Doosan B16X-7 Operation & Maintenance Manual
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Doosan B16X-7 Operation & Maintenance Manual

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  • Page 2 SB2392E03 Operation & Maintenance Manual FORKLIFTS B16X-7, B18X-7, B20X-7 (AC 48V) FBA12 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 ................ 75 Tire Inflation Information ......... 80 Safety Section Torque Specifications ..........81 Lubricant Specifications ......... 83 Important Safety Information ........4 Battery Discharge Indicator ........

  • Page 5: Information Section

    WARNING Continuing improvement and advancement of product design might have caused changes to your Your DOOSAN truck comes equipped with an lift truck which are not included in this publication. operator restraint system. Should it become Read, study and keep this manual with the lift truck.
  • 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 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.
  • Page 9 Safety Section General Warnings to Operator WARNING 16. Machine should be equipped with overhead Only trained and authorized personnel may guard or equivalent protection. Where load operate this machine. For safe operation, read requires it, use load backrest extension. Use and follow the operation and maintenance extreme caution if operating without these Manual furnished with this lift truck and observe...
  • 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 Seat Switch Warning Battery Disconnect Before Servicing 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

    DOOSAN dealer. We would like to draw your attention to the fact that any secondary Make sure all hydraulic controls are in the HOLD damages due to improper handling, insufficient position.
  • Page 15 Safety Section Operating the Lift Truck Make sure the lift truck horn, lights, backup alarm (if 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 Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Contact your DOOSAN dealer for repair or replacement. Do not approach a warm tire closer than the outside of the area represented by the shaded area in the Check lines, tubes and hoses carefully.

  • 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 operator restraint system. Use the lever at the left-hand side to adjust the seat to the position you desire. Make this seat adjustment before you drive the Seat Adjustment 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 Your DOOSAN truck comes equipped with a The system is designed to keep the operator on the DOOSAN operator restraint system. Should it become necessary to replace the seat for any...
  • Page 23 Safety Section Fasten the Seat Belt NOTE: The belt is designed to automatically adjust to your size and movement. A quick pull on the belt will confirm that the automatic adjuster will hold the belt position in the event of an accident. Release the Seat Belt 1.

  • 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 1. Capacity/Nameplates originally attached on either side of the stability base, the lift truck will forklifts sold by DOOSAN shall not be removed, tip to the side. altered or replaced without DOOSAN’s approval. 2. DOOSAN assumes no responsibility for lift trucks...

  • 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 Do not operate your truck close to another truck. operate forklifts near flammable Always keep a safe distance from other trucks and combustible materials. make sure there is enough distance to stop safely. avoid discoloration, deformation Never overtake other vehicles. combustion of materials (such as lumber, veneer board, paper products and other similar items), always park at least 30 cm (12 inches) away from...
  • 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 and 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 DOOSAN Model B16X-7 at rated load center 3 Load Capacity 1600 Load center Power type AC Electric Operator type Driver Seated P : Pneumatic, E : Solid Soft, C : Cushion 7 Tire Type P, E...
  • Page 35 General Section DOOSAN DOOSAN B18X-7 B20X-7 1800 2000 AC Electric AC Electric Driver Seated Driver Seated x 2 / 2 x 2 / 2 3300 3300 CLASS Ⅱ CLASS Ⅱ 35 x 100 x 900 40 x 100 x 900...
  • Page 36 General Section...

  • Page 37: Noise And Vibration

    General Section Noise and Vibration Noise at operator ear (measured by EN 12053) Unit : dB(A) Noise Level [ Unit : dB(A) ] Sound Pressure Level at Operator's Ear (Leq.) Model EN 12053 B16X-7 B18X-7 B20X-7 * Test Model : B20X-7...

  • Page 38: Capacity Chart

    General Section Capacity Chart SOLID SOFTER TIRE MODEL STD, FFL A. 2700 ~ 4500 mm MAST A. 4000 mm MAST E. 5500 mm MAST B. 4500 mm MAST F. 6000 mm MAST C. 4750 mm MAST D. 5000 mm MAST A.

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

    General Section Capacity Chart - with side shifter (Integrated) SOLID SOFTER TIRE MODEL STD, FFL A. 2700 ~ 4000 mm MAST A. 4000 mm MAST E. 5500 mm MAST B. 4500 mm MAST B. 4500 mm MAST F. 6000 mm MAST C.

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

    General Section Capacity Chart - with side shifter (Hook) SOLID SOFTER TIRE MODEL STD, FFL A. 2700 ~ 4000 mm MAST A. 4000 mm MAST E. 5500 mm MAST B. 4500 mm MAST B. 4500 mm MAST F. 6000 mm 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 Identification, 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 Mast Abbreviations - Crane Arm or Crane Boom. The identification plate indicates the type of mast - Tire Handler. installed on the lift truck when it left the factory. The 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 Monitoring Systems Indicator Economic, Standard or High operation 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 Located on the right side of the instrument panel. charging progress and the No.
  • Page 46 Operation Section DUAL TRA Relation between battery charge level and Dual traction fault FAULT number of visualized bars Drive right-side module low D-INV Battery charge level BDI Percent [%] temperature (- UNDERTEMP 90%< 40°C) 89% ~ 80% Drive left-side 79% ~ 70% module low L-INV 69% ~ 60%...
  • Page 47 Operation Section 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 FAULT saturated / FAULT error overcurrent Fingertip knob FINGERTIP Drive left-side output error FAULT module non- L-INVERTER saturated /...
  • 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.
  • 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 18.

  • 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 Electrical Braking (Plugging) 2. Hold the accelerator pedal down until the lift truck nearly comes to a complete stop. Release To slow, stop or change direction when traveling in the accelerator pedal. either direction, move the the directional control forward/reverse switch (1) to the opposite direction 3.

  • Page 59: 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 60: Finger Tip

    Operation Section Finger Tip Tilt Control knob Lift Control knob Tilt Forward - Push the knob forward Lower - Push the knob forward smoothly smoothly to tilt the lift forks forward. to lower the lift forks. Hold - Release the tilt knob. The knob will return to the center(hold) position and the Hold - Release the lift knob.
  • Page 61 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 62 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 63 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 64 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 65: 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 66 Operation Section Traveling With or Without a load Lift Truck Turning When traveling with or 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 67 Operation Section Unloading 3. As the steer wheel angle increases, the inside drive motor speed is progressively slowed down with respect to the outside drive motor speed. 1. Move the lift truck into the unloading position. 2. Tilt the mast forward only when directly over the unloading area.
  • Page 68 Operation Section Lifting Drums or Round Objects 1. Block drums or round objects. Tilt mast forward and slide fork tips along the floor to get under the load. 2. Tilt the mast back slightly until the load is cradled on the forks before lifting. 3.
  • Page 69 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 70: 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 PARKING BRAKE (EM) to protect electrical system from moisture damage. When leaving the operator’s station, park the lift 3.
  • Page 71 Operation Section [OUTSIDE BATTERY CONNECTOR] [INSIDE BATTERY CONNECTOR] 6. Disconnect the battery. 7. Block the wheels if parking on an incline.

  • Page 72: 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 73: 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 74: 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 75 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 76: Towing Information

    Block the lift truck wheels to prevent movement Consult your DOOSAN Lift Truck dealer for before releasing the brakes. The lift truck can towing a disabled lift truck. roll free if it is not blocked.
  • Page 77 Operation Section 6. Connect EM CONN B and EM CONN C. 7. Tighten the traction bar connected to the lift truck. 8. 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 78: 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 79 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 80 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 81 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 82 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 83: 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 B16X-7 front 18X7-8...

  • Page 84: 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 NOTE: Use only metric tools on most hardware for The following charts give general torques for bolts,...
  • Page 85 Maintenance Section Torques for Taperlock studs Torque for Metric Fasteners Standard Taperlock Stud Thread Size NOTICE Torque Inch N·m Ib·ft 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 86: 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 87 The API CD/TO-4 specification or MIL-L-2104D, E or F oils could be used. Multi-grade oils are not blended by DOOSAN for use in transmissions. Multi-grade oils which use Located on the left side of the instrument panel. high molecular weight polymers as viscosity index...

  • Page 88: 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 89: Battery

    Maintenance Section battery operation must prevented. Battery 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 90 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 91: 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 92: 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 Compartment °C °F System or System Viscosities Min Max Min Max Hydraulic & Power ISO VG 15 Steering System Hydraulic ISO VG 22 -30...

  • Page 93: Maintenance Intervals

    Maintenance Section Maintenance Intervals First 50 - 100 Service Hours or a Week NOTICE Drive Axle Oil – Change ........108 Never exceed the Maintenance Intervals specified in the manual. Defects and/or damage to the Every 500 Service Hours or 3 Months important functional components may be resulted in.

  • Page 94: 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. Compact Display Button Self Diagnostics - Test Test Circuits and Components The Micro-Controller has a built-in diagnostic system to provide aid in rapid troubleshooting of lift truck problems.

  • Page 95: 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 96 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 97 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 98: Carriage Roller Extrusion - Adjust

    Maintenance Section In diagnostic mode selected parameter is visualized Carriage Roller Extrusion – Adjust as follows: 1. Set the mast vertical. - In the area dedicated to speed and alarm signals, appears parameter number( flashing) 2. Lower the carriage completely. - Its actual value is displayed in the area reserved 3.

  • Page 99: Power Modules - Discharge

    Maintenance Section Power Modules – Discharge [OUTSIDE BATTERY CONNECTOR] 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 100 Maintenance Section [DRIVE CONTROLLER] [RUMP CONTROLLER] 1. Before touching any electrical components, the power modules must be discharged. Put a 90 ohm, 30 watt resistor in position between the terminals of the power modules as shown. Hold the resistor in this position for approximately ten seconds.

  • 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 Wheel Bolts - Check for Tightness Parking Brake – Test after Emergency Switch (Option) Stop Steer Wheels 1. Braking with the emergency switch during driving may cause damage to the parking brake. Typical example 2. Refered to parking brake test method in “Every 1.

  • Page 103: Drive Axle Gear Boxes

    Maintenance Section Drive Axle Gear Boxes NOTE: If there is a leak from drive axle, the oil level should be measured as follows. Measure Lubricant Level 1. Park the lift truck on a level surface. Raise the carriage high enough to gain access to the housing level/fill plugs.

  • Page 104: Greasing Point

    Maintenance Section Greasing Point...

  • Page 105: 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 106 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 107: Mast Channels - Lubricate

    Maintenance Section Battery - Check, Exchange, Mast Channels - Lubricate 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 108 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 109: 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 110: 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 111: 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. Drive Axle Oil – Change After first 50~100...

  • Page 112: 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 113: Cylinder Rod Extension - Adjust

    Maintenance Section Crosshead Rollers - Check Cylinder Rod Extension - Adjust 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 114: Mast Carriage, Chains And Attachments - Inspect, Adjust, Lubricate

    Maintenance Section 5. Raise and lower the carriage a few times to Mast Carriage, Chains and work lubricant into the chain links. Attachments - Inspect, Adjust, Lubricate 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 115: Mast Hinge Pins - Lubricate

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

  • Page 116: Overhead Guard - Inspect

    Maintenance Section Overhead Guard - Inspect Direction Control forward/reverse Switch- Check Look for any loose or damaged bolts. Replace damaged bolts or missing bolts with original Check tightness directional equipment part only. Retighten bolts to a torque of forward/reverse switch mounting bracket. Adjust if 60±10 N·m (45±7 lb·ft).

  • Page 117: Control Panel - Clean, Inspect

    Maintenance Section Control Panel - Clean, Inspect Park the lift truck level, with the forks lowered, Pressurized air can cause personal injury. parking brake engaged, directional control forward/reverse switch in NEUTRAL, and the key When using pressurized air for cleaning, wear a switch to OFF.
  • Page 118 Maintenance Section 5. Inspect the fuses for looseness, corrosion and broken connections. [OUTSIDE BATTERY CONNECTOR] [INSIDE BATTERY CONNECTOR] 6. Close the hood cover and connect the battery.

  • Page 119: 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 120: 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 and Pump Motor - Clean, Air Breather - Change Inspect Park the lift truck level, with the forks lowered, parking...
  • Page 121 Maintenance Section 3. Blow off the drive motor end shield with 205 kPa (30 psi) maximum air pressure, until dust is removed from the motor. Typical example 4. Install the floor plate. 5. Install and connect the battery. Lower the battery cover and adjust the seat.

  • Page 122: 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 123: Lift Chains - Test, Check, Adjust

    Maintenance Section Check for Equal Tension Lift Chains - Test, Check, Adjust 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 124 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 125: 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 126: 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 127: 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 128 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 129: Fork - Inspect

    The fork allowable difference. Contact your local should be withdrawn from service if angle (C) DOOSAN Lift Truck Dealer further exceeds 93 degrees or deviates by more than 3 information. degrees from an original angle other than 90...
  • Page 130 Maintenance Section the bottom fork hook. The load backrest extension may be used in place of the stop blocks in some cases. Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork. They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage.

  • Page 131: Hydraulic Oil - Check, Change

    Maintenance Section Hydraulic Oil - Check, Change 1. 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. 2.

  • Page 132: Environment Protection Section

    Environment Protection 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.

  • Page 133: Index

    Index Section Index Control Panel - Clean, Inspect ......114 Crosshead Rollers - Check ........110 12 Months Inspection ..........78 Crushing or Cutting Prevention ......13 Cylinder Rod Extension - Adjust ......110 Accelerator Pedal ............48 Adjusted Inflation Pressures ........80 Daily Inspection-Before First Use and at Each Adjustment of Armrest ..........61 Preventive Maintenance Inspection.......
  • Page 134 Index Section Lift Truck Stability............ 21 Lift Truck Turning ............ 63 General Hazard Information ........10 Lifting a Forklift using a Crane ....... 72 General Warnings to Operator ......... 6 Lifting Drums or Round Objects ......65 Greasing Point ............101 Lifting the Load............
  • Page 135 Index Section Overhead Guard Must Be In Place Warning ... 7 Tilt Steering Column ..........45 Overloading ..............76 Tire Inflation Information ......... 80 Tire Inflation ............. 80 Tire Shipping Pressure ........... 80 Tires and Wheels - Inspect ........107 Tires and Wheels - Inspect, Check...... 119 Parking Brake - Test ..........

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