Doosan D20G Disassembly/assembly

D20G, D25G, D30G with B3.3 Engine D20G, D25G, D30G with 4TNE98 Engine G20G, G25G, G30G with G424F Engine G20G, G25G, G30G with G424FE Engine SB4220E01 J a n . 2 0 0 8

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

Overhead Guard .................................................. 6 Forks.................................................................... 7 Backrest............................................................... 7 Carriage............................................................... 7 Mast....................................................................13 Standard Lift Cylinder..........................................28 Secondary Lift Cylinder .......................................31 Primary Lift Cylinder............................................34 Tilt Cylinder.........................................................37 Hydraulic Pump...................................................42 Steering Wheel....................................................51 Steering Unit .......................................................52 Brake Master Cylinder.........................................62 Steer Wheel & Bearing........................................64 Steering Knuckle, Kingpin, And Bearing ..............66 Steer Axle ...........................................................67 Steering Cylinder.................................................69 Hydraulic Control Valve.......................................73 Counterweight.....................................................80 Engine ................................................................81 WARNING Disconnect batteries before performance of any service work.

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

6 Overhead Guard Remove & Install Overhead Guard 1. Support overhead guard (1) with lifting straps and a hoist . 2. Remove the washers, nuts, and bolts (2). 3. Remove the washers, nuts, and two bolts (3). 4. Remove front overhead guard (1). Front over head guard (1) weighs approximately 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.

7 Forks Remove & Install Forks 1. Remove stopper bolt and washer (3). 2. Lift fork pin (1). 3. Use a suitable C-clamp, strap and hoist to support the fork as shown. 4. Slide the fork to slot (2) in the middle of the carriage 5. Remove the fork. The weight of the fork is approximately 50 kg (110 lb). 6. Repeat steps 1 through 4 for the remaining fork. 7. Install the forks in the reverse order of removal. 8. Put the forks in position. Lower both fork pins (1) to lock the forks in position. 9. Install stopper bolt and washer (3). Be careful not to miss this step. Backrest Remove & Install Backrest 1. Fasten a hoist to the backrest. Remove bolts (2) that fasten the backrest to the carriage. 2. Remove backrest (1). Backrest (1) weighs about 40 kg (90 lb). 3. install backrest (1) in the reverse order of removal. Carriage Remove & Install Carriage Start By: a. Remove stopper bolt and washer (3). b. Lift fork pin (1). Tools Needed A Retaining Ring Pliers 1

8 (Typical Example) (Typical Example) 1. Raise carriage (1). Position a wooden block as shown. Lower carriage (1) onto the wooden block. 2. Disconnect two hydraulic lines (4) from side shifter cylinder (2). Plug and cap all openings to prevent contamination and debris from entering system. WARNING To prevent personal injury be sure pressure in the hydraulic system has been released before disconnecting any hydraulic lines. Slowly loosen the cap of the hydraulic tank to release any pressure in the tank. Be cautious of hot hydraulic coil when any lines are disconnected in the hydraulic system. NOTE: For purposes of reassembly, identify and mark all hydraulic lines and connectors before removing or disconnecting. (Typical Example) 3. Remove four bolts (8) from the chain guard/hose support assembly (6). Set the hoses aside, clear of the primary cylinder and cross head. (Typical Example) 4. Remove two bolts (10) from the hose mounting bracket. Set the hoses aside. Remove two nuts (9) from the chain anchors. Set the chains aside, clear of the mast.

9 (Typical Example) 5. Use tool (A) to remove retainer ring(11) from the cross head shaft. 6. Remove cross head (12) from the shaft. (Typical Example) 7. Raise the inner mast to pull out carriage as shown. 8. Remove carriage (14) from bottom of inner mast (15). Carriage (14) weighs 116kg (255 lb). NOTE: Use the following steps to install the carriage. 9. Raise the inner mast to put in the carriage onto the mast, and lower the inner mast to cover carriage (1) bearing fully.

10 (Typical Example) 10. Install cross head (12) and retaining ring(11). (Typical Example) 11. Put the chains in position over cross head (12).Install nuts(9) onto the chain anchors to a torque of 270 ± 40 N•m (200 ± 30 lb•ft). Install bolts (10) onto the hose mounting bracket. (Typical Example) 12. Install chain guard/hose support assembly (6) and four bolts(8) to a torque of 8 ± 2 N•m (6 ± 1.5lb•ft) (Typical Example) 13. Connect two hydraulic line (4) in their original positions. End By: a. Install backrest. b. Install forks. Disassemble Carriage Start By: a. Remove carriage. (Typical Example) 1. Remove the roll pins and pins (2) to disconnect chains (1).

11 (Typical Example) 2. Remove four lower roller bearings (3) and the shims from the carriage. (Typical Example) 2. Remove screw (5) and washer (4). Remove top roller bearings (6) and the shims. Assemble Carriage NOTE: The standard, Full Free Lift and Full Free Triple Lift carriage load bearings are all adjusted the same way. The Full Free Triple Lift carriage is shown in the following illustrations. To make the carriage clearance adjustments, carriage must be removed from the mast. Use the procedure that follows to adjust carriage load bearings. Carriage adjustment (3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw. (7)Middle bearings. (8) Lower bearings. (A) Zero clearance. (B) 6.0 to 9.0 mm. (.236 to .354 in) clearance. (C) Minimum clearance. 1. Select lower bearings from the chart to obtain minimum clearance (B) between bearings and channel leg for full channel length. Use same bearing in all six locations. Mast And Carriage Bearings Part No. Bearing Size Bearing O.D.* D581814 Under Size 108.6 mm (4.276 in) D581815 Standard 109.6 mm (4.135 in) D581816 Over Size 110.7 mm (4.358 in) * Permissible tolerance ±0.08 mm (.003in)

12 2. Find narrowest point by ruler on the inner mast in the area where the bearings make contact. 3. Install enough shims (4) that have been divided into two equal groups behind bearings (3). At installation, there is to be contact [zero clearance (A)] between the bearings and the narrowest point of inner mast. 4. Do step 2 through 3 for other sets of bearings (8),(9). (Typical Example) (Typical Example) 5. Tighten screw (5) that holds the top bearings to the carriage to a torque of 34±7 N•m (25±5 lb•ft). (Typical Example) 6. Position chains (6) on the carriage. Install pins (7) and the roll pins. End By: a. Install carriage, raise the inner mast and insert the carriage from the bottom of inner mast.

13 Mast Remove & Install Mast Start By: a. Remove forks. b. Place truck on the pit so to disassemble and assemble the mast mounting caps. (Typical Example) 1. Support mast assembly (2) with a hoist and two straps (1) as shown. NOTICE Place identification marks on all hydraulic connectors and hoses to assure proper installation. Plug and cap all hydraulic connectors and hoses to avoid debris and contamination from entering the system. 2. Disconnect hose (3). 3. Disconnect the hydraulic return lines (not shown). WARNING Tilt cylinders (7) can drop when pin (6) is removed. To avoid component damage or personal injury, support tilt cylinder (7) while removing pin (6). 4. Remove bolt (5) from each side of mast assembly (2). 5. Remove pin (6) from the tilt cylinders on each side of the mast assembly (2). 6. Tilt backward mast assembly (2) fully with the hoist. Remove bolts (8) and cap (9) from each side of the base of mast assembly (2) in the pit.

14 WARNING Loosen the tension of straps to be connected with hoist when mast assembly (2) is tilted forward. If straps are too tight, mast assembly (2) could slide off when bolts(8) are removed. 7. Use the hoist to remove mast assembly (2) from the machine. 8. Install the mast in the reverse order of removal. End By: a. Install forks. b. Fill hydraulic oil to tank*. * Refer to the Operation and Maintenance Manual for further information. Disassemble Mast Start By: a. Remove primary lift cylinder. b. Remove mast. NOTE: The following disassembly and assembly procedure is for a full free triple lift mast. (Typical Example) 1. Remove hoses (1) along with the hose support clamps.

15 2. Remove hose sheave (3). 3. Remove chain nut (4) from the top of the mast(each side). (Typical Example) 4. Disconnect and remove chains (5) from the bottom of the mast. (STD Mast) (FFT Mast) 5. Remove top cylinder retainer bolt (6) from each side of the mast. 6. Disconnect lift hose (7) and return hose (8).

16 (STD Mast) 7. Remove cylinder bottom retainer bolt (9) from each side of mast. (STD mast only) (STD Mast) (FFT Mast) 8. Remove cylinder retainer brackets (10) from each cylinder. (STD Mast) (FFT Mast) 9. Fasten a nylon strap and hoist to lift cylinder, as shown. Hoist and remove lift cylinder (11). Each cylinder weighs about 50 kg (110 lb).

17 10. Check the condition of bearings (12) located in each of the tilt cylinder pin bores. Replace bearings (12) with new if worn or damaged. 11. Check the condition of the bearings (13) located in each of the mast mounting bores. Replace the bearings (13) with new if worn or damaged. (Typical Example) 12. Fasten nylon straps and hoist to inner channel (14). Remove inner channel (14). The weight of the inner channel is approximately 150kg (330 lb). (Typical Example) 13. Remove rollers (15) and the shims from the inner channel mast. (Typical Example) 14. Fasten nylon straps and a hoist to the intermediate mast channel (16). Remove mast channel (16).The intermediate mast channel weighs approximately 168kg (370 lb). (FFT mast only)

18 (Typical Example) 15. Remove rollers (17) and the shims from the intermediate mast channel. (FFT mast only) 16. Remove nylon pads (18) and the shims. (Typical Example) 17. Remove rollers (19) and the shims from the stationary mast channel. 18. Remove nylon pads (20) and the shims.

19 Assemble Mast NOTE: The standard, Full Free Lift and Full Free Triple Lift mast load bearings are all adjusted the same way. The mast shown in the following illustrations is the Full Free Triple Lift mast. 1. Make sure all parts are clean and free of dirt and foreign material. 2. Check all parts for damage, use new parts for replacement. A. Lower Bearing Adjustment of Intermediate Mast Mast Adjustment Lower Bearings (A)Zero clearance. (B)Minimum clearance. (C)Zero clearance. (3)Bearing. (4)Bearing. (5)Shims. (6)Shims. 3. Select lower bearings (3) and (4) from the chart to obtain minimum clearance (B) between bearing and channel leg for full channel length. Must use same bearing on left and right side. Mast And Carriage Bearings Part No. Bearing Size Bearing O.D.* D581814 Under Size 108.6 mm (4.276 in) D581815 Standard 109.6 mm (4.135 in) D581816 Over Size 110.7 mm (4.358 in) * Permissible tolerance ±0.08 mm (.003in) 4. Find narrowest point by ruler on the staionary mast in the area where the bearings make contact at 475 mm (18.7 in) channel lap. NOTE: When installing shims (2) behind bearings(1), make sure the amount of shim is divided equally when positioned behind each bearing (1). 5. Install the correct amount of shim (2) behind rollers until contact (zero clearance) is made between the rollers.

20 NOTICE When the correct amount of shim has been installed behind rollers (1) there will be contact (zero clearance)between the rollers and the inner mast at most narrow point of mast (refer to step 4). (Typical Example) (Typical Example) 6. Install 1 mm shim to each bearing of intermediate lower and stationary upper basically. Lifting by crane, insert intermediate mast into stationary mast from the upper side. NOTE: When installing shims (5) behind bearings (4), make sure the amount of shim is divided equally when positioned behind each bearing (4). Mast Adjustment Lower Bearings (A)Zero clearance. (B)Minimum clearance. (C)Zero clearance.(3)Bearing. (4)Bearing. (5)Shims. (6)Shims. (Typical Example) 7. Make sure intermediate mast lower bearings are properly shimmed in the stationary mast by rolling up and down and moving intermediate mast to right and left. If clearance between both masts can be detected, pull out the intermediate mast from the stationary mast with crane and add shim 0.5mm or 1 mm to both intermediate lower bearings.

21 (Typical Example) 8. In case of standard and full free mast, inner lower bearings can be easily extruded by pulling down the inner mast from the bottom of stationary mast. If intermediate mast is stuck and cannot move by rolling up and down, there might be excessive shim. Pull out the intermediate mast from the stationary mast and remove shim 0.5 mm to both intermediate lower bearings. Repeat same procedure of above until properly shimmed. There is to be contact zero clearance (C) between intermediate lower bearings and stationary channel at approximately 475 mm (18.7 in) channel lap. B. Upper Bearing Adjustment of Stationary Mast (Typical Example) 9. Lift by crane, and pull out intermediate mast from stationary mast. Install 1 mm shim to each bearing of stationary mast upper basically. Bearing should be selected D581814 under size bearing. Mast Adjustment Upper Bearings (D)Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum. (F)Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims. (Typical Example) 10. Make sure stationary mast upper bearings are properly shimmed by rolling up and down and moving intermediate mast to right and left. If clearance between both masts can be detected, pull out the intermediate mast from the stationary mast with crane and add shim 0.5 mm or 1 mm to both stationary upper bearings.

22 (Typical Example) 11. In case of standard and full free mast, stationary upper bearings can be easily extruded by pulling down the inner mast from the bottom of stationary mast. If intermediate mast is stuck and can-not move by rolling up and down, there might be excessive shim. Pull out the intermediate mast from the stationary mast and remove shim 0.5mm to both stationary upper bearings. Repeat same procedure of above until properly shimmed. There is to be contact zero clearance (C) between stationary upper bearings and the widest point of intermediate mast to be checked before. C. Upper Pad Adjustment Mast Adjustment Upper Bearings (D)Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum. (F)Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims. (Typical Example) 12. Install shims (8) behind each pad (7) until there is 0.80 mm (.031 in) maximum clearance (E) between the pads and the inner and intermediate masts with the masts at full extension. Lift by crane, and pull out intermediate mast from stationary mast and insert the shims behind each pad. In case of standard and full free mast, the pads of stationary upper can be easily extruded by pulling down the inner mast from the bottom of stationary mast.

23 D. Lower Bearing Adjustment of Inner Mast Mast Adjustment Lower Bearings (A)Zero clearance. (B)Minimum clearance. (C)Zero clearance.(3)Bearing. (4)Bearing. (5)Shims. (6)Shims. 13. Select lower bearings (3) and (4) from the chart to obtain minimum clearance (B) between bearing and channel leg for full channel length. Must use same bearing on left and right side. Mast And Carriage Bearings Part No. Bearing Size Bearing O.D.* D581814 Under Size 108.6 mm (4.276 in) D581815 Standard 109.6 mm (4.135 in) D581816 Over Size 110.7 mm (4.358 in) * Permissible tolerance ±0.08 mm (.003in) (Typical Example) 14. Find narrowest point by ruler on the intermediate mast in the area where the inner lower bearings make contact full length of intermediate mast excluding minimum channel lap 475 mm (18.7 in). (Typical Example) 15. Install 1 mm shim to each bearing of inner lower and intermediate upper basically. Lifting by crane, insert inner mast into intermediate mast from the upper side.

24 Mast Adjustment Lower Bearings(A) Zero clearance. (B)Minimum clearance. (C)Zero clearance.(3)Bearing. (4)Bearing. (5)Shims. (6)Shims. 16. Make sure inner mast lower bearings are properly shimmed in the intermediate mast by rolling up and down and moving inner mast to right and left. If clearance between both masts can be detected, pull down the inner mast from the bottom of inter-mediate mast. Inner lower bearings can be easily extruded. Add shim 0.5 mm or 1 mm to both inner lower bearings. If inner mast is stuck and cannot move by rolling up and down, there might be excessive shim. Pull out the inner mast from the intermediate mast and remove shim 0.5 mm to both inner lower bearings. Repeat same procedure of above until properly shimmed. There is to be contact zero clearance (C) between inner lower bearing sand intermediate channel at narrowest point. E. Upper Bearing Adjustment of intermediate Mast Follow same procedure with above B. F. Upper Pad Adjustment of Intermediate Mast Follow same procedure with above C. 17. If the bearings (13) were removed from the mast mounting blocks, install new ones. 18. Put a small amount of clean grease on mounting bores (11). 19. If the bearings (12) were removed from the tilt cylinder pin bores, install new ones.

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

26 23. Connect lift hose (7) and return hose (8). (STD Mast) (FFT Mast) 24. Install top retainer bolt (6) to the secondary cylinders). 25. Install hydraulic steel tube to each secondary cylinder. When install the steel tube, assembling angle should be kept as shown in above figure. (FFT mast only)

27 (Typical Example) 26. Connect chains (5) at the bottom of the mast. 27. Connect chains (4) at the chain bracket of stationary mast upper. 28. Install sheave of lift hose. (FFT mast only) 29. Install the lift hose support bracket (3) and hoses. (FFT mast only) 30. Install primary lift cylinder (2). (FFT mast only) (Typical Example) 31. Install carriage assembly from the bottom of inner mast. (Typical Example) 32. Install cross head (21) and retainer ring (24) and install chain sheave (23) and retainer ring (22). (FFT mast only)

28 33. Install carriage chains to primary lift cylinder. (FFT mast only) (Typical Example) 34. Install hydraulic hose (25) of side shifter to side shifter cylinder (26) 35. Install mast to lift truck. Standard Lift Cylinder Disassembly Start By: a. Remove standard lift cylinders. 1. Put standard lift cylinder (1) in position on vise (A). 2. Loosen set screw (2) with wrench (B).

29 3. Remove bearing (3) with wrench (C). 4. Remove rod (4) from the cylinder body. 5. Remove split rings (5) from the cylinder rod. 6. Remove O-ring seal (6) and back-up ring (7) from the bearing.. 7. Remove wiper seal (8) and seal (9) from the bearing.

30 Assembly 1. Install seal (2) in the bearing. 2. Install wiper seal (1). Install the seal with the lip toward the outside. NOTE: Install back-up ring (4) with the curved side contacting the O-ring seal. 3. Install O-ring seal (3) and back up ring (4) into the bearing.. 4. Install split rings (5) on the cylinder rod. 5. Install cylinder rod (6) in the cylinder body. 6. Install bearing (7) on the cylinder rod and tighten using wrench (C).

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

32 3. Remove rod (3) from the cylinder body. 4. Remove stop ring (4) from the cylinder rod. 5. Remove wear ring(5), U-packing(6) and backup ring(7). 6. Remove retaining ring(8), spacer(9) and check valve(10). 7. Remove ring (11), wear ring (12) and O-ring (13) from the bearing. 8. Remove wiper seal (14) and retaining ring (15) from the bearing. 9. Remove U-packing (16).

33 Assembly 1. Install U-packing (1) in the bearing. 2. Install wiper seal (2) and retaining ring (3). Install the seal with the lip toward the outside. 3. Install O-ring (4), wear ring (5) and ring (6) in the bearing. 4. Install check valve (7), retaining ring (8) and spacer (9). 5. Install stop rings (10) on the cylinder rod. 6. Install wear ring (11), U-packing (12) and backup ring (13). 7. Install cylinder rod (14) in the cylinder body. 8. Install bearing (15) on the cylinder rod and tighten using tool (B). End By: a. Install secondary lift cylinders.

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

35 Disassemble Primary Lift Cylinder Tools Needed A B Hydraulic Cylinder Repair Stand 1 Wrench Assembly 1 Start By: a. Remove primary lift cylinder. 1. Remove flow protector valve (1) from the cylinder body. 2. Remove bearing (2) with tool (A). 3. Remove rod (3) from the cylinder body. 4. Remove wear ring (4), U-packing (5) and backup ring (6). 5. Remove retaining ring (7), spacer (8) and check valve (9). 6. Remove O-ring (10) and two rings (11).

36 7. Remove wiper seal (12) and retaining ring (13) and U-packing (14) from the bearing. Assemble Primary Lift Cylinder Tools Needed A B Hydraulic Cylinder Repair Stand 1 Wrench Assembly 1 1. Install U-packing (1) in the bearing. 2. Install wiper seal (2) and retaining ring (3). Install the seal with the lip toward the outside. 3. Install O-ring seal (4) and two rings(5). 4. Install check valve (6), retaining ring (7) and spacer (8). 5. Install wear ring (9), U-packing (10) and back up ring (11) on the cylinder rod.

37 6. Install cylinder rod (9) in the cylinder body. 7. Install rod cover (10) on the cylinder body. Use tool (A) to tighten bearing. 8. Install flow protector valve (11) on the cylinder body.. 7. Install rod cover (10) on the cylinder body. Use tool (A) to tighten bearing. End By: a. Install primary lift cylinder. Tilt Cylinder Remove & Install Tilt Cylinder NOTE: The procedure for removing and installing the tilt cylinders is the same for both cylinders. WARNING If both tilt cylinders are removed at the same time the mast can fall. To avoid possible personal injury, make sure the mast is securely held in place or supported by a hoist before removing the tilt cylinders. WARNING To prevent personal injury, move the control levers backward and forward to release any pres-sure in hydraulic system. Slowly loosen the cap of the hydraulic tank to release any pressure in the tank. Be cautious of hot hydraulic oil when any lines are disconnected in the hydraulic system. 1. Disconnect elbow (2). Remove retainer bolt (3) and pin (1).

38 2. Remove retainer bolt (6) from pin (5). Remove pin (5). 3. Remove tilt cylinder (4). 4. Install the tilt cylinder in the reverse order of removal. 5. Adjust the tilting angle. Be sure to engage the rod into the anchor more than 32min. Also, inspect if both tilt cylinders have the uneven tilting.

39 Disassemble & Assemble Tilt Cylinder Tools Needed A Spanner Wrench 1 Start By: a. Remove tilt cylinder. (Typical Example) 1. Use tool (A) to remove head (1) from the cylinder body. NOTICE When the correct amount of shim has been installed behind rollers (1) there will be contact (zero clearance) between the rollers and the inner mast at most narrow point of mast (refer to step 4). 2. Remove rod assembly (2) from the cylinder body. 3. Remove nut (3) from the cylinder rod. 4. Remove piston and seal assembly (4) from the cylinder rod. 5. Remove head assembly (5). (Typical Example) 6. Remove spacer (6) from the cylinder rod. 7. Loosen the nut and bolt on the rod eye.Remove cylinder rod (7) and shims (8). 8. Remove seal assembly (10) and O-ring seal (9) from the piston.

40 9. Remove seal (11) from the spacer. 10. Remove O-ring seal (12) and back-up ring (13) from the head. 11. Remove seals (14), (15), and (16) from the head. NOTE: Use the following steps to assemble the tilt cylinder. 12. Install seal (14) in the head. Position the lip of the seal toward the inside of the head. 13. Install seal (15). 14. Install seal (16) in the cylinder head. Position the lip of seal (16) toward the outside of the cylinder head. NOTE: The curved side of back up ring (13) should contact O-ring seal (12). 15. Install O-ring seal (12) and back-up ring (13).Make sure the curved side of back-up ring (13) is in contact with O-ring seal (12).

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

42 Hydraulic Pump (A372287 for EM0K2 & EM0K3) Disassemble Hydraulic Pump a. Start by remove hydraulic pump. 1. Remove four cap screws (1) and washers. 2. Remove shaft seal (2) and washer from the housing. 3. Remove hydraulic pump part (3) from pump assembly. 4. Remove Seal (6) and (4) from pump part (5). 5. Remove wear plate (7) from pump assembly (4). 6. Remove gear assemblies (8) from the body(9).

43 7. Remove body (10) from pump assembly. 8. Remove wear plate (11). 9. Remove seal (11) and (12) from the body. Assemble Hydraulic Pump 1. It is important that the relationship of the back- plate, body, wear plate and front plate is correct. There are two half moon cavities in the body. NOTE: The smaller half moon port cavity must be on the pressure side of the pump. The side of wear plate with midsection cut out must be on suction side of pump. Suction side of back plate is always side with larger port boss. 2. Install seal (1) and (2) in groove of front plate (3). 3. Apply a thin coat of petroleum jelly or hydraulic oil to both milled gear pockets of body. Slip body onto front plate with half moon port cavities in body facing away from front plate.

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

45 10. Place washer over drive shaft into housing. Liberally oil shaft seal (13) and install over driveshaft, carefully so that rubber sealing lips are not cut. 11. Install four cap screws (14) and washers.

46 Hydraulic Pump (D514289 for EM0QM & EM0QN) Disassemble Hydraulic Pump A. Start by removing the hydraulic pump. 1. Remove snap ring (1) from pump assembly (2). 2. Remove four cap screws (3). 3. Remove hydraulic pump cover part from pump assembly. 1 2 3

47 4. Remove a plate seal and Back-up (4) from pump cover part. 5. Remove the side plate (5) from the body. 6. Remove gear assemblies (6) from the body. 4 5 6 6

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

49 Assemble Hydraulic Pump NOTE: The small half noon port cavity must be on the pressure side of pump. The side of wear plate must be on suction side of pump as bellow photo of the description (4) and please prepare a set of repair kit. 1. It is important that the relationship of the pump cover part, body and two side plates is correct. 2. Install new plate seal and Back-up (1) to pump cover part. 3. Install the body (2) to pump cover part (3). 4. Install the side plate (4) into the body. 5. Install gear assemblies (5) into the body. 6. Install the side plate (6) into the body. 1 2 3 4 5

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

51 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 a rubber hammer 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 on its original position. 5. Install cup (3) and nut (2). Tighten nut (2) to a torque of 80 ± 7 N•m (60 ± 5 lb•ft). 6. Install cap (1).

52 Steering Unit Remove & Install Steering Unit Start By: a. Remove floor plate. (1) Floor plate 1. Open the floor plate. 2. Loosen four bolts (2). 3. Disconnect five hoses (5) from steering unit (6). WARNING 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 sys-tem. NOTE: Identify and mark all hydraulic hoses for purposes of reassembly. 4. Remove two bolts (4). NOTICE Steering unit (6) and column (3) can separate after bolts (4) have all been removed, causing unit (6) 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 (6). 6. Install the steering unit in the reverse order of removal. End By: a. Install floor plate.

53 Disassemble Steering Unit Cleanliness is extremely important when repairing a steering unit. Work in a clean area. Before disconnecting lines, clean port area of unit thoroughly. Use a wire brush to remove foreign material and debris from around exterior joints of the unit. Although not all drawings show the unit in a vise, we recommend that you keep the unit in the vise during disassembly. Follow the clamping procedures explained throughout the manual. 1. Clamp unit in vise, meter end up. Clamp lightly on edges of mounting area. Use protective material on vise jaws. Housing distortion could result if jaws are over tightened. 2. Remove 5/16 inch cap screws and washers if applicable (7 each). 3. Remove end cap. 4. Remove seal from end cap. 5. Remove meter. Be careful not to drop star. 6. Remove seal from meter. 7. Remove drive spacer(s).

54 8. Remove drive. 9. Remove spacer plate. 10. Remove seal from housing. 11. Remove housing from vise. Place housing on a clean soft cloth to protect surface finish. Use a thin bladed screwdriver to pry retaining ring from housing. 12. Rotate spool and sleeve until pin is horizontal. Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing. Remove bushing.

55 13. Remove quad ring seal from seal gland bushing. 14. Use a thin bladed screwdriver to pry dust seal from seal gland bushing. Do not damage bushing. 15. Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly. 16. Remove spool and sleeve assembly from 14 hole end of housing. ATTENTION: Identify and mark all hydraulic hoses for purposes of reassembly. 17. Push pin from spool and sleeve assembly.

56 18. Push spool partially from control end of sleeve, then remove 4 centering springs from spool carefully by hand. 19. Push spool back through and out of sleeve. Rotate spool slowly when removing from sleeve. 20. Remove seal from housing. 21. Remove check ball seat. 22. Tip housing to remove check ball.

57 Assemble Steering Unit Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts. NOTE: Lubricate all seals with clean petroleum jelly such as Vaseline. Do not use excessive lubricant on seals for meter section. Refer to parts listings covering your steering unit when ordering replacement parts. A good service policy is to replace all old seals with new seals. 1. Use a needle nose pliers to lower check ball retainer into check valve hole of housing. Make sure retainer is straight (not tilted on edge) in housing. 2. Install check ball in housing. 3. Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm [.30in.] ID seal. Install seals on check ball seat as shown. 4. Lubricate check ball seat and seals thoroughly before installing seat in housing. When installing seat do not twist or damage seals. Install check ball seat in housing, insert open end of seat first. Push check ball seat to shoulder of hole. 5. Install set screw. Use a 1/4 inch hex key to torque set screw to 11 N•m [100 lb•in]. To prevent interference make sure top of set screw in slightly below housing mounting surface. 6. Assemble spool and sleeve carefully so that the spring slots line up at the same end. Rotate spool while sliding parts together. Some spool and sleeve sets have identification marks, align these marks. Test for free rotation. Spool should rotate smoothly in sleeve with finger tip force applied at splined end. 7. Bring spring slots of both parts in line and stand parts on end of bench. Insert spring installation tool through spring slots of both parts. Position 2pairs of centering springs on bench so that extended edge is down and arched center section is together. In this position, insert one end of entire spring set into spring installation tool, with spring notches facing sleeve. 8. Compress extended end of centering spring set and push into spool sleeve assembly with drawing installation tool at the same time. 9. Center the spring set in the parts so that they push down evenly and flush with the upper surface of the spool and sleeve. 10. Install pin through spool and sleeve assembly until pin is flush at both sides of sleeve.

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

59 16. Install seal gland bushing over the spool end with a twisting motion. Tap the bushing in place with a rubber hammer. Make sure the bushing is flush against the bearing race. 17. Install retaining ring in housing. After installing ring, tap on ring end or pry with screwdriver around entire circumference of ring to properly seat ring in groove. 18. Clamp housing in vise. Clamp lightly on edges of mounting area. Do not over tighten jaws. NOTE: Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the housing. ATTENTION: Clean the upper surface of the housing by wiping with the palm of clean hand. Clean each of the flat surfaces of the meter section parts in a similar way when ready for reassembly. Do not use cloth of paper to clean surfaces. 19. Install 73.5 mm [2.89 in.] ID seal in housing. 20. Install spacer plate. Align bolt holes in spacer plate with tapped holes in housing.

60 21. Rotate spool and sleeve assembly until pin is parallel with port face. Install drive, make sure you engage drive with pin. To assure proper alignment, mark drive as shown. Note relation- ship between slotted end of drive to splined end of drive when marking. 22. Install 73,5 mm [2.89 in.] ID seal in spacer plate or gerotor (meter) 23. With seal side of meter toward spacer plate, align star valleys on drive. Note the parallel relation-ship of reference lines A, B, C, and D. Align bolt holes without disengaging meter from drive.

61 24. Install drive spacer (s) when used, in meter. 25. Install 73,5 mm [2.89 in.] ID seal in gerotor (meter)or end cap, see notes. 26. Install end cap on gerotor, align holes. 27. Install 7 dry cap screws in end cap. Pretighten screws to 11-17 N•m [100-150 lb•in] then torque screws to specifications. Spacer Actual Displacement cm³/r(in³/r) Length mm[in.] 45 [ 2.8] None 60 [ 3.6] None 75 [ 4.5] None 95 [ 5.9] 3.56 [ .140] 120 [ 7.3] 6.10 [ .240] 145 [ 8.9] 10.29 [ .405] 160 [ 9.7] 12.19 [ .480] 185 [11.3] 15.62 [ .615] 230 [14.1] 21.97 [ .865] 295 [17.9] 28.45 [1.120] 370 [22.6] 41.15 [1.620] 460 [28.2] 53.67 [2.113] 590 [35.9] 66.37 [2.613] 740 [45.1] 91.77 [3.613]

62 Brake Master Cylinder Remove & Install Brake Master Cylinder (Boosted) 1. Remove the cotter pin from pin (1). Remove pin (1). NOTE: Plug and cap all openings to avoid contamination and debris from entering the system after removing any tubes or lines. 2. Disconnect wire harness from the pressure switch. 3. Disconnect tube (3) from master cylinder. 4. Remove clamps and disconnect hoses (4). 5. Support the brake master cylinder. Remove two bolts (6). 6. Remove the brake master cylinder. 7. Install the brake master cylinder in the reverse order of removal. 8. Bleed the brake system. Refer to the Testing and Adjusting Manual for further information. End By: Disassemble & Assemble Brake Master Cylinder Start By: a. Remove brake master cylinder. 1. Slip boot (4) off of body (5). 2. For purposes of reassembly, mark the position of nut (2) on yoke (1). Loosen nut (2) from plunger (3). 3. Separate yoke (1), nut (2), plunger (3) and boot (4). 4. Remove pressure switch (5).

63 5. Remove elbow (6) plug (7), washers (8) and connector (9) from master cylinder. 6. Remove bolt (10), washer (11), tube (12) and washer (13) from the body. 7. Remove the retaining spring (15) and washer (16) from the body. NOTE: Be sure to check the condition of seal (18) when disassembling the brake master cylinder. For purposes of reassembly, position seal (18) into the bore of body 8. Remove the components from body (5) as follows: a. Remove piston (17) and cup (18). b. Remove cup-primary (19). c. Remove spring (20) and spring seat (21). d. Remove check valve (22). e. Check the condition of the seals. Replace the seals with new if worn or damaged. 9. Assemble the brake master cylinder in the reverse order of disassembly End By: a. Install the brake master cylinder.

64 Steer Wheel & Bearing Remove Steer Wheel & Bearing NOTE: The procedure to remove the steer wheels is the same for the right and left steer wheel. 1. Support the steer axle with a floor jack or a wood block under the frame (A). 2. Remove wheel nuts (1) and wheel assembly (2). Steer wheel (2) weighs approximately 34kg (75Ib). 3. Remove wheel cap (3). 4. Straighten and remove split pin (4). 5. Remove nut (5) and washer (6). 6. Remove wheel hub assembly (7). Tools Needed A B C Floor Jack 1 Driver Set 1 Lock Nut Installer 1

65 7. Remove bearing cup (8) from the hub (7). 8. Remove seal, bearing cup and cone from the bank of hub. NOTE: Check the condition of all seals, bearings and components. If any parts are worn or damaged, use new parts for replacement. For purposes of assembly, lower the temperature of the bearing cups before installing into steer wheel (5). Use tooling (B) to install bearing cups and seals. 9. Pack bearing cones and lubricate the contact surfaces of the bearing cups with Multipurpose Grease. 10. Reverse the procedures and steps 2 through 9 to install the steer wheels and bearings. 11. Adjust the steer wheel bearings as follows: a. Use tool (C) to tighten nut (5) to a torque of 135 N•m (100 lb•ft) while slowly rotating steer wheel (5). b. Use tool (C) to loosen nut (5) completely. c. Use tool (C) to tighten nut (5) again to a torque of 50 ± 5 N•m (37 ± 4 lb•ft). d. Insert a split pin (4) into a hole of knuckle and then, bend over lock nut (5) 12. Install wheel cap (3). Be sure to pack the cap with Multipurpose Grease. 13. Install steer wheel (2) and tighten the bolts (1). 14. Remove tooling (A) and lower the lift truck.

66 Steering Knuckle, Kingpin, And Bearing Remove And Install Steering Knuckle, King Pins And Bearing Tools Needed A Drive Set 1 Start By: a. Remove steer wheels. NOTE: The procedure to remove and install the steering knuckle, kingpin, and bearing is the same for both sides of the lift truck. 1. Remove two bolts (2) and pin retaining plate (3). 2. Remove tie rod pin (1) and separate tie rod (4)from knuckle (5). 3. Remove the top grease nipple (6). 4. Remove the king pin retaining bolt (7) and nut (8). For purposes of reassembly, the torque for bolt (7) is 11 ± 1 N•m (8~9 lb•ft). 5. Remove the king pin (9).

67 6. Remove the knuckle (5), spacer (10) and shim (11). During the reassembly, the clearance between the knuckle and axle beam should be lower than 0.5mm. 7. Remove bearing (12) from steer axle (13). 8. Check the condition of bearings (12). Replace it with new one if worn or damaged. 9. Repeat steps 7 and 8 for the remaining seal, bear-ing and spacer in the other side of steer axle (13). 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 Tools Needed A Jack Stand 4 WARNING Be sure the pressure in the hydraulic system is released before any lines or hoses have been disconnected. 1. Put the lift truck on the plain ground. 2. For purposes 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 frame with a proper floor jack. Be careful to select the proper jack stand. Refer to the truck weight from the catalogue. 4. Loosen mounting bolts (2) until approximately two bolt threads are left in the mounting bosses.

68 5. Lower the steer axle onto the bolt heads with the floor jack or lift truck. 6. Remove bolts (2) and mounting caps (3) from the steer axle. 7. Remove steer axle (4). The steer axle weighs approximately 200kg (440 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). 10. Connect hoses (1).

69 Steering Cylinder Remove & Install Steering Cylinder Start By: a. Remove steer axle. 1. Remove the pin retaining bolt and pin (2) from the tie rod at each end of steering cylinder (1). 2. Remove four bolts (3). For installation purposes, the torque for bolts (3) is 250 ± 40 N•m (184 ± 29 lb•ft). 3. Remove steering cylinder (1). 4. Install steering cylinder (1) in the reverse order of removal.

70 Disassemble Steering Cylinder Tools Needed A Pliers 1 NOTE: Steering cylinder has two rods positioned between the cylinder end caps. These rods are attached to the cylinder end caps with nuts at each end. Remove the nuts and rods before removing the cylinder end caps from the cylinder tube. 1. Put location marks on end caps (1) as to their position on the steering cylinder tube. 2. Remove end caps (1) from the steering cylinder. 3. Remove bolts (2) and mounting caps (3) from the steer axle. 4. Use tool (A) to remove retaining rings (4) and rings (3) from the cylinder rod. 5. Remove piston (5) from the cylinder rod.

71 6. Remove and inspect O-ring seal (6). 7. Remove seal (7) from the piston. 8. Disassemble each end cap as follows: a. Remove O-ring seal (10). b. Remove wear ring (8). c. Remove u-cup seal (9). d. Remove wiper seal (11). Assemble Steering Cylinder Tools Needed A Pliers 1 1. Assemble each end cap as follows; a. Install O-ring seal (2). b. Install wear ring (1). c. Install u-cup seal (3). d. Install wiper seal (4). 2. Install seal (5) on the piston.

72 3. Install O-ring seal (6) on the cylinder rod. 4. Install piston (7) on the cylinder rod. 5. Install rings (8). 6. Use tool (A) to install retaining rings (9) on each side of the piston. 7. Install cylinder tube (10) on the rod assembly. 8. Install end caps (11) on cylinder tube (10). NOTE: Install the nuts and rods on steering cylinder rafter installing the cylinder end caps. End By: a. Install the steering cylinder.

73 Hydraulic Control Valve Remove And Install Hydraulic Control Valve WARNING Hydraulic oil under pressure can remain in the hydraulic system after the engine and pump have been stopped. Personal injury can result if the pressure is not released before any work is done to the hydraulic system. To prevent 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 seven lines (4) from control valve (3). 2. Remove the cotter pins, washers and pins (1) from linkages (2). 3. Support control valve (3). Remove bolts (5), control valve (3). 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.

74 Disassemble Hydraulic Control Valve Start by : NOTE: For the purpose of assembly, put identification mark on valve sections. a. disassembly of main valve. 1. remove main control valve, PF relief valve and port relief valve. 2. remove bolts to separate the valve sections: when separating the valve section, make sure that the O-ring and load check incorporated into the lateral face are not damaged and injured. b. disassembly of front cover. 1. remove O-ring(11) from the lateral face. 2. remove hex plug(6) and priority connector(5). 3. remove FD sleeve(4), ball retainer(7), steel ball(8), spring(9).

75 c. disassembly of lift section. 1. remove O-ring(13), poppet(9) and spring(10)from lateral face carefully not to damage the face. 2. remove two hex bolts(12) and cap(5). 3. after fixing the end of spool (2) not to be rotated, remove a set screw (7). 4. remove retainer spring(6), spring(8), seal plate(3). 5. take out spool(2) from body(1) with dust seal(4) slowly smoothly to prevent spool damage. 6. loose bolts(11), take out seal plate(8) and dust seal(4) from body. 7. Loose hex bolt(14). d. disassembly of tilt section. 1. remove O-ring(15), poppet(11) and spring from lateral face. 2. Loose bolts (14), and remove cap(7). 3. after fixing the end of spool (2) not to be rotated, remove a set screw (9). 4. remove retainer spring(8), spring (10), seal plate (5). 5. take out spool(2) from body(1) with dust seal(6) slowly smoothly to prevent spool damage. 6. loose bolts(13), take out seal plate(5) and dust seal(6) from body. 7. Loose hex bolt(14).

76 e. disassembly of auxiliary section. 1. remove O-ring(13), poppet(9) and spring (10) from lateral face. 2. Loose bolts(12), and remove cap(5). 3. after fixing the end of spool (2) not to be rotated, remove a set screw (7). 4. remove retainer spring(6), spring(8), seal plate(3). 5. take out spool(2) from body(1) with dust seal(4)slowly smoothly to prevent spool damage. 6. loose bolts(11), take out seal plate(3) and dust seal(4) from body. 7. Loose hex bolt(14). Assemble Hydraulic Control Valve Start by : NOTE: make sure all valve parts are clean and free of dirt. a. disassembly of auxiliary section. 1. fix section by using a vice for lateral(machined)faces not to be damaged. 2. install O-ring. And install priority connector(5)into the front cover by tightening toque 60. 3. incorporate ball retainer(7), steel ball(8) and spring(9) into FD spool(4), which is installed into FD cover front(1). 4. install O-ring and tighten hex bolt(6) into FD cover front(1) by 60N•m. 5. release a section from a vice, and install O- ring(11).

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

78 d. assembly of auxiliary section. 1. fix section by using a vice for lateral(machined)faces not to be damaged. 2. Install spool(2) into body(1) smoothly and slowly. A direction of spool access to body is same as that of spool disassembly. 3. dust seals(4) put on the end of spool by using a tool. NOTE: be careful not to damage a dust seal, as it could make an external leakage. 4. after fixing the spool end, install seal plate(3), spring retainer(6) and spring(8). And tighten set screw(7) by 14N•m. NOTE: make sure that set screw are tightened by a exact torque. In case of excessive drift of cylinder on neutral position. 5. put seal plate(3) on the end of spool and tighten two hex bolts(11) by 14N•m 6. install cap(7) and tighten two hex bolts(14) by14N•m. 7. release a section from a vise, and install O- ring(13), poppet(9) and spring(10) into lateral face. e. assembly of section. place each section in a row, insert tie rod, and tight- en nut by 27.4-31.4N•m. NOTE: in case of excessive torque, it could make as pool sticking. In case of insufficient torque, it could make an external leakage problem. Note Dust seal mounting procedure. This tool is needed when assemble tilt section (c, 3) and assemble auxiliary section (d, 3). 1. insert the dust seal(4) from the side with a champer the side without a champer(no more than c0.5)of tool(3). 2. insert the tool(2) into the tool(3). 3. insert the tool(1) into the tool(2) 4. insert the spool into the above assembly. (note that the dust seal(4) is in its right position) 5. remove the tool(1). 6. hit the tool(2) to insert the dust seal(4) into the valve body.

79 Cause and Measure on failure of control valve Problem: External leakage form dust seal Cause 1. damaged seal lip or seal worn away. 2. damaged spool. 3. contaminated seal plate. 4. higher back pressure of tank port. 5. penetraed foreign material such as paint and dirt. Measure 1. exchange dust seal. 2. exchange control valve section ass’y. 3. disassemble seal plate, and clean seal plate and tighten it by a standard torque. 4. Investigate hose or exchange return filter. 5. Clean it. Be careful not to damage spool. Problem: Inappropriate Spool motion Cause 1. foriegn material penetrates into spool. 2. deformation of spool by exteranl force. 3. bias wear of spool by biased force. 4. loosening of cap bolt. 5. high oil temp. 6. low oil temp. Measure 1. take spool out, and clean it. 2. exchange valve section ass’y. 3. exchange valve section ass’y. 4. tighten cap boly by standard torque. 5. Use in normal temperature. 6. Use in normal temperature. Problem: large drift of cylinder Cause 1. internal leakage of spool damage. 2. leakage of port relief valve and shut-off plug. 3. bias of spool position(not neutal position). 4. leakage of cylinder. Measure 1. change control valve section ass’y. 2. check if O-ring is normal. Or exchange it. 3. check an interference of lever link. 4. Check a cylinder. Problem: lower pressure(not to lift a load) Cause 1. contaminated relief valve. 2. strange wearing of relief valve poppet. 3. lower relief setting pressure. 4. O-ring damage of relief valve. 5. Damaged pump. Measure 1. overhaul relief valve ass’y. Clean its internalparts. 2. Exchange relief valve ass’y. 3. Adjust relief setting pressure to normal value. 4. Exchange O-ring. 5. Exchange pump.

80 Counterweight Remove & Install Counterweight Tools Needed A Link Bracket 1 1. Remove the washers and bolts (4) and exhaust pipe (5). 2. Support counter weight (6) with a hoist and tooling(A) as shown. 3. Remove towing pin (7). 4. Remove the washer plate and bolts (8). 5. Use the hoist and tooling (A) to remove counterweight (6). The weight of the counterweight is approximately 1753 kg (3865 lb). NOTE: The following steps are for installation of the counterweight. 6. Put counterweight (6) in position on the frame, and install bolt (8) and bolts (9). Tighten the bolts to a torque of 400 ± 50 N•m (300 ± 37 lb•ft). 7. Install towing pin (7).

81 Engine Remove & Install Engine Tools Needed A Link Bracket 1 NOTE: Procedures for Gasoline, L.P. and Diesel engines are all similar. The engine shown in the following illustrations is for Diesel B3.3 engine. Start by : a. Remove Overhead guard* b. Remove counterweight* c. Remove hood assembly* * Refer to the topics “Overhead guard”, “Counterweight” and “hood assembly” in this module 1. Remove two bolts (1) and floor plate (2). 2. Disconnect the two battery cables (1). Remove the washers, two bolts (2) and battery assembly (3). 3. Loosen the clamps and disconnect air cleaner hoses (4). 4. Remove mounting bracket (5) and air cleaner (6). 5. Loosen clamp assembly (7).

82 6. Remove the washers, two bolts not shown and tube assembly (9). 7. Remove the washers, two bolts and muffler assembly. 8. Loosen cock-drain from the radiator and drain coolant. 9. Loosen clamps and disconnect two radiator hoses (13). 10. Loosen the clamp and disconnect radiator overflow hose (14). 11. Loosen clamps and disconnect the two transmission cooler hoses (15). 12. Remove, eight bolts (16) and baffle assembly(17), if equipped.

83 (Typical Example) 13. Remove radiator mounting bolts (18). 14. For easy removal of radiator, loosen four bolts(19) and remove radiator (20). (Typical Example) 15. Disconnect wires (21) from starter assembly (22). 16. Disconnect wires (23) from alternator (24). NOTICE Place identification marks on all wires and connectors to assure proper assembly. 17. Disconnect connector (25) from transmission switch. 18. Disconnect engine wire harness (26).

84 19. Disconnect wire (27) from circuit breaker (28).To remove engine from the truck, other wires or connectors not shown should be disconnected. 20. Remove nut (29) and accel rod (30). 21. Remove two bolts (31). Push wiring (32) back toward the engine. Remove cover (33). (Typical Example) 22. Remove the six bolts (34) that hold the converter to the flywheel. During the reassembly, the tightening torque is 28 ± 7 N•m (40 ± 10 lb•ft). NOTE: At this point, make a final check to be sure all removals and disconnections have been made from the engine. (Typical Example) 23. Support engine with a hoist and tooling (A) as shown.

85 24. Remove the washers and bolts (35) from the converter housing. During the reassembly, the tightening torque is 55 ± 10 N•m (40 ± 10 lb•ft). (Typical Example) 25. Remove the nuts and washers (36) from two engine mounts, located on each side of the engine. During the reassembly, the tightening torque is 200 ± 25 N•m (147 ± 18 lb•ft) NOTICE Make sure the engine is supported underneath by suitable wooden blocks. Failure to support the engine will result in possible clamage. 26. Remove the engine with a hoist as shown. The engine weighs about 215 kg. 27. Install the engine in the reverse order of removal. End By : a. Install overhead guard* b. Install counterweight* c. Install hood assembly* Refer to the topics “Over head guard”, “Counterweight” and “Hood assembly” in this module.