KION Baoli D Series User manual

Original instructions
D series Forklift Truck
KBD50–70

Baoli - Your partner
About KION group
The KION Group is a global leader in industri-
al trucks, related services and supply chain
solutions. Across more than 100 countries
worldwide, the KION Group designs, builds
and supports logistics solutions that optimize
material and information flow within factories,
warehouses and distribution centers. The
Group is the largest manufacturer of industrial
trucks in Europe, the second-largest producer
of forklifts globally and a leading provider of
warehouse automation.
About Baoli forklift
With over 10,000 forklift trucks and warehouse
machines sold annually, Baoli is the interna-
tional, highly competitive material handling
manufacturer for the value segment. From
2009 onwards, Baoli has been fully integrated
and managed by the KION Group. Baoli's
headquarters and production facilities are lo-
cated in Jingjiang, Jiangsu province (near
Shanghai). Baoli provides whole product
range including diesel /gasoline/ LPG trucks
with load capacities of 1 to 32 tons and elec-
tric / warehouse trucks. The company has au-
tomated painting line, vehicle assembly line
and key components production line, which
provides strong base to ensure business
growth.
As a brand of the KION Group, our goal is to
be one of the leading brands in the mass ma-
terial handling industry. By combining compet-
itive advantages of KION’s operational excel-
lence with Baoli’s integrated manufacturing
platform, Baoli provides value-for-money prod-
ucts and service to our customers worldwide.
At Baoli, we strive to match the high quality of
our products with high quality services. With
an extensive network of sales partners, we are
at your service round the clock and around the
world.
Your local Baoli partner can offer you a com-
plete package from a single source, with ex-
pert advice on all aspects of sales and serv-
ices.
Please contact us:
KION Baoli(Jiangsu)Forklift CO.,Ltd.
Add: No. 8 Xinzhou Road, Economic Develop-
ment Zone,
Jingjiang, 214500, Jiangsu,China.
Tel: [phone]
Email: [e-mail]
Preface
I60138011501 EN - 10/2020

1 Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description of use and climatic conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EMC – Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . 9
2 Safety
Definition of terms used for responsible persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Competent person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Ground condition for using the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Regulations Relative to Forklift Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety regulations when driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety regulations in case of accidental lateral tipping . . . . . . . . . . . . . . . . . . . . . . . . 18
Exercise caution when handling gas springs and accumulators . . . . . . . . . . . . . . . . . 18
Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Disposal of consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table of contents
III60138011501 EN - 10/2020

3Overview
General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Display instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Truck identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Forklift Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
Mast serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Location of decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Operation
Instructions for running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Checks and inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pre-shift checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Daily checks before use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
Seat belt status and performance checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
Check the wheel nuts for correct tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
Check the condition and operation of chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
Refuelling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Diesel fuel - Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Engine coolant - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Climbing on/off the forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Adjustment of the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Adjustment of the driver’s seat*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DPF light and switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
Table of contents
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Changing the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inching control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
Start on an incline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
Steering system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
lifting system and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Operating the lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Operating attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
Handling loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Load centre distance and load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
Picking up a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
Transporting pallets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
Adjusting the fork spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
Driving with a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
Transport of swinging loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
Driving on loading bridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
Forklift towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cleaning the electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
Cleaning lifting chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
After washing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
Before exiting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Truck transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Truck Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Disposal of old trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5 Maintenance
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Pre-service preparatory work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Supply table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Table of contents
V60138011501 EN - 10/2020

Preventive maintenance service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Service schedule for Weichai WP4.1 engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Service schedule for ISUZU 6BG1-02 engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
Maintenance table for Cummins QSB4.5 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
Maintenance table for Doosan D34 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
Checking list for IC Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Weichai WP4.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Changing the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Check the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Changing the engine oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105
Change air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
Cleaning the air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
Emptying water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108
Replacing the fine fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Fuel system air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110
Adjustment of valve clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
Clean and check the injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
Isuzu 6BG1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Changing the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Check the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114
Changing the engine oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
Change air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116
Cleaning the air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116
Replacing the fine fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
Removal of water from the fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
Fuel system air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
Feed pump strainer cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119
Checking and adjusting the radiator fan V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
Cummins QSB4.5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Unusual System Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Changing the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
122
Check the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124
Changing the engine oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125
Change air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
126
Cleaning the air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127
Replacing the fine fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
128
Removal of water from the fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
Inspect the intake piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
130
Table of contents
VI 60138011501 EN - 10/2020

Doosan D34 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Replacing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132
Replacing the engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134
Clean the air filter insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134
Change the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
136
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
138
Bleeding Air From the Fuel Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
Draining Water From the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
Checking the belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
142
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Checking and cleaning the cooling fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Changing the coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
146
Checking the coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
148
Transmission system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Changing the hydraulic transmission oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Checking the oil level of the hydraulic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150
Changing the oil of the hydraulic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150
Checking the drive axle gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
151
Changing the drive axle gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
151
Steering axle and wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Cleaning and lubricating the steering axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Checking the tyres for damage and foreign matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153
Check the tyre inflation pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153
Checking the condition of the tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
154
Tighten the tyre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
154
Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Check the seat belt for condition and correct operation . . . . . . . . . . . . . . . . . . . . . . . . . 155
Checking the fastening of the engine bracket, overhead guard, tilt cylinder, steering axle
and wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
156
Control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Checking the operation of the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Checking that the driving brake is operating normally. . . . . . . . . . . . . . . . . . . . . . . . . . .
158
Checking that the inching controls are operating normally . . . . . . . . . . . . . . . . . . . . . . .
158
Checking the driving brake and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . .
158
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Checking battery charging status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Check the control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
160
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Hydraulic diagram-with 3691 function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Hydraulic diagram-priority valve with 3691 function for Doosan D34 engine . . . . . . . . .
162
Table of contents
VII60138011501 EN - 10/2020

Hydraulic diagram-without 3691 function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Changing the crude filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
164
Replacing the breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
164
Fill up the hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
165
Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
165
Load lifting system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Checking the fork arms and the fork arm quick release apparatus . . . . . . . . . . . . . . . . . 167
Checking the operation and installation of the lift mast, lifting chain and limit block . . . .
167
Lubricate the lift mast and chains with chain spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
168
Lubricating the lift mast and tilt cylinder bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
168
Adjusting the length of the lift chains, and lubricating using chain spray. . . . . . . . . . . . .
170
6 Technical data
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Datasheet for KBD50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Datasheet for KBD60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Datasheet for KBD70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Mast specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Annex
7 Electrical diagrams
with ISO3691 function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Electric schematic diagram - Cummins QSB4.5 with ISO3691. . . . . . . . . . . . . . . . . . . . 195
Electric schematic diagram-Doosan D24 with ISO3691 function . . . . . . . . . . . . . . . . . .
196
without ISO3691 function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Electric schematic diagram-Weichai WP4.1 w/o ISO3691 . . . . . . . . . . . . . . . . . . . . . . . 197
Electric schematic diagram - Isuzu 6BG1QC-02 w/o ISO3691 . . . . . . . . . . . . . . . . . . . .
198
Table of contents
VIII 60138011501 EN - 10/2020

1
Introduction

Introduction
Your Baoli forklift truck
With maximum economic efficiency, safety
and driving comfort. Yet, it is up to you, the
forklift truck operator, to take good care when
working and use its potential to the fullest.
During the manufacturing process (if affixed
with CE mark):
We adhered to all CE safety requirements.
We carried out all compliance tests required
by law.
This is proven by the CE stamp shown on the
identification plates.
The manual provides you important informa-
tion on activating, driving, operating and main-
taining a Baoli forklift truck.
Regularly and promptly complete the mainte-
nance checklists in accordance with the truck
operating instructions and use the specified
tools, cleaning products etc.
In order to maintain valid warranty service for
your forklift truck, please keep and save a
complete, detailed record of the maintenance
process.
All maintenance procedures must be recor-
ded; otherwise you will lose the warranty.
Users, especially forklift truck drivers and
maintenance personnel, must strictly follow
"national regulation and guidelines".
User shall be responsible for any loss caused
by improper use. Manufacturer Baoli, will not
be responsible for such loss.
If you want to use the forklift truck for purpo-
ses that are not mentioned in the user manual,
please contact dealers accredited by Baoli.
Any modification of your truck, in particular fit-
ting of equipment or conversion of the truck, is
prohibited without the permission of the manu-
facturer.
CAUTION
Taking into account stability and the specified mini-
mum braking distance, do not carry out stacking/
destacking operations on a slope.
The climbing degrees in the model parameters table
are ascertained from the forklift truck traction, and
only apply when going over small obstacles and driv-
ing on relatively flat surfaces.
Technical notes
This user manual must not be copied, transla-
ted or sent to a third party without the manu-
facturer's written consent.
Baoli’s business philosophy is to constantly
improve its products in terms of design and
structure. Hence, Baoli reserves the right to
change a forklift truck's design and technical
parameters at any time.
Hence, the company may refuse to take re-
sponsibility for any complaint with respect to
the technical parameters, illustrations, and in-
structions of this user manual.
Use dedicated work supplies according to
checking and maintenance overviews. Per-
form specified work regularly at the anticipated
time. To comply with warranty conditions,
please ensure that work carried out is recor-
ded in the registration documents for the in-
dustrial forklift truck.
Daily checks has to be performed by the cus-
tomer. Periodic service/maintenance work will
require specialist knowledge, measuring devi-
ces and often also special tools. Please con-
tact an authorized dealer to carry out this
work.
Service should only be carried out by qualified
personnel approved by Baoli (specialists).
For questions about the forklift truck and or-
ders for spare parts, please contact your local
Baoli dealer and leave an accurate shipping
address.
In order to maintain the original technical effi-
ciency of the forklift truck, please use authen-
tic Baoli spare parts when repairing.
Introduction
1
Introduction
2 60138011501 EN - 10/2020

When ordering spare parts, in addition to part
numbers, please provide the following infor-
mation:
Forklift model number:
Serial number/Year of manufacturing:
Delivery date:
Part numbers should be specified when order-
ing parts.
Part number of the lift mast:
Lifting height of the lift mast [mm]:
When taking delivery of the forklift truck, copy
data from the component identification plates
into this user manual.The relevant information
can be found on the identification plates on
the forklift truck.We recommend you write
down this information in the manual for future
reference.
Forklift truck handover
Before leaving the factory, every forklift truck
is carefully examined so that it is completely
up to standard and can be delivered to the
user in perfect condition.
In order to guarantee the forklift truck works
correctly, Baoli dealers are obliged to check
the following items before the handover:
Check whether the driving wheel nuts are
tightened
Check the battery status
Checking the hydraulic oil level
Check the braking function
Check the steering function
Check the traction function
Check the mast lift and attachments op-
erating function
To avoid the inconvenience of making a claim
after use, check the forklift truck is in perfect
condition and repair, and confirm your satis-
faction with the vehicle on the manufacturer's
product qualification certificate upon hand-
over.
NOTE
Every forklift truck is provided with the follow-
ing technical documents:
●
Operating instructions for the truck
●
EC Declaration of Conformity (applicable for
CE certified forklift trucks)
Introduction
1
Introduction
360138011501 EN - 10/2020

Intended use
The industrial truck may only be used as per-
mitted.
The industrial truck is used for moving and lift-
ing the loads indicated on the capacity rating
plate.
Damages and defects
Damages and other defects to industrial trucks
or to attachments must be reported to the Su-
pervisor immediately. Industrial trucks and at-
tachments which are not safe to operate may
not be used until they have been properly re-
paired.
Safety installations and switches may not be
removed or rendered unusable. Specified set-
tings may only be changed with the approval
of the manufacturer.
Danger areas
Danger areas are those areas in which per-
sons are in danger as a result of the move-
ments of industrial trucks, their operating
equipment, their load carrying devices (e.g.
their attachments) or the loaded goods. This
also includes the area which can be reached
by falling goods or lowering or falling operating
equipment and devices.
People must not stand in the danger area of
an industrial truck.
Working areas
Only the areas approved by the operating
company or its representative may be used for
transportation purposes. Loads may only be
deposited or stored at the intended places.
In operating areas with magnetic fields that
have a magnetic flux density greater than
5 mT, unintentional truck and lift mast move-
ments cannot be entirely excluded under un-
favourable circumstances. Components devel-
oped especially for use in such operating
areas must be used.
Driving routes
Driving routes shall be sufficiently paved, level
and free of objects. Drain channels and rail-
ways crossings, etc., shall be levelled and, if
necessary, covered with ramps in such a way
that they can be driven over without bumps as
far as possible.
Industrial trucks shall only be used on routes
without sharp curves, excessive slopes and
gates which are too narrow or too low.
Inclines used by industrial trucks shall not ex-
ceed the limits specified by the manufacturer
and must have an adequately rough surface.
Level and smooth transitions at the upper and
lower end shall prevent the load from touching
the floor or causing damages to the chassis.
The admissible area and point load of driving
lanes or routes may not be exceeded. There
shall be an adequate clearance between the
highest parts of industrial trucks or the load
and the fixed parts of the surrounding areas.
The EU Directive 89/654/EEC (Minimum Reg-
ulations for Health and Safety at Work) shall
be observed. The respective national regula-
tions apply for non-EU countries.
Danger points on driving lanes or routes shall
be secured or marked by the customary road
traffic signs and by additional warning signs, if
necessary.
When driving on public roads, the correspond-
ing regulations must be observed, as well as
country-specific restrictions for winter road
conditions.
Fire protection
The operating company is responsible for ade-
quate fire protection in the vicinity of the indus-
trial truck. Depending on the form of use, it is
responsible for additional fire protection on the
industrial truck. Enquiries should be directed
to the responsible supervisory authority in
case of doubt.
Introduction
1
Intended use
4 60138011501 EN - 10/2020

Attachments
Attachments shall only be used as permitted.
The driver shall be instructed in the handling
of attachments.
The attachment operating instructions are en-
closed for trucks that are delivered from the
factory with an attachment. Before commis-
sioning a truck with an attachment, you must
check that loads are handled securely. De-
pending on the type of attachment, it may be
necessary to make adjustments, e.g. pressure
settings or adjusting stops and operating
speeds. See the attachment operating instruc-
tions for the corresponding instructions.
If attachments are not supplied with the indus-
trial truck, the specifications of the industrial
truck manufacturer and the attachment manu-
facturer must be observed.
The attachments and the connection of power
supplies for powered attachments may only be
made by specialists in accordance with the
specifications of the manufacturer. The proper
functioning of the attachments shall be
checked after each installation before initial
use.
The permissible carrying capacity of the at-
tachments and the permitted load of the indus-
trial truck (carrying capacity and load moment)
combined with the attachments shall not be
exceeded., refer to additional capacity rating
plate.
Modifications, in particular attachments or
conversions, are not permitted to be made to
the industrial truck without the manufacturer’s
approval.
Trailers
Industrial trucks may only be used to tow trail-
ers if they are intended for this purpose by the
manufacturer and if they are fitted with the ap-
propriate trailer coupling. The maximum towed
load specified in the operating instructions for
unbraked or braked trailers must not be ex-
ceeded.
The towing industrial truck must be operated
in such away that safe driving and braking of
the towed vehicle is ensured for all driving
movements.
Impermissible use
DANGER
High risk of property damage, injury and death.
Avoid impermissible use.
The operating company or driver, and not the
manufacturer, is liable if the truck is used in a
manner that is not permitted.
The following list is exemplary and is not in-
tended to be exhaustive.
It is not permitted:
●
To use the truck to transport people (if the
truck is not designed for this purpose)
●
in areas where there is a risk of fire of ex-
plosion
●
for stacking/unstacking operations on
slopes
●
To stand on the fork arms when raised
●
To exceed the truck's maximum load ca-
pacity
●
To increase the truck's load capacity, e.g.
by attaching an additional weight.
Introduction
1
Impermissible use
560138011501 EN - 10/2020

Description of use and climat-
ic conditions
●
Indoor and outdoor use
●
Ambient temperature of -15°C ~ +45°C
Symbols used
The terms DANGER, WARNING, CAUTION,
NOTE and ENVIRONMENT NOTE are used
in these operating instructions. They are inten-
ded to draw attention to specific dangers or
unusual information that needs to be highligh-
ted:
DANGER
Means that failure to comply can risk the lives of
others and/or cause major damage to equipment.
WARNING
Means that failure to comply can result in the risk of
serious physical injury and/or major damage to
equipment.
CAUTION
Means that failure to comply can result in the risk of
major damage to equipment or destruction.
NOTE
This means that particular attention must be
paid to the specific technical meaning be-
cause this may not be obvious, even to a spe-
cialist.
ENVIRONMENT NOTE
The instructions listed here must be complied
with otherwise environmental damage may re-
sult.
CAUTION
This label is found on the truck in the
areas where particular care and atten-
tion are required from the operator.
Refer to the appropriate section in these
operating instructions.
For your safety, additional symbols are also
used. Please take these different symbols into
consideration.
Introduction
1
Description of use and climatic conditions
6 60138011501 EN - 10/2020

CE labelling
The manufacturer uses CE labelling to indi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus inva-
lidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the re-
sponsible authorities.
CE-Symbol

Introduction
1
CE labelling
760138011501 EN - 10/2020

EMC – Electromagnetic compatibility
Electromagnetic compatibility (EMC) is a key
quality feature of the truck.
EMC involves
●
limiting the emission of electromagnetic in-
terference to a level that ensures the trou-
blefree operation of other equipment in the
environment.
●
ensuring sufficient resistance to external
electromagnetic interference so as to guar-
antee proper operation at the planned us-
age location under the electromagnetic in-
terference conditions to be expected there .
An EMC test thus firstly measures the electro-
magnetic interference emitted by the truck and
secondly checks it for sufficient resistance to
electromagnetic interference with reference to
the planned usage location . A number of
electrical measures are taken to ensure the
electromagnetic compatibility of the truck .
CAUTION
The EMC regulations for the truck must be observed.
When replacing truck components the protective
EMC components must be installed and connected
again.
Introduction
1
EMC – Electromagnetic compatibility
8 60138011501 EN - 10/2020

EC declaration of conformity in accordance with Machinery Di-
rective
declaration of conformity
(lift trucks with internal combustion engines with a load capacity of≤10.000 kg)
EC / EU declaration of conformity
KION Baoli (Jiangsu) Forklift Co., Ltd.
No.8 Xinzhou Road, Economic Development Zone
214500, Jingjiang,China
We declare herewith that the machine
Industrial truck model:
IC Counterbalance Forklift Truck
Model: See EC declaration of conformity
Serial No.: See EC declaration of conformity
conforms to EC Machinery Directive 2006/42/EC in the latest valid version and to EMC Direc-
tive 2014/30/EU in the latest valid version, as determined for industrial trucks in the harmon-
ised standard EN 12895: 2015. In addition we declare, that radio equipment , if any, installed in
this machine, conforms to RED Directive 2014/53/EU in the latest version.
This declaration of conformity is issued under the sole responsibility of the manufacturer.
Person authorised to compile the technical file in accordance with the named directives.
See EC declaration of conformity
In addition, we hereby declare that the equipment conforms to the requirements of the Direc-
tive for Noise Emissions 2000/14/EC. The conformity was verified by the conformity assess-
ment procedure described in Annex V.
Measured sound power level LWA : dB
Guaranteed sound power level LWA : dB
Jingjiang, (date)
See EC declaration of conformity See EC declaration of conformity
Product Development Director Quality Manager
Introduction
1
EC declaration of conformity in accordance with Machinery Directive
960138011501 EN - 10/2020

Introduction
1
EC declaration of conformity in accordance with Machinery Directive
10 60138011501 EN - 10/2020