Doosan D35S-9 Manual

SB2504E00
Forklifts
D35S-9, D40S-9, D45S-9
D50C-9, D55C-9
FDB41, FDB42, FDB43, FDB44, FDB45 (DM03P Tier-4)
D40SC-9, D45SC-9, D50SC-9, D55SC-9
FDB41, FDB42, FDB43, FDB44 (DM03V Stage V)
2009
Operation &
Maintenance Manual
Translation of the original instruction
This document is the informational asset of Doosan Corporation. Thus, unauthorized
access, revision, distribution and copying of this document are strictly prohibited.

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
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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
Before Starting the Lift Truck ...........................12
Maintenance Information..................................14
If Optional Suspension Seat (weight adjusting
type) Equipped..................................................19
Avoiding Lift Truck Tipovers.............................22
Safety Rules......................................................24
How to Survive in a Tipover.............................30
General Section
Declaration of Conformity ........................................31
Specifications............................................................32
Noise and Vibration..................................................40
Capacity Chart..........................................................41
Capacity Chart (with Side Shifter)...........................43
Serial Number...........................................................57
Operator's Warning and Identification Plate...........58
Operation Section
Operator’s Station and Monitoring Systems...........60
Weight Scale Option (Load Cell Type)....................70
Seat Switch System .................................................81
Lift Truck Controls ....................................................82
Fuel and DEF/Ad-Blue Replenishment...................87
Before Starting the Engine.......................................88
After Starting the Engine..........................................92
Lift Truck Operation................................................100
Mono-Ped Control System (If Equipped)..............102
Operating Techniques............................................103
Parking the Lift Truck .............................................108
Lift Fork Adjustment ...............................................109
Storage Information................................................110
Transportation Hints...............................................111
Towing Information.................................................113
Parking Brake Forced Release Method................114
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck
Forks.......................................................................116
Tire Inflation Information........................................120
Torque Specifications............................................121
Cooling System Specifications..............................123
Specifications of Fuel and DEF/Ad-Blue..............125
Lubricant Specifications.........................................127
Lubricant Viscosities and Refill Capacities...........129
Maintenance Intervals............................................130
When Required ......................................................134
Every 10 Service Hours or Daily...........................143
First 50 - 100 Service Hours or a Week...............147
Every 500 Service Hours or 3 Months..................151
Every 1000 Service Hours or 6 Months................161
Every 2000 Service Hours or Yearly.....................167
Every 2500 Service Hours or 15 Months..............171
Every 5000 Service Hours or 30 Months..............172
Environment Protection Section
Environment Protection .........................................173
Index Section
Index .......................................................................174

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.
Somephotographsorillustrationsinthispublicationshow
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 trucks
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 andmaintenance
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 restraintsystem.
SAFE and EFFICIENT OPERATION of a lift truck
depends to a great extent on the skill and alertness on
thepartof the operator. To develop this skill the operator
should read and understand the Safe Driving Practices
contained in thismanual.
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
injuryordeath.
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 overheadguard.
This manual contains information necessary for Safe
Operation.Beforeoperatingalifttruckmakesurethatthe
necessaryinstructions are available and understood.
Operation
The OperationSectionis areference for the newoperator
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 thelift truck.
Operating techniques outlined in this publication are
basic. Skill and techniques developas theoperator gains
knowledge of the lift truck and its capabilities.

Information Section
-3
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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. Recommendedserviceshould 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 and
“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.
Themessage that appears under the warning, explaining thehazard, 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 possiblecircumstance that mightinvolve a potential hazard, and common sense
is always required.The warnings in this publication and on theproductare thereforenot all inclusive.Before any tool,
procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must be
sure thatit is safe for you and others. You should also ensure that the product will not be damaged or madeunsafe
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. Thespecifications, torques, pressures, measurements,adjustments, illustrations, and otheritems can
changeat any time.Thesechanges can affect theservice given to theproduct.Obtainthe completeandmostcurrent
information before starting any job. DOOSAN dealers have the most currentinformation 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 CFR1910.178 in theCode of Federal
Regulations, the National Fire ProtectionAssociation No.
505 (NFPA), American National Standards
Institute/Industrial Truck Standards Development
Foundation, ANSI/ITSDF B56.1 Safety Standardfor 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 thislift truck in accordance with
local regulations.
DOOSAN lifttrucks are manufacturedin 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 andauthorized
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 acloth,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 front side of the FCU.
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'sseat.
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
loadedmachines 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. When operating on a slope, place the load side on
the higher part ofthe slope.
7. Watch out for pedestrians and obstructions. Secure
enoughclearanceabove theoverheadguardso that
it will not bump against anything in the truck’s way.
8. Do notpermita person to rideon forks or machine at
any time.
9. Do not allow anyone to stand or pass under the
elevated portion of any machine.
10. Make 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. After parking, lower the forks to the floor. Put
directional control or shift lever in neutral. Set
parking/secondarybrake.Turn
“ ON - OFF ” switchoff.
Check 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
electricmachines.
19. Avoid overuse of the inching pedal as this may
cause the automatic transmission oil to overheat or
theclutchtoslip. Do notuse asa footrest or forlong
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.
Brake Pedal Adjustment Warning
WARNING
Improper adjustment could result in injury or death.
It has to be adjusted by drawing dimension on free
condition. For safe, don’t unfasten clevis and nut. It
has to be adjusted by trained personnel.
Located inside Brake pedal box.
Electrical Parking Brake
Push the front side of the parking brake switch
to engage the brake.
Pushe the rear side of the parking brake switch
to engage 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
atengineidleandcancausedamage,injuryordeath.
Always apply the parking brake when leaving the lift
truck. The parking brake is NOT automatically
applied.

Safety Section
-9-
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 on the shroud and upper cover.
Hot Muffler Warning
WARNING
Be careful not to touch muffler because it's very hot
when or after operating.
Located under muffler.

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 attachmentsso properclearance
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 asdebris, 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 arenot 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.
Alwaysuseloadbackrestextensionwhen the carriageor
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 operation the lift truck, do not depend only on
flashing lights or back-up alarm (if equipped) to warn
pedestrians.
Alwaysbeawareofpedestriansanddonot proceeduntil
thepedestriansareawareofyourpresenceandintended
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
lifttruck.Donotclimbonanypartofthemastoroverhead
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
workingin abuilding or dock, observe floorload limits and
overhead clearances.
NOTICE
InhalingFreongasthroughalitcigaretteorothersmoking
method or inhaling fumes released from a flame
contactingFreon cancause bodily harmor death.Do not
smoke when servicing airconditioners or wherever Freon
gas may be present.
LPG Truck contains 0.35kg of HFC-134a, of which the
CO2equivalentvalue is 0.572 tons.
Diesel Truck contains0.35kg ofHFC-134a, of whichthe
CO2equivalentvalue is 1.001 tons.
TheGWP of HFC-134ais 1,430.
This is only for the trucks with air-conditioner
option.
The above capacity information written on the film is
attached to the truck.

Safety Section
-11-
Inhaling Freongasthroughalitcigarette orother smoking
method or inhaling fumes released from a flame
contacting Freon can cause bodily harm or death. Do not
smoke when servicing airconditionersor 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 high pressure to clean
electrical components.
Report all needed repairs.
When you handle DEF/AD-Blue, wear protective
equipment and observe Precautions for Handling.
Inspect the part of the chain that is normally operated
over thecrosshead 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 ofits bore hole.
Inspectthe chain anchor and the anchorlinksfor wear.
Do not change any factory set adjustment values
(including engine rpm setting) unless you have both
authorization and training. Especially Safety equipment
andswitchesmaynotbe removedoradjustedincorrectly.
Repairs, adjustments and maintenances that are not
correct canmake a dangerous operatingcondition.
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 shoesand wipe your hands beforemounting.
Face the lift truck when mounting and dismounting.
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 theoperator's station.
Never get on or off a moving lift truck. Never jump off the
lift truck.
Keep hands and steering wheel free ofslippery material.

Safety Section
-12-
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 thelift truck is equipped with a lighting system
as required by conditions.
Make sureall hydraulic controls arein theHOLD 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.
Operatethelifttruckandcontrols onlyfrom 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 ofmast andattachments.
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 moveany of the controls if there
is a“DONOT OPERATE” orsimilar warningtagattached
to the start switch or controls.
Before Operating the Lift Truck
Test brakes, steering controls, horn and other devices for
proper operation. Report 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.

Safety Section
-13-
Operating the Lift Truck
Always keep the lift truck under control.
Obey all traffic rules and warning signs.
Neverleavethelifttruckwiththeengineoperating,orwith
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 observefloor load limits and overhead clearance.
Start, turn, and brake smoothly, slow down for turns,
grades, slippery or uneven surfaces.
Use special care when operation ongrades.Donotangle
across or turn on grades. Do not use lift truck on slippery
grades. Travel with forks downgrade when unloaded.
Travel with loadupgrade.
Do not overload, or handle offset, unstable, or loosely
stackedloads. Referto load capacity plate on the lift truck.
Use extreme caution when handing suspended, long,
high or wide load.
Tilt elevated load forward only when directly over
unloading areaand withload aslow 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 loador attachment obstructs visibility.
Use extreme caution if visibility is obstructed.
Stay in designated travel path, clear of dock edges,
ditches,otherdrop-offsandsurfaceswhichcannotsafely
support the lift truck.
Slow down and use extra care through doorways,
intersections and otherlocation where visibilityis reduced.
Slow down for 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 applied and wheel chocks in
place (or be certain unit is locked to the loading dock)
before enteringonto 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 capacityof
dock boards or bridge plates.

Safety Section
-14-
Lift Truck Parking
When leaving the operator station, park the lift truck in
authorizedareas only. Donotblock traffic.
 Park the lift truck on level ground, lowering the fork
and tilting the mast forward until the fork tips touch
the floor.
 Move the direction control lever to NEUTRAL.
 Engagetheparking brake.
 Turn the key switch off and remove the key.
 Turn the disconnect switch to OFF and remove the
key (if equipped).
 Block the drive wheels when parking on an incline.
WARNING
Do operate the disconnecting switch after 30
seconds from start key-off. (if equipped)
Otherwise Engine Control Unit (ECU) can be
damaged.
Maintenance Information
Perform all maintenance unless otherwise specified as
follows ;
 Park the lift truck in authorized areas only.
 Park the lift truck on level ground, lowering the fork
and tilting the mast forward until the fork tips touch
the floor.
 Place the transmission controls in neutral.
 Engage the parking brake.
 Stoptheengine.
 Remove the start switch key and turn the disconnect
switch OFF (if equipped).
 Block the drive wheels when parkingon an incline.
Pressure Air
Pressure air can cause personal injury. When using
pressure air for cleaning, wear a protective face shield,
protectiveclothing and protectiveshoes.
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 betreated by a doctor familiar with this type of injury
immediately.
Crushing orCutting 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
thelinkage areawillincrease or decrease withmovement
of the attachment.
Stay clear of all rotatingandmoving 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.

Safety Section
-15-
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 addingweight to, welding on, or cutting
or drillingholesinto 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 suchas fire extinguishers, first aid
kits and lights by welding brackets to or drilling holes in
any FOPS structure. See your DOOSAN dealer for
mountingguidelines.
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 filler 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.
Allowcoolingsystem components tocool 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 relateditems 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.

Safety Section
-16-
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 causea 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 operation 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
nonflammablesolvent 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.,
ifatall 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.
Do perform the regeneration of aftertreatment, hot
exhaust gas is emitted, in a safe outdoor environment.
Fire Extinguisher
Have a fire extinguisher-type BC and 1.5KG minimum
capacity-onrear overhead guardlegwith latchandknow
how to use it. Inspect and have it serviced as
recommended onits instruction plate.
Ether
Ether is poisonous and flammable.
Breathing ether vapors or repeated contact of ether with
skin can cause personal injury.
Use ether onlyin 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).
Discardcylindersinasafeplace.Donotpunctureorburn
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 anyloose 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 ballooninglocally.
 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 duringoperation.

Safety Section
-17-
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 representedby the shadedarea 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 foradjustingthe pressure.Nitrogen mixesproperly
with air.
Nitrogeninflated tires reduce the potentialofa tireexplosion,
because nitrogen does not support combustion. Also,
nitrogen helps prevent oxidation and the resulting
deterioration of rubberand corrosion of rim components.
Propernitrogeninflation equipmentand trainingin itsuseare
necessary to avoidover-inflation.A tireblowout or rim failure
can result from improper ormisused equipment.
Stand behind the tread and usea self-attaching chuck when
inflation a tire.
Servicing, changing tires and rims can be dangerous and
should be done only by trained personnel using propertools
andprocedures.If correctproceduresarenot followed while
servicing tires and rims, the assemblies could burst with
explosive force and cause serious personal injury or death.
Followcarefully the specific information providedby your tire
or rim servicing personnel or dealer.
DOOSAN forklift is equipped with wheels from different
manufacturers.
Please re-use theoriginalparts of the existing wheel, if there
is no deformation of the wheelafter checked. Mixing up new
and old parts may cause incomplete assembly that might
lead to unexpected dismantlement ofpartsand accident.