Daewoo Doosan Forklift D20-2 D25-2 D20S-2 D25S-2 D30S-2 Service Manual – PDF

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Daewoo Doosan Forklift D20-2 D25-2 D20S-2 D25S-2 D30S-2 Service Manual – PDF DOWNLOAD

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Daewoo Doosan Forklift D20-2 D25-2 D20S-2 D25S-2 D30S-2 Service Manual – PDF DOWNLOAD

Size : 45.3 MB
Format : PDF
Language : English
Brand: Daewoo Doosan
Type of machine: Forklift
Type of document: Service Manual
Model :
GC20-2, GC25-2, GC20S-2, GC25S-2, GC30S-2
G20-2, G25-2, G20S-2, G25S-2, G30S-2
D20-2, D25-2, D20S-2, D25S-2, D30S-2
Number of Pages: 958 Pages
Part Number: SB2032E01

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Daewoo Doosan Forklift D20-2 D25-2 D20S-2 D25S-2 D30S-2 Service Manual – PDF DOWNLOAD

Important Safety Information

• Most accidents involving product operation, maintenance and repair are caused by failure to observe
  basic safety rules or precautions. An accident can often be avoided by recognizing potentially
  hazardous situations before an accident occurs. A person must be alert to potential hazards. This
  person should also have the necessary training, skills and tools to perform these functions
  properly.
• Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
  result in injury or death.
  Do not operate or perform any lubrication, maintenance or repair on this product, until you have
  read and understood the operation, lubrication, maintenance and repair information.
• Safety precautions and warnings are provided in this manual and on the product. If these hazard
  warnings are not heeded, bodily injury or could occur to you or other persons .
• TABLE OF CONTENTS:

Daewoo Doosan Forklift D20-2 D25-2 D20S-2 D25S-2 D30S-2 Service Manual – PDF DOWNLOAD

SB2032E01 1
SB2003E00 2
SB2004E00 4
SB2005E00 12
Index 15
System Operation 17
Air Inlet And Exhaust System 36
Cooling System 31
Transaxle Oil Cooler 33
Dual Fuel System 28
System 29
Electrical System 37
Charging Circuit Operation 39
Electrical System Components 41
Starting Circuit Operation 38
Gasoline Fule System 20
Carburetor 21
General Information 17
Ignition System 18
Liquid Petroleum Fuel System 24
System With Gas/LP Carburetor 24
System With LP Carburetor 26
Lubrication System 34
Testing And adjusting 45
Air Inlet And Exhaust System 74
Camshaft Lobe Measurement 77
Cylinder Leakage Test 75
Restriction Lobe Measurement 75
Valve Clearance Adjustment 76
Cooling System 69
Belt Adjustment 73
Coolant Water 70
Cooling System Heat Problems 73
Cooling System Information And Maintenance Requirements 70
Cooling System Tests 71
Cooling System Visual Inspection 70
Electrical System 78
Alternators 82
Battery 79
Electrical System Test Equipment 78
Starting Motors 79
Fuel System 62
Accelerator Control Linkage Adjustment 63
Converter Pressure Test 69
Engine RPM Check 69
High Idle Speed Adjustment(Velocity Governor Adjustments) 64
Idle Mixture Adjustment – Gasoline 65
Idle Mixture Adjustment – LP 65
Low Idle Speed Adjustment 63
Power Mixture Adjustment 68
Ignition System 57
Ignition Commponent Checks 58
Ignition System Test 59
Ignition Timing Check And Adjustment 60
Lubrication System 74
Lubrication System Problems 74
Test Equipment 45
Troubleshooting 45
Troubleshooting Problem List: Gasoline Fuel System 45
Troubleshooting Problem List: Liquid Petroleum Fuel System 55
Troubleshooting Problem List: Gasoline Fuel System 46
Troubleshooting Problem List: Liquid Petroleum Fuel System 55
Specifications 85
Altermators103
Belt Tension105
Camshaft 94
Connecting Rod100
Crankshaft 95
Cylinder Block 93
Cylinder Head 89
Head Bolt Tightening Procedure 90
Valve Clearance 91
Cylinder Liner 98
Cylinder Liner Projection Procedure 98
Engine Mounting Groups102
Engine Timing100
Exhaust Manifold 89
Fuel Pump 88
Fuelock 86
Gas/LP Carburetor 86
Igition Sequence(Firing Order) 85
Ignition Timing 85
Intake Manifold 89
LP Fuel Converter 87
Oil Filter 88
Oil Pan 88
Oil Pump 89
Pistons 97
Radiator Cap102
Spark Plug 85
Starting Motors105
Valves 91
Water Temperature Regulator(Thermostat)103
SB2010E00106
Index115
Alternator123
Camshaft168
Carburetor124
Carburetor, Disassemble & Assemble124
Crankshaft And Main Bearings169
Cylinder Liners160
Distributor130
Distributor, Disassemble & Assemble132
Electric Fuel Pump143
Electric Staring Motor117
Electric Staring Motor, Disassemble & Assemble117
Exhaust Manifold142
Inlet Manifold141
Oil Filter And Base147
Oil Pan144
Oil Pump145
Pistons And Connecting Rod Assemblies155
Pistons And Connecting Rod Assemblies, Disassemblr & Assemble159
Radiator174
Rocker Shaft Assembly And Cylinder Head Assembly148
Spark Pluge139
Timing Chain Tensioner165
Timing Gear Cover164
Timing Gears And Plate167
Valve Cover143
Valves153
Water Pump139
Water Temperature Regulator137
SB2006E01176
Index178
Specifications180
Alternators200
Bosch K1 Series200
Delco Remy CS-121 Series200
Belt Tension198
Camshaft189
Carburetor Float Height184
Carburetors183
Low Idle Setting183
Power Mixture Setting183
Connecting Rods192
Crankshaft193
Cylinder Block195
Cylinder Head192
Electric Fuelock182
Engine Mount Groups198
Flywheel197
Flywheel Runout197
Flywheel Housing196
Flywheel Housing Runout196
Fuel Pumps185
Governors184
Ignition Coil180
Ignition Sequence (Firing Order)180
Ignition Timing180
LP Converter182
Manifolds186
Oil Filter186
Oil Pan185
Oil Pump186
Pistons And Rings191
Pressure Caps199
Spark Plug And Spark Plug Wires181
Starting Motors201
Nippondenso R14 Series201
Valve And Block Cover190
Water Pump199
Water Temperature Regulator
(Thermostat)199
Systems Operation202
Air Inlet And Exhaust System223
Cooling System220
LP or Dual Fuel System221
Dual Fuel System219
Electrical System225
Alternators226
Circuit Breaker227
Starting Motors225
Gasoline Fuel System205
Carburetor-Aisan206
Choke214
Governor214
Vacuum Advance215
General Information202
Ignition System203
Breakerless Ignition System203
Liquid Petroleum Fuel System215
Carburetor218
Converter216
Electric Fuelock Models215
Fuel Tank217
LP Relief Valve217
Lubrication System222
Timing Gears225
Testing And Adjusting228
Air Inlet And Exhaust System266
Camshaft Lobe Measurement269
Cylinder Leakage Test266
Cylinder Head Check270
Restriction Of Air Inlet And Exhaust266
Valve Clearance Adjustment267
Basic Block271
Flywheel And Flywheel Housing272
Oil Pump Installation271
Timing Gear Backlash Check271
Cooling System260
Belt Adjustment264
Cooling System Recommendation263
Cooling System Heat Problems262
Cooling System Tests260
Cooling System Visual Inspection260
Electrical System275
Alternators279
Battery275
Start Relay Tests279
Starting Motor276
Dual Fuel System258
Dual Fuel System Electrical Checks259
High Idle Speed Adjustment258
Idle Mixture Adjustment258
Low Idle Speed Adjustment258
Gasoline Fuel System251
Carburetor Adjustments251
Fuel Pump253
Governor Adjustments249
Accelerator Linkage Adjustment250
Mechanical Linkage250
Velocity Governor249
Ignition System242
Breakerless Ignition System Test244
Engine rpm Check246
Ignition Component Checks242
Ignition Timing Check And Adjustment247
Sensor Gap Adjustment246
Spark Plug Gap Check243
Liquid Petroleum Fuel System254
Carburetor Adjustment254
Converter Pressure Test257
Fuel Filter Check256
Inner Fuel System Leak Check256
Outer Fuel System Leak Check256
Recommendation For LP Fuel Systems257
Lubrication System265
Lubrication System Problems265
Oil Pressure Check266
Troubleshooting228
Troubleshooting Problem List:228
Gasoline Fuel System228
Liquid Petroleum Fuel System239
Dual Fuel System241
SB2011E01280
Index282
Air Cleaner287
Alternator284
Camshaft Bearings332
Coil285
Connecting Rod Bearings331
Crankshaft336
Crankshaft Front Seal335
Crankshaft Main Bearings329
Crankshaft Rear Seal336
Cylinder Head Assembly318
Distributor285
Electric Starting Motor284
Fan308
Fan Belt309
Fly Wheel333
Flywheel Housing334
Flywheel Ring Gear334
Front Housing326
Fuel Filter & Fuel Pump288
Fuel Line (Dual Fuel)300
Gas Carburetor297
Governor326
Inlet & Exhaust Manifolds291
LP Gas Carburetor293
LP Gas Converter296
LP Gas Fuelock295
Muffler290
Oil Filter & Adapter289
Oil Pan313
Oil Pump314
Pistons & Connecting Rods322
Radiator307
Rocker Shaft Assembly & Push Rods316
Timing Gears328
TORQUE SPECIFICATION TABLE283
Valve Cover309
Valve Lifters315
Valve Seat Inserts322
Valves320
Water Pump312
Water Temperature Regulator310
Water Temperature Sensor311
SB2012E02339
Index342
1 General Informations344
11 General Repair Instructions344
12 Engine Model and Serial Number344
13 Engine Specifications345
14 Engine Assembly349
2 Preventive Maintenance350
21 Preventive Maintenance350
22 Torque Specifications354
3 Major Maintenance355
31 Major Parts Fixing Bolts355
32 Engine Repair Kit358
33 Repair359
4 Engine Disassembly and Reassembly365
41 External Parts365
42 Internal Parts (Timing gear train)366
43 Inspection and Repair370
44 Reassembly386
5 Lubricating System398
51 General Description398
52 Oil Pump398
53 Oil Filter401
54 Oil Cooler402
6 Cooling System403
61 General Description403
62 Water Pump403
63 Thermostat406
7 Fuel System407
71 General Description407
72 Injection Nozzle409
73 Injection Pump Calibration410
8 Intake and Exhaust System413
81 Intake Manifold413
82 Exhaust Manifold413
9 Special Tool List414
Appendix416
– Engine Assembly(ELFFO)416
SB2013E02417
CONTENTS419
1 GENERAL INFORMATION420
11 General Repair Instructions420
12 Engine Specifications421
13 Torque Specifications422
14 Major Parts Fixing Bolts423
15 Engine Repair Kit429
16 Repair430
2 Engine Assembly436
21 General Description436
22 Disassembly437
23 Inspection and Repair447
24 Engine Reassembly463
3 Lubricating System479
31 General Description479
32 Oil Pump479
33 Oil Filter481
34 Oil Cooler483
4 Cooling System484
41 General Description484
42 Water Pump484
43 Thermostat487
5 Fuel System488
51 General Description488
52 Fuel Filter489
53 Injection Nozzle489
6 Special Tool List492
SB2007E01494
Index496
Specifications497
Alternator497
Systems Operation498
Alternator498
CS-121 Alternator Operation498
Alternator Components499
Alternator Operation Schematic501
Introduction498
Testing And Adjusting502
Alternator503
Alternator Output Test503
Machine Test503
Troubleshooting502
Troubleshooting Problem List502
Troubleshooting Problems502
SB2008E01506
Index508
Specifications509
Alternator509
Systems Operation511
Alternator511
Alternator Operation511
Alternator Components511
Alternator Operation Schematics513
Regulator Operation517
Introduction511
Testing And Adjusting519
Alternator Component Tests521
Brush Tests525
Capacitor Test522
Regulator Test521
Rectifier Tests524
Rotor Field Winding Tests523
Stator Tests523
Alternator Output Test520
Bench Test521
Machine Test520
Troubleshooting519
Troubleshooting Problem List519
Troubleshooting Problems519
Disassembly and Assembly526
Alternator526
Assemble Alternator528
Disassemble Alternator526
SB2009E01530
Index532
Specification533
Starting Motor533
Systems Operation535
Starting Motor535
Introduction535
Starting Motor Operation Diagrams538
Testing And Adjusting541
Starting Motor542
Off Machine No Load Test545
On Machine Starting Motor Diagnosis Procedure542
Starting Motor Component Tests546
Troubleshooting541
Troubleshooting Problem List541
Troubleshooting Problems541
Disassembly And Assembly551
Starting Motor551
Assemble Starting Motor554
Disassemble Starting Motor551
SB2033E01- Volumn II 0
SB2032E01558
SB2003E00559
SB2004E00561
SB2014E00569
Index572
Specifications574
Torque Converter574
Forward And Reverse Control Group574
Transaxle Solenoid574
Transaxle575
Final Drives And Wheels576
Drive Tire Installation578
Inching Valve579
Drive Wheel Installation579
Drive Axle Mounting Group580
Drive And Pump Group581
Modulating Valve Group582
Systems Operation583
General Information583
Transaxle584
Torque Converter584
Transaxle General Information585
Transaxle Power Flow587
Transaxle Hydraulic System592
Differential603
Final Drive604
Testing And Adjusting605
Troubleshooting605
Visual Checks605
Check List During Operation605
Check List From Operation Noises607
Check List From Pressure Tests608
Transaxle Tests And Adjustments610
Transaxle Pressure Tests610
Converter Stall Test612
Electric Control System Tests614
Inching Pedal Adjustment617
Transaxle Mechanical Adjustment619
Wheel Bearing Adjustment622
SB2015E00623
Index626
Transaxle628
Transaxle, Disassemble & Assemble630
Bevel Gear Clearances & Backlash Adjustment643
Engine, Torque Converter & Gerotor Pump Group646
Torque Converter & Gerotor Pump Group651
Separation & Connection Of Torque Converter & Gerotor Pump Group654
Gerotor Pump Group, Disassemble & Assemble655
Final Drives And Hubs (Shoe Brake Type)660
Final Drives And Hubs (Oil Cooled Disc Brake Type)662
Universal Joint664
Conuterweight665
SB2097E00667
Index669
Specifications670
Hydraulic Control valve670
Systems Operation671
Hydraulic System
(D20/25/30S-2, G20/25/30S-2, GC20/25/30S-2 Model)671
Hydraulic System (D20/25-2 Model Only)675
Anti-Stall And Remote Relief Valve678
Hydraulic Control Valve680
Assembly And Construction680
Valve Operation681
Flow Control And Relief Valve683
Check Valve684
Testing And Adjusting685
Troubleshooting685
Hydraulic System686
Relief Valve Pressure Check686
Flow Control Valve Adjustment687
Disassembly And Assembly688
General688
Unit Disassembly688
Cleaning, Inspection And
Repair689
Assembly691
SB2016E01693
Index696
Specifications698
Hydraulic Control Valve698
Remote Relief Valve698
Hydraulic pumps699
Lift Cylinders699
All Standard Or Full Free Triple Secondary699
Full Free Triple Lift And Full Free Lift Primary700
Full Free Lift Secondary700
Tilt Cylinders701
Sideshift Cylinder703
Mast703
Carriage704
Lift Relay Group705
Standard Lift705
Full Free Lift706
Full Free Triple Lift707
Lift And Tilt Mounting Group708
Steering Wheel709
Priority Valve709
Steering Gear710
Steer System Check Valve711
Steer Axle And Wheel711
Steer Tite Installation (GC Models Only)712
Steer Wheel Mounting (D, G Models Only)712
Brakes713
Shoe Type Brakes713
Oil Cooled Disc Brakes713
Brake Drum Surface Wear714
Parking Brake715
Systems Operation716
Hydraulic System716
Anti-Stall And Remote Relief Valve719
Hydraulic Control Valve720
Lift Cylinders And Mast725
Steering System728
Hydraulic Operation (Load Sensing Closed Center Steer Gear)728
Steering Cylinder729
Steering Gear730
Brake System732
Master Cylinder732
Shoe Type Brakes733
Oil Cooled Dise Brakes734
Parking Brake734
Testing And Adjusting735
Troubleshooting735
Visual Checks735
Performance Tests735
Hydraulic System And Mast736
Steering System739
Brake System (Shoe Type)740
Brake System (Oil Cooled Disc Type)741
Parking Brakes742
Hydraulic System742
Relief Valve Pressure Check742
Lift And Tilt Relief Valve Check And Adjustment743
Sideshift Relief Valve Check And Adjustment743
Flow Control Valve Adjustment744
Pump Efficiency Check744
Lift Cylinder Air Removal745
Mast And Carriage 746
Mast Adjustment746
Carriage Adjustment750
Chain Adjustments751
Chain Adjustment Check751
Chain Adjustment752
Chain Wear Test752
Tilt Cylinder Alignment753
Tilt Angle Check754
Tilt Cylinder Length Check754
Tilt Cylinder Adjustment754
Drift Test755
Drift Test For Lift System755
Drift Test For The Tilt System755
Steering System756
Steer Wheel Bearing Adjustment756
Steering Axle Stop Adjustment756
Steering Knuckle Bearing Preload Adjustment757
Steering System Air Removal757
Steering System Pressure Check758
Brake System760
Brake System Air Removal760
Brake Adjustment (Shoe Brakes Only)760
Pedal Adjustment762
Parking Brake Test762
Parking Brake Adjustment763
SB2017E01764
Index767
Hood (with seat) Assembly769
Overhead Guard769
Forks770
Backrest771
Carriage771
Carriage, Disassemble & Assemble774
Mast776
Mast, Disassemble & Assemble777
Secondary Lift Cylinders, Disassemble & Assemble787
Primary Lift Cylinder790
Primary Lift Cylinder, Disassemble & Assemble791
Tilt Cylinders793
Tilt Cylinders, Disassemble & Assemble794
Steering Wheel797
Steering Pump798
Steering Gear ( Pump), Disassemble & Assemble799
Brake Master Cylinder803
Brake Master Cylinder, Disassemble & Assemble803
Steer Wheels & Bearings806
Tie Rods808
Steering Knuckles, King Pins & Bearings809
Steer Axle810
Steering Cylinder812
Steering Cylinder, Disassemble & Assemble813
Brakes (Drum Type), Brake Adjuster & Wheel Cylinder816
Brakes (Oil Cooled Disc Type)819
Hydraulic Control Valves821
Hydraulic Control Valves, Disassemble & Assemble821
Priority Valve827
Priority Valve, Disassemble & Assemble828
Hydraulic Pump, Disassemble & Assemble829
Creeper & Brake Control Group831
Creeper & Brake Control Group, Disassemble & Assemble833
Inching Control Valve, Disassemble & Assemble837
SB2018E01838
SB2019E01841
SB2020E02847
Table of Contents848
Information Section849
Foreword849
Safety Section850
Important Safety Information850
Safety851
Warning Signs and Labels
4851
General Hazard Information855
Crushing or Cutting Prevention857
Burn Prevention858
Fire or Explosion Prevention858
Mounting and Dismounting860
Preparing to Start the Engine860
Starting the Engine861
Preparing to Operate the Lift Truck
14861
Operation the Lift truck861
Lift Truck Parking862
General Section863
Serial Number and Information of Noise and Vibration863
Operation Section867
Operator’s Station and Monitoring Systems867
Controls871
Seat875
Refueling876
Before Starting the Engine878
Lift Fork Adjustment880
Starting the Engine884
Dual Fuel System886

After Starting the Engine887
Lift Truck Operation888
Operating Techniques890
Parking the Lift Truck894
BEFORE STORAGE895
Transportation Hints896
Towing Information897
Maintenance Section898
Tire Inflation Information898
Torque Specifications899
Cooling System Specifications901
Fuel Specifications903
Lubricant Specifications905
Lubricant Viscosities and Refill Capacities907
Maintenance Intervals908
When Required909
Every 10 Service Hours or Daily923
First 100 Service Hours927
First 250 Service Hours929
Every 250 Service Hours or Monthly930
Every 500 Service Hours or 3 Months936
Every 1000 Service Hours or 6 Months943
Every 2000 Service Hours or 1 Year946
Index
Section955
Index955

S.M 20/2/2025