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Power Train

Testing And Adjusting

4.

Control panel operation not correct:

See the MicroController System Operation
module.

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.
See Armature Commutator Inspection and
Brush Inspection in Testing And Adjusting.
Make reference to Problem: Sparks At The 
Commutator And/Or Rapid Brush Wear.

6. 

Check for opens in the field coils:

Test coils according to procedures in Testing
And Adjusting. If there are opens, make a
replacement of the field assembly.

7. 

Check for a short circuit in the armature windings:

Loose field winding pole pieces, make the
necessary corrections.
Field armature bar insulation.
Repair or rebuild the insulation or make a
replacement of the armature.

8. 

Static return to off circuit actuated:

If the static return to off is actuated, the control
will not start again until the accelerator is
released and the directional control lever is
returned to neutral.

Problem 2: Traction will not operate through a
normal work period, but hydraulic operation is
normal.

Probable Cause:

1. 

Brakes have a defect, cause a resistance (lack of
free movement). Heat increases, which causes the
motor to stall:

Check the brake adjustment according to the
procedures in Testing And Adjusting in the
Vehicle Systems module.

2. 

Too much heat in MicroController control panel
because:

a. 

Extra heavy traction loads.

Decrease the duty cycle load.

b. 

Faulty thermal switch.
See the MicroController System Operation
module.

c. 

Too high current limit (C/L) setting.

Lower the setting on the C/L adjustments.

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.

Probable Cause:

1. 

Too small a battery equipped in the lift truck:

Use a larger battery for the complete work cycle
and normal work period.

2. 

Battery not being fully charged or equalized during
the battery charging operation:

Check the battery cells for an equalization
charge (a charge to make the specific gravity
the same in all cells). Check the battery charger
for defects.

3. 

Battery change interval is too long or changed
battery cooling time is too short. This decreases
the capacity and the ability of the battery:

Decrease the battery work duration before a
change. Increase the battery cooling time after
a charge before it is put to use.

4. 

Battery has one or more defective cells which
results in less than the rated capacity and ability of
the battery:

Replace the battery.

5. 

Traction system draws (make a consumption of)
too much battery power because of traction
system faults. Operation of the duty cycle
(complete working cycle) condition is not correct:

Check the brake adjustment according to the
procedures in Testing And Adjusting in the
Vehicle Systems module, Check the mechanical
components such as wheel bearings, axles,
etc., for corrections to eliminate the faults.
Change to a tire with less friction.

6. 

Hydraulic system draws too much battery power
because of lifting and tilting arrangements, or
hydraulic conditions are not correct for the duty
cycle:

Decrease hydraulic relief valve setting to the
capacity that only will be used.
Change to a smaller hydraulic pump.
Check the mast for restriction during operation.

7. 

Lift truck working more than the capacity of its
design with no available power after one work
shift:

Have available an extra (exchange) battery.
Decrease the speed and work load required to
complete the work shift.

10

Содержание B20S-2

Страница 1: ...Specifications Systems Operation Testing Adjusting Disassembly Assembly LiftT rucksPowerT rain B20S 2 B25S 2 B30S 2 BC20S 2 BC25S 2 BC30S 2 SB2025E01 Aug 1999...

Страница 2: ...owing 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 o...

Страница 3: ......

Страница 4: ...p Adjustments 21 Pinion Bearing Adjustment 24 Pinion Depth Check 24 Pinion Installation 22 Power Transfer Group 21 Power Transfer Group Bearing And Gear Clearance Backlash Adjustments 25 Troubleshooti...

Страница 5: ......

Страница 6: ...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...

Страница 7: ...tant terminals on motor frame 7 On the outside of the motor frame is cover 2 that can be removed for easy access to the brushes and the commutator Field coils 6 are fastened to the inside of the motor...

Страница 8: ...gears turn the axle shafts The power transfer group is used to send the power from the electric drive motor to the wheels When one wheel turns slower than the other the power transfer group lets the...

Страница 9: ...b 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...

Страница 10: ...l 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 inspect...

Страница 11: ...ome defective control panel failure or drive fuse to go bad Problem 3 Neither traction or hydraulic will last through a complete normal work period Probable Cause 1 Too small a battery equipped in the...

Страница 12: ...acks 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 mo...

Страница 13: ...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 Problem 7 Lift truck moves faster in one direction tha...

Страница 14: ...ing Probable Cause 1 Lubricant not to the specified level 2 Wrong type of lubricant 3 Wheel bearings out of adjustment or have a defect 4 Bevel gear and pinion not in adjustment for correct tooth cont...

Страница 15: ...ll Brushes 1 Brushes NOTICE Installation of the wrong brushes can cause early motor failure Always make sure the correct DAEWOO brushes are installed 5 Install new brushes 1 Make sure the brushes move...

Страница 16: ...e of each brush At least 85 of the brush contact surface of each brush must show wear If necessary do Steps 8 through 11 again until the correct wear can be seen on the brush contact surface NOTICE Ne...

Страница 17: ...pressed pressure air Do the test for grounds again If there is still an indication of a ground make a replacement of the armature Open Circuit Test Open Circuit Test 1 Put the digital multimeter Funct...

Страница 18: ...s will cause fast brush wear Threads on the Commutator Surface Threads grooves that look like threads on the commutator surface will also cause fast brush wear Grooves on the Commutator Surface Groove...

Страница 19: ...an open field coil Ground Test Ground Test 1 Field Terminal 2 Motor housing 1 Put the digital multimeter Function Range Switch on the 20M resistance scale 2 Put one test lead to either outer field ter...

Страница 20: ...ance scale 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 3 Do the test again with one test lead on the o...

Страница 21: ...here is an indication that brush wear is too fast see Troubleshooting Problem Sparks at the commutator and or rapid brush wear for probable causes of this problem 4 Inspect all brushes in the motors M...

Страница 22: ...other and must never be installed separately The same identification mark of letters and numbers is put on both the pinion and bevel gear Make sure they have the same identification mark before going...

Страница 23: ...ck 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 ad...

Страница 24: ...t in position 23 PINION SHIM CHART New Pinion Marking 10 08 06 04 02 0 02 04 06 08 10 10 0 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 0...

Страница 25: ...ion from nominal marked on end of pinion 77 92 mm 3 068 in required mounting distance 78 10 mm 3 075 in actual mounting distance from Step 3 77 92 mm 3 068 in required mounting distance 0 18 mm 0 007...

Страница 26: ...que is not correct add or remove shims 1 until it is correct Removal of shims 1 increases the rolling torque Adding shims 1 decreases the rolling torque Record the actual rolling torque after the shim...

Страница 27: ...e at the pinion recorded in Pinion Bearing Adjustment Step 6 by 0 63 to 0 88 N m 5 6 to 7 8 lb in 6 Measure backlash again After backlash and preload are correct bend a tab on each lockwasher 7 into a...

Страница 28: ...a curve toward the outside To correct this remove shims from under pinion bearing cup After this is done check gear clearance backlash and tooth contact again NOTE Several adjustments of both pinion...

Страница 29: ...ads 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 1 3 8 1 1 2 5 16 3 8 7 16 1 2 5 8 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 1 3 8 1 1 2 9 L 3 18 L 5 32 L 5 50 L 10 75 L 10 110 L 15...

Страница 30: ...220 L 30 325 L 50 450 L 70 600 L 90 775 L 100 1150 L 150 1610 L 200 2000 L 275 2700 L 400 9 L 3 18 L 5 40 L 7 70 L 10 110 L 15 160 L 20 240 L 35 330 L 50 440 L 65 570 L 75 840 L 110 1175 L 150 1450 L...

Страница 31: ...only Opening Temperature 135 L 4 275 L 10 F Closing Temperature 118 L 6 244 L 11 F Drive Motors Model Voltage 1 New Brush Size Minimum 2 New Commutator Minimum Thickness B width B length Brush Length...

Страница 32: ...s needed to obtain rolling torque of 0 85 to 1 70 N m 7 5 to 15 0 lb in at the pinion without the differential case assembly 5 Apply LOCTITE NO 609 Sealant to outside diameter of cap 5 prior to assemb...

Страница 33: ...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 temp...

Страница 34: ...ts 1 to a torque of 488 L 27 N m 360 L 20 lb ft Drive Tire Installation B Series The optional cushion drive tire must be installed as shown failure to do so will decrease machine stability and cause p...

Страница 35: ...ic tire wheel nuts 2 to a torque of 644 L 34 N m 475 L 25 lb ft Use crisscross procedure to tighten the nuts BC Series BC20S 2 BC25S 2 The drive tire must be installed as shown below Failure to do so...

Страница 36: ...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 betwee...

Страница 37: ...e wheels On B20 25 30S models remove the brake drum also 2 Remove brake return springs 1 2 and 3 with a suitable brake shoe spring tool 3 Remove brake retainer springs 4 Remove the brake shoes 4 Remov...

Страница 38: ...seals 19 and spring 17 from the wheel cylinder Install Brakes Brake Adjuster And Wheel Cylinder 1 Install spring 17 in the wheel cylinder NOTE Put clean brake fluid on the seals and inside of the whee...

Страница 39: ...and bolts 9 Tighten the bolts to a torque of 15 L 2 NIm 11 L 1 lbIft 7 Install plungers 8 Connect brake lines 7 and tighten the nuts to a torque of 14 L 2 NIm 10 L1 lbIft 8 Install wheel cylinder cov...

Страница 40: ...0W oil on the seal 4 Put the power transfer group in position on the drive axle housing Install the four bolts End By a Install final drives and hubs b Install transaxle Disassemble Power Transfer Gro...

Страница 41: ...ockwasher and washer 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 Remove ring 21 from the pinion shaft Remove...

Страница 42: ...ing bores of the housing assembly as shown Install bearing caps 1 and tighten the bolts 4 Measure the distance from the end of the pinion shaft to the bottom of the bar with an inside micrometer Recor...

Страница 43: ...end of pinion 77 91 mm 3 067 in required mounting distance 77 91 mm 3 067 in actual mounting distance 77 91 mm 3 067 in required mounting distance 0 mm 0 in thickness of shims that need to be added or...

Страница 44: ...shims for setting rolling torque are not shown in the parts book The part numbers are 15 Remove tooling E Measure the thickness of tooling E Subtract from this thickness the recorded end play from st...

Страница 45: ...n the carrier and the ten bolts Tighten the bolts to a torque of 70 L 15 NIm 50 L11 lbIft Put bearing cups 3 on the bearing cones 22 Put the carrier assembly in position in the housing assembly Instal...

Страница 46: ...lso use Quick Cure Primer if the temperature is below 10 C 50 F End By a Install power transfer group Final Drives And Hubs Remove Final Drives And Hubs Start By a Remove brakes 1 Bend back one of the...

Страница 47: ...g 10 from the shaft Install Final Drives And Hubs 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 2 Install lip seal 9 i...

Страница 48: ...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 L10 NIm 41 L 7 lbIft 8 Install bearing 2 locking washer 1 and nut 3 on...

Страница 49: ...lift truck in position on tooling A 2 Remove the bolts 1 and wheel 2 3 Remove bolts 3 and adapter 4 4 Remove bolts 5 and cover 6 5 remove the plates and discs 7 from hub 8 6 Remove piston 9 from hub 8...

Страница 50: ...nformation 8 Put Loctite No 17430 on the mating surfaces of hub 8 and the transaxle housing Install hub 8 and bolts 10 9 Install piston 9 10 Install the plates and discs 7 into hub 8 11 Put Loctite No...

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