SB2026E02 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 Systems Operation Brake System .........................................................17 Master Cylinder...............................................17 Oil Cooled Disc Brakes...................................18 Parking Brake .................................................19 Shoe Type Brakes ..........................................17 Steering System .....................................................47 Steering Axle Stop Adjustments .....................
Systems Operation Hydraulic System Basic Schematic 3 2 1 1 4 5 7 8 6 10 11 13 15 18 14 16 12 9 17 IDCS101S Basic Hydraulic Schematic(Lift Truck With Standard Lift and Full Free Lift Or Full Free Triple Lift) (1) Lift cylinders (primary for STD, secondary for FFL and FFTL). (2) Excess flow protector (FFL and FFTL). (3) Lift cylinder (primary for FFL and FFTL). (4) Excess flow protector. (5) Sideshift cylinder (if equipped). (6) Hydraulic control valve. (7) Flow regulator valve.
The return hydraulic oil from the cylinders flows through hydraulic control valve (6), line (14), into filter (10) and hydraulic tank (13). Relief valve poppet (9) will release extra pressure to the hydraulic tank when the pressure in the lift circuits goes higher than relief valve pressure shown in the Control Valve section of SPECIFICATIONS.
Hydraulic Control Valve CAUTION Hex head must face out of valve toward spring and plug. 4 5 7 2 6 9 3 8 1 10 IDCS102S (1) Relief Valve - Hydrostat. (2) Inlet/Outlet Body. (3) Center Spring. (4) Center Body. (5) Spool. (6) Tie Stud. (7) Quick Disconnect Gauge Body. (8) Check Valve. (9) Seal Rings. (10) Main Relief Valve. Assembly And Construction Above figure is a cross-section view showing construction and assembly of a three-section valve.
Valve Operation Lift Spool 4 1 6 OUT CENTER IN INLET OUTLET OUT Pressure to GGAH GGBH blocked By-pass blocked CENTER GGAH and GGBH blocked By-pass open IN GGAH to tank GGBH blocked By-pass open 2 3 5 7 IDCS103S (1) Control Valve Sensing Orifice. (2) Flow Control And Relief Valve-Hydrostat (3) Tank Passage. (4) By-pass Flow Control Orifice. (5) Cylinder Ports. (6) Pressure Passage. (7) By-pass Passage. IDCS104S Lift spool - used for control of single acting cylinder applications.
Tilt Spool Auxiliary Spool IN CENTER OUT IDCS106S IN Pressure to ÒBÓ ÒAÓ to tank By-pass blocked Pressure to ÒBÓ ÒAÓ to tank By-pass blocked CENTER ÒAÓ and ÒBÓ blocked By-pass open ÒAÓ and ÒBÓ blocked By-pass open OUT Pressure to ÒAÓ ÒBÓ to tank By-pass blocked Pressure to ÒAÓ ÒBÓ to tank By-pass blocked IDCS108S Auxiliary spool - directs flow to either end of a double acting cylinder. Flow from the end that is not under pressure is returned to tank via internal coring of the valve section.
Lift Cylinders and Mast Standard Lift (A) 1 IDCS001P 2 IDCS002P Standard Lift Mast (Typical Example) (A)Free lift period. Standard Lift Mast At Full Extension (Typical Example) (1) Lift cylinder. (2) Lift cylinder. The inner mast and carriage will continue to move up until they are in the extended position.
Full Free Triple Lift Mast 3 4 3 5 6 IDCS003P IDCS004P Full Free Triple Lift Mast (Typical Example) (3) Primary lift cylinder. (4) Crosshead. (5) Intermediate mast. (6) Inner mast. Full Free Triple Lift Mast At Free Lift (Typical Example) (3) Primary lift cylinder. When the movement of the primary cylinder is completed, pressure oil then works against the pistons in secondary cylinders (7).
4 6 5 7 IDCS005P Full Free Triple Lift Mast In The Extended Position (Typical Example) (3) Primary lift cylinder. (5) Intermediate mast. (6) Inner mast. (7) Secondary cylinder. The oil under pressure in the primary and secondary cylinders is released when the lift control lever is moved forward. Gravity and the weight of a load will cause the cylinders to move back into their housings. The secondary cylinders move completely back into their housings before the primary cylinder starts to move down.
Steering System Schematic 5 1 3 4 6 2 7 8 9 12 13 11 IDCS111S 10 Steering System Schematic (1) Steering gear. (2) Hose. (3) Hose (to hydraulic control valve). (4) Hose. (5) Hose. (6) Steering cylinder. (7) Load sensing signal hose. (8) Check valve. (9) Hose. (10) Hydraulic pump (BC20/25/30S-2). (11) Hydraulic tank. (12) Priority valve (BC20/25/30S-2). (13) Hydraulic pump with priority valve (B20/25/30S-2). The steering system uses hydraulic oil for its operation.
Steering Cylinder Steering cylinder (1) gives power assistance through the use of pressure oil at either end of the cylinder. The steering cylinder is double ended and the body of the cylinder is mounted stationary to the steer axle. The rod assemblies at both ends of the cylinder which allows the cylinder to move the link assemblies. 1 IDCS112S Steering Cylinder (1) Steering cylinder.
Steering Gear 1 A 2 B 3 4 5 6 7 8 9 10 11 12 IDCS113S Steering Gear (1) Spool. (2) Sleeve. (3) Outlet (to tank). (4) Inlet (for pump oil). (5) Internal pump gear. (6) External pump gear. (7) Centering springs. (8) Pin. (9) Left turn port. (10) Right turn port. (11) Body. (12) Drive. (A) Control section. (B) Metering section. Lift trucks use the load sensing, closed center (oil flow to steering gear only when needed) steering gear.
Oil Flow The oil from the priority valve flows through inlet (4). When the steering wheel is stationary (NEUTRAL), the oil is stopped by spool (1). The oil can not flow through the steering gear to the steering cylinder until the steering wheel is turned. 5 6 8 The steering wheel is connected to spool (1) by a shaft assembly and splines. When the steering wheel is turned, spool (1) turns a small amount until springs (7) are compressed. Then, sleeve (2) starts to turn.
When the brake pedal is first pushed, both pistons move into the master cylinder and push brake liquid through outlet (9) into the brake lines. when floating piston (7) seats on seal (10), the liquid that is pushed by piston (1) goes around cup seal (11), out through floating piston (7) and outlet (9). This action continues until the liquid pressure in piston (1) bore reaches the pressure that opens relief valve (5). The liquid, being pushed by piston (1), now returns to reservoir (4).
When the brake action first starts, primary shoe (15) comes in contact with the brake drum as it is in rotation. This contact of the primary shoe puts some force on secondary shoe (16) to help put it in position against the drum. Oil Cooled Disc Brakes 2 3 6 7 4 1 When the brake pedal is released the brake shoe springs pull the brake shoes and push wheel cylinder pistons back into wheel cylinder (12).
Parking Brake 5 4 6 1 12 2 IDCS119S IDCS118S Parking Brake (4) Spring. (5) Strap assembly. (6) Drum. (1) Lever. (2) Cable assembly. When the lever is pulled, cable assembly (3) compresses strap assembly (5) around drum (6). With the drum prevented from turning, all lift truck movement is stopped. The band-type parking brake is installed on the front of the electric drive motor. The parking brake control is actuated with the lever (1), and is released with lever (1).
Electric Motors Hydraulic Pump Motor 2 1 3 5 4 6 7 8 Electric Motor (1) Cover. (2) Thermal Switch. (3) Motor frame. (4) Brush. (5) Commutator. (6) Armature. (7) Field coil. (8) Fan. The hydraulic system is operated by a direct current (DC) motor. Electric storage batteries are the source of power for the (DC) motor. The motor brushes are held in the four brush holders. The 72/80V ÒSÓ motors have four brushes (4) and springs, while 36/48V ÒSÓ motors have eight brushes (4) and springs.
The motors are protected from over temperature by thermal switch (2). When the normally closed thermal switch is open, the amount of current through the motor is limited to allow the motor to cool. All motors are fan (8) cooled. The hydraulic pump motor is activated when the key and seat switches are closed and a lift, tilt or auxiliary lever is moved. In lift operation, the speed of the motor is variable. The larger the distance the lever is moved, the faster the motor will rotate.
Testing and Adjusting 3. Check all oil lines and connections for damage or leaks. Troubleshooting 4. Check all the lift chains and the mast and carriage welds for wear or damage. Troubleshooting can be difficult. A list of possible problems and corrections are on the pages that follow. Hydraulic System and Mast During a diagnosis of the hydraulic system, remember that correct oil flow and pressure are necessary for correct operation.
Hydraulic Oil Temperature (Too Hot) 3. The carriage or mast rollers (bearings) are worn and do not move (seized). When the temperature of the hydraulic oil gets over 98.8C (210d), polyurethane seals in the system start to fail. High oil temperature causes seal failure to become more rapid. There are many reasons why the temperature of the oil will get this hot. Problem: Lift cylinder extends too slowly. Probable Hydraulic Cause: 1. Not enough oil supply to lift cylinder. 1. Hydraulic pump is badly worn.
Problem: The mast does not tilt correctly or moves too slowly. Probable Hydraulic Cause: 2. Control valve leakage caused by worn valve spools. 3. The check valve or flow control valves in the control valve are bad. 1. There is an air leak, which lets air into the hydraulic system on the inlet side of the hydraulic pump. 4. Leakage of the cylinder lines or piston seals. 5. There is foreign material in the control valve. 2. The relief valve opens at low oil pressure. 3.
4. Seal cut on shoulder of pump or keyway during installation. Problem: Control valve spools have leakage around the seals. 5. Seal lips are dry and hardened from heat. Probable Cause: 1. There is foreign material under the seal. Problem: There is failure of the pump to deliver fluid. 2. The valve spools are worn. 3. The seal plates are loose. Probable Cause: 4. The seals have damage or are badly worn. 1. Low level of the oil in the tank. 2. There is a restriction in the pump inlet line.
Lift and Tilt Cylinders Problem: Steering wheel does not return to center position correctly. Problem: Leakage around the cylinder rod. Probable Cause: Probable Cause: 1. Steering gear covers are too tight. 1. Cylinder head (bearing) seals are worn. 2. Steering column is not in correct alignment. 2. Cylinder rod is worn, scratched or bent. 3. Valve spool in the steering gear has a restriction. 4. Priority valve check valve permits lift and tilt hydraulic oil to affect steering hydraulic circuit.
Problem: Lift truck does not turn when steering wheel is slowly turned. 3. Mechanical resistance at the pedal or shoe. 4. Restriction in the brake line. Probable Cause: 5. Bad wheel cylinder. 1. The oil level of the tank is low. 2. There is air in the steering system. Problem: Pedal resistance is not solid (spongy). Probable Cause: 3. The pump operation is not correct. 1. Leakage or low fluid level. 4. Dirt in the steering system. 2. Air in the brake hydraulic system. 5.
Problem: Brake will not make application. Problem: Pedal gradually goes to the floor (under normal pedal pressure). Probable Cause : Probable Cause: 1. Leakage or low fluid level. 1. Leakage or low brake fluid or oil level. 2. Air in the brake hydraulic system. 2. Defective master cylinder. 3. Master cylinder is loose. 4. Lining surface looks like glass(glazed) or worn. 5. Oil or brake fluid is on the lining. Problem: Extra (excessive) pedal travel (under normal pedal pressure). 6.
Problem: Brakes will not make application after being bled. Electric Motors Probable Cause: Before an analysis is made of any electric motor problems, always make reference to the troubleshooting section of MicroController Control System Module. 1. Leak in hydraulic line or connection. 2. Damaged cup seal or boot in the master cylinder. 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.
The key switch, seat switch, control valve switch, and the line contactor must be closed for the hydraulic pump motor to operate. Problem 2: Neither traction or hydraulic will last through a complete normal work period. Probable cause: 3. Not enough voltage. High resistance in battery cells or cables. Charge the battery or make a replacement of the battery. Check all the cells for one or more that has defects. Check the specific gravity of each cell.
Remove any restrictions in the hydraulic circuit. Make an inspection of the movable hydraulic attachments for restrictions. Check for components that slide, bearing wear, hinges binding and the correct amount of lubrication on necessary components. a. At installation, pull upon brush leads to make sure they return to contact with commutator correctly. See Brush Installation in Testing And Adjusting. b.
13. Restriction caused by system components. Operate the hydraulic and steering systems with an ammeter and a pressure gauge installed. If amperage draw and oil pressure are too high, see Testing And Adjusting and Specifications for the acceptable amperage draws and oil pressure, the system must be inspected for both mechanical and hydraulic restrictions. 3. Grade of brushes mixed. Make sure all of the brushes are of Caterpillar standards. Do not use other brands of brushes.
With the key switch off, remove cap (1) from nipple assembly (2) and connect the 28000 kpa (4000 psi) gauge to the nipple assembly. Hydraulic System Relief Valve Pressure Check Use the Pressure Gauge Kit to check the relief valve pressure. Lift Relief Valve Check and Adjustment 1. Turn the key switch on and activate the hydraulics until the hydraulic oil is at the normal operating temperature. WARNING 2.
Tilt and Sideshifter Relief Valve Check and Adjustment Lift Section 1. Turn the key switch on and activate the hydraulics until the hydraulic oil is at the normal operating temperature. Put the carriage in the full sideshift position. Remove nut tie stud here 2. With the motor at fast rpm, hold the sideshift position and watch the gauge. The gauge indication is the pressure that opens the relief valve. 1 IDCS121S 3. The correct pressure setting is shown in the chart. 4.
WARNING The oil will have high pressure present. To prevent personal injury, do not remove the bleed screws completely. Keep hands and feet away from any parts of the truck that move, because the forks will lower when the bleed screw is loosened. 4. Lift the forks high enough to put a load on all stages of the lift cylinders. IDCS122S Setscrew Locations (Standard Cylinders) NOTE: The Standard Lift mast has two secondary cylinders and no primary cylinders.
Mast and Carriage Mast And Carriage Bearings Mast Adjustment NOTE: The Standard, Full Free Lift and Full Free Triple Lift mast load bearings are all adjusted the same way. The mast shown in the following illustrations is the Full Free Triple Lift mast. Part No. Bearing Size Bearing O.D.* D581814 Under Size 108.6 mm (4.276 in) D581815 Standard 109.6 mm (4.135 in) D581816 Over Size 110.7 mm (4.358 in) * Permissible tolerance L 0.08mm (.
3 4 5 6 IDCD037P A B C IDCS123S Mast Adjustment Lower Bearings (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims. IDCD033P 3. Install 1 mm shim to each bearing of intermediate lower and stationary upper basically. Lifting by crane, insert intermediate mast into stationary mast from the upper side. NOTE: When installing shims (5) behind bearing (4), make sure the amount of shim is divided equally when positioned behind each bearing (4).
B. Upper Bearing Adjustment of Stationary Mast IDCD039P 5. In case of standard and full free mast, inner lower bearings can be easily extruded by pulling down the inner mast from the bottom of stationary mast. If intermediate mast is stuck and do not move rolling up and down, there might be excessive shim. Pull out the intermediate mast from the stationary mast and remove shim 0.5 mm to both intermediate lower bearings. Repeat same procedure of aboves until properly shimmed.
C. Upper Pad Adjustment D E 7 8 IDCD038P F 2. Make sure whether stationary mast upper bearings are properly shimmed by rolling up and down and moving intermediate mast to right and left. If clearance between both masts can be detected, pull out the intermediate mast from the stationary mast with crane and add shim 0.5 mm or 1 mm to both stationary upper bearings. 9 7 8 10 E IDCS124S Mast Adjustment Upper Bearings (D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum. (F) Zero clearance.
D. Lower Bearing Adjustment of Inner Mast 3 4 5 Mast And Carriage Bearings 6 Part No. Bearing Size Bearing O.D.* D581814 Under Size 108.6 mm (4.276 in) D581815 Standard 109.6 mm (4.135 in) D581816 Over Size 110.7 mm (4.358 in) * Permissible tolerance L 0.08mm (.003in) A B IDCD040P C IDCS123S 2. Find narrowest point by ruler on the intermediate mast in the area where the inner lower bearings make contact full length of intermediate mast excluding minimum channel lap 475 mm (18.7 in).
Carriage Adjustment 3 4 5 6 NOTE: The standard, Full Free Lift and Full Free Triple Lift carriage load bearings are all adjusted the same way. The Full Free Triple Lift carriage is shown in the following illustrations. To make the carriage clearance adjustments, carriage must be removed from the mast. Use the procedure that follows to adjust carriage load bearings. A 3 A B B 5 4 C C IDCS123S A Mast Adjustment Lower Bearings (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
Mast And Carriage Bearings Part No. Bearing Size Bearing O.D. D581814 Under Size 108.6 mm (4.276 in) D581815 Standard 109.6 mm (4.135 in) D581816 Over Size 110.7 mm (4.358 in) * Permissible tolerance L 0.08mm (.003in) IDCD016P 5 5. Tighten screw (5) that holds the top bearings to the carriage to a torque of 34 L 7 NIm (25 L 5 lbI ft) IDCD014P 2. Find narrowest point by ruler on the inner mast in the area where the bearings make contact. 11 3.
Chain Adjustment If the tension is not the same on both chains, do the procedure that follows: WARNING Personal injury can be caused by sudden movement of the mast and carriage. Blocks must be used to prevent the mast and carriage from any movement while the adjustments are made. Keep hands and feet clear of any parts that can move. 2 IDCD023P Outer Lift Chains (2) Chain anchor bolts. Chain Wear Test Chain wear test is a measurement of wear of the chain links and pins.
Carriage and Mast Height Adjustment Forks Parallel Check 1. Move the mast either forward or backward so it is in the vertical position. 1. Lift the mast and operate the tilt control lever, until the top surface of the forks is parallel with the floor. Place two straight bars, that are the same width as the carriage, across the forks as shown. Measure the distance from the bottom of each end of the two bars to the floor. The forks must be parallel within 3 mm (.
Tilt Cylinder Length Check Tilt Cylinder Alignment If the tilt cylinders are out of alignment, extra stresses in the mast assembly and the mast hinge area will result. To prevent damage, the tilt cylinders must stop evenly at the end of the tilt back and tilt forward strokes. Tilt Angle Check IDCD036P Tilt Cylinder Length Check 1. Tilt the mast to full forward position. Measure the extended length of the cylinder rods from the cylinder housing to the mast.
Drift Test WARNING Drift is movement of the mast or carriage that is the result of hydraulic leakage in the cylinders or control valve. Before testing the drift: Tilt cylinder pivot eyes can loosen if the torque on the pivot eye clamping bolt is not tight enough. This will let the tilt cylinder rod turn in the tilt cylinder eye. The cylinder rod may then twist our of the pivot eye and the tilt cylinder will be out of alignment or may let the mast fall and cause personal injury or damage.
Drift Test For The Tilt System Steering System 1. Put a rated capacity load on the forks on the lift truck. Operate the lift truck through a complete lift and tilt cycle until the oil is at normal temperature for operation, 45 to 55°C. Steer Wheel Bearing Adjustment 2. Put the mast in a vertical position. Raise a rated capacity load to a height of 2.5 meters (8.2 ft). In the case of trucks with less than 2.5 meters (8.2 ft) height extension, raise the load to the truckÕs maximum height.
Steering Axle Stop Adjustment Steering Knuckle Bearing Preload Adjustment 1 6 2 A 3 4 5 7 IDCS132S 9 8 IDCS133S Steer Angle (1) Bolt. (2) Nut. (3) Bolt. (4) Nut. (5) Bolts. (A) 80¡ angle Steering Knuckle Bearing Preload Adjustment (6) Steering link. (7) Shims. (8) Cover. (9) Bolts. Use the procedure that follows to make an adjustment to the steer axle turning angle. 1. During assembly of the steering knuckle, install the upper bearing cup, cone and seal. 1.
3. Move the seat to the normal position for operation, turn the key switch to the ON position and activate the hydraulic controls until the oil is at a temperature for normal operation. Steering System Pressure Check If the steering system does not work correctly, check the hydraulic tank for the correct oil level and the hoses and connections for leakage. If all these items are correct, use the Pressure Gauge Kit to check the steering hydraulic system and its relief pressure setting. 4.
Brake System NOTICE Do not let Valve be closed for more than 3 or 4 seconds or damage can be caused to the steering system components. Brake System Air Removal When the brake pedal resistance is spongy (not solid) it is usually an indication that there is air in the brake hydraulic system. The cause may be low fluid or oil level, leakage in the system, a broken brake line or a brake line that is not connected. a.
Brake Adjustment Drum Type Brakes 2 The brakes make an adjustment automatically when an application is made in forward and reverse. With each application, there will be an adjustment made until the lining-to-drum clearance is made small enough to stop the movement of automatic adjuster (7). Manual brake adjustment is necessary only when new brake shoes are installed and the automatic adjustment has been moved.
3 3 8 6 10 9 Y 4 X Z 5 5 6 7 IDCS139S 8 Brake Adjuster (3) star wheel. (6) Plate (8) Star wheel. (9) Screw. (10) Screw. (X) Distance 1.05 mm (.041 in). (Y) Distance 1.05 mm (.041 in). (Z) Distance 85 mm (3.35 in) IDCS138S Wheel Brakes (3) Star wheel. (4) Bolt. (5) Tongue. (6) Plate. (7) Adjuster. (8) Star wheel. 1. Check distance (X) and (Y) from the inside edge of star wheels (3) and (8) to the rounded edge of plate (6). Distance (X) or (Y) is 1.05 mm (.041 in) maximum.
If there is too much free play, the brake pedal will be low even with the correct brake adjustment. Parking Brake Test 1. Drive the lift truck with a rated load up a 15% incline. The master cylinder push rod must be adjusted so the brake pedal has 3.0 to 8.0 mm (.118 to .315 in) of free play from the pedal stop to the push rod contact point with the master cylinder piston.
Parking Brake Control Group Adjustment 4 2 Y 3 1 5 X IDCS144S Parking Brake Off (2) Cable assembly. (3) Jamb nut. (4) Brake strap assembly. (5) Spring. (Y) 70 L 0.5 mm (2.76 L 0.2 in). 2 1. Put the brake lever (1) in the fully raised OFF position. Seat the shoulder of cable assembly (2) against brake strap assembly (4) at ÒXÓ. Adjust overtravel spring (5) length (Y) to 70.0 L 0.5 mm (2.76 L 0.2 in). Tighten jamb nut (3). 6 7 7 6 Z IDCS143S Z Parking Brake Control Group (1) Brake lever.
Hydraulic Pump Motor Motor Brushes Brush Inspection NOTICE Installation of the wrong brushes can cause early motor failure. Always make sure the correct DAEWOO brushes are installed. 1. Measure the brush material on the longest side. 4. 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 Brush Measurement 2. Brush measurement: If the brush material 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 finger, do not use a commutator cleaner or seater stone that is shorter than 63.5 mm (2.50 in). 12.
Ground Test Open Circuit Test Ground Test Open Circuit Test 1. Digital multimeter can also be used to test for grounds. Put the Function/Range Switch on the 2M resistance (A) scale. When the test leads are put on the commutator and the shaft, the meter must give an indication of overload (OL). This means that the resistance is more than 2 megohms. 1. Put the digital muitimeter 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 IDCS156S Grooves on the Commutator Surface IDCS154S Grooves on the commutators surface are caused by a cutting material in the brush or atmosphere. Marks 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.
1 2 Brush Test (1) Field terminal. (2) Brush leads. IDCS158S 4. Put one test lead to one of outer field terminals (1). Put the other test lead to each of brush leads (2) that connect to the brush holders. There must be continuity to two of the leads with a resistance of less than 1 ohm. Pitch Bar-Marks on the Commutator Surface Pitch bar-marks cause low or burnt marks on the commutator surface. 5. Put one test lead the other outer field terminal.
Shunt Field Tests Open Circuit Test 1. Put the Function/Range Switch Switch of the digital multimeter on the 20M resistance (A) scale. Tools Needed Digital Multimeter Or Equivalent 2. Put one test lead to either shunt coil terminal. Put the other test lead to the motor housing. There must be more than one megohm resistance. Check both shunt coil terminals. 1 3. If the indication is less than one megohm, the shunt coil is grounded and must be replaced.
Thermal Switch (Thermostat) Tests Brush Life Estimate 1. Before installation of new brushes, inspect the armature commutator. See Armature Commutator Inspection in Testing and Adjusting. Tools Needed Digital Multimeter Or Equivalent 1 2. Do the steps and procedures for New Brush Installation in Testing and Adjusting. Open Circuit Test 3. Make the initial (first) inspection of brush wear between 250 smh and 500 smh.
Specifications (1) Torque for bolts that hold control valve sections together ...........40.5 L 2.5 NIm (360 L 24 lbIin). Hydraulic Control Valve (2) Adjust main system relief valve pressure for lift as shown above. See Relief Valve Pressure Check in Testing And Adjusting (3) Adjust secondary relief valve pressure for tilt and sideshift as shown above. See Relief Valve Pressure Check in Testing And Adjusting. 1 (4) Torque for plug ..29.5 L 1.5 NIm ( 264 L 12 lbIin) . (5) Torque for plug ..
Hydraulic Pumps Control Valve Pressure to Open Relief Valve and Current Draw (Amps) of Pump Motor Model Relief Pressure +500, -0 kPa Mast (+75, -0psi) Current Draw (Type E) Rotation is clockwise when seen from drive end. 36Volt Type of pump: Gear 48Volt Min. Max. Min. Max.
Full Free Triple Lift and Full Free Lift Primary Lift Cylinders Standard 1 1 1 2 IDCS170S IDCS169S (1) Put Thread Lock on the last three threads of bearing. (1) Put pipe sealant on the lost three threads of bearing. NOTE: All seals to be lubricated with hydraulic oil. (2) Torque for setscrews....6 L 1 NIm ( 53 L 9 lbIin) NOTE: All seals to be lubricated with hydraulic oil.
Full Free Triple Lift And Full Free Lift Secondary 1 1 IDCS171S (1) Put Thread Lock on the last three threads of bearing. NOTE: All seals to be lubricated with hydraulic oil.
Tilt Cylinders 3 2 1 4 X Z IDCS189S TILT CYLINDER CHART Model Tilt Gp Part No. Forward Tilt Angle* Backward Tilt Angle* Cyl.Stroke(X) mm(in) Cyl. Closed (z) mm(in) A215207 3 3 43.5(1.71) 525.0 (20.67) B20S-2 A215230 6 3 65.0 (2.56) 525.0 (20.67) B25S-2 A215206 3 5 58.0 (2.28) 510.3 (20.08) B30S-2 A215202 6 5 79.5 (3.13) 510.3 (20.08) A215209 10 5 107.0 (4.21) 510.3 (20.08) A215205 3 8 81.0 (3.19) 487.8 (19.21) BC20S-2 A215201 6 8 102.0 (4.02) 487.8 (19.
Mast A Carriage A 1 A B 1 2 B A 2 a 2 VIEW A-A 3 C B 1 3 A 3 VIEW A-A A A 4 B A C A B VIEW B-B B C VIEW B-B 1 C A IDCS172S (1) With mast at 475 mm (18.7 in) channel lap, equally shim both sides until contact (A) is made (zero clearance) between bearings and mast uprights. C (2) Equally shim both sides until contact (A) is made (zero clearance) between bearings and inner mast at narrowest point. (See Mast Adjustment in Testing And Adjusting).
Lift Relay Group - Standard Lift 1 WARNING Do not put a lift truck into service if the chain wear indication is 2% or more. A reading of 2% or more could cause damage or injury to persons. 2 (1) Put LOCTITE NO. 242 Thread Lock on the threads of the relay group locknuts after adjustment of the lift chains is completed. (2) Maximum chain wea........................Less than 2% (See Chain Wear Test in TESTING AND ADJUSTING).
Lift Relay Group - Full Free Lift 1 WARNING Do not put a lift truck into service if the chain wear indication is 2% or more. A reading of 2% or more could cause damage or injury to persons. 2 (1) Tighten bolts until contact is made with guard. (2) Put LOCTITE NO. 242 Thread Lock on the threads of the relay group locknuts after adjustment of the lift chains is completed. (3) Maximum chain wear Less than 2%(See Chain Wear Test in TESTING AND ADJUSTING).
Lift Relay Group - Full Free Triple Lift WARNING Do not put a lift truck into service if the chain wear indication is 2% or more. A Reading of 2% or more could cause damage or injury to persons. 1 (1) Maximum chain wear Less than 2%(See Chain Wear in TESTING AND ADJUSTING). (2) Put LOCTITE NO. 242 Thread Lock on the threads of the relay group locknuts after adjustment of the lift chains is completed. (3) Tighten bolts until contact is made with guide assembly.
(1) (Standard Mast or Full Free Triple Lift mast Only): With chains adjusted for equal tension, run mast to full lift. If mast does not kick (move) to one side, no shims are needed. If mast does kick (move) to one side, disconnect cylinder from the bar on that side. Add shim, connect cylinder, adjust chains and run mast to full lift to check for kick. Repeat process if necessary. The total shim pack must not be more than three shims maximum.
Steering Wheel Priority Valve (Incorporated with hydraulic pump) :B20/25/30S-2 1 IDCS179S Flow .......................................................Load sensing IDCS178S Relief valve (no adjustment) opens at: .............................8000 L 350 kPa ( 1160 L 50 psi) (1) Torque for steering wheel nut...........75 to 88 NIm ( 55 to 65 lbIft) Priority Valve :BC20/25/30S-2 Flow .......................................................Load sensing Relief valve (no adjustment) opens at: ..............
Steering Gear 1 2 3 VIEW C-C VIEW B-B TIGHTENING SEQUENCE FOR BOLTS A 4 C A SECTION A-A C 5 IDCS180S (1) Pin (1) in the body must be aligned with internal pump gear (gerotor) (2) and drive (3) as shown. (4) Tighten bolts in sequence shown. Tighten to a first torque of 14.1 L 2.8 NIm (125 L 25 lbIin) Tighten to a final torque of 28.2 L 2.8 NIm(250 L 25 lbIin) (5) Torque for plug 11.3 NIm(100 lbIin) Plug to be flush (even) with or below mounting surface.
(9) tapered Roller Bearing Axles Only: Torque for bolts that hold cover .....................................55 L 6 NIm(40 L 5 lbIin) Steer Axle and Wheel 3 A (10) Add or remove shims under cover until torque required to turn knuckle assembly is ...4.5 to 6.8 NIm (40 to 60 lb in) See Steering Knuckle Bearing Preload Adjustment in Testing And Adjusting section. 4 5 Steer Tire Installation B20/25/30S Models 1 2 6 IDCS181S 7 8 1 NOTE: Steer axles with tapered roller bearings shown.
(2) Torque for wheel cylinder mounting bolts ......................................15 L 2 NIm(11 L 1 lb ft) BC Models (3) Torque for adjuster mounting bolt (after it is centered) ............................72 L 5 NIm(55 L 4 lbIft) 1 (4) Adjuster dimensions: (X) or (Y) ........................1.05 mm (.041 in) maximum (X) + (Y) .....................1.3 L 0.3 mm(.051 L 0.12 in) (Z) .......................................................85 mm(3.
Parking Brake 1 A IDCS187S (1) Torque for brake drum retaining nut 50 L 20 NIm(37 L 15 ftIlb) (2) Clearance for brake drum and brake strap assembly at location marked (A) 0.25 - 0.50 mm (.010 - .020 in) See Parking Brake and Parking Brake Control Gp in Testing and Adjusting for brake and cable adjustment procedure.
Hydraulic Pump Motor HYDRAULIC PUMP MOTORS New Brush Size Thickness X Width X Length Minimum Brush Length * Minimum Commutator Diameter** 36/48 12.5 mm X 40.0 mm X 45.8 mm (.5 in X 1.57 in X 1.8 in) 19.0 mm (.75 in) 78 mm (3.07 in) 72/80 10.0 mm X 40.0 mm X 45.8 mm (.39 in X 1.57 in X 1.8 in) 20.0 mm (.75 in) Voltage *Measured on longest side. ** All rough edges (burrs) must be removed after the commutator is machined.
Machine chamfer on the commutator bars ........................................................0.40 mm (.016 in) Torque for the terminal bolts (not shown) that hold cable connection...............................14 NIm (10 lbIft) Depth of the insulation below commutator bars ............................................................1.0 mm (.04 in) Width of the insulation below commutator bars ........................................................0.76 mm (.
