A1n1 HD en PDF

HYDRAULIC SYSTEM
SECTION HD
CONTENTS
SERVICE DATA AND SPECIFICATIONS . . HD-2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-54
General Specifications . . . . . . . . . . . . . . . . HD-2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . HD-54
Inspection and Adjustment . . . . . . . . . . . . . HD-2 FULL-FREE CYLINDER . . . . . . . . . . . . . . . HD-55
Adjusting Shim . . . . . . . . . . . . . . . . . . . . . . HD-3 Construction . . . . . . . . . . . . . . . . . . . . . . . HD-55
Tightening Torque . . . . . . . . . . . . . . . . . . . HD-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . HD-58
TROUBLE DIAGNOSES AND Disassembly . . . . . . . . . . . . . . . . . . . . . . . HD-58
CORRECTIONS . . . . . . . . . . . . . . . . . . . . . HD-4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-59
PRECAUTIONS AND PREPARATION . . . . HD-8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-59
Precautions . . . . . . . . . . . . . . . . . . . . . . . . HD-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . HD-60
Special Service Tool . . . . . . . . . . . . . . . . . . HD-9 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . HD-60
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . HD-10 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . HD-61
Hydraulic Circuit Diagram . . . . . . . . . . . . . . HD-10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . HD-61
Disassembly and Assembly . . . . . . . . . . . . HD-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-25
OIL PUMP (GEAR PUMP) . . . . . . . . . . . . . . HD-26 NOTE:
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . HD-26 This section contains information and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . HD-26 specifications for both General Overseas Market
Disassembly . . . . . . . . . . . . . . . . . . . . . . . HD-27 (GOM) and North America. Therefore, ensure the
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-28 specifications or procedures you are looking at
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-29 are for the proper area.
Test Procedures . . . . . . . . . . . . . . . . . . . . . HD-30
HYDRAULIC CONTROL LEVER . . . . . . . . . HD-32
Mechanical Control System . . . . . . . . . . . . HD-32
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . HD-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . HD-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . HD-34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . HD-34
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-37
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-37
Hydraulic Test . . . . . . . . . . . . . . . . . . . . . . HD-37
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . HD-40
Construction . . . . . . . . . . . . . . . . . . . . . . . HD-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . HD-40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . HD-41
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-42
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . HD-43
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . HD-44
Construction . . . . . . . . . . . . . . . . . . . . . . . HD-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . HD-48
Installation (2W, 2F, 3F, 3V) . . . . . . . . . . . . . HD-52
Disassembly . . . . . . . . . . . . . . . . . . . . . . . HD-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-53
SERVICE DATA AND SPECIFICATIONS
General Specifications
Oil pump (Gear pump) Tilt cylinder
A1N1 series Applied model A1N1 series
Applied model Regular Large Stroke mm (in) 83 (3.27)
capacity capacity
Cylinder I.D. mm (in) 65 (2.56)
Pump type KFS 2320 KFS 2324
Cylinder O.D. mm (in) 78.5 (3.091)
CSNS CSNS
Piston rod diameter mm (in) 30 (1.18)
Drive type Direct coupled to motor
Tilt angle 2W, 2F 4°/ 6°
Gear system Single, Zero-backlash type
(Forward-backward)
3F, 3V 5°/ 5°
Normal discharge 20.2 24.0
m (US fl oz, lmp fl oz)/rev. (0.68, 0.71) (0.81, 0.84)
Lift (mast) cylinder
Maximum pressure 20.6 (205.9, 210, 2,986)
MPa (bar, kg/cm2, psi) Mast name 2W 2F 3F and 3V
Cylinder I.D. mm (in) 45 (1.77) 45 (1.77) 45 (1.77)
Control valve Cylinder O.D mm (in) 52 (2.05) 52 (2.05) 52 (2.05)
A1N1 series Piston rod diameter
35 (1.38) 32 (1.26) 35 (1.38)
mm (in)
Applied model Joystick
Mechanical
type
type Full-free cylinder
Valve type KVSF- KVSB- Mast name 2F and 3F 3V
65VPFLS 65PSL
Cylinder I.D. mm (in) 70 (2.76) 50 (1.97)
Main relief set pressure
16.7 (167.0, 170.34, 2,421) Cylinder O.D mm (in) 84 (3.31) 60 (2.36)
MPa (bar, kg/cm2, psi)
Piston rod diameter mm (in) 50 (1.97) 40 (1.57)
Tilt relief set pressure
MPa (bar, kg/cm2, psi) 9.3 (93.0, 94.86, 1,348)
Suction filter
The 3rd and 4th relief set
pressure Applied model A1N1 series
11.8 (118.0, 120.36, 1,711)
Filter type Wire gauze
Power steering relief set
Diameter mm (in) 100 (3.94)
pressure
6.9 (69.0, 70.38, 1,000)
MPa (bar, kg/cm2, psi) Filtration accuracy (mesh) 150
Relief valve type Cartridge Filter area cm2 (sq in) 620 (96.1)
Plunger type Cylinder, spring return
Micron filter
Rated flow rate
65 (17-1/8, 14-1/4)
(US gal, lmp gal)/min. Applied model A1N1 series
Filter type Filter paper (cartridge) type
Filtration size µm 20
Inspection and Adjustment
Hydraulic oil type and capacity Control valve
Unit: mm (in)
Applied model A1N1 series
Item Usable limit Remarks
Hydraulic oil Standard I.S.O. VG32
type Clearance between All models
Cold storage SAE No. 10W (I.S.O. VG15) 0.02 (0.0008)
plunger and valve
Oil capacity (US gal, lmp gal) 17.9 (4-3/4, 4)
Tilt cylinder
Oil pump (Gear pump)
Unit: mm (in)
Unit: mm (in)
Item Usable limit Remarks
Item Pump type Usable limit Remarks
Clearance between cylinder head bushing —
KFS 2320 20.961 Regular capacity 0.2 (0.008)
and piston rod
Gear shaft CSNS (0.8252)
Clearance between cylinder tube and piston 0.2 (0.008) —
O.D. KFS 2324 20.961 Large capacity
CSNS (0.8252)
HD-2
SERVICE DATA AND SPECIFICATIONS
Inspection and Adjustment (cont’d)

Lift cylinder
Unit: mm (in)
Item Usable Remarks
limit
Clearance between cylinder head —
0.2 (0.008)
bushings and piston rod
Clearance between cylinder tube —
0.7 (0.028)
and piston ring
Adjusting Shim
Unit: mm (in)
Item Usable Remarks
limit
Shim for aligning full-free cylinder Select proper number
1.0 (0.039)
parallel to inner mast of shims.
Shim for adjusting height of upper Select proper number
1.0 (0.039)
end of lift cylinder of shims.
Tightening Torque
Part name Nm (kg-m, ft-lb)
Oil pump-to-pump motor securing bolts 25 - 31 (2.5 - 3.2, 18 - 23)
Oil pump Intake connector 92 - 108 (9.3 - 11.0, 68 - 80)
Discharge connector 79 - 88 (8.0 - 9.0, 58 - 65)
M10 47 (4.8, 35)
Control valve assembly Assembly tie rod nut
M8 19 (1.9, 14)
Control valve Main relief valve assembly 49 (5.0, 36)
Tilt relief valve assembly 49 (5.0, 36)
Control valve assembly attaching bolt 20 - 22 (2.0 - 2.2, 14 - 16)
Striker attaching bolt 13 - 15 (1.3 - 1.6, 10 - 11)
Control lever
Lever bracket attaching nut 26 - 33 (2.6 - 3.3, 19 - 24)
Rod head lock nut 108 - 147 (11 - 15, 80 - 108)
Tilt cylinder
Cylinder head 350 - 400 (36 - 40, 259 - 295)
Cylinder head 2W, 3F and 3V 197 - 245 (20 - 25, 145 - 180)
(Lift Cylinder) 2F 197 - 225 (20 - 23, 145 - 166)
Cylinder mounting bolt 44 - 54 (4.4 - 5.6, 32 - 40)
U-bolt lock nut 26 - 32 (2.6 - 3.3, 19 - 24)
Lift cylinder Adjusting bolt lock nut 74 - 94 (7.5 - 9.6, 54 - 69)
Cylinder head 2F and 3F 300 - 370 (31 - 37, 202 - 272)
(Full-free cylinder) 3V 246 - 274 (25 - 28, 181 - 202)
2F and 3F 128 - 156 (13 - 16, 95 - 115)
Full-free cylinder mounting bolt
3V 44 - 54 (4.4 - 5.6, 32 - 40)
Oil tank mounting bolt 21 - 26 (2.1 - 2.7, 16 - 19)
Suction filter mounting bolt 5 - 6 (0.52 - 0.66, 3.8 - 4.7)
Oil tank
Micron filter unit mounting bolt 21 - 26 (2.1 - 2.7, 16 - 19)
Connector 79 - 88 (8 - 9, 59 - 64)
HD-3
TROUBLE DIAGNOSES AND CORRECTIONS
! CAUTION
• The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to
the user’s complaints and check the actual vehicle to fully understand under what conditions the
symptoms occur.
• For malfunctions closely related to pump motor, refer to MM section for diagnosis.
• For malfunctions closely related to control system, refer to CS section for diagnosis.
Oil Pump (Gear Pump)

Condition Probable cause Corrective action
• Low oil level in tank • Fill up oil to specified level.
No oil supplied from oil pump
• Clogged suction pipe or filter • Clean. If oil is dirty, replace with new.
• Worn gear shaft bushing or faulty packing ring • Replace with new one.
• Improperly adjusted relief valve • Readjust to specified pressure using
pressure gauge.
Low oil pump pressure • Air in the system • Retighten suction side piping.
• If oil level in tank is too low, add oil to
specified level.
• Do not operate pump until air bubbles in
tank are removed.
• Cavitation due to crushed suction hose or • Remove foreign matter and repair crushed
clogged filter hose.
• Air sucked from lose suction side joint • Retighten each joint.
Abnormal noise caused by oil pump • Excessive viscosity of oil • Replace with new oil having proper
viscosity.
• Air bubbles in hydraulic oil • Discharge air, remove foreign matter and
replace oil.
• Faulty oil seal or body seal • Replace seal with new one.
Oil leakage from oil pump • Worn sliding surfaces of gears (Increased inner • Replace oil pump with new one.
leakage)
HD-4
Control Valve
• Malfunctioning plunger • Clean foreign matter in hydraulic oil, or change
oil.
• Pump discharging oil is less than specified • Check pump performance and if necessary
amount. replace the damaged parts.
• Relief valve pressure set too low • Check and correct relief valve set pressure.
Fluctuation of steering side oil pressure
• [Standard: 6.9 MPa (68.6 bar, 70 kg/cm2, 995
psi)] (Refer to ST section.)
• Broken spring • Replace.
• Foreign matter caught in fixed orifice of • Disassemble and clean foreign matter.
plunger
• Clogged plunger damper orifice • Disassemble and check.
Poor steering response until specified
oil pressure is attained. • Malfunctioning plunger • Clean foreign matter from hydraulic oil, or
change oil.
Oil leaking • Damaged or scratched O-ring • Replace faulty O-ring.
• Lift lock valve does not operate. • Disassemble and clean the valve. In case
of solenoid operation failure, replace the
solenoid.
• Shuttle of proportional solenoid pressure- • Disassemble and clean the valve. However,
reducing valve or plunger of proportional when the plunger of the proportional solenoid
solenoid is stuck. is stuck, replace the valve because it cannot
Pump pressure does not rise. be disassembled.
• Lead wire or solenoid coil is broken. • Repair or replace the wire or coil.
• Input current of solenoid is small. • Check if the specified maximum current is
applied.
• Lift lock valve is open. • Check the operation of the lift lock solenoid.
• Check the operation of the lift lock valve.
• Spool of flow priority valve is stuck. • Disassemble and clean the valve.
• Foreign matter between sliding surfaces of • Clean valve housing and plunger.
valve housing and plunger
• Deteriorated oil • Change oil with new.
• Damaged return spring • Replace.
• Distorted valve housing mounted • Loosen mounting bolts and check.
Plunger sticks • Bent plunger • Replace valve housing and plunger as an
assembly.
• Shuttle of proportional solenoid pressure- • Disassemble and clean the valve. However,
reducing valve or plunger of proportional when the plunger of the proportional solenoid
solenoid is stuck. is stuck, replace the valve because it cannot
be disassembled.
Oil leakage from oil seal • Paint dust or dirt caught in oil seal • Remove seal and clean.
• Distorted seal plate • Clean seal plate and retighten bolts.
• Worn or damaged seal • Replace.
• Damaged plunger • Replace.
Lowered or tilted forward cylinder • Worn relief valve or damaged seat • Replace plunger and tilt valve housing as an
without control lever operation assembly.
• Oil leaking from cylinder • Check cylinder and replace faulty parts.
Load drops when changing control lever • Foreign matter caught in relief valve • Disassemble check valve and clean.
from NEUTRAL to RAISE position.
• Damaged poppet or check valve seat • Replace or repair by lapping.
Mast tilts forward when control lever is • Worn or damaged tilt lock plunger • Replace plunger and tilt valve housing as an
moved forward and backward while key assembly.
switch is OFF.
• Broken tilt lock plunger spring • Replace.
• Oil leakage from O-ring in tilt cylinder piston • Replace.
HD-5
Condition Probable cause Corrective actions

• Worn relief valve or damaged seat • Replace relief valve assembly.
Cylinder speed is too slow or cylinder does
• Foreign matter caught in relief valve • Clean or replace relief valve.
not operate.
• Faulty oil pump • Refer to “OIL PUMP”.
• Stuck or damaged tilt lock plunger • Replace plunger and tilt valve housing as
Mast is unstable or does not operate when an assembly.
control lever is moved to forward while key
switch is ON. • Foreign matter caught between valve and • Disassemble and clean.
plunger, making valve inoperative
Relief Valve
• Main poppet or pilot poppet is stuck and • Check for foreign objects in the engaged
kept open. area of the poppet.
Pressure does not rise at all. • The poppet should slide freely.
• Foreign object is caught in poppet seat.
• Clean all the parts thoroughly.
• Poppet seat is damaged. • Replace the damaged part.
Relief pressure is unstable.
• Clean all the parts thoroughly.
• Poppet is stuck. • Remove the flaw on the surface.
Relief pressure is abnormal. • Wear caused by foreign object • Replace the damaged part.
• Perform readjustment.
• Lock nut or adjusting screw is loosened.
• Damage to seat • Replace the damaged part or the worn
Oil leakage part.
• Wear of O-ring
• Each part should move smoothly.
• Each part is stuck due to foreign objects. • Check for scratch, scoring, and foreign
objects.
Pressure rise is delayed. • Air is trapped in relief valve. • Bleed air.
Tilt Cylinder
(Sliding surfaces between cylinder and piston
rod)
• Foreign matter in U-ring • Remove and clean or replace.
• Damaged U-ring • Replace.
• Foreign matter in lip of wiper ring • Remove and clean or replace.
• Damaged lip of wiper ring • Replace.
• Damaged sliding surface of piston rod • If damage is minor, repair using oilstone. If
serious, replace piston rod assembly.
• Flaked hard chromium plate of piston rod • Replace.
Oil leakage
(Connected portion of cylinder head and tube)
• Damaged O-ring • Replace.
(Welded portion of cylinder tube)

• Damage or cracks • Replace.
(Others)
• Loose connector • Tighten to specified torque.
• Degraded or damaged hose or tube • Replace.
• Damaged sliding surface of cylinder tube • If damage is minor, repair using oilstone. If
serious, replace cylinder tube.
• Damaged sliding surface of piston • Replace piston rod assembly.
Cylinder tilts forward without control lever
operation. • Damaged O-ring • Replace.
• Damaged backup ring • Replace.
• Faulty control valve • Refer to “CONTROL VALVE”.
HD-6

• Air in cylinder • Operate cylinder for about five minutes (10
Mast swings to and fro when brakes are - 20 strokes).
applied while driving.
• Oil leak from piston seal • Replace seal or cylinder.
Lift/Full-Free Cylinder
(Sliding surfaces between cylinder head and
piston rod)
• Foreign matter in U-ring • Remove and clean or replace.
• Damaged U-ring • Replace.
Oil leakage • Foreign matter in lip of wiper ring • Remove and clean or replace.
• Damaged lip of wiper ring • Replace wiper ring.
• Damaged sliding surface of piston rod • If damage is minor, repair using oilstone. If
serious, replace piston rod assembly.
• Flaked hard chromium plate of piston rod • Replace.
• Foreign matter in U-ring on piston side • Remove and clean or replace.

• Damaged lip of U-ring on piston side • Replace U-ring.
Cylinder is lowered without control lever
• Damaged sliding surface of cylinder tube • Replace cylinder tube.
operation or power is insufficient.
• Damaged sliding surface of piston ring • Replace piston ring.
• Faulty down safety valve • Replace down safety valve assembly.
• Degraded or broken plunger return spring • Replace flow regulator valve assembly.
of flow regulator valve
Abnormally low lowering speed of cylinder • Foreign matter in moving part of flow • Replace flow regulator valve assembly.
regulator valve
• Faulty down safety valve
• Replace down safety valve assembly
HD-7
PRECAUTIONS AND PREPARATION
Precautions
With Mechanical System
• For lift piping, fully tilt the masts forward, operate the control lever
several times forward, and turn key switch OFF. Operate the
control lever several times backward, and release the residual
pressure from piping.
• For lift piping, place the fork at the lowest position, and operate
the lift lever several times downward.
With Joystick System

• For tilt piping, first place the fork horizontal (tipped slightly forward)
and turn the key switch off. Next, loosen the piping and let set
while the remaining pressure escapes.
• For lift piping, place the fork at the lowest position, turn the key
switch off, loosen the shut-off valve and let the remaining pressure
escape.
• For attachment piping (3rd and 4th)
• Union connector
Place the attachment in neutral, turn the key switch off, loosen
the piping, and let set while the remaining pressure escapes.
• Coupling
Installing and removing the cup may be difficult if the remaining
pressure inside the piping is high. If this is the case, turn the key
switch ON and while idling tip the lever (3rd and 4th) backwards
or forwards, and one of the cups will come off. Then tip the lever
in the other direction and remove the other cup.
! CAUTION
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines is completely bled off.
• To prevent foreign matter from entering, always maintain a
clean workplace.
• When disconnecting pipes, cover the surrounding area with
rag and ensure oil does not contaminate other parts.
• Never allow foreign matter to enter pipes when connecting.
• Put disassembled parts on clean paper or rag and use care
not to contaminate, scratch or dent them.
• Always assign lifting operations to qualified operators
trained in slinging or hoisting procedures.
• When handling heavy parts, two people should perform the
work.
NOTE:
• For the removal, installation and service of pump motor, refer to
MM section.
• For the removal of instrument inner cover, floor mat and floor
panel, refer to BF section.
• For removal and installation of mast, refer to LM section.
HD-8
PRECAUTIONS AND PREPARATION
Special Service Tool

Purchase Locally
Tool number Description

Tool name
Measuring oil pressure
Pressure gauge
SST
HD-9
HYDRAULIC SYSTEM
Hydraulic Circuit Diagram

Mechanical Control Valve
1. Hydraulic oil pump 11. PS relief valve 21. Down safety valve
2. Hydraulic pump motor 12. Lift valve 22. Flow regulator valve
3. Suction filter 13. Shut-off valve 23. Steering wheel
4. Hydraulic oil tank 14. Tilt lock valve 24. PS valve
5. Micron filter 15. Tilt valve 25. PS cylinder
6. Relief valve for 4th valve 16. 3rd valve 26. Knob position correction solenoid valve (OPT)
7. Relief valve for 3rd valve 17. 4th valve 27. Tilt levelling solenoid valve (OPT)
8. Tilt relief valve 18. To attachment
9. Lift lock valve 19. Control valve
10. Main relief valve 20. Lift cylinder
HD-10
HYDRAULIC SYSTEM
Hydraulic Circuit Diagram (Cont’d)

Joystick Control Valve
1. Hydraulic oil pump 9. PS relief valve 17. Tilt cylinder

2. Hydraulic pump motor 10. Main relief valve 18. Lift cylinder
3. Suction filter 11. Lift valve 19. Down safety valve
4. Hydraulic oil tank 12. Tilt valve 20. Flow regulator valve
5. Micron filter 13. 3rd valve 21. Steering wheel
6. Relief valve for 4th valve 14. To attachment 22. PS valve
7. Relief valve for 3rd valve 15. 4th valve 23. PS cylinder
8. Shut-off valve 16. Control valve 24. Knob position correction
solenoid valve (OPT)
HD-11
HYDRAULIC SYSTEM
Disassembly and Assembly

! CAUTION
• Wrap seal tape securely around tapered threads. Never
allow pieces of seal tape to enter hydraulic pipes.
• O-rings are used in the connectors to connect each
hydraulic unit. Before assembling, attach a guide to threads
of connector and insert O-ring along with it so as not to
damage O-ring.
• Tighten connector by hand and after determining connector
position, tighten lock nut to the specified torque (refer to
Figure).
• Discharge hydraulic oil before removing suction hose.
• During assembling of hydraulic system, be careful not to
allow foreign material such as dust in hydraulic line.
• When fixing hoses, adjust their rotation direction and
position so that the hoses are not twisted and pulled.
• Check relief pressure for oil leakage and other
malfunctions.
• Insert the suction hoses and return hoses until the groove
end of pipe or connector.
HD-12
HYDRAULIC SYSTEM
Disassembly and Assembly (cont’d)

Hydraulic Piping
Tank - oil pump - control valve
HD-13
HYDRAULIC SYSTEM

Control Valve - Tilt Cylinder
HD-14
HYDRAULIC SYSTEM

Control valve - PS valve
HD-15
HYDRAULIC SYSTEM

Control valve - flow regulator valve (mast)
HD-16
HYDRAULIC SYSTEM

Mast Piping
2W mast
HD-17
HYDRAULIC SYSTEM

2F Mast
HD-18
HYDRAULIC SYSTEM

3F mast
HD-19
HYDRAULIC SYSTEM

3V mast
HD-20
HYDRAULIC SYSTEM

Attachment Piping
Control valve - mast
HD-21
HYDRAULIC SYSTEM

2W mast
HD-22
HYDRAULIC SYSTEM

2F mast
HD-23
HYDRAULIC SYSTEM

3F mast
HD-24
HYDRAULIC SYSTEM

3V mast
Inspection
Hoses
• Leaking, degraded or damaged hoses should be replaced.
• Leaking or damaged connectors should be replaced.
Tubes and pipes

• Leaking, bent, broken or scratched hoses should be replaced.
• Leaking or damaged connectors should be replaced.
HD-25
OIL PUMP (GEAR PUMP)
Removal
! CAUTION
• Clean the area surrounding the pump and remove dust.
• Because oil tends to spill, cover the area surrounding the
pipes with rag. (Especially opening for pump motor fan)
• Never allow foreign matter to enter pump or pipes.
1. Remove battery from the vehicle.

2. Remove floor mat and floor board.
3. Disconnect PS hose from control valve.
4. Disconnect LS hose (indicated by arrow in the figure on the left)
(for joystick control valve).
5. Disconnect high-pressure hose from pump.
6. Disconnect suction hose from pump.
7. Remove pump bolts, and then remove pump.
Installation
! CAUTION
• Apply molybdenum disulfide grease to the pump shaft.
Install in the reverse order of removal.
HD-26
Disassembly
! CAUTION
• Before disassembling, thoroughly clean dirt from outside of
pump body.
• Before disassembling, prepare new parts such as packings
and oil seals that are not reusable.
• When loosening bolt (1), be careful not to drop the pump
from the vise, and loosen the bolt slowly.
Disassemble in numerical order as shown in the figure.
NOTE:
• Before disassembly, put matching marks on between rear cover
(2) and pump body (8) and between pump body (8) and mounting
bracket (14).
• Straightly remove rear cover (2) in axial direction.
• Side plate (5) can be easily removed by lifting up the drive gear (6)
and the driven gear (7).
• Insert a slotted screwdriver into the back of oil seal, and then pry
the oil seal upward.
HD-27
Inspection
Clean all disassembled parts in cleaning oil and check for cracks and
damage.
Suction Body
Discharge Suction chamber
side Check the sliding mark of the gear teeth tip on the inner surface (at
side
the suction side).
Limit “a”:
Sliding mark
More than half-circumference
Gear hole Depth of sliding mark
Sliding
More than 0.20 mm (0.0079 in)
mark
Gear
Check the shaft and gear teeth face. In case of the following, replace
with a new one.
• The side face is rough to the extent that fingernails get caught.
• The teeth face is abnormally worn.
• The shaft diameter is less than the limit value.
Limit “d”: 20.961 mm (0.8252 in) dia.
Side Plate
Check the side plate. In case of the following, replace with new
ones.
• Severe roughness has been caused by many flaws which can be
felt by fingernails.
• The thickness of the side plate is less than the limit value.
Thickness of pressure plate:
Limit 2.927 mm (0.1152 in)
Mounting Bracket And Cover

Check the bearing for wear. In case of the following, replace with a
new one.
• Teflon coating is worn, and the brown-colored base metal is
exposed for 150° or more in the direction of the circumference
inside the bearing.
HD-28
Assembly
1. Wash each part.
2. Secure the cast surface of mounting bracket in a vise with the
mounting surface facing downward.
3. Securely insert seal plate and backup into the groove of

mounting bracket so as not to protrude from outer surface. Be
careful about the insertion direction of backup.
4. Install dowel pin to mounting bracket, and then install pump
body to mounting bracket while aligning it with dowel position.
At this time, dowel pin is the positioning pin. If it is hard to insert
dowel, tap and insert it using a plastic hammer.
5. Insert side plate into the bottom of pump body with the copper
alloy side facing up. Be careful about the intake side/exhaust
side of side plate.
When the side plate cannot be moved because it tilted, hold the
drive shaft end of drive gear and slightly push the higher side of
side plate to insert it easily.
6. Insert the drive gear and driven gear while aligning the matching
marks with it put on shaft end surface. Be careful about the drive
gear and driven gear.
After inserting gear, apply clean hydraulic fluid of 2 to 3 m (0.07
to 0.10 US fl oz, 0.07 to 0.11 Imp fl oz) to the tooth groove.
7. Insert side plate into the pump body with the copper alloy side
facing down. Be careful about the intake side/exhaust side.
8. Securely insert seal plate and backup into the groove of cover so
that they do not protrude from outer surface.
9. Install dowel pin to pump body, and then install cover while
aligning it with dowel position.
Be careful to prevent the seal plate and backup from dropping or
protruding. If the cover protrudes approximately 2 to 3 mm (0.08
to 0.12 in) between the pump body and cover after installing, the
cover might not be installed correctly in step 8. Check again.
10. Insert and temporarily tighten flanged bolt to the tightening
torque of 2.0 to 4.9 Nm (0.2 to 0.5 kgf-m, 2 to 3 ft-lb). The
thread should be in the wet condition.
HD-29
Assembly (cont’d)
11. After temporarily tightening, remove the pump from the vise.
Place the pump body horizontally with intake side facing up
on the stand under the mounting bracket and the cover. Tap
the pump body using a plastic hammer to adjust to the proper
position. This procedure should always be performed because it
is necessary to keep the performance after assembly,
12. Secure the pump on a vise again, and then tighten the bolt to
the specified torque.
Flange bolt
: 88 - 98 Nm (9 - 10 kgf-m, 65 - 72 ft-lb)
! CAUTION
• Always tighten bolts to the specified torque.
• If the tightening torque is outside the specified torque,
it may cause damage to the bolt and the hydraulic fluid
spouting from pump matching surface, which may cause
accident.
13. Remove the pump from the vise, and then rotate the shaft end
of drive gear using a tool. If it rotates lightly, there are no foreign
materials and no seal getting caught. (If any seal gets caught,
the shaft cannot rotate manually. Perform disassembly and
assembly again.)
14. Install oil seal to mounting bracket. Apply a thin film of clean
lithium grease to lip of oil seal.
When pressing in the oil seal, be careful not to damage the lip
and do not press in the oil seal obliquely. Wrap the front drive
gear shaft end with seal tape to prevent the lip from being
damaged. Always wipe off the tape.
15. Insert the snap ring for stopping the missing oil seal. Always use
a new snap ring.
Test Procedures
NOTE:
Perform the test under the following conditions.
• Heat the hydraulic oil to approximately 50°C
• Set to P mode in POWER MODE (refer to the CS section)
• Set to 8 in PUMP ACCELERATION LEVEL (refer to the CS section)
• Set to 100% in PUMP POWER LIMIT (refer to the CS section)
• Set to 100% in LIFT SPEED (refer to the CS section)
HD-30
Test Procedures (Cont’d)

After installing oil pump, follow test procedures as follows:
1. Check that oil level in tank is OK and install pressure gauge to
control valve.
! CAUTION
• For installing pressure gauge and adjusting oil pressure,
refer to “Hydraulic Test and Adjustment” in “CONTROL
VALVE”.
2. With pump running, turn adjusting screw on relief valve to

gradually raise pressure from 0 to 16.7 MPa (0 to 167.0 bar, 0
to 170.34 kg/cm2, 0 to 2,421 psi). Place hand on pump body to
check for temperature rise.
If temperature of pump body is excessively higher than that of
hydraulic oil, disassemble oil pump to make sure it is assembled
correctly.
3. Reset relief valve to specified pressure.
Relief valve set pressure

Main relief set pressure 16.7 (167.0, 170.34, 2,421)
Tilt relief set pressure 9.3 (93.0, 94.86, 1,348)
3rd, 4th relief set pressure 11.8 (118.0, 120.36, 1,711)
Power steering relief set pressure 6.9 (69.0, 70.38, 1,000)
4. Perform pump delivery test.

Measure fork lifting speed without load. If the speed is within
standard value, pump delivery is correct.
Lifting speed Lowering speed
without load (2W without load (2W mast)
Model
mast) mm/s (in/s)
mm/s (in/s)
L15V
A1N1 (36V) L18V 515 (20.28) 550 (21.65)
L20V
L15V
600 (23.62)
A1N1 (48V) L18V
550 (21.65)
L20V 580 (22.83)
5. Move fork up and down with and without load, and check that it
operates correctly.
HD-31
HYDRAULIC CONTROL LEVER
Mechanical Control System
Adjustment
Adjust the opened/closed area of control lever cover with the

following procedure.
1. Secure the striker on the center of long hole.
2. Connect the catcher and striker of control lever cover, and
then adjust the striker position so that there is no looseness on
control lever cover.
HD-32
CONTROL VALVE
Removal
! CAUTION
• Before discharging remaining pressure, lower lift fully and
tilt completely forward. Next, turn control lever toward
backward tilt side.
• When disconnecting pipes, turn key switch to OFF and
discharge remaining pressure in pipes.
• Never allow foreign matter to enter pipes or control valve.
• Because oil tends to spill, cover the area surrounding the
pipes with a shop cloth. (Especially opening for pump motor
fan)
1. Remove floor mat, floor panel.

3. Remove control lever (for mechanical). Remove clevis pin to
disconnect connection between control lever and control valve.
4. Disconnect harness connector inserted into control valve.
5. Remove high-pressure pipe, low-pressure hose, tilt pipe and lift

pipe. (Remove all pipes from control valve.)
For Joystick, disconnect pilot return hose from the pipe joint
under battery compartment.
6. Remove control valve attaching bolts to remove control valve

assembly with bracket from frame (indicated by arrows in the
figure on the left).
! CAUTION
• Before removing the control valve attaching bolts, support
the control valve using a wooden block to prevent it from
dropping.
• Be careful not to drop control valve because it is heavy and
slippery due to oil.
7. Remove bracket from control valve (indicated by arrows in the

figure on the left).
HD-33
CONTROL VALVE
Installation
To install, reverse the order of removal. Pay attention to the following
points.
• Never allow foreign matter to enter pipes or control valve.
• After connecting pipes, apply relief pressure to check for any oil
leaks.
• After connecting lever and control valve, adjust the clearance
between control valve switch and dog and implement centering by
referring to CS section.
Disassembly
Mechanical control valve
Lift Lock
Solenoid
Joystick control valve
HD-34
CONTROL VALVE
Disassembly (cont’d)
Inlet spool
Lift spool
HD-35
CONTROL VALVE
Tilt spool
3rd and 4th spool
HD-36
CONTROL VALVE
1. Remove bracket containing control valve switch from control
valve assembly. (for mechanical)
2. Remove relief valves from control valve assembly.
! CAUTION
• Do not disassemble relief valve assemblies because they
are replaced as an assembly.
• Do not loosen lock nut. If lock nut is loosed, be sure to
adjust set pressure after assembling.
3. Remove the tie rod, and disassemble the control valve to each
section.
Note:
Be careful not to lose poppets and poppet springs that are between
each section.
Inspection
• Clean the disassembled parts with detergent oil, and bleed air to
remove foreign objects thoroughly.
• Replace the parts with deformation, cracks, or other damage.
• Replace the O-ring and wiper ring with new ones.
Assembly
• Assemble in the reverse order of disassembly.
• Check for smooth operation.
Hydraulic Test
! CAUTION
• When performing hydraulic test, wear protective

eyeglasses. High pressure oil leaks can cause loss of vision
or other eye damage.
• Perform the test in an appropriate place to allow lifting of
the mast.
NOTE:
Perform the test under the following conditions.
• Heat the hydraulic oil to approximately 50°C
• Set to P mode in POWER MODE (refer to the CS section)
• Set to 8 in PUMP ACCELERATION LEVEL (refer to the CS section)
• Set to 100% in PUMP POWER LIMIT (refer to the CS section)
• Set to 100% in LIFT SPEED (refer to the CS section)
HD-37
CONTROL VALVE
Hydraulic Test (cont’d)

Pressure Test
1. Turn key switch to OFF.
2. Remove floor panel.
3. Remove plug of high pressure pipe connector at hydraulic pump.
4. Attach adapter to plug hole, then install pressure gauge.
5. Turn key switch to ON and operate control lever and read the
pressure referring to Table below.
Standard pressure
Main relief pressure 16.7 (167.0, 170.34, 2,421)
Tilt relief pressure 9.3 (93.0, 94.86, 1,348)
3rd, 4th relief pressure 11.8 (118.0, 120.36, 1,711)
Power steering relief pressure 6.9 (69.0, 70.38, 1,000)
6. If out of specification, adjust the pressure.
Pressure Adjustment
• Turn key switch to OFF, and then disconnect the battery
connection.
• Disconnect seat switch harness connection, and then connect the
seat switch harnesses on body harness side.
• Relief valve on control valve upper side
1. Remove control valve switch (for mechanical).
2. Loosen lock nut of relief valve assembly.
3. Connect battery cable, and then turn key switch to ON.
4. Push control valve switch to ON (for mechanical). Operate
control lever (for joystick).
5. Turn adjusting screw of relief valve to set standard pressure.
• If lower than the standard, turn clockwise.
• If greater than the standard, turn counterclockwise.
! CAUTION
• One rotation of the adjusting screw corresponds to a
pressure change of 6.9 - 7.8 MPa (68.6 - 78.5 bar, 70 - 80 kg/
cm2, 995 - 1,138 psi), so do not turn carelessly.
• Carefully adjust pressure, observing the pressure gauge
reading.
6. After completing adjustment, hold adjusting screw in place and

tighten lock nut.
7. Implement the pressure test again to check whether the set
pressure is correct.
• Relief valve on control valve lower side
2. Connect battery cable to the vehicle using an extension cable.
3. Turn key switch to ON and operate control lever.
4. Turn adjusting screw of relief valve to set standard pressure.
• If lower than the standard: Turn clockwise.
• If greater than the standard, turn counterclockwise.
HD-38
CONTROL VALVE
Hydraulic Test (cont’d)

! CAUTION
• One rotation of the adjusting screw corresponds to a
pressure change of 6.9 - 7.8 MPa (68.6 - 78.5 bar, 70 - 80
• kg/cm2, 995 - 1,138 psi), so do not turn carelessly.
• Carefully adjust pressure, observing the pressure gauge
reading.
5. After completing adjustment, hold adjusting screw in place and

tighten lock nut.
6. Implement the pressure test again to check whether the set
pressure is correct.
Shut-off Valve
• When the forks and masts cannot be lowered with/without load.
• First of all, check the following:
For mechanical valve

Check that lift lock valve (solenoid) operates normally. Refer to the
CS section.
For joystick valve

• Check that C1 solenoid and solenoid for lift operate normally. Refer
to the CS section.
• Operate the control valve lever toward the mast lowered side, and
then make sure that the pump motor operates (turns). If not, repair
the vehicle by referring to the CS section.
If the above steps are OK, the forks and masts can be lowered with
the following procedure.
1. Turn key switch to OFF, disconnect the battery connection, and
then remove battery from the vehicle.
2. Remove the floor mat and floor board.
3. Disconnect the PS piping (LS and PF).
4. Loosen lock nut of shut-off valve on the lower side of control
valve.
5. Loosen the screw counterclockwise until it stops.
6. Operate the control lever downward slowly.
Return
1. Screw in the screw until it stops.
2. Loosen lock nut.
3. Install the floor board and floor mat, and then install the battery.
! CAUTION
• Always return to the lift lock function after repair.
HD-39
TILT CYLINDER
Construction
1. Piston rod head 7. Wiper ring 13. Bush

2. Cylinder head 8. U-ring 14. Grease nipple
3. O-ring 9. Lock nut 15. Bolt
4. Cylinder tube assembly 10. Bush 16. Washer
5. Backup ring 11. Rod assembly 17. O-ring
6. O-ring 12. O-ring 18. Piston
Removal
! CAUTION
• When removing tilt cylinder, lift mast with wire or nylon

string and support cylinder with a block of wood so that it
does not fall.
• During work, be sure to keep your hands and feet out of
danger.
HD-40
TILT CYLINDER
Removal (cont’d)
1. Lower fork fully.
2. Remove pivot pin attaching bolt from the joint of outer mast and
pull out pivot pin.
3. Turn key switch to ON and set tilt cylinder to the maximum
backward tilt, then tilt forward to extend cylinder by about 10
mm (0.39 in). Turn key switch to OFF and disconnect battery
plug.
4. Disconnect two pipes connected to tilt cylinder at pipe
connectors.
! CAUTION
• Since oil tends to spill when pipes are disconnected, cover
the surrounding area with rag.
• Stuff stoppers into disconnected pipes to prevent oil spills.
5. Remove pivot pin attaching bolt from joint of body frame and pull
out pivot pin to remove tilt cylinder.
NOTE:
To separate left tilt cylinder on body side, first remove tilt cylinder
cover, then go to next step.
Disassembly
1. Hold cylinder in a vise with piping port down and put a plate
under port. Apply compressed air alternately to two ports and
activate piston rod to discharge oil from cylinder.
2. Loosen head lock nut, then remove rod head from piston rod
assembly.
3. Loosen cylinder head, then remove cylinder head from cylinder
tube assembly.
!
CAUTION
• Use care not to damage O-ring.
4. Remove piston rod assembly from cylinder tube assembly.
!
CAUTION
• Use care not to damage O-ring.
HD-41
TILT CYLINDER
5. Remove O-ring from piston rod assembly.
! CAUTION
• Do not disassemble piston rod assembly.
6. Remove O-ring and backup ring from cylinder head.
! CAUTION
• Replace removed O-ring and backup ring with new ones. Do
not reuse.
7. Remove U-ring and wiper ring using a screwdriver.
! CAUTION
• Replace removed U-ring and wiper ring with new ones. Do not
reuse.
Inspection
Cylinder Head
• Measure inside diameter of cylinder head and outside diameter of
piston rod and calculate the clearance. If the clearance is greater than
usable limit, replace cylinder head.
Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Usable limit: 0.2 mm (0.008 in)
Cylinder Tube
• Measure inside diameter of cylinder tube and outside diameter of
piston and calculate the clearance. If the clearance is greater than
usable limit, replace cylinder tube.
Standard: 0.03 - 0.15 mm (0.0012 - 0.0059 in)
• Check whether the interior is damaged. If damage is minor, repair
using oilstone. If serious, replace cylinder tube.
• If welded part is damaged, replace cylinder tube.
Piston Rod
• Check whether sliding surface is damaged. If damage is minor, repair
using oilstone. If serious, replace piston rod.
• If hard chromium plate flakes, replate piston rod or replace.
• If rod is bent, replace.
O-Ring, U-Ring, Wiper Ring And Backup Ring

Do not reuse. Always replace with new ones.
Assembly
To assemble, reverse the order of disassembly. Pay attention to the
following points.
• Lubricate each part with clean hydraulic oil.
• Never allow foreign matter to enter parts.
• Use new O-ring, U-rings, backup ring and wiper ring.
• Use care not to twist or damage O-ring.
HD-42
TILT CYLINDER
Assembly (cont’d)
• Use care not to damage O-ring and wiper ring with threads of
piston rod.
Rod head lock nut:
: 108 - 147 Nm (11 - 15 kg-m, 80 - 108 ft-lb)
Cylinder head:
: 350 - 400 Nm (36 - 40 kg-m, 259 - 295 ft-lb)
NOTE:
To prevent O-ring and wiper ring from being damaged, wrap vinyl
tape around threads of piston rod, then attach cylinder head
assembly.
Installation
To install, reverse the order of removal. Pay attention to the following
points.
Pivot pin attaching bolt:
: 26 - 32 Nm (2.6 - 3.3 kg-m, 18 - 24 ft-lb)
• After installing, operate cylinder for about five minutes (10 - 20
strokes).
HD-43
LIFT CYLINDER
Construction
2W mast
1. Dust seal 7. Fixing ring 13. Piston

2. U-ring 8. Wear ring 14. Piston ring
3. O-ring 9. Ball 15. Pull-in wire
4. Cylinder head 10. Pull-in wire 16. Washer
5. Cylinder tube assembly 11. Check valve
6. Piston rod 12. Spring
HD-44
LIFT CYLINDER
Construction (cont’d)
2F Mast, Right Hand
1. Wiper ring 6. Piston rod 11. Backup ring

2. U-ring 7. Fixing ring 12. Cushion part
3. O-ring 8. Wear ring 13. O-ring
4. Cylinder head 9. Pull-in wire 14. Bleed screw
5. Cylinder tube assembly 10. Piston 15. Seal washer
HD-45
LIFT CYLINDER
2F Mast, Left Hand
1. Wiper ring 6. Piston rod 11. Backup ring

2. U-ring 7. Fixing ring 12. Cushion part
3. O-ring 8. Wear ring 13. O-ring
4. Cylinder head 9. Pull-in wire 14. Bleed screw
5. Cylinder tube assembly 10. Piston 15. Seal washer
HD-46
LIFT CYLINDER
3F and 3V Mast
1. Dust seal 7. Fixing ring 13. Piston

2. U-ring 8. Wear ring 14. Piston ring
3. O-ring 9. Ball 15. O-ring
4. Cylinder head 10. Pull-in wire 16. Washer
5. Cylinder tube assembly 11. Check valve 17. Cushion part
6. Piston rod 12. Spring 18. O-ring
HD-47
LIFT CYLINDER
Removal
! CAUTION
• Be sure to keep hands and feet out of danger.
Preparation
1. Remove from mast carriage assembly with fork.
2. Jack up the front of vehicle to keep about 120 mm (4.72 in)
of clearance from lower end of outer mast to floor (refer to GI
section).
3. After setting mast vertical and lower lift cylinder at the lower end,
turn key switch OFF and disconnect the battery cable.
! CAUTION
• Be sure to lower lift cylinder fully to discharge remaining
pressure in pipes.
2W Lift Cylinder
1. Remove lift hose from lift cylinder.
! CAUTION
• Oil tends to spill if hoses are disconnected, so be sure to
block the end with stoppers.
2. Disconnect the hose between the lift cylinders.
3. Remove lock nut on the upper plane of lift cylinder to separate lift
cylinder from inner mast.
4. Lift up inner mast with lifting wire/nylon sling.
HD-48
LIFT CYLINDER
Removal (cont’d)
5. Remove lift cylinder attaching bolt and U-bolt, then remove lift
cylinder from the front.
! CAUTION
• Because lift cylinder is very heavy, two people should
perform this task.
• When removing U-bolt, support lift cylinder to prevent it
from falling.
2F Lift Cylinder
1. Remove lift hose from lift cylinder.
2. Disconnect the hose between the lift cylinders.
3. Disconnect the piping between the lift cylinder and full-free
cylinder.
! CAUTION
4. Remove the fixing bolt on the upper plane of lift cylinder to

separate lift cylinder from inner mast.
5. Lift up inner mast with lifting wire/nylon sling.
6. Remove lift cylinder attaching bolt and U-bolt, then remove lift
cylinder from the front.
! CAUTION
• Because lift cylinder is very heavy, two people should
perform this task.
from falling.
HD-49
LIFT CYLINDER
Removal (cont’d)
3F Lift Cylinder
1. Lift up the inner mast until the inner mast lower beam comes to
the position of the upper section of the outer mast tilt beam.
! CAUTION
• Because the chain and lift hose become saggy, make sure
that they are not caught while lifting up the inner mast.
2. Remove the chain anchor on the inner mast side, and remove
the mast chain from the inner mast.
3. Remove the hydraulic piping on the lower section of the full-free
cylinder.
4. Remove the hose pulley support on the upper section of the
middle mast, and remove the chain wheel.
5. Place a square timber of approximately 100 mm (3.94 in) height
under the inner mast, and lower the inner mast.
! CAUTION
• Make sure that the chain and the lift hose is not caught
while lowering the inner mast.
6. Fix the lifting tool to the upper beams of both the inner mast and
middle mast.
7. Remove the mounting bolt on the mast cylinder upper surface.
8. Lift up the inner mast and middle mast together, and remove the
upper section of the mast cylinder.
9. Disconnect the lift cylinder hose from the mast cylinder, remove
the lift hose clamp mounting bolt, and remove the cylinder from
the mast.
! CAUTION
10. Remove the bolt at the bottom end of the mast cylinder (lower
face of the outer mast support).
11. Remove the U-bolt, and remove the mast cylinder toward the
front of the vehicle.
! CAUTION
from falling.
• Because lift cylinder is heavy, two people should perform
this task.
HD-50
LIFT CYLINDER
Removal (cont’d)
3V Lift Cylinder
1. Remove the mast assembly from the forklift.
!! WARNING
• After removing the mast assembly, the middle and inner
rails will easily slide. Use ropes to firmly fasten the outer,
middle and inner rail top beams together.
2. Disconnect the high pressure hose at the lower end of the lift
cylinder.
3. Remove the lift chain at the chain adjusting bolt.
4. Remove the securing bolt from the upper end of the lift cylinder.
!! WARNING
• After removing the mast assembly, the middle and inner
rails will easily slide. Use ropes to firmly fasten the outer,
middle and inner rail top beams together.
5. Slide the middle rail together with the inner rail 250 mm (9.84 in)
in the upper direction.
! CAUTION
• Record the thickness and location of the adjusting shim

used to adjust the lift cylinder height in advance. The
adjustment shim is installed to the upper end of the lift
cylinder.
!! WARNING
• The middle and inner rails easily slide. Use ropes to firmly
fasten the outer, middle and inner rail top beams together.
HD-51
LIFT CYLINDER
Removal (cont’d)
6. Remove the bolt from the lower end of the lift cylinder.
7. Remove the lift cylinder securing U-bolt.

8. Remove the lift cylinder.
Lift cylinder
U-bolt
Lock nut
Installation (2W, 2F, 3F, 3V)

Installation is in the reverse order of removal. Pay attention to the
following points.
• Tighten bolt at the lower end of cylinder.
: 44 - 54 Nm (4.3 - 5.6 kg-m, 32 - 40 ft-lb)
Stopper • Fit the U-bolt into the cylinder, tighten the adjusting nut by hand,
Adjusting nut and fix with the lock nuts.
U-bolt
Lock nut : 26 - 32 Nm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
• Fit the stopper into the hole at the end of the adjusting bolt.
Adjusting bolt • Tighten the adjusting bolt, and check that the stopper contacts
with the cylinder. Then, further tighten for 1/2 to 1 turn and tighten
the lock nut.
: 74 - 94 Nm (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
Lock nut
• When tightening the lock nut, make sure that the adjusting nut
Cylinder
does not turn.
• For 2W mast, tighten the stud bolts on the set nuts to the bottom
of the threads. Apply thread lock to the threads of the stud bolt on
the cylinder side. And then tighten and fasten the stud bolt on the
top of the lift cylinder. So that the set nut does not become loose,
secure the stud bolt with a cotter pin.
HD-52
LIFT CYLINDER
Installation (2W, 2F, 3F, 3V) (cont’d)

• Securely wrap seal tape around tapered threads of pipes. Never
allow pieces of seal tape to enter hydraulic pipes.
• O-rings are used in the connectors to couple each hydraulic unit.
Before assembling, attach a guide to connector threads and insert
O-ring along with it so as not to damage O-ring.
• Tighten connector by hand and after determining connector
position, tighten lock nut to the specified torque.
Disassembly
1. Loosen cylinder head and remove from cylinder tube.
2. Disassemble cylinder head.
• Tap out wiper ring/dust seal using a screwdriver.
! CAUTION
• Replace removed wiper ring/dust seal with new one. (Never
reuse a wiper ring/dust seal after tapping it out because
outside diameter is reduced.)
• Remove U-ring using a screwdriver.
! CAUTION
• Replace removed U-ring with new one.
3. Remove piston rod assembly from cylinder tube.
! CAUTION
• Do not disassemble piston rod assembly.
Inspection
Cylinder head
Measure inside diameter of cylinder head and outside diameter of
piston rod and calculate the clearance. If the clearance is greater
than usable limit, replace cylinder head.
Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Piston Rod
• Check for bent. If excessive, replace with new one.
• Check whether sliding surface is damaged. If damage is minor,
repair using oilstone. If serious, replace piston rod.
• If hard chromium plating flakes, re-plate or replace piston rod.
Cylinder Tube
If the interior is damaged, replace cylinder tube.
Dust Seal (Wiper Ring), U-Ring, O-Ring, Wear Ring

And Piston Ring (Backup Ring)
HD-53
LIFT CYLINDER
Assembly
To assemble, reverse the order of disassembly. Pay attention to the
following points.
• Before assembling, lubricate each part with new hydraulic oil.
• Clean packings in petroleum-base hydraulic oil.
• During assembly, never allow foreign matter such as dust to enter
parts.
Cylinder head:
2W, 3F, 3V mast : 197 - 245 Nm
(20 - 25 kg-m, 145 - 180 ft-lb)
2F mast : 197 - 225 Nm
(20 - 23 kg-m, 145 - 166 ft-lb)
Adjustment
Bleeding Air
1. Add hydraulic oil up to the upper limit of level gauge.
2. Raise and lower mast slowly.
3. Lower mast fully and check the hydraulic oil capacity in tank.
If hydraulic oil level is reduced, fill up to the upper limit of level
gauge.
4. Repeat steps 2 and 3 until the hydraulic oil capacity is not
reduced.
5. Check that cylinder moves smoothly up and down.
Adjusting Of Cylinder Height

To prevent mast from being twisted and deformed, adjust the
cylinder height. Be sure to adjust, especially when replacing only one
cylinder.
1. Check that forklift is placed horizontally.
2. Remove lock nuts/fixing bolts at the upper ends of right and left
lift (mast) cylinders.
3. Fully and slowly raise mast without load, then check whether
right and left cylinders reach upper ends simultaneously.
4. If one cylinder is delayed, adjust delayed cylinder by inserting

shims.
Thickness of shim: 1.00 mm (0.039 in) (only one type)
5. Repeat the adjustment above until there is no difference between
the right and left cylinders.
6. For 2W mast, tighten the lock nut until it reaches the incomplete
thread of the stud bolt. At this time, the difference between the
upper beam and the lock nut is 1 mm (0.0394 in) or more.
HD-54
FULL-FREE CYLINDER
Construction
2F And 3F Mast
1. Cylinder tube assembly 8. Washer 14. Spring

2. Piston rod 9. Fuse piston 15. Cylinder head
3. Piston 10. Spring guide 16. O-ring
4. Pull-in wire 11. Wear ring 17. Backup ring
5. Ball 12. U-ring 18. U-ring
6. Check valve 13. Circlip 19. Wiper ring
7. Spring
HD-55
FULL-FREE CYLINDER
3V Mast, Right Hand
1. Wiper ring 6. Cylinder tube assembly 11. U-ring

2. U-ring 7. Piston rod 12. Wear ring
3. Backup ring 8. Ball 13. Washer
4. O-ring 9. Check valve 14. Circlip
5. Cylinder head 10. Spring
HD-56
FULL-FREE CYLINDER
3V Mast, Left Hand
1. Wiper ring 7. Piston rod 13. Washer

2. U-ring 8. Ball 14. Circlip
3. Backup ring 9. Check valve 15. Spring guide
4. O-ring 10. Spring 16. Spring
5. Cylinder head 11. U-ring 17. Hose burst valve
6. Cylinder tube assembly 12. Wear ring
HD-57
FULL-FREE CYLINDER
Removal
! CAUTION
• Be sure to keep hands and feet out of danger.
Preparation
1. Remove from mast carriage assembly with fork.
2. Jack up the front of vehicle to keep about 120 mm (4.72 in)
of clearance from lower end of outer mast to floor (refer to GI
section).
3. After setting mast vertical and lower full-free cylinder at the lower
end, turn key switch OFF and disconnect the battery cable.
! CAUTION
• Be sure to lower full-free cylinder fully to discharge
remaining pressure in pipes.
Procedures
1. Disconnect the hydraulic piping from the full-free cylinder.
! CAUTION
2. Lift up the full-free cylinder using a nylon sling or a lifting wire.

3. Remove the full-free cylinder mounting bolt. Lift up the full-free
cylinder, and remove it.
Disassembly
1. Loosen the cylinder head, and remove the cylinder head from the
cylinder tube.
2. Disassemble the cylinder head.
• Push the wiper ring out by hitting with a screwdriver.
! CAUTION
• Replace a removed wiper ring with a new one. (Because the
outer diameter of the removed wiper ring has been reduced,
it cannot be reused.)
• Remove the U-ring by prying with a screwdriver.
! CAUTION
• Replace removed U-rings with new ones.
3. Remove the piston rod assembly from the cylinder tube.
! CAUTION
• Do not disassemble the piston rod assembly.
HD-58
FULL-FREE CYLINDER
Inspection
Cylinder Head
Measure the cylinder head inner diameter and piston rod outer
diameter, and calculate the clearance. When the clearance exceeds
the limit value, replace the cylinder head.
Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Limit: 0.2 mm (0.008 in)
Piston Rod
• Check the piston rod for bending. When excessive bend is found,
replace the piston rod.
• Check the sliding face for damage. In case of minor damage,
repair with oil stone. In case of severe damage, replace the piston
rod.
• When the hard chromium plating is peeled off, plate again, or
replace the piston rod.
Cylinder Tube
When the inner face is damaged, replace the cylinder tube.
Wiper Ring, U-Ring, Backup Ring, O-Ring And Wear

Ring
Assembly
Assemble in the reverse order of disassembly. Pay attention to the
following:
• Before assembling, moisten the parts with hydraulic oil.
• Clean the packing with a petroleum hydraulic fluid.
• Prevent foreign objects from entering into the inside during
assembly.
• Tighten the cylinder head to the specified torque.
Cylinder head:
2F, 3F mast : 300 - 370 Nm
(31 - 37 kg-m, 202 - 272 ft-lb)
3V mast : 246 - 274 Nm
(25 - 28 kg-m, 181 - 202 ft-lb)
HD-59
FULL-FREE CYLINDER
Inner Mast Installation

Install in the reverse order of removal. Pay attention to the following:
Shim • 2F, 3F MAST:
Adjust with the shim so that the inner mast becomes parallel to
the full-free cylinder.
Shim thickness: 1.0 mm (0.039 in)
Then tighten the mounting bolt.
: 128 - 156 Nm (13 - 16 kg-m, 95 - 115 ft-lb)
Full-free cylinder
• 3V MAST:
Mounting bracket of full free cylinder to be inserted into the
notch of inner mast 2nd-beam. After surface A of 2nd-beam
touches surface B of mounting bracket, bolt is to be tightened.
(3V mast)
: 44 - 54 Nm (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
• Seal the taper threads of the piping with seal tape securely.
Prevent chips of the seal tape or other foreign object from entering
into the hydraulic piping.
• O-rings are used at the connectors which connect the hydraulic
units. When assembling, insert the connector with a guide on the
threads so that the O-ring is not damaged.
• Screw in the connector by hand. When the connector is
positioned, tighten the lock nut to the specified torque. (For the
tightening torque, refer to “Mast Piping”.)
Adjustment
Bleeding Air
1. Add hydraulic fluid to the upper limit of the level gauge.
2. Lift the mast slowly, then lower it slowly.
3. Lower the mast fully, and check the hydraulic fluid amount in the
tank. When the hydraulic fluid amount is low, add to the upper
limit of the level gauge.
4. Perform the operations mentioned in steps 2 and 3 above
repeatedly until the hydraulic fluid amount does not decrease.
5. Move the cylinder up and down, and check for smooth
operation.
HD-60
OIL TANK
Disassembly
Oil level gauge
HD-61
MEMO
HD-62

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HYDRAULIC SYSTEM

Inspection and Adjustment (cont’d)

Oil Pump (Gear Pump)

Condition Probable cause Corrective actions

• Damaged O-ring • Replace.

(Welded portion of cylinder tube)

Condition Probable cause Corrective action

• Foreign matter in U-ring on piston side • Remove and clean or replace.

With Joystick System

Special Service Tool

Tool number Description

Hydraulic Circuit Diagram

Hydraulic Circuit Diagram (Cont’d)

1. Hydraulic oil pump 9. PS relief valve 17. Tilt cylinder

Disassembly and Assembly

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Disassembly and Assembly (cont’d)

Tubes and pipes

1. Remove battery from the vehicle.

Install in the reverse order of removal.

Disassemble in numerical order as shown in the figure.

Mounting Bracket And Cover

3. Securely insert seal plate and backup into the groove of

Test Procedures (Cont’d)

2. With pump running, turn adjusting screw on relief valve to

Relief valve set pressure

4. Perform pump delivery test.

Mechanical Control System

Adjust the opened/closed area of control lever cover with the

1. Remove floor mat, floor panel.

5. Remove high-pressure pipe, low-pressure hose, tilt pipe and lift

6. Remove control valve attaching bolts to remove control valve

7. Remove bracket from control valve (indicated by arrows in the

Joystick control valve

3rd and 4th spool

• When performing hydraulic test, wear protective

Hydraulic Test (cont’d)

6. If out of specification, adjust the pressure.

6. After completing adjustment, hold adjusting screw in place and

Hydraulic Test (cont’d)

5. After completing adjustment, hold adjusting screw in place and

For mechanical valve

For joystick valve

1. Piston rod head 7. Wiper ring 13. Bush

• When removing tilt cylinder, lift mast with wire or nylon

4. Remove piston rod assembly from cylinder tube assembly.

6. Remove O-ring and backup ring from cylinder head.

7. Remove U-ring and wiper ring using a screwdriver.

O-Ring, U-Ring, Wiper Ring And Backup Ring

1. Dust seal 7. Fixing ring 13. Piston

1. Wiper ring 6. Piston rod 11. Backup ring