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

BRP7MS121

(2) Forks
Backrest
Η Remove shaft cover and bolt. Pin
Θ Remove fork set pin and then draw out Knob
Spring
the shaft.
Ι Carefully remove forks one by one.
Carriage

Fork
Center notch
BRP7RE03

(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. BRP7RE04

2-2
Θ While supporting lift chains, remove the
split pins and nuts from anchor bolts of
Lift chain
stationary upright.
Outer mast

Nut
Split pin

BRP7RE05

Ι Pull the chains out of the sheaves and

drape them over the front of the carriage. Reach
support
Mast
Lift
chain

15/23BRP-7
Reach
support

Lift
chain

18/20BRP-7
BRP7RE06

Κ 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
Middle mast
floor and does not bind while mast is
being raised.
Λ Inspect all parts for wear or damage.
Replace all worn or damaged parts. Lift
chain

Carriage

Block
BRP7RE07

2-3
(4) PIPING
Η Remove the return hoses and clamps
attached to the cylinder.
Θ Remove the return hoses from the
connector. To
Inner
mast control
Ι Remove hose assembly, connector, valve
down safety valve from the lift cylinder.
Κ Disconnect hose assembly from the flow
regulator.
Middle
mast

Lift
cylinder

Outer
mast

BRP7RE08

(5) LIFT CYLINDER

Η Loosen hexagonal bolts and remove
Shim
washers securing the lift cylinders to
inner mast. Shim
Θ Bind the lift cylinder with overhead hoist
rope and pull up so that the rope has no
slack or binding. Inner
mast
Make sure that the lift cylinder be
tightened firmly for safety.
Ι Loosen and remove hexagon nuts and
cylinder band securing cylinder to outer
Middle
mast. mast
Κ Using an overhead hoist, slowly raise the Lift
Lift cylinder
inner mast high enough to clear lift
cylinder
cylinder.
Λ Using an overhead hoist, draw out lift Outer
mast
cylinder carefully and put down on the
work floor.
BRP7RE09

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

Wire rope

BRP7RE10

(7) 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.
Θ Using an universal puller, remove the
load rollers.

Inner mast

Middle mast

Outer mast

BRP7RE11

2-5
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) 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, Inner
mast
adjust as follows so that the left and right
cylinders are synchronized at the Shim
maximum lifting height. Cylinder
Θ Assemble the cylinder rod to the inner rod
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. Outer
mast
ö If play is to RIGHT, install adjustment
BRP7RE12
shim to RIGHT cylinder.
ÂShim thickness : 1.0mm(0.04in)

2-6
2. POWER TRAIN ASSEMBLY
1) REMOVAL

Side door

BRJ7RE001

(1) Disconnect the battery cable. LINE

CONTACTOR

EMERGENCY
SWITCH

r
ecto
nn
co
ble
ca
ry
tte
Ba TRACTION
INVERTER

PUMP
INVERTER
15BRP7OM121

(2) Remove side door.

Side door

BRP7RE13

(3) Disconnect the hose, pipe and wiring from To control valve
pump & motor assembly. Mounting bolt
Loosen mounting nuts from frame and
then take out the assembly. Wiring
Pump
Pump motor
assembly
Hose
Mounting nut

To hyd tank BRP7RE15

2-7
(4) Disconnect the wiring.
Η Drive motor wiring
Θ EPS motor wiring.
(5) Loosen mounting bolts from frame and
Drive motor
then take out drive unit assembly.
EPS
motor

Mounting
bolt BRP7RE17

(6) Lift up the frame and support both side of

frame on wood block.

Jack up

Wood block
BRP7RE18

(7) Remove drive unit assembly from frame

by lifting.
Sustain the drive unit assembly properly
so that it may not fall down on the floor.

BRP7RE19

2-8
2) INSTALLATION
Installation is in the reverse order to
removal, but be careful of following points.
(1) Drive unit mounting bolts : 6EA
Drive motor
ÂTightening torque : 13.3~15.3kgfÂm
EPS
(96.2~110.6lbfÂft) motor

(2) Drive unit bracket mounting bolt : 9EA

ÂTightening torque : 12.8~14.0kgfÂm Mounting
bolt
(92.6~101.3lbfÂft) BRP7RE17

(3) Drive motor mounting bolts : 6EA

ÂTightening torque : 6.0~8.0kgfÂm
(43.4~57.9lbfÂft)
(4) EPS motor mounting bolts : 4EA
ÂTightening torque : 3.0~4.0kgfÂm
(21.7~28.9lbfÂft)

(5) Pump motor mounting nuts : 4EA To control valve

ÂTightening torque : 4.0~6.0kgfÂm Mounting bolt
(28.9~43.4lbfÂft)
(6) Pump motor mounting bolt : 4EA Wiring
ÂTightening torque : 4.0~6.0kgfÂm Pump
Pump motor
(28.9~43.4lbfÂft) assembly
Hose
Mounting nut

To hyd tank BRP7RE15

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

Side door

BRJ7RE002

(1) PUMP MOTOR LINE

CONTACTOR

Η Disconnect the battery cable.

EMERGENCY
SWITCH

r
ecto
nn
co
le
cab
ery
Batt
TRACTION
INVERTER

PUMP
INVERTER
15BRP7OM121

Θ Remove side door.

Side door

BRP7RE13

2-10
Ι Disconnect the hose, pipe and wiring To control valve
from pump & motor assembly. Mounting bolt

Loosen mounting nuts from frame and

then take out the assembly. Wiring
Κ Remove 2 mounting bolts fastening the Pump
Pump motor
pump & motor and then disengage the assembly
pump from motor. Hose
Mounting nut

To hyd tank BRP7RE15

(2) DRIVE MOTOR LINE

CONTACTOR

Η Disconnect the battery cable.

EMERGENCY
SWITCH

r
ecto
nn
co
le
cab
ery
Batt
TRACTION
INVERTER

PUMP
INVERTER
15BRP7OM121

Θ Remove side door.

Side door

BRP7RE13

Ι Disconnect wirings.
a. Drive motor wiring
b. EPS motor wiring

Drive motor
EPS
motor

BRP7RE17A

2-11
Κ Remove bolts connecting the motor and
drive unit.

Mounting
bolt
Mounting
bolt

BRP7RE22

Λ Tie wire rope around the drive motor and

lift up slowly.

Drive motor

Drive unit

BRP7RE23

Μ Put the motor on the clean work bench.

BRP7RE24

2-12
(3) EPS MOTOR LINE
CONTACTOR

Η Disconnect the battery cable.

EMERGENCY
SWITCH

r
ecto
nn
co
ble
ca
ttery
Ba TRACTION
INVERTER

PUMP
INVERTER
15BRP7OM121

Θ Remove side door.

Side door

BRP7RE13

Ι Disconnect wirings.
EPS
motor

BRP7RE25

Κ Loosen bolts and remove EPS motor

assembly.

EPS
motor

Mounting
bolt

BRP7RE26

2-13
(4) BATTERY REMOVAL LINE
CONTACTOR

Η Turn off the key.

EMERGENCY
SWITCH
Θ Release the lock screw of side support in r
frame. ecto
nn
co
ble
Ι Disconnect the battery connector. ca
ttery
Κ Pull out the battery and using a battery Ba TRACTION
INVERTER
hanger, carefully raise the battery
PUMP
INVERTER
assembly. 15BRP7OM121

15BRP7OM122

2-14
2) INSTALLATION
Installation is in the reverse order to
removal, but be careful of following points.

(1) PUMP MOTOR To control valve

Η Pump motor mounting nut. Mounting bolt

ÂTightening torque : 2.0~3.0kgfÂm

(14.5~21.7lbfÂft) Wiring
Θ Hydraulic pump mounting bolt
Pump
ÂTightening torque : 4.0~6.0kgfÂm Pump motor
assembly
(28.9~43.4lbfÂft) Hose
Mounting nut

To hyd tank BRP7RE15

(2) DRIVE MOTOR

Η Connection bolts between drive motor
and drive unit.
ÂTightening torque : 6~8kgfÂm Mounting
bolt
(43.4~57.8lbfÂft)
Mounting
bolt

BRP7RE22

(3) EPS MOTOR

Η EPS motor mounting bolts.
ÂTightening torque : 3.0~4.0kgfÂm
(21.7~28.9lbfÂft) EPS
motor

Mounting
bolt

BRP7RE26

2-15
(4) BATTERY INSTALLATION
Η Using a battery hanger, carefully put the
battery assembly compartment push the
battery assembly to the frame.
Θ Adjust the lock screw of side support in
frame.
Ι Connect the battery connector.
Κ Complete installation.
15BRP7OM122

LINE
CONTACTOR

EMERGENCY
SWITCH

tor
nec
con
able
r yc
tte
Ba TRACTION
INVERTER

PUMP
INVERTER
15BRP7OM87

2-16
4. TIRE & WHEEL ASSEMBLY
1) REMOVAL
(1) DRIVE TIRE & WHEEL ASSEMBLY
Η Lift up the frame
ö Lift up until the tire clear off the
ground.

Jack up

Wood block
BRP7RE18

Θ Remove wheel nuts attaching the drive

wheel and take off the drive wheel
assembly.
ÂWheel nuts : 7EA

Wheel nut
BRP7RE33

(2) LOAD WHEEL ASSEMBLY

Η Lift up wheel box assy and fix the
machine with blocks.

Jack up

Block Block
BRP7RE37

Θ Disassemble load tire assy Hex nut

Plain washer
- After removing retaining ring, pin, Retaining ring
washers and shims, take out load tire
Wheel box
assy. Special bolt
- Remove ball bearings from load tire Spacer
Bushing
assy if necessary and replace with new Pivot plate
bearings. Pin
Load tire
Ball bearing
Special washer
Round shim BRP7RE38

2-17
2) INSTALLATION
Installation is in the reverse order to removal,
but be careful of the following points.
(1) Drive wheel nuts
ÂTightening torque : 13.5~15.5kgfÂm
(98~112lbfÂft)

Wheel nut
BRP7RE34

(2) When assembling bearings in the wheel box Retaining

ring
assembly, it should be cleaned on the pin
and in the bore of the load tire assy in order
to prevent it from scratch or damage. Pivot
plate
Pin
(3) When inserting shims between wheel box
Load tire
assy and special washer, it should be kept
clearance within 0.5 mm.
Jack up

Block Block
BRP7RE43

2-18