D20S-3
Doosan D20S-3, D25S-3, D30S-3, D32S-3, D33S-3 User Manual
...
Disassembly &
Assembly
Lift Trucks Power Train
D20S-3, D25S-3, D30S-3, D32S-3
D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3),
D32S-3(B3.3), D33S-3(B3.3)
G20S-3, G25S-3, G30S-3
GC20S-3, GC25S-3, GC30S-3
G20E-3, G25E-3, G30E-3, G32E-3
GC20E-3, GC25E-3, GC30E-3, GC32E-3
G20P-3, G25P-3, G30P-3, G32P-3
GC20P-3, GC25P-3, GC30P-3, GC32P-3
SB2103E01
Jan.2004
1
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 ha v e 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 pub lications are pro vided in the description of operations where hazards
exist. W ARNING 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. W arnings in
this publication and on the product labels are identified by the f ollo wing 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 inf ormation.
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 involv e a potential hazard. The warnings in
this publication and on the product are therefore not all inclusiv e. 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. Y ou 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 illustration 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 inf ormation
available.
WARNING
Power Train Index
3
Index
Transmission
Assembly Input Shaft ...............................................16
Assembly Output Shaft ............................................19
Assembly Reverse Shaft..........................................11
Assembly Transmission Housing .............................20
Disassembly / Assembly Valve Body .......................26
Disassembly Input Shaft ..........................................14
Disassembly Output Shaft........................................19
Disassembly Reverse Shaft .......................................9
Disassembly Transmission Housing ..........................5
Drive Axle
Adjustment Bevel Pinion ..........................................37
Adjustment Disassembly /
Assembly of Bevel Pinion.........................................39
Assembly Bevel Pinion.............................................39
Assembly Carrier Diff ...............................................45
Assembly Crown wheel/Adjustment .........................42
Assembly Shaft As ...................................................31
Disassembly / Assembly Brake Parts.......................32
Disassembly / Assembly Differential ........................40
Disassembly / Assembly Hub Drive Axle..................33
Disassembly / Differential Assembly ........................34
Disassembly Axle .....................................................27
Disassembly Bevel Pinion ........................................35
Disassembly Shaft As...............................................31
Special Service Tools ...............................................51
Disconnect batteries before performance of any
service work.
WARNING
Power Train Disassembly & Assembly
5
Disassembly
Transmission Housing
1. Mount the transmission on a suitable jig.
2. Disconnect valve body, loosen the screws (1) with
socket head wrench 8 mm.
ATTENTION: Loosen bolts from outside to inwards!
3. Remove the Gasket (2) and oil dipstick (3).
4. To remove the torque converter housing,
loosen the upper housing screws.
(Hexagonal socket 17 mm)
5. Loosen the lower housing screws.
(Hexagonal socket 17 mm)
6. Install 2 jackbolts (M10, 30mm (1.2in)) in locations
(4) until they stop against bearing plate,
alternately tighten bolts to separate the torque
converter housing from the transmission.
2
1
1
3
IDCD501P
IDCD502P
IDCD503P
IDCD504P
IDCD505P
IDCD506P
4
Power Train Disassembly & Assembly
6
7. To remove strainer, loosen the screw with an allen
head wrench.
8. Lift the torque converter housing from the T/M
bearing plate.
9. Secure the eyebolts M10 to remove the torque
converter housing.
10. Remove the remaining screws between the T/M
bearing plate and the torque converter housing.
(Hexagonal socket 17 mm).
11. Secure the eyebolts M10 to remove the T/M
bearing plate.
12. Loosen the jam nut (1) to loosen the hand brake
adjustment with the ring spanner (22 mm) and the
threaded bolt (2) with the open ended spanner (10
mm).
2
1
IDCD507P
IDCD508P
IDCD509P
IDCD510P
IDCD511P
IDCD512P
Power Train Disassembly & Assembly
7
13. Turn the adjustment bolt until the strut (1) can be
removed from the brake band.
14. Remove the brake struts from the eccentric shaft.
15. Lower the loosened brake band into the housing.
Remove after dismounting the shaft.
16. Remove the output shaft.
17. Remove the input shaft with forward clutch.
18. Use the eyebolt M18 to lift the reverse shaft.
1
IDCD515P
IDCD518P
IDCD517P
IDCD516PIDCD513P
IDCD514P
Power Train Disassembly & Assembly
8
19. Remove the lube pump. (Hexagonal socket 13
mm)
20. Lift the lube pump with 2 screw drivers.
IDCD592P
IDCD593P
Power Train Disassembly & Assembly
9
Disassembly
Reverse Shaft
1. Disassemble the shaft with the 2-leg puller.
2. Remove the safety ball from the seat with a screw
driver.
3. Remove the double needle bearing.
4. Remove the snap ring (1) from the support disk
with the circlip pliers.
5. Lift the multiple disk body.
6. Remove the snap ring (2) while pressing the
return spring on the spring retainer with a
hydraulic press. Slowly relieve the tension of the
spring. (Tool Ref. No 1)
IDCD526P
IDCD521P
IDCD522P
IDCD524P
IDCD525P
IDCD523P
2
1
Power Train Disassembly & Assembly
10
7. Remove the parts - snap ring (1), spring
retainer(2) and return spring (3)
8. Lift the piston by using compressed air in the
lower bore.
9. Remove both R-rings before lifting the bearing (4).
10. ATTENTION: Open the R-rings before lifting!
11. Remove the bearing from the shaft with a 2-leg
puller.
1
2
3
4
IDCD529P
IDCD528P
IDCD527P IDCD530P
IDCD531P
Power Train Disassembly & Assembly
11
Assembly
Reverse Shaft
12. Heat bearing (1) to a temperature of 120°C
(248°F) and install it on the shaft.
13. After the bearing has cooled, the inner bearing
ring must be tapped into position.
14. Install both R-rings (2) in their grooves.
15. Inner and outer piston rings must be lubricated
with transmission oil.
16. Insert the piston.
ATTENTION: Canting the piston can cause damage.
17. Install return spring (3), spring retainer (4) and
snap ring (5).
IDCD534P
IDCD532P
IDCD535P
IDCD536P
IDCD537P
2
3
4
3
5
IDCD533P
Power Train Disassembly & Assembly
12
18. Install snap ring (1) by pressing the return spring.
(Tool Ref. No 1)
19. Elements of the multiple disk body: (2) pressure
disk, (3) inner separater disks, (4) outer clutch
disks, (5) support disk
20. Put the multiple disk body on the gear and install
the snap ring.
21. Align the teeth of the clutch disks.
22. Install the needle bearing.
23. Put the gear wheel on the shaft.
1
3
2
4
5
IDCD540P
IDCD543P
IDCD539P
IDCD542P
IDCD541PIDCD538P
Power Train Disassembly & Assembly
13
24. Lubricate the needle bearing before installing the
washer.
25. After installing the washer (1), put the ball (2) in
the hole.
26. Install the steel-washer (3).
ATTENTION: The ball must engage the notch!
27. Heat bearing (4) to a temperature of 120°C
(248°F) and install it on the shaft.
28. After cooling the bearing, the inner bearing ring
must be tapped to set bearing.
29. Install the R-ring (5).
IDCD549P
IDCD548P
IDCD547PIDCD544P
IDCD545P
IDCD546P
2
1
3
4
5
Power Train Disassembly & Assembly
14
Disassembly
Input Shaft
1. Disassemble the shaft with a 2-leg puller.
Remove R-ring before lifting the bearing.
2. After lifting the gear wheel (1), remove bearing (2)
and washer (3).
3. Lift the gear wheel.
4. Remove the ball from the seat with a magnet.
5. Remove the double needle bearing (4) and the
brass washer (5).
6. Remove the snap ring (6) from the support disk
with the circlip pliers and remove the disks.
2
3
1
4
5
6
IDCD555P
IDCD552P
IDCD554P
IDCD551P
IDCD550P
IDCD553P
Power Train Disassembly & Assembly
15
7. Remove the snap ring (1) while pressing the
return spring on the spring retainer with a
hydraulic press. Slowly relieve the tension of the
spring. (Tool Ref. No 1)
8. Lift the piston by using compressed air in a lower
bore, after removing the spring retainer and return
spring.
9. Remove both R-rings before lifting the bearing.
10. ATTENTION : Open the R-rings before lifting.
11. Lift the back bearing.
IDCD558P
IDCD557P
IDCD556P IDCD530P
IDCD559P
1
Loading...