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CHAPTER 10 HYDRAULIC SYSTEM

Chapter 10 HYDRAULIC SYSTEM


1. Specifications

Item Specifications
Type Gear type tandem pump
Manufacturer Shimadzu Corporation
Gear pump Maker model FD3-5214A1S1-R369
Control flow rate 115 L (42.27 US gal.)/2300 min-1
Drive method Directly coupled to torque converter
Type MSV08
Manufacturer SHIMAZU CORPORATION

Control valve Main relief


19.1 MPa (194.77 kgf/cm²) [2770.23 psi]
pressure
Priority relief
12.3 MPa (125.43 kgf/cm²) [1784.0 psi]
pressure
Model Variable
Flow regulator valve
Control flow rate 150 ± 12 L (39.63 ± 3.17 US gal.)/min
Inner diameter 80 mm (3.15 in.)
Lift cylinder
Stroke 1650 mm (64.96 in.)
Inner diameter 90 mm (3.54 in.)
Tilt cylinder
Stroke 229 mm (9.02 in.)
Working fluid quantity N level: 105 L (27.74 US gal.)

10-1
CHAPTER 10 HYDRAULIC SYSTEM
2. Structure
2.1 Hydraulic Line

2
3 4 2

14
16 15

13
12 11
10
9
8 5

7
6
17 609874

1. Tilt cylinder 10. Emergency valve


2. Lift cylinder 11. Tilt plunger
3. Down safety valve 12. Priority valve
4. Flow regulator valve 13. Main relief valve
5. Hydraulic tank 14. Lift plunger
6. Return filter 15. Relief valve
7. Suction strainer 16. Steering control valve
8. No.1 pump 17. Power cylinder
9. No.2 pump

Note: Also for steering control valve and power cylinder, see Chapter "STEERING SYSTEM".

10-2
CHAPTER 10 HYDRAULIC SYSTEM
2.2 Hydraulic Tank

2
4 3
1

1)

2)

7 5
609410
1. Cap 6. Suction strainer
2. Air breather 7. Return filter
3. Strainer 1) To hydraulic pump
4. Oil level gauge 2) From control valve
5. Drain plug

The hydraulic tank is located in the middle of right side frame, welded to the steel frame structure to form an integrated part.
The return oil from the lift cylinder will be merged to the return oil from the control valve and returns to the hydraulic tank
through the return filter.

10-3
CHAPTER 10 HYDRAULIC SYSTEM
2.3 Gear Pump

19 23 1 6 3 2 5 7 11 8 9 12 11 13 23 21

25 24 17 14, 16 4 6 17 20 15 10 11 18 15
22 18 12
609411
1. Front cover 14. Backup strip
2. Body 15. Backup strip, Gasket
3. Drive gear 16. Gasket
4. Driven gear 17. O-ring
5. Bearing 18. O-ring
6. Side plate 19. Bolt
7. Adapter plate 20. Bolt
8. Body 21. Bolt
9. Drive gear 22. Washer
10. Driven gear 23. Washer
11. Bearing 24. Oil seal
12. Side plate 25. Snapring
13. Rear cover

The gear pump is an outer gear pump which supplies hydraulic oil to activate hydraulic cylinders. In addition, this gear pump
has tandem pump configuration comprising of 1st and 2nd gear pumps.

10-4
CHAPTER 10 HYDRAULIC SYSTEM
2.4 Control Valve

2 3 4 5 6

5)

1
1) 2) 3)

4)

7
9
8

609412
1. Priority valve 1) T2: From steering control valve
2. Main relief valve 2) P2: From 2nd pump
3. Unload solenoid valve 3) PF: To steering control valve
4. Lift valve 4) P1: From 1st pump
5. Tilt valve 5) T1: To reserve tank
6. Attachment valve (option)
7. End cover
8. Lift look solenoid valve
9. Priority valve, Relief valve

The priority valve distributes a certain amount of hydraulic oil which is required to operate the power steering system to the
system and remaining oil to other systems for loading, regardless of amount of hydraulic oil supplied from No.1 gear pump.
The remaining oil from No. 1 pump and hydraulic oil from No. 2 gear pump are merged and used to operate loading actuators
such as lift cylinder and tilt cylinder. A tilt lock valve is incorporated in the system as a safety device in order to prevent the mast
from leaning forward when the tilt lever is unintentionally operated while the engine is not running.

10-5
CHAPTER 10 HYDRAULIC SYSTEM

Inlet section

4 5

1
7

609790
1. Tank oil passage 5. PF port
2. Main relief valve 6. MF oil passage
3. FD spool 7. PF relief valve
4. P1 port

10-6
CHAPTER 10 HYDRAULIC SYSTEM

Solenoid section

3 4 5 6

2 SB1

1
8 7

609285
1. Lift look solenoid valve 5. MF oil passage
2. Lift lock control oil passage 6. Unload poppet
3. Lift down oil passage 1 7. Unload solenoid valve
4. Lift down oil passage 2 8. Tank oil passage

10-7
CHAPTER 10 HYDRAULIC SYSTEM

Lift valve assembly

5 6

4 7

8
3
9

2 10

1 11

609286
1. Lift down oil passage 1 7. Emergency valve
2. Spring 8. Load check valve
3. Lift lock control oil passage 9. Parallel oil passage
4. Lift lock poppet 10. Lift spool
5. A1 port 11. Tank oil passage
6. Lift down oil passage 2

10-8
CHAPTER 10 HYDRAULIC SYSTEM

Tilt valve assembly

4 5 6
7

3 8

2
9

1
10

609287
1. Pilot spool 6. B2 port
2. Spring 7. Parallel oil passage
3. Shutoff plug 8. Shutoff plug
4. A2 port 9. Tilt spool
5. Load check 10. Tank oil passage

10-9
CHAPTER 10 HYDRAULIC SYSTEM

Attachment valve assembly

3 4 5
6

2 7

1 8

609288
1. Spring 6. Parallel oil passage
2. Shutoff plug 7. Shutoff plug
3. A3 port 8. Attachment spool
4. Load check 9. Tank oil passage
5. B3 port

10-10
CHAPTER 10 HYDRAULIC SYSTEM

control valve hydraulic circuit diagram

1 2
P2 A1 B2 A2 B3 A3

P1 T1

PF T2

5 4 3
7 6
8

609791
1. Priority valve 5. Lift spool
2. Lift lock valve 6. Unload solenoid valve
3. Attachment spool 7. Main relief valve
4. Tilt spool 8. Steering relief valve

10-11
CHAPTER 10 HYDRAULIC SYSTEM
2.5 Lift Cylinder

2 6 3 5 4 8 13 9 10 11

7 1 12

609415
1. Cylinder tube 8. Holder
2. Piston rod assembly 9. Piston ring
3. Cylinder head 10. U-ring assembly
4. Bushing 11. U-ring holder
5. U-ring 12. Stopper
6. Wiper ring 13. Spacer
7. O-ring

Two lift cylinders each of which is a single-motion type are installed to the left and right sides of the mast.
For lift cylinders with mast lift height of up to 6000 mm (236.22 in.), the outside diameter of piston rod is 60 mm (2.36 in.), while
for those with mast lift height of more than 6500 mm (255.91 in.) and no more than 7000 mm (275.59 in.), the outside diameter
is 65 mm (2.56 in.).
In addition, for lift cylinders with mast lift height from 5000 mm (196.85 in.) to 7000 mm (275.59 in.), each of them has a spacer
on the piston rod.

10-12
CHAPTER 10 HYDRAULIC SYSTEM
2.6 Tilt Cylinder

5 11 3 10 9 8 1 2 7 4 12
6

13 14 1)

609446
1. Cylinder tube 9. Buffer ring
2. Piston rod 10. Packing
3. Guide bushing 11. Dust seal
4. Piston 12. Self locknut
5. Tilt socket 13. Bolt, Spring washer
6. Bushing 14. Spacer, Shims
7. Piston seal 1) Stamped 7L or 7R
8. O-ring

The tilt cylinder is a double motion cylinder which is used to tilt the mast forward or rearward.
The spacer 14 is used when the tilt angle is 6 degrees rearward.

Kind of mast Tilt angle Forward -Rearward Letter stamped on the tilt cylinder
Simplex mast 6° - 12° 7L or 7R
Triplex mast 6° - 6° 7L or 7R

10-13
CHAPTER 10 HYDRAULIC SYSTEM
2.7 Flow Regulator Valve

10
2)

9 8 6 2

1)

11 13 1 3 7 14 4 12 13 5

609416
1. Body 10. Connector
2. Plug 11. Elbow
3. Piston 12. Spring pin
4. Spring 13. O-ring
5. Locknut 14. Snapring
6. Stopper 1) Controlled flow
7. Valve 2) Free flow
8. Disc spring
9. Plate

The flow regulator valve, located between lift cylinder and control valve, is a safety device which prevents the fork from falling
quickly by governing the hydraulic oil flow due to lowering of lift cylinder piston when a load is applied.

Hydraulic line
1

2) 2

1)
5
3 4
609417
1. Lift cylinder 5. Hydraulic tank
2. Flow regulator valve 1) Free flow port
3. Lift valve 2) Controlled flow port
4. Pump

10-14
CHAPTER 10 HYDRAULIC SYSTEM
2.8 Down Safety Valve

3) 3) 3 4 2
1

4) 5)

1) 2)

609418
1. Connector 1) Free flow
2. Valve 2) Controlled flow
3. Spring 3) G(PF)3/4-B
4. Spring pin 4) Numeral "230" is stamped
5) ø12 mm (0.4724 in.)

This valve is a safety valve which regulates the flow of oil to prevent the fork from moving down too quickly if the piping
between the lift cylinder and flow regulator valve is broken, or if the flow of return oil from the lift cylinder becomes excessive
due to a maladjusted regulator valve or a fault of another component.
+20 +5.28
Flow rate when the circuit is blocked: 230 0 L (60.77 0 US gal.)/min

10-15
CHAPTER 10 HYDRAULIC SYSTEM
2.9 Hydraulic System Diagram

7 8

18
1
2

10
19
20

1112 21
13 22
14 15
1)
2)
3)
4)
16
6 17 23
24 25
3
4 5

609447
1. Lift cylinder (RH) 16. T2
2. Tilt cylinder (RH) 17. Inlet cover
3. Flow regulator valve (Flow priority valve)
4. Down safety valve 18. Return hose
5. Tilt cylinder (LH) 19. Pump delivery hose
6. Lift cylinder (LH) 20. Gear pump
7. Steering valve 21. Breather
8. Power cylinder 22. Cap
9. Relief valve 23. Level gauge
10. Emergency valve 24. Suction strainer
11. T1 25. Return filter
12. End cover 1) Flare joint
13. Attachment 2) Steel pipe
14. Tilt 3) Rubber hose with fitting (HP)
15. Lift 4) Rubber hose (LP)

10-16
CHAPTER 10 HYDRAULIC SYSTEM
3. Removing Gear Pump
3.1 Preparation

(1) Start the engine, lower the fork to the bottom end, and set the mast to the vertical position.
(2) Stop the engine and remove the remaining pressure in the piping.
(3) Remove the floor plate.
(4) Place suitable containers to catch oil and remove each pipe.
(5) Take appropriate measures to prevent dirt and dust from entering the pipes and connectors.

3.2 Removal Sequence

2
1

6
4

1)
2)

609419
1. Split flange, Bolt, Spring washer 5. Delivery hose, O-ring
2. Delivery hose, O-ring 6. Hydraulic pump
3. Suction elbow, O-ring, Bolt, Washer 1) No.1 pump
4. Split flange, Bolt, Spring washer 2) No.2 pump

3.3 Suggestions for Removal

Suspend the gear pump with a rope before removing the gear pump.
Weight: 19.5 kg (42.99 lb.)

10-17
CHAPTER 10 HYDRAULIC SYSTEM
4. Removing Control Valve
4.1 Removal Sequence

Control valve

1 11
10 8

6 5 4 3 2
609875

1. Clevis pin, Rod 6. Hose


2. Tilt pipe, Clamp 7. Steering return hose
3. Lift pipe 8. Return hose
4. Steering hose 9. Unload solenoid connector
5. Delivery hose 10. Lift look solenoid connector
11. Control valve

Note: The standard control valve is a dual type.

10-18
CHAPTER 10 HYDRAULIC SYSTEM
5. Removing Lift Cylinders
5.1 Removal Sequence

5
4

5
1

3
6

7
8
609420
1. Return hose, Clamp 5. Cushion, Collar, Shims
2. Hose clamp 6. Lift cylinder bracket
3. High-pressure hose 7. Connector
4. Stopper bolt, Shims 8. Elbow, Down safety valve

Removing return hose


Disconnect the right and left lift cylinder return hoses at their connectors.
Note: Never touch the control valve lift lever because the mast could come down on the technician.
Lowering lift bracket
Carefully push the lift lever of control valve forward to lower the lift bracket.

10-19
CHAPTER 10 HYDRAULIC SYSTEM

Disconnecting high-pressure hoses


Remove the high-pressure hose from the connector at the 1 2
lower part of the lift cylinder. Place a container in position to
catch remaining oil inside the hoses.
Removing stopper bolt
- To lift the inner mast, wrap a cloth around it for
protection, and attach a wire rope winding a full circle
around the mast.
Remove the stopper bolt at the upper section of the
lift cylinder, and lift the inner mast to separate the 609421
cylinder rod ends from the mast.
1. Right cylinder 2. Left cylinder

Note: Shims are inserted at the rod end section of the lift
cylinders. Make a note of the location and number of
shims to ensure proper assembly.
- Place wood blocks under the inner mast that can
withstand the weight of mast, and untie the wire rope.
Removing lift cylinders
Attach a wire rope to the cylinder before removing the
cylinder clamp. Attach a wire rope to the lift cylinder from
the back of the mast, and slowly remove the lift cylinder.
609422

609423

10-20
CHAPTER 10 HYDRAULIC SYSTEM
6. Removing Tilt Cylinders
6.1 Preparation (#3)

(1) Start the engine, lower the forks to the bottom end and
set the mast to the full forward tilted position.
(2) Turn OFF the engine.
(3) Attach slings to the eye-bolts at both ends of the top
cross member on the outer mast, and then sling it with
a hoist.
(4) Remove the tilt cylinder pin 1 (See the figure below).
(5) Start the engine and retract the tilt cylinder rod to the
end.
(6) Turn OFF the engine.
609364

6.2 Removal Sequence

1
2

1
3

609448
1. Tilt cylinder pin 3. Tilt cylinder pin
2. Hose 4. Tilt cylinder

Note: The tilt cylinder pin 1 has been removed in the preparation work.
Removing hoses
Place a suitable container in an appropriate position to catch oil that still remains in the hose before removing the hose 2 from
the cylinder connector. Install caps to open connectors to protect the threads and to prevent oil leaks in case the tilt cylinder is
removed.

10-21
CHAPTER 10 HYDRAULIC SYSTEM
7. Disassembling Gear Pump
Note: The disassembly, repair, and assembly of the gear pump must be performed by the manufacturer, except in case of
emergency. In such a case, the pump must be disassembled/repaired/assembled carefully in accordance with the
disassembly procedure. In addition it should be noted that the pump manufacturer never assures the performance of a
pump that has been rebuilt.
7.1 Disassembly Sequence

13
14

22
16 23

21
15 17
18 11
19

20
19
18 9
17
12 5
10
2 4
1 6
7
8
7
6
3
609424
1. Bolt, Washer 13. Bolt, Washer
2. Rear cover 14. Front cover
3. Backup strip, Gasket 15. O-ring
4. Body 16. Body
5. Backup strip, Gasket 17. Backup strip, Gasket
6. Bearing 18. Bearing
7. Side plate 19. Side plate
8. Drive gear 20. Drive gear
9. Driven gear 21. Driven gear
10. Bolt, Washer 22. Snapring
11. Adapter plate 23. Oil seal
12. O-ring

10-22
CHAPTER 10 HYDRAULIC SYSTEM
7.2 Suggestions for Disassembly

(1) Remove bolts and washers 1, separate remaining parts as gear pump assembly, and then disassemble the assembly in a
step-by-step manner to obtain the parts ranging from rear cover 2 to driven gear 9.
(2) Do not tap parts such as front cover 14, rear cover 2, adapter plate 11 and bearings 6 and 18 with a metal hammer, as
these are made of aluminum alloy and can be easily damaged. Use either a wooden or a plastic hammer.

10-23
CHAPTER 10 HYDRAULIC SYSTEM
8. Inspecting and Repairing Gear Pump
(1) Drive and driven gears
- Check gear teeth flank and top faces for wear or
damage.
- Check the side faces of the gears for wear or damage.
- Check the shaft portion for wear or damage.

609425

(2) Check covers, body, and adapter plate for wear and
damage.

609426

(3) Check oil seal, gasket and O-ring for damage, wear, and
loss of flexibility.

609427

10-24
CHAPTER 10 HYDRAULIC SYSTEM
9. Assembling Gear Pump
9.1 Assembly Sequence

12 1 11* 9* 7 4 5 7 13* 14 2120 18 20 21 24 26

3* 2* 10* 8 6 8 15* 16 23* 22* 19 17 25*

609428
1. Front cover 14. Adapter plate
2. Oil seal* 15. O-ring*
3. Snapring* 16. Bolt, Washer
4. Body 17. Body
5. Drive gear 18. Drive gear
6. Driven gear 19. Driven gear
7. Side plate 20. Side plate
8. Bearing 21. Bearing
9. Backup strip* 22. Backup strip*, Gasket*
10. Gasket* 23. O-ring*
11. O-ring* 24. Rear cover
12. Bolt, Washer 25. Backup strip*, Gasket*, O-ring*
13. Backup strip*, Gasket* 26. Bolt, Washer

Note: Parts marked with * are included in the repair kit.

10-25
CHAPTER 10 HYDRAULIC SYSTEM
9.2 Suggestions for Assembly

(1) Replace each part indicated by an asterisk (*) (repair kit part) with a new one when assembling.
(2) Thoroughly degrease the mating surfaces of the cover 1, 14, 24, and bodies 4 and 17.
(3) Apply grease to the oil lip seal.
(4) Be careful not to damage the oil seal lip with a spline edge of drive gear 5.
(5) Bolts must be tightened evenly.

Ref. Item Tightening torque


55.9 to 62.7 N·m (5.70 to 6.39 kgf·m)
12 Bolt
[41.2 to 46.2 lbf·ft]
55.9 to 62.7 N·m (5.70 to 6.39 kgf·m)
16 Bolt
[41.2 to 46.2 lbf·ft]
38.2 to 43.1 N·m (3.90 to 4.39 kgf·m)
26 Bolt
[28.2 to 31.9 lbf·ft]

10-26
CHAPTER 10 HYDRAULIC SYSTEM
10. Disassembling Lift Cylinder
10.1 Disassembly Sequence

4 *
1

6 2
* 5

609429
1. Cylinder head, Wiper ring* 4. Piston rod
2. Holder, U-ring*, Bushing, O-ring* 5. Piston ring, U-ring*, Holder, Stopper
3. Spacer 6. Cylinder tube

Note:
- The part indicated with an asterisk is included in the seal kit.
- Do not disassemble U-ring, Bushing 2 and Wiper ring 1, if no abnormalities are found on them.

10-27
CHAPTER 10 HYDRAULIC SYSTEM
10.2 Suggestions for Disassembly

Removing piston rod


(1) Wrap the lift cylinder in a rag and hold it in a vise. Using
the hook wrench 1, remove the cylinder head.
(2) Be careful not to damage the piston seal when pulling
out the piston rod from the cylinder.

1
609430
1. Hook wrench

Ref. Special tool


1 Hook wrench 05312-10600

10-28
CHAPTER 10 HYDRAULIC SYSTEM
11. Inspecting and Repairing Lift Cylinder

Cylinder tube
(1) Check the cylinder bore for wear, damage or rust.
(2) Check the welded area for cracks, damage or dent.
Piston rod
(1) Check the piston rod for runout.
Support both ends of the piston rod with V-shaped
blocks, and measure the runout with a dial gauge
applying to the center of rod.
(2) Check the rod surface for rust, damage, scratch marks,
and wear. Replace the rod if significant damage is
found on its threads. 609406

Item Standard Limit


Runout of piston rod 0 mm 1 mm
(measurement) (0 in.) (0.04 in.)

Rings and packings


(1) Check the packing and U-ring for damage and
deformation.
(2) Check rings for deterioration.

10-29
CHAPTER 10 HYDRAULIC SYSTEM

6 5

3 4 1

2
609431

Ref. Item Specifications


+0.2 +0.008
[Piston] Inside diameter of cylinder Standard 80 0 mm (3.15 0 in.)
1
tube
Limit 80.25 mm (3.1594 in.)
0 0
Standard 6.0 -0.05 mm (0.236 -0.002 in.)
2 Thickness of piston ring
Limit 5.8 mm (0.228 in.)
-0.06 -0.0024
Standard 60 mm -0.13 (2.36 -0.005 in.) -0.06 -0.0024
[Cylinder head] Outside diameter of {Mast lift height 6500 to 7000: 65 mm -0.13 (2.60 -0.005 in.)}
3
piston rod
59.84 mm (2.3559 in.)
Limit
{Mast lift height 6500 to 7000: 64.84 mm (2.5528)}
+0.12 +0.0047
60 0 mm (2.36 0 in.)
Standard +0.12 +0.0047
Inside diameter of cylinder head {Mast lift height 6500 to 7000: 65 mm 0 (2.60 0 in.)}
4
bushing
60.17 mm (2.3689 in.)
Limit
{Mast lift height 6500 to 7000: 65.17 mm (2.5657 in.)}
5 Thread diameter Standard M90 × 2
6 Cylinder head tightening torque Standard 490 N·m (50.0 kgf·m) [361.6 lbf·ft]

10-30
CHAPTER 10 HYDRAULIC SYSTEM
12. Assembling Lift Cylinders
12.1 Assembly Sequence

1 5 4 3 2
̪ ̪ ̪ ̪
* * * *

609432
1. Piston rod 4. Cylinder tube
2. Piston ring, U-ring*, Holder, Stopper 5. Cylinder head, Wiper ring*, U-ring*
3. Spacer Bushing, O-ring*, Holder

Note: Spacer 3 is used in cylinders with mast lift height of more than 5 m (5.5 yd).

12.2 Suggestions for Assembly

(1) Replace each part indicated by an asterisk (*) (seal kit part) with new one, when assembling.
(2) Thoroughly clean all parts before assembly making sure they are completely free from dirt or dust.
(3) Apply oil to inside surfaces of U-rings, piston rings, O-rings, bushings, wiper rings, and cylinder before assembly.
(4) When holding the cylinder circumference in a vise, be careful not to distort the cylinder when tightening the vise.
(5) Before tightening the cylinder head, apply LOCTITE 638 to the threads of the cylinder tube.

Item tightening torque


Cylinder head 490 N·m (50.0 kgf·m) [361.6 lbf·ft]

10-31
CHAPTER 10 HYDRAULIC SYSTEM
13. Disassembling Tilt Cylinder
13.1 Disassembly Sequence

1) 5
1
*
4

2 * 4
* *
*
* * 3

609449
1. Tilt socket, Bolt, Spring washer 4. Cylinder tube, Bushing
2. Bushing, O-ring*, Dust seal*, Packing*, Buffer ring* 5. Spacer, O-ring*, Shim
3. Piston rod, Piston, Nut, Piston seal* 1) For tilt angle 6 degrees rearward

Note:
- Spacer 5 is for tilt angle 6 degrees rearward.
- Do not remove any bushings from the cylinder tube 4 or Tilt socket 1 unless it is defective.

13.2 Suggestions for Disassembly

1) Removing bushing
(1) Wrap the tilt cylinder in a rag and hold it in a vise. Using
hook wrench 1, remove the bushing.
(2) When removing the bushing from the piston rod, wrap
tape around the threads to avoid damages to the buffer
ring and packing in the bushing.

1
609433
1. Hook wrench

Ref. Special tool


1 Hook wrench 05312-21250

10-32
CHAPTER 10 HYDRAULIC SYSTEM
14. Inspecting and Repairing Tilt Cylinder

Cylinder tube
(1) Check the cylinder bore for wear, damage, or rust.
(2) Check the welded area for cracks, damage, or dents.
Piston rod
(1) Check the piston rod for distortion.
Support both ends of the piston rod with V-shaped
blocks, and measure the runout with a dial gauge
applying to the center of rod.
(2) Check the rod surface for rust, damage, scratch marks,
and wear.
Replace the rod if significant damage is found on its 609406
threads.

Rings and packings


(1) Check the packing and buffer ring lips for damage or distortion.
(2) Check rings for deterioration.

10-33
CHAPTER 10 HYDRAULIC SYSTEM

4 8 3 6 2 1 7
5

609434

Ref. Item Specifications


Standard 90 mm (3.54 in.)
1 Inside diameter of cylinder tube
Limit 90.12 mm (3.5480 in.)
-0.025 -0.001
2 [Bushing] piston rod outside diameter Standard 40 mm -0.064 (1.57 -0.0025in.)
0.075 to 0.139 mm
Standard
3 Clearance between rod and bushing (0.0030 to 0.0055 in.)
Limit 0.35 mm (0.0138 in.)
+0.085 +0.0033
Mast side socket bushing inside diameter Standard 40 0 mm (1.57 0 in.)
4
(press-fit condition)
Limit 40.6 mm (1.598 in.)
+0.085 +0.0033
Frame side head bushing inside diameter Standard 40 0 mm (1.57 0 in.)
5
(press-fit condition)
Limit 40.6 mm (1.598 in.)
Guide bushing threads diameter Standard M95 × 2.0

6 637 ± 64 N·m
Guide bushing Tightening torque (65.0 ± 6.5 kgf·m)
[470.1 ± 47.2 lbf·ft]
588 ± 29 N·m
7 Piston rod nut Tightening torque (60.0 ± 3.0 kgf·m)
[434.0 ± 21.4 lbf·ft]
262 ± 13 N·m
8 Tilt socket bolt Tightening torque (26.7 ± 1.3 kgf·m)
[193.4 ± 9.6 lbf·ft]

10-34
CHAPTER 10 HYDRAULIC SYSTEM
15. Assembling Tilt Cylinder
15.1 Assembly Sequence

1)

* *** * *

4 3 2 1
609435
1. Piston rod, Piston, Nut, Piston seal* 4. Socket, Bushing
2. Cylinder tube, Bushing 1) Stamp position
3. Bushing, Buffer ring*, Packing*, Dust seal*, O-ring*

Note: A part indicated with an asterisk is included in the seal kit

15.2 Suggestions for Assembly

(1) Replace each part indicated by an asterisk (*) (seal kit


part) with new one when assembling.
(2) Thoroughly clean all parts before assembly making sure
they are completely free from dirt or dust.
(3) Apply a coat of oil to inside surfaces of piston seals, O-
rings, packings, dust seals, and cylinder tube before
assembly.
(4) When holding the cylinder in a vise, be careful not to
distort the cylinder when tightening the vise.

501450

(5) Assembly procedure for piston seal of tilt cylinder


- To install piston seals, lightly compress and release
the piston seal 5 to 6 times by hand to make it soft.
- Secure the piston rod in a vise, making sure not to
cause damage to it, and apply a thin coat of oil to the
piston seal. Fit half of the seal into the piston groove,
and then press the other half into the groove.
(6) Pay attention to the orientation of packings and dust
seals when installing them into bushings.

501451

10-35
CHAPTER 10 HYDRAULIC SYSTEM
16. Disassembling Flow Regulator Valve
16.1 Disassembly Sequence

9
10
11
12

13

3 2

5
7
8
609436
1. Elbow, O-ring 8. Disc spring
2. Connector, O-ring 9. Snapring
3. Nut 10. Plate
4. Plug, O-ring 11. Valve
5. Spring 12. Piston
6. Pin 13. Body
7. Stopper

Note: Pin 6 through piston 12 are to be disassembled after removing the piston.

10-36
CHAPTER 10 HYDRAULIC SYSTEM
17. Inspecting and Repairing Flow Regulator Valve
(1) Check the spring for settling.
(2) Check contact surfaces between valve and piston for damage, and check sliding surface for flaws.
(3) Check sliding surfaces of piston and valve body for flaws.

Note: If there is damage to any part of it, replace the assembly.

18. Assembling Flow Regulator Valve


To assemble, follow the disassembly sequence in reverse.

19. Disassembling Down Safety Valve


19.1 Disassembly Sequence

1
3

4
609437
1. Spring pin 3. Spring
2. Valve 4. Connector, O-ring

20. Inspecting Down Safety Valve


(1) Check the valve orifice for clogging and damage.
(2) Check the spring for settling and damage.
(3) Check threaded portions for damage.
Note: If there is damage to any part of it, replace the assembly.

21. Assembling Down Safety Valve


To assemble, follow the disassembly sequence in reverse.

10-37
CHAPTER 10 HYDRAULIC SYSTEM
22. Inspecting and Adjusting Hydraulic System
22.1 Hydraulic Oil

Replace cloudy oil as it may be contaminated with water. Be careful when checking oil immediately after the operation of
hydraulic control lever, as foaming of oil may be mistaken as water in the oil.

22.2 Suction Strainer and Return Filter

Check for damage or clogging, and clean or replace.

22.3 Test Operation of Gear Pump

Test operation is to perform run-in of the pump and check the performance. It is desirable to perform the test operation on a
dedicated test stand, however, since the actual service is impossible, perform the test with the gear pump installed on the truck
as instructed below.

(1) Install an oil pressure gauge which can accommodate


25 MPa (255 kgf/cm²) [3626 psi] to the control valve.
Installing oil pressure gauge: Remove the plug of
delivery hose connector and install the following tools:
Connector: 64309-17733 (R(PT) 1/8 thread)
Hose: 64309-17722
Connector: 64309-17731 (For gauge installation)
Gauge: 64309-17712 (25 MPa (255 kgf/cm²) [3626 psi])
Note: Parts shown above are included in the 64309-17701
gauge kit.

609438

(2) Place the operating control lever in the NEUTRAL


position and run the engine at 500 to 1000 min-1. In the
neutral condition, the oil pressure gauge must indicate
0.981 MPa (10.003 kgf/cm²) [142.282 psi] or below.
Continue to run the engine in this condition for 10
minutes and check for any abnormal noise coming
from the pump.
(3) Next, run the engine without load at 1500 to 2000
min-1 for 10 minutes.
(4) Loosen the adjusting screw of relief valve under the
condition of Step (3) above and operate the lift lever to
the upward position. Next, adjust the adjusting screw
until the pressure becomes 2.94 MPa (29.98 kgf/cm²) 609439
[426.41 psi], and run the engine for 5 minutes. Then
raise the pressure in increments of 1.96 MPa (19.99 kgf/
cm²) [284.27 psi] and run the engine for 5 minutes
under each pressure until the preset pressure for relief
valve is attained.

(5) During the process of increasing the pressure, pay attention to the oil temperature, pump surface temperature, and listen
for abnormal sound from the pump. If the oil temperature or pump temperature abnormally rises, cancel the load and
lower the temperature to continue the test operation, or disassemble the pump again to inspect the inside.
(6) After above Steps (2) through (5) are completed, adjust the relief valve to the specified set pressure, and make sure that the
operation speed is normal.

10-38
CHAPTER 10 HYDRAULIC SYSTEM
22.4 Control Valve

External oil leak 1)


(1) Check for oil leaks from the joint between adjacent
valve housings sealed with an O-ring.
(2) Check for oil leaks from scraper and O-ring.
(3) Check for oil leaks from threaded connections.
Valve internal oil leak
As it is difficult to perform the oil leak check for the
complete control valve, check the control valve with it 2)
connected to each cylinder as described in Steps (1)
through (3).
501460
Note that measured value is the total amount of leaks from
lift spool, tilt spool, tilt lock valve, and check valves. 1) 3° to 4° 2) Approx. 1 m (1.1 yd)
(Oil temperature for measurement: Approx. 40°C [104°F]

(1) Place a load equal to the rated capacity on the forks,


and lift the forks approximately 1 m (1.1 yd). Never
stand under the load. Tilt the mast about 3 to 4 degrees
forward from the vertical position, and turn OFF the
engine.
(2) Quickly disconnect the oil return hose, and catch the oil
that comes out.

609440

Amount of oil discharged in 15 minutes


380 cc (23.2 cu in.) or less

(3) If cylinder drift or the forward tilting of the mast is


excessive even if the total amount of collected oil in 15
minutes is less than the specified value, measure the
internal oil leak of each cylinder. (The measurement is
the Standard, not the limit.)

609441

10-39
CHAPTER 10 HYDRAULIC SYSTEM

Adjusting main relief valve


(1) Install an oil pressure gauge which can accommodate 25 MPa (255 kgf/cm²) [3626 psi] on the control valve.
The gauge, connector, hose, etc. to be used are same as with the gear pump test operation.
(2) Start the engine and increase the engine speed to maximum, and then operate the tilt lever to the rearward position. If the
pressure gauge reading is 19.11 to 19.6 MPa (194.87 to 199.9 kgf/cm²) [2771.68 to 2842.7 psi] when the tilt cylinders reach
to the most rearward position, the main relief valve setting is correct.
(3) If the relief pressure is not satisfactory, loosen the locknut of the relief valve, and adjust the pressure with the adjusting
screw while observing the pressure gauge reading.
Note: The change in pressure by one full turn of the adjusting screw is approximately 17.8 MPa (181.5 kgf/cm²) [2581.7 psi].
(4) While holding the adjusting screw, tighten the locknut to secure the adjusting screw.
(5) After securing the adjusting screw, check the main relief valve set pressure again.

Main relief valve set pressure


+0.5 +5.10 +72.52
19.1 0 MPa (194.77 0 kgf/cm²) [2770.23 0 psi]

10-40
CHAPTER 10 HYDRAULIC SYSTEM
22.5 Adjusting Priority Relief Valve

(1) Install an oil pressure gauge which can accommodate 0


to 2.5 MPa (0.00 to 25.49 kgf/cm2) [0.00 to 362.9 psi] to
the position shown in the right figure.

609450

Ref. Item
1 Connector 91268-01700
2 Connector (R(PT)1/8 thread) 64309-17733
3 Hose 64309-17722
Connector
4 64309-17731
(For gauge installation)
5 Gauge 64309-17712

Note:
5
- Tools 2 through 5 are included in the gauge kit 64309-
17701. 4
- In ordinary practice, the oil pressure gauge to be used 3
shall accommodate twice the oil pressure to be
measured, however, in this case, the oil pressure 2
gauge included in the gauge kit shall be used.
1

609451

(2) Turn the engine ON and increase the engine speed to


the maximum, and then rotate the steering wheel to
the left end. If the pressure gauge reading is 10.78 to
11.27 MPa (109.93 to 114.92 kgf/cm²) [1563.51 to
1634.58 psi] when the steering cylinder reaches its
stroke end, the main relief valve setting is correct.
(3) If the relief pressure is not satisfactory, loosen the
locknut of the relief valve of priority valve, and adjust
the pressure with the adjusting screw while observing
the pressure gauge reading.
Note:
1
- The change in pressure by one full turn of the 609452
adjusting screw is approximately 17.74 MPa (180.90
1. Adjusting screw
kgf/cm²) [2572.97 psi].
- The oil pressure adjustment must be completed in a
short time.

(4) While holding the adjusting screw, tighten the locknut to secure the adjusting screw.
(5) After tightening, check the relief set pressure again.

Priority relief set pressure


12.3 MPa (125.43 kgf/cm²) [1783,97 psi]

10-41
CHAPTER 10 HYDRAULIC SYSTEM
22.6 Adjusting Overload Relief Valve (Option)

1) Install an oil pressure gauge which can accommodate 0 to 2.5 MPa (0.00 to 25.49 kgf/cm2) to the control valve.
Note: The installation equipment and tools are the same as those for main relief valve adjustment.
2) Turn the engine ON and increase the engine speed to maximum, and then operate the attachment lever to the forward or
rearward position. If the oil is relieved when the actuator pressure reaches the limit and the pressure gauge reads the
specified value, the relief valve setting is correct.

3) If the relief pressure is not satisfactory, loosen the


locknut of the relief valve, and adjust the pressure with
the adjusting screw while observing the pressure
gauge reading.
4) While holding the adjusting screw, tighten the locknut
to secure the adjusting screw.
5) After tightening, check the relief set pressure again.

609438

22.7 Adjusting Flow Regulator Valve

Measure the falling speed when the rated load is applied.


If the falling speed is not within the specification, adjust the
speed by loosening the locknut and adjusting the screwed-
in amount of the plug.

609442

Change in falling speed per a half turn of plug


Approx. 17 mm (0.67 in.)/sec

10-42
CHAPTER 10 HYDRAULIC SYSTEM
23. Tests
23.1 Vertical Drift Test

1) Pick up a load equal to the rated capacity, place the


mast to a vertical position, lift the forks about 1 to 1.5 m
(1.1 to 1.64 yd), and turn OFF the engine.
2) Mark a reference line on the mast, and measure the
amount of descent (retraction of the piston rods) for 10
minutes.
(Oil temperature for measurement: Approx. 40°C
[104°F]

609443

Vertical drift amount


Rod retraction stroke (with rated load)
100 mm (3.94 in.)/10 min

23.2 Tilt Drift Test

1) Pick up a load equal to the rated capacity, place the


mast to a vertical position, lift the forks about 50 cm (2.0
in.), and turn OFF the engine.
2) Measure the extension of tilt cylinder for 10 minutes.
(Oil temperature for measurement: Approx. 40°C
[104°F]

609444

Item Specifications
Natural forward tilt
63 mm (2.48 in.)/
Rod extension stroke
10 min
(with rated load)

10-43
CHAPTER 10 HYDRAULIC SYSTEM
24. Troubleshooting

Hydraulic tank

Condition Possible cause Action


Not enough oil Add
Oil viscosity is improper See Chapter "SERVICE DATA" and replace
Check the working conditions, and if overloaded,
Overloaded due to harsh operating conditions
urge the operator to stay within the load limit

Hydraulic tank heats Line is clogged, which generates a restriction to oil


Oil line cleaning
excessively line flow and causes local overheating
Relief valve is improperly adjusted Set pressure adjustment
Gear pump is worn Pump replacement
Clogs due to flattened outlet pipe or tube, etc. Repair or replace
Clogged oil cooler Clean
Shortage of oil due to a natural loss See Chapter "SERVICE DATA" and replace
Cylinders move too
Oil leaks due to damaged oil line, seals, etc. Repair or replace
slow
Oil viscosity is too high See Chapter "SERVICE DATA" and replace

Gear pump

Condition Possible cause Action


Inspecting, repairing, or replacing pump and
Gear pump does not suck oil
piping
Check the oil level and contamination
Cylinders move too Oil leaks from hydraulic line
Add or change oil if necessary
slow
Check control valve spools for misalignment
Oil level rises to an abnormal high level
Repair or replace
Gear pump internal leaks Pump replacement
Poor pumping of oil See Chapter "SERVICE DATA" and replace
- Check suction pipe for any flat portions or
loose connections. Retighten or replace if
necessary
Pump is too noisy
Cavitation - Check shaft oil seal for air-tightness. Replace
pump
- Check pump body for any outside
interference, repair
Pressure exceeds the rating Pump replacement
Pump case, drive - Check if return line has been blocked or
gear or pump port Distortion or damage due to external excessively restricted
flange is damaged strain or stress - Check if pipe connection has been
externally strained or stressed

10-44
CHAPTER 10 HYDRAULIC SYSTEM

Condition Possible cause Action


Oil leaks from oil seal Replace seal
Oil leaks through sliding surfaces of drive shaft Replace pump assembly
Oil leaks from pump Retighten
Bolts that secure the pump are loosened
Replace parts if required
Seal ring inside pump is deteriorated Replace O-ring

10-45
CHAPTER 10 HYDRAULIC SYSTEM

Control valve

Condition Possible cause Action


Valve opening pressure setting is too low Adjust pressure
Wash piston and check if it moves smoothly, or
Slow or no motion Sticking of relief valve/piston
replace relief valve assembly
of lift and tilt
cylinders Outer O-ring on relief valve body is damaged Replace O-ring
Spool stroke is not enough due to control lever
Adjust
looseness
Lift/tilt drift (descent
Control valve spool internal leaks Replace each block assembly
or forward tilt)
Replace O-ring (Check spool for scratches. If
Oil leaks at spool ring cap scratches are found, repair or replace block
assembly)
Oil leaks
Plug loose Tighten plug
O-ring damaged Replace O-ring

Lift and tilt cylinders

Condition Possible cause Action


Hydraulic tank oil level is too low See Chapter "SERVICE DATA" and replace
Mast will neither Relief valve malfunction
ascend nor tilt
forward or - Main valve jamming - Replace
backward - Valve spring broken - Replace
Gear pump malfunction Replace
Relief valve malfunction
- Reduction in relief set pressure - Adjust pressure
- Plunger or poppet seat defects - Replace
Unable to lift rated - Spring settling - Replace
load
- O-ring in valve case damaged - Replace
Gear pump malfunction Replace
Piston seal worn or damaged Replace
Engine speed too slow Adjust engine
Spool stroke is not enough due to loose control
Lifting speed is too Adjust
lever
slow
Tank strainer is clogged Wash or replace
Gear pump delivery volume is too low Repair or replace

Lowering speed of Sleeve seized in flow regulator valve Repair


lift cylinder is too Excessive oil flow resistance due to clogged flow Clean, repair hydraulic lines, or replace defective
slow regulator valve, flattened hose, or local clogging hoses
Piston rod deflection Repair or replace
Cylinder vibrates Bleed air by extending cylinder through its full
Air inclusion in hydraulic line
during operation stroke
Hydraulic oil level in the tank is too low Add oil

10-46
CHAPTER 10 HYDRAULIC SYSTEM

Condition Possible cause Action


Control valve spool internal leaks Replace each block assembly
Scratches on sliding surface of cylinder tube that
Repair or replace
can be felt by finger nail
Too much lift
cylinder drift Sliding surface of cylinder tube badly grooved Replace cylinder assembly
Piston seal damaged or distorted Replace seal
Oil leaks from hydraulic line Repair or replace
Control valve spool internal leaks Replace each block assembly

Too much tilt Foreign matter is trapped in the packing Replace packing
cylinder drift Piston seal damaged Replace seal
Abnormal distortion or oil leaks from hydraulic line Repair or replace
Lift cylinder or tilt Local severe scoring or rust on inner surface of
Repair or replace
cylinder will drift cylinder
(descend or tilt
forward) at a certain Cylinder distortion Replace
point
Foreign matter trapped between sealing members
Replace
such as oil seals and dust seals

Oil leaks from Inner or outer diameter of oil seal or dust seal
Replace
bushing damaged
O-ring damaged Replace O-ring
Abnormal distortion Repair or replace

10-47
CHAPTER 10 HYDRAULIC SYSTEM
25. Service Data
25.1 Gear Pump

2
1

609445

Ref. Item Specifications


Fork ascending speed (under rated load)
Standard 440 mm (17.32 in.)/sec
[Simplex mast] (at maximum engine speed)
Fork ascending speed (under no load)
Standard 470 mm (18.50 in.)/sec
(at maximum engine speed)
Fork descending speed (under rated load)
Standard 550 mm (21.65 in.)/sec
[Simplex mast] (at maximum engine speed)
Forward tilt angle [standard model with simplex mast] Standard 6°
Backward tilt angle [standard model with simplex mast] Standard 12°
Lift cylinder vertical drift (under rated load)
Standard 100 mm (3.94 in.)/10 min or less
(Retracted length of rod, oil temperature at 40 °C [104°F])
Tilt cylinder forward drift (under rated load) 63 mm (2.48 in.)/
Standard
(Extension length of rod, oil temperature at 40 °C [104°F]) 10 min or less
Discharge rate Standard 160/2300 L (42.27 US gal.)/min-1
Tightening 51 to 63 N·m (5.2 to 6.42 kgf·m)
1 Attaching bolts and nuts
torque [37.62 to 46.47 lbf·ft]
Tightening 37 to 48 N·m (3.8 to 4.9 kgf·m)
2 Delivery hose mounting bolts
torque [27.3 to 35.4 lbf·ft]

10-48
CHAPTER 10 HYDRAULIC SYSTEM
25.2 Control Valve

3
2

5 9 7 4
609801

Ref. Item Specifications


1 Main relief pressure Standard 19.1 MPa (194.77 kgf/cm²) [2770.23 psi]
2 Priority relief pressure Standard 12.3 MPa (125.43 kgf/cm²) [1784.0 psi]
53 to 65 N·m ( 5.40 to 6.63 kgf·m )
3 Tilt pipe Tightening torque
[39.09 to 47.94 lbf·ft]
45 ± 5 N·m ( 4.59 ± 0.51 kgf·m )
4 Tilt pipe connector Tightening torque
[33.19 ± 3.69 lbf·ft]
60 ± 6 N·m ( 6.12 ± 0.61 kgf·m )
5 Lift pipe connector Tightening torque
[44.25 ± 4.43 lbf·ft]
132.3 to 161.7 N·m(13.49 to 16.49 kgf·m)
6 Return pipe connector Tightening torque
[97.58 to 119.26 lbf·ft]
60 ± 6 N·m ( 6.12 ± 0.61 kgf·m )
7 Delivery hose connector Tightening torque
[44.25 ± 4.43 lbf·ft]
45 ± 5 N·m ( 4.59 ± 0.51 kgf·m )
8 Return pipe connector Tightening torque
[33.19 ± 3.69 lbf·ft]
Tie bolt 7/16" 63.7 to 73.5 N·m(6.50 to 7.49 kgf·m)
9 Tightening torque
1/2"12 [46.98 to 54.21 lbf·ft]

10-49
CHAPTER 10 HYDRAULIC SYSTEM
25.3 Hydraulic Tank

2 3
609494

Ref. Item Specifications


44 to 54 N·m (4.49 to 5.51 kgf·m)
1 Return filter Tightening torque
[32.45 to 39.83 lbf·ft]
44 to 54 N·m (4.49 to 5.51 kgf·m)
2 Suction strainer Tightening torque
[32.45 to 39.83 lbf·ft]
176 to 216 N·m (17.9 to 22.03 kgf·m)
3 Drain plug Tightening torque
[129.8 to 159.31 lbf·ft]

25.4 Flow Regulator Valve

609803

Ref. Item Specifications


Controlled flow rate (without load) Standard 150 ± 12 L ( 39.6 ± 3.2 US gal.)/min
1 Return pipe Tightening torque 118 N·m (12.0 kgf·m) [87.0 lbf·ft]

10-50
CHAPTER 10 HYDRAULIC SYSTEM
25.5 Lift Cylinder

6 5

3 4 1

2
609495

Ref. Item DP70NM


+0.2 +0.008
Standard 80 0 mm (3.15 0 in.)
1 Inside diameter of cylinder tube
Limit 80.25 mm (3.1594 in.)
-0.05 -0.002
Standard 60 0 mm (2.36 0 in.)
2 Piston ring thickness
Limit 5.8 mm (0.228 in.)
-0.06 -0.0024
Standard 60 -0.13 mm (2.36 -0.0051 in.)
(Mast height 6500 to 7000)
3 Outside diameter of piston rod
64.84 mm (2.5528 in.)
Limit
(Mast height 6500 to 7000)
+0.12 +0.0047
Standard 65 0 mm (2.56 0 in.)
(Mast height 6500 to 7000)
4 Cylinder head bushing inside diameter
65.17 mm (2.5657 in.)
Limit
(Mast height 6500 to 7000)
5 Cylinder head threads diameter Standard M90 × 2.0 mm
Tightening
6 Cylinder head holder 490 N·m (50.0 kgf·m) [361.4 lbf·ft]
torque

10-51
CHAPTER 10 HYDRAULIC SYSTEM
25.6 Tilt Cylinder

4 8 3 6 2 1 7
5

609434

Ref. Item Specifications


Standard 90 mm (3.54 in.)
1 Cylinder tube inside diameter
Limit 90.12 mm (3.5480 in.)
[Bushing] -0.025 -0.001
2 Standard 40 -0.064 mm (1.57 -0.0025 in.)
Outside diameter of piston rod
Standard 0.075 to 0.139 mm (0.0030 to 0.0055 in.)
3 Clearance between rod and bushing
Limit 0.35 mm (0.0138 in.)
+0.085 +0.0033
Mast side socket bushing inside diameter Standard 40 0 mm (1.57 0 in.)
4
(press-fit condition)
Limit 40.6 mm (1.598 in.)
+0.085 +0.0033
Frame side head bushing inside diameter Standard 40 0 mm (1.57 0 in.)
5
(press-fit condition)
Limit 40.6 mm (1.598 in.)
Guide bushing threads diameter Standard M95 × 2.0
6 637 ± 64 N·m (65.0 ± 6.5 kgf·m)
Guide bushing Tightening torque
[469.8 ± 47.2 lbf·ft]
588 ± 29 N·m (60. 0 ± 3.0 kgf·m)
7 Piston rod nut Tightening torque
[433.7 ± 21.4 lbf·ft]
262 ± 13 N·m (26.72 ± 1.33 kgf·m)
8 Tilt socket bolt Tightening torque
[193.24 ± 9.59 lbf·ft]

10-52