Daewoo B20S-2, Disassembly/Assembly

Page 1: ...ssembly L Li if ft t T Tr ru uc ck ks s V Ve eh hi ic cl le e S Sy ys st te em ms s B B2 20 0S S 2 2 B B2 25 5S S 2 2 B B3 30 0S S 2 2 B BC C2 20 0S S 2 2 B BC C2 25 5S S 2 2 B BC C3 30 0S S 2 2 SB202...

Page 2: ...lowing 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...

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Page 4: ...Hydranlic Control Valves 42 Hydraulic Control Valve Switch Group 5 Hydraulic Pump Motor 5 Mast 13 Master Cylinder 60 Parking Brake 61 Primary Lift Cylinder 32 Secondary Lift Cylinders 29 Standard Lif...

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Page 6: ...the screws lockwashers and nuts 7 Put the lever assemblies in position on the spools Install pins 2 the washers and cotter pins 8 Install rod assembly 1 the wire harness clip bolt and washer Connect...

Page 7: ...The following steps are for installation of the hydraulic pump motor 5 Install the two plates and blocks on the pump motor if they were removed Put the pump motor in position in the lift truck with to...

Page 8: ...in the reverse order of removal 7 Put the forks in position Lower both fork pins 1 to lock the forks in position Backrest Remove Install Backrest Start By a Remove forks 1 Fasten a hoist to the backr...

Page 9: ...he cap of the hydraulic tank to release any pressure in the tank Be cautious of hot hydraulic oil when any lines are disconnected in the hydraulic system NOTE For purposes of reassembly identify and m...

Page 10: ...aise the inner mast to pull out carriage as shown 9 Remove carriage from bottom of inner mast 15 Carriage 14 weighs 116kg 255 lb NOTE Use the following steps to install the carriage 10 Raise the inner...

Page 11: ...onto the hose mounting bracket 14 Install chain guard hose support assembly 6 and four bolts 8 15 Connect two hydraulic line 4 in their original positions End By a Install backrest b Install forks Di...

Page 12: ...t follows to adjust carriage load bearings Carriage Adjustment 3 Upper bearings 4 Shims 5 Bolt 6 Screw 7 Middle bearings 8 Lower bearings A Zero clearance B 6 0 to 9 0 mm 236 to 354 in clearance C Min...

Page 13: ...of inner mast 4 Do step 2 through 3 for other sets of bearings 8 9 5 Tighten screw 5 that holds the top bearings to the carriage to a torque of 34 L 7 NIm 25 L 5 lbIft 6 Shim stop bolt 11 as required...

Page 14: ...ebris and contamination from entering the system 2 Disconnect hose 3 3 Disconnect two hydraulic lines 4 Tilt cylinders 7 can drop when pin 6 is removed To avoid component damage or personal injury sup...

Page 15: ...from the machine 8 Install the mast in the reverse order of removal End By a Install forks b Fill hydraulic oil to tank Refer to the Operation And Maintenance Manual for further information Disassemb...

Page 16: ...nut 4 from the top of the mast each side 4 Disconnect and remove chains 5 from the bottom of the mast 5 Remove top cylinder retainer bolt 6 from each side of the mast 6 Remove cylinder retainer brack...

Page 17: ...mast mounting pins 11 from the mast mounting bores 10 Check the condition of the seals and bearings 12 located in each of the mast mounting bores Replace the seals and bearings 12 with new if worn or...

Page 18: ...channel 15 The intermediate mast channel weighs 168kg 370 lb 14 Remove rollers 16 and the shims from the intermediate mast channel 15 Remove nylon pads 17 and the shims 16 Remove rollers 18 and the sh...

Page 19: ...nd 4 from the chart to obtain minimum clearance B between bearing and channel leg for full channel length Must use same bearing on left and right side Permissible tolerance L 0 08 mm 003 in 4 Find nar...

Page 20: ...5 behind bearings 4 make sure the amount of shim is divided equally when positioned behind each bearing 4 Mast Adjustment Lower Bearings A Zero clearance B Minimum clearance C Zero clearance 3 Bearin...

Page 21: ...m 18 7 in channel lap B Upper Bearing Adjustment of Stationary Mast 9 Lifting by crane and pull out intermediate mast from stationary mast Install 1 mm shim to each bearing of stationary mast upper ba...

Page 22: ...er 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...

Page 23: ...olerance L 0 08mm 003in 14 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...

Page 24: ...and do not move rolling up and down there might be excessive shim Pull out the inner mast from the intermediate mast and remove shim 0 5 mm to both inner lower bearings Repeat same procedure of aboves...

Page 25: ...ationary mast 21 Install secondary cylinder mounting brackets 13 over the secondary cylinders 22 Install top retainer bolts 14 for the secondary cylinders 23 Install hydraulic steel tube to each secon...

Page 26: ...18 of lift hose 27 Install the lift hose support bracket 19 and hoses 28 Install primary lift cylinder Assemble primary lift cylinder retainer bolt 20 29 Install carriage assembly from the bottom of i...

Page 27: ...ide shifter to side shifter cylinder 23 33 Install mast to lift truck Standard Lift Cylinders Disassemble Standard Lift Cylinders Start By a Remove standard lift cylinders 1 Put standard lift cylinder...

Page 28: ...rench C 4 Remove rod 4 from the cylinder body 5 Remove split rings 5 from the cylinder rod 6 Remove O ring seal 6 and back up ring 7 from the bearing 7 Remove wiper seal 8 and seal 9 from the bearing...

Page 29: ...outside NOTE Install back up ring 4 with the curved side contacting the O ring seal 3 Install O ring seal 3 and back up ring 4 into the bearing 4 Install split rings 5 on the cylinder rod 5 Install c...

Page 30: ...l standard lift cylinders Secondary Lift Cylinders Disassemble Secondary Lift Cylinders Start By a Remove standard lift cylinders 1 Put standard lift cylinder 1 in position on tool A 2 Remove bearing...

Page 31: ...ear ring 5 U packing 6 and backup ring 7 6 Remove retaining ring 8 spacer 9 and check valve 10 7 Remove slyd ring 11 wear ring 12 and O ring 13 from the bearing 8 Remove wiper seal 14 and retaining ri...

Page 32: ...ing 4 Install check valve 7 retaining ring 8 and spac er 9 5 Install stop rings 10 on the cylinder rod 6 Install wear ring 11 U packing 12 and backup ring 13 7 Install cylinder rod 14 in the cylinder...

Page 33: ...ous of hot hydraulic oil when any lines are disconnected in the hydraulic system 1 Fasten nylon straps and hoist to the primary lift cylinder 2 Remove bolts 1 3 Remove bolt 2 4 Pull the cylinder out f...

Page 34: ...body 2 Remove bearing 2 with tool A 3 Remove rod 3 from the cylinder body 4 Remove wear ring 4 U packing 5 and backup ring 6 5 Remove retaining ring 7 spacer 8 and check valve 9 6 Remove O ring 10 and...

Page 35: ...seal 2 and retaining ring 3 Install the seal with the lip toward the outside 3 Install O ring seal 4 and two slyd rings 5 4 Install check valve 6 retaining ring 7 and spacer 8 5 Install wear ring 9 U...

Page 36: ...ble personal injury make sure the mast is securely held in place or supported by a hoist before removing the tilt cylinders To prevent personal injury move the control levers backward and forward to r...

Page 37: ...disassembly and assembly of the tilt cylinder 2 Remove rod assembly 2 from the cylinder body 3 Remove nut 3 from the cylinder rod 4 Remove piston and seal assembly 4 from the cylinder rod 5 Remove he...

Page 38: ...Position the lip of the seal toward the inside of the head 13 Install seal 15 14 Install seal 16 in the cylinder head Position the lip of seal 16 toward the outside of the cylinder head NOTE The curve...

Page 39: ...L 15 N m 70 L L 11 lb ft 19 Install seals 10 and O ring seal 9 on the pis ton 20 Install head assembly 5 on the cylinder rod 21 Install piston assembly 4 onto the cylinder rod 22 Install nut 3 Tighte...

Page 40: ...the nuts and rods A before removing the cylinder end caps from the cylinder tube 1 Put location marks on end caps 1 as to their position on the steering cylinder tube 2 Remove end caps 1 from the ste...

Page 41: ...h end cap as follows a Remove O ring seal 10 b Remove wear ring 8 c Remove u cup seal 9 Assemble Steering Cylinder 1 Assemble each end cap as follows a Install O ring seal 2 b Install wear ring 1 c In...

Page 42: ...ll retaining rings 8 on each side of the piston 7 Install cylinder tube 9 on the rod assembly NOTE Install the nuts and rods A on steering cylinder after installing the cylinder end caps see Remove In...

Page 43: ...rom the travel of other machines 1 Drain the hydraulic tank NOTE For purposes of reassembly put identifica tion marks on all lines tubes and hoses before any disconnections are made 2 Disconnect seven...

Page 44: ...5 Remove O ring seals 10 from the valve body 6 Remove lift and tilt valve spool assemblies 11 from the valve body 7 Remove seals 12 from the valve spools 8 Remove springs 13 from the valve spools 9 R...

Page 45: ...rings 18 and pop pets 19 Assemble Hydraulic Control Valves 1 Make sure all valve parts are clean and free of dirt 2 Install poppets 1 springs 2 and relief plugs 3 3 Install hydrostat 4 4 Install sprin...

Page 46: ...all O ring seals 10 to the valve body 8 Install seal 11 and spring 12 to the attachment valve spool 13 9 Install valve spool 13 to the valve body 10 Install retainer 14 dust cover 15 and bolt 16 to ea...

Page 47: ...ommend that you keep the unit in the vise during disassembly Follow the clamping procedures explained throughout the manual Gerotor Meter End 1 Clamp unit in vise meter end up Clamp lightly on edges o...

Page 48: ...g on a clean soft cloth to protect surface finish Use a thin bladed screwdriver to pry retaining ring from housing 12 Rotate spool and sleeve until pin is horizontal Push spool and sleeve assembly for...

Page 49: ...d the needle thrust bearing from spool and sleeve assembly 16 Remove spool and sleeve assembly from 14 hole end of housing ATTENTION Do not bind spool and sleeve in houst ing Rotate spool and sleeve a...

Page 50: ...removing from sleeve 20 Remove seal from housing 21 Remove set screw from housing 22 Screw a 10 24 machine screw into end of check ball seat Then by pulling on screw with a pliers lift seat out of ho...

Page 51: ...ce all old seals with new seals Control End 1 Use a needle nose pliers to lower check ball retainer into check valve hole of housing Make sure retainer is straight not tilted on edge in housing 2 Inst...

Page 52: ...ool is Position 2 pairs of centering springs on bench so that extended edge is down and arched center section is together In this position insert one end of entire spring set into spring installation...

Page 53: ...event the cross pin from dropping into the dis charge groove of the housing With the spool assem bly in this flush position check for free rotation within the housing by turning with light finger tip...

Page 54: ...er tighten jaws NOTE Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the housing ATTENTION Clean the upper surface of the housing by wiping with the palm o...

Page 55: ...lined end of drive when marking 22 Install 73 5 mm 2 89 in ID seal in spacer plate or gerotor meter 23 With seal side of meter toward spacer plate align star valleys on drive Note the parallel relatio...

Page 56: ...cap Pretighten screws to 11 to 17 NIm 100 to 150 lbIin then torque screws to specifications Actual Displacement Spacer cm3 r in3 r Length mm in 45 2 8 None 60 3 6 None 75 4 5 None 95 5 9 3 56 140 120...

Page 57: ...n the shaft Install cup 2 and nut 3 Tighten the nut to a torque of 80 L 7 NIm 60 L 5 lbIft 5 Install cap 1 on the steering wheel Steering Column Remove Steering Column Start By a remove steering wheel...

Page 58: ...eering gear 16 from steering column 15 Remove steering column 15 from the support assembly 8 Remove the nuts washers and bolts 18 Remove the bushings if a replacement is neces sary Remove support asse...

Page 59: ...ll bolts 4 Connect all kinds of connector 9 5 Connect wires 8 to the ignition switch Connect the four steering gear hoses to the steering gear 6 Put the cover and instrument group assembly in position...

Page 60: ...position under the steer axle 4 Loosen axle mounting bolts 2 until approximately two bolt threads are left in the mounting bosses 5 Lower the steer axle onto the bolt heads with the floor jack disconn...

Page 61: ...nstall Master Cylinder 1 Remove the rear floor plate from the lift truck Drain the brake fluid from the brake reservoir Disconnect hose 1 and line 4 from master cylinder 5 2 Remove the cotter pin wash...

Page 62: ...ilt cylinder connect con nector 4 If necessary adjust the accelerator control linkage See Accelerator Control Linkage Adjustment in the MicroCommand Control System module Parking Brake Remove And Inst...

Page 63: ...rking brake applied adjust off position stop bolts 15 and 16 until there is a clearance Y of 6 0 mm 24 in maximum between strap assembly 12 and bracket assembly 11 Tighten the nuts to hold the adjustm...

Page 64: ...move the battery the plate under the battery and the floor plates Drain the hydraulic tank Disconnect the hydraulic pump and steering pump hoses from the hydraulic tank 2 Remove nut 3 and the spacers...

Page 65: ...truck and put the drive motor in posi tion under it Attach a hoist to tool A and put the drive motor in position in the transaxle Install the six bolts that hold the drive motor to the transaxle 9 In...

Page 66: ...ight of the drive motor is 105 kg 232 lb Install tool B and a hoist and remove the bolts and the drive motor see Drive Motor in this module for placement of tool B NOTE The following steps are for ins...

Page 67: ...ng harness connector 5 Disconnect seven cables 6 and two wires 7 from the contactors at the bottom of the control panel 4 Loosen the two lower corner mounting bolts for the control panel Remove remain...

Page 68: ...nect positive battery cable 3 and negative battery cable 2 from the control panel 3 Install tooling A in the two holes at the top of the counterweight Attach a hoist The approximate weight of the coun...