5. THE RULES OF THE GAME: HOW DID THE EXCHANGE TAKE PLACE?
5.2. The Treaty System: smuggler’s diplomatic immunity
[Display Code] [Description] [Contraction]
1 Right traction motor speed RIGHT MOTOR SPD
2 Right traction motor speed reference R-MOTOR REF SPD
3 Left traction motor speed LEFT MOTOR SPD
4 Left traction motor speed reference L-MOTOR REF SPD
5 Lift lever voltage LIFT SENSOR OUT
6 Battery voltage BATT VOLTAGE
7 Right traction motor power module temperature R-INVERTER TEMP
8 Pump motor power module temperature P-INVERTER TEMP
9 Pump motor speed PUMP MOTOR SPD
10 Pump motor speed reference P-MOTOR REF SPD
11 Accelerator potentiometer voltage ACCEL 1ST OUT
12 Accelerator second Potentiometer voltage ACCEL 2ND OUT
13 Steering sensor voltage STEER SENSOR OUT
14 Left traction motor power module temperature L-INVERTER TEMP
15 Right traction motor phase current R-MOTOR I-U
16 Right traction motor phase current R-MOTOR I-V
17 Right traction motor phase current R-MOTOR I-W
18 Left traction motor phase current L-MOTOR I-U
19 Left traction motor phase current L-MOTOR I-V
20 Left traction motor phase current L-MOTOR I-W
21 Pump motor phase current P-MOTOR I-U
22 Pump motor phase current P-MOTOR I-V
23 Pump motor phase current P-MOTOR I-W
24 Right traction motor temperature R-MOTOR TEMP
25 Left traction motor temperature L-MOTOR TEMP
26 Pump motor temperature P-MOTOR TEMP
27 Seat switch hour meter SEAT H METER
28 Drive motor hour meter DRIVE H METER
29 Pump motor hour meter PUMP H METER
30 Seat switch SEAT SWITCH
31 Park brake switch PARK SWITCH
32 Start switch SRART SWITCH
33 Reverse traction direction switch REV SELECT SW
34 Forward traction direction switch FWD SELECT SW
35 Pedal brake switch PEDAL BRAKE SW
36 3/4 wheels selection switch 3 OR 4 WHEEL
37 Auxiliary 1 switch AUX 1 OUTPUT
38 Auxiliary 2 switch AUX 2 OUTPUT
39 High lift switch HIGH LIFT SWITCH
40 Tilt switch TILT SWITCH OUT
41 Main breaker command CONTACTOR
42 5V out 5V OUT
43 12V out 12V OUT
44 24V out 24V OUT
45 Buzzer command BUZZER
46 Fans command FAN
Specifications
Systems Operation Testing & Adjusting
Disassembly & Assembly
Lift Trucks Power Train
B15T-5, B18T-5, B20T-5 (AC 36V)
B15T-5, B18T-5, B20T-5 (AC 48V)
B15T-5, B18T-5, B20T-5 (SE 48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
B16X-5, B18X-5, B20X-5 (SE 48V)
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.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as shown below.
The meaning of this safety alert symbol is as follows : Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current information available.
WARNING
Specifications
Brake ...12
Drive Motor... 7
Final Drive ... 9
General Tightening Torques ... 5
Motor and Transmission ...11
Wheel Mounting ...10
Systems Operation
Drive Motor ...14Final Drive ...16
General Information...13
Testing And Adjusting
Brake ...36Connecting The Brake Cable ...36
Connecting The Hydraulic Brake System ...36
Replenishing With Transmission Fluid ...36
Drive Motor ...25
Armature Terminal Test ...33
Armature Tests ...29
Brush Holder Test...33
Brush Life Estimate ...34
Commutator Inspection ...31
Field Coil and Terminal Tests ...32
Motor Brushes ...27
Sensor Bearing ...26
Thermal Sensor Tests ...25
Thermal Switch Tests ...34
Motor and Transmission ...35
Troubleshooting ...17
Checks During Operation...17
Drive Motor...17
Transmission ...23
Visual Checks...17
Disassembly and Assembly
Drive Axle ...37Disassemble Drive Axle ...37
General Tightening Torques
General tightening torque for bolts, nuts and taperlock studs
The following charts give the standard torque values for bolts, nuts and taperlock studs of SAE Grade 5 or better quality.
Exceptions are given in other sections of the Service Manual
where needed. inches lbIft NIm*
1/4 9L 3 12L 4
Use these torques for bolts and nuts with standard threads
(Conversions are approximate)
thread
size standard torque
Use these torques for bolts and nuts on hydraulic valve bodies.
Use these torques for studs with taperlock
threads.
taperlock stud standard thread
torque
(NIIm)* (lbIIft)
M6 12L4 9L3
M8 25L7 18L5
M10 55L10 40L7
M12 95L15 70L10
M14 150L20 110L15
M16 220 L30 160L20
M18 325L50 240L35
M20 450L70 330L50
M22 600L90 440L65
M24 775L100 570L75
M27 1150L150 840L110
M30 1610L200 1175L150
M33 2000L275 1450L200
M36 2700L400 2000L300
ISO-International Standard Organization Hose clamps-worm drive band type
clamp intitial assembly reassembly or
torque on new hose retightening torque width
(NIIm)* (lbIIft) (NIIm)* (lbIIft)
15.9 mm (.625 inch) 7.5L0.5 65L5 4.5L0.5 40L5
13.5 mm (.531 inch) 4.5L0.5 40L5 3.0L0.5 2 L5
7.9 mm (.312 inch) 0.9L0.2 8L2 0.7L0.2 6L2
*1 newton meter(NIm) is approximately the same as 0.1 mkg.
[Usually, material strength identification on bolt head is with numbers (i.e., 8.8, 10.9, etc.)]
The chart on the right gives the torque for bolts and nuts with Grade 8.8.
NOTICE : Caution must be taken to avoid mixing metric and standard (customary) fasteners.
Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possible personal injury.
Original fasteners removed from the vehicle should be saved for assembly when possible. If new ones are required, caution must be taken to replace with one that is of same part no. and grade or better.
thread size (mm)
(AC)
Thermal switch
Warning temperature ... 155 L 4°C (311 L 10°F)
Machine chamfer on the commutator bars
... 0.40 mm (.016 in.) Torque for the terminal bolts (not shown) that hold cable connections ... 12 NIm (9 lbIft) Depth of the insulation below commutator bars ... 1.5 mm (.05 in.) Width of the insulation below commutator bars ... 0.8 mm (.031 in.)
Maximum difference between commutator high and low point (out of round) ... 0.03 mm (.001 in.) TIR Maximum difference between bar to bar
... 0.005 mm (.0002 in.) TIR Thermal switch
Opening temperature... 155 L 4°C (311 L 10°F) Closing temperature ... 145 L 6°C (293 L 11°F)
*As measured on longest side.
**All rough edges (burrs) must be removed after the commutator is machined.
Drive Motor
1New Brush Minimum 2New Commutator Minimum
Thickness B Width B Length Brush Length* Diameter Commutator Diameter**
12.5 mm B 32 mm B 35 mm 18 mm 80 mm 78 mm
(.49 in. B 1.25 in. B 1.37 in.) (.70 in.) (3.14 in.) (3.07 in.)
2
1
(1) Nut. (2) Flat head bolt. (3) Socket head loolt. (4) Socket head bolt. (5) Socket head bolt. (6) Air breather.
(7) Socket head bolt. (8) Plug-oil level. (9) Plug. (10) Drain plug. (11) Socket head bolt.
1
2 3 4 7 8
11
6 5
9 10
E
E
E E
0
(1) Apply LOCTITE NO.277 (or 271) Thread Lock to thread of nut.
Torque for nut that holds drive shaft
... 200 L 20 NIm (148 L 15 lbIft) (2) Apply LOCTITE NO.277 (or 271) Thread Lock to
threads of bolts.
Torque for flat head bolts that hold end plate ...8 L 3 NIm (5.9 L 2.2 lbIft) (3) Apply LOCTITE NO.277 (or 271) Thread Lock to
threads of bolts.
Torque for socket head bolts that hold carrier cover ...30 L 7 NIm (22 L 5 lbIft) (4) Apply LOCTITE NO.277 (or 271) Thread Lock to
threads of bolts.
(5) Apply LOCTITE NO.277 (or 271) Thread Lock to threads of bolts.
Torque for socket head bolts that hold housing ...25 L 7 NIm (18 L 5 lbIft) (6) Torque for air breather 70 L 10 NIm (52 L 7 lbIft) (7) Apply LOCTITE NO.277 (or 271) Thread Lock to
threads of bolts.
Torque for socket head bolts that hold housing ...30 L 7 NIm (22 L 5 lbIft) (8) Apply LOCTITE NO.572 to thread of oil level plug.
Torque for plug ...70 L 10 NIm (52 L 7 lbIft) (9) Torque for plug that holds piston rod
...70 L 10 NIm (52 L 7 lbIft) (10) Apply LOCTITE NO.572 to thread of drain plug.
L 10 NIm (52 L 7 lbIft)
(1) Nut. (2) Bolt.
2 1
(1) Torque for drive wheel mounting nut
... 180 NIm (133 lbIft) for soild soqter tire
... 140 NIm (103 lbIft) for cushion tire or pneumatic tire (2) Torque for bolt that hold housing to frame
... 240 NIm (177 lbIft) IOPS002I
(1) Torque for socket head bolts that hold
transmission and drive motor ... 55 NIm (41 lbIft) (1) Socket head bolt
1
IOPS003I
(1) Bleeder port. (2) Brake line (hydraulic line). (3) Brake cable. (a) In the operating condition. (b) Limit of wear.
mm
1 2 3
(1) Torque for bleeder port ... 50 NIm (37 lbIft) (2) Torque for brake line... 50 NIm (37 lbIft) (3) Torque for brake cable... 50 NIm (37 lbIft) (a) Stroke in the operating condition
...3 ~ 5 mm (0.12~0.20 in) (b) Limit of wear ...8 mm (0.31in)
Actuating stroke for the hand brake cable a. in the operating condition
b. limit of wear
General Information
Power Flow
(1) Final drive. (2) Drive motor.
2
1
IOPS005S
The power train for the BT/BX-5 MODEL Lift Trucks consist of two main components; drive motors (2) and final drives (1).
Electric storage batteries are used as a power source for the drive motors (2). The drive motor turns final drive (1), which turn the drive wheels.
(AC)
The motor is protected from over temperature by a thermal sensor.
If motor’s temperature reaches in 155 L 4°C (311 L 10°F), controller does overheat warning and operates by smallest performance.
The drive motor is activated when the parking brake is released, the key and seat switch are closed, a direction is selected and the accelerator pedal is depressed.
The drive motor powers the power transfer group through input gear.
4
10
7 8 5
6 1
Drive Motor
(1) Input gear. (2) Brush cover. (3) Thermal switch (thermostat). (4) Commutator. (5) Armature. (6) Field coils.
(7) Frame. (8) Brush holder. (9) Fan. (10) Bearing.
The drive system is operated by a direct current (DC)motor. Electric storage batteries are the source of power for the DC motor.
The drive motor is a series wound motor and uses a high temperature insulation. The field and armature circuits are in series, which provides a single path for the current.
Armature (5) is mounted with single row ball bearings at each end. The ball bearings are permanently lubricated with a high temperature lubricant.
The electrical connections to the motor are made at corrosion resistant terminals on motor frame (7). On the outside of the motor frame is the brush 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 frame.
Drive motor is protected from overheating by a thermal switch (thermostat) (3). The thermal switch opens at 154 L 4°C (311 L 10°F). It closes at 145 L 6°C (293 L 11°F). When the normally closed thermal switch is open, the amount of current through the motor is limited to allow the motor to cool. The motor has a fan for cooling.
The drive motor is activated when the parking brake is released, the key and seat switch are closed, a direction is selected and the accelerator pedal is depressed.
The drive motor powers the power transfer group through input gear (1).
(1) Pinion gear. (2) Helical gear. (3) Friction disc carrier. (4) Steel ball. (5) Lever plate. (6) Ring gear. (7) Planetary gear.
(8) Drive shaft. (9) Planetary carrier. (10) Brake cylinder. (11) Transmission housing. (12) Air breather. (13) Piston rod.
(14) Drain plug. (15) Friction and steel plate.
8 1
2 3
4 5 9
10
12 11
15 5
13 14 10
6 7
E
E
E E
This transmission is a helical and planetary gear transmission unit with an integrated, hydraulically and mechanically actuated wet disk brake.
This transmission consists of two assembly groups.
1. Helical gear transmission with connection for electric motor and helical gear step.
2. Basic transmission with planetary step, gear shaft and integrated brake.
When motor shaft turns, the helical pinion(1) connected on the motor shaft turns helical gear(2).
Helical gear(2) is jointed to sun gear of planetary gear set and the sun gear turns three planetary gears(7). Three planetary gears turn planetary carrier which is inserted into inner hole of planetary
gears(7). The planetary carrier is connected to drive shaft(8) and drive shaft turns rim mounted on drive shaft flange.
When hydraulic pressure is supplied to the brake cylinder(10), piston rod(13) rotates lever plate(5). As the lever plate is contacted to steel ball (4), it is
Troubleshooting
Visual Checks
Make a visual inspection of the truck to check for problems. Operate the truck in each direction.
Make a note of the noises that are not normal and find their source. If the operation is not correct, make reference to the Check List During Operation for
"Problems" and "Probable Causes".
Checks During Operation
Drive Motor
Before an analysis is made of any electric drive motor problem, always make reference to the Troubleshooting section of the MicroController System Operation module.
The lift truck can move suddenly. Battery voltage and high amperage is present. Injury to personnel or damage to the lift truck is possible. Safely lift both drive wheels off the floor. Put wood blocks or jack stands of the correct capacity under the frame so the drive wheels are free to turn. During any test or operation check, keep away from the drive wheels.
The Power unit will have to be discharged before any contact with the control panel is made. Disconnect the battery and discharge the Power unit. Rings, watches and other metallic objects should be removed from hands and arms when troubleshooting the MicroController Control System.
To prevent personal injury, never use air pressure that is more than 205 kPa (30 psi), and wear protective clothing and a face shield.
NOTICE
To prevent damage to electrical components, make sure the air line is equipped with a water filter when they are cleaned with air.
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 inspection is made to find the failure. The area around the motor must be well ventilated (air flow) and the motor is to be cooled before any repair work is done.
Water must not be used on any electrical equipment because of the danger of electric shock. If a fire is present, disconnect the electrical power and use a carbon dioxide extinguisher to put the flame out.
Do not operate the drive motors without a load, as too much speed may cause damage to the motor and injury to personnel.
<AC>
Problem 1 : Drive Motor Will Not Operate.
probable Cause :
1. Switch not closed (battery connector, key switch, seat switch, direction switch or parking brake switch) :
Close the switch. If it still does not operate test for power to the control panel and power flow through each switch with a voltmeter.
But the service brake switch should be opened.
2. Bad connection. Fuse blown :
Check battery connections. Check connections at battery connector. Check fuses, drive and logics. Replace fuse if blown.
Check the Drive motor and control panel for possible reasons for a blown fuse. Some causes are :
a. Operation under excessive MOSFET load, too high current limit (C/L).
b. Possible short circuit in power unit.
3. Low battery voltage:
Check battery terminal voltage. If too low, charge the battery.
Check all the cells for one or more that have defects.
Check the specific gravity of each cell. The maximum density difference from the highest to the lowest cell must not be more than .020 SG
WARNING
released and the directional control lever is returned to neutral.
6. Speed sensor is breakdown.
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 sensor.
See the MicroController System Operation module.
These can cause MOSFETS to become defective, control panel failure or drive fuse to go bad.
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 (makes 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.
frame (body) or drive motor body].
Probable Cause :
1. Dirty battery, electrolyte on top of cells and is in contact with the frame. Current flows through battery box, which places a voltage on the truck frame :
Clean the battery with baking soda and water solution.
2. Battery or control panel wire connections in contact with truck frame :
Make a continuity test and move the wire from contact.
Remove wires in sequence until the fault is cleared.
The fault will be in the wire last disconnected.
3. Dirty motor :
Remove metallic or carbon dust with air pressure.
4. Wet motor :
To dry the motor, heat it to 90°C (194°F).
Problem 5 : Lift truck will not get to top speed.
Probable Cause :
1. Battery not fully charged or battery has bad cells : Charge the battery. Check for bad cells. Replace battery if necessary.
2. A fault either in the drive motor, control panel or drive train :
Check lift truck speed in both directions. If the MicroController control panel needs to be tuned up, make adjustments as shown in the
respective MicroController System Operation module. If the drive motor is at fault, make the tests of the motor components in Testing And Adjusting.
trailers.
Probable Cause:
1. Unpolished or improperly positioned forks : Install tapered and polished forks. Position forks correctly for load being lifted.
2. Lift truck equipped with tires that have poor traction :
Install tires that have good traction per recommendation from DAEWOO Inc.
3. Lift truck work load is too heavy or the duty cycle too long :
Decrease the work load and/or duty cycle.
Problem 7 : Lift truck has slow acceleration.
Probable Cause:
1. Drive control overheated and the thermal switch opens :
NOTE : The thermal switch will warning if the temperature is 155 L 4°C (311 L 10°F).
Problem 1 : Drive Motor Will Not Operate.
probable Cause :
1. Switch not closed (battery connector, key switch, seat switch, direction switch or parking brake switch) :
Close the switch. If it still does not operate test for power to the control panel and power flow through each switch with a voltmeter.
But the service brake switch should be opened.
2. Bad connection. Fuse blown :
Check battery connections. Check connections at battery connector. Check fuses, drive and logics. Replace fuse if blown.
Check the Drive motor and control panel for possible reasons for a blown fuse. Some causes are :
a. Operation under excessive transistor load, too high current limit (C/L).
b. Operation under stall conditions.
c. Possible short circuit in drive motor, see Probable Causes 5, 6 and 7.
3. Low battery voltage:
Check battery terminal voltage. If too low, charge the battery.
Check all the cells for one or more that have defects.
Check the specific gravity of each cell. The maximum density difference from the highest to the lowest cell must not be more than .020 SG (specific gravity).
4. Control panel operation not correct : See the MicroController System Operation module.
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.
See Armature Commutator Inspection and Brush Inspection in Testing And Adjusting.