Chapter 11 Hydraulic System

Chapter 11 HYDRAULIC SYSTEM
1. Structure and Functions....................................................................... 11-1

1.1 Outline ................................................................................................................... 11-1
1.2 Hydraulic Circuit Diagram (for Trucks with MC Control Valve).............................. 11-2
1.3 Hydraulic Circuit Diagram (for Trucks with FC Control Valve)............................... 11-3
1.4 Hydraulic Tank....................................................................................................... 11-4
1.5 Hydraulic Pump (Gear Pump) ............................................................................... 11-5
1.6 Control Valve ......................................................................................................... 11-6
1.7 Flow Regulator Valve (for Trucks with FC Control Valve Only)............................. 11-8
1.8 Down Safety Valve ................................................................................................ 11-8
1.9 Lift Cylinder............................................................................................................ 11-9
1.10 Tilt Cylinder.......................................................................................................... 11-15
2. Disassembly and Reassembly........................................................... 11-16
2.1 Hydraulic Pump ................................................................................................... 11-16
2.2 Lift Cylinder.......................................................................................................... 11-19
2.3 Tilt Cylinder.......................................................................................................... 11-28
2.4 Flow Regulator Valve .......................................................................................... 11-31
2.5 Piping................................................................................................................... 11-32
2.6 Suction Strainer and Return Filter ....................................................................... 11-33
3. Inspection and Adjustment ................................................................ 11-34
3.1 Hydraulic Tank..................................................................................................... 11-34
3.2 Control Valve ....................................................................................................... 11-35
3.3 Descent Test ....................................................................................................... 11-37
3.4 Forward Tilt Test.................................................................................................. 11-37
4. Troubleshooting.................................................................................. 11-38
5. Service Data......................................................................................... 11-41
6. MC Control Valve ................................................................................ 11-44
6.1 Structure and Operation ...................................................................................... 11-44
6.2 Control Valve, Removal and Installation.............................................................. 11-53
6.3 Disassembly and Reassembly ............................................................................ 11-54
7. FC Control Valve ................................................................................. 11-59
7.1 Structure and Operation ...................................................................................... 11-59
7.2 Disassembly and Reassembly ............................................................................ 11-74
11
HYDRAULIC SYSTEM
Chapter 11 HYDRAULIC SYSTEM
1. Structure and Functions

1.1 Outline
7 8 4
12
13
2 16
15
9 14
1
11
5
10 3
213797
Main components
1 Pump suction strainer: 100-mesh metal strainer 6 Tilt cylinder
2 Hydraulic pump (gear pump): 7 Piping to tilt cylinder
A regular gear pump is directly coupled to the en- 8 Steering valve
gine PTO. See the "Hydraulic Pump" section for de- 9 Return oil line from steering valve
tails. 10 Oil line to steering cylinder
3 Hydraulic pump delivery hose: 11 Steering cylinder
The shape of this hose for the diesel-engine models 12 Return line
is different from that of the gasoline engine models, 13 Line leading to top of lift cylinder piston:
as the hydraulic pump locations of these two models This line is only installed in trucks that have a lift cyl-
are different. inder with a return line. It is not installed in trucks
4 Hydraulic control valve: with 3. 3 m (10.8 ft) or smaller lift. If this line is not in-
MC valve is installed as the standard valve. FC stalled, the branching hole from return line 16 is
valve is available as an option. The MC valve has a closed with a blind plug.
built-in flow regulator valve. but the FC valve does 14 Return filter:
not have a flow regulator valve. Both MC and FC This cartridge-type filter should be replaced at every
models take almost the same piping arrangement. oil change.
For more details, refer to "2.5 Piping." 15 Oil cap
5 Oil line to lift cylinder: 16 Level gauge
FC trucks have a flow regulator valve in a down-
stream section of this line. This line also has a hy-
draulic pressure sensor.
11-1
11-2
MC control valve assembly
T1
Steering
Tilt cylinder valve
HYDRAULIC SYSTEM
A3 Steering cylinder
B3
Hydraulic pump
A2
B2 Engine
Down safety valve Return filter Suction

strainer
A1
15μm 100 mesh Engine front
micron PTO
PF
1.2 Hydraulic Circuit Diagram (for Trucks with MC Control Valve)
P T2
(RH) (LH)
Lift cylinder
Main relief valve
18.1 +0.5
0 MPa
Steering system relief valve
+5 2 +72
+5 1 ton class: 8.8 +0.5
0 MPa (90 0 kgf/cm ) [1276 0 psi]
(185 0 kgf/cm2) +0.5 +5 2
0 psi]
2, 3 ton class: 10.3 0 MPa (105 0 kgf/cm ) [1494 +72
213798
[2625 +72
0 psi]
FC control valve assembly
T1
Steering
Tilt cylinder valve
B3
A3
b3 a3
B2
Steering cylinder
A2 a2
b2
Hydraulic pump
Flow regulator valve

A1 Engine
b1
Down safety a1
valve
Pp Return filter Suction
strainer
Engine front
15μm 100 mesh PTO
w
micron
w
1.3 Hydraulic Circuit Diagram (for Trucks with FC Control Valve)
w
(RH) (LH) c1
Lift cylinder
P PF T2
Steering system relief valve Pilot relief valve of main relief valve
+5 2 +72 +0.5 +5 +72
1 ton class: 8.8 +0.5
0 MPa (90 0 kgf/cm ) [1276 0 psi] 18.1 0 MPa (185 0 kgf/cm2) [2625 0 psi]
+0.5 +5 +72
213799
2, 3 ton class: 10.3 0 MPa (105 0 kgf/cm2) [1494 0 psi]
11-3
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
1.4 Hydraulic Tank

2
(c) 1
5
9
(b)
8
7
(a)
10
6
11
213800
Main Components
1 Hydraulic tank 5 Tank cover 6 Suction strainer
2 Cap Parts welded to tank cover 7 Return filter
3 Element 8 Hydraulic pump
(a) Suction pipe
4 Level gauge 9 Pump suction line
(b) Pipe for return line 10 Pump delivery line
(c) Pipe for level gauge 11 Drain plug
The hydraulic tank is located in the middle of the right Return filter 7 is attached to the end of return pipe (b).
side of the frame and becomes a part of the frame The return filter is a cartridge type of 15 μm with a
structure. built-in relief valve. When the filter is clogged, the relief
Three pipes (a) (b) and (c) are welded together to the valve activates to divert unfiltered oil into the tank.
tank cover 5. Suction strainer 6, return filter 7, level Periodic replacement is necessary. Oil filter replace-
gauge 4, and cap 2 are installed on the top of each of ment is recommended once a month after the pur-
the three pipes. chase of the lift truck or after conducting a major
overhaul that includes replacing parts.
Therefore, parts in the tank can be taken out as an
assembly if the tank cover is removed. The suction strainer 6 is 100 mesh screen gauze.
Filter replacement or strainer cleaning can easily be Clean the suction strainer at every oil replacement.
carried out once removing tank cover 5. On the models with a wet-type single disc clutch, the
Level gauge 4 is inserted in the level gauge pipe (c) return oil line is attached on the tank side.
where the opening is blocked by cap 2 that has an ele- The drain plug is installed at the bottom of the tank.
ment attached.
The two air holes on the side of cap 2 serve as a vent

for the air trapped inside the tank, which fluctuates
depending on the oil level. Element 3 installed in the
cap 2 serves as an air filter to prevent unclean outside
air from entering the hydraulic tank.
11-4
HYDRAULIC SYSTEM
1.5 Hydraulic Pump (Gear Pump)
4 13 12 9 6 3 11 10
Pump installed on engine

1 7 5 8 2
(Example: S4S diesel engine, 2 ton class)
213801
1 Front cover 8 Gasket (shaped like 3)

2 Rear cover 9 Gasket
3 Body 10 Hexagon socket head bolt
4 Drive gear 11 Washer
5 Driven gear 12 Shaft seal
6 Side plate 13 Snap ring
7 Bushing
Pump types Piping around pump
The pump in a standard truck is a single-gear pump as Since the pump mounting location of the gasoline
shown in the above illustration. engine is different from that of the diesel engine, the
A low-noise type pump is available as an option. The shapes of both the suction piping and delivery piping
low-noise pump works with discharge pressure pulsa- around the pump are different.
tion by making the backlash between gears smaller,
and thus the leak amounts between gears decrease
also. The appearance and structure of the low-noise
pump are the same as those of the standard pump
except for the number of teeth.
Installation of pump
The pump is directly installed to the engine front PTO,
but installed sides are reversed left from right for gaso-
line engines and a diesel engines.
Gasoline engines :
The pump is installed to the left side as viewed from
the flywheel side.
Diesel engines :
The pump is installed to the right side as viewed from
the flywheel side.
11-5
HYDRAULIC SYSTEM
1.6 Control Valve

There are two types of control valves: MC control valve and FC control valve.
1.6.1 MC Control Valve
2 3 4
1
9
7
6
8
5
T2
PF T1
B2
A2
P A1
213802
1 Lift control lever P : Inflow port of pump pressure oil

2 Tilt control lever PF : Pressure oil supply port to steering system
3 Attachment (#1) control lever
4 Attachment (#2) control lever T1 : Return port to tank
5 Inlet cover section (with built-in flow priority valve) T2 : Return port from steering system
6 Combination section (with built-in lift / tilt valve and
A1 : Port to lift cylinder
flow divider valve)
7 Attachment section A2 : Port to tilt cylinder rod
8 End section (with built-in unload valve [9]) B2 : Port to tilt cylinder head
9 Unload valve (with solenoid)
Most of the hydraulic control valves move mechani-

cally. When one of the control levers (1 through 4) is
operated, the spool valve starts to move up and down,
and exchanges pressure oils with the corresponding
hydraulic cylinders.
For detailed explanations on structure and operation,
and disassembly and reassembly, refer to "MC Control
Valve of section 6."
11-6
HYDRAULIC SYSTEM
1.6.2 FC Control Valve
3
1
2
9 10
7 8
4
11
T1
PF
B2
T2
A2
5
6 A1
P
213803
1 FC control box P : Inflow port of pump pressure oil

2 Input unit PF : Supply port of pressure oil to steering system
3 VCM (Vehicle Control Module)
4 Output unit T1 : Return port to tank
5 FC control valve assembly T2 : Return port from steering system
6 Inlet section (with built-in priority valve and lift valve)
A1 : Port to lift cylinder
7 Electromagnetic proportional pressure control valve
8 Lift valve A2 : Port to tilt cylinder rod
9 Tilt valve B2 : Port to tilt cylinder head
10 Attachment valve
11 Unload valve (with solenoid)
This hydraulic control is a solenoid valve. As the valve

spools move in proportion to control input of the FC
control box operated by the operator, the controller
and electromagnetic proportional pressure control
valve are used.
For detailed explanations on structure and operation,
and disassembly and reassembly, refer to "FC Control
Valve of section 7."
11-7
HYDRAULIC SYSTEM
1.7 Flow Regulator Valve (for Trucks with FC Control Valve Only)
From control valve To control valve
To From
lift cylinder lift cylinder
215233
The flow regulator valve is connected between the control valve and the lift cylinder. When the forks are lowered,
the valve regulates the oil flow as the load varies on the lift cylinder, thereby keeping the forks lowering speed con-
stant, irrespective of the load weight.
1.8 Down Safety Valve
When in normal condition
Broken area
When piping is broken 213805
The down safety valve is located at the bottom of the right lift cylinder. 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 regula-
tor 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.
11-8
HYDRAULIC SYSTEM
1.9 Lift Cylinder

Second lift cylinder for simplex mast and triplex mast
The internal drain pipe cylinder is a lift cylinder without a return pipe and with a check valve in the piston instead of
a return pipe.
The bottom of the piston has a cushion mechanism for soft landing.
(1) Cylinder without a return pipe
Mast used
Detail of inside
3 1 2 7 6 5 4
14 15 16 17 8 9 10 11 12 13
217403
Main Components
1 Cylinder tube 4 Pipe (integrated with cylinder tube) 7 U-ring, Backup ring
2 Piston rod assembly 5 Cushion bearing 8 Bushing
3 Cylinder head 6 Check valve 9 Wiper ring
10 X-ring
Cylinder dimensions (the length and stroke of cylinder vary depending on lift height.)
Unit: mm (in.)
Rod diame- Cylinder inside Cylinder outside
Mast ter diameter diameter Cushion Presence of
Truck type Lift height
type stroke return pipe
(d) (ID) (OD)
3400 or less
35 (1.38) 45 (1.77) 52 (2.05) 23 (0.91) No
(133.9 or less)
Simplex
1 ton class 3500 or higher
35 (1.38) 45 (1.77) 52 (2.05) 23 (0.91) Yes
(137.8 or less)
Triplex - 35 (1.38) 45 (1.77) 52 (2.05) 23 (0.91) No
3400 or less
40 (1.57) 50 (1.97) 57 (2.24) 23 (0.91) No
(133.9 or less)
Simplex
40 (1.57) 50 (1.97) 57 (2.24) 23 (0.91) Yes
(137.8 or less)
Triplex - 40 (1.57) 50 (1.97) 57 (2.24) 23 (0.91) No
3400 or less
45 (1.77) 55 (2.17) 63 (2.48) 23 (0.91) No
(133.9 or less)
Simplex
45 (1.77) 55 (2.17) 63 (2.48) 23 (0.91) Yes
(137.8 or less)
Triplex - 45 (1.77) 55 (2.17) 63 (2.48) 23 (0.91) No
11-9
HYDRAULIC SYSTEM
Cushion mechanism when piston descends

Action during piston descent
1 2 (B) Passage (a) Entrapped oil (A)
Groove
Descent Outflow
5 Passage (b) 4
213808
The above illustration shows an example of the piston

rod assembly2, which descends with the weight of the Outside diameter
The inside diameter without step
piston rod and pipe 4. The pipe 4 and cushion bearing is further smaller.
5 create a seal as the rod descends.
Cushion bearing 5 is pushed upward by entrapped oil
(A) and the piston and cushion bearing 5 make surface
contact at (B) area. This blocks the passage (a). The
only outflow passage for entrapped oil (A) is clearance
(b) between the bore of cushion bearing 5 and the out- Clearance of approx.
0.1 mm (0.004 in.)
side of pipe 4. This passage (b) becomes narrower as Cushion bearing
Pipe
the piston descends further. Therefore, the descend- 213809
ing speed of the piston becomes gradually slower and Image of pipe and cushion bearing
impulsive contact is avoided.
Action during piston ascent (initial stage)
1 2 (B) Passage (a)
Groove
Ascent Inflow
5 Passage (b) 4
213810
The above illustration shows an example of the follow- This action opens the (B) area, causing the passage
ing: (a) to open. Oil from the passage (a) and passage (b)
As the piston rod assembly descends, the oil flows which opens from the beginning flows in the piston
through the center of the piston and causes the cush- bottom, acting on the entire bottom surface of the pis-
ion bearing 5 to descend at the same time. The oil ton and pushing piston rod assembly 2 upward.
flowing in through the center of the piston activates the
cushion bearing.
11-10
HYDRAULIC SYSTEM
Cylinder of internal drain type

Entrapped oil and air
(There normally tends to be
negative pressure in this area.)
Groove
Check valve 213811
As the piston rod assembly ascends to the highest opens and discharges oil and air to pressure oil (inter-
possible position, the pressure of the oil and air nal drain). In the cylinder with a return pipe, this area is
entrapped between the rod and cylinder exceeds the connected to the hydraulic tank.
set pressure of the check valve. The check valve then
11-11
HYDRAULIC SYSTEM
1.9.1 Second lift cylinder for duplex mast

Detail of inside
4 5 9 2 1 6 3 7 8
To first Inflow and

cylinder outflow
Cushion stroke
21 mm (0.83 in.) 213812
Main Components
1 Cylinder tube 4 Holder 7 Check valve
2 Rod 5 Cylinder head 8 Spring
3 Piston 6 Cushion spool 9 Bleed valve
Action
Pressure oil first flows through the hollow area inside This cylinder is provided with a cushion mechanism
piston rod 2 and enters the first lift cylinder. Because which prevents the piston bottom from impulsively
the inside diameter of the first lift cylinder is larger than contacting the cylinder bottom during piston descent.
that of the second lift cylinder, the first lift cylinder (Refer to the illustration below.)
ascends first. The second lift cylinder starts to ascend Bleed valve 9 is a valve for bleeding air when the
after the first lift cylinder has completed ascent. hydraulic system is overhauled.
Action during piston descent

Fig. 1 7 Check valve 8 Spring 6 Cushion spool
The illustration on the right explains the movement of
cushion spool 6 when the piston descends. (To the
right of the illustration is the piston bottom.)
Outflow
Fig. 1:
This illustration shows an example in which cushion
spool 6 does not contact the cylinder bottom.
Cushion spool 6 extends out by spring 8. 7 Check valve
Fig. 2 6 Cushion spool Entrapped oil (A)
Fig. 2: B area
This illustration shows an example in which cushion
spool 6 contacts the cylinder bottom and gets under
Outflow
check valve 7 slightly. The check valve moves to the
left, blocking the B area. Oil (A) below the underside of
the piston is discharged through holes (two rows on
the right) of cushion spool 6.
For the shape of the check valve, refer to the image Fig. 3
drawing on the following page.
Fig. 3:
As the piston descends, cushion spool 6 gets under Outflow
the check valve further. As a result, the number of
holes through which oil can pass decreases and dis-
charge of entrapped oil (A) is restricted. The descend-
ing speed of the piston becomes slower and impulsive
213813
contact is avoided.
11-12
HYDRAULIC SYSTEM
Action during piston ascent

The illustration on the right explains movement of the
6 Cushion spool
check valve when the piston ascends. Fig. 4 7 Check valve
Fig. 4:
Inflow
The illustration shows a condition immediately before
piston ascent. Oil which flows through the hollow area
in cushion spool 6 acts on check valve 7.
Fig. 5:
Initial stage of ascent 3 Piston
Pressure oil pushes check valve 7 to the right. Pres-
(Oil flows along this
sure oil flows along the plane of the check valve and
plane.)
flows to the underside of the piston.
Seat plane Shape of
The "triangular shape" of check valve 7 is designed to (When the piston check valve
increase the initial inflow volume. The piston starts to descends, this
ascend. Fig. 5 plane seats.) 7 Check valve
Fig. 6:
The illustration shows an example in which cushion
Inflow
spool 6 has left the cylinder bottom and is ascending.
Fig. 6 6 Cushion spool

7 Check valve
Inflow
213814
11-13
HYDRAULIC SYSTEM
1.9.2 First cylinder for duplex mast and triplex mast

Detail of inside
Space(B) Cushion oil is filled in this area.

6 3 5 4 2 1 10 7 8 9
Inflow and
outflow
d ID OD
Air chamber(A) Oil passage Piston

213815
Main Components
1 Cylinder tube assembly 5 U-ring 9 Check valve
2 Piston rod assembly 6 Wiper ring 10 Stand tube
3 Cylinder head 7 Seal ring assembly
4 Bushing 8 Slide ring
Action
This cylinder, mounted on the center of the mast, acts In the descending stroke of the piston rod, cushion oil
first during the ascending stroke of the fork. in air chamber A is sucked in space B. The air cham-
The piston rod extends from the cylinder tube by pres- ber, stand tube, and check valve are related parts for
sure oil acting on the piston bottom. For prevention of cushioning action.
an impulsive approach of the piston and the cylinder Extra oil which leaks from around the piston and
head at the last stage of its ascent, cushion oil is enters space B returns from stand tube 10 to the cylin-
always filled in space B, between the cylinder tube and der bottom via check valve 9 at the last stage of cylin-
the piston rod. When the piston rod ascends, it der ascending.
ascends while pushing out cushion oil to air chamber
The stand tube always retains a certain amount of oil
A at its last stage. Thus, the last stage becomes
as cushion oil. A certain amount of cushioning oil must
smooth.
be filled in the overhauled cylinder.
Cylinder dimensions (The cylinder length and stroke vary depending on lift height)
Unit: mm (in.)
Cylinder inside Cylinder outside
Truck type Mast type Rod diameter
diameter diameter
1 ton class 55 (2.17) 70 (2.76) 82 (3.23)
Cylinders for the duplex mast and the tri-
2 ton class plex mast are of the same dimension and 55 (2.17) 75 (2.95) 86 (3.39)
same type.
3 ton class 65 (2.56) 85 (3.35) 97 (3.82)
11-14
HYDRAULIC SYSTEM
1.10 Tilt Cylinder
5 A 3 10 1 2 4 9 14 8
6 7
15 11 12 13
213816
Main Components
1 Cylinder 5 Socket 9 Piston seal 13 Buffer ring
2 Rod 6 Bearing 10 O-ring 14 Nut
3 Guide bushing 7 Seal 11 Dust seal 15 Clamp bolt
4 Piston 8 Bushing 12 Packing
The tilt cylinder is a double-acting type. To adjust right

and left imbalance of tilt angles when the mast is
attached, loosen the clamp bolt and turn the piston rod
with a spanner applied to area A.
Seal 7 helps extends the greasing intervals. Installa-

tion of this seal has extended greasing intervals up to
to 500 service hours.
Cylinder dimensions
Cylinder length and stroke vary depending on tilt
angles of forward and backward tilt.
Unit: mm (in.)
Cylinder Cylinder
Rod diam-
Truck type inside outside
eter
diameter diameter
1 ton class 25 (0.98) 63 (2.48) 73 (2.87)
2 ton class 30 (1.18) 70 (2.76) 82 (3.23)
3 ton class 35 (1.38) 80 (3.15) 93 (3.66)
11-15
HYDRAULIC SYSTEM
2. Disassembly and Reassembly

2.1 Hydraulic Pump
2.1.1 Removal and Installation
1 3
2
213817
Removal sequence
1 Pump delivery hose 3 Pump mounting bolt
2 Pump suction hose 4 Pump
Notice when removing :

(1) The installed positions and sizes of the suction
hose and delivery hose differ by model.
(2) Cover the pump and its surroundings with a shop
cloth in preparation for spilled oil.
(3) Take care not to allow foreign particles to enter
the pump and hose from their detached parts.
Installation
To install, follow the removal sequence in reverse.
Also follow the instructions given below.
Apply grease to the spline of the pump shaft before
installation.
Insert the gasket (diesel engine) or O-ring (gasoline
engine) between the pump and engine PTO.
Perform test operation after installing the pump. Refer
to 2.1.2 test operation.
11-16
HYDRAULIC SYSTEM
2.1.2 Disassembly and Reassembly

Disassembly
5
7 1
3 *
*
*
* *
* *
3
2 4 *
Parts marked with are included in the seal kit.
*
Parts without
8 * mark are not individual supply items. 213818
Sequence
1 Rear cover, Bolt, Washer, Bushing 5 Drive gear
2 Front cover, Snap ring, Shaft seal, Bushing 6 Driven gear
3 Gasket, Gasket (shaped like 3) 7 Side plate
4 Side plate 8 Body
Note: 1. The hydraulic pump is to be overhauled by Suggestions for Disassembly

the manufacturer only. Where it has to be
overhauled in field, be sure to follow the sug- (1) Since the front cover 2 and the rear cover 1 are
gestions for disassembly. Remember, field made of aluminum alloy. They may get easily
overhauling will release the manufacturer scratched. Do not forcibly tap them with a ham-
from any warranty claims. mer, use a wooden hammer or plastic hammer
instead.
2. Do not remove oil seal 2 and bushings unless
they are defective to require replacement. (2) When disassembling, do not remove the body,
gear and bushing by forcibly tapping them with a
hammer.
(3) Place disassembled parts in orderly sequence.
Especially, do not mistake the relative position of
the gear and bushing side plate.
11-17
HYDRAULIC SYSTEM
Inspection and Repair

(1) Drive and driven gears
(a) Check the gear teeth for wear, chipping or
other defects.
(b) Check the side faces of the gears for wear or
damage.
(c) Check the shafts for wear or damage.
(2) Covers, body and bushings
213819
Reassembly
To reassemble, follow the disassembly sequence in
reverse. Also follow the instructions given below.
(1) Replace the seal kit parts with new ones.
(2) Completely remove oil or grease on the mating
surfaces of covers 1, 2 and body 8.
(3) Visually check all the parts for cleanliness and
apply hydraulic oil to the inside surface of the
body before reassembly.
(4) Apply grease to the lip of the shaft seal.
(5) Be careful not to cause damage to the lip of shaft
seal by spline edges of drive gear 5.
(6) Tighten the bolts evenly and progressively.
(7) The pump is assembled properly if the pipe
wrench fitted on the pump shaft can be turned
easily by hand.
Test operation
Perform test operation after installing the pump.
(1) Check that the oil amount in the hydraulic tank is
sufficient.
(2) Attach a pressure gauge to the pump delivery
hose.
Refer to page 13-35 "Main Relief Valve."
(3) Start the engine, adjust the adjusting screw of the
main relief valve in sequence from 0 to 18.1 MPa
(0 to 185 kgf/cm2) [0 to 2625 psi], and check the
temperature rise of the pump body by touching it
by hand. If the temperature rise of the pump body
is substantial compared to the oil temperature
rise, disassemble again for checking.
(4) Set the relief valve to the specified pressure.
(5) Measure the lifting speed of the fork without a
load. If the speed is to the specified value, the
pump discharge volume is normal.
(6) Check that the fork operates normally by raising
and lowering it under load.
11-18
HYDRAULIC SYSTEM
2.2 Lift Cylinder

Simplex mast
5 4
2
1
213820
Removal sequence
1 Hose guard 4 Cylinder clamp (Cushion, Collar, Shim)
2 High-pressure hose 5 Lift cylinder, Bracket
3 Set bolt, Shim
Suggestions for Removal

(1) Removal of return hose (if equipped) From right-hand lift cylinder
Connector
Remove the hose guard. Start the engine, raise
the lift bracket to the highest position, and stop the
engine. Then, remove return hoses on the right
and left cylinders from the connector.
To tank
Note: Never touch the lift lever.
(2) Lowering of lift bracket
Gently operate the lift lever to lower the lift
bracket. From left-hand lift cylinder
214874
11-19
HYDRAULIC SYSTEM
(3) Disconnecting high-pressure hoses

Right-hand cylinder Left-hand cylinder
Disconnect the high-pressure hoses at the joints
indicated by arrows. Use a drip pan to catch oil
flowing out of the hoses.
213822
(4) Removing set bolts

(a) Remove the set bolt at the top of each lift cylin-
der. Lift the inner mast to separate the cylinder
rod ends. To lift the inner mast, hitch a sling
around the mast with protective rag.
Note: The rod end of either lift cylinder is shim adjust-
ed to eliminate the difference in stroke between
the cylinders. Before removing the set bolts,
make a record of the amount of shims fitted to
each cylinder.
213823
(b) Tie wood blocks under the inner mast and

detach the sling. Use the blocks strong enough
to support the mast.
213824
(5) Removing lift cylinders

Attach a lifting sling before removing the cylinder
clamp and mounting bolt. Lift the cylinder from the
rear side of the mast, and remove the cylinder.
214083
11-20
HYDRAULIC SYSTEM
Installation
(1) Extend and retract the lift cylinders several times
under no load condition to bleed air out of the cyl-
inder circuits and to make sure that the cylinders
move smoothly.
(2) Check the oil level in the hydraulic tank with an oil
level gauge. (Refer to the topics "Hydraulic Tank"
in the following section "Inspection and Adjust-
ment.")
(3) Check the lift height.
(4) After the lift cylinders or piston rods have been
replaced, check for difference in stroke between
the two cylinders. (Refer to "Chapter 12 MAST
AND FORKS.")
11-21
HYDRAULIC SYSTEM
Duplex and triplex mast removal

Note that the triplex mast is used as an example.
3
1 213826
Removal sequence
1 Nut 4 Chain wheel support assembly
2 Lift bracket assembly 5 Second lift cylinder
3 First lift cylinder

(1) Removing lift bracket assembly
(a) Lower the lift bracket assembly and place
wood blocks under the assembly. Tilt the mast
forward, lower the inner mast to the bottom,
then remove nuts 1 from the anchor bolts of the
first lift chains.
1
213827
(b) Position the mast upright. Raise the inner mast

until the upper rollers of the lift bracket become
free. Then, slowly move the truck in reverse to
separate from lift bracket 2.
213828
11-22
HYDRAULIC SYSTEM
(2) Removing first lift cylinder

(a) Hitch a sling on the first lift cylinder 3, and sus-
pend it with a crane. Wind the rope securely to
prevent slipping.
(b) Remove lift cylinder mounting bolts, and gently
remove the first lift cylinder 3.
213829
(3) Removing second lift cylinders

(a) Disconnect hoses from the second lift cylinders
5.
(b) Remove the set bolts at the upper sections of
the second lift cylinders 5, and lift the inner
mast for duplex mast or middle mast for triplex
mast approximately 55 cm (21.67 in.) using
slings.
213830
(c) Place wood blocks under the inner mast (for

duplex mast) or middle mast (for triplex mast).
Make sure the right and left wood blocks are
the same in height.
213824
11-23
HYDRAULIC SYSTEM
(d) Hitch a sling to second lift cylinder 5 behind the

mast, remove the cylinder clamp retaining bolts
and mounting bolt, then gently remove second
lift cylinder 5.
Wind the sling securely to the cylinder. The cyl-
inder cannot be lifted straight up since the mast
cross-member is located above the cylinder.
Tilt the cylinder and move it away from the
cross-member to remove. Be careful not to
have your hands caught between the cylinder
and mast.
213831
Installation
(1) Install chain wheel support assembly 4 parallel to
a line connecting the centers of chain anchor bolt
holes on first lift cylinder 3 to prevent chains from
twisting.
(2) Adjust the chain tensions.
Refer to "Chain Tension Inspection and Adjust-
Good Bad
ment of Section 12.2" of "Chapter 12 MAST AND
FORKS."
213832
(3) Extend and retract the lift cylinders several times
under no load condition to bleed air out of the cyl-
inder circuits and to make sure that the cylinders
move smoothly.
(4) After proper operation is confirmed, check the oil
level.
11-24
HYDRAULIC SYSTEM

1. Second lift cylinder for simplex mast and triplex mast
Disassembly
Tightening torque
1 ton class: 196 ± 45.1 N·m (20 ± 4.6 kgf·m) [145 ± 33 lbf·ft] (M49 × 1.5)
2 ton class: 235 ± 53.9 N·m (24 ± 5.5 kgf·m) [173 ± 40 lbf·ft] (M54 × 1.5)
Apply liquid gasket to 3 ton class: 275 ± 61.8 N·m (28 ± 6.3 kgf·m) [203 ± 46 lbf·ft] (M59 × 1.5)
circumference when
pressing in. Apply grease when assembling.
2 31 4 5 4 15 14 6 13 12 7 8 9 11 10
Seal in grease.
(Adhesion to
bushing is acceptable.) Apply ThreeBond #1901 when screwing in.
213833
First, disassemble into the three main parts: I, II, and IIIas seen below. Then disassemble each of the three main
parts individually.
I. Head sub-assembly (Consisting of the following parts, 1 thru 5.)
1 Cylinder head 3 X-ring 5 Bushing
2 Wiper ring 4 O-ring
II. Piston rod sub-assembly (Consisting of the following parts, 6 thru 13.)
6 Piston rod assembly 9 Bushing 12 Check valve
7 Backup ring 10 Snap ring 13 O-ring
8 U-ring 11 Cushion bearing
III. Cylinder tube assembly (Consisting of the following parts, 14 and 15.)
14 Cylinder tube sub-assembly 15 Plug
Note: The illustration shows a cylinder of the internal drain type without a return pipe. For structure of the cylinder
with a return pipe, refer to 1.9 Lift Cylinder.
Suggestions for Disassembly Suggestions for Reassembly
Pulling out piston To reassemble, follow the disassembly sequence in
Be careful not to damage the piston seals and cylinder reverse, and also observe the following points.
bore wall when pulling out the piston from the cylinder. (1) Clean the disassembled parts with high flash-
Inspections after Disassembly point solvent. Blow them dry with compressed air.
(1) Cylinder tube Do not apply compressed air to rubber parts.
(a) Check the bore wall for wear, grooving, (2) Apply hydraulic oil to the bore surface of cylinder
scratching or rusting. and also to the piston seal, O-ring, backup ring,
buffer ring, packing and dust seal.
(b) Check the welds for cracks or other defects.
(3) Apply liquid gasket (ThreeBond #1901) to the
(2) Piston rod thread. Tighten to the specified torque using hook
(a) Check the rod for deflection. wrench.
(b) Check for surface flaws such as grooving,

scratching, rusting or wear.
(3) Rings and packings
(a) Check lips for damage, wear, or deterioration.
11-25
HYDRAULIC SYSTEM
Second lift cylinder for duplex mast

Disassembly
Tightening torque
Tightening torque:
1 ton class: 206 ± 39.2 N·m (21 ± 4.0 kgf·m) [152 ± 29 lbf·ft] (M52 × 2)
1 ton class: 196 ± 35.3 N·m (20 ± 3.6 kgf·m)
[145 ± 26 lbf·ft] (M30 × 1.5)
2 ton class: 196 ± 35.3 N·m (20 ± 3.6 kgf·m)
Tightening torque: [145 ± 26 lbf·ft] (M33 × 1.5)
3.92 ± 0.98 N·m 3 ton class: 196 ± 35.3 N·m (20 ± 3.6 kgf·m)
Tightening torque: (0.4 ± 0.10 kgf·m) [145 ± 26 lbf·ft] (M36 × 1.5)
39.2 ± 0.98 N·m (0.4 ± 0.10 kgf·m) [2.9 ± 0.72 lbf·ft] [2.9 ± 0.72 lbf·ft]
Apply a threadlocker.
17 12 Be careful of the direction
2 1 3 4 5 7 6 8 16 15 13 11 10 9 14 when installing. Face slit
toward spring side.
Apply THREEBOND #1901 when screwing in. 213834
First, disassemble into four main parts: I, II, III, and IV as seen below. Then disassemble each of the four main parts
individually.
I. Holder sub-assembly (Consisting of the following parts, 1 thru 5.)
1 Holder 3 Backup ring 5 O-ring
2 Wiper ring 4 U-ring
II. Head sub-assembly (Consisting of the following parts, 6 and 7.)
6 Head 7 Bushing
III. Piston rod sub-assembly (Consisting of the following parts, 8 thru 15.)
8 Rod 11 Set screw 14 Spring
9 Piston 12 Check valve 15 Snap ring
10 Slide ring 13 Cushion spool
IV. Cylinder tube assembly (Consisting of the following parts, 16 and 17.)
16 Tube assembly 17 Plug

Pulling out piston To reassemble, follow the disassembly sequence in
bore wall when pulling out the piston from the cylinder. (1) Clean the disassembled parts with high flash-
Inspections after Disassembly point solvent. Blow them dry with compressed air.
(1) Cylinder tube Do not apply compressed air to rubber parts.
(a) Check the bore wall for wear, grooving, (2) Apply hydraulic oil to the bore surface of cylinder
scratching or rusting. and also to the piston seal, O-ring, backup ring,
(3) Tighten threads of important parts to the specified
(2) Piston rod torque as per the above illustration.
(a) Check the rod for deflection.
scratching, rusting or wear.
(3) Rings, packings and threads
(a) Check lips for damage, wear or deterioration.
(b) Check threads for damage.
11-26
HYDRAULIC SYSTEM
3. First cylinder for duplex mast and triplex mast

Disassembly
Tightening torque
1 ton class: 382 N·m (39 kgf·m) [282 lbf·ft] (M75 × 2)
2 ton class: 422 N·m (43 kgf·m) [311 lbf·ft] (M80 × 2)
3 ton class: 530 ± 122 N·m (54 ± 12 kgf·m) [391 ± 90 lbf·ft] (M95 × 2)
Tightening torque: 3.92 N·m (0.4 kgf·m) [2.9 lbf·ft]
2 1 5 3 4 6 14 7 13 8 10 9 11 12
Apply ThreeBond #1901

when screwing in. R side
Fill cushion oil (hydraulic oil) when assembling.

1, 2 ton classes: 75 to 85 cc (4.6 to 5.2 cu.in.)
3 ton class: 160 to 180 cc (9.8 to 11.0 cu.in.)
213835
First, disassemble into three main parts: I, II, and III as seen below. Then disassemble each of the three main parts
individually.
I. Cylinder head sub-assembly (Consisting of the following parts, 1 thru 6.)
1 Cylinder head 3 U-ring 5 O-ring
2 Wiper ring 4 Bushing 6 O-ring
II. Piston rod sub-assembly (Consisting of the following parts, 7 thru 12.)
7 Rod 9 Slide ring 11 Check valve
8 Piston 10 Seal ring assembly 12 Snap ring
III. Cylinder tube assembly (Consisting of the following parts, 13 and 14.)
13 Cylinder tube 14 Plug
sub-assembly

Pulling out piston rod To reassemble, follow the disassembly sequence in
bore wall when pulling out the piston rod from the cyl- (1) Clean the disassembled parts with high flash-
inder. point solvent. Blow them dry with compressed air.
Inspections after Disassembly Do not apply compressed air to rubber parts.
(1) Cylinder tube (2) Apply hydraulic oil to the bore surface of cylinder
and also to the piston seal, O-ring, backup ring,
(a) Check the bore wall for wear, grooving,
scratching or rusting.
(3) Be careful about the orientation when installing
the snap ring 12 of the check valve.
(2) Piston rod
(4) Fill hydraulic oil as cushion oil in the space
(a) Check the rod for deflection. between the tube and rod before reassembling
the cylinder head.
scratching, rusting or wear. (5) Tighten threads of cylinder head 1 to the specified
torque as per the above illustration.
(3) Rings, packings and threads
(a) Check lips for damage, wear, or deterioration.
(b) Check threads for damage.
11-27
HYDRAULIC SYSTEM
2.3 Tilt Cylinder

1
4
213836
Removal sequence
1 Tilt cylinder pin 3 Tilt cylinder pin
2 Hoses (2 pieces per one cylinder) 4 Tilt cylinder
Start by Installation
(1) Lower the forks to the bottom, and tilt the mast To install, follow the removal sequence in reverse.
fully forward. Also follow the instructions given below.
(2) Attach a lifting sling to the round holes, right and (1) After installing tilt cylinders, check the balance of
left, in the top cross-member of outer mast, and mast tilting angle. Adjust if necessary. Refer to
support the weight of the mast with a hoist. "Tilt Angle Adjustments" of Section 6.7 in "Chapter
12 MAST AND FORKS."
(1) Retracting piston rod
Remove tilt cylinder pin 1, and start the engine
and retract the piston rod fully. Stop the engine.
(2) Disconnecting hoses
Disconnect hoses 2 from the cylinder at the con-
nectors. Use a drip pan to catch oil flowing out of
the cylinder. Attach caps to the connectors of the
cylinder to protect the threads of the connectors
and to prevent oil from flowing out of the cylinder
when the cylinder is removed.
(3) Removing tilt cylinder
Remove tilt cylinder pin 3, and remove the cylin-
der.
11-28
HYDRAULIC SYSTEM

Disassembly
Tightening torque
1 ton class: 265 ± 29 N·m (27 ± 3.0 kgf·m) [195 ± 21 lbf·ft]
After tightening nuts,
crimp two locations.
3
4
5 2 7 6
8 9 10 15 16
14
12 13 17
Tightening torque 11
1
Tightening torque: 1 ton class: 127 ± 9.8 N·m (13 ± 1.0 kgf·m) [94 ± 7.2 lbf·ft]
153 to 182 N·m 2 ton class: 235 ± 19.6 N·m (24 ± 2.4 kgf·m) [173 ± 14.5 lbf·ft]
(15.6 to 19 kgf·m) 3 ton class: 392 ± 25 N·m (40 ± 2.5 kgf·m) [289 ± 18.4 lbf·ft]
[116 to 134 lbf·ft]
213837
First, disassemble into four main parts: I, II, III and IV as seen below. Then disassemble each of the four main parts
individually.
I. Tilt socket sub-assembly (Consisting of the following parts, 1 thru 5.)
1 Bolt, Nut 3 Seal 5 Grease nipple
2 Tilt socket 4 Bearing
II. Guide bushing sub-assembly (Consisting of the following parts, 6 thru 10.)
6 Guide bushing 8 Packing 10 O-ring
7 Dust seal 9 Buffer ring
III. Piston rod sub-assembly (Consisting of the following parts, 11 thru 15.)
11 Nut 13 Piston seal 15 Rod
12 Piston 14 Spacer
IV. Cylinder sub-assembly (Consisting of the following parts, 16 and 17.)
16 Cylinder assembly 17 Bushing
Note: 1. Before disassembly, make a record of the di-

mension from the holder edge to the socket
edge when the rod is fully pushed in. The re-
cord will be helpful for reassembly.
2. Do not disassemble the tilt socket bearing
and cylinder tube bushing unless abnormality
is found on inspection.
3. Do not disassemble the piston and nuts un-
less abnormality is found on inspection.
11-29
HYDRAULIC SYSTEM
Suggestions for Disassembly

Removing bushing
(1) Wrap the cylinder with a rag, and clamp it in a
vise. Using a wrench, remove the bushing from
the cylinder.
(2) When removing the bushing from the piston rod,
be careful not to rub the buffer ring, packing and
O-ring against the threads of the piston rod.
213838
Inspections after Disassembly
(1) Cylinder tube
(a) Check the bore wall for wear, grooving, scratch
marks and rusting.
(b) Check the welds for cracks.
(2) Piston rod
(a) Check for surface flaws such as grooving,
scratch marks, rusting and wear.
The rod must be replaced if its threads show a
sign of stripping or any other damage.
(3) Rings and packings
(a) Check each ring and packing for damage or
distortion.
(b) Also check for deterioration due to aging.
Suggestions for Reassembly
reverse, paying attention to the following points.
(1) Carefully clean all parts to remove any foreign
particle.
(2) Reassemble the cylinder in the reverse sequence
of the disassembling, apply hydraulic oil to the
bore wall of the cylinder tube, and also to sealing
parts; O-rings, piston seals, dust seals and pack-
ings. Pay attention to the orientation of parts.
(3) When clamping the cylinder tube in the vise, be
213839
careful not to distort the tube.
(4) Install the piston seal as follows:
(a) Before fitting the piston seal, squeeze it by
hand five or six times to soften it.
(b) Hold the piston in a vise, taking care not to
damage any part of the piston. Apply a thin
coat of hydraulic oil to the seal. Fit a portion of
the seal to the groove, and push the other por-
tion into the groove as shown.
(5) Tighten the thread to the specified torque. Refer
to the previous page for the torque. 213840
11-30
HYDRAULIC SYSTEM
2.4 Flow Regulator Valve

(Installed on trucks with FC control valve only)

Disassembly
3
5
Me
as
ure
4
215234
Sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring
Note: Before disassembling, measure the protrusion

of the plug. When assembling, adjust the pro-
trusion as before.

(1) Check the spring for fatigue.
(2) Check the sliding and contact surfaces of valve
and piston for damage.
(3) Check the sliding surfaces of piston and valve
body for damage.
Note: Replace the flow regulator valve as an assem-
bly if any part is defective.
Reassembly
reverse.
11-31
HYDRAULIC SYSTEM
2.5 Piping
(For piping around the mast, refer to "Chapter 12 MAST AND FORKS.")
1. Piping of MC control valve for diesel-engine truck
Steering valve
Tilt line
MC control valve
Left-hand tilt Hydraulic pump
cylinder (located on the left side of truck body)
Return line
Lift line (low pressure)
(high pressure)
Pump discharge oil line Return filter

(high pressure)
Suction strainer
Steering cylinder
Steering hydraulic line
Pump suction line (low pressure)
2. Piping of MC control valve for gasoline-engine truck
Hydraulic pump
(located on the right side
of truck body)
213842
11-32
HYDRAULIC SYSTEM
2.6 Suction Strainer and Return Filter

Cap
Tightening torque:
29 ± 3 N·m
(2.96 ± 0.31 kgf·m)
[3.8 ± 4.8 lbf·ft] Tank cover
Level gauge
Return filter Suction strainer

Tightening torque: Tightening torque:
49 ± 9.8 N·m 49 ± 9.8 N·m
(5.0 ± 1.0 kgf·m) (5.0 ± 1.0 kgf·m)
[36 ± 7.2 lbf·ft] [36 ± 7.2 lbf·ft]
213843

Removal
(1) Remove the suction hose from the pump.
(2) Remove the hose of the return line from the con-
trol valve.
(3) Remove all of tank cover mounting bolts.
(4) Lift up the tank cover. It can be pulled out from the
tank as shown in the above illustration.
(5) Remove the suction strainer and return filter.
Inspection
(1) Clean the suction strainer.
(2) The return filter is a scheduled replacement part.
Replace it when changing oil. In case of a new
truck or carrying out an overhaul, replace it after
the first month.
Installation
(1) Tighten the strainer and filter to the specified
torque.
(2) Securely install the pump suction hose, exercising
care to avoid sucking in air.
11-33
HYDRAULIC SYSTEM
3. Inspection and Adjustment

3.1 Hydraulic Tank
(1) Daily check of oil
Check oil for level, dirt and white turbidity (entry of
air, mixing of water).
(2) Adequate oil level during daily check
Check the oil level with the mast lowered.
Simplex mast: Between N and L level
Duplexmast: Between H and L level
Triplex mast: Between H and L level
The oil level must not exceed the H level when any
mast and attachment are lowered.
(3) Method of filling hydraulic tank with oil Maximum level for
H
duplex mast and
For recommended oil, refer to "Fuel and Lubricant triplex mast
Specifications of Section 4.2" in "Chapter 13 SER- N
Maximum level for
VICE DATA." L simplex mast
Minimum level
(a) Fill the hydraulic tank with oil with the mast low-
ered.
217407
(b) Repeat the ascent and descent of the mast a
few times, and then lower the mast completely
(c) Check the oil level with a level gauge. The
maximum acceptable level is the N level for the
simplex mast and the H level for the triplex
mast. If the level is low, replenish oil.
The oil level in the tank must not exceed the H level
when the mast, regardless of any combination of the
mast and attachment, is lowered.
(4) Inspection of suction strainer

Check the suction strainer for damage and clog-
ging. Clean it if it is dirty.
(5) Inspection of return filter
Check the return filter for damage. As this part
needs periodic replacement, replace it when the
replacement interval is reached. Refer to page 13-
33 "Removal and Installation of Suction Strainer
and Return Filter."
11-34
HYDRAULIC SYSTEM
3.2 Control Valve

(1) External leakage
(a) Check for oil leaks from the joint between adja-
cent valve housings sealed by O-ring.
(b) Check for oil leaks from the screw connections.
(2) Internal leakage
It is not practical to check the control valve alone for 3° to 4°
internal leakage. How to check the control valve in
place (under normal operating conditions) will be
described.
The internal leakage to be checked includes leakages
occurring at the lift spool, tilt spool, tilt lock valve and
check valves at the oil temperature of approximately 1 m (39.4 in.)
50°C (122°F). approx.
(a) Pick up a load equal to the rated capacity, and
lift it approximately 1 m (39.4 in.) high. Tilt the 213845
mast about 3° to 4° forward, and stop the

engine.
(b) Quickly disconnect the oil return hose, and
start collecting the oil coming out of the hose
as shown.
Unit: cc (cu in.)
Amount of oil collected for
20 (1.2) or less
15 minutes
(c) If the lift cylinders or tilt cylinders drift (the mast

tilts forward or the fork lowers) excessively in
spite of the fact that the amount of oil collected
for 15 minutes is less than 20 cc (1.2 cu in.),
measure the internal leakage of each cylinder. 213846
(The measurement is the assembly standard
and not the service limit.)
11-35
HYDRAULIC SYSTEM
(3) Main Relief Valve

Pressure gauge
(a) Install a pressure gauge capable of measuring
up to 25000 kPa (250 kgf/cm2) [3533 psi] to the
delivery hose connector.
(b) Move the tilt control lever to the backward tilt
+490
position. If the pressure is relieved at 18142 0
+5 +71
kPa (185 0 kgf/cm2) [2631 0 psi] when the tilt
cylinders reach the end of their stroke, the
main relief valve setting is correct.
(c) If the setting is incorrect, loosen the lock nut of R 1/8
adjusting screw and, while observing the pres-
sure gauge reading, slowly rotate the adjusting
screw until the gauge indicates the prescribed
set value. Steering system
relief valve
(d) While holding the adjusting screw, tighten the
Pump delivery
lock nut to secure the adjusting screw. hose
213847
(e) After securing the adjusting screw, recheck the
setting.
Remove the plug of R 1/8 from the metal end fittings of
Unit: kPa (kgf/cm2) [psi] the pump delivery hose and install a pressure gauge.
+490 +5
18142 0 (185 0)
Main relief valve setting +71
[2631 0 ]
(4) Adjustment of steering system relief valve

(a) Attach a pressure gauge capable of measuring
Pressure gauge
up to 25000 kPa (250 kgf/cm2) [3533 psi] to the Steering system
pump delivery hose connector (illustration on relief valve
the right).
(b) Set the control lever to neutral.
(c) Start the engine and run it at the medium
speed. Turn the steering wheel to the extreme
right or to left to relieve oil in the steering sys-
tem. The relief pressure must be within the G 1/8
range in the table below.
(d) If the relief pressure is outside the range,
remove the cap and turn the adjusting screw
for adjustment. Pump delivery
hose
(e) If the pressure is correct, tighten the lock nut
and check the relief pressure again.
213848
Set pressure of steering system relief valve
Unit: kPa (kgf/cm2) [psi]

Truck type
Items 2 ton class
1 ton class
3 ton class
+490 +490
8800 0 10300 0
Set pressure +5
(90 0 )
+5
(105 0)
+71 +71
[1276 0 ] [1494 0 ]
11-36
HYDRAULIC SYSTEM
3.3 Descent 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 descent (retraction of the piston rods) for 15
minutes.
Divide the measured value by two to obtain the
retraction of piston rods.
Unit: mm (in.)/15 min
Truck type
Items 2 ton class 213849
1 ton class
3 ton class
Descent (retraction of
the piston rods) with 50 (2.0) or less
rated load
3.4 Forward Tilt 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 rod
for 15 minutes.
Unit: mm (in.)/15 min
Truck type
Items 2 ton class
1 ton class
3 ton class
Amount of forward 213850
(extension of piston 20 (0.8) or less
rods) with rated load
11-37
HYDRAULIC SYSTEM
4. Troubleshooting
Not enough oil in hydraulic tank Refill.
Oil viscosity improper Change upon referring to "Fuel and
Lubricant Specifications" on chapter
13 Service data 4.2 Fuel and Lubri-
cant Specifications.
Overload Check working conditions and, if over-
loaded, urge the operator to stay
within the load limit.
Hydraulic tank heats
excessively Local overheating of oil line due to a large Clean oil line.
restriction to flow
Relief valve adjustment improper Readjust pressure setting.
Pressure drop due to fatigued or broken Disassemble or replace and readjust
Hydraulic springs pressure.
tank
Gear pump worn Replace pump.
Outlet pipe or tube flattened, or restriction Repair or replace.
to flow
Shortage of oil due to a natural loss Replenish oil upon referring to "Fuel
and Lubricant Specifications" on chap-
ter 13 Service data 4.2 Fuel and Lubri-
Cylinders move too Oil leakage due to damaged oil line and Repair or replace.
slow seals
Oil viscosity too high Change upon referring to "Fuel and
Lubricant Specifications" on chapter
13 Service data 4.2 Fuel and Lubri-
Gear pump does not pump oil Check pump and piping; repair or
replace.
Cylinders move too
Oil leakage from oil line Check oil for level and condition; add
slow
or change oil.
Gear pump internally leaking Replace pump.
Poor pumping Replenish oil upon referring to "Fuel
Cavitation (1) Check suction pipe for any flat por-
Noisy tion or loose connection; retighten
or replace.
(2) Check shaft oil seal for airtight-
ness; replace pump.
(3) Check pump body for any outside
Gear pump interference; repair.
Pressure too high Replace pump. (Check to see if relief
valve setting is correct.)
Distortion or damage due to external Replace pump.
Pump case, drive strain or stress
gear or pump port (1) Check to see if return line is
flange damaged blocked or restricted.
(2) Check to see if pipe connections
have been externally strained or
stressed.
Oil oozes out through the oil seal Replace shaft seal.
Oil oozes out onto the drive shaft sliding Replace whole pump assembly.
surfaces
Oil leakage from pump
Loose bolts that secure the pump Retighten. Replace if needed.
Degraded performance of sealing inside Replace gasket.
pump
11-38
HYDRAULIC SYSTEM
Relief valve set pressure lowered Readjust pressure.

Relief valve piston seizure Wash piston and check to see if it
moves smoothly; or replace whole
relief valve assembly.
Slow or no motion of lift
O-ring on relief valve body damaged Replace O-ring.
and tilt cylinders
Control lever installed loose, resulting in Adjustment
not enough spool stroke
Control Abnormal oil temperature rise Check control valve spool for
Valve misalignment; repair or replace.
Load descends or mast Control valve spool internally leaking Replace a leaky block assembly.
tilts forward
Oil leakage from spool ring cap Replace O-ring; check spool for
flaws and if any, repair or replace a
leaky block assembly.
Oil leakage
Loose plug Retighten plug.
O-ring damaged Replace O-ring.
Not enough oil in hydraulic tank Replenish oil upon referring to "Fuel
Mast will not lift or tilt
Relief valve out of order, because of:
forward or backward
(1) Seized main valve Replace.
(2) Broken valve spring Replace.
Gear pump defective Replace.
Relief valve out of order, because of:
(1) Too low a relief valve setting Readjust pressure.
(2) Defective plunger or poppet seat Replace.
Will not lift rated load (3) Fatigued or damaged spring Replace.
(4) Damaged O-ring in valve case Replace.
Lift and tilt Gear pump defective Replace.
cylinders
Piston seals worn or damaged Replace.
Engine speed too low Tune up engine.
Control lever installed loose, resulting in Adjustment
Lifting speed is too not enough spool stroke
slow
Tank strainer clogged Clean or replace.
Pump not delivering enough oil Repair or replace.
Sleeve seized in flow regulator valve Repair.
Lowering speed is too Dirt in flow regulator valve, abnormal Clean, repair system and replace
slow resistance to flow due to flattened hose or defective hose.
local clogging
Piston rod distorted Repair or replace.
Cylinder vibrates when Air trapped in oil circuit Bleed air by operating cylinder
actuated through full stroke.
Not enough oil in hydraulic tank Refill.
11-39
HYDRAULIC SYSTEM
Control valve spool internally leaking Replace a leaky block assembly.

Sliding (inside) surface of cylinder tube Repair or replace.
slightly grooved
Load descends fast Sliding (inside) surface of cylinder tube Replace cylinder assembly
badly grooved
Piston seals broken or distorted Replace seal kit.
Oil leakage from piping Repair or replace.
Control valve spool internally leaking Replace a leaky block assembly.
Foreign particles lodged in packing Replace packing.
Mast tilts forward (drift) Piston seals damaged Replace seals.
Lift and tilt
cylinders Other abnormal distortion, oil leakage Repair or replace.
from piping
Lift cylinders descend Sliding surface of cylinder tube badly Repair or replace.
or tilt cylinders tilt for- grooved or rusted at one point
ward (drift) at a certain
Cylinder tube distorted Replace.
point of stroke
Foreign particles lodged between sealing Replace.
members such as oil seals and dust seals
Oil leakage at bushing Oil seals and dust seals grooved Replace.
O-rings damaged Replace O-ring.
Cylinder abnormally distorted Repair or replace.
11-40
HYDRAULIC SYSTEM
5. Service Data
Truck type
Item
1 ton class 2 ton class 3 ton class
Forward tilt angle (standard truck with simplex
degrees A 6
mast)
Backward tilt angle (standard truck with sim-
degrees A 12
plex mast)
Lift cylinder descent amount (at rated load)
mm (in.) /
[Retracted length of rod, oil temperature at A 50 (2.0) or less
15 min
45°C]
Tilt cylinder forward tilt amount (at rated load)
mm (in.) /
[Extended length of rod, oil temperature at A 20 (0.8) or less
15 min
45°C]
MPa
Main relief valve setting A 18.1
+0.5 +5
(185 0 ) [2625
+72
0 ]
(kgf/cm2) [psi] 0
+0.5 +5 +0.5 +5 +0.5 +5

MPa 8.8 0 (90 0 ) 10.3 0 (105 0 ) 10.3 0 (105 0 )
Steering system relief valve setting A
(kgf/cm2) [psi] +72
[1276 0 ]
+72
[1494 0 ]
+72
[1494 0 ]
N·m
Tightening torque of return filter A 49 ± 9.8 (5.0 ± 1.0) [36 ± 7.2]
(kgf·m) [lbf·ft]
N·m
Tightening torque of suction strainer A 49 ± 9.8 (5.0 ± 1.0) [36 ± 7.2]
(kgf·m) [lbf·ft]
A: Standard value
Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class 3.5 ton class
Rod outside diameter 1 A 35 (1.38) 40 (1.57) 45 (1.77) 45 (1.77)
Cylinder inside diameter 2 A 45 (1.77) 50 (1.97) 55 (2.17) 60 (2.36)
Cylinder outside diameter 3 A 53 (2.09) 58 (2.28) 65 (2.56) 70 (2.76)
Second
cylinder for
simplex mast
and triplex
mast 1 2 3
217406
A: Standard value
11-41
HYDRAULIC SYSTEM
Unit: mm (in.)
Truck type
Item
Rod outside diameter 1 A 50.8 (2.0) 50.8 (2.0) 55 (2.17) 55 (2.17)
Cylinder outside diameter 3 A 83 (3.27) 87 (3.43) 97(3.82) 102 (4.72)
First cylinder
for duplex
mast and tri-
plex mast 1 2 3
217404
A: Standard value
Unit: mm (in.)
Truck type
Item
Rod inside diameter 1 A 16 (0.63) 16 (0.63) 20 (0.79) 24 (0.94)
Rod outside diameter 2 A 32 (1.26) 32 (1.26) 40 (1.57) 42 (1.65)
Cylinder outside diameter 4 A 53 (2.09) 53 (2.09) 58 (2.28) 65 (2.56)
Second
cylinder for
duplex mast
1 2 3 4
217405
A: Standard value
11-42
HYDRAULIC SYSTEM
Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Rod outside diameter 1 A 25 (1.0) 30 (1.2) 35 (1.4)
Cylinder inside diameter 2 A 63 (2.5) 70 (2.8) 80 (3.1)
Cylinder outside diameter 3 A 73 (2.9) 82 (3.2) 93 (3.5)
+0.085 +0.085 +0.085
32 0 32 0 32 0
Bushing inside diameter on head side 4 A +0.003 +0.003 +0.003
(1.3 0 ) (1.3 0 ) (1.3 0 )
0 0 0
35 -0.02 35 -0.02 35 -0.02
Bushing inside diameter on rod side 5 A 0 0 0
(1.4 -0.0008) (1.4 -0.0008) (1.4 -0.0008)
N·m 265 ± 29 314 ± 31 373 ± 37

Tightening torque of guide bushing 6 (kgf·m) A (27.0 ± 3.0) (32.0 ± 3.2) (38.0 ± 3.8)
[lbf·ft] [195.6 ± 21.4] [231.7 ± 22.9] [1275.3 ± 27.3]
N·m 127 ± 9.8 235 ± 19.6 392 ± 25
Tightening torque of nut 7 (kgf·m) A (13.0 ± 1.0) (24.0 ± 2.0) (40.0 ± 2.5)
[lbf·ft] [93.7 ± 7.2] [173.4 ± 14.5] [289.3 ± 18.5]
Tilt N·m 157 to 182 157 to 182 157 to 182

Tightening torque of tilt socket clamp
cylinder (kgf·m) A (16.0 to 18.6) (16.0 to 18.6) (16.0 to 18.6)
bolt 8
[lbf·ft] [115.9 to 134.3] [115.9 to 134.3] [115.9 to 134.3]
6 7
5 1 2 3 4
8
213855
A: Standard value
11-43
HYDRAULIC SYSTEM
6. MC Control Valve
6.1 Structure and Operation
6.1.1 MC Control Valve
5
P : Pressure oil inflow port from pump 4 9
PF : To steering control valve

7 6
T1 : To hydraulic tank (return line)
T2 : Return from steering control valve
A1 :To lift cylinder 1
A2 : To tilt cylinder rod end

B2 : To tilt cylinder head end
T2
PF T1
2 B2
8 A2
3 A1
P
213856
Main valves
1 Inlet cover section (with built-in priority valve) 6 End cover section (with built-in unload valve)
2 Lift valve (with built-in flow regulator valve) 7 Steering system relief valve
3 Tilt valve 8 Main relief valve
4 Attachment valve (1) 9 Unload valve (with solenoid)
5 Attachment valve (2)
The above illustration shows an external view of the returns, namely through the descent hydraulic circuit
four-valve type MC control valve. Any one of the two that has a built-in lock valve linked with the flow regu-
valve to five-valve type valves is installed on a truck lator valve and the seat switch.
depending on the lift truck specifications.
The most basic valve configuration is a two-valve type, Tilt valve 3 feeds and returns pressure oil to and from
combination of the lift and tilt. Adding attachment the tilt cylinder which tilts the mast forward or back-
valve(s) to this combination is three-valve type, four- ward. The tilt lock valve is assembled in the main
valve type or five-valve type valve. spool to ensure safety when the mast is tilted forward.
Inlet cover section 1 has a built-in priority valve. This Attachment valves 4 and 5 are direction control valves
valve is a flow divider valve which feeds a certain which feed pressure oil to actuators of the attach-
amount of the total inflow volume from the P port pref- ments.
erentially to the steering system and the extra flow vol-
ume to the cargo-handling valve.
In addition, the inlet cover section is provided with End cover section 6 is provided with unload valve 9.
main relief valve 8 and steering relief valve 7. This valve is linked with the seat switch, and is a sole-
noid valve which closes the parallel feeder (high-pres-
Each of these valves limits the maximum pressure to sure circuit) to hold pressure oil only when the seat
protect the system. switch is ON.
Lift valve 2 and tilt valve 3 are assembled adjacent to

the combination section.
Lift valve 2 is a direction control valve which feeds and
returns pressure oil to and from the lift cylinder. Oil
11-44
HYDRAULIC SYSTEM
6.1.2 Hydraulic Circuit Diagram of MC Hydraulic Control Valve

For the entire diagram of the hydraulic system, refer
to 1.2 Hydraulic Circuit Diagram.
9
T1
1 Priority valve
2 Main relief valve 8
3 Steering system relief valve
4 Lift valve
5 Second valve (operates in conjunction with lift
lowering switch)
6 Tilt valve A3
7
7 Attachment valve
8 Unload Valve B3
9 Solenoid for unload valve
10 Center bypass port
A2
11 Parallel feeder B2 6
P : Supplied oil from pump

PF : To steering valve 5 10
T2 : Return from steering valve

11
T1 :To hydraulic tank
A1
4
A1 :To lift cylinder
PF
A3 : To actuator for attachment valve
B3 : To actuator for attachment valve 3
1
P T2
2
213857
11-45
HYDRAULIC SYSTEM
6.1.3 Inlet Cover Section
PF restricted area EF restricted area

Control orifice Extra flow (EF flow)
Hole A P 2
1 Priority flow (PF flow)
5 PF
7
6
Ball check seat surface 3 4 Passage of extra flow (EF flow) 213858
1 Priority valve spool P : From hydraulic pump (pump port)

2 Spring PF : To steering valve (priority port)
3 Ball check
4 Ball retainer EF : To cargo-handling valve (extra port)
5 Damper chamber
6 Main relief valve
7 Steering system relief valve (PF relief valve)
8 Valve
The inlet section of the control valve consists of the When the flow volume flowing in the port P from the
main relief valve 6, which limits the maximum pressure pump increases, PF flow passing the control orifice is
of the hydraulic system. The priority valve which feeds going to increase. Then, differential pressure before
the pressure oil preferentially to the steering system, and after the control orifice becomes greater.
and the steering system relief valve 7, which limits The left edge face of the valve spool 1 acts on the
maximum pressure of the supplied pressure oil. hydraulic pressure before the control orifice, namely
The priority valve is a flow divider valve which divides pump pressure, and on the right edge face of the spool
supplied oil to a predetermined volume of priority flow acts on the PF flow pressure.
(PF flow) and extra flow (EF flow). PF flow and EF flow Therefore, when differential pressure becomes
are supplied to the steering system and the cargo-han- greater, the valve moves to the right, closes the PF
dling valves, respectively. restricted area and opens the EF restricted area,
The above illustration shows the position of priority releasing extra flow to the EF port. As a result, PF flow
valve spool 1 during operation (during pump rotation). decreases and differential pressure also decreases.
The priority flow (PF flow) of pressure oil which flows On the other hand, when the flow volume of pressure
in the port P flows in the following sequence: PF oil flowing in the port P decreases, PF flow flowing
restricted area→Hole A→Control orifice →Groove through the control orifice decreases and differential
between ball check 3 and ball retainer 4→Spring pressure also decreases. The spool moves to the left
chamber →PF port. and restricts extra flow. As a result, PF flow increases
This passage is always open and a certain volume of and differential pressure also increases.
oil is flowing toward the steering valve during opera- Differential pressure varies between extra flow and PF
tion. flow not only by the flow volume but also by operation
Extra flow (EF flow) passes the EF restricted area, of the fork. Differential pressure before and after the
flows in the EF port and then, in the center bypass port control orifice, however, can be kept constant by
of the load-handling valve. adjusting angles of the PF restricted area and EF
restricted area. As differential pressure is constant, PF
flow becomes constant.
11-46
HYDRAULIC SYSTEM
Valve 8 is an orifice that provides in oil inflow and out-

flow passages for damper chamber 5. This orifice 8 1
preferentially divers PF flow in a stable condition (no
occurrence of surging) by controlling the moving
speed of valve spool 1.
Movement of
When extra flow (EF flow) is increased, pressure oil in
valve spool
port P flows into damper chamber 5. As this passage
is the orifice on the edge of valve 8 only, movement of
valve spool 1 is slow. 5
When PF flow is insufficient, it is necessary to increase When increasing extra flow

PF flow by quickly restricting the EF restricted area.
For this, it is necessary to quickly discharge oil in
damper chamber 5. As the orifice on the circumfer-
ence as well as the orifice on the valve edge is in the
passage at this time, the spool can move to the left
quickly.
This action, when pressure of PF flow lowers, can pre- Movement of
valve spool
vent a kickback phenomenon caused on the steering
wheel.
Ball check 3 prevents backflow of PF flow. This is a

preventive measure for a kickback phenomenon. When restricting extra flow
213859
6.1.4 Main relief valve
This valve is a relief valve with a pilot valve. When 1
3 4 2
pressure in the P port reaches the set value, poppet
High-pressure
passage
valve 1 is pushed to the left (in the illustration), leaving
the seat. Pilot oil in the spring chamber flows in the
drain passage. Then, dump valve 2 moves to the left,
releasing a part or all of main flow to the low-pressure
passage.
This is a safety valve to protect the system. Low-pressure passage
To adjust, turn adjusting screw 3 to change preload of

spring 4. Drain passage of
pilot oil Spring chamber 213860
6.1.5 Steering system relief valve

(PF relief valve)
This valve is a relief valve of direct-acting type, and
Valve
acts when the steering wheel is fully turned.
This is a safety valve to protect the system. To adjust,
turn the adjusting screw to change preload of the
spring.
Low pressure
passage
Pressure
Spring adjusting
screw
PF flow passage
213861
11-47
HYDRAULIC SYSTEM
6.1.6 Lift valve
Oil passage for opening

load check valve
5 A1 8
4 2 7
Neutral
Descent Ascent
3 Center by pass port 1 T2

213862
Main Components
1 Lift spool 7 Flow regulator valve
2 Valve body 8 Shut-off valve
3 Return spring
4 Check valve
5 Load check valve A1 : Lift cylinder port
6 Solenoid valve T2 : Tank port
The above illustration shows the lift control valve when

spool 1 is at the "neutral position."
Neutral position
Spool 1 is placed at the "neutral position" by return
spring 3 and oil in the A1 port is blocked by load check
valve 5.
As the center bypass port is open, oil pressure flows
into the tilt valve without being blocked.
Ascending position of lift cylinder

Spool 1 moves to the right (as in the above illustration)
and blocks the center bypass port.
Pressure in the parallel feeder (high-pressure pas-
sage) rises and oil pressure pushes open check valve
4, reaching load check valve 5. Furthermore, oil pres-
sure pushes open load check valve 5, that flows in the
A1 port and in the bottom of the lift cylinder piston. And
it pushes the cylinder rod upward.
11-48
HYDRAULIC SYSTEM
Oil passage for opening load

Pilot oil check valve 5 A1 B 8
4 2 7
Neutral
Descent Ascent
3 Center bypass port 1 T2 213863
Descending position of lift cylinder : Action of flow regulator valve

The above illustration shows the lift control valve when Restricted area D
spool 1 is at "descending position." Chamber C Orifice (b) Valve spool Spring E
Adjusting
screw
Spool 1, pushed in body 2, is at the position as shown
in the illustration. The center bypass port is not
blocked. The secondary port of flow regulator valve 7 Primary
is open to the T2 port (return passage). pressure
When an operator sits on the seat, Vehicle Control Secondary

Secondary pressure
Module (VCM1-M) detects it, making an electric cur- pressure 213864
rent flow to solenoid valve 6 to activate the solenoid. The flow regulator valve keeps the maximum speed
When the solenoid activates, pilot oil behind load constant during cylinder descent regardless of the load
check valve 5 is released to the passage B. Thus, load weight on the fork.
check valve 5 moves to the left (in the illustration) by
pressure of the A1 port and oil in the A1 port flows to
the T2 port via flow regulator valve 7. Oil from the A1 port (primary pressure) passes through
the restricted area D and its pressure is reduced. This
pressure-reduced oil (secondary pressure) flows to
Shut-off valve 8 forcibly opens load check valve 5 if chamber C through the orifice (b) and moves the valve
the load check valve does not automatically activate spool to the right against the spring E, restricted area
due to malfunction of solenoid 6 or any other reason. D. The degree of this restriction is greater as the pri-
Just loosen the lock nut and push in the screw. mary pressure is higher. Thus, the secondary pressure
is made constant. If the secondary pressure is con-
stant, the outflow volume is constant.
The right part of this valve is a mechanism to stabilize

valve spool movement. Do not adjust this valve in field.
11-49
HYDRAULIC SYSTEM
6.1.7 Tilt valve

Passage A
(high-pressure passage) 3
6
A2 B2
2
Hole
Neutral
Forward tilt Backward tilt
1
5 4 Center bypass port T2
213865
Main Components
1 Tilt spool A2 : To tilt cylinder rod
2 Return spring B2 : To tilt cylinder head
3 Check valve
4 Tilt lock valve T2 : Tank port (return passage)
5 Tilt lock valve spring
6 Valve body
The above illustration shows the tilt control valve when Mast backward tilt position :
spool 1 is at the "neutral position."
Spool 1 moves to the right.
The B2 port is connected to the T2 port and the A2
Neutral position port is connected to passage A. The spool is posi-
Spool 1 is placed at the "neutral position" by return tioned to block the center bypass port, but as the spool
spring 2, and both the A2 port and B2 port are blocked is provided with a hole under the land, it does not block
by the spool. it completely. This is designed to prevent a large
As the center bypass valve is open, oil in the bypass amount of oil from flowing at one time and to avoid
port flows in the attachment valve. abrupt movement of the cylinder, a characteristic of
this valve.
When the center bypass port is blocked, pressure in

the parallel feeder rises. Pressure oil pushes open
check valve 3, flows in passage A and flows to the tilt
cylinder rod from the A2 port.
At the same time, oil in the tilt cylinder head flows to
the T2 passage.
These two actions pull the rod into the tilt cylinder.
11-50
HYDRAULIC SYSTEM
3
A2 B2 6
2
5
Hole
Forward tilt Neutral
4
T2
Passage A
1
(b)
(a)
Chamber
(c)
213866
Mast forward tilt position

The above illustration shows the tilt control valve when
spool 1 is at the "forward tilt position."
Spool 1 is pushed into body 6. Then, the B2 port is
connected to passage A.
At the same time the center bypass port is blocked.
This blockage, however, is not complete because
there is a hole under the land. This is designed to pre-
vent abrupt movement of the cylinder, a characteristic
of this valve.
As the center bypass port is blocked, pressure in the
parallel feeder rises, pushing open check valve 3 and
pressure oil flows to passage A.
Oil in passage A flows to the tilt cylinder head from the
B2 port and acts to push out the cylinder rod.
At the same time, pressure oil in passage A flows to
the chamber on the right end of tilt lock valve 4 via ori-
fice (a) and pushes the tilt lock to the left against
spring 5.
Then, return oil from the A2 port flows to the hole (b),
passage (c), orifice (d) and passage T2.
The tilt cylinder tilts forward due to pressure oil sup-
plied from the B2 port and "opening" of the return pas-
sage of the A2 port.
Tilt lock valve 4 does not operate unless the engine
runs and pressure oil is supplied from the pump.
This valve is a kind of a safety valve.
11-51
HYDRAULIC SYSTEM
6.1.8 Unload Valve
1 Solenoid valve
2 Valve
T1 : Tank port (return passage)

1
2
Pilot passage
Parallel feeder
(high-pressure line)
T1
213867
The above illustration shows the unload valve when

the engine stops.
When the seat switch is "open", solenoid valve 1 is

open and pilot oil in the back of valve 2 is connected to
the T1 passage.
Therefore, oil in the parallel feeder (high-pressure line)
lightly pushes up valve 2, flowing to the T1 port.
Namely, as hydraulic pressure cannot be held, the cyl-
inder cannot be moved even if the valve operating
lever is moved.
When an operator sits on the seat, the seat switch is

turned ON, actuating solenoid valve 1 to block the pilot
passage. Thus, the parallel feeder can hold oil pres-
sure.
This valve is a safety valve.
11-52
HYDRAULIC SYSTEM
6.2 Control Valve, Removal and Installation

Removal
(1) Remove the floor plate.
(2) Remove the clevis pin of the control lever rod and
separate the rod from the control valve spool.
(3) Disconnect each piping from the valve.
(a) Pump delivery hose
(b) Tilt pipe
(c) Lift pipe
(d) Return hose
(e) Supply pipe to steering valve
(f) Return hose from the steering valve
(4) Remove valve mounting bolts and nuts (arrows in
the illustration on the right) and remove the valve.
Tilt hoses
Clevis pin
MC control
valve
Lift hose
213868
Installation
Also follow the instructions given below:
Check the hydraulic oil level. Replenish it to the speci-
fied level if the level is low.
11-53
HYDRAULIC SYSTEM
6.3 Disassembly and Reassembly

6.3.1 Valve of Inlet Cover Section
Disassembly
10
9
5
4 2 6
3
1
Plug area
Locknut
Cap
7 8
213869
Sequence
I. Priority valve (1 thru 6)
1 Plug, O-ring 3 Spring 5 Ball
2 Spool assembly 4 Retainer 6 Plug, O-ring
II. Main relief valve (7)
7 Main relief valve
III. Steering system relief valve (8)
8 Steering system relief valve
IV. Other parts (9 and 10)
9 Plug, O-ring 10 O-ring

(1) Do not disassemble the main relief valve and the
relief valve of the steering system unless there is
any abnormality.
Note: When loosening the relief valve, apply a span-
ner to the plug area of the relief valve to re-
move. If the lock nut is loosened by mistake, the
set pressure of the relief valve changes. If it is
loosened by mistake, use a pressure gauge to
reset.
11-54
HYDRAULIC SYSTEM
6.3.2 Combination Section

Disassembly of Lift Valve
10 11 12 14 15
Protrusion amount of set screw

16
13
Protrusion
amount of
set screw
Return spring 7
Cap screw
5
8
2
4 9
1
213870
Sequence
I. Lift valve (1 thru 9)
1 Check valve, spring 4 Spool, return spring 7 Bolt
2 Bolt 5 Plate 8 Plate
3 Cap 6 Seal 9 Seal
II. Load check valve (10 thru 15)
10 Plug, O-ring 12 Check valve 14 O-ring
11 Spring 13 Solenoid valve 15 Shut-off valve
III. Flow regular valve (16)
16 Flow regulator valve

(1) Remove spool 4 from the combination valve body Remove it as an assembly without touching the
with the return spring and cap screw attached. adjusting screw and lock nut.
When disassembling, make a record of the protru-
(2) When removing the cap screw, hold the spool in a
sion amount of the set screw. Reassemble it to
vise with soft jaws (hard wooden plate or plastic
the same dimension.
plate) and remove the cap screw using a hexagon
wrench. Be careful of the spring jumping out. (4) Do not, in principle, disassemble or adjust shut-off
valve 15. When disassembling, make a record of
(3) Do not, in principle, disassemble or adjust flow
the protrusion amount of the set screw. Reassem-
regulator valve 16. If internal parts are damaged,
ble it to the same dimension.
replace it as an assembly.
11-55
HYDRAULIC SYSTEM
Disassembly of Lift Valve
5
3 12
7
10
11
2 6
4 9 8
14 1
13
213871
I. Sequence (1 thru 9)
1 Check valve, spring 4 Spool sub-assembly 7 Bolt
2 Bolt 5 Plate 8 Plate
3 Cap 6 Seal 9 Seal
II. Disassembly sequence of spool sub-assembly (10 thru 15)
10 Cap screw 12 Spring 14 Tilt lock valve
11 Spring retainer 13 Spring 15 Shut-off valve
III. Flow regulator valve (16)
16 Flow regulator valve

(1) Remove spool 4 from the body with spring 12 and
cap screw 10 attached.
(2) When removing cap screw 10, hold the spool in a
vise with soft jaws (hard wooden plate or plastic
plate) and remove the cap screw using a hexagon
wrench. Be careful of the spring jumping out.
Remove also the tilt lock valve.
Note: Do not disassemble and adjust the shut-off

valve 15 and flow regulator valve 16.
11-56
HYDRAULIC SYSTEM
6.3.3 End Cover Section

Disassembly of Unload Valve
Sequence
1 Solenoid valve
2 Plug, O-ring
3 Spring
4 Valve
5 Spring retainer
6 Ball
213872
Valve, spool and return spring
(1) Check the valve body for cracks, damaged sliding
surface and wear of check valve seat.
(2) Check the spool for damage, seizure, bend and
operating force.
(3) Check the tilt lock valve for damage and seizure.
213873
11-57
HYDRAULIC SYSTEM
Reassembly
reverse. Also follow the instructions given below.
(1) Clean disassembled parts with an appropriate sol-
vent, and apply compressed air to the parts to dry
and remove foreign matters.
(2) Apply hydraulic oil to all parts. Tie bolt
(3) Replace O-rings.

(4) Tighten tie bolts.
Tighten tie bolts evenly. Tightening them unevenly
or to inadequate torque can distort the valve body,
resulting in unsmooth movement of the spool.
(5) Install component valves after appropriate valve
bodies are installed with tie bolts.
(6) Check that the spools slide smoothly.
Note: The valve body and spool have been lapped as
a set. Do not change the combination. When ei- 213874
ther one of the two becomes necessary to re-
place, replace them together as an assembly.
11-58
HYDRAULIC SYSTEM
7. FC Control Valve
7.1 Structure and Operation
7.1.1 FC Control Valve – General
5
8 6 7 2
10
c1 SOL b1 SOL b2 SOL b3 SOL

9 3
1
B2 B3
PF
2 3
T2
P
T1
A1 a3 SOL
a2 SOL
a1 SOL 213875
1 Inlet valve assembly P : Supplied oil from hydraulic pump (oil inlet port)
2 Tilt valve assembly T1 : To hydraulic tank (return line)
3 Attachment Valve Assembly
4 End cover assembly T2 : Return from steering valve (oil return port)
5 Solenoid lead wire and connector PF : To steering system
6 Solenoid for unload valve
A1 : To lift cylinder
7 Emergency shut-off valve (for release of lift lock)
8 Main relief valve (pilot) A2 : To tilt cylinder rod end
9 PF relief valve (steering system relief valve) B2 : To tilt cylinder head end
10 Emergency shut-off valve (for use as attachment)
A3 : To actuator for attachment valve
B3 : To actuator for attachment valve
c1 SOL :Solenoid for unload valve
a1 SOL, b1 SOL: Solenoid for lift valve
a2 SOL, b2 SOL: Solenoid for tilt valve
a3 SOL, b3 SOL: Solenoid for attachment valve
Note: The above illustration shows a three-valve type

FC control valve.
For a two-valve type control valve, eliminate the
attachment valve. For four-valve type and five-
valve type control valves, add the attachment
valve(s) as appropriate.
11-59
HYDRAULIC SYSTEM
7.1.2 Hydraulic Circuit of FC Control Valve

For the entire hydraulic system diagram (for cargo
handling and steering), refer to 1.3 Hydraulic Circuit T1
Diagram (for Trucks with FC Control Valve).
For the structures and actions of individual compo- B3
nent valves, refer to the next and subsequent pages. A3
b3 a3
10
1 Flow priority valve
2 PF relief valve B2
3 Main relief valve A2
b2 a2
4 Pilot relief valve 9
5 Unload Valve
6 Resistance Valve
7 Reducing valve for pilot oil
8 Lift valve A1
9 Tilt valve
b1 a1
10 Attachment valve 8
Pp
P : Supplied oil from pump 3
PF : To steering system
4
7 6
T1 : To hydraulic tank
T2 : Return from steering system 1 2
A1 : To lift cylinder
c1 5
A3 : To actuator for attachment valve P PF T2
213876
B3 : To actuator for attachment valve

c1 : Solenoid for unload valve
a1, b1: Solenoid for lift valve
a2, b2: Solenoid for tilt valve
a3, b3: Solenoid for attachment valve
Pp : Pilot oil line (blank capped) for electromagnetic
proportional pressure control valve
11-60
HYDRAULIC SYSTEM
7.1.3 Component Valves of Inlet Valve Assembly

The inlet valve assembly is complete with eight components valves as described below.
A1
N N
b1 a1
8 3
M M
Pp
L P L
7
4
6
A1
c1 5
1
P PF T2 2
1 Flow priority valve

2 PF relief valve
K K 3 Main relief valve
4 Main relief valve (pilot)
5 Unload valve
6 Resistor valve
7 Pressure reducing valve
8 Lift control valve
3
4 1
Section M - M Section L - L
2 6
Section N - N Section K - K
Lift control valve 8

7
213877
11-61
HYDRAULIC SYSTEM
Flow Priority Valve and PF Relief Valve

Sliding Hole (r) (4 places)
F 2 B E 1 A G D P 3 C direction of spool
Small hole (S)
Flow (1 place)
direction
of oil
Valve 3 with spool 1

sliding to left
Valve 3 with spool 1

sliding to right
Check valve
PF
6 4 5
213883
1 Priority valve spool A: Passage of extra flow (EF flow)

2 Spring B: Passage of priority flow (PF) connecting to port PF
3 Valve C: Damper chamber
4 PF relief valve poppet D: Inlet port for PF flow in hollow portion of spool (1)
5 Spring E: Control orifice
6 Relief valve pressure adjusting screw F: PF restricted area
G: EF restricted area
P: Inlet port for oil from pump
PF: Control flow outlet port (feed port to steering system)
Function of Flow Priority Valve

The flow priority valve is a flow divider valve which
divides supplied oil into predetermined volumes of pri-
ority flow (PF flow) and extra flow (EF flow).
PF flow of oil is supplied to the steering system. Extra

flow of oil is supplied to the lift, tilt and attachment
valves for mast operations.
11-62
HYDRAULIC SYSTEM
Action Action of Valve 3

The illustrations on the previous page show the valve The valve 3 and the orifice (s) in the forward end of the
in operation. When the pump is not operating (the valve serve to control the moving speed of the valve
engine is stopped), the valve spool 1 is pressed by the spool 1 (especially when the restricted area G is
spring 2 to the rightmost position. opened) to prevent hunting due to sharp increase in
The extra flow restricted area G is closed. the volume of flow when the valve spool moves,
thereby stabilizing the flow of oil. In other words, when
the extra flow restricted area G opens, oil flows into
When the valve is in operation, oil introduced from the the damper chamber C, where the small orifice (s) in
port P enters the hollow portion of the valve spool from the forward end of the valve 3 is the only passage of
the inlet hole in the spool and passes through the con- oil so that the movement of the valve spool 1 is slow.
trol orifice E and PF restricted area F before it flows in
the passage B. This is the PF flow of oil. When the PF flow restricted area F opens, oil in the
chamber C is released. The release takes place
The pressure of PF flow acts on the left end of the quickly because four holes (r) on the circumference of
valve spool 1 to join the force of spring 2 in pressing the valve 3 and the small orifice (s) in the forward end
the valve spool 1 to the right. of the valve are used. As a result, the valve spool
In the meantime, oil entering the hollow portion of the moves to the right quickly to open the restricted area F.
valve spool 1 and flowing in the direction of the This prevents a kickback phenomenon on the steering
damper chamber C presses the valve 3 to the right. wheel.
The oil is released into the chamber C from the small
hole (s) in the forward end of the valve 3 and presses
the valve spool 1 to the left. Action of Port PF Check Valve
This valve holds pressure in the steering system to
prevent a kickback phenomenon.
When the volume of flow from the port P increases, PF
flow in the hollow portion of the valve spool 1
increases as well. As a result, the pressure difference Notice: Kickback phenomenon
between before and after the control orifice E This is a phenomenon in which steering pressure is
becomes greater, causing the valve spool 1 to move to affected by fluctuations in operating pressure during
the left and narrow the PF restricted area F. When the cargo handling operation and the steering wheel being
restricted area F is closed, PF flow decreases and the handled is caused to kickback. It occurs when PF port
pressure difference decreases as well. pressure cannot be maintained. The valve 3 described
above and port PF check valve are a means of pre-
When the volume of flow from the port P decreases, venting this kickback phenomenon.
PF flow in the hollow portion of the valve spool 1
decreases. As a result, the pressure difference PF relief valve
between before and after the control orifice E
This is a relief valve for priority flow (PF flow), that is
decreases. The valve moves to the right to close the
for the steering system.
extra flow restricted area G. The extra flow decreases
and PF flow increases, and as a result, the pressure The pressure of oil in the oil passage B shown in the
difference becomes greater. illustration on the previous page, or the oil pressure of
PF flow, is always applied to the valve poppet 4.
When the pressure of PF flow exceeds the specified
In actual load handling operations, not only the flow oil
value, the valve poppet 4 moves to the right against
supplied from the pump varies but differential pressure
the force of the spring 5, releasing oil into the drain
occurs between PR flow and MF flow. In such cases,
passage. In this way, oil pressure in the steering sys-
the valve spool 1 moves to make the pressure differ-
tem is maintained below set value.
ence between before and after the control orifice E
constant, stabilizing PF flow. The screw 6 is for set pressure adjustment. Turning it
clockwise increases set pressure.
For set pressure and setting procedure, refer to
"Inspection and Adjustment."
11-63
HYDRAULIC SYSTEM
Main Relief Valve, Pilot Relief Valve and Unload Valve
9
7
8 3
10
2
5 4
D 1
Drain passage
6
C
A 213884
1 Main relief valve 6 Spring A: Extra flow (EF flow) passage

2 Dump valve 7 Pressure adjusting screw C: Drain passage
3 Spring 8 Unload Valve
4 Pilot relief valve 9 Solenoid D: Oil passage
5 Poppet valve 10 Needle valve
Function of Component Valves Unload Valve

The pilot relief valve 4 and unload valve 8 are The unload valve 8, located between the back of the
arranged in parallel to serve as pilot valves for the dump valve 2 and an oil passage connecting to the
main relief valve 1. drain passage C as shown in the illustration, is a sole-
To be more specific, when either valve 4 or 8 opens, noid valve serving as a pilot relief valve for the main
the dump valve 2 overcomes the force of the spring 3 relief valve 1.
to lift, releasing high pressure oil in the oil passage A When the solenoid is energized by electric current that
into the drain passage C. flows through it, the needle valve 10 protrudes to close
the oil passage D. When the solenoid is not energized,
Pilot Relief Valve 4 it has the needle valve 10 retracted in it. Therefore, the
oil passage D is open.
This is a pilot valve for the main relief valve. When
pressure in the system exceeds the specified limit, the When the operator leaves the seat and the cargo han-
poppet valve 5 overcomes the force of the spring 6 to dling levers are in the neutral position, the solenoid is
move downward, releasing oil in the back of the dump not activated and oil in the passage D is released into
valve 2 into the drain passage. As a result, the dump the drain passage C. This causes the dump valve 2 of
valve of the main relief valve lifts to release some of the main relief valve to lift, releasing all extra flow of oil
EF flow into the drain passage. into the drain passage C. This valve thus ensures
safety and helps save engine output.
The screw 7 is for set pressure adjustment. Turning it
clockwise increases set pressure. For set pressure When the operator moves a cargo-handling lever, the
and setting procedure, refer to "Inspection and Adjust- solenoid 9 is energized. The needle valve 10 pro-
ment." trudes to close the oil passage D, making the entire
extra flow line (including pilot oil for electromagnetic
proportional pressure control valve) ready to work nor-
mally.
11-64
HYDRAULIC SYSTEM
Resistance Valve
3 2 C A B 4
Function of resistance valve
This is a valve to maintain pilot oil pressure for the
electromagnetic proportional pressure control valve of
the spool valve.
The illustration at the right shows a state where the
unload valve is open and the oil passage A has no oil
pressure built in it.
When the unload valve is closed, oil pressure of extra
flow in the oil passage A is increased. Oil enters the D
1 213885
cavity D from the hole C to cause the spool 2 to move
to the right against the force of the spring 4. As a
result, the oil passages A and B are opened and oil in 1 Resistance Valve 3 Slug
the oil passage is sent to the lift, tilt and attachment 2 Spool 4 Spring
valves.
A: Extra flow (EF flow) passage
In this way, the pressure in the oil passage A is main- B: Neutral passage in spool section
tained above a certain level during operation.
C: Hole
D: Cavity
Reducing Valve
3
Function of reducing valve
If extra oil is used directly as pilot oil for the electro- 2
magnetic proportional pressure control valve, the pres-
sure is too high for the purpose. This valve reduces
the pressure of extra flow to a proper level. A
E
F D
Action 1
When there is no oil pressure in the oil passage A, the B
spool 2 is pushed up by the spring 4 to the position
shown in the illustration at the right. When the spool is
in such state, the restricted area F is open to the maxi- C
mum and the oil passages A and B are open. 4
When oil pressure in the passage A is built up, oil

pressure in the passage B rises as well. Oil in the pas-
sage B enters the cavity E from the hole D and pushes
213886
down the spool 2 against the force of the spring 4. As
a result, the restricted area F is closed, supplied oil to
the passage B decreases and oil pressure (pilot oil 1 Reducing Valve 3 Slug
pressure) in the passage lowers. When oil pressure in 2 Spool 4 Spring
the passage B decreases, the spool 2 moves upward
to increase supplied oil to the passage B, raising oil A: Passage connected to extra flow passage (oil
before pressure reduction)
pressure in the passage B.
B: Passage of pilot oil supplied to electromagnetic
In this way, the pressure of pilot oil in the passage B is proportional pressure control valve (oil after pres-
maintained constant after pressure reduction. sure reduction
When oil pressure in the passage B becomes C: Drain passage
extremely high, the passage B is opened to the drain D: Hole
passage C and some of pilot oil is drained. E: Cavity
F: Restricted area
11-65
HYDRAULIC SYSTEM
Lift valve
22 20 16 15 3 17 11 2 19 10 A1
7
5
6
21
14
4
13
Solenoid b1 Solenoid a1
12 18 8 9 1 12
Proportional electromagnetic
pressure reducing valve
213887
Main Components
1 Main spool 9 Low-pressure passage 16 Oil passage
2 Load check valve 10 Passage to port (A1) 17 Spring
3 Lift lock valve 11 Passage of pilot oil for actuating 18 Drain passage
4 Cap (solenoid a1 side) load check valve 19 Orifice
5 Spring (solenoid a1 side) 12 Passage of pilot oil for actuating 20 Shut-off valve
6 Cap (solenoid b1 side) spool 21 Spring preload adjusting
7 Spring (solenoid b1 side) 13 Oil passage screw
8 Neutral passage 14 Oil passage 22 Spool head
15 Oil passage
Actuation of Valve with Attachment Lever in "Neu-

tral" Position
Proportional solenoids a1 and b1 are inactive when
the lift lever is in the "neutral position."
Since the electromagnetic proportional pressure con-
trol valve releases oil in the caps 4 and 6 into the drain
passage 18 through the passage 12, there is no pres-
sure in the caps.
Therefore, the main spool 1 is maintained in the posi-
tion shown in the illustration above by the springs 5
and 7 at both ends of the valve, with the passage to
the port A1 closed.
Extra flow of oil divided by the priority valve of the inlet
valve assembly flows into the tank through the neutral
passage.
For actuation of the electromagnetic proportional pres-
sure control valve, refer to 7.1.6 Actuation of Electro-
magnetic Proportional Pressure Control Valve.
11-66
HYDRAULIC SYSTEM
A1
2 1
6 7
4
Solenoid a1
Solenoid b1 12
(energized)
pressure reducing valve 213888
Actuation of Valve with Lift Lever in "Ascent" Posi-

tion
When the lift lever is moved into the "ascent" position,
an electric current proportional to the movement of the
lever is fed from the controller to the solenoid a1. The
solenoid is activated and pilot oil is released from the
electromagnetic proportional pressure control valve
into the cap 4 through the passage 12. Pilot oil pres-
sure in the cap is proportional to the movement of the
lift lever. Pilot oil in the cap moves the main spool 1 to
the left against the force of the spring 7.
Oil in the neutral passage pushes up the load check

valve 2 and flows into the lift cylinder from the port A1.
11-67
HYDRAULIC SYSTEM
19
20 16 15 3 17 11 2 19 5
A1
6
14
21
13
Solenoid b1 Solenoid a1
12 18
9 1
Actuation of valve with Lift Lever in "Descent" Actuation of Valve with Lowering Speed Selector
Position: Switch in ON Position:
When the lift lever is moved into the "descent" posi- When this switch is set to ON, the maximum oil pres-
tion, an electric current proportional to the movement sure in the cap 6 can be held at a low level. This
of the lever is fed from the controller to the solenoid makes the stroke of the main spool 1 shorter and the
b1. The solenoid b1 is activated and pilot oil is return passage more restricted than when the switch is
released from the electromagnetic proportional pres- not used, and the maximum descending speed is
sure control valve into the cap 6 through the passage decreased as a result.
12. Actuation of Lift Lock Valve 3 in Case of Emer-
Pilot oil pressure in the cap is proportional to the gency:
movement of the lift lever. In case the main spool is stuck for some reason when
Pilot oil in the cap moves the main spool 1 to the right the lift cylinder descends, the movement of the cylin-
against the force of the spring 5. der rod can be stopped by returning the lift lever to the
At this point of time, pilot oil pressure passes the oil "neutral position. "With the lift lever back in the "neu-
passages 13 and 14 into the cavity on the left end of tral" position, pressure oil in the cap is released into
the lift lock valve 3 and moves the lift lock valve to the the drain passage 18 via oil passage 12.
right against the force of the spring 17. The lift lock valve 3 is returned by the spring 17 and
When this takes place, oil in the pilot passage 11 of the the pilot passage 11 is closed. The load check valve 2
load check valve 2 flows to the low-pressure passage is seated to block the flow from the port A.
9 through the oil passages 15 and 16. Actuation of Shut-Off Valve 20:
This oil flow gives rise to a pressure difference This is a valve used when the lift lock valve 3 is stuck
between before and after the orifice 19, which causes for some reason and the mast cannot be lowered.
the load check valve 2 to lift, releasing oil in the lift cyl- Loosening the valve opens the pilot passage 11 of the
inder into the tank from the port A1 through the low- load check valve 2. The load check valve 2 is then
pressure passage 9. lifted to release oil in the lift cylinder into the low-pres-
In the meantime, extra flow of oil runs into the tank sure passage 9, allowing the mast to lower.
because the neutral passage is not closed despite full Working of Spring Force Adjusting Screw 21:
leftward stroke of the spool. This screw is for adjusting preload of the spring 5.
When the engine is stopped, even if the lift lever is Where the pressure of pilot oil in the cap 6 is constant,
moved into the "descent" position, the lift lock valve 3 if the preload of the spring changes, the spool stroke is
cannot be actuated due to lack of pilot oil pressure, changed, so is the descending speed.
leaving the cylinder up as a result. Use this screw for adjustment only when the descend-
ing speed is excessively different from set value.
Usually, leave the screw intact. Do not remove it at the
time of disassembly.
11-68
HYDRAULIC SYSTEM
7.1.4 Tilt valve assembly
7 3 12 13 2 9 1 11
A2 B2 5
6
4
14
16
solenoid a2 Solenoid b2
8 10
15
213890
Main Components
1 Main spool 9 High-pressure passage (parallel feeder)
2 Check valve 10 Low-pressure passage (to T1)
3 Tilt lock valve 11 Passage to port (B2)
4 Cap (solenoid b2 side) 12 Passage to port (A2)
5 Spring (solenoid b2 side) 13 Oil passage
6 Cap (solenoid a2 side) 14 Passage of pilot oil for valve spool
7 Spring 15 Drain passage
8 Neutral passage 16 Chamber
Actuation of Valve with Attachment Lever in "Neu-

tral" Position
When the tilt lever is in the "neutral" position, the pro-
portional solenoids a2 and b2 are inactive.
Since the electromagnetic proportional pressure con-
trol valve releases oil in the caps 4 and 6 into the drain
passage 15 through the passage 14, there is no pres-
sure in the caps.
Therefore, the main spool 1 is maintained in the posi-
tion shown in the illustration above, with the passages
to ports A2 and B2 closed.
Extra flow of oil divided by the priority valve of the inlet
valve assembly flows into the tank through the neutral
passage.
As pressure oil does not flow into the chamber 16, the
tilt lock valve 3 is pressed to the right by the spring 7.
11-69
HYDRAULIC SYSTEM
3 12 2 9 1
7 A2 B2
5
6
Solenoid a2 Solenoid b2
(activated) 14 (not activated)
8 10
Proportional electromagnetic pressure reducing valve

213891
Actuation of Valve with Tilt Lever in "Backward

Tilt" Position
When the tilt lever is moved into the "backward tilt"
position, an electric current proportional to the travel of
the lever is fed from the controller to the solenoid a2.
The solenoid a2 is activated and pilot oil is released
from the electromagnetic proportional pressure control
valve into the cap 6 through the passage 14.
Pilot oil pressure in the cap is proportional to the
movement of the lift lever.
The pressure of pilot oil in the cap, which is propor-
tional to the travel of the tilt lever, causes the main
spool 1 to move to the right against the force of the
spring 5 and closes the flow in the neutral passage 8.
As a result, pressure in the high-pressure passage 9
rises. Oil in the passage pushes open the check valve
2 to flow to the rod side of the tilt cylinder through the
passage 12 and port A2.
Oil from the port B2 flows into the tank through the
low-pressure passage 10.
The tilt lock valve 3 is pushed to the right by the spring
7.
11-70
HYDRAULIC SYSTEM
2 9 1
A2 B2 5
4
Solenoid b2
8 14
12 13
Solenoid a2
3 10
Orifice (d):
A cluster of orifices. Capable of
preventing quick outflow of oil.
7 (e) (d) (c) (b) (a) Damper (e)

213892
Actuation of Valve with Tilt Lever in "Forward Tilt" Actuation of Tilt Lock Valve in Case of Emergency
position
In case the main spool is stuck for some reason when
When the tilt lever is moved into the "forward tilt" posi- the mast tilts forward, returning the tilt lever to the
tion, an electric current proportional to the travel of the "neutral" position stops the movement of the cylinder
lever is fed from the controller to the solenoid b2. rod.
The solenoid b2 is activated and pilot oil is released With the tilt lever back in the "neutral" position, the
from the electromagnetic proportional pressure control unload valve of the inlet valve assembly is opened to
valve into the cap 4 through the passage 14. release extra flow of oil into the drain passage through
Pilot oil pressure in the cap is proportional to the the main relief valve.
movement of the lift lever. As a result, oil pressure in the passage 13 is reduced,
The pressure of pilot oil in the cap, which is propor- and oil pressure of the damper (e) is also reduced.
tional to the travel of the tilt lever, causes the main When this takes place, the tilt lock valve 3 is pushed to
spool 1 to move to the left against the force of the the right by the spring 7 and the route connecting the
spring 5 and closes the neutral passage 8. As a result, port A2 and low-pressure passage 10 is closed.
pressure in the high-pressure passage 9 rises. Oil in The tilt cylinder rod is brought into a locked state.
the passage pushes open the check valve 2 to flow to
the head side of the tilt cylinder through the passage
13 and port B2, causing the cylinder rod to expand.
At this point in time, part of pressure oil in the passage
13 flows into the oil passage (a) and enters the
damper (e) to cause the tilt lock valve 3 to move to the
left against the force of the spring 7.
As a result, oil at the rod side of the tilt cylinder, that is
oil from the port A2, passes through the passage (b),
passage (c) and orifice (d) in that order into the low-
pressure passage 10.
The cylinder rod is extended by two actions combined,
i.e., supply of oil pressure from the port B2 and release
of pressure oil from the A2 port, and tilts the mast for-
ward.
11-71
HYDRAULIC SYSTEM
7.1.5 Attachment Valve Assembly
9 2 11 7 1 10
14 15
A3 B3 4
5 3
12
Solenoid a3 Solenoid b3
6 8
13
213893
Main Components
1 Main spool 7 High-pressure passage 12 Passage of pilot oil for valve spool
2 Check valve (parallel feeder) 13 Drain passage
3 Cap (solenoid b3 side) 8 Low-pressure passage (to T1) 14 Shut-off valve
4 Spring (solenoid b3 side) 9 Passage to port (A3) 15 Shut-off valve
5 Cap 10 Passage to port (B3)
6 Neutral passage 11 Passage (high-pressure passage)
Actuation of Valve with Attachment Lever in "Neu- The pressure of pilot oil in the cap, which is propor-
tral" Position tional to the travel of the tilt lever, causes the main
When the attachment lever is in the "neutral" position, spool 1 to move to the right against the force of the
the proportional solenoids a3 and b3 are inactive. spring 4 and closes the flow in the neutral passage 6.
The electromagnetic proportional pressure control As a result, pressure in the high-pressure passage 7
valve releases oil in the caps 3 and 5 into the drain rises. Oil in the passage pushes open the check valve
passage 13 through the passage 12 so that there is no 2 to flow to the actuator of the attachments through the
pressure in the caps. passage 11 to 9 and port A3.
This maintains the main spool 1 in the position shown Oil from the port B3 flows to the tank from the low-
in the illustration above by the spring 4 with the pas- pressure passage 8.
sages connecting to the ports A3 and B3 closed. The shut-off valves 14 and 15 are for releasing oil from
Extra flow of oil divided by the priority valve of the inlet the ports A3 and B3 into the low-pressure passage 8,
valve assembly flows into the tank through the neutral respectively, in case of an emergency.
passage. Action of Valve When Solenoid b3 is Activated
Actuation of Valve When Solenoid a3 is Activated Activation of the solenoid b3 results in the action of the
When the solenoid a3 is activated, pilot oil flows into valve reverse to that when the solenoid a3 is activated.
the cap 5 through the passage 12. To be more specific, the valve spool 1 moves to the
Pilot oil pressure in the cap is proportional to the left, and oil flows to the attachment actuator from the
movement of the lift lever. port B3 and returns to the tank from the port A3.
For actuation of the electromagnetic proportional pres-
sure control valve, refer to Flow of Oil When Solenoid
is Activated.
11-72
HYDRAULIC SYSTEM
7.1.6 Actuation of Electromagnetic Proportional Pressure Control Valve

This is a solenoid-aided reducing valve that regulates
(reduces) pilot oil pressure from the reducing valve in 2 3
1
the inlet section to necessary level proportional to the
travels of load-handling lever before it is delivered to
the chamber 2.
Pressure in the chamber 2 is proportional to travel of 8
load-handling lever; the larger the travel, the higher
the pressure, hence the stroke of the main spool 3
increases. Inversely, if the travel is small, the pressure 10
is low and the stroke of the main spool 3 is short.
The valve consists of a solenoid part A and a pressure A B
regulator part B.
When neutral
The solenoid part A is activated by electric current fed 8
5 (a)
from the controller to protrude the solenoid rod 4 and 7
push the spool 5. The force of the solenoid rod 4 to 11
4
push the spool 5, that is thrust F, is proportional to the
travel of the lever, this is variance of electric current.
Flow of Oil with Cargo-Handling Lever in "Neutral" 6
Position
When the load-handling lever is in the "neutral" posi- (b)
tion, the solenoid is inactive with its rod retracted.
Solenoid rod 4 remains in the retracted position. There 10 (d) (c)
9 (e)
is no pressure of pilot oil from the reducing valve in the
inlet section because the unload valve is open and When solenoid is excited Restricted area
extra flow is released from the main relief valve into p
8 Pp
the drain passage. Also, the pilot oil passage 7 is 7 5
closed by the spool 5.
4
Oil in the chamber 2 flows to the drain passage
through the passages 8, (d), (c), (e), 9 and 10 in that
order. F P
Flow of Oil When Solenoid is Activated

When the solenoid is activated, the solenoid rod 4 pro- p
trudes and the spool 5 moves to the right.
(d) (c) (a) (b)
Pilot oil (Pp) entering the oil passage 7 flows through 213894
the oil passages (a), (c) and (d) into the chamber 2 via
the passage 8. 1 Cap
At the same time, oil flows into the chamber 11 from 2 Chamber
the oil passage (b) and pushes the spool 5 to the left 3 Main spool
against the thrust of the solenoid rod 4. 4 Solenoid rod
When the pressure of oil supplied into the chamber 2 5 Spool
overcomes the thrust of the solenoid rod 4, the spool 6 Wave washer
5 is allowed to push the rod to the left, closing the 7 Oil passage receiving pilot oil from reducing valve
restricted area to the oil passages (a) and (c). The 8 Passage of pilot oil for actuating valve spool
pressure of supplied oil lowers as a result. Inversely, 9 Return oil passage
when the pressure of oil supplied into the chamber 2 10 Drain passage
is overcome by the thrust of the solenoid rod 4, the 11 Chamber
spool 5 moves to the right, opening the restricted
area to the oil passages (a) and (c). The pressure of (a), (b), (c), (d), (e): Small oil passages
supplied oil rises as a result. p: Reduced oil pressure
In this way, the pressure in the chamber 2 is main- P: Force to push spool to left with p
tained proportional to the thrust of the solenoid rod 4. F: Thrust of solenoid rod
11-73
HYDRAULIC SYSTEM
7.2 Disassembly and Reassembly

7.2.1 Control valve assembly
7 6 4 3
2
5 1
Tightening torque:
16.7 ± 1.7 N·m
(1.7 ± 0.17 kgf·m)
[12 ± 1.3 lbf·ft]
B2 B3
Tightening torque:
P 44.1 ± 4.4 N·m
A2 (4.5 ± 0.45 kgf·m)
[33 ± 3.2 lbf·ft]
T3
A1
213897
1 Tie rod 5 Inlet valve assembly

2 End cover assembly 6 Emergency shut-off valve
3 Attachment Valve Assembly 7 Pilot relief valve
4 Tilt valve assembly
Suggestions for Disassembly (7) The main spool and valve body are in a set. If
either the main spool or valve body is damaged,
(1) Individual component valves can be removed sep-
the whole valve section must be replaced in an
arately, with tie rods tightened, that is as assem-
assembly.
bled.
To avoid damage, when removing the lift lock
(2) When disassembly becomes necessary, find the valve, etc. from the main spool, do not hold the
cause of the fault and determine the scope of dis- spool directly with a vise or pliers.
assembly. Depending on the nature of the fault,
(8) Wash removed parts with clean solvent. Dry them
not only replacement of affected valve but exten-
using compressed air and place them on clean
sive overhaul and flushing may be necessary.
sheets of paper or cloth.
(3) Prior to disassembly, clean the outside of the con-
(9) For disassembly of individual valves, refer to
trol valve assembly.
"Reassembly of Valves."
(4) During disassembly, check for dirt and other for-
eign matters in oil passages and stuck valves and
poppets.
(5) In normal disassembling operation, do not loosen
the lock nuts for adjusting screws of pilot relief
valve, PF relief valve (steering relief valve) and
flow adjuster kit.
If the lock nuts are loosened and the adjusting
screws are moved, readjustment after reassembly
is required.
(6) Use care not to damage the machined surfaces.
11-74
HYDRAULIC SYSTEM

Check valves for burrs, scratches, dents and other
surface defects.
(1) Check that all moving and sliding contact parts
move smoothly.
(2) Check for clogged orifices.
(3) Replace springs if they are broken or bent. Mea-
sure the free length of springs.

(1) Select a dust-free, clean place for reassembly.
(2) Perform reassembly, not section by section but by
first assembling spool-less housing and tightening
tie rod nuts to specified torque before proceeding
to install spools and poppets.
(3) Tighten nuts on tie rod bolts to specified torque.
Tighten tie bolts evenly. Tightening them unevenly
or to inadequate torque can distort the valve body,
resulting in unsmooth movement of the spool.
(4) Reassemble each valve with proper knowledge of
it. Pay particular attention to the orientation of
valve.
(5) Reassemble valves with great care. Take care so
that parts do not hit each other or metal tools.
Metal-to-metal collision damages the surfaces.
(6) Apply hydraulic oil to parts before they are
installed. Do not install them dry. Application of
grease facilitates the fitting of O-rings. Grease
used must be clean. Do not use grease in excess
of necessary minimum quantity.
(7) Replace all O-rings. When fitting O-rings in the
seal grooves, apply grease to them and seat them
firmly in the grooves using care not to damage.
(8) After the spools are installed, check that they
move smoothly.
(9) For reassembly of individual valves, refer to
"Reassembly of Valves."
11-75
HYDRAULIC SYSTEM
7.2.2 Reassembly of Valves

Valves in Inlet Valve Assembly (Part 1)
34.3 ± 3.4 N·m Tightening torque:
20.6 ± 2.1 N·m
(3.5 ± 0.3 kgf·m) 63.7 ± 6.4 N·m (6.5 ± 0.6 kgf·m) [47 ± 4.7 lbf·ft]
(2.1 ± 0.2 kgf·m)
[15.1 ± 1.6 lbf·ft] [25.3 ± 2.5 lbf·ft]
4 30 29 25 26 28 27 19
6 7 9 31 3 2
5 Tightening torque:
34.3 ± 3.4 N·m
(3.5 ± 0.3 kgf·m)
18
[25.3 ± 2.5 lbf·ft]
17
13
12
Tightening torque:
48 ± 4.8 N·m
(4.9 ± 0.5 kgf·m)
Tightening torque: 10 [35 ± 3.0 lbf·ft]
15.7 ± 1.6 N·m
(1.6 ± 0.16 kgf·m)
[11.5 ± 1.0 lbf·ft]
8 23 24
22 21 1 16 15 14 11
20
Tightening torque:
15.7 ± 1.6 N·m (1.6 ± 0.16 kgf·m) [11.5 ± 1.0 lbf·ft]
213898
Reassembly of lift control valve (1 to 19)

1 Lift spool 8 Spring seat 15 Spring [free length: 31.2mm
2 Spring 9 O-ring (1.228 in.)]
3 Valve 10 Bolt 16 Spring seat
4 Spool head 11 Cap 17 Bolt
5 Cap 12 Adjuster kit 18 Elbow
6 Spring seat 13 O-ring 19 O-ring
7 Spring [free length: 31.2mm 14 Spring seat
(1.228 in.)]
Reassembly of lift control valve (20 to 24)
20 Wave washer 22 O-ring 24 Bolt
21 Valve set 23 Solenoid valve assembly
Reassembly of load check valve and associated pilot oil line (25 to 31)
25 Poppet 28 Plug 31 Shut-off valve
26 Spring 29 O-ring
27 O-ring 30 Plug
11-76
HYDRAULIC SYSTEM

Lift control valve
(1) Fit the spring 2 in the lift spool 1 and install the
valve 3 in the direction shown in the illustration.
Then, install the spool head finger-tight and
tighten it up to the specified torque using a socket
wrench.
(2) With hydraulic oil applied, insert the lift spool 1
into place in the housing with care. Check that the
spool slides smoothly.
(3) Install the spring seat 6, spring 7, spring seat 8
and O-ring 9 in the cap 5.
(4) Install the cap 5 completed as above to the hous-
ing. Tighten the bolt 10 to the specified torque.
(5) Install the adjuster kit 12, O-ring 13, spring seat
14, spring 15 and spring seat 16 in the opposite
cap 11. If the adjuster kit was disassembled, it is
necessary to adjust the descending speed while
measuring after reassembly.
(6) Install the cap 11 completed as above to the hous-
ing. Tighten the bolt 17 to the specified torque.
(7) Fit the O-ring 19 on the elbow 18. Install the elbow
to the housing, and after it is positioned to face in
appropriate direction, tighten nut to the specified
torque.
Electromagnetic proportional pressure control

valve
(1) Install the valve set 21 with the wave washer 20
and O-ring 22. The valve set 21 is a set of parts,
and the component parts cannot be replaced indi-
vidually.
(2) Install the solenoid valve assembly 23 and tighten
the bolt 24 to the specified torque.
11-77
HYDRAULIC SYSTEM
Load Check Valve and Associated Pilot Oil Line Tightening torque: Unit: N·m (kgf·m) [lbf·ft]
34.3 ± 3.4 3 2 1
(1) Install parts in the sequence shown.
(3.5 ± 0.35)
4
(2) Screw in the plugs 28 and 30 to the specified [25.3 ± 2.5]
torque. Tightening torque:
9.8 ± 1.0 5
(3) For the shut-off valve assembly 31 that was taken (1.0 ± 0.1 )
[25.3 ± 2.5]
to pieces and removed, reassemble it in the fol-
lowing sequence. (See the illustration at the right.) Tightening torque: 6
Tightening first:
(a) Fit the O-ring 2 on the valve 1. Apply grease 16.2 ± 1.6 (1.7 ± 0.17) [12.2 ± 1.2]
around the O-ring and insert the valve in the Further tightening:
16.2 ± 1.6 (1.7 ± 0.17) [12.2 ± 1.2]
plug 4. 213899
(b) Fit the O-ring on the plug 4. Screw the plug into
the housing to the specified torque. 1 Valve 4 Plug
(c) Tighten the set screw 6 to a torque of 16.2 ± 2 O-ring 5 Lock nut
1.6 N·m (1.7 ± 0.17 kgf·m) [12.2 ± 1.2 lbf·ft]. 3 O-ring 6 Set screw
(d) Tighten the lock nut 5 to the specified torque.

(e) Further tighten the set screw 6 to a torque of
16.2 ±1.6 N·m (1.7 ± 0.17 kgf·m) [12.2 ± 1.2
lbf·ft].
11-78
HYDRAULIC SYSTEM
Tightening torque: 9 6 5 3 4 2 1 13 10
15.7 ± 1.6 N·m
(1.6 ± 0.16 kgf·m)
[11.5 ± 1.0 lbf·ft]
7 12
Tightening torque:
63.7 ± 6.4 N·m
Tightening torque after set 8 11 (6.5 ± 0.65 kgf·m)
pressure adjustment:
[47 ± 4.7 lbf·ft]
9.8 ± 1.0 N·m
(1.0 ± 0.1 kgf·m) 20
[7.2 ± 0.7 lbf·ft] Tightening torque:
Tightening torque: 14 19 34.1 ± 3.4 N·m
63.7 ± 6.4 N·m (3.5 ± 0.35 kgf·m)
(6.5 ± 0.65 kgf·m) 15 [25.3 ± 2.5 lbf·ft]
30
[47 ± 4.7 lbf·ft]
34.1 ± 3.4 N·m
Tightening torque: 28 (3.5 ± 0.35 kgf·m)
15.7 ± 1.6 N·m [25.3 ± 2.5 lbf·ft]
(1.6 ± 0.16 kgf·m)
[11.5 ± 1.0 lbf·ft]
26
Tightening torque after set 27 25 24 23 22 21 18 16 17

pressure adjustment:
9.8 ± 1.0 N·m
(1.0 ± 0.1 kgf·m)
[7.2 ± 0.7 lbf·ft] 213900
Reassembly of pilot relief valve (1 to 9)

1 Spring 4 O-ring 7 Screw
2 Valve 5 O-ring 8 Lock nut
3 Sleeve 6 Plate 9 Bolt
Reassembly of priority valve (10 to 15)
10 Spool set 13 Spring 15 O-ring
11 Plug (free length: 43.5 mm (1.7 in.))
12 O-ring 14 Plug
Reassembly of resistance valve (16 to 20)
16 Spool 18 Slug 20 O-ring
17 Spring 19 Plug
(free length: 36mm (1.4 in.))
Reassembly of PF Relief Valve (Steering Relief Valve) (21 to 30)
21 Spring 25 Plate 29 Plug (with O-ring 20)
22 Poppet 26 Screw 30 O-ring
23 Relief valve 27 Lock nut
24 O-ring 28 Bolt
11-79
HYDRAULIC SYSTEM
Pilot relief valve PF Relief Valve (Steering Relief Valve)

(1) Insert the spring 1 and valve 2 into place in the (1) Insert the spring 21 and poppet 22 into place in
housing. the housing.
(2) Fit the O-rings 4 and 5 on the sleeve 3. Apply (2) Fit the O-ring 24 on the relief valve 23. Apply
grease around the O-rings and push the sleeve 3 grease around the O-ring and insert the relief
into place in the housing. valve 23 into place in the housing.
(3) If the screw 7 for set pressure adjustment was dis- (3) If the screw 26 for set pressure adjustment was
assembled, drive the screw in the plate 6 and disassembled, drive the screw in the plate 25 and
install the lock nut 8 hand-tight. install the lock nut 27 hand-tight.
(4) Install the plate completed as above using the bolt (4) Install the plate completed as above using the bolt
9. Tighten the bolt to the specified torque. 28. Tighten the bolt to the specified torque.
(5) Install the valve to the truck and connect neces- (5) Fit the O-ring 30 on the plug 29, and screw in the
sary pipes. Finally, adjust set pressure for the plug to the specified torque.
relief valve. Refer to "Inspection and Adjustment."
If the screw for set pressure adjustment is intact (6) Install the valve to the truck and connect neces-
and set pressure for the relief valve remains sary pipes. Finally, adjust set pressure for the
unchanged, check for relief pressure only. relief valve.
Refer to "Inspection and Adjustment."
If the screw for set pressure adjustment is intact
Priority valve and set pressure for the relief valve remains
(1) Complete the spool set 10. Apply grease around unchanged, check for relief pressure only.
the completed spool set 10 and insert it carefully
into place in the housing.
(2) Insert the spring 13 into place. Fit the O-ring 15 on
the plug 14, and screw in the plug to the specified
torque.
(3) Fit the O-ring 12 on the plug 11, and screw in the
plug to the specified torque.
Resistance Valve
(1) Install the spring 17 and slug 18 in the spool 16.
Apply hydraulic oil to the spool and insert it care-
fully into place in the housing.
(2) Fit the O-ring 20 on the plug 19, and screw in the
plug to the specified torque.
11-80
HYDRAULIC SYSTEM

Tightening torque:
Tightening torque: 19.6 ± 2.0 N·m Tightening torque:
63.7 ± 6.4 N·m (2.0 ± 0.20 kgf·m) 63.7 ± 6.4 N·m (6.5 ± 0.65 kgf·m) [47 ± 4.7 lbf·ft]
(6.5 ± 0.65 kgf·m) [14.5 ± 1.48 lbf·ft] Tightening torque: 34.3 ± 3.4 N·m
[47 ± 4.7 lbf·ft] 3 19 20 18 17 (3.5 ± 0.35 kgf·m) [25.3 ± 2.5 lbf·ft]
4 2 1 5 6
7
26
Tightening torque: 24 Tightening torque:
36.3 ± 3.6 N·m 10 25 34.3 ± 3.4 N·m
(3.7 ± 0.4 kgf·m) (3.5 ± 0.35 kgf·m)
[26.7± 2.9 lbf·ft] [25.3 ± 2.5 lbf·ft]
11 21 8 9 23 22 13 16 1514 12
Tightening torque: Tightening torque: 34.3 ± 3.4 N·m
8.1 ± 0.9 N·m (3.5 ± 0.35 kgf·m) [25.3 ± 2.5 lbf·ft]
(0.8 ± 0.1 kgf·m)
[5.97 ± 0.6 lbf·ft] 28
147 ± 14 N·m
(15 ± 14.7 kgf·m)
[108 ± 10 lbf·ft]
213901
Reassembly of main relief valve (1 to 6)

1 Valve 3 Plug 6 O-ring
2 Spring 4 O-ring
(free length: 22 mm (0.9 in.)) 5 Plug
Parts of unload solenoid valve (7 to 11)
7 Poppet 9 O-ring 11 O-ring
8 Filter 10 Solenoid valve
Reassembly of reducing valve (12 to 18)
12 Spool 14 Spring 16 O-ring
13 Slug (free length: 23 mm (0.9 in.)) 17 Plug
15 Plug 18 O-ring
Installation of oil passage plugs (19 to 28)
19 Plug 23 O-ring 27 Connector assembly
20 O-ring 24 Plug 28 O-ring
21 Plug 25 O-ring
22 Plug 26 Plug
Main relief valve Reassembly of Reducing Valve

(1) Install the spring 2 in the valve 1. Apply hydraulic (1) Install the slug 13 and spring 14 in the spool 12.
oil to the valve and insert it into place in the hous- Apply hydraulic oil to the spool and insert it into
ing. place in the housing.
(2) Fit the O-ring 4 on the plug 3, and screw in the (2) Fit the O-ring 15 on the plug 15, and screw in the
plug to the specified torque. plug to the specified torque.
(3) Fit the O-ring 6 on the plug 5, and screw in the (3) Fit the O-ring 18 on the plug 17, and screw in the
plug to the specified torque. plug to the specified torque.
Reassembly of Unload Solenoid Valve Installation of Oil Passage Plugs
(1) Fit the filter 8 and O-ring 9 to the poppet 7, and Most plugs are fitted with O-rings.
insert the poppet into place in the housing.
Apply a thin coat of grease to O-rings, and screw in the
(2) Fit the O-ring 11 on the solenoid valve 10, and plugs to appropriate specified torque.
screw in the valve to the specified torque.
11-81
HYDRAULIC SYSTEM
Tilt valve
19

20.6 ± 2.1 N·m 20.6 ± 2.1 N·m
(2.1 ± 0.21 kgf·m) 3 2 1 18 12
10 11 (2.1 ± 0.21 kgf·m)
[15.2 ± 1.55 lbf·ft] 15 20 21 6
[15.2 ± 1.55 lbf·ft]
7 A2 B2 13
17
9
14
4
16 Solenoid a2 Solenoid b2
Tightening torque: Proportional electromagnetic
15.7 ± 1.6 N·m (1.6 ± 0.16 kgf·m) [11.5 ± 1.2 lbf·ft] 5
Reassembly of tilt control valve

1 Poppet 9 O-ring 16 Bolt
2 Spring 10 Spring seat 17 Cap
3 O-ring 11 Cap screw 18 O-ring
4 O-ring 12 Spring 19 Bolt
5 Spool (free length: 31.2 mm (1.2 in.)) 20 Plug
6 Valve 13 Spring seat 21 O-ring
7 Spring 14 Cap
8 Spool head 15 O-ring
Tilt Control Valve

(1) Install the parts 1 through 4 before combining the (5) Tighten the spool head 8 and cap screw 11 to the
housing sections. specified torque using hexagon wrenches.
(2) Install the valve 6 in the spool 5 in the direction (6) Fit the O-ring 15 on the cap 14. Install the cap to
shown in the illustration above, then install the the housing using the bolt 16.
spring 7 in position. Fit the O-ring 9 on the spool Tighten the bolt to the specified torque.
head 8, and install the spool head finger-tight.
(7) Fit the O-ring 18 on the cap 17. Install the cap to
(3) With hydraulic oil applied, insert the lift spool 5 the housing using the bolt 19. Tighten the bolt to
into place in the housing with care. Check that the the specified torque.
spool slides smoothly.
(8) Fit O-ring 26 on the plug 25. Screw the plug in the
(4) Install the spring seat 10 in position. Fit the spring housing to the specified torque.
12 and spring seat 13 to the cap screw 11, and
(9) Install the other plug.
drive the cap screw 11 in the spool with fingers.
11-82
HYDRAULIC SYSTEM
Attachment valve
Tightening torque: 15.7 ± 1.6 N·m 12
(1.6 ± 0.16 kgf·m) [11.5 ± 1.2 lbf·ft]
Tightening torque:
34.3 ± 3.4 N·m
(3.5 ± 0.35 kgf·m)
[25.3 ± 2.5 lbf·ft] Tightening torque: 20.6 ± 2.1 N·m
Tightening torque: 9.8 ± 1.0 N·m (2.1 ± 0.21 kgf·m) [15.2 ± 1.55 lbf·ft]
3 1
(1.0 ± 0.1 kgf·m) [12.2 ± 1.2 lbf·ft] 2
Tightening torque: 18 19 17 16 5 11 6 7 9 8
21
Tightening first: 16.2 ± 1.6 N·m
(1.7 ± 0.17 kgf·m) [12.2 ± 1.2 lbf·ft]
Further tightening: 16.2 ± 1.6 N·m 20 A3 B3
(1.7 ± 0.17 kgf·m) [12.2 ± 1.2 lbf·ft]
10
14
13
Tightening torque:
15.7 ± 1.6 N·m
(1.6 ± 0.16 kgf·m)
15
[11.5 ± 1.2 lbf·ft]
4
Solenoid a3
Solenoid b3
Reassembly of attachment control valve

1 Poppet 8 Spring seat 16 Valve
2 Spring 9 Cap screw 17 O-ring
3 O-ring 10 Cap 18 Plug
4 O-ring 11 O-ring 19 O-ring
5 Spool 12 Bolt 20 Set screw
6 Spring seat 13 Cap 21 Lock nut
7 Spring 14 O-ring
(free length: 31.2 mm (1.2 in.)) 15 Bolt
Attachment Control Valve

(1) Install the parts 1 through 4 before combining the (5) Fit the O-ring 14 on the cap 13, and install the cap
housing sections. to the housing using the bolt 15.
Tighten the bolt to the specified torque.
(2) With hydraulic oil applied, insert the lift spool 5
into place in the housing with care. (6) Fit the O-ring 17 on the valve 16, and insert the
Check that the spool slides smoothly. valve into place in the plug 18. Fit the O-ring 19 on
the plug, and screw the plug in the housing to the
(3) Install the spring seat 6, spring 7 and spring seat 8
specified torque
in position, and tighten the cap screw 9 to the
specified torque. (7) Tighten the set screw 20 to a torque of 16.2 ± 1.6
N·m (1.7 ± 0.17 kgf·m) [12.2 ± 1.2lbf·ft].
(4) Fit the O-ring 11 on the cap 10. Install the cap to
the housing using the bolt 12. (8) Tighten the lock nut to the specified torque.
Tighten the bolt to the specified torque.
(9) Further tighten the set screw 20 to a torque of
16.2 ± 1.6 N·m (1.7 ± 0.17 kgf·m) [12.2 ± 1.2lbf·ft].
(10)Install the other shut-off valve.
11-83

Chapter 11 Hydraulic System

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Chapter 11 Hydraulic System

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Chapter 11 HYDRAULIC SYSTEM

1. Structure and Functions....................................................................... 11-1

Chapter 11 HYDRAULIC SYSTEM

1. Structure and Functions

Down safety valve Return filter Suction

Flow regulator valve

1.4 Hydraulic Tank

The two air holes on the side of cap 2 serve as a vent

1.5 Hydraulic Pump (Gear Pump)

Pump installed on engine

1 Front cover 8 Gasket (shaped like 3)

1.6 Control Valve

1.6.1 MC Control Valve

1 Lift control lever P : Inflow port of pump pressure oil

Most of the hydraulic control valves move mechani-

1.6.2 FC Control Valve

1 FC control box P : Inflow port of pump pressure oil

This hydraulic control is a solenoid valve. As the valve

From control valve To control valve

1.8 Down Safety Valve

When in normal condition

When piping is broken 213805

1.9 Lift Cylinder

Cushion mechanism when piston descends

1 2 (B) Passage (a) Entrapped oil (A)

The above illustration shows an example of the piston

Action during piston ascent (initial stage)

1 2 (B) Passage (a)

Cylinder of internal drain type

Check valve 213811

1.9.1 Second lift cylinder for duplex mast

To first Inflow and

Action during piston descent

Action during piston ascent

Fig. 6 6 Cushion spool

1.9.2 First cylinder for duplex mast and triplex mast

Space(B) Cushion oil is filled in this area.

Air chamber(A) Oil passage Piston

1.10 Tilt Cylinder

The tilt cylinder is a double-acting type. To adjust right

Seal 7 helps extends the greasing intervals. Installa-

2. Disassembly and Reassembly

Notice when removing :

2.1.2 Disassembly and Reassembly

Note: 1. The hydraulic pump is to be overhauled by Suggestions for Disassembly

Inspection and Repair

2.2 Lift Cylinder

Suggestions for Removal

(3) Disconnecting high-pressure hoses

(4) Removing set bolts

(b) Tie wood blocks under the inner mast and

(5) Removing lift cylinders

Duplex and triplex mast removal

Suggestions for Removal

(b) Position the mast upright. Raise the inner mast

(2) Removing first lift cylinder

(3) Removing second lift cylinders

(c) Place wood blocks under the inner mast (for

(d) Hitch a sling to second lift cylinder 5 behind the

2.2.2 Disassembly and Reassembly

(b) Check for surface flaws such as grooving,

Second lift cylinder for duplex mast

Apply THREEBOND #1901 when screwing in. 213834