Baoli CPCD 100 Original Instructions Manual

Summary of CPCD 100

  • Page 1

    Original instructions.

  • Page 2: Operation & Service

    Operation & service manual 8-10t internal combustion counterbalanced forklift truck kion baoli (jiangsu) forklift co., ltd..

  • Page 3: Preface

    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 s...

  • Page 4: 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 t...

  • 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……………………………………………………………………………4...

  • Page 6

    6.5 main safety valve operation……………………………………………………..76 6.6 tilt lock valve operation…………………………………………………………77 6.7 hydraulic circulation s ystem (main circuit)……………………………………..78 6.8 troubleshooting………………………………………………………………….79 6.9 maintenance……………………………………………………………………...80 7. Lift cylinder & tilt cyli...

  • Page 7

    1 Ⅰ. About the forklift truck 1. External view and specification external view of internal forklift truck.

  • Page 8

    2 main specification g e n e ra l model cpcd80 -c cpcd80-w cpcd100 -c cpcd100-w cpcd80-cu1 cpcd100-cu1 power type diesel operating way sitting rated capacity kg 8000 10000 load center mm 600 dim e n s io n s lift height h mm 3000 free lift height h4 mm 205 210 fork size l×w×t mm 1500×160×75 1500×160...

  • Page 9

    3 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 convenientl...

  • Page 10

    4 main parts of forklift truck: no. Name contents 1 power system engine mounting, system of fuel, exhaust and coolant etc. 2 transmission torque converter, transmission, transmission shaft, etc. 3 drive axle housing, half shaft, differential, wheel reducer, brake, front wheel etc. 4 brake system whe...

  • Page 11

    5 Ⅱ. Safety instruction and operation of forklift truck it is important for drivers and managers to remember the principle of “first safety” and ensure the safety operation as the description of operation & service manual. Please read this manual thoroughly. This will give you a complete understandi...

  • Page 12

    6 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...

  • Page 13

    7 (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 star...

  • Page 14

    8 (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. (d) the left and right height of the plate must be equ...

  • Page 15

    9 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, de...

  • Page 16

    10 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. (c) cover components whi...

  • Page 17

    11 (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 ...

  • Page 18

    12 (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. Use care in n...

  • Page 19

    13 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 sudde...

  • Page 20

    14 (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...

  • Page 21

    15 (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 differe...

  • Page 22

    16 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. Horn button 6. Shift lever 16. Turn signal ...

  • Page 23

    17 the function and use method of operation device and meter is listed as follows: no. Name function use method 1 inching pedal couple or uncouple the transmission. When the pedal is pressed, the transmission is uncoupled. 2 button for stopping engine stop the engine. Pull the button to stop the eng...

  • Page 24

    18 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, ...

  • 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

    23 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. (...

  • Page 30

    24 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. Do not operate...

  • Page 31

    25 3. Recommended oil name brand or code quantity domestic overseas diesel refer to diesel engine manual or select gb252-81 light diesel: winter―10~―35# summer0# jisk2204/2# (general region) jisk2204/3# (cold region) 140l lubricant oil select refer to engine manual or working condition diesel:gb5323...

  • Page 32

    26 lubrication diagram.

  • Page 33

    27 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 betw...

  • Page 34: Of Forklift Truck

    28 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 operatin...

  • Page 35

    29 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 to...

  • Page 36

    30 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 17 p erf orm an ce rated speed rpm 2000 rated output kw 82.3 max. Torque (...

  • Page 37

    31 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

    32 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...

  • Page 39

    33 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...

  • Page 40

    34 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 coola...

  • Page 41

    35 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. 1.6.6 tighten ...

  • Page 42

    36 fig.1.13 fig.1.14 the material adjustment see table 3.2. Cylinder no. 1 2 3 4 5 6 i:inspiration valve e: exhaust valve i e 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 conf...

  • Page 43

    37 (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 brack...

  • Page 44

    38 the manometer is 500n/ cm 2 . (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 2 (limit value 255n/cm 2 ) 1.6.11 exhaust of i...

  • Page 45

    39 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 torque converter type 3-element,1-stage,2-phase type ...

  • Page 46

    40 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. Ball bearing 21. Forward clutch pack 6. Torque converter 14...

  • Page 47

    41 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 w...

  • Page 48

    42 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...

  • Page 49

    43 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. The clutc...

  • Page 50

    44 fig.2.4 forward shift clutch fig.2.5 reverse shift clutch fig.2.6 control valve.

  • Page 51

    45 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...

  • Page 52

    46 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 forwa...

  • Page 53

    47 2.9 trouble shooting (1) insufficient power parts problem possible cause and remedy torque converter a. Too low oil pressure 1. Lower oil level check oil level and add oil. 2. Air entering in resulting from loose connectors. Check connectors or oil pipes. Retighten each connectors or replace seal...

  • Page 54

    48 (2) too higher oil temperature parts problem possible cause and remedy torque converter 1. Lower oil level check oil level and add oil. 2. Blocked oil filter check, clean or replace. 3. Fly wheel bump against other parts. Check oil, if have dirt, replace it. 4. Air entering in resulting from loos...

  • Page 55

    49 (4) too lower transmission efficiency parts problem possible cause and remedy torque converter 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 is ineffective. Check and replace. 4. Shaft is broken. Check ...

  • Page 56

    50 3. Front axle the main specifications of the front axle: type full-floating type, integral shaped main reduction gear type spiral bevel pinion type reduction ratio 6.33 final reduction gear type planetary gear type reduction ratio 3.58 total reduction ratio 22.66 amount of oil main reduction gear...

  • Page 57

    51 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 5. Taper roller bearing 12. Braking plate and shell assembly 19. Half-...

  • Page 58

    52 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. Carrier 25. Seal retainer 6. Side gear 16. Lock nut 26. Oil seal ...

  • Page 59

    53 fig. 3.3 final reduction gear 3.4 troubleshooting trouble cause correction oil leaks from differential carrier. Loose bolt or broken gasket of differential carrier. Retighten or replace. Breather is clogged. Clean or replace. Oil seal is worn or damaged. Replace. Noisy differential gear is worn, ...

  • Page 60

    54 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. The power brake works...

  • Page 61

    55 fig. 4.2 position of brake pedal.

  • Page 62

    56 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 ...

  • Page 63

    57 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 s...

  • Page 64

    58 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 shoul...

  • Page 65

    59 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

    60 4.5 troubleshooting problem possible cause remedy poor braking force fluid leakage from brake system repair maladjustment of brake shoe clearance adjust brake overheating check for dragging poor contact between brake drum and friction piece adjust foreign matter adhered on friction piece repair o...

  • Page 67

    61 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. The s...

  • Page 68

    62 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 ...

  • 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

    64 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 oi...

  • Page 71

    65 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 ...

  • Page 72

    66 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 num...

  • Page 73

    67 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...

  • Page 74

    68 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 pres...

  • Page 75

    69 5.3.6 steering unit troubleshooting problem possible cause remedy oil leakage oil leaks from the connection surface of valve body, stator and rear cap due to the dirty. Clean. The rubber ring is worn. Replace rubber ring. The washer of limit bolt is uneven. Grind or replace washer. Hard steering ...

  • Page 76

    70 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 smo...

  • Page 77

    71 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 pus hes the knuckle steering through tie rod, causing wheel’s deflection and truck...

  • Page 78

    72 (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 ...

  • Page 79

    73 6. Hydraulic system hydraulic oil pump type gear pump displacement 32 ml/r 36 ml/r control valve type two-pool type with relief valve, flow divider and tilt self-locking valve setting pressure 19 mpa dividing pressure 12 mpa flow rate 25 l/min 6.1 general description the hydraulic system mainly c...

  • Page 80

    74 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...

  • Page 81

    75 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 bac...

  • Page 82

    76 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 ...

  • Page 83

    77 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 ...

  • Page 84

    78 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 secur...

  • Page 85

    79 6.8 troubleshooting problem possible cause remedies gear pump can not be pressurized. Parts worn. Disassembly, repair or replace parts. Blocked oil pipe. Make the oil pipe through. Blocked oil tank or filter. Clean dirty or replace oil. Too high oil stickiness or oil temperature. Use recommended ...

  • Page 86

    80 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...

  • Page 87

    81 7. Lift cylinder & tilt cylinder lift cylinder type single-action piston type, with cut-off valve bore diameter Φ100 stroke 1495mm (only for 3m lift height) tilt cylinder type double-action piston type bore diameter Φ115 stroke 242mm 7.1 lift cylinder the two lift cylinders of single acting type ...

  • Page 88

    82 fig.7.1 lift cylinder 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. Ball bearing 16. Snap ring 17. Spring 18. Cut-off valve 19. Upper b...

  • Page 89

    83 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...

  • Page 90

    84 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 p...

  • Page 91

    85 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...

  • Page 92

    86 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. The outer masts are...

  • Page 93

    87 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 ...

  • Page 94

    88 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 r...

  • Page 95

    89 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. Height, and ensure gap b b...

  • Page 96

    90 (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 r...

  • Page 97

    91 9. Electric system 9.1 general description the electric system for this forklift truck is of the single-pole type. It mainly consists of the following systems (see the principle diagram in fig9.1, fig9.2): (1) charge system this system contains generator, battery, charging indictor, etc. It suppl...

  • Page 98

    92 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. When the meter works abnormally, contact with o...

  • 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

    95 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. T urn the key switch clockwise to the first “o...

  • Page 102

    96 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”...

  • Page 103

    97 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 ...

  • 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

    Production improve suggestion sheet (feedback) 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...

  • Page 109: Note

    103 note.

  • Page 110

    104.

  • 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 sp...

  • Page 112

    106 incurring any obligation..