Doosan G40SC-5, G50SC-5 Disassembly/Assembly

Vehicle System

Disassembly & Assembly

D35S-5, D40S-5, D45S-5, D50C-5, D55C-5

D40SC-5, D45SC-5, D50SC-5, D55SC-5

G35S-5, G40S-5, G45S-5, G50C-5, G55C-5

G40SC-5, G45SC-5, G50SC-5, G55SC-5

GC35S-5, GC40S-5, GC45S-5

GC50C-5, GC55C-5

SB4267E00

May. 2007

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.

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 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.

DOOSAN 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 DOOSAN 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. DOOSAN dealers have the most current information available.

1

Vehicle Systems 3

Index

Disassembly & Assembly....................... 5

Hood (with seat) .................................................... 5

Overhead Guard.................................................... 6

Tilt Cylinders ......................................................... 7

Secondary Lift Cylinders........................................ 9

Primary Lift Cylinder ............................................ 12

Hydraulic Control Value ....................................... 15

Washing .............................................................. 17

Inspection............................................................ 17

Assembling.......................................................... 18

Relief Valve Maintenance .................................... 20

Steering Wheel.................................................... 29

Steering Unit ....................................................... 30

Brake Hydraulic Booster ...................................... 39

Tie Rods.............................................................. 43

Steering Knuckles, Kingpins, And Bearings ....... 44

Steer Axle............................................................ 45

Steering Cylinder ................................................. 46

Tires And Rims (Steer) ........................................ 48

Hydraulic Control Valves...................................... 49

Hydraulic Pump ................................................... 50

General Instruction .............................................. 51

Disassembly Process .......................................... 51

Counterweight ..................................................... 56

Hydraulic Oil Filter Assembly ............................... 57

Drive Axle and T/M .............................................. 57

Engine................................................................. 58

WARNING

Disconnect batteries before performance of any service work.

Index

Disassembly & Assembly

Hood (with seat)

Remove & Install Hood (with seat)

Assembly

1

WARNING

The hood and seat assembly can fall when nut

(1) is removed from the support cylinder rod. To avoid personal injury, support the seat and hood assembly before removing 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.

2

4.

Remove the bolts (2) from the cover. Remove cover.

3

5.

Remove the washers and four bolts (3).

4

6.

Release latch (4). Use the hoist to remove hood and seat assembly. The hood and seat assembly weighs approximately 52 kg (115 lb).

7.

Install the hood and seat assembly in the reverse order of removal.

Vehicle Systems 5 Disassembly & Assembly

Overhead Guard

Remove & Install Overhead Guard

1.

Support overhead guard (1) with lifting straps and a hoist.

2.

Remove 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 approximately 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.


Tilt Cylinders

Remove & Install Tilt Cylinders

NOTE: The procedure for removing and installing the tilt cylinders is the same for both cylinders.

WARNING

If both tilt cylinders are removed at the same time the mast can fall. To avoid possible personal injury, make sure the mast is securely held in place or supported by a hoist before removing the tilt cylinders.

WARNING

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) from pin (5). Remove pin

(5).

3.

Remove tilt cylinder (4).

4.

Install the tilt cylinder in the reverse order of removal.


Disassemble & Assemble Tilt Cylinders

Start By: a.

Remove tilt cylinder.

1.

Remove eye (1) from the rod assembly (4).

2.

Remove rod cover (2) from the cylinder tube (3) using a spanner wrench.

NOTICE

Use extra care not to damage the 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.

Remove O-ring seal (11) and backup ring (12) from the rod cover (2).

9.

Remove wiper seal (13), backup ring (14), Upacking (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.

3.

Remove rod (3) from the cylinder body.


4.

Remove 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.


Assemble Secondary Lift Cylinders

1.

Install bush (13) and seal (12).

2.

Install wiper seal (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.


8.

Install head assembly (2) on the cylinder rod and tighten using tool.

End By : a.

Install secondary lift cylinders.

Primary Lift Cylinder

Remove & Install Primary Lift Cylinder

Start By : a.

Remove carriage.

WARNING

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.

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.

Install primary lift cylinder (3) in the reverse order of removal.

End By : a.

Install carriage.


Disassemble Primary Lift Cylinder

Start 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.


Assemble Primary Lift Cylinder

1.

Install back-up ring (7) and seal (8) in the bearing.

Install the seal with the lip toward the inside.

2.

Install wiper seal (6). Install the 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.


Hydraulic Control Value

Disassembling

Keep following precautions for disassembling.

1.

The main equipment has to be leveled, with all the working units grounded, engine stopped, and the actuator has to be depressurized. If disassemble the actuator while it is pressurized, high pressure oil or part may ejected out which is very dangerous.

2.

Release the air pressure in tank(for pressurized tanks)

3.

Clean up the surroundings of the part to be disassembled, and take care that foreign matter does not enter the valve.

4.

Mark the disassembled parts or arrange them on work bench in the order of assembly in order not to confuse the order of assembling.

5.

Replace all the seals(O-rings, back-up rings) which were disassembled with new seals.

6.

Since the spool is matched with the valve housing by clearance control, it is not replaceable for quality. Protect it from impact of falling down.

7.

Protect the sealing faces of the fitting surfaces in all sections from impact or scratch.

8.

In order to minimize internal leak, the clearance of spool is kept as small as possible. Disassembling and assembling the spool may deform the spool.

Therefore, full assembly replacement, when necessary, is recommended.

Refer to the attached Parts List for the dimensions and torques of the screws and plugs related with the disassembling.

Disassembling Valve Assembly

The assembling number shall be in compliance with the attached Assembly Parts List: Representative

Parts No. C0240-41001.

1.

Place the valve assembly on level work table, with the mounting side down. Remove the nuts(1) and

(3) for the tie rod, at the end of the outlet section.

2.

Slowly remove each spool section assembly in the reverse order as in the outlet section.

Take care not to lose poppet, springs, or o-rings in the fitting face of each section.

3.

Remove the tie rods (2) & (4) from the inlet section assembly.

Disassembling the Inlet Section

Assembly

The combination number shall be in accordance with the attached Part List No. C0213-41001.

Fix the unit on the vise softly, covering the fitting face of the inlet section assembly to prevent damage.

1.

Remove socket head bolt(14), remove cap(13), and remove the spool(2) in sub-assembly state from the inlet housing(1). The seal plate(5), wiper(4), and O-ring(3) on the cap(13) side have to be remain affixed to the spool(2)

【 Cautions for Removing Spool 】

When removing the spool, take it out correctly to prevent dent or scratch. Dent or scratch may harm the housing hole when removing the spool, or may make it impossible to reinsert the spool, or may cause malfunction even able to be inserted. Each spool has to be marked and arranged on work bench, etc., to prevent confusion in reassembling. If assembled wrong, the actuator will fail to operate properly, which may cause serious danger.

【 Fig. 2 – 1 】


2.

Hold the spool (2) on a vise by inserting rigid wood pieces(Fig. 2-1) etc. to prevent damage on the surface. Remove the cap screw(11), disassemble spring seat(7) and spring(6), and remove wiper(4) and O-ring(3). At this time, take care that cap screw or other parts are not ejected out by the spring force.

3.

Remove the screw(15) on the spool head, remove the seal plate(5), wiper(4) and O-ring(3).

4.

Unscrew and remove the solenoid valve (24 ） , remove spring(22) and poppet(21).

5.

Take off plug(18), and remove spring(17) and poppet(16).

6.

Unscrew the lock nut on the shut-of valve(20).

Turn the set screw by 1 or 2 turns and take it off inwardly, and take out the main body of the shutoff valve.

7.

Remove the socket head bolt(40), take out the solenoid(38). Since an O-ring is mounted on the in-low part of the solenoid providing large friction force, do not apply excessive force to twist it.

Remove shuttle(36) and spring(37) from inside to outside.

8.

Unscrew the two relief valve assemblies(41) and remove them from the assembly.

Though the two valves are identical in appearance, however, since the pressure settings for the main relief and second relief valves are different, mark the two relief valves for distinguish them.

【 Cautions for Disassembling the Relief Valve 】

In principle, the relief valve has to be replaced in assembly unit. Therefore, do not disassemble it except when necessary.

If it is necessary to disassemble, refer to the Relief Valve Maintenance

Manual. Mark each part for identification in assembling.

9.

Take out plug(52), remove spring(51) and spool(50).

10.

Take out plug(30) and remove spool(26) and spring(27) in assembly state.

Hold the sub-assembled spool(26) with a vise using rigid wood pieces(Fig. 2-1) to prevent damage on spool surface. Take out plug(29) and remove the check valve(28) from inside.

11.

Take out plug(34) and remove spring(33) and poppet assembly(32).

Then, remove the main poppet from the poppet assembly(32).

The poppet assembly was described as the unload valve in the Operation Section earlier.

12.

Take out the two plugs (42) and (59).

These three plugs are only for open/close, without internal sub-parts. Therefore, do not disassemble them except when necessary.

13.

Finally, remove the O-rings and wipers on each disassembled part.

Disassembling the Spool Section

Assembly for Tilting

The combination No. shall be in accordance with the attached Part List (Part No.: C0213-41201).

Fig. 2-2 is the detail drawing.

1.

Take out the O-rings(12) & (18) from the fitting surface, remove spring(11) and poppet(10).

2.

Unscrew the socket head bolt(14) and take out the cap(6).

3.

Loosen the screw(13) on the opposite side, remove seal plate(3), wiper(5), and O-ring(4).

Take out the spool(2) in sub-assembled state from the valve housing(1). At this time, remove the seal plate(3), wiper(5) and O-ring(4), on the cap side, as mounted on the spool(2).


4.

Hold the spool(2) in a vise using rigid wood pieces(Fig. 2-1) to prevent damage. Remove cap screw(8) and remove spring seat(7), spring(9), wiper(5) and O-ring(4). At this time, take care that cap screw or other parts are not ejected out by the force of the spring(9).

5.

Remove spring(16) from inside the spool(2).

Remove the valve(15) from the spool(2) by unscrewing the M4 screw at its end.

Disassembling the Spool Section

Assembly for Attachment

The combination shall be in accordance with the attached Parts List(Part No. C0213-41202).

The disassembling of the Part No. C0213-41203 in the attached Parts List is same as this section, therefore, not described.

1.

Remove O-rings(12), (18) from the fitting surface, and remove spring(11) and poppet(10).

2.

Unscrew socket head bolt(15) and remove cap(6).

Take out the spool(2) from the valve housing(1) in sub-assembled state. At this time, remove seal plate(3), wiper(5) and O-ring(4) on the cap side as mounted on the spool.

3.

Remove the screw(13) on the opposite side.

Remove seal plate(3), O-ring(4) and wiper(3).

4.

Hold the spool(2) in a vise using rigid wood pieces(Fig. 2-1) to prevent damage. Remove cap screw(8) and remove spring seat(7), spring(9), wiper(5) and O-ring(4). At this time, take care that the cap screw or other parts are not ejected out by the force of the spring(9)

The disassembled parts have to be arranged in order to identify their assembly position on work bench, shelf, etc.

Washing

Wash all the disassembled parts completely with mineral oil.

Dry the washed parts with compressed air and arrange them on clean paper or cloth for inspection.

Inspection

Inspect all the parts if they have any burr, scratch, dent, or any other defect.

1.

Confirm that the spool surfaces are free from scratch or dent.

Small scratch can be removed with oil stone or cloth with lapping material.

2.

Reciprocating parts must move smoothly. All the holes and paths must be free from foreign matter.

3.

Worn, deformed, or broken spring must be replaced.

4.

Check that the sealing face of the valve housing is smooth, free from dust, rust, or dent.

5.

Remove any dent or scratch on the check valve seat of valve housing by lapping. Take care not to leave any lapping material in the valve.

6.

If relief valve is not in normal order, inspect it in compliance with the Relief Valve Maintenance

Manual.

7.

Replace all the O-rings and back-up rings with new ones.

8.

Check that there is no residual coating debris around the housing holes and plug seats.

In the event that coating debris is in the valve, it will cause malfunction and oil leak.


Assembling

Take following cares when handling the O-rings.

1.

Do not use any defective O-ring, whether the defect was made in forming or handling,

2.

Apply grease or hydraulic oil on O-ring and their seats for full lubrication

3.

Do not stretch O-ring severely. Otherwise, it may be deformed.

4.

Do not roll-in the O-ring when mounting it.

If O-ring is twisted, it may cause oil leak.

Take following cares when handling the spool.

1.

Keep specified torque. Excessive torque will cause malfunction of spool.

2.

Take care that the spool, spring, and cap screws are combined in the same assembly as they were before the disassembling.

Take following cares when assembling section assembly and valve assembly.

1. O-rings in the fitting face must not protrude out.

2.

Before assembling, following points must be free from any washing or hydraulic oil.

・ Fitting faces of each section, outside of O-ring grooves.

・ Capping surfaces, outside the O-ring grooves.

If oil is left at above points, it may be mistaken as the oil leak.

Assembling the Valve Housing

1.

Assemble poppet(10), spring(11), O-rings(12),

(15) or (18) on each section surface.

2.

Insert the tie rods(2), (4) (P/N C0240-41001, attached Parts List) to fix them in the inlet section.

Assemble the valve housings of each section in correct order. Finally, assemble the outlet housing.

On the tie rod, tighten nuts(1), (3) to specified torque. Take care that the spring(11) on the fitting surface does not hinder.

Spool Subassembly

With reference to the attached Part List of each section assemblies, mount O-ring, wiper and seal plate on the spool in specified order. Insert spring between the spring seats and mount it on the spool with cap screw.

Hold the spool in a vise with rigid wood pieces (Fig.

2-1) to prevent damage during assembling. Apply grease around the spring.

As shown in Fig. 5-1, the wiper must be mounted with the protruded part facing outwards.

Be careful that the valve and spring are inserted in the hollow space of the tilt spool only.

Protrusion

O-ring

Wiper

Spool

Seal Plate

Seal Hole

【 Fig. 5 － 1

Valve Hosing

】


Assembling Inlet Section Assembly

Combination number shall be in accordance with the attached Part List (P/N: C0213-41001).

Tightening torque of each part shall be in compliance with the Parts List.

Orifice F

【 Fig.5-2 】

1.

Mount O-rings and wipers on each plug.

2.

If the two plugs (42) and (59) were removed, tighten them at the original position.

3.

Insert the main poppet into the poppet (unload valve) to make the poppet assembly(32), and insert it into the inlet housing(1).

Then, insert the spring(33) into the main poppet, and tighten the plug(34) making sure that its end is inserted in the inside of the spring(33).

4.

Take care when assembling the spool(26) because the valve(28) is directional.

As shown in 【 Fig.5-2 】 , assemble with the orifice

Ｆ inside the plug(29), and insert the plug(29) into the spool(26).

Then, while holding the spool(26) in a vise with rigid wood pieces(Fig. 2-1) to prevent damage, tighten the plug(26).

Finally, insert the spring(27) into the subassembled spool(26), insert it into the inlet housing(1) and tighten the plug(30).

5.

Insert spring(51) into the spool(50), tighten plug(52).

6.

Assemble two relief valve assemblies (41) in the original mounting ports. Take care not to confuse the position.

7.

Insert shuttle(36) into spring(37) and insert them into inlet hosing(1).

At this time, the shuttle(36) may be ejected out by spring(37) force. Place the solenoid(38) on the end of the shuttle, slowly insert them into the position where they will not come out by the friction of the O-ring in the in-low part, and tighten with socket head bolt.

Coil Dia.

8.

Insert poppet into the main body of the shut-off valve (20), mount them on the inlet housing(1).

And then tighten with set screw. Finally, join lock nut onto the set screw.

9.

Insert spring(17) into poppet(16).

Make sure to insert the larger diameter part of the spring(17) into the poppet as shown in.

If assembled in opposite, the spring may be broken.

Insert the poppet(16) inserted with spring(17)

Into plug(18), tighten to the inlet housing(1) so that the Poppet(16).

10.

Insert poppet(21) and spring(22) into inlet housing(1). Tighten by turning the solenoid valve.

11.

Assemble O-ring(3) and wiper(4) in the seal hole on the spool head side of inlet housing(1). Fix the seal plate(5) with screw(15).

12.

Finally, insert the sub-assembled spool(2) from the opposite side of the inlet housing(1), cover with cap(13), and tighten with screw(15).

【 Cautions For Inserting Spool 】

Insert the spool slowly, vertically to the axis of the hole. Reciprocate the spool with hands to check if there is any resistive or uneven feeling which may cause malfunction of the spool.


Assembling Spool Section Assembly

The combination numbers shall in accordance with the pertinent Parts List.

Tightening torques of each part must be in compliance with the Parts List.

1.

Assemble O-ring(4) and wiper(5) in the seal hole on the spool head side of the valve hosing (1). Fix the seal plate(3) with screw(15).

2.

Insert the sub-assembled spool(2) from the opposite side of the valve hosing(1). Cover with cap(6) and fix with screw(13).

Confirmation of Assembly Work

【 Cautions for Assembling Work 】

Check if there is any unassembled, missing part after assembling. Missing part may cause oil leak.

Pressure Adjustment after Assembling

As shown in the main relief valve and second relief valve(Fig. 6-1), loosen the adjust kit(5) to release pressure in all the circuits. Set the engine at the rated rpm, block the circuit and slowly adjust the pump port pressure to be the set pressure indicated in the drawing, with the adjust kit(39). When adjusted, tighten and lock with nut.

Relief Valve Maintenance

Main Relief Valve, Second Relief Valve

Disassembling

The combination numbers shall be in accordance with the attached Part List(P/N: C0003-30020) and

Fig. 6-1.

Loosen the lock nut on the adjust kit (5) and remove

Spring (3) and pilot poppet (2) from the plug (4).

Since the pilot seat (1) has a hole at the end of the

Plug, do not disassemble it.

【 Cautions for Disassembling Relief Valve 】

Relief valve has to be replaced in assembly unit, in principle. Do not disassemble it unless necessary.

The main poppet is built in the unload valve, as described in the paragraph 1.2.


Washing, Inspection

Wash all parts with clean mineral oil. Dry with compressed air for inspection.

1.

The poppet seats and plugs must be free from defect and smooth.

2.

Main poppet and unload valve must be able to reciprocate lightly and smoothly.

Outside of the main poppet and the inside of the unload valve must be free from scratch or damage.

3.

Spring (3) must be free from fracture, deformation or wear.

4.

The main poppet and pilot seat(1) holes must be free from foreign matters.

5.

O-rings and back-up rings must be replaced with new ones.

If allowable scratch is identified, remove it by lapping.

If any part is found to be defective, replace with a new relief valve assembly.

Assembling

1.

Mount O-ring and back-up ring on the pilot seat(1) and adjust kit(5).

2.

Insert poppet(2) and spring(3) into the plug(4), and temporarily assemble the adjust kit(5) mounted with O-ring.

3.

Insert into the inlet housing and adjust the pressure.

Assembling work of main poppet shall be in compliance with the paragraph 5.3.

Note: Ｏ -rings and back-up rings must be replaced with new rings, not reused.

Pressure Adjustment

1.

Install an accurate pressure gauge at the circuit inlet

2.

Operate the pump at the rated rpm

3.

Replace the spool of the control valve, read the pressure gauge at the end of the cylinder stroke.

4.

Turn the adjuster clockwise until desired pressure is reached.

Each turn of adjuster will raise 17.7MPa of pressure ← （ reference value ）

5.

At the specified pressure, hold the adjuster and tighten with lock nut. Specified torque: 27 ～ 31 Ｎ

・ｍ

6.

Raise the pressure again to check if the specified pressure is obtained

Note: When the main and second relief valves are operated simultaneously, the setting pressure of the main relief valve takes the precedence.

Installation

Take following cares at installation

・ Pipe line must not exert unnecessary force to valve.

・ Mounting bolts must be tightened with same torque.

・ Welding work near valve may damage the seals by excessive heat or scatter.

・ Do not uncover valve ports until piping connection to prevent dust from coming in.

Operation

・ Valve arrangement must be in correct order.

Check that the hydraulic oil is clean, raise pressure slowly(inching operation at low idle), confirm that there is no external oil leak.

・ Use hydraulic oil of which the annealing point is

82 ～ 113 ℃ .

・ Do not raise the pressure in the relief valve higher than the specified setting pressure

・ Make sure to provide sufficient warming up of the machine before operation.

Especially, when starting up while the temperatures of the hydraulic oil and valve is cold, take following cares to prevent sticking of the spool by thermal shock.

・ Do not operate the main and second relief valves successively during the warming up operation.

Circulate the hydraulic oil in the actuators to raise temperature of all the parts evenly.

・ Inching operation or composite operation may cause local heating, therefore, must not be carried out while the system is cold.


Ref.No. GZ-MS-V0030


Ref.No. GZ-MS-V0030


Ref.No. GZ-MS-V0030


Ref.No. GZ-MS-V0030


Ref.No. GZ-MS-V0030


Ref.No. GZ-MS-V0030


Ref.No. GZ-MS-V0030


Steering Wheel

Remove & Install Steering Wheel

1.

Remove cap (1) from the steering wheel.

1

3

2

2.

Remove nut (2) and washer (3) from the steering wheel shaft. Put location marks on the steering wheel and the steering wheel shaft for installation purposes.

3.

Remove the steering wheel from the shaft.

NOTE: Use the following steps to install the steering wheel.

4.

Put the steering wheel on the steering wheel shaft in its original position.

5.

Install washer (3) and nut (2). Tighten nut (2) to a torque of 80 ± 7 N•m (60 ± 5 lb•ft).

6.

Install cap (1).


Steering Unit

Remove & Install Steering Unit

Start By: a.

Remove covers from steering wheel group

.

WARNING

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.

NOTE: Identify and mark all hydraulic hoses for purposes of reassembly.

1.

Disconnect (4) tubes and (1) hose assembled to steering unit.

3

1

2

2.

Remove four bolts (1).

NOTICE

Steering unit (2) and column (3) can separate after bolts (1) have all been removed, causing unit (2) to fall. To avoid damaging components, support the steering pump while removing bolts (1).

3.

Support steering unit (2) while removing the remaining two bolts (1). Remove steering unit (2).

4.

Install the steering unit in the reverse order of removal.

End By : a.

Install the cover on steering wheel group.


Disassemble Steering Unit

Cleanliness is extremely important when repairing a steering unit. Work in a clean area. Before disconnecting lines, clean port area of unit thoroughly.

Use a wire brush to remove foreign material and debris from around exterior joints of the unit.

Although not all drawings show the unit in a vise, we recommend that you keep the unit in the vise during disassembly. Follow the clamping procedures explained throughout the manual.

Gerotor (Meter) End

IDCD278S

1.

Clamp unit in vise, meter end up. Clamp lightly on edges of mounting area. Use protective material on vise jaws. Housing distortion could result if jaws are overtightened.


IDCD279S

Seal

End Cap Cap Screw

2.

Remove 5/16 inch cap screws and washers if applicable (7 each).

3.

Remove end cap.

4.

Remove seal from end cap.

Seal

Spacer(s)

IDCD280S

5.

Remove meter. Be careful not to drop star.

6.

Remove seal from meter.

7.

Remove drive spacer(s).


IDCD281S

Seal

8.

Remove drive.

9.

Remove spacer plate.

10.

Remove seal from housing.

Control End

IDCD282S

Spacer Plate

Drive

11.

Remove housing from vise. Place housing on a clean soft cloth to protect surface finish. Use a thin bladed screwdriver to pry retaining ring from housing.

Seal Gland

Bushing

IDCD283S

12.

Rotate spool and sleeve until pin is horizontal.

Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing. Remove bushing.

Dust

Seal

IDCD284S

Quad

Ring

Seal

Seal

Gland

Bushing

13.

Remove quad ring seal from seal gland bushing.

14.

Use a thin bladed screwdriver to pry dust seal from seal gland bushing. Do not damage bushing.

Vehicle Systems Disassembly & Assembly 32

Bearing

Race

Needle

Thrust

Bearing

Bearing

Race

IDCD285S

Bearing

Race

15.

Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly.

Pin

IDCD286S

16.

Remove spool and sleeve assembly from 14 hole end of housing.

ATTENTION: Do not bind spool and sleeve in housing.

Rotate spool and sleeve assembly slowly when removing from housing.

17.

Push pin from spool and sleeve assembly.


IDCD287S

18.

Push spool partially from control end of sleeve, then remove 4 centering springs from spool carefully by hand.

19.

Push spool back through and out of sleeve.

Rotate spool slowly when removing from sleeve.

20.

Remove seal from housing.

Seal

IDCD288S

Check Ball Seat

Check Ball

21.

Remove check ball seat.

22.

Tip housing to remove check ball.


Assemble Steering Unit

Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage.

Clean all metal parts in clean solvent. Blow dry with air.

Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts.

NOTE: Lubricate all seals with clean petroleum jelly such as Vaseline.

Do not use excessive lubricant on seals for meter section.

Refer to parts listings covering your steering unit when ordering replacement parts. A good service policy is to replace all old seals with new seals.

Check Ball

Seat

IDCD289S

Check Ball

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.

Install check ball in housing

3.

Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm

[.30 in.] ID seal. Install seals on check ball seat as shown.

4.

Lubricate check ball seat and seals thoroughly before installing seat in housing. When installing seat do not twist or damage seals. Install check ball seat in housing, insert open end of seat first.

Push check ball seat to shoulder of hole.

5.

Install set screw. Use a 1/4 inch hex key to torque set screw to 11 N·m [100 lb·in]. To prevent interference make sure top of set screw in slightly below housing mounting surface.


Control Sleeve

Spring Slot

Spring Slot

Identification

Marks

Control

Spool

IDCD290S

6.

Assemble spool and sleeve carefully so that the spring slots line up at the same end. Rotate spool while sliding parts together. Some spool and sleeve sets have identification marks, align these marks. Test for free rotation. Spool should rotate smoothly in sleeve with finger tip force applied at splined end.

IDCD291S

7.

Bring spring slots of both parts in line and stand parts on end of bench. Insert spring installation tool through spring slots of both parts. 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 tool, with spring notches facing sleeve.

8.

Compress extended end of centering spring set and push into spool sleeve assembly withdrawing installation tool at the same time.

9.

Center the spring set in the parts so that they push down evenly and flush with the upper surface of the spool and sleeve.

10.

Install pin through spool and sleeve assembly until pin is flush at both sides of sleeve.


Pin

IDCD292S

11.

Position the spool and sleeve assembly so that the splined end of the spool enters the 14 hole end of housing first.

ATTENTION: Be extremely careful that the parts do not tilt out of position while inserting. Push parts gently into place with slight rotating action, keep pin nearly horizontal. Bring the spool assembly entirely within the housing bore until the parts are flush at the meter end or 14 hole end of housing.

Do not pull the spool assembly beyond this point to prevent the cross pin from dropping into the discharge groove of the housing. With the spool assembly in this flush position, check for free rotation within the housing by turning with light finger tip force at the splined end.

Needle

Thrust

Bearing

Seal

IDCD293S

Bearing

Race(2

)

12.

Place housing on clean lint free cloth. Install

47.5 mm [1.86 in.] ID seal in housing.

13.

Install 2 bearing races and the needle thrust bearing in the order shown.

14.

Install 25 mm [1 in.] ID dust seal in seal gland bushing, flat or smooth side must face down towards bushing.

15.

Install the quad ring seal in seal gland bushing.

Smooth seal in place with your finger. Do not use any seal that falls freely into pocket of bushing.


Seal

Gland

Bushing

(with seals)

Retainin g Ring

IDCD294S

16. Install seal gland bushing over the spool end with a twisting motion. Tap the bushing in place with a rubber hammer. Make sure the bushing is flush against the bearing race.

Screwdriver

Dust Seal

Retaining

Ring

Seal Gland

Bushing

Quad Ring

Seal

IDCD295S

17.

Install retaining ring in housing. After installing ring, tap on ring end or pry with screwdriver around entire circumference of ring to properly seat ring in groove.

IDCD296S

18.

Clamp housing in vise. Clamp lightly on edges of mounting area. Do not over 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 of clean hand. Clean each of the flat surfaces of the meter section parts in a similar way when ready for reassembly. Do not use cloth of paper to clean surfaces.

IDCD293S

19.

Install 73.5 mm [2.89 in.] ID seal in housing.

20.

Install spacer plate. Align bolt holes in spacer plate with tapped holes in housing.


Port Face Drive

Pin Parallel with Port

Face

IDCD298S

Pin

21.

Rotate spool and sleeve assembly until pin is parallel with port face. Install drive, make sure you engage drive with pin. To assure proper alignment, mark drive as shown. Note relationship between slotted end of drive to splined end of drive when marking.

Seal

IDCD299S

22.

Install 73.5 mm [2.89 in.] ID seal in spacer plate or gerotor (meter).

Seal Groove this Side of Gerotor (Meter)

Star Valley

Drive

(Marked)

A

B

C

D

IDCD300S

Pin Port Face

23.

With seal side of meter toward spacer plate, align star valleys on drive. Note the parallel relationship of reference lines A, B, C, and D.

Align bolt holes without disengaging meter from drive.


IDCD301P

Actual

Displacement

3

㎤ /r(in/r)

45 [2.8]

60 [3.6]

75 [4.5]

95 [5.9]

120 [7.3]

145 [8.9]

160 [9.7]

185 [11.3]

230 [14.1]

295 [17.9]

370 [22.6]

460 [28.2]

590 [35.9]

740 [45.1]

Seal

Drive Spacer(s)

Spacer

Length mm [in.]

None

None

None

3.56 [.140]

6.10 [.240]

10.29 [.405]

12.19 [.480]

15.62 [.615]

21.97 [.865]

28.45 [1.120]

41.15 [1.620]

53.67 [2.113]

66.37 [2.613]

91.77 [3.613]

24.

Install drive spacer (s) when used, in meter.

25.

Install 73.5 mm [2.89 in.] ID seal in gerotor

(meter) or end cap, see notes.

26.

Install end cap on gerotor, align holes.

IDCD302P

27.

Install 7 dry cap screws in end cap. Pretighten screws to 11-17 N·m [100-150 lb·in] then torque screws to specifications.


Brake Hydraulic Booster

Remove and Install Brake Hydraulic

Booster

Flow Control Valve

Brake Booster

1.

Remove the floor plate.

2.

Disconnect pressure line (1).

3.

Disconnect the line from Flow contol valve to

Booster (2).

4.

Disconnect return line (3).

5.

Disconnect pressure line (4).

6.

Disconnect return line (5) and brake reservoir line

(6).

7.

Disconnect brake line (7).

NOTE: The following steps are for installation of the brake master cylinder.

1.

Installation is the reverse order of removal. Be sure to check the leakage between the connections.

2.

Remove the air (bleed the brake lines). See the topic of Brake System Air Removal.

3.

Install the floor plate over the brake hydraulic booster.


Disassemble & assemble brake valve

1 . Take off bellows (4) and lift push rod (3), remove vent air (25) and bolts (28).

2 . Separate the front housing (1) and rear housing (2), remove servo spring (10), servo piston (9) and master piston (5).


3.

Take off seal u-cup (14) from master piston (5). Notice the direction of the seal.

4.

Remove lock washer (6) and ball (7) from servo piston (9). Pull off piston ring (8), seal u-cup (13), seal ucup (12) and seal u-cup (11) in sequence. Notice the direction of each seal.

No Color Material

11 Translucency

12

13

Black

Yellow

Urethane

NBR Hs70

Urethane


5.

Remove relief plug (18), o-ring (19), spring (17), shims (16) and piston (15) from front housing (1).

6.

Remove check valve parts from rear housing (2): plug (26), o-ring (27), cage (24), spring (23), ball (21) and o-ring (22). Remove o-ring (20).

7.

Assemble brake valve in the reverse order of disassembly.


Tie Rods

Remove And Install Tie Rods

Tools Needed A B

Floor Jack 1

Drive Set 2

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 split pins (2). Remove pins (1).

3. Remove tie rod (4) and dust seals (3).

4. Use tooling (B) to remove bearings (5) from the tie rod.

5. Use tooling (B) to install new bearings (5) in the tie rod.

6. Install the tie rod in the reverse order of removal.


Steering Knuckles, Kingpins,

And Bearings

Remove And Install Steering Knuckles,

King Pins And Bearings

Tools Needed A

Drive Set

Start By: a. remove steer wheels

NOTE: The procedure to remove and install the steering knuckles, kingpins, and bearings is the same for both sides of the lift truck.

1

1. Remove two split pins (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 ± 1 N•m (8

± 1 lb•ft).


6. Remove kingpin (8) and knuckle (9).

7. Remove spacer (11), bearing cup (13) and bearing cone (12).

8. Check the condition of lip type seal (10). Replace seal (10) with new if worn or damaged.

9. Repeat steps 7 and 8 for the remaining seal, bearing and spacer in the other side of knuckle (9).

NOTICE

Check the condition of all seals, bearings and components. If any parts are worn or damaged use new parts for replacement.

10. Lubricate the pins, king pins and bearings.

11. Install the steering knuckle, kingpins and bearings in the reverse order of removal.

End By: a.

Install steer wheels.

Steer Axle

Remove & Install Steer Axle

Tools Needed

Jack Stand

WARNING

A

4

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 debris from entering the system.

3. Support the steer axle with a floor jack.

4. Loosen 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.


6. Remove bolts (2) and mounting caps (3) from the steer axle.

7. Remove steer axle (4). The steer axle weighs180 kg (400 lb).

NOTE : Use the following steps to install the steer axle.

8. Use a floor jack to position steer axle (4).

NOTE: Use bolts (2) and cap (3) to align steer axle

(4) with the mounting bosses while raising steer axle

(4) into position with the floor jack.

9. Seat steer axle (4) as follows: a. 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 split (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 installation purposes, the torque for bolts (3) is 240 ± 30 N•m (178 ± 22 lb•ft) .

4. Remove steering cylinder (1).

5. Install steering cylinder (1) in the reverse order of removal.


Disassemble And Assemble Steering

Cylinder

Start By : a. Remove steering cylinder.

1. Put the steering cylinder in position in a vise.

2. Loosen head (1) from tube (2) with a spanner wrench.

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.


9. Remove O-ring seal (12) and backup ring (13) from each head (1).

10. Remove wiper seal (14), backup ring (15), Upacking (16) and DU-bush (17) from the bore of each head.

NOTE : Assemble the steering cylinder in the reverse order of disassembly.

Tires And Rims (Steer)

Remove And Install Tires And Rims

(Steer)

1.

Put a hydraulic 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 430 ± 35 N I m

(318 ± 25 lb I ft) .

6. Lower the steer axle and remove the hydraulic jack.


Hydraulic Control Valves

Remove And Install Hydraulic Control

Valves

WARNING

Hydraulic oil under pressure can remain in the hydraulic system after the engine and pump have been stopped. Personal injury can result if the pressure is not released before any work is done to the hydraulic system. To prevent possible personal injury, turn the engine off and move the control levers to make sure the hydraulic pressure is released before 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.

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 four bolts (2), nut and control valve (1).

4. Install the control valve in the reverse order of removal.

5.

Fill the hydraulic tank to the correct level with fluid.

Refer to the Operation And Maintenance Manual for further information.


Hydraulic Pump

Remove and Install Hydraulic Pump

Start By : a. Remove counterweight.

1. Drain the oil from the hydraulic tank.

2. Disconnect three oil lines (1) from the pump elbows.

3. Fasten a hoist to pump (5).

Remove bolts (4) that hold the pump in place.

Remove the pump and plate assembly.

The weight of the pump is 30 kg (132 lb) .

NOTE: The following steps are for installation of the hydraulic pump.

4. Inspect seals for damage. Install new seals, if needed.

5. 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) .

6. Connect three oil lines (1) to the pump elbows.

7. Fill the hydraulic tank with oil to the correct level.

See the Operation and Maintenance Manual.

End By : a. Install counterweight.


General Instruction

Cleanliness

1.

Cleanliness is the primary means of assuring satisfactory hydraulic pump life.

Components such as flanges and covers are best cleansed in soap and hot water, then air dried.

Gears should be washed in solvent, air dried, and oiled immediately.

Certain cleaning solvents are flammable. Do not allow sources of ignition in the area when using cleaning solvents.

2.

Protect all exposed surfaces and open cavities from damage and foreign material.

Gear journals and gear faces are super finished.

Take care not to touch these surfaces after oil and solvent.

Lubrication of moving parts

During assembly, all running surfaces (Bearing and wear plate) must be lightly lubricated with a clean oil or aerosol lubricant.

Tools required for assembly

1.

Socket sets

2.

Internal snap ring pliers

3.

Shaft seal sleeve or clear tape

4.

Torque wrench (200lbf ∙ ft capacity)

5.

Plastic hammer

6.

Torque wrench box end adapters

Disassembly Process

Rear section

Loosen and remove the clamp bolts (18) from rear working section (1).

Related parts

Washer (22), Rear cover (4), Dowel pin(35),

Square-ring (26).

1.

Remove driving gear (10), driven gear (12) with thrust plate parts (8, 23, 29), keeping gear as straight as possible, and working section (1) also.

Related parts

Back-up ring (29), O-ring (23), Thrust plate (8),

Working body (1), Square ring (26).


Center section

1.

Remove through shaft (33) from driving shaft (11).

2.

Remove the flange(32) and the working section

(2) with dowel pin (35).

Related parts

Square ring(26)

3.

Remove driving gear (11), driven gear (13) with thrust plate parts (8, 23, 29), keeping gear as straight as possible, from first working body(3).

Related parts

Back-up ring (29), O-ring (23), Thrust plate (8).

4.

Remove through shaft(34) from driving shaft(14).

5.

Loosen and remove the clamp bolt(17) with washer(21), and then remove the working section(3) from mounting flange(5)

Related parts. Square ring(25), Dowel pin (35)

Front section

1.

Remove the snap-ring (28) and shaft seal (27),

And then remove mounting flange (5) from working section (3).

2.

Remove driving gear(14), driven gear(15) with through shaft(34) and thrust plate parts(9,24,30) from the working body(3), keeping gear as straight as possible,

Related parts

Plug (19), Back-up ring (30), O-ring (24), Thrust plate (9).


Reassembly Process

Information for assembly way of thrust plates

It is important that all of thrust plate parts in this hydraulic pump should be assembled such as below picture during reassembly. Picture 8, 9 show assembling sequence and direction.

(19) Plug

(24) O-ring

(15) Driven gear (30) Back-up ring

Front cover area

1.

Insert the shaft seal (27) carefully and fit it inside of mounting flange (5) with proper tool.

2.

Fit the snap-ring(28) in pre-arranged position with proper tool.


Center section

1.

Fit the square ring (25) on the pre-arranged groove of the working section (3).

Smear clean grease on the square ring (25) to avoid drifting away of square ring from the working section (3).

2.

Locate the o-ring (24) on the groove pre-arranged on the thrust plate (9).

3.

Then, locate back-up ring (30) on the groove prearranged on the seals (9, 24) with plug (19).

Smear clean grease on the seal(24,30)

(The front and rear thrust plates and seals and back-up ring are same.)


4.

Insert the driving gear (14) and driven gear (15) into working section (3) while keeping the gears straight.

Locate thrust plate(9+24+30) with care for the direction

5.

Locate the completed mounting flange (5+27+28) to working section (3) while tacking care not to give any damage on the shaft seal by edge of shaft(14).

6.

Insert the through shaft (34) to rear side of the driving shaft (14).

7.

Tighten the bolt (17) with washer (21) in a cross pattern to torque valve of 140Nm.

8.

Locate the o-ring (23) on the groove ore-arranged on the thrust plate (8).

9.

Then, locate back-up ring (29) on the groove prearranged on the seals (8, 23).



10.

Insert the driving shaft(11) and driven gear (13) including the completed thrust plate(8+23+29) into working section(3) while keeping the plate straight.


11.

Insert the through shaft (33) into driving shaft

(11), and then locate the working body (2) and flange (32) after inserting the squaring ring (26) to body (2).

Smear clean grease on the square ring (26) to avoid drifting away of square ring from the working body (2).

Rear section

1.

Locate the o-ring (23) on the groove pre-arranged on the thrust plate (8).

2.

Then, locate back-up ring (29) on the groove prearranged on the seals (8, 23).



3.

Locate the driving gear(10) and driven gear(12) with thrust plate parts(8+23+29) into working section(2).

4.

Insert the dowel pin(35) into the working section

(2) and then, locate the rear working section (1) to working section (2) while keeping the gear straight.

Smear clean grease on the square ring (26) to avoid drifting away of square ring from the rear working section (1).

5.

Locate the rear cover(4) after inserting the square ring(26) and the dowel pin(35) into the rear working section(1).

Smear clean grease on the square ring(26) to avoid drifting away of square ring(26) from the rear cover(4).


6.

Tighten the bolt (18) with washer (22) in a cross pattern to torque valve of 45Nm.

Check that the pump rotate freely when the driving shaft is turned by hand. If not a thrust plate seal may be pinched.

Reference

PIC.23 Torque configuration for hydraulic pump

Counterweight

Remove And Install Counterweight

1.

Install two eyebolts in the counterweight. Fasten a hoist to the eyebolts as shown.

2.

Remove two bolts (1), washers that hold the counterweight to the frame. Remove the counterweight. The weights of the different counterweight go from a minimum of 1830 kg

(3630 lb) to a maximum of 3120 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), washers that hold the counterweight in place. Tighten torque : 600 ± 50

N•m (442 ± 37 lb•ft).


Hydraulic Oil Filter Assembly

Remove And Install Hydraulic Oil Filter

Assembly

1.

Disconnect four oil lines (1).

2.

Remove hydraulic tank cover (2).

3.

Remove the oil filter from hydraulic tank cover.

NOTE: The following steps are for installation of the hydraulic oil filter assembly.

4.

Install the hydraulic oil filter assembly in position on hydraulic tank cover.

5.

Install the hydraulic tank cover (2) with six bolts and washers.

6.

Connect four oil lines (1).

7.

Fill hydraulic oil tank to the correct level. See the

Operation and Maintenance Manual.

Drive Axle and T/M

Remove & Install Transaxle

Tools Needed A B

Stand 2

Link Bracket

Start By : a.

Remove mast * b.

Remove floor plate.

* Refer to the mast systems Disassembly &

Assembly section for further information.

1

1.

Raise the machine until tires are approximately 1 to 2 inches off of the floor. Position the machine on tooling (A).

2.

Disconnect brake tubes (7) and parking cables from drive axle.

3.

Disconnect accel cable (8).

4.

Disconnect wires (9) from solenoid valves and wire from transmission temperature sender.

5.

Disconnect two cooling hoses (10).

6.

Loosen bolts (11) and remove drive axle mounting bracket (12).


7.

Support the engine with a hoist and tooling (B).

8.

Support transaxle assembly with a floor jack and wood block.

9.

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.

10.

Remove bolts (14) and nuts from the converter housing.

11.

Use the floor jack to move transaxle assembly from beneath the machine.

12.

Install transaxle in the reverse order of removal.

13.

Bleed the brake system.

Refer to the topic “Brake System Air removal” in the Testing and Adjusting section of Vehicle

Systems.

14.

Fill all fluids to their correct levels.

End By : a.

Install floor plate.

Vehicle Systems 58 b.

Install mast *

* Refer to the Mast System Disassembly &

Assembly Section for further information.

Engine

Remove & Install Engine

Tools Needed A

Link Bracket 1

NOTE: Procedures for LP gas and diesel engines are all similar. The engine shown in the following illustrations is for diesel engine.

Start By : a.

Remove overhead guard * b.

Remove hood (with seat) assembly * c.

Remove counterweight * d.

Remove floor plate. e.

Remove hydraulic control valve *

* Refer to the topics “Overhead Guard”, “Hood (with seat) Assembly”, “Counterweight” and “Hydraulic

Control Valve” 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.

Disconnect fuel lines from the engine.

5.

Disconnect accel cable and engine stop motor cable from the engine.

6.

Loosen nuts (6) and disconnect exhaust tube (7).

7.

Disconnect engine wire harness (8). Disconnect wires from the alternator (9). To remove engine from the truck, other wires or connectors not shown should be disconnected.

8.

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.

9.

Support engine with a hoist and tooling (A).

Support transaxle with wood block.

10.

Remove bolts (13) and nuts from the converter housing.


11.

Remove bolts (14) and nuts from two engine mounts, located on each side of the engine.

NOTICE

Make sure the engine is supported underneath by suitable wooden blocks. Failure 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 “Hydraulic Control Valve”,

“Hood (with seat) Assembly”, “Counterweight” and

“Overhead Guard”.


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