Vehicle System: Disassembly & Assembly

SB4220E01
Jan.2008
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
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication. Specific safety
warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this
product, until you have read and understood the operation, lubrication, maintenance and repair
information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1
Index
Hood (with seat) Assembly ................................... 5
Overhead Guard .................................................. 6
Forks.................................................................... 7
Backrest............................................................... 7
Carriage ............................................................... 7
Mast....................................................................13
Standard Lift Cylinder..........................................28
Secondary Lift 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.
Vehicle System 3 Index

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

6. Release latch. Use the hoist to remove hood and
2. Remove nut (1) from the support cylinder. seat assembly (4). The hood and seat assembly
Remove the cylinder rod from the bracket. weighs approximately 52 kg (115 lb)
3. Lower the hood.

7. Install the hood and seat assembly in the reverse
order of removal.
4. Remove the bolts (2) from the cover. Remove

cover.
Vehicle System 5 Disassembly & Assembly

Overhead Guard
Remove & Install Overhead Guard
3. Remove the washers, nuts, and two bolts (3).
4. Remove front overhead guard (1). Front over

1. Support overhead guard (1) with lifting straps and head guard (1) weighs approximately 30 kg (66 lb).
a hoist
.
2. Remove the washers, nuts, and bolts (2). 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.

Forks Backrest
Remove & Install Forks 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 (1) in the reverse order of removal.
Carriage
1. Remove stopper bolt and washer (3). Remove & Install Carriage
2. Lift fork pin (1).
Tools Needed A
3. Use a suitable C-clamp, strap and hoist to support
Retaining Ring Pliers 1
the fork as shown.
4. Slide the fork to slot (2) in the middle of the

carriage
Start By:
5. Remove the fork. The weight of the fork is a. Remove stopper bolt and washer (3).
approximately 50 kg (110 lb).
b. Lift fork pin (1).
6. Repeat steps 1 through 4 for the remaining fork.
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.

NOTE: For purposes of reassembly, identify and
mark all hydraulic lines and connectors
before removing or disconnecting.
(Typical Example)
(Typical Example)
3. Remove four bolts (8) from the chain guard/hose

support assembly (6). Set the hoses aside, clear
of the primary cylinder and cross head.
(Typical Example)
1. Raise carriage (1). Position a wooden block as

shown. Lower carriage (1) onto the wooden block.
2. Disconnect two hydraulic lines (4) from side

shifter cylinder (2). Plug and cap all openings to
prevent contamination and debris from entering
system. (Typical Example)
4. Remove two bolts (10) from the hose mounting

bracket. Set the hoses aside. Remove two nuts
WARNING (9) from the chain anchors. Set the chains aside,
clear of the mast.
To prevent personal injury be sure pressure in
the hydraulic system has been released before
disconnecting any hydraulic lines. Slowly loosen
the cap of the hydraulic tank to release any
pressure in the tank. Be cautious of hot
hydraulic coil when any lines are disconnected
in the hydraulic system.

(Typical Example)
5. Use tool (A) to remove retainer ring(11) from the

cross head shaft.
6. Remove cross head (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.

(Typical Example) (Typical Example)
10. Install cross head (12) and retaining ring(11). 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)
11. Put the chains in position over cross head

(12).Install nuts(9) onto the chain anchors to a
torque of 270 ± 40 N•m (200 ± 30 lb•ft).
Install bolts (10) onto the hose mounting bracket.
(Typical Example)
1. Remove the roll pins and pins (2) to disconnect

chains (1).
(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)
2. Remove four lower roller bearings (3) and the

shims from the carriage.
(Typical Example)
Carriage adjustment (3) Upper bearings. (4) Shims.
2. Remove screw (5) and washer (4). Remove top (5) Bolt. (6) Screw. (7)Middle bearings. (8) Lower
roller bearings (6) and the shims. bearings. (A) Zero clearance. (B) 6.0 to 9.0 mm.
(.236 to .354 in) clearance. (C) Minimum clearance.
Assemble Carriage
1. Select lower bearings from the chart to obtain
NOTE: The standard, Full Free Lift and Full Free minimum clearance (B) between bearings and
Triple Lift carriage load bearings are all channel leg for full channel length. Use same
adjusted the same way. The Full Free Triple bearing in all six locations.
Lift carriage is shown in the following
illustrations.
Mast And Carriage Bearings
To make the carriage clearance adjustments,
Part No. Bearing Size Bearing O.D.*
carriage must be removed from the mast.
D581814 Under Size 108.6 mm (4.276 in)
Use the procedure that follows to adjust carriage
load bearings. 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)
2. Find narrowest point by ruler on the inner mast in
the area where the bearings make contact. 6. Position chains (6) on the carriage. Install pins (7)
and the roll pins.
3. Install enough shims (4) that have been divided
into two equal groups behind bearings (3). At End By:
installation, there is to be contact [zero clearance
(A)] between the bearings and the narrowest point a. Install carriage, raise the inner mast and insert the
of inner mast. carriage from the bottom 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).

Mast
Remove & Install Mast
Start By:
a. Remove forks.
b. Place truck on the pit so to disassemble and

assemble the mast mounting caps.
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).
(Typical Example) 5. Remove pin (6) from the tilt cylinders on each
side of the mast assembly (2).
1. Support mast assembly (2) with a hoist and two
straps (1) as shown.
6. Tilt backward mast assembly (2) fully with the

hoist.
Remove bolts (8) and cap (9) from each side of
the base of mast assembly (2) in the pit.
NOTICE
Place identification marks on all hydraulic

connectors and hoses to assure proper installation.
Plug and cap all hydraulic connectors and hoses to
avoid debris and contamination from entering the
system.
2. Disconnect hose (3).
3. Disconnect the hydraulic return lines (not shown).

Disassemble Mast
WARNING
Start By:
Loosen the tension of straps to be connected
with hoist when mast assembly (2) is tilted a. Remove primary lift cylinder.
forward. If straps are too tight, mast assembly
(2) could slide off when bolts(8) are removed. b. Remove mast.
NOTE: The following disassembly and assembly

7. Use the hoist to remove mast assembly (2) from
procedure is for a full free triple lift mast.
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.
(Typical Example)
1. Remove hoses (1) along with the hose support

clamps.

(FFT Mast)
2. Remove hose sheave (3).
5. Remove top cylinder retainer bolt (6) from each
3. Remove chain nut (4) from the top of the side of the mast.
mast(each side).
(Typical Example)
4. Disconnect and remove chains (5) from the

bottom of the mast.
6. Disconnect lift hose (7) and return hose (8).
(STD Mast)

(STD Mast)
(STD Mast)
7. Remove cylinder bottom retainer bolt (9) from

each side of mast. (STD mast only)
(FFT Mast)
9. Fasten a nylon strap and hoist to lift cylinder, as

(STD Mast) shown. Hoist and remove lift cylinder (11). Each
cylinder weighs about 50 kg (110 lb).
(FFT Mast)
8. Remove cylinder retainer brackets (10) from each

cylinder.

(Typical Example)
10. Check the condition of bearings (12) located in
each of the tilt cylinder pin bores. Replace 13. Remove rollers (15) and the shims from the
bearings (12) with new if worn or damaged. inner channel mast.
(Typical Example)
11. Check the condition of the bearings (13) located
in each of the mast mounting bores. Replace 14. Fasten nylon straps and a hoist to the
the bearings (13) with new if worn or damaged. intermediate mast channel (16). Remove mast
channel (16).The intermediate mast channel
weighs approximately 168kg (370 lb). (FFT
mast only)
(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)
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.

Assemble Mast
NOTE: The standard, Full Free Lift and Full Free
Triple Lift mast load bearings are all Part No. Bearing Size Bearing O.D.*
adjusted the same way. The mast shown in
the following illustrations is the Full Free D581814 Under Size 108.6 mm (4.276 in)
Triple Lift mast.
D581815 Standard 109.6 mm (4.135 in)
1. Make sure all parts are clean and free of dirt and
foreign material. D581816 Over Size 110.7 mm (4.358 in)
2. Check all parts for damage, use new parts for * Permissible tolerance ±0.08 mm (.003in)
replacement.
A. Lower Bearing Adjustment of Intermediate

Mast
4. Find narrowest point by ruler on the staionary

mast in the area where the bearings make contact
at 475 mm (18.7 in) channel lap.
NOTE: When installing shims (2) behind bearings(1),

make sure the amount of shim is divided
equally when positioned behind each
bearing (1).
5. Install the correct amount of shim (2) behind

rollers until contact (zero clearance) is made
between the rollers.
Mast Adjustment Lower Bearings (A)Zero clearance.

(B)Minimum clearance. (C)Zero clearance. (3)Bearing.
(4)Bearing. (5)Shims. (6)Shims.
3. Select lower bearings (3) and (4) from the chart to

obtain minimum clearance (B) between bearing
and channel leg for full channel length. Must use
same bearing on left and right side.

NOTICE
When the correct amount of shim has been installed

behind rollers (1) there will be contact (zero
clearance)between the rollers and the inner mast at
most narrow point of mast (refer to step 4).
(Typical Example) Mast Adjustment Lower Bearings (A)Zero clearance.

(B)Minimum clearance. (C)Zero clearance.(3)Bearing.
(Typical Example)
6. Install 1 mm shim to each bearing of intermediate (Typical Example)

lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary 7. Make sure intermediate mast lower bearings are
mast from the upper side. properly shimmed in the stationary mast by rolling
up and down and moving intermediate mast to
right and left. If clearance between both masts
NOTE: When installing shims (5) behind bearings can be detected, pull out the intermediate mast
(4), make sure the amount of shim is divided from the stationary mast with crane and add shim
equally when positioned behind each 0.5mm or 1 mm to both intermediate lower
bearing (4). bearings.

(Typical Example)
8. In case of standard and full free mast, inner lower

bearings can be easily extruded by pulling down
the inner mast from the bottom of stationary mast.
If intermediate mast is stuck and cannot move by
rolling up and down, there might be excessive
shim. Pull out the intermediate mast from the
stationary mast and remove shim 0.5 mm to both
intermediate lower bearings. Repeat same
procedure of above until properly shimmed. There
is to be contact zero clearance (C) between Mast Adjustment Upper Bearings (D)Zero clearance. (E) 0.80
intermediate lower bearings and stationary mm (.031 in) Clearance maximum. (F)Zero clearance. (7)
channel at approximately 475 mm (18.7 in) Pads. (8) Shims. (9) Shims. (10) Shims.
channel lap.
B. Upper Bearing Adjustment of Stationary Mast
(Typical Example)
10. Make sure stationary mast upper bearings are

(Typical Example) properly shimmed by rolling up and down and
moving intermediate mast to right and left. If
9. Lift by crane, and pull out intermediate mast from clearance between both masts can be detected,
stationary mast. Install 1 mm shim to each bearing pull out the intermediate mast from the stationary
of stationary mast upper basically. Bearing should mast with crane and add shim 0.5 mm or 1 mm
be selected D581814 under size bearing. to both stationary upper bearings.

C. Upper Pad Adjustment
(Typical Example)
11. In case of standard and full free mast, stationary

upper bearings can be easily extruded by pulling
down the inner mast from the bottom of
stationary mast. If intermediate mast is stuck and
can-not move by rolling up and down, there
might be excessive shim. Pull out the
intermediate mast from the stationary mast and
remove shim 0.5mm to both stationary upper
bearings. Repeat same procedure of above until
properly shimmed. There is to be contact zero
clearance (C) between stationary upper bearings
and the widest point of intermediate mast to be Mast Adjustment Upper Bearings (D)Zero clearance. (E) 0.80
checked before. 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 intermediate
masts with the masts at full extension. Lift by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded
by pulling down the inner mast from the bottom
of stationary mast.

D. Lower Bearing Adjustment of Inner Mast
(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 (18.7 in).
Mast Adjustment Lower Bearings (A)Zero clearance.

(B)Minimum clearance. (C)Zero clearance.(3)Bearing.
13. Select lower bearings (3) and (4) from the chart
to obtain minimum clearance (B) between
bearing and channel leg for full channel length.
Must use same bearing on left and right side.
(Typical Example)
15. Install 1 mm shim to each bearing of inner lower

and intermediate upper basically. Lifting by crane,
insert inner mast into intermediate mast from the
Part No. Bearing Size Bearing O.D.*
upper side.
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)

E. Upper Bearing Adjustment of intermediate
Mast
Follow same procedure with above B.
F. Upper Pad Adjustment of Intermediate Mast
Follow same procedure with above C.
Mast Adjustment Lower Bearings(A) Zero clearance. 17. If the bearings (13) were removed from the mast
(B)Minimum clearance. (C)Zero clearance.(3)Bearing. mounting blocks, install new ones.
18. Put a small amount of clean grease on mounting
bores (11).
16. Make sure inner mast lower bearings are
properly shimmed in the intermediate mast by
rolling up and down and moving inner mast to
right and left. If clearance between both masts
can be detected, pull down the inner mast from
the bottom of inter-mediate mast. Inner lower
bearings can be easily extruded. Add shim 0.5
mm or 1 mm to both inner lower bearings. If inner
mast is stuck and cannot move by rolling up and
down, there might be excessive shim. Pull out
the inner mast from the intermediate mast and
remove shim 0.5 mm to both inner lower
bearings. Repeat same procedure of above until
properly shimmed. There is to be contact zero
clearance (C) between inner lower bearing sand
intermediate channel at narrowest point. 19. If the bearings (12) were removed from the tilt
cylinder pin bores, install new ones.

(STD Mast) (STD Mast)
(FFT Mast) (FFT Mast)
20. Fasten a hoist and nylon strap to secondary 21. Install secondary cylinder mounting brackets
cylinder (11). Install secondary cylinders (11) into (10) over the secondary cylinders.
the stationary mast.
(STD Mast)
22. Install cylinder bottom retainer bolt (9) to each

side of mast. (STD mast only)

(STD Mast)
23. Connect lift hose (7) and return hose (8). (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)

(Typical Example)
30. Install primary lift cylinder (2). (FFT mast only)
26. Connect chains (5) at the bottom of the mast.
27. Connect chains (4) at the chain bracket of

stationary mast upper.
(Typical Example)
28. Install sheave of lift hose. (FFT mast only)
31. Install carriage assembly from the bottom of
inner mast.
29. Install the lift hose support bracket (3) and hoses.
(FFT mast only) (Typical Example)
32. Install cross head (21) and retainer ring (24) and
install chain sheave (23) and retainer ring (22).
(FFT mast only)

Standard Lift Cylinder
Disassembly
Start By:
a. Remove standard lift cylinders.
33. Install carriage chains to primary lift cylinder.

(FFT mast only)
1. Put standard lift cylinder (1) in position on vise (A).
(Typical Example)
34. Install hydraulic hose (25) of side shifter to side

shifter cylinder (26)
2. Loosen set screw (2) with wrench (B).
35. Install mast to lift truck.

3. Remove bearing (3) with wrench (C). 6. Remove O-ring seal (6) and back-up ring (7) from
the bearing..
4. Remove rod (4) from the cylinder body.

7. Remove wiper seal (8) and seal (9) from the
bearing.
5. Remove split rings (5) from the cylinder rod.

Assembly
4. Install split rings (5) on the cylinder rod.
1. Install seal (2) in the bearing.
2. Install wiper seal (1). Install the seal with the lip
toward the outside.
5. Install cylinder rod (6) in the cylinder body.
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..
6. Install bearing (7) on the cylinder rod and tighten

using wrench (C).

Secondary Lift Cylinder
Disassembly
Tools Needed A B
Hydraulic Cylinder Repair Stand 1
Wrench Assembly 1
Start By:
7. Tighten setscrew (8) with wrench (B) to a torque
a. Remove standard lift cylinders.
of 6 ± 1 N•m (53 ± 9 lb•in).
End By:
a. Install standard lift cylinders.
1. Put standard lift cylinder (1) in position on tool (A).
2. Remove bearing (2) with tool (B).

3. Remove rod (3) from the cylinder body. 7. Remove ring (11), wear ring (12) and O-ring (13)
from the bearing.
4. Remove stop ring (4) from the cylinder rod.

8. Remove wiper seal (14) and retaining ring (15)
5. Remove wear ring(5), U-packing(6) and backup from the bearing.
ring(7).
9. Remove U-packing (16).
6. Remove retaining ring(8), spacer(9) and check

valve(10).

Assembly
5. Install stop rings (10) on the cylinder rod.
6. Install wear ring (11), U-packing (12) and backup

1. Install U-packing (1) in the bearing.
ring (13).
2. Install wiper seal (2) and retaining ring (3). Install
the seal with the lip toward the outside.
7. Install cylinder rod (14) in the cylinder body.
3. Install O-ring (4), wear ring (5) and ring (6) in the
bearing.
8. Install bearing (15) on the cylinder rod and tighten

using tool (B).
End By:
4. Install check valve (7), retaining ring (8) and a. Install secondary lift cylinders.
spacer (9).

Primary Lift Cylinder
Remove & Install Primary Lift
Cylinder
Start By:
a. Remove carriage.
WARNING
To prevent personal injury, move the control
levers backward and forward to release any 3. Pull the cylinder out far enough to disconnect
pres-sure in hydraulic system. Slowly loosen the elbow (3). Remove primary lift cylinder (4). Weight
cap of the hydraulic tank to release any pressure is 27 kg (60 lb).
in the tank. Be cautious of hot hydraulic oil when
any lines are disconnected in the hydraulic NOTE: The following steps are for the installation of
system.
the primary lift cylinder.
4. Put primary lift cylinder (4) in position on the mast.
5. Connect elbow (3).
6. Install bolt (2), and bolts (1).
End By:
a. Install carriage.
1. Fasten nylon straps and hoist to the primary lift

cylinder.
2. Remove bolts (1).

Disassemble Primary Lift Cylinder
Tools Needed A B
Wrench Assembly 1
Start By:
a. Remove primary lift cylinder.
4. Remove wear ring (4), U-packing (5) and backup

ring (6).
1. Remove flow protector valve (1) from the cylinder

body.
5. Remove retaining ring (7), spacer (8) and check

valve (9).
2. Remove bearing (2) with tool (A).
3. Remove rod (3) from the cylinder body. 6. Remove O-ring (10) and two rings (11).

7. Remove wiper seal (12) and retaining ring (13) 3. Install O-ring seal (4) and two rings(5).
and U-packing (14) from the bearing.
Assemble Primary Lift Cylinder
Tools Needed A B
Wrench Assembly 1
4. Install check valve (6), retaining ring (7) and

spacer (8).
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.
5. Install wear ring (9), U-packing (10) and back up

ring (11) on the cylinder rod.

Tilt Cylinder
Remove & Install Tilt Cylinder
NOTE: The procedure for removing and installing
the tilt cylinders is the same for both
cylinders.
WARNING
If both tilt cylinders are removed at the same
time the mast can fall. To avoid possible
6. Install cylinder rod (9) in the cylinder body. personal injury, make sure the mast is securely
held in place or supported by a hoist before
7. Install rod cover (10) on the cylinder body. Use removing the tilt cylinders.
tool (A) to tighten bearing.
8. Install flow protector valve (11) on the cylinder

body..
WARNING
7. Install rod cover (10) on the cylinder body. Use
tool (A) to tighten bearing. To prevent personal injury, move the control
levers backward and forward to release any
End By: pres-sure in hydraulic system. Slowly loosen the
cap of the hydraulic tank to release any pressure
in the tank. Be cautious of hot hydraulic oil when
a. Install primary lift cylinder. any lines are disconnected in the hydraulic
system.
1. Disconnect elbow (2). Remove retainer bolt (3)

and pin (1).

2. Remove retainer bolt (6) from pin (5). Remove pin
(5).
3. Remove tilt cylinder (4).
4. Install the tilt cylinder in the reverse order of

removal.
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.

Disassemble & Assemble Tilt 4. Remove piston and seal assembly (4) from the
cylinder rod.
Cylinder
5. Remove head assembly (5).
Tools Needed A
Spanner Wrench 1
Start By:
a. Remove tilt cylinder.
(Typical Example)
6. Remove spacer (6) from the cylinder rod.
7. Loosen the nut and bolt on the rod eye.Remove

cylinder rod (7) and shims (8).
(Typical Example)
1. Use tool (A) to remove head (1) from the cylinder

body.
NOTICE
When the correct amount of shim has been installed

behind rollers (1) there will be contact (zero
clearance) between the rollers and the inner mast at
most narrow point of mast (refer to step 4).
8. Remove seal assembly (10) and O-ring seal (9)

from the piston.
2. Remove rod assembly (2) from the cylinder body.
3. Remove nut (3) from the cylinder rod.

9. Remove seal (11) from the spacer. 12. Install seal (14) in the head. Position the lip of
the seal toward the inside of the head.
13. Install seal (15).
14. Install seal (16) in the cylinder head. Position the

lip of seal (16) toward the outside of the cylinder
head.
10. Remove O-ring seal (12) and back-up ring (13)

from the 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 contact with O-ring seal (12).
11. Remove seals (14), (15), and (16) from the head.
NOTE: Use the following steps to assemble the tilt

cylinder.

16. Install seal (11) in the spacer. 19. Install seals (10) and O-ring seal (9) on the
piston.
(Typical Example)
20. Install head assembly (5) on the cylinder rod.
17. Install spacer (6).
21. Install piston assembly (4) onto the cylinder rod.
18. Install shims (8) and rod eye (2). Tighten the bolt
on rod eye (2) to a torque of 95 ±15 N•m (70 ±11 22. Install nut (3). Tighten nut (3) to a torque of 270
lb•ft). ± 30 N•m (200 ± 22 lb•ft).
(Typical Example)
23. Install the rod assembly in the cylinder body.

Hydraulic Pump
(A372287 for EM0K2 & EM0K3)
Disassemble Hydraulic Pump

a. Start by remove hydraulic pump.
4. Remove Seal (6) and (4) from pump part (5).
1. Remove four cap screws (1) and washers.
5. Remove wear plate (7) from pump assembly (4).
2. Remove shaft seal (2) and washer from the

housing.
6. Remove gear assemblies (8) from the body(9).
3. Remove hydraulic pump part (3) from pump

assembly.

Assemble Hydraulic Pump
1. It is important that the relationship of the back-
plate, body, wear plate and front plate is correct.
There are two half moon 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.
7. Remove body (10) from pump assembly.
2. Install seal (1) and (2) in groove of front plate (3).

8. Remove wear plate (11).
3. Apply a thin coat of petroleum jelly or hydraulic oil

9. Remove seal (11) and (12) from the body.
to both milled gear pockets of body. Slip body
onto front plate with half moon port cavities in
body facing away from front plate.

4. Place new wear plate (4), seal. The side of the 7. Install wear plate (7) into housing.
wear plate with the mid section cut-away must be
on the suction side of pump.
8. Install seal (11) and (10) to pump part (9).
5. Place body (5) onte the body..
9. Install hydraulic pump part (12) to pump assembly.
6. Dip gear assemblies (6) into oil and slip into front
plate bushings and gears into pockets of body.

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.

Hydraulic Pump
(D514289 for EM0QM & EM0QN)
3
Disassemble Hydraulic Pump

A. Start by removing the hydraulic pump.
2. Remove four cap screws (3).
2
3. Remove hydraulic pump cover part from pump
assembly.
1. Remove snap ring (1) from pump assembly (2).

4 6
4. Remove a plate seal and Back-up (4) from pump

cover part.
6. Remove gear assemblies (6) from the body.
5. Remove the side plate (5) from the body.

7
7. Remove the side plate (7) from the body.
8. Remove the body (8) from pump assembly.
9. Finished.

Assemble Hydraulic Pump
NOTE: The small half noon port cavity must be on

the pressure side of pump. The side of wear
plate must be on suction side of pump as
bellow photo of the description (4) and
please prepare a set of repair kit.
4
4. Install the side plate (4) into the body.
1. It is important that the relationship of the pump 5

cover part, body and two side plates is correct.
2. Install new plate seal and Back-up (1) to pump

cover part.
5. Install gear assemblies (5) into the body.
3
2
3. Install the body (2) to pump cover part (3).

6. Install the side plate (6) into the body.

7
10
7. Install new plate seal and Back-up (7) to pump 9. Install four cap screws (10).
cover part (7).
9 11
8
11
8 9
10. Install a new snap ring (11) into pump assembly.
8. Install pump cover part (8) to pump assembly (9).
11. Finished.

Steering Wheel 3. Use a rubber hammer to remove the steering
wheel from the shaft.
Remove & Install Steering Wheel 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).
1. Remove cap (1) from the steering wheel.
2. Remove nut (2) and cup (3) from the steering

wheel shaft. Put location marks on the steering
wheel and the steering wheel shaft for installation
purposes.

Steering Unit
WARNING
Remove & Install Steering Unit
To prevent personal injury be sure pressure in
Start By: the hydraulic system has been released before
disconnecting any hydraulic lines. Slowly loosen
a. Remove floor plate. the cap of the hydraulic tank to release any
pressure in the tank. Be cautious of hot
hydraulic oil when any lines are disconnected in
the hydraulic 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

(1) Floor plate
bolts (4) have all been removed, causing unit (6) to
fall. To avoid damaging components, support the
1. Open the floor plate.
steering pump while removing bolts (4).
5. Support steering unit (5) while removing the

remaining two bolts (4). Remove steering unit (6).
6. Install the steering unit in the reverse order of

removal.
End By:
a. Install floor plate.
2. Loosen four bolts (2).
3. Disconnect five hoses (5) from steering unit (6).

Disassemble Steering Unit
Cleanliness is extremely important when repairing a
steering unit. Work in a clean area. Before
disconnecting lines, clean port area of unit
thoroughly. Use a wire brush to remove foreign
material and debris from around exterior joints of the
unit.
Although not all drawings show the unit in a vise, we

recommend that you keep the unit in the vise during
disassembly. Follow the clamping procedures
explained throughout the manual.
2. Remove 5/16 inch cap screws and washers if

applicable (7 each).
3. Remove end cap.
4. Remove seal from end cap.
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.
5. Remove meter. Be careful not to drop star.
6. Remove seal from meter.
7. Remove drive spacer(s).

8. Remove drive.
9. Remove spacer plate.

11. Remove housing from vise. Place housing on a
10. Remove seal from housing. 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.

13. Remove quad ring seal from seal gland bushing.
14. Use a thin bladed screwdriver to pry dust seal 16. Remove spool and sleeve assembly from 14
from seal gland bushing. Do not damage bushing. hole end of housing.
ATTENTION: Identify and mark all hydraulic hoses

for purposes of reassembly.
17. Push pin from spool and sleeve assembly.
15. Remove 2 bearing races and the needle thrust

bearing from spool and sleeve assembly.

18. Push spool partially from control end of sleeve, 21. Remove check ball seat.
then remove 4 centering springs from spool
carefully by hand. 22. Tip housing to remove check ball.
19. Push spool back through and out of sleeve.

Rotate spool slowly when removing from sleeve.
20. Remove seal from housing.

Assemble Steering Unit
Check all mating surfaces. Replace any parts that
have scratches or burrs that could cause leakage.
Clean all metal parts in clean solvent. Blow dry with
air. Do not wipe dry with cloth or paper towel
because lint or other matter can get into the
hydraulic system and cause damage. Do not use a
coarse grit or try to file or grind these parts.
NOTE: Lubricate all seals with clean petroleum jelly

such as Vaseline.
6. Assemble spool and sleeve carefully so that the
spring slots line up at the same end. Rotate spool
Do not use excessive lubricant on seals for meter
while sliding parts together. Some spool and
section.
sleeve sets have identification marks, align these
Refer to parts listings covering your steering unit
marks. Test for free rotation. Spool should rotate
when ordering replacement parts. A good service
smoothly in sleeve with finger tip force applied at
policy is to replace all old seals with new seals.
splined end.
1. Use a needle nose pliers to lower check ball

7. Bring spring slots of both parts in line and stand
retainer into check valve hole of housing. Make
parts on end of bench. Insert spring installation
sure retainer is straight (not tilted on edge) in
tool through spring slots of both parts. Position
housing.
2pairs of centering springs on bench so that
extended edge is down and arched center section
2. Install check ball in housing.
is together. In this position, insert one end of
entire spring set into spring installation tool, with
3. Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm
spring notches facing sleeve.
[.30in.] ID seal. Install seals on check ball seat as
shown.
8. Compress extended end of centering spring set
and push into spool sleeve assembly with drawing
4. Lubricate check ball seat and seals thoroughly
installation tool at the same time.
before installing seat in housing. When installing
seat do not twist or damage seals. Install check
9. Center the spring set in the parts so that they
ball seat in housing, insert open end of seat first.
push down evenly and flush with the upper
Push check ball seat to shoulder of hole.
surface of the spool and sleeve.
5. Install set screw. Use a 1/4 inch hex key to torque
10. Install pin through spool and sleeve assembly
set screw to 11 N•m [100 lb•in]. To prevent
until pin is flush at both sides of sleeve.
interference make sure top of set screw in slightly
below housing mounting surface.

11. Position the spool and sleeve assembly so that
the splined end of the spool enters the 14 hole
end of housing first.
ATTENTION: Be extremely careful that the parts do 12. Place housing on clean lint free cloth. Install
not tilt out of position while inserting. Push parts 47,5mm [1.86 in.] ID seal in housing.
gently into place with slight rotating action, keep pin
nearly horizontal. Bring the spool assembly entirely 13. Install 2 bearing races and the needle thrust
within the housing bore until the parts are flush at bearing in the order shown.
the meter end or 14 hole end of housing. Do not pull
the spool assembly beyond this point to prevent the 14. Install 25 mm [1 in.] ID dust seal in seal gland
cross pin from dropping into the discharge groove of bushing, flat or smooth side must face down
the housing. With the spool assembly in this flush towards bushing.
position, check for free rotation with in the housing
by turning with light finger tip force at the splined 15. Install the quad ring seal in seal gland bushing.
end. Smooth seal in place with your finger. Do not use
any seal that falls freely into pocket of bushing.

16. Install seal gland bushing over the spool end
with a twisting motion. Tap the bushing in place 18. Clamp housing in vise. Clamp lightly on edges of
with a rubber hammer. Make sure the bushing is mounting area. Do not over tighten jaws.
flush against the bearing race.
NOTE: Check to insure that the spool and sleeve
are flush or slightly below the 14 hole
surface of the housing.
ATTENTION: Clean the upper surface of the

housing by wiping with the palm of clean hand.
Clean each of the flat surfaces of the meter section
parts in a similar way when ready for reassembly.
Do not use cloth of paper to clean surfaces.
17. Install retaining ring in housing. After installing

ring, tap on ring end or pry with screwdriver
around entire circumference of ring to properly
seat ring in groove.
19. Install 73.5 mm [2.89 in.] ID seal in housing.
20. Install spacer plate. Align bolt holes in spacer

plate with tapped holes in housing.

21. Rotate spool and sleeve assembly until pin is
parallel with port face. Install drive, make sure
you engage drive with pin. To assure proper
alignment, mark drive as shown. Note relation-
ship between slotted end of drive to splined end
of drive when marking.
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.
22. Install 73,5 mm [2.89 in.] ID seal in spacer plate

or gerotor (meter)

24. Install drive spacer (s) when used, in meter.
25. Install 73,5 mm [2.89 in.] ID seal in gerotor

(meter)or end cap, see notes.
26. Install end cap on gerotor, align holes.
27. Install 7 dry cap screws in end cap. Pretighten

Actual Displacement Spacer screws to 11-17 N•m [100-150 lb•in] then torque
cm³/r(in³/r) screws to specifications.
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] 91.77 [3.613]

Brake Master Cylinder Disassemble & Assemble Brake
Master Cylinder
Remove & Install Brake Master Start By:
Cylinder (Boosted) a. Remove brake master cylinder.
1. Remove the cotter pin from pin (1). Remove pin 1. Slip boot (4) off of body (5).
(1).
2. For purposes of reassembly, mark the position of
NOTE: Plug and cap all openings to avoid nut (2) on yoke (1). Loosen nut (2) from plunger
contamination and debris from entering the (3).
system after removing any tubes or lines.
3. Separate yoke (1), nut (2), plunger (3) and boot
2. Disconnect wire harness from the pressure switch. (4).
3. Disconnect tube (3) from master cylinder.
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. 4. Remove pressure switch (5).
End By:

5. Remove elbow (6) plug (7), washers (8) and NOTE: Be sure to check the condition of seal (18)
connector (9) from master cylinder. 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 the

reverse order of disassembly
6. Remove bolt (10), washer (11), tube (12) and End By:
washer (13) from the body.
a. Install the brake master cylinder.
7. Remove the retaining spring (15) and washer (16)

from the body.

Steer Wheel & Bearing
Remove Steer Wheel & Bearing
Tools Needed A B C
Floor Jack 1
Driver Set 1
Lock Nut Installer 1
NOTE: The procedure to remove the steer wheels is

the same for the right and left steer wheel. 4. Straighten and remove split pin (4).
1. Support the steer axle with a floor jack or a wood 5. Remove nut (5) and washer (6).
block under the frame (A).
2. Remove wheel nuts (1) and wheel assembly (2).

Steer wheel (2) weighs approximately 34kg (75Ib).
6. Remove wheel hub assembly (7).
3. Remove wheel cap (3).

7. Remove bearing cup (8) from the hub (7).
8. Remove seal, bearing cup and cone from the

bank of hub.
NOTE: Check the condition of all seals, bearings

and components. If any parts are worn or
damaged, use new parts for replacement.
For purposes of assembly, lower the
temperature of the bearing cups before
installing into steer wheel (5). Use tooling (B)
to install bearing cups and seals.
9. Pack bearing cones and lubricate the 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 ± 4 lb•ft).
d. Insert a split pin (4) into a hole of knuckle and
then, bend over lock nut (5)
12. Install wheel cap (3). Be sure to pack the cap

with Multipurpose Grease.
13. Install steer wheel (2) and tighten the bolts (1).
14. Remove tooling (A) and lower the lift truck.

Steering Knuckle, Kingpin,
And Bearing
Remove And Install Steering
Knuckle, King Pins And Bearing
Tools Needed A
Drive Set 1
Start By:
a. Remove steer wheels. 3. Remove the top grease nipple (6).
NOTE: The procedure to remove and install the

steering knuckle, kingpin, and bearing is the
same for both sides of the lift truck.
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).
1. Remove two bolts (2) and pin retaining plate (3).
2. Remove tie rod pin (1) and separate tie rod

(4)from knuckle (5).
5. Remove the king pin (9).

Steer Axle
Remove & Install Steer Axle
Tools Needed A
Jack Stand 4
WARNING
Be sure the pressure in the hydraulic system is
6. Remove the knuckle (5), spacer (10) and shim released before any lines or hoses have been
(11). During the reassembly, the clearance disconnected.
between the knuckle and axle beam should be
lower than 0.5mm.
7. Remove bearing (12) from steer axle (13). 1. Put the lift truck on the plain ground.
8. Check the condition of bearings (12). Replace it 2. For purposes of reassembly, put identification
with new one if worn or damaged. marks on hoses (1). Disconnect hoses (1). Plug
and cap all openings to prevent contamination
9. Repeat steps 7 and 8 for the remaining seal, and debris from entering the system.
bear-ing and spacer in the other side of steer axle
(13). 3. Support the frame with a proper floor jack. Be
careful to select the proper jack stand. Refer to
the truck weight from the catalogue.
NOTICE
Check the condition of all seals, bearings and

components. If any parts are worn or damaged use
new parts for replacement.
10. Lubricate the pins, king pins and bearings.
11. Install the steering knuckle, kingpins and

bearings in the reverse order of removal.
End By:
a. Install steer wheels. 4. Loosen mounting bolts (2) until approximately two
bolt threads are left in the mounting bosses.

5. Lower the steer axle onto the bolt heads with the 9. Seat steer axle (4) as follows:
floor jack or lift truck. a. Install bolts (2) through cap (3) and into the
mounting bosses approximately two bolt
6. Remove bolts (2) and mounting caps (3) from the threads
steer axle. b. Use the floor jack to raise steer axle (4) into
the mounting boss.
c. Tighten bolts (2).
7. Remove steer axle (4). The steer axle weighs

approximately 200kg (440 lb).
10. Connect hoses (1).
NOTE: Use the following steps to install the steer
axle.
8. Use a floor jack to position steer axle (4).
NOTE: Use bolts (2) and cap (3) to align steer axle
(4) with the mounting bosses while raising
steer axle(4) into position with the floor jack.

Steering Cylinder
Remove & Install Steering Cylinder
Start By:
a. 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.

Disassemble Steering Cylinder
Tools Needed A
Pliers 1
NOTE: Steering cylinder has two rods positioned

between the cylinder end caps. These rods
are attached to the cylinder end caps with
nuts at each end. Remove the nuts and rods
before removing the cylinder end caps from
the cylinder tube. 4. Use tool (A) to remove retaining rings (4) and
rings (3) from the cylinder rod.
1. Put location marks on end caps (1) as to their

position on the steering cylinder tube.
5. Remove piston (5) from the cylinder rod.
2. Remove end caps (1) from the steering cylinder.
3. Remove bolts (2) and mounting caps (3) from the

steer axle.

Assemble Steering Cylinder
Tools Needed A
Pliers 1
6. Remove and inspect O-ring seal (6).
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).
7. Remove seal (7) from the piston.
2. Install seal (5) on the piston.
8. Disassemble 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).

3. Install O-ring seal (6) on the cylinder rod. 7. Install cylinder tube (10) on the rod assembly.
4. Install piston (7) on the cylinder rod.
8. Install end caps (11) on cylinder tube (10).

5. Install rings (8).
NOTE: Install the nuts and rods on steering cylinder
6. Use tool (A) to install retaining rings (9) on each rafter installing the cylinder end caps.
side of the piston.
End By:
a. Install the steering cylinder.

Hydraulic Control Valve
Remove And Install Hydraulic
Control Valve
WARNING
Hydraulic oil under pressure can remain in the
hydraulic system after the engine and pump
have been stopped. Personal injury can result if
the pressure is not released before any work is
done to the hydraulic system. To prevent 3. Support control valve (3). Remove bolts (5),
possible personal injury, turn the engine off and control valve (3).
move the control levers to make sure the
hydraulic pressure is released before any fitting, 4. Install the control valve in the reverse order of
plug, hose or component is loosened, tightened,
removed or adjusted. Always move the lift truck removal.
to a clean and level location away from the travel
of other machines. 5. Fill the hydraulic tank to the correct level with fluid.
Refer to the Operation And Maintenance Manual
for further information.
NOTE: For purposes of reassembly, put

identification marks on all lines, tubes and
hoses before any disconnections are made.
1. Disconnect seven lines (4) from control valve (3).
2. Remove the cotter pins, washers and pins (1)

from linkages (2).

Disassemble Hydraulic Control b. disassembly of front cover.
Valve 1. remove O-ring(11) from the lateral face.
Start by : 2. remove hex plug(6) and priority connector(5).

NOTE: For the purpose of assembly, put 3. remove FD sleeve(4), ball retainer(7), steel
identification mark on valve sections. ball(8), spring(9).
a. disassembly of main valve.
1. remove main control 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.

c. disassembly of lift section. d. disassembly of tilt section.
1. remove O-ring(13), poppet(9) and 1. remove O-ring(15), poppet(11) and spring

spring(10)from lateral face carefully not to from lateral face.
damage the face.
2. Loose bolts (14), and remove cap(7).
2. remove two hex bolts(12) and cap(5).
3. after fixing the end of spool (2) not to be
3. after fixing the end of spool (2) not to be rotated, remove a set screw (9).
rotated, remove a set screw (7).
4. remove retainer spring(8), spring (10), seal
4. remove retainer spring(6), spring(8), seal plate (5).
plate(3).
5. take out spool(2) from body(1) with dust
5. take out spool(2) from body(1) with dust seal(6) slowly smoothly to prevent spool
seal(4) slowly smoothly to prevent spool damage.
damage.
6. loose bolts(13), take out seal plate(5) and dust
6. loose bolts(11), take out seal plate(8) and dust seal(6) from body.
seal(4) from body.
7. Loose hex bolt(14).
7. Loose hex bolt(14).

Assemble Hydraulic Control Valve
Start by :
NOTE: make sure all valve parts are clean and free
of dirt.
e. disassembly of auxiliary section.
1. remove O-ring(13), poppet(9) and spring (10)

from lateral face.
2. Loose bolts(12), and remove cap(5).
3. after fixing the end of spool (2) not to be a. disassembly of auxiliary section.
rotated, remove a set screw (7).
1. fix section by using a vice for
4. remove retainer spring(6), spring(8), seal lateral(machined)faces not to be damaged.
plate(3).
2. install O-ring. And install priority
5. take out spool(2) from body(1) with dust connector(5)into the front cover by tightening
seal(4)slowly smoothly to prevent spool toque 60.
damage.
3. incorporate ball retainer(7), steel ball(8) and
6. loose bolts(11), take out seal plate(3) and dust spring(9) into FD spool(4), which is installed
seal(4) from body. into FD cover front(1).
7. Loose hex bolt(14). 4. install O-ring and tighten hex bolt(6) into FD
cover front(1) by 60N•m.
5. release a section from a vice, and install O-

ring(11).

b. assembly of lift section.
c. assembly of tilt section.
lateral(machined)faces not to be damaged. 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 2. Install spool(2) into body(1) smoothly and
same as that of spool disassembly. slowly. A direction of spool access to body is
same as that of spool disassembly.
3. dust seals(4) put on the end of spool by using
a tool (Fig 8-9) 3. dust seals(6) put on the end of spool by using
Note : be careful not to damage a dust seal, a tool
as it could make an external leakage. Note : be careful not to damage a dust seal,
as it could make an external leakage.
4. after fixing the spool end, install seal
plate(3),spring retainer(6) and spring(8). And 4. install pilot spool(3) and spring (4) into a
tighten set screw(7) by 14NIm bottom of spool.
NOTE: make sure that set screws are 5. after fixing the spool end, install seal plate(5),
tightened by a exact torque. In case of spring retainer(8) and spring(10). And tighten
excessive torque, it could make inappropriate set screw(9) by 14N•m
spool motion. Incase of in sufficient torque
make a excessive drift of cylinder on neutral NOTE: make sure that set screws are
position. tightened by a exact torque. In case of
excessive torque, it could make inappropriate
5. install cap(5) and tighten two hex bolts(12) spool motion. incase of in sufficient torque, it
by14N•m. could make a excessive drift of cylinder on
neutral position.
6. put seal plate(3) on the end of spool and
tighten hex bolts(11) by 14N•m. 6. install cap(7) and tighten two hex bolts(14)
by14N•m.
7. install hex plug with O-ring by 35N•m.
7. put seal plate(5) on the end of spool and
8. release a section from a vise, and install O- tighten hex bolts(13) by 14N•m.
ring(13), poppet(9) and spring(10) into lateral
face. 8. 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 leakage problem.
Note Dust seal mounting procedure.
d. assembly of auxiliary section.

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(4) put on the end of spool by using

a tool.
NOTE: be careful not to damage a dust seal,

as it could make an external leakage.
4. after fixing the spool end, install seal plate(3),

spring retainer(6) and spring(8). And tighten
set screw(7) by 14N•m.
NOTE: make sure that set screw are

tightened by a exact torque. In case of
excessive drift of cylinder on neutral position.
This tool is needed when assemble tilt section (c, 3)

5. put seal plate(3) on the end of spool and and assemble auxiliary section (d, 3).
tighten two hex bolts(11) by 14N•m
1. insert the dust seal(4) from the side with a
6. install cap(7) and tighten two hex bolts(14) champer the side without a champer(no more
by14N•m. than c0.5)of tool(3).
2. insert the tool(2) into the tool(3).
7. release a section from a vise, and install O- 3. insert the tool(1) into the tool(2)
ring(13), poppet(9) and spring(10) into lateral 4. insert the spool into the above assembly.
face. (note that the dust seal(4) is in its right position)
5. remove the tool(1).
6. hit the tool(2) to insert the dust seal(4) into the
valve body.

Cause and Measure on failure of
control valve
Problem: External leakage form dust seal Problem: large drift of cylinder
Cause Cause
1. damaged seal lip or seal worn away. 1. internal leakage of spool damage.
2. damaged spool. 2. leakage of port relief valve and shut-off plug.
3. contaminated seal plate. 3. bias of spool position(not neutal position).
4. higher back pressure of tank port. 4. leakage of cylinder.
5. penetraed foreign material such as paint and Measure

dirt.
1. change control valve section ass’y.
Measure
2. check if O-ring is normal. Or exchange it.
1. exchange dust seal.
3. check an interference of lever link.
2. exchange control valve section ass’y.
4. Check a cylinder.
3. disassemble seal plate, and clean seal plate
and tighten it by a standard torque.
Problem: lower pressure(not to lift a load)
4. Investigate hose or exchange return filter.
Cause
5. Clean it. Be careful not to damage spool.
1. contaminated relief valve.
Problem: Inappropriate Spool motion
2. strange wearing of relief valve poppet.
Cause
3. lower relief setting pressure.
1. foriegn material penetrates into spool.
4. O-ring damage of relief valve.
2. deformation of spool by exteranl force.
5. Damaged pump.
3. bias wear of spool by biased force.
4. loosening of cap bolt. Measure
5. high oil temp. 1. overhaul relief valve ass’y. Clean its

internalparts.
6. low oil temp.
2. Exchange relief valve ass’y.
Measure
3. Adjust relief setting pressure to normal value.
1. take spool out, and clean it.
4. Exchange O-ring.
2. exchange valve section ass’y.
5. Exchange pump.
3. exchange valve section ass’y.
4. tighten cap boly by standard torque.
5. Use in normal temperature.
6. Use in normal temperature.

Counterweight
Remove & Install Counterweight
Tools Needed A
Link Bracket 1
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.
1. Remove the washers and bolts (4) and exhaust
pipe (5). 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. Install towing pin (7).
2. Support counter weight (6) with a hoist and

tooling(A) as shown.

Engine
Remove & Install Engine
Tools Needed A
Link Bracket 1
NOTE: Procedures for Gasoline, L.P. and Diesel

engines are all similar. The engine shown in
the following illustrations is for Diesel B3.3
engine.
2. Disconnect the two battery cables (1). Remove
Start by :
the washers, two bolts (2) and battery assembly
a. Remove Overhead guard* (3).
b. Remove counterweight*
c. Remove hood assembly*
* Refer to the topics “Overhead guard”,

“Counterweight” and “hood assembly” in this module
3. Loosen the clamps and disconnect air cleaner

hoses (4).
1. Remove two bolts (1) and floor plate (2).
4. Remove mounting bracket (5) and air cleaner (6).
5. Loosen clamp assembly (7).

6. Remove the washers, two bolts not shown and 11. Loosen clamps and disconnect the two
tube assembly (9). transmission cooler hoses (15).
7. Remove the washers, two bolts and muffler

assembly.
12. Remove, eight bolts (16) and baffle

assembly(17), if equipped.
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).

(Typical Example)
16. Disconnect wires (23) from alternator (24).
13. Remove radiator mounting bolts (18).
NOTICE
Place identification marks on all wires and

connectors to assure proper assembly.
14. For easy removal of radiator, loosen four

bolts(19) and remove radiator (20).
17. Disconnect connector (25) from transmission

switch.
18. Disconnect engine wire harness (26).
(Typical Example)
15. Disconnect wires (21) from starter assembly (22).

(Typical Example)
19. Disconnect wire (27) from circuit breaker (28).To
remove engine from the truck, other wires or 22. Remove the six bolts (34) that hold the converter
connectors not shown should be disconnected. to the flywheel. During the reassembly, the
tightening torque is 28 ± 7 N•m (40 ± 10 lb•ft).
20. Remove nut (29) and accel rod (30).
NOTE: At this point, make a final check to be sure

all removals and disconnections have been
made from the engine.
21. Remove two bolts (31). Push wiring (32) back

toward the engine. Remove cover (33).
(Typical Example)
23. Support engine with a hoist and tooling (A) as

shown.

24. Remove the washers and bolts (35) from the End By :
converter housing. During the reassembly, the
tightening torque is 55 ± 10 N•m (40 ± 10 lb•ft). a. Install overhead guard*
b. Install counterweight*
c. Install hood assembly*
Refer to the topics “Over head guard”,

“Counterweight” and “Hood assembly” in this
module.
(Typical Example)
25. Remove the nuts and washers (36) from two

engine mounts, located on each side of the
engine. During the 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.

Vehicle System: Disassembly & Assembly

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Vehicle System: Disassembly & Assembly

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SB4220E01

D20G, D25G, D30G with B3.3 Engine

Standard Lift Cylinder..........................................28

Secondary Lift Cylinder .......................................31

Brake Master Cylinder .........................................62

Steering Knuckle, Kingpin, And Bearing ..............66

Vehicle System 3 Index

5. Remove the washers and four bolts (3).

1. Raise the hood. Support the hood with a hoist.

3. Lower the hood.

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

Vehicle System 5 Disassembly & Assembly

3. Remove the washers, nuts, and two bolts (3).

4. Remove front overhead guard (1). Front over

6. Remove rear Leg (5).

Vehicle System 6 Disassembly & Assembly

1. Fasten a hoist to the backrest. Remove bolts (2)

2. Remove backrest (1). Backrest (1) weighs about

3. install backrest (1) in the reverse order of removal.

4. Slide the fork to slot (2) in the middle of the

7. Install the forks in the reverse order of removal.

8. Put the forks in position. Lower both fork pins (1)

9. Install stopper bolt and washer (3). Be careful not

Vehicle System 7 Disassembly & Assembly

3. Remove four bolts (8) from the chain guard/hose

1. Raise carriage (1). Position a wooden block as

2. Disconnect two hydraulic lines (4) from side

4. Remove two bolts (10) from the hose mounting

Vehicle System 8 Disassembly & Assembly

5. Use tool (A) to remove retainer ring(11) from the

6. Remove cross head (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

NOTE: Use the following steps to install the carriage.

9. Raise the inner mast to put in the carriage onto

Vehicle System 9 Disassembly & Assembly

11. Put the chains in position over cross head

1. Remove the roll pins and pins (2) to disconnect

12. Install chain guard/hose support assembly (6)

Vehicle System 10 Disassembly & Assembly

2. Remove four lower roller bearings (3) and the

D581816 Over Size 110.7 mm (4.358 in)

* Permissible tolerance ±0.08 mm (.003in)

Vehicle System 11 Disassembly & Assembly

4. Do step 2 through 3 for other sets of bearings

5. Tighten screw (5) that holds the top bearings to

Vehicle System 12 Disassembly & Assembly

b. Place truck on the pit so to disassemble and

4. Remove bolt (5) from each side of mast assembly

6. Tilt backward mast assembly (2) fully with the

Place identification marks on all hydraulic

2. Disconnect hose (3).

3. Disconnect the hydraulic return lines (not shown).

Vehicle System 13 Disassembly & Assembly

NOTE: The following disassembly and assembly

8. Install the mast in the reverse order of removal.

b. Fill hydraulic oil to tank*.

* Refer to the Operation and Maintenance Manual