8B100 11

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

1.1 Outline ................................................................................................................... 11-1
1.2 Hydraulic Circuit Diagram (for models with MC control valve) .............................. 11-2
1.3 Hydraulic Circuit Diagram (for models 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 (models with FC control valve only) ................................... 11-8
1.8 Down Safety Valve ................................................................................................ 11-8
1.9 Lift Cylinder............................................................................................................ 11-9
1.10 Tilt Cylinder.......................................................................................................... 11-12
2. Disassembly and Reassembly........................................................... 11-13
2.1 Hydraulic Pump ................................................................................................... 11-13
2.2 Lift Cylinder.......................................................................................................... 11-16
2.3 Tilt Cylinder.......................................................................................................... 11-29
2.4 Flow Regulator Valve .......................................................................................... 11-32
2.5 Piping................................................................................................................... 11-33
2.6 Suction Strainer and Return Filter ....................................................................... 11-34
3. Inspection and Adjustment ................................................................ 11-35
3.1 Hydraulic Tank..................................................................................................... 11-35
3.2 Control Valve ....................................................................................................... 11-37
3.3 Natural Descent Test........................................................................................... 11-39
3.4 Natural Forward Tilt Test ..................................................................................... 11-39
4. Troubleshooting.................................................................................. 11-40
5. Service Data......................................................................................... 11-43
6. MC Control Valve ................................................................................ 11-47
6.1 Outline ................................................................................................................. 11-47
6.2 Names of Parts.................................................................................................... 11-48
6.3 Control Valve Operation ...................................................................................... 11-50
6.4 Pressure Control (Relief) Valve Operation .......................................................... 11-59
6.5 Flow Regulating Valve (FRV) .............................................................................. 11-62
6.6 Cautions for use .................................................................................................. 11-63
7. FC Control Valve ................................................................................. 11-65 11
7.1 Structure and Functions ...................................................................................... 11-65
7.2 Procedures and Suggestions for Removal and Installation................................. 11-85
7.3 Disassembly and Reassembly ............................................................................ 11-86
HYDRAULIC SYSTEM
Chapter 11 HYDRAULIC SYSTEM
1. Structure and Functions

1.1 Outline
7
8
4 16
10
9 14
3
5 15
13
2 1
11
12
217099
Main components and their Functions

1 Pump suction strainer: 6 Tilt cylinder
100-mesh metal strainer 7 Piping to tilt cylinder
2 Hydraulic pump (gear pump): 8 Steering valve
A regular gear pump is directly coupled to the trans- 9 Oil feed line to steering valve P port
mission PTO. 10 Return oil line from steering valve
Refer to "Hydraulic Pump." 11 Oil line to steering cylinder
3 Hydraulic pump delivery hose 12 Steering cylinder
4 Hydraulic control valve: 13 Return line
MC valve is installed as the standard valve. FC 14 Return line:
valve is available as an option. The MC valve has a This is a cartridge type filter. Replace the return filter
built-in flow regulator valve, but the FC valve does at every oil change.
not have a flow regulator valve. Both MC and FC 15 Level gauge
models have almost the same piping arrangement. 16 Oil filter cap
For more details, refer to "2.5 Piping."
5 Oil line to lift cylinder:
Flow regulator valve is installed at the end of this
line for all lift truck models with FC valve.
11-1
FHS A4
11-2
B4
MC
Brake valve
P port: MAX 11 MPa
A3 (MAX 112.2 kgf/cm2)
Steering valve
HYDRAULIC SYSTEM
[MAX 1595.6 psi]

B3 A port: MAX 9 MPa (4.0 - 5.5 t)
L (MAX 91.8 kgf/cm2)
[MAX 1305.5 psi]
R
LS Parking brake
A2 T P
Steering cylinder emergency relief port
Tilt cylinder B2
)( )(
A P
Drum brake unit T
Flow regulator valve

T1
100 L/min T2 P
(6102.4 cu.in./min) (40 to 45 t) Front axle assembly
115 L/min
(7017.7 cu.in./min) (50 to 55 t)
)(
)(
Gear pump
A1
Drum brake unit
PTO
Gear pump for brake
Down safety valve
Parking brake Set pressure

4.9 MPa
M Release pressure: 4.9 MPa(50.0 kgf/cm2) [710.8 psi]
1.2 Hydraulic Circuit Diagram (for models with MC control valve)
(50.0 kgf/cm2 )
Pressure resistance: 7 MPa(71.4 kgf/cm2) [1015.4 psi] [710.8 psi]
TM ASSY
PF T P
)(
LS
)(
Suction strainer
(R) (L) T2 Return filter 100 mesh
P T 34μm Max: 120 L/min(7.32 cu.in./min)
Lift cylinder
Max: 125 L/min(7.63 cu.in./min)
Main relief pressure LS port relief pressure

19.1+0.5
0 MPa at 120 L/min 11.8 MPa at 1.5 L/min
(194.8+5.1
0 kgf/cm2 at 120 L/min) (120.3 kgf/cm2 at 1.5 L/min)
+72.5
215348
[2770.5 0 psi at 7322 cu.in./min] [1711.6 psi at 61.0 cu.in.]
Brake valve
P port: MAX 11 MPa
(MAX 112.2 kgf/cm2)
[MAX 1595.6 psi]
FHS A port: MAX 9 MPa (4.0 t)
(MAX 91.8 kgf/cm2)
Hydraulic control valve [MAX 1305.5 psi] Parking brake
FC MAX 9 MPa (4.5 to 5.5 t) Emergency relief port
T1 (MAX 91.8 kgf/cm2)
[MAX 1305.5 psi]
Bleed off valve
SLB Steering valve
B4 L A P
A4 SA4 SB4 R
Drum brake unit T
(attachment)
T P
Tilt cylinder T1
Front axle T2 P
assembly
Steering cylinder
A3 SA3 SB3
(attachment)
Gear pump
Drum brake unit
PTO
Flow regulator valve

Gear pump for brake
B2 PB
100 L/min
(6102.4 cu.in./min) (40 to 45 t) A2 SA2 SB2 Set pressure 4.9 MPa
(tilt)
Parking brake
115 L/min M 2 (50.0 kgf/cm2)
(7017.7 cu.in./min) (50 to 55 t) Release pressure: 4.9 MPa (50.0 kgf/cm ) [710.8 psi]
TM ASSY 2 [710.8 psi]
Pressure resistance: 7 MPa (71.4 kgf/cm ) [1015.4 psi]
Down safety Gear ratio 1:1
valve T P
Load check
valve
A1
(lift) Suction strainer
SA1 SB1
100 mesh
Return filter
34µm
1.3 Hydraulic Circuit Diagram (for models with FC control valve)
(R) (L)
Lift cylinder
Reducing SLA
valve
Flow divider Main release
valve
PF relief valve
PF
Main relief pressure

P T2 19.8+0.5
0 MPa at 120 L/min
2
(201.9+5.1
0 kgf/cm at 120 L/min)
[2872.0+72.5
0 psi at 7.32 cu.in./min]
Pilot relief valve PF port relief valve
19.1+0.5
0 MPa at 1.2 L/min 12.8+0.5
0 MPa at 120 L/min
2 2
(194.8 +5.1
0 kgf/cm at 1.2 L/min)
(130.5 +5.1
0 kgf/cm at 120 L/min)
[185.7+72.5 psi at 7.32 cu.in./min)]
215349
[2770.5+72.5
0 psi at 0.73 cu.in./min] 0
11-3
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
1.4 Hydraulic Tank
2
3
4
(c) 5
1
6
(b)
(a)
10 7
9
12 11
215258
Main components
1 Hydraulic tank 6 Tank cover 7 Suction strainer
2 Cap Parts welded to tank cover 8 Return filter
3 Ring 9 Hydraulic Pump
(a) Suction pipe
4 Element 10 Pump suction line
5 Level gauge (b) Pipe for return line 11 Pump delivery line
(c) Pipe for level gauge (oil filler opening) 12 Drain plug
The hydraulic tank is located in the middle of the right Return filter 8 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 filter cartridge of 15 μm with a
structure. built-in relief valve. When the filter is clogged, the relief
valve activates to divert unfiltered oil into the tank.
Three pipes (a) (b) and (c) are welded together to the Periodic replacement is necessary. Also, oil filter
tank cover 5. Suction strainer 6, return filter 7, level replacement is recommended one month after the pur-
gauge 4, and cap 2 are installed on the top of each of chase of the lift truck or after conducting a major over-
the three pipes. haul that includes replacing parts.
Thus, parts inside the tank can be removed as an

assembly if the tank cover is removed. The pump suction strainer 7 is a 100 mesh metal
Filter replacement or strainer cleaning can easily be strainer. Clean the suction strainer at every oil replace-
carried out once removing tank cover 5. ment.
Level gauge 5 is inserted in the level gauge pipe (c) On the models with a wet-type single disc clutch, the
where the opening is blocked by cap 2 equipped with return oil line is attached on the tank side.
an element.
The drain plug is installed at the bottom of the tank.
The two air holes on the side of cap 2 are vent holes
for air inside tank to enter and exist according to oil
level change. Element 4 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 transmission

1 7 5 8 2
215309
Main components
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
The standard lift truck model is equipped with a single-
gear pump like the one shown in the illustration above.
Installation of pump
The pump is directly coupled to PTO in the transmis-
sion.
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
1
2
P 7
4
B2
3
5
T2
A2
PF A1
215341
Main components
1 Lift control lever P : Inflow port of pump pressure oil
2 Tilt control lever PF : Pressure oil supply port to steering system
3 Inlet section (with built-in flow priority valve)
4 Combination Section T1 : Return port to tank
(with built-in lift / tilt valve and flow divider valve) T2 : Return port from steering system
5 End section (with built-in unload valve [9])
A1 : Port to lift cylinder
6 Unloader valve (with solenoid)
7 Lift lock valve (with solenoid) A2 : Port to tilt cylinder rod
B2 : Port to tilt cylinder head
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 allows the supply or return flow of pressure oil
between 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
B2
7 8 9 10 B3
4
A1
11
11 A2
P A3
PF
6 T1
5
215342
Main components
1 FC control box P : Inflow port of pump pressure oil
2 Input unit PF : Pressure oil supply port 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
A3 : Port to attachment
11 Unload valve (with solenoid)
B3 : Port to attachment
This hydraulic control is a mechanically-controlled

valve. A controller and an electromagnetic proportional
pressure control valve are used to enable the valve
spools to move in response to the control input from
the FC control box operated by an operator.
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 (models 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 the load on the lift cylinder, thereby keeping the forks
control valve and the lift cylinder. When the forks are lowering speed constant, irrespective of the load
lowered, the valve regulates the oil flow according to weight.
1.8 Down Safety Valve
Broken area
When in normal condition When piping is broken
216407
The down safety valve is located at the bottom of the which prevents sudden fall of the forks in case hoses
right lift cylinder. This valve serves as a safety valve are damaged.
11-8
HYDRAULIC SYSTEM
1.9 Lift Cylinder

1.9.1 Simplex Mast Cylinder and Triplex Mast Second Cylinder
Inlet and 7 6 5 *4 *3 *2 1
outlet port
Plug (shipping
and storage)
Bottom end Top end
Head of shell
Passage C Chamber A Space B

8 9
217264
Main components
1 Retainer 4 Spacer 7 Wiper ring
2 Shell assembly 5 Check valve 8 Cushion sleeve
3 Rod 6 piston seal 9 Piston
Note: Dimensions of the parts marked * vary accord-

ing to specifications (lift height).
The lift cylinder raises and lowers the mast.

Oil passage at bottom of
When the operator performs mast raising control, the
piston becomes narrower 8
pressure oil from port A1 of the lift valve acts on the as piston moves down.
bottom surface of the piston 9, causing the piston 9
and the rod 3 to move up together. As the rod 3 moves
up, the air and oil in space B between the shell assem-
bly 2 and the rod 3 flow through passage C and into
chamber A. When the pressure in chamber A has
reached 0.007 to 0.14 MPa (0.07 to 1.4 kgf/cm2) [1.0
to 20.3 psi], the check valve 5 starts to open, releasing
the trapped oil and air into pressure oil.
217265
The cushion sleeve 8 prevents the bottom of the piston
9 from ramming onto the cylinder head at the last
stage of the piston down-stroke through the process
described below.
During a down-stroke of the piston, the oil at the bot-
tom of the piston is forced to flow through the gap
between the inner wall of the sleeve 8 and the cylinder
head. The gap becomes smaller as the piston moves
down, further limiting the flow of oil. This prevents
large impact that would otherwise occur by hard con-
tact between the piston and cylinder with a down-
stroke cushioning feature.
11-9
HYDRAULIC SYSTEM
1.9.2 Duplex Mast Second Cylinder

GP40N, GP45N, DP40NM, DP45NM
To lift valve 7 6 5 *4 *3 *2 1 To first cylinder
From lift valve
From first cylinder
Bottom end Top end
Plug 9 8 Plug
(shipped and storage) (shipped and storage)
GP50CN, GP50N, GP55N, DP50CNM, DP50NM, DP55NM

7 6 5 *4 *3 *2 1
9 8
217266
Main components
1 Retainer 4 Spacer 7 Wear ring
2 Shell assembly 5 Piston 8 Bleed screw
3 Rod 6 Piston seal 9 Sleeve

The duplex mast second cylinder has a function of In the mast lowering phase, the second cylinder oper-
raising and lowering the duplex inner mast. This cylin- ates before the first cylinder.
der starts to operate after the first cylinder has com-
During a down-stroke of the piston, the oil at the bot-
pleted its operations.
tom of the piston is forced to flow through the gap
When the operator performs mast raising control, the between the inner wall of the sleeve 9 and the cylinder
pressure oil from port A1 of the lift valve enters the head. The gap becomes smaller as the piston moves
inlet port of the cylinder. The oil then flows through the down, further limiting the flow of oil. This prevents
inside of the rod 3, comes out of the outlet port, and large impact that would otherwise occur by hard con-
goes to the first cylinder. Since the bore of the first cyl- tact between the piston and cylinder head, providing
inder is larger than that of the second cylinder, the pis- the cylinder with a down-stroke cushioning feature.
ton in the first cylinder receives oil pressure with a
See the illustration (illustration No.217265) on page
larger area than the piston in the second cylinder. This
11-9
makes the first cylinder operate at a lower oil pressure
than the second cylinder. In other words, the first cylin- The bleed screw 8 is provided to purge air from the
der operates first, with the second cylinder starting to system
operate only after the first cylinder has completed its
operations.
Pressure oil acts on the bottom of the piston 5, push-
ing up the piston and rod 3 together.
The cushion sleeve 9 prevents the bottom of the piston
5 from ramming onto the cylinder head at the last
stage of the piston down-stroke through the process
described below.
11-10
HYDRAULIC SYSTEM
1.9.3 First Cylinder of Duplex Mast and Triplex Mast
Inlet and 7 6 5 4 *3 *2 1
outlet port
(2 pieces)
Bottom end Top end
8 Passage C Chamber A Space B
217267
Main components
1 Retainer 4 Stand tube 7 Wear ring
2 Shell assembly 5 Piston 8 Check valve
3 Rod 6 Piston seal

This cylinder, installed in the center of the mast, is the

first to operator in the rising phase of the mast.
When the operator performs mast raising control, the
pressure oil from port A1 of the bottom surface of the
piston 5, causing the piston 5 and the rod 3 to move up
together. As the rod 3 moves up, the air and oil in
space B between the shell assembly 2 and the rod 3
flow through passage C and into chamber A. when the
pressure in chamber A has reached 0.5 MPa (5.3 kgf/
cm2) [75 psi], the check valve 8 starts to open, releas-
ing the trapped oil and air into pressure oil.
The stand tube 4 prevents the piston 5 from ramming
onto the retainer 1 at the last stage of the piston up-
stroke through the process described below.
The stand tube 4 ensures that a certain volume of oil
remains in the top end of the piston. The piston cannot
reach the top end of its travel unless the oil were
drained completely. The stand tube prevents the oil
from being drained, providing the cylinder with an up-
stroke cushioning feature.
11-11
HYDRAULIC SYSTEM
1.10 Tilt Cylinder
5 A 3 11 12 1 2 4 8 6
OD
ID
d
14 9 10 7 13
215300
Main components
1 Cylinder 6 Bushing 11 Back-up ring
2 Piston rod assembly 7 Piston seal 12 O-ring
3 Rod guide 8 Guide ring 13 Snap ring
4 Spacer 9 Wiper ring 14 Clamp bolt
5 Socket 10 Nut ring
The tilt cylinder is a double-acting type. To adjust the

right and left imbalances of the tilt angles when the
mast is attached, loosen the clamp bolt and then turn
the piston rod with a spanner fitted to area A of the pis-
ton rod.
Seal 7 helps to extend the grease supply intervals of
the grease nipples. Installation of this seal has
extended the grease supply interval to 500 hundred
hours.
Cylinder Dimensions
Cylinder length and stroke vary depending on forward
and backward tilt angle.
Unit: mm (in.)
Cylinder Cylinder
Rod diam- inside outside
Truck model
eter (d) diameter diameter
(ID) (OD)
4.0, 4.5
40.0 (1.58) 80.0 (3.15) 92.0 (3.62)
ton class
5.0C, 5.0, 5.5
40.0 (1.58) 90.0 (3.55) 105.0 (4.13)
ton class
11-12
HYDRAULIC SYSTEM
2. Disassembly and Reassembly

2.1 Hydraulic Pump
2.1.1 Removal and Installation
2
215308
Removal sequence
1 Pump delivery hose 3 Pump mounting bolt
2 Pump suction hose 4 Pump
Notes during removal:

(1) The installed positions and sizes of the suction
hose and delivery hose differ by model.
(2) Wrap the pump and its surroundings with cloth in
case of a oil spill.
(3) Be careful not to allow any foreign materials to
enter the pump and hose from disconnected sec-
tions.
Installation
For installation, follow the removal sequence in
reverse by following the instructions below.
Apply grease to the spline of the pump shaft before
installation.
Insert the gasket between the pump and PTO in the
transmission.
Conduct operation test after the pump has been
installed. Refer to "2.1.2 Disassembly and Reassem-
bly" and "Operation test."
11-13
HYDRAULIC SYSTEM
2.1.2 Disassembly and Reassembly

Disassembly
5
7 1
3*
*
*
*
*
* *
3*
2 4
Parts marked * are components of the seal kit.

8 Parts without * are unavailable parts.
215855
Disassembly 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. As a general rule, only the gear pump manu- Suggestions for Disassembly
facturer should disassemble, repair, and re-
assemble. As a general rule, only the gear (1) Do not forcibly tap the front cover 2 and rear cover
pump manufacturer should disassemble, re- 1 with a hammer as they are made of an alumi-
pair, and reassemble. Only in the case of an num alloy and can be easily damaged. Use either
emergency or unavoidable situation, the dis- a wooden hammer or a plastic hammer.
assembly and reassembly of the gear pump (2) When disassembling, do not forcibly remove the
is allowed. In such case, follow the instruc- body, gear, bushing, etc. by tapping with a ham-
tions described here. A field overhaul will re- mer.
lease the pump manufacturer from any
(3) Place the disassembled parts in an orderly
warranty claims if you decide to perform the
sequence. Note the relative position of the gear
repairs yourself.
and bushing side plate for correct reassembly.
2. Do not remove shaft seal 2 and bushing 1 un-
less a defect is found.
11-14
HYDRAULIC SYSTEM
Inspection and Repair

(1) Drive and driven gears
(a) Check the gear teeth surface and tip for wear
or damage.
(b) Check the side faces of the gears for wear or
damage.
(c) Check the shafts for wear or damage.
(2) Check the covers, body and bushings for wear or
damage.
213819
Reassembly
For reassembly, follow the disassembly sequence in
(1) Replace all the seal kit parts marked (*) with new
ones.
(2) Completely remove oil or grease from the mating
surfaces of the covers 1, 2 and the 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 shaft seal lip.
(5) Be careful not to cause damage to the lip of shaft
seal or the spline edges of drive gear 5.
(6) Tighten the bolts evenly and progressively.
(7) The pump shaft should be lightly turned with a
pipe wrench when assembled.
Operation test
Conduct operation test after the pump has been
installed.
(1) Ensure that there is sufficient oil in the hydraulic
tank.
(2) Attach a pressure gauge to the pump delivery
hose. Refer to "Main Relief Valve of 3.2 Control
Valve."
(3) Start the engine, and gradually turn the adjusting
screw of the main relief valve from 0 to 19.1 Mpa
(0 to 185 kgf/cm2) [0 to 2625 psi], and check the
temperature rise of the pump body by touching it
by hand. Compare the temperature rise of the
pump body against the oil temperature rise. If the
temperature of the pump body is abnormally
higher, disassemble and reassemble the pump for
a second inspection.
(4) Set the relief valve to the specified pressure.
(5) Measure lifting speed of the forks under no load
weight. If the measured speed meets the speci-
fied value, the pump oil discharge amount is nor-
mal.
(6) Check that the forks move up and down smoothly
under load.
11-15
HYDRAULIC SYSTEM
2.2 Lift Cylinder

Simplex Mast
5 4
2
1
215343
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) To right-hand lift cylinder To left-hand lift cylinder
Remove the hose guard. Start the engine, raise
the lift bracket to the highest position, and then
stop the engine. Disconnect the return hoses at
the connectors on the right and left cylinders.
Note: Do not touch the lift lever while removing the re-
turn hose.
To tank
215867
(2) Lowering lift bracket
Slowly lower the lift bracket with the lift lever.
11-16
HYDRAULIC SYSTEM
(3) Disconnecting high-pressure hoses

Disconnect the high-pressure hoses at the joints Right cylinder Left cylinder
indicated by the arrows. Have a container avail-
able to catch remaining oil inside the hoses.
215983
(4) Removing set bolts

(a) Remove the set bolt from the top of each lift
cylinder. Lift the inner mast to separate the cyl-
inder rod ends. To lift the inner mast, tie a wire
rope to the inner mast cross member with a
cloth wrapped around for protection, and take
one complete turn around the member.
Note: Shims are inserted at the rod end of the lift cyl-
inders to eliminate difference in stroke between
the right and left cylinders. Before removing the
set bolts, record how many shims are inserted 215849
in each cylinder.
(b) Place wood blocks under the inner mast to

support it, and untie the wire rope. Use wood
blocks strong enough to support the mast.
213824
(5) Removing lift cylinders

Tie a wire rope to the lift cylinder from the back of
the mast, and slowly remove the lift cylinder. Tie a
wire rope to the lift cylinder before removing the
cylinder clamps.
215850
11-17
HYDRAULIC SYSTEM
Installation
(1) Extend and retract the lift cylinders several times
under a no load condition to bleed air out of the
cylinders. Make sure that the cylinders move
smoothly.
(2) After confirmation, check the level of the hydraulic
oil with an oil level gauge. For the hydraulic oil
level check, refer to "Inspection and Adjustment of
Hydraulic Tank."
(3) Make sure that the lift height is correct.
(4) After the lift cylinders or piston rods are replaced,
be sure to check for stroke imbalance between
the two cylinders. For check and adjustment, refer
to "Chapter 12 MAST AND FORKS."
11-18
HYDRAULIC SYSTEM
Duplex and Triplex Mast Removal

Triplex mast is used as an example
4
2
3
1
215878
Removal sequence
1 Nut 4 Chain wheel support assembly
2 Lift bracket assembly (with forks) 5 Second lift cylinder
3 First lift cylinder

(1) Removing lift bracket assembly
(a) Lower the lift bracket assembly onto wood
blocks. Tilt the mast forward, and lower the
inner mast to the bottom to provide slack in
chains. Remove nuts 1 from the anchor bolts of
the first lift chains.
1
215879
(b) Tilt the mast vertical, and lift the inner mast
until the upper rollers of the lift bracket 2
become free. Then, slowly move the truck in
reverse to separate it from the lift bracket.
213828
11-19
HYDRAULIC SYSTEM
(2) Removing first lift cylinder

(a) Tie a wire rope to the first lift cylinder 3, and
suspend it with a hoist. Secure the wire rope
firmly so that it will not slip.
(b) Remove the mounting bolts from the lift cylin-
der 3, and slowly raise the first lift cylinder 3 to
remove.
215851
(3) Removing second lift cylinders

(a) Disconnect hoses from the second lift cylinders
5.
(b) Remove the set bolts from the top of the sec-
ond lift cylinders 5. Tie a wire rope either to the
middle or inner mast, and suspend the mast by
approximately 550 mm (21.65 in.) off the
ground.
215852
(c) Place wood blocks under the inner mast (for

duplex mast) or the middle mast (for triplex
mast). Make sure that both wood blocks are
the same height.
213824
11-20
HYDRAULIC SYSTEM
(d) Tie a wire rope to the second lift cylinder from

behind the mast, and suspend the cylinder with
a hoist. Remove the clamp bolts from the cylin-
der to separate the second lift cylinder 5 from
the mast. Then slowly lift the cylinder.
When raising the lift cylinder, do not lift the lift
cylinder straight up because the lift cylinder will
strike against the mast cross member. Tilt the
lift cylinder to clear the cross member while
removing. Keep hands away from any part of
the lift cylinder or mast to prevent a risk of
injury.
215853
Installation
(1) Install chain wheel support in parallel with the
chain anchor bolt holes on the first lift cylinder.
Improper installation as shown in the illustration
on the right could cause a twist in the chain.
(2) Adjusting chain tensions.
For adjusting chain tension, refer to "14.2 Chain
Good Bad
Tension Inspection and Adjustment" of "Chapter
12 MAST AND FORKS."
213832
(3) Extend and retract the lift cylinders several times
under the no-load condition to bleed air out of the
cylinders. Make sure that the cylinders move
smoothly.
(4) After confirmation, check the level of the hydraulic
oil with an oil level gauge.
11-21
HYDRAULIC SYSTEM

Simplex mast cylinder and triplex mast second cylinder
Disassembly
Unit: N·m (kgf·m) [lbf·ft]

Truck model
4.0, 4.5 ton class 5.0C, 5.0, 5.5 ton class
Item
Simplex Triplex Simplex Triplex
mast mast mast mast
Cylinder bolt size M68 × 1.5 M73 × 1.5
250 to 280 300 to 350
Tightening torque for cylinder (25.5 to 28.6) (30.6 to 35.7)
[184.5 to 206.6] [221.4 to 258.3]
Apply grease when assembling.

2 1 3 5 4 16 6 13 15 14 12 11 7 8 10 9
Apply DELO 5249 when screwing in.

215984
Disassembly sequence: First, disassemble the second cylinder into the following three main parts (I through III),
and then disassemble the main parts into components.
I. Head sub-assembly (including parts 1 through 5)
1 Bushing guide 3 Rod seal 5 Rod guide ring
2 Wiper ring 4 O-ring
II. Piston rod sub-assembly (Including parts 6 through 15)
6 Piston rod assembly 10 Bushing 14 Snap ring
7 Piston seal 11 Circlip 15 Spacer
8 Piston guide ring 12 Washer
9 Snap ring 13 Check valve
III. Cylinder tube assembly (including parts 16)
16 Cylinder tube assembly
11-22
HYDRAULIC SYSTEM
Suggestions for Disassembly

Removing Piston
Be careful not to damage the piston seals and cylinder
bore wall when pulling out the piston from the cylinder.
Inspections after Disassembly

(1) Cylinder tube
(a) Check the bore wall for excessive wear,
scratching, or rusting.
(b) Check the welds for cracks or dents.
(2) Piston rod
(a) Check the rod for deflection.
(b) Check the rod surface for scratches, rust or
wear.
(3) Rings and packings
(a) Check the lips for damage, wear, or deteriora-
tion.
Suggestions for Reassembly
(1) Clean the disassembled parts with a cleaning sol-
vent. Blow off foreign materials with compressed
air. Be careful not to blow compressed air at rub-
ber parts.
(2) Apply a clean coat of hydraulic oil to every sliding
surface and sealing surface.
(3) Apply DELO 5249 to the threads of the cylinder
head, and tighten the cylinder head to the speci-
fied torque using a hook wrench.
11-23
HYDRAULIC SYSTEM
Second lift cylinder for duplex mast

Disassembly
(GP40N1, GP45N1, DP40NM1, DP45NM1)
Tightening torque
270 to 298 N·m
(27.5 to 30.4 kgf·m)
[199.3 to 219.9 lbf·ft]
18 10 11 7 8 9 13 12 14 17 6 5 4 3 1 2 15
16
217268
I. Holder sub-assembly (including parts 1 through 5)
1 Retainer 3 Rod seal 5 O-ring
2 Wiper ring 4 Back-up ring
II. Piston rod sub-assembly (including parts 6 through 16)
6 Rod 10 Circlip 14 Spacer
7 Wear ring 11 Sleeve 15 Plug, O-ring
8 piston seal 12 Pull-in wire 16 Air bleed screw, Washer seal
9 Nylon ring 13 Piston
III. Cylinder tube assembly (including parts 17 and 18)
17 Cylinder tube assembly 18 Plug, O-ring
11-24
HYDRAULIC SYSTEM
(GP50CN1, GP50N1, GP55N1, DP50CNM1, DP50NM1, DP55NM1)
Tightening torque
298 to 325 N·m
(30.4 to 33.1 kgf·m)
[219.9 to 240.0 lbf·ft]
20 12 13 9 10 11 15 14 16 19 8 6 75 7 4 1 3 2 17
18
217271
I. Holder sub-assembly (including parts 1 through 5)
1 Retainer 4 Back-up ring 7 O-ring
3 Rod seal 6 Sleeve
8 Rod 12 Circlip 16 Spacer
9 Wear ring 13 Sleeve 17 Plug, O-ring
10 Piston seal 14 Pull-in wire 18 Air bleed screw, Washer seal
11 Nylon ring 15 Piston
19 Cylinder tube assembly 20 Plug, O-ring
11-25
HYDRAULIC SYSTEM

Removing Piston
bore wall when pulling out the piston from the cylinder.
(1) Cylinder tube
(2) Piston rod
(b) Check the rod surface for scratching, rusting or
wear.
(3) Rings, packings and threaded portions
tion.
(b) Check the threaded portions for damage.
ber parts.
(3) Tighten bolts, nuts or screws of important parts to
the specified torque shown in the illustration
above.
11-26
HYDRAULIC SYSTEM
First cylinder for duplex mast and triplex mast

Disassembly
Tightening torque
515 to 542 N·m
(52.5 to 55.3 kgf·m)
[380.1 to 400.0 lbf·ft]
10 11 13 7 8 9 12 14 15 16 6 5 4 1 3 2
217272
Disassembly sequence: First, disassemble the first cylinder into the following three main parts (I through III), and
then disassemble the main parts into components.
I. Cylinder head sub-assembly (including parts 1 through 6)
1 Retainer 3 Rod seal 5 O-ring
2 Wiper ring 4 Back-up ring
6 Rod 10 Circlip 14 Pull-in wire
7 Wear ring 11 Washer 15 Piston
8 Piston seal 12 Check valve
9 Nylon ring 13 O-ring
16 Cylinder tube assembly
11-27
HYDRAULIC SYSTEM

Removing piston rod
bore wall when pulling out the piston rod from the cyl-
inder.
(1) Cylinder tube
(2) Piston rod
(b) Check the rod surface for scratching, rusting or
wear.
(3) Rings, packings and threaded portions
tion.
(b) Check the threaded portions for damage.
ber parts.
(3) Pay attention to the orientation when installing the
snap ring 12 of the check valve.
(4) Before installing the cylinder head, fill the space
between the tube and rod.
(5) Tighten the cylinder head 1 to the specified torque
shown in the illustration above.
11-28
HYDRAULIC SYSTEM
2.3 Tilt Cylinder

4
3 2
215260
Removal sequence
1 Tilt cylinder pin 3 Tilt cylinder pin
2 Hoses (2 pcs. per cylinder) 4 Tilt cylinder
Preparation Installation
(1) Lower the forks to the ground level, and tilt the For installation, follow the removal sequence in
mast fully forward. reverse by following the instructions below.
(2) Install eyebolts into the bolt holes on the cross (1) After installing tilt cylinders, check balance of the
member of the outer mast, and attach a lifting mast tilt angle. Adjust if necessary. For mast tilt
sling to the eyebolts, to support the mast with a angle adjustment, refer to "6.7 Adjustment of Mast
hoist. Tilt Angle" of "Chapter 12 MAST AND FORKS."

(1) Retracting piston rod
After removing tilt cylinder pin 1, start the engine.
Fully retract the piston rod, and stop the engine.
(2) Disconnecting hoses
Disconnect hoses 2 from the cylinder side of the
connectors. Before disconnecting the hoses,
place a container under the connectors to catch
oil. Attach caps to the cylinder nipples to protect
the threads from damage and to prevent oil from
flowing out through them during cylinder removal.
(3) Removing tilt cylinder
Remove tilt cylinder pin 3, and remove the cylin-
der.
11-29
HYDRAULIC SYSTEM

Disassembly
2 4 5 7 6 13 14 12 11 8 16
1 3 9 10 15
Tightening torque Tightening torque

270 ± 27 N·m 400 ± 40 N·m
(27.5 ± 2.8 kgf·m) (40.8 ± 4.1 kgf·m)
[199.3 ± 19.9 lbf·ft] [295.2 ± 29.5 lbf·ft]
217273
Disassembly sequence: First, disassemble the tilt cylinder into the following four main parts (I through IV), and then
disassemble the main parts into components.
I. Tilt socket sub-assembly (including parts 1 and 2)
1 Bolt, Spring washer 2 Tilt socket
II. Guide bushing sub-assembly (including parts 3 through 7)
3 Guide bushing 5 Nut ring 7 Back-up ring
III. Piston rod sub-assembly (including parts 8 through 12)
8 Snap ring 10 Guide ring 12 Spacer
9 Piston 11 Piston seal 13 Rod
IV. Cylinder sub-assembly (including parts 13 and 15)
14 Cylinder assembly 15 Bushing 16 Grease nipple
Note: 1. Before disassembly, record the distance from

the holder edge to the socket edge with the
rod in a fully retracted position. This will be
helpful during reassembly.
2. Do not disassemble the tilt socket bearing
and the cylinder tube bushing unless a defect
is found during inspection.
3. Do not disassemble the piston and snap ring
unless a defect is found during inspection.
11-30
HYDRAULIC SYSTEM

Removing Bushing
(1) Wrap the cylinder with a rag, and clamp it in a
vise. Using a wrench, remove the guide bushing
from the cylinder.
(2) When removing the guide bushing from the piston
rod, be careful not to rub the dust seal, packing
and O-ring against the threads of the piston rod.

(1) Cylinder tube
(a) Check the bore wall for wear, scratch marks, or
rusting. 213838
(b) Check the welds for cracks, damage, or dents.

(2) Piston rod
(a) Check the rod surface for rusting, damage,
scratch marks and wear. The rod must be
replaced if significant damage is found on its
threads.
(3) Rings and packings
(a) Check the lips of the packings, dust seals, and
piston seals for damage or distortion.
(b) Check each ring for deterioration.

(1) Before reassembly, thoroughly clean each part
and make sure that they are free from foreign
materials.
(2) Reassemble the cylinder in the reverse order of
the disassembly while applying hydraulic oil to
such parts as O-rings, piston seals, dust seals,
packings and the bore wall of the cylinder tube.
Also, pay attention to the orientation when install-
ing. 213839
(3) When clamping the cylinder tube in the vise, be

careful not to distort the tube.
(4) Assembly procedure for piston seal.
(a) Before fitting the piston seal, squeeze it by
hand five or six times to soften it.
(b) Secure the piston in a vise, while taking care
not to damage any part of the piston, and then
apply a thin coat of hydraulic oil to the piston
seal. Fit half of the seal into the piston groove,
and then press the other half into the groove.
213840
(5) Tighten the nuts and bolts to the specified torque.
For tightening torque values, refer to the previous
page.
11-31
HYDRAULIC SYSTEM
2.4 Flow Regulator Valve

(Models with FC control valve only)

Disassembly
3
5
Me
as
ure
4
215234
Disassembly sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring, Shims
Note: Before disassembly, measure and record the

distance from the end face of valve body 5 to
the top of the plug 2 (plug protrusion). During
assembly, be sure to set the protrusion to the
the same dimension.

(1) Check the spring for settling.
(2) Check the sliding and contact surfaces of the
valve and the piston for damage.
(3) Check the sliding surfaces of the piston and the
valve body for damage.
Note: Replace the flow regulator valve as an assem-
bly if any of the components are found to be de-
fective.
Reassembly
reverse.
11-32
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 model

Steering valve Tilt line
Left side MC control valve

Pump discharge oil line
Tilt cylinder (high pressure)
Return line (low pressure)
Lift line (high pressure)

Return filter
Suction strainer
Steering cylinder
Steering hydraulic line
Hydraulic Pump
Pump suction line (low pressure)
Located on the right side of truck body
2. Piping of FC control valve for gasoline model

Steering valve Tilt line
FC control valve
Left side
Tilt cylinder Pump discharge oil line (high pressure)
Return line (low pressure)
Lift line (high pressure)

Return filter
Suction strainer
Steering cylinder
Steering hydraulic line

Hydraulic Pump Pump suction line (low pressure)
Located on the
right side of truck body
215261
11-33
HYDRAULIC SYSTEM
2.6 Suction Strainer and Return Filter
Cap
Level gauge
Tank cover
215262

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 the mounting bolts from the tank
cover.
(4) Lift the tank cover. The tank cover can be
removed as shown from the position in the illustra-
tion above.
(5) Remove the suction strainer and the return filter
from the cover.
Inspection
(1) Clean the suction strainer.
(2) The return filter is a scheduled replacement part.
Replace the return filter at every oil change. Also
replace the return filter one month after the use of
a new lift truck or one month after every overhaul.
Installation
(1) Tighten the strainer and filter to the specified

torque.
(2) When installing a pump suction hose, be careful
not to allow the suction hose to suck outside air.
11-34
HYDRAULIC SYSTEM
3. Inspection and Adjustment

3.1 Hydraulic Tank
(1) Daily check of oil
Check hydraulic oil level when truck is on level
ground, check for cleanliness and white turbidity
(mixing of air or water).
(2) Proper oil level for daily check
Check the level of the hydraulic oil with the mast
fully lowered.
Unit: m (in.)
Simplex mast L level
3.7 to 5.5
Duplex mast L level
(146 to 217)
Triplex mast L level Maximum Triplex: 6.0 to 7.0 m (236 to 276 in.)
H
level Simplex: 3.7 to 5.5 m (146 to 217 in.)
6.0 to 7.0
Triplex mast H level Duplex: 3.7 to 5.5 m (146 to 217 in.)
(236 to 276) N Triplex: 3.7 to 5.5 m (146 to 217 in.)
proper level
The oil level must be higher than the L level and Minimum L
Maximum level for
lower than the H level when the mast is fully low- level simplex mast
ered, regardless of mast type or any combination
213844
of the mast and attachment.
Lift height m (in.)
Refill 7.0 (276) Refill

capacities 6.5 (256) capacities
G(D)P 6.0 (236) 6.0 (236) G(D)P
40, 45 5.5 (217) 5.5 (217) 50C, 50, 55
5.0 (197) 5.0 (197)
67 liter 81 liter
H 4.7 (185) H
(4.1 cu.in.) (4.9 cu.in.)
39 mm 4.5 (177)
(1.5 in.) 4.3 (169)
L 62 liter 4.0 (157) 4.0 (157) 74.5 liter L
(3.8 cu.in.) 3.7 (146) 3.7 (146) 3.7 (146) (4.5 cu.in.)
3.5 (138)
3.3 (130) 3.3 (130)
130 mm 3.0 (118) 3.0 (118)
(5.1 in.) 2.9 (114)
Simplex Duplex Triplex
mast mast mast
216034
11-35
HYDRAULIC SYSTEM
(3) Filling hydraulic tank with oil

For recommended oil, refer to "4.2 Fuel and Lubri-
cant Specifications" of "Chapter 13 SERVICE
DATA."
(a) Lower the mast to ground level, and fill the
hydraulic tank with oil.
(b) Move the mast up and down several times, and
then lower the mast.
(c) Check the level of the hydraulic oil with a level
gauge. Replenish hydraulic oil to the pre-
scribed level if it is insufficient.
The oil level in the tank must not exceed the H level
when the mast is lowered, regardless of mast type or
any combination of the mast and attachment.
(4) Inspection of suction strainer

Check the suction strainer for damage or clog-
ging. Clean the suction strainer if it is dirty.
(5) Inspection of return filter
Check the return filter for damage. As the return
filter is a scheduled replacement part, replace the
filter as scheduled. Refer to "2.6.1 Removal and
Installation."
11-36
HYDRAULIC SYSTEM
3.2 Control Valve

(1) External oil leakage
(a) Check for oil leaks from the joint between adja-
cent valve housings sealed by O-ring.
(b) Check threaded connections for oil leaks.
(2) Internal oil leakage
To check oil leaks of the control valve, connect the
3° to 4°
control valve to each cylinder for inspection. Follow the
inspection procedures (a) through (c) below.
Note that the oil leaks amount to be measured is the
total amount of leaks from lift spool, tilt spool, tilt lock
valve, and check valves. (The oil temperature should
be set at approximately 50°C [122°F] during measure-
ment.) 1m (39.4 in.) approx.
(a) Pick up a load equal to the rated capacity, and

lift it approximately 1 m (3.28 in.) high. Tilt the 213845
mast about 3° to 4° forward, and stop the

engine.
(b) Quickly disconnect the oil return hose, and
catch the oil coming out of this hose.
Unit: cc (cu.in.)
Amount of oil discharged 25 or less
for 15 minutes (1.5 or less)
(c) If the lift cylinders or tilt cylinders drift (the mast

tilts forward or the forks lower) excessively
even if the total amount of collected oil for 15
minutes is less than 25 cc (1.5 cu.in.), measure
the internal leakage of each cylinder. (The
measured amount is the benchmark, not the 215993
service limit.)
11-37
HYDRAULIC SYSTEM
(3) Main relief valve

(a) Install a 25 MPa (254.9 kgf/cm2) [3626.3 psi] Main relief valve
pressure gauge to the mounting port of the R 1/8
pump delivery hose (Illustration on the right).
(b) Move the tilt control lever to the backward tilt
position. If the pressure gauge reading is at
+0.5 +5.1 +72.5
19.1 0 MPa (194.8 0 kgf/cm2) [2770.5 0 psi]
when the tilt cylinders reach the end of their
stroke, the main relief valve setting is correct.
Pressure
(c) If the relief pressure is incorrect, loosen the gauge
lock nut of the relief valve, and then adjust by
rotating the adjusting screw while observing
the pressure gauge reading. Pump delivery hose
(d) While holding the adjusting screw, tighten the
lock nut to secure the adjusting screw.
(e) After securing the adjusting screw, check the
215263
main relief valve set pressure again.
Unit: MPa (kgf/cm2) [psi]

+0.5
19.1 0
Main relief valve set +72.5
pressure (194.8 0 )
+5.1
[2770.5 0 ]
Remove the R 1/8 plug from the metal end fittings of

the pump delivery hose and attach a pressure gauge
to it.
(4) Adjustment of steering system relief valve

Steering system relief valve
(a) Install a 25 MPa [254.9 kgf/cm2] (3626.32 psi)
pressure gauge to the mounting port of the Pressure gauge
pump delivery hose (illustration on the right).
R 1/8
(b) Place the control levers to the neutral position.
(c) Start the engine and run it at medium speed.
Turn the steering wheel to the extreme right or
extreme left to relieve oil in the steering sys-
tem. The relief pressure must be within the
range in the table below.
(d) If the relief pressure is outside the range,
remove the cap and turn the adjusting screw
for adjustment.
(e) After adjustment, tighten the lock nut. Check Pump delivery hose
the relief pressure again.
Unit: MPa (kgf/cm2) [psi] 215264

+0.5
12.8 0
Steering system relief +72.5
valve set pressure (130.5 0 )
+5.1
[1856.7 0 ]
11-38
HYDRAULIC SYSTEM
3.3 Natural Descent Test

(1) Pick up a load equal to the rated capacity, place
the mast in a vertical position, lift the forks about 1
to 1.5 m (3.3 to 4.9 in.), and stop the engine.
(2) Mark a reference line on the mast, and measure
the amount of descent (retraction of the piston
rods) for 15 minutes. Divide the measured value
by two to obtain the natural descent.
Unit: mm (in.)/15 min

Item All truck model
Natural descent of piston
50 (1.97) or less 215306
(at rated load)
3.4 Natural Forward Tilt Test

(1) Pick up a load equal to the rated capacity, place
the mast to a vertical position, lift the fork about
500 mm (19.7 in.), and stop the engine.
(2) Measure the extension of tilt cylinder piston rod
for 15 minutes.
Unit: mm (in.)/15 min

Natural forward tilt
20 (0.79) or less
(at rated load)
215307
11-39
HYDRAULIC SYSTEM
4. Troubleshooting
Item Condition Possible cause Action

Hydraulic tank oil level is too low. Refill.
Change oil referring to "4.2 Fuel and
Oil viscosity is improper. Lubricant Specifications" in "Chapter
13 SERVICE DATA."
Overload Check working conditions and, if over-
loaded, instruct the operator to stay
within the load limit.
Hydraulic tank heats Line is clogged, which generates a restric- Clean oil line.
excessively. tion to oil line flow and causes local over-
heating.
Relief valve is improperly adjusted. Readjust pressure setting.
Hydraulic Set pressure drops due to spring settling Disassemble or replace, and readjust
tank or damage. pressure.
Gear pump is worn. Replace pump.
Outlet pipe or tube is flattened, or flow is
Repair or replace.
restricted.
Oil level is too low due to normal oil con- Refill oil referring to "4.2 Fuel and
sumption. Lubricant Specifications" of "Chapter
13 SERVICE DATA."
Cylinder movement is Oil leaks due to damaged oil line, seals, Repair or replace
too slow. etc.
Oil viscosity is too high. Change oil referring to "4.2 Fuel and
Lubricant Specifications" of "Chapter
13 SERVICE DATA."
Check pump and piping, repair or
Gear pump does not suck oil.
replace.
Cylinder movement is
Check oil level and condition, add or
too slow. Oil leaks from oil line.
change oil.
Gear pump internally leaks. Replace pump.
Pumping is poor. Refill oil referring to "4.2 Fuel and
13 SERVICE DATA."
Cavitation (1) Check suction pipe for any flat por-
tion or loose connection. Retighten or
Pump is too noisy. replace if necessary.
(2) Check shaft oil seal for air tight-
ness. Replace pump if necessary.
(3) Check pump body for any outside
Gear pump interference. Repair if necessary.
Pressure is too high. Replace pump. (Check to see if relief
valve setting is correct.)
Distortion or damage due to external (1) Check to see if return line is
Pump case, drive gear
strain or stress. blocked or restricted. Replace pump if
or pump port flange is
necessary.
damaged.
(2) Check to see if pipe connections
have been externally strained or
stressed. Replace pump if necessary.
Oil leaks from oil seal. Replace shaft seal.
Oil leaks from drive shaft sliding surface. Replace whole pump assembly.
Oil leaks from pump. Loose pump securing bolts. Retighten. Replace if needed.
Seal performance inside pump is deterio-
Replace gasket.
rated.
11-40
HYDRAULIC SYSTEM

Relief valve set pressure is decreased. Readjust pressure.
Relief valve piston does not move Wash piston and check to see if it
smoothly. moves smoothly; or replace whole
relief valve assembly.
Lift/tilt ascending speed
is too slow or no move- O-ring on relief valve body is damaged. Replace O-ring.
ment.
Spool stroke is not enough due to control Adjust.
lever looseness.
Control Oil temperature rises drastically. Check spool for misalignment; repair
valve or replace.
Lift/tilt natural descent Control valve spool internally leaks. Replace as a block assembly.
or natural forward tilt
Oil leaks from spool ring cap. Replace O-ring, also check spool for
scratches. If scratches are found,
repair or replace block assembly.
Oil leaks.
Loose plug Retighten plug.
O-ring is damaged. Replace O-ring.
Hydraulic oil level is too low. Refill oil referring to "4.2 Fuel and
13 SERVICE DATA."
Mast will not move
Relief valve is out of order, because of:
upwards or tilt forward
or backward. (1) Seized main valve Replace.
(2) Broken valve spring Replace.
Gear pump is defective. Replace.
Relief valve is out of order, because:
(1) Relief valve setting is too low. Readjust pressure.
(2) Plunger or poppet seat is defective. Replace.
Mast will not lift rated
(3) Spring settles. Replace.
load.
(4) O-ring in valve case is damaged Replace.
Gear pump is defective. Replace.
Piston seals are worn or damaged. Replace.
Engine speed is too low. Tune up engine.
Spool stroke is not enough due to loose Adjust.
Lift and tilt Ascending speed is too control lever.
cylinders slow.
Tank strainer is clogged. Clean or replace.
Gear pump cannot pump enough oil. Repair or replace.
Flow regulator valve sleeve is sticking. Repair.
Lift cylinder descent Excessive oil flow resistance due to dirt Clean or repair hydraulic circuit.
speed is too slow. contamination in the flow regulator valve, Replace a defective hose.
flattened hose or local clogging.
Piston rod is distorted. Repair or replace.
Cylinder vibrates when Air is trapped in oil circuit. Bleed air by operating cylinder
actuated. through full stroke.
Hydraulic oil level is too low. Refill.
Control valve spool internally leaks. Replace as a block assembly.
Sliding (inside) surface of cylinder tube Repair or replace.
shows scoring marks.
Lift cylinder natural
Sliding (inside) surface of cylinder tube
descent is excessive. Replace cylinder assembly.
shows severe scoring marks.
Piston seals is damaged or distorted. Replace seal kit.
Oil leaks from piping. Repair or replace.
11-41
HYDRAULIC SYSTEM

Control valve spool internally leaks. Replace as a block assembly.
Foreign particles are lodged in packing. Replace packing.
Tilt cylinder natural for-
ward tilt is excessive. Piston seals are damaged. Replace seals.
Other abnormal distortion, oil leaks from
Repair or replace.
piping.
Lift cylinders descent Local severe scoring or rust on inner sur-
Repair or replace.
or tilt cylinders tilt for- face of cylinder.
Lift and tilt
ward (drift) occurs at a
cylinders Cylinder tube is distorted. Replace.
certain point of stroke.
Oil leaks from bushing. Foreign particles are lodged between Replace.
sealing members such as oil seals and
dust seals.
Oil seals and dust seals have scratches. Replace.
O-ring is damaged. Replace O-ring.
Cylinder is abnormally distorted. Repair or replace.
11-42
HYDRAULIC SYSTEM
5. Service Data

Forward tilt angle (standard model with simplex mast) degree A 6
Backward tilt angle (standard model with simplex mast) degree A 12
Lift cylinder natural descent amount (at rated load) (Retracted mm (in.)/
A 50 (1.97) or less
length of rod, oil temperature at 45 °C[113 ºF]) 15 min
Tilt cylinder natural forward tilt amount (at rated load) mm (in.)/
A 20 (0.79) or less
(Extended length of rod, oil temperature at 45 °C[113 ºF]) 15 min
MPa
Main relief valve setting pressure (kgf/cm2) A 19.1
+0.5
0 (194.8
+72.5
0 ) [2770.5
+5.1
0 ]
[psi]
MPa
Steering system relief valve setting pressure (kgf/cm2) A 12.8
+0.5
0 (130.5
+72.5
0 ) [1856.7
+5.1
0 ]
[psi]
N·m
Tightening torque for return filter (kgf·m) A 49 ± 9.8 (5.00 ± 1.00) [36.14 ± 7.23]
[lbf·ft]
N·m
Tightening torque for suction strainer (kgf·m) A 49 ± 9.8 (5.00 ± 1.00) [36.14 ± 7.23]
[lbf·ft]
A: Standard value
Unit: mm (in.)
5.0C, 5.0, 5.5 ton
Item 4.0, 4.5 ton class
class
Simplex mast Rod outside diameter 1 A 50 (1.97)
cylinder
Cylinder inside diameter 2 A 65 (2.56) 70 (2.76)
and
Triplex mast Cylinder outside diameter 3 A 73 (2.87) 79 (3.11)
second cylinder
Thread size of cylinder head 4 A M68 × 1.5 M73 × 1.5
N·m 250 to 280 300 to 350
Tightening torque for cylinder head 5 (kgf·m) A (25.5 to 28.6) (30.6 to 35.7)
[lbf·ft] [184.5 to 206.6] [221.4 to 258.3]
cc 150
Sealed-in amount of cushion oil 6 A
(cu.in.) (9.15)
5 4 6
1 2 3
217277
A: Standard value
11-43
HYDRAULIC SYSTEM
Unit: mm (in.)
Truck model
Item 5.0C, 5.0, 5.5 ton
4.0, 4.5 ton class
class
First cylinder for Rod outside diameter 1 A 65 (2.56)
duplex mast and
triplex mast
Cylinder outside diameter 3 A 115 (4.53) 127 (5.00)
N·m 515 to 542 569 to 596
Tightening torque for cylinder head 4 (kgf·m) A (52.5 to 55.3) 58.0 to 60.8)
[lbf·ft] [380.1 to 400.0] 419.9 to 439.8]
cc 40 to 45 60 to 65
(cu.in.) (2.44 to 2.75) (3.66 to 3.97)
5 4
1 2 3
217278
A:Standard Value
Unit: mm (in.)
Truck model
Item
4.0, 4.5 ton class
Second Rod outside diameter 1 A 45 (1.77)
lift cylinder
Cylinder inside diameter 2 A 55 (2.17)
for duplex mast
Cylinder outside diameter 3 A 65 (2.56)
N·m 270 to 298
Tightening torque for cylinder head 4 (kgf·m) A (27.5 to 30.4)
[lbf·ft] [199.3 to 219.9]
cc 25 to 30
(cu.in.) (1.52 to 1.83)
5 4
1 2 3
217279
A:Standard Value
11-44
HYDRAULIC SYSTEM
Unit: mm (in.)
Truck model
Item
5.0C, 5.0, 5.5 ton class
Second Rod outside diameter 1 A 51 (2.01)
lift cylinder
Cylinder inside diameter 2 A 60 (2.36)
for duplex mast
Cylinder outside diameter 3 A 70 (2.76)
N·m 298 to 325
Tightening torque for cylinder head 4 (kgf·m) A (30.4 to 33.1)
[lbf·ft] [219.9 to 240.0]
cc 25 to 30
(cu.in.) (1.52 to 1.83)
5 4
1 2 3
217280
A:Standard Value
11-45
HYDRAULIC SYSTEM
Unit: mm (in.)
Truck model
Item
4.0, 4.5 ton class 5.0C, 5.0, 5.5 ton class
Tilt cylinder Rod outside diameter 1 A 40 (1.57)
Cylinder outside diameter 3 A 92 (3.62) 105 (4.13)
Bushing inside diameter on head side 4 A +0.10 +0.0039
41 +0.05 (1.61 +0.0020)
Bushing inside diameter on rod side 5 A 4.0 (1.57)
N·m 400 ± 40
Tightening torque for guide
(kgf·m) A (40.8 ± 4.1)
bushing 6
[lbf·ft] [295.2 ± 29.5]
N·m 270 ± 27
Tightening torque for tilt socket
(kgf·m) A (27.5 ± 2.8)
clamp bolt 7
[lbf·ft] [199.3 ± 19.9]
4 1 2 3 5
217281
A:Standard Value
11-46
HYDRAULIC SYSTEM
6. MC Control Valve
6.1 Outline
This multiple control valve (MSV06A) is a manual con-
trol valve for exclusive use of load control of lift truck. It
is a combined control valve incorporating a steering
flow priority valve, an electromagnetic lift lock valve,
an electromagnetic unload valve and a flow control
valve.
6.1.1 Hydraulic circuit
A hydraulic control system of this valve is of an open
center parallel circuit arrangement (Fig. 1). It has a 2
center bypass function so that an oil pressure source T P 1
becomes free of load when a spool is in the neutral T2
position. When more than one spool is fully stroked, 3
their moving sections act simultaneously, but they do )(
not always act in the same manner. This is because of LS PF
)(
the pressure difference between moving sections, as
they have different loads and areas. In this situation, a
10
moving section under the smallest load pressure acts
first, and the one under the largest load acts last. In a
9
hydraulic control system it is necessary to adjust a
stroke of each valve according to its load pressure so
that all moving sections operate in the same manner. 12 4
A1
For example, a change-over valve under a heavy load
pressure must be fully stroked while change-over
)(
)(
5
valves under smaller load pressure may need only half
13
of the full stroke.
6
1 Priority valve 11
2 Main relief valve
)( )(
3 Steering system relief valve 7

B2
4 Lift valve A2
5 Lift lock valve
6 Solenoid for lift lock valve
7 Tilt valve
8 Attachment valve 8
B3
9 Unloader valve
10 Solenoid for unloader valve A3
11 Center bypass port
12 Solenoid for lift lock valve
13 Flow regulator valve
216063
Fig. 1 An example of a hydraulic circuit
11-47
HYDRAULIC SYSTEM
6.2 Names of Parts
Tilt valve
assembly Attachment valve assembly
End cover section
Inlet section
T2 port B3 port
P port
LS port
B2 port
T port
A3 port
A1 port
PF port
A2 port
216071
Fig. 2 Outline (3-way valve)
A1 port
Flow regulator valve Lock poppet
Return spring
Spool Tank line
216072
Fig. 3-1 Lift circuit
11-48
HYDRAULIC SYSTEM
Lift lock valve releasing screw
Solenoid valve for lift lock

valve control
Tank line
Solenoid valve for
unload valve control
To lift spool
Unload valve control line

Tank line
Unload valve Load check for A1
216073
Fig. 3-2 Electromagnetic control section
P line Priority valve
Main relief valve

PF port
Steering system relief valve
To control orifice
Tank line
To load valve
LS line
216074
Fig. 3-3 Priority valve section
11-49
HYDRAULIC SYSTEM
6.3 Control Valve Operation

This control valve features a multi-directional control
valve that controls actuators by changing oil flows. A
lift valve assembly (lift body) is composed of an inte-
grated combination of steering control circuits and lift
control circuits, and to which the tilt section or attach-
ments are connected.
The lift valve assembly (lift body) consists of a main
relief valve, a steering circuit flow priority valve, a LS
relief valve, an electromagnetic unload valve, an elec-
tromagnetic lift lock valve and a flow control valve
(FRV). This manual multiple connection change-over
valve assembly is available in 2, 3, 4 and 5 ports
including a valve section.
6.3.1 Priority valve
A steering priority valve has a valve mechanism that
feeds hydraulic oil to a power steering unit in prefer- P line
ence to a load handling unit. This priority valve is a Main relief valve
load-sensing priority-type valve that provides a PF port
dynamic signal to the steering unit, incorporating a To
built-in relief valve in the LS circuit (Fig. 4). PF relief valve
steering valve
To control orifice
Tank line To load valve

LS line
216076
Fig. 4 Priority Valve
(1) The hydraulic oil from P port passes through a PF
EF throttle PF throttle
throttle section and a control orifice inside the
spool, and flows out of LS port. When the flow
from P port increases, the flow that passes
P PF
through the control orifice also increases. Then a
pressure difference before and after the control
orifice is increased; as a result, the spool moves
in the direction to close the PF throttle and to open
an EF throttle. In other words, when the flow of LS EF
input oil exceeds certain limits, the EF throttle is Movement of priority valve
opened to drain excess oil, and thereby control-
ling the increases in pressure difference. As a 216078
result, the flow of oil out of LS port remains con- Fig. 5 Hydraulic oil flow in the LS circuit
stant (Fig. 5).
(2) When the pressure in the LS port increases, the

spool moves in the direction to close the EF throt-
tle because the pressure difference before and
after the control orifice decreases. This movement
P PF
increases EF throttle resistance, and the EF throt-
tle resistance causes the pressure in the pump to
increase. As a result, the pressure difference
before and after the control orifice remains con-
stant (Fig. 6). LS EF
Movement of priority valve
216079
Fig. 6 Operation when LS port under load pressure
11-50
HYDRAULIC SYSTEM
(3) When the pressure in the downstream from the

EF throttle valve is increased due to a load han-
dling operation, the pressure in the P port is
increased, causing an increase in the pressure P PF
difference before and after the control orifice.
Then the spool moves in the direction to close the
PF throttle and to open the EF throttle, causing an
increase in the PF throttle resistance. As a result, LS EF
the increase in the pressure difference before and W
Movement of priority valve
after the control orifice is limited so that the flow
from LS port as well as the pressure difference
216080
before and after the control orifice remains con-
Fig. 7 Operation by load handling operation
stant (Fig. 7).
(4) When the PF flow occurs, the pressure in the P

PF throttle
port is decreased, causing an increase in the EF throttle
pressure difference before and after the control P PF
orifice. Then the spool moves in the direction to
close the EF throttle. This causes EF throttle
resistance to increase, and thereby increasing the
pump pressure. As a result, the pressure differ- LS EF
ence before and after the control orifice remains Movement of
constant. Based on these characteristics, the priority valve
pressure difference before and after the throttle of
the steering unit located in the downstream from
PF port is maintained at a constant level, and the 216081
PF flow rate can be changed by adjusting throttle Fig. 8 Operation by steering operation
angle.
11-51
HYDRAULIC SYSTEM
6.3.2 Unload valve

A solenoid valve on the lower part of the lift body is
used for a pilot pressure which is supplied to the
unload valve in a high pressure circuit of load handling
operation. Having energizing and deenergizing, this
value functions as follows:
(1) When an electromagnetic solenoid is deener-

gized: Tank line
The hydraulic oil that passed through the orifice
inside the unload poppet flows into the tank pas-
sage through a solenoid valve. This flow creates a High
pressure difference before and after the orifice, pressure passage
causing the unload poppet to open so that the
high pressure circuit is opened to the tank pas-
sage. As a result, the hydraulic oil from the high
pressure passage cannot flow into load operation
sections, and thereby locking the load handling
operation (Fig. 9). 216082
Fig. 9 De-energized condition
(2) When an electromagnetic solenoid is energized:
When the electromagnetic solenoid is energized, Tank line
the flow of oil from the solenoid valve is blocked
so that the flow in the orifice inside the unload
High pressure
poppet stops. As a result, the unload poppet is
passage
closed, thereby allowing oil to flow from the high
pressure passage to the load handling operation
sections (Fig. 10).
216083
Fig. 10 Energized condition
11-52
HYDRAULIC SYSTEM
6.3.3 Lift Section

(1) Neutral
A1 port
The discharged oil from the pump returns to the Flow regulator valve
tank through the unload passage. As the A1 port Lock poppet
is blocked, the hydraulic oil will not flow into the lift
cylinder (Fig. 11).
Return spring
Spool Tank line 216084

Fig. 11 Lift neutral
(2) Spool in pulled-out position (Lift up)
Flow regulator valve A1 port
The unload passage is closed so that the dis-
charged oil from the pump flows into the high Lock
poppet
pressure passage, and flows out of A1 port by
opening the load check valve and the lock poppet. Return
The return spring returns the spool to the neutral spring
position (Fig. 12).
Spool Unload passage Tank line 216085

Fig. 12 Lift up
(3) Spool in pushed position (Lift down)
Flow regulator valve A1 port
Even when the spool is moved in the pushed posi-
tion, the unload passage is not closed so that the Lock
discharged oil from the pump will return to the poppet
tank passage (Fig. 13-1). Return
spring
Spool
Unload passage Tank line 216086
Fig. 13-1 lift down
(a) When an electromagnetic solenoid is deener-
gized:
The return oil from A1 port is blocked by a lock
poppet so that the lowering operation is locked
(Fig. 13-2).
216087
Fig. 13-2 Deenergized condition
11-53
HYDRAULIC SYSTEM
(b) When an electromagnetic solenoid is ener-

gized:
The return oil from A1 port flows to the sole-
noid valve after passing through a control ori-
fice of lock poppet, and then flows into the
return passage. This flow creates a pressure
fluctuation in the direction in which the lock
poppet is opened. The flow that has passed
through the lock poppet returns to the tank, as
the spool land is opened to the tank passage.
The return spring returns the spool to the neu-
216088
tral position (Fig. 13-3).
Fig. 13-3 Energized condition
11-54
HYDRAULIC SYSTEM
6.3.4 Tilt Section

(1) Neutral
The discharged oil from the pump returns to the tank through the unload passage. Since the A2 and B2 ports
are blocked, the hydraulic oil will not flow into the tilt cylinder (Fig. 14).
Parallel passage Load check

B2 port A2 port
Pilot spool
Unload passage
Tank line 216089
Fig. 14 Tilt section
(2) Spool in pulled-out position (backward tilt)

The unload passage is closed so that the discharged oil from the pump flows into parallel passage, and flows
out of A2 port by opening the load check valve. The return oil from B2 port flows back to the tank through the
tank passage. When the cylinder load pressure exceeds a relief valve set pressure, the relief valve is actuated
so that the hydraulic oil returns to the tank passage. The return spring returns the spool to the neutral position
(Fig. 15).

B2 port A2 port
Spool in pulled-out position
Unload passage
216090
Fig. 15 Spool in pulled-out position
11-55
HYDRAULIC SYSTEM
(3) Spool in pushed position (forward tilt)

The unload passage is closed so that the discharged oil from the pump flows into the parallel passage, and
flows out of B2 port by opening the load check valve. The return flow from the A2 port goes back to the tank by
passing through the passage in the spool of tilt lock valve, which is allowed when hydraulic pressure at the pilot
spool is sufficient to overcome the force of spool spring. When the cylinder load pressure exceeds a relief valve
set pressure, the relief valve is actuated so that the hydraulic oil returns to the tank passage. The return spring
returns the spool to the neutral position (Fig. 16).

B2 port A2 port
Spool in pushed position
Unload passage
216091
Fig. 16 Spool in pushed position
(4) Tilt lock mechanism

A tilt spool comprises a tilt locking mechanism, which is activated if there is no oil flow in the main valve, and
when activated, the tilt cylinders will not move even if the tilt down operation is conducted. If the spool is pushed
(forward tilt operation) when no oil is being supplied by the pump, the oil in the tilt cylinder pressured side is
forced against the A2 port, however, this flow is stopped because the pilot pressure is not supplied to the pilot
spool, keeping the return passage to the tank closed.

B2 port A2 port
Unload passage
216092
Fig. 17 Tilt lock condition
11-56
HYDRAULIC SYSTEM
6.3.5 Attachment Section

(1) Neutral
The discharged oil from the pump returns to the tank through the unload passage. Since both A and B ports are
blocked, the hydraulic oil will not flow into the cylinder (Fig. 18).

B2 port A2 port
Unload passage Tank line 216093

Fig. 18 Attachment section
(2) Spool in pulled-out position

The unload passage is closed so that discharged oil from the pump flows into parallel passage, and flows out of
A port by opening the load check valve. The return oil from B port flows back to the tank through the tank pas-
sage. When the cylinder load pressure exceeds a relief valve set pressure, the relief valve is actuated so that
the hydraulic oil returns to the tank passage. The return spring returns the spool to the neutral position (Fig.
19).
B2 port Parallel passage Load check A2 port
Spool in pulled-out position
Unload passage
216094
Fig. 19 Spool in pulled-out position
11-57
HYDRAULIC SYSTEM
(3) Spool in pushed position

The unload passage is closed so that the discharged oil from the pump flows into the parallel passage and
flows out of B port by opening the load check valve. The return oil from A port flows back to tank through the
tank passage. When the cylinder load pressure exceeds a relief valve set pressure, the relief valve is actuated
so that the hydraulic oil returns to the tank passage. The return spring returns the spool to the neutral position
(Fig. 20).

B2 port A2 port
Unload passage
216095
Fig. 20 Spool pushed-in position
11-58
HYDRAULIC SYSTEM
6.4 Pressure Control (Relief) Valve Operation

Four types of relief valves are available (in MSV06A).
A main relief valve controls maximum pressure in a cir-
cuit, and a LS (load sensing) relief valve that is incor-
porated in the lift body controls maximum pressure in a
SL flow. A port relief valve can be incorporated in
every port after the tilt section in order to control maxi-
mum pressure at the port. This port relief valve also
incorporates the anti-cavitation function when the port
is under negative pressure.
6.4.1 Main Relief Valve

(1) When the relief valve is not activated:
Main poppet
The relief valve remains balanced when circuit Seat
pressure is sufficiently lower than a set pressure. Sleeve
Pilot poppet
The hydraulic oil fills the spring chamber after
passing through the orifice in the main poppet.
The hydraulic oil in the spring chamber acts on
the pilot poppet, but the force of spring pushes the
pilot poppet against the seat so that the flow to the
tank passage is blocked. The flow is also blocked
by the main poppet which is pressed against the
sleeve seat by a spring and hydraulic pressure Orifice
Spring chamber
due to area differences. As a result, 100% volume 216096
of oil that is fed to the circuit flows into an operat- Fig. 21-1 Main relief valve
ing section (Fig. 21-1).
(2) When the relief valve is activated:

The pressure in the circuit is increased due to a
load pressure, and when the pressure reaches a
set pressure, the relief valve looses its balance,
and starts to activate. When the circuit pressure
reaches a set pressure, the oil starts to flow into
the tank as the hydraulic pressure opens the pilot
poppet. This oil flow creates a differential pres-
sure before and after the orifice in the main pop-
pet, and by the force of differential pressure, the
main poppet is opened so that the hydraulic oil
flows into the tank passage from P port. As a 216097
result, the maximum pressure is adjusted (Fig. 21- Fig. 21-2 Main relief valve operation
2).
11-59
HYDRAULIC SYSTEM
6.4.2 Steering System Relief Valve

A LS relief valve is a direct-acting valve in which a
spring pushes the main poppet against the valve body
seat. When the pressure in the LS flow exceeds a set
pressure, the main poppet is forced open, thereby
controlling the pressure (Figs. 22-1 and 22-2).
216098
Fig.22-1 Steering system relief valve
216099
Fig.22-2 Steering system relief valve operation
11-60
HYDRAULIC SYSTEM
6.4.3 Port Relief Valve

(1) When the port relief valve is not activated: Main poppet Middle piston
When the pressure in the circuit is sufficiently
Seat A or B port
lower than a set pressure, a relief valve remains Pilot poppet
balanced. The hydraulic oil from A or B port fills a
spring chamber by passing through the orifice of
the middle piston in the main poppet, and extends
to the pilot valve seat. However, as the force of
spring pushes the pilot poppet against the seat,
the flow of oil to the tank is blocked. The flow is
also blocked by the main poppet which is pressed Orifice
against the sleeve seat by a spring and hydraulic
Spring chamber Tank line
force created by area differences. As a result, 216100
100% volume of oil that is fed to the circuit flows Fig. 23-1 Port relief valve
into operating sections (Fig. 23-1).
(2) When the port relief valve is activated:

The pressure in the circuit is increased due to a
load pressure, and when the pressure reaches a
set pressure, the relief valve looses its balance,
and starts to activate. When the circuit pressure
reaches a set pressure, the oil starts to flow into
the tank as the hydraulic pressure pushes up the
pilot poppet. Then a differential pressure is cre-
ated in the orifice of the middle piston, and by the
differential pressure, the middle piston is pressed
Tank line
against the end of the pilot poppet. And then the
pressure in the spring chamber starts to 216101
decrease, and a pressure fluctuation before and Fig. 23-2 Port relief valve operation
after the main poppet is created. This pressure
opens the main poppet so that oil flows into tank
through the tank port passage. As a result, the
pressure in the circuit is maintained to a set pres-
sure (Fig. 23-2).
(3) Anti-cavitation function:

When the pressure in the A or B port is decreased
with respect to the pressure in the tank passage,
a force is created in the direction to open the main
poppet due to area differences before and after
the main poppet, and thereby allowing the flow
from the tank passage to A or B port. As a result,
the generation of negative pressure in the actua-
tor is prevented (Fig. 23-2).
11-61
HYDRAULIC SYSTEM
6.5 Flow Regulating Valve (FRV)

The FRV is a flow control valve that limits a maximum
flow rate during lowering operation of the cylinder. The
flow rate of the hydraulic oil returning from the lift cylin-
der is regulated by an inching operation of a lift spool,
however, when the spool is fully opened, the spool
cannot control flow rates. Therefore, a valve which
limits flow rates is required when the flow of oil
exceeds a specified limit.
Control orifice Secondary

(1) When flow rates are less than a specified limit: Spring chamber pressure chamber
The hydraulic oil returning from A1 port passes
through a variable throttle valve, a secondary Spool
pressure chamber and a control orifice, and then
heads to a change-over spool. While flow rates
are less than a specified limit, the change-over
spool does not activate so that a lowering opera-
tion is allowed without restriction (Fig. 24-1).
Variable throttle valve 216102

Fig. 24-1 Flow Regulator Valve (FRV)
(2) When flow rates reach a specified limit:
When flow rates from A1 port increases and a dif-
ferential pressure across the control orifice
exceeds a specified limit, the spool moves left-
ward by the force of the pressure difference
before and after the spool. Then the variable throt-
tle valve limits the input flow rates to keep a differ-
ential pressure constant. This operation makes it
possible to keep the maximum flow rates constant
and to limit the flow rate (Fig. 24-2).
216103
Fig. 24-2 FRV operation
11-62
HYDRAULIC SYSTEM
6.6 Cautions for use
Conduct transportation, installation, pipe installation

and operation safely and properly by observing the
following instructions.
6.6.1 Transportation
When carrying MC control valves, hold the valve bod-
ies and handle them with care. Do not hold an
exposed section of the spool, electromagnetic sole-
noid coil, and spool cap section, and do not drop or hit
them against other hard objects.
6.6.2 Installation
(1) A mounting surface should be sufficiently flat. If a
mounting surface is uneven, tightening the mount-
ing bolts may distort the valve bodies, which may
lead to interference with the movement of spool.
(2) Install the valve in a position so that an exposed
section of the spool can be protected from being
contaminated with soils and dust.
(3) When attempting to connect a link lever rod to the
spool end, make sure the force (push and pull)
exerted on the spool is applied coaxially with the
spool. If a force is applied in a radial direction, it
may result in oil leaks from dust steal or it may
cause interference with the movement of spool.
6.6.3 Pipe Installation

(1) Do not remove plugs from each port before piping
connection is made. Plugs will prevent entry of dirt
and dust.
(2) Be sure to tighten piping joints to the specified
torque. Overtightening may cause valve body dis-
tortion, which may result in interference with the
spool movement.

Port size G1 G3/4 G1/2 G3/8 M16 flare couplings
147 ± 14.7 98.1 ± 9.8 58.5 ± 5.9 39.2 ± 3.9 39 to 49
Tightening
(15.0 ± 1.5) (10.0 ± 1.0) (6.0 ± 0.6) (4.0 ± 0.4) (4.0 to 5.0)
torque
[108.4 ± 10.8] [72.4 ± 7.2] [43.2 ± 4.4] [28.9 ± 2.9] [28.8 to 36.2]
(3) Thoroughly clean the inside of pipes, hoses and

couplings before assembling them. Keep the
hydraulic oil clean during operation. If the hydrau-
lic oil is polluted with foreign materials, they may
cause trouble by entering into the orifices or pas-
sages in the spools of relief valves.
11-63
HYDRAULIC SYSTEM
6.6.4 Miscellaneous
(1) When painting in the vicinity of valve after the con-
trol valve installation, care should be taken to pre-
vent the paint from adhering to the spool exposed
section and dust seals.
(2) Do not move the relief valve adjusting screw
unless absolutely necessary. When it becomes
necessary to move the relief valve adjusting
screw, be sure to adjust it while observing pres-
sure gauge.
11-64
HYDRAULIC SYSTEM
7. FC Control Valve
7.1 Structure and Functions
7.1.1 Control valve
T2
3 10
Viewed from point A
5
Electromagnetic proportional pressure
control valve energizing current
9
A
6 7
PF B2
4 A1 B3
A2
A3
T1
10 11
This illustration shows the three-way type.

216112
1 FC control box (for lift, tilt and attachment levers) P: From hydraulic pump
2 Input unit T1: To hydraulic tank (return oil)
3 VCM controller
4 Output unit T2: From steering valve (return oil)
5 Inlet section PF: To steering valve
6 Tilt section
A1: To lift cylinder
7 Attachment section
8 End cover section A2: To tilt cylinder (rod end)
9 Electromagnetic proportional pressure control valve B2: To tilt cylinder (head end)
10 Main relief valve (for lift/tilt levers)
A3: To attachment actuator
11 Main relief valve (for attachment lever)
B3: To attachment actuator
11-65
HYDRAULIC SYSTEM
General
This control valve assembly consists of the following
assemblies:
(1) Inlet section
(2) Tilt section
(3) Attachment section
(4) End cover section
The electromagnetic proportional pressure control
valve and the unload solenoid valve for each of the lift,
tilt and attachment valves are energized by electric
current from the output unit. The controller determines
the amount of the current through calculation based on
the amount of movement of FC control box.
Functions of Inlet Section

(1) Forms the inlet of hydraulic oil from the hydraulic
pump.
(2) Functions as a priority valve that always preferen-
tially supplies hydraulic oil to the steering valve.
(3) Controls the oil pressure to the lift/tilt circuit (func-
tions as a bleed-off valve of the circuit).
(4) Controls supply of pilot oil amount to the main
spool of each control valve, and also functions as
a pressure reducing valve that controls the pilot
pressure.
(5) Functions as a lift valve that controls hydraulic oil
supply to and return oil amount from the lift cylin-
der that creates fork lifting and lowering actions.
Functions of Tilt Section

Controls hydraulic oil supply to and return oil amount
from the tilt cylinder that creates forward and back-
ward tilt actions of the mast.
Functions of Attachment Section
Controls hydraulic oil supply to and return oil amount
from the attachment operating hydraulic actuator.
Functions of End Cover Section
Controls the amount of hydraulic oil to the attachment
circuit and, also functions as a bleed-off valve that
maintains the attachment circuit pressure below the
maximum permissible level.
11-66
HYDRAULIC SYSTEM
7.1.2 FC Hydraulic System Circuit

Hydraulic System Description Using Circuit Diagram
For the overall hydraulic system circuit, refer to "1-3
Hydraulic Circuit Diagram (for models with FC control
valve.)"
For the construction of each valve, refer to the opera-
tional description of the relevant valve.
1 Priority valve
2 Steering relief valve
3 Pressure reducing valve 16 17
4 Pilot oil passage to electromagnetic proportional T1
pressure control valve 15 18
SLB
Oil pressure circuits and valves for lift/tilt circuit (5 thru
11)
B4
5 Lift spool ATT 12
A4 SA4 SB4
6 Tilt spool 19
7 Bleed-off valve 14
8 Supply oil passage to lift/tilt circuit ATT
B3
9 Load pressure A3 SA3 SB3 12

10 Unload solenoid valve (SLA)
11 Relief valve
B2
TILT
Oil passages and valves for attachment circuit A2 SA2 SB2 6
(12 thru 19) 13
12 Attachment spool
8
13 Supply oil passage to attachment circuit
14 Supply oil passage to attachment circuit A1 5
LIFT
15 Bleed-off valve SA1 SB1
16 Load pressure
4
17 Unload solenoid valve (SLB)
18 Relief valve
7 19
19 Shuttle valve
P: From hydraulic pump SLA 11
PF 10
PF: To steering valve
1
T2: From steering valve 2
P T2
T1: To hydraulic tank
3 9
216065
11-67
HYDRAULIC SYSTEM
The FC hydraulic system features the lift/tilt and in their neutral positions. The supply oil is blocked by
attachment circuits that are arranged in parallel. the lift or tilt main spool.
The hydraulic oil from the hydraulic pump flows The oil that has reached bleed-off valve 7 after pass-
through the P port into the inlet section of the control ing through priority valve 1 has nowhere to go except
valve. passage 13 of the attachment circuit.
The hydraulic oil is then directed to flow priority valve 1 The oil flows to passage 13, but it is blocked by the
as supply oil and also to pressure reducing valve 3 to attachment control valve that is in the neutral position.
create pilot oil. The oil then is forced to flow through bleed-off valve 14
and T1 port to the hydraulic tank.
The pilot oil having created by passing through pres-
sure reducing valve 3 is then directed to the electro- Oil flow with the FC lift or tilt lever moved to an
magnetic proportional pressure control valves (SA1 operating position:
and SB1; SA2 and SB2; SA3 and SB3; SA4 and SB4) Solenoid valve 10 is energized, enabling the load
that are attached to the lift/tilt valve and attachment pressure to act on the spool of bleed-off valve 7.
control valve. The pilot oil is used as pressure to move
The proportional solenoid valve of the lift or tilt valve is
spool of each valve.
also energized, causing the main spool to be pushed
Priority valve 1 preferentially supplies the steering cir- into the valve housing by the amount proportional to
cuit with hydraulic oil. When the delivery rate is high, the amount in which the FC control lever is moved.
the excess oil after distribution to the steering valve is
As a result, the oil flowing through supply oil passage
directed to bleed-off valve 7, from which the pressure
8 to the control valve enters one end of the cylinder
oil is directed to lift/tilt circuit and attachment circuit for
and the oil on the opposite side of the piston drains
the use in operating the lift and tilt cylinders and the
into the return passage.
hydraulic actuator of the attachment.
The oil flows through passage 8 at a constant rate that
Bleed-off valve 7 keeps constant the pressure differ-
is made proportional to the amount of the FC control
ence between the lift and the tilt spool (which functions
lever movement by the function of bleed-off valve 7.
as a throttle) in control valve 5 or 6 in order that the lift/
tilt circuit is always supplied with a constant amount of Excess oil flows through supply oil passage 13 into the
oil for a given amount of the FC control lever move- attachment circuit.
ment.
Owing to the function of this valve, the cylinder can Oil flow with the FC attachment lever moved to an
always extend and retract at a speed proportional only operating position:
to the amount of the FC control lever movement under
Solenoid valve 17 is energized, enabling the load
any load condition.
pressure to act on the spool of bleed-off valve 15.
Excess of oil to the lift/tilt circuit is directed to the
The proportional solenoid valve of the attachment
attachment circuit.
valve is also energized, causing the main spool to be
Load pressure 9 shown by dotted line in the hydraulic pushed into the valve housing by the amount propor-
circuit diagram on the previous page represents the oil tional to the amount of movement of the FC control
passage that transmits the static pressure, i.e., the lever.
load pressure created by passing through a spool (or a
As a result, the oil flowing through supply oil passage
throttle).
13-1 to attachment spool 12 enters one end of the cyl-
Unload solenoid valve 10 allows the load pressure oil inder and the oil on the opposite side of the piston
to drain into the return line when it is deenergized and drains into the return passage.
blocks the passage to the return line when it is ener-
The oil flows through passage 13-1 at a constant rate
gized. It functions as a "load pressure switch."
that is made proportional to the amount of the FC con-
trol lever movement by the function of bleed-off valve
Oil flow with all the FC control levers in their neu- 15.
tral positions: Excess oil flows through the T1 port into the hydraulic
When all the FC control levers are in their neutral posi- tank.
tions, unload solenoid valves 10 and 17 are deener-
gized, allowing the load pressure oil to drain into the
return passage, so that no load pressure builds up.
The proportional solenoid valves of all the control
valves are deenergized, so the main control spools are
11-68
HYDRAULIC SYSTEM
7.1.3 Operation of Valves in Hydraulic System

11 9 16 14 13 12 15
6 5 17 4 10 3 2 7
208827
Priority valve and pressure reducing valve

1 P port (inlet of pressure oil from hydraulic pump) 11 Steering system relief valve
2 Oil passage (from P port 1) 12 Pressure reducing valve (for pilot oil to electromag-
3 Priority valve netic proportional control valve)
4 Priority valve spool 13 Shuttle valve
5 Oil passage (to PF port 9) 14 Spring
6 Spring 15 Pilot oil passage
7 Valve (to electromagnetic proportional control valve)
8 Chamber 16 Return oil passage (to hydraulic tank)
9 PF port (to steering valve) 17 Orifice
10 Excess oil passage (to bleed-off valve)
11-69
HYDRAULIC SYSTEM
Priority Valve Pressure Reducing Valve

This valve directs the hydraulic oil delivered from the Pressure reducing valve 12 reduces the pressure of
hydraulic pump to the steering system, giving it priority the pump-delivered oil to the pressure (pilot pressure)
over the steering control circuits. that is appropriate for being handled by the electro-
Incoming hydraulic oil from P port 1 enters priority magnetic proportional pressure control valve.
valve 3 and pressure reducing valve 12. The hydraulic oil entering pressure reducing valve 12
The hydraulic oil having entered priority valve 3 then through P port 1 flows through the hollow in shuttle 13
flows as follows: that is sliding in the sleeve of valve 7 and is directed
through pilot oil passage 15 to the electromagnetic
(1) The hydraulic oil flows through passage 2, the hol-
proportional pressure control valve.
low in spool 4, then orifice 17, where it is throttled
before flowing into passage 5. The hydraulic oil When the pressure of the oil in pilot oil passage 15 is
then goes out of passage 5 through PF port 9 (ball high, shuttle 13 moves leftward against the force of
check valve equipped connector) and is directed spring 14.
to the steering valve. This narrows the port whose opening varies with the
(2) Part of the hydraulic oil that flows through pas- relative position of the holes in the sleeve and shuttle
sage 2 and enters the hollow of spool 4 flows 13, reducing the rate at which the hydraulic oil flows
through valve 7 and reaches chamber 8. This into the pressure reducing valve and thus lowering the
hydraulic oil applies a leftward force to spool 4. pressure in passage 15 to the standard design pres-
This leftward force balances with the rightward sure.
force of spring 6 at a certain position of spool 4 When the pressure in pilot oil passage 15 is low,
and the spool settles there. In this condition, the actions of the valve components are reverse to those
hydraulic oil is supplied to the steering system at a mentioned above, causing the pressure in passage 15
certain rate and the excess hydraulic oil flows into to increase back to the standard design pressure.
passage 10 through passage 2.
(3) When the delivery rate of the hydraulic pump
increases, spool 4 is moved left further allowing
the excess hydraulic oil to flow through passages
2 into passage 10 and then to the bleed-off valve.
Valve 7 has a function of making the hydraulic oil
flow into chamber. This function is necessary to
cause spool 4 to move left slowly but to cause it to
move right quickly such that the flow of excess
hydraulic oil is limited before a shortage in supply
of hydraulic oil to the steering system could occur.
Steering system relief valve 11 is a safety valve
that protects the steering system against exces-
sively high pressures. The set pressure of the
+0.5 +0.5 +0.5
valve is 11.8 0 MPa (120 0 kgf/cm2) [1712 0 psi].
11-70
HYDRAULIC SYSTEM
Unload Solenoid Valves

These valves are ON/OFF solenoid valves that either
allow load pressure oils to flow to the relevant bleed- 1
off valves or interrupt them. The solenoid valve for the
lift/tilt circuit is incorporated in the inlet section and that 3
for the attachment circuit is incorporated in the end
cover section.
Both the solenoid valves are identical in construction 2
as shown in the illustration on the right. When the FC
4
control lever is in the neutral position, solenoid 1 is not
energized, leaving rod 2 in the raised position. The 208828
hydraulic oil in passage 3 can then flow to passage 4 Solenoid valve
that returns to the hydraulic tank.
When the FC control lever is moved to a position other 1 Solenoid
than the neutral, solenoid 1 is energized, forcing rod 2 2 Rod
downward to close passage 3 and 4 in the poppet. The 3 Passage for load pressure oil
load pressure oil in passage 3 then builds up. 4 Passage to hydraulic tank
11-71
HYDRAULIC SYSTEM
Bleed-off Valves
A B
3 1
Tilt valve C
5 6
B
C
A
From lift valve
2 4
14 9
10 1 12
SLA
To tank
7
13
8
11
208829
1 Supply hydraulic oil passage to lift/tilt circuit (con- 8 Bleed-off valve

nected to excess oil passage from priority valve) 9 Chamber for load pressure oil
2 Passage (load pressure take-out chamber) 10 Spool
3 Load check valve 11 Spring
4 Load pressure oil passage 12 Passage to attachment circuit
5 Shuttle valve 13 Chamber
6 Filter 14 Relief valve
7 Unload solenoid valve (SLA)
11-72
HYDRAULIC SYSTEM
Bleed-off Valve Operation—in Relation to Load Pressure

Basic operation of the bleed-off valve is described on The oil from port B pushes down the steel ball in valve
the section "Priority Valve of 7.1.3 Operation of Valves 5 and closes port A while opening the passage from
in Hydraulic System" in conjunction with operation of port B to port C.
the valves related with it. The following points 1 Through the above mentioned process, the load pres-
through 5 are a summary of the description on that sure oil from port B flows to port C and then to filter 6.
page which should be read for better understanding of The filtered pilot oil flows into chamber 9 in bleed-off
the detailed description of bleed-off valve operation valve 8.
that follows them.
1 The FC hydraulic system of consists of the follow- In bleed-off valve 8, the position of spool 10 is deter-
mined by the balance of different forces as follows:
ing main circuits:
(1) Lift/tilt circuit (a) The oil in supply passage 1 (with a pressure
(2) Attachment circuit equal to that of the hydraulic oil in the passage
2 These circuits are provided with each of bleed-off before the throttle) enters chambers 13, push-
valves, which are completely identical in both the ing spool 10 left and attempting to make part of
type and operation. the hydraulic oil in passage 1 flow into passage
(1) The bleed-off valve for the lift/tilt circuit is in- 12.
corporated in the inlet section.
(b) The load pressure in chamber 9 and spring 11
(2) The bleed-off valve for the attachment circuit
is incorporated in the end cover section. together push spool 10 right, preventing the oil
3 Bleed-off valve 8 is a pressure control valve that in passage 1 from flowing into passage 12.
creates a constant flow amount by making con- Spool 10 is settled in a position where the
stant difference in static pressure between the up- pressure in chamber 13 (pressure before throt-
tle) balances with the combined force of spring
stream side and downstream side of the throttle of
11 and pressure in chamber 9 (pressure after
the lift or tilt valve spool. (The flow amount is a
throttle). The bleed-off valve maintains a con-
product of the throttle flow amount and opening
stant pressure difference in the following pro-
area of the throttle.)
cess.
4 The static pressure of oil flowing through the throat
(throttle) of the lift or tilt valve is led through load When the pressure difference is too large:
pressure oil passage 4 to bleed-off valve. Too large pressure difference means that too large an
5 Unload solenoid valve 7 is located part-way along oil amount is supplied to the actuator. Spool 10 then
load pressure oil passage 4 and allows load pres- moves left to allow the hydraulic oil in supply oil pas-
sure oil to flow to bleed-off valve 8 or diverts it to sage 1 to flow into passage 12. This reduces the
the hydraulic tank. amount of supply oil and thus reduces the pressure
difference.
The diagram on the preceding page shows the tilt
spool, bleed-off valve and shuttle valve in the states in When the pressure difference is too small:
which they are placed when the FC control lever is Too small pressure difference means that too small an
placed in the "tilt backward" position. oil amount is supplied to the actuator.
The tilt spool is moved right, allowing the hydraulic oil Spool 10 then moves right to reduce oil flow from pas-
in the supply oil passage 1 to flow to passage 2. The sage 1 into passage 12. This increases the amount of
hydraulic oil then pushes up load check valve 3 to supply oil and thus increases the pressure difference.
open its way to the rod end of the tilt cylinder. The
Through the above process, the bleed-off valve keeps
mast is tilted backward as a result.
an constant oil amount passing through the throttle for
The load pressure oil in passage 4 is led from passage any FC control lever position. Therefore, the hydraulic
2 which constitutes a throttle, so its pressure is the oil amount supplied to the cylinder is proportional only
static pressure of the hydraulic oil flowing through the to the opening created by the main spool of control
throttle. valve that moves in proportion to the FC control lever
The load pressure oil flows to shuttle valve 5. movement. Relief valve 14 serves as the lift/tilt or
attachment circuit relief valve. When relief valve 14
Shuttle valve 5 selects the high pressure oils that enter
opens, the load pressure is released. This causes
from port A and port B and allows the selected oil to
spool 10 to move left and allows the oil in passage 1 to
flow out to port C.
flow into passage 12.
In the shown case where supply hydraulic oil is flowing +0.5
The set pressure of relief valve 14 is 19.1 0 MPa(195
to the tilt cylinder, the pressure of the tilt load pressure +0.5 +71
0 kgf/cm2)[2771 0 psi]with both the lift/tilt circuit and
oil in port B is higher than that of the lift load pressure
attachment circuit.
oil in port A.
11-73
HYDRAULIC SYSTEM
Bleed-off Valve of Attachment Circuit

The bleed-off valve for the attachment circuit is identi-
cal with that for the lift/tilt circuit in both the shape and
function. Both the bleed-off valves have very similar
construction and operate on the same principle. The
bleed-off valve for the attachment circuit is incorpo-
6 4
rated in the end cover section.
5
1 Bleed-off valve
2 Supply hydraulic oil passage to attachment circuit
3 Return line to oil tank
4 Load pressure oil passage
5 Unload solenoid valve
6 Relief valve of attachment circuit
1
3 2
208830
Bleed-off valve of attachment circuit
11-74
HYDRAULIC SYSTEM
7.1.4 lift Valve
16 8 15 2 6 11 13 14 10
A1
4 3 4 12 19
SA1 SB1
17 18 9 5 7 1 Electromagnetic proportional
pressure control valve
208831
Main components
1 Lift spool 7 Passage (load pressure take-out 13 Passage
2 Load check valve chamber) 14 Passage
3 Lift lock valve 8 Passage to A1 port 15 Load pressure take-out port
4 Cap 9 Passage to hydraulic tank 16 Shut-off valve
5 Shuttle valve 10 Passage to hydraulic tank 17 Spring force adjusting screw
6 Oil passage of lift/tilt circuit 11 Load check valve operating pilot 18 Spring
oil passage 19 Spring
12 Passage in cap screw
Condition with FC control lever in Neutral Position

Since both the electromagnetic proportional pressure
control valves (SA1 and SB1) are deenergized, lift
spool 1 does not move in either direction and is held in
its neutral position by centering springs 18 and 19 that
are housed in right and left caps 4.
The hydraulic oil from the passage of lift/tilt circuit in
the bleed-off valve enters passage 6 but cannot flow
further as the outlet of passage 6 is blocked by lift
spool 1.
Since the return oil passage from the A1 port is also
blocked by load check valve 2, the hydraulic oil in the
lift cylinder cannot be drained.
11-75
HYDRAULIC SYSTEM
8 7 2 6
A1
4 19
SA1 SB1
Electromagnetic proportional 5 15 1
208832
Operation with FC control lever in Lift-up Position

When an operator moves the FC control lever in the
lift-up direction, the controller supplies the electromag-
netic proportional pressure control valve (SA1) with
current that is proportional to the amount of movement
of the FC control lever.
The valve then allows hydraulic oil of the pressure cor-
responding to the amount of the FC control lever
movement to flow into left cap 4.
The pressure of the hydraulic oil having entered the
cap pushes right main spool 1 against the force of
spring 19.
Spool 1 moves right more as the amount of the FC
control lever movement increases.
The hydraulic oil in oil passage 6 of the lift/tilt circuit
flows to passage 7 and then to passage 8. The
hydraulic oil then makes its way to the A1 port by
pushing up load check valve 2.
The supply hydraulic oil from the A1 port flows through
the flow regulator valve and acts on the lower end of
the lift cylinder piston to extend the piston rod, thus lift-
ing the mast.
The pressure in passage 7 (load pressure) is taken out
from port 15. The load pressure is led to shuttle valve
5, which compares it with the load pressure from the
tilt valve and allows the higher of the load pressures to
be led to the bleed-off valve.
For operation of the electromagnetic proportional pres-
sure control valve, refer to "7.1.7 Electromagnetic Pro-
portional Pressure Control Valve."
11-76
HYDRAULIC SYSTEM
16 8 2 6 11 3 10
A1
12 4
SA1 SB1
17 18 9 1 13 14 Electromagnetic proportional
208833
Operation with FC control lever in Lift-down Position

When the operator moves the FC control lever in the result, the cylinder contracts, causing the mast to
lift-down direction, the controller supplies the electro- lower.
magnetic proportional pressure control valve (SB1) When an operator places the lowering speed selector
with current that is proportional to the amount of move- switch in the cabin in the ON position, the maximum
ment of the FC control lever. The valve thus allows amperage setting of the current to the proportional
hydraulic oil of the pressure corresponding to the solenoid valve is lowered. This causes rise of the pres-
amount of movement of the FC control lever to flow sure in cap 4 to be limited to a pressure lower than
into right cap 4. usual even when the FC control lever is fully moved.
The pressure of the hydraulic oil having entered the Under this condition, main spool can move only in a
cap pushes left main spool 1 against the force of limited amount, so that the return passage portion
spring 18. between passage 8 and passage 9 is narrowed. This
Spool 1 moves left more as the amount of the FC con- makes the maximum mast lowering speed slower than
trol lever movement increases. usual.
The hydraulic oil having entered cap 4 also flows Shut-off valve 16 is provided as an emergency valve
through passage 12 and pushes left the lift lock valve that provides means to lower the mast if lift lock valve
3. This causes the hydraulic oil in passage 11 that 3 becomes stuck by some cause. Loosening the set
leads to the spring side (upper side in the drawing) of screw after loosening the lock nut allows the hydraulic
load check valve 2 to drain to the hydraulic tank oil from the A1 port to directly flow to passage 9
through passage 13, the space around the periphery bypassing load check valve 2.
of lift lock valve 3, passage 14 and passage 10. Spring force adjusting screw 17 is used to adjust the
Load check valve 2 is always kept under the pressure preload of spring 18 in the cap when the mast lowering
that comes through the A1 port and acts on its force. speed deviates excessively from the standard design
With the hydraulic oil behind load check valve 2 having speed. This screw must not be used unless an adjust-
drained into the hydraulic tank as mentioned above, ment is absolutely necessary. Fine adjustments of the
the valve is lifted by the A1 port oil pressure. lowering speed can be performed by changing the rel-
evant setting of the controller. For detailed information
The A1 port oil that originates from the lift cylinder on the adjustment, refer to the "Chapter 3 ELECTRIC
flows through passage 8 and then passage 9. Since SYSTEM."
passage 9 opens the hydraulic tank, the hydraulic oil
from the cylinder can be drained into the tank. As a
11-77
HYDRAULIC SYSTEM
7.1.5 Tilt Valve
3 9 2 6 1 10
Tilt cylinder Tilt cylinder

rod end head end
A2 B2
4 13 14 4
SA2 SB2
7 12 11 5 8 Electromagnetic proportional
208834
Main components
1 Tilt spool 8 Passage to B2 port
2 Load check valve 9 Passage to hydraulic tank
3 Tilt lock valve 10 Passage to hydraulic tank
4 Cap 11 Passage
5 Lift/tilt circuit oil passage 12 Passage for load pressure
6 Passage (load pressure take-out chamber) 13 Spring
7 Passage to A2 port 14 Spring

Since both the electromagnetic proportional pressure
control valves (SA2 and SB2) are generalized, tilt
spool 1 moves in neither direction and is held in its
neutral position by centering springs 13 and 14 that
are housed in right and left caps 4.
The hydraulic oil from the passage of lift/tilt circuit in
the bleed-off valve enters passage 5 but cannot flow
further as the outlet of passage 5 is blocked by tilt
spool 1.
The hydraulic oil from A2 port and B2 port are also
blocked by tilt spool 1.
11-78
HYDRAULIC SYSTEM
7 11 2 5 8 10
Rod end Head end
A2 B2
4 14
SA2 SB2
Electromagnetic proportional 6 1
208835
Operation with FC control lever in Tilt-backward Position

When an operator moves the FC control lever in the tilt For operation of the electromagnetic proportional pres-
backward direction, the controller supplies the electro- sure control valve, refer to "7.1.7 Electromagnetic Pro-
magnetic proportional pressure control valve (SA2) portional Pressure Control Valve."
with current that is proportional to the amount of move-
ment of the FC control lever to energize the solenoid
of the valve to the degree corresponding to the amount
of the current. The valve then allows hydraulic oil of
the pressure corresponding to the amount of the FC
control lever movement to flow into left cap 4. The
pressure of the hydraulic oil having entered the cap
pushes right tilt spool 1 against the force of spring 14.
Tilt spool 1 moves right more as the amount of the FC
control lever movement increases.
The hydraulic oil in oil passage 5 of the lift/tilt circuit
flows to passage 6. The hydraulic oil then makes its
way by pushing up load check valve 2 to the A2 port
through passage 11 and then passage 7.
The output hydraulic oil from the A2 port enters the rod
end of the tilt cylinder and acts on the piston to retract
the cylinder rod.
Simultaneously, with the hydraulic oil flow to the rod
end of the cylinder, the hydraulic oil from the head end
flows through the B2 port, passage 8 and passage 10
(return oil passage) to the hydraulic tank.
By the two hydraulic oil flows created through the pro-
cess mentioned above, the tilt cylinder rod retracts
such that the mast tilts back.
11-79
HYDRAULIC SYSTEM
Rod end 2 Head end 8

A2 B2
13 4
SA2 SB2
9 7 (a) 11 6 5 1
Electromagnetic proportional
Tilt lock valve (3)
(d) (e) (c) (b) Chamber

Spring (g) Valve spool (f) Damper
208836
Operation with FC control lever in Tilt-forward oil in passage 7 flows through the following passages
Position in the order of mention before it is drained through
When an operator moves the FC control lever in the tilt passage 9 to the hydraulic tank.
forward direction, the controller supplies the electro- Passage 7 → Passage (b) → Passage (c) → Passage
magnetic proportional pressure control valve (SB2) (d) → Passage 9
with current that is proportional to the amount of move- By the two hydraulic oil flows created through the pro-
ment of the FC control lever. The valve allows hydrau- cess mentioned above, the tilt cylinder rod extends
lic oil of the pressure corresponding to the amount of such that the mast tilts forward.
movement of the FC control lever to flow into right cap
4. The pressure of the hydraulic oil having entered the
cap pushes left tilt spool 1 against the force of spring Emergency Measure Taken by Operator
13. Should the main spool stick during forward tilting oper-
The hydraulic oil in oil passage 5 of the lift/tilt circuit ation, an operator needs to take the following actions:
flows to passage 6. The hydraulic oil then makes its (1) Return the FC control lever to the neutral position.
way pushing up load check valve 2 to passage 11. The The SLA and SLB solenoid valves are opened,
hydraulic oil then enters passage 8, goes out of the B2 lowering the pressure in the system.
port and flows into the head end of the tilt cylinder, act-
ing on the piston to extend the cylinder rod. (2) Shut down the engine to stop supply of hydraulic
oil to the circuit. The pressure in passage 11 will
Part of the hydraulic oil in passage 11 also flows
be released.
through hole (a) in tilt spool 1 into the chamber at the
right end of tilt lock valve 3, pushing left spool (f) By taking the two actions described above, valve spool
against the force of spring (g). The hydraulic oil in the (f) moves right, preventing the rod end oil in the tilt cyl-
spring chamber is drained through hole (e) as spool (f) inder from returning to the hydraulic tank. This stops
moves left. forward tilting of the mast.
When spool "f" in tilt lock valve 3 moves left, the

hydraulic oil in the passage connecting the rod end of
the tilt cylinder and the A2 port as well as the hydraulic
11-80
HYDRAULIC SYSTEM
7.1.6 Attachment Valve
8 2 5 4 9
A3 B3
3 11 12 3
SA3 SB3
6 10 1 7 Electromagnetic proportional
216109
Main Components
1 Attachment spool 7 Passage to B3 port
2 Load check valve 8 Passage to hydraulic tank
3 Cap 9 Passage to hydraulic tank
4 Attachment circuit oil passage 10 Passage
5 Passage (load pressure take-out chamber) 11 Spring
6 Passage to A3 port 12 Spring

Since the electromagnetic proportional pressure con-
trol valves (SA3/SA4 and SB3/SB4) are deenergized,
attachment spool 1 is held in the neutral position by
springs 11 and 12 housed in right and left caps 3 with-
out moving in either direction.
The hydraulic oil from the passage of attachment cir-
cuit enters passage 4 but cannot flow further as the
outlet of passage 4 is blocked by attachment spool 1.
Hydraulic oils from the A3 and B3 ports are also
blocked by attachment spool 1.
The attachment valve for the No.4 attachment circuit

is identical with that for the No. 3 attachment circuit.
11-81
HYDRAULIC SYSTEM
2 4 9
A3 B3
12
SA3 SB3
6 10 5 1 7
216110
Operation with SA3 Solenoid Energized

When electromagnetic proportional pressure control
valve (SA3) is energized, attachment spool 1 moves
right against the force of spring 12.
This causes the hydraulic oil in attachment circuit oil
passage 4 to flow to passage 5. The hydraulic oil then
makes its way to the A3 port by raising load check
valve 2 and passing through passages 6 and 10.
The pressure of the hydraulic oil going out of the A3
port acts on the hydraulic actuator of the attachment.
The return oil from the hydraulic actuator enters the
control valve through the B3 port and then flows
through passage 7 and passage 9 (return oil passage)
to the hydraulic tank.
For operation of the electromagnetic proportional pres-
sure control valve, refer to "7.1.7 Electromagnetic Pro-
portional Pressure Control Valve."
11-82
HYDRAULIC SYSTEM
8 2 4
A3 B3
11
SA3 SB3
6 10 5 1 7
216111
Operation with SB3 Solenoid Energized

When electromagnetic proportional pressure control
valve (SB3) is energized, main spool moves left
against the force of spring 11.
This causes the hydraulic oil in attachment circuit oil
passage 4 to flow to passage 5. The hydraulic oil then
makes its way to the B3 port by raising load check
valve 2 and passing through passages 7 and 10.
The pressure of the hydraulic oil going out of the B3
port acts on the hydraulic actuator of the attachment.
The attachment now moves opposite to the direction in
which it moves when the SA3 solenoid is energized.
The return oil from the hydraulic actuator enters the
control valve through the A3 port and then flows
through passage 6 and passage 8 (return oil passage)
to the hydraulic tank.
11-83
HYDRAULIC SYSTEM
7.1.7 Electromagnetic Proportional Pressure Control Valve

valve is a pressure reducing valve that regulates the
1 2 3
pressure of the oil entering chamber 2 in cap 1 of the
control valve, i.e., the pressure that pushes spool 3.
This valve regulates the oil pressure in such a way that
the oil pressure level is proportional to the amount of
movement of the FC control lever. The more the FC
control lever is moved, the greater the pressure of the
oil in the chamber becomes, and, as a result, the more
8
the movement of main spool 3.
valve consists of solenoid (electromagnet) section A 10
and pressure control valve section B. A B
When energized by a current from the controller, sole- Neutral
noid section A pushes out rod 4 which in turn pushes 4 f 5 8 (a) 7 6
spool 5.
The force (or the thrust) with which rod 4 pushes spool
5 is proportional to a current value from the controller
which determines the current value in proportion to the
amount of the movement of the FC control lever.
Oil Flow When FC Control Lever is in Neutral Posi-
tion
Since no current is supplied to the solenoid, it remains 10 9 (e) (d) (c) (b) 11
deenergized; rod 4 does not extend rightward. Spool 5
is kept pushed left by spring 6 (the state shown in the Solenoid Pp: Supply oil pressure
illustration). energized P: Leftward force resulting from Pp
The main spool operating oil in passage 7 (hydraulic F: Thrust of solenoid actuated rod
oil having been pressure-regulated by the reducing 4 5 Pp 8 a 7 11
valve incorporated in the inlet section) is blocked by
spool 5.
The hydraulic oil entering chamber 2 in cap 1 flows
through passages 8 →(d) → (c) →(e) and returns to F P
the hydraulic tank passing through chamber 9, pas-
sage (f) and chamber 10 under no pressure.
Oil Flow When Solenoid is Energized
The energized solenoid extends rod 4, which moves 9 e d c b Pp
216069
right spool 5 against the force of spring 6.
1 Cap
The pressure in passage 7 reaches passage 8 through 2 Chamber
small passages (a) → (c)→ (d) and enters chamber 2. 3 Main spool
The hydraulic oil also flows through passage (b) in the 4 Solenoid-actuated rod
spool, enters chamber 11, and acts on spool 5 in the 5 Spool
direction opposite to that of the thrust of rod 4. 6 Spring
If the pressure of the hydraulic supply oil to chamber 2 7 Passage for pilot oil from reducing valve
becomes greater than the thrust of rod 4, the spool 8 Passage to/from chamber 2
moves left, allowing the hydraulic oil in passage (c) to 9 Return oil chamber
drain into return passage 9. Conversely, if the supply 10 Return oil passage
oil pressure is smaller than the thrust of rod 4, spool 5 11 Chamber
moves right, blocking flow of the hydraulic oil to pas-
(a) thru (f):
sage 9 and increasing further the supply oil pres-
sure.This means that the supply oil pressure is created Small oil passages formed in spool and sleeve of pres-
in proportion to the strength of the thrust of rod 4. sure control valve section
11-84
HYDRAULIC SYSTEM
7.2 Procedures and Suggestions for Removal and Installation

7.2.1 Removal
This illustration shows the four-way type.

208983A
Sequence
1 Electric wires of proportioning solenoids 5 Pipe to steering valve
(to be disconnected at connectors) 6 Return hose from steering valve
2 Tilt pipe, Connector, O-ring 7 Return hose to hydraulic tank
3 Pump delivery hose 8 Nuts for valve mounting studs, bolt, control valve as-
4 Lift line (with flow regulator valve) sembly
Start by:
(1) Lower the forks to the floor with the mast in verti-
cal position, and release the residual pressure in
the pipes, before disconnecting them.
(2) Remove the floor plate.
Bolt Control valve Stud,Nut
Suggestion for Removal
(1) Disconnect the control valve end of each pipe and
hose. If necessary, loosen the clamps so the
pipes and hoses do not obstruct removal of the
control valve.
(2) Remove the bolts and nuts that mount the control
valve to the dashboard, and remove the control
valve. Stud,Nut Stud,Nut
Installation
208824
Follow the removal sequence in reverse. During instal-
Front view
lation, conduct the following inspection.
Check the hydraulic oil level. If the oil level is low, add
hydraulic oil to the specified level.
11-85
HYDRAULIC SYSTEM
7.3 Disassembly and Reassembly
SB1 SB2 4 SB3 3
2
5
1
Tightening torque:
7
44.1 ± 4.4N·m
6 (4.5 ± 0.42kgf·m)
[33 ± 3lbf·ft]
SA1 SA2 SA3
208826
Sequence
1 Tie rod nut 5 Inlet section (with lift section)
2 End cover section 6 Pressure relief valve for lift/tilt circuit
3 Attachment section 7 Pressure relief valve for attachment circuit
4 Tilt section
The sequence shown above should be followed

when completely disassembling the control valve
assembly. The control valve assembly may be disas-
sembled partially when oil pressure relief, inspection
and/or troubleshooting of a particular section is nec-
essary.
11-86
HYDRAULIC SYSTEM

(1) Thoroughly clean the exterior of the control valve
assembly.
(2) Be careful not to scratch the finished surface of
each port.
(3) Remove the relief valve and steering system relief
valve from the valve housing. Do not disassemble
the removed valves unless they require repairs.
(4) If loosening an adjusting screw is absolutely nec-
essary, make an alignment mark before loosening
it so that the original setting can be restored at the
time of reassembly.
(5) Remove the nut from each tie rod. Then the valve
sections can be removed one after another,
beginning with the end cover section.
(6) Each mating surface of every valve section is fit-
ted with O-rings. Be careful not to scratch, or oth-
erwise damage the O-rings as well as the mating
surface.
(7) Holding a valve spool may be necessary when its
cap bolt is removed or reinstalled. When holding
the valve spool, use a water pliers or other suit-
able tool with jaws covered by rubber pads or
other suitable material to prevent the external sur-
face of the spool from being damaged.
(8) If the spool is damaged, the whole valve assembly
must be replaced since spools are not available
individually.
For the disassembly and reassembly instructions
of each valve section, refer to the relevant section.
Reassembly
To reassemble, follow the disassembly sequence in
reverse.
11-87
HYDRAULIC SYSTEM
7.3.1 Disassembly of Individual Valve Sections

Inlet Section
8
6
4
2 3
1
5 7
10
11
12
13
14
208837
11-88
HYDRAULIC SYSTEM
Valves incorporated in inlet section

1 Lift valve 7 Steering relief valve
2 Priority valve 8 Shut-off valve assembly
3 Bleed-off valve 9 Relief valve for lift/tilt circuit
4 Electromagnetic proportional pressure control valve 10 Solenoid valve (SLA)
(SB1) 11 Strainer
5 Electromagnetic proportional pressure control valve 12 High-pressure selector valve
(SA1) 13 Connector assembly
6 Pressure reducing valve 14 Load check valve

Lift valve1 Pressure reducing valve 6
(1) Place the spool on a bench in a horizontal posi- Remove socket head plug 1, then remove reducing
tion, then unscrew socket head bolts 1 to remove valve set 2 and the spring.
caps 2 on both ends of the lift spool. Do not The sleeve and shuttle of the valve set have been
loosen adjuster kit 7. selectively matched with each other; the combination
must not be altered.
(2) Remove cap screws 4 on both ends of spool 3 by
unscrewing them using a hexagon wrench
engaged in the socket in each of their heads. Be Steering relief valve 7
careful not to drop the small valves inside spool 3.
(1) Remove socket head bolts 1, then remove plate 2
(3) Remove spring and spring guide sets 8. and adjusting screw 3 together. Adjusting screw 3
(4) Carefully draw spool 3 out of the valve housing, should not be loosened except when absolutely
then take valves 5 and 6 and the small springs out necessary; doing so alters the relief pressure set-
of the spool. ting.
(2) Remove valve 4, poppet 5 and spring.
Priority valve 2
(1) Remove socket head plug 1, then remove spool Shut-off valve assembly 8
set 3. If the valve inside the spool set is removed, The shut-off valve assembly should not be removed
the plug that is not staked must be removed. No except when necessary. If necessary for inspection or
detail parts lower than spool set 3 are available as other purposes, it can be disassembled as follows:
spare parts.
Unscrew plug 1 to remove the shut-off valve as a unit
(2) Remove socket head plug 2, then remove the without separating adjusting screw 2 from it. Disas-
spring. semble the unit further if necessary.
Bleed-off valve 3 Relief valve 9

(1) Remove socket head plug 1, then remove spool 2. Unscrew valve body 1 to remove the relief valve as an
assembly. Adjusting screw 2 should not be loosened
(2) Remove socket head plug 3, then remove spring.
except when absolutely necessary; doing so alters the
relief pressure setting and necessitates readjustments.
Electromagnetic proportional pressure control
valves 4,5
Unload solenoid valve (SLA) 10
(1) Remove socket head bolts 1 to remove solenoid
Remove the solenoid valve.
valve 2.
(2) Remove the valve set and spring. Sleeve 3 and
spool 4 of the valve set have been selectively Strainer 11
matched with each other; the combination must Remove socket head plug 1, then remove strainer 2
not be altered. from the valve housing. Finally remove the orifice.
11-89
HYDRAULIC SYSTEM
High-pressure selector valve 12

Remove the socket head plug 1 (valve body), then
remove high-pressure selector valve as a set. If the
steel ball needs to be inspected, remove plug 2 to take
out the steel ball. The high-pressure selector valve is
available only in the form of a set.
Connector assembly 13
Remove connector body 1, then remove the connector
assembly. The connector is replaceable only in the
form of an assembly.
Load check valve 14

Remove socket head plug 1, then remove valve 2 and
the spring.
11-90
HYDRAULIC SYSTEM
Tilt Section
Valves incorporated in tilt section
1 Tilt spool
2 Electromagnetic proportional pressure control
valve (SB2)
valve (SA2)
4 Load check valve 2
3

Tilt spool 1
(1) Place the spool on a bench in a horizontal posi-
tion, then unscrew socket head bolts 1 to remove
caps 2 on both ends of the tilt valve.
engaged in the socket in each of their heads. Be
careful not to let drop tilt lock valve 5 inside spool
3.
(3) Remove spring and spring guide sets 6. 4
(4) Carefully draw spool 3 out of the valve housing,
then take tilt lock valve 5 and small spring out of
the spool.

valves
3
(1) Remove socket head bolts 1 to remove solenoid 3
valve 2.
(2) Remove valve set 3. Sleeve 4 and spool 5 of the
valve set have been selectively matched with
each other; the combination must not be altered.
Load check valve

Remove socket head plug 1, then remove valve 2 and 208838
the spring.
11-91
HYDRAULIC SYSTEM
Attachment Section
Valves incorporated in attachment section
(In a 4-way type control valve assembly, the shuttle
valve is incorporated in the No.4 valve. For its disas-
sembly procedure, refer to the section of "Inlet Sec-
tion."
1 Attachment spool
2
valve (SB3) 3
valve (SA2)
4 Load check valve 1

Attachment Spool
(1) Place the spool on a bench in a horizontal posi-
tion, then unscrew socket head bolts 1 to remove
caps 2 on both ends of the attachment valve.
4
engaged in the socket in each of their heads.
(3) Remove spring and spring guide sets 5.
(4) Carefully draw spool 3 out of the valve housing.

valves
3
(1) Remove socket head bolts 1 to remove solenoid 3
valve 2.
(2) Remove valve set 3 and the spring. Sleeve 4 and
spool 5 have been selectively matched with each
other. The combination must not be altered.
Load check valve 208839

Remove socket head plug 1, then remove valve 2 and
the spring.
11-92
HYDRAULIC SYSTEM
End Cover Section

Valves incorporated in end cover section
1 Relief valve for attachment circuit
2 Bleed-off valve
3 Strainer
4 Unload solenoid valve (SLB)

Relief valve
Remove valve body 1, then remove the relief valve as
an assembly. Adjusting screw 2 should not be loos- 2
ened except when absolutely necessary; doing so
alters the relief pressure setting and necessitates 4
readjustment. 3
Bleed-off valve
(1) Remove socket head plug 1, then remove spool 2.
(2) Remove socket head plug 3, then remove the
spring.
1
Strainer
Remove socket head plug 1, then remove strainer 2
from the valve housing. Finally remove the orifice.
208840
Unload solenoid valve (SLB)
Remove the solenoid valve.
Cleaning
Wash all disassembled parts with clean solvent.
Use compressed air to dry parts. Place parts on clean
paper or cloth for inspection.
11-93
HYDRAULIC SYSTEM
Inspection
Inspect each part for burrs, scratches, dents and other
surface flaws.
(1) Remove burrs with an oil stone or by lapping com-
pound. If a part has excessive scratches that may
cause oil leaks or malfunctions, replace the part or
the section assembly.
The valve housings and spools must be used in orig-

inal combinations. Since these parts are not inter-
changeable, if scratches and dents are minor, correct
flaws with an oil stone or lapping compound. Main
spools are not available individually. If any has a sig-
nificant defect, replace the valve assembly.
(2) Make sure all moving and sliding parts operate

smoothly. Make sure there are no foreign particles
in grooves and oil passages.
(3) Check orifices for clogs.
(4) Replace broken or bent springs.
(5) Replace all seals, and O-rings with new parts.
General Precautions to Be Observed When Per-

forming Reassembling Operation
Most problems experienced by hydraulic devices are
attributable to the following three causes:
(1) Use of contaminated hydraulic oil
(2) Use of improper types of oil
(3) Carelessness during reassembling operation
Performing daily maintenance properly and being suf-
ficiently careful in handling parts during assembly work
are essential to prevent above mentioned problems.
Described below are the precautions to be observed
when performing reassembling operation.
(a) Perform reassembling operation in a clean, dust-
free place.
(b) Handle every part carefully. Avoid hitting a metal
part against another; the parts may be dented or
otherwise damaged.
(c) Assemble parts while lubricating them with clean
hydraulic oil.
(d) Understand the construction of each device before
assembling its components. (Especially, be sure to
install valves and spools in correct directions.)
(e) Do not reuse O-rings but replace them with new
ones. Be careful not to damage them during instal-
lation. Make sure O-rings are fitted correctly in
sealing grooves.
(f) Observe tightening torques wherever they are
specified.
11-94
HYDRAULIC SYSTEM
7.3.2 Reassembly of Valve Sections

Valves Incorporated in Inlet Section (Part 1)
216070
Lift valve components (1 thru 20)

Sequence
1 Lift spool 8 Spring seat 14 Spring
2 Spring 9 O-ring [free length: 42.4 mm (1.669 in.)]
3 Valve 10 Cap screw 15 Spacer
4 Spring seat 11 Spring 16 Cap
5 Cap screw [free length: 47 mm (1.850 in.)] 17 O-ring
6 Valve 12 Cap 18 Bolt
7 Spring 13 O-ring 19 O-ring
20 Adjuster kit
Bleed-off valve components (21 thru 27)

Sequence
21 Spool 23 O-ring 25 Spring
22 Orifice 24 Plug 26 O-ring
27 Plug
Pressure relief valve components (28 thru 30)

Sequence
28 Relief valve assembly 29 O-ring 30 O-ring
11-95
HYDRAULIC SYSTEM
Suggestions for Reassembly Bleed-off valve

Lift valve (1) Screw orifice 22 into spool 21, then insert the
(1) Place the housing on a bench such that spool 1 spool slowly and carefully into the valve housing.
will be in its horizontal position, then insert the (2) Install spring 25.
spool carefully into the housing. Pay attention to
(3) Fit the O-rings on socket head plugs 24 and 27,
the direction of the spool (see illustration).
then screw the socket head plugs into the housing
(2) Insert spring 2 and then valve 3 into spool 1. and tighten them to the torque shown below.
Install spring seat 4 on the spool, then screw cap
screw 5 into the spool and finger-tighten it. Unit: N·m (kgf·m) [lbf·ft]
147 ± 14.7
(3) Insert valve 6 and spring 7 into spool 1, install Tightening torque (15 ± 1.5)
spring seat 8 on the spool, then lightly screw cap [108 ± 10]
screw 10 (fitted with O-ring 9) into the spool.
(4) Tighten cap screws 5 and 10 on both ends of
Pressure relief valve
spool 1 to the torque shown below using a hexa-
gon wrench engaged in the socket in each cap (1) Fit O-rings 29 and 30 on relief valve assembly 28,
screw. Check the spool for smooth movement. screw the relief valve assembly into the housing,
and tighten it to the torque shown below.
20.6 ± 2.1 Unit: N·m (kgf·m) [lbf·ft]
Tightening torque (2.1 ± 0.2) 39.2 ± 5.0
[15.1 ± 1.4] Tightening torque (4 ± 0.5)
[29 ± 3.6]
(5) Install spring 11, then install cap 12 (fitted with O- (2) When the lock nut was loosened inadvertently, the
ring 17) with socket head bolts 18 by tightening adjusting screw setting may have been changed
them to the torque shown below. so the relief pressure setting must be readjusted.
Unit: N·m (kgf·m) [lbf·ft] For the adjustment procedure, refer to "Main
15.7 ± 1.6 Relief Valve" in the "Inspection and Adjustment"
Tightening torque (1.6 ± 0.16) section.
[11.5 ± 1.0]
(6) Install spring 14 and spacer 15, then install cap 16

(fitted with O-ring 17) with socket head bolts 18 by
tightening them to the same torque as that of step
(5).
(7) When adjuster kit 20 was inadvertently disassem-
bled, reassemble and temporarily adjust it, then
install it on cap screw 16. After performing later a
mast lowering speed test and adjusting the speed
properly by turning its adjusting screw, tighten the
lock nut to the torque shown below.
48 ± 4.8
Tightening torque (4.9 ± 0.5)
[35 ± 3.5]
11-96
HYDRAULIC SYSTEM
216104
Priority valve components (1 thru 6)

Sequence
1 Spool set 3 O-ring 5 Plug
2 Plug 4 Spring 6 O-ring
Pressure reducing valve components (7 thru 11)

Sequence
7 Spring 9 Reducing valve set 11 O-ring
8 Seat assembly 10 Plug
Steering system pressure relief valve components (12 thru 19)

Sequence
12 Spring 15 O-ring 18 Adjusting screw
13 Poppet 16 Plate 19 Lock nut
14 Valve 17 Bolt
Shut-off valve assembly components (20 thru 25)

Sequence
20 Valve 22 Plug 24 Set screw
21 O-ring 23 O-ring 25 Lock nut
11-97
HYDRAULIC SYSTEM
Suggestions for Reassembly Steering system relief valve

Priority valve (1) Insert spring 12 into the housing.
(1) Insert spool set 1 carefully into the housing. (2) Install poppet 13 in position, then push valve 14
(2) Fit O-ring 3 on socket head plug 2, screw the (fitted with O-ring 15) into housing.
socket head plug into the housing and lightly (3) When the setting of adjusting screw 18 was not
tighten it. disturbed, install plate 16 (fitted with adjusting
(3) Install spring 4, then screw socket head plug 5 (fit- screw 18 and lock nut), then tighten socket head
ted with O-ring 6) into the housing and finger- bolt 17 to the torque shown below.
tighten it. Unit: N·m (kgf·m) [lbf·ft]
(4) Tighten socket head plugs 2 and 5 to the torque 15.7 ± 1.6
shown below. Tightening torque (1.6 ± 0.16)
[11.5 ± 1.2]
147 ± 14.7
(4) When adjusting screw 18 was turned inadver-
Tightening torque (15 ± 1.5) tently, loosen lock nut 19 and adjust the pressure
[108 ± 11] setting by turning adjusting screw 18. For the
adjustment procedure, refer to "Steering System
Relief Valve" in the "Inspection and Adjustment"
Pressure reducing valve section.
(1) Insert spring 7 into housing.
(2) Install spring seat 8, then insert reducing valve set Shut-off valve
9 into the housing. The sleeve and shuttle of valve When the shut-off valve assembly was removed from
set 9 are selectively matched parts. the housing, disassemble it completely and clean the
(3) Screw plug 10 fitted with O-ring 11 into the hous- seating surface of the assembly and valve 20, then
ing and tighten it to the torque shown below. proceed as follows:
Unit: N·m (kgf·m) [lbf·ft] (1) Replace the O-ring with a new one and reassem-
63.7 ± 6.4 N·m ble the components.
Tightening torque (6.5 ± 0.65 kgf·m) (2) Screw plug 22 into the housing and tighten it to
[47 ± 4.7 lbf·ft]
the torque shown below.
34.3 ± 3.4
[25.3 ± 2.5]
(3) Tighten set screw 24 to the torque shown below.

16.2 ± 1.6
[12.2 ± 1.2]
(4) Tighten lock nut 25 to the torque shown below.

9.8 ± 1.0
[7.2 ± 0.7]
(5) Tighten set screw 24 to the torque shown below.

16.2 ± 1.6
[12.2 ± 1.2]
11-98
HYDRAULIC SYSTEM
216105
Filter components (1 thru 4)

Sequence
1 Orifice 3 Plug
2 Strainer 4 O-ring
Shuttle valve components (5 thru 7)

Sequence
5 Valve set 7 O-ring
6 O-ring
Load check valve components (8 thru 11)

Sequence
8 Valve 10 Plug
9 Spring 11 O-ring
Filter components (12 thru 13)

Sequence
12 Connector 13 O-ring
11-99
HYDRAULIC SYSTEM

Filter
(1) Screw orifice 1 into the housing.
(2) Screw filter 2 into the housing and tighten it to the
torque shown below. Do not overtighten the filter.
7.8
Tightening torque (0.8)
[5.7] max.
(3) Fit O-ring 4 on socket head plug 3, screw the plug

into the housing and tighten it to the torque shown
below.
24.5± 2.5
[18 ± 1.8]
Shuttle valve
Fit O-rings 6 and 7 on valve set 5, screw the valve set
into the housing and tighten it to the torque shown
below.
29.4± 2.9
Tightening torque (3 ± 0.3)
[21.7 ± 2.1]
Load check valve

(1) Insert valve 8 into the housing.
(2) Install spring 9 in position.
(3) Fit O-ring 11 on socket head plug 10, screw the
plug into the housing and tighten it to the torque
shown below.
63.7± 6.4
[47 ± 4.7]
11-100
HYDRAULIC SYSTEM

valve components (1 thru 9)
Sequence
1 Sleeve
2 O-ring
3 O-ring
4 O-ring
5 Spring
6 Spool
7 O-ring
8 Solenoid valve assembly
9 Bolt
Load pressure unload solenoid valve components

(10 thru 14)
Sequence
10 Poppet
11 Filter
12 O-ring
13 Solenoid valve assembly
14 O-ring 208844

Electromagnetic proportional pressure control valve
(1) Fit O-rings 2, 3 and 4 on sleeve 1, then insert the
sleeve into the housing.
(2) Insert spring 5 and spool 6 into sleeve 1, paying
attention to the direction of spool 6.
(3) Fit O-ring 7 in the housing, then place solenoid
assembly 8 in position and secure it by tightening
socket head bolts 9 to the torque shown below.
15.7 ± 1.6
[11.6 ± 1.2]
Unload solenoid valve

(1) Fit filter 11 and O-ring 12 on poppet 10, then
install the poppet in the housing.
(2) Fit O-ring 14 on solenoid valve assembly 13, then
screw the solenoid valve assembly into the hous-
ing and tighten it to the torque shown below.
36.3 ± 3.9
[26.8 ± 3]
11-101
HYDRAULIC SYSTEM
Tilt Section
216107
Tilt valve components (1 thru 17)
Sequence
1 Tilt spool 5 Spring 9 Spring guide 13 Cap
2 Valve 6 Spring guide 10 Spring 14 O-ring
3 Spring 7 O-ring 11 Spring guide 15 Cap
4 Spring guide 8 Cap screw 12 Cap screw 16 O-ring
17 Bolt

Sequence
18 Valve 19 Spring 20 Plug 21 O-ring
Other components Reassembly of electromagnetic proportional pres-

O-rings are fitted in their grooves formed in the mating sure control valve
surfaces of this tilt section. Make sure they are cor- Follow the same procedure as that for the electromag-
rectly seated in the grooves. For the location and netic proportional pressure control valve of the lift sec-
quantity of O-rings, refer to the separate Parts Manual. tion. Refer to "Electromagnetic proportional pressure
control valve of 7.3.2 Reassembly of Valve Sections,
Valves Incorporated in Inlet Section (Part3)."
11-102
HYDRAULIC SYSTEM

Tilt valve
(1) Insert spool 1 into the valve housing carefully. Pay
attention to the direction of the spool (see illustra-
tion).
(2) Insert valve 2 and then spring 3 into spool 1.
Install spring guide 4, spring 5 and spring guide 6
on the spool, then screw cap screw 8 (fitted with
O-ring 7) into the spool and finger-tighten it.
(3) Install spring guide 9, spring 10 and spring guide
11 on spool 1, then screw cap screw 12 into the
spool and finger-tighten it.
(4) Using a hexagon wrench engaged in the socket in
each of cap screws 8 and 12, tighten the cap
screws to the torque shown below. Check the
spool for smooth movement.
40.2 ± 4.0
[30 ± 3]
(5) Fit O-ring 14 on cap 13, then secure the cap with
socket head bolts 17 by tightening them to the
torque shown below.
Fit O-ring 16 on cap 15, then secure the cap with
socket head bolts 17 by tightening them to the
torque shown below.
15.7 ± 1.6
[11.5 ± 1.0]
Load check valve

(1) Install valve 18 in the valve housing.
(2) Install spring 19.
(3) Fit O-ring 21 on plug 20, then screw the plug into
the housing and tighten it to the following torque.
63.7 ± 6.4
[47 ± 4.7]
11-103
HYDRAULIC SYSTEM
Attachment Section
8 8
Tightening torque:
34.3±3.4 N·m
12 11 9 10 (3.5±0.4 kgf·m)[25±2.5 lbf·ft]
A B
4 3 5 3 4 6
2 7 1 7 2 5
208846
Attachment valve components (1 thru 8)

Sequence
1 Attachment spool 4 Spring guide 7 O-ring
2 Spring guide 5 Cap screw 8 Bolt
3 Spring 6 Cap

Sequence
9 Valve 11 Plug 12 O-ring
10 Spring
Other components Reassembly of electromagnetic proportional pres-
O-rings are fitted in their grooves formed in the mating sure control valve
surfaces of this attachment section. Make sure they Follow the same procedure as that for the electromag-
are correctly seated in the grooves. For the location netic proportional pressure control valve of the lift sec-
and quantity of O-rings, refer to the separate Parts tion. Refer to "Electromagnetic proportional pressure
Manual. control valve of 7.3.2 Reassembly of Valve Sections,
In a 4-way type control valve, the shuttle valve should
be installed in the No.4 valve. For the installation pro-
cedure, refer to the relevant instructions in the "Inlet
Section,"
11-104
HYDRAULIC SYSTEM

Attachment valve
(1) Insert spool 1 carefully into the valve housing.
(2) On the right end of the spool, install spring guide
2, spring 3 and spring guide 4, then screw cap
screw 5 into the spool and finger-tighten it.
(3) Do the same operation as step (2) for the other
end of spool 1.
(4) Using a hexagon wrench engaged in the socket of
each cap screw, tighten both the cap screws to
the torque shown below. Check the spool for
smooth movement.
40.2 ± 4.0
[30 ± 3]
(5) Fit O-ring 7 on cap 6, place the cap in position and

secure it with socket head bolts 8 by tightening
them to the torque shown below.
15.7 ± 1.6
[11.5 ± 1.0]
Load check valve

(1) Install valve 9 in the valve housing.
(2) Install spring 10 in position.
(3) Fit O-ring 12 on plug 11, then screw the plug into
the housing and tighten it to the torque shown
below.
63.7 ± 6.4
[47 ± 4.7]
11-105
HYDRAULIC SYSTEM
End Cover Section
216108
Bleed-off valve components (1 thru 7)
Sequence
1 Spool 5 Spring
2 Orifice 6 Plug
3 Plug 7 O-ring
4 O-ring

Bleed-off valve Unload solenoid valve
(1) Screw orifice 2 into spool, then insert the spool Refer to "Unload solenoid valve of 7.3.2 Reassembly
carefully into the housing. of Valve Sections, Valves Incorporated in Inlet Section
(2) Install spring 5 in position. (Part3)."
(3) Screw socket head plugs 3 and 6 fitted with O-

rings 4 and 7 into the housing and tighten them to Relief valve
the torque shown below. Refer to "Relief valve of 7.3.1 Disassembly of Individ-
Unit: N·m (kgf·m) [lbf·ft] ual Valve Sections, Inlet Section."
147 ± 14.7
Tightening torque (15 ± 1.5)
[108 ± 10] Filter
Refer to "Filter of 7.3.2 Reassembly of Valve Sections,
11-106

8B100 11

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

8B100 11

Загружено:

Авторское право:

Доступные форматы

Chapter 11 HYDRAULIC SYSTEM

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

Chapter 11 HYDRAULIC SYSTEM

1. Structure and Functions

Main components and their Functions

[MAX 1595.6 psi]

Flow regulator valve

Parking brake Set pressure

Main relief pressure LS port relief pressure

Flow regulator valve

Main relief pressure

1.4 Hydraulic Tank

Thus, parts inside the tank can be removed as an

1.5 Hydraulic Pump (Gear Pump)

Pump installed on transmission

1.6 Control Valve

1.6.1 MC Control Valve

Most of the hydraulic control valves move mechani-

1.6.2 FC Control Valve

This hydraulic control is a mechanically-controlled

1.7 Flow Regulator Valve (models with FC control valve only)

From control valve To control valve

1.8 Down Safety Valve

When in normal condition When piping is broken

1.9 Lift Cylinder

Bottom end Top end

Passage C Chamber A Space B

Note: Dimensions of the parts marked * vary accord-

The lift cylinder raises and lowers the mast.

1.9.2 Duplex Mast Second Cylinder

Bottom end Top end

GP50CN, GP50N, GP55N, DP50CNM, DP50NM, DP55NM

Note: Dimensions of the parts marked * vary accord-

1.9.3 First Cylinder of Duplex Mast and Triplex Mast

Bottom end Top end

8 Passage C Chamber A Space B

Note: Dimensions of the parts marked * vary accord-

This cylinder, installed in the center of the mast, is the

1.10 Tilt Cylinder

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

2. Disassembly and Reassembly

Notes during removal:

2.1.2 Disassembly and Reassembly

Parts marked * are components of the seal kit.

Inspection and Repair

2.2 Lift Cylinder

Suggestions for Removal

(3) Disconnecting high-pressure hoses

(4) Removing set bolts

(b) Place wood blocks under the inner mast to

(5) Removing lift cylinders

Duplex and Triplex Mast Removal

Suggestions for Removal

(2) Removing first lift cylinder

(3) Removing second lift cylinders

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

(d) Tie a wire rope to the second lift cylinder from

2.2.2 Disassembly and Reassembly

Unit: N·m (kgf·m) [lbf·ft]

Apply grease when assembling.

Apply DELO 5249 when screwing in.

Suggestions for Disassembly