Doosan BC20S-5 Manual

SB2346E00
Operation &
Maintenance Manual
LIFT TRUCKS
BC20S-5, BC25S-5, BC25SE-5
BC30S-5, BC32S-5
B20S-5, B25S-5, B30S-5, B32S-5
0609

WARNING
Do not start, operate or service this machine unless you have read and understood
these instructions and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive training
before operating or maintaining the machine.
This manual should be kept with the machine for reference and periodically
reviewed by the machine operator and by all personnel who will come into contact
with it.
The following warning is provided pursuant to California Health & Safety Code Sections
25247.5 et, seq,
WARNING
California Proposition 65
Engine Exhaust, some of its constituents, and certain vehicle components contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
WASH HANDS AFTER HANDLING.

Table of Contents
G1
Table of Contents
Information Section
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Foreword ..............................................................2G
Safety Section
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Important Safety Information .................................4G
Safety...................................................................5G
Warning Signs and Labels.............................5G
General Hazard Information......................... 10G
Lift Chains ................................................... 11G
Operation Information.................................. 11G
Maintenance Information .............................13G
Operator Restraint System (If Equipped)...... 16G
Avoiding Lift Truck Tipover ..........................21G
Safety Rules................................................ 23G
How to Survive in a Tipover (If Operator
Restraint System Equipped) ........................ 28G
General Section
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Specifications .....................................................29G
Noise and Vibration............................................. 35G
Capacity Chart .................................................... 36G
Capacity Chart - With Side Shifter (Integrated) ....38G
Capacity Chart - With Side Shifter (Hook on).......40G
Serial Number..................................................... 42G
Operator’s Warning and Indentification Plate.......43G
Operation Section
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Operator’s Station and Monitoring Systems.........45G
Lift Truck Controls...............................................52G
Before Operating the Lift Truck ...........................56G
Lift Truck Operation ............................................59G
Mono-Ped Control System (Option).....................62G
Finger Tip (Option).............................................. 63G
Operating Techniques.........................................66G
Parking the Lift Truck.......................................... 69G
Lift Fork Adjustment............................................ 71G
Storage Information ............................................ 72G
Transportation Hints............................................73G
Towing Information .............................................74G
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck
Forks...................................................................75G
Tire Inflation Information......................................79G
Torque Specifications..........................................80G
Lubricant Specifications.......................................82G
Battery Discharge Indicator .................................84G
Battery ................................................................85G
Cold Storage Applications ...................................87G
Lubricant Viscosities and Refill Capacities ...........89G
Maintenance Intervals .........................................90G
When Required ...................................................92G
Every 10 Service Hours or Daily ........................100G
First 50 - 100 Service Hours or 3 Months...........106G
Every 250 Service Hours or Monthly..................107G
Every 500 Service Hours or 3 Months................113G
Every 1000 Service Hours or 6 Months..............118G
Every 2000 Service Hours or Yearly ..................123G
Environment Section
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Environment Protection .....................................129G
Index Section
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Index.................................................................130G

Information Section
G2
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
G3
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 Infracore BG 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
G4
Important Safety Information
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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
G5
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
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
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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
G6
General Warnings to Operator
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. The emergency switch uses in emergency really.
When you use often emergency switch by key
switch, you can cause fatal mistake to your
machine.
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20. If user operates continuously pushing work or
both brake pedal and accelerator pedal were
depressed at the same time, main electric parts
were able to damage.

Safety Section
G7
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.
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.
IB9O004P
Located on the Overhead Guard.

Safety Section
G8
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.
Parking Brake Warning
WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied.
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Located on the top left side of the cowl.
Battery Restraint Warning
Located on front of battery cover.
WARNING
Before operating truck, ensure that hood is
securely locked by hood latch, and turn stopper
to locking position. Otherwise, a battery may
come out of a truck in case of tipover. It could
cause the risk of serious injury or death.

Safety Section
G9
Battery Disconnect Before Servicing
Warning
AC
WARNING
Disconnect battery from truck and also
discharge high voltages from capacitor banks
with a 150 ohm, 25 watt Resistor before
attempting to service this truck.(B+, B-)
(36V/48V)
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(80V)
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Seat Switch Warning
WARNING
Install any seat to this seat frame. Switch must
shut off all power when operator is not seated.
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Safety Section
G10
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.
Inhaling Freon gas through a lit cigarette or other
smoking method or inhaling fumes released from a
flame contacting Freon can cause bodily harm or
death. Do not smoke when servicing air conditioners
or wherever Freon gas may be present.
Never put maintenance fluids into glass containers.
Use all cleaning solutions with care.
Do not use steam, solvent, or high pressure to clean
electrical components.
Report all needed repairs.

Safety Section
G11
Lift Chains
Inspect the part of the chain that is normally
operated over the crosshead roller. When the chain
bends over the roller, the movement of the parts
against each other causes wear.
Inspect to be sure that chain link pins do not extend
outside of the bore hole.
If any single link pin is extended beyond its
connecting corresponding link, it should be
suspected of being broken inside of its bore hole.
Inspect the chain anchor and the anchor links for
wear.
Do not change any factory set adjustment values
(including engine rpm setting) unless you have both
authorization and training. Especially Safety
equipment and switches may not be removed or
adjusted incorrectly. Repairs, adjustments and
maintenances that are not correct can make a
dangerous operating condition.
For any checkup, repair, adjustments, maintenance
and all other work concerning your forklift truck,
please contact your DOOSAN dealer. We would like
to draw your attention to the fact that any secondary
damages due to improper handling, insufficient
maintenance, wrong repairs or the use of other than
original DOOSAN spare parts waive any liability by
DOOSAN.
Operation Information
Mounting and Dismounting
Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands before
mounting.
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.
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
G12
Make sure the lift truck horn, lights, backup alarm (if
equipped) and all other devices are working properly.
Check for proper operation of mast and attachments.
Pay particular attention to unusual noises or erratic
movement which might indicate a problem.
Make sure service and parking brakes, steering, and
directional controls are operational.
Make sure all personnel are clear of lift truck and
travel path.
Refer to the topic "Lift Truck Operation" in the
"Operation Section" of this manual for specific
starting instructions.
Starting the Lift Truck
Do not start the engine or move any of the controls if
there is a "DO NOT OPERATE" or similar warning
tag attached to the start switch or controls.
Before Operating the Lift Truck
Test brakes, steering controls, horn and other
devices for proper operation. Report any faulty
performance. Do not operate lift truck until repaired.
Learn how your lift truck operates. Know its safety
devices. Know how the attachments work. Before
moving the lift truck, look around. Start, turn and
brake smoothly.
An operator must constantly observe his lift truck for
proper operation.
Operating the Lift Truck
Always keep the lift truck under control.
Obey all traffic rules and warning signs.
Never leave the lift truck with the engine operating,
or with the parking brake disengaged.
Operate the engine only in a well ventilated area.
Lower the mast, with or without load, before turning
or traveling. Tip over could result. Watch out for
overhead obstructions.
Always observe floor load limits and overhead
clearance.
Start, turn, and brake smoothly. Slow down for turns,
grades, slippery or uneven surfaces.
Use special care when operating on grades. Do not
angle across or turn on grades. Do not use a lift
truck on slippery grades. Travel with forks
downgrade when unloaded. Travel with load
upgrade.
Do not overload, or handle offset, unstable, or
loosely stacked loads. Refer to load capacity plate
on the lift truck. Use extreme caution when handling
suspended, long, high or wide load.
Tilt an elevated load forward only when directly over
unloading area and with load as low as possible.
Do not stunt ride or indulge in horseplay.
Always look and keep a clear view of the path of
travel.
Travel in reverse if load or attachment obstructs
visibility. Use extreme caution if visibility is
obstructed.
Stay in designated travel path, clear of dock edges,
ditches, other 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
and avoid pedestrians, other vehicles, obstruction,
pot holes and other hazards or objects in the path of
travel.

Safety Section
G13
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.
zPark the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips
touch the floor.
zMove the direction control lever to NEUTRAL.
zEngage the parking brake.
zTurn the key switch off and remove the key.
zTurn the disconnect switch to OFF (if equipped).
zBlock the drive wheels when parking on an
incline.
Maintenance Information
Perform all maintenance unless otherwise specified
as follows :
zPark the lift truck in authorized areas only.
zPark the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips
touch the floor.
zPlace the control lever in neutral.
zEngage the parking brake.
zRemove the start switch key and turn the
disconnect switch OFF (if equipped).
zBlock 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.

Safety Section
G14
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.
Burn Prevention
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
Only trained and designated personnel should
inspect, recharge or exchange batteries.
Always wear protective glasses when working with
batteries.
Service, exchange and handle batteries only in
authorized areas when proper safety and ventilation
facilities are provided.
Do not smoke, or expose battery to sparks or flame
when checking, charging or servicing battery. Keep
chains and metallic tools away from top of battery.
Batteries give off flammable fumes which can
explode.
Highly explosive gases are especially hazardous
toward the end of the charging period as the battery
approaches a full charge condition.
Electrolyte is an acid and can cause personal injury
if it contacts skin or eyes.
Service batteries in accordance with battery
manufacture instructions.
Refer to the topic "Batteries" in the "Maintenance
Section" of this manual.

Safety Section
G15
Fire or Explosion Prevention
All fuels, most lubricants and some coolant mixtures
are flammable.
Do not smoke in areas where batteries are charged,
or where flammable materials are stored.
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.
Do not operate in areas where explosive gases exist
or are suspected.
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.
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.
zEnd fittings damaged or leaking.
zOuter covering chafed or cut and wire
reinforcing exposed.
zOuter covering ballooning locally.
zEvidence of kinking or crushing of the flexible
part of hose.
zArmoring embedded in the outer cover.
zEnd fittings displaced.
Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during
operation.
Tire Information
Explosions of air-inflated tires have resulted from
heat-induced gas combustion inside the tires. The
heat, generated by welding or heating rim
components, external fire, or excessive use of
brakes can cause gaseous combustion.
A tire explosion is much more violent than a blowout.
The explosion can propel the tire, rim and axle
components as far as 500 m (1500 ft) or more from
the lift truck. Both the force of the explosion and the
flying debris can cause personal injury or death, and
property damage.
Do not approach a warm tire closer than the outside
of the area represented by the shaded area in the
above drawing.
Dry nitrogen (N2) gas is recommended for inflation
of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure.
Nitrogen mixes properly with air.

Safety Section
G16
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.
Operator Restraint System (If
Equipped)
Warning Signs and Labels
Your DOOSAN lift truck has the following tipover
warning decals.
Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or see
the pictures. When cleaning the labels use a cloth,
water and soap. Do not use solvent, gasoline, etc.
You must replace a label if it is damaged, missing or
cannot be read. If a label is on a part that is replaced,
make sure a new label is installed on the replaced
part. See you DOOSAN Lift Truck dealer for new
labels.
The most effective method of preventing serious
injury or death to yourself or others is to familiarize
yourself with the proper operation of the lift truck, to
be alert, and to avoid actions or conditions which
can result in an accident.
WARNING
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.

Safety Section
G17
The "Survive in tipover" warning is located on the
overhead guard. It shows the proper use of the
operator restraint system.
Seat Adjustment
Move the lever, slide the seat to the desired position,
and release the lever.
Adjust the seat before operating the lift truck. After
adjusting, set the seat to make sure it is properly
locked. DO NOT adjust the seat while the truck is in
motion.
WARNING
Do NOT place your hand or fingers under the
seat. Injury may occur as the seat moves up and
down.

Safety Section
G18
If Optional Suspension Seat Equipped
Forward and Backward Adujstment
G
The seat can be adjusted by pushing the lever on
the right side of seat.
G
Adjust the seat before operating the lift truck. After
adjusting, set the seat to make sure it is properly
locked. DO NOT adjust the seat while the truck is in
motion.
Weight adjustment
Pull the weight adjustment lever upwards and move
right or left side.
Adjust to driver’s weight in 7 steps (50 ~ 110 kg)
G
G
NOTICE
Do not place your hand or fingers under the seat.
Injury may occur as the seat moves up and down.
G
GG
Backrest Inclination
The backrest angle can be adjusted by using the
lever on the left side of seat.
Forward and Backward
Adujstment