SB4256E01 Jan.
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.
Index Hydraulic Control Valves.................................... 5 Disassembly & Assembly.................................. .9 Hood (with seat) ................................................ 9 Overhead Guard.............................................. 10 Forks............................................................... 11 Backrest .......................................................... 11 Carriage .......................................................... 12 Assemble Carriage ...................
Hydraulic Control Valves Removal and Install ation 5 WARNING 3 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.
Disassembly of Hydraulic Control Valve Start By : a. Remove hydraulic control valve. NOTICE : For the sake of convenience in assembly, put an identification mark on all valves. Cover the all openings with plug to protect from dirt and dust. 2. Release the bolt (4) and take apart the valve sections. 3. Release the screw (5) and separate return cap from valve. Then, remove the spool from the valve in downward direction (cap side). 1.
7 7 Assembly of Control valve 7 1. Make sure that all valve parts are clean and free from dirt and dust. 7 7 7 IDCD221P 2. Assemble the spool (1), return cap (2) and valve section, then fasten the screw (3). Replace seals with the new one in case of leakage from cap side or spool side caused by dent or scar on spool 4 4 4 4 4. Separate O-ring seals (7) from valve body. Be careful not to miss the small spring and ball. 4 4 IE0M117S Spring Ball 5.
4. Dust and dirt should be cleaned when you assemble and disassemble the lift lock valve 7. Assemble the poppet (1), spring (2), relief plug (3) into relief valve. Inspect the poppet and replace it with new one if it has scar or dent. NOTE : Until the repaired valve is mounted on the lift truck, be sure to plug all openings. 5. Install and tighten the tie rods (7). Be sure that you have to tighten the tie rods to the proper torque. 6. Install solenoid valve on the lift section.
Disassembly & Assembly 3 Hood (with seat) Remove & Install Hood (with seat) Assembly 5. Remove the washers and four bolts (3). 1 4 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). 6. Release latch (4). Use the hoist to remove hood and seat assembly. The hood and seat assembly weighs approximately 52 kg (115 lb). 1. Raise the hood. Support the hood with a hoist. 7.
Overhead Guard Remove & Install Overhead Guard 3. Remove the washers, nuts, and two bolts (3). 4. Remove front overhead guard (1), Front overhead guard (1) weighs approximately 30 kg (66 lb). 1. Support overhead guard (1) with lifting straps and a hoist. 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. 2. Remove the washers, nuts, and two bolts (2).
Forks Backrest Remove & Install Forks Remove & Install Backrest 1 1 2 2 IDCD003P IDCD001 1. Fasten a hoist to the backrest. Remove bolts (2) that fasten the backrest to the carriage. 2. Remove backrest (1). Backrest (1) weighs approximately 40 kg (90 lb). 3. Install backrest (1) in the reverse order of removal. IDCD002P 1. Lift fork pin (1). 2. Use a suitable C-clamp, strap and hoist to support the fork as shown. 3. Slide the fork to slot (2) in the middle of the carriage. 4. Remove the fork.
NOTE: For purposes of reassembly, identify and mark all hydraulic lines and connectors before removing or disconnecting. Carriage Remove & Install Carriage for STD, FFL & FFT Tools Needed Retaining Ring Pliers A 1 Start By: a. Remove forks. b. Remove backrest. 2 6 1 IDCD004P 3. Remove four bolts (5) from the chain guard/hose support assembly (6). Set the hoses aside, clear from the primary cylinder and cross head. 9 4 1. Raise carriage (1). Position a wooden block as shown.
8. Remove carriage from bottom of inner mast (15). Carriage (14) weighs approximately 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. 4. Remove two bolts (9) from the hose mounting bracket. Set the hoses aside. Remove two nuts (10) from the chain anchors. Set the chains aside, clear from the mast. 11 12 IDCD008 10.
Remove & Install Carriage for Quad Mast Start By: a. Remove forks. b. Remove backrest. 6 13 1. Raise carriage and remove stopper bolts (13). 2 12. Install chain guard/hose support assembly (6) and four bolts (5) to a torque of 28 ± 7 N·m (20 ± 5 lb·ft). 1 IDCD004P 4 13. Connect two hydraulic line (4) in their original positions. End By: 4 a. Install backrest. 2. Raise carriage (1). Position a wooden block as shown. Lower carriage (1) onto the wooden block. b. Install forks. 3.
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 system. 15 NOTE: For purposes of reassembly, identify and mark all hydraulic lines and connectors before removing or disconnecting. 14 6 IDCD010P 6. Raise the inner mast to pull out carriage as shown. 8 7.
Disassemble Carriage 6 Start By: 8 a. Remove carriage. 10. Install chain guard/hose support assembly (6) and four bolts (8) to a torque of 28 ± 7 N·m (20 ± 5 lb·ft). Typical Example 1. Remove the roll pins and pins (2) to disconnect chains (1). 4 11. Connect two hydraulic line (4) in their original positions. 13 2. Remove four lower roller bearings (3) and theshims from the carriage. 12. Install stopper bolt (13) on the inner mast. End By: a. Install backrest. b. Install forks. 3.
Mast And Carriage Bearings Part No. Bearing Size D581814 Under Size D581815 Standard D581816 Over Size 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. Bearing O.D. * 108.6 mm (4.276 in) 109.6 mm (4.276 in) 110.7 mm (4.358 in) * Permissible tolerance ± 0.08 mm (.
5. Tighten screw (5) that holds the top bearings to the carriage to a torque of 34 ±7 N·m (25 ±5 lb·ft) 11 IDCD009 6. In case of Quad mast shim stop bolt (11) as required to obtain a 6 to 9 mm (.24 to .35 in) lap with top carriage stop on the inner upright. 8 6 7 9 IDCD011P 7. 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.
Mast 4 Remove & Install Mast Start By: 5 a. Remove forks. 6 7 1 3. Disconnect two hydraulic lines (4). 2 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). 1. Support mast assembly (2) with a hoist and two straps (1) as shown. 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).
Disassemble Mast for FFT WARNING NOTE : The standard, Full Free Lift and Full Free Triple Lift mast are almost the same way. The mast shown in the following illustrations is the Full Free Triple Lift mast. 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. Start By: 7. Use the hoist to remove mast assembly (2) from the machine. a. Remove primary lift cylinder. 8.
5 IDCD024P 4. Disconnect and remove chains (5) from the bottom of the mast. 7. Fasten a nylon strap and hoist to secondary cylinder (9) as shown. Remove secondary cylinders (9). Each cylinder weighs 50 kg (110 lb). 10 6 IDCD028P IDCD025P 8. Check the condition of bearings (10) located in each of the tilt cylinder pin bores. Replace bearings (10) with new if worn or damaged. 5. Remove top cylinder retainer bolt (6) from each side of the mast. 8 11 IDCD029P IDCD026P 6.
15 12 IDCD033P IDCD030P 10. Check the condition of the bearings (12) located in each of the mast mounting bores. Replace the bearings (12) with new if worn or damaged. 13. Fasten nylon straps and a hoist to the intermediate mast channel (15). Remove mast channel (15). The intermediate mast channel weighs approximately 168kg (370 lb). 16 13 17 IDCD031P IDCD034P 14. Remove rollers (16) and the shims from the intermediate mast channel. 11. Fasten nylon straps and hoist to inner channel (13).
Disassemble Quad Mast Start By: a. Remove primary lift cylinder. b. Remove mast. 5 NOTE: The following disassembly and assembly procedure is for Quad Mast. 5-1 1 4. Disconnect and remove chains (5) and chain anchor block (5-1) from the bottom of the mast. 1 1. Remove all hoses (1) along with the hose support clamps. 6 5. Remove top cylinder retainer bolt (6) from each side of the mast. 3 4 4 8 2. Remove hose sheave (3). 3. Remove chain nut (4) from the top of the mast (each side). 6.
IDCD030P IDCD027P 7. Fasten a nylon strap and hoist to secondary cylinder (9) as shown. Remove secondary cylinders (9). Each cylinder weighs 50 kg (110 lb). 10. Check the condition of the bearings (12) located in each of the mast mounting bores. Replace the bearings (12) with new if worn or damaged. NOTE: LH, RH secondary cylinders are different. Identity or mark each cylinder for purpose of reassembly. 10 IDCD028P 11. Fasten nylon straps and hoist to inner channel (13). Remove inner channel (13).
13. Fasten nylon straps and a hoist to the inner intermediate mast channel. Remove that mast channel and then remove the onter intermediate mast channel (15) in the same way. The each intermediate mast channel weighs 168kg (370 lb). 16 17 IDCD034P 14. Remove rollers (16) and the shims from the intermediate mast channels. 15. Remove nylon pads (17) and the shims. 18 19 IDCD035P 16. Remove rollers (18) and the shims from the stationary mast channel. 17. Remove nylon pads (19) and the shims.
Assemble FFT 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. Also, the actual appearance would be different partially 1. Make sure all parts are clean and free of dirt and foreign material. IDCD036P 2. Check all parts for damage, use new parts for replacement. A. Lower Bearing Adjustment of Intermediate Mast 4.
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) 1 3 4 5 6 2 A B C IDCD037P IDCS123S Mast Adjustment Lower Bearings (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims. IDCD033P 6. Install 1 mm shim to each bearing of intermediate lower and stationary upper basically.
D E 7 8 F 9 IDCD039P 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.
C. Upper Pad Adjustment D E 7 8 IDCD039P F 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 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 stationary upper bearings. Repeat same procedure of above until properly shimmed.
D. Lower Bearing Adjustment of Inner Mast 3 4 5 6 IDCD031P 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. A B 3 C 4 5 6 IDCS123S Mast Adjustment Lower Bearings (A) Zero clearance. (B)Minimum clearance. (C)Zero clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims. 13.
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. IDCD041P 17. If the bearings were removed from the mast mounting blocks, install new ones. 20. Fasten a hoist and nylon strap to secondary cylinder (12). Install secondary cylinders (12) into the stationary mast. 13 11 IDCD042P IDCD026P 18. Put a small amount of clean grease on mounting pins (11).
19 13° 15° IDCD044P 27. Install the lift hose support bracket (19) and hoses. IDCS322S 23. Install hydraulic steel tube to each secondary cylinder. When install the steel tube, assembling angle should be kept as shown in above figure. 16 IDCD045P 28. Install primary lift cylinder. IDCD024P 24. Connect chains (16) at the bottom of the mast. 18 16 IDCD023P IDCD010P 25. Connect chains (16) at the chain bracket of stationary mast upper. 29.
20 IDCD008P 30. Install cross head (20) to primary lift cylinder. 33. Install mast to lift truck. 31. Install carriage chains to primary lift cylinder. 22 21 32. Install hydraulic hose (21) of side shifter to side shifter cylinder (22).
Assemble Quad 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 Outer Intermediate Mast IDCD036P 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.
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) 1 2 IDCD037P Mast Adjustment Lower Bearings (A, B, C) Zero clearance. (D) Minimum clearance. (3, 4, 5) Bearing (6, 7, 8) Shims. 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.
IDCD039P 8. If intermediate mast is stuck and cannot move by rolling up and down, there might be excessive shim. Pull out the outer intermediate mast from the stationary mast and remove shim 0.5 mm to both outer 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. Mast Adjustment Upper Bearings (E, F, G) Zero clearance. (H) 0.
C. Upper Pad Adjustment 11. If outer intermediate mast is stuck and cannot move by rolling up and down, there might be excessive shim. Pull out the outer intermediate mast from the stationary mast and remove shim 0.5 mm to both stationary upper bearings. Repeat same procedure of above until properly shimmed. There is to be contact zero clearance (G) between stationary upper bearings and the widest point of intermediate mast to be checked before. Mast Adjustment Upper Bearings (E, F, G) Zero clearance.
D. Inner Intermediate Mast Adjustment. Follow same procedure with above A~C. E. Lower Bearing Adjustment of Inner Mast IDCD040P 14. Find narrowest point by ruler on the inner intermediate mast in the area where the inner lower bearings make contact full length of inner intermediate mast excluding minimum channel lap 475 mm (18.7 in). Mast Adjustment Lower Bearings (A, B, C) Zero clearance. (D) Minimum clearance. IDCD031P 15.
F. Upper Bearing Adjustment of Inner Intermediate Mast Follow same procedure with above B. G. Upper Pad Adjustment of Inner Intermediate Mast Follow same procedure with above C. Mast Adjustment Lower Bearings (A, B, C) Zero clearance. (D) Minimum clearance. IDCD041P (3, 4, 5) Bearing (6, 7, 8) Shims. 17. If the bearings were removed from the mast mounting blocks, install new ones. 16.
Hole Hole Bar 20. Fasten a hoist and nylon strap to secondary cylinder (12). Install secondary cylinders (12) into the stationary mast. 23. Put the end bar of cylinder into the hole of stationary mast’s lower stay, then the angles of part become spontaneously 45°. 13 16-1 16 21. Install secondary cylinder mounting brackets (13) over the secondary cylinders. 24. Connect chains (16) and anchor block (16-1) at the bottom of the mast. 18 16 19 14 16 22.
Lift Hose 27. Install the lift hose along with the hose support clamps. 30. Install carriage chains to primary lift cylinder. 22 21 IDCD005P 28. Install primary lift cylinder and assemble bolt (a). 31. Install hydraulic hose (21) of side shifter to side shifter cylinder (22). 32. Install mast to lift truck. IDCD010P 29.
Standard Lift Cylinder 4 Disassemble Standard Lift Cylinder Start By: a. Remove standard lift cylinders. 1 IDCD409P 4. Remove rod (4) from the cylinder body. A IDCD399P 5 1. Put standard lift cylinder (1) in position on vise (A). IDCD409P 5. Remove split rings (5) from the cylinder rod. 2 B IDCD007P 2. Loosen set screw (2) with wrench (B). 6. Remove O-ring seal (6) and back-up ring (7) from the bearing. C 8 9 3 IDCD407P 3. Remove bearing (3) with wrench (C). IDCD411P 7.
Assemble Standard Lift Cylinder 6 2 1 5. Install cylinder rod (6) in the cylinder body. IDCD411P 1. Install seal (2) in the bearing. 2. Install wiper seal (1). Install the seal with the lip toward the outside. C 7 3 IDCD407P 6. Install bearing (7) on the cylinder rod and tighten using wrench (C). 4 IDCD410P NOTE : Install back-up ring (4) with the curved side contacting the O-ring seal. 8 3. Install O-ring seal (3) and back up ring (4) into the bearing. B IDCD406P 7.
Secondary Lift Cylinder Disassemble Secondary Lift Cylinder Tools Needed Hydraulic Cylinder Repair Stand Wrench Assembly A 1 3 B 1 Start By: a. Remove standard lift cylinders. IDCD204P 3. Remove rod (3) from the cylinder body. A 1 5 4 IDCD201P IDCD206P 1. Put standard lift cylinder (1) in position on tool (A). 7 6 4. Remove stop ring (4) from the cylinder rod. B 5. Remove wear ring(5), U-packing(6) and backup ring(7). 2 IDCD203P 2. Remove bearing (2) with tool (B). 10 8 9 IDCD207P 6.
7. Remove ring (11), wear ring (12) and O-ring (13) from the bearing. 16 14 15 IDCD209P 8. Remove wiper seal (14) and retaining ring (15) from the bearing. 9. Remove U-packing (16).
Assemble Secondary Lift Cylinder 10 11 1 2 IDCD206P 13 12 3 5. Install stop rings (10) on the cylinder rod. IDCD209P 6. Install wear ring (11), U-packing (12) and backup ring (13). 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. 14 4 5 IDCD204P 6 7. Install cylinder rod (14) in the cylinder body. IDCD208P 3. Install O-ring (4), wear ring (5) and ring (6) in the bearing.
Primary Lift Cylinder Remove & Install Primary Lift Cylinder Start By: a. Remove carriage. WARNING 3. Pull the cylinder out far enough to disconnect elbow (2). Remove primary lift cylinder. Weight is roughly 27 kg (60 lb). 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.
Disassemble Primary Lift Cylinder Tools Needed A Hydraulic Cylinder Repair Stand 1 Wrench Assembly 4 B 1 Start By: a. Remove primary lift cylinder. IDCD211P 1 4. Remove piston seal (4). 5 6 IDCD210P 1. Remove flow protector valve (1) from the cylinder body. IDCD212P 2 5. Remove retaining ring (5), and check valve (6). A 3 IDCD215P 7 2. Remove rod cover (2) with tool (A). IDCD213P 3. Remove rod (3) from the cylinder body. 6. Remove O-ring (7).
8 9 10 4 IDCD214P IDCD213P 7. Remove wiper seal (8) and retaining ring (9) and Upacking (10) from the rod cover. 3. Install O-ring seal (4). Assemble Primary Lift Cylinder Tools Needed A Hydraulic Cylinder Repair Stand 1 5 B 6 Wrench Assembly 1 2 3 IDCD212P 4. Install check valve (5), retaining ring (6). 1 8 IDCD214P 1. Install U-packing (1) in the rod cover. 7 2. Install wiper seal (2) and retaining ring (3). Install the seal with the lip toward the outside. IDCD211P 5.
10 2 9 A 3 IDCD215P 6. Install cylinder rod (9) in the cylinder body. WARNING 7. Install rod cover (10) on the cylinder body. Use tool (A) to tighten bearing. 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. 11 1. Disconnect the connector (1).
Disassemble & Assemble Tilt Cylinders 4. Remove piston and seal assembly (4) from the cylinder rod. Tools Needed Spanner Wrench 5. Remove head assembly (5). A 1 6 7 Start By: a. Remove tilt cylinder. A 8 1 IDCD423P 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). 2 IDCD421P 10 1. Use tool (A) to remove head (1) from the cylinder body.
11 14 15 16 IDCD253P IDCD426P 9. Remove seal (11) from the spacer. 12. Install seal (14) in the head. Position the lip of the seal toward the inside of the head. 13. Install seal (15). 12 14. Install seal (16) in the cylinder head. Position the lip of seal (16) toward the outside of the cylinder head. 13 12 IDCD425P 10. Remove O-ring seal (12) and back-up ring (13) from the head. 13 IDCD425P NOTE: The curved side of back up ring (13) should contact O-ring seal (12). 14 15.
10 11 9 IDCD258P IDCD424P 16. Install seal (11) in the spacer. 2 8 19. Install seals (10) and O-ring seal (9) on the piston 5 6 4 3 IDCD423P IDCD422P 17. Install spacer (6). 20. Install head assembly (5) on the cylinder rod. 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). 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). IDCD427P 23.
Disassemble & Assemble Master hydraulic Pump for D20/25/30S-5, G20/25/30E-5, G20/25/30P-5 ,GC20/25/30E-5, GC20/25/30P-5 4. Remove a gear assemble (4) from a gear body (5) 1. Remove the eight screw bolts (1). 5. Remove a wear plate (6) from a bottom of gear body. 2. Remove a mounting flange (2) from pump assembly. 6. Remove a seal (7) and a back up gasket (8) from a wear plate. 3. Remove a wear plate (3) from pump assembly.
Disassembly of Pump for D33SC, D35SC, G33P, G35P 7. Remove gear body (9). 1 .Put the unit back side down to your work place. 8. Remove a seal (10) from gear body. 2. Remove all fasteners, bolts and units. 9. Remove a seal (11) from an end block (12). 10. Assemble the pump in the reverse order of disassembly. 3. Put all removed parts on a safe place. Tightening torque of each screw bolt; 34 to 37 N.
4. Remove the mounting flange (1) and gear sets (2) from the bottom of body. 8. Check balance plates, and sealing parts. 5. Remove the snap ring (3). 9. Assemble new sealing parts, the rubber seal first (4), the plastic seal (5) on top. 10. Remove the section seal (6) from the mounting flange (7). 6. Use proper and safe tools for the operation 7. Push out shaft seal Vehicle System 11. Clean all mounting faces of the mounting flange from sealant and dirt.
12. Be careful, avoid mechanical surface damages. 2. Assemble carefully the gear set (3). 13. Clean all mounting faces of body from sealant and dirt. 3. Put the upper balance plate (4) on top of the gear set. Position is rotation sensitive! Assembly of pump for D33SC, D35SC, G33P, G35P 4. Prepare the shaft seal for assembly. Use a proper assembly fixture 1. Assemble the lower balance plate (1) into the body (2), sealing parts can be fixed with grease. Position is rotation sensitive! 5.
6. Press in the shaft seal to bottom of the shaft seal bore. 10. Put a rope of Loctite sealant out side the interlock track on the body (it's for corrosion protection) 7. Assemble the snap ring. 11. Fit an assembly fixture for shaft sea protection to the drive shaft. 8. Check the section seal. Use of a new one is recommended in each case. 12. The assembly fixture should be oiled with clean hydraulic fluid to lubricate the shaft seal lip during assembly. 9. Clean all assembly faces again.
13. Fit the mounting flange careful from top down to the body. Fit the interlock track correct. 14. Remove the shaft seal protection fixture careful. 15. Fit fasteners, bolts or nuts with correct assembly torque.
Steering Wheel Remove & Install Steering Wheel 1 1. Remove cap (1) from the steering wheel. 2 3 2. Remove nut (2) and washer (3) from the steering wheel shaft. Put location marks on the steering wheel and the steering wheel shaft for installation purposes. 3. 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 washer (3) and nut (2).
1. Disconnect (4) tubes and (1) hose assembled to steering unit. Steering Unit Remove & Install Steering Unit 3 Start By: a. Remove covers from steering wheel group 1 . 2 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 system. 2. Remove four bolts (1).
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.
Seal Gland Bushing Spacer Plate Seal IDCD283S Drive 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. IDCD281S 8. Remove drive. 9. Remove spacer plate. 10. Remove seal from housing. Control End Dust Seal Quad Ring Seal Seal Gland Bushing IDCD284S 13. Remove quad ring seal from seal gland bushing. IDCD282S 14.
Needle Thrust Bearing Bearing Race Bearing Race IDCD285S IDCD287S 15. Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly. 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. Seal Pin IDCD286S 16. Remove spool and sleeve assembly from 14 hole end of housing.
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.
Needle Thrust Bearing Pin Bearing Race(2) Seal IDCD292S 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.
Retaining Ring Seal Gland Bushing (with seals) IDCD294S IDCD296S 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. 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.
Seal Groove this Side of Gerotor (Meter) Star Valley Port Face Drive A B Pin Parallel with Port Face Drive (Marked) C D Pin IDCD298S 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 relationship between slotted end of drive to splined end of drive when marking. Pin Port Face IDCD300S 23. With seal side of meter toward spacer plate, align star valleys on drive.
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. Seal Drive Spacer(s) 26. Install end cap on gerotor, align holes. IDCD301P Actual Displacement ㎤/r(in/r) Spacer IDCD302P 3 45 [2.8] 60 [3.6] 75 [4.5] 95 [5.9] 120 [7.3] 145 [8.9] 160 [9.7] 185 [11.3] 230 [14.1] 295 [17.9] 370 [22.6] 460 [28.2] 590 [35.9] 740 [45.1] Vehicle System Length mm [in.] None None None 3.56 [.140] 6.10 [.240] 10.29 [.405] 12.19 [.480] 15.62 [.
Master cylinder 2 Remove & Install Master cylinder NOTE : Plug and cap all openings to avoid contamination and debris from entering the system after removing any tubes or lines. 1. Before disconnecting the lines to master cylinder(1), prepare the proper plugs. 3. Disconnect the yoke (3) from bell crank. 4. Dismount the master cylinder. 5. Install the waster cylinder in the reverse order of removal. 6. Fill the oil reservoir with the correct oil recommended at Operating & Maintenance manual. 7.
Master Cylinder Disassemble & assemble brake valve 1. Take off bellows (4) and lift push rod (3), remove vent air (25) and bolts (28). 2. Separate the front housing (1) and rear housing (2), remove servo spring (10), servo piston (9) and master piston (5). 3. Take off seal u-cup (14) from master piston (5). Notice the direction of the seal.
4. Remove lock washer (6) and ball (7) from servo piston (9). Pull off piston ring (8), seal u-cup (13), seal u-cup (12) and seal u-cup (11) in sequence. Notice the direction of each seal. No Color Material 11 Translucency Urethane 12 Black NBR Hs70 13 Yellow Urethane 5. Remove relief plug (18), o-ring (19), spring (17), shims (16) and piston (15) from front housing (1).
6. Remove check valve parts from rear housing (2): plug (26), o-ring (27), cage (24), spring (23), ball (21) and oring (22). Remove o-ring (20). 7. Assemble brake valve in the reverse order of disassembly.
Steer Wheel & Bearing Cushion truck 4 < Old type before 2008 year truck > Tools Needed Floor Jack Dirver Set Lock Nut Installer A 1 B C 1 5 1 NOTE : The procedure to remove the steer wheels is the same for the right and left steer wheel. 5. Remove bearing cone (4) from steer wheel (5). 6. Remove steer wheel (5). Steer wheel (5) weighs 34 kg (75 lb). 5 1 IDCD072P 6 7 A IDCD070P 1. Support the steer axle with a floor jack (A). IDCD073P 2. Remove wheel cap (1). 7.
Pneumatic Truck and Cushion Truck sice 2008 year 5 Tools Needed A Floor Jack 1 B Torque wrench 1 Lock Nut Installer 8 IDCD074P C 1 NOTE : The procedure to remove the steer wheels is the same for the right and left steer wheel. 9. Remove bearing cup (8) from the front of steer wheel (5). 1. Support the steer axle or CTWT with a proper jack or hoist. NOTE : Check the condition of all seals, bearings and components. If any parts are worn or damaged use new parts for replacement.
6. Remove bearing cone and cup from steer hub. NOTE : Check the condition of all seals, bearings and components. If any parts are worn or damaged use new parts for replacement use tooling (C) to install bearing cups. 4 7. Pack bearing cones, and Iubricate the contact surfaces of the bearing cups with Multipurpose Grease. 3 5. Remove bearing lock nut (3) with the jig (4) like the picture. < Unit : mm > 8. After putting the bearings, put the bearing lock nut (3). 4 9.
a. Use tool (4) to tighten nut (3) to a torque of 135 N•m (100 Ib•ft) while slowly rotating steer wheel. b. Use tool (4) to loosen nut (3) completely. c. Use tool (4) to tighten nut (3) again to a torque of 50±5 N•m (37±4 Ib•ft). 2 1 10. Put the bearing lock washer (2). Check out if two mounting bolt holes are aligned with the holes at bearing lock nut. If it doesn’t match, rotate the bearing lock nut clockwise about, /32 turn. 11. Assemble (2) bolts after Loctite 242 is applied. 12.
Tie Rod Steering Knuckle, Kingpin, and Bearing Remove and Install Tie Rod Tools Needed Floor Jack Driver Set A 1 Remove and Install Steering Knuckle, King Pins and Bearing B 2 Tools Needed Drive Set Start By : a. Remove steer wheels. Start By: NOTE : The procedure to remove and install the tie rod is the same for each steer wheel. a. remove steer wheels A 1 NOTE : The procedure to remove and install the steering knuckles, kingpins, and bearings is the same for both sides of the lift truck.
10 14 11 12 13 IDCD081P 4. Remove four bolts (5) and cover (6). 7. Remove spacer (11), bearing cup (13) and bearing cone (12). 8. Check the condition of lip type seal (14). Replace seal (14) 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 (10). NOTICE Check the condition of all seals, bearings and components. If any parts are worn or damaged use new parts for replacement. 5. Remove the nut (7) and bolt (8).
Steer Axle Remove & Install Steer Axle Tools Needed Jack Stand A 4 WARNING 2 Be sure the pressure in the hydraulic system is released before any lines or hoses have been disconnected. 6. Remove bolts (2) and mounting caps (3) from the steer axle. 3 1 1. Put the lift truck in position with a jacket. 7. Remove steer axle (4). The steer axle weighs approximately 200 kg (440 lb). 2. Disconnect tube (1). Plug and cap all openings to prevent contamination and debris from entering the system.
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. Steering Cylinder Remove & Install Steering Cylinder 9. Seat steer axle (4) as follows: Start By: a. Install bolts (2) through cap (3) and into the mounting bosses approximately two bolt threads. a. Remove steer axle. b. Use the floor jack to raise steer axle (4) into the mounting boss. 1 c. Tighten bolts (2). 2 1.
Disassemble Steering Cylinder Start By : a. Remove steering cylinder. 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. 5. Disassemble each rod cover as follows. a. Remove retaining ring (5) and dust wiper (6). b. Remove U-packing (7). c. Remove O-ring (8) and back up ring (9). d. Remove DU-bush (10). 3. Remove cylinder tube (2) from the rod assembly. 4. Remove piston seal (3) and wear ring (4).
Assemble Steering Cylinder 3. Install cylinder tube (2) on the rod assembly. 4. Install rod covers (1) on cylinder tube (2). 1. Assemble each rod cover as follows ; End By : a. Install DU-bush (10). a. Install the steering cylinder. b. Install back up ring (9) and O-ring (8) c. Install u-packing (7). d. Install dust wiper (6) and retaining ring (5). 2. Install piston seal (3) and wear ring (4).
Universal Joint Counterweight Remove and Install Universal Joint Remove & Install Counterweight Tools Needed Link Bracket 4 A 4 NOTE : Steps 1 through 3 are for L.P. and Gas model machines only. After steps 1 through 4 have been done, the removal procedure is the same for all models. For gasoline model machines, go to step 5. 1. Remove the L.P. fuel tank. Refer to the Operation & Maintenance manual for further information. 1 3 2 IDCD090P 1. Remove four bolts (1). 2.
4 5 NOTE : The following steps are for installation of the counterweight. 4. Remove the washers and bolts (4) and exhaust pipe (5) for the diesel truck. 8. Put counterweight (6) in position on the frame, and install bolt (8) and bolts (9). Tighten the bolts to a torque of 400 ± 60 N·m (300 ± 45 lb·ft). 6 NOTE : This completes the installation of the counter weight for gasoline model machines. For L.P.
Removal and Installation of Drive axle Start by : a. Remove the mast. Refer to the topic of " Mast " in this module for the further information. b. Remove the drive tire. c. Drain the drive axle oil. 4. Disconnect the brake tube. 5. Disassemble the nuts for mounting the drive axle. For the purpose of reassembly, the torque is 460 +/60 N.m (354 +/- 45 lb.ft). 1. Raise the machine and put the rigid block under the frame. To be safe. 2. Disassemble the u-joint.
Removal of Transmission Start by : a. Remove the mast. Refer to the topic of " Mast " in this module for the further information. b. Remove the drive tire. c. Drain the transmission oil. 4. Disconnect the parking cable. d. Disassemble Drive axle. 5. Dismount the front plate. 1. Disconnect two hoses assembled to the hydraulic pump. 6. Disconnect all harnesses, connectors and hoses. 7. After removing the trans. housing cover, disassemble the torque converter plate from the flywheel.
< Unit : mm > < Unit : mm > 11. Dismount the transmission from the engine.
Removal and Installation of Engine Start by : a. Remove the mast. Refer to the topic of " Mast " in this module for the further information. b. Remove the drive tire. c. Drain the transmission oil. d. Drain the engine oil. 3. Dismount the air cleaner and hose to the intake. e. Drain the coolant. 4. Disconnect the battery cable and dismount the battery. f. Disassemble Drive axle. 5. Disconnect LP hose to fuel lock. 1. Dismount the overhead guard, hood and counter weight. 6. Dismount the sub.
7. Disconnect the exhaust tube. 8. Disconnect all harnesses, connectors to the engine. 9. Disconnect the coolant hose to LP regulator. 10. Dismount the assembled transmission and engine together. 11. Discount the transmission from the engine. 12. Reassembly in the reverse order of disassembly. For the purpose of reassembly, the torque of bolts for mounting the transmission is 240 +/- 40 N·m (180 +/- 30 lb·ft). The torque of bolts for mounting the engine is 55 ± 10 N·m (40±8lb·ft) with Loctite # 262.
