Doosan B20S-5 Operation & Maintenance Manual
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Doosan B20S-5 Operation & Maintenance Manual

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Operation &
Maintenance Manual
LIFT TRUCKS
BC20S-5, BC25S-5, BC25SE-5
BC30S-5, BC32S-5
B20S-5, B25S-5, B30S-5, B32S-5
SB2346E00
0609

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  • Page 1 SB2346E00 Operation & Maintenance Manual LIFT TRUCKS BC20S-5, BC25S-5, BC25SE-5 BC30S-5, BC32S-5 B20S-5, B25S-5, B30S-5, B32S-5 0609...
  • Page 2 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 3: Table Of Contents

    Table of Contents Table of Contents Information Section Maintenance Section Foreword .............. 2 Inspection, Maintenance and Repair of Lift Truck Forks..............75 Tire Inflation Information........79 Safety Section Torque Specifications..........80 Lubricant Specifications........82 Important Safety Information ......... 4 Battery Discharge Indicator .........84 Safety ..............5 Battery ..............85 Warning Signs and Labels ......

  • Page 4: Information Section

    WARNING Continuing improvement and advancement of product design might have caused changes to your Your DOOSAN truck comes equipped with an lift truck which are not included in this publication. operator restraint system. Should it become Read, study and keep this manual with the lift truck.
  • Page 5 Information Section Operation Environment Management Note that DOOSAN Infracore BG is ISO 14001 The Operation Section is a reference for the new operator and a refresher for the experienced one. certified which is harmonized with ISO 9001. This section includes a discussion of gauges,...

  • Page 6: 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 7: Safety

    See your dealer for new labels. U.S.A., operate this lift truck in accordance with local regulations. Training Required To Operate or Service DOOSAN lift trucks are manufactured according to Warning the regulations and standards laid down in EU Machinery Directive 98/37/EC and EMC directive 89/336/EC.
  • Page 8 Safety Section 17. Parking-Lower lifting mechanism to floor. Put General Warnings to Operator directional control or shift lever in neutral. Set parking/secondary brake. Turn "ON - OFF" WARNING switch off. Chock wheels if machine is on incline. Disconnect battery when storing electric Only trained and authorized personnel may...
  • Page 9 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 10 Safety Section No Riders Warning Battery Restraint Warning WARNING To avoid personal injury, allow no riders. A lift truck is designed for only one operator and no riders. Located on front of battery cover. WARNING Before operating truck, ensure that hood is securely locked by hood latch, and turn stopper to locking position.
  • Page 11 Safety Section Battery Disconnect Before Servicing Seat Switch Warning Warning WARNING Install any seat to this seat frame. Switch must WARNING 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-) (36V/48V)

  • Page 12: General Hazard Information

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

  • Page 13: Lift Chains

    Make sure the lift truck is equipped with a lighting please contact your DOOSAN dealer. We would like system as required by conditions. to draw your attention to the fact that any secondary...
  • Page 14 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 Never leave the lift truck with the engine operating, movement which might indicate a problem.

  • Page 15: Maintenance Information

    Safety Section Always overhead guards except where Maintenance Information operation conditions do not permit. Do not operate lift truck in high stacking areas without overhead Perform all maintenance unless otherwise specified guards. as follows : When stacking, watch for falling objects. Use load Park the lift truck in authorized areas only.
  • Page 16 Only trained and designated personnel should To avoid possible weakening of the Falling Objects inspect, recharge or exchange batteries. Protective Structure (FOPS), consult a DOOSAN dealer before altering, by adding weight to, welding Always wear protective glasses when working with on, or cutting or drilling holes into the structure.
  • Page 17 Do not approach a warm tire closer than the outside tubes and hoses. Leaks can cause fires. Contact of the area represented by the shaded area in the your DOOSAN dealer for repair or replacement. above drawing. Check lines, tubes and hoses carefully. Do not use Dry nitrogen (N2) gas is recommended for inflation your bare hand to check for leaks.

  • Page 18: 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 19 Safety Section WARNING Do NOT place your hand or fingers under the seat. Injury may occur as the seat moves up and down. The "Survive in tipover" warning is located on the overhead guard. It shows the proper use of the operator restraint system.
  • Page 20 Safety Section Weight adjustment If Optional Suspension Seat Equipped Forward and Backward Adujstment Pull the weight adjustment lever upwards and move right or left side. The seat can be adjusted by pushing the lever on Adjust to driver’s weight in 7 steps (50 ~ 110 kg) the right side of seat.
  • Page 21 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 22 Safety Section Hold the plate of the belt and allow the belt to slowly WARNING retract. If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. 3. Be sure to fasten the belt across your hips, not across your abdomen.

  • Page 23: Avoiding Lift Truck Tipover

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tipover Lift Truck Stability The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the combined CG of the truck and load. The lift truck Counterbalanced lift truck design is based on the has moving parts and, therefore, has a CG that balance of two weights on opposite sides of a...
  • Page 24 If the CG moves outside of the line forklifts sold by DOOSAN shall not be removed, on either side of the stability base, the lift truck will altered or replaced without DOOSAN’s approval. tip to the side.

  • Page 25: Safety Rules

    Safety Section Safety Rules Do not operate a lift truck unless you are in the operator’s seat. Keep hands and feet inside the operator’s compartment. Do not put any part of the body outside of the operator’s compartment. Never Only properly trained and authorized personnel put any part of body into the mast structure or should operate forklift trucks.
  • Page 26 Safety Section Do not overload. Always handle loads within the Do not raise anyone on the forks of your lift truck rated capacity shown on the capacity plate. unless using an approved safety cage. Do not let Do not add extra counterweight to the truck. An other people ride on the truck.
  • Page 27 Safety Section Do not elevate the load with the mast tilted forward. Do not permit anyone to stand or walk under the Do not tilt the elevated loads forwards. load or lifting mechanism. The load can fall and This will cause the lift truck to tip over forward. cause injury or death to anyone standing below.
  • Page 28 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 29 Safety Section Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and Never overtake other vehicles.

  • Page 30: 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 tip over, 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 31: General Section

    General Section Specifications CHARACTERISTICS Manufacturer Model Capacity at rated load center lb(kg) Load center distance in(mm) Power type eletric,diesel,gas,Lp-gas Operator type stand-on, driver seated Tire P=pneumatic,E=elastic,C=cushion Wheels(x=driven) number of front/rear DIMENSIONS Lift with STD maximum fork height with rated load in(mm) two-stage mast free lift...
  • Page 32 General Section 36/48V DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN BC20S-5 BC25S-5 BC25SE-5 BC30S-5 BC32S-5 4000(2000) 5000(2500) 5000(2500) 6000(3000) 6500(3000) 24(500) 24(500) 24(500) 24(500) 24(600) AC electric AC electric AC electric AC electric AC electric driver seated driver seated driver seated driver seated...
  • Page 33 General Section Specifications CHARACTERISTICS Manufacturer Model Capacity at rated load center Load center distance Power type eletric,diesel,gas,Lp-gas Operator type stand-on, driver seated Tire P=pneumatic,E=elastic,C=cushion Wheels(x=driven) number of front/rear DIMENSIONS Lift with STD maximum fork height with rated load two-stage mast free lift Fork carriage ISO Class...
  • Page 34 General Section DOOSAN DOOSAN DOOSAN BC20S-5 BC25S-5 BC30S-5 2000 2500 3000 AC electric AC electric AC electric driver seated driver seated driver seated x 2/2 x 2/2 x 2/2 3230 3230 3230 1050x100x40 1050x100x40 1050x125x45 297x905 297x905 282x954 6/10 6/10...
  • Page 35 General Section Specifications CHARACTERISTICS Manufacturer Model Capacity at rated load center Kg (lb) Load center distance mm (in) Power type eletric,diesel,gas,Lp-gas Operator type stand-on, rider seated Tire P=pneumatic,E=elastic,C=cushion Wheels(x=driven) number of front/rear DIMENSIONS maximum fork height with rated load mm (in) Lift with STD two-stage mast free lift...
  • Page 36 General Section DOOSAN DOOSAN DOOSAN DOOSAN B20S-5 B25S-5 B30S-5 B32S-5 2000(4000) 2500(5000) 3000(6000) 3200(6400) 500(24) 500(24) 500(24) 500(24) electric electric electric electric AC drive AC drive AC drive AC drive AC hyd. AC hyd. AC hyd. AC hyd. No steering...

  • Page 37: Noise And Vibration

    General Section Noise and Vibration Noise at operator ear (measured by PREN 12053) unit:dB(A) Noise Level[unit:Db(A)] Model Sound Pressure Level at operator’s Ear(Leq) B(C)20S-5 PREN 12053 B(C)25S-5 B(C)30S-5 70.0 B(C)32S-5 * Test Model : B32S-5...

  • Page 38: Capacity Chart

    General Section Capacity Chart MODEL STD, FFL C. 6010 mm MAST A. 2030 – 4960 mm MAST A. 3900 – 4730 mm MAST B. 5560 mm MAST C. 5560 mm MAST A. 2030 – 4350 mm MAST A. 3900 - 4290 mm MAST D.
  • Page 39 General Section Capacity Chart MODEL STD, FFL C. 6010 mm MAST A. 2030 – 4350 mm MAST A. 3900 – 4730 mm MAST B. 4960 mm MAST B. 5560 mm MAST D. 5560 mm MAST A. 2030 – 4350 mm MAST A.

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

    General Section Capacity Chart - With Side Shifter (Integrated) MODEL STD, FFL C. 4960 mm MAST D. 5560 mm MAST A. 2030 – 3950 mm MAST A. 3900 mm MAST E. 6010 mm MAST B. 4350 mm MAST B. 4290 mm MAST C.
  • Page 41 General Section Capacity Chart - With Side Shifter (Integrated) MODEL STD, FFL C. 4960 mm MAST D. 5560 mm MAST A. 2030 – 3950 mm MAST A. 3900 mm MAST E. 6010 mm MAST B. 4350 mm MAST B. 4290 mm MAST C.

  • Page 42: Capacity Chart - With Side Shifter (Hook On)

    General Section Capacity Chart - With Side Shifter (Hook on) MODEL STD, FFL C. 4960 mm MAST D. 5560 mm MAST A. 2030 – 3950 mm MAST A. 3900 mm MAST B. 4350 mm MAST B. 4290 mm MAST E. 6010 mm MAST C.
  • Page 43 General Section Capacity Chart - With Side Shifter (Hook on) MODEL STD, FFL D. 5560 mm MAST A. 2030 – 4350 mm MAST A. 3900 mm MAST E. 6010 mm MAST B. 4960 mm MAST B. 4290 mm MAST C. 4730 mm MAST D.

  • Page 44: 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 45: Operator's Warning And Indentification Plate

    General Section Operator’s Warning and Indentification Plate Familiarize yourself with the information on the ldentification, Lift Capacity and Attachment Plates. Do not exceed allowable lift truck working capacity load ratings. Operator’s Warning Plate Identification, Lift Capacity and Attachment Plate Lift Truck Capacity Rating DO NOT exceed allowable lift truck working capacity load ratings.
  • Page 46 General Section Mast Abbreviations - Crane Arm or Crane Boom. The identification plate indicates the type of mast - Tire Handler. installed on the lift truck when it left the factory. The type of mast is indicated by an abbreviation. - Container Top Handler.

  • Page 47: Operation Section

    Operation Section Operator’s Station and Monitoring Systems Read and understand the “Safety”, “Operation” and “Maintenance” sections before operating the lift truck. Key Switch Seat Switch the seat switch is located under the operator’s seat. The key switch is located on the right side of the steering column.
  • Page 48 Operation Section Display Segments Monitoring Systems Indicator(Compact Display) The display gives the following information about the operating state of the system: Lift truck speed (expressed in kmh or mph) Handbrake active, indicated by the warning symbol Safety contact open, indicated both by EE blinking message visualized in timemeter area and by relative symbol.
  • Page 49 Operation Section Relation between battery charge level and Table 4 : Case of a 80V system number of visualized bars BATTERY CHARGE BATTERY VOLTAGE LEVEL [ V ] Table 1 : Case of a generic system Discharged battery Voltage < 75.7 V DISPLAY BATTERY CHARGE 10 %...
  • Page 50 Operation Section Calibration – ESH, to select desired operating Capacitors not CAP NOT charged CHARGED mode. In particular you can choose between E-S-H Drive right module R-INV or PROGRAMMABLE WORKING : Overtemperature OVERTEMP Drive left module L-INV - Pressing E-S-H (economic, standard, high) button, Overtemperature OVERTEMP you change energetic mode and update related...
  • Page 51 Operation Section NOTE: if active mode is one of L1, L2 or L3 limitations and you change operating mode Low oil level of the brakes; red colour LED. (from PROGRAMMABLE WORKING to E- S- H), software automatically sets operating Seat Belt warning (Option) : red color mode to economic one LED for 10 seconds.
  • Page 52 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. by the display panel. To adjust the steering column, raise the handle(1) OFF - Push down on the left side of the and move the steering column to the desired switch to turn both front and rear flood...
  • Page 53 Operation Section Emergency Switch (If Equipped) OFF - Push the emergency switch button to disconnect the electrical circuits. (It must be done after the key switch is turned off. If use often this button by the key switch, the electric system can make a problem.

  • Page 54: Lift Truck Controls

    Operation Section Lift Truck Controls Parking Brake Service Brake Pedal NOTICE Do not engage the parking brake while the lift truck is moving unless an emergency arises. The use of the parking brake as a service brake in regular operation will cause severe damage to the parking brake system.
  • Page 55 Operation Section Accelerator Pedal Directional Control Lever NOTICE The service brake and accelerator pedals should not be used at the same time, except for emergency situations. Use of both the brake and accelerator pedals at the same time may cause the drive motor to overheat.
  • Page 56 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 left.
  • Page 57 Operation Section Sideshift Attachment Control (If Equipped) The sideshift attachment control is located at the operator’s right side front. The sideshift attachment control lever is the lever at the right. Sideshift Left(1) - Push the lever forward smoothly to shift the carriage to the left. Sideshift Hold(2) - Release the sideshif attachment lever.

  • Page 58: 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 59 Operation Section Batteries give off flammable fumes that can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear protective glasses when working with batteries.
  • Page 60 Operation Section 17. Make sure the battery is charged before operating the lift truck. A fully charged battery will cause “9 Segments” to be displayed on the BDI display. 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.

  • Page 61: 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 62 Operation Section 6. Release the service brake pedal. 7. Push down on the accelerator pedal to obtain the desired travel speed. Release the pedal to decrease travel speed. 8. To change the lift truck direction of travel, electrical braking(plugging) can be used to slow or stop the lift truck.
  • Page 63 Operation Section Electrical Braking (Plugging) 2. Hold the accelerator pedal down until the lift truck nearly comes to a complete stop. Release the accelerator pedal. To slow, stop or change direction when traveling in either direction, move the directional control lever 3.

  • Page 64: Mono-Ped Control System (Option)

    Operation Section Mono-Ped Control System (Option) Forward-Push the left side (2) of the pedal for FORWARD direction travel. Neutral-The lift truck should not move when the Mono-Ped pedal is released.. Reverse-Push the right side (1) of the pedal for REVERSE direction travel. The MONO-PED pedal controls the speed and direction of the lift truck.

  • Page 65: Finger Tip (Option)

    Operation Section Finger Tip (Option) Function of Knobs Tilt Control knob If finger tip control option is equipped, the hall-effect type electric knobs replace convention control valve levers. Lift Control knob Tilt Forward - Push the knob forward smoothly to tilt the lift forks forward. Hold - Release the tilt knob.
  • Page 66 Operation Section Sideshift Attachment Control Warning Lamp Sideshift Left - Push the knob forward The state of the finger tip ECU can be checked by smoothly to shift the carriage to the left. the external warning lamp blinking. Sideshift Hold - Release the sideshift Blinking Lamp State attachment knob.
  • Page 67 Operation Section Adjustment of Armrest Up and Down Adjustment To move the armrest down, turn the knob(2) By using 4 knobs, adjust the position of the armrest counterclockwise. to give the operator the best comfortable position of arm. knob #1 - Forward and backward adjustment knob #2 - Up and down adjustment knob #3 - Clockwise and Counterclockwise rotation adjustment...

  • Page 68: 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 69 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 70 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 71: Parking The Lift Truck

    Operation Section Parking the Lift Truck NOTICE Parking or storage of electric lift trucks outdoor can cause lift truck system damage or failure. Park or store all electric lift trucks inside a building to protect electrical system from moisture damage. When leaving the operator’s station, park the lift 3.
  • Page 72 Operation Section Typical : B25S-5 Typical : BC25S-5 6. Disconnect the battery. 7. Block the wheels if parking on an incline. Packing Alarm Warning (If Equipped) When leaving the operator’s station without engaging the parking brake, a warning buzzer will sound.

  • Page 73: Lift Fork Adjustment

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

  • Page 74: Storage Information

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

  • Page 75: Transportation Hints

    Check the state and local laws governing weight, width and length of a load. Contact your DOOSAN Lift Truck dealer for shipping instructions for your lift truck. 1. Always block the trailer or the rail car wheels before loading the lift truck.

  • Page 76: Towing Information

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

  • Page 77: Inspection, Maintenance And Repair Of Lift Truck Forks

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following provides practical guidelines for Forks should be properly sized to the weight and inspection, maintenance and repair of lift truck forks. length of the loads, and to the size of the machine It also provides general information on the design on which they are used.
  • Page 78 Maintenance Section Repetitive Overloading Causes of Fork Failure Repetitive cycling of loads which exceeds the Improper Modification or Repair fatigue strength of the material can lead to fatigue failure. The overload could be caused by loads in Fork failure can occur as a result of a field excess of the rated fork capacity and by use of the modification involving welding, flame cutting or forks tips as pry bars.
  • Page 79 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 80 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 81: 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. Ply Rating or Size Shipping preeeure Strength Index B20/25/30/32S-5 18 x 7 – 8...

  • Page 82: Torque Specifications

    Maintenance Section Torque Specifications Metric Hardware - This lift truck is almost totally Torque for Standard Bolts, Nuts metric design. Specifications are given in metric and Taperlock Studs U.S. Customary measurement. Metric hardware must be replaced with metric hardware. Check parts books for proper replacement. NOTICE NOTE: Use only metric tools on most hardware for The following charts give general torques for bolts,...
  • Page 83 Maintenance Section Torques for Taperlock studs Torque for Metric Fasteners Standard Taperlock Stud Thread Size NOTICE Torque Inch N•m lb•in Be very careful never to mix metric with U.S. 8±3 6±2 customary (standard) fasteners. Mismatched or 5/16 17±5 13±4 incorrect fasteners will cause lift truck damage or malfunction and may even result in personal injury.

  • Page 84: 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 85 The API GL 4 specification or SAE 80W oils could be used. NOTE: Multi-grade oils blended DOOSAN for use in transmissions. Multi- grade oils which use high molecular weight polymers as viscosity index improvers lose their viscosity effectiveness by permanent and temporary shear of the viscosity index Located on the left site of the cowl.

  • Page 86: Battery Discharge Indicator

    Maintenance Section Battery Discharge Indicator The battery discharge indicator should be observed This specification varies with different battery frequently before and during operation. manufacturers. See the manufacturer’s specifications for specific gravity at 80% discharge. If information is not available from the battery supplier, use 1.140 specific gravity level.

  • Page 87: Battery

    Maintenance Section Battery The lift truck operator must not start his shift with a battery that has been taken off a charger too soon. Batteries are designed to be charged and allowed When using pressure air for cleaning purposes, to cool and stabilize. A battery should never be wear a protective face shield and protective disconnected from a charger until the charge cycle clothing.
  • Page 88 Maintenance Section A battery should never be left in a discharged state because of sulfate formation. This reduces battery NOTICE life drastically. To extend life always recharge the DISPOSAL OF OLD BATTERY battery without delay after it has been discharged. Careless disposal of a battery can harm the Repeated over discharging of the battery will environment and can be dangerous to persons.

  • Page 89: Cold Storage Applications

    Maintenance Section Cold Storage Applications When an electric lift truck is operated in cold Hydraulic System storage applications, at temperatures as low as - 20°C (-4°F), the battery capacity is decreased. Operation at cold temperatures can also cause mechanical failures, short circuits and too much wear due to the formation of ice crystals.
  • Page 90 Maintenance Section 3. Put MPGM grease on the chains at one-week intervals. 4. Check chains very carefully for wear on the link plate edges, caused when they run over the sheaves. Check the chains regularly for cracked links, loss of shape in the holes, and corrosion.

  • Page 91: 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 Imperial Liters U.S. Gal Compartment °C °F System or System Viscosities Min Max Min Max Hydraulic & Power Hydraulic ISO VG 22 Steering System and Power...

  • Page 92: Maintenance Intervals

    Maintenance Section Maintenance Intervals Every 500 Service Hours or 3 Months NOTICE Drive Axle Oil - Change ........113 All maintenance and repair, except every 10 service Cylinder Rod Extension - Adjust ......114 hours or daily, on the lift truck must be performed Crosshead Rollers - Check........114 by qualified and authorized personnel only.
  • Page 93 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS PAGE Back - up Alarm (If Equipped) Test Check, Exchange, Battery Change Brake System Check Oil Level Carriage Roller Extrusion Adjust Compact Display Keys Control Panel Clean, Inspect Crosshead Rollers Check Cylinder Rod Extension Adjust...

  • Page 94: When Required

    Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any aperation or maintenance procedures. Self Diagnostics - Test 5. Move the key switch to OFF. Compact Display Keys Test Circuits and Components The Micro-Controller has a built-in diagnostic system to provide aid in rapid troubleshooting of lift truck problems.

  • Page 95: Run Time Diagnostic

    Maintenance Section UP key Run Time Diagnostic 1. Pressing of this key, 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 key Remember that pressing this key you can toggle between slow running and normal working condition (if the lift truck is already in speed limitation mode).
  • Page 96 Maintenance Section · º ° º ° º ° º ° º ° º °...
  • Page 97 Maintenance Section Table 11 : List of accessible parameters in diagnostic mode (from 1th to 54th).

  • Page 98: Carriage Roller Extrusion - Adjust

    Maintenance Section In diagnostic mode selected parameter is visualized Carriage Roller Extrusion – Adjust as follows: 1. Set the mast vertical. - In the area dedicated to speed and alarm signals, appears parameter number( flashing) 2. Lower the carriage completely. - Its actual value is displayed in the area reserved 3.
  • Page 99 Maintenance Section Power Modules – Discharge 2. Open the rear door. (36V / 48V) Personal injury could result if power modules have not been discharged properly. Battery voltage and high amperage are present. The power modules must be discharged before any contact with the electrical control system is made.

  • Page 100: Fuses - Replace

    If it is necessary to replace fuses frequently, an electrical problem exist. Contact your DOOSAN Lift Truck dealer. Horn - 10 amps DC/DC converter- 10 amps Lights(1) - 10 amps Lights(2) - 10 amps FAN - 10amps Key Switch - 10amps (36V / 48V) Check the operation of the seat adjusters.

  • Page 101: Wheel Bolts - Check For Tightness

    Maintenance Section Drive Axle Gear Boxes Wheel Bolts - Check for Tightness NOTE: If there is a leak from drive axle, the oil level Steer Wheels should be measured as follows. Measure Lubricant Level Typical example 1. Inspect tightness of wheel nuts in a sequence opposite each other 100 N•m (75 lb•ft).

  • Page 102: 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 aperation 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 103 Maintenance Section 12. Move the directional lever to NEUTRAL. 9. Inspect the drive axle housing and the ground for oil leaks. Refer to “Drive Axle” in “Every 1000 Service Hours or 6 Months” section, if an oil leak is found. 13.

  • Page 104: 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. Typical : B25S-5 The channels on the roller-type mast require a break-in period.
  • Page 105 Maintenance Section Check Electrolyte 3. Check the specific gravity of the battery. If the 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 106: Check

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

  • Page 107: Tires And Wheels - Inspect

    Maintenance Section Tires and Wheels - Inspect Inflate the tires, if necessary. See “Tire Inflation Information” section of this manual. Inspect tires and valve stems for wear, cuts, gouges and foreign objects. Back - up Alarm (If Equipped) - Test Check all components carefully and replace any cracked, badly worn, damaged and severely rusted With the key switch on, apply the service brake and...

  • Page 108: First 50 - 100 Service Hours Or 3 Months

    Maintenance Section First 50 - 100 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 aperation or maintenance procedures. Drive Axle - Change Oil After first 50~100...

  • Page 109: Every 250 Service Hours Or Monthly

    Maintenance Section Every 250 Service Hours or Monthly You must read and understand the warnings and 5. Clean the housing base. instructions contained in the Safety section of this manual, before performing any aperation or maintenance procedures. Hydraulic Return Filter - Change Filter Element Hot oil and components can cause personal injury.

  • Page 110: Brake System - Check Oil Level

    Maintenance Section Brake System - Check Oil Level 3. Engage the parking brake. 4. Release the service brake. The brake system reservoir is located at the right side of the steering column. If the parking brake has the correct adjustment, the lift truck will be held in place.

  • Page 111: Mast Hinge Pins - Lubricate

    Maintenance Section Mast Hinge Pins - Lubricate Tilt Cylinders - Check, Adjust, Lubricate Lubricate two fittings Chassis Pivot Eyebolts – Lubricate 1. Lower the forks and tilt the mast forward. Typical Example 1. Remove floor plates. 2. Lubricate the mast hinge pins. One fitting on each side of the mast.

  • Page 112: Hydraulic And Power Steering

    Maintenance Section Mast Pivot Eyes – Lubricate Hydraulic and Power Steering System - Check Typical Example 1. Operate the lift truck for a few minutes to warm the oil. 1. Lubricate two fittings for the mast pivot eyes, one on each side of the pin. 2.

  • Page 113: Steer Angle Switches - Check

    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 114 Maintenance Section 5. Raise and lower the carriage a few times to work lubricant into the chain links. NOTICE Lubricate chains more frequently than normal where the atmosphere can cause corrosion to components, or when lift truck must work in rapid lift cycles.

  • Page 115: 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 aperation or maintenance procedures. Drive Axle Oil - Change See topic, “ Drive Axle Oil - Change ” in “ First 50 - 100 Service Hours ”.

  • Page 116: 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 117: Mast Hinge Pin - Lubricate

    Maintenance Section Mast Hinge Pin – Lubricate Steering - Lubricate Lubricate one fitting Typical Example 1. Lower the forks and the carriage. Lubricate fitting on steer axle. Overhead Guard - Inspect 2. Lubricate the two fittings for the mast hinge pins, one on each side of the mast.

  • Page 118: Control Panel - Clean, Inspect

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

  • Page 119: Directional Lever - Check

    Maintenance Section Directional Lever - Check Check the tightness of the directional lever mounting bracket. Adjust if needed. Check for ease of movement of directional lever. Adjust if needed. Check for loose wiring. Secure wiring if needed.

  • Page 120: Every 1000 Service Hours Or 6 Months

    Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any aperation or maintenance procedures. Drive & Pump Motor - Clean, Inspect Typical : B25S-5 4.
  • Page 121 Maintenance Section Battery voltage and high amperage are present. The power modules must be discharged before any contact with the control panel is made. Personal injury could result if it has not been discharged properly. 9. Blow off the drive motor end shield with 205 kPa (30 psi) maximum air pressure, until dust is removed from the motor.

  • Page 122: Tires And Wheels - Inspect, Check

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

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

    Maintenance Section Check for Equal Tension Lift Chains - Test, Check, Adjust Lift Chain Wear Test Inspect the part of the chain that is normally operated over the cross head roller. When the chain bends over the roller, the movement of the parts against each other causes wear.
  • Page 124 Maintenance Section Carriage Chain Adjustment Mast Chain Adjustment - FF,FFT QUAD Mast Make sure that carriage height is correct. If correct, adjust the chain for equal tension. If not, adjust the chain for correct carriage height by adjusting anchor nuts(1),(2). NOTE: See the previous section, “Carriage Roller Extrusion”...

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

  • Page 126: Steer Wheel Bearings - Reassemble

    Maintenance Section Steer Wheel Bearings - Reassemble Park the lift truck level with the forks lowered, parking brake engaged, and directional control lever in NEUTRAL. NOTE: The procedure is shown on a BC-Series lift truck. It is the same for B, BC-Series lift trucks.
  • Page 127 Maintenance Section 4. Remove the locknut, lock washer and flat 8. Install the outer wheel bearing and the out washer. Remove the outer wheel bearing. washer. Install a new lock washer and fit the locknut. Typical Example 9. Tighten the locknut to 135 N•m (100 lb•ft), while turning wheel hub to seat the bearing.

  • Page 128: Fork - Inspect

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

  • Page 131: Environment Section

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

  • Page 132: Index

    Index Section Index Drive Wheels............93 During Storage ............67 12 Months Inspection.......... 73 Electrical Braking (Plugging)........55 Emergency Switch..........58 Emergency Switch (If Equipped)......45 Adjusted Inflation Pressures........ 74 ENTER key ............86 Adjustment of Armrest......... 59 E-S-H key ............87 After Storage ............67 Every 10 Service Hours or Daily ......85 Attachment Abbreviations (includes Special Forks) Every 1000 Service Hours or 6 Months....85 ................
  • Page 133 Index Section Run Time Diagnostic ...........87 LED Indicators ............ 42 Lift Chain Adjustment........113 Lift Chain Wear Test ......... 113 Lift Chains ............82 Seat Adjustment..........44 Lift Chains - Test, Check, Adjust ....... 113 Seat Switch............38 Lift Control knob..........57 Self Diagnostics - Test.........86 Lift Control Lever ..........

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