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Table of Contents
Related Manuals for Doosan B30X-7 PLUS
Summarization of Contents
Information Section Overview
Foreword Details
Manual should be stored in operator's compartment. Contains safety, operation, transportation, lubrication, and maintenance info.
Safety Section Introduction
Lists basic safety precautions and identifies warning signs and labels used on the lift truck.
Operator Restraint System Information
Manual contains safety, operation, and maintenance info for the DOOSAN operator restraint system.
Operational and Environmental Information
Operation Section Overview
Reference for new and experienced operators on gauges, switches, controls, attachments, and transportation.
Maintenance Section Overview
Guide to equipment care with illustrated, step-by-step instructions grouped by servicing intervals.
Maintenance Intervals Guide
Use service hour meter to determine intervals. Calendar intervals can be used if more convenient.
Environmental Management System
Doosan's Environmental Commitment
Details Doosan's ISO 14001 certification and its environmental management system.
Critical Safety Information
Important Safety Information
Accidents caused by not observing safety rules. Need for alertness, common sense, and training.
General Safety Guidelines
Safety Rules and Regulations
Rules and regulations for lift trucks, paraphrased from CFR, NFPA, ANSI/ITSDF, and EU directives.
Warning Signs and Labels Identification
Identifies specific safety signs on your lift truck, their location, and hazard description.
Training Required for Operation and Service
Warning about improper operation or maintenance. Emphasizes proper training and manual understanding.
Operator Safety Warnings
General Warnings for Operator Safety
Lists 20 general warnings for operators regarding safe operation, load handling, and truck control.
Specific Safety Hazards and Equipment
Hand Placement Hazard Warning
Warning against placing hands in mast area. 'No hands' warning shown on mast.
No Standing On Forks Warning
Warning against standing or riding on forks or under forks. Shown on lift cylinder.
Load Backrest Required Warning
Operation without load backrest is hazardous. Label located on the load backrest.
Overhead Guard Required Warning
Operation without overhead guard is hazardous. Guard conforms to ANSI B56.1 and FEM Section IV.
Operational Safety Warnings
No Riders Warning
Warning to avoid personal injury; lift truck is for one operator only, no riders.
Parking Brake Operation Warning
Parking brake engages automatically. Do not exit before engaged. Emergency switch use can damage brake.
Battery Restraint System Warning
Ensure hood is locked and stopper is in locking position to prevent battery coming out in tipover.
Electrical System Safety
Battery Disconnect Before Servicing Warning
Disconnect battery and discharge high voltages before servicing. Shows controller diagrams.
Seat Switch Safety Warning
Install seat correctly. Switch must shut off power when operator is not seated.
General Hazard Identification
General Hazard Information
Details hazards like proper tagging, protective equipment, load handling, pedestrian awareness, and fluid hazards.
Component Safety and Operation
Lift Chains Inspection Procedure
Instructions for inspecting lift chains for wear, damage, and proper link pin extension.
Operation Information: Mounting and Dismounting
Steps for safely mounting and dismounting the lift truck, emphasizing using both hands and handgrips.
Before Starting the Lift Truck Checks
Procedures for walk-around inspection, seat adjustment, and ensuring controls are operational.
Lift Truck Operation and Safety
Operating the Lift Truck Safely
Guidelines on keeping the truck under control, obeying traffic rules, and safe operation practices.
Starting the Lift Truck Procedures
Instructions for starting the lift truck, including checks and avoiding 'DO NOT OPERATE' tags.
Pre-Operation Checks
Testing brakes, steering, horn, and other devices. Learning truck operation and attachment functions.
Operational and Safety Procedures
Loading or Unloading Trucks/Trailers
Procedures for loading/unloading trucks/trailers, ensuring brakes are applied and chocks are used.
Lift Truck Parking Procedures
Steps for parking the lift truck in authorized areas, including lowering forks and engaging the parking brake.
General Maintenance Information
General instructions for performing maintenance, including parking location and switch operations.
Pressure Air Safety Precautions
Safety precautions when using pressurized air for cleaning, including pressure limits and protective gear.
Fluid Penetration Hazard Warning
Warning about escaping fluid under pressure causing injury. Seek medical attention if injected.
Crushing or Cutting Prevention Tips
Tips for supporting equipment, staying clear of moving parts, and avoiding adjustments while moving.
Component Safety and Hazards
Burn Prevention Warnings
Warnings about hot oil and components, hydraulic tank pressure, and relieving system pressure.
Battery Safety Precautions
Safety guidelines for working with batteries, including protective gear, ventilation, and avoiding sparks/flames.
Falling Objects Protective Structure (FOPS)
Information on the FOPS, its purpose, limitations, and restrictions on altering the structure.
Fire, Explosion, and Tire Safety
Fire or Explosion Prevention Measures
Precautions for flammable materials, electrical connections, fuels, lubricants, and welding.
Fire Extinguisher Requirements
Requirement for a BC type fire extinguisher and proper use and inspection.
Lines, Tubes, and Hoses Safety Guidelines
Guidelines for inspecting and repairing high-pressure lines, tubes, and hoses to prevent leaks and fires.
Tire Information and Safety Precautions
Warnings about tire explosions, safe distances, and recommended nitrogen inflation.
Tire and Restraint System Safety
Nitrogen Inflated Tires Benefits
Benefits of nitrogen tires reducing explosion risk, preventing oxidation, and tire deterioration.
Operator Restraint System: Tipover Warnings
Describes tipover warning decals and the importance of familiarizing oneself with safe operation.
Warning Signs and Labels Maintenance
Instructions to ensure all safety signs are readable, clean or replace damaged labels.
Seat Adjustment Ergonomics
Seat Adjustment: Forward and Backward
Instructions for forward/backward adjustment of Daewon and Grammer seats before driving.
Seat Weight Adjustment Hazard Warning
Warning about placing hands under the seat during weight adjustment due to suspension movement.
Seat Adjustment Caution
Caution regarding potential injury from seat suspension movement during up/down adjustment.
Seat and Restraint System Adjustments
Daewon Seat Weight Input Adjustment
Instructions for adjusting Daewon seat weight input based on user's weight (50-130 kg).
Grammer Seat Weight Input Adjustment
Instructions for adjusting Grammer seat weight input based on user's weight (50-170 kg).
Backrest Inclination Adjustment
Instructions for tilting the backrest backward or forward using the lever.
Lumbar Support Adjustment (Grammer Seat)
Instructions for adjusting lumbar support on a Grammer seat by tilting the lever.
Seat Belt System Safety
Seat Belt System Function
Explains the operator restraint system's purpose in tipover situations and its design to keep operator secure.
Seat Belt Inspection Procedures
Procedures for inspecting seat belts for tears, winding device function, and proper fastening to the seat.
Fastening the Seat Belt Correctly
Instructions for fastening the seat belt correctly, ensuring the plate clicks into the buckle.
Seat Belt Safety and Release
Seat Belt Hazard Warning
Warning about fastening the seat belt across the abdomen potentially causing injury in an accident.
Releasing the Seat Belt Procedure
Instructions for releasing the seat belt by pushing the buckle button and allowing slow retraction.
Lift Truck Stability and Tipover Prevention
Avoiding Lift Truck Tipover Principles
Explains lift truck stability based on balance, center of gravity (CG), and factors affecting it.
Lift Truck Stability Fundamentals
Counterbalanced design principle based on balancing weights. Load must balance truck weight.
Stability and Center of Gravity Factors
Defines CG and factors affecting stability like load size, height, tilt, tire pressure, and surface condition.
Load Capacity and Stability Base
Lift Truck Stability Base Requirements
CG must stay within the stability base (triangle between front wheels and steer pivot) to prevent tipover.
Capacity Load and Load Center Information
Explains how capacity load is determined by weight and load center, and where to find rating plates.
Essential Safety Rules for Operation
General Safety Rules for Operators
Rules for authorized personnel, seat position, hand/foot placement, sudden movements, and wet conditions.
Additional Operational Safety Rules
Load Handling and Ground Condition Safety
More rules on load handling, overloading, ground conditions, signs, and preventing tipover.
Advanced Operation Safety Rules
Load Stability and Tipover Prevention Rules
Rules on not allowing riders, handling loads, avoiding tipover, and operating on inclines.
Site-Specific Safety Rules
Site Safety Rules for Ramps and Crossings
Rules on stacking, inclines, rough terrain, railroad crossings, loose objects, and bridge plates.
Vehicle Interaction and Parking Safety
Vehicle Interaction and Parking Safety Rules
Rules on operating near other trucks, pushing/towing, parking, and keeping distance from materials.
Lift Truck Characteristics and Towing
Forklift Truck Characteristics vs. Cars
Highlights differences from cars: small tires, no suspension, heavy weight, changing CG.
Special Attachments Safety and Training
Mentions availability of attachments, their safety implications, and recommends special training.
Towing Information and Procedures
Information on towing in emergencies, speed limits, and the draw bar.
Tipover Survival Procedures
How to Survive a Tipover (Operator Restraint)
Instructions to reduce injury risk in a tipover by using the restraint system and following provided instructions.
General Section: Compliance Documents
Declaration of Conformity (EU)
Declares equipment conforms to EC Directives and harmonized standards, lists manufacturer details.
General Section: UK Compliance
Declaration of Conformity (UK)
Declares equipment conforms to UK regulations and standards, lists manufacturer and representative details.
Lift Truck Specifications
Technical Specifications: B25X-7 PLUS
Detailed technical specifications for the lift truck, including dimensions, weight, performance, and power train.
Model Specification Comparison
Technical Specifications: B30X-7 PLUS & B35X-7 PLUS
Comparative specifications for B30X-7 PLUS and B35X-7 PLUS models, including dimensions and performance.
Noise and Vibration Levels
Operator Ear Noise Levels
Operator ear noise levels measured by PREN 12053, with and without cabin.
Lift Truck Load Capacity Charts
Capacity Chart: Standard and FFL Masts
Charts showing load capacity based on mast type and model, for standard and full free lift masts.
Capacity Charts with Integrated Side Shifter
Capacity Chart: Integrated Side Shifter
Load capacity charts for models with integrated side shifters, across various mast types.
Capacity Charts with Hook-on Side Shifter
Capacity Chart: Hook-on Side Shifter
Load capacity charts for models with hook-on side shifters, across various mast types.
Vehicle Identification
Serial Number Recording
Section for recording lift truck serial numbers for quick reference.
Operator Information Plates
Operator Warning and Identification Plates
Familiarization with identification, lift capacity, and attachment plates. Avoid exceeding load ratings.
Technical Reference Data
Mast Type Abbreviations
Explanation of abbreviations used to indicate mast types installed on the lift truck.
Operation Section: Operator Controls
Operator Station and Monitoring Systems
Overview of operator controls and monitoring systems, emphasizing reading Safety, Operation, and Maintenance sections.
Key Switch Functionality
Location and function of the key switch for turning power on/off and its relation to the power steering motor.
Seat Switch Safety Feature
Function of the seat switch located under the operator's seat, which connects/disconnects electrical circuits.
Safety Interlock Systems
Seat Belt Switch Functionality
Function of the seat belt switch; electric circuit cuts off if belt is not worn. Notes on sequence errors.
Lift Neutral Sensor Function
Location and function of the lift neutral sensor in the main control valve for safety purposes.
System Monitoring and Indicators
Monitoring Systems Indicator Overview
Explanation of symbols on the instrument panel and their functions, including speed and battery indicators.
Display Segments Information
Information provided by the display: lift truck speed, warning symbols, and time gauge/odometer.
LED Indicator Functions
Description of the 4 LEDs on the COMPACT display for warning messages, lamps, and seat belt warnings.
System Status and Codes
Battery Charge Level Indicator Table
Table showing relation between battery charge level (BDI) and visualized bars on the display.
Abbreviated System Codes Reference
Table of abbreviated codes used to display system operating conditions and their meanings.
System Codes Reference (Continued)
Abbreviated System Codes (Continued)
Continuation of the table listing abbreviated codes for various system faults and conditions.
Audio System Operation and Precautions
Audio System Overview and Power
Information on the audio system, its power supply, and authorized service centers.
Audio System Safety Precautions
Safety warnings for the audio system, including avoiding rain/moisture and using included components.
Safe Operation of Audio Functions
Precautions for safe operation of audio functions, keeping volume low, and minimizing display viewing.
Audio System Controls Layout
Location of Controls: Front View
Diagram and description of buttons and controls on the front view of the audio system.
Audio System Display and Connectors
Display Window Functionality
Explanation of the display window's function areas, indicators for Bluetooth, DAB, and USB/AUX.
Rear View and Connectors Guide
Details on antenna jacks, I/O connector, and list of available rear view connections and their functions.
Audio System Basic Operation
Getting Started: Turning Unit On/Off
Instructions for turning the audio unit on/off using ignition key and power button.
Adjusting Volume Directly
Instructions for using the VOLUME dial to control audio volume, including available range.
Muting the Sound Quickly
How to mute the sound using the MUTE button and restore it.
Setting the Sound Parameters
Guide to accessing sound settings, adjusting EQ, BASS, MIDDLE, TREBLE, and BALANCE.
Bluetooth Feature Setup
Setting the Bluetooth Mode
Steps to select Bluetooth mode, pair devices, set MIC/H/F volume, and manage phone book.
DAB and System Function Settings
Setting the DAB Feature
Instructions for setting DAB features like Service follow and Short label, and turning the feature on/off.
Setting System Functions
Guide to configuring system functions: Bluetooth ON/OFF, scroll, loudness, beep, and software.
Region and System Software Management
Setting the Region for Radio/DAB
Instructions for setting the radio/DAB region (Europe, Asia, North America) for proper reception.
Checking and Updating System Software
Procedure for checking and updating the system software using a USB device.
Radio Operation and Station Saving
Radio: Tuning in a Radio Station
Instructions for selecting radio bands (FM/AM) and tuning stations using TUNE dial or auto-scan.
Saving Radio Stations Manually
How to save up to 6 preset channels for FM1, FM2, AM1, and AM2 bands.
Saving Radio Stations Automatically
How to automatically save up to 6 preset channels for FMA and AMA bands using AST button.
Preset and DAB Station Listening
Listening to a Preset Radio Station
How to listen to saved preset radio stations using PRESET buttons.
DAB: Listening to a DAB Station
Instructions for entering DAB mode, displaying service/ensemble names, and tuning DAB stations.
DAB Service and Ensemble Search
Changing the DAB Service
Procedure to show DAB service list and select desired service name using TUNE dial.
Seeking Full Ensemble Stations
How to automatically seek available ensembles by pressing and holding ENTER or DAB button.
USB Player Operation Precautions
USB Player: Handling Precautions
Precautions for using USB devices, including connection timing, compatibility, formatting, and avoiding abrupt disconnection.
MP3/WMA Support and USB Playback
MP3/WMA File Format Support
Details on supported MP3/WMA file formats, bit rates, sampling frequencies, and disc types.
Playing a USB Device
Steps for playing a USB device: plug in, select USB mode, and use playback controls.
USB Playback Control
Changing Song Information Display
How to display file information like name, playing time, ID3 Tag, or folder name using the INFO button.
Controlling USB Playback
Instructions for navigating tracks/folders, fast forward/rewind, pausing, and searching for songs.
USB Playback Mode Selection
Changing USB Playback Mode
How to select Repeat playback mode (file/folder) and Random playback mode (folder/device).
Bluetooth Technology and Music
Bluetooth Wireless Technology Overview
Explanation of Bluetooth wireless technology, its functions, and connection status indicators.
Bluetooth Music Mode Operation
Details on using Bluetooth Audio mode, compatibility, and potential sound issues.
Bluetooth Device Pairing and Music Playback
Pairing and Connecting Your Bluetooth Device
Step-by-step guide for pairing and connecting Bluetooth devices to the unit.
Playing Bluetooth Music
Instructions for selecting BT Audio mode and playing music from a connected Bluetooth device.
Bluetooth Playback and Call Management
Controlling Bluetooth Music Playback
How to control Bluetooth music playback, including track navigation and checking connected device info.
Answering and Making Bluetooth Calls
Instructions for answering, rejecting, and making calls using the Bluetooth hands-free function.
Bluetooth Call Feature Operations
Bluetooth Call Feature Operations
Details on switching between handset/hands-free modes, call waiting, and ending calls.
Troubleshooting Common and Audio Issues
Troubleshooting: Common System Issues
Table of common symbol issues (no sound, noise) and their possible causes and remedies.
Troubleshooting: Radio/DAB Issues
Table of radio/DAB issues (no reception, seeking time, poor reception) and their causes/remedies.
Troubleshooting Connectivity Issues
Troubleshooting: USB Connection Issues
Table of USB issues (not working, no audio) and their possible causes and remedies.
Troubleshooting: Bluetooth Connection Issues
Table of Bluetooth issues (function not working, no audio) and their causes/remedies.
Functional Safety System Overview
Functional Safety System Description
Overview of safety functions that switch the vehicle to neutral for safety purposes.
Seat and Seat Belt Interlock
Details the seat and seat belt interlock, including sequence errors and how to clear alarms.
Seat Belt Switch Functionality
Explains the seat belt switch function, its effect on electric circuits, and handling sequence errors.
FR Control System Faults
Describes FR control faults (EE/AF) triggered by incorrect neutral position or FNR knob issues.
Lever Neutral Detection Safety
Function of lift neutral sensor; lift is only available when lever is neutral, prevents FL error.
Parking Brake Operation Notes
Notes on the parking brake engaging automatically and how to release it.
Performance Level Standards
Performance Level Based on ISO Standards
Shows Performance Level based on ISO 13849-1/2:2015 for counterbalance and reach trucks.
Lift Truck Control Systems
Parking Brake Control
Instructions for parking brake activation, release, and warnings against misuse.
Service Brake Pedal Operation
Location and function of the service brake pedal for slowing or stopping the lift truck.
Accelerator Pedal Operation
Location and function of the accelerator pedal for controlling travel speed and warnings about simultaneous use.
Directional Control Switch Operation
Directional Control: Forward/Reverse Switch
Explains operation of the forward/reverse switch for driving direction and its role in wait mode.
Lift and Tilt Control Levers
Lift Control Lever Operation
Instructions for operating the lift control lever to lower, hold, and raise the lift forks smoothly.
Tilt Control Lever Operation
Instructions for operating the tilt control lever to tilt forks forward, hold, or tilt back smoothly.
Attachment and Speed Control Features
Sideshift Attachment Control Operation
Instructions for operating the sideshift control lever to move the carriage left, hold, or right.
Auto Tilt Control (If Provided)
Operation of the auto tilt controller to stop the mast at 90 degrees angle and smooth load control.
Speed Limit Functionality (If Provided)
Explanation of the speed limit function and how to select modes (1500, 2000, 2500 rpm).
Guardian Stability System (GSS)
GSS Functionality and Options
Details the GSS basic function and options like forward tilt angle limit and alarm.
Pre-Operation Inspection Procedures
Walk-Around Inspection Checklist
Thorough walk-around inspection steps for safety and maximum service life, covering various components.
Pre-Operation Checks and Adjustments
Pre-Operation Checks (Continued)
Inspection of battery compartment, seat/steering adjustment, and battery discharge indicator.
Battery Status and Performance
Pre-Operation Battery Charge Check
Ensuring battery is charged before operation and notes on battery performance.
Better Battery Performance Advice
Notice on not starting a shift with a partially charged battery and proper charging cycles.
Lift Truck Operation Steps
Lift Truck Operation: Basic Steps
Steps for operating the lift truck: seat adjustment, seat belt, neutral position, turning on key, and moving.
Electrical Braking Technique
Electrical Braking (Plugging) Procedure
How to use electrical braking by moving the directional control lever to slow or stop the truck.
Optional Control Systems
Steering Knob (If Equipped)
Information on the optional steering knob for slow travel and its limitations.
Mono-Ped Control System (Option)
Explanation of the Mono-Ped pedal for controlling forward/reverse travel and speed.
Finger Tip Control Operations
Lift Control Knob Operation
Instructions for operating the lift control knob to lower, hold, and raise the forks smoothly.
Tilt Control Knob Operation
Instructions for operating the tilt control knob to tilt forks forward, hold, or tilt back smoothly.
Attachment and Emergency Controls
Sideshift Attachment Control Operation
Instructions for operating the side shift control knob to move carriage left, stop, or right.
Emergency Switch Operation
Instructions for using the emergency switch to stop the forklift in an emergency situation.
Directional Control Switch Operation
Directional Control Switch Functionality
Explains operation of the directional control switch for forward, neutral, and reverse travel.
Additional Control Systems
Horn Button Operation
Location and function of the horn button on the directional control switch.
Auto Tilt Control (If Provided)
Operation of the auto tilt controller to stop the mast at 90 degrees angle and smooth load control.
Auto Clamp Control (If Provided)
Operation of auto clamp switch for AUX2 knob, and conditions for AUX2 locking.
Armrest Adjustment Ergonomics
Armrest Adjustment Procedures
Instructions for adjusting armrest positions using two devices: forward/backward and upward/downward.
Operating Techniques for Load Handling
Inching into Loads Procedure
Guidance on moving the truck slowly into position, engaging the load squarely, and spacing forks.
Lifting the Load Safely
Steps for lifting loads carefully, tilting the mast back, and moving the truck in reverse.
Traveling and Turning Techniques
Traveling With or Without a Load
Tips for traveling with loads low, uphill/downhill, and reversing with bulky loads for better vision.
Lift Truck Turning Techniques
Techniques for turning sharp corners and in narrow aisles, considering counterweight swing.
Turning Dynamics Explained
Lift Truck Turning (Continued)
Explanation of how steer wheel angle affects drive motor speeds during turning.
Load Unloading and Handling
Unloading Lift Truck Procedures
Steps for unloading: positioning, tilting mast forward over area, depositing load, and backing away.
Lifting Drums or Round Objects
Procedure for lifting drums/round objects: blocking, tilting mast, sliding forks, and lifting.
Attachment Safety Instructions
Safety for Transporting Suspended Loads
Warnings for suspended loads: reduced capacity, adapting speed, securing loads, and expert certification.
Safety for Transporting Wide Loads
Guidance on load lateral CG, stability, swing, shift, and visibility when handling wide loads.
Lift Truck Parking Procedures
Parking the Lift Truck Safely
Steps for parking: applying service brake, neutral control, parking brake engagement, and turning off the key.
Lift Truck Parking Final Steps
Parking the Lift Truck (Continued)
Final steps for parking: disconnecting the battery and blocking wheels on inclines.
Lift Fork Adjustment Procedure
Lift Fork Adjustment for Hook-on Type
Instructions for adjusting fork spread (hook-on type), ensuring centering and locking.
Storage Information and Procedures
Storage: Before Extended Storage
Measures for extended storage: washing, drying, housing indoors, lubricating, and covering batteries.
Storage: During Storage Recommendations
Recommendation to drive the truck monthly to coat moving parts and charge the battery.
Storage: After Storage Treatment
Treatment before operation after storage: draining water, wiping grease, checking battery charge.
Transportation and Lifting Guidelines
Transportation Hints: Shipping Preparations
Checks for shipping: travel route clearance, removing slippery materials, and obeying load regulations.
Machine Lifting and Tiedown Information
Guidelines for lifting and tiedown, emphasizing proper equipment, weight, and tiedown locations.
Forklift Lifting Procedures with Crane
Lifting a Forklift using a Crane
Safety warnings and procedures for lifting an electric forklift with a crane, including battery removal.
Forklift Securing to Carrier
How to Fix Forklift to a Carrier
Steps for fixing the forklift to a carrier: parking, mast position, neutral controls, and securing with hooks.
Towing Disabled Lift Trucks
Towing Information: Procedures and Warnings
Detailed instructions and warnings for towing a disabled lift truck, emphasizing safety and low speeds.
Towing Procedures (Continued)
Towing Information (Continued)
Connect EMCONN B and EMERGENCY C, tighten traction bar, remove chocks, and tow carefully.
Maintenance Section: Fork Care
Inspection, Maintenance, and Repair of Lift Truck Forks
Guidelines for fork inspection, maintenance, repair, design, application, and common failure causes.
Fork Failure Analysis
Causes of Fork Failure
Details common causes of fork failure: improper repair, bending, fatigue, repetitive overloading, and wear.
Fork Inspection Procedures
Fork Inspection: First Installation
Steps for inspecting forks upon first installation: size, length, type, and blade level.
Fork Inspection: Daily and Preventive
Daily and preventive inspection steps: checking for cracks, weld areas, and positioning locks.
Fork Maintenance Schedule and Practices
12 Months Fork Inspection Requirement
Requirement for forks inspection every 12 months, or every 6 months for multi-shift operations.
Fork Maintenance and Repair Guidelines
Guidelines on proper fork repairs, modifications, and parts that should not be attempted.
Fork Repair and Modification Rules
Fork Repairs and Modifications
Details allowed repairs (sanding, grinding) and prohibited modifications (flame cutting, welding cracks).
Detailed Fork Inspection Points
Fork Inspection Details
Inspection points: cracks, weld areas, fork tips, bent blades, shank wear, and positioning locks.
Fastener Torque Specifications
Torque Specifications: Metric Hardware
Specifications for metric hardware, emphasizing using metric tools and correct replacement parts.
Torque for Standard Hose Clamps
Torque values for initial installation and reassembly of worm drive band hose clamps.
Torque for Standard Bolts, Nuts, Taperlock Studs
General torques for SAE Grade 5 or better bolts, nuts, and taperlock studs.
Taperlock Stud and Metric Fastener Torques
Torques for Taperlock Studs
Torque specifications for various inch-sized taperlock studs.
Torque for Metric Fasteners
Precautions and torque values for metric fasteners, emphasizing correct matching and Grade 8.8 bolts.
Lubricant Specifications and Recommendations
Lubricant Specifications: General Information
Classifications and abbreviations for lubricants, SAE nomenclature, and MIL specifications.
Chain and Linkage Oils (DEO or EO)
Recommended engine oils for chains and linkages, including European, API, and Military specs.
Hydraulic Oils (HYDO) Recommendations
Recommended commercial classifications and viscosity for hydraulic system oil.
Drive Axle Oil and Grease Specifications
Drive Axle Oil Recommendations
API GL-4 or MIL-L-2105A oils recommended; multi-grade oils not blended by Doosan.
Lubricating Grease (MPGA) Usage
Use Multipurpose Molybdenum Grease (MPGM) or grease with molybdenum disulfide.
Battery Discharge Indicator Monitoring
Battery Discharge Indicator Operation
How to observe the battery discharge indicator (BDI) and interpret its readings for battery status.
Battery Maintenance and Charging
Battery: General Information and Care
Factors affecting battery life: operator, charging, maintenance. Cleaning tips and low battery operation warnings.
Battery Charging Procedures
Guidance on battery charging cycles, cooling/stabilizing, equalizing charges, and preventing over-discharge.
Battery Temperature and Cleaning Procedures
Battery: Temperature and Cleaning
Critical electrolyte temperature limits, cleaning procedures, and using distilled water.
Battery Disposal Notice
Notice on proper disposal of old batteries to protect the environment and personnel.
Cold Storage Operation and Battery Care
Cold Storage Applications: Precautions
Effects of cold temperatures on battery capacity and components, and warm-up procedures.
Battery Care in Cold Storage
Important points for cold storage: fully charged battery, warm storage area, no discharged batteries below freezing.
Hydraulic System and Lift Chain Maintenance
Hydraulic System: Oil and Filter Change
Instructions for draining hydraulic system and filling with specified oil, and changing the return filter.
Lift Chains: Cleaning and Lubrication
Procedures for cleaning lift chains with solvent and lubricating with molybdenum disulfide (MPGM) grease.
Lift Chains: Wear Check Procedure
Checking chains for wear on link plate edges, cracked links, and corrosion.
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities and Refill Capacities
Tables showing lubricant viscosities for various ambient temperatures and refill capacities.
Maintenance Interval Schedules
Maintenance Intervals: Notices
Notices regarding exceeding intervals, performing maintenance, and proper disposal of waste oil.
Maintenance: When Required Tasks
List of maintenance tasks required based on specific conditions or needs.
Maintenance: Every 10 Hours or Daily
Daily inspection tasks including walk-around, mast channels, battery, indicators, and tires.
Maintenance: First 150 Hours or 2 Weeks
Maintenance task for the first 150 hours or 2 weeks: drive axle oil change.
Maintenance: Every 500 Hours or 3 Months
Tasks for every 500 hours/3 months: tilt cylinders, cylinder rod extension, rollers, mast hinge pins, steering, guard, panel, controls.
Maintenance: Every 1000 Hours or 6 Months
Tasks for every 1000 hours/6 months: air breather, drive/pump motor, tires, lift chains, hydraulic filter.
Maintenance: Every 2000 Hours or Yearly
Tasks for every 2000 hours/yearly: hydraulic/power steering system, steer wheel bearings, fork inspection, hydraulic oil change.
Environment Protection Guidelines
Section dedicated to environmental protection procedures and responsible disposal.
Maintenance Schedule Summary
Quick Reference: Maintenance Schedule
A table summarizing maintenance items, services, pages, and intervals (When Required, Every X Hours/Weeks/Months/Years).
Troubleshooting and Diagnostics
Maintenance: Self Diagnostics Test
Instructions for performing self-diagnostics tests on circuits and components for troubleshooting.
Maintenance: Compact Display Button Functions
Explanation of the E-S-H, UP, DOWN, and ENTER keys on the compact display for calibration/diagnostics.
Diagnostic Mode Operations
Maintenance: Button Functions for Diagnostics
Functions of UP, DOWN, TURTLE, and E-S-H buttons for parameter adjustment and mode selection.
Maintenance: Run Time Diagnostic Procedure
Procedure for entering diagnostic mode to test system analog and digital signals.
Diagnostic Mode Parameter List
Diagnostic Mode Parameter List (1-48)
Table listing accessible parameters in diagnostic mode (1-48) for analysis.
Interpreting Diagnostic Mode Display
Diagnostic Mode Display Interpretation
How selected parameters are visualized in diagnostic mode (analogue/digital input) and how to exit.
Carriage Roller Extrusion Adjustment
Carriage Roller Extrusion Adjustment Steps
Steps to adjust carriage roller extrusion for mast verticality, carriage lowering, and measurement.
Power Module Discharge Safety
Power Modules Discharge Procedure
Procedure for discharging power modules before contact with electrical system to prevent injury.
Fuse Replacement and Seat Lubrication
Fuses Replacement Instructions
Location of fuses, purpose, and instructions for replacing fuses with the same type and size.
Seat Lubrication Procedure
Instructions for checking seat adjuster operation and lightly oiling seat slider tracks.
Wheel Bolt Tightness and Drive Axle Lubrication
Wheel Bolts Check for Tightness
Procedure for inspecting tightness of wheel nuts on steer and drive wheels.
Drive Axle Gear Boxes: Lubricant Level
Steps to measure lubricant level in drive axle gear boxes, including raising carriage and using plugs.
Greasing Points Identification
Greasing Points Overview Diagram
Diagrams showing greasing points for mast, tilt cylinders, hood hinge, and other key areas.
Daily Maintenance: Walk-Around Inspection
Daily Walk-Around Inspection Steps
Detailed steps for daily walk-around inspection of operator compartment, panel, horn, mast, carriage, tires, guard, hydraulics.
Daily Inspection Continued
Walk-Around Inspection (Continued)
Continued inspection steps: drive axle housing, seat adjustment, steering wheel, directional control, key switch, LCD display, brakes.
Mast Channel Lubrication and Battery Access
Mast Channels Lubrication Procedure
Instructions for lubricating mast channels on roller-type masts for break-in period and wear prevention.
Battery Access for Check/Exchange/Change
Procedure for accessing the battery, including tilting steering column, releasing hood latch, and disconnecting battery.
Battery Electrolyte Check and Exchange
Check Electrolyte Levels
Steps for inspecting battery compartment, cleaning top, checking specific gravity, and electrolyte levels.
Battery Exchanging Procedure
Steps for exchanging batteries, including accessing, removing, charging, installing, and connecting.
Battery Charging and Indicator Checks
Battery Charging Safety Provisions
Warnings and provisions for venting charging gases, opening compartment lids, and keeping vent plugs closed.
Battery Charging with Battery Installed
Steps for charging the battery while installed in the lift truck, including safety warnings.
Indicator Check: System Status
Checking the LCD display for battery discharge status and brake oil level.
Tires and Wheels Inspection
Tires and Wheels Inspect and Check
Instructions for inspecting tires, valve stems, rims, and checking inflation pressure.
Initial Drive Axle Oil Change
First 150 Hours/2 Weeks: Drive Axle Oil Change
Procedure for changing drive axle oil after initial 150 hours and subsequent 2000 hours or yearly.
500 Hour/3 Month Maintenance Tasks
500 Hours/3 Months: Tilt Cylinders
Lubrication of chassis pivot eyebolts and checking pivot eye pins for tilt cylinders.
500 Hours/3 Months: Mast Pivot Eyes
Lubrication of mast pivot eyes and checking mast pivot eye pins for loose retainer bolts and wear.
500 Hour/3 Month Maintenance Tasks (Cont.)
Cylinder Rod Extension Adjustment
Steps to adjust cylinder rod extension by loosening bolts, turning rod, and tightening to torque.
Crosshead Rollers Inspection
Checking crosshead rollers, guards, and retainer rings by operating the mast through a lift cycle.
500 Hour/3 Month Lubrication and Inspection
Mast Hinge Pins Lubrication
Lubricating mast hinge pins, one fitting on each side of the mast.
Steering Mechanism Lubrication
Lubricating the fitting on the steer axle for the steering mechanism.
Overhead Guard Inspection
Inspecting overhead guard for loose/damaged bolts, bent sections, and retightening to specified torque.
Control Panel and Directional Switch Checks
Control Panel Cleaning and Inspection
Procedure to clean and inspect the control panel, including disconnecting battery and discharging capacitors.
Direction Control Switch Check
Checking tightness of directional control switch bracket, ease of movement, and wiring.
Brake and Hydraulic System Checks
Parking Brake Test Procedure
Testing the parking brake by driving up an incline and stopping with service brakes.
Hydraulic Oil Level Check
Steps to check hydraulic oil level after warming oil, lowering forks, and removing dipstick.
Switch, Mast, Chain, and Attachment Maintenance
Steer Angle Switches Check and Clean
Cleaning steer angle switches with air pressure and checking switch operation and bracket tightness.
Mast Carriage, Chains, Attachments Service
Inspecting carriage, chains, and attachments for operation, noises, loose parts, wear, and lubricating chains.
Chain Maintenance and Adjustments
Mast Carriage, Chains, Attachments Service (Cont.)
Inspects chain anchors and links for wear. Notes on performing necessary repairs and adjustments.
1000 Hour/6 Month Maintenance Tasks
1000 Hours/6 Months: Air Breather Change
Procedure for changing the air breather, including opening hood and installing a new one.
1000 Hours/6 Months: Drive & Pump Motor Service
Steps to clean and inspect drive and pump motors, including battery disconnection and blocking wheels.
Drive & Pump Motor Service (Continued)
Drive & Pump Motor Clean/Inspect (Continued)
Continued steps for motor cleaning: fastening lift chains, lifting truck, removing stands, and blowing off dust.
Tires and Wheels Inspection and Check
Tires and Wheels Inspect and Check
Instructions for inspecting tires, valve stems, rims, and checking inflation pressure.
Tires and Wheels Inspection (Continued)
Tires and Wheels Inspect and Check (Continued)
Continued instructions for installing drive wheel nuts and reversing lifting procedure for front of truck.
Lift Chain Testing and Adjustment
Lift Chains: Test, Check, and Adjust
Procedure for lift chain wear test, calculating wear rate, and replacing chains if wear exceeds 2%.
Lift Chains: Check for Equal Tension
Checking lift chains for equal tension by lifting carriage and mast, and ensuring tension is the same.
Lift Chains: Adjustment Procedure
Procedure for adjusting lift chains if tension is not the same, ensuring carriage height is correct.
Chain Adjustment Procedures
Carriage Chain Adjustment
Adjusting carriage chains for equal tension and correct height, using anchor nuts.
Mast Chain Adjustment (FF, FFT Mast)
Adjusting mast chains for FF/FFT masts for equal tension and correct mast height.
Hydraulic Return Filter Replacement
Hydraulic Return Filter Change Procedure
Procedure for changing the hydraulic return filter, including loosening bolts and installing a new filter.
2000 Hour/Yearly Maintenance: Hydraulic System
Hydraulic, Power Steering System Service
Steps to change hydraulic oil and filter element, including warming oil, draining, and refilling.
Hydraulic System Service (Continued)
Hydraulic, Power Steering System Service (Cont.)
Continued steps for hydraulic system service: checking leaks, retracting cylinders, and filling oil to full mark.
Steer Wheel Bearing Reassembly
Steer Wheel Bearings Reassembly Steps
Procedure for reassembling steer wheel bearings, including lifting wheels, removing hub cap, and straightening lockwasher tangs.
Steer Wheel Bearing Reassembly (Continued)
Steer Wheel Bearings Reassembly (Cont.)
Continued steps for steer wheel bearing reassembly: removing locknut/washer, installing wheel, and tightening nuts.
Steer Wheel Bearing Reassembly (Final Steps)
Steer Wheel Bearings Reassembly (Final)
Final steps for steer wheel bearing reassembly: tightening locknut, loosening, retightening, and lowering truck.
Fork Inspection Procedures
Fork Inspection: Cracks and Wear
Instructions for inspecting forks for cracks, weld areas, heel section, and checking blade/shank wear.
Fork Inspection: Angle and Straightness
Checking fork blade angle and straightness of the upper face and shank.
Fork Inspection Details (Continued)
Fork Inspection: Height Difference and Wear
Checking fork tip height difference and blade/shank wear, with recommendations for replacement.
Fork Inspection: Mountings and Retention
Inspecting fork mountings for wear, deformation, and checking positioning locks and retention devices.
Fork Inspection Details (Final)
Fork Inspection: Markings and Parallelism
Checking fork markings for legibility and fork parallelism using straight bars and measurements.
Environment Protection Section
Environment Protection: Servicing Precautions
Using authorized areas and containers for servicing fluids, and proper disposal of materials.
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