Daewoo D35S-2, Disassembly/Assembly

Page 1: ...Disassembly Assembly Lift Trucks Vehicle Systems D35S 2 D40S 2 D45S 2 D40SC 2 D45SC 2 D50SC 2 G35S 2 G40S 2 G45S 2 G40SC 2 G45SC 2 G50SC 2 SB2204E00 Jun 1999 ...

Page 2: ...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 produ...

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Page 4: ...rol Valve 27 Hydraulic Oil Filter Assembly 37 Hydraulic Pump 33 Overhead Guard 6 Primary Lift Cylinder 12 Secondary Lift Cylinders 9 Steer Axle 23 Steering Cylinder 24 Steering Knuckles Kingpins And Bearings 22 Steering Unit 15 Steering Wheel 15 Tie Rods 21 Tilt Cylinders 7 Tires And Rims Steer 26 Transaxle 37 3 ...

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Page 6: ...moving nut 1 1 Raise the hood Support the hood with a hoist 2 Remove nut 1 from the support cylinder Remove the cylinder rod from the bracket 3 Lower the hood 4 Remove the bolts 2 from the cover Remove cover 5 Remove the washers and four bolts 3 6 Release latch 5 Use the hoist to remove hood and seat assembly 4 The hood and seat assembly weighs 52 kg 115 lb 7 Install the hood and seat assembly in ...

Page 7: ...emove the washers nuts and two bolts 2 3 Remove the washers nuts and two bolts 3 4 Remove front overhead guard 1 Front overhead guard 1 weighs 30 kg 66 lb 5 Remove the washers nuts and four bolts 4 6 Remove rear Leg 5 7 Install front overhead guard 1 and rear leg 5 in the reverse order of removal 6 IDCD055P IDCD056P IDCD057P IDCD058P 1 3 4 5 2 ...

Page 8: ...efore removing the tilt cylinders To prevent personal injury move the control levers backward and forward to release any pressure in hydraulic system 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 1 Disconnect elbow 2 Remove retainer bolt 3 and pin 1 2 Remove retainer bolt 6 fr...

Page 9: ... highly finished surface of the cylinder rod and the bore of the clylinder tube during disassembly and assembly of the tilt cylinder 3 Remove rod assembly 4 from the cylinder body 4 Remove pin 5 inside hole and nut 6 from the cylinder rod 4 5 Remove piston 7 from the cylinder rod 6 Remove O ring seal 8 from the cylinder rod 7 Remove wear ring 9 and slipper seal 10 from the piston 8 ICCD002P ICCD00...

Page 10: ...acking 15 and DU bush 16 from the rod cover NOTE Assemble the tilt cylinder in the reverse order of disassembly Secondary Lift Cylinders Disassemble Secondary Lift Cylinders Start By a Remove secondary lift cylinders 1 Put secondary lift cylinder 1 in position as shown 2 Remove head assembly 2 with tool 9 ICCD007P ICCD008P 11 12 16 15 14 13 2 ...

Page 11: ...ove retaining ring 4 and piston 5 from the cylinder rod 5 Remove O ring seal 6 from the cylinder rod 6 Remove O ring seal 7 back up ring 8 and seal 9 from the piston 7 Remove O ring seal 10 from the head assembly 8 Remove wiper seal 11 seal 12 and bush 13 from the head assembly 10 ...

Page 12: ...eal 11 Install the seal with the lip toward the outside 3 Install O ring seal 10 onto the head assembly 4 Install seal 9 back up ring 8 and O ring seal 7 on the piston 5 Install O ring seal 6 on the cylinder rod 6 Install piston 5 and retaining ring 4 on the cylinder rod 7 Install cylinder rod 3 in the cylinder body 11 ...

Page 13: ... forward to release any pressure in hydraulic system 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 1 Fasten nylon straps and hoist to the primary lift cylinder 2 Remove bolt 1 3 Pull the cylinder out far enough to disconnect hydraulic hose 2 Remove primary lift cylinder 3 4 In...

Page 14: ...art By a Remove primary lift cylinder 1 Remove bearing 1 2 Remove rod 2 from the cylinder body 3 Remove split rings 3 from the cylinder rod 4 Remove O ring seal 4 and back up ring 5 from the bearing 5 Remove wiper seal 6 back up ring 7 seal 8 and rings 9 from the bearing 13 ...

Page 15: ...e seal with the lip toward the outside 3 Install rings 9 in the bearing NOTE Install the back up ring with the curved side contacting the O ring seal 4 Install the back up ring 5 and O ring seal 4 on the bearing 5 Install split rings 3 on the cylinder 6 Install cylinder rod 2 in the cylinder body 7 Install bearing 1 on the cylinder body Tighten the bearing 1 End By a Install primary lift cylinder ...

Page 16: ...ng steps to install the steering wheel 4 Put the steering wheel on the steering wheel shaft in its original position 5 Install cup 3 and nut 2 Tighten nut 2 to a torque of 80 L 7 N m 60 L 5 lb ft 6 Install cap 1 Steering Unit Remove Install Steering Unit Start By a Remove steering wheel 1 Open the access cover for the fuse panel Remove horn switch and open the top cover 2 Loosen two bolts 1 Slide ...

Page 17: ...sing unit 5 to fall To avoid damaging components support the steering pump while removing bolts 4 5 Support steering unit 5 while removing the remaining two bolts 4 Remove steering unit 5 and steering column 2 6 Install the steering unit in the reverse order of removal End By a Install steering wheel Disassemble Assemble Steering Unit Start By a Remove steering unit from the truck 1 Remove the elb...

Page 18: ...5 from steering unit body 2 8 Remove sleeve 16 from the body 9 Remove the components from sleeve 16 as follows a Remove pin 18 from spool 17 and sleeve 16 b Remove spool 17 from sleeve 16 c Remove two bearing races 19 20 and bearing 21 from spool 17 d Remove six springs 23 and ring 22 from spool 17 10 Remove O ring seal 24 and king ring 25 from body 11 Check the condition of dust seal ring 26 Repl...

Page 19: ...he following steps are for assembling the steering pump 16 Install washer 37 and plug 36 into the steering unit body 17 Install housing 35 and poppet 34 into the pump body 18 Install spring 32 and plug 31 into body 2 Tighten plug 31 to a torque 50 N m 37 lb ft 19 Install washer 28 and plug 27 into body 2 Tighten plugs to a torque 30 N m 22 lb ft 18 ICCD087P ICCD088P ICCD089P 27 2 35 32 31 34 ICCD0...

Page 20: ...ed toward sleeve 16 21 Install springs 23 into spool 17 22 Install spool 17 into sleeve 16 23 Install pin 18 ring 22 two bearing races 19 20 and bearing 21 in their original positions on spool 17 24 Install sleeve 16 into steering unit body 2 25 Install O ring seal 15 into body 2 26 Install check valve ball 14 and screw 13 Tighten the screw 13 27 Install suction valve balls 12 and pins 11 in their...

Page 21: ...n in the illustration 30 Install O ring seal 8 and housing 3 31 Install O ring seal 10 and cap 4 NOTICE To assure proper operation of the steering unit make sure bolts 5 are clean and dry before installing Tighten bolts 5 in the sequence shown in the illustration 32 Install bolts 5 into cap 4 Tighten bolts 5 in correct sequence to a torque of 30 L 6 N m 22 L 4 4 lb ft End by a Install steering uni...

Page 22: ...ake System Air Removal in Testing And Adjusting 8 Install the floor plate over the brake master cylinder Tie Rods Remove And Install Tie Rods Start By a Remove steer wheels NOTE The procedure to remove and install the tie rod is the same for each steer wheel 1 Support the steer axle with a floor jack A Position the wheel to gain access to the tie rods 2 Remove two pin retaining bolts 2 Remove pins...

Page 23: ...nuckles kingpins and bearings is the same for both sides of the lift truck 1 Remove pin retaining bolt 2 Remove pin 1 2 Position the tie rod away from the steering knuckle 3 Remove four bolts 3 and cover 4 4 Remove four bolts 5 and cover 6 5 Remove the nut and bolt 7 For the purpose of reassembly the torque for bolt 7 is 11 L 1 N m 8 L 1 lb ft Tools Needed A Drive Set 1 22 IACD215P 5 IACD216P 7 6 ...

Page 24: ...ngs in the reverse order of removal End By a Install steer wheels Steer Axle Remove Install Steer Axle Be sure the pressure in the hydraulic system is released before any lines or hoses have been disconnected 1 Put the lift truck in position on tooling A 2 For the purpose of reassembly put identification marks on hoses 1 Disconnect hoses 1 Plug and cap all openings to prevent contamination and deb...

Page 25: ... Install bolts 2 through cap 3 and into the mounting bosses approximately two bolt threads b Use the floor jack to raise steer axle 4 into the mounting boss c Tighten bolts 2 11 Connect hoses 1 Steering Cylinder Remove Install Steering Cylinder 1 Remove the pin retaining bolt 4 and pin 2 from the tie rod at each end of steering cylinder 1 2 Disconnect two hoses 5 3 Remove four bolts 3 For installa...

Page 26: ...h 3 Remove rod assembly 3 from the tube 2 4 Remove retaining ring 5 with a plier and ring 6 from each side of piston 7 that holds piston in position on rod 3 5 Remove piston 7 from the rod 3 6 Remove O ring seal 8 from the rod 7 Remove seal ring 9 and backup seal 10 from the piston 8 Loosen the head in the opposite end of the tube 25 ICCD065P 1 2 ICCD066P 2 3 ICCD066P 2 3 ICCD068P 5 6 3 7 ICCD069P...

Page 27: ...aulic jack in position under the steer axle 2 Loosen nuts 1 that hold the tire and rim in place 3 Lift the steer axle until the tire is clear of the ground Remove nuts 1 Remove the tire and rim NOTE The following steps are for installation of the tires and rims steer 4 Put the tire and rim in position on the hub 5 Install nuts 1 that hold the tire and rim in place Tighten the nuts to a torque of 4...

Page 28: ...usted Always move the lift truck to a clean and level location away from the travel of other machines NOTE For purposes of reassembly put identification marks on all lines tubes and hoses before any disconnections are made 1 Disconnect hydraulic lines 2 from control valve 1 2 Remove the cotter pins washers and pins from linkages 3 Support control valve 1 Remove circuit braker plate 4 Remove three ...

Page 29: ...t section assembly 2 from the valve body 3 Remove O ring 3 from inlet section assembly 2 4 Remove relief valve 4 and O ring 5 5 Remove lift section assembly 6 from the valve body 6 Remove plug 7 and O ring 8 from the lift section assembly 6 7 Remove O ring 9 poppet 10 and spring 11 from the lift section assembly 6 8 Remove two screws 12 and cap 13 from lift section assembly 28 IACD223P IACD224P 1 ...

Page 30: ...he spool end 21 from the spool with a wrench The centering spring 22 has a slight preload and will extend to its free length when the spool end is removed 13 Remove the spring seats 23 and 24 centering spring 22 and seal plate 25 14 Remove tilt section assembly 26 from the valve body 15 Remove O ring 27 poppet 28 and spring 29 from tilt section assembly 26 16 Remove two screws 30 and cap 31 from t...

Page 31: ...om the spool The centering spring 38 has a slight preload and will extend to its free length when the spool end is removed 20 Remove spring seats 39 and 40 spring 38 and 42 and piston 41 21 Remove side shift section assembly 43 and fourth section 44 from the valve body NOTE Do step 7 through 13 except step 9 to disassemble valve spools of side shift and fourth section assembly 30 IACD234P IACD233P...

Page 32: ...on assembly 2 The torque for the relief valve is 65 N m 575 lb in 4 Install the spring seats 23 and 24 centering spring 22 and seal plate 25 on the lift spool 5 Compress the spring with spool end 21 and tighten spool end Torque the spool end to 8 11 N m 70 97 lb in 6 Install the wiper seals 19 and O ring 20 to the spool 18 7 Install the spool 18 seal plate 17 and the screws 16 8 Install relief val...

Page 33: ... Torque the spool end to 8 11 N m 70 97 lb in NOTE Do step 6 7 9 and 10 to assemble the tilt spool to the tilt section assembly NOTE Do same steps to assemble the side shift section and fourth section assembly 14 Assemble all the sections on the studs 15 Install the nuts 1 that hold the valve sections together Tighten the single top nut to torque of 100 N m 885 lb in and two bottom nuts to torque ...

Page 34: ... of the pump is 30 kg 132 lb NOTE The following steps are for installation of the hydraulic pump 5 Inspect seals for damage Install new seals if needed 6 Fasten a hoist to pump 5 Put the pump and plate assembly in position and install the bolts that hold the pump in place The weight of the pump is 30 kg 132 lb 7 Connect three oil lines 1 to the pump elbows 8 Connect U joint 3 in position and insta...

Page 35: ... 1 3 Remove the cover 2 Take care not to damage precision machined surfaces 4 Remove the bush 3 and examine it carefully Replace if damaged 5 Remove seal 4 and backup seal 5 from the bush 6 Remove O ring 6 from the body 7 7 Carefully remove the drive gear 8 and idler gear 9 Take great care not to strike the shafts against hard surfaces which could damage the gear teeth 8 Remove the pump body 7 Tak...

Page 36: ...es and lever upwards Take care not to damage precision machined surfaces 13 Remove balance plate 15 seal 16 backup seal 17 drive gear 18 and idler gear 19 from the body 14 Take great care not to strike the shafts against hard surfaces which could damage the gear teeth 14 Remove the balance plate 20 and seals from the body 35 IACD245P IACD246P IACD247P IACD248P IACD249P IACD250P 10 14 12 15 16 17 1...

Page 37: ...s 1 washers that hold the counterweight to the frame Remove the counterweight The weights of the different counterweight go from a minimum of 1650 kg 3630 lb to a maximum of 2350 kg 5170 lb NOTE The following steps are for installation of the counterweight 3 Install two eyebolts in the counterweight Fasten a hoist to the eyebolts 4 Put the counterweight in position on the frame and install bolts 1...

Page 38: ...and washers 6 Connect four oil lines 1 7 Fill hydraulic oil tank to the correct level See the Operation and Maintenance Manual Transaxle Remove Install Transaxle Start By a Remove mast b Remove floor plate Refer to the mast systems Disassembly Assembly section for further information 1 Raise the machine until tires are approximately 1 to 2 inches off of the floor Position the machine on tooling A ...

Page 39: ...ack and wood block 11 Remove housing cover Remove bolts 13 that hold the converter to the flywheel NOTE At this point make a final check to be sure all removals and disconnections have been made from the transaxle 12 Remove bolts 14 and nuts from the converter housing 13 Use the floor jack to move transaxle assembly from beneath the machine 14 Install transaxle in the reverse order of removal 15 B...

Page 40: ... assembly c Remove counterweight d Remove floor plate e Remove hydraulic control valve Refer to the topics ÒOverhead GuardÓ ÒHood with seat AssemblyÓ ÒCounterweightÓ and ÒHydraulic Control ValveÓ in this module 1 Disconnect all hoses from radiator 3 Loosen bolts 1 and 2 and remove radiator 3 2 Disconnect air intake hose 4 3 Disconnect battery cables and remove battery 5 and battery tray assembly 4...

Page 41: ... Remove bolts 10 and disconnect U joint 11 from the engine 9 Remove housing cover Remove bolts 12 that hold the converter to the flywheel NOTE At this point make a final check to be sure all removals and disconnections have been made from the engine 10 Support engine with a hoist and tooling A Support transaxle with wood block 11 Remove bolts 13 and nuts from the converter housing 40 IACD264P 7 6 ...

Page 42: ...e to support engine will result in possible damage 13 Remove the engine with a hoist 14 Install the engine in the reverse order of removal End By a Install hydraulic control valve b Install floor plate c Install hood with seat assembly d Install counterweight e Install Overhead guard Refer to the topics ÒHydraulic Control ValveÓ ÒHood with seat AssemblyÓ ÒCounterweightÓ and ÒOverhead GuardÓ 41 IAC...