SB2025E01 Aug.
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.
Index Disassembly & Assembly Systems Operation Drive Motor............................................................... Final Drive ................................................................ General Information.................................................. Power Transfer Group.............................................. Brakes, Brake Adjuster And Wheel Cylinder...........36 6 8 5 7 Final Drives And Hubs.............................................45 Oil Cooled Disc Type Brake .............
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). The drive motor turns power transfer group (2). The power is sent through the power transfer group to the axles. The axle turns final drive (1), which is part of the drive wheels.
Drive Motor 3 2 1 4 5 6 7 8 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) motor. Electric storage batteries are the source of power for the DC motor. The four motor brushes are held in four brush holders (8). A spring holds each of the brushes against commutator (4) as the brushes wear.
Power Transfer Group 3 2 1 5 4 6 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 frame in the front of the lift truck. ItÕs a double reduction unit with the final reduction through spiral hypoid pinion (4) and bevel gear (1). transfer group lets the inside wheel stop or turn slower in relation to the outside wheel.
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. The reduction in size between the axle shaft and the hub causes the hub to turn at a slower speed.
Troubleshooting WARNING If an electrical failure or an overload of the motor is present, personnel must not breathe the toxic fumes which are a product of the burnt insulation. All power must be disconnected from the motor before any inspection is made to find the failure. The area around the motor must be well ventilated (air flow) and the motor is to be cooled before any repair work is done. Water must not be used on any electric equipment because of the danger of electrical shock.
4. Control panel operation not correct: See the MicroController System Operation module. These can cause transistors to become defective, control panel failure or drive fuse to go bad. Problem 3: Neither traction or hydraulic will last through a complete normal work period. 5. Brushes are worn: Inspect the drive motor commutator for burnt marks or scoring (scratches). Make corrections or make a repair of the armature commutator and replace the brushes as necessary.
Problem 4: Sparks at the commutator and/or rapid brush wear. c. Brush movement causes arcing and brush wear: Check the brush springs for cracks, and overheat signs (blue). Compare spring force with a new brush spring. Check the brush holder for oversize (larger size than for brush). Replace the brush spring if necessary. d. Loose brush leads or motor bus bar connections. Loose cable connections at motor terminals. Results are: Probable Cause: 1. Worn brushes: Make a replacement of the brushes.
7. Restriction caused by components: Correct and make adjustments to wheel brakes and parking brakes that drag. Make changes to tires with less restriction. Check and correct wheel bearing torques. Problem 7: Lift truck moves faster in one direction than the other direction with the same amount of accelerator pedal movement in Bypass mode (speed).
2. Current limit (C/L) circuit has a defect: Make test to the MicroController control panel as stated in the respective service module. Repair or replace components as necessary. 8. Loose or worn side bearings. 9. Noise in the drive wheel reduction components. 3. Unpolished or improperly positioned forks: Install tapered and polished forks. Position forks correctly for load being lifted. Problem 2: Noise at different intervals. 4.
Drive Motor Motor Brushes 1 Brush Inspection 1. Measure the brush material on the longest side. 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 move freely in the brush holders. Use a piece of plain bond paper to remove brush material if there is a restriction of brush movement. 2. If the brush length is less than 19 mm (.
WARNING NOTICE Never use air pressure that is more than 205 kPa (30 psi). Make sure the line is equipped with a water filter. Wear eye protection when seating, polishing or cleaning the motor with air pressure. During the seating and polishing procedure, keep fingers away from components in rotation. For prevention of injury to fingers, do not use a commutator cleaner or brush seater stone that is shorter than 63.5 mm (2.50 in.). 12.
Ground Test Open Circuit Test Ground Test. Open Circuit Test A digital multimeter can also be used to test for grounds. Put the Function/Range Switch on the 2M resistance (½) scale. When the test probes are put on the commutator and the shaft, the meter must give an indication of over load (OL). This means that the resistance is more than 2 megohms. 1. Put the digital multimeter Function / Range Switch on the 200 ohm resistance (½) scale. 2. Put one test lead on one commutator bar.
Commutator Inspection Surfaces of Commutators that need Replacement EHPS009B EHPS011B Marks on the Commutator Surface Grooves on the Commutator Surface Marks on the commutator surface are an indication that metal has moved from the commutator surface to the carbon brushes. Marks will cause fast brush wear. Grooves on the commutators surface are caused by a cutting material in the brush or atmosphere.
Ground Test 2 1 EHPS013B Ground Test (1) Field Terminal. (2) Motor housing. Pitch BarÐMarks on the Commutator Surface Pitch barÐmarks cause low or burnt marks on the commutator surface. 1. Put the digital multimeter Function/Range Switch on the 20M resistance (½) scale. 2. Put one test lead to either outer field terminal (1) and the other test lead to the motor housing (2). There must be more than one megohm resistance. Field Coil and Terminal Tests Tools Needed Digital Multimeter Or Equivalent 3.
Armature Terminal Test 1. Put the digital multimeter Function/Range Switch on the 20M resistance (½) scale. Tools Needed Digital Multimeter Or Equivalent 1 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. Test for Continuity 3. Do the test again with one test lead on the other outer brush terminal. Brush Holder Test Tools Needed Digital Multimeter Or Equivalent 1 1 Brush Test 1.
Thermal Switch Tests Brush Life Estimate Tools Needed Digital Multimeter Or Equivalent 1. Before installation of new brushes, make an inspection of the armature commutator, see Armature Commutator Inspection in Testing and Adjusting. 1 Open Circuits Test 2. Do the steps and procedures for New Brush Installation in Testing and Adjusting. 3. Make the initial (first) inspection of brush wear between 250 smh and 500 smh.
6. The smh estimate of brush life can be used if the machine is to work at the same rate (duty cycle), the battery is not discharged too much or the battery cells have not become damaged. If the machine is made to work harder, the battery is discharged too much, or the battery cells become damaged, the motor temperature will get hot very fast. This will cause rapid wear of the brush. Bevel gears and pinions are available in sets that are machined for each other and must never be installed separately.
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.
Old Pinion Marking +.10 +.10 0 PINION SHIM CHART New Pinion Marking +.08 +.06 +.04 +.02 0 -.02 -.04 -.06 -.08 -.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 (0.001 in.) +.06 -0.04mm -0.02mm (0.002 in.) (0.001 in.) +.04 -0.06mm -0.04mm -0.02mm (0.002 in.) (0.002 in.) (0.001 in.) +.02 -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.
Pinion Depth Check Pinion Bearing Adjustment Tools Needed: Tools Needed: Pinion Bearing Preload Gauge (A) Dial Indicator Group (B). Pinion Depth Gauge (A). 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. Install bearing caps (1) and tighten the bolts. Pinion Bearing Preload Adjustment (1) Shim pack (2) Bearing cone (3) Locknut (4) Pinion gear 2.
4. In order to get bearing preload, subtract 0.05 mm (.002 in.) from the shim pack thickness found in Step 3. This is the shim pack thickness that needs to be installed. Power Transfer Group Bearing and Gear Clearance (Backlash) Adjustments 5. Install the correct thickness of shims (1), bearing cone (2), the washer, lockwasher, and nut (3). Tighten nut (3) to a torque of 180 L 25 N¥m (135 L 18 lb¥ft). Tools Needed: Dial Indicator Group (A) 4 1 3 2 Rolling Torque Check 5 6.
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 paint on the bevel gear teeth. Turn the pinion in both directions and check the marks made on the bevel gear teeth. Install Carrier Assembly (5) Bearing cap (6) Bolts 3.
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). To correct this, add shims under pinion bearing cup. After this is done, check gear clearance (backlash) and tooth contact again. d.
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 Use these torques for bolts and nuts with standard threads (conversions are approximate). standard thread Standard thread Use these torque for bolts and nuts on hydraulic valve bodies.
Metric fasteners Metric ISO thread torque thread size (mm) (N¥m)* (lb¥ft) 12 L 4 25 L 7 55 L 10 9L3 18 L 5 40 L 7 95 L 15 150 L 20 220 L 30 70 L 10 110 L 15 160 L 20 325 L 50 450 L 70 600 L 90 240 L 35 330 L 50 440 L 65 775 L 100 1150 L 150 570 L 75 840 L 110 1610 L 200 2000 L 275 2700 L 400 1175 L 150 1450 L 200 200 L 300 M6 M8 [Usually, material strength identification on bolt head is with numbers (i.e., 8.8, 10.9, etc.
Drive Motor Drive Motors Model B20S-2, B25S-2 B30S-2 Voltage (1) New Brush Size Thickness B width B length Minimum Brush Length* 36/48 12.5 mm B 25.0 mm B 45.8 mm (.49 in. B 0.98 in. B 1.8 in.) 19.0 mm (.75 in.) 117.4 mm (4.62 in.) 36/48 16.0 mm B 28.0 mm B 45.8 mm (.63 in. B 1.10 in. B 1.80 in.) 19.0 mm (.75 in.) 119.0 mm (4.69 in.) 12.5 mm B 40.0 mm B 45.8 mm 19.0 mm (.75 in.) 117.4 mm (4.62 in.) BC20S-2, BC25S-2, BC30S-2 B20S, B25S B30S, BC20S BC25S, BC30S 72/80 (.49 in. B 1.57 in. B 1.
Power Transfer Group 2 3 1 4 5 2 7 6 (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 rolling torque of ...........................2.12 to 2.
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 and install on axle shaft.
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. failure to do so will decrease machine stability and cause possible personal injury. Cushion Tire Install the cushion tire so that the edge of the tire is even with the outside edge of the wheel.
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. Pneumatic Tire Mounting Tighten the pneumatic tire wheel nuts (2) to a torque of ................
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. Distance (Y) is......25.4 L 0.8 mm (1.00 L .03 in.
Disassembly & Assembly 4 Brakes, Brake Adjuster And Wheel Cylinder Remove Brakes, Brake Adjuster And Wheel Cylinder Tools Needed A Jack Stand 1 3. Remove brake retainer springs (4). Remove the brake shoes. 5 1 2 6 3 1. Put the lift truck in position on tooling (A), and remove the drive wheels. On B20/25/30S models, remove the brake drum also. 4. Remove bolts (6) to remove wheel cylinder cover (5). 2. Remove brake return springs (1), (2) and (3) with a suitable brake shoe spring tool.
Install Brakes, Brake Adjuster And Wheel Cylinder 11 19 18 12 7. Remove bolt (11) to remove brake adjuster (12). 20 17 1. Install spring (17) in the wheel cylinder. 14 13 NOTE: Put clean brake fluid on the seals and inside of the wheel cylinder before assembly. 2. Install pistons (18) with seals (19) in the wheel cylinder. 3. Install dust caps (20). 16 15 8. Disassemble the brake adjuster. Remove springs (15) from the adjuster. Remove bolt (14), wheel (16) and shims (13).
11 4 12 5. Install brake adjuster (12) and bolt (11) that holds it. Tighten the bolt to a torque of 72 L 5 NIm (55 L 4 lbIft). See Brake Adjuster Installation in Testing And Adjusting for further adjustments. 9. Install the brake shoes and brake retainer springs (4). 1 7 2 9 8 10 3 10. Install brake return springs (1), (2) and (3) with a suitable brake spring tool. 6. Install wheel cylinder (10) and bolts (9). Tighten the bolts to a torque of 15 L 2 NIm (11 L 1 lbIft). 11.
Disassemble Power Transfer Group Power Transfer Group Tools Needed Remove And Install Power Transfer Group Tools Needed Link Bracket 1 Handle 1 A Bearing Puller 1 Spanner Wrench Start By: A B Spanner Wrench C 1 1 Start By: a. Remove transaxle a. Remove power transfer group. b. Remove final drives and hubs 1 1 2 2 1. Mark the bearing caps and locknuts for proper installation. Bend the tab on the lockwasher back. Remove locknuts (2) with tooling (A) and the lockwashers.
5 6 12 21 13 15 22 17 11 7 9 8 18 3. Use a hammer and punch to remove roll pin (6) from the carrier. Remove pin (8), side gears (7) and the thrust washers. 19 23 20 IDCD356S 4. Remove axle gears (9) and the thrust washers. If bearing cones (5) need to be replaced, use tool (B) and a press to remove them from the carrier. 6. Remove outer bearing cone (17), shims (23) and ring (22) from the pinion shaft. Pull pinion shaft (12) out of gear (15) and the housing assembly.
Assemble Power Transfer Group TOOLS NEEDED A C D E F Spanner Wrench 1 Handle 1 Spanner Wrench 12 21 13 11 1 Pinion Depth Gauge 1 Shim Pack, 4.0 mm (.16Ó) 1 Dial Indicator Set 1 18 1 15 22 17 2 3 5 19 23 20 IDCD356S 13 21 15 10 4 1. Install bearing cups (18) and (20) without shims (19) behind cup (18) in the housing assembly. Press bearing cone (13) on the pinion shaft. 17 11 2. Position pinion shaft (12) into the housing assembly.
6. Calculate the required shim thickness as follows: the nominal mounting distance L deviation from nominal (as marked on the end of the pinion in millimeters, either + or - number) = required mounting distance. The measured distance (from Step 5) - the required mounting distance = required shim thickness. The measured distance must be within 0.03 mm (.001 in) of the required mounting distance. If it is, the correct thickness of shims have been installed.
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: 22 17 E 12. Put ring (21) in position on the pinion shaft. Put gear (15) in position in the housing assembly with the side that has a recessed hub next to ring (21). Put the pinion shaft in the housing assembly and through gear (15). PART NO. THICKNESS 924760 0.04 mm (.002 in) 924761 0.08 mm (.003 in) 924762 0.12 mm (.005 in) 924763 0.
3 4 18. Check the rolling torque of the pinion as shown. It must be 0.85 to 1.70 NIm (7.5 to 15.0 lbIin). If the rolling torque is not correct, add or remove shims (23) until it is correct. Removal of shims (23) increases rolling torque. Adding shims (23) decreases the rolling torque. Record the actual rolling torque after the shims have been added or removed. Do not put the cap over the pinion nut yet. 21. Put bevel gear (4) on the carrier and the ten bolts.
Final Drives And Hubs Remove Final Drives And Hubs Tools Needed A Spanner Wrench 10 1 Start By: 11 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. 2 3 1 27. Put Gasket Maker on cover (10) and the housing assembly. Also, use Quick Cure Primer if the temperature is below 10 °C (50 °F). End By: 4 a. Install power transfer group. 1. Bend back one of the tabs in locking washer (1). 2.
Install Final Drives And Hubs 6 8 Tools Needed Spanner Wrench Driver set 7 A B 1 1 10 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. 9 7. Remove lip seal (9) from the housing. 9 10 2. Install lip seal (9) in the housing with tool group (B) and a suitable press. Install the seal with the lip toward the inside. 8.
2 3 6 8 1 7 4 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. Put Loctite No.242 Thread Sealant on th threads of the bolts that hold the spindle. 8. Install bearing (2) locking washer (1) and nut (3) on the spindle. 5. Put spindle (7) in position, and install bolts (6) that hold it.
Oil Cooled Disc Type Brake 5 6 Remove & Install Brakes (Oil Cooled Disc Type) Tools Needed Jack Stand A 4 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). 7 8 IDCD382S 5. remove the plates and discs (7) from hub (8). 1. Put the lift truck in position on tooling (A). 2. Remove the bolts (1) and wheel (2). 8 9 10 3 4 6. Remove piston (9) from hub (8). 7. Remove bolts (10) and hub (8). 3.
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. 6 5 8 4 6 3 11. Put Loctite No.17430 on the mating surfaces of hub (8) and cover (6). Install bolts (5) and cover (6). 12. Install adapter (4) and bolts (3). 13. Install bolts (1) and wheel (2). 9 8 14. Bleed the brake system.
