Doosan GC33E-5 Specifications

SB4256E01
Jan. 2008
Vehicle System
Disassembly & Assembly
D20S-5, D25S-5, D30S-5, D33S-5, D35C-5
G20E-5, G25E-5, G30E-5
GC20E-5, GC25E-5, GC30E-5, GC33E-5
G20P-5, G25P-5, G30P-5, G33P-5, G35C-5
GC20P-5, GC25P-5, GC30P-5, GC33P-5
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
Index
Hydraulic Control Valves.................................... 5
Disassembly & Assembly.................................. .9
Hood (with seat) ................................................ 9
Overhead Guard.............................................. 10
Forks............................................................... 11
Backrest .......................................................... 11
Carriage .......................................................... 12
Assemble Carriage .......................................... 17
Mast ................................................................ 19
Assemble FFT Mast ........................................ 26
Assemble Quad Mast ...................................... 34
Standard Lift Cylinder ...................................... 42
Secondary Lift Cylinder.................................... 44
Primary Lift Cylinder ........................................ 47
Tilt Cylinder ..................................................... 50
Steering Wheel................................................ 60
Steering Unit ................................................... 61
Master cylinder ................................................ 70
Master Cylinder ............................................... 71
Steer Wheel & Bearing .................................... 74
Tie Rod ........................................................... 78
Steering Knuckle, Kingpin, and Bearing ........... 78
Steer Axle........................................................ 80
Steering Cylinder ............................................. 81
Universal Joint................................................. 84
Counterweight ................................................. 84
WARNING
Disconnect batteries before performance of any
service work.
Vehicle System
3
Index
Hydraulic Control Valves
Removal and Install ation
5
WARNING
3
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.
IDCD088P
3. Support control valve (3). Remove three bolts (5),
nut and control valve (3).
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.
2
1
3
4
IDCD087P
NOTE : For purposes of reassembly, put identification
marks on all lines, tubes and hoses before any
disconnections are made.
1. Disconnect seven lines (4) from control valve (3).
2. Remove the cotter pins, washers and pins (1) from
linkages (2).
Vehicle System
5
Disassembly & Assembly
Disassembly of Hydraulic Control
Valve
Start By :
a. Remove hydraulic control valve.
NOTICE : For the sake of convenience in assembly,
put an identification mark on all valves.
Cover the all openings with plug to protect from dirt
and dust.
2. Release the bolt (4) and take apart the valve
sections.
3. Release the screw (5) and separate return cap from
valve. Then, remove the spool from the valve in
downward direction (cap side).
1. If necessasy, release the nut (2) and separate the
solenoid valve (1) from plunger (3).
Vehicle System
6
Disassembly & Assembly
7
7
Assembly of Control valve
7
1. Make sure that all valve parts are clean and free
from dirt and dust.
7
7
7
IDCD221P
2. Assemble the spool (1), return cap (2) and valve
section, then fasten the screw (3). Replace seals
with the new one in case of leakage from cap side
or spool side caused by dent or scar on spool
4
4
4
4
4. Separate O-ring seals (7) from valve body.
Be careful not to miss the small spring and ball.
4
4
IE0M117S
Spring
Ball
5. Take apart the relief valve into plug (8), spring (9)
and poppet (10).
3. Install O-ring seals (4) on the valve body. Make sure
that the small ball and spring are installed.
6. If necessary, separate the lift lock valve (11) from
the lift block.
Vehicle System
7
Disassembly & Assembly
4. Dust and dirt should be cleaned when you
assemble and disassemble the lift lock valve
7. Assemble the poppet (1), spring (2), relief plug (3)
into relief valve. Inspect the poppet and replace it
with new one if it has scar or dent.
NOTE : Until the repaired valve is mounted on the lift
truck, be sure to plug all openings.
5. Install and tighten the tie rods (7). Be sure that you
have to tighten the tie rods to the proper torque.
6. Install solenoid valve on the lift section. Before
assembly, inspece the O-rings (8) and replace
damaged or worn O-rings with new ones.
Vehicle System
8
Disassembly & Assembly
Disassembly & Assembly
3
Hood (with seat)
Remove & Install Hood (with seat)
Assembly
5. Remove the washers and four bolts (3).
1
4
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).
6. Release latch (4). Use the hoist to remove hood and
seat assembly. The hood and seat assembly weighs
approximately 52 kg (115 lb).
1. Raise the hood. Support the hood with a hoist.
7. Install the hood and seat assembly in the reverse
order of removal.
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.
Vehicle System
9
Disassembly & Assembly
Overhead Guard
Remove & Install Overhead Guard
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).
1. Support overhead guard (1) with lifting straps and a
hoist.
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.
2. Remove the washers, nuts, and two bolts (2).
Vehicle System
10
Disassembly & Assembly
Forks
Backrest
Remove & Install Forks
Remove & Install Backrest
1
1
2
2
IDCD003P
IDCD001
1. Fasten a hoist to the backrest. Remove bolts (2)
that fasten the backrest to the carriage.
2. Remove backrest (1). Backrest (1) weighs
approximately 40 kg (90 lb).
3. Install backrest (1) in the reverse order of removal.
IDCD002P
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
approximately 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.
Vehicle System
11
Disassembly & Assembly
NOTE: For purposes of reassembly, identify and mark
all hydraulic lines and connectors before removing or
disconnecting.
Carriage
Remove & Install Carriage for STD,
FFL & FFT
Tools Needed
Retaining Ring Pliers
A
1
Start By:
a. Remove forks.
b. Remove backrest.
2
6
1
IDCD004P
3. Remove four bolts (5) from the chain guard/hose
support assembly (6). Set the hoses aside, clear
from the primary cylinder and cross head.
9
4
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.
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.
Vehicle System
12
Disassembly & Assembly
8. Remove carriage from bottom of inner mast (15).
Carriage (14) weighs approximately 116kg (255 lb).
NOTE: Use the following steps to install the carriage.
9. Raise the inner mast to put in the carriage onto the
mast, and lower the inner mast to cover carriage
(1) bearing fully.
4. Remove two bolts (9) from the hose mounting
bracket. Set the hoses aside. Remove two nuts (10)
from the chain anchors. Set the chains aside, clear
from the mast.
11
12
IDCD008
10. Install cross head (12) and retaining ring (11).
11
12
5. Use tool (A) to remove retainer ring (11) from the
cross head shaft.
9
6. Remove cross head (12) from the shaft.
IDCD008P
10
15
11. Put the chains in position over cross head (12).
Install nuts (9) onto the chain anchors to a torque
of 270 ± 40 N·m (200 ± 30 lb·ft).
Install bolts (10) onto the hose mounting bracket.
14
IDCD010P
7. Raise the inner mast to pull out carriage as shown.
Vehicle System
13
Disassembly & Assembly
Remove & Install Carriage for Quad
Mast
Start By:
a. Remove forks.
b. Remove backrest.
6
13
1. Raise carriage and remove stopper bolts (13).
2
12. Install chain guard/hose support assembly (6) and
four bolts (5) to a torque of 28 ± 7 N·m (20 ± 5
lb·ft).
1
IDCD004P
4
13. Connect two hydraulic line (4) in their original
positions.
End By:
4
a. Install backrest.
2. Raise carriage (1). Position a wooden block as
shown. Lower carriage (1) onto the wooden block.
b. Install forks.
3. Disconnect two hydraulic lines (4) from side shifter
cylinder (2). Plug and cap all openings to prevent
contamination and debris from entering system.
Vehicle System
14
Disassembly & Assembly
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.
15
NOTE: For purposes of reassembly, identify and mark
all hydraulic lines and connectors before removing or
disconnecting.
14
6
IDCD010P
6. Raise the inner mast to pull out carriage as shown.
8
7. Remove carriage from bottom of inner mast (15).
Carriage (14) weighs 116kg (255 lb).
NOTE: Use the following steps to install the carriage.
8. Raise the inner mast to put in the carriage onto the
mast, and lower the inner mast to cover carriage
bearing fully.
4. Remove four bolts (8) from the chain guard/hose
support assembly (6). Set the hoses aside, clear of
the primary cylinder and cross head.
12
9
9-1
9
9. Put the chains in position over cross head (12).
Install nuts (9) onto the chain anchors to a torque of
800 ± 100 N·m (600 ± 75 lb·ft).
5. Set the hoses aside. Remove two nuts (9) from the
chain anchors. And remove nuts (9-1) of clamp
together. Set the chains aside, clear of the mast.
Vehicle System
15
Disassembly & Assembly
Disassemble Carriage
6
Start By:
8
a. Remove carriage.
10. Install chain guard/hose support assembly (6) and
four bolts (8) to a torque of 28 ± 7 N·m (20 ± 5
lb·ft).
Typical Example
1. Remove the roll pins and pins (2) to disconnect
chains (1).
4
11. Connect two hydraulic line (4) in their original
positions.
13
2. Remove four lower roller bearings (3) and theshims
from the carriage.
12. Install stopper bolt (13) on the inner mast.
End By:
a. Install backrest.
b. Install forks.
3. Remove screw (5) and washer (4). Remove
toproller bearings (6) and the shims.
Vehicle System
16
Disassembly & Assembly
Mast And Carriage Bearings
Part No.
Bearing Size
D581814
Under Size
D581815
Standard
D581816
Over Size
Assemble Carriage
NOTE: 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.
Bearing O.D. *
108.6 mm (4.276 in)
109.6 mm (4.276 in)
110.7 mm (4.358 in)
* Permissible tolerance ± 0.08 mm (.003in)
To make the carriage clearance adjustments, carriage
must be removed from the mast.
Use the procedure that follows to adjust carriage load
bearings.
3
A
4
B 5
IDCD014P
C
A
A
2. Find narrowest point by ruler on the inner mast in
the area where the bearings make contact.
VIEW A-A
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.
6
B
C
B
VIEW B-B
C
C
4. Do step 2 through 3 for other sets of bearings (8),
(9).
7
A
C VIEW C-C 8
4
A
IDCS125S
3
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.
IDCD015P
3
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.
5
IDCD016P
Vehicle System
17
Disassembly & Assembly
5. Tighten screw (5) that holds the top bearings to the
carriage to a torque of 34 ±7 N·m (25 ±5 lb·ft)
11
IDCD009
6. In case of Quad mast 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.
8
6
7
9
IDCD011P
7. Position chains (6) on the carriage. Install pins
(7) and the roll pins.
End By:
a. Install carriage, raise the inner mast and insert the
carriage from the bottom of inner mast.
Vehicle System
18
Disassembly & Assembly
Mast
4
Remove & Install Mast
Start By:
5
a. Remove forks.
6
7
1
3. Disconnect two hydraulic lines (4).
2
WARNING
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).
1. Support mast assembly (2) with a hoist and two
straps (1) as shown.
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).
3
8
NOTICE
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.
IDCD020P
6. Tilt forward mast assembly (2) about 8° with the
hoist. Remove bolts (8) from each side of the base
of mast assembly (2).
2. Disconnect hose (3).
Vehicle System
19
Disassembly & Assembly
Disassemble Mast for FFT
WARNING
NOTE : The standard, Full Free Lift and Full Free
Triple Lift mast are almost the same way. The mast
shown in the following illustrations is the Full Free
Triple Lift mast.
Loosen 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
slide off when bolts (8) are removed.
Start By:
7. Use the hoist to remove mast assembly (2) from the
machine.
a. Remove primary lift cylinder.
8. Install the mast in the reverse order of removal.
b. Remove mast.
End By:
NOTE: The following disassembly and assembly
procedure is for a full free triple lift mast.
a. Install forks.
b. Fill hydraulic oil to tank*.
* Refer to the Operation And Maintenance Manual for
further information.
1
IDCD021P
1. Remove hoses (1) along with the hose support
clamps.
3
4
IDCD023P
2. Remove hose sheave (3).
3. Remove chain nut (4) from the top of the mast
(each side).
Vehicle System
20
Disassembly & Assembly
5
IDCD024P
4. Disconnect and remove chains (5) from the bottom
of the mast.
7. Fasten a nylon strap and hoist to secondary
cylinder (9) as shown. Remove secondary cylinders
(9). Each cylinder weighs 50 kg (110 lb).
10
6
IDCD028P
IDCD025P
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.
5. Remove top cylinder retainer bolt (6) from each side
of the mast.
8
11
IDCD029P
IDCD026P
6. Remove cylinder retainer brackets (8) from each
cylinder.
Vehicle System
9. Remove mast mounting pins (11) from the mast
mounting bores.
21
Disassembly & Assembly
15
12
IDCD033P
IDCD030P
10. Check the condition of the bearings (12) located in
each of the mast mounting bores.
Replace the bearings (12) with new if worn or
damaged.
13. Fasten nylon straps and a hoist to the intermediate
mast channel (15). Remove mast channel (15).
The
intermediate
mast
channel
weighs
approximately 168kg (370 lb).
16
13
17
IDCD031P
IDCD034P
14. Remove rollers (16) and the shims from the
intermediate mast channel.
11. Fasten nylon straps and hoist to inner channel (13).
Remove inner channel (13). The weight of the
inner channel is 150kg (330 lb).
15. Remove nylon pads (17) and the shims.
18
19
14
IDCD032P
IDCD035P
12. Remove rollers (14) and the shims from the inner
channel mast.
16. Remove rollers (18) and the shims from the
stationary mast channel.
17. Remove nylon pads (19) and the shims.
Vehicle System
22
Disassembly & Assembly
Disassemble Quad Mast
Start By:
a. Remove primary lift cylinder.
b. Remove mast.
5
NOTE: The following disassembly and assembly
procedure is for Quad Mast.
5-1
1
4. Disconnect and remove chains (5) and chain anchor
block (5-1) from the bottom of the mast.
1
1. Remove all hoses (1) along with the hose support
clamps.
6
5. Remove top cylinder retainer bolt (6) from each side
of the mast.
3
4
4
8
2. Remove hose sheave (3).
3. Remove chain nut (4) from the top of the mast
(each side).
6. Remove cylinder retainer brackets (8) from each
cylinder.
Vehicle System
23
Disassembly & Assembly
IDCD030P
IDCD027P
7. Fasten a nylon strap and hoist to secondary cylinder
(9) as shown. Remove secondary cylinders (9).
Each cylinder weighs 50 kg (110 lb).
10. Check the condition of the bearings (12) located in
each of the mast mounting bores.
Replace the bearings (12) with new if worn or
damaged.
NOTE: LH, RH secondary cylinders are different.
Identity or mark each cylinder for purpose of
reassembly.
10
IDCD028P
11. Fasten nylon straps and hoist to inner channel (13).
Remove inner channel (13). The weight of the
inner channel is 150kg (330 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.
11
14
IDCD029P
IDCD032P
9. Remove mast mounting pins (11) from the mast
mounting bores.
Vehicle System
12. Remove rollers (14) and the shims from the inner
channel mast.
24
Disassembly & Assembly
13. Fasten nylon straps and a hoist to the inner
intermediate mast channel. Remove that mast
channel and then remove the onter intermediate
mast channel (15) in the same way. The each
intermediate mast channel weighs 168kg (370 lb).
16
17
IDCD034P
14. Remove rollers (16) and the shims from the
intermediate mast channels.
15. Remove nylon pads (17) and the shims.
18
19
IDCD035P
16. Remove rollers (18) and the shims from the
stationary mast channel.
17. Remove nylon pads (19) and the shims.
Vehicle System
25
Disassembly & Assembly
Assemble FFT Mast
NOTE: 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. Also, the
actual appearance would be different partially
1. Make sure all parts are clean and free of dirt and
foreign material.
IDCD036P
2. Check all parts for damage, use new parts for
replacement.
A. Lower Bearing Adjustment of Intermediate Mast
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.
4
NOTE: When installing shims (2) behind bearings (1),
make sure the amount of shim is divided equally when
positioned behind each bearing (1).
3
5
6
5. Install the correct amount of shim (2) behind rollers
until contact (zero clearance) is made between the
rollers.
A
B
C
IDCS123S
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.
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 (4.276 in)
D581816
Over Size
110.7 mm (4.358 in)
* Permissible tolerance ± 0.08 mm (.003 in)
Vehicle System
26
Disassembly & Assembly
NOTICE
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)
1
3
4
5
6
2
A
B
C
IDCD037P
IDCS123S
Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
IDCD033P
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.
IDCD039P
7. Make sure 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.
NOTE: When installing shims (5) behind bearings (4),
make sure the amount of shim is divided equally when
positioned behind each bearing (4).
Vehicle System
27
Disassembly & Assembly
D
E
7
8
F
9
IDCD039P
8. In case of standard and full free mast, inner lower
bearings can be easily extruded by pulling down the
inner mast from the bottom of stationary mast. If
intermediate mast is stuck and cannot move by
rolling up and down, there might be excessive shim.
Pull out the intermediate mast from the stationary
mast and remove shim 0.5 mm to both intermediate
lower bearings. Repeat same procedure of above
until properly shimmed. There is to be contact zero
clearance (C) between intermediate lower bearings
and stationary channel at approximately 475 mm
(18.7 in) channel lap.
7
8
10
E
IDCS124S
Mast Adjustment Upper Bearings
(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
B. Upper Bearing Adjustment of Stationary Mast
IDCD038P
10. Make sure stationary mast upper bearings are
properly shimmed 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 stationary upper bearings.
IDCD033P
9. Lift by crane, and pull out intermediate mast from
stationary mast. Install 1 mm shim to each bearing
of stationary mast upper basically. Bearing should
be selected D581814 under size bearing.
Vehicle System
28
Disassembly & Assembly
C. Upper Pad Adjustment
D
E
7
8
IDCD039P
F
11. In case of standard and full free mast, stationary
upper bearings can be easily extruded by pulling
down the inner mast from the bottom of stationary
mast. If intermediate mast is stuck and cannot
move by rolling up and down, there might be
excessive shim. Pull out the intermediate mast
from the stationary mast and remove shim 0.5 mm
to both stationary upper bearings. Repeat same
procedure of above until properly shimmed. There
is to be contact zero clearance (C) between
stationary upper bearings and the widest point of
intermediate mast to be checked before.
7
9
8
E
10
IDCS124S
Mast Adjustment Upper Bearings
(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
IDCD033P
12. Install shims (8) behind each pad (7) until there is
0.80 mm (.031 in) maximum clearance (E)
between the pads and the inner and intermediate
masts with the masts at full extension. Lift by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded by
pulling down the inner mast from the bottom of
stationary mast.
Vehicle System
29
Disassembly & Assembly
D. Lower Bearing Adjustment of Inner Mast
3
4
5
6
IDCD031P
15. Install 1 mm shim to each bearing of inner lower
and intermediate upper basically. Lifting by crane,
insert inner mast into intermediate mast from the
upper side.
A
B
3
C
4
5
6
IDCS123S
Mast Adjustment Lower Bearings
(A) Zero clearance. (B)Minimum clearance. (C)Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
13. 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.
A
B
Mast And Carriage Bearings
Part No.
Bearing Size
D581814
Under Size
D581815
Standard
D581816
Over Size
Bearing O.D. *
108.6 mm (4.276 in)
109.6 mm (4.276 in)
110.7 mm (4.358 in)
C
IDCS123S
* Permissible tolerance ± 0.08mm (.003in)
Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
16. Make sure inner mast lower bearings are properly
shimmed in the intermediate mast by rolling up
and down and moving inner mast to right and left.
If clearance between both masts can be detected,
pull down the inner mast from the bottom of
intermediate mast. Inner lower bearings can be
easily extruded. Add shim 0.5 mm or 1 mm to
both inner lower bearings. If inner mast is stuck
and cannot move by rolling up and down, there
might be excessive shim. Pull out the inner mast
from the intermediate mast and remove shim 0.5
mm to both inner lower bearings. Repeat same
procedure of above until properly shimmed. There
is to be contact zero clearance (C) between inner
lower bearings and intermediate channel at
narrowest point.
IDCD040P
14. Find narrowest point by ruler on the intermediate
mast in the area where the inner lower bearings
make contact full length of intermediate mast
excluding minimum channel lap 475 mm (18.7 in).
Vehicle System
30
Disassembly & Assembly
E. Upper Bearing Adjustment of intermediate Mast
Follow same procedure with above B.
F. Upper Pad Adjustment of Intermediate Mast
Follow same procedure with above C.
IDCD041P
17. If the bearings were removed from the mast
mounting blocks, install new ones.
20. Fasten a hoist and nylon strap to secondary
cylinder (12). Install secondary cylinders (12) into
the stationary mast.
13
11
IDCD042P
IDCD026P
18. Put a small amount of clean grease on mounting
pins (11). Install mounting pins (11) into mast
mounting blocks.
21. Install secondary cylinder mounting brackets (13)
over the secondary cylinders.
14
IDCD025P
IDCD043P
19. If the bearings were removed from the tilt cylinder
pin bores, install new ones.
Vehicle System
22. Install top retainer bolts (14) for the secondary
cylinders.
31
Disassembly & Assembly
19
13°
15°
IDCD044P
27. Install the lift hose support bracket (19) and hoses.
IDCS322S
23. Install hydraulic steel tube to each secondary
cylinder. When install the steel tube, assembling
angle should be kept as shown in above figure.
16
IDCD045P
28. Install primary lift cylinder.
IDCD024P
24. Connect chains (16) at the bottom of the mast.
18
16
IDCD023P
IDCD010P
25. Connect chains (16) at the chain bracket of
stationary mast upper.
29. Install carriage assembly from the bottom of inner
mast
26. Install sheave (18) of lift hose.
Vehicle System
32
Disassembly & Assembly
20
IDCD008P
30. Install cross head (20) to primary lift cylinder.
33. Install mast to lift truck.
31. Install carriage chains to primary lift cylinder.
22
21
32. Install hydraulic hose (21) of side shifter to side
shifter cylinder (22).
Vehicle System
33
Disassembly & Assembly
Assemble Quad 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 Outer
Intermediate Mast
IDCD036P
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.
NOTE: 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 Adjustment Lower Bearings
(A, B, C) Zero clearance. (D) Minimum clearance.
(3, 4, 5) Bearing (6, 7, 8) Shims.
3. Select lower bearings (3), (4) and (5) from the chart
to obtain minimum clearance (D) between bearing
and channel leg for full channel length. Must use
same bearing on left and right side.
Part No.
D581814
D581815
D581816
Mast And Carriage Bearings
Bearing Size
Bearing O.D. *
Under Size
108.6 mm (4.276 in)
Standard
109.6 mm (4.276 in)
Over Size
110.7 mm (4.358 in)
* Permissible tolerance ± 0.08 mm (.003 in)
Vehicle System
34
Disassembly & Assembly
NOTICE
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)
1
2
IDCD037P
Mast Adjustment Lower Bearings
(A, B, C) Zero clearance. (D) Minimum clearance.
(3, 4, 5) Bearing (6, 7, 8) Shims.
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.
IDCD039P
7. Make sure outer intermediate mast lower bearings
are properly shimmed in the stationary mast by
rolling up and down and moving outer 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.
NOTE: When installing shims (5) behind bearings (4),
make sure the amount of shim is divided equally when
positioned behind each bearing (4).
Vehicle System
35
Disassembly & Assembly
IDCD039P
8. If intermediate mast is stuck and cannot move by
rolling up and down, there might be excessive shim.
Pull out the outer intermediate mast from the
stationary mast and remove shim 0.5 mm to both
outer intermediate lower bearings. Repeat same
procedure of above until properly shimmed. There is
to be contact zero clearance (C) between
intermediate lower bearings and stationary channel
at approximately 475 mm (18.7 in) channel lap.
Mast Adjustment Upper Bearings
(E, F, G) Zero clearance. (H) 0.80 mm (.031 in) Clearance
maximum. (9) Pads. (10) Shims. (11, 12, 13) Shims.
B. Upper Bearing Adjustment of Stationary Mast
IDCD039P
IDCD033P
10. Make sure stationary mast upper bearings are
properly shimmed 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 stationary upper bearings.
9. Lift by crane, and pull out intermediate mast from
stationary mast. Install 1 mm shim to each bearing
of stationary mast upper basically. Bearing should
be selected D581814 under size bearing.
Vehicle System
36
Disassembly & Assembly
C. Upper Pad Adjustment
11. If outer intermediate mast is stuck and cannot
move by rolling up and down, there might be
excessive shim. Pull out the outer intermediate
mast from the stationary mast and remove shim
0.5 mm to both stationary upper bearings. Repeat
same procedure of above until properly shimmed.
There is to be contact zero clearance (G) between
stationary upper bearings and the widest point of
intermediate mast to be checked before.
Mast Adjustment Upper Bearings
(E, F, G) Zero clearance. (H) 0.80 mm (.031 in) Clearance
maximum. (9) Pads. (10) Shims. (11, 12, 13) Shims.
IDCD033P
12. Install shims (10) behind each pad (9) until there is
0.80 mm (.031 in) maximum clearance (H)
between the pads and the inner and intermediate
masts with the masts at full extension. Lift by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded by
pulling down the inner mast from the bottom of
stationary mast.
Vehicle System
37
Disassembly & Assembly
D. Inner Intermediate Mast Adjustment.
Follow same procedure with above A~C.
E. Lower Bearing Adjustment of Inner Mast
IDCD040P
14. Find narrowest point by ruler on the inner
intermediate mast in the area where the inner
lower bearings make contact full length of inner
intermediate mast excluding minimum channel lap
475 mm (18.7 in).
Mast Adjustment Lower Bearings
(A, B, C) Zero clearance. (D) Minimum clearance.
IDCD031P
15. Install 1 mm shim to each bearing of inner lower
and inner intermediate upper basically. Lifting by
crane, insert inner mast into intermediate mast
from the upper side.
(3, 4, 5) Bearing (6, 7, 8) Shims.
13. 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.
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 (4.276 in)
D581816
Over Size
110.7 mm (4.358 in)
* Permissible tolerance ± 0.08mm (.003in)
Vehicle System
38
Disassembly & Assembly
F. Upper Bearing Adjustment of Inner Intermediate
Mast
Follow same procedure with above B.
G. Upper Pad Adjustment of Inner Intermediate
Mast
Follow same procedure with above C.
Mast Adjustment Lower Bearings
(A, B, C) Zero clearance. (D) Minimum clearance.
IDCD041P
(3, 4, 5) Bearing (6, 7, 8) Shims.
17. If the bearings were removed from the mast
mounting blocks, install new ones.
16. Make sure inner mast lower bearings are properly
shimmed in the intermediate mast by rolling up
and down and moving inner mast to right and left.
If clearance between both masts can be detected,
pull down the inner mast from the bottom of
intermediate mast. Inner lower bearings can be
easily extruded. Add shim 0.5 mm or 1 mm to both
inner lower bearings. If inner mast is stuck and
cannot move by rolling up and down, there might
be excessive shim. Pull out the inner mast from
the inner intermediate mast and remove shim 0.5
mm to both inner lower bearings. Repeat same
procedure of above until properly shimmed. There
is to be contact zero clearance (C) between inner
lower bearings and inner intermediate channel at
narrowest point.
11
IDCD042P
18. Put a small amount of clean grease on mounting
pins (11). Install mounting pins (11) into mast
mounting blocks.
IDCD043P
19. If the bearings were removed from the tilt cylinder
pin bores, install new ones.
Vehicle System
39
Disassembly & Assembly
Hole
Hole
Bar
20. Fasten a hoist and nylon strap to secondary
cylinder (12). Install secondary cylinders (12) into
the stationary mast.
23. Put the end bar of cylinder into the hole of
stationary mast’s lower stay, then the angles of
part become spontaneously 45°.
13
16-1
16
21. Install secondary cylinder mounting brackets (13)
over the secondary cylinders.
24. Connect chains (16) and anchor block (16-1) at the
bottom of the mast.
18
16
19
14
16
22. Install top retainer bolts (14) for the secondary
cylinders.
25. Connect chains (16) at the chain bracket of
stationary mast upper.
26. Install sheave (18) of lift hose.
Vehicle System
40
Disassembly & Assembly
Lift Hose
27. Install the lift hose along with the hose support
clamps.
30. Install carriage chains to primary lift cylinder.
22
21
IDCD005P
28. Install primary lift cylinder and assemble bolt (a).
31. Install hydraulic hose (21) of side shifter to side
shifter cylinder (22).
32. Install mast to lift truck.
IDCD010P
29. Install carriage assembly from the bottom of inner
mast
Vehicle System
41
Disassembly & Assembly
Standard Lift Cylinder
4
Disassemble Standard Lift Cylinder
Start By:
a. Remove standard lift cylinders.
1
IDCD409P
4. Remove rod (4) from the cylinder body.
A
IDCD399P
5
1. Put standard lift cylinder (1) in position on vise (A).
IDCD409P
5. Remove split rings (5) from the cylinder rod.
2
B
IDCD007P
2. Loosen set screw (2) with wrench (B).
6. Remove O-ring seal (6) and back-up ring (7) from
the bearing.
C
8
9
3
IDCD407P
3. Remove bearing (3) with wrench (C).
IDCD411P
7. Remove wiper seal (8) and seal (9) from the bearing.
Vehicle System
42
Disassembly & Assembly
Assemble Standard Lift Cylinder
6
2
1
5. Install cylinder rod (6) in the cylinder body.
IDCD411P
1. Install seal (2) in the bearing.
2. Install wiper seal (1). Install the seal with the lip
toward the outside.
C
7
3
IDCD407P
6. Install bearing (7) on the cylinder rod and tighten
using wrench (C).
4
IDCD410P
NOTE : Install back-up ring (4) with the curved side
contacting the O-ring seal.
8
3. Install O-ring seal (3) and back up ring (4) into the
bearing.
B
IDCD406P
7. Tighten setscrew (8) with wrench (B) to a torque of
6±1 N·m (53±9 lb·in).
End By:
a. Install standard lift cylinders.
IDCD409P
4. Install split rings (5) on the cylinder rod.
Vehicle System
43
Disassembly & Assembly
Secondary Lift Cylinder
Disassemble Secondary Lift Cylinder
Tools Needed
Hydraulic Cylinder Repair Stand
Wrench Assembly
A
1
3
B
1
Start By:
a. Remove standard lift cylinders.
IDCD204P
3. Remove rod (3) from the cylinder body.
A
1
5
4
IDCD201P
IDCD206P
1. Put standard lift cylinder (1) in position on tool (A).
7
6
4. Remove stop ring (4) from the cylinder rod.
B
5. Remove wear ring(5), U-packing(6) and backup
ring(7).
2
IDCD203P
2. Remove bearing (2) with tool (B).
10
8
9
IDCD207P
6. Remove retaining ring(8), spacer(9) and check
valve(10).
Vehicle System
44
Disassembly & Assembly
7. Remove ring (11), wear ring (12) and O-ring (13)
from the bearing.
16
14
15
IDCD209P
8. Remove wiper seal (14) and retaining ring (15) from
the bearing.
9. Remove U-packing (16).
Vehicle System
45
Disassembly & Assembly
Assemble Secondary Lift Cylinder
10
11
1
2
IDCD206P
13
12
3
5. Install stop rings (10) on the cylinder rod.
IDCD209P
6. Install wear ring (11), U-packing (12) and backup
ring (13).
1. Install U-packing (1) in the bearing.
2. Install wiper seal (2) and retaining ring (3). Install
the seal with the lip toward the outside.
14
4
5
IDCD204P
6
7. Install cylinder rod (14) in the cylinder body.
IDCD208P
3. Install O-ring (4), wear ring (5) and ring (6) in the
bearing.
B
15
IDCD203P
IDCD207P
7
8
8. Install bearing (15) on the cylinder rod and tighten
using tool (B).
9
End By :
4. Install check valve (7), retaining ring (8) and spacer
(9).
Vehicle System
a. Install secondary lift cylinders.
46
Disassembly & Assembly
Primary Lift Cylinder
Remove & Install Primary Lift
Cylinder
Start By:
a. Remove carriage.
WARNING
3. Pull the cylinder out far enough to disconnect elbow
(2). Remove primary lift cylinder. Weight is roughly
27 kg (60 lb).
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.
NOTE : The following steps are for the installation of
the primary lift cylinder.
4. Put primary lift cylinder (3) in position on the mast.
5. Connect elbow (2).
6. Install bolt bolts (1).
1
End By:
a. Install carriage.
IDCD059P
1. Fasten nylon straps and hoist to the primary lift
cylinder.
2. Remove bolts (1).
Vehicle System
47
Disassembly & Assembly
Disassemble Primary Lift Cylinder
Tools Needed
A
Hydraulic Cylinder Repair Stand
1
Wrench Assembly
4
B
1
Start By:
a. Remove primary lift cylinder.
IDCD211P
1
4. Remove piston seal (4).
5
6
IDCD210P
1. Remove flow protector valve (1) from the cylinder
body.
IDCD212P
2
5. Remove retaining ring (5), and check valve (6).
A
3
IDCD215P
7
2. Remove rod cover (2) with tool (A).
IDCD213P
3. Remove rod (3) from the cylinder body.
6. Remove O-ring (7).
Vehicle System
48
Disassembly & Assembly
8
9
10
4
IDCD214P
IDCD213P
7. Remove wiper seal (8) and retaining ring (9) and Upacking (10) from the rod cover.
3. Install O-ring seal (4).
Assemble Primary Lift Cylinder
Tools Needed
A
Hydraulic Cylinder Repair Stand
1
5
B
6
Wrench Assembly
1
2
3
IDCD212P
4. Install check valve (5), retaining ring (6).
1
8
IDCD214P
1. Install U-packing (1) in the rod cover.
7
2. Install wiper seal (2) and retaining ring (3). Install
the seal with the lip toward the outside.
IDCD211P
5. Install wear ring (7), piston seal (8) on the cylinder
rod.
Vehicle System
49
Disassembly & Assembly
10
2
9
A
3
IDCD215P
6. Install cylinder rod (9) in the cylinder body.
WARNING
7. Install rod cover (10) on the cylinder body. Use tool
(A) to tighten bearing.
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.
11
1. Disconnect the connector (1). Remove retainer bolt
(2) and pin (3).
IDCD210P
5
8. Install flow protector valve (11) on the cylinder body.
End By:
6
4
a. Install primary lift cylinder.
Tilt Cylinder
2. Remove retainer bolt (6) from pin (5). Remove pin
(6).
Remove & Install Tilt Cylinders
3. Remove tilt cylinder (4).
NOTE: The procedure for removing and installing the
tilt cylinders is the same for both cylinders.
4. Install the tilt cylinder in the reverse order of
removal.
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.
Vehicle System
50
Disassembly & Assembly
Disassemble & Assemble Tilt
Cylinders
4. Remove piston and seal assembly (4) from the
cylinder rod.
Tools Needed
Spanner Wrench
5. Remove head assembly (5).
A
1
6
7
Start By:
a. Remove tilt cylinder.
A
8
1
IDCD423P
6. Remove spacer (6) from the cylinder rod.
7. Loosen the nut and bolt on the rod eye Remove
cylinder rod (7) and shims (8).
2
IDCD421P
10
1. Use tool (A) to remove head (1) from the cylinder
body.
9
NOTICE
Use extra care not to damage the highly finished
surface of the cylinder rod and the bore of the cylinder
body during disassembly and assembly of the tilt
cylinder.
IDCD424P
2. Remove rod assembly (2) from the cylinder body.
4
8. Remove seal assembly (10) and O-ring seal (9)
from the piston.
3
5
IDCD422P
3. Remove nut (3) from the cylinder rod.
Vehicle System
51
Disassembly & Assembly
11
14
15
16
IDCD253P
IDCD426P
9. Remove seal (11) from the spacer.
12. Install seal (14) in the head. Position the lip of the
seal toward the inside of the head.
13. Install seal (15).
12
14. Install seal (16) in the cylinder head. Position the
lip of seal (16) toward the outside of the cylinder
head.
13
12
IDCD425P
10. Remove O-ring seal (12) and back-up ring (13)
from the head.
13
IDCD425P
NOTE: The curved side of back up ring (13) should
contact O-ring seal (12).
14
15. Install O-ring seal (12) and back-up ring (13).
Make sure the curved side of back-up ring (13) is in
contact with O-ring seal (12).
15
16
IDCD426P
11. Remove seals (14), (15), and (16) from the head.
NOTE: Use the following steps to assemble the tilt
cylinder.
Vehicle System
52
Disassembly & Assembly
10
11
9
IDCD258P
IDCD424P
16. Install seal (11) in the spacer.
2
8
19. Install seals (10) and O-ring seal (9) on the piston
5
6
4
3
IDCD423P
IDCD422P
17. Install spacer (6).
20. Install head assembly (5) on the cylinder rod.
18. Install shims (8) and rod eye (2). Tighten the bolt
on rod eye (2) to a torque of 95±15 N·m (70±11
lb·ft).
21. Install piston assembly (4) onto the cylinder rod.
22. Install nut (3). Tighten nut (3) to a torque of
270±30 N·m (200±22 lb·ft).
IDCD427P
23. Install the rod assembly in the cylinder body.
Vehicle System
53
Disassembly & Assembly
Disassemble & Assemble Master
hydraulic Pump
for D20/25/30S-5, G20/25/30E-5, G20/25/30P-5
,GC20/25/30E-5, GC20/25/30P-5
4. Remove a gear assemble (4) from a gear body (5)
1. Remove the eight screw bolts (1).
5. Remove a wear plate (6) from a bottom of gear
body.
2. Remove a mounting flange (2) from pump assembly.
6. Remove a seal (7) and a back up gasket (8) from a
wear plate.
3. Remove a wear plate (3) from pump assembly.
Vehicle System
54
Disassembly & Assembly
Disassembly of Pump
for D33SC, D35SC, G33P, G35P
7. Remove gear body (9).
1 .Put the unit back side down to your work place.
8. Remove a seal (10) from gear body.
2. Remove all fasteners, bolts and units.
9. Remove a seal (11) from an end block (12).
10. Assemble the pump in the reverse order of
disassembly.
3. Put all removed parts on a safe place.
Tightening torque of each screw bolt; 34 to 37 N.m
Vehicle System
55
Disassembly & Assembly
4. Remove the mounting flange (1) and gear sets (2)
from the bottom of body.
8. Check balance plates, and sealing parts.
5. Remove the snap ring (3).
9. Assemble new sealing parts, the rubber seal first (4),
the plastic seal (5) on top.
10. Remove the section seal (6) from the mounting
flange (7).
6. Use proper and safe tools for the operation
7. Push out shaft seal
Vehicle System
11. Clean all mounting faces of the mounting flange
from sealant and dirt.
56
Disassembly & Assembly
12. Be careful, avoid mechanical surface damages.
2. Assemble carefully the gear set (3).
13. Clean all mounting faces of body from sealant and
dirt.
3. Put the upper balance plate (4) on top of the gear
set. Position is rotation sensitive!
Assembly of pump
for D33SC, D35SC, G33P, G35P
4. Prepare the shaft seal for assembly. Use a proper
assembly fixture
1. Assemble the lower balance plate (1) into the body
(2), sealing parts can be fixed with grease. Position
is rotation sensitive!
5. The shaft seal should be packed with some grease.
Vehicle System
57
Disassembly & Assembly
6. Press in the shaft seal to bottom of the shaft seal
bore.
10. Put a rope of Loctite sealant out side the interlock
track on the body (it's for corrosion protection)
7. Assemble the snap ring.
11. Fit an assembly fixture for shaft sea protection to
the drive shaft.
8. Check the section seal. Use of a new one is
recommended in each case.
12. The assembly fixture should be oiled with clean
hydraulic fluid to lubricate the shaft seal lip during
assembly.
9. Clean all assembly faces again.
Vehicle System
58
Disassembly & Assembly
13. Fit the mounting flange careful from top down to
the body. Fit the interlock track correct.
14. Remove the shaft seal protection fixture careful.
15. Fit fasteners, bolts or nuts with correct assembly
torque.
Vehicle System
59
Disassembly & Assembly
Steering Wheel
Remove & Install Steering Wheel
1
1. Remove cap (1) from the steering wheel.
2
3
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).
Vehicle System
60
Disassembly & Assembly
1. Disconnect (4) tubes and (1) hose assembled to
steering unit.
Steering Unit
Remove & Install Steering Unit
3
Start By:
a. Remove covers from steering wheel group
1
.
2
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.
2. Remove four bolts (1).
NOTE : Identify and mark all hydraulic hoses for
purposes of reassembly.
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.
Vehicle System
61
Disassembly & Assembly
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.
End Cap Cap Screw
Seal
Gerotor (Meter) End
IDCD279S
2. Remove 5/16 inch cap screws and washers if
applicable (7 each).
3. Remove end cap.
4. Remove seal from end cap.
Seal
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.
Spacer(s)
IDCD280S
5. Remove meter. Be careful not to drop star.
6. Remove seal from meter.
7. Remove drive spacer(s).
Vehicle System
62
Disassembly & Assembly
Seal Gland
Bushing
Spacer Plate
Seal
IDCD283S
Drive
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.
IDCD281S
8. Remove drive.
9. Remove spacer plate.
10. Remove seal from housing.
Control End
Dust
Seal
Quad
Ring
Seal
Seal
Gland
Bushing
IDCD284S
13. Remove quad ring seal from seal gland bushing.
IDCD282S
14. Use a thin bladed screwdriver to pry dust seal from
seal gland bushing. Do not damage bushing.
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.
Vehicle System
63
Disassembly & Assembly
Needle
Thrust
Bearing
Bearing
Race
Bearing
Race
IDCD285S
IDCD287S
15. Remove 2 bearing races and the needle thrust
bearing from spool and sleeve assembly.
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
Pin
IDCD286S
16. Remove spool and sleeve assembly from 14 hole
end of housing.
Check Ball Seat
ATTENTION: Do not bind spool and sleeve in housing.
Rotate spool and sleeve assembly slowly when
removing from housing.
Check Ball
IDCD288S
21. Remove check ball seat.
17. Push pin from spool and sleeve assembly.
22. Tip housing to remove check ball.
Vehicle System
64
Disassembly & Assembly
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.
Control Sleeve
Spring Slot
Spring Slot
Identification Control
Spool
Marks
NOTE: Lubricate all seals with clean petroleum jelly
such as Vaseline.
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.
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
Check Ball
IDCD289S
IDCD291S
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.
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.
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.
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.
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.
Vehicle System
10. Install pin through spool and sleeve assembly until
pin is flush at both sides of sleeve.
65
Disassembly & Assembly
Needle
Thrust
Bearing
Pin
Bearing
Race(2)
Seal
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.
IDCD293S
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.
Vehicle System
66
Disassembly & Assembly
Retaining
Ring
Seal
Gland
Bushing
(with seals)
IDCD294S
IDCD296S
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.
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.
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.
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.
Vehicle System
67
Disassembly & Assembly
Seal Groove this Side of Gerotor (Meter)
Star Valley
Port Face
Drive
A
B
Pin Parallel
with Port
Face
Drive
(Marked)
C
D
Pin
IDCD298S
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.
Pin
Port Face
IDCD300S
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.
Seal
IDCD299S
22. Install 73.5 mm [2.89 in.] ID seal in spacer plate or
gerotor (meter).
Vehicle System
68
Disassembly & Assembly
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.
Seal
Drive Spacer(s)
26. Install end cap on gerotor, align holes.
IDCD301P
Actual
Displacement
㎤/r(in/r)
Spacer
IDCD302P
3
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]
Vehicle System
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]
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.
69
Disassembly & Assembly
Master cylinder
2
Remove & Install Master cylinder
NOTE : Plug and cap all openings to avoid
contamination and debris from entering the system
after removing any tubes or lines.
1. Before disconnecting the lines to master cylinder(1),
prepare the proper plugs.
3. Disconnect the yoke (3) from bell crank.
4. Dismount the master cylinder.
5. Install the waster cylinder in the reverse order of
removal.
6.
Fill the oil reservoir with the correct oil
recommended at Operating & Maintenance manual.
7. Bleed the brake system. Refer to the Testing and
Adjusting Manual for the further information.
2. Disconnect the hoses and the tubes assembled to
master cylinder, one by one.
Be sure that the oil in reservoir will be brained once
the hose (2) is disconnected.
NOTE : Put the proper marking on the hoses not to be
confused. Also, after being disconnected, put the
proper plug or plugging on the hoses and tube.
Vehicle System
70
Disassembly & Assembly
Master Cylinder
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.
Vehicle System
71
Disassembly & Assembly
4. Remove lock washer (6) and ball (7) from servo piston (9). Pull off piston ring (8), seal u-cup (13), seal u-cup
(12) and seal u-cup (11) in sequence. Notice the direction of each seal.
No
Color
Material
11
Translucency
Urethane
12
Black
NBR Hs70
13
Yellow
Urethane
5. Remove relief plug (18), o-ring (19), spring (17), shims (16) and piston (15) from front housing (1).
Vehicle System
72
Disassembly & Assembly
6. Remove check valve parts from rear housing (2): plug (26), o-ring (27), cage (24), spring (23), ball (21) and oring (22). Remove o-ring (20).
7. Assemble brake valve in the reverse order of disassembly.
Vehicle System
73
Disassembly & Assembly
Steer Wheel & Bearing
Cushion truck
4
< Old type before 2008 year truck >
Tools Needed
Floor Jack
Dirver Set
Lock Nut Installer
A
1
B
C
1
5
1
NOTE : The procedure to remove the steer wheels is
the same for the right and left steer wheel.
5. Remove bearing cone (4) from steer wheel (5).
6. Remove steer wheel (5). Steer wheel (5) weighs 34
kg (75 lb).
5
1
IDCD072P
6
7
A
IDCD070P
1. Support the steer axle with a floor jack (A).
IDCD073P
2. Remove wheel cap (1).
7. Remove seal (6) from the back of steer wheel (5).
8. Remove bearing cone (7) and the bearing cup from
the back of steer wheel (5).
2
3
IDCD071P
3. Bend the tab in locking washer (2) clear of the slot
in nut (3).
4. Use tool (C) to remove nut (3). Remove locking
washer (2)
Vehicle System
74
Disassembly & Assembly
Pneumatic Truck and
Cushion Truck sice 2008 year
5
Tools Needed
A
Floor Jack
1
B
Torque wrench
1
Lock Nut Installer
8
IDCD074P
C
1
NOTE : The procedure to remove the steer wheels is
the same for the right and left steer wheel.
9. Remove bearing cup (8) from the front of steer
wheel (5).
1. Support the steer axle or CTWT with a proper jack
or hoist.
NOTE : Check the condition of all seals, bearings and
components. If any parts are worn or damaged use
new parts for replacement. For purposes of assembly,
lower the temperature of the bearing cups and before
installing into steer wheel (5). Use tooling (B) to install
bearing cups and seals.
2. Remove wheel cap.
2
10. Pack bearing cones (4) and (7), and lubricate the
contact surfaces of the bearing cups with
Multipurpose Grease.
1
11. Reverse the procedures and steps 4 through 9 to
install the steer wheels and bearings.
12. Adjust the steer wheel bearings as follows:
a. Use tool (C) to tighten nut (3) to a torque of
135 N·m (100 lb·ft) while slowly rotating steer
wheel (5).
3. Remove the Bolts (1).
4. Remove the bearing lock washer (2).
b. Use tool (C) to loosen nut (3) completely.
c. Use tool (C) to tighten nut (3) again to a torque of
50 ± 5 N·m (37 ± 4 lb·ft).
d. Bend a tab of locking washer (2) into a slot of nut
(3).
13. Install wheel cap (1).
14. Remove tooling (A) and lower the lift truck.
Vehicle System
75
Disassembly & Assembly
6. Remove bearing cone and cup from steer hub.
NOTE : Check the condition of all seals, bearings and
components. If any parts are worn or damaged use
new parts for replacement use tooling (C) to install
bearing cups.
4
7. Pack bearing cones, and Iubricate the contact
surfaces of the bearing cups with Multipurpose
Grease.
3
5. Remove bearing lock nut (3) with the jig (4) like the
picture.
< Unit : mm >
8. After putting the bearings, put the bearing lock nut
(3).
4
9. By using the tool (4), adjust the bearing as follows.
Vehicle System
76
Disassembly & Assembly
a. Use tool (4) to tighten nut (3) to a torque of 135
N•m (100 Ib•ft) while slowly rotating steer wheel.
b. Use tool (4) to loosen nut (3) completely.
c. Use tool (4) to tighten nut (3) again to a
torque of 50±5 N•m (37±4 Ib•ft).
2
1
10. Put the bearing lock washer (2). Check out if two
mounting bolt holes are aligned with the holes at
bearing lock nut. If it doesn’t match, rotate the
bearing lock nut clockwise about, /32 turn.
11. Assemble (2) bolts after Loctite 242 is applied.
12. Pack the multipurpose grease inside the cap.
13. Fit the cap.
14. Remove a jack and lower the lift truck.
Vehicle System
77
Disassembly & Assembly
Tie Rod
Steering Knuckle, Kingpin,
and Bearing
Remove and Install Tie Rod
Tools Needed
Floor Jack
Driver Set
A
1
Remove and Install Steering
Knuckle, King Pins and Bearing
B
2
Tools Needed
Drive Set
Start By :
a. Remove steer wheels.
Start By:
NOTE : The procedure to remove and install the tie
rod is the same for each steer wheel.
a. remove steer wheels
A
1
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
4
2
2
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 (1).
1. Remove pin retaining bolt (2). Remove pin (1).
3. Remove tie rod (4) and dust seals (3).
2. Position the tie rod away from the steering knuckle.
5
IDCD082P
4. Use tooling (B) to remove bearings (5) from the tie
rod.
3. Remove four bolts (3) and cover (4).
5. Use tooling (B) to install new bearings (5) in the tie
rod.
6. Install the tie rod in the reverse order of removal.
Vehicle System
78
Disassembly & Assembly
10
14
11
12
13
IDCD081P
4. Remove four bolts (5) and cover (6).
7. Remove spacer (11), bearing cup (13) and bearing
cone (12).
8. Check the condition of lip type seal (14). Replace
seal (14) 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
(10).
NOTICE
Check the condition of all seals, bearings and
components. If any parts are worn or damaged use
new parts for replacement.
5. Remove the nut (7) and bolt (8). For purposes of
reassembly, the torque for bolt (7) is 11 ± 1 N·m(100
± 9 lb·ft).
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.
6. Remove kingpin (9) and knuckle (10).
Vehicle System
79
Disassembly & Assembly
Steer Axle
Remove & Install Steer Axle
Tools Needed
Jack Stand
A
4
WARNING
2
Be sure the pressure in the hydraulic system is
released before any lines or hoses have been
disconnected.
6. Remove bolts (2) and mounting caps (3) from the
steer axle.
3
1
1. Put the lift truck in position
with a jacket.
7. Remove steer axle (4). The steer axle weighs
approximately 200 kg (440 lb).
2. Disconnect tube (1). Plug and cap all openings to
prevent contamination and debris from entering the
system.
NOTE : Use the following steps to install the steer axle.
4
2
8. Use a floor jack to position steer axle (4).
3. Support the steel 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.
Vehicle System
80
Disassembly & Assembly
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.
Steering Cylinder
Remove & Install Steering Cylinder
9. Seat steer axle (4) as follows:
Start By:
a. Install bolts (2) through cap (3) and into the
mounting bosses approximately two bolt
threads.
a. Remove steer axle.
b. Use the floor jack to raise steer axle (4) into the
mounting boss.
1
c. Tighten bolts (2).
2
1. Remove the pin retaining bolt and pin (2) from the
tie rod at each end of steering cylinder (1).
1
1
10. Connect tube (1).
3
2. Remove four bolts (3). For installation purposes, the
torque for bolts (3) is 300 ± 40 N·m (220 ±30 lb·ft).
3. Remove steering cylinder (1).
4. Install steering cylinder (1) in the reverse order of
removal.
Vehicle System
81
Disassembly & Assembly
Disassemble Steering Cylinder
Start By :
a. Remove steering cylinder.
1. Put location marks on end caps (1) as to their
position on the steering cylinder tube.
2. Remove end caps (1) from the steering cylinder.
5. Disassemble each rod cover as follows.
a. Remove retaining ring (5) and dust wiper (6).
b. Remove U-packing (7).
c. Remove O-ring (8) and back up ring (9).
d. Remove DU-bush (10).
3. Remove cylinder tube (2) from the rod assembly.
4. Remove piston seal (3) and wear ring (4).
Vehicle System
82
Disassembly & Assembly
Assemble Steering Cylinder
3. Install cylinder tube (2) on the rod assembly.
4. Install rod covers (1) on cylinder tube (2).
1. Assemble each rod cover as follows ;
End By :
a. Install DU-bush (10).
a. Install the steering cylinder.
b. Install back up ring (9) and O-ring (8)
c. Install u-packing (7).
d. Install dust wiper (6) and retaining ring (5).
2. Install piston seal (3) and wear ring (4).
Vehicle System
83
Disassembly & Assembly
Universal Joint
Counterweight
Remove and Install Universal Joint
Remove & Install Counterweight
Tools Needed
Link Bracket
4
A
4
NOTE : Steps 1 through 3 are for L.P. and Gas model
machines only. After steps 1 through 4 have been
done, the removal procedure is the same for all
models. For gasoline model machines, go to step 5.
1. Remove the L.P. fuel tank. Refer to the Operation &
Maintenance manual for further information.
1
3
2
IDCD090P
1. Remove four bolts (1).
2. Remove four bolts and nuts (2) and flange
assembly (3).
3. Remove yoke shaft assembly (4).
Use the following steps to assemble the universal
joint.
4. Install the yoke shaft assembly (4) into transmission.
2. Disconnect fuel line (1) from the LP converter.
5. Put the flange assembly in the position between the
drive axle and the yoke shaft assembly (4).
6. Apply loctite #242 thread lock to threads of the bolts
(1) and the bolts (2).
7. Tighten the bolts (1) and the bolts (2) to a torque of
75 ± 5 N·m (55.4 ± 3.7 lb·ft).
3
2
IDCD092P
3. Remove the washers and bolts (2) from each side
of L.P. tank mounting bracket (3). Remove mounting
bracket (3).
Vehicle System
84
Disassembly & Assembly
4
5
NOTE : The following steps are for installation of the
counterweight.
4. Remove the washers and bolts (4) and exhaust pipe
(5) for the diesel truck.
8. Put counterweight (6) in position on the frame, and
install bolt (8) and bolts (9). Tighten the bolts to a
torque of 400 ± 60 N·m (300 ± 45 lb·ft).
6
NOTE : This completes the installation of the counter
weight for gasoline model machines. For L.P. Gas
model machines, reverse the procedures and Steps 1
through 3 and 5 to complete installation of the L.P.
tank mounting bracket and gas line. For diesel model
machines, reverse the procedures and steps 4 through
5 to complete installation of exhaust pipe and cover
A
5. Support counter weight (6) with a hoist and tooling
(A) as shown.
The weight of the counter weight is approximately
2,100kg (4,630 lb).
8
6. Remove the washer plate and bolts (8).
7. Use the hoist and tooling (A) to remove counter
weight (6). The weight of the counterweight is
approximately 2,100 kg (4,630 lb).
Vehicle System
85
Disassembly & Assembly
Removal and Installation of Drive
axle
Start by :
a. Remove the mast.
Refer to the topic of " Mast " in this module for the
further information.
b. Remove the drive tire.
c. Drain the drive axle oil.
4. Disconnect the brake tube.
5. Disassemble the nuts for mounting the drive axle.
For the purpose of reassembly, the torque is 460 +/60 N.m (354 +/- 45 lb.ft).
1. Raise the machine and put the rigid block under the
frame. To be safe.
2. Disassemble the u-joint. For the purpose of
reassembly, apply MoS2 grease on the spline.
6. Remove the drive axle.
3. Disassemble three hoses to the lube pump.
Vehicle System
86
Disassembly & Assembly
Removal of Transmission
Start by :
a. Remove the mast.
Refer to the topic of " Mast " in this module for the
further information.
b. Remove the drive tire.
c. Drain the transmission oil.
4. Disconnect the parking cable.
d. Disassemble Drive axle.
5. Dismount the front plate.
1. Disconnect two hoses assembled to the hydraulic
pump.
6. Disconnect all harnesses, connectors and hoses.
7.
After removing the trans. housing cover,
disassemble the torque converter plate from the
flywheel. For the purpose of reassembly, the torque
is 45 +/- 7 N.m (34 +/- 5 lb.ft).
8. Suspend the transmission and engine by hoist,
separately.
9. Reassembly in the reverse order of disassembly.
For the purpose of reassembly, the torque of bolts
for mounting the transmission is...............................
............................... 240 +/- 40 N.m (180 +/- 30 lb.ft).
2. Disconnect the inching cable.
10. Adjust the powertain assembly after inserting Ø4
mm pin into the hole of trqnsmission housing
3. Dismount the accel pedal.
Vehicle System
87
Disassembly & Assembly
<Pneumatic truck>
< Unit : mm >
<Cushion truck>
< Unit : mm >
11. Dismount the transmission from the engine.
Vehicle System
88
Disassembly & Assembly
Removal and Installation of Engine
Start by :
a. Remove the mast.
Refer to the topic of " Mast " in this module for the
further information.
b. Remove the drive tire.
c. Drain the transmission oil.
d. Drain the engine oil.
3. Dismount the air cleaner and hose to the intake.
e. Drain the coolant.
4. Disconnect the battery cable and dismount the
battery.
f. Disassemble Drive axle.
5. Disconnect LP hose to fuel lock.
1. Dismount the overhead guard, hood and counter
weight.
6. Dismount the sub. Assembled LP Regulator.
2. Dismount the radiator.
Vehicle System
89
Disassembly & Assembly
7. Disconnect the exhaust tube.
8. Disconnect all harnesses, connectors to the engine.
9. Disconnect the coolant hose to LP regulator.
10. Dismount the assembled transmission and engine
together.
11. Discount the transmission from the engine.
12. Reassembly in the reverse order of disassembly.
For the purpose of reassembly, the torque of bolts
for mounting the transmission is 240 +/- 40 N·m
(180 +/- 30 lb·ft). The torque of bolts for mounting
the engine is 55 ± 10 N·m (40±8lb·ft) with Loctite
# 262.
Vehicle System
90
Disassembly & Assembly