Product Type:
Forklift Truck Service Workshop Repair Manual
Product Name:
DOOSAN Forklift Truck Service Workshop Shop Repair Manual B15T-5 B18T-5 B20T-5 B16X-5 B18X-5 B20X-5
Model Codes Covered:
B15T-5, B18T-5, B20T-5, B16X-5, B18X-5, B20X-5
Target Audience:
Professional forklift technicians, maintenance departments, fleet managers, and skilled DIY mechanics working on Doosan B-Series 5th generation electric forklifts.
Manual Value Proposition:
Provides essential, detailed technical information crucial for maintaining and repairing these specific Doosan models, ensuring optimal performance, longevity, and safety. It is the definitive resource for authorized service and repair.
Manual Advantage:
Comprehensive 500-page document offering in-depth technical data, diagrams, and procedures specifically for the B15T-5, B18T-5, B20T-5, B16X-5, B18X-5, B20X-5 series forklifts.
Primary Models Covered:
B15T-5, B18T-5, B20T-5 (AC 36V, 48V) and B16X-5, B18X-5, B20X-5 (AC 48V)
Type:
Full Workshop / Service / Repair Manual
Format:
Likely Digital (PDF) or Printed Booklet (details not specified, but typical for this type of manual)
Major Systems:
Engine, Powertrain, Electrical System, Hydraulic System, Chassis, Operator Compartment, Safety Systems, Cooling System, Fuel System, Braking System, Steering System, Drive Axle, Lift/Tilt Mechanisms, Mast Systems
Mast And Forks:
Detailed information on mast assembly, lift chains, side shift mechanisms, fork assembly, and related hydraulic components.
Steering System:
Coverage of the steering mechanism, including electrical steering components, tie rods, and alignment procedures.
Braking System Details:
Coverage of service brakes, parking brakes, and potentially regenerative braking system components and maintenance.
Repair And Maintenance:
Detailed troubleshooting guides, diagnostic procedures, repair instructions, maintenance schedules, component replacement, adjustments, inspections, overhaul procedures, electrical wiring diagrams, hydraulic schematics
Electrical Diagnostics:
Detailed wiring diagrams for all electrical circuits, troubleshooting procedures for sensors, actuators, and control modules, including AC motor controller diagnostics.
Hydraulic System Repair:
Schematics for hydraulic systems, troubleshooting for lift, tilt, and steering functions, component replacement (pumps, valves, cylinders), and bleeding procedures.
Troubleshooting Electrical:
Systematic approach to diagnosing electrical faults using multimeters, oscilloscopes, and the forklift's diagnostic interface.
Mast Maintenance:
Procedures for inspecting and lubricating mast channels, lift chains, and rollers, as well as adjusting chain tension.
Depth Of Information:
Comprehensive coverage for both routine maintenance and major repairs, including complete disassembly and reassembly of components, advanced diagnostics, and technical specifications for all covered systems.
Component Overhaul:
Instructions for the complete disassembly, inspection, repair, and reassembly of major components such as drive motors, hydraulic pumps, and steering units.
Torque Specifications:
Precise torque values for all critical fasteners and bolts throughout the forklift, ensuring correct assembly and preventing component damage.
Digital Format:
Assumed PDF (Portable Document Format) for digital distribution, allowing for searchability and easy printing of specific sections.
Print Readability:
High quality, suitable for clear reproduction of diagrams, schematics, and text. Expect clarity for technical illustrations and wiring diagrams.
Printed Format Binding:
If printed, likely spiral-bound or comb-bound for lay-flat usability in a workshop environment.
Printed Format Paper:
If printed, expected to be on durable paper stock, possibly with heavier weight for cover and protective elements.
Manual Scope:
This is a comprehensive workshop manual, covering all aspects of repair and maintenance, not a condensed user guide or parts list.
Engine Type:
Electric AC Motor
Ac Motor Technology:
Detailed information on the AC traction and hydraulic motors used, including specifications, testing procedures, and common failure modes.
Voltage Options:
36V and 48V (AC)
Motor Controller Diagnostics:
Specific fault codes generated by the AC motor controller, their meanings, and troubleshooting steps.
Power Source:
Battery Electric (specific battery types, capacities, and charging procedures would be detailed within the manual)
Transmission Type:
Electric Drive System (typically integrated with the motor and drive axle)
Drive Configurations:
Likely single motor driving a differential axle. Manual will detail any variations.
Controller Details:
The manual will cover AC motor controllers, regenerative braking, and power management systems.
Drive Control System:
In-depth explanation of the electronic drive control system, regenerative braking functionality, acceleration and deceleration profiles, and power limit settings.
Model Capacity Range:
Capacities range from approximately 1500 kg (B15T-5) to 2000 kg (B20T-5, B20X-5).
Turning Radius:
Manual will list the minimum turning radius for different mast configurations and tire types, crucial for maneuverability in confined spaces.
Operator Compartment Design:
Ergonomic design focusing on operator comfort and safety. Manual will detail operator controls, seating adjustments, and visibility features.
Mast Lift Heights:
Manual will specify available mast types (e.g., Duplex, Triplex) and their corresponding lift heights and lowered/extended dimensions.
Vehicle Weights:
Manual will provide operating weights, axle load capacities (front/rear), and battery weight estimations.
Axle Loading Specifications:
Detailed breakdown of laden and unladen axle weights, essential for understanding load distribution and stability requirements.
Battery Weight And Compartment Specifications:
Details on the battery compartment dimensions, access, and the importance of correct battery weight for stability.
Safety Standards:
Compliance with relevant industry safety standards (e.g., ANSI/ITSDF B56.1, ISO 3691). Manual will detail safety interlocks, warning systems, and operational safety guidelines.
Operator Assist Features:
Features such as automatic braking, speed reduction on turns, and advanced control systems for stability. Troubleshooting and calibration for these systems will be covered.
Parking Brake System:
Information on the operation, adjustment, and maintenance of the parking brake, typically an electronic or automatic system.
Structural Safety:
Overhead guard design, load backrest, seat belts, and structural integrity of the chassis. Manual will cover inspection and maintenance of these components.
Operator Interface:
Modern operator consoles with digital displays for system status, battery charge, error codes, and operational parameters. Manual will cover interpretation of these displays.
Control System Features:
Advanced electronic control units (ECUs) managing motor speed, lift functions, and safety features. Manual will provide diagnostics for ECU-related fault codes.
Operator Presence System:
Information on the operator presence system (seat sensor) and troubleshooting if it malfunctions.
Diagnostic Ports And Capabilities:
Details on diagnostic connectors and communication protocols for advanced diagnostic tools. Potential for telematics integration may be mentioned.
Routine Maintenance Schedule:
Manual will detail recommended service intervals for daily checks, weekly inspections, monthly maintenance, and annual services, including lubrication, filter changes, and system checks.
Battery Maintenance Schedule:
Guidelines for battery watering, equalization, and inspection to maximize lifespan and performance.
Hydraulic Fluid Type:
Likely a high-quality ISO VG 32 or VG 46 hydraulic oil. Specific Doosan recommended fluid grades and capacities will be provided.
Lubricant Specifications:
Manual will specify greases and lubricants for various points (e.g., mast rollers, steering components, drive axle) according to Doosan's standards.
Brake Fluid Type:
If applicable (e.g., for certain brake systems), specifications for brake fluid type and bleeding procedures.
Common Wear Items And Diagnostics:
The manual will aid in diagnosing common wear items and potential issues such as battery performance degradation, controller faults, hydraulic leaks, and wear on lift chains and tires. It will provide troubleshooting flowcharts for these scenarios.
Troubleshooting Charts:
Flowcharts and decision trees for diagnosing common faults and error codes displayed by the forklift's control system.
Doosan Industrial Vehicle History:
Doosan is a global leader in material handling equipment with a long history of innovation and reliability. The B-Series represents their modern approach to electric forklift design.
B Series Development:
The '-5' designation typically signifies a specific generation or major update in Doosan's forklift technology, focusing on improved efficiency, performance, and operator ergonomics.
Manufacturing Focus:
Doosan forklifts are manufactured with a focus on durability and performance in demanding industrial environments. Specific manufacturing locations are generally global.
