6) OUTLET SECTION

(1) Operation . d the secondary relief valve (with built-in anu.

The outlet section contams the tank port an
cavitation feature).

OUTLET o

o o

22B7HS17

(2) Operation of relief valve at setting pressure

When the pressure at outlet reaches to setting pressure, the pilot poppet which is in the main
relief valve is opened by pressure. At this condition the flow divert from the pump directly to the
tank line.

OUTLET
o

22B7HS18

6-12
7) MAIN RELIEFVALVE . .
n,is valve is a type of p1lot pistan to prevent hydraulic components and pipes trom being broken by
high pressure so, it keep~ under pressure limitad.
Relief valve pressure vanes by 130 kgf/cm2 in accordance wtth 1 revolution of adjust bolt.

2 11 4 5 12 1 13 14 17

7 8 10 16 9 15
6 3

T 2
. Main reliefvalve : 190 kgf/cm
2
. Secondary main relief valve : 130 kgf/cm
[~ (For 3,4 spool only)
p

. NOTE : 1) Max. pressure of relief valve : 250 kgf/cm2 f/cm2

2) Used pressure of hyd control valve : 190 kg
22B7HS20

13 Pilot poppet
7 Main spring
1 Pilot seat 14 Pilot spring
8 Piston Adjust screw
2 O-ring 15
9 Body O-ring
3 Mainpoppet 16
10 O-ring 17 Lock nut
4 Backup ring
11 Backup ring
5 O-ring
12 O-ring
6 Socket

6-13
4. LIFT CYLINDER

2 14 15 7 6 4,5
1
9

11

-- -- -- ---1-- --

0255HS18

6 Wear ring 11 0-ring

1 Tube assembly
7 Retaining ring 12 Guide
2 Rod
8 Gland 13 DU bushing
3 Piston
9 Dustwiper 14 Spacer
4 Piston seal
10 Rodseal 15 O-ring
5 Back up ring

5. TILT CYLINDER

23 12,13 8 17 16 11 ,10 15,14 9 1 2 6 4 5 3 7

24 24

22e7H524

1 Tube assembly 9 Dubushing 17 Lockwasher

2 Rod 10 Rod seal 18 Rod eye
3 Piston 11 Backup ring 19 Spherical bearing
4 Gtyd ring 12 Dustwiper 20 Hexagon bolt
5 Wear ring 13 Snap ring 21 Spring washer
6 O-ring 14 O-ring 22 Lock nut
7 Nylon nut 15 Back up ring 23 Grease nipple
8 Gland 16 O-ring 24 0-ring

6-14
@ROUP 2 OPERATIONAL CHECKS ANO TROUBLESHOOTING
1. OPERATIONAL CHECKS
1) CHECK ITEM
(1) Check visually for defonnation, cracks or
damage of rod.
(2) Set mast vertical and raise 1 m from
ground. Waij for 1Ominutes and measure
hydraulic drift (amount forks move down
and amount mast tilts forward).
. Check condition
22SH9HS16
- Hydraulic oíl : Nonnal operating temp
(SOºC)
- Mast substantially vertical.
- Rated capac~ load. Within s· {after 10min)
• Hydraulic drift
- Oown (Downward movement of forks)
: Within 100mm (3.9in)
- Forward (Extension of tilt cylinder)
:Within 5º
(3) lf the hydraulic drift is more than the
specified value, replace the control valve
or cylinder packing.
Check that clearance between tilt cylinder
22BH9HS17
bushing and mounting pin is within
standard range.
Standard

2) HYDRAULIC OIL
(1) Using dipstick, measure oil level, and oíl if
Highest - -
necessary. leve!
(2) When changing hydraulic oil, clean
suction strainer(screwed into outlet port
pipe) and line filter(screwed into inlet
pipe). Une filter uses paper element, so Lowest - - -
leve!
replace periodically(every 6 months or
1000 hours) B15AOM116

3) CONTROL VALVE
(1) Raise forks to maximum height and
measure oíl pressure.
Check that oíl pressure is 190 kgf/cm 2
(2700 psi).

6-15
2. TROUBLESHOOTING
1) SYSTEM
Remedy
Problem Cause
___,,
. Replace spool or valve body.
Large fork lowering speed . Seal inside control valve detective.
• Replace.
. Oil leaks from joint or hose.
. Replace packing.
. Seal inside cylinder detective.
Large spontaneous tilt of • Tilting backward : Check valve defec- . Clean or replace.
-
mast tive.
. Tilting forward : tilt lock valve detect- . Clean or replace.

ive.
. Oil leaks from joint or hose. • Replace.
• Seal inside cylinder detective. • Replace seal.
Slow fork lifting or slow mast • Lack of hydraulic oil. · Addoíl.
tílting • Hydraulic oíl mixed with aír. • Bleed aír.
• Oíl leaks from joint or hose. • Replace.
• Excessive restríction ot oil tlow on • Clean filter.
pump suction side.
• Reliet valve fails to keep specified • Adjust reliet valve.
pressure.
• Poor sealing inside cylínder. • Replace packing.
• High hydraulic oil viscosity. · Change to ISO VG46.
• Mast fails to move smoothly. · Adjust roll to rail clearance.
• Oil leaks from lift control valve spool. · Replace spool or valve body.
• Oíl leaks from tilt control valve spool. • Replace spool or valve body.
Hydraulic system makes · Excessive restriction ot oil flow pump • Clean filter.
abnormalsounds suction side.
• Gear or bearíng in hydraulic pump · Replace gear or bearing.
detective.
Control valve lever is locked · Foreign matter jammed between sp- • Clean.
ool and valve body.
· Valve body detective. · Tighten body mounting bolts unitormly.

High oíl temperatura · Lack ot hydraulic oil. · Addoil.

· High oil viscosity. · Change to ISO VG46.
· Oil filter clogged. • Clean tílter.

6-16 .4-
 2) HYDRAULIC GEAR PUMP
Problem Cause Remedy
Pump does not develop full • System relief valve set too low or · Check system relief valve for proper
pressure leaking. setting.
· Oil viscosity too low. · Change to proper viscosity oil.
· Pump is wom out. · Repair or replace pump.
Pump will not pump oil · Reservoir low or empty. · Fill reservoir to proper level.
· Suction strainer clogged. • Clean suction strainer.
Noisy pump caused by · Oil too thick. · Change to proper viscosity.
cavitation · Oil filter plugged. • Clean filters.
· Suction line plugged or too small. · Clean line and check for proper size.
Oil heating · Oil supply low. · Fill reservoir to proper level.
• Contaminated oil. · Drain reservoir and refill with clean oil.
· Setting of relief valve too high or too · Set to correct pressure.
low.
· Oil viscosity too low. • Drain reservoir and fill with proper
viscosity.
Foaming oil • Low oil level. • Fill reservoir to proper level.
• Air leaking into suction line. • Tighten fittings, check condltion of
line.
• Wrong kind of oil. · Drain reservoir, fill with non-foaming
oil.
Shaft seal leakage • Wom shaft seal. • Replace shaft seal.
· Wom shaft in seal area. • Replace drive shaft and seal.

3) MAIN RELIEF VALVE

Problem Cause Remedy
Can't get pressure • Poppet D, E or K stuck open or · Check for foreign matter between
contamination under seat. poppets D, E or K and their mating
parts. Parts must slide freely.
Erratic pressure . Pilot poppet seat damaged. • Aeplace the relief valva.
• Poppet C sticking in D. · Clean and remove surface
marks for free movement.
Pressure setting not correct . Normal wear. Lock nut & adjust · See *Test of main control valva.
screw loose.
Leaks • Damaged seats. • Replace the relief valva.
• Worn O-rings. • Instan seal and spring kit.
• Parts sticking due to contamination. • Disassemble and clean.
* A good pressure gauge must be installed in the line which is in communication wlth the main relief. A
load must be applied in a manner to reach the set pressure of the main relief unlt.
Toen, follow these steps :

• Loosen lock nut.

• Set adjusting nut to desired pressure setting.
· lf desired pressure setting cannot be achieved, add or remove shims as required.
• Tighten lock nut.
• Retest in similar manner as above.

6·17
 4) LIFT CYLINDER

Problem Cause Remedy

Oil leaks out from rod cover
through rod
• Foreign matters on packing.
• Unallowable score on rod.
• Unusual distortion of dust seal.
• Replace packing.
------
· Smooth rod surface with an oil s
· Replace dust seal. tone.
• Chrome plating is striped. • Replace rod.
Oil leaks out from cylinder rod
cover thread
Aod spontaneously retract
• 0-ring damaged.

• Seores on inner surface of tube.

• Replace O-ring.
------
· Smooth rod surface with a n ~
• Unallowable score on the inner · Replace cylinder tube. ne.
surface of tube.

---
· Foreign matters in piston seal. • Replace piston seal.
Wear (clearance between · Excessive clearance between • Replace wear ring.
cylinder tube and wear ring) cylinder tube and wear ring.
Abnormal noise is produced
during tilting operation
· lnsufficient lubrication of anchor pin
or worn bushing and pin.
• Lubricate or replace.
--
· Bent tilt cylinder rod. • Replace.
-

6-18
@ROUP 3 DISASSEMBLY ANO ASSEMBLY

Check immediately that any spare parts you receive have not been damaged in shipment.
AlWays work in a clean environment.
wash all components in solvent and blow dry with compressed air before refitting.
Take care not to damage rubber seals.
Avoid damaging precision machined surfaces.
components should fit into their housings without excessive force. lf force is necessary, this normally
means that the component does not have the correct dimensional tolerances of is aligned incorrectly.
When hand pressure is insufficient, only use press or rubber hammer to fil components.
Never strike components wlth steel hammers.
Steel bush must be fitted only with a sultable press.
Do not use hammers to flt bearings.
Always respect the direction of rotation when assembling components.

6-19
1. HYDRAULIC GEAR PUMP
1) DISASSEMBLY

(1) Mounting flange

<D Loosen and remove the assembling bolts
and washers from the pump.

® Remove mounting flange from the body.

@ Remove the snap-ring with proper tool

(only when it is needed to replace shaft
seal).
Remove the shaft seals taking care not
to give any damage on the surface of
shaft hole ( only when it is needed to
replace shaft seal.).
Replace the shaft seal if damaged.

6-20
(2) Working section
CD Remove the pressure plate with
prearranged parts, O-ring & back up ring
from the working section and examine it
carefully.
@ Remove square ring posited on the
groove of body.
@ Pull out driving gear & driven gear
keeping gears as straight as possible.
2289GP04
© Change damaged seals into new one.

@ Replace the 0-ring & back-up ring on the

thrust plates.
* Locate O-ring on the groove of thrust
plage & back-up ring upon the O-ring
and fix them in their posltion wlth sorne
grease.

(3) Priority valve block

CD Remove priority valve block from the
body.

@ Change damaged O-ring or damaged

parts.

s~21
2) ASSEMBLING
(1) Assembled priority valva block to the
working section.

(2) Assemble mounting flange to the working

section.
lBE Locate mounting flange as straight as
possible, in order to avoid any damage to
the shaft seal by shaft.

(3) Tighten the bolts with in a crisscross

pattern to a torque value of 45 Nm.

(4) Check that the pump rotates freely when

the drive shaft is turned by hand, if not a
possible, plate seal may be pinched.

6-22
2. MAIN CONTROL VALVE (with OPSS)
1) ASSEMBLY
(1) General
CD Ensure that the assembly area will be clean and free of contamination.
® Use a flat (within 0.2 mm) work surface when bolting the valve sections together.
® Use calibrated torque wrenches and instrumentation.
© Addijional auxiliary valve sections may be added to the main control valve in a similar manner as
indicated below.

(2) Block subassembly

NUT
2.4-2.9 k
(17.4-21 1

2287HS21

Q) Attach all the O-rings to the appropriate grooves between the spool sections.
@ Stack the valve sections such that all the work ports are facing up, the spool ends are all in the
® same direction, and they are resting on a flat (w~in 0.2 mm), unijorm surface.
© lnsert all the tie rods through the drilled holes in each of the housings.
Press the sections together, being carefully not to damage sealing surfaces or seals.
@ lnstall nuts to both ends of all tie rods and progressively torque in a circular pattem until reaching
a torque of 2.4-2.9 kgf, m (17.4-21 lbf • ft) on all tie rods. Periodically, rnake sure that the valve
remains flat while applying torque.

6-23
 Lift lock check valva
4.5-5.0 kgl m - - 1'---<l Solenoid V/v .
(32.5-36.2 lbf ft) ¡ 0.5-1.0 kg¡.~11
(3.6-7.21bf ft)
Solenoid vaiv
cartidge e
(Norma11y closed¡
3.5-4.0 k!lf-m
(25.3-30 lbf,ft)
v_:-4'~'=
.},""f'l

•
Main relief valve
~ 4.5-5.0 kgf,m
(32.5-36.2 lbl•ft)
~ Cap

Bolt : M6X1 .0 Bolt: M6X1.0 Auxiliary relief valve

1.0-1.5 kgl•m 1.0-1 .5 kgl•m 4.5-5.0 kgl•m
(7.2-10.8 lbl·ft) (7.2-10.8 lbl•ft) (32.5-36.2 lbl·ft)
15BT9HS2SS

(3) lnlet section

CD Instan the main relief valve assembly into the lower side cavity of the inlet section, as illustrated.
Torque to 4.5-5.0 kgf •m(32.5-36.2 lbf · ft).
® Instan the plug assembly in the tank port of the inlet section. Torque to 4.5-5.0 kgf · m(32.5-36.2
lbf · ft)

(4) Lift section

CD Toe spool assembly should already consist of the lift spool, the return spring, one spring seat on
either end of the spring, the seal plate, a spool seal, and a dust wiper. An of these are assembled
on the end of the spool oppostte the clevis.
® lnsert the clevis end of the spool into the right-hand side of the spool bore(the tanest end of the
housing). Place the spool cap over the spool and spring assembly and connect the cap to the
housing using two bolts. Torque both bolts altematively until a torque of 1.0-1 .5 kgf. m(7.2-10.8
lbf • ft) is reached on both bolts.
® Instan the second spool seal and dust wiper over the clevis end of the spool and retain with a
seal plate and two bolts.Torque both bolts alternatively until a torque of 1.0~1.5 kgf . m(7.2-10.8
lbf • fl) is reached on both bolts.
© Toe load check assembly is inserted into the top center cavity. Torque to 3.5-4.0 kgf . m(25.3-30
lbf · ft)
® Toe normany closed solenoid is instaned in the rightmost cavity on the top of the section.Torque
to 3.5-4.0 kgf · m(25.3-30 lbf · ft)
@ Instan the lift lock check valve assembly in the remaining open cavity in the top of the housing.
Torque to 4.5-5.0 kgf · m(32.5-36.2 lbf . ft)
(J) Instan the needle valve subassembly in the cavity on the inlet-facing surface of the housing.
Torque to 1.0-1 .5 kgf · m(7.2- 10.8 lbf . ft)

6-24
 Uh lock check valva Q
4.5- 5.0 kgf m - -Q Solenold vlv coil
(32.5-36.2 lbf ft) y - 0.5-1 .0 kgf•m
(3.6-7.2 lbf ft)
Spring - ,
oad check valva Solenoid valva
cartldge
.5-4.0 kgt-m (Normally closed)
25.3- 30 lbf•ft)
3.5--4.0 kgf-m
(25.3-30 lbf·ft)

Main rellet valve

4.5-5.0 kgf-m

6( Cap
(32.5- 36.2 lbf·h)
J Seal plata

Bolt : M6X1 .0 Bolt : M6X1.0 1

1.0-1 .5 kgf•m Auxiliary relief valva
1.0-1.5 kgf•m 4.5-5.0 kgf•m
(7.2-10.8 lbf•ft) (7.2-10.8 lbf-ft) (32.5-36.2 lbf.ft)

15BT9HS25S

(5) Tilt section

<D The spool assembly should already consist of the tilt spool(with tilt plunger and spring inserted
into the bore on the spring end), the retum spring, one spring seat on either end of the spring,
the seal plate, a spool seal, and a dust wiper. AII of these are assembled on the end of the spool
opposite the clevis.
® lnsert the clevis end of the spool into the right-hand side of the spool bore(the tallest end of the
housing). Place the spool cap over the spool and spring assembly and connect the cap to the
housing using two bolts. Torque both bolts altematively until a torque of 1.0-1.5 kgf • m(7.2-10.8
lbf • ft) is reached on both bolts.
@ lnstall the second spool seal and dust wiper over the clevis end of the spool and retain with a
seal plate and two bolts. Torque both bolts alternatively until a torque of
1.0-1 .5kgf • m(7.2-1 O.Blbf • ft) is reached on both bolts.
© The load check assembly is inserted into the top center cavity. Torque to 3.5-4.0 kgf • m(25.3- 30
lbf · ft).
® Instan the anti-cavitation check valve in the housing cavity on the clevis end directly above the
spool assembly. Torque to 4.5-5.0 kgf · m(32.5- 36.2 lbf · ft).
@ Instan the plug in the housing cavity above the spool assembly. Torque to 3.5-4.0 kgf · m(25.3-30
lbf • ft).

6-25
 Llft lock check~valve
4.5-5.0 kgf m Solenoid v/v col(

Plug
4.5-5.0 kgf-m
(32.5-36.2 lbf-~
LJ
(32.5-36.2 lbf lt)

Load check valva

3.5-4.0 kgf-m -
(25.3-30 lbf·lt)
Sprlng -

y -
1 0.5- 1.0 kQf-rn
(3.6-7 ,2 lbf lt)

Solenold varve
cartidge
(Normany closed)
3.5-4.0 kQf-m
(25.3-30 lbf-lt)

~ --o=--- l..

eedie valva
a
.0-1.5 kgf m
7.2-10.8 lbf

1
Main relief valva
4.5- 5.0 kgf•m
(32.5-36.2 lbf·lt)
¡ Seal plata

Bolt : M6X1 .0 Bolt : M6X1 .O Auxiliary relief valva

1.0-1.5 kgf-m 1.0-1.5 kgf-m 4.5-5.0 kgf-m
(7.2-10.8 lbf.ft) (7.2-10.8 lbf·lt) (32.5-36.2 lbf·ft)

15BT9HS25$

(6) Auxiliary section

* Same procedure for all aux sections, but spool assembly components may vary.
CD Toe spool assembly should already consist of the proper aux spool, the return spring, one spring
seat on either end of the spring, the seal plate, a spool seal, and a dust wiper. AII of these are
assembled on the end of the spool opposite the clevis.
® lnsert the clevis end of the spool into the right-hand side of the spool bore (the tallest end of the
housing). Place the spool cap over the spool and spring assembly and connect the cap to the
housing using two bolts. Torque both bolts alternatively until a torque of 1.0-1.5 kgf • m (7.2-10.8
lbf • ft) is reached on both bolts.
@ Instan the second spool seal and dust wiper over the clevis end of the spool and retain with a
seal plate and two bolts. Torque both bolts altematively until a torque of 1.0-1.5 kgf . m(7.2-10.8
lbf • ft) is reached on both bolts.
© Toe load check assembly is inserted into the top center cavity. Torque to 3.5-4.0 kgf . m (25.3-30
lbf · ft}.
(7) Outlet section
CD Instan the secondary main relief valve into the cavity on the clevis end of the housing.
Torque to 4.5-5.0 kgf · m (32.5-36.2 lbf • ft)

6-26
2) OISASSEMBLY
(1) General
(D Subassemblies (such as relief valves, check valves, and spools) may be removed wlthout having
to loosen the tie rods and disassembling the entire valve.
@ Disassemble the valve sections on a flat working surface.
@ Ensure that the disassembly area will be clean and free of contamination.
© Keep the disassembly area neat to avoid loss or damage of parts.

(2) Oisassembly
(D Loosen the tie rod nuts and remove the tie rods from the valve sections.
@ Remove 0-rings between valve sections and set aside to avoid damage.
@ Spools, relief valves, load check valves, lift lock poppet, solenoid valves, and plugs can all be
removed from the valve sections. Refer to the associated assembly procedures, above, for
specific torque and handling details. lnspect and repair or replace the assemblies as complete
unlts, as may be necessary.
© Valve components are precision ltems, and care must be taken when handing them to avoid
damage or the introduction of contamination that could adversely affect performance.

6-27
3. MAIN CONTROL VALVE

Solenoid valve for lift

Uft section block

/

Solenoid valve for tilt

Tilt section block

Reach & auxiliary section block

11 pin

Adapter ~
\)

15BT9HS34

1) ASSEMBLY INSTRUCTION
(1) General
CD Ensure that the assembly area will be clean and free of contamination.
@ Use a flat (within 0.5 mm} work surface when belting the valve sections together.
® Use calibrated torque wrenches and instrumentation.

(2) Block subassembly

CD Attach all the 0-rings to the appropriate grooves between the spool sections.
@ Stack the valve sections as below picture on a flat surface.
® lnsert all the tie rods through the drilled holes in each of the housings. ~

© Press the sections together being careful not to damage sealing surfaces or seals.
@ lnstall nuts to tie rods and progressively torque in a circular pattern until reaching a torque ol
2.3 kgf •cm2 (23 Nm) on all tie rods.

6-28
(3) Lift block solenoid assembly
(j) The solenoide is installed upper side and below side cav~ies in lift block. Torque to 4.1 kgf · cm2
® (40 Nm)
@ Instan the O-ring, coil, O-ring and washer to the assemblied cartridge.
lnsert the lock washer to the groove of the cartridge.
(4) Tilt & Auxiliary section assembly
(j) The solenoid is instaned upper side and below side in tilt & auxiliary block with bolts.
Torque to 1 kgf · m(10 Nm)
® Instan the coil, 0-ring and washer to the assemblied cartridge.
@ lnsert the snap ring to the groove of the cartridge.
© lnsert the roll pin to the pin hole on the front side of each block.
@ Place the 0-rings in the O-ring grooves.
@ lnsert the ancillary blocks to the each bocly with bolts.

2) DISASSEMBLY INSTRUCTION
(1) General
(j) Disassemble the valve sections on a flat working surface.
® Ensure that the disassembly area will be clean and free of contamination.
@ Keep the disassembly area neat to avoid loss or damage of parts.

(2) Perform the assembly in reverse arder

Q) Remove the solenoid valves and ancillary blocks from the main blocks.
® Loosen the tie-rods from the valve section.
@ Remove the seals between valve section.
© Valve components are precision items, and care must be taken when handing them to avoid
damage or the introcluction of contamination that could adversely affect performance.

6-29
4. LIFT CYLINDER
1) STRUCTURE

9-©
8

10
1
~ -6 p
e
11- - c )

13-{3 9----3
~ - 5

,2---8 ~ -4

LJ
C~P
Down control valva

,.--U
o A

,-~-=-~1
1 1 1
B

1 - 1 1
1 - 1 1

2 A1 :::: 1 B
L ___ _J

□
Down safaty valva

15- - c )
7-(0

2297HS26

1 Tubeassy 6 Wear ring 11 O-ring

2 Rod assy 7 Retaining ring 12 Guide
3 Piston 8 Gland 13 Du bushing
4 Piston seal 9 Dust wiper 14 Spacer
5 Backup ring 10 Rod seal 15 O-ring

6-30
2) DISASSEMBLY
(1) Hold the cylindertube in a vice, loosen the 11, Guide
cylinder head and remove lt.
Remove the spacer from the cylinder tube
and knock out the bushing. Hook a
wrench in the hole in the retainer at the
piston end and tum. Lever up the edge ot
the guide, then turn the guide in again and
the guide can be removed. D35ACO168

3) CHECK AND INSPECTION mm (in)

Checkitem Standard size Repair limit Remedy

Clearance between 0.072-0.288 0.5 Replace

cylilder rod &bushing (0.003-0.011) (0.020) bushing

Clearance between 0.05-0.030 0.5 Replace

piston ring &tube (0.002- 0.012) (0.020) piston ring

4) ASSEMBLY
(1) Soak the pisten ring in hydraulic oil at a
temperature of 40 to so·c, expand the
inside diameter and assemble on the
piston. 1nstall a piston seal.
Bend the edge of the guide and rotate it to
instan the guide completely.

035AC0169

6-31
5. TILT CYLINDER
1) STRUCTURE

15~

10 11~ ~
\ j\\J
16 17iJ~
22 13
a
12~
~~
\J
21 20

~
19/

2287HS23

1 Tubeassy 9 Du bushing 17 Lockwasher

2 Rod 10 Rod seal 18 Rod eye
3 Piston 11 Back up ring 19 Spherical bearing
4 Piston seal 12 Dustwiper 20 Hexagon bolt
5 Wearring 13 Snap ring 21 Spring washer
6 O-ring 14 O-ring 22 Hexagon nut
7 Nylon nut 15 Back up ring 23 Grease nipple
8 Gland 16 O-ring 24 O-ring (seal lock type)

6-32
2) DISASSEMBLY

(1) Hold the parallel parts of the cylinder tube

bottom in a vice and mark the rod head
end to show how much it is screwed in
'
then remove the rod head. Next, hook a
wrench into the notch at the cylinder head
and remove the cylinder head from
cylinder tube.
When doing this, wind tape round the
0255HS28
threaded part of the rod and be careful
not to damage the dust seal and rod seal
inside cylinder head.

3) CHECK AND INSPECTION mm (in)

Check item Standard size Repairlimit Remedy

Clearance between 0.072-0.288 0.5
Replace bushing
cylinder rod &bushing (0.003-0.011) (0.020)
Clearance between rod 0.10-0.35 0.6
Replace bushing
head bushing &pin (0.004-0.014) (0.024)

6-33
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CA:,,,L
_'-"S_-Y"_S
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M

G"'-" 1 Coo'()Ol'lerile<:eoon 7·1

GrouP 2Se::tricalcircul------ ---H
G~ 3 ElectliCC01T9CJlen1's>•· 7-3
@@P t COMPONENT LOCA~~~TION 7 ELECTRICAL SYSTE~

24 23 222120

yJ
1/
'ir--19
- - - - - - -.....
-~
11 ,·,·
.J•.

/ 1 1
, 1.. l
.;¿_' ,J.'.
'"'e,;.'\
,~ 18
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22998.02

1 Combination switch 10 Pump controller 19 Beacon lamp switch (opt)

2 Parking micro switch 11 Traction controller 20 Head lamp swttch (opt)
3 Accelerator assy 12 SBR switch assy 21 Working lamp swttch (opt)
4 Fan assy 13 Fan assy 22 Beacon swttch (opt)
5 High hom 14 Contactor 23 Socket assy
6 Orive motor 15 Back up alarm 24 Emergency swttch assy
7 E/M contactor 16 Rasher untt assy 25 Display
8 Fuse box assy 17 Relay 26 DC-DC converter
9 Pumpmotor 18 Working lamp (opt)

7-1