GROUP 2 REMOVAL AND INSTALLATION OF UNIT

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

1. MAST
1) REMOVAL

Fork Carriage Piping Mast

(1) Forks
Anchor pin
① Lower the fork carriage until the forks are
approximately 25mm(1in) from the floor. Carriage

② Release fork anchor pins and slide one Backrest

fork at a time toward the center of the
carriage where a notch has been cut in
the bottom plate for easy removal. Fork
③ Remove only one fork at a time.
On larger forks it may be necessary to Center notch
use a block of wood.
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(2) Backrest(If necessary)

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

D255RE03

(3) Carriage
① 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.
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¤Ł While supporting lift chains, remove the
nuts from the chain anchors of stationary Lift chain
upright.
Outer mast

Nut
L255RE05

③ Pull the chains out of the sheaves and

Mast
drape them over the front of the carriage.

Carriage &
backrest

Lift chain

Block
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④ Slowly raise inner mast upright until mast

clears top of fork carriage. Move carriage
to work area and lower the mast. Inner mast

Make sure that carriage remains on

floor and does not bind while mast is
being raised.
⑤ Inspect all parts for wear or damage.
Carriage & backrest
Replace all worn or damaged parts.

Lift chain
L255RE07
(4) PIPING
① Remove the return hoses and clamps
attached to the cylinder.
② Remove the return hoses from the
connector. Band
clamp Hose
clamp
③ Remove hose assembly, connector,
Return
down safety valve from the lift cylinder. hose

④ Disconnect hose assembly from the flow

regulator. Lift
cylinder Return
hose

L255RE08

(5) LIFT CYLINDER

① Loosen hexagonal bolts and remove Inner
washers securing the lift cylinders to mast Stud
bolt
inner mast.
② Bind the lift cylinder with overhead hoist
rope and pull up so that the rope has no
slack or binding.
Make sure that the lift cylinder be
tightened firmly for safety.
Cylinder Outer
③ Loosen and remove hexagon nuts and band mast
cylinder band securing cylinder to outer
mast.
④ Using an overhead hoist, slowly raise the
inner mast high enough to clear lift
cylinder.
⑤ Using an overhead hoist, draw out lift
cylinder carefully and put down on the Lift cylinder
work floor. L255RE09
(6) INNER MAST
① 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.

Inner
mast
Outer
mast

L255RE10

(7) MAST SUPPORT CAP

① Attach a crane to the stay at the top of
the outer mast, and raise enough to
sustain jacked up machine.
※ This operation is carried out from
under the machine, so use a pit, or if
there is no pit, jack up the machine Outer
mast
and loosen with on impact wrench.
② Remove the mounting bolts from the cap
then slowly raise the outer mast.
Tilt cylinder
(8) TILT CYLINDER PIN
① Loosen the bolt and remove the pin.

Pin

Mounting bolt

Mast
support cap
Bushing
L255RE11
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) MAST SUPPORT CAP
① Check the mast support cap and spring pin for wear.
② Jack up the machine so that the front is raised and then using an overhead hoist assemble outer
mast to drive axle unit.
③ Tighten mounting bolts to mast support cap. Coat the loctite(#277).
·Tightening torque : 19.9~26.9kgf·m(144~195lbf·ft)
(2) TILT CYLINDER PIN
Hold the mast with a crane, operate the tilt control lever and aligh the holes, then knock the pin.
(3) LIFT CYLINDER INSTALLATION AND ADJUSTMENT
① 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.
② 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. POWER TRAIN ASSEMBLY
1) REMOVAL

B153RE00

(1) Mast
Refer to section on mast.

(2) Brake piping and T/M cooling piping

Disconnect the brake pipes and T/M Brake
cooling pipes from powerline assembly. Brake master
pipe cylinder

Powerline T/M cooling

assembly pipe
D255RE13

(3) Parking brake cable

Disconnect parking brake cable from the Parking brake
cable Parking brake
wheel brake assembly. lever

Wheel
brake(RH)
Wheel
brake(LH)
L255RE14

(4) Dashboard
Loosen hexagonal bolts and remove
dashboard.

Bolt

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 (5) Flexible plate
Remove the cover on the top face of the T/C cover
torque converter housing then remove the
Mounting
8 mounting bolts installed to the engine bolt
flywheel.
To rotate the flywheel, remove 1 mounting Engine
bolt, then insert a turning tool in the
mounting hole. One man must turn the
engine fan by hand while the other turns Powerline
assembly
the flywheel.
L255RE15

(6) Powerline assembly

Crane
Mounting
① Attach a crane to the front frame and bolt
raise the machine enough for truck to
slide under powerline assembly. Powerline
assembly
② Put the block between the truck and
powerline assembly. Frame
③ Remove support cap bolts from the Support cap
Truck
frame and then slowly pull out the truck.
L255RE16

2) INSTALLATION
Installation is the reverse order of removal,
Crane
but be careful of the following points.
(1) Tightening torque of mounting bolt for Mounting
powerline assembly. T/C cover bolt(1)
·Bolt(1) : 2.7~4.1kgf·m(19.5~29.7lbf·ft)
Bolt(2) : 5.9~8.9kgf·m(42.7~64.4lbf·ft)

Frame
Support cap

Mounting bolt(2)
Powerline
assembly
L255RE17
3. ENGINE
Lever the torque converter, transmission and drive axle inside the frame, the remove the engine
assembly.
1) REMOVAL
(1) Overhead guard
Remove the wiring for rear combination
lamp, working lamp, head lamp and Crane

flasher lamp on the stay of the overhead

guard and then raise it together with the
bonnet.
Overhead guard

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(2) Floor plate

Uncover the floor mat first and then
remove the floor plate.
Floor mat

Floor plate

Frame

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(3) Engine accessory
Overflow
Remove all wiring harnesses, cables and Reservoir hose
hoses among the engine, dashboard and tank
Radiator
frame.
Hose
① Wiring harness to alternator and starter.
Engine
② Wiring harness for oil pressure and assembly
engine water.

Hose

L255RE20

(4) Radiator hose

Open the drain valve of the radiator and
drain the cooling water, then remove the
radiator hose.

(5) Mounting bolt

Mounting
Attach a crane to the engine hook and bolt
raise, then remove the left and the right
mounting bolts. Raise the engine slightly,
sliding towards the radiator, then lift up.
※ When sliding the engine, if it hits the
radiator it will damage the radiator, so it
is better to remove the radiator if
possible.
Engine assembly

L255RE21
2) INSTALLATION
A 5.9~8.9kgf m
Installation is in the reverse order to (42.7~64.4lbf.ft)

removal, but be careful of the following

points.
(1) Tighten the engine mounting bolts(A) and
nuts.
2.7~4.1kgf.m
(2) Tighten the engine mounting bracket bolts. (19.5~29.7lbf.ft)

Do not remove the bolts unless necessary. A

7.5kgf.m
※ Loctite is coated on the thread of bolt. (54.2lbf.ft)
5.9~8.9kgf.m
So if the bolts must be removed, coat (42.7~64.4lbf.ft)

the loctite(#243) when installing.

※ Before installing the bolts, loctite in the L255RE22
holes should be removed by a tap.

(3) Radiator hoses

·Distance to insert hose : 40mm(1.57in)
(4) Air cleaner hose
Insert the air cleaner hose securely and fit
a clamp. Air cleaner
Distance to insert hose Muffler

·Air cleaner hose : 40mm(1.57in)

·Engine end : 20mm(0.8in)

Engine assembly

L255RE23
4. WHEEL BRAKE
1) REMOVAL
(1) Front wheel
Put a block under the mast and tilt
forward, or jack up the bottom of the frame
to raise the front wheels off the ground,
then loosen the hub nuts to remove
wheels.

Hub nut

D255RE24

(2) Brake, drum assembly

The oil seal inside the hub acts as a seal
for the axle shaft end. Therefore when
removing or installing the brake and drum
assembly, remove or install in a straight Wheel brake
line to prevent twisting the seal up and Drum
down or to the right and left. Oil seal
Bearing
Hub
D255RE25

2) INSTALLATION
Installation is in the reverse order to
Wheel brake
removal, but be careful of the following
points.
Drive axle
(1) Coat the mounting bolts with loctite and
tighten to 19.6kgf·m(141lbf·ft).

Drum
Mounting bolt
D255RE26

(2) When replacing the oil seal inside the hub,

be careful to install the seal in the correct
direction(Lip on outside) and knock into
place.

L15C3RE27
(3) Wipe the inside of the brake drum clean,
coat the lip of the seal with grease, and
assemble the brake and drum assembly.
Adjust a spring balance to the hub bolt
Spring balance
and adjust the nut to give a starting force
of 12 to 20kgf(27~44lbf).
Measuring starting
torque

L15C3RE28

(4) Tightening torque of hub nut for front

wheel.
·25~30kgf·m(181~217lbf·ft)
Coat the hub bolt with molybdenum
disulphide.
5. REAR AXLE
1) REMOVAL

Mounting bolt

(Loctite #277)

Counterweight

L255RE29

(1) Counterweight
Install a lifting tool in the hole in the counterweight, and raise it with a crane.
Remove the mounting bolts and raise the counterweight slightly and move it to the rear side.
·Weight of counterweight(standard)
HLF20-5 1170kg(2580lb) HLF20C-5 1080kg(2380lb)
HLF25-5 1470kg(3240lb) HLF25C-5 1460kg(3220lb)
HLF30-5 1800kg(3970lb) HLF30C-5 1900kg(4190lb)
(2) Rear wheels
※ Before removing rear wheels lift up the
rear side with a crane or jack up. Rear wheel
Remove cap, split pin and then loosen Castle nut
castle nut.
Take out rear wheel assembly with Taper
roller
taper roller bearing and oil seal. bearing

Cap
L255RE30

(3) Hose
Drain hydraulic oil in the hoses and
cylinder before removing them.

S
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S

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Loosen long connector and then

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cy
lin
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disconnect the hoses.

Hose

L255RE31

(4) Mounting bolts

Trunnion
Put a block under the steering axle, block
support on a truck and raise the frame Truck

with a crane.
Remove the mounting bolts installed to
S
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er
in
g

the frame, and pull out to the rear.

S

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cy
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※ There are shims between the trunnion

r

block and the steering axle to prevent

play.
L255RE32