GROUP 2 REMOVAL AND INSTALLATION OF UNIT

Remove and install following units as explained in the flow chart.

1. MAST
1) REMOVAL

Backrest & fork Carriage Piping Mast

(1) Backrest
Remove bolts securing backrest to fork Backrest
carriage. Lift backrest straight up and
remove it from carriage.
Carriage Bolt

Fork

BR147RE02

(2) Forks
Fork set pin
Remove shaft cover and bolt.
Remove fork set pin and then draw out
the shaft. Shaft
Carriage
Carefully remove forks one by one.

Fork

Cover
Bolt
BR147RE03

(3) Carriage
With the mast vertical, raise the carriage
high enough to place blocks under the
load forks. This is done to create slack in
the load chains when the carriage is
lowered. Lower the carriage all the way
down to the floor. Make sure the carriage
is level, this will prevent any binding when
the mast is raised.
BR147RE04

2-2
While supporting lift chains, remove the
Lift chain
split pins and slide out chain anchor pins
from the chain anchors of stationary Outer mast
upright.

Nut
BR147RE05

Pull the chains out of the sheaves and

Mast
drape them over the front of the carriage.

Carriage

Lift chain

Block
BR147RE06

Slowly raise inner mast upright until mast

clears top of fork carriage. Move carriage
Inner mast
to work area and lower the mast.
Make sure that carriage remains on
floor and does not bind while mast is
Lift chain
being raised.
Inspect all parts for wear or damage.
Replace all worn or damaged parts.

Carriage

Block

BR147RE07

2-3
(4) PIPING
Remove the return hoses and clamps Inner mast
attached to the cylinder.
Remove the return hoses from the
connector.
Remove hose assembly, connector, Return
hose
down safety valve from the lift cylinder.
Band
Disconnect hose assembly from the flow clamp Hose
clamp
regulator. Lift TO MCV
cylinder

BR147RE08

(5) LIFT CYLINDER

Loosen hexagonal bolts and remove
Inner mast
washers securing the lift cylinders to
inner mast.
Bind the lift cylinder with overhead hoist Shim
rope and pull up so that the rope has no
slack or binding.
Make sure that the lift cylinder be
Cylinder
tightened firmly for safety. band
Loosen and remove hexagon nuts and Outer mast
cylinder band securing cylinder to outer
mast. Lift
Using an overhead hoist, slowly raise the cylinder
inner mast high enough to clear lift
cylinder.
Using an overhead hoist, draw out lift
cylinder carefully and put down on the
work floor.
BR147RE09

2-4
(6) MAST REMOVAL
Crane
Pass wire rope around the inner and
outer masts to allow lifting them out with
a hoist.
Remove the stopper pin at the end of
reach cylinder and then remove the
stopper bolt at the end of guide rail. Mast
Draw out the mast from the guide rail with
Wire rope
lifting up.
Lower the mast and place it on stand.

Draw out

Stopper pin

Stopper bolt

BR147RE10-1

(7) INNER MAST

Using an overhead hoist raise the inner
mast straight and carefully draw out of
outer mast section.
Be careful the mast not to swing or fall.
Using an universal puller, remove the
load rollers.
Inner mast

Outer mast

Outer mast
stopper
bracket

Load roller

BR147RE10

2-5
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
Installation procedure for each of mast component is the reverse of the removal procedure.
(1) LIFT CYLINDER INSTALLATION AND ADJUSTMENT
Assemble the lift cylinder inside the outer
mast, then tighten the stopper bolt. If the
cylinder assembly has been replaced,
adjust as follows so that the left and right
cylinders are synchronized at the
maximum lifting height.
Assemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
If play is to LEFT, install adjustment
shim to LEFT cylinder.
If play is to RIGHT, install adjustment
L15C3RE12
shim to RIGHT cylinder.
Shim thickness : 1.0mm(0.04in)

2-6
2. POWER TRAIN ASSEMBLY
1) REMOVAL

BR147RE001

(1) Disconnect the battery cable and then pull

out the battery to battery stand or carrier.

Battery
Disconnect
battery
Battery cable
stand or
carrier BR147RE12

(2) Remove steering joint parts.

Sprocket

Pin

Universal joint

BR147RE13

(3) Disconnect the hose, pipe and wiring from

pump & motor assembly. Pump & motor assembly

Loosen mounting nuts from the bracket

and then take out the assembly. Wiring
Hose
Pipe

To hyd tank

To MCV
Mounting nut
BR147RE15

2-7
(4) Remove brake cable. Brake cam

Wrench

Brake cable
BR147RE16

(5) Disconnect the wiring.

Drive motor
Drive motor wiring
EPS motor wiring.

EPS
motor

BR147RE17

(6) Jack up the frame and support both side

of frame on wood block.

BR147JB09

(7) Remove the support bolts and pull out the

link pins.
When removing link pins, use care not
to damage link pin. Link pin

Wrench Link pin

Bolt Link pin

BR147RE18

2-8
 (8) Remove drive unit assembly from frame
by lifting. Wire rope

Drive unit
assembly
BR147RE19

2) INSTALLATION
Installatron is in the reverse order to
removal, but be careful of following points.
(1) Link pin support bolts. Link pin
Tightening torque : 4.0~6.0kgf m
Wrench Link pin
(28.9~43.4lbf ft)

Bolt Link pin

BR147RE18

(2) Hyd pump & pump motor mounting.

Tightening torque : 4.0~6.0kgf m Pump & motor assembly
(28.9~43.4lbf ft)
Wiring
Hose
Pipe

To hyd tank

To MCV
Mounting nut
BR147RE15

2-9
3. ELECTRICAL COMPONENTS
Before removing each component, disconnect cables and earth lines attached to the component.
1) REMOVAL

BR147RE002

(1) PUMP MOTOR

Disconnect the battery cable and then
pull out the battery to battery stand or
carrier.
Battery
Disconnect
battery
Battery cable
stand or
carrier BR147RE12

Remove side door.

Side door

BR147RE20

2-10
 Disconnect the hose, pipe and wiring
from pump & motor assembly. Pump & motor assembly

Loosen mounting nuts from the bracket

and then take out the assembly. Wiring
Hose
Pipe

To hyd tank

To MCV
Mounting nut
BR147RE15

Remove 2 socket bolts fastening the

Pump & motor assembly
pump & motor and then disengage the
pump from motor.

Socket bolt
BR147RE21

(2) DRIVE MOTOR

Disconnect the battery cable and then
pull out the battery to battery stand or
carrier.
Battery
Disconnect
battery
Battery cable
stand or
carrier BR147RE12

Remove side door.

Side door

BR147RE20

2-11
Remove brake cable. Brake cam

Wrench

Brake cable
BR147RE16

Disconnect wirings. Drive motor

a. Drive motor wiring
b. EPS motor wiring

EPS
motor

BR147RE17

Remove bolts connecting the motor and

drive unit.

Bolt

BR147RE22

Tie wire rope around the drive motor and Wire rope
lift up slowly.

BR147RE23

2-12
 Put the motor on the clean work bench.

BR147RE24

(3) EPS MOTOR

Disconnect the battery cable and then
pull out the battery to battery stand or
carrier.

Battery
Disconnect
battery
Battery cable
stand or
carrier BR147RE12

Remove side door.

Side door

BR147RE20

Disconnect wirings.

EPS
motor

BR147RE25

2-13
 Loosen bolts and remove EPS motor
assembly.
EPS
motor

BR147RE26

(4) BATTERY ASSEMBLY

When the spare battery is used for
continuous operation or it is required to
check the battery, motor, etc., remove the
battery through the following procedure: Disconnect

Disconnect the battery connector.

BR147OM120

Put the battery stand to the battery

stopper side.

Battery
stand

BR147OM133

Disengage the battery stopper pin and

remove battery cover from side frame.

Pin

Battery Battery
stand cover
BR147OM134

2-14
Adjust the height of the roller of the stand
to that of the roller of the vehicle.
Slide the battery to the stand.

Battery

Battery
stand
BR147OM139

The same procedure is applied when the

optional battery carrier is used.

Battery

Battery
carrier
BR147OM135

2-15
2) INSTALLATION
Installation is in the reverse order to
removal, but be careful of following points.

(1) PUMP MOTOR

Pump & motor assembly
Pump motor mounting nut.
Tightening torque : 4.0~6.0kgf m
(28.9~43.4lbf ft)
Hydraulic pump mounting bolt
Tightening torque : 4.0~6.0kgf m
(28.9~43.4lbf ft)

Socket bolt
BR147RE21

(2) DRIVE MOTOR

Connetion bolts between drive motor and
drive unit.
Tightening torque : 1.8~2.2kgf m
(13~16lbf ft)

Bolt

BR147RE22

(3) EPS MOTOR

EPS motor mounting bolts.
Tightening torque : 1.8~2.2kgf m EPS
(13~16lbf ft) motor

BR147RE26

2-16
4. CASTER LINK ASSEMBLY

BR147RE003

1) REMOVAL
(1) Disconnect the battery cable and then pull
out the battery to battery stand or carrier.

Battery
Disconnect
battery
Battery cable
stand or
carrier BR147RE12

(2) Remove floor mat and floor plate.

Floor mat

Floor plate

BR147RE28

(3) Remove inspection cover by loosening the

screw.

Inspection
cover

Screw
BR147RE29

2-17
(4) Remove bolt, pin, spring and brake cable
to remove the brake pedal assembly. Brake
cable

Spring

Pin
Brake Bolt
pedal
BR147RE30

(5) Remove lock nut from the top end of

Lock
support bolt for spring at caster side(lower nut
side).
Spring and support bolts are dropped
Caster
down. assy
Spring

Support
bolt
BR147RE31

(6) Remove lock bolt for No.3 link pin(lowest

one) and pull out the link pin by punching
from the battery store place. Bolt
(7) Jack up the rear side of frame and remove No.3 Link pin
the caster assembly.

Caster assy

BR147RE32

2-18
2) INSTALLATION
Installation is in the reverse order to
removal, but be careful of the following
points.
(1) No.3 link pin(lowest one) fixing bolt.
Tightening torque : 2.0~3.0kgf m Bolt
(14.5~21.7lbf ft)
No.3 Link pin

Caster assy

BR147RE32

(2) Lock nut fixing the support bolt.

Lock
Tightening torque : 12~15kgf m nut
(87~109lbf ft)

Caster
assy
Spring

Support
bolt
BR147RE31

2-19
5. TIRE & WHEEL ASSEMBLY
1) REMOVAL
(1) DRIVE TIRE & WHEEL ASSEMBLY
Jack up the frame
Jack up until the tire clear off the
ground.

BR147JB09

Remove 6 flange bolts attaching the

drive wheel and take off the drive wheel
assembly.

Flange
bolt

Drive wheel assy

BR147RE33

(2) CASTER WHEEL ASSEMBLY

Remove floor mat and floor plate. Floor mat

Floor plate

BR147RE28

Remove the end cover at upper end of

steering shaft.

End cover

Caster assy

BR147RE34

2-20
 Remove bolt and take out the steering
shaft & caster wheel assembly from axle
fork. Bolt

Axle fork
Steering shaft
& caster wheel assy
BR147RE35

Remove remained bearing from the axle

fork.

Axle fork
Bearing
Bearing cover

BR147RE36

(3) LOAD WHEEL ASSEMBLY

Jack up the reach legs and fix the
machine with blocks.

Jack up

Block BR147RE37

Take off the load wheel cap, and remove

castle nut, and claw washer in success-
ion.
Remove the load wheel together with
Load wheel with
bearing. bearing
Claw washer

Bolt
Castle nut
Wheel cap
BR147RE38

2-21
2) INSTALLATION
Installation is in the reverse order to removal,
but be careful of the following points.
(1) Drive wheel flange bolts
Tightening torque :
HBR14/15/18-7 : 19~22kgf m
(137~159lbf ft)
HBR20/25-7 : 13.5~15.5kgf m
(98~112lbf ft)
Flange
bolt

Drive wheel assy

BR147RE33

(2) Caster wheel bolts.

Tightening torque : 8~12kgf m
(58~87lbf ft)
Bolt

Axle fork
Steering shaft
& caster wheel assy
BR147RE35

(3) Load wheel bolts.

Tightening torque : 4.5~5.5kgf m
(33~40lbf ft)

Load wheel with

bearing
Claw washer

Bolt
Castle nut
Wheel cap
BR147RE38

2-22