Baoli CPCD20 Operation And Service Manual Download

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Fig8.3-1 Diagram of harness (4JG2 engine)

Fig8.3-2 Diagram of harness (Dachai 498 engine)

Fig8.3-3 Diagram of harness (Xinchai 498 engine)

Fig8.3-4 Diagram of

Fig8.3-4 Diagram of harness (Y

harness (Yanmar 4TNE98 engine)

anmar 4TNE98 engine)

Central control box

00 Power(-)

01 Power,

Power, horn

horn

02 Power,

Power, lamp

lamp

03 Power,

Power, meter

meter

04 Power,

Power, switch

switch

05 Switch,

Switch, turning

turning lamp

lamp

06 Power,

ignition

Power,

ignition

07 Switch,

Switch, light

light

08 Switch,

Switch, start

start

09 Power,

Power, headlamp

headlamp

https://www.besttruckmanuals.com/

Summary of Contents for CPCD20

Page 1: ...1 1 https www besttruckmanuals com ...

Page 2: ...D20 25 30 35F Internal Combustion Counterbalanced Forklift Truck Internal Combustion Counterbalanced Forklift Truck OPERATION SERVICE MANUAL OPERATION SERVICE MANUAL KION Baoli Jiangsu Forklift Co Ltd KION Baoli Jiangsu Forklift Co Ltd 2 3 5T 2 3 5T https www besttruckmanuals com ...

Page 3: ...operation wide vision flexible steering advantages such as good performance easy operation wide vision flexible steering reliable braking powerful and reliable braking powerful and aesthetic appearance aesthetic appearance This manual states the specifications operation maintenance main assemblies This manual states the specifications operation maintenance main assemblies constructions and working...

Page 4: ...aution plate 19 19 Ⅲ Ⅲ Periodic inspection and servicing Periodic inspection and servicing 24 24 1 General rules on inspection and maintenance 1 General rules on inspection and maintenance 24 24 2 Inspection content 2 Inspection content 25 25 3 Periodic replacement table 3 Periodic replacement table 30 30 4 Lubrication c 4 Lubrication chart hart 31 31 5 Weekly maintenance 5 Weekly maintenance 32 3...

Page 5: ...heel brake 55 55 4 6 Troubleshoot 4 6 Troubleshoot 56 56 5 Steering system 5 Steering system 57 57 5 1 Hand wheel 5 1 Hand wheel 58 58 5 2 Cycloid gear type powered steering unit 5 2 Cycloid gear type powered steering unit 58 58 5 3 Inspection after reassembling the 5 3 Inspection after reassembling the steering system steering system 59 59 5 4 Troubleshooting of steering system 5 4 Troubleshootin...

Page 6: ... 1 General description 78 78 8 2 Brief explanation for operation 8 2 Brief explanation for operation 79 79 8 3 Instructions of meter panel 8 3 Instructions of meter panel 80 80 8 4 Principle diagram of electrical system 8 4 Principle diagram of electrical system 85 85 8 5 Diagram of harness 8 5 Diagram of harness 85 85 Note Note 93 93 EC DECLARATION OD CONFORMITY EC DECLARATION OD CONFORMITY 94 94...

Page 7: ...bout F series out F series forklift truck forklift truck 1 External view and technical parameter 1 External view and technical parameter Fig1 1 External view Fig1 1 External view https www besttruckmanuals com ...

Page 8: ...0PR PR Tread Tread Front Front B2 B2 mm 970 mm 970 1000 1000 Rear Rear B3 B3 mm mm 970 970 Wheelbase Wheelbase Y Y mm mm 1650 1650 1700 1700 1760 1760 Ground clearance Ground clearance full load no load full load no load Mast Mast M M mm mm 85 85 105 105 110 110 135 135 Frame Frame F F 140 140 145 145 170 170 175 175 F series forklift trucks mentioned in this manual F series forklift trucks mentio...

Page 9: ...nd hidden type tilt cylinder device The forklift truck can be fitted with 2 stage type mast and hidden type tilt cylinder device The forklift truck can be fitted with 2 stage or 3 stage full free or 3 stage full free lift mast having different lifting height even all lift mast having different lifting height even all kinds of the attachments kinds of the attachments according to the needs of the c...

Page 10: ...ch may be adjusted because of may be adjusted because of configuration difference or technology optimization configuration difference or technology optimization 1 1 Outer Outer mast mast 2 2 Inner Inner mast mast 3 3 Lift Lift chain chain 4 4 Lift Lift cylinder cylinder 5 5 Load Load backrest backrest 6 6 Fork Fork location location pin pin 7 7 Lift Lift bracket bracket 8 8 Fork Fork 9 9 Driving D...

Page 11: ...ng lever lever attachment attachment 8 8 Combination Combination meter meter 9 9 T Tool ool kit kit 10 10 Acceler Accelerator ator pedal pedal 11 11 Brake Brake pedal pedal 12 12 Ignitio Ignition n switch switch 13 13 Release Release lever lever parking parking brake brake 14 14 Inching Inching pedal pedal 15 15 Adjust Adjust lever lever steering steering wheel wheel 16 16 Parking Parking brake br...

Page 12: ...o not leave the switch in the ON position when the Do not leave the switch in the ON position when the engine is stopped It may cause over discharge of the engine is stopped It may cause over discharge of the battery battery Do not operate the starter motor for more than 15 Do not operate the starter motor for more than 15 seconds continuously Return the switch to the OFF seconds continuously Retu...

Page 13: ...ing lever lever Fig 1 3 5 Fig 1 3 5 1 1 Lower Lower 2 2 Raise Raise Raise and lower the forks Raise and lower the forks Raise Pull backward Raise Pull backward Lower Push forward Lower Push forward The lifting speed can be adjusted by the degree of The lifting speed can be adjusted by the degree of accelerator pedal depression and lever operating stroke accelerator pedal depression and lever opera...

Page 14: ...hifted to forward reverse the vehicle will move even the accelerator pedal stays neutral vehicle will move even the accelerator pedal stays neutral 7 7 Parking Parking brake brake pedal pedal Fig 1 3 16 Fig 1 3 16 Parking brake release lever Parking brake release lever Fig 1 3 13 Fig 1 3 13 1 Press down 1 Press down 2 Release lever 2 Release lever Use the parking brake pedal Use the parking brake ...

Page 15: ... Operating the vehicle without firm locking of the engine Operating the vehicle without firm locking of the engine hood is very dangerous Be sure to check firm locking hood is very dangerous Be sure to check firm locking before operating the vehicle before operating the vehicle 3 3 Fork Fork Fig Fig 1 2 8 1 2 8 1 Fork stopper 1 Fork stopper Lift each fork stopper and turn to release so that forks ...

Page 16: ...g for 200 new forklift truck working for 200 hours hours 2 Inspection before operation 2 Inspection before operation Please pay attention to the following items in order to make the vehicle working with Please pay attention to the following items in order to make the vehicle working with high efficiency and lengthen its service life high efficiency and lengthen its service life 1 The forklift truc...

Page 17: ...s seconds As the engine doesn t work As the engine doesn t work after some times starting should check and after some times starting should check and remove remove the trouble do not keep the starting motor engaged for a long time the trouble do not keep the starting motor engaged for a long time c Follo c Following the start of the engine it s necessary to set the engine on idle running wing the ...

Page 18: ...ral condition of the truck b While washing the body of the truck check general condition of the truck Especially check the truck Especially check the truck s s body for recess or damage and tyres for wear and nails or body for recess or damage and tyres for wear and nails or stones in the tread stones in the tread c Fill the oil tank up with the appointed fuel c Fill the oil tank up with the appoi...

Page 19: ...aulic reservoir and fuel rom the hydraulic reservoir and fuel tank tank d Remove the cylinder d Remove the cylinder cap check the valves and cap check the valves and the rocker shafts for the the rocker shafts for the clearance clearance in normal data in normal data e Add cooling fluid to specified level e Add cooling fluid to specified level f Perform f Perform pre operation checks carefully pre...

Page 20: ...d mast of the truck all have their appointed sling position appointed sling position 4 Towing of forklift truck 4 Towing of forklift truck a The draw bar a The draw bar is installed below the is installed below the counter weight When operating the counter weight When operating the draw bar draw bar first extract it first extract it and fasten a steel wire and fasten a steel wire then install the ...

Page 21: ... turn on the key switch select the position of direction 10 Connect the power and turn on the key switch select the position of direction switch check the truck for normal operation by turning steering wheel depress the switch check the truck for normal operation by turning steering wheel depress the accelerator pedal softly to accelerator pedal softly to keep proper acceleration keep proper accel...

Page 22: ... or little volume prevent the collapse of stacked goods tighten them Forbid loading loose or little volume goods without pallet goods without pallet 24 When loading the goods lower the forks to the floor After the fork inserting 24 When loading the goods lower the forks to the floor After the fork inserting stacked goods the fork arms should be in contact with the goods Drive the truck with stacke...

Page 23: ...t take the protection measures if necessary protection measures if necessary 39 Before the truck decelerating and stopping d 39 Before the truck decelerating and stopping don t on t change gear to reverse shift change gear to reverse shift so as to ensure the so as to ensure the safe loading safe loading 40 When the truck stops and the engine is on idle position the mast must be tilted 40 When the...

Page 24: ... or you may be space or you may be choked by the tail choked by the tail gas The tail gas s exhausting standard shouldn t gas The tail gas s exhausting standard shouldn t be lower than the no load mechanical vehicle exhaust standard ruled by the nation that be lower than the no load mechanical vehicle exhaust standard ruled by the nation that users are in If users are in If in Europe nation the ad...

Page 25: ...CPCD35F 86 86 dB A dB A 104 104 dB A dB A 107 107 dB A dB A 0 84 0 84 m s m s 2 2 CPQD30F CPQD30F 86 86 dB A dB A 103 103 dB A dB A 105 105 dB A dB A 0 85 0 85 m s m s 2 2 CPQD35F CPQD35F 87 87 dB A dB A 104 104 dB A dB A 105 105 dB A dB A 0 87 0 87 m s m s 2 2 7 Caution plate 7 Caution plate The caution plates stuck on the vehicle indicate the operating method and The caution plates stuck on the ...

Page 26: ...Nameplate of forklift truck 4 Lubrication system 4 Lubrication system 5 Capacity chart 5 Capacity chart 6 Inspections before 6 Inspections before starting starting 7 Adjust parking brake 7 Adjust parking brake https www besttruckmanuals com ...

Page 27: ...ng brake 9 Add hydraulic oil 9 Add hydraulic oil 10 Add fuel gasoline 10 Add fuel gasoline 11 Add fuel 11 Add fuel 12 Add antifreeze 12 Add antifreeze 13 Tyre safety charging tyre 13 Tyre safety charging tyre https www besttruckmanuals com ...

Page 28: ...rklift truck 2 2 5t forklift truck 3 3 5t forklift truck 3 3 5t forklift truck 15 Sling point indication 15 Sling point indication 16 Sling decal 16 Sling decal 17 Forbid entering into the space behind the mast 17 Forbid entering into the space behind the mast https www besttruckmanuals com ...

Page 29: ...erson 19 Hand caution 19 Hand caution 20 Fan hurting hand 20 Fan hurting hand 21 Hood crushing hand 21 Hood crushing hand 22 Belt pulley thumb hand decal 22 Belt pulley thumb hand decal 23 Overturn caution 23 Overturn caution https www besttruckmanuals com ...

Page 30: ...ering and braking system 3 Check the reliability of mast driving axle and steering axle connecting with the 3 Check the reliability of mast driving axle and steering axle connecting with the frame frame 4 Check all wheels for 4 Check all wheels for tightness tightness Irregular inspection Irregular inspection 1 Check the reliability of each welding joints of the mast frame and so on 1 Check the re...

Page 31: ...l of the vehicle manual or according to the decal of the vehicle 2 After the adjust 2 After the adjustment check if air is ment check if air is not leaking from the valve not leaking from the valve Damage crack and wear of tyres and rims Damage crack and wear of tyres and rims Check the tyres for damage and wear and the rims for bending Check the tyres for damage and wear and the rims for bending ...

Page 32: ...ngine coolant is not visible through the filler port fill appropriate appropriately diluted coolant ly diluted coolant LLC to the port LLC to the port Note Note To close and tighten the radiator cap match the pawl on the To close and tighten the radiator cap match the pawl on the reverse side of the cap with the notch on the filler port and turn reverse side of the cap with the notch on the filler...

Page 33: ...il according to the request of the engine or the corresponding section of the request of the engine or the corresponding section of the manual manual Leakage inspection Leakage inspection Check the engine compartmen Check the engine compartment for t for any oil or any oil or fuel leakage fuel leakage Check the radiator if it is clogged and check if there are any Check the radiator if it is clogge...

Page 34: ...normality is found is found Inching and brake pedal Inching and brake pedal inspection inspection 1 Inching and brake pedal 1 Inching and brake pedal 1 Manually depress the inching and brake pedal to check the 1 Manually depress the inching and brake pedal to check the play until a resistance is felt play until a resistance is felt The value of inching and brake pedal play The value of inching and...

Page 35: ... the vehicle inspected by a If anything unusual is found have the vehicle inspected by a professional serviceman professional serviceman Steering wheel inspection Steering wheel inspection Perform the inspection after starting the Perform the inspection after starting the engine engine 1 Check the steering wheel play with the rear wheel set in the 1 Check the steering wheel play with the rear whee...

Page 36: ...ooner whichever comes sooner Every 6 Every 6 Weeks Weeks 3 3 6 6 12 12 Months Months Every Every 250 250 500 500 1000 1000 2000 2000 Hours Hours Engine oil Engine oil Engine oil filter Engine oil filter Cooling water Cooling water except LLC LLC is every 2 except LLC LLC is every 2 years years Air cleaner ele Air cleaner element ment Fuel filter Fuel filter Torque converter oil Torque converter oi...

Page 37: ...Oil Oil tank tank A A MP MP grease grease 9 9 Engine Engine crankcase crankcase B B Engine Engine oil oil 10 10 Pump Pump transmission transmission device device C C Hypoid Hypoid gear gear oil oil 1 11 1 Foot Foot operating operating assy assy D D Hydraulic Hydraulic oil oil 12 12 Direction Direction column column locking locking mechanism mechanism E E Hydraulic Hydraulic transmission transmissi...

Page 38: ... Element 1 Element 1 Tap the element filter paper lightly without causing any 1 Tap the element filter paper lightly without causing any damage or blow dust off with compressed air 7kg cm damage or blow dust off with compressed air 7kg cm 2 2 or or less from inside less from inside 2 After element cleaning remove any dust in the evacuator 2 After element cleaning remove any dust in the evacuator v...

Page 39: ...ng lines on the level gauge among the gridding lines on the level gauge Retightening of bolts and nuts Retightening of bolts and nuts Retighten each bolt and nut on the chassis and Retighten each bolt and nut on the chassis and load handling load handling system system Greasing mast and steering Greasing mast and steering linkage linkage Grease in accordance with the l Grease in accordance with th...

Page 40: ...olant must be antifreeze coolant must be used used When long life coolant LLC is used it must be changed once When long life coolant LLC is used it must be changed once every two years every two years Freezing temperature varies depending on the amount of Freezing temperature varies depending on the amount of antifreeze added antifreeze added Freeze protection temperature Freeze protection tempera...

Page 41: ...The sedimenter separates the water contained in the fuel It is integrated with the fuel filter integrated with the fuel filter If the sedimenter warning lamp comes on immediately drain If the sedimenter warning lamp comes on immediately drain water according to the following procedure because the water according to the following procedure because the accumulated water in the sedimenter is above th...

Page 42: ...and adjoining area When the battery is dead When the battery is dead 1 Dead battery vehicle 1 Dead battery vehicle 2 Engine hanger 2 Engine hanger 3 To frame 3 To frame 4 Booster cable 4 Booster cable 5 Rescue battery 5 Rescue battery When a booster cable is available it is possible to start the When a booster cable is available it is possible to start the engine using the battery of engine using ...

Page 43: ...Marfakmultipurpose Marfakmultipurpose 2 3 Multifak EP 2 2 3 Multifak EP 2 Mobil grease Mobil grease Shell retinax Shell retinax grease grease Esso multipurpose Esso multipurpose grease H grease H MP 20 MP 20 120 120 MoS MoS2 2 EP lithium grease EP lithium grease Mobil grease Mobil grease XHP 222 special XHP 222 special Shell alvania HDX2 Shell alvania HDX2 grease grease Coolant Coolant fluid fluid...

Page 44: ...CPQ Y D CPQ Y D 20 25 30F H1 20 25 30F H1 Mitsubishi Mitsubishi K21 K21 27 8 31 2 27 8 31 2 2250 2250 133 9 143 7 133 9 143 7 1600 1600 4 4 89 83 89 83 2 065 2 065 CPQ Y D CPQ Y D 15 20 25F H2 15 20 25F H2 Nissan Nissan K25 K25 34 2 37 4 34 2 37 4 2300 2300 164 8 176 5 164 8 176 5 1600 1600 4 4 89 100 89 100 2 488 2 488 CPQ Y D CPQ Y D 20 25 30 35F H3 20 25 30 35F H3 Parallel table for engine and ...

Page 45: ...ease of pressure can cause a steam extreme care when removing the cap the sudden release of pressure can cause a steam flash which would cause a flash which would cause a serious personal injury serious personal injury Lower the Lower the running speed of the engine running speed of the engine to moderate speed after the cooling system cooled then turn to idle speed loosen cap to moderate speed af...

Page 46: ...Fig2 1 They torque converter and an electron gear shifting transmission case See Fig2 1 They feature the following feature the following 1 With an inching valve the inching operation can be done under the condition that 1 With an inching valve the inching operation can be done under the condition that the engine runs at both the engine runs at both high and low speed high and low speed 2 Each of t...

Page 47: ... The reducer located in the front of the transmission is used to reduce the speed and The reducer located in the front of the transmission is used to reduce the speed and increase the torque from the output shaft of the transmission and transfer them to the increase the torque from the output shaft of the transmission and transfer them to the differential It consists primarily of a small spiral be...

Page 48: ...wheel is changed by the idler pulley to cause partial liquid return the impeller at an angle and changed by the idler pulley to cause partial liquid return the impeller at an angle and produce so large reaction torque driving the idler pulley that the value of output torque is produce so large reaction torque driving the idler pulley that the value of output torque is more than that of input torqu...

Page 49: ... the inching valve converter via a relief valve set pressure of 0 5 0 7MPa and another to the inching valve and the slide valve The oil out of the torque converter is cooled by an oil radiator and and the slide valve The oil out of the torque converter is cooled by an oil radiator and used to lubricate the hydraulic clutches and finally returns used to lubricate the hydraulic clutches and finally ...

Page 50: ...dy remedy Torque Torque converter converter A T A Too low oil pressure oo low oil pressure 1 1 Lower Lower oil oil level level Check Check oil oil level level and and add add oil oil 2 Air entering in resulting from loose 2 Air entering in resulting from loose connections connections Check connection or oil pipe Check connection or oil pipe Retighten each connection or Retighten each connection or...

Page 51: ... replace oil oil 6 6 Lower Lower oil oil flow flow Check Check pipe pipe and and replace replace 7 7 Worn Worn bearing bearing Check Check and and replace replace Gear box Gear box 1 1 Slipped Slipped clutch clutch Replace Replace friction friction piece piece of of clutch clutch 2 2 Worn Worn bearing bearing Check Check and and replace replace 3 Noisy gear box 3 Noisy gear box Parts Parts Problem...

Page 52: ... replace seal seal ring ring 2 2 Incorrect Incorrect connection connection of of case case Check Check tighten tighten or or replace replace 3 3 Loose Loose connector connector and and oil oil pipe pipe Check Check tighten tighten or or replace replace 4 4 Loose Loose drain drain plug plug Check Check tighten tighten or or replace replace 5 Oil spray from vent hole 5 Oil spray from vent hole Check...

Page 53: ...g m and then loosen it for 1 2 turn 1 2 turn 3 Put the spring 3 Put the spring balance up on the bolt to balance up on the bolt to measure the hubs starting torque When measure the hubs starting torque When the starting torque arrives to the specified the starting torque arrives to the specified value lock the nuts slowly value lock the nuts slowly Starting torque Starting torque 5 to 15 kg m Fig3...

Page 54: ...heel hub hub 12 12 Adjusting Adjusting nut nut 3 3 Wheel Wheel brake brake 8 8 T Tapered apered roller roller bearing bearing 13 13 Lock Lock nut nut 4 4 Brake Brake drum drum 9 9 Oil Oil seal seal 5 5 Oil Oil seal seal 10 10 Ty Tyre re Fig3 2 Fig3 2 Add Add grease grease Fig3 3 Fig3 3 Measure Measure starting starting torque torque https www besttruckmanuals com ...

Page 55: ...case case Connecting bolt of reducer is loose Connecting bolt of reducer is loose or worn or worn shim shim Tighten or replace Tighten or replace Blocked Blocked air air hole hole Clean Clean or or replace replace Worn Worn or or damaged damaged oil oil seal seal Replace Replace Noisy Noisy differential differential Worn Worn or or damaged damaged gear gear Replace Replace Worn Worn or or damaged ...

Page 56: ...heel Wheel brake brake 2t 2t 2 5t 2 5t 3t 3t 3 5t 3 5t Ty Type pe Duo servo Duo servo type type with with parking parking brake brake Operating Operating cylinder cylinder bore bore 28 58mm 28 58mm Size friction pieces Size friction pieces L W T L W T 324 60 7mm 324 60 7mm 348 76 8mm 348 76 8mm Area friction pieces Area friction pieces 194 4cm 194 4cm 2 2 4 4 264cm 264cm 2 2 4 4 Inner Inner diamet...

Page 57: ...Thus each operating cylinder piston is forced outwards This to the operating cylinder Thus each operating cylinder piston is forced outwards This brings the friction pieces on the brake shoes come into contact with the brake drum and brings the friction pieces on the brake shoes come into contact with the brake drum and slows or stops the truck Meanwhile the cavity behind the piston is filled with...

Page 58: ...ded on each end of the front axle The brake shoe one end of it being connected to the anchor each end of the front axle The brake shoe one end of it being connected to the anchor pin and the other to pin and the other to the adjuster is stressed on the backing plate by the spring and the adjuster is stressed on the backing plate by the spring and spring spring pull rod The primary brake shoe is pr...

Page 59: ...the parking pull rod turns right around the point A so that the point B of the rod raises After release the brake pedal the parking pull rod turns left with the spring rod raises After release the brake pedal the parking pull rod turns left with the spring force so that the point B of the rod lowers Fig4 3 force so that the point B of the rod lowers Fig4 3 As As the the clearance clearance between...

Page 60: ...there re any worn or damaged parts If necessary Inspect all parts to make sure if there re any worn or damaged parts If necessary repair or replace with new one repair or replace with new one 1 1 Check the operating cylinder body s inner surface and the piston periphery Check the operating cylinder body s inner surface and the piston periphery surface for rusting Then measure the clearance between...

Page 61: ...lem Probable Probable cause cause Remedy Remedy Poor Poor braking braking 1 Fluid 1 Fluid leaks leaks from from brake brake system system Repair Repair 2 Maladjustment 2 Maladjustment of of brake brake shoe shoe clearance clearance Adjust Adjust the the adjuster adjuster 3 Brake 3 Brake overheating overheating Check Check for for dragging dragging 4 Poor contact between brake drum and friction 4 P...

Page 62: ...system Bleed Bleed air air 4 Maladjustment 4 Maladjustment of of brake brake pedal pedal Readjust Readjust 5 Steering system 5 Steering system 2t 2t 2 5t 2 5t 3t 3t 3 5t 3 5t Steering system Steering system Rear wheel powered steering Rear wheel powered steering Type of steering unit Type of steering unit Cycloid gear type powered steering unit Cycloid gear type powered steering unit Model of stee...

Page 63: ... steering wheels which rear wheels of the forklift truck are steering wheels which make the tail section of the truck swing out when turning The make the tail section of the truck swing out when turning The turning method can be mastered easily through practice turning method can be mastered easily through practice 5 2 Cycloid gear type powered steering unit 5 2 Cycloid gear type powered steering ...

Page 64: ...eration if the be turned any more to see if they are identical each other and check the operation if the steering handwheel for smoothness during above operation steering handwheel for smoothness during above operation 2 Check the arrangement of the hydraulic pipeline and the turning direction for 2 Check the arrangement of the hydraulic pipeline and the turning direction for correctness correctne...

Page 65: ...pring damaged damaged or or elasticity elasticity insufficient insufficient Replace Replace Excessive Excessive noise noise T Too oo low low oil oil level level in in oil oil tank tank Refill Refill oil oil Suction Suction pipeline pipeline or or oil oil filter filter blocked blocked Clean Clean or or replace replace Oil leakage Oil leakage Seals of guide sleeve pipeline or joint Seals of guide sl...

Page 66: ... Thrust bearing bearing 14 14 Hub Hub 7 7 Needle Needle bearing bearing 15 15 Hub Hub bolt bolt 8 8 King King pin pin 16 16 Hub Hub nut nut 5 5 1 Steering cylinder 5 5 1 Steering cylinder The steering cylinder is of double action piston type The seal unit consists of the The steering cylinder is of double action piston type The seal unit consists of the supporting ring and O ring Yx ring seal is a...

Page 67: ...allation of the hub slightly knock at it with a wooden hammer 4 To ensure firm installation of the hub slightly knock at it with a wooden hammer and in the meantime rotate the hub for 3 and in the meantime rotate the hub for 3 4 turns 4 turns 5 Tighten the castle nut and align one of its notches with a hole drilled in the 5 Tighten the castle nut and align one of its notches with a hole drilled in...

Page 68: ...2 2 5t 9 MPa 3t 10 5 Mpa 3 5t 7 MPa 2 2 5t 9 MPa 3t 10 5 Mpa 3 5t Flow Flow rate rate 1 11L min 1L min 2 2 5t 2 2 5t 13L min 13L min 3 3 5t 3 3 5t Lift Lift cylinder cylinder Ty Type pe Single action Single action piston piston type type with with cut off cut off valve valve Bore Dia Bore Dia φ φ 50 2 2 5t 50 2 2 5t φ φ 56 3 3 5t 56 3 3 5t Stroke Stroke 1495mm 1495mm Only Only for for 3m 3m lift l...

Page 69: ...on s the lining plate press on the side face of gear the side face of gear owing to outleting oil between the lining plate and pump body This pump uses owing to outleting oil between the lining plate and pump body This pump uses pressure balance type bearings and a special lubrication method so as to minimum the pressure balance type bearings and a special lubrication method so as to minimum the g...

Page 70: ...essure passage ow pressure passage G G and reduce chamber Q pressure In this way the system pressure may keep unvaried and reduce chamber Q pressure In this way the system pressure may keep unvaried The setting pressure may be adjusted by the adjusting screw H The setting pressure may be adjusted by the adjusting screw H The construction of the flow divider is quite simple It is of direct overflow...

Page 71: ...anger for system and safety If the oil pressure i If the oil pressure is different s different with standard value according to with standard value according to the measure method specified the measure method specified in JB T3300 specialized in JB T3300 specialized servicemen adjust the pressure as follows servicemen adjust the pressure as follows a Screw out the measured hole plug from the inlet...

Page 72: ...lower part of ow regulator valve and reaches the lower part of the lift cylinder to push the piston up When push the lift spool the circuit between the the lift cylinder to push the piston up When push the lift spool the circuit between the lower part of the lift cylinder and the oil tank is connected and the piston begins to lower part of the lift cylinder and the oil tank is connected and the pi...

Page 73: ... the outer mast by bolts and pins while its top i e piston rod head is connected with the upper beam of the outer connected with the upper beam of the outer mast mast The piston fastened to the piston rod with spring wire is fitted with oil seals and The piston fastened to the piston rod with spring wire is fitted with oil seals and wearing on wearing on its outer periphery its outer periphery At ...

Page 74: ...d B B oil oil holes holes C C D D E E and and F F and and the the chamber chamber G G to to the the lift lift cylinder cylinder without without any any regulation When the lift spool valve is placed in the regulation When the lift spool valve is placed in the down position the oil flows in the down position the oil flows in the reverse position When the oil passes the throttle plate 5 and a pressu...

Page 75: ...d with two Yx rings and one wear ring on its circumference A bushing press fitted to the inner side of the and one wear ring on its circumference A bushing press fitted to the inner side of the guide sleeve supports the piston rod The guide sleeve is fitted with dust seal snap ring guide sleeve supports the piston rod The guide sleeve is fitted with dust seal snap ring Yx ring and O ring to preven...

Page 76: ...d repair it following tables and repair it 1 Control valve 1 Control valve Problem Problem Possible Possible cause cause Remedy Remedy Lower oil pressure and Lower oil pressure and lower oil amount of the lower oil amount of the steering oil circuit steering oil circuit Spool is held up Spool is held up Disassembly and clean Disassembly and clean renew oil renew oil Slide Slide surface surface bro...

Page 77: ...ring Spring is is worsen worsen Replace Replace spring spring Valve seat surface is Valve seat surface is worsen worsen Adjust or replace relief Adjust or replace relief valve valve Oil leakage inside Oil leakage inside Valve seat surface is Valve seat surface is worsen worsen Correct valve seat surface Correct valve seat surface Adjusting pressure h Adjusting pressure higher igher V Valve is held...

Page 78: ...ring in resulting from loose suction connections loose suction connections Retighten the connection Retighten the connection T Too oo high high oil oil stickiness stickiness Use Use oil oil with with proper proper stickiness stickiness Air bubble in oil Air bubble in oil Find out cause and correc Find out cause and correct them t them Oil leakage Oil leakage Oil seal or seal ring in pump Oil seal ...

Page 79: ...ting forward and backward by operating the tilt cylinder The outer mast is made of C shaped channel and main rollers and side the tilt cylinder The outer mast is made of C shaped channel and main rollers and side rollers are assembled on the upper part of i rollers are assembled on the upper part of it The inner mast is m t The inner mast is made of J shaped channel ade of J shaped channel and the...

Page 80: ...rk pin turn 1 4 circle the fork clearance must be adjusted according to the fork pull the fork pin turn 1 4 circle the fork clearance must be adjusted according to the loaded goods the loaded goods 7 1 4 Roller position Fig7 2 7 1 4 Roller position Fig7 2 There are two kinds of rollers main roller and side roller They are separately There are two kinds of rollers main roller and side roller They a...

Page 81: ...he inner mast The thickness of the shim is inner mast The thickness of the shim is 0 2mm or 0 5mm 0 2mm or 0 5mm 4 Adjust the tightness of lift chains 4 Adjust the tightness of lift chains Notice Please pay more regard to safety when adjusting the lift cylinder at an Notice Please pay more regard to safety when adjusting the lift cylinder at an elevated height elevated height Fig7 3 Adjustment of ...

Page 82: ... bracket and rollers inside the lift bracket and fasten them with snap rings fasten them with snap rings 7 2 4 Replace rollers Fig7 6 7 2 4 Replace rollers Fig7 6 1 Use the same way as 1 Use the same way as 7 2 3 to disassemble the lift bracket f 7 2 3 to disassemble the lift bracket from the inner mast rom the inner mast 2 Let the truck parking on the horizontal ground and wedge up the front whee...

Page 83: ...minus earth It The electric system for this forklift truck is single wire system with minus earth It mainly consists of the mainly consists of the following systems following systems 1 Charge system 1 Charge system This system contains generator battery charging indictor etc It supplies current for This system contains generator battery charging indictor etc It supplies current for all the electri...

Page 84: ...on lamp turning brake signal backing lamp turning brake signal backing 21W yellow 21W red 5W red 10W white 21W yellow 21W red 5W red 10W white Warning lamp optional Warning lamp optional 21W 21W 8 2 Brief explanation for 8 2 Brief explanation for operation operation 1 Starting 1 Starting There is a starting protection circuit in the control box f There is a starting protection circuit in the contr...

Page 85: ... lamp lights while the engine is working it means something is wrong with the charging lamp lights while the engine is working it means something is wrong with the charging circuit and you must stop working circuit and you must stop working and check as soon as possible and check as soon as possible 7 Oil pressure signal 7 Oil pressure signal Before starting the engine put the key switch to the Be...

Page 86: ...ing position immediately and then run to corresponding working position 2 When the meter 2 When the meter is during self check the LCD displays Baoli welcome is during self check the LCD displays Baoli welcome When running normally When running normally the the LCD displays running well LCD displays running well When there is error the LCD displays Running error When there is error the LCD display...

Page 87: ...t with Baoli dealer for inspection for inspection 6 Warning lamp 6 Warning lamp parking brake parking brake option option The warning lamp will light when the parking The warning lamp will light when the parking brake unit is engaged Check if the brake unit is engaged Check if the warning lamp warning lamp is failed when releasing the brake unit and is failed when releasing the brake unit and runn...

Page 88: ...r other loose fan belt dirty radiator belt or other abnormities in cooling system may lead abnormities in cooling system may lead temporary over heating Check the cooling temporary over heating Check the cooling system system 10 Indicator charge 10 Indicator charge a Lighting lamp indicates an abnormality of the a Lighting lamp indicates an abnormality of the charging system while the engine is ru...

Page 89: ...ion If the controller measures abnormal condition the trouble light will flashes regularly the error the trouble light will flashes regularly the error code can be checked out according to the code can be checked out according to the flashing flashing The function applies to the electric control type The function applies to the electric control type engine engine 14 Warning lamp 14 Warning lamp ai...

Page 90: ...lower than 1200 m 1 Elevation is lower than 1200 meters eters 2 Working temperature is between 25 2 Working temperature is between 25 and 40 and 40 3 Relative humidity is not larger than 95 3 Relative humidity is not larger than 95 8 3 2 Cautions 8 3 2 Cautions 1 Forbid wetting the meter When washing the truck don t let water into 1 Forbid wetting the meter When washing the truck don t let water i...

Page 91: ...4 Diagram of Fig8 3 4 Diagram of harness Y harness Yanmar 4TNE98 engine anmar 4TNE98 engine Central control box Central control box 00 Power 00 Power 01 01 Power Power horn horn 02 02 Power Power lamp lamp 03 03 Power Power meter meter 04 04 Power Power switch switch 05 05 Switch Switch turning turning lamp lamp 06 06 Power ignition Power ignition 07 07 Switch Switch light light 08 08 Switch Switc...

Page 92: ...utral 18 18 Generator Generator N N 19 19 Generator Generator F F 20 20 Charging Charging indicating indicating 21 21 Switch Switch forward forward 22 22 Switch Switch reverse reverse 23 23 Lamp Lamp reverse reverse Central control box Central control box 00 Power 00 Power 01 01 Power Power horn horn 02 02 Power Power lamp lamp 03 03 Power Power meter meter 04 04 Power Power switch switch 05 05 Sw...

Page 93: ...utral neutral 18 18 Generator Generator N N 19 19 Generator Generator F F 20 20 Charging Charging indicating indicating 21 21 Switch Switch forward forward 22 22 Switch Switch reverse reverse 23 23 Lamp Lamp reverse reverse Central control box Central control box 00 Power 00 Power 01 01 Power Power horn horn 02 02 Power Power lamp lamp 03 03 Power Power meter meter 04 04 Power Power switch switch ...

Page 94: ...power 13 13 Preheating Preheating fuse fuse 14 Starter 14 Starter 15 15 Optional Optional power power 1 1 16 16 Optional Optional power power 2 2 17 17 Indicating Indicating neutral neutral 18 18 Generator Generator N N 19 19 Generator Generator F F 20 20 Charging Charging indicating indicating 21 21 Switch Switch forward forward 22 22 Switch Switch reverse reverse 23 23 Lamp Lamp reverse reverse ...

Page 95: ...89 89 Fig8 3 1 Diagram of harness 4JG2 engine Fig8 3 1 Diagram of harness 4JG2 engine https www besttruckmanuals com ...

Page 96: ...90 90 Fig8 3 2 Diagram of harness Dachai 498 engine Fig8 3 2 Diagram of harness Dachai 498 engine https www besttruckmanuals com ...

Page 97: ...91 91 Fig8 3 3 Diagram of Fig8 3 3 Diagram of harness Xinchai 498engine harness Xinchai 498engine https www besttruckmanuals com ...

Page 98: ...92 92 Fig8 3 4 Diagram of Fig8 3 4 Diagram of harness Y harness Yanmar 4TNE98 engine anmar 4TNE98 engine NOTE NOTE https www besttruckmanuals com ...

Page 99: ...93 93 https www besttruckmanuals com ...

Page 100: ...94 94 KION Baoli Jiangsu KION Baoli Jiangsu Forklift Co Ltd Forklift Co Ltd https www besttruckmanuals com ...

Page 101: ... Jiangsu Jiangsu China China www baoli mh com www baoli mh com We reserve the right to make any We reserve the right to make any changes or modifications of pictures and specifications in this changes or modifications of pictures and specifications in this manual without giving previous notice and without manual without giving previous notice and without incurring any obligation incurring any obli...

Page 102: ...https www besttruckmanuals com ...

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