KION Baoli D Series Original Instructions Manual Download

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Original instructions

D series Forklift Truck

KBD50–70

Summary of Contents for Baoli D Series

Page 1: ...Original instructions D series Forklift Truck KBD50 70 ...

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Page 3: ...e 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 adv...

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Page 5: ...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 Hydraul...

Page 6: ...ormance 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 eng...

Page 7: ... 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 S...

Page 8: ...t 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 ...

Page 9: ...le 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 dr...

Page 10: ...ting 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 Doosa...

Page 11: ...1 Introduction ...

Page 12: ...e 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 ...

Page 13: ...nd 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...

Page 14: ...s 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...

Page 15: ...ll 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 to...

Page 16: ...uipment 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 th...

Page 17: ...ed 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 7 60138011501 EN 10 2020 ...

Page 18: ...he 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 regul...

Page 19: ... 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 th...

Page 20: ...Introduction 1 EC declaration of conformity in accordance with Machinery Directive 10 60138011501 EN 10 2020 ...

Page 21: ...2 Safety ...

Page 22: ... of symptoms that require checks to be carried out such as based on the results of a hazard assessment or a daily inspec tion Recent professional involvement in the field of the industrial truck test in question and an appropriate further qualification are es sential The qualified person must have ex perience of carrying out the test in question or of carrying out similar tests Moreover this perso...

Page 23: ...id footwear should be worn to ensure safe driving and braking The driver must be familiar with the operating instructions and have access to them at all times The driver must have read and understood the operating manual have familiarised himself with safe opera tion of the truck be physically and mentally able to drive the truck safely DANGER The use of drugs alcohol or medications that affect re...

Page 24: ... the truck and noti fy the authorised service centre Maintain appropriate distances from high voltage overhead cables Comply with the safety distances established by the compe tent authorities Never raise loads using just one fork arm Position the load on the fork carriage or in such a way that the centre of gravity of the load is as close as possible to the fork car riage The load must be positio...

Page 25: ...ing the truck In order for the truck to be used suitable ground must have the following characteris tics Even and level Hard Sturdy Free of obstacles Properly prepared for the purpose Safety Regulations Relative to Forklift Use The operator must familiarize himself with the forklift to be able to better describe any defects and assist maintenance personnel The operator trained and authorized to us...

Page 26: ... safety regulations Unrepaired damage or defective and worn components Insufficient maintenance and testing Use of incorrect consumables Exceeding test intervals The manufacturer is not held responsible for accidents involving the truck caused by the failure of the operating company to comply with these regulations either intentionally or carelessly Stability The stability of the truck has been te...

Page 27: ...an exces sive volume during travel or when handling loads can affect the operator s attention There is a risk of acci dent Do not use devices during travel or when handling loads Set the volume so that warning signals can still be heard WARNING In areas where use of mobile phones is prohibited use of a mobile phone or radio telephone is not per mitted Switch off the devices Visibility when driving...

Page 28: ... springs Gas springs are complex components that are subject to high internal pressures up to 300 bar They may under no cir cumstances be opened unless instructed to do so and may be installed only when not under pressure If required the authorised service centre will de pressurise the gas spring in accordance with the reg ulations before removal Gas springs must be dep ressurised before recycling...

Page 29: ... truck and are hazardous to your health Do not allow the fluids to come into contact with the skin Avoid inhaling spray Penetration of pressurised fluids into the skin is particularly dangerous if these fluids escape at high pressure due to leaks in the hydraulic system In case of such injury immediate medical assistance is required To avoid injury use appropriate per sonal protective equipment e ...

Page 30: ...id contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly when combined with water Spilt oil should be removed immediately with oil binding agents and disposed of according to the regulations ENVIRONMENT NOTE Oil...

Page 31: ...pilt battery acid with plenty of water Follow the statutory regulations ENVIRONMENT NOTE Dispose of used battery acid in line with the applicable regulations Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair main tenance and cleaning must be collected prop erly and disposed of in accordance with the national regulations for the country in which the truck is being use...

Page 32: ...osed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste man agement company for disposal purposes Safety 2 Environmental considerations 22 60138011501 EN 10 2020 ...

Page 33: ...following sound pres sure level Continuous sound pressure level in the driv er s compartment Model Continuous sound pressure level in the driver s compart ment Measured sound pow er level Guaranteed sound power level LpAZ Measurement uncertainty KpA EN12053 2000 14 EC KBD 50 85 dB A 4 dB A 109 dB A 111 dB A KBD 60 85 dB A 4 dB A 110 dB A 111 dB A KBD 70 86 dB A 4 dB A 110 dB A 111 dB A The values ...

Page 34: ...tion on the seat Weighted effective value of ac celeration to which the body feet or seat surface is subjec ted Measurement uncertainty KBD 50 70 Seat 0 9 m s2 0 3 m s2 Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel or the operating devices in trucks is less than 2 5 m s2 There are therefore no measure ment guidelines for these measurements The persona...

Page 35: ...3 Overview ...

Page 36: ...General View Mast Overhead guard Towing pin Steering wheels Driving wheels 1 2 3 4 5 Counterweight Load backrest Forks Engine hood 6 7 8 9 Overview 3 General View 26 60138011501 EN 10 2020 ...

Page 37: ...h Lifting lowering operating lever Forward tilting back tilting operating lever Direction control switch 1 2 3 4 5 6 7 8 9 Horn button steering wheel Display instrument Steering column adjusting lever Side shift operating lever Button to stop the engine Fixtures operating lever Lamp switch 10 11 12 13 14 15 16 17 Overview 3 Operating controls 27 60138011501 EN 10 2020 ...

Page 38: ...lowering operating lever Forward tilting back tilting operating lever Direction control switch 1 2 3 4 5 6 7 8 9 Horn button steering wheel Display instrument Steering column adjusting lever Side shift operating lever Button to stop the engine Fixtures operating lever Lamp switch 10 11 12 13 14 15 16 17 Overview 3 Operating controls 28 60138011501 EN 10 2020 ...

Page 39: ... brake indicator Tyre pressure alarm indicator Neutral position indicator Battery charging indicator 1 2 3 4 5 Engine breakdown indicator Fault indicator Glow indicator Oil pressure indicator Right turn indicator 6 7 8 9 10 Overview 3 Display instrument 29 60138011501 EN 10 2020 ...

Page 40: ...tor light indicator light Glow indicator Seat indicator light 1 2 3 4 5 Right turn indicator Torque converter oil temperature indicator Engine oil pressure indicator Battery charging indicator light Parking brake indicator light 6 7 8 9 10 Overview 3 Display instrument 30 60138011501 EN 10 2020 ...

Page 41: ...ue converter oil temperature indicator Water separator light indicator light Left turn indicator 1 2 3 4 Neutral position indicator Parking brake indicator light Seat indicator light Right turn indicator 5 6 7 8 Overview 3 Display instrument 31 60138011501 EN 10 2020 ...

Page 42: ...osition indicator Battery charging indicator light Clogged air filter indicator light 1 2 3 4 5 6 7 DPF reprocessing indicator light High Ex haust System Temperature warning light Yellow light Fault indicator Glow indicator Engine oil pressure indicator DPF reprocessing stop indicator light Red light 8 9 10 11 12 Overview 3 Display instrument 32 60138011501 EN 10 2020 ...

Page 43: ...at are too light weight to guarantee stability G Traction motor power H Traction battery voltage I Nominal capacity Production number NOTE The production number is used to identify the truck It can be found on the nameplate and must be referred to in all technical questions The production number contains the following coded information 1 Production location 2 Model 3 Year of manufacture 4 Sequenti...

Page 44: ...wing coded information Line A 1 Production location 2 Product number of mast 3 Year of manufacture 4 Sequential number Line B 1 Mast information 2 Truck capacity 3 Mast type 4 Lifting height 5 Truck model Overview 3 Truck identification 34 60138011501 EN 10 2020 ...

Page 45: ...Location of decals NOTE The labels mentioned below are only for illus tration purposes please rely on the decals ad hering to your own truck Overview 3 Location of decals 35 60138011501 EN 10 2020 ...

Page 46: ... oil tank Decal information Adding coolant 1 2 3 4 5 6 7 8 9 10 11 12 Decal information Caution Danger due to shearing Warning sign Danger due to overheating of radiator Warning sign Danger due to shearing Danger to the driver s head with engine hood not fully closed Warning sign Do not allow water to inlet Warning sign Always lifting by lifting gear attachment point Warning sign Preventing water ...

Page 47: ...mp off if the truck is tipping over Brace feet Hold on tight Lean in the opposite direction to which the truck is tipping Manufacturer s name Decal information Forward Reverse 24 25 Overview 3 Location of decals 37 60138011501 EN 10 2020 ...

Page 48: ...Overview 3 Location of decals 38 60138011501 EN 10 2020 ...

Page 49: ...4 Operation ...

Page 50: ...rews must be tightened before starting the truck prior to testing and after each wheel replacement The wheel nuts should be tightened at least once every 100 operating hours The wheel screws must be tightened in a diagonal se quence Tightening torque Front tyres double front tyres Ball nut M30x1 5 1844 5 Nm Column nut M20x1 5 525 5 Nm Rear tyres Ball nut M20x1 5 525 5 Nm Operation 4 Instructions f...

Page 51: ...components installed on the truck Make sure that seat switch is working cor rectly Check that the brakes work correctly checking their travel and efficiency Check the tyre pressure and wear condi tions Visually inspect wheels for correct tight ness Make sure that the lights work correctly if applicable Visually check that the chains are taut Make sure that the start stop key works cor rectly Check...

Page 52: ...k the condition of the belt pull the seat belt 1 all the way out of the retractor 2 and check the seat belt for damage CAUTION The seat belt must be replaced if it is cracked worn or has been damaged in an accident Carefully check the connection between the seat belt and the seat Carefully check the connection between the seat and the panel cover below Operation 4 Checks and inspection 42 60138011...

Page 53: ... alarming in 3 sec onds Check the wheel nuts for correct tightness Visually check the markings in the wheel nuts and rims are correctly attached re tighten with torque spanner if necessary Tightening torque Front tyres double front tyres Ball nut M30X1 5 1844 5 N m Column nut M20X1 5 525 5 N m Rear tyres Column nut M20X1 5 525 5 N m Visually check if the column is deformed or whether the hole for ...

Page 54: ... the rims and nuts Re tighten with torque spanner if gap exits Check the wheels and rims for wear and deformation change the tyres if there is any deformation Check the condition and operation of chain Check load chains for any distortion before operation Operation 4 Checks and inspection 44 60138011501 EN 10 2020 ...

Page 55: ...before operation Lift and lower the lifting mast without load for one round to check the operation of lift ing chain for any abnormal sound or block Contact your service center if chains are suffering abnormal force Operation 4 Checks and inspection 45 60138011501 EN 10 2020 ...

Page 56: ...or use naked flames while refuelling Open the engine hood Remove the fuel tank cap 1 and refuel Close the fuel tank cap 1 Close the engine hood Diesel fuel Specifications CAUTION Risk of component damage if non approved fuels are used Use only approved fuels with the following specifica tions If non approved fuels are used compliance with specified emission values and the service life of the engin...

Page 57: ...ot to exceed 0 35 by volume Less than 0 1 is prefer red Total aromatics content should not exceed 35 by volume Less than 30 is prefer red PAH polycyclic aromatic hydrocarbons content should be below 10 by volume Metal content of Na Mg Si and AI should be equal to or lower than 1 mass ppm Test analysis method JPI 5S 44 95 Lubricity Wear mark of WS 1 4 should be Max 0 018 in 460 μ m at HFRR test NOT...

Page 58: ...en engine life Prevent dirt and debris from contaminating engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine cool ants This may adversely affect the proper ties of the engine coolant Engine coolant specifications Use a Long Life Coolant LLC or an Extended Life Coolant ELC that meets or exceeds the following guideli...

Page 59: ...ting dismounting the forklift First place your left foot on the step Grip the handrail or overhead guard beam and mount the truck from the left hand side Use the step and handrail or overhead guard beam to dismount from the left hand side CAUTION Do not mount or dismount the truck from the right hand side unless it is an emergency Operation 4 Climbing on off the forklift 49 60138011501 EN 10 2020 ...

Page 60: ...ings have all engaged properly Do not place any objects in the driver s ro tation range Pull the handle 1 to make horizontal ad justments to the driver s seat Slide the driver s seat to find the best oper ating position relative to the steering wheel the accelerator and braking pedals and the joystick NOTE Remaining in a sitting position for long periods of time puts a great amount of pressure on ...

Page 61: ...ged Adjusting the seat backrest Do not put pressure on the seat backrest while engaging it Turn the knob 2 clockwise Move the backrest forwards and backwards until the driver finds the best sitting position Release the knob Optional part Seat belt DANGER Fasten your seat belt when using the forklift truck The seat belt may only be used by one person Operation 4 Seat belt 51 60138011501 EN 10 2020 ...

Page 62: ...t belt is not locked ask a quality technician to check the problem Unfastening the seat belt Press the red button 4 on the seat belt socket 1 and release the seat belt buckle Hold the seat belt to make it return to the retractor DANGER Do not fasten the seat belt over hard or fragile items in the driver s pockets as this may result in unexpected accidents Do not place items between the body and th...

Page 63: ...r then stops working The key will automatically return back to Ⅰ postion with the function of spring force when removing hands from key CAUTION Do not keep the ignition switch in the I position while the engine is shut down This results in a discharged battery When the engine is working do not switch the starter switch to the II position otherwise starter motor will be in danger of being damaged D...

Page 64: ...th low visi bility Press the horn button 1 on the steering wheel to sound the horn Direction indicator light switch CAUTION Direction indicator light switch cannot automatically return to the Neutral position which is different of general passenger cars Reset it manually R Turn Right N Neutral L Turn Left Operation 4 Switches 54 60138011501 EN 10 2020 ...

Page 65: ...hen hot exhaust gas is vented from the engine Ensure that there is no combustible material around the exhaust pipe DPF reprocessing request indicator light The DPF reprocessing request indicator light 1 will flash when forced or service regenera tion is needed This light will come on when starting forced or service regeneration When the driver disables regeneration this in dicator light 2 will app...

Page 66: ...nly adjust the steering column when the truck is stationary Angle adjustment Pull down the handle 1 clockwise Move the steering column into the required position Pull back the handle anti clockwise to its original position DPF forced regeneration switch DPF regeneration disabled switch 1 2 Operation 4 Adjusting the steering column 56 60138011501 EN 10 2020 ...

Page 67: ...etailed informat NOTE When the ignition switch is turned on the dis play unit will perform a self test during which the whole of the display screen will illuminate for about 2 seconds The following display elements will illuminate the battery charging indicator oil pressure warning light Wait until the preheat indicator goes out Turn the ignition key to the Ⅱ position After the engine starts Immed...

Page 68: ...herefore only permitted when looking directly behind you CAUTION Always tilt the mast backwards and lower the fork arms to the ground around 300mm 400mm CAUTION Check the safety around the forklift and sound the horn before starting the truck Sit in the driver s seat and fasten the safety belt Start the engine Operation 4 Driving 58 60138011501 EN 10 2020 ...

Page 69: ...ightly tilt the lift mast backwards Release the parking brake 1 and the cor responding LED will turn off Move direction selection lever 2 in the re quired drive direction A FORWARDS B BACKWARDS Operation 4 Driving 59 60138011501 EN 10 2020 ...

Page 70: ...celerator pedal The speed of the forklift truck accelerates in relation to the increase in pedal travel Reversing Place the direction lever in the reverse di rection Steadily press the accelerator pedal The speed of the forklift truck accelerates in relation to the increase in pedal travel Operation 4 Driving 60 60138011501 EN 10 2020 ...

Page 71: ...ction of the forklift truck during operation is strictly prohibited Reversing direction during opera tion will result in damage to the forklift truck Inching control NOTE The inching control is only available for forklift with hydraulic torque convertor drive type Used in conjunction with the accelerator ped al the inching control pedal 1 enables the driver to carry out precise and flexible truck ...

Page 72: ...ient of more than 15 When parking on an incline apply the parking brake 5 Fully depress the drive brake pedal 2 Place the direction lever 4 in the neutral di rection Apply the parking brake 5 Move the direction lever to forward position Smoothly and gradually release the drive brake pedal Release the parking brake and the truck will now move without rolling backwards Operation 4 Driving 62 6013801...

Page 73: ...e steering wheel to be turned with minimum ef fort Its advantages are more apparent when operating in narrow aisles Start the engine and switch on the forklift Turn the steering wheel to the limit stop in both directions If sufficient force is applied to the steering wheel the steered wheels can be turned while the truck is stationary without the position of the wheels changing on the steering axl...

Page 74: ... pedal The accelerator pedal 1 increases the engine speed With this pedal released the engine runs at idle rpm Driving brake pedal Press the brake pedal 2 to slow or stop the truck At the same time the brake lights come on Inching pedal while the inching pedal 3 is pressed the oil pressure in the hydraulic clutch drops accord ingly the needle of the oil pressure gauge swings to the left allowing t...

Page 75: ...Pull down the parking brake lever 1 until the lock position is reached and the parking brake indicator light comes on Releasing the parking brake Release the parking brake lever 1 The parking brake will return to its original posi tion and the parking brake indicator light will turn off DANGER The forklift truck must not be operated if there are problems with the braking system If there is a fault...

Page 76: ...ifting system and at tachments Keep in mind the maximum lift height Take note of the switching symbols with ar rows Operation of the control lever must be slow and steady Lifting lowering and tilting speeds depend on the range of motion of the control level The control lever will automatically return to neutral when released Lifting the fork carriage DANGER If any danger occurs when raising the li...

Page 77: ...ors clips etc Please do not ex ceed the working pressure of attachments dur ing operation and ensure that operation is in compliance with datasheets One or two addi tional control levers can be installed to operate attachments NOTE Below is a description of attachment opera tions The forklift truck can be configured with different operating levers Take note of the switching symbols with ar rows Op...

Page 78: ...n the ground Push the control lever 3 forwards and move to the left Push the control lever 3 backwards and move to the right Operating fixtures Push the control lever 4 forwards to open the jig Push the control lever 4 backwards to clamp the jig Operation 4 lifting system and attachments 68 60138011501 EN 10 2020 ...

Page 79: ...E The centre of gravity of a load is not necessa rily located at the central point of the load it self The load capacity refers to the weight of goods able to be lifted to a specified height within a given load centre distance NOTE Check the load limits In the following circum stances please contact your authorised Baoli dealer before operating Before lifting irregular loads or goods that sway Whe...

Page 80: ...ake sure that the dimen sions and weight of the load are within the approved standard specified in the Techni cal parameters chapter and on the load rat ing plate Before operating an attachment read the load capacity data plate on the attachment Picking up a load DANGER Do not use the fork arms or pallet to lift a person Operation 4 Handling loads 70 60138011501 EN 10 2020 ...

Page 81: ...est or install a guard grille on the overhead guard DANGER Overload danger Strictly adhere to the permissible load indicated on the load rating plate DANGER When a load is raised it is not permitted for anyone to stand beneath the suspended cargo Always keep the load lowered and the mast tilted backwards when driving industrial forklift trucks Transporting pallets As a rule loads e g pallets must ...

Page 82: ... ped al Apply the parking brake and set the direc tion lever to neutral position Place the lift mast in the vertical position Raise or lower the fork carriage to the cor rect height Operate the sideshift if needed Release the parking brake and at the same time fully depress the service brake inching control pedal Set the direction lever in the forward direc tion Using the service brake inching con...

Page 83: ...ke the fol lowing precautions when handling hot molten loads Drive the truck at low speed and exercise caution when braking steering and acceler ating so as to avoid spilling the hot solution Do not drive on slopes when handling a hot molten load When necessary limit the mast lowering speed Travel with the forks tilted back slightly and the load as low as possible to the floor ap proximately 30cm ...

Page 84: ...ping over the load wheels or drive wheels Tipping the truck at right angles to the direc tion of travel Risk of crushing of guide persons Reduced visibility DANGER Loss of stability Slipping or swinging suspended loads can lead to a loss of stability and cause the truck to tip over When transporting suspended loads observe the following instructions Instructions for transporting suspended loads Sw...

Page 85: ... as hanging loads is not permitted Driving on loading bridges DANGER Risk of accident if the truck crashes Steering movements can cause the tail end to veer off the loading bridge towards the edge This may cause the truck to crash The lorry driver and the truck driver must agree on the lorry s departure time Before driving across a loading bridge ensure that it is properly attached and secured and...

Page 86: ...ching control ped al Apply the parking brake and set the manual direction lever to neutral Place the lift mast in the vertical position Raise the fork carriage to the correct height Operate the sideshift if needed Release the parking brake and at the same time fully depress the service brake inching control pedal Set the manual direction lever in the for ward direction Using the service brake inch...

Page 87: ...goods DANGER Do not leave the truck while the load is raised Towed load DANGER There is an increased risk of accident when using a trailer Using a trailer changes the truck handling character istics When towing operate the truck such that the trailer train can be safely driven and braked at all times The maximum permissible speed when towing is 5 km h Do not exceed the permissible speed of 5 km h ...

Page 88: ... damage to components The maximum towed load only applies when towing unbraked trailers on a level surface maximum devia tion 1 and on firm ground The towed load must be reduced if towing on gradients If necessary notify the authorised service centre of the application conditions The service centre will provide the re quired data Inform the authorised service centre CAUTION Risk of damage to compo...

Page 89: ... forks if necessary so they will not drag dur ing towing Otherwise remove the forks from the carriage Attach the towing vehicle to the truck at the coupling pin 1 using a towing bar After connection ensure that the coupling pin is fully inserted through both of its bores in the counterweight Release the parking brake A driver must steer the truck during towing NOTE Power assistance will not be ava...

Page 90: ...e truck components Strictly adhere to the following steps Only use high pressure cleaners with a maximum output power of 50 bar and at a maximum temperature of 85 C When using high pressure cleaners make sure there is a distance of at least 20 cm between the nozzle and the object being cleaned Do not aim the cleaning jet directly at adhe sive labels or information signs DANGER Risk of fire Deposit...

Page 91: ...ts with wa ter can damage the electrical system Cleaning electrical system parts with water is forbidden Use dry cleaning materials in accord ance with the manufacturer s specifi cations Do not remove covers etc Clean the electrical system parts with a metal free brush and blow the dust off with low pressure compressed air Cleaning lifting chains WARNING Risk of accident Lifting chains are safety ...

Page 92: ... g with com pressed air Sit in the driver s seat and start up the truck in accordance with the regulations CAUTION Risk of short circuits If any moisture has penetrated into the electrical system despite the precautionary measures tak en the system must first be dried using com pressed air Before exiting the truck Before exiting the truck lower the forks to the ground tilt the mast forwards Apply ...

Page 93: ...nsure that no personnel are in the vicinity of the crane Comply with the load capacity rating marked on the crane nameplate Never walk under a suspended load CAUTION Use a spreader and crane with sufficient load capaci ty to lift the truck For the weight of the truck see the manufacturer s nameplate NOTE Before hoisting the truck fasten the slings to the given lifting points These lifting points a...

Page 94: ...truck clean it thor oughly and perform inspection as the following procedures Wipe away grease oil etc covering the body of the truck with waste cloth if needed While washing the body of the truck check general condition of the truck Especially check the truck s body for recess or dam age and tires for wear and nails or stones in the tread Fill the oil tank with the appointed fuel Check for leakag...

Page 95: ...l Perform pre operation checks carefully Check coolant level and replenish if neces sary Start the engine and warm up thor oughly before operation WARNING At any time your lift truck is found to be in need of re pair defective or in any way unsafe the condition should be reported to be supervisor immediately and the truck should be taken out of service until it has been restored to safe operating ...

Page 96: ...el AdBlue urea solution engine oil cooling fluid hydraulic oil and fluids from air conditioning systems The following parts are to be collected sep arately and recycled catalytic converters metal components containing copper and aluminium tyres large plastic components consoles fluid containers and glass NOTE The operating company is responsible for ad herence to the directives as well as addition...

Page 97: ...5 Maintenance ...

Page 98: ...garding the use handling and disposal of fuel and lubricat ing oil General information In order to keep the forklift truck in good work ing condition it must undergo regular service and maintenance All service and mainte nance operations such as oil changes must be performed strictly in accordance with the indications below Maintenance work must be recorded in the warranty booklet Please re tain m...

Page 99: ...and remove the ignition key When maintenance needs to be carried out under the lifted fork carriage and mast measures must be taken to prevent the fork carriage or mast from accidentally falling When work needs to be carried out at the front end of the forklift truck the mast should be secured to prevent backwards tilting DANGER The negative electrode of the rechargeable battery must be disconnect...

Page 100: ...aking sys tem Brake fluid Hydraulic brake so hydraulic oil ok Bearings lu bricating grease fit tings Lubricating grease NLGL 2 lithium grease 0 07KG Cooling sys tem Coolant fluid LLC PD 2A See section En gine coolant Specifications Weichai WP4 1 Radiator water tank 26L Cummins QSB4 5 Radiator water tank 24L ISUZU 6BG1QC 02 Radiator water tank 24L Compensation box 2 5L Doosan D34 Radiator water tan...

Page 101: ...ter or re place filter element Check the coolant and add enough capacity Replace coolant Once a year Fasten cooling pipe clamp Fasten the air intake pipe hose and flange connector Check air filter maintenance lamp or indicator Clean the air filter dust cup automatic dust discharge type excepted Change air filter main element See vehicle manual for details Change air filter safety ele ment After th...

Page 102: ...el filter element replacement 12 Feed pump strainer cleaning 13 injection nozzle check 14 Coolant level and fouling check 15 Coolant leakage check 16 Radiator filler cap fitting condition 17 Fan belt tension check Replace if necessary 18 Coolant temperature registration 19 Coolant replacement every 6 months 20 Radiator external face cleaning 21 Cooling system circuit cleaning 22 Radiator filler ca...

Page 103: ...lter element replacement 31 Engine starting conditions and noise conditions 32 Exhaust smoke condition 33 Cylinder compression pressure 34 Valve clearance check Maintenance 5 Preventive maintenance service schedule 93 60138011501 EN 10 2020 ...

Page 104: ...eatment Exhaust Piping Check Air Intake Piping Check Maintenance Procedures at 250 Hours or 3 Months Radiator Hoses Check Air Intake Piping Check Radiator Check Charge Air Cooler Check Charge Air Piping Check Maintenance Procedures at 500 Hours or 6 Months Fuel Filter Spin On Type Change Lubricating Oil and Filters Change Engine Coolant Antifreeze Check Batteries Check Battery Cables and Connectio...

Page 105: ...e Procedures at 2000 Hours or 2 Years Vibration Damper Viscous Check Vibration Damper Rubber Check Engine Steam Cleaning Clean Crankcase Breather External Check Cooling System Flush Maintenance Procedures at 2000 Hours Crankcase Ventilation Filter Change Maintenance Procedures at 5000 Hours or 4 Years Overhead Set Adjust Maintenance 5 Preventive maintenance service schedule 95 60138011501 EN 10 20...

Page 106: ...urs Cooling fan belt tension Inspect every 1 000 hrs or 6 months and replace if re quired Replace every 3 000 hrs or 3 years Lubrication syste Lubricating device and oil leakage Capacity and condition of en gine oil Engine oil filter Engine oil API CJ 4 Fuel system Fuel line and connection unit Fuel volume Water draining from water separator Fuel injection time Inspect and adjust if required Injec...

Page 107: ...concentration of antifreeze and ad ditives NOTE Service interval varies depending on engine oil diesel fuel quality and operation condi tions Determine service intervals by analyzing the engine oil properties under working condi tions after analyzing the result of the test 1 000 hr interval is only for the customer who get the confirmation from DI for the machine usage profile Maintenance 5 Preven...

Page 108: ...iskid device of the whole truck replace if necessary Driving power system First 50H Every 250H Every 500H Every 1000H Yes No Check the abnormal noise of the trans mission and driving wheel and if any oil leakage Check the gearbox oil level of the driving wheel re fill or change if necessary Check the mechanical linkage of brake assy is tightly fitted and without any abrasion Check and inspect if t...

Page 109: ...tus of the display unit and fault code if any Check the battery voltage and the con dition tightness of cables and connec tions Check if the engine starts normally Check if the operation condition of alter nator is normally Check the tightness of fuses and con nections Check if emergency power off switch is functioning properly Check the warning light horn head lights signal lamp are operating cor...

Page 110: ...nd respi rator if fitted Check the gear pump for correct assem bly any damage or oil leaks Check valve for proper function and oil leakage Load lifting system First 50H Every 250H Every 500H Every 1000H Yes No Check the mast for abrasion and defor mation replace if necessary Check forks and fork carriage for abra sion and damage Check the load backrest for correct in stallation and damage Check th...

Page 111: ...f attachments and fittings Check hydraulic pipes and connection of the attachments Lubricate the attachments Lubrication and Cleaning First 50H Every 250H Every 500H Every 1000H Yes No Lubricate the forklift according to the lu brication chart Clean the forklift thoroughly Testing First 50H Every 250H Every 500H Every 1000H Yes No Carry out a functional test and test drive NOTE The maintenance wor...

Page 112: ...itants such as salt water fertilizer or chemical products it needs to be thoroughly cleaned after each use Compressed air and a mixture of cold water and detergent may be used for cleaning CAUTION Do not direct water jets at the truck Do not use sol vents or petrol based fluids for cleaning as this may damage electrical components or plastic parts Maintenance 5 Preparations 102 60138011501 EN 10 2...

Page 113: ...affect lubrication Avoid overfilling Overfilling may result in white smoke overspeed or internal damage CAUTION Please pay attention to environmental protection Dispose of used oil according to related laws and regulations Failure to comply with laws and regula tions will result in serious damage to the environ ment Comply with EPA guidelines or government meas ures for the correct handling of haz...

Page 114: ...e oil cap 1 Add the specified amount of oil into the oil filler on the side of the upper part of the en gine Wait three minutes and check the oil level Add more oil as necessary Replace the oil cap and tighten by hand Over tightening may damage the cap Check the engine oil level NOTE The oil level must be checked before starting the engine or at least 10 or 20 minutes after the engine is shut down...

Page 115: ...intenance data table Add Oil to the max oil level if the oil level is below the Min level Fully re insert the dipstick Close the bonnet Changing the engine oil filter Remove the oil filter 1 anti clockwise with a filter wrench Clean the mounting surface of the engine oil filter Lightly coat the new filter sealing ring with a thin layer of engine oil Hand fit the new filter to the filter cover and ...

Page 116: ...uring installation and that it is installed in the cor rect direction Install the filter insert back into the air filter housing 3 Reinstall the air filter cover NOTE Make sure to replace the air filter insert every 12 months or after 6 cleanings Cleaning the air filter insert Please note that the air filter shown in the fig ure is for illustration purposes only Clogged filter inserts may have an ...

Page 117: ...ng debris compressed air or pressurised water or gas from damaging your eyes Failure to follow this instruction may result in injury If the filter insert is damaged heavily soiled or oily replace it with a new insert CAUTION The air filter insert requires more frequent cleaning when the engine is running in dusty environments Clean the inside of the air filter head cover 1 Fit the filter insert 2 ...

Page 118: ...comply with laws and regula tions will result in serious damage to the environ ment Comply with EPA guidelines or government meas ures for the correct handling of hazardous materials such as oil diesel and engine coolant Irresponsible handling of hazardous materials such as dumping hazardous waste into water channels on the ground into groundwater or drainage ditches is prohibited Carry out the fo...

Page 119: ...the engine check to see that the fuel filter indicator light in the instrument has turned off CAUTION Perform the Fuel system air bleeding after the water in the fuel is drained Replacing the fine fuel filter Remove the old fuel filter element 1 Apply lubricating oil on the sealing port Tighten the filter by hand until the sealing surface is secured with the interface Continue tighten the filter b...

Page 120: ...njury CAUTION Please pay attention to environmental protection Waste engine oil should be disposed of in accord ance with relevant laws and regulations Non compli ance may cause serious damage to the environment Comply with EPA guidelines or other government measures for correct disposal of hazardous materials such as engine oil diesel and coolant Please con tact your local authority or recycling ...

Page 121: ...ut in the cold state Clean and check the injection noz zle Visually inspect the injector and nozzle pro tection for clogging or damage Clean or re place if necessary If necessary use an injection nozzle tester to check the static injection starting pressure and the fuel spray conditions When the injection starting pressure is too high or too low or the fuel spray pattern is im proper an abnormal f...

Page 122: ...arefully to avoid damage Do not use hard metal tools to clean the valve needle Check for burrs damage rust and wear paying attention to the body and seat of the valve needle After thoroughly cleaning the valve needle insert it into the nozzle body checking whether the valve needle is able to slide down by its own gravity Maintenance 5 Weichai WP4 1 Engine 112 60138011501 EN 10 2020 ...

Page 123: ...affect lubrication Avoid overfilling Overfilling may result in white smoke over speed or internal damage CAUTION Please pay attention to environmental protection Dispose of used oil according to related laws and regulations Failure to comply with laws and regula tions will result in serious damage to the environ ment Comply with EPA guidelines or government meas ures for the correct handling of ha...

Page 124: ...he oil cap 1 Add the specified amount of oil into the oil filler on the side of the upper part of the en gine Wait three minutes and check the oil level Add more oil as necessary Replace the oil cap and tighten by hand Over tightening may damage the cap Check the engine oil level NOTE The oil level must be checked before starting the engine or at least 10 or 20 minutes after the engine is shut dow...

Page 125: ...aintenance data table Add Oil to the max oil level if the oil level is below the Min level Fully re insert the dipstick Close the bonnet Changing the engine oil filter Remove the oil filter 1 anti clockwise with a filter wrench Clean the mounting surface of the engine oil filter Lightly coat the new filter sealing ring with a thin layer of engine oil Hand fit the new filter to the filter cover and...

Page 126: ... during installation and that it is installed in the cor rect direction Install the filter insert back into the air filter housing 3 Reinstall the air filter cover NOTE Make sure to replace the air filter insert every 12 months or after 6 cleanings Cleaning the air filter insert Please note that the air filter shown in the fig ure is for illustration purposes only Clogged filter inserts may have a...

Page 127: ...ing debris compressed air or pressurised water or gas from damaging your eyes Failure to follow this instruction may result in injury If the filter insert is damaged heavily soiled or oily replace it with a new insert CAUTION The air filter insert requires more frequent cleaning when the engine is running in dusty environments Clean the inside of the air filter head cover 1 Fit the filter insert 2...

Page 128: ...el Carry out the following steps to drain water in the fuel filter Loosen the drain plug and drain the sedi mented water Be sure to tighten the drain plug on comple tion of draining CAUTION Perform the Fuel system air bleeding after the water in the fuel is drained Fuel system air bleeding The entry of air into the fuel system will cause hard engine starting or engine malfunction When once the ser...

Page 129: ...ng action until no bubbles are visible in the flowing fuel No More bub ble in the fuel indicates that are bleeding is completed Tighten the bleeding screws and the feed pump knob on the completion of bleeding Start the engine and check the fuel system for fuel leak Feed pump strainer cleaning The strainer is incorporated in the feed pump inlet side joint bolt Clean the stainer with the compressed ...

Page 130: ...herwise prema ture belt wear would result because of uneven belt length Adjusting procedure Belt tension adjustment is made by pivoting the alternator at the alternator mounting bolt Loosen the alternator adjusting plate bolt 1 and the alternator mounting bolt Pivot the alternator at the mounting bolt to ward the engine left or right hand side as required Tighten the mounting bolt and adjusting bo...

Page 131: ... with poor quality will result in premature belt wear or belt elongation leading to engine damage such as overheat There fore use of genuine fan belts are highly recom mended Maintenance 5 Isuzu 6BG1 Engine 121 60138011501 EN 10 2020 ...

Page 132: ... regulations may result in death or serious injury CAUTION Only use designated oil Other types of oil may affect quality of use and shorten the service life of the en gine or internal parts Avoid contamination of the engine by dirt or dust Be fore removing the oil cap carefully clean the oil cap dipstick and surrounding areas Avoid mixing different brands of oil Mixing different brands of oil will...

Page 133: ... ditches is prohibited Drain the oil using the following steps Ensure that the engine is in a horizontal po sition Start the engine and run until it reaches op erating temperature Stop the engine Remove the oil cap to ventilate the crank case This is beneficial for bleeding the oil Place an oil pan under the engine to collect the used oil Remove the oil drainage plug 1 and allow the oil to flow in...

Page 134: ...ck the engine oil level NOTE The oil level must be checked before starting the engine or at least 10 or 20 minutes after the engine is shut down When the oil level is necessary while the engine is running stop the engine and keep it stationary 10 or 20 mins until the oil thoroughly flows down to the crankcase Ensure that the truck is parked in a horizon tal position Open the bonnet Maintenance 5 C...

Page 135: ... engine lubrication Only use engine oil in line with the maintenance data table Add Oil to the max oil level if the oil level is below the Min level Fully re insert the dipstick Close the bonnet Changing the engine oil filter Remove Clean the area around the lubricating oil fil ter head Use oil filter wrench to remove the filter Clean the gasket surface of the filter head NOTE The O ring can stick...

Page 136: ...al under the cap be careful to peel the seal back Puncturing the seal with a knife or sharp object can create debris in the oil container Install the filter on the oil filter head Tighten the filter until the gasket contacts the filter head surface Tighten 3 4 to 1 turn after the gasket makes contact with the filter head Change air filter insert Please note that the air filter shown in the fig ure...

Page 137: ...ct on engine performance Make sure to pe riodically clean the air filter insert Loosen the nut and remove the air filter head cover Pull out the air filter insert 1 Remove dust from the filter by blowing out ward through the filter using compressed air 2 Remove dust using minimum air pres sure in order to avoiding damaging the in sert CAUTION Flying object hazard Wear eye protection when carrying ...

Page 138: ... the inside of the air filter head cover 1 Fit the filter insert 2 in the air filter housing 3 Refit the air filter cover and tighten the air filter head cover onto the air filter housing Replacing the fine fuel filter Remove the old fuel filter element 1 Maintenance 5 Cummins QSB4 5 Engine 128 60138011501 EN 10 2020 ...

Page 139: ...s Cummins Inc requires a fuel water separator or fuel filter be installed in the fuel supply sys tem Drain the water and sediment from the sepa rator daily Spin on Type Shut off the engine Use your hand to open the drain valve Turn the valve counterclockwise approximately 3 turns until the valve drops down 25 4mm 1 in and draining occurs Drain the filter sump until clear fuel is visi ble CAUTION W...

Page 140: ...ged pipes and tighten loose clamps as necessary to prevent the air system from leaking Torque Value 8 n m 71 in lb Check for corrosion under the clamps and hoses of the intake system piping Corro sion can allow corrosive products and dirt to enter the intake system Disassemble and clean as required Maintenance 5 Cummins QSB4 5 Engine 130 60138011501 EN 10 2020 ...

Page 141: ... wipe the part of the oil level gauge with the reference line Insert the oil level gauge again CAUTION Wiping the engine oil gauge with a dirty cloth causes foreign matter to enter the engine and may lead to engine faults Remove the oil level gauge again and check the level and condition of the oil Check whether there is engine oil smeared between the upper limit A and lower limit B on the oil lev...

Page 142: ...or rags in your pock ets etc ENVIRONMENT NOTE Follow the regulations of the public institutions in your area when disposing of used oil Dumping engine oil on the ground in sewers drains rivers and seas etc can cause severe environmental contamination Disposing of en gine oil incorrectly without complying with treatment regulations can be punished as a vi olation of treatment regulations Remove the...

Page 143: ...r to enter the engine CAUTION Overfilling engine oil past the upper limit on the oil level gauge can cause faults in the engine If the en gine oil has been overfilled past the upper limit the engine oil must be drained until the engine oil is be tween the upper and lower limits on the oil level gauge CAUTION Do not use unspecified engine oil additives Install the oil filler cap after adding the en...

Page 144: ... the oil filter thoroughly Apply a thin layer of engine oil to the rubber packing B in the new oil filter A Temporarily mount the oil filter by turning it by hand Use a filter wrench to tighten the oil filter to a tightening torque of 16 20 N m Clean the air filter insert Clogged filter inserts may have an adverse im pact on engine performance Make sure to pe riodically clean the air filter insert...

Page 145: ...g compressed air or pressur ised water jets in order to prevent dust flying debris compressed air or pressurised water or gas from damaging your eyes Failure to follow this instruction may result in injury Clean the air filter element every 200 hours If the filter insert is damaged heavily soiled or oily replace it with a new insert CAUTION The air filter requires more frequent cleaning when the e...

Page 146: ... ing 6 Refit the air filter cover and tighten the air filter head cover onto the air filter housing Change the air filter Loosen the nut 1 anti clockwise and re move the air filter head cover 2 Maintenance 5 Doosan D34 Engine 136 60138011501 EN 10 2020 ...

Page 147: ... and inner air fil ter insert 5 back into the air filter housing 6 Reinstall the air filter head cover Disconnect the inlet hose form the air inlet When the engine is running cover the in take opening e g using cardboard or a metal plate The air filter blockage warning light in the display should light up To pre vent damage do not continue to block the intake opening after the warning light illumi...

Page 148: ...e with a new fuel filter CAUTION We recommend using the recommended genuine fuel filter Using imitation or recycled parts may cause severe engine faults and damage CAUTION Do not reuse the remaining fuel which was used in the previous fuel filter or fuel in the tank in the new fuel filter CAUTION New fuel filters must be assembled without any fuel in them Maintenance 5 Doosan D34 Engine 138 601380...

Page 149: ...h the fuel filter cap Turn the fuel filter 3 4 to tighten it Connect the water in fuel sensor connector to the fuel filter Keep the area around the fuel filter clean and free of foreign matter such as fuel Bleed the air from the fuel supply line Maintenance 5 Doosan D34 Engine 139 60138011501 EN 10 2020 ...

Page 150: ...filter counterclockwise to loosen it Turn the pump handle 2 counterclockwise to loosen it Pump the pump handle until fuel comes out of the air bleed valve Fix the pump handle in place Turn the air bleed valve 1 clockwise to tighten it Maintenance 5 Doosan D34 Engine 140 60138011501 EN 10 2020 ...

Page 151: ...ttom of the fuel filter to loosen it CAUTION Do not use a tool to loosen the drain valve Other wise the drain valve may be damaged Drain the water in the fuel filter with the drain valve 1 for around 10 seconds Maintenance 5 Doosan D34 Engine 141 60138011501 EN 10 2020 ...

Page 152: ...o inspect whether the pointer on the auto tensioner is in dicating that it is time for a replacement as well as whether there is any damage to the belt due to external factors Replace the belt set in the event that the pointer on the auto tensioner indicates that it is time for a replacement or cases where damage to the belt from external factors has been confirmed and there are concerns of se ver...

Page 153: ... cracks oil over heating and wear The PIN HOLE shown by the arrow is the pointer and the belt replacement period is indicated when this pointer enters the hor izontal range Maintenance 5 Doosan D34 Engine 143 60138011501 EN 10 2020 ...

Page 154: ... The minimum maximum range indication is a reference value the belt must be inspec ted according to its maintenance schedule Maintenance 5 Doosan D34 Engine 144 60138011501 EN 10 2020 ...

Page 155: ...tion leading to over heating Please formulate rules for daily checking and periodic cleaning of the cooling fins NOTE Please note that the air filter shown in the fig ure is for illustration purposes only Carefully remove the radiator from the counterweight assembly Use or com pressed air to blow dust and dirt from the radiator and cooling fins If the cooling fins are very dirty wipe with detergen...

Page 156: ...ase wear eye protection and rubber gloves If coolant accidentally makes contact with eyes or skin please rinse with clean water Failure to comply with the above operating guidance may result in minor injuries ENVIRONMENT NOTE Please pay attention to environmental protec tion Please comply with these procedures when handling hazardous waste Failure to comply with these procedures may result in seri...

Page 157: ...er tank with coolant Fill the radiator water tank with coolant Fill the radiator water tank with coolant ac cording to the following steps These proce dures are suitable for filling radiator water tanks for the first time or refilling after clean ing Please note the following steps are based on the example of a typical compensa tion box Check to ensure that the engine cylinder block drain plug and...

Page 158: ...When the engine is running and the engine cool ant is at normal temperature the coolant level should be at the level of the upper marking If the coolant level is not at the up per marking add more coolant to the com pensation box until the coolant level rea ches the upper marking Checking the coolant level Frequently check the engine coolant level by observing the compensation box Fill the com pen...

Page 159: ...he crude oil filter Slowly pull out the crude oil filter so that the oil flows into the container Unscrew the crude oil filter from the oil filter seat Unscrew the fastening nut on the crude oil filter then remove the filter insert Replace it with a new crude oil filter insert Fit the filter insert followed by the bottom cover onto the filter spindle then tighten the nut Refit the crude oil filter...

Page 160: ... oil of the hydraulic transmission ENVIRONMENT NOTE Observe precautions for handling fuel and lu bricants Place a container under the right side of the truck chassis Remove the floor plate Unscrew the oil drain plug 2 Fully drain the oil of the gearbox transmis sion gear Wipe the drain plug area clean Refit the drain plug and washer ENVIRONMENT NOTE Properly dispose of the waste hydraulic oil Unsc...

Page 161: ...gear oil until oil flows out of the oil level aperture NOTE Please refer to the chapter on replacing the drive axle gearbox oil for steps to take when adding gear oil Changing the drive axle gearbox oil Emptying the gear oil Ensure the forklift truck is stopped on a lev el surface Unscrew the plug of the oil filler port 1 so that the gear oil is easier to discharge Place a container under the driv...

Page 162: ...ing It is therefore preferable to use a pressurised filling tool otherwise the filling process will take a relatively long time Even when oil flows out of the filler port this does not mean that the oil level is full wait 5 8 minutes until the gear oil fills the gaps in the gearing Use gear oil in accordance with the referred instructions only Refit the plugs of the filler port and oil level hole ...

Page 163: ...gn matter Secure the forklift truck to prevent the wheels from turning apply the parking brake Place wedges under the tyres that have not yet been raised Raise truck with jack until wheels are off the ground Prop up with square timber Check that the wheels are able to turn free ly and remove all obstructions Change abraded or damaged tyres Check the tyre inflation pressure NOTE Low pneumatic press...

Page 164: ... tyres Superelastic tyres Superelastic tyres must be changed before the profile reaches the maximum wear al lowed The maximum wear of the tyre manu facturer is indicated by a line on the side 1 along the circumference of the tyre DANGER If the forklift truck is used on wet or slippery surfa ces replace the tyres before the thickness of the tread drops below 1 mm Tighten the tyre nuts Check the spe...

Page 165: ...o the weight of the driver To avoid injury please do not stack objects in the re clining range of the seat To avoid accidents check all adjustments before commencing operation The seat belt should be fastened before the forklift truck is used The seat belt must be replaced after an accident has occurred If the seat belt is tangled around the driver s seat the seat and seat stability must be checke...

Page 166: ...ive Check the fastening and wear condition of the engine bracket elements tilt cylinder counterweight wheel drive overhead guard and steering axle Tighten all loose screws bolts and nuts Replace damaged parts Touch up the paint work where necessary Maintenance 5 Chassis frame 156 60138011501 EN 10 2020 ...

Page 167: ... stationary Release the parking brake lever which should return to its initial position Turn off the engine and pull down the park ing brake lever 1 the truck should remain stationary NOTE If the parking brake is defective please con tact an authorised Baoli dealer Maintenance 5 Control system 157 60138011501 EN 10 2020 ...

Page 168: ...10mm Press the brake pedal until felt resistance NOTE Check the free movement around 5mm 8mm Checking that the inching controls are operating normally Check for abnormalities in the depression and return of the inching control pedal 3 Check the free movement of the inching control pedal by pushing it with your hand until resistance is felt Checking the driving brake and ad justing if necessary NOT...

Page 169: ...ge state and quality of the battery by means of the magic eye on top of the bat tery For an explanation of indicator states see the markings on the battery For exam ple green indicates good black indicates charging required and white indicates that the battery is damaged and needs replacing Refit the bonnet NOTE If the truck is not used for a long time check the battery on a monthly basis and rech...

Page 170: ...k the fuses accordingly Check and replace the fuses as the following schedule Set the ignition switch to the OFF position Remove the fuse box cover and check the fuse If the fuse is burnt replace it with a new fuse CAUTION Use the fuse of the same specification as the original one Maintenance 5 Electrics 160 60138011501 EN 10 2020 ...

Page 171: ...Hydraulics Hydraulic diagram with 3691 function Maintenance 5 Hydraulics 161 60138011501 EN 10 2020 ...

Page 172: ...Hydraulic diagram priority valve with 3691 function for Doosan D34 engine Maintenance 5 Hydraulics 162 60138011501 EN 10 2020 ...

Page 173: ...Hydraulic diagram without 3691 function Maintenance 5 Hydraulics 163 60138011501 EN 10 2020 ...

Page 174: ...hen remove the cover assembly Slowly pull out the cover assembly so that the oil flows back into the tank Unscrew the suction filter 2 from the cover assembly Screw in the new filter until tightened Refit the cover assembly to the frame using the fastening screws Refit the bracket and pedal pad Refit the engine cover Replacing the breather filter ENVIRONMENT NOTE Please handle liquids and lubricat...

Page 175: ... hydraulic oil through the oil inlet Oil volume approximately 120L for mast be low 4500mm 125L for mast exceeding 4500mm Use the dipstick to check the oil level The oil level should reach the upper marking on the dipstick Close the bonnet Start the engine and run it for a while Check the oil level again Check the seals Checking the hydraulic oil level ENVIRONMENT NOTE Please follow the instruction...

Page 176: ...ould be between the upper and lower markings on the dipstick WARNING The hydraulic oil must be checked while the engine is stopped and the forklift is in horizontal level When required fill the hydraulic oil up to the upper marking Re fit the oil dipstick Safely refit the engine cover Maintenance 5 Hydraulics 166 60138011501 EN 10 2020 ...

Page 177: ...n the mast channel and lifting chains Check the working status of the lifting chains along with any signs of abrasion paying particular attention to the area around the chain wheels Check that the chain fixed pins are secure Replace damaged lifting chains Check the status and tightness of the lift mast column mast channel surfaces and roller Check the status and working condition of the limit bloc...

Page 178: ...ozzle Immediately blow the chain dry after clean ing to remove water both on the chain sur face and inside the hinge pins Move the chain several times during the blow drying process Immediately apply chain spray and keep the chain moving while doing so NOTE The lifting chains are a safety component The use of cold cleaning agents chemical cleaning agents corrosive liquids or liquids containing aci...

Page 179: ... on the left and right tilt cylinder pivots at the drive axle from above Using lubricating grease lubricate the grease nipples 2 on the left and right tilt cylinder pivots at the chassis from above Maintenance 5 Load lifting system 169 60138011501 EN 10 2020 ...

Page 180: ...the lift chains NOTE As lift chains stretch with use they must be adjusted both on the left and right hand side Completely lower the mast Loosen the locknut 2 Adjust chain length with the adjusting nut 1 at the chain anchor NOTE While the mast is in vertical position and the forks is lowered to the ground ensure the lift ing chain is in tight state If not adjust it until rectified Tighten the lock...

Page 181: ...e the mast is in vertical position and the forks is lowered to the ground ensure the lift ing chain is in tight state If not adjust it until rectified Tighten the locknut 2 Completely free lifting and triple masts only Lubricating the chains with chain spray Use specified chain spray to coat the chains and channel surfaces NOTE If the truck is used in the food industry please use lubricating greas...

Page 182: ...Maintenance 5 Load lifting system 172 60138011501 EN 10 2020 ...

Page 183: ...6 Technical data ...

Page 184: ...Dimensions Technical data 6 Dimensions 174 60138011501 EN 10 2020 ...

Page 185: ... to fork face x mm 622 622 622 622 Wheel Base y mm 2250 2250 2250 2250 Weights Service Weight Kg 8400 8400 8400 8815 Axle loading laden front rear Kg 12080 1420 12080 1420 12080 1420 12295 1520 Axle loading unladen front rear Kg 4220 4260 4220 4260 4220 4260 3720 5095 Wheels chassis frame Tyres SE Super elastic PN Pneumatic PN PN PN SE Front Tyres Size 8 25 15 14PR Rear Tyres Size 8 25 15 14PR Fro...

Page 186: ... Centre of Wheelbase laden m2 mm 190 190 190 190 Working aisle width with pal let 1000 x 1200 cross ways Ast m m 5162 5162 5162 5162 Working aisle width with pal let 800 x 1200 crossways Ast m m 5362 5362 5362 5362 Turning Radius Wa mm 3340 3340 3340 3340 Turning Point Minimum Dis tance from the Truck Center Line b13 mm 1095 1095 1095 1095 Performance data Driving speed with without load km h 27 2...

Page 187: ... 2300 Cylinder Number Displace ment cm3 6 6494 4 4090 4 4500 4 3400 On board voltage 24 24 24 24 Others Drive Control Type Hydraulic torque con verter Hydraulic tor que converter Hydraulic torque con verter Hydraulic tor que converter Noise at Operator s Ear dB A 100 100 100 88 Volume fuel tank L Kg 140 117 140 117 140 117 125 104 Towing coupling type DIN Pin Pin Pin Pin Technical data 6 Datasheet...

Page 188: ...0 1590 13450 1590 13650 1685 Axle loading unladen front rear Kg 4080 4960 4080 4960 4080 4960 3933 5387 Wheels chassis frame Tyres SE Super elastic PN Pneumatic PN PN PN SE Front Tyres Size 8 25 15 14PR Rear Tyres Size 8 25 15 14PR Front Track Width b10 mm 1470 1470 1470 1470 Rear Track Width b11 mm 1700 1700 1700 1700 Dimension and overall sizes Mast lift forward backward Graus 6 12 6 12 6 12 6 1...

Page 189: ...00 x 1200 crossways Ast m m 5487 5487 5487 5487 Turning Radius Wa mm 3460 3460 3460 3460 Turning Point Minimum Dis tance from the Truck Center Line b13 mm 1095 1095 1095 1095 Performance data Driving speed with without load km h 22 27 22 27 22 27 24 24 Lifting speed with without load mm s 420 555 420 555 420 555 480 650 Lowering speed with without load mm s 350 285 350 285 350 285 460 410 Pulling ...

Page 190: ...Others Drive Control Type Hydraulic tor que convert er Hydraulic tor que convert er Hydraulic tor que convert er Hydraulic tor que convert er Noise at Operator s Ear dB A 100 100 100 88 Volume fuel tank L Kg 140 117 140 117 140 117 125 104 Towing coupling type DIN Pin Pin Pin Pin Technical data 6 Datasheet for KBD60 180 60138011501 EN 10 2020 ...

Page 191: ...0 1760 14820 1760 15080 1860 Axle loading unladen front rear Kg 3960 5640 3960 5640 3960 5640 4220 5780 Wheels chassis frame Tyres SE Super elastic PN Pneumatic PN PN PN SE Front Tyres Size 8 25 15 14PR Rear Tyres Size 8 25 15 14PR Front Track Width b10 mm 1470 1470 1470 1470 Rear Track Width b11 mm 1700 1700 1700 1700 Dimension and overall sizes Mast lift forward backward Graus 6 12 6 12 6 12 6 1...

Page 192: ...00 x 1200 crossways Ast m m 5492 5492 5492 5492 Turning Radius Wa mm 3460 3460 3460 3460 Turning Point Minimum Dis tance from the Truck Center Line b13 mm 1095 1095 1095 1095 Performance data Driving speed with without load km h 22 27 22 27 22 27 24 24 Lifting speed with without load mm s 420 555 420 555 420 555 480 650 Lowering speed with without load mm s 350 285 350 285 350 285 460 410 Pulling ...

Page 193: ...Others Drive Control Type Hydraulic tor que convert er Hydraulic tor que convert er Hydraulic tor que convert er Hydraulic tor que convert er Noise at Operator s Ear dB A 100 100 100 88 Volume fuel tank L Kg 140 117 140 117 140 117 125 104 Towing coupling type DIN Pin Pin Pin Pin Technical data 6 Datasheet for KBD70 183 60138011501 EN 10 2020 ...

Page 194: ...10 210 5500 4500 5500 6400 3850 6929 210 210 3 6 6000 4300 5200 6100 4100 7429 210 210 VFM Full free duplex 2500 5000 6000 7000 2195 3929 1279 826 6 12 2700 2310 4129 1394 941 2750 2335 4179 1419 966 3000 2460 4429 1544 1091 3250 2585 4679 1669 1216 3300 2610 4729 1694 1241 3500 2710 4929 1794 1341 3750 2835 5179 1919 1466 4000 3010 5429 2094 1641 4250 3135 5679 2219 1766 4500 3260 5929 2344 1891 ...

Page 195: ...6000 4000 5000 5300 3160 7275 2244 1791 Technical data 6 Mast specification 185 60138011501 EN 10 2020 ...

Page 196: ...Technical data 6 Mast specification 186 60138011501 EN 10 2020 ...

Page 197: ...king the Engine Oil 131 Checking the fastening of the engine bracket overhead guard tilt cylinder steering axle and wheel drive 156 Checking the fork arms and the fork arm quick release apparatus 167 Checking the hydraulic oil level 165 Checking the oil level of the hydraulic transmission 150 Checking the operation and installation of the lift mast lifting chain and limit block 167 Checking the op...

Page 198: ... Forklift towing 79 Forward 60 Fuel system air bleeding 110 118 G General information 88 General View 26 H Handling gas springs and accumulators 18 Hydraulic diagram priority valve with 3691 function for Doosan D34 engine 162 Hydraulic diagram without 3691 function 163 Hydraulic fluid 19 I Impermissible use 5 Inching control 61 Inspect the intake piping Cummings QSB4 5 130 Instructions for running...

Page 199: ...gulations when driving 17 Seat belt 51 Fastening 52 Malfunction due to cold weather condi tions 52 Releasing 52 Seat belt status and performance checks 42 Service schedule for ISUZU 6BG1 02 en gine 92 Service schedule for Weichai WP4 1 en gine 91 Stability 16 Start on an incline 62 Steering system 63 Summary 88 supply table 90 Switches 53 Symbols 6 T Technical notes 2 Tighten the tyre nuts 154 Tow...

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Page 202: ...KION Baoli Jiangsu Forklift Co Ltd Add No 8 Xinzhou Road Economic Development Zone Jingjiang 214500 Jiangsu China 0086 523 80161860 export baoli mh com en baoli mh com 60138011501 EN 10 2020 3 ...

Page 203: ...Original instructions D series Forklift Truck KBD50 70 Annex ...

Page 204: ...7 Electrical diagrams ...

Page 205: ...with ISO3691 function Electric schematic diagram Cummins QSB4 5 with ISO3691 Electrical diagrams 7 with ISO3691 function 195 60138011501 EN 10 2020 ...

Page 206: ...Electric schematic diagram Doosan D24 with ISO3691 function Electrical diagrams 7 with ISO3691 function 196 60138011501 EN 10 2020 ...

Page 207: ...without ISO3691 function Electric schematic diagram Weichai WP4 1 w o ISO3691 Electrical diagrams 7 without ISO3691 function 197 60138011501 EN 10 2020 ...

Page 208: ...Electric schematic diagram Isuzu 6BG1QC 02 w o ISO3691 Electrical diagrams 7 without ISO3691 function 198 60138011501 EN 10 2020 ...

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Page 210: ...KION Baoli Jiangsu Forklift Co Ltd Add No 8 Xinzhou Road Economic Development Zone Jingjiang 214500 Jiangsu China 0086 523 80161860 export baoli mh com en baoli mh com 60138011501 EN 10 2020 3 ...

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KION Baoli D Series, Original Instructions Manual

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