Doosan D50S-5 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
Specifications............................................................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 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 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 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 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 industrial 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 amendments 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 in 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.