Kbet18 Operation Manual

KION Baoli (Jiangsu) Forklift Co.
, Ltd
KBET18 Operator Manual (North America) Rev00 1

KION Baoli (Jiangsu) Forklift Co., Ltd
CONTENT
I Introduction ............................................................................................................................. 5
1. Scope ......................................................................................................................... 6
2. Obligations of the Equipment Owner ........................................................................ 7
3. Operator Responsibilities .......................................................................................... 8
4. Proper Use ................................................................................................................. 9
5. Hazard messages ..................................................................................................... 10
II Safety ................................................................................................................................... 11
1. Before Operation ................................................................................................... 122
2. Operator Daily Checklist ......................................................................................... 12
3. Operating Position ................................................................................................. 133
4. Pedestrians ............................................................................................................. 133
5. Travel ..................................................................................................................... 144
6. Lifting and Lowering ............................................................................................. 155
7. Inclines, Ramps, Docks, Elevators ........................................................................ 155
8. Avoiding Falls and Tip-overs................................................................................. 166
9. Suspended Loads ................................................................................................... 177
10. Parking .............................................................................................................. 177
11. Battery Safety ................................................................................................... 188
12. Safety During Maintenance .............................................................................. 188
13. Operator Warning Decal ................................................................................... 222
III Overview ............................................................................................................................ 27
1. Specifications .......................................................................................................... 28
2. Description ............................................................................................................ 300
3. General forklift view ............................................................................................. 311
4. Operating Controls ................................................................................................ 344
5. Decal Locations ..................................................................................................... 509
6. Data Plate.................................................................................................................. 50
IV Use and Operation .............................................................................................................. 54
1. Forklift Transport and Lifting .................................................................................. 55
1.1 Transporting the Forklift ............................................................................ 55
1.2 Hoisting the Truck ...................................................................................... 56
2. Commissioning and Breaking-In ........................................................................... 587
3. Daily Checks Before Use ...................................................................................... 587
4. Use of Truck .......................................................................................................... 598
4.1 Stepping on/off the truck .......................................................................... 598
4.2 Starting the forklift ................................................................................... 609
4.3 Forklift Operation ....................................................................................... 60

4.4 Forklift Braking/Stopping ........................................................................ 621
4.5 Leaving Truck .......................................................................................... 632
4.6 Steering the Forklift ................................................................................. 643
4.7 Speed Restriction ..................................................................................... 654
4.8 Stopping the Forklift in an Emergency .................................................... 654
4.9 Forklift Use in Cold-Storage Rooms ........................................................ 665
5. Adjustment of the Fork Distance ........................................................................... 676
6. Towing Trailers...................................................................................................... 676
7. Forklift Towing ...................................................................................................... 676
8. Changing the Battery ............................................................................................. 687
9. Connecting the Battery to an External Charger ..................................................... 721
V Periodic inspection and servicing ........................................................................................ 74
1. Recommended lubricants ........................................................................................ 75
2. Daily inspection ....................................................................................................... 76
2.1 Vehicle uprightness .................................................................................... 76
2.2 Check for leakage....................................................................................... 76
2.3 Check Wheels and Tires ............................................................................. 77
2.4 Check Decal Condition .............................................................................. 77
2.5 Lights ......................................................................................................... 78
2.6 Check Overhead Guard .............................................................................. 78
2.7 Check hydraulic oil level............................................................................ 79
2.8 Brake fluid inspection ................................................................................ 79
2.9 Brake pedal inspection ............................................................................... 80
2.10 Parking brake inspection ............................................................................ 80
2.11 Loading handling system ........................................................................... 80
2.12 Steering wheel inspection........................................................................... 82
2.13 Horn check ................................................................................................. 82
2.14 Drivers’ seat adjustment ............................................................................. 83
2.15 Check Braking Function............................................................................. 83
2.16 Check Steering Function ............................................................................ 83
2.17 Chain tension check and adjustment .......................................................... 84
2.18 Fork arm check ........................................................................................... 84
3. Changing a Fuse ...................................................................................................... 86
4. Routine Lubrication ................................................................................................. 87
4.1 Fork Carriage Guide Greasing ............................................................................ 87
4.2 Trunnions Greasing ............................................................................................ 88
4.3 Lubricate Lift Chain ........................................................................................... 89
4.4 Rolling Tracks Greasing ..................................................................................... 90

4.5 Check Gear Unit Oil Level ................................................................................. 91
5. Scheduled Maintenance ........................................................................................... 92
VI Diagrams ............................................................................................................................ 94
Product improve suggestion sheet (Feedback) ................................................................ 98


Introduction

1. Scope
This manual contains operating and periodic maintenance instructions as well as
specifications for the industrial truck to which it applies. If this manual applies to a trailer or
other towed equipment, then operation or maintenance of the towing vehicle is outside the
scope of this manual. Important safety rules and descriptions of some operating hazards
and how to avoid them are also included. The manual is intended to assist the owner and
operators in maximizing safety and efficiency in material handling while achieving
maximum product life. It describes how to correctly and safely operate and maintain the
truck and all standard variants available at the time of printing. Special designs, special
attachments, or other custom modifications carried out by the manufacturer to meet
specialized customer requests are not covered in this manual.
This manual is not a training manual and is not to be used as the basis for formal training.
It is intended to supplement such training with information specific to this truck as well as
applicable good practices and safety rules which may be general in nature. This manual
cannot address every possible hazard or potential accident situation. Ultimately it is the
responsibility of the owner and operator(s) of the equipment to avoid or correct such
potential dangers.
To assist in keeping the truck in good operating condition, a separate section devoted to
maintenance is included in this manual. This section contains a list of items to be checked
daily by the operator. It also has a schedule for maintenance procedures to be performed
at regular intervals by those responsible for truck maintenance. All of these procedures
are essential for safe operation and maximum service life of the truck. Scheduled
maintenance tasks or repairs must only be performed by qualified forklift technicians.
Details and instructions for performing such work are outside the scope of this manual.
This information is covered in the applicable service manual available from authorized
dealers.
The descriptions and specifications included in this manual were in effect at the time of
printing. KION North America Corporation reserves the right to make improvements and
changes without notice and without incurring obligation. Please check with your authorized
dealer for information on possible updates or revisions.

2. Obligations of the Equipment Owner

The Occupational Safety and Health Administration (O.S.H.A.) requires employers of
industrial truck operators to adhere to a number of regulations regarding operation. These
regulations are codified in section 1910.178 of title 29 of the Code of Federal Regulations.
This section establishes a number of specific rules pertaining to truck operation,
inspection and maintenance, and areas of use. It is up to the owner to ensure that use and
maintenance of any powered industrial truck is consistent with these rules.
In addition, 29 CFR 1910.178 describes required operator training in detail. It requires
employers to establish and maintain a training program to ensure that all operators of
powered industrial trucks are competent and trained in the safe and proper operation of
powered industrial trucks.
Many of the rules set forth in 29 CFR 1910.178 are based on the American National
Standards Institute’s (ANSI/ITSDF) B56 standards. The owner should be familiar with 29
CFR 1910.178 as well as the ANSI/ITSDF B56 standards. Other federal standards may
apply depending on specific industry. Owners should also be aware of any state OSHA
rules that may differ from the federal rule. This equipment meets all applicable
requirements of the ANSI/ITSDF B56 standards at time of manufacture. 29 CFR 1910.178
prohibits any modifications and/or additions which affect capacity or safe operation of
industrial trucks without prior written approval of the manufacturer. An owner should
consult the authorized dealer if the owner’s intended application for a truck is inconsistent
with the designated performance characteristics of that truck. KION North America
Corporation will not assume, and expressly disclaims, any liability for injuries or damages
arising from or caused by unauthorized modification, removal, disconnection or
disengagement of any part from any of its trucks. It is recommended that all replacement
parts be of OEM (Original Equipment Manufacturer) origin.

3. Operator Responsibilities
It is the responsibility of the operator to operate any powered industrial truck in a safe
manner. In order to do this, all operators must have completed training in the safe
operation of powered industrial trucks. Operators must know and understand all general
safety rules as well as any safety information specific to the environment in which they will
be working. They must then practice these safe operating procedures whenever using a
truck.
In addition, all operators must be familiar with the specific truck they use. Therefore they
must be familiar with the procedures for correct and safe operation explained in this
manual. They must understand the potential hazards and safety precautions covered in
the manual. This manual however, cannot cover all possible hazards. Operators must be
able to identify any hazards that may exist or arise in their work environment and know
how to avoid or correct them.
Finally, operators are responsible for identifying and reporting any truck that is in unsafe
condition. They must know how to inspect the truck they operate and they must perform
this inspection before placing a truck in service each day. Operators must not operate a
truck found to be damaged or malfunctioning.

4. Proper Use
The truck is designed for lifting, transporting and stacking palletized or other stable loads.
The maximum load to be lifted is specified on the truck data plate. The truck is not
designed or intended to lift personnel.
The truck may be operated outdoors or in buildings only on surfaces that are flat and
stable. Transporting of loads (in the lowered position) on inclines and ramps is permitted if
the incline surface is flat and stable. Lifting of loads or transport of elevated loads is
prohibited on inclines and ramps. If the truck is operated on public roads it must be
equipped with lights and any other devices as required by state or local law. If the truck is
to be operated in refrigerated storage areas, it must be equipped with an optional cold
storage package suitable for the specific application. (Not available on all models.) A truck
must not be operated in any hazardous environment unless the truck carries the
designation appropriate for that environment per 29 CFR 1910.178. It is the responsibility
of the owner to ensure the safety of all operating areas and surfaces and to restrict the
truck to the uses and areas for which it is designed and rated.

5. Hazard messages
Hazard symbols and messages are placed in this manual and on the truck to provide
instructions and identify specific areas where potential hazards exist and special
precautions should be taken. Operators must understand the meaning of these symbols
and messages. Damage to the truck, as well as serious injury or death to the operator or
others may result if the instructions conveyed by these symbols and messages are not
followed.
CAUTION
Indicates a potentially hazardous situation, which if not avoided, may result in minor
or moderate injury.
WARNING
Indicates a potentially hazardous situation which if not avoided could result in death
or serious injury.
DANGER
Indicates an imminently hazardous situation which if not avoided will result in death
or serious injury.
NOTE
Indicates further information presented to ensure clarification of a particular item.
ENVIRONMENTAL NOTE
The information contained herein must be observed, otherwise environmental
damage may occur.

II
Safety

1. Before Operation
Before using the truck, inspect the work area. It should be neat, well lit, adequately
ventilated, and free from hazardous material. Aisles and roadways should be unobstructed
and well-marked.
Operators must know the UL classification for the truck and use the truck only in
permissible areas.
Ensure that there are no loose objects on the truck or in the operator compartment,
especially on the floor plate where they could interfere with pedal operation (if equipped)
or foot room.
Fire extinguishers and other emergency equipment should be visible and easy to reach.
Wear safety equipment when required. Don’t smoke in "No Smoking" areas, or while
charging batteries or refueling combustion engine trucks.
Never operate the truck with greasy hands. This will make the controls slippery and result
in loss of truck control.
Any questions or concerns about safety should be brought to the attention of a supervisor.
If an accident should occur, it must be reported immediately.
WARNING
Unauthorized modifications to the truck can result in injury or death. Do not remove,
disable or modify any safeguards or other safety devices. These include any
alarms, lights, mirrors, overhead guards, and load backrest extensions. If present,
an overhead guard is intended to provide protection to the operator from falling
objects, but cannot protect from every possible impact.
2. Operator Daily Checklist

At the beginning of each shift, inspect your truck by using the Daily Checklist. If necessary,
refer to the Maintenance section of this manual for details on how to carry out this
inspection. Check for damage and maintenance problems. Any necessary repairs must be
completed before the truck is operated. In addition to daily inspection, scheduled
maintenance is vital to safe operation of the truck. Adhere to the inspection, lubrication
and maintenance schedule given in the Maintenance section of this manual.
NOTE
Any repairs or maintenance to the truck must be performed only by trained and
authorized technicians.

3. Operating Position
Face the truck when mounting and dismounting. Maintain a three-point contact, one foot
and two hands with the truck when mounting or dismounting. Never exit a moving truck.
The normal operating position is defined as being seated on the seat with the seat belt
fastened and hands and feet inside the operator’s compartment on or near the controls.
WARNING
Risk of injury!
Operate the truck only when you are in the normal operating position. Always keep
hands and feet inside the operator’s compartment during operation. Keep hands. Feet
and legs out of the upright.
WARNING
Risk of injury!
Do not place yourself between the mast and the body of the truck. Do not use the mast
as a ladder. Do not transport personnel at any time. Do not lift personnel using the forks
of the truck, or with a work platform. The truck is not designated to lift personnel.
4. Pedestrians
Watch out for pedestrians. Always yield the right-of-way to pedestrians. Do not drive the
truck up to anyone standing in front of a rack or fixed object. Do not pass another truck
travelling in the same direction at an intersection, blind spot or other dangerous location.
Sound the horn at intersections and other locations where vision is obstructed. Always
look in the direction of travel. Rules for handling and disposing of operating materials
Never engage in stunt driving or horseplay. Use lights in dark and dim areas. Always
ensure that there are no pedestrians in the truck’s rear swing area before turning. Watch
for pedestrians around the truck.
DANGER
Risk of injury!
Watch for people in your work area because they may not watch for you, even if you
have lights or alarms.

WARNING
Risk of injury!
Do not walk under raised forks at any time.
WARNING
Risk of injury!
Do not transport personnel at any time. Do
not lift personnel using the forks of the truck,
or with a work platform. The truck is not
designed to lift personnel.
5. Travel
The truck is designed for operation on smooth, dry surfaces such as warehouse and
factory floors, loading docks or paved areas. Under all travel conditions operate the truck
at a speed that will permit it to be brought to a stop in a safe manner. Avoid running over
loose objects on the roadway surface.
WARNING
Loss of control!
Do not travel at excessive speeds; keep your truck under control at all times .
Travel with the forks near the floor, tilted back to cradle any load whenever possible.
Never begin travel before the mast is fully lowered and tilted into travel position. Never
raise the mast during travel. During travel, always watch for overhead obstructions such
as lights, wiring, pipes, sprinkler systems, doorways, etc.
When travelling in reverse, always turn around to face the direction of travel and ensure a
direct view in the direction of travel. Do not rely on mirrors when travelling in reverse.
When handling bulky loads that restrict your vision, operate the truck in reverse to improve
visibility. Unstable loads are a hazard to you and to your fellow workers. Make certain that
all loads are secured and evenly positioned on the forks.

Do not move railroad cars or trailers with this truck, or use it to operate or close railroad
car doors.
6. Lifting and Lowering

Always ensure there is adequate overhead clearance before raising the forks. Before
lifting any load or retrieving one from an elevated location, make certain that the load is
stable and evenly positioned on the forks. Never lift a load with one fork.
Use extreme care when maneuvering loads into or out of storage locations. Never turn the
truck while maneuvering with the forks raised. Always check for mast or carriage hang-up
before maneuvering out of any storage location with or without a load on the forks.
WARNING
Attempting to move the truck if the lift chains become slack can result in injury from
carriage free-fall.
Always raise the forks before you move. Watch for slack chain condition. Slack chains
indicate that the mast or carriage is hung-up. Do not attempt to repair this yourself,
always get a trained mechanic.
7. Inclines, Ramps, Docks, Elevators

If you must travel on an incline, do so with caution. Do not operate truck on a wet incline.
Keep the forks upgrade to maintain control when travelling up or down an incline with a
loaded truck.
Keep the forks downgrade when travelling up or down an incline with an empty truck.
DANGER
Tip-over will occur if you turn while travelling on a ramp or travel at an angle
other than straight up or straight down a ramp.
Never turn on an incline or ramp either loaded or unloaded. Travel straight up or straight
down.
Be aware that when descending an incline your stopping distance will be greater than
when on a level surface. Reduce your speed, and ensure that there is adequate clear
space at the bottom of the ramp to stop and turn.
To avoid hazards associated with a dock, you should personally check that the trailer
brakes have been applied, wheel chocks are in place, and that any trailer-to-dock locking
systems are being utilized. The impact of moving in and out of a trailer may cause the
trailer to creep or move. Confirm that the driver will not move the trailer until you are done.

Do not drive the truck onto an elevator without specific authorization. Verify that the
capacity of the elevator exceeds the weight of the truck and the weight of the load.
Approach elevators slowly and ensure that the elevator car is level with the floor before
entering. Enter elevators squarely with the load end leading. Ensure that no part of the
truck or load contacts any part of the elevator other than the floor. Once on the elevator,
neutralize the truck controls, shut off the power, and set the brakes. Any before the truck is
allowed to enter or leave.
Be especially cautious when driving the truck on ramps or bridge plates. Be sure to
maintain a safe distance from each edge. Before driving the truck over a ramp or bridge
plate, verify that its position is secured to prevent movement. Never exceed the rated
capacity of a ramp or bridge plate.
8. Avoiding Falls and Tip-overs

Lift truck tip-overs can cause serious injury or death. Following all safety rules when
operating a lift, truck is the best way to prevent injury.
 Never exceed the lifting capacity listed on the data plate.
 Extreme caution should be taken when working around docks, dock boards and
trailers.
 Travel with the load or forks close to the ground and tilted back. Watch for overhead
obstructions. Perform all truck movements smoothly and at a speed that will give you
time to react in an emergency.
 An unloaded truck can tip over also. Caution must be taken when using an unloaded
truck as well as a loaded one.
 Never travel with mast extended. Never turn while travelling on a ramp or incline.
 Never travel up or down an incline at an angle to the incline direction. Always travel
straight up or straight down any ramp or incline.
Lateral tip-over can occur with a combination of speed and sharpness of turn. This
condition of instability is even more likely with an unloaded truck. With the load raised,
lateral tip-over can occur while turning and/or braking when travelling in reverse or
accelerating and turning while travelling forward. Lateral tip-over can occur loaded or
unloaded on a ramp. Longitudinal tip-over can occur with a combination of overloading
and load elevated. This condition is even more likely with forward tilt, braking in forward
travel, accelerating rearward or mast extended.
WARNING
Jumping from the truck during a tip-over can result in severe injury or death.
If the truck starts to tip over, DO NOT JUMP!
Stay in the seat, hold onto the steering wheel tightly, brace feet, and lean away from the
direction of impact.

9. Suspended Loads
Traveling with suspended loads on cable or chain can induce swinging.
 Swinging of loads can cause truck tip over.
 Avoid suspending loads if possible.
 If necessary carry suspended loads low.
 Use a partner with a rope or tether to stop swinging.
 Operate truck slowly.
10. Parking
When you are finished with the truck, observe proper shutdown procedures.
 Never park on a grade.
 Always come to a complete stop before leaving truck.
 Place travel controls in neutral.
 Lower forks fully to the floor. If the forks can be tilted, tilt them forward.
 If the truck has a manual parking brake, apply it.
 Turn the truck off.
 If the truck has a key switch and the operator is more than 25 ft. (7.5 m) away, or out
of sight of the truck, the key should be removed.
WARNING
Failure to properly shut down the truck may allow inadvertent movement and result in
collision.
Never park on a grade. Always set the parking brake and turn the key switch off. And
always place the direction switch in neutral.

WARNING
Improper parking can interfere with emergency response.
Do not block stairways, main passageways or emergency routes. Do not block access
to fire or emergency equipment.
11. Battery Safety
WARNING
Batteries contain dissolved sulfuric acid, which is poisonous and caustic. Batteries also
can produce explosive gases.
Remain aware of the following information.
 Wear protective equipment (protective apron and gloves) and protective glasses when
working with battery acid. If clothing, skin or eyes come into contact with battery
acid, immediately flush the affected areas with water. If acid contacts the eyes, seek
medical attention at once. Clean spilled battery acid immediately with large amounts
of water.
 Remove any metal rings, bracelets, bands, or other jewelry before working with or
near batteries or electrical components.
 Never expose batteries to open flame or sparks.
 Areas in which batteries are stored or charged must be well ventilated to prevent
concentration of explosive gases.
 If a battery is charged while installed in the truck, the battery cover must remain
completely open during the entire charging period.
 Shorting of battery terminals can cause burns, electrical shock, or explosion. Do not
allow metal parts to contact the top surface of the battery. Make sure all terminal caps
are in place and in good condition.
 Batteries may only be charged, serviced, or changed by properly trained personnel.
Always follow all instructions provided by the manufacturers of the battery, charger,
and forklift truck.
12. Safety During Maintenance
Personnel Qualifications
Only qualified personnel authorized by the owner are permitted to perform maintenance or
repair work. All items listed in the Scheduled Maintenance Charts must be performed by
qualified forklift technicians only. They must have knowledge and experience sufficient to
assess the condition of a forklift truck and the effectiveness of the protective equipment
according to established principles for testing forklift trucks. Any evaluation of safety must
be unaffected by operational and economic conditions and must be conducted solely from
a safety standpoint.

Daily inspection procedures and simple maintenance checks, e.g. checking the hydraulic
oil level or checking the fluid level in the battery, may be performed by operators. This
does not require training as described above.
Hazardous Substances
Oils
WARNING
Oils are flammable!
- Always comply with applicable legal regulations.
- Do not allow oil to come into contact with hot engine parts.
- Do not smoke in areas where oils are used or stored.
WARNING
Oils are toxic!
- Avoid skin contact, inhalation, or ingestion.
- If oil mist or vapors have been inhaled, seek fresh air.
- If oil comes into contact with the eyes, flush thoroughly (at least 10 minutes)
with water and then seek medical assistance.
- If oil is swallowed, do not induce vomiting. Seek medical assistance
immediately.
WARNING
Prolonged intensive contact with the skin can result in loss of natural skin oils and
irritate the skin.
- Avoid skin contact.
- Wear protective gloves, long sleeves, and eye protection.
- If oil contacts the skin, wash the affected area with soap and water.
- Change oil-soaked shoes or clothing immediately.

Pressurized Hydraulic Oil

WARNING
Like other oils, hydraulic oil is flammable, toxic and a skin irritant.
 Do not allow hydraulic fluid to come into contact with hot motor parts
 Avoid inhalation or skin contact of hydraulic oil.
 Refer to the safety information under “Oils”.
WARNING
Hydraulic oil is pressurized during operation of the forklift truck and may remain
pressurized after shut down. An escaping stream of pressurized hydraulic oil can cause
serious injury.
 If pressurized hydraulic oil is found to be escaping from the truck, shut down the
truck immediately and have the leak repaired before returning the truck to
service.
 Only trained service personnel should attempt to repair any portion of the
hydraulic system.
 Do not allow hydraulic fluid to come into contact with the skin.
 Avoid inhaling spray or mist created by escaping hydraulic oil.
 Penetration of pressurized 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 help prevent injury, use appropriate personal protective equipment (e.g.
protective gloves, long sleeves and industrial goggles.)
ENVIRONMENTAL NOTE
Hydraulic oil is a potent contaminant of water.
- Recycle used hydraulic oil if possible.
- Always store hydraulic oil in appropriate containers.
- Avoid spills.
- Spilled hydraulic oil should be removed with oil-binding agents at once and
disposed of according to local regulations.
- If recycling is not possible, dispose of used hydraulic oil according to local
regulations.

Battery Acid
WARNING
Battery acid contains dissolved sulfuric acid. This is toxic.
 Avoid contact and consumption.
 In case of injury, seek medical advice immediately.
WARNING
Battery acid contains dissolved sulfuric acid. This is corrosive.
- When working with battery acid, always wear protective clothing and eye
protection.
- Do not allow any acid to get onto clothing or skin or into the eyes; if this does
happen, rinse immediately with plenty of clean water.
- In case of injury, seek medical advice immediately.
- Immediately rinse away spilled battery acid with plenty of water.
ENVIRONMENTAL NOTE
Dispose of used battery acid according to local regulations.

13. Operator Warning Decal
Data plate
The data plate is designed to inform personnel
of truck capacity and other important truck
specifications. The operator should locate,
read, and understand the data plate prior to
using the forklift truck.
DANGER
Risk of tip-over.
Never attempt to lift a load greater than the maximum capacity listed on this plate.
Parking brake warning decal

This decal reminds operators to engage the parking
brake lever whenever it is necessary to set the parking
brake as it is not automatically applied
Voltage decal
These decals indicate the proper battery voltage for the
trucks electrical system. Using a battery of wrong voltage
could damage the truck.

Operator warning decal
This decal lists a number of fundamental safety points that are crucial to safe operation.
Operators must understand these items and remain aware of them during truck operation.
Trainer operator warning decal

This decal states the requirement that only trained and
authorized personnel are to operate truck.
Test or service warning decal

This decal gives important safety information for
personnel servicing or testing the truck.

Never stand or walk under forks warning decal
This decal warns personnel not to stand or walk on, or
under, the forks at any time. This applies to operators as
well as all others.
Do not lift personnel warning decal

This decal states that the operator should never
use the forks for lifting personnel for any reason.
Even if special work platforms for lifting
personnel are available, they are not to be used
with this truck to lift personnel.
Crushed fingers warning decal

This decal is placed in areas where parts move
close together during normal truck operation.
The decal warns personnel to keep hands clear
of these areas at all times.
No step warning decal

This decal warns personnel of moving parts
that are unsafe to step or stand upon.

Tip-over warning decal

This decal warns operators that tip-over accidents can be avoided by
operating the truck as instructed in the operator’s manual. Operators are
reminded to fasten the seat belt to minimize the risk of injury if a tip-over
does occur. This decal also reminds operators to slow down while
turning to avoid tip-over. In case of tip-over, the decal instructs operators
to stay in the seat, hold onto the steering wheel tightly, brace feet, and
lean away from the direction of impact.
WARNING
Jumping from the truck during a tip-over can result in severe injury or
death.
If the truck starts to tip over, DO NOT JUMP!
Stay in the seat, hold onto the steering wheel tightly, brace feet, and
lean away from the direction of impact.
Back up alarm warning decal

This decal is present if the truck is equipped with a
back-up alarm. The decal reminds the operator that the
alarm must sound anytime the truck is moving in
reverse. It also warns the operator to maintain a clear
view in the direction of travel.


III
Overview

1. Specifications
Figure 1.1 Outside View

Technical parameters
KBET18 Specifications (6-30-16)

Metric Imperial
1.1 Manufacturer (abbreviation) UOM BAOLI UOM BAOLI

Distinguishing mark
1.2 Model designation KBET18/4.7m-triplex KBET18/4.7m-triplex

1.2.1 Chassis configuration 3-Wheel 3-Wheel
1.3 Power unit: battery, diesel, LP, gas Electric Electric
1.4 Operation: manual, pedestrian, rider standing, rider seated, order picker Seated Seated
1.5 Rated capacity/rated load Q kg 1600 lb 3500
1.6 Load centre distance c mm 600 in 24
1.8 Load distance, centre of drive axle to fork x mm 375 in 14.7
1.9 Wheel base y mm 1295 in 51
2.1 Service weight (with battery) kg 3700 lb 8150
Weight
2.1a Service weight (without battery) kg 2880 lb 6350

2.2 Axle loading, with load front/rear kg 5160/320 lb 11375/705
2.3 Axle loading, without load front/rear kg 1900/1800 lb 4190/3970
3.1 Tire type: cushion, cushion super elastic, pneumatic S/E S/E
Tyres/chassis
3.2 Tire size, front 18x7-8 18x7-8

3.3 Tire size, rear 16x6-8 16x6-8
3.5 Wheels, number front/rear (× = driven wheels) 2x/2 2x/2
3.6 Tread, front b10 mm 890 in 35
3.7 Tread, rear b11 mm 205 in 8
4.1 Mast/fork carriage tilt forward/backward α /β ° 5/5 ° 5/5
4.2 Height of mast lowered h1 mm 2185 in 86
4.3 Free lift h2 mm 1185 in 46.6
4.4 Lift h3 mm 4700 in 185
4.5 Height of mast extended h4 mm 5542 in 218
4.7 Height of overhead guard (cabin) h6 mm 2015 in 79
Basic dimensions
4.8 Seat height relating to SIP/stand height h7 mm 958 in 38

4.12 Height of tow coupling h10 mm 600 in 24
4.19 Overall length l1 mm 2965 in 116.7
4.20 Length to fork face l2 mm 1895 in 74.6
4.21 Overall width b 1/b 2 mm 1066 in 42
4.22 Fork dimensions DIN ISO 2331 s/e/l mm 35*120*1070 in 1.4*4.7*42
4.23 Fork carriage: class Class II Class II
4.24 Fork carriage: width b3 mm 968 in 38.1
4.31 Ground clearance under mast, with load m1 mm 120 in 4.7
4.32 Ground clearance, center of wheelbase m2 mm 110 in 4.3
4.33 Aisle width with pallet 40" x 48" across forks Ast mm 3240 in 127.6
4.35 Turning radius Wa mm 1550 in 61
Electric engine Performance data
5.1 Travel speed, with/without load km/h 14/15.5 mph 8.7/9.6

5.2 Lift speed, with/without load m/s 0.28/0.45 fpm 55/88.6
5.3 Lowering speed, with/without load m/s 0.46/0.42 fpm 90.5/82.7
5.5 Drawbar pull, with/without load kN 8.7 lbf 1956
5.7 Gradeability, with/without load % 20/20 % 20/20
5.10 Service brake Electric/mechanical Electric/mechanical
6.1 Drive motor rating (60 min. rating) kW 2x6.5 kW 2x6.5
6.2 Lift motor (15% rating) kW 15 kW 15
6.3 Battery compartment dimension (l x w x h) mm 975/544/590 in 38.4/21.4/23.2
6.4 Battery voltage U V 48 V 48
6.4.1 nominal capacity K 5 K5 Ah 505/525/595 Ah 505/525/595
6.5 Battery weight kg 810~920 lb 1786~2028
10.1 Operating pressure for attachments bar 160 bar 160
Misc.
10.7 Sound pressure level at the driver’s seat dB(A) ≤75 dB(A) ≤75
Drive control AC AC

2. Description
General
The KBET series of forklifts are solid tire, sit-down Electrical-powered counterbalanced
models (ITA class 2).
Power train
The power transmission system is powered by batteries, and the motor through a gearbox
transmission work directly on the drive wheels.
Hydraulic system
The hydraulic system utilizes fluid pressurized by a gear pump driven directly by the motor.
The pump is gravity fed from a fluid reservoir incorporated into the vehicle frame. Working
hydraulics are controlled by a hydraulic spool valve which diverts fluid to the desired
hydraulic function as selected by the operator through control levers.
Steering system
The rear-wheel steering system is hydraulically operated and controls the rear wheel
angle through a hydraulic cylinder mounted to the steering axle assembly. Positioning of
the cylinder is based on steering wheel movement which actuates a proportional valve at
the base of the steering column.
Mast
The truck is equipped with a triple mast consisting of an inner, intermediate, and outer
upright and a fork carriage. A pair of lift cylinders raises and lowers the intermediate
upright during lifting and lowering. The inner upright is raised by a pair of lift chains routed
over pulleys on the intermediate upright and anchored to the stationary outer upright. This
arrangement results in a telescopic relationship between the mast uprights. A second pair
of chains is used to raise and lower the fork carriage along the inner upright. These are
routed over a free-lift cylinder dedicated to providing free-lift operation to allow the fork
carriage to move independently to the top of the uprights before they begin to move. This
allows lifting through the lower part of the lift range in areas where overhead clearance is
limited.
Electrical system
A 48-volt battery-powered electrical system provides current for starting and control
functions, and also provides the vehicle power. The system battery is charged by charger.
A main control unit processes signals from sensors, interlocks, and operator controls and
generates the appropriate release and output signals to truck functions or the operator
display unit.

3. General forklift view
General front view
1. Fork arms 7. Overhead guard

2. Front wheels 8. Mast
3. Tilt cylinders A. Forward
4. Lift control lever panel D. Right
5. Seat I. Backwards
6. Rear wheels S. Left

General rear view
1. Counterweight 7. Dashboard
2. Trailer coupling 8. Rear lights
3. Rear wheels A. Forward
4. Battery cover D. Right
5. Handle for climbing on/off I. Backwards
6. Steering wheel S. Left

Internal view
1. Battery plug /outlet 4. Hood support gas springs

2. Battery 5. Electronic panel
3. Battery cover

4. Operating Controls
6 7 8
5 9
10
4
11
2
1
1. Accelerator pedal 7. Steering wheel

2. Service brake pedal 8. Operating lever, turning lamps
3. Expansion reservoir 9. Ignition switch with start key
4. Parking brake 10. Emergency stop button
5. Steer column tilt lever 11. Multifunction panel
6. Direction lever

Start/stop key
The switch has two positions: 0=Circuit de-energized (Key removal position)
I=Live circuit
Emergency stop pushbutton

Pressing the pushbutton cuts off the power to the live parts of the truck.
WARNING
This pushbutton must be used only in emergencies; repeated use of this device may
cause problems with the electronic equipment. Remove the cause of the emergency
block. Restore the functions of the forklift by proceeding as follows:
Turn the key of the switch to position "0";
Release the pushbutton by rotating it clockwise, and the button will release
automatically.
Return the key of the switch to position "I".
NOTE
When restarting the truck, if unusual behavior or alarm messages recur, have the truck
inspected by service personnel.

Hydraulic control levers
WARNING
The truck is equipped with a safety system that disables all the hydraulic functions when
the operator is not seated on board.
The functions of the levers are indicated by the label located on the top of the knob.
Lifting control lever

This lever controls the lifting of the fork arms and must be operated to raise or lower the
load.
- To raise the fork arms, move the lever backward "B".
- To lower the fork arms, move the lever forward "A".
Tilt control lever

This lever controls the inclination of the lift “Tilt” and fork arms.
-To tilt the lift forward, move the lever towards " A ".
-To tilt the lift backward, move the lever towards" B ".

Side shift control lever (option)

This lever shifts the forks to the side. It is used to align the fork arms with the load pick-up
or deposit position.
- To shift the fork arms to the left, position the lever forward "A".
- To shift the fork arms to the right, position the lever backward "B".
Supplementary equipment control lever (option)

This lever controls supplementary equipment. Its use will be indicated by special stickers.

Horn button
Press the plastic cover (1) in the center of steering wheel to sound the horn when
necessary.
Steering wheel
The steering wheel is operated in the conventional manner, that is, when the wheel is
turned right the truck will turn to the right; when the wheel is turned left, the truck will turn
to the left. The steer wheels are located at the rear of the truck. The rear of the truck will
therefore swing out when a turn is made.

Steering column tilt angle adjustment

The steering column tilt angle may be adjusted within a range of 4.5 degrees to suit
individual operators. The steering column is unlocked by turning the locking lever (1)
counterclockwise and locked by turning it clockwise.
After the adjustment, move the steering wheel back and forth to confirm that the lever is
not loose.
WARNING
Driving with the tilt angle locking lever loose can cause a collision due to loss of control.
Adjust the steering column tilt angle only when the vehicle is stationary.
Parking brake
The parking brake must be applied every time the operator leaves the truck:
- To apply the parking brake, pull the lever (1) into position "A", making it travel at least 3
clicks. The corresponding indicator light on the control panel will light up.
- To release the parking brake, pull the lever further into position "A", press the button (2),
and while keeping the button pressed return the lever to position "B".

NOTE
A switch is located under the parking brake lever. This micro switch ensures that
the truck cannot be operated when the parking brake is applied.
Service brake
The service brake pedal (1) is positioned next to the driving pedals.
Pressing the pedal (1) causes the forklift to slow down until it stops.
Direction lever
F FORWARD
N NEUTRAL
R REVERSE
The direction lever is mounted on the steering column and is used to select forward or
reverse. The direction lever must be in neutral at start-up.

Travel
Traveling is performed using the direction lever on the steering wheel and pressing the
accelerator pedal (2).
Operated in position "F", the truck moves "FORWARD";
Operated in position "R", the truck moves "BACKWARD";
Positioned in the center, the forklift remains in neutral.
Seat adjusting lever

The operator’s seat may be adjusted to a position which is comfortable and provides easy
access to all hand and foot controls. The seat is unlocked by moving the adjusting lever to
the left. Before driving the truck, adjust operator’s seat and make sure that it is securely
locked.

Lights
Front lights
Two head lights (1) and combination lights (2) (turn signal and clearance) are installed at
the front side of the truck.
Rear combination lights

The combination lights (3) at the rear contain turn signals, tail/clearance lights, brake lights,
and back-up lights.

Light switch
The head lights, clearance lights, and tail lights are controlled by a three-position switch on
the end of the turn signal lever (1) according to the following chart:
Position
0(OFF) 1st 2nd
Light
Clearance light (amber) OFF ON ON
Head Light (white) OFF OFF ON
Tail Light (red) OFF ON ON
CAUTION
These lights will operate regardless of key switch position. Ensure they are off when not
required to avoid inadvertent discharge of the battery.
Turn signal lever

Use the lever (1) to operate the turn signals. Pulling the lever back operates the right-hand
turn signal. Pushing it forward operates the left-hand turn signal.
NOTE
The turn signal lever does not automatically return to the neutral position. It must be
moved back to neutral manually when the signal is no longer needed.

Hood
The hood can be opened to provide access to the battery compartment.
Opening:
 Move the seat forward and tilt it before opening the hood. To open the hood,
lift upward on the hood lock lever (1). The lock will release and the hood can
be raised with little effort due to the aid of a spring-assisted damper strut.
Closing:
 Lift up the hood slightly to unload the strut then lightly press the lock collar (2)
on the strut. This will release the lock. Close the hood gently and press down
until the hood latches securely.
DANGER
Operating the vehicle without locking the hood is very dangerous.
Confirm that the hood is securely closed before operating the vehicle.

Fork stops
The fork spacing should be adjusted according to loads to be handled. Fork stops are
provided to lock the forks in position. To adjust fork spacing, pull up the fork stop on either
fork and turn it until it is held in the up position. Shift the fork to the desired position. Turn
the fork stop again until it locks into position. Wiggle the fork to confirm secure positioning.
WARNING
Incorrect fork position can result in an unstable or unbalanced load.
Always position the forks so that the center of gravity of the load is centered between
the forks. Both forks must be the same distance from the centerline of the truck.
Multifunction panel
The multifunction panel is the interface between truck and operator. It displays information
on the display, and some adjustments can be made using the respective pushbuttons.

Traveling speed (km/h)
Hand brake switch, lamp lights when pulling the hand brake
With safety seat switch open, meter indicates seat symbol, main
contactor can’t be connected and truck can’t travel until seat switch
closes.
Hour meter/Odometer
Turning angle, indicating the position of rear wheel
Maintenance required indication

Remind the users to maintain and service the forklift truck.
Slow-speed operating
With the lamp on, the traveling speed and lifting speed will be reduced
in slow-speed mode. Increases parameters when in adjusting mode.
Traveling speed (Indicated from “0-9”)
Overheated motor temperature warning
Battery level (indicated by 9 segments)

1. When the Battery capacity display 1 or 2 segments, please charge.
2. The Battery capacity display 1 segments, the 1 segments will start
flashing must be immediately charged.
3. keep using , the Battery capacity will display 0，the fault code 12,
low-power states , start limiting functional。
 lift and auxiliary movements of the mast are disabled ( the
hydraulic steering function remains active when requested);
 the output current of the traction and pump controller is reduced
to about 50% of the maximum output current used by the forklift
truck;
 the speed of the traction motor is reduced to 800rpm.
Press E-S-H button, you can set operating mode for system.
(E-economic mode, S-midrange mode, H-high mode)
H-High mode: High acceleration, decelerate rate, max. grade ability,
suitable for loading large quantity goods in short time and climbing
abrupt slope, this mode wastes electricity, only used when necessary.
S-Midrange mode: The parameter lower than High mode
E-Economic mode: The parameter has been optimized. Working on
this mode in general for saving electricity.

1. Start the key switch, press ENTER button for 3 seconds, enter into
adjust and diagnosis mode.
2. When operating, press for 3sec, enter into diagnose mode.
3. Quit when pressing ENTER under diagnosing mode, the enter key
is used for setting new parameter.
1. Reduce the parameter in adjusting mode when pressing this key.
2. The parameter can be reduced in adjusting mode.

3. Press the key for 1sec, to toggle between mileage or hours.
NOTE
At a subzero environment, the display may not indicate any signal. This does not
preclude normal operation of the truck, but the display of the fault codes is blocked.

Fault code Description Fault code Description
1 Max. battery voltage 2 Min. battery voltage
3 Pedal trimmer fault 5 Eprom alarm
6 Pre-charge 8 Power
25
9 Inverter 11 Capacitors
12 Low battery voltage 13 Over-heating motor
19
15 Motor current offset alarm 17 Main breaker
16
18 Watchdog timer alarm 20 Power inverter over-heating
22
37 Alarm on 5V encoder voltage 38 Alarm on 12V output voltage
50 Pump motor commands 61 Motor blocking over-heating

active on start 62
65
63 Seat switch open on start 64 Wrong start
74 Encoder alarm 77 Motor thermal sensor alarm
75 78
80 Inverter temperature alarm 83 CRC fault alarm
81
84 Bank CRC restored 90 Steering sensor alarm
91 Brake pedal switch alarm 98 Capacitors pre-charge too slow
99 Capacitors pre-charge timeout
Safety step & safety grip

Safety steps are provided on left sides of the truck. A hand grip rail is provided on the front
left pillar of the overhead guard. Use the safety step and hand grip whenever entering or
leaving the truck.
Towing pin
The towing pin is integrated into the counterweight, and is used to tow the truck if
necessary.

5. Decal Locations
1. Warning decal, no step 6. Warning decal, sit-down rider 11. Warning decal, tip-over
instructions
2. Lifting point decal (both side) 7. Warning decal, trained operators 12. warning decal,
only pe5rsonnel/forklifts
3. Warning decal, pinch point 8. Warning decal, do not lift personnel 13. Warning decal, service
precautions
4. Data plate 9. Warning decal, hood latch 14. Decal, battery voltage
5. Warning decal, back-up alarm 10. Warning decal, parking brake

6. Data Plate
(1) MODEL – shows the model (8) BATTERY WEIGHT – (electric trucks
designation of the truck. only) – shows the allowable weight
(2) SERIAL No./Year – shows the serial range (MAX and MIN) for the battery
number and year of manufacture of in pounds and kilograms.
the individual truck. (9) BACK TILT – shows the maximum
(3) MADE IN – shows the country in angle that the mast can be tilted
which the truck was originally back.
manufactured. (10) LIFT TYPE – shows a letter
(4) TRUCK WEIGHT – shows the weight corresponding to the type of mast
of the truck (in pounds and kilograms) construction as follows:
with forks. This weight does not S for single masts
include the battery on electric trucks. D for double masts
(5) BATTERY VOLTAGE – (electric T for triple masts
trucks only) – shows the system Q for quad masts
voltage of the truck. (11) (Diagram) – illustrates the
(6) AMP-HR MAX – (electric trucks only) dimensions A, B, C, and D used in
–shows the maximum current CAPACITY chart (14).
capacity in amp-hrs. for any battery (12) DRIVE TIRES – shows the required
to be used in the truck. size and type of drive tire.
(7) BATTERY TYPE – (electric trucks (13) TRUCK TYPE – shows the
only) – shows the required battery designation of the truck with respect
designation, as outlined in ANSI to hazardous environments as
B56.1. A battery of the correct outlined in 29CFR1910.178. This
designation must be installed in order designation corresponds to the
for the TRUCK TYPE designation to environment(s) in which the truck is
be valid. approved for use.

(14) CAPACITY – shows the maximum load weight (in pounds and kilograms) that
can be safely lifted for the corresponding devices listed under ATTACHMENT(S). In
order to achieve a listed capacity safely, the lift height must be kept within the
corresponding value shown in column C and the load center of gravity must be
within the corresponding values shown in columns A, B, and D.


IV
Use and Operation

1. Forklift Transport and Lifting
1.1 Transporting the Forklift
The forklift is normally transported by truck and train complete with Mast. The forklift must
be secured to the transport means during transport using appropriate restraint systems.
Block the wheels with wedges to prevent even the slightest movement.
Environmental Conditions for Transport and Storage

The forklift must be protected from atmospheric agents during transport and storage, and
it must be suitably protected in salty environments.

1.2 Hoisting the Truck
This section explains the attachment of lifting equipment to the truck for the purpose of
hoisting it. Many methods of rigging to a crane or hoist are possible. Explanation of such
methods as well as operation of lifting equipment is outside the scope of this manual. Both
the attachment of lifting equipment to the truck and the hoisting operation itself must be
performed by personnel experienced in rigging.
WARNING
Lifting equipment of insufficient capacity can fail and cause severe injury or death.
Ensure that all lifting slings, hardware, or other equipment has sufficient capacity to
carry the weight of the truck. Refer to the truck data plate for truck weight. If a battery is
installed, its weight must be added to the truck weight listed on the data plate.

 Lower the mast fully, and tilt it fully back.

 Disconnect the battery.
 Attach lifting slings at the towing pin on the rear (1), and the outer sides of the
top cross member of the outer upright on the mast (2) to provide a three-point
lifting arrangement. Secure the slings on the mast so they will not slide together.
Ensure that the towing pin is fully inserted through both of its bores in the
counterweight.
 Adjust the slings and lifting device so that they will not contact the overhead
guard during the lifting process. If a spreader bar is not used, the truck can be
lifted with the rear wheels higher than the front wheels to achieve clearance
between the lifting equipment and the overhead guard or its attached accessories
such as lights. Remove the forks if necessary.
WARNING
The overhead guard will be damaged if it is contacted by lifting equipment that is under
tension from lifting. This can result in later failure of the overhead guard and the risk of
severe injury or death. Ensure that no part of any lifting equipment contacts the
overhead guard during lifting.
Ensure that slings or any other lifting equipment will remain clear of any sharp edges,
hydraulic lines or hoses, or attached items such as lights or brackets throughout the lifting
process.

2. Commissioning and Breaking-In

If the forklift must be towed, see the section on towing.
The forklift does not require special breaking-in operations.
WARNING
Wheel mounting hardware sometimes requires several cycles of tightening before it fully
seats. For this reason, wheel mounting screws or nuts will often work loose in the period
immediately following initial tightening
When placing a new truck into service, the wheel mounting screws or nuts must be
checked for tightness every 10 hours until no further loosening is detected. See the
procedure for checking wheels and tires in the Maintenance section.
3. Daily Checks Before Use

Perform the checks listed below on a daily basis to keep forklift in good condition. These
checks supplement and do not replace the scheduled maintenance operations.
 Visually check the correct positioning and fastening of the various truck safety
components illustrated in the "Safety devices "paragraph: overhead guard, shear
protection net (if applicable), load rack ,fork stop blocks, fork retaining device,
chain retaining device, chain tension rod retaining device, fork carriage retaining
device. etc.
 Check that the seat switch sensor works correctly.
 Make sure that the seat belt works correctly.
 Make sure that the brakes work correctly, checking their travel and efficiency.
 Make sure that the horn and the reverse gear warning buzzer work correctly.
 Check the tire condition.
 Make sure that the lights work correctly (if applicable).
 Visually check that the lift chains are taut.
 Check the automatic return to neutral position of the direction lever.
 Check the battery electrolyte level and density (see battery manual).
 Check that the emergency stop pushbutton works correctly.

 Make sure that the battery air vent (A) located under the seat is not obstructed.
Remove any rags or other objects that may obstruct correct ventilation of the
battery. Even the slightest movement.
If any malfunction is noted, have the truck inspected by qualified maintenance personnel
before use.
4. Use of Truck
4.1 Stepping on/off the truck

After having performed the daily checks, carry out the following operations to use the
truck:
 Step on to the truck from the left-hand side by placing your left foot on the non-slip
step plate (B) while gripping the handle (A) with your hand. For versions with cab
(option), open the door. using the respective handle/pushbutton and step on to the
truck as described previously.
 To step off the truck, in versions with cab open the door using the handle or
pushbutton, and for all versions use the step plate (B) and handle (A).
4.2 Starting the forklift
Sit on the seat and fasten the seat belt, if the truck has a closed cab, check that the door is
closed before starting the truck.
NOTE
There is a sensor on the seat that detects the presence of the operator when seated on
the driver’s seat. Activation of this sensor enables operation of the truck.
 Check the emergency pushbutton
 Check that the EMERGENCY stop pushbutton (1) is not pressed.
Insert the key

Insert the key (2) and turn it to position "I". The display lights up, indicating that the
electrical circuits are operating.

NOTE
The electronic equipment performs a check on the sequence of truck starting
operations. Any actuations during this phase (e.g.: accelerator pedal, lift lever, etc.) will
generate alarm signals.
4.3 Forklift Operation
Release the parking brake (1), and the relative LED (2) will turn off.
NOTE
For all driving conditions, check that the fork arms are raised at least 5 cm above the
ground and that the lift is tilted backwards.
Move the lever to the desired direction of travel (A or B), then press the accelerator pedal
(1).

NOTE
For all driving conditions, check that the fork arms are raised at least 5 cm above the
ground and that the lift is tilted backwards.
NOTE
If the truck does not move, check that there are no fault codes active.
4.4 Forklift Braking/Stopping
To stop the truck, release the accelerator（1）.

Press the service brake pedal (2) progressively until the truck comes to a complete stop.
The stop lamps turn on in the rear lights unit.
Block the forklift by applying the parking brake (3).
WARNING
Harsh braking can cause loss of load.
Do not brake harshly when carrying a load on the forks. Always tilt the mast back
when carrying a load on the forks.

If it is necessary to reverse direction of travel while driving without a load on the fork arms,
this operation can be performed rapidly without using the service braking by moving the
lever from the current position to the new position. This is called counter-current braking
(or “plugging”). The degree of braking force is then dependent on accelerator (1) position.
4.5 Leaving Truck
When leaving the machine, lower the forks to the ground.

Block the forklift by applying the parking brake (3).
Turn the truck off by turning the key (2) to position "0", and remove the key from the panel.

WARNING
NEVER LEAVE the truck without having first applied the parking brake (3) and removed
the key
NEVER LEAVE the truck on a slope. If the truck must be left on a slope, suitable wheel
chocks (4) must be positioned under the front wheels.
4.6 Steering the Forklift
A special viewer (1) on the display indicates the position of the wheels by means of seven
marks, indicating the steering direction to the operator.
When the central reference mark "C" is blackened, the truck is steering straight ahead.
NOTE
Depending on the positioning of the rear wheels and whether the accelerator pedal is
pressed, the respective marks on the display light up.

With the right mark "C" blackened: the lever at “A” position pressing pedal (1) causes the
truck to rotate anticlockwise "A"; the lever at “B” position causes the truck to rotate
clockwise "B".
4.7 Speed Restriction
Speed reduction systems are routinely installed on all forklift versions, which cut in in the
following cases:
 When the forklift is turning.
 When the battery is low.
NOTE
Service personnel authorized by the manufacturer can change or introduce other speed
restrictions upon request.
4.8 Stopping the Forklift in an Emergency
In case of an emergency, press the emergency stop button (1); the truck will go into
neutral if it is in gear, then press the brake pedal to stop.

NOTE
After pressing the emergency stop button, follow the instructions provided in the
"EMERGENCY STOP button" paragraph in chapter"3".
4.9 Forklift Use in Cold-Storage Rooms
A truck specifically equipped for cold-storage rooms must be used when working at
Trucks equipped for working in cold climates and cold-storage rooms may be used at a
minimum temperature of - continuous service during work shifts in
cold-storage rooms and at -32°C (- -continuous service in cold-storage
rooms.
CAUTION
The truck must always be parked outside the cold zone/cold-storage room.
CAUTION
If the truck has been working in environments at temperatures below -
and it is taken outside the cold-storage room, let it stand either for a sufficiently long
time to allow evaporation of any condensation (at least 30 minutes) or a sufficiently
short time to prevent the formation of any condensation (less than 10 minutes).
Avoid the formation of ice on the forklift.
CAUTION
NEVER drive the truck into the cold-storage room when condensation has formed
on it

5. Adjustment of the Fork Distance

 Raise the locking lever (1) or raise and rotate the
knob (2) by 180°depending on the type of lock,
(1) or (2), installed on the fork arms.
 Move the fork arms (3) in relation to the
dimensions of the load to be lifted.
 Be careful to maintain an equal distance of the
two fork arms from the center line of the fork
carriage.
 Check that the locking occurs inside one of the
notches provided on the fork carriage.
WARNING
For greater load stability, the distance between the two
fork arms must be as large as possible while remaining
consistent with the load’s lifting points so that the load’s
center of gravity is at the center of the fork arms.
WARNING
For greater load stability, the position of the fork arms
must be as symmetric as possible with respect to the
center of the fork carriage.
6. Towing Trailers
The forklift is not qualified to tow trailers.
7. Forklift Towing
During the towing operation, the operator must be on board the truck in order to perform
the steering and braking operations.

NOTE
Use non-metallic cables for towing.
Place the direction lever (1) in neutral.
8. Changing the Battery
WARNING
Specialized training is required to handle batteries safely.
Batteries may only be changed by properly trained personnel in accordance with the
instructions of the battery manufacturer and the following procedure.
NOTE
The battery must always be changed on the right-hand side of the truck. A slot is
provided in the overhead guard to accommodate lifting equipment.
WARNING
If any lifting equipment (forklift trucks or other lifting equipment) used to change a
battery has insufficient load carrying capability and/or forks whose length is too short,
there is a risk of accidental injury or death.
Use only equipment of sufficient size and load carrying capability to change batteries.

WARNING
Batteries must not be changed if the truck is bearing any load. The weight of the battery
affects truck stability so there is a risk of the truck tipping over with injury to operators or
bystanders if a battery is changes while the truck is loaded always lower the forks fully
so they are resting on the ground before changing
 Park the truck safely.

 Fully lower the fork carriage.
 Tilt the mast forwards until the fork arms touch the ground.
 Apply the parking brake.
 Switch off the key switch.
 Press the emergency stop button.
 Open the battery covers (1)
 Pull the battery plug (2) out of the battery socket.

WARNING
Shorting of battery terminals can cause burns, electrical shock, or explosion.
Do not allow metal parts to contact the top surface of the battery. Make sure all terminal
caps are in place and in good condition.
 Carefully move the lifting gear into position over the battery.
 Insert the hooks of the lifting gear into the openings provided for this purpose in the
battery case.
 Carefully lift the battery (A) and move it slowly out of the truck chassis (B).
 Check the battery for leaking acid, cracked housing or raised plates.
 Check that the battery plug and cable are in good condition and leave the battery in a
safe place.

WARNING
Batteries of incorrect size or weight will affect truck stability and cause the risk of
tip-over.
Install only batteries whose weight meets the specification listed on the truck data plate.
WARNING
Use of a fuel cell can affect truck stability and cause the risk of tip-over.
Contact the factory for written approval for use of a fuel cell with the truck. Do not install
a fuel cell in the truck without written approval.
 Carefully position the replacement battery in the battery box. Disconnect and remove
all lifting equipment.
 Plug the battery plug into the battery connector socket.
 Close the battery cover.
 Pull out the emergency stop button and the truck is ready for service.
WARNING
Batteries produce explosive gasses.
Always store batteries in well ventilated areas.

9. Connecting the Battery to an External Charger
WARNING
Specialized training is required to charge batteries safely.
Batteries may only be charged by properly trained personnel in accordance with the
instructions of the charger manufacturer and the following procedure.
WARNING
Explosive gasses are released during battery charging
Charge batteries only in well ventilated areas.
 Park the truck safely

 Fully lower the fork carriage
 Tilt the lift mast forwards

The fork arms must touch the ground.
 Apply the parking brake
 Switch off the key switch
 Press the emergency stop button
 Open the battery cover(s)
WARNING
Dangerous concentrations of explosive gasses can occur during battery charging if the
battery cover is not open.
The battery cover must be left completely open during the entire charging period to
allow ventilation.
 Remove the battery plug (2) from the connecting socket (3).
 Attach the connector plug of the external battery charger to the battery plug (2)
 Switch on the battery charger.

Periodic inspection and servicing

1. Recommended lubricants
Capacities listed below are approximate. Actual fill levels should always be determined
from the corresponding level marks on reservoirs or dipsticks.
Element to be Quantit International

Lubricants
supplied y specifications
Hydraulic L-HM46 ISOVG46
*
circuit L-HM32(cold storage) ISOVG32
Bearings and
grease - JISK2220/2#
nipples
Grease:
Axle support -
MOLYCOTETypeP40
Oil: SAE-80W/API
Reductions 0.6 l
AMBRA AXF80W90 GL4/UTTO
Lubricant
Chains - STRUCTOV ISO VG 150
FHD
Oil-immersed 0.2 l (0.2
dot3
brakes qts.)
*: Hydraulic Fluid capacity is 15L (15.8 qts.) for masts of maximum fork height of 4700mm
(185 inches) or less. Higher masts have capacity of 20L (21.1 qts.)

2. Daily inspection
The following inspection tasks in this section should be carried out by the operator or
designated service personnel before each shift or at least daily. This inspection is not part
of the regularly scheduled maintenance listed elsewhere in this chapter and is not
intended to replace any of it. Regularly scheduled maintenance must be performed by a
qualified forklift technician at the intervals indicated.
If any problem affecting safety is noted, it must be repaired immediately by a trained forklift
technician. The truck must not be operated until such repairs are complete. This list does
not cover attachments or other truck modifications not manufactured by Baoli. Refer to the
respective manufacturer’s documentation for maintenance information pertaining to such
items.
WARNING
To prevent accidents during maintenance activities, the truck must be secured against
unintentional movement or start-up. Before beginning any maintenance, the mast
should be fully lowered, the parking brake should be on and the key switch turned off.
The truck must remain in this state throughout the maintenance process except for
individual maintenance activities that specifically require otherwise.
2.1 Vehicle uprightness
With the truck on a flat surface, confirm that is does not lean to one side or the other. If so
check for damage to tires, wheels, or undercarriage.
2.2 Check for leakage
Check the entire truck as well as the surface beneath it for signs of fluid leakage.

2.3 Check Wheels and Tires
Check the tires for damage and wear, and the rims for bending. The truck is equipped
from the factory with solid tires. They can be worn down to the wear mark on the sidewall.
Also check for even wearing between front and rear or left and right.
Check wheel mounting hardware for looseness. This is especially important if a wheel has
recently been removed and reinstalled for repairs, replacement, or any other reason. Have
any loose wheel mounting hardware tightened to the following torque before operation.
The wheel nuts should be tightened to 135Nm. (100ft-lbs)
WARNING
Wheel mounting hardware sometimes requires several cycles of tightening before it fully
seats. For this reason, wheel mounting screws or nuts will often work loose in the period
immediately following initial tightening.
Whenever a wheel is removed and replaced for any reason, the wheel mounting screws
or nuts must be checked for tightness every 10 hours thereafter until no further
loosening is detected.
WHEELS
solid
Type
front rear
1800kg 18x7-8 16×6-8
2.4 Check Decal Condition
Inspect all decals and the data/capacity plate for condition and legibility. Decal locations
are given in the Overview section of this manual. Refer to the decal descriptions in the
Safety section of this manual if necessary. Any damaged or unreadable decals must be
replaced.

2.5 Lights
In addition to the working lights, the truck is equipped with brake lights, tail lights, back-up
lights, and turn signals. Actuate each light to verify proper operation. Have an assistant
verify brake light operation if necessary. Ensure lenses are clean and undamaged.
2.6 Check Overhead Guard
The overhead guard is for your protection. Make certain that it is securely mounted and all
structural members are secure.

2.7 Check hydraulic oil level
 Ensure the vehicle is parked on a level surface with the forks lowered completely
and the electrical power off.
 Open the battery cover and remove the hydraulic oil cap.
 Wipe the dipstick attached to the oil cap with a clean cloth, and reinsert the cap
firmly onto the filler neck.
 Remove the cap again and read the level. For maximum fork heights of 4700 mm
(185 in) or less, the level should be at the 15 L (15.8 qts.) mark. For greater mast
lift heights, the level should be at the 20 L (21.1 qts.) mark.
 If the oil level is insufficient, add oil. Spilled or splashed oil must be wiped off
thoroughly.
2.8 Brake fluid inspection
*(1) Reservoir tank
With the electrical power off, check the level of the brake fluid in the reservoir tank. The
level should be within 6 mm of the mark on the side of the tank.
If the level is lower, add brake fluid up to the mark. If brake fluid is consumed rapidly, the
brake system may have leakage.

WARNING
Never use any oil other than brake fluid.
Do not allow dirt to get into the reservoir tank. Even a small amount of dirt in the brake
fluid may affect normal braking.
Ensure that the small vent hole in the diaphragm on the underside of the reservoir tank
cap is not clogged with dirt.
2.9 Brake pedal inspection
*(1) Brake pedal

*(2) Brake pedal floor clearance
1. Depress the brake pedal (2) fully, and check the floor clearance (2). This is the
clearance between the pedal and floor. Floor clearance must be ≥ 90mm. (3.5 in)
2. Ensure that the pedal remains firm during braking and does not bleed down under
continued pressure.
3. Also check that the pedal operates smoothly through its range.
4. Check pedal free play by pressing lightly until resistance is felt. Pedal free play should
be within 5 mm to 8 mm. (0.2-0.3 in)

2.10 Parking brake inspection
*(1) Parking brake handle

*(2) Parking brake release button
1. Fully pull the parking brake handle and check if the brake is functioning normally.
2. After fully pulling the parking brake handle, pressure the parking brake release button
and confirm that the parking brake is released.
2.11 Loading handling system
 Check the installation state of fork, if any crack or bending.

 Check fork stoppers for correct installation.
 Check for mast distortion, chain tension and oil leakage from cylinders and piping.
 Operate the lift and tilt levers to check their function.
 Check the load backrest for loose mounting bolts. Retighten where needed.
 Sound the horn as a warning and actuate the lift and tilt levers to be certain that
the carriage moves up and down properly and the mast can be tilted smoothly.
Make certain that the relief valve can be heard to operate when the mast reaches
the stroke end. Also listen for unusual noise as the mast rises and lowers.
 Check the tension and condition of the lift chains. Inspect the chains for broken
link plates, broken or deformed pins, rust, and stiffness. Inspect the chain anchors
and hardware for damage as well.

 To check the tension, raise the fork about 5cm above the ground and push the
middle of the chain with the thumb. Make certain the tension for the right and left
chains is even. If uneven tension is found, loosen the lock nut (A) of anchor pin
and adjust the chain, turning the adjusting nut (B) of the chain anchor one.
2.12 Steering wheel inspection
Perform the following inspections after switch on the power switch.

 Check free stroke of the steering wheel with the rear wheel set in the straight
traveling direction.
 The free stroke of steering wheel when idling: 50-100mm (2-4 in)
 Turn the steering wheel in the circumferential direction and also move it up and
down to check if there is any looseness.
2.13 Horn check
Press the horn button to confirm horn operation.

2.14 Drivers’ seat adjustment
Make sure the driver’s seat is securely mounted. Inspect the seat belt for fraying or
damage. Buckle the belt and check that the buckle holds securely and that it releases
easily and completely when the release button is pressed.
WARNING
A malfunctioning or defective seat belt can result in injury or death in case of accident.
Do not use the truck if the seat belt is defective. If any defect in the function of the seat
or seat belt is noticed, the truck must be removed from service until the cause is
corrected.
The seat belt must be replaced after an accident. The seat and its fastening must also
be checked by trained technicians after an accident.
2.15 Check Braking Function
Operate the truck slowly forward and press the brake pedal to confirm that the brakes
function properly and do not pull to one side.
2.16 Check Steering Function
Turn the steering wheel traveling slowly to see that the steering forces are equal in both
directions and that the steering axle functions smoothly.

2.17 Chain tension check and adjustment
Check that the chains are equally tensioned and, if necessary, adjust them as described
below:
 Turn off the forklift and perform the operations preliminary to maintenance.
 Unscrew the screw (2)
 Adjust the tension of the chain (3) by operating on the nut (1).
 When the adjustment is finished, reassemble the screw retainer (2).

2.18 Fork arm check
The fork arm check must be carried out thoroughly by expert personnel, in order to detect
all damage, breakage, deformation, etc., which could reduce safety in use.
 Wear check
Measure the sample section (ZC) as indicated in the drawing and compare it with sections
A, B, C. Maximum wear permitted at points A, B, C, is 10% compared with the sample
section.
 Deformation check
With the fork arms mounted on the plate in the working position, check that the height
difference of the tips is not greater than 3% of the length of the same. E.g.: length (L) cm
120 = (120 x 3/100) = 3.6cm
 Check for cracks
Visually check that there are no cracks on the fork arms, especially in the fork heel and
attachment areas. In case of doubt, check using a dye penetrant test.

3. Changing a Fuse
 Park the Truck on a flat surface, lower the mast, turn off the key switch, and press
the emergency stop button.
 Raise the battery cover (1) as indicated in the relative paragraph.

 The power fuse (2) is positioned on the electronic units, while the service fuses (3,
4, 5, 6, 7, and 8) are positioned in the relative fuse box.
 Power Fuses (2)
 Loosen the screws and replace the fuse, then retighten the screws.
 Service and Auxiliary Fuses (3, 4, 5, 6, 7, 8)
 Change the blown fuse in the fuse box.
 Fuse Values

 "2" = Traction and Pump power fuse 700A

 "3" = DC-DC start signal fuse 10A
 "4" = Blade fuse for starting switch 10A
 "5" = Blade fuse for lights converter 10A
 "6" = Reserve fuse
 "7" = Reversing lights fuse 10A
 "8" = Blade fuse for horn 10A
 "9" = Brake lamp fuse 7.5A
CAUTION
Before changing a fuse, eliminate the cause that led to its blowing. The blown-out fuse
must be replaced with a fuse of the same amperage only. Do not tamper with the
forklift’s electrical system.
4. Routine Lubrication
4.1 Fork Carriage Guide Greasing

NOTE
Clean the carriage guides before greasing.
Grease the guides (1) using a brush.

NOTE
For the type of lubricant to use, follow the indications provided in the "Recommended
Lubricants" table.
4.2 Trunnions Greasing

NOTE
Before greasing, clean the heads of the grease nipples.
Grease the trunnions using the grease nipples (1) located on both sides of the mast.
NOTE
For the type of lubricant to use, follow the indications provided in the "Recommended
Lubricants" table.

4.3 Lubricate Lift Chain

NOTE
If the truck is used in an environment with a particularly aggressive atmosphere, it is
advisable to perform lubrication with water-repellent adhesive grease in addition to the
normal lubrication.
Lubricate using a spray for chains.
NOTE
For the type of lubricant to use, follow the indications provided in the "Supply" table at
the end of this chapter.

4.4 Rolling Tracks Greasing

NOTE
If the truck is used in an environment with a particularly aggressive atmosphere, it is
advisable to perform lubrication with water-repellent adhesive grease in addition to the
normal lubrication.
Use a brush to lubricate the rolling tracks on the various parts of the lift mast (1) using
the type of grease indicated in the “Recommended Lubricants” table.

4.5 Check Gear Unit Oil Level

There is one gear unit on each side of the truck. Each gear unit is located immediately inboard
of each front wheel.
 Park the vehicle on flat and solid ground, and cut off the electrical power.
 Unscrew the nut (1) that is located to the front of the truck.
 The nut is located on the right-hand side of the transmission. Remove the cap,
wipe the nut and reinsert it.
 Remove the nut again to check the oil level. The level should be in the upper
portion of the hole.
 The nut (2) is located at the bottom of the transmission is oil plug, which is
removing the transmission oil.

5. Scheduled Maintenance
General
In order to keep the forklift safe and in good condition, have it serviced according to the
scheduled maintenance operations indicated in the following "synoptic table of
maintenance intervals".
Scheduled Maintenance Table

Operation hours work
Check wheel nut tightening 100 check
Parking brake check 200 check
Chain tension check and adjustment 1000 check
Check hydraulic tank oil level 1000 cleaning
Cleaning of the electronic panel 1000 cleaning
Lubricating the steering axle 1000 Lubricating
Fork carriage guide lubrication 1000 Lubricating
Service brake check 200 check
Trunnions greasing 1000 Lubricating
Rolling tracks greasing 1000 check
Grease rear wheel bearings 1000 check
Seat belt blocking system check 1000 check
Lubricate lift chain 1000 Lubricating
（1）
Chain check and maintenance •
（3）
Change gearbox oil •
Check and adjust lift clearances 1000 check
(2)
Change hydraulic oil filter cartridge •
Protective roof tightening screws check 1000 check
（1）
Check fork wear •
Check brake oil level daily check
Change hydraulic system oil 2400 change
Change brake oil 2400 change
CAUTION
When the forklift is used in dusty environments, at below zero temperatures and for
especially heavy uses, it is necessary to reduce the interval between the various
scheduled maintenance operations.

(1) = To be carried out absolutely every 3 months or according to current legislation.
(2) = Every 1000 hours or at least every 12 months.
(3) =First change after 100 hours, then every 1000 hours or every year.
ENVIRONMENTAL NOTE
Proceed as follows at each lubrication operation:
 Follow the safety precautions for the lubricant;
 Before lubricating, carefully clean the component to be lubricated;
 Use suitable binders if the lubricating product should spill;
 Keep the product in a suitable and compliant place, as per the instructions supplied
with the product;
 Dispose of the lubricating product in compliance with the current laws.

Diagrams



1. Head lamp
Front combination
2.
lamp
3. Flash light
4. Inching relay
5. Meter assy.
6. Start switch
7. Turning switch
8. Direction switch
9. Lamp switch
10. Hand brake
11. Main harness
12. Brake switch
13. Horn
14. Accelerator
15. Inching switch
16. Lift potentiometer
17. Socket assy.
18. Battery assy.
19. Controller assy.
20. Rear working lamp
21. Rear tail lamp
22. Back-up buzzer
23. Fuse box
24. DC commutator
Steering
25.
potentiometer
26. Lift motor
27. Traction motor
28. Seat switch
29. Emergency switch

Product improve suggestion sheet (Feedback)
Product name
Serial No. Product lot number
Date of delivery Start use date
Use company
Suggestion content:
To improve our forklift trucks, absorb your valuable suggestion; please send to us
suggestion content.

NOTES

KION North America Corporation

2450 West 5th North Street
Summerville, S.C. 29483
Phone 1 843 875 8000
Email :BaoliService.na@kiongroup.com

Kbet18 Operation Manual

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KION Baoli (Jiangsu) Forklift Co.

KBET18 Operator Manual (North America) Rev00 1

KBET18 Operator Manual (North America) Rev00 1

KBET18 Operator Manual (North America) Rev00 2

KBET18 Operator Manual (North America) Rev00 3

KBET18 Operator Manual (North America) Rev00 4

KBET18 Operator Manual (North America) Rev00 5

KBET18 Operator Manual (North America) Rev00 6

2. Obligations of the Equipment Owner

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KBET18 Operator Manual (North America) Rev00 9

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KBET18 Operator Manual (North America) Rev00 11

2. Operator Daily Checklist

KBET18 Operator Manual (North America) Rev00 12

KBET18 Operator Manual (North America) Rev00 13

KBET18 Operator Manual (North America) Rev00 14

6. Lifting and Lowering

7. Inclines, Ramps, Docks, Elevators

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8. Avoiding Falls and Tip-overs

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11. Battery Safety

12. Safety During Maintenance

KBET18 Operator Manual (North America) Rev00 18

KBET18 Operator Manual (North America) Rev00 19

Pressurized Hydraulic Oil

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13. Operator Warning Decal

Parking brake warning decal

KBET18 Operator Manual (North America) Rev00 22

Trainer operator warning decal

Test or service warning decal

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Do not lift personnel warning decal

Crushed fingers warning decal

No step warning decal

KBET18 Operator Manual (North America) Rev00 24

Tip-over warning decal

Back up alarm warning decal

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Figure 1.1 Outside View

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KBET18 Specifications (6-30-16)

1.1 Manufacturer (abbreviation) UOM BAOLI UOM BAOLI

1.2 Model designation KBET18/4.7m-triplex KBET18/4.7m-triplex

2.1a Service weight (without battery) kg 2880 lb 6350

3.2 Tire size, front 18x7-8 18x7-8

4.8 Seat height relating to SIP/stand height h7 mm 958 in 38

5.1 Travel speed, with/without load km/h 14/15.5 mph 8.7/9.6

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3. General forklift view

General front view

1. Fork arms 7. Overhead guard

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General rear view

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