5M100

Service Manual
Chassis & Mast FC/MC

FB16CPN EFB27-00011-up
FB18CPN EFB27-50011-up
FB16PN EFB28-00011-up
99759-5M100
FOREWORD
This service manual is a guide for servicing Mitsubishi Forklift Trucks.
The long productive life of your forklift truck(s) depends on regular and proper servicing, servicing consistent with what you
will learn by reading this service manual.
Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to
start a test, repair or rebuild the forklift truck.
The descriptions, illustrations and specifications contained in this manual are for forklift trucks with serial numbers in effect at
the time of printing.
Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring
obligations. For your convenience the instructions are grouped by systems as an easy reference.
Safety related signs Meanings

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
RWARNING
injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
RCAUTION
injury, or damage to your machine.
NOTE Indicates a condition that can cause damage to or shorten service life of the machine.
Unauthorized copying and lending are prohibited.
i
1. Safety
R WARNING
- The proper and safe lubrication and maintenance for these forklift trucks, recommended by Mitsubishi Forklift Trucks, are
outlined in the SERVICE MANUAL. Read and understand the SERVICE MANUAL before performing any lubrication or
maintenance on these trucks. Improper performance of lubrication or maintenance procedures is dangerous and could
result in injury or death. The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes
it important to use caution when performing service work.
- Do not operate these trucks unless you have read and understood the instructions in the SERVICE MANUAL. Improper
truck operation is dangerous and could result in injury or death.
A knowledge of the system and/or components is important (8) Be careful when removing cover plates. Gradually
before the removal or disassembly of any component. remove the last two bolts or nuts located at opposite
ends of the cover or device and pry cover loose to
Because of the size of some of the truck components, the relieve any springs or other pressures, before removing
serviceman or mechanic should check the weights noted in the last two bolts or nuts completely.
this Manual. (9) Be careful when removing filler caps, breathers and
Use proper lifting procedures when removing any plugs on the truck. Wrap a cloth around the cap or plug
to prevent being sprayed or splashed by liquids under
components. pressure. Be aware that the danger of being sprayed or
Following is a list of basic precautions that should always be splashed is ever greater if it is immediately after
stopping the truck, as fluids is very hot.
observed.
(10) Use tools well maintained. And use the tools in proper
(1) Read and understand all warning plates and decals on way.
the truck before operating, lubricating or repairing the (11) Reinstall all fasteners with same part number. Do not
product. use a lesser quality fastener if replacements are
(2) Always wear protective glasses and protective shoes necessary.
when working around trucks. In particular, wear (12) If possible, make all repairs with the truck parked on a
protective glasses when using a hammer or sledge on level, hard surface. Block truck so it does not roll while
any part of the truck or its attachments with a hammer working on or under truck.
or sledge. (13) Before starting to work on truck, hang "Do not Operate"
Use welders gloves, hood/goggles, apron and other tag in the Operator Compartment.
protective clothing appropriate to the welding job
being performed. Do not wear loose fitting or torn (14) Repairs, which require welding, should be performed
clothing. Remove all rings from fingers when working only with the appropriate reference information and by
on machinery. personnel adequately trained and knowledgeable in
welding procedures. Determine the type of metal and
(3) Do not work on any truck that is supported only by lift select the correct welding procedure and electrodes,
jacks or a hoist. Always use blocks or jack stands to rods or wire to provide a weld metal strength
support the truck before performing any disassembly. equivalent at least to that of parent metal.
(4) Lower the forks or other implements to the ground (15) Do not damage wiring during the removal process. Do
before performing any work on the truck. If this cannot not reuse the damaged wiring. Reinstall the wiring
be done, make sure the forks or other implements are paying attention not to contact sharp corners or hot
blocked correctly to prevent them from dropping parts. Place wiring away from oil pipe.
unexpectedly.
(16) Be sure all protective devices including guards and
(5) Use steps and grab handles (if applicable) when shields are properly installed and functioning correctly
mounting or dismounting a truck. Clean any mud or before starting a repair.
debris from steps, walkways or work platforms before If a guard or shield must be removed to perform the
using. Always face truck when using steps, ladders and repair work, use extra caution.
walkways. When it is not possible to use the designed
access system, provide ladders, scaffolds, or work (17) Always support the mast and carriage to keep carriage
platforms to perform safe repair operations. or attachments raised when maintenance or repair
work is performed, which requires the mast in the
(6) To avoid back injury, use a hoist when lifting raised position.
components which weigh 23 kg (51 lb) or more. Make
sure all chains, hooks, slings, etc., are in good condition (18) Loose or damaged fuel, lubricant and hydraulic lines,
and are of the correct capacity. Be sure hooks are tubes and hoses could cause fires. Do not bend or strike
positioned correctly. Lifting eyes are not to be side high pressure lines or install ones which have been
loaded during a lifting operation. bent or damaged. Inspect lines, tubes and hoses
carefully. Do not check for leaks with your hands. Pin
(7) To avoid burns, be alert of the hot sections and hot hole (very small) leaks could result in a high velocity oil
fluids in lines, tubes and compartments, even when idle stream that will be invisible close to the hose. This oil
or off. could penetrate the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.
ii
(19) Tighten connections to the correct torque. Make sure
that all heat shields, clamps and guards are installed
correctly to avoid excessive heat, vibration or rubbing
against other parts during operation. Shields that
protect against oil spray onto hot exhaust components
in event of a line, tube or seal failure, must be installed
correctly.
(20) Relieve all pressure in air, oil or water systems before
any lines, fittings or related items are disconnected or
removed.
Place blocks to prevent a device from falling if it is in the
raised position. Release the residual pressure when
removing a pressurized device.
(21) Do not operate a truck if any rotating part is damaged
or contacts any other part during operation.
Any high speed rotating component that has been
damaged or altered should be checked for balance
before reusing.
2. How to Use This Manual
2.1 Truck Model
MC Truck (Manual Control System)

Mechanically controlled hydraulic system (conventional
lever system)
501489
FC (Fingertip Control System) Truck

This model allows a fingertip operation of lifting and tilting
jobs, and may improve the job efficiency with less operation
fatigue.
501490
iii
3. Symbols and Abbreviations
Symbol or
Meanings
abbreviation
OP. Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
4. Units
- SI Units are used in this manual.
- The following table shows the conversion of SI unit and customary unit.
Item SI unit Metric unit Yard-pound unit

Force 1N 0.102 kgf 0.225 lbf
Pressure 1 MPa 10.1972 kgf/cm2 145.038 psi
Torque 1 N·m 0.102 kgf·m 0.7376 lbf·ft
1 mm - 0.039 in.
Length
1m - 3.281 feet
Weight 1 kg - 2.205 lb
Temperature 1 °C - °F=1.8 x °C+32
Volume 1L - 0.264 US.gal.
iv
TABLE OF CONTENTS
Chapter 1 GENERAL INFORMATION

1. Model View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
2. Truck Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
3. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
4. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Chapter 2 VEHICLE ELECTRICAL COMPONENTS

1. Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
1.1 MC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
1.2 FC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2. Disassembling Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.1 Disassembling Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
3. Reassembling Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
4. Meter panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
4.1 Functions of Meter panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
4.2 Adjusting and Setteing of Meter panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
4.3 Error Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
5. Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
6. Lighting Switch (Rear Work Lamp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
6.1 Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
6.2 Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
7. Horn Switch and Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . .2-26
7.1 MC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
7.2 FC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
8. Troubleshooting of Lighting and Horn Systems . . . . . . . . . . . . . . . . .2-27
9. Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
10. Combination Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
10.1 Direction lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
10.2 Light Switch and Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
11. Disassembling Accelerator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
11.1 Disassembling Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
11.2 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
12. Joystick Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
13. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Chapter 3 POWER TRAIN

1. Removing batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
2. Removing front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3. Removing Transfer Assemblies, Traction motors . . . . . . . . . . . . . . . . .3-3
4. Installing Transfer Assemblies, Traction motors and Calipers . . . .3-4
5. Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
TOC-1
TABLE OF CONTENTS
Chapter 4 TRANSFER UNITS

1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
2. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
2.1 External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
2.2 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
3. Disassembling Transfer Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
3.2 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4. Inspecting Transfer Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
5. Reassembling Transfer Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
5.1 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
6. Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Chapter 5 REAR AXLE

1. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
1.1 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
1.2 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
2. Removing Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
2.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
2.2 Removing Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
3. Installing Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
4. Removing Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
4.2 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
4.3 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5. Installing Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
6. Disassembling Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
6.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
7. Inspecting Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
8. Installing Steering Cylinder and Hydraulic Pipe . . . . . . . . . . . . . . . . . 5-12
8.1 Installation Sequerce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
9. Assembling Knuckle and Kingpin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
9.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
9.2 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
10. Assembling Rear Axle Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
10.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
11. Removing Steering Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
12. Installating Steering Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
13. Disassmbling Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
TOC-2
TABLE OF CONTENTS
14. Inspecting Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

15. Reassembling Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
15.1 Reassebly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
15.2 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
16. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
16.1 Adjusting of Steering Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
16.2 Adjusting of Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
17. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
18. Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
18.1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
18.2 Steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28
Chapter 6 BRAKE SYSTEM

1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
2. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
2.1 Outline of Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
2.2 Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
2.3 Electro-magnetic Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
3. Removing Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
3.1 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
4. Disassembling Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
4.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
5. Inspecting and Adjusting Master Cylinder . . . . . . . . . . . . . . . . . . . . . .6-8
6. Reassembling Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
7. Inspecting and Adjusting Brake Pedal Assembly . . . . . . . . . . . . . . . .6-12
8. Adjusting and Manual Releasing Magnet Brake . . . . . . . . . . . . . . . . .6-14
9.1 Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
9.2 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
10. Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
10.1 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
10.2 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Chapter 7 STEERING SYSTEM

1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
2. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
2.1 Outline of Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
3. Removing Steering Linkage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
3.1 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
3.2 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
4. Inspecting Steering Linkage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
5. Installing Steering Linkage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
6. Removing PS Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
TOC-3
TABLE OF CONTENTS

7. Installing PS Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
8. Disassembling PS Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
8.1 Hydraulic oil drain procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
8.2 Disassembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
9. Reassembling PS Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
10. Inspecting PS Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
12. Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
12.1 PS Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
12.2 Reservoir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Chapter 8 HYDRAULIC SYSTEM

1. Spcifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
1.1 MC model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
1.2 FC model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
2. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
2.1 Hydraulic Line (MC Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
2.2 Hydraulic Line (FC Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
2.3 Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
2.4 Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
3. Removing Control Valve (MC Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
4. Installing Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
5. Removing Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
5.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
6. Installing Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
7. Removing Suction Filter and Return Filter . . . . . . . . . . . . . . . . . . . . . . 8-11
7.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8. Installing Suction Filter and Return Filter . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.1 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
9. Removing Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
10. Removing Lift Cylinders (Triplex Mast and Duplex Mast) . . . . . . . . . 8-17
11. Installing Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
11.1 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
12. Removing Tilt Cyinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
12.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
TOC-4
TABLE OF CONTENTS

13. Disassembling Lilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-24
13.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-24
14. Reassembling Lilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-28
14.1 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-28
14.2 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31
15. Disassembling Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-33
16. Reassembling Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-34
16.1 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-34
17. Inspecting and Adjusting Hydraulic System . . . . . . . . . . . . . . . . . . . . .8-35
17.1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-35
17.2 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-37
17.3 Adjusting Main Relief Valve (MC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-38
17.4 Adjusting Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-39
17.5 Adjusting Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-40
17.6 Adjusting Lilt Cylinder Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-41
17.7 Inspecting Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-41
18. Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-42
18.1 Vertical Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-42
18.2 Tilt Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-42
20. Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-48
20.1 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-48
20.2 Control Valve (MC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49
20.3 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49
20.4 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-53
21. MC Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-54
21.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-54
21.2 Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-55
21.3 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-56
21.4 Structure-Inlet Cover Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-60
21.5 Structure Lift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-61
21.6 Structure Tilt Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-62
22. Construction and Function of FC Control Valve . . . . . . . . . . . . . . . . .8-64
22.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-65
22.2 FC Hydraulic System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-66
22.3 Bleed-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-68
22.4 Lift valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-70
22.5 Tilt valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-74
22.6 Attachment valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-77
23. Removing FC Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-80
23.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-80
23.2 Removal sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-80
24. Installing FC Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-80
25. Disassembly of FC Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-81
TOC-5
TABLE OF CONTENTS
25.1 Disassembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81

26. Reassembly of FC Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
27. Valves included in the inlet section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83
28. Disassembling Inlet Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
28.1 Disassembly sequence (part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
29. Valves included in tilt section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88
30. Disassembling Tilt Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89
31. Valves incorporated in attachment section . . . . . . . . . . . . . . . . . . . . . 8-91
32. Disassembling Attachment section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
33. Disassembling End Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94
33.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94
34. Inspection of end plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
34.1 Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
35. Reassembly inlet section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96
35.2 Disassembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98
36. Reassembling tilt section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100
37. Assembling attachment section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-101
38. Solenoid Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
39. Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104
Chapter 9 MAST AND FORKS

1. Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
1.1 Mast Model Code Stamping Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
1.2 Explanation of Mast Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
1.3 Mast Code and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
2.1 Simplex Mast (Dual-stage Panoramic Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
2.2 Duplex Mast (Dual-stage Full Free Panoramic Mast) . . . . . . . . . . . . . . . . . . . 9-3
2.3 Triplex Mast(Triple-stage Full Free Panoramic Mast) . . . . . . . . . . . . . . . . . . 9-4
2.4 Operation of Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TOC-6
TABLE OF CONTENTS
2.5 Operation of Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

3. Removing Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
4. Installing Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9
5. Removing Triplex Mast, Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
6. Installing Triplex Mast, Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14
7. Disassembling Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
7.3 Inspecting Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17
7.4 Reassembling Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
8. Disassembling Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21
8.3 Inspecting Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-22
8.4 Reassembling Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-22
9. Disassembling Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-25
10. Inspecting Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-27
11. Reassembling Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-27
12. Inspecting and Adjusting Mast and Forks . . . . . . . . . . . . . . . . . . . . . . .9-30
12.1 Forks (all mast models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-30
12.2 Chain Tension Adjustment - Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-32
12.3 Chain Tension Adjustment - Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-34
12.4 Chain Tension Adjustment - Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-35
12.5 Clearance Adjustment on Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-36
12.6 Mast Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-40
12.7 Main Roller Shim Replacement - Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . .9-43
12.8 Main Roller Shim Replacement - Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . .9-44
12.9 Main Roller Shim Replacement - Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . .9-45
12.10 Mast Strip Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-46
12.11 Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-47
12.12 Lift Cylinder Stroke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-47
14. Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-50
14.1 Simplex Mast, Duplex Mast, Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-50
TOC-7
TABLE OF CONTENTS
Chapter 10 Service Data

1. Inspection Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
2. Periodic Replacement of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
2.1 Critical Safety Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
3. Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . . 10-8
3.1 Metric fine thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
3.2 Metric coarse thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
4. Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
4.1 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
4.2 Recommended Oils and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
4.3 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
5. Weight of Major Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
6. Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Chapter 11 Panel cabin

1. Battery exchange or battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
2. Cleaning Top Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
3. Replacing Top Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
TOC-8
CHAPTER 1 GENERAL INFORMATION
Chapter 1 GENERAL INFORMATION
1. Model View
501180
1-1
2. Truck Models Covered
This Service Manual provides service and maintenance information for the following trucks:
Truck model Model code - Serial number

FB16CPN EFB27-00011
FB18CPN EFB27-50011
FB16PN EFB28-00011
FB18PN EFB28-50011
FB20PN EFB29-00011
1-2
3. Serial Number Locations
501508
1. Name plate 2. Mast number
1-3
4. Specifications
This specification describes the truck with simplex 3.3 m mast.
SPECIFICATION UNIT FB16CPN FB18CPN FB16PN FB18PN FB20PN

1600 1800 1600 1800 2000
RATED CAPACITY kg (lb)
(3527) (3968) (3527) (3968) (4409)
mm
LOAD CENTER 500 (19.69) 500 (19.69)
(in.)
mm
MAXIMUM FORK HEIGHT 3325 (130.91) 3325 (130.91)
(in.)
mm
FREE LIFT 115 (4.53) 115 (4.53)
(in.)
0.6/0.5 0.6/0.44 0.6/0.5 0.6/0.44 0.6/0.4
m/s
LIFT SPEED (UNLOADED/LOADED) (118.11/ (118.11/ (118.11/ (118.11/ (118.11/
(mph)
98.43) 86.61) 98.43) 86.61) 78.74)
PERFORMANCE
LOWERING SPEED m/s 0.5/0.52 0.5/0.52

(UNLOADED/LOADED) (mph) (98.43/102.36) (98.43/102.36)
TILT ANGLE (FORWARD/BACKWARD) deg 5/7.5 5/7.5
FORWARD km/h
17/17 (10.56/10.56) 17/17 (10.56/10.56)
TRAVEL (UNLOADED/LOADED) (mph)
SPEED REVERSE km/h
17/17 (10.56/10.56) 17/17 (10.56/10.56)
(UNLOADED/LOADED) (mph)
mm
MINIMUM TURNING RADIUS 1900 (74.80) 2015 (79.33)
(in.)
WORKING AISLE WIDTH
mm 3473 3473 3588 3588 3599
1000 x 1200 mm
(in.) (136.73) (136.73) (141.26) (141.26) (141.69)
(39.37 x 47.24 in.) PALLETS
WORKING AISLE WIDTH
mm 3273 3273 3388 3388 3399
800 x 1200 mm
(in.) (128.86) (128.86) (133.39) (133.39) (133.82)
(31.50 x 47.24 in.) PALLETS
1-4

mm 3193
OVERALL LENGTH 3072 (120.94) 3182 (125.28)
(in.) (125.71)
LENGTH TO FORK FACE mm 2273
2152 (84.72) 2262 (89.05)
(INCLUDES FORK THICKNESS) (in.) (89.49)
mm 1140
OVERALL WIDTH 1090 (42.91) 1090 (42.91)
(in.) (44.88)
TO TOP OF MAST mm
2125 (83.66) 2125 (83.66)
LOWERED (in.)
OVERALL mm
MAST EXTENDED 4342 (170.94) 4342 (170.94)
HEIGHT (in.)
TO TOP OF OVERHEAD mm
2050 (80.71) 2050 (80.71)
GUARD (in.)
mm
LOAD DISTANCE 373 (14.69) 373 (14.69) 384 (15.12)
(in.)
mm
WHEELBASE 1446 (56.93) 1556 (61.26)
(in.)
mm
SEAT HEIGHT 976 (38.43) 976 (38.43)
DIMENSIONS
(in.)
mm
TOW COUPLING HEIGHT 575 (22.64) 575 (22.64)
(in.)
mm
FRONT 920 (36.22) 920 (36.22) 938 (36.93)
(in.)
TREAD
mm
REAR 898 (35.35) 898 (35.35)
(in.)
mm
FRONT TIRE HEIGHT 215 (8.46) 215 (8.46)
(in.)
mm
REAR TIRE HEIGHT 190 (7.48) 190 (7.48)
(in.)
mm
AT MAST 95 (3.74) 95 (3.74)
GROUND (in.)
CLEARANCE mm
AT FRAME 85 (3.35) 85 (3.35)
(in.)
LENGTH x WIDTH x mm 1150 x 100 x 35 1150 x 100 x 35
THICKNESS (in.) (45.28 x 3.94 x 1.38) (45.28 x 3.94 x 1.38)
FORK 920 to 240
mm 920 to 240 920 to 240
FORK SPACING (OUTSIDE) (36.22 to
(in.) (36.22 to 9.45) (36.22 to 9.45)
9.45)
2195 2250 2080 2145 2310
WEIGHT (WITHOUT BATTERY) kg (lb)
(4839) (4960) (4586) (4729) (5093)
NAME SOLID PNEUMATIC SOLID PNEUMATIC
FRONT
SIZE 18 x 7-8 18 x 7-8 200/50-10
TIRE
NAME SOLID PNEUMATIC SOLID PNEUMATIC

REAR
SIZE 16 x 6-8 16 x 6-8
1-5

VOLTAGE V 48 48
AMP/
CAPACITY 625 750
5hr
BATTERY
MAXIMUM WEIGHT kg (lb) 900 (1984) 1075 (2370)

MINIMUM WEIGHT kg (lb) 810 (1786) 975 (2150)
mm 834 x 638 x 630 834 x 748 x 630
COMPARTMENT MAXIMUM SIZE
(in.) (32.83 x 25.12 x 24.80) (32.83 x 29.45 x 24.80)
TYPE INDUCTION INDUCTION
ELECTRIC MOTOR
FOR DRIVE kw/

OUTPUT 4.5 x 2 4.5 x 2
60min
FOR TYPE INDUCTION INDUCTION

HYDRAULIC OUTPUT (15 % DUTY) kW 11.5 11.5
TYPE OF DRIVE AC TRANSISTOR AC TRANSISTOR
CONTROL
TYPE OF HYDRAULIC AC TRANSISTOR AC TRANSISTOR
MPa
(kgf/
RELIEF VALVE SETTING OF CONTROL VALVE 18.1 (184.57) [2625.2] 18.1 (184.57) [2625.2]
cm2)
[psi]
1-6
6 20 15 14
21
8
7 9
12
18 17 13
16
10
2 11 19
5
4
501185
1. MAXIMUM FORK HEIGHT 12. SEAT HEIGHT

2. FREE LIFT 13. TOW COUPLING HEIGHT
3. MINIMUM TURNING RADIUS 14. TREAD FRONT
4. OVERALL LENGTH 15. TREAD REAR
5. LENGTH TO FORK FACE (INCLUDES FORK THICKNESS) 16. FRONT TIRE HEIGHT
6. OVERALL WIDTH 17. REAR TIRE HEIGHT
7. OVERALL HEIGHT (TO TOP OF MAST LOWERED) 18. GROUND CLEARANCE (AT MAST)
8. OVERALL HEIGHT (MAST EXTENDED) 19. GROUND CLEARANCE (AT FRAME)
9. OVERALL HEIGHT (TO TOP OF OVERHEAD GUARD) 20. FORK SPACING (OUTSIDE)
10. LOAD DISTANCE 21. TILT ANGLE (FORWARD/BACKWARD)
11. WHEELBASE
1-7
CHAPTER 2 VEHICLE ELECTRICAL COMPONENTS
Chapter 2 VEHICLE ELECTRICAL COMPONENTS
1. Console
1.1 MC Model
7 2 8 4
3
5
6
1
603001
1. Meter panel 6. Parking switch

2. Key switch 7. Direction lever
3. Lighting switch (rear work lamp) 8. Light switch and turn signal switch
4. Horn switch 9. Accelerator pedal
5. Emergency stop switch
2-1
1.2 FC Model
7 2 8 4 1
9
5
10
603076
1. Meter panel 6. Parking switch

2. Key switch 7. Direction lever
3. Lighting switch (rear work lamp) 8. Light switch and turn signal switch
4. Horn switch 9. Accelerator pedal
5. Emergency stop switch 10. Joystick box
2-2
2. Disassembling Console
2.1 Disassembling Sequence
7
10
12
4
11
5
8
3
6
2
603063
1. Kick panel 7. Column panel (2)

2. Parking switch 8. Key switch
3. Lighting switch (Rear work lamp) 9. Steering wheel assembly
4. Emergency stop switch (MC model) 10. Combination switch
5. Meter panel 11. Tilt steering column lock/unlock handle
6. Column panel (1) 12. Steering column assembly
2-3
2.2 Suggestions for Disassembly
R CAUTION
- Turn the key switch to the off position.
- Record places of the harness connections before disassembling.
- Do not disassemble the combination switch.
Removal of parking switch, emergency stop switch,

Meter panel and lighting switch
2
(1) Remove the kick panel.
3 1
(2) Disconnect the harness connector of the parking
switch, and remove the switch.
(3) Disconnect the harness connector of the lighting
switch (rear work lamp), and remove the switch.
603065
1. Kick panel 3. Lighting switch (Rear work

2. Parking switch lamp)
(4) Disconnect the harness connector of the emergency

stop switch, and remove the switch.
Note: This step is not necessary for FC model.
1
(5) Disconnect the harness connector of the Meter panel,
and remove the Meter panel.
2
603064
1. Emergency stop switch (MC 2. Meter panel assembly

model)
Disassembly of key switch and combination switch

(1) Remove the column panel (1) and (2). 2 4
(2) Disconnect the harness connector of the key switch,
and remove the switch. 3
(3) Remove the steering wheel assembly.
1
603066
1. Column panel (1) 3. Key switch

2. Column panel (2) 4. Steering wheel assembly
2-4
(4) Disconnect the harness connector of the combination

switch, and remove the switch. 1
(5) Remove the spring from the pedal bracket.
(6) Remove the handle.
5
(7) Disconnect the harness connector of the steering 2
column assembly, and remove the column.
4
3
603067
1. Combination switch 4. Tilt steering column lock/

2. Spring unlock handle
3. Pedal bracket 5. Steering column assembly
3. Reassembling Console
Follow the removal sequence in reverse.
4. Meter panel
4.1 Functions of Meter panel
1 3 5 2 6 4 8
ORJ
MOJ
TOTAL 123456.0HR
10/ 9/1
9/ 1 8:56
1 1 00KG
7
9 10 11 12 13 14 15 16 17 18
603002
1. Battery discharge indicator 10. Error warning

2. Speedometer 11. Parking brake warning
3. Calendar 12. Seat belt warning
4. Clock 13. Battery warning
5. Slow speed mode monitor (Turtle mark) 14. Brake fluid warning
6. Hour meter 15. Overheat warning
7. Load meter (option) 16. Service indicator
8. Mode select switch 17. Mast lock
9. Wheel indicator 18. Neutral lock
2-5
Battery discharge indicator

The battery discharge indicator shows the discharged status
of the battery. 5)
When the battery capacity is less than 20%, all green
1) 2) 3) 4)
segments are disappeared and two red segments stay on.
When the capacity is less than 10%, one red segment is
flashed with the outline of the gauge. When the capacity is
empty, only the outline of the gauge is flashed.
603024
1) Full charged 4) Empty

2) Less than 20 % 5) Charge the battery immediately
3) Less than 10%
R CAUTION
- Do not over-discharge. The battery life can be shorten by over-discharging. Charge the battery as soon as possible when
all green segments are disappeared.
Speedometer
The traveling speed is displayed by 20 stages.
"km/h" or "mph" can be selected.
1
Refer to the Speedometer setting for details.
2
502872
Calendar and clock (Date and time)

The current date and time are displayed.
Date : EU calender (D/M/Y) or US calender (M/D/Y) can be
selected.
Time : 24 hours format or 12 hours format (AM/PM) can be
selected.
Refer to the Date setting and Clock setting for details.
Slow speed mode monitor (Turtle mark)

When the slow speed mode button ( W button) is pushed,
the turtle mark is indicated on the screen with the preset
limit speed.
Hour meter
The hour meter shows the total hours of turning on the key
switch.
Load meter (option)
The load weight is displayed only for the model with load
sensor.
2-6
Mode select switch

There are five types of buttons;
t and y buttons : Move the cursor to select the value.
(R) button : Move the cursor to the next item.
E button : Change the normal screen and adjustment menu
screen.
W button : The slow speed mode is activated.
Refer to Adjusting and Setting for details.
603039
Wheel indicator
1 2
The wheel direction is displayed when the direction lever is
in neutral (N) position. 3 4 5
The travel direction is displayed by arrow when the
direction lever is in forward (F) or reverse (R) position.
Note: Because the icon shows the travel direction of vehicle, 6 7 8
it may be different from the wheel direction.
502134
1. Wheel direction (Direction lever 5. Right-hand reverse
is in Neutral.) 6. Reverse
2. Travel direction 7. Left-hand reverse
3. Forward 8. Left-hand Forward
4. Right-hand forward
2-7
Warning icons
When the abnormality is detected, the warning icon is displayed. At the maximum, 8 icons are displayed at the same time.
Icon Name When OFF When ON or flashing Remarks

Error warning No abnormalities or errors Some abnormalities or The error code is displayed
are detected. errors are detected. instead of hour meter,
calendar, clock and load
meter.
Parking brake Parking brake disengaged Parking brake engaged
warning
Seat belt warning Seat belt is fastened. Seat belt is not fastened
when operator sits on seat
(seat switch is turned on).
Battery warning Normal battery condition Flashing indicates battery Message “BATTERY LOW” is
needs to be recharged displayed instead of hour
soon. meter.
ON indicates battery needs
to be recharged and lifting
function inoperable.
Brake fluid warning Normal fluid level Low fluid level
Overheat warning Controller, drive motors Overheating Overheating causes a

and pump motor in normal significant output loss.
temperature When component
temperature returns to
normal level, output power
returns.
Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached.
Mast lock The lift and/or tilt lever is The lift and/or tilt lever is
placed to the neutral operated when operator is
position and operator sits not sitting properly in seat
in seat properly. for approximately 3
seconds.
Neutral lock Key switch is turned on Key switch is turned on
when the direction lever is when direction lever is not
in the NEUTRAL position in the NEUTRAL position
and the accelerator pedal is and operator is not sitting
not depressed. properly in seat for
approximately 3 seconds.
2-8
4.2 Adjusting and Setting of Meter panel
NOTE R
Perform the adjustment or setting under following conditions.
(1) Apply the parking brake.
(2) Place the direction lever in NEUTRAL.
(3) Turn the key switch to the on position.
Load Zero setting (optional)

(1) Turn the key switch ON and the normal screen 1
appears.
501873
Screen 1
(2) Push E button and screen 2 appears.

Move the cursor to "LOAD ZERO SET" by pushing t or
y button.
>
501874
Screen 2
(3) Push (R) button. Then the screen 3 appears.
>
501875
Screen 3
2-9
(4) Select the operation by pushing t or y button. Then

the screen 4 appears.
>
501876
Screen 4
(5) Push (R) button. Then setting is complete.
Load Meter setting (optional)
(1) Turn the key switch ON and the screen 1 appears.
501873
Screen 1
>
501877
Screen 2
2-10
(3) When you select "SET", the screen 3 appears.
>
501878
Screen 3
(4) Move the cursor to "LOAD METER" by pushing t or y

button.
>
501879
Screen 4
(5) Push (R) button. Then screen 5 appears.
>
501880
Screen 5
(6) Select the operation by pushing t or y button.
>
501881
Screen 6
2-11
(7) Push (R) button. Then screen 7 appears. The current

unit is blinking.
>
501882
Screen 7
(8) Select the unit of load meter “KG” or “LBS” by pushing

t or y button.
>
501881
Screen 8
Speedometer setting
501873
Screen 1
2-12
>
501877
Screen 2
(3) When you select "SET", the screen 3 appears.
501883
Screen 3
(4) Move the cursor to "SPEED METER" by pushing t or y

button.
501884
Screen 4
(5) Push (R) button. Then screen 5 appears.

(6) Select the operation by pushing t or y button.
501885
Screen 5
2-13
(7) Push (R) button, and screen 6 appears. The current unit
is blinking.
501886
Screen 6
(8) Select the unit of speed meter “KPH” or “MPH” by

pushing t or y button.
501885
Screen 7
Date setting

(2) Push E button and adjustment menu screen appears.
(3) Move the cursor to "DATE" by pushing t or y button.
>
501887
Screen 1
2-14
(4) Push (R) button, and then screen 2 appears.
501888
Screen 2
(5) Push (R) button, and the value of year is blinking.

Set the year by pushing t or y button.
501889
Screen 3
(6) After setting of the year, push (R) button, and then
screen 4 appears.
501890
Screen 4
(7) Push (R) button, and the value of month is blinking.

Set the month by pushing t or y button.
501891
Screen 5
2-15
(8) After setting of the month, push (R) button, and then
501892
Screen 6
(9) Push (R) button again, and the value of day is blinking.
Set the day by pushing t or y button.
501893
Screen 7
(10) After setting of the day, push (R) button, and then the
screen 8 appears.
501894
Screen 8
(11) Push (R) button again, and the parameter of format is

blinking.
Select the format “US calendar (M/D/Y)” or “EU calendar
(D/M/Y)” by pushing t or y button.
501895
Screen 9
2-16
(12) After setting of the format, push (R) button, and then
501896
Screen 10
(14) If you want to change the setting, select "CANCEL" on

the screen 11.
501897
Screen 11
Clock setting

(2) Push E button and adjustment menu screen appears.
(3) Move the cursor to "CLOCK" by pushing t or y button.
>
501898
Screen 1
(4) Push (R) button, and then the screen 2 appears.
> HOUR 0
M I NUTE 5
FORMAT **H
501899
Screen 2
2-17
(5) Push (R) button, and the value of hour is blinking.

Set the hour 0 to 23 by pushing t or y button.
501900
Screen 3
(6) After setting of the hour, push (R) button, and then the
screen 4 appears.
501901
Screen 4
(7) Push (R) button, and the value of minute is blinking.

Set the minute 0 to 59 by pushing t or y button.
501902
Screen 5
(8) After setting of the minute, push (R) button, and then
501903
Screen 6
2-18
(9) Push (R) button, and the parameter of format is

blinking.
Select the format “12H (AM/PM)” or “24H” by pushing
t or y button.
501904
Screen 7
(10) After setting of the format, push (R) button, and then
501905
Screen 8

the screen 9.
501897
Screen 9
2-19
Display contrast setting
501873
Screen 1
(2) Push E button and the screen 2 appears.
>
501877
Screen 2
(3) Move the cursor to "CONTRAST" by pushing t or y

button.
501906
Screen 3
(4) Push (R) button. Then screen 4 appears. The current

parameter is blinking.
501907
Screen 4
2-20
(5) Select the parameter 1 to 16 by pushing t or ybutton.
501908
Screen 5

the screen 6.
>
501877
Screen 6
2-21
4.3 Error Code List
Error Error
Description Description
code code
E0 Traction Motor R.H., Overheating H2 Tilt Lever, Faulty Setting
E1 Traction Motor L.H., Overheating H3 Attach 1 Lever, Faulty Setting
E2 Pump Motor, Overheating H4 Attach 2 Lever, Faulty Setting
E5 Traction Inverter R.H., Overheating (L) Seat Switch, Faulty Setting For Hydraulic
E6 Traction Inverter L.H., Overheating EE FNR Lever Fault
E7 Pump Inverter, Overheating 60 Display Communication Fault
E9 PS Controller, Overheating 61 Logic Card Initialize Failure
14 Traction Motor Current Sensor R.H. Fault 62 Logics Fault
15 Traction Motor R.H. Over-current 63 Traction Inverter R.H. Fault
16 Traction Motor R.H. Stall Timer 64 Traction Inverter L.H. Fault
24 Traction Motor Current Sensor L.H. Fault 65 Pump Inverter Fault
25 Traction Motor L.H. Over-current 67 Input Unit Fault
26 Traction Motor L.H. Stall Timer 68 Output Unit Fault
34 Pump Motor Current Sensor Fault 71 EPS Controller Fault
35 Pump Motor Over-current 72 Contactor Coil Fault
40 Line Contactor Fault 74 Hydraulic Lock Solenoid Fault
41 Steering Contactor Fault 75 Parking Brake Fault
45 Traction Motor R.H. Open 76 PDS Buzzer Fault
46 Traction Motor L.H. Open 78 Battery Voltage Too Low
47 Pump Motor Open 79 Battery Voltage Too High
49 EPS motor Open (Lo) Battery Consumption Too Much
50 Tire Angle Sensor Fault 80 Tilt Angle Sensor Fault
51 Accelerator Sensor Fault 81 Load Sensor Fault
52 Traction Motor R.H. Pulse Input Fault 82 Handle Sensor Fault
53 Traction Motor L.H. Pulse Input Fault A4 EPS motor Current Sensor Fault
54 FC Lever Fault A5 EPS motor Over-current
55 Output Unit Solenoid Fault A7 PS Handle Brake Fault
56 Output Unit Solenoid Current Leak A8 Battery side way exchange interlock
E FNR Lever or Accelerator, Faulty Setting None Battery Consumption Much
(E) Seat Switch, Faulty Setting For Traction None Brake Oil, Low Level
H1 Lift Lever, Faulty Setting None RTC Battery Low
2-22
5. Key Switch
2
1 3
1)
2)
3) ST IG
B
90°
603072
1. Key 1) OFF position

2. Key switch 2) ON position
3. Key harness 3) ON (START) position
6. Lighting Switch (Rear Work Lamp)
2)
1) 3)
603083
1) OFF position
2) ON position
3) ON position
2-23
6.1 Lamps
8 9
7
2
4 3
1 5
603074
1. Head lamp 6. Rear work lamp

2. Headguard harness 7. Rear lamp bracket
3. Grommet 8. Flange bolt
4. Blank plate 9. Grommet
5. Flange bolt
2-24
6.2 Specification Chart
Lamp Type External diagram 12V/48V Quantity Remarks

Head lamp Halogen lamp 48V 2
LED lamp - 2 Option
Rear work lamp Halogen lamp 48V 1
LED lamp - 1 Option
2-25
7. Horn Switch and Emergency Stop Switch
7.1 MC Model
Horn switch
Push the switch and the horn sounds.
2 1)
1
Emergency stop switch
- Pull the switch to release.
2)
- Push the switch to apply.
603078
1. Horn switch 1) Release

2. Emergency stop switch 2) Apply
(common with FC model)
7.2 FC Model
Horn switch
Push the switch and the horn sounds. 2 1)
1
Emergency stop switch
- Pull the switch to release.
- Push the switch to apply.
2)
603079
1. Horn switch 1) Release

2. Emergency stop switch 2) Apply
2-26
8. Troubleshooting of Lighting and Horn Systems
Complaint Possible cause Remedy

Lamps-general Will not light Dead or weak battery Recharge or replace.
Fuses blown out Check and replace.
Open or short in circuit Repair or replace.
Poor grounding Clean ground spot and re-make
connection.
Bulbs burnt out Replace.
Will light dimly Dead or weak battery Check and recharge.
Burned contact points in switches Repair or replace.
Loose terminals Retighten.
Dirty lenses Clean.
Waterdrops inside lenses Dry and replace packings.
Bulbs expired service life Replace.
Head lamps Will not light Lighting switch defective Replace.
Other lamps The lamp will not Lamp switch defective Correct if improperly installed : replace if
light internally defective.
Horn Will not give blast of Fuse blown out Check and replace.
sound
Open or short in circuit Repair or replace.
Horn or horn switch defective Replace or repair.
Will give ugly blast Horn switch defective Replace.
of sound
Horn defective Replace.
2-27
9. Parking Brake Switch
OFF ON
24.0° 24.0°
2)
1)
1 2 3 9 10
10
ON
OFF
9 2 3
1
603084
1) Release 2) Apply
2-28
10. Combination Switch
1 2
1) 4)
2) 1(( 5)
3) 6)
7) 8)
9)
500038
1. Direction lever 5) Neutral (N)

2. Light switch and turn signal switch 6) Right turn (R)
1) Forward (F) 7) Light switch OFF
2) Neutral (N) 8) Light switch 1
3) Reverse (R) 9) Light switch 2
4) Left turn (L)
2-29
10.1 Direction lever
F
N 1((
1 2 3 4 5
R F1
N
R1
4
2
5 1 3
603080
10.2 Light Switch and Turn Signal Switch
L
N
R
1 2 3
T-1 T-2 T-3 L-1 L-2 L-3

L 1
N 2
R 3
T-2 T-1
L-1 T-3
L-3 L-2
603081
1. OFF 3. Meter panel lamp Glows
2. Meter panel lamp Glows Tail lamps Glow
Tail lamps Glow Small lamps Glow
Small lamps Glow Front work lamps Glow
2-30
11. Disassembling Accelerator Control
11.1 Disassembling Sequence
2
3
5
8
4
603071
1. Spring 6. Plate, Lever

2. Link ball 7. Spring, Bushing, Shim washer, Shaft, Spacer
3. Truss screw, nut 8. Case
4. Potentiometer 9. Accelerator pedal
5. Bracket
2-31
11.2 Adjusting
1
1) 3
4
5
2)
4)
2
3)
6
603068
1. Accelerator pedal 6. Potentiometer

2. Floor plate 1) Released position
3. Truss screw 2) Pedal height
4. Jam nut 3) Rod length
5. Link ball 4) Truss screw length
Adjusting accelerator linkage

(1) Adjust the rod length to adjust the accelerator pedal
height at the released position.
Specified dimension when pedal is released

93 ± 5 mm
2) Pedal height
(3.661 ± 0.197 in.)
Approx. 158 mm
3) Rod length
(Approx. 6.220 in.)
2-32
(2) Turn the key switch to the off position.

(3) Unplug the connector of the potentiometer.
(4) Insert the adapter for easy adjustment, then connect
7
the potentiometer again.
(5) Turn the key switch to the on position.
(6) Apply DC 5 ± 0.5 V voltage between Red (+) and Black
(GND) .
(7) Measure the voltage at following sections. 8
- Between White (OUT 1) and Black (GND)
- Between Blue (OUT 2) and Black (GND) 1) 603069
(8) So that the voltage of both sections is 3.10 V or more,
adjust dimension 4) of the truss screw. 1. Blank 6. White (OUT 1)
2. Blue (OUT 2) 7. Potentiometer
3. Red (+) 8. Adapter
4. Green (Ground line) 1) To body harness
5. Black (GND)
Specified dimension
Approx. 27 mm
4) Truss screw length
(Approx. 1.063 in.)
Adjusting potentiometer
(1) Perform the step 2 to 7 in Accelerator linkage
adjustment procedure. 1 2
(2) So that the voltage of both sections is as follows, adjust
the mounting angle of the potentiometer by using the 3
flat head screw.
2)
39°
1) 603070
1. Lever 1) At lever rotated 39° position

2. Potentiometer 2) At pedal release position
3. Flat head screw
Specified voltage
1) At lever rotated 39° More than 3.20 V and
position less than 4.50 V
At pedal released
2) 0.85 ± 0.1 V
position
2-33
12. Joystick Box
This system, unlike the conventional mechanical control, is
4)
electronically actuated to reduce the effort required of the 2) 2
operator in moving the control levers forklift, tilt and 1 1)
attachment functions. 1)
5)
3)
603075
1. Tilt control lever 2) Backward

2. Lift control lever 3) Forward
1) Neutral 4) Raise
5) Lower
- This system provides the following safety functions:

(3) When the emergency switch is in the ON (pushed)
position, the lift, tilt and attachment functions will not
work even if the control levers are moved.
(4) When the seat switch is not ON (the operator is not
seated), the lift, tilt and attachments functions will not
work even if the control levers are moved.
(5) The error detection indicator R in the meter panel
alerts the operator to malfunctions involving the
electrical system and also an inoperable status. (If any
problem occurs in the lift system, for example, the
system becomes inoperative.)
13. Fuses
(1) 325A: LINE FUSE 1)
(2) 40A: PS FUSE (3)
(3) 10A: LAMP FUSE
(4) 10A: KEY-FUSE
2)
(1)
(4)
(2)
3)
501566
1) Contactor Assy 3) PS Contactor

2) Line Contactor
2-34
CHAPTER 3 POWER TRAIN
Chapter 3 POWER TRAIN
1. Removing Batteries
(1) Disconnect the battery plug.
(2) Open the battery cover, and lock it in the open position.
(3) Remove the side covers (L.H., R.H.) and front covers
(L.H., R.H.).
501140
(4) Attach suspending ropes or adequate lifting device to

the batteries.
501141
Item Value
Battery weight 865 kg (1907 lb)
To remove/install the battery, remove the battery retaining

pin.
501571
3-1
2. Removing Front Wheels
(1) Pull the parking brake switch and block the rear wheels.
(2) Loosen the wheel nuts by two turns. Then, raise the
front end of the truck using a hoist or the hydraulic
system.
- Hoisting
Using a sling and eye-bolts at both ends of the cross
member at the top of the outer mast, lift the front end
of the truck with a hoist.
501048
(3) Remove the wheel nuts.

(4) Remove the wheel.
Item 1 ton class 2 ton class

Tire size of
18 x 7-8 200/50-10
front wheels
3-2
3. Removing Transfer Assemblies, Traction Motors
2)
1)
A 1 1
501116
1. Frame 1) Motor mounting bolts, 3 places

2) Mounting bolt to the body, 6 places
(1) Remove the mast assembly. Refer to "MAST AND

FORKS."
(2) Remove all the electric wirings, solenoid brake cable,
and hydraulic lines connected to the motor and
transfer.
(3) Hitch a sling to lift the motor. Wind the sling to prevent
it from falling.
(4) Place a jack under the transfer, and support the transfer
with the jack.
(5) Loosen the bolts that secure the transfer to the frame,
and slightly pull the transfer with the jack away from
the frame.
After making sure that the transfer can be pulled out 501117
horizontally, remove the bolts that secure the transfer
to the frame, and remove the transfer with the jack
from the frame.
Item Value
Total weight of transfer, Traction
70 kg (154.3 lb)
motor
3-3
4. Installing Transfer Assemblies, Traction Motors and Calipers
Follow the removal sequence in reverse. For installation,
follow the instructions below.
R CAUTION
When mounting the transfer assembly on the frame, do not insert a finger into the bolt hole to check the hole alignment.
(1) Be sure to tighten bolts to the specified torque.
2
1
501118
Item Tightening torque

1 Traction motor mounting bolt 23.4 to 28.6 N·m (2.39 to 2.92 kgf·m) [17.3 to 21.1 lbf·ft]
2 Transfer assembly mounting bolt 135 to 165 N·m (13.8 to 16.8 kgf·m) [99.6 to 121.7 lbf·ft]
3 Hub nut 216 to 264 N·m (22.0 to 26.9 kgf·m) [159.3 to 194.7 lbf·ft]
(2) Bleed the brake oil line.

(Refer to BRAKE SYSTEM section.)
3-4
(3) Pour oil into the transfer cases:

Remove oil level plug.
Remove oil filler plug.
Pour appropriate oil from the oil inlet. Make sure the oil
fills up to the level plug.
Tighten the oil level and inlet plugs. 2
1
2
1)
1 501120
1. Oil level plug 1) Front of Vehicle

2. Oil filler plug
Item Value
Oil quantity 0.53 liter (0.14 U.S. gal.)
3-5
5. Service Data
Truck Models Specified value

23.4 to 28.6 N·m (2.39 to 2.92 kgf·m)
1 Traction motor mounting bolt
[17.3 to 21.1 lbf·ft]
135 to 165 N·m (13.8 to 16.8 kgf·m)
2 Transfer assembly mounting bolt Tightening torque
[99.6 to 121.7 lbf·ft]
216 to 264 N·m (22.0 to 26.9 kgf·m)
3 Hub nut
[159.3 to 194.7 lbf·ft]
2
1
501118
3-6
CHAPTER 4 TRANSFER UNITS
Chapter 4 TRANSFER UNITS
1. Specifications
Item Specification
Constant-mesh type, 2 stages (helical gears)
Gear type
Epicyclic Gear
Reducing gear ratio 4.778 X 5.571 = 26.62
2. Structure
2.1 External View
7 1) 2 4 1) 7
1 3
5
5
500885
1. Transfer (left) 5. Frames

2. Traction motor (left) 6. Wheel hubs
3. Transfer (right) 7. Front tires
4. Traction motor (right) 1) Mast support mounting sections
4-1
2.2 Structure
13 14 11 10 9 18 17 15 16
20 19
12 4 3 6
1 21
2 1
500887
1. Traction motor 12. Output carrier

2. Main case 13. Wheel hub
3. Input gear 14. Cover
4. 2nd gear 15. Brake lever
5. Friction plate 16. Adjusting bolt
6. Mating plate 17. Air bleeder
7. Plate 18. Bleeder screw
8. Pin 19. Breather
9. Sun gear 20. Plug (oil filler port)
10. Planetary gear 21. Plug (oil level)
11. Planetary pin
The right and left transfers are coupled to the traction In the service brake system, the mating plate and friction
motors. plate are brought into contact with each other to brake by
actuating the brake lever to compress the plates through
The driving force of the traction motor is transmitted to the
the pin.
wheels through the second gear, planetary gear and output
carrier.
The output shaft is equipped with two tapered roller
bearings so that it can withstand heavy loads.
Item Value
Transfer reducing gear ratio 26.62
4-2
3. Disassembling Transfer Units
3.1 Preparation
(1) Remove the mast assembly. (For removal of mast, see Chapter 9, MAST AND FORKS.)
(2) Remove the front wheels. (For removal of front wheels, see Chapter 3, POWER TRAIN.)
3.2 Disassembly Sequence
60
5957
58
8 10 56 7
43
9
16 1
2
1213 A
11 52
14 17 51
15 52
51
52
A 55 51
27 4 54 52
5 6 3
34 53 35
52 4544
53 37
52 35 3839
33
28 50 3637
49 38
32 48
47
30 46
19 25 35
18 24 36
23 37
22 38
21 39
20 42
29 41
31
40
26
500888
4-3
1. Plug (oil filler) 30. Cover
2. O-ring 31. Oil seal
3. Drain plug 32. Tapered roller bearing (outer race)
4. O-ring 33. Tapered roller bearing (outer race)
5. Plug (oil level) 34. Needle bearing
6. O-ring 35. Snap ring
7. Breather 36. Plate
8. Split pin 37. Planetary gears
9. Clevis pin 38. Needle bearings
10. Bushing 39. Thrust washers
11. Brake lever 40. Output carrier assembly
12. Adjusting bolt 41. Output carrier
13. Nut 42. Planetary pin
14. Bolt 43. Main case
15. Brake cylinder assembly 44. Thrust washer
16. Pin 45. Thrust bearing
17. O-ring 46. Sun gear
18. Bolt 47. 2nd gear
19. Bolt 48. Ball bearing
20. Hub cap 49. Bolt
21. Bolt 50. Brake cover
22. Lock plate 51. Friction plates
23. Lock nut 52. Disc springs
24. Washer 53. Mating plates
25. O-ring 54. Plate
26. Wheel hub 55. Pin
27. Tapered roller bearing (inner race) 56. Input gear
28. Tapered roller bearing (inner race) 57. Input plate
29. Oil seal retainer 58. Ball bearing
59. Snap ring
60. Snap ring
4-4
Suggestions for Disassembly
(1) Remove the motor and transfer as one unit from the
body. (Mounting bolt: 6 places)
Separate the motor from the transfer. (Mounting bolt: 3 1) 2)
places)
500889
1) Mounting bolt, 6 places 2) Motor mounting bolt, 3 places
(2) Remove the oil filler plug and drain plug to drain oil.
Remove the breather.
1
3
2 500890
1. Breather 3. Oil level plug

2. Oil filler plug 4. Drain plug
(3) Remove the brake related parts.

Note: The right and left brake cylinders are similar. Do not
confuse the right and left cylinders.
500891
Note: There is difference in position of bleeder and port

between right and left.
1 1
2 2
1) 2) 501195
1. Bleeder 1) Brake cylinder left side

2. Port 2) Brake cylinder right side
4-5
(4) Place the transfer assembly on square wood blocks

with the motor side facing downward.
500892
(5) Remove the cover assembly, output carrier assembly

and wheel hub assembly from the main case assembly.
Loosen the bolts, and remove the cover assembly from
the main case by tapping around the cover with a
plastic hammer.
If it is difficult to remove, tap the main case while
suspending it with the crane.
500893
(6) While tapping lightly around the hub cap with a plastic
hammer, remove the hub cap from the wheel hub.
Remove the bolts, lock plate, lock nut, washer and O-
ring.
500895
(7) Remove the output carrier assembly from the cover

assembly.
(8)
(9) Remove the bearing while tapping around the wheel
hub with a plastic hammer.
Remove the oil seal retainer and tapered bearing inner
race using a puller.
500898
4-6
(10) Remove the snap ring, and remove the plate, planetary
gear, needle bearing and thrust washer from the
output carrier assembly.
500899
(11) Remove the thrust washer, thrust bearing and sun gear,
2nd gear (ball bearing).
500901
(12) Remove the brake cover from the main case using a
jack bolt (M6).
500902
Note: Remove the mating plates, disc springs, friction plates

and plate.
Be careful not to drop or lose the disc springs.
500903
4-7
(13) Remove the snap ring 1) from the main case.
Remove the input gear assembly from the main case.
Remove the snap ring 2), input plate and ball bearing
from the input gear.
2)
1) 500904
1) Snap ring 1) Snap ring
4-8
4. Inspecting Transfer Units
(1) Check the gear teeth and splines for damage and wear.
(2) Check the bearing for damage, wear, rotational
resistance and abnormal noise.
(3) Check the main case and cover for cracks and other
damage.
(4) Check the oil seal and retainer for damage on the
contact face.
(5) Replace the oil seal and O-ring with new ones if
damage is found during removal.
(6) Checking friction and mating plates
- Check the friction plate for seizure, local contact,
deflection, or other damage. 500905
- Check the mating plate for heat spots (scattered black
burn spots).
- Check the inner teeth for wear and damage.
- Measure the thickness of each plate.
Note: If any of above is found in any one of plates, replace all
of the plates.
Item Standard Limit

2.6 ± 0.1 mm 2.3 mm
Friction plate
(0.102 ± 0.004 in.) (0.0906 in.)
2 ± 0.1 mm 1.8 mm
Mating plate
(0.08 ± 0.004 in.) (0.0709 in.)
4-9
5. Reassembling Transfer Units
5.1 Reassembly Sequence
1 9 11 10 12 13 40 24 19 58
6 5 3 30 2
7
51
8
53
31
54 52
55
37 56
20
21
22
36
23
35 34 33 32 39 38 28 26 25
16
17
18
27 4 2914 15 41 59
44, 45 42, 43
49
57
46, 47
50
48 500906
4-10
1. Cover 31. Output carrier
2. Tapered roller bearing (outer race) 32. O-ring
3. Tapered roller bearing (outer race) 33. Washer
4. Needle bearing 34. Lock nut
5. Oil seal 35. Lock plate
6. Wheel hub 36. Bolt
7. Oil seal retainer 37. Hub cap
8. Tapered roller bearing (inner race) 38. Thrust bearing
9. Thrust washer 39. Thrust washer
10. Needle bearing 40. Sun gear
11. Planetary gear 41. Main case
12. Plate 42. Level plug
13. Snap ring 43. O-ring
14. Input gear 44. Filler plug
15. Ball bearing 45. O-ring
16. Input plate 46. Drain plug
17. Snap ring 47. O-ring
18. Snap ring 48. Breather
19. Pin (for brake) 49. Bolt
20. Pin 50. Bolt
21. O-ring 51. Brake lever
22. Plate 52. Nut
23. Friction plate 53. Adjusting bolt
24. Disc spring 54. Bushing
25. Mating plate 55. Clevis pin
26. Brake cover 56. Split pin
27. Bolt 57. Bolt
28. Ball bearing 58. Brake cylinder assembly
29. 2nd gear (Air bleeder, bleeder screw, spring, piston, seal,
housing, pin and cover)
30. Tapered roller bearing (inner race)
59. Traction motor
Note: Do not confuse the mounting position, orientation, and number of the disc springs.
If misassembled, it could cause a premature wear of friction plates and brake force decrease.
4-11
Assembling procedure
(1) Cover related parts, assembling
- Install the tapered roller bearing outer races to the
cover.
- Install the oil seal.
- Install the needle bearing for input gear by tapping it.
(To install the bearing, use a jig appropriate for the
diameter of bearing and hold the jig against the
bearing and tap the jig with a hammer.
Note: Apply to grease (lithium soap base, consistency NLGI
No. 2) the oil seal lip.
500907
(2) Wheel hub related parts, assembling

- Install the oil seal retainer while applying liquid packing
to the contact surface with the wheel hub.
- Install the tapered roller bearing inner race.
500908
(3) Output carrier related parts, assembling

(Assembling planetary gear)
- Insert the planetary pin to the thrust washer, and install
the needle bearing and then the planet gear. Lastly,
install the plate and snap ring.
500899
4-12
(4) Main case related parts, assembling

- Install the main case dowel pin and the pin for brake.
- Install oil level plug, O-ring, oil filler plug, O-ring, drain
plug, O-ring and breather.
- Insert the input plate, and fit the snap ring into the
input gear.
- Install the ball bearing to the input gear.
Note:
- The one side of ball bearing has shield. Face the shield 1
side to the motor mounting side.
- Cover the input gear motor mounting holes (82 mm
1)
(3.23 in.)) to prevent dust from entering.
500910
1. Shield 1) Shielded area
- Install the input gear assembly to the main case by

tapping the ball bearing.
1 2 3
- Install the plate, disc spring, friction plate and then
mating plate.
4 500911
1. Disc spring 3. Plate

2. Mating plate 4. Friction plate
Tool Part number

Brake installer 97967-00200
Note: To install the disc springs, orient then it as shown in

the figure. (4 pcs/set x 6 sets = 24 pcs/unit)
- Install the brake cover and secure it with bolts.
- Install the ball bearing into the 2nd gear and install it on
the brake cover.
- Remove the brake installer and install the sun gear.
While applying grease, install the thrust washer and 1
thrust bearing to the sun gear.
501196
1. Brake installer
4-13
(5) Output carrier, cover and wheel hub assemblies,

assembling
- Install the wheel hub assembly and tapered roller
bearing.
- Install the cover assembly to the output carrier
assembly.
- Install the O-ring and washer to the output carrier and
secure it with look nut by hand.
500912
(6) Adjusting preload

Make sure that the wheel hub assembly have a 1 to 2
mm play in axial direction after tightening the lock nut
by hand.
- Check for dragging by moving each part.
- Tighten the lock nut from the above loosened
condition to the hub rotary torque plus 1.0 to 3.0 N·m
(0.1 to 0.3 kgf·m) [0.74 to 2.21 lbf·ft]
- Install the lock plate and secure it with bolts. Install the
hub cap.
500913
Hub rotary torque

Hub rotary torque when the lock nut is loosened plus 1.0 to
3.0 N·m (0.1 to 0.3 kgf·m) [0.74 to 2.21 lbf·ft]
- Install the lock plate to the lock nut and tighten with
bolt.
Install the hub cap to the wheel hub. 1)
(7) Overall assembly 2)
- Apply liquid packing to the contact area between the
main case and the cover.
- Install the cover assembly to the case assembly.
- Secure the assembly to the main case with the bolts.
Tighten the bolts to the specified torque.
Note:
- Fit together by moving the sun gear and the planetary 500914
gear.
- Insert a bar into the bolt hole as a guide for easy
assembling.
Ref. Item Tightening torque

200.3 ± 20.0 N·m
1) Bolt (20.42 ± 2.04 kgf·m)
[147.73 ± 14.75 lbf·ft]
13.7 ± 1.4 N·m
2) Bolt (1.40 ± 0.14 kgf·m)
[10.10 ± 1.03 lbf·ft]
4-14
(8) Brake related parts, assembling

- Keep the transfer assembly lying on its side and install it
to the brake assembly. (Right and left differ in shape.) 12
- Insert the pin and O-ring, and while holding the brake
lever with the pin, secure the clevis pin and split pin.
- Loosen the nut. 1)
- Move the brake lever to the arrow direction 1) by hand
to bring the brake plates in close contact with each
other. (Required force: approx. 98 N (10 kgf) [22.03 lbf]) 2)
- Tighten the adjusting bolt unit it comes into contact
with the case by hand. 500915
- Tighten the nut by hand.
1. Nut 2. Adjusting bolt
- If the dimension 2) is 8 mm (0.32 in.) or less, replace,
friction plates.
- From the above position, loosen the adjusting bolt one
turn.
- Tighten the nut to secure the adjusting bolt in that
position.
(Tightening torque: 6.9 ± 1.4 N·m
(0.7 ± 0.14 kgf·m) [5.09 ± 1.03 lbf·ft])
Dimension 2)
8 mm (0.32 in.)
(9) Installing the motor

- Remove the cover from the input gear motor mounting
holes (82 mm (3.23 in.)), which provided to prevent dust
from entering, and install the motor to the transfer.
(Refer to the POWER TRAIN.) 3
- Install the transfer unit to the frame.
- Make sure the transfer drain plug is tightened securely,
and then remove the oil filler plug and oil level plug.
- Add oil from the oil filler port until oil flows out of the oil
level port. (Oil capacity: 0.53 L (0.14 U.S. gal.)) 2
- Check joints for oil leaks. 1 500916
Note: Use only approved oil.
1. Oil filler plug 3. Drain plug
2. Oil level plug
4-15
6. Service Data
Ref. Item Specified value

Hub rotary torque when the lock nut is
1 Preload of tapered roller bearing Hub rotary torque loosened plus 1.0 to 3.0 N·m
(0.1 to 0.3 kgf·m) [0.74 to 2.21 lbf·ft]
200.3± 20.0 N·m
2 Cover mounting bolt Tightening torque (20.42 ±2.04 kgf·ft)
[147.73 ± 14.75 lbf·ft]
13.7± 1.4 N·m
3 Cover mounting bolt Tightening torque (1.40 ±0.14 kgf·ft)
[10.10 ± 1.03 lbf·ft]
500917
4-16
CHAPTER 5 REAR AXLE
Chapter 5 REAR AXLE
1. Structure
1.1 Rear Axle
10 1 6 10
6 9
3
2
3
5
1) 3
4 2)
11
501005
1. Rear axle 8. Wheel hubs

2. Steering cylinder 9. Hydraulic oil pipes
3. Tie rods 10. Rear wheels
4. Knuckles 11. Steering sensor assembly
5. Kingpins 1) Steering cylinder rod
6. Stopper bolts 2) Knuckle
7. Pins
5-1
CHAPTER 5 REAR AXLE
1.2 Steering Cylinder
12 8 4 9
10
6 7 5 8 11
13 1 2
4 3
501008
1. Cylinder tube 8. Snap ring
2. Piston rod 9. O-rings
3. Piston 10. Guide rings
4. Cylinder head 11. Piston seals (inner, outer)
5. Bushing 12. Spherical bearing
6. Wiper 13. Tie rod
7. U-seal
5-2
CHAPTER 5 REAR AXLE
2. Removing Rear Wheels
2.1 Preparation
(1) Park the truck on level ground.

(2) Lower the forks until the fork tips touch the floor.
(3) Apply the parking brake.
(4) Place the direction lever in the NEUTRAL position.
(5) Turn the key switch off position.
(6) Prepare tools, jack and wheel blocks.
(7) Block the wheel diagonally opposite to a raised wheel.
501518
Jack capacity
3 tons (6700 lbf), minimum
2.2 Removing Wheels
(1) Loosen the wheel nuts about two rotations.

(2) Position the jack under the truck at the specified
1
jacking point.
501519
1. Wheel nut
Note: Only loosen the wheel nuts. Do not remove them.
(3) Raise the lift truck by operating the jack until the tire
just clears the ground. 1
(4) Remove the wheel nuts (loosened in step 1).
2
(5) Firmly hold the wheel with both hands and remove it
from the truck.
501520
1. Wheel nut 2. Countersink
5-3
CHAPTER 5 REAR AXLE
(6) Position the jack under the counterweight at the

recessed point and raise the rear wheel.
(7) Place the jack stand under the frame to support it.
501521
R CAUTION
Be careful NOT to strip the bolt threads when removing the
wheel.
501522
5-4
CHAPTER 5 REAR AXLE
3. Installing Rear Wheel
(1) Install the wheel and tighten the wheel nuts finger tight
until their clamping surfaces come into full-face contact
with the counter bores in the rim. 1
4 3
2 5
501523
Note: Make sure the clamping surfaces of the wheel nuts and countersinks are free of dirt.
(2) Lower the forklift truck by operating the jack until the
tire just touches the ground. Then tighten the wheel
nuts in the sequence shown, in two or three steps, to
the specified torque.
(3) Lower the forklift truck fully and restore the jack and
tire.
(4) Make sure the tire pressure is correct.
(5) After tire replacement, drive the forklift truck for a while
and then recheck the torque of the wheel nuts.
(6) Lower the lift truck by operating the jack until the tire
just touches the ground. Then tighten the wheel nuts in
the sequence shown, in two or three steps, to the
specified torque.
(7) Lower the lift truck fully and restore the jack and tire.
(8) Make sure the tire pressure is correct.
(9) After tire replacement, drive the lift truck for a while
and then recheck the torque of the wheel nuts.
Tightening torques for wheel nuts
Torque
156.9±15.7 N·m (16 ± 1.6 kgf·m)[115.7 ± 11.6 lbf·ft)
5-5
CHAPTER 5 REAR AXLE
4. Removing Rear Axle Assembly
(With the steering cylinder and wheel hubs attached)
Remove the rear wheels before removing the rear axle.
Refer to “Removing Rear Wheels” as mentioned before. Be
sure to follow the preparation and follow the suggestions
for removal.
4.1 Preparation
(1) After removing the rear tires, lift the truck

approximately 500 mm (19.69 in.) from the ground.
Remove the jack stands under the rear axle, and insert a
carriage.
Insert the carriage so that the rear axle can be removed
to the side.
(2) Place wood blocks under the counter weight on both
sides.
501013
4.2 Removal Sequence
1
3
5 2
4
5
3
501006
1. Steering hose 4. Rear axle assembly

2. Steering sensor connector 5. Thrust washer
3. Rear axle supports
5-6
CHAPTER 5 REAR AXLE
4.3 Suggestions for Removal
(1) Remove the steering hose. Put a plug on the removed

hose to prevent oil leakage.
Plug: 05530-30300 (G 3/8)
(2) Remove the connector of sensor.
Do not touch the sensor connector pin.
The function of sensor may be destructed by static
electricity.
(3) Before removing the rear axle support bolt, pry the rear
axle assembly with a bar, and measure the front and
rear clearances. If the total value is 0.8 mm (0.03 in.) or
more, insert thrust washers to adjust the clearances
when installing the bolt.
(4) After removing the rear axle support bolt, remove the
rear axle assembly to the side square to the vehicle
R CAUTION
The rear axle must be removed from the vehicle body while being supported with a jack.
Since the contact surfaces between the rear axle and jack are both steel, and the frictional force generating between them is
small.
Put a piece of nonslip material such as rubber sheet between the contact surfaces to avoid the rear axle slipping off the jack.
Perform the procedure with the utmost care.
5-7
CHAPTER 5 REAR AXLE
5. Installing Rear Axle Assembly
Follow the removal sequence in reverse. Carry out the
following procedures.
Adjusting bearing support clearances
Adjust the front and rear clearances by using thrust washers

so that the total clearance becomes 0.8 mm (0.03 in.) or less.
Note: Insert thrust washers evenly.
501014
Item Value
0.8 mm (0.031 in.)
Thrust washer type
2.0 mm (0.079 in.)
Removing support bushing
Do not remove the bushing in the support unless it is

necessary.
If not, replace the bushing together with the support
assembly, or break and remove the bushing.
Assemble a new bushing so that the match mark faces
downward.
1 501015
1. Bushing joint
5-8
CHAPTER 5 REAR AXLE
6. Disassembling Rear Axle Assembly
1) 24 25 27 1)
26
13
28
15
21
22 18 9 6 29
17
4
3
14 2
30
1
11 10 10
5
23
23
7 8
19
16 12 13
20 501007
5-9
CHAPTER 5 REAR AXLE
1. Cap 16. Shim
2. Bolt 17. Thrust bearing
3. Lock plate 18. Knuckle
4. Lock nut 19. Oil seal
5. Bearing (inner race) 20. Needle bearing
- Remove parts 6 through 8 as an assembly. 21. Oil seal
6. Hub 22. Needle bearing
7. Oil seal 23. Snap ring, Tie rod bushing assembly, Oil seal, Steel ball
8. Bearings (outer race) 24. Bolt, Spring washer
9. Oil seal retainer and Bearing (inner) 25. Pipe, Elbow, O-ring
10. Bolts, Spring washers, Plain washers, Spacers, Tie rod 26. Elbow, O-ring
pins, Grease nipples 27. Bolt, Spacer, spring washer, Nut
11. Dust seal, Retainer 28. Steering cylinder
12. Dust seal, Retainer 29. Bolt
13. Tie rod 30. Steering sensor assembly
14. Stopper bolt, Lock nut
15. Kingpin
(1) Remove the cap from hub.

Remove the bolt, lock plate, lock nut, and bearing
(inner race) from the knuckle.
(2) Removing the Oil seal retainer and inner bearing. Use
puller to remove the retainer and inner bearing from
the knuckle.
(3) Do not remove the taper roller bearings (outer race)
that are pressed into hub unless it is necessary.
(4) Inspect the snap rings and tie rod bushings, and do not
remove unless it is necessary.
(5) Keep removed shims in a packed condition (as
assembled). This facilitates the determination of the
optimum shim thickness at reassembly. 501016
1
2
3
4
501017
1. Steering cylinder 3. Tie rod bushing

2. Knuckle 4. Snap ring
5-10
CHAPTER 5 REAR AXLE
7. Inspection Rear Axle Assembly
Tie rods and pins Needle bearings and thrust bearings

- Make sure that the pins are free of any surface flaws Examine the bearings for damage, seizure, flaking, defective
such as grooving or stepped wear. Examine the tie rod rotation and noise. Replace if defective.
pin weld for cracking.
Knuckles and hub
- Examine the bearings for wear or damage.
Inspect the inside of each knuckle for wear or damage. Be
- Examine the tie rods for damage and alignment.
sure to examine for casting cracks. Check the tie rod pin
Inspect the welds for signs of cracks.
bearing. Examine the wheel nut threads for damage.
Note: If a pin must be replaced, replace its spherical bearing
or bushing as well. Hydraulic pipes
Inspect the hydraulic pipes for cracks, especially at the joints
Kingpins
with the end fittings. Check for leaks.
Check the kingpins for any surface flaws such as grooving or
stepped wear. Inspect the pins for cracks at the bearing Cylinder rod
shoulder. Examine the rod for surface or plating damage. Inspect the
rod for straightness. Examine the piston for damage. Check
Kingpin bearings and hub bearings
the tie rod pin hole (spherical bearing) for damage or wear.
Examine the rollers and bearing races for grooving, abrasive
wear, pitting, bruising, or corrosion. Replace both the outer
and inner races of the damaged bearing.
10
3
4
8 9
11
1 2
5
6 501263
1. Tie rod 7. Thrust bearing

2. Tie rod pin 8. Knuckle
3. Kingpin 9. Hub
4. Kingpin bearing 10. Hydraulic pipe
5. Hub bearing 11. Cylinder rod
6. Needle bearing
5-11
CHAPTER 5 REAR AXLE
8. Installing Steering Cylinder and Hydraulic Pipe
8.1 Installation Sequence
2
5 8 7
1
6 3
4
1)
501018
1. Rear axle 5. O-ring, Elbow
2. Grease nipple 6. O-ring, Elbow
3. Steering cylinder 7. Hydraulic pipe
4. Bolt, Spring washer, Nut 8. Bolt, Spring washer
Ref. Tightening torque

176 ± 10 N·m
1) (17.9 ± 1.0 kgf·m)
[130 ± 7.4 lbf·ft]
5-12
CHAPTER 5 REAR AXLE
9. Assembling Knuckle and Kingpin
9.1 Assembly Sequence
17 17
14
12
10
2 8
1 11
1) 13 16 15
18 18
6
9 5 4)
3)
4
3
2)
7
501019
1. Needle bearing 12. Oil seal

Length: 30 mm (1.18 in.) 13. Retainer, Dust seal
2. Oil seal 14. Tie rod
3. Needle bearing 15. Pin (knuckle side)
Length: 33 mm (1.3 in.)
16. Pin (cylinder side)
4. Oil seal
17. Spacers, Plain washers, Lock washers, Bolts
5. Knuckle
18. Grease nipples
6. Thrust bearing
1) Upper boss
7. Shim
2) Lower boss
8. Kingpin
3) Clearance: 0.3 mm (0.01 in.) or less
9. Stopper bolt, Lock nut
4) Parts of the rod
10. Tie rod bushing
11. Snap ring
5-13
CHAPTER 5 REAR AXLE
9.2 Suggestions for Reassembly
(1) Use the installer to insert and press fit the needle
bearing into the kingpin bore in the rear axle upper
boss from outside.
(2) Use the installer to insert and press fit the oil seal into 2
the kingpin bore with the lip positioned as shown in the 3
illustration.
501020
1. needle bearing 3. Upper boss

2. oil seal
(3) Use the special tool to insert and press-fit the needle
bearing into the kingpin bore in the rear axle lower 2
boss from outside. 3
(4) Use the special tool to insert and press fit the oil seal
into the kingpin bore with the lip positioned as shown
in the illustration.
501021
1. needle bearing 3. Lower boss

2. oil seal
(5) Temporarily install the bearing and knuckle in the rear

axle body and measure the clearance The clearance
must be 0.3 mm (0.01 in.) or less for both the right and
left sides of the axle. If the clearance exceeds the
specification, adjust it with the shim. The shim is
available in two thicknesses: 0.6 mm (0.02 in.) and 0.2
mm (0.008 in.).
(6) Grease the roller surfaces of each needle bearing, oil
seal lip surface, and periphery of both kingpin ends,
and then insert the kingpin from under the rear axle.
(7) Visually check the alignment of the stopper bolt hole in
the knuckle and the locking hole in the kingpin, then
lock the kingpin in the knuckle holding the stopper bolt
and nut.
(8) Install the grease nipples, fill grease in the kingpin and
bearings through the grease nipples.
5-14
CHAPTER 5 REAR AXLE
Tie rod
Replace the dust seals with new ones. Install the pins and
link the knuckle to the steering cylinder through the tie rod.
Fill in grease through grease nipples.
1
2 3
501021
1. Dust seals 3. Grease nipple

2. Grease nipple (Knuckle side)
(Cylinder side)
5-15
CHAPTER 5 REAR AXLE
10. Assembling Rear Axle Hub
10.1 Assembly Sequence
1 2 3
9
10
11
12
7
6 4 5
501023
1. Oil seal retainer 7. Wheel bolt
2. Bearing (inner) 8. Bearing (inner)
- Assemble parts 3 to 7 prior to final assembly. 9. Lock nut
3. Hub 10. Lock plate
4. Bearing (outer) 11. Bolt
5. Bearing (outer) 12. Cap
6. Oil seal
5-16
CHAPTER 5 REAR AXLE
(1) Install the oil seal retainer as shown in the illustrated

direction.
(2) Install the bearing (outer).
501024
(3) Tapping with hammer, fit the wheel bolt into the hub
bolt hole.
(4) Using the installer, press fit the bearing (outer) to the
new hub.
(5) Using the installer, press fit the oil seal to the hub.
(6) Pack grease into the rear axle hubs. See the illustration
for proper grease filling condition. Apply grease to the 1)
bearing cage. Fill grease to approximately 80 % of the
cavity. Do not supply grease to the full level. Filling
grease to the maximum level causes excessive heat
generation and quickly deteriorates the grease. When
coating oil seal lips with grease, be careful not to apply
too much grease, as an excessive amount of grease can
cause leaks.
501025
1) Fill “AUTOLEX A” grease.
5-17
CHAPTER 5 REAR AXLE
Adjusting procedure of wheel bearing reassembly
(1) Apply oil or grease to the contact surface of the lock nut
with the bearing.
1) 2)
(2) Turn the hub by hand and tighten the lock nut until the
turn becomes difficult. Then, loosen the lock nut by
approx. 60 degrees from the position. 5)
(3) Turn the hub back and forth two to three times in the
above condition to settle the inner and outer races of
the bearing.
(4) Turn the hub by hand again and tighten the lock nut
until the turn becomes heavy.
3)
(5) Insert the tab of the lock plate aligning with the knuckle
groove and gradually loosen the lock nut until a hole
position of the lock plate aligns with the screw position 4) 501026
of the lock nut. Then, secure the lock nut and lock plate
with two bolts. 1) Lock plate shape 3) Thickness of 3.2 mm (0.126 in.)
Note: Reverse the lock plate to changes the hole position. 2) Diameter of 6.5 mm (0.256 in.) 4) 17°
Equally spaced 5) Tab
(See the illustration on the right.)
(6) Turn the hub back and forth two to three times and
make sure that the tangential force or hub bolt to start
rotation is within the range shown below. If out of the
range, readjust. In case of a long-used bearing, aim a
low value of the allowance.
Item Value
0.5 to 5 N·m
Preload of hub bearing
(0.05 to 0.51 kgf·m)
(Torque)
[0.37 to 3.69 lbf·ft]
6.7 to 67 N
Tangential force on hub
(0.7 to 6.8 kgf)
bolt
[1.5 to 15.1 lbf]
5-18
CHAPTER 5 REAR AXLE
11. Removing Steering Sensor
(1) Remove the bolts.
1 501264
1. Bolts
(2) Remove the Steering sensor assembly.

1)
501265
Ref. Tightening torque

1.57 to 2.35 N·m
1) (0.16 to 0.24 kgf·m)
[1.16 to 1.73 lbf·ft]
12. Installing Steering Sensor Assembly

Do not touch the sensor connector pin.
The function of sensor may be destructed by static
electricity.
5-19
CHAPTER 5 REAR AXLE
13. Disassembling Steering Cylinder
6
13 12 2 4
10
7 5 611
8 9 2
11
501027
1. Nut, Washer, Tie rod 8. Cylinder tube
2. Cylinder heads, Wiper seal, U-seal, Bushing, Snap ring, 9. Piston rod and Piston
O-rings 10. Guide rings
3. Snap ring 11. Piston seal
4. O-rings 12. Ring
5. Bushing 13. Spherical bearing
6. U-seal
7. Wiper seal
Note: Do not remove bearing from piston rod if not

necessary.
5-20
CHAPTER 5 REAR AXLE
Mark cylinder heads

Mark the cylinder heads for correct reassembly before they 1)
are disassembled from the cylinder.
1)
501028
1) Mark
14. Inspecting Steering Cylinder
Cylinder tube
- Check the bore surface for wear, scuffs, scratches or
rust.
- Check the welds for cracks.
Piston rod
- Check the rod surface for rust, scratches or dents.
Ref. Item Standard Limit

Inside diameter of 63.0 mm 63.15 mm
1
cylinder tube (2.480 in.) (2.486 in.)
Diameter of piston 40 mm
2 -
rod (1.57 in.)
2 1
501029
5-21
CHAPTER 5 REAR AXLE
15. Reassembling Steering Cylinder
* *
14 15 4 10 9 *
*
3 3
* * 5 6 *
8 7 2
4 11 13 12
1
501030
1. Piston rod and Piston 9. O-ring *
2. Piston seal * 10. O-ring *
3. Guide rings * 11. Cylinder tube
4. Cylinder head 12. Tie rod
5. Bushing 13. Nut, Washer
6. Snap ring 14. Spherical bearing
7. U-seal * 15. Ring
8. Wiper seal *
Note: * Parts with * mark are included in the repair kit.
5-22
CHAPTER 5 REAR AXLE
(1) Replace the repair kit parts shown in the above figure
when assembling.
(2) Clean the parts completely before assembling, and
make sure that no dust is on them.
(3) Apply oil to the piston seal, O-ring, wiper seal and inside
the cylinder before assembling.
(4) Procedure for installing piston seal

(Piston seal consists of inner seal and outer seal)
- Grip the inner piston seal lightly by hand five or six
times to soften the seal before installation.
- Place the piston rod in a vise. Use care not to damage
the rod when holding it. Slightly apply oil on the inner
piston seal. Insert one side of the seal into the fitting
groove of the piston, and insert the other side.
- After installing the inner piston seal, install the outer
piston seal.
501031
(5) Assemble the U-seal and wiper seal as shown.
2 1 501032
1. U-seal 2. Wiper seal
(6) Align marks on the cylinder head to marks on the

cylinder tube. Tighten nuts.
1)
1)
501028
1) Mark

21 ± 2 N·m
Tightening torque of nuts (2.1 ± 0.2 kgf·m)
[15.5 ± 1.5 lbf·ft]
5-23
CHAPTER 5 REAR AXLE
16. Adjustment
16.1 Adjusting of Steering Sensor
Place the screw hole near the center of the slot.

Turn the steering wheel and check that the wheel turning 2
angle as specified.
1
501035
1. Screw hole 2. Slot
16.2 Adjusting of Minimum Turning Radius
(1) Measure the turn angle of the rear wheel by using a

turning radius gauge.
(2) If the turning angle is out of the specified range, adjust 1
the angle by the stopper bolt. 2
501033
1. Stopper bolt 2. Lock nut

(left and right)
Item Value
Turning Inward 80°40’

angle Outward 60°
66.7 ± 6.67 N·m
Tightening torque of
(6.8 ± 0.68 kgf·m)
stopper bolt nut
[49.2 ± 4.92 lbf·ft]
(3) While driving the vehicle at low speed, turn the steering
wheel fully in both directions, and check the diameter
of the tire tracks at the outside of the rear wheel in both
turning operations.
5-24
CHAPTER 5 REAR AXLE
(4) Minimum turning radius R is obtained from half of the

turning diameter plus the length from the center of the
rear tire to the outside edge of the counterweight.
501034
Truck Model Minimum turning radius

Standard type 2015 mm (79.3 in.)
Compact type 1900 mm (74.8 in.)
5-25
CHAPTER 5 REAR AXLE
17. Troubleshooting
Situation Possible causes Action

Insufficient grease in rear axle Add grease.
Heavy steering wheel operation Refer to STEERING SYSTEM,
Faulty steering system
troubleshooting section.
Wear or breakage of taper roller
Replace the bearing.
bearing
Wobbling of rear tire
Refer to STEERING SYSTEM, and inspect
Faulty steering system
or repair.
Different tire types of right and left
Replace with genuine tires.
Uneven or early wear of rear tires wheels
Excessive wheel turning angle Adjust with the stopper bolt
5-26
CHAPTER 5 REAR AXLE
18. Service Data
18.1 Rear axle

1) Toe-in Standard value 0°
2) Caster Standard value 0°
3) Camber Standard value 0°
4) Inward Standard value 84°40’
Steering angle
5) Outward Standard value 60°
0.5 to 5.0 N
Tangential force at hub bearing
1 Standard value (0.05 to 0.51 kgf)
(Increase from preload)
[0.11 to 1.12 lbf]
Standard value 0.8 mm (0.03 in.) or less
2 Front and back clearance for center pin
Limit 1.2 mm (0.047 in.)
176 ± 10 N·m
3 Tightening torque of steering cylinder bolt Standard value (17.9 ± 1.0 kgf·m)
[130 ± 7.4 lbf·ft]
66.7 ± 6.67 N·m
4 Tightening torque of stopper bolt nut Standard value (6.8 ± 0.68 kgf·m)
[49.2 ± 4.92 lbf·ft]
5 Allowable tread groove depth (wear limit) 5 mm (0.2 in.)
1 5
3
2
501036
1) 2) 3) 4) 5)
501184
5-27
CHAPTER 5 REAR AXLE
18.2 Steering cylinder

Standard 63.0 mm (2.480 in.)
1 Inside diameter of cylinder tube
Limit 63.15 mm (2.486 in.)
2 Diameter of piston rod Standard 40 mm (1.57 in.)
21 ± 2 N·m
3 Tightening torque of nut Standard (2.1 ± 0.2 kgf·m)
[15.5 ± 1.5 lbf·ft]
1 2
501037
5-28
CHAPTER 6 BRAKE SYSTEM
Chapter 6 BRAKE SYSTEM
1. Specifications
For the wheel brake, refer to the chapter of "TRANSFER UNITS."
Item Specification
Type magnet brake system
Brake outside diameter 167.5 mm (6.595 in.)
Brake disc effective diameter 166 mm (6.535 in.)
Clearance between armature and stator 0.10 to 0.25 mm (0.004 to 0.01 in.)
Parking brake
Voltage DC 24 V
Current 1.29 A
Static friction torque 38 N·m (3.87 kgf·m) [28.03 lbf·ft] or more
Insulation classification F type
6-1
2. Structure
2.1 Outline of Brake System
606001
1. Parking switch 4. Traction motor

2. Brake pedal assembly 5. Electro-magnetic brake assembly
3. Reservoir tank
The brake pedal assembly is mounted on the left side of the The electro-magnetic brake assembly is mounted on the
accelerator pedal. traction motor. When the parking switch is pushed to apply,
When you depress the brake pedal, the wheel brake is the magnet brake holds rotation of the traction motor shaft.
applied and stops the front wheel. For the wheel brake, refer When it is pushed to release, the vehicle can travel.
to the chapter of "TRANSFER UNITS".
6-2
2.2 Brake Pedal Assembly
4
6
1
9
7
2 3
8
606002
1. Pedal bracket 6. Reservoir tank

2. Brake pedal 7. Reservoir hose
3. Pedal pad 8. Adjustment bolt
4. Spring 9. Microswitch
5. Master cylinder
When brake pedal is pressed, the push rod of the master The adjustment bolt is used to set the brake pedal height.
cylinder is pushed and the brake fluid in master cylinder is The installation length of the switch is pre-adjusted. When
discharged. the pedal is pressed, the microswitch activates and
When the pedal is released, the brake fluid returns to the transmits signal to the traction inverter, the operating
master cylinder. speed of the traction motor is controlled.
Brake fluid is supplied to the master cylinder from the
reservoir tank located under the center of the dashboard.
6-3
Master cylinder
7
6
5
4
2
3
13 17
14 11
15
12
8 10
16 9
606003
1. Cylinder body 10. Clamp

2. Piston 11. Bleeder valve
3. Secondary cup 12. Bleeder cap
4. Spacer 13. Push rod
5. Primary cup 14. Nut
6. Thimble 15. Yoke
7. Spring 16. Boots
8. Snap ring 17. Cap
9. Union
6-4
2.3 Electro-magnetic Brake Assembly
8 7
3
5
4 1
10
11
2
606004
1. Electro-magnetic brake assembly for left side 7. Rotor

2. Electro-magnetic brake assembly for right side 8. Armature
3. Brake cover 9. Rotor hub
4. Brake plate 10. Stator
5. Spacer 11. Spring
6. Plate
The electro-magnetic brake is mounted on the traction When the parking switch is pressed to release, the electric
motor. current is applied to the stator of brake. The armature is
As a general rule, you don't have to adjust the brake. attracted to it, and the rotor becomes able to turn.
The stopping force is cut off.
When the parking switch is pressed to apply, the electric
current is not applied to the brake and the armature is
forced on the rotor by the spring.
The stopping force is provided to the traction motor.
6-5
3. Removing Master Cylinder
R CAUTION
(1) Remove the column panel (1), (2) and steering wheel
assembly.
2 3
1
606021

2. Column panel (2)
(2) Remove the following panels.

- Kick panel 4
- Front panel (L1)
- Front panel (L2) 3
- Valve lever panel 5
- Front panel (main)
1
2 606022
1. Kick panel 4. Valve lever panel

2. Front panel (L1) 5. Front panel (main)
3. Front panel (L2)
(3) Remove the snap pin, plain washer and clevis pin.
(4) Remove the master cylinder mounting bolt, nut and 2
washer. 3
(5) Remove the master cylinder.
4 5
(6) Prepare a drip pan for the brake fluid and remove the
brake pipes and reservoir hose.
7 6
(7) Drain the brake fluid to a drip pan completely.
1 5 606023
1. Master cylinder 5. Bolt, nut, washer

2. Snap pin 6. Brake pipe
3. Plain washer 7. Reservoir hose
4. Clevis pin
6-6
4. Disassembling Master Cylinder
17
11
12
7 10
9
6
5
4
2
3
8
16 2)
13
14 3)
15
1) 606005
1. Cylinder body 11. Bleeder valve

2. Piston 12. Bleeder cap
3. Secondary cup 13. Push rod
4. Spacer 14. Nut
5. Primary cup 15. Yoke
6. Thimble 16. Boots
7. Spring 17. Cap
8. Snap ring 1) Push rod assembly
9. Union 2) Piston assembly
10. Clamp 3) Cylinder assembly
Ref. Clamp tightening torque

1.96 to 2.94 N·m
10 (20 to 30 kgf·cm)
[14.75 to 22.13 lbf·ft]
6-7
5. Inspecting and Adjusting Master Cylinder
R CAUTION
- Before performing this inspection, clean the part with a wash oil, and then blow oils away by compressed air.
- Bleed air after finishing the inspection.
- Replace the piston assembly at every disassembling or annually.
Cylinder body
1
- Check the inner surface of the cylinder for rust,
corrosion and scuffing.
- Check the inlet port and relief port for clogging.
3
606006
1. Inner surface 3. Relief port

2. Inlet port
Piston assembly
- Check the piston for damage or deterioration, and
replace if any damage or deterioration are found.
1
- Check the rubber parts for damage and swelling.
- Replace the primary cup and secondary cup once a 4 2
year.
- Replace the spring once a year.
3
606007
1. Piston 3. Primary cup

2. Spring 4. Secondary cup
Item Standard Limit

Primary cup lip-side outside 19.8 ± 0.2 mm
19.6 mm (0.77 in.)
diameter (0.78 ± 0.008 in.)
Secondary cup lip-side 20.1 ± 0.2 mm
19.9 mm (0.78 in.)
outside diameter (0.79 ± 0.008 in.)
Item Standard
Free length of Spring 83± 0.7 mm (3.27 ± 0.03 in.)
6-8
Clearance between piston assembly and cylinder

body
- Measure the clearance between piston assembly and
cylinder body.
If the clearance exceeds the limit, replace both cylinder 1)
and piston assembly.
606025
1) Measure the clearance
Item Standard Limit

Less than
Clearance between piston
0.02 to 0.105 mm 0.2 mm (0.0079 in.)
assembly and cylinder body
(0.0008 to 0.0041 in.)
Bleeder valve
- Replace the bleeder valve once a year.
Other parts
- Check the push rod assembly and boot for damage.
Air bleeding
Be sure to bleed the master cylinder of air in the following cases.
- After the master cylinder is disassembled for maintenance.
- When brake pedal movement is spongy.
R CAUTION
- Use the specified brake oil [DOT-3] or [DOT-4]. Do not mix any mineral oil.
- Do not use any mineral oil as brake fluid.
- During the air bleeding, keep the brake oil level in the reservoir tank by refilling.
(1) Remove the original push rod from the master cylinder.
1 2
(2) Loosen the bolt for pedal height adjustment.
(3) Remove the brake microswitch.
(4) Insert the special rod into the master cylinder, and fit
the end into the link hole. 3
Note: To bleed air completely, the piston of the master
cylinder must be pressed down to the bottom several
times. The standard push rod is not long enough for
this purpose. Therefore, use a special rod (longer one)
instead.
606015
1. Brake pedal 3. Special rod

2. Link hole
Tool name Part number

Special rod 97967-00400
6-9
(5) Tighten bleeder valve.

(6) Fill the tank with brake fluid. Don’t feed with pressure.
(7) Loosen bleeder valve of master cylinder while pushing 2
brake pedal.
1)
2)
1 606018
1. Bleeder valve 1) Push

2. Special rod 2) Loosen
(8) Tighten bleeder valve on the condition that pedal is

fully depressed. After tightening, release pedal.
(9) Repeat step 7 and 8 until internal air is completely
come out of cylinder. 2
Note: Keep the brake oil level in the reservoir tank by 1)
refilling.
(10) Tighten bleeder valve.
(11) Remove the special rod and install the original push
2)
rod.
(12) Confirm if oil leaks.
1 606019
1. Bleeder valve 1) Push to the bottom

2. Special rod 2) Tighten
6-10
6. Reassembling Master Cylinder
R CAUTION
- Do not use any mineral oil as brake fluid.
- Use only specified brake oil DOT-3] or [DOT-4]. Do not mix any mineral oil.
Follow the disassembly sequence in reverse.

Also follow the instructions below.
- Clean metal parts with a volatile cleaning solution, and
thoroughly dry using compressed air.
- Apply mineral oil on the surface of each parts
- Apply a thin coat of following grease or brake fluid on
the inner surface of the cylinder body and the piston
cup.
Specified grease
Metal Rubber #20
- Fill the rubber grease between the piston and

secondary cup. 1 1)
606026
1. Secondary cup 1) Fill the rubber grease
6-11
7. Inspecting and Adjusting Brake Pedal Assembly
Inspecting brake pedal linkage

- Check any cracks or damages at welded parts.
- Check the bushing for wear. 2
- Check the Brake pin for abnormal wearing. 1
1)
2) 3 606010
1. Brake pedal 1) Bushing inner diameter

2. Bushing 2) Brake pin outer diameter
3. Brake pin
Item Standard Limit

Bushing inner diameter 20.0 mm (0.79 in.) 20.15 mm (0.7933 in.)
Brake pin outer diameter 20.0 mm (0.79 in.) 19.9 mm (0.784 in.)
Adjusting pedal gap

- If the gap between the brake pedal and the pedal 1) 1) 2
bracket is 1 mm (0.04 in.) or larger at right end or left 2
end, insert shims to minimize a gap.
1 3
606011
1. Pedal bracket 3. Shim

2. Bushing 1) Gap
Specified gap between the brake pedal

and pedal bracket
Smaller than 1 mm (0.04 in.)
Adjusting master cylinder rod length

- Adjust cylinder rod length to following on the
condition that rod touches to the piston softly and 2
tighten the yoke with nut. 3 1)
606012
1. Master cylinder 1) Master cylinder rod length

2. Rod
Specified length of master cylinder rod

90.5 ± 1.5 mm (3.56 ± 0.06 in.)
6-12
Adjusting pedal installation 1) 2

(1) The adjustment bolt length in order to achieve such 3
condition that cylinder piston is completely returned
and there is a pedal play by 5 mm (0.2 in.) at the pedal
tip.
(2) In (1) condition, confirm if pedal height dimension is 1
within following value.
(3) In case dimension is out of range, readjust rod and
dimension in order to achieve (1) condition 3)
2) 4) 606013
1. Brake pedal 2) Pedal stroke (brake activating

2. Adjustment bolt point)
3. Microswitch 3) Pedal free play
1) Bolt length 4) Pedal height from floor plate
Item Standard
Item Standard
Pedal stroke
Adjustment bolt length 36.5 ± 1 mm (1.4 ± 0.04 in.) 65 mm (2.56 in.)
(brake activating point)
Pedal height from floor
77 ± 5 mm (3 ± 0.2 in.) Pedal free play 5 mm (0.2 in.)
plate
Adjusting microswitch installation

(1) Adjust microswitch position in order to switch on/off 2
during 10 to 20 mm (0.393 to 0.787 in.) pedal stroke.
(2) In case of full pedal stroke, switch roller movement shall
be within following. 2)
1)
1
606014
1. Brake pedal 1) Pedal stroke (microswitch

2. Microswitch switching point)
2) Switch roller movement
Item Standard
Pedal stroke
(microswitch switching 10 to 20 mm (0.39 to 0.79 in.)
point)
Switch roller movement 2 to 4 mm (0.08 to 0.16 in.)
6-13
8. Adjusting and Manual Releasing Magnet Brake
Adjusting 4 3
As a general rule, you don’t have to adjust the magnet brake
assembly.
1
- When adjusting out of necessity, loosen or tighten the
screw so that the clearance between armature and 2
stator is within following.
Note: Prevent the rotor from interfering with the armature
and stator. 1)
606020
1. Screw 4. Stator
2. Rotor 1) Air gap
3. Armature
Specified clearance between armature and stator

Smaller than 1 mm (0.04 in.)
Manual release of magnet brake

When the vehicle does not start up or cannot travel by
electrical abnormality, release the brake by the following
methods.
(1) Loosen the brake plate mounting bolts, and remove

the brake plate. 1 2
(2) Tighten the bolts again.
606024
1. Bolt 2. Brake plate
6-14
9. Troubleshooting
9.1 Brake Pedal Assembly
For the wheel brake, refer to the chapter of "TRANSFER UNITS".

Fluid line leak or low fluid level in reserve tank Repair and add fluid.
Fluid leak from brake pipe joint Tighten, or replace pipe and joint.
Trapped air in hydraulic line Bleed air from master cylinder.
Brake can not be applied.
Fluid leak caused by piston cup wear of master Replace. Change fluid with the
cylinder recommended type if the cup is distorted.
Wear of mating plate or uneven contact with For the wheel brake, refer to the chapter of
friction plate of wheel brake "TRANSFER UNITS".
Trapped air in hydraulic line Bleed air from master cylinder.
Faulty master cylinder or piston cup Replace piston cup.
Low oil level in master cylinder Add brake fluid.
Brake pedal stroke is Excessive clearance of master cylinder push rod Adjust.
excessive.
Replace piston cup of master cylinder. If
Brake fluid leak from master cylinder piston cup is deformed, replace brake fluid
(use genuine brake fluid).
Fault of microswitch installation Adjust the microswitch position.
Malfunction of microswitch Replace.
Brake can not be released.
Unbalanced braking
Brake squeaks. Refer to the chapter of "* TRANSFER UNITS".
Brake drags.
Braking only at one side.
6-15
9.2 Parking Brake

Fault of the parking switch wiring Check the wiring.
Malfunction of parking brake switch Replace the parking switch.
Battery is empty Charge.
Check the wiring.
Electrical system malfunction Refer to the topic of “Adjusting and
Manual Releasing Magnet Brake”.
Brake can not be released.
Measure the resistance of the coil at
20 °C (68 °F).
Malfunction of magnet brake coil
When the value is out of 18.2Ω
±10%, replace the brake.
Refer to the section of “8. Adjusting
Electrical abnormality and Manual Releasing Magnet
Brake”.
Adjust or replace the magnet brake
The brake air gap is too large
Insufficient brake release assembly.
Low battery voltage Check and charge the battery.
Brake can not be applied. Malfunction of magnet brake Replace the magnet brake assembly.
Abnormal noise from brake Malfunction of magnet brake Replace the magnet brake assembly.
6-16
10. Service Data
10.1 Brake Pedal

Pedal height
1 Standard 77 ± 5 mm (3 ± 0.2 in.)
(between upper pedal edge and floor)
2 Pedal stroke (brake activating point) Standard 65 mm (2.56 in.)
3 Free play of brake pedal Standard 5 mm (0.2 in.)
4 Master cylinder push rod length Standard 90.5 ± 1.5 mm (3.6 ± 0.06 in.)
5 Microswitch activating pedal stroke Standard 10 to 20 mm (0.39 to 0.79 in.)
6 Microswitch roller movement Standard 2 to 4 mm (0.08 to 0.16 in.)
7 Bushing inner diameter
Limit 20.15 mm (0.7933 in.)
8 Brake pin outer diameter
Limit 19.9 mm (0.784 in.)
Gap between the brake pedal and
9 Standard Smaller than 1 mm (0.04 in.)
pedal bracket
6
7
8
9 9
3
5 2
1
606016
6-17
10.2 Master Cylinder

1 Cylinder body inside diameter Standard 19.05 mm (0.75 in.)
- Maximum stroke Standard 30 mm (1.2 in.)
Standard Less than 0.02 to 0.105 mm (0.0008 to 0.0041 in.)
- Clearance between cylinder and piston
Limit 0.2 mm (0.0079 in.)
Standard 19.8 ± 0.2 mm (0.78 ± 0.008 in.)
2 Primary cup lip-side outside diameter
Limit (Replace once a year.)
Secondary cup lip-side outside Standard 20.1 ± 0.2 mm (0.79 ± 0.008 in.)
3
diameter Limit (Replace once a year.)
Standard 83± 0.7 mm (3.27 ± 0.03 in.)
4 Return spring free-movement length
Limit (Replace once a year.)
5 Tightening torque of bleeder valve Standard 6.9 to 8.8 N·m (70 to 90 kgf·cm) [51.63 to 66.38 lbf·ft]
6 Tightening torque of clamp bolt Standard 1.96 to 2.94 N·m (20 to 30 kgf·cm) [14.75 to 22.13 lbf·ft]
4
2
606017
6-18
CHAPTER 7 STEERING SYSTEM
Chapter 7 STEERING SYSTEM
1. Specifications
Item Specification
Type Electronic hydraulic power steering
Diameter of steering wheel 245 mm (9.7 in.)
Manufacturer EIKO ELECTRIC INDUSTRIAL
PS motor 600W, DC 48V
Rating
3000 min-1, 60 min
Manufacturer TAKAKO
PS pump assembly Flow rate 11.34 liter/min (3.0 U.S. gal./min)
Relief valve pressure 13.5 MPa (137.7 kgf/cm2) [1958 psi]
Operating oil volume (including cylinder and piping) 850 cc (51.9 cu. in.)
7-1
2. Structure
2.1 Outline of Steering System
3
6
5 9
8
7 607002
1. Steering wheel 6. Reservoir tank

2. Steering unit 7. Steering cylinder
3. PS controller 8. Rear axle
4. PS motor 9. Steering sensor
5. PS pump assembly
The steering system of this vehicle is electrically controlled Then the oil goes out of the steering cylinder and returns to
and hydraulically operated. the PS pump assembly.
Turning angle of the rear wheel is detected by the steering
When the operator turns the steering wheel, its angle is
sensors in the rear axle and it is transmitted to the logics
detected by the steering unit and transmitted to the PS
unit. Then the logics unit controls the wheel indicator on
controller. Then the PS controller drives the EPS motor to
the display panel via CAN communication.
flow the oil from the reservoir tank through the PS pump
assembly. The oil is forced to flow to steering cylinder
through the valve of the PS pump. This pushes the piston in
steering cylinder and turn the rear wheel.
7-2
PS Pump Assembly
2
1 3
6 4 5
8 9 10
7
607003
1. Lubricating point for tank 6. Relief valve

2. Cylinder port (right) 7. Check valve
3. Lubricating point for pump 8. Tank
4. Reservoir tank port 9. Port block
5. Cylinder port (left) 10. Housing
7-3
Hydraulic Circuit Diagram
10
1
2
8
6
9 7
607014
1. Cylinder port (right) 6. Pump

2. Cylinder port (left) 7. PS motor
3. Relief valve 8. Reservoir tank
4. Shuttle valve 9. Tank
5. Check valve 10. Steering cylinder
7-4
3. Removing Steering Linkage Assembly
6
9
8
7
10
1
607004
1. Kick panel 6. Combination switch

2. Column panel (1) 7. Handle
3. Column panel (2) 8. Spring
4. Key switch 9. Steering column assembly
5. Steering wheel assembly 10. Steering unit
7-5
R CAUTION
- Do not disassemble the combination switch.
(1) Remove the kick panel.

1
607005
1. Kick panel
(2) Remove the column panel (1) and (2).

(3) Disconnect the harness connector of the key switch,
2 4
and remove the switch.
(4) Remove the steering wheel assembly. 3
1
603066
1. Column panel (1) 3. Key switch

(5) Disconnect the harness connector of the combination

switch, and remove the switch. 1
(6) Remove the handle.
(7) Remove the spring.
4
(8) Disconnect the harness connector of the steering 3
column assembly, and remove the steering column
2
assembly.
607006
1. combination switch 3. Spring

2. Handle 4. Steering column
7-6
4. Inspecting Steering Linkage Assembly
R CAUTION
- Park the forklift on a level surface, with the forks lowered, parking brake applied, the direction lever in neutral position.
5. Installing Steering Linkage Assembly

During installation, conduct the following. 2
- When install the set screw to the handle, apply
THREEBOND [#1401] or equivalent.
1
607007
1. Set screw 2. Handle
7-7
6. Removing PS Pump Assembly
4
3
6
7
9
607008
1. Rear cover 6. PS hose

2. Reservoir tank 7. PS pump assembly, PS pump bracket
3. Low pressure hose 8. PS motor
4. Elbow, O-ring 9. Joint
5. PS hose assembly
7-8
R CAUTION
- When hydraulic hoses are disconnected, cap them to prevent dust from entering into hydraulic components and hoses.
- When the O-ring is disturbed, replace it with the new one.
(1) Open the battery cover.

(2) Remove the rear cover.
1
2
607017
1. Battery cover 2. Rear cover
(3) Prepare a drip pan for the oil and remove the reservoir
tank.
(4) Remove the low pressure hose.
1
607009
1. Reservoir tank 2. Low pressure hose
(5) Disconnect the elbows and PS hoses.

5 1
(6) Disconnect the harness connectors of the EPS motor
and PS pump assembly.
(7) Remove the PS pump assembly with the PS motor. 1 2
3 4
2
3 607010
1. Elbow (with O-ring) 3. Harness connector

2. PS hose 4. PS motor
5. PS pump assembly
7-9
(8) Remove the EPS motor from the PS pump assembly.

2
607011
1. PS motor 2. PS pump assembly
7. Installing PS Pump Assembly

During installation, conduct the following. 1
- When install the EPS motor to the PS pump assembly,
fill molybdenum grease around the spline section of
the joint.
2
607018
1. Joint 2. Spline section
7-10
8. Disassembling PS Pump Assembly
R CAUTION
- Do not disassemble the pump body.
When damaged, replace the whole pump assembly.
8.1 Hydraulic oil drain procedure
(1) Prepare a drip pan for the hydraulic oil.

(2) Remove the plug (1).
1 607020
1. Plug (1)
(3) Drain the hydraulic oil from the pump body.

1 2
607021
1. Pump body 2. Relief valve
(4) Remove the plug (2) and (3).

1 2
607022
1. Plug (2) 2. Plug (3)
7-11
(5) Drain the hydraulic oil from the tank and pump body.
(6) Disassemble the PS pump assembly. 1
2 607023
1. Tank 2. Relief valve
7-12
17
11
4
35 13 18 1 3
12 2
8 36 14 19
28 20
7
6
5
34
33 32
31 30
29 28 27
25 26
16 24
23
10 15
9 22
21
607019
1. Pump body 19. Backup ring

2. Oil seal 20. O-ring
3. Spacer 21. Check valve S/A
4. Snap ring 22. Backup ring
5. Hexangular bolt 23. O-ring
6. washer 24. Backup ring
7. Tank 25. O-ring
8. O-ring 26. Plug
9. Plug 27. O-ring
10. O-ring 28. Shuttle valve
11. Plug 29. Pin
12. O-ring 30. Body
13. Plug 31. O-ring
14. O-ring 32. Backup ring
15. Plug 33. Backup ring
16. O-ring 34. O-ring
17. Relief valve S/A 35. Plug
7-13
9. Reassembling PS Pump Assembly
R CAUTION
- After reassembling, be sure to perform internal flushing of the PS pump assembly.

During installation, conduct the followings.
4
7
1 6
5
8
3
501948
1. 20 to 22.8 N·m (2.04 to 2.32 kgf·m) [14.75 to 16.82 lbf·ft] 6. 20 to 22.8 N·m (2.04 to 2.32 kgf·m) [14.75 to 16.82 lbf·ft]
2. 48 to 52 N·m (4.89 to 5.30 kgf·m) [35.40 to 38.35 lbf·ft] 7. 20 to 22.8 N·m (2.04 to 2.32 kgf·m) [14.75 to 16.82 lbf·ft]
3. 28 to 32 N·m (2.86 to 3.26 kgf·m) [20.65 to 23.60 lbf·ft] 8. 10.4 to 11.8 N·m (1.06 to 1.20 kgf·m) [7.67 to 8.70 lbf·ft]
4. 28 to 32 N·m (2.86 to 3.26 kgf·m) [20.65 to 23.60 lbf·ft] 9. 0.6 to 0.7 N·m (0.06 to 0.07 kgf·m) [0.44 to 0.52 lbf·ft]
5. 10.4 to 11.8 N·m (1.06 to 1.20 kgf·m) [7.67 to 8.70 lbf·ft]
- When replacing the oil seal, apply grease on the lip.

- When replacing the O-ring, apply grease.
Item Standard value

Grease Shell Alvania Grease #2
7-14
10. Inspecting PS Pump Assembly
R CAUTION
- Park the forklift on a level surface, with the forks lowered, parking brake applied, the direction lever in neutral position.
PS pump oil
Check the following.
- Oil level
- Contamination
- Clouding (mixing of air or oil)
Note: Keep the oil level within "MAX" and "MIN" marks on
the reservoir tank.
607013
Item Specified value

Oil volume (including
850 cc (51.9 cu. in.)
cylinder and piping)
11. Troubleshooting
Item Problem Possible cause Remedy

Steering wheel Though steering wheel EPS motor malfunction Repair or replace.
assembly is operated the wheel
PS pump assembly malfunction Repair or replace.
direction is not
changed. Valve in PS pump malfunction Replace.
Faulty piston seal of rear axle cylinder Replace.
Mixing to oil of foreign particles Clean or replace.
Bent or clogging hydraulic hose Repair or replace.
Insufficient oil in reservoir tank Replenish.
Heavy steering wheel
Steering unit malfunction Replace.
operation
Instability in steering Steering angle sensor in steering unit
Replace.
wheel operation malfunction
Steering sensor in rear axle malfunction Replace.
Valve in PS pump malfunction Replace.
Faulty piston seal of rear axle cylinder Replace.
Mixing to oil of foreign particles Clean or replace.
Bent or clogging hydraulic hose Repair or replace.
7-15
12. Service Data
12.1 PS Pump Assembly

Displacement Standard 6.3 cc/rev (0.4 cu. in./rev)
Rated flow rate Standard 11.34 liter (3.0 U.S. gal.)
Rated operating pressure Standard 8 MPa (81.6 kgf/cm2) [1160 psi]
Maximum operating pressure
Standard 13.5 MPa (137.8 kgf/cm2) [1958 psi]
(Relief valve pressure)
607015
12.2 Reservoir Tank

Oil volume (including cylinder and piping) Standard 850 cc (51.9 cu. in.)
7-16
CHAPTER 8 HYDRAULIC SYSTEM
Chapter 8 HYDRAULIC SYSTEM
1. Specifications
1.1 MC model
Item Specification
Type Gear pump
Model type TMG1-18
Gear pump
Displacement 18.9 cc/rev. (1.15 cu.in./rev.)
Drive system Direct connection with pump motor
Type MSV04A8232
Control valve
Main relief pressure 18.1 MPa (184.57 kgf ·cm2) [2625.2 psi]
Simplex Mast (Dual-stage Inside diameter 45 mm (1.77 in.)

Panoramic Mast) lift cylinder Stroke 1645 mm (64.76 in.)
Inside diameter 60 mm (2.36 in.)
Simplex Mast (Dual-stage 2000/2560, 4480/5000 : 70 mm (2.76 in.)
Panoramic Mast) tilt cylinder Stroke 2760 - 4090 : 88 mm (3.46 in.)
5500/6000 : 59 mm (2.32 in.)
Duplex Mast (Dual-stage Full Inside diameter 45 mm (1.77 in.)
Free Panoramic Mast)
first lift cylinder Stroke 850 mm (33.46 in.)
Hydraulic
system Duplex Mast (Dual-stage Full Inside diameter 45 mm (1.77 in.)
second lift cylinder Stroke 1595 mm (62.80 in.)

tilt cylinder Stroke 77 mm (3.03 in.)
Triplex Mast (Triple-stage Inside diameter 45 mm (1.77 in.)

Panoramic Mast)

Panoramic Mast)

Panoramic Mast) 3710 - 4750 : 77 mm (3.03 in.)
tilt cylinder Stroke
5090 - 7000 : 59 mm (2.32 in.)
Low level 12.1 L (3.20 U.S. gal)
Operating oil volume
High level 13.3 L (3.51 U.S. gal)
8-1
1.2 FC model
Item Specification
Type Gear pump
Model type TMG1-18
Gear pump
Rated discharge volume 18.9 cc/rev. (1.15 cu.in./rev.)
Drive system Direct connection with pump motor
+0.50 +5.10 +72.50
Control valve Main relief pressure 18.1 -0.00 MPa (185 -0.00 kgf/cm2) [2625 -0.00 psi]
Simplex Mast (Dual-stage Inside diameter 45 mm (1.77 in.)

Panoramic Mast) lift cylinder Stroke 1645 mm (64.76 in.)
Inside diameter 60 mm (2.36 in.)
Simplex Mast (Dual-stage 2000/2560, 4480/5000 : 70 mm (2.76 in.)
Panoramic Mast) tilt cylinder Stroke 2760 - 4090 : 88 mm (3.46 in.)
5500/6000 : 59 mm (2.32 in.)
Hydraulic
system

tilt cylinder Stroke 77 mm (3.03 in.)

Panoramic Mast)

Panoramic Mast)

Panoramic Mast) 3710 - 4750 : 77 mm (3.03 in.)
tilt cylinder Stroke
5090 - 7000 : 59 mm (2.32 in.)
Low level 12.1 L (3.20 U.S. gal)
Operating oil volume
High level 13.3 L (3.51 U.S. gal)
8-2
2. Structure
2.1 Hydraulic Line (MC Model)
7
6 1
3
2
4
11 9
10
608001
1. Hydraulic tank 7. Down safety valve

2. Gear pump 8. First lift cylinder (Duplex mast and Triplex mast system)
3. Control valve 9. Return filter
4. Down safety valve 10. Suction filter
5. Lift cylinder 11. Pump motor
6. Tilt cylinder
The hydraulic system is constructed as shown above. (The When the lift lever or tilt lever is operated, the
figure shows the hydraulic system for the Duplex mast microswitches located in the spool of the control valve send
system.) signals to the logic card in the main controller. Based on
The major difference between FC model and MC model is received signals, the logic card drives the pump motor and
only the control valve. operates the oil pump.
8-3
2.2 Hydraulic Line (FC Model)
7
6 1
3
2
4
11 9
10
608002
1. Hydraulic tank 7. Down safety valve

2. Gear pump 8. First lift cylinder (Duplex mast and Triplex mast system)
3. Control valve 9. Return filter
4. Down safety valve 10. Suction filter
5. Lift cylinder 11. Pump motor
6. Tilt cylinder
The hydraulic system is constructed as shown above. (The When the lift lever or tilt lever is operated, the
figure shows the hydraulic system for the Duplex mast microswitches located in the spool of the control valve send
system.) signals to the logic card in the main controller. Based on
The major difference between FC model and MC model is received signals, the logic card drives the pump motor and
only the control valve. operates the oil pump.
8-4
2.3 Lift and Tilt Cylinders
5 6 7
608092
1. Simplex Mast lift cylinder 3. Duplex Mast second lift cylinder

Triplex Mast second lift cylinder 4. Tilt cylinder
2. Duplex Mast and Triplex Mast first lift cylinder
The left and right lift cylinders are a single-acting type. Air The left and right tilt cylinders are a double-acting type. The
and oil remaining inside air chamber 5 of the rod and inside piston rod carries a screw-on socket. This socket is to be
rod chamber 6 between the tubes open check valve 7 when repositioned by turning, as necessary, when the cylinder is
compressed, thus the air and oil flow out of the cylinder. connected to the outer mast. The right and left cylinders are
hydraulically connected to each other. The tilt angle can be
Only the second cylinders of the Duplex Mast are provided
increased or decreased by means of spacer and shim of each
with bleeding valves.
cylinder.
8-5
2.4 Down Safety Valve
3
2
608008
1. Normal 3. Burst
2. When hose burst
The down safety valve is located at the bottom of second lift If the piping between the lift cylinder and control valve is
cylinder. This safety valve regulates the flow of oil to broken, or if the flow of return oil from the lift cylinder
prevent the fork from moving down too quickly in the becomes excessive due to a maladjusted control valve or a
following situations: fault of another component.
8-6
3. Removing Control Valve (MC Model)
3.1 Preparation
Before disconnecting the hydraulic hoses and pipes, release

internal oil pressure as following.
(1) Sit on the seat and turn the key switch to the on
position.
Note: You must sit on the seat. Otherwise, the mast is not
operated because of the Mast Interlock System.
(2) Push the lift lever forward to lower the fork on the
ground.
(3) Repeat pushing forward and releasing the lift lever a
few times between lowering and neutral positions to
release the internal pressure.
Note: Do not pull the lift lever nor operate any other
hydraulic levers. (If the hydraulic motor runs, high
pressure is applied to all hydraulic circuits.)
(4) Turn the key switch to the off position and disconnect
the battery plug.
R WARNING
Prepare a drip pan to catch remaining oil in the pipes and hoses before disconnecting each pipe. Further, take appropriate
measures for the connections of pipes and control valves to prevent dust and dirt from entering in the opening.
R CAUTION
- Record places of the lead wire connections before removal.
(1) Remove the floor plates.
(2) Remove the snap pin and disconnect the control lever
rod from the control valve spool.
2 4
(3) Disconnect the control valve connector.
(4) Disconnect the microswitches at connector.
3 6
5
1
608013
1. Control valve 4. Snap pin, washer

2. Control lever rod 5. Control valve connector
3. Clevis pin 6. Microswitch connector
8-7
(5) Disconnect following hoses from the control valve.

- Tilt hoses 5
- High-pressure hose (from the gear pump)
- Return (low-pressure) hose (from the hydraulic tank) 1
- Lift pipe
- Attachment hose (when with attachment)
Note: Prepare a drip pan to catch remaining oil inside the
hoses. 2
Plug the hose openings to prevent from leaking.
4 3 608014
1. Tilt hose 4. Lift pipe

2. High-pressure hose 5. Attachment hose
3. Return (low-pressure) hose
(6) Remove a bolt , nuts, Lock washers, valve washers,

valve grommets and valve spacers. 1 5 6
43
2
608015
1. Bolt 4. Plain washer

2. Nut 5. Valve grommet
3. Spring washer 6. Valve spacer
(7) Remove the bolt and remove the control valve from the
vehicle body. 1
608080
1. Bolt
4. Installing Control Valve

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.
8-8
5. Removing Gear Pump
5.1 Preparation

position.
ground.
the battery plug.
R WARNING
R CAUTION
- Record places of the lead wire connections before removal.
- Do not disassemble the gear pump.
When damaged, replace the whole gear pump assembly.
(2) Disconnect following hoses from the gear pump.

- High-pressure hose (from the control valve)
- Low-pressure hose (from the hydraulic tank) 2
Note: Prepare a drip pan to catch remaining oil inside the 3
hoses.
(3) Disconnect lead wires of the pump motor. 4
1
608009
1. High-pressure hose 3. Lead wires

2. Low-pressure hose 4. Pump motor
8-9
(4) Remove flange bolt for the motor bracket, and hoist the
pump motor with the motor bracket.
1
1
2 608010
1. Flange bolt 2. Motor bracket
Tightening torque for flange bolt

38.6 to 47.2 N·m (4.0 to 4.8 kgf ·m) [28.5 to 34.8 lbf·ft]
(5) Remove the flange nuts, and remove the pump motor
with cushion and gear pump from the motor bracket.
3
1
608012
1. Flange nut 3. Pump motor

2. Cushion (1) 4. Motor bracket
Tightening torque for flange nut

10.9 to 13.3 N·m (1.1 to 1.4 kgf ·m) [8.0 to 9.8 lbf·ft]
(6) Remove the washer assembled bolt, and remove the

gear pump from the pump motor. 1
2
(7) Remove the elbow and connector.
4
3
5 608071
1. Pump motor 3. Gear pump

2. Washer assembled bolt 4. Elbow
5. Connector

Washer assembled bolt 19.6 to 24.5 N·m (2.0 to 2.5 kgf ·m) [14.5 to 18.1 lbf·ft]
Elbow 69 ± 7 N·m (7.04± 0.71 kgf ·m) [50.89 ± 5.16 lbf·ft]
Connector 108 ± 11 N·m (11.01± 1.12 kgf ·m) [79.66 ± 8.11 lbf·ft]
8-10
6. Installing Gear Pump
During installation, conduct the following.
- Check the hydraulic oil level. If the oil level is low, add
oil to the specified level.
- When install the gear pump to the pump motor, fill

molybdenum grease around the spline section.
608011
1. Spline section
7. Removing Suction Filter and Return Filter

7.1 Preparation

position.
ground.
the battery plug.
R WARNING
8-11
(2) Disconnect following hoses from the hydraulic tank.

- Low-pressure hose (from the gear pump), hose clip 2
- Low-pressure hose (2) (from the control valve), hose 1
clip
Note: Prepare a drip pan to catch remaining oil inside the
hoses.
502011
1. Low-pressure hose, hose clip 2. Low-pressure hose (2), hose clip
(3) Remove the Tank cap.

1
(4) Remove the Tank cover and gasket.
(5) Remove the return filter and suction filter from the tank
cover. 2
3
4
502012
1. Tank cap (with oil level gauge) 3. Return filter

2. Tank cover, Gasket 4. Suction filter
Tightening torque for tank cover mounting bolt

3.0 N·m (0.3 kgf ·m) [2.2 lbf·ft]
8. Installing Suction Filter and Return Filter

8.1 Suggestions for Installation
(1) Replace the packings and O-ring with new parts.
8-12
9. Removing Lift Cylinders (Simplex Mast)
5
6
1 1
7 6
5
1
7
3
8
4 7
9
608016
1. Nuts, Self locking nuts, Clamps 6. Seat, Cushion, Collar, Shims

2. Fork, Lift bracket 7. Lift cylinder, Bracket, Spring pin
3. Hose guard 8. O-ring, T-joint
4. High-pressure hose 9. Down safety valve assembly
5. Washer assembled bolt, Shims
8-13
R WARNING
Shims are inserted at the rod end section of the lift cylinders. Record how many shims are inserted in each cylinder before
removal.
(1) Lower lift bracket assembly, and place wood blocks

under the assembly. Tilt the mast forward, and lower
the inner mast to the bottom. Slacken the lift chains,
and remove the nuts from the anchor bolts.
3
1
2
608017
1. Nut 3. Clamp
2. Self-locking nut
Tightening torque for nut

98 to 147 N·m (10.0 to 15 kgf ·m) [72.3 to 109 lbf·ft]
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free.
(3) Back the truck away from the lift bracket and fork
assembly.
608072
(4) Lift the mast to the maximum lift position, and turn the
key switch off.
(5) Remove the hose guard .
(6) Operate the lift lever gradually to lower the masts.
2
(7) Repeat operating the lift lever a few times between
lowering and neutral positions to release the internal
pressure. 3
1 608018
1. Hose guard 3. Spring washer

2. Bolt
8-14
(8) Disconnect the high-pressure hoses at the joints

indicated by arrows. Use a drip pan to catch oil flowing
out of the hoses. 1 2
3
4
3 608019
1. Right-hand cylinder 2. Left-hand cylinder
Item Tightening torque for high-pressure hose

3 49.0 ± 4.9 N·m (5.0 ± 0.5 kgf ·m) [36.1 ± 3.6 lbf·ft]
4 58.8 ± 5.9 N·m (6.0 ± 0.6 kgf ·m) [43.4 ± 4.4 lbf·ft]
(9) Record the amount and thickness of shims and

cylinders to which the shims are fitted. 1
(10) Remove the washer assembled bolts at the top of each
lift cylinder. Lift the inner mast to separate the cylinder 1
rod ends. To lift the inner mast, hitch a sling around the
mast with protective rag. 2
2
608020
1. Washer assembled bolt 2. Shim
8-15
(11) 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.
608028

cylinders to which the shims are fitted.
(13) Hitch a sling securely to lift cylinder rear side of the
mast. Then remove cylinder bracket retaining bolts,
and gently remove lift cylinder.
5
4
6
4
2
1
3 608023
1. Cylinder bracket 4. Cushion

2. Shim 5. Seat
3. Lift cylinder 6. Collar
8-16
10. Removing Lift Cylinders (Triplex Mast and Duplex Mast)
Note: That the Triplex Mast is used as an example.
9 5 8 8
7 4
4
4
2
1
10
6 3
4 9
10
10
1
608024
1. Nuts, Self locking nut, Clamp 6. First lift cylinder, Shims

2. Fork, Lift bracket 7. Chain wheel support assembly, Chain guard
3. Hose guard 8. Seat, Cushion, Collar, Shims
4. High-pressure hose, Hose clip, T-joint 9. Second lift cylinder, Bracket, Spring pin
5. Bolt, Spring washer, Shims 10. Down safety valve assembly, T-joint, O-ring
8-17
Triplex Mast - Mast height 6500/7000
6 5 4 1
1 4 8 7
5
3
2 6
1
608073
1. Return hose 5. Rubber hose clamp

2. T-joint 6. Washer assembled bolt
3. Hose clamp 7. Elbow
4. Hose clamp 8. Hose nipple

under the assembly. Tilt the mast forward, lower the
inner mast to the bottom, then remove nuts from the
anchor bolts of the first lift chains. 4
1
2
3
608025
1. Clamp 3. Self-locking nut

2. Nut 4. Chain guard
Tightening torque for nut

98 to 147 N·m (10.0 to 15.0 kgf ·m) [72.3 to 109.0 lbf·ft]
(2) Position the mast upright. Raise the inner mast until
main rollers of lift bracket assembly become free. Then,
slowly move the vehicle in reverse to separate from lift
bracket assembly.
608026
8-18
(3) Disconnect the high-pressure hose from the first

cylinder.
2
608074
1. High-pressure hose 2. Hose clip
Tightening torque for high-pressure hose

58.8 ± 5.9 N·m (6.0 ± 0.6 kgf ·m) [43.4 ± 4.4 lbf·ft]
(4) Hitch a sling to the first lift cylinder, and suspend the
cylinder with a hoist. Wind the sling securely around
the lift cylinder to prevent slipping.
(5) Remove the washer assembled bolts, and gently
dismount first lift cylinder.
3
1
2
608029
1. Washer assembled bolt 3. First lift cylinder

2. Shim
(6) Remove the hose guard.
1 608075
1. Hose guard 3. Spring washer

2. Bolt
(7) Remove the hose clamp.

(8) Disconnect the hydraulic piping at the joints indicated
by arrows. Use a drip pan to catch oil flowing out of the
hoses.
8-19
Triplex Mast
- High-pressure hose
- Return hose (lift height 6500/7000 model)
3 2
5
1
4
5 608027
1. Right-hand second cylinder 3. Return hose (lift height 6500/

2. Left-hand second cylinder 7000)

4 58.8 ± 5.9 N·m (6.0 ± 0.6 kgf ·m) [43.4 ± 4.4 lbf·ft]
5 49.0 ± 4.9 N·m (5.0 ± 0.5 kgf ·m) [36.1 ± 3.6 lbf·ft]
Duplex Mast
- High-pressure hose
- Oil pipe 3
2
1 4
3
4 608070
1. Right-hand second cylinder 2. Left-hand second cylinder

3 58.8 ± 5.9 N·m (6.0 ± 0.6 kgf ·m) [43.4 ± 4.4 lbf·ft]
4 49.0 ± 4.9 N·m (5.0 ± 0.5 kgf ·m) [36.1 ± 3.6 lbf·ft]

(10) Remove the washer assembled bolt at the top of
second lift cylinders. Lift the inner mast (Duplex Mast)
or middle mast (Triplex Mast) approximately 550 mm
(21.67 in.) using slings.
1
2
3
608030
1. Washer assembled bolt 3. Second lift cylinder

2. Shim
8-20
(11) Tie wood blocks under the inner mast (Duplex Mast) or
middle mast (Triplex Mast). Use blocks strong enough
to support the mast.
Make sure the right and left wood blocks are the same
in height.
608028

(13) Hitch a sling securely to second lift cylinder behind the
mast. Then remove cylinder bracket retaining bolts,
and gently remove second lift cylinder.
The cylinder cannot be lifted straight up since the mast
cross-member is located above the cylinder. Tilt the 45
cylinder and move it away from the cross-member to 6
remove. Be careful not to place the hands between the
cylinder and mast. 4
12
608031
3
1. Cylinder bracket 4. Cushion
2. Shim 5. Seat
3. Second lift cylinder 6. Collar
8-21
11. Installing Lift Cylinder
Follow the removal procedure in reverse. Observe the
following instructions during installation.
11.1 Suggestions for Installation
Simplex Mast
(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 the section on Inspection and
Adjustment.)
(3) Check to make sure that the Mast height is correct.
(4) Check to make sure that the oil is not leaked from
anywhere.
(5) After the lift cylinders or piston rods have been
replaced, check for difference in stroke between the
two cylinders. (Refer to CHAPTER 9 MAST AND FORK.)
Triplex Mast and Duplex Mast

(1) Install chain wheel support assembly parallel to a line
connecting the centers of chain anchor bolt holes on
first lift cylinder to prevent chains from twisting.
(2) Adjust the chain tensions. (Refer to the section on
Inspection and Adjustment.)
(3) 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.
(4) After proper operation is confirmed, check the oil level 608032
in the hydraulic tank. (Refer to the section on Inspection
and Adjustment.)
(5) Check to make sure that the Mast height is correct.
(6) Check to make sure that the oil is not leaked from
anywhere.
(7) After the lift cylinders or piston rods have been
replaced, check for difference in stroke between the
two cylinders. (Refer to CHAPTER 9 MAST AND FORK.)
8-22
12. Removing Tilt Cylinders
12.1 Preparation
(1) Block the front wheels.

(2) Lower the forks to the bottom, and tilt the mast fully
forward.
(3) Hitch lifting slings to the top crossmember of the outer
mast by using wire rope. Support the weight of the
mast with the hoist.
Note: Wrap the mast in cloth to protect from wire rope.
608045
R CAUTION
Attach caps to the connectors of the cylinder to protect the threads of the connectors and to prevent oil from flowing out of
the cylinder when the cylinder is removed.
(1) Remove tilt pin of the mast side, and turn the key switch 1 1
to on position.
(2) Retract the piston rod fully, and turn the key switch to
off position.
(3) Disconnect high-pressure hoses from the cylinder at
the connectors. Use a drip pan to catch oil flowing out
of the cylinder.
(4) Remove the tilt pin of the vehicle side, and remove the 4
cylinder. 3
2 608044
1. High-pressure hose 3. Tilt pin, bolt, lock washer,

2. Tilt pin, bolt, lock washer, spacer, plain washer
spacer 4. Tilt cylinder
8-23
13. Disassembling Lilt Cylinder
Simplex Mast, Triplex Mast Second Lift Cylinder
1
* 2
6
* 5
608037
1. Bearing 4. Check valve, Washer, Circlip, Bushing, Snap ring

2. Wiper ring*, Seal*, Rod guide ring*, O-ring* 5. Piston seal*, Piston guide ring*
3. Spacer (depends on lifting height 6. Piston rod assy
Simplex mast : 3.7 m (146 in.) or more, 7. Cylinder assy
Triplex mast : 6.0 m (236 in.) or more)
Remove parts 4 through 6 as sub assembly from part 7.
Note: The part marked with * is included in the seal kit.
8-24
Duplex Mast, Triplex Mast First Lift Cylinder
1 * 2
3 *
* 4
608040
1. Retainer 4. Check valve, O-ring*, Washer, Circlip*

2. Wiper*, Rod seal*, Backup ring*, O-ring* 5. Piston rod, Piston
Remove parts 3 through 5 as sub-assembly from part 6. 6. Cylinder shell
3. Nylon ring*, Piston seal*, Wear ring*
8-25
Duplex Mast Second Lift Cylinder
10
6
5 *
9
4
3 *
8
7
2 1
*
11
608042
1. Retainer 6. Spacer
Remove parts 3 through 10 as sub-assembly from part 7. Circlip
11.
8. Sleeve
2. Wiper*, Rod seal*, Backup ring*, O-ring*
9. Piston rod
3. Backup ring*, Piston seal*, Wear ring*
10. Bleed screw, Seal washer
4. Piston
11. Cylinder shell
5. Pull-in wire*
8-26
Triplex Mast Second Lift Cylinder (Mast height 6500/7000)
* * * * * * * *
4 4 7 7 7 8 8 3 3 9 8 2 2 2 1 2
4 5 6
*
608076
1. Retainer 6. Check valve

2. Wiper*, Rod seal*, O-ring*, Backup ring * 7. Piston seal*, Backup ring*, Wear ring*
3. O-ring, Spacer 8. Rod, Wire ring
4. Circlip*, Sleeve 9. Shell assy
5. Washer
8-27
14. Reassembling Lilt Cylinder
* * * * * *
13 11 12 14 15 1 10 2 9 8 7 6
3 4 5
608039
1. Piston rod, Piston 9. Spacer

Install parts 2 through 9 to part 1. 10. Cylinder assy
2. Check valve 11. Bearing
3. Washer Install parts 12 through 15 to part 11.
4. Circlip 12. Seal*
5. Bushing 13. Wiper ring*
6. Snap ring 14. Rod guide ring*
7. Piston guide ring* 15. O-ring*
8. Piston seal*
8-28
* * * * * * * *
13 12 14 15 1 6 7 8 9
11 10 2 3 4 5
* *
608041
1. Piston rod, Piston 9. Wear ring*

Install parts 2 through 9 to part 1. 10. Cylinder shell
2. Check valve 11. Retainer
3. O-ring* Install parts 12 through 15 to part 11.
4. Washer 12. Rod seal*
5. Circlip* 13. Wiper*
6. Nylon ring* 14. Backup ring*
7. Piston seal* 15. O-ring*
8. Nylon ring*
8-29
* * * *
8 7 5 6 10 4 3 2 1
9
11
608043
1. Retainer 7. Piston
2. Wiper*, Rod seal* 8. Backup ring*, Piston seal*, Wear ring*
3. Backup ring*, O-ring* 9. Sleeve, Circlip
4. Piston rod 10. Cylinder shell
Install parts 1, 2, 3, 5, 6, 7 to part 4. 11. Seal washer, Bleed screw
5. Spacer
6. Pull-in wire*
8-30
Triplex Mast Second Lift Cylinder (Mast height 6500/7000)
* * * * * * * *
4 4 8 7 6 1 1 9 9 10 1 15 14 12 11 13
6 3 2
* 608077
1. Piston, rod, Wire ring 9. O-ring, Spacer

2. Check valve 10. Shell assy
3. Washer 11. Retainer
4. Circlip * 12. Rod seal*
5. Sleeve 13. Wiper*
6. circlip*, Backup ring* 14. Backup ring*
7. Piston seal* 15. O-ring*
8. Wear ring*

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

200 to 230 N·m
Bearing tightening torque (20.4 to 23.5 kgf·m)
[148 to 170 lbf·ft]
8-31

(3) Fill the space between the cylinder tube and piston rod
with the specified amount of hydraulic oil before
installing the retainer.
Item Standard value
20 to 25 cc
Amount of hydraulic oil
(1.2 to 1.5 cu. in.)
(4) Tighten the retainer to the specified torque.

353 to 380 N·m
Retainer tightening torque (36 to 39 kgf·m)
[260 to 280 lbf·ft]

(2) Apply hydraulic oil to the sliding sections on the
cylinder tube inner surface and piston rod outer surface
before installation.
(3) Tighten the piston and holder to the specified torque.
Item Standard value

170 to 240 N·m
Holder tightening torque (17.3 to 24.5 kgf·m)
[125.3 to 177.0 lbf·ft]
(4) Tighten the set screws (2 locations) to specified torque.

4.5 to 5.0 N·m
Set screw tightening torque (0.46 to 0.51 kgf·m)
[3.3 to 3.7 lbf·ft]
Triplex Mast Second Lift Cylinder (Mast height 6500/

7000)
(1) Replace all of the seal kit parts to new ones when
assembling.
(2) Thoroughly clean all parts before reassembly making
sure they are completely free from dirt or dust.
(4) Tighten the retainer to the specified torque.
Tightening torque
244 to 271 N·m (24.9 to 27.6 kgf ·m) [180 to 200 lbf·ft]
8-32
15. Disassembling Tilt Cylinder
*
4
1 *
3
*
**
2
608046
1. Head, Spherical bearing, Grease nipple 3. Piston

2. Guide bushing 4. Cylinder tube, Cylinder head, Bushing
8-33
16. Reassembling Tilt Cylinder
4 3 1 2
* * * * *
1)
608047
1. Piston 1) Loctite 638

2. Cylinder tube, Cylinder head, Bushing
3. Guide bushing
4. Head, Spherical bearing, Grease nipple
8-34
17. Inspecting and Adjusting Hydraulic System
R WARNING
Provide a fence around the lift truck to prevent the access of unauthorized people, as the front wheels rotates during the oil
pressure measurement.
Extend the gauge kit with the extending hose to secure the job safety.
17.1 Hydraulic Oil
R CAUTION
Keep the oil level within "H" and "L" marks on the level gauge.
Oil level
(1) Lower the fork on the flat ground.
(2) Check the hydraulic oil level using the gauge of the cap.
Note: Be careful when checking oil immediately after the 1)
operation of control lever, as bubbles of oil is
sometimes mistaken for water contamination.
611008
1. Correct level range
Item Limit
Lifting height under Low level : 12.1 L (3.2 U.S. gal)
6500 High level : 13.3 L (3.5 U.S. gal)
Lifting height 6500 Low level : 11.3 L (3.0 U.S. gal)
or more High level : 12.5 L (3.3 U.S. gal)
Inspecting oil condition

Check for the oil level, contamination and clouding (mixing
of air or oil).
Appearance Smell Conditions Countermeasure

Transparent. Color is almost
Normal Normal No need to change
same as new one.
Different oil may be Check viscosity.
Transparent but color is thin. Normal
mixed. If normal, it is usable.
Air and/or water are Separate water.
Color is changed to milky white. Normal
mixed. Then, it is usable.
Color is changed to dark brown. Bad Oxidized Exchange.
Transparent but with small Filter it. Then, it is
Good Foreign article is mixed.
black dusts. usable.
Suction filter, return filter

Check for damage or clogging, and clean or replace.
8-35
Draining hydraulic oil

(1) Prepare a drip pan for the hydraulic oil.
(2) Lift the front of the vehicle until the front tires are off
the ground.
(3) Place jack stands under the frame on both sides at the
front.
(4) Place a drip pan under the plug hole.
(5) Remove the plug and drain the hydraulic oil 1
completely.
608050
1. Plug
8-36
17.2 Control Valve
External oil leaks

Check the following.
- Oil leaks from O-rings between housings
- Oil leaks from scraper O-ring
- Oil leaks from bolt sections
Oil leaks 1
Since it is difficult to measure the amount of oil leaks from
the dismounted control valve, inspect oil leaks with the
control valve connected to the cylinder by following the
steps 1 through 3 following:
The internal leakage to be checked includes leakages
occurring at the lift spool, tilt spool, tilt lock valve and check
valves at the oil temperature of approximately 40°C (104°F).
(1) Place rated load on the forks and lift it to a height of 2
608053
approximately 1 m (3.3 ft). Tilt the masts approximately
3 or 4 degrees forward from the upright position, then
turn the key switch to the off position. 1. 3 to 4 degree 2. Approx. 1 m (3.3 ft)
(2) Remove the lift pipe, and collect oil from the port.
1
608054
1. A1 port (lift pipe is connected)
Item Standard
22.5 cc (1.37 cu. in.) max.
Oil drained
(15 minutes)
(3) When the vertical drift distance (Refer to topic of

“Vertical Drift Test” under chapter of “Test”) and tilt drift
distance (Refer to topic of “Tilt Drift Test” under chapter
of “Test”) are large, check the amount of oil leakage
from each cylinder even if the amount of oil drained in
15 minutes is less than standard volume above.
(Measured amount of oil leakage is a standard value; it
does not denote the allowable limit.)
Releasing lift lock
R WARNING
- Except when emergency, do not release lift lock forcibly.
- When releasing lift lock, turn the screw with enough attention.
8-37
When the forklift truck operation becomes impossible with

the masts or forks raised, release the lift lock on the control
valve.
- Control valve of MC model
(1) Loosen the lock nut and turn the set screw clockwise. 2
608078
1. Lock nut 2. Screw
- Control valve of FC model

(1) Loosen the lock nut and turn the set screw
counterclockwise.
2 608079
1. Lock nut 2. Screw
17.3 Adjusting Main Relief Valve (MC model)
R CAUTION
- Use 20 MPa {200 kgf/cm} pressure gauge.
- Turn the adjusting screw of the control valve gradually, because it is very sensitive.
(1) Turn the key switch to off position.

(2) Release pressure in the pipings. (Refer to “Preparation”
of under “Removing Control Valve”) 2
(3) Remove the gauge port plug and connect the pressure
gauge with the adapter. 1
3
608055
1. Control valve 3. High pressure hose

2. Gauge port
8-38
(4) Turn the key switch to the on position, and pull the Lift
lever to the top end.
1
(5) Read the indication of the pressure gauge with pulling 2
the Lift lever.
608060
1. Pressure gauge 2. Main relief valve

3. Adjusting screw
Item Standard
18.1 MPa
Main relief valve set
(184.57 kgf ·cm2)
pressure
[2625.2 psi]
(6) If the relief pressure is out of this specification, loosen

the lock nut of the relief valve, and while observing the
gauge indication, adjust the pressure using the
adjusting screw.
(7) While pressing the adjusting screw, tighten the lock nut
securely.
(8) After tightening the lock nut, check the set pressure of
the relief valve again.
17.4 Adjusting Microswitch
Microswitches of low-speed lift, tilt and attachment

1
(1) Adjust the microswitch position to activate the switch
when the spool moves from 0.7 mm to 1.2 mm from the
neutral position. (the lever is moved from 15 to 25 mm
at the top of the lever from the neutral position. )
(2) After adjustment, apply THREEBOND [#1401] or an
equivalent product on both fixing nuts of the switch.
2)
1)
608021
1. Microswitch
Ref. Item Standard

0.1 to 0.6 mm
1) Dimension with the (0.004 to 0.024 in.)
hydraulic lever in
neutral position 24.6 mm
2)
(0.969 in.)
8-39
Microswitch of high-speed lift 1

(1) Adjust the microswitch position to activate the switch
when the spool moves from 5 mm to 5.5 mm from the
neutral position.
(2) After adjustment, apply THREEBOND [#1401] or an
equivalent product on both fixing nuts of the switch.
2)
1) 608022
1. Microswitch
Ref. Item Standard

0.1 to 0.6 mm
1) Dimension with the (0.004 to 0.024 in.)
hydraulic lever in
neutral position 29 mm
2)
(1.142 in.)
17.5 Adjusting Tilt Cylinder
(1) Tilt the masts backward to the maximum position.

(2) Measure the backward tilt angles of both right and left
tilt cylinders. 2
(3) To adjust, loosen the socket tightening bolt, turn the tilt
cylinder rod, and adjust the cylinder stroke until the
right and left tilt cylinders are tilted at the same angle.
Note: The forward tilt angle of the masts is automatically set
when the backward tilt angle is adjusted.
1
608056
1. Bolt 2. Hexagonal section
Specified tilt angle (Forward / Backward)

5° - 7.5°
8-40
17.6 Adjusting Lift Cylinder Stroke
R CAUTION
When lowering the piston rod, operate the lift lever to lower the masts and release oil from the cylinder.
- Gently raise the inner masts, and observe the right and
left piston rod stopping conditions when they reach
the maximum lift position.
- If the upper parts of the inner masts shake at the
moment of stopping, make adjustment with shims.
Improper adjustment causes the inner mast to slant
slightly when the mast is stopped, and also causes the
lift cylinder with a longer cylinder stroke to shake when
the lift cylinder is stopped.
204698
(1) Raise the inner masts, and place wood blocks under the
inner masts. Lower the masts until the inner masts
contact the wood blocks.
608028
(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. 1
(3) Raise the piston rod, then tighten the lift cylinder
stopper bolt. Remove the wood blocks from under the
inner masts. 2
(4) Lower the inner masts gently, and check to see if the
piston rods move smoothly until the inner masts reach
the lowest position.
608057
1. Stopper bolt 2. Shim
17.7 Inspecting Piping
(1) Check the piping for oil leaks.

(2) Check the rubber hoses for damage, twisting and
sagging.
8-41
18. Tests
18.1 Vertical Drift Test
(1) 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 to the off position.
(2) Draw a reference line on a mast, and measure the
descent (retraction of lift cylinder) for 15 minutes. 2 1
608058
1. Outer mast 2. Inner mast
Item Standard
Rod retraction stroke in the vertical drift test 1 ton class
50 mm (1.97 in.)/15 min
(at the rated load)
2 ton class max.
(Oil temperature: 40 to 50°C (104 to 122°F))
18.2 Tilt Drift Test
(1) Set the masts upright with rated load, raise the forks
approximately 500 mm (19.7 in.), then turn the key
switch to the off position.
(2) Measure the amount of the tilt cylinder extension after
15 minutes.
608059
Item Standard
Rod retraction stroke in the tilt drift test 1 ton class
(at the rated load) 22 mm (0.87 in.)/15 min.
(Oil temperature: 40 to 50°C (104 to 122°F)) 2 ton class
8-42
19. Troubleshooting

Improper oil viscosity Change oil.
Excessive workload caused by severe
Reduce the work load.
work condition
Local heating caused by large
Check and repair the line.
resistance due to clogged line
Hydraulic tank heats
extremely Improper adjustment of relief valve Adjust.
Low set pressure due to spring fatigue
Replace the spring.
Hydraulic tank or damage
Worn gear pump Replace.
Flattened discharge line or clogged line Check and repair or replace the line.
Inspect any damages on hoses.
Hydraulic oil is bubbled Air is mixed
Re-tighten of the hose clamp.
Air and/or water are mixed Change oil.
Color of hydraulic oil is
changed Oxidized or contaminated with foreign
Change oil.
articles
Check hydraulic oil level. Check suction
Insufficient pump suction
Pump produces loud line and pump for air sucking.
abnormal noise Check suction line and pump for air
Cavitation
sucking. Tighten or replace as required.
Applied pressure exceeded rating Adjust pressure.
Damage in pump case
or pump port flange Deformation or damage caused by
Oil pump Relief the external force.
external force
Oil leaks from oil seal Replace.
Oil leaks from sliding surface of drive
Replace oil seals
Oil leaks from pump shaft
Loose pump tightening bolt Tighten.
Deteriorated seal inside pump Replace the seal.
8-43

Disassemble and clean. Proportional
Sticking of shuttle in proportional
solenoid cannot be disassembled. If
electromagnetic valve or plunger in
plunger in proportional solenoid is
proportional solenoid
sticking, replace solenoid.
Pump pressure does not Open circuit in lead wire or solenoid
increase. Repair or replace.
coil
Check to make sure specified maximum
Low input current to solenoid
current is supplied.
Sticking of spool in flow priority valve Disassemble and clean.
Abnormally high oil temperature flow
Remove the cause that is reducing fluid.
in pipe
Replace hydraulic fluid and clean
Dirty hydraulic fluid
hydraulic circuits.
Overtightened pipe port joint Check tightening torque.
Loosen mounting bolts, and check
Improper valve housing installation
valve housing installation.
Install pressure gauge on inlet and
Excessively high pressure
Spool sticks. cylinder circuit, and check pressure.
Foreign particles stuck on spring seat Disassemble and clean.
Bent spool Replace valve assembly.
Control valve Disassemble and clean. Proportional
Sticking of shuttle in proportional
solenoid cannot be disassembled. If
electromagnetic valve or plunger in
plunger in proportional solenoid is
proportional solenoid
sticking, replace solenoid.
Uneven temperature distribution inside
Warm up entire hydraulic circuits.
valve
Oil leaks from cylinder Check cylinders.
Oil bypassing valve spool Replace valve.
Load cannot be
maintained. Remove and clean overload relief valve
Leaks from overload relief valve or shut-
or hut-off valve (housing and relief
off valves
valve seat section).
Load drops when spool
Foreign particles stuck on load check
is switched from neutral Disassemble and clean.
valve.
to lift.
Paint adhesion on seal Remove and clean seal.
Check filter in return circuit for clogs, or
High back pressure in return circuit of
check foreign particles stuck in return
valve
pipe.
Oil leaks from oil seal.
Foreign particles stuck on seal Remove and clean seal
Loose cap Clean cap and tighten cap bolts.
Rips or scratches on seal Replace seal.
8-44

Malfunction of pump Check pressure, or replace pump.
Clogs in relief valve Disassemble and clean relief valve.
Malfunction of relief valve Check according to service procedures.
Worn cylinders Repair or replace.
Hydraulic system
Hydraulic
operates abnormally or Excessive load Check circuit pressure.
system
does not operate at all.
Cracking in valve Replace valve.
Low oil level in tank Add oil.
Clogged filter in circuit Clean or replace filter.
Flow restriction in circuit pipe Check pipes.
Open passage due to sticking of main Check poppet joint for foreign -
Pressure does not poppet or pilot poppet particles. Poppet must slide freely.
increase at all.
Foreign particles stuck on poppet seat Clean all parts thoroughly.
Scratches on poppet seat Replace damaged parts.

Relief pressure is
Clean all parts thoroughly.
unstable. Sticking of poppet Remove surface scratches.
Wear due to abrasion by dust particles Replace damaged parts.
Relief Valve Incorrect relief pressure.
Loose lock nut and adjusting screw Readjust.
Damaged seats Replace damaged or worn parts.
Worn O-rings All parts must move smoothly.
Oil leaks.
Check there is no scratch, dent or
Sticking of parts due to foreign particles
foreign particles.
Pressure increases
Air in relief valve Bleed air.
slowly.
8-45

Insufficient oil in hydraulic tank Replenish.
Relief valve malfunction
(1) Sticking of main valve Repair or replace.
(2) Broken valve spring
Masts do not rise or tilt
in either forward or Gear pump malfunction Repair or replace.
backward direction Malfunction of the microswitch of the
Repair or replace.
control valve
Over-discharge of the battery Charge the battery.
Operator is not seated Sit down the seat.
(1) Low relief set pressure
(2) Faulty plunger or poppet seat Repair or replace.
Rated load cannot be (3) Spring settling
lifted (4) Damaged valve case O-ring
Gear pump malfunction Repair or replace.
Worn or damaged piston seal Replace.
Insufficient oil (due to natural oil
Replenish.
consumption)
Oil leaks from oil line or due to
Replace the seal.
damaged seal
Oil viscosity higher than specified Change oil.
Check oil line and pump. Repair or
Lift and tilt Cylinders operate very No oil suction by gear pump
replace.
cylinders slowly
Oil leaks from hydraulic circuit Check oil line.
Abnormal oil temperature rise Inspect the hydraulic system.
Over-discharge of the battery Charge the battery
(1) Low relief set pressure Repair or replace.
(2) Plunger does not work properly
Slow pump rotation Check pump. Adjust or repair.
Insufficient spool stroke due to loose
Tighten.
operation lever
Rising speed is very slow
Clogged hydraulic tank filter Repair or replace.
Insufficient gear pump discharge
Check pump and suction line.
volume
Bent hydraulic hose or large resistance
Lowering speed is very
in hydraulic circuit due to sectional Repair or replace.
slow
clogging
Bent piston rod Replace.
Cylinders shake during
Air mixed in hydraulic piping Check piping and repair.
operation
Insufficient operating oil in tank Replenish.
Activation timing of lift microswitches
There is too much shock Adjust.
is improper
when starting to rise
Malfunction of relief valve Replace
8-46

Leaks inside control valve spool Replace valve.
Large or deep scratches on sliding
Large gravitational-pull surface of cylinder tube that are Replace.
lowering distance in lift enough to be detected by finger nails
cylinders
Damage or deformation of piston seal Replace.
Oil leaks from hydraulic piping Repair.
Leaks inside control valve spool Replace.
Lodging of foreign particles on packing Clean or replace.
Large gravitational-pull
Damage of piston seal Replace.
lowering distance in tilt
cylinders Scratches on piston seal Replace.
Lift and tilt
cylinders Abnormal shape deformation or leaks
Repair or replace.
from hydraulic piping
Lift cylinders or tilt Large sectional scratches or rusting on
Replace.
cylinder drop or tilt inner surface of cylinder
forward naturally at
certain position Deformation of cylinder Replace.
Lodging of foreign particles on seal Clean or replace.

Damage of the packing in the cylinder Replace.
Oil leaks from retainer
Looseness of retainer Tighten.
Damage on the rod Repair or replace.
Oil leaks from cylinder Damage of the welded part Replace.
8-47
20. Service Data
20.1 Gear Pump

Forward tilt angle
- Standard 5°
[Standard simplex mast truck]
Backward tilt angle
- Standard 7.5°
[Standard simplex mast truck]
Lift cylinder vertical drift (at rated load) 50 mm
- (Rod retraction stroke) (Oil temperature Standard (1.97 in.)
40 to 50 °C (104 to 122 °F)) (15 minutes)
Tilt cylinder drift (at rated load) 22 mm
- (Rod extension stroke) (Oil temperature Standard (0.87 in.)
40 to 50 °C (104 to 122 °F)) (15 minutes)
- Displacement Standard 18.9 cc (1.15 cu.in.)/rev
1 Tightening torque for mounting bolts Standard 19.6 to 24.5 N·m (2.0 to 2.5 kgf ·m) [14.5 to 18.1 lbf·ft]
2 Tightening torque for elbow Standard 69 ± 7 N·m (7.04± 0.71 kgf ·m) [50.89 ± 5.16 lbf·ft]
3 Tightening torque for connector Standard 108 ± 11 N·m (11.01± 1.12 kgf ·m) [79.66 ± 8.11 lbf·ft]
3
608091
8-48
20.2 Control Valve (MC)

- Rated flow rate Standard 60 L/min (3661.98 cu.in/min) [15.85 U.S.gal./min]
- Main relief valve setting Standard 18.1 MPa (184.57 kgf ·cm2) [2625.2 psi]
20.3 Lift Cylinder
Lift Cylinders (Simplex Mast, Triplex Mast second cylinder)

1 Inside diameter of cylinder Standard 45 mm (1.77 in.)
2 Outside diameter of piston rod Standard ø35 mm (1.38 in.)
170 to 240 N·m
3 Tightening torque for retainer Standard (17.3 to 24.5 kgf·m)
[125.4 to 177.0 lbf·ft]
4 Amount of hydraulic oil Standard 57 cc (3.48 cu.in.)
2 1 4
608034
8-49
Lift Cylinders (Duplex Mast, Triplex Mast first cylinder)

2 Outside diameter of piston rod Standard ø50.8 mm (2.00 in.)
353 to 380 N·m
3 Tightening torque for retainer Standard (36 to 39 kgf·m)
[260 to 280 lbf·ft]
4 Amount of hydraulic oil Standard 20 to 25 cc (1.2 to 1.5 cu.in.)
2 1
3 4
608067
8-50
Lift Cylinders (Duplex Mast second cylinder)

Retainer thread diameter Standard M52 x 2
3 170 to 240 N·m
Tightening torque for retainer Standard
(17.3 to 24.5 kgf·m) [125.3 to 177.0 lbf·ft]
4.5 to 5.0 N·m
4 Tightening torque for air bleed screw Standard (0.46 to 0.51 kgf·m)
[3.3 to 3.7 lbf·ft]
4 1 2
3
608068
8-51
Lift Cylinders (Triplex Mast second cylinder, Mast height :6500/700)

244 to 271 N·m
3 Tightening torque for retainer Standard
(24.9 to 27.6 kgf ·m) [180 to 200 lbf·ft]
1 2
608066
8-52
20.4 Tilt Cylinder

1 Inside diameter of cylinder shell Standard 60 mm (2.36 in.)
Outside diameter of
2 Guide bushing Standard 25 mm (0.98 in.)
piston rod
1 2
608065
8-53
21. MC Control Valve
21.1 General Description
3) 4)
6
2)
A1
T
A2
P 1
5 B2
1)
4 5)
3 2
501572
1. Inlet cover section 1) P : Pressure oil inflow port from pump

2. Lift valve (with built-in flow regulator valve) 2) T : To hydraulic tank (return line)
3. Tilt valve 3) A1 : To lift cylinder
4. Attachment valve 4) A2 : To tilt cylinder rod end
5. End cover section 5) B2 : To tilt cylinder head end
6. Main relief valve
The above illustration shows an external view of the MC Tilt valve 3 feeds and returns pressure oil to and from the tilt
control valve. Any one of the three valve to four-valve type cylinder which tilts the mast forward or backward. The tilt
valves is installed on a truck depending on the lift truck lock valve is assembled in the main spool to ensure safety
specifications. when the mast is tilted forward.
The most basic valve configuration is a two-valve type, Attachment valves 4 and 5 are direction control valves
combination of the lift and tilt. Adding attachment valve(s) which feed pressure oil to actuators of the attachments.
to this combination is three-valve type or four-valve type
valve.
The inlet cover section is provided with main relief valve 6.
The valve limits the maximum pressure to protect the
system.
Lift valve 2 and tilt valve 3 are assembled adjacent to the
combination section.
Lift valve 2 is a direction control valve which feeds and
returns pressure oil to and from the lift cylinder. Oil returns,
namely through the descent hydraulic circuit that has a
built-in lock valve linked with the flow regulator valve and
the seat switch.
8-54
21.2 Hydraulic Circuit Diagram
9
8
10 13 14 15 16 17
11
12
6
1 2 4
5
3
608081
1. Pump motor 10. Gauge port

2. Gear pump 11. Pump port
3. Hydraulic tank 12. Tank port
4. Return filter 13. A1 port (lift cylinder)
5. Suction filter 14. B2 port (tilt forward)
6. Control valve 15. A2 port (tilt backward)
7. Lift cylinder with down safety valve 16. B3 port (attachment)
8. Tilt cylinder 17. A3 port (attachment)
9. Attachment
8-55
21.3 Hydraulic Circuit
Lift Up
9
8
10 13 14 15 16 17
11
12
6
1 2 4
5
3
608082

9. Attachment
8-56
Lift Down
9
8
10 13 14 15 16 17
11
12
6
1 2 4
5
3
608083

9. Attachment
8-57
Tilt Forward
9
8
10 13 14 15 16 17
11
12
6
1 2 4
5
3
608085

9. Attachment
8-58
Tilt Backward
9
8
10 13 14 15 16 17
11
12
6
1 2 4
5
3
608084

9. Attachment
8-59
21.4 Structure - Inlet Cover Section
1)
P
501573
1. Main relief valve 1) P : From hydraulic pump (pump port)
The inlet section of the control valve has of the main relief
valve, which limits the maximum pressure of the hydraulic
system.
Main relief valve

This valve is a relief valve with a pilot valve. When pressure 3 4 1 2
in the P port reaches the set value, poppet valve 1 is pushed
to the left (in the illustration), leaving the seat. Pilot oil in the
spring chamber flows in the drain passage. Then, dump 2)
valve 2 moves to the left, releasing a part or all of main flow
to the low-pressure passage.
This is a safety valve to protect the system.
To adjust, turn adjusting screw 3 to change preload of 1)
spring 4.
5 6 501574
1. Poppet valve 5. Drain passage of pilot oil

2. Dump valve 6. Spring chamber
3. Turn adjusting screw 1) Low-pressure passage
4. Change preload of spring 2) High-pressure passage poppet
8-60
21.5 Structure - Lift Valve
4 5 6 7 8 9 10
3
11
15 14 13 13 12
501575
1. Set, screw 9. Check case assy

2. Cap 10. Emergency plug assy
3. Coil assy 11. FRV
4. Solenoid valve 12. Lift spool
5. O-ring 13. Dust seal
6. Plug retainer assy 14. Plate seal
7. Spring 15. Spring retainer
8. Poppet
The above illustration shows the lift control valve when

spool 1 is at the "neutral position."
8-61
21.6 Structure Tilt Valve
12
3
1) 2) 6
A2 B2
2
7
9
8 10
T2 1
5 4 11 3) 501576
1. Tilt spool 9. Neutral

2. Return spring 10. Backward tilt
3. Check valve 11. Center bypass port
4. Tilt lock valve 12. Passage A (high-pressure passage)
5. Tilt lock valve spring 1) A2 : To tilt cylinder rod
6. Valve body 2) B2 : To tilt cylinder head
7. Hole 3) T2 : Tank port (return passage)
8. Forward tilt
The above illustration shows the tilt control valve when Mast backward tilt position :
spool 1 is at the "neutral position."
The B2 port is connected to the T2 port and the A2 port is
Neutral position connected to passage A. The spool is positioned to block
Spool 1 is placed at the "neutral position" by return spring 2, the center bypass port, but as the spool is provided with a
and both the A2 port and B2 port are blocked by the spool. hole under the land, it does not block completely. This is
As the center bypass valve is open, oil in the bypass port designed to prevent a large amount of oil from flowing at a
flows in the attachment valve. time to avoid abrupt movement of the cylinder, a
characteristic of this valve.
When the center bypass port is blocked, pressure in the
parallel feeder rises. Pressure oil pushes open check valve 3,
flows in passage A and flows to the tilt cylinder rod from the
A2 port.
At the same time, oil in the tilt cylinder head flows to the T2
passage.
These two actions pull the rod into the tilt cylinder.
8-62
3
A2 B2 6
2 2
5
2)
4) 5)
4
T2
1)
(b) 1
(a)
(c) 3)
501577
1) Passage A 4) Forward tilt
2) Hole 5) Neutral
3) Chamber
Mast forward tilt position

The above illustration shows the tilt control valve when
spool 1 is at the "forward tilt position."
Spool 1 is pushed into body 6. Then, the B2 port is
connected to passage A.
At the same time the center bypass port is blocked. This
blockage, however, is not complete because there is a hole
under the land. This is designed to prevent abrupt
movement of the cylinder, a characteristic of this valve.
As the center bypass port is blocked, pressure in the parallel
feeder rises, pushing open check valve 3 and pressure oil
flows to passage A.
Oil in passage A flows to the tilt cylinder head from the B2
port and acts to push out the cylinder rod.
At the same time, pressure oil in passage A flows to the
chamber on the right end of tilt lock valve 4 via orifice (a)
and pushes the tilt lock to the left against spring 5.
Then, return oil from the A2 port flows to the hole (b),
passage (c), orifice (d) and passage T2.
The tilt cylinder tilts forward due to pressure oil supplied
from the B2 port and "opening" of the return passage of the
A2 port.
Tilt lock valve 4 does not operate unless the engine runs and
pressure oil is supplied from the pump.
This valve is a kind of an anti-disaster valve.
8-63
22. Construction and Function of FC Control Valve
SB1 SB2 SB3

1) 7)
3)
P B3
A1
B2 5)
T A3
6)
2)
SA1 SA2 SA3
6
1 2 4)
3
A2
4
501187
13. Inlet Section 1) P: From hydraulic pump

14. Tilt Section 2) T: To hydraulic tank (return oil)
15. Attachment section 3) A1: To lift cylinder
16. End plate 4) A2: To tilt cylinder (rod end)
17. Electromagnetic proportional solenoid valve 5) B2: To tilt cylinder (head end)
18. Main relief valve (Pilot valve) 6) A3: To attachment actuator
7) B3: To attachment actuator
8-64
22.1 Outline
This control valve assembly consists of the following

assemblies:
(1) Inlet section 1
(2) Tilt section 2
(3) Attachment section 3
(4) End plate 4
The electromagnetic proportional solenoid valve and the
lift-lock solenoid valve for lift, tilt and attachment valves are
energized by electric current from the output unit. The
controller determines the amount of the current through
calculation based on the amount of movement of joystick.
Functions of Inlet Section 1
(1) Hydraulic oil inflow port from pump.
(2) Controls the oil pressure to the lift/tilt / and attachment
circuits
(functions as a bleed-off valve of the circuit).
(3) It works as a lift valve to raise and lower the forks by
supplying hydraulic oil to the cylinder and controlling
return flow from the lift cylinder.
Functions of Tilt Section 2
Controls hydraulic oil supply to tilt cylinder and return oil
amount from the tilt cylinder for forward and backward tilt
actions of the mast.
Functions of Attachment Section 3
Controls hydraulic oil supply to the hydraulic actuator and
return oil amount from hydraulic actuator for attachment
operation.
8-65
22.2 FC Hydraulic System Circuit
Overview of Hydraulic System with Circuit Diagram

For the construction of each valve, refer to the operational
description of the relevant valve.
4) 16
18 15 14
ATTACHMENT B3
17 A3
17
3)
15
18
11
TILT
13 A2
B2
2) 12
18 7
LIFT
10
A1
1) 9 8
6
20 5
4 19
Pump 3
1
Tank 2
500971
Note: Hydraulic circuit for lift and valve (3-10) 7. From hydraulic pump 20.Attachment spool
Hydraulic circuit for attachment and valve (14-18) 8. To hydraulic tank 21.Port for relief valve
9. Bleed-off valve (BO valve) 22.Port relief valve (OP)
10.Relief valve (Pilot valve) 23.Double pilot check valve
11.Lift lock solenoid valve 24.Shuttle valve
12.Shut-off valve 25.Supply oil gallery to the circuit
13.Lift spool 26.Load pressure (Load sensing)
14.Flow control valve 1) Inlet section
15.Lift lock valve 2) Tilt section
16.Lift cylinder 3) Attachment section
17.Tilt spool 4) End plate
18.Tilt lock valve
(counter-balance valve)
19.Tilt cylinder
8-66
The FC hydraulic system features the lift/tilt and attachment Oil flow with all the joysticks in their neutral
circuits that are arranged in parallel. positions:
The hydraulic oil from the hydraulic pump flows through When all the joysticks are in their neutral positions, valves
the P port into the inlet section of the control valve. The are de-energized without current, allowing the load
hydraulic oil from the section is directly sent to the bleed-off pressure oil to drain into the return passage, no load
valve 3, and utilized as a working oil to move the lift/tilt pressure builds up.
cylinders and hydraulic actuator of the attachment.
The electromagnetic proportional solenoid valves of all the
The bleed-off valve 3 keeps the differential pressure among control valves are de-energized, so the main control spools
lift spool , tilt spool and attachment spool 14 constant. The are in their neutral positions.
lift spool 7, tilt spool 11 and attachment spool 14 are
The supply of oil is interrupted with lift, tilt and attachment
installed in the inlet section 1) ,tilt section 2) and attachment
spools. The load pressure 20 is also interrupted, and the
section 3) in control valve. They work as throttles and supply
bleed-off valve 3 is relieved.
certain amount of oil to the lift/tilt/attachment circuit
corresponding to the joystick operation.
The oil flowed into the bleed-off valve 3 is sent to the
Owing to the function of bleed-off valve 3, the cylinder can
hydraulic tank through the T port.
always extend and retract at a speed proportional only to
the amount of the joystick movement under any load Oil flow with the lift/tilt/attachment joystick moved
conditions. to an operating position:
Load pressure 20 shown by dotted line in the hydraulic When an electric current goes through the electromagnetic
circuit diagram on the previous page represents the oil proportional solenoid valve in lift/tilt/attachment control
passage that transmits the static pressure, i.e., the load valve, the load pressure 20 is applied to the spool of bleed-
pressure created by passing through the spool (or throttle). off valve 3. The main spool is pushed to the valve housing
side in proportion to the amount of joystick movement.
As a result, the oil flowing through supply oil passage 19 to
the control valve enters one end of the cylinder and the oil
on the opposite side of the piston drains into the return
passage.
The oil flows through passage 19 at a constant rate that is
made proportional to the amount of the joystick movement
by the function of bleed-off valve 3.
The excessive oil flows from bleed-off valve 3 to the
hydraulic tank through T port.
8-67
22.3 Bleed-off valve
1) B A
B2
3
A2 B
5 A
SA2
T T C
SB2
4 1 2(B)
2) 12
P 1 T 10 8
7
11
9
SB1 SA1
6 1
500980
1. Hydraulic oil supply passage to lift/tilt / attachment 7. Pressure oil chamber

circuits 8. Spool
2. Passage (load pressure open chamber) 9. Spring
3. Tilt lock valve 10. Oil passage to tank
4. Passage for load pressure oil 11. Chamber
5. Shuttle valve 12. Pilot valve (relief valve)
6. Bleed-off valve 1) Tilt section
2) Inlet section
8-68
Bleed-off Valve Operation in Relation to Load
Pressure
(1) The FC hydraulic system consists of the following main In the shown case where hydraulic supply oil is flowing to
circuits: the tilt cylinder, the pressure of the tilt load pressure oil in
- Circuit for lift tilt / attachment port B is higher than that of attachment load pressure oil in
(2) The bleed-off valve for the lift/tilt / attachment circuit is port A.
incorporated in the inlet section.
(3) Bleed-off valve 6 is a pressure control valve that creates The hydraulic oil from port B pushes down the steel ball in
a constant flow amount by making constant the valve 5 and closes port A while opening the passage from
difference in static pressure between the upstream side port B to port C.
and downstream side of the throttle of the lift/tilt/
attachment valve spool. (The flow amount is a product The load pressure oil of port B flows to port C, then pilot oil
of the throttle flow amount and opening area of the flows from there to the chamber of bleed-off valve 6.
throttle. )
(4) The static pressure of oil flowing through the throat In bleed-off valve 6, the position of spool 8 is determined by
(throttle) of the lift/tilt/attachment valve is led through the balance of different forces as follows:
load pressure oil passage 2 to bleed-off valve.
- The hydraulic oil in supply passage 1 (with a pressure
The diagram on the preceding page shows the tilt spool,
equal to that of the oil in the passage before the
bleed-off valve and shuttle valve in the states in which they
throttle) enters chambers 11, pushing spool 8 left and
are placed when the joystick is placed in the "tilt backward" attempting to make part of the oil in passage 1 flow
position. into passage 10.
The tilt spool is moved right, allowing the hydraulic oil in the - The load pressure in chamber 7 and spring 9 together
supply oil passage 1 to flow to passage 4. push spool 8 left, preventing the hydraulic oil in
passage 1 from flowing into passage 10.
The hydraulic oil then pushes up the check valve of tilt lock Spool 8 is settled in a position where the pressure in
valve 3 to open its way to the rod end of the tilt cylinder. The chamber 11 (pressure before throttle) balances with
mast is tilted backward as a result. the combined force of spring 9 and pressure in
The load pressure oil in passage 2 is led from passage 4 chamber 7 (pressure after throttle).
which constitutes a throttle, so its pressure is the static The bleed-off valve maintains a constant pressure
pressure of the hydraulic oil flowing through the throttle. difference in the following process.
When the pressure difference is too large: Too large
The load pressure oil flows to shuttle valve 5. pressure difference means that too large an oil amount is
Shuttle valve 5 selects the high pressure oils that enter from supplied to the actuator.
port A and port B and allows the selected oil to flow out to Spool 8 then moves right to allow the hydraulic oil in oil
port C. supply passage 1 to flow into passage 10.
This reduces the amount of supply oil and thus reduces the
pressure difference.
When the pressure difference is too small: Too small
pressure difference means that too small an oil amount is
supplied to the actuator.
Spool 8 then moves left to reduce hydraulic oil flow from
passage 1 into passage 10. This increases the amount of
supply oil and thus increases the pressure difference.
Through the above process, the bleed-off valve keeps an
constant oil amount passing through the throttle according
to the position of joystick. Therefore, the hydraulic oil
amount supplied to the cylinder is proportional only to the
opening created by the spool of control valve that moves in
proportion to the joystick movement. Pilot valve (relief
valve) 12 serves as the lift/tilt or attachment circuit relief
valve. When Pilot valve 12 opens, the load pressure is
released. This causes spool 8 to move right and allows the
hydraulic oil in passage 1 to flow into passage 12.
The set pressure of pilot valve 12 is
+0.5 +.5 +72.5
18.1 0 MPa (185 0 kgf/cm2) [2625 0 psi] both in lift/tilt
and attachment circuits.
8-69
22.4 Lift Valve
1 2
10
P
3) T 3)
A
2) SL 2)
5 1) 1)
1) - 1) 6 2) - 2)
A1
A
SL
3 3) - 3) 9 4
8
P T
SB1 SA1
11 12
7 500979
1. From hydraulic pump 7. Electromagnetic proportional pressure control valve

2. To hydraulic tank (Lift spool)
3. BO valve (bleed-off valve) 8. Pressure-compensated flow control valve
4. Pilot valve (Relief valve) 9. Lift lock valve
5. Lift lock solenoid valve 10. To lift cylinder
6. Shut-off valve 11. Spring
12. Spring
8-70
P T 4
SB1 SA1
12
11 3
1
501189
Condition When Joystick is in Neutral Position

The electricity in both of the electromagnetic proportional
solenoid valves (SA1 and SB1) does not flow, springs 11 and
12 installed in the right and left are placed in the center, and
the lift spool 7 remains in the center without moving in
either direction.
The hydraulic oil to lift/tilt/attachment of bleed-off valve
enters oil passage 1, and the oil remains there as the exist of
lift spool 7 of oil passage 1 is blocked.
Since the return oil passage from the A1 port is also blocked
by lift lock valve 9, the hydraulic oil in the lift cylinder cannot
be drained.
8-71
2) - 2) 3) - 3)
15 16
A1 3 P T
9
SB1 SA1
13 14 7 1 13
501190
Operation when Joystick is in Lift-up Position

When an operator moves the joystick in the lift-up direction,
the controller supplies the electromagnetic proportional
solenoid valve (SA1) with current that is proportional to the
amount of movement of the joystick.
Lift spool 7 is pushed to the left.
Lift spool 7 moves further to the left as the amount of the
joystick movement increases.
The hydraulic oil in oil passage 1 of lift/tilt/attachment
circuit flows to oil passage 13.
Then the oil pushes up pistons of check valve 14 and lift lock
valve 9, and flows to A1 port.
The hydraulic oil from the A1 port flows to the lift cylinder
bottom, and extends the piston rod to lift the mast.
The pressure in passage 13 (load pressure) is released from
port 15. This load pressure is sent to shuttle valve 16, and
there it is compared with the load pressure from the tilt or
attachment valve. And the higher load pressures is sent to
the bleed-off valve 3.
8-72
2) - 2) 3) - 3)
G T
A1 P T
9
19 19
SB1 SA1
T T
5 1) - 1)
17
8 19 18 T
501191
Operation when Joystick is in Lift-down Position
The oil pressure in G chamber of of lift lock valve 9 is At the same time, when lift lock solenoid 5 is turned ON, the
connected to cylinder port A1, and the lift lock valve 9 is pressure in G chamber is drained to tank port T and the
closed by the difference of area when the pressure is the pressure balance of lift lock valve 9 is disturbed. This results
same. in the movement of piston to the left and the opening of lift
lock valve.
When an operator moves the joystick in the lowering
The hydraulic oil from the lift cylinder returns to the tank,
direction, the controller supplies the electromagnetic
being restricted by the pressure-compensated control valve
proportional solenoid valve (SB1) with current that is
8, to adjust the descending speed of lift cylinder.
proportional to the amount of movement of the joystick
lever. The A1 port hydraulic oil that comes from the lift cylinder
flows through passage 18 and then passage 19.
Lift spool 7 is pushed to the right.
Since passage 19 opens to the hydraulic tank, the hydraulic
Lift spool 7 moves further to the right as the amount of the
oil from the cylinder can be drained into the tank. As a result,
the cylinder will be retracted, causing the mast to lower.
Shut-off valve 7 is provided as an emergency valve that
provides means to lower the mast if lift lock valve 9 is stuck
for some reason. Loosening the set screw after loosening
the lock nut, the hydraulic oil from the A1 port opens lift lock
valve 9, and flows directly to passage T.
8-73
22.5 Tilt Valve
B2 4
2
A2
3
5
8
SA2
T T
SB2
9 7 1 10
6
500984
1. Tilt spool 6. Passage to B2 port
2. Tilt lock valve (counter-balance valve) 7. Passage to A2 port
3. Pilot check valve 8. Load pressure passage
4. Piston 9. Spring
5. Shuttle valve 10. Spring

Since both of the electromagnetic proportional solenoid
valves (SA2 and SB2) are de-energized, springs 9 and 10
position in the center, and tilt spool 1 moves in neither
direction remaining in the neutral position.
The hydraulic oil of lift/tilt/attachment in bleed-off valve
enters oil passage P, and the oil remains there as the exist of
the passage P is blocked by the tilt spool 1.
The hydraulic oil from A2 port and B2 port is also blocked by
tilt lock valve 2 and pilot check valve 3.
8-74
B2 4
2
A2
3
5
6 7
PP SA2
T
SB2
1
500986
Operation when Joystick is in Tilt-backward Position

When an operator moves the joystick in the backward tilt
proportional solenoid valve (SB2) with current that is
proportional to the amount of movement of the joystick.
The current in the solenoid valve is in proportion to the
current.
Tilt spool 1 is pushed to the right.
Tilt spool 1 moves further to the right as the amount of the
The hydraulic oil in oil passage P of lift/tilt/attachment
circuit flows to oil passage 6. The oil pushes up the valve of
tilt lock valve 2 and flows to B2 port.
The hydraulic oil comes out from the B2 port enters the rod
end of the tilt cylinder and acts on the piston to retract the
cylinder rod.
Simultaneously, with the hydraulic oil flow to the rod end of
the cylinder, the hydraulic oil from the head end flows
through the A2 port, passage 7 and passage T (return oil
passage) to the hydraulic tank.
By the two hydraulic oil flows created through the process
mentioned above, the tilt cylinder rods retract and the mast
tilts back.
8-75
11
B2
2
A2
3
4 7
6
T
SB2 SA2
1 500987
Operation When Joystick is in Tilt-Forward Position The hydraulic oil in the oil passage connecting the rod end
of tilt cylinder and B2 port is finally discharged into the
When an operator moves the joystick in the tilt-forward
hydraulic tank through oil passage 6.
proportional solenoid valve (SA2) with current that is By the two hydraulic oil flows created through the process
proportional to the amount of movement of the joystick. mentioned above, the tilt cylinder rod extends and the mast
The current in the solenoid valve is in proportion to the tilts forward.
current.
Operator Emergency Actions
Tilt spool 1 is pushed to the left. Should the tilt spool stick during forward tilting operation,
The hydraulic oil in oil passage P of lift/tilt/attachment the operator needs to take the following actions:
circuit flows to oil passage 7. The hydraulic oil pushes up (1) Place the joystick in the neutral position. The pressure
pilot check valve 3, then goes out of the A2 port, and flows of the hydraulic system will go down.
into the head end of the tilt cylinder. As a result the piston (2) Shut down the engine to stop hydraulic oil supply to
moves to extend the cylinder. the circuit. The pressure in passage 8 will be released.
By taking the two actions described above, piston 11 in tilt
A portion of hydraulic oil in oil passage 7 flows through oil
lock valve 2 moves right, preventing the rod end oil in the
passage 8 and into the chamber of tilt lock valve 2. Piston 11
tilt cylinder from returning to the hydraulic tank. This stops
in tilt lock valve 2 moves to the left, and tilt lock valve 2
the mast from tilting forward.
opens.
8-76
22.6 Attachment Valve
4 3
3
B3 A3
PP SA3
T T
SB3
P
7 5
6 1 8
500988
1. Attachment spool 5. Passage to B3 port
2. Shuttle valve 6. Passage to A3 port
3. Pilot check valve 7. Spring
4. Piston 8. Spring

Since the electromagnetic proportional solenoid valves
(SA3/SA4 and SB3/SB4) are de-energized, attachment spool
1 is held in the neutral position by springs 7 and 8 in right
and left without moving in either direction.
The hydraulic oil from the passage of attachment circuit
enters passage P, but cannot flow further as the outlet of
passage P is blocked by attachment spool 1.
Hydraulic oil from A3 and B3 is also blocked by pilot check
valve 3.
R CAUTION
The attachment valve for the No. 4 attachment circuit is identical with that for the No. 3 attachment circuit.
8-77
4
3 3
B3 A3
2
7
6
SA3
T K T
SB3
P
5 6 1 8
500990
Operation When SA3 Solenoid is Energized

When electromagnetic proportional solenoid valve (SB3) is
energized, attachment spool 1 moves right and pushes
spring 8.
In this movement, the hydraulic oil in oil passage P of
attachment circuit flows to oil passage 5.
The hydraulic oil flows into oil passage 5, pushes up pilot
check valve 3 and flows to B3 port.
The pressure of the hydraulic oil that comes out from the B3
port acts on the hydraulic actuator of the attachment.
The return oil from the hydraulic actuator enters the control
valve through the A3 port, and then flows through pilot
check valve 3 and passage 6 to the hydraulic tank.
8-78
4 3
3
B3 A3
SA3
T J T
SB3
P
7 5
6 1
500989
Operation When SB3 Solenoid is Energized

When electromagnetic proportional solenoid valve (SA3) is
energized, main spool moves light and pushes spring 7.
In this movement, the hydraulic oil in oil passage P of
attachment circuit flows to oil passage 5.
The hydraulic oil flows into oil passage 5, pushes up pilot
check valve 3 and flows to B3 port.
The pressure of the hydraulic oil that comes out from the B3
port acts on the hydraulic actuator of the attachment.
The return oil from the hydraulic actuator enters the control
valve through the A3 port, and then flows through pilot
check valve 3 and passage 6 to the hydraulic tank.
8-79
23. Removing FC Control Valve
23.1 Preparation
(1) Place the mast in vertical position, lower the forks, and
before removing pipes, release the residual pressure in
the pipes.
(2) Remove the floor plate.
6 1
2
4
5
3 501266
1. Electric wires of proportioning solenoids (remove the 4. Lift line

connectors) 5. Return hose to hydraulic tank
2. Tilt pipe, Connector, O-ring 6. valve mounting bolt
3. Pump delivery hose
(1) Remove the control valve at the end of each pipe and
hose. If necessary, loosen the clamps so the pipes and
hoses do not obstruct removal of the control valve.
(2) Remove the bolts that secure the control valve to the
dashboard, and remove the control valve.
24. Installing FC Control Valve
To install, follow the removal sequence in reverse. Also
follow the instructions below.
Check the hydraulic oil level. If the oil level is low, add
hydraulic oil to the specified level.
8-80
25. Disassembly of FC Control Valve
1
2
8
6 5 4 3
500992
1. Tie rod nut 5. Inlet section (with lift section)
16.7 ± 1.7 N·m (1.70 ± 0.17 kgf·m) [12.32 ± 1.25 lbf·ft] 6. Pressure relief valve for lift/tilt / attachment circuit
2. End plate 7. Shut-off valve assembly
3. Attachment section
4. Tilt Section
R CAUTION
The above shows the complete disassembling sequence of control valve assembly. The control valve assembly can be
disassembled partially when a pressure release, inspection and/or troubleshooting for a specific valve section is required.
8-81
(1) Thoroughly clean the exterior of the control valve

assembly.
(2) Be careful not to damage the finished surface of each
port.
(3) Do not loosen the lock nut of the pilot relief valve
adjusting screw during regular disassembly.
If the lock nut is loosened and the adjusting screw is
moved, the readjustment must be performed.
(4) If loosening an adjusting screw is absolutely necessary,
make an alignment mark before loosening it so that the
original setting can be restored at the time of
reassembly.
(5) Remove the nut from tie rod. Then each part in valve
section, starting with the end plate, can be removed.
(6) O-ring is mounted to each mating surface of valve
section. Be careful not to damage the O-ring and
mating surface when removing.
(7) When removing/installing valve speed cap, the valve
spool must be held firmly. When holding the valve
spool, use a water pliers or other suitable tool with jaws
covered by rubber pads or other suitable material to
prevent the external surface of the spool from being
damaged.
(8) If a spool is damaged, the whole valve assembly must
be replaced since the spool is not replaced separately.
For disassembly and reassembly of each valve, see the
relevant section.
26. Reassembly of FC Control Valve
Reassembly is reverse of disassembly.
8-82
27. Valves Included in the Inlet Section
1
500998
1. Lift valve 4. Lift lock valve
2. Bleed-off valve 5. Shut-off valve
3. Flow control valve 6. Relief valve for lift/tilt /attachment circuit
(Pressure-compensated flow control valve)
8-83
28. Disassembling Inlet Section
28.1 Disassembly Sequence (Part 1)
1517 18 14 2623 25 22 24
16
12 20
13 21
19
1 2 5 3 4 6 10 9 11 8 7
500994
1. Solenoid valve assembly 14. Spool
2. Spring 15. Plug
3. Plain washer 16. O-ring
4. Valve 17. Spring
5. O-ring 18. Valve
6. Spool 19. Spring
7. Solenoid valve assembly 20. Plug
8. Spring 21. O-ring
9. Plain washer 22. Sleeve
10. Valve 23. O-ring
12. Plug 25. Valve
13. O-ring 26. Spring
Note: Lift spool (1 to 11)
Bleed-off valve (12 to 21)
Relief valve (22 to 26)
- Arrange springs 2 and 8 so that they are correctly - Do not disassemble the removed sleeve 22 unless it is
installed to its original position. necessary.
8-84
1 3 2 16 17
15 14
4 12
5 13
8 7 9 10 6 11
500995
1. Solenoid valve assembly 10. Valve

3. O-ring 12. Plug
4. Plug 13. O-ring
5. O-ring 14. Nut
6. Spool 15. Screw
7. Plug 16. Valve
9. Spring
Note: Flow control valve (4 to 13)
Shut-off valve (14 to 17)
8-85
4 6 5 8 7
13
1
9
10
3
14
15
12 11
500996
1. Valve assembly 9. Poppet

2. O-ring 10. Valve
3. O-ring 11. Valve
5. Plug 13. Plug
6. O-ring 14. Plug
7. Spring 15. Plug
8. Spring
Note: Lift lock valve (1 to 15)
8-86
1 2
4
5
10
8
11 6
7
12 9
500997
1. Plug 7. O-ring
2. O-ring 8. O-ring
3. Spring 9. Steel ball
4. Valve 10. Plug
5. Orifice 11. Plug
6. Plug 12. Orifice
Note: Shuttle valve (6 to 12)
8-87
Lift valve Lift lock valve

(1) Place the spool horizontally on the workbench. Do not remove the lift lock valve unless it is absolutely
(2) Remove the electromagnetic proportional solenoid 4 necessary. (Reassembling is difficult.)
on both ends of spool 3 by unscrewing them using a If removal is necessary for inspection or other purposes,
hexagon wrench engaged in the socket in each of their follow the instructions below:
heads. Be careful not to drop the valve in spool.
(3) Remove the spring and plane washer. (1) Remove the body of lift lock valve as an assembly.
(4) Carefully pull-out the spool from valve housing, then (2) Remove the valve and spring from the housing.
pull-out the valve from spool. Shut-off valve assembly
Bleed-off valve Do not remove the shut-off valve unless it is absolutely
(1) Remove socket head plug 3, and remove the spool. necessary.
(2) Remove socket head plug 3, and remove the spring.
If necessary, disassemble the bleed-off valve further. If removal is necessary for inspection or other purposes,
follow the instructions below:
Flow control valve
(Pressure-compensated flow control valve) (1) Loosen the lock nut of shut-off valve and loosen the set
Same to the bleed-off valve 3. screw.
If necessary, disassemble the flow control valve further. (2) Remove the valve from the housing.
Relief valve
Remove the relief valve assembly from the valve body. Do
not loosen the adjusting screw unless it is absolutely
necessary. Loosening adjusting screw will change the
setting, and re-adjustment will be required.
29. Valves Included in Tilt Section
B2 5
2
A2
3
4
SA2
T T
SB2
1
501192
1. Tilt spool 3. Pilot check valve
2. Tilt lock valve 4. Shuttle
5. Piston
8-88
30. Disassembling Tilt Section
23 26 25 24 20
18
19
22 17
21
11 6 4 3
5
12 1613 14 15 9 8 10 7
2
1
500999
1. O-ring 14. Valve
2. Valve 15. Spool
4. O-ring 17. Plug set (plug)
5. Steel ball 18. O-ring
6. Solenoid valve assembly 19. O-ring
7. Spring 20. Piston
8. Plain washer 21. Plug
9. Valve 22. O-ring
10. O-ring 23. Counterbalance valve
11. Solenoid valve assembly 24. O-ring
Tilt spool (6 to 16)
Pilot check valve (17 to 22)
Tilt lock valve (23 to 26)
8-89
12 13 11 18 17 16 25 26 23 22 21
8 9 10 27 14 19 20 15 24
6 5 3 1 2
4 7
501000
1. Plug 15. Piston

2. O-ring 16. Buck up ring
4. Valve 18. Buck up ring
5. Ball valve 19. Buck up ring
6. Pin 20. O-ring
7. Plug 21. Snap ring
8. Plug 22. Spring seat
10. Spring 24. Valve
11. Stopper 25. Buck up ring
12. Stopper 26. O-ring
13. Spring 27. Body
14. Spring seat
Note: Pilot check valve (1 to 7)
Tilt lock valve (8 to 27)
8-90
Tilt spool
(1) Place the spool horizontally on a bench, remove socket
head bolt, and remove the electromagnetic
proportional solenoid on both ends of the tilt valve.
(2) Pay attention to the valve in the spool not to drop it.
(3) Remove the spring and plane washer.
(4) Carefully pull out the spool out from the valve housing.
Tilt lock valve
(1) Remove the tilt lock valve as an assembly from the
valve body.
(2) Remove the socket plug and pull-out the big/small
springs, stopper and spring seat.
(3) Carefully pull out the piston with the pull-out bolt.
(4) Remove the snap ring on the opposite side and remove
the valve and spring.
Pilot check valve
(1) Remove the socket plug as an assembly and remove
the internal plug with a hexagonal wrench.
(2) Remove the big/small springs and pin.
Shuttle valve
Carefully pull out the valve by hooking a thin hexagonal
wrench or the like in the hole.
Pay attention not to drop the steel ball.
31. Valves Incorporated in Attachment Section
4 2
2
B3 A3
SA3
T T
SB3
P
501193
1. Attachment spool 3. Shuttle valve
2. Pilot check valve 4. Piston
8-91
32. Disassembling Attachment Section
11 6
12 1613 14 15 9 8 10 7 4 3
5
2
1
501002
1. O-ring 9. Valve
2. Valve 10. O-ring
3. O-ring 11. Solenoid valve assembly
5. Steel ball 13. Plain washer
6. Solenoid valve assembly 14. Valve
7. Spring 15. Spool
Attachment spool (6 to 16)
8-92
10 13 1517 12 18 11 19 2 9 3 8 6 4 1
16 7
14 5
501003
1. Plug 11. O-ring

4. O-ring 14. Plug
5. Plug 15. O-ring
8. Spring 18. Valve
9. Valve 19. Piston
10. Plug
Note: Pilot check valve (1 to 19)
8-93
Attachment spool
(1) Place the spool horizontally on a bench, remove socket
head bolt, and remove the electromagnetic
proportional solenoid on both ends of the attachment
valve.
(2) Be careful not to drop the valve in spool.
(3) Remove the spring and plane washer.
(4) Carefully pull spool out of the valve housing.
Pilot check valve
(1) Remove the socket plug as an assembly and remove
the internal plug with a hexagonal wrench.
(2) Remove the valve and spring.
Shuttle valve
Carefully pull out the valve by hooking a thin hexagonal
wrench or the like in the hole.
Pay attention not to drop the steel ball.
33. Disassembling End Cover Plate
Parts included in the end cover plate
1
2
2
500993
1. Plug 2. O-ring
33.1 Cleaning
Clean all the disassembled parts with clean solvent.

Dry the parts using compressed air.
Place parts on clean paper or cloth for inspection.
8-94
34. Inspecting End Plate
Inspect each part for burrs, scratches, dents and other
surface flaws.
(1) Remove burrs with an oil stone or lapping compound. If
a part has excessive scratches that may cause oil leak or
malfunction, replace the part or the section assembly.
R CAUTION
Never change the original combinations of the valve housings and spools. Since these parts are not interchangeable, if
scratches and dents are minor, remove flaws with an oil stone or lapping compound. The main spool cannot be replaced
separately. If the spool has any damage that cannot be repaired, replace the valve assembly.
(2) Make sure all moving and sliding parts move smoothly.
Make sure there are no foreign material in grooves and
oil passages.
(3) Check orifice clogging.
(4) Replace broken or bent springs.
(5) Replace all seals and O-rings with new ones.
34.1 Precautions for Reassembly
Most problems with hydraulic system can occur due to the

following three reasons.
(1) Hydraulic oil is contaminated.
(2) Improper types of fluid
(3) Carelessness during assembly.
To avoid problems due to above causes, be sure to perform
daily maintenance properly. Also pay close attention when
handling parts during assembly.
Observe the following precautions during assembly.
- Assembly work shall be accomplished in a clean dust-
free area.
- Handle parts carefully. Avoid hitting a metal part
against another; the parts may be dented or damaged.
- Apply clean hydraulic oil to parts when assembling.
- Before assembling the parts, be sure to understand its
structure. Especially, make sure the correct orientation
of valves and spools when assembling.)
- Do not reuse O-rings. Replace O-rings with new ones.
Be careful not to damage O-ring when installing. Make
sure O-rings are fitted correctly in sealing grooves.
- Be sure to observe tightening torques wherever they
are specified.
8-95
35. Reassembling Inlet Section
4 3
1 2
12
8 7
9 11
10
13
15
14
16 17
19
18
501194
8-96
No. Part name Procedure Value

1 Orifice Apply screw locking agent. Loctite 242
14.7 ± 1.5 N·m (1.50 ± 0.15 kgf·m)
2 Plug Tightening torque
[10.84 ± 1.11 lbf·ft]
3 Orifice Apply screw locking agent. Loctite 242
8.8 ± 1.0 N·m (0.90 ± 0.10 kgf·m)
[6.49 ± 0.74 lbf·ft]
60 ± 6 N·m (6.12 ± 0.61 kgf·m)
[44.25 ± 4.43 lbf·ft]
55 ± 5.5 N·m (5.61 ± 0.56 kgf·m)
6 Valve body Tightening torque
[40.57 ± 4.06 lbf·ft]
54.9 ± 5.5 N·m (5.60 ± 0.56 kgf·m)
7 Screw (component of shut off valve) Tightening torque
[40.57 ± 4.06 lbf·ft]
44.1 ± 4.4 N·m (4.50 ± 0.45 kgf·m)
8 Nut Tightening torque
[10.84 ± 1.11 lbf·ft]
63.7 ± 6.4 N·m (6.50 ± 0.65 kgf·m)
[46.98 ± 4.72 lbf·ft]
7.8 ± 1.0 N·m (0.80 ± 0.10 kgf·m)
[5.75 ± 0.74 lbf·ft]
63.7 ± 6.4 N·m (6.50 ± 0.65 kgf·m)
[46.98 ± 4.72 lbf·ft]
60 ± 6 N·m (6.12 ± 0.61 kgf·m)
12 Solenoid valve assembly Tightening torque
[44.25 ± 4.43 lbf·ft]
15.7 ± 1.6 N·m (1.60 ± 0.16 kgf·m)
13 Plate tightening bolt Tightening torque
[11.58 ± 1.18 lbf·ft]
9.8 ± 1.0 N·m (1.00 ± 0.10 kgf·m)
14 Nut (component of pilot relief) Tightening torque
[7.23 ± 0.74 lbf·ft]
7.8 ± 1.0 N·m (0.80 ± 0.10 kgf·m)
[5.75 ± 0.74 lbf·ft]
63.7 ± 6.4 N·m (6.50 ± 0.65 kgf·m)
[46.98 ± 4.72 lbf·ft]
63.7 ± 6.4 N·m (6.50 ± 0.65 kgf·m)
[46.98 ± 4.72 lbf·ft]
15.7 ± 1.6 N·m (1.60 ± 0.16 kgf·m)
18 Solenoid valve assembly tightening bolt Tightening torque
[11.58 ± 1.18 lbf·ft]
15.7 ± 1.6 N·m (1.60 ± 0.16 kgf·m)
[11.58 ± 1.18 lbf·ft]
Note:
(1) Tighten the screw 7 to the specified torque, and tighten the nut 8 to the specified torque. Then, tighten the screw 7 again
to the specified torque.
(2) Do not loosen the nut 14 (component of pilot relief) unless the disassembling is necessary. When the shut-off valve is
disassembled, the pressure adjustment is required before tightening the nut 14.
8-97
4 6 5 8 7
13
1
9
10
3
14
15
12 11
500996
1. Valve assembly 9. Poppet

2. O-ring 10. Valve
3. O-ring 11. Valve
5. Plug 13. Plug
6. O-ring 14. Plug
7. Spring 15. Plug
8. Spring
8-98
Lift valve
(1) Place the housing on a workbench so that spool can be
inserted horizontally to the housing, and carefully
insert the spool into the housing. Pay attention to the
orientation of the spool (see illustration).
(2) Set the housing to install the lift lock valve vertically
when assembling the lift lock valve.
Insert valve 11 and spring 12 into the housing, and
carefully insert the assembled lift lock valve. (See the
illustration.)
8-99
36. Reassembling Tilt Section
4 3
1 2 5
7
501001

39.2 ± 4.9 N·m (4.00 ± 0.50 kgf·m)
[28.91 ± 3.61 lbf·ft]
39.2 ± 4.9 N·m (4.00 ± 0.50 kgf·m)
2 Counterbalance valve Tightening torque
[28.91 ± 3.61 lbf·ft]
34.3 ± 3.4 N·m (3.50 ± 0.35 kgf·m)
[25.30 ± 2.51 lbf·ft]
123 ± 12.3 N·m (12.54 ± 1.25 kgf·m)
4 Plug set Tightening torque
[90.72 ± 9.07 lbf·ft]
63.7 ± 6.4 N·m (6.50 ± 0.65 kgf·m)
[46.98 ± 4.72 lbf·ft]
15.7 ± 1.6 N·m (1.60 ± 0.16 kgf·m)
[11.58 ± 1.18 lbf·ft]
15.7 ± 1.6 N·m (1.60 ± 0.16 kgf·m)
[11.58 ± 1.18 lbf·ft]
8-100
37. Assembling Attachment Section
2 4
1 3
501004

98 ± 10 N·m (9.99 ± 1.02 kgf·m)
[72.28 ± 7.38 lbf·ft]
126 ± 12.6 N·m (12.85 ± 1.28 kgf·m)
[92.93 ± 9.29 lbf·ft]
98 ± 10 N·m (9.99 ± 1.02 kgf·m)
[72.28 ± 7.38 lbf·ft]
126 ± 12.6 N·m (12.85 ± 1.28 kgf·m)
[92.93 ± 9.29 lbf·ft]
15.7 ± 1.6 N·m (1.60 ± 0.16 kgf·m)
[11.58 ± 1.18 lbf·ft]
15.7 ± 1.6 N·m (1.60 ± 0.16 kgf·m)
[11.58 ± 1.18 lbf·ft]
8-101
38. Solenoid Control Valve
External oil leaks

(1) Oil leaks from O-rings between housings
(2) Oil leaks from scraper O-ring
(3) Oil leaks from bolt sections
Oil leaks 1
Since it is difficult to measure the amount of oil leaks from
the dismounted control valve, inspect oil leaks with the
control valve connected to the cylinder by following the
steps (1) through (3) below:
The internal leakage to be checked includes leakages
occurring at the lift spool, tilt spool, tilt lock valve and check
valves at the oil temperature of approximately 50ºC (122ºF).
(1) Place rated load on the forks and lift it to a height of 2
approximately 1 m (3.3 ft). Tilt the masts approximately 608053
3 or 4 degrees forward from the upright position, then
turn the key switch off. 1. 3 to 4 degree 2. Approx. 1 m (3.3 ft)
(2) Remove the oil return hose, and collect oil from the
port.
Standard volume of oil drained in 15 minutes

20 cc (1.22 cu. in.) max.
(3) When the gravitational-pull lowering distance and

forward tilt distance are large, check the amount of oil
leakage from each cylinder even if the amount of oil
drained in 15 minutes is less than 20 cc (1.22 cu.in.).
(Measured amount of oil leakage is a standard value; it
does not denote the allowable limit.) P B3
A1
B2
1 T A3
501267
1) T: To hydraulic tank (return

oil)
8-102
Adjustment of main relief valve

(1) Mount an oil pressure gauge with a measuring range of
24.5 MPa (250 kgf/cm2) [3553 psi] on the delivery pipe.
2
1
501268
1. Connector 2. Gauge, Connector, Hose
Special tool Part number

Connector 97967-00500
Hose 64309-17722
64309-17731
Connector
(for gauge mounting)
64309-17712
Gauge
24.5 MPa (250 kg/cm2) [3553 psi]
Note: The above parts are included in the 64309-17701 kit.
(2) 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 18.1 MPa (185
kgf/cm2) [2625 psi], it is normal.
(3) 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.
(4) While pressing the adjusting screw, tighten the lock nut
securely.
(5) After tightening the lock nut, check the set pressure of
the relief valve again.
Main relief valve setting pressure

+0.5 +.5 2 +72.5
18.1 0 MPa (185 0 kgf/cm ) [2625 0 psi]
8-103
39. Service Data
Every 12 months or 2000 hours

Pre-operation inspection
Remarks
Inspection/maintenance schedule and item to be checked
Service standard
Oil leaks z z z z
Safety valves z z z z
Control valves
(FC Model) 18.1 MPa
Release pressure measurement z (185 kgf/cm2)
[2631 psi]
8-104
CHAPTER 9 MAST AND FORKS
Chapter 9 MAST AND FORKS
1. Mast System
The following table shows the combination of truck types and mast models.
Model 1 ton class 2 ton class

Simplex mast 5AE15Ccc 5AE20Ccc
Duplex mast 5BE15Ccc 5BE20Ccc
Triplex mast 5CE15Ccc 5CE20Ccc
Note: “cc” means maximum lifting height [30: 3000 mm (118 in.)]
1.1 Mast Model Code Stamping Position
501038
1.2 Explanation of Mast Model Code
5 AE 15 C 30
1 2 3 4 5
501039
1. Generation record of truck 4. Generation record of mast

(1 to 9) (A 6 B 6 C···Z)
2. Mast type 5. Maximum lifting height
3. Applicable truck model [30: 3000 mm (118 in.)]
designation
1.3 Mast Code and Type
Code Mast type

AE Simplex mast
BE Duplex mast
CE Triplex mast
9-1
2. Description
2.1 Simplex Mast (Dual-stage Panoramic Mast)
7)
1
1)
2 1) 6)
2)
2), 3) 4)
4)
3)
5)
4
5) 7)
6)
501040
1. Inner mast 1) Main roller

2. Outer mast 2) Main roller
3. Lift chain 3) Main roller
4. Lift bracket 4) Side roller
5) Main roller
6) Main roller
7) Mast strip
The Simplex mast features two lift cylinders placed behind Mast strips are fitted to the top end of outer mast.
the mast columns, right and left, to provide the maximum These strips are for backing up the inner mast when the
visibility. mast is tilted backward.
Diam. of Main Roller 1 ton class 2 ton class

S 99 mm (3.90 in.)
M 100 mm (3.94 in.)
L 101 mm (3.98 in.)
LL 102 mm (4.02 in.)
9-2
2.2 Duplex Mast (Dual-stage Full Free Panoramic Mast)
7
1) 2)
3) 4)
6 4
2 5
10
5) 6)
501041
1. Lift chain 9. Mast upper main roller

2. First lift cylinder 10. Mast lower main roller
3. Second lift cylinder 1) Cross section of mast upper main roller
4. Inner mast 2) Cross section of mast strip
5. Outer mast 3) Cross section of lift bracket upper main roller
6. Lift bracket 4) Cross section of chain wheel
7. Chain wheel 5) Cross section of mast lower main roller
8. Lift bracket main roller 6) Cross section of lift bracket side roller
The duplex mast raises the forks without increasing the When the first lift cylinder rod extends fully, the second lift
overall mast height (free lift) until the load backrest reaches cylinders raise the assembly consisting of the lift bracket,
the mast height. first lift cylinder and inner mast.
The mast assembly consists of the inner mast, outer mast, The shoulder sections of the mast main rollers contact the
lift bracket, backrest, first lift cylinder and second lift mast rails. The rollers are installed perpendicular to the
cylinders. sliding surfaces.
The first lift cylinder raises the lift bracket, while the second The main rollers used in the 1 ton and 2 ton classes are the
cylinders operate the inner mast and lift bracket. same as those in the Simplex mast.
For lifting operation, hydraulic oil is first sent to the first lift
cylinder which raises the forks until the cylinder rod reaches
its stroke end.
9-3
2.3 Triplex Mast (Triple-stage Full Free Panoramic Mast)
10
8
1) 2)
1
9
11
3 3) 4)
4
5
6
2
7 5) 6)
12
7) 8)
501042
1. First lift chain 11. Mast upper main roller

2. First lift cylinder 12. Mast lower main roller
3. Second lift chain 1) Cross section of mast upper main roller
4. Second lift cylinder 2) Cross section of mast strip
5. Inner mast 3) Cross section of lift bracket upper main roller
6. Middle mast 4) Cross section of hose pulley
7. Outer mast 5) Cross section of side roller
8. Lift bracket 6) Cross section of second chain wheel
9. Second chain wheel 7) Cross section of mast lower main roller
10. Lift bracket main roller 8) Cross section of first chain wheel
The triplex mast raises the forks without increasing the For lifting operation, hydraulic oil is first sent to the first lift
overall mast height (free lift) until the load backrest reaches cylinder which raises the forks until the cylinder rod reaches
the mast height. its stroke end.
The mast assembly consists of the inner mast, middle mast, When the first lift cylinder rod extends fully, the second lift
outer mast, lift bracket, backrest, first lift cylinder and cylinders raise the assembly consisting of the lift bracket,
second lift cylinders. first lift cylinder, inner mast and middle mast.
The first lift cylinder raises the lift bracket, while the second The shoulder sections of the mast main rollers contact the
cylinder operates the three-stage telescopic mechanism mast rails. The rollers are installed perpendicular to the
and lift bracket. Two pairs of lift chains are installed. The sliding surfaces.
cylinders and lift chains are designed for smooth and
The main rollers used in the 1 ton and 2 ton classes are the
effective operation.
same as those in Simplex mast.
9-4
2.4 Operation of Duplex Mast
4) 4
1) 2) 3)
501043
1. Inner mast 1) Forks on the ground

2. First lift cylinder 2) Maximum free lift
3. Second lift cylinder 3) Maximum lift
4. Outer mast 4) Free-lift height
2.5 Operation of Triplex Mast
1
2
4
5
4) 7
1) 2) 3)
501044
1. Inner mast 1) Forks on the ground

2. First lift cylinder 2) Maximum free lift
3. First lift chain 3) Maximum lift
4. Middle mast 4) Free-lift height
5. Second lift chain
6. Second lift cylinder
7. Outer mast
9-5
3. Removing Simplex Mast
5 4
1
6 7
2
501045
1. Nuts 5. High-pressure hose for lift cylinder

2. Fork, Lift bracket assembly 6. Mast support cap
3. Tilt socket pin 7. Mast support bushing
4. Tilt cylinder
9-6
Removing lift bracket assembly

(1) Lower the lift bracket assembly, and place wood blocks
the inner mast to the bottom, then remove nuts from
the anchor bolts.
1
2
501046
1. Anchor bolt 2. Nuts
(2) Tilt the mast back to the vertical position. Raise the
inner mast until main rollers of lift bracket become free.
Then slowly move the truck in reverse to separate the
lift bracket assembly.
(3) Removing lift cylinder high pressure hose Lower the
mast to the bottom, and disconnect the lift hose at the
flow regulator valve. 1
2
501047
1. Main rollers 2. Lift bracket
Separating mast and tilt cylinders

(1) Hitch a sling to the mast. Using two eye-bolts and a
sling as shown, support the mast with a hoist.
501048
R CAUTION
Be sure to use a hoist with enough capacity to support the mast assembly.
9-7
(2) Remove the tilt socket pins, and separate the mast 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.
501049
1. Tilt socket pin
Removing mast support caps

(1) Mark the caps to ensure the correct reassembling
before removing them.
(2) Remove cap mounting bolts. Dismount the mast
assembly from vehicle in the suspended condition.
With the lift bracket side facing up, place the mast
assembly horizontally on wooden blocks on the level
ground.
Note: Lay the mast assembly on the floor, so that you have
enough space to disassemble the parts.
1
1)
501051
1. Mast support cap 1) Marks
9-8
4. Installing Simplex Mast
To install, follow the removal sequence in reverse, and
follow the steps below:
1
(1) Procedure for mounting mast support bushings and 2
caps.
- Apply grease to the inner surfaces of caps and mast 3
support bushings.
- Install mast support bushings and caps in the same
direction as it was before disassembly.
- Be sure to tighten the support tightening bolts
securely.
1 501052
1. Mast support bushing 3. Nipple

2. Mast support cap
Bolt tightening torque

59.1 to 72.3 N·m
(60.3 to 7.37 kgf·m)
[43.6 to 53.3 lbf·ft]
- Adjust using shims so that the clearance is less than

1 mm.
(Standard shim thickness: 2.0 mm) 1
501182
1. Shim
(2) Adjust the chain tensions.

(Refer to the Inspection and adjustment section.)
Tighten the locknuts to the specified torque.
2
3 501053
1. Clamp 3. Locknut
2. Nut

98 to 147 N·m
Locknut (10 to 15 kgf·m)
[72.3 to 109 lbf·ft]
9-9
(3) Air bleeding of lift cylinders

Due to internal drain type cylinder, the lift cylinders do
not require air bleeding.
(4) After proper operation is confirmed, check the oil level.
9-10
5. Removing Triplex Mast, Duplex Mast
The following describes the procedures for removing and reinstalling the mast assemblies of Duplex Mast and Triplex Mast.
Note that the Triplex Mast is used as an example.
2
6 7 5
501054
1. Nuts 5. High-pressure hose for lift cylinders

2. Fork, Lift bracket assembly 6. Mast support cap
3. Tilt socket pin 7. Mast support bushing
4. Tilt cylinder
9-11
Removing lift bracket assembly

the inner mast to the bottom, then remove nuts from
the anchor bolts of the first lift chains.
501055
1. Anchor bolt 2. Nuts
(2) Tilt the mast back to the vertical position. Raise the
inner mast until main rollers of the lift bracket become
free. Then, slowly move the vehicle in reverse to
separate the lift bracket assembly.
1
2
501047
1. Main rollers 2. Lift bracket
(3) Disconnecting return hose for lift cylinder

(For high-lift cylinder model)
- Stop the engine and disconnect hose at the hose clamp
of return connector.
(4) Removing lift cylinder high pressure hose Lower the
mast to the bottom, and disconnect the lift hose at the
flow regulator valve.
1
501197
1. Return hose (For high-lift

cylinder model)
Separating mast and tilt cylinders

(1) Hitch a sling to the mast. Using two eye-bolts and a
sling as shown, support the mast with a hoist.
501056
9-12
R CAUTION
Be sure to use a hoist with enough capacity to support the mast assembly.
(2) Remove the tilt socket pins, and separate the mast 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.
501049
1. Tilt socket pin
Removing mast support caps

(1) Mark the caps to ensure the correct reassembling
before removing them.
(2) Remove cap mounting bolts. Dismount the mast
assembly from vehicle in the suspended condition.
assembly horizontally on wooden blocks on the level
ground.
Note: Lay the mast assembly on the floor, so that you have
enough space to disassemble the parts.
1 1) 501057
1. Mast support cap 1) Marks
9-13
6. Installing Triplex Mast, Duplex Mast
To install, follow the removal sequence in reverse, and
1
(1) Procedure for mounting mast support bushings and 2
caps.
- Apply grease to the inner surfaces of caps and mast 3
support bushings.
- Apply grease to the bushing inner surface and grooves.
- Be sure to tighten the support tightening bolts
securely.
1 501052
1. Mast support bushing 3. Nipple

2. Mast support cap
Bolt tightening torque

59.1 to 72.3 N·m
(60.3 to 7.37 kgf·m)
[43.6 to 53.3 lbf·ft]

1 mm.
501182
1. Shim
(2) Adjust the chain tensions.

(Refer to the Inspection and Adjustment section.)
Tighten the locknuts to the specified torque.
2
3
501183
1. Clamp 3. Locknut
2. Nut

98 to 147 N·m
[72.3 to 109 lbf·ft]
9-14
(3) Air bleeding lift cylinders.

In the Duplex mast, only the second lift cylinders are
provided with air bleeding valves.
The other lift cylinder does not require air bleeding
since it is an internal drain type cylinder.
(4) After proper operation is confirmed, check the oil level.
9-15
7. Disassembling Simplex Mast
10
12
3 15
11 10
13
9
16 8
2
18
17
6 8
6
7
6 14
1 4
5
501058
1. Nuts 10. Cylinder clamps, Seats, Shims, Cushion, Collar, Bolts

2. Forks, Lift bracket 11. Bolt, Shims
3. Backrest 12. Mast strip, Shims
4. Main roller, Shims 13. Main roller, Shims
6. Side roller, Brackets, Shims 15. Inner mast
7. Hose guard 16. Lift cylinders
8. Lift hoses, Rubber hose, 17. Mast cap, Bolt, Washer, Shims
T-joint, Down safety valve 18. Outer mast
9. Chain wheel, Snap ring
9-16
(1) Removing mast strips and main rollers

Remove bolts to free the lift cylinder.
Displace the tops of the two lift cylinders from the inner
mast. Slide inner mast toward the bottom of outer
mast, and remove main rollers and mast strips.
(2) Inner mast removal

After removing the main rollers, hitch a sling to the
inner mast crossmember and slide the inner mast to the
upper side of the outer mast to clear the outer mast
roller shafts. Hitch a sling to the inner mast again and
remove it from the outer mast.
501059
7.3 Inspecting Simplex Mast
Mast
- Check each roller for wear, binding or other defects.
- Check each roller on rolling surface for pitting or other
defects.
- Check the mast member and the welded joints of
crossmembers, shafts and supports for cracks.
- Check the mast support bushings for wear or other
defects.
501060
Lift bracket
- Check the main rollers and side rollers for smooth
rotation. Inspect each roller for wear and cracks.
- Check the welded portions of the bracket for cracks.
- Check the finger bar for bend or distortion.
501061
Item Standard
Distortion of finger bar 5 mm (0.2 in.) or less
9-17
Lift chains, chain wheels and chain wheel supports

- Measure the length of each chain to make sure that two
chains are equal in length. Also check the chains for
wear, sign of breakage, link binding and twist.
- Check each chain anchor bolt for cracks or defects on
thread.
- Check each chain wheel support and chain wheel for
crack or wear. Check that the wheels rotate smoothly.
Item Standard Limit
Length of lift chain 1 ton class 317.5 mm (12.50 in.) 327 mm (12.87 in.)
(per 20 links) 2 ton class 381 mm (15.00 in.) 392 mm (15.43 in.)
Mast strips
Check the mast strips for damage, wear or distortion.
7.4 Reassembling Simplex Mast
To reassemble, follow the disassembly sequence in reverse,

and follow the steps below:
Longitudinal clearance adjustment between mast

and lift bracket 1)
Rollers for mast and lift bracket are available in four sizes
(diameters) for the selective use. Select a size that will
provide the longitudinal clearance of 1 mm (0.04 in.) or less.
1)
1 2 501062
1. Lower roller 1) Clearance

2. Upper/middle roller
Roller size
Diam. of
1 ton class 2 ton class
Main Roller
S 99 mm (3.90 in.)
M 100 mm (3.94 in.)
L 101 mm (3.98 in.)
LL 102 mm (4.02 in.)
9-18
Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims.
1
501070
1. Shims
(2) To install main rollers on shafts, use a driving tool. Be

careful not to strike the outer roller surface with the
driving tool.
Place the roller with its larger chamfered side facing
outside.
501072
Cylinder clamp
(3)
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.
1 501063
1. Shims
Mast support
- Apply grease to the inside surfaces of the caps. 1
- Apply grease to the bushing inner surface and grooves. 2
- Install mast support bushings and install the mast.
3
1 501052
1. Inner bushing 1) Chamfered faces

2. Inner cap
9-19

1 mm.
- Apply grease to the support with grease gun.
501182
1. Shims
Precautions for installing chain anchor kit

Be careful not to confuse the center plate with the link plate.
501065
1. Link plate 3. Link

(stamped mark on surface) 4. Split pin
2. Center plate
(no stamped mark)
9-20
8. Disassembling Duplex Mast
Preparation
horizontally on wood blocks. Use a wood block as a wedge
to prevent the inner mast from sliding.
10
14 16
15 1
13
4
9
11
6 5 8 14
6 1 8
12
1
12
2 9
3
2 18
17
7
501066
1. Hose and pipes for first cylinder, Clamp 10. Bolt, Washer, Shims
2. Bolt, Washer, Shims 11. Mast strip, Shims
3. First lift cylinder 12. Main rollers, Shims
4. Chain guard 13. Inner mast
5. Chain wheel support, Pin 14. Second lift cylinder
6. Chain wheels, Snap rings 15. Cylinder bracket
7. Hose guard, Bolt, Washer 16. Plug, O-ring
8. Hoses for lift cylinders, Down safety valve 17. Mast cap, Bolt, Washer, shims
9. Cushion, Collar, Shims, Bolt, Washer, Clamp 18. Outer mast
Note: For lift bracket disassembly procedure, refer to the

simplex mast, as the procedure is the same.
9-21
Removing first lift cylinder

(1) Remove retaining bolts from the first lift cylinder.
1
(2) Hitch slings on first lift cylinder, and slowly remove the
cylinder.
Use two slings. Wind or tie slings securely to prevent
from slipping.
501067
1. First lift cylinder
Removing main rollers and mast strips

(1) Remove clamp bolts from the second lift cylinders.
2 1
(2) Remove bolts from the upper rod sections of the
second lift cylinders, and place the cylinders on the
outer mast.
(3) Check the number of shims and the shim thickness at
the rod end sections.
(4) Lower the inner mast, then remove main rollers, mast
strips and shims.
1 501068
1. Main rollers 2. Mast strips
Removing inner mast

Using slings, lift and remove inner mast, steering it to pass 2
over the roller shaft sections of outer mast.
1 501069
1. Inner mast 2. Outer mast
8.3 Inspecting Duplex Mast
Follow the inspection procedure described in the Simplex

mast section.
8.4 Reassembling Duplex Mast
To reassembling, follow the removal sequence in reverse,

and follow the steps below:
9-22
Main rollers
1
501070
1. Shims
(2) When replacing lift bracket main rollers, make sure the
clearance between each roller and mast surface is 1 mm
(0.04 in.) or less.
1)
501071
1. Clearance
Roller size
Diam. of
Main Roller
S 99 mm (3.90 in.)
M 100 mm (3.94 in.)
L 101 mm (3.98 in.)
LL 102 mm (4.02 in.)
(3) To install main rollers on shafts, use a driving tool. Be

careful not to strike the outer roller surface with the
driving tool.
Position the roller so that its large curbed side facing
outside.
501072
9-23
Installing second lift cylinder

When installing second lift cylinders, make sure the
cylinders are parallel to the mast to prevent torsional stress
on the lift cylinders when the mast is positioned at the
bottom. Adjust the installation positions of lift cylinder
brackets with shims. 3
1
2 501073
1. Second lift cylinder 3. Shim

2. Lift cylinder bracket
Installing first lift cylinder

The first lift cylinder must be installed parallel to the mast
when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using shims,
adjust the backward inclination so that clearance at section
20 mm
2) is 0 to +0.5 mm (0 to +0.02 in.) larger than clearance at 1
section 1). (0.79 in.)
2)
1) 501074
1. Shim
Precautions for installation of chain anchor kit

501075

2. Center plate
(no stamped mark)
9-24
9. Disassembling Triplex Mast
Preparation
horizontally on wood blocks. Use a wood block as a wedge
to prevent the inner and middle masts from sliding.
15 17
9 16 1
15
23 26 1
10
28 22
25
12 24
21 19
7 6 8
7 8
27 14 30
5 13 29
20
3 19
2 4
11 18
501076
1. Hose for first lift cylinder, Clamp, Bolt, Washer 16. Chain wheel, Snap ring
2. Bolt, Washer 17. Chain wheel, Hose pulley, Shaft, Snap ring
3. Shims 18. Hose guard, Bolt, Washer
4. First lift cylinder 19. Hoses for lift cylinders, Down safety valve
5. Chain guard 20. T-Joint
6. Chain wheel support, Pin 21. Bolt, Seat, Cushion, Collar
7. Chain wheels, Snap rings 22. Cushion, Shims
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
12. Inner mast 27. Main roller, Shims
13. Nuts 28. Middle mast
14. Lift chain (for second lift cylinder) 29. Mast Cap, Bolt, Washer, Shims
15. Chain guard, Bolt, Washer 30. Outer mast
Note: For lift bracket disassembly procedure, refer to the

simplex mast, as the procedure is the same.
9-25

(1) Remove retaining bolts from the first lift cylinder.
(2) Hitch slings on lift cylinder, and slowly remove the 1
cylinder.
Use two slings. Wind or tie slings securely to prevent
from slipping.
501077
1. First lift cylinder
Removing inner mast and main rollers

Lower the inner mast so that the main rollers can be 1
removed. Remove main rollers and mast strips. 3
2 501078
1. Inner mast 3. Mast strip

2. Main roller
Removing inner mast

Using slings, lift and remove the inner mast, steering it to
pass over the roller shaft sections of the middle mast.
1 501079
1. Inner mast
9-26
Removing main rollers from middle mast and outer

mast 2
(1) Remove clamp bolts from the second lift cylinders. 4
(2) Remove bolts from the upper rod sections of the
second lift cylinders, and place the cylinders on the
outer mast.
(3) Check the number of shims and the shim thickness at 1
the rod end sections.
(4) Lower the middle mast so that main rollers can be
removed. Then, remove the main rollers, mast strips 3
and shims.
1 501080
1. Main roller 3. Outer mast

2. Middle mast 4. Second lift cylinder
10. Inspecting Triplex Mast

Follow the inspection procedure described in the Simplex
mast.
11. Reassembling Triplex Mast
To reinstall, follow the removal sequence in reverse, and
Main rollers
2
501081
5. Main roller 1. Shims
(2) When replacing lift bracket main rollers, make sure

clearance between each roller and mast surface is 1 mm 2
(0.04 in.) or less. 1 3
1)
4 501082
1. Inner mast 3. Outer mast

2. Middle mast 4. Lift bracket
1) Clearance
9-27
Roller size
Diam. of
Main Roller
S 99 mm (3.90 in.)
M 100 mm (3.94 in.)
L 101 mm (3.98 in.)
LL 102 mm (4.02 in.)
To install main rollers on shafts, use a driving tool. Be careful

not to strike the outer roller surface with the driving tool.
Position the roller so that its large curbed side facing
outside.
501072
Installing second lift cylinders

When installing second lift cylinders, make sure the
cylinders are parallel to the mast to prevent torsional stress
on the lift cylinders when the mast is positioned at the
bottom. Adjust the installation positions of lift cylinder
brackets with shims. 2
1
501083
1. Lift cylinder 2. Shim
Installing first lift cylinders

The first lift cylinder must be installed parallel to the mast
when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using shims,
adjust the backward inclination so that clearance at section
20 mm
2) is 0 to +0.5 mm (0 to +0.02 in.) larger than clearance at 1
section 1). (0.79 in.)
2)
1) 501074
1. Shim
9-28
Precautions for installation of chain anchor kit

501075

2. Center plate
(no stamped mark)
9-29
12. Inspecting and Adjusting Mast and Forks
12.1 Forks (all mast models)
1) 2)
6) 3)
4) 5)
501084
1) Outside jaws 100% 4) Fork OK

2) Inside jaws 90% 5) Replace fork with 10 % wear
3) New fork arm shank cross section = 100% (Not for use on full tapered forks.)
6) 50 mm (2 in.)
Fork calipers perform two tasks at once.

They measure the thickness of the fork arm shank and then
automatically indicate what a 10 % wear factor would be
when the calipers are applied to the blade cross section.
Forks are often mistreated and forgotten. As insubstantial as It’s true that most forks are customized to the truck by
they seem, neglecting forks could make them dangerous. model and capacity: they are big and heavy and thought of
as indestructible. But forks can be abused or ruined in the
Forks carry larger loads than almost any lifting device but
course of daily work.
there are no mandatory requirements for maintenance or
inspection.
You can find thousands of extra parts for lift trucks in some
fleet repair shops, but you’ll seldom see spare forks. Even
when all the trucks on the fleet are the same, fleet
maintenance managers rarely order spare forks. Forks last a
long time if treated properly, but they can deceive by
looking as good from most viewing angles when they are
worn as when they are new.
9-30
Here are some examples of ways that forks can be damaged:

- Forks can be overloaded either by picking up a load too
far out on the forks, or simply by picking up loads
heavier than the truck rating.
- Maintenance shops may bend forks back into shape,
weld on them, or drill holes through them. Lift truck
users can add attachments to the truck that stress the
forks. Drum clamps and portable booms can be
supported on the forks, but what is contained in the
drum or on the boom hook makes the safety difference.
- Forks are often used to open rail car doors and break
loads out or away from other loads. They are also used
to pick up capacity loads not seated against the fork
shank and to pick up off-balanced loads far from the
side of the truck. The fork tips are sometimes inserted
under other fork trucks to lift them during maintenance
operations.
- Lift trucks may collide with building columns and walls,
and though the forks show no discernible bend, they
may be damaged beyond safety.
- Any time excessive heat is applied to any part of a fork
during repair, for instance, hidden damage may occur.
The fork itself is a concern but so are the hooks that secure
them to the lift carriage.
DESIGNED TO TAKE A BEATING
Forks for counterbalanced and straddle lift trucks are not
just bent bars of steel. The manufacturing process is careful
and precise with many checks and inspections critical to
their safety. Some factors essential to fork manufacture
include the steel, the bend and thickness of the heel, the
welding of the hooks that hold them on the carriage, and
the heat treatment of the finished product.
9-31
12.2 Chain Tension Adjustment - Simplex Mast
Note: Follow the same chain tightening procedure for all

masts except for the Simplex Mast chains on the lift
bracket side.
R 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) On the level ground, position the mast at a right angle

to the ground surface, lower the forks to the ground,
and make sure the lift cylinder rods are contracted fully.
(2) Secure the anchor bolts on the lift bracket side by
tightening the upper nuts and double nuts.
(3) Adjust the chain tensions by turning the nut on the lift 1
cylinder side. With the mast standing perpendicular to
the ground, lift the forks slightly, then press the chains
alternately at a midpoint between the chain wheel and
the secured end of the chain to make sure the tension is
the same in both chains. 2
Note: Tilting the mast slightly forward causes the chains to
sag, thus making it easier to adjust the chain tensions 3 501053
with the double nuts (upper).
1. Clamp 3. Locknut
(4) Hold the locknut and tighten the locknut to the 2. Nut
specified torque.
501085

98 to 147 N·m
[72.3 to 109 lbf·ft]
9-32
(5) With the lift cylinder rods fully contracted, make sure
the amount of protrusion of each lift bracket main roller
is 40 % of the roller diameter or less.
(6) Make sure that the chain tension is correct with the
mast in vertical (0°) position.
1) 501086
1) 40% or less
9-33
12.3 Chain Tension Adjustment - Duplex Mast

(2) Secure the anchor bolts on the lift bracket side by
tightening the upper nuts and double nuts.
501122
(3) Adjust the chain tensions by turning the nut on the lift
the same in both chains.
sag, thus making it easier to adjust the chain tensions
501085
(4) Hold the nut and tighten the locknut to the specified
torque.
1) 501086
1) 40% or less

98 to 147 N·m
[72.3 to 109 lbf·ft]
is 40 % of the roller diameter or less.
9-34
12.4 Chain Tension Adjustment - Triplex Mast
Adjust each of the first and second chains (total of four).

(2) Secure the anchor bolts on the lift bracket (first chains)
side and the lower inner mast section (second chains)
by tightening the upper nuts and double nuts.
Note: When installing the second chains (between the inner
mast and the outer mast) in the Triplex mast, adjust
the chain tensions to be slightly tighter. If the chains
are loose, damage can occur to the hose pulley.
501123
(3) Adjust the chain tensions by turning the nut on the lift
the same in both chains.
sag, thus making it easier to adjust the chain tensions
501085
(4) Hold the nut and tighten the locknut to the specified
torque.
1)
501124
1) 40% or less

98 to 147 N·m
[72.3 to 109 lbf·ft]
is 40% of the roller diameter or less.
9-35
12.5 Clearance Adjustment on Lift Bracket
Note: The adjustment procedure for the lift bracket is the

same for the Simplex mast, Duplex mast and Triplex
mast.
Longitudinal clearance adjustment on lift bracket

main rollers
(1) Raise the forks slightly from the floor.
(2) Insert a bar between the upper part of lift bracket and
the inner mast, and push the inner mast to one side.
Using feeler gauges, measure the clearance F between
the main roller and inner mast on the opposite side.
501087
Item Standard
Clearance 1.0 mm (0.039 in.) or less
(3) If the clearance is out of specification, use oversize

rollers.
1 2 501088
1. Lower roller 2. Upper/middle roller
Roller sizes
Diam. of
Main Roller
S 99 mm (3.90 in.)
M 100 mm (3.94 in.)
L 101 mm (3.98 in.)
LL 102 mm (4.02 in.)
(4) Lift bracket main rollers (upper and center rollers)

The upper rollers should be the same in size or 1-rank
larger than the center rollers.
9-36
Lateral clearance adjustment on lift bracket main

rollers and side rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inner mast with its contact
point rested on the side of the lift bracket.
(3) Go over to the opposite side of the mast, and push the
lift bracket to one side with a bar. Set the indicator to
zero.
501089
(4) Insert a bar between the inner mast and lift bracket on
the indicator side, and push the lift bracket to the
opposite side. 1
1
(5) Read the indicator. 1)
2 2
501090
1. Upper main roller 2. Weld plate
Ref. Item Standard

0.1 to 0.5 mm
1) Clearance
(0.004 to 0.020 in.)
(6) Adjust clearance 1) between the center main roller and

weld plate at the maximum lift position by increasing or
decreasing the thickness of the shim.
Do not install any shim at upper main roller.
If clearance is excessive, increase the thickness of shims (a)

as required. Increase the thickness of shims (b) by the same 1
amount that are added to shims (a). Shim (a) is available in
two sizes: 1 mm (0.04 in.) and 0.5 mm (0.020 in.). Shim (b) is 3
available in only one size, 1 mm (0.04 in.). If shims (a) are
increased by 0.5 mm (0.020 in.), shims (b) do not need to the
increased by the equal amount.
501091
1. Inner mast 3. Shim (b)

2. Shim (a)
9-37
(7) Lower the lift bracket slightly from the top, then adjust
clearance 2) between the side roller and mast by
increasing or decreasing the thickness of the shims.
2)
1
1
501092
1. Side roller
Ref. Item Standard

0.1 to 0.5 mm
2) Clearance
(0.004 to 0.020 in.)
Adjust the side roller clearance by adding shims between

the roller bracket and lift bracket.
1
2
3
501093
1. Shims 3. Bracket
2. Roller
9-38
(8) With the lift bracket at the top, adjust clearance 3) with
shims.
3) 501094
Ref. Item Standard

0.1 to 0.5 mm
3) Clearance
(0.004 to 0.020 in.)
501095
1. Shims
9-39
12.6 Mast Clearance Adjustment
Note:
Adjust mast clearances at the locations indicated
below.
(1) Simplex Mast and Duplex Mast: Main rollers between
the outer mast and inner mast
(2) Triplex Mast: Main rollers between the outer mast and
middle mast, and main rollers between the middle
mast and inner mast.
Longitudinal clearance adjustment on mast main

rollers
(1) Tilt the mast fully backward.
(2) Using feeler gauges, measure the clearance between
the inner mast lower roller and outer mast.
501096
Item Standard
Clearance 1.0 mm (0.039 in.) or less
(3) If the clearance is out of the specification, use oversize

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

rollers
(2) Set a dial indicator on the inside of the outer mast with
its contact point rested on the inner mast.
inner mast against the outer mast. Set the indicator to
zero.
501097
9-40
(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.
501098
Item Standard
0.1 to 0.5 mm
Clearance
(0.004 to 0.020 in.)
(6) If the clearance is out of specification, adjust by shims.

Note: Refer to Main Roller Shim Replacement.
501099
1. Shims
9-41
Lateral clearance adjustment on outer mast main

rollers
(2) Set a dial indicator on the outer mast with its contact
point rested on the inner mast.
outer mast against the inner mast with a bar. Set the
indicator to zero.
(4) Insert a bar between the outer and inner mast, and
push the inner mast to the opposite side.
(5) Read the indicator.
501100
501101
Item Standard
0.1 to 0.5 mm
Clearance
(0.004 to 0.020 in.)
(6) If the clearance is out of specification, adjust it by shims.

Note: Refer to Main Roller Shim Replacement.
501102
1. Shims
9-42
12.7 Main Roller Shim Replacement - Simplex Mast
Remove the lift bracket from the mast

Note: Refer to “Removing lift bracket assembly.”
Lower the inner mast below the outer mast as

follows:
(1) Raise the front end of the truck by 150 to 200 mm (5.91
to 7.87 in.), and place jack stands to support the truck.
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to
the crossmember of outer mast with rope. For the truck
without crossmember, securely fasten to vehicle body
with a rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in
advance as they drop easily in this condition. 501103
9-43
12.8 Main Roller Shim Replacement - Duplex Mast

Note: Refer to “Removing lift bracket assembly” section.

(1) Hitch a sling on the first lift cylinder, and suspend it with
a hoist. Wind the sling securely to prevent slipping.
(2) Remove lift cylinder mounting bolts, and slowly
remove the first lift cylinder.
501104
Position the inner mast lower than the outer mast by

following the steps below:
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to
the crossmember of outer mast with rope. For the truck
without crossmember, securely fasten to vehicle body
with a rope.
501103
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
advance as they drop easily in this condition.
9-44
12.9 Main Roller Shim Replacement - Triplex Mast

Note: Refer to “Removing lift bracket assembly section.

(1) Hitch a sling on the first lift cylinder, and suspend it with
a hoist. Wind the sling securely to prevent slipping.
(2) Remove lift cylinder mounting bolts, and slowly
remove the first lift cylinder.
501104
Position the inner mast lower than the middle mast

by following the steps below:
(2) Hitch slings to the upper cross-member of the inner
mast, and suspend with a hoist.
(3) Remove the chain guards for the second lift chain
wheels.
(4) Dismount the second lift chains on the outer mast side,
and place them in front of the inner mast.
(5) Lower the inner mast until main rollers can be removed.
(6) Place wood blocks under the inner mast to support. 501103
Note: In this condition, second lift cylinders cannot be
dismounted.
9-45
Position the middle mast lower than the outer mast

by following the steps below:
(1) Lift the inner mast to the height of the middle mast,
then place wood blocks to support.
(2) Hitch slings to both middle mast and inner mast, and
suspend them with a hoist.
(3) Remove set bolts from the upper sections of the middle
mast lift cylinders, then lift the middle mast and inner
mast.
(4) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the lower
outer mast section. Tilt the cylinders by moving the top
sections towards the center of the truck, then secure
the cylinders to the cross-member of the outer mast
with a rope. For the truck without crossmember,
securely fasten to vehicle body with a rope.
(5) Lower the middle mast and inner mast until main
rollers can be removed.
(6) Place wood blocks under the middle mast and inner
mast to support.
501105
12.10 Mast Strip Adjustment
(1) Check the clearance with the clearance between the

outer mast rollers and inner mast set to zero (0) in
maximum lift position.
501106
Item Standard
0.1 to 0.5 mm
Clearance
(0.004 to 0.020 in.)
9-46
(2) If the clearance is out of specification, adjust it by shims.

Note: Refer to Main Roller Shim Replacement. 1
(3) After adjusting all clearances, move the mast and lift
bracket slowly to make sure that they move smoothly
through their full stroke.
501107
1. Shims
12.11 Tilt Angle Adjustment
(1) Adjust the tire pressure correctly and park the truck on
the level floor.
(2) Tilt the mast fully backward and turn the key switch to
off.
(3) Measure the backward tilt angle of the mast at both
sides.
(4) To adjust the tilt angle, loosen the bolt of tilt cylinder
socket, and adjust the rod length by turning the rod.
Adjust cylinders so that there is no difference in tilt
angle between the cylinders, left and right. 1
Note: It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted.
501108
1. Bolt
Item Standard
Forward - backward tilt angle 5° - 7.5° (STD)
(5) After adjusting the tilt angle, tighten the socket bolts to
the specified torque.
Tightening torque for tilt cylinder socket bolt

157 to 182 N·m
(16 to 18.6 kgf·m)
[116 to 135 lbf·ft]
12.12 Lift Cylinder Stroke Adjustment
(1) Slowly raise the inner mast, and observe the right and
left piston rod stopping conditions when they reach
the maximum lift position.
(2) If the upper parts of the inner mast shake at the
moment of stopping, make adjustment with shims.
Improper adjustment causes the inner mast to slant
slightly when the mast is stopped, and also causes the
lift cylinder with a longer cylinder stroke to shake when
the lift cylinder is stopped.
501109
9-47
(3) Adjusting method

- Raise the inner mast, and place wood blocks under the
inner mast. Lower the mast until the inner mast
contacts the wood blocks.
- 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 mast and release oil from the cylinder.
501110
- Raise the piston rod, then tighten the lift cylinder

stopper bolt. Remove the wood blocks under the inner
mast.
- Lower the inner mast slowly, and check to see if the

piston rods move smoothly until the inner mast reaches
the lowest position. 1
Bleeding lift cylinders
When air and oil remaining inside the air chamber of the rod 2
and inside the rod chamber between the tubes are
compressed, they open the check valve and flow out of the
cylinder. Therefore, there is no need to bleed the lift
cylinders.
501111
1. Set bolt 2. Shims
Shim adjustment for mast support bushing section

Adjust using shims so that the clearance is less than 1 mm.
501182
1. Shim
9-48
13. Troubleshooting

Faulty rotation of rollers Apply grease or replace rollers.
Lift bracket, inner mast or middle mast Improper mast strip clearance Adjust with shims.
does not rise or lower smoothly.
Improper main roller or side roller Adjust longitudinal and lateral
clearance clearances.
Uneven chain tension between right
Adjust chain tension.
and left chains
Excessive side roller clearance Adjust by adding shims.
Lift bracket or inner mast is lopsided. Uneven adjustment of shims between
right and left lift cylinders (at maximum Adjust by removing shims.
lift position)
Lift bracket retaining stopper in contact Adjust chain tension.
Faulty rotation of rollers Apply grease or replace rollers.
Mast generate abnormal noise Defective hose pulley bearing (for
Replace.
triplex mast system only)
Damaged gaskets in lift cylinders Replace.
Lift cylinders descent due to leaks.
Internal leak of control valve Replace.
Re-tighten, or replace bushings and
Entire masts shake Worn mast support bushings and caps
caps.
Masts are deformed in shape. Uneven cargo load or overload Replace assembly.
Bent finger bars Repair or replace.
Bent forks Replace.
Uneven fork end heights
Mast deformation due to uneven cargo
Repair or replace.
load
Increase oil temperature by raising and
Low oil temperature
lowering lift bracket.
Second lift cylinders move when first lift No clearance for lift bracket roller
cylinder operates. Readjust rollers.
surfaces
(Duplex and Triplex mast systems)
Clogged pipes Inspect and clean hydraulic lines.
Improper air bleeding Bleed hydraulic system.
Spongy operation of fall-prevention
function when lifting operation is Improper air bleeding Bleed hydraulic system.
stopped.
9-49
14. Service Data
14.1 Simplex Mast, Duplex Mast, Triplex Mast
Truck models 1 ton class 2 ton class

Difference in height between fork tips Standard 5 mm (0.20 in.)
317.5 mm 381 mm
Standard
Chain (12.5 in.) (15.00 in.)
Length of lift chains (per 20 links)
327 mm 392 mm
Limit
(12.87 in.) (15.43 in.)
S Standard 99 mm (3.90 in.)
M Standard 100 mm (3.94 in.)
Diameter of main roller
L Standard 101 mm (3.98 in.)
Roller
LL Standard 102 mm (4.02 in.)
42 ± 0.1 mm
Diameter of side roller Standard
(1.65 ± 0.004 in.)
1 Width of outer mast Standard 610 mm (24 in.)
Simple mast,
3 Width of inner mast Standard 516 mm (20.3 in.)
Duplex mast
4 Width of lift bracket Standard 408 mm (16.1 in.)
Dimension
1 Width of outer mast Standard 610 mm (24 in.)
(Reference)
2 Width of middle mast Standard 516 mm (20.3 in.)
Triplex mast
3 Width of inner mast Standard 426 mm (16.8 in.)
4 of lift bracket Standard 318 mm (12.5 in.)
Clearance between main roller
5 Standard 1.0 mm (0.04 in.) or less
circumference and mast thrust surface
Clearance between main roller side surface 0.1 to 0.5 mm
Mast 7 Standard
and mast thrust surface (0.004 to 0.020 in.)
Clearance between inside mast and mast 0.1 to 0.5 mm
9 Standard
strip (0.004 to 0.020 in.)
Clearance between upper and lower roller
Clearances 6 circumference and inner mast thrust Standard 1.0 mm (0.04 in.) or less
surface
Clearance between middle roller side 0.1 to 0.5 mm
7 Standard
Lift bracket surface and inner mast thrust plate (0.004 to 0.020 in.)
Clearance between lower roller side surface 0.1 to 0.5 mm
7 Standard
and inner mast thrust surface (0.004 to 0.020 in.)
Clearance between side roller 0.1 to 0.5 mm
8 Standard
circumference and inner mast surface (0.004 to 0.020 in.)
59.1 to 72.3 N·m
Mast support bolts Standard (6.03 to 7.37 kgf·m)
[43.6 to 53.3 lbf·ft]
Tightening torque
98 to 103 N·m
Locknut Standard (10 to 10.5 kgf·m)
[72.3 to 76.01 lbf·ft]
Finger bar bend Standard 5.0 mm (0.2 in.) or less
9-50
7 9
6
7
7
8
7
6
8 7
5 7 3
7 7
7 7 2
3
4
1 1
501112
Mast width is slightly wide at the lower portion than at the

upper portion.
Measure the clearance at the mast upper position.
1)
2)
3) 501113
1. Clamp 3. Locknut
2. Nut
9-51
CHAPTER 10 SERVICE DATA
Chapter 10 Service Data
1. Inspection Standards
Inspect and conduct maintenance according to the specified hour meter indication or the number of calendar days, whichever
comes first.
3 : Check C : Clean L : Lubrication R : Replacement
Periodic Inspection
Pre-operation Inspection
Interval
Every 12 Months or
Every 6 Months or
After 1 Months or
Remarks
1000 Hours
2000 Hours
200 Hours
Inspection/Maintenance Location and Item
Service Standard
Abnormal noise during rotation 3 3 3

Commutator contamination,
3 EPS motor (DC)
streaks and wear irregularities
Replace brush R EPS motor (DC)
Motors
Looseness of connections 3 3
Grease replacement in motors,
L
shafts and couplings
Insulation resistance 3
Inverters Inverter nut looseness 3 3
Electrolyte levels 3 3 3 Inspection: Every week or 50 hours
Specific gravity of electrolyte after Inspection: Every week or 50 hours
3 3
charging Specific gravity: 1.28
Voltage of each cell 3 48 V, 36 V
Electrical system
Terminal corrosion, damage,

Batteries 3 3
contamination and looseness
Case damage and contamination,
3
and fluid leaks
Insulation resistance 3 3
Charge level 3 3
Contact looseness, damage and
Contactors 3 3
wear
Control valve microswitch
3 3
operating condition
Damage and mounting looseness 3 3
Foot brake switch operating
Micro 3 3
condition
switches
Damage, mounting looseness 3 3
Parking brake switch operating
3 3
condition
Damage and mounting looseness 3 3
10-1
Periodic Inspection
Interval
Every 12 Months or
Every 6 Months or
After 1 Months or
Remarks
1000 Hours
2000 Hours
200 Hours
Service Standard
Controller operating condition

3 3
(1) Seat switch
(2) Forward/reverse selector switch 3 3
(3) Control valve switch 3 3
(4) Brake switch 3 3
(5) Accelerator 3 3
Main (6) Line/PS contactors 3 3

controller (7) Key switch 3 3 3
(8) Forward 3 3
Electrical system
(9) Reverse 3 3
(10) Regeneration bypass 3 3
Internal contamination and
3 3
damage
Over-current limit value 3
Fuse mounting looseness 3 3
Fuses
Fuse capacity 3
Wire harness damage and clamp
3 3
looseness
Terminal connection looseness
Wiring 3 3
and taping condition
Battery connector contacts and
3 3
bolt looseness
L.H.: 0.53 liter (0.145 U.S. gal.)
Power transmitting system
R.H.: 0.53 liter (0.145 U.S. gal.)

Transfer oil level and
R R Change a month later or 200 hrs
contamination
has passed after the replacement
Transfers of the part.
Oil leaks 3 3 3
Bolt looseness
10-2
Periodic Inspection
Interval
Every 12 Months or
Every 6 Months or
After 1 Months or
Remarks
1000 Hours
2000 Hours
200 Hours
Service Standard
Tire cracking and damage 3 3 3

Tire tread depth 3 3 3
Tires Abnormal tire wear 3 3 3
Metal pieces, rocks, other foreign
Drive system
3 3 3
materials on tires
Hub bolts Damage and looseness 3 3 3
Rims and
Damage 3 3 3
wheel discs
Wheel Wheel bearing rattle 3

bearings Abnormal noise in wheel bearings 3
Looseness, rattling and operating
Steering 3 3 3
condition
wheel
Steering system
Sensor mounting looseness 3 3

Deformation, cracking and
3
damage
Rear axle
Oil leaks 3 3 R
Bolt looseness 3
Free play 3 3 3 5 to 7 mm (0.20 to 0.28 in.)
Distance between depressed brake
3 3 3
pedal and floor board
Air trapped in fluid 3 3
Brakes
Braking performance 3 3 3
Braking system
Uneven braking performance

3 3 3
between right and left
Reservoir tank level and oil leaks 3 3 3 R 1.35 cc (8.2 cu. in.)
Parking Lock condition 3 3 3

brake Braking performance 3 3 3 3rd or 4th notch engagement
Damage, leaks and contact with
Hoses and 3 3 3
other parts
pipes
Looseness of links and clamps 3 3 3
10-3
Periodic Inspection
Interval
Every 12 Months or
Every 6 Months or
After 1 Months or
Remarks
1000 Hours
2000 Hours
200 Hours
Service Standard
Clearance between brake cylinder

3 TBD
and lever
Braking system
Brake Brake cylinder and lever operating

3
cylinder and condition
lever Rusting of pins 3
Brake cylinder oil leaks and
3 3 3
damage
Fork and stopper pin damage 3 3 3
Forks—wear and distortion 3 3 3
Forks
Cracking and wear in fork base and
3 3 3
tooth weld
Cracking in cross-member welds of
3
outer and inner masts
Cracking in welds of tilt cylinders
3
and masts
Cracking in welds of outer masts
3
and cylinder support
Masts and Cracking in lift bracket welds 3

lift bracket Roller bearing rattle 3
Wear and damage of mast support
3
metal
Lift system
Cracking and damage in rollers,

3
roller pins and welds
Mast operating condition and
3 3 3 3
mounting looseness
Allowed lift chain stretch:
Length of lift chains (20 links) 3 3 3 1 ton class: 327 mm (12.87 in.)
2 ton class: 392 mm (15.43 in.)
Chain deformation, damage,
3 3 3
lubrication and rusting
Chains and
chain wheels Chain bushing coupling, bolt
3 3
deformation and damage
Chain wheel deformation and
3
damage
Chain wheel bearing rattle 3 3
Attachment abnormality and
Attachments 3 3 3
mounting conditions
10-4
Periodic Inspection
Interval
Every 12 Months or
Every 6 Months or
After 1 Months or
Remarks
1000 Hours
2000 Hours
200 Hours
Service Standard
Looseness, deformation and

damage of rods, rod bolts and rod 3
ends
Cylinder operating condition 3 3 3
Drift lowering distance:
Cylinders Drift lowering and forward tilting 50 mm (1.97 in.)/15 min
3
distances Drift forward tilting distance:
22 mm (0.87 in.)/15 min
Cylinder oil leaks and damage 3 3 3
Wear and damage of piston and
3
cylinder shaft bearings
Oil leaks, abnormal noise, wear in
Oil pump drive unit, and mounting 3 3 3
Hydraulic system
looseness
N level: 12.1 [11.3]
liter (3.2 [2.98] U.S. gal)
Oil level and contamination 3 3 3 R H level: 13.3 [12.5]
Hydraulic liter (3.5 [3.3] U.S. gal)
tank *[ ] is oil circulation
Suction strainer C
Return filter clogging R R
Operation Linkage looseness 3 3 3

levers Lever functions 3 3 3
Oil leaks 3 3 3
Safety valves 3 3 3
Control
+490
valves 18142 0 kPa
+5
Release pressure measurement 3 kgf/cm2)
(185 0+71
[2631 0 psi]
10-5
Periodic Inspection
Interval
Every 12 Months or
Every 6 Months or
After 1 Months or
Remarks
1000 Hours
2000 Hours
200 Hours
Service Standard
Mounting looseness 3 3 3
Head guard
and backrest Deformation, cracking and 3 3 3
damage
Turn signal operation and
3 3 3
mounting condition
Alarm device operation and
3 3 3
mounting condition
Lamp operation and mounting
3 3 3
condition
Safety Backup warning device operation
Safety devices and others
3 3 3
devices and mounting condition
Rear-view mirror dirtiness and
3 3 3
damage
Rear-view mirror image and
3 3 3
condition
Proper function of seat belt and
3 3 3
hip restraint
Instruments Instrument operations 3 3 3
Seat Looseness and damage 3 3 3
Damage and cracking in frame and
Vehicle body 3
cross-members
Inspection of chassis lubricating
Oil and 3 3
conditions after cleaning
grease
replacement Confirmation of oil replacement R R
intervals
10-6
2. Periodic Replacement of Parts
Replace the following critical safety-related parts and elements according to the specified intervals.
Replacement Interval
Parts for Periodic Replacement Method After 1 month of 2000 service 4000 service
initial Use hours or 1 year hours or 2 years
Hose and rubber parts of brake master
1 Replace z
cylinder*
2 Rubber parts of transfer brake* Replace z
3 High pressure hoses of hydraulic system* Replace z
4 Rubber parts of power steering cylinder* Replace z
5 Hoses of steering system* Replace z
6 Lift chains* Replace z
7 Hydraulic tank return oil filter Replace z
Note: “ * ” mark indicates critical safety parts.

2.1 Critical Safety Parts
3
5
3 1
501676
10-7
3. Tightening Torques for Standard Bolts and Nuts
3.1 Metric fine thread
With spring washer

Nominal size Pitch
500244 500245 500246
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 5.46 9.6 0.98 7.08 12.7 1.30 9.37
8 (0.31) 1.25 (0.05) 16.7 1.70 12.32 22.6 2.30 16.67 30.4 3.10 22.42
10 (0.39) 1.25 (0.05) 34.3 3.50 25.30 45.1 4.60 33.26 69.6 7.10 51.33
12 (0.47) 1.25 (0.05) 63.7 6.50 46.98 82.4 8.40 60.77 122.6 12.50 90.42
14 (0.55) 1.5 (0.06) 102.0 10.40 75.23 132.4 13.50 97.65 192.2 19.60 141.76
16 (0.63) 1.5 (0.06) 157.9 16.10 116.46 202.0 20.60 148.99 287.3 29.30 211.90
18 (0.71) 1.5 (0.06) 224.6 22.90 165.65 292.2 29.80 215.51 413.8 42.20 305.20
20 (0.79) 1.5 (0.06) 310.9 31.70 229.30 404.0 41.20 297.97 573.8 58.51 423.21
22 (0.87) 1.5 (0.06) 413.8 42.20 305.20 537.5 54.81 396.43 763.0 77.80 562.75
24 (0.94) 1.5 (0.06) 547.2 55.80 403.59 711.0 72.50 524.40 1006.2 102.60 742.12
27 (1.06) 1.5 (0.06) 794.3 80.99 585.84 1032.6 105.29 761.59 1451.1 147.97 1072.47
30 (1.18) 1.5 (0.06) 1100.3 112.20 811.53 1430.8 145.90 1055.29 2012.3 205.19 1484.17
33 (1.30) 1.5 (0.06) 1467.1 149.60 1082.06 1907.4 194.50 1406.80 2680.2 273.30 1976.78
36 (1.42) 1.5 (0.06) 1918.2 195.70 1414.77 2493.8 254.29 1839.30 3497.1 356.60 2579.29
39 (1.54) 1.5 (0.06) 2461.5 251.00 1815.48 3198.8 326.18 2359.28 4469.9 455.80 3296.77
10-8
Without spring washer

Nominal size Pitch
500244 500245 500246
6 (0.24) 1 (0.04) 8.6 0.88 6.34 10.8 1.10 7.97 14.7 1.50 10.84
8 (0.31) 1.25 (0.05) 19.6 2.00 14.46 26.5 2.70 19.55 36.6 3.73 26.99
10 (0.39) 1.25 (0.05) 41.2 4.20 30.39 53.0 5.40 39.09 81.4 8.30 60.04
12 (0.47) 1.25 (0.05) 74.5 7.60 54.95 97.1 9.90 71.62 144.2 14.70 106.35
14 (0.55) 1.5 (0.06) 119.6 12.20 88.21 155.9 15.90 114.98 226.5 23.10 167.06
16 (0.63) 1.5 (0.06) 182.4 18.60 134.53 237.3 24.20 175.02 338.3 34.50 249.51
18 (0.71) 1.5 (0.06) 263.8 26.90 194.57 343.2 35.00 253.13 487.4 49.70 359.48
20 (0.79) 1.5 (0.06) 365.8 37.30 269.80 475.6 48.50 350.78 674.7 68.80 497.63
22 (0.87) 1.5 (0.06) 486.4 49.60 358.74 632.5 64.50 466.50 897.3 91.50 661.80
24 (0.94) 1.5 (0.06) 643.3 65.60 474.47 836.5 85.30 616.96 1183.7 120.70 873.04
27 (1.06) 1.5 (0.06) 934.6 95.30 689.31 1216.0 124.00 896.86 1707.3 174.09 1259.22
30 (1.18) 1.5 (0.06) 1294.5 132.00 954.76 1682.8 171.60 1241.15 2367.3 241.39 1746.00
33 (1.30) 1.5 (0.06) 1726.0 176.00 1273.01 2243.8 228.80 1654.91 3153.8 321.59 2326.09
36 (1.42) 1.5 (0.06) 2256.5 230.10 1664.28 2934.1 299.19 2164.05 4114.0 419.50 3034.28
39 (1.54) 1.5 (0.06) 2896.0 295.31 2135.94 3763.8 383.79 2775.99 5258.3 536.19 3878.26
10-9
3.2 Metric coarse thread
With spring washer

Nominal size Pitch
500247 500248 500249
10 (0.39) 1.5 (0.06) 33.3 3.40 24.56 43.1 4.39 31.79 67.7 6.90 49.93
12 (0.47) 1.75 (0.07) 58.8 6.00 43.37 76.5 7.80 56.42 115.7 11.80 85.33
14 (0.55) 2 (0.08) 96.4 9.83 71.10 124.5 12.70 91.82 182.4 18.60 134.53
16 (0.63) 2 (0.08) 147.1 15.00 108.49 191.2 19.50 141.02 274.6 28.00 202.53
18 (0.71) 2.5 (0.10) 203.0 20.70 149.72 264.8 27.00 195.30 383.4 39.10 282.78
20 (0.79) 2.5 (0.10) 286.4 29.20 211.23 371.7 37.90 274.15 536.4 54.70 395.62
22 (0.87) 2.5 (0.10) 383.4 39.10 282.78 499.2 50.90 368.18 725.9 74.02 535.39
24 (0.94) 3 (0.12) 492.3 50.20 363.10 640.4 65.30 472.33 924.8 94.30 682.09
27 (1.06) 3 (0.12) 724.7 73.90 534.50 942.2 96.08 694.92 1350.4 137.70 995.99
30 (1.18) 3.5 (0.14) 969.9 98.90 715.35 1259.2 128.40 928.72 1843.7 188.00 1359.82
33 (1.30) 3.5 (0.14) 1328.8 135.50 980.06 1727.0 176.10 1273.75 2477.2 252.60 1827.06
36 (1.42) 4 (0.16) 1676.0 170.90 1236.13 2180.0 222.29 1607.86 3199.9 326.29 2360.09
39 (1.54) 4 (0.16) 2219.2 226.29 1636.77 2884.1 294.09 2127.17 4118.8 419.99 3037.82
42 (1.65) 4.5 (0.18) 2754.7 280.90 2031.73 3581.4 365.20 2641.46 5137.7 523.89 3789.31
10-10
Without spring washer

Nominal size Pitch
500247 500248 500249
10 (0.39) 1.5 (0.06) 39.2 4.00 28.91 51.0 5.20 37.62 79.4 8.10 58.56
12 (0.47) 1.75 (0.07) 69.6 7.10 51.33 90.2 9.20 66.53 135.3 13.80 99.79
14 (0.55) 2 (0.08) 112.8 11.50 83.20 146.1 14.90 107.76 215.7 21.99 159.09
16 (0.63) 2 (0.08) 172.6 17.60 127.30 224.6 22.90 165.65 323.6 33.00 238.67
18 (0.71) 2.5 (0.10) 239.3 24.40 176.50 311.9 31.80 230.04 451.1 46.00 332.71
20 (0.79) 2.5 (0.10) 336.4 34.30 248.11 437.4 44.60 322.60 630.6 64.30 465.10
22 (0.87) 2.5 (0.10) 392.3 40.00 289.34 587.4 59.90 433.24 842.4 85.90 621.31
24 (0.94) 3 (0.12) 578.6 59.00 426.75 753.2 76.80 555.52 1088.5 110.99 802.82
27 (1.06) 3 (0.12) 852.2 86.90 628.54 1108.2 113.00 817.35 1588.7 162.00 1171.75
30 (1.18) 3.5 (0.14) 1140.5 116.30 841.18 1481.8 151.10 1092.90 2168.3 221.10 1599.23
33 (1.30) 3.5 (0.14) 1563.2 159.40 1152.94 2031.9 207.19 1498.63 2915.5 297.29 2150.33
36 (1.42) 4 (0.16) 1972.1 201.10 1454.52 2564.4 261.49 1891.37 3765.8 384.00 2777.47
39 (1.54) 4 (0.16) 2610.5 266.19 1925.37 3393.1 345.99 2502.58 4845.5 494.10 3573.80
42 (1.65) 4.5 (0.18) 3241.1 330.49 2390.47 4212.9 429.59 3107.22 6044.8 616.39 4458.34
10-11
4. Lubrication Instructions
4.1 Lubrication Chart
4 6
2 1
501679
Ref. Lubricating point Lubricant/grease Period

1 Mast support (Each side)
Multipurpose-type grease
2 Mast strips, roller surfaces (each side)
3 Lift chain (Each side) Engine oil
Every 1000 hour or 6 months
4 Tilt socket (each side)
5 Tie rod pins (4 places) Multipurpose-type grease
6 King pins (4 places)
10-12
4.2 Recommended Oils and Greases
Recommendation for Ambient Temperatures °C (°F)
-30 -20 -10 0 10 20 30

Item Recommendation
(-22) (-4) (14) (32) (50) (68) (86)
SUMICO 5L022
Transfer Oil KROON F1052
SHELL DONAX TDL
Hydraulic Oil API service classification CD SAE 5W SAE 10W
Rear axle Oil ISO VG15
Brake Fluid F.M.V.S.S. No. 116 - DOT3 or DOT4 (SAE J1703)
Wheel
NLGI No.2 grade multipurpose type (lithium base), consistency: 265 - 295
Grease bearings
Chassis NLGI No.1 grade multipurpose type (lithium base), consistency: 310 - 340
Note:
- Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate
when mixed. It is best to stick with the same brand at successive service intervals.
- For lubricants for the steering actuator and steering gear, consult your Mitsubishi forklift truck dealer.
4.3 Capacity
Item Truck model

Transfer 0.55 L (0.15 U.S. gal)
-Simplex mast (less than 6000 mm (236.22 in.)
MIN: 12.1 L (3.20 U.S. gal)
-Duplex mast (less than 4000 mm (157.48 in.)
MAX: 13.3 L (3.51 U.S. gal)
Hydraulic tank -Triplex mast (less than 6000 mm (236.22 in.)
MIN: 11.3 m (3.0 in.)
Triplex mast 6500/7000 mm (255.91/275.59 in.)
MAX: 12.5 m (3.3 in.)
MIN: 60 cc (3.66 cu in.)
Brake fluid reservoir tank
MAX: 102 cc (6.22 cu in.)
PS pump reservoir tank fluid level 850 cc (51.87 cu in.)
10-13
5. Weight of Major Devices
Unit: kg (lb)
Truck model
Item
FB16CPN FB18CPN FB16PN FB18PN FB20PN
566 (1248) 621 (1369) 424 (935) 490 (1080) 621 (1369)
Counterweight
(MARK: L) (MARK: LL) (MARK: S) (MARK: M) (MARK: LL)
Transfer 37 (82)
Traction Motor 37 (82)
Pump Motor 37 (82)
EPS Motor 4 (9)
Rear Axle 100 (220)
Head Guard 60.32 (133) 62.5 (138)
simplex
475 (1047) 490 (1080)
3.3 m
duplex
Mast 495 (1091) 510 (1124)
3.3 m
triplex
650 (1433) 665 (1466)
4.8 m
10-14
6. Special tools
Ref. No. Part number Name Illustration
1 97967-00200 Brake installer
2 97967-00300 Socket
3 97967-00400 Special rod
4 97967-00500 Connector
5 64309-17722 Hose
6 64309-17731 Connector

7 64309-17712 Gauge
/2
C

10-15
CHAPTER 11 PANEL CABIN
Chapter 11 Panel Cabin
1. Battery Exchange or Battery Charging
(1) Open the left side steel door (if present)
(2) Open the right side steel door (if present). Unlock the opening mechanism at the top side by pulling knob downwards.
Open the door until the mechanism at the top side locks again.
(3) Open the left side PVC door (if present) by unzipping the door from lower front to rear side upper corner. Pull the PVC door
to the backside so that it is clear from the battery hood.
(4) Open the right side PVC door (if present) by opening the patch at the top side near the battery slot and fix it to the front
side. Unzip the rear zipper to the rear side upper corner. Unzip the front zipper from the bottom side to the top side and
separate the zippers. Pull the door to the backside so that it is clear from the battery hood.
(5) Open the rear window (if present) by unlocking both left and right side latches and pushing the rear window to the
maximum opening angle.
(6) Open the latch at the roof side by pulling the handle downwards and simultaneously rotating the handle 1/4 turn. Push
the latch upwards and backwards until it rests on the rubber stopper on the roof
(7) Open the battery hood and exchange or charge the battery as normal.
(8) Close rear windows and doors in opposite order after battery is exchanged or charged.
Note:
- For zipping up the right hand side PVC door the rear zipper must be kept in the corner position to leave enough slack to
fix the front side zipper again. DO NOT use excessive force to connect the front side zipper.
- For closing the right hand side steel door the lock mechanism must be unlocked again by pulling the knob downwards.
Taken care that the opening mechanism returns to the original position correctly.
2. Cleaning Top Roof
- Wash polycarbonate top window with a mild soap or detergent and lukewarm water, using a clean sponge or a soft cloth.
Rinse well with clean water. DO NOT scrub or use brushes or abrasives on these products.
- Filter for the heater (if present) must be cleaned every 1000 hours or 6 months. Filter must be cleaned with dry air only.
3. Replacing Top Roof
(1) The top roof must be replaced if any scratches are visible or if reduced transparency does not allow safe load handling at
heights anymore.
(2) Screws and washers with which window is fixed to Overhead Guard at rear side must be released. Window to be replaced
must be cut loose from kit. Take window out and remove kit from Overhead Guard structure.
(3) Clean Overhead Guard and treat with primer
(4) Replace top screen only by OEM original product.
(5) Put foam seal on Overhead Guard structure under dash
(6) Put new screen under rib at front side of Overhead Guard and fix at rear side with screws with washer
(7) Apply kit to fill gap between Overhead Guard structure and top screen to ensure watertight fitment.
4. Maintenance
- The washer bottle for the front and rear wipers is located under the floor plate. To fill the washer tank please remove the
floor mat and floor plates, release the filler cap and fill up. Use appropriate fluids.
- Fuses for all panel cabin features are located in a designated panel cab fuse box integrated into the cabin harness and
located near the fixation of the rear right side over head guard leg to the frame. Box can be accessed by opening the
battery hood. Fuses are used for;
- Heater element (2x)
- Heater fan
- Wipers
- 12V connection
11-1
Mitsubishi Forklift Trucks Service Manual FB16CPN, FB18CPN, FB16PN, FB18PN, FB20PN Forklift Trucks 99759-5M100
???????
Mitsubishi Caterpillar Forklift Europe B.V.
Hefbrugweg 77
1332 AM Almere,
The Netherlands
Copyright © 2011 by MCFA. All Rights Reserved. Printed in The Netherlands
99759-5M100 09/11

5M100

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

5M100

Загружено:

Авторское право:

Доступные форматы

Service Manual

Chassis & Mast FC/MC

Safety related signs Meanings

Unauthorized copying and lending are prohibited.

MC Truck (Manual Control System)

FC (Fingertip Control System) Truck

Item SI unit Metric unit Yard-pound unit

Chapter 1 GENERAL INFORMATION

Chapter 2 VEHICLE ELECTRICAL COMPONENTS

Chapter 3 POWER TRAIN

Chapter 4 TRANSFER UNITS

Chapter 5 REAR AXLE

14. Inspecting Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

Chapter 6 BRAKE SYSTEM

Chapter 7 STEERING SYSTEM

6.1 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Chapter 8 HYDRAULIC SYSTEM

12.2 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-23

25.1 Disassembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81

Chapter 9 MAST AND FORKS

2.5 Operation of Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

Chapter 10 Service Data

Chapter 11 Panel cabin

Truck model Model code - Serial number

1. Name plate 2. Mast number

SPECIFICATION UNIT FB16CPN FB18CPN FB16PN FB18PN FB20PN

LOWERING SPEED m/s 0.5/0.52 0.5/0.52

SPECIFICATION UNIT FB16CPN FB18CPN FB16PN FB18PN FB20PN

NAME SOLID PNEUMATIC SOLID PNEUMATIC

SPECIFICATION UNIT FB16CPN FB18CPN FB16PN FB18PN FB20PN

MAXIMUM WEIGHT kg (lb) 900 (1984) 1075 (2370)

FOR DRIVE kw/

FOR TYPE INDUCTION INDUCTION

TYPE OF HYDRAULIC AC TRANSISTOR AC TRANSISTOR

1. MAXIMUM FORK HEIGHT 12. SEAT HEIGHT

1. Meter panel 6. Parking switch

1. Meter panel 6. Parking switch

1. Kick panel 7. Column panel (2)

Removal of parking switch, emergency stop switch,

1. Kick panel 3. Lighting switch (Rear work

(4) Disconnect the harness connector of the emergency

1. Emergency stop switch (MC 2. Meter panel assembly

Disassembly of key switch and combination switch

1. Column panel (1) 3. Key switch

(4) Disconnect the harness connector of the combination

1. Combination switch 4. Tilt steering column lock/

1. Battery discharge indicator 10. Error warning

Battery discharge indicator

1) Full charged 4) Empty

Calendar and clock (Date and time)

Slow speed mode monitor (Turtle mark)

Mode select switch

Icon Name When OFF When ON or flashing Remarks

Overheat warning Controller, drive motors Overheating Overheating causes a

Load Zero setting (optional)

(2) Push E button and screen 2 appears.

(3) Push (R) button. Then the screen 3 appears.

(4) Select the operation by pushing t or y button. Then

(5) Push (R) button. Then setting is complete.

Load Meter setting (optional)

(1) Turn the key switch ON and the screen 1 appears.

(2) Push E button and screen 2 appears.

(3) When you select "SET", the screen 3 appears.