Page 1 SB2203E00 Vehicle Systems D & A SB2204E00 Hydraulic System Schematic SB2205E00 Electric System Schematic SB2206E00 Mast Systems SB2207E00 OPERATION & MAINTENANCE Operation & Maintenance Menual SB2301E02 Models ; 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 WARNING Do not operate this machine unless you have The proper and safe lubrication and maintenance for this machine, recommended by DAEWOO, are read and understand the instructions in the outlined in the OPERATION & MAINTENANCE OPERATOR'S GUIDE. Improper machine GUIDE for this machine.
Page 3 Reinstall the wiring so it is not damaged nor will it can be hazardous to your health. Components in be damaged in operation by contacting sharp DAEWOO products that may contain asbestos fibers are brake pads, brake band and lining corners, or by rubbing against some object or hot assemblies, clutch plates and some gaskets.
Page 4 SB2004E00 D e c . 1 9 9 8 Specifications TORQUE SPECIFICATIONS...
Page 5 STANDARD TORQUE FOR METRIC FASTENERS NOTE : Take care to avoid mixing metric and inch dimensioned fasteners. Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possible injury. Exceptions to these torques are given in the Service Manual where needed.
Page 6 STANDARD TORQUE FOR INCH FASTENERS Exceptions to these torques are given in the Service Manual where needed. INCH NUTS AND BOLTS THREAD STANDARD TORQUE SIZE inch ± ± ± ± 5/16 18.0 ± ± ± ± 7/16 ± ± ± ±...
Page 7 O-RING FACE SEAL FITTINGS O-RING FACE SEAL FITTING O-RING GROOVE STRAIGHT THREAD O-RING PORT FITTING END O-RING FACE SEAL NUT O-RING IDAS001B STRAIGHT THREAD O-RING FITTING (FOR O-RING FACE SEAL FITTING ONLY) THREAD STANDARD TORQUE SIZE inch ± ± 15 lb 5/16-24 ±...
Page 8 FITTING INSTALLATION 1. Put locknut (3), backup washer (4) and O-ring seal HYDRAULIC LINE INSTALLATION (5) as far back on fitting body (2) as possible. Hold these components in this position. Turn the fitting 1. For a metal tube to hose installation, install the tube into the part it is used on until backup washer (4) just and tighten all bolts finger tight.
Page 9 FLARED AND STRAIGHT THREAD O-RING FITTINGS û O-RING SWIVEL NUTS FLARED û FITTING-PLUG IDAS004B û FLARED AND STRAIGHT THREAD O-RING FITTINGS (EXCEPT O-RING FACE SEAL FITTINGS) THREAD NOMINAL TUBE O.D. STANDARD TORQUE SIZE inch METRIC INCH ± ± 3.18 .125 5/16 ±...
Page 10 FLARED AND 45 INVERTED FLARE FITTINGS û û INVERTED FLARED FLARED û û IDAS007B û FLARED AND 45 û INVERTED FLARE FITTINGS THREAD NOMINAL TUBE O.D. STANDARD TORQUE SIZE inch METRIC INCH ± ± 3.18 .125 5/16 ± ± 4.76 .188 ±...
Page 11 AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS O-RING FLARE û IDAS010B AIR CONDITIONING FITTINGS û FLARE FITTING END O-RING FITTING END STEEL TUBES ALUMINUM TUBES THREAD SIZE STANDARD TORQUE STANDARD TORQUE STANDARD TORQUE inch ± ± ± ± ± ± 5/8-18 ±...
Page 12 SB2201E00 J u n . 1 9 9 9 Service Manual Diesel Engine 5.8 Liter (DB58) D35S-2, D40S-2, D45S-2 D40SC-2, D45SC-2, D50SC-2...
Page 13 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 14 TO THE CUSTOMERS This operation and maintenance manual is designed to serve as a reference for DHI's customers and distributors who wish to gain basic product knowledge on DHI's DB58 Diesel engine. To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
Page 15: Table Of Contents
CONTENTS 1. GENERAL INFORMATION ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ 1.1.
Page 16 6. The use of proper tools and special tools where specified is important for efficient and reliable service operation. 7. Use genuine DAEWOO parts exclusively. 8. Used cotter pins, gaskets, O-rings, oil seals, lock washers and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.
Page 17: Engine Specifications
1.2. Engine Specifications Engine Model DB 58 Items Engine type Water cooled, 4 cycle, vertical in-line, overhead valve Combustion chamber type Direct injection Cylinder liner type Dry type Timing gear system Gear drive type Number of piston ring Compression ring 2, oil ring 1 No.
Page 18: Torque Specifications
1.3. Torque Specifications ¥ Standards bolts The torque values given in the following table should be applied where a particular torque is not specified. (Unit : kg ¥m) Bolt identification Bolt diameter pitch Low carbon steel High carbon steel Alloy steel 0.4-0.8 0.5-1.0 1.25...
Page 19 1.4. Major Parts Fixing Bolts ¥ Cylinder Head and Block (Unit : kg ¥m) 2.1 L 0.5 11.5L05. (hexagon bolt) : (Torque Control Method) 5.3 L 1 4 Kg m + 90û+60û(0~30û) (docoecagon bolt) : (Angle Control Method) 2.7 L 0.25 (19.5 L 1.8) preheating plug 5.3 L 1...
Page 20 ¥ Intake and Exhaust Manifold(DB58) (Unit : kg ¥m) 2.6 L 0.5 2.9 L 0.3 EJM1007S - 5 -...
Page 21 ¥ Cylinder Block (Unit : kg ¥ m) 5.3 L 1 2.6 L 0.5 2.6 L 0.5 2.6 L 0.5 2.1 L 0.5 24.1 L 1 EJM1002S - 6 -...
Page 22 ¥ Oil Pan and Dipstick (Unit : kg ¥ m) 2.9 L 0.3 2.6 L 0.5 8.0 L 1.0 EJM1003S - 7 -...
Page 23 ¥ Cam Shaft and Rocker Arm (Unit : kg ¥ m) 3.1 L 0.5 3.1 L 0.5 2.6 L 0.5 2.6 L 0.5 16 L 1.5 Engine oil application 5.5 L 1 EJM1004S - 8 -...
Page 24 ¥ Crankshaft, Piston, and Flywheel (Unit : kg ¥ m) A type : 12 L 0.25 B type : 9.25 L 0.25 Mark : ON BOLT HEAD B type A type 60 L 5 22.3 L 2.2 EJM1005S - 9 -...
Page 25 Thermostat and Thermostat Housing ¥ (Unit : kg ¥ m) 2.6 L 0.5 5.3 L 1 5.3 L 1 5.3 L 1 5.3 L 1 EJM1006S - 10 -...
Page 26 Timing Gear Case and Flywheel Housing ¥ (Unit : kg ¥ m) 1.75 L 0.5 2.6 L 0.5 2.6 L 0.5 3.75 L 0.9 16.0 L 1.0 Outside 16.0 L 1.0 EJM1010S - 11 -...
Page 27 Oil Cooler, Oil Filter and Oil Pump ¥ (Unit : kg ¥ m) 5.3 L 1.0 5.3 L 1.0 5.3 L 1.0 5.3 L 1.0 5.3 L 1.0 2.6 L 0.5 2.6 L 0.5 EJM1011S - 12 -...
Page 28 Fuel System ¥ (Unit : kg ¥ m) 1.9 L 0.2 1.3 L 0.2 3.1 L 0.2 4.2 L 0.8 EJM1013S - 13 -...
Page 29 1.5. Maintenance 1.5.1. Replacement of Oil Filter ¥ Removal <Remover and Installer> 1) Remove filter as turning it counterclock wise. 2) Do not reuse the used filter. ¥ Assembly 1) Wipe the oil filter mounting face with a clean rag to install a new filter.
Page 30 1.5.3. Water separator 1) Drain plug should be loosened to remove water in fuel filter if necessary. 2) When assembling plug, make to surely keep the forque to be 1.2 L 0.3 kg ¥ m 1.5.4. Injection Nozzle • Disassembly Procedure 1) Fix the injection nozzle with a vise.
Page 31 Carefully keep away from skin and keep off from tester because pressure of nozzle tester is very high when inject. EJM1025S EJM1026S Injection Condition Check (Operating the Nozzle Tester) 1) Tighten cap nut (1) 2) Check injection nozzle opening pressure 3) Check the injection nozzle sparay condition EJM1027S Prior to injecting the fuel completely, compress 4~6...
Page 32 1.5.5. Feed Pump Strainer 1) Release joint bolt A 2) Remove strainer with screwdriver, and wash strainer with light gasoline if necessary. EJM1029S Strainer 1.5.6. Air Bleeding EJM1030S 1) Release the feed pump cap (1) on the Injection pump. 2) Release an air bleed nut (2) on the Injection pump. 3) Operate feed pump as visually seeing until completely remove an air.
Page 33 1.5.7. Cooling System ¥ Cooling Fan Belt Adjustment Depress 1) Check cooling fan belt for cracking and damage. here 2) Check the drive belt deflection by applying a force of 10kg midway between the water pump pulley (2) and the alternator pulley (3). About 3) Adjust the belt tension by loosening the alternator 10mm...
Page 34 1) Bring the piston in either the #1 cylinder or the #6 cylinder to Top dead Center on the compression stroke by turning the crankshaft until the TDC notchecd line on the crankshaft pulley is aligned with the timing pointer. Check to see if there is play in the #1 intake and exhaust valve rocker arms.
Page 35 1.5.10. Injection Timing Carefully keep away dust or foreign articles not to be entered into injection pump when adjusting injection timing. ¥ Checking Procedure 1) Align the crankshaft pulley TDC mark with the pointer. Remove the inspection hole cover at the front of the injection pump on the timing gear case cover.
Page 36 4) Remove the delivery valve holder (1), the valve seat (2), valve spring (3), the delivery valve (4) from the #1 plunger. 5) Assemble the delivery holder (1) and tighten specified torque. Do not assemble valve spring, valve seat and delivery valve.
Page 37 9) Remove delivery valve holder from #1 plunger. 10) Assemble the delivery valve intenal parts at the Holder devilvery valve holder. 11) Assemble the delivery valve holder assembly to #1 plunger and tighten with the specified torque. Seat 4.25 L 0.25 kg ¥m Delivery Valve Holder Torque Spring Delivery Valve...
Page 38 1.6. Engine Repair Parts EJM1053S 1. Cylinder head gasket 17. Gear case to cylinder block gasket 2. Cylinder head cover gasket 18. Cover to timing gear case gasket 3. Inlet manifold gasket 19. Relief valve O-ring 4. Exhaust manifold gasket 20.
Page 39: Engine Disassembly And Assembly
2. Engine Disassembly and Assembly 2.1. Engine External Parts EJM2001I - 24 -...
Page 40: Disassembly
2.2. Disassembly 2.2.1. External Parts svc1 <Disassembly Steps> 1. Cooling fan 5. Injection pump 2. Fuel retrun pipe 6. Oil pipe (Oil filter to oil cooler) 3. Injection pipe 7. Oil filter 4. Injection nozzle - 25 -...
Page 41 2.2.2. External Parts Disassembly Steps SVC2 <Disassembly Steps> 1. Dipstick and guide tube 4. Generator 2. Starter motor 5. Fan pulley 3. Fan belt 6. Cylinder Head cover - 26 -...
Page 42 2.2.3. Major Structured Parts I : Repair Kit EJM2010S <Diassembly Steps> 1. Rubber hose ; coolant by-pass 9. Oil pump driving pinion 2. Rocker arm shaft assembly 10. Starting handle nut 3. Push rod 11. Taper bushing 4. Cylinder head bolt 12.
Page 43 Rocker Arm Shaft Orderly release rocker arm shaft fixed bolts.(as shown in figure) EJM2013S Cylinder Head Bolts Orderly release cylinder head bolts.(as shown in figure) Front EJM2014S Crankshaft Pulley Nuts Crank shaft pulley Use 54mm wrench when removing the crank shaft pulley nut.
Page 44 2.2.4. Major Structured Parts II : Repair kit EJM2018S <Diassembly Steps> 1. Oil Cooler 9. Timing gear case 2. Oil Pan 10. Idle gear shaft 3. Oil Pump and Coupling 11. Crank shaft bearing cap 4. Fly wheel housing 12. Crank shaft bearing (lower part) 5.
Page 45 Idler Gear Prior to disassembly, measure as following. Standard Limit Idle Gear End Play 0.058-0.115 mm 0.2 mm Feeler gauge EJM2019S Standard Limit Timing Gears Backlash 0.10-0.17 mm 0.3 mm The backlash of crank shaft gear & cam shaft gear is equal to idle gear backlash.
Page 46 2.2.5. Rocker Arm, and Rocker Arm Shaft Disassembly Steps EJM2023S <Disassembly Steps> 1. Bracket 3. Spring 2. Rocker arm 4. Rocker arm shaft - 31 -...
Page 47 2.2.6. Cylinder Head Disassembly Steps EJM2024S <Disassembly Steps> 1. Exhaust manifold and gasket 7. Spring seat (upper) or *Valve rotator 2. Intake manifold and gasket 8. Valve spring 3. Coolant outlet pipe 9. Spring seat (lower) 4. Thermostat 10. Valve 5.
Page 48 2.2.7. Piston and Connecting Rod Disassembly Steps EJM2028S <Disassembly Steps> 1. Piston rings 4. Piston 2. Snap ring 5. Connceting rod bearing 3. Piston pin and connecting rod - 33 -...
Page 49 Remove the piled up carbon at the upper of cylinder bore to prevent damage of piston when removing it. Carbon deposits EJM2029I Piston Rings Remove the piston ring with piston ring remover. Piston ring remover EJM2030I Snap Ring and Piston Pin 1) Use the snap ring pliers when removing the snap ring.
Page 50 2.3. Inspection and Repair Adjust and repair if necessary, and replace the excessively worn or damaged parts which were found at inspction. 2.3.1. Cylinder Head Lower face flatness 1) Use a straight edge and a feeler guage to measure the four sides and the two diagonals of the cylinder head lower face.
Page 51 2.3.2. Valve Stem and Valve Guide Clearance Measuring Method-1 1) Install of dial gauge needle with valve stem assembled as figure. Set up calibrator to "O". 2) Shake well valve head. Record total dial indicator reading. Valve and guide set must be replaced if measured value was exceeded the specified limit.
Page 52 Valve Depression 1) Install the valve (1) to the cylinder head (2). 2) Measure valve depression with a depth gauge or calibrator from the bottom of cylinder head. Seat insert and valve must be replaced if the measured value exceeds the specified limit. When replacing valve, the valve guide must be surely replaced.
Page 53 Correction of Valve Seat Insert 1) Remove the carbon deposits from the valve seat 60˚ insert surface. 2) Remove the rough areas with a valve cutter (15˚, 30˚ or 75˚) Do not cut the valve seat insert too much. EJM2045I Contacting Angle(B) Standard...
Page 54 2.3.3. Valve Spring • Valve Spring Free Length Measure the valve spring with the vernier caliper. Replace the spring if the measured value is out of the specified limit. Standard Limit Exhaust and Intake Valve 49.0 mm 47.0 mm EJM2049I Spring Free Length •...
Page 55 2.3.4. Tappet Check the valve tappets whether excessive wear and damage or not. Inferiority of Pitting Clack contact Irregularity of EJM2041I contact Measure the outside diameter of tappets with a micrometer. Standard Limit Tappet Outside Diameter 27.97-27.98mm 27.92mm EJM2052S Measure the clearance between tappets and cylinder hole with a dial indicator Standard Limit...
Page 56 2.3.6. Rocker Arm Correction Check the valve stem contact part of roker arm. Grind contact surface with an abrasive if it is irregularly contacted. Replace the rocker arm if it is extremely damaged. EJM2055S Rockder Arm Shaft and Rocker Arm Check the disassembled parts whether damaged or not.
Page 57 Standard Limit Clearance Between Rocker Arm 0.01-0.05 mm 0.2 mm Bushing and Shaft 3) Check the rocker arm shaft oil port whether alien substance is in it or not. Clean the rocker arm shaft oil port with an air if necessary.
Page 58 3) Align oil port of the cam shaft and the cylinder oil port. oil ports EJM2064S 4) Measure the cam lobe with the micrometer. Replace the cam shaft if the measured value is out of the specified limit. Standard Limit Cam Lobe Height (C-D) 7.71 mm 7.21 mm...
Page 59 Inspection of the Cylinder Liner Projection 1) Set up the straight measure (1) at the top part of liner. 2) Measure liner projection with the feeler gauge (2). Limit Projection of cylinder Liner 0.03-0.10 mm Inequality of liner projection to other clylinder must be less than 0.03mm.
Page 60 Measurement of Cylinder Liner Outside Diameter 1) Measure the liner outside diameter from (1), (2) & (3) measuring point toward X-X, Y-Y. Location of the Measuring point. (1) 20.0 (2) 105.0 (3) 195.0 2) Average value for 6 measurements should be used to moderately determine the liner grade.
Page 61 2.3.10. Piston • Selection of Piston Grade Correctly selected pistion grade to operate engine efficiently. Meassure the bore after assembling the cylinder liner. Determine piston grade after assembling liner. EJM2077I • Measurement of Cylinder Liner Bore 1) To be measured at 2 points. Cylinder Liner Bore Measuring Point (1) : 20mm Cylinder Liner Bore Measuring Point (2) : 105mm 2) Measure cylinder liner bore from (1), (2) &...
Page 62 • Piston Ring and Piston Ring Groove Clearance Measure the piston ring and the piston ring groove clearance with a feeler gauge. Measure it around of the piston. Replace the piston ring if the measured value is out of the specified limit. EJM2080S •...
Page 63 • Piston Pin Measure the pin outside diameter with micrometer. Replace the pin if the measured value is out of the specified limit. Standard Limit Piston Pin Outside Diameter 36.000-36.005 mm 35.95 mm EJM2083S • Piston Pin Hole Measure diameter of the pin hole with inside dial gauge.
Page 64 2.3.11. Connecting Rod • Connecting Rod Alignment Measure the alignment between big end and small end with connecting rod balancer. Replace the connecting rod if the measured value is out of the specified limit. Connecting Rod alignment ( at 100 mm distance) Standard Limit EJM2087S...
Page 65 • Check of Connecting Rod Bearing 1) Assemble the bearing to connecting rod cap. 2) Check the tension of connecting rod bearing. Replace the bearing if the tension is lack. 3) Tighten the connecting rod bearing cap to the specified bolt torque. A type B type Bolt Torque...
Page 66 • Crankshaft Main Bearing Inside Diameter 1) Tighten to the specified torque after assembling cap for the arrow of the bearing cap to be toward front of engine. 2) Measure main bearing diameter with a inside dial gauge. Main Bearing Cap Torque 24.1 1 kg •m Main Bearing Diameter...
Page 67 • Crankshaft Run-Out 1) Mount the crankshaft on a set of V-blocks. 2) Set up the dial indicator to the center of crankshaft journal. 3) Slowly rotate the crank shaft. Read the dial indicator (TIR) as you turn the crankshaft. Replace the crank shaft if the crank shaft measured value is out of the specified limit.
Page 68 • Grinding Limit of Crankshaft Classification Limit Crank Jouranl Outside Diameter 79.405 mm Crank pin Outside Diameter 63.424mm Use the undersize bearing (0.25, 0.5 mm) when the main bearing clearance was in excess of limit. Regrind the crank shaft in comply with below standard if undersize bearing is used.
Page 69 2.3.13. Flywheel and Flywheel Housing (Rear Oil Seal) • Inspection of Ring Gear Replace the ring gear when wear of damage is found. If the ring gear tooth are broken or excessively worn, the ring gear must be replaced. • Disassembly of Ring Gear Disassemble the ring gear with a hammer and a chisel.
Page 70 2.4. Reassembly 2.4.1. General Parts EJM2103S <Order of Assembly > 1. Piston 4. Piston ring 2. Piston pin and connecting rod 5. Connecting rod bearing 3. Snap ring - 55 -...
Page 71 • Piston and Connecting Rod Heater of piston Heat piston approximately 60˚C. 1) Assemble the piston and connecting rod with the pin. EJM2104S • Piston Pin Snap Ring Piston head 1) Assemble the piston pin and piston ring with snap ring plier.
Page 72 • Assembly parts of Cylinder Head 8 : Repair Kit EJM2107S <Order of Assembly> 1. Valve stem oil seal 7. Thermostat housing and gasket 2. Intake and exhaust valves 8. Thermostat 3. Spring seat(Lower) 9. Coolant outlet pipe 4. Intake and exhaust valve sping 10.
Page 73 • Valve Stem Oil Seal 1) Spread the engine oil to oil seal and the assembled part. 2) Assemble the valve stem oil seal. EJM2109S • Intake and Exhaust Valves 1) Put the cylinder head on plate. 2) Spread the engine oil to valve stem. 3) Assemble valves in guicle.
Page 74 • Intake Manifold and Gasket Unchamfered corner 1) Assemble the intake manifold of which unchamfered corner is toward up and rear of engine. 2) After assembling intake manifold, and assemble the bolt to the specified torque in order. (see figure) Intake Manifold Bolt Torque 2.
Page 75 • Assembly of Rocker Arm and Rocker Arm Shaft EJM2119S <Order of Assembly> 1. Rocker arm shaft 3. Rocker arm 2. Spring 4. Bracket • Rocker Arm Shaft Assemble the rocker arm shaft of which oil hole is toward up. - 60 -...
Page 76 2.4.2. Inside parts • Main Components (I) 8 : Repair Kit EJM2120S <Order of Assembly> 1. Crank shaft bearing 8. Idler gear shaft 2. Crank shaft 9. Idler gear 3. Thrust bearing 10. Piston and ocnnecting rod 4. Crankshaft bearing and crank shaft bearing cap 11.
Page 77 Caution Oil port and oil groove Correctly set up for upper bearing • Crank shaft Bearing (Upper Half) All upper bearing have oil port and groove. • Crank shaft Bearing(Lower Half) No oil port and oil groove for lower bearing EJM2122S •...
Page 78 Tightened Torque 24. 0 1 kg •m 4) Check it whether the crank shaft is smoothly rotated by hand or not. Spread of Engine Oil EJM2126S • Timing Gear Case Tighten timing gear case bolt to the specified torque. Tightened Torque 0.5 kg •m EJM2127S •...
Page 79 • Piston and Connecting Rod 1) Fix the position of piston ring (see figure) 2) Spread engine oil to piston, pinston ring, connecting rod bearing. 3) Piston front mark should be directed to front of engine. EJM2131S 4) Use the piston ring compressor when assembling Piston ring compresser pistion.
Page 80 Oil Pump mounting Bolt Torque 1.0 kg •m Coupling Bolt EJM2135S • Flywheel Housing Tighten bolt to specified torque after liquid gusket is applied on the gasket. Bolt Torque 16.1 1 kg •m EJM2172S • Oil Pan 1) Install an oil fan after putting on oil fan gasket and liquid gasket between cyliner block and oil fan.
Page 81 • Major Component Reassembly Parts (II) : Repair Kit EJM2139S <Reassembly Steps> 1. Rubber hose 9. Oil pump driving pinion 2. Push rod 10. Crankshaft pulley nut 3. Rocker arm and rocker arm shaft 11. Taper bushing 4. Cylinder head bolt 12.
Page 82 • Flywheel 1) Apply engine oil on the flywheel bolt. 2) Orderly tighten the fly wheel bolt.(see figure) Bolt Torque 22.3 2.2 kg •m Lubricate with enging oil EJM2142S • Injection Pump Tighten the injection pump bolts to a specified torgue for "C"...
Page 83 • Water Pump Spread liquid gasket Prior to putting the gasket, spread a liquid gasket. EJM2146S • Cylinder Head Gasket Front, TOP Make sure mark "Top" is up and mark "Front" is down. Front EJM2147S • Assembled Cylinder Head Orderly and repeatedly tighten bolts with engine oil at the cylinder head, as shown in figure.
Page 84 2.4.3. External Parts(A) SVC2 <Reassembly Steps> 1. Cylinder head cover 4. Fan belt 2. Fan pulley 5. Starter motor 3. Generater 6. Dipstick and guide tube - 69 -...
Page 85 • Cylinder Head Cover Orderly tighten the bolt as it is shown in figure. Bolt Torque 0.5 kg •m EJM2172I • Fan Belt Adjust the fan belt tension See the 1.5.7. colling fan belt. • Starter Motor Tighten bolts to the specified torque after assembling a starter motor to fly wheel housing.
Page 86 2.4.4. External Parts (B) SVC1 <Reassembly Steps> 1. Oil filter 5. Injection nozzle 2. Oil pipe (Oil filter to oil cooler) 6. Fuel return pipe 3. Injection pump 7. Cooling fan 4. Injection pipe - 71 -...
Page 87 • Injection Nozzle Ajdust the injection opening pressure with an Dust cover adjustment screw. Use a new gasket and dust cover when assembling the nozzle. Torque 0.2 kg •m Nozzle gasket EJM2163S • Fuel Injection Pipe Surely tighten the delivery valve holder to a specified torque.
Page 88: System Of Lubrication
3. System of Lubrication 3.1. General Description (13) (14) (15) (16) (17) (18) (19) (20) (10) (12) (21) (22) (23) (11) (24) EJM3001I (1) Full flow filter (13) Oil pressure and oil filter warning lamp (2) By-pass valve (14) Starter switch (3) Valve opening pressure 1kg/cm (15) Battery (4) Valve opening pressure 8kg/cm...
Page 89: Oil Pump
3.2. Oil Pump • Disassembly EJM3002S <Order of disassembly> 1. Strainer 4. Pinion 2. Suction pipe 5. Drive shaft and gear 3. Cover and dowel 6. Pinion gear shaft - 74 -...
Page 90 • Inspection and repair Visually Inspect the disassembled parts whether there are excessive wear or damage. Use a feeler gauge to measure the clearance between the oil pump cover (oil pump case) inside surface and the driven gear. If the clearance exceeds the specified limit, the drive gear and/or the oil pump cover must be replaced.
Page 91 3.3. Oil Cooler • Disassembly EJM3008S <System of Disassembly> 1. Element. 4. O-ring ; plug 2. Element gasket 5. By-pass valve spring 3. By-pass vlave plug 6. By-pass valve Inspection and Repair Correct and replace it if there are worn or defect parts. - 76 -...
Page 92 • Reassembly Reassembly is reverse order of disassembly. EJM3009S <Reassembly order> 1. By-pass valve 4. By-pass valve plug 2. By-pass valve spring 5. Element gasket 3. O-ring : plug 6. Element. • Oil cooler element tigthening bolts Tighten the bolts with the specified torque after assembling an oil cooler element.
Page 93: Cooling System
4. Cooling System 4.1. General Description Water pipe Thermostat Cylinder head Radiator Reserve tank Cylinder block Water pump EJM4001I - 78 -...
Page 94 4.2. Coolant Pump Disassembly EJM4003S <Disassembly order> 1. Pulley 5. Pulley Flange 2. Cover 6. Snap ring 3. Gasket 7. Seal 4. Impeller 8. Impeller shaft - 79 -...
Page 95 Remover • Impeller Remove the impeller with a jig. EJM4005S • Hub Remove the bearing by pressing with a bench press. Bench press EJM4006S • Snap Ring Remove the snap ring with a snap ring plier. EJM4007S • Seal Unit and Washer Seal Remove the seal unit with a hammer.
Page 96 • Reassembly EJM4013S <Reassembly order> 1. Unit Bearing 5. Impeller 2. Seal 6. Gasket 3. Snap Ring 7. Cover 4. Pulley Fiange 8. Pulley - 81 -...
Page 97 • Unit Bearing Spreading of multipurposable grease With bench press, set up the unit bearing at the pump. Outside from sealed surface EJM4011I • Snap Ring Assemble the snap ring with a snap ring plier. EJM4007S • Pulley Center Assemble pulley center with a bench press. EJM4015S •...
Page 98: Fuel System
5. Fuel System 5.1. General Description Injection nozzle Fuel filter Injection pump Fuel tank EJM5001I - 83 -...
Page 99: Fuel Filter
5.2. Fuel Filter • Disassembly EJM5020S <Disassembly> 1. Cover 4. Cartriage 2. Seal ring 5. Bolt ass’y 3. Plug screw Refer to section 1.5.2., 1.5.3. for information on the cartridge type fuel filter. Inspection and repair Make the necessary adjustments, rapairs, and part replacements if excessive wear or damage is discovered during inspection.
Page 100 5.3. Injection Nozzle • Disassembly EJM5003S <Disassembly> 1. Nozzle holder cap nut. 7. Retaining nut. 2. Cap nut gasket. 8. Injection nozzle. 3. Nozzle adjusting screw. 9. Injection pipe connector. 4. Spring seat. 10. Connector gasket. 5. Push rod spring. 11.
Page 101 Inspection and Repair Correct and replace it if there are worn or defect parts. • Push Rod Spring Check wear, damage and corrosion, etc. EJM5005S • Nozzle Holder Push Rod 1. Check the nozzle holder push rod curvature. 2. Check whether connected surface with needle valve is damaged or not.
Page 102 • Reassembly Reassembly is reverse order of disassembly. EJM5008S <Reassembly order> 1. Nozzle holder body 7. Pushrod spring 2. Connector gasket 8. Spring seat 3. Injection pipe connector 9. Nozzle adjusting screw 4. Injectin nozzle 10. Cap nut gasket 5. Retaining nut 11.
Page 103 Nozzle Connector Torque 5.5±0.5 kg • m EJM5009S • Injection Nozzle Clean injection nozzle Assemble nozzle to be correctly fixed to dowel pin on nozzle hold body. EJM5010S • Retaining Nut Torque 7±1 kg • m EJM5011S • Adjustment of Screw Adjust with the adjustment screw.
Page 104: Injection Pump
5.4. Injection Pump 5.4.1. Adjustment of Injection quantity. 101605-9630 Injection quantity shonld be adjusted, 0000000000(Serial NO) seeing adjustment data of injection pump model as Pump NO. 101062-8120 described below. NP-PE S6A95C410RS2000 LICENCE BOSCH EJM5014I 5.3.2. Calibration data <Test conditions> Injection pump 101605-9630 Injection nozzle D.P.I.C.
Page 105 5.4.2. Injection Pump Disassembly 133a 131a 130a 132a 104a 112a 115a 118a 117a 92a 93a 91a 101a 154 152 91 93 92 122 121 18 23 20 21 196 195 194 192 191 EJM5018S 1. Pump Housing 56. Shim 117a. Pipe connectin bolt 2.
Page 106 5.4.3. Governor Disassembly 4 236 6 10 9 183 170 181 130 150 103 102 100 10 44 174 211 207 205 182 47 141 332 136 220 50 13 201203 80 238 49 39 190 198 192 EJM5019S 1. Governor housing 80.
Page 107 6. Cause of Trouble, Diagnosis and Troubleshooting 1) Starting Trouble Statement Cause Remedy Start Motor (1) Magenetic switch does not operate when turn starter swicth Trouble of circuit 1. Distribution inferiority, disconnection, connection inferiority, Correction 2. starter switch connection inferiority Replacement 3.Coil disconnection of magenetic switch, strain Replacement...
Page 108 Statement Cause Remedy Insufficient of compression pressure (1) Damage of cylinder head gasket, replacement (2) Piston, piston ring or cylinder liner wore, replacement (3) Piston ring Strain, replacement (4) Unfitness of valve clearance, adjustment (5) Valve and seat connection inferiority, adjustment (6) Valve stem attachment replacement...
Page 109 Statement Cause Remedy (4) Nozzle injection pressure or unsuitable of injection angle correction or replacement (5) Decline function feed pump correction or replacement (6) Shortage of suction valume Maitenance of air cleaner (7) Throttle valve fix correction or replacement Overheat (1) Shortage of coolant Suppliment &...
Page 110 5) Fuel consumption excessive Statement Cause Remedy Trouble of (1) Uncorrect of injection timing adjustment fuel system (2) Fuel injection excessive valume adjustment Other (1) clutch skip correction or replacement (2) brake inferiority correction or replacement (3) unsuitable tire pressure adjustment (4) unsuitable of gear selection seelection gear due to load...
Page 111 SB2134E00 O c t . 1 9 9 8 Service Manual DAEWOO Automotive Comp.Ltd. HC45 Series Alternators...
Page 112 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 114 Index Specifications Alternator..............5 Systems Operation Alternator..............6 HC 45 Alternator Operation ......6 Alternator Components ......7 Alternator Operation Schematic ....9 Introduction ............6 Testing And Adjusting Alternator ............... 11 Alternator Output Test ......11 Machine Test .......... 11 Troubleshooting.............
Page 116 DAEWOO D.A.C. Series Voltage Part No. Part No. A124041 219154 HC45 ICBS401P HC45 Alternator End View ALTERNATOR SPECIFICATIONS DAEWOO Part No. A124041 D.A.C. HC45 Voltage Rating Polarity Neg. Gnd. Rotation Test Speed 5000 rpm Rated Output (Cold) 28.5 L 0.4V...
Page 117 Systems Operation The alternator converts mechanical and magnetic Alternator energy to alternating current (AC) and voltage. This process is done by rotating a direct current (DC) electromagnetic field (rotor) inside a three phase Introduction stator. The alternating current and voltage (generated by the stator) are changed to direct current by a three phase, full wave rectifier system using six silicone The HC45 D.A.C.
Page 118 Alternator Components ICBS403P Alternator Components-Inside View of Rear Frame (2) Rear frame. (7) Brush holder. (9) Regulator. (10) Rectifier. The major components of the alternator are stator (4), rotor (3), rectifier (10), regulator (9), brush holder (7) and frames (2) and (5). The HC45 alternators feature a high ampere output per pound of weight, with a totally new and different regulator.
Page 119 ICBS404P Rotor (1) Slip rings. (3) Rotor. (8) Internal fan. Rotor (3) consists of a core, coils and slip rings (1). The rotor provides the magnetic field between the rotor field winding and the stator. Slip rings (1) provide the surfaces for brush contact. Internal fan (8) pulls air through the rear frame to cool the ICBS402S rectifier bridge and regulator.
Page 120 Alternator Operation Schematic The field current is sufficient to cause the alternator to turn on when the engine is started. At engine idle The integral charging system schematic and speeds, voltage induced in the stator will cause the explanation that follow indicate the terminals and stator to supply field current and also output voltage basic circuitry for the HC45 series alternator.
Page 121 Testing And Adjusting Problem 2: Alternator Charge Rate Is Low Or Not Regular Probable Cause: Troubleshooting 1. Loose Drive Belt For Alternator: Adjust the alternator drive belt. 2. Loose Alternator Drive Pulley: Troubleshooting can be difficult. On the page that Check the pulley for wear.
Page 122 Alternator Alternator Output Test NOTE: If the HC45 alternator fails this test, it must be replaced. It is only serviced as a complete unit. Tools Needed Digital Multimeter or Equivalent AC/DC Clamp-On Ammeter Machine Test 1. Put the multimeter positive (+) lead on the Bat terminal of the alternator.
Page 123 FAULT CONDITIONS AND POSSIBLE CAUSES CHART Current At Voltage After About Voltage After About Voltage After About Start-Up 10 Min. Is Below Spec. 10 Min. Is In Spec. 10 Min. Is Above Spec. Repair alternator (Defective Turn on all accessories. regulator, open stator phase, If voltage drops below spec., Below Specification.
Page 124 SB2135E00 O c t . 1 9 9 8 Service Manual Poong Sung R4.5 Reduction Starting Motor...
Page 125 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 127 Index Specifications Starting Motor............5 Systems Operation Starting Motor............7 Introduction ............7 Starting Motor Operation Diagrams ....10 Testing And Adjusting Starting Motor............14 Off Machine No Load Test ........ 17 On Machine Starting Motor Diagnosis Procedure ............. 14 Starting Motor Component Tests ......
Page 129 Specification Starting Motor ICBS403I ICBS406P Poong Sung Specifications...
Page 130 REDUCTION STARTING MOTOR SPECIFICATIONS Starting Motor Series R4.5 Rated Voltage 24 V Solenoid (Switch): Pull-In Winding Resistance 0.86 ½ Hold-In Winding Resistance 2.88 ½ Pull-In Winding Current Draw at 24V 45 A Hold-In Winding Current Draw at 24V 15 A No Load Test: Minimum Voltage 24 V...
Page 131 Systems Operation Starting Motor Introduction The Poong Sung Reduction Starting Motor is a medium duty unit that is offered in 24 Volt versions. ICBS407P Poong Sung Starting Motor The starting Motor is used to turn the engine flywheel fast enough to make the engine run. The starting motor has a solenoid.
Page 132 Starting Motor Components ICBS403I Starting Motor Components (1) Housing. (2) Armature. (3) Brushes. (4) Brush holder. (5) Starting motor case. (6) Frame. (7) Idler reduction gear. (8) Overrunning clutch gear. (9) Field winding. (10) Pinion gear. (11) Overrunning clutch. (12) Solenoid (switch). The major components of the starting motor are case (5), field winding (9), armature (2), brushes (3), brush holder (4), gears (7) and (8), pinion gear (10),...
Page 133 Brushes (3) are made of carbon and conduct electricity. The brushes transmit current from the field winding to the commutator. There are four brushes. Two of the brushes are positive (+) and are welded to the field winding leads. Two of the brushes are negative and are connected to case ground.
Page 134 General Information ICBS406S Solenoid (Switch) (12) Solenoid. (17) Solenoid contacts. (18) Hold-in coil. (19) Pull-in coil. (20) Return spring. (21) Plunger. Solenoid (12) contains solenoid contacts (17), hold-in coil (18), pull-in coil (19), return spring (20) and plunger (21). When the ignition or key start switch is closed, pull-in coil (19) and hold-in coil (18) are 11 12 13 energized.
Page 135 Operation 11 12 13 14 15 ICBS409S Solenoid Contacts Closed ICBS408S (1) Armature reduction gear. (2) Armature. (3) Field winding. (4) Brushes. (5) Idler reduction gear. Ignition Or Key Start Switch Closed (6) Overrunning clutch gear. (7) Pinion. (8) Overrunning clutch. (1) Armature reduction gear.
Page 136 ICBS410S Ignition Or Key Start Switch Released (1) Armature reduction gear. (2) Armature. (3) Field winding. (4) Brushes. (5) Idler reduction gear. (6) Overrunning clutch gear. (7) Pinion. (8) Overrunning clutch. (9) Solenoid contacts. (10) Plunger. (11) Return spring. (12) Hold-in winding. (13) Solenoid. (14) Pull-in winding. (15) Ignition or key start switch.
Page 137 Testing And Adjusting 5. Solenoid windings disconnected or short circuited: Replace the solenoid (switch). 6. Ignition or key start switch or solenoid or relay (if Troubleshooting equipped) damaged: Replace ignition or key start switch or solenoid or Troubleshooting can be difficult. Following is a list of relay as needed.
Page 138 5. Damaged or broken armature or idler or clutch Starting Motor gear: Replace armature or idler gear or overrunning clutch as needed. On Machine Starting Motor Diagnosis Procedure Problem 3: Armature turns and pinion engages ring gear, but engine does not crank. The following is a simplified procedure intended to help the serviceman to determine if a starting motor Probable Cause:...
Page 139 ICBS404I Typical Starting Circuit (1) Test point. (2) Test point. (3) Test point. (4) Test point. (5) Test point. (W) Pull-in coil. (X) Hold-in coil. General Information The starting motor solenoid has two coils. Pull-in coil All starting systems are made up of four elements. (W) draws about 40 amps and hold-in coil (X) requires They are the ignition or key start switch, start relay, about 5 amps.
Page 140 Battery voltage (power) available during cranking If the starting motor cranks real slow or not at all, do varies according to the temperature of the batteries. the following procedure: The following chart is a guide as to what to expect 1.
Page 141 8. Turn the engine over by hand to make sure it is not locked up. Check oil viscosity and any external loads that would affect engine rotation. DIGITAL 9. Is the engine locked up and/or hard to turn? MULTIMETER CLAMP-ON a.
Page 142 No Load Test Results Starting Motor Component Tests Following are some no load test results that could be Tools Needed seen and corresponding possible problems. Digital Multimeter or Equivalent 1. Rated current draw and no load speed indicates Growler Tester normal starting motor condition.
Page 143 Field Winding Continuity Test Armature Tests Armature Short Circuit Test ICBS413S Field Winding Continuity Test (1) Field winding leads. (2) Motor (Mtr) terminal lead. ICBS414S 1. Put the multimeter on the 200 ohm resistance (½) scale. Touch the meter leads between field Armature Short Circuit Check (3) Armature.
Page 144 Armature Ground Test Armature Runout Check ICBS415S ICBS416S Armature Winding Ground Test Armature Runout Check (3) Armature. (5) Commutator. 1. Put the multimeter on the 20M resistance (½) 1. Check the armature runout (TIR) of commutator scale. Touch one meter lead on each commutator (5).
Page 145 Brush and Brush Holder Checks Brush Holder Test ICBS418S Depth Of Segment Mica (X) Depth of segment mica. ICBS419S 3. Measure the depth of commutator segment mica. The minimum depth should be 0.20 mm (.008 in.) Brush Holder Insulation Test (6) Brush holder plate.
Page 146 Brush Length Check Overrunning Clutch Check ICBS420S ICBS421S Brush Length Measurement Overrunning Clutch Check. (X) Brush Length. (9) Housing. (10) Pinion. 1. Measure brush length (X) for wear. The new and 1. Visually inspect the overrunning clutch for minimum brush lengths are shown in damage.
Page 147 Disassembly And Assembly Starting Motor NOTE: The disassembly and assembly that follows is of a R2.0 series starting motor. The other motors are similar. Disassemble Starting Motor Start By: ICBD403S a. remove starting motor 3. Remove motor case (3) from solenoid (2). ICBD401S ICBD404S 1.
Page 148 ICBD405S ICBD407S 5. Remove armature (8) from motor case (3). It may 7. Remove housing (4) from solenoid (2). be necessary to use a plastic or rubber hammer to drive the case from the armature. ICBD408S ICBD406S 8. Remove overrunning clutch (9) from the housing (4).
Page 149 ICBD409S ICBD411S 9. Remove steel ball (10) from overrunning clutch 11. Remove retainer (12) and rollers (13) from (9). housing (4). ICBD410S ICBD412S 10. Remove idler gear (11) from housing (4). 12. Remove return spring (14) from solenoid (2). NOTICE Do not use a liquid cleaning agent to clean the armature, field winding, or overrunning clutch.
Page 150 Assemble Starting Motor ICBD412S 1. Install return spring (14) into solenoid (2). ICBD413S R2.0 Series Reduction Starting Motor (1) Motor (Mtr) Terminal Lead Wire. (2) Solenoid. (3) Starting Motor Case. (4) Drive End Housing. (5) Brush Springs. (6) Brushes. (7) Brush Holder. (8) Armature. (9) Overrunning Clutch.
Page 151 ICBD407S ICBD409S 4. Put steel ball (10) into overrunning clutch (9). 6. Put drive end housing (4) on solenoid (2) and install the screws. Tighten the screws to a torque of 0.6 to 0.9 NIm (5 to 8 lbIin). ICBD408S ICBD405S 5.
Page 152 LEAD WIRE GROMMET ICBD414S ICBD415S 8. Put brush holder (7) in position over the 10. If the motor case has an end frame (15), install it commutator. Put the positive brushes [connected onto the case. Engage the tab on the end frame to motor case (3)] in the positive holders with the lead wire grommet on the motor case.
Page 153 ICBD401S 12. Connect lead wire (1) to the motor (Mtr) terminal of solenoid (2). End By: a. install starting motor Poong Sung Specifications...
Page 154 SB2110E00 F e g . 1 9 9 8 Specifications Systems Operation Testing & Adjusting Gasoline Engine GM V ortec V6 (4.3 Liter)
Page 155 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, Iubrication, maintenance or repair procedures you choose.
Page 157 Index Specifications Alternator ...............13 Ignition System ............29 Balance Shaft............16 Breakerless Ignition System ......29 Belt Tension ............13 Liquid Petroleum Fuel System .......22 Camshaft..............16 Carburetor ............25 Carburetors ..............7 Converter ............23 Cylinder Heads ............18 Electric Fuelock Models ........22 Distributor..............8 Fuel Tank ............24 Electric Fuelock............7 LP Relief Valve ..........24 Engine Assembly ...........19 Lubrication System ..........28...
Page 158 Governor Adjustment ..........56 Velocity Governor ...........56 Ignition System ............48 Ignition Component Checks ......48 Ignition Timing Check & Adjust .......50 Spark Plug Gap Check ........49 Liquid Petroleum Fuel System .......56 Carburetor Adjustments ........56 Converter Pressure Test .........59 Fuel Filter Check ..........58 Inner Fuel System Leak Check .......59 Outer Fuel System Leak Check ......58 Recommendation For LP Fuel Systems ..59...
Page 159 Specifications Ignition Timing Ignition Sequence (Firing Order) ENGINE TIMING CONNECTIONS FLYWHEEL TIMING MARKS Install Timing Light Clamp on No. 1 Spark Plug Wire Connect Red Clip to Positive (+) Battery Terminal Connect Black Clip to a Good Ground IAGS003S IAGS001S The correct timing is when the flywheel housing Engine firing order ........1-6-5-4-3-2 pointer is in alignment with the correct mark on the...
Page 160 LP Governor LP Converter IAGS006S MAIN SPEED ADJUSTING SCREW IAGS005S (1) Adjust the LP high idle speed ..2600 L 50 rpm (1) Turn all the screws in until contact is made with cover, then tighten screws thoroughly from one NOTE : Clockwise rotation of the main adjusting side to the opposite side until all the screws have screw will increase the engine speed, and a good seat.
Page 161 Electric Fuelock Carburetors Low Idle Setting IAGS008S Resistance of solenoid ........18 ohms IAGS010S (1) Adjust the LP low idle speed to..700 L 25 rpm. Spark Plug & Spark Plug Wires Idle Mixture Setting IAGS009S Spark plug gap (gasoline & LP) ..1.5 mm (.06 in) IAGS011S Torque for spark plugs (New Head) ............30 N ¥...
Page 162 Power Mixture Setting Distributor IAGS012S (1) Adjust power mixture to maximum rich (R) setting (initial setting). (2) Tighten nylon vacuum fitting finger tight plus an additional 360û (one full turn). Then turn farther to desired location. See Carburetor Adjustments of the Liquid Petroleum IAGS013S Fuel System in the Testing And Adjusting section.
Page 163 Sensor Gap IAGS014S The Air gap (X) between the trigger wheel and the module is preset by General Motors. Therefore no adjustment can be made or is required. Pole Piece Pickup Coil IAGS015S GM 4.3 Liter Gasoline Engine 9 of 75 Specifications...
Page 164 Starting Motor Delco Remy PG260 IAGS016S Rotation is Clockwise When Seen From the Drive End. For complete specifications on the starting motors, see the Starting Motor Coverage chart for the correct Service Module. STARTING MOTOR COVERAGE Starting Motor Manufacturer/Series Part Number A232158 Reduction Minimum speed with no load......2925 rpm...
Page 165 Oil Pan Oil Filter IAGS020S IAGS018S Tightning Specifications for Oil Filter Tightning Specifications for Oil Pan (1) ..............Oil Pan (1) Wipe clean the filter adapter in the area that the new filter makes contact. Put clean engine oil on (2) Torque for Plug......45 N ¥ m (33 Ib ¥ ft) the new filter gasket.
Page 166 Exhaust Manifolds Intake Manifolds INITIAL TIGHTENING SEQUENCE FINAL TIGHTENING SEQUENCE IAGS021S IAGS023S Exhaust Manifold Left Side Tightning Specifications for Intake Manifolds Intake manifold bolt in three steps using sequence shown in IAGS023S First pass ........3 N ¥ m (27 Ib ¥ ft) Second pass .......12 N ¥...
Page 167 Belt Tension Alternator For complete alternator specifications, see the Alternator Coverage chart for the correct Service Module ALTERNATOR COVERAGE Alternator Manufacturer/Series Part Number 8C5510 Delco Remy/CS-121 Delco Remy CS-121 Series IAGS024S Belt tension is preset at the factory and cannot be changed.
Page 168 Flywheel Housing Flywheel IAGS029S IAGS027S (1) Flywheel housing bolts should be torqued to (1) Torque for the bolts that hold the flyweel to the .......40 to 45 N ¥ m (30 to 35 Ib ¥ ft) crankshaft ......100 N ¥ m (74 Ib ¥ ft) (2) Use a torch.
Page 169 Flywheel Runout Pressure Cap For checking procedure, see Flywheel And Flywheel Housing in the Testing And Adjusting section. Face Runout (Axial Eccentricity). IAGS032S For testing procedure, see Cooling System Tests in the Testing And Adjusting section. Pressure valve opening pressure ........85 to 110 kPa (12 to 16 psi) IAGS030S Vacuum valve opening pressure...
Page 170 Camshaft Balance Shaft IAGS034S IAGS035S (1) Torque for camshaft sprocket bolts (1) Front Bearing Journal Diameter ..........20 N ¥ m (15 Ib ¥ ft) ...55.985 to 55.001 mm (2.1648 to 2.1654 in) (2) Torque for retainer mounting bolts (2) Rear Bearing Journal Diameter ..........12 N ¥...
Page 171 Front Gear Cover IAGS036S Height of camshaft lobes. IAGS037S (A)Intake lobe ......7.018 mm (.2763 in.) (1) The front gear cover (1) of the engine must be (B)Exhaust lobe ......7.252 mm (.2855 in.) replaced if it is removed for any reason. The cover is made of high impact plastic but can warp do to (C)Maximum permissible difference actual &...
Page 172 Cylinder Heads Valve Clearence Tools Needed Torque Angle Meter IAGS039S (1) The 4.3 liter engine has screw-in rocker arm studs with positive stop shoulders, NO valve adjustment is necessary. When the valve train requires IAGS038S service you simply tighten the rocker arm nuts to 25 N •...
Page 173 Fastener Tightening Spark Plugs Balance Shaft Driven Gear Bolt Cylinder Head (New) ....30 N ¥ m (22 Ib ¥ ft) ......20 N ¥ m (15 Ib ¥ ft) (Plus 35 Degrees) Cylinder Head (All Subsequent Installation) Camshaft Retainer Bolt....12 N ¥ m (106 Ib ¥ in) ..........20 N ¥...
Page 174 Piston Pin Rear Bearing Journal Clearance Diameter ....23.545-23.548 mm (.927-.926 in) .......0.0254-0.09144 mm (.001-.0036 in) Clearance in Piston..0.0254 mm (.001 in) MAX. Fit In Connecting Rod Valve System .....0.02032-0.04064 mm (.0008-.0016 in) Interference Valve Lifter .........Hydraulic Roller Valve Rocker Arm Ratio ........1.50:1 Exhaust Manifold Valve Lash......Net Lash No Adjustment Surface Flatness .....0.254 mm (.010 in) MAX.
Page 175 Systems Operation General Information IAGS040S Basic Vortec 4.3 Liter V6 Engine Bore..........101.6 mm (4.00 in) Rotation of Crankshaft (when seen from the front) ..............Clockwise Stroke..........88.39 mm (3.480 in) Rotation of Camshaft (when seen from the front) Cubic Capacity........4.3 L (262 CID) ..............Clockwise Number and Arrangement of Cylinders....1-6 NOTE : Front of engine is oposite to flywheel end...
Page 176 Liquid Petroleum Fuel System The basic components of this liquid petroleum (LP) fuel system are: the fuel tank, the fuel filter and relief valve, fuelock (2), converter (1) and carburetor (3). Electric Fuelock Models Liquid fuel is sent to fuelock (2) by the pressure in the fuel tank, which is approximately 1030 kPa(150psi).
Page 177 Electric Fuelock Converter IAGS003P Converter Components (1) LP fuel inlet opening. (2) Primary regulator valve. (3) Primary valve pin. (4) Fulcrum. IAGS042S (5) Primary diaphragm with lever. (6) Cover. (7) Secondary diaphragm. (8) LP fuel outlet opening. Electric Fuelock (2) Fuelock. Fuelock (2) is electrically activated by an oil pressure switch.
Page 178 The converter is a combination regulator and The vaporizing chamber decreases LP fuel pressure vaporizer. It receives liquid fuel through opening (1) from the tank to less than atmospheric pressure. This at tank pressure from the fuelock. The fuel is expansion of the pressurized liquid fuel into vapor, available inside converter vaporizing chamber (9) can result in freezing the heat from the engine...
Page 179 atmosphere. the action of the relief valve prevents When starting the engine, the intake stroke of piston damage to the fuel lines and other components of the (9) causes lower than atmosphere pressure (vacuum) fuel system. The position of the valve is in a direction in the carburetor.
Page 180 Air Velocity Governor Operating valve shaft. The tension of the cantilever spring is adjusted by means of the main adjustment screw (4). Principal When the air velocity force acting on the valve equals the opposing spring force, the valve assumes a position which controls the amount of fuel reaching Description the engine.
Page 181 Distributor Vacuum Control Unit Carburetor Carburetor Intake Manifold IAGS046S Distributor Vacuum Control (1) Carburetor butterfly valve. (2) Valve. When the carburetor butterfly valve (1) is closed, as In this way, when the engine is operating at a speed illustrated in (a), the vacuum below it causes the below the governor set speed, the carburetor will piston valve (2) in the governor to move against its control the distributor vacuum control unit.
Page 182 Lubrication System IAGS047S Engine Lubrication Diagram A Lubrication schematic is shown in IAGS047S. The The timing chain is drip fed from the front camshaft gear type oil pump is driven from the distributor shaft, bearing. The pistons and piston pins are lubricated by which is gear driven from the camshaft.
Page 183 Ignition System Breakerless Ignition System Coil Lead (Secondary) 4-Terminal Connector Ignition Coil Connector Terminals IAGS048S Ignition System Schematic (1) Battery. (2) Ignition switch. (3) Coil. (4) Distributor. (5) Spark plug. voltage current into high voltage current to make a spark at the gap of the spark plug. The coil has two windings around a soft iron core.
Page 184 Operation Electrical System The ignition system can be divided into two parts, the The electrical system is a 12 volt, negative ground primary (low voltage) and the secondary (high system that has two basic circuits. The two circuits voltage) circuits. are the starting circuit and the charging circuit.
Page 185 Delco Remy PG260 Alternators The alternators used on these engines have three phase, full-wave. rectified output. They are the brush type. Refer to the Alternator Coverage chart for detailed systems operation information Alternator Coverage Alternator Manufaturer/ Part Number Series Delco Remy/CS-121 8C5510 IAGS049S Rotation is clockwise when seen from the drive end.
Page 186 A solid state regulator is installed in or on the back of Circuit Breaker the alternator. Two brushes conduct current, through two slip rings, to the rotor field. Some alternators have a capacitor mounted on them. The capacitor protects the rectifier from high voltages. It also suppresses electrical noise through a radio, if equipped.
Page 187 Timing Gears & Chain IAGS051S Camshaft Timing Chain and Sprockets (1) Crankshaft gear. (2) Camshaft gear. (3) Timing chain. There are two timing gears and one timing chain on The hydraulic pump is driven by a short U-joint this model. The two gears are the crankshaft gear (1) connected to the crankshaft pulley.
Page 188 Transmission Oil Cooler 2 Speed Power Shift Transmission RADIATOR IAGS052S Transmission Oil Cooler (D35S, D40S, G35S, G40S) (1) Oil line. (2) OIl line. On models equipped with a power shift transmission When the machine is equipped with a hydrostatic, the oil cooler is located in the outlet section of the power shift transmission or transaxle, a transmission radiator, Oil flows from the rear housing (torque oil cooler lis installed in the outlet section of radiator...
Page 189 Testing And Adjusting Troubleshooting Problem List: Gasoline Fuel System 1. Engine crankshaft will not turn when the ignition Troubleshooting switch is turned to the start position. 2. Engine will not start. Adhere to the following warnings when performing 3. Engine misfires or runs rough. any tests or adjustments while the engine is running.
Page 190 30. With starting motor on, pinion engages ring gear, Problem 2: Engine will not start. but engine does not crank. Probable Cause : 31. Starting motor continues to run after ignition 1. Slow cranking speed : switch has been released. Make reference to Problem 28.
Page 191 Problem 3: Engine misfires or runs rough. 10. Head gasket leaks : Make a replacement of the gasket and other Probable Cause : components as needed. 1. Weak spark to combustion chambers : 11. Bent or broken push rod : See Problem 2 for correction.
Page 192 Problem 5 : Stall at low engine speed (rpm). 3. Weak spark to combustion chambers : Check the wiring for cracks and the connections Probable Cause : for opens. 1. Fuel pressure is low : Check distributor cap for cracks and sensors for Make sure there is fuel in the fuel tank (LP) defects.
Page 193 Problem 8 : Too much vibration. Problem 11 : Oil in cooling system. Probable Cause : Probable Cause : 1. Loose bolts or nuts that hold pulleys onto 1. Defect in head gasket : crankshaft : Install a new head gasket. 2.
Page 194 2. Damage to camshaft : 5. Worn lobes on camshaft : Make replacement of parts with damage. Clean Check valve clearance. engine thoroughly. See Valve Clearance Adjustment in Testing And Adjusting. 3. Damage to tappet (valve lifter) : Clean engine thoroughly. Check for free movement of valves or bent valve stems.
Page 195 3. Too much oil in the valve compartment : 2. Not enough air for combustion : Check return passages to oil pan. Check air cleaner for restrictions. 4. Worn piston rings : Check air inlet hose and air horn for restriction. Inspect and install new piston rings.
Page 196 7. Carburetor has wrong adjustments : Problem 24 : Engine uses too much lubrication Make adjustment to carburetor. oil. See Carburetor Adjustments in Testing And Probable Cause : Adjusting. 1. Too much lubrication oil in engine : 8. Plugged positive crankcase ventilation valve : Remove extra oil.
Page 197 4. Loose or defective radiator cap or low water level Problem 27 : Early combustion. in radiator : Probable Cause : Tighten or test the radiator cap. See Cooling System Tests in Testing And 1. Wrong ignition timing : Adjusting. Make adjustment to timing.
Page 198 6. Ignition switch or solenoid damaged (burned or 4. Clutch section of pinion drive/overrunning clutch loose parts) : slips : Replace ignition switch or solenoid. Replace pinion drive/overrunning clutch. 7. Excessive voltage drop in cables, damaged NOTE: For more information on the starting motor, cables, loose cable connections, or terminal see the respective starting motor service module : connections corroded :...
Page 199 NOTE: For more information on the alternator, see Problem 36 : Alternator is noisy. the respective alternator service module : Delco Probable Cause : Remy CS-121 Series Alternators. 1. Drive belt for alternator is worn or defective : Install a new drive belt for the alternator. Problem 34 : Alternator charge rate is low or not regular.
Page 200 Troubleshooting Problems : Liquid 15. Worn or damaged exhaust valves : Replace the exhaust valve. make a diagnosis of Petroleum Fuel System the cause for the damaged valves. Problem 1 : Engine will not start. Problem 2 : Engine runs, but loses power. Probable Cause : Probable Cause : 1.
Page 201 3. Converter secondary valve seat not operating Problem 6 : Converter is freezing during normal correctly (stuck) : operation. Repair the valve seat. Probable Cause : 4. No carburetor vacuum to the converter and no 1. Low coolant level : manifold vacuum to the vacuum switch : Fill radiator.
Page 202 Ignition System 1. Inspect distributor cap (1). Look for breaks, cracks or dirt inside and on the outside. Clean the distributor cap inside and out. Adhere to the following warnings when performing any tests or adjustments while the engine is running. WARNING Work carefully around an engine that is running.
Page 203 NOTE : The Electrical System Analyzer can be used 3. Clean any deposits of carbon from inside of the on the ohmmeter scale for the spark plug resistance spark plugs. Make a replacement of the spark plug test. if too much carbon, or burnt electrode is present. NOTE : Do not use a spark plug that has a defect.
Page 204 Ignition Timing Check and Adjust 1. The timing wire plug on the 1996 4.3liter engine must be unplugged and reconnected as shown before the engine can be timed. Black Browin Purple/White IAGS053S IAGS002S Timing Plate In Stored Position Standard EST Timing Plug (6) Timing Plate.
Page 205 6. As the timing light "flashes" (goes ON and OFF), Delco Electronic Spark Timing look at the alignment of the stationary timing mark (EST) Distributor (s) with the flywheel timing marks (s). 7. The correct timing for the LP model truck is as Description follows @ 700 rpm ......4ûBTDC.
Page 206 Delco Distributor Component Testing NOTICE In the test procedures that follow, check the ignition coil and each component of the distributor separately to identify defective or good components. These tests can be made with the distributor and coil mounted on the engine or on the repair bench.
Page 207 Pickup Coil Testing Ignition Coil Testing Pickup Coil Scrape Clean Leads Metal Disconnected Ground From Module TEST Ohmmeter TEST Ohmmeter B+ Terminal B+ Terminal TEST Ohmmeter 4-Terminal C-& TAC C- & TAC B+ & C- IAGS004S Terminal Terminal Terminals Ohmmeter IAGS059S Testing Ignition Coil Testing Pickup Coil...
Page 208 Engine RPM Check 1. Turn analyzer power switch "On". 2. Turn the analyzer selector switch to the "Lo" for low idle rpm, to "Hi" for high idle rpm. 3. Clip inductive pick-up onto any spark plug wire with the arrow pointing to the spark plug. 4.
Page 209 Accelerator Linkage Adjustment (G35S & G40S) (46.5û) FRAME IAGS060S Accelerator Linkage Adjustment (1) Accelerator pedal. (2) Nut. (3) Bolt To adjust the accelerator linkage, do the steps that follows : 1. With the engine OFF and the accelerator pedal (1) in the UP position with Dimension (A) 87mm (3.43 in), loosen nut (2).
Page 210 Governor Adjustments Liquid Petroleum Fuel System Adhere to the following warnings when performing Velocity Governor any tests or adjustments while the engine is running : WARNING High Idle Speed Adjustment-Hoof Governor Work carefully around an engine that is running. Engine parts that are hot, or part that are moving, can cause personal injury.
Page 211 4. Check to be sure the low idle speed is set Tools Needed correctly. Electrical System Analyzer See Low Idle Speed Adjustment in Testing And Adjusting. 1. Make sure the setting for ignition timing is correct. 5. Turn idle mixture screw clockwise or See Ignition Timing in the Testing And Adjusting.
Page 212 8. The correct mixture will be that setting just before Outer Fuel System Leak Check the engine rpm drops. WARNING CO Meter Method LP gas is highly flammable. To prevent personal Tools Needed injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system.
Page 213 Inner Fuel System Leak Check 5. If there is fuel flow, the leakage problem must be found either in the fuelock or the converter. 6. Push in primer button (4) on the converter to open the converter fuel regulator valve. 7.
Page 214 Cooling System 2. Check coolant level in the cooling system. 3. Look for leaks in the system. Adhere to the following warnings when performing any tests or adjustments while the engine is running : 4. Look for bent radiator fins. be sure that air flow through the radiator does not have a restriction.
Page 215 IAGS021P Pressure Cap Test 2. Put the pressure cap on the Cooling System IAGS065S Pressurizing Pump Group. Pressure Cap Diagram 3. Look at the gauge for the pressure that makes the (A) Sealing surface of cap and radiator. pressure cap open. It must be as follows : Cap 9Y1791....85 to 110 kPa (12 to 16 psi) NOTE : Current Models have two radiator caps.
Page 216 4. The thermostat must start to open when the temperature is 80 to 80 to 84c (176 to 184d). the thermostat must be fully open at 94c (202d). Cooling System Heat Problems To check if there is a good reason for heat problems do the checks that follow : 1.
Page 217 NOTICE DAEWOO prefers the use of distilled water or deionized water to reduce the potential and severity DAEWOO recommends that the coolant mix contain of chemical insolubility.
Page 218 Most commercial antifreezes are formulated for gasoline Lubrication System engine applications and will, therefore, have high silicate content. Adhere to the following warnings when performing any tests or adjustments while the engine is running : Make proper antifreeze additions. WARNING Adding pure antifreeze as a makeup solution for cooling system top-up is an unacceptable practice.
Page 219 Oil leakage into the combustion area if the cylinders Oil Pressure Check can be the cause of blue smoke. There are three possible ways for oil leakage into the combustion area of the cylinders : 1. Oil leakage between worn valve guides and valve stems.
Page 220 Air Inlet And Exhaust System The cylinder leakage test is a way of finding the smallest of cylinder leaks. Air is applied to the Adhere to the following warnings when performing cylinder at a controlled volume and pressure any tests or adjustments while the engine is running : measures the percentage of air leakage.
Page 221 13. Gauge readings should be about the same for all cylinders. Readings of 20 Percent leakage or more indicate excessive leakage and loss in compression. 14. Air escaping through the carburetor indicates a leaking intake valve. Air escaping through the exhaust pipe indicates a leaking exhaust valve.
Page 222 Cylinder Head Check Tools Needed Cylinder Head Stand IAGS071S End to End Check (1) Straight edge. (2) Feeler gauge. IAGS024S Cylinder Head Check (A) Cylinder Head Stand. 1. After removal of the cylinder head place it on a cylinder head stand. 2.
Page 223 Flywheel And Flywheel Housing Tools Needed Dial Indicator Test Group IAGS066S Flywheel Housing Face Runout Check (A) Bottom. (B) Right side. (C) Top. (D) Left side. IAGS030S Flywheel Housing Face Runout Tooling Set Up 3. With dial indicator set at 0.0mm (.000 in) at location (A), turn the crankshaft and read the indicator at NOTE : Remove the spark plugs so the flywheel will locations (B), (C) and (D).
Page 224 Flywheel Checks Outside Diameter Check NOTE : The flywheel housing may have to be Face Runout Check removed to make this runout check. IAGS030S IAGS031S Flywheel Face Runout Check Flywheel Outside Diameter Runout Check 1. Install the dial indicator as shown. Force the 1.
Page 225 Electrical System Battery Most of the electrical system components can be tested on the engine. The wiring insulation must be in good condition. The wire and cable connections must be clean and tight and the battery fully charged. If the on engine test shows a defective component, the component must be removed for more tests.
Page 226 Starting Motor WARNING For detailed testing and adjusting information, see Never disconnect any charging unit circuit or battery the Starting Motor Coverage chart for the correct circuit cable from the battery when the charging unit Service Module. is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the STARTING MOTOR COVERAGE...
Page 227 On Machine Starting Motor Diagnosis Procedure START SWITCH START RELAY WH/BK RD/WH MTR BAT STARTER MOTOR BATTERY IAGS068S Typical 12 Volt Starting Circuit (1) Test point. (2) Test point. (3) Test Point. (4) Test Point. (5) Test Point. (X) Hold-in coil. (W) Pull-in coil The following simplified procedure is intended to help The starting motor solenoid has two functions : the serviceman determine if a starting motor needs to...
Page 228 The result of these switches and relays is to permit a If the starting motor cranks real slow or does not 5 amp dash-mounted switch to turn on a 500 to 1000 crank at all, do the following procedure : amp motor used to crank an engine.
Page 229 7. Are all the voltages within specifications ? Start Relay Tests a. If the voltage drops are correct, go to Step 8, to 1. Put the multimeter on the 200 ohm scale. check the engine. 2. Put the multimeter lead to the 85 and 86 terminals. b.
Page 230 SB2111E00 F eg . 1 9 9 8 Disassembly & Assembly Gasoline Engine GM V ortec V6 ( 4.3 Liter)
Page 231 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, Iubrication, maintenance or repair procedures you choose.
Page 233 Index General Information Pistons & Connecting Rods ........41 Rocker Arms & Push Rod ........28 Engine Assembly............. 6 Engine Characteristics ..........5 Starter Motor ............12 Starter Relay ............13 Fastener Tightening ..........6 Timing Chain ............37 General Description ..........5 Torsional Damper ..........
Page 235 The engine operates according to the Toroidal com- and new ones should be prepared for installation bustion system developed by Daewoo Heavy as normal function of the parts can not be main- Industrial Co. of Korea and AVL Co. of Austria.
Page 236 Fastener Tightening Balance Shaft Driven Gear Bolt ......20 NIm (15 lbIft) (Plus 35 Degrees) Spark Plugs Camshaft Retainer Bolt....12 NIm (106 lbIin) Cylinder Head (New) ....30 NIm (22 lbIft) Camshaft Sprocket Bolts ....28 NIm (21 lbIft) Cylinder Head (All Subsequent Installation) Coolant Sensor ........20 NIm (15 lbIft) ..........20 NIm (15 lb¦Uft) Connecting Rod Nut...
Page 237 Piston Pin Balance Shaft Diameter....23.545-23.548 mm (.927-.926 in) Front Bearing Journal Diameter Clearance in Piston ..0.0254 mm (.001 in) MAX....55.985-55.001 mm (2.1648-2.1654 in) Fit In Connecting Rod Rear Bearing Journal Diameter ..0.02032-0.04064 mm (.0008-.0016 in) Interference ....38.084-38.100 mm (1.4994-1.500 in) Rear Bearing Journal Clearance Exhaust Manifold ......0.0254-0.09144 mm (.001-.0036 in)
Page 238 General tightening torque for bolts, nuts and taperlock studs The following charts give the stan- dard toque values for bolts, nuts and taperlock studs of SAE Grade 5 or better quality. Exceptions are given in thread other sections of the Service Manual size standard torque where needed.
Page 239 GM 4.3 Liter V6 Gasoline Engine NOTE: The following information is provided for trained repair personnel as an aid in disassembly and assembly of this engine. The order was chosen as a matter of convenience. The photoÕs were taken to visually represent the detail being illustrated and may not be representative of the actual view the repair person will observe.
Page 240 Install Air Cleaner Housing Assembly A31999-03 IAED023P 4. Install outer filter element (3) in the housing. IAED026P 1. Put air cleaner housing (8) in position and install the three nuts (7) that hold it. Install pressure indi- cator (6). IAED022P 5.
Page 241 Fan Belt Remove & Install Fan A51342-01 Remove & Install Fan Belt A51087-01 IAGD001P 1. Reposition belt tensioner. CAUTION IAGS024S This tensioner is spring loaded. 1. Remove the four bolts (2) and lock washers. 2. Remove belt from location (Serpentine Belt) being 2.
Page 242 Alternator Starter Motor Remove & Install Alternator Remove & Install Starter Motor B31018-01 A61564-01 IAGD004P IAGD002P 1. Disconnect wire (1) and wire (2). 1. Remove wires (1) from the starting motor IAGD003P IAGD005P 2. Remove bolts and washers (3), & (4) and the 2.
Page 243 Starter Relay LP Gas Fuelock Remove & Install Starter Relay Remove & Install LP Gas Fuelock A61999-01 A2C885-01 IAGD007P IAGD009P 1. Remove four (1) wires from the relay. 1. Disconnect fuel line (1). 2. Disconnect wire (2). 3. Remove fuelock (3) NOTE: For the installation of the LP gas fuelock, reverse the removal steps.
Page 244 LP Gas Converter LP Gas Carburetor Remove & Install LP Gas Converter Remove and install LP Gas A2C241-01 Carburetor A27186-01 Start By: Removing LP Gas Fuelock IAGD011P IAGD010P 1. Disconnect hose (1). 1. Remove lines (1). 2. Remove two bolts and washers (2). 3.
Page 245 NOTE: For installation of the LP gas carburetor, reverse the removal steps. 6. Inspect and replace the gasket if necessary. Disassemble LP Gas Carburetor A21786-07 Start By: Remove LP Gas Carburetor IAGD016P 4. The air valve ring (8) from the inner carburetor body will be seperated from the diaphragm.
Page 246 Governor Remove and Install Governor A25396-1 Start By: Remove accelerator rod, fuel and air intake lines from carburetor. IAGD019P 7. Loosen the bolt and remove stop (16). 8. Remove two screws (14). Remove throttle plate (15). 9. Remove shaft assembly (17) from the throttle body.
Page 247 LP Fuel Shut-off Switch Oil Pressure Alarm Sender Remove & Install LP Fuel Shut-off Remove & Install Oil Pressure Switch A29992-01 Sensor Switch IAGD026P IAGD024P 1. Disconnect The plug from the wiring harness. 1. Disconnect The wire from the sending unit. 2.
Page 248 Water Pump Remove & Install Water Pump A55360-01 Start By: a. Draining coolant from radiator. b. Remove by-pass hose and c. LP hose from pump. d. Remove fan belt. IAGD031P 4. Remove pump from engine. 5. Remove gasket and clean surface. NOTE: For the installation of the Water Pump, reverse the removal steps.
Page 249 Water Temperature Regulator Remove & Install Water Temperature Regulator A56681-01 Start By: a. Draining coolant from radiator. b. Removing upper radiator hose from thermostat housing. IAGD035P NOTE: For installation of the thermostat, reverse the removal steps and torque mounting bolts to 25 NI I m (18 lbI I ft.).
Page 250 High Mounted Fan Bracket Crankshaft Pulley Remove & Install High Mounted Fan Remove & Install Crankshaft Pulley Bracket A12660-01 Start By: Start By: Removing fan belt a. Remove fan belt. b. Remove wires from alternator. IAGD038P IAGD036P 1. Remove three allen head bolts (3) and one center bolt (1) from pulley (2).
Page 251 Torsional Damper 1. Install the stud(part of J39046) to the crankshaft. Remove Torsional Damper From Thread the stud fully into the tapped hole in the Engine A12661-02 crankshaft. NOTICE The inertial weight section of the torsion damper assem- bles to the hub with a rubber sleeve. The removal procedure must be followed (with the prop- er tools) or movement of the inertia weight section of the hub will destroy the tuning of the torsional damper and...
Page 252 Coil Engine Flywheel Remove & Install Coil B33222-01 Engine Flywheel Removal A13366-02 Start By: Separating the engine and transmission. NOTE: The engine has been removed for better photo illustration. 1. Fasten a link bracket to the flywheel and attach a hoist to support the weight.
Page 253 Flywheel Ring Gear Distributor Remove Distributor B33300-02 Remove & Install Flywheel Ring Gear A13387-01 Start By: Removing the flywheel. 1. Use a torch to heat the ring gear around the entire circumference. Remove flywheel ring gear from flywheel. Care should be exercised not to damage the flywheel.
Page 254 Install Distributor B33300-03 Disassemble Distributor B33300-07 Start By: Removing the distributor. IAGD047P IAGD048P 1. Install the distributor (1) in position in the intake manifold. Make sure that the rotor (2) is in align- ment with the scribe mark and number one cylinder. 1.
Page 255 Assemble Distributor B33300-08 9. Wipe distributor base and module clean, apply sili- cone lubricant between module and base for heat dissipation. 10. Attach module (11) to base with two screws (10). Connect pickup coil (9) connector to module and mount coil. 11.
Page 256 Intake Manifold Install the Intake Manifold A32549-03 Remove Intake Manifold A32549-02 Start By: a. Remove fuel lines and linkage from carburetor. b. Remove coolant bypass line from manifold. c. Remove the distributor from the manifold. IAGD055P 1. Apply RTV sealant to the front and rear of engine block extending 1.5 inches up the port faces as shown.
Page 257 Exhaust Manifold Remove Exhaust Manifold Start By: Remove the crossover pipe from the intake manifolds. IAGD057P 4. Apply thread lock and assemble bolts to intake manifold. IAGD059P 1. Remove the bolts from the exhaust(s) manifolds. 2. Remove the manifold(s) from the engine Install Exhaust Manifold A32549-03 IAGD058P 5.
Page 258 Valve Covers Rocker Arms & Push Rods Remove Valve Covers A17257-02 Remove Valve Rocker Arms & Push Rods A17702-02 IAGD061P IAGD063P 1. Remove three bolts and washers from each cover. 1. Remove nut, ball, rocker arm. 2. Remove valve covers and gaskets from engine Install Valve Covers A17257-03 IAGD064P 2.
Page 259 Install Valve Rocker Arms & Push Valve Lifters Rods A17702-03 Remove Valve Retainers & Lifters Start By: a. Removing valve covers b. Removing intake manifold c. Removing rocker arms & push rods IAGD065P 1. Install push rods IAGD068P 1. Remove three bolts from the valve lifter retainers. IAGD066P 2.
Page 260 Install Valve Retainers & Lifters Cylinder Heads NOTE: When new lifters or a new camshaft has Remove Cylinder Heads Assemblies been installed, change the oil and filter. Add engine A17429-02 oil supplement GM P/N 1052367 or equivalent to the new oil. Start By: a.
Page 261 IAGD077P IAGD075P 3. Remove cylinder heads from block. 2. Assemble cylinder heads to block 3. Apply sealing compound (GM P/N 12346004) to the threads of the bolts, then assemble bolts to cylinder head. IAGD076P 4. Remove head gasket. IAGD078P Install Cylinder Heads Assemblies A17429-03 4.
Page 262 Valves Install valves 1. Check all parts for damage. If any parts are dam- Remove valves aged or worn, use new parts for replacement. 2. Make sure all parts are clean and free of dirt and Start By: Removing the cylinder head foreign material.
Page 263 Oil Pan Install Oil Pan A43591-03 Remove Oil Pan A43591-02 Start By: Placing truck on jack for safety. IAGD082P 1. Place new gasket to oil pan. IAGD080P 1. Remove ten bolts and two nuts from the oil pan. IAGD083P 2. Apply sealant to the four locations . IAGD081P NOTICE Apply RTV sealant (GM P/N 12346141) or equivalent...
Page 264 IAGD084P IAGD005S 3. Place oil pan in location, assemble ten bolts and 5. Use a feeler gauge to check the clearance two nuts to mount the oil pan in place. Do not between the oil pan-to-transmission bell housing tighten at this time. contact points as shown.
Page 265 Oil Pump Replace Oil Pump A41663-03 Remove Oil Pump A41663-02 Start By: Remove oil pan. IAGD087P 1. Replace oil pump, retainer and pump drive shaft to engine. Make sure that the slot on the pump drive shaft is aligned with the tang on the distributor IAGD085P shaft.
Page 266 Front Cover Install Front Cover A16999-03 1. Install new front cover to engine. Remove Front Cover A16999-02 NOTICE NOTICE Any time the front cover is removed, the cover must Any time the front cover is removed, the cover must be replaced upon re-assembly. If the cover that was removed is reinstalled, oil leaks may develop.
Page 267 Timing Chain Install Timing Chain A16387-03 Remove Timing Chain A16387-02 Start By: a. Bring engine number 1 cylinder to TDC. b. Removing front cover from engine. IAGD094P 1. Align all timing marks. 2. Install camshaft gear and chain to location. 3.
Page 268 Camshaft Install Camshaft A17174-03 Start By: Remove Camshaft A17174-02 a. Coat camshaft lobes and journals with Engine Oil Supplement (GM P/N 1052367) or equiva- Start By: lent. a. Removing Camshaft Gear and bolts b. Apply Engine Oil Supplement (GM P/N b.
Page 269 Camshaft Bearings Install Camshaft Bearings A17174-03 Remove Camshaft Bearings A17174-02 NOTICE The outer camshaft bearing must be installed first. Start By: Remove camshaft from engine . These bearings serve as a guide for the pilot, and help center the inner bearings during the installation 1.
Page 270 Balance Shaft Install Balance Shaft Remove Balance Shaft Start By: a. Removing Timing chain. b. Removing Camshaft Gear and bolts. IAGD100P NOTICE During installation of balance shaft be careful not to damage bearings. IAGD098P 1. Remove screws from flange. IAGD101P 1.
Page 271 Crankshaft Sprocket Pistons & Connecting Rods Remove The Crankshaft Sprocket Remove Pistons & Connecting Rods A14999-02 Start By: Removing Crankshaft pulley and Damper Assembly. Start By: a. Remove cylinder head assembly b. Remove oil pump. NOTE: The Piston Rod Bearings were marked with a punch for correct re-assembly.
Page 272 Install Pistons & Connecting Rods A14999-03 IAGD105P 4. Put tape or rubber hose (1) over the connecting IAGD107P rod threads to prevent damage to the crankshaft when the connecting rod and piston is being removed. 1. Put tape or rubber hose over the connecting rod bolts.
Page 273 Disassemble Pistons & Connecting Rods A14999-07 NOTICE The piston must be installed so the notch in the piston Start By: Remove pistons and connecting rods. faces the front of the engine. IAGD011S IAGD109P 1. Remove the rings from the piston with a ring expander.
Page 274 Assemble Pistons & Connecting Crankshaft Rear Oil Seal Rods Remove Crankshaft Rear Oil Seal 1. Check all parts for damage. If any parts are dam- A1226-02 aged use new parts for replacement. 2. Make sure all parts are clean free of dirt and for- Start By: Removing the engine from the truck.
Page 275 Install Crankshaft Rear Oil Seal A1226-03 Tool Required: Seal Installer IAGD113P 4. Tighten the screws securely with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft. IAGD112P 5. Turn the handle on the tool until it bottoms. Then remove the tool.
Page 276 Remove The Crankshaft Rear Oil Install The Crankshaft Rear Oil Seal Seal Housing A1226-02 Housing A1226-03 Start By: Start By: Clean the gasket surface. a. Removing the engine from the truck. 1. Install a new gasket to the block. b. Then remove the oil pan. NOTE: It is not necessary to use sealant to hold the gasket in place.
Page 277 Crankshaft Remove The Crankshaft A12264-01 Start By: a. Removing engine from truck b. Remove oil pan. c. Remove connecting rods and bearings NOTICE Be sure to mark bearings, rod and piston assemblies so when they are installed they will be in the correct IAGD117P location.
Page 278 Install The Crankshaft A12264-03 Start By: a. Making sure everything is clean. b. Then lubricate all moving parts before they are installed. IAGD121P 4. Assemble lower crankshaft bearings to crankshaft bearing caps. 5. Install crankshaft bearing caps (except rear cap) and bolts to the block.
Page 279 SB2202E00 J u n . 1 9 9 9 Specifications Systems Operation Testing & Adjusting Disassembly & Assembly Lift Trucks Power Train 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 280 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 282 Index Testing And Adjusting Specifications Brake Drum Diameter ..........8 Additional Checks (Electrical System) .....46 Inching Pedal Adjustment ........42 Differential ..............7 Power Shift Transmission ........37 Drive Axle..............8 Converter Staal Test..........39 Shimming of Transmission Shaft Assembly ..40 Drive Axle Mounting Group ........7 Transmission Pressure Tests .......37 Drive Wheel Installation ..........7 Solenoid Test............46...
Page 283 Power Train Specifications...
Page 284 Specifications General Tightening Torque GENERAL TIGHTENING TORQUE FOR BOLTS, NUTS AND TAPERLOCK STUDS The following charts give the standard torque values for bolts, nuts and taperlock studs of SAE Grade 5 or better quality. Exceptions are given in other sections of Service Manual where needed. THREAD DIAMETER STANDARD TORQUE inches...
Page 285 Torque Converter Transmission Pump (1) Clearance between outside of drive gear and crescent ....0.36 to 0.43mm(.014 to .017 in) (1) Torque for bolts (plate to torque converter....45 L 7 N¥m (33 L 5 lb¥ft) Apply LOCTITE NO. 292 sealant to threads of bolts.
Page 286 Transmission Drive Axle Mounting Group (18 5 lb . ft) Apply Loctite 92 (18 5 lb.ft) (51 11 lb . ft) Apply Loctite 262 (1) Torque for bolts ..600 L 50 N¥m (440 L 35 lb¥ft) Apply LOCTITE NO. 292 sealant to threads of bolts. (33 5 lb .
Page 287 Drive Axle Wheel Brakes 12 8 (1) Torque for bolts ......145 N¥m (107 lb¥ft) (1) Torque for bolts ..19 to 22 N¥m (14 to 16 lb¥ ft) Apply Loctite 262 to threads. (2) Torque for bolts ..120 L 20 N¥m (90 L 15lb¥ft) (2) Torque for bolts ......120 N¥m (88 lb¥ft) Apply Loctite 262 to threads.
Page 288 Systems Operation General Information Power Shift Transmission (1) Engine. (2) Torque converter. (3) Power Shift transmission. (4) Drive axle. (5) Drive wheels. The basic components of the power train are : engine Power from the transmission is sent through its (1), torque converter (2), power shift transmission (3), output gear through the spiral bevel gear set to the drive axle (4) and drive wheels (5).
Page 289 Torque Converter The torque converter has four main parts : housing (4), impeller(pump) (3), turbine (1) and stator (2). The housing is connected to the engine flywheel through flex plate (6). Impeller (3) and housing (4) are connected and turn with the engine flywheel at engine speed.
Page 290 Power Shift Transmission The transmission is a constant mesh power shift transmission and gives two forward and two reverse speeds. The transmission has four clutches that are engaged hydraulically and released by spring force. The direction and speed are changed electrically. Illustration A (1) Gear(Reverse low).
Page 291 Power Flow In Low Speed Reverse Power Flow in Low Speed Reverse. (1) Input shaft. (2) Cylinder clutch(reverse). (3) Cylinder clutch (Forward). (4) Counter shaft. (5) Gear(Reverse low). (6) Clutch(Reverse low). (7) Piston. (8) Clutch(Reverse high). (9) Gear(Reverse high). (10) Output shaft. (11) Output gear(low). (12) Output gear(high).
Page 292 Power Flow In High Speed Reverse Power Flow in High Speed Reverse (1) Input shaft. (2) Cylinder clutch(reverse). (3) Cylinder clutch (Forward). (4) Counter shaft. (5) Gear(Reverse low). (6) Clutch(Reverse low). (7) Piston. (8) Clutch(Reverse high). (9) Gear(Reverse high). (10) Output shaft. (11) Output gear(low). (12) Output gear(high).
Page 293 Power Flow In Low Speed Forward Power Flow in Low Speed Forward (1) Input shaft. (2) Cylinder clutch(reverse). (3) Cylinder clutch (Forward). (4) Counter shaft. (5) Gear(Reverse low). (6) Clutch(Reverse low). (7) Piston. (8) Clutch(Reverse high). (9) Gear(Reverse high). (10) Output shaft. (11) Output gear(low). (12) Output gear(high).
Page 294 Power Flow In High Speed Forward Power Flow in High Speed Forward (1) Input shaft. (2) Cylinder clutch(reverse). (3) Cylinder clutch (Forward). (4) Counter shaft. (5) Gear(Reverse low). (6) Clutch(Reverse low). (7) Piston. (8) Clutch(Reverse high). (9) Gear(Reverse high). (10) Output shaft. (11) Output gear(low). (12) Output gear(high).
Page 295 Drive Axle (1) Carrier Assembly. (2) Drvie Shaft. (3) Hub Assembly. (4) Pinion Gear. (5) Ring Gear. (6) Differential Pinion Gears. (7) Spider. (8) Side Gears. (9) Bearings. (10) Plate. (11) Planetary Gears. (12) Planetary Carrier. The main components of the drive axle are : Carrier The wheel hubs run on tapered roller bearings (9).
Page 296 Wheel Brake Components. Automatic Adjustment Clearance ICPS023S ICPS017S (1) Wheel Cylinder. (2) Wheel Cylinder Pistons. Brake Adjuster (3) Secondary Shoe. (4) Return Springs. (5) Primary Shoe. (1) Adjusting Bolt. (2) Sleeve. (3) U-shaped bracket. (6) Return Spring. (4) Adjusting Lever. (5) Adjusting Screw (6) Spring. (7) Adjusting Wheel (8) Spring.
Page 297 PUMP PRESSURE CONVERTER OUTLET LUBRICATION PRESSURE CONVERTER INLET PRESSURE CLUTCH PRESSURE ACCUMULATOR PRESSURE TRANSMISSION HYDRAULIC SYSTEM 1. Main regulator volve. 8. Forward high clutch. 15. Lube priority valve. 22. Passage. 22. Passage. 29. Passage. 29. Passage. 2. Directional selector valve. 9.
Page 298 Transmission Hydraulic System From the outlet of the torque converter the oil goes (1) Main regulator valve. (2) Directional selector valve. past cooler bypass valve (11), through the oil cooler (3) Speed selector valve. (4) Inching valve. external inlet line and into oil cooler (10). Cooler (5) Inching plunger.
Page 299 PUMP PRESSURE CONVERTER OUTLET LUBRICATION PRESSURE CONVERTER INLET PRESSURE CLUTCH PRESSURE ACCUMULATOR PRESSURE TRANSMISSION HYDRAULIC SYSTEM 1. Main regulator volve. 8. Forward high clutch. 15. Lube priority valve. 22. Passage. 22. Passage. 29. Passage. 29. Passage. 2. Directional selector valve. 9.
Page 300 Transmission Hydraulic Controls-Neutral (1) Main regulator valve. (2) Directional selector valve. (3) Speed selector valve. (4) Inching valve. (5) Inching plunger (6) Reverse high clutch. (7) Reverse low clutch. (8) Forward high clutch. (9) Forward low clutch. (10) Oil cooler. (11) Oil cooler bypass valve.
Page 301 PUMP PRESSURE CONVERTER OUTLET LUBRICATION PRESSURE CONVERTER INLET PRESSURE CLUTCH PRESSURE TRANSMISSION HYDRAULIC SYSTEM ACCUMULATOR PRESSURE 1. Main regulator volve. 8. Forward high clutch. 15. Lube priority valve. 22. Passage. 22. Passage. 29. Passage. 29. Passage. 2. Directional selector valve. 9.
Page 302 Transmission Hydraulic Controls-Low Speed Forward (1) Main regulator valve. (2) Directional selector valve. (3) Speed selector valve. (4) Inching valve. (5) Inching plunger. (6) Reverse high clutch. (7) Reverse low clutch. (8) Forward high clutch. (9) Forward low clutch. (10) Oil cooler. (11) Oil cooler bypass valve.
Page 303 PUMP PRESSURE CONVERTER OUTLET LUBRICATION PRESSURE CONVERTER INLET PRESSURE CLUTCH PRESSURE ACCUMULATOR PRESSURE TRANSMISSION HYDRAULIC SYSTEM 1. Main regulator volve. 8. Forward high clutch. 15. Lube priority valve. 22. Passage. 22. Passage. 29. Passage. 29. Passage. 2. Directional selector valve. 9.
Page 304 Transmission Hydraulic Controls-High Speed Forward (1) Main regulator valve. (2) Directional selector valve. (3) Speed selector valve. (4) Inching valve. (5) Inching plunger. (6) Reverse high clutch. (7) Reverse low clutch. (8) Forward high clutch. (9) Forward low clutch. (10) Oil cooler. (11) Oil cooler bypass valve. (12) Converter regulator valve.
Page 305 PUMP PRESSURE CONVERTER OUTLET LUBRICATION PRESSURE CONVERTER INLET PRESSURE CLUTCH PRESSURE ACCUMULATOR PRESSURE TRANSMISSION HYDRAULIC SYSTEM 1. Main regulator volve. 8. Forward high clutch. 15. Lube priority valve. 22. Passage. 22. Passage. 29. Passage. 29. Passage. 2. Directional selector valve. 9.
Page 306 Transmission Hydraulic Controls-Low Speed Reverse (1) Main regulator valve. (2) Directional selector valve. (3) Speed selector valve. (4) Inching valve. (5) Inching plunger. (6) Reverse high clutch. (7) Reverse low clutch. (8) Forward high clutch. (9) Forward low clutch. (10) Oil cooler. (11) Oil cooler bypass valve.
Page 307 PUMP PRESSURE CONVERTER OUTLET LUBRICATION PRESSURE CONVERTER INLET PRESSURE CLUTCH PRESSURE TRANSMISSION HYDRAULIC SYSTEM ACCUMULATOR PRESSURE 1. Main regulator volve. 8. Forward high clutch. 15. Lube priority valve. 22. Passage. 22. Passage. 29. Passage. 29. Passage. 2. Directional selector valve. 9.
Page 308 Transmission Hydraulic Controls-High Speed Reverse (1) Main regulator valve. (2) Directional selector valve. (3) Speed selector valve. (4) Inching valve. (5) Inching plunger. (6) Reverse high clutch. (7) Reverse low clutch. (8) Forward high clutch. (9) Forward low clutch. (10) Oil cooler. (11) Oil cooler bypass valve. (12) Converter regulator valve.
Page 309 PUMP PRESSURE CONVERTER OUTLET LUBRICATION PRESSURE CONVERTER INLET PRESSURE CLUTCH PRESSURE TRANSMISSION HYDRAULIC SYSTEM ACCUMULATOR PRESSURE 1. Main regulator volve. 8. Forward high clutch. 15. Lube priority valve. 22. Passage. 22. Passage. 29. Passage. 29. Passage. 2. Directional selector valve. 9.
Page 310 Transmission Hydraulic Controls-Inching Valve Operation(In Valve Function Chart Low Speed FORWARD) This chart gives a description of the function of the (1) Main regulator valve. (2) Directional selector valve. (3) Speed selector valve. (4) Inching valve. valves in the hydraulic control valve. (5) Inching plunger.
Page 311 Testing And Adjusting 4. Check the strainer behind the transmission oil plug and the filter foreign material. a. Particles of friction paper material give an Troubleshooting indication of a clutch failure. b. Metallic(metal) particles in the filter give an Troubleshooting can be difficult. A list of possible indication of wear or mechanical failure in the problems and corrections is on the pages that follow.
Page 312 h. Leakage inside the transmission. Problem : Clutch engagement is slow or loss of 1. Control valve gasket has damage. power during engagement. 2. Worn or broken metal seal rings on clutch shaft. Probable Cause : 3. Worn or broken seals around clutch piston. i.
Page 313 Problem : Low stall speed. Problem : Vehicle operates in one direction and creeps in that direction in NEUTRAL. Engine Probable Cause : stalls when shifted to the other direction. 1. Engine performance is not correct. Probable Cause : 2. The one-way clutch of the torque converter does 1.
Page 314 Problem : Noise in the control valve. Problem : Low main line pressure. Probable Cause : Probable Cause : 1. Air in the hydraulic system. 1. Low oil level. a. Air leakage on suction side of the pump. 2. Main regulator valve movement is restricted. b.
Page 315 Problem : Low converter pressure. Problem : Noise at different intervals. Probable Cause : Probable Cause : 1. Main regulator valve movement is restricted. 1. Ring gear does not run even. Problem : Converter outlet pressure or cooler a. bolts on drive gear not tightened correctly. inlet pressure is low.
Page 316 Problem : Drive wheels do not turn(drive shaft Power Shift Transmission turning). Probable Cause : Transmission Pressure Tests 1. Broken axle shaft. Raise the front of the lift truck off of the floor. Put wood blocks or jack stands of the correct capacity under it to a.
Page 317 9 6 7 Transmission Pressure Taps (1) Converter pressure tap. (2) Main line pressure tap. (3) Inching pressure tap. (4) Reverse lube pressure tap. (5) Forward lube pressure tap. (6) Forward low clutch pressure tap. (7) Forward high clutch pressure tap. (8) Reverse low clutch pressure tap.
Page 318 Converter Stall Test WARNING The converter stall test is a test to check engine power. It can also be used to locate a problem in the transmission when the condition of the engine is Make tests in a clear, level area only, There must known.
Page 319 Stall speeds that are low are an indication that the engine performance is not correct or the one-way clutch of the torque converter does not hold in reverse direction. If the one-way clutch has a defect, the stall speed will probably be more than 800 RPM low.
Page 320 Wheel Brakes Adjustment Setting Procedure The brakes make an adjustment automatically when During setting, the parking brake must be released i. an application is made in forward and reverse. With e. the cables should not be tensioned. each application, there will be an adjustment made, until the lining-to-drum clearance is made small 1.
Page 321 CAUTION : Correction of wheels which are not Inching Pedal Adjustment equally difficult to turn may only be carried out at the brake cables and not at the automatic adjuster. To check the inching valve adjustment and operation do the procedure that follows. 13.
Page 322 Inching Pedal Adjustment (1) Locknut. (2) Setscrew. (3) Pedal. (4) Pedal Mounting Bracket. (5) Locknut. (6) Rod. (7) Inching Spool. (8) Stetscrew. (9) Locknut. (X) 165 mm (6.5 in) 1. With the inching pedal in the released position. 7. Make an application of the inching pedal. With the loosen locknut (1).
Page 323 Transmission Electrical System Troubleshooting Transmission Control Schematic (1) Connector A. (2) Connector B. Function Conn A Conn B Neutral Start None Pin 6 (WH/BU) and Pin 8 (WH/BK) D(G)35/40/45S-2 Forward Pin 1 (RD) Pin 1 (GN/YL) D(G)40/45/50SC-2 Reverse Pin 5 (BU) Pin 1 (GN/YL) 2nd Speed Pin 6 (WH)
Page 324 Solenoids Voltage Check Solenoids Voltage Check (1) Forward solenoid. (2) High and Low solenoid. (3) Reverse solenoid. Reverse : System voltage between reverse solenoid (BU wire) and battery negative. Forward : System voltage between forward solenoid (RD wire) and battery negative. 2nd Speed : System voltage between H/L solenoid Wiring Harness From Transmission Selector Lever (A) Connector A.
Page 325 Additional Checks Solenoid Test System Voltage Check This test will determine if the soldnoid coil is energizing and the plunger is shifting to permit oil If the transmission will not operate, one of the first flow. checks that should be performed is a check of the system voltage.
Page 326 3. Put clean transmission oil on the tines (tangs) and Disassembly & Assembly on the lip of the lip type seal. 4. Carefully move the converter into position in the Torque Converter transmission. Be careful not to cause damage to the lip type seal.
Page 327 Transmission Control Valve Disassemble Transmission Control Valve Start By: a. Remove transmission control valve, [See the topic, Disassemble Transmission] 3. Put identification on each of the five valve keepers (pin and stop) as to their location in the control valve. 1.
Page 328 Assemble Transmission Control Valve Tools Needed T011 Seal Installer 1. Thoroughly clean all the parts of the transmission control valve. Put clean transmission oil on all of the parts of valve body. 2. If the lip type seal was removed, use tool (A) and 7.
Page 329 7. Put selector valve (19) in the same bore from 11. Put lube valves (3), separator plate (2) and which it was removed. Install spring (18), plug (17) gasket in position on the valve body. and o-ring. 12. Install screws (1) that hold the separator plate and valve body together.
Page 330 Transmission Disassemble Transmission Tools Needed Tools Needed Eye Bolt Start By: 4. Remove rubber caps (6) ad bolts (7). a. Remove torque converter 5. Remove control valve (8) and the separator plate b. Remove drive axle from the transmission. Remove the gasket for the separator plate. 1.
Page 331 13. Inspect the bushing (18) in the drive gear. If the bushing has a large amount of wear, make a replacement of the bushing and drive gear as a unit. The parts can not be ordered separately. 14. Remove driven gear (19) from pump body. Remove lip type seal (20).
Page 332 19. Remove bearing cups and shims (26). 25. Remove plug (36) and o-ring, spring (37) and screen (38) from the case. NOTE : Bearing cups and their shims will be in cover or on the shafts in transmission case. Put identification on each of bearing cups and shims as to their location on transmission cover or shaft in transmission case.
Page 333 29. For high speed forward clutch assembly, remove 33. Remove a pressure plate, seven clutch discs and bearing cone (44) with gear pulley. seven clutch plates from the cylinder. 30. Remove two thrust washes (45) and gear (46). 34. Push down on the retainer (48) by a press and remove snap ring (49) with a screwdriver.
Page 334 37. For low speed forward clutch assembly, remove 39. Remove two thrust washes (56) and pin (57). seal rings (51) from shaft. Remove bearing (52), thrust washer (53), gear 40. Push down on the retainer (58) by a press and (54), needle bearing, spacer and needle bearing.
Page 335 Assemble Transmission 1. Thoroughly clean all the parts of the transmission. Put clean transmission oil on all of the inner parts. 44. Remove bearing cups (63) from the transmission case. NOTE: Put identification on bearing cups to use at assembly. 2.
Page 336 5. Install seal ring on the piston (60). Put clean 11. Put clean transmission oil on each side of the transmission oil on the seal ring. clutch plates and clutch discs. Install seven clutch plates, seven clutch discs in the cylinder with the 6.
Page 337 16. Put clean transmission oil on each side of the 20. Install gear (46), thrust washes (45) and bearing clutch plates, and clutch discs. Install seven cone (44) with tool. clutch plates, seven clutch discs in the cylinder with the following procedure. NOTICE a.
Page 338 23. Carefully put the counter shaft assembly (42) in 26. Install screen (38), spring (37) and plug (36), in position in the transmission case. the transmission case. 24. Carefully put the input shaft assembly (41) in position in the transmission case. Install output shaft assembly (40) into output gear assembly (43).
Page 339 32. Put bearing cups and their shins (26) in the 4) Measure the dimension ÔYÕ from surface of transmission cover. transmission cover to bottom of bore where bearing cup is installed. NOTE: Bearing cups and their shims should be put into their location on transmission cover so as to fit 5) Calculate required shim thickness as following on their shafts in transmission case.
Page 340 34. Put a new gasket for the transmission cover (25) 41. Install screw (13) that holds the stator support in position on the transmission case. Carefully (14) to the pump body. put transmission cover (25) in on the case as straight as possible.
Page 341 44. Install torque converter housing in position. 47. Put solenoids (5) and o-ring into position on the Install bolts (9) and washes that hold torque valve body. Slide pins (4) in position. converter housing to the transmission. Tighten the bolts to a torque of 70 L 15 N¥m (51 L 11 48.
Page 342 Drive Axle Disassembly Prior to disassembly clean axle housing carefully. A great help is a bright, spacious working place, free of dirt and chips. The necessary working steps are described and illustrated in the correct sequence. Parts only available as assembly groups will not be stripped any further.
Page 343 7. Remove stop ring (9) and pull off sun gear (10) 11. Remove wheel hub assembly (14) from the axle from the axle shaft. flange by using bearing puller. 8. Loosen the bolts (11) and remove them. 12. With the aid of a copper mandrel and a hammer drive bearings out of the wheel hub.
Page 344 Removal And Strip Down Of The Removal and strip down of the axle Brake housing 1. Remove the 2 tension springs (1) with the aid of 1. Loosen the bolts (1) and remove them. pliers or a screwdriver from the brake downholding. Fasten link bracket to the housing and a hoist.
Page 345 6. Loosen and remove the bolts (6) on the differential 9. Loosen locknut (7). housing. 10. By means of a plastic hammer drive bevel pinion shaft (8) carefully out of the bearing seat. NOTE : Take care that bevel pinion shaft is not damaged when driving it out.
Page 346 Reassembly Clean all parts with a suitable cleaning agent and remove residues of LOCTITE. WARNING Keep away cleaning agent from your skin, do not drink it or inhale its vapours ! Wear safety gloves and goggles! In case of skin contact rinse immediately with a lot of water! If by mistake the cleaning agent was swallowed, call 12.
Page 347 Determination of Installation Dimension For Bevel Pinion Shaft 2. Shim ring thickness determined has to be obtained by combining shim rings of variable thickness. Place shim rings into bearing seat. With the aid of a copper mandrel drive bearing outer race into the bearing seat of the housing until contact.
Page 348 Measurement Bearing Play of Bevel Adjustment Of Bearing Preload On Pinion Shaft Bevel Pinion Shaft 1. Install bearing cup. Put the spacer into the pinion shaft and place shims determined on the spacer. With the following method the dimensions can be used to determine the shim ring (2) thickness.
Page 349 Presassembly Differential 4. Place differential assembly into the carrier. Locate bearing cups and screws into the housing halves. It is advantageous to fix the torsional backlash now. This is done by means of the screws. Position dial gauge with magnetic stand right- angled to a tooth flank and measure the torsional backlash rotating the bevel gear.
Page 350 Contact Pattern Check Assembly Of Carrier Into Axle Housing For a contact pattern check it is necessary to apply marking ink onto 3-4 tooth flanks of the crown gear. Have the ink-marked tooth flanks get into mesh with the bevel pinion several times. A better recognition of the contact pattern is possible, when the bevel pinion is braked slightly.
Page 351 2. Lead brake cable through the provided borehole of 5. Install preassembled wheel hub onto axle flange the brake carrier and hook it on the pressure rod until contact. Insert bearing cone. of the brake shoes. Assemble brake shoes, compression springs and tension springs as described in the Disassembly Section in reverse order.
Page 352 When new parts are used, shim thickness should be determined as follows. a. Place the axle tube and wheel hub assembly in a position with wheel hub torward the upside of the assembly. b. Measure distance from axle tube face to inner bearing face of wheel hub outside.
Page 353 SB2203E00 J u n . 1 9 9 9 Specifications Systems Operation Testing & Adjusting 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 354 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 356 Index Specifications Booster-Brake ............6 Hydraulic Control Valve ..........5 Hydraulic Pump ............6 Steering Gear ............7 Steering Wheel And Gear Group.......7 Steer Wheels And Steer Axle ........7 Tilt Cylinder ..............6 Tilt Cylinder Installation..........6 Systems Operation Brake System ............21 Control Valve ............10 Hydraulic System............8 Steering System ............17 Steering Unit ............18 Testing And Adjusting...
Page 358 (3) Torque for main relief valve ..65 N¥m (575 lb¥in) (4) Torque for secondary relief valve....45 N¥m (398 lb¥in) Main relief valve pressure (3) L 250 kPa (D35S-2, D40S-2, D40SC-2) ..19400 (2813 L 36 psi) (G35S-2, G40S-2, G40SC-2) Main relief valve pressure (3) (D45S-2, D45SC-2, D50SC-2)..21400 L 250 kPa...
Page 359 Hydraulic Pump Tilt Cylinder Installation IACS102I ICCS033S Large Section Of Pump (Hydraulic Controls and Steering) : A 1. Adjust clevises (2) to have Forward Tilt Angle (A) and backward Tilt Angle (B) as per Tilt Cylinder Small Section Of Pump (Brake) : B specifications.
Page 360 Steering Wheel And Gear Steer Wheels And Steer Axle Group IACS105I IACS104I (1) Torque for nut ..430 L 35 N¥m (317 L 26 lb¥ft) (2) Steer wheel bearing adjustment : (1) Torque for nut....80 L 7 N¥m (60 L 5 lb¥ft) a.
Page 361 Systems Operation Hydraulic System 11 16 IACS106I Basic Hydraulic Schematic. (1) Lift Cylinders. (2) Excess Flow Protector. (3) Sideshift Cylinder(Option). (4) Flow Regulator. (5) Hydraulic Control Valve. (6) Tilt Cylinders. (7) Relief Valve (Lift). (8) Relief Valve (Tilt and sideshift). (9) Hydraulic Oil Filter. (10) Hydraulic Oil Tank. (11) Priority Valve.
Page 362 The maximum speed when the lift cylinders are lowered is controlled by flow regulator (4). Excess flow protector (2) will act as flow regulator if an oil line between protector and flow regulator (4) is broken when the mast is raised or lowered. This prevents a sudden fall of the mast or carriage if an oil line is broken.
Page 363 Control Valve Lift Valve Neutral Position IACS107I Control Valve for Lift (Shown in NEUTRAL Position) (1) Spool. (2) Outlet to Head end of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage for Pump Oil. (6) Chamber. (7) Passage for Return Oil. (8) Passage. (9) Chamber. (10) Spring. (11) Secondary Relief Valve. Oil from pump enters the valve through a passage in the inlet section.
Page 364 Lift Position IACS108I Control Valve for Lift (Shown in LIFT Position) (1) Spool. (2) Outlet to Head end of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage for Pump Oil. (6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring. (11) Secondary Relief Valve. When the control lever is moved to the LIFT position, lift spool (1) is moved into the valve.
Page 365 Lower Position IACS109I Control Valve for Lift (Shown in LOWER Postion) (1) Spool. (2) Outlet to Head end of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage for Pump Oil. (6) Chamber. (7) Passage for Return Oil. (8) Passage. (9) Chamber. (10) Spring. (11) Secondary Relief Valve When the control lever for lift is moved to the LOWER position, lift spool (1) moves until a path is opened between outlet (2) and passage for return oil...
Page 366 Tilt Neutral Position IACS110I Tilt Spool in Neutral Position (1) Spool. (2) Outlet to Rod end of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage for Pump Oil. (6) Chamber. (7) Outlet to Head end of Tilt Cylinders. (8) Passage for Return Oil. (9) Spring. (10) Spool. (11) Passage. (12) Chamber. (13) Spring.
Page 367 Tilt Forward Position IACS111I Tilt Spool in Forward Position (1) Spool. (2) Outlet to Rod end of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage for Pump Oil. (6) Chamber. (7) Outlet to Head end of Tilt Cylinders. (8) Passage for Return Oil. (9) Spring. (10) Spool. (11) Passage. (12) Chamber.
Page 368 Tilt Back Position 11 15 Tilt Spool in Tilt Back Position (1) Spool. (2) Outlet to Rod end of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage for Pump Oil. (6) Chamber. (7) Outlet to Head end of Tilt Cylinders. (8) Passage for Return Oil. (9) Spring. (10) Spool. (11) Passage. (12) Chamber.
Page 369 Relief Valve If the control lever is held in the end position after the cylinder rod is fully extended or retracted, the flow of oil from outlet to the cylinders is stopped. The oil under pressure must be released. The pressure oil flows through relief valve, then returns to tank.
Page 370 Steering System Hydraulic Operation (Load Sensing Closed Center Steering System) ICCS113I Steering System Schematic (1) Steering Unit. (2) Hose (To Hydraulic Tank). (3) Priority Valve. (4) Hose (From Hydraulic Pump). (5) Hose (to Control Valve). (6) Hose. (7) Hose. (8) Steering Cylinder. (9) Check Valve (in Steering Unit). (10) Hose (From Priority Valve). (11) Hydraulic Main Pump. (12) Hydraulic Tank.
Page 371 Steering Unit Oil Flow TANK OIL (SUPPLY) METERED OIL RETURN OIL ICCS017S Steering Unit (Shown in RIGHT TURN Position) (1) Spool. (2) Sleeve. (3) Outlet to Tank. (4) Check Valve. (5) Inlet from Pump. (8) Centering Springs. (9) Pin. ICCS016S (10) Left Turn Port.
Page 372 TANK OIL (SUPPLY) METERED OIL RETURN OIL ICCS018S ICCS019S Steering Unit (Shown in a LEFT TURN Position) Spool And Sleeve (1) Spool. (2) Sleeve. (3) Outlet to Tank. (5) Inlet From Pump. (1) Spool. (2) Sleeve. (18) Slots for Spring. (19) Holes For pin. (9) Pin.
Page 373 TANK OIL (SUPPLY) METERED OIL RETURN OIL 15 16 EMERGENCY ICCS021S ICCS020S Pump Gears In The Metering Section Steering Unit (6) Rotor. (7) Stator. (9) Pin. (13) Drive. (3) Outlet to Tank. (4) Check Valve. (10) Left Turn Port. (11) Right Turn Port. (15) Passage. (16) Gerotor. When the steering wheel is turned, in either direction, (17) Passage.
Page 374 Brake System Brake System Schematic (1) Hydraulic Pump. (2) Hydraulic Booster. (3) Suction Filter. (4) Hydraulic Oil Tank. (5) Hydraulic Line (from Pump to Hydraulic Booster). (6), (7) Hydraulic Line (from Hydraulic Booster to Brake). (8) Hydraulic Line (from Hydraulic Booster to Filter). (9) Hydraulic Line (from Hydraulic Booster to Hydraulic Oil Tank). (10) Brake. The hydraulic pump (1) is connected to the engine The master cylinder section in the hydraulic booster power take off and supply the hydraulic oil to the...
Page 375 Testing & Adjusting Visual Checks A visual inspection is the first step when diagnosis of a problem is made of the hydraulic system, hydraulic Troubleshooting brake systems and their components. Lower the mast and carriage to the ground. If the mast and carriage cannot be on the ground, make sure they Troubleshooting can be difficult.
Page 376 Hydraulic Oil Temperature (Too Hot). 2. Drift rates in the cylinders. Cylinder drift is caused by a leakage past cylinder pistons, O-ring seals in When the temperature of the hydraulic oil gets over the control valve, check valves that do not seat 98.8ûC(210ûF), polyurethane seals in the system start correctly or poor adjustment or fit in the control to fail.
Page 377 Probable Mechanical Cause : Hydraulic Control Valve 1. Damage or failure of the piston rods on the tilt Problem : The control spools do not move freely. cylinders. Probable Cause : Problem : The carriage will not lower correctly. 1. The viscosity of the oil is too high. Probable Hydraulic Cause : 2.
Page 378 Problem : Spools do not return to neutral. Problem : Foreign material behind the wiper rings which causes scratches on the cylinder rod. Probable Cause : Probable Cause : 1. The springs are broken. 1. The wiper rings shown wear and do not remove 2.
Page 379 Problem : Leakage on the shaft seal. Problem : Too much force needed to turn steering wheel. Probable Cause : Probable Cause : 1. The shaft seal is worn. 1. Relief valve is open. 2. The inner parts of the pump body are worn. 2.
Page 380 Problem : Oil leakage at the pump Brake System Probable Cause : Problem : Brake engagement is slow (hard brake pedal). 1. Loose hose connections. Probable Cause : 2. Bad shaft seal. 1. Low supply of hydraulic fluid in the system. Problem : Low oil pressure.
Page 381 3. Oil or grease on the brake linings. Hydraulic System 4. Pedal linkage out of adjustment. Relief Valve Pressure Check 5. Brake lines have damage. 6. Not enough pressure in the brake hydraulic WARNING booster. Hydraulic oil, under pressure can remain in the 7.
Page 382 The gauge shows relief valve opening pressure. The correct pressure setting is 19,400 (L250) kPa Steer Wheel Bearing Adjustment (2,813(L36) psi) for D35S-2/D40S-2/ D40SC-2, G35S-2/G40S-2/G40SC-2 model or 21,400 (L250) kPa (3,103(L36) psi) for D45S-2/D45SC- 2/D50SC-2, G45S-2/G45SC-2/G50SC-2 model. ICCS025P Outer Wheel Bearing (1) Outer Wheel Bearing.
Page 383 Steer Axle Stop Adjustment WARNING FRONT OF TRUCK To prevent personal injury, apply the parking brakes and put blocks in front of drive wheels to stop any movement of the truck. 1. Raise the steer wheels just enough from the floor so steer wheels can be turned freely.
Page 384 3. Lift a capacity load to take the weight off of the steer axle. Turn the steering wheel as rapidly as possible to remove the air in the steering cylinder and lines. FRONT OF TRUCK 4. Add oil immediately when the valve spool of the metering pump is activated to replace oil that flows through the circuit.
Page 385 Steering System Pressure Check 5. The indication on the pressure gauge is the steering relief setting pressure of 16000 kPa (2280 psi). If the indication is correct and a problem If the steering system does not work correctly, check exists, then there is possibly a mechanical failure the hydraulic tank for the correct oil level and the in the steering system.
Page 386 Brake System Parking Brake Adjustment Brake System Air Removal When the brake pedal resistance is spongy (not solid) it is usually an indication that there is air in the brake hydraulic system. The cause may be low fluid or oil level, leakage in the system, a broken brake line or a brake line that is not connected.
Page 387 Parking Brake Test Tilt Cylinder Alignment ICCS032P Parking Brake Test (Typical Example) 1. Drive the lift truck fully loaded up a 15% incline. 2. Halfway up the incline stop the lift truck with the service brake. Apply the parking brakes. 3.
Page 388 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 389 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 391 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 393 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 394 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 395 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 396 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 397 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 398 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 399 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 400 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 401 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 402 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 403 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 404 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 405 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 406 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 407 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 408 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 409 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 410 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 411 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 412 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 413 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 414 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 415 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 416 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 417 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 418 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 419 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 420 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 421 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 422 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 423 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 424 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 425 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 426 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 427 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 428 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 429 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.
Page 430 SB2205E00 J u n . 1 9 9 9 Schematic Lift Trucks Hydraulic System 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 431 MODEL : D35S-2, D40S-2, D45S-2 D40SC-2, D45SC-2, D50SC-2 G35S-2, G40S-2, G45S-2 G40SC-2, G45SC-2, G50SC-2 Item Components Hydraulic Pump Priority Valve Steering Unit Steering Cylinder Flow Regulator Flow Protector-Primary Flow Protector-Secondary, Standard Lift Cylinder-Primary Lift Cylinder-Secondary, Standard Tilt Cylinder Hydraulic Filter...
Page 432 SB2206E00 J u n . 1 9 9 9 Schematic Lift Trucks Electric System 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 433 WIRING SCHEMATIC-ELEC MODEL : D35S-2, D40S-2, D45S-2 D40SC-2, D45SC-2, D50SC-2 for DB58 E/G...
Page 434 WIRING SCHEMATIC-ELEC MODEL : G35S-2, G40S-2, G45S-2 G40SC-2, G45SC-2, G50SC-2 for GM VORTEC V6 E/G...
Page 435 WIRING SCHEMATIC-ELEC MODEL : D(G)35/40/45S-2, D(G)40/45/50SC-2 for OPTION...
Page 436 SB2207E00 J u n . 1 9 9 9 Disassembly & Assembly Testing & Adjusting Lift Trucks Mast 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 437 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 439 Index Disassembly & Assembly Backrest ..............5 Carriage ..............6 Forks ................5 Mast .................10 Testing & Adjusting Carriage Adjustment ..........20 Carriage and Mast Height Adjustment.....21 Chain Adjustments...........20 Chain Wear Test ............21 Drift Test..............23 Forks Parallel Check ..........22 Lift & Tilt Mounting Group Adjustment .....24 Mast mounting Group Adjustment ......25 Tilt Cylinder Adjustment ...........23 Tilt Cylinder Alignment ..........22...
Page 441 Disassembly & Assembly Backrest Remove & Install Backrest Forks Remove & Install Forks 1. Fasten a hoist to the backrest. Remove bolts(2) that fasten the backrest to the carriage. 2. Remove backrest (1). Backrest weighs 74 kg (163 lb). 3. Install backrest(1) in the reverse order of removal. 1.
Page 442 Carriage Remove & Install Carriage Start By: a. Remove forks. b. Remove backrest. 3. Remove four nuts (7) from the chain anchors. Set the chains aside, clear of the mast. 4. Remove cross head (8) from the primary cylinder. IBCD510P 1.
Page 443 Disassemble Carriage Start By : a. Remove carriage. b. Remove side shifter. 8. Install cross head (8) onto the primary cylinder. 9. Put the chains in position over cross head. (8). Install nuts (7) onto the chain anchors to a torque L L 70 N¥m (370 L L 50 lb¥ft).
Page 444 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. To make the carriage clearance adjustments, carriage must be removed from the mast.
Page 445 2. Install enough shims (1) that have been divided 5. Install roller (5) with bushing and washer, washer into two equal groups behind bearngs (2). At (6), adjust pin (7) and nut on each side of the installation, there is to be 1.5 mm clearance carriage.
Page 446 Mast Remove & Install Mast Start By : a. Remove forks. Typical Example NOTICE Place identification marks on all hydraulic connectors and hoses to assure prope installation. Plug and cap all hydraulic connectors and hoses to avoid debris and contamination from entering the system. 1.
Page 447 Disassemble Mast Start By : a. Remove carriage and side shifter. b. Remove mast. NOTE : The following disassembly and assembly procedure is for a full free triple lift mast. 7. Remove bolt (4) from each side of mast assembly (2).
Page 448 6. Loosen four bolts and remove chains (13) with 9. Check the condition of bearings (17) located in anchor (12) from the bottom of the mast (each each of the tilt cylinder pin bores. Replace side). bearings (17) with new if worn or damaged. 7.
Page 449 13. Move inner mast channel (21) upward. 16. Move intermediate mast channel (22) downward. 17. Remove bearings (25) and the shims from the stationary mast channel. 14. Fasten nylon straps and hoist to inner mast channel (21). Remove inner mast channel. The weight of the inner mast channel is 250 kg (550 lb).
Page 450 Assemble Mast NOTICE NOTE : The standard, Full Free Lift and Full Free When the correct amount of shim has been installed Triple Lift mast load bearings are all adjusted the behind bearings, there will be contact (zero clearance) same way. The mast shown in the following between the bearings and the mast at most narrow illustrations is the Full Free Triple Lift mast.
Page 451 6. Install 1mm shim and bearing (3) of intermediate 7. Make sure intermediate mast lower bearings are lower basically. 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.
Page 452 10. Install 1 mm shim to each bearing of stationary 11. Make sure stationary mast upper bearings are mast upper basically. 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.
Page 453 C. Lower Bearing Adjustment of Inner Mast 16. Lifting by crane, insert inner mast (9) into intermediate mast (10) from the upper side. Mast Adjustment Lower Bearings (A) Zero Clearance. (B) Zero Clearance. (1) Bearing. (2) Shims. (3) Bearing. (4) Shims. Mast Adjustment Lower Bearings.
Page 454 19. Install bracket (13) with hose sheaves on the 22. If the bearings (15) were removed from the tilt intermediate mast. cylinder pin bores, install new ones. NOTE : Turn over mast assÕy and lay down with hoist crane so that front of mast is faced to upper direction.
Page 455 26. Install chain anchors (18) at the bottom of the 28. Install block (21) and elbow (20). intermediate mast. Tighten the bolts to a torque of 940 L L 60 N¥m (694 L L 44 lb¥ft). 29. Connect the hoses (23), (24) and tube (22). 30.
Page 456 Testing & Adjusting Chain Adjustments Chain Adjustment Check Carriage Adjustment 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. To make the carriage clearance adjustments, carriage must be removed from the mast.
Page 457 2. Make adjustments to chain anchor nuts (1) or bolts Carriage and Mast Height (2) for equal tension of the mast and carriage Adjustment chains. 3. Put LOCTITE NO.242 Thread Lock on the threads 1. Move the mast either forward or backward so it is of the locknuts after the adjustment is completed.
Page 458 Forks Parallel Check Tilt Cylinder Alignment 1. Lift the mast and operate the tilt control lever, until If the tilt cylinders are out of alignment, extra stresses the top surface of the forks is parallel with the in the mast assembly and the mast hinge area will floor.
Page 459 Drift Test Tilt Cylinder Adjustment Drift is movement of the mast or carriage that is the result of hydraulic leakage in the cylinders or control WARNING valve. Before testing the drift: Tilt cylinder pivot eyes can loosen if the torque on the pivot eye clamping bolt is not tight enough.
Page 460 Lift & Tilt Mounting Group Adjustment VIEW A-A (1) With chains adjusted for equal tension, run mast to full lift. If mast does not kick (move) to one side, no shims are needed. If mast does kick (move) to one side, disconnect cylinder rod from the bolt on that side.
Page 461 Mast Mounting Group Adjustment DETAIL A 1. Apply clean grease to surface of bearing (6) before pin (5) installation. 2. Install block (4) with bolt (2) and washer (3). Tighten the bolt to a torque of 600 L 70 N¥m (440 L 50 lb¥ft).
Page 462 SB2301E02 Operation & Maintenance Manual LIFT TRUCKS D35S-2, D40S-2, D45S-2 G35S-2, G40S-2, G45S-2 D40SC-2, D45SC-2, D50SC-2 G40SC-2, G45SC-2, G50SC-2...
Page 463 WARNING Do not start, operate or service this machine unless you have read and understood these instructions and received proper training. Unsafe or improper use of the machine may cause serious injury or death. Operators and maintenance personnel must read this manual and receive training before operating or maintaining the machine.
Page 464 Information Section Table of Contents Information Section Maintenance Section Foreword ..............2 Tire Inflation Information........71 Torque Specifications .........72 Cooling System Specifications......74 Safety Section Fuel Specifications ..........76 Important Safety Information........4 Lubricant Specifications ........78 Safety ..............5 Lubricant Viscosities and Refill Capacities ..80 Warning Signs and Labels ......5 Maintenance Intervals ........81 General Hazard Information.......9 When Required ..........82...
Page 465: Information Section
WARNING basic. Skill and techniques develop as the operator gains knowledge of the lift truck and its capabilities. Your DAEWOO truck comes equipped with an operator restraint system. Should it become necessary to replace the seat for any reason, it should only be replaced with another DAEWOO operator restraint system.
Page 466 Hours or 3 MonthsÓ, also service those items listed under ÒEvery 250 Service Hours or MonthlyÓ and ÒEvery 10 Service Hours or DailyÓ. Environment Management Note that DAEWOO INDUSTRIAL VEHICLE DIVI- SION is ISO 14001 certified which is harmonized with ISO 9001. Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by internal and external inspection entities.
Page 467: Safety Section
The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current infor- mation available.
Page 468: Safety
Directives 89 / 655 /EC and 89 / 391 /EC and its amendments for the safe use of DAEWOO lift trucks. The most effective method of preventing serious injury or death to the lift truck operator or others is...
Page 469 Safety Section 8. Do not permit riders on forks or machine at any time. 9. Do not allow anyone to stand or pass under the elevated portion of any machine. 10. Be sure operating surface can safely support machine. 11. Operate machine and attachments only from operator's position.
Page 470 Safety Section WARNING WARNING Contents under pressure may be hot. Allow to Do not stand or ride on the forks. Do not stand cool before opening. or ride on a load or pallet on the forks. Do not stand or walk under the forks. IAOY003I IAOY005I Located on the radiator top tank by the radiator cap.
Page 471 Safety Section WARNING WARNING Operation without this device in place may be To avoid personal injury, allow no riders. A lift hazardous.This guard conforms to A.N.S.I.B56.1 truck is designed for only one operator and no and F.E.M.Section IV.This design has been test- riders.
Page 472: General Hazard Information
Safety Section General Hazard Information Always use the overhead guard. The overhead guard is intended to protect the lift truck operator from overhead obstructions and from falling objects. A truck that is used for handing small objects or uneven loads must be fitted with a load backrest. If the lift truck must be operated without the over- head guard in place due to low overhead clearance, use extreme care.
Page 473: Operation Information
Safety Section Inhaling freon gas through a lit cigarette or other Operation Information smoking method or inhaling fumes released from a flame contacting freon can cause bodily harm or Mounting and Dismounting death. Do not smoke when servicing air conditioners or wherever freon gas may be present.
Page 474 Safety Section underneath or close to the lift truck before operat- for proper operation. ing the lift truck. Operating the Lift Truck Operate the lift truck and controls only from the operator's station. Always keep the lift truck under control. Make sure the lift truck horn, lights, backup alarm (if Obey all traffic rules and warning signs.
Page 475 Safety Section Loading or Unloading Trucks/Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers.
Page 476: Maintenance Information
The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes. To avoid possible weakening of the Falling Objects Protective Structure (FOPS), consult a DAEWOO Fluid Penetration dealer before altering, by adding weight to, welding on, or cutting or drilling holes into the structure.
Page 477 Safety Section Burn Prevention Fire or Explosion Prevention Coolant All fuels, most lubricants and some coolant mix- tures are flammable. At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to Fuel leaked or spilled onto hot surfaces or electrical heaters or the engine contain hot water or steam.
Page 478 Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Contact your DAEWOO dealer for repair or replacement. Check lines, tubes and hoses carefully. Do not use IAOY012I your bare hand to check for leaks.
Page 479: Operator Restraint System (If Equipped)
Warning Signs and Labels Nitrogen inflated tires reduce the potential of a tire explosion, because nitrogen does not support com- Your DAEWOO lift truck has the following tipover bustion. Also, nitrogen helps prevent oxidation and warning decals. the resulting deterioration of rubber and corrosion of rim components.
Page 480 DO NOT adjust the seat while the truck is in motion. WARNING Your DAEWOO truck comes equipped with a DAEWOO operator restraint system. Should it The ÒSurvive in tipoverÓ warning is located on the become necessary to replace the seat for any overhead guard.
Page 481 Safety Section The system is designed to keep the operator on the WARNING seat and in the operatorÕs compartment in the event of a tipover. Inspection WARNING 3. In the event of a tipover, the seat and restraint system should be inspected for damage and replaced, if necessary.
Page 482: Avoiding Lift Truck Tipovers
Safety Section Avoiding Lift Truck Tipovers WARNING Lift Truck Stability If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. INSO023I Counterbalanced lift truck design is based on the balance of two weights on opposite sides of a ful- crum (the front axle).
Page 483 Safety Section Stability and Center of Gravity Lift Truck Stability Base CG-Truck will tip over CG truck Combined CG CG load INSO025I INSO027I The stability of the lift truck is determined by the For the lift truck to be stable (not tip over forward or location of its CG;...
Page 484 NOTE : If the load is not uniform, the heaviest por- tion should be placed closer to the backrest and centered on the forks. NOTICE 1. Capacity/Nameplates originally attached to forklifts sold by DAEWOO shall not be removed, altered replaced without DAEWOO’s approval.
Page 485 Safety Section INSO032S INSO035S DONÕT start, turn, or stop quickly. DONÕT turn on, or drive across an incline. Sudden movement can cause the lift truck to tipover. INSO036S DONÕT tilt elevated loads forwards! This can cause INSO033S the lift truck to tipover forward. DONÕT crowd.
Page 486 Safety Section INSO038S INSO041S DONÕT pick up an off center load! Such a load DONÕT jump off if your truck starts to tipover! increases the possibility of a tipover to the side. Stay in your seat to survive. INSO039S INSO042I DONÕT drive on slippery surfaces! Sand, gravel, DONÕT compromise safety.
Page 487: How To Survive In A Tipover (If Operator Restraint System Equipped)
Safety Section How to Survive in a Tipover (If Operator Restraint System FASTEN SEAT BELT TIPOVER CAN OCCUR Equipped) IF TRUCK IS IMPROPERLY HOLD ON TIGHT TO LEAN AWAY LEAN OPERATED. DON'T JUMP BRACE FEET STEERING WHEEL FROM IMPACT FORWARD INJURY OR DEATH IN CASE OF TIPOVER WARNING...
Page 488 Safety Section FASTEN SEAT BELT TIPOVER CAN OCCUR IF TRUCK IS IMPROPERLY HOLD ON TIGHT TO LEAN AWAY LEAN OPERATED. DON'T JUMP BRACE FEET STEERING WHEEL FROM IMPACT FORWARD INJURY OR DEATH IN CASE OF TIPOVER WARNING COULD RESULT. LEAN AWAY INSO050I Lean away from the direction of fall.
Page 489: General Section
General Section Specifications CHARACTERISTICS Manufacturer UNIT Model D(G)35S-2 D(G)40SC-2 D(G)40S-2 Capacity at rated load center 3500 4000 4000 Load center distance Power type electric, diesel, gas, lp-gas diesel LP-GAS diesel LP-GAS diesel LP-GAS Operator type stand-on, rider seated rider-seated rider-seated rider-seated Tire type c = cushion, p = pneumatic...
Page 490 General Section D(G)45SC-2 D(G)45S-2 D(G)50SC-2 4500 4500 5000 diesel LP-GAS diesel LP-GAS diesel LP-GAS rider - seated rider - seated rider - seated 2/ 2 2/ 2 2/ 2 INTERSECTING RIGHT 3000 3000 3000 ANGLE AISLE MINIMUM AISLE-90 STACK 50 X 150 X 1050 50 X 150 X 1200 50 X 150 X 1200 8/ 10...
Page 491: Noise And Vibration
General Section Noise and Vibration Noise at operator ear (measured by prEN) unit : dB (A) unit : dB (A) Model Sound level (Leg) Model Sound level (Leg) D35S-2 G35S-2 D40S-2 G40S-2 D45S-2 G45S-2 86.5 84.8 D40SC-2 G40SC-2 D45SC-2 G45SC-2...
Page 492: Capacity Chart
General Section Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD, FFL 3500 4000 3000 3500 2500 3000 2000 2500 1500 2000 1000 1500 1000 1100 1200 1000 1100 1200 A. 3000, 3300, 3650, 4000mm MAST A. 4000mm MAST E. 5600mm MAST B.
Page 493 General Section Capacity Chart DOUBLE TIRE DOUBLE TIRE MODEL STD, FFL 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1100 1200 1000 1100 1200 A. 3000, 3300, 3650, 4000mm MAST A. 4000mm MAST E. 5600mm MAST B.
Page 494 General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE MODEL STD, FFL 3500 4000 3000 3500 2500 3000 2000 2500 1500 2000 1000 1500 1000 1100 1200 1000 1100 1200 A. 3000, 3300, 3650, 4000mm MAST A. 4000mm MAST E.
Page 495 General Section Capacity Chart (with Side Shifter) DOUBLE TIRE DOUBLE TIRE MODEL STD, FFL 4000 4000 A B C 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1100 1200 1000 1100 1200 A. 3000, 3300, 3650, 4000mm MAST A.
Page 496 General Section Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD, FFL 4000 4000 3500 3500 3000 3000 2500 2000 2500 1500 2000 1000 1500 1000 1100 1200 1000 1100 1200 A. 3000, 3300, 3650, 4000, 4250mm MAST A. 4000, 4250mm MAST E.
Page 497 General Section Capacity Chart DOUBLE TIRE DOUBLE TIRE MODEL STD, FFL 4000 4000 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1100 1200 1000 1100 1200 A. 3000, 3300, 3650, 4000, 4250, 4850mm MAST A. 4000, 4250mm MAST E.
Page 498 General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE MODEL STD, FFL 3500 4000 3000 3500 2500 3000 2000 2500 1500 2000 1000 1500 1000 1100 1200 1000 1100 1200 A. 3000, 3300, 3650, 4000mm MAST A. 4000mm MAST E.
Page 499 General Section Capacity Chart (with Side Shifter) DOUBLE TIRE DOUBLE TIRE MODEL STD, FFL 3500 3500 3000 3000 2500 2500 2000 1500 2000 1000 1100 1200 1000 1100 1200 A. 3000, 3300, 3650, 4000, 4250mm MAST A. 4000mm MAST E. 5600mm MAST B.
Page 500: Serial Number
General Section Serial Number Serial Number Locations For quick reference, record your lift truckÕs serial numbers in the spaces provided below the pho- tographs. IA3M2011 Transmission Serial Number IA3M2009 Lift Truck Serial Number P0007399 DRIVE AXLE Serial Number IA3M2010 5.8. liter Diesel Engine Serial Number IA3M2012 Typical Example Side Shifter Serial Number...
Page 501: Operatorõs Warning And Identification Plate
General Section Operator's Warning and Identification Plate Familiarize yourself with the OPERATOR'S WARING, IDENTIFICATION, LIFT CAPACITY and ATTACHMENT PLATES. DO NOT exceed CAPACITY AS EQUPPED load ratings. Operator’s Warning Plate Identification, Lift Capacity and Attachment Plate IA3M1002 IA3M1001 Located by the right side of the operatorÕs seat on the engine compartment cover.
Page 502 General Section Attachment Abbreviations (includes Special Forks) SC-Special Carriage-increased width, height or outreach SSS - Shaft-type Sideshift Carriage HSS - Hook-type Sideshift Carriage (ITA) CW - Counterweight SF - Special Forks SWS - Swing Shift, Sideshift RAM - Ram or Boom DBCBH - Double Cube Block Handler HFP - Hydraulic Fork Positioner CR - Crane Arm or Crane Boom...
Page 503: Operation Section
Operation Section Operator’s Station and Monitoring Systems Instrument Panel 4. Fuel Level Gauge - Indicates fuel level. (Diesel and gasoline) 5. Engine Coolant Gauge - Indicates coolant temperature. If the pointer moves beyond the green band while operating the lift truck, overheating is indicated. Park the lift truck and stop the engine.
Page 504 Operation Section Engine Compartment IA3M3002 7. Horn Switch - Push on the horn but- ton to sound the horn. IA3M3047 1. The engine compartment is accessible by pulling the latch and raising the hood and seat assembly. ( Note : unlock latch before pulling-if key equipped) IA3M3003 8.
Page 505 Operation Section Circuit Breaker Electrical Disconnect Switch (If Equipped) IA3M4006 Diesel Truck IA3M3048 1. ON-Connects the battery for electri- cal power to all electrical circuits. 2. OFF-Disconnects the battery from all electrical circuits. Seat NOTE : Seat arrangments may vary. Basic opera- tion will be similar.
Page 506: Lift Truck Controls
Operation Section Lift Truck Controls Direction Control Lever Transmission Inching Control Pedal IA3M3007 IA3M3009 1. Forward - Push the lever forward for FORWARD direction travel. Inching Control Pedal - Pushing down on the inching pedal, modulates the 2. Neutral - Move the lever to center hydraulic pressure to the clutch packs, position for NEUTRAL.
Page 507 Operation Section Service Brake Pedal Parking Brake Lever IA3M3010 IA3M3013 Push DOWN on the brake pedal to Pull the lever BACK to engage the park- slow or stop the lift truck. ing brake. RELEASE the brake pedal to allow the Push the lever FORWARD to release lift truck to move.
Page 508 Operation Section Tilt Control Sideshift Attachment (If Equipped) IA3M3015 1. Mast Tilt Forward - Push the lever IA3M3016 FORWARD smoothly to tilt the mast 1. Sideshift Left - Push the lever FOR- forward. WARD to shift the carriage to the left. 2.
Page 509: Refueling
Operation Section Refueling Diesel Engine Equipped WARNING Explosive fumes may be present during refueling. Do not smoke in refueling areas. Lift truck should be refueled only at designated safe locations. Safe outdoor locations are preferable to those indoors. IA3M3019 Stop the engine and get off the lift truck during 1.
Page 510 Operation Section Changing LP-Gas Tanks 1. Park the lift truck on level ground, with the park- ing brake applied, the transmission in NEUTRAL, the forks lowered and the engine running at low idle. IA0O023P 6. Check to be sure that the LP-Gas warning plate is in position on the lift truck, and is legible.
Page 511 Operation Section IA0O025P 11. Position the replacement tank so that the locat- ing pin (dowel) is in place. 12. Clamp the tank securely. 13. Connect the fuel supply line. 14. Open the fuel valve by slowly turning the valve counterclockwise. If the fuel valve is opened too quickly, a back pressure check valve will shut off the fuel supply.
Page 512: Before Starting The Engine
Operation Section Before Starting the Engine Walk-Around Inspection 6. Inspect the tires and wheels for cuts, gouges, for- eign objects, inflation pressure and loose or missing bolts. Make a thorough walk-around inspection before mounting the lift truck or starting the engine. Look for such items as loose bolts, debris buildup, oil or coolant leaks.
Page 513 Operation Section 10. Inspect the engine compartment for oil, coolant 14. In case of LPG truck, if needed, change LPG and fuel leaks. Fuel Tank as the procedure of changing LP-Gas tanks in Refueling Section. WARNING Personal injury may occur from accidents caused by improper seat adjustment.
Page 514: Lift Fork Adjustment
Operation Section Lift Fork Adjustment Hook-type Fork knowledgeable of the material used and the required welding and heat treatment process. For load stability, always adjust the forks as wide as Users should evaluate the economics of returning possible. Position the load evenly on both forks. the forks to the manufacutrer for repairs or pur- chasing new forks.
Page 515 Operation Section ¥ Welded forks A variety of devices such as rams, attachment Standard Tire platens, special purpose forks and some large forks Forks may be fabricated from cold or hot rolled steel. Causes of Fork Failure 1. Improper Modification or Repair. Fork failure Plywood can occur as a result of a field modification involv- ing welding, flame cutting or other similar process-...
Page 516 Operation Section ¥ Repetitive Overloading and capacity. Also list any special characteristic- sspecified in the fork design.Record the date and Repetitive cycling of loads which exceeds the results of each inspection, making sure the follow- fatigue strength of the material can lead to fatigue ing information is included : failure.
Page 517 Operation Section Daily Inspection - Before First ¥ Heel sections may be ground with a carbon stone to remove minor surface cracks or defects. Polish Use and at Each Preventive the inside radius of the heel section to increase the Maintenance Inspection fatigue life of the fork.
Page 518: Starting The Engine
Operation Section Starting the Engine Prestart Conditions Starting a Cold Diesel Engine NOTE : The engine will not start unless the trans- 1. Turn the key to the ON position. The start pre- mission directional control lever is in the heat light will come ON.
Page 519 TIVE(-) to NEGATIVE(-). IA0O021P Attach ground cable last, remove first. All lift 1. Open the tank fuel valve by slowly turning the trucks equipped with DAEWOO built internal valve counterclockwise. Observe the LP -Gas combustion engines are NEGATIVE(-) ground. gauge(if equipped).
Page 520: After Starting The Engine
Operation Section After Starting the Engine Observe all indicator lights and gauges frequently during operation, to make sure all systems are working properly. All of the indicator lights will come ON with the ignition switch in the ON position before the engine is started. IA3M3031 6.
Page 521: Lift Truck Operation
Operation Section Lift Truck Operation Power Shift Transaxle WARNING 1. Start the engine. See topic ÒStarting the EngineÓ A lift truck with the engine running but without an operator can move slowly (creep) if the transmission is engaged. This could result in personal injury. Always place the transmission control lever in the NEUTRAL (center) positon and apply the parking brake before dismounting the lift truck.
Page 522 Operation Section IA3M3011 IA3M3011 11. To stop the lift truck when traveling in either 7. To change the lift truck direction of travel, release direction, release the accelerator pedal. the accelerator pedal. 12. Push down on the service brake pedal and 8.
Page 523 Operation Section Auto Shift Controller ASC - 200 (If Equipped) Product Description Adjustments The Autoshift controller is an electrical control sys- tem, specially designed for use on forklift trucks ( Low-High Shift Point ) ( Direction Inhibit Point ) with internal combustion engines. NOTCH Vehicle Speed NOTCH Vehicle Speed Its primary purpose is to prevent the operator from...
Page 524 Operation Section Diagnostics Features Operation ASC-200 has internal indicator on the right side of This system can basically operate in 2 preselected the controller for displaying the selected gear and modes. the abnormal condition. Automatic mode : selected as factory-setting. ¥...
Page 525 Operation Section Manual Mode ( Fail-Safe mode ) The system still allows movement of the vehicle in case of controller breakdown by selecting the manual mode with the Fail-Safe mode Switch in the controller. WARNING In the manual mode, direction inhibition func- tion can not be operated normally.
Page 526: Operating Techniques
Operation Section Operating Techniques Inching into Loads Lifting the Load 1. Lift the load carefully and tilt the mast back a short distance. IA3M3032 Typical Example IA3M3034 1. Move the lift truck slowly FORWARD into posi- Typical Example ton and engage the load. The lift truck should be square with load, forks spaced evenly between 2.
Page 527 Operation Section Travelling With the Load Unloading NOTICE Travel with the load as low as possible, while still maintaining ground clearance. IA3M3037 Typicl Example 1. Move the lift truck into the unloading position. IA3M3036 Typical Example 1. Travel with the load uphill on upgrades and downgrades.
Page 528 Operation Section Turning IA3M3038 Typical Example IA3M3040 3. Deposit the load and BACK away carefully to 1. When turning sharp corners, keep close to the disengage the forks. inside corner. Begin the turn when the inside drive wheel meets the corner. IA3M3039 Typcial Example IA3M3041...
Page 529 Operation Section Lifting Drums or Round Objects Operating in hot weather Keep the following points in mind when you oper- ate the lift truck in hot weather. 1. Check the radiator. Clogging can cause over- heating. Clean them out regularly with a blast of compressed air, also, check for leakage of water.
Page 530: Parking The Lift Truck
Operation Section Parking the Lift Truck IA3M1015 IA3M3044 5. Turn the key in the ignition switch to the OFF 1. Park in an authorized area only. Do not block position and remove the key. traffic. IA3M3029 IA0O021P 2. Place the transmission controls in NEUTRAL. NOTE : If a LP - Gas equipped lift truck is stopped 3.
Page 531: Storage Information
Operation Section Storage Information Before Storage To Operate the Lift Truck After a Long Time Storage Before storing your lift truck, clean and inspect as the following procedures. ¥ remove covers and antirust from each of the com- ponents and exposed parts. ¥...
Page 532: Transportation Hints
NOTICE width and length of a load. Remove ice, snow or other slippery material from the shipping vehicle and the loading dock. Contact your DAEWOO Lift Truck dealer for ship- ping instructions for your lift truck. IA3M3045 IA3M3045 Always block the trailer or the rail car wheels before loading the lift truck.
Page 533: Towing Information
The lift truck inclines or poor surface conditions. can roll free if it is not blocked. Consult your DAEWOO Lift Tuck dealer for towing Follow the recommendations below, to proper- a disabled lift truck. ly perform the towing procedure.
Page 534: Maintenance Section
Maintenance Section Tire Inflation Information Tire Inflation Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures. Ply Rating Shipping Pressure Size Strength Index 7.00X12 Steer 8.25X15 Drive 300X15 Drive 7.50X16 Drive dual IAOM001S Standard tire, ply rating and inflation pressures.
Page 535: Torque Specifications
Maintenance Section Torque Specifications Torques for Standard Bolts, Nuts Metric Hardware - This lift truck is almost totally metric design. and Taperlock Studs Specifications are given in metric and U.S.Customary measurement. Metric hardware must be replaced with metric NOTICE hardware. Check parts books for proper replace- The following charts give general torques for ment.
Page 536 Maintenance Section Torques for Taperlock Studs Thread Size Standard Taperlock Studs Torque Metric ISO** Thread Inch Standard Torque N•m* lb•ft Thread Size Inch N•m* lb•ft 12L4 5/16 17L5 13L4 35L5 26L4 25L7 18L5 7/16 45L10 33L7 55L10 41L7 95L15 70L11 65L10 48L7 110L20...
Page 537: Cooling System Specifications
The engine cooling system is normally protect- ed to -28°C(-20°F) with antifreeze, when DAEWOO prefers the use of distilled water or shipped from the factory unless special deionized water to reduce the potential and severi- requirements are defined.
Page 538 Maintenance Section Antifreeze Minimum Acceptable Water Water Content Limits gr/gal (ppm) Make proper antifreeze additions. Chlorides 2.4 (40) maximum Sulfates 5.9 (100) maximum Adding pure antifreeze as a makeup solution for Total Hardness 10 (170) maximum cooling system top-up is an unacceptable practice. Total Solids 20 (340) maximum It increases the concentration of antifreeze in the...
Page 539: Fuel Specifications
Maintenance Section Fuel Specifications Fuel Information Fuel Types DAEWOO Diesel Engines have the ability to burn Use only fuel as recommended in this section. a wide variety of fuels. These fuels are divided into two general groups, preferred and permissible.
Page 540 (American Society of Testing Materials) D-2896 method. (ASTM D-2896 can normally be found at your local technological society, library or college). DAEWOO recommends infrared analysis (in con- junction with wear metal analysis) of used oil in determining the effectiveness of oil TBN and acid neutralization.
Page 541: Lubricant Specifications
Maintenance Section Lubricant Specifications Lubricant Information Hydraulic Oil ( HYDO ) The following commercial classifications can be Certain abbreviations follow Society of Automotive used in the hydraulic system. Engineers (SAE) J754 nomenclature and some classifications follow SAE J183 abbreviations. ¥ API CF-4/SG, CF-4/SF, CE/SG, CE/SF, CD/SG, or CD/SF The MIL specifications are U.S.A.
Page 542 The API CD/TO-2 or CD/TO-4 specification or MIL-L-2104D,E or F oils could be used. NOTE : Multi-grade oils are not blended by DAEWOO for use in transmissions. Multi-grade oils which use high molecular weight polymers as viscosity index improvers lose their viscosity effec-...
Page 543: Lubricant Viscosities And Refill Capacities
Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities REFILL CAPACITIES-(APPROXIMATE) LUBRICANT VISCOSITIES FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment U.S. Liters ° C ° F Compartment Oill or System Gal. Viscosities or System Engine SAE 10W30 -20 +40 +104 Engine Crankcase Crankcase SAE 15W40 -15 +50...
Page 544: Maintenance Intervals
Maintenance Section Maintenance Intervals Every 250 Sevice Hours or NOTICE Monthly All maintenance and repair, except Every 10 Hydraulic Oil Level - Check ..... . .103 Service Hours or Daily, on the lift truck must Drive Axle Oil Level - Check .
Page 545: When Required
Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Water Separator (Diesel Engine) - Carburetor ( Gasoline and LP - Gas Engine ) - Adjust Drain If the engine is hard to start or the exhaust is smoking, the carburetor may need adjusting.
Page 546: Fuel Filters - Check, Clean, Change
Maintenance Section LP-Gas and Dual Fuel Engines - Clean, Fuel Filters - Check, Clean, Replace Change Park the lift truck in an authorized refueling area Diesel Engine-Change Filter Element with the forks lowered, parking brake applied and the transmission in NEUTRAL. Park the lift truck with the forks lowered, parking brake applied, transmission in neutral, engine stopped and cool.
Page 547: Priming The Fuel System (Diesel Engine)
Maintenance Section 4. Remove cover w/magnet (1), O-ring (2) and fil- Priming the Fuel System ter element (3) from bottom cover (4). (Diesel Engine) 5. Wash the filter element (3) in clean, nonflammable Bleeding the Fuel System solvent. After changing the fuel filter, or after having ser- 6.
Page 548: Seat, Hood Latch & Cylinder - Check, Lubricate
Maintenance Section Seat, Hood Latch & Cylinder - Fuses, Bulbs and Circuit Breaker Check, Lubricate - Change, Reset Fuses NOTE : If a fuse filament separates, use only the same type and size fuses for replacement. If the filament in a new fuse separates, have the circuits and instruments checked.
Page 549 Maintenance Section Circuit Breaker IA3M4005 cal Example Typical Example IA3M4002 Fuses are identified as follows : 1. Raise the hood and seat assembly. Make sure the support cylinder securely holds the hood open. 1. Horn - 10 amp. 2. Head/Rear Lamp - 15 amp 3.
Page 550: Air Intake System - Check, Clean, Change
Maintenance Section Air Intake System - Check, Clean, Changing Filter Element ( Diesel Engine ) Change Precleaner (If Equipped) NOTICE Never service precleaner with the engine run- NOTICE ning. Never service precleaner with the engine run- ning. IA3M4008 Service the air cleaner when the red taget in the service indicator stays locked in the visible posi- IA3M4007 tion with the engine stopped.
Page 551 Maintenance Section Changing Filter Element ( LP Gas NOTICE Engine ) Do not allow dirty air to enter the intake hose when cleaning the inside of the air cleaner NOTICE housing. Never service precleaner with the engine run- ning. 5. Check the air cleaner housing for loose latches. 6.
Page 552 Maintenance Section 4. Clean the inside of air cleaner housing and the Changing Secondary Element cover. Inspect all connections between the air cleaner and engine. Check intake hose for cracks, Relace the secondary element after the primary damage and loose clamps. Tighten or replace element has been cleaned three times or yearly.
Page 553 Maintenance Section Direct air on the inside and outside of the element Clean Filter Elements along the lengh of the pleats. Check the element for any tears, rips or damage. WARNING Water-280 kPa (40 psi) Maximum Pressure Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.
Page 554: Distributor & Spark Plug - Check
Maintenance Section Distributor & Spark Plug - Check Spark Plugs (Gasoline and LP-Gas Engines) - Check Distributor (Gasoline and LP-Gas Engnes) - Check Park the lift truck with the forks lowered, parking brake applied, transmission in neutral and the Park the lift truck with the forks lowered, parking engine stopped.
Page 555: Tires And Wheels - Check, Inspect
Maintenance Section effects of corrosion. Sand blasting is recommend- Tires and Wheels - Check, ed for removal of rust. Inspect Check all components carefully and replace WARNING any cracked, badly worn, damaged and severe- ly rusted or corroded parts with new parts of the same size and type.
Page 556: Wheel Bolts And Nuts
Maintenance Section Wheel Bolts and Nuts - Inspect Drive Wheels Inspect Tightness NOTICE Do not lubricate ball seas of wheels or ball faces of wheel nuts. Be sure mounting faces of hub, wheel nuts and flat mounting surfaces are clean. Tighten wheel nuts again after 24 hours of IAOM4015 operation.
Page 557: Every 10 Service Hours Or Daily
Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Oil Level - Check Coolant Level - Check, Clean, Change WARNING Check Coolant Level...
Page 558: Air Cleaner Indicator - Check
Maintenance Section Air Cleaner Indicator - Check Checking Service Indicator ( Diesel Engine ) IA3M4025 3. Start and run the engine to stabilize the coolant level in the filler neck. If low add coolant until it reaches the top of the filler neck. Install the radia- tor cap.
Page 559: Walk-Around Inspection - Inspect
Maintenance Section 6. Inspect the instrument panel for broken gauges Walk - Around Inspection - and indicator lights. Inspect 7. Test the horn and other safety devices for prop- For maximum service life of the lift truck, make a er operation. thorough walk-around inspection.
Page 560: Mast Channel - Lubricate
Maintenance Section Mast Channels - Lubricate Transmission Oil Level - Check WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1. Start and operate the lift truck until the engine reaches normal operating temperature.
Page 561: First 50 - 100 Service Hours
Maintenance Section First 50 - 100 Service Hours You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. 3. Remove blocking from the rear of the lift Transmission Oil &...
Page 562: Drive Axle Oil - Change
Maintenance Section Drive Axle Oil - Change NOTE : Change the differential oil on lift trucks that are operated under wet conditions or measure oil level on lift trucks that operate under dry condi- tions. Clean the housing breather under either condition.
Page 563: Parking Brake - Test, Adjust
Maintenance Section 6. To drain the differential housing, remove the 2. Halfway up the incline, stop the lift truck with the housing drain plug. Allow the lubricant to drain. service brake. 7. Clean and install the housing drain plug. 8. Remove the oil level plug. 9.
Page 564: First 250 Service Hours
Maintenance Section First 250 Service Hours You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Return Filter - Change 3. Install new filter assembly in the hydraulic tank cover.
Page 565: Engine Valve Lash Adjustment - Check, Adjust
Maintenance Section Engine Valve Lash Adjustment - Check, Adjust ( Diesel Engine ) Park the lift truck with the forks lowered, parking brake applied, transmission in NEUTRAL and the engine stopped and cold. NOTE : Initial valve lash adjustment on a new or rebuilt engine only, is recommended at the first scheduled oil change interval, due to initial wear and seating of valve train components.
Page 566: Every 250 Service Hours Or Monthly
Maintenance Section Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Oil Level - Check Drive Axle Oil Level - Check WARNING At operating temperature, the hydraulic tank is hot and under pressure.
Page 567: Attachment & Mast - Inspect, Lubricate
Maintenance Section Attachment & Mast - Inspect, Lubricate 1. Operate the lift, tilt and attachment controls. Listen for unusual noises. These may indicate a need for repair. 2. Check for loose bolts and nuts on the carriage. Remove any debris from the carriage and mast. 3.
Page 568: Steering Mechanism - Check, Lubricate
Maintenance Section Steering Mechanism - Check, Lubricate IA3M4044 IA3M4043 1. Lubricate the steer axle king pins, total of four fittings. Two on the right side and two on the left side. 2. Lubricate the steering link bearings, total of four fittings.
Page 569: Battery Terminal - Clean, Inspect
Maintenance Section Battery Terminal - Clean, Inspect Engine Oil and Filter - Change Engine Crankcase (Diesel Engine) WARNING The percentage of sulfur in the fuel will affect the Batteries give off flammable fumes that can engine oil recommendations. If the fuel has over explode.
Page 570 Maintenance Section 13. Stop the engine and measure the oil level. Maintain the oil level between the MAX. and MIN marks on dip stick. 14. Close hood and seat assembly. NOTICE Servicing of the engine oil and oil filter element has large affects on the engine performance as well as the engine life.
Page 571: Pcv Valve System - Inspect, Clean
Maintenance Section PCV Valve System - Inspect, Clean Gasoline and LP-Gas Engines IA3M4095 5. Remove and discard oil filter element. 6. Wipe sealing surface of oil filter element mounting base. Make sure all of the old gasket is removed. IA3M4095 1.
Page 572: Every 500 Service Hours Or 3 Months
Maintenance Section Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Belts ( Diesel Engine ) - Check, Adjust 1.
Page 573: Tilt Cylinders - Check, Adjust, Lubricate
Maintenance Section tionary by the tilt eye. If it is not, the O-ring inside Tilt Cylinders - Check, Adjust, the collar may need to be replaced. To adjust back Lubricate tilt, spacers must be added or removed. Chassis Pivot Eyebolts/Lubricate IA3M4102 Typical Example IA3M4053...
Page 574: Crosshead Rollers - Inspect
Maintenance Section Crosshead Rollers - Inspect 1. Operate the mast through a lift cycle. Watch the chains move over the crosshead rollers. Make sure the chain is tracking over the rollers properly. IA3M4058 2. Lubricate 2 side thrust roller fittings, one on each side of the mast.
Page 575: Parking Brake - Test, Adjust
Maintenance Section Parking Brake - Test, Adjust NOTE : Be sure area around the lift truck is clear of personnel and obstructions. 1. Drive the lift truck, fully loaded, forward up a 15% incline. IA3M3013 5. Turn adjusting screw on parking lever to the left side slightly 6.
Page 576: Inching & Brake Control Shaft - Lubricate
Maintenance Section Inching & Brake Control shaft - Overhead Guard - Inspect Lubricate IA3M4065 IA3M4064 1. Check tightness of overhead guard mounting bolts at 80 N ¥ m (60 lb ¥ ft). 1. Lubricate two fittings for the inching and brake pedal control shaft.
Page 577: Steer Suspension - Inspect
Maintenance Section Steer Suspension - Inspect IA3M4066 1. Inspect the suspension mounting bolts.Tighten suspension mounting bolts, if necessary, to 240L30 N ¥ m (180L20 lb ¥ ft). IA3M4067 2. Look for leaks at the power steering hose con- nections. 3. Remove any trash buildup on the suspension or the steer axle.
Page 578: Every 1000 Service Hours Or 6 Months
Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Return Filter & Breather - Change WARNING Hot oil and components can cause personal injury.
Page 579: Lift Chains - Check, Adjust
Maintenance Section To Adjust Lift Chains - Check, Adjust IA3M4071 IA3M4070 1. Loosen locknut(1) and turn nut(2), on the loose 1. Check the lift chains for wear. Complete instruc- chain to equalize temsion on the lift chains. tions on the use of the tool are furnished. 2.
Page 580: Every 1500 Service Hours
Maintenance Section Every 1500 Service Hours You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Drive Axle Oil - Change 6. To drain the differential housing, remove the housing drain plug.
Page 581: Every 2000 Service Hours Or 1 Year
Maintenance Section Every 2000 Service Hours or 1 Year You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Steer Wheel Bearings - Repack Park the lift truck level with the forks lowered, parking brake engaged, transmission in NEUTRAL and the engine stopped.
Page 582: Cooling System - Clean, Change
Maintenance Section Cooling System - Clean, Change WARNING At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine IA3M4077 has been stopped and the filler cap is cool enough to touch with your bare hand.
Page 583 Maintenance Section IA3M4078 Typical Ewample 3. Open radiator drain valve. Allow the coolant to drain. Drain the recovery bottle. 4. Close radiator drain valve and install block drain plug. Fill the cooling system with 1 kg (2 lb) sodi- um bisulphate per 40 liters (10 gallons) of water. Most commercial cooling system cleaners can be used.
Page 584: Forks - Inspect
Inspectors should be trained and qualified in accordance with The American Societly for Non- Destructive Testing, Level ll Qualifications. Contact your local DAEWOO Lift Truck Dealer for further information. - 121 -...
Page 585 Maintenance Section IAOM096I IAOM097I 4. Check the difference in height of one fork tip to 3. Check the straightness of the upper face of the other when mounted on the fork carrier. blade (D) and the front face of shank (E) with a A difference in fork tip height can result in uneven straight edge.
Page 586 Maintenance Section IAOM098I IAOM099I 5. Check the fork blade (J) and shank (H) for wear 6. Check the fork mountings (K) for wear, crushing with special attention to the heel (G). The fork and other local deformation, which can cause should be withdrawn from service if the thickness excessive side to side wobble of the forks.
Page 587 Maintenance Section IA3M4086 IA3M4086 IAOM1001 8. Check fork markings (N) for legibility. Renew 9. a. Lift the mast and operate the control lever, markings as required to retain legibility. until the top surface of the forks is parallel with the floor. Place two straight bars that are the same width as the carriage, across the forks as shown.
Page 588: Every 2500 Service Hours Or 6 Months
Maintenance Section Every 2500 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Oil - Check, Clean, Change WARNING Hot oil and components can cause personal injury.
Page 589: Environment Protection
Maintenance Section Environment Protection Section Environment Protection When servicing this lift truck, use an authorized ser- vicing area and an approved container to collect coolant, oil, fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items are disconnected or removed.
Page 590: Index
Index Section Index E lectrical Disconnect Switch (If Equipped) ..42 Accelerator Pedal ....... .44 Engine Compartment .
Page 591 Index Section Ignition Timing (Gasoline, & LP-Gas Engines) Operating Techniques ......63 Check, Adjust ....... . 92 Operation the Lift Truck .
Page 592 Index Section Starting the Engine ......55 Steer Suspension - Inspect .....114 Steer Wheel Bearings - Repack .

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D40s-2 D45s-2 D40sc-2 D45sc-2 D50sc-2 G35s-2 ... Show all

Daewoo D35S-2 Service Manual

Table of Contents

2 Engine Disassembly and Assembly

3 System of Lubrication

4 Cooling System

5 Fuel System

Table of Contents

Safety Section

General Section

Operation Section

Maintenance Section

Maintenance Intervals

Every 10 Service Hours or Daily

First 50-100 Service Hours

First 250 Service Hours

Every 1500 Service Hours

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Table of Contents