Daewoo BC20S BC25S BC30S Electric Lift Truck Service Manual PDF

Description

Daewoo BC20S BC25S BC30S Electric Lift Truck Service Manual  SB2034E02 PDF DOWNLOAD

DESCRIPTION

Daewoo BC20S / BC25S / BC30S Electric Lift Truck — Complete Factory Service Manual (PDF Download)

This is the complete official Daewoo factory service manual for the BC20S, BC25S, BC30S, B20S-2, B25S-2, B30S-2 and BC25SE-2 electric counterbalanced lift trucks, compiled under form number SB2034E02 (April 1999). At 499 pages, this is one of the most comprehensive service references available for the Daewoo S-Series electric forklift range, covering all battery voltage variants (36V, 40V, 72V, 80V) and every major system from the MicroController drive logic through to the hydraulic mast assembly and scheduled maintenance procedures.

Whether you’re diagnosing a stored error code on the Central Vehicle Monitoring System (CVMS), adjusting the drive motor field shunt, rebuilding the power transfer group, or resetting the battery discharge indicator, this manual provides factory step-by-step procedures, circuit schematics, torque specifications, and test data to get the truck back in service.

📋 File Details

📚 Complete Table of Contents

FRONT MATTER

• Service Manual Contents Index (SB2034E02)
• Safety — General precautions, hazardous materials, lubrication and maintenance warnings (SB2003E00)
• Torque Specifications — Standard torque for metric fasteners (M6–M36, nuts, bolts and taperlock studs) (SB2004E00)

SECTION 1 — DRIVE & CONTROL SYSTEM: MicroController Control System (SB2023E01) — 152 pages

Specifications

• Component Measurements (transistors T1P, T2P, T1D, T2D)
• Console, Contactors, Control Panel layout
• Current Measurements, Direction Switch, Display layout
• Fuses, Head Capacitor, Instrument Panel
• Thermal Switch, Transistor Connections
• Symbol Library & CVMS International Pictorial Symbols

Systems Operation

• General Information — Logic unit, battery selection jumpers
• Operational Circuit Elements — Battery Discharge Indicator (BDI), CVMS, on-board run-time diagnostics
• Drive Circuit: Power circuit, control circuit, current limit, field shunt circuit, flyback circuit, bypass circuit, electrical braking (regenerative and plugging), failure protection circuit, thermal protection circuits
• Hydraulic Pump Motor Circuit — Flyback, lift control, lift power, power steering (idle and in-use), shunt field, tilt and auxiliary control
• Actuation Circuit — Capacitor charging circuit
• Accessory Circuits — DC-DC converter, horn circuit, hour meter circuit
• Wait Mode

Testing and Adjusting

• Preparation Tests and Checks — Control and power system operational checks
• Built-In Diagnostic Operation
  • “Run Time” Diagnostics (Lift Truck in Operation)
  • “Self” Diagnostics (Lift Truck in Operation)
  • Accessing and Erasing Stored Error Codes
  • Quick Diagnostic Procedure
• System Tests and Adjustment — Discharging head capacitor, logics removal, run-time tests, test equipment
• Component Tests: Accelerator control, head capacitor, CVMS self test, conductor & switch continuity, contactor (bypass and field shunt) activation, contactor components, current sensor, DC-DC converter, diode replacement, display (CVMS), driver board (on-vehicle and off-vehicle), logic unit quick reference voltage check, resistors R322 and R312, thermal switch, transistors T1P/T2P/T1D/T2D replacement, valve control card
• Electrical System Adjustments: Accelerator control linkage, BDI adjustment, bypass dropout / stall protection, current limit test and adjustment, electrical braking (regen and plugging), current test and adjustment, field shunt pickup test, lift sensor, parking brake switch, repid tune-up procedure, tilt and auxiliary speed/switches adjustment, valve control card adjustment

Options

• Option Switches, Programmable Features, Activating Default Settings

Troubleshooting

• Troubleshooting Check List
• Troubleshooting Problem List (64 fault conditions)

SECTION 2 — POWER TRAIN (SB2025E01, Aug. 1999) Models: B20S-2, B25S-2, B30S-2, BC20S-2, BC25S-2, BC30S-2

Systems Operation

• General Information | Drive Motor | Power Transfer Group | Final Drive

Testing and Adjusting

• Drive Motor: Motor brushes, armature tests, commutator inspection, field coil and terminal tests, brush holder test, brush life estimate, armature terminal test, thermal switch tests
• Final Drive: Wheel bearing adjustment
• Power Transfer Group Adjustments: Pinion installation, pinion depth check, pinion bearing adjustment, power transfer group bearing and gear clearance (backlash) adjustments
• Troubleshooting: Visual checks, drive motor, power transfer group and final drive

Specifications

• Drive Motor, Power Transfer Group, Final Drive
• Drive Axle Mounting Group, Drive Tire Installation
• General Tightening Torque Table

Disassembly & Assembly

• Brakes, Brake Adjuster and Wheel Cylinder
• Power Transfer Group
• Final Drives and Hubs
• Oil Cooled Disc Type Brake

SECTION 3 — VEHICLE SYSTEMS (SB2026E02 + Vehicle Systems D&A SB2028E02)

Systems Operation

• Hydraulic System: Basic schematic, basic oil flow, hydraulic control valve (lift, tilt, sideshift), lift cylinders and mast
• Brake System: Master cylinder, oil cooled disc brakes, parking brake, shoe type brakes
• Electric Motors: Hydraulic pump motor operation
• Steering System: Schematic, steering cylinder, steering gear operation

Testing and Adjusting

• Brake System: Brake adjustment, brake system air removal, parking brake adjustment and control group adjustment, parking brake test, pedal adjustment
• Hydraulic Pump Motor: Armature tests, brush holder test, brush life estimate, commutator inspection, field coil and terminal tests, motor brushes, shunt field tests, thermal switch (thermostat) tests
• Hydraulic System: Flow control valve adjustment, relief valve pressure check, standard lift cylinder air removal
• Mast and Carriage: Carriage adjustment, carriage and mast height adjustment, chain adjustments, chain wear test, drift test, forks parallel check, mast adjustment, tilt cylinder alignment
• Steering System: Steering axle stop adjustments, steering knuckle bearing preload adjustment, steering system pressure check, steering wheel bearing adjustment

Troubleshooting

• Visual Checks | Hydraulic System and Mast | Brake System (including oil cooled disc type) | Electric Motors | Steering System

Specifications

• Brakes, Carriage, Hydraulic Control Valve, Hydraulic Pumps, Hydraulic Pump Motor
• Lift and Tilt Mounting Group, Lift Cylinders (Standard, Full Free Triple Lift primary & secondary), Lift Relay Groups
• Mast, Parking Brake, Priority Valve (with hydraulic pump assembler), Steer Axle and Wheel, Steering Gear, Steering Wheel, Steer Tire Installation, Tilt Cylinders

Disassembly & Assembly

• Brake system components | Final drives and hubs | Oil cooled disc brake | Steering components | Lift and tilt cylinders (complete seal replacement procedures with step-by-step illustrated guides)

SECTION 4 — HYDRAULIC SYSTEM SCHEMATIC (SB2027E02)

• Full hydraulic circuit schematic for BC20/25/30S and B20/25/30S-2 models
• Priority valve routing, pump circuits, lift/tilt/steering lines

SECTION 5 — ELECTRIC SYSTEM SCHEMATIC (SB2022E00)

• Complete electrical circuit schematic
• MicroController wiring, contactor circuits, sensor connections, accessory wiring

SECTION 6 — OPERATION & MAINTENANCE MANUAL (SB2068E05) Models: BC20S-2, BC25S-2, BC25SE-2, BC30S-2 (36V, 40V, 72V, 80V)

Safety Section

• OSHA compliance references, EU Machinery Directive 98/37/EC and EMC 89/336/EC
• Warning signs and labels (location and replacement)
• Operator restraint system, tipover procedure (fasten seat belt, hold on tight, brace feet, lean away, don’t jump)
• Lift truck stability, center of gravity, crushing/cutting prevention
• Avoiding tipovers on inclines and during turning

General Section

• Operator’s warning and identification plate
• Lift truck capacity rating system
• Mast abbreviations (STD, FF, FFT, QUAD, SPEC)

Operation Section

• Monitoring Systems Indicator — CVMS symbol identification
• Run Time Diagnostics — LED display during operation
• Battery Discharge Indicator (BDI) — 9-to-0 countdown, 80% discharge interrupt
• Electrical Braking (Plugging) — operation procedure
• Gauges, switches, lift controls, attachment controls
• Starting, operating and stopping the lift truck

Maintenance Section

• Lubrication and maintenance schedule
• Self-diagnostic procedures (Stored Error Codes, Run/Diagnostic mode)
• Reverse direction contactor test procedure
• Battery care, charging procedures
• Periodic inspection intervals

✅ Who Needs This Manual?

• Forklift technicians servicing Daewoo BC20S, BC25S, BC30S electric lift trucks
• Warehouse maintenance engineers needing MicroController diagnostic and stored error code procedures
• Independent service centres performing power train or hydraulic system rebuilds
• Fleet maintenance teams managing Daewoo/Doosan S-Series electric forklifts (36V–80V)
• Technicians needing the complete CVMS self-diagnostic and component test procedures

🏭 Keep Your Daewoo Forklift Fleet Running — Get the Manual Right Now

With 499 pages of official Daewoo factory documentation including MicroController troubleshooting with full error code access procedures, power train disassembly guides, hydraulic and electric circuit schematics, and the complete operator maintenance manual — this is the definitive S-Series workshop reference. Purchase now for an instant PDF download and have the complete factory service data on your tablet or PC within seconds.