Doosan SB4239E Service Manual – D15S-5 to GC33E-5 Lift Trucks, Diesel/LPG/Gas Engines

Description

The Doosan SB4239E Service Manual is the complete multi-volume workshop library for Doosan counterbalance lift trucks, covering the D15S-5, D18S-5 and D20SC-5 diesel range, the G15S-5, G18S-5 and G20SC-5 LP/gasoline range, the GC15S-5, GC18S-5 and GC20SC-5 cushion-tyre range, the G20E-5 through G30E-5 and GC20E-5 through GC33E-5 chassis, and the B13T-5 through B20X-5 and B15S-5 through BC20SC-5 mast-equipped trucks. Issued as form SB4239E in September 2010, this PDF bundles every system-specific service manual, diagnostic flow chart, specification table, wiring and hydraulic schematic, and disassembly/assembly procedure into one indexed document that a technician can search by symptom, system or component.

File Details

• Manual type: Multi-volume factory service manual compilation
• Document numbers: SB4239E / SB4240E01
• Publication date: September 2010
• Language: English
• Page count: Approximately 1,188 pages
• File format: PDF
• Brand: Doosan
• Series covered: D15S-5 through D20SC-5, G15S-5 through G20SC-5, GC15S-5 through GC20SC-5, G20E-5 through G30E-5, GC20E-5 through GC33E-5, B13T-5 through B20X-5, B15S-5/BC15S-5 through BC20SC-5

Chapters Covered

• Service Manual Contents (SB4240E01)
• Safety (SB2003E00)
• Torque Specifications (SB2004E00)
• Engine
  • A2300 Diesel Engine (SB4106E01)
  • V2403 Diesel Engine (SB4400E00)
  • G420F(E) LP/Gasoline Engine (SB4241E01)
  • Delco Remy CS-121 Series Alternator (SB2007E02)
  • CS-105D Series Alternator (SB4050E00)
• Power Train (SB4243E00)
• Power Train D & A (SB4248E00)
• Vehicle Systems (SB4365E00)
• Vehicle Systems D & A (SB4245E01)
• Mast System (SB2143E04)
• Hydraulic System Schematic (SB4246E00)
• Electric Systems Schematic (SB4247E01)
• Operation & Maintenance Manual (SB2353E / SB2354E)

What makes this Doosan SB4239E service manual different from a single-system book is that it hands you the complete diagnosis and repair chain from the operator’s warning plate through the last bearing torque. The engine chapters for the A2300 and V2403 diesels and the G420F(E) LP/gasoline engine document troubleshooting logic charts by symptom — will not crank, cranks but will not start, hard start, surging, rough idle, misfiring, low power, excessive smoke, low oil pressure, coolant loss, contaminated coolant, compression knocks and excessive fuel consumption — then walk you into the specific repair procedure. The power train section covers the torque converter, transmission, forward and reverse clutch packs, valve body, drive axle, differential, final drives and wheel bearings, with tightening torques and pressure-test procedures. The vehicle systems volume covers the control valve in section-by-section detail (inlet, lift, tilt, auxiliary, outlet), the hydraulic gear pump, steering unit, priority valve, brake master cylinder and wheel cylinders, plus the delayed engine shutdown system and the Operator Sensing System (OSS).

Engine Coverage in Detail

The A2300 diesel chapter opens with engine external components and specifications, then moves through coolant system, fuel system, air system, lubricating system and electrical system, with each section giving troubleshooting logic, removal, disassembly, inspection, assembly and installation. Injection pump timing uses both the dial indicator method and the gear-train alignment method, and the fuel system chapter includes the Robert Bosch VE pump, governor adjustments, manual shutdown levers, advance timing mechanism and electrical shut-off valve testing. The G420F(E) LP/gasoline engine chapter covers the MI-07 engine management system in depth: SECM 48-pin module, coil-on-plug ignition, electronic throttle body, TMAP, camshaft and crankshaft position sensors, oxygen sensors, LP regulator (N-2007 and N-2001), CA100 mixer, fuel trim valves and the full diagnostic fault code list with flash-code reading, clearing and corrective actions. The alternator chapters cover both the Delco Remy CS-121 and CS-105D units with output testing, fault-condition charts and terminal diagnostics.

Diagnostics, Schematics and Testing

The troubleshooting logic charts in the engine sections are structured cause-by-cause with a correction reference back to the exact procedure page, so a technician can follow a symptom to the repair without jumping between volumes. The electric schematic drawings cover the D15S-5, D18S-5, D20SC-5 diesel chassis as well as the G15S/18S/20SC-5 and GC15S/18S/20SC-5 LP and dual-fuel chassis, plus the G20/25/30/32E-5 variants. The hydraulic schematic covers the lift, tilt, sideshift, priority valve and steering circuits with relief pressure values by model. The mast system module covers forks, backrest, carriage, mast assembly, chain adjustment, chain wear test, carriage roller extrusion, tilt cylinder alignment and drift testing. Every torque value, clearance, wear limit and adjustment figure is presented in both metric and inch units where the original document does so.

Operation & Maintenance Manuals Included

Two full operation and maintenance manuals are bound into this PDF — SB2353E for the D15S-5, D18S-5, D20SC-5, G15S-5, G18S-5 and G20SC-5, and SB2354E for the GC15S-5, GC18S-5 and GC20SC-5. These add the operator-facing material that a service manual alone does not carry: safety decals and their locations, capacity charts (with and without sideshift), serial number locations, operator’s station and monitoring systems, seat switch system, lift truck controls, refuelling procedure for diesel, gasoline and LP-gas, starting procedure for each fuel, operating techniques, parking, storage, transportation, towing, fork inspection and maintenance, tyre inflation, torque specifications, cooling system specifications, fuel specifications, lubricant specifications and the full maintenance interval schedule from every 10 service hours to every 3000 service hours or 18 months.

Who This Manual Is For

This Doosan SB4239E service manual is written for the working technician, the fleet maintenance shop and the owner-operator who services their own lift truck. It assumes access to standard hand tools and to the special tools called out in the procedures, and it assumes the reader is prepared to work from measured values rather than guesswork. Because the document bundles several factory service manuals, the depth varies by section — the engine chapters are the most detailed, the schematic modules are the most compact — but every chapter is complete as issued by the manufacturer. Whether you are diagnosing a no-start on an A2300 diesel, chasing an MIL fault code on a G420F(E) LP truck, rebuilding a forward clutch pack, adjusting mast chains, or testing the delayed engine shutdown system, the procedure and the specification are in this file.

Get Instant Access

Everything on this page is delivered as a single PDF that downloads immediately after checkout — no shipping, no waiting, no physical binder to lose. Keep it on the shop laptop, the tablet on the service cart, or the phone in your pocket, and print the pages you need for the job in front of you. The Doosan SB4239E Service Manual is the reference you reach for when the lift truck is down and the answer has to be right the first time.

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