Doosan D20S-3, D25S-3, D30S-3, D32S-3, D33S-3 User Manual

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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

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 .

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 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.

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 Index

Disassembly

Transmission Housing

IDCD501P

1. Mount the transmission on a suitable jig.

IDCD502P

2. Disconnect valve body, loosen the screws (1) with socket head wrench 8 mm.

ATTENTION: Loosen bolts from outside to inwards!

IDCD504P

4. To remove the torque converter housing, loosen the upper housing screws. (Hexagonal socket 17 mm)

IDCD505P

5. Loosen the lower housing screws. (Hexagonal socket 17 mm)

IDCD506P

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.

IDCD503P

3. Remove the Gasket (2) and oil dipstick (3).

Power Train Disassembly & Assembly

IDCD507P

7. To remove strainer, loosen the screw with an allen head wrench.

IDCD510P

10. Remove the remaining screws between the T/M bearing plate and the torque converter housing. (Hexagonal socket 17 mm).

IDCD508P

8. Lift the torque converter housing from the T/M bearing plate.

IDCD509P

9. Secure the eyebolts M10 to remove the torque converter housing.

IDCD511P

11. Secure the eyebolts M10 to remove the T/M bearing plate.

IDCD512P

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).

Power Train Disassembly & Assembly

13. Turn the adjustment bolt until the strut (1) can be removed from the brake band.

IDCD516PIDCD513P

16. Remove the output shaft.

IDCD517P

IDCD514P

17. Remove the input shaft with forward clutch.

14. Remove the brake struts from the eccentric shaft.

IDCD518P

IDCD515P

15. Lower the loosened brake band into the housing. Remove after dismounting the shaft.

18. Use the eyebolt M18 to lift the reverse shaft.

Power Train Disassembly & Assembly

IDCD592P

19. Remove the lube pump. (Hexagonal socket 13 mm)

IDCD593P

20. Lift the lube pump with 2 screw drivers.

Power Train Disassembly & Assembly

Disassembly

Reverse Shaft

IDCD521P

1. Disassemble the shaft with the 2-leg puller.

IDCD522P

2. Remove the safety ball from the seat with a screw driver.

IDCD524P

4. Remove the snap ring (1) from the support disk with the circlip pliers.

IDCD525P

5. Lift the multiple disk body.

IDCD526P

6. Remove the snap ring (2) while pressing the return spring on the spring retainer with a

IDCD523P

3. Remove the double needle bearing.

Power Train Disassembly & Assembly

hydraulic press. Slowly relieve the tension of the spring. (Tool Ref. No 1)

IDCD527P IDCD530P

7. Remove the parts - snap ring (1), spring retainer(2) and return spring (3)

10. ATTENTION: Open the R-rings before lifting!

IDCD531P

IDCD528P

8. Lift the piston by using compressed air in the lower bore.

11. Remove the bearing from the shaft with a 2-leg puller.

IDCD529P

9. Remove both R-rings before lifting the bearing (4).

Power Train Disassembly & Assembly

Assembly

Reverse Shaft

IDCD532P

12. Heat bearing (1) to a temperature of 120°C (248°F) and install it on the shaft.

IDCD533P

13. After the bearing has cooled, the inner bearing ring must be tapped into position.

IDCD535P

15. Inner and outer piston rings must be lubricated with transmission oil.

IDCD536P

16. Insert the piston.

ATTENTION: Canting the piston can cause damage.

IDCD537P

IDCD534P

14. Install both R-rings (2) in their grooves.

Power Train Disassembly & Assembly

17. Install return spring (3), spring retainer (4) and

snap ring (5).

18. Install snap ring (1) by pressing the return spring. (Tool Ref. No 1)

IDCD541PIDCD538P

21. Align the teeth of the clutch disks.

IDCD539P

19. Elements of the multiple disk body: (2) pressure disk, (3) inner separater disks, (4) outer clutch disks, (5) support disk

IDCD542P

22. Install the needle bearing.

IDCD543P

IDCD540P

20. Put the multiple disk body on the gear and install the snap ring.

Power Train Disassembly & Assembly

23. Put the gear wheel on the shaft.

24. Lubricate the needle bearing before installing the

washer.

IDCD547PIDCD544P

27. Heat bearing (4) to a temperature of 120°C (248°F) and install it on the shaft.

IDCD545P

25. After installing the washer (1), put the ball (2) in the hole.

IDCD546P

26. Install the steel-washer (3).

ATTENTION: The ball must engage the notch!

IDCD548P

28. After cooling the bearing, the inner bearing ring must be tapped to set bearing.

IDCD549P

29. Install the R-ring (5).

Power Train Disassembly & Assembly

Disassembly

Input Shaft

IDCD550P

1. Disassemble the shaft with a 2-leg puller. Remove R-ring before lifting the bearing.

IDCD551P

2. After lifting the gear wheel (1), remove bearing (2) and washer (3).

IDCD553P

4. Remove the ball from the seat with a magnet.

IDCD554P

5. Remove the double needle bearing (4) and the brass washer (5).

IDCD555P

6. Remove the snap ring (6) from the support disk with the circlip pliers and remove the disks.

IDCD552P

3. Lift the gear wheel.

Power Train Disassembly & Assembly

IDCD556P IDCD530P

7. Remove the snap ring (1) while pressing the return spring on the spring retainer with a

10. ATTENTION : Open the R-rings before lifting.

hydraulic press. Slowly relieve the tension of the spring. (Tool Ref. No 1)

IDCD559P

IDCD557P

11. Lift the back bearing.

8. Lift the piston by using compressed air in a lower

bore, after removing the spring retainer and return spring.

IDCD558P

9. Remove both R-rings before lifting the bearing.

Power Train Disassembly & Assembly

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