Baoli F 2-3.5T Series Operation And Service Manual Download Page 78

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Air entering into the pump

suction pipe

Add oil into oil tank

Replace oil seal

Noisy oil pump

Worn suction pipe or

Worn suction pipe or blocked

blocked

oil filter

Correct pipe or repair filter

Air entering in resulting from

loose suction connections

Retighten the connection

Too

oo high

high oil

oil stickiness

stickiness

Use

Use oil

oil with

with proper

proper stickiness

stickiness

Air bubble in oil

Find out cause and correc

Find out cause and correct them

t them

Oil leakage

Oil seal or seal ring in pump

broken down

Replace

Pump

Pump broken

broken down

down

Replace

7. Lifting system

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Summary of Contents for F 2-3.5T Series

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

Page 2: ...20 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...

Page 3: ...peration 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...

Page 4: ...ution plate 19 19 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 Inspecti...

Page 5: ...eel 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...

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...

Page 7: ...out 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 besttruckman...

Page 8: ...R 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 fu...

Page 9: ...d 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...

Page 10: ...h 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 Inne...

Page 11: ...g 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 swi...

Page 12: ...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...

Page 13: ...ng 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...

Page 14: ...ifted 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 1...

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...

Page 16: ...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 wit...

Page 17: ...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...

Page 18: ...al 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 w...

Page 19: ...ulic 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 rocke...

Page 20: ...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 instal...

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...

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 flo...

Page 23: ...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 reve...

Page 24: ...e 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 me...

Page 25: ...PCD35F 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...

Page 26: ...ameplate 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 parki...

Page 27: ...g 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 chargi...

Page 28: ...klift 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...

Page 29: ...rson 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 cau...

Page 30: ...ring 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 fram...

Page 31: ...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 Dam...

Page 32: ...gine 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 ma...

Page 33: ...l 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 eng...

Page 34: ...rmality 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 ch...

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...

Page 36: ...oner 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 filte...

Page 37: ...k 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 F...

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 blo...

Page 39: ...g 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...

Page 40: ...lant 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...

Page 41: ...he 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 sedimente...

Page 42: ...nd 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...

Page 43: ...fakmultipurpose 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 M...

Page 44: ...54 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 2...

Page 45: ...ase 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 seriou...

Page 46: ...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...

Page 47: ...g2 2 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...

Page 48: ...heel 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...

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...

Page 50: ...y 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...

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...

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 pip...

Page 53: ...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...

Page 54: ...eel 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...

Page 55: ...ase 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 rep...

Page 56: ...eel 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 Siz...

Page 57: ...hus 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...

Page 58: ...ed 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 p...

Page 59: ...he 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 brak...

Page 60: ...here 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...

Page 61: ...em 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...

Page 62: ...em 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 Steeri...

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 turnin...

Page 64: ...ration 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 durin...

Page 65: ...ring 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 oi...

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...

Page 67: ...llation 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 mean...

Page 68: ...7 MPa 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 a...

Page 69: ...n 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 a...

Page 70: ...ssure 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 Th...

Page 71: ...nger 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...

Page 72: ...ower 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...

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...

Page 74: ...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...

Page 75: ...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 s...

Page 76: ...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...

Page 77: ...ing 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...

Page 78: ...ing 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 p...

Page 79: ...ing 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 rolle...

Page 80: ...k 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...

Page 81: ...e 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 Pleas...

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 w...

Page 83: ...inus 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...

Page 84: ...ation 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...

Page 85: ...mp 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 work...

Page 86: ...ng 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...

Page 87: ...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 t...

Page 88: ...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 t...

Page 89: ...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 b...

Page 90: ...ower 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...

Page 91: ...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...

Page 92: ...tral 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 r...

Page 93: ...tral 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 Lam...

Page 94: ...ower 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 Gener...

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...

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

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