Doosan D20S-9 Manual

Forklifts
Operation &
Maintenance Manual
Translation of the original instruction
2211
SB2503E04
This document is the informational asset of Doosan Industrial Vehicle Co., Ltd. Thus,
unauthorized access, revision, distribution and copying of this document are strictly prohibited.
D20S-9, D25S-9, D30S-9, D33S-9, D35C-9
FDA2A, FDA2B, FDA2C, FDA2D, FDA2E
DM02-LEF03 De-Tier/ DM02-MFF07 Stage V

WARNING
Breathing diesel engine exhaust exposes you to chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING

Table of Contents
-1-
Table of Contents
Information Section
Foreword................................................................2
Safety Section
Important Safety Information..................................4
Safety.....................................................................5
Warning Signs and Labels..............................5
Electronic Parking Brake.................................9
General Hazard Information..........................10
Operation Information ...................................11
Maintenance Information...............................14
Burn Prevention ............................................15
Fire or Explosion Prevention.........................15
Operator Restraint System............................17
Avoiding Lift Truck Tipover............................22
Safety Rules..................................................24
How to Survive in a Tipover..........................30
General Section
Declaration of Conformity.....................................31
Specifications.......................................................33
Noise and Vibration..............................................41
Capacity Chart (Without Sideshifter Pneumatic)..42
Capacity Chart (With Sideshifter Pneumatic).......46
Serial Number......................................................50
Operator's Warning and Identification Plate.........52
Operation Section
Operator’s Station and Monitoring Systems.........53
Seat Switch System .............................................78
Functional safety System.....................................79
Performance Level ...............................................80
Lift Truck Controls................................................83
Refueling..............................................................85
Before Starting the Engine...................................86
Starting the Engine...............................................88
Lift Truck Operation..............................................90
Finger Tip (Option)...............................................92
TMS(Lin-Q) (Option) ............................................98
Electronic Controlled Diesel Engines (DI DM02VA,
DM02P)..............................................................102
Operating Techniques........................................108
Parking the Lift Truck.........................................112
Lift Fork Adjustment...........................................113
Storage Information............................................114
Transportation Hints...........................................115
Towing Information.............................................117
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck
Forks.................................................................. 119
Tire Inflation Information.................................... 123
Torque Specifications ........................................ 124
Cooling System Specifications........................... 126
Fuel Specifications............................................. 128
Lubricant Information......................................... 130
Lubricant Viscosities and Refill Capacities ........ 132
Maintenance Intervals........................................ 133
When Required.................................................. 137
Every 10 Service Hours or Daily........................ 148
First 50 - 100 Service Hours or a Week............. 154
Every 500 Service Hours or 3 Months............... 159
Every 1000 Service Hours or 6 Months............. 167
Every 2000 Service Hours or Yearly.................. 171
Every 2500 Service Hours or 15 Months........... 175
Every 5000 Service Hours or 30 Months........... 176
Environment Protection Section
Environment Protection ..................................... 177
Index Section
Index.................................................................. 178

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.
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.

Information Section
-3-
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 service 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 10 Service Hours or Daily”.
Environment Management
Note that Doosan Industrial Vehicle 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. LIFE-CYCLE
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 might 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, maintenance 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 product. Obtain the complete
and most current information before starting any job. DOOSAN dealers have the most current information
available.

Safety Section
-5-
Safety
The safety rules and regulations in this section are
representative of some, but not all rules and
regulations that apply to lift trucks. Rules and
regulations are paraphrased without representation
that they have been reproduced verbatim.
Please refer to 29 CFR 1910.178 in the Code of
Federal Regulations, the National Fire Protection
Association No. 505 (NFPA), American National
Standards Institute/Industrial Truck Standards
Development Foundation, ANSI/ITSDF B56.1
Safety Standard for Low lift and High Lift Trucks, UL
558 Fire Safety Standard for Internal Combustion
Engine-Powered Industrial Trucks and subsequent
revisions for a complete list of rules and regulations
as to the safe operation of powered industrial lift
trucks. Since regulations vary from country to
country outside of U.S.A., operate this lift truck in
accordance with local regulations.
DOOSAN lift trucks are manufactured in accordance
with the National Fire Protection Association (NFPA)
No. 505 and the American National Standards
Institute, Inc. / Industrial Truck Standards
Development Foundation (ANSI/ITSDF) B56.1,
Safety Standard for Low and High Lift Trucks and,
for European models, according to the regulations
and standards laid down in EU Machinery Directive
2006/42/EC and EMC directive 2014/30/EU.
The most effective method of reducing the risk of
serious injury or death to you or others is for you to
know how to properly operate this lift truck, to be
alert and to avoid actions or conditions that could
cause accidents.
Do not operate a lift truck if it is in need of
maintenance, repair or appears to be unsafe in any
way. Report all unsafe conditions immediately to
your supervisor, then contact your authorized lift
truck dealer. 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 steering wheel.
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 Warning to Operator
Located on the right side of the operator's seat (STD).
Located on the overhead guard. (If Convenience
Package Equipped).
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 to ensure stability and
durability of the truck.
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 Fork Warning
No Standing Under Fork 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 valve.
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 (STD) or on
front of the hood (Convenience Package).
Moving Fan Warning
WARNING
To avoid personal injury, stay clear of moving
fan.
Located inside the engine compartment cover.

Safety Section
-9-
Electronic Parking Brake
Push the front side of the parking brake
switch to engage the brake.
Push the rear side of the parking brake
switch to release the 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.
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 mm (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.
NOTICE
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.
The Machine contains 0.35kg of HFC-134a, of which
the CO2 equivalent value is 0.501 tons.
The GWP of HFC-134a is 1,430.
Thisis only for thetruckswith air-conditioner option.
The above capacity information written on the film
is attached to the truck.

Safety Section
-11-
Never put maintenance fluids into glass containers.
Use all cleaning solutions with care.
Do not use steam, solvent, or high pressure to clean
electrical components.
Report all needed repairs.
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 wears.
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. Please be
aware that Doosan assumes no responsibility for
any secondary damages resulting from improper
handling, insufficient maintenance or faulty repairs.
Use of Doosan genuine parts is recommended when
servicing parts.
Operation Information
Mounting and Dismounting
Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands before
mounting.
Use both hands and 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.
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 lift 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 seat
back.
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.
Operate the lift truck and controls only from the
operator's station.

Safety Section
-12-
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 a 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.
Use special care when operating on grades. Do not
angle across or turn on grades. Do not use 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 the 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 drop-offs 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,
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 applied 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.
• Park the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips
touch the floor.
• Move the direction control lever to NEUTRAL.
• Engage the parking brake.
• Turn the key switch off and remove the key.
• Turn the disconnect switch to OFF (if
equipped).
• Do operate the disconnecting switch after 30
seconds from start key-off. (if equipped)
• Otherwise Engine Control Unit (ECU) can be
damaged.
• Block the drive wheels when parking on an
incline.

Safety Section
-14-
Maintenance Information
Perform all maintenance unless otherwise specified
as follows:
• Park the lift truck in authorized areas only.
• Park the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips
touch the floor.
• Place the transmission controls in neutral.
• Engage the parking brake.
• Stop the engine.
• Remove the start switch key and turn the
disconnect switch OFF (if equipped).
• 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 handling 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 flame
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 exhaust 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 replacement.
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.
• End fittings damaged or leaking.
• Outer covering chafed or cut and wire
reinforcing exposed.
• Outer covering ballooning locally.
• Evidence of kinking or crushing of the flexible
part of hose.
• Armoring embedded in the outer cover.
• 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.

Safety Section
-17-
Dry nitrogen (N
2
) 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.
DOOSAN forklift is equipped with wheels from
different manufacturers.
Please re-use the original parts of the existing wheel,
if there is no deformation of the wheel after checked.
Mixing up new and old parts may cause incomplete
assembly that might lead to unexpected
dismantlement of parts and accident.
Operator Restraint System
Warning Signs and Labels
Your DOOSAN forklift 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 forklift 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.