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D35S-5
Operation & Maintenance Manual
Doosan D35S-5 - Operation & Maintenance Manual
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SB2355E01
Operation &
Maintenance Manual
LIFT TRUCKS
D35S-5, D40S-5, D45S-5, D50C-5, D55C-5
G35S-5, G40S-5, G45S-5, G50C-5, G55C-5
D40SC-5, D45SC-5, D50SC-5, D55SC-5
G40SC-5, G45SC-5, G50SC-5, G55SC-5
0705
https://www.forkliftpdfmanuals.com/
2
Table of Contents
Main Page
Table of Contents
3
Information Section
4
Foreword
4
Safety Section
6
Important Safety Information
6
Safety
7
General Hazard Information
12
Operation Information
13
Before Starting the Lift Truck
13
Maintenance Information
16
Operator Restraint System (if Equipped)
19
Avoiding Lift Truck Tipovers
23
Safety Rules
25
How to Survive in a Tipover (if Operator Restraint System Equipped)
30
General Section
32
Specifications
32
Noise and Vibration
40
Capacity Chart
41
Capacity Chart (with Side Shifter)
43
Serial Number
55
Operator's Warning and Identification Plate
57
Operation Section
59
Operator's Station and Monitoring Systems
59
Seat Switch System (if Equipped)
63
Lift Truck Controls
64
Refueling
67
Before Starting the Engine
70
Starting the Engine
72
After Starting the Engine
74
Lift Truck Operation
110
Mono-Ped Control System (Option)
112
Auto Shift Controller ASC - 200 (if Equipped)
113
Operating Techniques
116
Parking the Lift Truck
120
Lift Fork Adjustment
121
Storage Information
122
Transportation Hints
123
Towing Information
124
Maintenance Section
125
Inspection, Maintenance and Repair of Lift Truck Forks
125
Tire Inflation Information
129
Torque Specifications
130
Cooling System Specifications
132
Fuel Specifications
134
Lubricant Specifications
136
Lubricant Viscosities and Refill Capacities
139
First 250 Service Hours or a Month Maintenance Intervals
140
Default Chapter
140
Maintenance Intervals
140
Adjust
143
Test Fuel System for Leaks (LP Engine Only)
143
When Required
144
Priming the Fuel System (Diesel Engine Only)
146
Seat, Hood Latch & Support Cylinder - Check, Lubricate
146
Fuses, Bulbs & Circuit Breaker - Change, Reset
147
Fuse & Relay (LP Engine Only)
148
Circuit Breaker
148
Tires and Wheels - Check, Inspect
149
Carriage Roller Extrusion - Check, Adjust
150
Every 10 Service Hours or Daily
151
Inspect Engine for Fluid Leaks
151
Engine Oil Level - Check
151
Coolant Level - Check, Clean
151
Air Cleaner Indicator - Check
152
Walk - Around Inspection - Inspect
153
Mast Channels - Lubricate
154
Transmission Oil Level - Check
154
First 50 - 100 Service Hours or a Week
155
Engine Oil & Filter (Diesel Engine Only) - Change
155
Transmission Oil, Oil Filter & Strainer - Clean, Change
156
Drive Axle Oil - Check, Clean, Change
158
Parking Brake - Test, Adjust
159
First 250 Service Hours or a Month
161
Hydraulic Return Filter - Change
161
Every 250 Service Hours or Monthly
162
Air Intake System - Check, Clean
162
Brake Oil Level - Check
163
Hydraulic Oil Level - Check
165
Drive Axle Oil Level - Check
165
Mast, Carriage, Lift Chains, & Attachments - Check, Lubricate
166
Carriage Side Rollers - Lubricate
167
Steering Mechanism - Check, Lubricate
167
Battery Terminal - Clean, Inspect
168
Engine Oil & Filter - Change
168
Wheel Bolts and Nuts - Inspect
169
Every 500 Service Hours or 3 Months
170
Belts (Diesel Engine Only) - Check, Adjust
170
Mast Hinge Pins - Lubricate
170
Tilt Cylinders - Check, Adjust, Lubricate
171
Crosshead Rollers - Inspect
172
Carriage Side Rollers Thrust (if Equipped) - Lubricate
172
Carriage Sideshifter (if Equipped) - Lubricate
172
Parking Brake - Test, Adjust
173
Circulation Pump Belt (OCDB & LP Engine Only. if Eguipped) - Check, Adjust
173
Drive Axle Oil & Strainer (OCDB Only) - Check, Clean, Change
173
Inching & Brake Control Shaft - Lubricate
174
Horn & Lights (if Equipped) - Check
174
Inspect Vacuum Lines and Fittings (LP Engine Only)
174
Fuel Trim Valve(FTV) Inspection (G643E Engine Only)
175
Inspect Electrical System (LP Engine Only)
175
Overhead Guard - Inspect
175
Steer Suspension - Inspect
175
Every 1000 Service Hours or 6 Months
176
Fuel Filters - Change
176
Air Intake System - Change
176
Fuel Lines & Fittings - Check
177
Hydraulic Return Filter - Change
178
Air Breather - Change
178
Transmission Oil, Oil Filter & Strainer - Clean, Change
178
Lift Chains - Test, Check, Adjust
178
Universal Joint - Inspect
181
Every 1500 Service Hours or 9 Months
182
Drive Axle Oil (Shoe Brake Only) - Check, Clean, Change
182
Inspect Ignition System (LP Engine Only)
182
Replace Spark Plugs (LP Engine Only)
182
Replace LP Fuel Filter Element (LP Engine Only)
183
Fuel Filter (LP Engine Only)
183
Disassembly
183
Testing Fuel Lock-Off Operation (LP Engine Only)
184
Every 2000 Service Hours or Yearly
185
Steer Wheel Bearings - Reassemble
185
Cooling System - Clean, Change
186
Fork - Inspect
187
Every 2500 Service Hours or 15 Months
189
Hydraulic Oil - Check, Clean, Change
189
Inspect Battery System
189
Checking the TMAP Sensor (LP Engine Only)
190
Inspect for Intake Leaks (LP Engine Only)
190
Replace PCV Valve and Breather Element - Change (LP Engine Only)
190
Replace Oxygen Sensor (G643E Engine Only)
190
Index Section
191
Index
191
Table of Contents
197
Information Section
198
Foreword
198
Safety Section
200
Important Safety Information
200
Safety
201
Warning Signs and Labels
201
General Hazard Information
206
Operation Information
207
Before Starting the Lift Truck
207
Maintenance Information
210
Operator Restraint System (if Equipped)
213
If Optional Suspension Seat (Weight Adjusting Type) Equipped
214
Avoiding Lift Truck Tipovers
217
Safety Rules
219
How to Survive in a Tipover (if Operator Restraint System Equipped)
224
General Section
226
Specifications
226
Noise and Vibration
228
Capacity Chart
229
Capacity Chart (with Side Shifter)
230
Capacity Chart
231
Capacity Chart (with Side Shifter)
232
Serial Number
233
Operator's Warning and Identification Plate
234
Operation Section
236
Operator's Station and Monitoring Systems
236
Seat Switch System (if Equipped)
240
Lift Truck Controls
241
Refueling
244
Before Starting the Engine
246
Starting the Engine
248
After Starting the Engine
250
Lift Truck Operation
274
Mono-Ped Control System (Option)
276
Auto Shift Controller ASC - 200 (if Equipped)
277
Operating Techniques
280
Parking the Lift Truck
284
Lift Fork Adjustment
285
Storage Information
286
Transportation Hints
287
Towing Information
288
Maintenance Section
289
Inspection, Maintenance and Repair of Lift Truck Forks
289
Tire Inflation Information
293
Torque Specifications
294
Cooling System Specifications
296
Fuel Specifications
298
Lubricant Specifications
299
Lubricant Viscosities and Refill Capacities
301
First 250 Service Hours or a Month Maintenance Intervals
302
Default Chapter
302
Maintenance Intervals
302
When Required
306
Test Fuel System for Leaks (LP Engine Only)
306
Seat, Hood Latch & Support Cylinder - Check, Lubricate
306
Fuses, Bulbs & Circuit Breaker - Change, Reset
307
Fuse & Relay (LP Engine Only)
308
Circuit Breaker
308
Tires and Wheels - Check, Inspect
309
Carriage Roller Extrusion - Check, Adjust
310
Every 10 Service Hours or Daily
311
Inspect Engine for Fluid Leaks
311
Engine Oil Level - Check
311
Coolant Level - Check, Clean
311
Air Cleaner Indicator - Check
312
Walk - Around Inspection - Inspect
313
Mast Channels - Lubricate
314
Transmission Oil Level - Check
314
First 50 - 100 Service Hours or a Week
315
Transmission Oil, Oil Filter & Strainer - Clean, Change
315
Drive Axle Oil - Check, Clean, Change
317
Parking Brake - Test, Adjust
318
First 250 Service Hours or a Month
320
Hydraulic Return Filter - Change
320
Every 250 Service Hours or Monthly
321
Air Intake System - Check, Clean
321
Hydraulic Oil Level - Check
323
Drive Axle Oil Level - Check
323
Brake Oil Level - Check
323
Mast, Carriage, Lift Chains, & Attachments - Check, Lubricate
324
Carriage Side Rollers - Lubricate
325
Steering Mechanism - Check, Lubricate
325
Battery Terminal - Clean, Inspect
326
Engine Oil & Filter - Change
326
Wheel Bolts and Nuts - Inspect
327
Every 500 Service Hours or 3 Months
328
Mast Hinge Pins - Lubricate
328
Tilt Cylinders - Check, Adjust, Lubricate
328
Crosshead Rollers - Inspect
329
Carriage Side Rollers Thrust (if Equipped) - Lubricate
329
Carriage Sideshifter (if Equipped) - Lubricate
330
Parking Brake - Test, Adjust
330
Circulation Pump Belt (OCDB & LP Engine Only. if Eguipped) - Check, Adjust
330
Drive Axle Oil & Strainer (OCDB Only) - Check, Clean, Change
331
Horn & Lights (if Equipped) - Check
332
Inspect Vacuum Lines and Fittings (LP Engine Only)
332
Fuel Trim Valve(FTV) Inspection (G643E Engine Only)
332
Inspect Electrical System (LP Engine Only)
332
Overhead Guard - Inspect
333
Steer Suspension - Inspect
333
Every 1000 Service Hours or 6 Months
334
Air Intake System - Change
334
Fuel Lines & Fittings - Check
335
Hydraulic Return Filter - Change
335
Air Breather - Change
335
Transmission Oil, Oil Filter & Strainer - Clean, Change
335
Lift Chains - Test, Check, Adjust
335
Universal Joint - Inspect
337
Every 1500 Service Hours or 9 Months
338
Drive Axle Oil (Shoe Brake Only) - Check, Clean, Change
338
Inspect Ignition System (LP Engine Only)
338
Replace Spark Plugs (LP Engine Only)
338
Replace LP Fuel Filter Element (LP Engine Only)
339
Fuel Filter (LP Engine Only)
339
Disassembly
339
Testing Fuel Lock-Off Operation (LP Engine Only)
340
Every 2000 Service Hours or Yearly
341
Steer Wheel Bearings - Reassemble
341
Cooling System - Clean, Change
342
Fork - Inspect
343
Every 2500 Service Hours or 15 Months
345
Hydraulic Oil - Check, Clean, Change
345
Inspect Battery System
345
Checking the TMAP Sensor (LP Engine Only)
346
Inspect for Intake Leaks (LP Engine Only)
346
Replace PCV Valve and Breather Element - Change (LP Engine Only)
346
Replace Oxygen Sensor (G643E Engine Only)
346
Index Section
347
Index
347
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