Covered Models Lp Engine G430E G643E:
G20P-3, G25P-3, G30P-3, G32P-3, G33P-3, GC20P-3, GC25P-3, GC30P-3, GC32P-3 (with G430E Tier LP Engine); G35S-2, G40S-2, G45S-2, G50C-2, G50S-2, G60S-2, G70S-2 (with G643E Tier LP Engine)
Covered Models Lp Engine G420E G424E:
G15S-2, G18S-2, G20SC-2, GC15S-2, GC18S-2, GC20SC-2 (with G420E Tier LP Engine); G20E-3, G25E-3, G30E-3, G32E-3, GC20E-3, GC25E-3, GC30E-3, GC32E-3 (with G424E Tier LP Engine)
Covered Models Electric Microcontroller 5 Series:
B20S-5, B25S-5, B30S-5, B32S-5, BC20S-5, BC25S-5, BC30S-5, BC32S-5, BC25SE-5
Covered Models Electric Operation Maintenance 3 Series:
B20S-3, B25S-3, B30S-3
Covered Models Electric Specifications Systems B Series:
B13T-2, B15T-2, B18T-2 (48V: P/N A154600, P/N A154240; 36V: P/N A154600, P/N A154701)
Covered Models Electric Specifications Systems B Series 5:
B20S-5, B25S-5, B30S-5, B32S-5, BC20S-5, BC25S-5, BC30S-5, BC32S-5, BC25SE-5
Covered Transmissions:
Three Speed Power Shift Transmission: 3WG 116/161 (FV - 00001 ~ UP, FX - 00001 ~ UP, GS - 00001 ~ UP, F1 - 00003 ~ UP, F2 - 00004 ~ UP, F3 - 000010 ~ UP)
Estimated Page Count:
Very Comprehensive (Exact page count not specified, but implied to be extensive)
Manual Type:
Factory Workshop Repair Service Manual; Operation & Maintenance Manual; Specifications; Systems Operation; Testing & Adjusting
Language:
English (Presumed based on typical OEM manuals for global markets)
Format:
PDF (High Quality)
Engine Systems:
LP Gas Engine (G430E, G643E, G420E, G424E Tiers): Fuel system, ignition system, cooling system, lubrication system, intake and exhaust systems, engine diagnostics, troubleshooting, repair procedures, overhaul.
Electric Powertrain Systems:
Electric Forklift Powertrain: Motor control systems, battery management, controller diagnostics, wiring diagrams, charging systems, regenerative braking systems.
Transmission Systems:
Three Speed Power Shift Transmission (3WG 116/161): Hydraulic system, torque converter, gear selection, lubrication, troubleshooting, repair, and adjustment.
Hydraulic Systems:
Hydraulic Lift and Tilt System: Pump, cylinders, valves, hoses, filters, fluid specifications, pressure testing, troubleshooting, and repair.
Electrical Systems:
Electrical System: Wiring harnesses, lighting, sensors, control modules, fuses, relays, battery system, starter, alternator (for IC models), diagnostic codes, troubleshooting, and component testing.
Steering And Braking Systems:
Steering System: Hydraulic power steering, steering linkages, wheel alignment. Braking System: Hydraulic brakes, parking brake, brake adjustments, fluid specifications.
Chassis And Body:
Chassis, frame, mast assembly, forks, counterweight, operator compartment, body panels, maintenance access points.
Microcontroller Control Systems:
Advanced Microcontroller Systems: Specific diagnostic procedures, parameter settings, software updates, fault code interpretation, and troubleshooting for B-Series electric models.
Maintenance Procedures:
Preventive maintenance schedules, lubrication points, filter changes, fluid level checks and top-offs, battery maintenance (electric models), tire pressure checks.
Diagnostic Procedures:
Troubleshooting guides for all major systems, diagnostic fault codes (DTCs), on-board diagnostics (OBD) information (where applicable), symptom-based troubleshooting, electrical system diagnostics.
Repair Procedures:
Step-by-step repair instructions for engine components, transmission overhaul, hydraulic system repairs, electrical component replacement, mast and fork repairs, steering and brake system repairs.
Testing And Adjustment:
System testing procedures, pressure checks, valve adjustments, component calibration, performance testing, alignment procedures.
Specifications And Data:
Torque specifications for fasteners, fluid capacities, fluid types, electrical resistance values, pressure settings, dimensional data, performance specifications.
Depth Of Coverage:
Comprehensive. Covers everything from basic maintenance and inspections to in-depth component overhaul, advanced diagnostics, and troubleshooting for both Internal Combustion (IC) and Electric models.
Diagnostic Complexity:
Advanced. Includes detailed diagnostic flowcharts, fault code interpretations, and procedures for using diagnostic tools specific to Doosan forklifts and their controller systems.
Rebuild Procedures:
Full rebuild procedures for engines, transmissions, hydraulic pumps, and motors are included, providing component-level detail.
Typical Intervals:
Daily checks, weekly inspections, monthly services, annual major services. Specific intervals for fluid changes, filter replacements, and component inspections are detailed for each model and operating condition.
Engine Oil Spec:
API Service Category (e.g., CH-4, CI-4) and viscosity grade (e.g., 10W-30, 15W-40) are specified based on engine type and operating temperature. Specific Doosan-approved oils may be listed.
Hydraulic Fluid Spec:
ISO VG classification (e.g., 32, 46) and fluid type (e.g., anti-wear hydraulic oil) are specified. Refer to manual for exact Doosan recommended fluids.
Transmission Fluid Spec:
Specific ATF (Automatic Transmission Fluid) or hydraulic fluid type for the power shift transmission is provided, along with capacity. Electric forklifts may have gearbox oil specifications.
Coolant Spec:
Ethylene glycol based antifreeze/coolant with specific corrosion inhibitors, and appropriate mix ratio with distilled water. Typically a 50/50 mix.
Common Wear Items:
Wear on mast rollers, fork tips, brake pads/shoes, hydraulic hoses, and electrical connectors. Battery degradation in electric models.
Engine Specific Issues:
Potential for LP fuel system leaks, ignition system issues, and cooling system malfunctions (overheating, leaks) depending on age and maintenance. Manual provides diagnostics for these.
Electric Specific Issues:
Controller faults, battery capacity loss, connection issues in high-voltage systems, traction motor wear. Manual provides detailed troubleshooting for controller codes.
