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Baoli CPCD 80 Operating And Servicing Manual

8-10t internal combustion counterbalanced forklift truck
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  • Page 1 Original instructions...
  • Page 2 OPERATION & SERVICE MANUAL 8-10t Internal Combustion Counterbalanced Forklift Truck KION Baoli (Jiangsu) Forklift Co., Ltd.
  • Page 3 PREFACE Thank you for selecting BAOLI forklift truck! Your trust is a great honor to us! 8-10 ton internal combustion counterbalanced forklift trucks adopt hydraulic transmission with advanced TCM continuous speed control and integral drive axle with wheel reducer, so they have a lot of advantages such as good traction and travel performance, easy operation, reliable brake, wide visibility and safe performance.

  • Page 4: Table Of Contents

    CONTENTS Ⅰ. About the forklift truck ..…….………………………........1 1. External view and specification……………………………………………………1 2. Characteristic of forklift truck………………………………………………………3 Ⅱ. Safety instruction and operation of forklift truck ………………………5 1. Handling a new forklift truck………………………………………………………5 2. Inspection before operation………………………………………………………5 3. Start and stop of the engine………………………………........6 4.
  • Page 5 2.2 Torque converter…………………………………………………………………41 2.3 Charging pump……………………………………………………………………42 2.4 Hydraulic clutch…………………………………………………………………..43 2.5 Control valve and inching valve…………………………………………………43 2.6 Hydraulic circulation system…………………………………………………….45 2.7 Principle……………………………………………………………………………46 2.8 Caution when the trouble occurs………………………………………………46 2.9 Trouble shooting…………………………………………………………………47 3. Front axle……………………………………………………………………………50 3.1 General description…………………………………………………………….50 3.2 Main reduction gear & differential……………………………………………….50 3.3 Final reduction gear………………………………………………………………50 3.4 Troubleshooting…………………………………………………………………53 3.5 Service data……………………………………………………………………….53...
  • Page 6 6.5 Main safety valve operation……………………………………………………..76 6.6 Tilt lock valve operation…………………………………………………………77 6.7 Hydraulic circulation system (Main circuit)……………………………………..78 6.8 Troubleshooting………………………………………………………………….79 6.9 Maintenance……………………………………………………………………...80 7. Lift Cylinder & tilt Cylinder……………………………………………………….81 7.1 Lift cylinder……………………………………………………………………….81 7.2 Flow regulator…………………………………………………………………….83 7.3 Tilt cylinder……………………………………………………………………….84 8. Lifting system……………………………………………………………………….85 8.1 General description…………………………………………………………….85 8.2 Inner &...

  • Page 7: Ⅰ. About The Forklift Truck

    Ⅰ . About the forklift truck 1. External view and specification External view of internal forklift truck...
  • Page 8 Main specification CPCD80-W CPCD100 CPCD100-W CPCD80 Model CPCD80-CU1 CPCD100-CU1 Power type Diesel Operating way Sitting Rated capacity 8000 10000 Load center Lift height 3000 Free lift height L×W×T 1500×160×75 1500×160×80 Fork size Fork outside spread (Min./Max.) 320/2015 420/2144 α/β Mast tilt angle 6/12 6/12 Front overhang...

  • Page 9: Characteristic Of Forklift Truck

    2. Characteristic of forklift truck The forklift truck has advantages as follows: 1. The hydraulic steering device makes steering flexible and the double ladder like steering bridge makes the turning radius minor. 2. The braking system employs oil brake, makes it possible to manipulate conveniently and brake reliably.
  • Page 10 Main parts of forklift truck: Name Contents engine mounting, system of fuel, exhaust and Power system coolant etc. torque converter, transmission, transmission shaft, Transmission etc. housing, half shaft, differential, wheel reducer, Drive axle brake, front wheel etc. Brake system wheel brake and parking brake steering wheel, steering shaft, cycloid gear type Steering system powered steering unit and steering axle assy etc.

  • Page 11: Ⅱ. Safety Instruction And Operation Of Forklift Truck

    Operation & Service Manual. Please read this manual thoroughly. This will give you a complete understanding of Baoli forklift truck and you will operate them correctly and safely. 1. Handling a new forklift truck The performance and service life of the forklift truck depends heavily upon the way you handle it during the break-in period.

  • Page 12: Start And Stop Of The Engine

    etc. (6) Check for all the terminals and plugs in normal state. Check the meters, lamps, switches and electric circuit if they are running properly. (7) Check every pedal for free stroke and the levers for looseness and smooth operation. Check lifting system, actuate the lifting and tilting levers to be certain that the lift bracket moves up and down properly and the mast can be tilted smoothly.

  • Page 13: Shipping, Loading And Unloading, Slinging And Towing Of Forklift Truck

    (2) Stop the engine First set the engine on idle running for five minutes, so as to cool the engine gradually, and then turn off the ignition switch, so the engine is stopped to work. Notice： ．While the engine running, does not turn the start switch to “START” position, or it will damage the starting motor.

  • Page 14: Parking And Storing

    (2) Load and unload the forklift truck (a) Use the plate with enough length, width and strength. (b) Pull the parking brake and use jacks to stop the wheel. (c) Fasten the plate on the center of the cabin, there must be no grease on the plate.
  • Page 15 accidental roll. The forklift truck is forbidden parking on a steep slope. (b) Park your forklift truck in the area where designated or traffic conditions permit. If necessary, put a signpost or signal lights around the truck. (c) Park your forklift truck on the solid ground. Avoid soft ground, deep mud or slippery surfaces.

  • Page 16: Information Of Safety Operation

    Perform the following service and checks in addition to the “Daily storage” service: (a) Taking the rainy season into consideration, park the truck at a higher and hard ground. (b) Apply antirust oil to the exposed parts such as piston rods and shafts which tends to rust.
  • Page 17 (3) When operating the truck, observe and follow all nameplates stuck on the truck. The nameplates must be replaced if lost or damaged. (4) Daily maintenance should be done before or after using the truck. Anytime you find that the truck is not functioning normally, operation of the truck should be halted and check or repair at once.
  • Page 18 (15) The starting, turning, driving, braking and stopping of the truck should be done smoothly. When turning on the humid or slippery road, the truck should be decelerated. (16) Because the forklift truck turns by the rear wheels, the end counterweight may swing widely when turning.
  • Page 19 under upraised forks. (27) When lifting the load, according to the weight of the load, accelerate properly and then pull the lifting lever. (28) The load descends for the gravity, at this time, the engine must be in idle position, and the lever must be pulled slowly to prevent the load from sudden falling. (29) When loading and unloading goods, keep the mast vertical and the truck is in braking state.
  • Page 20 (42) Don’t open the radiator cap when the engine is very hot. (43) After one day’s working, the fuel tank should be added oil to prevent the humidity in the fuel tank from becoming the blob and then interfusing the fluid. (44) When leaving, engage the hand brake, lower the forks on the ground and let the shift lever to neutral, make the engine flameout or cut down the electric supply.
  • Page 21 (54) According to the Directive 2000/14/EC and based on EN12053 standard，the noise pressure level at the operator’s position and the measured sound power level and the guaranteed sound power level is referred to the following table. But the noise of the forklift truck may fluctuate due to different operation and the influence of the external environment.

  • Page 22: Operation Device And Meter

    7. Operation device and meter 1. Inching pedal 11. Air filter indicator (option) 2. Button for stopping engine 12. Water temp. gauge 3. Brake pedal 13. Sedimentor indicator (option) 4. Parking brake lever 14. Hour meter 5. Hand wheel adjusting lever 15.
  • Page 23 The function and use method of operation device and meter is listed as follows: Name Function Use method When the pedal is pressed, Couple or uncouple the Inching pedal the transmission is transmission. uncoupled. Button for Pull the button to stop the Stop the engine.

  • Page 24: Caution Plate

    8. Caution plate The caution plates attached on the vehicle indicates the operating method and instructions. Before driving it, please be sure to read them thoroughly. If the caution plate drops, stick it again. When maintaining, check if the caution plate is complete and the writing is legible, if necessary, please replace them.
  • Page 25 (4) Lubrication system (5) Capacity chart (6) Inspections before starting...
  • Page 26 (7) Adjust parking brake (8) Add hydraulic oil (9) Add fuel (10) Add antifreeze (11) Tyre safety decal (charging tyre) (12) Tyre pressure decal (charging tyre)
  • Page 27 (13) Cautions for high voltage (14) Sling point indication (15) Sling decal (16) Forbid entering into the space behind the mast (17) Forbid conveying person...
  • Page 28 (18) Hand caution decal (19) Fan hurting hands (20) Hood crushing hands Energy accumulator decal Belt pulley thumb hand decal...

  • Page 29: Ⅲ. Periodic Inspection And Servicing

    Ⅲ . Periodic inspection and servicing During operating the forklift truck, it is necessary to operate carefully, service and maintain periodically to make the forklift truck keep in good condition. 1. General rules on inspection and maintenance (1) Only use genuine parts provided by our company. (2) Only use genuine or recommended oil when replacing or adding.

  • Page 30: Essentials Of Servicing

    2. Essentials of servicing (1) Some critical components must be replaced according to demands periodically. Use genuine parts only. (2) Use the same model oil only when replacing or adding. (3) If any damage or fault is found, stop the truck and report the condition to the manager.

  • Page 31: Recommended Oil

    3. Recommended oil Brand or code Name Quantity Domestic Overseas Refer to diesel engine manual JISK2204/2# select GB252-81 light Diesel (general region) 140L diesel: JISK2204/3# (cold region) Winter―10～―35# Summer0# Select refer to engine manual SAE10W (Winter) Lubricant oil or working condition SAE30 (Summer) diesel:GB5323-85 Hydraulic oil...
  • Page 32 Lubrication diagram...

  • Page 33: Routine Check Before Daily Operation

    5. Routine check before daily operation (1) Check the storage of fuel. (2) Check if any leak or damage found on the oil pipe, water hose, vent-pipe and hydraulic parts. (3) Check whether the hydraulic hose storage attain to the regular capacity, the oil level should be at the middle position between the upper and lower scale marks of oil level meter.

  • Page 34: Ⅳ. Construction, Principle, Adjustment And Maintenance Of Forklift Truck

    Ⅳ . Construction, principle, adjustment and maintenance of forklift truck In order to keep good condition of your truck, you must have an intimate understanding of the construction, principle, adjustment and maintenance of the forklift truck. When find damage or a fault at the truck, stop operating the truck and inform a professional serviceman.

  • Page 35: Engine Disposition

    1.2 Engine disposition The engine used for 8-10t forklift truck includes the import engine 6BG1 (ISUZU), the home engine 6102BG6 (Zhaoyang). Engine model 6102BG6A A-6BG1QC QSB4.5 Place of production Zhaocai Japan(ISUZU) Cummins,Inc. Rated output / Speed kw/rpm 80.9/2500 82.3/2000 82/2200 Rated torque / Speed N.m/rpm 353/1600 416/1400-1600...
  • Page 36 Fig.1.2 A-6BG1QC diesel engine Main performance and disposition of A-6BG1QC Model A-6BG1QC Type 4-cycle,water-cooled,overhead valve No. of cylinder—bore×stroke 6-105mm×125mm Total displacement (L) 6.494 Compression ratio Rated speed rpm 2000 Rated output kw 82.3 Max. torque (N.m/rpm) 416/1400-1600 Full-load fuel consumption g/kwh 233 No-load Min.

  • Page 37: Inspection And Adjustment Of Engine

    1.3 Inspection and adjustment of engine In order to keep good condition of your truck, you must carry out periodic inspection and adjustment of power system. (1) Regularly clear the dust of air cleaner. (2) Regularly replace oil filter and fuel filter. (3) Check and apply the coolant periodically.
  • Page 38 1.4.2 Fuel sensor The function of the fuel sensor is to change the oil in the oil tank to the electric through the bobber up and down sport, in the end transfer to the fuel chart in the dashboard, let others to know the oil quantity directly. See Fig.1.4. (a) Once every 600 hours operation, it is required to replace the filter assembly.

  • Page 39: Coolant System

    1.5 Coolant system The coolant system composed with water pump, fan, radiator and the ancillary radiator, the water pump installed in the engine, the crank through the V-series tape to drive the water pump work. 1.6 Check and adjustment To have a good work state, it needs to check and research on the engine termly. The main point is as following: 1.6.1 Cleaning of the air condition (Fig.1.6) (1) Take out the filter.
  • Page 40 1.6.3 Replacement of oil filter (Fig.1.8) (1) Use the filter specially spanner disassemble and change. (2) Along with the around of the new oil filter seal o-ring, add little lube then install, when it contact the filter, screw 2/3 circle. Fig.1.8 1.6.4 Vice radiator (Fig.1.9) (1) Check the coolant in the vice radiator...
  • Page 41 1.6.5 Adjust the fan belt If the fan belt is loose, tighten it. See Fig.1.10. Step: loosen the fixed bolt B and C of generator, move the generator out. Press the A section of belt with the force of 10kg strength, the flexible degree is about 10mm, then tighten the bolt B,C orderly.
  • Page 42 Fig.1.13 Fig.1.14 The material adjustment see Table 3.2. Cylinder NO. I:inspiration valve E: exhaust valve △ △ △ △ △ △ 1st cyl. in TDC ※ ※ ※ ※ ※ ※ 6th cyl. in TDC 1.6.8 Fuel injection ignition time affirmation (1) Affirm if the "assemble countermark"...
  • Page 43 (3) Loosen the 1st cylinder injection pipe, dismantle the spring on drain valve bracket and drain valve, then install the drain valve bracket on injection pump. See Fig1.17. Fig.1.17 4) While charging pump transmit fuel, it turn the crank shaft clockwise , when the fuel lever of drain valve bracket up to the stop position, stop turning the crank shaft.

  • Page 44: Precautions Of Cooling System

    the manometer is 500N/ cm (3) Running the starting device by plenty battery, meter the pressure at this time. (4) Measure the other 5 cylinder by the same way, and measure 2 times, then figure out each average value; compression pressure: 304N/cm (limit value 255N/cm 1.6.11 Exhaust of injection pump ( Fig 1.20) (1) Loosen core vent of injection pump.

  • Page 45: Drive Unit

    2. Drive unit Drive unit consists of torque converter and a hydraulic transmission. The structure of the hydraulic transmission refers to Fig.2-1, the structure of the torque converter refers to Fig.2-2. Main technical parameter Item Parameter Type 3-element,1-stage,2-phase type Torque 12.5″(Φ315) ratio 3.1 Torque converter ratio converter...
  • Page 46 Fig.2.1 Torque converter transmission 1. Control valve 9. Parking brake 17. Oil seal 2. Charging pump 10. Strainer 18. Ball bearing 3. Ball bearing 11. Oil seal 19. Gear 4. Drive shaft 12. Gear 20. Reverse clutch pack 5. Ball bearing 13.

  • Page 47: Torque Converter

    2.2 Torque converter The torque converter consists of pump wheel installed on input shaft, a turbine wheel installed on output shaft and stator wheel fixed on torque converter body. Pump rotor is driven by elastic plate, the elastic plate is connected with flywheel, the pump rotor start turning while the engine is running.

  • Page 48: Charging Pump

    Fig.2.2 Torque conv Fig 2.2 Torque converter 2.3 Charging pump Fig 2.3 shows the structure of charging pump. The charging pump consists of drive gear, driven gear, case and cover. They are fixed on the head of torque converter housing. The drive gear is driven by pump wheel, driven gear and drive gear, the charging pump feeds oil in the under part of transmission to each part of it.

  • Page 49: Hydraulic Clutch

    2.4 Hydraulic clutch Fwd clutch see Fig 2.4, reverse clutch see Fig.2.5. There is a hydraulic clutch fixed on transmission, the drive gear on the side of clutch is engaged with the corresponding driven gear, the drive gear on the side of reverse clutch is engaged with the opposite gear.
  • Page 50 Fig.2.4 Forward shift clutch Fig.2.5 Reverse shift clutch Fig.2.6 Control valve...

  • Page 51: Hydraulic Circulation System

    2.6 Hydraulic circulation system (see Fig. 2.7) When the engine is started and the charging pump is put into operation, the torque converter fluid in the oil tank (transmission case) is forcibly sent to the control 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.

  • Page 52: Principle

    Fig. 2.7 Hydraulic circulation system 2.7 Principle The torque converter consists primarily of a pump wheel connected to the input shaft, a turbine wheel connected to the output shaft, and a stator wheel fixed to the housing. The transmission consists of charging pump, hydraulic clutch, the forward gear and reverse gear.

  • Page 53: Trouble Shooting

    2.9 Trouble shooting (1) Insufficient power Parts Problem Possible cause and remedy A. Too low oil pressure 1. Lower oil level Check oil level and add oil. Check connectors or oil pipes. 2. Air entering in resulting from Retighten loose connectors. each connectors or replace seals.
  • Page 54 (2) Too higher oil temperature Parts Problem Possible cause and remedy 1. Lower oil level Check oil level and add oil. 2. Blocked oil filter Check, clean or replace. 3. Fly wheel bump against other Check oil, if have dirt, replace it. parts.
  • Page 55 (4) Too lower transmission efficiency Parts Problem Possible cause and remedy 1. Elasticity plate is broken. Check turn noise and replace. 2. Lower oil amount. Check oil level and add oil. 3. Driving system of oil pump Torque Check and replace. is ineffective.

  • Page 56: Front Axle

    3. Front axle The main specifications of the front axle: Type Full-floating type, integral shaped Type Spiral bevel pinion type Main reduction gear Reduction ratio 6.33 Type Planetary gear type Final reduction gear Reduction ratio 3.58 Total reduction ratio 22.66 Main reduction gear 10 L Amount of oil...
  • Page 57 Fig.3.1 Front axle 1. Breaking dial 8. Lock nut(in) 15. Roller bearing 2. Wheel assembly 9. Prevent-loosen gasket 16. Steel ball 3. Tyre 10. Lock nut(out) 17. Pinion gear shaft 4. Oil seal 11. Inner-gear seat 18. Thrust washer Braking plate and shell 5.
  • Page 58 Fig. 3.2 Reducer & differential 1. Adjust nut 11. Flange half 21. O-ring 2. Cap 12. Side gear 22. Spacer 3. Lock plate 13. Thrust washer 23. Shim 4. Taper roller bearing 14. Roller bearing 24. Taper roller bearing 5. Plain half 15.

  • Page 59: Troubleshooting

    Fig. 3.3 Final reduction gear 3.4 Troubleshooting Trouble Cause Correction Loose bolt or broken gasket of Retighten or replace. differential carrier. Oil leaks from Breather is clogged. Clean or replace. differential carrier. Oil seal is worn or damaged. Replace. Gear is worn, damaged or broken. Replace.

  • Page 60: Brake System

    4. Brake system 4.1 General description The brake system consists of two wheel brakes installed on the front axle and parking brake on the propeller shaft. 4.2 Power brake (see Fig.4.1) The wheel brake system consists of brake pedal, brake valve, power accumulator and brake.
  • Page 61 Fig. 4.2 Position of brake pedal...
  • Page 62 4.2.2 Brake valve (Fig. 4.3) (1) Non-brake state Since the brake valve A port is open, the nozzle of the pump and powered steering is interlinked, the operation of steering is normal in the state of non-brake. When the brake pedal isn’t been pressed, the oil pressure in the chamber D won’t go up in that the port B is close.
  • Page 63 opens and oil flows to the energy reservoir. Now the piston shifts to the left, the warning switch doesn’t ring. The reservoir storages the maximum energy along with the oil pressure rises constantly, the oil pressure is 13 MPa, this value is controlled by the safety valve. The energy reservoir storages the pressure energy, there are safety valve and pressure alarm switch inside it.

  • Page 64: Parking Brake

    4.3 Parking brake The parking brake is of internal expansion and lining type, and built in the output shaft of the torque converter transmission. The operation of the parking brake is shown in Fig.4.5. When the forklift truck parks on a slope with standard capacity, the hand operation force should below 300N.
  • Page 65 Fig.4.6 clamp brake 1 clamp body 6 dustproof cover 11 deflate spile 2 rectangle ring seal 7 O-ring seal 12 deflate seat 3 rub piece assy 8 bolt 13 nut 4 below crock cover 9 above crock cover 14 bolt 5 pump plunger 10 pin shaft...

  • Page 66: Troubleshooting

    4.5 Troubleshooting Problem Possible cause Remedy Fluid leakage from brake system Repair Adjust Maladjustment of brake shoe clearance Check for dragging Brake overheating Poor Poor contact between brake drum and friction Adjust braking piece force Repair or replace Foreign matter adhered on friction piece Foreign matter mixed in brake fluid Replace Maladjustment of brake pedal...

  • Page 67: Steering System

    5. Steering system 5.1 General description Steering system contains mainly a steering hand wheel, a steering column, a cardan joint, a powered steering unit, a steering axle and a steering cylinder. The steering shaft is connected with the steering unit and steering hand wheel by the joint.

  • Page 68: Cycloid Gear Type Powered Steering Unit

    5.3 Cycloid gear type powered steering unit The steering unit can transmit the pressure oil from the flow divider by pipes to the steering cylinder in terms of the rotating angle of the hand wheel. When the engine stop running, the charging pump will not work, in this case a man-powered steering should be adopted.
  • Page 69 5.3.1 Steering unit assy Fig.5.2 Cycloid gear type powered steering unit 1. Spacing sleeve 6. Joint sleeve 2. Valve body 7. Rotor 3. Valve core 8. Stator 4. Interlock shaft 9. Valve sleeve 5. Spring piece...
  • Page 70 5.3.2 Work principle Valve bore, valve sleeve, valve body in the redirector makes up of along valve, having an effect of controlling the direction of the oil flow. Rotor and stator makes up of cycloid mesh, having an effect of measure element when turning, to make sure that the oil quantity in oil crock and corner of steering wheel makes direct ratio;...
  • Page 71 5.3.3 Usage of the steering unit (1) Install the steering unit When installing the steering unit, it must ensure concentric with the connecting shaft, axial clearance can avoid propping by valve core, checking the hand wheel if it can return to the neutral position flexibly after installing. The allowable flow rate of the inlet oil pipe is 1-1.5m/s, the allowable flow rate of the outlet oil pipe is 4-5m/s.
  • Page 72 5.3.4 Check and maintenance of the steering unit In order to keep the steering system in good working condition and avoid accidents, it is necessary to check the steering system regularly. The structure of steering unit is referred to Fig5.4. (1) Regularly check water, foreign matter and acid number of the working oil, if necessary, replace it with new oil.
  • Page 73 b. Order of assembly valve core-spring piece-valve sleeve-shift arm-shim-valve body-slip ring-block ring- front cover-steel ball-screw cover-block plate-interlock shaft -rotor-stator -spacing sleeve-back cover. Fig5.4 Structure of steering unit 5.3.5 Inspection on reassembly of steering system (1) Check the arrangement of the hydraulic pipeline and the turning direction for correctness.
  • Page 74 of the steering wheel with the parking detent, to measure the operation of steering, which must be under 150N. (5) Measure the pressure with pressure meter (15-20MPa), cutoff valve and soft tube in Fig. 5.4. Remove the split-flow valve to the line of the turning implement, engage a line with pressure meter on the side of diffluent valve, engage a line with breaking valve on the side of turning implement, then make the engine run at a slack speed.
  • Page 75 5.3.6 Steering unit troubleshooting Problem Possible cause Remedy Oil leaks from the connection surface of valve body, stator and rear cap due to Clean. the dirty. leakage The rubber ring is worn. Replace rubber ring. The washer of limit bolt is uneven. Grind or replace washer.

  • Page 76: Steering System Troubleshooting

    5.4 Steering system troubleshooting 5.4.1 Inspection after reassembling the steering system (1) Check the force when turning the steering handwheel to right and left until it can’t be turned any more to see if they are identical each other and check the operation if the steering handwheel for smoothness during above operation.

  • Page 77: Rear Axle

    5.5 Rear axle The rear axle is primarily composed of an axle body, right and left knuckles, tie rods, wheels, hubs and steering cylinder. The steering axle is of cranks and slider mechanism. The cylinder piston rod pushes the knuckle steering through tie rod, causing wheel’s deflection and truck’s steering.
  • Page 78 (4) Rear wheel bearing pre-load adjustment a. As shown in Fig5.7, fill up the chamber formed by wheel hubs, wheel hub bearing and wheel hub covers with lubricating grease. Coat the lips of the oil seals with lubricating grease. b. Press the hub bearing into the hub and fit the hub on the knuckle shaft. c.

  • Page 79: Hydraulic System

    6. Hydraulic system Type Gear pump Hydraulic oil pump Displacement 32 ml/r 36 ml/r Two-pool type with relief valve, flow divider Type and tilt self-locking valve Setting 19 MPa Control pressure valve Dividing 12 MPa pressure Flow rate 25 L/min 6.1 General description The hydraulic system mainly consists of main pump, control valve, high &...

  • Page 80: Control Valve Operation

    outlet section. Each section is sealed with O-ring, and the oil passage at the high pressure side is given a check valve. Caution: Don’t adjust the pressure of the main relief valve at will. If the pressure is too high, the hydraulic system and hydraulic component may be damaged. When maintaining or using, if oil pressure isn’t the same as the standard value, on the basis of JB/TT3300 test way, the professional serviceman should adjust the pressure according to the following procedures:...
  • Page 81 Fig.6.2 Middle position (2) Push slide valve (See Fig.6.3) At that time, the middle passage is off. The oil that is come from the oil enter will push out the one-way valve, and inflood cylinder port B. The oil that is expelled from the cylinder port A will pass the low-pressure passage and be back to fuel tank.

  • Page 82: Main Safety Valve Operation

    6.5 Main safety valve operation (1)The main safety valve must be installed between the cylinder HP port and LP passage. The oil that pass through the valve core will be acting on the different diameter surface A & B, so the core K of the one-way valve and the core D of the main safety valve will be firmly fall into the valve base.

  • Page 83: Tilt Lock Valve Operation

    6.6 Tilt lock valve operation Tilt lock valve is used for preventing the shaking of the mast (because the tilt cylinder maybe cause the inside negative pressure), at the same time, it can avoid the danger that the mast will be tilted due to the wrong operation (hit the tilt operation staff) when the engine is off.

  • Page 84: Hydraulic Circulation System (Main Circuit)

    6.7 Hydraulic circulation system (Main circuit) The hydraulic system sketch sees Fig. 6.10. The hydraulic circulation system of the main circuit is complicated with the hydraulic for power steering. The hydraulic piping is of O-ring fitting type with excellent sealing performance, providing secure oil tightness. The hydraulic oil sent from the rear main pump flows directly to the control valve, while the hydraulic oil sent from the front main pump is divided by the flow divider valve in two portions for steering and load handling operation.

  • Page 85: Troubleshooting

    6.8 Troubleshooting Problem Possible cause Remedies Disassembly, repair or replace Parts worn. parts. Gear pump Blocked oil pipe. Make the oil pipe through. can not be Blocked oil tank or filter. Clean dirty or replace oil. pressurized. Too high oil stickiness or oil Use recommended oil.

  • Page 86: Maintenance

    6.9 Maintenance 6.9.1 Detaching of multi-way valve Detach the valve from forklift and clean it. (1) Loose bolts and separate each part ,please note that 1-way valve or spring on contact surface shall be kept well. (2) Loose the bolts at a side of slide valve end as well as at cover side, and then detach them together with valve leather, o-ring and sealing washer.

  • Page 87: Lift Cylinder & Tilt Cylinder

    7. Lift cylinder & tilt cylinder Type Single-action piston type, with cut-off valve Lift Φ100 Bore diameter cylinder Stroke 1495mm (Only for 3m lift height) Type Double-action piston type Tilt Φ115 Bore diameter cylinder Stroke 242mm 7.1 Lift cylinder The two lift cylinders of single acting type are used and located behind each outer mast frame.
  • Page 88 1. Adjusting pacer 2. Dust ring 3. Yx ring 4. Cylinder cap 5. Bushing 6. O-seal ring 7. Cylinder body 8. Piston rod 9. Snap ring, steel 10. Wear ring 11. Yx ring 12. Piston 13. Lift chain 14. Chain wheel 15.

  • Page 89: Flow Regulator

    7.2 Flow regulator The flow regulator is located between the control valve and the high pressure ports of the two lift cylinders, near the left lift cylinder. The structure of the flow regulator valve is shown in Fig7.2. When the lift spool valve is placed in the “lift” position, the oil from the control valve flows through the oil chambers A and B, C, oil holes H, G, D, E, and the chamber I to the lift cylinder without any regulation.

  • Page 90: Tilt Cylinder

    7.3 Tilt cylinder Two tilt cylinders of double acting type are provided at 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 with pins. The tilt cylinder assembly consists primarily of a cylinder body, cylinder cap, piston and piston rod.

  • Page 91: Lifting System

    8. Lifting system 8.1 General description The lifting system is of two-stage, rolling telescopic mast type. The inner mast frames have J-shaped section. The outer mast frames have C-shaped section. The masts of forklift trucks all contain a free lift range. The structure of the mast sees Fig. 8.1 and Fig8.2.

  • Page 92: Roller Position

    8.2 Inner & outer mast The mast assembly is of the free lift range-contained two stage telescopic type consisting of the inner and outer mast, and is sustained by mast supports. The mast supports are welded to the bottom of the outer mast, being extended from the axle housing.
  • Page 93 of the fork, pull the fork pin turn 1/4 circle, the fork clearance must be adjusted according to the loaded goods. 8.4 Roller position There are three kinds of rollers, main roller, side roller group and side roller. They are separately mounted on the inner mast, outer mast and lift bracket. The main rollers sustain the main loads from front, which can’t be adjusted, and rear direction and the side rollers sustain the side loads with the left and right side clearance adjusted by the gasket group, this will make the inner mast and lift bracket move freely.

  • Page 94: Adjustment Of Lifting System

    8.5 Adjustment of lifting system a. The clearance between the inner mast and the guide plate of the outer mast is 0.5-1.0mm, which is adjusted by the spacer of the guide plate. The clearance between the side roller and the channel beam is 0.3-0.8mm, which is adjusted by the axial bolt inner the roller.
  • Page 95 8.6.2 Carriage adjustment (1) Park forklift on horizontal place and let mast vertical. (2) Put the bottom of fork onto ground, screw the adjustable nut at the end of joint and let main idler wheel come out l/4-l/3 of its radius. See Fig8.6. Fig.8.6 (3) Lift fork to Max.
  • Page 96 (6) Replace the main rollers. ·Disassemble all the snap rings and take out the main rollers with a drawing tool except the adjusting shims. ·Ensure the new rollers have the same types as the replaced rollers. Install the new rollers inside the lift bracket and fasten them with snap rings. 8.6.4 Replace rollers (Fig8.10) (1) Use the same way as 8.5 to disassemble the lift bracket from the inner mast.

  • Page 97: Electric System

    The instrument panel adopts Curtis internal-combustion engine meter core. The fuel meter and water temperature meter are ten solid state bars of multicolor LED display. The hour meter in the BAOLI instrument panel is solid state digital display with back lamp.
  • Page 98 b. Forbid wetting the meter. When washing the truck, don’t let water into the meter, if it happens, clean it with dry cloth. c. Don’t pull the plug of the meter and harness for the connection. d. Forbid impacting or scratching the meter strongly. e.
  • Page 99 Fig.9.1 Principle diagram of electric system (domestic) CPCD80-100CY...
  • Page 100 Fig.9.2 Principle diagram of electric system (imported) CPCD80-100W...

  • Page 101: Brief Explanation For Operation

    9.2 Brief explanation for operation (1) Starting There is a starting protection circuit in the control box for the forklift truck. You have to shift the direction switch in neutral before you start the engine. Otherwise, you can not start the engine. Turn the key switch clockwise to the first “on”...
  • Page 102 When you need to reverse the forklift truck, pull the direction switch backward and the transmission is in reverse gear. Then the backing lamps (white) in the rear combination lamps are on and the buzzer sounds. (6) Charging signal Before you start the engine, put the key switch to the first “on” position and the charging lamp is on.

  • Page 103: Precautions When Using The Battery

    Fig9.4 LED Combined instrument 1. Fuel meter 5. Charge indicator 2. Water temperature meter 6. Neutral indicator 3. Hour meter 7. Filter indicator 4. Oil pressure indicator 8. Water separator signal 9.3 Precautions when using the battery (1) Gases produced by the battery can be explosive. Do not smoke, use an open flame, and create an arc or sparks in the vicinity of the battery.
  • Page 104 Fig9.5.1 Diagram of meter harness (domestic) CPCD80-100CY...
  • Page 105 Fig9.5.2 Diagram of meter harness (imported) CPCD80-100W...
  • Page 106 Fig9.5.3 Diagram of main harness (domestic) CPCD80-100CY...
  • Page 107 Fig9.5.4 Diagram of main harness (imported) CPCD80-100W...

  • Page 108: Product Improve Suggestion Sheet

    Production improve suggestion sheet (feedback) Production name Factory number Produce lot number Leave factory date Start use date Use company Suggestion content: To improve our forklift trucks, absord your valuable suggestion, please send to us suggestion content. We also ask your understanding for the fact that, due to on-going improvement of parts and equipment the numerical values given in the manual are subject to change without notice.

  • Page 109: Note

    NOTE...
  • Page 111 KION Baoli (Jiangsu) Forklift Co., Ltd. Service Hotline: 400-828-2789 Tel: +86 523 8461 6148 Fax: +86 523 8461 6126 P.C.: 214500 Add: No. 8 Xinzhou Road·Economic Development Zone·Jingjiang·Jiangsu·China www.baoli-mh.com * We reserves the right to make any changes or modifications of pictures and specifications in this...
  • Page 112 incurring any obligation.

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