Doosan B25X-7 PLUS Operation & Maintenance Manual
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Doosan B25X-7 PLUS Operation & Maintenance Manual

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  • Page 2 B25X-7 PLUS, B30X-7 PLUS, B35X-7 PLUS FBA17,FBA19,FBA20 80 Volt 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. 2301...
  • Page 3 WARNING Do not start, operate or service this machine unless you have read and understood these instructions and received proper training. Unsafe or improper use of the machine may cause serious injury or death. Operators and maintenance personnel must read this manual and receive training before operating or maintaining the machine.

  • 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 ..............101 Tire Inflation Information ........106 Safety Section Torque Specifications ........107 Lubricant Specifications ........109 Important Safety Information ........4 Battery Discharge Indicator ........

  • Page 5: Information Section

    WARNING Read, study and keep this manual with the lift truck. Your DOOSAN truck comes equipped with an Whenever a question arises regarding your lift truck, operator restraint system. Should it become...

  • Page 6: Operation

    Information Section Operation Environment Management The Operation Section is a reference for the new Doosan Industrial Vehicle is ISO 14001 certified operator and a refresher for the experienced one. which is harmonized with ISO 9001. Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL...

  • Page 7: Safety Section

    The warnings in this publication and on the product are therefore not all inclusive. Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must be sure that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

  • Page 8: Safety

    U.S.A., operate this lift truck in accordance with local regulations. Training Required to Operate or Service 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 12. Do not handle unstable or loosely stacked General Warnings to Operator loads. WARNING 13. Use minimum tilt when picking up or Only trained and authorized personnel may depositing a load. operate this machine. For safe operation, read and follow the operation and maintenance Manual furnished with this lift truck and observe 14.
  • 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 Located beside the operator's station.
  • Page 12 Safety Section Battery Disconnect Before Servicing Seat Switch Warning Warning WARNING WARNING Install any seat to this seat frame. Switch must shut off all power when operator is not seated. Disconnect battery from truck also discharge high voltages from capacitor banks with a 150 ohm, 25 watt Resistor before attempting to service this truck.(B+, B-) [DRIVE CONTROLLER-80V]...

  • Page 13: General Hazard Information

    Safety Section possibility of falling objects from any adjacent General Hazard Information storage or work area. Make sure the load is stable and fully supported by the carriage and the load backrest extension (if equipped). Do not raise loads any higher than necessary and never raise a load higher than 1830 mm (72 in) with the overhead guard removed.

  • Page 14: Lift Chains

    Make sure the directional control forward/reverse from improper handling, insufficient maintenance or switch is in the NEUTRAL position. faulty repairs. Use of Doosan genuine parts is recommended when servicing parts. Check the parking brake lamp to verify engagement of the parking brake.
  • Page 15 Safety Section Make sure the lift truck horn, lights, backup alarm (if Operating the Lift Truck equipped) and all other devices are working properly. Always keep the lift truck under control. Check for proper operation of mast and attachments. Obey all traffic rules and warning signs. Pay particular attention to unusual noises or erratic movement which might indicate a problem.

  • Page 16: Maintenance Information

    Safety Section Always overhead guards except where Maintenance Information operation conditions do not permit. Do not operate Perform all maintenance unless otherwise specified lift truck in high stacking areas without overhead as follows : guards. Park the lift truck in authorized areas only. ...

  • Page 17: Burn Prevention

    To avoid possible weakening of the Falling Objects Batteries Protective Structure (FOPS), consult a DOOSAN dealer before altering, by adding weight to, welding Only trained and designated personnel should on, or cutting or drilling holes into the structure.

  • Page 18: Fire Or Explosion Prevention

    Leaks can cause fires. Contact above drawing. your DOOSAN dealer for repair or replacement. Dry nitrogen (N2) gas is recommended for inflation of tires. If the tires were originally inflated with air, 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 Use the lever at the left-hand side to adjust the seat operator restraint system. to the position you desire. Make this seat adjustment before you drive the vehicle.
  • Page 21 Safety Section Daewon Seat (Weight Input Adjustable) Grammer Seat (Weight Input Adjustable) Pulling the weight adjusting lever upward, move it right or left to adjust the weight input based on your Lumbar Support Adjustment weight (50–130 kg). Grammer Seat (Weight Input Adjustable) 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 1. Grip the plate (connector) of the belt and pull the belt from the retractor. Then insert the plate into Your DOOSAN truck comes equipped with a the slot of the buckle until a snap is heard. Pull DOOSAN operator restraint system. Should it on the belt to confirm it is latched.
  • Page 23 Safety Section Release the Seat Belt WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. Push the button of the buckle to release the belt. The belt will automatically retract when released. Hold the plate of the belt and allow the belt to slowly retract.

  • Page 24: Avoiding Lift Truck Tipover

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tipover Lift Truck Stability The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the Counterbalanced lift truck design is based on the combined CG of the truck and load.
  • 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 Only properly trained and authorized personnel body outside of the operator’s compartment. Never 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 other people ride on the truck. Lift trucks are Do not add extra counterweight to 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 load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards. cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.
  • 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 Check the condition of your forklift truck after the Do not operate your truck close to another truck. day's work. Always keep a safe distance from other trucks and make sure there is enough distance to stop safely. operate forklifts near...
  • Page 31 Safety Section There are many special attachments available to Forklift trucks are not cars. They often have small replace the forks on a lift truck. tires, no suspension, and are very heavy. All carry safety implications and special training in The forklift's center of gravity will also change when their operation is highly recommended.

  • 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 Industrial Vehicle Co., Ltd. 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 34 468, Injung-ro, Dong-gu, Incheon, Korea 22503 Authorized Representative and Compiler of Technical File According to Supply of Machinery (Safety) Regulations 2008 Doosan Industrial Vehicle UK Ltd. Mr. Chankyo Chung 12 Kilvey Road, Brackmills Industrial Estate, Northampton, NN4 7BQ, UK herewith declare...

  • Page 35: Specifications

    General Section Specifications Manufacturer DOOSAN Model B25X-7 PLUS 2,500 Load Capacity at rated load center Load center Power type Electric Operator type Driver Seated Tire Type P : Pneumatic, E : Solid Soft, C : Cushion P, E x 2 / 2...
  • Page 36 General Section DOOSAN DOOSAN B30X-7 PLUS B35X-7 PLUS 3,000 3,500 Electric Electric Driver Seated Driver Seated P, E P, E x 2 / 2 x 2 / 2 3,230 3,000 CLASSIII CLASSIII 45 x 125 x 1,050 45 x 125 x 1,050...

  • Page 37: Noise And Vibration

    Noise at operator ear (measured by PREN 12053) unit:dB(A) Noise Level [ Unit : dB(A) ] Sound Pressure Level at Operator's Ear (Leq.) Model EN 12053 B25X-7 PLUS W/O Cabin With Cabin B30X-7 PLUS B35X-7 PLUS *Test Model : B35X-7 PLUS...

  • Page 38: Capacity Chart

    General Section Capacity Chart MODEL STD, FFL D. 5560mm MAST A. 2030 - 3600mm MAST C. 4960mm MAST A. 3900mm MAST E. 6010mm MAST B. 4350 mm MAST B. 4290mm MAST C. 4730mm MAST D. 6010mm MAST A. 2030 - 3600mm MAST A.

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

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

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

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

  • Page 41: Serial Number

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

  • Page 42: Operator's Warning And Identification Plate

    General Section Operator’s Warning and Identification Plate Familiarize yourself with the information on the ldentification, Lift Capacity and Attachment Plates. Do not exceed allowable lift truck working capacity load ratings. Lift Truck Capacity Rating Operator’s Warning Plate Located on the right side of the operator’s seat on DO NOT exceed allowable lift truck working the battery cover.
  • Page 43 General Section - Crane Arm or Crane Boom. Mast Abbreviations 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: Operator's Station And Monitoring Systems

    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 key switch is located on the right side of the the seat switch is located under the operator’s seat. steering column.

  • Page 45: Seat Belt Switch

    Operation Section Seat Belt Switch Lift Neutral Sensor The lift neutral sensor is located in the main control The seat belt switch is located next to the valve at the bottom of the operating lever. operator’s seat. If the lift lever is not neutral when the forklift is OPEN - If the operator does not wear the started or the operator returns to the forklift, the lift seat belt, the electric circuit will cut off.

  • Page 46: Display Segments

    Operation Section Speedometer having graduations from 0 Monitoring Systems Indicator (low) to 9 (high) segments. Battery voltage level gauge having 9 segments. Table 1 shows the relationship between the battery charging progress and the No. of blocks. Both 36V/48V systems have the same relationship. Warning code EL indicates that the batteries are Located on the middle of the console cover panel.
  • Page 47 Operation Section Relation between battery charge level and Code Description Abbreviation number of visualized bars Right EM brake R-EM BRAKE shorted Battery charge level BDI Percent [%] EM brake 75%< EM brake mechanical 74% ~ 67% WARN warning 66% ~ 59% Controller 58% ~ 52% PAR CHANGE...
  • Page 48 Operation Section Code Description Abbreviation Code Description Abbreviation Drive left-side Pump input at PUMP SIGN module L-MOTOR start up overheated OVERTEMP Lift neutral sensor LIFT (145°C) and lift lever UNMATCH Pump module mismatch P-MOTOR overheated Fingertip controller EXTENSION OVERTEMP (145°C) failure FAULT Sitting sequence...
  • Page 49 Operation Section Code Description Abbreviation Forward/reverse FR UNIT lever connection OPEN open Display CAN DISPLAY CAN Communication error Right side controller CAN R-CONT CAN communication error Pump CAN P-CONT CAN Communication error Fingertip CAN module F-KNOB CAN communication error Temperature difference MOTOR TEMP between right side...

  • Page 50: Tilt Steering Column

    Operation Section Front and Rear Floodlights Switch Tilt Steering Column Located on the right side of the instrument panel. Located on the lower front of the steering column. OFF – Push the switch down to turn off the To adjust the steering column, raise the handle(1) headlamp and rear lamp /rear.
  • Page 51 Operation Section Sitting sequence Emergency Switch (If Equipped) In order to use the forklift, sitting and putting on the seat belt must proceed in the correct sequence. The operator must first sit on the seat and then fasten the seat belt. If this sequence is not performed correctly, the operation of the vehicle may be restricted and an alarm will be activated.

  • Page 52: Audio System (Radio/Usb Player/Bluetooth)

    Operation Section Audio System (Radio/USB Player/Bluetooth) Precaution Use the proper power supply Safety information This product is designed to operate with a DC 14.4 V or 28.8 V, negative-ground battery system. WARNING Use authorized service centers To reduce the risk of fire or electric shock, do This product is made of precision parts.

  • Page 53: Location Of Controls

    Operation Section Location of controls Front view 1. BAND button: selects AM/FM Radio mode. ENTER/AST button with I◀◀TUNE▶▶I dial. (Call) button: accept incoming a call or enter • Radio/DAB: plays radio frequencies with superior the call log mode, switch between hands-free reception for 5 seconds each (press);...

  • Page 54: Display Window

    Operation Section Display window Rear view/Connectors 1. Antenna jack: To plug the FM antenna cable. 1. Function display area for showing the function 2. DAB Antenna jack: To plug the DAB antenna mode. cable. (Bluetooth) indicator for the Bluetooth 3. I/O connector: To plug the I/O cable. connection.

  • Page 55: Getting Started

    Operation Section Setting the sound Getting started Turning the unit on/off 1. Press MENU button to enter the Settings menu mode. • After entering MENU mode, press MENU button 1. Turn your car’s ignition key to ACC or IGN (ON) to return to the previous item.

  • Page 56: Setting The Bluetooth Mode

    Operation Section list, then press this dial. Setting the Bluetooth mode • When the connected device is deleted, Bluetooth stops working. If you select another device in "SELECT" mode or turn the vehicle off and on, it will try to connect with the next priority Bluetooth device.
  • Page 57 Operation Section Setting the DAB feature Setting the system functions 1. During the Settings menu mode, turn the 1. During the Settings menu mode, turn the VOLUME dial to select the "DAB" as below, then VOLUME dial to select the "SYSTEM" as below, press this dial;...
  • Page 58 Operation Section Setting the region Checking/updating the system 1. During the System settings mode, turn the 1. During the System settings mode, turn the VOLUME dial to select the "AREA" as below, VOLUME dial to select the "SOFTWARE" as then press this dial; below, then press this dial;...

  • Page 59: Tuning In A Radio Station

    Operation Section Saving radio stations manually Radio You can save up to 6 preset channels each for  Tuning in a radio station FM1, FM2, AM1 and AM2 band. If change the stations while driving, use preset  button to prevent accidents 1.

  • Page 60: Listening To A Preset Station

    Operation Section Listening to a preset station DAB (option for DAB service region) Listening to a DAB station 1. Press the BAND button repeatedly to select the band. • You can select the FM1, FM2, FMA or AM1, AM2, 1. Press the DAB button to enter the DAB mode. AMA radio band.
  • Page 61 Operation Section Changing the DAB service 1. Press the ENTER button to show the DAB service list. 2. To change the DAB service, turn the ▶▶I TUNEI◀◀ dial to select the desired Service name, then press this dial. Seeking the full Ensemble stations 1.

  • Page 62: Usb Player

    Operation Section separate drive used to install application programs and it USB player may not be possible to play songs from such drives for the reasons as described above. Handling precautions for USB device The device may not support normal operation when When using the external USB device, make sure to using formats such as HDD Type, CF, or SD Memory.
  • Page 63 Operation Section About MP3/WMA Playing a USB device This unit can play MP3 (WMA) files with .mp3, .wma (lower case letters) or .MP3 and .WMA (capital letters) file name extensions. This unit can display ID3 Tag (Version 1.0, 1.1, 2.2, 2.3 or 2.4) information for MP3 files, such as the album name and the artist.

  • Page 64: Controlling The Playback

    Operation Section Changing the song information 3. Press the [5 D-] or [6 D+] button to moves to the previous or next folder. 1. Press the [4 INFO] button repeatedly to display • [5 D-]: move to previous folder information about the file being played. [6 D+]: move to next folder •...

  • Page 65: Change The Playback Mode

    Operation Section Change the playback mode 1. Press the [2 RPT] button to select the Repeat playback mode • : The current file plays repeatedly. • : The current folder plays repeatedly. • Off: Cancels repeat playback. 2. Press the [3 RDM] button to select the Random playback mode.

  • Page 66: About Bluetooth Wireless Technology

    Operation Section About Bluetooth music mode Bluetooth Bluetooth Audio mode can be used only if a Bluetooth About Bluetooth wireless technology Audio device has been connected. Bluetooth® Wireless Technology refers to a short- If the Bluetooth device is disconnected while Bluetooth distance wireless networking technology which uses a music is active, then the music will also stop.
  • Page 67 Bluetooth music pairing mode directly. play mode when entering and exiting, the 4. Search and select device “Doosan” in your device does not play automatically. Bluetooth device, then confirm • The Bluetooth registration standby proceeds for 1 minute.

  • Page 68: Answering A Call

    Operation Section Controlling the playback Making a call by recentry 1. To call the recentry connected number, press 1. While playing, turn the ▶▶I TRACK I◀◀ dial (Call) button to display recent call to moves to the previous or next track. number.
  • Page 69 Operation Section 3. To switch from hands-free mode to the phone handset mode, press the Call) button. To returns the phone conversation to hands- free mode, press the (Call) button.. 4. Call waiting feature When a new call comes in during a call, "Call in" and the incoming call information are displayed alternately.

  • Page 70: Troubleshooting

    Operation Section Troubleshooting Common Symbol Possible causes Possible remedies Sound is not generated. MUTE is set to ON. Set MUTE to OFF. (refer to 6 page) Keep electromagnetic-wave There electromagnetic-wave generator s away from the unit and the Noise generator near the unit or its electrical wiring of the unit.
  • Page 71 Operation Section Symbol Possible causes Possible remedies Please use after formatting the USB into USB memory is damaged. FAT 16/32 format. Remove any foreign substances on the USB memory has been contaminated. contact surface of the USB memory and USB port. A separately purchased USB HUB is being Directly connect the USB memory with used.

  • Page 72: Functional Safety System

    Operation Section the forklift, Lift function is only available when Functional safety System lever is at the neutral position. The truck uses proximity sensor to detect whether the lever is WARNING neutral. The lift neutral sensor is located in the These are the functions added for functional main control valve at the bottom of the safety.

  • Page 73: 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 74: Lift Truck Controls

    Operation Section Lift Truck Controls Accelerator Pedal Parking Brake NOTICE NOTICE The service brake and accelerator pedals should Do not operate the emergency switch while the not be used at the same time, except for emergency situations. Use of both the brake and forklift is in motion, unless in an emergency case.
  • Page 75 Operation Section If the driver stands up from the driver's seat while Directional control the lift truck is in operation, the seat switch will be forward/reverse switch 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 76 Operation Section Lift Control Lever Tilt Control Lever The forks’ lift control is located at the operator’s The forks’ tilt control is located at the operator’s right side front. The lift control lever is the lever at right side front. The tilt control lever is the lever at the center.
  • Page 77 Operation Section Sideshift Attachment Control (If Auto tilt control (If provided) 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 78 Operation Section GSS – Guardian Stability System (option) This option is applicable to FFL (Full Free Lift) and FFT (Full Free Triple) Mast vehicles. The GSS function consists of a basic function and several sub-options that can be added separately. Basic option - When the mast is switched from the primary section to the secondary section, the height sensor detects this and the function is executed.

  • Page 79: 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 80 Operation Section Inspect battery compartment loose connections, frayed cables and properly secured battery restraint. WARNING 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 14.
  • Page 81 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. 17.

  • Page 82: 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 83 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 directional control lever (1) to the opposite direction while keeping the 3.

  • Page 84: Mono-Ped Control System (Option)

    Operation Section Steering Knob (If Equipped) Mono-Ped Control System There is a steering knob available for inclusion with (Option) 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 85: Finger Tip

    Operation Section Finger Tip Lift Control knob Tilt Control knob Lower - Push the knob forward smoothly Tilt Forward - Push the knob forward to lower the lift forks. smoothly to tilt the lift forks forward. Hold - Release the lift knob. The knob will Hold - Release the tilt knob.

  • Page 86: Emergency Switch

    Operation Section Sideshift Attachment Control Emergency Switch WARNING In an emergency situation, must press the emergency switch to stop the forklift. If there is no emergency switch, turn off the key switch to cut off the battery power. The side shift attachment controller is at the front- right side of the driver, and the side shift control lever is at the right as shown in the figure.
  • Page 87 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 88 Operation Section Horn Button Auto Tilt Control (If provided) 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 89: Forward And Backward Adjustment

    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 90: 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 91 Operation Section Traveling With or Without a load Lift Truck Turning When traveling with and without a load, travel with the fork as low as possible, while still maintaining good floor clearance height. 1. When turning sharp corners, keep close to the inside corner.
  • Page 92 Operation Section 3. As the steer wheel angle increases, the inside drive motor speed is progressively slowed down with respect to the outside drive motor speed.
  • Page 93 Operation Section Unloading Lift Truck Lifting Drums or Round Objects 1. Move the lift truck into the unloading position. 1. Block drums or round objects. Tilt mast forward and slide fork tips along the floor to get under 2. Tilt the mast forward only when directly over the the load.
  • Page 94 Operation Section Safety instructions for attachments when transporting suspended loads WARNING Swinging/Wide loads and a reduced residual capacity can result in accidents Adapt the travel speed to the load, less than walking pace. Secure swinging loads for example with lifting slings.

  • Page 95: 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. PARKING BRAKE (EM) Park or store all electric lift trucks inside a building to protect electrical system from moisture damage. 3.
  • Page 96 Operation Section [OUTSIDE BATTERY CONNECTOR] [INSIDE BATTERY CONNECTOR] 6. Disconnect the battery. 7. Block the wheels if parking on an incline.

  • Page 97: 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 in each fork to side the fork on the carriage bar. 2.

  • Page 98: 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 99: Transportation Hints

    Remove ice, snow or other slippery material from width and length of a load. the shipping vehicle and the loading dock. 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 100 Operation Section Lifting a Forklift using a Crane WARNING Batteries of an electric forklift must be removed before lifting. Lifting an electric forklift without removing the batteries can lead to serious injury to the workers or damage to the equipment by electric shock or leakage of electrolyte.
  • Page 101 Operation Section How to Fix Forklift to a Carrier The rope/chain must have sufficient length for fixing. Park the vehicle on a level ground. Set the mast vertically. Lower the fork or attachment to the lowest position. Set all the operating devices to Neutral Position.

  • Page 102: 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 103 Operation Section Connect EM CONN B and EMERGENCY C. Tighten the traction bar connected to the lift truck. Remove the wheel chocks. Tow the lift truck carefully. Do not tow the lift truck faster than 2km/h (1.2 mph). NOTICE Release the parking brake to prevent excessive wear and damage to the parking brake system.

  • Page 104: Maintenance Section

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following provides practical guidelines for Report 5057 -Inspection and Repair of Fork Arms inspection, maintenance and repair of lift truck forks. and ISO Standard 2330 - Fork Arms-Technical It also provides general information on the design Characteristics and Testing.

  • Page 105: Bent Or Twisted Forks

    Maintenance Section Repetitive Overloading Causes of Fork Failure Improper Modification or Repair Repetitive cycling of loads which exceeds the 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 106: Fork Inspection

    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 107: Maintenance And Repair

    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 108 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 109: 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 B25/30/35X-7 PLUS 18X7-8 Steer...

  • Page 110: Torque Specifications

    Maintenance Section Torque Specifications Metric Hardware - This lift truck is almost totally Torque for Standard Bolts, Nuts metric design. Specifications are given in metric and Taperlock Studs U.S. Customary measurement. Metric hardware must be replaced with metric hardware. Check parts books for proper replacement. NOTICE Use only metric tools on most hardware for proper The following charts give general torques for bolts,...
  • Page 111 Maintenance Section Torques for Taperlock studs Torque for Metric Fasteners Standard Taperlock Stud Thread Size Torque NOTICE Inch N·m lb·in 8±3 6±2 Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or 5/16 17±5 13±4 incorrect fasteners will cause lift truck damage or 35 ±5 26±4 malfunction and may even result in personal injury.

  • Page 112: 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 113 The API GL-4 specification or MIL-L-2105A oils could be used. Multi-grade oils are not blended by DOOSAN for use in transmissions. Multi-grade oils which use high molecular weight polymers as viscosity index improvers lose their viscosity effectiveness by...

  • Page 114: Battery Discharge Indicator

    Maintenance Section Battery Discharge Indicator The battery discharge indicator should be observed frequently before and during operation. A fully charged battery will cause a “9 segments” to be displayed on the LCD display. As the battery is discharged, the LCD display will count down, 9, 8, 7, and etc., until “EL”...

  • Page 115: Battery

    Maintenance Section the battery. Battery Low battery operation will cause higher than normal current in the electrical system. This can damage WARNING contactor tips or shorten motor brush life. When using pressure air for cleaning purposes, Batteries that have been fully charged should have wear a protective face shield and protective a tag attached for identification.

  • Page 116: Personnel Only

    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 temperatures are maintained through use or abuse, • DISPOSAL OF OLD BATTERY reduced battery service life can be expected. Careless disposal of a battery can harm the Battery condition is important for a long life.

  • Page 117: Cold Storage Applications

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

  • Page 118: Hydraulic System

    Maintenance Section Hydraulic System Drain the hydraulic system and fill it with SAE 5 or ISO VG 15, MIL-H-5606A hydraulic oil Lift Chains 1. Remove chains Clean them nonflammable cleaning solvent. 2. Put chains molybdenum disulfide (MPGM) grease for one hour. Then, before installation, hang the chains, where they will not move, for three hours.

  • Page 119: 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 Imperial Liters U.S. Gal °C °F Compartment or System or System Viscosities Min Max Min Max Hydraulic & ISO VG 15 Power Steering Hydraulic System...

  • Page 120: Maintenance Intervals

    Maintenance Section Maintenance Intervals Every 500 Service Hours or 3 Months NOTICE Tilt Cylinders ............135 Cylinder Rod Extension - Adjust ......136 Never exceed the Maintenance Intervals specified Crosshead Rollers - Check ........ 136 in the manual. Defects and/or damage to the Mast Hinge Pins - Lubricate .......
  • Page 121 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Air Breather Change Check, Exchange, Battery Change Carriage Roller Extrusion Adjust Compact Display Button Control Panel Clean, Inspect Crosshead Rollers Check Cylinder Rod Extension Adjust Direction Control forward/reverse Switch Check Drive &...

  • Page 122: When Required

    Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Self Diagnostics - Test Compact Display Button Test Circuits and Components The Micro-Controller has a built-in diagnostic system to provide aid in rapid troubleshooting of lift truck problems.

  • Page 123: Down Button

    Maintenance Section UP Button Run Time Diagnostic 1. Pressing of this button, in calibration and diagnostic mode, you increase the number of the parameter displayed. 2. In calibration phase, you increase the numeric value of the parameter displayed. TURTLE Button Remember that pressing this button you can toggle between slow running and normal working condition (if the lift truck is already in speed limitation mode).
  • Page 124 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 125 Maintenance Section In diagnostic mode selected parameter is visualized as follows: - In the area dedicated to speed and alarm signals, appears parameter number(flashing) - Its actual value is displayed in the area reserved to the time meter. In particular, if the selected parameter is: Analogue input: COMPACT display shows the parameter value, expressed in the unit of Table 11...

  • Page 126: Carriage Roller Extrusion - Adjust

    4. Measure the distance from the bottom of the inner upright to the bottom of carriage bearing. 5. The measurement (A) must be as follows in Chart below. B25X-7 PLUS Height of carriage roller extrusion (A) STD mast FF mast...

  • Page 127: Power Modules - Discharge

    Maintenance Section 1. Disconnect the battery. Power Modules – Discharge WARNING 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 128: Fuses - Replace

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

  • Page 129: Wheel Bolts - Check For Tightness

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

  • Page 130: Greasing Point

    Maintenance Section Greasing Point...

  • Page 131: 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 132 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 133: Mast Channels - Lubricate

    Maintenance Section Mast Channels - Lubricate Battery - Check, Exchange, Change Battery Access Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor. 1. Tilt the steering column to the full upright position and move the seat fully rearward.
  • Page 134 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 135: Battery Charging

    Maintenance Section Battery Charging WARNING 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 136: Tires And Wheels - Inspect

    Maintenance Section Check Inflation Pressure Tires and Wheels - Inspect (If equipped with pneumatic tires) Inspect tires and valve stems for wear, cuts, Measure the tire air pressure on each tire. gouges and foreign objects. Inflate the tires, if necessary. See “Tire Inflation Check all components carefully and replace any Information”...

  • Page 137: First 150 Service Hours Or 2 Weeks

    Maintenance Section First 150 Service Hours or 2 Weeks 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 5. Fill the drive axle housing with oil filling plug After the first 150 hour of operation, subsequently hole, the accurate amount of oil is defined by after every 2000 hours or yearly.

  • Page 138: 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. Mast Pivot Eyes - Lubricate Tilt Cylinders Chassis Pivot Eyebolts - Lubricate 1.

  • Page 139: Cylinder Rod Extension - Adjust

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

  • Page 140: Mast Hinge Pins - Lubricate

    Maintenance Section Mast Hinge Pins - Lubricate Steering Mechanism - Lubricate Lubricate two fittings Lubricate one fitting 1. Lower the forks and tilt the mast forward. Lubricate fitting on steer axle. Overhead Guard - Inspect 2. Lubricate the mast hinge pins. One fitting on each side of the mast.

  • Page 141: Control Panel - Clean, Inspect

    Maintenance Section Control Panel - Clean, Inspect WARNING Park the lift truck level, with the forks lowered, parking brake engaged, directional control lever in Pressurized air can cause personal injury. NEUTRAL, and the key switch to OFF. When using pressurized air for cleaning, wear a 1.

  • Page 142: Direction Control Forward/Reverse Switch- Check

    Maintenance Section 5. Inspect all wiring for loose connections, frayed Direction Control forward/reverse cables and loose mounting bolts. Switch- Check 6. Inspect the fuses for looseness, corrosion and broken connections. [OUTSIDE BATTERY CONNECTOR] Check tightness directional forward/reverse switch mounting bracket. Adjust if needed.

  • Page 143: 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. WARNING 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 144: Steer Angle Switches - Check, Clean

    Maintenance Section Steer Angle Switches - Check, Mast Carriage, Chains and Clean Attachments - Inspect, Adjust, Lubricate 1. Clean steer angle switches with 205 kpa (30 psi) maximum air pressure until dust is removed. 1. Operate the lift, tilt and attachment controls. Listen for unusual noises.
  • Page 145 Maintenance Section 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. 6. Inspect the chain anchors and individual links for wear, loose pins or cracked leaves. NOTE: Have all repairs and adjustments made as required...

  • Page 146: Every 1000 Service Hours Or 6 Months

    Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Air Breather - Change Drive & Pump Motor - Clean, Inspect Park the lift truck level, with the forks lowered, parking...
  • Page 147 Maintenance Section 11. Install the floor plate. 5. Fasten lift chains, of equal length, in lift 12. Slowly lift the front of the lift truck and remove openings in the front of the lift truck. the stands. Lower the lift truck to the floor. Remove the chains.

  • Page 148: Tires And Wheels - Inspect, Check

    Maintenance Section Tires and Wheels - Inspect, Check WARNING Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies could burst with explosive force and cause serious physical injury or death.

  • Page 149: 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 150 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 151: Hydraulic Return Filter - Change

    Maintenance Section Hydraulic Return Filter - 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, directional control forward/reverse switch in NEUTRAL and the key switch to OFF.

  • Page 152: 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 153: 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. 1.
  • Page 154 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 155: Fork - Inspect

    Maintenance Section Fork - Inspect 2. Check the angle between the upper face of the blade and the front face of the shank. The fork Forks should be inspected, at a minimum, every 12 should be withdrawn from service if angle (C) months.
  • Page 156 Contact your local DOOSAN Lift Truck Dealer further When adjusting the fork spacing, the forks are information. prevented from sliding off the end of the carriage by stop blocks.
  • Page 157 Maintenance Section 8. Check fork markings (N) for legibility. Renew 9. a. Lift the mast and operate the tilt control lever, markings as required to retain legibility. until the top surface of the forks is parallel with the floor. Place two straight bars that are the same width as the carriage, accross the forks as shown.

  • Page 158: Hydraulic Oil - Check, Change

    Maintenance Section Hydraulic Oil - Check, Change Drive Axle Oil - Change See topic, “Drive Axle Oil - Change” in “First 150 Service Hours or 2 Weeks”. 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.

  • Page 159: Environment Protection Section

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

  • Page 160: Index

    Index Section Compact Display Button ........119 Index Control Panel - Clean, Inspect ......138 Crosshead Rollers - Check ........ 136 Crushing or Cutting Prevention ......13 Cylinder Rod Extension - Adjust ......136 12 Months Inspection ......... 104 DAB (option for DAB service region) ....57 Accelerator Pedal ..........
  • Page 161 Index Section Fuses – Replace ..........125 Lift Neutral Sensor ..........42 Lift Truck Capacity Rating ........39 Lift Truck Controls ..........71 Lift truck Operation Mode ........46 Lift Truck Operation ..........79 General Hazard Information ......... 10 Lift Truck Parking ..........13 General Warnings to Operator .......
  • Page 162 Index Section Setting the sound ..........52 Operating Techniques .......... 87 Setting the system functions ........ 54 Operating the Lift Truck ........12 Shipping ............... 96 Operation Information ........... 11 Sideshift Attachment Control (If Equipped) ..74 Operation ............... 3 Sideshift Attachment Control .......
  • Page 163 Index Section Walk-Around Inspection ........76 Walk - Around Inspection - Inspect ....128 Warning Signs and Labels ........ 5,16 Wheel Bolts - Check for Tightness ..... 126 When Required ..........119...

This manual is also suitable for:

B30x-7 plusB35x-7 plus

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