Length (with Fork) 7410 8380 Overall Height (at Mast) 3300 Min.
  • Page 11 Item Unit CPCD160-CU-06I Rated Load 16000 Load Centre Standard Lift Height 4000 Mast Tilt (fwd/bwd) 15/12 Wheelbase 3650 Tread (fwd/bwd) 1885/2100 Overhang (fwd/bwd） 1040/900 Overall Width 2560 Overall Length (with Fork) 7510 Overall Height (at Mast) 3800 Min. Under clearance (at Mast) Min.

  • Page 12: Ⅲ. Primary Assembly Introduce Of Forklift

    Ⅲ. Primary Assembly of Forklift Truck Primary Assembly of Forklift Truck Name Contents Engine Mounting Includes engine, air cleaner Cooling System Includes cooler, tubes, compensator Exhaust System Includes muffler, exhaust, hoses Oil Cooling System Includes Tor-con oil cooler, tubes of Tor-con Transmission Includes transmission, tor-con, transmission shaft etc.

  • Page 13: Ⅳ. The Structure, Principle, Adjustment And Maintenance Of Forklift

    The power of engine is transferred to the driving system by a flywheel through a torque converter. The power of forklift CPCD140～160-CU1,CU2 CPCD160-CU-06I is provided by diesel engine Cummins6BTA 5.9 imported from USA. The power of forklift CPCD160Cu3,Cu4 is provided by diesel engine Cummins6QSB6.7 imported from...

  • Page 14: Transmission Device

    2.2 Base Structure and Performance of Forklift Truck (1) Structure and Parameter of Transmission ～ Item Unit CPCD140 160-Cu Type Torque Circular Diameter Convertor Stall Torque Ratio 2.066...
  • Page 15 (2) Hydraulic torque converter a) Function of hydraulic torque converter Its main functions include: achieving automatic shift(wich means to vary speed without pause), increasing traction force, improving the working performance of engine, preventing engine from extinguishing, upgrading speed-varying quality and facilitating gear shift .
  • Page 16 stator wheel. When the reaction torque acts in the reverse direction, the stator wheel rotates idly. In this state the input torque becomes equal to the output torque so that high performance is ensured. As the phase of torque transmission in changed by the mechanical means(clutch), the torque convertor is called the 2-phase type.
  • Page 17 control interlocking etc. 2.3 Manipulation (1) Before starting the vehicle, the driver must switch the shifting lever of gearbox to neutral position. It would be best not to loosen the parking brake to ensure safety. (2) The parking brake should be released when the gearbox is put into gear and the vehicle is ready to go.
  • Page 18 gearbox and the axle should be removed or the vehicle should be shipped. (9) If the vehicle pulls up and the engine and gearbox linked to it are still running, the engine stalling is not allowed. 2.4 Maintenance (1) Oil filling The proper amount of oil stipulated should be filled before the gearbox is used.
  • Page 19 The oil pressure of the gearbox should be controlled by pressure control valve, the normally manipulated oil pressure is 15-17bar and the main oil pressure will be decrease at the moment of shifting, which is resulted from the oil filling in oil cylinder of clutch.

  • Page 20: Drive Axle

    2.5 Trouble shooting (1) Abnormal noise Cause for trouble Check method Remedy Check the sound of rotation Fracture of elastic plate Replace elastic plate under the low speed Bearing damaged or worn Disassemble and check Replace Fracture of gear Disassemble and check Replace Spline worn Disassemble and check...
  • Page 21 dust and water resistant ability and free from maintenance. (2) Big braking torque, safe and reliable. (3) Equipped with caliper disc type parking brake. 3.2 Structure (1) Differential and hub reduction gear The differential mechanism is mainly made of differential case, drive bevel gear, driven bevel gear, half shaft gear and bearing etc.
  • Page 22 (4)Spring (5)Pushrod (6)Washer (7)Adjusting stud (8)Locking nut (9)Oil chamber (10)Oil seal (11)O ring (12)Dust ring Fig.3-1 Parking Brake Primary Parameter of Drive Axle CPCD140～160-Cu Type Full-flowing, Box-weled axle Tire 12.00－24－20PR Drive Axle 8.5-24 Air Pressure 0.88MPa Type Helical Bevel Gear Type...

  • Page 23: Troubleshooting

    3.4 Maintenance and Trouble-shooting (1) Check the oil level of main drive, hub reduction gear and brake oil tank of drive axle for every 100 hours and fill the gear oil of the same type if necessary. Check the working state of ventilation cock and clean it if necessary. (2) Check the tightening state of connecting bolt of drive axle every 400 hours and tighten the bolt based on the tightening torque of 2000Nm.
  • Page 24 Fig. 4-1 Steering System The main specifications of the steering system Item CPCD140～160 Type of the steering system Rear wheel with steering powered Type 530-5289/842-1256 Emission Capacity （ml/min） Powered Steering Max pressure of intake Unit （bar） Max pressure of working back（bar）...

  • Page 25: Steering Axle

    torsion. 4.3 Steering System Troubleshooting Problem Analyses of Trouble Remedies Pump damaged or breaking down Replace Fail to turn handwheel Flow-divider blocked or damaged Clean or replace Hose or joint damaged or pipeline blocked Clean or replace Too low oil pressure from flow-divider Adjust pressure Air in oil circuit of steering system Exhaust air...
  • Page 26 Fig. 5-1 Steering Axle The main specifications of the steering axle Model CPCD140～160 Type Supporting in middle Steering Inner wheel 80° angle Outer wheel 56.19º Interval 1800mm Steering axle King Inner obliquity 0° Outer obliquity 1° of wheel Weight 1240 Tire 12.00-20-18PR...

  • Page 27: Brake System

    and then tighten it again to a torque of 9.8Nm.； (4) To As shown in follows ,with lubricating grease ,fill up the chamber formed by wheel hubs, wheel hub bearings , wheel hub covers and coat of the lips ensure the installation of the nut is firmed, slightly knock at it with wooden hammer and in the meantime, rotate the nut for 3～4 turns.
  • Page 28 6.3 Cooling system The system is a independent circuit. The pressure oil is going from the accumulator charge valve the brake fluid box. Oil is passing through the power brake, thus cooling recycle which can run to optimum brake ability. The system is pan-hydraulic wetness braking (basic circuit showing).
  • Page 29 Parking brake consists of a brake disc and a brake working cylinder. The power spring in the cylinder load force on the disc in order to achieve parking. The system can be used as exigent braking. But it cause the disc weared out badly. So it must replace the disc after the second exigent braking.
  • Page 30 parking braking rcuit is 7.5MPa. The pressure in the accumulator is checked periodical so that it esure the vehicle is safety. The method is as following: (1) Pedal eight continuous after stopping and push and pull the manual control valve more than five.
  • Page 31 (1) Air bleed (2)Cooling oil outlet or wear inspection hole (3) Hydraulic line (4)Cooling oil inlet or drain plug Fig.6-1 Inside of Hub for Drive Axle...

  • Page 32: Electric System

    Wetness Braking Back Valve (one-way) Braking 0.5bar Foot Lamp SW. Braking Accumulator 2.5L Valve Low-pressure Warning SW. for Accumulator Globe Valve Accumu- lator 1L Hand Braking Valve Spring loaded Parking Cylinder Pump Braking Lamp Pressure SW. Intake Oil Filter Return Oil Filter Fig.6-2 Working Principle of Brake System 7.
  • Page 33 When there are more than one fault existing on the engine, press the Increment and Decrement switch at the right side of the fault diagnosis switch so as to realize the functions of increment and decrement. Please turn off the fault diagnosis switch before engine is started.
  • Page 34 Fig.7-1.1 Integration Electric Plate(CPCD140-160-CU1,CU2,CPCD160-CU-06I)
  • Page 35 Fig.7-1.2 Integration Electric Plate(CPCD140-160-CU3,CU4) (2) Charging Devices This devices contains generator, battery, charging indicator, etc. It supplies electric energy for all the electric devices. Voltage：24V (3) Start System This system mainly consists of automatic pre-heating unit，key switch, start protection circuit, start motor, etc. The function of this system is starting the engine.
  • Page 36 Fig.7-2.1 Electric Principle Drawing(CPCD140-160-CU1,CU2,CPCD160-CU-06I)
  • Page 37 Fig.7-2.2 Electric Principle Drawing(CPCD140-160-CU3,CU4) (5) Instruments It mainly consists of hour meter, fuel meter, water temperature meter, voltage meter, tacho meter, oil temperature meter, oil pressure meter, brake pressure meter and charging indicator, oil pressure indicator, left turning indicator, right turning indicator, brake indicator, parking indicator.
  • Page 38 of the forklift truck. Fig.7-3 Electric Principle Drawing of Instrument (6) Lighting and Signal Instruments They include all kinds of illuminating lamps, signal lamp, horn and buzzer, etc. Headlight：35W Front combination lamp: farness light/near light:75W/70W, turning/front: 21W/8W Rear combination lamp: (turning / rear / reverse / braking): 21W (red) / 8W (red) / 10W (white) / 21W (red) Warning lamp: (optional)21W Rear lamp: (optional)70W...
  • Page 39 Fig.7-4 Electric Principle Drawing of Lighting and Signal Instruments...
  • Page 40 (7) Cab Fig.7-5 Electric Principle Drawing of Cab (8) Air-condition It can be cold and warm ,it changes temperature in the cab. 7.3 Brief Explanation for operation 7.3.1 Starting There is a starting protection circuit in the shiftlever the forklift truck. You have to shift the shiftlever in neutral before you start the engine.
  • Page 41 Fig.7-6 Key Switch Turn the key switch clockwise to the second “on”position (starting position), then start the engine. Release the brake switch before starting, Otherwise, the forklift truck can not step because the drive unit is cut off. After engine starting，push the shiftlever forward (that is in forward shifts), then pedal accelerator shift, the forklift truck runs faster and you can begin to work.
  • Page 42 off . (4) Reverse signal: When you need to reverse the forklift truck, pull the shiftlever backward and the transmission is in reverse shift. Then the reverse lamps (white) in the rear combination lamps are on and the buzzer sounds. (5) Charging Signal: Before you start the engine, put the key switch to the first “on”...
  • Page 43 0 0 0 0 0 0 (1)Voltage Meter (2)Oil Temperature Meter of the tor-con (3)Brake Pressure Meter (4)Hour Meter (5)Speed Meter (6)Oil Pressure of the tor-con (7)Water Temperature Meter (8)Fuel meter (9)Left Turning lamp (10)Brake signal (11)Charging Signal (12)Oil Pressure Signal (13)Manual/autometic alternative Signal (14)Alarm lamp of Braking oil pressure low (15)the headlights on full beam...
  • Page 44 Fig.7-8 Control Panel of Air-condition Notice： a) The battery can produce combustibility air, it has explosion danger, it must be forbidden short circuit, light and fireworks. b) The electrolyte is a sparse vitriol, it is danger if skin or eye touches it. If shin touches electrolyte, it must be flush with the water immediately.
  • Page 45 Fig.7-9.1 Wiring Harness（CPCD140-160-CU1,CU2,CPCD160-CU-06I）...
  • Page 46 Fig.7-9.2 Wiring Harness（CPCD160-CU3,CU4）...
  • Page 47 Fig.7-10 Relay Control Box-1 Fig.7-11 Relay Control Box-2...

  • Page 48: Hydraulic System

    8. Hydraulic System Primary Parameter of Hydraulic System Type of Forklift Truck CPCD140～160 Type A10VO60DFR+A10VO60DFR Front Pump 60ml/rpm Hydraulic Output Pump Rear Pump 60ml/rpm Driven Type of Pump Power Output of Transmission Control Valve Type M7-22-3X Priority-steering Type M7-22-3X valve...
  • Page 49 the main pump. It has following advantages: long service life, low noise level, wide range of controls, high power/weight ratio. The flow of two Pumps will converge in the control valve first and there is divided by the driver’s intention into two parts, one being sent to lift cylinder, tilt cylinder or extension cylinder, and another to the power steering unit in variable flow rate to operate the steering cylinder.
  • Page 50 Fig.8-2 The Principle of Control Valve When the oil from the leader hydraulic control valve puts up the spool of the main valve, its displacement becomes the direct proportion with the pressure. With the valve spool moving, inlet of the throttle measuring box(7) is opened, and then, oil from the pump flows into its inlet.
  • Page 51 movement precision of cylinders will be improved. This causes that the speed of cylinders not only frees from the influence of work pressure, but also operates steady. (2) Priority Valve The construction of the Priority Valve is quite simple. There is the priority valve that the oil is supplied by the working service of the pump.
  • Page 52 that you need, screw back the screw of the LS overflow and keeps its pressure on 200 bar. Fig.8-3 Control Valve (4) Pilot Joystick The control valve is opened by the pilot pressure controlling. Human factors engineering is used in the Joystick. So it is very comfortable to operate for the driver. It is be of following advantages: ------It is be of responds well ------Operating force is small...
  • Page 53 It is be of twin shafts about the Joystick.It may control the lift cylinder or tilt cylinder by 360 rotation 。when the driver pushes up the Joystick small ,the mast begins to move slowly.If the driver wants to increase speed of the mast ,he needs continue pushing to the Joystick;When the driver pushes up the Joystick to direction of 45 ,he can abtain two...
  • Page 54 ------When two cylinders are operated in parallel, he pressure relief valve also prevents excessive cylinder pressure occurring due to uneven loading of the cylinders. ------With summing circuits, only one pump should be engaged to lower the load in order to avoid pressure intensification. Fig.8-6 Cylinder Safety Lock Valve (6)The principle of Hydraulic system diagram...
  • Page 55 Fig.8-7 The principle of Hydraulic system diagram...

  • Page 56: Hoist System

    9. Hoist System The main specifications see table： ～ Model CPCD140 160-Cu Mast type 2-stage telescopic mast, Rolling type, C-shaped outer mast, C-shaped inner mast Cross Section of Inner Mast Cross Section of Outer Mast Max. Lift Heiget(S.T.D) 3000 mm（standard）-6500mm Foreward Tilt 6°、5°、3°...
  • Page 57 9.1 General Description The hoist system is adopted the two-stage, rolling telescopic mast type. The inner mast and outer mast frame have C-shape section of CPCD140, CPCD150, CPCD160. 9.2 Outer & Inner Mast The inner mast make up of top beam assembly, left section steel and right section steel, roll shaft, crossbeam etc.
  • Page 58 be adjusted by adjusting the cylinder caps. (4) Make use of the spacer of the lift cylinder to adjust the error occurred between the right and left cylinders in height. 9.54 Lift Cylinder Assembly Lift Cylinder Assembly make up of lift cylinders, lift chain assembly, sheave assembly etc.
  • Page 59 (16)Washer (17) Nut M6 (18)Cut-off valve Fig.9-1 CPCD140～CPCD160 Lift cylinder form 9.6 Flow Regulator Flow Regulator (throttle) is located between the control valve and the high pressure ports of the two lift cylinders, near the left lift cylinder. Flow regulator is used to limit the fall speed of forks and side suspenders when over loading.
  • Page 60 The flow regulator serving both as a flow regulating valve while forks are being lowering and a safety device if hoses between the control valve and lift cylinders are damaged due to any reason. The operation of the flow regulator valve is given below： See Fig.9-2，With the forks upraised，high pressure oil leads from the control valve then flows into the chamber A, and pushes the sleeve to the left.
  • Page 61 Two tilt cylinders of double acting type are mounted on each side of the frame. The front end of the piston rod is installed on the mast and the cylinder tail is on the frame by pins. The tilt cylinder assembly consists primarily of a cylinder body, cylinder cap, piston and piston rod.

This manual is also suitable for:

Cpcd150Cpcd160-cu2Cpcd160-cu1Cpcd160-cu3Cpcd160-cu4Cpcd160-cu-06i