Doosan D20G Specifications Systems Operation Testing & Adjusting Download

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Vehicle System

Specification
System Operation
Testing & Adjusting

D20G, D25G, D30G with B3.3 Engine
D20G, D25G, D30G with 4TNE98 Engine
G20G, G25G, G30G with G424F Engine
G20G, G25G, G30G with G424FE Engine

SB4219E01
Jan. 2008

Summary of Contents for D20G

Page 1: ... System Specification System Operation Testing Adjusting D20G D25G D30G with B3 3 Engine D20G D25G D30G with 4TNE98 Engine G20G G25G G30G with G424F Engine G20G G25G G30G with G424FE Engine SB4219E01 Jan 2008 ...

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Page 3: ...ollowing symbol Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on the produc...

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Page 5: ...ing 32 Visual Checks 32 Performance Tests 32 Hydraulic Oil Temperature Too Hot 32 Hydraulic System and Mast 33 Hydraulic Pump 36 Hydraulic Control Valve 37 Steering System 38 Brake System 39 Parking Brake 40 Hydraulic System 41 Relief Valve Pressure Check 41 Lift Cylinder Air Removal Only FFT FFL Mast 43 Delayed Engine Shutdown System 44 Operation 44 Diagram of Delayed Engine Shutdown System 45 Tr...

Page 6: ...System 64 Steer Wheel Bearing Adjustment 64 Steering Axle Stop Adjustment 65 Steering Knuckle Bearing Preload Adjustment 65 Steering System Pressure Check 66 66 Brake System 67 Brake System Air Removal 67 Brake Adjustment 67 Parking Brake Test 71 Parking Brake Adjustment 71 ...

Page 7: ... shown above See Relief valve pressure check in Testing Adjusting 4 Torque for screws 6 2 N m 53 20 lb in CONTROL VALVE ITEM psi kPa bar Kgf EU USA LIFT TILT 2 630 35 18 100 250 181 2 5 185 2 5 2 0t NON EU NON USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 EU USA LIFT TILT 2 840 35 19 500 250 195 2 5 199 2 5 2 5t NON EU NON USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 EU USA LIFT TILT 3 13...

Page 8: ...E98 Engine Displacement 26 5 rev Rotation is counter clockwise when seen from drive end Type of pump Gear A601502 for G20 25 30G Rotation is counter clockwise when seen from drive end Type of pump Gear Displacement 29ml rev Lift Cylinder Flow rate of flow protector FFL and FFT Mast D700495 45 to 53 liter min A215044 90 to 106 liter min STD Mast A371156 85 to 90 liter min Standard 1 Put pipe sealan...

Page 9: ...Lift Primary 1 Put pipe sealant on the last three threads of cap NOTE All seals to be lubricated with hydraulic oil Full Free Triple Lift And Full Free Lift Secondary 1 Put pipe sealant on the last three threads of cap NOTE All seals to be lubricated with hydraulic oil ...

Page 10: ...282 6 12 167 6 57 514 20 24 A375322 6 6 110 4 33 571 22 48 A375324 6 4 92 3 62 589 23 19 D20G G20G D25G G25G D30G G30G A375335 6 10 148 5 83 533 20 98 Permissible tolerance of 1 2 1 Adjust pivot eye to dimension Z with cylinder closed 2 Torque for bolt 95 15 N m 70 10 lb ft 3 Torque for head 270 30 N m 200 22 lb ft 4 Torque for piston nut 270 30 N m 200 22 lb ft ...

Page 11: ...60mm 4 315in D581816 Oversize 110 70mm 4 358in Permissible tolerance of 0 08 mm 003 in Carriage 1 Select bearings from the chart to obtain minimum clearance C between bearings and channel leg for full channel length Use same bearing at all six locations 2 Equally shim both sides until contact A is made zero clearance between bearings and inner mast at narrowest point 3 Shim bolt as needed to obtai...

Page 12: ... 2 or more could cause damage or injury to persons 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 wear Less than 2 See Chain Wear Test in TESTING ADJUSTING 3 Distance from bottom of inner mast to bottom of lower bearing on carriage must be even flush with the inner mast ...

Page 13: ...s 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 ADJUSTING 4 Distance from bottom of inner mast to bottom of lower bearing on carriage must be 41 1 5 mm 1 61 0 6 in Bottom of inner mast must be even flush with bottom of stati...

Page 14: ...ain wear Less than 2 See Chain Wear in TESTING 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 4 Distance from bottom of inner mast to bottom of lower bearing on carriage must be 41 1 5 mm 1 61 0 6 in Bottom of inner mast be even flush with bottom of stat...

Page 15: ...tal shim pack must not be more than three shims maxi mum 2 Install bearing outer race to a depth of F 4 5 0 8 mm 177 031 in 3 Tilt cylinder installation shown 4 Install bearing outer race to a depth of G 4 5 0 8 mm 177 031 in 5 Std Mast Only Tighten the bolt until the middle plastic shim touches the cylinder slightly 6 Std Mast Only Tighten the nut until the U Bolt touches the cylinder slightly Re...

Page 16: ...ick move to one side hold lift cylinder tube on that side and loosen bearing 1 4 turn and check mast again Loosen bearing until kicking movement stops or gap H reaches 3 0 mm 12 in approximately 1 5 turns whichever is less Insert shims 11 under bearing it may be necessary to loosen bearing an additional amount of turns to install shims Tighten bearing again 12 Tighten the bolt of mounting mast the...

Page 17: ...th internal pump gear gerotor 2 and drive 3 as shown 4 Tighten bolts in sequence shown Tighten to a first torque of 14 1 2 8 N m 125 25 lb in Tighten to a final torque of 28 2 2 8 N m 250 25 lb in 5 Torque for plug 11 3 N m 100 lb in Plug to be flush even with or below mounting surface ...

Page 18: ...t 1 completely Tighten it again to 50 5 N m 37 4 lb ft c Insert the pin 2 into lock nut 1 and bend it over nut 3 Torque for bolt that holds pin 11 1 N m 100 9 lb ft 4 6 Loosen nuts 5 on both sides Adjust bolts 4 to get steering knuckle turning angle A of 76 to 77 5 See Steering Axle Stop Adjustment in Testing And Adjusting section 8 Tapered Roller Bearing Axles Only Torque for bolts that hold stee...

Page 19: ...uts that hold steer wheel 120 20 N m 90 15 lb ft Shoe Brake 1 Axle shaft bolt 110 10N m 81 7 4 lb ft 2 Nut 200 10N m 148 7 4 lb ft 3 Torque for bolts that hold plate to final drive cover 180 30N m 133 22 lb ft 4 Torque for nuts that hold brake drum to hub 460 20N m 339 15 lb ft ...

Page 20: ...3 Lift Cylinder Primary 4 Flow Protector Secondary 5 Side Shfit Cylinder 6 Tilt Cylinder 7 Control Valve 8 Hydraulic Line To Steering Unit 9 Relief valve Auxiliary 10 Relief Valve Main 11 Gear Pump 12 Suction Filter 13 Return Filter 14 Hydraulic Tank 15 21 Hydraulic Line 22 Flow Regulator Valve FFT mast 12 Engine 1 6 5 3 1 2 4 STD mast 4 7 11 13 14 8 9 10 15 18 19 20 21 16 22 ...

Page 21: ...turn 13 and back to a hydraulic tank 14 The relief valve main 10 releases the excessive pressure to the hydraulic tank when the pressure in the lift circuit or tilt circuit goes higher than setting pressure shown at CONTROL VALVE SECTION of SPECIFICATION The relief valve auxiliary 9 releases the excessive pressure to the hydraulic tank when the pressure in auxiliary circuit goes higher than settin...

Page 22: ...inder 6 Tilt Cylinder 7 Control Valve 8 Hydraulic Line To Steering Unit 9 Relief valve Auxiliary 10 Relief Valve Main 11 Gear Pump 12 Suction Filter 13 Return Filter 14 Hydraulic Tank 15 24 Hydraulic Line 25 Flow Regulator Valve 26 Solenoid Block 27 Lift Lock Solenoid 28 Unload Solenoid 29 Emergency Manual Over Ride Valve FFT mast 12 Engine 1 6 5 3 1 2 4 STD mast 4 7 11 13 14 8 9 10 15 16 18 19 20...

Page 23: ...n 3 seconds or a start key is off The solenoid valve 27 for lift lock is electrically connected to the electric on off switch beneath a seat When the operator leaves a seat for more than 3 seconds or a start key is off the solenoid valve become off This leads to block the lowering flow passage Once the operator sits on seat and a start key is on the solenoid valve becomes on and immediately loweri...

Page 24: ...ns to control the loading Oil from Port P goes from throttle hole check valve PF throttling part inside of spool FD into PF port If oil from port P is increased pressure difference will be generated in front and back of throttle hole Because of the pressure difference on ends of FD spool the spool goes toward the part to shut the PF throttle part And then pressure difference goes down as well as P...

Page 25: ... the tank Meanwhile oil from Port Are turns to tank through the back flow path open by the spool And the spool comes back to the neutral position by reset spring Working principle of tilting valve 1 Neutral Position Oil from the pump returns to the tank through unload path 2 Tilting up of spool While unload path is closed oil from pump opens a load check through parallel path and flow out from Por...

Page 26: ...r doesn t work even spool down is performed When spool is down with no coming oil tank path from Port A is closed since no pressure to open pilot spool Therefore no action is done by a tilt cylinder which is in a lock condition Working Principle of Accessory Valve Section 1 Neutral Position Oil from the pump returns to tank through unload path 2 Spool up When unload path is closed oil opens a load...

Page 27: ...Relief Valve 1 Free Action Condition of relief valve When the circuit pressure is lower than the rated values relief valve keeps balance Pressure at Port P is filled in the spring chamber through poppet throttle hole By the work of spring force and oil pressure main poppet is squashed into the seat of slip while the pilot poppet is also in the condition of close by the force of spring Therefore al...

Page 28: ... omitted here Over load Relief Valve Port Over flow Valve Working principle is same as main relief valve Below is only the description of cavitation proof When working port pressure is lower than that off low back port main poppet is open and flow back oil goes into working port to play the function of cavitation ...

Page 29: ...rainer to hydraulic pump 8 The pump sends the oil through hose 11 to prioriey valve 12 The priority valve 12 supplies 12 Lpm of all pump flow to steering gear 1 and make it s remaider flow go to the sections of control valve 6 Check valve 5 in priority valve 12 is in hose 10 near the steering gear to prevent oil flow back to priority valve 12 priority which could cause a sudden jerk of the steerin...

Page 30: ... are met The steering gear has two main sections control section A and pump or metering section B These two sections work together to send oil to the steering cylinder Oil from the priority valve goes through inlet 4 into the control section of the steering gear When the steering wheel is turned the control section sends the oil to and from the metering section and also to and from the steering cy...

Page 31: ...uses a rotation of gear 5 inside gear 6 This rotation of the gear sends a controlled metered flow of pilot oil back through body 11 This oil flows to port 9 or 10 and then to the steering cylinder Port 9 or 10 that is not used for pressure oil to the steering cylinder is used for return oil from the other end of the steering cylinder Pump Gears In Metering Section 5 Internal pump gear 6 External p...

Page 32: ...ton moves into the master cylinder and push brake liquid through outlet into the brake lines When floating piston seats on seal the liquid that is pushed by piston goes around cup seal out through loading piston and outlet This action continues until the liquid pressure in piston bore reaches the pressure that opens relief valve The liquid being pushed by piston now returns to reservoir 1 Cup seal...

Page 33: ... automatic adjustment are adjusted on the reverse braking action In this example the drum rotation is counterclockwise in reverse which causes a counterclockwise rotation of the brake shoes Secondary shoe 4 moves away from cylinder 2 that causes link 1 to move toggle lever 6 in a clockwise rotation Link 8 is connected to the lower part of toggle lever 6 and to adjustment lever 9 By this connection...

Page 34: ...lug line or component is removed make sure all hydraulic pressure is released Visual Checks A visual inspection of the hydraulic system and its components is the first step when a diagnosis of a problem is made Lower the carriage to the floor and follow these inspections 1 Measure the oil level Look for air bubbles in the oil tank 2 Remove the filter element and look for particles removed from the...

Page 35: ...en the relief valve Relief valve pressures that are too low will cause a decrease in the lift and tilt characteristics of the lift truck Pressures that are too high will cause a decrease in the life of hoses and components 2 Drift rates in the cylinders Cylinder drift is caused by a leakage past cylinder pistons O ring seals in the control valve check valves that do not seat correctly or poor adju...

Page 36: ...lt spool has a restriction 7 The priority valve does not work correctly 8 Seals in tilt cylinder worn or damaged 9 Unload function doesn t work correctly Probable Mechanical Cause 1 Damage or failure of the tilt cylinders 2 Mast mounting pins seized Problem The carriage will not lower correctly Probable Cause 1 There are restrictions in the lift line 2 The lift spool in the control valve has a res...

Page 37: ... and twisted 180 degree clockwise Probable Electric Cause 1 Not to supply the electric power to solenoid valve in solenoid block Probable Hydraulic cause 1 A broken lift lock solenoid valve in solenoid block Probable Mechanical Cause 1 Lift cylinder damaged or bent 2 Load roller defective bearing or not adjusted correctly 3 Not enough lubricant on the parts of mast which that moves Problem Safety ...

Page 38: ... valve setting is too low 4 The oil is too thin 5 There is air leakage in the system 6 The pump has too much wear 7 The system operates at too high a pressure a Relief valve setting too high b Attachment components cause a restriction during movement c Restrictions in flow control valve load check valve and in oil lines 8 Severe hydraulic usage Problem Leakage on the shaft seal Probable Cause 1 Th...

Page 39: ...d check valve and seat show wear 3 Sudden loss of pump oil pressure 4 Damage to the relief valve which causes low oil pressure Problem Spools do not return to neutral Probable Cause 1 The springs are broken 2 The spool is bent 3 The system or valve has foreign particles in it 4 The control linkage is not in alignment 5 The fastening bolts of the valve have too much torque Problem No motion or slow...

Page 40: ...alve check valve permits lift and tilt hydraulic oil to affect steering hydraulic circuit Problem Oil leakage at the pump Probable Cause 1 Loose hose connections 2 Detective shaft seal Problem Low oil pressure Probable Cause 1 Low oil level 2 Priority valve relief valve spring weak 3 Relief valve priority valve will not move from the open position 4 Oil leakage inside or outside of the system 5 De...

Page 41: ... shoe adjustment not correct 2 Brake pedal adjustment not correct 3 Mechanical resistance at the pedal or shoe 4 Restriction in the brake line 5 Defective wheel cylinder Problem Pedal resistance is not solid spongy Probable Cause 1 Leakage or low fluid level 2 Air in the brake hydraulic system 3 Loose master cylinder mounting Problem Hard pedal Probable Cause 1 Mechanical resistance on the pedal o...

Page 42: ... adjustment or is bent Problem Not braking evenly or rough feeling of braking chatter Probable Cause 1 Lining surface looks like glass glazed or worn 2 Oil or brake fluid is on the lining 3 Defective contact between the lining and drum 4 Loose lining 5 Brake drum out of round 6 Loose wheel bearing 7 Defective wheel cylinder Parking Brake Problem Brake will not make application Probable Cause 1 Par...

Page 43: ...sure is released before any fitting plug hose or component is loosened tightened removed or adjusted Always move the lift truck to a clean and level location away from the travel of other machines Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are made Pressure Tap Location 1 Pressure tap With the engine off remove cap 1 from nipple assemb...

Page 44: ... control lever in the full tilt back position and watch the gauge The gauge indication is the pressure that opens the relief valve 3 The correct pressure setting is shown in the chart 4 If an adjustment to the relief valve setting is necessary loosen nut 5 Relief Valve Adjustment 5 Locknut 6 Stud 5 Turn setscrew 6 clockwise to increase or counterclockwise to decrease the pressure setting of the re...

Page 45: ... high enough to put a load on all stages of the lift cylinders Typical example Setscrew Locations Standard Cylinders NOTE The Full Free and Full Free Triple Lift mast has one primary and two secondary cylinders 5 Locate the setscrew on each lift cylinder Slowly open setscrews no more than one turn The weight of the carriage will force air and hydraulic oil out of the cylinders through the setscrew...

Page 46: ...engine shutdown system will interrupt the fuel supply to the engine thereby saving the engine from the critical damage 1 Low engine oil pressure The warning MIL lamp will turn on when the oil pressure drops to approximately 28KPa 4 psi and the delayed engine shutdown System will interrupt the fuel supply to the engine after thirty seconds 2 Hot engine coolant The warning MIL lamp will turn on when...

Page 47: ...Vehicle System Testing and Adjusting 45 Diagram of Delayed Engine Shutdown System G20 25 30G G424F E ENGINE LP TRUCK G20 25 30G G424F E ENGINE GAS TRUCK ...

Page 48: ... 161 15 Low Oil Pressure Fault Low engine oil pressure 521 52 Transmission Oil Temperature Excessive transmission oil temperature 933 Diagnostic Fault Codes DFC PROBABLE FAULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK 151 15 ECT Range High Coolant sensor disconnected or open circuit 1 Turn on MIL 2 Delayed Engine Shutdown 3 Check Engine Light Check if ECT sensor connector is disconnected or for a...

Page 49: ...Vehicle System Testing and Adjusting 47 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G20 25 30G G424F E LP ...

Page 50: ...Vehicle System Testing and Adjusting 48 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G20 25 30G G424F E GAS ...

Page 51: ...utral shift feature Transmission is automatically shifted to the neutral when the operator leaves the seat with the engine running and the direction lever in forward or reverse To restore the lift truck return the directional lever to the neutral position and then reselect a direction of travel either forward or reverse The transmission will then re engage 4 Water separator sediment warning only d...

Page 52: ...em Schematic SOL_VALVE_UNLOAD SOL_VALVE_LIFT LOCK INDICATOR AS SEAT BELT SWITCH SEAT SWITCH AIR CLEANER SWITCH FUSE CIRCUIT BREAKER IGNITION SW DIR SWITCH RELAY CREEPING SPEED PILOT BUZZER FWD BATTERY FUSE PARKING BRAKE SW REV LP PR SW SEDIMENT SW CONTROLLER VCS ...

Page 53: ...een controller SW3 and GND 12V is no problem 1 Buzzer warning 2 Neutral light 3 No drive operation 1 Seat switch open 2 Relay REV FWD Creep speed defect 3 Directional switch defect 4 Wiring defect 5 FWD REV Solenoid defect 6 Controller defect 1 Check seat switch 2 Check relay REV FWD Creep speed 3 Check FWD REV Solenoid 4 Check continuity of wire from relay creeping speed 85 to controller C RELAY ...

Page 54: ...lock Unload Solenoid 3 Check continuity of wire from solenoid lift lock 2 or solenoid unload 2 to controller ISO3691 VALVE 4 Check continuity of wire from solenoid lift lock 1 or solenoid unload 1 to controller IGN 5 Measure the voltage between controller IGN and controller ISO3691 VALVE 12V is no problem 1 Air cleaner light 1 Air cleaner switch short 2 Wiring defect 1 Check air cleaner switch 2 C...

Page 55: ...arings A Lower Bearing Adjustment of Intermediate Mast Mast Adjustment Lower Bearings A Zero clearance B Minimum clearance C Zero clearance 3 Bearing 4 Bearing 5 Shims 6 Shims 1 Select lower bearings 3 and 4 from the chart to obtain minimum clearance B between bearing and channel leg for full channel length Use same bearing on left and right side Mast And Carriage Bearings Part No Bearing Size Bea...

Page 56: ...ually when positioned behind each bearing 4 Mast Adjustment Lower Bearings A Zero clearance B Minimum clearance C Zero clearance 3 Bearing 4 Bearing 5 Shims 6 Shims 4 Make surer intermediate mast lower bearings are properly shimmed in the stationary mast 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 m...

Page 57: ...ermediate lower bearings Repeat same procedure of above until properly shimmed There is to be contact zero clearance C between intermediate lower bearings and stationary channel at approximately 475 mm 18 7 in channel lap B Upper Bearing Adjustment of Stationary Mast 1 Lift by crane and pull out intermediate mast from stationary mast Install 1 mm shim to each bearing of stationary mast upper Beari...

Page 58: ...tationary mast and remove shim 0 5 mm to both stationary upper bearings Repeat same procedure of above until properly shimmed There is to be contact zero clearance C between stationary upper bearings and the widest point of intermediate mast to be checked before C Upper Pad Adjustment Mast Adjustment Upper Bearings D Zero clearance E 0 80 mm 031 in Clearance maximum F Zero clearance 7 Pads 8 Shims...

Page 59: ... right side 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 0 08mm 003in 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...

Page 60: ... There is to be contact zero clearance C between inner lower bearings and intermediate channel at narrowest point E Upper Bearing Adjustment of intermediate Mast Follow same procedure with above B F Upper Pad Adjustment of Intermediate Mast Follow same procedure with above C Carriage Adjustment NOTE The standard Full Free Lift and Full Free Triple Lift carriage load bearings are all adjusted the s...

Page 61: ...3 Install enough shims 4 that have been divided into two equal groups behind bearings 3 At installation there is to be contact zero clearance A between the bearings and the narrowest point of inner mast 4 Do step 2 through 3 for other sets of bearings 5 Tighten screw 5 that holds the top bearings to the carriage to a torque of 34L7 N m 25L5 lb ft Chain Adjustment Chain Adjustment Check Chain Adjus...

Page 62: ... 1 or bolts 2 for equal tension of the mast and carriage chains 3 Put LOCTITE NO 242 Thread Lock on the threads of the locknuts after the adjustment is completed Outer Lift Chains 2 Chain Anchor Bolts Chain Wear Test Chain wear test is a measurement of wear of the chain links and pins Do the steps that follow to check chain wear 1 Lift the mast and carriage enough to put tension on the lift chains...

Page 63: ...he bearing must be even flush with the inner mast If the above measurements are not correct make adjustments to the chains to get the correct measurement See Chain Adjustments in TESTINGAND ADJUSTING Forks Parallel Check 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 ac...

Page 64: ... sure that the mast is not twisted The tilt angle is determined by the tilt cylinders used See tilt cylinders in specifications to determine the tilt angle from the cylinder being used Tilt Cylinder Length Check 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 The difference of length between ...

Page 65: ... cylinders or control valve Before testing the drift WARNING Personal injury can be caused by sudden movement of the mast or carriage Use woodblocks and clamps to hold the mast in this position Keep hands and feet clear of any parts that can move 1 Check the chain adjustment and tilt cylinder alignment and make necessary adjustments 2 Lift the mast approximately 762 mm 30 in Use wood blocks and cl...

Page 66: ...height extension raise the load to the truck s maximum height Tilt Drift Check 3 The tilt drift is measured as the charge in the tilt cylinder stroke Measure any drift of the mast for ten minute period Drift for shall not exceed 35 5 mm 1 40 in Steering System Steer Wheel Bearing Adjustment Bearing Adjustment 1 Nut 2 Lock 1 Tighten nut 1 slowly to 135 N m 100 lb ft while the wheels is rotated in b...

Page 67: ...ection and do the same procedure for the opposite stop bolts This will give a maximum cramp angle of 76 Steering Knuckle Bearing Preload Adjustment Steering Knuckle Bearing Preload Adjustment 4 Steering link 5 Shims 6 Bearing 1 During assembly of the steering knuckle install the thrust bearing and bushing without shims 2 Measure the clearance between bearing 6 and the axle beam 3 Take an average o...

Page 68: ...ition for operation start the engine and activate the hydraulic controls until the oil is at a temperature for normal operation 4 Turn the steer wheels to the left or right against the stops and make a note of the indication on the pressure gauge 5 The indication on the pressure gauge must be the priority valve relief setting of 9 000 0 300 kPa 1 305 0 43 psi If the indication is correct and a pro...

Page 69: ...screw 5 Fill remote reservoir 1 again with the correct fluid to the level explained in Step 1 Brake Adjustment The brakes make an adjustment automatically when an application is made in reverse but only after an application has been made in the forward direction With each reverse brake application there happens an adjustment until the lining to drum clearance is made small enough to stop the movem...

Page 70: ...red conduct the burning on the brake shoes and linings for 5 10 minutes Pedal Adjustment The brake pedal must have proper free play to let the master cylinder piston return to the release position and open the relief outlet Approximately 5 mm of free play on the pedal is required Hydraulic pressure in the brake lines goes back through the relief opening and releases the brakes If there is no pedal...

Page 71: ...per bolt for the brake pedal to meet 130 135 mm A between end of pedal floor plate For reference the distance B between the top of transmission and pedal shown below is about 353 mm 3 After finish the adjustment tighten the bolt with nut 130 135 mm 353 mm ...

Page 72: ... height of Inching Pedal with the brake pedal s by inching rod 6 Adjust the engaging point of inching pedal to the brake pedal when the stroke of inching spool becomes 2 mm 7 Make sure the same level of 2 pedals 8 Finally check the distance between floor plate end of brake pedal should be 130 mm 9 Test the brake performance and adjust once again if required additionally ...

Page 73: ...brakes Apply the parking brake 3 If the parking brake has the correct adjustment the lift truck can be held in this position 4 If the parking brake does not hold do the steps in parking Brake Adjustment Parking Brake Adjustment 1 Put the control lever in the released position 2 Turn the screw 1 on the lever in clockwise direction to tighten the cable assembly with driver 3 Turn the screw 1 on the ...

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