Baoli CPCD 100 Specifications

1 Ⅰ. About forklift truck 1. External view and technical parameter External view

2 Technical parameter General Manufacturer KION Baoli Model CPC(D)20 CPQ(Y)D20 CPC(D)25 CPQ(Y)D25 CPC(D)30 CPQ(Y)D30 CPC(D)35 CPQ(Y)D35 Power typ

3 2. Characteristic The forklift truck has advantages as follows: 1. The hydraulic steering device makes steering flexible and the double ladder like

4 Main system of forklift truck No. Name Content 1 Power system engine mounting, system of fuel, exhaust and cooling (inc. torque converter oil cool

5 Ⅱ. Safety instruction and operation of forklift truck It is important for drivers and managers to remember the principle of “first safety” and ensu

6 found on the oil pipes, water hoses, vent-pipes and the piping joints, pumps and valves etc. (6) Check for all the terminals and plugs in normal st

7 there is no trouble, operation may be allowed. (2) Stop the engine First set the engine on idle running for five minutes, so as to cool the engine

8 (3) Sling the forklift truck (a) Only the specially trained personnel can sling the truck. (b) Sling points should be always at the positions speci

9 5. Parking and storing (1) Safe parking (a) Park your forklift truck on a level ground preferably in a wide area. If parking on a slope is unavoida

10 (c) Put the key switch in “OFF” position and turn off the engine, operate the lever of the control valve several times and release the residual pr

11 6. Information of safety operation (1) The forklift truck belongs to special equipment. Only trained and authorized operator shall be permitted to

12 shouldn’t be too fast in either case. (14) When tilting the mast forward or backward to the limit or lifting the fork to the maximum height, retur

13 standing under the lift bracket or being lifted with forks. Never permit anyone to stand or walk under upraised forks. (27) When lifting the load,

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 preve

15 of the forklift truck may fluctuate due to different operation and the influence of the external environment. (55) The driver feels the vibration

16 (2) General information when operating (3) Nameplate of forklift truck (4) Lubrication system (5) Capacity chart

17 (6) Inspections before starting (7) Adjust parking brake (8) Add hydraulic oil (9) Add fuel (gasoline) (10) Add fuel

18 (11) Add antifreeze (12) Tyre safety decal (charging tyre) (13) Tyre pressure decal (charging tyre) 2-2.5t forklift truck 3-3.5t

19 (15) Sling decal (16) Forbid entering into the space behind the mast (17) Forbid conveying person (18) Hand caution decal (

PREFACE The new type BAOLI forklift truck is of internal combustion balance weight type, which adopts advanced TCM transmission, wide vision mast s

20 (20) Hood crushing hands (21)Belt pulley thumb hand decal (21) Overturn caution decal

21 Ⅲ. Periodic inspection and servicing During operating the forklift truck, it is necessary to operate carefully, service and maintain periodically

22 2. Essentials of servicing (1) Some critical components must be replaced according to demands periodically. Use genuine parts only. (2) U

23 3. Recommended oil, grease and coolant Name Brand or code Quantity Domestic Overseas Gasoline 90# JISK2202/2# 60L Diesel Refer to diesel engine m

24 Ⅳ. Construction, principle, adjustment and maintenance of forklift truck In order to keep good condition of your forklift truck, you must ha

25 Parallel table for engine and forklift model which is coincidence and stuck with CE label: Engine model The guaranteed Sound power level LwA(dB) 2

26 diesel engine type trucks. The difference is that the gasoline type is fitted with oil suction pipe and the diesel type with oil return pipe. 1.4.

27 (b) Loosen the circle wheel and remove the cap. (c) Loosen the nut and take the filter element out. (d) Clean or replace the filter element. (e) A

28 2. Mechanical drive system 2.1 Clutch Type Dry single plate type Operation Foot-pedal type Friction piece outer diameter 275mm Friction piece inne

29 2.1.2 Maintenance A. Adjustment of clutch pedal (1) Remove the floor board. (2) Loose the lock-nut of the stopper bolt. (3) Turn the stopper bolt

30 2.2 Mechanical drive unit Transmission Type Manual-shift, slide type synchromesh mechanism Shift No. FWD 2 BWD 2 Gear Ratio FWD 1st/2nd

31 Fig 2.3 Transmission 1. Snap ring 13. O-ring seal 25. Forward gear 37. Tapered roller bearing 2. Snap ring 14. Slide bolt 2

32 Fig 2.4 Reducer and differential 1. Gear ring 5. Shim 9. Adjusting shim 13. Column pin 2. Pin 6. O-ring seal 10. Gear 1

33 3. Hydraulic drive unit Torque converter Type Three elements, single stage, two phases Torque ratio 3 Set pressure 0.5～0.68 MPa Charging pump Type

34 Fig3.1 Hydraulic drive unit 1. Forward clutch 18. Safety valve cover 35. Output gear 2. Oil filter 19. Inner-hexagon plug 36. Idl

35 3.2 Torque converter (Fig 3.2) The torque converter mainly consists of an impeller, a turbine and a guide wheel. The liquid, from the impeller dr

36 3.3 Hydraulic circuit (See Fig3.3) After the engine is started, the charging pump inhales the oil from the oil tank. The pressure oil from

37 3.4 Towing disabled truck Pay attention to the following items when the forklift truck to be repaired is towed by other truck: (1) Remove t

38 (2) Higher oil temperature Parts Problem Possible cause and remedy Torque converter 1. Lower oil level Check oil level and add oil 2. Blocked oil

39 (4) Too low transmission efficiency Parts Problem Possible cause and remedy Torque converter 1. Elasticity plate is broken Check noise and replace

CONTENTS Ⅰ. About forklift truck……………………………………………………………… 1 1. External view and technical parameter………………………………………… 1 2. Characteristic…………………

40 4. Drive system Type Front wheel drive, axle body and frame fastened together, fully floating type Forklift truck 2t, 2.5t 3t 3.5t Single tyre (2

41 and inner rim. Pay attention to the following points: (a) Put the air valve rod in the notch of the rim and make it face outside. (b) Make the top

42 Fig4.2 Add grease Fig4.3 Measure starting torque

43 4.3 Troubleshoot Problem Probable cause Remedy Oil leaks from the reducer case Connecting bolt of reducer is loose or worn shim Tighten or replac

44 5. Brake system Type of brake system Front two-wheel braking, internal expansion, hydraulic type Pedal ratio 5.66 Master cylinder bore 19.05mm Wh

45 At the same time, the brake fluid in each operating cylinder is pressurized by the return spring, returning into the master cylinder through the c

46 Fig5.2 Wheel brake 1. Spring 8. Return spring 15. Spring pull rod 2. Cup 9. Adjusting lever 16. Parking pull rod 3. Piston 10. Second

47 Fig5.3 Clearance self-adjuster 5.4 Parking brake lever (Fig5.4) The parking brake lever is of a cam type. The brake force can be adjus

48 5.5 Inspection of wheel brake Inspect all parts to make sure if there’re any worn or damaged parts. If necessary, repair or replace with new one.

49 5.6 Troubleshoot Problem Probable cause Remedy Poor braking 1.Fluid leaks from brake system Repair 2.Maladjustment of brake shoe clearance Adjust

50 6. Steering system 2t, 2.5t 3t 3.5t Steering system Rear wheel powered steering Type of steering unit Cycloid gear type powered steering unit M

51 6.2 Hand wheel Hand wheel is operated in normal way, that is to say, when turning the hand wheel right, the truck will turn right. When turning

52 6.4 Inspection after reassembling the steering system (1) Check the force when turning the steering handwheel to right and left until it can’t be

53 6.6 Steering axle The steering axle is of section-boxed welded construction type (Fig6.3). It includes axle body, steering cylinder, tie

54 6.6.1 Steering cylinder (Fig6.4) The steering cylinder is of double-action piston type. The seal unit consists of the supporting ring and O-ring,

55 (6) 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 wit

56 7. Hydraulic system Hydraulic oil pump Type Gear pump Displacement 31.5 ml/r Control valve Type Two-pool type with relief valve, flow divider an

57 Fig7.1 Hydraulic oil pump

58 Relief valve and flow divider (see Fig7.3) The relief valve consists of main valve A and proceeding valve B. When the spool of the control valve i

59 ▲Setting pressure of the relief valve (Fig7.4) The pressure of the relief valve has been set before delivery. Don’t adjust the pressure

3.3 Hydraulic circuit…………………………………………………………………… 38 3.4 Towing disabled truck…………………………………………………………… 39 3.5 Troubleshoot……………………………………………………………………… 39

60 7.4 Hydraulic oil circuit (Fig7.5) The oil from the hydraulic pump comes to the control valve first and there is divided by the flow divider into

61 7.5 Lift cylinder (Fig7.6) The lift cylinder is of single-action piston type. It consists of cylinder body, piston rod, piston and cylinder head e

62 7.6 Flow regulator valve (Fig7.7) The flow regulator valve, located in the lift cylinder circuit to limiting the descending speed of l

63 7.7 Tilt cylinder (Fig7.8) The tilt cylinder is of double-acting type. Each truck has two cylinders which are installed on two sides of the mast,

64 7.8 Hydraulic pipe-line Fig7.9 Hydraulic pipe-line

65 7.9 Troubleshoot If the hydraulic system occurs trouble, find out the possible cause according to the following tables and repair it. (1) Control

66 (2) Hydraulic oil pump Problem Possible cause Remedy Oil can not be pumped out Lower oil level in oil tank Add oil up to specified oil level B

67 8. Lifting system The lifting system is the type of lifting and descending vertically with the two-stage rollers. It consists of the i

68 8.2 Lift bracket The lift bracket moves up and down smoothly along the channel of the inner mast by the main rollers. The main rollers mounted on

69 8.5 Maintenance and adjustment 8.5.1 Adjustment of lift cylinder (Fig8.3) When replace the lift cylinder, inner mast or outer mast, we shall readj

70 (3) Make the fork down to the ground and tilt backward fully. Adjust the adjusting nut for the end nipple of the upper chain and make the two chai

71 shims. ·Install the new rollers and the shims disassembled before. (8) Hang up the inner mast to let all the rollers in the mast. (9) Reassemble t

72 9. Electrical system 9.1 General description The electric system for this forklift truck is single wire system with minus earth. It mainly consist

73 9.2 Brief explanation for operation (1) Starting There is a starting protection circuit in the control box for the forklift truck. You have

74 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 an

75 (11) Hour meter It indicates the temperature of the coolant for the engine. 9.3 Precautions when using the battery (1) Avoid the short

76 Fig9.1-1 Principle diagram of electrical system (ISUZU engine) Central control box 00 Power(-) 01 Power, horn 02

77 Fig9.1-2 Principle diagram of electrical system (Xinchang engine) Central control box 00 Power(-) 01 Power, hor

78 Fig9.1-3 Principle diagram of electrical system (Mitsubishi gasoline engine) Central control box 00 Power(-) 01

79 Fig9.2-1 Diagram of harness (ISUZU 4JG2 engine)

8. Lifting system………………………………………………………………………… 69 8.1 Inner and outer mast…………………………………………………………… 69 8.2 Lift bracket………………………………………………………………………… 70

80 Fig9.2-2 Diagram of harness (ISUZU engine electron shift)

81 Fig9.2-3 Diagram of harness (Mitsubishi engine electron shift)

82 Fig9.2-4 Diagram of Yanmar harness (electron shift)

83 Product improve suggestion sheet (feedback) Product name Serial No. Product lot number Date of delivery Start use date Use company Suggest

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