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
Η Lower the fork carriage until the forks are
Cylinder
approximately 25mm(1in) from the floor. retainer pin Carriage
Θ Release fork retainer and remove cover. Fork
Slide one hanger bar at a time out of retainer pin
carriage assembly.
Fork
Ι Remove only one fork at a time.
ö On larger forks it may be necessary to
use a block of wood.

180D7ERE51

(2) CARRIAGE
Crane
Η 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
Block
carriage is level, this will prevent any
binding when the mast is raised.

180D7ERE53

Θ While supporting lift chains, remove nuts

from the anchor bolt.
Inner mast

Lift chain

Anchor bolt

Outer mast
Nut
Split pin

Carriage
180D7ERE54

2-2
Ι Pull the chains out of the sheaves and
drape them over the front of the carriage.
Inner mast

Outer mast
Work lamp assy

Lift
chain

Block

180D7ERE55

Κ Slowly raise inner mast upright until mast

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

Block

Lift
chain

Carriage

180D7ERE56

2-3
(3) PIPING
Η Remove the hoses and clamps attached
to the cylinder.
ö Put blind plugs in the piping immediately
after removing hoses. Inner mast

This prevents the hydraulic oil from

flowing out and also prevents dust and
dirt from getting in.

Lift cylinder

Outer mast

Outer mast

180D7ERE57

Ι Remove the lubrication pipes and

Outer mast
clamps.

Pipe

Pipe

180D7ERE571

2-4
(4) LIFT CYLINDER
180D-7E V400~V500 180D-7E V550~V700
Η Loosen and remove hexagon bolts and
washers securing lift cylinders to inner
mast.
Θ Bind the lift cylinder with overhead hoist
rope and pull up so that the rope has no
slack or binding.
Make sure the lift cylinder be tightened
firmly for safety.
Ι Loosen and remove hexagon bolts and Inner mast
nuts securing lift cylinders to outer mast.
Κ Using an overhead hoist, slowly raise the
inner mast high enough to clear lift
cylinder.
Λ Using an overhead hoist, draw out lift Lift
cylinder
cylinder carefully and put down on the
work floor.

Outer mast

180D7ERE58

2-5
(5) INNER MAST
Η Using an overhead hoist raise the inner
mast straight and carefully draw out of Inner mast
outer mast section.
Be careful the mast not to swing or
fall.

Outer mast

180D7ERE59

(6) TILT CYLINDER PIN

(7) MAST SUPPORT PIN Outer mast

Attach a crane to the stay at the top of the

outer mast, and raise it.
Tilt cylinder
Remove the mounting bolts and pins from
drive axle, then slowly raise outer mast.
ö This operation is carried out under the Tilt cylinder pin
machine, so use a pit, or if there is no pit,
jack up the machine and loosen with an Mast mounting pin
impact wrench.

180D7ERE60

2-6
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
ö Installation procedure for each of mast component is the reverse of the removal procedure.
(1) MAST SUPPORT PIN
Check the mast support pins for wear, then install pins into the mast support bracket and drive
axle.
(2) TILT CYLINDER PIN
Hold the mast with a crane, operate the tilt control lever and align the holes, then knock the pin.
(3) LIFT CYLINDER INSTALLATION AND ADJUSTMENT
Η 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 maxi-
mum lifting height.
Θ Assemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
ö If play is to LEFT, install adjustment shim
to LEFT cylinder.
ö If play is to RIGHT, install adjustment
D503RE03
shim to RIGHT cylinder.
ÂShim thickness : 1.0mm(0.04in)

2-7
2. POWER TRAIN ASSEMBLY
1) REMOVAL

Mast

Brake piping

Drive axle
Mounting bolts
holding to engine
flywheel
Inching
harness

T/M & axle cooling

Floor plate
piping

Flexible plate
mount bolt

100D7RE04

(1) Mast
Refer to section on mast(Page 2-2)

2-8
(2) Brake piping
Disconnect the brake hydraulic hoses Brake hose
Return
from the brake housing of drive axle unit. hose
When disconnecting the brake
hydraulic hoses, take care that oil
should not be spilt on the floor.
If someone slips due to oil spillage, it
can cause to do him severe injuries. Drive axle
In case of spilling out of the oil on the
floor, wipe it off immediately in order to 100D7RE05
prevent someone from unexpected
accident.

(3) Drive axle

ö Before removing the drive axle unit, drain
all of the oil from the axle.
Η Jack up the machine and then put the
block under the frame.
ö If there is a pit, use the pit for safety.
Θ Loosen hexagonal bolts connecting drive
axle to the propeller shaft.

Ι Prepare the truck under the drive axle 1. Block

unit to support it. 4. Axle
mtg bolt
3. Truck
Κ Remove mounting bolts fixing the axle to 2. Axle & shaft
the frame and then carefully draw the mtg bolt
truck out of the vehicle with the drive axle
unit.

110D7ERE07

(4) Inching linkage Brake valve assembly

Η Remove bolt and screw fixing the inching
linkage assembly. Bolt
Bolt
Θ Disconnect harness cable from the
Bolt
inching pedal assembly.
Screw
Inching
pedal
Harness
100D7RE21

2-9
(5) Transmission and axle cooling piping
Η Disconnect cooling hose and connector
Radiator
from the transmission. assembly

ö Make sure that the transmission cooling

Transmission
oil has been drained from the line. assembly

IN
Cooling
OUT hose
180D7ERE10

Θ Disconnect axle cooling hose and Radiator

connector from the axle. assembly

ö Make sure that the axle cooling oil has Cooling

hose
been drained from the line.

OUT
AXLE OIL
PUMP

IN
When disconnecting the oil cooling
hoses, take care that oil should not be T
R
H

N
LE

IO
T
T

C
U

spilt on the floor.

U
O

S
N
R
U
T
E
R
H
R
T
LE
IN

If someone slips due to oil spillage, it Cooling

Drive hose
can cause to do him severe injuries. axle

LH
T
In case of spilling out of the oil on the

LE
LH

T
T

U
LE

O
IN
floor, wipe away immediately it in order
180D7ERE22
to prevent someone from unexpected
accident.

(6) Flexible plate

Η Remove the cover on the top face of the
torque converter housing then remove 4 Transmission
pieces of the mounting bolts installed to
the engine flywheel.
Engine
To rotate the flywheel, remove 1
Flexible plate
mounting bolt, then insert a turning tool in
the mounting hole. One man must turn Cover Bolt
the engine fan by hand while the other 180D7ERE11
turns the flywheel.

(7) Mounting bolts holding to flywheel

housing
Bolt 2
Η Remove the transmission assembly from
the torque converter housing by loosen-
ing 12 pieces of the mounting bolts. Engine

Bolt 1

Transmission
180D7ERE12

2-10
Θ Using a moving truck slowly pull out
transmission assembly to the front.

Transmission

Truck

180D7ERE13

2-11
2) INSTALLATION
Installation is the reverse order to removal,
but be careful of the following points. Bolt 2

(1) Tightening torque of mounting bolts Η to

flywheel housing. Engine
Η 
5.5~8.3kgfÂm (39.8~60.0lbfÂft) Bolt 1

(2) Tightening torque of mounting to the fly

wheel bolts Θ for flexible plate. Transmission
Θ 
3.9~5.1kgfÂm (28.2~36.9lbfÂft) 180D7ERE12

(3) Tightening torque of mounting bolts Ι, Κ

for propeller shaft.
Ι 
9.8~14.8kgfÂm (70.9~107lbfÂft)
Κ 
13~17kgfÂm (94~123lbfÂft)
(4) Tightening torque of mounting bolts Λ for
drive axle.
Λ 
85~115kgfÂm (615~832lbfÂft)

Block

Axle
mounting
bolt 5
Truck

Axle & shaft 4

mtg bolt
3

110D7ERE14

2-12
3. ENGINE
Lever the torque converter, transmission and front axle inside the frame, then remove the engine
assembly.
1) REMOVAL

T/C housing Mounting bolts

cover holding to engine
flywheel
Engine
hood
Engine
accessory

Shroud Mounting bolts

Overhead Radiator
guard hose

Air cleaner
hose

100D7RE25

(1) Engine hood

Mounting bolt
Η Engine cover (LH, RH)
Engine
Remove engine cover by loosening the cover(RH) Engine
mounting bolts. cover(LH)

180D7ERE17

2-13
 Θ Engine cover(center)
Mounting bolt License plate
a. Pull upside the precleaner by loosening
Radiator
the bolts and seal in the air intake hole Rear cover
cover(RH)
of air cleaner. Precleaner
Mounting
bolt
b. Remove engine cover and radiator
cover upward. Engine cover
Rear
cover(LH)

180D7ERE18

(2) Torque converter housing cover and

mounting bolts. See page 2-12.

Transmission

Engine
Flexible plate

Cover Bolt

180D7ERE11

(3) Engine accessory

Remove all wiring harnesses, cables and
Engine assembly
hoses around the engine, dashboard and
frame.
Η Wiring harness to alternator and starter.
Θ Wiring harness for oil pressure and
engine water temperature gauges.
Ι Cables for meters, buttons and
accelerator pedal.
Κ Hoses to fuel tank and air cleaner.
Λ Exhaust pipe.
(4) Radiator hose
Open the drain valve of the radiator and
drain the cooling water, then remove the
radiator hose. 180D7ERE19

2-14
 (5) Engine mounting bracket
Attach a crane to the engine hook and
raise, then remove mounting bolts. Raise Bolt
the engine slightly, slide towards the
radiator, then lift up.
ö When sliding the engine, be careful of the
collision of engine and radiator.

Bolt

Rubber mount
180D7ERE93

2) INSTALLATION
Installation is the reverse order to removal,
but be careful of the following points.
(1) Tighten the engine mounting bolts and Mounting bolt
85~115 kgf.m
nuts. (614~832 lbf.ft)
(2) Tighten the engine mounting bracket Mounting bolt
9.9~14.7 kgf.m
bolts. (72~106 lbf.ft)
ö Do not remove the bolts unless necess-
ary. Loctite is coated over the threads of
bolt. So, once the bolts were removed,
coat them with loctite(#277) when
installing.
ö Before installing the bolts, loctite in the
180D7ERE94
holes should be removed by a tap

(3) Tightening torque of mounting bolt

installed to torque converter housing.
ÂSee page 2-12, 2) INSTALLATION. Air cleaner

(4) Radiator hoses Muffler

ÂDistance to insert hose : 80mm(31in)
(5) Air cleaner hose Radiator
hose
Insert the air cleaner hose securely and fit
a clamp.
Radiator

Engine
Radiator
hose

180D7ERE95

2-15
4. REAR AXLE
1) REMOVAL

Counter Mounting
Rear wheel Hose
weight bolt

Mounting pin

Mounting bolt

180D7ERE30

(1) Counterweight
Hold the counterweight with hoist bars, and raise it with a crane.
Remove the mounting bolts, raise slightly and move it slowly to rear side.
ÂWeight of counterweight (standard)
180D-7E : 7,585kg (16,720lb)
ÂTightening torque : 199Ü29.9kgfÂm (1440Ü216lbfÂft)

2-16
(2) Rear wheel
Remove mounting bolt and hub nut with
socket wrench and then carefully take out
the tire assembly.

100D7RE31

(3) Hose
Disconnect the hose from the steering
axle and then drain out oil from the hoses. Steering axle
When disconnecting the hoses, take RH

care that oil should not be spilt on the

LH
floor.
If someone slips due to oil spillage, it
Hose
can cause to do him severe injuries.
In case of spilling out of the oil on the 100D7RE32
floor, wipe away immediately it in order
to prevent someone from unexpected
accident.

(4) Mounting bolt

Support
Put a block under the steering axle,
support on a truck, an raise the frame with
a crane. Remove the mounting bolts
installing to the frame, and pull out to the
rear.
There are shims between the support and
Steering axle
steering axle to prevent play.
Support

110D7ERE33

2-17