GROUP 2 REMOVAL AND INSTALLATION OF UNIT
Remove and install following units as explained in the flow chart.
1. MAST
1) REMOVAL
(1) FORKS Backrest
Η Lower the fork carriage until the forks are
approximately 25mm(1in) from the floor.
Pin
Θ Release fork anchor pins and slide one
fork at a time toward the center of the Knob
Spring
carriage where a notch has been cut in
the bottom plate for easy fork removal.
Ι Remove only one fork at a time. Carriage
ö On larger forks it may be necessry to use Fork
a block of wood. Center notch D357RE51
(2) BACKREST(IF NECESSARY)
Η Remove bolts securing backrest to fork
carriage, lift backrest straight up and Backrest
remove it from carriage.
Bolt
Carriage D357RE52
(3) CARRIAGE
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 carriage
is level, this will prevent any binding when
the mast is raised. D357RE53
2-2
Θ While supporting lift chains, remove nuts
Chain
from the anchor bolt. Outer
mast
Anchor
bolt
Nut
D357RE54
Ι Pull the chains out of the sheaves and
drape them over the front of the carriage.
Mast
Carriage
Lift chain
Block
D357RE55
Κ Slowly raise inner mast upright until mast
clears top of fork carriage. Move carriage
to work area and lower the mast. Mast
Make sure that carriage remains on
floor and does not bind while mast is
being raised.
ö Inspect all parts for wear or damage. Block
Replace all worn or damaged parts.
Carriage
Lift chain D357RE56
2-3
(4) PIPING
Η Remove the bulk hoses and clamps
attached to the cylinder.
Θ Remove the return hose from the down
control valve.
Bulk hose
ö Put blind plugs in the piping immediately
after removing hoses.
This prevents the hydraulic oil from
Lift cylinder
flowing out and also prevents dust and
dirt from getting in.
Return hose
D357RE57
(5) LIFT CYLINDER
Η Loosen and remove hexagon bolts and Hex bolt
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 Clamp
slack or binding. Inner
mast
Make sure the lift cylinder be tightened
firmly for safety.
Ι Loosen and remove hexagon bolts and
nuts securing lift cylinders to outer mast. LIft Outer
cylinder 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
cylinder carefully and put down on the Hex bolt
work floor.
Bracket
D357RE58
2-4
(6) INNER MAST
Η 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
D357RE59
(7) TILT CYLINDER PIN
(8) MAST SUPPORT PIN
Attach a crane to the stay at the top of the
outer mast, and raise it.
Remove the mounting bolts and pins from Outer
drive axle, then slowly raise outer mast. mast
ö This operation is carried out under the Tilt cylinder
machine, so use a pit, or if there is no pit,
jack up the machine and loosen with an
impact wrench. Tilt cylinder
pin
Frame
Bearing
Mast
mounting
pin
D357RE60
2-5
2) INSTALLATION
After assembling mast components tatally 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)
2-6
2. POWER TRAIN ASSEMBLY
1) REMOVAL
D503RE04
(1) Mast
Refer to section on mast(Page 2-2)
2-7
(2) Brake piping Brake pipe
Disconnect the brake piping from the
brake housing of drive axle unit.
Brake valve
Drive axle
D357RE05
(3) Parking brake cable
Disconnect parking brake cable from the
Parking
brake housing of drive axle unit. Parking brake
brake lever
cable
Drive axle
D357RE06
(4) Drive axle
ö Before removing the drive axle unit, drain
all of the oil from the axle.
Η Loosen hexagonal bolts connecting drive
axle to the transmission.
ö If there is a pit, use the pit for safety.
Θ Jack up the machine and then put the
block under the frame.
3. Truck
Ι Prepare the truck under the drive axle
2. Block
unit to support it.
Κ Remove trunnion fixing the axle to the 4. Trunnion
frame and then carefully draw the truck
out of the vehicle with the drive axle unit.
1. Drive axle & T/M
mounting bolt D357RE07
2-8
(5) Inching linkage
Remove bolt fixing the linkage assembly Inching pedal
to T/M control valve.
Bolt
T/M
control
valve D357RE09
(6) Transmission cooling piping
Radiator
Η Disconnect cooling hose and connector T/M cooling hose
assy
from the transmission.
ö Make sure that the coolant be drained
from the hose.
Transmission
assy D357RE10
(7) Torque converter
Cover
Η Remove the cover on top face of the
torque converter housing then remove Bolt
the 4 mounting bolts installed on the
T/M
engine flywheel. To rotate the flywheel,
remove 1 mounting bolt, then insert a
turning tool in the mounting hole. One
man must turn the engine fan by hand Drive Torque
while the other turns the flywheel. axle converter
D357RE11
(8) Mounting bolts holding to flywheel
housing
Η Remove the transmission assembly from Torque
converter Pin
the torque converter housing by loosen-
T/M
ing the mounting bolts.
Remove torque converter housing from
the engine flywheel by loosening the
mounting bolts and pins. Drive Bolt
axle D503RE12
2-9
Θ Using a moving truck slowly pull out
transmission assembly to the front.
Truck Block
D3573RE13
2) INSTALLATION
Installation is the reverse order to removal,
but be careful of the following points. Torque
converter Pin
(1) Tightening torque of mounting bolt for
T/M
torque converter housing.
Â5.5~8.3kgfÂm(40~60lbfÂft)
Drive Bolt
axle D357RE12
(2) Tightening torque of mounting bolt for
drive axle.
Â65.8~89.0kgfÂm(476~644lbfÂft)
Truck
Block
Trunnion
Drive axle & T/M
mounting bolt D357RE14
2-10
3. ENGINE
Lever the torque converter, transmission and front axle inside the frame, then remove the engine
assembly.
1) REMOVAL
D503RE25
(1) Overhead guard
Remove the wiring for rear combination
lamp, working lamp, head lamp and
flasher lamp on the stay of the overhead
guard and then raise it together with the
bonnet.
D357RE17
2-11
(2) Torque converter housing cover, mounting
bolts installed to flywheel housing.
For details, see page 2-9.
Engine
(3) Engine accessory
Remove all wiring harnesses, cables and
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. D357RE18
(5) Mounting bolt
Attach a crane to the engine hook and
raise, then remove mounting bolts. Raise
the engine slightly, slide towards the
radiator, then lift up.
ö When sliding the engine, be careful of the
collision engine and radiator. Engine
Frame
D357RE19
2) INSTALLATION
Installation is the reverse order of removal, Loctite #243
but be careful of the following points.
(1) Tighten the engine mounting bolts and 5.5-8.3kgf.m
(40-60lbf.ft)
nuts.
Mounting bolt
(2) Tighten the engine mounting bracket bolts. 7.5kgf.m(54.2lbf ft)
ö Do not remove the bolts unless necessary.
Loctite is coated over the threads of bolt.
So, once the bolts were removed, coat
them with loctite(#243) when installing. Shim
ö Before installing the bolts, loctite in the Nut
holes should be removed by a tap.
D357RE20
2-12
(3) Tightening torque of mounting bolt
installing to torque converter housing.
Â6.0~8.9kgfÂm(43~64lbfÂft)
(4) Radiator hoses
ÂDistance to insert hose : 42mm(1.65in)
(5) Air cleaner hose
Η Insert the air cleaner hose securely and
fit a clamp.
Θ Distance to insert hose
ÂAir cleaner hose : 89mm(3.5in)
ÂEngine end(MHI) : 60mm(2.36in)
ÂEngine end(HMC) : 64mm(2.5in)
D357RE21
2-13
5. REAR AXLE
1) REMOVAL
D357RE30
(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)
35DS-7/35D-7 : 1,820kg(4,010lb)
40DS-7/40D-7 : 2,200kg(4,850lb)
45DS-7/45D-7 : 2,550kg(5,620lb)
2-14
(2) Rear wheel
Remove mounting bolt and hub nut with
socket wrench and then carefully take out
the tire assembly.
D357RE31
(3) Hose
D357RE32
(4) Mounting bolt
Put a block under the steering axle, Steering axle Support
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 to prevent play. Support
Mounting bolt
D357RE33
2-15
