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Daewoo D35S-2 Disassembly/Assembly

Lift trucks vehicle systems
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Disassembly &
Assembly
Lift Trucks Vehicle Systems
D35S-2,
D40SC-2,
G35S-2,
G40SC-2,
D40S-2,
D45SC-2,
G40S-2,
G45SC-2,
D45S-2
D50SC-2
G45S-2
G50SC-2
SB2204E00
J u n . 1 9 9 9

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Summary of Contents for Daewoo D35S-2

  • Page 1 SB2204E00 J u n . 1 9 9 9 Disassembly & Assembly Lift Trucks Vehicle Systems D35S-2, D40S-2, D45S-2 D40SC-2, D45SC-2, D50SC-2 G35S-2, G40S-2, G45S-2 G40SC-2, G45SC-2, G50SC-2...
  • Page 2 If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

  • Page 4: Table Of Contents

    Index Brake Hydraulic Booster ..........21 Counterweight............36 Engine..............39 Hood Assembly............5 Hydraulic Control Valve ...........27 Hydraulic Oil Filter Assembly........37 Hydraulic Pump ............33 Overhead Guard ............6 Primary Lift Cylinder ..........12 Secondary Lift Cylinders..........9 Steer Axle ..............23 Steering Cylinder .............24 Steering Knuckles, Kingpins And Bearings .....22 Steering Unit ............15 Steering Wheel ............15 Tie Rods..............21...

  • Page 6: Hood Assembly

    Disassembly & Assembly Hood (with seat) Assembly Remove & Install Hood (with seat) Assembly IACD203P 5. Remove the washers and four bolts (3). IACD201P WARNING The hood and seat assembly can fall when nut (1) IDCD054P is removed from the support cylinder rod. To avoid personal injury, support the seat and hood assembly before removing nut (1).

  • Page 7: Overhead Guard

    Overhead Guard Remove & Install Overhead Guard IDCD057P 3. Remove the washers, nuts, and two bolts (3). 4. Remove front overhead guard (1), Front overhead guard (1) weighs 30 kg (66 lb). IDCD055P 1. Support overhead guard (1) with lifting straps and a hoist.

  • Page 8: Tilt Cylinders

    Tilt Cylinders Remove & Install Tilt Cylinders NOTE : The procedure for removing and installing the tilt cylinders is the same for both cylinders. WARNING IACD205P If both tilt cylinders are removed at the same time 2. Remove retainer bolt (6) from pin (5). Remove pin the mast can fall.
  • Page 9 Disassemble & Assemble Tilt Cylinders Start By: a. Remove tilt cylinder. ICCD004P 4. Remove pin (5) inside hole and nut (6) from the cylinder rod (4). 5. Remove piston (7) from the cylinder rod. ICCD002P 1. Remove eye (1) from the rod assembly (4). ICCD005P 6.

  • Page 10: Secondary Lift Cylinders

    Secondary Lift Cylinders Disassemble Secondary Lift Cylinders Start By : a. Remove secondary lift cylinders. ICCD007P 8. Remove O-ring seal (11) and backup ring (12) from the rod cover (2). 1. Put secondary lift cylinder (1) in position as shown. ICCD008P 9.
  • Page 11 3. Remove rod (3) from the cylinder body. 6. Remove O-ring seal (7), back-up ring (8) and seal (9) from the piston. 4. Remove retaining ring (4) and piston (5) from the cylinder rod. 7. Remove O-ring seal (10) from the head assembly. 5.
  • Page 12 Assemble Secondary Lift Cylinders 5. Install O-ring seal (6) on the cylinder rod. 1. Install bush (13) and seal (12). 2. Install wiper seal (11). Install the seal with the lip toward the outside. 6. Install piston (5) and retaining ring (4) on the cylinder rod.

  • Page 13: Primary Lift Cylinder

    8. Install head assembly (2) on the cylinder rod and 1. Fasten nylon straps and hoist to the primary lift tighten using tool. cylinder. End By : 2. Remove bolt (1). a. Install secondary lift cylinders. Primary Lift Cylinder Remove & Install Primary Lift Cylinder Start By : a.
  • Page 14 Disassemble Primary Lift Cylinder Start By : a. Remove primary lift cylinder. 4. Remove O-ring seal (4) and back-up ring (5) from the bearing. 1. Remove bearing (1). 2. Remove rod (2) from the cylinder body. 5. Remove wiper seal (6), back-up ring (7), seal (8) and rings (9) from the bearing.
  • Page 15 Assemble Primary Lift Cylinder 5. Install split rings (3) on the 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.

  • Page 16: Steering Unit

    Steering Wheel Steering Unit Remove & Install Steering Wheel Remove & Install Steering Unit Start By: a. Remove steering wheel. IACD206P 1. Remove cap (1) from the steering wheel. IACD208P IDCD064P IACD209P 2. Remove nut (2) and cup (3) from the steering wheel shaft.
  • Page 17 Disassemble & Assemble Steering Unit Start By : a. Remove steering unit from the truck. IACD210P 3. Remove two bolts (4). WARNING To prevent personal injury be sure pressure in the ICCD079P hydraulic system has been released before disconnecting any hydraulic lines. Slowly loosen 1.
  • Page 18 ICCD081P ICCD084P 4. Remove the components from housing (3) as follows: a. Remove plate (6) from housing (3). b. Remove shaft (7) from gerotor (9). c. Remove gerotor (9) from housing (3). d. Remove O-rings seal (8) from housing (3). e.
  • Page 19 ICCD087P ICCD089P 12. Remove plug (27) and washer (28) from steering 16. Install washer (37) and plug (36) into the steering unit body. unit body. ICCD088P ICCD088P 13. Remove plug (31) and spring (32) from the body 17. Install housing (35) and poppet (34) into the (2).
  • Page 20 ICCD086P ICCD083P 20. Install dust seal ring (26). Install O-ring seal (24) 24. Install sleeve (16) into steering unit body (2). with king-ring (25) into body. 25. Install O-ring seal (15) into body (2). ICCD085P ICCD082P NOTICE 26. Install check valve ball (14) and screw (13). For purposes of installation, note that springs (23) are Tighten the screw (13).
  • Page 21 ICCD090P ICCD091P NOTICE To assure proper operation of the steering unit, make sure bolts (5) are clean and dry before installing. Tighten bolts (5) in the sequence shown in the illustration. ICCD081P 28. Install plate (6) onto steering unit body. NOTICE Make sure the notch of shaft (7) properly seats on pin (18) when installed into body and spool (17).

  • Page 22: Brake Hydraulic Booster

    Brake Hydraulic Booster Tie Rods Remove And Install Brake Hydraulic Remove And Install Tie Rods Booster Tools Needed Floor Jack Drive Set Start By : a. Remove steer wheels. NOTE : The procedure to remove and install the tie rod is the same for each steer wheel. IACD211P 1.

  • Page 23: Steering Knuckles, Kingpins And Bearings

    Steering Knuckles, Kingpins, And Bearings Remove And Install Steering Knuckles, King Pins And Bearings Tools Needed Drive Set IACD215P Start By: 4. Remove four bolts (5) and cover (6). 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.

  • Page 24: Steer Axle

    Steer Axle Remove & Install Steer Axle Tools Needed Jack Stand WARNING IACD217P Be sure the pressure in the hydraulic system is 6. Remove kingpin (8) and knuckle (9). released before any lines or hoses have been disconnected. IDCD081P IACD218P 7.

  • Page 25: Steering Cylinder

    6. Remove bolts (2) and mounting caps (3) from the Steering Cylinder steer axle. 7. Remove steer axle (4). The steer axle weighs180 Remove & Install Steering Cylinder kg (400 lb). NOTE : Use the following steps to install the steer axle.
  • Page 26 Disassemble And Assemble Steering Cylinder Start By : a. Remove steering cylinder. ICCD068P 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). ICCD065P 1.

  • Page 27: Tires And Rims (Steer)

    Tires And Rims (Steer) Remove And Install Tires And Rims (Steer) ICCD094P 9. Remove O-ring seal (12) and backup ring (13) from each head (1). IA3M4014 1. Put a hydraulic jack in position under the steer axle. 2. Loosen nuts (1) that hold the tire and rim in place. 3.

  • Page 28: Hydraulic Control Valve

    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 IACD222P been stopped. Personal injury can result if the pressure is not released before any work is done 3.
  • Page 29 Disassemble Hydraulic Control Valve Start By : a. Remove hydraulic control valve. IACD225P 5. Remove lift section assembly (6) from the valve body. IACD223P NOTE : For purpose of assembly, put identification marks on all valve sections. 1. Remove three nuts (1) to separate the valve sections.
  • Page 30 IACD228P IACD230P 9. Remove relief valve (14) and O-ring (15) from lift 14. Remove tilt section assembly (26) from the valve section assembly. body. 10. Remove two screws (16) and seal plate (17). 11. Remove lift spool (18). IACD231P 15. Remove O-ring (27), poppet (28) and spring (29) from tilt section assembly (26).
  • Page 31 IACD233P IACD235P 17. Remove two screws (32) and seal plate (33). 20. Remove spring seats (39 and 40), spring (38 and 42) and piston (41). 18. Remove tilt spool (34). IACD236P IACD234P 21. Remove side shift section assembly (43) and 19.
  • Page 32 Assemble Hydraulic Control Valve NOTICE Do not use caustic (corrosive) materials to clean any parts in this valve group. Caustic materials will cause corrosion and damage to parts. IACD229P 1. Make sure all valve parts are clean and free of dirt. 4.
  • Page 33 IACD227P IACD235P 12. Install piston (41), spring (42), spring seats (39 9. Install cap (13) and two screws (12). and 40) and spring (38) on the tilt spool assembly. 13. Compress the spring with spool end (37). Torque the spool end to 8 ~ 11 N¥m (70 ~ 97 lb¥in). NOTE : Do step 6, 7, 9 and 10 to assemble the tilt spool to the tilt section assembly.

  • Page 34: Hydraulic Pump

    6. Fasten a hoist to pump (5). Put the pump and Hydraulic Pump plate assembly in position and install the bolts that hold the pump in place. The weight of the pump is 30 kg (132 lb). Remove and Install Hydraulic Pump 7.
  • Page 35 Disassemble And Assemble Hydraulic Pump IACD242P 4. Remove the bush (3) and examine it carefully. Replace if damaged. IACD239P 5. Remove seal (4) and backup seal (5) from the 1. Position the pump vertically in the vise with the bush. drive shaft facing down, and tighten the vise.
  • Page 36 IACD245P IACD248P 9. Remove the spacer (10). 12. Remove the body (14). If necessary insert two screwdrivers in the recesses and lever upwards. Take care not to damage precision machined surfaces. IACD246P 10. Remove splined coupling (11) and O-rings (12). IACD249P 13.

  • Page 37: Counterweight

    Counterweight Remove And Install Counterweight IACD251P 15. Remove O-ring (21) from the flange (22). 16. Remove the flange (22) from the vise. IACD252P 17. Assemble the hydraulic pump in the reverse order of disassembly. 1. Install two eyebolts in the counterweight. Fasten a hoist to the eyebolts as shown.

  • Page 38: Hydraulic Oil Filter Assembly

    Hydraulic Oil Filter Assembly Transaxle Remove And Install Hydraulic Oil Remove & Install Transaxle Filter Assembly Tools Needed Stand Link Bracket Start By : a. Remove mast * b. Remove floor plate IACD222P * Refer to the mast systems Disassembly & Assembly section for further information.
  • Page 39 IACD256P IACD259P 3. Remove cover (5). 9. Support the engine with a hoist and tooling (B). 10. Support transaxle assembly with a floor jack and wood block. IACD257P 4. Remove cowl plate (6). Disconnect brake tubes (7) IACD260P and parking cables from drive axle. 11.

  • Page 40: Engine

    End By : a. Install floor plate. b. Install mast * * Refer to the Mast System Disassembly & Assembly Section for further information Engine IACD262P 2. Disconnect air intake hose (4). Remove & Install Engine 3. Disconnect battery cables and remove battery (5) and battery tray assembly.
  • Page 41 IACD264P IACD267P 6. Loosen nuts (6) and disconnect exhaust tube (7). 8. Remove bolts (10) and disconnect U-joint (11) from the engine IACD265P IACD260P 9. Remove housing cover. Remove bolts (12) that hold the converter to the flywheel. NOTE : At this point, make a final check to be sure all removals and disconnections have been made from the engine.
  • Page 42 IACD269P 12. 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.

This manual is also suitable for:

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