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Doosan D20S-9 Operation & Maintenance Manual

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  • Page 2 FDA2A, FDA2B, FDA2C, FDA2D, FDA2E DM02-LEF03 De-Tier/ DM02-MFF07 Stage V Translation of the original instruction This document is the informational asset of Doosan Industrial Vehicle Co., Ltd. Thus, unauthorized access, revision, distribution and copying of this document are strictly prohibited. 2211...
  • 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 ..............119 Tire Inflation Information ........123 Safety Section Torque Specifications ........124 Cooling System Specifications ......126 Important Safety Information ........4 Fuel Specifications ..........

  • Page 5: Information Section

    The DOOSAN operator restraint system Some photographs or illustrations in this publication can minimize injuries. The DOOSAN operator show details or attachments that can be different restraint system keeps the operator substantially from your lift truck.
  • Page 6 For example, at “Every 500 Service Hours or 3 Months”, also service those items listed under “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

    Since regulations vary from country to Service Warning country outside of U.S.A., operate this lift truck in accordance with local 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 with load trailing. General Warning to Operator On grade operations travel with load up grade. Watch out for pedestrians and obstructions. Check overhead clearances. Do not permit riders on forks or machine at any time. Do not allow anyone to stand or pass under the elevated portion of any machine.
  • Page 10 Safety Section Pressure Warning No Standing On Fork Warning No Standing Under Fork 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. Do not stand or walk under the forks.
  • Page 11 Safety Section Overhead Guard Must Be In Place Moving Fan Warning Warning WARNING WARNING To avoid personal injury, stay clear of moving fan. 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 valve.

  • Page 12: Electronic Parking Brake

    Safety Section Electronic Parking Brake Push the front side of the parking brake switch to engage the brake. Push the rear side of the parking brake switch to release the brake. Applying the parking brake puts the transmission in NEUTRAL. The parking brake must be applied when leaving the lift truck and when starting the engine.

  • Page 13: General Hazard Information

    Safety Section Always use load backrest extension when the General Hazard Information carriage or attachment does not fully support the load. The load backrest extension is intended to prevent the load or any part of the load from falling backwards into the operator's station. When operating the lift truck, do not depend only on flashing lights or back-up alarm (if equipped) to warn pedestrians.

  • Page 14: Operation Information

    Operate the lift truck and controls only from the Use of Doosan genuine parts is recommended when operator's station. servicing parts. -11-...
  • 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 Safety Section Loading or Unloading Trucks/Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers.

  • Page 17: Maintenance Information

    To avoid possible weakening of the Falling Objects Protective Structure (FOPS), consult a DOOSAN Pressure Air dealer before altering, by adding weight to, welding Pressure air can cause personal injury. When using on, or cutting or drilling holes into the structure.

  • Page 18: Burn Prevention

    Safety Section Burn Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant mixtures Coolant are flammable. At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to Fuel leaked or spilled onto hot surfaces or electrical heaters or the engine contain hot water or steam.
  • Page 19 Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Contact your DOOSAN dealer for repair or replacement. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks.

  • Page 20: Operator Restraint System

    A tire make sure a new label is installed on the replaced blowout or rim failure can result from improper or part. See you DOOSAN forklift dealer for new labels. misused equipment. The most effective method of preventing serious...
  • Page 21 Safety Section WARNING Do not place your hand or fingers under the seat. Injury may occur as the seat moves up and down. If Optional Suspension Seat (weight adjusting type) Equipped Forward and Backward Adjustment The seat can be adjusted by pushing the lever on the The “Survive in tipover”...
  • Page 22 Safety Section Weight adjustment Backrest Inclination Pull the weight adjustment lever upwards and move The backrest angle can be adjusted by using the lever on the left side of seat. right or left side. Adjust to driver’s weight in 7 steps (50 ~ 110 kg) NOTICE Do not place your hand or fingers under the seat.
  • Page 23 WARNING Your DOOSAN truck comes equipped with a 1. Grip the plate (connector) of the belt and pull the 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 24 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 25: 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 Counterbalanced lift truck design is based on the combined CG of the truck and load.
  • Page 26 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. WARNING 2. DOOSAN assumes no responsibility for lift trucks...

  • 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 raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the rated capacity shown on the capacity plate. Do not let other people ride on the truck. Do not add extra counterweight to the truck. An 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 lifting mechanism. The load can fall and cause Do not tilt the elevated loads forwards. injury or death to anyone standing below. This will cause the lift truck to tip over forward.
  • Page 30 Safety Section Do not drive in forward direction when loads restrict Do not stack or turn on ramps. your visibility. Operate your lift truck in reverse to Do not attempt to pick-up or deposit a load unless improve visibility except when moving up a ramp. the lift truck is level.
  • Page 31 Safety Section Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully lower the forks to the floor, put direction lever in Always keep a safe distance from other trucks and NEUTRAL position, engage the parking brake, and make sure there is enough distance to stop safely.
  • Page 32 Safety Section An unloaded forklift may be easier to tip over than a Do not operate forklifts near flammable or loaded truck. combustible materials. When traveling without a load, the risk of lateral avoid discoloration, deformation overturn is greater. combustion of materials (such as lumber, veneer board, paper products and other similar items), always park at least 30 cm (12 inches) away from them.

  • 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. Brace your feet and keep them within the operator’s compartment.

  • Page 34: General Section

    468, Injung-Ro, Dong-Gu, Incheon, Korea 22503 Authorized Representative, Compiler of Technical File According to 2006/42/EC and Keeper of Technical File According to 2000/14/EC Doosan Industrial Vehicle Europe N.V., Mr. Chankyo Chung, Europark-Noord 36 A, 9100 Sint-Niklaas, Belgium herewith declare that the following equipment conforms with the appropriate requirements of the Directives...
  • Page 35 2008 and Keeper of Technical File According to Noise Emission in the Environment by Equipment for use Outdoors Regulation 2001 Doosan Industrial Vehicle UK Ltd. Mr. Chankyo Chung 12 Kilvey Road, Brackmills Industrial Estate, Northampton, NN4 7BQ, UK herewith declare...

  • Page 36: Specifications

    General Section Specifications 1.1 Manufacturer Doosan 1.2 Model designation D20S-9 1.3 Drive: Diesel, Gasoline, LP Diesel 1.4 Operator type: Hand, Pedestrian, Standing, Seated, Order-picker Seated 1.5 Load Capacity 2,000 1.6 Load Center 1.8 Load Distance: Center of Driveaxle to fork 1.9 Wheelbase...
  • Page 37 General Section 5.10 Service Brake foot/hyd 7.1 Engine Manufacturer/type DI/DM02VA STAGE-5 7.2 Engine power according to DIN ISO1585 45.6 7.3 Rated Speed 2,200 7.3.1 Torque at 1/min N•m 300Nm / 1,200~1,400 7.4 Number of Cylinders/Displacement -/cm 4/2,392 7.5 Fuel Consumption according to VDI Cycle l/h or kg/h 7.10 Battery Voltage/normal capacity V/Ah...
  • Page 38 General Section Doosan Doosan Doosan Doosan D25S-9 D30S-9 D33S-9 D35C-9 Diesel Diesel Diesel Diesel Seated Seated Seated Seated 2,500 3,000 3,250 3,500 1,700 1,700 1,700 1,700 4,030 4,530 4,615 4,720 5,724/806 6,518/1,012 6,892/973 7,302/918 1,780/2,250 1,780/2,750 1,760/2,855 1,755/2,965 7.00x15-12 28x9x15-12...
  • Page 39 General Section 5.10 foot/hyd foot/hyd foot/hyd foot/hyd DI/DM02VA STAGE-5 DI/DM02VA STAGE-5 DI/DM02VA STAGE-5 DI/DM02VA STAGE-5 45.6 45.6 45.6 45.6 2,200 2,200 2,200 2,200 7.3.1 300 Nm / 1,200~1,400 300 Nm / 1,200~1,400 300 Nm / 1,200~1,400 300 Nm / 1,200~1,400 4/2,392 4/2,392 4/2,392...
  • Page 40 General Section Specifications 1.1 Manufacturer Doosan 1.2 Model designation D20S-9 1.3 Drive: Diesel, Gasoline, LP Diesel Operator type: Hand, Pedestrian, Standing, Seated, Seated Order-picker 1.5 Load Capacity lb (kg) 4,000 (2,000) 1.6 Load Center in (mm) 24 (500) 1.8 Load Distance: Center of Driveaxle to fork in (mm) 18.9 (480)
  • Page 41 General Section 5.10 Service Brake foot/hyd 7.1 Engine Manufacturer/type DI/DM02P De-tier (T4F) 7.2 Engine power according to DIN ISO1585 hp(N) 62 (45.6) 7.3 Rated Speed 2,200 203.5 ft•lbs 7.3.1 Torque at 1/min ft•lbs(N•m) (276 Nm /1,500) 7.4 Number of Cylinders/Displacement -/cc(-/cm 4/2,392 gal/h or lb/h...
  • Page 42 General Section Doosan Doosan Doosan Doosan D25S-9 D30S-9 D33S-9 D35C-9 Diesel Diesel Diesel Diesel Seated Seated Seated Seated 5,000 (2,500) 6,000 (3,000) 6,500 (3,250) 7,000 (3,500) 24 (500) 24 (500) 24 (500) 24 (500) 18.9 (480) 19.1 (485) 19.1 (485) 19.5 (495)
  • Page 43 General Section DI/DM02P De-tier (T4F) DI/DM02P De-tier (T4F) DI/DM02P De-tier (T4F) DI/DM02P De-tier (T4F) 62 (45.6) 62 (45.6) 62 (45.6) 62 (45.6) 2,200 2,200 2,200 2,200 203.5 ft•lbs 203.5 ft•lbs 203.5 ft•lbs 203.5 ft•lbs 7.3.1 (276 Nm /1,500) (276 Nm /1,500) (276 Nm /1,500) (276 Nm /1,500) 4/2,392...

  • Page 44: Noise And Vibration

    Power level (L Operator’s ear (Leq.) Level By Noise Directive according to EN12053 according to EN13059 2000/14/EC Model Guaranteed Sound (m/s dB(A) dB(A) Mean Uncertainty STAGE5 (DM02VA E/G) D20S-9, D25S-9, D30S-9, D33S-9, D35C-9 (W/O Cabin) * NA: Not Applicable -41-...

  • Page 45: Capacity Chart (Without Sideshifter Pneumatic)

    General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL 2200 2200 2000 2000 1800 1800 1600 1600 1400 1400 1200 1200 1000 1000 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 2030 – 4960mm mast 2950 - 5110 5560 C.
  • Page 46 General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL 3400 3400 3100 2800 2900 2500 2200 2400 1900 1600 1300 1900 1000 1400 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 2030 - 4350 2950 - 4290 4960...
  • Page 47 General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL 2200 2200 2000 2000 1800 1800 1600 1600 1400 1400 1200 1200 1000 1000 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 2950 - 5560 2030 - 4960 6010...
  • Page 48 General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL 3400 3400 3100 2800 2900 2500 2200 1900 2400 1600 1300 1900 1000 1400 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 2030 –...

  • Page 49: Capacity Chart (With Sideshifter Pneumatic)

    General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL 2200 2200 2000 2000 1800 1800 1600 1600 1400 1400 1200 1200 1000 1000 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 2030 - 4960 3900 4290...
  • Page 50 General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL 3400 3400 3100 3200 2800 3000 2500 2800 2200 2600 1900 2400 1600 2200 1300 2000 1000 1800 1600 1400 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 3900 2030 - 3950...
  • Page 51 General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL 2200 2200 2000 2000 1800 1800 1600 1600 1400 1400 1200 1200 1000 1000 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 3900 2030 - 4960 4290...
  • Page 52 General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL 3400 3400 3200 3100 3000 2800 2800 2500 2600 2200 2400 1900 2200 1600 2000 1300 1800 1000 1600 1400 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 2030 - 3950 3900...

  • Page 53: Serial Number

    General Section Serial Number Serial Number Locations Power Shift Transmission Serial Number •_____________________________ For quick reference, record your lift truck's serial numbers in the spaces provided below the photographs. Lift Truck Serial Number •_____________________________ Drive Axle Serial Number •_____________________________ 2.4 liter Diesel Engine (DM02VA, DM02P) Serial Number •_____________________________ Side Shifter Serial Number (If Equipped)
  • Page 54 General Section Attachment Abbreviations (Includes Special Forks) - Special Carriage-increased width, height or outreach - Shaft-type Sideshift Carriage - Hook-type Sideshift Carriage (ITA) - Counterweight - Special Forks - Swing Shift, Sideshift - Ram or Boom DBCBH - Double Cube Block Handler - Hydraulic Fork Positioner - Crane Arm or Crane Boom - Tire Handler...

  • Page 55: 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 right side of the operator's seat. Located on the cowl to the right side of the steering column.

  • Page 56: 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. Due to the various options available, typical instrument panels are shown. 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 57 Operation Section 1. Diesel Engine Water in Fuel Filter 6. Transmission Oil Temperature Indicator Light - Indicates when the engine Gauge - Shows transmission oil is running, there is water in the fuel filter temperature If the gauge pointer exceeds 100cc. moves beyond the red band during operation, the engine is overheated.
  • Page 58 Operation Section 13. Mast Interlock – Alarm warning lights used. The lamp lights up with a message popping when operator leaves the seat without up 10 hours prior to the required timing of SCR applying parking brake and then, operation cleaning.
  • Page 59 Operation Section High-temperature Exhaust Lamp Electrical Disconnect Switch (If During SCR cleaning, the temperature of the Equipped) exhaust emissions exceeds 600 °C. When this lamp lights up, the operator should warn other people around not to approach the vehicle or touch the exhaust system, particularly at the back of the vehicle.
  • Page 60 Operation Section Engine Compartment 1. The engine compartment is accessible by pulling the latch. NOTE: Unlock latch before pulling-if key equipped 2. The hood and seat assembly is held up by a support cylinder. Make certain the air cylinder is operating properly and securely hold the hood up before doing anything in the engine compartment.
  • Page 61 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. -58-...
  • Page 62 Operation Section Menu - Vehicle - Option Menu - Vehicle - Option - Pin Code Access Menu - Vehicle - Option - Multi Torque The anti-theft function allows vehicle start-up only after entering the password. ECO: Fuel economy operation mode. STANDARD: Ordinary operation mode.
  • Page 63 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 setting, rated load setting). the seat is occupied and the safety belt is on. Menu - Vehicle - Emission regulation Zero setting under no-load condition.
  • Page 64 Operation Section Menu - Display - Unit Menu Setting for SI unit system and US unit system Menu - Display Menu - Display - Time Current time setting Menu - Display - Rear View camera (If the rear view camera is equipped) Menu - Display - Software Version Camera connection setting while reversing Instrument panel firmware, graphic version and VCU...
  • Page 65 Operation Section Menu - Display - Software Update New firmware version can be updated through the USB memory. -62-...
  • Page 66 Operation Section Menu - Maintenance - Consumable Item Menu Management The replacement cycles and amount (in hours) of Menu - Maintenance use 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...
  • Page 67 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(1) to set the weight of the mast assembly to be zero.
  • Page 68 Operation Section 3. Specifying a Maximum Measuring Scale Weight Scale Option (Load Cell This step is to specify the rated capacity of the Type) vehicle on which the load cell is installed. With this weight scale option, the operator can measure and limit the load's weight using a display Since the device does not weigh a load heavier than the set capacity (determines to be overloaded), it is...
  • Page 69 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 70 Operation Section Audio System (AM/FM Tuner with USB/AUX Player) 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. Radio mode: Plays frequencies with superior 3.
  • Page 71 Operation Section Display window 1. USB/AUX indicators: When the External Device is connected, indicator is lights up. 2. MP3/WMA indicators: When the Audio Stream is detected, indicator is lights up. 3. Stereo [ST] indicator for FM stereo station: When a stereo Broadcast is received, indicator is lights 4.
  • Page 72 Operation Section Rear view/Connectors 1. Antenna jack: To plug the FM antenna cable. 2. I/0 connector: To plug the 1/0 cable. <ARA-5080WF: 18 Pin> <ARA-5081WF: 18 Pin> 1. Front R (+) 1. Tel Mute 2. Rear R (+) 2. Rear R (+) 3.
  • Page 73 Operation Section Setting the sound Getting started Turning the unit on/off MENU 1. Press MENU button repeatedly to select the Sound setting mode as below; • BAS (Bass): sets the bass sound level. (-5 ~ +5) 1. Turn your car's ignition key to ACC or IGN (ON) position.
  • Page 74 Operation Section Setting the Loudness mode Radio Setting the region of radio reception LOUD 1. When the power is turned on, press and hold the buttons more 3 seconds at the same time as below; 1. Press the LOUD button to turn loudness mode on/off.
  • Page 75 Operation Section Tuning in a station Radio Saving radio stations manually You can save up to 6 preset channels each for FM 1, FM2, FMA, AM 1, AM2, and AMA. If change the stations while driving, use preset button to prevent accidents. 1.
  • Page 76 Operation Section Listening to a preset station USB player Before MP3 [WMA] USB playback This unit cannot play the following files; • MP3 files encoded with MP3i and MP3 PRO format. - MP3 files encoded in an inappropriate format. 1. Press AM or FM button repeatedly to select the - MP3 files encoded with Layer 1/2.
  • Page 77 Operation Section Playing a USB device INFO 4. Press the [4 INFO] button repeatedly to display information about the file being played. The information displayed includes the file name, playing time, ID3 Tag or folder name information saved with the song. If there is no information on the playing file, then the unit will display "NO INFO".
  • Page 78 Operation Section Controlling the playback Change the playback mode 1. While playing, press the SCN button to begin the 1. While playing, turn the ▶▶│TRACK│◀◀ dial Intro scan playback. left/right to moves to the previous or next track. • When pressed shortly, scans the beginning parts •...
  • Page 79 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 80 Operation Section Listening to DMB sound (lf Equipped) AUX player Listening to auxiliary audio equipment 1. By connecting the optional DMB receiver, you can listen the DMB source provided for the vehicle. By connecting an optional portable audio device to the AUX input jack (stereo mini jack) on the unit and When the DMB receiver is turned power on, the then simply selecting the source, you can listen on...

  • Page 81: Seat Switch System

    Operation Section Seat Switch System NOTICE Prior to operating the lift truck, be sure to understand and check the SEAT SWITCH SYSTEM. While in normal operation and on level ground, select a direction with the directional lever and with the park brake released. You will note that the truck will move slowly in the selected direction.

  • Page 82: Functional Safety System

    Operation Section than the set angle if the Accel pedal is not Functional safety System pressed. Depending on whether the vehicle is loaded or not, the inclination of the slope can be WARNING changed. -. Even if the vehicle has the same specification, These are the functions added for functional the amount of pushback may differ due to the tire safety.

  • Page 83: Performance Level

    Operation Section Performance Level The table below shows the Performance Level based on ISO 13849-1/2:2015 regarding the PLr(Required Performance Level) of EN 1175:2020. The SRP/CS (Safety-related parts of control systems) consists of the parts in Category B, 1, 2, 3, and 4, while the control action to achieve a safe state under Clause 4.5 of EN 1175:2020 belongs to the control systems of Category 2.
  • Page 84 Operation Section 4.7.2.2b 4.7.2.3 4.7.2.4 4.7.2.5 4.7.3 4.9.1.2.1 4.9.1.2.2 4.9.2.3a 4.9.2.3b 4.9.2.5 4.9.2.6 5.3.4 -81-...
  • Page 85 Operation Section Circuit Breaker Seat NOTE: Seat arrangements may vary. Basic operation will be similar. Seat adjustment should be checked at the beginning of each shift and when operators change. Lock the seat into position before operating, to prevent an unexpected seat change. Adjust seat to allow full brake pedal travel with operator’s back against seat back.

  • Page 86: Lift Truck Controls

    Operation Section Lift Truck Controls Direction Control Lever Service Brake Pedal 1. Forward - Push the lever forward for Push DOWN on the brake pedal to slow or FORWARD direction travel. stop the lift truck. 2. Neutral - Move the lever to center RELEASE the brake pedal to allow the lift position for NEUTRAL.
  • Page 87 Operation Section Electronic Parking Brake Tilt Control 1. Mast Tilt Forward - Push the lever Push the front side of the parking brake FORWARD smoothly to tilt the mast switch to engage the brake. forward. Push the rear side of the parking brake 2.

  • Page 88: Refueling

    Operation Section Refueling Gasoline or Diesel Engine Equipped WARNING Explosive fumes 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 89: 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. Look for such items as loose bolts, debris buildup, oil or coolant leaks. Check condition of tires, mast, carriage, forks or attachments.
  • Page 90 Operation Section 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. To position the seat, PUSH the lever away from the seat track and move the seat forward or backward to a comfortable position.

  • Page 91: Starting The Engine

    Operation Section Starting the Engine Prestart Conditions Diesel Engine NOTE: The engine will not start unless the Starting Diesel Engine at Cold transmission directional control lever is in 1. Turn ignition the key to the ON position. The start the NEUTRAL position. pre heat light will come ON.
  • Page 92 ON with the engine running, unless Attach ground cable last, remove first. All lift trucks water in fuel filter exceeds 100cc. Stop the engine equipped with DOOSAN built internal combustion immediately and drain the water if the light comes engines are NEGATIVE (-) ground.

  • Page 93: Lift Truck Operation

    Operation Section Lift Truck Operation Power Shift Transmission/Drive axle 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 travel speed.
  • Page 94 Operation Section Inching To change the lift truck direction of travel, release the accelerator pedal. NOTE: The purpose of the inching pedal is to provide precise lift truck inching control at Push down on the service brake pedal to reduce the very slow travel speed and high engine rpm.

  • Page 95: Finger Tip (Option)

    Operation Section Finger Tip (Option) 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 Hold - Release the lift knob.
  • Page 96 Operation Section Sideshift Attachment Control Emergency Switch OFF - Push the emergency switch button to The side shift attachment controller is at the front- disconnect the electrical circuits. (It must be right side of the driver, and the side shift control lever done after the key switch is turned off) is at the right as shown in the figure.
  • Page 97 Operation Section If the driver stands up from the driver's seat while the Directional Control Switch forklift 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 in the respective direction.
  • Page 98 Operation Section Horn Button Auto Tilt Control Located in the right side of the directio nal control switch. The auto tilt controller is at the rear side of the tilt Push in on the horn button to sound th knob. Press the auto tilt switch to turn on the switch e horn.
  • Page 99 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 position. knob #1 - forward, backward adjustment knob #2 - upward, downward adjustment Forward and Backward Adjustment Turn No.
  • Page 100 Operation Section DM02VA, DM02P Diesel Engine Introduction The DM02VA, DM02P engine which is a high-power engine in compliance with the Stage5 and TIER4 Engine Emissions Standard is provided with various systems. The DM02VA, DM02P engine is equipped with a turbo- charger intercooler system that compresses and cools air and feed it to the intake manifold.

  • Page 101: Tms(Lin-Q) (Option)

    Operation Section TMS(Lin-Q) (Option) Safety Precautions care to ensure that it does not fall and make sure that it is secured properly. This information is intended to protect the safety and property of the user. • Do not block any vents or heat sinks. Doing so may cause a fire.
  • Page 102 Operation Section • Product Configuration and Functions CAN data (J1939) collection • The TMS (LIN-Q) terminal is configured and Data collection from various vehicle sensors connected as shown in the figure below. A separate • Periodic transmission of collected data harness cable assembly is required to connect it to •...
  • Page 103 Operation Section Names and Functions of Parts There are two types of connectors: A (black) and B (natural). The pin map is shown in the table below. Terminal Body • CONNECTOR Main (776276-1, Black) Name Type Description FUEL_ Signal Input Analog (with Input ADC) Input...
  • Page 104 A. User Registration You must perform user registration in order to use the product. To register a user, visit the dealer from which the product was purchased or go to https://lin-q.doosan-iv.com. For more details, refer to the Lin-Q user manual.

  • Page 105: Electronic Controlled Diesel Engines (Di Dm02Va, Dm02P)

    Operation Section Electronic Controlled Diesel Engines (DI DM02VA, DM02P) 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 Coolant Temperature Sensor Intake Manifold Pressure Sensor Pressure Relief Valve (PRV)
  • Page 106 Operation Section Description 1612 Injector 1639 Fan Speed too High Fault 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...
  • Page 107 Operation Section Description 4365 DEF Temperature Sensor 4374 DEF Supply Pump Motor 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...
  • Page 108 Operation Section Description 520601 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 109 Check Lamp Reduction Display Warning Stage Normal ENGINE MALFUNCTION Level 1 Reduced Reduced Continuous CALL DOOSAN SERVICE AGENT Engine Power Reduced! ENGINE MALFUNCTION CALL DOOSAN Level 2 Blinking Limp Home Limp Home Continuous SERVICE AGENT Engine is in Limp Home...
  • Page 110 Inducement Condition Offence Stage (within 40hrs) Normal DPF/SCR SYSTEM MALFUNCTION Impeded EGR Level1 At starting & Every 20min CALL DOOSAN SERVICE AGENT ≥ 95% of detected Engine Power will be Reduced counter value for DPF/SCR SYSTEM MALFUNCTION severe Level2 36~100hrs...

  • Page 111: 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 Typical Example should be square with load, forks spaced evenly 2.
  • Page 112 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 113 Operation Section Lifting Drums or Round Objects Typical Example 4. Lower the carriage and forks to the travel 1. Block drums or round objects. Tilt the mast position or to the park position. FORWARD and slide the fork tips along the floor to get under the load.
  • Page 114 Operation Section Safety instructions for attachments when transporting suspended load 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 115: Parking The Lift Truck

    Operation Section Parking the Lift Truck 5. Turn the key in the ignition switch to the OFF position and remove the key. 6. Turn the disconnect switch to OFF (if equipped). Do operate the disconnecting switch after 30 seconds from start key-off. Otherwise Engine Control Unit (ECU) can be damaged.

  • Page 116: 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 117: Storage Information

    Operation Section Storage Information Before Storage To Operate the Lift Truck after a 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. •...

  • Page 118: Transportation Hints

    Check the state and local laws governing weight, width and length of a load. NOTICE Contact your DOOSAN Lift Truck dealer for shipping Remove ice, snow or other slippery material from the instructions for your lift truck. shipping vehicle and the loading dock.
  • Page 119 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 3.

  • Page 120: Towing Information

    Operation Section Towing Information Consult your DOOSAN Lift Tuck dealer for towing a WARNING disabled lift truck. Personal injury or death could result when towing a disabled lift truck incorrectly. Block the lift truck wheels to prevent movement before releasing the brakes. The lift truck can roll free if it is not blocked.
  • Page 121 Operation Section How to Return the Electronic Parking How to Release the Electronic Brake Parking Brake 1. Secure the wheels with blocks. 2. By using a spanner, fully remove the nut installed parking brake spool under NOTICE transmission oil filter. In the case of the electronic parking brake, it always stays engaged when the ignition is off, regardless of where the parking switch is positioned.

  • Page 122: Maintenance Section

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for Some countries have standards or regulations which inspection, maintenance and repair of lift truck forks. apply specifically to the inspection and repair of forks. It also provides general information on the design Users also...
  • Page 123 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. Fork failure can occur as a result of a field The overload could be caused by loads in excess of modification involving welding, flame cutting or other the rated fork capacity and by use of the forks tips as similar processes which affect the heat treatment...
  • Page 124 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 125 Maintenance Section Check the fork arm before and after the second 12 Months Inspection application of the test load. It shall not show any Forks should be inspected, at a minimum, every 12 permanent deformation. months. If the truck is being used in a multi-shift or Consult the fork manufacturer for further heavy duty operation, they should be checked every information as may be applicable to the specific...

  • Page 126: 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 Pressure Ply Rating or Size Strength Index 6.5X10 6.5X10 7.0X15 28X9-15 250X15 Standard tire, ply rating and inflation pressures. WARNING The operating inflation pressure is based on the weight of a ready - to - work machine without...

  • Page 127: Torque Specifications

    Maintenance Section Torque Specifications Metric Hardware Torque for Standard Bolts, Nuts, 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 128 Maintenance Section Torques for Taperlock Studs Torque for Metric Fasteners Thread Size Standard Taperlock Stud Torque NOTICE Inch N·m lb·ft Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or 8 ± 3 6 ± 2 incorrect fasteners will cause lift truck damage or 5/16 17 ±...

  • Page 129: Cooling System Specifications

    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 130 DOOSAN recommends that the coolant mix contain DOOSAN prefers the use of distilled water or 50% commercially available automotive antifreeze, deionized water to reduce the potential and severity or equivalent and acceptable water to maintain and of chemical insolubility.

  • Page 131: Fuel Specifications

    Specification performance. ASTM D975 No.1D/2D • Consult your Doosan representative for more EN590:96 information. IS0 8217 DMX International BS 2869-A1 or A2 United Kingdom • The ash content must not exceed 0.01% by JIS K2204 Grade No. 2 Japan volume.
  • Page 132 FAME (Fatty Acid Methyl Esters), are being used as somewhat lower density. extenders for mineral oil derived diesel fuels. Doosan approves the use of up to 100% HVO for Doosan approves the use of bio-diesel fuels that do engines in accordance with the EU standard not exceed a blend of 7% (by volume) of FAME with EN15940.

  • Page 133: Lubricant Information

    ISO viscosity grade of 32 • Gasoline/LP Engine: API SJ or higher would normally be selected. NOTE: Engine Oil Service hours can be extended to 500 hours by using Doosan supplied specific oil. Please consult Doosan dealer NOTICE about it.
  • Page 134 Use heavy duty hydraulic brake fluid certified by oil F oils could be used. supplier to meet the latest version of following NOTE: Multi-grade oils blended classifications. DOOSAN for use in transmissions. • ISO 6743/4 Multi-grade oils which use high molecular • AFNOR NFE 48-603 weight polymers viscosity...

  • Page 135: 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 System Liters U.S Gal. Compartment °C °F Engine Crankcase w/Filter 2.27 or System Viscosities Min Max Diesel DM02VA, DM02P SAE 5W30 Fuel Tank...

  • Page 136: Maintenance Intervals

    Maintenance Section Hydraulic Oil Level – Check ....... 153 Maintenance Intervals First 50 - 100 Service Hours or a Week NOTICE Engine Oil & Filter (DM02VA/P Engine Only) - Never exceed the Maintenance Intervals specified in Change .............. 154 the manual. Defects and/or damage to the important Drive Axle Oil, Transmission Oil, Oil Filter &...
  • Page 137 Maintenance Section Adjust ..............171 Steer Wheel Bearings - Reassemble ....171 Cooling System – Clean, Change ...... 172 Forks – Inspect ........... 173 Every 2500 Service Hours or 15 Months Hydraulic Oil - Check, Clean, Change ....175 Inspect Battery System ........175 Every 5000 Service Hours or 30 Months DPF Maintenance (DM02VA Stage5 Engine Only) - Ash Cleaning ............
  • Page 138 Maintenance Section Quick Reference to Maintenance Schedule First Every ITEMS SERVICES PAGE Air Intake System Check, Clean Air Intake System Change Battery Terminal Clean, Inspect Belts (Only for Air-con Compressor) Check, Adjust Brake Oil Level Check Carriage Roller Extrusion Adjust Check the pivot eye pins for loose retainer bolts and wear.
  • Page 139 Maintenance Section Quick Reference to Maintenance Schedule First Every ITEMS SERVICES PAGE Mast Channels Lubricate Mast Hinge Pin Lubricate Inspect, Mast, Carriage, Lift Chains & Attachments Lubricate Overhead Guard Inspect Parking Brake Test, Adjust 158,164 Parking Brake Inspect Priming the Fuel System (D20/25/30/33S-9, D35C-9 DM02VA, DM02P Diesel Engine Only) Check, Seat, Hood Latch &...

  • Page 140: 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. When required indicates no set schedule for review or replacement. This should be done based on operational conditions and operational environment.
  • Page 141 Maintenance Section Element”. The primary element should be replaced after 3 months service. In case of harsh application having 5. Clean the inside of air cleaner housing and the lots of dirt, please clean and replace the primary cover. Inspect all connections between the air element more often.

  • Page 142: Fuel Tank Filter Cap And Screen (If Equipped) - Clean

    Maintenance Section Checking Element Seat, Hood Latch & Support Cylinder - Check, Lubricate Insert a light inside the clean dry element and examine it. Discard the element if tears, rips or damage are found. Wrap and store good elements in a clean, dry place. Fuel Tank Filter Cap and Screen (If Equipped) - Clean Park the lift truck with the forks lowered, parking...

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

    Maintenance Section Check the fuses. Use a flashlight, if necessary. Fuses are identified as follows: 1. Horn - 10 amps. 2. Head/Rear Lamp - 15 amps. 3. Fwd./Rev. Solenoid, lamp Relay & Back-up Lamp/alarm - 10 amps. 4. Instrument Panel & Fuel Shutoff - 15 amps. 5.
  • Page 144 Maintenance Section 13. BAT - 10A : Horn Bulbs 14. BAT – 10A : VCU Power Bulbs are identified as follows: 15. BAT – 25A : Fuel heater 1. Bulb-head lamp halogen (12V-35W) 16. BAT – 25A : Fuel heater *2.

  • Page 145: Battery Terminal - Clean, Inspect

    Maintenance Section Battery Terminal - Clean, Inspect Priming the Fuel System (D20/25/30/33S-9, D35C-9 DM02VA, WARNING DM02P Diesel Engine Only) Batteries give off flammable fumes that can In any one of the following cases, the fuel system explode. requires priming. Do not smoke when observing the battery electrolyte levels.

  • Page 146: Water Separator

    Maintenance Section Water Separator (D20/25/30/33S-9, Tires and Wheels - Inspect, Check D35C-9 DM02VA, DM02P Engine WARNING Only) - Check, Drain Servicing and changing tires and rims can be 1. If the engine check lamp indicates any fault dangerous and should be done only by trained related to water separator, remove the water in personnel using proper tools and procedures.

  • Page 147: Carriage Roller Extrusion - Adjust

    Maintenance Section Carriage Roller Extrusion – Adjust DPF Regeneration (Stage5 Only) 1. Set the mast vertical. DPF Regeneration - Display Pop-up 2. Lower the carriage completely. In order that the DPF system may maintain its exhaust cleaning efficiency at a proper level, it 3.
  • Page 148 Maintenance Section Cabin DPF Regeneration switch Automatic Regeneration DPF Regeneration inhibited The ECU attempts to start Regeneration during working “Automatic Rege neration” at a proper If automatic Regeneration is failed, you should carry moment after determining the moment. it out a while after the vehicle starts working. Once automatic Regeneration starts, the high temperature indicator lamp lights up with a popup A pop-up on the Display warns the operator to...
  • Page 149 Maintenance Section Press this switch and release it after 3 sec, SCREEN Cleaning will be started and the engine speed will be increased. Screen pop-up provides information on the warning up and cleaning process. Warming up process Proceeding Completed -146-...
  • Page 150 Maintenance Section Information - correlation between Symbol and message (Display) 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 Regeneration in 10hr Need Engine Warm up Request Service Should Do Regeneration in 5hr...

  • Page 151: 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 Drive Axle Oil Level - Check 1.

  • Page 152: Coolant Level - Check

    Maintenance Section Coolant Level – Check WARNING At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filter cap is cool enough to touch with your bare hand.

  • Page 153: Inspect Foot Pedal Operation

    Maintenance Section expansion bottle. Inspect Foot Pedal Operation 6. Stop the engine. Verify foot pedal travel is smooth without sticking. 7. Inspect the cooling system for leaks, hose cracks WARNING or loose connections. When acceleration pedal harness WARNING connected or disconnected, should be worked key OFF condition.

  • Page 154: Walk - Around Inspection - Inspect

    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 155: Mast Channels - Lubricate

    Maintenance Section Mast Channels – Lubricate Parking Brake - Inspect Inspection from Operator's Seat, Engine The channels on the roller-type mast require a break-in period. Apply a light film of lubricant on the channels where the rollers ride. This will prevent metal peel until the rollers set a pattern.

  • Page 156: Hydraulic Oil Level - Check

    Maintenance Section Parking Brake Hydraulic Oil Level – Check WARNING NOTE: The parking brake is required to be adjusted to hold the lift truck with capacity At operating temperature, the hydraulic tank is load on a 15% grade. hot and under pressure. Hot oil can cause burns.

  • Page 157: 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. Replenishing Engine Oil Engine Oil & Filter (DM02VA/P Engine Only) - Change WARNING The engine oil in a new engine becomes...
  • Page 158 Maintenance Section Replacing Engine Oil • Special tools Figure Part No. / Name Oil /Filter Cap 110910-00628 • Tightening Torque Part Tightening Torque Drain plug 3 kgf • Use the genuine engine oil approved / recommended by the manufacturer. • Oil capacity Close the oil refill cap (2) and install the oil level gauge.

  • Page 159: Drive Axle Oil, Transmission Oil, Oil Filter & Strainer - Check, Clean, Change

    Maintenance Section Drive Axle Oil, Transmission Oil, Oil Filter & Strainer - Check, Clean, Change WARNING 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, direction control lever in NEUTRAL and the engine stopped.

  • Page 160: Parking Brake - Test, Adjust

    Maintenance Section 10. Start the engine. Parking Brake - Test, Adjust 11. With the service brake applied and engine at Parking Brake Testing low idle, shift the direction control lever to forward and reverse to fill the clutches. 12. Shift the direction control lever into NEUTRAL. NOTICE Engage the parking brake.
  • Page 161 Maintenance Section Parking Brake Adjusting 1. Park the lift truck on a level surface, lowered the NOTICE forks, shift the transmission to NEUTRAL and shut OFF the engine and block the wheels If the parking brake is adjusted several times and there is no normal braking force, the transmission securely.

  • Page 162: 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. Air Intake System – Change Engine Oil & Filter (DM02VA/P with CJ-4 Grade Only) –...

  • Page 163: Belts - Check, Adjust (Only For Air-Con Compressor)

    Maintenance Section 4. Wipe sealing surface of oil filter element Belts - Check, Adjust (Only for Air- mounting base. Make sure the entire old gasket con Compressor) is removed. 5. Before installing a new filter element, apply a small amount of clean engine oil to the filter element gasket.

  • Page 164: Mast Hinge Pin - Lubricate

    Maintenance Section Mast Hinge Pin – Lubricate Mast Pivot Eyes - Lubricate Typical Examp Lower the forks and tilt the mast forward. Lubricate the two fittings for the mast hinge pins, one Typical Example on each side of the mast. Lubricate two fittings for the mast pivot eyes, one on each side of the pin.

  • Page 165: Crosshead Rollers - Inspect

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

  • Page 166: Overhead Guard - Inspect

    Maintenance Section Overhead Guard – Inspect Steer Suspension – Inspect Check tightness of overhead guard mounting bolts at 95 N m (70 lb ft). • • Inspect the suspension mounting bolts. Tighten Check overhead guard for bent or cracked sections. suspension mounting bolts, if necessary, to 240 ±...

  • Page 167: Inching & Braking Control Shaft - Lubricate

    Maintenance Section Inching & Braking Control Shaft - Fuel Filter (DM02VA/P Engine with Lubricate Main Filter only) - 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.

  • Page 168: Wheel Bolts & Nuts - Inspect

    Maintenance Section Install a new fuel filter and assemble the fuel Wheel Bolts & Nuts – Inspect filter cap. Inspect Tightness Connect the wire harness connector and fuel Steer Wheels hose connector. When connecting the fuel hose, take care to prevent foreign material from entering the hose.

  • Page 169: Filter In The Air Compressor (Optional) - Check, Replacement

    Maintenance Section Filter in the Air Compressor (optional) - Check, Replacement 1. The air filter should be checked every 250 hours and replaced every 500 hours. 2. When checking and replacing the air filter, remove the screws as indicated below. 4.

  • Page 170: 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. Hydraulic Return Filter, Breather & Strainer - Check, Change WARNING Hot oil and components can cause personal injury.

  • Page 171: 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 wears.
  • Page 172 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 173: Universal Joint - Inspect

    Maintenance Section if necessary(460 ± 60 N · m or 340 ± 44 lbf · ft) Universal Joint – Inspect Engine Oil Filter – Change (DM02VA/P Engine) Refer to page 145~146, “Engine Oil & Filter (DM02VA Engine Only) – Change. WARNING Hot oil and components can cause personal injury.

  • Page 174: 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 procedure. Drive Axle Oil, Transmission Oil, Oil Filter & Strainer - Clean, Change See the topic, "Drive axle Oil, Transmission Oil, Oil Filter &...

  • Page 175: Cooling System - Clean, Change

    Maintenance Section turning wheel hub to seat the bearing. 10. Loosen the locknut. Retorque it to 50 ± 5N m (37 • ± 4 lb ft). Bend the lock washer tang to secure • locknut. 11. Install the hub cap. 12.

  • Page 176: Forks - Inspect

    Check the angle between the upper face of the allowable difference. Contact your local blade and the front face of the shank. The fork DOOSAN Lift Truck Dealer further should be withdrawn from service if angle (C) information. exceeds 93 degrees or deviates by more than 3...
  • Page 177 Maintenance Section 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 178: 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. Hydraulic Oil - Check, Clean, Inspect Battery System Change Clean battery outer surfaces with a mixture of baking soda and water.

  • Page 179: 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 (DM02VA Stage5 Engine Only) - Ash Cleaning WARNING Ash cleaning services is recommended by the designated repair shop, if not, it can lead to...

  • Page 180: 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. After servicing, dispose of those materials in an authorized place and container.

  • Page 181: Index

    Index Section Causes of Fork Failure ........120 Index Center of Gravity (CG) ......... 22 Changing Primary Element ........ 159 Changing Secondary Element ......159 Chassis Pivot Eyebolts - Lubricate ..... 161 Check for Equal Tension ........168 12 Months Inspection ......... 122 Check Inflation and Damage ......
  • Page 182 Index Section Change ............... 154 High-temperature Exhaust Lamp ......56 Engine Oil & Filter (DM02VA/P with CJ-4 Grade Only) Hood Opening ............96 – Change ............159 Hook-on type Fork..........113 Engine Oil (DEO and EO) ........130 Horn and Lights (If Equipped) - Check ....164 Engine Oil Filter –...
  • Page 183 Index Section Lift Truck Stability ..........22 Operator Restraint System ........17 Lifting a Forklift using a Crane ......116 Operator’s Station and Monitoring Systems ..53 Lifting Drums or Round Objects ......110 Overhead Guard – Inspect ......... 163 Lifting the Load ...........
  • Page 184 Index Section Stability and Center of Gravity ......22 Warning Signs and Labels ........17 Starting a Warm Diesel Engine (Mechanical Engine) Warning Signs and Labels ........5 ................88 Water Separator (D20/25/30/33S-9, D35C-9 Starting Diesel Engine at Cold ......88 DM02VA, DM02P Engine Only) - Check, Drain .

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