Doosan D20G Disassembly/Assembly Download

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Vehicle System

Disassembly & Assembly

Brake Master Cylinder

Remove & Install Brake Master
Cylinder (Boosted)

Remove the cotter pin from pin (1). Remove pin

(1).

NOTE:

Plug and cap all openings to avoid

contamination and debris from entering the
system after removing any tubes or lines.

Disconnect wire harness from the pressure switch.

Disconnect tube (3) from master cylinder.

Remove clamps and disconnect hoses (4).

Support the brake master cylinder. Remove two

bolts (6).

Remove the brake master cylinder.

Install the brake master cylinder in the reverse

order of removal.

Bleed the brake system. Refer to the Testing and

Adjusting Manual for further information.

End By:

Disassemble & Assemble Brake

Master Cylinder

Start By:

Remove brake master cylinder.

Slip boot (4) off of body (5).

For purposes of reassembly, mark the position of

nut (2) on yoke (1). Loosen nut (2) from plunger
(3).

Separate yoke (1), nut (2), plunger (3) and boot

(4).

Remove pressure switch (5).

Summary of Contents for D20G

Page 1: ...Vehicle System Disassembly Assembly D20G D25G D30G with B3 3 Engine D20G D25G D30G with 4TNE98 Engine G20G G25G G30G with G424F Engine G20G G25G G30G with G424FE Engine SB4220E01 J a n 2 0 0 8 ...

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Page 3: ... by the following symbol Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on t...

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Page 5: ... Cylinder 31 Primary Lift Cylinder 34 Tilt Cylinder 37 Hydraulic Pump 42 Steering Wheel 51 Steering Unit 52 Brake Master Cylinder 62 Steer Wheel Bearing 64 Steering Knuckle Kingpin And Bearing 66 Steer Axle 67 Steering Cylinder 69 Hydraulic Control Valve 73 Counterweight 80 Engine 81 WARNING Disconnect batteries before performance of any service work ...

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

Page 8: ...aps and a hoist 2 Remove the washers nuts and bolts 2 3 Remove the washers nuts and two bolts 3 4 Remove front overhead guard 1 Front over head guard 1 weighs approximately 30 kg 66 lb 5 Remove the washers nuts and four bolts 4 6 Remove rear Leg 5 7 Install front overhead guard 1 and rear leg 5 in the reverse order of removal ...

Page 9: ... 7 Install the forks in the reverse order of removal 8 Put the forks in position Lower both fork pins 1 to lock the forks in position 9 Install stopper bolt and washer 3 Be careful not to miss this step Backrest Remove Install Backrest 1 Fasten a hoist to the backrest Remove bolts 2 that fasten the backrest to the carriage 2 Remove backrest 1 Backrest 1 weighs about 40 kg 90 lb 3 install backrest ...

Page 10: ...any hydraulic lines Slowly loosen the cap of the hydraulic tank to release any pressure in the tank Be cautious of hot hydraulic coil when any lines are disconnected in the hydraulic system NOTE For purposes of reassembly identify and mark all hydraulic lines and connectors before removing or disconnecting Typical Example 3 Remove four bolts 8 from the chain guard hose support assembly 6 Set the h...

Page 11: ... 12 from the shaft Typical Example 7 Raise the inner mast to pull out carriage as shown 8 Remove carriage 14 from bottom of inner mast 15 Carriage 14 weighs 116kg 255 lb NOTE Use the following steps to install the carriage 9 Raise the inner mast to put in the carriage onto the mast and lower the inner mast to cover carriage 1 bearing fully ...

Page 12: ...70 40 N m 200 30 lb ft Install bolts 10 onto the hose mounting bracket Typical Example 12 Install chain guard hose support assembly 6 and four bolts 8 to a torque of 8 2 N m 6 1 5lb ft Typical Example 13 Connect two hydraulic line 4 in their original positions End By a Install backrest b Install forks Disassemble Carriage Start By a Remove carriage Typical Example 1 Remove the roll pins and pins 2...

Page 13: ...djustments carriage must be removed from the mast Use the procedure that follows to adjust carriage load bearings Carriage adjustment 3 Upper bearings 4 Shims 5 Bolt 6 Screw 7 Middle bearings 8 Lower bearings A Zero clearance B 6 0 to 9 0 mm 236 to 354 in clearance C Minimum clearance 1 Select lower bearings from the chart to obtain minimum clearance B between bearings and channel leg for full cha...

Page 14: ... contact zero clearance A between the bearings and the narrowest point of inner mast 4 Do step 2 through 3 for other sets of bearings 8 9 Typical Example Typical Example 5 Tighten screw 5 that holds the top bearings to the carriage to a torque of 34 7 N m 25 5 lb ft Typical Example 6 Position chains 6 on the carriage Install pins 7 and the roll pins End By a Install carriage raise the inner mast a...

Page 15: ...l hydraulic connectors and hoses to avoid debris and contamination from entering the system 2 Disconnect hose 3 3 Disconnect the hydraulic return lines not shown WARNING Tilt cylinders 7 can drop when pin 6 is removed To avoid component damage or personal injury support tilt cylinder 7 while removing pin 6 4 Remove bolt 5 from each side of mast assembly 2 5 Remove pin 6 from the tilt cylinders on ...

Page 16: ... remove mast assembly 2 from the machine 8 Install the mast in the reverse order of removal End By a Install forks b Fill hydraulic oil to tank Refer to the Operation and Maintenance Manual for further information Disassemble Mast Start By a Remove primary lift cylinder b Remove mast NOTE The following disassembly and assembly procedure is for a full free triple lift mast Typical Example 1 Remove ...

Page 17: ... 3 3 Remove chain nut 4 from the top of the mast each side Typical Example 4 Disconnect and remove chains 5 from the bottom of the mast STD Mast FFT Mast 5 Remove top cylinder retainer bolt 6 from each side of the mast 6 Disconnect lift hose 7 and return hose 8 ...

Page 18: ...tainer bolt 9 from each side of mast STD mast only STD Mast FFT Mast 8 Remove cylinder retainer brackets 10 from each cylinder STD Mast FFT Mast 9 Fasten a nylon strap and hoist to lift cylinder as shown Hoist and remove lift cylinder 11 Each cylinder weighs about 50 kg 110 lb ...

Page 19: ... the bearings 13 with new if worn or damaged Typical Example 12 Fasten nylon straps and hoist to inner channel 14 Remove inner channel 14 The weight of the inner channel is approximately 150kg 330 lb Typical Example 13 Remove rollers 15 and the shims from the inner channel mast Typical Example 14 Fasten nylon straps and a hoist to the intermediate mast channel 16 Remove mast channel 16 The interme...

Page 20: ...xample 15 Remove rollers 17 and the shims from the intermediate mast channel FFT mast only 16 Remove nylon pads 18 and the shims Typical Example 17 Remove rollers 19 and the shims from the stationary mast channel 18 Remove nylon pads 20 and the shims ...

Page 21: ...ct lower bearings 3 and 4 from the chart to obtain minimum clearance B between bearing and channel leg for full channel length Must use same bearing on left and right side Mast And Carriage Bearings Part No Bearing Size Bearing O D D581814 Under Size 108 6 mm 4 276 in D581815 Standard 109 6 mm 4 135 in D581816 Over Size 110 7 mm 4 358 in Permissible tolerance 0 08 mm 003in 4 Find narrowest point b...

Page 22: ...m the upper side NOTE When installing shims 5 behind bearings 4 make sure the amount of shim is divided equally when positioned behind each bearing 4 Mast Adjustment Lower Bearings A Zero clearance B Minimum clearance C Zero clearance 3 Bearing 4 Bearing 5 Shims 6 Shims Typical Example 7 Make sure intermediate mast lower bearings are properly shimmed in the stationary mast by rolling up and down a...

Page 23: ... channel at approximately 475 mm 18 7 in channel lap B Upper Bearing Adjustment of Stationary Mast Typical Example 9 Lift by crane and pull out intermediate mast from stationary mast Install 1 mm shim to each bearing of stationary mast upper basically Bearing should be selected D581814 under size bearing Mast Adjustment Upper Bearings D Zero clearance E 0 80 mm 031 in Clearance maximum F Zero clea...

Page 24: ...arance C between stationary upper bearings and the widest point of intermediate mast to be checked before C Upper Pad Adjustment Mast Adjustment Upper Bearings D Zero clearance E 0 80 mm 031 in Clearance maximum F Zero clearance 7 Pads 8 Shims 9 Shims 10 Shims Typical Example 12 Install shims 8 behind each pad 7 until there is 0 80 mm 031 in maximum clearance E between the pads and the inner and i...

Page 25: ... And Carriage Bearings Part No Bearing Size Bearing O D D581814 Under Size 108 6 mm 4 276 in D581815 Standard 109 6 mm 4 135 in D581816 Over Size 110 7 mm 4 358 in Permissible tolerance 0 08 mm 003in Typical Example 14 Find narrowest point by ruler on the intermediate mast in the area where the inner lower bearings make contact full length of intermediate mast excluding minimum channel lap 475 mm ...

Page 26: ... stuck and cannot move by rolling up and down there might be excessive shim Pull out the inner mast from the intermediate mast and remove shim 0 5 mm to both inner lower bearings Repeat same procedure of above until properly shimmed There is to be contact zero clearance C between inner lower bearing sand intermediate channel at narrowest point E Upper Bearing Adjustment of intermediate Mast Follow...

Page 27: ...d nylon strap to secondary cylinder 11 Install secondary cylinders 11 into the stationary mast STD Mast FFT Mast 21 Install secondary cylinder mounting brackets 10 over the secondary cylinders STD Mast 22 Install cylinder bottom retainer bolt 9 to each side of mast STD mast only ...

Page 28: ...ose 7 and return hose 8 STD Mast FFT Mast 24 Install top retainer bolt 6 to the secondary cylinders 25 Install hydraulic steel tube to each secondary cylinder When install the steel tube assembling angle should be kept as shown in above figure FFT mast only ...

Page 29: ...per 28 Install sheave of lift hose FFT mast only 29 Install the lift hose support bracket 3 and hoses FFT mast only 30 Install primary lift cylinder 2 FFT mast only Typical Example 31 Install carriage assembly from the bottom of inner mast Typical Example 32 Install cross head 21 and retainer ring 24 and install chain sheave 23 and retainer ring 22 FFT mast only ...

Page 30: ...T mast only Typical Example 34 Install hydraulic hose 25 of side shifter to side shifter cylinder 26 35 Install mast to lift truck Standard Lift Cylinder Disassembly Start By a Remove standard lift cylinders 1 Put standard lift cylinder 1 in position on vise A 2 Loosen set screw 2 with wrench B ...

Page 31: ...mbly 29 3 Remove bearing 3 with wrench C 4 Remove rod 4 from the cylinder body 5 Remove split rings 5 from the cylinder rod 6 Remove O ring seal 6 and back up ring 7 from the bearing 7 Remove wiper seal 8 and seal 9 from the bearing ...

Page 32: ...ith the lip toward the outside NOTE Install back up ring 4 with the curved side contacting the O ring seal 3 Install O ring seal 3 and back up ring 4 into the bearing 4 Install split rings 5 on the cylinder rod 5 Install cylinder rod 6 in the cylinder body 6 Install bearing 7 on the cylinder rod and tighten using wrench C ...

Page 33: ...6 1 N m 53 9 lb in End By a Install standard lift cylinders Secondary Lift Cylinder Disassembly Tools Needed A B Hydraulic Cylinder Repair Stand 1 Wrench Assembly 1 Start By a Remove standard lift cylinders 1 Put standard lift cylinder 1 in position on tool A 2 Remove bearing 2 with tool B ...

Page 34: ...e stop ring 4 from the cylinder rod 5 Remove wear ring 5 U packing 6 and backup ring 7 6 Remove retaining ring 8 spacer 9 and check valve 10 7 Remove ring 11 wear ring 12 and O ring 13 from the bearing 8 Remove wiper seal 14 and retaining ring 15 from the bearing 9 Remove U packing 16 ...

Page 35: ...outside 3 Install O ring 4 wear ring 5 and ring 6 in the bearing 4 Install check valve 7 retaining ring 8 and spacer 9 5 Install stop rings 10 on the cylinder rod 6 Install wear ring 11 U packing 12 and backup ring 13 7 Install cylinder rod 14 in the cylinder body 8 Install bearing 15 on the cylinder rod and tighten using tool B End By a Install secondary lift cylinders ...

Page 36: ...any pressure in the tank Be cautious of hot hydraulic oil when any lines are disconnected in the hydraulic system 1 Fasten nylon straps and hoist to the primary lift cylinder 2 Remove bolts 1 3 Pull the cylinder out far enough to disconnect elbow 3 Remove primary lift cylinder 4 Weight is 27 kg 60 lb NOTE The following steps are for the installation of the primary lift cylinder 4 Put primary lift ...

Page 37: ...1 Wrench Assembly 1 Start By a Remove primary lift cylinder 1 Remove flow protector valve 1 from the cylinder body 2 Remove bearing 2 with tool A 3 Remove rod 3 from the cylinder body 4 Remove wear ring 4 U packing 5 and backup ring 6 5 Remove retaining ring 7 spacer 8 and check valve 9 6 Remove O ring 10 and two rings 11 ...

Page 38: ...eded A B Hydraulic Cylinder Repair Stand 1 Wrench Assembly 1 1 Install U packing 1 in the bearing 2 Install wiper seal 2 and retaining ring 3 Install the seal with the lip toward the outside 3 Install O ring seal 4 and two rings 5 4 Install check valve 6 retaining ring 7 and spacer 8 5 Install wear ring 9 U packing 10 and back up ring 11 on the cylinder rod ...

Page 39: ...ng the tilt cylinders is the same for both cylinders WARNING If both tilt cylinders are removed at the same time the mast can fall To avoid possible personal injury make sure the mast is securely held in place or supported by a hoist before removing the tilt cylinders WARNING To prevent personal injury move the control levers backward and forward to release any pres sure in hydraulic system Slowly...

Page 40: ...olt 6 from pin 5 Remove pin 5 3 Remove tilt cylinder 4 4 Install the tilt cylinder in the reverse order of removal 5 Adjust the tilting angle Be sure to engage the rod into the anchor more than 32min Also inspect if both tilt cylinders have the uneven tilting ...

Page 41: ... 1 there will be contact zero clearance between the rollers and the inner mast at most narrow point of mast refer to step 4 2 Remove rod assembly 2 from the cylinder body 3 Remove nut 3 from the cylinder rod 4 Remove piston and seal assembly 4 from the cylinder rod 5 Remove head assembly 5 Typical Example 6 Remove spacer 6 from the cylinder rod 7 Loosen the nut and bolt on the rod eye Remove cylin...

Page 42: ...lt cylinder 12 Install seal 14 in the head Position the lip of the seal toward the inside of the head 13 Install seal 15 14 Install seal 16 in the cylinder head Position the lip of seal 16 toward the outside of the cylinder head NOTE The curved side of back up ring 13 should contact O ring seal 12 15 Install O ring seal 12 and back up ring 13 Make sure the curved side of back up ring 13 is in cont...

Page 43: ...ten the bolt on rod eye 2 to a torque of 95 15 N m 70 11 lb ft 19 Install seals 10 and O ring seal 9 on the piston 20 Install head assembly 5 on the cylinder rod 21 Install piston assembly 4 onto the cylinder rod 22 Install nut 3 Tighten nut 3 to a torque of 270 30 N m 200 22 lb ft Typical Example 23 Install the rod assembly in the cylinder body ...

Page 44: ...Pump a Start by remove hydraulic pump 1 Remove four cap screws 1 and washers 2 Remove shaft seal 2 and washer from the housing 3 Remove hydraulic pump part 3 from pump assembly 4 Remove Seal 6 and 4 from pump part 5 5 Remove wear plate 7 from pump assembly 4 6 Remove gear assemblies 8 from the body 9 ...

Page 45: ...oon cavities in the body NOTE The smaller half moon port cavity must be on the pressure side of the pump The side of wear plate with midsection cut out must be on suction side of pump Suction side of back plate is always side with larger port boss 2 Install seal 1 and 2 in groove of front plate 3 3 Apply a thin coat of petroleum jelly or hydraulic oil to both milled gear pockets of body Slip body ...

Page 46: ...d section cut away must be on the suction side of pump 5 Place body 5 onte the body 6 Dip gear assemblies 6 into oil and slip into front plate bushings and gears into pockets of body 7 Install wear plate 7 into housing 8 Install seal 11 and 10 to pump part 9 9 Install hydraulic pump part 12 to pump assembly ...

Page 47: ...Disassembly Assembly 45 10 Place washer over drive shaft into housing Liberally oil shaft seal 13 and install over driveshaft carefully so that rubber sealing lips are not cut 11 Install four cap screws 14 and washers ...

Page 48: ... 46 Hydraulic Pump D514289 for EM0QM EM0QN Disassemble Hydraulic Pump A Start by removing the hydraulic pump 1 Remove snap ring 1 from pump assembly 2 2 Remove four cap screws 3 3 Remove hydraulic pump cover part from pump assembly 1 2 3 ...

Page 49: ...Vehicle System Disassembly Assembly 47 4 Remove a plate seal and Back up 4 from pump cover part 5 Remove the side plate 5 from the body 6 Remove gear assemblies 6 from the body 4 5 6 6 ...

Page 50: ...Vehicle System Disassembly Assembly 48 7 Remove the side plate 7 from the body 8 Remove the body 8 from pump assembly 9 Finished 7 8 ...

Page 51: ...ow photo of the description 4 and please prepare a set of repair kit 1 It is important that the relationship of the pump cover part body and two side plates is correct 2 Install new plate seal and Back up 1 to pump cover part 3 Install the body 2 to pump cover part 3 4 Install the side plate 4 into the body 5 Install gear assemblies 5 into the body 6 Install the side plate 6 into the body 1 2 3 4 ...

Page 52: ... Assembly 50 7 Install new plate seal and Back up 7 to pump cover part 7 8 Install pump cover part 8 to pump assembly 9 9 Install four cap screws 10 10 Install a new snap ring 11 into pump assembly 11 Finished 7 9 8 8 9 10 11 11 ...

Page 53: ...ocation marks on the steering wheel and the steering wheel shaft for installation purposes 3 Use a rubber hammer to remove the steering wheel from the shaft NOTE Use the following steps to install the steering wheel 4 Put the steering wheel on the steering wheel shaft on its original position 5 Install cup 3 and nut 2 Tighten nut 2 to a torque of 80 7 N m 60 5 lb ft 6 Install cap 1 ...

Page 54: ...lic tank to release any pressure in the tank Be cautious of hot hydraulic oil when any lines are disconnected in the hydraulic sys tem NOTE Identify and mark all hydraulic hoses for purposes of reassembly 4 Remove two bolts 4 NOTICE Steering unit 6 and column 3 can separate after bolts 4 have all been removed causing unit 6 to fall To avoid damaging components support the steering pump while remov...

Page 55: ...awings show the unit in a vise we recommend that you keep the unit in the vise during disassembly Follow the clamping procedures explained throughout the manual 1 Clamp unit in vise meter end up Clamp lightly on edges of mounting area Use protective material on vise jaws Housing distortion could result if jaws are over tightened 2 Remove 5 16 inch cap screws and washers if applicable 7 each 3 Remo...

Page 56: ...ousing from vise Place housing on a clean soft cloth to protect surface finish Use a thin bladed screwdriver to pry retaining ring from housing 12 Rotate spool and sleeve until pin is horizontal Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing Remove bushing ...

Page 57: ...ry dust seal from seal gland bushing Do not damage bushing 15 Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly 16 Remove spool and sleeve assembly from 14 hole end of housing ATTENTION Identify and mark all hydraulic hoses for purposes of reassembly 17 Push pin from spool and sleeve assembly ...

Page 58: ...om control end of sleeve then remove 4 centering springs from spool carefully by hand 19 Push spool back through and out of sleeve Rotate spool slowly when removing from sleeve 20 Remove seal from housing 21 Remove check ball seat 22 Tip housing to remove check ball ...

Page 59: ...heck ball seat in housing insert open end of seat first Push check ball seat to shoulder of hole 5 Install set screw Use a 1 4 inch hex key to torque set screw to 11 N m 100 lb in To prevent interference make sure top of set screw in slightly below housing mounting surface 6 Assemble spool and sleeve carefully so that the spring slots line up at the same end Rotate spool while sliding parts togeth...

Page 60: ...ool assembly beyond this point to prevent the cross pin from dropping into the discharge groove of the housing With the spool assembly in this flush position check for free rotation with in the housing by turning with light finger tip force at the splined end 12 Place housing on clean lint free cloth Install 47 5mm 1 86 in ID seal in housing 13 Install 2 bearing races and the needle thrust bearing...

Page 61: ...n groove 18 Clamp housing in vise Clamp lightly on edges of mounting area Do not over tighten jaws NOTE Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the housing ATTENTION Clean the upper surface of the housing by wiping with the palm of clean hand Clean each of the flat surfaces of the meter section parts in a similar way when ready for reassembly Do...

Page 62: ...er alignment mark drive as shown Note relation ship between slotted end of drive to splined end of drive when marking 22 Install 73 5 mm 2 89 in ID seal in spacer plate or gerotor meter 23 With seal side of meter toward spacer plate align star valleys on drive Note the parallel relation ship of reference lines A B C and D Align bolt holes without disengaging meter from drive ...

Page 63: ...l 7 dry cap screws in end cap Pretighten screws to 11 17 N m 100 150 lb in then torque screws to specifications Spacer Actual Displacement cm r in r Length mm in 45 2 8 None 60 3 6 None 75 4 5 None 95 5 9 3 56 140 120 7 3 6 10 240 145 8 9 10 29 405 160 9 7 12 19 480 185 11 3 15 62 615 230 14 1 21 97 865 295 17 9 28 45 1 120 370 22 6 41 15 1 620 460 28 2 53 67 2 113 590 35 9 66 37 2 613 740 45 1 91...

Page 64: ...4 Remove clamps and disconnect hoses 4 5 Support the brake master cylinder Remove two bolts 6 6 Remove the brake master cylinder 7 Install the brake master cylinder in the reverse order of removal 8 Bleed the brake system Refer to the Testing and Adjusting Manual for further information End By Disassemble Assemble Brake Master Cylinder Start By a Remove brake master cylinder 1 Slip boot 4 off of b...

Page 65: ...al 18 when disassembling the brake master cylinder For purposes of reassembly position seal 18 into the bore of body 8 Remove the components from body 5 as follows a Remove piston 17 and cup 18 b Remove cup primary 19 c Remove spring 20 and spring seat 21 d Remove check valve 22 e Check the condition of the seals Replace the seals with new if worn or damaged 9 Assemble the brake master cylinder in...

Page 66: ... left steer wheel 1 Support the steer axle with a floor jack or a wood block under the frame A 2 Remove wheel nuts 1 and wheel assembly 2 Steer wheel 2 weighs approximately 34kg 75Ib 3 Remove wheel cap 3 4 Straighten and remove split pin 4 5 Remove nut 5 and washer 6 6 Remove wheel hub assembly 7 Tools Needed A B C Floor Jack 1 Driver Set 1 Lock Nut Installer 1 ...

Page 67: ... contact surfaces of the bearing cups with Multipurpose Grease 10 Reverse the procedures and steps 2 through 9 to install the steer wheels and bearings 11 Adjust the steer wheel bearings as follows a Use tool C to tighten nut 5 to a torque of 135 N m 100 lb ft while slowly rotating steer wheel 5 b Use tool C to loosen nut 5 completely c Use tool C to tighten nut 5 again to a torque of 50 5 N m 37 ...

Page 68: ...procedure to remove and install the steering knuckle kingpin and bearing is the same for both sides of the lift truck 1 Remove two bolts 2 and pin retaining plate 3 2 Remove tie rod pin 1 and separate tie rod 4 from knuckle 5 3 Remove the top grease nipple 6 4 Remove the king pin retaining bolt 7 and nut 8 For purposes of reassembly the torque for bolt 7 is 11 1 N m 8 9 lb ft 5 Remove the king pin...

Page 69: ...g pins and bearings 11 Install the steering knuckle kingpins and bearings in the reverse order of removal End By a Install steer wheels Steer Axle Remove Install Steer Axle Tools Needed A Jack Stand 4 WARNING Be sure the pressure in the hydraulic system is released before any lines or hoses have been disconnected 1 Put the lift truck on the plain ground 2 For purposes of reassembly put identificat...

Page 70: ...e the following steps to install the steer axle 8 Use a floor jack to position steer axle 4 NOTE Use bolts 2 and cap 3 to align steer axle 4 with the mounting bosses while raising steer axle 4 into position with the floor jack 9 Seat steer axle 4 as follows a Install bolts 2 through cap 3 and into the mounting bosses approximately two bolt threads b Use the floor jack to raise steer axle 4 into th...

Page 71: ... Remove steer axle 1 Remove the pin retaining bolt and pin 2 from the tie rod at each end of steering cylinder 1 2 Remove four bolts 3 For installation purposes the torque for bolts 3 is 250 40 N m 184 29 lb ft 3 Remove steering cylinder 1 4 Install steering cylinder 1 in the reverse order of removal ...

Page 72: ...aps with nuts at each end Remove the nuts and rods before removing the cylinder end caps from the cylinder tube 1 Put location marks on end caps 1 as to their position on the steering cylinder tube 2 Remove end caps 1 from the steering cylinder 3 Remove bolts 2 and mounting caps 3 from the steer axle 4 Use tool A to remove retaining rings 4 and rings 3 from the cylinder rod 5 Remove piston 5 from ...

Page 73: ...each end cap as follows a Remove O ring seal 10 b Remove wear ring 8 c Remove u cup seal 9 d Remove wiper seal 11 Assemble Steering Cylinder Tools Needed A Pliers 1 1 Assemble each end cap as follows a Install O ring seal 2 b Install wear ring 1 c Install u cup seal 3 d Install wiper seal 4 2 Install seal 5 on the piston ...

Page 74: ...nder rod 5 Install rings 8 6 Use tool A to install retaining rings 9 on each side of the piston 7 Install cylinder tube 10 on the rod assembly 8 Install end caps 11 on cylinder tube 10 NOTE Install the nuts and rods on steering cylinder rafter installing the cylinder end caps End By a Install the steering cylinder ...

Page 75: ...ased before any fitting plug hose or component is loosened tightened removed or adjusted Always move the lift truck to a clean and level location away from the travel of other machines NOTE For purposes of reassembly put identification marks on all lines tubes and hoses before any disconnections are made 1 Disconnect seven lines 4 from control valve 3 2 Remove the cotter pins washers and pins 1 fr...

Page 76: ...trol valve PF relief valve and port relief valve 2 remove bolts to separate the valve sections when separating the valve section make sure that the O ring and load check incorporated into the lateral face are not damaged and injured b disassembly of front cover 1 remove O ring 11 from the lateral face 2 remove hex plug 6 and priority connector 5 3 remove FD sleeve 4 ball retainer 7 steel ball 8 sp...

Page 77: ...h dust seal 4 slowly smoothly to prevent spool damage 6 loose bolts 11 take out seal plate 8 and dust seal 4 from body 7 Loose hex bolt 14 d disassembly of tilt section 1 remove O ring 15 poppet 11 and spring from lateral face 2 Loose bolts 14 and remove cap 7 3 after fixing the end of spool 2 not to be rotated remove a set screw 9 4 remove retainer spring 8 spring 10 seal plate 5 5 take out spool...

Page 78: ...ut seal plate 3 and dust seal 4 from body 7 Loose hex bolt 14 Assemble Hydraulic Control Valve Start by NOTE make sure all valve parts are clean and free of dirt a disassembly of auxiliary section 1 fix section by using a vice for lateral machined faces not to be damaged 2 install O ring And install priority connector 5 into the front cover by tightening toque 60 3 incorporate ball retainer 7 stee...

Page 79: ... ring by 35N m 8 release a section from a vise and install O ring 13 poppet 9 and spring 10 into lateral face c assembly of tilt section 1 fix section by using a vice for lateral machined faces not to be damaged 2 Install spool 2 into body 1 smoothly and slowly A direction of spool access to body is same as that of spool disassembly 3 dust seals 6 put on the end of spool by using a tool Note be ca...

Page 80: ...n two hex bolts 11 by 14N m 6 install cap 7 and tighten two hex bolts 14 by14N m 7 release a section from a vise and install O ring 13 poppet 9 and spring 10 into lateral face e assembly of section place each section in a row insert tie rod and tight en nut by 27 4 31 4N m NOTE in case of excessive torque it could make as pool sticking In case of insufficient torque it could make an external leaka...

Page 81: ...gh oil temp 6 low oil temp Measure 1 take spool out and clean it 2 exchange valve section ass y 3 exchange valve section ass y 4 tighten cap boly by standard torque 5 Use in normal temperature 6 Use in normal temperature Problem large drift of cylinder Cause 1 internal leakage of spool damage 2 leakage of port relief valve and shut off plug 3 bias of spool position not neutal position 4 leakage of...

Page 82: ... A as shown 3 Remove towing pin 7 4 Remove the washer plate and bolts 8 5 Use the hoist and tooling A to remove counterweight 6 The weight of the counterweight is approximately 1753 kg 3865 lb NOTE The following steps are for installation of the counterweight 6 Put counterweight 6 in position on the frame and install bolt 8 and bolts 9 Tighten the bolts to a torque of 400 50 N m 300 37 lb ft 7 Ins...

Page 83: ...B3 3 engine Start by a Remove Overhead guard b Remove counterweight c Remove hood assembly Refer to the topics Overhead guard Counterweight and hood assembly in this module 1 Remove two bolts 1 and floor plate 2 2 Disconnect the two battery cables 1 Remove the washers two bolts 2 and battery assembly 3 3 Loosen the clamps and disconnect air cleaner hoses 4 4 Remove mounting bracket 5 and air clean...

Page 84: ... bolts and muffler assembly 8 Loosen cock drain from the radiator and drain coolant 9 Loosen clamps and disconnect two radiator hoses 13 10 Loosen the clamp and disconnect radiator overflow hose 14 11 Loosen clamps and disconnect the two transmission cooler hoses 15 12 Remove eight bolts 16 and baffle assembly 17 if equipped ...

Page 85: ...loosen four bolts 19 and remove radiator 20 Typical Example 15 Disconnect wires 21 from starter assembly 22 16 Disconnect wires 23 from alternator 24 NOTICE Place identification marks on all wires and connectors to assure proper assembly 17 Disconnect connector 25 from transmission switch 18 Disconnect engine wire harness 26 ...

Page 86: ... 21 Remove two bolts 31 Push wiring 32 back toward the engine Remove cover 33 Typical Example 22 Remove the six bolts 34 that hold the converter to the flywheel During the reassembly the tightening torque is 28 7 N m 40 10 lb ft NOTE At this point make a final check to be sure all removals and disconnections have been made from the engine Typical Example 23 Support engine with a hoist and tooling ...

Page 87: ...reassembly the tightening torque is 200 25 N m 147 18 lb ft NOTICE Make sure the engine is supported underneath by suitable wooden blocks Failure to support the engine will result in possible clamage 26 Remove the engine with a hoist as shown The engine weighs about 215 kg 27 Install the engine in the reverse order of removal End By a Install overhead guard b Install counterweight c Install hood a...

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