BAIC D80S-5 Lift Truck Operation & Maintenance Manual PDF Download (EN)

SB2356E01 Operation & Maintenance Manual LIFT TRUCKS D50S-5, D60S-5, D70S-5 D80S-5, D90S-5 G50S-5, G60S-5, G70S-5 0705

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Table of Contents Table of Contents Information Section Foreword .....................................................................2 Safety Section Safety ..........................................................................5 Warning Signs and Labels .................................5 General Hazard Information.............................10 Operation Information.......................................11 Maintenance Information..................................14 Operator Restraint System (If Equipped)........17 Avoiding Lift Truck Tipover...............................21 Safety Rules......................................................23 How to Survive in a Tipover (If Operator Restraint System Equipped) ............................28 General Section Specifications............................................................30 Noise &Vibration.......................................................38 Capacity Chart - Without Side Shifter .....................39 Capacity Chart - With Side Shifter ..........................41 Serial Number...........................................................43 Operator's Warning and Identification Plate...........45 Operation Section Operator’s Station and Monitoring Systems...........47 Seat Switch System .................................................52 Lift Truck Controls ....................................................56 Refueling ...................................................................60 Before Starting the Engine.......................................63 Starting the Engine...................................................66 After Starting the Engine..........................................69 Lift Truck Operation................................................105 Auto Shift Controller ASC-200/201 (If Equipped) ..107 Operating Techniques............................................112 Parking the Lift Truck .............................................116 Lift Fork Adjustment ...............................................117 Storage Information................................................118 Transportation Hints...............................................119 Towing Information.................................................120 Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks .......................................................................121 Tire Inflation Information........................................125 Torque Specifications ............................................126 Cooling System Specifications..............................128 Fuel Specifications.................................................130 Lubricant Specifications.........................................132 Maintenance Intervals............................................136 When Required ......................................................140 Every 10 Service Hours or Daily...........................147 First 50-100 Service Hours or a Week .................152 First 250 Service Hours or a Month......................159 Every 250 Service Hours or Monthly....................160 Every 500 Service Hours or 3 Months..................168 Every 1000 Service Hours or 6 Months................172 Every 1500 Service Hours or 9 Months................178 Every 2000 Service Hours or Yearly.....................181 Every 2500 Service Hours or 15 Months..............185 Index Section Index .......................................................................187 1

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Information Section Foreword Safety The Safety Section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs and labels used on the lift truck. Read and understand the basic precautions listed in the Safety Section before operating or performing lubrication, maintenance and repair on this lift truck. Operator Restraint System (If Equipped) Literature Information This manual should be stored in the operator's compartment in the literature holder or seat back literature storage area. This manual contains safety, operation, transportation, lubrication and maintenance information.

Some photographs or illustrations in this publication show details or attachments that can be different from your lift truck. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your lift truck which are not included in this publication. Read, study and keep this manual with the lift truck. Whenever a question arises regarding your lift truck, or this publication, please consult your DOOSAN dealer for the latest available information. This manual contains safety, operation and maintenance information for the DOOSAN operator restraint system. Read, study and keep it handy.

Your DOOSAN truck comes equipped with an operator restraint system. Should it become necessary to replace the seat for any reason, it should only be replaced with another DOOSAN operator restraint system. Photographs or illustrations guide the operator through correct procedures of checking, operation and maintenance of the DOOSAN operator restraint system. SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness on the part of the operator. To develop this skill the operator should read and understand the Safe Driving Practices contained in this manual.

Forklift trucks seldom tipover, but in the rare event they do, the operator may be pinned to the ground by the lift truck or the overhead guard. This could result in serious injury or death. Operator training and safety awareness is an effective way to prevent accidents, but accidents can still happen. The DOOSAN operator restraint system can minimize injuries. The DOOSAN operator restraint system keeps the operator substantially within the confines of the operator's compartment and the overhead guard. This manual contains information necessary for Safe Operation. Before operating a lift truck make sure that the necessary instructions are available and understood. 2 WARNING

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Information Section Operation The Operation Section is a reference for the new operator and a refresher for the experienced one. This section includes a discussion of gauges, switches, lift truck controls, attachment controls, transportation and towing information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the lift truck. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the lift truck and its capabilities. Maintenance The Maintenance Section is a guide to equipment care.

The illustrated, step-by-step instructions are grouped by servicing intervals. Items without specific intervals are listed under "When Required" topics. Items in the "Maintenance Intervals" chart are referenced to detailed instructions that follow. Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.

Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the "Maintenance Intervals" chart might be necessary. Perform service on items at multiples of the original requirement. For example, at "Every 500 Service Hours or 3 Months", also service those items listed under "Every 250 Service Hours or Monthly" and "Every 10 Service Hours or Daily". Environment Management Note that DOOSAN INDUSTRIAL VEHICLE DIVISION is ISO 14001 certified which is harmonized with ISO 9001. Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by internal and external inspection entities.

LIFECYCLE ANALYSIS has also been made through out the total product life. ENVIRONMENT MANAGEMENT SYSTEM includes DESIGN FOR ENVIRONMENT from the initial stage of the design. ENVIRONMENT MANAGEMENT SYSTEM considers environmental laws & regulations, reduction or elimination of resource consumption as well as environmental emission or pollution from industrial activities, energy saving, environment friendly product design(lower noise, vibration, emission, smoke, heavy metal free, ozone depleting substance free, etc.), recycling, material cost reduction, and even environmentally oriented education for the employee. 3

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