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HELI CPCD120-C2Z-09 Operation & Service Manual
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HELI CPCD120-C2Z-09 Operation & Service Manual

Counterbalanced type forklift truck with engine 12-20t
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OPERATION & SERVICE
MANUAL
Counterbalanced Type Forklift Truck with Engine
12-20t

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Summary of Contents for HELI CPCD120-C2Z-09

  • Page 1 OPERATION & SERVICE MANUAL Counterbalanced Type Forklift Truck with Engine 12-20t...
  • Page 2 FORWARD This Manual mainly describes the performance, structure, operation and maintenance of CPCD120 and 135, CPCD140, 150 and 160, CPCD180 and 200 forklift trucks (CPCD120 - C2Z / CZG - 09, CPCD135 / 150 / 160 - C2Z / CZG - 06, CPCD140 / 150 / 160 - C2Z / CZG - 09, CPCD140 / 150 / 160 - C2Z / CZG - 12, CPCD180 / 200-CZG / CZ1G - 12) to facilitate correct use and maintenance by the operators.

  • Page 3: Table Of Contents

    Contents Safe Operation Procedures and Daily Maintenance of Forklift Truck ........1 II Main Technical Parameters of Forklift Truck ................7 Introduction to Main Components of Forklift Trucks ............11 Structure, Principle, Adjustment and Maintenance of Forklift Trucks ......12 1 Power system ........................

  • Page 4: I Safe Operation Procedures And Daily Maintenance Of Forklift Truck

    Safe Operation Procedures and Daily Maintenance of Forklift Truck Forklift truck drivers and management personnel must keep in mind the concept of "safety first", and carry out safe and standard operation according to the Operation and Maintenance Manual and Driver's Manual of the forklift truck. Transportation of forklift truck Pay attention to the following matters when handling and transporting the forklift truck: (1) Apply the parking brake;...
  • Page 5 Safe operation procedures for forklift truck (1) Forklift truck drivers must be trained and obtain a driving license before they can drive the forklift trucks; (2) Drivers shall wear shoes, hats, clothing and gloves for safety protection when operating; (3) All control and alarm devices must be checked before driving, and operation is allowed only after any damage or defect found is repaired;...
  • Page 6 (13) For a high-lift forklift truck, try to make the mast tilt backward, and it shall tilt forward and backward within the minimum range during the loading and unloading operations; (14) Be careful and drive slowly when driving on a wharf or temporary planking; (15) When refueling, the driver shall get off the vehicle and shut down the engine.
  • Page 7 problem with the tightness of the cooling system, it should be eliminated as soon as possible. Otherwise, the auxiliary water tank will lose its function, resulting in an incorrect judgment of the coolant level and finally affecting the service life of the engine. (3) When antifreeze is used as the cooling medium, it is strictly prohibited to add water and different types of antifreeze at will.
  • Page 8 Oil for forklift truck Recommended Name Designation (code) Brand Fuel (diesel) 0# in summer, -10# in winter Lubricating oil for drive axle gear GL-5 (80W/90) Total Transmission oil CH-4 (15W40) Total Engine lubricating oil CJ-4 (15W40) and above Total Hydraulic oil L-HM46 Total (except...
  • Page 9 Lubrication system diagram...

  • Page 10: Main Technical Parameters Of Forklift Truck

    II Main Technical Parameters of Forklift Truck Main Technical Parameters CPCD120- CPCD135-C CPCD150-C CPCD160-C Parameter Unit C2Z/CZG- 2Z/CZG-06 2Z/CZG-06 2Z/CZG-06 Rated lifting capacity 12000 13500 15000 16000 Load center Standard lifting height 3000 Inclination angle of mast 6/12 (forward/backward) Wheel base 3250 Wheel distance 1904/2120...
  • Page 11 Main Technical Parameters CPCD140-C CPCD150-C2Z/ CPCD160-C2Z/CZ Parameter Unit 2Z/CZG-09 CZG-09 G-09 Rated lifting capacity 14000 15000 16000 Load center Standard lifting height 3000 Inclination angle of mast 6/12 (forward/backward) Wheel base 3500 Wheel distance 1895/2120 (front/rear) Overhang (front/rear) 935/850 Overall width 2560 Full length (with fork) 7105...
  • Page 12 Main Technical Parameters CPCD140-C2Z/ CPCD150-C2 CPCD160-C2Z/ Parameter Unit CZG-12 Z/CZG-12 CZG-12 Rated lifting capacity 14000 15000 16000 Load center 1200 Standard lifting height 3000 Inclination angle of mast 6/12 (forward/backward) Wheel base 3750 Wheel distance 1895/2120 (front/rear) Overhang (front/rear) 935/850 Overall width 2560 Full length (with fork)
  • Page 13 Main Technical Parameters CPCD180-CZG/ CPCD200-CZG/CZ1 Parameter Unit CZ1G-12 G-12 Rated lifting capacity 18000 20000 Load center 1200 Standard lifting height 4000 Inclination angle of mast 6/12 (forward/backward) Wheel base 4000 Wheel distance (front/rear) 1895/2120 1927/2120 Overhang (front/rear) 1015/850 Overall width 2660 Full length (with fork) 8305...

  • Page 14: Introduction To Main Components Of Forklift Trucks

    III Introduction to Main Components of Forklift Trucks Refer to the following table for main components of the forklift truck: Name Contents Installation of engine Mainly including engine and air filter Mainly including radiator, water pipe, auxiliary water tank and Cooling system hydraulic oil radiator Exhaust system...

  • Page 15: Structure, Principle, Adjustment And Maintenance Of Forklift Trucks

    IV Structure, Principle, Adjustment and Maintenance of Forklift Trucks Outline Drawing of the Vehicle Power system 1.1 Introduction The power system includes engine installation, intake system, cooling system, and exhaust system. The engine is connected to the transmission device. The engine bracket is connected to the frame through a cushion rubber pad to reduce vibration.

  • Page 16: Transmission Device

    supplied for dedicated use with Cummins to ensure normal use of the engine. Refer to the operation and maintenance manual of the engine for details of operation and maintenance of the engine. 1.2 Main parameters of Cummins engine Parameters CumminsB6.7 Type Four-stroke, turbocharged, intercooled and in-line Cylinder quantity - cylinder...
  • Page 17 (4) The hydraulic clutch is equipped with specially treated paper friction plates and steel plates to improve the wear resistance of the friction pairs. The oil line of the hydraulic torque converter is equipped with high-quality filters, which improve the cleanliness of the oil and prolong the service life of the hydraulic torque converter.
  • Page 18 Under the action of centrifugal force, the liquid is sprayed out to the turbine cascade along the pump impeller cascade, transmitting the torque to the output shaft. After leaving the turbine, the liquid changes its direction under the action of the guide wheel, so that it flows into the pump impeller at the best angle.
  • Page 19 operate solenoid valves; and the functions of lock control, automatic shift, engine overspeed prevention, and interlocking control according to the sensing signals. 2.3 Operation (1) Before starting the vehicle, place the transmission shift lever in the neutral position. To ensure safety, it is recommended not to release the parking brake first.
  • Page 20 engine cannot stall. 2.4 Maintenance 2.4.1 Refueling Before the transmission is used, it shall be filled with the specified oil with an appropriate quantity. At the first refueling, the oil storage volume of external components such as filters, oil pipes and coolers shall be considered, so the amount of oil to be added is slightly more than that in the future.
  • Page 21 the transmission in the neutral position. Under normal circumstances, the temperature should drop to the normal value within 2-3 minutes. Otherwise, it indicates that the system fails, and troubleshooting is required before further operation. 2.4.3 Oil pressure control The oil pressure of the transmission is controlled by the pressure control valve. The normal operating oil pressure is 15-17 bars.

  • Page 22: Drive Axle

    speed Bearing is damaged or Remove and check Replace worn Gear breaks Remove and check Replace Spline is worn Remove and check Replace Oil supply pump is too Remove and check Repair or replace noisy Loose bolt Remove and check Tighten or replace Oil level is too high Check the scale of the oil dipstick...
  • Page 23 for operation. This axle is maintenance-free and is featured by large load, favorable dustproof and waterproof effect; (2) The braking torque is large, ensuring safety and reliability; (3) It is equipped with caliper disc parking brake. 3.1.2 Introduction to structure 3.1.2.1 Differential and wheel reducer The differential is mainly composed of differential housing, driving bevel gear, driven bevel gear, axle shaft gear, and bearing.
  • Page 24 pressure. The brake cylinder is integrated with the brake caliper assembly. Parking brake is realized by operating the parking brake valve in the cab. Parking brake can also be used as emergency brake. Emergency brake will cause serious wear of the brake friction lining, which must be replaced after two emergency brakes.
  • Page 25 other impurities. (4) Troubleshooting See the following table for the causes and troubleshooting methods: Fault Cause Troubleshooting Method Connecting bolts of the main reducer housing Tighten or replace are loose or gaskets are damaged Oil leakage from the main reducer housing The vent hole is blocked Clean or replace The oil seal is worn or damaged...
  • Page 26 gear to bear the radial force. The wheel reducer consists of a sun gear, a set of planetary gears and an internal gear ring. The sun gear meshes with the planetary gear, which is installed on the shaft of the planet carrier, and the planetary gear meshes with the ring gear.
  • Page 27 (1) Cylinder and brake caliper assembly (2) Piston (3) Friction plate (4) Spring (5) Push rod (6) Washer (7) Adjusting stud (8) Locknut (9) Oil chamber (10) Oil seal (11) O-ring (12) Dust ring 3.2.3 Main parameters of drive axle CPCD140/150/160-C2Z/CZG-09 CPCD180-CZG/C CPCD200-CZ...

  • Page 28: Steering System

    (2) Check the fastening of the drive axle connecting bolts every 400 hours. If the bolts are loose, tighten them with a tightening torque of 2000Nm. (3) Replace the gear oil of the main drive and wheel reducer and the oil in the brake oil tank every 1000 hours.
  • Page 29 Fig. 4-1 Steering System...
  • Page 30 The main parameters of the steering system are shown in the table below: CPCD140/150/160-C2Z/CZG-09 CPCD120-C2Z/CZG-09 and Item CPCD135/150/160-C2Z/CZG CPCD140/150/160-C2Z/CZG-12 CPCD180/200-CZG/CZ1G-12 Steering system type Rear wheel steering with PAS Model 530-5289/842-1256 411-0526-001 Displacement (ml/min) Fully-hyd Maximum raulic inlet pressure steering (bar) gear Maximum operating back...
  • Page 31 When the steering wheel turns right/left (with PAS), the valve element is in the right/left turn position relative to the valve sleeve. In this case, the oil circuit directly linking the oil pump to the oil tank is cut off, the oil circuit to the steering cylinder is opened, and the piston rod extends to drive the steering wheel to deflect.
  • Page 32 maximum operating pressure. The steering cylinder shall have its oil pipe joint faced upward for air bleeding. The oil tank shall be generally installed above the steering gear, and the oil suction pipe shall be inserted into the oil so that oil can be replenished during manual steering while mixing air into oil can be avoided.

  • Page 33: Steering Axle

    To keep the steering system operating in good conditions and prevent any accident, it is necessary to regularly check the operating oil for its moisture, mechanical impurities and acid value. If one of the measured values exceeds the original value required on the label, the operating oil shall be changed with new one.
  • Page 34 and rear pin shafts so that the axle body can swing around pin shafts. There are left and right steering knuckles on the left and right sides of the steering axle respectively. The rear hub is installed on the steering knuckle shaft with two tapered roller bearings. Wheels are pried onto hubs through rims. An oil seal is installed inside the bearing so that grease remains inside the hub and steering knuckle chamber.
  • Page 35 The main parameters of the steering axle are shown in the table below: CPCD120-C2Z/CZ CPCD140/150/160-C2Z/ CPCD180/200-CZG/C G-09 and CZG-09 and Z1G-12 Forklift truck model CPCD135/150/160 CPCD140/150/160-C2Z/ -C2Z/CZG-06 CZG-12 Type Support of central support shaft Inner 80.1° 80° wheel Outer 55.6º 58.9º...

  • Page 36: Brake System

    slotted nut and tighten the nut with a torque of 9.8 Nm again; (4) Gently knock the hub with a wooden hammer and turn the hub for 3-4 turns to ensure that the hub is not loose; (5) Tighten the slotted nut so that the slot is aligned with the cotter pin hole on the steering knuckle;...
  • Page 37 CPCD140/150/160-C2Z/CZG-09, CPCD140/150/160-C2Z/CZG-12 and CPCD180/200-CZG/CZ1G-12 adopt full-hydraulic wet brakes. The brake system of this machine can be classified into the following three parts: 6.1 Service brake The service brake is used for speed control and braking during general traveling and is also called as foot brake.
  • Page 38 integrated valve block. Once the brake pedal is depressed, the HP oil stored in the accumulator of the service brake circuit flows to the axle wheel brake via the service brake valve. After the brake pedal is released, the hydraulic oil in the axle wheel brake flows back to the oil tank via the service brake valve. The oil pressure output from the service brake valve is in direct proportion to the operating force acting on the brake pedal.
  • Page 39 subtle. Moreover, water and impurities will not enter the brake since this device is placed in a sealed oil sump, thus realizing advantages such as large braking torque, long service life, strong resistance to decline and pollution and maintenance-free. To extend the service life of the friction plate used for the oil-immersed wet multi-disc brake and to realize the optimal braking effect, an independent cooling circuit is specially equipped for this machine, to dissipate the heat of the forklift truck due to frequent braking.
  • Page 40 the parking brake switch below the steering wheel). If the oil pressure in the accumulator of the brake circuit is below 8 MPa in case of system faults during operation, the LP alarm lamp of the accumulator will be ON. In this case, stop operating for troubleshooting. The parking brake is made up of a brake disc and a brake cylinder installed on the front axle input shaft.
  • Page 41 allowed. Only special filling tools can be used. Only special filling tools can be used. Such tools are accessories indispensable to the accumulator and can be used for filling, exhausting, testing and filling pressure correction of the accumulator. The filling pressure of the accumulator in the service and parking brake circuits is 7.5 MPa.
  • Page 42 Fig. 6-1 Inside View of Drive Axle Hub...
  • Page 43 Fig. 6-2 Schematic Diagram of Brake System (Applicable to CPCD120-C2Z/CZG-09 and...
  • Page 44 CPCD135/150/160-C2Z/CZG-06 Models) Fig. 6-2 Schematic Diagram of Brake System (Applicable to CPCD140/150/160-C2Z/CZG-09, CPCD140/150/160-C2Z/CZG-12 and CPCD180/200-CZG/CZ1G-12 Models)

  • Page 45: Electrical System

    Electrical system *** Important Safety Tips*** (1) The driver must turn off the main power switch of the vehicle after working. (2) The main power switch must be turned off during maintenance of the vehicle. (3) The main power switch must be turned off and the plug-ins of the electric control equipment must be separated before using welding equipment on the vehicle.
  • Page 46 Indicator group 1 Indicator group 2 CAN bus instruments Cover plate Fault warning light of cooling system POI indicator (1) Indicator group 1: left turn indicator, low beam indicator, parking brake indicator and low braking pressure alarm (2) Indicator group 2: “Non-charging” indicator, clearance lamp indicator, right turn indicator and headlamp (high beam) indicator (3) POI indicator: Please do not turn off the key switch and the main power switch when the POI indicator works!
  • Page 47 Legend of Instrument Identification (3) CAN bus instruments Fig. 7-1 Integral Outlook of Instrument The LCD is in the main display interface shown in Fig. 7-2 by default when the instrument is powered-on.
  • Page 48 DTCs are detected, the Logo of the manufacturer will be displayed here, as shown in (HELI) in Fig. 1. When data have not been received from the CAN bus for 10s, the instrument will judge a fault in the CAN communication function.

  • Page 49: Fuel Gauge

    can display the specific oil pressure accurately. The oil pressure symbol is in gray if such fault as “Low Oil Pressure” is not detected from the bus, and is in red for warning if such fault is detected (as shown in Fig.
  • Page 50 Return Down Table 7-1 Functional Definitions of Keys The menu selected can be moved upwards or downwards by pressing down the Up or Down key, and corresponding interface of the menu can be entered by pressing down the OK key, or the Return key can be pressed down to return to the main display interface.
  • Page 51 Engine information page (see the engine page for other pages) Select the “Engine Information” in the main menu and then press down the OK key to enter the Engine Information page (as shown in Fig. 7-4). Fig. 7-4 Engine Information Page The Engine Information page has listed the main working parameters of the engine, including speed, voltage, engine oil pressure, coolant temperature, working hours, load percentage under the current speed and the liquid level of urea.
  • Page 52 Operation of light combination switch: Neutral: Turn off the clearance lamp and the headlamp; Gear 1: Turn on the clearance lamp; Gear 2: Turn on the headlamp (low beam) and the clearance lamp remains ON; Gear 3: Turn on the headlamp (high beam) and the clearance lamp remains ON; Turn on the right turn light by pushing forwards from neutral;...
  • Page 53 gear 1, 2 or 3 Reverse gear 1 (R1), high level (24V) output from AD1, AD3 and AD5 Reverse gear 2 (R2), high level (24V) output from AD3 and AD5 Reverse gear 3 (R3), high level (24V) output from AD2, AD3 and AD5 Reverse gear 4 (R4), high level (24V) (unused) output from AD1, AD2, AD3 and AD5 7.1.3 Console...
  • Page 54 NOTE: The warning indicators and the indicators are tested at position 1 of the ignition keyhole. 2) Press the ignition key, turn it to position 3 to start, and release it immediately after the engine is started; do not depress the accelerator pedal. 3) After the engine is started, check the engine oil pressure gauge to see if the oil pressure is within the set range.
  • Page 55 Schematic Diagram of A/C Controller NOTE: If the coolant temperature is low, the temperature of the air blown in the cab will not change even if the temperature control button is set to the maximum temperature. NOTE: To remove the glass fog quickly, please select the high gear for air supply and turn the wind direction towards the glass.
  • Page 56 week to ensure good lubrication inside the compressor and optimal operation of the A/C. (4) On-board audio SL130, as an on-board audio system, has various functions such as FM digital tuning radio, USB/SD/MMC MP3, clock, electronic volume control, sound processing, MP3 breakpoint memory, and power-off radio memory.
  • Page 57 From left: front wiper (washer) switch, rear wiper (washer) switch, top wiper (washer) switch, fan switch, USB charging port (6) Rocker switch group 2 From left: diagnostic switch, cruise switch, transmission manual/automatic selector switch, emergency light switch, front work light switch, rear work light switch, warning light switch, cooling fan full speed switch, regeneration switch, regeneration inhibition switch 7.1.4 Cab accessories...
  • Page 58 integrated into the interior lamp. 7.2 Electrical components of vehicle body 7.2.1 Power supply and power system (1) Battery Model: 6-QW-120Ah (2 pcs.) Location: under the electrical compartment on the left side of the vehicle body. Inspection and maintenance: every 200 h * Check whether the fixing bolts of the battery on the bracket are tightened to ensure secure installation.
  • Page 59 plenty of soapy water, and then seek medical help. In case battery sulfuric acid splashes into the eyes, rinse immediately with plenty of water and seek medical help immediately. (2) Generator (please refer to the attached engine manufacturer's instructions) Generator: output power: 28 V/70 A; with a built-in regulator and non-charging alarm indication. In the case of the generator or charging line failure, the non-charging alarm indicator in the cab will be Routine maintenance: Check whether the connection is in good condition.
  • Page 60 to the "Start" position when the engine works properly. Do not exhaust the engine or drag the complete vehicle with the starter. (4) Engine (please refer to the attached engine manufacturer's instructions) WARNING: Before starting the engine in a closed place, check whether there is good ventilation because the exhaust gas is toxic.
  • Page 61 NOTE: See the attachment of the manual for the operation instructions for the engine after-treatment. Precautions for Engine Use: ◆ Welding on components of the complete machine is not recommended. If welding is necessary, disconnect the connector of ECM (engine control system) and remove the (+) positive and (-) negative cables of the battery from the battery.
  • Page 62 160 MPa. ◆ After the engine is started, it must run at idle speed for 3-5 min before loading. After running at full load, it must run at idle speed for 3-5 min before stopping. ◆ It is recommended not to start the engine when a fault code is not identified; do not run the engine at high speed or with load after starting.
  • Page 63 Indicator Indicator Meaning Mark Yellow warning indicator. When the fault indicator is on, it indicates that the fault needs to be eliminated as soon as possible. Red shutdown indicator: When the fault indicator is on, it indicates that the engine needs to be shut down safely as soon as possible and the fault shall be eliminated in time.
  • Page 64 system and instrument display, convenient for routine maintenance and servicing. Left foot brake pedal 2. Connecting harness 3. Oil temperature sensor 4. Alarm lamp 5. Gear lever 6 Shift valve 7. Transmission oil filter switch 8. System expansion connection 9. Display 10 Engine speed sensor 11.
  • Page 65 Transmission control unit (TCU) TCU, like the "brain" of transmission, has the following functions: Manual/Automatic shift control of transmission, inching control of engine for neutral starting relay control, reversing relay control, etc.; shift lever input detection, shift solenoid valve state detection, input and output speed detection;...
  • Page 66 A wrench symbol will be displayed if a fault is detected, and the fault code will be displayed when the gear is in the neutral position. If more than one fault is detected, each fault code will be displayed in turn.
  • Page 67 Three (3) horizontal Manual gear 3; stripes Four (4) horizontal Manual gear 4; stripes 4 horizontal stripes Automatic gearshift; and 2 arrows 6WG: Torque converter lock-up The engine and turbine speeds do not reach clutch ON; Horizontal stripe the determined values (shift values specified flashing in the procedure), and the clutch does not 4WG: Downshift command...
  • Page 68 ④ Display of abnormal AEB-mode start: Display Meaning Remarks Symbol Connection between AEB-Starter and diagnostic plug; The AEB-Starter button is pressed; K1~K4, Measuring clutches K1~K4, KV~KR; x refers to 1, 2, 3, 4, V and R coil. KV~KR - and Kx Waiting to start and initialize clutch Kx;...
  • Page 69 2) Definitions of run commands: NORMAL There is no fault in the transmission system or the fault has no impact on the transmission control; the TCU will continue to work unless there are some restrictions under special circumstances (see the table below).
  • Page 70 TCU will detect a fault that seriously affects the control system; TCU will disconnect all clutch solenoid valves and cut off the power supply of VPS and VPS2, the brake will work, all functions between ADM1 and ADM8 will be lost, and the transmission will be kept in the neutral position.
  • Page 71 Logic errors: shaft line signal Shaft signal feedback Check the harness detected by TCU between TCU and the feedback line shaft cannot run command: switch; connected, or fails to be 5050 connected because normal Check mechanical problems; connection signal of the feedback line The shaft connection reflects switch.
  • Page 72 faulty; normal connector; The oil temperature sensor is Check internally faulty; temperature sensor. The plug lead is grounded. Reducer temperature sensor input terminal short-circuited power supply or open-circuited Check line Too high voltage measured: No response. between TCU and The harness connected to the uses the sensor;...
  • Page 73 voltage signals neutral the sensor; measured at terminals CCO position; there is Check and CCO2 do not match: no change in a connector; non-inching state. The connecting line is faulty; Check run command: The sensor is internally inching sensor. faulty; normal Engine speed sensor input terminal short-circuited to...
  • Page 74 to TCU; run command: The turbine speed sensor is limp home internally faulty; The plug-in pin is directly connected to the power supply or is not in contact. command: The input end of the turbine substitute clutch 1. Check the line speed sensor is grounded control between TCU and...
  • Page 75 Logic error: Internal speed sensor input 1. Check the line The internal speed measured between TCU and by TCU exceeds the limit the speed sensor; value, and after a period of Check This fault occurs time, the measured speed is run command: connector;...
  • Page 76 incorrect. limp home The output speed is zero, which is inconsistent with Special instruction other speed signals for gear selection If the torque converter is not command: in neutral position and the substitute clutch Check the clearance speed change operation is control of the output speed completed, the output speed...
  • Page 77 is running internal line of the transmission. 1. Check the line Change TCU to Clutch K2 is short-circuited from TCU to the neutral position with the power supply transmission; Run the command measured resistance Check "limp home" value of valve K2 exceeds connector from If the fault of...
  • Page 78 internally faulty. "TCU-shutdown" Check is running internal line of the transmission. Clutch K3 is short-circuited and grounded 1. Check the line The measured resistance of Change TCU to from TCU to the valve K3 exceeds the limit neutral position transmission; value, and the voltage is too Run the command Check...
  • Page 79 There is a problem with command regulator; the line or connector, which "TCU-shutdown" Check is connected to the output is running internal line of the end of another regulator of transmission. TCU; regulator internally faulty. 1. Check the line Change TCU to from TCU to the neutral position transmission;...
  • Page 80 regulator another clutch is internally faulty. not removed, TCU transmission; is still in neutral Check position, and the resistance command regulator; "TCU-shutdown" Check is running internal line of the transmission. 1. Check the line Change TCU to Clutch KR is short-circuited from TCU to the neutral position with the power supply...
  • Page 81 voltage at the output end, between which may be caused by reversing alarm short circuit and grounding: device and TCU; The line is grounded; Measure resistance reverse buzzer reversing alarm internally faulty; device. connector lead grounded; reverse relay short-circuited with power supply and gives an 1.
  • Page 82 TCU detects an incorrect but the reducer is TCU; voltage signal at the output not working Check pin, which may be caused by command: connector between the disconnection of the normal the torque converter output end: clutch and TCU; The line is not connected to Measure TCU;...
  • Page 83 the power supply normal the reducer coil; TCU detects a wrong voltage Check signal, which may be caused connector between short-circuited power supply: reducer coil; The line power supply; Measure resistance The reducer coil is reducer coil. internally faulty; The connector or lead is directly connected to the power supply.
  • Page 84 connected to TCU; The alarm signal output device is short-circuited to Check line the ground between TCU and TCU detects an incorrect the alarm device; voltage signal at the output No response. Check the connector end, which may be caused by 5620 between the alarm command:...
  • Page 85 signal is incorrect; Check signal of the speed The sensor clearance size is sensor; incorrect; Check The clutch is faulty. signal of the output speed sensor; Replace clutch. Check pressure of clutch Clutch K2 slips TCU sets an inching speed Check the main on the locked clutch K2.
  • Page 86 judge the clutch as a slipper another clutch is system; clutch: not removed, TCU Check will be in neutral clearance K4 has a low pressure; position internal speed The main pressure of run command: sensor; the system is low; TCU shutdown Check internal speed...
  • Page 87 The sensor clearance sensor; size is incorrect; Check signal of the turbine The clutch is faulty. speed sensor; Replace clutch. Cool The oil tank temperature is transmission; too high No response. 5700 Check the oil level; TCU detects that the oil tank command: temperature exceeds...
  • Page 88 The brake solenoid valve is short-circuited with Check line ground between TCU and TCU detects an incorrect the brake solenoid voltage signal at the output valve; pin, which may be caused by Check the connector No response. short circuit between the TCU BD 5750 command: grounding of the line:...
  • Page 89 TCU at the AU1 pin is less voltage at the AU1 than 4V (the sensor rated pin (which shall be voltage of 5V) 5V). Check the battery Low Battery Voltage capacity; Change to neutral The measured power voltage Check line position is less than 10V (for 12V between the battery...
  • Page 90 display, and the potential TCU shutdown plug-in; detected at the plug-in is Replace the display. always high: The line or connector is damaged directly connected to the power supply; The display is internally faulty. The display output end is grounded 1.
  • Page 91 Open circuit: R12≈R1P≈R1C≈R2P≈R2C≈∞ Short to ground: R12≈0, R1C≈R2C≈0, R1P≈R2P≈∞ Short to battery: R12≈0, R1C≈R2C≈∞, R1P≈R2P≈0 7.2.3 Hydraulic air cooling system (1) Controller The hydraulic air cooling system uses the controller supporting SAE J1939 protocol to adjust the fan speed. The controller can detect the fault of the output port and realize self-protection of the controller.
  • Page 92 temperature Output IO Function Name IO Function Description Name Fan drive solenoid Current feedback C2-1 valve feedback detection signal Fan drive solenoid C2-6 PWM signal output valve drive output When the system detects a fault in the fan C2-5 Fan fault output High-level output system, the pin will output the system voltage at a high level...
  • Page 93 fan speed demand will be zero and the minimum fan speed will be maintained; when the water temperature is higher than 95° C, the fan speed demand will be 100% and the fan will be running at the maximum speed; if the water temperature is within this range, the fan speed demand will be calculated proportionally).
  • Page 94 The CAN bus is faulty 3 green and 3 red The engine speed is abnormal/the sensor 4 green and 3 red is faulty When the cooling system fault warning light is on, the following faults may occur in the system: fan drive solenoid valve fault, CAN bus fault, temperature sensor fault, fan reverse solenoid valve fault, fan pressure sensor fault, steering pressure sensor fault, engine speed and fan speed sensor fault.
  • Page 95 Rear combination lamp - 3W/Pcs. Clearance lamp Rear combination lamp - Braking 3W/Pcs. Rear combination lamp - Steering 3W/Pcs. Rear combination lamp - 3W/Pcs. Reversing Interior lamp 3W/Pcs. (1) Lamp After the operator operates the light combination switch to the headlamp control position, the headlamps will be lit;...
  • Page 96 the interior lamp will be lit for lighting inside the cab. 7.3 Electrical compartment The electrical compartment is located on the left side of the vehicle and contains a central distribution box, relay box, and fuse box. For details of the label and location distribution of fuses and relays, see the graphical representation on the device label.
  • Page 97 (3) Layout of relay control box (GN592-40101) (4) Introduction to functions of fuse and relay NOTE: If a fuse is burnt, find out the cause in the corresponding electrical system. Fuse Specifications_Functions Specification Function Note Preheater Fuse 1 Starter Fuse 2 1FU1 Key switch 1FU2...
  • Page 98 1FU7 Post-processing power supply Relay control box Transmission controller power 2FU1 supply Automatic/overriding selective 2FU2 switch Relay control box-1 2FU3 Reversing horn/light 3FU1 Instrument 3FU2 Indicator 3FU3 Parking brake switch 3FU4 Parking brake solenoid valve Relay control box-2 3FU5 Fork selective solenoid valve 3FU6 Hydraulic control handle 3FU7...
  • Page 99 5FU5 Reverse radar (optional) 5FU6 Radio 5FU7 Air conditioner Two-way fuse box 2 5FU8 Air heater (optional) Relay control box-1 5FU9 Weighing system (optional) 6FU1 Internet of vehicles Relay control box Relay Number_Control Function Note Control Function Startup Starter relay (K1) Control power supply Main power contactor (MK) Preheating...
  • Page 100 Tip: Refer to the following table for a routine electrical inspection Routine Electrical Inspection Every Every Every Every Year Item Inspection Content Week Month Months Months (2,400h) (8h) (40h) (200h) (600h) (1,200h) Cable connection ○ ○ ○ ○ ○ Batteries and surface cleaning Internal and external ○...
  • Page 101 as the original one is required. (3) It is prohibited to modify the circuit system of the forklift truck without the permission of the manufacturer and the agent. (4) When performing the work involving welding on the chassis, the connector of the electric control equipment must be disconnected.
  • Page 102 The electric brush is worn excessively Clean the toner or replace the electric and excessive toner is accumulated brush armature stator short-circuited to the ground or Repair or replace damaged The oil bearing bushing is worn Replace the oil bearing bushing There is adhesion between starter relay Replace the starter relay contacts...
  • Page 103 The horn is faulty Replace The light switch power fuse is Replace blown out The light switch is faulty Repair or replace The light power fuse is blown Replace The light is not on The light control relay is Repair or replace faulty The lamp is faulty Repair or replace...
  • Page 104 The top wiper motor is faulty Replace The top wiper motor is poorly Repair grounded The roof lamp and fan power Replace the fuse fuse is blown out The cab roof lamp and The switch is faulty Replace fan don't work The roof lamp and fan are Replace faulty...
  • Page 105 R134a leakage in the system. Check with a high-pressure and low-pressure gauge to determine whether there is R134a The evaporator fan and condensate fan The inlet and outlet of the liquid reservoir are work properly, connected inversely. Check the expansion valve and the for ice blockage or filth blockage, replace the evaporator and...
  • Page 106 reading of the high-pressure gauge orifice of the is high, while that of the expansion valve is low-pressure gauge is low. blocked by ice. The temperature After the cooling system is turned controlled switch is Inspect whether the temperature on, there is only wind but no cool in poor contact or the controlled switch is damaged air.
  • Page 112 This drawing is only applicable to CPCD140/150/160-C2Z/CZG-09, CPCD140/150/160-C2Z/CZG-12 and CPCD180/200-CZG/CZ1G-12 models...

  • Page 114: Hydraulic System

    Hydraulic system 8.1 Overview The hydraulic system of the forklift truck is a load sensing control system, which consists of hydraulic pump, multi-way valve, steering gear, pilot control handle, hydraulic integrated valve (pilot oil source part), hydraulic motor, speed limit valve, balance valve, pipeline accessories, oil tank, etc. When the engine is running, the transmission drives the oil pump to suck oil from the oil tank and deliver it to the multi-way valve.
  • Page 115 Alarm Pressure Gear Disengagement 15Bar Pressure Parking Brake 100Ba Pressure Full-load 310mm/s 310mm/s 370mm/s 298mm/s Lifting Speed Descending 300-600mm/s Speed 8.1.2 Working principle of hydraulic system (1) The followings apply to CPCD120-C2Z/CZG-09 and CPCD135/150/160-C2Z/CZG-06 forklift trucks The duplex/triple gear pump driven by the transmission sucks hydraulic oil from the hydraulic oil tank through the oil suction filter and supplies it to the whole hydraulic system in two ways.
  • Page 116 Fig. 8-1 Schematic Diagram of Hydraulic System (2) The following content applicable CPCD140/150/160-C2Z/CZG-09 CPCD140/150/160-C2Z/CZG-12 models The duplex plunger pump driven by the transmission sucks high pressure oil from the hydraulic oil tank and supplies it to the main multi-way valve. One oil pump in the hydraulic system is used to supply oil to the tilting, sideshifting pitch control, and steering systems, or to the system lift when the systems do not require oil or the oil is excessive.
  • Page 117 Fig. 8-2 Schematic Diagram of Hydraulic System (3) The following content is applicable to CPCD180/200-CZG/CZ1G-12 models The duplex plunger pump driven by the transmission sucks high pressure oil from the hydraulic oil tank and supplies it to the main multi-way valve. One oil pump in the hydraulic system is used to supply oil to the tilting, sideshifting pitch control, and steering systems, or to the system lift when the systems do not require oil or the oil is excessive.
  • Page 118 . 8-3 Schematic Diagram of Hydraulic System 8.2 Introduction to main components 8.2.1 The followings apply to CPCD120-C2Z/CZG-09 and CPCD135/150/160-C2Z/CZG-06 forklift trucks 8.2.1.1 Gear pump The gear pump is the Parker triple pump (50+50+16) ml/r. Fig. 8-2 Gear Pump...
  • Page 119 8.2.1.2 Multi-way valve The main spool control mode is pilot control, the set pressure of the main safety valve is 20 Mpa, and the set pressure of the secondary relief valve of the third and fourth valves is 14 Mpa. It integrates the function of balance valve, and the main function is to ensure the smooth mast action in the process of forward leaning, and ensure that there is no danger in case of misoperation, improving the safety of the vehicle.
  • Page 120 Fig. 8-5 Pilot Control Handle 8.2.1.4 Priority valve The set pressure of the priority valve safety valve is 17.5 Mpa. Identification and meaning of each oil port: Port P Priority valve oil inlet Port T Priority valve oil return port Port LS Fully-hydraulic steering gear signal port Port CF...
  • Page 121 time, the pressure at port LS is zero, oil is fed to the right end of the valve element, and the hydraulic pressure acts on the right end of the valve element to overcome the pre-pressure of spring 2, so that the valve element moves to the left.
  • Page 122 cylinder, tilt cylinder, pitch control cylinder, and steering mechanism through the control of the valve. The working principle of the plunger load variable displacement pump is to automatically adjust the displacement of the pump according to the load signal of the control valve, so that the output flow of the pump is equal to the flow required by the actuator, without overflow loss.
  • Page 123 Fig. 8-3 Multi-way Valve The multi-way valve is the Parker K220LS series multi-way valve. The valve body is composed of a steering priority valve, 4-way valve and tail valve, with a closed center structure. When the valve element is in the middle position, the oil pumped by the duplex plunger pump is supplied to the steering valve block for the steering action of the vehicle.
  • Page 124 the priority valve through port LSO, since the set spring pressure of the priority valve is less than the set value of the pressure compensator in the main pump, it can be ensured that the pressure oil provided by the pump is supplied preferentially to the steering system. The flow rate of the steering system can be set as required.
  • Page 125 Fig. 8-6 Balance Valve 8.2.2.5 Hydraulic oil tank breather cap The hydraulic oil tank breather cap, or air filter, serves as the breathing apparatus of the oil tank to ensure the balance between internal and external pressure of the oil tank. Blockage will cause cavitation in the oil pump and greatly reduce the service life of the oil pump.
  • Page 126 As the main cleaning equipment of hydraulic oil in the system, the oil return filter plays a crucial role in the cleanliness of the system oil and the proper functioning of hydraulic components. It is installed in the hydraulic oil tank and the whole filter element is below the liquid level, and it is equipped with a bypass valve and a check valve.
  • Page 127 Fig. 8-1 Hydraulic Pump Fig. 8-2 Oil Drain Port of Hydraulic Pump 8.2.3.2 Multi-way valve Fig. 8-3 Multi-way Valve...
  • Page 128 The multi-way valve is the Parker K220LS series multi-way valve. The valve body is composed of a steering priority valve, 4-way valve and tail valve, with a closed center structure. When the valve element is in the middle position, the oil pumped by the duplex plunger pump is supplied to the steering valve block for the steering action of the vehicle.
  • Page 129 Fig. 8-4 Pilot Control Handle Fig. 8-5 Schematic Diagram of Lifting Link Pilot Control 8.2.3.4 Balance valve A balance valve is mainly composed of a case, main spool, pilot valve, control piston, and damping hole. The balance valve is mainly used to prevent the mast vibration caused by the negative pressure inside the tilt cylinder, and avoid the danger of mast tilting caused by inadvertent maloperation (collision with the pilot handle) when the engine is flamed out.
  • Page 130 The hydraulic oil tank breather cap, or air filter, serves as the breathing apparatus of the oil tank to ensure the balance between internal and external pressure of the oil tank. Blockage will cause cavitation in the oil pump and greatly reduce the service life of the oil pump. The filter is easy to install, has a large ventilation capacity, and can be removed and installed manually.
  • Page 131 Operating pressure: 1.6Mpa 8.2.4 following content applicable CPCD120-C2Z/CZG-09, CPCD135/150/160-C2Z/CZG CPCD140/150/160-C2Z/CZG-09 CPCD140/150/160-C2Z/CZG-12 forklift trucks 8.2.4.1 Hydraulic integrated valve block The hydraulic integrated valve block integrates the filling valve, pilot oil source valve and parking brake solenoid valve on previous models together, and it has the advantages of small size and easy installation: Fig.
  • Page 132 Fig. 8-10 Heat Dissipation System Use and maintenance The regular maintenance of forklift truck hydraulic system is an important guarantee to ensure the reliable operation of the vehicle hydraulic system. The main work is to check the sealing of the system regularly, replace the filter element, replace the hydraulic oil, etc.
  • Page 133 Main fault analysis and troubleshooting methods Faults Fault Causes Troubleshooting Method ① The wear and clearance between ① Replace the worn parts or oil pump. oil pump gear and pump body are ② Replace with a new piston seal ring. excessive.

  • Page 134: Lifting System

    pump is incorrect. ① There is internal leakage of the ① Replace the O-ring, repair the valve stem multi-way reversing valve. and re-adjust the fit clearance between the ② The O-ring of the tilt cylinder valve stem and the hole to the specified Large value.
  • Page 135 Inner mast section Outer mast section Lifting height 3,000mm (standard) MAX 6,500mm Tilting forward 6° , 3° Tilting backward 12° , 6° Roller 189.5mm outer diameter Lifting chain LH3244, 4X4, P=50.8 Fork lifting method Hydraulic Mast tilting method Hydraulic Method for fork spacing Hydraulic adjustment Overview...
  • Page 136 suspension beam of the frame with a pin shaft. Point B of the outer mast is connected to the body through the tilt cylinder, and the forward and backward tilting actions are realized under the push-and-pull action of the tilt cylinder. Tilt angle: 6° for forward tilting/ 12° for backward tilting (standard), 6°...
  • Page 137 at points C and D at the lower end of the inner mast. As shown in the figure: 9.1.2 Main parameters internal external mast structures CPCD140/150/160-C2Z/CZG-09 and CPCD140/150/160-C2Z/CZG-12. 9.1.2.1 Main parameters of the lifting system are shown in the table: CPCD140/150/160-C2Z/CZG-09 and Forklift truck model CPCD140/150/160-C2Z/CZG-12...
  • Page 138 Section of outer mast Lifting height 3,000mm (standard) MAX 6,500mm Tilting forward 6° , 3° Tilting backward 12° , 6° Roller 210mm outer diameter Composite roller Slider Adjustable slider Lifting chain LH3244, 4X4, P=50.8 Fork lifting method Hydraulic Mast tilting method Hydraulic Method for fork spacing Hydraulic...
  • Page 139 The channel steel of the outer mast is assembled and welded with ordinary low alloy structural steel plates, with an F-shaped section. A pair of composite rollers are installed on the upper part of the mast. This type of roller is composed of main rollers and lateral slider rollers to bear longitudinal load and transverse load.
  • Page 140 9.1.3.1 Main parameters of the lifting system are shown in the table: Forklift truck model CPCD180/200-CZG/CZ1G-12 Two-stage telescopic and integrated mast, C-shaped Mast type welded inner mast, and C-shaped welded outer mast Inner mast section Outer mast section Lifting height 4,000mm (standard) MAX 6,500mm Tilting forward 6°...
  • Page 141 A two-stage telescopic CC-shaped integrated mast is used for the lifting system, which is mainly composed of inner and outer mast assembly, top beam assembly, sideshifting pitch control fork, lift cylinder mounting assembly, hose pulley block assembly, mast pipeline assembly, tilt cylinder, etc. 9.1.3.2 Inner and outer masts The inner mast assembly is composed of top beam mounting plate, left and right mast channel steel, main roller shaft, upper and lower beams, etc.
  • Page 142 The channel steel the inner mast has a C-shaped section, and 2 pairs of composite rollers are installed at the lower end of the inner mast. As shown in the figure: 9.1.2 Attachment 9.1.2.1 Standard configuration of hydraulic pitch control fork for CPCD120-C2Z/CZG-09 and CPCD135/150/160-C2Z/CZG-06 models The hydraulic pitch control fork consists of a fork arm carrier, fork tandem axle, pitch control cylinder, main roller, side roller, fork, etc., which rolls in the inner mast through 4 groups of rollers...
  • Page 143 9.1.2.2 Standard configuration of sideshifting pitch control fork CPCD140/150/160-C2Z/CZG-09, CPCD140/150/160-C2Z/CZG-12 and CPCD180/200-CZG/CZ1G-12 models The sideshifting pitch control fork consists of a fork arm carrier, bracket, sideshifting pitch control cylinder, fork, etc., which rolls in the inner mast through 4 groups of composite rollers installed on the fork arm carrier.
  • Page 144 9.1.3 Lifting cylinder mounting assembly The lift cylinder mounting assembly consists of a lift cylinder, chain assembly, sprocket assembly, etc. Two single-acting lift cylinders are respectively fixed to the rear of both sides of the outer mast, the bottom of the cylinder is fixed to the cylinder support of the outer mast assembly, and the top of the cylinder is connected to the top beam of the inner mast assembly by bolts.
  • Page 145 to drive the chain so that the fork arm carrier is lifted, thus driving the fork to rise. When the lift lever is pushed forward, the dead weight of the piston rod, fork arm carrier, fork, etc. forces the piston to move down, and the oil under the piston is squeezed out of the cylinder through the rodless chamber oil port.
  • Page 146 9.1.3.2 Speed limit valve The speed limit valve (i.e. throttle valve) is installed on the oil line between the multi-way valve and the high-pressure oil ports of the two lift cylinders. It is installed at the rodless chamber oil port of the lift cylinder.
  • Page 147 increases and pushes the valve element against the spring force to move to the right, making opening B narrow, so the flow of oil from chamber B into chamber C is reduced, that is, the descending speed of the fork is limited (speed reduction). 9.1.4 Tilt cylinder Lug ring, 2.
  • Page 148 pitch control operations are prohibited. 9.2 Adjustment of lifting system (1) The fork falls vertically to the ground to adjust the lifting chain, so as to ensure that the distance between the center of the lower roller of the fork arm carrier and the lower edge of the inner mast is equal;...
  • Page 149 replace the hose with wrinkles and cracks. 10) Check the paint protection of the mast to ensure no rust and corrosion. 11) Check the tilt cylinder and the lift cylinder to ensure that the two groups of cylinders are synchronized when they are moving respectively and synchronized based on pressure maintaining when they are stationary.
  • Page 150 ● Introduction The chain installed on the forklift truck must be inspected and maintained regularly according to the following table. Maintenance Inspection Lubrication Working conditions of components Adjustment of tightness and arrangement Wear condition ● Lubrication In order to keep the chain in good working condition, it is necessary to lubricate the chain and other sliding parts properly and frequently.
  • Page 151 this grease is that it has good fluidity and easy penetration during lubrication. When the diluent evaporates, a layer of viscous lubricating surface can be left. A noticeable feature of the chain is the resistance to high pressure. Some anti-friction solid coatings are very useful, even if the lubricant has completely disappeared, they still guarantee the lubrication effect.
  • Page 152 device and parts under pressure shall be inspected more carefully. All components shall also be checked to prevent the chain piece from falling off the pin shaft and to determine if the hinged joint is locked. Check at least every 12 months or every 1,000 hours ●...
  • Page 153 Check for wear at least every 6 months or 1,000 hours. (4) Lubrication 1) Lubricant Lubricant is added to protect the smooth rotation and sliding of the parts. Insufficient lubrication will cause excessive wear and jamming of the moving parts. 3# lithium-based grease is used for Heli heavy-duty forklift trucks.

  • Page 154: Cab Tilting System

    Precautions for applying the lubricant: 1) Clean the grease nozzle before applying the lubricant; 2) Use a grease gun to inject the lubricant into the grease nozzle until the old lubricant is squeezed out; 3) Clean the excessive lubricant; 4) For the sliding surface, such as the channel steel surface, scrape off the old lubricant on the sliding surface, and apply the lubricant to the contact surface of the slider.
  • Page 155 Basic principles: A After the reversing valve of the manual pump is rotated to upturning, the hydraulic lock is automatically unlocked after pressurization by the manual pump or electric pump, and the cab is rolled over to the designed angle; B The hydraulic cylinder comes with a hydraulic control non-return valve, in order to ensure that the cab will not fall quickly due to oil pipe rupture in the rollover process;...

  • Page 156: Operation Instructions For Dpf Regeneration Of Heavy-Duty Euro V/China Iv Diesel

    High-pressure oil pipe D190ES0602-600 High-pressure oil pipe D190ES0804-600 Cylinder C50305631A Manual pump pressure lever 9F3000A 10.4 Oil products Low-viscosity hydraulic oil is used (10# ground aviation hydraulic oil is recommended (manufacturer: Beijing Kunlun); O# ground aviation hydraulic oil must be used in cold regions, such as the northeast of China).
  • Page 157 >> Time of Regeneration Indicator 1 State Indicator 2 State Description Operation The exhaust temperature is higher It is a safety tip, than the warning temperature or and there is no need for the driver to active regeneration is under way. take actions It is recommended to stop immediately DPF regeneration reminder...
  • Page 158 OPERATION & SERVICE MANUAL www.helichina.com Add/No.668, FangXing Road, Hefei, China Post Code/230000 Customer Service Hotline/4001-600761 S395-1:2023 Service Tel/+86-551-63648005,63689000 E-mail/heli@helichina.com All rights reserved...

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