HYDRAULIC SYSTEM

SECTION HD
CONTENTS
SPECIFICATIONS ..............................................HD-2 Inspection ..................................................... HD-32
Hydraulic Pump (Gear Pump) ........................HD-2 Assembly ...................................................... HD-32
Control Valve ..................................................HD-2 Installation .................................................... HD-32
Tilt Cylinder .....................................................HD-2 Hydraulic Pressure Test and Adjustment ..... HD-33
SERVICE DATA ..................................................HD-5 LIFT (MAST) CYLINDER .................................. HD-35
Hydraulic Oil for Use and Oil Level ................HD-5 Component Parts Location ........................... HD-35
Adjustment Value ...........................................HD-5 Trouble Diagnosis and Corrections .............. HD-36
Parts for Adjustment .......................................HD-5 Description ................................................... HD-36
Tightening Torque ..........................................HD-6 Mast Cylinder (3F Mast) Inner
TROUBLE DIAGNOSIS ......................................HD-7 Part Drain Method ........................................ HD-40
Hydraulic Pump (Gear Pump) ........................HD-7 Full Free Cylinder (2F, 3F Mast) .................. HD-40
Control Valve ..................................................HD-7 Removal ....................................................... HD-41
Tilt Cylinder ....................................................HD-8 Installation .................................................... HD-44
Lift (Mast) Cylinder .........................................HD-9 Adjustment ................................................... HD-45
SERVICE INFORMATION ..................................HD-9 TILT CYLINDER ............................................... HD-46
HYDRAULIC PIPING ........................................HD-10 Component Parts Location ........................... HD-46
Hydraulic Circuit Diagram (MC models) .......HD-11 Removal ....................................................... HD-47
Hydraulic Piping ...........................................HD-13 Disassembly ................................................. HD-47
HYDRAULIC PUMP ..........................................HD-21 Assembly ...................................................... HD-48
Component Parts Location ...........................HD-21 TROUBLE DIAGNOSIS AND
Component Parts Location ...........................HD-22 CORRECTIONS ................................................ HD-49
Removal (e.g. Vehicles with REPLACEMENT OF HYDRAULIC FLUID ....... HD-50
Gasoline Engines) ........................................HD-22 INSPECTION .................................................... HD-50
Disassembly .................................................HD-23 HYDRAULIC FINGERTIP CONTROL .............. HD-50
Inspection .....................................................HD-23 Hydraulic piping ............................................ HD-50
Assembly ......................................................HD-24 Joystick System Option ................................ HD-51
Test Operation ..............................................HD-25 Hydraulic Circuit Diagram (FC models) ........ HD-52
CONTROL VALVE ............................................HD-27 Installation .................................................... HD-53
Component Parts Location ...........................HD-27 Disassembly ................................................. HD-53
Specifications ...............................................HD-28 EMERGENCY LOWERING OF MAST ............. HD-54
Lift lock .........................................................HD-29
Unload Valve ................................................HD-30
Removal .......................................................HD-31
Disassembly .................................................HD-31
SPECIFICATIONS

Hydraulic Pump (Gear Pump)

SPECIFICATIONS

Vehicle type 1D2 Series

1D1 Series

Engine type K21+QD32 K25 QD32

Theoretical discharge volume cc (lmp fl oz) 24.0 (0.84) 32.8 (1.15) 29.4 (1.03)
2
Discharge pressure [MPa (bar, kg/cm , psi)] 18.1 (181.4, 185, 2,631)

Control Valve
Vehicle type 1D1 Series 1D2 Series

Main relief pressure [MPa (bar, kg/cm2, psi)] 18.1 (181.4, 185, 2,631)

Normal flow rate [l (US gal, Imp gal)/min] 85 (22-1/2, 18-3/4)

Power steering relief pressure

7.8 (78.5; 80; 1,138) 8.8 (88.3; 90; 1,280)
[MPa (bar, kg/cm2, psi)]

Tilt Cylinder
Vehicle type 1D1 Series 1D2 Series

Cylinder type Double acting, piston

- 3700 169 (6.65) 161 (6.34)

2F
4000 - 4200 114.5 (4.51) 110 (4.33)
Stroke [mm
- 3700 169 (6.65) 161 (6.34)
(in)] 2W
4000 - 5000 114.5 (4.51) 110 (4.33)

3F, 3V All height 114.5 (4.51) 110 (4.33)

Cylinder bore inner diameter [mm (in)] 65 (2.56) 70 (2.76)

Cylinder bore outer diameter [mm (in)] 77 (3.03) 84 (3.31)

Piston rod diameter [mm (in)] 25 (0.98) 30 (1.18)

- 3700 6° - 12°
2F
4000 - 4200 6° - 6°
Tilt angle
- 3700 6° - 12°
(Forward tilt - backward tilt) 2W
4000 - 5000 6° - 6°

3F, 3V All height 6° - 6°

HD-2
SERVICE DATA AND SPECIFICATIONS

General Specifications
LIFT CYLINDER (Except 3V mast)
Mast name 2W 3000 2F 3000 3F 5500
Model & lifting 1D1 1D2 G1D2 1D1 1D2 G1D2 1D1 1D2 G1D2
capacity 15, 18 20, 25 30 15, 18 20, 25 30 15, 18 20, 25 30
Lift cyl. Lift cyl. Lift cyl. Lift cyl. Lift cyl. Lift cyl.
1,500 1,500 1,500 1,470 (57.87) 1,470 (57.87) 1,470 (57.87) 1,780 (70.08) 1,780 (70.08) 1,780 (70.08)
Stroke mm (in)
(59.06) (59.06) (59.06) Full-free cyl. Full-free cyl. Full-free cyl. Full-free cyl. Full-free cyl. Full-free cyl.
765 (30.12) 765 (30.12) 765 (30.12) 970 (38.19) 970 (38.19) 970 (38.19)
Cylinder ID
45 (1.77) 50 (1.97) 55 (2.17) 45 (1.77) 45 (1.77) 50 (1.97) 45 (1.77) 45 (1.77) 50 (1.97)
mm (in)
Cylinder OD
Lift 55 (2.17) 60 (2.36) 65 (2.56) 55 (2.17) 55 (2.17) 60 (2.36) 55 (2.17) 55 (2.17) 60 (2.36)
mm (in)
cyl.
Piston rod
diameter 35 (1.38) 40 (1.57) 45 (1.77) 32 (1.26) 35 (1.38) 38 (1.50) 32 (1.26) 35 (1.38) 38 (1.50)
mm (in)

Mast name 2W 3000 2F 3000 3F 5500

Model & lifting 1D1 1D2 G1D2 1D1 1D2 G1D2 1D1 1D2 G1D2
capacity 15, 18 20, 25 30 15, 18 20, 25 30 15, 18 20, 25 30
Cylinder ID
70 (2.76) 75 (2.95) 80 (3.15) 70 (2.76) 75 (2.95) 80 (3.15)
mm (in)
Full
Cylinder OD
free 83 (3.27) 87 (3.43) 92 (3.62) 83 (3.27) 87 (3.43) 92 (3.62)
mm (in) —
lift
cyl. Piston rod
diameter 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00)
mm (in)

LIFT CYLINDER (3V mast)

LIFT CYLINDER FULL-FREE CYLINDER

Cylinder Piston rod Cylinder Piston rod

Stroke ±3.5 (Tube) inner outer Stroke ±3.5 (Tube) inner outer
Series Ton Mast name diameter diameter diameter diameter

mm mm mm mm mm mm

3V360 1,235 565

3V405 1,385 640

3V450 1,535 715

3V490 1,670 780

1D1
45 36 50 40
15/18
3V525 1,780 845

3V575 1,935 940

3V633 2,100 1,065

3V688 2,250 1,190

HD-3
SERVICE DATA AND SPECIFICATIONS
General Specifications (Cont’d)
LIFT CYLINDER FULL-FREE CYLINDER

Cylinder Piston rod Cylinder Piston rod

Stroke ±3.5 (Tube) inner outer Stroke ±3.5 (Tube) inner outer
Series Ton Mast name diameter diameter diameter diameter

mm mm mm mm mm mm

3V360 1,235 565

3V405 1,385 640

3V450 1,535 715

1D2 3V490 1,670 780

20/25 50 40 55 45
3V525 1,780 845

3V575 1,935 940

3V633 2,100 1,065

3V688 2,250 1,190

3V385 1,285 640

3V430 1,435 715

3V470 1,570 780

3V505 1,680 845

G1D2
55 45 60 50.8
30 3V555 1,835 940

3V600 1,935 1,065

3V650 2,060 1,190

3V700 2,250 1,250

Suction filter
Applied model 1D1/1D2
Filter type Wire gauze
Diameter mm (in) 100 (3.94)
Filtration accuracy (mesh) 125
Filter area cm2 (sq in) 620 (96.1)

Micron filter
Applied model 1D1/1D2
Filter type Filter paper (cartridge) type
Filtration sizeµm 20

HD-4
SERVICE DATA

Hydraulic Oil for Use and Oil Level

SERVICE DATA

1D2 Series
Vehicle type
1D1 Series
2.0, 2.5 ton 3.0 - 3.2 ton
Item

Hydraulic fluid type hydraulic oil I.S.O. VG32

Oil level Oil level

35.9 (9-1/2; 7-7/8) 46.4 (12-1/4; 10-1/2) 51.4 (13-5/8; 11-3/8)
[l (US gal, Imp gal)] in tank

Adjustment Value
Control valve
Unit: mm (in)

Item Repair limit Remarks

Clearance between plunger and valve 0.02 (0.0008) All vehicle

Tilt cylinder
Unit: mm (in)

Item Repair limit Remarks

Clearance between cylinder head bushing and piston rod 0.2 (0.008)

Clearance between cylinder tube and piston 0.2 (0.008)

Lift (mast) cylinder

Unit: mm (in)

Item Repair limit Remarks

Clearance between cylinder head bushing and piston rod 0.2 (0.008)

Clearance between cylinder tube and piston 0.7 (0.028)

Parts for Adjustment

Unit: mm (in)

Part name Thickness type Remarks

Use by selecting a number

Parallel adjustment shim for mounting to the full free cylinder’s inner mast 1.0 (0.039)
of sheets.

Use by selecting a number

Lift cylinder top edge height adjusting shim 1.0 (0.039)
of sheets.

HD-5
TROUBLE DIAGNOSIS

Tightening Torque
Unit: N•m (kg-m, ft-lb)

Location Tightening torque

Pump assembly bolt 46 - 48 (4.7 - 5.0, 34 - 35)
Pumpmounting bolt 25 - 31 (2.5 - 3.2, 18 - 22)
Hydraulic pump Pipe connector at intake side G1 91.4 - 108.9 (9.3 - 11, 68 - 80)
Pipe connector at suction side G1/2 79 - 88 ( 8 - 9; 58 -65)
Nut at hose side G1/2 39 - 44 (4 - 4.5; 29 - 32)
Control valve assembly
M10 25 (2.6, 18)
Tie rod nut
3/4 79 - 88 (8.0 - 9.0, 59 - 64)
Control valve
Connector 1/2 39 - 44 (4.0 - 4.5, 29 - 32)
3/8 34 - 39 (3.5 - 4.0, 25 - 28)
Control valve assembly nuts 20 - 29 (2.0 - 3.0, 15 - 21)
Rod head lock bolt 108 - 147 (11 - 15, 80 - 108)
1D1 Series 206 (21.0, 152)
Piston tightening nut
1D2 Series 343 (35 ; 253)
Tilt cylinder
1D1 Series 265 - 421 (27 -43; 195 - 310)
Cylinder head
1D2 Series 295 - 469 (30-48; 218 - 346)
Connector 1/4 20 - 39 (2.0 - 4.0, 15 - 28)
Lift cylinder 2W, 1D1 170 - 240 (17.3 - 24.5; 125 - 175)
Cylinder head
(Apply Three Bond #1901 at 1D2 240 - 305 (24.5 - 31.1; 175 - 225)
thread portion.)
3F/3V 1D1/1D2 170 - 240 ( 17.3 -24.5; 125 -175)
2W, 3F, 3V 44 - 54 (4.4 - 5.6, 33 - 39)
Cylinder-retaining bolt
Top edge 78 - 98 (8.0 - 9.9, 58 - 72)
Bolt 2F
Bottom edge 44 - 54 (4.4 - 5.6, 33 - 39)
U-bolt lock nut 26 - 32 (2.6 - 3.3, 20 - 23)
Adjust bolt lock nut 74 - 94 (7.5 - 9.6, 55 - 69)
2F,3F 1D1 353 - 380 (36 - 38.7; 260 - 280)
2F,3F 1D2 380 - 407 (38.7 - 41.5 ; 280 - 300)
Cylinder head
3V 1D1 240 - 305 (24.5 - 31.1 ; 175 - 225)
3V 1D2 270 - 340 (27.5 - 34.7; 200 - 250)
Full free cylinder
Air plug 2.94 - 4.90 (0.30 - 0.49, 2.2 - 3.6)
Cylinder-retaining bolt 128 - 156 (13 - 16, 95 - 115)
2.75 ton or less 93 - 127 (9.4 - 13.0, 69 - 93)
Lift chain mounting nut
3.0 ton 142 - 192 (14 - 20, 105 - 141)

HD-6
TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS
If the hydraulic system functions incorrectly, identify the possible causes by referring to the table below and take
appropriate actions.

Hydraulic Pump (Gear Pump)

Condition Possible cause Corrective action

No oil from hydraulic pump • Low oil level in tank • Add oil to specified level.
• Clogged suction pipe or filter • Clean oil line and tank. If oil is dirty,
change.

Low discharge pressure on oil pump • Gear shaft bushing wear or faulty backing • Replace it with a new one.
ring
• Poor adjustment of relief valve • By using oil pressure gauge, raise
pressure at the specified level.
• While air is taken in • Check for looseness of pipe at suction
side.
• When oil level in tank is low, fill the oil at
the specified level on the specified
conditions.
• When air bubbles are observed in the
tank, leave it until they disappear.

Noise is emitted from hydraulic pump. • Cavitations are caused by hose • Correct hose deformation by removing
deformation at suction side or filter foreign objects.
clogging.
• Air intake from suction joint part • Tighten connecting rod nut.
• Operating fluid viscosity is too high. • Replace it with operating fluids of
appropriate viscosity.
• Air bubbles are mixed in operating fluid. • Bleed air, remove foreign objects and
replace operating fluids.

Operating fluid leaks from hydraulic pump. • Pump oil seal or poor body seal. • Replace it with a new one.
• Wear of gear sliding surface (increase of • Replace it with a new one.
internal leak)

Control Valve
Condition Possible cause Corrective action

Stick symptom of plunger • Dust adhered in the valve housing and • Clean valve housing and plunger.
plunger sliding part
• Contamination of operating fluid • Replace operating fluid.
• Damage of return spring • Replace it with a new one.
• Valve housing is mounted in strain. • Loosen mounting bolts and check.
• Bending of plunger • Replace valve housing and plunger as an
assembly.

Oil leak from oil seal • Entry of foreign material, painting powder • Clean by removing seal.
and dust
• Distortion of seal plate • Clean seal plate and tighten the bolt.
• Wear or damage of seal • Replace it with a new one.
• Damage of plunger • Replace it with a new one.

Cylinder’s natural downing or natural • Valve housing and plunger wear • Replace valve housing and plunger as an
forward tilt assembly.
• Oil leak from cylinder • Check cylinder and replace any
inoperative parts.

When control lever is shifted up from neutral • Foreign objects are caught in the load • Disassemble check valve and clean.
position to the upper position, it does not check valve.
operate smoothly. (It temporarily drops at • Poppet of load check valve or seat part • Replace or perform lapping correction.
the initial operation.) damage

HD-7
TROUBLE DIAGNOSIS/SERVICE INFORMATION

Condition Possible cause Corrective action

At engine stop, if control lever is operated in • Wear or damage of tilt lock plunger • Replace plunger and tilt housing valve as
tilt forward, mast is tilted forward. an assembly.
• Spring breakage of tilt lock plunger • Replace it with a new one.
• Oil leakage from tilt cylinder piston O-ring • Replace it with a new one.

Cylinder insufficient speed or poor operation • Relief valve wear or seat surface damage • Replace relief valve assembly.
• Poor operation by entry of foreign material
in relief valve • Clean or replace relief valve.
• Hydraulic pump malfunction
• Refer to "(1) Hydraulic pump (gear pump)"
for details.

Mast is unstable or does not move when • Stuck and damage of tilt lock plunger • Replace plunger and tilt housing valve as
control lever is moved to "forward tilt" while an assembly.
engine is running. • Because foreign material is entered into • Disassemble and clean.
the space between valve and tilt lock
plunger, valve does not move.

Tilt Cylinder
Condition Possible cause Corrective action

Oil leakage (Sliding surface between cylinder head and

piston rod)
• U-ring is damaged, or foreign matter is • Replace it with a new one.
entered.
• Foreign material in wiper ring lips portion • Remove and clean. Or replace it with a
• Wiper ring lips damage new one.
• Piston rod sliding surface damage • Replace wiper ring.
• Damage that can be modified shall be
smoothed by oilstone. When the
modification is not possible, replace it with
• Peeling of piston rod hard chromium as assembly.
plating • Replace it with a new one.
(Connecting part between cylinder head
and cylinder tube)
• O-ring damage
(Cylinder tube welding part) • Replace it with a new one.
• Damage and crack
(Others) • Replace it with a new one.
• Looseness of hose connector
• Deterioration and damage of hose and • Tighten to the specified torque.
tube • Replace it with a new one.

Cylinder tilts forward without control lever • Cylinder tube sliding surface damage • Damage that can be modified shall be
operation smoothed by oilstone. When the
modification is not possible, replace it with
a new one.
• Piston sliding surface damage • Replace piston rod as an assembly.
• Piston O-ring damage • Replace it with a new one.
• Backup ring damage • Replace it with a new one.
• Control valve malfunction • Refer to "(2) Control valve" for details.

Mast swings back and forth when brake is • Mix of air • Operate cylinder for about five minutes
applied at proceeding backward. (10 to 20 strokes) and bleed air.
• Replace O-ring and cylinder with new
• Leakage from piston O-ring ones.

HD-8
HYDRAULIC PIPING

Lift (Mast) Cylinder

Condition Possible cause Corrective action

Oil leakage • U-ring damage on cylinder head side, • Replace it with a new one.
(Sliding surface between cylinder head or mixed entry of foreign matter
and piston rod) • Foreign material in wiper ring lips • Remove and clean. Or replace it with
portion a new one.
• Wiper ring lips damage • Replace wiper ring.
• Piston rod sliding surface damage • Damage that can be modified shall be
smoothed by oilstone. When the
modification is not possible, replace it
with as assembly.
• Peeling of piston rod hard chromium • Replace it with a new one.
plating

Cylinder lowering without control lever • Lips damage on piston U-ring, or • Replace it with a new one.
operation, poor power output mixed entry of foreign matter
• Cylinder tube sliding surface damage • Replace it with a new one.
• Piston ring sliding surface damage • Replace it with a new one.
• Down safety valve malfunction • Replace down safety valve.

Lowering of cylinder at an unusual • Flow regulator valve plunger return • Replace flow regulator valve as an
speed spring worn out and breakage assembly.
(Extremely slow) • Fixing of foreign material at flow • Replace flow regulator valve as an
regulator valve sliding part assembly.
• Down safety valve malfunction • Replace down safety valve.

CAUTION:

• The possible causes and corrective actions shown in the table should be deemed as the referential
information. Customer's complaints must be listened to carefully. Check the actual vehicle status when
diagnosing.
SERVICE INFORMATION

CAUTION:

• When removal and installation, turn ignition switch OFF to

stop engine and then turn ignition switch ON to release any
residual pressure from the piping. (due to the lift and tilt lock
function)
• To prevent foreign objects from entering, be careful to keep
clean at workshop.
• When cutting off pipes, be careful to avoid splashing
hydraulic fluid to other parts by covering waste cloth around
the cutting areas.
• When connecting pipes, be careful not to enter foreign
objects from entering into pipes.
• Place disassembled parts on clean cloth or clean sheet of
paper. Be careful not to stain, scratch or damage parts.
• Lifting should be performed only by a technician who has
received training for slinging or hoisting.
• Operation involving heavy load should be performed by two
persons.
NOTE:
• For installation and removal of mast, refer to "LM" section.

HD-9
HYDRAULIC PIPING

HYDRAULIC PIPING

Screw tightening torque [N•m (kg-m) Ft./Lbs]:

G1/4 19.7 - 39.2 (2 - 4) 15 - 29
G3/8 29.5 - 58.8 (3 - 6) 22 - 43
G1/2 58.9 - 98.0 (6 - 10) 44 - 72

PS flow dividing valve built in the control valve. For this reason, oil
pressure is supplied to a control valve for piping of one from a pump.
In addition, steering box is supplied via control valve.

HD-10
HYDRAULIC PIPING

Hydraulic Circuit Diagram (MC models)

HD-11
HYDRAULIC PIPING

Hydraulic Piping (Flow regulator valve)

HD-12
HYDRAULIC PIPING

Hydraulic Piping
2W mast piping

HDT0233L.tif V

2F mast piping

HD-13
HYDRAULIC PIPING

3F mast piping

HDT0205L.tif V

HD-14
HYDRAULIC PIPING

3V mast piping

HDM0105

HD-15
HYDRAULIC PIPING

2W Attachment piping

HDT0206L.tif Y

HD-16
HYDRAULIC PIPING

2F attachment piping

HD-17
HYDRAULIC PIPING

3F attachment piping

HD-18
HYDRAULIC PUMP

3V attachment piping

HDM0106

HD-19
HYDRAULIC PUMP

Carriage piping

HDT0168J.tif V

HDT0137P.tif V

HD-20
HYDRAULIC PUMP

HYDRAULIC PUMP
Component Parts Location
SGP1 type

HDT0207L.tif X

HD-21
HYDRAULIC PUMP

Component Parts Location

HDT0208L.tif X

Removal (e.g. Vehicles with Gasoline Engines)

• Remove the air cleaner.
Disconnect the intake hose and suction tube and the hydraulic pump
connection.

CAUTION:

• Extracting a small amount of oil from the tank in advance by using an

oil pan is recommended. Otherwise, some oil will inevitably overflow
from the tank when the suction hose is disconnected.
• Loosen the two mounting bolts and remove the hydraulic pump.

HD-22
HYDRAULIC PUMP

CAUTION:

• Cover the surrounding area with a shop cloth in order to

prevent contamination due to any oil overflow.
• Ensure that no foreign materials get into the hydraulic pump
and piping through the openings.

Disassembly

CAUTION:

• Before disassembly, always remove any contamination from

the pump surfaces.
• Before disassembly, prepare new parts for all necessary
consumables such as gasket and oil seal.
• Before disassembly, put a pair of alignment marks on the
body and rear cover as well as the body and front cover.
• Do not remove the oil seal unless it is necessary (e.g. oil
leakage).
• Before removing the bearing boxes, always put an
HDT0011.tif identification mark on each bushing so that their original
mounting positions are easily identified.

Inspection
Clean disassembled parts with solvents, and check any crack or
damage.

Gasket, 3-shape gasket

• When pump disassembly, always replace with a new one.

Drive gear, driven gear

• If any cracks or damage in axle and gear, replace with pump
assembly.
• If any damage or wear in gear teeth and tooth top, replace with
pump assembly.
• Spline of drive gear is badly deformed, replace with pump
assembly.
• When outer diameter part of shaft is worn, replace with pump
assembly.

HD-23
HYDRAULIC PUMP

Bushing
• If seizure, unusual wear (deep striation, step wear etc.), replace
with pump assembly.
• Also, be careful of press-in direction of oil seal. (Face dust lip to
outside.).

CAUTION:

• Malfunction in seized, unusual wear, persistent high pressure

for which no specified cause can be found, oil viscosity is too
low or high, contamination may be the cause. Check relief
pressure of relief valve and oil.

Body
• Remains of contact of the gear tooth point are replacing with pump
assembly, when it becomes beyond a semicircle circumference.
• Replace pump assembly, if there are creep phenomenon (face is
ruined and rasp) in contact surface with bushing.
HDT0013.tif

Assembly
Install in the reverse order of removal, follow the instructions below.
• Clean each part with treated oil before assembly. Blow air to
prevent the entry of foreign objects.
• Gasket and 3-shape gasket apply operating fluid and then install.
• Do not confuse the order of attachment and the directions of each
part article (distinction by the side of drive driven, distinction of front
rear side, etc.).
• When insert shaft of drive gear into oil seal of front cover, wrap
vinyl tape around the spline at shaft edge to avoid damage. When
resin layer of inner surface of bushing is worn, replace with pump
assembly.
• Tighten pump assembly bolt crisscross pattern. Divide into 3 - 4
HDT0014.tif times without fastening with regulation torque at once, when
binding tight, and increase and fasten torque one by one.
Tightening torque [N•m (kg-m) Ft./Lbs]:
88.2 - 93.1(9 - 9.5) 65 - 69
• Check putting in little oil from exhaust duct and an intake duct after
an assembly, turning a drive gear shaft by hand, and turning
smoothly.

HD-24
HYDRAULIC TEST

Test Operation
After installing the pump, perform a test operation by following the
steps below.
1. Remove rocker cover.
1. Verify that the oil level in the tank is correct. Attach an oil pressure
gauge to the control valve.
HDT0015.tif
CAUTION:

• For the details on how to attach an oil pressure gauge and

adjust the oil pressure, refer to "7. Control Valve".

2.Actuate the pump. While raising the hydraulic pressure from 0 to

18.1 MPa (0 to 185 kg/cm2) step by step using the adjusting screw
on the relief valve, check the resultant temperature rise by touching
the pump body.
If the pump body is too hot in comparison with the hydraulic fluid
temperature, the pump may be assembled incorrectly.
Disassemble, inspect and reassemble the pump.
3.Set the relief valve set pressure.

Relief valve set pressure

[MPa (kg/cm2)PSI]

Vehicle type
1D1 Series 1D2 Series
Item

Main relief valve set pressure 18.1 (185) 2624

HD-25
HYDRAULIC TEST

4. Checking of the pump displacement

Measure the fork rising speed with no load. If the speed is in the
specified range, the pump displacement is normal.
Rising speed with no load
Vehicle (mm/sec, in./sec.)
Ton Engine Option
model
2W mast 2F mast 3F mast 3V mast
K21 630 590 590 550

1D1 K21 Low noise 460 450 450 410

1.5 & 1.8
type QD32 690 640 640 630
QD32 Low noise 540 530 530 480
K25 700 670 660 650
K25 Low noise 590 610 610 550
2.0 & 2.5
QD32 660 660 650 610
QD32 Low noise 580 560 550 530
K25 580 520 560 560

1D2 K25 Low noise 500 500 480 470

3.0
type QD32 550 510 530 520
QD32 Low noise 470 430 460 440
K25 580 520 560 560
K25 Low noise 500 500 480 470
3.2
QD32 550 510 530 520
QD32 Low noise 470 430 460 440

5. Lower and raise the fork with no load and check for any incorrect
operations.

HD-26
CONTROL VALVE

CONTROL VALVE
Component Parts Location

Cargo control valve

• Feature:
To address human mistakes in the cargo handling lever operation,
the control valve now incorporates a lift lock valve and unload
valve.

HDT0211L.tif X

HD-27
CONTROL VALVE

Flow dividing valve

HDT0212L.tif X

Specifications
Vehicle type
1D1 type 1D2 type
Item

Type MSV04
Main relief valve set pressure [MPa (kg/m2) PSI] 18.1 (185) 2624
Relief valve type Cartridge type
Cylindrical spring
Plunger type
return type
Normal flow rate (l/min, Qts/min) 85, 89.8

HD-28
CONTROL VALVE

Lift lock

HDT0213L.tif W

6. Function
While the operator is not seated in the seat, the lift will not lower
even if the cargo handling lever is moved to the downward
direction.
7. System
The lift lock valve inside the cargo control valve enables the lift
lowering operation only when the seat switch is ON (operator is
seated).
NOTE:
This function may be effective against the following risks
• When the operator gets on or off the vehicle, a part of the operator's body
inadvertently pushes the lift lever with, almost causing personal injuries.
• The operator leans toward the mast for some reason and inadvertently
pushes the lift lever. The resultant fork operation almost catches the
operator's body and could cause personal injury.

HD-29
CONTROL VALVE

8. Release
When it becomes impossible to cancel the lock function of a lift
lock, it cancels with a lift lock release screw.

Method
• Loosen screw lock nut of lift lock release and tighten screw for lift lock
release screw. Then move the lift lever down, the fork will be lowered.
• After repairing lift lock malfunction, loosen lift lock release screw to the
original location (where operation force is light). Then be sure to
securely lock by lock nut.

CAUTION:

• During loading works, the seat switch turns OFF only 3

seconds after the operator is unseated. This is to prevent any
abrupt stop of cargo handling operations due to the above
protective function. Keep in mind that the above protection
will not work for 3 seconds after standing up from the seat.

Unload Valve

HDT0214L.tif W

HD-30
CONTROL VALVE

9. Function
While the operator is not seated on the seat, the fork will not tilt
forward even if the cargo lever is moved to the forward tilt
position. (The engine is idling.)
10.System
• The unload valve inside the cargo control valve routes the
hydraulic pressure to the bypass circuit while the operator is not
seated. In an idling state, this prevents the cargo control valve
pressure from building up and thus locks the tilt lock valve.
• When the seat switch turns ON (operator is seated), the unload
valve closes the bypass circuit and allows the tilt lock valve to be
released.

CAUTION:

• In a fast idle state, the increased internal pressure of the cargo

control valve releases the tilt lock valve, canceling the tilt lock
function.
NOTE:
This function may be effective against the following risks
• When the operator gets on or off the vehicle, a part of the operator's body
inadvertently pushes the tilt lever, almost dropping the cargo from the fork.

CAUTION:

• The seat switch turns OFF only 3 seconds after the operator is
unseated. This is to prevent any abrupt stop of cargo
handling operations due to the above protective function.
Keep in mind that the tilt lock function will not work for 3
seconds after standing up from the seat.

Removal
2. Tilt the mast fully backward and lower the mast to the lowest stop.
3. Return the mast to the neutral position.
4. Turn the key switch to ON (do not start the engine) and release
the residual pressure from the piping.

CAUTION:

• Ensure that no foreign materials get into the piping and

control valve.
• The control valve is heavy. When removing it, hold it carefully
and securely so that it will not slip from hands.

Disassembly

CAUTION:

• Do not disassemble the main relief valve assembly. It

must be replaced as an assembly.
• Do not loosen the lock nut. If it is loosened, the set pressure
must always be adjusted after assembly and installation.
HDT0018.tif • Do not loosen the poppet (load check) and poppet spring
located on the inlet housing-to-outlet housing interface.

HD-31
CONTROL VALVE

Inspection
Clean disassembled parts with solvents, blows with air and a foreign
materials etc. is removed completely.
If deformation, cracks, damage and unusual wear are found, replace
it.

O-ring, wiper ring

• When disassembly, always replace with a new one.

Valve housing and plunger

• Measure the inner and outer diameters of the plunger. If the gap
between the plunger and the housing exceeds the specified limit,
replace the housing and plunger as an assembly.
Tolerance limit of gap between plunger and
housing (mm, in.): 0.02, 0.0008

Assembly
Install in the reverse order of removal, follow the instructions below.
• The housing pieces must be assembled in the correct order.
• Ensure that no foreign materials get into the control valve.
• Apply hydraulic oil or grease to the O-rings, O-ring attaching faces,
wiper rings and plunger.
• Tie rod nut
Tightening torque [N•m (kg-m) Ft./Lbs.] :
24.5 - 29.4 (2.5 - 2.9) 23.7 - 28.4 (M10 size × 3)
24.5 - 29.4 (2.5 - 2.9) 23.7 - 28.4 (M8 size × 2)
• Main relief valve assembly
Tightening torque [N•m (kg-m) Ft./Lbs]: 49 (5.0) 47.3

Installation
Install in the reverse order of removal, follow the instructions below.
• Ensure that no foreign materials get into the piping and control
valve.
• Control valve assembly nuts
Tightening torque [N•m(kg-m) Ft./Lbs.]:
20 - 29 (2.0 - 3.0) 19.3 - 28.0
• After connecting the piping, apply relief pressure and make sure
that no fluid leakage is present.

CAUTION:

• After installation, operate lift and tilt, perform tilt relief for 3
seconds at high idle and bleed the valve.

HD-32
LIFT (MAST) CYLINDER

Hydraulic Pressure Test and Adjustment

CAUTION:

• When checking the hydraulic pressure, always wear

protective goggles. High-pressure hydraulic fluid may blow
out and hit eyes. There is a possibility of high-pressure
operation oil leaking and becoming blind in an eye.
• This inspection includes mast-raising operations. Ensure that
sufficient clearance is secured around the vehicle.

Hydraulic pressure test

1. Turn the key switch to OFF. (Verify that the engine is stopped.)
2. Remove the floor mat and floorboard.
3. Remove the high-pressure pipe connector plug from the pump
port of the control valve.
HDT0215L.tif 4. Install the adapter to the plug hole and connect an oil pressure
gauge.
Adapter connector tightening torque
[N•m (kg-m) Ft./Lbs.]: 39.2 - 44.1 (4 - 4.5) 37.9 - 45.6

5. Start the engine. Referring to the table below, operate the control
lever and check the pressure reading.
MPa (kg/cm2 ) PSI
Vehicle type
1D1 1D2
Lever operation

Raising, forward tilting, backward

18.1 (185) 2624
tilting positions

6. If the measured pressure is outside the specified range, adjust the

hydraulic pressure.

Hydraulic pressure adjustment

1. Remove the cap nut from the main relief valve assembly and
loosen the lock nut.
2. Start the engine and fully open the throttle. While operating the
lever, adjust the hydraulic pressure by turning the adjust screw of
the main relief valve.
HDT0216L.tif To raise the pressure : Turn clockwise
To lower the pressure : Turn counterclockwise

CAUTION:

• Remember that one turn of the adjust screw causes a

pressure change of 6.9 to 7.8 MPa (70 to 80 kg/cm2) (1000 to
1131 PSI). Do not attempt to turn the adjust screw to a large
angle in one step.
• Make sure to turn the adjust screw little by little while
observing the pressure gauge reading.

3. After adjustment, hold the adjust screw securely and tighten the
lock nut. Then attach the cap nut.
4. Check the pressure again.

HD-33
LIFT (MAST) CYLINDER

Mounting adjustment of limit switch bracket

HDT0234L.tif U

HD-34
LIFT (MAST) CYLINDER

LIFT (MAST) CYLINDER

Component Parts Location

HDT0242L.tif X

CAUTION:

• During disassembly, in the case of withdrawal of piston rod

ASSY from cylinder tube, be sure to unplug first.

HD-35
LIFT (MAST) CYLINDER

Trouble Diagnosis and Corrections

Conditions Possible causes Action
Oil leakage from packing on U-ring (cylinder head)
cylinder head side • Mixed entry of foreign matter Remove foreign matter.
• Lip part damage of U-ring is inner and outer Replace U-ring with a new one.
surfaces
Wiper ring
• Mixed entry of foreign matter in wiper ring lip Remove foreign matter.
portion.
• Wiper ring lips damage Replace wiper ring with a new one.
Piston rod
• Piston rod sliding surface damage For small damage, make the sliding surface
smooth by using an oilstone. For large damage,
replace piston rod assembly with a new one.
• Peeling of hard chromium plating Replacement of piston rod assembly
Cylinder lowering without U-ring (piston)
control lever operation and • Mixed entry of foreign matter Remove foreign matter.
poor power output with piston • Lip portion damage of U-ring inner/outer diameter Replacement of U-ring assembly
side on damage of packing
• Cylinder tube sliding surface damage Replacement of cylinder tube assembly
• Piston ring sliding surface damage Replacement of piston ring

Description
The 2W mast incorporates the soft landing function. The soft landing
function automatically decelerates the fork lowering speed just
before the fork contacts with the ground. It is activated 23 mm, 0.91
in., (or 46 mm, 1.81 in., if measured from the fork position) before the
piston bottom stroke end.
HDT0235L.tif

System operation
1. When the piston position is higher than the point 23mm, 0.91 in.,
upward from the bottom stroke end, the hydraulic fluid below the
piston flows out freely.

HDT0140P.tif

HD-36
LIFT (MAST) CYLINDER

2. When the piston lowers further, the bottom projection gets into the
cushion bearing, creating a new hydraulic fluid chamber. In this
state, the hydraulic fluid in the cushion chamber must pass
through the narrow ring-like gap between the cushion bearing and
the bottom projection, resulting in slowdown of the piston
HDT0232L.tif movement.

3. The piston makes the last 23 mm, 0.91 in., stroke at a decreased
speed. This is the mechanism of the soft landing.

HDT0235L.tif

Lift cylinder (2w mast)

Component Parts Location
Inside part drain method

HDT0236L.tif V

CAUTION:

• When pulling out a piston rod, be sure to unplug first. (To

prevent piston from being damaged)

HD-37
LIFT (MAST) CYLINDER

Component Parts Location

Inside drain method

HDT0218L.tif X

CAUTION:

• Unplug when perform disassembly.

HD-38
LIFT (MAST) CYLINDER

Description
NOTE:
• Usually, when it descends from cylinder maximum height by empty load,
the air by the side of a rod passes along the check valve of a piston with
operation oil, and enters a cushion room. When it is repeated, rod side will
become a vacuum.
• When operation oil infiltrates into a rod side, it is returned to a cushion
room through a check valve, and maintaining a normal state is continued.

HDT0219L.tif

Mast cylinder (2f mast)

Component Parts Location

HDT0240L.tif V

HD-39
LIFT (MAST) CYLINDER

Mast Cylinder (3F Mast) Inner Part Drain Method

Component Parts Location

HDT0238L.tif V

Full Free Cylinder (2F, 3F Mast)

Component Parts Location

HDT0239L.tif V

HD-40
LIFT (MAST) CYLINDER

Removal

CAUTION:

• Be careful not to get caught of hands and legs, when perform

the procedure.

Preparation for lift (mast) cylinder removal

1. Remove the carriage assembly together with the fork.
(Refer to the LM section.)
HDT0220L.tif 2. Jack up the vehicle front so that about 120 mm ground clearance
is created under the outer mast bottom end. (Refer to the GI
section.)
3. Operate a control lever, a mast fully backward and descend to the
bottom dead end. Then, a mast neutrality, a key switch is turned
OFF, and engine is suspended.

CAUTION:

• Always lower the lift (mast) cylinder to the bottom stroke end
to release any residual pressure from the piping.

2W lift cylinder, 2F mast cylinder

1. Remove the upper retaining nut (2W mast) of the lift (mast)
cylinder or bolt (2F mast).
2. Suspend the inner mast with a nylon sling or wire.
3. Remove the lift (mast) hose, return hose (2W mast) and lift pipe
HDT0221L.tif (2F mast) from the lift (mast) cylinder.

CAUTION:

• Plug the hose openings to prevent hydraulic fluid leakage.

HDT0222L.tif

4. Remove the lower retaining bolt from the lift (mast) cylinder.

HDT0223L.tif

HD-41
LIFT (MAST) CYLINDER

5. Remove the U-bolt and remove the lift (mast) cylinder from the
front.

CAUTION:

• When removing the lift (mast) cylinder, always work with an

assistant. The cylinder is very heavy.
• When removing the U-bolt, always support the lift (mast)
cylinder so that it will not fall down.

HDT0220L.tif

3F mast cylinder
1. Suspend and lift the inner mast so that the inner mast lower beam
is located above the outer mast tilt beam.

CAUTION:

• While lifting the inner mast, ensure that the slackened chain
and hoses are not pinched.

2. Remove the chain anchor at the inner mast side and separate the
mast chain from the inner mast.
3. Remove the hydraulic piping from the bottom of the full free
cylinder.
4. Remove the hose pulley support from the top of the middle mast
HDT0035P.tif and remove the chain wheel.
5. Place a square wood block of 100 mm, 39.4 in.,G in height under
the inner mast and lower the inner mast.

CAUTION:

• When lowering the inner mast, ensure that the chain and
hoses are not pinched.

6. Attach the suspender hook to the upper beams of the inner mast
and middle mast.

HD-42
LIFT (MAST) CYLINDER

7. Remove the upper retaining bolt from the mast cylinder.

8. Suspend and lift the inner mast and middle mast together and
remove the mast cylinder top.
9. Separate the mast cylinder hose from the mast cylinder. Separate
the mast hose from the mast by removing the mast hose clamp-
HDT0179P.tif retaining bolt.

CAUTION:

• Plug the hose openings to prevent hydraulic fluid leakage.

HDT0224L.tif

10.Remove the lower retaining bolt (below surface of outer mast

support) from the mast cylinder.

HDT0034.tif

11.Remove U-bolt and remove the mast cylinder from the front.

HDT0225L.tif CAUTION:

• When removing the U-bolt, always support the mast cylinder

so that it will not fall down.
• When removing the mast cylinder, always work with an
assistant. The cylinder is very heavy.

HD-43
LIFT (MAST) CYLINDER

Full free cylinder

1. Remove the carriage assembly together with the fork.
(Refer to the LM section.)
2. Operate a control lever, a mast fully backward and descend to the
bottom dead end. Then, a mast vertically, a key switch is turned
OFF, and engine is suspended.

CAUTION:

• Always lower the full free cylinder to the bottom stroke end to
release any residual pressure from the piping.

3. Remove hydraulic pipe from the full free cylinder.

CAUTION:

• Plug the pipe openings to prevent hydraulic fluid leakage.

4. Suspend the full free cylinder with a nylon sling or wire.

5. Remove full free cylinder-retaining bolt, and remove full free
cylinder by pulling up.

LMT0215L.tif

Installation

Full free cylinder (2F, 3F mast)

Install in the reverse order of removal, follow the instructions below.
• Add an appropriate number of shims to make the inner mast
cylinder and full free cylinder parallel to each other.
Shim thickness (mm, in.) : 1.0, 0.039
LMT0036.tif • Cylinder-retaining bolt
Tightening torque [N•m (kg-m) Ft./Lbs] :
128 - 157 (13 - 16) 94.5 - 116

Lift cylinder, mast cylinder

• Position the cylinder to the lower beam hole of the outer mast and
set the piston rod to the cylinder-retaining bracket of the inner
mast.
• Tighten the lower retaining bolt of the cylinder.
Tightening torque [N•m (kg-m) Ft./Lbs] :
44 - 54 (4.4 - 5.6) 32 - 40
• Tighten the upper retaining nut or bolt of the cylinder.
Tightening torque [N•m (kg-m) Ft./Lbs.] :
44 - 54 (4.4 - 5.6) 32 - 40 (2W, 3F mast)
78 - 98 (8.0 - 9.9) 58 - 72 (2F mast)
• Tentatively attach the clamp to the cylinder with the clamp bolt.

HD-44
LIFT (MAST) CYLINDER

• Align the U-bolt to the mast-side bracket and attach the nut to the
outer mast, hand tighten only.
• Next, tighten the double nut to the specified torque.
Tightening torque [N•m (kg-m) Ft./Lbs] :
26 - 32 (2.6 - 3.3) 19 - 24
HDT0225L.tif • Handtighten adjust bolt, and make sure that stopper contacted the
cylinder. Additionally, tighten by tightening lock nut 1/2 to 1
rotation.
Tightening torque [N•m (kg-m) Ft./Lbs] :
26 - 32 (2.6 - 3.3) 19 - 24

• Make sure to seal the taper threads of the piping using a seal tape.
Do not allow seal tape fragments etc. to enter hydraulic pipes.
• The hydraulic units use an O-ring seal at the couplings. When
attaching an O-ring, always use an O-ring guide over the coupling
thread so that the O-ring is not damaged.
• When connecting a coupling, first tighten the lock nut by hand so
that the coupling and the pipe are aligned correctly. Then tighten
the lock nut to the specified torque.
NOTE:
• After installing the cylinders, adjust the cylinder height referring to the LM
section.

Adjustment

Bleeding
1. Add hydraulic fluid to the upper limit of the level gauge.
2. Raise the mast slowly. Then lower it slowly.
3. After lowering the mast to the bottom stroke end, check the
hydraulic fluid level in the tank. If hydraulic fluid is reduced, add it
to the upper limit of the level gauge.
4. Repeat steps 2 and 3 until the hydraulic fluid level in the tank is
kept unchanged.
5. Raise and lower the cylinder to check for smooth operation.

2F, 3F mast
NOTE:
• In addition, no need to bleed the full free cylinder (2F, 3F mast). Full stroke
is repeated 7 to 8 times.

HDT0039.tif

HD-45
TILT CYLINDER

TILT CYLINDER
Component Parts Location

HDT0226L.tif V

HD-46
TILT CYLINDER

Removal
• Lower fork to the bottom dead end.
• In connection with an outer mast, remove bolt and the pivot pin of
a tilt cylinder.

HDT0227L.tif

• Remove 2 hydraulic pipes to tilt cylinder in connector.

• In connection with a body frame, remove bolt, pivot pin and tilt
cylinder.

HDT0228L.tif

Disassembly
• Cylinder is pinched with a vise, from two ports, compressed air is
sent by turns, a piston rod is operated, and oil is extracted from a
cylinder.
• Loosen the thread of cylinder head, remove cylinder head from
cylinder tube.

CAUTION:

• Be careful not to damage O-ring.

• Remove piston rod assembly from cylinder tube assembly.

CAUTION:

• Be careful not to damage O-ring.

• Remove pin bushing from rod head. (Rotate bushing and pull out
from long hole.)

HDT0229L.tif

HD-47
TILT CYLINDER

• Loosen the bolt of rod head, remove rod head from piston rod
ASSY.
• Remove cylinder head.
• Remove piston O-ring and backup ring of piston.

HDT0230L.tif

Cylinder head
• Remove O-ring by pulling it by holding two fingers.
• Remove U-ring and wiper ring by using a screwdriver.

CAUTION:
HDT0231L.tif
• When the U-ring and wiper ring are removed once, always
replace them with new ones.

Assembly
• Assemble in the reverse order of disassembly.

CAUTION:

• For each part, lubricate with an operating fluid.

• When assembly, be sure to avoid foreign matter such dust
from entering.
• O-ring prevention from torsion.
• When insert the cylinder head to piston rod, avoid damaging
O-ring, wiper ring, etc. with screw thread.
• When install pin bushing to rod head, assemble the grease
slot of a rod head and the slot of the pin bushing perimeter
are in agreement.

[N•m (kg-m) Ft./Lbs.]

Vehicle
1D1 type 1D2 type
Item
Rod head tightening nut 108 - 147 (11 - 15) 80 - 109

Piston tightening nut 206 (21 ; 152) 343 (35; 253)

265 - 421 295 - 469

Cylinder head tightening torque
(27 -43; 195 -310) (30 - 48; 218 - 346)

HD-48
TROUBLE SHOOTING

TROUBLE DIAGNOSIS AND CORRECTIONS

Conditions Possible causes Action

U-ring (cylinder head)

• Mixed entry of foreign material in packing Remove foreign material.
portion
• Damage in U-ring Replace U-ring with a new one.

Wiper ring
• Mixed entry of foreign material in wiper Remove foreign material.
Oil leakage from sliding surface
ring lip portion
between cylinder head and
• Wiper ring lips damage Replace wiper ring with a new one.
piston rod assembly
Piston rod
• Piston rod sliding surface damage Make the small sliding surface smooth by
using an oilstone.
For large damage, replace piston rod
assembly with a new one.
• Peeling of hard chromium plating Replacement of piston rod assembly

Oil leakage from cylinder head O-ring

and cylinder tube • O-ring damage Replacement of O-ring

Oil leakage from cylinder tube Cylinder tube

welding part • Damage of cylinder tube welding part Replacement of cylinder tube assembly

Cylinder tube
• Cylinder tube sliding surface damage Replacement of cylinder tube
(For small damage, make it smooth by
using an oilstone.)

Cylinder tilts forward without Piston

control lever operation • Piston sliding surface damage Replacement of piston rod assembly

O-ring
• O-ring damage Replacement of O-ring

Backup ring
• Backup ring damage Replacement of backup ring

Looseness of connector
• Deterioration of tube and hose Hydraulic pressure is slowly operated in a
cylinder, some cylinder tube ports by the
side of high pressure and connectors of a
Mixed entry of air into cylinder hose are loosened, and air is extracted.
If oil begins to appear from a connector
part, a connector will operate a grade
cylinder for 5 minutes (10 - 20 times) in
total.

HD-49
HYDRAULICS

REPLACEMENT OF HYDRAULIC FLUID

Inspection
Dirt or deterioration of hydraulic fluid causes malfunction of control valve. Hydraulic oil must be replaced per
maintenance schedule.

Replacement procedures
1. Start engine, raise lift cylinder full stroke.
2. Control lever is returned neutrally, engine is stopped and the lift
cylinder upper side hose is removed.
3. Control lever is operated to lift cylinder descent, a lift cylinder is
dropped gradually, and the oil in a lift cylinder is returned to a tank.
4. Remove tank drain plug and drain the oil.
5. Install drain plug of each hose and tank, fill in new hydraulic fluid.
6. When hydraulic fluid is replaced, following the instructions below.

CAUTION:

• Deposition dust in tank must be completely cleaning.

(Remove drain plug under side.)
• Clean suction filter and hydraulic fluid cap.
• Oil level should supply with oil to come in the middle of the
maximum line of a level gauge, and a minimum line, when oil
has entered in piping, hydraulic power unit.

HYDRAULIC PIPING FINGERTIP CONTROL

HYDRAULIC FINGERTIP CONTROL

Hydraulic piping

Installing after removal hydraulic pipe, follow the instruction below.

CAUTION:

• Make sure to seal the taper threads using a seal tape. Do not
allow seal tape fragments etc. to enter hydraulic pipes.
• The hydraulic units use an O-ring seal at the couplings. When
attaching an O-ring, always use an O-ring guide over the
coupling thread so that the O-ring is not damaged. When
connecting a coupling, first tighten the lock nut by hand so
that the coupling and the pipe are aligned correctly. Then
tighten the lock nut to the specified torque.

• Tightening torque is as the torque shown in "HYDRAULIC

PIPING".

HD-50
HYDRAULIC FINGER TIP CONTROL

Joystick System Option

• For tilt piping, first place the fork horizontal (tipped slightly forward)
and turn the key switch off. Next, loosen the piping and let set while
the remaining pressure escapes.
• For lift piping, place the fork at the lowest position, turn the key
switch off, loosen the shut-off valve and let the remaining pressure
escape.
• For attachment piping (3rd and 4th)
• Union connector
Place the attachment in neutral, turn the key switch off, loosen the
piping, and let set while the remaining pressure escapes.
• Coupling
Installing and removing the cup may be difficult if the remaining
pressure inside the piping is high. If this is the case, turn the key
switch ON and while idling tip the lever (3rd and 4th) backwards or
forwards, and one of the cups will come off. Then tip the lever in
the other direction and remove the other cup.
In 1D1/1D2, combination switch auto return function is operated by
steering wheel operation.
CAUTION:

• Before removing hydraulic lines or piping, the oil pressure

remaining in hydraulic lines is completely bled off.
• To prevent foreign matter from entering, always maintain a
clean workplace.
• When disconnecting pipes, cover the surrounding area with
rag and ensure oil does not contaminate other parts.
• Never allow foreign matter to enter pipes when connecting.
• Put disassembled parts on clean paper or rag and use care
not to contaminate, scratch or dent them.
• Always assign lifting operations to qualified operators trained
in slinging or hoisting procedures.
• When handling heavy parts, two people should perform the
work.
• For the removal of instrument inner cover, floor mat and floor panel,
refer to BF section.
• For removal and installation of mast, refer to LM section.

HD-51
HYDRAULIC FINGER TIP CONTROL

Hydraulic Circuit Diagram (FC models)

1. Hydraulic pump 6. Tilt valve 11. Down safety valve

2. Suction filter 7. Attachment valve (Opt) 12. Micron filter
3. Power steering cylinder 8. Lift cylinder 13. Hydraulic fluid tank
4. Control valve 9. Tilt cylinder 14. Power steering valve
5. Lift valve 10. Flow regulator valve 15. Tilt leveling solenoid valve (Opt)
16. C1 / Unload solenoid valve

HD-52
HYDRAULIC FINGER TIP CONTROL

Installation
To install, reverse the order of removal. Pay attention to the following points.
• Never allow foreign matter to enter pipes or control valve.
• After connecting pipes, apply relief pressure to check for any oil leaks.
• After connecting lever and control valve, adjust the clearance between control valve switch and dog and
implement centering by referring to VC section.

Disassembly

JOYSTICK CONTROL VALVE

HD-53
EMERGENCY LOWERING OF MAST

Hydraulic Test
EMERGENCY LOWERING OF MAST

Emergency lowering shutt-off valve

• When the forks and masts cannot be lowered with/without load.
• First of all, check the following:

For joystick valve

• Check that C1 solenoid and solenoid for lift operate normally. Refer
to the VC section.
• Operate the control valve lever toward the mast lowered side, and
then make sure that the pump operates (turns). If not, repair the
vehicle by referring to the VC section.

If the above steps are OK, the forks and masts can be lowered with
the following procedure.
1. Turn key switch to OFF, disconnect the battery connection.
2. Remove the floor mat and floor board.

3. Loosen lock nut of shut-off valve on the lower side of control valve.
4. Loosen the screw counterclockwise until it stops.

CAUTION:
Mast will begin to lower when screw is first turned.

Return
1. Screw in the screw until it stops.
2. Tighten lock nut.
3. Install the floor board and floor mat, and then install the battery.

CAUTION:

Always return to the lift lock function after repair.

HD-54