KION Baoli KBD50 User Manual (English)

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Original instructions

D series Forklift Truck

KBD50–70

Table of Contents5
Introduction12
Intended Use14
Impermissible Use15
Description of Use and Climatic Conditions16
Symbols Used16
CE Labelling17
EMC - Electromagnetic Compatibility18
EC Declaration of Conformity in Accordance with Machinery Directive19
Safety21
Definition of Terms Used for Responsible Persons22
Operating Company22
Specialist22
Competent Person22
Drivers22
Safety Regulations24
General Safety Regulations24
Exhaust Gases25
Ground Condition for Using the Truck25
Safety Regulations Relative to Forklift Use25
Residual Dangers, Residual Risks26
Safety Regulations When Driving27
Safety Regulations in Case of Accidental Lateral Tipping28
Exercise Caution When Handling Gas Springs and Accumulators28
Safety Regulations for Handling Consumables29
Permissible Consumables29
Hydraulic Fluid29
Oils30
Battery Acid31
Disposal of Consumables31
Environmental Considerations32
Disposal of Components and Batteries32
Packaging33
Emissions33
Overview35
General View36
Operating Controls37
Display Instrument39
Truck Identification43
Forklift Identification Plate43
Production Number43
Mast Serial Numbers44
Location of Decals45
Operation49
Instructions for Running-In50
Checks and Inspection51
Pre-Shift Checks51
Daily Checks before Use51
Seat Belt Status and Performance Checks52
Check the Wheel Nuts for Correct Tightness53
Check the Condition and Operation of Chain54
Refuelling56
Diesel Fuel - Specifications56
Engine Coolant - Specifications58
Climbing On/Off the Forklift59
Seat Belt60
Adjustment of the Driver's Seat60
Adjustment of the Driver's Seat61
Seat Belt61
Switches63
DPF Light and Switch65
Adjusting the Steering Column66
Starting the Engine67
Start the Engine67
Engine Shutdown67
Driving68
Forward70
Reversing70
Changing the Drive Direction71
Inching Control71
Start on an Incline72
Parking73
Steering System73
Brake System74
Lifting System and Attachments76
Operating the Lifting Device76
Operating Attachments77
Handling Loads79
Load Centre Distance and Load Capacity79
Capacity Chart80
Picking up a Load80
Transporting Pallets81
Adjusting the Fork Spacing82
Loading82
Driving with a Load83
Transport of Swinging Loads84
Driving on Loading Bridges85
Unloading86
Towed Load87
Forklift Towing89
Cleaning90
Cleaning the Truck90
Cleaning the Electrical System91
Cleaning Lifting Chains91
After Washing92
Before Exiting the Truck92
Truck Transport93
Truck Storage94
Disposal of Old Trucks95
Maintenance97
Summary98
General Information98
Pre-Service Preparatory Work99
Supply Table100
Preventive Maintenance Service Schedule101
Service Schedule for Weichai WP4.1 Engine101
Service Schedule for ISUZU 6BG1-02 Engine102
Maintenance Table for Cummins QSB4.5 Engine104
Maintenance Table for Doosan D34 Engine106
Checking List for IC Truck108
Preparations112
Cleaning the Truck112
Weichai WP4.1 Engine113
Changing the Engine Oil113
Check the Engine Oil Level114
Changing the Engine Oil Filter115
Change Air Filter Insert116
Cleaning the Air Filter Insert116
Emptying Water Separator118
Replacing the Fine Fuel Filter119
Fuel System Air Bleeding120
Adjustment of Valve Clearance121
Clean and Check the Injection Nozzle121
Isuzu 6BG1 Engine123
Changing the Engine Oil123
Check the Engine Oil Level124
Changing the Engine Oil Filter125
Change Air Filter Insert126
Cleaning the Air Filter Insert126
Replacing the Fine Fuel Filter128
Removal of Water from the Fuel128
Fuel System Air Bleeding128
Feed Pump Strainer Cleaning129
Checking and Adjusting the Radiator Fan V-Belt130
Cummins QSB4.5 Engine132
Unusual System Noise132
Changing the Engine Oil132
Check the Engine Oil Level134
Changing the Engine Oil Filter135
Change Air Filter Insert136
Cleaning the Air Filter Insert137
Replacing the Fine Fuel Filter138
Removal of Water from the Fuel139
Inspect the Intake Piping140
Doosan D34 Engine141
Checking the Engine Oil141
Replacing Engine Oil142
Replacing the Engine Oil Filter144
Clean the Air Filter Insert144
Change the Air Filter146
Replacing the Fuel Filter148
Bleeding Air from the Fuel Delivery Line150
Draining Water from the Fuel Filter151
Checking the Belt Tension152
Cooling System155
Checking and Cleaning the Cooling Fins155
Changing the Coolant156
Checking the Coolant Level158
Transmission System159
Changing the Hydraulic Transmission Oil Filter159
Checking the Oil Level of the Hydraulic Transmission160
Changing the Oil of the Hydraulic Transmission160
Checking the Drive Axle Gearbox Oil161
Changing the Drive Axle Gearbox Oil161
Steering Axle and Wheels163
Cleaning and Lubricating the Steering Axle163
Checking the Tyres for Damage and Foreign Matter163
Check the Tyre Inflation Pressure163
Checking the Condition of the Tyres164
Tighten the Tyre Nuts164
Chassis Frame165
Check the Seat Belt for Condition and Correct Operation165
And Wheel Drive166
Control System167
Checking the Operation of the Parking Brake167
Checking that the Driving Brake Is Operating Normally168
Checking that the Inching Controls Are Operating Normally168
Checking the Driving Brake and Adjusting if Necessary168
Electrics169
Checking Battery Charging Status169
Check the Control Box170
Hydraulics171
Hydraulic Diagram-With 3691 Function171
Hydraulic Diagram-Priority Valve with 3691 Function for Doosan D34 Engine172
Hydraulic Diagram-Without 3691 Function173
Changing the Crude Filter174
Replacing the Breather Filter174
Fill up the Hydraulic Oil175
Checking the Hydraulic Oil Level175
Load Lifting System177
Checking the Fork Arms and the Fork Arm Quick Release Apparatus177
Checking the Operation and Installation of the Lift Mast, Lifting Chain and Limit Block177
Lubricate the Lift Mast and Chains with Chain Spray178
Lubricating the Lift Mast and Tilt Cylinder Bearings178
Adjusting the Length of the Lift Chains, and Lubricating Using Chain Spray180
Technical Data Dimensions184
Datasheet for KBD50185
Datasheet for KBD60188
Datasheet for KBD70191
Mast Specification194
Annex203
Electrical Diagrams204
With ISO3691 Function205
Electric Schematic Diagram - Cummins QSB4.5 with ISO3691205
Electric Schematic Diagram-Doosan D24 with ISO3691 Function206
Without ISO3691 Function207
Electric Schematic Diagram-Weichai WP4.1 W/O ISO3691207
Electric Schematic Diagram - Isuzu 6BG1QC-02 W/O ISO3691208

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KION Baoli KBD50 Specifications

General

Brand	KION
Model	Baoli KBD50
Category	Trucks
Language	English

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