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Summary of Contents for CPCD 80

Page 1: ...Original instructions...

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

Page 3: ...lies 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...

Page 4: ...r 16 8 Caution plate 18 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...

Page 5: ...rential 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 Troublesho...

Page 6: ...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 adjus...

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

Page 8: ...all 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 m...

Page 9: ...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 fr...

Page 10: ...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 s...

Page 11: ...ngine 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 Inspe...

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 sta...

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 Singl...

Page 14: ...t 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 stee...

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 eng...

Page 16: ...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 fro...

Page 17: ...onal 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 l...

Page 18: ...ng 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 In...

Page 19: ...ked 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 dr...

Page 20: ...xcessively 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...

Page 21: ...he 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 accid...

Page 22: ...ine 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 i...

Page 23: ...he 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 indicat...

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 S...

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: ...he 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 br...

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...

Page 31: ...e 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 at...

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

Page 33: ...eter 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 wo...

Page 34: ...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 fue...

Page 35: ...1 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 CONFORM...

Page 36: ...nder 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 2...

Page 37: ...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...

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 loosin...

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...

Page 40: ...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...

Page 41: ...1 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...

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...

Page 43: ...n 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 conditi...

Page 44: ...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 idl...

Page 45: ...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...

Page 46: ...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 I...

Page 47: ...le 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 fro...

Page 48: ...ging 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 t...

Page 49: ...ination 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 converte...

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

Page 51: ...he 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 sele...

Page 52: ...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 i...

Page 53: ...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 o...

Page 54: ...w 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...

Page 55: ...l 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 c...

Page 56: ...nd 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 o...

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...

Page 58: ...r 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...

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 washer...

Page 60: ...m 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...

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 fo...

Page 63: ...ch 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 T...

Page 64: ...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 pla...

Page 65: ...p 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 plunge...

Page 66: ...ign 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 b...

Page 67: ...360 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 115 85 Stroke mm 2 216 Divider Setting pre...

Page 68: ...l 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...

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: ...g 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 ru...

Page 71: ...l 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...

Page 72: ...g 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 th...

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 m...

Page 74: ...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...

Page 75: ...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 re...

Page 76: ...lve 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...

Page 77: ...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 bea...

Page 78: ...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 Agai...

Page 79: ...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...

Page 80: ...ure 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 p...

Page 81: ...e 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...

Page 82: ...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 pressur...

Page 83: ...cture 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 inp...

Page 84: ...he 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 pist...

Page 85: ...n 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...

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 v...

Page 87: ...ng 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...

Page 88: ...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...

Page 89: ...amber 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 a...

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 pres...

Page 91: ...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 Inne...

Page 92: ...tice 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...

Page 93: ...e 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 l...

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...

Page 95: ...ee 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 brac...

Page 96: ...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 Disass...

Page 97: ...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 stoppi...

Page 98: ...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 Fro...

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: ...tarting 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...

Page 102: ...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 switc...

Page 103: ...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 ta...

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: ...gestion 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...

Page 109: ...103 NOTE...

Page 110: ...104...

Page 111: ...x 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 specif...

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

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