CONTENTS
SECTION 1 GENERAL
Group 1 Safety hints 1-1
Group 2 Specifications 1-5
Group 3 Periodic replacement 1-13
SECTION 2 REMOVAL AND INSTALLATION OF UNIT
Group 1 Structure 2-1
Group 2 Removal and Installation of Unit 2-2
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and operation 3-1
Group 2 Troubleshooting 3-24
Group 3 Disassembly and assembly 3-28
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function 4-1
Group 2 Operational checks and troubleshooting 4-15
Group 3 Tests and adjustments 4-18
SECTION 5 STEERING SYSTEM
Group 1 Structure and function 5-1
Group 2 Operational checks and troubleshooting 5-11
Group 3 Disassembly and assembly 5-13
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function 6-1
Group 2 Operational checks and troubleshooting 6-15
Group 3 Disassembly and assembly 6-19
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location 7-1
Group 2 Electrical circuit 7-2
Group 3 Component specification 7-11
Group 4 Connector destination 7-12
Group 5 Troubleshooting 7-14
SECTION 8 MAST
Group 1 Structure 8-1
Group 2 Operational checks and troubleshooting 8-5
Group 3 Adjustment 8-8
Group 4 Removal and installation 8-9
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function 6-1
Group 2 Operational checks and troubleshooting 6-15
Group 3 Disassembly and assembly 6-19
SECTION 6 HYDRAULIC SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. HYDRAULIC CIRCUIT
D503HS01
1 Hydraulic gear pump 8 Tilt cylinder
2 Flow regulator 9 Lift cylinder
3 Priority valve 10 Suction filter
4 Main control valve 11 Return filter
5 Steering unit 12 Down control valve
6 Brake valve 13 Down safety valve
7 Steering cylinder 14 Hydraulic tank
6-1
1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION
D503HS02
When the lift control lever is pulled back, the spool on the first block is moves to lift position.
The oil from hydraulic gear pump(1) flows into main control valve(4) and then goes to the large
chamber of lift cylinder(9) by pushing the load check valve of the spool.
The oil from the small chamber of lift cylinder(9) returns to hydraulic oil tank(14) at the same time.
When this happens, the forks go up.
6-2
2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION
D503HS03
When the lift control is pushed forward, the spool on the first block is moved to lower position.
The work port(B1) and the small chamber and the large chamber are connected to the return
passage, so the lift will be lowered due to its own weight.
6-3
3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION
D503HS04
When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward
position.
The oil from hydraulic gear pump(1) flows into main control valve(4) and then goes to the large
chamber of tilt cylinder(8) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder(8) returns to hydraulic tank(14) at the same time.
When this happens, the mast tilt forward.
6-4
4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION
D503HS05
When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward
position.
The oil from hydraulic gear pump(1) flows into main control valve(4) and then goes to the small
chamber of tilt cylinder(8) by pushing the load check valve of spool.
The oil at the large chamber of tilt cylinder(8) returns to hydraulic tank(14) at the same time.
When this happens, the mast tilt backward.
6-5
2. HYDRAULIC GEAR PUMP
1) STRUCTURE
D503HS06
1 Retaining ring 7 Drive gear 12 Nut
2 Seal retainer 8 Driven gear 13 Stud bolt
3 Seal gland 9 Wear plate 14 Front cover kit
4 Inner shaft seal 10 Center section 15 Rear cover kit
5 Outer shaft seal 11 Lock washer 16 Coupling kit
6 O-ring seal
6-6
3. MAIN CONTROL VALVE
1) STRUCTURE (3 Spool)
Port name Size
Inlet port 1-5/16-12UN
Outlet port 1-5/16-12UN
Gauge port PF1/4
Work port 1-1/16-12UN
D353HS07
1 Special nut 15 Screw 29 Spool housing
2 O-ring 16 Wiper 30 Spool housing
3 Plug 17 O-ring 31 Spool housing
4 O-ring 18 Spring seat 32 Outlet housing
5 O-ring 19 Spring 33 Puppet
6 Plug 20 Spool end 34 Tie rod
7 Spool cap 21 Spring 35 Tie rod
8 Seal plate 22 Spool 36 Special nut
9 Spring seat 23 Main relief valve 37 Inlet section assy
10 Spool end 24 Spool 38 Outlet section assy
11 Spring 25 Piston 39 Spool section assy
12 O-ring 26 Spool 40 Spool section assy
13 Cap screw 27 O-ring 41 Spool section assy
14 Plug 28 Inlet housing
6-7
2) LIFT SECTION OPERATION
(1) Lift position
Load check valve(1)
SECTION A-A
B1
A A
D353HS08
When the lift control lever is pulled back, the spool moves to the right and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into lift cylinder
port(B1).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off
of the neutral passage.
The return oil from cylinder flows into the tank.
6-8
(2) Lower position
D353HS09
When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is
closed.
The spool moves to the lift lower position, opening up the neutral passage to tank and (B1)
6-9
3) TILT SECTION OPERATION
(1) Tilt forward position
D353HS10
When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into tilt cylinder
port(A2).
The pump pressure reaches proportionally the load of cylinders and fine control finished by closing
the neutral passage.
The return oil from cylinder port(B2) flows into the tank through the hole of the tilt lock spool.
6-10
(2) Tilt backward position
D353HS11
When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flows into tilt cylinder
port(B2). The pump pressure reaches proportionally the load of cylinder and fine control finished by
shut off of the neutral passage.
The return oil from cylinder port(A2) flows into the tank via the low pressure passage.
6-11
4) MAIN RELIEF VALVE
(1) Pressure setting
A good pressure gauge must be installed in
the line which is in communication with the
work port relief. A load must be applied in a
manner to reach the set pressure of the relief
unit.
Procedure
Loosen lock nut.
Set adjusting nut to desired pressure
setting.
If desired pressure setting cannot be
achieved, add or remove shims as required.
Tighten lock nut.
Retest in similar manner as above.
The oil pressure in the high pressure port
HP has reached the setting of the pilot
puppet spring force and unseats the pilot
puppet E and oil flows around the puppet
through the cross drilled holes and to the
low pressure area LP.
6-12
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The loss of oil behind puppet C, effected by
the opening of pilot puppet E, causes
puppet C to move back and seat against
pilot puppet E. This shuts off the oil flow to
the area behind relief valve puppet D, and
causes a low pressure area internally.
D353HS20
The imbalance of pressure on the inside as
compared to that of the high pressure port
HP, forces the relief valve puppet D to open
and relieve the oil directly to the low
pressure chamber LP in the valve.
D353HS21
As anti void
The anti-void unit supplies oil to the high
K G
pressure port HP when cavitation has
occurred. A lower pressure exists in the A
port HP compared to the low pressure
chamber LP. The difference between the HP
effective area of diameter A and G causes
imbalance of the check valve puppet K
which unseats, thus allowing oil from the low
pressure chamber LP to enter the port HP 7406S6-28(1)
and fill the void.
6-13
4. LIFT CYLINDER
D503HS12
1 Tube assy 7 O-ring 12 Wear ring
2 Rod 8 O-ring 13 Retaining ring
3 Gland 9 Piston 14 Spacer
4 DU bushing 10 Piston seal 15 O-ring
5 Rod seal 11 Back up ring 16 Spacer
6 Dust wiper
5. TILT CYLINDER
D503HS13
1 Tube assy 9 O-ring 17 Rod eye
2 Rod 10 Back up ring 18 Hexagon bolt
3 Gland 11 O-ring 19 Hexagon nut
4 DU bushing 12 Piston 20 Spring washer
5 Rod seal 13 O-ring 21 DU bushing
6 Back up ring 14 Glyd ring 22 DU bushing
7 Dust wiper 15 Wear ring 23 Tilt cylinder spacer
8 Snap ring 16 Nylon nut 24 O-ring
6-14
