Daewoo D35S-2, D40S-2, D45S-2, D45SC-2, D40SC-2 Disassembly/assembly

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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

SB2204E00 Jun. 1999

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.

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.

WARNING

Vehicle Systems Index

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 Disassembly & Assembly5

Disassembly & Assembly

Hood (with seat) Assembly

Remove & Install Hood (with seat) Assembly

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.

2. Remove nut (1) from the support cylinder. Remove

the cylinder rod from the bracket.

3. Lower the hood.

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

cover.

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

6. Release latch (5). Use the hoist to remove hood

and seat assembly (4). The hood and seat assembly weighs 52 kg (115 lb).

7. Install the hood and seat assembly in the reverse

order of removal.

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WARNING

Vehicle Systems Disassembly & Assembly

Overhead Guard

Remove & Install Overhead Guard

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

a hoist.

2. Remove the washers, nuts, and two bolts (2).

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

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

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

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

6. Remove rear Leg (5).

7. Install front overhead guard (1) and rear leg (5) in

the reverse order of removal.

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Vehicle Systems Disassembly & Assembly

Tilt Cylinders

Remove & Install Tilt Cylinders

NOTE : The procedure for removing and installing

the tilt cylinders is the same for both cylinders.

If both tilt cylinders are removed at the same time the mast can fall. To avoid possible personal injury, make sure the mast is securely held in place or supported by a hoist before removing the tilt cylinders.

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).

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.

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WARNING

Vehicle Systems Disassembly & Assembly

Disassemble & Assemble Tilt Cylinders

Start By:

a. Remove tilt cylinder.

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

2. Remove rod cover (2) from the cylinder tube (3)

using a spanner wrench.

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.

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

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

cylinder rod (4).

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

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

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

the piston.

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Vehicle Systems Disassembly & Assembly

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

from the rod cover (2).

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.

Secondary Lift Cylinders

Disassemble Secondary Lift Cylinders

Start By :

a. Remove secondary lift cylinders.

1. Put secondary lift cylinder (1) in position as shown.

2. Remove head assembly (2) with tool.

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Vehicle Systems Disassembly & Assembly

3. Remove rod (3) from the cylinder body.

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

cylinder rod.

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

6. Remove O-ring seal (7), back-up ring (8) and seal

(9) from the piston.

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

8. Remove wiper seal (11), seal (12) and bush (13)

from the head assembly.

Vehicle Systems Disassembly & Assembly

Assemble Secondary Lift Cylinders

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

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

toward the outside.

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

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

on the piston.

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

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

cylinder rod.

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

Vehicle Systems Disassembly & Assembly

8. Install head assembly (2) on the cylinder rod and

tighten using tool.

End By :

a. Install secondary lift cylinders.

Primary Lift Cylinder

Remove & Install Primary Lift Cylinder

Start By :

a. Remove carriage.

1. Fasten nylon straps and hoist to the primary lift

cylinder.

2. Remove bolt (1).

3. Pull the cylinder out far enough to disconnect

hydraulic hose (2). Remove primary lift cylinder (3).

4. Install primary lift cylinder (3) in the reverse order

of removal.

End By :

a. Install carriage.

WARNING

Vehicle Systems Disassembly & Assembly

Disassemble Primary Lift Cylinder

Start By :

a. Remove primary lift cylinder.

1. Remove bearing (1).

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

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

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

the bearing.

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

and rings (9) from the bearing.

Vehicle Systems Disassembly & Assembly

Assemble Primary Lift 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.

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.

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

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.

Vehicle Systems Disassembly & Assembly

Steering Wheel

Remove & Install Steering Wheel

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.

3. Use hammer (A) to remove the steering wheel

from the shaft.

NOTE : Use the following steps to install the steering wheel.

4. Put the steering wheel on the steering wheel shaft

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).

Steering Unit

Remove & Install Steering Unit

Start By:

a. Remove steering wheel.

1. Open the access cover for the fuse panel.

Remove horn switch and open the top cover.

2. Loosen two bolts (1). Slide directional control

switch (3) off of steering column (2). Set switch (3) aside, clear of the steering column.

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3. Remove two bolts (4).

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 oil when any lines are disconnected in the hydraulic system.

NOTE : Identify and mark all hydraulic hoses for

purposes of reassembly.

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

NOTICE

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

5. Support steering unit (5) while removing the

remaining two bolts (4). Remove steering unit (5) and steering column (2).

6. Install the steering unit in the reverse order of

removal.

End By :

a. Install steering wheel.

Disassemble & Assemble Steering Unit

Start By :

a. Remove steering unit from the truck.

1. Remove the elbows (1) from the body.

2. Remove seven bolts (5) from gerotor housing (3).

NOTICE

Make a note of the position of special bolt with a pin. It is located at a mark in line with check valve.

3. Separate housing (3) and cap (4) from steering

unit body (2).

Vehicle Systems Disassembly & Assembly16

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Vehicle Systems Disassembly & Assembly

4. Remove the components from housing (3) as

follows:

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

5. Remove suction valve balls (12) and pins (11).

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

7. Remove O-ring seal (15) from steering unit body

(2).

8. Remove sleeve (16) from the body.

9. Remove the components from sleeve (16) as

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

bearing (21) from spool (17).

d. Remove six springs (23) and ring (22) from

spool (17).

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

body.

11. Check the condition of dust seal ring(26).

Replace seals with new if worn or damaged.

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Vehicle Systems Disassembly & Assembly

12. Remove plug (27) and washer (28) from steering

unit body.

13. Remove plug (31) and spring (32) from the body

(2).

14. Remove poppet (34) and relief valve housing (35)

from the body.

15. Remove plug (36) and washer (37) from the

body.

NOTE : The following steps are for assembling the steering pump.

16. Install washer (37) and plug (36) into the steering

unit body.

17. Install housing (35) and poppet (34) into the

pump body.

18. Install spring (32) and plug (31) into body (2). Tighten plug (31) to a torque 50 N¥m (37 lb¥ft).

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

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Vehicle Systems Disassembly & Assembly

20. Install dust seal ring (26). Install O-ring seal (24)

with king-ring (25) into body.

NOTICE For purposes of installation, note that springs (23) are installed in two stacks of three. Make sure the curves of the two stacks are in contact and positioned in the center of spool (17). The notched side of springs (23) must be positioned toward sleeve (16).

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).

24. Install sleeve (16) into steering unit body (2).

25. Install O-ring seal (15) into body (2).

26. Install check valve ball (14) and screw (13).

Tighten the screw (13).

27. Install suction valve balls (12) and pins (11) in

their original positions into the steering unit body.

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Vehicle Systems Disassembly & Assembly

28. Install plate (6) onto steering unit body.

NOTICE

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

29. Install shaft (7) into body (2) and spool (17).

NOTICE

Gerotor (9) must be aligned with shaft (7) and pin (18) as shown in the illustration.

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

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

NOTICE

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

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).

End by :

a. Install steering unit to the truck.

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Vehicle Systems Disassembly & Assembly

Brake Hydraulic Booster

Remove And Install Brake Hydraulic Booster

1. Remove the floor plate over the brake hydraulic

booster.

2. Disconnect pressure line (3).

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

4. Disconnect brake line (5).

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

6. Remove hydraulic booster (2).

NOTE : The following steps are for installation of the

brake master cylinder.

NOTE : Installation is reverse order of removal.

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

topic Brake System Air Removal in Testing And Adjusting.

8. Install the floor plate over the brake master

cylinder.

Tie Rods

Remove And Install Tie Rods

Start By :

a. Remove steer wheels.

NOTE : The procedure to remove and install the tie

rod is the same for each steer wheel.

1. Support the steer axle with a floor jack (A).

Position the wheel to gain access to the tie rods.

2. Remove two pin retaining bolts (2). Remove pins (1).

3. Remove tie rod (4) and dust seals (3).

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.

Tools Needed A B

Floor Jack 1

Drive Set 2

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Vehicle Systems Disassembly & Assembly

Steering Knuckles, Kingpins, And Bearings

Remove And Install Steering Knuckles, King Pins And Bearings

Start By:

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.

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

2. Position the tie rod away from the steering

knuckle.

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

4. Remove four bolts (5) and cover (6).

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).

Tools Needed A

Drive Set 1

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Vehicle Systems Disassembly & Assembly

6. Remove kingpin (8) and knuckle (9).

7. Remove spacer (11), bearing cup (13) and bearing

cone (12).

8. Check the condition of lip type seal (10). Replace

seal (10) with new if worn or damaged.

9. Repeat steps 7 and 8 for the remaining seal,

bearing and spacer in the other side of knuckle (9).

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.

Steer Axle

Remove & Install Steer Axle

Be sure the pressure in the hydraulic system is released before any lines or hoses have been disconnected.

1. Put the lift truck in position on tooling (A).

2. For the purpose of reassembly, put identification

marks on hoses (1). Disconnect hoses (1). Plug and cap all openings to prevent contamination and debris from entering the system.

3. Support the steer axle with a floor jack.

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

Tools Needed A

Jack Stand 4

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Vehicle Systems Disassembly & Assembly

6. Remove bolts (2) and mounting caps (3) from the

steer axle.

7. Remove steer axle (4). The steer axle weighs180

kg (400 lb).

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.

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

mounting boss.

c. Tighten bolts (2).

11. Connect hoses (1).

Steering Cylinder

Remove & Install Steering Cylinder

1. Remove the pin retaining bolt (4) and pin (2) from

the tie rod at each end of steering cylinder (1).

2. Disconnect two hoses (5).

3. Remove four bolts (3). For installation purposes, the torque for bolts (3) is 240 LL30 N¥m (178 LL22

lb¥ft).

4. Remove steering cylinder (1).

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

removal.

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Vehicle Systems Disassembly & Assembly

Disassemble And Assemble Steering Cylinder

Start By :

a. Remove steering cylinder.

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

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

wrench.

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

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).

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

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

the piston.

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

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Vehicle Systems Disassembly & Assembly

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

from each head (1).

10. Remove wiper seal (14), backup ring (15), U-

packing (16) and DU-bush (17) from the bore of each head.

NOTE : Assemble the steering cylinder in the reverse order of disassembly.

Tires And Rims (Steer)

Remove And Install Tires And Rims (Steer)

1. Put a hydraulic jack in position under the steer

axle.

2. Loosen nuts (1) that hold the tire and rim in place.

3. Lift the steer axle until the tire is clear of the

ground. Remove nuts (1). Remove the tire and rim.

NOTE : The following steps are for installation of the tires and rims (steer).

4. Put the tire and rim in position on the hub.

5. Install nuts (1) that hold the tire and rim in place. Tighten the nuts to a torque of 430 L 35 NIIm (318 LL25 lbIIft).

6. Lower the steer axle and remove the hydraulic

jack.

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Hydraulic Control Valves

Remove And Install Hydraulic Control Valves

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 possible personal injury, turn the engine off and move the control levers to make sure the hydraulic pressure is released before any fitting, plug, hose or component is loosened, tightened, removed or adjusted. Always move the lift truck to a clean and level location away from the travel of other machines.

NOTE : For purposes of reassembly, put

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

1. Disconnect hydraulic lines (2) from control valve

(1).

2. Remove the cotter pins, washers and pins from

linkages.

3. Support control valve (1). Remove circuit braker plate (4). Remove three bolts (3), nut and control valve (1).

4. Install the control valve in the reverse order of removal.

5. Fill the hydraulic tank to the correct level with fluid. Refer to the Operation And Maintenance Manual for further information.

Vehicle Systems Disassembly & Assembly27

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Vehicle Systems Disassembly & Assembly

Disassemble Hydraulic Control Valve

Start By :

a. Remove hydraulic control valve.

NOTE : For purpose of assembly, put identification

marks on all valve sections.

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

sections.

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

body.

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

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

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

body.

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

7. Remove O-ring (9), poppet (10) and spring (11) from the lift section assembly (6).

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

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Vehicle Systems Disassembly & Assembly

9. Remove relief valve (14) and O-ring (15) from lift

section assembly.

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

11. Remove lift spool (18).

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 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

spring (22) and seal plate (25).

14. Remove tilt section assembly (26) from the valve

body.

15. Remove O-ring (27), poppet (28) and spring (29)

from tilt section assembly (26).

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

section assembly.

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Vehicle Systems Disassembly & Assembly

17. Remove two screws (32) and seal plate (33).

18. Remove tilt spool (34).

19. Remove the wiper seals (35) and O-rings (36).

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

NOTE : Remove the spool end (37) from the spool. The centering spring (38) has a slight preload and will extend to its free length when the spool end is removed.

20. Remove spring seats (39 and 40), spring (38 and

42) and piston (41).

21. Remove side shift section assembly (43) and

fourth section (44) from the valve body.

NOTE : Do step 7 through 13 except step 9 to disassemble valve spools of side shift and fourth section assembly.

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Vehicle Systems Disassembly & Assembly

Assemble Hydraulic Control Valve

NOTICE

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

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

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).

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

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

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).

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).

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Vehicle Systems Disassembly & Assembly

9. Install cap (13) and two screws (12).

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

assembly.

12. Install piston (41), spring (42), spring seats (39

and 40) and spring (38) on the tilt spool assembly.

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

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

NOTE : Do step 6, 7, 9 and 10 to assemble the tilt spool to the tilt section assembly.

NOTE : Do same steps to assemble the side shift section and fourth section assembly.

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.

IACD226P

IACD227P

10813

IACD235P

IACD223P

Vehicle Systems Disassembly & Assembly

Hydraulic Pump

Remove and Install Hydraulic Pump

Start By :

a. Remove counterweight.

1. Drain the oil from the hydraulic tank.

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

elbows.

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.

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

30 kg (132 lb).

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

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

9. Fill the hydraulic tank with oil to the correct level.

See the Operation and Maintenance Manual.

End By :

a. Install counterweight

IACD237P

IACD238P

Vehicle Systems Disassembly & Assembly

Disassemble And Assemble Hydraulic Pump

1. Position the pump vertically in the vise with the

drive shaft facing down, and tighten the vise. Do not over-tighten. Take care to avoid damaging machined surfaces. Make a reference mark vertically down the pump to enable you to reassemble the pump sections in the same position.

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

3. Remove the cover (2). Take care not to damage

precision machined surfaces.

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

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

6. Remove O-ring (6) from the body (7).

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

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

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

IACD239P

IACD240P

IACD241P

IACD242P

IACD243P

IACD244P

369

Vehicle Systems Disassembly & Assembly

9. Remove the spacer (10).

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

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

12. Remove the body (14). If necessary insert two

screwdrivers in the recesses and lever upwards. Take care not to damage precision machined surfaces.

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.

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

the body.

IACD245P

IACD246P

IACD247P

IACD248P

IACD249P

IACD250P

Vehicle Systems Disassembly & Assembly

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

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

17. Assemble the hydraulic pump in the reverse

order of disassembly.

Counterweight

Remove And Install Counterweight

1. Install two eyebolts in the counterweight. Fasten a

hoist to the eyebolts as shown.

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 LL50 N¥m (442 LL37 lb¥ft).

IACD251P

IACD252P

IACD253P

Vehicle Systems Disassembly & Assembly

Hydraulic Oil Filter Assembly

Remove And Install Hydraulic Oil Filter Assembly

1. Disconnect four oil lines (1).

2. Remove hydraulic tank cover (2).

3. Remove the oil filter from hydraulic tank cover.

NOTE : The following steps are for installation of the

hydraulic oil filter assembly.

4. Install the hydraulic oil filter assembly in position

on hydraulic tank cover.

5. Install the hydraulic tank cover (2) with six bolts

and washers.

6. Connect four oil lines (1).

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

Operation and Maintenance Manual.

Transaxle

Remove & Install Transaxle

Start By :

a. Remove mast *

b. Remove floor plate

* Refer to the mast systems Disassembly &

Assembly section for further information.

1. Raise the machine until tires are approximately 1 to 2 inches off of the floor. Position the machine on tooling (A).

NOTE : Put identification marks on all wiring, hoses and lines to assure proper installation.

2. Disconnect hoses (1) and brake tubes (2). Loosen bolts (3) and remove pedal assembly (4).

IACD222P

IACD255P

Tools Needed A B

Stand 2

Link Bracket 1

Vehicle Systems Disassembly & Assembly

3. Remove cover (5).

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

and parking cables from drive axle.

5. Disconnect accel cable (8).

6. Disconnect wires (9) from solenoid valves and wire

from transmission temperature sender.

7. Disconnect two cooling hoses (10).

8. Loosen bolts (11) and remove drive axle mounting

bracket (12).

9. Support the engine with a hoist and tooling (B).

10. Support transaxle assembly with a floor jack and

wood block.

11. Remove housing cover.

Remove bolts (13) 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 transaxle.

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

housing.

13. Use the floor jack to move transaxle assembly

from beneath the machine.

14. Install transaxle in the reverse order of removal.

15. Bleed the brake system.

Refer to the topic ÒBrake System Air removalÓ in the Testing and Adjusting section of Vehicle Systems.

16. Fill all fluids to their correct levels.

IACD259P

IACD257P

IACD258P

IACD260P

IACD256P

Vehicle Systems Disassembly & Assembly

End By :

a. Install floor plate.

b. Install mast *

* Refer to the Mast System Disassembly & Assembly

Section for further information

Engine

Remove & Install Engine

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 *

c. Remove counterweight *

d. Remove floor plate.

e. Remove hydraulic control valve *

* Refer to the topics ÒOverhead GuardÓ, ÒHood (with

seat) AssemblyÓ, ÒCounterweightÓ and ÒHydraulic Control ValveÓ in this module.

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

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

2. Disconnect air intake hose (4).

3. Disconnect battery cables and remove battery (5)

and battery tray assembly.

4. Disconnect fuel lines from the engine.

5. Disconnect accel cable and engine stop motor

cable from the engine.

Tools Needed A

Link Bracket 1

IACD262P

IACD263P

IACD261P

Vehicle Systems Disassembly & Assembly

6. Loosen nuts (6) and disconnect exhaust tube (7).

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.

8. Remove bolts (10) and disconnect U-joint (11) from the engine

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.

10. Support engine with a hoist and tooling (A).

Support transaxle with wood block.

11. Remove bolts (13) and nuts from the converter

housing.

IACD264P

IACD265P

IACD266P

IACD267P

IACD260P

131210

Vehicle Systems Disassembly & Assembly

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.

IACD269P

Daewoo D35S-2, D40S-2, D45S-2, D45SC-2, D40SC-2 Disassembly/assembly

Specifications and Main Features

Frequently Asked Questions

User Manual