Doosan D20S-5 Manual
SB2349E02
SB2349E02
Operation &Operation &
Maintenance ManualMaintenance Manual
LIFT TRUCKSLIFT TRUCKS
D20S-5, D25S-5, D30S-5, D33S-5, D35C-5D20S-5, D25S-5, D30S-5, D33S-5, D35C-5
G20E-5, G25E-5, G30E-5G20E-5, G25E-5, G30E-5
GC20E-5, GC25E-5, GC30E-5, GC33E-5GC20E-5, GC25E-5, GC30E-5, GC33E-5
G20P-5, G25P-5, G30P-5, G33P-5, G35C-5G20P-5, G25P-5, G30P-5, G33P-5, G35C-5
GC20P-5, GC25P-5, GC30P-5, GC33P-5GC20P-5, GC25P-5, GC30P-5, GC33P-5
07120712
Table of ContentsTable of Contents
-1--1-
Table of ContentsTable of Contents
Information SectionInformation Section
ForeForewordword..........................................................................................................................2..............2
Safety SectionSafety Section
ImportanImportant t SafeSafety ty InfoInformationrmation ...................................................................4.....4
SafeSafetyty ................................................................................................................................5..................5
Warning Signs and Warning Signs and LabelsLabels ...............................................................5.5
Parking brakeParking brake...............................................................................9...........................9
General General Hazard Hazard Information.......Information............................................... 1010
Operation Operation Information........Information.................................................................. 1111
Maintenance Maintenance Information........Information........................................................ 1414
Operator ROperator Restraint System(Iestraint System(If Equipped).......f Equipped)....... 1717
Avoiding LiAvoiding Lift Truck ft Truck Tipover......Tipover.................................................... 2121
Safety Safety RulesRules ........................................................................................................ 2323
How to Survive in a TipoverHow to Survive in a Tipover ...................................................... 2828
General SectionGeneral Section
SpecificaSpecificationstions.................................................................................................................... 3030
Noise Noise and and VibrationVibration................................................................................................ 4242
Capacity ChCapacity Chart (Without Sidesart (Without Sideshifter Pneumatic)..hifter Pneumatic).. 4343
Capacity ChCapacity Chart (With Sideshifart (With Sideshifter Pneumatic).......ter Pneumatic)....... 4747
Capacity Chart (Without SidesCapacity Chart (Without Sideshifter cushion).....hifter cushion)......... 5151
Capacity Chart (With SideshifCapacity Chart (With Sideshifter cushion)ter cushion)........................ 5555
Serial Serial NumbeNumberr.................................................................................................................. 5959
Operator's Warning aOperator's Warning and Identification nd Identification PlatePlate.................. 6262
Operation SectionOperation Section
Operator’s Station and MOperator’s Station and Monitoring Systems.......onitoring Systems........... 6363
Seat Switch Seat Switch System (If System (If Equipped).....Equipped)............................................. 6767
Lift Lift Truck Truck ControlsControls .................................................................................................... 6969
RefuelRefuelinging .................................................................................................................................. 7171
BefoBefore re Starting the Starting the Engine.....................................Engine..................................... 7474
StartinStarting g the the EngineEngine.................................................................................................. 7676
Dual Dual Fuel Fuel SystemSystem...................................................................................................... 7979
Lift Lift Truck Truck OperaOperationtion................................................................................................ 8282
Mono-Ped Control System (OMono-Ped Control System (Option).........ption)...............................117117
Auto Shift Auto Shift Controller ASC-1Controller ASC-100 (If Equipped)00 (If Equipped)............118118
OperaOperating ting TechniqueTechniques..........................................s.......................................... 121121
Parking Parking the the Lift Lift TruckTruck ...................................................................................... 125125
Lift Lift Fork Fork AdjustmentAdjustment ..........................................................................................126126
Storage Storage InformaInformationtion............................................................................................ 127127
TranspoTransportation rtation HintsHints .......................................................................................... 128128
Towing Towing InforInformationmation.............................................................................................. 129129
Maintenance SectionMaintenance Section
Inspection, Maintenance and Repair of Lift TruckInspection, Maintenance and Repair of Lift Truck
ForksForks ............................................................................................................................................130130
Tire Tire InflatioInflation n InforInformation.......................................134mation.......................................134
Torque Torque SpecificaSpecificationstions......................................................................................135135
Cooling System Cooling System SpecificatioSpecifications............................ns..............................137137
Fuel Fuel SpecificaSpecifications...............................................tions.................................................139139
LubricLubricant ant InfoInformationrmation........................................................................................141141
Lubricant ViscositiLubricant Viscosities and Refill Capacitieses and Refill Capacities ..................143143
MaintenaMaintenance nce IntervalIntervalss ....................................................................................144144
When When RequiRequiredred .......................................................................................................... 148148
Every 10 Every 10 Service Hours Service Hours or or Daily.......Daily.............................................155155
First 50 - 100 Service Hours or a First 50 - 100 Service Hours or a Week.........Week..............161.....161
First 250 First 250 Service Hours oService Hours or a r a Month.......Month...................................166166
Every 250 Every 250 Service Hours or Service Hours or Monthly.........Monthly........................167.....167
Every 500 Every 500 Service Hours or Service Hours or 3 3 Months...Months...............................176176
Every 1000 Service HoEvery 1000 Service Hours or 6 Monthsurs or 6 Months ............................185185
Every 1500 Service HoEvery 1500 Service Hours or 9 Monthsurs or 9 Months ............................191191
Every 2000 Service Hours or YearlyEvery 2000 Service Hours or Yearly ......................................194194
Every 2500 Service HoEvery 2500 Service Hours or 15 Monthsurs or 15 Months ........................201201
Every 3000 Service HoEvery 3000 Service Hours or 18 Monthsurs or 18 Months ........................204204
Index SectionIndex Section
IndexIndex ............................................................................................................................................205205
Information SectionInformation Section
-2--2-
ForewordForeword
Literature InformationLiterature Information
This manual should be stored in the operator’sThis manual should be stored in the operator’s
compartment in the literature holder or seat backcompartment in the literature holder or seat back
literature storage area.literature storage area.
This manual contains safety, operation,This manual contains safety, operation,
transportation, lubrication and maintenancetransportation, lubrication and maintenance
information.information.
Some photographs or illustrations in Some photographs or illustrations in this publicationthis publication
show details or attachments that can be differentshow details or attachments that can be different
from your lift truck. Guards and covers might havefrom your lift truck. Guards and covers might have
been removed for illubeen removed for illustrativstrative purposes.e purposes.
Continuing improvement and advancement ofContinuing improvement and advancement of
product design might have caused changes to yourproduct design might have caused changes to your
lift truck which are not included in this publication.lift truck which are not included in this publication.
Read, study and keep this manual with the lift truck.Read, study and keep this manual with the lift truck.
Whenever a question arises regaWhenever a question arises regarding your lift truck,rding your lift truck,
or this publication, please consult your DOOSANor this publication, please consult your DOOSAN
dealer for the latest available information.dealer for the latest available information.
SafetySafety
The Safety Section lists basic The Safety Section lists basic safety precautions. Insafety precautions. In
addition, this section identifies the text andaddition, this section identifies the text and
locations of warning signs and labels used on thelocations of warning signs and labels used on the
lift truck.lift truck.
Read and understand the basic precautions listedRead and understand the basic precautions listed
in the Safety Section before operating orin the Safety Section before operating or
performing lubrication, maintenance and repair onperforming lubrication, maintenance and repair on
this lift truck.this lift truck.
Operator Restraint System (If Equipped)Operator Restraint System (If Equipped)
This manual contains safety, operation andThis manual contains safety, operation and
maintenance information for the DOOSAN operatormaintenance information for the DOOSAN operator
restraint system. Read, study and keep restraint system. Read, study and keep it handy.it handy.
WARNING
WARNING
Your DOOSAN truck comes equipped with anYour DOOSAN truck comes equipped with an
operator restraint system. Should it becomeoperator restraint system. Should it become
necessary to replace the seat for any reason, itnecessary to replace the seat for any reason, it
should only be replaced with another DOOSANshould only be replaced with another DOOSAN
operator restraint system.operator restraint system.
Photographs or illustrations guide the operatorPhotographs or illustrations guide the operator
through correct procedures of checking, operationthrough correct procedures of checking, operation
and maintenance of the DOOSAN operatorand maintenance of the DOOSAN operator
restraint system.restraint system.
SAFE and EFFICIENT OPERATION of a lift truckSAFE and EFFICIENT OPERATION of a lift truck
depends to a great extent on the skill and alertnessdepends to a great extent on the skill and alertness
on the part of the operator. To develop this skill theon the part of the operator. To develop this skill the
operator should read and understand the Safeoperator should read and understand the Safe
Driving Practices contained in this manual.Driving Practices contained in this manual.
Forklift trucks seldom tipover, but in the rare eventForklift trucks seldom tipover, but in the rare event
they do, the operator may be pinned to the groundthey do, the operator may be pinned to the ground
by the lift truck or the overhead guard. This couldby the lift truck or the overhead guard. This could
result in serious injury or death.result in serious injury or death.
Operator training and safety awareness is anOperator training and safety awareness is an
effective way to prevent accidents, but accidentseffective way to prevent accidents, but accidents
can still happen. The DOOSAN operator restraintcan still happen. The DOOSAN operator restraint
system can minimize injuries. The DOOSANsystem can minimize injuries. The DOOSAN
operator restraint system keeps the operatoroperator restraint system keeps the operator
substantially within the confines of the operator’ssubstantially within the confines of the operator’s
compartment and the overhead guard.compartment and the overhead guard.
This manual contains information necessary forThis manual contains information necessary for
Safe Operation. Before operating a lift truck, makeSafe Operation. Before operating a lift truck, make
sure that the necessary instructions are availablesure that the necessary instructions are available
and understood.and understood.
OperationOperation
The Operation Section is a reference for the newThe Operation Section is a reference for the new
operator and a refresher for the operator and a refresher for the experienceexperienced one.d one.
This section includes a discussion of gauges,This section includes a discussion of gauges,
switches, lift truck controls, attachment controls,switches, lift truck controls, attachment controls,
transportation and towing itransportation and towing information.nformation.
Photographs and illustrations guide the operatorPhotographs and illustrations guide the operator
through correct procedures of checking, starting,through correct procedures of checking, starting,
operating and stopping the lift truoperating and stopping the lift truck.ck.
Operating techniques outlined in this publicationOperating techniques outlined in this publication
are basic. Skill and techniques develop as theare basic. Skill and techniques develop as the
operator gains knowledge of the lift truck and itsoperator gains knowledge of the lift truck and its
capabilities.capabilities.
Information SectionInformation Section
-3--3-
MaintenanceMaintenance
TheThe Maintenance Section is a guide to equipmentMaintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions arecare. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items withoutgrouped by servicing intervals. Items without
specific intervals are listed under “When Required”specific intervals are listed under “When Required”
topics. Items in the “Maintenance Intervals” charttopics. Items in the “Maintenance Intervals” chart
are referenced to are referenced to detaileddetailedinstructions that follow.instructions that follow.
Maintenance IntervalsMaintenance Intervals
Use the service hour meter to determine servicingUse the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hourmonthly, etc.) can be used instead of service hour
meter intervals if they provide more convenientmeter intervals if they provide more convenient
servicing schedules and approximate the indicatedservicing schedules and approximate the indicated
service hour meter reading. Recommended serviceservice hour meter reading. Recommended service
should always be performed at the interval thatshould always be performed at the interval that
occurs first.occurs first.
Under extremely severe, dusty or wet operatingUnder extremely severe, dusty or wet operating
conditions, more frequent lubrication than isconditions, more frequent lubrication than is
specified in the “Maintenance Intervals” chart mightspecified in the “Maintenance Intervals” chart might
be necessary.be necessary.
Perform service on items at multiples of the originalPerform service on items at multiples of the original
requirement. For example, at “Every 500 Servicerequirement. For example, at “Every 500 Service
Hours or 3 Months”, also service those items listedHours or 3 Months”, also service those items listed
under “Every 250 Service Hours or Monthly” andunder “Every 250 Service Hours or Monthly” and
“Every 10 Service Hours or “Every 10 Service Hours or Daily”.Daily”.
Environment ManagementEnvironment Management
Note that DOOSAN INFRACORE is ISO 14001Note that DOOSAN INFRACORE is ISO 14001
certified which is harmonized with ISO 9001.certified which is harmonized with ISO 9001.
Periodic ENVIRONMENTAL AUDITS &Periodic ENVIRONMENTAL AUDITS &
ENVIRONMENTAL PERFORMANCEENVIRONMENTAL PERFORMANCE
EVALUATIONS have been made by internal andEVALUATIONS have been made by internal and
external inspection entities. LIFE-CYCLEexternal inspection entities. LIFE-CYCLE
ANALYSIS has also been made through out theANALYSIS has also been made through out the
total product life. ENVIRONMENT MANAGEMENTtotal product life. ENVIRONMENT MANAGEMENT
SYSTEM includes DESIGN FOR ENVIRONMENTSYSTEM includes DESIGN FOR ENVIRONMENT
from the initial stage ofrom the initial stage of the design. ENVIRONf the design. ENVIRONMENTMENT
MANAGEMEMANAGEMENT NT SYSTEM considers SYSTEM considers environmentalenvironmental
laws & regulations, reduction or elimination oflaws & regulations, reduction or elimination of
resource consumption as well as environmentalresource consumption as well as environmental
emission or pollution from industrial activities,emission or pollution from industrial activities,
energy saving, environment-friendly productenergy saving, environment-friendly product
design(lower noise, vibration, emission, smoke,design(lower noise, vibration, emission, smoke,
heavy metal free, ozone depleting substance free,heavy metal free, ozone depleting substance free,
etc.), recycling, material cost reduction, and evenetc.), recycling, material cost reduction, and even
environmentally oriented education for theenvironmentally oriented education for the
ememployee.ployee.
Safety SectionSafety Section
-4--4-
Important Safety Important Safety InformationInformation
Most accidents involving product operation, maintenance and repair are caused by failure to observe basicMost 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 situationssafety 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. Personsbefore an accident occurs. A person must be alert to potential hazards, and use common sense. Persons
must also have the nmust also have the necessary training, skills and tools before aecessary training, skills and tools before attempting to perform these functions.ttempting to perform these functions.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and couldImproper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have readDo not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and reand understood the operation, lubrication, maintenance and repair information.pair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazardSafety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or warnings are not heeded, bodily injury or death could occur to you or othedeath could occur to you or other persons.r persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING”The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING”
as shown below.as shown below.
WARNING
WARNING
The meaning of this safety alert symbol is as follows:The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Attention! Become Alert! Your Safety is involved.involved.
The message that appears under the warning, explaining the hazard, can be either written or pictoriallyThe message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in thisOperations that may cause product damage are identified by NOTICE labels on the product and in this
publication.publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard, and commonDOOSAN 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.sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, proBefore any tool, procedure, work method or operating technique nocedure, work method or operating technique not specifically recommended by DOOSAN ist 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 beused, 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 undamaged or made unsafe by the operation, lubrication, maintenance or repair psafe by the operation, lubrication, maintenance or repair procedures you choose.rocedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available atThe 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, andthe 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 theother 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 currentcomplete and most current information before starting any job. DOOSAN dealers have the most current
information ainformation available.vailable.
Safety SectionSafety Section
-5--5-
SafetySafety
The safety rules and regulations in this section areThe safety rules and regulations in this section are
representative of some, but not all rules andrepresentative of some, but not all rules and
regulations noted under the Occupational Safetyregulations noted under the Occupational Safety
and Health Act (OSHA) and are paraphrasedand Health Act (OSHA) and are paraphrased
without representation that the OSHA rules andwithout representation that the OSHA rules and
regulations have been repregulations have been reproduced verbatim.roduced verbatim.
Please refer to 1910. 178 in Federal Register Vol.Please refer to 1910. 178 in Federal Register Vol.
37, No. 202, the National Fire Protection37, No. 202, the National Fire Protection
Association No. 505 (NFPA), American NationalAssociation No. 505 (NFPA), American National
Standard, ANSI B56. 1 Safety Standard for Low liftStandard, ANSI B56. 1 Safety Standard for Low lift
and High Lift Trucks and and High Lift Trucks and subsequent revissubsequent revisions for aions for a
complete list of OSHA rules and regulations as tocomplete list of OSHA rules and regulations as to
the safe operation of powered industrial lift trucks.the safe operation of powered industrial lift trucks.
Since regulations vary from country to countrySince regulations vary from country to country
outside in U.S.A., operate this lift truck inoutside in U.S.A., operate this lift truck in
accordance with local raccordance with local regulations.egulations.
DOOSAN lift trucks are manufactured according toDOOSAN lift trucks are manufactured according to
the regulations and standards laid down in EUthe regulations and standards laid down in EU
Machinery Directive 98/37/EC and EMC directiveMachinery Directive 98/37/EC and EMC directive
89/336/EC. Please refer to the Directives89/336/EC. Please refer to the Directives
89/655/EC and 89/391/EC and its amendments for89/655/EC and 89/391/EC and its amendments for
the safe use the safe use of DOOSAN lift trucks.of DOOSAN lift trucks.
The most effective method of preventing seriousThe most effective method of preventing serious
injury or death to the lift truck operator or others isinjury or death to the lift truck operator or others is
for the lift truck operator to be familiar with thefor the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and toproper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in anavoid actions or conditions which can result in an
accident.accident.
Do not operate a lift truck if in need of repair,Do not operate a lift truck if in need of repair,
defective or in any way unsafe. Report all defectsdefective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attemptand unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained andany adjustments or repairs unless trained and
authorized to do so.authorized to do so.
Warning Signs and LabelsWarning Signs and Labels
There are several specific safety signs on your liftThere are several specific safety signs on your lift
truck. Their exact location and description of thetruck. Their exact location and description of the
hazard are reviewed in this section. Please take thehazard are reviewed in this section. Please take the
time to fatime to familiarmiliarize yourself with these ize yourself with these safety signs.safety signs.
Make sure that you can read all warning andMake sure that you can read all warning and
instruction labels. Clean or replace these labels ifinstruction labels. Clean or replace these labels if
you cannot read the words or see the pictures.you cannot read the words or see the pictures.
When cleaning the labels use a cloth, water andWhen cleaning the labels use a cloth, water and
soap. Do not use solvent, gasoline, etc.soap. Do not use solvent, gasoline, etc.
You must replace a label if it is damaged, missingYou must replace a label if it is damaged, missing
or cannot be read. If a label is on a part that isor cannot be read. If a label is on a part that is
replaced, make sure a new label is installed on thereplaced, make sure a new label is installed on the
replaced part. See your dealer for new labels.replaced part. See your dealer for new labels.
Traing Required To Operate or ServiceTraing Required To Operate or Service
WarningWarning
Located on the right side of the Located on the right side of the steering wheel.steering wheel.
WARNING
WARNING
Improper operation or maintenance could resultImproper operation or maintenance could result
in injury or death. Do not operate in injury or death. Do not operate or work on theor work on the
lift truck unless you are properly trained. Readlift truck unless you are properly trained. Read
and understand the Operation and Maintenanceand understand the Operation and Maintenance
Manual. Additional manuals are available fromManual. Additional manuals are available from
DOOSAN Lift Truck dealers.DOOSAN Lift Truck dealers.
This label also provides allowable lift truck capacityThis label also provides allowable lift truck capacity
informationinformation
Safety SectionSafety Section
-6--6-
General Warning to OperatorGeneral Warning to Operator
Located on the right side of the operator's seatLocated on the right side of the operator's seat
(STD(STD).).
Located onLocated on the overhead guard (If Conveniencethe overhead guard (If Convenience
Package EquippedPackage Equipped).).
WARNING
WARNING
Only trained and authorized personnel mayOnly trained and authorized personnel may
operate this machine. For safe operation, readoperate this machine. For safe operation, read
and follow the operation and maintenanceand follow the operation and maintenance
Manual furnished with this lift truck andManual furnished with this lift truck and
observe the following warnings:observe the following warnings:
1.1. Before starting machine. Check all controls andBefore starting machine. Check all controls and
warning devices for proper operation.warning devices for proper operation.
2.2. Refer to machine identification plate forRefer to machine identification plate for
allowable machine capacity. Do not overload.allowable machine capacity. Do not overload.
Operate machines equipped with attachmentsOperate machines equipped with attachments
as partially loaded machines when not handlingas partially loaded machines when not handling
a load.a load.
3.3. Put directional control or shift lever in neutralPut directional control or shift lever in neutral
before “ON - OFF” switch is turned on.before “ON - OFF” switch is turned on.
4.4. Start, turn and brake smoothly. Slow down forStart, turn and brake smoothly. Slow down for
turns, slippery or uneven surfaces. Extremelyturns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid poor surfaces should be repaired. Avoid runningrunning
over loose objects or holes in the roadwayover loose objects or holes in the roadway
surfaces. Use extreme caution when turning onsurfaces. Use extreme caution when turning on
inclines.inclines.
5.5. Travel with load as low as possible and tiltedTravel with load as low as possible and tilted
back. If load interferes with visibility, travel withback. If load interferes with visibility, travel with
load trailing.load trailing.
6.6. On grade operations travel with load up grade.On grade operations travel with load up grade.
7.7. Watch out for pedestrians and obstructions.Watch out for pedestrians and obstructions.
Check overhead clearances.Check overhead clearances.
8.8. Do not permit riders on forks or machine at anyDo not permit riders on forks or machine at any
time.time.
9.9. Do not allow anyone to stand or pass under theDo not allow anyone to stand or pass under the
elevated portion of any machine.elevated portion of any machine.
10.10.Be sure operating surface can safely supportBe sure operating surface can safely support
machine.machine.
11.11.Operate machine and attachments only fromOperate machine and attachments only from
operator's position.operator's position.
12.12.Do not handle unstable or loosely stackedDo not handle unstable or loosely stacked
loads.loads.
13.13.Use minimum tilt when picking up or depositingUse minimum tilt when picking up or depositing
a load.a load.
14.14.Use extreme care when handling long, high, orUse extreme care when handling long, high, or
wide loads.wide loads.
15.15.Forks should be completely under load andForks should be completely under load and
spread apart as far as load permits.spread apart as far as load permits.
16.16.Machine should be equipped with overheadMachine should be equipped with overhead
guard or equivalent protection. Where loadguard or equivalent protection. Where load
requires it, use a load backrest extension. Userequires it, use a load backrest extension. Use
extreme caution if operating without theseextreme caution if operating without these
devices.devices.
17.17.Parking - Lower lifting mechanism to floor. PutParking - Lower lifting mechanism to floor. Put
directional control or shift lever in neutral. Setdirectional control or shift lever in neutral. Set
parking/secondary brake. Turn “ON - OFF”parking/secondary brake. Turn “ON - OFF”
switch off. Chock wheels if switch off. Chock wheels if machine is on machine is on incline.incline.
Disconnect battery when storing electricDisconnect battery when storing electric
machines.machines.
1818..Observe safety rules when handling fuel forObserve safety rules when handling fuel for
engine powered machine and when changingengine powered machine and when changing
batteries for electric batteries for electric machines.machines.
Safety SectionSafety Section
-7--7-
Pressure WarningPressure Warning
WARNING
WARNING
Contents under pressure may be hot. Allow toContents under pressure may be hot. Allow to
cool before cool before opening.opening.
Located on the radiator top tank by the radiatorLocated on the radiator top tank by the radiator
cap.cap.
Hand Placement WarningHand Placement Warning
WARNING
WARNING
No hands. Do not place hands in this area. DoNo hands. Do not place hands in this area. Do
not touch, lean on, or reach through the mast ornot touch, lean on, or reach through the mast or
permit others to do so.permit others to do so.
Located on the mast.Located on the mast.
No Standing On Fork WarningNo Standing On Fork Warning
No Standing Under Fork WarningNo Standing Under Fork Warning
WARNING
WARNING
Do not stand or ride on the forks. Do not standDo not stand or ride on the forks. Do not stand
or ride on a load or pallet on the forks. Do notor ride on a load or pallet on the forks. Do not
stand or walk under the forks.stand or walk under the forks.
Located on the liLocated on the lift cylinder.ft cylinder.
Load Backrest Must Be In PlaceLoad Backrest Must Be In Place
WarningWarning
WARNING
WARNING
Operation without this device in place may beOperation without this device in place may be
hazardous.hazardous.
Located on the lLocated on the load backrest.oad backrest.
Safety SectionSafety Section
-8--8-
Overhead Guard Must Be In PlaceOverhead Guard Must Be In Place
WarningWarning
WARNING
WARNING
Operation without this device in place may beOperation without this device in place may be
hazardous. This guard conforms tohazardous. This guard conforms to
A.N.S.I.B56.1 and F.E.M.Section IV. This designA.N.S.I.B56.1 and F.E.M.Section IV. This design
has been tested with an impact of appropriatehas been tested with an impact of appropriate
valve.valve.
Located on the Located on the Overhead Guard.Overhead Guard.
No Riders WarningNo Riders Warning
WARNING
WARNING
To avoid personal injury, allow no riders. A liftTo avoid personal injury, allow no riders. A lift
truck is designed for only one operator and notruck is designed for only one operator and no
riders.riders.
Located beside the operator's station (STD) or onLocated beside the operator's station (STD) or on
front of the hood (Conveniencefront of the hood (ConveniencePackage).Package).
Moving Fan WarningMoving Fan Warning
WARNING
WARNING
To avoid personal injury, stay clear of movingTo avoid personal injury, stay clear of moving
fan.fan.
Located inside the engine compartment cover.Located inside the engine compartment cover.
Safety SectionSafety Section
-9--9-
Parking brakeParking brake
Pull the lever BACK to engage thePull the lever BACK to engage the
parking brake.parking brake.
Push the lever FORWARD to releasePush the lever FORWARD to release
the parking brake.the parking brake.
Applying the parking brake puts the transmission inApplying the parking brake puts the transmission in
NEUTRAL. The parking brake must be appliedNEUTRAL. The parking brake must be applied
when leaving the lift truck and when starting thewhen leaving the lift truck and when starting the
engine. If the operator leaves the seat withoutengine. If the operator leaves the seat without
applying the parking brake, an audible alarm willapplying the parking brake, an audible alarm will
sound.sound.
WARNING
WARNING
When leaving machine apply parking brake!When leaving machine apply parking brake!
Parking brake is Parking brake is not automatically applied.not automatically applied.
Alarm will sound if parking brake is Alarm will sound if parking brake is not applied.not applied.
WARNINGWARNING
Correct adjustment is necessary to provideCorrect adjustment is necessary to provide
adequate braking. See the MAINTENANCEadequate braking. See the MAINTENANCE
section for adjustment procedures. The liftsection for adjustment procedures. The lift
truck may creep at engine idle and can causetruck may creep at engine idle and can cause
damage, injury or death. Always apply thedamage, injury or death. Always apply the
parking brake when leaving the lift truck. Theparking brake when leaving the lift truck. The
parking brake is parking brake is NOT automatically applied.NOT automatically applied.
Safety SectionSafety Section
-10--10-
General Hazard InformationGeneral Hazard Information
Attach a “Do Not Operate” or similar warning tag toAttach a “Do Not Operate” or similar warning tag to
start switch or controls before servicing or repairingstart switch or controls before servicing or repairing
the lift truck.the lift truck.
Do not start or service the lift truck when a “DODo not start or service the lift truck when a “DO
NOT OPERATE” or similar warning tag is attachedNOT OPERATE” or similar warning tag is attached
to the start switch or controls.to the start switch or controls.
Wear a hard hat, protective glasses and otherWear a hard hat, protective glasses and other
protective equipment as required by job protective equipment as required by job conditions.conditions.
Know the width of your attachments so properKnow the width of your attachments so proper
clearance can be maintained when operating nearclearance can be maintained when operating near
fences, boundary obstacles, etc.fences, boundary obstacles, etc.
Do not wear loose clothing or jewelry that can catchDo not wear loose clothing or jewelry that can catch
on controls or other parts oon controls or other parts of the lift truck.f the lift truck.
Keep the lift truck, especially the deck and steps,Keep the lift truck, especially the deck and steps,
free of foreign material such as debris, oil tools andfree of foreign material such as debris, oil tools and
other items which are not part of the other items which are not part of the lift truck.lift truck.
Secure all loose items such as lunch boxes, toolsSecure all loose items such as lunch boxes, tools
and other items which are not part of the and other items which are not part of the lift truck.lift truck.
Know the appropriate work-site hand signals andKnow the appropriate work-site hand signals and
who gives them. Accept signals from one personwho gives them. Accept signals from one person
only.only.
Always use the overhead guard. The overheadAlways use the overhead guard. The overhead
guard is intended to protect the lift truck operatorguard is intended to protect the lift truck operator
from overhead obstructions and from fallingfrom overhead obstructions and from falling
objects.objects.
A truck that is used for handing small objects orA truck that is used for handing small objects or
uneven loads must be fitted with a load backrest.uneven loads must be fitted with a load backrest.
If the lift truck must be operated without theIf the lift truck must be operated without the
overhead guard in place due to low overheadoverhead guard in place due to low overhead
clearance, use extreme care. Make sure there iclearance, use extreme care. Make sure there is nos no
possibility of falling objects from any adjacentpossibility of falling objects from any adjacent
storage or work area. Make sure the load is stablestorage or work area. Make sure the load is stable
and fully supported by the carriage and the loadand fully supported by the carriage and the load
backrest extension (if equipped).backrest extension (if equipped).
Do not raise loads any higher than necessary andDo not raise loads any higher than necessary and
never raise a load higher than 1830 mm (72 in) withnever raise a load higher than 1830 mm (72 in) with
the overhead guard removed.the overhead guard removed.
Always use load backrest extension when theAlways use load backrest extension when the
carriage or attachment does not fully support thecarriage or attachment does not fully support the
load. The load backrest extension is intended toload. The load backrest extension is intended to
prevent the load or any part of the load from fallingprevent the load or any part of the load from falling
backwards into the operator's station.backwards into the operator's station.
When operating the lift truck, do not deWhen operating the lift truck, do not depend only onpend only on
flashing lights or back-up alarm (if equipped) toflashing lights or back-up alarm (if equipped) to
warn pedwarn pedestrians.estrians.
Always be aware of pedestrians and do notAlways be aware of pedestrians and do not
proceed until the pedestrians are aware of yourproceed until the pedestrians are aware of your
presence and intended actions and have movedpresence and intended actions and have moved
clear of the lift truck and/or load.clear of the lift truck and/or load.
Do not drive lift truck up to anyone standing in frontDo not drive lift truck up to anyone standing in front
of an object.of an object.
Obey all traffic rules and warning signs.Obey all traffic rules and warning signs.
Keep hands, feet and head inside the operatorKeep hands, feet and head inside the operator
station. Do not hold onto the overhead guard whilestation. Do not hold onto the overhead guard while
operating the lift truck. Do not climb on any part ofoperating the lift truck. Do not climb on any part of
the mast or overhead guard or permit others to dothe mast or overhead guard or permit others to do
so.so.
Do not allow unauthorized personnel to ride on theDo not allow unauthorized personnel to ride on the
forks or any other part of forks or any other part of the lift truck, at any time.the lift truck, at any time.
When working in a building or dock, observe floorWhen working in a building or dock, observe floor
load limits and overhead clearances.load limits and overhead clearances.
Safety SectionSafety Section
-11--11-
Inhaling Freon gas through a lit cigarette or otherInhaling Freon gas through a lit cigarette or other
smoking method or inhaling fumes released from asmoking method or inhaling fumes released from a
flame contacting Freon can cause bodily harm orflame contacting Freon can cause bodily harm or
death. Do not smoke when servicing airdeath. Do not smoke when servicing air
conditioners or wherever Freon gas may beconditioners or wherever Freon gas may be
present.present.
Never put maintenance fluids into glass cNever put maintenance fluids into glass containers.ontainers.
Use all cleaning solutions with care.Use all cleaning solutions with care.
Do not use steam, solvent, or high pressure toDo not use steam, solvent, or high pressure to
clean electrical components.clean electrical components.
Report all needed repairs.Report all needed repairs.
Inspect the part of the chain that is normallyInspect the part of the chain that is normally
operated over the crosshead roller. When the chainoperated over the crosshead roller. When the chain
bends over the roller, the movement of the partsbends over the roller, the movement of the parts
against each other causes wears.against each other causes wears.
Inspect to be sure Inspect to be sure that chain link pins do not extendthat chain link pins do not extend
outside of the bore hole.outside of the bore hole.
If any single link pin is extended beyond itsIf any single link pin is extended beyond its
connecting corresponding link, it should beconnecting corresponding link, it should be
suspected of being broken inside of its bore hole.suspected of being broken inside of its bore hole.
Inspect the chain anchor and the anchor links forInspect the chain anchor and the anchor links for
wear.wear.
Do not change any factory set adjustment valuesDo not change any factory set adjustment values
(including engine rpm setting) unless you have both(including engine rpm setting) unless you have both
authorization and training. Especially Safetyauthorization and training. Especially Safety
equipment and switches may not be removed orequipment and switches may not be removed or
adjusted incorrectly. Repairs, adjustments andadjusted incorrectly. Repairs, adjustments and
maintenances that are not correct can make amaintenances that are not correct can make a
dangerous operating condition.dangerous operating condition.
For any checkup, repair, adjustments, maintenanceFor any checkup, repair, adjustments, maintenance
and all other work concerning your forklift truck,and all other work concerning your forklift truck,
please contact your DOOSAN dealer. We wouldplease contact your DOOSAN dealer. We would
like to draw your attention to the fact that anylike to draw your attention to the fact that any
secondary damages due to improper handling,secondary damages due to improper handling,
insufficient maintenance, wrong repairs or the useinsufficient maintenance, wrong repairs or the use
of other than original DOOSAN spare parts waiveof other than original DOOSAN spare parts waive
any liability by any liability by DOOSANDOOSAN..
Operation InformationOperation Information
Mounting and DismountingMounting and Dismounting
Mount and dismount the lift truck carefully.Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands beforeClean your shoes and wipe your hands before
mounting.mounting.
Use both hands and face the lift truck whenUse both hands and face the lift truck when
mounting and dismounting.mounting and dismounting.
Use the handgrips for Use the handgrips for mounting and dismounting.mounting and dismounting.
Do not try to climb on or off the lift truck whenDo not try to climb on or off the lift truck when
carrying tools or supplies.carrying tools or supplies.
Do not use any controls as handholds whenDo not use any controls as handholds when
entering or leaving the operator's station.entering or leaving the operator's station.
Never get on or off a moving lift truck. Never jumpNever get on or off a moving lift truck. Never jump
off the lift truck.off the lift truck.
Keep hands and steering wheel free of slipperyKeep hands and steering wheel free of slippery
material.material.
Before Starting the Lift TruckBefore Starting the Lift Truck
Perform a walk-around inspection daily and at thePerform a walk-around inspection daily and at the
start of each shift. Refer to the topic “Walk-aroundstart of each shift. Refer to the topic “Walk-around
Inspection” in “Every 10 Service Hours or Daily”Inspection” in “Every 10 Service Hours or Daily”
section of this section of this manual.manual.
Adjust the seat so that full brake pedal travel canAdjust the seat so that full brake pedal travel can
be obtained with the operator's back against thebe obtained with the operator's back against the
seat back.seat back.
Make sure the lift truck is equipped with a lightingMake sure the lift truck is equipped with a lighting
system as required by conditions.system as required by conditions.
Make sure all hydraulic controls are in the HOLDMake sure all hydraulic controls are in the HOLD
position.position.
Make sure the direction control lever is in theMake sure the direction control lever is in the
NEUTRAL position.NEUTRAL position.
Make sure the parking brake is engaged.Make sure the parking brake is engaged.
Make sure no one is standing and/or working on,Make sure no one is standing and/or working on,
underneath or close to the lunderneath or close to the lift truck before operatingift truck before operating
the lift truck.the lift truck.
Operate the lift truck and controls only from theOperate the lift truck and controls only from the
operator's station.operator's station.
Safety SectionSafety Section
-12--12-
Make sure the lift truck hMake sure the lift truck horn, lights, backup alarm (iforn, lights, backup alarm (if
equipped) and all other devices are workingequipped) and all other devices are working
properly.properly.
Check for proper operation of mast andCheck for proper operation of mast and
attachments. Pay particular attention to unusualattachments. Pay particular attention to unusual
noises or erratic movement which might indicate anoises or erratic movement which might indicate a
problem.problem.
Make sure service and parking brakes, steering,Make sure service and parking brakes, steering,
and directional controls are operational.and directional controls are operational.
Make sure all personnel are clear of lift truck andMake sure all personnel are clear of lift truck and
travel path.travel path.
Refer to the topic “Lift Truck Operation” in theRefer to the topic “Lift Truck Operation” in the
“Operation Section” of this manual for specific“Operation Section” of this manual for specific
starting instructions.starting instructions.
Starting the Lift truckStarting the Lift truck
Do not startDo not start the engine or move any of the controlsthe engine or move any of the controls
if there is if there is a “DO NOT OPERATE” or similar warninga “DO NOT OPERATE” or similar warning
tag attached totag attached tothe start switch or controls.the start switch or controls.
Before Operating the Lift TruckBefore Operating the Lift Truck
Test brakes, steering controls, horn and otherTest brakes, steering controls, horn and other
devices for proper operation. Report any faultydevices for proper operation. Report any faulty
performance. Do not operate lift truck until repaired.performance. Do not operate lift truck until repaired.
Learn how your lift truck operates. Know its safetyLearn how your lift truck operates. Know its safety
devices. Know how the attachments work. Beforedevices. Know how the attachments work. Before
moving the lift truck, look around. Start, turn andmoving the lift truck, look around. Start, turn and
brake smoothly.brake smoothly.
An operator must constantly observe his lift truckAn operator must constantly observe his lift truck
for proper operation.for proper operation.
Operating the Lift TruckOperating the Lift Truck
Always keep the lift truck undAlways keep the lift truck under control.er control.
Obey all traffic rules and warning signs.Obey all traffic rules and warning signs.
Never leave the lift truck with the engine operating,Never leave the lift truck with the engine operating,
or with the paror with the parking brake disengaged.king brake disengaged.
Operate the engine only in a well ventilated area.Operate the engine only in a well ventilated area.
Lower a mast, with or without load, before turningLower a mast, with or without load, before turning
or traveling. Tip over could result. Watch out foror traveling. Tip over could result. Watch out for
overhead obstructions.overhead obstructions.
Always observe floor load limits and overheadAlways observe floor load limits and overhead
clearance.clearance.
Start, turn, and brake smoothly. Slow down forStart, turn, and brake smoothly. Slow down for
turns, grades, slippery or uneven sturns, grades, slippery or uneven surfaces.urfaces.
Use special care when operating on grades. Do notUse special care when operating on grades. Do not
angle across or turn on grades. Do not use lift truckangle across or turn on grades. Do not use lift truck
on slippery grades. Travel with forks downgradeon slippery grades. Travel with forks downgrade
when unloaded. Travel with load upgrade.when unloaded. Travel with load upgrade.
Do not overload, or handle offset, unstable, orDo not overload, or handle offset, unstable, or
loosely stacked loads. Refer to load capacity plateloosely stacked loads. Refer to load capacity plate
on the lift truck. Use extreme caution whenon the lift truck. Use extreme caution when
handling suspended, long, high or wide handling suspended, long, high or wide load.load.
Safety SectionSafety Section
-13--13-
Tilt the elevated load forward only when directlyTilt the elevated load forward only when directly
over unloading area and with load as low asover unloading area and with load as low as
possible.possible.
Do not stunt ride or indulge in Do not stunt ride or indulge in horseplay.horseplay.
Always look and keep a clear view of the path ofAlways look and keep a clear view of the path of
travel.travel.
Travel in reverse if load or attachment obstructsTravel in reverse if load or attachment obstructs
visibility. Use extreme caution if visibility isvisibility. Use extreme caution if visibility is
obstructed.obstructed.
Stay in designated travel path, clear of dock edges,Stay in designated travel path, clear of dock edges,
ditches, other drop-offs and surfaces which cannotditches, other drop-offs and surfaces which cannot
safely support the lift truck.safely support the lift truck.
Slow down and use extra care through doorways,Slow down and use extra care through doorways,
intersections and other location where visibility isintersections and other location where visibility is
reduced.reduced.
Slow down for cross aisles, turns, ramps, dips,Slow down for cross aisles, turns, ramps, dips,
uneven or slippery suruneven or slippery surfaces and in congested areas,faces and in congested areas,
avoid pedestrians, other vehicles, obstruction, potavoid pedestrians, other vehicles, obstruction, pot
holes and other hazards or objects in the path ofholes and other hazards or objects in the path of
travel.travel.
Always use overhead guards except whereAlways use overhead guards except where
operation conditions do not permit. Do not operateoperation conditions do not permit. Do not operate
lift truck in high stacking areas without overheadlift truck in high stacking areas without overhead
guards.guards.
When stacking, watch for falling objects. Use loadWhen stacking, watch for falling objects. Use load
backrest extension and overhead guard.backrest extension and overhead guard.
Refer to the topic “Operation Techniques” in theRefer to the topic “Operation Techniques” in the
“Operation Section” of this “Operation Section” of this manual.manual.
Loading or Unloading Trucks/TrailersLoading or Unloading Trucks/Trailers
Do not operate lift trucks on trucks or trailers whichDo not operate lift trucks on trucks or trailers which
are not designed or intended for that purpose. Beare not designed or intended for that purpose. Be
certain truck or trailer brakes are applied and wheelcertain truck or trailer brakes are applied and wheel
chocks in place (or be certain unit is locked to thechocks in place (or be certain unit is locked to the
loading dock) before entering onto trucks or trailers.loading dock) before entering onto trucks or trailers.
If trailer is not coupled to tractor, make sure theIf trailer is not coupled to tractor, make sure the
trailer landing gear is properly secured in place. Ontrailer landing gear is properly secured in place. On
some trailers, extra supports may be needed tosome trailers, extra supports may be needed to
prevent upending or prevent upending or corner dipping.corner dipping.
Be certain dock plates are in good condition andBe certain dock plates are in good condition and
properly placed and secured. Do not exceed theproperly placed and secured. Do not exceed the
rated capacity of dock boards or bridge plates.rated capacity of dock boards or bridge plates.
Lift Truck ParkingLift Truck Parking
When leavingWhen leavingthetheoperator station, park the lift truckoperator station, park the lift truck
in authorized areas only. Do not block trafficin authorized areas only. Do not block traffic..
Park the lift truck level, with the Park the lift truck level, with the forks lowered andforks lowered and
the mast tilted forward until the fork tips touch thethe mast tilted forward until the fork tips touch the
floor.floor.
Move the direction control Move the direction control lever to NEUTRAL.lever to NEUTRAL.
Engage the parking brake.Engage the parking brake.
Turn the key switch off and remove the Turn the key switch off and remove the key.key.
Turn the disconnect switch to OTurn the disconnect switch to OFF (if equipped).FF (if equipped).
Block the drive wheels when parking on anBlock the drive wheels when parking on an
incline.incline.
Safety SectionSafety Section
-14--14-
Maintenance InformationMaintenance Information
Perform all maintenance unless oPerform all maintenance unless otherwise specifietherwise specifiedd
as follows:as follows:
Park the lift truck in authorized areas only.Park the lift truck in authorized areas only.
Park the lift truck level, with the Park the lift truck level, with the forks lowered andforks lowered and
the mast tilted forward until the fork tips the mast tilted forward until the fork tips touch thetouch the
floor.floor.
Place the transmission controls in neutral.Place the transmission controls in neutral.
Engage the parking brake.Engage the parking brake.
Stop the engine.Stop the engine.
Remove the start switch key and turn theRemove the start switch key and turn the
disconnect switch OFF (if equipped).disconnect switch OFF (if equipped).
Block the drive wheels when parking on anBlock the drive wheels when parking on an
incline.incline.
Pressure AirPressure Air
Pressure air can Pressure air can cause personal injury. When usingcause personal injury. When using
pressure air for cleaning, wear a protective facepressure air for cleaning, wear a protective face
shield, protective clothing and protective shoes.shield, protective clothing and protective shoes.
The maximum air pressure must be below 205 kPaThe maximum air pressure must be below 205 kPa
(30 psi) for (30 psi) for cleaning purposes.cleaning purposes.
Fluid PenetrationFluid Penetration
Always Always use use aa board or cardboard when checkingboard or cardboard when checking
for a leak. Escaping fluid under pressure, even afor a leak. Escaping fluid under pressure, even a
pinhole size leak, can penetrate body tissue,pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid iscausing serious injury, and possible death. If fluid is
injected into your skin, it must be treated by ainjected into your skin, it must be treated by a
doctor familiar with this typedoctor familiar with this typeof injury iof injury immediatemmediately.ly.
Crushing or Cutting PreventionCrushing or Cutting Prevention
Support equipment and attachments properly whenSupport equipment and attachments properly when
working beneath them. Do not depend on hydraulicworking beneath them. Do not depend on hydraulic
cylinders to hold it up. Any attachment can fall if acylinders to hold it up. Any attachment can fall if a
control is moved, or if a hydraulic line bcontrol is moved, or if a hydraulic line breaks.reaks.
Never attempt adjustments while the lift truck isNever attempt adjustments while the lift truck is
moving or the engine is running unless otherwisemoving or the engine is running unless otherwise
specified.specified.
Where there are attachment linkages, theWhere there are attachment linkages, the
clearance in the linkage area will increase orclearance in the linkage area will increase or
decrease with movement of the decrease with movement of the attachment.attachment.
Stay clear of all rotating and moving parts.Stay clear of all rotating and moving parts.
Keep objects away from moving fan Keep objects away from moving fan blades.blades.
They will throw or cut any object or tool that falls orThey will throw or cut any object or tool that falls or
is pushed into them.is pushed into them.
Do not use a kinked or frayed wire rope cable.Do not use a kinked or frayed wire rope cable.
Wear gloves when handling the wire rope cable.Wear gloves when handling the wire rope cable.
Retainer pins, when struck with force, can fly outRetainer pins, when struck with force, can fly out
and injure nearby persons. Make sure the area isand injure nearby persons. Make sure the area is
clear of people when driving retainer pins.clear of people when driving retainer pins.
Wear protective glasses when striking a retainer pinWear protective glasses when striking a retainer pin
to avoid injury to your eyes.to avoid injury to your eyes.
Chips or other debris can fly off Chips or other debris can fly off objects when struck.objects when struck.
Make sure no one can be injured by flying debrisMake sure no one can be injured by flying debris
before striking any object.before striking any object.
Falling Objects Protective Structure (FOPS)Falling Objects Protective Structure (FOPS)
This is an attached guard located above theThis is an attached guard located above the
operator's compartment and secured to the liftoperator's compartment and secured to the lift
truck.truck.
To avoid possible weakening of the Falling ObjectsTo avoid possible weakening of the Falling Objects
Protective Structure (FOPS), consult a DOOSANProtective Structure (FOPS), consult a DOOSAN
dealer before altering, by adding weight to, weldingdealer before altering, by adding weight to, welding
on, or cutting or drilling holes into the on, or cutting or drilling holes into the structure.structure.
The overhead guard is not intended to protectThe overhead guard is not intended to protect
against every possible impact. The overhead guardagainst every possible impact. The overhead guard
may not protect against some objects penetratingmay not protect against some objects penetrating
into the operator's station from the sides or ends ofinto the operator's station from the sides or ends of
the lift truck.the lift truck.
The lift truck is equipped with an overhead guardThe lift truck is equipped with an overhead guard
and FOPS as standard. If there is a possibility ofand FOPS as standard. If there is a possibility of
overhead objects falling through the guard, theoverhead objects falling through the guard, the
guard must be equipped with smaller holes or aguard must be equipped with smaller holes or a
Plexiglas cover.Plexiglas cover.
Any altering done that is not specifically authorizedAny altering done that is not specifically authorized
by DOOSAN invalidates DOOSAN's FOPSby DOOSAN invalidates DOOSAN's FOPS
certification. The protection offered by this FOPScertification. The protection offered by this FOPS
will be impaired if it hawill be impaired if it has been subjected to structurals been subjected to structural
damage. Structural damage can be caused by andamage. Structural damage can be caused by an
overturn accident, by falling objects, etc.overturn accident, by falling objects, etc.
Do not mount any item such as fire extinguishers,Do not mount any item such as fire extinguishers,
first aid kits and lights by welding brackets to orfirst aid kits and lights by welding brackets to or
drilling holes in any FOPS structure. See yourdrilling holes in any FOPS structure. See your
DOOSAN dealer for DOOSAN dealer for mounting guidelines.mounting guidelines.
Safety SectionSafety Section
-15--15-
Burn PreventionBurn Prevention
CoolantCoolant
At operating temperature, the engine coolant is hotAt operating temperature, the engine coolant is hot
and under pressure. The radiator and all lines toand under pressure. The radiator and all lines to
heaters or the engine contain hot water or steam.heaters or the engine contain hot water or steam.
Any contact can cause severe bAny contact can cause severe burns.urns.
Steam can cause personal injury.Steam can cause personal injury.
Check the coolant level only after engine has beenCheck the coolant level only after engine has been
stopped and the filter cap is cool enough to removestopped and the filter cap is cool enough to remove
with your bare hand.with your bare hand.
Remove the cooling system filter cap slowly toRemove the cooling system filter cap slowly to
relieve pressure.relieve pressure.
Cooling system additive contains alkali that canCooling system additive contains alkali that can
cause personal injury. Avoid contact with the skincause personal injury. Avoid contact with the skin
and eyes and do not dand eyes and do not drink.rink.
Allow cooling system components to cool beforeAllow cooling system components to cool before
draining.draining.
OilsOils
Hot oil and components can cause personal injury.Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact theDo not allow hot oil or components to contact the
skin.skin.
At operation temperature, the hydraulic tank is hotAt operation temperature, the hydraulic tank is hot
and can be under pressure.and can be under pressure.
Remove the hydraulic tank filter cap only after theRemove the hydraulic tank filter cap only after the
engine has been stopped and the filter cap is coolengine has been stopped and the filter cap is cool
enough to remove with your bare hand.enough to remove with your bare hand.
Remove the hydraulic tank filter cap slowly toRemove the hydraulic tank filter cap slowly to
relieve pressure.relieve pressure.
Relieve all pressure in air, oil fuel or coolingRelieve all pressure in air, oil fuel or cooling
systems before any lines, fittings or related itemssystems before any lines, fittings or related items
are disconnected or removed.are disconnected or removed.
BatteriesBatteries
Batteries give off flammable fumes which canBatteries give off flammable fumes which can
explode.explode.
Do not smoke when observing the batteryDo not smoke when observing the battery
electrolyte levels.electrolyte levels.
Electrolyte is an acid and can cause personal injuryElectrolyte is an acid and can cause personal injury
if it contacts skin or eif it contacts skin or eyes.yes.
Always wear protective glasses when working withAlways wear protective glasses when working with
batteries.batteries.
Fire or Explosion PreventionFire or Explosion Prevention
All fuels, most lubricants and some coolantAll fuels, most lubricants and some coolant
mixtures are flammable.mixtures are flammable.
Fuel leaked or spilled onto hot suFuel leaked or spilled onto hot surfaces or electricalrfaces or electrical
components can cause a fire.components can cause a fire.
Do not smoke while refueling or in a refueling area.Do not smoke while refueling or in a refueling area.
Do not smoke in Do not smoke in areas where baareas where batteries are charged,tteries are charged,
or where flammable materials are stoor where flammable materials are stored.red.
Batteries in series can be located in separateBatteries in series can be located in separate
compartments. When using jumper cables alwayscompartments. When using jumper cables always
connect positive(+) cable to positive(+) terminal ofconnect positive(+) cable to positive(+) terminal of
battery connected to starter solenoid andbattery connected to starter solenoid and
negative(-) cable from external source to starternegative(-) cable from external source to starter
negative(-) terminal.negative(-) terminal.
(If not equipped with starter negative(-) terminal,(If not equipped with starter negative(-) terminal,
connect to engine block.)connect to engine block.)
See the Operation Section of this manual forSee the Operation Section of this manual for
specific starting inspecific starting instructistructions.ons.
Clean and tighten all electrical connections. CheckClean and tighten all electrical connections. Check
daily for loose or frayed electrical wires. Have alldaily for loose or frayed electrical wires. Have all
loose or frayed electrical wires tightened, repairedloose or frayed electrical wires tightened, repaired
or replaced before operating the or replaced before operating the lift truck.lift truck.
Keep all fuels and lubricants stored in properlyKeep all fuels and lubricants stored in properly
marked containers and away from all unauthorizedmarked containers and away from all unauthorized
persons.persons.
Store all oily rags or other flammable material in aStore all oily rags or other flammable material in a
protective container, in a safe protective container, in a safe place.place.
Do not weld or flame cut on pipes or tubes thatDo not weld or flame cut on pipes or tubes that
contain flammable fluids. Clean them thoroughlycontain flammable fluids. Clean them thoroughly
with nonflammable solvent before welding or flamewith nonflammable solvent before welding or flame
cutting on them.cutting on them.
Remove all flammable materials such as fuel, oilRemove all flammable materials such as fuel, oil
and other debris before they accumulate on the liftand other debris before they accumulate on the lift
truck.truck.
Do not expose the Do not expose the lift truck to flames, bulift truck to flames, burning brush,rning brush,
etc., if at all possible.etc., if at all possible.
Shields, which protect hot exhaust componentsShields, which protect hot exhaust components
from oil or fuel spray in the event of a line, tube orfrom oil or fuel spray in the event of a line, tube or
seal failure, must be seal failure, must be installed correctly.installed correctly.
Do not operate in areas where explosive gasesDo not operate in areas where explosive gases
exist or are suspected.exist or are suspected.
Safety SectionSafety Section
-16--16-
Fire ExtinguisherFire Extinguisher
HaveHave a fire extinguisher-type BC and 1.5KGa fire extinguisher-type BC and 1.5KG
minimum capacity-on rear overhead guard leg withminimum capacity-on rear overhead guard leg with
latch and know how to use it. Inspect and have itlatch and know how to use it. Inspect and have it
servicedservicedas recommended on its as recommended on its instruction plate.instruction plate.
EtherEther
Ether is poisonous and flammable.Ether is poisonous and flammable.
Breathing ether vapors or repeated contact of etherBreathing ether vapors or repeated contact of ether
with skin can cause personal injury.with skin can cause personal injury.
Use ether only in Use ether only in well-ventiwell-ventilated areas.lated areas.
Do not smoke while changing Do not smoke while changing ether cylinders.ether cylinders.
Use ether with care to avoid fires.Use ether with care to avoid fires.
Do not store replacement ether cylinders in livingDo not store replacement ether cylinders in living
areas or areas or in the operator's compartment.in the operator's compartment.
Do not store ether cylinders in direct sunlight or atDo not store ether cylinders in direct sunlight or at
tempetemperatures ratures above above 39°39°C (10C (102°2°F).F).
Discard cylinders in a safe place. Do not punctureDiscard cylinders in a safe place. Do not puncture
or burn cor burn cylinders.ylinders.
Keep ether cylinders out of the reach ofKeep ether cylinders out of the reach of
unauthorized personnel.unauthorized personnel.
Lines, Tubes and HosesLines, Tubes and Hoses
Do not bend or strike high pressure lines. Do notDo not bend or strike high pressure lines. Do not
install bent or damaged lines, tubes or hoses.install bent or damaged lines, tubes or hoses.
Repair any loose or damaged fuel and oil lines,Repair any loose or damaged fuel and oil lines,
tubes and hoses. Leaks can cause fires. Contacttubes and hoses. Leaks can cause fires. Contact
your DOOSAN dealer for repair your DOOSAN dealer for repair or replacement.or replacement.
Check lines, tubes and hoses carefully. Do not useCheck lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board oryour bare hand to check for leaks. Use a board or
cardboard to check for leaks. See Fluid Penetrationcardboard to check for leaks. See Fluid Penetration
in the Safety Section for more details. Tighten allin the Safety Section for more details. Tighten all
connections to the recommended torque. Replace ifconnections to the recommended torque. Replace if
any of the following conditions are found.any of the following conditions are found.
End fittings damaged or leaking.End fittings damaged or leaking.
Outer covering chafed or cut and wire reinforcingOuter covering chafed or cut and wire reinforcing
exposed.exposed.
Outer covering ballooning locally.Outer covering ballooning locally.
Evidence of kinking or crushing of the flexibleEvidence of kinking or crushing of the flexible
part of hose.part of hose.
Armoring embedded in the ouArmoring embedded in the outer cover.ter cover.
End fittings displaced.End fittings displaced.
Make sure that all clamps, guards and heat shieldsMake sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbingare installed correctly to prevent vibration, rubbing
against other parts, and excessive heat duringagainst other parts, and excessive heat during
operation.operation.
Tire InformationTire Information
Explosions of air-inflated tires have resulted fromExplosions of air-inflated tires have resulted from
heat-induced gas combustion inside the tires. Theheat-induced gas combustion inside the tires. The
heat, generated by welding or heating rimheat, generated by welding or heating rim
components, external fire, or excessive use ofcomponents, external fire, or excessive use of
brakes can brakes can cause gaseous combustion.cause gaseous combustion.
A tire explosion is much more violent than aA tire explosion is much more violent than a
blowout. The explosion can propel the tire, rim andblowout. The explosion can propel the tire, rim and
axle components as far as 500 m (1500 ft) or moreaxle components as far as 500 m (1500 ft) or more
from the lift truck. Both the force of the explosionfrom the lift truck. Both the force of the explosion
and the flying debris can cause personal injury orand the flying debris can cause personal injury or
death, and property damage.death, and property damage.
Do not approach a warm tire closer than theDo not approach a warm tire closer than the
outside of the area represented by the shaded areaoutside of the area represented by the shaded area
in the above drawing.in the above drawing.
Safety SectionSafety Section
-17--17-
Dry nitrogen (NDry nitrogen (N22) gas is recommended for inflation) gas is recommended for inflation
of tires. If the tires were originally inflated with air,of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure.nitrogen is still preferred for adjusting the pressure.
Nitrogen mixes properly with air.Nitrogen mixes properly with air.
Nitrogen inflated tires reduce the potential of a tireNitrogen inflated tires reduce the potential of a tire
explosion, because nitrogen does not supportexplosion, because nitrogen does not support
combustion. Also, nitrogen helps prevent oxidationcombustion. Also, nitrogen helps prevent oxidation
and the resulting deterioration of rubber andand the resulting deterioration of rubber and
corrosion of rim components.corrosion of rim components.
Proper nitrogen inflation equipment and training inProper nitrogen inflation equipment and training in
its use are necessary to avoid over-inflation. A tireits use are necessary to avoid over-inflation. A tire
blowout or rim failure can result from improper orblowout or rim failure can result from improper or
misused equipment.misused equipment.
Stand behind the tread and use a self-attachingStand behind the tread and use a self-attaching
chuck when inflation a tire.chuck when inflation a tire.
Servicing, changing tires and rims can beServicing, changing tires and rims can be
dangerous and should be done only by traineddangerous and should be done only by trained
personnel using proper tools and procedures. Ifpersonnel using proper tools and procedures. If
correct procedures are not followed while servicingcorrect procedures are not followed while servicing
tires and rims, the assemblies could burst withtires and rims, the assemblies could burst with
explosive force and cause serious personal injuryexplosive force and cause serious personal injury
or death. Follow carefully the specific informationor death. Follow carefully the specific information
provided by your tire or rim servicing personnel orprovided by your tire or rim servicing personnel or
dealer.dealer.
Operator Restraint System(IfOperator Restraint System(If
Equipped)Equipped)
Warning Signs and LabelsWarning Signs and Labels
Your DOOSAN lift truck has the following tipoverYour DOOSAN lift truck has the following tipover
warning decals.warning decals.
Make sure that you can read all safety signs. CleanMake sure that you can read all safety signs. Clean
or replace these if you cannot read the words oror replace these if you cannot read the words or
see the pictures. When cleaning the labels use asee the pictures. When cleaning the labels use a
cloth, water and soap. Do nocloth, water and soap. Do not use solvent, gasoline,t use solvent, gasoline,
etc. You must replace a label if it is damaged,etc. You must replace a label if it is damaged,
missing or cannot be read. If a label is on a partmissing or cannot be read. If a label is on a part
that is replaced, make sure a new label is installedthat is replaced, make sure a new label is installed
on the replaced part. See you DOOSAN Lift Truckon the replaced part. See you DOOSAN Lift Truck
dealer for new labels.dealer for new labels.
The most effective method of preventing seriousThe most effective method of preventing serious
injury or death to yourself or others is to familiarizeinjury or death to yourself or others is to familiarize
yourself with the proper operation of the lift truck, toyourself with the proper operation of the lift truck, to
be alert, and to avoid actions or conditions whichbe alert, and to avoid actions or conditions which
can result in an accident.can result in an accident.
WARNING
WARNING
Tipover can occur if the truck is improperlyTipover can occur if the truck is improperly
operated. In the event of tipover, injury or deathoperated. In the event of tipover, injury or death
could result.could result.
Safety SectionSafety Section
-18--18-
The “Survive in tipover” warning is located on theThe “Survive in tipover” warning is located on the
overhead guard. It shows the proper use of theoverhead guard. It shows the proper use of the
operator restraint system.operator restraint system.
Seat AdjustmentSeat Adjustment
Move the lever, slide the seat to the desiredMove the lever, slide the seat to the desired
position, and release the lposition, and release the lever.ever.
Adjust the seat before operating the lift truck. AfterAdjust the seat before operating the lift truck. After
adjusting, set the seat to make sure it is properlyadjusting, set the seat to make sure it is properly
locked. Do not adjust the seat while the truck is inlocked. Do not adjust the seat while the truck is in
motion.motion.
WARNING
WARNING
Do not place your hand or fingers under theDo not place your hand or fingers under the
seat. Injury may occur as the seat moves upseat. Injury may occur as the seat moves up
and down.and down.
If Optional Suspension Seat (weightIf Optional Suspension Seat (weight
adjusting type) Equippedadjusting type) Equipped
Forward and Backward AdjustmentForward and Backward Adjustment
The seat can be adjusted by pushing the lever onThe seat can be adjusted by pushing the lever on
the right side of seat.the right side of seat.
Adjust the seat before operating the lift truck.Adjust the seat before operating the lift truck.
After adjusting, set the seat to make sure it isAfter adjusting, set the seat to make sure it is
properly locked. Do not adjust the seat while theproperly locked. Do not adjust the seat while the
truck is in motion .truck is in motion .
Forward and BackwardForward and Backward
AdjustmentAdjustment
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