FB16KT - 1 99719 56100t
FB16KT - 1 99719 56100t
FB16KT - 1 99719 56100t
MC/FC
Chassis, Mast & Options
FB16KT EFB4A-00011-up
FB18KT EFB5A-00011-up
FB20KT EFB5A-50001-up
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.
Disassembly sequence
Sequence
1. Cover, Bolt, Washer (part name)
2. Output shaft (part name)
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
VEHICLE ELECTRICAL
COMPONENTS
Console box, Key switch, Lamp specification chart 2
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
211267
Models
1-1
GENERAL INFORMATION
211129
1-2
GENERAL INFORMATION
[Chassis]
FB 16 K T
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
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 1
NOTE
103043
For setting the clock and selection of KPH or MPH,
refer to “Selection of KPH or MPH” and “Setting the
clock”.
9 8
10
1 2 3 4 5 6 7
Operations 208077
2-1
VEHICLE ELECTRICAL COMPONENTS
2-2
VEHICLE ELECTRICAL COMPONENTS
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 3 ON Controller overheat
2-3
VEHICLE ELECTRICAL COMPONENTS
Indication Condition
2-4
VEHICLE ELECTRICAL COMPONENTS
Horn cable
Monitor cable
2
211132
1 Key switch
2 Lighting switch
2-5
VEHICLE ELECTRICAL COMPONENTS
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
VEHICLE ELECTRICAL COMPONENTS
Direction Lever
Structure
211135
1 Lever 3 Connector
2 Harness 4 Screw
2-7
VEHICLE ELECTRICAL COMPONENTS
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
2-8
VEHICLE ELECTRICAL COMPONENTS
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
VEHICLE ELECTRICAL COMPONENTS
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
Item Bulb
Quantity Bulb color Remarks
Lamp 48 V External diagram
205833
2-10
VEHICLE ELECTRICAL COMPONENTS
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
2-11
VEHICLE ELECTRICAL COMPONENTS
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
VEHICLE ELECTRICAL COMPONENTS
(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
VEHICLE ELECTRICAL COMPONENTS
Nomenclature
5
1
6 2
211139
2-14
VEHICLE ELECTRICAL COMPONENTS
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
VEHICLE ELECTRICAL COMPONENTS
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
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
211141
VEHICLE ELECTRICAL COMPONENTS
VEHICLE ELECTRICAL COMPONENTS
LED (red)
211142
2-18
VEHICLE ELECTRICAL COMPONENTS
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
2-19
VEHICLE ELECTRICAL COMPONENTS
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
LED (red)
A type
B type
2-20
VEHICLE ELECTRICAL COMPONENTS
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.
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
SW2
OFF
Up 8 7 6 5 3 2 1
4 ON
SW3
OFF
8 7 6 5 4 2 1 ON
3
2-stage
4-wheel 3V 2-ton
full-free
205002A
2-21
VEHICLE ELECTRICAL COMPONENTS
B type
Contact type
Noncontact type
211144
205053A
2-22
VEHICLE ELECTRICAL COMPONENTS
2-23
VEHICLE ELECTRICAL COMPONENTS
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
VEHICLE ELECTRICAL COMPONENTS
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
VEHICLE ELECTRICAL COMPONENTS
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
VEHICLE ELECTRICAL COMPONENTS
2-27
VEHICLE ELECTRICAL COMPONENTS
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)
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
No
No
2-28
VEHICLE ELECTRICAL COMPONENTS
Troubleshooting Procedure
Is grinding sound generated Yes (1) Check equipment for interference and looseness.
when equipment operates? (2) If abnormality is found, correct problem.
No
Yes
2-29
VEHICLE ELECTRICAL COMPONENTS
Troubleshooting Procedure
NG
Check fuse. Replace fuse, and inspect harness.
OK
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
VEHICLE ELECTRICAL COMPONENTS
Troubleshooting Procedure
2-31
VEHICLE ELECTRICAL COMPONENTS
1
! CAUTION
Before lowering the mast, be sure that there is no
one standing under the mast.
! CAUTION
Leaving nut 1 loose is dangerous: the mast might
suddenly start going down by itself.
2-32
VEHICLE ELECTRICAL COMPONENTS
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
VEHICLE ELECTRICAL COMPONENTS
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.
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
VEHICLE ELECTRICAL COMPONENTS
2-35
POWER TRAIN
Lock/unlock lever
211152
3-1
POWER TRAIN
! CAUTION
After raising the front end, place wood blocks
under the frame to prevent the truck from falling.
210757
206920
211153
3-2
POWER TRAIN
206922
3-3
POWER TRAIN
(i)
(ii)
(iii)
(v)
(iv)
(vi)
206824
3-4
POWER TRAIN
(2)
206925
3-5
POWER TRAIN
Left Right
transfer transfer
(iii)
Gravity
center
(ii) (ii)
(i)
(i)
Frame
Frame
(iv) Gravity (iii) (iv)
center
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.
Front of vehicle
3 4 4 3
5 5
2
1 1
206785
3-7
POWER TRAIN
1.09 1.86
Oil quantity
(0.29) (0.49) Front
of
vehicle
Right transfer
(2)
(1)
206786
3-8
POWER TRAIN
Service Data
A : Standard value
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
4-1
TRANSFER UNITS
Front of vehicle
7
7
A 8 8 A
6 6
1 3
4
5
2
206785
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
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
Bolts marked with × : Bolts for mounting transfer units to frame 211046
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
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
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.
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
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
Preload
Tangential force 59 to 88 N
206791
on hub bolt (6 to 9 kgf)
[13.3 to 19.8 lbf]
108 ± 10 N·m
Bolt tightening torque (11.0 ± 1.0 kgf·m)
206792
[79.7 ± 7.4 lbf·ft]
4-7
TRANSFER UNITS
Transfer
211049
4-8
REAR AXLE
2
3
4
19
18
11
8
10 12
13
14
15
16
17
16 206811
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
2 3
206812
15 × 4.5 × 8
Tire size (15 × 5 × 11.5)
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
211050
Installation
Follow the removal sequence in reverse.
NOTE
Tighten the wheel nuts evenly to the specified torque.
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
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.
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
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
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
206820
5-8
REAR AXLE
5-9
REAR AXLE
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
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
5-12
REAR AXLE
12
Clearance – 0.01 to 0.035 mm = Shim thickness
(0.0004 to 0.0014 in.) 207206
45 ± 7 N·m
Bolt tightening torque (4.6 ± 0.7 kgf·m)
[33.2 ± 5.2 lbf·ft]
5-13
REAR AXLE
5-14
REAR AXLE
Truck Model
1 ton class 2 ton class
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]
211052
5-15
BRAKE SYSTEM
Specifications .......................................................................................... 6 – 1
Structure and Functions ....................................................................... 6 – 2
Caliper Assembly ...................................................................................... 6 – 3
Brake Pedal Assembly .............................................................................. 6 – 4
Master Cylinder ........................................................................................ 6 – 5
Parking Brake Lever .................................................................................. 6 – 6
Procedures and Suggestions for Disassembly and
Reassembly ............................................................................................. 6 – 7
Master Cylinder ........................................................................................ 6 – 7
6
Inspection and Adjustment ................................................................. 6 – 9
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
1 ton class 2 ton class
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
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
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 fluid 6
5
3 7
1
4
211053
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
6-5
BRAKE SYSTEM
8
3
2
211055
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.
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
Adjustment bolt B
206825B
6-9
BRAKE SYSTEM
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.
6-11
BRAKE SYSTEM
Service Data A: Standard value
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
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
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
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
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
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
Structure and Functions ....................................................................... 7 – 2
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
1 ton class 2 ton class
Items
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
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
13
T L R P
5 6 7 8 1 9 10 2 11 3 12 4
208230
7-3
STEERING SYSTEM
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
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
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
208233
208234
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.
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
11.3 N·m
Tightening torque for set
(1.2 kgf·m)
screw
[8.3 lbf·ft] 208237
NOTE
200670
Check that the control spool rotates smoothly in the
control sleeve.
7-10
STEERING SYSTEM
207184
208239
207195
7-11
STEERING SYSTEM
NOTE
Check that the spool and sleeve are flush with or
slightly below the surface of the housing.
208240
208241
7-12
STEERING SYSTEM
O-ring
Drive spacer
208244
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
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
7-15
STEERING SYSTEM
Service Data
A: Standard value
Unit: mm (in.)
Truck Models
1 ton class 2 ton class
Items
Steering
control
2 1
valve
208246
7-16
HYDRAULIC SYSTEM
Specifications ........................................................................................... 8 – 1
Specifications
Truck Model
1 ton class 2 ton class
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)
8-1
HYDRAULIC SYSTEM
8-3
HYDRAULIC SYSTEM
Hydraulic Line
8
6
6
5
7
7
1
2
S
R
207772
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
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
15 13 14 13 12 11 10 1 12 13
3 5 4 2
206992
11 10 12 13
17 16 15 1 2
8
6
9
14 3 5 4 203489
207776
13 10 11 12 14
3 4 9 5 6 8 1 2 7
203490
8-7
HYDRAULIC SYSTEM
207765
(Duplex and triplex mast first cylinder)
2
1 3
000825B
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
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
Normal
Burst
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
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
206994
8-11
HYDRAULIC SYSTEM
Control Valve
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 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
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
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]
208636
8-15
HYDRAULIC SYSTEM
Lift Cylinders
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
204873A
8-16
HYDRAULIC SYSTEM
204933
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
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
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
207616
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
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
Disassembly
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
8-23
HYDRAULIC SYSTEM
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
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
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
170 to 240
Holder tightening torque (17.3 to 24.5)
[125.3 to 177.0]
8-27
HYDRAULIC SYSTEM
Tilt Cylinders
1
Procedures and Suggestions for Removal
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
❋
❋
❋
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. 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.
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
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.
8-31
HYDRAULIC SYSTEM
Disassembly
203559
Sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring, Shims
NOTE
Replace the flow regulator valve as an assembly if any
defect is found.
8-32
HYDRAULIC SYSTEM
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.
8-33
HYDRAULIC SYSTEM
Hydraulic Tank
Oil
Oil level, contamination, clouding (mixing of air or oil)
Truck Model
1 ton class 2 ton class
Mast
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
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
NOTE
The forward tilt angle of the masts is automatically set
when the backward tilt angle is adjusted.
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)
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
! 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
NOTE
If the roller is pressed hard against the spool, loosen
nut A and readjust.
206243
206244
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
Hydraulic Circuit Diagram
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
Oil pump
Damage in pump case, Applied pressure exceeded rating.
drive gear or pump
port flange Deformation or damage caused by external force
8-42
HYDRAULIC SYSTEM
8-43
HYDRAULIC SYSTEM
Service Data
A : Standard value
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
Item
Simplex mast
Simplex mast
33.3
Mounting bolts
A (3.39)
N·m (kgf·m) [lbf·ft]
[24.6]
Tightening torque
N·m (kgf·m) [lbf·ft]
Tie bolts (3/8 in.) A 19 (1.9) [14]
8-44
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
Item
Duplex mast
— —
Lift speed (rated load/no load) A
mm/sec (in./sec)
Duplex mast
Duplex mast
Triplex mast
— —
Lift speed (rated load/no load) A
mm/sec (in./sec)
Triplex mast
Triplex mast
8-45
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
Item
[Piston] 45
A
Inside diameter of cylinder tube 1 (1.77)
Lift cylinders (Simplex mast) (Triplex mast second)
4 2 1
207765
Flow regulator Return
filter
Tightening torque
A 45 (4.59) [33.2]
N·m (kgf·m) [lbf·ft]
Flow rate (no load)
A 48 (12.7)
liter (U.S. gal)/min
valve
8-46
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
Item
[Piston] 70
A
Inside diameter of cylinder tube 1 (2.76)
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)
N·m (kgf·m) [lbf·ft]
[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
1 ton class 2 ton class
Item
[Piston] 45
A
Inside diameter of cylinder tube 1 (1.77)
A 32
Diameter of piston rod 2
(1.26)
170 to 240
Tightening torque for holder 3
A (17.3 to 24.5)
N·m (kgf·m) [lbf·ft]
[125.1 to 177.0]
Lift cylinders (Duplex mast second cylinders)
1 2
4
000825C
8-48
HYDRAULIC SYSTEM
Truck Model
1 ton class 2 ton class
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]
N·m (kgf·m) [lbf·ft]
[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
8-51
HYDRAULIC SYSTEM
Control Valve
Inlet Section
207433
8-52
HYDRAULIC SYSTEM
207434
Operation
8-53
HYDRAULIC SYSTEM
207435
8-54
HYDRAULIC SYSTEM
207436
8-55
HYDRAULIC SYSTEM
Lift Section
207437
8-56
HYDRAULIC SYSTEM
yy;
yy
y
;yy
;;
y
;;y
y;;
yy
; A
yy
;;
y
;yy
;;
y
;y
;
;;
yy
;;
yy
Operation
Neutral
Blocking oil
8-57
HYDRAULIC SYSTEM
E2 E4
E3
A 2
1
High-pressure oil
Pilot oil
207439
8-58
HYDRAULIC SYSTEM
4 3
A
2
1
Low-pressure oil
Pilot oil
207440
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
8-60
HYDRAULIC SYSTEM
“b1” SOL
Low-pressure oil
207442
8-61
HYDRAULIC SYSTEM
Tilt Section
207443
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
8-64
HYDRAULIC SYSTEM
E4
E2
A B
E3
1 2
High-pressure oil
Low-pressure oil
Pilot oil 207446
8-65
HYDRAULIC SYSTEM
Attachment Section
A
B
“a3” SOL “b3” SOL
207447
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
8-68
HYDRAULIC SYSTEM
A B
1 2
High-pressure oil
Low-pressure oil
Pilot oil
207450
8-69
HYDRAULIC SYSTEM
Relief Valve
HP
Chamber D
Main poppet C
207451
207452
207453
8-70
HYDRAULIC SYSTEM
Disassembly
8-71
HYDRAULIC SYSTEM
Disassembly of Sections
1 5 6 7 4 3
Shut-off valve
11
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.
NOTE
Do not loosen adjuster kit 11 (17 Hex) unless it is
necessary, as loosening the adjuster kit changes relief
pressure.
8-73
HYDRAULIC SYSTEM
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.
Shut-off Valve
4 6 5 3 1 2
1 Nut
2 Set screw
3 Plug
4 Poppet
5 O-ring
6 O-ring
8-75
HYDRAULIC SYSTEM
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
207564
Sequence
1 Cap, Bolt, Spring 3 Spring
2 Spool 4 Spring seat
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.
8-78
HYDRAULIC SYSTEM
Reassembly
Reassembly of Sections
11 7 6 5 8 9
Shut-off valve
10
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.
Unit: N·m (kgf·m) [lbf·ft]
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).
Unit: N·m (kgf·m) [lbf·ft]
71 ± 2
Tightening torque (7.1 ± 0.2)
[51.8 ± 1.5]
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
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.
Unit: N·m (kgf·m) [lbf·ft]
12 to 14
Tightening torque (1.2 to 1.4)
[8.76 to 10.2]
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
! 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
207565
Sequence
1 Sleeve 5 Shuttle
2 O-ring 6 O-ring
3 O-ring 7 Solenoid, Bolt
4 O-ring
8-84
HYDRAULIC SYSTEM
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
8-85
HYDRAULIC SYSTEM
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]
(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
! 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
Unit: mm (in.)
Hexagon nut
width across flats: 17 (0.67) 6
(0.24)
Adjuster
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
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
8-90
HYDRAULIC SYSTEM
8-91
HYDRAULIC SYSTEM
Relief Valve
8-92
R
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
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
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
Lift lock valve Lift up
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
High-pressure oil P T2
Pilot oil
Low-pressure oil
From Pump From Steering Control Valve
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
Lift lock valve Lift up
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
High-pressure oil P T2
Pilot oil
Low-pressure oil
From Pump From Steering Control Valve
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
Lift lock valve Lift up
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
High-pressure oil P T2
Pilot oil
Low-pressure oil
From Pump From Steering Control Valve
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
Lift lock valve Lift up
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
High-pressure oil P T2
Pilot oil
Low-pressure oil
From Pump From Steering Control Valve
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
Lift lock valve Lift up
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
High-pressure oil P T2
Pilot oil
Low-pressure oil
From Pump From Steering Control Valve
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
Lift lock valve Lift up
Inlet Section
Shut-off
valve
Pilot
relief
valve Main relief
valve
High-pressure oil P T2
Pilot oil
Low-pressure oil
From Pump From Steering Control Valve
207461
8-100
MAST AND FORKS
Mast Systems
NOTE : Maximum fork lift height [118 in. (30 : 3000 mm)]
211100
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)
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
207608
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
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
203598
203600
9-5
MAST AND FORKS
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
207084
9-6
MAST AND FORKS
! 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
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
To install, follow the removal sequence in reverse, and
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
1 ton class 2 ton class
Item
74 N·m 178 N·m
Bolt tightening
(7.5 kgf·m) (18.2 kgf·m)
torque
[54 lbf·ft] [132 lbf·ft]
Tightening torque
Tightening Torque
9-8
MAST AND FORKS
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
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
! CAUTION
Be sure to use a hoist with enough capacity to
support the mast assembly. 207614
207086
9-10
MAST AND FORKS
Installation
To install, follow the removal sequence in reverse, and
follow the steps below:
1. Procedure for installing mast support bushings 7 and 6
caps 6. 7
Chamfered faces
203712
Truck Model
1 ton class 2 ton class
Item
74 N·m 178 N·m
Bolt tightening
(7.5 kgf·m) (18.2 kgf·m)
torque
[54 lbf·ft] [132 lbf·ft]
Tightening torque
Tightening Torque
98 to 103 N·m
Double nut (lower) ➀ (10 to 10.5 kgf·m)
[72.3 to 76.0 lbf·ft]
9-11
MAST AND FORKS
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
207089
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
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.)
Diam. of 1 ton class 2 ton class
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
207094
9-15
MAST AND FORKS
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.
207619
207620
207621
9-17
MAST AND FORKS
Reassembly
To reinstall, follow the removal sequence in reverse, and
follow the steps below:
1. Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims 12.
207622
207623
202263
207632
9-18
MAST AND FORKS
201752
200383
9-19
MAST AND FORKS
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.
207626
9-21
MAST AND FORKS
207627
Reassembly
To reinstall, follow the removal sequence in reverse, and
follow the steps below:
1. Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims.
207630
207629
9-22
MAST AND FORKS
202263
207631
201752
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
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
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
Unit: N·m (kgf·m) [lbf·ft]
9-25
MAST AND FORKS
207633
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).
207634
9-26
MAST AND FORKS
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.
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).
207636
9-27
MAST AND FORKS
NOTE
The adjustment procedure for the lift bracket is the same
for the Simplex Mast, Duplex Mast and Triplex Mast.
9-28
MAST AND FORKS
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
207098
0.1 to 0.5 mm
Clearance G3
(0.004 to 0.020 in.)
207158
9-29
MAST AND FORKS
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.)
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.
(5) Read the indicator.
0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)
207101
NOTE
207102
0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.)
207103
9-31
MAST AND FORKS
NOTE
207104
NOTE
Refer to Removal and Installation section, “1. Lift
bracket removal.”
9-32
MAST AND FORKS
NOTE
Refer to “Removing lift bracket” section in the
HYDRAULIC SYSTEM.
207616
9-33
MAST AND FORKS
NOTE
Refer to “Removing lift bracket” section in the
HYDRAULIC SYSTEM.
207616
(5) Lower the inner mast until main rollers can be removed.
(6) Place wood blocks under the inner mast for support.
(7) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in
advance as they drop easily under this condition.
NOTE
In this condition, second lift cylinders cannot be
dismounted.
9-34
MAST AND FORKS
207640
9-35
MAST AND FORKS
0.1 to 0.5 mm
Clearance L
(0.004 to 0.020 in.)
200391
NOTE
NOTE
It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted.
9-36
MAST AND FORKS
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
(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.
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.
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.
Spongy operation of
fall-prevention function when Improper air bleeding Bleed hydraulic system.
lifting operation is stopped.
9-38
MAST AND FORKS
Service Data
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)
Service Data
Truck Models 1 ton class 2 ton class
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
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
10-1
SERVICE DATA
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
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
10-2
SERVICE DATA
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
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
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
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
10-4
SERVICE DATA
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
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
10-5
SERVICE DATA
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
Safety devices and others
Head guard Mounting looseness
and backrest Deformation, cracking and damage
10-6
SERVICE DATA
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.
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
206930
10-8
SERVICE DATA
Lubricant Quantities
Truck Models
1 ton class 2 ton class
Items
Recommended Lubricant
Grease: NLGI No. 1, NLGI No. 2
Brake fluids: SAE J1703f
Hydraulic, transfer and rear axle oils: SAE 5W, SAE 10W
Truck Models
FB16KT FB18KT FB20KT
Item
Power line
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)
Lift bracket (including backrest) 93.34 (205.8) 93.34 (205.8) 108.22 (238.6)
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
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
10-10
SERVICE DATA
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
10-11
SERVICE DATA
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
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
10-12
SERVICE DATA
➀ 203544 ➄ 203552
➁ 200447 ➅ 200448
➂ 200446 ➆ 203556
➃ 203551 ➇ 206997
10-13
OPTIONS
11
OPTIONS
208115
11-1
OPTIONS
Buzzer
Washer
Bolt with washer
Clip band
Terminal
Terminal
208116
11-2
OPTIONS
211102
11-3
OPTIONS
208120
11-4
TECHNICAL PUBLICATIONS FEEDBACK
(Please Print)
Dealer name: Submitted by:
Address: P. O. Box:
City: State:
Zip code: Country:
(Please print)
Explanation of discrepancy or omission:
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
99719-56100 Copyright © 2005 by MCFA. All Rights Reserved. Printed in The Netherlands