Baoli F Series Installation and operating instructions

1

F-Series
CPCD20/25/30/35F
CPQ(Y)D20/25/30/35F
InternalCombustionCounterbalancedForkliftTruck
OPERATION & SERVICE MANUAL
KION Baoli (Jiangsu) Forklift Co., Ltd.
2-3.5T

PREFACE
F-series balance weight type forklift trucks with engine are designed on the base of
the advanced features available from both local and foreign designs. These trucks are
suitable to handle, transport and stack goods in factories, mines, stations, ports, freight
yards, warehouses and used widely in food processing, textiles and other light industries.
The use of forklift trucks fitted with kinds of attachments will become extensive.
F-series forklift trucks feature a wide-vision mast system, full hydraulic steering unit,
self-boost brake, stepless speed control, parking brake device with foot pedal, integral
overhead guard and high quality large screen combination meter, so they have a lot of
advantages such as good performance, easy operation, wide vision, flexible steering,
reliable braking, powerful and aesthetic appearance.
This manual states the specifications, operation, maintenance, main assemblies’
constructions and working principles of F-series forklift trucks so as to help operators to
use the trucks correctly and attain the highest functions. It is necessary to read over the
manual before operating or maintaining the forklift trucks. The rules and notices in this
manual should be abided seriously by all relative persons to enable these trucks in
optimized working state for long period and bring the highest efficiency.
The relevant content in this manual might not correspond with the actual condition
because of technical improvement. Our products are subject to improvements and
changes without notice.

CONTENTS
Ⅰ. About F-series forklift truck……………………………………………………………
1
1. External view and technical parameter…………………………………………………
1
2. Characteristic………………………………………………………………………………
3
3. Main system………………………………………………………………………………
3
4. Main components…………………………………………………………………………
4
5. Operation device and instrument panel…………………………………………………
5
Ⅱ. Safety instruction and operation of forklift truck…………………………………
10
1. Handling a new forklift truck………………………………………………………………
10
2. Inspection before operation………………………………………………………………
10
3. Start and stop of the engine………………………………………………………………
11
4. Parking and storing………………………………………………………………………
12
5. Shipping, loading and unloading, slinging and towing of forklift truck………………
13
6. Information of safety operation……………………………………………………………
15
7. Caution plate………………………………………………………………………………
19
Ⅲ. Periodic inspection and servicing……………………………………………………
24
1. General rules on inspection and maintenance…………………………………………
24
2. Inspection content…………………………………………………………………………
25
3. Periodic replacement table………………………………………………………………
30
4. Lubrication chart……………………………………………………………………………
31
5. Weekly maintenance………………………………………………………………………
32
6. Self service…………………………………………………………………………………
34
7. Recommended oil and grease for forklift truck…………………………………………
36
Ⅳ. Construction, principle, adjustment and maintenance of forklift truc………………
38
1. Power system……………………………………………………………………………
38
4
1.1 General description………………………………………………………………………
38
1.2 Engine parameter and appropriate truck model………………………………………
38
0
1.3 Inspection and adjustment of engine…………………………………………………
39
1.4 Precautions of cooling system…………………………………………………………
…
39
2. Hydraulic drive unit………………………………………………………………………
40
2.1 General description………………………………………………………………………
40

2.2 Reducer and differential…………………………………………………………………
42
2.3 Torque converter…………………………………………………………………………
43
0
2.4 Hydraulic circuit…………………………………………………………………………
44
2.5 Towing disabled truck……………………………………………………………………
44
2.6 Troubleshoot………………………………………………………………………………
45
3. Drive system………………………………………………………………………………
47
3.1 General description………………………………………………………………………
47
3.2 Assembly of wheel hub…………………………………………………………………
47
3.3 Troubleshoot………………………………………………………………………………
50
4. Brake system……………………………………………………………………………
51
4.1 General description………………………………………………………………………
51
4.2 Master cylinder……………………………………………………………………………
51
4.3 Wheel brake………………………………………………………………………………
52
4.4 Operating device of parking brake………………………………………………………
54
4.5 Inspection of wheel brake………………………………………………………………
55
4.6 Troubleshoot………………………………………………………………………………
56
5. Steering system…………………………………………………………………………
57
5.1 Hand wheel………………………………………………………………………………
58
5.2 Cycloid gear type powered steering unit………………………………………………
58
5.3 Inspection after reassembling the steering system……………………………………
59
5.4 Troubleshooting of steering system……………………………………………………
59
5.5 Steering axle………………………………………………………………………………
60
6. Hydraulic system…………………………………………………………………………
63
6.1 General description………………………………………………………………………
63
6.2 Hydraulic oil pump………………………………………………………………………
63
6.3 Control valve & flow divider……………………………………………………………
63
6.4 Hydraulic oil circuit………………………………………………………………………
67
6.5 Lift cylinder………………………………………………………………………………
68
6.6 Flow regulator valve………………………………………………………………………
69
6.7 Tilt cylinder………………………………………………………………………………
70
6.8 Troubleshoot………………………………………………………………………………
71

7. Lifting system……………………………………………………………………………
73
7.1 General description………………………………………………………………………
73
7.2 Maintenance and adjustment……………………………………………………………
75
8. Electric system……………………………………………………………………………
78
8.1 General description………………………………………………………………………
78
8.2 Brief explanation for operation…………………………………………………………
79
8.3 Instructions of meter panel………………………………………………………………
80
8.4 Principle diagram of electrical system…………………………………………………
85
8.5 Diagram of harness………………………………………………………………………
85
Note……………………………………………………………………………………………
93
EC DECLARATION OD CONFORMITY…………………………………………………
94

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Ⅰ. About F-series forklift truck
1. External view and technical parameter
Fig1.1 External view

2
Technical parameter
General
Manufacturer
KION Baoli
Model
CPCD20F
CPQ(Y)D20F
CPCD25F
CPQ(Y)D25F
CPCD30F
CPQ(Y)D30F
CPCD35F
CPQ(Y)D35F
Power type
Diesel/Gasoline/LPG
Rated capacity
kg
2000
2500
3000
3500
Load center
mm
500
Performance
Overall
dimension
Length to fork face
L1
mm
2564
2634
2775
2814
Overall width
B1
mm
1150
1236
Mast lowered height
H1
mm
2050
2080
2230
Mast extended height
H3
mm
4040
4273
Overhead guard height
H2
mm
2150
2180
Lift height
H
mm
3000
Free lift height
H4
mm
140
145
Fork size
L×W×T
mm
1070×120×40
1070×120×45
1070×125×45
1075×130×45
Mast tilt angle
α/β
deg
6 / 11
Front overhang
X
mm
484
489
494
500
Turning radius
R
mm
2220
2290
2400
2490
Self weight
kg
3510
3810
4320
4620
Chassis
Tyre
Front
7.00-12-12PR
28×9-15-12PR
28×9-15-14PR
Rear
6.00-9-10PR
6.50-10-10PR
Tread
Front
B2
mm
970
1000
Rear
B3
mm
970
Wheelbase
Y
mm
1650
1700
1760
Ground clearance
(full load/no load)
Mast
M
mm
85 / 105
110 / 135
Frame
F
140 / 145
170 / 175
F-series forklift trucks mentioned in this manual correspond in different
engines, please refer to the following table.
Model of forklift truck
Model of engine
Diesel
CPCD20F
XINCHANG BPG490,ISUZU C240,YANMAR 4TNE92
CPCD25F
XINCHANG BPG490,DACHAI CA498,ISUZU C240,ISUZU 4JG2PE,YANMAR
4TNE92
CPCD30F
XINCHANG BPG490,XINCHANG BPG495,XINCHANG BPG498,DACHAI
CA498,ISUZU C240,ISUZU 4JG2PE,YANMAR 4TNE98
CPCD35F
XINCHANG BPG495,XINCHANG BPG498,DACHAI CA498,ISUZU 4JG2PE,
YANMAR 4TNE98
Gasoline
CPQ(Y)D20/25F
MITSUBISHI 4G64-31ZG,NISSAN K21,NISSAN K25
CPQ(Y)D30/35F
MITSUBISHI 4G64-31ZG,NISSAN K25
Notice: Please refer to AD sheet of F-series forklift truck about other technical
parameters or new engine configuration not mentioned in this manual.

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2. Characteristic
(1) The hydraulic steering device and transverse steering axle makes steering
flexible and the turning radius minor.
(2) The braking system employs hydraulic brake, makes it possible to manipulate
conveniently and brake reliably.
(3) Hydraulic transmission type forklift trucks are provided with a drive unit including a
hydraulic torque converter and an electron transmission box. They feature the following:
·Hydraulic torque converter can change the speed automatically with no limitation
and output torque makes the forklift truck have good performance of drawing.
·The inching device makes it easy for the drivers to aim the fork to the cargo.
·The use of hydraulic transmission ensures the engine operate smoothly for the
sudden increase of load. At work, the forklift truck that needs starting and shifting
frequently, electron transmission device can achieve smooth shift and raise working
efficiency, simplify operation, reduce the driver’s labor intensity and reduce requirement of
the driver’s operation skill.
(4) The mast is high intensity and wide vision for the use of two stage CC extension
type mast and hidden-type tilt cylinder device. The forklift truck can be fitted with 2-stage
or 3-stage full free lift mast having different lifting height, even all kinds of the attachments
according to the needs of the clients.
(5) The forklift truck can be chosen different height mast and driver’s cab according to
the operating into container or out container.
(6) Specific outline adopts streamline design, wider operating vision and larger
driving space. It has advantages such as low noise, vibration damping, dustproof,
comfortable operation, safety and reliability.
3. Main system
No.
Name
Contents
1
Power system
engine mounting, fuel, exhaust and cooling system(inc.
torque converter oil cooler) etc.
2
Transmission
system
torque converter, gear box, transmission shaft, gearshift etc.
3
Drive axle
axle housing, half shaft, brake, front wheel etc.
4
Brake system
wheel brake and parking brake etc.
5
Steering system
steering wheel, cycloid gear type powered steering unit 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
Lifting system
mast, fork, lift bracket, load backrest, tilt cylinder, lift
cylinder, lift chain, mast roller etc.

4
4. Main components
Fig1.2
Size & slinging parameter of the main parts that can be disassembled
Max. outline size (mm)
Min. slinging capacity
(Kg)
Counter weight
1130×739×955
1700
Standard mast
1935×854×600
730
Lift bracket
(with load backrest)
1200×1197×260
170
Fork
1150×660×125
80
Notice: The above-mentioned size and capacity is only for a reference, which
may be adjusted because of configuration difference or technology optimization.
1. Outer mast
2. Inner mast
3. Lift chain
4. Lift cylinder
5. Load backrest
6. Fork location pin
7. Lift bracket
8. Fork
9. Driving wheel
10. Tilt cylinder
11. Turning wheel
12. Engine hood
13. Refueling lid
14. Operator’s seat
15. Counter weight
16. Flasher (option)
17. Rear combination lamp
18. Overhead guard
19. Head lamp
20. Front combination lamp
21. Steering wheel