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Vehicle

Systems

Testing

and

Adjusting

Loosen nut (2).

Tighten screw (1) to a torque of 5.6 to 6.8 N·m (50

to 60 lb·in).

Loosen screw (1) 1.2 to 1.5 turns, hold in this

position and tighten nut (2).

Parking Brake Adjustment

(7) Switch Assembly. (8) Screws.

Loosen screws (8).

Adjust switch assembly (7) until switch actuation

occurs between the 2nd. Or 3rd click as the
parking brake is engaged. Tighten screws (8).

IDCS219S

Содержание D15S-5

Страница 1: ...Vehicle System Specification Systems Operation Testing Adjusting D15S 5 D18S 5 D20SC 5 G15S 5 G18S 5 G20SC 5 GC15S 5 GC18S 5 GC20SC 5 SB4365E01 June 2011...

Страница 2: ......

Страница 3: ...ollowing symbol WARNING 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...

Страница 4: ......

Страница 5: ...lic Schematic 24 Control Valve 26 External View 26 Circuit Schematic 26 Inlet Section 27 Lift Section 28 Tilt Section 30 Auxiliary Section 31 Outlet Section 32 Relief Valve 33 Hydraulic Steering syste...

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Страница 7: ...040 50 14 000 350 D18S G C 18S 5 STD FF FFT 2 880 35 19 860 250 D20SC G20SC 5 STD FF FFT 3 125 35 21 550 250 1 Torque for nuts that hold control valve sections together 24 to 28 N m 18 to 21 lb ft 2 T...

Страница 8: ...tion is counterclockwise when seen from drive end Type of pump Gear For test use SAE 10W oil at 65 C 150 F Pump output 19 5 cm rev 1 19 in rev Sideshift Cylinder 1 Torque for head 270 35 N m 200 25 lb...

Страница 9: ...of 6 1N m 53 9 lb in NOTE All seals to be lubricated with hydraulic oil Full Free Triple and Full Free Lift Primary 1 Put Pipe Sealant on the last three threads of bearing 2 Put Pipe Sealant of the l...

Страница 10: ...s of bleed screw and tighten to a torque of 6 1 N m 53 9 lb in NOTE All seals to be lubricated with hydraulic oil Full Free Triple Lift Secondary 1 Put Pipe Sealant on the last three thread of bearing...

Страница 11: ...5 mm 400334 00015 GC15 18S 5 6 10 392 5 mm 73 mm D518224 6 10 392 5 mm 82 mm A252107 1 Adjust pivot eye to dimension Y with cylinder open extended 2 Torque for bolt 95 15 N m 70 10 lb ft 3 With mast...

Страница 12: ...hicle Systems Specifications 10 Steering Wheel 1 Torque for steering wheel nut 75 to 88 N m 55 to 65 lb in Priority Valve Flow Load sensing Relief valve no adjustment opens at 8 285 350 kPa 1 200 50 p...

Страница 13: ...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 T...

Страница 14: ...ations 12 Forward and Reverse Control Group 1 Torque for bolts four 3 4 to 3 9 N m 30 to 34 5 lb in 2 Torque for bolts two 2 8 to 3 4 N m 25 to 30 lb in Brake SHOE 1 Torque for wheel cylinder bolts 1...

Страница 15: ...ne 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 dro...

Страница 16: ...Vehicle Systems Specifications 14 Diagram of Delayed Engine Shutdown System G424I E G424F E ENGINE LP TRUCK G424I E G424F E ENGINE GAS DF TRUCK...

Страница 17: ...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 ACTI...

Страница 18: ...Vehicle Systems Specifications 16 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G424I E LP...

Страница 19: ...Vehicle Systems Specifications 17 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G424I E GAS DF E G OIL PR E G CHECK ENG GND NEAR COILS...

Страница 20: ...Vehicle Systems Specifications 18 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G424F E LP...

Страница 21: ...Vehicle Systems Specifications 19 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G424F E GAS DF...

Страница 22: ...l 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 r...

Страница 23: ...chematic 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 FUS...

Страница 24: ...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 R...

Страница 25: ...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 cont...

Страница 26: ...w protector primary 3 lift cylinder primary 4 flow protector secondary standard 5 side shift cylinder 6 control valve 7 solenoid valve for lift lock 8 tilt cylinder 9 relief valve auxiliary 10 solenoi...

Страница 27: ...he operator leaves a seat for more than 3 seconds or a start key is off the solenoid valve becomes off which leads to block the lowing flow passage Once a start key is on and operator sits on seat the...

Страница 28: ...Vehicle Systems Systems Operation 26 Control Valve External View 4 Spool I C Truck Valve Circuit Schematic 4 Spool I C Truck Valve...

Страница 29: ...nection as well as a diagnostic inlet pressure gage port new feature to be added When the operator is not seated the solenoid valve is in the normally open position which helps divert flow from the pu...

Страница 30: ...nction with a lift lock check valve When the operator is not seated the solenoid valve is not energized which ensures that pressures are equalized across the lift lock valve closed and prevents loweri...

Страница 31: ...normally closed solenoid valve Important Note Before opening the secondary needle valve make sure personnel and equipment are safely positioned to avoid accidents Be careful to operate this secondary...

Страница 32: ...ing notches and cylinder head Simultaneously the high pressure acts on the end of the tilt lock plunger to move it towards the spring end of the spool This plunger movement opens additional spool mete...

Страница 33: ...ion In general one work port is pressurized by high pressure oil from the parallel passage past the load check valve past the metering notches and to the cylinder Simultaneously oil from the other wor...

Страница 34: ...Vehicle Systems Hydraulic System Operation 32 Outlet Section The outlet section contains the tank port and the secondary relief valve with built in anti cavitation feature...

Страница 35: ...lows through piston 11 of the main relief valve The pressure oil opens pilot valve 14 This lets the oil flow go through spring chamber 13 to passage 7 The oil then returns to tank When the pilot valve...

Страница 36: ...f mast operation are filled The fluid is pulled from a hydraulic tank 11 to a hydraulic pump 10 Pump supplies a fluid through a hydraulic hose 15 to a priority valve 12 When the steering unit 1 is neu...

Страница 37: ...the hydraulic tank A check valve is installed into the port of steering unit connected to hydraulic line 9 to prevent a fluid back to priority valve right after a turn is made Relief valve in priorit...

Страница 38: ...ics are met The steering unit 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 g...

Страница 39: ...e causes 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...

Страница 40: ...ter 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...

Страница 41: ...put it in position against the drum Automatic Adjustment Brakes with automatic adjustment are adjusted on the reverse braking action In this example the drum rotation is counterclockwise in reverse wh...

Страница 42: ...end lock 5 away from nut 6 Adjust nut 6 so lever 4 is against stop 3 3 Tighten nut 6 finger tight and bend lock 5 to hold in place 4 Loosen nut 2 5 Tighten screw 1 to a torque of 5 6 to 6 8 N m 50 to...

Страница 43: ...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 Meas...

Страница 44: ...e control valve check valves that do not seat correctly or poor adjustment or fit in the control valve spools 3 Cycle times in the lift and tilt circuits Cycle times that are too long are the result o...

Страница 45: ...The lift spool in the control valve has a restriction caused by foreign material and does not operate freely 3 The lift cylinder flow regulator valve has a restriction 4 Air in the hydraulic system P...

Страница 46: ...ted Problem Safety lift lock doesn t work Safety lift lock function Once the operator leaves a seat more than 3 seconds or a start key is off the lift cylinder doesn t lower even though lift spool is...

Страница 47: ...luid Probable Cause 1 Low Level of the oil in the tank 2 There is a restriction in the pump inlet line 3 There is air leakage in the pump inlet line 4 The viscosity of the oil is wrong 5 The pump has...

Страница 48: ...bable Cause 1 The relief valve is not correctly set or will not move in base and or is worn 2 There is air in the system 3 Dirt or foreign particles between relief valve control poppet and its seat 4...

Страница 49: ...uit Problem Oil leakage at the pump Probable Cause 1 Loose hose connections 2 Defective shaft seal Problem Low oil pressure Probable Cause 1 Low oil level 2 Priority valve relief valve spring weak 3 R...

Страница 50: ...drag Probable Cause 1 Brake shoe adjustment not correct 2 Brake pedal adjustment not correct 3 Mechanical resistance at the pedal or shoe 4 Restriction in brake line 5 Bad wheel cylinder Problem Peda...

Страница 51: ...lining 4 Air in the brake hydraulic system 5 Bad master cylinder 6 Linkage is not in correct adjustment or is bent Problem Not braking evenly or rough feeling of braking chatter Probable Cause 1 Linin...

Страница 52: ...lower when the bleed screw is loose 4 Lift the forks high enough to put a load on all stages of the lift cylinders The illustrations shown are of a full free triple lift mast Lift Cylinder Air Removal...

Страница 53: ...re 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 perso...

Страница 54: ...indication is the pressure that opens the relief valve at the end of lift cylinder stroke 3 The correct pressure setting is shown in the chart 4 If an adjustment to the relief valve setting is necess...

Страница 55: ...rrect pressure setting is shown in the chart 4 If an adjustment to the relief valve setting is necessary loosen locknut 7 Relief valve Adjustment 7 Locknut 8 Stud 5 Turn stud 8 clockwise to increase o...

Страница 56: ...irection until the steering cylinder internal stop is reached 4 Adjust stop bolt 1 5 Tighten nut 2 Turn the steer wheel the opposite direction and do the same procedure for the opposite stop bolts Thi...

Страница 57: ...ull Be ready to add oil when the engine is started Do not let oil level go below the outlet to the pump 2 Start the engine and keep at low idle Add oil immediately to the tank or reservoir as needed N...

Страница 58: ...cause personal injury Before any steering system hydraulic lines or components are disconnected make sure all hydraulic pressure is released in the steering system Move the steer wheels to the left a...

Страница 59: ...e indication on pressure gauge 6 b If the indication is approximately the pressure shown in Step 5 then the steering gear has a hydraulic failure c If the indication is too low or too high then the pr...

Страница 60: ...ssure is still on the brake pedal then let the pedal return to the original position 3 Do Step 2 again as many times as necessary until the brake fluid is free of air 4 Use the procedure in Steps 2 an...

Страница 61: ...the gap D for engaging brake pedal by inching pedal D should be approx 9 5mm 5 The distance E between the shaft center and its mounting bracket should be 82 5mm 6 The stroke of inching spool should b...

Страница 62: ...do the steps in parking Brake Adjustment Parking Brake Adjustment Parking Brake Adjustment 1 Screw 2 Nut 3 Stop 4 Lever 5 Lock 6 Nut NOTICE Turn the adjustment screw clockwise to tighten Turning the...

Страница 63: ...0 to 60 lb in 7 Loosen screw 1 1 2 to 1 5 turns hold in this position and tighten nut 2 Parking Brake Adjustment 7 Switch Assembly 8 Screws 8 Loosen screws 8 9 Adjust switch assembly 7 until switch ac...

Страница 64: ......

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