Doosan D35S-9 Operation & Maintenance Manual
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Doosan D35S-9 Operation & Maintenance Manual

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  • Page 2 FDB41, FDB42, FDB43, FDB44, FDB45 (DM03P Tier-4) D40SC-9, D45SC-9, D50SC-9, D55SC-9 FDB41, FDB42, FDB43, FDB44 (DM03V Stage V) Translation of the original instruction This document is the informational asset of Doosan Corporation. Thus, unauthorized access, revision, distribution and copying of this document are strictly prohibited. 2009...
  • Page 3 WARNING WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside. •...

  • Page 4: Table Of Contents

    `Table of Contents Table of Contents Information Section Maintenance Section Foreword ..............2 Inspection, Maintenance and Repair of Lift Truck Forks ............... 116 Tire Inflation Information ........120 Torque Specifications ..........121 Safety Section Cooling System Specifications ......123 Specifications of Fuel and DEF/Ad-Blue ....125 Important Safety Information ........

  • Page 5: Information Section

    This manual contains information necessary for Safe Whenever a question arises regarding your lift truck, or Operation. Before operating a lift truck make sure that the this publication, please consult your DOOSAN dealer for necessary instructions are available and understood. the latest available information.
  • Page 6 For example, at “Every 500 Service Hours or 3 Months”, also service those items listed under and “Every 10 Service Hours or Daily”. Environment Management Note that DOOSAN INDUSTRIAL VEHICLE is ISO 14001 certified which is harmonized with ISO 9001. Periodic ENVIRONMENTAL AUDITS &...

  • Page 7: Safety Section

    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.

  • Page 8: Safety

    U.S.A., operate this lift truck in accordance with Training Required to Operate or Service local regulations. Warning DOOSAN lift trucks are manufactured in accordance with the National Fire Protection Association (NFPA) No. 505 and the American National Standards Institute, Inc. / Industrial Truck Standards Development Foundation (ANSI/ITSDF) B56.1, Safety Standard for Low and High...
  • Page 9 Safety Section 14. Use extreme care when handling long, high or wide General Warnings to Operator loads to ensure stability and durability of the truck. 15. Forks should be completely under load and spread apart as far as load permits. 16.
  • Page 10 Safety Section Pressure Warning No Standing On Forks Warning, No Standing Under Forks Warning WARNING WARNING Contents under pressure may be hot. Allow to cool before opening. Do not stand or ride on the forks. Do not stand or ride on a load or pallet on the forks.
  • Page 11 Safety Section Overhead Guard Must Be In Place Warning Electrical Parking Brake 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). Push the front side of the parking brake switch to engage the brake.
  • Page 12 Safety Section No Riders Warning Hot Muffler Warning WARNING WARNING To avoid personal injury, allow no riders. A lift truck Be careful not to touch muffler because it's very hot is designed for only one operator and no riders. when or after operating. Located beside the operator’s station.

  • Page 13: General Hazard Information

    Safety Section Do not raise loads any higher than necessary and never General Hazard Information 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.

  • Page 14: Operation Information

    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. -11-...

  • Page 15: Before Starting The Lift Truck

    Safety Section Starting the Lift Truck 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.
  • Page 16 Safety Section Travel in reverse if load or attachment obstructs visibility. Operating the Lift Truck Always keep the lift truck under control. Use extreme caution if visibility is obstructed. Obey all traffic rules and warning signs. Stay in designated travel path, clear of dock edges, ditches, other drop-offs and surfaces which cannot safely Never leave the lift truck with the engine operating, or with support the lift truck.

  • Page 17: Maintenance Information

    Safety Section Lift Truck Parking Maintenance Information When leaving the operator station, park the lift truck in Perform all maintenance unless otherwise specified as authorized areas only. Do not block traffic. follows ; Park the lift truck in authorized areas only. ...
  • Page 18 Do not mount any item such as fire extinguishers, first aid or removed. kits and lights by welding brackets to or drilling holes in any FOPS structure. See your DOOSAN dealer for Batteries mounting guidelines. Batteries give off flammable fumes which can explode.
  • Page 19 Repair any loose or damaged fuel and oil lines, tubes and Do not weld or flame cut on pipes or tubes that contain hoses. Leaks can cause fires. Contact your DOOSAN flammable fluids. Clean...
  • Page 20 Follow carefully the specific information provided by your tire or rim servicing personnel or dealer. DOOSAN forklift is equipped with wheels from different manufacturers. Please re-use the original parts of the existing wheel, if there is no deformation of the wheel after checked.
  • Page 21 It shows the proper use of the operator is installed on the replaced part. See you DOOSAN Lift restraint system. Truck dealer for new labels.

  • Page 22: If Optional Suspension Seat (Weight Adjusting Type) Equipped

    Safety Section Weight adjustment If Optional Suspension Seat (weight adjusting type) Equipped Pull the weight adjustment lever upwards and move right or left side. Forward and Backward Adjustment Adjust to driver’s weight in 7 steps (50 ~ 110 kg) The seat can be adjusted by pushing the lever on the WARNING right side of seat.
  • Page 23 Then insert the plate into the slot become necessary to replace the seat for any reason, of the buckle until a snap is heard. Pull on the belt to it should only be replaced with another DOOSAN confirm it is latched. operator restraint system.
  • Page 24 Safety Section WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. 3. Be sure to fasten the belt across your hips, not across your abdomen. NOTE: The belt is designed to automatically adjust to your size and movement.

  • Page 25: Avoiding Lift Truck Tipovers

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tipovers Lift Truck Stability The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the combined CG of the truck and load. The lift truck has moving parts and, Counterbalanced lift truck design is based on the balance therefore, has a CG that moves.
  • Page 26 Capacity/Nameplates originally attached WARNING forklifts sold by DOOSAN shall not be removed, altered or replaced without DOOSAN's approval. Dynamic forces (braking, acceleration, turning) also affect stability and can produce tipover even when DOOSAN assumes no responsibility for lift trucks the CG is within the stability triangle.

  • Page 27: Safety Rules

    Safety Section Safety Rules Do not operate a lift truck unless you are in the operator’s seat. Keep hands and feet inside the operator’s compartment. Do not put any part of the Only properly trained and authorized personnel body outside of the operator’s compartment. Never should operate forklift trucks.
  • Page 28 Safety Section Do not overload. Always handle loads within the rated Do not raise anyone on the forks of your lift truck. capacity shown on the capacity plate. Do not let other people ride on the truck. Do not add extra counterweight to the truck. Lift trucks are designed to carry loads, not people.
  • Page 29 Safety Section Do not elevate the load with the mast tilted forward. Do not permit anyone to stand or walk under the load or Do not tilt the elevated loads forwards. lifting mechanism. The load can fall and cause injury or This will cause the lift truck to tip over forward.
  • Page 30 Safety Section Do not stack or turn on ramps. Do not drive in forward direction when loads restrict your Do not attempt to pick-up or deposit a load unless the lift visibility. Operate your lift truck in reverse to improve truck is level.
  • Page 31 Safety Section Park your lift truck in authorized areas only. Fully lower Do not operate your truck close to another truck. the forks to the floor, put direction lever in NEUTRAL Always keep a safe distance from other trucks and make position, engage the parking brake, and turn the key to sure there is enough distance to stop safely.
  • Page 32 Safety Section operate forklifts near flammable An unloaded forklift may be easier to tip over than a combustible materials. loaded truck. avoid discoloration, deformation When traveling without a load, the risk of lateral combustion of materials (such as lumber, veneer overturn is greater.

  • Page 33: How To Survive In A Tipover

    Safety Section How to Survive in a Tipover WARNING In the event of a tipover, the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided. Spread your legs wide and secure the feet to the inner sides of the compartment.

  • Page 34: General Section

    Applicable EC Directives : 2006/42/EC, 2014/30/EU, 2000/14/EC, (EU) 2016/1628 Applicable harmonized standard : EN 16307-1;2013+A1;2015, EN ISO 3691-1;2015 EN 1175-2;1998+A1;2010, EN 1175-3;1998+A1;2010 EN 12895;2015+A1:2019 * Remark - Tier 4 Final – Diesel : D35S-9, D40S-9, D45S-9, D50C-9, D55C-9, D55C-9, D40SC-9, D45SC-9, D50SC-9, D55SC-9 (Doosan DM03P engine) -31-...

  • Page 35: Specifications

    General Section Specifications CHARACTERISTICS Model designation D35S-9 D40S-9 Drive: Diesel, Gasoline, LP Diesel Diesel Operator type: Hand, Pedestrian, Standing, Seated, Seated Seated Order-picker Load Capacity kg (lb) 3,500 (8,000) 4,000 (9,000) Load center mm (in) 600 (24) 600 (24) Load Distance: Center of Driveaxle to fork...
  • Page 36 General Section COMBUSTION ENGINE Engine Manufacturer/type 55.4 (74) 55.4 (74) Engine power according to DIN ISO1585 kW (hp) Rated Speed 2200 ~ 2300 2200 ~ 2300 7.3.1 Torque at 1/min Nm (ft·lbs) 360 @ 1,400 (265.4) 360 @ 1,400 (265.4) 4 / 3409 4 / 3409 Number of Cylinders/Displacement...
  • Page 37 General Section Specifications CHARACTERISTICS D50C-9 Model designation D45S-9 D55C-9 Diesel Diesel Diesel Drive: Diesel, Gasoline, LP Operator type: Hand, Pedestrian, Standing, Seated, Seated Seated Seated Order-picker 4,500 (10,000) 5,000 (11.000) 5,500 (12,000) Load Capacity kg (lb) 600 (24) 600 (24) 600 (24) Load center mm (in)
  • Page 38 General Section COMBUSTION ENGINE Engine Manufacturer/type Engine power according to DIN ISO1585 55.4 (74) 55.4 (74) 55.4 (74) kW (hp) Rated Speed 2200 ~ 2300 2200 ~ 2300 2200 ~ 2300 360 @ 1,400 360 @ 1,400 360 @ 1,400 7.3.1 Torque at 1/min Nm (ft·lbs)
  • Page 39 General Section Specifications CHARACTERISTICS Model designation D40SC-9 D45SC-9 Diesel Diesel Drive: Diesel, Gasoline, LP Operator type: Hand, Pedestrian, Standing, Seated, Seated Seated Order-picker Load Capacity kg (lb) 4,500 (10,000) 5,500 (12,000) 500 (19.7) 500 (19.7) Load center mm (in) Load Distance: Center of Driveaxle to fork mm (in) 560 (22) 570 (22.5)
  • Page 40 General Section COMBUSTION ENGINE Engine Manufacturer/type 55.4 (74) 55.4 (74) Engine power according to DIN ISO1585 kW (hp) Rated Speed 2200 ~ 2300 2200 ~ 2300 7.3.1 Torque at 1/min Nm (ft·lbs) 360 @ 1,400 (265.4) 360 @ 1,400 (265.4) 4 / 3409 4 / 3409 Number of Cylinders/Displacement...
  • Page 41 General Section Specifications CHARACTERISTICS D50SC-9 Model designation D55SC-9 Diesel Diesel Drive: Diesel, Gasoline, LP Operator type: Hand, Pedestrian, Standing, Seated, Seated Seated Order-picker Load Capacity kg (lb) 5,000 (11.000) 5,500 (12,000) 500 (19.7) 500 (19.7) Load center mm (in) Load Distance: Center of Driveaxle to fork mm (in) 560 (22) 570 (22.5)
  • Page 42 General Section COMBUSTION ENGINE Engine Manufacturer/type 55.4 (74) 55.4 (74) Engine power according to DIN ISO1585 kW (hp) Rated Speed 2200 ~ 2300 2200~2300 7.3.1 Torque at 1/min Nm (ft·lbs) 360 @ 1,400(265.4) 360 @ 1,400 (265.4) 4 / 3409 4 / 3409 Number of Cylinders/Displacement cc (cm...

  • Page 43: Noise And Vibration

    General Section Noise and Vibration Noise Noise Level [Unit : dB(A)] Sound Pressure Level at Operator’s ear (Leq.) Model prEN12053 D35/40/45S-9, D50/55C-9 D40/45/50/55SC-9 80.6 (Cabin) D35/40/45S-9, D50/55C-9 76.4 D40/45/50/55SC-9 (OVHG) Vibration (weighted overall value) Unit : m/sec Measuring place Model Seat Steering Wheel Floor Plate...

  • Page 44: Capacity Chart

    General Section Capacity Chart SINGLE TIRE SINGLE TIRE STD, FFL 4000 4000 3500 3500 3000 3000 2500 2000 2500 1500 2000 1000 1500 1000 1100 1200 1000 1100 1200 A. 3000/3300/3650/4000/4250/4850mm A. 4000/4250/4500/4700mm B. 5250mm B. 5150mm C. 5600mm D. 6050mm E.
  • Page 45 General Section Capacity Chart SINGLE TIRE SINGLE TIRE STD, FFL 5500 5500 5000 5000 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 1000 1100 1200 1000 1100 1200 A. 3000/3300/3450/3650/4000mm A. 3575/3875/4125/4575mm B.

  • Page 46: Capacity Chart (With Side Shifter)

    General Section Capacity Chart DOUBLE TIRE DOUBLE TIRE STD, FFL 4000 4000 3500 3500 3000 3000 2500 2000 2500 1500 2000 1000 1500 1000 1100 1200 1000 1100 1200 A. 3000/3300/3650/4000/4250/4850mm A. 4000/4250/4500/4700mm B. 5250mm B. 5150mm C. 5600mm D. 6050mm E.
  • Page 47 General Section Capacity Chart DOUBLE TIRE DOUBLE TIRE STD, FFL 5500 5500 5000 5000 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 1000 1100 1200 1000 1100 1200 A. 2750/3050/3400/3750/4000mm A. 3575/3875/4125/4575mm B.
  • Page 48 General Section Capacity Chart SINGLE TIRE SINGLE TIRE STD, FFL 4500 4500 4000 4000 3500 3500 3000 3000 2500 2000 2500 1500 2000 1000 1500 900 1000 1100 1200 900 1000 1100 1200 A. 3000/3300/3650/4000/4250mm A. 4000/4250mm G. 6500mm B. 4850mm B.
  • Page 49 General Section Capacity Chart SINGLE TIRE SINGLE TIRE STD, FFL 6000 6000 5500 5500 5000 5000 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 1000 1100 1200 900 1000 1100 1200 A. 2750/3050/3400/3750mm A.
  • Page 50 General Section Capacity Chart DOUBLE TIRE DOUBLE TIRE STD, FFL 4500 4500 4000 4000 3500 3500 3000 3000 2500 2000 2500 1500 2000 1000 1500 900 1000 1100 1200 900 1000 1100 1200 A. 3000/3300/3650/4000/4250mm A. 4000/4250/4500/4700mm B. 4850mm B. 5150mm C.
  • Page 51 General Section Capacity Chart DOUBLE TIRE DOUBLE TIRE STD, FFL 6000 6000 5500 5500 5000 5000 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 900 1000 1100 1200 900 1000 1100 1200 A.
  • Page 52 General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE STD, FFL 4000 4000 3500 3500 3000 3000 2500 2000 2500 1500 2000 1000 1500 1000 1100 1200 1000 1100 1200 A. 3000/3300/3650/4000/4250mm A. 4000/4250mm B. 5250mm B. 4500/4700mm C.
  • Page 53 General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE STD, FFL 5500 5500 5000 5000 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 1000 1100 1200 1000 1100 1200 A. 2750/3050/3400/3750/4000mm A.
  • Page 54 General Section Capacity Chart (with Side Shifter) DOUBLE TIRE DOUBLE TIRE STD, FFL 4000 4000 3500 3500 3000 3000 2500 2000 2500 1500 2000 1000 1500 1000 1100 1200 1000 1100 1200 A. 3000 / 3300 / 3650 / 4000mm A.
  • Page 55 General Section Capacity Chart (with Side Shifter) DOUBLE TIRE DOUBLE TIRE STD, FFL 5500 5500 5000 5000 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 1000 1100 1200 1000 1100 1200 A. 2750/3050/3400/3750/4000mm A.
  • Page 56 General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE STD, FFL 4500 4000 3500 4000 3000 3500 2500 3000 2000 2500 1500 2000 1000 1500 900 1000 1100 1200 900 1000 1100 1200 A. 3000/3300/3650/4000mm A. 4000/4250mm G. 6500mm B.
  • Page 57 General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE STD, FFL 6000 6000 5500 5500 5000 5000 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 900 1000 1100 1200 900 1000 1100 1200 A.
  • Page 58 General Section Capacity Chart (with Side Shifter) DOUBLE TIRE DOUBLE TIRE STD, FFL 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 900 1000 1100 1200 900 1000 1100 1200 A. 3000/3300/3650/4000mm A. 4000/4250mm G.
  • Page 59 General Section Capacity Chart (with Side Shifter) DOUBLE TIRE DOUBLE TIRE STD, FFL 6000 6000 5500 5500 5000 5000 4500 4500 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 900 1000 1100 1200 900 1000 1100 1200 A.

  • Page 60: Serial Number

    General Section Serial Number Serial Number Locations For quick reference, record your lift truck’s serial numbers in the spaces provided below the photographs. Transmission Serial Number Lift Truck Serial Number Drive Axle Serial Number Engine Serial Number (DM03V, DM03P) Side Shifter Serial Number (If Equipped) -57-...

  • Page 61: Operator's Warning And Identification Plate

    General Section Operator's Warning and Identification Plate Familiarize yourself with the OPERATOR'S WARNING Plate, and IDENTIFICATION, LIFT CAPACITY and ATTACHMENT PLATES. Do not exceed capacity as equipped load ratings. Operator’s Warning Plate Identification, Lift Capacity and Attachment Plate Located on the cowl to the right side of the steering column.
  • Page 62 General Section Mast Abbreviations Attachment Abbreviations (Includes Special Forks) STD - Standard Mast (single inner member, low free lift) SC - Special Carriage-increased width, height or FF - Full Free Lift Mast (single inner member with high outreach free lift duplex cylinder) SSS - Shaft-type Sideshift Carriage FFT - Triple Lift Mast (two inner members) with either low or full free lift characteristics.

  • Page 63: Operation Section

    Operation Section Operator’s Station and Monitoring Systems Instrument Panel Your lift truck may not have the same indicator or warning lights as shown in the illustrations. However, the symbols on the indicators and lights on your panel identify what those particular items are. Also, the symbol for each of the items is identified and an explanation of their function and location is described on the following pages.
  • Page 64 Operation Section 1. Diesel Engine Water in Fuel Filter 7. Engine Malfunction Indicator Light (MIL) Indicator Light - Indicates when the engine - Engine control system is equipped with is running, there is water in the fuel filter built-in fault diagnostics. Detected system exceeds 100cc.
  • Page 65 Operation Section cleaning. The cleaning process takes about 30 13. Mast interlock – Alarm warning lights minutes, with this lamp flickering. Press the when operator leaves the seat without applying cleaning switch for about 3 seconds to start the parking brake and then, operation of mast is automatically interrupted.
  • Page 66 Down button. 10) Enter button. 11) Rear view camera operation button (manual). Menu Consists of the Doosan model and the Crown model. Upon selecting either model, the corresponding brand logo will be displayed at the time of initial starting. -63-...
  • Page 67 Operation Section Menu - Vehicle - Option forward/backward switching is only possible at the selected speed. Menu - Vehicle - Option - Pin Code Access Menu - Vehicle - Option - Multi Torque ECO: Fuel economy operation mode. STANDARD: Ordinary operation mode. The anti-theft function allows vehicle start-up only HIGH: Heavy duty operation mode.
  • Page 68 Operation Section Menu - Vehicle - Option - Weight Scale Menu - Vehicle - Option - Seat Belt Interlock There are three sub-menus: (No load setting, load This safety function enables operation only when the setting, rated load setting). seat is occupied and the safety belt is on. Menu - Vehicle - Emission regulation Zero setting under no-load condition.
  • Page 69 Operation Section Menu - Vehicle - TCU Menu - Vehicle - Change Password New password and setting by confirming Menu - Vehicle - TCU - Auto Clutch Calibraiton Menu After any service below, should conduct the auto clutch calibration. See the topic, "Drive axle Oil, Transmission Oil, Oil Filter &...
  • Page 70 Operation Section Menu - Display - Rear View camera Menu - Display - Time (If the rear view camera is equipped) Current time setting Camera connection setting while reversing Menu - Display - Software Version Menu - Display - Language Instrument panel firmware, graphic version and VCU Setting for Korean, English, Chinese and Spanish firmware version can be checked.
  • Page 71 Operation Section Menu - Maintenance - Consumable Item Menu Management The replacement cycles and amount (in hours) of use Menu - Maintenance of consumable items can be checked. Menu - Maintenance - Input/Output Signal Analogue Menu - Maintenance - Fault Details The vehicle analogue signal can be checked Menu - Maintenance - Input/Output Signal Digital Details of faults that currently occur can be checked.
  • Page 72 Operation Section Weight Scale Mode (Optional - Hydraulic) This option enables the operator to measure and limit the weight of the load using the LCD display. Use “WEIGHT SCALE” under the “VEHICLE” menu. Zero Setting Raise the forks by 1 m as unloaded and press ENTER to set the weight of the mast assembly to be zero.

  • Page 73: Weight Scale Option (Load Cell Type)

    Operation Section Weight Scale Option (Load Cell Type) With this weight scale option, the operator can 3. Specifying a Maximum Measuring Scale measure and limit the load's weight using a display This step is to specify the rated capacity of the vehicle on which the load cell is installed.
  • Page 74 Operation Section 6. Reference Load Lift Put a reference load that weighs as much as the set value on the attachment (e.g. forks). You should align the centers of gravity of the attachment and of the reference load. Raise the mast approx. 300 mm from the ground vertically.
  • Page 75 Operation Section Circuit Breaker Electrical Disconnect Switch (If Equipped) Circuit Breaker - Protects the main electrical 1. ON-Connects the battery for electrical power circuits. To reset the circuit breaker, push the to all electrical circuits. button in. It is located in the engine compartment. 2.
  • Page 76 Operation Section Audio System (AM/FM Tuner with USB/AUX Player, If equippied) Location of controls LOUD MENU INFO 1. AM button: Select AM Radio mode. 8. SCN/AST button with｜◀◀ TUNE/TRACK ▶▶｜dial 2. FM button: Select FM Radio mode. 3. USB button: Select USB player. Radio mode: Plays frequencies with superior reception for 5 seconds each (press);...
  • Page 77 Operation Section Display window Rear view/Connectors Antenna jack: To plug the FM antenna cable. USB/AUX indicators: When the External Device I/0 connector: To plug the 1/0 cable. is connected, indicator is lights up. MP3/WMA indicators: When the Audio Stream is <ARA-5080WF: 18 Pin>...
  • Page 78 Operation Section • VOL (Volume): sets the sound volume level. Getting started (VOL 0 ~ VOL 41) Turning the unit on/off 2. Turn the VOLUME dial left/right 1. Turn your car's ignition key to to adjust the value of the level, ACC or IGN (ON) position.
  • Page 79 Operation Section Tuning in a station Radio Setting the region of radio reception 1. Press the AM or FM button to change the band in order of AM1. When the power is turned on, press and hold the AM2. FM1 or FM2. buttons more 3 seconds at the same time as below;...
  • Page 80 Operation Section Saving radio stations manually USB player You can save up to 6 preset channels each for FM 1, Before MP3 [WMA] USB playback FM2, FMA, AM 1, AM2, and AMA. This unit cannot play the following files; If change the stations while driving, use preset button to prevent accidents.
  • Page 81 Operation Section 4. Press the [4 INFO] button Change the playback mode INFO repeatedly to display information 1. While playing, press the SCN about the file being played. button to begin the Intro scan playback. The information displayed includes the file name, playing time, ID3 Tag or folder name information •...
  • Page 82 Operation Section About MP3/WMA When disconnecting the USB, an abnormal sound may occur occasionally. This unit can play MP3 (WMA) files with .mp3, .wma (Iower case letters) or .MP3 and .WMA (capital letters) Abruptly disconnecting the external USB device while file name extensions.
  • Page 83 Operation Section Listening to DMB sound (lf Equipped) AUX player By connecting the optional DMB receiver, you Listening to auxiliary audio equipment can listen the DMB source provided for the By connecting an optional portable audio device to vehicle. the AUX input jack (stereo mini jack) on the unit and then simply selecting the source, you can listen on When the DMB receiver is turned power on, the your car speakers.

  • Page 84: Seat Switch System

    4. If seat or seat switch replacement becomes necessary, be sure to use genuine DOOSAN lift truck seconds after leaving the seat, the SEAT SWITCH parts. Lift trucks should never be operated without an...

  • Page 85: Lift Truck Controls

    Operation Section Lift Truck Controls Direction Control Lever Auto Shift (AUTO) Selector Switch 1. Forward - Push the lever forward for FORWARD direction travel. 2. Neutral - Move the lever to center position for NEUTRAL. This switch is used to select auto/manual shift on the gearshift.
  • Page 86 Operation Section Multi-torque SCR Cleaning - DeSOx Switch ECO: Fuel economy operation mode. STANDARD: Ordinary operation mode. HIGH: Heavy duty operation mode. This switch initiates regular regeneration process of the The above figure shows the multi torque screen on post-treatment device. ...
  • Page 87 Operation Section 3. The switch returns to the normal position of "2" after pressed by the operator to position "1". However, it does not return when pressed to position "3" and the operator shall return the switch from position "3". 4.
  • Page 88 Operation Section Transmission Inching Control Pedal Service Brake Pedal Inching Control Pedal - Pushing down the Push DOWN on the brake pedal to slow or stop inching pedal, modulates the hydraulic pressure the lift truck. to the clutch packs, permitting disc slippage. RELEASE the brake pedal to allow the lift truck Further pushing the pedal completely relieves clutch to move.
  • Page 89 Operation Section Parking Brake Switch Tilt Control 1. Mast Tilt Forward - Push the lever Push the front side of the parking brake switch to FORWARD smoothly to tilt the mast forward. engage the brake. 2. Mast Hold - When the lever is released it will Pushe the rear side of the parking brake switch return to the HOLD or center position.

  • Page 90: Fuel And Def/Ad-Blue Replenishment

    Operation Section Fuel and DEF/Ad-Blue Replenishment Diesel Engine Equipped WARNING Explosive fumes may be present during refueling. Do not smoke in refueling areas. Lift truck should be refueled only at designated safe locations. Safe outdoor locations are preferable to those indoors. Stop the engine and get off the lift truck during refueling.

  • Page 91: Before Starting The Engine

    Operation Section Before Starting the Engine Walk - Around Inspection Make a thorough walk-around inspection before mounting the lift truck or starting the engine. Make sure there are no such problems as loose bolts, debris buildup, oil or coolant leaks. Check condition of tires, mast, carriage, forks or attachments.
  • Page 92 Operation Section 13. Observe the engine coolant level in the coolant recovery bottle. With the engine cold, maintain the level to the COLD mark. If the recovery bottle is empty, also fill the radiator at the top tank. 16. To position the seat, PUSH the lever away from the seat track and move the seat forward or backward to a comfortable position.
  • Page 93 Operation Section Starting the Engine Prestart Conditions Diesel Engine NOTE: The engine will not start unless the transmission Starting a Cold Diesel Engine directional control lever is in the NEUTRAL 1. Turn the key to the ON position and the start preheat position.
  • Page 94 Always connect the external power source cables in parallel with the lift truck battery cables : POSITIVE(+) to POSITIVE(+) and NEGATIVE(-) to NEGATIVE(-). Attach ground cable last, and remove it first. All lift trucks equipped with DOOSAN built internal combustion engines have NEGATIVE(-) ground connections. -91-...

  • Page 95: After Starting The Engine

    Operation Section After Starting the Engine Observe all indicator lights and gauges frequently during 4. Observe the diesel fuel level gauge (4) for operation, to make sure all systems are working properly. fuel level in the tank. All of the indicator lights will come ON with the ignition switch in the ON position before the engine is started.
  • Page 96 Operation Section Diesel Engine Engine and After-treatment System DM03P/V Diesel Engine Introduction The DM03P/V engine which is a high-power engine in compliance with the Required Engine Emissions Standard is provided with various systems(DM03P: T4F, DM03V: Stage5). The DM03P/V engine is equipped with a turbo-charger intercooler system that compresses and cools air and feed it to the intake manifold.
  • Page 97 Operation Section Electronic Controlled Diesel Engines (DI DM03P/V) Check the display as follows: Menu – Maintenance – Details of Repair. Description Timeout Error of CAN EGR Valve Accel pedal Throttle valve Accel pedal Water in fuel Engine Oil Pressure Sensor Intake Manifold Pressure Sensor Intake manifold temperature Sensor Atmospheric Pressure Sensor...
  • Page 98 Operation Section Description 1761 DEF Tank Level Sensor 1867 ECU over temperature for SCR Monitoring 2789 Turbine inlet temperature 2791 EGR H-Bridge Driver 3031 DEF Tank Temperature sensor 3216 Upstream NOx sensor 3217 Upstream NOx sensor 3219 Upstream NOx sensor 3224 Upstream NOx sensor 3226...
  • Page 99 Operation Section Description 4781 DPF Soot mass too high status (> 120%) 5313 Rail pressure sensor 5419 Throttle valve 5435 DEF pressure check error 5436 DEF Reverting valve 5491 DEF Pressure line heater 5571 Common rail pressure relief valve 5629 DPF differential pressure 5706 DEF Supply module heater...
  • Page 100 Operation Section Description 520618 520641 520642 520643 520696 520697 520698 520699 520700 520701 520702 520703 520704 520705 520706 520707 520707 520723 SCR Inducement Fault Level1 (EGR Block) 520724 SCR Inducement Fault Level2 (EGR Block) 520725 SCR Inducement Fault Level3 Final inducement (EGR Block) 520726 SCR Inducement Fault Warning (EGR Block) 520727...
  • Page 101 LCD Display Engine Check Torque Buzzer RPM Limit Method Message on the Display Lamp Reduction Warning Stage Normal ENGINE MALFUNCTION CALL DOOSAN Level1 Reduced Reduced Continuous SERVICE AGENT Engine Power Reduced! ENGINE MALFUNCTION CALL DOOSAN Blinking Limp home Limp home Continuous...
  • Page 102 Inducement Condition Offence Stage (within 40hrs) Normal Impeded DPF/Aftertreatment SYSTEM MALFUNCTION At starting & Every Level1 CALL DOOSAN SERVICE AGENT ≥ 95% of 20min detected Engine Power will be Reduced counter value for DPF/Aftertreatment SYSTEM MALFUNCTION severe 36~100hrs Every 10min...

  • Page 103: Lift Truck Operation

    Operation Section Lift Truck Operation Power Shift Transaxle 1. Start the engine. See topic “Starting the Engine.” 5. Release the service brake. 6. Push down on the accelerator pedal to obtain the desired travel speed. Release the pedal to decrease 2.
  • Page 104 Operation Section 7. To change the lift truck direction of travel, release the Inching accelerator pedal. NOTE: The purpose of the inching pedal is to provide 8. Push down on the service brake pedal to reduce the precise lift truck inching control at very slow lift truck speed as necessary.

  • Page 105: Mono-Ped Control System (If Equipped)

    Operation Section Steering Knob (If Equipped) Mono-Ped Control System There is a steering knob available for inclusion with (If Equipped) new truck deliveries. This option is solely intended for slow travel situations when two handed steering is not The MONO-PED pedal controls the speed and possible due to hydraulic operations.

  • Page 106: Operating Techniques

    Operation Section Operating Techniques Inching into Loads Lifting the Load 1. Lift the load carefully and tilt the mast back a short distance. Typical Example 1. Move the lift truck slowly FORWARD into position and engage the load. The lift truck should be square Typical Example with load, forks spaced evenly between pallet 2.
  • Page 107 Operation Section Traveling With the Load Unloading NOTICE Travel with the load as low as possible, while still maintaining ground clearance. Typical Example 1. Move the lift truck into the unloading position. Typical Example 1. Travel with the load uphill on upgrades and downgrades.
  • Page 108 Operation Section Turning Typical Example 3. Deposit the load and BACK away carefully to 1. When turning sharp corners, keep close to the inside disengage the forks. corner. Begin the turn when the inside drive wheel meets the corner. Typical Example 4.
  • Page 109 Operation Section Lifting Drums or Round Objects Operating in hot weather Keep the following points in mind when you operate the lift truck in hot weather. 1. Check the radiator. Clogging can cause overheating. Clean them out regularly with a blast of compressed air, also, check for leakage of water.
  • Page 110 Operation Section Safety instructions for attachments when transporting suspended loads WARNING Swinging/wide loads and a reduced residual capacity can result in accidents Adapt the travel speed to the load, less than walking pace. Secure swinging loads for example with lifting slings.

  • Page 111: Parking The Lift Truck

    Operation Section Parking the Lift Truck Park the lift truck on level ground, lowering the forks and tilting the mast forward until the fork tips touch the floor. Block the drive wheels when parking on an incline. 1. Park in an authorized area only. Do not block traffic 5.

  • Page 112: Lift Fork Adjustment

    Operation Section Lift Fork Adjustment WARNING When adjusting the fork spread, be careful not to pinch your hand between forks and the carriage slot. Hook - on type Fork 1. Move up the hook pin to the free position. 2. Raise the hook pin in each fork to side the fork on the carriage bar.

  • Page 113: Storage Information

    Operation Section Storage Information To Operate the Lift Truck After a Before Storage Long Time Storage Before storing your lift truck, clean and inspect as the following procedures. Remove covers and antirust from each of the  components and exposed parts. Wipe away grease, oil, etc.

  • Page 114: Transportation Hints

    NOTICE Remove ice, snow or other slippery material from the Contact your DOOSAN Lift Truck dealer for shipping shipping vehicle and the loading dock. instructions for your lift truck. Always block the trailer or the rail car wheels before loading the lift truck.
  • Page 115 Operation Section Lifting a Forklift using a Crane How to Fix Forklift to a Carrier 1. The rope/chain must have sufficient length for fixing. WARNING 2. Park the vehicle on a level ground. 1. If lifting rope breaks, serious injury/damage may occur.

  • Page 116: Towing Information

    Personal injury or death could result when towing a conditions. disabled lift truck incorrectly. Consult your DOOSAN Lift Tuck dealer for towing a Block the lift truck wheels to prevent movement disabled lift truck. before releasing the brakes. The lift truck can roll free if it is not blocked.

  • Page 117: Parking Brake Forced Release Method

    Maintenance Section Parking Brake Forced Release Method Restoration of Parking Brake Forced Release Method 1 NOTICE 1. Secure the wheels with blocks. When the engine stalls, the electronic parking brake 2. Use a spanner to fully loosen the nut on the parking remains applied at all times regardless of the status of the brake valve in front of the transmission by turning it in parking brake switch.
  • Page 118 Maintenance Section Parking Brake Forced Release Method 2 (In Restoration of Parking Brake Forced Case That the Engine Does Not Start) Release Method 2 1. Secure the tires with wooden blocks. 1. Secure the tires with wooden blocks. 2. Use a hex wrench to fully loosen the plugs in the 2.

  • Page 119: Inspection, Maintenance And Repair Of Lift Truck Forks

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for Users may also refer to the International Organization For inspection, maintenance and repair of lift truck forks. It Standardization - ISO Technical Report 5057 - Inspection also provides general information on the design and and Repair of Fork Arms and ISO Standard 2330 - Fork application of forks and the common cause of fork failures.
  • Page 120 Maintenance Section Repetitive Overloading  Causes of Fork Failure Repetitive cycling of loads which exceeds the fatigue Improper Modification or Repair strength of the material can lead to fatigue failure. The overload could be caused by loads in excess of the rated Fork failure can occur as a result of a field modification fork capacity and by use of the forks tips as pry bars.
  • Page 121 Maintenance Section Fork Inspection First Installation 1. Inspect forks to ensure they are the correct size for the truck on which they will be used. Make sure they are the correct length and type for the loads to be handled. If the forks have been previously used, perform the “12 Month Inspection”.
  • Page 122 Maintenance Section Consult the fork manufacturer for further 12 Months Inspection information as may be applicable to the specific fork involved. Forks should be inspected, at a minimum, every 12 months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked every six months.

  • Page 123: Tire Inflation Information

    Maintenance Section Tire Inflation Information Tire Inflation Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures. Shipping Ply Rating or Pressure Size Strength Index 7.00X12 Steer 8.25X15 Drive 300X15 Drive 7.50X16 Drive dual Standard tire, ply rating and inflation pressures.

  • Page 124: Torque Specifications

    Maintenance Section Torque Specifications Torque for Standard Bolts, Nuts, Metric Hardware and Taperlock Studs Most of the nuts, bolts, studs, and threaded holes in your lift truck are metric. In this manual we provide specifications in both metric and U.S. customary measurement.
  • Page 125 Maintenance Section Torques for Taperlock Studs Torque for Metric Fasteners Standard Taperlock Stud Torque Thread Size NOTICE Inch Be very careful never to mix metric with U.S. customary N·m lb·ft (standard) fasteners. Mismatched or incorrect fasteners will cause lift truck damage or malfunction and may even 8 ±...

  • Page 126: Cooling System Specifications

    In fact, coolant is as important as the quality of fuel and lubricating oil. NOTICE DOOSAN recommends that the coolant mixture contain 50% commercially available automotive antifreeze, and 50% water. The coolant mix with concentration of antifreeze smaller than 30% does not provide sufficient corrosion protection.
  • Page 127 DOOSAN recommends that the coolant mix contain 50% commercially available automotive antifreeze, or DOOSAN prefers the use of distilled water or deionized equivalent and acceptable water to maintain and water to reduce the potential and severity of chemical adequate water pump cavitation temperature for efficient insolubility.

  • Page 128: Specifications Of Fuel And Def/Ad-Blue

    Maintenance Section Specifications of Fuel and DEF/Ad-Blue General Fuel Information Diesel Specifications Use only the fuel recommended in this section. These engines utilize Tier 4 standards, the use of Ultra Low Sulfer Diesel (ULSD) is mandatory for these engines. Diesel Fuel Specification Location NOTICE ASTM D975 No.1D/2D S15...
  • Page 129 Methyl Esters), are being used as extenders for mineral oil derived diesel fuels. Doosan approves the use of bio-diesel fuels that do not exceed a blend of 5% (in volume) of FAME with 95% (by volume) of approved mineral oil derived diesel fuel. Such bio-diesel fuels are known in the marketplace as B5 diesel fuels.

  • Page 130: Lubricant Specifications

    Consult your DOOSAN Lift Truck dealer for purging instructions. Consult the EMA Lubricating Oils Data Book for a listing of oil brands.
  • Page 131 This oil is formulated for transmissions and drive trains only, and should not be used in engines. Shortened engine life will result. NOTE: MuIti-grade oils are not blended by DOOSAN for use in transmissions. Multi-grade oils which use high molecular weight polymers as viscosity...

  • Page 132: Lubricant Viscosities And Refill Capacities

    Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Capacities for Refilling Lubricant Viscosities Refill Capacities-(Approximate) for Ambient (Outside) Temperatures °C °F Compartment U.S. Compartment or System Liters or System Viscosities Min Max Min Max Gal. SAE 5W30 -30 +30 -22 86 Engine Crankcase w/Filter 12.6 3.33...

  • Page 133: Maintenance Intervals

    Maintenance Section First 50 - 100 Service Hours or a Week Maintenance Intervals Engine Oil & Filter – Change ......... 147 Drive Axle Oil, Transmission Oil, Oil Filter & Strainer NOTICE - Clean, Change ............. 148 Parking Brake - Test, Adjust........150 Never exceed the Maintenance Intervals specified in the manual.
  • Page 134 Maintenance Section Every 2500 Service Hours or 15 Months Hydraulic Oil - Check, Clean, Change ....171 Inspect Battery System .......... 171 Every 5000 Service Hours or 30 Months DPF Maintenance (DM03V Stage 5 Engine Only) - Ash Cleaning............172 Environment Protection Environment Protection ..........
  • Page 135 Maintenance Section Quick Reference to Maintenance Schedule Every ITEMS SERVICES PAGE Air Breather Change Air Intake System Check, Clean Air Intake System Change Battery Terminal Clean, Inspect Belt Check, Adjust Brake Oil Level Check Carriage Roller Extrusion Check, Adjust Carriage Side Rollers Lubricate Carriage Side Rollers Thrust (If Equipped) Lubricate...
  • Page 136 Maintenance Section Quick Reference to Maintenance Schedule Every ITEMS SERVICES PAGE Mast Channels Lubricate Mast Hinge Pins Lubricate Mast, Carriage, Lift Chains, & Attachments Check, Lubricate Overhead Guard Inspect Parking Brake Test, Adjust 149, 158 Priming the Fuel System SCR Cleaning - DeSOx Seat, Hood Latch &...

  • Page 137: When Required

    Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Battery Terminal - Clean, Inspect SCR Cleaning - DeSOx SCR Cleaning - DeSOx Display Pop-up WARNING In order that the SCR system may maintain its exhaust Batteries give off flammable fumes that can explode.
  • Page 138 Maintenance Section Automatic SCR Cleaning The ECU attempts to start SCR cleaning during NOTICE working—“automatic SCR cleaning”—at a proper moment after determining the moment. Once automatic Keep monitoring the vehicle condition via the SCREEN SCR cleaning starts, the high temperature indicator lamp display.
  • Page 139 Maintenance Section If automatic SCR cleaning is failed, you should carry it out Press this switch and release it after 3 sec, SCREEN a while after the vehicle starts working. Cleaning will be started and the engine speed will be increased.
  • Page 140 Maintenance Section Display for SCR Cleaning As shown in the table below, for your information, we provide Information about correlation between Symbol and message (Display). State SYMBOL Lamp Message on the Display Recommend SCR Cleaning in 10hr Need Engine Warm up Request Service SCR Should Do SCR Cleaning in 5hr Cleaning...

  • Page 141: Water Separator

    Maintenance Section Water Separator Discharge of Foreign Matter in the Fuel 1. If the engine check lamp indicates any fault related to water separator, remove the water in the separator The pressure sensor warning function is activated when immediately, regardless of regular maintenance foreign substances are detected in the fuel.

  • Page 142: Priming The Fuel System

    Maintenance Section Priming the Fuel System Seat, Hood Latch & Support Cylinder - Check, Lubricate In any one of the following cases, the fuel system requires priming. Before starting up the engine for the first (priming completed at factory), exhaust all fuel and refuel the fuel tank.

  • Page 143: Fuses, Bulbs & Circuit Breaker - Change, Reset

    Maintenance Section Bulbs Fuses, Bulbs & Circuit Breaker - Change, Reset Bulbs are identified as follows: Fuses [ Diesel Engine] 1. Bulb - head lamp halogen (24V - 55W) NOTE: If a fuse filament separates, use only the same *2. Bulb - back up (24V - 10W) type and size fuses for replacement.

  • Page 144: Circuit Breaker

    Maintenance Section Circuit Breaker Tires and Wheels - Check, Inspect WARNING Servicing and 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 physical injury or death.

  • Page 145: Carriage Roller Extrusion - Check, Adjust

    Maintenance Section When tires are changed, be sure to clean all rim parts and, Carriage Roller Extrusion - Check, if necessary, repaint to stop detrimental effects of Adjust corrosion. Sand blasting is recommended for removal of rust. 1. Set the mast vertical. 2.

  • Page 146: Every 10 Service Hours Or Daily

    Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Inspect Engine for Fluid Leaks Coolant Level - Check, Clean 1.

  • Page 147: Inspect Engine For Exhaust Leaks

    Maintenance Section Walk - Around Inspection - Inspect For maximum service life of the lift truck, make a thorough walk-around inspection. Look around and under the truck for such items as loose or missing bolts, debris or dirt buildup, fuel, oil or coolant leaks and cut or gouged tires.

  • Page 148: Transmission Oil Level - Check

    Maintenance Section Transmission Oil Level - Check Mast Channels – Lubricate WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1. Start and operate the lift truck until the engine reaches normal operating temperature.

  • Page 149: Hydraulic Oil Level - Check

    Maintenance Section Hydraulic Oil Level – Check Drive Axle Oil Level – Check WARNING WARNING At operating temperature, the hydraulic tank is hot Hot oil and components can cause personal injury. and under pressure. Do not allow hot oil or components to contact skin. Hot oil can cause burns.

  • Page 150: First 50 - 100 Service Hours Or A Week

    Maintenance Section First 50 - 100 Service Hours or a Week You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. 10. Fill the crankcase. See “Refill Capacities”. Engine Oil &...

  • Page 151: Drive Axle Oil, Transmission Oil, Oil Filter & Strainer - Clean, Change

    Maintenance Section 2. Wash the strainer (screen, 1), spring (2) and drain Drive Axle Oil, Transmission Oil, Oil plug (3) in clean, nonflammable solvent. Dry and Filter & Strainer - Clean, Change install the strainer, spring and drain plug. 3. Raise the hood and seat assembly. WARNING Hot oil and components can cause personal injury.
  • Page 152 Maintenance Section When the oil temperature is 40°C approximately, the cold side mark on the dipstick is applicable. When the oil temperature is 80°C approximately, the hot side mark on the dipstick is applicable. 14. Check for oil leaks at the filter and drain plug. 15.

  • Page 153: Parking Brake - Test, Adjust

    Maintenance Section Parking Brake - Test, Adjust Parking Brake Testing WARNING If the parking brake is used for emergency braking NOTICE while the vehicle is running, the parking brake must be tested. If the forklift continues to move even when the OSHA requires the parking brake to hold the lift truck, parking brake is on, park the vehicle in a safe place with capacity load, on a 15% grade.

  • Page 154: Every 500 Service Hours Or 3 Months

    Maintenance Section Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Servicing Filter Element Air Intake System - Check, Clean Precleaner (If Equipped) NOTICE Never service precleaner with the engine running.
  • Page 155 Maintenance Section 2. Rotate the element slightly to separate it from its base Cleaning Primary Filter Elements and remove it from the air cleaner housing. 3. Clean and inspect the element or replace with a new WARNING element. See topic, “Cleaning Primary Filter Elements”.

  • Page 156: Fuel Filter - Change

    Maintenance Section Water - 280 kPa (40 psi) Maximum Pressure Fuel Filter - Change The fuel filter element must be replaced on a regular basis to prevent foreign materials from entering the diesel fuel system. Stop and cool down the engine. Disconnect wire harness connector (1) and disconnect the fuel hose (2) connected to the fuel filter port.

  • Page 157: Engine Oil & Filter - Change (With Cj-4 Grade Only)

    Maintenance Section Engine Oil & Filter - Change (with Tilt Cylinders - Check, Adjust, CJ-4 Grade Only) Lubricate See topic, “Engine Oil & Filter - Change” in “First 50-100 Chassis Pivot Eyebolts Service Hours”. WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

  • Page 158: Crosshead Rollers - Inspect

    Maintenance Section Cylinder Rod Extension Crosshead Rollers - Inspect NOTE: The following description is for forward tilt. For 1. Operate the mast through a lift cycle. Watch the cylinder rod back tilt, the collar should be chains move over the crosshead rollers. Make sure stationary by the tilt eye.

  • Page 159: Carriage Side Rollers Thrust (If Equipped) - Lubricate

    Maintenance Section Carriage Side Rollers Thrust (If Carriage Sideshifter (If Equipped) – Equipped) - Lubricate Lubricate 1. Raise the carriage high enough to gain access to the 1. Lubricate 4 (6) fittings. The forks may have to be side thrust rollers on the back side of the carriage. moved to gain access to all of the fittings.

  • Page 160: Mast, Carriage, Lift Chains, & Attachments - Check, Lubricate

    Maintenance Section Mast, Carriage, Lift Chains, & Attachments - Check, Lubricate 1. Operate the lift, tilt and attachment controls. Listen for unusual noises. These may indicate a need for repair. 2. Inspect for loose bolts and nuts on the carriage. Remove any debris from the carriage and mast.

  • Page 161: Parking Brake - Test, Adjust

    Maintenance Section Parking Brake - Test, Adjust Overhead Guard – Inspect See topic, “Parking Brake - Test, Adjust” in “First 50-100 Service Hours.” Horn & Lights (If Equipped) – Check 1. Press horn button, to determine if horn is operational. 2.

  • Page 162: Steer Suspension - Inspect

    Maintenance Section Steering Mechanism - Check, Steer Suspension - Inspect Lubricate 1. Inspect the suspension mounting bolts. Tighten suspension mounting bolts, if necessary, to 240+30 1. Lubricate the steer axle king pins, total of four fittings. N·m (180+20 lb·ft). Two on the right side and two on the left side. 2.

  • Page 163: Wheel Bolts And Nuts - Inspect

    Maintenance Section Drive Wheels Wheel Bolts and Nuts – Inspect Inspect Tightness NOTICE Do not lubricate ball seas of wheels or ball faces of wheel nuts. Be sure mounting faces of hub, wheel nuts and flat mounting surfaces are clean. Tighten wheel nuts again after 24 hours of operation.

  • Page 164: Every 1000 Service Hours Or 6 Months

    Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Air Intake System - Change Fuel Lines & Fittings - Check Visually inspect fuel lines and fittings for physical damage.

  • Page 165: Fuel Filter (With Pre/Main Filter) - Change

    Maintenance Section Install a new fuel filter and assemble the fuel filter cap. Fuel Filter (with Pre/Main Filter) – Change Connect the wire harness connector and fuel hose connector. When connecting the fuel hose, take care to The fuel filter element must be replaced on a regular prevent foreign material from entering the hose.

  • Page 166: Belt - Check, Adjust

    Maintenance Section Belt – Check, Adjust Hydraulic Return Filter - Change 1. The belt is equipped with an auto tensioner which WARNING automatically adjusts the belt tension so there is no need for extra adjustment of the tension. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

  • Page 167: Air Breather - Change

    Maintenance Section Air Breather - Change Lift Chains - Test, Check, Adjust Park the lift truck on level ground, with the forks lowered, Lift Chain Wear Test the parking brake engaged, the transmission in Inspect the part of the chain for its normal operation over NEUTRAL, and the engine stopped.
  • Page 168 Maintenance Section Check for Equal Tension Carriage Chain Adjustment Make sure that carriage height is correct. If correct, adjust the chain for equal tension. If not, adjust the chain for correct carriage height by adjusting anchor nuts (1),(2). NOTE: See the previous section, “Carriage Roller Extrusion”...

  • Page 169: Universal Joint - Inspect, Lubricate

    Maintenance Section Mast Chain Adjustment - FF, FFT Mast Universal Joint - Inspect, Lubricate Typical example for FF mast 1. Inspect for loose retaining bolts. Check for worn or damaged bearings. 2. Have worn or damaged bearings replaced. Tighten the bolts if necessary. Typical example for FFT mast Make sure that mast height is correct.

  • Page 170: Every 2000 Service Hours Or Yearly

    Maintenance Section Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Drive Axle Oil, Transmission Oil, Oil Filter & Strainer - Clean, Change See the topic, "Drive axle Oil, Transmission Oil, Oil Filter &...

  • Page 171: Cooling System - Clean, Change

    Maintenance Section 11. Install the hub cap. 8. Close the drain valve and install the block drain plug. Fill the system with neutralizing solution, 250g (1/2 lb) 12. Raise the lift truck and remove the blocking Lower sodium carbonate per 40 liters (10 gallons) of water. the lift truck to the ground.

  • Page 172: Forks - Inspect

    3 percent of blade length (L). Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift Truck Dealer for 2. Check the angle between the upper face of the blade further information.
  • Page 173 Maintenance Section 5. Check the fork blade (J) and shank (H) for wear with 8. Check fork markings (N) for legibility. Renew special attention to the heel (G). The fork should be markings as required to retain legibility. withdrawn from service if the thickness is reduced to a.

  • Page 174: Every 2500 Service Hours Or 15 Months

    Maintenance Section Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. 6. Stop the engine and check the oil level. With all Hydraulic Oil - Check, Clean, cylinders retracted, maintain the oil level to the FULL Change...

  • Page 175: Every 5000 Service Hours Or 30 Months

    Maintenance Section Every 5000 Service Hours or 30 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures DPF Maintenance (DM03V Stage 5 Engine Only) - Ash Cleaning WARNING Ash cleaning services is recommended by the designated repair shop, if not, it can lead to damage...

  • Page 176: Environment Protection

    Maintenance Section Environment Protection When servicing this lift truck, use an authorized servicing area and an approved container to collect coolant, oil, fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items are disconnected or removed. After servicing, dispose of those materials in an authorized place and container.

  • Page 177: Index

    Index Section Changing Primary Element ........161 Index Changing Secondary Element ......161 Chassis Pivot Eyebolts .......... 154 Check Coolant Level ..........143 Check for Equal Tension ........165 Check Inflation and Damage ......... 141 12 Months Inspection ..........119 Checking Element ..........
  • Page 178 Index Section Environment Protection ......... 116, 173 Improper Modification or Repair ......117 Every 10 Service Hours or Daily ......143 Inching into Loads ..........103 Every 1000 Service Hours or 6 Months ....161 Inching..............101 Every 2000 Service Hours or Yearly ..... 167 Inspect Battery System ..........
  • Page 179 Index Section Mono-Ped Control System (If Equipped) ....102 Method 2 ..............115 Mounting and Dismounting ........11 Moving Fan Warning ..........9 Multi-torque ............... 83 Safety instructions for attachments when transporting suspended loads ....... 107 Safety instructions for attachments when No Riders Warning .............
  • Page 180 Index Section Torques for Taperlock Studs ......... 122 Towing Information ..........113 Training Required to Operate or Service Warning ... 5 Transmission Inching Control Pedal ....... 85 Transmission Oil (TDTO) ........128 Transmission Oil Level - Check ......145 Transmission Speed Range Lever ......82 Transportation Hints ..........

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