Daewoo Doosan Forklift BC15S to BC20SC Service Manuals SB4163E00 – PDF DOWNLOAD

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Daewoo Doosan Forklift BC15S to BC20SC Service Manuals SB4163E00 – PDF DOWNLOAD

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Daewoo Doosan Forklift BC15S to BC20SC Service Manuals SB4163E00 – PDF DOWNLOAD

Language :English
Pages :457
Downloadable : Yes
File Type : PDF

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Daewoo Doosan Forklift BC15S to BC20SC Service Manuals SB4163E00 – PDF DOWNLOAD

SAFETY

• 1. Readandunderstand all Warning plates and decals on the machine before operating, lubricating or repairing the product.
• 2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when pounding on any part of the machine or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery.
• 3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly.
• 4. Lower the forks or other implements to the ground before performing any work on the machine. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.
• 5. Use steps and grab handles (if applicable) when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.
• 6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.
• 7. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.
• 8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.
• 9. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.
• 10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.
• 11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts.
• 12. If possible, make all repairs with the machine parked on a level, hard surface. Block machine so it does not roll while working on or under machine

TABLE OF CONTENTS:

Daewoo Doosan Forklift BC15S to BC20SC Service Manuals SB4163E00 – PDF DOWNLOAD

SB4163E00 1
SB2003E00 3
SB2004E00 5
SB4164E00 13
Index 17
Specifications 19
Component measurements 19
Control Panel (Layout) 23
Current Measurements 19
Transistor Measurements 20
Console 21
Contactors 22
Display Layout 21
Direction Switch 21
Fuses 22
Head Capacitor 22
Instrument Panel 21
Thermal Switch – Control Panel 22
Tip Clearance (Gap) 22
Transistor Connections 20
Systems Operation 25
Accessory Circuits 39
Actuation Circuit 40
Control Circuit 42
DC-DC Converter 39
Flyback Circuit 46
Horn Circuit 39
Hour Meter Circuit 39
Hydraulic Pump Motor Circuit 41
Power Circuit 43
Behind Logic Unit 31
General Information 32
Logic Unit 32
Drive Circuit 47
Bypass Circuit 52
Control Circuit 47
Current Limit 51
Failure Protection Circuit 53
Flyback Circuit 50
Power Circuit 48
Thermal Protection Circuits 53
Location of Control Panel Components 30
Operational Circuit Elements 33
Accelerator Control 38
Battery Discharge Indicator (BDI) 37
Central Vehicle Monitoring System
(CVMS) International Pictorial Symbols 35
Central Vehicle Monitoring System 33
Contactors 36
Current Sensor 36
On Board “Run Time” Diagnostics
(Fault Detection) 33
Wait Mode 36
Symbol Library 29
Systems Operation 25
Glossary 25
Testing And Adjusting 54
Electrical System Adjustments130
Accelerator Control Linkage130
Activating Default Settings138
Battery Discharge Indicator (BDI) Adjustment134
Current Limit Test and Adjustment136
Electrical Braking (Plugging) Current
Test and Adjustment137
Lift Sensor131
Parking Brake Switch130
Programmable Features137
Programmable or Settable Option Features139
Quick Procedure for Programmable Features138
Rapid Tune-Up Procedure133
Setting Procedure Option Features137
Tilt and Auxiliary Switches132
Valve Control Card Adjustment131
Preparation Tests and Checks 54
Accessing Stored Error Codes 62
Battery Load Test 55
Battery Maintenance 55
Battery Tests 54
Built-In Diagnostic Operation 58
Cell Voltage Test 55
Control and Power System
Operational Checks 57
Erased Stored Error Codes 63
Hydrometer Test 55
Quick Diagnostic Procedure 63
Removal of Shorts to Chassis 56
Resistance to Chassis Checks 56
“Run Time” Diagnostics (Lift Truck in Operation) 58
Saving Service Records 62
“Self” Diagnostics (Lift Truck not in Operation) 59
Stored Error Codes 63
Visual Checks 56
System Tests and Adjustments112
Capacitor (Head)118
Component Tests115
Conductor and Switch Continuity118
Contactor Components119
Contactors119
Current Sensor121
Diode Replacement122
Diodes122
Discharging Head Capacitor
(HEAD CAP)112
Driver Board (Off Vehicle)125
Driver Board (On Vehicle)123
Logic Unit Quick Reference Voltage
Check115
Logics Removal113
Resistors (PR1 and PR2)128
“Run Time” Tests113
Test Equipment112
Thermal Switch129
Transistor Replacement DTR1 and
HTR1127
Transistors DTR1 and HTR1127
Troubleshooting 54
Troubleshooting Check List 54
Troubleshooting Problem List 64
SB4165E00143
Index147
Specifications149
Drive Motor151
Final Drives And Wheels152
General Tightening Torque149
Power Transfer Group152
Wheel Bearing Adjustment153
Systems Operation154
Differential And Drive Axles156
Drive Motor154
Power Transfer Group155
Testing And Adjusting157
Drive Motor162
Armature Terminal Test167
Armature Tests163
Brush Holder Test167

Brush Life Estimate168
Commutator Inspection165
Field Coil and Terminal Tests166
Motor Brushes162
Thermal Switch Tests168
Power Transfer Group Adjustments169
Pinion Depth Check170
Pinion Installation169
Power Transfer Group Bearing and
Clearance (Backlash)
Adjustments 171
Transaxle Adjustments169
Troubleshooting157
Checks During Operation157
Drive Motor157
Power Transfer Group and Final Drive161
Visual Checks157
Disassembly & Assembly173
Differential177
Drive Axle173
Power Transfer Group181
Special Service Tools and Jigs186
SB4166E00189
Index193
Specifications195
Hydraulic Control Valve195
Hydraulic Pump196
Hydraulic Pump Motor203
Lift Cylinders197
Priority Valve200
Sideshift Cylinder196
Steer Axle And Wheel202
Steering Unit201
Steering Wheel200
Tilt Cylinders199
Systems Operation204
Brake System219
Control Valve208
Electric Motors222
Hydraulic System204
Steering System215
Testing & Adjusting223
Brake System238
Hydraulic Pump Motor241
Hydraulic System234
Steering System236
Troubleshooting223
SB4167E00249
Index253
Brake Master Cylinder283
Control Panel284
Counterweight294
Drive Motor292
Drive Wheel292
Hood(with seat) Assembly255
Hydraulic Control Valve257
Hydraulic Pump Motor263
Overhead Guard256
Primary Lift Cylinder271
Priority Valve282
Standard Lift Cylinder267
Steer Wheels Bearings285
Steering Axle288
Steering Cylinder288
Steering Knuckles,
Kingpins And Bearings290
Steering Wheel277
Tie Rods287
Tilt Cylinders273
Trans-Axle293
SB2143E03295
Index299
Disassembly & Assembly301
Forks301
Backrest301
Carriage302
Mast305
Testing & Adjusting318
Carriage Adjustment318
Carriage and Mast Height
Adjustment320
Chain Adjustments319
Chain Wear Test319
Forks Parallel Check320
Tilt Cylinder Alignment321
Drift Test321
Tilt Cylinder Adjustment322
Lift & Tilt Mounting Group Adjustment323
Mast mounting Group
Adjustment324
SB4168E00325
SB4169E00327
SB2338E00329
Table of Contents331
Information Section332
Foreword332
Safety Section334
Important Safety Information334
Safety335
Warning Signs and Labels335
General Hazard Information339
Operation Information341
Maintenance Information343
Operator Restraint System(If Equipped)346
Avoiding Lift Truck Tipover350
Safety Rules352
How to Survive in a Tipover357
General Section358
Specifications358
Capacity Chart without Sideshifter360
Capacity Chart with Hook-On type Sideshifter362
Capacity Chart with Integral type Sideshifter364
Noise and Vibration366
Serial Number367
Operator’s Warning and Identification Plate368
Operation Section370
Operator’s Station and Monitoring Systems370
Lift Truck Control375
Before Operating the Lift Truck379
Operating Techniques385
Parking the Lift Truck388
Lift Fork Adjustment390
Storage Information391
Transportation Hints392
Towing Information393
Maintenance Section394
Inspection, Maintenance and Repair of Lift Truck Forks394
Torque Specifications398
Battery Discharge Indicator400
Battery401
Lubricant Specifications403
Cold Storage Applications405
Lubricant Viscosities and Refill Capacities407
Maintenance Intervals408
When Required410
Every 10 Service Hours or Daily425
First 50 – 100 Service Hours or a Week430
First 250 Service Hours or a Month431
Every 250 Service Hours or Monthly432
Every 500 Service Hours or 3 Months437
Every 1000 Service Hours or 6 Months441
Every 2000 Service Hours or Yearly447
Every 2500 Service Hours or 15 Months453
Environment Section454
Environment Protection454
Index Section455
Index455

S.M 2/2/2025