SB2204E00

Jun. 1999

Disassembly &
Assembly
Lift Trucks Vehicle Systems
D35S-2, D40S-2, D45S-2
D40SC-2, D45SC-2, D50SC-2
G35S-2, G40S-2, G45S-2
G40SC-2, G45SC-2, G50SC-2
 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 ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ 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.

DAEWOO 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 DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.

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. DAEWOO dealers have the most current information
available.

1
 Index

Brake Hydraulic Booster ..........................................21

Counterweight..........................................................36
Engine......................................................................39
Hood Assembly..........................................................5
Hydraulic Control Valve ...........................................27
Hydraulic Oil Filter Assembly...................................37
Hydraulic Pump .......................................................33
Overhead Guard ........................................................6
Primary Lift Cylinder ................................................12
Secondary Lift Cylinders............................................9
Steer Axle ................................................................23
Steering Cylinder .....................................................24
Steering Knuckles, Kingpins And Bearings .............22
Steering Unit ............................................................15
Steering Wheel ........................................................15
Tie Rods...................................................................21
Tilt Cylinders ..............................................................7
Tires And Rims (Steer) ............................................26
Transaxle .................................................................37

Vehicle Systems 3 Index

Disassembly & Assembly
3
Hood (with seat) Assembly

Remove & Install Hood (with seat)

Assembly

IACD203P

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

IACD201P

WARNING

The hood and seat assembly can fall when nut (1)
IDCD054P
is removed from the support cylinder rod. To avoid
personal injury, support the seat and hood
assembly before removing nut (1). 6. Release latch (5). Use the hoist to remove hood
and seat assembly (4). The hood and seat
assembly weighs 52 kg (115 lb).
1. Raise the hood. Support the hood with a hoist.
7. Install the hood and seat assembly in the reverse
order of removal.
2. Remove nut (1) from the support cylinder. Remove
the cylinder rod from the bracket.

3. Lower the hood.

IACD202P

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

cover.

Vehicle Systems 5 Disassembly & Assembly

Overhead Guard

Remove & Install Overhead Guard

3
IDCD057P

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

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

IDCD055P guard (1) weighs 30 kg (66 lb).

1. Support overhead guard (1) with lifting straps and

a hoist.

IDCD058P

5. Remove the washers, nuts, and four bolts (4).

IDCD056P
6. Remove rear Leg (5).

2. Remove the washers, nuts, and two bolts (2). 7. Install front overhead guard (1) and rear leg (5) in
the reverse order of removal.

Vehicle Systems 6 Disassembly & Assembly

Tilt Cylinders
5
Remove & Install Tilt Cylinders

NOTE : The procedure for removing and installing

the tilt cylinders is the same for both cylinders.

WARNING IACD205P 4 6

If both tilt cylinders are removed at the same time

2. Remove retainer bolt (6) from pin (5). Remove pin
the mast can fall. To avoid possible personal
(5).
injury, make sure the mast is securely held in
place or supported by a hoist before removing the
3. Remove tilt cylinder (4).
tilt cylinders.
4. Install the tilt cylinder in the reverse order of
removal.

3
IACD204P

WARNING

To prevent personal injury, move the control

levers backward and forward to release any
pressure in hydraulic system. Slowly loosen the
cap of the hydraulic tank to release any pressure
in the tank. Be cautious of hot hydraulic oil when
any lines are disconnected in the hydraulic
system.

1. Disconnect elbow (2). Remove retainer bolt (3)

and pin (1).

Vehicle Systems 7 Disassembly & Assembly

Disassemble & Assemble Tilt
Cylinders
Start By:

a. Remove tilt cylinder.

5

1
4

7 6
ICCD004P

4. Remove pin (5) inside hole and nut (6) from the
cylinder rod (4).

5. Remove piston (7) from the cylinder rod.

4
ICCD002P
8

1. Remove eye (1) from the rod assembly (4).

ICCD005P

6. Remove O-ring seal (8) from the cylinder rod.

2
3
ICCD003P
10
2. Remove rod cover (2) from the cylinder tube (3)
using a spanner wrench.

9
NOTICE
Use extra care not to damage the highly finished
surface of the cylinder rod and the bore of the clylinder
tube during disassembly and assembly of the tilt
cylinder. ICCD006P

7. Remove wear ring (9) and slipper seal (10) from

3. Remove rod assembly (4) from the cylinder body. the piston.

Vehicle Systems 8 Disassembly & Assembly

 11 Secondary Lift Cylinders

Disassemble Secondary Lift

Cylinders
Start By :
2

a. Remove secondary lift cylinders.

12
ICCD007P

8. Remove O-ring seal (11) and backup ring (12)

from the rod cover (2).

16

15
1. Put secondary lift cylinder (1) in position as shown.
13
14
ICCD008P

9. Remove wiper seal (13), backup ring (14), U-

packing (15) and DU-bush (16) from the rod cover.

NOTE : Assemble the tilt cylinder in the reverse

order of disassembly.

2. Remove head assembly (2) with tool.

Vehicle Systems 9 Disassembly & Assembly

3. Remove rod (3) from the cylinder body. 6. Remove O-ring seal (7), back-up ring (8) and seal
(9) from the piston.

4. Remove retaining ring (4) and piston (5) from the

cylinder rod. 7. Remove O-ring seal (10) from the head assembly.

5. Remove O-ring seal (6) from the cylinder rod. 8. Remove wiper seal (11), seal (12) and bush (13)
from the head assembly.

Vehicle Systems 10 Disassembly & Assembly

Assemble Secondary Lift
Cylinders

5. Install O-ring seal (6) on the cylinder rod.

1. Install bush (13) and seal (12).

2. Install wiper seal (11). Install the seal with the lip
toward the outside.

6. Install piston (5) and retaining ring (4) on the

cylinder rod.

3. Install O-ring seal (10) onto the head assembly.

7. Install cylinder rod (3) in the cylinder body.

4. Install seal (9), back-up ring (8) and O-ring seal (7)
on the piston.

Vehicle Systems 11 Disassembly & Assembly

8. Install head assembly (2) on the cylinder rod and 1. Fasten nylon straps and hoist to the primary lift
tighten using tool. cylinder.

End By : 2. Remove bolt (1).

a. Install secondary lift cylinders.

Primary Lift Cylinder

Remove & Install Primary Lift

Cylinder
Start By :

a. Remove carriage.
3. Pull the cylinder out far enough to disconnect
hydraulic hose (2). Remove primary lift cylinder
WARNING (3).

To prevent personal injury, move the control 4. Install primary lift cylinder (3) in the reverse order
levers backward and forward to release any of removal.
pressure in hydraulic system. Slowly loosen the
cap of the hydraulic tank to release any pressure End By :
in the tank. Be cautious of hot hydraulic oil when
any lines are disconnected in the hydraulic a. Install carriage.
system.

Vehicle Systems 12 Disassembly & Assembly

Disassemble Primary Lift Cylinder
Start By :

a. Remove primary lift cylinder.

4. Remove O-ring seal (4) and back-up ring (5) from

the bearing.

1. Remove bearing (1).

2. Remove rod (2) from the cylinder body.

5. Remove wiper seal (6), back-up ring (7), seal (8)

and rings (9) from the bearing.

3. Remove split rings (3) from the cylinder rod.

Vehicle Systems 13 Disassembly & Assembly

Assemble Primary Lift Cylinder

5. Install split rings (3) on the cylinder.

1. Install back-up ring (7) and seal (8) in the bearing.

Install the seal with the lip toward the inside.

2. Install wiper seal (6). Install the seal with the lip
toward the outside.

3. Install rings (9) in the bearing.

6. Install cylinder rod (2) in the cylinder body.

7. Install bearing (1) on the cylinder body. Tighten the

bearing (1).

End By :

a. Install primary lift cylinder.

NOTE : Install the back-up ring with the curved side
contacting the O-ring seal.

4. Install the back-up ring (5) and O-ring seal (4) on

the bearing.

Vehicle Systems 14 Disassembly & Assembly

Steering Wheel Steering Unit

Remove & Install Steering Wheel Remove & Install Steering Unit
Start By:

a. Remove steering wheel.

IACD206P

1. Remove cap (1) from the steering wheel.

IACD208P

2
3
2
3

IDCD064P

IACD209P
2. Remove nut (2) and cup (3) from the steering
wheel shaft. Put location marks on the steering
1. Open the access cover for the fuse panel.
wheel and the steering wheel shaft for installation
Remove horn switch and open the top cover.
purposes.
2. Loosen two bolts (1). Slide directional control
3. Use hammer (A) to remove the steering wheel
switch (3) off of steering column (2). Set switch (3)
from the shaft.
aside, clear of the steering column.
NOTE : Use the following steps to install the steering
wheel.

4. Put the steering wheel on the steering wheel shaft

in its original position.

5. Install cup (3) and nut (2). Tighten nut (2) to a

torque of 80 L 7 N¥m (60 L 5 lb¥ft).

6. Install cap (1).

Vehicle Systems 15 Disassembly & Assembly

 4
Disassemble & Assemble Steering
Unit
Start By :

a. Remove steering unit from the truck.

IACD210P

3. Remove two bolts (4).

1

WARNING

To prevent personal injury be sure pressure in the ICCD079P

hydraulic system has been released before
disconnecting any hydraulic lines. Slowly loosen
1. Remove the elbows (1) from the body.
the cap of the hydraulic tank to release any pressure
in the tank. Be cautious of hot hydraulic oil when
any lines are disconnected in the hydraulic system. 5

3 4
NOTE : Identify and mark all hydraulic hoses for
purposes of reassembly. 2

4. Disconnect five hoses from steering unit (5).

NOTICE
Steering unit (5) and column (2) can separate after ICCD080P
bolts (4) have all been removed, causing unit (5) to
fall. To avoid damaging components, support the 2. Remove seven bolts (5) from gerotor housing (3).
steering pump while removing bolts (4).

NOTICE
5. Support steering unit (5) while removing the Make a note of the position of special bolt with a pin.
remaining two bolts (4). Remove steering unit (5) It is located at a mark in line with check valve.
and steering column (2).

6. Install the steering unit in the reverse order of

removal. 3. Separate housing (3) and cap (4) from steering
unit body (2).
End By :

a. Install steering wheel.

Vehicle Systems 16 Disassembly & Assembly

 17 16

7 9 10
6

8 3 4

23
ICCD081P ICCD084P

4. Remove the components from housing (3) as 22 17

21
follows:
a. Remove plate (6) from housing (3).
b. Remove shaft (7) from gerotor (9). 19
c. Remove gerotor (9) from housing (3).
d. Remove O-rings seal (8) from housing (3).
e. Remove O-ring seal (10) from cap (4).

20 23 18
ICCD085P

12 9. Remove the components from sleeve (16) as

11
follows :
a. Remove pin (18) from spool (17) and sleeve
(16).
b. Remove spool (17) from sleeve (16).
c. Remove two bearing races (19), (20) and
14 13 bearing (21) from spool (17).
ICCD082P d. Remove six springs (23) and ring (22) from
spool (17).
5. Remove suction valve balls (12) and pins (11).

6. Remove screw (13) and check valve ball (14). 25

26

24
16
ICCD086P

15 10. Remove O-ring seal (24) and king-ring (25) from

ICCD083P
body.

7. Remove O-ring seal (15) from steering unit body 11. Check the condition of dust seal ring(26).
(2). Replace seals with new if worn or damaged.

8. Remove sleeve (16) from the body.

Vehicle Systems 17 Disassembly & Assembly

 28 27
37 36

ICCD087P ICCD089P

12. Remove plug (27) and washer (28) from steering 16. Install washer (37) and plug (36) into the steering
unit body. unit body.

32 35 2 32 35 2

31 31
34 34

ICCD088P ICCD088P

13. Remove plug (31) and spring (32) from the body 17. Install housing (35) and poppet (34) into the
(2). pump body.

14. Remove poppet (34) and relief valve housing (35) 18. Install spring (32) and plug (31) into body (2).
from the body. Tighten plug (31) to a torque 50 N¥m (37 lb¥ft).

28 27
37 36

ICCD089P ICCD087P

15. Remove plug (36) and washer (37) from the 19. Install washer (28) and plug (27) into body (2).
body. Tighten plugs to a torque 30 N¥m (22 lb¥ft).

NOTE : The following steps are for assembling the

steering pump.

Vehicle Systems 18 Disassembly & Assembly

 25

26 2

16

24
15
ICCD086P ICCD083P

20. Install dust seal ring (26). Install O-ring seal (24) 24. Install sleeve (16) into steering unit body (2).
with king-ring (25) into body.
25. Install O-ring seal (15) into body (2).

22 17
21

19

12
11

20 23 18
ICCD085P 13
14
ICCD082P

NOTICE
26. Install check valve ball (14) and screw (13).
For purposes of installation, note that springs (23) are
Tighten the screw (13).
installed in two stacks of three. Make sure the curves
of the two stacks are in contact and positioned in the
27. Install suction valve balls (12) and pins (11) in
center of spool (17). The notched side of springs (23)
their original positions into the steering unit body.
must be positioned toward sleeve (16).

17 16

23
ICCD084P

21. Install springs (23) into spool (17).

22. Install spool (17) into sleeve (16).

23. Install pin (18), ring (22), two bearing races (19),
(20) and bearing (21) in their original positions on
spool (17).

Vehicle Systems 19 Disassembly & Assembly

 2 7

4 5

1 3
ICCD090P ICCD091P

NOTICE
9 10
6
7 To assure proper operation of the steering unit, make
sure bolts (5) are clean and dry before installing.
Tighten bolts (5) in the sequence shown in the
illustration.

8 3 4
5

ICCD081P 3
4
28. Install plate (6) onto steering unit body. 2

NOTICE
Make sure the notch of shaft (7) properly seats on pin
(18) when installed into body and spool (17).
ICCD080P

29. Install shaft (7) into body (2) and spool (17). 32. Install bolts (5) into cap (4). Tighten bolts (5) in
correct sequence to a torque of 30 L 6 N¥m (22
L 4.4 lb¥ft).

NOTICE End by :
Gerotor (9) must be aligned with shaft (7) and pin (18)
as shown in the illustration. a. Install steering unit to the truck.

30. Install O-ring seal (8) and housing (3).

31. Install O-ring seal (10) and cap (4).

Vehicle Systems 20 Disassembly & Assembly

Brake Hydraulic Booster Tie Rods

Remove And Install Brake Hydraulic Remove And Install Tie Rods
Booster
Tools Needed A B
Floor Jack 1
7 4 1
Drive Set 2

Start By :
5
a. Remove steer wheels.

NOTE : The procedure to remove and install the tie

rod is the same for each steer wheel.

6 2 3
IACD211P
1

1. Remove the floor plate over the brake hydraulic

3
booster.

2. Disconnect pressure line (3).

3. Disconnect return line (4) and supplement line (1).

4

4. Disconnect brake line (5).

2
5. Remove pin (6) and bolts (7). IACD212P

6. Remove hydraulic booster (2). 1. Support the steer axle with a floor jack (A).
Position the wheel to gain access to the tie rods.
NOTE : The following steps are for installation of the
brake master cylinder. 2. Remove two pin retaining bolts (2). Remove pins (1).

NOTE : Installation is reverse order of removal. 3. Remove tie rod (4) and dust seals (3).

7. Remove the air (bleed the brake lines). See the

topic Brake System Air Removal in Testing And 5
Adjusting.

8. Install the floor plate over the brake master

cylinder.

IACD213P

4. Use tooling (B) to remove bearings (5) from the tie rod.

5. Use tooling (B) to install new bearings (5) in the tie rod.

6. Install the tie rod in the reverse order of removal.

Vehicle Systems 21 Disassembly & Assembly

Steering Knuckles, Kingpins,
And Bearings

Remove And Install Steering

Knuckles, King Pins And Bearings

Tools Needed A
5 6
Drive Set 1 IACD215P

Start By: 4. Remove four bolts (5) and cover (6).

a. remove steer wheels

NOTE : The procedure to remove and install the

steering knuckles, kingpins, and bearings is the same
for both sides of the lift truck.

IACD216P

5. Remove the nut and bolt (7). For the purpose of

reassembly, the torque for bolt (7) is 11 L 1 N¥m
(8 L 1 lb¥ft).
2
IACD212P

1. Remove pin retaining bolt (2). Remove pin (1).

2. Position the tie rod away from the steering

knuckle.

IACD214P

3. Remove four bolts (3) and cover (4).

Vehicle Systems 22 Disassembly & Assembly

 9
Steer Axle

Remove & Install Steer Axle

Tools Needed A
8 Jack Stand 4

IACD217P WARNING

Be sure the pressure in the hydraulic system is

6. Remove kingpin (8) and knuckle (9).
released before any lines or hoses have been
disconnected.
9

10

11 12
13

IDCD081P

IACD218P 1
7. Remove spacer (11), bearing cup (13) and bearing
cone (12).
1. Put the lift truck in position on tooling (A).
8. Check the condition of lip type seal (10). Replace
seal (10) with new if worn or damaged. 2. For the purpose of reassembly, put identification
marks on hoses (1). Disconnect hoses (1). Plug
9. Repeat steps 7 and 8 for the remaining seal, and cap all openings to prevent contamination and
bearing and spacer in the other side of knuckle debris from entering the system.
(9).

3
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.

2 4
11. Install the steering knuckle, kingpins and bearings
IACD219P
in the reverse order of removal.

End By: 3. Support the steer axle with a floor jack.

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
floor jack
Vehicle Systems 23 Disassembly & Assembly
6. Remove bolts (2) and mounting caps (3) from the Steering Cylinder
steer axle.

7. Remove steer axle (4). The steer axle weighs180 Remove & Install Steering Cylinder
kg (400 lb).

NOTE : Use the following steps to install the steer 1 2

axle.

4
IACD212P

2 4 1. Remove the pin retaining bolt (4) and pin (2) from
IACD219P the tie rod at each end of steering cylinder (1).

8. Use a floor jack to position steer axle (4).

NOTE : Use bolts (2) and cap (3) to align steer axle
3
(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 the 5
IACD218P
mounting boss.
c. Tighten bolts (2).
2. Disconnect two hoses (5).

3. Remove four bolts (3). For installation purposes,

the torque for bolts (3) is 240 L 30 N¥m (178 L 22
lb¥ft).

4. Remove steering cylinder (1).

5. Install steering cylinder (1) in the reverse order of

removal.

IACD218P 1

11. Connect hoses (1).

Vehicle Systems 24 Disassembly & Assembly

Disassemble And Assemble 5
Steering Cylinder
Start By :

a. Remove steering cylinder.

1 2 7

6 3
ICCD068P

4. Remove retaining ring (5) with a plier and ring (6)

from each side of piston (7) that holds piston in
position on rod (3).

5. Remove piston (7) from the rod (3).

ICCD065P
8
1. Put the steering cylinder in position in a vise.

2. Loosen head (1) from tube (2) with a spanner

wrench.

3 2

ICCD069P

6. Remove O-ring seal (8) from the rod.

ICCD066P
10

3. Remove rod assembly (3) from the tube (2).

ICCD070P

7. Remove seal ring (9) and backup seal (10) from

the piston.

8. Loosen the head in the opposite end of the tube.

Vehicle Systems 25 Disassembly & Assembly

 13 Tires And Rims (Steer)

Remove And Install Tires And Rims

1 (Steer)

12
ICCD094P

9. Remove O-ring seal (12) and backup ring (13)

from each head (1).

1
17
IA3M4014

1. Put a hydraulic jack in position under the steer

16 axle.

2. Loosen nuts (1) that hold the tire and rim in place.
15
3. Lift the steer axle until the tire is clear of the
14
ground. Remove nuts (1). Remove the tire and
ICCD095P rim.

NOTE : The following steps are for installation of the

10. Remove wiper seal (14), backup ring (15), U- tires and rims (steer).
packing (16) and DU-bush (17) from the bore of
each head. 4. Put the tire and rim in position on the hub.

NOTE : Assemble the steering cylinder in the reverse 5. Install nuts (1) that hold the tire and rim in place.
order of disassembly. Tighten the nuts to a torque of 430 L 35 NIIm
(318 L 25 lbIIft).

6. Lower the steer axle and remove the hydraulic

jack.

Vehicle Systems 26 Disassembly & Assembly

Hydraulic Control Valves 1 3 4

Remove And Install Hydraulic

Control Valves

WARNING

Hydraulic oil under pressure can remain in the

hydraulic system after the engine and pump have IACD222P
been stopped. Personal injury can result if the
pressure is not released before any work is done 3. Support control valve (1). Remove circuit braker
to the hydraulic system. To prevent possible plate (4). Remove three bolts (3), nut and control
personal injury, turn the engine off and move the valve (1).
control levers to make sure the hydraulic pressure
is released before any fitting, plug, hose or 4. Install the control valve in the reverse order of
component is loosened, tightened, removed or removal.
adjusted. Always move the lift truck to a clean and
level location away from the travel of other 5. Fill the hydraulic tank to the correct level with fluid.
machines. Refer to the Operation And Maintenance Manual
for further information.

IACD221P

NOTE : For purposes of reassembly, put

identification marks on all lines, tubes and hoses
before any disconnections are made.

1. Disconnect hydraulic lines (2) from control valve

(1).

2. Remove the cotter pins, washers and pins from

linkages.

Vehicle Systems 27 Disassembly & Assembly

Disassemble Hydraulic Control
Valve
Start By :

a. Remove hydraulic control valve.

6
IACD225P

5. Remove lift section assembly (6) from the valve

body.
1

2
7 6

IACD223P
8

NOTE : For purpose of assembly, put identification

marks on all valve sections.

1. Remove three nuts (1) to separate the valve

sections. 10 11

2. Remove inlet section assembly (2) from the valve 9

IACD226P
body.

6. Remove plug (7) and O-ring (8) from the lift

2 section assembly (6).
4 5

7. Remove O-ring (9), poppet (10) and spring (11)

from the lift section assembly (6).

3 13
12

IACD224P

3. Remove O-ring (3) from inlet section assembly (2).

4. Remove relief valve (4) and O-ring (5).

IACD227P

8. Remove two screws (12) and cap (13) from lift

section assembly.

Vehicle Systems 28 Disassembly & Assembly

 15 14 26

17
18
16
IACD228P IACD230P

9. Remove relief valve (14) and O-ring (15) from lift 14. Remove tilt section assembly (26) from the valve
section assembly. body.

10. Remove two screws (16) and seal plate (17).

26 28
11. Remove lift spool (18).

19 24 29

23

20
21 27
IACD231P

25
22 15. Remove O-ring (27), poppet (28) and spring (29)
from tilt section assembly (26).
IACD229P

12. Remove the wiper seals (19) and O-rings (20)

from the spool. Check the condition of O-rings
and wiper seals and replace with new ones if
needed.

NOTE : Remove the spool end (21) from the spool 31

30
with a wrench. The centering spring (22) has a slight
preload and will extend to its free length when the
spool end is removed.

13. Remove the spring seats (23 and 24), centering IACD232P
spring (22) and seal plate (25).

16. Remove two screws (30) and cap (31) from tilt
section assembly.

Vehicle Systems 29 Disassembly & Assembly

 37 39 38 40

42

41
32
33

34

IACD233P IACD235P

17. Remove two screws (32) and seal plate (33). 20. Remove spring seats (39 and 40), spring (38 and
42) and piston (41).
18. Remove tilt spool (34).

44

35

43

37

IACD236P
36 38
IACD234P

21. Remove side shift section assembly (43) and

19. Remove the wiper seals (35) and O-rings (36). fourth section (44) from the valve body.
Check the condition of wiper seals and O-rings
and replace with new ones if needed. NOTE : Do step 7 through 13 except step 9 to
disassemble valve spools of side shift and fourth
NOTE : Remove the spool end (37) from the spool. section assembly.
The centering spring (38) has a slight preload and
will extend to its free length when the spool end is
removed.

Vehicle Systems 30 Disassembly & Assembly

Assemble Hydraulic Control Valve 19 24

23

NOTICE
Do not use caustic (corrosive) materials to clean any 20
parts in this valve group. Caustic materials will cause 21
corrosion and damage to parts.

25
22

1. Make sure all valve parts are clean and free of dirt. IACD229P

4. Install the spring seats (23 and 24), centering

2
4 5 spring (22) and seal plate (25) on the lift spool.

5. Compress the spring with spool end (21) and

tighten spool end. Torque the spool end to 8 ~
11 N¥m (70 ~ 97 lb¥in).

6. Install the wiper seals (19) and O-ring (20) to the

spool (18).
3

IACD224P 15 14

2. Install O-ring (3) to inlet section assembly (2).

3. Install relief valve (4) with O-ring (5) to inlet section

assembly (2). The torque for the relief valve is
65 N¥m (575 lb¥in).
17
18
16
IACD228P

7. Install the spool (18), seal plate (17) and the

screws (16).

8. Install relief valve (14) with O-ring (15) to lift

section assembly. The torque for the relief valve is
45 N¥m (398 lb¥in).

Vehicle Systems 31 Disassembly & Assembly

 37 39 38 40

13 42
12
41

IACD227P IACD235P

9. Install cap (13) and two screws (12). 12. Install piston (41), spring (42), spring seats (39
and 40) and spring (38) on the tilt spool assembly.

7 6 13. Compress the spring with spool end (37).

Torque the spool end to 8 ~ 11 N¥m (70 ~ 97 lb¥in).
8
NOTE : Do step 6, 7, 9 and 10 to assemble the tilt
spool to the tilt section assembly.

NOTE : Do same steps to assemble the side shift

section and fourth section assembly.

10 11

IACD226P 9

10. Install O-ring (9), poppet (10) and spring (11) to

lift section assembly (6).

11. Install O-ring (8) and plug (7) to the lift section 1
assembly.

IACD223P

14. Assemble all the sections on the studs.

15. Install the nuts (1) that hold the valve sections
together.
Tighten the single top nut to torque of 100 N¥m
(885 lb¥in) and two bottom nuts to torque of
65 N¥m (575 lb¥in).

End By :

a. Install hydraulic control valve.

Vehicle Systems 32 Disassembly & Assembly

Hydraulic Pump 6. Fasten a hoist to pump (5). Put the pump and
plate assembly in position and install the bolts that
hold the pump in place. The weight of the pump is
Remove and Install Hydraulic Pump 30 kg (132 lb).

Start By : 7. Connect three oil lines (1) to the pump elbows.

a. Remove counterweight. 8. Connect U-joint (3) in position and install bolts (2).

1. Drain the oil from the hydraulic tank. 9. Fill the hydraulic tank with oil to the correct level.
See the Operation and Maintenance Manual.

End By :

a. Install counterweight
1

5
IACD237P

2. Disconnect three oil lines (1) from the pump

elbows.

3 2 4
IACD238P

3. Remove bolts (2) and disconnect U-Joint (3).

4. Fasten a hoist to pump (5). Remove bolts (4) that

hold the pump in place. Remove the pump and
plate assembly. The weight of the pump is 30 kg
(132 lb).

NOTE : The following steps are for installation of the

hydraulic pump.

5. Inspect seals for damage. Install new seals, if

needed.

Vehicle Systems 33 Disassembly & Assembly

Disassemble And Assemble 4 5
Hydraulic Pump 3

IACD242P

4. Remove the bush (3) and examine it carefully.

IACD239P
Replace if damaged.

5. Remove seal (4) and backup seal (5) from the

1. Position the pump vertically in the vise with the bush.
drive shaft facing down, and tighten the vise. Do
not over-tighten. Take care to avoid damaging 6. Remove O-ring (6) from the body (7).
machined surfaces. Make a reference mark
vertically down the pump to enable you to
reassemble the pump sections in the same 9
position.

8
1

IACD243P

7. Carefully remove the drive gear (8) and idler gear

IACD240P (9). Take great care not to strike the shafts against
hard surfaces which could damage the gear teeth.

2. Use a wrench to remove four screws (1).

IACD244P

IACD241P
8. Remove the pump body (7). Take care not to
damage precision machined surfaces. Carefully
3. Remove the cover (2). Take care not to damage examine all components. Replace any damaged or
precision machined surfaces. worn ones.

Vehicle Systems 34 Disassembly & Assembly

 10 14

IACD245P IACD248P

9. Remove the spacer (10). 12. Remove the body (14). If necessary insert two
screwdrivers in the recesses and lever upwards.
Take care not to damage precision machined
11 12 surfaces.

15
16

17

18 14
IACD246P

19
10. Remove splined coupling (11) and O-rings (12).
IACD249P

13 13. Remove balance plate (15), seal (16), backup

seal (17), drive gear (18) and idler gear (19) from
the body (14). Take great care not to strike the
shafts against hard surfaces which could damage
the gear teeth.

20

IACD247P

11. Remove four nuts (13) with a spanner.

IACD250P

14. Remove the balance plate (20) and seals from

the body.

Vehicle Systems 35 Disassembly & Assembly

 Counterweight
22

21 Remove And Install Counterweight

IACD251P

15. Remove O-ring (21) from the flange (22).

16. Remove the flange (22) from the vise.

IACD252P
17. Assemble the hydraulic pump in the reverse
order of disassembly.
1. Install two eyebolts in the counterweight. Fasten a
hoist to the eyebolts as shown.

IACD253P

2. Remove two bolts (1), washers that hold the

counterweight to the frame. Remove the
counterweight. The weights of the different
counterweight go from a minimum of 1650 kg
(3630 lb) to a maximum of 2350 kg (5170 lb).
NOTE : The following steps are for installation of the
counterweight.
3. Install two eyebolts in the counterweight. Fasten a
hoist to the eyebolts.
4. Put the counterweight in position on the frame and
install bolts (1), washers that hold the
counterweight in place. Tighten torque : 600 L 50
N¥m (442 L 37 lb¥ft).

Vehicle Systems 36 Disassembly & Assembly

Hydraulic Oil Filter Assembly Transaxle

Remove And Install Hydraulic Oil Remove & Install Transaxle

Filter Assembly
Tools Needed A B
Stand 2
Link Bracket 1

2
Start By :
1
a. Remove mast *

b. Remove floor plate

IACD222P
* Refer to the mast systems Disassembly &
Assembly section for further information.
1. Disconnect four oil lines (1).
1. Raise the machine until tires are approximately 1
2. Remove hydraulic tank cover (2). to 2 inches off of the floor. Position the machine on
tooling (A).
3. Remove the oil filter from hydraulic tank cover.
NOTE : Put identification marks on all wiring, hoses
NOTE : The following steps are for installation of the and lines to assure proper installation.
hydraulic oil filter assembly.

4. Install the hydraulic oil filter assembly in position

on hydraulic tank cover.
3
5. Install the hydraulic tank cover (2) with six bolts
and washers.
1

6. Connect four oil lines (1).

7. Fill hydraulic oil tank to the correct level. See the

Operation and Maintenance Manual. 4
2
IACD255P

2. Disconnect hoses (1) and brake tubes (2).

Loosen bolts (3) and remove pedal assembly (4).

Vehicle Systems 37 Disassembly & Assembly

 5

IACD256P IACD259P

3. Remove cover (5). 9. Support the engine with a hoist and tooling (B).

10. Support transaxle assembly with a floor jack and

6
wood block.

11

12 13
IACD257P

4. Remove cowl plate (6). Disconnect brake tubes (7) 14

IACD260P
and parking cables from drive axle.

11. Remove housing cover.

10 Remove bolts (13) that hold the converter to the
9
flywheel.

NOTE : At this point, make a final check to be sure

all removals and disconnections have been made
8 from the transaxle.

12. Remove bolts (14) and nuts from the converter

housing.

IACD258P 13. Use the floor jack to move transaxle assembly

from beneath the machine.

5. Disconnect accel cable (8). 14. Install transaxle in the reverse order of removal.

6. Disconnect wires (9) from solenoid valves and wire 15. Bleed the brake system.
from transmission temperature sender. Refer to the topic ÒBrake System Air removalÓ in
the Testing and Adjusting section of Vehicle
7. Disconnect two cooling hoses (10). Systems.

8. Loosen bolts (11) and remove drive axle mounting 16. Fill all fluids to their correct levels.
bracket (12).

Vehicle Systems 38 Disassembly & Assembly

End By :

a. Install floor plate.

4
b. Install mast *

* Refer to the Mast System Disassembly & Assembly

Section for further information
5

Engine IACD262P

2. Disconnect air intake hose (4).

Remove & Install Engine
3. Disconnect battery cables and remove battery (5)
Tools Needed A and battery tray assembly.

Link Bracket 1

NOTE : Procedures for LP gas and diesel engines

are all similar. The engine shown in the following
illustrations is for diesel engine.

Start By :

a. Remove overhead guard *

b. Remove hood (with seat) assembly *

IACD263P
c. Remove counterweight *

d. Remove floor plate. 4. Disconnect fuel lines from the engine.

e. Remove hydraulic control valve * 5. Disconnect accel cable and engine stop motor
cable from the engine.
* Refer to the topics ÒOverhead GuardÓ, ÒHood (with
seat) AssemblyÓ, ÒCounterweightÓ and ÒHydraulic
Control ValveÓ in this module.

IACD261P

1. Disconnect all hoses from radiator (3). Loosen

bolts (1) and (2) and remove radiator (3).

Vehicle Systems 39 Disassembly & Assembly

 6
10 11
7
IACD264P IACD267P

6. Loosen nuts (6) and disconnect exhaust tube (7). 8. Remove bolts (10) and disconnect U-joint (11)
from the engine

12
13

IACD265P
IACD260P

9. Remove housing cover.

Remove bolts (12) that hold the converter to the
flywheel.

NOTE : At this point, make a final check to be sure

all removals and disconnections have been made
from the engine.

9
10. Support engine with a hoist and tooling (A).
Support transaxle with wood block.
IACD266P
11. Remove bolts (13) and nuts from the converter
housing.
7. Disconnect engine wire harness (8). Disconnect
wires from the alternator (9). To remove engine
from the truck, other wires or connectors not
shown should be disconnected.

Vehicle Systems 40 Disassembly & Assembly

 14

IACD269P

12. Remove bolts (14) and nuts from two engine

mounts, located on each side of the engine.

NOTICE
Make sure the engine is supported underneath by
suitable wooden blocks. Failure to support engine will
result in possible damage.

13. Remove the engine with a hoist.

14. Install the engine in the reverse order of removal.

End By :

a. Install hydraulic control valve *

b. Install floor plate.

c. Install hood (with seat) assembly *

d. Install counterweight *

e. Install Overhead guard.*

* Refer to the topics ÒHydraulic Control ValveÓ, ÒHood

(with seat) AssemblyÓ, ÒCounterweightÓ and
ÒOverhead GuardÓ.

Vehicle Systems 41 Disassembly & Assembly