Baoli CPCD 100, Operating And Servicing Manual

Page 1: ...Original instructions ...

Page 2: ...OPERATION SERVICE MANUAL 8 10t Internal Combustion Counterbalanced Forklift Truck KION Baoli Jiangsu Forklift Co Ltd ...

Page 3: ...blies constructions and working principles so as to be completely familiar with the truck to get the most of it and to help the operators to use the trucks correctly and attain the highest functions It is necessary to read over the manual before they operate the trucks or service personnel serve these trucks Besides this Operation and Service Manual there is Operator s Manual which includes import...

Page 4: ...er 16 8 Caution plate 18 Ⅲ Periodic inspection and servicing 23 1 General rules on inspection and maintenance 23 2 Essentials of servicing 24 3 Recommended oil 25 4 Lubrication system 25 5 Routine check before daily operation 27 6 Precautions of cooling system 27 7 Notes during brake in 27 Ⅳ Construction principle adjustment and maintenance of forklift truck 28 1 Power system 28 1 1 General descri...

Page 5: ...erential 50 3 3 Final reduction gear 50 3 4 Troubleshooting 53 3 5 Service data 53 4 Brake system 54 4 1 General description 54 4 2 Power brake 54 4 3 Parking brake 58 4 4 Wheel brake 58 4 5 Troubleshooting 60 5 Steering system 61 5 1 General description 61 5 2 Hand wheel 60 5 3 Cycloid gear type powered steering unit 62 5 4 Steering system troubleshooting 70 5 5 Rear axle 71 6 Hydraulic system 73...

Page 6: ...r 83 7 3 Tilt cylinder 84 8 Lifting system 85 8 1 General description 85 8 2 Inner outer mast 85 8 3 Lift bracket 85 8 4 Roller position 86 8 5 Adjustment of lifting system 88 8 6 Maintenance and adjustment 88 9 Electric system 91 9 1 General description 91 9 2 Brief explanation for operation 95 9 3 Precautions when using the battery 97 9 4 Harness 97 Product improve suggestion sheet 102 NOTE 103 ...

Page 7: ...1 Ⅰ About the forklift truck 1 External view and specification External view of internal forklift truck ...

Page 8: ...verall dimensions Length to fork face L1 mm 3940 4258 Overall width B1 mm 2245 Mast lowered height H1 mm 2695 2845 Mast extended height H3 mm 4445 4307 Overhead guard height H2 mm 2565 Turning radius R mm 3700 3900 Performance No load full load Travel speed km h 28 24 28 22 Lift speed mm sec 480 350 410 350 390 280 390 300 Max gradeability 20 Self weight kg 11080 12860 Chassis Tyre Front 9 00 20 1...

Page 9: ...k have good performance of drawing b The slight travel device makes it easy for the drivers to aim the truck to the position of cargo c At work for the forklift truck that need starting and shifting frequently achievement of smooth gear shifting control can raise working efficiency simplify operation reduce the driver s labor intensity and reduce requirement of the driver s operation skill 5 The t...

Page 10: ...d gear type powered steering unit and steering axle assy etc 6 Hydraulic system pump valve HP oil pipe LP oil pipe connectors etc 7 Electric system lamps and lanterns battery meter harness etc 8 Load system mast fork carriage load backrest tilt cylinder lift cylinder lift chain mast roller etc Weight of the main parts that can be disassembled Model Specification 8T 10T Balance weight Slinging capa...

Page 11: ... engine oil pan transmission driving axle and hydraulic oil tank check and readjust the clearance of the driving and driven gear in the reducer after the new forklift truck working for 200 hours 2 Inspection before operation Please pay attention to the following items in order to make the vehicle working with high efficiency and lengthen its service life 1 The forklift truck adopts the home or imp...

Page 12: ... the parking brake at the braking position b When starting put the key into the start switch turn it in the counter clockwise preheat 15 20 seconds and then turn it in the clockwise to START so the starting motor works When your hand is away from the key it automatically returns to ON by spring force Every starting time shouldn t morn than 15 seconds Restarting should be after 30 seconds As the en...

Page 13: ... jacks to prevent the forklift trucks from moving in the cabin c Pay attention to the overall length width height when loading unloading and shipping and conforming the regulations is necessary d Single transporting if necessary after disassembling the mast and balance weight Model Mast Balance weight Dimension mm Weight kg Dimension mm Weight kg 8T 2450 2175 850 2423 1980 1166 1325 4193 10T Mast ...

Page 14: ...ft truck must be slung in the appointed position 4 Towing of forklift truck a The towing pin is installed below the counter weight When towing the forklift truck first extract the pin and fasten a steel wire then install the pin back b When towing the forklift truck release the hand brake lever c The towing pin only used for following situation while the forklift truck can t move or while transpor...

Page 15: ... truck Especially check the truck s body for recess or damage and tyres for wear and nails or stones in the tread c Fill the oil tank up with the appointed fuel d Check for leakage of hydraulic oil engine oil fuel or coolant e Apply grease where needed f Check for looseness of hub nuts and cylinder piston rod joints Check the surface of piston rod for damage g Check mast rollers to see that they r...

Page 16: ...e engine oil in crankshaft case of the engine discharge the gear oil or hydraulic transmission oil in differential and gear box after cleaning up then renew oil c Discharge foreign matter and water from the hydraulic reservoir and fuel tank d Remove the cylinder cap the valves and the rocker shafts check for the clearance in normal data e Add cooling fluid to specified level f Perform pre operatio...

Page 17: ...ional instruction we supplied and operate the truck following it strictly 8 Users select Lengthening fork in order to carry widening loads Pay much attention not to overload and observe the allowable load and the capacity chart stuck on the truck Careful driving should be taken when traveling and turning 9 The unloaded forklift truck with attachment should be operated as a loaded truck 10 Connect ...

Page 18: ...ing on a slope 19 The stability of the truck is influenced by the wind force during outside operation you must notice specially 20 Be careful and slow driving over a dock or temporary paving slab 21 Insert forks deeply under goods Adjust fork s distance according to the dimension of goods Make the loads distribute on the forks evenly to avoid tilt and slide of goods 22 Don t pick the loads with si...

Page 19: ...cked goods at a low speed at the same time pay much attention to sharp and hard objects near the goods otherwise the tyres will be pricked 35 Pay attention to pedestrian obstacle and bumpy road when driving Pay attention to the clearance over the forklift truck 36 Keep your head hands arms feet and legs within the confines of the cab Never allow other persons on the forklift truck 37 Tilt the mast...

Page 20: ...excessively replace it immediately 48 The overhead guard is main part which is strong enough to meet safety standard and protect the operator from falling materials It s very dangerous to dismantle or rebuild the overhead guard because these conditions could lead to an accident 49 A load backrest shall be used as protection against back falling objects on the fork It s very dangerous to dismantle ...

Page 21: ...the driver depends on the working condition etc road operation method so the actual vibration frequency must be determined according to environment condition when necessary 56 To prevent the fire accident or other unpredictable event prepare the fire extinguishers in advance and operate them according to the instructions 57 Preventive maintenance services should be done before or after using the t...

Page 22: ...gine 12 Water temp gauge 3 Brake pedal 13 Sedimentor indicator option 4 Parking brake lever 14 Hour meter 5 Hand wheel adjusting lever 15 Horn button 6 Shift lever 16 Turn signal lever 7 Oil pressure indicator 17 Accelerator pedal 8 Fuel gauge 18 Lift lever 9 Charge signal 19 Tilt lever 10 Neutral signal ...

Page 23: ...the battery condition of charge Lamp comes on when the ignition switch is set at on 10 Neutral signal Indicate the neutral position Shift lever is in neutral position it lights up 11 Air filter indicator option It will warn when the air filter is blocked Exceed standard resistance it flashes 12 Water temp gauge Indicate the temperature of engine coolant Ignition switch is set at on 13 Sedimentor i...

Page 24: ... 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 1 Safety mark People are forbidden to stand on or down the fork 2 General information when operating 3 Nameplate of forklift truck ...

Page 25: ...19 4 Lubrication system 5 Capacity chart 6 Inspections before starting ...

Page 26: ...20 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: ...21 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: ...22 18 Hand caution decal 19 Fan hurting hands 20 Hood crushing hands Energy accumulator decal Belt pulley thumb hand decal ...

Page 29: ... the manager Do not operate the truck until it has been repaired completely Regular inspection 1 Check the seal and the reliability of the hydraulic system 2 Check the reliability of the steering and braking system 3 Check the reliability of mast driving axle and steering axle connecting with the frame 4 Check all wheels for tightness Irregular inspection 1 Check the reliability of each welding jo...

Page 30: ... Steering link lever Replace grease 1000 4 Parking brake lever Add grease 200 5 Pin foot brake Add grease 200 6 Drive axle body Replace gear oil 2400 7 Braking oil Add Whenever necessary 8 Pin tilting cylinder Add lubricating grease 400 9 King pin knuckle Replace grease 1000 10 Hydraulic tank and filter Clean 1000 11 Hydraulic oil Replace 1000 12 Lift chain Replace 3000 If damaged replace it 13 H ...

Page 31: ...se and coolant should follow relevant automobile standard The waster of the forklift truck must be reclaimed obeying the relevant laws and regulations Incorrect treatment will pollute water soil and atmosphere etc Wear a helmet safety shoes and working clothes to avoid contacting with body when adding oil grease and coolant 4 Lubrication system NO Position Grease point Type Time hours 50 100 500 1...

Page 32: ...26 Lubrication diagram ...

Page 33: ...meter whether work normally 6 Precautions of cooling system 1 Use extreme care when removing the radiator pressure cap In pressure system the sudden release of pressure can cause a steam flash which would cause a serious personal injury Loosen cap slowly to allow steam to escape After that tighten cap securely 2 Check the radiator coolant reservoir fluid level It should between FULL and LOW mark A...

Page 34: ...at the truck stop operating the truck and inform a professional serviceman Use genuine parts of our company for replacement 1 Power system 1 1 General description Power system consists of the engine fuel system cooling system and exhaust system The engine is connected with the frame by rubber cushion to avoid vibration Fig 1 1 For the construction and adjustment of engine please refer to the opera...

Page 35: ...U1 CPCD100 CU1 Parallel table for engine and forklift model which is coincidence and stuck with CE label Engine model The guaranteed sound power level LwA dB 2000 14 EC Exhausting 2004 26 EC CE CONFORMITY 2006 42 EC Truck model Diesel engine Cummins Inc QSB4 5 111 StageⅢA yes CPCD80 CU1 CPCD100 CU1 Note The sound power level LWA according to 2000 14 EC standard the exhausting according to 2004 26 ...

Page 36: ...inder bore stroke 6 105mm 125mm Total displacement L 6 494 Compression ratio 17 Performance 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 speed rpm 700 Weight kg 450 Dimension mm 1129 5 672 0 860 0 Injection start pressure kg cm2 kg cm2 Compress pressure kg cm2 kg cm2 ...

Page 37: ...s of the engine during using the forklift truck Especially after maintaining the engine it s necessary to verify the discharge indicator ensure that discharge value is fit for the national standard so as to minimum damage to the person and environment 1 4 Fuel system The fuel system composed with the fuel tank filter fuel sensor 1 4 1 Fuel tank The fuel tank is a welded construction integrated wit...

Page 38: ... around of the new filter s seal before installation it should be screwed 2 3 circles again when the filter s seal touches the body of engine c When the warning lamp is on drain all the water by loosing the draining switch Note Turn off the draining switch after draining water Fig 1 4 Fuel filter 1 4 3 Fuel filter The fuel filter was installed in the engine enters hose used to filtrate the fuel su...

Page 39: ... Cleaning of the air condition Fig 1 6 1 Take out the filter 2 Check the dust and the damage of the filter fist puff away from inside to outside to clean with low pressure air if it s jammed and can t clean or has been damage change a new one 3 Clean the dust in the cover Fig 1 6 Air condition 1 6 2 Replacement of fuel filter Fig 1 7 1 Use the filter specially spanner disassemble if damage or bloc...

Page 40: ...g 1 8 when the antifreeze under the LOW scale it means need to add coolant add to the 2 3 scale of the up and down scale 2 Change the coolant a Stop working more than half an hour wait it cooling then open the radiator cover and loose the water outlet valve under the radiator b Loose the engine water outlet valve release all the coolant c After releasing screw down those two valve which mentioned ...

Page 41: ...11 2 Tighten the twisting moment to 93Nm then tighten the bolt orderly 3 Turn the bolt 90 degree and tighten them Fig 1 11 1 6 7 Valve clearance adjustment 1 Turn the crank shaft clockwise make the TC mark on shock absorber of belt coincide with the pointer 2 Inspect the hole cover affirm the position of soleplate mark and pointer If the soleplate mark coincide with hand position show the 1st cyli...

Page 42: ... I E I E I E I E I E 1st cyl in TDC 6th cyl in TDC 1 6 8 Fuel injection ignition time affirmation 1 Affirm if the assemble countermark is in conformity with the place of injection pump flange See Fig1 15 2 Put the 1st cylinder to the TDC position turn the crank shaft about 30 counterclockwise See Fig1 16 Fig 1 15 Fig 1 16 ...

Page 43: ...on time adjustment 1 Dismantle pipe installed on injection pump 2 Loosen installed bolt of injection pump 3 While affirm the ignition time according 1 5 7 gist turn it over engine under advance condition turn it to engine under delay condition 4 After adjustment tighten all the bolt of injection pump affirm the ignition time again 5 Assemble the drain valve used in the 1st cylinder and install eac...

Page 44: ...e sudden release of pressure can cause a steam flash which would cause a serious personal injury Lower the running speed of the engine to moderate speed after the cooling system cooled then turn to idle speed loosen cap slowly to allow steam to escape the cap can be removed After that make sure the cap is tightened securely 2 Check the radiator coolant reservoir fluid level It should between FULL ...

Page 45: ...ure Mpa 1 2 1 5 Weight kg 295 Oil amount l 20 Oil type NO 6 torque converter oil SAE10W 2 1 General description The power shift transmission mounted on the forklift truck has excellent features as follows 1 An inching valve provides the machine with improved inching performance Due to this valve the lift truck is allowed to perform inching operation regardless of whether the engine is at low RPM o...

Page 46: ...g 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 Ball bearing 21 Forward clutch pack 6 Torque converter 14 Shaft 22 Input plate 7 Ball bearing 15 Bearing cover 23 Transmission output shaft 8 Gear 16 Output shaft ...

Page 47: ...gle reduce the moment of output reduce to it finally the liquid flow into idler pulley in the reverse direction and then the above counterforce moment act backward Under the circumstance the torque from output shaft is less than the input shaft s To prevent the phenomenal there is a unilateralism clutch installed in idler pulley when the counterforce moment act backward the idler pulley running fr...

Page 48: ...rging 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 Fig 2 3 Charging pump ...

Page 49: ...tination and abrasion on clutch surface When pressure oil acts to piston the clutch and steel plate which fitted together are pressed so the clutch transfer the power to drive gear from torque converter The transfer flow of power from torque to transmission is as follows Turbine wheel input shaft clutch drum steel plate clutch disk forward or reverse gear output shaft 2 5 Control valve and inching...

Page 50: ...44 Fig 2 4 Forward shift clutch Fig 2 5 Reverse shift clutch Fig 2 6 Control valve ...

Page 51: ...the filter When the selector valve is in neutral position the circuit from the selector valve to the clutch is closed Therefore the fluid is joined with the torque converter filling fluid When the selector spool is set to the forward or reverse position fluid flows into the accumulator due to action of modulate valve so that pressure rises gradually During this time the clutch starts to engage Whe...

Page 52: ...s follows Turbine wheel main shaft clutch drum steel plate clutch plate forward or reverse gear output shaft 2 8 Caution when the trouble occurs When the truck cannot run by itself due to trouble and it must be dragged with another machine be sure to observe the following requirements 1 Remove the propeller shaft between the transmission and the differential 2 Set the shift lever in neutral positi...

Page 53: ...l damaged Check and replace B Fly wheel damaged Check oil if have dirt replace it Gear box A Unsuitable oil or air bubble Check oil 1 Air entering in resulting from loose connections Check connectors or oil pipes Retighten each connector or replace seals 2 Too lower oil pressure or air bubble in oil Measure and adjust pressure B Slipped clutch 1 Oil pressure lower Measure and adjust pressure 2 Sea...

Page 54: ...ow Check pipes and replace 7 Worn bearing Check and replace Gear box 1 Slipped clutch Replace friction piece of clutch 2 Worn bearing Check and replace 3 Noisy gear box Parts Problem Possible cause and remedy Torque converter 1 Elasticity plate is broken Check noise and replace elasticity plate 2 Damaged or worn bearing Check or replace 3 Gear is broken Check or replace 4 Spline is worn Check or r...

Page 55: ...il pressure of the clutch 4 Shaft is broken Check and replace 5 Clutch cap is broken Check and replace 6 Retainer ring of clutch cap is broken Check and replace 7 Foreign matters mixed in oil tank of clutch Check clean or replace 8 Spline of shaft is worn Check and replace 5 Oil leakage Parts Problem Possible cause and remedy Torque Converter or Gear Box 1 Worn seal ring Check and replace seal rin...

Page 56: ...and drive pinions which are all assembled on the main reduction gear carrier as shown in Fig 3 2 and is fitted to the axle housing through packing 3 3 Final reduction gear The final reduction gear is of the planet gear type consisting of a sun gear planetary gears and an internal gear Two final reduction gears are installed on each end of the axle housing The sun gear is splined to the axle shaft ...

Page 57: ... gasket 16 Steel ball 3 Tyre 10 Lock nut out 17 Pinion gear shaft 4 Oil seal 11 Inner gear seat 18 Thrust washer 5 Taper roller bearing 12 Braking plate and shell assembly 19 Half bearing cover 6 Wheel assembly 13 Inner gear ring 20 Pinion gear bracket 7 Taper roller bearing 14 Pinion gear 21 Clamp brake ...

Page 58: ...er 23 Shim 4 Taper roller bearing 14 Roller bearing 24 Taper roller bearing 5 Plain half 15 Carrier 25 Seal retainer 6 Side gear 16 Lock nut 26 Oil seal 7 Pinion gear 17 Adjust bolt 27 Flange 8 Spiral bevel pinion 18 Drive pinion 28 O ring 9 Spider 19 Taper roller bearing 29 Washer 10 Thrust washer 20 Bearing cage 30 Lock nut ...

Page 59: ... necessary 3 5 Service data Parts Item Standard value mm Differential Tightening torque of ring gear set bolt 140 160 N m Tightening torque of cross case set bolt 140 160 N m Thickness of pinion washers 1 562 1 613 Axle housing Tightening torque of the set bolt for axle housing and differential carrier 150 175 N m Tightening torque set bolt securing axle housing to frame 630 946 N m Tightening tor...

Page 60: ...em the pressure oil is divided to two directions one for the brake valve and the other for the energy reservoir They are controlled by the stroke of the brake pedal 4 2 1 Position of brake pedal Fig 4 2 The brake pedal and the inching pedal are mounted on the left side of the frame by a bracket The piston of the brake valve is actuated through the push rod by the operation of the brake pedal The i...

Page 61: ...55 Fig 4 2 Position of brake pedal ...

Page 62: ... order to make the oil pressure in the chamber D lower the max adjusting oil pressure E When your foot releases the pedal the valve sleeve 7 returning to the original position relies on the opposite force the process of the brake ends 3 Reservoir working performance When the oil pump stops working engine flameout or damage the reservoir is on working performance A Press the brake pedal valve sleev...

Page 63: ...tch inside it Preventive maintenance should be done by authorized serviceman Failure to use will cause crack Depressurization treatment should be done when the truck parking or preventive maintenance The method to decrease the pressure After the engine is flameout press the brake pedal for 5 to 8 times then the pressure of reservoir in brake system can be decreased Fig 4 3 Brake valve 1 Plug 5 Rec...

Page 64: ...c direction 4 4 Wheel brake Fig 4 6 Wheel brake is clamp brake installing symmetry around Clamp brake consists of clamp body operating cylinder four by one couple rub pieces two by one couple brake plate The structure is seen in the picture The wheel brake is consisting of a pair of brake shoes operating cylinder a adjuster 3 4 return springs and backing plates Two wheel brakes are provided on eac...

Page 65: ...mp 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: ...eign matter adhered thereto Repair or replace Deformed backing plate or loose bolts Repair or replace Deformed shoe or incorrect installation Repair or replace Worn friction piece Replace Loose wheel bearing Replace Uneven braking Oil contaminated friction piece Repair or replace Malfunction operating cylinder Repair or replace Eccentric brake drum Repair or replace Maladjustment clearance of fric...

Page 67: ...60 Steering unit Type BZZ powered steering unit Displacement min 280 Rated pressure MPa 16 Steering cylinder Type Double action type Cylinder dia Rod dia mm Φ115 Φ85 Stroke mm 2 216 Divider Setting pressure MPa 12 5 Rated displacement l min 27 Steering axle Type Transverse cylinder type Steering angle outside inside 76 54 Rear tread mm 1700 Interval of knuckle spindle mm 1500 Diameter of cardan jo...

Page 68: ...el When the engine stop running the charging pump will not work in this case a man powered steering should be adopted The sketch map of powered steering system is shown as Fig 5 1 The structure of the steering unit is shown as Fig 5 2 Fig 5 1 Hydraulic steering system 1 Hand wheel and steer shaft 5 Steering cylinder 2 Oil pump 6 Steering axle 3 Flow control valve 7 Hose 4 Hydraulic steering unit ...

Page 69: ...63 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: ...ng system the oil from oil pump passes through the lumen of valve bore to oil box Fig 5 2 a When turning by power oil from oil pump pass through the along valve to cycloid pin wheel mesh force rotor running following steering wheel and press the ration oil to the left or the right of crock force turning wheel to turn by power and oil in the other cylinder flows back to oil box Fig 5 2 b c When eng...

Page 71: ...il of the steering unit can prevent the oil from flowing into the oil for the manpower turning 5 Cleaning pipes of the system and closed oil tank can reduce the oil pollution 6 Trial run Clean the oil tank and add oil to the top level before trial run Loose the bolt connector of the steering cylinder and bleed air at the low speed of the oil pump Disassemble the piston rod and steering wheel turn ...

Page 72: ...ng the steering join 50 100ml pressure oil in the orifice turn the valve bore to right and left then install and practice the truck if they are not abnormal b Valve body block plate stator rotor and the connection surface of the back cover must be kept clean and they can t be hurt c Notice that the whorl cover most be lower than the surface of the valve body d Block ring and slip ring have an inve...

Page 73: ... any more to see if they are identical each other and check the operation if the steering handwheel for smoothness during above operation 3 After assembling a steering system put up the turning wheel make the engine to run at a slack speed then turn the steering wheel slowly and do it times and times to exhaust the air in the hydraulic pipeline and cylinder Check whether voice for it to turns is n...

Page 74: ...g valve is closed the pressure meter will show its pressure If the pressure is over 12MPa it shows that the diffluent valve has malfunction But if the pressure is too low it shows that the oil pump has malfunction or the spring of the diffluent valve has rupture In this circumstance the time of the closed of the parking valve can t be over 15 seconds Notice The oil pump provides pressure oil to ma...

Page 75: ...e divider is lower than the working pressure or the divider is blocked by the dirty Adjust the pressure of the divider or clean it Steering malfunction Spring piece is broken off The hand wheel can t return to neutral position automatically Replace the spring piece Shift arm is broken off or deformed Replace the shift arm Drive shaft is broken off or deformed Replace the drive shaft Mutual positio...

Page 76: ...alve spool blocked Disassemble repair or replace Flow control valve spool worn Replace as assembly Oil pressure does not rise Relief valve stuck open Replace as assembly Oil pressure higher than relief set pressure Relief valve stuck closed Replace as assembly Noisy relief valve Relief valve vibrating Replace as assembly Too high oil temperature Relief valve stuck closed Replace as assembly Hard s...

Page 77: ...t and left knuckles On the knuckle a hub for installing a wheel thereon is installed by two bearings The hub is provided with an oil seal for grease The knuckle is installed between two bosses with bearings through which a king pin is inserted Lubricate all bearings by a nozzle installed on the top cover users must add lubricant in time 3 Steering cylinder The steering cylinder is of double action...

Page 78: ...e hub slightly knock at it with a wooden hammer and in the meantime rotate the hub for 3 4 turns e Tighten the castle nut and align one of its notches with a hole drilled in the steering knuckle f Again slightly knock at the hub with a wooden hammer and in this time rotate manually the hub for 3 4 turns to ensure its smooth rotation with a specified torque of 2 94 7 8N m g If the torque value nece...

Page 79: ...e valve body with the spools 6 2 Main pump The main pump consists primarily of a drive gear driven gear and pump body which contain the two gears and other components The drive gear is in mesh with the driven gear 6 3 Control valve See Fig 6 1 The control valve is a sectional type consisting of the inlet section plunger section and outlet section which are assembled with three bolts At the inlet s...

Page 80: ...sure according to the following procedures a Screw the plug screw off the inlet port of the control valve install a 25MPa oil pressure gauge b Operate the tilt lever measure the pressure when the oil pressure stroke to the end c When the oil pressure isn t the same as the standard value twist the adjusting nut twist it clockwise raise oil pressure on the contrary reduce oil pressure d After adjust...

Page 81: ...he slide valve will replace to the middle position recur to the replacement spring 3 Pull slide valve See Fig 6 4 This moment the middle position passage is off The oil that is come from the oil enter port will push out the one way valve and inflood cylinder port A the oil that is expelled from the cylinder port B will pass the low pressure passage and be back to fuel tank The slide valve will rep...

Page 82: ...e precursor valve core E will be open and the oil will inflood the hole via the valve core circumference then reach the LP passage See Fig 6 6 3 Once the precursor valve core E is open the back pressure of the core C will be reduced so the core C will be shift to the right direction then be on the core E As a result the back oil route of the core D will be cut off the inside pressure will be also ...

Page 83: ...icture the port A is connect with the front of the tilt cylinder and the port B is with the behind When pull the tilt operation staff pull slide valve the oil that is come from the oil pump will be inpour A and the oil that is come from B port will be back to Oil tank As a result the mast will be retroverted On the other hand push the tilt operation staff push slide valve the oil that is come from...

Page 84: ...the oil tank passing through the valve When the lift lever is pulled the hydraulic oil from the control valve flows through the flow regulator valve and reaches the lower part of the lift cylinder piston to push up the piston rod When the lift lever is pushed the circuit between the lower part of the lift cylinder piston and the oil tank is opened and the piston begins to descend due to the weight...

Page 85: ...en down Replace O ring seal O ring seal connections of valve body broken down Replace O ring seal Spool can not be reset Return spring become deformed Replace return spring There is dirty between valve body and spool valve Clean Valve body deformed with the too tight coupling bolt Retighten coupling bolt The pressure of the relief valve is not right Pressure regulating spring deformed Replace pres...

Page 86: ... oil and check if there is any burrs or scars replace it if necessary valve body slide valve and valve rod shall be in good order replace complete part if necessary 1 Clamp the slice valve with table vice and then assemble valve rod and spring in right direction 2 Put O ring valve leather sealing washer spring and its base in good order into end of slide valve and then cover it and tighten the bol...

Page 87: ...long the inner surface of the cylinder by high pressure oil An oil seal and bushing are installed on the cylinder cap which is screwed into the cylinder body The bushing supports the piston rod and the oil seal prevents dust from entering the cylinder The upper end of the piston rod and inner mast upper beam is locked with bolts When the lift lever is tilted backward high oil pressure is sent into...

Page 88: ...r 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 Ball bearing 16 Snap ring 17 Spring 18 Cut off valve 19 Upper beam ...

Page 89: ...hamber I oil holes E D G H and chambers C B A to the valve Then there is pressure difference between chamber A and C Turn on the ball valve 4 a pressure difference overcomes the force of the spring 9 and moves the valve core 5 right thus the oil flow being decreased by narrowing of the hole G and H and reduces the oil flow passing through the throttle plate The flow regulator valve serving both as...

Page 90: ... 3 When the tilt lever in the driver s room is tilted forward high pressure oil enters from the cylinder tail to shift the piston forward tilting the mast forward 6 With the tilt lever tilted high pressure oil enters from the cylinder cap side This shifts the piston to the rear causing the mast to tilt backward 12 Fig7 3 Tilt cylinder 1 Ear ring 7 Guide sleeve 13 Piston 2 Dust ring 8 O ring 14 Pis...

Page 91: ...r 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 Fig8 1 Mast 8t 1 Fork 2 Lift bracket 3 Lift chain 4 Inner mast 5 Outer mast 6 Tilt cylinder 7 Lift cylinder Fig8 2 Mast 10t 1 Fork 2 Lift bracket 3 Lift chain 4 Inner mast 5 Outer mast 6 Tilt cylinder 7 Lift cylinder ...

Page 92: ...otice Please pay more regard to safety when maintaining the main rollers and side rollers on the upper of outer mast 8 3 Lift bracket At the lift brackets end rollers that roll along the inside of the inner mast frames are installed on the end roller shafts with snap rings The end roller shafts are welded to the lift brackets The side rollers that roll along on the inside of the inner mast frames ...

Page 93: ...re 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 See Fig8 3 Fig8 4 Fig8 3 Roller mounting 8t forklift Fig8 4 Roller ...

Page 94: ... be equal d Make use of the spacer of the lift cylinder to adjust the error occurred between the right and left cylinders in height 8 6 Maintenance and adjustment 8 6 1 Adjustment of lift cylinder Fig8 5 When replace the lift cylinder inner mast or outer mast we shall readjust the stroke of the lift cylinder as following 1 Install the piston rod in the upper beam of the inner mast without shims 2 ...

Page 95: ...See Fig8 7 Fig 8 7 4 Put down the fork and tilt to specified position adjust the nut at chain upside and tensility of two chains should be same See Fug8 8 Fig 8 8 8 6 3 Replace rollers of the lift bracket 1 Place a pallet on the forks and let the truck parking on the horizontal ground 2 Make the forks and the pallet down to the ground 3 Disassemble the end nipple of the upper chain and take the ch...

Page 96: ...e lift cylinder and the inner mast Hang up the inner mast not to loose the shims of the piston rod heads 5 Disassemble the connecting bolts for the lift cylinder and the bottom of the outer mast Disassemble the lift cylinders and the oil pipes between the two cylinders without loosen the oil pipe joints 6 Main rollers on the upper outer mast will be showed on the top of the inner mast as soon as m...

Page 97: ...e This system consists of the key switch relay for stopping engine and automatic device for stopping engine For the truck equipped with a homemade engine this system is controlled by a cable for stopping engine 4 Instruments It mainly consists of hour meter fuel meter water temperature meter charge signal oil pressure indicator neutral signal air filter indicator and sedimentor indicator They are ...

Page 98: ...y e When the meter works abnormally contact with our company for maintenance 5 Lighting and signal device They include all kinds of illuminating lamps signal lamps horn and buzzer etc Headlight 55W Front combination lamp turning front 21W 5W Rear combination lamp turning rear brake backing up 21W yellow 5W red 21W red 10W white Rear combination lamp down 55W yellow Warning lamp optional 21W Rear l...

Page 99: ...93 Fig 9 1 Principle diagram of electric system domestic CPCD80 100CY ...

Page 100: ...94 Fig 9 2 Principle diagram of electric system imported CPCD80 100W ...

Page 101: ...starting position then start the engine After engine starting push the direction switch forward that is forward gearshift then pedal accelerator the forklift truck runs faster and you can begin to work When pull the direction switch backward that is in reverse gearshift the backing lamp is on and the buzzer sounds 2 Lamp switch Pull the lamp switch to the first on position the front lamps and rear...

Page 102: ...s working it indicates low lubricating oil pressure and you must stop working and check the lubricating system as soon as possible 8 Water separator signal Before you start the engine put the key switch to the first on position and the water separator alarm lamp is on After engine starting the water separator alarm lamp is automatically off If this lamp becomes on while the engine is working it me...

Page 103: ...e of battery is made of the dilute sulphuric acid Handling should be taken care When the electrolyte adheres to eye skin and clothes it causes to lose eyesight and burns When an accident is occurred take the emergency first aid and consult a physician immediately 3 Dealing with the waste and worn batteries according to relevant laws and regulations 9 4 Harness Allowable current carrying of standar...

Page 104: ...98 Fig9 5 1 Diagram of meter harness domestic CPCD80 100CY ...

Page 105: ...99 Fig9 5 2 Diagram of meter harness imported CPCD80 100W ...

Page 106: ...100 Fig9 5 3 Diagram of main harness domestic CPCD80 100CY ...

Page 107: ...101 Fig9 5 4 Diagram of main harness imported CPCD80 100W ...

Page 108: ...ggestion 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 Production name Factory number Produce lot number Leave factory date Start use date Use company ...

Page 109: ...103 NOTE ...

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Page 111: ...ax 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 manual without giving previous notice and without Edition ME05 02 2010 ...

Page 112: ...106 incurring any obligation ...