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Doosan B22X-7 Operation & Maintenance Manual

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  • Page 2 Maintenance Manual FORKLIFTS B22X-7, B25X-7, B30X-7, B35X-7 B25XL-7 FBA16, FBA17, FBA19, FBA20, FBA18 80 Volt Original Instruction This document is the informational asset of Doosan Corporation. Thus, unauthorized access, revision, distribution and copying of this document are strictly prohibited. 1712...

  • 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 ................ 76 Tire Inflation Information ......... 80 Safety Section Torque Specifications ..........82 Lubricant Specifications ......... 84 Important Safety Information ........4 Battery Discharge Indicator ........

  • Page 5: Information Section

    WARNING Continuing improvement and advancement of Your DOOSAN truck comes equipped with an product design might have caused changes to your operator restraint system. Should it become lift truck which are not included in this publication.
  • Page 6 Operation Environment Management The Operation Section is a reference for the new Note that DOOSAN CORPORATION INDUSTRIAL operator and a refresher for the experienced one. VEHICLE BG is ISO 14001 certified which is This section includes a discussion of gauges,...

  • 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

    Training Required To Operate or Service U.S.A., operate this lift truck in accordance with local Warning regulations. DOOSAN lift trucks are manufactured in accordance with the National Fire Protection Association (NFPA) No. 505 and the American National Standards Institute, Inc.
  • Page 9 Safety Section General Warnings to Operator 17. Lower the lifting fork on the floor for parking the truck. Set the forward/reverse switch at neutral. WARNING Check that parking brake lamp is on, and turn the ignition switch to OFF position. Chock the Only trained and authorized personnel may wheels when parking the truck on a slope.
  • Page 10 Safety Section Hand Placement Warning Load Backrest Must Be In Place Warning WARNING WARNING Operation without this device in place may be hazardous. No hands. Do not place hands in this area. Do not touch, lean on, or reach through the mast or permit others to do so.
  • Page 11 Safety Section No Riders Warning Battery Restraint Warning WARNING To avoid personal injury, allow no riders. A lift truck is designed for only one operator and no riders. Located on front of battery cover. WARNING Before operating truck, ensure that hood is securely locked by hood latch, and turn stopper to locking position.
  • Page 12 Safety Section Battery Disconnect Before Servicing Seat Switch Warning Warning WARNING WARNING Install any seat to this seat frame. Switch must shut off all power when operator is not seated. Disconnect battery from truck also discharge high voltages from capacitor banks with a 150 ohm, 25 watt Resistor before attempting to service this truck.(B+, B-) [DRIVE CONTROLLER]...

  • Page 13: General Hazard Information

    Safety Section Do not raise loads any higher than necessary and General Hazard Information never raise a load higher than 1830 mm (72 in) with the overhead guard removed. Always use load backrest extension when the carriage or attachment does not fully support the load.

  • Page 14: Lift Chains

    Make sure the lift truck is equipped with a lighting please contact your DOOSAN dealer. We would like system as required by conditions. to draw your attention to the fact that any secondary...
  • Page 15 Safety Section Make sure the lift truck horn, lights, backup alarm (if Operating the Lift Truck equipped) and all other devices are working properly. Always keep the lift truck under control. Check for proper operation of mast and attachments. Obey all traffic rules and warning signs. Pay particular attention to unusual noises or erratic movement which might indicate a problem.

  • Page 16: Maintenance Information

    Safety Section Always overhead guards except where Maintenance Information operation conditions do not permit. Do not operate lift truck in high stacking areas without overhead Perform all maintenance unless otherwise specified guards. as follows : When stacking, watch for falling objects. Use load Park the lift truck in authorized areas only.
  • Page 17 Only trained and designated personnel should To avoid possible weakening of the Falling Objects inspect, recharge or exchange batteries. Protective Structure (FOPS), consult a DOOSAN dealer before altering, by adding weight to, welding Always wear protective glasses when working with on, or cutting or drilling holes into the structure.
  • Page 18 Do not approach a warm tire closer than the outside tubes and hoses. Leaks can cause fires. Contact of the area represented by the shaded area in the your DOOSAN dealer for repair or replacement. above drawing. Check lines, tubes and hoses carefully. Do not use Dry nitrogen (N2) gas is recommended for inflation your bare hand to check for leaks.

  • Page 19: Operator Restraint System (If Equipped)

    Servicing, changing tires and rims can be dangerous make sure a new label is installed on the replaced and should be done only by trained personnel using part. See you DOOSAN Lift Truck dealer for new proper tools and procedures. If correct procedures labels.
  • Page 20 Safety Section Grammer Seat (Weight Input Adjustable) The "Survive in tipover" warning is located on the overhead guard. It shows the proper use of the Use the lever at the left-hand side to adjust the seat operator restraint system. to the position you desire. Make this seat adjustment before you drive the vehicle.
  • Page 21 Safety Section Daewon Seat (Weight Input Adjustable) Grammer Seat (Weight Input Adjustable) Pulling the weight adjusting lever upward, move it right or left to adjust the weight input based on your weight (50–130 kg). Grammer Seat (Weight Input Adjustable) Lumbar Support Adjustment Grammer Seat (Weight Input Adjustable) Pulling the weight adjusting lever forward by turning, move it up or down to adjust the weight input based...
  • Page 22 WARNING 1. Grip the plate (connector) of the belt and pull the Your DOOSAN truck comes equipped with a DOOSAN operator restraint system. Should it belt from the retractor. Then insert the plate into become necessary to replace the seat for any the slot of the buckle until a snap is heard.
  • Page 23 Safety Section Release the Seat Belt WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. Push the button of the buckle to release the belt. The belt will automatically retract when released. Hold the plate of the belt and allow the belt to slowly retract.

  • Page 24: Avoiding Lift Truck Tipover

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tipover 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 Counterbalanced lift truck design is based on the has moving parts and, therefore, has a CG that balance of two weights on opposite sides of a...
  • Page 25 If the CG moves outside of the line forklifts sold by DOOSAN shall not be removed, on either side of the stability base, the lift truck will altered or replaced without DOOSAN’s approval. tip to the side.

  • Page 26: 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 body outside of the operator’s compartment. Never Only properly trained and authorized personnel put any part of body into the mast structure or should operate forklift trucks.
  • Page 27 Safety Section Do not overload. Always handle loads within the Do not raise anyone on the forks of your lift truck rated capacity shown on the capacity plate. unless using an approved safety cage. Do not let Do not add extra counterweight to the truck. An other people ride on the truck.
  • Page 28 Safety Section Do not elevate the load with the mast tilted forward. Do not permit anyone to stand or walk under the Do not tilt the elevated loads forwards. load or lifting mechanism. The load can fall and This will cause the lift truck to tip over forward. cause injury or death to anyone standing below.
  • Page 29 Safety Section Do not stack or turn on ramps. Do not drive in forward direction when loads restrict Do not attempt to pick-up or deposit a load unless your visibility. Operate your lift truck in reverse to the lift truck is level. Do not turn on or drive across improve visibility except when moving up a ramp.
  • Page 30 Safety Section operate forklifts near flammable Do not operate your truck close to another truck. combustible materials. Always keep a safe distance from other trucks and avoid discoloration, deformation make sure there is enough distance to stop safely. combustion of materials (such as lumber, veneer Never overtake other vehicles.
  • Page 31 Safety Section Forklift trucks are not cars. They often have small There are many special attachments available to tires, no suspension, and are very heavy. replace the forks on a lift truck. The forklift's center of gravity will also change when All carry safety implications and special training in carrying loads.

  • Page 32: How To Survive In A Tipover (If Operator Restraint System Equipped)

    Safety Section How to Survive in a Tipover (If Operator Restraint System Equipped) 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.

  • Page 33: General Section

    Doosan Corporation Industrial Vehicle BG. 468, Injung-ro, Dong-gu, Incheon, Korea 22503 Authorized Representative, Compiler of Technical File According to 2006/42/EC Doosan Industrial Vehicle Europe N.V. Mr. Chankyo Chung Europark-Noord 36A, 9100 Sint-Niklaas, Belgium herewith declare that the following equipment conforms with the appropriate requirements of the Directives 2006/42/EC(Machinery Directive), and 2014/30/EU (EMC Directive) based on its design and type, as brought into circulation by us.

  • Page 34: Specifications

    General Section Specifications Manufacturer Model at rated load center Load Capacity Load center Power type Operator type P : Pneumatic, E : Solid Soft, C : Cushion Tire Type Number of front / rear Wheels (x=Driven) with STD 2-stage mast Max.Fork Height 10 Free Lift ISO Class...
  • Page 35 General Section DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN B22X-7 B25X-7 B25XL-7 B30X-7 B35X-7 2200 2500 2500 3000 3500 AC Electric AC Electric AC Electric AC Electric AC Electric Driver Seated Driver Seated Driver Seated Driver Seated Driver Seated P, E P, E...
  • Page 36 General Section...

  • Page 37: Noise And Vibration

    General Section Noise and Vibration Noise at operator ear (measured by PREN 12053) unit:dB(A) Noise Level [ Unit : dB(A) ] Sound Pressure Level at Operator's Ear (Leq.) Model EN 12053 B22X-7 B25X-7 B25XL-7 69.7 B30X-7 B35X-7 *Test Model : B35X-7...

  • Page 38: Capacity Chart

    General Section Capacity Chart MODEL STD, FFL C. 6010mm MAST A. 2030 – 3600 mm MAST A. 3900 – 4730 mm MAST B. 4960 mm MAST B. 5560 mm MAST D. 5560mm MAST A. 2030 - 3600mm MAST C. 4960mm MAST A.

  • Page 39: Capacity Chart - With Side Shifter (Integrated)

    General Section Capacity Chart - With Side Shifter (Integrated) MODEL STD, FFL C. 4960mm MAST D. 5560mm MAST A. 2030 – 3600 mm MAST A. 3900 mm MAST B. 4350 mm MAST B. 4290 mm MAST E. 6010mm MAST C. 4730mm MAST D.

  • Page 40: Capacity Chart - With Side Shifter (Hook On)

    General Section Capacity Chart - With Side Shifter (Hook on) MODEL STD, FF C. 4960mm MAST D. 5560mm MAST A. 2030 – 3600 mm MAST A. 3900 mm MAST B. 4350 mm MAST B. 4290 mm MAST E. 6010mm MAST C.

  • Page 41: Serial Number

    General Section Serial Number Serial Numbers Locations For quick reference, record the serial numbers in space provide below illustration photographs. Lift Truck Serial Number...

  • Page 42: Operator's Warning And Identification Plate

    General Section Operator’s Warning and Identification Plate Familiarize yourself with the information on the ldentification, Lift Capacity and Attachment Plates. Do not exceed allowable lift truck working capacity load ratings. Operator’s Warning Plate Identification, Lift Capacity and Attachment Plate Lift Truck Capacity Rating DO NOT exceed allowable lift truck working capacity load ratings.
  • Page 43 General Section - Hydraulic Fork Positioner, Non Sideshift. Mast Abbreviations - Crane Arm or Crane Boom. The identification plate indicates the type of mast installed on the lift truck when it left the factory. The - Tire Handler. type of mast is indicated by an abbreviation. - Container Top Handler.

  • Page 44: Operation Section

    Operation Section Operator’s Station and Monitoring Systems Read and understand the “Safety”, “Operation” and “Maintenance” sections before operating the lift truck. Key Switch Seat Switch the seat switch is located under the operator’s seat. The key switch is located on the right side of the steering column.
  • Page 45 Operation Section Economic, Standard or High Operation Monitoring Systems Indicator mode Speedometer having graduations from 0 (low) to 9 (high) segments. Battery voltage level gauge having 9 segments. Table 1 shows the relationship between the battery charging progress and the No. of blocks. Both Located on the middle of the console cover panel.
  • Page 46 Operation Section Relation between battery charge level and Controller PAR CHANGE number of visualized bars parameter change FAULT fault DUAL TRA Battery charge level BDI Percent [%] Dual traction fault FAULT 90%< Drive right-side 89% ~ 80% module low D-INV 79% ~ 70% temperature (- UNDERTEMP...
  • Page 47 Operation Section voltage VOLT over / low voltage FAULT Min. battery MIN BATT Fingertip controller EXT TIME voltage VOLT CAN error FAULT Pedal trimmer Fingertip controller EXT CUR ACCEL FAULT failure current over 18A FAULT Drive right-side Fingertip controller EXT POWER module non- D-INVERTER 12V/5V voltage...
  • Page 48 Operation Section Front and Rear Floodlights Switch Tilt Steering Column Located on the right side of the instrument panel. Located on the lower front of the steering column. OFF – Push the switch down to turn off the To adjust the steering column, raise the handle(1) headlamp and rear lamp /rear.
  • Page 49 Operation Section Emergency Switch (If Equipped) OFF - Push the emergency switch button to disconnect the electrical circuits. (It must be done after the key switch is turned off) ON - Pull the emergency switch button to connect the electrical circuit.

  • Page 50: Lift Truck Controls

    Operation Section Lift Truck Controls Parking Brake Service Brake Pedal NOTICE Do not operate the emergency switch while the forklift is in motion, unless in an emergency case. Using the parking brake in place of the service brake damages the parking brake severely. Service Brake - The service brake pedal is located on the floor of the operator’s compartment.
  • Page 51 Operation Section Accelerator Pedal Directional control forward/reverse switch NOTICE The service brake and accelerator pedals should not be used at the same time, except for emergency situations. Use of both the brake and accelerator pedals at the same time may cause the drive motor to overheat.
  • Page 52 Operation Section If the driver stands up from the driver's seat while Tilt Control Lever the lift truck is in operation, the seat switch will be activated and the drive motor will be turned off after 3 s. In this case, release the accelerator pedal and close the seat switch, return the forward/reverse switch to neutral and then shift it to desired position.
  • Page 53 Operation Section Auto tilt control (If provided) Sideshift Attachment Control (If Equipped) The auto tilt controller is on the left side of the tilt knob. Press the auto tilt switch to turn on the switch The sideshift attachment control is located at the lamp and push the tile knob forward.

  • Page 54: Before Operating The Lift Truck

    Operation Section Before Operating the Lift Truck Walk-Around Inspection For your own safety and maximum service life of the lift truck, make a thorough walk-around inspection before mounting the lift truck or starting to move it. Look for such items as loose bolts, trash build-up, oil leaks, condition of tires, mast, carriage, forks or attachments.
  • Page 55 Operation Section 11. Inspect the battery compartment for loose connections, frayed cables properly secured battery restraint. Batteries give off flammable fumes that can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.
  • Page 56 Operation Section Better Battery Performance NOTICE The lift truck operator must not start a shift with a battery that has been taken off a charger too soon. A battery should never be disconnected from a charge until the charge cycle has been completed. The batteries that have been fully charged should have a tag attached for identification.

  • Page 57: Lift Truck Operation

    Operation Section Lift Truck Operation Be sure no one is working on or near the lift truck. Keep the lift truck under control at all times. Reduce speed when maneuvering in tight quarters or when braking over a rise. Do not allow the lift truck to overspeed downhill. Use the service brake pedal to reduce speed when traveling down hill.
  • Page 58 Operation Section 6. Step on the acceleration pedal lightly and release it to release the parking brake. 7. Push down on the accelerator pedal to obtain the desired travel speed. Release the pedal to decrease travel speed. 8. To change the lift truck direction of travel, electrical braking(plugging) can be used to slow or stop the lift truck.
  • Page 59 Operation Section Electrical Braking (Plugging) 2. Hold the accelerator pedal down until the lift truck nearly comes to a complete stop. Release the accelerator pedal. To slow, stop or change direction when traveling in either direction, move the directional control lever 3.

  • Page 60: Mono-Ped Control System (Option)

    Operation Section Steering Knob (If Equipped) Mono-Ped Control System (Option) There is a steering knob available for inclusion with new truck deliveries. This option is solely intended for slow travel situations when two handed steering is not possible due to hydraulic operations. Forward-Push the left side (2) of the pedal for FORWARD direction travel.

  • Page 61: Finger Tip

    Operation Section Finger Tip Lift Control knob Tilt Control knob Lower - Push the knob forward smoothly Tilt Forward - Push the knob forward to lower the lift forks. smoothly to tilt the lift forks forward. Hold - Release the lift knob. The knob will Hold - Release the tilt knob.
  • Page 62 Operation Section Sideshift Attachment Control Emergency Switch The side shift attachment controller is at the front- OFF - Push the emergency switch button right side of the driver, and the side shift control to disconnect the electrical circuits. (It lever is at the right as shown in the figure. must be done after the key switch is turned off) Side shift Left (1) –...
  • Page 63 Operation Section If the driver stands up from the driver's seat while Directional Control Switch the forklift truck is in operation, the seat switch will be activated and the drive motor will turned off after 3 s. In this case, release the accelerator pedal and close the seat switch, return the forward/reverse switch to neutral and then shift it to desired position in the respective direction.
  • Page 64 Operation Section Auto Tilt Control (If provided) Horn Button The auto tilt controller is at the rear side of the tilt Located in the right side of the directional knob. Press the auto tilt switch to turn on the switch control switch.
  • Page 65 Operation Section Adjustment of Armrest Up and Down Adjustment Turn No. 2 knob leftwards (CCW) to adjust the arm Using the two adjustment device, adjust the rest position up/down. positions of the arm rests to a comfortable positions. knob #1 - forward, backward adjustment knob #2 - upward, downward adjustment Forward and Backward Adjustment Turn No.

  • Page 66: Operating Techniques

    Operation Section Operating Techniques NOTE: The photographs and line art used in the following Operating Techniques, are typical examples and may not apply to your particular lift truck. Inching into Loads Lifting the Load 1. Move the lift truck slowly forward into position and engage the load.
  • Page 67 Operation Section Traveling With or Without a load Lift Truck Turning When traveling with and without a load, travel with the fork as low as possible, while still maintaining good floor clearance height. 1. When turning sharp corners, keep close to the inside corner.
  • Page 68 Operation Section 3. As the steer wheel angle increases, the inside drive motor speed is progressively slowed down with respect to the outside drive motor speed.
  • Page 69 Operation Section Unloading Lift Truck Lifting Drums or Round Objects 1. Move the lift truck into the unloading position. 1. Block drums or round objects. Tilt mast forward and slide fork tips along the floor to get under 2. Tilt the mast forward only when directly over the the load.
  • Page 70 Operation Section Safety instructions for attachments when transporting suspended loads WARNING Swinging 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 71: Parking The Lift Truck

    Operation Section Parking the Lift Truck NOTICE Parking or storage of electric lift trucks outdoor can cause lift truck system damage or failure. Park or store all electric lift trucks inside a building to protect electrical system from moisture damage. PARKING BRAKE (EM) When leaving the operator’s station, park the lift truck in authorized areas only.
  • Page 72 Operation Section [OUTSIDE BATTERY CONNECTOR] [INSIDE BATTERY CONNECTOR] 6. Disconnect the battery. 7. Block the wheels if parking on an incline.

  • Page 73: Lift Fork Adjustment

    Operation Section Lift Fork Adjustment 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 in each fork to side the fork on the carriage bar. 2.

  • Page 74: Storage Information

    Operation Section Storage Information Before Storage To place the machine in storage for an extended period of time, the following measures must be taken to ensure that it can be returned to operation with minimal service. 1. After every part is washed and dried, the machine should be housed in a dry building.

  • Page 75: Transportation Hints

    Check the state and local laws governing weight, width and length of a load. Contact your DOOSAN Lift Truck dealer for shipping instructions for your lift truck. 1. Always block the trailer or the rail car wheels before loading the lift truck.
  • Page 76 Operation Section Lifting a Forklift using a Crane How to Fix Forklift to a Carrier The rope/chain must have sufficient length for fixing. Batteries of an electric forklift must be removed before lifting. Lifting an electric Park the vehicle on a level ground. forklift without removing the batteries can lead to serious injury to the workers or Set the mast vertically.

  • Page 77: Towing Information

    Personal injury or death could result when inclines or poor surface conditions. towing a disabled lift truck incorrectly. Consult your DOOSAN Lift Truck dealer for Block the lift truck wheels to prevent movement towing a disabled lift truck. before releasing the brakes. The lift truck can roll free if it is not blocked.
  • Page 78 Operation Section Connect EM CONN B and EMERGENCY C. Tighten the traction bar connected to the lift truck. Remove the wheel chocks. Tow the lift truck carefully. Do not tow the lift truck faster than 2km/h (1.2 mph). NOTICE Release the parking brake to prevent excessive wear and damage to the parking brake system.

  • Page 79: Inspection, Maintenance And Repair Of Lift Truck Forks

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following provides practical guidelines for Users also refer International inspection, maintenance and repair of lift truck forks. Organization for Standardization - ISO Technical It also provides general information on the design Report 5057 -Inspection and Repair of Fork Arms and application of forks and the common cause of and ISO Standard 2330 - Fork Arms-Technical...
  • Page 80 Maintenance Section Repetitive Overloading Causes of Fork Failure Repetitive cycling of loads which exceeds the Improper Modification or Repair fatigue strength of the material can lead to fatigue failure. The overload could be caused by loads in Fork failure can occur as a result of a field excess of the rated fork capacity and by use of the modification involving welding, flame cutting or forks tips as pry bars.
  • Page 81 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 82 Maintenance Section 4. A fork should be load tested before being 12 Months Inspection returned to service on completion of repairs authorized and done in accordance with the Forks should be inspected, at a minimum, every 12 manufacturer’s recommendations. months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked Most manufacturers and standards require the every six months.
  • Page 83 Maintenance Section Insulation resistance inspection Insulation resistance should conducted accordance with following standard at least once a year to ensure operator’s safety. DIN EN 1175, DIN 43539  VDE 0117, VDE 0510  DZ.U. 2003 NR 193 POZ. 1890 art 12 ...

  • Page 84: Tire Inflation Information

    Maintenance Section Tire Inflation Information Tire Inflation Tire Shipping Pressure The inflation pressures shown in the following chart are cold inflation shipping pressures for tires on DOOSAN lift trucks. Shipping Ply Rating or pressure Size Strength Index B22/25/30/35X-7 18X7-8 Steer...

  • Page 85: Torque Specifications

    Maintenance Section Torque Specifications Metric Hardware - This lift truck is almost totally Torque for Standard Bolts, Nuts metric design. Specifications are given in metric and Taperlock Studs U.S. Customary measurement. Metric hardware must be replaced with metric hardware. Check parts books for proper replacement. NOTICE Use only metric tools on most hardware for proper The following charts give general torques for bolts,...
  • Page 86 Maintenance Section Torques for Taperlock studs Torque for Metric Fasteners Standard Taperlock Stud Thread Size NOTICE Torque Inch N·m lb·in Be very careful never to mix metric with U.S. 8±3 6±2 customary (standard) fasteners. Mismatched or 5/16 17±5 13±4 incorrect fasteners will cause lift truck damage or malfunction and may even result in personal injury.

  • Page 87: Lubricant Specifications

    If the hydraulic oil becomes cloudy, water or air is entering the system. Water or air in the system will cause pump failure. Drain the fluid, retighten all hydraulic suction line clamps, purge and refill the system. Consult your DOOSAN Lift Truck dealer for purging instructions.
  • Page 88 The API GL-4 specification or MIL-L-2105A oils could be used. Multi-grade oils are not blended by DOOSAN for use in transmissions. Multi-grade oils which use high molecular weight polymers as viscosity index Located on the left site of the cowl.

  • Page 89: Battery Discharge Indicator

    Maintenance Section Battery Discharge Indicator The battery discharge indicator should be observed If information is not available from the battery frequently before and during operation. supplier, use 1.140 specific gravity level. A fully charged battery will cause a “9 segments” to be displayed on the LCD display.

  • Page 90: Battery

    Maintenance Section Battery battery operation must prevented. Operation with a low battery may cause damage to the battery. Low battery operation will cause higher than normal current in the electrical system. This can damage When using pressure air for cleaning purposes, contactor tips or shorten motor brush life.
  • Page 91 Maintenance Section The battery’s maximum temperature is critical. The electrolyte temperature should never exceed 43°C NOTICE (110°F) either while operating or charging. If higher • DISPOSAL OF OLD BATTERY temperatures are maintained through use or abuse, reduced battery service life can be expected. Careless disposal of a battery can harm the environment and can be dangerous to persons.

  • Page 92: Cold Storage Applications

    Maintenance Section Cold Storage Applications When an electric lift truck is operated in cold Hydraulic System storage applications, at temperatures as low as - 20°C (-4°F), the battery capacity is decreased. Operation at cold temperatures can also cause mechanical failures, short circuits and too much wear due to the formation of ice crystals.

  • Page 93: Lubricant Viscosities And Refill Capacities

    Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities LUBRICANT VISCOSITIES REFILL CAPACITIES-(APPROXIMATE) FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment or U.S. Imperial Liters °C °F Compartment System or System Viscosities Min Max Min Max Hydraulic & Power ISO VG 15 -40 Steering System Hydraulic ISO VG 22 -30...

  • Page 94: Maintenance Intervals

    Maintenance Section Maintenance Intervals Every 500 Service Hours or 3 Months NOTICE Tilt Cylinders............108 Cylinder Rod Extension - Adjust ......109 Never exceed the Maintenance Intervals specified Crosshead Rollers - Check ........109 in the manual. Defects and/or damage to the Mast Hinge Pins - Lubricate .........

  • Page 95: 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. Self Diagnostics - Test Compact Display Button Test Circuits and Components The Micro-Controller has a built-in diagnostic system to provide aid in rapid troubleshooting of lift truck problems.

  • Page 96: Run Time Diagnostic

    Maintenance Section Moreover, ENTER button is used to confirm the Run Time Diagnostic new value of the parameter in calibration procedure UP Button 1. Pressing of this button, in calibration and diagnostic mode, you increase the number of the parameter displayed. 2.
  • Page 97 Maintenance Section Parameter Number Parameter Name Left traction motor speed [rpm] Left traction motor speed standard [rpm] Right traction motor speed [rpm] Right traction motor speed standard [rpm] Lift voltage [mV] Battery voltage [V·10] Left traction motor power supply module temperature [ºC / °F] Pump motor power supply module temperature [ºC / °F] Pump motor speed [rpm] Pump motor speed standard [rpm]...
  • Page 98 Maintenance Section 12V output [mV] Auto tilt switch 3 [digit] Fan command [digit] Table 11 : List of accessible parameters in diagnostic mode (from 1th to 48th).

  • Page 99: Carriage Roller Extrusion - Adjust

    NOTE: If an alarm occurs when diagnostic mode is Chart below. enabled, and the system is working as usual, display returns automatically to its B22X-7, B25X-7, B25XL-7 typical visualization mode. However you Height of carriage roller extrusion (A) can enter diagnostic mode again, pressing...

  • Page 100: Power Modules - Discharge

    Maintenance Section Power Modules – Discharge 1. Disconnect the battery. Personal injury could result if power modules have not been discharged properly. Battery voltage and high amperage are present. The power modules must be discharged before any contact with the electrical control system is made.

  • Page 101: Fuses - Replace

    Otherwise, electrical damage can result. If it is necessary to replace fuses frequently, an electrical problem exist. Contact your DOOSAN Lift Truck dealer. Seat - Lubricate Backup & Stop Lamp – 5 A ISO Relay & POWER – 5 A FAN & FINGERTIP –...

  • Page 102: Wheel Bolts - Check For Tightness

    Maintenance Section Drive Axle Gear Boxes Wheel Bolts - Check for Tightness NOTE: If there is a leak from drive axle, the oil level Steer Wheels should be measured as follows. Measure Lubricant Level Typical example 1. Inspect tightness of wheel nuts in a sequence opposite each other 140 N•m (105 lb·ft).

  • Page 103: Greasing Point

    Maintenance Section Greasing Point...

  • Page 104: 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. Walk - Around Inspection - Inspect 6. Inspect the tires, valve stems and wheels for cuts, gouges, foreign objects and loose or missing nuts.
  • Page 105 Maintenance Section 12. Move the directional control forward/reverse 9. Inspect the drive axle housing and the ground switch to NEUTRAL. for oil leaks. Refer to “Drive Axle” in “When Required” section, if an oil leak is found. 13. Turn the key switch to ON. 10.

  • Page 106: Mast Channels - Lubricate

    Maintenance Section Mast Channels - Lubricate Battery - Check, Exchange, Change Battery Access Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor. 1. Tilt the steering column to the full upright position and move the seat fully rearward.
  • Page 107 Maintenance Section 3. Check the specific gravity of the battery. If the Check Electrolyte specific gravity reading is below 1.150, the battery must be charged. NOTICE The battery should not be used if a difference in specific gravity between two cells is greater than .020.

  • Page 108: Indicator - Check

    Maintenance Section Battery Charging When charging, proper provision must be made for venting of the charging gases. Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed. With Battery Installed in Lift Truck 1.

  • Page 109: Tires And Wheels - Inspect

    Maintenance Section Tires and Wheels - Inspect Inflate the tires, if necessary. See “Tire Inflation Information” section of this manual. Inspect tires and valve stems for wear, cuts, gouges and foreign objects. Check all components carefully and replace any cracked, badly worn, damaged and severely rusted or corroded parts with new parts of the same size and type.

  • Page 110: 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. 7. Screw the oil air – breather, level checking plug, Drive Axle Oil - Change oil filling plug and drain plug with the seal rings.

  • Page 111: 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. Tilt Cylinders Mast Pivot Eyes - Lubricate Chassis Pivot Eyebolts - Lubricate 1.

  • Page 112: Cylinder Rod Extension - Adjust

    Maintenance Section Cylinder Rod Extension - Adjust Crosshead Rollers - Check Check Operation 1. Operate the mast through a lift cycle. Watch the chains move over the crosshead rollers. Make sure the chain is tracking over the rollers properly. 1. Tilt the mast to the full forward position. Typical example 2.

  • Page 113: Mast Hinge Pins - Lubricate

    Maintenance Section Mast Hinge Pins - Lubricate Steering Mechanism - Lubricate Lubricate two fittings Lubricate one fitting 1. Lower the forks and tilt the mast forward. Lubricate fitting on steer axle. Drive Axle Oil - Change See topic, “Drive Axle Oil - Change” in “First 50 – 100 Service Hours or a week”.

  • Page 114: Control Panel - Clean, Inspect

    Maintenance Section Control Panel - Clean, Inspect Pressurized air can cause personal injury. Park the lift truck level, with the forks lowered, parking brake engaged, directional control lever in When using pressurized air for cleaning, wear a NEUTRAL, and the key switch to OFF. protective face shield, protective clothing and protective shoes.

  • Page 115: Direction Control Forward/Reverse Switch- Check

    Maintenance Section Direction Control forward/reverse 4. Inspect all wiring for loose connections, frayed Switch- Check cables and loose mounting bolts. 5. Inspect the fuses for looseness, corrosion and broken connections. [OUTSIDE BATTERY CONNECTOR] Check tightness directional forward/reverse switch mounting bracket. Adjust if needed.

  • Page 116: Parking Brake - Test

    Maintenance Section Parking Brake - Test Hydraulic Oil Level - Check NOTE: Be sure area around the lift truck is clear of personnel and obstructions. 1. Drive the lift truck with a rated load up a 15% incline. To prevent personal injury, the operator must be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move.

  • Page 117: Steer Angle Switches - Check, Clean

    Maintenance Section Steer Angle Switches - Check, Mast Carriage, Chains and Clean Attachments - Inspect, Adjust, Lubricate 1. Clean steer angle switches with 205 kpa (30 psi) maximum air pressure until dust is removed. 1. Operate the lift, tilt and attachment controls. Listen for unusual noises.
  • Page 118 Maintenance Section 5. Raise and lower the carriage a few times to work lubricant into the chain links. NOTICE Lubricate chains more frequently than normal where the atmosphere can cause corrosion to components, or when lift truck must work in rapid lift cycles.

  • Page 119: 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. Drive & Pump Motor - Clean, Air Breather - Change Inspect Park the lift truck level, with the forks lowered, Open the hood.
  • Page 120 Maintenance Section Battery voltage and high amperage are present. The power modules must be discharged before any contact with the control panel is made. Personal injury could result if it has not been discharged properly. 9. Blow off the drive motor end shield with 205 kPa (30 psi) maximum air pressure, until dust is 4.

  • Page 121: Tires And Wheels - Inspect, Check

    Maintenance Section Tires and Wheels - Inspect, Check 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 122: Lift Chains - Test, Check, Adjust

    Maintenance Section Lift Chains - Test, Check, Adjust Check for Equal Tension Lift Chain Wear Test Inspect the part of the chain that is normally operated over the cross head roller. When the chain bends over the roller, the movement of the parts against each other causes wear.
  • Page 123 Maintenance Section Carriage Chain Adjustment Mast Chain Adjustment - FF, FFT Mast 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 124: Hydraulic Return Filter - Change

    Maintenance Section Hydraulic Return Filter - Change Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Park the lift truck level with the forks lowered, parking brake engaged, directional control forward/reverse switch in NEUTRAL and the key switch to OFF.

  • Page 125: 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. Hydraulic, Power Steering System Change Oil and Filter Element 3.

  • Page 126: Steer Wheel Bearings - Reassemble

    Maintenance Section Steer Wheel Bearings - Reassemble Park the lift truck level with the forks lowered, parking brake engaged, and directional control forward/reverse switch in NEUTRAL. 7. Check for oil leaks. 8. Retract all cylinders. 9. Turn the key switch to OFF. 10.
  • Page 127 Maintenance Section 4. Remove the locknut, lockwasher and flat 7. While rotating the wheel, tighten the locknut to washer. Remove the outer wheel bearing. 34 N·m (24 lb·ft). Loosen the nut completely. Tighten the nut again to a torque of 11±3 N·m (8±2 lb·ft) and lock within this range.

  • Page 128: Fork - Inspect

    Maintenance Section Fork - Inspect 2. Check the angle between the upper face of the blade and the front face of the shank. The fork should be withdrawn from service if angle (C) Forks should be inspected, at a minimum, every 12 exceeds 93 degrees or deviates by more than 3 months.
  • Page 129 Contact your local DOOSAN Lift Truck Dealer further When adjusting the fork spacing, the forks are information. prevented from sliding off the end of the carriage by stop blocks.
  • Page 130 Maintenance Section 8. Check fork markings (N) for legibility. Renew 9. a. Lift the mast and operate the tilt control lever, markings as required to retain legibility. until the top surface of the forks is parallel with the floor. Place two straight bars that are the same width as the carriage, accross the forks as shown.

  • Page 131: Hydraulic Oil - Check, Change

    Maintenance Section Hydraulic Oil - Check, Change Operate the lift truck a few minutes to warm the oil. Park the lift truck level, with the forks lowered, parking brake engaged, directional control forward/reverse switch in NEUTRAL and the key switch to OFF. Remove the hydraulic tank drain plug.

  • Page 132: Environment Protection Section

    Environment Protection Section Environment Protection 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.

  • Page 133: Index

    Index Section Index Crosshead Rollers - Check ........109 Crushing or Cutting Prevention ......13 Cylinder Rod Extension - Adjust ......109 12 Months Inspection ..........79 Daily Inspection-Before First Use and at Each Preventive Maintenance Inspection....... 78 Direction Control forward/reverse Switch- Check ................
  • Page 134 Index Section General Warnings to Operator ......... 6 Lifting Drums or Round Objects ......66 Greasing Point ............100 Lifting the Load............63 Literature Information ..........2 Load Backrest Must Be In Place Warning ....7 Loading or Unloading Trucks/Trailers ....13 Lubricant Information ..........
  • Page 135 Index Section Tire Inflation ............. 81 Tire Shipping Pressure ........... 81 Parking Brake - Test ..........113 Tires and Wheels - Inspect ........106 Parking Brake Warning ..........8 Tires and Wheels - Inspect, Check...... 118 Parking Brake ............47 Torque for Metric Fasteners ........83 Parking the Lift Truck ..........68 Torque for Standard Bolts, Nuts and Taperlock Power Modules –...

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