Doosan GC15S-5 Manual

SB2354E00
Operation &
Maintenance Manual
LIFT TRUCKS
GC15S-5, GC18S-5, GC20SC-5
0703

Table ofContents
1
Table of Contents
Information Section
Foreword....................................................................2
Safety Section
Important Safety Information....................................4
Safety .........................................................................5
Warning Signs and Labels ................................5
Operation Information..................................... 11
Maintenance Information................................ 14
Pressure Air..................................................... 14
Fluid Penetration............................................. 14
Crushing or Cutting Prevention...................... 14
Burn Prevention .............................................. 15
Operator Restraint System (If Equipped)...... 17
Avoiding Lift Truck Tipovers........................... 22
Safety Rules.................................................... 24
How to Survive in a Tipover ........................... 29
General Section
Specifications.......................................................... 31
Noise and Vibration................................................ 33
Serial Number......................................................... 34
Operator's Warning and Identification Plate......... 35
Operation Section
Operator's Station and Monitoring Systems......... 37
Seat Switch System (If Equipped)......................... 40
Lift Truck Controls .................................................. 43
Refueling................................................................. 46
Before Starting the Engine..................................... 48
Starting the Engine................................................. 50
After Starting the Engine........................................ 53
Lift Truck Operation................................................ 81
Operating Techniques............................................ 83
Parking the Lift Truck ............................................. 87
Lift Fork Adjustment................................................ 88
Storage Information................................................ 89
Transportation Hints............................................... 90
Towing Information................................................. 91
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck
Forks........................................................................92
Torque Specifications.............................................96
Cooling System Specifications...............................98
Fuel Specifications................................................100
Lubricant Specifications .......................................101
Lubricant Viscosities and Refill Capacities.........104
Maintenance Intervals ..........................................105
When Required.....................................................107
Every 10 Service Hours or Daily..........................111
First 50-100 Service Hours or a Week................115
First 250 Service Hours or a Month.....................118
Every 250 Service Hours or Monthly...................119
Every 500 Service Hours or 3 Months.................125
Every 1000 Service Hours or 6 Months..............129
Every 1500 Service Hours or 9 Months..............134
Every 2000 Service Hours or Yearly...................136
Every 2500 Service Hours or 15 Months............141
Every 3000 Service Hours or 18 Months............145
Every 4500 Service Hours or two Years.............145
Index Section
Index......................................................................146

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 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 and
maintenance information for the DOOSAN operator
restraint system. Read, study and keep it handy.
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 injuryor 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.
W ARN I N G

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 250 Service Hours or Monthly” and
“Every 10 Service Hours or Daily”.
Environment Management
Note that DOOSAN Infracore VHEICLE B.G. 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 orientededucation 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
mustalso 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.
The meaning ofthissafety alertsymbol 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.
W ARN I N G

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
89/336/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
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 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 your dealer for new labels.
Training Required To Operate or
Service Warning
Located on the right 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.

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 apartas 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.

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 4.
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.
Packing brake
Pull the lever BACK to engage the
parking brake.
Push the lever FORWARD to release
the parking brake.