HELI CPCD120 Manual

Forklift truck

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This manual accounts for "HELI" Forklift Truck of CPCD120 and CPCD135

type, includes its performance, structure, 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

Table of Contents

Troubleshooting

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Summary of Contents for HELI CPCD120

Page 1 FOREWORD This manual accounts for “HELI” Forklift Truck of CPCD120 and CPCD135 type, includes its performance, structure, 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 Ι. Safety rules for Operation and Daily Maintenance of Forklift Truck………………2 . Main Specifications Ⅱ ………………………………………………………………7 Ⅲ. Primary Assembly of Forklift Truck………………………………………………8 Ⅵ. The Structure, Principle, Adjustment and Maintenance of Forklift………………9 1. Dynamic System……………………………………………………………………9 2. Drive Unit…………………………………………………………………………13 3. Drive Axle…………………………………………………………………………25 4.
Page 3: Ι. Safety Rules For Operation And Daily Maintenance Of Forklift Truck
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》&《OPERATION MANUAL》. 1.
Page 4 (7) Release the parking lever. (8) Make trying operation of the mast for lifting, lowing and Fwd/Bwd tilting and the truck for steering and braking. 4. Operation of Forklift Truck (1) Only trained and authorized operator shall be permitted to operate the truck. (2) Wear all the safety guards, such as shoes, helmet, clothing and gloves while operating the truck.
Page 5 goods on it should not fall down or the protection measures must be taken if necessary. (13) Tilt the mast of the high lift forklift truck as backward as possible while the truck working. Use minimum forward tilt angle and Min. reverse tilt when loading and unloading.
Page 6: Fuel（Diesel
d) Check parking brake; e) Check instruments, lighting, switches and wiring to see if they work normally or not. (2) Oil used for forklift trucks Name Code Brand No.0 in summer， Fuel（Diesel） No.10 in winter Lubricant for Gears 85W/90GL-5 Tor-con Oil SG/CF4 15W-40 Great Wall Lubricant for engine...
Page 7 (4) The Table of Lubrication System...
Page 8: Ⅱ. Main Specifications
Ⅱ. Main Specifications Model Unit CPCD120 CPCD120 CPCD135 Specifications Load Centre Rated Load 12000 13000 Standard Lift Height 3000 Lifting Speed (loaded) mm/s Lowing Speed (loaded) mm/s Mast Tilt (fwd/bwd) 6°/12° ° km/h 28/29 Travel Speed Min. Turning Radius 4400...
Page 9: Ⅲ. Primary Assembly Of Forklift Truck
Ⅲ. Primary Assembly of Forklift Truck Primary Assembly of Forklift Truck Name Contents Includes engine mounting, fuel system, exhaust system Dynamic System and cooling system(lnc. Oil cooling system of Tor-con) Includes transmission, tor-con, transmission shaft and Transmission System transmission control linkage Includes axle house, half shafts, differential, hub Drive Axle reduction, brake and front wheels...
Page 10: Ⅵ. The Structure, Principle, Adjustment And Maintenance Of Forklift
Ⅵ. The Structure, Principle, Adjustment and Maintenance of Forklift 1. Dynamic System 1.1 General Description The dynamic system includes the engine mounting, fuel system, cooling system and exhaust system, etc. The engine is connected with the frame of the forklift through a rubber cushion to reduce vibration.
Page 11 c) Clean up the cap of dust-collector. d) Replace it every 1200 hours or six months. Fig.1.2 Air Cleaner (2) Fuel filter a) Remove the filter with the special spanner. If damaged or blocked, replace it. b) Apply several drops of fuel to the around of the new filter’s seal before installation and it should be screwed 2/3 circles again when the filter’s seal touches the body of filter.
Page 12 (3) Oil filter a) Remove the oil filter with the spanner and replace it with a new one. b) Apply several drops of engine oil to the around of the new filter’s seal before installation and it should be screwed 2/3 circles again when the filter’s seal touches the body of engine.
Page 13 Fig.1.4 Fuel Sensor 1.4 Cooling System The cooling system is composed a water pump, fan, radiator and tank. The water pump is installed on the engine. The crank shaft drives the water pump through the V-belt. 1.4.1 Inspection and adjustment of cooling system (1) Check the cooling water level of the tank (2) Replace the cooling water a) Wait 30 minutes after shutting off the engine.
Page 14: Drive Unit
(4) Radiator of transmission oil Check the seal and clean status of the radiator. 2. Drive Unit The drive unit includes a torque converter and a transmission. The main specification see table 2.1. The structure of the drive unit see Fig.2.1. Table 2.1 Item Unit...
Page 15 Fig.2.1 Hydraulic Transmission (1) Control valve (9) Parking brake (17) Oil seal (2) Charging pump (10) Oil filter (18) Ball bearing (3) Ball bearing (11) Oil seal (19) Gear (4) Shaft (12) Gear (20) Reverse clutch pack (5) Ball bearing (13) Ball bearing (21) Forward clutch pack (6) Torque converter...
Page 16 2.1 General Description The transmission adopted in this machine is a rational combination of torque converter with power-shift type transmission. It has the following features. (1) The inching valve is provided so as to improve the inching performance. Hence, the inching performance can be maintained when starting and at any rotational speed of engine.
Page 17 In this case the output shaft torque becomes smaller than the input shaft torque. So as to prevent this phenomenon, a free wheel (one-way clutch) is provided on the stator. 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.
Page 18 2.3 Charging Pump The construct of charging pump See Fig.2.3. Charging pump consists of driving gear, inner gear (driven gear), shuck and cover, mounted on the upper end of the tor-con housing. Driving gear is driven by pump wheel, idle gear and oil pump driven gear, the oil pump supply oil in lower half of the transmission for every area of the transmission.
Page 19 are prevented. When hydraulic pressure affects the piston, the alternately arranged sintered plates and steel plates are depressed so that the clutch group is made integral and transmits power from the torque converter to the drive gear. Accordingly, power transmission route from the Tor-Co-transmission is as follows: Turbine wheel-Main shaft-Clutch drum-Steel plate-Sintered plate-Forward or reverse gear-Output shaft.
Page 20 2.5 Control Valve Control valve see Fig.2.6. The control valve is provided on the upper part of transmission case. The change spool and inching spool are incorporated in the valve body. The clutch relief valve is designated to adjust the hydraulic pressure of the hydraulic pressure of the transmission clutch.
Page 21 valve from the pump through the strainer. The fluid sent from the charging pump is divided to two directions in the torque converter case, one for torque converter and the other for transmission. Fig.2.7 Tor-con Hydraulic System Pressure of the fluid for clutch is adjusted to 1.2 to 1.5MPa with the relief valve. And then it is supplied to the control valve.
Page 22 While the forward or reverse clutch is operating, another clutch is rotating between the sintered plates and the steel plates. Therefore this part is lubricated with oil sent from the oil cooler to prevent seizure of plates. When the brake pedal is depressed and the inching valve is actuated, most of hydraulic oil supplied to the clutch is drained from the inching valve and returns to the transmission case.
Page 23 Table2.2 Possible Causes Checking Method Remedy A.Oil pressure too low. (1)Low oil level. Check oil level. Add oil. (2)Air sucked from suction Check joints and pipe. Retighten side. replace packing. (3)Clogged oil filter. Disassemble and check. Clean or replace. (4)Insufficient discharge of Disassemble and check.
Page 24 Table2.3 Possible Causes Checking Method Remedy (1)Low oil level. Check oil level. Add oil. (2)Clogged oil filter. Disassemble and check. Clean or replace. (3)Flywheel is in contact Drain oil from oil filter or Replace. with other parts. oil tank and check for foreign matter.
Page 25 Table2.5 Possible Causes Checking Method Remedy (1)Input plate broken. Check rotational sound at Replace. check whether front cover rotates. (2)Lack of oil. Check oil level. Add oil. (3)Driving system of oil Disassemble and check. Replace. pump malfunctioning. (4)Shaft is broken. Disassemble and check.
Page 26: Drive Axle
3. Drive Axle 3.1 General Description The drive axle that consists of a main reduction, differential, hub reduction and brakes is bolted to the front support of the frame. The masts are installed on the front support of the frame. 3.2 Main reduction and Differential The main reduction and differential consists primarily of a cross case, ring gear and drive pinions, which are all assembled on the differential carrier, and is fitted to...
Page 27: Electric System
3.4 Troubleshooting Guide (See Table3.1) Table3.1 Cause Trouble Correction Loose bolt or broken gasket of Replace or retighten. Oil leaks from differential carrier. differential Breather is clogged. Clean or replace. carrier Oil seal is worn or damage. Replace. Gear is worn, damaged or broken. Replace.
Page 28 4.2 Generator (Refer to the instruction of engine manufacture provided with the machine) Routine maintenance: Check if the wiring is good. For every 1600 hours, carefully clean slip ring and check the wear and connection condition of the carbon brush. If necessary, change carbon brush handles with same type as the original.
Page 29 ● Take away the tightening hoop on the lamp holder. ● Pull off the connection plug. ● Change halogen bulb. ● Plug in the connection plug. ● Fix the tightening hoop on the lamp holder. ● Tighten the cover. ● Install the lamp frame. (2) Main lamp’s light adjustment If the overhead lamp is erroneously fixed, it must be adjusted by following steps: ●...
Page 30 ● Take away the lamp shade. ● Change bulbs. 4.4.4 Yellow warning light, rotating lamp (21W bulb) Bulb Change: ● Take away the tightening screws (12) of the lamp shade. ● Change bulb. 4.4.5 Rear working lamp (35W bulb) 4.4.6 Inside lamp (5W column lamp) Bulb Change: ●...
Page 31 The relay control box is shown in Fig.4.1 below. Fig.4.1 Relay Control Box The protection function definition of relays Type Protect function Power source for width light/instrument light relay D07JD2914 Dipped headlight relay D07JD2914 Headlight on full beam relay D07JD2914 Horn relay D07JD2914 Working lamp relay...
Page 32 4.5 Electronic Control Elements Prevent that the forklift is improperly operated when install the electronic control element. The mistaken operation might damage the sensitive electronic control elements on it, so we suggest the following preventive measures will be taken: (1) For the work relating to the welding on the chassis, disconnect the connector of the electronic control elements.
Page 33 L - On -low speed M - On - medium speed H - On - high speed (2) Temperature setting knob Use temperature setting knob to choose suitable temperature. Refrigeration or heating. Fig.4.2 The Air Conditioning Control Panel CAUTION If engine water temperature is low, the air temperature sent to the cab will not change even the temperature adjusting knob is turned to the max.
Page 34 temperature at preset temperature. The water dripping under the vehicle due to normal condensation is produced from the moisture removal of the system. WARNING Even in cold season, make sure the air conditioner is turned on for at least 5 minutes each week to ensure good lubrication inside the compressor and optimal operation of the air conditioner.
Page 35 Fig.4.3 Engine Starting (1) Engine starting CAUTION Before engine starting, make sure that the gearlever is at neutral and the engine emergency stop button is not pushed down. a) Plug in the ignition key and turn clockwise to 1 “ON” position. CAUTION Ignition keyhole position 1 tests warning lamp and indicator lamps.
Page 36 Before traveling operation, check the battery cell warning light, low engine oil pressure and low braking oil warning lights. If one of the warning lights is on, it means there is trouble. Please contact the service department of Heli. Start the vehicle according to following procedures: a) Connect parking brake button (on the right front of the control box) and step down the braking pedal.
Page 37 parking braking pedal. Step on the accelerator pedal slowly. CAUTION Reverse gear shift can be used only when the engine is running at low speed and the forklift is in still position. The forklift can not be moved or run on downgrade road when it is in neutral gear.
Page 38 Fig.4.4 Instrument Console Assembly (1)Left steering indicator (2)Engine pre-heat indicator (3)Air filter plug indicator (4)Neutral indicator (5)Parking brake indicator (6)Engine oil pressure low indicator (7)Sedimentor indicator (8)Charging indicator (9)Right steering indicator (10/11)Spare (12)Tachometer/ Hour meter (13)Fuel gauge (14)Voltage meter (15)Engine coolant temperature (16)Brake barometer 4.11 Fault Analysis and Maintenance of the Electrical System 4.11.1 Instrument system...
Page 39 ● Short circuit of the external wiring of water temperature sensor; ● Short circuit inside the water temperature sensor; ● Incorrect wiring of water temperature indicator. b) Due to the fault of engine ● Overheat of water jacket of engine due to obstruction by water scale; ●...
Page 40 Possible cause: a) Caused by the air pressure gauge itself. b) Short circuit of the external wiring of the air pressure sensor. c) Internal short circuit of air pressure sensor. Remedy: Check the wiring of the air pressure gauge indicator. Check if there is short circuit in the wiring of and inside the sensor.
Page 41 Possible cause: The brake status switch (2A1.8, 31 wirings) is normally closed and short circuit. Remedy: Disconnect the wiring of brake status switch (2A1.8, 31 wirings), check if it is in normally closed position and if not, check where the short circuit is. (12) The warning lamp for air filter often brightens up Possible cause: The air filter switch is normally closed;...
Page 42 (4) The flash of the steering lights becomes faster Possible cause: Bulbs are damaged. Remedy: Change bulbs. 4.11.3 Power system (1) The engine can not start Possible cause: The speed control lever is not on the neutral gear. K1 relay is poorly closed.
Page 43: Braking System
The role of the braking system is to make the forklift reduce speed or stop when it is traveling with no load or full load. CPCD120-Wx uses air-over-hydraulic brake system. Its working principle is that the air compressor draws air directly from the atmosphere through air filter and increases its pressure.
Page 44 The braking system of the machine is divided into two parts. One part is braking by air-brake. The other part is inching (micro-motion) pedal on the left side. They realize the micro-motion of the forklift by controlling the inching valve on the transmission case with flexible shaft cable.
Page 45 Fig.5.3 Air-brake Valve (3) Air-booster pump The role of the air-booster pump is to raise the braking fluid pressure by the adjustable oil cylinder and transfer the energy to brake caliper disc to realize fast braking of the front axle. The outline is shown in the following diagram. Fig.5.4 Air-booster Pump (4) Oil-water separator combination valve The role of oil-water separator in the air-over-hydraulic braking system is to...
Page 46 separate the water in the high-pressure air and lube oil in the air-compressor. The outline is shown in the following diagram. Fig.5.5 Oil-water Separator Combination Valve 5.3 Description of Operation and Maintenance The main tasks of the routine maintenance of air-over-hydraulic braking system are the discharge of the condensed water and the operation of the braking fluid and air-compressor system.
Page 47: Steering System
5.4 Parking Brake The parking brake is of internal expanding shoe type and installed on an intermediate shaft output end of the rear side of the transmission. Refer to following diagram for the parking bake operation. The manual operating force shall not be more than 300N when the forklift is making parking braking on a slope in standard load operation.
Page 48 pressure variety for the variety of the steering load. It is fairly no infection between the working circuit of steering system and the others. The main flow preferential provide to the working circuit of steering system. So steering reliably and system economically.
Page 49 under the function of centering spring, make the sleeve to be in the middle position. The oil from oil pump shall pass valve sleeve hole and valve core hole and return to the oil tank through oil sump. Then the two chambers of the steering oil cylinder and hydraulic motor shall be closed and the steering wheel shall remain at the original deflection angle (as shown in Diagram b).
Page 50 gear will connect with the pipe of oil pump, the connection marked “Return”(回) will connect with oil reservoir. The connections marked “Left”(左) and “Right”(右) will be connected with the left and right chambers of the cylinder respectively. The flow rate allowable in the suction pipe is 1—1.5m/s, pressure oil pipe and return oil pipe 4—5m/s.
Page 51: Troubleshooting
(6) Operation maintenance Check leakages, oil level in the reservoir and working conditions every day. Chang filter elements and oil regularly according to requirements. Hydraulic oil condition can be checked by putting one drop of oil on absorbent paper. If there is a black spot in the center of oil stain, it will be changed.
Page 52 diagrams below). It consists of steering axle body, steering oil cylinder, connecting rod and steering wheel. The steering trapezium uses crank slide mechanism. The piston rod of the oil cylinder pushes steering knuckle to turn through the connecting rod. It results in the deflection of deflection wheel and steering is thus realized. The steering axle is connected on the tail frame of the vehicle by integral pins so that the axle can sway around the pins.
Page 53 swivel pin are supported by needle bearing. There are oil seals at the two ends of the bearing. There is grease nipple on the upper end of the swivel pin. 6.4.3 Steering wheel bearing pre-load adjustment (1) With lubricating grease, fill up the chamber formed by wheel hubs, wheel hub bearings, wheel hub covers and coat of the lips of the oil seals.
Page 54: Hydraulic System
7. Hydraulic System 7.1 General Description The hydraulic system is consisted of power unit, actuation unit, operating unit and accessory device. The high pressure oil from the main oil pump shall go through multiple-channel valve to provide oil for the lifting system. The multiple-channel valve shall control the lifting-up, lowering-down and tilting of the gantry and the actions of accessory tools.
Page 55 7.2 Maintenance of the Main Parts 7.2.1 Gear Pump The oil pump consists of front and rear gear pumps. The gear pump used for the forklift has a pair of external-engagement gears and the working principle is as shown in Fig.7.2. A pair of engaged involute gears is fixed inside the housing of the pump with the two end faces of the gears being sealed up.
Page 56 Fig.7.3 Gear Pump (1)Pump body (2)Driving gear (3)Driven gear (4)Front cover (5)Rear cover (6)Lining plate (7)Seal ring (8)Ring (9)Oil seal (10)Snap ring 7.2.2 Control valve The control valve (4 spool type) consists of six valve housings, spools, one relief valve and one flow divider. The six valve housings are assembled together with three stud bolts and nuts.
Page 57 inlet Safety Dir. ex- Reposition Working return Bolt valve body valve change valve mechine cover spool valve body Fig.7.5 Control Valve (4 spool type) (1) Lift spool valve (a) Neutral position The high pressure oil discharged from the pump returns to the oil tank through the mid-passage.
Page 58 (c) Drawing-out of Spool (Fig.7.8) With the mid-passage closed, the oil from the main oil-inlet pushes up the check valve and flows into the port “A”. The return oil from the port “B” flows through the low-pressure passage to the Fig.7.8 Drawing-out Position oil tank.
Page 59 low-pressure passage. Fig.7.10 Tilt Forward (c) Push-in state of the spool valve (of the pump not at work) (Fig.7.11) As the pump stops working, spool valve is pushed in, there is no oil flowing into the cylinder interface “B” and pressure at part “B” does not rise. Consequently, the follow-up valve does not work;...
Page 60 (4) Safety valve (Fig.7.5) pressure adjustment The pressure of the safety valve shall not be adjusted by non-professional personnel. The adjustment shall follow following procedures: a) Screw off the plug of the measuring hole on the inlet of the multiple-channel valve.
Page 61 Faults Possible reasons Solutions The working (1)The gap between the valve body and (1)Repair or change the sliding mechanism sliding valve has increased due to valve. shall settle wearing. down (2)The position of sliding valve is not (2)Keep sliding valve position obviously in alignment.
Page 62 Fig.7.12 Operating of the Control Valve 7.2.4 Oil tank The oil tank is a part of the frame located on the right box body. There are a inlet filter and a return filter in the oil tank.
Page 63 Steering cyl. To rear pump To front pump Lift cyl. From control valve Oil filter (F & R pump) Oil add cap From brake system Breather Fig.7.13 Oil Tank 7.3 Maintenance of Main Pump The main components consist of pump body, front-end cover, back-end cover, driving and driven gear and oil seal etc, the basic structure of which is shown as Fig.
Page 64 Fig.7.14 Main Pump (1)Pump body (2)Driving gear (3)Driven gear (4)Front cover (5)Rear cover (6)Lining plate (7)Seal ring (8)Ring (9)Oil seal (10)Snap ring (11)Bolt (12) Washer 7.4 Maintenance, Trouble Analysis and Trouble Shooting of the Hydraulic System 7.4.1 Maintenance Check whether there exits seepage or serious oil leaking phenomenon on the pipe joint, lifting cylinder, tilting cylinder, oil pump, full-hydraulic steering unit and steering cylinder of the transmission system before and after the work shift.
Page 65: Troubleshooting
Under normal circumstance, the oil liquid inside operation oil tank should be changed after operation for 1200～1500 hours. Oil liquids of different brands can not be mixed for use. 7.4.2 Trouble analysis and troubleshooting Trouble Cause Trouble shooting (1) Excessive wearing between the (1) Replace the wearable parts or oil pump gear and pump body and oil pump.
Page 66 Trouble Cause Trouble shooting (1) Inner leakage of control valve. (1) Replace O-ring seal, repair valve rod and reassign the coupling gap between valve rod and hole to Excessive 0.01～0.02. Self Tilting (2) Inner leakage (2) Replace. of the Tilting damaged O-ring seal of piston rod Cylinder of the tilting cylinder.
Page 67: Lifting Cylinder And Tilting Cylinder
8. Lifting Cylinder and Tilting Cylinder Truck Model 13.5t Item Type Single-acting piston type Lift Cylinder bore dia. φ110 Cylinder O.D. of piston rod φ85 Stroke 1500 Type Double-acting piston type Tilt Cylinder bore dia. φ135 Cylinder O.D. of piston rod φ70 Stroke (6°/12°) 8.1 Lift Cylinder...
Page 68 (1) Shim (2) Dust ring (3) Yx-ring seal (4) Cover (5) Bushing (6) O-ring seal (7) Cylinder body (8) Piston rod (9) O-ring seal (10) Support ring (11) Yx-ring seal (12) Nut, lock (13) Cotter pin (14) Chain (15) Sheave (16) Bearing (17) Snap ring (18) Spring...
Page 69 8.2 Flow Regulator Valve 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. The structure of the flow regulator as shown in Fig.8.3.
Page 70 To lift cyl. To control valve Fig.8.3 The Structure of the Flow Regulator (1)Spring (2)Valve sleeve (3)Spring (4)Nylon ball (5)Valve core (6)Throttle plate (7)Snap ring (8)Valve body (9)Spring (10)Connector 8.3 Tilt Cylinder (1) Ear ring (2) Shim (3)Adjust sleeve (4)Dust ring (5)Snap ring (6) Yx-ring seal (7) Guide Sleeve...
Page 71: Hoist System
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.
Page 72 (1) Inner and outer mast Inner and outer masts are all welded parts. Outer mast bottom is fixed at driving axle with pin. The middle part of outer mast is connected with frame by tilted cylinder and can be tilted forward and backward under the action of tilted cylinder. Outer mast channel steel is a weldment of common low-alloy structural steel with C-section and with its upper part being fixed with a pair of side roller.
Page 73 horizontal load shall be on the side rollers. Two cylinders are installed on the carriage. The end of the piston rod of one cylinder is fixed on the left fork, while the end of the piston rod of the other cylinder installed on right fork. The space adjustment are controlled by the operating lever.
Page 74 axis pins and tightness of pins. Make sure that lifting cylinder and tilting cylinder are working normally. The operation should be stopped if there is any abnormality and can only resume after the troubles are eliminated. (4) Chain ● Introduction The forklift is provided with chain, which must be checked and maintained regularly according to requirements shown in the following table.
Page 75 ISO VG46460. The oil with less viscosity can be applied to lower outdoor temperature and smaller chain. Compared with more viscous lubricating oil, the diluted oil enters into the chain joints easily and achieves better result of lubrication. After a long interval without lubrication, liquid grease diluted with diluent can be used.
Page 76 Take the chain apart regularly to clean it completely and check if there is any trouble with it and then lubricate the whole chain again if possible. ● Cracks and damages of chain pieces Usually, visual check is only limited to the outer chain piece and chain piece fringe, overlooking cracks on pin shaft and chain piece hole fringe.
Page 77 straight and flat part of chain, fix the maximum extension limit at 2% although 3% is reachable in normal conditions. The fixing of the extension limit will take the following points into account: a) Abrasion of parts affects the strength of chain; b) Hard face abrasion.
Page 78 disc similarly. If pin shaft head abrasion exceeds 25% or the outside abrasion of chain piece is over 20% of its thickness, you are required to check if there is any fault with it and change the chain. ● Interval Check abrasion conditions at least every 6 months or 1000 hours.

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Cpcd135