Vehicle System: Specification System Operation Testing & Adjusting

SB4255E01
Jan. 2008
Vehicle System
Specification
System Operation
Testing & Adjusting
D20S-5, D25S-5, D30S-5, D33S-5, D35C-5

G20E-5, G25E-5, G30E-5
GC20E-5, GC25E-5, GC30E-5, GC33E-5
G20P-5, G25P-5, G30P-5, G33P-5, G35C-5
GC20P-5, GC25P-5, GC30P-5, GC33P-5
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional
safety precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where
hazards exist. WARNING labels have also been put on the product to provide instructions and to identify
specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other
persons. Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
1
System Operation
Index
Hydraulic Schematic........................................... 20
Specification
Control Valve...................................................... 22
Hydraulic Control Valve........................................ 5 External Configuration..................................... 22
Hydraulic Pump ................................................ 6 Hydraulic Circuit .............................................. 22
Inlet Block - Key On......................................... 23
Lift Spool Neutral Position - Solenoid and Key Off
Lift Cylinders........................................................ 6 ....................................................................... 23
Full Free Triple Lift and Full Free Lift Primary.... 7 Lift Spool Neutral Position - Solenoid and Key On
Full Free Triple Lift and Full Free Lift Secondary7 ....................................................................... 24
Lift Secondary .................................................. 7 Lift Spool - Positioned to Lift ............................ 24
Tilt Cylinder ...................................................... 8 Lift Spool - Positioned to Lower ....................... 25
Tilt Cylinder ...................................................... 8 Tilt Spool - Positioned for Forward Tilt ............. 25
Tilt Spool - Positioned for Backward Tilt........... 26
Auxiliary Spool - Positioned for Left Hand Shifting
Mast .................................................................... 9
....................................................................... 26
Carriage............................................................... 9 Auxiliary Spool - Positioned for Right Hand
Shifting............................................................ 27
Pressure and Flow Control Section.................. 27
Lift Relay Group..................................................10
Flow Control Adjustment - Tilt and Auxiliary..... 28
Standard Lift....................................................10
Full Free Lift ....................................................11
Full Free Triple ................................................12 STEERING SYSTEM.......................................... 29
Quad Lift .........................................................13 Hydraulic Schematic........................................ 29
Steering Cylinder............................................. 30
Steering Gear.................................................. 31
Lift & Tilt Mounting Group....................................14
Steering Wheel................................................15
Brake Power Master Cylinder ............................. 33
Oil Cooled Disc Brake ..................................... 35
Steering Gear .....................................................16
Parking Brake ................................................. 35
Steer Axle and Wheel .........................................17
Steer Tire Installation ..........................................18
Delayed Engine Shutdown System ..................... 36
(GC Models Only) ...............................................18 Operation ........................................................ 36
Steer Wheel Mounting.........................................18 Diagram of Delayed Engine Shutdown System 37
Trouble shooting of Delayed Engine Shutdown
Oil Cooled Disc Brake.........................................18
System............................................................ 38
Parking Brake .....................................................19 Diagnostic Fault Codes ................................... 38
Delayed Engine Shutdown System Schematic. 39
OSS (Operator Sensing System) ........................ 42

Operation ........................................................ 43
Symbols of OSS.............................................. 43
Operator Sensing System Schematic .............. 44
Trouble shooting of Operator Sensing System. 45
Vehicle System 3 Index

Testing and Adjusting
Troubleshooting ..................................................47
Visual Checks..................................................47
Performance Test ............................................47
Hydraulic System and Mast .............................49
Hydraulic Pump ...............................................50
Hydraulic Control Valve ...................................51
Lift and Tilt Cylinders .......................................52
Steering System ..............................................53
Steering System ..............................................53
Power Master Cylinder ....................................54
Brake System..................................................55
Hydraulic System................................................56
Relief Valve Pressure Check ...........................56
Standard Lift Cylinder Air Removal ..................58
Mast and Carriage ..............................................59

Mast Adjustment - STD, FFL & FFT .................59
Mast Adjustment - Quad ..................................64
Carriage Adjustment ........................................69
Quad Mast.......................................................71
Chain Adjustment ............................................72
Chain Wear Test .............................................73
Carriage and Mast Height Adjustment..............74
Forks Parallel Check........................................74
Tilt Cylinder Alignment.....................................75
Drift Test .........................................................77
Steering System .................................................78

Steer Wheel Bearing Adjustment .....................78
Steering Axle Stop Adjustment ........................78
Steering Knuckle Bearing Preload Adjustment .79
Steering System Pressure Check ....................79
Brake System .....................................................81

Brake System Air Removal ..............................81
Parking Brake Test ..........................................81
Parking Brake Adjustment ...............................82
Vehicle System 4 Index

Specification
Hydraulic Control Valve
CONTROL VALVE
Main Relief Tilt, Auxiliary
Pressure Relief Pressure
D20S-5
G20E-5 18,100 ± 350 Kpa 15,500 ± 350 Kpa
G20P-5
(1) Torque for bolts that hold control valve sections
GC20E-5 2,625 ± 50 psi 2,250 ± 50 psi
Together .............40.5±2.5 N·m (360±24 lb·in)
GC20P-5
D25S-5 (2) Torque for nut......... 4.9±0.5 N·m (43±12 lb·in)
G25E-5 19,500 ± 350 Kpa 15,500 ± 350 Kpa
G25P-5 (3) Torque for nut......... 4.9±0.5 N·m (43±12 lb·in)
GC25E-5 2,825 ± 50 psi 2,250 ± 50 psi
GC25P-5 (4) Torque for plug.............. 1±0.5 N·m (9±5 lb·in)
D30S-5
G30E-5 (5) Torque for screws... 5.4±2.7 N·m (48±24 lb·in)
G30P-5
21,550 ± 350 Kpa 15,500 ± 350 Kpa
GC30E-5 (6) Adjust main relief valve pressure for lift as
GC30P5 shown above. See Relief Valve Pressure Check
3,125 ± 50 psi 2,250 ± 50 psi
G32E-5 in Testing And Adjusting.
G32P-5
D33SC-5 (7) Adjust secondary relief valve pressure for tilt
24,000 (+500,0) Kpa 15,500 ± 350 Kpa
D35SC-5 and side shift as shown above. See Relief Valve
G33P-5 Pressure Check in Testing And Adjusting.
3,490 +75,-0 psi 2,250 ± 50 psi
G35P-5
(8) Torque for plug......5.5±2.5 N·m (492±24 lb·in)
(9) Torque for plug....63.7±2.5 N·m (564±24 lb·in)
(10) Torque for plug........................ 55.5±2.5 N·m

(492±24 lb·in)
(11) Torque for plug......30±2.5 N·m (260±24 lb·in)
(12) Adjust tilt and side shift flow rate by using 6mm
hex-wrench if required. See Flow Control Valve
Adjustment in Testing And Adjusting.
(13) Torque for plug....................... 63.7±2.5 N·m

(564±24 lb·in)
Vehicle System 5 Specification

Hydraulic Pump Lift Cylinders
Standard
Type of pump : gear

Displacement
D518161 : 30.6 cc/rev for D20/25/30S-5 (Tier-Ⅱ)
D518162 : 27.7cc/rev for G20/25/30(E)P-5 &
GC20/25/30/32(E)P-5
D20/25/30S-5(Tier-Ⅲ) 2
D514185 : 29.0cc/rev for D33S/35SC-5 &
G33/35P-5
Maximum working pressure : 25Mpa (250bar)

Maximum speed : 2600 rpm
Rotation : clockwise when seen from shaft end
1. Put pipe sealant on the last three threads of

bearing.
2. Torque for setscrews ....6±1 N·m ( 53 ± 9 lb·in)
NOTE: All seals to be lubricated with hydraulic oil.

Full Free Triple Lift and Full Free Lift Full Free Triple Lift and Full Free Lift
Primary Secondary
1. Put pipe sealant on the last three threads of 1. Put pipe sealant on the last three threads of
bearing. bearing.
NOTE : All seals to be lubricated with hydraulic oil. NOTE: All seals to be lubricated with hydraulic oil.

Tilt Cylinder
TILT CYLINDER GROUP

PART NO
TILT STD FF FFT
ANGLE D.G20/25S-5 GC20/25S-5 D.G20/25S-5 GC20/25S-5 D.G20/25S-5 GC20/25S-5
(FOR-BWD) D.G30/32/33S-5 GC30/32S-5 D.G30/32/33S-5 GC30/32S-5 D.G30/32/33S-5 GC30/32S-5
D35C-5 D35C-5 D35C-5
3˚ - 3˚ − − − A215192 A215207
6˚ - 3˚ A215179 A215203 − − A215179 A215203
3˚ - 5˚ A215191 A215206 A215191 A215206 A215191 A215206
6˚ - 5˚ A215174 A215202 A215174 A215202 A215174 A215202
10˚ - 5˚ − A215209 − A215209 − A215209
3˚ - 8˚ A215190 A215205 A215190 A215205 A215190 −
6˚ - 8˚ A215173 A215201 A215173 A215201 A215173 −
3˚ - 10˚ A215189 − A215189 − − −
6˚ - 10˚ A215172 − A215172 − − −
* Permissible tolerance of 1/2°
(1) Adjust pivot eye to dimension (Z) with cylinder

closed.
(2) Torque for bolt….…95 ± 15 N·m ( 70 ± 10 lb·ft)
(3) Torque for head…………………..270 ± 30 N·m

(200 ± 22 lb·ft)
(4) Torque for piston nut……………. 270 ± 30 N·m

(200 ± 22 lb·ft)

Mast Carriage
IDCS172S
1. With mast at 475 mm (18.7 in) channel lap,

IDCS173S
equally shim both sides until contact (A) is made
(zero clearance) between bearings and mast
uprights. 1. Select bearings from the chart to obtain minimum
clearance (C) between bearings and channel leg
2. With mast at full extension, shim behind pads for full channel length. Use same bearing at all
until there is clearance (B) between the mast six locations.
uprights and the pads of……...0.80 mm (.031 in)
2. Equally shim both sides until contact (A) is made
3. Select lower bearings from the chart to obtain (zero clearance) between bearings and inner
minimum clearance (C) between bearing and mast at narrowest point.
channel leg for full channel length. Use same
bearing on left and right side. 3. Shim bolt as needed to obtain a 6.0 to 9.0 mm
(.236 to .354 in) overlap (B) between bolt (3) and
(See Mast Adjustment in Testing & Adjusting). the carriage stop on the inner upright.
(See Carriage Adjustment in Testing & Adjusting).
MAST BEARING CHART
4. Torque for screw..........34±7 N·m (360 ±24 lb·in)
108.60mm
D581814 Undersize
(4.276in)
109.60mm CARRIAGE BEARING CHART
D581815 Standard
(4.315in) Part No. Bearing Size Bearing OD*
110.70mm
D581816 Oversize 108.60mm
(4.358in) D581814 Undersize
* Permissible tolerance of ± 0.08 mm (.003 in). (4.276in)
109.60mm
D581815 Standard
(4.315in)
110.70mm
D581816 Oversize
(4.358in)
*Permissible tolerance of ± 0.08 mm (.003 in).

Lift Relay Group WARNING
Do not put a lift truck into service if the chain
Standard Lift wear indication is 2% or more. A reading of 2%
or more could cause damage or injury to
persons.
1. Put LOCTITE NO. 242 Thread Lock on the

threads of the relay group locknuts after
adjustment of the lift chains is completed.
2. Maximum chain we………Less than 2% (See

Chain Wear Test in TESTING & ADJUSTING).
3. Distance from bottom of inner mast to bottom of

lower bearing on carriage must be even (flush)
with the inner mast.
IDCS174S

Full Free Lift WARNING
wear indication is 2% or more. A reading of 2%
persons.
1 2
1. Tighten bolts until contact is made with guard.

3. Maximum chain wear………Less than 2% (See

Chain Wear Test in TESTING & ADJUSTING).

2 lower bearing on carriage must be 41±1.5 mm
(1.61 ±0.6 in). Bottom of inner mast must be
even (flush) with bottom of stationary mast.
Adjust inner first.
3
IDCS175S

Full Free Triple WARNING
wear indication is 2% or more. A Reading of 2%
persons.
1
1. Maximum chain wear………………Less than 2%

(See Chain Wear in TESTING & ADJUSTING).

2 threads of the relay group locknuts after
3
3. Tighten bolts until contact is made with guide
assembly.
1 4. Distance from bottom of inner mast to bottom of
lower bearing on carriage must be 41±1.5 mm
(1.61 ± 0.6 in). Bottom of inner mast be even
(flush) with bottom of stationary mast. Adjust
inner mast first
IDCS193S

Quad Lift WARNING
wear indication is 2% or more. A Reading of 2%
persons.
1
2 1. Maximum chain wear................. Less than 2%
(See Chain Wear in TESTING & ADJUSTING).
1
3. Tighten bolts until contact is made with guide

assembly.

3 2 lower bearing on carriage must be 41±1.5 mm
(1.61 ± 0.6 in). Bottom of inner mast be even
(flush) with bottom of stationary mast. Adjust
inner mast first
1
4

Lift & Tilt Mounting Group 1. (Standard Mast, Full Free Triple Lift Mast or
Quad Lift Mast Only) With chains adjusted for
equal tension, run mast to full lift. If mast does
not kick (move) to one side, no shims are
needed. If mast does kick (move) to one side,
disconnect cylinder from the bar on that side.
Add shim, connect cylinder, adjust chains and
run mast to full lift to check for kick. Repeat
process if necessary. The total shim pack must
not be more than three shims maximum.
2. Install bearing outer race to a depth of (F)

4.5± 0.8 mm (.177 ± .031 in).
3. Tilt cylinder installation shown.
4. Bearing split to be located at angle (D) 45±15°
5. Install bearing outer race to a depth of (G)

4.5± 0.8 mm (.177 ± .031 in).
6. (Full Free Lift Mast Only):

Tighten nuts until U-bolt is firm against cylinder,
do not apply standard torque.
7. (Full Free Lift Mast Only):

With chains adjusted for equal tension run mast
to full lift. If mast does not kick (move) to one
side, no shims are needed. If mast does kick
(move) to one side, hold lift cylinder tube on that
side and loosen bearing 1/4 turn and check
mast again. Loosen bearing until kicking
IDCS176S
(movement) stops or gap (H) reaches 3.0 mm
(.12 in) (approximately 1.5 turns), whichever is
less. Insert shims (8) under bearing (it may be
necessary to loosen bearing an additional
amount of turns to install shims). Tighten
7 bearing again.
6
DETAIL E
8 H
IDCS177S

Steering Wheel
IDCS206S
1. Torque for steering wheel nut ..........................

...................................... 80 ± 6 N·m (60 ± 4 lb·ft)

Steering Gear
IDCS180S
(1) Pin (1) in the body must be aligned with internal

pump gear (gerotor) (2) and drive (3) as shown.
(4) Tighten bolts in sequence shown.
Tighten to a first torque of........ 14.1 ± 2.8 N·m

(125 ± 25 lb·in)
Tighten to a final torque of........28.2 ± 2.8 N·m
(250 ± 25 lb·in)
(5) Torque for plug ................11.3 N·m (100 lb·in)
Plug to be flush (even) with or below mounting

surface.

Steer Axle and Wheel (3) Loosen nuts ⑥ and ⑧ on both sides. Adjust
bolts to get steering knuckle turning angle (A) of
78 to 80°.
See Steering Axle Stop Adjustment in Testing
And Adjusting section.
(4) Torque for bolts ⑨ that hold steer cylinder to

axle beam…………300 ± 40 N·m (220 ± 30 lb·Ift)
9
1 2
10
NOTE: Steer axles with tapered roller bearings

shown. (5) Torque for bolts ① that hold cover
………………………... 55 ± 6 N·m (40 ± 5 lb·ft)
(1) Do the steps that follow for steer wheel bearing
adjustment. (6) Add or remove shims ③ under cover until
torque required to turn knuckle assembly is
a. Tighten nut ① slowly to 135 N·m (100 lb·ft) ……………………...4.5 to 6.8 N·m (40 to 60 lb·in)
while turning the wheel. See Steering Knuckle Bearing Preload
Adjustment in Testing & Adjusting.
b. Loosen nut ① completely.
Tighten it again to ....................... 50 ± 5 N·m
(37 ± 4 lb·Ift)
c. Assemble lock washer ② and align the hole

for assembling the bolt. If the holes does not
match, turn nut ① about 1/32 turn clockwise.
d. Apply loctite 242 on the threads of bolts ③

and tighten them at ................... 8 ± 3 N·m
(6 ± 2 lb·ft).
(2) Torque for bolt ④ that holds pin ....11±1 N·m

(100 ± 9 lb·ft)

Steer Tire Installation Steer Wheel Mounting
(GC Models Only)
1
1
A
IDCS210S
IDCS184S (1) Torque for bolts that hold steer wheel ............
............................120 ± 20 N·m (90 ±15 lb·ft)
GC20E/P-5, GC25E/P-5 Models
IDCS209S
GC30E/P-5, GC32E/P-5 Model
(1) Install tires to dimension (A) or (B) of .............

................................. 17 ± 2 mm (.67 ± .08 in)

Oil Cooled Disc Brake
IDCS211S
(1), (2) Put LOCTITE NO.17430 Liquid Gasket on

contact surface area of the axle flange cover
assembly and cover before installation.
(3) Thickness of one new Plate ...2.50 ± .064 mm

(.100 ± .0025 in)
Thickness of one new friction disc: .................
........................ 4.59 ±.13 mm (.181 ± .005 in)
Minimum depth of grooves before the

replacement of frictiondine is necessary .........
...........................................0.32 mm (.013 in)
Soak new discs in drive axle oil for one hour
before installing.

System Operation
Hydraulic Schematic
Basic Hydraulic Actuator System Schematic

1. Lift cylinder-secondary; 2. Flow protector-primary; 3. Lift cylinder-primary; 4. Flow protector-secondary; 5. Cylinder;
6. Tilt cylinder; 7. Control valve; 8. Unload solenoid valve; 9. Lift lock solenoid valve; 10. CF line to steering unit;
11. LS line to steering unit; 12. Brake reservoir; 13. Brake power master cylinder; 14. Relief valve - Tilt/Aux;
15. Relief valve - Main; 16. Needle valve; 17. Drive axle; 18. Gear pump; 19. Suction filter; 20. Return oil filter;
21. Main oil supply line; 22. Return oil line; 23. Hydraulic tank; 24. Brake boost pressure line
Vehicle System 20 System Operation

The hydraulic gear pump (18) is driven off the The lift cylinder lowering speed is controlled by a
transmission PTO which draws oil from the flow regulator valve integrated into lift spool.
hydraulic oil tank (23). Oil is supplied to the first
control valve (7) section through hydraulic line (21). Levers of control valve move spools within the
This section also contains the priority valve that control valve. The movement of spool allows fluid
distributes oil to the following areas based on, 1st for lift, tilt, and side shift (5) functions. The return
brakes, 2nd steering, and 3rd implement flow hydraulic fluid from each cylinder flows through
demand (mast/tilt/auxiliary functions). A constant control valve, hydraulic line (22), through the filter-
flow of 0.8 GPM is provided by the priority valve to return (20), and back to a hydraulic tank.
the brake power master cylinder (13). From the
CF port, oil flows through hydraulic line (10) to the If the pressure in the lift circuit goes higher than the
steering unit. From the LS port, oil flows through pressure setting shown in the CONTROL VALVE
hydraulic line (11) to the steering unit. The SECTION of SPECIFICATION, the main relief valve
remaining oil from the control valve and the power (15) opens to control system pressure and dump
master cylinder is returned to the hydraulic tank excess pressure to the hydraulic tank. If the
through hydraulic lines (22). pressures in the tilt and/or auxiliary circuits go
higher than the pressure setting shown in the
The safety unloader solenoid of the priority valve CONTROL VALVE SECTION of SPECIFICATION,
section prevents oil flow through the control valve the secondary relief valve (14) opens to control
when the operator has left the seat thereby system pressure and dump excess pressure to the
preventing any function regardless of lever position. hydraulic tank.
Unloader solenoid valve (8) is electrically connected
to the seat switch. The solenoid valve (8) is turned Flow protectors (2) & (4) integrated in the lift
off within 3 seconds of the operator leaving the seat. cylinders provide a controlled decent of the mast
System pressure drops to less than 7 bar (100 PSI) and/or carriage if a critical hydraulic line is broken.
and oil is diverted to tank instead of flowing through Sudden dropping of the mast and/or carriage is
the control valve. Once the operator returns to the controlled.
seat, the solenoid valve is turned on opening oil
flow to the control valve and immediately returning The speed of forward/backward tilt and side shift
normal work function to the control valve. cylinder extension are controlled by individually
adjustable flow controls internal to each section of
An additional safety lift lock function is also included the control valve. Additionally, the counter-
which works much the same as the unloader balance valve (or tilt lock valve) in the tilt spool
solenoid mentioned above. This solenoid valve (9) prevents cavitations (development of air pocket) in
prevents lowering of the carriage and/or mast when tilt cylinder. For a complete hydraulic circuit, see
the operator leaves the seat more then 3 seconds, the foldout, in the back of this module.
or the key switch is off. When the solenoid is off,
oil flow is prevented from exiting the lift cylinders if
the lever is pushed accidentally. Normal operation
returns once the key switch is turned on or the
operator returns to the seat.
A needle valve (16) on the side of the lift section

can be used in an emergency should the lowering
function not work normally. Approximately one
half turn counter-clockwise makes it possible to
lower the mast and/or carriage when the lift spool is
shifted for lowering. After lowering the mast or
carriage to the ground and with the start key off,
inspect for possible causes of the malfunction.
Refer to the detailed trouble shooting guide will be
shown in TESTING and ADJUSTING.

Control Valve
External Configuration
Hydraulic Circuit

Inlet Block - Key On
Lift Spool Neutral Position - Solenoid and Key Off
The above figure shows the lift spool in neutral position with key switch off. The solenoid valve is de-
energized and blocks lift cylinder return oil flow through the control valve passage to tank. Lift lock also
blocks fluid passage of lift cylinder to tank.

Lift Spool Neutral Position - Solenoid and Key On
The above figure shows the lift spool in neutral position with key switch on. The solenoid valve is energized
and opens to allow oil flow to tank. The lift lock remains closed and blocks oil flow through passage to tank.
Lift Spool - Positioned to Lift
With lift spool pulled out, fluid goes through a load check valve, spool and lift lock to lift cylinder. Lift cylinder
is extended.

Lift Spool - Positioned to Lower
With lift spool pushed in, fluid passes from lift cylinder to tank. The fluid goes through lift lock, lift spool, flow
regular valve and tank and the lift cylinder lowers. The flow regulator valve permits a consistent lowering
speed of lift cylinder regardless of load.
Tilt Spool - Positioned for Forward Tilt
On shifting tilt spool in, the fluid passage of pump to tilt cylinder is made. Pump fluid goes through a load
check valve, tilt spool to a head side of tilt cylinder. At the same time, the fluid of rod side of tilt cylinder goes
through the tilt lock to tank. The tilt cylinder is moved forward.

Tilt Spool - Positioned for Backward Tilt
On shifting tilt spool out, the fluid passage of pump to tilt cylinder is made. Pump fluid goes through a load
check valve, tilt spool to a rod of tilt cylinder. At the same time, the fluid of a head side of tilt cylinder goes
through spool to tank. The tilt cylinder is moved backward.
Auxiliary Spool - Positioned for Left Hand Shifting

Auxiliary Spool - Positioned for Right Hand Shifting
Pressure and Flow Control Section
The main relief valve (system R/V) limits the MAX. lift pressure. The auxiliary relief valve limits the max. tilt
and auxiliary system relief pressure. The hydrostat will by-pass the remaining flow back to tank according to
the flow control valve in tilt and auxiliary section.

Flow Control Adjustment - Tilt and Auxiliary
Tilt and auxiliary sections have the capability to adjust flow to the actuating cylinders. Clockwise rotation of
the adjustment screw will increase hydraulic flow to the cylinders and increase extension or retraction speed.
Counter-clockwise rotation of the adjustment screw will decrease hydraulic flow to the cylinders and reduce
extension or retraction speed.

STEERING SYSTEM
Hydraulic Schematic
Steering system schematic

1. Steering unit; 2. Priority valve end of control valve; 3. Steering CF line; 4. Left turn hydraulic line;
5. Right turn hydraulic line; 6. Power steering cylinder; 7. Steering LS line; 8. Steering return oil line;
9. Pump oil supply line; 10. Control & Priority valve return oil line; 11. Hydraulic oil tank; 12. Pump;
13. Suction filter; 14. Return filter; 15. Transmission PTO

The priority valve is integrated to the first block of Steering Cylinder
control valve. This section distributes oil to the
following areas based on, 1st brakes, 2nd steering, Steering cylinder (1) gives power assistance through
and 3rd implement flow demand (mast/tilt/auxiliary the use of pressure oil at either end of the cylinder
functions). The priority valve (2) supplies oil from piston.
the pump (12) to brakes and steering unit (1) as
needed. The fluid is drawn from the hydraulic tank The steering cylinder is double ended and the body of
(11) by the pump (12). The pump supplies fluid the cylinder is mounted stationary to the steer axle.
through hydraulic hose (9) to a first block of control The rod assembly is connected to the steering link
valve (2). assembles at both ends of the cylinder which allows
the cylinder to move the link assemblies.
When the steering unit (1) is neutral position, pilot
pressure in load sensing line (7) is reduced and the
spool of the priority valve is moved downward.
Most fluid goes passes through the neutral passage 1
of control valve and hydraulic line (10) back to
hydraulic tank (11)
When making a right turn, pilot pressure is

increased in load sensing line (7) forcing the priority
valve spool to moved toward the right. Oil flows
through hydraulic line (3) to the steering unit.
From the steering unit the oil flows through a
hydraulic line (5) filling the cylinder. This forces
the cylinder piston toward to opposite end of the Steering Cylinder (Typical Example)
cylinder for a right turn. The piston movement (1) Steering cylinder.
displaces oil from the opposite end of the cylinder
which returns to the steering unit though hydraulic
line (4) and hydraulic line (10) to the hydraulic tank
(11).
During a left turn, a pilot pressure is again

increased in load sensing line (7) which moves the
spool of priority valve upward. A fluid flows through
a hydraulic line (3) to a steering unit. From the
steering unit, the fluid flows through a hydraulic line
(4) to a power steering cylinder (6) to make a left
turn. The return fluid flows through a hydraulic line
(5) back to steering unit, a hydraulic line (8) and into
the hydraulic tank.
A check valve is installed into the port of steering

unit connected to hydraulic line(3) to prevent a fluid
back to priority valve right after a turn is made,
Relief valve in steering unit will open if steering
pressure goes above 9,000 (+300,-0) kPa or 1,305
(+43, -0) psi.

Steering Gear
A B
2 3 4 5 6
8 9 10 11 12
IDCS113S
Steering Gear
(1) Spool. (2) Sleeve. (3) Outlet (to tank). (4) Inlet (for pump oil). (5) Internal pump gear. (6) External pump gear. (7) Centering springs.
(8) Pin. (9) Left turn port. (10) Right turn port. (11) Body. (12) Drive. (A) Control section. (B) Metering section.
Lift trucks use the load sensing, closed center (oil Oil from the control valve goes through inlet (4) into
flow to steering gear only when needed) steering the control section of the steering gear. When the
gear. steering wheel is turned, the control section sends
the oil to and from the metering section and also to
All lift truck hydraulic lines serve a dual purpose in and from the steering cylinder.
that they serve both the steering and cylinder
hydraulics through the use of a priority valve. The The metering section is a small hydraulic pump. It
priority valve sends oil to the steering gear before controls (meters) the oil that goes to the steering
the needs of the cylinder hydraulics are met. cylinder. As the steering wheel is turned faster,
there is an increase in the flow of oil to the steering
The steering gear has two main sections: control cylinder. This increased flow causes the main valve
section (A), and pump or metering section (B). spool to move farther. As the spool moves farther,
These two sections work together to send oil to the more oil can flow from the priority valve or power
steering cylinder. steering pump to the steering cylinder, and a faster
turn is made.

Oil Flow
The oil from the control valve flows through inlet

(4). When the steering wheel is stationary 5 6 8
(NEUTRAL), the oil is stopped by spool (1). The oil
can not flow through the steering gear to the
steering cylinder until the steering wheel is turned.
The steering wheel is connected to spool (1) by a

shaft assembly and splines. When the steering
wheel is turned, spool (1) turns a small amount until
springs (7) are compressed. Then, sleeve (2) starts
to turn. As long as the steering wheel is turned, the
spool and sleeve both turn as a unit, but they turn a
few degrees apart.
When the spool and sleeve are a few degrees apart,

oil passages are opened between them. This lets
the pump oil from inlet (4) flow through passages in
body (11) to the metering section. 12
When the steering wheel is turned, pin (8) turns

IDCS114S
with the sleeve and causes drive (12) to turn also.
The drive causes a rotation of gear (5) inside gear Pump Gears In Metering Section
(6). This rotation of the gear sends a controlled (5) Internal pump gear. (6) External pump gear. (8)
(metered) flow of pilot oil back through body (11). Pin. (12) Drive.
This oil flows to port (9) or (10) and then to the
steering cylinder. Port (9) or (10), that is not used
for pressure oil to the steering cylinder, is used for If the steering wheel rotation is stopped, springs(7)
return oil from the other end of the steering cylinder. will move sleeve(2) back in alignment with spool(1)
(NEUTRAL position). This will close passages
between the metering section and control section
and the steering gear will be in the NEUTRAL
position.
When the engine is off, the steering gear can be

manually operated. The control section will work as
a pump. The oil that is returned from the steering
cylinder is not returned to the tank. The suction of
the control section will open an internal check valve
and let return oil from the steering cylinder go to the
inlet side of the control section. During power
operation, supply pressure keeps the check valve
closed.

Brake Power Master Cylinder

Relief valve (7) is built into the power master
cylinder to prevent exceeding 40 bar (580 PSI)
pressure within chamber (3). As pressure builds,
the sleeve of the relief valve shifts and
compresses the spring. This opens boost
chamber (3) to drain chamber (8) preventing
over-pressurizing the system. This limits
excessive reaction force of the brake pedal.
In case of accidental engine shut down the

system becomes mechanically operated. With no
hydraulic boost the result is greater brake pedal
force is required to stop the truck.
Fig 4: Detail - Boost Not Applied (2 -> 6)
The flow divider provides continual flow of 0.8 GPM

through the brake spool to “P” port (4) of power master
cylinder. When the brake pedal is not pushed (neutral
position), the fluid goes through the flow passage (2)
between the master piston (1) and servo piston (6), flow
passage (5) and chamber (8), then returns to tank, as
shown in Fig 1.
When the brake pedal is pushed, the master piston (1)

advances toward the servo piston (6). Oil flowing
through oil passage (2) is restricted and increases
pressure in chamber (3) which pushes the servo piston
more to the right. The master and servo pistons
continue to move independently in reaction to the flow
and pressure changes until a balance is reached where
the force in chamber (3) equals the force working
against servo piston in chamber (10) plus the reaction
force of spring (15) and flow passage (2) is closed (ref:
Fig 3 & Fig 4). Pressure then builds up to assist in brake
application. The operator feels the feed-back force as
pressure increases in chamber (3).
When the brake pedal is released, return spring (15)

forces master piston (1) and a servo piston (6) to return
to the initial position (or neutral position). As these
pistons return, displaced oil within chamber (10) is
replenished through check valve (11) from reservoir
(14). When the pistons have moved past the
replenishing orifice (9), pressure in chamber (10) drops
to zero and oil from reservoir (14) can now pass through
the orifice.

Oil Cooled Disc Brake Parking Brake
3
1 2
2
7 5 6 4 3
8
IDCS211-1S
Disc Brake Assembly

(1) Inlet (from brake valve). (2) Passage. (3) Plates (five). Parking Brake Linkage
(4) Discs (four). (5) Piston. (6) Seal. (7) Seal. (1) Cable Assembly. (2) Switch. (3) Lever.
(8) Passage (for cooling oil).
The band-type parking brake is installed on the input
shaft clutch pack inside the transmission. The parking
When the brake pedal is pushed down, the brake brake control assembly is mounted on the cowl. The
valve pushes brake liquid through the brake valve parking brake is controlled with a lever. The control
outlet, the brake lines, to inlet (1) of each disc brake lever is connected to the parking brake with a cable
assembly. Liquid flows through inlet (1), passage (2) assembly (1).
and pushes on piston (5). Piston (5) pushes against
plates (3) and friction discs (4) to stop any movement The parking brake is activated when the control lever
of the lift truck. The five separator plates (3) are is pulled. When the operator pulls the control lever,
splined to the wheel cover and the four friction discs cable assembly (1) pulls lever (3) which will turn cam
(4) are splined to the hub. During brake activation the and push strut (5). This will tighten brake band (6) on
piston seals (6) and (7) are deflected by the brake the input shaft clutch pack and stop any lift truck
movement.
piston movement.
To prevent driving when the parking brake is activated
When the brake pedal is released, the brake liquid (engaged) switch (2) is opened. This will put the
pressure is released and seals (6) and (7) return to transmission in neutral so the lift truck can not be
their original position. This seal retraction gives the driven.
running clearance needed between plates (3) and
discs (4). This action will release the brakes on the lift
truck. As the seals retract brake liquid is returned to
the brake valve. The piston automatically slides
outward from the cylinder bore as the friction discs
wear. This new location then becomes the beginning
or at rest position of the seals. This will maintain the
proper clearances of the discs and plates.
When the brakes are activated, heat is generated by 5

4
plates (3) and discs (4). Drive axle oil in a separate
brake cooling circuit flows through passage (8) and 6
cools the plates and discs during normal operation.
Parking Brake
(4) Cam. (5) Strut. (6) Brake Band.

Delayed Engine Shutdown System
Operation
The delayed engine shutdown system will shut the
engine down if no proper action is taken by the
operator. This system makes use of the engine
oil pressure switch, transmission oil temperature
switch and water (coolant) temperature sensor to
get the required truck condition.
If an engine damaging condition arises, such as too

much oil pressure drop, this system will alert the
operator by warning MIL Lamp.
If the operator ignores this warning and does not

shutdown the engine within thirty seconds, this
delayed engine shutdown system will interrupt the
fuel supply to the engine, thereby saving the engine
from the critical damage.
1. Low engine oil pressure

The warning MIL lamp will turn on when the oil
pressure drops to approximately 28KPa (4 psi) and
the delayed engine shutdown system will interrupt
the fuel supply to the engine after thirty seconds.
2. Hot engine coolant

The warning MIL lamp will turn on when the coolant
temperature reaches approximately 115℃(239℉)
and the delayed engine shutdown system will
interrupt the fuel supply to the engine after thirty
seconds.
3. Hot transmission oil

The warning MIL lamp will turn on when the
transmission oil temperature reaches approximately
125℃(257℉) and the delayed engine shutdown
system will interrupt the fuel supply to the engine
after thirty seconds.

Diagram of Delayed Engine Shutdown System
G420F(E) / G424F(E) ENGINE – LP TRUCK
G420F(E) / G424F(E) ENGINE – GAS & DF TRUCK

Trouble shooting of Delayed Engine Shutdown System
When the ignition key is turned on, the MIL Lamp will illuminate and remain on until the engine is started.
Once the engine is started, the MIL Lamp will go out unless one or more fault conditions are present. If a
detected fault condition exists, the fault or faults will be stored in the memory of the small engine control
module (SECM).
Once an active fault occurs, the MIL Lamp will illuminate and remain ON. This signals the operator that a
fault has been detected by the SECM. If the MIL Lamp turns on while operating the lift truck, park the lift
truck and stop the engine, and then check the follows.
Delayed Engine shutdown : Some faults, such as low oil pressure, will cause the MIL Lamp to illuminate
for 30 seconds and then shut down the engine
CODE
FAULT DESCRIPTION
(M104 CODE)
Engine Coolant Temperature Sensor Input is High.
ECT Over
Normally set if coolant sensor wire has been disconnected or 151(15)
Range High
circuit has opened to the SECM
ECT Over Engine Coolant Temperature is High.
Temperature The sensor has measured an excessive coolant temperature 161(15)
Fault typically due to the engine overheating
Low Oil
Low engine oil pressure 521(52)
Pressure Fault
Transmission
Excessive transmission oil temperature 933
Oil Temperature
Diagnostic Fault Codes

DFC PROBABLE FAULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK
151 ECT Range High (1) Turn on MIL Check if ECT sensor connector is
(15) Coolant sensor (2) Delayed Engine disconnected or for an open ECT
disconnected Shutdown circuit SECM (Signal) Pin B15 to ECT
or open circuit (3) Check Engine Light Pin 3 SECM (Sensor GND) Pin B1 to
ECT Pin 1
161 ECT Over Temperature (1) Turn on MIL Check coolant system for radiator
(15) Fault (2) Delayed Engine blockage, proper coolant level and for
Engine coolant Shutdown leaks in the system.
temperature is high. (3) Check Engine Light Possible ECT short to GND, check
The sensor has ECT
measured an excessive signal wiring SECM (Signal) Pin B15 to
coolant temperature ECT pin 3 SECM (Sensor GND) pin B1
typically due to the to ECT pin 1 SECM (System GND) pin
engine overheating. A16, B 17 Check regulator for coolant
leaks
521 Low Oil Pressure Fault (1) Turn on MIL Check engine oil level
(52) Low engine oil pressure (2) Delayed Engine Check electrical connection to the oil
Shutdown pressure switch SECM Pin B9 to Oil
(3) Check Engine Light Pressure Switch
933 Trans Oil Temperature (1) Turn on MIL Refer to drive train manufacturer’s
Excessive Transmission (2) Delayed Engine Transmission service procedures
oil temperature Shutdown

Delayed Engine Shutdown System Schematic
DELAYED ENGINE SHUTDOWN : G420F(E) - LP

ENG GND
NEAR COILS
E/G OIL PR
E/G CHECK
DELAYED ENGINE SHUTDOWN : G420F(E) - GAS&DF

DELAYED ENGINE SHUTDOWN : G424F(E) - LP

DELAYED ENGINE SHUTDOWN : G424F(E) - GAS&DF

OSS (Operator Sensing System)
Operation 4. Water separator (sediment) warning – only diesel
Water separator lamp indicates when the engine
Operator Sensing System is operated by seat is running and there is much water in the fuel
switch built into the seat. If the operator leaves the filter exceeding 100cc.
seat without applying the parking brake within three If the lamp turns on with the engine running, park
seconds after leaving the seat, Operator Sensing the lift truck and stop the engine. Drain some fuel
System will automatically disengage the (and any water) until clean fuel flows from the
transmission and interrupt the operation of mast. filter which approximately takes 5 to 6 seconds.
In addition, the warning lamp and buzzer are
operated in order to prevent the unintentional 5. Mast interlock
movement. Alarm warning lights when operator leaves the
seat without applying parking brake and then,
operation of mast is automatically interrupted .
Symbols of OSS
6. Air cleaner warning
Alarm warning lights if the dust is chock – full at
the air clean.
1. Parking alarm
Alarm warning lights when the operator leaves
the seat without applying parking brake.
2. Seat belt indicator

Seat belt warning lights for 10 seconds reminds
the operator to fasten seat belt.
The truck is normally operated although warning
lamp is turned on.
3. Neutral shift feature

Transmission is automatically shifted to the
neutral when the operator leaves the seat with
the engine running and the direction lever in
forward or reverse. To restore the lift truck, return
the directional lever to the neutral position and
then, reselect a direction of travel (either forward
or reverse). The transmission will then re-engage.

System Operation
SEAT SWITCH
SEAT BELT SWITCH
AIR CLEANER SWITCH
PARKING
BRAKE SW
44
Operator Sensing System Schematic
INDICATOR AS
PILOT BUZZER RELAY FUSE FUSE
REV FWD CREEPING SPEED
SOL_VALVE_LIFT LOCK
CIRCUIT BREAKER
SOL_VALVE_UNLOAD
LP PR SW DIR SWITCH IGNITION SW
CONTROLLER - VCS
BATTERY
SEDIMENT SW
Vehicle System
Trouble shooting of Operator Sensing System
CONDITION PROBABLE FAULT CORRECTIVE ACTION
1. Buzzer warning 1. Seat switch open 1. Check seat switch
2. Parking brake 2. Parking brake switch open 2. Check parking brake switch
light
3. Controller defect 3. Check continuity of wire from seat switch to
controller (SW2)
4. Wiring defect
4. Measure the voltage between
controller(SW2) and GND : 12V is no
problem
1. Seat belt 1. Seat switch open 1. Check seat switch
warning light
2. Controller defect 2. Check continuity of wire from seat belt switch
to controller (SW3)
3. Wiring defect
controller(SW3) and GND : 12V is no
problem
1. Buzzer warning 1. Seat switch open 1. Check seat switch
2. Neutral light 2. Relay (REV/FWD/Creep 2. Check relay (REV/FWD/Creep speed)

speed) defect
3. No drive 3. Check FWD/REV Solenoid
operation 3. Directional switch defect
4. Check continuity of wire from relay creeping
4. Wiring defect speed (85) to controller (C/RELAY)
5. FWD/REV Solenoid defect 5. Check continuity of wire from relay-

REV(86)or Dir SW(3) to controller (REW SW)
6. Controller defect
6. Check continuity of wire from relay-
FWD(86)or Dir SW(2) to controller (FWD
SW)
1. Buzzer warning 1. Sediment switch short 1. Check sediment switch
2. Water separator 2. Wiring defect 2. Check continuity of wire from sediment

warning light switch to controller (AUX2)
3. Controller defect
controller(AUX2) and GND : 12V is no
problem

CONDITION PROBABLE FAULT CORRECTIVE ACTION
1. Buzzer 1. Seat switch open 1. Check seat switch
warning
2. Fift lock / Unload 2. Check Lift lock/Unload Solenoid
2. Mast interrupt solenoid defect
light 3. Check continuity of wire from solenoid-lift lock(2)
3. Wiring defect or solenoid-unload(2) to controller (ISO3691
3. No mast VALVE)
operation 4. Controller defect
4. Check continuity of wire from solenoid-lift lock(1)
or solenoid-unload(1) to controller (IGN)
5. Measure the voltage between controller(IGN)

and controller(ISO3691 VALVE) : 12V is no
problem
1. Air cleaner 1. Air cleaner switch short 1. Check air cleaner switch
light
2. Wiring defect 2. Check continuity of wire from air cleaner switch
to air cleaner lamp

Testing and Adjusting Visual Checks
A visual inspection of the hydraulic system and its
Troubleshooting components is the first step when a diagnosis of a
problem is made. Lower the carriage to the floor
Troubleshooting can be difficult. A list of possible and follow these inspections;
problems and corrections are on the pages that
follow. 1. Measure the oil level. Look for air bubbles in the
oil tank.
This list of problems and corrections will only give
an indication of where a problem can be and what 2. Remove the filter element and look for particles
repairs are needed. Normally, more or other repair removed from the oil by the filter element. A
work is needed beyond the recommendations on magnet will separate ferrous particles from
the list. Remember that a problem is not necessarily nonferrous particles (piston rings, O-ring seals,
caused only by one part, but by the relation of one etc.).
part with other parts. This list can not give all
possible problems and corrections. The serviceman 3. Check all oil lines and connections for damage or
must find the problem and its source, then make the leaks.
necessary repairs.
4. Check all the lift chains and the mast and
Tools needed carriage welds for wear or damage.
Fittings Group 1
The Fitting Group is used to make the pressure Performance Test

tests of the hydraulic system. Before any test is
made, visually inspect the complete hydraulic The performance tests can be used to find leakage
system for leakage of oil and for parts that have in the system. They can also be used to find a bad
damage. valve or pump. The speed of rod movement when
the cylinders move can be used to check the
condition of the cylinders and the pump.
WARNING Lift, lower, tilt forward and tilt back the forks several
times.
To prevent personal injury when testing and
adjusting the hydraulic system, move the 1. Watch the cylinders as they are extended and
machine to a smooth horizontal location and retracted. Movement must be smooth and
lower the mast and carriage to the ground, regular.
make sure they are blocked correctly to keep
them from a fall that is not expected. Move away 2. Listen for noise from the pump.
from machines and personnel that are at work.
There must be only one operator. Keep all other 3. Listen for the sound of the relief valve. It must not
personnel away from the machine or where the open except when the cylinders are fully
operator can see the other personnel. extended or retracted without load on forks.
Before any hydraulic pressure plug, line or

component is removed, make sure all hydraulic
pressure is released.
Vehicle System 47 Testing & Adjusting

Hydraulic Oil Temperature (Too Hot) Hydraulic System and Mast
When the temperature of the hydraulic oil gets over During a diagnosis of the hydraulic system,
98.8°C (210°F), polyurethane seals in the system remember that correct oil flow and pressure are
start to fail. High oil temperature causes seal failure necessary for correct operation. The output of the
to become more rapid. There are many reasons pump (oil flow) increases with an increase in motor
why the temperature of the oil will get this hot. speed (rpm) and decreases when motor speed
(rpm) is decreased. Oil pressure is caused by
1. Hydraulic pump is badly worn. resistance to the flow of oil.
2. Heavy hydraulic loads that cause the relief valve Visual checks and measurements are the first step
to open. when troubleshooting a possible problem. Then do
the Operation Checks and finally, do instrument
3. The setting on the relief valve is too low. tests with pressure gauges.
4. Too many restrictions in the system. Use the Fittings Gauge, a stop watch, a magnet, a
thermometer and a mm (inch) ruler for basic tests to
5. Hydraulic oil level in the tank is too low. measure:
6. High Pressure oil leak in one or more circuits. 1. The pressure of the oil to open the relief valve.
Relief valve pressures that are too low will cause
7. Very dirty oil. a decrease in the lift and the tilt characteristics of
the lift truck. Pressures that are too high will
8. Air in the hydraulic oil. cause a decrease in the life of hoses and
components.
NOTE : If the problem is because of air in the oil, it
must be corrected before the system will operate at 2. Drift rates in the cylinders. Cylinder drift is
normal temperatures. There are two things that caused by a leakage past cylinder pistons, O-ring
cause air in the oil (aeration). These are: seals in the control valve, check valves that do
not seat correctly or poor adjustment or fit in the
a. Return oil to the tank goes in above the level of control valve spools.
the oil in the tank.
3. Cycle times in the lift and tilt circuits: Cycle times
b. Air leaks in the oil suction line between the pump that are too long are the result of leakage, pump
and the tank. wear and/or pump speed (rpm).

Hydraulic System and Mast Problem: Mast does not move smoothly.
Problem: The hydraulic system will not lift the load. Probable Hydraulic Cause:
Probable Hydraulic Cause: 1. Air in the hydraulic system.
1. There is an air leak, which lets air into the 2. Relief valve sticks or defective.
hydraulic system on the inlet side of the hydraulic
pump. 3. Damaged cylinders.
2. The relief valve opens at low oil pressure. Probable Mechanical Cause:
3. The hydraulic pump has too much wear. 1. Not enough lubricant on the parts of the mast
that move.
4. The priority valve does not work correctly.
2. Load rollers defective or not adjusted correctly.
5. The load is not correct.
3. Mast rollers not shimmed correctly.
6. Unload function doesn’t work correctly.
4. Mast assembly is damaged or not in alignment.
Probable Mechanical Cause:
Problem: The mast does not tilt correctly or moves
too slowly.
1. The mast is not in alignment with the other lifting
components and does not move freely.
Problem Hydraulic Cause:
2. Not enough lubricant on the parts of the mast
1. There is a restriction in the hydraulic tilt lines.
that move.
2. There is an air leak, which lets air into the
3. The carriage or mast rollers bearings are worn
hydraulic system on the inlet side of the hydraulic
and do not move (seized).
pump.
4. Mast shimmed too tight.
3. The relief valve opens at low oil pressure.
Problem: Lift cylinder extends too slowly.
4. The hydraulic pump has too much wear.
Probable Hydraulic Cause:
5. The internal valve of the tilt spool is stuck
1. Not enough oil supply to lift cylinder.
6. Control valve tilt spool has a restriction
2. Defective lift cylinder seals.
7. The priority valve does not work correctly.
3. Relif pressure ser too low.
8. Seals in tilt cylinder worn or damaged.
Provable Mechanical Cause:
1. Damage or failure of the tilt cylinders.
2. Mast mounting pins seized.

Problem: The carriage will not lower correctly. Hydraulic Pump
Safety lift lock function: Once the operator Problem: Noise in the pump.
leaves a seat more than 3 seconds or a start
key is off, the lift cylinder doesn’t lower even Probable Cause:
though lift lever is pulled for lowering. If the
operator is seated or, a key is on, the lowering 1. The oil level is low.
will normally work immediately.
2. The oil is thick (viscosity too high) or seals..
Probable Hydraulic Cause: 3. The pump inlet line has a restriction in it (strainer
plugged).
1. The electric switch (on-off) below a seat got
damaged. 4. Worn parts in the pump.
2. The electric parts (relay and controller) related to 5. Oil is dirty.
a solenoid valve in lift section of control valve got
failed. 6. Air leaks into the inlet line.
Probable Mechanical Cause: Problem: The oil temperature is too high.
1.Lift poppet (lift lock) damaged and contaminated. Probable Cause:

2. Needle valve is loosened. 1. The oil level is low.
Problem: The lift or tilt cylinders do not hold their 2. There is a restriction in an oil passage.
position with the valve control levers in neutral
position.
3. The relief valve setting is too low.
Probable Cause:
4. The oil is too thin.
1. The valve spools do not hold their positions
5. There is air leakage in the system.
because the springs for the valve spools are
weak or broken.
6. The pump has too much wear.
2. Control valve leakage caused by worn valve
7. The system operates at too high a pressure.
spools or seals.
a. Relief valve setting too high.
3. The check valves in the control valve are
defective.
b. Attachment components cause a restriction
during movement.
4. Leakage of the cylinder lines or piston seals.
c. Restrictions in flow control valve, load check
5. There is foreign material in the control valve.
valve and in oil lines.
8. Severe hydraulic usage.

Problem: Leakage at the pump shaft seal. Hydraulic Control Valve
Probable Cause: Problem: The control spools do not move freely.
1. The shaft seal is worn. Probable Cause:
2. There is a broken gasket behind the seal. 1. The temperature of the oil is too high.
3. The inner parts of the pump body are worn. 2. There is foreign material in the fluid.
4. Operation with too low oil level in tank causes 3. The fitting connections in the valve body are too
suction on the seal. tight.
5. Seal cut on shoulder of pump or keyway during 4. The mounting bolts of the valve assembly do not
installation. have the correct torque and have twisted the
body.
6. Seal lips are dry and hardened from heat.
5. Linkage of the lift and tilt levers does not operate
Problem: There is a failure pump to deliver the smoothly.
fluid.
6. Bent lift or tilt spools.
Probable Cause:
7. Damage to the return springs of the spools.
1. Low level of the oil in the tank.
8. The valve is not at normal temperature for
2. There is a restriction in the pump inlet line. operation.
3. There is air leakage in the pump inlet line. Problem: Control valve spools have leakage
around the seal.
4. The viscosity of the oil is wrong.
Probable Cause:
1. There is some foreign material under the seal.
6. Failure of the pump shaft or coupling.
2. The valve spools are worn.
7. The bolts of the pump do not have the correct
torque. 3. The seal plates are loose.
8. Filter by-pass not working or installed backwards. 4. The seals have damage or are badly worn.
Problem: The load lowers when the lift spool is

moved from the neutra position to the raise
position.
Probable Cause:
1. There is some foreign material in the load check

valve area.
2. The load check valve and seat show wear.
3. Sudden loss of pump oil pressure.
4. Damage to the relief valve which causes low oil

pressure.

Problem: Spools do not return to neutral. Lift and Tilt Cylinders
Probable Cause: Problem: Leakage around the cylinder rod.
1. The springs are broken. Probable Cause:
2. The spool is bent. 1. Cylinder head (bearing) seals are worn.
3. The system or valve has foreign particles in it. 2. Cylinder rod is worn, scratched or bent.
4. The control linkage is not in alignment. Problem: There is leakage of oil inside the cylinder
or loss of lift or tilt power.
5. The fastening bolts of the valve have too much
torque. Probable Cause:
Problem: No motion or slow, then a too sudden 1. The piston seals are worn and let oil go through.
action of the hydraulic system.
2. Cylinder has damage.
Probable Cause:
Problem: The piston rods show wear.
1. The relief valve is not correctly set, or will not
move in base and/or is worn. Probable Cause:
2. There is air in the system. 1. The cylinders are not in correct alignment.
3. Dirt or foreign particles between relief valve 2. Oil is dirty.

control poppet and its seat.
Problem: Foreign material behind the wiper rings
4. Valve body has a crack inside. causing scratches on the cylinder rod.
5. Spool not moved to a full stroke. Probable Cause:
1. The wiper rings show wear and do not remove

dirt and foreign material.

Problem: Low oil pressure.
Steering System
Probable Cause:
Problem: Too much force needed to turn
steering wheel. 1. Low oil level.
Probable Cause: 2. Priority valve relief valve spring weak.
1. Priority valve releases pressure oil at a low 3. Relief valve (priority valve) will not move from the
setting. Open position.
2. Pump oil pressure is low, worn pump. 4. Oil leakage inside or outside of the system.
3. Steering gear covers are too tight. 5. Defective pump.
4. Steering column not aligned with steering gear. Problem: Pump makes noise and the steering
cylinder rod does not move smoothly.
5. Priority valve spool is held in one position.
Probable Cause:
6. Steering gear without lubrication.
1. Air in the steering hydraulic circuit.
7. Low fluid level in the hydraulic supply tank.
8. Steer axle damaged.
3. Loose connection of the oil line on the inlet side
9. Worn steer cylinder piston seal. of the pump.
Problem: Steering wheel does not return to center 4. The viscosity of the oil is wrong.
position correctly.
5. The oil level in the hydraulic tank is low.
Probable Cause:
6. Worn steer cylinder piston seal.
1. Steering gear covers are too tight.
Problem: Lift truck does not turn when steering
2. Steering column is not in correct alignment. wheel is slowly turned.
3. Valve spool in the steering gear has a restriction. Probable Cause:
4. Priority valve check valve permits lift and tilt 1. The oil level of the tank is low.
hydraulic oil to affect steering hydraulic circuit.
2. There is air in the steering system.
Problem: Oil leakage at the pump.
3. The pump operation is not correct.
Probable Cause:
4. Dirt in the steering system.
1. Loose hose connections.
5. Steering gear operation is not correct.
2. Detective shaft seal.
6. Steering cylinder has worn parts.
7. Restriction in the steer axle linkage.

Problem: The temperature of the oil is too hot.
Power Master Cylinder
Probable Cause: Problem: Low power braking pressure or loss of
power braking
1. The viscosity of the oil is wrong.
Probable Cause:
2. Air mixed with the oil.
1. Insufficient pedal stroke.
3. The relief valve is set too high (priority valve).
2. Lines connected to wrong ports.
4. There is a restriction in the line circuit.
3. Insufficient brake flow from the first section of
5. Unit being held in relief mode for long periods of control valve due to a stuck brake spool.
time.
4. Relief valve in brake valve damaged.
5. Seals of servo piston in brake valve got damaged.
Problem: Low manual braking pressure or loss

of manual braking
Probable Cause:
1. Insufficient pedal stroke.
2. Air in lines.
3. Damaged servo piston seals and sleeve due to

contamination.
Problem: Pedal instability
Probable Cause:
1. Air in lines.
2. Damaged a check valve of brake port in the first

section of control valve.
3. Damaged a spring of relief valve in brake valve.
4. Damaged a spring for brake spool in the first

section of control valve.
Problem: External leakage
Probable Cause:
1. Damaged master piston or seal of master piston.
2. Casting porosity.
3. Fitting or line leakage.

Brake System Problem: Hard pedal.
Probable Cause:
NOTE: If excessive force is applied to the brake
pedal, the pedal can be forced to the end of the
1. Mechanical resistance at pedal or disc assembly.
stroke. This is normal and should not be interpreted
as a problem.
2. Restriction in the brake line.
Problem: Pedal resistance is not solid (spongy)
(under normal pedal pressure). 3. Defective brake valve.
Probable Cause: 4. Brake discs look like glass (glazed) or are worn.
1. Air in the brake hydraulic system.

Problem: Both brake disc assemblies will not
2. Brake valve is loose. release all the way (drag).
3. Servo piston seals worn or defective in brake Probable Cause:

valve.
1. Brake disc assemblies defective (stuck pistons).
4. Piston seals worn or defective in drive axle brake.
2. Brake disc uneven (out of flat).
5. Low oil level of reservoir.
3. Restriction in the brake line.
Problem: Extra (excessive) pedal travel (under
normal pedal pressure). 4. Defective brake valve.
Probable Cause: Problem: Brakes will not make application after

being bled.
1. Pedal adjustment is not correct.
Probable Cause:
2. Air in the brake hydraulic system.
1. Leak in hydraulic line or connection.
3. Brake valve is loose.
2. Damaged seals in the brake valve.
4. Servo piston seals worn or defective in brake
valve.
Problem: Brake oil low in master cylinder
reservoir, fluid must be added frequently.
5. Low oil level of reservoir.
Probable Cause:
6. Piston seals worn or defective in drive axle brake.
Problem: Brake will not make application. 1. Leak in hydraulic line or connection.
Probable Cause: 2. Damaged seals in the brake valve.
1. Low oil level of reservoir of brake valve. 3. Leak in the disc assemblies.
2. Air in the brake hydraulic system. Parking Brakes
3. Linkage adjustment is incorrect or bent. Problem: Brake will not make application.
4. Defective brake valve. Probable Cause :
5. Bent plates or discs in drive axle brake. 1. Parking brake assembly is out of adjustment.
6. Piston seals worn or defective in drive axle brake. 2. Parking brake control cable is out of adjustment.
3. Worn brake band.

Hydraulic System
Relief Valve Pressure Check
Tools Needed
Fittings Group
CONTROL VALVE
D20S-5
G20E-5 18,100 ± 350 Kpa 15,500 ± 350 Kpa
G20P-5
(1) gage plug (PF 1/2 thread) (2) Nipple assembly
GC20E-5 2,625 ± 50 psi 2,250 ± 50 psi
GC20P-5
D25S-5 With the engine off, remove the gage plug from
G25E-5 19,500 ± 350 Kpa 15,500 ± 350 Kpa nipple assembly (2) and connect the 28,000 KPa
G25P-5 (4000 psi) gauge to the nipple assembly.
GC25E-5 2,825 ± 50 psi 2,250 ± 50 psi
GC25P-5 Lift Relief Valve Check and Adjustment
D30S-5
G30E-5 1. Start the engine and activate the hydraulics until
G30P-5 21,550 ± 350 Kpa 15,500 ± 350 Kpa the hydraulic oil is at the normal operating
GC30E-5 temperature.
GC30P-5 3,125 ± 50 psi 2,250 ± 50 psi
G32E-5 2. Lift mast to maximum fork height without load on
G32P-5 forks. Increase engine rpm to high idle. Hold the
D33SC-5 lift control lever in the lifting position and watch
24,000 (+500,-0) Kpa 15,500 ± 350 Kpa
D35SC-5 the gauge. The gauge indication is the pressure
G33P-5 that opens the relief valve at the end of lift
3,490 (+75,-0) psi 2,250 ± 50 psi
G35P-5 cylinder stroke.
Use the Fittings Group to check the relief valve Caution: Make sure there is adequate ceiling
pressure. height. Lift cylinder must be fully extended. Mast
should be in the vertical position and truck
WARNING parked on level ground.
Hydraulic oil, under pressure can remain in the
3. The correct pressure setting is shown in the chart.
hydraulic system after the engine and pump have
been stopped. Personal injury can be caused if this
pressure is not released before any work is done on
the hydraulic system. To prevent possible injury,
lower the carriage to the ground, turn the engine off
and move the control levers to make sure all
hydraulic pressure is released before any fitting,
plug, hose or component is loosened, tightened,
removed or adjusted. Always move the lift truck to a
clean and level location away from the travel of
other machines. Be sure that other personnel are
not near the machine when the engine is running
and tests or adjustments are made.
Relief Valve Adjustment.
(3) Lock Nut. (4) Stud.

Tilt and Sideshift Relief Valve Check and Flow Control Valve Adjustment
Adjustment
The tilt and first attachment speeds can be adjusted
1. Start the engine and activate the hydraulics until at the control valves. They can be adjusted by
the hydraulic oil is at the normal operating turning the plug in the hydraulic control valve body.
temperature. Put the mast in the full tilt back The lift speed can not be adjusted. Do the
position. procedure that follows to change the flow control
assembly.
2. With the engine at high idle, hold the tilt control
lever in the full tilt back position and watch the
gauge. The gauge indication is the pressure that WARNING
opens the relief valve. Hydraulic oil, under pressure can remain in the
hydraulic system after the engine and pump
3. The correct pressure setting is shown in the chart. have been stopped. Personal injury can be
caused if this pressure is not released before
4. If an adjustment to the relief valve setting is any work is done on the hydraulic system. To
necessary, loosen nut (5). prevent possible injury, lower the carriage to
the ground, turn the engine off and move the
control levers to make sure all hydraulic
pressure is released before any fitting, plug,
hose or component is loosened, tightened,
removed or adjusted. Always move the lift truck
to a clean and level location away from the
travel of other machines. Be sure that other
personnel are not near the machine when the
engine is running and tests or adjustments are
made.
Relief Valve Adjustment

(5) Locknut. (6) Stud.
5. Turn setscrew (6) clockwise to increase or

counterclockwise to decrease the pressure
setting of the relief valve.
6. Tighten the locknut and check the pressure

setting again for correct adjustment.
1. Remove the nut from the slotted tie-stud of main

hydraulic valve
2. Remove the slotted tie-stud from the valve.
3. Use Hex Wrench (6mm or 1/4 inch), turn the flow

control adjuster (1) clockwise to increase the flow
or counterclockwise to decrease the flow.
4. Assemble the tie stud in the valve. Torque the

stud to 40.5 ± 2.5 N·m (360 ± 24 lb·in)
5. Reinstall the nut on the tie bolt.

Standard Lift Cylinder Air Removal 5. Locate the setscrew on each lift cylinder. Slowly
open setscrews no more than one turn. The
weight of the carriage will force air and hydraulic
After the standard lift cylinder has been disassembled oil out of the cylinders through the setscrews.
and then assembled again, it may be necessary to Close the setscrews before all the pressure is out
remove the air (bleed) from the cylinder. of the cylinders. This will prevent air from
entering through the setscrews.
1. With no load, lift and lower the mast and carriage
through one complete cycle. 6. Repeat Steps 4 and 5 until there are no air
bubbles at the setscrews.
2. With the forks on the floor, check the oil level in
the hydraulic tank. Add oil (if necessary) to bring 7. After all the air is removed, tighten the setscrews
the oil level to the full mark. to a torque of 5 to 7 N·m (45 to 60 lb·in).
3. With no load, lift and lower the mast and carriage 8. Fill the hydraulic tank to the full mark.
again through four complete cycles.
9. Lift and lower the mast and carriage again
WARNING through one complete cycle. If the mast does not
operate smoothly, repeat Steps 3 through 9.
The oil will have high pressure present. To
prevent personal injury, do not remove the
bleed screws completely. Keep hands and feet
away from any parts of the truck that move,
because the forks will lower when the bleed
screw is loosened.
4. Lift the forks high enough to put a load on all

stages of the lift cylinders.
Setscrew Locations
(Standard Cylinders)
NOTE: The Standard Lift mast has two secondary

cylinders and no primary cylinders. The Full
Free Triple Lift mast has one primary and two
secondary cylinders.

Mast and Carriage
Mast And Carriage Bearings
Part No. Bearing Size Bearing O.D.*
Mast Adjustment - STD, FFL & FFT D581814 Under Size 108.6 mm(4.276 in)
D581815 Standard 109.6 mm(4.135 in)
NOTE: The Standard, Full Free Lift and Full Free D581816 Over Size 110.7 mm(4.358 in)
Triple Lift mast load bearings are all adjusted the * Permissible tolerance ±0.08mm (.003in)
same way. The mast shown in the following
illustrations is the Full Free Triple Lift mast.
To make the mast clearance adjustments, mast

must be removed from the lift truck.
Carriage, chain and lift cylinder must be removed

from the mast for easy adjustments.
Use the procedure that follows to adjust the load

bearings.
A. Lower Bearing Adjustment of Intermediate Mast

2. Find narrowest point by ruler on the stationary
4 5 6 mast in the area where the bearings make
3
contact at 475 mm (18.7 in) channel lap.
IDCS123S
Mast Adjustment Lower Bearings

(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
1. Select lower bearings (3) and (4) from the chart to

obtain minimum clearance (B) between bearing and
bearing on left and right side.

3 4 5 6
C
IDCS123S

(A, B, C) Zero clearance. (D) Minimum clearance.
(3, 4, 5) Bearing. (6, 7, 8) Shims.
3. Install 1 mm shim to each bearing of intermediate
lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary mast
from the upper side.
NOTE: When installing shims (5) behind bearing (4),

make sure the amount of shim is divided equally when
positioned behind each bearing (4).
4. Make surer outer intermediate mast lower

bearings are properly shimmed in the stationary
mast by rolling up and down and moving outer
intermediate mast to right and left. If clearance
between both masts can be detected, pull out the
intermediate mast from the stationary mast with
crane and add shim 0.5 mm or 1 mm to both
intermediate lower bearings.

B. Upper Bearing Adjustment of Stationary
Mast
5. In case of standard and full free mast, inner lower

bearings can be easily extruded by pulling down
the inner mast from the bottom of stationary mast.
If intermediate mast is stuck and cannot move by
rolling up and down, there might be excessive 1. Lift by crane, and pull out intermediate mast from
shims. Pull out the intermediate mast from the stationary mast. Install 1 mm shim to each
stationary mast and remove shim 0.5 mm to both bearing of stationary mast upper. Bearing should
intermediate lower bearings. Repeat same be part number D581814 under size bearing.
procedure of above until properly shimmed.
There is to be contact zero clearance (C)
between intermediate lower bearings and
stationary channel at approximately 475 mm
(18.7 in) channel lap. D E
9
8
10 E
IDCS124S
Mast Adjustment Upper Bearings

(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.

C. Upper Pad Adjustment
D E
2. Make sure stationary mast upper bearings are 9 7

properly shimmed by rolling up and down and
moving intermediate mast to right and left. If
clearance between both masts can be detected, 8
pull out the intermediate mast from the stationary
mast with crane and add shim 0.5 mm or 1 mm
to both stationary upper bearings.
10 E
IDCS124S

(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
3. In case of standard and full free mast, stationary

upper bearings can be easily extruded by pulling
down the inner mast from the bottom of
1. Install shims (8) behind each pad (7) until there is
stationary mast. If intermediate mast is stuck and
0.80 mm (.031 in) maximum clearance (E)
cannot move by rolling up and down, there might
between the pads and the inner and intermediate
be excessive shims. Pull out the intermediate
masts with the masts at full extension. Lift by
mast from the stationary mast and remove shim
crane, and pull out intermediate mast from
0.5 mm to both stationary upper bearings.
stationary mast and insert the shims behind each
Repeat same procedure of above until properly
pad. In case of standard and full free mast, the
shimmed. There is to be contact zero clearance
pads of stationary upper can be easily extruded
(C) between stationary upper bearings and the
by pulling down the inner mast from the bottom
widest point of intermediate mast to be checked
of stationary mast.
before.

D. Lower Bearing Adjustment of Inner Mast
D581814 Under Size 108.6 mm(4.276 in)
D581815 Standard 109.6 mm(4.135 in)
3 4 5 6 D581816 Over Size 110.7 mm(4.358 in)
* Permissible tolerance ± 0.08mm (.003in)
C 2. Find narrowest point by ruler on the intermediate

mast in the area where the inner lower bearings
make contact full length of intermediate mast
excluding minimum channel lap 475 mm (18.7 in).
IDCS123S

(A) Zero Clearance. (B) Minimum Clearance. (C) Zero
Clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
1. Select lower bearings (3) and (4) from the chart

to obtain minimum clearance (B) between
bearing and channel leg for full channel length.
Use same bearing on left and right side.
3. Install 1 mm shim to each bearing of inner lower

and intermediate upper basically. Lift by crane,
insert inner mast into intermediate mast from the
upper side.

Mast Adjustment - Quad
NOTE: The Standard, Full Free Lift, Full Free Triple
Lift and Quad Lift mast load bearings are all
D581814 Under Size 108.6 mm(4.276 in)
adjusted the same way. The mast shown in the
following illustrations is mainly the Full Free Triple D581815 Standard 109.6 mm(4.135 in)
Lift mast, but for necessary points illustrations of D581816 Over Size 110.7 mm(4.358 in)
Quad Lift mast are inserted. * Permissible tolerance ±0.08mm (.003in)
To make the mast clearance adjustments, mast

must be removed from the lift truck.
Carriage, chain and lift cylinder must be removed

from the mast for easy adjustments.
Use the procedure that follows to adjust the load

bearings.
A. Lower Bearing Adjustment of Outer

Intermediate Mast
2. Find narrowest point by ruler on the stationary

mast in the area where the bearings make
contact at 475 mm (18.7 in) channel lap.

(3, 4, 5) Bearing. (6, 7, 8) Shims.
1. Select lower bearings (3), (4) and (5) from the chart
to obtain minimum clearance (D) between bearing and
channel leg for full channel length. Use same bearing
on left and right side.

(3, 4, 5) Bearing. (6, 7, 8) Shims.
3. Install 1 mm shim to each bearing of intermediate

lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary
mast from the upper side.
NOTE: When installing shims (5) behind bearing (4),

make sure the amount of shim is divided equally
when positioned behind each bearing (4).
4. Make surer outer intermediate mast lower

bearings are properly shimmed in the stationary
mast by rolling up and down and moving outer
intermediate mast to right and left. If clearance
between both masts can be detected, pull out the
intermediate mast from the stationary mast with
crane and add shim 0.5 mm or 1 mm to both
intermediate lower bearings.

B. Upper Bearing Adjustment of Stationary
Mast
5. In case of standard and full free mast, inner lower

bearings can be easily extruded by pulling down
the inner mast from the bottom of stationary mast.
If outer intermediate mast is stuck and cannot 1. Lift by crane, and pull out intermediate mast from
move by rolling up and down, there might be stationary mast. Install 1 mm shim to each
excessive shims. Pull out the outer bearing of stationary mast upper. Bearing should
intermediate mast from the stationary mast and be part number D581814 under size bearing.
remove shim 0.5 mm to both outer intermediate
lower bearings. Repeat same procedure of
above until properly shimmed. There is to be
contact zero clearance (C) between intermediate
lower bearings and stationary channel at
approximately 475 mm (18.7 in) channel lap.

(E, F, G) Zero clearance.
(H) 0.80 mm (.031 in) Clearance maximum.
(9) Pads. (10) Shims. (11, 12, 13) Shims.

C. Upper Pad Adjustment
2. Make sure stationary mast upper bearings are

properly shimmed by rolling up and down and
moving intermediate mast to right and left. If
clearance between both masts can be detected,
pull out the intermediate mast from the stationary
mast with crane and add shim 0.5 mm or 1 mm
to both stationary upper bearings.

(E, F, G) Zero clearance.
(H) 0.80 mm (.031 in) Clearance maximum.
(9) Pads. (10) Shims. (11, 12, 13) Shims.
3. In case of standard and full free mast, stationary

upper bearings can be easily extruded by pulling
down the inner mast from the bottom of
stationary mast. If outer intermediate mast is
stuck and cannot move by rolling up and down,
there might be excessive shims. Pull out the
outer intermediate mast from the stationary mast
and remove shim 0.5 mm to both stationary
upper bearings. Repeat same procedure of
above until properly shimmed. There is to be
contact zero clearance (G) between stationary
upper bearings and the widest point of
1. Install shims (10) behind each pad (9) until there
intermediate mast to be checked before.
is 0.80 mm (.031 in) maximum clearance (H)
between the pads and the inner and intermediate
masts with the masts at full extension. Lift by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded
by pulling down the inner mast from the bottom
of stationary mast.

D. Inner Intermediate Mast Adjustment Mast And Carriage Bearings
Follow the same procedure with above A~C. D581814 Under Size 108.6 mm(4.276 in)
D581815 Standard 109.6 mm(4.135 in)
D581816 Over Size 110.7 mm(4.358 in)
E. Lower Bearing Adjustment of Inner Mast
* Permissible tolerance ± 0.08mm (.003in)
2. Find narrowest point by ruler on the inner

intermediate mast in the area where the inner
lower bearings make contact full length of inner
intermediate mast excluding minimum channel
lap 475 mm (18.7 in).

(3, 4, 5) Bearing. (6, 7, 8) Shims.
1. Select lower bearings (3), (4) and (5) from the

chart to obtain minimum clearance (D) between
bearing and channel leg for full channel length.
Use same bearing on left and right side.
3. Install 1 mm shim to each bearing of inner lower

and inner intermediate upper basically. Lift by
crane, insert inner mast into intermediate mast
from the upper side.

Carriage Adjustment
STD, FFL & FFT
NOTE: The standard, Full Free Lift and Full Free

Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is
shown in the following illustrations.
To make the carriage clearance adjustments,

carriage must be removed from the mast.
Use the procedure that follows to adjust carriage

load bearings.
3 4 B 5
A

VIEW A-A
(3, 4, 5) Bearing. (6, 7, 8) Shims. A A
6
4. Make sure inner mast lower bearings are
properly shimmed in the intermediate mast by B B C
rolling up and down and moving inner mast to
right and left. If clearance between both masts
can be detected, pull down the inner mast from
VIEW B-B
the bottom of intermediate mast. Inner lower 7
bearings can be easily extruded. Add shim 0.5 C C
mm or 1 mm to both inner lower bearings. If inner A
mast is stuck and cannot move by rolling up and
down, there might be excessive shim. Pull out
the inner mast from the inner intermediate mast
and remove shim 0.5 mm to both inner lower
bearings. Repeat same procedure of above until
properly shimmed. There is to be contact zero C VIEW C-C 8 A
clearance (C) between inner lower bearings and IDCS125S
inner intermediate channel at narrowest point.
Carriage Adjustment
F. Upper Bearing Adjustment of Inner (3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Middle Bearings. (8) Lower Bearings. (A) Zero Clearance.
Intermediate Mast (B) 6.0 to 9.0 mm. (.236 to .354 in) Clearance.
(C) Minimum Clearance.
Follow same procedure with above B.
1. Select lower bearings from the chart to obtain
minimum clearance (B) between bearings and
G. Upper Pad Adjustment of Inner bearing in all six locations.
Intermediate Mast
Follow same procedure with above C.

D581814 Under Size 108.6 mm(4.276 in)
D581815 Standard 109.6 mm(4.135 in)
D581816 Over Size 110.7 mm(4.358 in)
* Permissible tolerance ±0.08mm (.003in)
5. Tighten screw (5) that holds the top bearings to

the carriage to a torque of 34±7 N·m (25±5 lb· ft)
2. Find narrowest point by ruler on the inner mast in

the area where the bearings make contact.
3. Install enough shims (4) that have been divided

into two equal groups behind bearings (3). At
installation, there is to be contact [zero clearance
(A)] between the bearings and the narrowest
point of inner mast. 6. Shim stop bolt (11) as required to obtain a 6 to 9
mm (.24 to .35 in) lap with top carriage stop on the
4. Do step 2 through 3 for other sets of bearings. inner upright.
IDCD015P

Quad Mast
To make the carriage clearance adjustments, carriage
must be removed from the mast.
D581814 Under Size 108.6 mm(4.276 in)
Use the procedure that follows to adjust carriage load D581815 Standard 109.6 mm(4.135 in)
bearings. D581816 Over Size 110.7 mm(4.358 in)
* Permissible tolerance ±0.08mm (.003in)
3 4 B 5
A
VIEW A-A
A A
6
B B C
2. Find narrowest point by ruler on the inner mast in

the area where the bearings make contact.
VIEW B-B
7 3. Install enough shims (4) that have been divided
C C
A into two equal groups behind bearings (3). At
installation, there is to be contact [zero clearance
(A)] between the bearings and the narrowest
point of inner mast.
4. Do step 2 through 3 for other sets of bearings.

C VIEW C-C 8 A
IDCS125S
Carriage Adjustment
(3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Middle Bearings. (8) Lower Bearings. (A) Zero Clearance.
(B) 6.0 to 9.0 mm. (.236 to .354 in) Clearance.
(C) Minimum Clearance.
1. Select lower bearings from the chart to obtain

minimum clearance (B) between bearings and
channel leg for full channel length. Use same IDCD015P
bearing in all six locations.

Chain Adjustment
If the tension is not the same on both chains, do the

procedure that follows:
WARNING
Personal injury can be caused by sudden
5 movement of the mast and carriage. Blocks
must be used to prevent the mast and carriage
from any movement while the adjustments are
made. Keep hands and feet clear of any parts
5. Tighten screw (5) that holds the top bearings to the that can move.
carriage to a torque of 34±7 N·m (25±5 lb· ft)
11
6. Shim stop bolt (11) as required to obtain a 6 to 9

mm (.24 to .35 in) lap with top carriage stop on the
inner upright.
Chain Adjustment
1
Chain Adjustment Check 2
Inner Lift Chains

(1) Chain Anchor Nuts. (2) Chain Anchor Bolt
1. Lift the mast and carriage and put blocks under

the mast and carriage to release the tension from
the lift chains.
2. Make adjustments to chain anchor nuts (1) or

bolts (2) for equal tension of the mast and
Chain Adjustment Check carriage chains.
Lift the carriage and mast high enough to put their 3. Put LOCTITE NO.242 Thread Lock on the
full weight on the carriage and mast chains. Check threads of the locknuts after the adjustment is
the chains, and make sure the tension is the same. completed.

Chain Wear Test
Chain wear test is a measurement of wear of the

chain links and pins. Do the steps that follow to
check chain wear.
1. Lift the mast and carriage enough to put tension

on the lift chains.
2 2. Measure precisely ten links of chain distance at

the center of pins in millimeter.
A chain wear gauge can also be used.
3. Calculate chain wear rate.

1
2 * For STD, FF, FFT Mast
1
2 New one pitch = 19.05 mm (D20/25/30/32S Model)
25.40 mm (D33S,
G33P Model)
Chain wear rate (%)

= Actual measurement - 190.5 x100 (D20/32S Model)
190.5
Outer Lift Chains
(1) Chain Anchor Nuts.
(2) Chain Anchor Bolts. = Actual measurement - 254 x100 (D33S,G33P Model)
254
* For Quad Mast
- Carriage & Outer Mast Chain
Chain wear rate (%)

= Actual measurement - 254 x100
254
- Inner Mast Chain
Chain wear rate (%)

= Actual measurement - 190.5 x100
190.5
WARNING
wear indication is 2% or more. A reading of 2%
persons.
4. If the chain wear indication is 2% or more,

replace the lift chain.

Carriage and Mast Height Adjustment Forks Parallel Check
1. Move the mast either forward or backward so it is 1. Lift the mast and operate the tilt control lever,
in the vertical position. until the top surface of the forks is parallel with
the floor. Place two straight bars, that are the
2. Lower the carriage completely. same width as the carriage, across the forks as
shown. Measure the distance from the bottom of
each end of the two bars to the floor. The forks
must be parallel within 3 mm (.12 in) for Full
Tapered and Polished (FTP) forks, all other forks
6.4 mm (.25 in), for their complete length.
2. If not parallel, determine which one is defective

and replace it.
IDCS191S
3. On Full Free Lift Full Free Triple Lift and Quad

Lift models, the bottom of the inner mast must be ’
even with the bottom of the stationary mast.
Forks Parallel Check
(Typical Example)
4. Measure the distance from the bottom of the
inner upright to the bottom of carriage bearing.
5. The measurement (A) must be as follows:

STD ......................................................... Zero
FFL, FFTL & Quad... 41±1.5 mm (1.61± .06 in)
NOTE: On Standard Lift models the bearing must

be even (flush) with the inner mast. If the above
measurements are not correct, make adjustments
to the chains to get the correct measurement. See
Chain Adjustments in TESTING AND ADJUSTING.

Tilt Cylinder Alignment
If the tilt cylinders are out of alignment, extra

stresses in the mast assembly and the mast hinge
area will result. To prevent damage, the tilt
cylinders must stop evenly at the end of the tilt back
and tilt forward strokes.
Tilt Angle Check
Tilt Angle Check (Typical Example)
The tilt angle of the mast must be checked in the

full tilt back and full tilt forward positions. A tilt
indicator or a protractor can be used to measure the
angle. Both sides of the mast must be checked to
make sure that the mast is not twisted.
The tilt angle is determined by the tilt cylinders used.

See tilt cylinders in specifications to determine the
tilt angle from the cylinder being used.

Tilt Cylinder Length Check WARNING
Tilt cylinder pivot eyes can loosen if the torque on
the pivot eye clamping bolt is not tight enough.
This will let the tilt cylinder rod turn in the tilt
cylinder eye. The cylinder rod may then twist our
of the pivot eye and the tilt cylinder will be out of
alignment or may let the mast fall and cause
personal injury or damage. When the rod lengths
are made even, the tilt angle differences or the
mast alignment will no longer be a problem.
3. Tighten bolt (2) and the nut to a torque of 95 ± 15

IDCS009P
N·m (70 ± 10 lb·ft). If the nuts had been
Tilt Cylinder Length Check removed completely, it needs to be replaced with
the new ones.
1. Tilt the mast to full forward position. Measure the
extended length of the cylinder rods from the 4. With mast at full back tilt, install shims (4) as
cylinder housing to the mast. The difference of required to permit no gap between spacer (5)
length between the two cylinder rods must be
and head (6). Shim so mast does not twist at full
within 3.18 mm (.125 in) of each other.
tilt back.
Tilt Cylinders With Tilt Back Limiting Group
IDCS129S
Tilt Cylinder Adjustment

(1) Pivot eye. (2) Bolt. (3) Rod. (4) Shims. (5) Spacer.
(6) Head.
1. With the mast at full forward tilt, loosen bolt (2).
2. Slide spacer (5) back so rod (3) can be turned

into or out of pivot eye (1) to obtain the correct
length or angle.

Drift Test Drift Test For The Tilt System
Drift is movement of the mast or carriage that is the 1. Put a rated capacity load on the forks on the lift
result of hydraulic leakage in the cylinders or control truck. Operate the lift truck through a complete lift
valve. Before testing the drift: and tilt cycle until the oil is at normal temperature
for operation, 45 to 55 °C (113 to 131 °F).
WARNING 2. Put the mast in a vertical position. Raise a rated

Personal injury can be caused by sudden capacity load to a height of 2.5 meters (8.2 ft). In
movement of the mast or carriage. Use wood the case of trucks with less than 2.5 meters (8.2 ft)
blocks and clamps to hold the mast in this height extension, raise the load to the truck’s
position. Keep hands and feet clear of any parts maximum height.
that can move.
1. Check the chain adjustment and tilt cylinder

alignment and make necessary adjustments.
2. Lift the mast approximately 762 mm (30 in). Use

wood blocks and clamps to hold the mast in this
position.
3. Check the mast hinge bolts to make sure they are

tight.
4. Remove the blocks and clamps and lower the mast. Tilt Drift Check.
3. The tilt drift is measured as the charge in the tilt

Drift Test For Lift System
cylinder stroke. Measure any drift of the mast for
ten minute period.
1. Secure a rated capacity load on the forks of the lift Drift for shall not exceed 35.5 mm (1.40 in).
truck. Operate the lift truck through a complete lift
and tilt cycle until the oil is at normal temperature
of operation, 45 to 55 °C (113 to 131 °F).
2. Put the mast in a vertical position.

Raise a rated capacity load to a sufficient height to
test the lift cylinders.
3. Measure any drift of the carriage for a ten minute

period. Drift for all models shall not exceed 100.0
mm (4.00 in).

Steering System Steering Axle Stop Adjustment
Steer Wheel Bearing Adjustment

1
12 2
A
1
2
3
4 5
Bearing Adjustment
(1)Nut (2) Lock Washer IDCS132S
Steer Angle
(1) Bolt. (2) Nut. (3) Bolt. (4) Nut. (5) Bolts. (A) 80° angle.
1. Tighten nut (1) slowly to 135 N·m (100 lb·ft)
while the wheels is rotated in both directions to
put the bearings into position. Use the procedure that follows to make an adjustment
to the steer axle turning angle.
2. Loosen nut (1) completely. Tighten nut (1) again
to.............................. 50 ± 5 N·m (37 ± 4 lb·ft) . 1. Adjust the cylinder rod extension so it is equal on
both sides of the axle.
3. Put the lock washer (2) on the nut and align the
hole. In case of no match, rotate the nut (1) 2. Loosen nuts (2) and (4) on both sides of the steer
about 1/32 turn clockwise. axle.
4. Apply loctite 242 on the threads of bots and 3. Turn the steer wheel one direction until the steer
tighten them at 8±3 N·m (6±2 lb·ft). cylinder rod extension measures 94mm(3.7 in)
more than the straight ahead measurement.
4. Adjust stop bolt (1) on one side and stop bolt (3)
on the other.
5. Tighten nut (2) on one side and nut (4) on the

other side. Turn the steer wheel the opposite
direction and do the same procedure for the
opposite stop bolts. This will give a maximum
cramp angle of 80°

Steering Knuckle Bearing Preload Steering System Pressure Check
Adjustment
If the steering system does not work correctly,
check the hydraulic tank for the correct oil level and
the hoses and connections for leakage. If all these
items are correct, use the Pressure Gauge Kit to
6
check the steering hydraulic system and its relief
pressure setting.
7 8 9 Hydraulic Steering Gear

(1) Elbow (Pressure line from priority valve).
IDCS133S
WARNING
Steering Knuckle Bearing Preload Adjustment Hydraulic pressure can cause personal injury.
(6) Steering link. (7) Shims. (8) Cover. (9) Bolts.
Before any steering system hydraulic lines or
components are disconnected, make sure all
1. During assembly of the steering knuckle, install hydraulic pressure is released in the steering
the upper bearing cup, cone and seal. system. Move the steer wheels to the left and
right and then to the straight forward direction.
2. Install lower bearing group cover (8) without
shims. Tighten two opposed cover bolts (9) to a Check steering system relief pressure as follows:
torque of 5.6 N·m (50 lb·in).
1. Turn the engine off.
3. Measure the clearance between cover (8) and
the axle beam at each bolt with a feeler gauge. 2. Remove plug from elbow(1)
Install pressure-checking adapter(4) and connect
4. Take an average of the measurements found in pressure-tube (5) and pressure gage (6).
Step 3. Select shims (7) equal in thickness to the Pressure gage(6) has a range of 28,000 kpa
average clearance. (4,000psi).
5. Remove the bearing group and install shims (7), 3. Move the seat to the normal position for
cover (8) and bolts (9). Tighten bolts (9) to a operation, turn the key switch to the ON position
torque of 55±6 N·m (40±5 lb·ft). and activate the hydraulic controls until the oil is
at a temper-ature for normal operation.
6. With steering links (6) disconnected from the
steering cylinder, check knuckle for 4.5 to 6.8 4. Turn the steer wheels to the left or right against
N·m(40 to 60 lb·in) of rolling torque. Add or the stops and make a note of the indication on
remove shims from cover (8) to obtain the proper the pressure gauge.
rolling torque.
5. The indication on the pressure gauge must be
7. Connect links (6) to the steering cylinder. Tighten the priority valve relief setting of 9000 + 300 kPa
cylinder mounting bolts (5) to a torque of 460 ± (1305+43.5 psi). If the indication is correct and a
60 N·m (340 ± 40 lb·ft). problem exists, then there is possibly a
mechanical failure in the steering system.

6. If the indication is not correct, then there is
steering hydraulic failure in the components.
(6)
(5)
M10 X 1.0 THD
(4)
IDCS134S
(4) Pressure-Checking Adapter. (5) Pressure-Tube.

(6) Pressure Gauge.
7. If the steering gear and the priority valve are

working properly, the steering cylinder is
defective and must be repaired.
8. Correct the problem and check steering relief

valve pressure again.
a. With the engine running, turn the steer wheels in

any directions and read the indication on
pressure gauge (6).
b. If the indication is approximately the pressure

shown in Step 5, then the steering gear has a
hydraulic failure.
c. If the indication is too low or too high, then the

priority valve or its components must be replaced.

Brake System Parking Brake Test
Brake System Air Removal WARNING

To prevent personal injury, the operator must
When the brake pedal resistance is spongy (not be ready to use the service brake if the parking
solid) it is usually an indication that there is air in brake is not adjusted correctly and the lift truck
the brake hydraulic system. The cause may be low starts to move.
fluid or oil level, leakage in the system, a broken
brake line or a brake line that is not connected. To
remove air from the brake system, do the procedure 1. Drive the fully loaded lift truck forward up a 15%
that follows. incline.
2. Half way up the incline, stop the lift truck with the
service brakes. Make an application of the
parking brake.
3. If the parking brake has the correct adjustment,

the lift truck will be held in this position.
4. If the parking brake does not hold, do the steps in

Parking Brake Adjustment.
IDCS213P
Right Bleed Screw Location (Left Not Shown)

(1) Bleed Screw.
1. Check the hydraulic oil level in oil reservoir and

fill if needed. See Operation and Maintenance
Manual.
2. Start the engine and keep it at low idle.
3. Put pressure on the brake pedal and open bleed

screw (1) to let air out of the system. Close bleed
screw (1), while pressure is still on the brake
pedal, then let the pedal return to the original
position.
4. Do Step 3 again as many times as necessary

until the brake liquid is free of air.
5. Use the procedure in Steps 3 and 4 again,

except this time use the left bleed screw (not
shown).
6. Check the hydraulic oil level again and fill as

required. See Operation and Maintenance
Manual.

Parking Brake Adjustment
NOTICE
Turn the adjustment screw clockwise to tighten.
Turning the screw too far counterclockwise could
5 allow parts to fall into the bottom of the transmission.
The transmission would then require disassembly to
remove the parts.
6
4 1. Put the parking brake control in the released
position.
1
2 2. Make sure lever (4) is against stop (3). If against
stop, go to Step 5. If not against stop, go to Step
3 3.
3. In case of the old cable with locking plate, bend

lock (5) away from nut (6). Loosen nut (6) until
lever (4) is against stop (3).
In case of the new cable with locking block, the
function of the lock and the nut is combined to the
block. So, there is nothing to be bent.
IDCS212S
Parking Brake Adjustment 4. Tighten nut (6) finger tight and bend lock (5) to
(1) Screw. (2) Nut. (3) Stop. (4) Lever. (5) Lock. (6) Nut hold in place. Be sure to do this correctly.
5. Loosen nut (2).

< Old cable with locking plate >
6. Tighten screw (1) to a torque of 5.6 to 6.8 N·m
(50 to 60 lb·in).
7. Loosen screw (1) 1.2 to 1.5 turns, hold in this

position and tighten nut (2).
< New cable with locking block >

7
8
IDCS219S
Parking Brake Adjustment

(7) Switch Assembly. (8) Screws.
8. Loosen screws (8).
9. Adjust switch assembly (7) until switch actuation

occurs between the 2nd. or 3rd. click as the
parking brake is engaged. Tighten screws (8).

Vehicle System: Specification System Operation Testing & Adjusting

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SB4255E01

D20S-5, D25S-5, D30S-5, D33S-5, D35C-5

OSS (Operator Sensing System) ........................ 42

Vehicle System 3 Index

Mast and Carriage ..............................................59

Steering System .................................................78

Brake System .....................................................81

Vehicle System 4 Index

(9) Torque for plug....63.7±2.5 N·m (564±24 lb·in)

(10) Torque for plug........................ 55.5±2.5 N·m

(11) Torque for plug......30±2.5 N·m (260±24 lb·in)

(13) Torque for plug....................... 63.7±2.5 N·m

Vehicle System 5 Specification

Type of pump : gear

Maximum working pressure : 25Mpa (250bar)

1. Put pipe sealant on the last three threads of

2. Torque for setscrews ....6±1 N·m ( 53 ± 9 lb·in)

NOTE: All seals to be lubricated with hydraulic oil.

Vehicle System 6 Specification

Vehicle System 7 Specification

TILT CYLINDER GROUP

* Permissible tolerance of 1/2°

(1) Adjust pivot eye to dimension (Z) with cylinder

(2) Torque for bolt….…95 ± 15 N·m ( 70 ± 10 lb·ft)

(3) Torque for head…………………..270 ± 30 N·m

(4) Torque for piston nut……………. 270 ± 30 N·m

Vehicle System 8 Specification

1. With mast at 475 mm (18.7 in) channel lap,

*Permissible tolerance of ± 0.08 mm (.003 in).

Vehicle System 9 Specification

1. Put LOCTITE NO. 242 Thread Lock on the

2. Maximum chain we………Less than 2% (See

3. Distance from bottom of inner mast to bottom of

Vehicle System 10 Specification

1. Tighten bolts until contact is made with guard.

2. Put LOCTITE NO. 242 Thread Lock on the

3. Maximum chain wear………Less than 2% (See

4. Distance from bottom of inner mast to bottom of

Vehicle System 11 Specification

1. Maximum chain wear………………Less than 2%

2. Put LOCTITE NO. 242 Thread Lock on the

Vehicle System 12 Specification

3. Tighten bolts until contact is made with guide

4. Distance from bottom of inner mast to bottom of

Vehicle System 13 Specification

2. Install bearing outer race to a depth of (F)

3. Tilt cylinder installation shown.

4. Bearing split to be located at angle (D) 45±15°

5. Install bearing outer race to a depth of (G)

6. (Full Free Lift Mast Only):

7. (Full Free Lift Mast Only):

Vehicle System 14 Specification

1. Torque for steering wheel nut ..........................

Vehicle System 15 Specification

(1) Pin (1) in the body must be aligned with internal

(4) Tighten bolts in sequence shown.

Tighten to a first torque of........ 14.1 ± 2.8 N·m

(5) Torque for plug ................11.3 N·m (100 lb·in)

Plug to be flush (even) with or below mounting