Daewoo B20S-2 Quick start guide

Disassembly &
Assembly
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SB2028E02
Aug. 1999

Important Safety Information
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following 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 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,
lubrication, 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.
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Vehicle Systems Index
Index
Accelerator Control Switch.....................................61
Backrest....................................................................7
Carriage....................................................................7
Control Panel..........................................................66
Counterweight ........................................................67
Drive Motor.............................................................63
Forks.........................................................................7
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 Lift Cylinders...........................................26
Steer Axle ...............................................................59
Steering Column.....................................................56
Steering Cylinder....................................................39
Steering Unit...........................................................46
Steering Wheel.......................................................56
Tilt Cylinders...........................................................35
Transaxle................................................................65
3

Vehicle Systems Disassembly & Assembly
Disassembly And Assembly
Hydraulic Control Valve
Switch Group
Remove And Install Hydraulic
Control Valve Switch Group
1. Remove the cover over the hydraulic control valve.
Disconnect connector (3). Remove the bolt, washer
and rod assembly (1).
2. Remove the cotter pins, pins (2), the washers and
the lever assemblies.
3. Remove the screws, nuts. lockwashers and cams
(8). Remove three bolt that hold the switch group.
4. If necessary, remove switches (6), sensor (5) and
board assembly (7) from the bracket.
OTE: The following steps are for installation of the
hydraulic control valve switch group.
5. Install the switches, sensor and board assembly on
the bracket if they were removed. Install the switch
group on the control valve.
6. Put cams (8) in position on the spools. Install 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 connector (3). Adjust the switch
group if necessary. See Lift Sensor Adjustment and
Tilt And Auxiliary Switch Adjustment in the Micro
Command Control System.
Hydraulic Pump Motor
Remove And Install Hydraulic Pump
Motor
OTE: Photos shown are of an BC series truck, the B
series truck is similar.
1. Remove the battery, the plate under the battery and
the floor plates. Mark the wires and cables for
proper installation. Disconnect two wires (1) and
two cables (2) from the hydraulic pump motor.
2. Remove two bolts and hydraulic pump (3) from the
pump motor. Remove the pump coupling if
necessary. Pull the pump away from the motor, but
keep the pump above the level of the hydraulic tank
to prevent oil leakage from the pump.
Tools eeded A
Hook 1
Shackle 1
Link Bracket 2
5
IDCD305S
1
1
2
2
3
3
5
6
8
7

Vehicle Systems Disassembly & Assembly
OTE: If upper bolts (4) are removed, blocks (5) will
fall inside the channel.
3. Loosen, but do not remove, upper two mounting
bolts (4). Remove lower two mounting bolts (6), and
slide the pump motor and plates to the rear of the
truck.
4. The weight of the pump motor is 48 kg (105 lb).
Attach tooling (A) and a hoist to the pump motor,
and remove it from the lift truck. Remove the two
plates and blocks from the motor if necessary.
OTE: 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 tooling (A) and a hoist.
6. Slide the pump motor to the front of the lift truck.
Install two lower bolts (6). Tighten bolts (4) and (6).
7. Put hydraulic pump (3) in position on th pump
motor. Make sure the coupling is in alignment with
the pump motor armature. Install the two bolts that
hold the pump on the pump motor.
8. Connect two cables (2) and wires (1) to the pump
motor. Install the plate over the motors, the battery
and floor plates.
6
IDCD306S
IDCD307S
4
5
6
IDCD308S

Vehicle Systems Disassembly & Assembly
Forks
Remove & Install Forks
1. Lift fork pin(1).
2. Use a suitable C-clamp, strap and hoist to support
the fork as shown.
3. Slide the fork to slot(2) in the middle of the
carriage.
4. Remove the fork. The weight of the fork is 50 kg
(110 lb).
5. Repeat steps 1 through 4 for the remaining fork.
6. Install the forks 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 backrest. Remove bolts(2)
that fasten the backrest to the carriage.
2. Remove backrest (1). Backrest(1) weighs 40kg
(90lb).
3. Install backrest(1) in the reverse order of removal.
End By:
a. Install forks.
Carriage
Remove & Install Carriage
Start By:
a. Remove forks.
b. Remove backrest.
Tools eeded A
Retaining Ring Pliers 1
7
1
2
1
2
IDCD001P
IDCD002P
IDCD003P

Vehicle Systems Disassembly & Assembly
1. Raise carriage(1). Position a wooden block as
shown. Lower carriage(1) onto the wooden block.
2. Disconnect two hydraulic lines(4) from side shifter
cylinder (2). Plug and cap all openings to prevent
contamination and debris from entering system.
To prevent personal injury be sure pressure in the
hydraulic system has been released before
disconnecting any hydraulic lines. Slowly loosen
the 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.
OTE: For purposes of reassembly, identify and
mark all hydraulic lines and connectors before
removing or disconnecting.
3. Remove four bolts(8) from the chain guard/hose
support assembly(6). Set the hoses aside, clear of
the primary cylinder and cross head.
4. Remove two bolts (10) from the hose mounting
bracket. Set the hoses aside. Remove two nuts(9)
from the chain anchors. Set the chains aside,
clear of the mast.
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8
2
1
8
10
9
6
4
IDCD004P
IDCD005P
IDCD006P
IDCD007P

Vehicle Systems Disassembly & Assembly
Typical Example
5. Use tool(A) to remove retainer ring(11) from the
cross head shaft.
6. Remove cross head(12) from the shaft.
7. Remove carriage bolts(13).
8. Raise the inner mast to pull out carriage as
shown.
9. Remove carriage from bottom of inner mast(15).
Carriage(14) weighs 116kg(255 lb).
OTE: Use the following steps to install the carriage.
10. Raise the inner mast to put in the carriage onto
the mast, and lower the inner mast to cover
carriage(1) bearing fully.
11. Install carriage bolts(13).
9
11
15
14
12
13
13
IDCD008P
IDCD010P
IDCD009P
IDCD009P

Vehicle Systems Disassembly & Assembly
12. Install cross head(12) and retaining ring(11).
13. Put the chains in position over cross head(12).
Install nuts(9) onto the chain anchors.
Install bolts(10) 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.
Disassemble Carriage
Start By:
a. Remove carriage.
Typical Example
1. Remove the roll pins and pins(2) to disconnect
chains(1).
10
IDCD009P
IDCD006P
IDCD011P
8
1
2
6
11
12
IDCD008P IDCD005P
4
10
9

Vehicle Systems Disassembly & Assembly
2. Remove four lower roller bearings(3) and the
shims from the carriage.
3. Remove screw(5) and washer(4). Remove top
roller bearings(6) and the shims.
Assemble Carriage
OTE : The standard, Full Free Lift and Full Free
Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is shown
in the following illustrations.
To make the carriage clearance adjustments,
carriage must be removed from the mast.
Use the procedure that 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) Minimum clearance.
1. Select lower bearings from the chart to obtain
minimum clearance (B) between bearings and
channel leg for full channel length. Use same
bearing in all six locations.
* Permissible tolerance L0.08 mm (.003in)
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)
11
3
4
5
6
IDCD012P
IDCD013P
A
AA
B
B
CC
34B5
C
6
C
7
A
A
8
C
VIEW C-C
VIEW B-B
VIEW A-A
IDCS125S

Vehicle Systems Disassembly & Assembly
2. Find narrowest point by ruler on the inner mast in
the area where the bearings make contact.
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 (8),
(9).
5. Tighten screw (5) that holds the top bearings to the
carriage to a torque of 34 L7 NIm (25 L5 lbIft)
6. Shim stop bolt (11) as required to obtain a 6 to 9
mm (.24 to .35 in) lap with top carriage stop on the
inner upright.
7. Position chains(6) on the carriage. Install pins(7)
and the rolt pins.
End By:
a. Install carriage, raise the inner mast and insert the
carriage from the bottom of inner mast.
12
3
5
3
4
IDCD014P IDCD009P
IDCD011P
IDCD015P
IDCD016P
11
7
9
6
8

Vehicle Systems Disassembly & Assembly
Mast
Remove & Install Mast
Start By:
a. remove forks
b. drain the hydraulic oil to tank
1. Support mast assembly(2) with a hoist and two
straps as shown.
OTICE
Place identification marks on all hydraulic connectors
and hoses to assure proper installation. Plug and cap
all hydraulic connectors and hoses to avoid debris 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,
support tilt cylinder(7) while removing pin(6).
4. Remove bolt(5) from each side of mast assembly(2).
5. Remove pin(6) from the tilt cylinders on each side
of the mast assembly(2).
6. Tilt forward mast assembly(2) about 8° with the
hoist.
Remove bolts(8) from each side of the base of
mast assembly(2).
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IDCD017P
IDCD020P
IDCD019P
IDCD018P
2
3
7
6
5
4
8

Vehicle Systems Disassembly & Assembly
Loose the tension of straps to be connected with
hoist when mast assembly(2) is tilted forward.
If straps are too tight, mast assembly(2) could be
got off when bolts(8) are removed.
7. Use the hoist to remove mast assembly(2) 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.
Disassemble Mast
Start By:
a. Remove primary lift cylinder.
b. Remove side shift cylinder.
c. Remove mast.
OTE: The following disassembly and assembly
procedure is for a full free triple lift mast.
1. Remove hoses(1) along with the hose support
clamps.
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IDCD021P
1

Vehicle Systems Disassembly & Assembly
2. Remove hose sheave (3).
3. Remove chain 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 brackets(8) from each
cylinder.
15
IDCD025P
IDCD023P
IDCD024P
IDCD026P
4
3
6
8
5

Vehicle Systems Disassembly & Assembly
7. Fasten a nylon strap and hoist to secondary
cylinder(9) as shown. Remove secondary
cylinders(9). Each cylinder weighs 50 kg(110 lb).
8. Check the condition of bearings(10) located in
each of the tilt cylinder pin bores. Replace
bearings(10) with new if worn or damaged.
9. Remove 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 damaged. Seal lips should be forward
outside
11. Fasten nylon straps and hoist to inner
channel(13). Remove inner channel(13). The
weight of the inner channel is 150kg(330 lb).
12. Remove rollers(14) and the shims from the inner
channel mast.
16
13
10
IDCD027P IDCD030P
IDCD031P
IDCD032P
IDCD028P
IDCD029P
11
14
9
12

Vehicle Systems Disassembly & Assembly
13. Fasten nylon straps and a hoist to the intermediate
mast channel(15). Remove mast 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 shims from the
stationary mast channel.
17. Remove nylon pads(19) and the shims.
17
15
18
19
16
17
IDCD033P IDCD035P
IDCD034P

Vehicle Systems Disassembly & Assembly
Assemble Mast
OTE: The standard, Full Free Lift and Full Free
Triple Lift mast load bearings are all adjusted the
same way. The mast shown in the following
illustrations is the Full Free Triple Lift mast.
1. Make sure all parts are clean and free of dirt and
foreign material.
2. Check all parts for damage, use new parts for
replacement.
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.
3. Select lower bearings (3) and (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 L0.08 mm (.003 in)
4. Find narrowest point by ruler on the staionary
mast in the area where the bearings make contact
at 475 mm (18.7 in) channel lap.
OTE: When installing shims (2) behind bearings
(1), make sure the amount of shim is divided equally
when positioned behind each bearing (1).
5. Install the correct amount of shim (2) behind
rollers until contact (zero clearance) is made
between the rollers.
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)
18
IDCS123S
IDCD036P
345 6
A
C
B

Vehicle Systems Disassembly & Assembly
OTICE
When the correct amount of shim has been installed
behind rollers (1) there will be contact (zero clearance)
between the rollers and the inner mast at most narrow
point of mast (refer to step 4)
6. Install 1 mm shim to each bearing of intermediate
lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary
mast from the upper side.
OTE: When installing shims (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) Bearing. (4) Bearing. (5) Shims. (6) Shims.
7. Make sure whether 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 mast from the stationary mast with
crane and add shim 0.5 mm or 1 mm to both
intermediate lower bearings.
19
IDCD037P
IDCD033P
IDCD039P
345 6
A
C
B
IDCS123S
1
2