Staging Cylinder, Three Stage Mast
Contents
1. Install piston 14 on rod 24 Install nut 11 on cylinder rod 24 Torque cylinder piston nut to 60 65 ft lb 81 88 Nem Apply clean hydraulic fluid to piston rod assembly Coat inside of cylinder tube 9 and gland assembly with clean fluid Carefully slide gland assembly onto piston cylinder rod 24 Be sure rod end does not cut or nick wiper 23 and seal 22 upon installation Install piston and rod into cylinder tube 9 Be careful not to nick or cut piston seals on the edge of cylinder tube or when sliding over groove within tube Install gland assembly into cylinder tube 9 Use care not to nick or cut seals are upon installation Install retainer 10 Check installation by making sure piston rod assembly moves fairly easy within tube assembly without binding Install bearing 20 If removed install roller bearing and clevis assembly Master Service Manual 2000 08 04 KOMATSU F code Section C code PS 6 9 6660 Tilt Cylinder Assembly FR23S 2A FR15DR 2A Version no T code 001 396 397 5 Installation 1 GE ANE A Install tilt cylinder on carriage reach front frame Secure with mounting pin 5 with roll pin 6 Properly connect correct hydraulic hoses to the top and bottom of tilt cylinder Remove blocking and chains Fill hydraulic reservoir with new clean oil Connect battery connector to the truck Operate tilt to remove air from hydraulic hoses and check operation of the whol2. F code Section C code 6 9 6660 Tilt Cylinder Assembly FR23S 2A FR15DR 2A Version no T code 001 396 397 1 Removal 1 Park the truck on a level surface and apply the brake Raise reach approximately 12 inches 304 mm and block so reach will not lower Pivot carriage upward and block to prevent carriage reach from lowering Turn key switch to OFF and disconnect battery connector from the truck Relieve pressure on tilt cylinder Remove hydraulic hoses from tilt cylinder and mark their position Remove roll pin 6 and top mounting pin 5 Remove tilt cylinder from truck Repeat procedure on other side of truck as needed Master Service Manual 2000 08 04 497 F code Section C code PS S6 9 6660 Tilt Cylinder Assembly FR23S 2A FR15DR 2A Version no T code 001 396 397 2 Disassembly 1 Before disassembly clean exterior of tilt cylinder in a cleaning solution to remove all contamination 2 Be sure all hydraulic fluid has been removed from cylinder Stroking the piston rod will help force fluid out 3 Put base end of cylinder in a vise equipped with soft jaws 4 If necessary remove roller bearing 3 at base of cylinder rod 24 Remove roll pin 1 and slide mounting pin 4 from clevis 26 5 Remove retainer 10 by rotating gland with a spanner wrench from cylinder tube 9 6 Remove gland assembly seals rings rod and piston and piston seals 7 Remove and discard
3. Install retainer 3 and secure with four cap screws 4 3 Properly connect correct hydraulic hoses to front and rear of tilt cylinder 4 Remove blocking and chains 5 Fill hydraulic reservoir with new clean oil 6 Connect battery connector to the truck 7 Operate tilt to remove air from hydraulic hoses and check operation of whole hydraulic system 8 After running the hydraulic system check and fill hydraulic reservoir with more new clean oil 494 Master Service Manual 2000 08 04 F code Section C code PS S6 9 6660 K Tilt Cylinder Assembly FR23S 2A FR15DR 2A Version no T code 001 396 397 Tilt Cylinder Assembly FR23S 2A FR15DR 2A Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 495 F code Section C code PS 6 9 6660 Tilt Cylinder Assembly FR23S 2A FR15DR 2A Version no T code 001 396 397 Item es Item ZEN Item EH No Description No Description No Description SE ee E 3 1 Pin roll 10 Retainer 19 Ring sealing 2 Washer 11 Nut lock 20 Bearing 3 Bearing 12 Washer flat 21 Ring guide F7 4 Pin 13 Ring guide 22 Seal rod 5 ES 14 Piston 23 Wiper rod 6 Pin roll 15 O ring 24 Rod cylinder H gt e 7 Tilt cylinder 16 Ring sealing 25 Nut assembly 8 Bearing 17 O ring 26 Clevis 9 Tube cylinder 18 O ring 496 Master Service Manual 2000 08 04 KOMATSU Komatsu Forklift U S A Inc
4. Ring guide 15K Wiper 8 Piston K Kit Seal items marked with K The lift cylinders are the positive displacement type meaning there are NO seals on the lower end of the cylinder rod The lift cylinder can be resealed without removing from the truck 478 Master Service Manual 2000 08 04 F code Section C code PS 6 6 6620 K Freelift Cylinder Three Stage Mast Version no T code 001 395 396 397 398 399 1 Removal 1 Park the truck on a level surface and apply the brake 2 Fully extend cylinder to inspect rod 9 for gouges or pits If gouges or pits are detected cylinder must be removed for repair 3 Lift carriage reach and securely block 4 Lower cylinder so chains hoses and electric cables are loose 5 Turn key switch to OFF and disconnect battery connector from the truck 6 Remove chains hoses and electric cables from the crosshead 7 Remove crosshead from cylinder rod 8 Clean the exterior of the lift cylinder Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 479 F code Section C code PS S6 6 6620 Freelift Cylinder Three Stage Mast Version no T code 001 395 396 397 398 399 480 2 Disassembly 1 Remove bearing 12 from the cylinder tube 3 2 Remove and discard seal 14 back up ring 11 O ring 10 rod wiper 15 and ring guide 13 from bearing 12 Use care NOT to damage the inside of the bearing 12 3 A
5. the cylinder tube 2 Remove and discard rod wiper 16 seal 15 wear ring 9 and O ring 13 from the bearing 14 Discard seal 15 Use care NOT to damage the inside of the bearing 3 Assembly 1 Install new bearing 14 seal 15 wear ring 9 O ring 13 and rod wiper 16 2 The lip of the wiper must face outward 3 It is not necessary to replace wear ring 9 unless the cylinder was removed for rod repair 4 Installation 1 Install bearing in the cylinder tube 2 Raise cylinder rods hydraulically 3 Install bolts in the top end of the staging cylinder 4 Connect battery connector to the truck 5 Test for proper operation O Komatsu Forklift U S A Inc Master Service Manual 2002 01 15 475 F code Section C code PS S6 6 6620 K Freelift Cylinder Three Stage Mast Version no 001 T code 395 396 397 398 399 Freelift Cylinder Three Stage Mast e gal T 5 oh CO CH LC Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 477 F code Section C code PS S6 6 6620 Freelift Cylinder Three Stage Mast Version no T code 001 395 396 397 398 399 Item SR Item be No Description No Description S 1 Washer seal 9 Rod cylinder 2 Screw 10K O ring 3 Tube cylinder 11K Ring back up 4 Ring retainer 12 Bearing 5 Plunger assembly 13K Ring guide E Spring 14K Seal Sen e 7K
6. ATSU Tilt Cylinder Assembly FR18S 2A Version no T code 002 395 398 399 2 Disassembly 1 Before disassembly clean exterior of tilt cylinder 1 in a cleaning solution to remove all contamination 2 Be sure all hydraulic fluid has been removed from cylinder Stroking piston rod will help force fluid out 3 Put trunnion of cylinder in a vise equipped with soft jaws 4 Remove bearing retainer 13 from cylinder tube 5 Remove bearing assembly seal 6 back up ring 8 cylinder rod 10 and piston seals 6 Remove and discard all seals 6 O rings 9 and 11 back up rings 8 and 12 and rod wiper 5 7 Inspect mounting bushings 2 located at both ends of cylinder Do not remove bushings unless found to be unfit for further service O Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 491 F code Section C code PS 6 8 6660 Tilt Cylinder Assembly FR18S 2A Version no T code 002 395 398 399 3 Inspection 1 Carefully clean all parts in a cleaning solution and position on a clean work surface 2 Check cylinder rod 10 for damage Look for gouges scratches corrosion or evidence of unusual wear Minor surface damage can be repaired by the use of fine abrasion cloth or stoning Be extremely careful not to remove the chrome plating Deeper damage will require replacement of piston rod assembly Make sure threads on rod are free of damage 3 Check cylinder bore for any damage Part
7. F code Section C code PS 6 5 6610 KOMATSU Staging Cylinder Three Stage Mast Version no T code 001 395 396 397 398 399 Staging Cylinder Three Stage Mast Item No Description Item No Description Screw 9 ee 2 Washer seal 7 S 10 Piston 3 Cylinder tube 1 port i 11 Ring retainer 4 Cylinder tube 2 ports 12 Rod cylinder 5 Plugger assembly a 13 Oring mile Pr 6 Spring 14 Bearing 7 Plug ds ae 15 Seal rod Pg O ring SE 16 Wiper Komatsu Forklift U S A Inc Master Service Manual 2002 01 15 473 F code Section C code 6 5 6610 Staging Cylinder Three Stage Mast Version no T code 001 395 396 397 398 399 1 Bearing Removal 1 Park the truck on a level surface and apply the brake 2 Fully extend the cylinders to inspect rod 12 for gouges or pits If gouges or pits are detected remove cylinder for repair 3 Lift mast so inner column is raised approximately 12 inches 305 mm Securely block mast 4 Remove bolts from top end of staging cylinder rods Lower cylinder rods hydraulically 5 Turn key switch to OFF and disconnect battery connector from the truck 6 Clean the exterior of the lift cylinder 474 Master Service Manual 2002 01 15 F code Section C code S6 5 5000 KOMATSU Staging Cylinder Three Stage Mast Version no T code 001 395 396 397 398 399 2 Disassembly 1 Remove bearing 14 from
8. all seals and rod wiper 23 8 Inspect mounting bearing 8 located at base end of cylinder tube 9 Do not remove bearing unless found to be unfit for further service 498 Master Service Manual 2000 08 04 F code Section C code 6 9 6660 KOMATSU Tilt Cylinder Assembly FR23S 2A FR15DR 2A Version no T code 001 396 397 3 Inspection Carefully clean all parts in a cleaning solution and position on a clean work surface 2 Check piston rod 24 for damage Look for gouges scratches corrosion or evidence of unusual wear Minor surface damage can be repaired by use of fine abrasion cloth or stoning Be extremely careful not to remove the chrome plating Deeper damage will require replacement of piston rod assembly Make sure threads on rod are free of damage 3 Check cylinder bore for any damage Parts with deep gouges or pitted surfaces will require replacement 4 Check threaded section of cylinder tube 9 to be sure threads have not been damaged Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 499 F code PS Section 6 9 C code 6660 Tilt Cylinder Assembly FR23S 2A FR15DR 2A Version no 001 500 T code 396 397 4 Assembly 1 10 11 12 Install new guide ring 21 seal 22 and rod wiper 23 in gland assembly The lip of the wiper must face outward Install new piston seals 15 and 17 guide ring 13 and sealing ring 16 on piston 14
9. cated at base end of the cylinders Do not remove bearing unless found to be unfit for further service 484 Master Service Manual 2000 08 04 F code Section C code S6 7 6650 KOMATSU Reach Cylinder Assembly Version no T code 002 395 396 397 3 Inspection Carefully clean all parts in a cleaning solution and position them on a clean work surface 2 Check piston rod for damage Look for gouges scratches corrosion or evidence of unusual wear Minor surface damage can be repaired by use of fine abrasion cloth or stoning Be extremely careful to not remove chrome plating Deeper damage will require replacement of rod assembly Make sure the threads on the rod are free of damage 3 Check cylinder bore for any damage Parts with deep gouges or pitted surfaces will require replacement 4 Check threaded section of cylinder tube to be sure threads have not been damaged Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 485 F code PS Reach Cylinder Assembly Version no 002 486 Section S6 7 T code 395 396 397 C code 6650 4 Assembly 1 Install new O ring 7 back up ring 8 ring guide 10 seal 11 and rod wiper 12 in bearing assembly 9 The lip of the wiper must face outward Install new ring guide 20 back up rings 17 and 8 on piston 19 Apply clean hydraulic fluid to rod cylinder 13 Coat inside of cylinder tube and bearing assembly w
10. e hydraulic system 7 After running the hydraulic system check and fill hydraulic reservoir with new clean oil Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 501
11. ith clean fluid Carefully slide spacer 16 if used and bearing assembly 9 onto cylinder rod Be sure rod end does not cut or nick wiper upon installation Install cylinder assembly consisting of the rod 13 piston 19 and lock nut 21 into cylinder tube 23 or 24 Be careful not to nick or cut piston seals on the edge of cylinder tube or when sliding over groove within tube Torque cylinder piston lock nut 21 to 47 94 ft lb 65 Nem Install bearing assembly into cylinder tube Use care not to nick or cut seals upon installation Install retainer 22 Check installation by making sure piston rod assembly moves smoothly within tube assembly without binding Install bearing 25 Master Service Manual 2000 08 04 KOMATSU F code Section C code PS S6 7 6650 Reach Cylinder Assembly Version no T code 002 395 396 397 5 Installation 1 N O a P Connect battery connector to the truck Turn key switch to ON Raise reach to full freelift height Install reach cylinder rear cylinder mounting pins 5 Secure mounting pins with roll pins 3 Lower reach assembly Install reach cylinder front mounting pins 4 Secure mounting pins with roll pins 3 Connect correct hydraulic hoses to reach cylinders Remove blocking and chains Fill hydraulic reservoir with new clean oil Operate reach to remove air from hydraulic hoses and check operation of the whole hydraulic system 8 After running the h
12. ode PS S6 7 6650 Reach Cylinder Assembly Version no T code 002 395 396 397 1 Removal 1 Park the truck on a level surface and apply the brake Extend the reach about 1 2 3 4 of the total reach Block and chain the reach mechanism to prevent movement of the reach mechanism Relieve pressure on the reach cylinders Remove hoses from the reach cylinder Remove roll pins 3 Remove front mounting pins 4 Raise reach assembly above full freelift Remove roll pins 3 Remove rear cylinder mounting pins 5 Remove reach cylinder from truck Turn key switch to OFF Disconnect battery connector from the truck Master Service Manual 2000 08 04 483 F code Section C code PS S6 7 6650 Reach Cylinder Assembly Version no T code 002 395 396 397 2 Disassembly 1 Before disassembly clean exterior of the reach cylinder in a cleaning solution to remove all contamination 2 Be sure all hydraulic fluid has been removed from the cylinder Stroking the piston rod will help force fluid out 3 Put base end of cylinder in a vise equipped with soft jaws 4 Remove bearing retainer 22 and bearing 9 by rotating bearing with a spanner wrench from cylinder tube 23 or 24 5 Remove bearing assembly seal 11 rings 8 and 17 and cylinder assembly consisting of the rod 13 piston 19 and lock nut 21 Discard seal 11 6 Remove and discard rod wiper 12 7 Inspect mounting bearing 25 lo
13. s with deep gouges or pitted surfaces will require replacement 4 Check threaded section of cylinder tube to be sure threads have not been damaged 492 Master Service Manual 2000 08 04 KOMATSU Komatsu Forklift U S A Inc F code Section C code S6 8 6660 Tilt Cylinder Assembly FR18S 2A Version no T code 002 395 398 399 4 Assembly 1 Install new seals 6 O ring 9 backup ring 8 and rod wiper 5 in bearing assembly The lip of the wiper must face outward Install new O ring 11 and back up ring 12 on cylinder rod 10 Apply clean hydraulic fluid to cylinder rod assembly Coat the inside of the cylinder barrel and bearing assembly with clean fluid Carefully slide bearing assembly on cylinder rod Be sure rod end does not cut or nick wiper 5 and seal 6 upon installation Install rod into cylinder barrel Be careful not to nick or cut piston seals on the edge of cylinder barrel or when sliding over groove within barrel Install bearing assembly into cylinder barrel Use care not to nick or cut seals upon installation Check installation by making sure cylinder rod assembly moves fairly easy within barrel assembly without binding Install bearing fastening ring and retainer Master Service Manual 2000 08 04 493 F code Section C code S6 8 6660 Tilt Cylinder Assembly FR18S 2A Version no T code 002 395 398 399 5 Installation 1 Install cylinder on reach front frame 2
14. ssembly 1 Install new back up ring 11 O ring 10 seal 14 rod wiper 15 and guide ring 13 2 The lip of the wiper must face outward 4 Installation 1 Install crosshead chains hoses and electric cables 2 Connect battery connector to the truck 3 Test for proper operation Master Service Manual 2000 08 04 F code Section C code PS S6 7 6650 K Reach Cylinder Assembly Version no T code 002 395 396 397 Reach Cylinder Assembly PE db m DI Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 481 F code Section C code PS S6 7 6650 Reach Cylinder Assembly Version no T code 002 395 396 397 Item Se Item E Item Or No Description No Description No Description 2 Ss 1 Reach cylinder 10K Ring guide 19Q Piston assembly right F was PRE 7 2 Reach cylinder 11K Seal 20K Ring guide assembly left 3 Pin roll 12K Wiper 21Q Nut lock 4 Pin clevis 13Q Rod cylinder 22K Retainer 5 Pin clevis 14 Nut 23 Tube cylinder right 6 Fitting grease 15 Clevis 24 Tube cylinder left 7K Oring 16 Spacer 25 Bearing 8K Ring backup 17K Ring backup K Kit seal Items marked with K 9 Bearing 18K O ring Kit rod assembly items marked with Q 482 Master Service Manual 2000 08 04 KOMATSU Komatsu Forklift U S A Inc F code Section C c
15. ydraulic system check and fill hydraulic reservoir with new clean oil Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 487 KOMATSU F code Section C code PS 6 8 6660 Tilt Cylinder Assembly FR18S 2A Version no T code 002 395 398 399 Tilt Cylinder Assembly FR18S 2A 5 ba 7 Ne Description eet Description Description j 1 To cylinder assembly 6 Seal O Ring 2 Bushing EE 7 Bearing cylinder Ring back up 3 Retainer cylinder WI 8 Ring back up 13 Retainer 4 Screw cap 9 ORing 14 Tube cylinder 5 Wiper 10 Rod cylinder IT Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 489 F code Section C code PS 6 8 6660 Tilt Cylinder Assembly FR18S 2A Version no T code 002 395 398 399 490 1 Removal 1 Master Service Manual Park the truck on a level surface and apply the brake Raise reach approximately 12 inches 305 mm and block so reach will not lower Pivot carriage upward and block to prevent carriage reach from lowering Turn key switch to OFF Disconnect battery connector from the truck Relieve pressure on tilt cylinder assembly 1 Remove retainer 3 and cap screws 4 securing cylinder to carriage reach Remove hydraulic hoses from tilt cylinder assembly 1 Remove tilt cylinder assembly 1 from the truck 2000 08 04 F code Section C code PS S6 8 6660 KOM
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