Doosan D50S-5, D70S-5, D80S-5, D90S-5, D60S-5 Operation & Maintenance Manual
...
SB2356E03
Operation &
Maintenance Manual
FORKLIFTS
D50S-5, D60S-5, D70S-5
D80S-5, D90S-5
G50S-5, G60S-5, G70S-5
1304
Original Instruction
Table of Contents
1
Table of Contents
Information Section
Foreword ..................................................................... 2
Safety Section
Important Safety Information ..................................... 4
Safety .......................................................................... 5
Warning Signs and Labels ................................. 5
General Hazard Information ............................. 10
Operation Information ....................................... 11
Maintenance Information .................................. 14
Operator Restraint System (If Equipped) ........ 17
Avoiding Lift Truck Tipover ............................... 21
Safety Rules ...................................................... 23
How to Survive in a Tipover (If Operator
Restraint System Equipped) ............................ 29
General Section
Declaration of Conformity ........................................ 31
Specific ations ............................................................ 32
Noise &Vibration ....................................................... 48
Capacity Chart - Without Side Shifter ..................... 49
Capacity Chart - With Side Shifter .......................... 51
Serial Number ........................................................... 53
Operator's Warning and Identification Plate ........... 55
Operation Section
Operator’s Station and Monitoring Systems ........... 57
Seat Switch System ................................................. 67
Lift Truck Controls .................................................... 67
Refueling ................................................................... 72
Before Starting the Engine ....................................... 75
Starting the Engine ................................................... 78
After Starting the Engine .......................................... 81
Lift Truck Operation ................................................ 117
Auto Shift Controller ASC-202/204/208 (If Equipped)
................................................................................. 119
Operating Techniques ............................................ 124
Parking the Lift Truck ............................................. 128
Lift Fork Adjustment ............................................... 129
Storage Information ................................................ 130
Transportation Hints ............................................... 131
Towing Information ................................................. 132
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck
Forks ....................................................................... 133
Tire Inflation Information ........................................ 137
Torque Specifications ............................................ 138
Cooling System Specifications .............................. 140
Fuel Specifications ................................................. 142
Lubricant Specifications ......................................... 144
Maintenance Intervals ............................................ 148
When Required ...................................................... 152
Every 10 Service Hours or Daily ........................... 159
First 50-100 Service Hours or a Week ................. 164
First 250 Service Hours or a Month ...................... 171
Every 250 Service Hours or Monthly .................... 172
Every 500 Service Hours or 3 Months .................. 180
Every 1000 Service Hours or 6 Months ................ 184
Every 1500 Service Hours or 9 Months ................ 190
Every 2000 Service Hours or Yearly..................... 193
Every 2500 Service Hours or 15 Months.............. 197
Every 3000 Service Hours or 18 Months.............. 199
Index
Index ....................................................................... 200
Information Section
2
Foreword
Literature Information
This manual should be stored in the operator's
compartment in the literature holder or seat back
literature storage area.
This manual contains safety, operation,
transportation, lubrication and maintenance
information.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your lift truck. Guards and covers might have
been removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
lift truck which are not included in this publication.
Read, study and keep this manual with the lift truck.
Whenever a question arises regarding your lift truck,
or this publication, please consult your DOOSAN
dealer for the latest available information.
Safety
The Safety Section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the lift truck.
Read and understand the basic precautions listed in
the Safety Section before operating or performing
lubrication, maintenance and repair on this lift truck.
Operator Restraint System (If Equipped)
This manual contains safety, operation and
maintenance information for the DOOSAN operator
restraint system. Read, study and keep it handy.
WARNING
Your DOOSAN truck comes equipped with an
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DOOSAN
operator restraint system.
Photographs or illustrations guide the operator
through correct procedures of checking, operation
and maintenance of the DOOSAN operator restraint
system.
SAFE and EFFICIENT OPERATION of a lift truck
depends to a great extent on the skill and alertness
on the part of the operator. To develop this skill the
operator should read and understand the Safe
Driving Practices contained in this manual.
Forklift trucks seldom tipover, but in the rare event
they do, the operator may be pinned to the ground
by the lift truck or the overhead guard. This could
result in serious injury or death.
Operator training and safety awareness is an
effective way to prevent accidents, but accidents
can still happen. The DOOSAN operator restraint
system can minimize injuries. The DOOSAN
operator restraint system keeps the operator
substantially within the confines of the operator's
compartment and the overhead guard.
This manual contains information necessary for Safe
Operation. Before operating a lift truck make sure
that the necessary instructions are available and
understood.
Information Section
3
Operation
The Operation Section is a reference for the new
operator and a refresher for the experienced one.
This section includes a discussion of gauges,
switches, lift truck controls, attachment controls,
transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the lift truck.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the lift truck and its capabilities.
Maintenance
The Maintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without specific
intervals are listed under "When Required" topics.
Items in the "Maintenance Intervals" chart are
referenced to detailed instructions that follow.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart might
be necessary.
Perform servi ce on items at multiples of the original
requirement. For example, at "Every 500 Service
Hours or 3 Months", also service those items listed
under "Every 250 Service Hours or Monthly" and
"Every 10 Service Hours or Daily".
Environment Management
Note that DOOSAN INDUSTRIAL VEHICLE
DIVISION is ISO 14001 certified which is
harmonized with ISO 9001. Periodic
ENVIRONMENTAL AUDITS & ENVIRONMENTAL
PERFORMANCE EVALUATIONS have been made
by internal and external inspection entities.
LIFECYCLE ANALYSIS has also been made
through out the total product life. ENVIRONMENT
MANAGEMENT SYSTEM includes DESIGN FOR
ENVIRONMENT from the initial stage of the design.
ENVIRONMENT MANAGEMENT SYSTEM
considers environmental laws & regulations,
reduction or elimination of resource consumption as
well as environmental emission or pollution from
industrial activities, energy saving, environment
friendly product design(lower noise, vibration,
emission, smoke, heavy metal free, ozone depleting
substance free, etc.), recycling, material cost
reduction, and even environmentally oriented
education for the employee.
Safety Section
4
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards, and use common sense. Persons
must also have the necessary training, skills and tools before attempting to perform these functions.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING"
as shown below.
WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that m ight involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is
used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, m aintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the produc t. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
inform ation available.
Safety Section
5
Safety
The safety rules and regulations in this section are
representative of some, but not all rules and
regulations noted under the Occupational Safety
and Health Act (OSHA) and are paraphrased
without representation that the OSHA rules and
regulations have been reproduced verbatim.
Please refer to 1910. 178 in Federal Register Vol.
37, No. 202, the National Fire Protection Association
No. 505 (NFPA), American National Standard, ANSI
B56. 1 Safety Standard for Low lift and High Lift
Trucks and subsequent revisions for a complete list
of OSHA rules and regulations as to the safe
operation of powered i ndustrial lift trucks. Since
regulations vary from country to country outside in
U.S.A., operate this lift truck in accordance with local
regulations.
DOOSAN lift trucks are manufactured according to
the regulations and standards laid down in EU
Machinery Directive 98/37/EC and EMC directive
2004/108/EC. Please refer to the Directives 89/655/
EC and 89/391/EC and its am endments for the safe
use of DOOSAN lift trucks.
The most effective method of preventing serious
injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in an
accident.
Do not operate a lift truck if in need of repair,
defective or i n any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and
authorized to do so.
Warning Signs and Labels
There are several specific safety signs on your lift
truck. Their exact location and description of the
hazard are reviewed in this section. Please take the
time to familiarize yourself with these safety signs.
Make sure that you can read all warning and
instruction labels. Clean or replace these labels if
you cannot read the words or see the pictures.
When cleaning the labels use a cloth, water and
soap. Do not use solvent, gasoline, etc.
You must replace a label if it is damaged, missing or
cannot be read. If a label is on a part that is replaced,
make sure a new label is installed on the replaced
part. See your dealer for new labels.
Training Required To Operate or Service
Warning
Located on the right side of the fire wall.
WARNING
Improper operation or maintenance could result
in injury or death. Do not operate or work on the
lift truck unless you are properly trained. Read
and understand the Operation and Maintenance
Manual. Additional manuals are available from
DOOSAN Lift Truck dealers.
This label also provides allowable lift truck capacity
information.
Safety Section
6
General Warnings to Operator
Located on the right side of the operator's seat.
WARNING
Only trained and authorized personnel may
operate this machine. For safe operation, read
and follow the operation and maintenance
Manual furnished with this lift truck and observe
the following warnings :
1. Before starting machine. Check all controls and
warning devices for proper operation.
2. Refer to machine identification plate for
allowable machine capacity. Do not overload.
Operate machines equipped with attachments
as partially loaded machines when not handling
a load.
3. Put directional control or shift lever in neutral
before "ON-OFF" switch is turned on.
4. Start, turn and brake smoothly. Slow down for
turns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid running
over loose objects or holes in the roadway
surfaces. Use extreme caution when turning on
inclines.
5. Travel with load as low as possible and tilted
back. If load interferes with visibility, travel with
load trailing.
6. On grade operations travel with load up grade.
7. Watch out for pedestrians and obstructions.
Check overhead clearances.
8. Do not permit riders on forks or machine at any
time.
9. Do not allow anyone to stand or pass under the
elevated portion of any machine.
10. Be sure operating surface can safely support
machine.
11. Operate machine and attachments only from
operator's position.
12. Do not handle unstable or loosely stacked loads.
13. Use minimum tilt when picking up or depositing
a load.
14. Use extreme care when handling long, high, or
wide loads.
15. Forks should be completely under load and
spread apart as far as load permits.
16. Machine should be equipped with overhead
guard or equivalent protection. Where load
requires it, use load backrest extension. Use
extreme caution if operating without these
devices.
17. Parking-Lower lifting mechanism to floor. Put
directional control or shift lever in neutral. Set
parking/secondary brake. Turn "ON - OFF"
switch off. Chock wheels if machine is on incline.
Disconnect battery when storing electric
machines.
18. Observe safety rules when handling fuel for
engine powered machine and when changing
batteries for electric machines.
19. Avoid overuse of the inching pedal as this may
cause the automatic transmission oil to overheat
or the clutch to slip. Do not use as a footrest or
for long periods of time.
20. If user operates continuously pushing work or
both brake pedal and accelerator pedal were
depressed at the same time, it may cause the
automatic transmission oil to overheat or the
clutch to slip.
Safety Section
7
Pressure Warning
WARNING
Contents under pressure may be hot. Allow to
cool before opening.
Located on the radiator top tank by the radiator cap.
Hand Placement Warning
WARNING
No hands. Do not place hands in this area. Do
not touch, lean on, or reach through the mast or
permit others to do so.
Located on the mast.
No Standing On Forks Warning, No
Standing Under Forks Warning
WARNING
Do not stand or ride on the forks. Do not stand
or ride on a load or pallet on the forks. Do not
stand or walk under the forks.
Located on the lift cylinder.
Load Backrest Must Be In Place Warning
WARNING
Operation without this device in place may be
hazardous.
Located on the load backrest.
Safety Section
8
Overhead Guard Must Be In Place
Warning
WARNING
Operation without this device in place may be
hazardous. This guard conforms to A.N.S.I.B56.1
and F.E.M. Section IV. This design has been
tested with an impact of appropriate value.
Located on the Overhead Guard.
No Riders Warning
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
Located beside the operator's station.
Moving Fan Warning
WARNING
To avoid personal injury, stay clear of moving
fan.
Located inside the engine compartment cover.
Parking Brake
Pull the lever BACK to engage the
parking brake.
Push the lever FORWARD to release
the parking brake.
Applying the parking brake puts the transmission in
NEUTRAL. The parking brake must be applied when
leaving the lift truck and when starting the engine. If
the operator leaves the seat without applying the
parking brake, an audible alarm will sound.
Safety Section
9
WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied.
Alarm will sound if parking brake is not applied.
WARNING
Correct adjustment is necessary to provide
adequate braking. See the MAINTENANCE
section for adjustment procedures. The lift truck
may creep at engine idle and can cause damage,
injury or death. Always apply the parking brake
when leaving the lift truck. The parking brake is
NOT automatically applied.
Safety Section
10
General Hazard Information
Attach a "Do not Operate" or similar warning tag to
start switch or controls before servicing or repairing
the lift truck.
Do not start or service the lift truck when a "DO NOT
OPERATE" or similar warning tag is attached to the
start switch or controls.
Wear a hard hat, protective glasses and other
protective equipment as required by job conditions.
Know the width of your attachments so proper
clearance can be maintained when operating near
fences, boundary obstacles, etc.
Do not wear loose clothing or jewelry that can catch
on controls or other parts of the lift truck.
Keep the lift truck, especially the deck and steps,
free of foreign material such as debris, oil tools and
other items which are not part of the lift truck.
Secure all loose items such as lunch boxes, tools
and other items which are not part of the lift truck.
Know the appropriate work-site hand signals and
who gives them. Accept signals from one person
only.
Always use the overhead guard. The overhead
guard is intended to protect the lift truck operator
from overhead obstructions and from falling objects.
A truck that is used for handing small objects or
uneven loads must be fitted with a load backrest.
If the lift truck must be operated without the
overhead guard in place due to low overhead
clearance, use extreme care. Make sure there is no
possibility of falling objects from any adjacent
storage or work area. Make sure the load is stable
and fully supported by the carriage and the load
backrest extension (if equipped).
Do not raise loads any higher than necessary and
never raise a load higher than 1830 m m (72 in) with
the overhead guard removed.
Always use load backrest extension when the
carriage or attachment does not fully support the
load. The load backrest extension is intended to
prevent the load or any part of the load from falling
backwards into the operator's station.
When operating the lift truck, Do not depend only on
flashing lights or back-up alarm (if equipped) to warn
pedestrians.
Always be aware of pedestrians and Do not proceed
until the pedestrians are aware of your presence
and intended actions and have moved clear of the
lift truck and/or load.
Do not drive lift truck up to anyone standing in front
of an object.
Obey all traffic rules and warning signs.
Keep hands, feet and head inside the operator
station. Do not hold onto the overhead guard while
operating the lift truck. Do not climb on any part of
the mast or overhead guard or permit others to do
so.
Do not allow unauthorized personnel to ride on the
forks or any other part of the lift truck, at any time.
When working in a building or dock, observe floor
load limits and overhead clearances.
Inhaling Freon gas through a lit cigarette or other
smoking method or inhaling fumes released from a
flame contacting Freon can cause bodily harm or
death. Do not smoke when servicing air conditioners
or wherever Freon gas may be present.
Never put maintenance fluids into glass containers.
Use all cleaning solutions with care.
Do not use steam, solvent, or hi gh pressure to clean
electrical components.
Report all needed repairs.
Safety Section
11
Inspect the part of the chain that is normally
operated over the crosshead roller. When the chain
bends over the roller, the movement of the parts
against each other causes wear.
Inspect to be sure that chain link pins Do not extend
outside of the bore hole.
If any single link pin is extended beyond its
connecting corresponding link, it should be
suspected of being broken inside of its bore hole.
Inspect the chain anchor and the anchor links for
wear.
Do not change any factory set adjustment values
(including engine rpm setting) unless you have both
authorization and training. Especially Safety
equipment and switches may not be removed or
adjusted incorrectly. Repairs, adjustments and
maintenances that are not correct can make a
dangerous operating condition.
For any checkup, repair, adjustments, maintenance
and all other work concerning your forklift truck,
please contact your DOOSAN dealer. We would like
to draw your attention to the fact that any secondary
damages due to improper handling, insufficient
maintenance, wrong repairs or the use of other than
original DOOSAN spare parts waive any liability by
DOOSAN.
Operation Information
Mounting and Dismounting
Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands before
mounting.
Face the lift truck when mounting and dism ounting.
Use both hands face the lift truck when mounting
and dismounting.
Use the handgrips for mounting and dismounting.
Do not try to climb on or off the lift truck when
carrying tools or supplies.
Never get on or off a moving lift truck.
Do not use any controls as handholds when entering
or leaving the operator's station.
Never get on or off a moving lift truck. Never jump
off the li ft truck.
Keep hands and steering wheel free of slippery
material.
Before Starting the Lift Truck
Perform a walk-around inspection daily and at the
start of each shift. Refer to the topic "Walk-around
Inspection" in "Every 10 Service Hours or Daily"
section of this manual.
Adjust the seat so that full brake pedal travel can be
obtained with the operator's back against the
seatback.
Make sure the lift truck is equipped with a lighting
system as required by conditions.
Make sure all hydraulic controls are in the HOLD
position.
Make sure the direction control lever is in the
NEUTRAL position.
Make sure the parking brake is engaged.
Make sure no one is standing and/or working on,
underneath or close to the lift truck before operating
the lift truck.
Safety Section
12
Operate the lift truck and controls only from the
operator's station.
Make sure the lift truck horn, lights, backup alarm (if
equipped) and all other devices are working
properly.
Check for proper operation of mast and attachments.
Pay particular attention to unusual noises or erratic
movement which might indicate a problem.
Make sure service and parking brakes, steering, and
directional controls are operational.
Make sure all personnel are clear of lift truck and
travel path.
Refer to the topic "Lift Truck Operation" in the
"Operation Section" of this manual for specific
starting instructions.
Starting the Lift Truck
Do not start the engine or move any of the controls if
there is a "DO NOT OPERATE" or similar warning
tag attached to the start switch or controls.
Before Operating the Lift Truck
Test brakes, steering controls, horn and other
devices for proper operation. Report any faulty
performance. Do not operate lift truck until repaired.
Learn how your lift truck operates. Know its safety
devices. Know how the attachments work. Before
moving the lift truck, look around. Start, turn and
brake smoothly.
An operator must constantly observe his lift truck for
proper operation.
Operating the Lift Truck
Always keep the lift truck under control.
Obey all traffic rules and warning signs.
Never leave the lift truck with the engine operating,
or with the parking brake disengaged.
Operate the engine only in a well ventilated area.
Lower the mast, with or without load, before turning
or traveling. Tip over could result. Watch out for
overhead obstructions.
Always observe floor load limits and overhead
clearance.
Start, turn, and brake smoothly. Slow down for turns,
grades, slippery or uneven surfaces.
Watch the road carefully for any obstacle when
driving the truck. Do not go fast over bumps, pot
holes or other rough grounds, otherwise the engine
might go OFF by a severe impact.
In case of engine going OFF, press the brake pedal
at one time as hard as possible in order to stop the
truck. Pressing the brake pedal several times has a
risk that the brake would not work.
Use special care when operating on grades. Do not
angle across or turn on grades. Do not use a lift
truck on slippery grades. Travel with forks
downgrade when unloaded. Travel with load
upgrade.
Do not overload, or handle offset, unstable, or
loosely stacked loads. Refer to load capacity plate
on the lift truck. Use extreme caution when handling
suspended, long, high or wide load.
Safety Section
13
Tilt an elevated load forward only when directly over
unloading area and with load as low as possible.
Do not stunt ride or indulge in horseplay.
Always look and keep a clear view of the path of
travel.
Travel in reverse if load or attachment obstructs
visibility. Use extreme caution if visibility is
obstructed.
Stay in designated travel path, clear of dock edges,
ditches, other dropoffs and surfaces which cannot safely support the lift
truck.
Slow down and use extra care through doorways,
intersections and other location where visibility is
reduced.
Slow down for cross aisles, turns, ramps, dips,
uneven or slippery surfaces and in congested areas
and avoid pedestrians, other vehicles, obstruction,
pot holes and other hazards or objects in the path of
travel.
Always use overhead guards except where
operation conditions Do not permit. Do not operate
lift truck in high stacking areas without overhead
guards.
When stacking, watch for falling objects. Use load
backrest extension and overhead guard.
Refer to the topic "Operation Techniques" in the
"Operation Section" of this manual.
Loading or Unloading Trucks/Trailers
Do not operate lift trucks on trucks or trailers which
are not designed or intended for that purpose. Be
certain truck or trailer brakes are appl ied and wheel
chocks in place (or be certain unit is locked to the
loading dock) before entering onto trucks or trailers.
If trailer is not coupled to tractor, make sure the
trailer landing gear is properly secured in place. On
some trailers, extra supports may be needed to
prevent upending or corner dipping.
Be certain dock plates are in good condition and
properly placed and secured. Do not exceed the
rated capacity of dock boards or bridge plates.
Lift Truck Parking
When leaving the operator station, park the lift truck
in authorized areas only. Do not block traffic.
z Park the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips
touch the floor.
z Move the direction control lever to NEUTRAL.
z Engage the parking brake.
z Turn the key switch off and remove the key.
z Turn the disconnect switch to OFF.
z Block the drive wheels when parking on an
incline.
Safety Section
14
Maintenance Information
Perform all maintenance unless otherwise specified
as follows :
z Park the lift truck in authorized areas only.
z Park the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips
touch the floor.
z Place the transmission controls in neutral.
z Engage the parking brake.
z Stop the engine.
z Remove the start switch key and turn the
disconnect switch OFF (if equipped).
z Block the drive wheels when parking on an
incline.
Pressure Air
Pressure air can cause personal injury. When using
pressure air for cleaning, wear a protective face
shield, protective clothing and protective shoes.
The maximum air pressure must be below 205 kPa
(30 psi) for cleaning purposes.
Fluid Penetration
Always use a board or cardboard when checking for
a leak. Escaping fluid under pressure, even a
pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is
injected into your skin, it must be treated by a doctor
familiar with this type of injury immediately.
Crushing or Cutting Prevention
Support equipment and attachments properly when
working beneath them. Do not depend on hydraulic
cylinders to hold it up. Any attachment can fall if a
control is moved, or if a hydraulic line breaks.
Never attempt adjustments while the lift truck is
moving or the engine is running unless otherwise
specified.
Where there are attachment linkages, the clearance
in the linkage area will increase or decrease with
movement of the attachment.
Stay clear of all rotating and moving parts.
Keep objects away from moving fan blades. They
will throw or cut any object or tool that falls or is
pushed into them.
Do not use a kinked or frayed wire rope cable. Wear
gloves when handli ng the wire rope cable.
Retainer pins, when struck with force, can fly out
and injure nearby persons. Make sure the area is
clear of people when driving retainer pins.
Wear protective glasses when striking a retainer pin
to avoid injury to your eyes.
Chips or other debris can fly off objects when struck.
Make sure no one can be injured by flying debris
before striking any object.
Falling Objects Protective Structure (FOPS)
This is an attached guard located above the
operator's compartment and secured to the lift truck.
To avoid possible weakening of the Falling Objects
Protective Structure (FOPS), consult a DOOSAN
dealer before altering, by adding weight to, welding
on, or cutting or drilling holes into the structure.
The overhead guard is not intended to protect
against every possible impact. The overhead guard
may not protect against some objects penetrating
into the operator's station from the sides or ends of
the lift truck.
The lift truck is equipped with an overhead guard
and FOPS as standard. If there is a possibility of
overhead objects falling through the guard, the
guard must be equipped with smaller holes or a
Plexiglas cover.
Any altering done that is not specifically authorized
by DOOSAN invalidates DOOSAN’s FOPS
certification. The protection offered by this FOPS will
be impaired if it has been subjected to structural
damage. Structural damage can be caused by an
overturn accident, by falling objects, etc.
Do not mount any item such as fire extinguishers,
first aid kits and lights by welding brackets to or
drilling holes in any FOPS structure. See your
DOOSAN dealer for mounting guidelines.
Safety Section
15
Burn Prevention
Coolant
At operating temperature, the engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot water or steam.
Any contact can cause severe burns.
Steam can cause personal injury.
Check the coolant level only after engine has been
stopped and the filter cap is cool enough to remove
with your bare hand.
Remove the cooling system filter cap slowly to
relieve pressure.
Cooling system additive contains alkali that can
cause personal injury. Avoid contact with the skin
and eyes and Do not drink.
Allow cooling system components to cool before
draining.
Oils
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact the
skin.
At operation temperature, the hydraulic tank is hot
and can be under pressure.
Remove the hydraulic tank filter cap only after the
engine has been stopped and the filter cap is cool
enough to remove with your bare hand.
Remove the hydraulic tank filter cap slowly to relieve
pressure.
Relieve all pressure in air, oil fuel or cooling systems
before any lines, fittings or related items are
disconnected or removed.
Batteries
Batteries give off flammable fumes which can
explode.
Do not smoke when observing the battery electrolyte
levels.
Electrolyte is an acid and can cause personal injury
if it contacts skin or eyes.
Always wear protective glasses when working with
batteries.
Fire or Explosion Prevention
All fuels, most lubricants and some coolant mixtures
are flammable.
Fuel leaked or spilled onto hot surfaces or electrical
components can cause a fire.
Do not smoke while refueling or in a refueling area.
Do not smoke in areas where batteries are charged,
or where flammable materials are stored.
Batteries in series can be located in separate
compartments. When using jumper cables always
connect positive(+) cable to positive(+) terminal of
battery connected to starter solenoid and negative(-)
cable from external source to starter negative(-)
terminal.
(If not equipped with starter negative (-) terminal,
connect to engine block.)
See the Operation Section of this manual for specific
starting instructions.
Clean and tighten all electrical connections. Check
daily for loose or frayed electrical wires. Have all
loose or frayed electrical wires tightened, repaired or
replaced before operating the lift truck.
Keep all fuels and lubricants stored in properly
marked containers and away from all unauthorized
persons.
Store all oily rags or other flammable material in a
protective container, in a safe place.
Do not weld or flame cut on pipes or tubes that
contain flammable fluids. Clean them thoroughly
with nonflammable solvent before welding or flam e
cutting on them.
Remove all flammable materials such as fuel, oil
and other debris before they accumulate on the lift
truck.
Do not expose the lift truck to flames, burning brush,
etc., if at all possible.
Shields, which protect hot exhaus t components from
oil or fuel spray in the event of a line, tube or seal
failure, must be installed correctly.
Do not operate in areas where explosive gases exist
or are suspected.
Safety Section
16
Fire Extinguisher
Have a fire extinguisher-type BC and 1.5KG
minimum capacity-on rear overhead guard leg with
latch and know how to use it. Inspect and have it
serviced as recommended on its instruction plate.
Ether
Ether is poisonous and flammable.
Breathing ether vapors or repeated contact of ether
with skin can cause personal injury.
Use ether only in well-ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living
areas or in the operator's compartment.
Do not store ether cylinders in direct sunlight or at
temperatures above 39°C (102°F).
Discard cylinders in a safe place. Do not puncture or
burn cylinders.
Keep ether cylinders out of the reach of
unauthorized personnel.
Lines, Tubes and Hoses
Do not bend or strike high pressure lines. Do not
install bent or damaged lines, tubes or hoses.
Repair any loose or damaged fuel and oil lines,
tubes and hoses. Leaks can cause fires. Contact
your DOOSAN dealer for repair or replacem ent.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. See Fluid Penetration
in the Safety Section for more details. Tighten all
connections to the recommended torque. Replace if
any of the following conditions are found.
z End fittings damaged or leaking.
z Outer covering chafed or cut and wire
reinforcing exposed.
z Outer covering ballooning locally.
z Evidence of kinking or crushing of the flexible
part of hose.
z Armoring embedded in the outer cover.
z End fittings displaced.
Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during
operation.
Tire Information
Explosions of air-inflated tires have resulted from
heat-induced gas combustion inside the tires. The
heat, generated by welding or heating rim
components, external fire, or excessive use of
brakes can cause gaseous combustion.
A tire explosion is much more violent than a blowout.
The explosion can propel the tire, rim and axle
components as far as 500 m (1500 ft) or more from
the lift truck. Both the force of the explosion and the
flying debris can cause personal injury or death, and
property damage.
Do not approach a warm tire closer than the outside
of the area represented by the shaded area in the
above drawing.
Dry nitrogen (N2) gas is recommended for inflation
of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure.
Nitrogen mixes properly with air.
Nitrogen inflated tires reduce the potential of a tire
explosion, because nitrogen does not support
combustion. Also, nitrogen helps prevent oxidation
and the resulting deterioration of rubber and
corrosion of rim components.
Proper nitrogen inflation equipment and training in
its use are necessary to avoid over inflation. A tire
blowout or rim failure can result from improper or
misused equipment.
Stand behind the tread and use a self-attaching
chuck when inflation a tire.
Servicing, changing tires and rims can be dangerous
and should be done only by trained personnel using
proper tools and procedures. If correct procedures
are not followed while servicing tires and rims, the
assemblies could burst with explosive force and
cause serious personal injury or death. Follow
carefully the specific information provided by your
tire or rim servicing personnel or dealer.
Safety Section
17
Operator Restraint System (If
Equipped)
Warning Signs and Labels
Your DOOSAN lift truck has the following tipover
warning decals.
Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or see
the pictures. When cleaning the labels use a cloth,
water and soap. Do not use solvent, gasoline, etc.
You must replace a label if it is damaged, missing or
cannot be read. If a label is on a part that is replaced,
make sure a new label is installed on the replaced
part. See you DOOSAN Lift Truck dealer for new
labels.
The most effective method of preventing serious
injury or death to yourself or others is to familiarize
yourself with the proper operation of the lift truck, to
be alert, and to avoid actions or conditions which
can result in an accident.
WARNING
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.
The "Survive in tipover" warning is located on the
overhead guard. It shows the proper use of the
operator restraint system.
Seat Adjustment
Move the lever, slide the seat to the desired position,
and release the lever.
Adjust the seat before operating the lift truck. After
adjusting, set the seat to make sure it is properly
locked. Do not adjust the seat while the truck is in
motion.
WARNING
Do not place your hand or fingers under the seat.
Injury may occur as the seat moves up and
down.
Safety Section
18
If Optional Suspension Seat Equipped
Forward and Backward Adjustment
The seat can be adjusted by pushing the lever on
the right side of seat.
Adjust the seat before operating the lift truck. After
adjusting, set the seat to make sure it is properly
locked. DO NOT adjust the seat while the truck is in
motion.
Weight adjustment
Pull the weight adjustment lever upwards and move
right or left side.
Adjust to driver’s weight in 7 steps (50 ~ 110 kg)
NOTICE
Do not place your hand or fingers under the seat.
Injury may occur as the seat moves up and down.
Backrest Inclination
The backrest angle can be adjusted by using the
lever on the left side of seat.
Forward and Backward
Adjustment
Safety Section
19
Seat Belt
The Operator Restraint System, Prevents the
operator from the operator's compartment in the
event of forward or side tipover. The system is
designed to keep the operator on the seat and in the
operator's compartment in the event of tipover.
Inspection
1. If the seat belt is torn, if pulling motion is
interrupted during extension of the belt, or if the
belt cannot be inserted into the buckle properly,
replace the seat bel t assembly.
2. Belt Maintenance – Every 500 service hours.
Check that the belt fastening works properly and
that winding device is free from run lock when
jerked. Check that the belt is suitably fastened to
the seat. Check that the seat is correctly
secured to the hood and the chassis. On visual
inspection, fastenings must be intact, otherwise,
contact the safety manager.
WARNING
Your DOOSAN truck comes equipped with a
DOOSAN operator restraint system. Should it
become necessary to replace the seat for any
reason, it should only be replaced with another
DOOSAN operator restraint system.
3. In the event of tipover, the seat and restraint
system should be inspected for damage and
replaced, if necessary.
NOTE: Operator restraints shall be examined at the
regular truck service intervals. It is
recommended that they be replaced if any
of the following conditions are found:
z Cut or frayed strap
z Worn or damaged hardware including
anchor points
z Buckle or retractor malfunction
z Loosen stitching
WARNING
The seat belt may cause the operator to bend at
the waist. If you are pregnant or have suffered
from some abdominal disease, consult a doctor
before you use the seat belt.
Fasten the Seat Belt
1. Grip the plate (connector) of the belt and pul l the
belt from the retrac tor. Then insert the plate into
the slot of the buckle until a snap is heard. Pull
on the belt to confirm it is latched.
2. Make sure the belt is not twisted.
Safety Section
20
WARNING
If you fasten the belt across your abdomen, the
belt may injure your abdomen in an accident.
3. Be sure to fasten the belt across your hips, not
across your abdomen.
NOTE: The belt is designed to automatically adjust
to your size and movement. A quick pull on
the belt will confirm that the automatic
adjuster will hold the belt position in the
event of an accident.
Release the Seat Belt
Push the button of the buckle to release the belt.
The belt will automatically retract when released.
Hold the plate of the belt and allow the belt to slowly
retract.
Safety Section
21
Avoiding Lift Truck Tipover
Lift Truck Stability
Counterbalanced lift truck design is based on the
balance of two weights on opposite sides of a
fulcrum (the front axle). The load on the forks must
be balanced by the weight of the lift truck.
The location of the center of gravity of both the truck
and the load is also a factor. This basic principle is
used for picking up a load. The ability of the lift truck
to handle a load is discussed in terms of center of
gravity and both forward and sideways stability.
Center of Gravity (CG)
The point within an object, at which the whole weight
of the object m ay be regarded as being
concentrated, is called the center of gravity or CG. If
the object is uniform, its geometric center will
coincide with its CG. If it is not uniform, the CG
could be at a point outside of the object. When the
lift truck picks up a load, the truck and load have a
new combined CG.
Stability and Center of Gravity
The stability of the lift truck is determined by the
location of its CG; or, if the truck is loaded, the
combined CG of the truck and load. The lift truck
has moving parts and, therefore, has a CG that
moves. The CG moves forward or backward as the
mast is tilted forward or backward. The CG moves
up or down as the mast moves up or down. The CG
and, therefore, the stability of the loaded lift truck,
are affected by a number of factors such as:
z the size, weight, shape and position of the load
z the height to which the load is li fted
z the amount of forward or backward tilt
z tire pressure
z dynamic forces created when the lift truck is
accelerated, braked or turned
z condition and grade of surfaces on which the lift
truck is operated
These same factors are also im portant for unloaded
lift trucks. They tip over sideways easier than a
loaded lift truck carrying its load in the lowered
position.
Safety Section
22
Lift Truck Stability Base
For the lift truck to be stable (not tip over forward or
to the side), the CG must stay within the area of the
lift truck stability base – a triangular area between
the front wheels and the pivot of the steer wheels. If
the CG moves forward of the front axle, the lift truck
will tip forward. If the CG moves outside of the line
on either side of the stability base, the lift truck will
tip to the side.
WARNING
Dynamic forces (braking, acceleration, turning)
also affect stability and can produce tipover
even when the CG is within the stability triangle.
Capacity Load (Weight and Load Center)
The capacity load of the lift truck is shown on the
capacity/nameplate riveted to the truck. It is
determined by the weight and load center. The load
center is determined by the location of the CG of the
load.
The load center shown on the nam eplate is the
horizontal distance from the front face of the forks,
or the load face of an attachment, to the CG of the
load. The location of the CG in the vertical direction
is the same as the horizontal dimension.
Remember that, unless otherwise indicated, the
capacity load shown on the nameplate is for a
standard lift truck with standard backrest, forks and
mast, and having no special-purpose attachment. In
addition, the capacity load assumes that the load
center is no further from the top of the forks than it is
from the face of the backrest. If these conditions Do
not exist, the operator may have to reduce the safe
operating load because the truck stability may be
reduced. The lift truck should not be operated if its
capacity/nameplate does not indicate capacity load.
NOTE: If the load is not uniform, the heaviest
portion should be placed closer to the
backrest and centered on the forks.
NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DOOSAN shall not be removed,
altered or replaced without DOOSAN’s approval.
2. DOOSAN assumes no responsibility for lift trucks
placed in service without a valid DOOSAN
Nameplate.
3. If necessary to change your specification,
contact your DOOSAN lift truck dealer.
Safety Section
23
Safety Rules
Only properly trained and authorized personnel
should operate forklift trucks. Wear a hard hat and
safety shoes when operating a lift truck. Do not wear
loose clothing.
Inspect and check the condition of your forklift truck
using the operator's check list before starting work.
Immediately report to your supervisor any obvious
defects or required repairs.
Do not operate your truck in unauthorized areas.
Know your forklift truck and think safety.
Do not compromise safe ty.
Follow all safety rules and read all warning signs.
Do not operate a lift truck unless you are in the
operator’s seat. Keep hands and feet inside the
operator’s compartment. Do not put any part of the
body outside of the operator’s compartment. Never
put any part of body into the mast structure or
between the mast and the truck
Do not start, stop, turn or change direction suddenly
or at high speed. Sudden movement can cause the
lift truck to tip over. Slow the speed of your truck and
use the horn near corners, exits, entrances, and
near people.
Never operate a lift truck with wet hands or shoes.
Never hold any controls with grease on your hands.
Your hands or feet will slide off of the controls and
cause an accident.
Safety Section
24
Do not raise anyone on the forks of your lift truck.
Do not let other people ride on the truck. Lift trucks
are designed to carry loads, not people.
Do not operate your truck without the load backrest
extension and overhead guard. Keep the load
against the backrest with the mast tilted backward.
Do not lift or move loads that are not safe. Do not
pick up an off center load. Such a load increases the
possibility of a tipover to the side. Make sure loads
are correctly stacked and positioned across both
forks. Always use the proper size pallet. Position the
forks as wide as possible under the load. Position
loads evenly on the forks for proper balance. Do not
lift a load with one fork.
Do not overload. Always handle loads within the
rated capacity shown on the capacity plate.
Do not add extra counterweight to the truck. An
overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.
Do not drive on soft ground.
Observe all signs, especially those on maximum
permitted floor loadings, elevator capacities and
clearance heights.
Handle loads carefully and check them closely for
stability and balance.
Do not drive on slippery surfaces.
Sand, gravel, ice or mud can cause a tipover.
If unavoidable, slow down.
Safety Section
25
Do not permit anyone to stand or walk under the
load or lifting mechanism. The load can fall and
cause injury or death to anyone standing below.
Look out for overhead obstructions when raising or
stacking loads. Do not travel with a raised load. Do
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.
Do not move loose loads that are higher than the
load backrest.
Be alert for falling loads when stacking.
Travel with the load tilted back and the forks as low
as possible.
This will increase stability to the truck and load and
permit better visibility for you.
Do not elevate the load with the mast tilted forward.
Do not tilt the elevated loads forwards.
This will cause the lift truck to tip over forward.
Do not jump off if your truck starts to tip over.
Stay in your seat to survive.
Go up ramps in forward direction and down ramps in
reverse direction when m oving loads.
Never elevate a load with the forklift truck on an
incline.
Go straight off and s traight down. Use an assistant
when going up or down a ramp with a bulky load.
Safety Section
26
Do not stack or turn on ramps.
Do not attempt to pick-up or deposit a load unless
the lift truck is level. Do not turn on or drive across
an incline.
Do not go over rough terrain. If unavoidable, slow
down.
Cross railroad tracks slowly and diagonally
whenever possible. A rail road crossing can give a
loaded forklift truck a real jolt. For smoother crossing,
cross the railroad diagonally so one wheel crosses
at a time.
Avoid running over loose objects. Look in the
direction of travel. Look out for other persons or
obstructions in your path of travel. An operator must
be in full control of his lift truck at all times.
Do not drive in forward direction when loads restrict
your visibility. Operate your lift truck in reverse to
improve visibility except when moving up a ramp.
Be careful when operating a lift truck near the edge
of a loading dock or ramp. Maintain a safe distance
from the edge of docks, ramps and platforms.
Always watch tail swing.
The truck can fall over the edge and cause injury or
death.
Do not operate on bridge plates unless they can
support the weight of the truck and load. Make sure
that they are correctly positioned. Put blocks on the
vehicle you enter to keep it from moving.
Safety Section
27
Do not operate your truck close to another truck.
Always keep a safe distance from other trucks and
make sure there is enough distance to stop safely.
Never overtake other vehicles.
Do not use your lift truck to push or tow another
truck.
Do not let another push or tow your truck.
If a truck will not move, call a service technician.
Forklift trucks may only be refueled at specially
reserved locations. Switch off the engine when
refueling.
Smoking and handling of naked flames during
refueling are strictly prohibited. This prohibition also
applies during the changing of the LPG (liquefied
propane gas) tank.
Mop up spilt fuel and Do not forget to close the fuel
tank before restarting the engine.
Park your lift truck in authorized areas only. Fully
lower the forks to the floor, put direction lever in
NEUTRAL position, engage the parking brake, and
turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condi tion of your forklift truck after the
day's work.
Exhaust from all internal com bustion engines
contains carbon monoxide, a colorless, odorless,
tasteless, poisonous gas. Exposure to carbon
monoxide can cause serious injury or health
problems, including death, and avoid unnecessary
idling of the engine. If nausea, dizziness or
headaches are experienced stop the truck and seek
fresh air.
Safety Section
28
Do not operate forklifts near flammable or
combustible materials.
To avoid the discoloration, deformation or
combustion of materials (such as lumber, veneer
board, paper products and other similar items),
always park at least 30 cm (12 inches) away from
them.
.
Forklift trucks are not cars. They often have small
tires, no suspension, and are very heavy.
The forklift's center of gravity will also change when
carrying loads.
Avoid uneven bumps, pot holes and other hazards
whenever possible.
Carrying a load suspended on a chain or a cable
may unbalance a truck.
Take extra care around pedestrians with a
suspended load as it may sway or even strike them.
An unloaded forklift may be easier to tip over than a
loaded truck.
When traveling without a load, the risk of lateral
overturn i s greater .
There are many special attachments available to
replace the forks on a lift truck.
All carry safety implications and special training in
their operation is highly recommended.
The counterweight draw bar should not be used for
towing the forklift or for towing another forklift.
Towing is only advised in emergencies, by trained
operators and at low speed, no faster than 2 km/h,
to a convenient location for repair.
Safety Section
29
How to Survive in a Tipover (If
Operator Restraint System
Equipped)
WARNING
In the event of a tipover, the risk of serious
injury or death will be reduced if the operator is
using the operator restraint system and follows
the instructions provided.
Always use operator restraint system.
Don’t jump.
Hold on tight.
Brace your feet and keep them within the operator's
compartment.
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