FB16KT - 1 99719 56100t

Service Manual
MC/FC
Chassis, Mast & Options
FB16KT EFB4A-00011-up
For use with FB16KT-FB20KT

Controller Service Manual. 99719-56100
FOREWORD
This service manual is a guide to servicing of Mitsubishi forklift trucks. The instructions are
grouped by systems to serve the convenience of your ready reference.
Long productive life of your lift truck depends to a great extent on correct servicing —
servicing consistent with what you will learn from this service manual. Read the respective
sections of this manual carefully and familiarize yourself with all the components you will
work on, before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are of the trucks with
the serial numbers in effect at the time it was approved for printing. Mitsubishi reserves the
right to change specifications or design without notice and without incurring obligation.
Safety Related Signs
The following safety related signs are used in this service

manual to emphasize important and critical instructions:
Indicates a specific potential hazard

! WARNING that could result in serious bodily
injury or death.
Indicates a specific potential hazard that

! CAUTION
may result in bodily injury, or damage
to, or destruction of, the machine.
Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine.
Pub. No. 99719-56100

HOW TO READ THIS MANUAL
Disassembly diagram (example)
Each disassembly diagram is followed

by Disassembly sequence and
Suggestions for disassembly.
Disassembly sequence
Sequence
1. Cover, Bolt, Washer (part name)
2. Output shaft (part name)
Suggestion for disassembly

(1) Output shaft removal
Unit: mm (in.)
0.020 to 0.105
A
(0.00079 to 0.00413)
Clearance between
cylinder and piston 0.15
B
(0.0059)
A: Standard value B: Repair or service limit
! WARNING
SAFETY
! WARNING ! WARNING
The proper and safe lubrication and Do not operate this truck unless you have read
maintenance for this forklift truck, and understand the instructions in the
recommended by Mitsubishi forklift truck, are OPERATION & MAINTENANCE MANUAL.
outlined in the OPERATION & MAINTENANCE Improper truck operation is dangerous and
MANUAL for these trucks. could result in injury or death.
Improper performance of lubrication or
maintenance procedures is dangerous and
4. Lower the forks or other implements to the ground
could result in injury or death. Read and
before performing any work on the truck. If this
understand the OPERATION & MAINTENANCE
cannot be done, make sure the forks or other
MANUAL before performing any lubrication or
implements are blocked correctly to prevent them
maintenance.
from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
The serviceman or mechanic may be unfamiliar with mounting or dismounting a truck. Clean any mud
many of the systems on this truck. This makes it or debris from steps, walkways or work platforms
important to use caution when performing service before using. Always face truck when using
work. A knowledge of the system and/or components steps, ladders and walkways. When it is not
is important before the removal or disassembly of any possible to use the designed access system,
component. provide ladders, scaffolds, or work platforms to
Because of the size of some of the truck components, perform safe repair operations.
the serviceman or mechanic should check the weights 6. To avoid back injury, use a hoist when lifting
noted in this Manual. Use proper lifting procedures components which weigh 23 kg (50 lb.) or more.
when removing any components. Make sure all chains, hooks, slings, etc., are in
Following is a list of basic precautions that should good condition and are of the correct capacity. Be
always be observed. sure hooks are positioned correctly. Lifting eyes
1. Read and understand all warning plates and decals are not to be side loaded during a lifting
on the truck before operating, lubricating or operation.
repairing the product. 7. To avoid burns, be alert for hot parts on trucks
2. Always wear protective glasses and protective which have just been stopped and hot fluids in
shoes when working around trucks. In particular, lines, tubes and compartments.
wear protective glasses when pounding on any 8. Be careful when removing cover plates.
part of the truck or its attachments with a hammer Gradually back off the last two bolts or nuts
or sledge. Use welders gloves, hood/goggles, located at opposite ends of the cover or device and
apron and other protective clothing appropriate to pry cover loose to relieve any spring or other
the welding job being performed. Do not wear pressure, before removing the last two bolts or
loose-fitting or torn clothing. Remove all rings nuts completely.
from fingers when working on machinery. 9. Be careful when removing filler caps, breathers
3. Do not work on any truck that is supported only and plugs on the truck. Hold a rag over the cap or
by lift jacks or a hoist. Always use blocks or jack plug to prevent being sprayed or splashed by
stands to support the truck before performing any liquids under pressure. The danger is even greater
disassembly. if the truck has just been stopped because fluids
can be hot.
10. Always use tools that are in good condition and 19. Tighten connections to the correct torque. Make
be sure you understand how to use them before sure that all heat shields, clamps and guards are
performing any service work. installed correctly to avoid excessive heat,
11. Reinstall all fasteners with same part number. vibration or rubbing against other parts during
Do not use a lesser quality fastener if operation. Shields that protect against oil spray
replacements are necessary. Do not mix metric onto hot exhaust components in event of a line,
fasteners with standard nuts and bolts. tube or seal failure, must be installed correctly.
12. If possible, make all repairs with the truck 20. Relieve all pressure in air, oil or water systems
parked on a level, hard surface. Block truck so it before any lines, fittings or related items are
does not roll while working on or under truck. disconnected or removed. Always make sure all
raised components are blocked correctly and be
13. Disconnect battery and discharge any capacitors
alert for possible pressure when disconnecting
(electric trucks) before starting to work on truck.
any device from a system that utilizes pressure.
Hang “Do not Operate” tag in the Operator’s
Compartment. 21. Do not operate a truck if any rotating part is
damaged or contacts any other part during
14. Repairs, which require welding, should be
operation. Any high speed rotating component
performed only with the benefit of the
that has been damaged or altered should be
appropriate reference information and by
checked for balance before reusing.
personnel adequately trained and knowledgeable
in welding procedures. Determine type of metal
being welded and select correct welding
procedure and electrodes, rods or wire to provide
a weld metal strength equivalent at least to that
of parent metal.
15. Do not damage wiring during removal
operations. Reinstall the wiring so it is not
damaged nor will it be damaged in operation by
contacting sharp corners, or by rubbing against
some object or hot surface. Do not connect
wiring to a line containing fluid.
16. Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.
18. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for
leaks with your hands. Pin hole (very small)
leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can
penetrate the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.
GROUP INDEX
GROUP INDEX Items
GENERAL INFORMATION Serial number locations, Dimensions, Technical data 1
VEHICLE ELECTRICAL
COMPONENTS
Console box, Key switch, Lamp specification chart 2
POWER TRAIN Procedure and suggestions for removal and installation 3
TRANSFER UNITS Procedures and suggestions for disassembly and reassembly 4
REAR AXLE Rear axle, Rear wheels 5
BRAKE SYSTEM Caliper, Brake pedal, Master cylinder 6
STEERING SYSTEM Steering control valve 7

Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve,
HYDRAULIC SYSTEM Down safety valve 8
MASTS AND FORKS Simplex mast, Duplex mast, Triplex mast 9

Inspection standards, Periodic replacement of parts, Lubrication
SERVICE DATA standards, Main component weight, Tightening torque for standard bolts 10
and nuts, Special tools
OPTIONS Rearview mirror kit, Backup buzzer kit, Working lamp kit, Tire kit 11
GENERAL INFORMATION
1
Vehicle Exterior ....................................................................................... 1–1
Models ....................................................................................................... 1–1
Serial Number Locations ...................................................................... 1–2
Chassis and Mast Model Identification ............................................ 1–3
Dimensions .............................................................................................. 1–4
Technical Data ......................................................................................... 1–5
GENERAL INFORMATION
Vehicle Exterior
Control lever Joystick box

(MC models) (FC models)
211267
Models
This manual applies to FB16KT, FB18KT and FB20KT.
Truck Model Serial Number

FB16KT EFB4A-00011-up (48V)
1-1
GENERAL INFORMATION
Serial Number Locations

Mast number Chassis number Nameplate
211129
1-2
GENERAL INFORMATION
Chassis and Mast Model Identification
[Chassis]
FB 16 K T
Three wheel models
Generation designator
Maximum capacity
16: 1600 kg (3500 lb)
18: 1800 kg (4000 lb)
20: 2000 kg (4400 lb)
Battery type
[Mast]
4 G 15 A 30
Maximum lifting height

[“30” stands for 3000 mm (118 in.)]
Order of the minor change

(“A” for the original, “B” for the first change, “C” for
the second change, and so on)
Applicable truck model designation

15: 1 ton class
20: 2 ton class
Kind of mast
G: simplex mast
H: duplex mast
J: triplex mast
Major change
(“1” for the original, “2” for the first change, and so
on up to “9”)
1-3
GENERAL INFORMATION
Dimensions
B E F
211130
1-4
GENERAL INFORMATION
Technical Data
Truck Models FB16KT FB18KT FB20KT
Class 1.6 ton 1.8 ton 2.0 ton
Load Capacity/Load Center N (kgf)/mm 15690 (1600)/500 17650 (1800)/500 19610 (2000)/500
[lbf/in.] [3500/20] [4000/20] [4400/20]
Truck size Length to Fork Face A mm (in.) 1893 (74.5) 1996 (78.6) 2032 (80.0)
Width B mm (in.) 1070 (42.1) 1070 (42.1) 1130 (44.5)
Height of Overhead
C 2040 (80.3) 2040 (80.3) 2040 (80.3)
Guard mm (in.)
Wheelbase D mm (in.) 1307 (51.5) 1410 (55.5) 1410 (55.5)
Service Weight (W/O Battery) kg (lb) 1700 (3748) 1765 (3891) 1975 (4354)
mm 913/170 913/170 935/170
Tread Front/Rear E/F
(in.) (35.9/6.7) (35.9/6.7) (36.8/6.7)
Tires Number Front/Rear 2/2 2/2 2/2
Tires Size Front 18 × 7-8 18 × 7-8 200/50-10
Rear 15 × 4.5-8 15 × 4.5-8 15 × 4.5-8
Turning Radius mm (in.) 1517 (59.7) 1620 (63.8) 1645 (64.8)
Travel Speeds Unloaded/Loaded km/h (mph) 16/14 (9.9/8.7) 16/14 (9.9/8.7) 16/14 (9.9/8.7)
Gradeability Loaded % 19 17 15
Lift Speeds Unloaded/Loaded m (in.)/sec 0.60/0.40 (23.6/15.7) 0.60/0.39 (23.6/15.4) 0.60/0.38 (23.6/15.0)
Lowering Speed Unloaded/Loaded m (in.)/sec 0.50/0.52 (19.7/20.5) 0.50/0.52 (19.7/20.5) 0.50/0.52 (19.7/20.5)
Battery Voltage V 48 48 48
Battery Rated Capacity (5 hrs.) MAX Ah 600 720 720
Battery Compartment Size mm 521 × 1006 × 650 624 × 1006 × 650 624 × 1006 × 650
Length × Width × Height (in.) (20.5 × 39.6 × 25.6) (24.6 × 39.6 × 25.6) (24.6 × 39.6 × 25.6)
Tilt Angle (forwards-backwards) 6°-7° 6°-7° 6°-7°
Traction Motor, 60 min rating kW 2 × 4.5 2 × 4.5 2 × 4.5
Hydraulic Motor kW 11.5 11.5 11.5
Steering Motor, 60 min rating kW 0.54 0.54 0.54
Traction Motor Control Method IGBT CHOPPER IGBT CHOPPER IGBT CHOPPER
Hydraulic Motor Control Method IGBT CHOPPER IGBT CHOPPER IGBT CHOPPER
1-5
VEHICLE ELECTRICAL COMPONENTS
Console Box ............................................................................................ 2 – 1

Functions of Central Vehicle Monitor System ............................................ 2 – 1 2
Electrical Components in Console Box ..................................................... 2 – 5
Disassembly and Reassembly .................................................................. 2 – 6
Direction Lever ........................................................................................ 2– 7
Accelerator Control ............................................................................... 2– 8
Key Switch ............................................................................................... 2– 9
Lighting Switch ....................................................................................... 2– 9
Fuses ......................................................................................................... 2 – 10
Lamp Specification Chart .................................................................... 2 – 10
Troubleshooting of Lighting and Horn Systems ............................ 2 – 11
Joystick Box ............................................................................................ 2 – 12
Finger-tip Control System .................................................................... 2 – 14
Nomenclature ........................................................................................... 2 – 14
Maintenance Precautions ......................................................................... 2 – 15
Operating Principles ................................................................................. 2 – 16
How to Set Controller ................................................................................ 2 – 20
Troubleshooting ........................................................................................ 2 – 25
Console Box 1
1 Central vehicle monitoring system 6

(CVMS)
2 Mode selector button 2
3 Steering tilt lever
4 Key switch 5
5 Lighting switch
3
6 Mode check button
4
NOTE
103043
For setting the clock and selection of KPH or MPH,
refer to “Selection of KPH or MPH” and “Setting the
clock”.
Functions of Central Vehicle Monitor System (CVMS)
9 8
10
1 2 3 4 5 6 7
Operations 208077
No. Monitor name When OFF When ON or flashing Remarks

1 Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached.
Motor brush wear Drive motor and pump motor Brushes are worn. After brushes are replaced,
2 indicator brushes in operable condition indicator turns OFF.
2-1
No. Monitor name When OFF When ON or flashing Remarks

Controller/motor Controller, drive motors and Overheating Overheating causes a
overheat indicator pump motor in normal significant output loss. When
3 temperature component temperature returns
to normal levels, output power
returns.
Remaining Normal battery condition Flashing indicates
battery charge battery needs to be
warning light recharged soon.
4 ON indicates battery
needs to be recharged
and lifting function
inoperable.
5 Brake fluid level indicator Normal fluid level Low fluid level
6 Parking brake warning Parking brake disengaged Parking brake
light disengaged
7 Malfunction lamp Normal Vehicle malfunction
Speedometer
8 KPH, MPH
Error indicator
Battery discharge When no bars show, vehicle is drivable but lifting Indicates remaining battery
9
indicator function is inoperable. power.
Hour meter 1 2 3 4 5
Advances every 0.1 hour
10
(Number advances every 6 minutes.)
Hour indication
2-2
Selection of KPH or MPH

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position. Button 1 Button 2
4. Push and hold button 1 for one to two seconds.

NOTICE: Display will show KPH and a 24-hour clock
until it is changed. When MPH is selected, the
clock will change to a 12-hour clock.
Setting the clock 103043

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position.
4. Push and hold button 1 until the minutes’ display
flashes.
5. Release button 1.
6. Adjust the minutes with button 2.
7. Push button 1 and release when the hours’ display
flashes.
8. Adjust the hour with button 2.
9. Push button 1 to lock in the time.
Error code display
Indication Condition
E When key switch is set to (ON) with direction lever in (F) or (R)
position. Turns OFF when the lever is set to (N).
E 0 ON Right drive motor overheat
E 1 ON Left drive motor overheat
E 2 ON Pump motor overheat
E 3 ON Controller overheat
E 4 ON Worn right drive motor brush
E 5 ON Worn left drive motor brush
E 6 ON Worn pump motor brush
H 1 ON Faulty setting of lift lever
H 2 ON Faulty setting of tilt lever
2-3
Error code display
Indication Condition
H 3 ON Faulty setting of attach-1 lever
H 4 ON Faulty setting of attach-1 lever (Option)
2-4
Electrical Components in Console Box
Horn cable
Monitor cable
2
Direction lever switch cable

1
211132
1 Key switch
2 Lighting switch
2-5
Disassembly and Reassembly

Disassembly
2
6
4
211133
Sequence
1 Console box (front panel) 5 Console box (rear panel)
2 Central vehicle monitor panel 6 Key switch
3 Direction lever 7 Light switch
4 Steering tilt lever
Disassembly procedure
(1) Remove the front panel and monitor panel from the
console box.
(2) Disconnect the harness connectors from the horn and T-nut
direction lever.
(3) Remove the screw from the steering tilt lever, and Tilt steering
remove the lever from the rear panel of the console lock lever
box. Screw
(4) Remove the rear panel.
211134
Reassembly
Follow the disassembly procedure in reverse.
2-6
Direction Lever
Structure
211135
1 Lever 3 Connector
2 Harness 4 Screw
2-7
Accelerator Control
Accelerator pedal
Initial position
Stopper bolt
1.5 to 2.5
Lock nut
Switching position
of idle switch
Floor plate
30 to 32 mm
(1.18 to 1.26 in.)
Accelerator lever
Accelerator
Adjusting screw
Position meter
211136
Adjustment procedure
(1) Disconnect the battery plug.
(2) Set the stopper bolt to 30 to 32 mm (1.18 to 1.26 in.)
from the floor to the upper face of bolt.
(3) Adjust the mounting angle of the position meter using
the adjusting screw so the switch inside the position
meter turns on when the accelerator lever is moved 1.5°
to 2.5° from the initial position. 206805B
Make sure the inside switch turns ON by checking the

continuity between the two terminals (indicated by
arrows) using an ohmmeter.
2-8
Key Switch
Terminal B M
Connection Main fuse
Logic card
destination Battery
● (OFF) ●
I (ON) ● ●
206806
Lighting Switch
Terminal 2 5 3 6
Connection Battery Battery Head Working
destination lamps lamp 2
6 3 5 2 3
OFF ● ●
5
ON (1) ● ● ● 21 6
ON (2) ● ● ● ●
Head
Lamp Fuse
Working
Lamp
211137
2-9
Fuses
Capacity (A) Location Main connecting device
500 Main fuse
325 Main controller Pump motor
50 Steering motor
15 Key switch, Lighting switch
Fuse holder
10 Power relay
NOTE
Refer to Parts Manual for proper replacement fuses.
Lamp Specification Chart
Item Bulb
Quantity Bulb color Remarks
Lamp 48 V External diagram
Head lamps 2 Clear 45 W
Working lamp 1 Clear 45 W
205833
2-10
Troubleshooting of Lighting and Horn Systems
Complaint Possible cause Remedy

Will not light a) Dead or weak battery Recharge or replace.
b) Fuses blown out Check and replace.
c) Open or short in circuit Repair or replace.
d) Poor grounding Clean ground spot and
re-make connection.
Lamps-general
e) Bulbs burnt out Replace.

Will light dimly a) Dead or weak battery Check and recharge.
b) Burned contact points in switches Repair or replace.
c) Loose terminals Retighten.
d) Dirty lenses Clean.
e) Waterdrops inside lenses Dry and replace packings.
f) Bulbs expired service life Replace.
lamps
Head
Will not light a) Lighting switch defective Replace.

b) Bulbs burnt out Replace.
Other lamps
Working lamp will a) Working lamp switch defective Correct if improperly

not light installed: replace if
internally defective.
b) Bulbs burnt out Replace.
Will not give blast a) Fuse blown out Check and replace.
of sound b) Open or short in circuit Repair or replace.
c) Horn switch defective Replace.
Horn
d) Horn defective Replace.

e) Horn button defective Repair or replace.
Will give an a) Horn switch defective Replace.

offensive blast of b) Horn defective Replace.
of sound
2-11
Joystick Box
Description
This system, unlike the conventional mechanical
control, is electronically actuated to reduce the effort
required of the operator in moving the control levers for
lift, tilt and attachment functions.
101466
(1) In the duplex and triplex full free masts, more oil
returns from the 1st lift cylinder than from the 2nd
lift cylinders to allow the 1st lift cylinder to retract
faster for better maneuverability.
2-12
(2) This system provides the following safety functions:
(a) When the pump motor is not running, the lift, functions will not work even if the control
tilt and attachment functions will not work levers are moved.
even if the control levers are moved. (d) The fault detection indicator in the LED
(b) When the emergency switch is in the ON alerts the operator to malfunctions involving
(pushed) position, the lift, tilt and attachments the electrical system and also an inoperable
functions will not work even if the control status. (If any problem occurs in the lift
levers are moved. system, for example, the system becomes
(c) When the seat switch is not ON (the operator is inoperative.)
not seated), the lift, tilt and attachments
2-13
Finger-tip Control System
Nomenclature
5
1
6 2
211139
1 Solenoid control valve 5 Emergency switch

2 Flow regulator valve 6 FC control levers (finger-control system)
3 Seat switch
4 Controller
2-14
Maintenance Precautions
The FC model contains a microcomputer. The followings
are precautions to be observed in performing any
maintenance on the FC model.
(1) When removing the controller cover, make sure to
protect the controller from outside mositure and water.
Controller
(2) Use the controller setting switch, to make sure the
control system is within truck specifications.
NOTE
101489A
Improper setting of the system will result in an
inability to lower the forks while inching. (See “How
to Set Controller.”)
A type
(3) Before performing repairs that require welding, be sure
to disconnect the battery plug and the controller from
the system connectors.
(4) When handling the controller by hand, never touch its
electrical terminals, or your body charge will rupture
some of the electronic components in the internal
controller circuits. Setting
switches
B type
Setting
switches
211140
2-15
Operating Principles (3) Supply power to the controller is initiated from the
Power Relay through a 10-Amp fuse and emergency
(1) The system is activated by turning OFF the switch. Pressing this switch into the ON position
emergency switch when the key switch is switched shuts down the controller without shutting down the
to the ON position and seat switch is ON (activated Main Controller.
when the operator is properly seated).
(4) With the starter switch turned ON and emergency
(2) As the control levers (joysticks) are moved to switch turned OFF, the proportioning solenoid are
operate the equipment (mast and forks), the amount under control of the joysticks. With the Pump
of lever movement will be translated into an Motor shut down (and hence the hydraulic pump
electrical signal: this signal goes into the controller, standing still), the spools in the control valves are
where it is converted into an output signal. At this inoperative because no pressure develops in their
point the controller issues an ON signal to the pilot chambers. Consequently, the equipment
unload solenoid, thereby turning ON the solenoid remains inoperative even when the starter switch is
which introduces hydraulic pressure into the control turned ON and emergency switch is turned OFF.
valve.The output signal applies to the proportioning
solenoid selected by the direction of the joystick
movement. Inside the control valve of the solenoid,
the spool is forced to slide, altering the internal oil
passage to by directing the oil to the corresponding
cylinders. The spool keeps on sliding until it comes
to the position where the pressure of its pilot
chamber becomes equal to the force of its centering
spring. In the meantime, the cylinder extends or
retracts against its load. As the joystick is moved
back to its neutral position, the signal to the
proportioning solenoid dies - this lowers the pilot
chamber pressures and allows the centering spring
to push the spool to its neutral position, whereby the
line to the cylinder shuts off: the pressure in the line
is now trapped, holding the cylinder in position. At
the same time , the ON signal to the unload solenoid
goes OFF, so that the part of the system, actuating
the equipment, goes into no-load state.
2-16
Finger-control system diagram
Joystick box
Control Emergency
Console box lever switch
(joystick)
CN4
Power supply
Seat
switch
Key
switch
Lever stroke signal

Fuse ON-OFF signal
15A CN5 12V
DC/DC
I O converter
Proportioning N U
solenoid + - T
Power relay
2-17
Battery Controller
Control 48V
valve
unit (12V)
Setting CN33
window
Flow control signal CN34
Lift cylinder
CN35
Drive controller
Hydraulic
pump Pump motor drive
Indicator signal Pump motor control signal 0 to 4

OUT IN
211141
(5) In addition to the functions described above, the

A type LED (red)
controller monitors the supply voltage and the
Rubber cover
electrical connections for the control levers
(joysticks), solenoids and other input/output
devices, and alerts the operator to a problem. When
a malfunction occurs, the fault detection indicator
and the LED on the controller flicker or light. Such
a problem is usually a fault in the harness or
connector and must be located by inspecting. The
hydraulic components such as pump control valve B type
are not monitored.
LED (red)
211142
2-18
Fault
LED flickering pattern Problem detected Symptom detection
indicator
LED flickers LED flickers LED flickers
(Normal) OFF
Open- or short-circuit in
No power supply to
control lever (with starter
particular system
switch in ON position)
ON
Open- or short-circuit in No power supply to

solenoid particular system
Control lever neutral position No power supply to

LED flickers
displaced particular system

OFF
Open- or short-circuit in
control lever (with starter
switch in ON position)
LED flickers
Seat switch OFF, or open- No power supply

circuit in it to all systems OFF
LED remains ON or OFF Problem in controller

204995
2-19
How to Set Controller

Set the controller on any of the following occasions:
Occasion Setting
After mast has been changed, or an optional Resetting of setting switches
equipment added
After control valve lift section solenoid has Adjustment of maximum lowering speed (when required)
been replaced (or control valve replaced)
After controller assembly has been replaced • Resetting of setting switches
• Adjustment of maximum lowering speed (when required)
• Adjustment of brightness at which light sensor operates
(when required)
Setting window
(with rubber cover)
Controller checker
connection jack(with
rubber cover)
Connectors
Setting window (without rubber cover)
Lowering speed adjusting knob

To be installed with this side up
LED (red)
Setting switches (dual inline package)
A type
Setting window (without rubber cover)

To be installed with this side up
Setting switches (dual inline package)
B type
LED (red) Lowering speed adjusting knob 211143
2-20
1. Setting switches
The controller has a total of 16 setting switches.
NOTE
Use a screwdriver to move each switch. The switch is
made of resin; be careful not to damage the switch
head.
(1) Switch setting pattern (Black dot indicates switch 205001

head.)
A type
Auxiliary ON : Check mode
(Set to OFF) OFF : Nomal mode
Pump motor Switch Communication Switch
Oil pressure Switch Seat switch Switch position position
sensor position position control speed
Equipped 3-wheel 1200 bps

Equipped
vehicle
Not Not 4-wheel 9600 bps

equipped equipped vehicle
SW2
OFF
Up 8 7 6 5 3 2 1
4 ON
SW3
OFF
8 7 6 5 4 2 1 ON
3
Switch Switch Switch Switch

Vehicle type position Mast No. of stages position Vehicle class position
position
2-stage 1-ton
3-wheel 2V
panoramic
2-stage
4-wheel 3V 2-ton
full-free
Domestic 3-stage 4V 3-ton

4-wheel full-free
205002A
2-21
B type
Contact type
Noncontact type
211144
(2) Example of setting

Truck: FB16KT
No. of stages: 3 V
Mast: 2G15A (2-stage panoramic)
205053A
2-22
2. Failures resulting from incorrect setting

(1) Incorrect setting for truck size (1 ton, 2 ton) or
incorrect model setting
(a) Incorrect setting will result in abnormal lowering
speed and inching feel. If a setting for a 1 ton
class is made on a 2 ton class, for example, the
lowering speed will be abnormally low. If a
setting for a 2 ton class is made on a 1 ton class,
the lowering speed will be abnormally high.
(2) Incorrect setting for number of control valve spools
(a) If the setting made for the number of spools is
greater than the actual number (FAULT lamp
lights and error code is displayed), the equipment
does not operate.
(Regarded as open-circuit in control valve
solenoid or joystick.)
(b) If the setting made for the number of spools is less
than the actual number, only the devices equal to
the number of the set spools will be actuated.
(3) Incorrect setting for mast
(a) A setting for a dual-stage full free mast or triple-
stage full free mast on a truck with dual-stage
panoramic mast will not affect the lowering speed.
(b) If the setting is made for dual-stage panoramic
mast on a truck with dual-stage full free or triple-
stage full free mast, the lowering speed of the 1st
lift cylinder will be abnormally low. This setting
will not affect the lowering speed of the 2nd lift
cylinders.
(4) Controller check (Be sure to set to OFF.)
If set to ON, the equipment operates faster and
disallows inching operation.
2-23
3. Lowering speed adjusting knob

(1) This knob is for increasing or decreasing the maximum
lowering speed.
(2) Adjust the knob to obtain the required lowering speed.
“0” is for minimum lowering speed and “F” is for
maximum speed.
NOTE
205004
1) Use a screwdriver to turn the knob.
2) This knob can be turned endlessly in both
directions.
3) Be careful not to damage the groove of the knob
by a screwdriver.
4. Working precautions
(1) When installing the controller, position it correctly. Be
careful not to turn it upside down.
(2) When resetting or adjusting the controller on the truck,
be sure to turn OFF the starter switch and lighting
switch.
(3) When removing the rubber cover, check to see if the
sealing label was removed in the past. (If this label has
been removed, ask the user for the removed label). 205037
(4) Be careful not to damage the rubber cover when it is
removed from the controller.
(5) Do not allow any foreign matter to enter the controller
through the setting window.
2-24
Troubleshooting
1. Preparatory steps
(1) The system receives supply power when the battery
connector is connected, the key switch is turned to the
ON position, and the emergency switch is turned OFF.
The finger-tip control becomes operable after the seat
switch closes (when operator is seated).
(2) Before deciding to replace a blown fuse, make sure that
the harness connectors in the power line are all in
sound condition, free of any sign of short-circuits.
(3) Use the test-use connector (Special tool) for checking
the connector-to-connector lines for continuity, for 205038
reading the voltage across two terminals and the ohmic
resistance of a line.
(4) When coupling or uncoupling a connector, make sure
that the key switch is turned OFF and the battery
connector is disconnected. Never try to insert or
forcibly pull off the connector, or its pins may be
damaged. When coupling a connector, be sure to insert
the half portion into its self-locking position.
(5) Before starting troubleshooting work, check the items
in the table below.
2-25
Conditions in
Check item What to check Remedy
the machine
Key switch OFF Hydraulic line Hoses, pipes and connectors for Repair leaking or
Emergency switch damage and sign of leak. damaged parts.
ON
Hydraulic devices Check control valve and hydraulic Repair damaged
cylinders for damage and oil leaks. or leaking parts,
if any.
Electrical connectors Check connectors for tightness, burns Repair.
and wires and breakage; check wires for insulator
stripping and signs of rubbing.
Key switch ON System check lamp Check the lamp goes ON and OFF Replace lamp
Emergency switch properly; if not, check its bulb. bulb if blown.
OFF
LED indicator (red) Be sure that red LEDs go ON and OFF Proper functioning
in the controller correctly. of LED indicator
is essential to
troubleshooting.
Hydraulic devices With your hands kept off control levers, Refer to the sections
see if solenoid valves and hydraulic dealing with control
pump are making any abnormal sound. valve and hydraulic
pump, respectively.
Operate control lever to see if any (Proper function
abnormal sound, indicative of flow of solenoid valves
throttling, comes from control solenoid is essential to
valve or from any other solenoid valve. troubleshooting.)
Work attachments Check each work attachment for the See “5. Trouble-
following: shooting guide for
(a) Does it work properly? solenoid control
(b) Does it “inch” properly? valves” on page 2-35.
(c) Does mast go down with proper
speed?
2-26
2. Troubleshooting cases as examples

(1) Explanatory notes and reminders
(a) In the text and diagrams to follow, electrical
connectors are abbreviated CN. An individual CN
will be identified by a number suffix (used in the
electrical wiring and connection diagrams).
Male Female
(b) In the flowchart, the numerical notation in the
(As seen from the connector’s end face)
box, , is a circuit number. The terminals of
a connector will also be identified by circuit 205042
numbers. As to the configuration of terminals in
each connector, refer to the wiring diagram.
(c) The wiring diagrams show the connector’s
terminal configuration on its male side: remember,
the configuration on the female side is a mirror
image of the male-side configuration.
(d) In trouble cases cited hereunder, “check the
connector coupling” means “uncouple and then
couple the connector, inserting the connector half
way to self-locking position.”
(e) In trouble cases cited, “continuity check”. A
continuity check will be indicated for some
harnesses. This direction also applies to “check
the connector coupling”: when checking a
connector as in (d), above, be sure to check the
connector for circuit continuity immediately after
coupling it.
(f) When reading a voltage with a circuit tester, be
sure to distinguish between polarities, (+) and (-),
so that the tester will not suffer internal damage.
Component Trouble symptom

Control levers Short-circuit
Solenoid valves Short-circuit, oil leakage
2-27
(2) Case 1: No motion of hydraulic cylinders.

Troubleshooting Procedure
No
Is error code displayed? (1) Operate lever.
Yes Defect in solenoid
(2) Does solenoid control valve
Yes control valve
produce grinding sound?
No Is model setting of controller
Reset correct?
No
Yes LED flashing to indicate
normal condition
Is error code "57"? Check LED condition. (1.2/1.2-second
Yes Continuous ON ON/OFF cycle)
Check LED condition. (Remains ON) OFF

LED
ON or
OFF flashing to Refer to Refer to
flashing Check drive
indicate Case 4. Case 3. system.
Refer to Refer to error
Case 4. Case 3.
Check LED flashing pattern or

error code to identify problem.
*
LED repeats 0.3-sec ON and 2.1-sec
OFF operations, or error code "54" (1) Check connection of applicable lever harness and connector.
is displayed. Lift lever: CN5 and CN33
Yes Tilt lever: CN6 and CN33
Open- or short-circuit in equipment
lever. (2) If there is no abnormality in connection, replace lever assembly.
No
LED repeats 0.6-sec ON and 0.6- (1) Check connection of applicable solenoid harness and connector.
sec OFF operations, or error code Yes Lift D: CN27 and CN35
"55" is displayed. Lift U: CN24 and CN35
Open- or short-circuit in solenoid. (2) If there is no abnormality in connection, replace solenoid.
No
LED repeats 1.2-sec ON and 0.6-

sec OFF operations twice, or error (1) Operate each lever several times.
Yes
code "H5" is displayed. (2) If problem is solved, turn off power switch, then turn it on again.
Deviation of lever neutral position. (3) If problem remains, go to item marked with *.
No
LED repeats 1.2-sec ON and 0.3-

sec ON operations three times, or (1) Check connection of applicable device harness and connector.
Yes
error code "E" is displayed. Seat switch and emergency switch
Seat switch turned OFF. (2) If there is no abnormality in connection, replace device.
No
Check drive system.
2-28
(3) Case 2: No inching motion of hydraulic cylinders.
Is grinding sound generated Yes (1) Check equipment for interference and looseness.
when equipment operates? (2) If abnormality is found, correct problem.
No
Is model setting of controller No

correct? Reset
Yes
Disconnect connectors CN5 thru

CN8 of applicable lever, and
measure resistance.
(1) With lever in neutral, is

resistance approx. 2.5 kΩ?
(2) Move lever slowly in
forward and backward Yes Faulty control valve
directions.
Go to Case 3.
Does resistance continuously
change between 0 and 5 kΩ?
Resistance should not
suddenly increase or decrease.
No
Check connection of applicable

lever harness and connector.
Lift lever: CN5 and CN33 If there is no abnormality in
Tilt lever: CN6 and CN33 connection, replace lever.
2-29
(4) Case 3: Controller’s LED (red) will not go ON.
NG
Check fuse. Replace fuse, and inspect harness.
OK
Is power supplied to controller?

Is voltage 12 V or higher? Yes Check connection of connectors
Measure voltage between terminals CN33, CN34 and CN35.
61 and 62 and between terminals 63
and 62 of connector CN35. Yes
No Replace FC controller.
Is voltage 48 V? Yes
Measure voltage between terminals Replace DC/DC converter.
27 and 337 of connector CN9.
No
Check harness continuity.
Check connection of connector
CN35, and reconnect.
2-30
(5) Case 4: Controller’s LED (red) remains ON.
Is power supplied to controller?

Is voltage 12 V or higher? No Is voltage between terminals 27 and 337 of connector
Measure voltage between terminals
CN9 approx. 48 V?
61 and 62 and between terminals 63
and 62 of connector CN35. No
Yes
Replace DC/DC
Yes
converter.
Check connection of connectors Check continuity in power
CN33, CN34 and CN35. supply wiring in control
box.
No Yes
No
Clean contact Correct problems.
surfaces of Replace FC
connectors and controller.
retighten bolts.
2-31
3. How to move the mast in an emergency

If the truck fails during operation, and you have to drive it
(engine is OK) or tow it to some distant place like the Lift section
Tilt section
repair shop, follow the instructions below.
2
1
! CAUTION
Before lowering the mast, be sure that there is no
one standing under the mast.
(1) Mast lowering

(a) Loosen lock nut 1 on the lift section of the control
valve.
(b) Using an Allen wrench, slowly loosen screw 2.
This allows the mast to go down by gravity:
tighten screw 2 and the mast will stop.
211145
(c) Tighten lock nut 1.
! CAUTION
Leaving nut 1 loose is dangerous: the mast might
suddenly start going down by itself.
2-32
(2) How to cope with a failed (open-circuit) seat switch

Your troubleshooting investigation might reveal that the
seat switch is an open-circuit or otherwise faulted and will
not function.
In this case, you can create temporary circuit continuity
through the seat switch line. The method is explained in the
illustration. The seat switch is part of the safety system. Be
sure to replace it with a new one as soon as possible.
205012A
! CAUTION
Illustrated above is a band-aid method
permissible only in an emergency situation. Be
sure to restore the seat switch line to the normal
hookup after replacing the failed switch.
2-33
4. How to clean harness connectors and system

components
(1) Open-circuit trouble is often due to the harness
connectors and components in dirty conditions: dust,
together with greasy matter, forms grime which, in
time, penetrates electrical connections, resulting in
loose metal-to-metal contact, or worse, electrical
separation of surface in contacts. For this reason, it is
essential that the connectors and components be
cleaned at each periodic inspection and at the time of 205046
servicing the machine. Instead of a commonly used
solvent, use Electronic parts cleaner (in the manner
illustrated on the right).
Electronic parts
Three Bond 29B
cleaner
NOTE
The cleaner liquid is volatile. All you have to do is
just give a strong spray to wash off grime. No need to
wipe off the sprayed liquid.
(2) After checking the connector for continuity, wash it as

above. Then, uncouple the connector and spray contact
surface activator onto contact surfaces. Now, install
and remove the connector several times to wet the
surfaces thoroughly with the activator liquid. After
coupling up the connector, make sure that it is in
locked state.
Contact surfaces
Three Bond 2501S (aerosol)
activator
NOTE
Do not spray too much: bear in mind that this spray
liquid reacts with some resins (plastic materials).
205047
2-34
5. Troubleshooting guide for solenoid control valves
Trouble symptom Possible cause Remedy

The pump discharge pressure 1. Sticky plunger in proportioning Disassemble and clean by washing.
will not build up solenoid of reducing valve, or If the plunger is sticky, replace the
sticky shuttle in reducing valve solenoid.
2. Open in lead wire or in solenoid Repair or replace.
coil
3. Input current to solenoid too Check to make sure that solenoid is
small drawing specified maximum input
current.
4. Unload valve stuck open • Check unload solenoid for action.
• Check unload valve for action.
5. Spool stuck in flow-divider Disassemble and clean by washing.
valve
Sticky spool Sticky plunger in proportioning Disassemble and clean by washing.
solenoid of reducing valve, or If plunger is sticky, replace solenoid.
sticky shuttle in reducing valve.
2-35
POWER TRAIN
Procedure and Suggestions for Removal and Installation ......... 3–1

Removal .................................................................................................... 3–1
Installation ................................................................................................. 3–7
Service Data ............................................................................................ 3–9 3
POWER TRAIN
Procedures and Suggestions for Removal and Installation

Removal
1. Remove the masts.
(Refer to MASTS AND FORKS section.)
2. Removing batteries
(1) Disconnect the battery plug.
(2) Open the battery cover, and lock it in the open
position.
(3) Remove the side covers (L.H., R.H.) and front
covers (L.H., R.H.).
Lock/unlock lever
211152
(4) Attach suspending ropes or adequate lifting device

to the batteries.
Unit: kg (lb)
Truck Model FB18KT,
FB16KT
Item FB20KT
Battery weight 1090 1225
(maximum) (2403) (2700)
(5) Remove the battery retaining plate and pin, and

then remove the batteries. 206918
3-1
POWER TRAIN
3. Removing front wheels

(1) Pull the parking brake lever and block the rear
wheels.
(2) Loosen the wheel nuts by two turns. Then, raise
the front end of the truck using a hoist or the
hydraulic system.
(a) Hoisting
Using a sling and eye-bolts at both ends of the
cross member at the top of the outer mast, lift the
front end of the truck with a hoist.
(b) Using hydraulic system
Tilt the mast fully backward and place wood
blocks under the mast. Tilt the mast forward to
raise the front end.
! CAUTION
After raising the front end, place wood blocks
under the frame to prevent the truck from falling.
210757
(3) Remove the wheel nuts.

(4) Remove the wheel.
Truck Model Solid pneumatic tire Solid tire

1 ton class 2 ton class
Item
Tire size of front 18 × 7 - 8 200/50-10
wheels
206920
4. Removing steps and floor plates

(1) Steps (L.H., R.H.) (3)
(2) Step plates (L.H., R.H.) Floor plate B
(3) Floor plate
(1) (1)
(2)
Remove floor plate B. Floor plate A
Disconnect the accelerator connector mounted on the
back side of the floor plate, then remove floor plate A. (2)
211153
3-2
POWER TRAIN
5. Removing steering hoses

Disconnect the steering hoses and pipes at the
connectors.
206922
6. Removing delivery pipe and drive motor harness

MC models
(1) Remove the drive motor harness at the connector.
Delivery pipe
Disconnect the harnesses of the brush wear
sensors and temperature sensors located on the
right and left sides.
(2) The harnesses are secured to the delivery pipe
with clamps. Loosen the clamps, and remove the
delivery pipe.
211154
3-3
POWER TRAIN
7. Removing brake components
(i)
(ii)
(iii)
(v)
(iv)
(vi)
206824
(1) Loosen the parking brake lever, and remove

parking brake cable assemblies (i) (L.H.) and (ii)
(R.H.).
Disconnect the parking brake cables at the
calipers, and keep the cables together on the frame
near the center brake.
(2) Position a drip pan, and disconnect brake fluid
tube (iii) at the master cylinder.
(3) Disconnect brake pipes (iv, v) (L.H., R.H.) at the
master cylinder. Disconnect the branch brake
hoses (L.H., R.H.) from the brake pipes.
(4) Remove brake pedal assembly (vi).
3-4
POWER TRAIN
8. Removing return hoses

Remove return hose (1) from the control valve, and
(1)
return hose (2) from the lift cylinder.
(2)
206925
9. Remove drive motors cables (L.H., R.H.).

Remove the generators (speed sensors) of the transfers (3) (3)
(L.H., R.H.).
10. Removing tension rods and brackets Left (2) (2) Right
transfer (4) transfer
Loosen right and left nuts (1) by approximately 6 mm
(0.24 in.).
Remove bolts (2), and take out bracket (3) and tension (1)
bolt (4) together from each side of the vehicle.
206926
3-5
POWER TRAIN
11. Removing transfer assemblies, drive motors and

calipers
Left Right
transfer transfer
(iii)
Gravity
center
(ii) (ii)
(i)
(i)
Frame
Frame
(iv) Gravity (iii) (iv)
center
206927
Remove the transfer assemblies with the drive motors

and calipers mounted.
First, dismount the left transfer, lower it, then pull it
out from the front of the vehicle. Then, dismount the Cow hitch
right transfer, lower it, then pull it out from the front.
(1) When suspending the assembly, position the wire
rope at the gravity center.
The suspending wire rope must be cow hitched.
When using a textile sling, make two loops to 206928
prevent slipping.
(2) Remove bolt (i) from the lower part of the step Total weight of transfer, 115 kg
and remove bolt (ii) from the frame, then remove drive motor and caliper (253.5 lb)
the assembly.
(3) Remove bolt (iii), and dismount the caliper
assembly.
(4) Remove bolt (iv) and dismount the drive motor.
(See illustration No. 206927.)
3-6
POWER TRAIN
Installation
Follow the removal sequence in reverse. For installation,
follow the instructions below.
! CAUTION
When mounting the transfer assembly on the
frame, do not insert a finger into the bolt hole to
check hole alignment.
1. Be sure to tighten bolts to the specified torque.
Front of vehicle
3 4 4 3
5 5
2
1 1
206785
A: Standard value Unit: N·m (kgf·m) [lbf·ft]

Drive motor mounting bolt 1 A 60 ± 12 (6.1 ± 1.2) [44.25 ± 8.85]
Transfer assembly mounting bolt 2 A 508 ± 51 (51.8 ± 5.2) [374.7 ± 37.6]
Tightening torque Bracket mounting bolt 3 A 176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]
Bolt nut 4 A 231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]
Hub nut 5 A 157 (16) [115.8]
2. Bleed the brake oil line.

(Refer to BRAKE SYSTEM section.)
3-7
POWER TRAIN
3. After installing the parking brake cable, be sure to

adjust.
(Refer to BRAKE SYSTEM section.)
4. Pour oil into the transfer cases:
Left transfer
Remove oil level plug (1).
Remove oil inlet plug (2).
(2)
Pour appropriate oil in the oil inlet. Make sure the oil
level reaches the level plug location.
Unit: liter (U.S. gal)
(1)
Left transfer Right transfer
1.09 1.86
Oil quantity
(0.29) (0.49) Front
of
vehicle
Right transfer
(2)
(1)
206786
5. Bleeding hydraulic oil line and inspecting oil level

Operate the tilt cylinders in the forward and backward
directions to bleed the tilt cylinders. Operate the lift
cylinders in the vertical directions to fill the cylinders
with oil.
Lower the lift cylinders to the lowest position, and
check the oil level gauge. If the oil level is low, add oil
to the specified level.
6. Checking steering oil line
Operate the steering wheel to make sure that it operates
smoothly.
3-8
POWER TRAIN
Service Data
A : Standard value
Truck Models 1 ton class 2 ton class

Item
Drive motor mounting bolt 1 A 60 ± 12 (6.1 ± 1.2) [44.25 ± 8.85]
Tightening torque Transfer assembly mounting bolt 2 A 508 ± 51 (51.8 ± 5.2) [374.7 ± 37.6]
N·m Bracket mounting bolt 3 A 176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]
(kgf·m)
[lbf·ft] Bolt nut 4 A 231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]
Hub nut 5 A 157 (16) [115.8]
3 4 4 3
Power Line
5 5
2
1 1
206785
3-9
TRANSFER UNITS
Specifications .......................................................................................... 4 – 1
Structure and Functions ....................................................................... 4 – 2
Procedures and Suggestions for Disassembly and
Reassembly ............................................................................................. 4 – 4
Disassembly ............................................................................................. 4 – 4
Inspection after Disassembly .................................................................... 4 – 5
4
Reassembly .............................................................................................. 4 – 6
Service Data ............................................................................................ 4 – 8
TRANSFER UNITS
Specifications
Truck Model
Item 1 ton class 2 ton class
Gear type Constant-mesh type, 3 stages (helical gears)

Transfer
58 x 81 x 45 =17.478
Reducing gear ratio
24 18 28
4-1
TRANSFER UNITS
Structure and Functions (Part 1)
Front of vehicle
7
7
A 8 8 A
6 6
1 3
4
5
2
206785
1 Transfer (left) 6 Wheel hub

2 Traction motor (left) 7 Front tire
3 Transfer (right) 8 Bracket
4 Traction motor (right) 9 Tension rod
5 Frame Section A: Mast support mounting section
Since two traction motors are installed in a limited Sections A support masts.
space, the traction motors are offset in position.
Tension rod 9 connects brackets 8, and includes a
turnbuckle to serve as a thrust rod for the left and right
transfer units.
4-2
TRANSFER UNITS
Structure and Functions (Part 2)
18
7 Left side
9 10 14 5
6
17
11 18
Front of vehicle
6 12 13
Right side
4
17
16
15
3 1
15
2 (View from left side)
Bolts marked with × : Bolts for mounting transfer units to frame 211046
1 Traction motor 8 Main case 15 Ball bearing

2 Input gear 9 Nut 16 Generator
3 Second gear 10 Plate (DC motor models only)
4 Third gear 11 Spacer 17 Oil level plug
5 Output shaft 12 Retainer 18 Air breather
6 Wheel hub 13 Taper roller bearing
7 Cover 14 Oil seal
The left and right transfer units are identical, and are The generator detects rotating speed.
mounted on the frame with bolts marked with an × in Helical gears are used for reduced operating noise.
the diagram.
The output shaft is provided with two taper roller
The left and right transfer units are installed to the bearings to withstand heavy loads.
traction motors. The motor shafts are jointed to the
involute splines of the input gears.
Transfer reducing
Driving force is transmitted via the input gear, second 17.478
gear ratio
gear, third gear, then to the output shaft that rotates the
wheel hub.
4-3
TRANSFER UNITS
Procedures and Suggestions for Disassembly and Reassembly

Preparation
1. Remove the power train consisting of the transfer, 2. Drain oil from the transfer.
traction motor and caliper. (Refer to Removal and 3. Remove the traction motor and caliper.
Installation of Power Train.)
Disassembly
8
12
9 19
7
6
5
4
3 10
11
18
16
17 14
15 13
18
2 16 14
1
211047
Sequence
1 Bolt 10 Output shaft, O-ring
Remove parts 2 to 12 as sub-assembly. 11 Taper roller bearing
2 Cover 12 Oil seal
3 Cap 13 Input gear
4 Nut 14 Ball bearing
5 Plate 15 Second gear
6 Spacer, O-ring 16 Ball bearing
7 Wheel hub, Hub bolt 17 Third gear
8 Taper roller bearing 18 Ball bearing
9 Retainer 19 Main case, Dowel pin
4-4
TRANSFER UNITS
Suggestions for Disassembly
1. Removing nut 4
Nut 4 is secured to output shaft 10 by punching.
Use a chisel to scrape punched section carefully. Do not
scratch output shaft 10.
Nut 4 is not reusable.
206789
2. Cover 2
Outer laces of taper bearings 8 and 11 that are press-fit into
cover 2 do not have to be disassembled if inspection finds
no abnormality.
Remove oil seal 12, and use a new seal.
Inspection after Disassembly

1. Inspect the gear teeth and splines for wear and damage.
2. Inspect the bearings for wear, damage, rotating
resistance and noise.
3. Inspect main case 19 and cover 2 for cracking and
damage.
4. Inspect the oil seal contact surface of retainer 9 for
scratches and damage.
4-5
TRANSFER UNITS
Reassembly
1 12
6 4 5
11
10
9 14
7 3 2
14
13
15
16
16
18
17
18
19
211048
Sequence
Assemble parts 1 to 4 prior to final assembly. 8 Spacer, O-ring
1 Cover 9 Plate
2 Taper roller bearing (outer) 10 Nut
3 Taper roller bearing (outer) 11 Cap
4 Oil seal 12 Main case
5 Output shaft, Inner lace of taper roller bearing 13 Third gear
2, O-rings 14 Ball bearing
Assemble parts 6 and 7, and inner lace of taper roller 15 Second gear
bearing 3 prior to final assembly. 16 Ball bearing
6 Wheel hub, Hub bolt 17 Input gear
7 Retainer 18 Ball bearing
Install sub-assemblies 5 and 6 in cover 1. 19 Bolt
4-6
TRANSFER UNITS
Suggestions for Reassembly

1. Inspect the mounting surfaces of cover 1 and main case
Unit: mm
12 for dents and burrs, and clean the surfaces.
2. To install oil seal 4, use a jig. Tap the jig to fit the oil 3- φ16.5
seal evenly. 2- φ18
Apply a thin coat of liquid gasket (Three Bond #1104) 80
109
on the oil seal mounting surface of cover 1.
50
68
54
3. Tighten nut 10, and check the preload of taper roller
.2
bearings 2 and 3. 10
When tightening the nut, insert vinyl tubes on three
symmetrical locations relative to the hub bolt and use a
hub holding tool. 207207
Hub holding tool: To be fabricated at service location
NOTE
Cut a vinyl tube with an inside diameter of 14 mm

(0.55 in.) into pieces of 25 mm (1 in.) in length, and
use these vinyl tube pieces to protect the screw sections
when using the spring scale for measurement.
Preload
Tangential force 59 to 88 N
206791
on hub bolt (6 to 9 kgf)
[13.3 to 19.8 lbf]
4. After checking preload, stake one side of nut 10 with a

dull punch to secure the nut in place.
Make sure the groove is flattened completely and the
Unit: mm (in.)
flattened area measures more than 4 mm (0.16 in.) in
diameter.
5. When installing cover 1 sub-assembly on main case

12, apply a thin coat of liquid gasket (Three Bond
#1104) on the mounting surfaces.
φ4
Tighten bolt 19 to the specified torque. (0.16)
108 ± 10 N·m
Bolt tightening torque (11.0 ± 1.0 kgf·m)
206792
[79.7 ± 7.4 lbf·ft]
4-7
TRANSFER UNITS
Service Data A: Standard value

Unit: mm (in.)
Truck Model
Item
Input gear and second gear 1 A 0.11 to 0.24 (0.0043 to 0.0094)
Gear backlash Second gear and third gear 2 A 0.11 to 0.24 (0.0043 to 0.0094)
Third gear and output shaft 3 A 0.12 to 0.30 (0.0047 to 0.0118)
Preload of output shaft and taper roller bearing 4
Tangential force on hub bolt A 59 to 88 (6 to 9) [13.3 to 19.8]
N (kgf) [lbf]
Tightening torque of cover mounting bolt 5
N·m (kgf·m) [lbf·ft] A 108 ± 10 (11.0 ± 1.0) [79.7 ± 7.4]
Transfer
211049
4-8
REAR AXLE

Rear Wheels ............................................................................................. 5 – 2
Procedures and Suggestions for Removal and Installation ........ 5 – 3
Rear Wheels ............................................................................................. 5 – 3
Rear Axle .................................................................................................. 5 – 4
Reassembly ............................................................................................. 5 – 7
5
Steering Axle ............................................................................................ 5 – 7
Rear Axle Assembly .................................................................................. 5 – 10
Inspection and Adjustment ................................................................. 5 – 14
Making sure of Minimum Turning Radius .................................................. 5 – 14
Service Data ............................................................................................ 5 – 15
REAR AXLE
Structure and Functions
2
3
4
19
18
11
8
10 12
13
14
15
16
17
16 206811
1 Housing 8 Oil seal 15 Taper roller bearing

2 Pinion gear 9 Steering axle 16 Nut
3 Rack gear 10 Wheel hub 17 Lock washer
4 Piston 11 Hub bolt 18 Hydraulic oil inlet (left
5 Cap 12 Hub nut wheel)
6 Taper roller bearing 13 Oil seal 19 Hydraulic oil inlet (right
7 Taper roller bearing 14 Taper roller bearing wheel)
The rear axle is coupled with the pinion gear and rack The steering axle connected to the pinion gear is linked
gear. The rack gear is mounted with pistons on both to two symmetrically arranged rear wheels. The
ends, and converts the reciprocal motion generated by steering axle and the taper roller bearing of the pinion
oil pressure to the rotational movement of the pinion gear support the rear wheel load.
gear. The pinion gear serves as a steering device.
5-1
REAR AXLE
Rear Wheels
Solid Pneumatic Tire Solid Tire
φ292.1 mm (11.5 in.)

φ203.2 mm (8 in.)
φ381 mm (15 in.)
φ381 mm (15 in.)

4
114.3 mm (4.5 in.)

127 mm (5 in.)
2 3
206812
1 Steering axle 3 Wheel nut

2 Rear wheel 4 Rim
15 × 4.5 × 8
Tire size (15 × 5 × 11.5)
Dimensions in parentheses ( ) are for solid tires.
5-2
REAR AXLE
Rear Wheels
Removal
1 Wheel nut
2 Rear wheel
Sequence
1. Pull the hand brake lever, and place wheel stoppers at
the front wheels.
1
2. Turn the key switch ON, and turn the steering wheel all 2
the way to either the right or the left.

3. Locate the hub nut on the one side of the vehicle where 206813
it is visible from the rear. Loosen the hub nut by
turning it two or three rotations.
4. Turn the steering wheel to the opposite direction, and
loosen the hub nut on the opposite side by turning it
two or three rotations.
5. Turn the key switch OFF, and lift the back of the
vehicle until the rear tires are off the ground.
a. Place a jack at the rear center (under the draw bar
pin) of the counterweight, and lift.
b. Attach a wire rope to the draw bar pin and lift with
a crane.
6. After the back of the vehicle is lifted, place jack stands
under the frame on both sides at the rear as a safety
measure.
7. Turn the key switch ON, turn the steering wheel, and
remove the right and left tires.
8. Turn the key switch OFF.
211050
Installation
Follow the removal sequence in reverse.
NOTE
Tighten the wheel nuts evenly to the specified torque.
Wheel nut 157 N·m

101212
tightening torque (16 kgf·m)
[116 lbf·ft]
5-3
REAR AXLE
Rear Axle
Removal (Part 1)
12
2
13
4
5
1
11
3 8
10
6
7
9
206815
Sequence
1 Battery cover, Gas spring, Seat 8 Hose (hydraulic suction)
2 Controller cover 9 Pipe (hydraulic delivery)
3 Battery 10 Motor, Hydraulic pump
4 Battery shield 11 Hose (hydraulic return)
5 Controller 12 Hose (rear axle return)
6 Bracket 13 Hydraulic tank
7 Hose (steering suction)
Preparation
1. Remove the rear wheels.
(Refer to Rear Wheel Removal procedure.)
2. Disconnect the battery plug located on the right side of
the foot area of the operator’s seat to cut off power.
5-4
REAR AXLE
Suggestions for Removal

The rear axle is mounted to the counterweight. To remove
the rear axle, it is necessary to remove all the surrounding
components such as the motor, hydraulic pump, hydraulic
tank and controller.
Removing battery cover

Before removal, open the battery cover and disconnect the
seat switch terminal. Remove the gas spring from the
frame, and remove the hinge bolts located on the
counterweight. The seat does not have to be removed.
Removing controller
Remove all cables connected to the controller. During
removal, record cable connecting locations so that they can
be reconnected to the original positions. Disconnect all
harness connectors, and bind them to keep them out of the
way during rear axle removal.
Removing motor and hydraulic pump

Disconnect the cables and harness connectors of the motor.
Arrange an oil pan to receive drained oil, and remove hoses
7, 8 and pipe 9. Do not remove the pipe on the suction side.
Removing hydraulic tank

Disconnect hoses 11, 12, then remove the hydraulic tank.
Since the tank contains oil, keep the tank balanced during
removal.
5-5
REAR AXLE
Removal (Part 2)
15
16
14
17
206816
Sequence
14 Connector 16 Steering hose
15 Overflow hose 17 Rear axle assembly and Steering axle
assembly

A steering sensor is mounted on the top of the rear axle. Be
careful not to damage the sensor when lifting the assembly.
Installation
Follow the removal sequence in reverse.
Suggestions for Installation
Tighten the rear axle assembly mounting bolts to the
specified torque.
Bolt tightening torque 436 N·m (44.5 kgf·m) [322 lbf·ft]
5-6
REAR AXLE
Steering Axle
Disassembly
6
5
4
3
2
1 206817
Sequence
1 Cap 6 Wheel hub, Hub bolt
2 Nut 7 Oil seal
3 Lock washer 8 Taper roller bearing
4 Nut 9 Steering axle
5 Taper roller bearing

1. Removing wheel hubs
Use a puller to remove the wheel hubs from the steering
axle.
5-7
REAR AXLE
Reassembly
3 2 5 6 7
211051
Sequence
1 Steering axle 6 Nut
2 Taper roller bearing 7 Lock washer
3 Oil seal 8 Nut
4 Wheel hub 9 Cap
5 Taper roller bearing

1. Assembling wheel hubs
(1) Insert the inner races of the taper roller bearings using
the bearing installer A (special tool).
A
Special tool needed
Bearing installer A 91268 - 01500
206820
5-8
REAR AXLE
(2) Filling insides of rear axle hubs with grease

Insert grease into the rear axle hubs. See the diagram
for proper grease filling condition. Add grease to the
roller holding devices. Fill grease to approximately
80% of the cavity. Do not add grease to the full level.
Adding grease to the maximum level causes excessive
heat generation and quickly deteriorates the grease.
When coating oil seal lips with grease, be careful not to
apply too much grease, as an excessive amount of
grease can cause leaks.
Refilling with grease 206821
2. Preload adjustment and lock nut

First, adjust the inside nut, next tighten the outside nut
(lock nut) to the specified torque, and then check the
preload. To measure the preload, attach a spring
balance to one of the hub bolts, then read the force to
start the rotation of hub.
Use the following allowable ranges when readjusting
used bearings.
Outside nut
0.5 to 5 N·m Inside nut
206821
Preload of hub bearing (0.051 to 0.51 kgf·m)
[0.37 to 3.7 lbf·ft]
6.5 to 65 N
Tangential force on hub bolt (0.66 to 6.6 kgf)
[1.46 to 14.6 lbf]
157 N·m
Lock nut tightening torque (16 kgf·m)
[116 lbf·ft]
5-9
REAR AXLE
Rear Axle Assembly

Disassembly
14 2
17
Section A
4
10 11
12 9
7
A 1 3
15
16
6
13 4
207204
Sequence
1 Bolt 10 Bolt, washer
2 Plate 11 Piston assembly
3 Shim 12 Rack gear
4 Pinion gear 13 Oil seal
5 Taper roller bearing (inner) 14 Oil seal
6 Taper roller bearing (inner) 15 Taper roller bearing (outer)
7 Bolt, washer 16 Taper roller bearing (outer)
8 Cap 17 Housing
9 Seal, O-ring
5-10
REAR AXLE
Suggestions for Disassembly Press

1. Removal of the pinion gear
17
Remove bolt 1, plate 2 and shim 3. Position housing
17 on a base, and use a press to remove pinion gear 4.
2. Inspect taper roller bearing (inner) 6 which is press-fit

in pinion gear 4 and taper roller bearings 15, 16 which 4 207205
are press-fit in housing 17. If the roller bearings are in
good condition, they do not have to be removed.

1. Housing
Inspect the sliding surface of piston assembly 11 for
damage.
If there are small scratches on the surface, use
sandpaper to remove the scratches.
2. Pinion gear and rack gear

Inspect the tooth surfaces for damage. Inspect the
steering axle mounting screw at the lower pinion gear
section for damage. Inspect the contact section of the
oil seal at the lower pinion gear section for damage.
3. Taper roller bearing

Inspect the rolling contact surface of the bearing.
4. Inspect the contact section of the oil seal of plate 2 for

damage.
5. Oil seal, O-ring and other parts

Replace oil seals 4, 5, other seals, O-ring 9, and piston
seal of piston assembly 11 with new parts.
5-11
REAR AXLE
Reassembly
4 16
Section A
12
8 7
6 9
11
10
A 17 15 B
14
13
12 207204
5
Sequence
1 Housing 10 Cap
2 Taper roller bearing (outer) 11 Bolt, washer
3 Taper roller bearing (outer) 12 Pinion gear
4 Oil seal 13 Taper roller bearing (inner)
5 Oil seal 14 Taper roller bearing (inner)
6 Rack gear 15 Shim
7 Piston assembly 16 Plate
8 Bolt, washer 17 Bolt
9 Seal, O-ring B: Overflow port
For reassembly, follow the disassembly sequence in

reverse.
1. When inserting oil seals 4, 5 into housing 1, use a
backing plate and strike the oil seals uniformly to set
the seals evenly into position.
5-12
REAR AXLE
2. Before installing piston assembly 7, apply sealant

1E2200J on the periphery of the piston and the sliding
surface of housing 1.
3. When installing taper roller bearings (inner) 13, 14,

coat them with hydraulic oil.
4. Coat the lips of oil seals 4, 5 with hydraulic oil and

install the seals.
5 To adjust the bearing end play after the installation of

taper roller bearings 13, 14, measure clearance 14 Clearance
between pinion gear 12 and taper roller bearing 14.
Subtract a value of 0.01 to 0.035 mm (0.0004 to 0.0014
in.) from the measured value, and insert a shim having
the thickness of the calculated value, then tighten plate
16.
12
Clearance – 0.01 to 0.035 mm = Shim thickness
(0.0004 to 0.0014 in.) 207206
6. Tighten bolt 17 to the specified torque.
45 ± 7 N·m
Bolt tightening torque (4.6 ± 0.7 kgf·m)
[33.2 ± 5.2 lbf·ft]
7. After reassembly, pour hydraulic oil into overflow port

B until the oil surface reaches the overflow port. Cover
the overflow port with tape.
5-13
REAR AXLE
Inspection and Adjustment
Making sure of Minimum Turning Radius

(1) While operating the vehicle at low speed, turn the
steering wheel all the way to the right, then to the left,
and check the diameter of the tire tracks in both turning
operations.
(2) Calculate minimum turning radius R by dividing the
turning diameter by two then adding the distance
R
between the center of the outside rear wheel and the
outside edge of the counterweight.
Unit : mm (in.)
206822
Item
Minimum turning radius
Truck Model
FB16KT 1517 (59.7)
FB18KT 1620 (63.8)
FB20KT 1645 (64.8)
5-14
REAR AXLE
Truck Model
Item
Preload of hub bearing 1
N·m (kgf·m) [lbf·ft] A 0.5 to 5.0 (0.051 to 0.51) [0.37 to 3.7]
Tangential force on hub bolt

N (kgf) [lbf] A 6.5 to 65 (0.66 to 6.6) [1.46 to 14.6]
Rear axle Lock nut 2 A 157 (16) [116]

Tightening
torque Rear axle tightening bolt 3 A 436 (44.5) [322]
N·m Steering axle tightening bolt 4 A 224 (22.9) [166]
(kgf·m)
Wheel nut 5 A 157 (16) [116]
[lbf·ft]
Plat bolt 6 A 45 ± 7 (4.6 ± 0.7) [33.2 ± 5.2]
211052
5-15
BRAKE SYSTEM
Specifications .......................................................................................... 6 – 1
Caliper Assembly ...................................................................................... 6 – 3
Brake Pedal Assembly .............................................................................. 6 – 4
Master Cylinder ........................................................................................ 6 – 5
Parking Brake Lever .................................................................................. 6 – 6
Reassembly ............................................................................................. 6 – 7
Master Cylinder ........................................................................................ 6 – 7
6
Pad Clearance Adjustment ....................................................................... 6 – 9
Brake Pedal Adjustment ............................................................................ 6 – 9
Brake Switch Installation ........................................................................... 6 – 10
Brake Fluid Line Bleeding ......................................................................... 6 – 10
Parking Brake Adjustment ......................................................................... 6 – 10
Troubleshooting ....................................................................................... 6 – 11
Service Data ............................................................................................ 6 – 12
BRAKE SYSTEM
Specifications
Truck Model
Item
Type Hydraulic (mechanical) motor disc brake system
Brake disc effective
162 (6.378)
diameter mm (in.)
Disc outside diameter
200 (7.874)
mm (in.)
Disc thickness
10 (0.39)
mm (in.)
Disc effective thickness
9 (0.35)
mm (in.)
Brake Main brake and Pad area
28.8 × 2 (4.46 × 2)
system parking brake cm2 (in2.)
Pad thickness
5 (0.2)
mm (in.)
Pad effective thickness
4 (0.16)
mm (in.)
The minimum clearance of
0.4 (0.016)
disc and pads mm (in.)
Pad material NS 179
Wheel cylinder inside
19.05 (0.75)
diameter mm (in.)
Wheel cylinder area
2.85 (0.44)
cm2 (in2.)
6-1
BRAKE SYSTEM
8 1
4
206824
1 Caliper assembly 5 Reservoir tank

2 Brake disc 6 Parking lever assembly
3 Traction motor 7 Equalizer bracket
4 Brake pedal assembly 8 Lever D
The brake pads clamp the brake disc, mounted on the The brake pedal assembly is mounted on the left side of
traction motor, to provide stopping force. the frame.
The caliper assemblies are installed on the rib section The cable linked to the parking lever pulls lever D of
of the traction motor. the caliper to provide stopping force.
6-2
BRAKE SYSTEM
Caliper Assembly
8 7 15 1
3
B 17
9
10
4 2 11
8 5 14 13
1
7 16
8
10
6
11
13 12
A 4
206825
1 Body assembly 8 Pin 15 Spring

2 Lever A 9 Spring 16 Bleeder screw
3 Lever B 10 Pad assembly 17 Brake disc
4 Pin, Split pin 11 Bolt, Washer A: Brake fluid inlet
5 Lever C 12 Adjustment bolt B: Parking brake cable
6 Lever D 13 Adjustment bolt
mounting hole
7 Pin, Split pin 14 Lock nut, Washer
The brake pads clamp the brake disc, mounted on the link sides, causing the pad assembly to clamp the brake
traction motor, to provide stopping force. disc. When the parking brake cable connected to
The caliper assemblies are installed on the traction section B pulls the lever in the direction of the arrow,
motor. Pressurized brake fluid entering from section A the pad assembly operates mechanically. Adjustment
pushes the piston into the cylinder of the body bolts 12, 13 and spring 15 maintain proper clearances
assembly. The piston then presses pin 7, which then between the brake disc and pads. The caliper assembly
pushes levers C and D to an open position. Levers A installed on the opposite side of the vehicle is
and B move with pin 4 as the fulcrum and open their symmetrically constructed.
6-3
BRAKE SYSTEM
Brake Pedal Assembly
Brake fluid 6
5
3 7
1
4
211053
1 Pedal bracket 5 Master cylinder

2 Brake pedal 6 Adjustment bolt
3 Brake link 7 Brake switch
4 Return spring
The brake pedal assembly is mounted on the left side of Brake fluid is supplied to the master cylinder from the
the frame. reservoir tank located under the left side of the
The adjustment bolt is used to set the brake pedal dashboard.
height.
The installation length of the brake switch is pre-
adjusted. When the pedal is pressed, the switch
activates and controls the operating speed of the
traction motor.
6-4
BRAKE SYSTEM
Master Cylinder
12
1 7
8
2 4 3
10 11 9
14
15
16 5 6 17 18
211054
1 Cylinder body 10 Clevis

2 Safety ring 11 Nut
3 Piston 12 Filter
4 Secondary cup 13 Gasket
5 Primary cup 14 Clevis pin
6 Spring pad 15 Snap pin
7 Spring 16 Valve
8 Dust cover 17 Valve body
9 Push rod 18 Valve seal
The inside diameter of the cylinder is 19.05 mm (3/4

in.), and the maximum stroke is 30 mm (1.2 in.).
6-5
BRAKE SYSTEM
Parking Brake Lever
Maximum stroke: 50°
8
3
2
211055
1 Lever body 5 Stopper

2 Gear 6 Spring
3 Notch 7 Hook
4 Grip 8 Pin
The parking brake lever is mounted on the left side of The maximum lever stroke is 50 degrees. There are a
the dashboard. total of 14 gear teeth. Adjust the parking brake so that
When the grip is pulled, the parking brake cable moves the brake activates and applies force when the third or
fourth tooth of gear 2 engages with the notch.
the pad assembly of the caliper to clamp the brake disc
and apply stopping force.
Notch 3 engages with gear 2 to retain the lever in
Grip operating effort 294 N (30 kgf) [66 lbf]
position. To release the parking brake, pull the grip and
press stopper 5. This disengages the gear from the
notch, and the lever returns to the original position.
6-6
BRAKE SYSTEM
Master Cylinder
Disassembly
❋ 7 8
6
5
4
3
2
211056
Sequence
1 Clevis, Nut, Push rod, Clevis pin, Snap pin 6 Spring
2 Dust cover 7 Valve body, Valve seal
3 Safety ring 8 Cylinder body
4 Secondary cup, Piston 9 Filler, Gasket
5 Spring pad, Primary cup, Valve
NOTE
Parts marked with (❋) are included in the repair kit.
6-7
BRAKE SYSTEM
1. Cylinder body
(1) Check the inner surface of the cylinder for rust,
corrosion and scuffing.
(2) Check the inlet port and relief port for clogging.
And check the joint bolts and boot for damage.
A : Standard value
2. Piston
B : Service or repair limit
Check the piston for damage, and replace if damaged.
If the clearance between the piston and cylinder 0.020 to 0.105 mm
A
Clearance between (0.0008 to 0.0041 in.)
exceeds the limit, replace both cylinder and piston.
cylinder and piston 0.2 mm
3. Return spring B
(0.0078 in.)
Replace the return spring once a year.
4. Primary cup, Secondary cup and Valve

Inspect rubber parts for damage and swelling. Replace
the primary cup, secondary cup and valve once a year.
Reassembly
Follow the disassembly sequence in reverse. Also
follow the instructions below.
(1) Clean metal parts with a volatile cleaning solution,
and thoroughly dry using compressed air.
(2) Apply a thin coat of brake rubber grease (Metal
Rubber #20) or brake fluid on the inner surface of
the cylinder and the piston cup.
6-8
BRAKE SYSTEM
Pad Clearance Adjustment

Pad B
Use adjustment bolt A to adjust pad A clearance. Pad B
moves as adjustment bolt A is turned.
Therefore, use adjustment bolt B to adjust pad B clearance.
One rotation of adjustment bolt A moves pads A and B
approximately 1 mm (0.04 in.) to the right or left according Clearance
to the direction of the bolt rotation. One rotation of
Pad A
adjustment bolt B moves pad B approximately 1 mm (0.04
Adjustment bolt 206825A
in.) to the right or left according to the direction of the bolt
rotation.
Adjust the clearance to a range of 0.4 to 1.1 mm (0.0157 to
0.0433 in.) at the tip on each side. Adjustment bolt A
After adjustment, tighten the lock nut.
2.94 to 5.88 N·m

Lock nut tightening torque (30 to 60 kgf·cm)
[2.17 to 4.34 lbf·ft]
Adjustment bolt B
206825B
Brake Pedal Adjustment

(1) Use the stopper bolt to adjust pedal height A (distance C
between frame and the top of pedal pad). D
(2) Set push rod length B to the specified dimension, and
install the push rod into the master cylinder. The A’ A
clearance between the push rod and piston should be Stopper bolt
0.5 to 1.5 mm (0.02 to 0.06 in.). The pedal play C
should be 3 to 9 mm (0.12 to 0.35 in.).
(3) After adjustment, check to make sure that pedal stroke
D (brake activating point) is as specified.
Unit : mm (in.)
Truck Model
Item 1 ton class 2 ton class
Pedal height A 202.1 206830

from floor plate (7.96)
Pedal height A’ 208.1
from frame (8.19)
Push rod length B 118.6 (4.67)
Free play C 3 to 9 (0.12 to 0.35)
Pedal stroke D 25 to 38
(brake activating point) (1.0 to 1.5)
6-9
BRAKE SYSTEM
Brake Switch Installation

(ON/OFF point)
(1) Use the adjustment bolt to adjust the brake pedal Brake switch
0.7 to 1.3 mm
height, then tighten the lock nut. (0.027 to 0.05 in.)
(2) By rotating the push rod of the brake master cylinder,
adjust the clearance between the push rod and piston to
a range of 0.5 to 1.5 mm (0.019 to 0.059 in.).
When properly adjusted, the pedal should travel a
distance of 3 to 9 mm (0.12 to 0.35 in.) when pressed.
Lock nut
(3) Install the brake switch, and adjust so that the switch
205753
activates when the brake pedal is pressed 7 to 13 mm
(0.27 to 0.51 in.). Then, tighten the lock nut.
The brake switch should turn ON and OFF with pedal
movement of 0.7 to 1.3 mm (0.027 to 0.051 in.).
Brake Fluid Line Bleeding
When any part of the brake fluid system is disassembled for
repair or when brake pedal movement is spongy, bleed the
brake fluid line as follows:
(1) Attach a clear vinyl tube to the bleeder screw of the
right caliper assembly, which is located furthest from
the master cylinder. Place the other end of the tube into
a jar filled with brake fluid.
(2) Check the brake fluid level in the reserve tank. Add if
the level is low.
(3) Pump the brake pedal several times, and then keep the
pedal pressed. While holding the pedal pressed, loosen
the bleeder screw. While brake fluid is flowing into the
vinyl tube, tighten the bleeder screw.
(4) Repeat the above procedure until no air bubbles are in
the brake fluid.
Repeat the same procedure to bleed the left caliper
assembly.
After air bleeding is completed, add brake fluid in the
tank to the specified level.
Parking Brake Adjustment
When the pad clearances are adjusted to approximately 1.1
mm (0.043 in.), the notch should engage with the third or
fourth tooth of the gear when the parking brake lever is
pulled.
If the pads are worn, tighten the adjustment bolts of the
calipers to adjust the clearances. To adjust the cable length,
use the cable adjustment bolt.
206833
6-10
BRAKE SYSTEM
Troubleshooting *
Oil leak from master cylinder Inspect cylinder. If no abnormality
primary cup is found, replace piston cup.
Oil leak from caliper cylinder If piston cup is deformed, replace
cup cup and brake fluid (use genuine
Inadequate braking force brake fluid).
Oil leak from oil pipe joint Re-tighten, or replace pipe
and joint.
Worn lining Replace.
Oil adhesion on lining Clean with brake component
cleaner and repair or replace.
Air in hydraulic system Bleed master cylinder and

caliper cylinder.
Faulty master cylinder or Replace piston cup.
piston cup
Excessive pedal stroke
Low oil level in master cylinder Add brake fluid.
Foot Excessive clearance of master Adjust.
brake cylinder push rod
Brake fluid leak Refer to above section marked
with *.
Oil or grease adhesion on Clean with brake component cleaner

Imbalance in braking lining or disc and repair. If oil and grease cannot be
power removed from lining, replace lining.
Brake disc wobbling or loose Replace disc. If problem is caused
mounting by loose mounting, re-adjust and
re-tighten.
Lining surface too smooth Replace brake pad.

Worn lining
Brake squealing
Loose caliper tightening bolt Re-tighten.
Dirty disc Clean with brake component cleaner.
Inadequate clearance Adjust to standard clearance

Parking brake stroke too
between disc and lining value.
short
Parking brake cable too short Adjust cable length using
adjustment bolt.
Abnormal noise from Inadequate clearance between Adjust to standard clearance

Parking hand brake during brake pad and disc value.
brake driving Warped brake disc Repair brake disc according to
repair standard, or replace.
Parking brake cable too long Adjust cable length using

adjustment bolt.
Parking brake not
producing stopping force Brake lining worn beyond Replace brake pad.
limit
Excessive clearance between Adjust clearance between
brake pad and disc brake pad and disc.
6-11
BRAKE SYSTEM
Unit: mm (in.)
Truck Model
Item
Pedal height 1
A 202.1 (7.96)
(between upper pedal edge and floor)
Pedal stroke 2 (brake activating point) A 25 to 38 (1.0 to 1.5)
Free play 3 A 3 to 9 (0.12 to 0.35)
Push rod length 4
A 118.6 (4.67)
(standard assembly dimension)
Clearance between piston and push rod 5 A 0.5 to 1.5 (0.019 to 0.059)
Brake switch activating pedal stroke 6 A 7 to 13 (0.27 to 0.51)
Brake switch activating dimension 7 A 0.7 to 1.3 (0.027 to 0.05)
Brake 2
6
pedal 3
5
4
206831
6-12
BRAKE SYSTEM
Unit: mm (in.)
Truck Model
Item
+0.052 +0.00205
Cylinder body inside diameter 1 A 19.05 0 (0.7500 0 )
+0.020 +0.0079
Piston outside diameter 2 A 19.05 -0.053 (0.7500 -0.00209 )
A 0.020 to 0.105 (0.00079 to 0.00413 )
Clearance between cylinder and piston
B 0.2 (0.08)
0 0
A 20 -0.3 (0.79 -0.012)
Primary cup lip-side outside diameter 3
B (Replace once a year.)
A 20.2 ± 0.2 (0.795 ± 0.008 )
Secondary cup lip-side outside diameter 4
Master B (Replace once a year.)
cylinder A 46.8 (1.843 )
Return spring free-movement length 5
B (Replace once a year.)
1 5
4 2
3
211057
6-13
BRAKE SYSTEM
Unit: mm (in.)
Truck Model
Item
Tightening Pad assembly tightening
A 17.65 to 26.48 (180 to 270) [13.02 to 19.53]
torque bolt 1
N·m
(kgf·m) Adjustment bolt lock nut 2 A 2.94 to 5.88 (30 to 60) [2.17 to 4.34]
[lbf·ft] Bleeder screw 3 A 6.86 to 11.77 (70 to 120) [5.06 to 8.68]
A 5 (0.2)
Pad lining thickness 4
B 1 (0.039)
Lever D pin hole stroke with 1.1 mm
(0.043 in.) of clearance between brake A 5 (0.197)
disc and pad 5
Lever D pin hole stroke with 4 mm
A 20 (0.787)
(0.196 in.) of pad thickness wear 6
Brake disc thickness 7 A 10 (0.394)
Caliper
2 1
206832
6-14
STEERING SYSTEM
Specifications .......................................................................................... 7 – 1
General ..................................................................................................... 7 – 2
Steering Control Valve .............................................................................. 7 – 3
Procedures and Suggestions for Removal and Installation ....... 7 – 4
Steering Column Assembly ....................................................................... 7 – 4
Steering Control Valve .......................................................................... 7 – 6
Disassembly ............................................................................................. 7 – 6
Inspection ................................................................................................. 7 – 8
Reassembly .............................................................................................. 7 – 9
Hydraulic Circuit Diagram .................................................................... 7 – 14 7
Troubleshooting ...................................................................................... 7 – 15
Service Data ............................................................................................ 7 – 16
STEERING SYSTEM
Specifications
Truck Models
Items
Type All hydraulic power steering
Diameter of steering wheel mm (in.) 328 (12.9)
Manufacturer Ognibene
Steering control valve
Flow rate liter (cu. in.) /min 7.6 (464)
7-1
STEERING SYSTEM
General
5
7
E H
F
D
B A
F E
1
C
J
6 3 2 206834
1 Hydraulic tank 5 Steering wheel

2 Hydraulic pump 6 Steering cylinder
3 Steering pump 7 Hydraulic control valve
4 Steering control valve
The steering system is an open-center type, and uses a Overflow oil at the pinion gear of the rear axle returns
dedicated steering pump to feed oil. to the hydraulic tank.
The steering pump has a built-in relief valve to protect Oil from the hydraulic pump enters the hydraulic
the steering control valve and rear axle assembly. control valve for loading operation.
Oil enters the steering control valve to provide In the steering system, oil flows as follows:
directional control of the rear axle. When the steering
wheel is not operated, oil returns to the hydraulic tank A ➞ C ➞ D ➞ [ EF ] ➞ G ➞ H
via the hydraulic control valve.
7-2
TROUBLESHOOTING FOR CONTROL CIRCUITS
Steering Control Valve
13
T L R P
5 6 7 8 1 9 10 2 11 3 12 4
208230
1 Long housing 8 Drive shaft P: Pump port

2 Spacer plate 9 Control sleeve T: Tank port
3 “Gerotor” set 10 Control spool L: Cylinder port (left)
4 End cap 11 Spacer R: Cylinder port (right)
5 Thrust needle 12 Spacer
6 Centering spring 13 Check valve
7 Pin
7-3
STEERING SYSTEM
Steering Column Assembly

Removal
1
3
8
5
4
B
2
9
B
8
10 6
A
9 A
211085
Sequence
1 Steering wheel, Cap, Nut, Washer 7 Hose, Pipe, Hose clamp, Connector, O-ring
2 Console box (front panel) 8 Tilt steering lock lever, Spacer, Shaft, Bolt,
3 Central vehicle monitor panel Split pin
4 Forward/reverse lever 9 Pin, Washer, Split pin
5 Console box (rear panel) 10 Steering column assembly
6 Floor plate
7-4
STEERING SYSTEM
Suggestion for Removal
Steering wheel removal

Use the Wheel puller (special tool).
Special tool needed
Wheel puller 91268 - 10600
205770
Inspection
(1) Steering wheel free play
Check the free play with the key switch in the ON
position.
(2) Steering effort
(a) Apply the parking brake with the key switch in the
ON position, operate the lift lever to raise and
lower the lift bracket until the hydraulic oil
temperature increases to 30 to 60°C (86 to 140°F).
(b) Attach a spring scale to the rim (or a spoke) of the
steering wheel. Pull the scale in a tangential
direction and read the scale just as the wheel
begins to turn. 206836A
2.2 N·m
Steering effort (0.22 kgf·m)
[1.62 lbf·ft]
22 N
Spring balance
(2.2 kgf)
reading
[4.9 lbf]
7-5
STEERING SYSTEM
Steering Control Valve
Disassembly
11
6
12
10
208232
Sequence
1 End cap, Bolts, O-ring and Spacers 7 Control sleeve
2 “Gerotor” set, O-ring 8 Control spool
3 Drive shaft, Spacer plate and O-ring 9 Pin
4 Retaining ring 10 Centering springs
5 Seal gland bushing, O-ring, Oil seal and 11 Check valve, Check ball retainer, Ball, O-ring,
Dust seal Check seat and Screw
6 Thrust needle, Race bearing 12 Long housing
7-6
STEERING SYSTEM

(1) Retaining ring removal
Remove the ring from the housing by prying the end of
the ring out of the groove. Do not damage the
machined surface.
208233
(2) Seal gland bushing removal

Position the control spool and control sleeve assembly
so that the pin is even with the center of the assembly.
Remove the bushing.
208234
(3) Control spool and sleeve removal

Remove the control spool and sleeve assembly from
the housing by pulling it toward the end of the housing
opposite to the flange. Remove the pin from the
assembly.
NOTE
To prevent damage to the housing, slowly pull out the
assembly while twisting.
208235
NOTE
Before removing the spool from the sleeve, put a mark
across the spool and sleeve so that the spool can be
installed in the same position.
(4) Control spool and sleeve disassembly
200668
Pull the control spool from the sleeve enough to permit
removal of the centering springs. Remove the centering
7-7
STEERING SYSTEM
Inspection
Spool movement in housing and sleeve
(a) Check for sliding movement in the sub-assembly
condition.
(b) If any defective movement is found, check sliding
surfaces.
If any defect such as abnormal wear, scratch, burr or
rust is found, replace the entire unit with a new one.
7-8
STEERING SYSTEM
Reassembly
9 7 10
12
4 5 3 6 1 11
208236
Sequence
1 Long housing 7 Thrust needle, Race bearings
2 Check valve, Check ball retainer, Ball, O-ring, 8 Seal gland bushing, Oil seal, Dust seal and
Check seat and Set screw O-ring
3 Control sleeve 9 Retaining ring
4 Control spool 10 Drive shaft, Spacer plate and O-ring
5 Centering springs 11 “Gerotor” set, O-ring
6 Pin 12 End cap, O-ring, Spacer and Bolts
Start by :
(a) Replace worn or defective parts.
(b) Wash all metal parts and blow dry.
(c) Replace O-rings and seals.
(d) Apply grease to O-rings and other sealing parts.
7-9
STEERING SYSTEM

(1) Check valve assembling
Put the retainer in position on the housing. Put the seat
in position in the housing with the hole at the bottom.
Apply Loctite 271 to the threads of the set screw and
tighten the screw to the specified torque.
11.3 N·m
Tightening torque for set
(1.2 kgf·m)
screw
[8.3 lbf·ft] 208237
(2) Control spool and sleeve assembling

Check the direction in which the spring groove of the
sleeve is aligned with that of the spool and then, slide
the spool into the sleeve while twisting the spool.
If there are any alignment marks made at the time of
disassembly or alignment marks installed by the
manufacturer, use the marks to align the assemblies.
NOTE
200670
Check that the control spool rotates smoothly in the
control sleeve.
(3) Centering spring installation

Align the spring grooves of the spool-and-sleeve and
stand the spool-and-sleeve on a flat bench. Use the
spring inserting tool to install springs. Place each set
of three springs back to back and pinch six springs in
the tool with notches on both sides facing downward.
See the illustration on the right.
200671
As shown in the illustration, push one end of the
springs with fingers and push the springs into the
spool-and-sleeve groove. In case there is no inserting
tool, assemble the springs by inserting them one by one
and right and left alternately.
Spring inserting tool 97157 - 00100
7-10
STEERING SYSTEM
(4) Control spool and sleeve assembly installation to

housing
Insert the pin into the hole of the control spool-and-
sleeve assembly and align both ends of the pin with the
outside diameter of the sleeve. Insert the spool-and-
sleeve assembly into the housing from the rear (in the
direction as shown in the illustration).
Insert the spool-and-sleeve assembly while slowly
twisting it with the pin kept at a horizontal position. 208238
Insert the spool-and-sleeve assembly until its rear edge
face becomes flush with the edge face of the housing.
Do not insert any further.
(5) Seal installation
• Install the dust seal on the seal gland bushing to
place the flat side facing the bushing.
• Install the quad ring seal in the bushing by
smoothing it into place with your finger.
207184
(6) Reassembling the seal gland bushing

• Install the bushing assembly over the spool end with
a twisting motion. Tap it into place with a soft head
mallet. Make sure the bushing is flush against the
bearing race.
208239
• Install the retaining ring in the housing and pry it

with a screwdriver around the entire circumference
to ensure a good sitting.
207195
7-11
STEERING SYSTEM
(7) Reassembling the wear plate

• Clamp the housing in a vise, equipped with soft jaws
or softened with rag. Clamp lightly over the flats of
the flange. Do not overtighten the vise jaws.
NOTE
Check that the spool and sleeve are flush with or
slightly below the surface of the housing.
208240
• Install the O-ring in the housing. Place the spacer

plate on the housing and align the bolt holes with the
tapped holes in the housing.
208241
(8) Reassembling the drive shaft

Turn the control spool-and-sleeve assembly to make Port surface
the port surface of the housing parallel with the pin. Drive
Insert the drive shaft to engage the pin in the yoke of
the drive shaft. To ensure positioning in the following
work process, draw a line such as line B in the Pin parallel with
illustration right below on the end face of the drive port surface
shaft spline with a felt-tip pen. Pin

208242
7-12
STEERING SYSTEM
(9) Reassembling the Gerotor set

• Install O-ring in the Gerotor set. Gerotor set star valley A
• Face the O-ring side of the Gerotor set toward the
spacer plate side. Fit the Gerotor set into the drive B
shaft by aligning the root (line A) of the Gerotor set
with line B of the drive shaft.
Drive(marked) C
Check that lines A, B, C, and D are in parallel with
each other. D
Align bolt holes of the Gerotor set with the drive

shaft and star kept engaged.
This procedure is important in determining the valve
timing of this unit.
Pin Port surface

208243
(10) Reassembling the end cap

• Install the drive spacer in the Gerotor set. Install the End cap
O-ring in the end cap. Install the end cap in the
Gerotor set and align the holes. Cap screw
O-ring
Drive spacer
208244
• Apply oil to bolt threads and tighten bolts evenly in

the sequence as shown in the illustration on the right.
The tightening torque is shown in the table below.
17 N·m
Initial torque for (1.7 kgf·m)
screws [12.5 lbf·ft]
31.2 N·m
Finishing torque for (3.2 kgf·m)
screws [23 lbf·ft] 200677
After installing the end cap, install the steering shaft to the
spool and make sure the spool rotates smoothly.
7-13
R
Hydraulic control valve L

STEERING SYSTEM
(DC motor, FC models)

T1
Steering cylinder
B4
A4 Orbit roll
b4 a4 Displacement 63 cc/rev.
Relief 6.5 MPa
B3
Hydraulic Circuit Diagram
A3
3 T P
b3 a3 Pump motor
B2 36 / 48V Dual voltage
Steering motor
11.56 kW (48V) Operation
A2 0.55 kW Operation
b2 a2 M M
Gear pump
Displacement Gear pump (Steering)
7-14
A1 24.5 cc/rev. EU :Displacement
4.0 cc/rev.
b1 a1
Return Suction
filter strainer
15 μm 100 mesh
18.1 MPa
2.5 MPa
P T2
211086
STEERING SYSTEM
Troubleshooting
Clogged metering section Disassemble and clean.

Control valve
Faulty spool operation Disassemble and clean.
malfunction
Faulty bearing Disassemble and
replace.
Heavy steering
Rear axle cylinder
wheel operation Faulty piston seal Replace.
malfunction
Others Flattened pipe, mixing of Clean or replace oil line.

foreign particles
Control valve Sticking of spool or sleeve Replace.

malfunction Damaged centering spring Replace.
Instability in
steering wheel
operation Flattened pipe, mixing of Clean or replace oil line.
Others foreign particles
Faulty piston seal in rear Replace.
axle cylinder
7-15
STEERING SYSTEM
Service Data
A: Standard value
Unit: mm (in.)
Truck Models
Items
Steering effort (at steering wheel rim)

N·m (kgf·m) [lbf·ft]
(Standard value measured with key switch ON, A 2.2 (0.22) [1.62]
steering wheel turning speed of 1 revolution/sec, and
stationary swing operation)
Steering
wheel Inside wheel A 83°
Turning angle deg
Outside wheel A 56°
Steering wheel nut A 53.9 to 58.8 (5.5 to 6.0) [39.8 to 43.4]

Tightening torque
Steering bracket bolts A 29.4 (3) [21.7]
Displacement cc (cu. in.)/rev. A 63 (3.84)
Rated flow rate liter (cu. in.)/min. A 7.6 (464)
Maximum operating pressure

A 6.5 (66.3) [943]
MPa (kgf/cm2) [psi]
End cap bolts 1 A 31.2 (3.2) [23]

Tightening torque
Check valve set screw 2 A 11.3 (1.2) [8.3]
Steering
control
2 1
valve
208246
7-16
HYDRAULIC SYSTEM
Specifications ........................................................................................... 8 – 1
Mechanical Control Type (MC model) ................................................ 8 – 3

Structure and Functions............................................................................. 8 – 4
Hydraulic Line .......................................................................................... 8 – 4
Control Valve ........................................................................................... 8 – 5
Lift and Tilt Cylinders ............................................................................... 8 – 8
Flow Regulator Valve ............................................................................... 8 – 9
Down Safety Valve ................................................................................... 8 – 9
Gear Pump ................................................................................................ 8 – 10
Procedures and Suggestions for Removal and Installation ...................... 8 – 10
Control Valve ............................................................................................. 8 – 12
Procedures and Suggestions for Removal and Installation ...................... 8 – 12 8
Procedures and Suggestions for Disassembly and Reassembly.............. 8 – 13
Lift Cylinders.............................................................................................. 8 – 16
Dual-stage Panoramic Mast (Simplex Mast) .......................................... 8 – 16
Triple-stage Full Free Panoramic Mast (Triplex Mast)............................. 8 – 19
Simplex Mast, Triplex Mast Second Cylinders........................................ 8 – 22
Duplex Mast, Triplex Mast First Cylinder ................................................ 8 – 24
Duplex Mast Second Cylinders .............................................................. 8 – 26
Tilt Cylinders.............................................................................................. 8 – 28
Flow Regulator Valve ................................................................................. 8 – 32
Suction Strainer and Return Filter.............................................................. 8 – 33
Inspection and Adjustment......................................................................... 8 – 34
Hydraulic Tank ......................................................................................... 8 – 34
Control Valve ........................................................................................... 8 – 35
Lift Cylinders and Tilt Cylinders ............................................................... 8 – 37
Test .......................................................................................................... 8 – 38
Adjustment Values of Microswitches ........................................................ 8 – 39
Procedures for Adjusting Microswitches .................................................. 8 – 40
Hydraulic Circuit Diagram .......................................................................... 8 – 41
Troubleshooting ......................................................................................... 8 – 42
Service Data .............................................................................................. 8 – 44
Finger-tip Control Type (FC model) ................................................... 8 – 51

Control Valve ............................................................................................ 8 – 52
Inlet Section ............................................................................................ 8 – 52
Lift Section .............................................................................................. 8 – 56
Tilt Section .............................................................................................. 8 – 62
Attachment Section ................................................................................. 8 – 66
Relief Valve ............................................................................................. 8 – 70
Disassembly ............................................................................................ 8 – 71
Cleaning .................................................................................................. 8 – 78
Inspection ................................................................................................ 8 – 78
Reassembly ............................................................................................. 8 – 79
Service Information.................................................................................. 8 – 88
Troubleshooting ......................................................................................... 8 – 90
Hydraulic Circuit Diagram ......................................................................... 8 – 93
HYDRAULIC SYSTEM
Specifications
Truck Model
Item
Type Gear pump
Model type TMG1A23A3H8-L511
Gear pump Rated discharge volume 24.5 (1.49)
cc/rev. (cu. in./rev.)
Drive system Direct connection with pump motor
Type KVS (equipped with microswitches)
Control valve Main relief pressure
18142 (185) [2631]
kpa (kgf/cm2) [psi]
Type Variable type
Flow regulator
Control flowrate
Hydraulic system
valve 48 (12.7)
liter/min (U.S. gal./min)
Simplex mast lift Inside diameter mm (in.) 45 (1.77)

cylinder Stroke mm (in.) 1645 (64.76)
Duplex and Triplex Inside diameter mm (in.) 70 (2.75)
mast first lift
cylinder Stroke mm (in.) 850 (33.46)
Duplex mast second Inside diameter mm (in.) 45 (1.77)
lift cylinder Stroke mm (in.) 1595 (62.80)
Triplex mast Inside diameter mm (in.) 45 (1.77)
second lift cylinder Stroke mm (in.) 1525 (60.00)
Inside diameter mm (in.) 63 (2.48)
Tilt cylinder
Stroke mm (in.) 82 (3.23)
Operating oil volume N level: 14.7 (3.88)
liter (U.S. gal) H level: 16.8 (4.44)
8-1
HYDRAULIC SYSTEM
Mechanical Control Type (MC Model)
8-3
HYDRAULIC SYSTEM
Hydraulic Line
View from operator’s seat
8
6
6
5
7
7
1
2
S
R
207772
1 Hydraulic tank 6 Lift cylinder

2 Gear pump 7 Tilt cylinder
3 Control valve S: To steering pump (DC motor models only)
4 Flow regulator valve R: From rear axle
5 Down safety valve 8 First lift cylinder (three-stage and two-stage
full-free panorama mast system)
When the lift lever or tilt lever is operated, the The steering pump line is a dedicated oil line for the
microswitches located in the spool of the control valve steering function. Although the steering system shares
send signals to the logic card in the main controller. the hydraulic oil with the hydraulic system, it uses its
Based on received signals, the logic card drives the own oil pump with a built-in relief valve to provide
pump motor and operates the oil pump. drive power.
The oil flows from the oil pump to the hydraulic system Refer to Steering System section.
in the same way as in engine-powered models.
8-4
HYDRAULIC SYSTEM
Control Valve
Description
8 11 12 13 14
10
10
6 7
2 3 4 207773
1 Inlet cover 8 Main relief valve

2 Lift valve assembly 9 Tie-bolt
3 Tilt valve assembly 10 Nut
4 Attachment valve assembly 11 Lift switch 1 (Microswitch)
5 End cover 12 Lift switch 2 (Microswitch)
6 Pump port 13 Tilt switch (Microswitch)
7 To tank 14 Attachment switch (Microswitch)
The control valve structure is shown above. The parts The microswitches located on top of the control valve
are joined together by three tie-bolts. turn ON and OFF according to the spool movement,
Since a lapping process is used for the coupling of the and send lift and tilt signals to the logic card.
body and spool, the body and spool combination cannot The lift valve is equipped with two microswitches for
be changed. two-step lift speed selection.
The inlet cover contains the main relief valve. The lift
valve assembly contains the load check valve. The tilt
valve spool contains the tilt lock valve.
8-5
HYDRAULIC SYSTEM
Lift valve assembly
15 13 14 13 12 11 10 1 12 13
3 5 4 2
206992
1 Body 6 Cap 11 Spring

2 Spool 7 Seats 12 Plugs
3 Plates 8 Screw 13 O-rings
4 O-rings 9 Spring 14 Orifice
5 Wipers 10 Poppet 15 Connector
Tilt valve assembly
11 10 12 13
17 16 15 1 2
8
6
9
14 3 5 4 203489
1 Body 7 Seats 13 Screws

2 Spool 8 Screw 14 Bolts
3 Plates 9 Spring 15 Tilt lock valve
4 O-rings 10 Poppet 16 Spring
5 Wipers 11 Spring 17 O-ring
6 Cap 12 O-ring
8-6
HYDRAULIC SYSTEM
Attachment valve assembly
207776
1 Spring 5 Spring 9 O-rings

2 Poppet 6 Cap 10 Wipers
3 O-ring 7 Screw 11 Plates
4 Bolts 8 Seats 12 Screws
Main relief valve
13 10 11 12 14
3 4 9 5 6 8 1 2 7
203490
1 Cap 6 Pilot poppet 11 Backup ring

2 Plug 7 Lock nut 12 O-ring
3 Sleeve 8 Pilot spring 13 O-ring
4 Main poppet 9 Spring 14 O-ring
5 Pilot seat 10 O-ring
8-7
HYDRAULIC SYSTEM
Lift and Tilt Cylinders

Lift cylinder (Simplex mast)
(Triplex mast second cylinder)
207765
(Duplex and triplex mast first cylinder)
2
1 3
000825B
(Duplex mast second cylinder)
000825C
Tilt cylinder
202771
The left and right lift cylinders are a single-acting type. The left and right tilt cylinders are a double-acting type.
Air and oil remaining inside air chamber 1 of the rod The piston rod carries a screw-on socket. This socket is
and inside rod chamber 2 between the tubes open check to be repositioned by turning, as necessary, when the
valve 3 when compressed, thus the air and oil flow out cylinder is connected to the outer mast. The right and
of the cylinder. left cylinders are hydraulically connected to each other.
Only the second cylinders of the Duplex Mast are The tilt angle can be increased or decreased by means
provided with bleeding valves. of spacer and shim of each cylinder.
8-8
HYDRAULIC SYSTEM
Flow Regulator Valve

From control valve To control valve
To lift cylinder From lift cylinder

203558
The flow regulator valve is located between each lift lowering speed regardless of load when the loaded forks
cylinder and control valve. It limits the flow of oil are lowered.
forced out of the cylinder to keep a constant safe
Down Safety Valve
Normal
Burst
When hose burst

204971
The down safety valve is located at the bottom of regulator valve is broken, or if the flow of return oil
second lift cylinder. This safety valve regulates the from the lift cylinder becomes excessive due to a
flow of oil to prevent the fork from moving down too maladjusted regulator valve or a fault of another
quickly in the following situations: component.
If the piping between the lift cylinder and flow
8-9
HYDRAULIC SYSTEM
Gear pump
Procedures and Suggestions for Removal

and Installation
1. Gear pump
The gear pump is mounted on the counterweight.
The rear axle is also connected to the counterweight,
and the rear axle must be removed after other
components are dismounted. For the removal of the
motor and gear pump, refer to the procedures for rear
axle removal and installation.
After the parts are removed from the counterweight,
disconnect the suction pipe from the gear pump, then
remove the gear pump from the motor.
NOTE
Do not remove the rear wheel during preparation
work.
2. Steering pump
4
4
9
1 6 8
7
2
3
211088
Sequence
1 Step (R.H.) 6 Delivery pipe
2 Step plate 7 Motor, Steering pump
3 Floor plate (A, B) 8 Connector, Suction pipe, (O-ring)
4 Cord (positive and negative wires) 9 Connector, Delivery pipe, (O-ring)
5 Suction hose
8-10
HYDRAULIC SYSTEM

1. Disconnect the battery plug in order to cut off the
power.
The battery plug is located at the side of the operator’s
foot.
206994
2. Remove the floor plate, and remove floor plate B.

Disconnect the accelerator connector from the back
side of the floor plate, then remove the two bolts to
take off floor plate A.
3. When disconnecting the suction hose and delivery
pipe, place a drip pan to catch drained oil.
8-11
HYDRAULIC SYSTEM
Control Valve

and Installation
Removal
(1) Remove the floor plate.
(2) Remove the clevis pin from the control lever rod, and
disconnect the rod from the control valve spool.
(3) Disconnect the microswitches at connector 1.
207775
(4) Remove the pipes.

2 Tilt pipe MC models
3 Delivery hose
3
4 Tilt pipe
5 Lift pipe
6 Return hose 2
4 6
5
211089
(5) Remove the bolts and nuts that mount the control valve
to the dashboard, and remove the control valve.
Installation 206881
Follow the removal procedure in reverse. During
installation, conduct the following inspection.
Check the hydraulic oil level. If the oil level is low, add oil
to the specified level.
8-12
HYDRAULIC SYSTEM
Disassembly
24
1
25
2 26
28
31 29
32
17
27
23
30 19
16
20
21 11
15
13
18 6
12
22 8
9
5
14
7
4
10
3
206993
8-13
HYDRAULIC SYSTEM
Disassembly sequence
1 Tie-bolt, Nut 17 Cap, Bolt
2 End cover 18 Spool
3 Main relief valve, O-ring 19 Screw, O-ring, Seat, Spring
4 Inlet cover, O-ring 20 Plate, Wiper, O-ring
5 O-ring 21 Tilt lock valve, Spring
6 Cap, Bolt 22 Plate, Wiper, O-ring, Screw
7 Spool 23 Tilt valve body
8 Screw, Seat, Spring 24 O-ring
9 Plate, Wiper, O-ring 25 Spring, Poppet
10 Plate, Wiper, O-ring, Screw 26 Cap, Bolt
11 Connector, O-ring 27 Spool
12 Plug, O-ring 28 Screw, Seat, Spring
13 Plug, O-ring, Spring, Poppet 29 Plate, Wiper, O-ring
14 Lift valve body 30 Plate, Wiper, O-ring, Screw
15 O-ring 31 Shut-off valve assembly
16 Spring, Poppet 32 Attachment valve body
Suggestions for disassembly
1. Main relief valve

Do not disassemble main relief valve 3 unless it has an
abnormality. Also, do not disassemble shut-off valve
assembly 31 (option) mounted on the attachment valve
unless it has an abnormality.
NOTE
When removing the main relief valve, be sure to loosen
the plug section. If the lock nut is accidentally
loosened, be sure to reset the pressure using a pressure
gauge, as the relief set pressure changes when the lock
nut is loosened. 205878
2. Removing spool
When removing spool 7 from the valve body, pull out the
spool together with screw 8, plate 9 and other parts.
Remove spools 18 and 27 in the same way.
3. Removing screw
Hold the spool in a vice using protective plates (hard wood
pieces or aluminum plates), and use a hexagon wrench to
remove the screw. Carefully remove the screw since the
internal spring force can eject the screw when it is
loosened.
205028
NOTE
Do not remove the orifice from the lift body valve
unless it has an abnormality.
8-14
HYDRAULIC SYSTEM
Inspection after disassembly
Valve, spool and return spring

(1) Check for cracks in the valve body, damage on the
sliding surfaces, and wear of the check valve seat
surface.
(2) Check the spool for damage, seizure, bend and
operating force.
(3) Check the tilt lock valve for damage and seizure.
203517
Reassembly
Follow the disassembly procedure in reverse.
(1) Clean removed parts with cleaning oil and dry with
compressed air to remove foreign particles. 19 N·m
(1.9 kgf·m)
(2) Coat parts with hydraulic oil. [13.7 lbf·ft]
(3) Replace O-rings with new parts. 46 N·m 2
(4.7 kgf·m)
(4) Tighten the tie-bolt to the specified torque. [34 lbf·ft]
1
➀ 46 N·m
(4.7 kgf·m)
[34 lbf·ft]
Tie-bolt tightening torque
➁ 19 N·m
(1.9 kgf·m)
[13.7 lbf·ft]
(5) Make sure the spool moves smoothly.
208636
8-15
HYDRAULIC SYSTEM
Lift Cylinders

Dual-stage Panoramic Mast (Simplex Mast)
207768
Sequence
1 Nuts 4 Hose guard 7 Cylinder clamp,
2 Fork, Lift bracket 5 High-pressure hose Cushion, Collar, Shims
3 Return (low-pressure) hose 6 Set bolt, Shims 8 Lift cylinder, Bracket
1. Lift bracket removal

(1) Tilt the mast forward, and lower the inner mast to the
bottom. Slacken the lift chains, and remove the nuts
from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free. Then, back the
truck away from the lift bracket and fork assembly.
204873A
8-16
HYDRAULIC SYSTEM
2. Removing return hose

Lift the mast to the maximum lift position, and turn the key
switch off. Disconnect the return hose from the right and
left lift cylinders at the connectors.
Removing hose guard

With the masts at the maximum lift position, remove the
hose guard from the front side.
Lowering masts 204932

Operate the lift lever gradually to lower the masts.
3. Disconnecting high-pressure hoses

Disconnect the high-pressure hoses at the joints indicated
by arrows. Use a drip pan to catch oil flowing out of the
hoses.
204933
4. Removing set bolts

(1) Remove the set bolt at the top of each lift cylinder. Lift
the inner mast to separate the cylinder rod ends. To lift
the inner mast, hitch a sling around the mast with
protective rag.
NOTE
The rod end of either lift cylinder is shim adjusted to
eliminate the difference in stroke between the
cylinders. Before removing the set bolts, make a
record of the amount of shims and cylinders to which
the shims are fitted.
204934
(2) Tie wood blocks under the inner mast, and detach the
sling. Use blocks strong enough to support the mast.
Make sure the right and left wood blocks are the same
in height.
202983
8-17
HYDRAULIC SYSTEM
5. Removing lift cylinders

Hitch a sling to the lift cylinder from the rear side of the
mast, and remove the cylinder. Hitch the sling before
removing the cylinder clamp.
204935
Installation
To install, follow the removal sequence in reverse, and
follow the instructions below:
1. Extend and retract the lift cylinders several times under
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
2. Check the oil level in the hydraulic tank with an oil
level gauge. (Refer to Hydraulic Tank section,
Inspection and Adjustment.)
3. Check to make sure that the lift height is correct.
4. After the lift cylinders or piston rods have been
replaced, check for difference in stroke between the
two cylinders. (Refer to Group 9 MAST AND FORK.)
8-18
HYDRAULIC SYSTEM
The following describes the procedures for removing and installing the mast assembly. Note that the triple-stage full
free panoramic mast (Triplex Mast) is used as an example.
Triple-stage Full Free Panoramic Mast (Triplex Mast)
207612
Sequence
1 Nuts 3 First lift cylinder
2 Lift bracket assembly 4 Chain wheel support assembly
5 Second lift cylinder
1. Removing lift bracket assembly 2

(1) Lower lift bracket assembly 2, and place wood blocks
under the assembly. Tilt the mast forward, lower the
inner mast to the bottom, then remove nuts 1 from the
anchor bolts of the first lift chains. 1
207613
8-19
HYDRAULIC SYSTEM
(2) Position the mast upright. Raise the inner mast until
main rollers 6 of lift bracket assembly 2 become free.
Then, slowly move the vehicle in reverse to separate
from lift bracket 2.
6
2
207762
2. Removing first lift cylinder 3

(1) Hitch a sling to the first lift cylinder 3, and suspend the
cylinder with a hoist. Wind the sling securely around
the lift cylinder to prevent slipping.
(2) Remove the lift cylinder connecting and mounting
bolts, and gently dismount first lift cylinder 3.
207616
3. Removing second lift cylinders 5

(1) Disconnect hoses from second lift cylinders 5.
(2) Remove stopper bolts at the upper sections of second
lift cylinders 5, and lift the inner mast (dual-stage full
free panoramic mast) or middle mast (triple-stage full
free panoramic mast) approximately 550 mm (21.67
in.) using slings.
207617
8-20
HYDRAULIC SYSTEM
(3) Place wood blocks under the inner mast (dual-stage full
free panoramic mast) or middle mast (triple-stage full
free panoramic mast).
Make sure the right and left wood blocks are the same
in height.
202983
(4) Hitch a sling to second lift cylinder 5 behind the mast,

remove cylinder clamp retaining bolts, and gently
remove second lift cylinder 5.
Hitch the sling securely to the cylinder. The cylinder
cannot be lifted straight up since the mast cross-member
is located above the cylinder. Tilt the cylinder and
move it away from the cross-member to remove. Be
careful not to place the hands between the cylinder and
mast.
207618
Installation
To reinstall, follow the removal sequence in reverse, and
follow the instructions below:
(1) Install chain wheel support assembly 4 parallel to a line
connecting the centers of chain anchor bolt holes on
first lift cylinder 3 to prevent chains from twisting.
(2) Adjust the chain tensions.
Good Bad
(See the section on Inspection and Adjustment.)
(3) Extend and retract the lift cylinders several times under 207638
no load condition to bleed air out of the cylinder circuits
and to make sure that the cylinders move smoothly.
(4) After proper operation is confirmed, check the oil level.
8-21
HYDRAULIC SYSTEM

Simplex Mast, Triplex Mast Second Cylinders
Disassembly
❋: Parts contained in seal kit
2❋
207769
Sequence
1 Bearing 4 Piston rod, Piston seal, Piston guide ring
2 Wiper ring, O-ring, Rod guide rings, Seal 5 Cylinder tube
3 Spacer
8-22
HYDRAULIC SYSTEM
Reassembly
10 6 7 8 9 1 5 4 2 3
❋ ❋ ❋ ❋ ❋ ❋
207765
Sequence
1 Piston rod 6 Bearing
2 Piston guide ring Install 7 through 10 to 6, and screw into 5.
3 Piston seal 7 Seal
4 Spacer 8 Rod guide rings
5 Cylinder tube 9 O-ring
10 Wiper ring

1. Use all parts in the seal kit to replace removed parts.
2. After installing seal kit parts, apply hydraulic oil before
assembling the cylinder tube and piston rod.
3. Tighten the bearing to the specified torque.
200 to 230 N·m

Bearing tightening torque (20.4 to 23.5 kgf·m)
[148 to 170 lbf·ft]
8-23
HYDRAULIC SYSTEM
Duplex Mast, Triplex Mast First Cylinder
Disassembly
1 2
3
7
211090
Sequence
1 Cylinder head assembly 4 Piston seal
2 O-rings, Wiper ring, Backup ring, Seal 5 Snap ring, Washer, Check valve
Remove parts 3 through 6 as sub-assembly from 6 Piston rod, Piston
part 8. 7 Screw, Washer
3 Piston guide ring 8 Cylinder tube
8-24
HYDRAULIC SYSTEM
Reassembly
11 10 9 13 12 5 6
❋ ❋ ❋ ❋ 8 ❋ 1 7 ❋ ❋
❋ 2 3 4
14 (Washer only)
000825B
Sequence
1 Piston rod, Piston 8 Cylinder head assembly
Install parts 2 through 6 to part 1. Install parts 9 through 11 to part 8.
2 Check valve 9 Seal
3 Washer 10 Backup ring
4 Snap ring 11 Wiper ring
5 Piston seal 12 Backup ring, O-ring
6 Piston guide ring 13 O-ring
7 Cylinder tube 14 Washer, Screw

1. Use all parts in the seal kit to replace removed 4. Tighten the cylinder head to the specified torque.
parts.
300 to 350 N·m
2. After installing seal kit parts, apply hydraulic oil Cylinder head tightening
(30.6 to 35.7 kgf·m)
before assembling the cylinder tube and piston rod. torque
[221.3 to 258.1 lbf·ft]
3. Fill the space between the cylinder tube and piston
rod with the specified amount of hydraulic oil
before installing the cylinder head. 5. Tighten the screw to specified torque.
3.92 N·m
75 cc Plug tightening torque (0.4 kgf·m)
Amount of hydraulic oil
(4.58 cu. in.) [2.9 lbf·ft]
8-25
HYDRAULIC SYSTEM
Duplex Mast Second Cylinders
Disassembly
10
6
5❋
9
3❋
1
2❋
11
211091
Sequence
1 Retainer 6 Spacer
Remove parts 3 through 10 as sub-assembly from 7 Snap ring
part 11. 8 Sleeve
2 Wiper ring, Rod seal, O-ring, Backup ring 9 Piston rod
3 Backup ring, Piston seal, Wear ring 10 Bleed screw, Seal washer
4 Piston 11 Cylinder tube
5 Pull-in wire
NOTE
Spacer is installed in the cylinder with lifting height of
3.7 m (146 in.) or more.
8-26
HYDRAULIC SYSTEM
Reassembly
8 6 3 2
❋ 7 5 ❋ 10 4 ❋ ❋ 1
9
11
000825C
Sequence
1 Retainer 6 Pull-in wire
2 Wiper ring, Rod seal 7 Piston
3 Backup ring, O-ring 8 Backup ring, Piston seal, Wear ring
4 Piston rod 9 Sleeve, Snap ring
Install parts 1, 2, 3, 5, 6, 7 to Part 4 10 Cylinder tube
5 Spacer 11 Seal washer, Bleed screw

1. Use all parts in the seal kit to replace removed 4. Tighten the set screws (2 locations) to the specified
parts. torque.
2. Apply hydraulic oil to the sliding sections on the Unit: N·m (kgf·m) [lbf·ft]
cylinder tube inner surface and piston rod outer
4.5 to 5.0
surface before installation.
Set screw tightening torque (0.46 to 0.51)
3. Tighten the piston and holder to the specified [3.3 to 3.7]
torque.
Unit: N·m (kgf·m) [lbf·ft]
170 to 240
Holder tightening torque (17.3 to 24.5)
[125.3 to 177.0]
8-27
HYDRAULIC SYSTEM
Tilt Cylinders
1
4
and Installation
Removal
Sequence
1 Rubber hose
2 Tilt socket pin, Bolt, Washer
3 Tilt cylinder pin, Bolt, Washer
4 Tilt cylinder
2 3
206883
Start by:
(1) Lower the forks to the bottom, and tilt the mast fully
forward.
(2) Hitch lifting slings to the top crossmember of the outer
mast by using eye-bolts. Support the weight of the mast
with the hoist.
205740
8-28
HYDRAULIC SYSTEM

2
❋
❋
❋
❋
4
3 ❋
207770
Sequence
1 Tilt socket, Bolt, Nut, Spherical bearing, 3 Piston rod assembly, Piston seal
Grease nipple 4 Cylinder tube, Bushing
2 Guide bushing, O-ring, Dust seal, Rod packing,
Buffer ring
NOTE
Do not remove the tilt socket bearing and cylinder tube
bushing unless they are defective.
8-29
HYDRAULIC SYSTEM
Removing bushing
Wrap the cylinder with a rag, and clamp it in a vise. Using
a wrench, remove the guide bushing from the cylinder.
1. Cylinder tube
(1) Check the bore wall for wear, grooving, scratches and
rusting. 200351
(2) Check the welds for cracks.
2. Piston rod
Check for surface flaws such as grooving, scratches, rusting
and wear. The rod must be replaced if its threads show a
sign of stripping or any other damage.
3. Packings and rings

Replace all parts contained in the seal kit, once the cylinder
is disturbed.
8-30
HYDRAULIC SYSTEM
Reassembly
8 7 5 6 9 2
11 12 14 10 1 ❋ ❋ ❋ ❋ ❋ 4 ❋ 3
13
211093
Sequence
1 Piston rod assembly 8 Dust seal
2 Piston seal 9 O-ring
3 Bushing 10 Tilt socket
4 Cylinder tube 11 Spherical bearing
5 Guide bushing 12 Seals (AC motor models only)
6 Buffer ring 13 Bolt, Washer, Nut
7 Packing 14 Grease nipple

1. Use all parts in the seal kit to replace removed 4. Mount the tilt cylinder to the vehicle body and
parts. check the front-and -back tilting angle of the mast,
2. After installing seal kit parts, apply hydraulic oil then tighten the bolt and nut on the tilt socket to the
before assembling the cylinder tube and piston rod. specified torque.
3. Tighten the guide bushing to the specified torque. 157 to 182 N·m
Bolt and nut on the tilt
(16.0 to 18.6 kgf·m)
socket
265 ± 29 N·m [115.8 to 134.2 lbf·ft]
Guide bushing tightening
(27 ± 3 kgf·m)
torque 5. The piston rod does not normally have to be
[195 ± 21.4 lbf·ft]
disassembled. If the piston is replaced, however,
install a new self-locking nut and tighten to the
specified torque.
127 ± 9.8 N·m

Self-locking nut tightening
(13 ± 1.0 kgf·m)
torque
[94 ± 7.2 lbf·ft]
8-31
HYDRAULIC SYSTEM
Flow Regulator Valve
Disassembly
203559
Sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring, Shims

1. Check spring for fatigue.
2. Check seat and sliding faces of the valve and piston.
3. Check the sliding surfaces of the piston and valve body
for damage.
NOTE
Replace the flow regulator valve as an assembly if any
defect is found.
8-32
HYDRAULIC SYSTEM
Suction Strainer and Return Filter

and Installation
Removal
1
The hydraulic tank is mounted on the counterweight.
Before dismounting the hydraulic tank, remove other parts 2
such as the motor, gear pump and controller. For the
6
removal sequence, refer to Removal (Part 1) section in 4
REAR AXLE.
5
Sequence 3 6 7
1 Hose (rear axle return), Clamp
2 Hose (suction), Clamp
3 Hose (return), Clamp
4 Cap, Oil level gauge
5 Coupling
6 Return pipe, Return filter, O-ring
7 Suction pipe, Suction strainer, Packing, Plate
8 Hydraulic tank
8
206885
Inspection
Clean the parts. Replace parts that are clogged or damaged.
Installation
Follow the removal procedure in reverse. Observe the
following instructions during installation.
(1) When replacing the strainer or filter, observe the
specified tightening torque during installation to the
pipe.
Tightening torque 49 ± 9.8 N·m

for strainer and filter (5 ± 1 kgf·m)
(installation to pipes) [36 ± 7.2 lbf·ft]
(2) Replace the packings and O-ring with new parts.

206886
8-33
HYDRAULIC SYSTEM
Hydraulic Tank
Oil
Oil level, contamination, clouding (mixing of air or oil)
Tank capacities and mast types

Unit: liter (U.S. gal)
Truck Model
Mast
Two-stage panorama masts Lift

2.0 to 6.0 m N level: 14.7 (3.88)
(Simplex mast) H level: 16.8 (4.44)
(79 to 236 in.)
Two-stage full-free masts Lift

2.8 to 4.0 m N level: 14.7 (3.88)
(Duplex mast) H level: 16.8 (4.44)
(110 to 157 in.)
Three-stage full-free masts Lift

3.7 to 7.0 m N level: 14.7 (3.88)
(Triplex mast) H level: 16.8 (4.44)
(146 to 276 in.)
NOTE
In all models, and in any combinations of mast and
attachment, the oil level in the tank should not exceed
the H level when the masts are lowered.
Suction strainer
Damage, clogging
Return filter
Damage, clogging
8-34
HYDRAULIC SYSTEM
Solenoid Control Valve

(1) External oil leaks
(a) Oil leaks from O-rings between housings
(b) Oil leaks from scraper O-ring
(c) Oil leaks from bolt sections
(2) Oil leaks

Since it is difficult to measure the amount of oil leaks from
3° to 4°
the dismounted control valve, inspect oil leaks with the
control valve connected to the cylinder by following the
steps (a) through (c) below:
The internal leakage to be checked includes leakages
occurring at the lift spool, tilt spool, tilt lock valve and
check valves at the oil temperature of approximately 50°C
(122°F). Approx. 1 m
(3.3 ft)
(a) Place rated load on the forks and lift it to a height of
approximately 1 m (3.3 ft). Tilt the masts 207764
approximately 3 or 4 degrees forward from the upright
position, then turn the key switch off.
(b) Remove the oil return hose, and collect oil from the
port.
Standard volume of oil 20 cc

drained in 15 minutes (1.22 cu. in.) max.
(c) When the gravitational-pull lowering distance and

forward tilt distance are large, check the amount of oil
leakage from each cylinder even if the amount of oil
drained in 15 minutes is less than 20 cc (1.22 cu.in.).
(Measured amount of oil leakage is a standard value; it
does not denote the allowable limit.)
211094
(3) Adjustment of main relief valve
(a) Mount an oil pressure gauge with a measuring range of
24.5 MPa (250 kgf/cm ) [3556 psi] on the delivery pipe.
2
Special tool needed
64309-17733
Connector (R (PT) 1/8 thread)
Hose 64309-17722
Connector 64309-17731
(for gauge mounting)
211095
64309-17712
Gauge 24.5 Mpa (250 kg/cm ) [3553 psi]
2
NOTE
The above parts are included in the 64309-17701 kit.
8-35
HYDRAULIC SYSTEM
(b) Operate the tilt lever, and tilt the masts backward to the
maximum position. When the tilt cylinder reaches the
limit in its backward tilt movement, check the oil
pressure gauge. If the gauge indicates 18142 kPa (185
kgf/cm2) [2625 psi], it is normal.
(c) If the relief pressure is not normal, loosen the lock nut
of the relief valve, and while observing the gauge
indication, adjust the pressure using the adjusting
screw.
(d) While pressing the adjusting screw, tighten the lock nut
securely.
(e) After tightening the lock nut, check the set pressure of
the relief valve again.
+490
18142 0 kPa
Main relief valve
(185 +50 kgf/cm )
2
setting pressure
[2631 +71
0 psi]
8-36
HYDRAULIC SYSTEM
Lift Cylinders and Tilt Cylinders
(1) Adjustment of mast tilt angle

(a) Adjust the air pressure of the tires, and place the
vehicle on level ground.
(b) Tilt the masts backward to the maximum position.
(c) Measure the backward tilt angles of both right and left
tilt cylinders.
(d) To adjust, loosen the socket tightening bolt, turn the tilt
cylinder rod, and adjust the cylinder stroke until the
right and left tilt cylinders are tilted at the same angle. 206890
NOTE
The forward tilt angle of the masts is automatically set
when the backward tilt angle is adjusted.
Forward tilt – Backward tilt

6° – 7°
(STD)
(2) Adjustment of right and left lift cylinder strokes

(a) Gently raise the inner masts, and observe the right and
left piston rod stopping conditions when they reach the
maximum lift position.
(b) If the upper parts of the inner masts shake at the
moment of stopping, make adjustment with shims.
Improper adjustment causes the inner mast to slant
slightly when the mast is stopped, and also causes the
lift cylinder with a longer cylinder stroke to shake 204698
when the lift cylinder is stopped.
Adjustment method
(1) Raise the inner masts, and place wood blocks under the
inner masts. Lower the masts until the inner masts
contact the wood blocks.
202983
8-37
HYDRAULIC SYSTEM
(2) Loosen the stopper bolt located at the upper part of the
lift cylinder that stopped first. Lower the piston rod,
and insert a shim at the upper piston rod end.
NOTE
When lowering the piston rod, operate the lift lever to
lower the masts and release oil from the cylinder.
(3) Raise the piston rod, then tighten the lift cylinder
stopper bolt. Remove the wood blocks from under the 200365
inner masts.
(4) Lower the inner masts gently, and check to see if the
piston rods move smoothly until the inner masts reach
the lowest position.
Test
(1) Gravitational-pull lowering test
(a) Set the masts upright with rated load, raise the masts
approximately 1 to 1.5 m (3.3 to 4.9 ft), then turn the
key switch off.
(b) Draw a reference line on a mast, and measure the
descent (retraction of lift cylinder) for 15 minutes.
Unit: mm/15 min (in./15 min)
206891
Gravitational-pull lowering
50 (1.97) max.
distance (with load)
(2) Gravitational-pull forward tilt test

(a) Set the masts upright with rated load, raise the forks
approximately 500 mm (19.7 in.), then turn the key
switch off.
(b) Measure the amount of the tilt cylinder extension after
15 minutes.
Unit: mm/15 min (in./15 min)
Truck Models
Item 206892
Gravitational-pull
forward tilt distance 22 (0.87) 22 (0.87)
(with load)
Inspection of Piping
(1) Check the piping for oil leaks.
(2) Check the rubber hoses for damage, twisting and
sagging.
8-38
HYDRAULIC SYSTEM
Adjustment Values of Microswitches

(1) The ON timings of the lift and tilt microswitches are
indicated in the following table.
(2) With the control valve dismounted from the vehicle,
check the amount of spool travel. With the control
valve mounted on the vehicle, check the operating
stroke of the control lever knob section.
• Lever operating distances for microswitch activation
Unit: mm (in.)
Pulling of lever Pushing of lever
Lift switch 1 18.9 to 25.3 –

(0.744 to 1.0)

(2.23 to 2.48)
Tilt switch 11.9 to 18.9 11.9 to 18.9

(0.47 to 0.744) (0.47 to 0.744)
3-stage switch 11.9 to 18.9 11.9 to 18.9

(0.47 to 0.744) (0.47 to 0.744)

(0.47 to 0.744) (0.47 to 0.744)
• Spool travel distances for microswitch activation

Unit: mm (in.)
Pulling of lever Pushing of lever

(0.06 to 0.078)

(0.177 to 0.197)
206242
Tilt switch 1.0 to 1.5 1.0 to 1.5
(0.04 to 0.06) (0.04 to 0.06)

(0.04 to 0.06) (0.04 to 0.06)

(0.04 to 0.06) (0.04 to 0.06)
(3) If the measured values deviate from the standard values
listed in the table, make adjustments by following the
procedures on the following page.
! WARNING
If the switch ON timing is too late relative to the
spool movement, the masts move suddenly,
disallowing precise control. Adjust the switch ON
timing accurately especially for the forward tilt
operation, as improper adjustment can cause
accidents.
8-39
HYDRAULIC SYSTEM
Procedures for Adjusting Microswitches

(Nut A for roller extension adjustment, nut B for securing
switch in position)
(1) Adjustment of roller extension
As shown in the diagram, turn nut A to adjust the
amount of roller extension. Temporarily tighten nut B
when the roller contacts the spool lightly.
NOTE
If the roller is pressed hard against the spool, loosen
nut A and readjust.
206243
(2) Adjustment of roller position (height) Adjustment of lift switch height

Adjustment in dismounted control valve
Loosen nut B slightly. With the roller contacting the
tapered section of the spool, move the roller back a
distance equaling the specified spool travel distance,
and secure it in place.
During the above procedure, the attachment
microswitch roller should be positioned at a midpoint
of the tapered section of the spool.
206244
Adjustment in mounted control valve

Adjustment of tilt and attachment switch height
After checking the roller extension as described in
above (1), operate the lever to check the ON timing.
To check the ON timing, listen to the switching sound
when the test area is quiet, or use the lift speed check
of the I/O self-diagnosis function when the test area is
noisy (motor rotation may be used as a means of
operation confirmation).
To adjust, loosen nut B slightly and move the switch.
206245
NOTE
When the lever is in the neutral position, the switch
roller should not contact the spool.
8-40
R
Hydraulic control valve
(DC motor, MC models ) L
T1
B4 Steering cylinder
Orbit roll
A4 Displacement 63 cc/rev.
Relief 6.5 MPa
B3
A3 T P
B2 Pump motor
A2 36/48V Dualvoltage Steering motor
Std. tilt
11.56kW Operation 0.55 kW Operation
cylinder
at 4.8V
8V
M M
Gear pump
Flow A1 Gear pump (Steering)
Displacement
regurator 24.5 cc / rev. Displacement
4.0 cc/rev.
8-41
18.1 MPa Return Suction
filter strainer
P T2 15 μm 100 mesh
Lift cylinder
with down safety valve
211096
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Troubleshooting
Improper oil viscosity

Excessive workload caused by severe work condition
Local heating caused by large resistance due
Hydraulic tank heats to clogged line
Hydraulic tank
extremely Improper adjustment of relief valve
Low set pressure due to spring fatigue or damage
Worn gear pump
Flattened discharge line or clogged line
Insufficient pump suction

Pump produces loud
abnormal noise
Cavitation
Oil pump
Damage in pump case, Applied pressure exceeded rating.
drive gear or pump
port flange Deformation or damage caused by external force
Oil leaks from oil seal

Oil leaks from sliding surface of drive shaft
Oil leaks from pump
Loose pump tightening bolt
Deteriorated seal inside pump
8-42
HYDRAULIC SYSTEM
Insufficient oil in hydraulic tank

Masts do not rise or Relief valve malfunction
tilt in either forward (1) Sticking of main valve
or backward direction (2) Broken valve spring
Oil pump malfunction
Relief valve malfunction
(1) Low relief set pressure
Rated cargo load (2) Faulty plunger or poppet seat
cannot be lifted (3) Spring fatigue
(4) Damaged valve case O-ring
Oil pump malfunction
Worn or damaged piston seal
Insufficient oil (due to natural oil consumption)
Oil leaks from oil line or due to damaged seal
Cylinders operate Oil viscosity higher than specified
very slowly No oil suction by gear pump
Oil leaks from hydraulic circuit
Abnormal oil temperature rise
Slow pump rotation
Rising speed is very Insufficient spool stroke due to loose operation
slow lever
Clogged tank strainer
Insufficient gear pump discharge volume
Lift cylinder
lowering speed is Sticking of flow regulator valve piston
very slow Clogged flow regulator valve, bent hydraulic
hose, or large resistance in hydraulic circuit due to
Lift and tilt cylinders sectional clogging
Cylinders shake Bent piston rod

during operation Air mixed in hydraulic piping
Insufficient operating oil in tank
Leaks inside control valve spool
Scratches on sliding surface of cylinder tube
Large gravitational- that are deep enough to be detected by finger
pull lowering nails
distance in lift Large scratches on sliding surface of cylinder
cylinders tube
Damage or deformation of piston seal
Oil leaks from hydraulic piping
Large gravitational- Leaks inside control valve spool

pull forward tilt Lodging of foreign particles on packing
distance in tilt Damaged piston seal
cylinder Scratches on piston seal
Abnormal shape deformation or leaks from
hydraulic piping
Lift cylinders or
tilt cylinder drop or Large sectional scratches or rusting on inner
tilt forward naturally surface of cylinder
at certain position Deformed cylinder
Lodging of foreign particles on seal
Oil leaks from bushing Scratches on oil seal or periphery of dust seal
Damaged O-ring
Abnormal shape deformation
8-43
HYDRAULIC SYSTEM
Service Data
A : Standard value
Unit: mm (in.)
Truck Model
Item
Simplex mast FB16KT, FB16NT:

Lift speed (rated load) 400 (15.7) FB20KT, FB20NT
A FB18KT, FB18NT: 380 (15.0)
mm/sec (in./sec) 390 (15.4)
Simplex mast
Simplex mast
Lowering speed (rated load) A 520 (20.5)

mm/sec (in./sec)
Forward tilt angle A 6°

Backward tilt angle A 7°
Lift cylinder rod drift (rated load)

Oil temperature 45 °C (113 °F) A 50 (1.97), max
mm (in.)/15 min.
Tilt cylinder rod drift (forward) (rated load)

Oil temperature 45 °C (113 °F) A 22 (0.87), max 22 (0.87), max
mm (in.)/15 min.
Main relief valve setting
A 18142 +490 +5 +71
+0 (185 +0) [2631+0 ]
kPa (kgf/cm2) [psi]
Power steering relief valve setting
A 6500 (66.3) [943]
kPa (kgf/cm2) [psi]
Capacity A 24.5 (1.49)

cc (cu. in.)/rev
Hydraulic pump
33.3
Mounting bolts
A (3.39)
[24.6]
Tie bolts (1/2 in.) A 46 (4.7) [34]

Control
valve
Tightening torque
Tie bolts (3/8 in.) A 19 (1.9) [14]
8-44
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
Item
Duplex mast
— —
Lift speed (rated load/no load) A
mm/sec (in./sec)
Duplex mast
Duplex mast
Lowering speed (rated load) A — —

mm/sec (in./sec)

No. 1
Oil temperature 45 °C (113 °F) A —
mm (in.)/15 min.
No. 2
mm (in.)/15 min.
Triplex mast
— —
Lift speed (rated load/no load) A
mm/sec (in./sec)
Triplex mast
Triplex mast
Lowering speed (rated load) A — —

mm/sec (in./sec)

No. 1
Oil temperature 45 °C (113 °F) A —
mm (in.)/15 min.
No. 2
mm (in.)/15 min.
8-45
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
Item
[Piston] 45
A
Inside diameter of cylinder tube 1 (1.77)
Lift cylinders (Simplex mast) (Triplex mast second)
Diameter of piston rod 2 A 35 (1.38)

Bearing thread diameter 3 A M48 × 1.5
200 to 230
Tightening torque for bearing 4
A (20.4 to 23.5)
[148 to 170]
4 2 1
207765
Flow regulator Return
filter
Tightening torque
A 45 (4.59) [33.2]
Flow rate (no load)
A 48 (12.7)
liter (U.S. gal)/min
valve
Tightening torque of elbow and connector

(for mounting on flow regulator valve) A 63.7 (6.5) [47]
8-46
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
Item
[Piston] 70
A
Diameter of piston rod 2 A 55 (2.16)
Cylinder head thread diameter 3 A M75 × 2
Lift cylinders (Duplex mast, triplex mast first cylinder)
300 to 350
Tightening torque for cylinder head 3
A (30.6 to 35.7)
[221.3 to 258.1]
Tightening torque for plug 4 A 3.92 (0.4) [2.9]
Amount of hydraulic oil 5 75
A
cc (cu. in.) (4.58)
2 3 1 5
000825B
8-47
HYDRAULIC SYSTEM
A: Standard value
Unit: mm (in.)
Truck Model
Item
[Piston] 45
A
A 32
Diameter of piston rod 2
(1.26)
170 to 240
Tightening torque for holder 3
A (17.3 to 24.5)
[125.1 to 177.0]
Lift cylinders (Duplex mast second cylinders)
Holder thread diameter 3 A M52 × 2

4.5 to 5.0
Air bleed screw tightening torque 4
A (0.46 to 0.51)
[3.3 to 3.7]
1 2
4
000825C
8-48
HYDRAULIC SYSTEM
Truck Model
Item
63
Inside diameter of cylinder tube 1 A
(2.48)
[Guide bushing] 25
A
Diameter of piston rod 2 (0.98)
0
(2.48) 35–0.012
Inside diameter of tilt socket bushing (fitted) 3 A 0
(1.38 –0.0005)
32 +0.085
0
Inside diameter of cylinder tube head bushing (fitted) 4 A
(1.26 +0.003
0 )
[Guide bushing]
A M68 × 2
Thread diameter 5
[Guide bushing]
Tightening torque 5 A 265 ± 29 (27 ± 3) [195.3 ± 21.7]
[Tilt socket]
A M24 × 1.5
Tilt cylinders
Thread diameter 6
Tilt socket bolt 7 A 157 to 182 (16.0 to 18.6) [115.7 to 134.5]
Tightening torque
N·m (kgf·m) [lbf·ft] 127 ± 9.8 (13 ± 1.0)
Self-locking nut 8 A
[94 ± 7.2]
6 5 8
3 4
2
7 1
202771
8-49
HYDRAULIC SYSTEM
8-50
HYDRAULIC SYSTEM
Finger-tip Control Type (FC Model)

For the component descriptions other than control valve, refer to the
Mechanical Control Type (MC model).
8-51
HYDRAULIC SYSTEM
Control Valve
Inlet Section
Structure and Names of Parts
207433
1 Inlet spool A: Low-pressure channel

2 Dividing valve B: Control oil passage: Used for sections No.1 and
3 Pilot relief valve No.2.
4 Main relief valve C: Pilot oil passage: Used to produce primary
5 Shut-off valve pressure for proportional electromagnetic pressure
6 High-pressure selector valve: Closes low- control valve.
pressure oil passage when pressure difference is D: Surplus oil passage: Used for section No.3 and
generated between (E1) and (E2). subsequent circuits.
E: Control pressure oil passage: Receives oil from
(E1) or (E2).
8-52
HYDRAULIC SYSTEM
207434
Operation
All Spool Sections in Neutral

Oil from port P enters land (a) of dividing valve 2. The movement of inlet spool 1 opens section (c),
Pilot oil from the dividing valve flows to oil passages allowing oil to flow to land (b). Oil passes through oil
(C) and (E1). Since oil passage (C) is closed as all passage (D) and enters section No. 3. Oil then returns
main spools are in neutral, an increase of pressure P to the tank because the spools are in neutral.
operates pilot relief valve 3. Because there is no During this process, pressure levels in chamber (d) and
pressure in oil passage (E2), oil passage (E1) is chamber (e) are controlled by section (c) to remain
connected to oil passage (E) by high-pressure selector balanced, thus generates required pressure.
valve 6. Therefore, there is no pressure difference
between P, (a), (d), (e) and (c).
When pressure P increases, pressure (pressure in oil
passage (C) + spring force) in chamber (d) exceeds
pressure in chamber (e), thus moving inlet spool 1 to
the right.
8-53
HYDRAULIC SYSTEM
207435
Sections No. 1 and No. 2 Spool Switching
Example: When Section No. 1 (lift) is Used

When the section No. 1 spool moves to the right, oil When the volume of oil flowing from P to A1 is large:
flows from land (f) to land (h). As oil is restricted by Pressure difference between (f) and (h) becomes large,
section (g), differential pressure results. During this and inlet spool 1 moves to the right, thus decreasing oil
process, oil at (d) and (f) have the same pressure. Oil flow to A1.
from (h) flows through oil passage (E3), then enters When the volume of oil flowing from P to A1 is small:
chamber (e) due to the high-pressure selector valve
operated by pressure in oil passages (E4) and (E1) that Pressure difference between (f) and (h) becomes small,
are connect by the high-pressure selector valve, thus and inlet spool 1 moves to the left, thus increasing oil
making pressure levels in (e) and (h) equal. As a result, flow volume to A1.
inlet spool 1 positions itself at a location where it is When the opening area at (g) changes during spool
balanced. stroke, the flow volume is also controlled.
The same operation principle applies to Section No. 2.
8-54
HYDRAULIC SYSTEM
207436
No. 3 (attachment) Spool Switching

When the section No. 3 spool moves to the right,
negative pressure at port A3 is applied to chamber (d).
Due to pressure difference from chamber (e), inlet spool
1 positions itself at a location where it is balanced.
8-55
HYDRAULIC SYSTEM
Lift Section
207437
1 Cap A: Low-pressure oil passage

2 Cap B: Control channel
3 Orifice C: Pilot oil passage
4 Orifice D: Surplus oil channel
5 Proportional solenoid E2-E4:
6 Load check valve Control pressure oil passages
7 Lift lock valve F: Primary pressure oil passage
8 Shut-off valve G: Secondary pressure oil passage
9 High-pressure selector valve H: Drain oil passage
8-56
HYDRAULIC SYSTEM
yy;
yy
y
;yy
;;
y
;;y
y;;
yy
; A
yy
;;
y
;yy
;;
y
;y
;
;;
yy
;;
yy
Operation
Neutral
Blocking oil
Because there is no input to the proportional solenoid,

207438
Surplus oil separated from pilot oil at the inlet section

the proportional electromagnetic pressure control valve passes through the surplus oil channel and enters
sends pressure in the cap to the drain oil passage. Thus, section No. 3.
the spool stays in the position indicated in the diagram
due to the spring force, and cylinder port A remains
closed.
8-57
HYDRAULIC SYSTEM
E2 E4
E3
A 2
1
“a1” SOL “b1” SOL
High-pressure oil
Pilot oil
207439
“a1” Solenoid Operation in Spool Switching

Activation of the proportional electromagnetic pressure Oil flows through the control channel and enters
control valve on the “a1” SOL side results in the cylinder port A. At the same time, oil flows through oil
generation of pilot pressure in cap 1, which exceeds the passage (E3) to the high-pressure selector.
force of spring in cap 2 and pushes the spool to the
right.
8-58
HYDRAULIC SYSTEM
4 3
A
2
1
Low-pressure oil
Pilot oil
207440
“b1” Solenoid Operation in Spool Switching

Activation of the proportional electromagnetic pressure In the load check valve, the pilot oil passage connects
control valve on the “b1” SOL side results in the to the low-pressure channel. As a result, pressure
generation of pilot pressure in cap 2, which exceeds the difference before and after orifices 3, 4 causes the valve
force of spring in cap 1 and pushes the spool to the left. to lift, thus sending oil from cylinder port A to the low-
The pilot pressure also applies force on the lift lock pressure channel and into the tank.
valve in the spool, moving the valve in the left direction
against spring force and opening the pilot oil passage in
the load check valve.
8-59
HYDRAULIC SYSTEM
4 3
;;
y
;
yy;;
yy
y
;y
;
;
y;
y
;;
yy
;
y
;;
yy
;
y
;;
yy
A
2
;yy
y;y
y
;;
;
;;
yy
;;
yy
“b1” SOL
Blocking oil
207441
Emergency Lift Lock Mechanism

With the proportional electromagnetic pressure control Consequently, pressure equalizes before and after
valve on the “b1” SOL side in activation (lift in orifices 3, 4, and the load check valve returns to its seat
lowering operation), if spool sticking should occur, by spring force to lock the cylinder.
deactivation of the proportional electromagnetic
pressure control valve cancels pilot pressure in cap 2.
As a result, the lift lock valve moves to the position
indicated in the diagram, and the pilot oil passage
closes.
8-60
HYDRAULIC SYSTEM
“b1” SOL
Low-pressure oil
207442
Manual Lift Lowering Operation

In case the proportional electromagnetic pressure
control valve on the “b1” SOL side malfunctions and
disallows lift lowering operation, opening the shut-off
valve creates a pilot oil passage to allow the operation
of the load check valve.
8-61
HYDRAULIC SYSTEM
Tilt Section
207443
1 Cap A: Low-pressure oil passage

2 Cap B: Control channel
3 Damper chamber C: Surplus oil channel
4 High-pressure selector valve
5 Load check valve
6 Tilt lock valve
8-62
HYDRAULIC SYSTEM
yy
;
y
;;
;
yyy
;;;
y A B
;yy
y
yy
;;
y
;yy
;;
;;
;;;
yyy
;; y
yy
;;
;;;
yyy
yy;
yy
;;
y
;y;
; y
yy
;;
;;
yy
Operation
Neutral
Blocking oil
207444
Because there is no input to the proportional solenoid, Surplus oil separated from pilot oil at the inlet section
the proportional electromagnetic pressure control valve passes through the surplus oil channel and enters
sends pressure in the cap to the drain oil passage. Thus, section No. 3.
the spool stays in the position indicated in the diagram Since no pressure is fed to the damper chamber, the tilt
due to the spring force, and cylinder ports A and B lock valve is pressed to the right by the spring.
remain closed.
8-63
HYDRAULIC SYSTEM
E4
E2 B
A
E3
2
1
High-pressure oil
Low-pressure oil
Pilot oil 207445

Activation of the proportional electromagnetic pressure Oil at the bottom side flows to the low-pressure channel
control valve on the “a2” SOL side results in the through cylinder port B.
generation of pilot pressure in cap 1, which exceeds the Since no pressure is fed to the damper chamber, the tilt
force of spring in cap 2 and pushes the spool to the lock valve is pressed to the right by the spring.
right.
Oil from the control channel lifts the load check valve
and flows through cylinder port A to the rod side of the
tilt cylinder. At the same time, oil flows to the high-
pressure selector through oil passage (E4).
8-64
HYDRAULIC SYSTEM
E4
E2
A B
E3
1 2
High-pressure oil
Low-pressure oil
Pilot oil 207446

Activation of the proportional electromagnetic pressure In this process, pressure travels from the control
control valve on the “b2” SOL side results in the channel to the damper chamber, and pushes the tilt lock
generation of pilot pressure in cap 2, which exceeds the valve to the left against the spring force. As a result,
force of spring in cap 1 and pushes the spool to the left. the oil passage to the low-pressure channel opens to
Oil from the control channel lifts the load check valve allow oil from the rod side to flow into the low-pressure
and flows through cylinder port B to the bottom side of channel through cylinder port A.
the tilt cylinder. At the same time, oil flows to the high-
pressure selector through oil passage (E4).
8-65
HYDRAULIC SYSTEM
Attachment Section
Cylinder port A Cylinder port B

C
A
B
207447
1 Cap A: Low-pressure channel

2 Cap B: Neutral channel
3 Load check valve C: Parallel feeder (High-pressure channel)
8-66
yy;;
y
;;
yyy
;
y;
y
HYDRAULIC SYSTEM
yy;;
;;
;
y ;y
y
yy
;;;
yyy
;;
yy
;
y ;
A B
yy
;;;;
yyy
;;
yy
;;;
yy
;
y
;y
y;yy
;;
;
y
yy
;;
;;
yy
Operation
Neutral
Blocking oil
207448
Because there is no input to the proportional solenoid, Surplus oil separated from pilot oil at the inlet section
the proportional electromagnetic pressure control valve passes through the neutral channel into the tank.
sends pressure in the cap to the drain oil passage. Thus,
the spool stays in the position indicated in the diagram
due to the spring force, and cylinder ports A and B
remain closed.
8-67
HYDRAULIC SYSTEM
A B
2
1
High-pressure oil
Low-pressure oil
Pilot oil
207449

Activation of the proportional electromagnetic pressure Oil from the control channel lifts the load check valve
control valve on the “a3” SOL side results in the and flows through cylinder port A to the cylinder.
generation of pilot pressure in cap 1, which exceeds the Return oil from the cylinder enters the low-pressure
force of spring in cap 2 and pushes the spool to the channel through cylinder port B.
right.
8-68
HYDRAULIC SYSTEM
A B
1 2
High-pressure oil
Low-pressure oil
Pilot oil
207450

Activation of the proportional electromagnetic pressure Oil from the control oil channel lifts the load check
control valve on the SOL “b3” side results in the valve and flows through cylinder port B to the bottom
generation of pilot pressure in cap 2, which exceeds the side of the cylinder.
force of spring in cap 1 and pushes the spool in the left Return oil from the cylinder enters the low-pressure
direction. channel through cylinder port A.
8-69
HYDRAULIC SYSTEM
Relief Valve
Main and Secondary Relief Valve Operations

The main and secondary valves are installed between
neutral oil passage HP and low-pressure oil passage LP,
and perform the following operations.
(1) Chamber D is filled with oil entering through orifices
in main poppet C, thus main poppet C and sleeve E are Sleeve E
firmly seated because of the difference in area sizes.
LP Pilot poppet F
HP
Chamber D
Main poppet C
207451
(2) When pressure in HP reaches the preset pilot spring

force, pilot poppet F opens. Oil flows around the pilot
poppet and passes through the holes and enters low-
pressure passage LP.
207452
(3) Because pilot poppet F opens, oil flows from HP to

chamber D through orifices in main poppet C. This oil
flow results in pressure differences between HP and
chamber D, thus causing main poppet C to open and
allow oil to flow directly from HP to LP.
207453
8-70
HYDRAULIC SYSTEM
Disassembly
Disassembly of Valve Assembly

Clean the exterior thoroughly.
Be careful not to scratch machined port surfaces.
Remove the main relief valve, overload relief valve and
shut-off valve from the valve housing. Do not disassemble
the removed valves unless they need repair.
Remove the end nut from the tie rod. Spool sections can
be dismounted in sequence, starting from the outlet
section.
The mating surfaces are mounted with load check valve
poppet, spring and O-rings. Do not scratch or damage the
mating surfaces.
For disassembly and reassembly instructions, refer to the
applicable sections.
8-71
HYDRAULIC SYSTEM
Disassembly of Sections
Disassembly of Inlet Section Assembly
1 5 6 7 4 3
Shut-off valve
11
Main relief valve

8 9 10
207560
Sequence
1 Plug, O-ring 7 Valve
2 Plug, O-ring 8 Plug, O-ring
3 Spring 9 Spring
4 Spool 10 Pilot poppet
5 Cap screw, O-ring 11 Adjuster kit, O-ring
6 Spring
NOTE
All O-rings must be replaced with new parts during reassembly. Replacement O-rings are supplied in a repair kit.
8-72
HYDRAULIC SYSTEM
Spool
(1) Loosen plug 1 (27 Hex) by rotating two to three turns.
Dismount orifice plug 2 (27 Hex) from inlet housing 1.
Spring 3 can be removed together with the plug.
(2) Slowly pull out spool 4 assembly by holding it at the
spring guide section.
(3) Remove cap screw 5 (5 Hex), and remove spring 6 and
valve 7 from spool 4.
Main Relief Valve

Refer to the “Main Relief Valve Setting Procedures” on
page 8-88.
Pilot Relief Valve

Loosen plug 8 (19 Hex), then remove it together with
spring 9 and pilot poppet 10 from inlet housing 1.
NOTE
Do not loosen adjuster kit 11 (17 Hex) unless it is
necessary, as loosening the adjuster kit changes relief
pressure.
Inspection After Disassembly

(1) Check the springs for fatigue.
(2) Check the sliding surfaces of the piston and valve for
damage.
8-73
HYDRAULIC SYSTEM
Disassembly of Lift Section Assembly
Load check valve

9 8 7 5 2 6 Shut-off valve
10 3 4 1
207561
Sequence
1 Cap, Bolt, Spring 5 Plug, O-ring 8 Poppet
2 Spool, Spring 6 Plug, O-ring 9 Connector assembly
3 Cap 7 Spring 10 Adjuster kit, O-ring
4 Spool-head
8-74
HYDRAULIC SYSTEM
Spool
(1) Unscrew socket-head bolt (5 Hex) from cap 1, and
remove cap 1.
(2) Remove spool 2 assembly from valve housing.
NOTE
Do not loosen lock nut 10 of the adjuster kit mounted
on cap 3.
Load Check Valve

Remove plug 5 (10 Hex) and plug 6 (23 Hex). Remove
spring 7 and poppet 8.
Shut-off Valve
4 6 5 3 1 2
1 Nut
2 Set screw
3 Plug
4 Poppet
5 O-ring
6 O-ring
(1) Loosen nut 1 (12 Hex), then loosen set screw 2 (4

Hex) by rotating two to three turns. Remove plug 3
207562
assembly (22 Hex).
(2) Remove poppet 4 from plug 3. Remove set screw 2
and nut 1.
8-75
HYDRAULIC SYSTEM
Disassembly of Tilt Section Assembly
1 3 4 2
207563
Sequence
1 Cap, Bolt, Spring 3 Spring
2 Spool 4 Valve
Spool
(1) Unscrew socket-head bolt (5 Hex) from cap 1 (on one
side), and remove cap 1.
(2) Remove spool 2 assembly from valve housing.
(3) Remove spring 3 and valve 4 from spool 2.
8-76
HYDRAULIC SYSTEM
Disassembly of Attachment Section Assembly
207564
Sequence
1 Cap, Bolt, Spring 3 Spring
2 Spool 4 Spring seat

For disassembly procedures, refer to the tilt section.
8-77
HYDRAULIC SYSTEM
Cleaning
Wash all disassembled parts with clean solvent.
Use compressed air to dry parts. Place parts on clean
paper or cloth for inspection.
Inspection
Inspect each part for burrs, scratches, dents and other
surface flaws.
(1) Remove burrs with an oil stone or by lapping
compound. If a part has excessive scratches that may
cause oil leaks or malfunctions, replace the part or the
section assembly.
NOTE
The valve housings and spools must be used in original
combinations. Since these parts are not interchangeable,
if scratches and dents are minor, correct flaws with an
oil stone or lapping compound.
(2) Make sure all moving and sliding parts operate

smoothly. Make sure there are no foreign particles in
grooves and oil passages.
(3) Check orifices for clogs.
(4) Replace broken or bent springs.
(5) If the main relief valve does not operate smoothly,
inspect the valve (refer to the “Main Relief Valve
Setting Procedures” on page 8-88).
(6) Replace all seals, wipers and O-rings with new parts.
8-78
HYDRAULIC SYSTEM
Reassembly
Reassembly of Sections
Reassembly of Inlet Section Assembly
11 7 6 5 8 9
Shut-off valve
10
Main relief valve

4 3 2
207560
Sequence
1 Adjuster kit, O-ring 7 Cap screw, O-ring
2 Pilot poppet 8 Spool
3 Spring 9 Spring
4 Plug, O-ring 10 Plug, O-ring
5 Valve 11 Plug, O-ring
6 Spring
8-79
HYDRAULIC SYSTEM
Spool
(1) Install O-ring on cap screw 7 (5 Hex), insert the spring
guide section in the spring, then tighten the cap screw
on spool 8.
12 to 14
Tightening torque (1.2 to 1.4)
[8.76 to 10.2]
(2) Install O-ring on plug 11, and screw the plug into inlet
housing by rotating two to three full turns.
(3) Slowly insert the above spool assembly from the
opposite side. Make sure the spool assembly slides
smoothly before it contacts plug 10. Install the spool
assembly into inlet housing, and make sure it slides
smoothly.
(4) Tighten plug 10 (27 Hex) and plug 11 (27 Hex).
71 ± 2
Tightening torque (7.1 ± 0.2)
[51.8 ± 1.5]
Main Relief Valve

Refer to the “Main Relief Valve Setting Procedures” on
page 8-88.
Pilot Relief Valve

Install spring 3 and pilot poppet 2 on plug 4, and insert the
plug into inlet housing and tighten.
23 ± 1
[16.8 ± 0.73]
NOTE
If adjuster kit 1 (17 Hex) is loosened, after installation
on the vehicle, adjust the set screw (6 Hex) using a
pressure gauge. After adjustment, tighten the hexagon
nut (17 Hex) to lock in position.
8-80
HYDRAULIC SYSTEM
Reassembly of Lift Section Assembly
2 3 4 6 9 5
1 13 8 14 11 7 12 10
207561
Sequence
1 Adjuster kit, O-ring 6 Plug, O-ring 11 Spring seat
2 Connector assembly 7 Spool-head 12 Spring
3 Poppet 8 Cap, Bolt 13 Cap, Bolt, Spring
4 Spring 9 Spool, Spring 14 Spring
5 Plug, O-ring 10 Spacer
8-81
HYDRAULIC SYSTEM
Spool
(1) Hold spool 9 with a vice that has protective boards
(hard wood) on the clamping faces.
Install spool-head 7 (5 Hex) and tighten.
12 to 14
[8.76 to 10.2]
(2) Insert spacer 10 and spring 12, in the bottom section

of spool, insert spring seat 11 in the head section of
spool 9, and install O-ring on cap 13, insert spring 12,
then screw socket-head bolt on cap 13.
(3) Firmly tighten four socket head bolts (5 Hex) on caps
8 and 13.
9 to 11
[6.57 to 8.03]
Load Check Valve

(1) Insert poppet 1 into the valve housing. After making
sure it moves smoothly, insert spring 2.
(2) Install O-rings 3, 4 on plugs 5, 6, and install the plugs
on the valve housing.
71 ± 2
[51.8 ± 1.5]
207566
(3) Install connector assembly 7, and tighten the lock nut
(24 Hex).
53 ± 1
[38.7 ± 0.73]
8-82
HYDRAULIC SYSTEM
Shut-off Valve
1 2 3 4 5 6
Sequence
1 Poppet
2 O-ring
3 O-ring
4 Plug
5 Nut
6 Set screw
Suggestions for Reassembly 207562
(1) Install O-ring 2 on poppet 1, and insert the poppet into

plug 4.
(2) Insert O-ring 3 on the valve housing.
(3) Install plug 4 on the valve housing.
(4) Install set screw 6 (4 Hex) in plug 4 and tighten.
10 to 12
Tightening torque (1 to 1.2)
[7.3 to 8.76]
(5) Screw nut 5 (12 Hex). While holding set screw 6 (4

Hex) with a wrench to prevent it from turning, tighten
the nut.
10 to 12
Tightening torque (1 to 1.2)
[7.3 to 8.76]
! CAUTION
Be sure to tighten the set screw. If the set screw
is not tightened, the valve cannot hold the neutral
position, thus leading to hazardous situations.
8-83
HYDRAULIC SYSTEM
Reassembly of proportional electromagnetic pressure control valve
207565
Sequence
1 Sleeve 5 Shuttle
2 O-ring 6 O-ring
3 O-ring 7 Solenoid, Bolt
4 O-ring

(1) Install O-rings 2, 3, 4 on sleeve 1. (4) Position proportional solenoid 7 on valve housing
(2) Insert shuttle 5 into sleeve 1. Make sure it slides so the solenoid lead wire faces upward. Install the
smoothly. solenoid on the valve housing with Allen wrench (4
Hex).
(3) Insert sleeve 1 into valve housing, and install O-
ring 6. Unit: N·m (kgf·m) [lbf·ft]
7 to 9
[5.11 to 6.57]
8-84
HYDRAULIC SYSTEM
Reassembly of Tilt Section Assembly
2 3 4 1
6 7 5
207563A
Sequence
1 Spool 5 Spring seat
2 O-ring 6 Spring
3 Spring 7 Cap, Bolt
4 Valve

(1) Insert spring seat 5 in the head section of spool 1,
install O-ring 2 on cap 7, insert spring 6, then
screw socket-head bolt on cap 7. (Conduct this
procedure on both sides.)
(2) Tighten four socket head bolts (5 Hex) to secure
caps 7, in place.
9 to 11
[6.57 to 8.03]
For the proportional electromagnetic pressure control

valve, refer to page 8-84.
8-85
HYDRAULIC SYSTEM
Reassembly of Attachment Section Assembly

For reassembly procedures, refer to the tilt section.
Reassembly of Valve Assembly

(1) Set the assembled inlet section, spool section and outlet
section assemblies in their original installation
positions.
(2) Position the inlet section so that its mating surface
faces upward, and screw the tie rod.
NOTE
After tightening the tie rod by hand, tighten with pliers
slightly more.
(3) Pay attention to the O-rings and the load check valve
spring on the mating surfaces. Mount each section, and
tighten nuts.
(4) Place the assembled valve assembly on a flat and level
surface or table to ensure that the valve mounting
surface is horizontal. Tighten nuts to the specified
torque. [Horizontal deviation of valve mounting
surface: 0.3 mm (0.01 in.) or less]
Nut tightening torque

Cylinder port side 46 (4.7) [34]
Valve mounting side 19 (1.9) [13.7]
(5) Install the main relief valve, overload relief valve and
shut-off valve.
Relief valve service procedures are described in the
following section.
To install the shut-off valve, follow the steps below.
8-86
HYDRAULIC SYSTEM
Installation of Shut-off Valve

1 2 3
(1) Loosen nut 2, loosen set screw 3 by two to three turns,
then tighten plug 1 on the valve housing.
60 to 70
[44.3 to 51.6]
(2) Tighten set screw 3 on the plug.

Unit: N·m (kgf·m) [lbf·ft] 207562
18.6 to 21.6
[13.7 to 15.9]
(3) While holding the set screw with a wrench to prevent it

from turning, tighten the nut 2.
18.6 to 21.6
[13.7 to 15.9]
! CAUTION
When the shut-off valve is removed from the valve
housing, be sure to loosen the nut and the set
screw as described above. Do not reinstall the
shut-off valve without conducting this procedure;
otherwise, oil can leak from cylinder ports or
other parts.
Be sure to tighten the set screw. If the set screw
is not tightened, the valve cannot hold the neutral
position, thus leading to hazardous situations.
8-87
HYDRAULIC SYSTEM
Service Information
Cartridge-type Relief Valve Setting Procedure
Main Relief Valve
Unit: mm (in.)
Hexagon nut
width across flats: 17 (0.67) 6
(0.24)
Adjuster
Tightening torque: 27 to 31 N·m Lock nut

(2.8 to 3.2 kgf·m)
[20.2 to 23.1 lbf·ft]
207455A
Install a high-precision pressure gauge on the inlet (4) While holding the adjuster in position, tighten the
circuit (circuit on pump port side). lock nut.
After installing the pressure gauge, follow the steps (5) Conduct the test again to check the set pressure.
below. The set pressure remains at about the same level
Loosen the lock nut. Make sure that several ridges on when the pump is operating at its maximum speed.
the adjuster screw are engaged with the housing.
Follow directions below to set the adjuster with a
wrench.
(1) Operate the pump at low speed (approx. 1/4 of
maximum rpm).
The pump should operate at an adequate speed
when applied with set pressure.
(2) Move one spool in the control valve to the end of
the stroke, and read the indicator on the pressure
gauge.
(3) Turn the adjuster clockwise until the required set
pressure is achieved.
Unit: MPa (kgf/cm ) [psi]
2
Pressure change per one

18.1 (185) [2631]
adjuster rotation
8-88
HYDRAULIC SYSTEM
Installation
Make sure there is no excessive force on the pipes.
Welding work near the valves may damage lead wires due
to heat and spatter.
Cover the connectors at the end of lead wires when
painting.
To prevent dust and other particles from entering the
valves, do not remove the protective plugs from ports until
pipes are connected.
Operation
Before operation, make sure the hydraulic circuits and
fluid are in normal condition.
Use only hydraulic fluid (oil) with an aniline point
between 80 and 113°C (176 and 235.4°F).
Do not set the pressure of the main relief valve and relief
valve above the specified pressure levels.
The difference between the set pressure levels of the main
relief valve and relief valve must be more than 1.5 MPa (15
kgf/cm ) [213 psi].
2
8-89
HYDRAULIC SYSTEM
Troubleshooting
Control Valve (general)
Problem Possible cause Remedy

Pump pressure does 1. Sticking of shuttle in proportional Disassemble and clean.
not increase. electromagnetic valve or plunger in Proportional solenoid cannot be disassembled.
proportional solenoid If plunger in proportional solenoid is sticking,
replace solenoid.
2. Open circuit in lead wire or solenoid coil Repair or replace.
3. Low input current to solenoid Check to make sure specified maximum
current is supplied.
4. Sticking of spool in flow priority valve Disassemble and clean.
Spool sticks. 1. Abnormally high oil temperature flow in Remove cause that is reducing fluid.
pipe
2. Dirty hydraulic fluid Replace hydraulic fluid and clean hydraulic
circuits.
3. Overtightened pipe port joint Check tightening torque.
4. Improper valve housing installation Loosen mounting bolts, and check valve
housing installation.
5. Excessively high pressure Install pressure gauge on inlet and cylinder
circuit, and check pressure.
6. Foreign particles stuck on spring seat Disassemble and clean.
7. Bent spool Replace valve assembly.
8. Sticking of shuttle in proportional Disassemble and clean.
electromagnetic valve or plunger in Proportional solenoid cannot be disassembled.
proportional solenoid If plunger in proportional solenoid is sticking,
replace solenoid.
9. Uneven temperature distribution inside Warm up entire hydraulic circuits.
valve
Load cannot be 1. Oil leaks from cylinder Check cylinders.
maintained. 2. Oil bypassing valve spool Replace valve.
3. Leaks from overload relief valve or Remove and clean overload relief valve or
shut-off valve shut-off valve (housing and relief valve seat
section).
Load drops when spool 1. Foreign particles stuck on load check Disassemble and clean.
is switched from valve
neutral to lift.
Oil leaks from oil seal. 1. Paint adhesion on seal Remove and clean seal.
2. High back pressure in return circuit of Check filter in return circuit for clogs, or
valve check foreign particles stuck in return pipe.
3. Foreign particles stuck on seal Remove and clean seal.
4. Loose cap Clean cap and tighten cap bolts.
5. Tears or scratches on seal Replace seal.
8-90
HYDRAULIC SYSTEM
Hydraulic System (general)

Hydraulic system 1. Malfunction of pump Check pressure, or replace pump.
operates abnormally or 2. Clogs in relief valve Disassemble and clean relief valve.
does not operate at all.
3. Malfunction of relief valve Check according to service procedures.
4. Worn cylinders Repair or replace.
5. Excess load Check circuit pressure.
6. Cracking in valve Replace valve.
7. Low oil level in tank Add oil.
8. Clogged filter in circuit Clean or replace filter.
9. Flow restriction in circuit pipe Check pipes.
8-91
HYDRAULIC SYSTEM
Relief Valve

Pressure does not 1. Open passage due to sticking of main • Check poppet joint for foreign particles.
increase at all. poppet or pilot poppet Poppet must slide freely.
2. Foreign particles stuck on poppet seat • Clean all parts thoroughly.
Relief pressure is 1. Scratches on poppet seat • Replace damaged parts.
unstable.
2. Sticking of poppet • Clean all parts thoroughly.
• Remove surface scratches.
Incorrect relief 1. Wear due to abrasion by dust • Replace damaged parts.
pressure. particles
• Readjust.
2. Loose lock nut and adjusting screw
Oil leaks. 1. Damaged seats Replace damaged or worn parts.
2. Worn O-rings All parts must move smoothly.
3. Sticking of parts due to foreign Check there is no scratch, dent or foreign
particles particles.
Pressure increases 1. Air in relief valve Bleed air.
slowly.
8-92
R
Hydraulic control valve L

(DC motor, FC models)
T1
Steering cylinder
B4
A4 Orbit roll
b4 a4 Displacement 63 cc/rev.
Relief 6.5 MPa
B3
A3
3 T P
b3 a3 Pump motor
B2 36 / 48 V Dual voltage
Steering motor
11.56 kW (48V) Operation
A2 0.55 kW Operation
Std. tilt
cylinder b2 a2 M M
Gear pump
Displacement Gear pump (Steering)
A1 24.5 cc / rev. EU: Displacement
4.0 cc/rev.
Flow
regulator
b1 a1
8-93
Return Suction
filter strainer
15 μm 100 mesh
18.1 MPa
2.5 MPa
P T2
Lift cylinder
211098
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Hydraulic Circuits
Neutral
T1 To Tank
Att. Section
B3
A3 Att. a3
To Att. cyl. Att. b3
Tilt Section
B2 Tilt
A2 Backward
a2
Tilt Forward
To Tilt cyl.
b2
Tilt lock
valve
Lift Section
Unload
valve Shut-off
valve
A1
To Lift cyl.
Lift down a1
b1
Lift lock valve Lift up
Inlet Section
Shut-off
valve
Flow regulator valve
Pilot
relief
valve Main relief
valve
High-pressure oil P T2
Pilot oil
Low-pressure oil
From Pump From Steering Control Valve
207455
8-94
HYDRAULIC SYSTEM
Tilt Forward
T1 To Tank
Att. Section
B3
A3 Att. a3
Tilt Section
B2 Tilt
A2 Backward
a2
Tilt Forward
To Tilt cyl.
b2
Tilt lock
valve
Lift Section
Unload
valve Shut-off
valve
A1
To Lift cyl.
Lift down a1
b1
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
Pilot oil
Low-pressure oil
207456
8-95
HYDRAULIC SYSTEM
Tilt Backward
T1 To Tank
Att. Section
B3
A3 Att. a3
Tilt Section
B2 Tilt
A2 Backward
a2
Tilt Forward
To Tilt cyl.
b2
Tilt lock
valve
Lift Section
Unload
valve Shut-off
valve
A1
To Lift cyl.
Lift down a1
b1
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
Pilot oil
Low-pressure oil
207457
8-96
HYDRAULIC SYSTEM
Lift Up
T1 To Tank
Att. Section
B3
A3 Att. a3
Tilt Section
B2 Tilt
A2 Backward
a2
Tilt Forward
To Tilt cyl.
b2
Tilt lock
valve
Lift Section
Unload
valve Shut-off
valve
A1
To Lift cyl.
Lift down a1
b1
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
Pilot oil
Low-pressure oil
207458
8-97
HYDRAULIC SYSTEM
Lift Down
T1 To Tank
Att. Section
B3
A3 Att. a3
Tilt Section
B2 Tilt
A2 Backward
a2
Tilt Forward
To Tilt cyl.
b2
Tilt lock
valve
Lift Section
Unload
valve Shut-off
valve
A1
To Lift cyl.
Lift down a1
b1
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
Pilot oil
Low-pressure oil
207459
8-98
HYDRAULIC SYSTEM
Att. A3
T1 To Tank
Att. Section
B3
A3 Att. a3
Tilt Section
B2 Tilt
A2 Backward
a2
Tilt Forward
To Tilt cyl.
b2
Tilt lock
valve
Lift Section
Unload
valve Shut-off
valve
A1
To Lift cyl.
Lift down a1
b1
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
Pilot oil
Low-pressure oil
207460
8-99
HYDRAULIC SYSTEM
Att. B3
T1 To Tank
Att. Section
B3
A3 Att. a3
Tilt Section
B2 Tilt
A2 Backward
a2
Tilt Forward
To Tilt cyl.
b2
Tilt lock
valve
Lift Section
Unload
valve Shut-off
valve
A1
To Lift cyl.
Lift down a1
b1
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
Pilot oil
Low-pressure oil
207461
8-100
MAST AND FORKS
Mast Systems .......................................................................................... 9 – 1

Mast Type Code Stamping Position .......................................................... 9 – 1
Explanation of Mast Type Code ................................................................ 9 – 1
Mast Types ............................................................................................... 9 – 1
Description ............................................................................................... 9 – 2
Dual-stage Panoramic Mast (Simplex Mast) ............................................. 9 – 2
Dual-stage Full Free Panoramic Mast (Duplex Mast) ................................ 9 – 3
Triple-stage Full Free Panoramic Mast (Triplex Mast) ................................ 9 – 4
Operation of Dual-stage Full Free Panoramic Mast ................................... 9 – 5
Operation of Triple-stage Full Free Panoramic Mast ................................. 9 – 5
Removal and Installation ...................................................................... 9 – 6
Mast and Lift Bracket Assembly ................................................................. 9 – 6
Dual-stage Panoramic Mast (Simplex Mast) ........................................... 9 – 6
Triple-stage Full Free Panoramic Mast (Triplex Mast) .............................. 9 – 9
Disassembly and Reassembly ............................................................ 9 – 12 9
Dual-stage Panoramic Mast (Simplex Mast) ............................................. 9 – 12
Dual-stage Full Free Panoramic Mast (Duplex Mast) ................................ 9 – 16
Triple-stage Full Free Panoramic Mast (Triplex Mast) ................................ 9 – 20
Forks ........................................................................................................ 9 – 24
Chain Tension Adjustment ........................................................................ 9 – 25
Clearance Adjustment on Lift Bracket ....................................................... 9 – 28
Mast Clearance Adjustment ...................................................................... 9 – 30
Main Roller Shim Replacement.................................................................. 9 – 32
Mast Strip Adjustment ............................................................................... 9 – 36
Tilt Angle Adjustment ................................................................................ 9 – 36
Lift Cylinder Stroke Adjustment ................................................................. 9 – 37
Troubleshooting ...................................................................................... 9 – 38
Service Data ............................................................................................ 9 – 39
MAST AND FORKS
Mast Systems
This manual applies to the following vehicle models (names).
Mast Types Dual-stage Dual-stage Full Free Triple-stage Full Free

Model Panoramic Mast System Panoramic Mast System Panoramic Mast System
1 ton class 2G15A 2H15A 2J15A
2 ton class 1G20A 1H20A 1J20A
NOTE : Maximum fork lift height [118 in. (30 : 3000 mm)]
Mast Type Code Stamping Position Mast Types
Code Mast Type
Dual-stage panoramic masts

G
Simplex mast
Dual-stage full free panoramic masts

H
Duplex mast
Triple-stage full free panoramic masts

J
Triplex mast
211100
Explanation of Mast Type Code

Example: 2 G 15 A 30
Maximum fork lift height [118 in. (30 : 3000 mm)]

Revision code (A ➞ B ➞ C ··· Z)
Representative model (not allowable load)
Mast type
Major revision record (1 to 9)
9-1
MAST AND FORKS
Description
207082
Unit: mm (in.)
Diam. of 1 ton class 2 ton class
Main Roller
S 99 (3.90)
207760
M 100 (3.94)
L 101 (3.98)
LL 102 (4.02)
1 Inner mast A: Main roller

2 Outer mast B: Main roller
3 Lift chain C: Main roller
4 Lift bracket D: Side roller
5 Mast-support bearing cap E: Main roller
F: Main roller
G: Mast strip
The panoramic mast features two lift cylinders placed Mast strips are fitted to the top end of outer mast.
behind the mast columns, right and left, to provide These strips are for backing up the inner mast when the
maximum visibility. mast is tilted backward.
9-2
MAST AND FORKS
Dual-stage Full Free Panoramic Mast (Duplex Mast)
207608
1 Lift chain 5 Outer mast 8 Lift bracket main roller

2 First lift cylinder 6 Lift bracket 9 Mast upper main roller
3 Second lift cylinder 7 Chain wheel 10 Mast lower main roller
4 Inner mast
The duplex mast provides a free lift amount until the When the first lift cylinder rod extends fully, the second
top of lift bracket reaches the mast height. lift cylinders raise the assembly consisting of the lift
The mast assembly consists of the inner mast, outer bracket, first lift cylinder and inner mast.
mast, lift bracket, first lift cylinder and second lift The shoulder sections of the mast main rollers contact
cylinders. the mast rails. The rollers are installed perpendicular to
The first lift cylinder raises the lift bracket, while the the sliding surfaces.
second cylinders operate the inner mast and lift bracket. The main rollers used in the 1 ton and 2 ton classes are
For lifting operation, oil is first sent to the first lift the same as those in dual-stage panoramic mast
cylinder which raises the forks until the cylinder rod (simplex mast).
reaches its stroke end.
9-3
MAST AND FORKS
207609 207610
1 First lift chain 5 Inner mast 9 Second chain wheel

2 First lift cylinder 6 Middle mast 10 Lift bracket main roller
3 Second lift chain 7 Outer mast 11 Mast upper main roller
4 Second lift cylinder 8 Lift bracket 12 Mast lower main roller
The triplex mast provides a free lift amount until the top For lifting operation, oil is first sent to the first lift
of lift bracket reaches the mast height. cylinder which raises the forks until the cylinder rod
The mast assembly consists of the inner mast, middle reaches its stroke end.
mast, outer mast, lift bracket, first lift cylinder and When the first lift cylinder rod extends fully, the second
second lift cylinders. lift cylinders raise the assembly consisting of the lift
The first lift cylinder raises the lift bracket, while the bracket, first lift cylinder, inner mast and middle mast.
second cylinder operates the three-stage telescopic The shoulder sections of the mast main rollers contact
mechanism and lift bracket. Two pairs of lift chains are the mast rails. The rollers are installed perpendicular to
installed. The cylinders and lift chains are designed for the sliding surfaces.
smooth and effective operation. The main rollers used in the 1 ton and 2 ton classes are
the same as those in dual-stage panoramic mast
(simplex mast).
9-4
MAST AND FORKS
Operation of Dual-stage Full Free Panoramic Mast
Operation of Triple-stage Full Free Panoramic Mast
203598
203600
9-5
MAST AND FORKS
Removal and Installation
Mast and Lift Bracket Assembly

207761
Sequence
1 Nuts 5 Low-pressure hose
2 Forks, Lift bracket 6 High-pressure hose for lift cylinders
3 Tilt socket pins 7 Mast support cap
4 Tilt cylinders 8 Mast support bushing
1. Lift bracket removal

(1) Tilt the mast forward, and lower the inner mast to the
bottom. Slacken the lift chains, and remove the nuts
from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free. Then, back the
truck away from the lift bracket and fork assembly.
207084
9-6
MAST AND FORKS
2. Removing lift cylinder high pressure hoses

Lower the mast to the bottom position, disconnect the
hoses at the flow regulator valve.
3. Removing tilt cylinders

(1) Hitch a sling to the mast. Using two eye-bolts and a
sling as shown, support the mast with a hoist.
! CAUTION
Be sure to use a hoist with enough capacity to
support the mast assembly.
204845
(2) Remove the tilt socket pins, and separate the masts
from the tilt cylinders.
(3) Turn the key switch to ON and pull back the tilt lever to
contract the tilt cylinder rods.
(4) Turn the key switch to OFF and disconnect the high-
pressure hose from tilt cylinders.
207086
4. Removing mast support bearing caps

(1) Mark the bearing caps to ensure the correct
reassembling before removing them.
(2) Remove the cap bolts and lift off the mast assembly.
Lay it down flat on a level floor.
NOTE
Lay the mast assembly on the floor, so that you have
enough space to disassemble the parts.
207087
9-7
MAST AND FORKS
Installation
follow the steps below:
7
1. Procedure for mounting mast support bushings 7 and 7
caps 7.
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) Install mast support bushings 7 and caps 7, making sure
that the sides with larger chamfered area face toward
the center of the vehicle.
Apply grease
(3) Be sure to tighten the support tightening bolts securely.
Chamfered faces
203712
Truck Model
Item
74 N·m 178 N·m
Bolt tightening
(7.5 kgf·m) (18.2 kgf·m)
torque
[54 lbf·ft] [132 lbf·ft]
2. Adjust the chain tensions.

(Refer to the Inspection and adjustment section.)
Tighten the nuts to the specified torque.
Tightening torque
Tightening Torque
55.8 to 56.8 N·m

Upper nut ➁ (5.7 to 5.8 kgf·m)
[41.2 to 41.9 lbf·ft]
102709
98 to 103 N·m
Double nut (lower) ➀ (10 to 10.5 kgf·m)
[72.3 to 76.0 lbf·ft]
3. Air bleeding of lift cylinders

Due to internal drain type cylinder, the lift cylinders do
not require air bleeding.
4. After proper operation is confirmed, check the oil level.
9-8
MAST AND FORKS
Mast and Lift Bracket Assembly

The following describes the procedures for removing and reinstalling the mast assemblies of dual-stage full free
panoramic mast (Duplex Mast) and triple-stage full free panoramic mast (Triplex Mast). Note that the triple-stage
full free panoramic mast (Triplex Mast) is used as an example.
207777
Sequence
1 Nuts 5 Low-pressure hose
2 Fork, Lift bracket assembly 6 Mast support cap
3 Tilt socket pin 7 Mast support bushing
4 High-pressure hose for lift cylinders

1. Removing lift bracket assembly 2
(1) Lower lift bracket assembly 2, and place wood
blocks under the assembly. Tilt the mast forward,
lower the inner mast to the bottom, then remove
nuts 1 from the anchor bolts of the first lift chains.
207613
9-9
MAST AND FORKS
(2) Position the mast upright. Raise the inner mast until
main rollers 8 of the lift bracket become free. Then,
slowly move the vehicle in reverse to separate from lift
bracket 2.
8
2
207762
2. Separating mast and tilt cylinders

(1) Lower the inner mast. Hitch a sling to the upper cross-
member of the outer mast. For sling attachment, install
eye-bolts in the holes on the right and left sides. Use a
crane and lift.
! CAUTION
Be sure to use a hoist with enough capacity to
support the mast assembly. 207614
(2) Place wood blocks under the tilt cylinder mounting

sections, and remove pins.
(3) Turn the key to ON, and pull back the tilt lever to
contract the tilt cylinder rods.
(4) Disconnect high-pressure hose from tilt cylinders.
207086
3. Removing mast support caps 6

(1) Mark caps 6 to ensure the caps are reinstalled in
original positions during reassembly.
(2) Remove cap mounting bolts. Dismount the mast
assembly from vehicle in the suspended condition.
With the lift bracket side facing up, place the mast
assembly horizontally on wooden blocks on the level
ground. 6
207615
9-10
MAST AND FORKS
Installation
1. Procedure for installing mast support bushings 7 and 6
caps 6. 7
(1) Apply grease to the inner surfaces of caps and mast

support bushings.
(2) Install mast support bushings 7 and caps 6, making sure
that the sides with larger chamfered area face toward
the center of the vehicle.
(3) Be sure to tighten the support tightening bolts securely. Apply grease
Chamfered faces
203712
Truck Model
Item
74 N·m 178 N·m
Bolt tightening
(7.5 kgf·m) (18.2 kgf·m)
torque
[54 lbf·ft] [132 lbf·ft]
2. Adjust the chain tensions.

(Refer to the Inspection and adjustment section.)
Tighten the nuts to the specified torque.
Tightening torque
Tightening Torque
55.8 to 56.8 N·m

[41.2 to 41.9 lbf·ft]
98 to 103 N·m
[72.3 to 76.0 lbf·ft]
3. Bleeding lift cylinders.

102709
In the dual-stage full free panoramic mast, only the
second lift cylinders are provided with air bleeding
valves.
The other lift cylinder does not require air bleeding
since it is an internal drain type cylinder.
4. After proper operation is confirmed, check the oil level.
9-11
MAST AND FORKS

Disassembly
13 11
16
3
12
11
14
10
2
18
9
8
17
6 8
6
6 15
1
4
5
207763
Sequence
1 Nuts 10 Snap ring, Chain wheel
2 Forks, Lift bracket 11 Cylinder clamps, Seats, Shims, Cushion,
3 Backrest Collar, Bolts
4 Main roller, Shims 12 Bolt, Shims
5 Main roller, Shims 13 Mast strip, Shims
6 Side roller, Brackets, Shims 14 Main roller, Shims
7 Hose guard 15 Main roller, Shims
8 Lift hose (high pressure), 16 Inner mast
Rubber hose, T-joint, Down safety valve 17 Lift cylinders
9 Low-pressure hose 18 Outer mast

1. Removing mast strips and main rollers
Remove bolts 11, 12 to free lift cylinder 17.
Displace the tops of the two lift cylinders from
inner mast 16. Slide inner mast 16 toward the
bottom of outer mast 18, and remove main rollers
14, 15 and mast strips 13.
9-12
MAST AND FORKS
2. Inner mast removal

After removing the main rollers, hitch a sling to the
inner mast crossmember and slide the inner mast to the
upper side of the outer mast to clear the outer mast
roller shafts. Hitch a sling to the inner mast again and
remove it from the outer mast.
207089

1. Mast
(1) Check each roller for wear, binding or other defects.
(2) Check each roller on rolling surface for pitting or other
defects.
(3) Check the mast member and the welded joints of cross-
members, shafts and supports for cracks.
(4) Check the mast support bushings for wear or other
defects.
207090
2. Lift bracket
(1) Check the main rollers and side rollers for smooth
rotation. Inspect each roller for wear and cracks.
(2) Check the welded portions of the bracket for cracks.
(3) Check the finger bar for bend or distortion.
A: Standard value
5 mm (0.2 in.),
Distortion of finger bar A
maximum 207091
9-13
MAST AND FORKS
3. Lift chains, chain wheels and chain wheel supports

(1) Measure the length of each chain to make sure that two
chains are equal in length. Also check the chains for
wear, sign of breakage, link binding and twist.
(2) Check each chain anchor bolt for cracks or defects on
thread.
(3) Check each chain wheel support and chain wheel for
crack or wear. Check that the wheels rotate smoothly.

Unit: mm (in.)
Truck Model 1 ton class 2 ton class
Item
Length of lift chain A 318 (12.52) 381 (15.00)
(per 20 links) B 327 (12.87) 392 (15.43)
4. Mast strips
Check the mast strips for damage, wear or distortion.
Reassembly
To reassemble, follow the reverse of disassembly procedure,
and follow the steps below:
1. Longitudinal clearance adjustment between mast
and lift bracket
Rollers for mast and lift bracket are available in three
sizes (diameters) for selective use. Select the size that
will provide a longitudinal clearance of 1 mm (0.04
in.) or less.
Roller sizes
Unit: mm (in.)
Main Roller 207096
S 99 (3.90)
M 100 (3.94)
L 101 (3.98)
LL 102 (4.02)
9-14
MAST AND FORKS
2. Cylinder clamps
Install each lift cylinder in place (in vertical position)
by fitting to the support, and see if there is any
space between the outer mast and cylinder. Reduce the
space, if any, to zero by shimming.
207093
3. Mast supports
Mast cap
Bushing
(1) Apply grease to the inside surfaces and grooves of the
caps.
(2) Install mast support bushings and caps orienting the
chamfered faces inward.
Place wood blocks under mast to facilitate greasing
work.
Apply grease
Chamfered faces
203712
4. Precautions for installing chain anchor kit

Be careful not to confuse the center plate with the link
plate.
207094
1 Link plate (stamped mark on surface)

2 Center plate (no stamped mark)
3 Link
4 Split pin
9-15
MAST AND FORKS
Dual-stage Full Free Panoramic Mast (Duplex Mast)

Disassembly
207607
Sequence
1 High-pressure hose for first cylinder, 11 Mast strip, Shims
Clamp 12 Main roller, Shims
2 Bolt, Washer, Shims 13 Stopper cushion, Cushion plate, Shims, Bolt,
3 First lift cylinder Washer
4 Chain guard 14 Inner mast
5 Chain wheel support, Pin 15 Second lift cylinder
6 Chain wheel, Snap ring 16 Cylinder bracket
7 Cylinder guard, Bolt, Washer 17 O-ring, Plug
8 High-pressure hose 18 Mast cap, Bolt, Washer
9 Cushion, Collar, Shims, Bolt, Washer, Clamp 19 Outer mast, Grease nipple
10 Bolt, Washer, Shims
NOTE
For lift bracket disassembly procedure, refer to the
dual-stage panoramic mast (simplex mast), as the
procedure is the same.
9-16
MAST AND FORKS
Preparation
With the lift bracket side facing up, place the mast
horizontally on wood blocks. Use a wood block as a wedge
to prevent the inner and middle masts from sliding.

(1) Remove retaining bolts from the first lift cylinder.
(2) Hitch slings on first lift cylinder 3, and gently remove
the cylinder.
Use two slings. Wind or tie slings securely to prevent
from slipping.
207619
2. Removing main rollers 12 and mast strips 11

(1) Remove clamp bolts from the second lift cylinders.
(2) Remove bolts from the upper rod sections of the second
lift cylinders, and place the cylinders on the outer mast.
(3) Check the number of shims and the shim thickness at
the rod end sections.
(4) Lower the inner mast, then remove main rollers 12,
mast strips and shims 11.
207620
3. Removing inner mast 14

Using slings, lift and remove inner mast 14, steering it
to pass over the roller shaft sections of outer mast 19.
207621

Follow the inspection procedure described in the dual-stage
panoramic mast (simplex mast).
9-17
MAST AND FORKS
Reassembly
1. Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims 12.
207622
(2) When replacing lift bracket main rollers, make sure

clearance A between each roller and mast surface is 1
mm (0.04 in.) or less.
207623
(3) To install main rollers on shafts, use a driving tool. Be

careful not to strike the outer roller surface with the
driving tool.
Place the roller with its larger chamfered side facing
outside.
202263
2. Installing second lift cylinders

When installing second lift cylinders 15, make sure the
cylinders are parallel to the mast to prevent torsional
stress on the lift cylinders when the mast is positioned
at the bottom. Adjust the installation positions of lift
cylinder brackets 16 with shims 9.
207632
9-18
MAST AND FORKS
3. Installing first lift cylinder

The first lift cylinder must be installed parallel to the
mast when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using
shims 2, adjust the backward inclination so that
clearance at section B is 0 to + 0.5 mm (0 to + 0.02 in.)
larger than clearance at section A.
201752
4. Precaution for installation of chain anchor kit

plate.
200383

3 Link
4 Split pin
9-19
MAST AND FORKS

Disassembly
207606
Sequence
1 Hose for first lift cylinder, Clamp, Bolt, Washer 17 Snap ring, Hose pulley, Shaft, Snap ring,
2 Bolt, Washer Chain wheel
3 Shims 18 Hose guard, Bolt, Washer
4 First lift cylinder 19 Hose, clamp, Bolt, Washer
5 Chain guard 20 Joint, Connector, Bolt, Washer
6 Chain wheel support, Pin 21 Bolt, Seat, Cushion, Collar
7 Snap ring, Chain wheel 22 Cushion, Shims, Bracket
8 Nut (chain for second lift cylinder) 23 Bolt, Washer, Shims
9 Mast strip, Shims 24 Second lift cylinder
10 Main roller, Shims 25 Mast strip, Shims
11 Main roller, Shims 26 Main roller, Shims
12 Inner mast 27 Main roller, Shims
13 Nuts 28 Middle mast
14 Lift chain (for second lift cylinder) 29 Cap, Bolt, Washer
15 Chain guard, Bolt, Washer 30 Outer mast, Grease nipple
16 Snap ring, Chain wheel
9-20
MAST AND FORKS
NOTE
For lift bracket disassembly procedure, refer to the
Preparation
dual-stage panoramic mast (simplex mast), as the
With the lift
procedure bracket
is the same. side facing up, place the mast
horizontally on wood blocks. Use a wood block as a wedge
to prevent the inner and middle masts from sliding.

(1) Remove retaining bolts from the first lift cylinder.
(2) Hitch slings on lift cylinder 4, and gently remove the
cylinder.
Use two slings. Wind or tie slings securely to prevent
from slipping.
2. Removing inner mast and main rollers

Lower inner mast 12 so that the main rollers can be
removed. Remove main rollers 10, 11 and mast strips
207624
9.
3. Removing inner mast

Using slings, lift and remove the inner mast 12,
steering it to pass over the roller shaft sections of the
207625
middle mast.
207626
9-21
MAST AND FORKS
4. Removing main rollers 26, 27 from middle mast 28

and outer mast 30
Remove the bolts that are holding second lift cylinders
24. Place the cylinder rod ends on the outer mast.
Lower middle mast 28 so that main rollers 26, 27 can
be removed. Then, remove the main rollers.
207627

Follow the inspection procedure described in the dual-stage
panoramic mast (simplex mast).
Reassembly
1. Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims.
207630
(2) When replacing lift bracket main rollers, make sure

clearance A between each roller and mast surface is 1
mm (0.04 in.) or less.
207629
9-22
MAST AND FORKS
(3) To install main rollers on shafts, use a driving tool. Be

careful not to strike the outer roller surface with the
driving tool.
Place the roller with its larger chamfered side facing
outside.
202263
2. Installing second lift cylinders 24

When installing second lift cylinders 24, make sure the
cylinders are parallel to the mast to prevent torsional
stress on the lift cylinders when the mast is positioned
at the bottom. Adjust the installation positions of lift
cylinder brackets with shims 22.
207631
3. Installing first lift cylinders

The first lift cylinder must be installed parallel to the
mast when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using
shims 3, adjust the backward inclination so that
clearance at section B is 0 to + 0.5 mm (0 to + 0.02 in.)
larger than clearance at section A.
201752
4. Precautions for installation of chain anchor kit

plate.
3 Link
4 Split pin
200383
9-23
MAST AND FORKS
Forks
1. Carefully inspect the forks for cracks. Special attention
should be given to the heel section A, all weld areas and
mounting brackets B.
Forks with cracks should be removed from service.
Magnetic particle inspection is generally preferred due
to its sensitivity and the ease of interpreting the results.
101628
2. Check the difference in height of one fork tip to the

other when mounted on the fork carrier. A difference in
fork tip height can result in uneven support of the load
and cause problems when loaded.
The maximum allowable difference in fork tip
elevation C is 5 mm (0.20 in.) for pallet forks.
Replace one or both forks when the difference in fork
tip height exceeds the maximum allowable difference.
101629
3. Check the fork blade D. The fork should be withdrawn

from service if the thickness is reduced to less than the
allowable thickness.
Fork blade length may also be reduced by wear,
especially on tapered forks and platens. Withdraw the
forks from service when the blade length exceeds the
repair/service limit.
Unit: mm (in.)
Tolerant 101630
Thickness Repair or
Standard value
service limit
Truck Model
FB16KT
FB18KT 35 ± 1 (1.38 ± 0.04) 33 (1.34)
FB20KT
9-24
MAST AND FORKS
Chain Tension Adjustment

Two-stage panoramic mast (Simplex Mast)
NOTE
Follow the same chain tightening procedure for all
masts except for the Simplex Mast chains on the lift
bracket side.
! WARNING
Personal injury can be caused by sudden
movement of the mast and lift bracket. Use blocks
to fix the mast and lift bracket from any movement
while the adjustments are made. Keep hands and
feet clear of any parts that can move.
1. Have the truck on the level floor, with the mast vertical,
and the fork lowered to the bottom.
Check that the lift cylinders are fully retracted.
2. Loosen the double nut (lower) ➀ and upper nut ➁.
3. Set the anchor bolts with double nut (upper) ➂.
4. Raise the forks slightly and push the chains inward
midway between the chain wheel and anchor alternately
to check the tension. When adjusting the chains by 102709
means of the double nut (upper) ➂ , tilt the mast
forward to slacken the chains to facilitate adjustment.
5. Turn double nut (upper) ➂ to adjust the chain tension.
Then, hold the anchor bolt in place with a wrench and
tighten upper nut ➁ to the specified torque.
6. Hold double nut (upper) ➂ in place with a wrench, and
tighten double nut (lower) ➀ to the specified torque.
Tightening Torque
55.8 to 56.8 N·m

102708
[41.2 to 41.9 lbf·ft]
98 to 103 N·m
[72.3 to 76.0 lbf·ft]
7. With the lift cylinder rods fully contracted, make sure

the amount of protrusion of each lift bracket main roller
is 40% of the roller diameter or less.
8. Make sure that the chain tension is correct with the
mast in vertical (0°) position. 207634
9-25
MAST AND FORKS
Dual-stage full free panoramic mast

(Duplex Mast)
1. On the level ground, position the mast at a right angle

to the ground surface, lower the forks to the ground,
and make sure the lift cylinder rods are contracted fully.
2. Secure the anchor bolts on the lift bracket side by
tightening the upper nuts and double nuts.
207633
3. Adjust the chain tensions by turning the double nuts

(upper) on the lift cylinder side. With the mast standing
perpendicular to the ground, lift the forks slightly, then
press the chains alternately at a midpoint between the
chain wheel and the secured end of the chain to make
sure the tension is the same in both chains.
NOTE
Tilting the mast slightly forward causes the chains to 102708
sag, thus making it easier to adjust the chain tensions
with the double nuts (upper).
4. Tighten the upper nuts and double nuts on the cylinder

side to the specified torque.
6. Conduct final adjustment with the mast positioned
perpendicular to the ground.
207634
9-26
MAST AND FORKS
Triple-stage full free panoramic mast

(Triplex Mast)
Adjust each of the first and second chains (total of four).
1. On the level ground, position the mast perpendicular to

the ground surface, lower the forks to the ground, and
make sure the lift cylinder rods are fully contracted.
2. Secure the anchor bolts on the lift bracket (first chains)
side and the lower inner mast section (second chains)
by tightening the upper nuts and double nuts.
NOTE
When installing the second chains (between the inner
mast and the outer mast) in the triple-stage full free
panoramic mast, adjust the chain tensions to be 207635
slightly tighter. If the chains are loose, damage can
occur to the hose pulley.
3. Adjust the chain tensions by turning the double nuts

(upper) on the lift cylinder side. With the mast standing
perpendicular to the ground, lift the forks slightly, then
press the chains alternately at a midpoint between the
chain wheel and the secured end of the chain to make
sure the tension is the same in both chains.
NOTE
Tilting the mast slightly forward causes the chains to
sag, thus making it easier to adjust the chain tensions 102708
with the double nuts (upper).
4. Tighten the upper nuts and double nuts on the cylinder

side to the specified torque.
6. Conduct final adjustment with the mast positioned
perpendicular to the ground.
207636
9-27
MAST AND FORKS
Clearance Adjustment on Lift Bracket
NOTE
The adjustment procedure for the lift bracket is the same
for the Simplex Mast, Duplex Mast and Triplex Mast.
1. Longitudinal clearance adjustment on lift bracket

main rollers
(1) Raise the forks slightly from the floor.
(2) Insert a bar between the upper part of lift bracket and
the inner mast, and push the inner mast to one side.
Using feeler gauges, measure the clearance F between
the main roller and inner mast on the opposite side.
0.1 to 1.0 mm
Clearance F (0.004 to 0.039 in.)
207095
(3) If the clearance F is out of specification, use oversize
rollers.
Roller sizes Unit: mm (in.)
Main Roller
S 99 (3.90)
M 100 (3.94)
L 101 (3.98)
LL 102 (4.02) 207096
(4) Lift bracket main rollers (upper and center rollers)

The upper rollers should be the same in size or 1-rank
larger than the center rollers.
2. Lateral clearance adjustment on lift bracket main
rollers and side rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inner mast with its contact
point rested on the side of the lift bracket.
(3) Go over to the opposite side of the mast, and push the
203818
lift bracket to one side with a bar. Set the indicator to
zero.
(4) Insert a bar between the inner mast and lift bracket on
the indicator side, and push the lift bracket to the
opposite side.
(5) Read the indicator.
0.1 to 0.5 mm
Clearance G1 (0.004 to 0.020 in.)
(6) Adjust clearance G1 between the center main roller and
weld plate ➁ at the maximum lift position by
increasing or decreasing the thickness of the shim.
202276
Do not install any shim at upper main roller ➀.
9-28
MAST AND FORKS
For the lift bracket upper main roller or center main

roller, to extend 0.5 mm (0.02 in.), insert a 0.5 mm
(0.02 in.) shim (a) on its inside and remove the 0.5 mm
(0.02 in.) shim (b) from the lower stopper, then tighten
the bolts.
207156
(7) Lower the lift bracket slightly from the top, then adjust
clearance G2 between the side roller and mast by
increasing or decreasing the thickness of the shims.
0.1 to 0.5 mm
Clearance G2
(0.004 to 0.020 in.)
202277
Adjust the side roller clearance by adding shims

between the roller bracket and lift bracket.
207098
(8) With the lift bracket at the top, adjust clearance G3

with shims.
0.1 to 0.5 mm
Clearance G3
(0.004 to 0.020 in.)
207158
9-29
MAST AND FORKS
Mast Clearance Adjustment
NOTE
Adjust mast clearances at the locations indicated
below.
1. Simplex Mast and Duplex Mast: Main rollers
between the outer mast and inner mast
2. Triplex Mast: Main rollers between the outer mast
and middle mast, and main rollers between the
middle mast and inner mast.
207157
1. Longitudinal clearance adjustment on mast main
rollers
(1) Tilt the mast fully backward.
(2) Using feeler gauges, measure the clearance H between
the inner mast lower roller and outer mast.
0.1 to 1.0 mm
Clearance H
(0.004 to 0.039 in.)
(3) If the clearance H is out of the specification, use

oversize rollers.
207099
Roller sizes
Unit: mm (in.)
Main Roller
S 99 (3.90)
M 100 (3.94)
L 101 (3.98)
LL 102 (4.02)
2. Lateral clearance adjustment on inner mast main

rollers
(2) Set a dial indicator on the inside of the outer mast with
its contact point rested on the inner mast.
inner mast against the outer mast. Set the indicator to
zero.
204886
9-30
MAST AND FORKS
(4) Insert a bar between the outer and inner masts on the
indicator side, and push the inner mast to the opposite
side.
0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)
207101
(6) If the clearance J is out of specification, adjust by

shims.
NOTE
Refer to Main Roller Shim Replacement.
207102
3. Lateral clearance adjustment on outer mast main

rollers
(2) Set a dial indicator on the outer mast with its contact
point rested on the inner mast.
outer mast against the inner mast with a bar. Set the
indicator to zero.
(4) Insert a bar between the outer and inner mast, and push 204889
the inner mast to the opposite side.
0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.)
207103
9-31
MAST AND FORKS
(6) If the clearance K is out of specification, adjust it by

shims.
NOTE
207104
Main Roller Shim Replacement
Procedure for replacing main roller shims

(Simplex Mast)
1. Remove the lift bracket from the mast.
NOTE
Refer to Removal and Installation section, “1. Lift
bracket removal.”
2. Lower the inner mast below the outer mast as follows:

(1) Raise the front end of the truck, and support that end
with block.
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to
the crossmember of outer mast with rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner 202961
and outer masts. Remove the mast strips and shims in
advance as they drop easily under this condition.
9-32
MAST AND FORKS

[Dual-stage full free panoramic mast (Duplex Mast)]
NOTE
Refer to “Removing lift bracket” section in the
HYDRAULIC SYSTEM.
2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and suspend it
with a hoist. Wind the sling securely to prevent
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.
207616
3. Position the inner mast lower than the outer mast by

following the steps below:
with block.
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to 202961
the crossmember of outer mast with rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner
9-33
MAST AND FORKS

[Triple-stage full free panoramic mast (Triplex Mast)]
NOTE
Refer to “Removing lift bracket” section in the
HYDRAULIC SYSTEM.
2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and suspend it
with a hoist. Wind the sling securely to prevent
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.
207616
3. Position the inner mast lower than the middle mast by

with block.
(2) Hitch slings to the upper cross-member of the inner
mast, and suspend with a hoist.
(3) Remove the chain guards for the second lift chain
wheels.
(4) Dismount the second lift chains on the outer mast side,
and place them in front of the inner mast. 207639
(5) Lower the inner mast until main rollers can be removed.
(6) Place wood blocks under the inner mast for support.
NOTE
In this condition, second lift cylinders cannot be
dismounted.
9-34
MAST AND FORKS
4. Position the middle mast lower than the outer mast by

(1) Lift the inner mast to the height of the middle mast,
then place wood blocks for support.
(2) Hitch slings to both middle mast and inner mast, and
suspend with a hoist.
(3) Remove set bolts from the upper sections of the middle
mast lift cylinders, then lift the middle mast and inner
mast.
(4) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the lower outer
mast section. Tilt the cylinders by moving the top
sections towards the center of the vehicle, then secure
the cylinders to the cross-member of the outer mast
with a rope.
(5) Lower the middle mast and inner mast until main rollers
can be removed.
(6) Place wood blocks under the middle mast and inner
mast for support.
207640
9-35
MAST AND FORKS
Mast Strip Adjustment

1. Check the clearance L with the clearance between the
outer mast rollers and inner mast set to zero (0) in
0.1 to 0.5 mm
Clearance L
(0.004 to 0.020 in.)
200391
2. If the clearance L is out of specification, adjust it by

shims.
NOTE
3. After adjusting all clearances, move the mast and lift

bracket slowly to make sure that they move smoothly 200392
through their full stroke.
Tilt Angle Adjustment

1. Adjust the tire pressure correctly and park the truck on
the level floor.
2. Tilt the mast fully backward and turn the key switch to
off.
3. Measure the backward tilt angle of the mast at both
sides.
4. To adjust the tilt angle, loosen the bolt of tilt cylinder
socket, and adjust the rod length by turning the rod. Bolt
Adjust cylinders so that there is no difference in tilt
angle between the cylinders, left and right. 207105
NOTE
It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted.
Forward – backward tilt

6° – 7° (standard)
angle
9-36
MAST AND FORKS
5. After adjusting the tilt angle, tighten the socket bolts to

the specified torque.
127 to 152 N·m

Tightening torque for tilt
(13 to 15.5 kgf·m)
cylinder socket bolt
[94 to 112 lbt·ft]
Lift Cylinder Stroke Adjustment

1. Gently raise the inner masts, and observe the right and
left piston rod stopping conditions when they reach the
2. If the upper parts of the inner masts shake at the

moment of stopping, make adjustment with shims.
Improper adjustment causes the inner mast to slant
slightly when the mast is stopped, and also causes the
lift cylinder with a longer cylinder stroke to shake when 204698
the lift cylinder is stopped.
3. Adjusting method
(1) Raise the inner masts, and place wood blocks under the
inner masts. Lower the masts until the inner masts
contact the wood blocks.
(2) Loosen the stopper bolt located at the upper part of the
lift cylinder that stopped first. Lower the piston rod,
and insert a shim at the upper piston rod end.
NOTE
When lowering the piston rod, operate the lift lever to 202983
lower the masts and release oil from the cylinder.
(3) Raise the piston rod, then tighten the lift cylinder
stopper bolt. Remove the wood blocks from under the
inner masts.
(4) Lower the inner masts gently, and check to see if the
piston rods move smoothly until the inner masts reach
the lowest position.
Bleeding lift cylinders

When air and oil remaining inside the air chamber of the
rod and inside the rod chamber between the tubes are
compressed, they open the check valve and flow out of the
cylinder. Therefore, there is no need to bleed the lift
cylinders.
200365
9-37
MAST AND FORKS
Troubleshooting
Lift bracket, inner masts and Faulty rotation of rollers Apply grease or replace rollers.
middle masts do not rise or Improper mast strip clearance Adjust with shims.
lower smoothly. Improper main roller or side roller Adjust front-to-back and
clearance right-to-left clearances.
Uneven chain tension between right and Adjust chain tension.

left chains
Excessive side roller clearance Adjust by adding shims.
Lift bracket or inner masts are
lopsided. Uneven adjustment of shims between Adjust by removing shims.
right and left lift cylinders
(at maximum lift position)
Lift bracket retaining stopper in contact Adjust chain tension.
Faulty rotation of rollers Apply grease or replace rollers.

Masts generate abnormal noise
Defective hose pulley bearing Replace.
(for triple-stage full free panoramic
mast system only)
Lift cylinders descent due to Damaged gaskets in lift cylinders Replace.

leaks. Internal leak of control valve Replace.
Entire masts shake Worn mast support bushings and caps Re-tighten, or replace bushings
and caps.
Masts are deformed in shape. Uneven cargo load or overload Replace assembly.
Bent finger bars Repair or replace.

Uneven fork end heights Bent forks Replace.
Mast deformation due to uneven cargo Repair or replace.
load
Low oil temperature Increase oil temperature by

raising and lowering lift
Second lift cylinders move when bracket.
first lift cylinder operates. No clearance for lift bracket roller Readjust rollers.
(triple-stage full free panoramic surfaces
mast system)
Clogged pipes Inspect and clean hydraulic line.
Improper air bleeding Bleed hydraulic system.
Spongy operation of
fall-prevention function when Improper air bleeding Bleed hydraulic system.
lifting operation is stopped.
9-38
MAST AND FORKS
Service Data
Simplex Mast, Duplex Mast

Unit: mm (in.)
Item
Difference in height between fork tips A 5 (0.20)
920 × 100 × 35 ± 1
A (36.2 × 3.94 × 1.38 ± 0.039)
Thickness of forks (width × thickness)
Chains 920 × 100 × 33
(36.2 × 3.94 × 1.34) B (36.2 × 3.94 × 1.34)
A 318 (12.52) 381 (15.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43)
S A 99 (3.90)
M A 100 (3.94)
Diameter of main roller
Rollers L A 101 (3.98)
LL A 102 (4.02)
Diameter of side roller A 42 ± 0.1 (1.65 ± 0.004)
Width of outer mast B A 610 (24)
Simple mast,
Duplex mast Width of inner mast B2 A 516 (20.3)
Width of lift bracket C A 408 (16.1)
Dimensions
(Reference) Width of outer mast B A 610 (24)
Width of middle mast B1 A 516 (20.3)
Triplex mast
Width of inner mast B2 A 426 (16.8)
Width of lift bracket C A 318 (12.5)
Clearance between main roller circumference
A 1.0 (0.04) or less
and mast thrust surface H
Masts Clearance between main roller side surface
and mast thrust surface G A 0.1 to 0.5 (0.004 to 0.020)
Clearance between inside mast and mast strip G2 A 0.1 to 0.5 (0.004 to 0.020)
Clearance between upper and lower roller A 1.0 (0.04) or less
Clearances circumference and inner mast thrust surface F
Clearance between middle roller side
surface and inner mast thrust plate G A 0.1 to 0.5 (0.004 to 0.020)
Lift brackets
Clearance between lower roller side
surface and inner mast thrust surface G A 0.1 to 0.5 (0.004 to 0.020)
Clearance between side roller circumference

and inner mast surface G1 A 0.1 to 0.5 (0.004 to 0.020)
Mast support bolts A 74 (7.5) [54] 178 (18.2) [132]

Tightening torque
Upper nut ➁ A 55.8 to 56.8 (5.7 to 5.8) [41.2 to 41.9]
Double nut (lower) ➀ A 98 to 103 (10 to 10.5) [72.3 to 76.0]
Finger bar bend A 5.0 (0.2) or less
9-39
MAST AND FORKS
Service Data
Item
G
G2
F
G
G
G1
G
F
G1 G
H G
B2
G G
G G
B2 B1
C
Lift bracket
B B
Simplex mast, Triplex mast
Duplex mast
Mast width is slightly wide at the lower portion than at the upper portion.
Measure the clearance at the mast upper position. 208742
102709
9-40
SERVICE DATA
Inspection Standards ............................................................................10 – 1

Periodic Replacement of Parts ..........................................................10 – 7
Critical Safety Parts ..................................................................................10 – 7
Lubricating Standards ..........................................................................10 – 8
Lubrication Chart ......................................................................................10 – 8
Lubricant Quantities ..................................................................................10 – 9
Recommended Lubricant ..........................................................................10 – 9
Main Component Weights ...................................................................10 – 9
Tightening Torques for Standard Bolts and Nuts .......................... 10 – 10
Special Tool Table .................................................................................. 10 – 12
10
SERVICE DATA
Inspection Standards
Inspect and conduct maintenance according to the specified hourmeter indication or the number of calendar days,
whichever comes first.
: Inspect or clean
: Replace or adjust
Periodic Inspection
Pre-operation Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
Every Month or
Inspection/Maintenance Location and Item
1200 Hours
2400 Hours
Service Standard
200 Hours
600 Hours
Electrical system
Abnormal noise during rotation
Brush wear and Drive motors,

Brush length limit: 19 mm (0.75 in.)
rotating Pump motor
smoothness Steering motor Brush length limit: 13 mm (0.51 in.)
Brush spring fatigue
Brush contact wear pattern and
Motors side working face amount
Commutator contamination,
streaks and wear irregularities
Looseness of connections
Grease replacement in motors,
shafts and couplings
Insulation resistance
Electrolyte levels Inspection: Every week or 50 hours
Specific gravity of electrolyte after Inspection: Every week or 50 hours
charging Specific gravity: 1.28
Voltage of each cell 48 V
Batteries Terminal corrosion, damage,

contamination and looseness
Case damage and contamination,
and fluid leaks
Insulation resistance
Charge level
Contactors Contact looseness, damage and

wear
10-1
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
Every Month or
1200 Hours
2400 Hours
Service Standard
200 Hours
600 Hours
Control valve microswitch
operating condition
Damage and mounting looseness
Foot brake switch operating
Micro condition
switches
Damage, mounting looseness
Hand brake switch operating
condition
Damage and mounting looseness
Controller operating condition
(1) Seat switch
(2) Forward/reverse selector switch
(3) Control valve switch
(4) Brake switch
Main (5) Accelerator switch

controller (6) Line contactors
(7) Forward
(8) Reverse
(9) Regeneration bypass
Internal contamination and damage
Over-current limit value
Fuse mounting looseness
Fuses
Fuse capacity
Wire harness damage and
clamp looseness
Wiring Terminal connection looseness and

taping condition
Battery connector contacts and
bolt looseness
Power transmitting system
Transfer oil level and L.H.: 1.09 liter (0.29 U.S. gal)
contamination R.H.: 1.86 liter (0.49 U.S. gal)
Transfers
Oil leaks
Bolt looseness
10-2
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
Every Month or
1200 Hours
2400 Hours
Service Standard
200 Hours
600 Hours
Drive system
Tire cracking and damage
Tire tread depth
Tires Abnormal tire wear
Metal pieces, rocks, other foreign
materials on tires
Hub bolts Damage and looseness
Rims and
wheel discs Damage
Wheel bearing rattle
Wheel
bearings Abnormal noise in wheel bearings
Grease replacement
Steering system
Play, looseness, rattling and
Steering Play: 15 to 30 mm (0.6 to 1.2 in.)
operating condition
wheel
Gear box mounting looseness
Deformation, cracking and damage
Rear axle Oil leaks
Bolt looseness
Braking system
Free play 3 to 9 mm (0.12 to 0.35 in.)
Distance between depressed brake
pedal and floor board
Air trapped in fluid
Brakes
Braking performance
Uneven braking performance
between right and left
Reservoir tank level and oil leaks 99 cc (6.04 cu. in.)
Parking Lock condition
brake Braking performance 3rd or 4th notch engagement
Rods and Operating condition
cables Looseness of links and clamps
10-3
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
Every Month or
1200 Hours
2400 Hours
Service Standard
200 Hours
600 Hours
Damage, leaks and contact with
Hoses and other parts
pipes
Looseness of links and clamps
Clearance between brake disc and
0.4 to 1.1 mm (0.016 to 0.043 in.)
pad
Brake disc mounting looseness
Brake discs Brake pad wear Service limit : 1 mm (0.039 in.)

and pads Brake pad operating condition
Rusting of pins
Return spring fatigue and damage
Brake disc wear and damage Service limit : 9 mm (0.354 in.)
Lift system
Fork and stopper pin damage
Allowed fork thickness wear limit:
Forks Forks—wear and distrotion
33 mm (1.3 in.)
Cracking and wear in fork base
and tooth weld
Cracking in cross-member welds
of outer and inner masts
Cracking in welds of tilt cylinders
and masts
Cracking in welds of outer masts
and cylinder support
Masts and Cracking in lift bracket welds
lift bracket Roller bearing rattle
Wear and damage of mast support

metal
Cracking and damage in rollers,
roller pins and welds
Mast operating condition and
mounting looseness
10-4
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
Every Month or
1200 Hours
2400 Hours
Service Standard
200 Hours
600 Hours
Allowed lift chain stretch:
Length of lift chains (20 links) 1 ton class: 327 mm (12.87 in.)
2 ton class: 392 mm (15.43 in.)
Chain deformation, damage,
Chains and lubrication and rusting
chain wheels Chain bushing coupling, bolt
deformation and damage
Chain wheel deformation and
damage
Chain wheel bearing rattle
Attachments Attachment abnormality and

mounting conditions
Hydraulic system
Looseness, deformation and
damage of rods, rod bolts and
rod ends
Cylinder operating condition
Drift lowering distance:
Cylinders Drift lowering and forward 50 mm (1.97 in.)/15 min
tilting distances Drift forward tilting distance:
22 mm (0.87 in.)/15 min
Cylinder oil leaks and damage
Wear and damage of piston and
cylinder shaft bearings
Oil pump Oil leaks, abnormal noise, wear in

drive unit, and mounting looseness
N level: 14.7 liter (3.88 U.S. gal)
Hydraulic Oil level and contamination
H level: 16.8 liter (4.44 U.S. gal)
tank
Filter clogging
Operation Linkage looseness
levers Lever functions
Oil leaks
Control Safety valves

valves 18142 + 0490 kPa
Release pressure measurement (185 + 05 kgf/cm2)
[2631 + 071 psi]
10-5
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
Every Month or
1200 Hours
2400 Hours
Service Standard
200 Hours
600 Hours
Safety devices and others
Head guard Mounting looseness
and backrest Deformation, cracking and damage
Turn signal operation and

mounting condition
Alarm device operation and
mounting condition
Lamp operation and mounting
condition
Safety Backup warning device operation
devices and mounting condition
Rear-view mirror dirtiness and
damage
Rear-view mirror image and
condition
Proper function of seat belt and
hip restraint
Instruments Instrument operations
Seat Looseness and damage
Vehicle Damage and cracking in frame and
body cross-members
Inspection of chassis lubricating
Oil and conditions after cleaning
grease
replacement Confirmation of oil replacement
intervals
10-6
SERVICE DATA
Periodic Replacement of Parts
Replace the following critical safety-related parts and elements according to the specified intervals.
Replacement Interval
Parts for Periodic Replacement Method After 1
Every Every Every Every
Month of
Month 6 Months Year 2 Years
Initial Use
1 * Rubber parts in brake master cylinder Replace
2 * Rubber parts in brake caliper cylinders Replace
3 * High-pressure hoses for lift and tilt Replace
systems
4 * Lift chains Replace
Hydraulic tank return oil filter Replace
Note: “ * ” mark indicates critical safety parts.
Critical Safety Parts
3
1
206929
10-7
SERVICE DATA
Lubricating Standards
Lubrication Chart
❋
❋
Lift chain HO
MPG Mast support
❋
Roller surface
Mast strip MPG
❋
MPG Tilt socket
❋
Lift bracket side roller MPG
Brake fluid BF
❋
MPG Tilt cylinder
❋
Transfer HO HO
Hydraulic oil HO
Every week or 50 hours
Every month or 200 hours
Every 6 months or 1200 hours
Every 12 months or 2400 hours
: Inspection, replenishment MPG: Multipurpose grease

: Replacement BF: Brake fluid
❋: Parts located on both sides of vehicle HO: Hydraulic oil
206930
10-8
SERVICE DATA
Lubricant Quantities
Truck Models
Items
L.H.: 1.09 (0.29)

Transfer oil capacity liter (U.S. gal)
R.H.: 1.86 (0.49)
N level: 14.7 (3.88)

Hydraulic system oil capacity liter (U.S. gal)
H level: 16.8 (4.44)
Brake fluid capacity cc (cu. in.) 99 (6.04)
Recommended Lubricant
Grease: NLGI No. 1, NLGI No. 2
Brake fluids: SAE J1703f
Hydraulic, transfer and rear axle oils: SAE 5W, SAE 10W
Main Component Weights

Unit: kg (lb)
Truck Models
FB16KT FB18KT FB20KT
Item
740 805 955

Counterweight
(1631) (1775) (2105)
Power line
72.4 72.4 72.4

Transfer
(159.6) (159.6) (159.6)
40 40 40
Traction motor
(88.2) (88.2) (88.2)
70 70 70
Head guard
(154.3) (154.3) (154.3)
33 33 33
Rear axle
(72.8) (72.8) (72.8)
Mast [3.3 m (130 in.), Simplex]
Outer mast 164.84 (363.4) 164.84 (363.4) 164.84 (363.4)
Inner mast 136.73 (301.4) 136.73 (301.4) 136.73 (301.4)
Lift bracket (including backrest) 93.34 (205.8) 93.34 (205.8) 108.22 (238.6)
Forks (set of two) 78.4 (172.8) 78.4 (172.8) 78.4 (172.8)
Lift cylinders, etc. 78.47 (173) 78.47 (173) 78.47 (173)
Mast [3.3 m (130 in.), Duplex] 566 (1248) 566 (1248) 577 (1272)
Mast [4.8 m (189 in.), Triplex] 691 (1523) 691 (1523) 702 (1548)
10-9
SERVICE DATA
Tightening Torque for Standard Bolts and Nuts
With Spring Washer 101656
Nominal Size Pitch
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 0.24 1 0.04 7.4 0.75 5.4 9.6 0.98 7.1 12.7 1.3 9.4
8 0.32 1.25 0.05 16.7 1.7 12.3 22.6 2.3 16.6 30.4 3.1 22.4
10 0.39 1.25 0.05 34.3 3.5 25.3 45.1 4.6 33.3 69.6 7.1 51.4
12 0.47 1.25 0.05 63.7 6.5 47.0 82.4 8.4 60.8 122.6 12.5 90.4
14 0.55 1.5 0.06 102.0 10.4 75.2 132.4 13.5 97.6 191.2 19.5 141.8
16 0.63 1.5 0.06 154.9 15.8 114.3 202.0 20.6 149.0 287.3 29.3 211.9
18 0.71 1.5 0.06 224.6 22.9 165.6 292.2 29.8 215.5 413.8 42.2 305.2
20 0.79 1.5 0.06 310.9 31.7 229.3 404.0 41.2 298.0 573.7 58.5 423.1
22 0.87 1.5 0.06 413.8 42.2 305.2 537.4 54.8 396.4 763.0 77.8 562.7
24 0.95 1.5 0.06 547.2 55.8 403.6 711.0 72.5 524.4 1006.2 102.6 742.1
27 1.06 1.5 0.06 794.3 81.0 585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30 1.18 1.5 0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33 1.30 1.5 0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36 1.42 1.5 0.06 1918.2 195.6 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39 1.54 1.5 0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8
Metric Without Spring Washer 101656
fine
thread Nominal Size Pitch
6 0.24 1 0.04 8.6 0.88 6.4 10.8 1.1 8.0 14.7 1.5 10.8
8 0.32 1.25 0.05 19.6 2.0 14.5 26.5 2.7 19.5 36.6 3.7 26.8
10 0.39 1.25 0.05 41.2 4.2 30.4 53.0 5.4 39.1 81.4 8.3 60.0
12 0.47 1.25 0.05 74.5 7.6 55.0 97.1 9.9 71.6 144.2 14.7 106.3
14 0.55 1.5 0.06 119.6 12.2 88.2 155.9 15.9 115.0 226.5 23.1 167.1
16 0.63 1.5 0.06 182.4 18.6 134.5 237.3 24.2 175.0 338.3 34.5 249.5
18 0.71 1.5 0.06 263.8 26.9 194.6 343.2 35.0 253.2 487.4 49.7 359.5
20 0.79 1.5 0.06 365.8 37.3 269.8 475.6 48.5 350.8 674.7 68.8 497.6
22 0.87 1.5 0.06 486.4 49.6 358.8 632.5 64.5 466.5 897.3 91.5 661.8
24 0.95 1.5 0.06 643.3 65.6 474.5 836.5 85.3 617.0 1183.7 120.7 873.0
27 1.06 1.5 0.06 934.6 95.3 689.3 1215.0 123.9 896.2 1707.3 174.1 1259.3
30 1.18 1.5 0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33 1.30 1.5 0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36 1.42 1.5 0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39 1.54 1.5 0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3
Remarks : 1. The tolerance on these torques is ±10%.

2. These torques are for “dry” condition.
10-10
SERVICE DATA
With Spring Washer 101656
Nominal Size Pitch
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
10 0.39 1.5 0.06 33.3 3.4 24.6 43.1 4.4 31.8 67.7 6.9 49.9
12 0.47 1.75 0.07 58.8 6.0 43.4 76.5 7.8 56.4 115.7 11.8 85.3
14 0.55 2 0.08 96.4 9.8 70.9 124.5 12.7 91.9 182.4 18.6 134.5
16 0.63 2 0.08 147.1 15.0 108.5 191.2 19.5 141.0 274.6 28.0 202.5
18 0.71 2.5 0.10 203.0 20.7 149.7 264.8 27.0 195.3 383.4 39.1 282.8
20 0.79 2.5 0.10 286.4 29.2 211.2 371.7 37.9 274.1 536.4 54.7 395.6
22 0.87 2.5 0.10 383.4 39.1 282.8 499.2 50.9 368.2 715.9 73.0 528.0
24 0.95 3 0.12 492.3 50.2 363.1 640.4 65.3 472.3 924.8 94.3 682.1
27 1.06 3 0.12 724.7 73.9 534.5 942.2 96.1 695.1 1350.4 137.7 996.0
30 1.18 3.5 0.14 969.9 98.9 715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33 1.30 3.5 0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36 1.42 4 0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39 1.54 4 0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42 1.65 4.5 0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4
Metric Without Spring Washer 101656
coarse
thread Nominal Size Pitch
10 0.39 1.5 0.06 39.2 4.0 28.9 51.0 5.2 37.6 79.4 8.1 58.6
12 0.47 1.75 0.07 69.6 7.1 51.4 90.2 9.2 66.5 135.3 13.8 99.8
14 0.55 2 0.08 112.8 11.5 83.2 146.1 14.9 107.8 215.7 22.0 159.1
16 0.63 2 0.08 172.6 17.6 127.3 224.6 22.9 165.6 323.6 33.0 238.7
18 0.71 2.5 0.10 239.3 24.4 176.5 311.9 31.8 230.0 451.1 46.0 332.7
20 0.79 2.5 0.10 336.4 34.3 248.1 437.4 44.6 322.6 630.6 64.3 465.1
22 0.87 2.5 0.10 392.3 40.0 289.3 587.4 59.9 433.3 842.4 85.9 621.3
24 0.95 3 0.12 578.6 59.0 426.7 753.2 76.8 555.5 1088.5 111.0 802.9
27 1.06 3 0.12 852.2 86.9 628.5 1108.2 113.0 817.3 1588.7 162.0 1171.7
30 1.18 3.5 0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33 1.30 3.5 0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36 1.42 4 0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39 1.54 4 0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42 1.65 4.5 0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4
Remarks : 1. The tolerance on these torques is ±10%.

2. These torques are for “dry” condition.
10-11
SERVICE DATA
Special Tool Table
Reference Truck Models 1 ton 2 ton

Part No. Name
No. Application class class
1 64309-17701 Gauge kit Measurement of hydraulic pressure
2 91268-01500 Installer Installation of rear axle inner bearing and inner race
3 91268-01400 Installer Installation of rear axle outer bearing and inner race
Steering wheel
4 91268-10600 Removal of steering wheel
puller
5 91268-03200 Puller Removal of steering column and needle roller bearing
6 91268-01600 Installer Installation of tilt cylinder tube bushing
7 09305-00680 Hook wrench Removal and installation of tilt cylinder guide bushing
09305-00520 Hook wrench Removal and installation of lift cylinder guide bushing
Removal and installation of first lift cylinder guide

09305-00750 Hook wrench
bushing
8 97157-00100 Spring installer Installation of centering spring in steering gear
10-12
SERVICE DATA
Gauge kit Puller
➀ 203544 ➄ 203552
Installer Unit: mm (in.) Installer Unit: mm (in.)
➁ 200447 ➅ 200448
Installer Unit: mm (in.) Hook wrench
➂ 200446 ➆ 203556
Steering wheel puller Unit: mm (in.) Spring installer
➃ 203551 ➇ 206997
10-13
OPTIONS
Rearview Mirror Kit ................................................................................11 – 1

Backup Buzzer Kit .................................................................................11 – 2
Working Lamp Kit ...................................................................................11 – 3
Tire Kit (Solid) ..........................................................................................11 – 4
11
OPTIONS
Rearview Mirror Kit
208115
11-1
OPTIONS
Backup Buzzer Kit
Buzzer
Washer
Bolt with washer
Clip band
Terminal
Terminal
208116
11-2
OPTIONS
Working Lamp Kit
For Forward Removable Type

For Backward
211102
11-3
OPTIONS
Tire Kit (solid)
208120
11-4
TECHNICAL PUBLICATIONS FEEDBACK
(Please Print)
Dealer name: Submitted by:
Address: P. O. Box:
City: State:
Zip code: Country:
The following discrepancy or omission has been discovered in:

❑ Operation & Maintenance Manual ❑ Option Bulletin
❑ Part List/Manual ❑ Special Instruction
❑ Service Manual ❑ Service Data Manual
❑ Electronic Manual ❑ Other:
Publication # Engine model #
Truck model #
T Issue date #
Truck serial #
T Page #
(Please print)
Explanation of discrepancy or omission:
Please fax or mail completed form to:
Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2121 W. Sam Houston Parkway N. P.O. Box 30171
Houston, TX 77043-2305 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695
Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

RCB No.: 199203169H
Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-6861-9277
Mitsubishi Forklift Trucks Service Manual FB16KT, FB18KT, FB20KT, Forklift Trucks 99719-56100
Mitsubishi Caterpillar Forklift Europe B.V.
Hefbrugweg 77 1332 AM
Almere, The Netherlands
99719-56100 Copyright © 2005 by MCFA. All Rights Reserved. Printed in The Netherlands

FB16KT - 1 99719 56100t

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Service Manual

For use with FB16KT-FB20KT

Safety Related Signs

The following safety related signs are used in this service

Indicates a specific potential hazard

Indicates a specific potential hazard that

Indicates a condition that can cause

Pub. No. 99719-56100

Disassembly diagram (example)

Each disassembly diagram is followed

Suggestion for disassembly

GROUP INDEX Items

GENERAL INFORMATION Serial number locations, Dimensions, Technical data 1

POWER TRAIN Procedure and suggestions for removal and installation 3

TRANSFER UNITS Procedures and suggestions for disassembly and reassembly 4

REAR AXLE Rear axle, Rear wheels 5

BRAKE SYSTEM Caliper, Brake pedal, Master cylinder 6

STEERING SYSTEM Steering control valve 7

MASTS AND FORKS Simplex mast, Duplex mast, Triplex mast 9

Control lever Joystick box

This manual applies to FB16KT, FB18KT and FB20KT.

Truck Model Serial Number

Serial Number Locations

Chassis and Mast Model Identification

Three wheel models

Maximum lifting height

Order of the minor change

Applicable truck model designation

Console Box ............................................................................................ 2 – 1

1 Central vehicle monitoring system 6

Functions of Central Vehicle Monitor System (CVMS)

No. Monitor name When OFF When ON or flashing Remarks

No. Monitor name When OFF When ON or flashing Remarks

Selection of KPH or MPH

4. Push and hold button 1 for one to two seconds.

Setting the clock 103043

Error code display

E 0 ON Right drive motor overheat

E 1 ON Left drive motor overheat

E 2 ON Pump motor overheat

E 4 ON Worn right drive motor brush

E 5 ON Worn left drive motor brush

E 6 ON Worn pump motor brush

H 1 ON Faulty setting of lift lever

H 2 ON Faulty setting of tilt lever

Error code display

H 3 ON Faulty setting of attach-1 lever

H 4 ON Faulty setting of attach-1 lever (Option)

Electrical Components in Console Box

Direction lever switch cable

Disassembly and Reassembly

Make sure the inside switch turns ON by checking the

Refer to Parts Manual for proper replacement fuses.

Lamp Specification Chart

Head lamps 2 Clear 45 W

Working lamp 1 Clear 45 W

Troubleshooting of Lighting and Horn Systems

Complaint Possible cause Remedy

e) Bulbs burnt out Replace.

Will not light a) Lighting switch defective Replace.

Working lamp will a) Working lamp switch defective Correct if improperly

d) Horn defective Replace.

Will give an a) Horn switch defective Replace.