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Summary of Contents for Daewoo B20S-2
- Page 1 SB2025E01 A u g . 1 9 9 9 Specifications Systems Operation Testing & Adjusting Disassembly & Assembly Lift T rucks Power T rain B20S-2, B25S-2, B30S-2 BC20S-2, BC25S-2, BC30S-2...
- Page 2 If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubri- cation, maintenance or repair procedures you choose.
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Page 4: Table Of Contents
Index Disassembly & Assembly Systems Operation Brakes, Brake Adjuster And Wheel Cylinder...36 Drive Motor............... 6 Final Drive ..............8 Final Drives And Hubs..........45 General Information..........5 Power Transfer Group..........7 Oil Cooled Disc Type Brake ........48 Power Transfer Group ..........39 Testing And Adjusting Drive Motor..............14 Armature Terminal Test ........19... -
Page 6: Systems Operation
Systems Operation General Information Power Flow (1) Final drive (2) Power transfer group (3) Drive motor The power train for the B, BC MODEL Lift Trucks consists of three main components: drive motor (3), power transfer group (2) and final drive (1). Electric storage batteries are used as a power source for drive motor (3). -
Page 7: Drive Motor
Drive Motor Drive Motor (1) Shaft. (2) Cover. (3) Thermal switch (thermostat). (4) Commutator. (5) Armature assembly. (6) Field coils. (7) Frame. (8) Brush holder. The drive system is operated by a direct current (DC) The four motor brushes are held in four brush hold- motor. -
Page 8: Power Transfer Group
Power Transfer Group Power Transfer Group (1) Bevel gear (2) Differential case (3) Helical gear (4) Spiral hypoid pinion (5) Input Gear (6) Drive Motor Shaft The power transfer group is mounted under the transfer group lets the inside wheel stop or turn slow- frame in the front of the lift truck. -
Page 9: Final Drive
Final Drive Final Drive (1) Axle shaft (2) Hub (3) Drive wheel (4) spindle The power transfer group turns axle shaft (1). The gear teeth on the end of axle shaft (1) engage the gear teeth of hub (2). The gear teeth of hub (2) are on the inside diameter of the hub, which causes the rotation of the hub to be the same as the axle shafts. -
Page 10: Troubleshooting
Troubleshooting WARNING If an electrical failure or an overload of the motor Visual Checks is present, personnel must not breathe the toxic fumes which are a product of the burnt insulation. Make a visual inspection of the truck to check for All power must be disconnected from the motor problems. - Page 11 4. Control panel operation not correct: These can cause transistors to become defective, See the MicroController System Operation control panel failure or drive fuse to go bad. module. Problem 3: Neither traction or hydraulic will last 5. Brushes are worn: through a complete normal work period.
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Page 12: Testing And Adjusting
The duty cycle is too heavy, change the duty adaptable to the motor: cycle. Make sure all the brushes are of DAEWOO standards. Do not use other brands of brushes. 3. Defective drive motor: See Armature Commutator Inspection in Testing f. -
Page 13: Testing And Adjusting
Disassemble motor, remove the debris with air pressure. If necessary, dry the motor with heat to 90¡C (194¡F) 3. Grades of brushes mixed: Make sure all the brushes are of DAEWOO standards. Do not use other brands of brushes. Power Train Testing And Adjusting... -
Page 14: Power Transfer Group And Final Drive
Nut on drive gear not tightened correctly. Install tires that have good traction per b. Drive gears have a defect (warped). recommendation from DAEWOO Inc. 2. Loose or broken bearings. 5. Lift truck work load is too heavy or the duty cycle too long: 3. -
Page 15: Drive Motor
Install Brushes (1) Brushes. NOTICE Installation of the wrong brushes can cause early motor failure. Always make sure the correct DAEWOO brushes are installed. Brush Measurement 5. Install new brushes(1). Make sure the brushes 2. If the brush length is less than 19 mm (.75 in) on move freely in the brush holders. -
Page 16: Armature Tests
WARNING NOTICE Never use air pressure that is more than 205 kPa (30 Wear eye protection when seating, polishing or psi). Make sure the line is equipped with a water filter. cleaning the motor with air pressure. During the seating and polishing procedure, keep fingers away from components in rotation. - Page 17 Ground Test Open Circuit Test Ground Test. Open Circuit Test A digital multimeter can also be used to test for 1. Put the digital multimeter Function / Range Switch grounds. Put the Function/Range Switch on the 2M on the 200 ohm resistance (½) scale. resistance (½) scale.
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Page 18: Commutator Inspection
Commutator Inspection Surfaces of Commutators that need Replacement EHPS009B EHPS011B Grooves on the Commutator Surface Marks on the Commutator Surface Grooves on the commutators surface are caused by Marks on the commutator surface are an indication a cutting material in the brush or atmosphere. that metal has moved from the commutator surface to the carbon brushes. -
Page 19: Field Coil And Terminal Tests
Ground Test EHPS013B Ground Test Pitch BarÐMarks on the Commutator Surface (1) Field Terminal. (2) Motor housing. Pitch barÐmarks cause low or burnt marks on the 1. Put the digital multimeter Function/Range Switch commutator surface. on the 20M resistance (½) scale. 2. -
Page 20: Armature Terminal Test
Armature Terminal Test 1. Put the digital multimeter Function/Range Switch Tools Needed on the 20M resistance (½) scale. Digital Multimeter Or Equivalent 2. Put one test lead to an outer brush terminal (1) and the other test lead to the motor housing (2). There must be more than one megohm resistance. -
Page 21: Brush Life Estimate
Thermal Switch Tests Brush Life Estimate Tools Needed 1. Before installation of new brushes, make an Digital Multimeter Or Equivalent inspection of the armature commutator, see Armature Commutator Inspection in Testing and Adjusting. Open Circuits Test 2. Do the steps and procedures for New Brush Installation in Testing and Adjusting. -
Page 22: Power Transfer Group Adjustments
6. The smh estimate of brush life can be used if the Bevel gears and pinions are available in sets that are machine is to work at the same rate (duty cycle), machined for each other and must never be installed the battery is not discharged too much or the separately. -
Page 23: Pinion Installation
Pinion Installation Pinion Configuration (2) Shim pack. (3) Bearing cup. (4) Bearing cup. (5) Bearing cone. (6) Pinion gear. (7) Bearing cone. (8) Locknut. (9) Ring. (10) Gear. (11) Ring. NOTE: The adjustment procedures that follow only cover the shim set configuration. Look for additional service publications to provide more detailed information on the change. - Page 24 PINION SHIM CHART New Pinion Marking Pinion +.10 +.08 +.06 +.04 +.02 -.02 -.04 -.06 -.08 -.10 Marking +.10 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm +0.16mm +0.18mm +0.20mm (0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.) (0.004 in.) (0.005 in.) (0.006 in.) (0.006 in.) (0.007 in.) (0.008 in.) +.08 -0.02mm +0.02mm...
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Page 25: Pinion Bearing Adjustment
Pinion Depth Check Pinion Bearing Adjustment Tools Needed: Tools Needed: Pinion Bearing Preload Gauge (A) Pinion Depth Gauge (A). Dial Indicator Group (B). Pinion Depth check (1) Bearing cap (A) Pinion Depth Gauge 1. Put the bar and discs of tool (A) in the bearing bores of the housing assembly as shown. -
Page 26: Power Transfer Group Bearing And Gear Clearance (Backlash) Adjustments
4. In order to get bearing preload, subtract 0.05 mm Power Transfer Group Bearing and (.002 in.) from the shim pack thickness found in Gear Clearance (Backlash) Step 3. This is the shim pack thickness that needs Adjustments to be installed. Tools Needed: 5. - Page 27 Correct Tooth Contact Setting 7. Check the tooth contact pattern as follows. Check the tooth contact setting between the bevel gear and pinion after the gear clearance (backlash) and bearing preload adjustments have been made as follows. a. Put a small amount of Prussian blue, red lead or Install Carrier Assembly paint on the bevel gear teeth.
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Page 28: Final Drive
Final Drive Wheel Bearing Adjustment Short Heel Contact Setting c. If bevel pinion shaft is too far away from bevel gear, short toe contact will be the result as shown. The teeth of pinion will be in contact with toe ends of convex faces (part that makes a curve toward the outside), and top edge of heel end of concave faces (part that makes a curve toward the inside). -
Page 29: General Tightening Torque
General tightening torque for bolts, nuts and taperlock studs The following charts give the standard torque values for bolts, nuts and taperlock studs of SAE Grade 5 or better quality. Exceptions are given in other sections of the Service Manual where needed. thread size Standard torque inches... -
Page 30: Specifications
Metric fasteners Metric ISO thread torque thread size (mm) (N¥m)* (lb¥ft) 12 L 4 9 L 3 25 L 7 18 L 5 55 L 10 40 L 7 [Usually, material strength identification on bolt 95 L 15 70 L 10 head is with numbers (i.e., 8.8, 10.9, etc.)] The chart on the right gives the torque for 150 L 20... -
Page 31: Drive Motor
Voltage B width B length Thickness Brush Length* Diameter Commutator Diameter** 12.5 mm B 25.0 mm B 45.8 mm B20S-2, B25S-2 19.0 mm 117.4 mm 111.0 mm (4.37 in.) 36/48 (.49 in. B 0.98 in. B 1.8 in.) B30S-2 (.75 in.) (4.62 in.) -
Page 32: Power Transfer Group
Power Transfer Group (8) Apply Loctite No. 242 to six bolts (10). (9) Apply 6V1541 Primer and Loctite No. 17430 to cover (9) and housing assembly (8) prior to assembly. (1) Torque for bolts (1) that hold ring gear to differential case assembly ....70 L 15 N¥m (50 L 11 lb¥ft) (2) Adjust differential bearings with locknut (2) to a... -
Page 33: Final Drive
Final Drive (1) Apply Loctite No.242 Thread Lock to thread of bolt (1) and tighten to a torque of ............115 L 14 N¥m (2) Torque for wheel mounting bolts (2) ......270 L 25 N¥m (200 L 18 lb¥ft) (3) Torque for bolts (3) holding service brake ........55 L 10 N¥m (41 L 7 lb¥ft) (4) Heat retainer (4) to a temperature of 371 to 427¡C (700 to 801¡F) for no more than four hours... -
Page 34: Drive Axle Mounting Group
Drive Axle Mounting Group (1) Install four bolts (1) that fasten drive axle housing to the chassis frame. Tighten bolts (1) to a torque of ......488 L 27 N¥m (360 L 20 lb¥ft) Drive Tire Installation B Series WARNING The optional cushion drive tire must be installed as shown. - Page 35 BC Series BC20S-2, BC25S-2 WARNING The drive tire must be installed as shown below. Failure to do so will decrease the stability of the lift truck and can cause injury to the operator. Cushion Tire Mounting Tighten the cushion tire wheel mounting bolts (1) to a torque of ....270 L 25 N¥m (200 L 18 lb¥ft) Install the tire so that the edge of the tire is even with the outside edge of the wheel.
- Page 36 BC30S-2-Narrow Axle BC30S Models-Narrow Axle Install the tire so there is distance (X) between the edge of the tire and the outside edge of the wheel. Distance (X) is .....21.4 L 0.8 mm (.84 L .03 in.) BC30S-2 wide Axle BC30S Models-Wide Axle Install the tire so there is distance (Y) between the edge of the tire and the outside edge of the wheel.
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Page 37: Disassembly & Assembly
Disassembly & Assembly Brakes, Brake Adjuster And Wheel Cylinder Remove Brakes, Brake Adjuster And Wheel Cylinder Tools Needed Jack Stand 3. Remove brake retainer springs (4). Remove the brake shoes. 1. Put the lift truck in position on tooling (A), and 4. - Page 38 Install Brakes, Brake Adjuster And Wheel Cylinder 7. Remove bolt (11) to remove brake adjuster (12). 1. Install spring (17) in the wheel cylinder. NOTE: Put clean brake fluid on the seals and inside of the wheel cylinder before assembly. 2.
- Page 39 5. Install brake adjuster (12) and bolt (11) that holds 9. Install the brake shoes and brake retainer springs it. Tighten the bolt to a torque of 72 L 5 NIm (55 L (4). 4 lbIft). See Brake Adjuster Installation in Testing And Adjusting for further adjustments.
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Page 40: Power Transfer Group
Power Transfer Group Disassemble Power Transfer Group Tools Needed Remove And Install Power Transfer Spanner Wrench Group Handle Bearing Puller Tools Needed Spanner Wrench Link Bracket Start By: Start By: a. Remove transaxle a. Remove power transfer group. b. Remove final drives and hubs 1. - Page 41 15 22 17 3. Use a hammer and punch to remove roll pin (6) from the carrier. Remove pin (8), side gears (7) and the thrust washers. IDCD356S 4. Remove axle gears (9) and the thrust washers. If 6. Remove outer bearing cone (17), shims (23) and bearing cones (5) need to be replaced, use tool ring (22) from the pinion shaft.
- Page 42 Assemble Power Transfer Group 15 22 17 TOOLS NEEDED A C D E F Spanner Wrench Handle Spanner Wrench Pinion Depth Gauge Shim Pack, 4.0 mm (.16Ó) Dial Indicator Set IDCD356S 1. Install bearing cups (18) and (20) without shims (19) behind cup (18) in the housing assembly.
- Page 43 6. Calculate the required shim thickness as follows: 9. After the pinion depth is correct, remove tool (D) and the nominal mounting distance L deviation from pinion shaft (12) again. nominal (as marked on the end of the pinion in millimeters, either + or - number) = required mounting distance.
- Page 44 NOTE: Be sure to measure each shim in shim pack (E) separately. The shims for setting rolling torque are not shown in the parts book. The part numbers are: PART NO. THICKNESS 924760 0.04 mm (.002 in) 924761 0.08 mm (.003 in) 924762 0.12 mm (.005 in) 924763...
- Page 45 18. Check the rolling torque of the pinion as shown. 21. Put bevel gear (4) on the carrier and the ten bolts. Tighten the bolts to a torque of 70 L 15 It must be 0.85 to 1.70 NIm (7.5 to 15.0 lbIin). If NIm (50 L 11 lbIft).
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Page 46: Final Drives And Hubs
Final Drives And Hubs Remove Final Drives And Hubs Tools Needed Spanner Wrench Start By: a. Remove brakes. 26. After all the adjustments have been completed, put Bearing Mount Compound on the outside diameter of cap (11) and install it. 27. - Page 47 Install Final Drives And Hubs Tools Needed Spanner Wrench Driver set 5. Remove bolts (6), and remove spindle (7). 6. Remove shaft assembly (8). 1. Install bearing (10) with a press. Heat the retainer to 317 to 427°C (700 to 801°F) and install it against bearing (10) with a press.
- Page 48 3. Install shaft assembly (8) in the housing. 7. Put hub and cover assembly (4) in position on the housing, and install the bolts that hold it. Tighten the bolts to a torque of 55 L 10 NIm (41 L 7 lbIft). 4.
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Page 49: Oil Cooled Disc Type Brake
Oil Cooled Disc Type Brake Remove & Install Brakes (Oil Cooled Disc Type) Tools Needed Jack Stand NOTE : The procedure to remove and install oil cooled disc type brakes is the same for both sides of the machine. 4. Remove bolts (5) and cover (6). IDCD382S 5. - Page 50 NOTE : Use the following steps to install the oil cooled disc type brakes. If new discs (7) are installed, soak the discs in transmission drive train oil for one hour prior to installation. Refer to the Operation and Maintenance Manual for further information. 11.
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