Baoli CPCD 100 Specifiche

Original instructions

5 Ⅱ. Safety usage, operation, maintenance and service of forklift truck It is important for drivers and managers to remember the principle of “first

95 b. Forbid wetting the meter. When washing the truck, don’t let water into the meter, if it happens, clean it with dry cloth. c. Don’t pull the plu

96 Fig.9.1 Principle diagram of electric system (domestic) CPCD50-70CY

97 Fig.9.2 Principle diagram of electric system (imported) CPCD50-70W

98 9.2 Brief explanation for operation (1) Starting There is a starting protection circuit in the control box for the forklift truck. You hav

99 on. (5) Backing signal When you need to reverse the forklift truck, pull the direction switch backward and the transmission is in reverse gear. Th

100 Fig9.4 LED Combined instrument 1. Fuel meter 5. Charge indicator 2. Water temperature meter 6. Neutral indicator 3. Hour meter 7. F

101 Fig9.5.1 Diagram of meter harness (domestic) CPCD50-70CY

102 Fig9.5.2 Diagram of meter harness (imported) CPCD50-70W

103 Fig9.5.3 Diagram of main harness (domestic) CPCD50-70CY

104 Fig9.5.4 Diagram of main harness (imported) CPCD50-70W

6 (5) Check hydraulic oil and brake fluid for leakage. Check if any leak or damage found on the oil pipes, water hoses, vent-pipes and the

105 Production improve suggestion sheet (feedback) Suggestion content: To improve our forklift trucks, absord your valuable sugge

106 NOTE

107

7 steering operation for its flexibility, tyre pressure for its conformance to the standard. If there is no trouble, operation may be allowed. (2) S

8 have their appointed sling position. The above-mentioned data is only for a reference, which may be adjusted because of configura

9 (1) Safe parking (a) Park your forklift truck on a level ground preferably in a wide area. If parking on a slope is unavoidable, pull the pa

10 pipes. (d) Remove the key and keep it in a secure place. ·Long time storage Perform the following service and checks in addition to the

11 operator shall be permitted to operate and service the truck. (2) Wear the safety guards, such as clothing, shoes, helmet and gloves while operat

12 descending of the goods. When the goods are lifted or descended, the initial speed shouldn’t be too fast in either case. (14) When tilting the mas

13 200mm-300mm from the floor. (25) When handling bulky loads which block your view, operate the forklift truck in reverse or have a guide. (26) Whi

14 (39) Before the truck decelerating and stopping, don’t change gear to reverse shift, so as to ensure the safe loading. (40) When the truck s

PREFACE Thank you for selecting BAOLI forklift truck! Your trust is a great honor to us! 5-7 Ton internal combustion counterbalanced forklift tru

15 an elevation of 1000 meters and temperature between -20℃and 40℃, relative humidity is 95%. Careful operation must observe under other adverse circ

16 7. Operation device and meter 1. Inching pedal 11. Air filter indicator (option) 2. Button for stopping engine 12

17 The function and use method of operation device and meter is listed as follows: No Name Function Use method 1 Inching pedal Couple or uncouple th

18 8. Caution plate The caution plates attached on the vehicle indicates the operating method and instructions. Before driving it, please be sure t

19 (4) Lubrication system (5) Capacity chart (6) Inspections before starting

20 (7) Adjust parking brake (8) Add hydraulic oil (9) Add fuel (10) Add antifreeze (11) Tyre safety decal (charging tyre) (12) T

21 (13) Cautions for high voltage (14) Sling point indication (15) Sling decal (16) Forbid entering into the space behind the mast

22 (18) Hand caution decal (19) Fan hurting hands (20) Hood crushing hands Energy accumulator decal Belt pulley thumb ha

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

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

CONTENTS Ⅰ. About the forklift truck...…….………………………...1 1. External view and specification…………………………………………

25 3. Recommended oil Name Brand or code Quan -tity Domestic Overseas Diesel Refer to diesel engine manual or select GB252-81 light diesel： Winter-

26 Lubrication diagram

27 5. Routine check before daily operation (1) Check the storage of fuel. (2) Check if any leak or damage found on the oil pipe, water hose, vent-pip

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

29 1.2 Engine disposition The engine used for 5-7t forklift truck includes the import engine 6BG1 (ISUZU), the home engine 6102BG6 (Zhaoyang). Type

30 Fig.1.2 A-6BG1QC diesel engine Main performance and disposition of A-6BG1QC Model A-6BG1QC Type 4-cycle,water-cooled,overhead val

31 1.3 Inspection and adjustment of engine In order to keep good condition of your truck, you must carry out periodic inspection and adj

32 1.4.2 Fuel sensor The function of the fuel sensor is to change the oil in the oil tank to the electric through the bobber up and down sport, in th

33 1.4.3 Fuel filter The fuel filter was installed in the engine enters hose, used to filtrate the fuel supply to the engine. There also have other

34 1.6.3 Replacement of oil filter (Fig.1.8) (1) Use the filter specially spanner disassemble and change. (2) Along with the around of the new o

2.1 General description…………………………………………………………….39 2.2 Torque converter…………………………………………………………………41 2.3 Charging pump……………………………………………………………………42 2.4

35 1.6.5 Adjust the fan belt If the fan belt is loose, tighten it. See Fig.1.10. Step: loosen the fixed bolt B and C of generator, move the generator

36 Fig.1.13 Fig.1.14 The material adjustment s

37 (3) Loosen the 1st cylinder injection pipe, dismantle the spring on drain valve bracket and drain valve, then install the drain v

38 (1) Dismantle heat spark plug and fuel injection pipe. (2) Install manometer on the heat spark plug of 1st cylinder, the demarcate value of the ma

39 2. Drive unit Drive unit consists of torque converter and a hydraulic transmission. The structure of the hydraulic transmission refers t

40 Fig.2.1 Torque converter transmission 1. Control valve 9. Parking brake 17. Oil seal 2. Charging pump 10. Strainer 18. Ba

41 2.2 Torque converter The torque converter consists of pump wheel installed on input shaft, a turbine wheel installed on output shaft and stator

42 Fig.2.2 Torque conv Fig 2.2 Torque converter 2.3 Charging pump Fig 2.3 shows the

43 2.4 Hydraulic clutch Fwd clutch see Fig 2.4, reverse clutch see Fig.2.5. There is a hydraulic clutch fixed on transmission, the dr

44 Fig.2.4 Forward shift clutch Fig.2.5 Reverse shift clutch Fig.2.6 Control valve

6.3 Control valve…………………………………………………………………….76 6.4 Control valve operation………………………………………………………….77 6.5 Main safety valve operation……………………………………………

45 2.6 Hydraulic circulation system (see Fig. 2.7) When the engine is started and the charging pump is put into operation, the torque co

46 Fig. 2.7 Hydraulic circulation system 2.7 Principle The torque converter consists primarily of a pump wheel connected to the

47 2.9 Trouble shooting (1) Insufficient power Parts Problem Possible cause and remedy Torque converter A. Too low oil pressure 1. Lower oil level Ch

48 (2) Too higher oil temperature Parts Problem Possible cause and remedy Torque converter 1. Lower oil level Check oil level and add oil. 2. Blocke

49 (4) Too lower transmission efficiency Parts Problem Possible cause and remedy Torque converter 1. Elasticity plate is broken. Check turn noise and

50 3. Front axle The main specifications of the front axle: Type Full-floating type, integral shaped Main reduction gear Type Spiral bevel pinion ty

51 gear. However, since the ring gear is fixed to the spindle, the pinion gears revolve around the sun gear while spinning themselves. The pinion gea

52 Fig. 3.2 Reducer & differential 1. Adjust nut 11. Flange half 21. O-ring 2. Cap 12. Side gear 22. Spacer 3. Lock plate

53 Fig. 3.3 Final reduction gear 3.4 Troubleshooting Trouble Cause Correction Oil leaks from differential carrier. Loose bolt or broken gaske

54 4. Brake system 4.1 General description The brake system consists of two wheel brakes installed on the front axle and parking brake on the propell

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

55 Fig. 4.2 Position of brake pedal 4.2.2 Brake valve (Fig. 4.3) (1) Non-brake state Since the brake valve A port is o

56 return spring 6 is compressed to the left. B. A port is closed owing to the shift of the part 7, and chamber D disconnects with the port o

57 pressure alarm switch inside it. Preventive maintenance should be done by authorized serviceman. Failure to use will cause crack. Depressurization

58 4.3 Vacuum booster Using the vacuum booster with the power cylinder can make the forklift truck brake. Vacuum booster boosts brake f

59 control valve push rod 1 and piston 5 shift backward, the air valve 4 keeps away from the vacuum valve port. Thus the brake process ends. 4.3.2 As

60 Fig4.5 Outline of vacuum booster and master cylinder

61 4.4 Parking brake The parking brake is of internal expansion and lining type, and built in the output shaft of the torque converter transmission.

62 Fig. 4.8 Wheel brake 1. Primary brake shoe 6. Pull rod 11. Spring 2. Return spring 7. Secondary brake shoe 12. Adjust

63 4.6 Troubleshooting Problem Possible cause Remedy Poor braking force Fluid leakage from brake system Repair Maladjustment of brake shoe clearance

64 5. Steering system 5.1 General description Steering system contains mainly a steering hand wheel, a steering column, a cardan joint, a pow

2 Main specification General Model CPCD50 CPCD60 CPCD70 Power type Diesel Rated capacity kg 5000 6000 7000 Load center mm 500 Dimensions Li

65 5.2 Hand wheel Hand wheel is operated in normal way, that is to say, when turning the hand wheel right, the truck will turn ri

66 5.3.1 Steering unit assy Fig.5.2 Cycloid gear type powered steering unit 1. Spacing sleeve 6. Joint sleeve 2. Valv

67 5.3.2 Work principle Valve bore, valve sleeve, valve body in the redirector makes up of along valve, having an effect of controlling the

68 5.3.3 Usage of the steering unit (1) Install the steering unit When installing the steering unit, it must ensure concentric with the conne

69 In order to keep the steering system in good working condition and avoid accidents, it is necessary to check the steer

70 If disassemble from the rear cover, before removing the valve core and valve sleeve, firstly get out valve ball, or the valve body will be dama

71 of the steering wheel with the parking detent, to measure the operation of steering, which must be under 150N. (5) Measure the pressure with press

72 5.3.6 Steering unit troubleshooting Problem Possible cause Remedy Oil leakage Oil leaks from the connection surface of valve body, stator and re

73 5.4 Steering system troubleshooting 5.4.1 Inspection after reassembling the steering system (1) Check the force when turning the steering handwhee

74 5.5 Rear axle The rear axle is primarily composed of an axle body, right and left knuckles, tie rods, wheels, hubs and steering cylinder. The stee

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

75 (4) Rear wheel bearing pre-load adjustment a. As shown in Fig5.7, fill up the chamber formed by wheel hubs, wheel hub bearing and wheel h

76 6. Hydraulic system Hydraulic oil pump Type Gear pump Displacement 32 ml/r 36 ml/r Control valve Type Two-pool type with relief valve, flow

77 Caution: Don’t adjust the pressure of the main relief valve at will. If the pressure is too high, the hydraulic system and hydraulic component m

78 Fig.6.2 Middle position (2) Push slide valve (See Fig.6.3) At that time, the middle passage is off. The oil that is come from the oil

79 6.5 Main safety valve operation (1)The main safety valve must be installed between the cylinder HP port and LP passage. The oil that pass thr

80 6.6 Tilt lock valve operation Tilt lock valve is used for preventing the shaking of the mast (because the tilt cylinder maybe cause the inside neg

81 6.7 Hydraulic circulation system (Main circuit) The hydraulic system sketch sees Fig. 6.10. The hydraulic circulation system of the main circuit

82 the piston rod. When the lift lever is pushed, the circuit between the lower part of the lift cylinder piston and the oil tank is opened, and the

83 6.9 Maintenance 6.9.1 Detaching of multi-way valve Detach the valve from forklift and clean it. (1) Loose bolts and separate each part, please not

84 7. Lift cylinder & tilt cylinder Lift cylinder Type Single-action piston type, with cut-off valve Bore diameter Φ80mm Stroke 1495mm (Only for

4 Main parts of forklift truck No. Name Contents 1 Power system engine mounting, system of fuel, exhaust and coolant etc. 2 Transmission torqu

85 Note: Please pay more regard to safety when adjusting the lift cylinder. Fig.7.1 Lift cylinder 1. Adjusting pacer 2.

86 7.2 Flow regulator The flow regulator is located between the control valve and the high pressure ports of the two lift cylinders, ne

87 7.3 Tilt cylinder Two tilt cylinders of double acting type are provided at each side of the frame. The front end of the piston rod is instal

88 8. Lifting system 8.1 General description The lifting system is of two-stage, rolling telescopic mast type. The inner mast frames have J-shaped se

89 sustained by upper retaining rollers and lower side rollers. As we mentioned above, the mast assembly and lift brackets are designed with rigidity

90 Fig8.2 Roller mounting 8.5 Adjustment of lifting system a. The clearance between the inner mast and the guide plate of the outer mast i

91 (3) Install shims between the top of the piston rod of the cylinder which stop first and the upper beam of the inner mast. The thickness of the sh

92 Fig.8.5 Fig.8.6 8.6.3 Replace rollers of

93 (5) Disassemble the connecting bolts for the lift cylinder and the bottom of the outer mast. Disassemble the lift cylinders and the oil pipes betw

94 9. Electric system 9.1 General description The electric system for this forklift truck is of the single-pole type. It mainly consists