99709-86140-10 - Hydraulic System

HYDRAULIC SYSTEM
1. Specifications ............................................................................................................. 10-3
2. Structure and Functions ............................................................................................. 10-4

2.1 Hydraulic Line ..................................................................................................................................... 10-4
2.2 Hydraulic Tank .................................................................................................................................... 10-5
1
2.3 Hydraulic Pump (Gear Pump)............................................................................................................. 10-6
2.4 Control Valve ...................................................................................................................................... 10-7 2
2.5 Lift Cylinder ......................................................................................................................................... 10-8
2.6 Tilt cylinder.......................................................................................................................................... 10-9
2.7 Flow Regulator Valve........................................................................................................................ 10-10
3
2.7.1 Schematic ............................................................................................................................................... 10-10
2.8 Down Safety Valve............................................................................................................................ 10-11 4
2.9 Piping of Hydraulic System ............................................................................................................... 10-12
3. Removal and Installation .......................................................................................... 10-13 5

3.1 Preparation for Removal (1).............................................................................................................. 10-13
3.1.1 Hydraulic Pump (Gear Pump) ................................................................................................................. 10-13
3.1.2 Control Valve........................................................................................................................................... 10-14
6
3.2.1 Lift Cylinders ........................................................................................................................................... 10-15 7
3.3.1 Tilt cylinder .............................................................................................................................................. 10-17
8
4. Disassembly and Reassembly ................................................................................. 10-19
4.1 Hydraulic Pump (Gear Pump)........................................................................................................... 10-19 9
4.1.1 Disassembly ............................................................................................................................................ 10-19
4.1.2 Inspection and Repair ............................................................................................................................. 10-20
4.1.3 Reassembly ............................................................................................................................................ 10-22 10
4.2 Control Valve .................................................................................................................................... 10-24
4.2.1 Disassembly of each assembly ............................................................................................................... 10-24
4.2.2 Inlet Cover Disassembly ......................................................................................................................... 10-25
11
4.2.3 Lift Valve Disassembly ............................................................................................................................ 10-26
4.2.4 Tilt Valve Disassembly ............................................................................................................................ 10-28 12
4.2.5 Attachment Valve Disassembly............................................................................................................... 10-30
4.2.6 End Cover Disassembly .......................................................................................................................... 10-32
4.3 Lift Cylinders ..................................................................................................................................... 10-33 13
4.3.1 Disassembly ............................................................................................................................................ 10-33
4.3.3 Reassembly ............................................................................................................................................ 10-36
14
10-1
HYDRAULIC SYSTEM
4.4 Tilt Cylinder ....................................................................................................................................... 10-37

4.4.1 Disassembly ............................................................................................................................................ 10-37
4.4.3 Reassembly ............................................................................................................................................ 10-40
4.5.1 Disassembly ............................................................................................................................................ 10-41
4.5.3 Reassembly ............................................................................................................................................ 10-42
4.6 Down Safety Valve............................................................................................................................ 10-42
4.6.1 Disassembly ............................................................................................................................................ 10-42
4.6.2 Inspection ................................................................................................................................................ 10-42
4.6.3 Reassembly ............................................................................................................................................ 10-42
5. Inspection and Adjustment ....................................................................................... 10-43

5.1 Hydraulic oil ...................................................................................................................................... 10-43
5.2 Suction strainer, Return filter ............................................................................................................ 10-43
5.3 Hydraulic Pump Test Run ................................................................................................................. 10-43
5.4 Control Valve .................................................................................................................................... 10-44
5.4.1 External leakage ..................................................................................................................................... 10-44
5.4.2 Internal leakage....................................................................................................................................... 10-44
5.4.3 Main Relief Valve .................................................................................................................................... 10-45
5.5 Steering System Relief Valve ........................................................................................................... 10-46
5.6 Adjustment of overload relief valve (option)...................................................................................... 10-47
5.7 Adjusting flow regulator valve ........................................................................................................... 10-47
6. Testing ..................................................................................................................... 10-48

6.1 Lift cylinder drift test .......................................................................................................................... 10-48
6.2 Tilt cylinder drift test .......................................................................................................................... 10-48
7. Troubleshooting ....................................................................................................... 10-49
8. Service Data............................................................................................................. 10-53

8.1 Gear pump ........................................................................................................................................ 10-53
8.2 Control Valve .................................................................................................................................... 10-54
8.3 Hydraulic Tank .................................................................................................................................. 10-55
8.5 Lift cylinder........................................................................................................................................ 10-56
8.6 Tilt cylinder........................................................................................................................................ 10-57
10-2
HYDRAULIC SYSTEM
1. Specifications
Truck Model DP60 DP70

Type Gear
Manufacturer Shimadzu
Hydraulic pump Model FGP30 + SP20
Rated output 115 L (7015 cu.in.) / 2300 rpm
Drive Directly driven by torque converter
Priority relief valve
10.78 MPa (110 kgf/cm2) [1563 psi]
setting
Model KVS
Control valve
Manufacturer Kayaba
Main relief valve set-
19.11 MPa (195 kgf/cm2) [2770 psi]
ting
Flow regulator Type Variable (adjustable)
valve Flow rate 165 ± 12 L (10065 ± 732 cu.in.)
Inside diamete 80 mm (3.15 in.)
Lift cylinders
Stroke 1650 mm (64.96 in.)
Inside diameter 90 mm (3.54 in.)
Tilt cylinders
Stroke 229mm (9.02 in.)
Hydraulic tank capacity N level: 105 L (6405 cu.in.)
10-3
HYDRAULIC SYSTEM
2. Structure and Functions

2.1 Hydraulic Line
209444
1 Suction strainer 8 Lift cylinder (R.H.) 15 Steering valve

2 Hydraulic pump 9 Lift cylinder (L.H.) 16 Steering cylinder
3 Pump delivery hose 10 Flow regulator valve 17 Oil return line from steering valve
4 Control valve inlet cover section 11 End cover section 18 Hydraulic tank
5 Hydraulic control valve 12 Return line 19 Breather
6 Tilt cylinder (L.H.) 13 Return filter 20 Cap
7 Tilt cylinder (R.H.) 14 Oil feed line to steering valve
The hydraulic system of this truck includes the mast control utes the remainder of the oil to the mast control circuit. In
circuit and the full-hydraulic steering system circuit. the standard configuration, the following three valve sec-
The oil drawn by the hydraulic pump 2 from the hydraulic tions are used for the mast control purposes:
tank 18 flows into the control valve inlet cover section 4 (1) Lift control valve section
through the pump delivery hose 3. (2) Tilt control valve section
The flow priority valve in the control valve inlet cover sec-
(3) Attachment control valve section
tion 4 preferentially distributes the oil to the steering valve
The lift control valve section controls the operation of the
15 through the oil feed line 14. The priority valve distrib-
lift cylinders 8 and 9 to raise or lower the mast.
10-4
HYDRAULIC SYSTEM
The tilt control valve section controls extension and retrac- The return oils from the steering valve and mast control cyl-
tion of the tilt cylinders 6 and 7 to cause the mast to lean inders go to the hydraulic tank through the control valve’s
forward or backward. end cover section 11 and return hose 12.
The attachment control valve section controls the operation
of the attachment actuators.
2.2 Hydraulic Tank
2
4 3
To hydraulic pump
From control
valve
7 5
206518
1 Cap 5 Drain plug
2 Air breather 6 Suction strainer
3 Strainer 7 Return filter
4 Oil level gage
The hydraulic tank is an all-welded structure and is bolted

to the middle of the right-hand side frame member. Oil is
lifted from the tank through suction strainer (105 µ) by the
gear pump. The oil returning from the lift cylinders joins
the oil returning from the hydraulic and steering control
valves and returns to the tank through return filter (25 µ).
10-5
HYDRAULIC SYSTEM
2.3 Hydraulic Pump (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 22 20 18 15 12 10 11 18 15
204621
1 Front cover 10 Driven gear 19 Bolt

2 Body 11 Bearing 20 Bolt
3 Drive gear 12 Side plate 21 Bolt
4 Driven gear 13 Rear cover 22 Washer
5 Bearing 14 Backup strip 23 Washer
6 Side plate 15 Backup strip, Gasket 24 Oil seal
7 Adapter plate 16 Gasket 25 Snap ring
8 Body 17 O-ring
9 Drive gear 18 O-ring
The gear pump (an external-gear type) pumps the hydraulic

oil that is needed to activate the hydraulic cylinders. It has a
tandem structure that effectively consists of a No. 1 gear
pump and a No. 2 gear pump.
10-6
HYDRAULIC SYSTEM
2.4 Control Valve
6 2 3 4
5
1
P1
PF
T2 P2
7 205530A
1 Priority valve P1 From No.1 pump.
2 Lift valve P2 From No.2 pump
3 Tilt valve PF To steering control valve
4 Attachment valve (option) T1 To tank
5 End cover T2 From steering control valve
6 Main relief valve
7 Priority valve, Relief valve
The priority valve serves to distribute a required quantity of

pressured oil for power steering as well as an extra quantity
for loading regardless how much oil is discharged from
No.1 gear pump. The extra oil from No.1 gear pump joins
with the pressured oil from No.2 gear pump to be used to
operate the loading equipment including lift cylinder and
tilt cylinder, etc. This forklift truck has a tilt lock valve
installed as a safety device that can prevent the mast from
tilting forward should the tilt lever be operated carelessly
while the engine is stopping.
10-7
HYDRAULIC SYSTEM
2.5 Lift Cylinder
2 6 3 5 4 8 13 9 10 11
7 1 12 205531
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
The two lift cylinders are a single-acting type. One is

located on the left-hand side of the mast, and one is located
on the right-hand side of the mast.
On a truck with a maximum mast lift height of 6 m (19.8 ft),
the piston rod outside diameter is 60 mm (2.36 in.).
On a truck with a mast lift height of 6.5 m to 7 m (21.5 to
23.1 ft), the piston rod outside diameter is 65 mm (2.56 in.).
On a truck with a mast lift height of 5 m to 7 m (16.5 to 23.1
ft), the piston rod of each lift cylinder is fitted with a spacer.
10-8
HYDRAULIC SYSTEM
2.6 Tilt cylinder
5 12 10 3 9 8 1 2 7 4 11 6
15 13 14
Letter stamped D
View A
205759
1 Cylinder tube 7 Piston seal 13 Spacer
2 Piston rod 8 O-ring 14 O-ring
3 Guide bushing 9 Packing 15 Shim
4 Piston 10 Dust seal
5 Socket kit 11 Self-locking nut
6 Bushing 12 Nut
This tilt cylinder is of a dual-working type capable of mak-

ing the mast tilted forward and backward.
Spacer 13 is used for creating backward tilt angle 6.
Raised height of Tilt angle for- Letter stamped on

mast ward-backward tilt cylinder
3 to 5 m 6°– 12° D
5.5 to 7 m 6°– 6° D
10-9
HYDRAULIC SYSTEM
2.7 Flow Regulator Valve
A 10
Free flow
of oil
9 8 6 2
Control flow
of oil
11 13 1 3 7 14 4 12 13 5
205532
1 Body 8 Disc springs

2 Plug 9 Plate
3 Piston 10 Connector
4 Spring 11 Elbow
5 Lock nut 12 Spring pin
6 Stopper 13 O-ring
7 Valve 14 Snap ring
The flow regulator valve for controlling the lowering speed This valve controls the flow of oil from the cylinder,
of loaded forks is located between the lift cylinder and con- depending on the load, to maintain safe lowering speed.
trol valve.
2.7.1 Schematic
1 Lift cylinder
1
2 Flow regulator valve
3 Lift valve
4 Pump
B 2
5 Hydraulic tank
A:Free flow port
B:Control flow port
A
5
3
4
205551
10-10
HYDRAULIC SYSTEM
2.8 Down Safety Valve
G (PF) 3/4-B
3 4 2
1
Identification 230
φ 12
Control flow
Free flow of oil of oil
204626
6 Connector 8 Spring
7 Valve 9 Spring pin
The down safety valve is built in the bottom of left-hand lift

cylinder. This valve interrupts the flow of oil from the lift
cylinder when the hose between the lift cylinder and flow
regulator valve is ruptured, thereby preventing loaded forks
from unsafely free falling.
+20
230 0 L/min
Control flow rate +1220
(14036 0 cu.in./min)
10-11
HYDRAULIC SYSTEM
2.9 Piping of Hydraulic System
209454
10-12
HYDRAULIC SYSTEM
3. Removal and Installation

3.1 Preparation for Removal (1)
(1) Start the engine and lower the forks to the bottom.
Then, make the mast vertical.
(2) Stop the engine and remove the residual pressure from
the pipe.
(3) Remove the floor plate.
(4) Prepare a container to catch the oil, then disconnect
each pipe.
(5) Take preventive measures so as not to allow dirt or dust
from entering in each opening of the pipes and connec-
tors.
3.1.1 Hydraulic Pump (Gear Pump)
2
1
6
4
No. 1 pump
No. 2 pump
209488
(1) Sequence
1 Split flange, Bolts, Spring washers 4 Split flange, Bolt, Spring washers
2 Delivery hose, O-ring 5 Delivery hose, O-ring
3 Suction elbow, O-ring, Bolts, Washers 6 Hydraulic pump
(2) Suggestion for Removal

To remove the hydraulic pump, have it in a sling with a
hoist..
Weight of gear pump 19.5 kg (43 lb)
10-13
HYDRAULIC SYSTEM
3.1.2 Control Valve
1
3
8
4
6
7
208584
(1) Sequence
1 Control lever assembly, Clevis pin 6 Steering delivery pipe
2 Attachment pipe 7 Pipe and hose assembly
3 Tilt pipes, Connectors, O-rings 8 Return hose, Connector
4 Lift pipe 9 Control valve
5 Main delivery hose, Elbow, O-ring
(2) Start by
(a) Before disconnecting the pipes from the control valve,
bring the mast to the vertical position and place the
fork to the lowest position in order to release the resid-
ual pressure in the pipes.
(b) Support the weight of the mast with a crane.
(c) If an attachment is connected, take necessary measures
to prevent it from moving.
(d) Remove the floor plate and dashboard cover.
10-14
HYDRAULIC SYSTEM

(1) Start the engine and raise the lift bracket to the highest
position, then stop the engine.
3.2.1 Lift Cylinders
5
4
5
1
3
6
7
8
204631
(1) Removal sequence
1 Return hose, Clamp 5 Cylinder clamp, Cushion, Collar, Shim
2 Hose clamp 6 Lift cylinder, Bracket
3 High-pressure hose 7 Connector
4 Stopper bolt, Shim 8 Elbow, Down-safety valve
(2) Removing return hose

Disconnect each return hose for the right and left lift
cylinders at their connectors.
NOTE
During this operation never touch the lift lever of the con-
trol valve.
(3) Lower the lift bracket.
Push the lift lever of the control valve forward slowly to
lower the lift bracket.
10-15
HYDRAULIC SYSTEM
(4) Removing high-pressure hose

Remove the high-pressure hose from the joint at the
lower part of the lift cylinder. Prepare containers to
catch oil, which should remain in the high-pressure Right cylinder Left cylinder
hose.
(5) Removing stopper bolt
(a) Before lifting up the inner mast, wrap the inner mast
with a protective cloth and put the wire rope over there
in such a way that includes an extra turn.
Remove the stopper bolt at the upper section of the lift
cylinder, and lift the inner mast up to separate the cylin-
der rod end from the mast. 204933
NOTE
As the rod end section of the lift cylinder has some shims
inserted, record how many number of shims inserted in
which cylinder, right or left, before removal.
(b) Place wooden blocks with enough strength to support
the weight of the inner mast under the mast, then
remove the wire rope.
(6) Removing lift cylinder
Put a wire rope on the lift cylinder before removing the
cylinder clamp.Hoist the lift cylinder from the rear of
the mast with a rope to carefully remove it.
204632
204633
10-16
HYDRAULIC SYSTEM

(1) Start the engine and lower the forks to the bottom.
Then, fully tilt the mast forward.
(2) Stop the engine.
(3) Put a wire rope to the right and left lifting eyes pro-
vided in the cross-member at the top of the outer mast
and support the outer mast with a crane.
(4) Remove tilt cylinder pin 1 (see the illustration below).
(5) Start the engine, and retract the tilt cylinder rod to the
minimum.
(6) Stop the engine.
204581A
3.3.1 Tilt cylinder
204701
10-17
HYDRAULIC SYSTEM
(1) Removal sequence

1 Tilt cylinder pin 3 Tilt cylinder pin
2 Hose 4 Tilt cylinder
NOTE
Tilt cylinder pin 1 has been already removed during the pre-
paratory operation.
(2) Removing hose
Disconnect hose 2 from the connection to the cylinder.
Prepare a container to catch oil, which should remain in
the hose.Put a cap, etc. to the opening of the connector
disconnected to protect the thread section in addition to
prevent oil in the tilt cylinder from flowing out when it
is removed.
10-18
HYDRAULIC SYSTEM
4. Disassembly and Reassembly

4.1 Hydraulic Pump (Gear Pump)
NOTE
As a general rule, disassembly, repair, and reassembly of
the gear pump should be performed by the gear pump’s
manufacturer. If an emergency situation forces you to per-
form these tasks, work carefully in accordance with the sug-
gestions for disassembly described later. The gear pump’s
manufacturer cannot guarantee the gear pump’s perfor-
mance in such circumstances.
4.1.1 Disassembly
13
14
22
23
16
21
15 17
18 11
19
20
19
18
9
17
5
12 10
4
2 6
1
7
8
7
6
205535
10-19
HYDRAULIC SYSTEM
(1) Sequence
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 Snap ring
11 Adapter plate 23 Oil seal
12 O-ring
(2) Suggestions for Disassembly

(a) After removing each bolt and washer 1, remove the
first of the gear pump assemblies and sequentially
remove the parts from the rear cover 2 to the driven
gear 9.
(b) The front cover 14, rear cover 2, adapter plate 11, and
bearings 6, 18 are made of an aluminum alloy that can
be damaged easily. Do not strike them with a metal
hammer. Use a wooden hammer or plastic hammer
instead.
205535-1
4.1.2 Inspection and Repair

(1) Check each of the drive and driven gears for
(a) damage and wear on the tooth flanks and tooth tips;
(b) damage and wear on the side faces; and
(c) damage and wear on the shaft.
10-20
HYDRAULIC SYSTEM
(2) Check cover, body, and adapter plate for any damage or
wear.
205535-2
(3) Check oil seal, gasket, and O-ring for damage, wear or
setting.
205535-3
10-21
HYDRAULIC SYSTEM
4.1.3 Reassembly
12 1 *11 *9 7 4 5 7 *13 14 21 20 18 20 21 24 26
*3 *2 *10 8 6 8 *15 16 *23 *22 19 17 *25
204621A
(1) Sequence
1 Front cover 10 Gasket 19 Driven gear
2 Oil seal 11 O-ring 20 Side plate
3 Snap ring 12 Bolt, Washer 21 Bearing
4 Body 13 Backup strip, Gasket 22 Backup strip, Gasket
5 Drive gear 14 Adapter plate 23 O-ring
6 Driven gear 15 O-ring 24 Rear cover
7 Side plate 16 Bolt, Washer 25 Backup strip, Gasket, O-ring
8 Bearing 17 Body 26 Bolt, Washer
9 Backup strip 18 Drive gear
NOTE
Marked * are the parts included in the repair kit.
10-22
HYDRAULIC SYSTEM
(2) Suggestion for Reassembly

(a) During reassembly, do not forget to replace the Repair
Kit parts marked with an asterisk (*) in the figure.
(b) Completely remove oil from the mating surfaces of the
cover 1 and 14 and 24 and body 4 and 17.
(c) Apply grease to the oil seal lip.
(d) Be careful not to damage the lip of the oil seal with the
spline edges of drive gear 5.
(e) Tighten the bolts evenly.
55.9 to 62.7 N•m
Tightening torque of bolt 12 (5.7 to 6.4 kgf•m)
[41.2 to 46.2 lbf•ft]
55.9 to 62.7 N•m
[41.2 to 46.2 lbf•ft]
38.2 to 43.1 N•m
[28.2 to 31.8 lbf•ft]
10-23
HYDRAULIC SYSTEM
4.2 Control Valve

4.2.1 Disassembly of each assembly
6 6
4 5
3 4
3
2
2
3-valve type control valve
2-valve type control valve
1 6
6
5 1
5 5
5 5
4 4
3 3
2 2
4-valve type control valve 5-valve type control valve
1
1
211511
(1) Disassembly sequence
1 Tie bolt, Nut, Washer 4 Tilt valve assembly
2 Inlet cover assembly 5 Attachment valve assembly
3 Lift valve assembly 6 End cover
(2) Reassembly
Reassemble in the reverse order of disassembly se-
quence.
(3) Suggestion for reassembly
(a) Tighten the tie bolts (securing the valve housings) as
evenly as possible to prevent distorsion of the hous- A
ings. Remember, a failure to follow this precaution will
result in sluggish movement of the spools.
65 N•m (6.6 kgf•m)

Tightening torque for tie bolts A
[48 lbf•ft]
101 N•m (10.3 kgf•m)
Tightening torque for tie bolts B
[74 lbf•ft]
B
NOTE 205530
Do not use liquid packing.
10-24
HYDRAULIC SYSTEM
4.2.2 Inlet Cover Disassembly

(1) Sequence
1 Relief valve assembly
2 O-ring 1
3 Inlet cover *2
(2) Suggestions for Disassembly 3

(a) Do not disassemble the relief valve unless pressure
adjustment is impossible to make.
(3) Inspection and Repair 211512

(a) Check the inlet cover for cracks. Check the relief valve
for worn seat surface. Repair if necessary. NOTE
Parts marked with * are repair kit parts.
(4) Reassembly
To reassemble, follow the disassembly sequence in re-
verse and do the following steps.
(5) Suggestions for Reassembly

(a) Replace the part marked with an asterisk (*) in the
illustration with appropriate replacement part in the
repair kit.
(b) Take extreme care that foreign matter like dust is not
trapped in the assembly.
(c) Tighten the relief valve assembly to the specified
torque.
127 ± 10 N•m
Relief valve tightening
(13 ± 1 kgf•m)
torque
[94 ± 7 lbf•ft]
10-25
HYDRAULIC SYSTEM
4.2.3 Lift Valve Disassembly

(1) Sequence
1 O-ring
15
2 O-ring
3 Plug
*16
4 Spring 17
5 Load check valve
6 O-ring
7 End cover, Bolt 5
18 4
8 Spacer bolt
9 Spring seat *2
10 Spring
3
11 Washer *1
12 Spring seat *6 *14
13 Plate 13
14 Wiper 12
10
15 Plate 9 11
16 Wiper
8
17 Spool
7
18 Valve body
(2) Inspection and Repair

(a) Check the valve body for cracks and damaged sliding
contract surface. Check the load check valve for worn 211513
seat surface. Repair if necessary.
(b) Check the spool for damage, seizure or bend. Repair if
NOTE
necessary.
(c) Check the spring for damage in fatigue.
10-26
HYDRAULIC SYSTEM
(3) Reassembly
(4) Suggestsions for Reassembly
(a) Replace the parts marked with an asterisk (*) in the
illustration with appropriate replacement parts in the
repair kit.
(c) Apply an even coat of oil to the spool before fitting it
into the valve body.
(d) Tighten the following parts to the appropriate specified
torques.
196 ± 10 N•m
Plug 3 (20 ± 1 kgf•m)
[145 ± 7 lbf•ft]
12 ± 1 N•m
End cover 7 attaching bolt (1.2 ± 0.1 kgf•m)
[9 ± 0.7 lbf•ft]
12 ± 1 N•m
Spacer bolt 8 (1.2 ± 0.1 kgf•m)
[9 ± 0.7 lbf•ft]
CAUTION
Overtightening these parts may bulge the spool to
prevent its smooth movement.
NOTE
10-27
HYDRAULIC SYSTEM
4.2.4 Tilt Valve Disassembly

(1) Sequence
1 O-ring
2 Spring 15
3 Load check valve
*16
4 End cover, Bolt 17
5 Spacer bolt
6 Spring seat
3
7 Spring 2
8 Washer 18
9 Spring seat *1
10 O-ring
11 Spring
12 Popet
12
13 Plate
11 *10
14 Wiper
*14
15 Plate 13
9
16 Wiper
7
17 Spool 8
6
18 Valve body 5
(2) Inspection and Repair 4

NOTE
necessary.
(c) Check the springs for damage in fatigue.
10-28
HYDRAULIC SYSTEM
(3) Reassembly
repair kit.
(c) Apply an even coat of oil to the spools before fitting
them into the valve body.
(d) Install the spool 16 correctly into place.
(e) Tighten the following parts to the appropriate specified
torques.
196 ± 10 N•m
Plug 3 (20 ± 1 kgf•m)
[145 ± 7 lbf•ft]
12 ± 1 N•m
[9 ± 0.7 lbf•ft]
12 ± 1 N•m
[9 ± 0.7 lbf•ft]
CAUTION
Overtightening these parts may bulge the spools
to prevent its smooth movement.
NOTE
10-29
HYDRAULIC SYSTEM
4.2.5 Attachment Valve Disassembly

(1) Sequence
1 O-ring
2 O-ring
12
3 Load check valve
4 End cover, Bolt
*13
5 Spacer bolt 14
6 Spring seat 15
*16
7 Spring
8 Washer *17 3
2
9 Spring seat 18
10 Plate
11 Wiper *17 *1
12 Plate *16
13 Wiper *11
15
14 Spool 10
15 Plug 9
7
16 O-ring *8
6
17 Packing 5
18 Valve body 4

NOTE
necessary.
(c) Check the springs for damage in fatigue.
10-30
HYDRAULIC SYSTEM
(3) Reassembly
repair kit.
(c) Apply an even coat of oil to the spool before fitting it
into the valve body.
(d) Tighten the following parts to the appropriate specified
torques.
196 ± 10 N•m
Plug 15 (20 ± 1 kgf•m)
[145 ± 7 lbf•ft]
12 ± 1 N•m
[9 ± 0.7 lbf•ft]
12 ± 1 N•m
[9 ± 0.7 lbf•ft]
CAUTION
Overtightening these parts may bulge the spool to
prevent its smooth movement.
NOTE
10-31
HYDRAULIC SYSTEM
4.2.6 End Cover Disassembly

(1) Sequence
1 O-ring
2 End cover
*1 2
(a) Check the end cover for cracks. Repair if necessary.
(3) Reassembly
verse and do the following.
(a) Replace the part marked with an asterisk (*) in the
211516
repair kit.
NOTE
(b) Take extreme care that foreign matter like dust is not Parts marked with * are repair kit parts.
NOTE
10-32
HYDRAULIC SYSTEM
4.3 Lift Cylinders

4.3.1 Disassembly
NOTE
205536
(1) Sequence
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
Do not remove the U-ring, bushing 2, and wiper ring 1
unless they appear abnormal when inspected.
10-33
HYDRAULIC SYSTEM
(2) Removal of piston rod

(a) Wrap the cylinder tube with cloth, and hold it in a vise.
Remove the guide bushing with the hook wrench A.
Special tool needed
Hook wrench A 05312 - 10600
(b) Be careful not to damage the piston seals when withil-

lustration the piston rod from the cylinder.
When withillustration the piston rod from the shell, take A
care not to damage the rings.
602303

(1) Cylinder tube
(a) Check the inside surface of the cylinder for wear, dam-
age, or rust.
(b) Check the welded part for cracks, damage, and dent.
(2) Piston rod
(a) Check the piston rod if it may cause runout.
Support both ends of the piston rod with V-shaped
blocks, and measure its runout using a dial gauge at the
center while turning the piston rod.
(b) Check the rod surfaces for rust, damage, sliding trace,
200319
and dent.
Replace the piston rod, if it is seriously damaged in the
threaded part.
0 mm
Standard value
Runout of piston rod (0 in.)
(measurement) Repair or service 1 mm
limit (0.0394 in.)
10-34
HYDRAULIC SYSTEM
(3) Ring and packing (b) Check each ring for deterioration.
(a) Check the lips of packing and buffer ring for damage or
distortion.
Item Service Date
+0.2 +0.0079
Standard value 80 0 mm (3.15 0 in.)
[Piston section] Inside diameter of cylinder tube 1
Repair or service limit 80.25 mm (3.1594 in.)
0 0
Standard value 60-0.05 mm (2.36 -0.00197 in.)
Thickness of piston ring 2Standard value
-0.06 -0.00236
60-0.13 mm (2.36-0.00512 in.)
-0.06
Standard value (Mast height 6500 to 7000: 65-0.13 mm
-0.00236
[Cylinder head section] Outside diameter of piston rod 3 [2.56-0.00512 in.])
59.84 mm (2.3559 in.)
Repair or service limit (Mast height 6500 to 7000: 64.84 mm
[2.5528 in.])
+0.12 +0.0047
60 0 mm (2.36 0 in.)
+0.12
Standard value (Mast height 6500 to 7000: 65 0 mm
+0.0047
Inside diameter of cylinder head bushing 4 [2.56 0 in.])
60.17 mm (2.3689 in.)
Repair or service limit (Mast height 6500 to 7000: 65.17 mm
[2.5657 in.])
Thread diameter 5 Standard value M90 × 2 mm (0.0788 in.)
Cylinder head tightening torque 6 Standard value 490 N•m (50 kg•m) [362 lbf•ft]
6 5
3 4 1
205531A
10-35
HYDRAULIC SYSTEM
4.3.3 Reassembly
NOTE
Marked * are the parts included in the seal kit.
1 5 4 3 2
* * * *
205531B
NOTE
The spacer 3 is fitted in the cylinder if the truck has a mast
lift height of 5 m (16.5 ft) or greater.
(1) Sequence
1 Piston rod 4 Cylinder tube
2 Piston ring, U-ring, Holder, Stopper 5 Cylinder head, Wiper ring, U-ring, Bushing, O-ring,
3 Spacer Holder

(a) When performing reassembly, replace each part
marked * in the illustration with a new one from the
seal kit.
(b) Clean all parts thoroughly before reassembling them.
Keep them free of dirt and other foreign substances until
they are assembled.
(c) Smear oil on the U-rings, piston ring, O-ring, bushing,
wiper ring, and cylinder bore before assembling the
parts.
(d) When clamping the cylinder in a vise, tighten the vise
carefully so as not to deform the cylinder.
(e) Before fitting the cylinder head, apply adhesive to the
thread of the cylinder tube.
490 N•m
Cylinder head tightening
(50 kg•m)
torque
[361 lbf•ft]
10-36
HYDRAULIC SYSTEM
4.4 Tilt Cylinder

4.4.1 Disassembly
NOTE
Used on truck capable of 6° forward

and rearward tilt angles
*
*
**
204639B
(1) Sequence
1 Socket, bushing, nut 4 Cylinder tube, Bushing
2 Bushing, O-ring, Dust seal, Packing 5 Shim
3 Piston rod, Piston, Nut, Piston seal 6 Collar, O-ring
NOTE
(a) The collars 6 are used on a truck capable of a 6° for-
ward and rearward tilt angles.
(b) The shims 5 are for right-left tilt-angle adjustment.
(c) Do not remove the bushings that are press-fitted into
the cylinder tube 4 and socket 1 unless they appear
abnormal when inspected.
10-37
HYDRAULIC SYSTEM
(2) Removal of bushing

(a) Wrap the tilt cylinder with rags and grip it in a vise.
Remove thte bushing using a hook wrench A.
Special tool needed
Hook wrench A 05312 - 21250
(b) Before removing the bushing from the piston rod, wrap
vinyl tape around the threaded part of the piston rod to
avoid damaging the buffer ring and packing inside the
bushing. A
When withillustration the piston rod from the shell, take
200351
care not to damage the rings.

(1) Cylinder tube
(a) Check the inside surface of the cylinder for wear, dam-
age, or rust.
(b) Check the welded part for cracks, damage, and dent.
(2) Piston rod
(a) Check the piston rod if it may cause runout.
Support both ends of the piston rod with V-shaped
blocks, and measure its runout using a dial gauge at the
center while turning the piston rod.
(b) Check the rod surfaces for rust, damage, sliding trace,
and dent. 200319
Replace the piston rod, if it is seriously damaged in the
threaded part.
10-38
HYDRAULIC SYSTEM
(3) Ring and packing

(a) Check the lips of packing and buffer ring for damage or
distortion.
(b) Check each ring for deterioration.
Item Service Date
Standard value 90 mm (3.548 in.)
Inside diameter of cylinder tube 1
-0.025 -0.00096
[Bushing section] Outside diameter of piston rod 2 Standard value 40-0.064 mm (1.57-0.00252 in.)
Standard value 0.075 to 0.139 mm (0.00296 to 0.00548 in.)
Clearance between rod and bushing
+0.085 +0.00355
Inside diameter of bushing at the mast side 3 (under Standard value 40 0 mm (1.57 0 in.)
press-fit) Repair or service limit 40.6 mm (1.598 in.)
+0.085 +0.00355
Inside diameter of bushing at the frame side 4 (under Standard value 40 0 mm (1.57 0 in.)
[Bushing] Thread diameter 5 Standard value M95 × 2.0 mm (0.0788 in.)
637 ± 64 N•m
Tightening torque of bushing 5 Standard value (65 ± 6.5 kgf•m)
[470 ± 47.2 lbf•ft]
588 ± 29.4 N•m
Tightening torque of piston rod nut 6 Repair or service limit (60 ± 3 kgf•m)
[4.34 ± 21.7 lbf•ft]
Standard value M38 × 1.5 mm
[Socket]Thread diameterTightening torque of rod socket 539 to 637 N•m
nut 7 Standard value (55 to 65 kgf•m)
[398 to 470 lbf•ft]
2 1 6
5
7 4
3
204640B
10-39
HYDRAULIC SYSTEM
4.4.3 Reassembly
NOTE
Stamped mark
* *** * *
44 3 2 1
204640D
(1) Sequence
1 Piston rod, Piston, Nut, Piston seal 3 Bushing, Packing, Dust seal, O-ring
2 Cylinder tube, Bushing 4 Socket, Bushing, Nut

(a) When performing reassembly, replace each part
marked * in the illustration with a new one from the
seal kit.
(b) Clean all parts thoroughly before reassembling them.
Keep them free of dirt and other foreign substances
until they are assembled.
(c) Smear oil on the piston seal, O-ring, packing, dust seal,
and cylinder bore before assembling the parts.
(d) When clamping the cylinder in a vise, tighten the vise
200352
carefully so as not to deform the cylinder.
(e) Install the tilt cylinder’s piston seal as follows:
• Soften the piston seal by gently squeezing it five or six
times by hand.
• Grip the piston rod in a vise (be careful not to damage it),
then smear a little oil on the piston seal. Fit one side of the
piston seal into the installation groove in the piston, then
push the other side into position.
(f) Make sure the packing and dust seal are aligned cor-
rectly when pressing them into the bushing.
204641
10-40
HYDRAULIC SYSTEM

4.5.1 Disassembly
9
10
11
12
13
3 2
5
7
8
205537
(1) Disassembly Sequence
1 Elbow, O-ring 5 Spring 9 Snap ring
2 Connector, O-ring 6 Pin 10 Plate
3 Nut 7 Stopper 11 Valve
4 Plug, O-ring 8 Disk spring 12 Piston
13 Body
NOTE NOTE
Disassembly for pin 6 to piston 12 should be performed When any of the parts are damaged, replace the whole
after pulling out the piston. assembly.
(1) Check the spring for deterioration.
(2) Check each contact surface of the valve and piston for
damage or sliding trace.
(3) Check each sliding surface of the piston and valve
body for damage.
10-41
HYDRAULIC SYSTEM
4.5.3 Reassembly
Reassembly should be followed in the reverse order of dis-
assembly.
4.6 Down Safety Valve

4.6.1 Disassembly
(1) Sequence
1 Spring pin
2 Valve
3 Spring 2
4 Connector, O-ring 1
3
4.6.2 Inspection
4
(1) Check the valve orifice for clogging or damage.
(2) Check the spring for fatigue. 200355
(3) Check for stripped threads.
NOTE
Replace the down safety valve as an assembly if any part is
defective.
4.6.3 Reassembly
To reassemble, follow the reverse of disassembly sequence.
10-42
HYDRAULIC SYSTEM
5. Inspection and Adjustment

5.1 Hydraulic oil
Cloudy oil should be changed, since any water is suspected
to mix in. When the oil is checked immediately after operat-
ing the hydraulic lever, be careful not to mistake the bub-
bles of oil as a mixture with water.
5.2 Suction strainer, Return filter
Check for damage or clogging, and clean or replace.
5.3 Hydraulic Pump Test Run
The purpose of test run is to break-in the overhauled pump
and verify its performance. The use of a pump testing
equipment, specially designed as such and commonly used 205539A
in the service shop, is recommended but is not mandatory.
The following procedure, however, assumes that the pump
is installed on the truck:
(1) Install a pressure gauge capable of measuring up to 25
MPa (250 kgf/cm2) [3555 psi].
To install the pressure gauge, remove the plug from the
delivery hose connector and attach the following tools:
Connector 64309 - 17733 (R 1/8 thread)

Hose 64309 - 17722
Connector 64309 - 17731 (for gauge)
64309 - 17712
Gauge
25MPa (250 kgf/cm2) [3555 psi]
NOTE
These tools are included in the gauge kit 64309 - 17701. 205540A
(2) With the control levers in neutral, run the engine at a
speed between 500 and 1000 rpm, holding the dis-
charge pressure at a level not higher than 0.981 MPa
(10 kgf/cm2) [142 psi]. Run the pump under this condi-
tion for 10 minutes for break-in, listening for noise.
(3) Raise the engine speed to a speed between 1500 and
2000 rpm, and run the engine for another 10 minutes in
the no-load condition.
(4) While the pump is being so run, loosen the adjusting
screw, and shift the control levers into operating posi-
tions. Next set the adjusting screw, to obtain a gauge
reading of 2.94 MPa (30 kgf/cm2) [427 psi], and run for
5 minutes at this pressure. Following this, raise the
pressure by changing the setting of adjusting screw in
increments of 1.96 MPa (20 kgf/cm2) [284 psi] each,
running the pump for 5 minutes at each raised pressure
until, finally, the prescribed set pressure of the relief
valve is reached.
10-43
HYDRAULIC SYSTEM
(5) Pay attention to the temperatures of oil and pump sur-

faces and to the running noise while raising the pres-
sure and, if any abnormal condition is noted, bring the
pump to no-load condition to cool the oil or pump or,
as necessary, discontinue the test run, and overhaul the
pump once again. Do not keep on raising the pressure
when an abnormal condition is noted.
(6) After doing Steps (2) thru (5) above, reset the relief
valve as specified and operate the fork and mast to see
if the lift and tilt cylinders work with the specified
speeds.
5.4 Control Valve

3° to 4°
5.4.1 External leakage
(1) Check for oil leaks from the joint between adjacent
valve housings sealed by O-ring.
(2) Check for oil leaks from the scrapers sealed by O-
rings.
(3) Check for oil leaks from the screw connections.
5.4.2 Internal leakage
1 m (3.3 ft),
It is not practical to check the control valve alone for inter- approx.
nal leakage. How to check the control valve in place (under
normal operating conditions) will be described.
204646
The internal leakage to be checked includes leakages occur-
ring at the lift spool, tilt spool, tilt lock valve and check
valves.
Test oil temperature 50°C (122°F), approx.
(1) Pick up a load equal to the rated capacity, and lift it

approximately 1 m (3.3 ft) high. Tilt the mast about 3°
to 4° forward, and stop the engine.
(2) Quickly disconnect the oil return hose, and start col-
lecting the oil coming out of this hose as shown.
Amount of oil collected for

380 cc (23.2 cu in.)
15 minutes
205541
(3) If the lift cylinders or tilt cylinders drift (the mast tilts
forward or the fork lowers) excessively in spite of that
the amount of oil collected for 15 minutes is less than
380 cc (23.2 cu in.), measure the internal leakage of
each cylinder. (The measurement is the assembly stan-
dard and not the service limit.)
205539A
10-44
HYDRAULIC SYSTEM
5.4.3 Main Relief Valve

(1) Install a pressure gauge capable of measuring up to 25
MPa (250 kgf/cm2) [3555 psi] to the delivery hose con-
nector. Use the gauge, connectors and hose used for
testing the gear pump.
(2) Start the engine and run it at the maximum speed.
Move the tilt control lever to the backward tilt position.
+0.49 +5
If the pressure is relieved at 19.12 0 MPa (195 0 kgf/
2 +71
cm ) [2773 0 psi] when the tilt cylinders reach the end
of their stroke, the main relief valve setting is correct.
(3) If the setting is incorrect, loosen the lock nut of adjust-
ing screw and, while observing the pressure gauge
reading, slowly rotate the adjusting screw until the
gauge indicates the prescribed set value.
NOTE
One rotation of the adjusting screw changes the pressure by
approximately 17.8 MPa (181 kgf/cm2) [2574 psi].
(4) While holding the adjusting screw, tighten the lock nut
to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the setting.
+0.49
19.12 0 MPa
+5
Main relief valve setting (195 0 kgf/cm2)
+71
[2773 0 psi]
10-45
HYDRAULIC SYSTEM
5.5 Steering System Relief Valve

(1) Install a hydraulic pressure gauge to the position indi-
cated in the figure to the right.
3
Connector 1 91268 - 01700
Hose 2 64309 - 17722
64309 - 17712 2
Gauge 3
25 MPa (255 kgf/cm2) [3627 psi]
NOTE
Tools 1 to 3 are included in the gauge kit.
1
206983
(2) Start the engine, and turn the steering wheel fully to the
left at the maximum engine speed. When the steering
wheel stroke reaches the limit, check the pressure
gauge. The steering system relief valve is in good con-
dition if the oil pressure is relieved and the gauge read-
ing becomes as the following standard value.
11.8 to 12.29 MPa

Steering system relief valve
(120 to 125 kgf/cm2)
setting
[1707 to 1778 psi]
(3) If the steering system relief valve opening pressure is

out of specification, adjust the valve properly.
B2 B3
A1 A2 A3
Steering system relief valve 208808
10-46
HYDRAULIC SYSTEM
5.6 Adjustment of overload relief valve (option)

(1) Connect an oil pressure gauge (reading: 0 to 25 MPa)
on the left side of the control valve.
NOTE
Connect the pressure gauge using the same fittings and
tools as with the adjustment of main relief valve.
(2) Start the engine and bring it to the maximum speed,
then operate the lever for the attachment either forward
or backward.The relief valve is normal if the oil can be
successfully relieved and the hand of the pressure
gauge points to the specified oil pressure when the oil
pressure of the actuator reaches the limit.
(3) If the relief pressure is not satisfactory, loosen the lock
nut of the relief valve adjusting screw and adjust the
pressure while observing the gauge reading.
(4) Tighten the lock nut to secure the adjusting screw while
holding it by hand.
(5) After securing the adjusting screw, recheck the relief
valve pressure setting.
211827
5.7 Adjusting flow regulator valve
Measure the lowering speed under the rated load.
If the lowering speed does not meet the standard value,
loosen the lock nut and adjust the speed by means of an
amount to turn in the plug.
Increment/decrement of the
Approx.17 mm
lowering speed per 1/2 turn of
(0.67 in.)/sec.
plug
205546
10-47
HYDRAULIC SYSTEM
6. Testing
6.1 Lift cylinder drift test
(1) Pick up a load equal to the rated capacity, place the
mast to a vertical position, lift the fork 1 to 1.5 m (3.3
to 4.9 ft), and stop the engine.
(2) Mark a reference line on the mast, and measure the
drift (retraction of the piston rods) for 15 minutes.
Lift cylinder drift (in 15 minutes 55 mm (2.2 in.),

under rated load weight) maximum
200996
6.2 Tilt cylinder drift test

(1) Pick up a load equal to the rated capacity, place the
mast to a vertical position, lift the fork about 50 cm (20
in.), and stop the engine.
(2) Measure the extension of tilt cylinder piston rods for 15
minutes.

Tilt cylinder drift (in 15
15 mm (0.59 24 mm (0.94
minutes under rated load
in.) in.)
weight)
204654
10-48
HYDRAULIC SYSTEM
7. Troubleshooting
• Not enough oil • Refill.
• Inappropriate oil viscosity • Refer to the “List of Applicable
Lubricant”, and replace.
• Operating conditions are hard and • Check the working conditions, and
over-loaded. if over-loaded, urge the operator to
stay within the load limit
Hydraulic tank heats • Local overheating of oil line due to • Clean oil line.
excessively
a large restriction to flow
• Relief valve adjustment improper • Adjust pressure setting.
Hydraulic tank • Hydraulic pump worn • Replace pump.
• Outlet-side line flattened or restric- • Repair or replace.
tion to flow
• Clogging of oil cooler • Clean
• Shortage of oil due to a natural loss • Refer to the “List of Applicable
Lubricant”, and add oil.
Cylinders move too • Oil leakage due to damaged oil • Repair or replace.
slow line, seal, etc.
• Oil viscosity is too high • Refer to the “List of Applicable
Lubricant”, and change oil.
10-49
HYDRAULIC SYSTEM
• Gear pump does not pump-in oil • Check pump and piping. Repair or
replace if required.
• Oil leaks from part of the hydraulic • Check the oil level and contamina-
Cylinders move too line tion. Add or change oil if neces-
slow sary.
• Oil level abnormally high • Check the control valve spools for
misalignment. Repair or replace.
• Hydraulic pump internal leakage • Replace pump.
• Poor pumping of oil • Refer to the “List of Applicable
• Cavitation Lubricant”, and add oil.
(1) Check suction pipe for any flat
portion or loose connection.
Pump too noisy Retighten or replace.
(2) Check shaft oil seal for air-tight-
ness. Replace the pump.
(3) Check pump body for any out-
Gear pump
side interference. Repair.
• Subjected to pressure greater than • Check if pressure control valve
that rated operates normally. Replace the
pump.
Pump case, drive gear • Distortion or damage due to exter- • Replace pump.
or pump port flange nal strain or stress (1) Check if the return line has been
damage blocked or restricted to flow.
(2) Check if pipe connection has
been externally strained or
stressed.
• Oil leakage from oil seal • Replace seal.
• Oil leakage through sliding sur- • Replace pump assembly.
faces of drive shaft
Oil leakage from pump
• Pump securing bolt loose • Retighten, and replace parts if
required.
• Seal ring inside pump deteriorated • Replace O-ring.
10-50
HYDRAULIC SYSTEM
• Too low valve opening pressure • Adjust the pressure.

setting
• Relief valve piston sticks • Clean piston and check to see if it
moves smoothly; or replace relief
Slow or no motions of valve assembly.
lift and tilt cylinders • Outer O-ring on relief valve body • Replace O-ring.
damaged
• Control lever installed loose, • Readjust.
Control Valve resulting in not enough spool
stroke
Lift drops or tilts for- • Control valve spool internal leak- • Replace each block assembly.
ward age
• Oil leakage from spool ring cap • Replace O-ring; check spool. If
necessary, repair or replace each
Oil leakage block assembly.
• Plug loose • Retighten.
• O-ring damaged • Replace O-ring.
• Insufficient oil in hydraulic tank • Refer to the “List of Applicable

Lubricant”, and add oil.
Mast will not ascend, • Relief valve defects • Replace.
tilt forward or back-
(1) Main valve jammingn
ward.
(2) Valve spring fracture • Replace.
• Hydraulic pump defects • Replace.
• Relief valve defectsn • Adjust the pressure.
(1) Too low valve opening pressure
setting
Unable to lift rated

(2) Plunger or poppet seat defects • Replace.
load (3) Spring deteriorated • Replace.
(4) O-ring in valve case damaged • Replace.
• Hydraulic pump defects • Replace.
Lift and tilt cylinder
• Piston seal worn or damaged • Replace.
• Engine speed too slow • Adjust engine
• Control lever installed loose, • Readjust
resulting in not enough spool
Lifting speed too slow
stroke
• Clogging of tank strainer • Wash or replace.
• Gear pump delivery rate too low • Repair or replace.
• Sleeve seized in flow regulator • Repair
valve
• Hydraulic line extremely restricted • Clean or repair the hydraulic sys-
Lowering speed of lift
cylinder too slow from smooth flowing due to dirt tem or replace defective hose.
clogged in flow regulator valve, or
hydraulic hose fractured or locally
stopped.
10-51
HYDRAULIC SYSTEM
• Piston rod bend • Repair or replace.

Cylinder vibrates dur- • Air mixed in hydraulic line • Bleed air by operating cylinder
ing operation across full stroke.
• Insufficient oil in tank • Refill.
• Control valve spool internal leak- • Replace each block assembly.
age
• Scratches on sliding surface of cyl- • Repair or replace.
inder tube that can be felt by finger
Lift cylinder descend nail.
excessively
• Sliding surface of cylinder tube • Replace cylinder assembly.
badly grooved
• Piston seal damaged or distorted • Replace seal.
• Oil leakage from hydraulic line • Repair or replace.
• Control valve spool internal leak- • Replace each block assembly.
Lift and tilt cylinder age
Tilt cylinder tilt for- • Foreign matter lodged in packing • Replace packing.
ward excessively • Piston seal damaged • Replace seal.
• Abnormal distortion or oil leakage • Repair or replace.
from hydraulic line
Lift cylinder or tilt cyl- • Inside surface of cylinder badly • Repair or replace.
inder will descend or grooved or rusted
tilt forward at a certain
point • Cylinder distortion • Replace.
• Foreign matter lodged in oil seal or • Replace.

dust seal
Oil leakage from • Inner or outer diameter of oil seal • Replace.
bushing or dust seal damaged
• O-ring damaged • Replace O-ring.
• Abnormal distortion • Repair or replace.
10-52
HYDRAULIC SYSTEM
8. Service Data
8.1 Gear pump
Fork ascending speed (under the rated load)[Dual pan- 440 mm/sec
Standard value
orama mast] (at maximum engine speed) (86 fpm)
Fork ascending speed (under no load) (at maximum 470 mm/sec
Standard value
engine speed) (92.5 fpm)
Fork descending speed (under the rated load)[Dual pan- 550 mm/sec
Standard value
orama mast] (at maximum engine speed) (108 fpm)
Forward tilt angle [Standard dual panorama mast truck] Standard value 6°
Backward tilt angle [Standard dual panorama mast
Standard value 12°
truck]
Free descending amount of lift cylinder (under rated 55 mm/15 min maximum
Standard value
load)(Oil temperature: 45°C) (rod retraction length) (2.2 in./15 min maximum)
Free tilting angle of tilt cylinder (under rated load)(Oil 15 mm (0.59 in.) 24 mm (0.94 in.)
Standard value
temperature: 45°C) (rod extension length) /15 min maximum /15 min maximum
Discharge capacity Standard value 115/2300 L/rpm
Mounting bolt and nut tightening torque 1 Standard value 56.8 N•m (5.79 kgf•m) [41.9 lbf•ft]
37 to 48 N•m (3.77 to 4.89 kgf•m)
Delivery hose mounting bolt tightening torque 2 Standard value
[27.3 to 35.4 lbf•ft]
2 1
205547
10-53
HYDRAULIC SYSTEM
8.2 Control Valve

19.11 to 19.6 MPa (194.9 to 199.9 kgf/cm2)
Main relief pressure 1 Standard value
[2772.0 to 2843.0 psi]
10.78 to 11.27 MPa (109.9 to 114.9 kgf/cm2)
Priority relief pressure 2 Standard value
[1563.7 to 1634.8 psi]
(at neutral) Standard value 126 N (12.85 kgf) [28.33 lbf]
Spool operating effort
(at maximum engine speed) Standard value 158 N (16.11 kgf) [35.52 lbf]
Tilt pipe tightening torque 3 Standard value 58.8 N•m (5.690 kgf•m) [41.159 lbf•ft]
117.6 ± 11.8 N•m (11.993 ± 1.203 kgf•m)
Tilt pipe connector tightening torque 4 Standard value
[86.743 ± 8.704 lbf•ft]
39 to 49 N•m (3.977 to 4.997 kgf•m)
Check valve tightening torque 5 Standard value
[28.782 to 36.162 lbf•ft]
118 N•m (12.03 kgf•m)
Lift pipe connector tightening torque 6 Standard value
[87.08 lbf•ft]
137 N•m (13.97 kgf•m)
Return pipe connector tightening torque 7 Standard value
[101.11 lbf•ft]
Delivery hose connector tightening torque 8 Standard value 118 N•m (12.03 kgf•m) [87.08 lbf•ft]
Return pipe connector tightening torque 9 Standard value 49 N•m (4.997 kgf•m) [36.16 lbf•ft]
59 N•m (6.02 kgf•m)
Return pipe connector tightening torque 10 Standard value
[43.54 lbf•ft]
Tie-bolt tightening torque 7/16“11 Standard value 65 N•m (6.63 kgf•m) [47.97 lbf•ft]
1/2”12 Standard value 101 N•m (10.30 kgf•m) [74.5 lbf•ft]
9 10
4
11
12
1
7
5
2 6
211318
10-54
HYDRAULIC SYSTEM
8.3 Hydraulic Tank

Return filter tightening torque 1 Standard value 49 N•m (5 kgf•m) [36.1 lbf•ft]
Suction strainer tighetning torque 2 Standard value 49 N•m (5 kgf•m) [36.1 lbf•ft]
176 to 196 N•m (17.9 to 19.9 kgf•m)
Drain plug tightening torque 3 Standard value
[130 to 145 lbf•ft]
3 2
205529
Regulated flow rate (under no load) Standard value 150 ± 12 L/min (9153.6 ± 732.3 cu.in./min)
Return pipe tightening torque 1 Standard value 118 N•m (12 kgf•m) [87.1 lbf•ft]
205549
10-55
HYDRAULIC SYSTEM
8.5 Lift cylinder

+0.2 +0.00788
Standard value 80 0 mm (3.147 0 in.)
Cylinder tube inside diameter 1
0 0
Standard value 60 -0.05 mm (2.36 -0.00197 in.)
Piston ring thickness 2
-0.06
65 -0.13 mm
-0.06
60 -0.13 mm -0.00236
(2.36-0.00512 in.)
Standard value -0.00236
(2.36-0.00512 in.) (maslift height:
Piston rod outside diameter 3 6.5 to 7 m)
64.84 mm (2.5528 in.)
Repair or service limit 59.84 mm (2.3559 in.) (maslift height:
6.5 to 7 m)
+0.12
650 mm
+0.12
60 0 mm +0.00473
(2.56 0 in.)
Standard value +0.00473
(2.36 0 in.) (maslift height:
Cylinder head bushing inside diameter 4 6.5 to 7 m)
65.17 mm (2.5657 in.)
Repair or service limit 60.17 mm (2.3689 in.) (maslift height:
6.5 to 7 m)
Nominal size of cylinder head thread 5 Standard value M90 × 2.0 mm (0.0788 in.)
Cylinder head bolt tightening torque 6 Standard value 490 N•m (49.969 kgf•m) [361.4 lbf•ft]
6 5
3 4 1
205531A
10-56
HYDRAULIC SYSTEM
8.6 Tilt cylinder

Standard value 90 mm (3.54 in.)
Inside diameter of cylinder tube 1
-0.025 -0.00099
[Bushing]Outside diameter of piston rod 2 Standard value 40 -0.064 mm (1.57-0.00252 in.)
Standard value 0.075 to 0.139 mm (0.00296 to 0.00548 in.)
Clearance between rod and bushing
+0.085 -0.00335
Inside diameter of socket bushing at the mast side 3 Standard value 40 0 mm (1.57 0 in.)
(under press-fit) Repair or service limit 40.6 mm (1.598 in.)
Inside diameter of bushing at the frame side 4 (under Standard value 40 mm (1.57 in.)
Thread diameter of guide bushing 5 Standard value M95 × 2.0 mm (0.0788 in.)
637 ± 64 N•m (65 ± 6.6 kgf•m)
Guide bushing tightening torqueStandard value Standard value
[470.1 ± 47.2 lbf•ft]
588 ± 29 N•m (59.96 ± 2.958 kgf•m)
Tightening torque of piston rod nut 6 Standard value
[433.7 ± 21.4 lbf•ft]
539 to 637 N•m (54.97 to 64.97 kgf•m)
Tightening torque of rod socket nut 7 Standard value
[397.6 to 469.9 lbf•ft]
Tilt hose tightening torque Standard value 49 N•m (5.00 kgf•m) [36.1 lbf•ft]
2 1 6
5
7 4
3
204640B
10-57
HYDRAULIC SYSTEM
10-58

99709-86140-10 - Hydraulic System

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What are the main components of the hydraulic system?

What are the main components of the hydraulic system?

What are the steps involved in removing hydraulic components?

What are the steps involved in removing hydraulic components?

HYDRAULIC SYSTEM

1. Specifications ............................................................................................................. 10-3

2. Structure and Functions ............................................................................................. 10-4

3. Removal and Installation .......................................................................................... 10-13 5

4.4 Tilt Cylinder ....................................................................................................................................... 10-37

5. Inspection and Adjustment ....................................................................................... 10-43

6. Testing ..................................................................................................................... 10-48

7. Troubleshooting ....................................................................................................... 10-49

8. Service Data............................................................................................................. 10-53

Truck Model DP60 DP70

2. Structure and Functions

1 Suction strainer 8 Lift cylinder (R.H.) 15 Steering valve

2.2 Hydraulic Tank

The hydraulic tank is an all-welded structure and is bolted

2.3 Hydraulic Pump (Gear Pump)

1 Front cover 10 Driven gear 19 Bolt

The gear pump (an external-gear type) pumps the hydraulic

2.4 Control Valve

The priority valve serves to distribute a required quantity of

2.5 Lift Cylinder

1 Cylinder tube 8 Holder

The two lift cylinders are a single-acting type. One is

2.6 Tilt cylinder

This tilt cylinder is of a dual-working type capable of mak-

Raised height of Tilt angle for- Letter stamped on

2.7 Flow Regulator Valve

1 Body 8 Disc springs

2.8 Down Safety Valve

The down safety valve is built in the bottom of left-hand lift

2.9 Piping of Hydraulic System

3. Removal and Installation

3.1.1 Hydraulic Pump (Gear Pump)

(2) Suggestion for Removal

Weight of gear pump 19.5 kg (43 lb)

3.1.2 Control Valve

3.2 Preparation for Removal (2)

(2) Removing return hose

(4) Removing high-pressure hose

3.3 Preparation for Removal (3)

3.3.1 Tilt cylinder

(1) Removal sequence

4. Disassembly and Reassembly

(2) Suggestions for Disassembly

4.1.2 Inspection and Repair

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

(2) Suggestion for Reassembly

4.2 Control Valve

65 N•m (6.6 kgf•m)

4.2.2 Inlet Cover Disassembly

(2) Suggestions for Disassembly 3

(3) Inspection and Repair 211512

(5) Suggestions for Reassembly

4.2.3 Lift Valve Disassembly

(2) Inspection and Repair

4.2.4 Tilt Valve Disassembly

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