Daewoo D40S-2 Disassembly/Assembly

Disassembly &

Assembly

Lift Trucks Vehicle Systems

D35S-2, D40S-2, D45S-2

D40SC-2, D45SC-2, D50SC-2

G35S-2, G40S-2, G45S-2

G40SC-2, G45SC-2, G50SC-2

SB2204E00

Jun. 1999

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety

rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an

accident occurs. A person must be alert to potential hazards. This person should also have the necessary

training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,

maintenance and repair on this product.

Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety

precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.

Specific safety warnings for all these publications are provided in the description of operations where hazards

exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.

If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in

this publication and on the product labels are identified by the following symbol.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result

in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and

understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this

publication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in

this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating

technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and

others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,

maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the

time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other

items can change at any time. These changes can affect the service given to the product. Obtain the complete

and most current information before starting any job. DAEWOO dealers have the most current information

available.

WARNING

1

Vehicle Systems Index

Index

Brake Hydraulic Booster..........................................21

Counterweight..........................................................36

Engine......................................................................39

Hood Assembly..........................................................5

Hydraulic Control Valve ...........................................27

Hydraulic Oil Filter Assembly...................................37

Hydraulic Pump .......................................................33

Overhead Guard ........................................................6

Primary Lift Cylinder ................................................12

Secondary Lift Cylinders............................................9

Steer Axle ................................................................23

Steering Cylinder .....................................................24

Steering Knuckles, Kingpins And Bearings .............22

Steering Unit ............................................................15

Steering Wheel ........................................................15

Tie Rods...................................................................21

Tilt Cylinders ..............................................................7

Tires And Rims (Steer) ............................................26

Transaxle .................................................................37

3

Vehicle Systems Disassembly & Assembly5

Disassembly & Assembly

Hood (with seat) Assembly

Remove & Install Hood (with seat)

Assembly

The hood and seat assembly can fall when nut (1)

is removed from the support cylinder rod. To avoid

personal injury, support the seat and hood

assembly before removing nut (1).

1. Raise the hood. Support the hood with a hoist.

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

the cylinder rod from the bracket.

3. Lower the hood.

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

cover.

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

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

and seat assembly (4). The hood and seat

assembly weighs 52 kg (115 lb).

7. Install the hood and seat assembly in the reverse

order of removal.

WARNING

IACD201P

IACD202P

IDCD054P

IACD203P

1

3

5

4

2

Vehicle Systems Disassembly & Assembly

Overhead Guard

Remove & Install Overhead Guard

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

a hoist.

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

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

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

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

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

6. Remove rear Leg (5).

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

the reverse order of removal.

6

IDCD055P

IDCD056P

IDCD057P

IDCD058P

1

3

4

5

2

Vehicle Systems Disassembly & Assembly

Tilt Cylinders

Remove & Install Tilt Cylinders

NOTE : The procedure for removing and installing

the tilt cylinders is the same for both cylinders.

If both tilt cylinders are removed at the same time

the mast can fall. To avoid possible personal

injury, make sure the mast is securely held in

place or supported by a hoist before removing the

tilt cylinders.

To prevent personal injury, move the control

levers backward and forward to release any

pressure in hydraulic system. Slowly loosen the

cap of the hydraulic tank to release any pressure

in the tank. Be cautious of hot hydraulic oil when

any lines are disconnected in the hydraulic

system.

1. Disconnect elbow (2). Remove retainer bolt (3)

and pin (1).

2. Remove retainer bolt (6) from pin (5). Remove pin

(5).

3. Remove tilt cylinder (4).

4. Install the tilt cylinder in the reverse order of

removal.

WARNING

7

IACD204P

IACD205P

2

6

5

4

3

1

Vehicle Systems Disassembly & Assembly

Disassemble & Assemble Tilt

Cylinders

Start By:

a. Remove tilt cylinder.

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

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

using a spanner wrench.

NOTICE

Use extra care not to damage the highly finished

surface of the cylinder rod and the bore of the clylinder

tube during disassembly and assembly of the tilt

cylinder.

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

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

cylinder rod (4).

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

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

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

the piston.

8

ICCD002P

ICCD003P

ICCD005P

ICCD006P

ICCD004P

1

4

8

10

9

2

3

4

7

6

5

Vehicle Systems Disassembly & Assembly

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

from the rod cover (2).

9. Remove wiper seal (13), backup ring (14), U-

packing (15) and DU-bush (16) from the rod cover.

NOTE : Assemble the tilt cylinder in the reverse

order of disassembly.

Secondary Lift Cylinders

Disassemble Secondary Lift

Cylinders

Start By :

a. Remove secondary lift cylinders.

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

2. Remove head assembly (2) with tool.

9

ICCD007P

ICCD008P

11

12

16

15

14

13

2

Vehicle Systems Disassembly & Assembly

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

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

cylinder rod.

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

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

(9) from the piston.

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

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

from the head assembly.

10

Vehicle Systems Disassembly & Assembly

Assemble Secondary Lift

Cylinders

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

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

toward the outside.

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

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

on the piston.

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

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

cylinder rod.

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

11

Vehicle Systems Disassembly & Assembly

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

tighten using tool.

End By :

a. Install secondary lift cylinders.

Primary Lift Cylinder

Remove & Install Primary Lift

Cylinder

Start By :

a. Remove carriage.

To prevent personal injury, move the control

levers backward and forward to release any

pressure in hydraulic system. Slowly loosen the

cap of the hydraulic tank to release any pressure

in the tank. Be cautious of hot hydraulic oil when

any lines are disconnected in the hydraulic

system.

1. Fasten nylon straps and hoist to the primary lift

cylinder.

2. Remove bolt (1).

3. Pull the cylinder out far enough to disconnect

hydraulic hose (2). Remove primary lift cylinder

(3).

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

of removal.

End By :

a. Install carriage.

WARNING

12

Vehicle Systems Disassembly & Assembly

Disassemble Primary Lift Cylinder

Start By :

a. Remove primary lift cylinder.

1. Remove bearing (1).

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

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

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

the bearing.

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

and rings (9) from the bearing.

13

Vehicle Systems Disassembly & Assembly

Assemble Primary Lift Cylinder

1. Install back-up ring (7) and seal (8) in the bearing.

Install the seal with the lip toward the inside.

2. Install wiper seal (6). Install the seal with the lip

toward the outside.

3. Install rings (9) in the bearing.

NOTE : Install the back-up ring with the curved side

contacting the O-ring seal.

4. Install the back-up ring (5) and O-ring seal (4) on

the bearing.

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

6. Install cylinder rod (2) in the cylinder body.

7. Install bearing (1) on the cylinder body. Tighten the

bearing (1).

End By :

a. Install primary lift cylinder.

14

Vehicle Systems Disassembly & Assembly

Steering Wheel

Remove & Install Steering Wheel

1. Remove cap (1) from the steering wheel.

2. Remove nut (2) and cup (3) from the steering

wheel shaft. Put location marks on the steering

wheel and the steering wheel shaft for installation

purposes.

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

from the shaft.

NOTE : Use the following steps to install the steering

wheel.

4. Put the steering wheel on the steering wheel shaft

in its original position.

5. Install cup (3) and nut (2). Tighten nut (2) to a

torque of 80

L 7 N¥m (60 L 5 lb¥ft).

6. Install cap (1).

Steering Unit

Remove & Install Steering Unit

Start By:

a. Remove steering wheel.

1. Open the access cover for the fuse panel.

Remove horn switch and open the top cover.

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

switch (3) off of steering column (2). Set switch (3)

aside, clear of the steering column.

15

IACD208P

IACD206P

IACD209P

IDCD064P

1

2

1

3

2

3

3. Remove two bolts (4).

To prevent personal injury be sure pressure in the

hydraulic system has been released before

disconnecting any hydraulic lines. Slowly loosen

the cap of the hydraulic tank to release any pressure

in the tank. Be cautious of hot hydraulic oil when

any lines are disconnected in the hydraulic system.

NOTE : Identify and mark all hydraulic hoses for

purposes of reassembly.

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

NOTICE

Steering unit (5) and column (2) can separate after

bolts (4) have all been removed, causing unit (5) to

fall. To avoid damaging components, support the

steering pump while removing bolts (4).

5. Support steering unit (5) while removing the

remaining two bolts (4). Remove steering unit (5)

and steering column (2).

6. Install the steering unit in the reverse order of

removal.

End By :

a. Install steering wheel.

Disassemble & Assemble Steering

Unit

Start By :

a. Remove steering unit from the truck.

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

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

NOTICE

Make a note of the position of special bolt with a pin.

It is located at a mark in line with check valve.

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

unit body (2).

WARNING

Vehicle Systems Disassembly & Assembly16

ICCD079P

ICCD080P

1

5

3

2

4

IACD210P

4

5

Vehicle Systems Disassembly & Assembly

4. Remove the components from housing (3) as

follows:

a. Remove plate (6) from housing (3).

b. Remove shaft (7) from gerotor (9).

c. Remove gerotor (9) from housing (3).

d. Remove O-rings seal (8) from housing (3).

e. Remove O-ring seal (10) from cap (4).

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

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

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

(2).

8. Remove sleeve (16) from the body.

9. Remove the components from sleeve (16) as

follows :

a. Remove pin (18) from spool (17) and sleeve

(16).

b. Remove spool (17) from sleeve (16).

c. Remove two bearing races (19), (20) and

bearing (21) from spool (17).

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

spool (17).

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

body.

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

Replace seals with new if worn or damaged.

17

ICCD081P

ICCD082P

ICCD083P

ICCD086P

ICCD084P

ICCD085P

9

7

6

10

17

16

23

17

22

21

19

4

12

14

11

2

16

25

26

24

15

13

3

8

18

23

20

Vehicle Systems Disassembly & Assembly

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

unit body.

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

(2).

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

from the body.

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

body.

NOTE : The following steps are for assembling the

steering pump.

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

unit body.

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

pump body.

18. Install spring (32) and plug (31) into body (2).

Tighten plug (31) to a torque 50 N¥m (37 lb¥ft).

19. Install washer (28) and plug (27) into body (2).

Tighten plugs to a torque 30 N¥m (22 lb¥ft).

18

ICCD087P

ICCD088P

ICCD089P

27

2

35

32

31

34

ICCD088P

2

35

32

31

34

28

ICCD087P

27

28

36

37

ICCD089P

36

37

Vehicle Systems Disassembly & Assembly

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

with king-ring (25) into body.

NOTICE

For purposes of installation, note that springs (23) are

installed in two stacks of three. Make sure the curves

of the two stacks are in contact and positioned in the

center of spool (17). The notched side of springs (23)

must be positioned toward sleeve (16).

21. Install springs (23) into spool (17).

22. Install spool (17) into sleeve (16).

23. Install pin (18), ring (22), two bearing races (19),

(20) and bearing (21) in their original positions on

spool (17).

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

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

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

Tighten the screw (13).

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

their original positions into the steering unit body.

19

ICCD086P

25

26

24

ICCD085P

17

22

21

19

18

23

20

ICCD084P

16

23

17

ICCD082P

ICCD083P

12

14

11

2

16

15

13

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Daewoo D40S-2 Disassembly/Assembly

Daewoo D40S-2 Disassembly/Assembly

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