You are on page 1of 68

HYDRAULIC SYSTEM

Structure and Function .........................................................................10 – 1


Hydraulic Line ...........................................................................................10 – 1
Hydraulic Tank ..........................................................................................10 – 2
Hydraulic Pump (Gear Pump) ...................................................................10 – 3
Control Valve ............................................................................................10 – 4
Inlet Cover ................................................................................................10 – 5
Lift Valve ...................................................................................................10 – 6
Tilt Valve ...................................................................................................10 – 7
Attachment Valve ......................................................................................10 – 8
Flow Regulator Valve ................................................................................10 – 9
Down Safety Valve .................................................................................... 10 – 10
Lift Cylinder ............................................................................................... 10 – 11
Tilt Cylinder ............................................................................................... 10 – 14
Schematic of the Hydraulic System .......................................................... 10 – 15
Piping of the Hydraulic System ................................................................. 10 – 16
Removal and Installation ...................................................................... 10 – 17
Hydraulic Pump (Gear Pump) ................................................................... 10 – 17
Control Valve ............................................................................................ 10 – 18
Lift Cylinders ............................................................................................. 10 – 20 10
Tilt Cylinders ............................................................................................. 10 – 26
Hydraulic Pump (Gear Pump) ............................................................. 10 – 27
Disassembly ............................................................................................. 10 – 27
Inspection and Repair ............................................................................... 10 – 28
Reassembly .............................................................................................. 10 – 29
Control Valve ........................................................................................... 10 – 30
Disassembly ............................................................................................. 10 – 30
Inspection and Repair ............................................................................... 10 – 31
Reassembly .............................................................................................. 10 – 31
Lift Cylinders ........................................................................................... 10 – 32
Simplex Mast Cylinder/Triplex Mast Second Cylinder ............................... 10 – 32
First Cylinder of Duplex Mast and Triplex Mast ......................................... 10 – 36
Second Cylinder of Duplex Mast (GP40K, GP40KL, DP40K, DP40KL) ..... 10 – 39
Second Cylinder of Duplex Mast (GP45K, GP50K, DP45K, DP50K) ........ 10 – 42
Tilt Cylinders ............................................................................................ 10 – 44
Disassembly ............................................................................................. 10 – 44
Inspection and Repair ............................................................................... 10 – 45
Reassembly .............................................................................................. 10 – 47
Flow Regulator Valve ............................................................................. 10 – 48
Disassembly ............................................................................................. 10 – 48
Inspection and Repair ............................................................................... 10 – 48
Reassembly .............................................................................................. 10 – 48
Down Safety Valve ................................................................................. 10 – 49
Disassembly ............................................................................................. 10 – 49
Inspection ................................................................................................. 10 – 49
Reassembly .............................................................................................. 10 – 49
Inspection and Adjustment ................................................................. 10 – 50
Hydraulic Tank .......................................................................................... 10 – 50
Hydraulic Pump Test Run ......................................................................... 10 – 51
Control Valve ............................................................................................ 10 – 52
Main Relief Valve ...................................................................................... 10 – 53
Steering System Relief Valve .................................................................... 10 – 54
Flow Regulator Valve ................................................................................ 10 – 55
Lift and Tilt Cylinders ................................................................................ 10 – 55
Testing ....................................................................................................... 10 – 57
Troubleshooting ...................................................................................... 10 – 58
Service Data ............................................................................................ 10 – 62
HYDRAULIC SYSTEM

Structure and Functions

Hydraulic Line

7 15
16

12

11 2
19
20
5 18
14

10

4 17 1 13

9 6

208749

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


2 Hydraulic pump 9 Lift cylinder (L.H.) 16 Steering cylinder
3 Pump delivery hose 10 Flow regulator valve 17 Oil return line from steering
4 Control valve inlet cover 11 End cover section valve
section 12 Return line 18 Hydraulic tank
5 Hydraulic control valve 13 Return filter 19 Breather
6 Tilt cylinder (L.H.) 14 Oil feed line to steering 20 Cap
7 Tilt cylinder (R.H.) valve

The hydraulic system of this truck includes the mast (1) Lift control valve section
control circuit and the full-hydraulic steering system (2) Tilt control valve section
circuit. (3) Attachment control valve section
The oil drawn by the hydraulic pump 2 from the The lift control valve section controls the operation of
hydraulic tank 18 flows into the control valve inlet the lift cylinders 8 and 9 to raise or lower the mast.
cover section 4 through the pump delivery hose 3. The tilt control valve section controls extension and
The flow priority valve in the control valve inlet cover retraction of the tilt cylinders 6 and 7 to cause the mast
section 4 preferentially distributes the oil to the steering to lean forward or backward.
valve 15 through the oil feed line 14. The priority valve The attachment control valve section controls the
distributes the remainder of the oil to the mast control operation of the attachment actuators.
circuit. In the standard configuration, the following
three valve sections are used for the mast control The return oils from the steering valve and mast control
purposes: cylinders go to the hydraulic tank through the control
valve's end cover section 11 and return hose 12.
10-1
HYDRAULIC SYSTEM

Hydraulic Tank

1 2 8 7

To hydraulic
6 pump

From control valve

Closed by a plug.

3 5 4

208750

1 Cap 5 Return filter


2 Oil level gauge 6 Return pipe
3 Drain plug 7 Air breather
4 Suction strainer 8 Tank cover

The hydraulic tank is made of welded steel plates and


located at mid-portion of the right side frame, forming an
integral part of the frame.
In addition to an air breather 7, the hydraulic tank is
equipped with a suction strainer 4 (100 meshes) and a
return filter 5 (25 microns) to keep the oil clean.
The return filter has a built-in relief valve. The hydraulic
oil normally flows through the filter before it returns to the
hydraulic tank. If the filter is clogged, the relief valve
opens, allowing the oil to bypass the filter and return
directly to the tank.
When the truck is in operation, the inside of the tank is
always kept pressurized by the functions of the cap and
breather. This helps prevent ingress of dust into the tank
and improve the efficiency of the pump.

10-2
HYDRAULIC SYSTEM

Hydraulic Pump

Hydraulic pump
Engine
Universal joint

208805

This is a hydraulic pump capable of developing very high


pressure on its discharge side. A special arrangement is
incorporated in the pump construction for the purpose of
keeping to a minimum the clearance between the side plate
and pump gear.

Hydraulic Pump (Gear Pump)

208696

1 Mounting flange 6 Cover 11 Bushing


2 Body 7 Oil seal 12 Gasket
3 Drive gear 8 Snap ring 13 Plain washer
4 Driven gear 9 Backup strip 14 Hex socket head bolt
5 Side plates 10 Gasket (3-shaped)

10-3
HYDRAULIC SYSTEM

Control Valve

6 2 3 4

7 8
This illustration shows the three-valve type. 202974A

1 Inlet cover (incorporating flow priority valve) P: From hydraulic pump


2 Lift valve PF: To steering control valve
3 Tilt valve (incorporating tilt lock valve) T1: To hydraulic tank
4 Attachment valve T2: From steering control valve
5 End cover A1: To lift cylinder (to flow regulator valve)
6 Main relief valve
7 Steering system relief valve
(PF port relief valve)
8 Plug [Overload relief valve (optional)]

The control valve is a combination of different valves The main relief valve 6 is a safety valve that regulates
as shown above. The inlet cover 1 incorporates the flow the pump delivery pressure below the maximum level
priority valve which distributes oil to the steering to prevent the hydraulic system from being damaged by
system in an amount sufficient for assisting the steering an excessive pressure.
operation regardless of the delivery rate of the The steering system relief valve 7 is also a safety valve.
hydraulic pump. The flow priority valve distributes the This valve regulates the power steering system pressure
excess oil for the forklift operation. (The flow priority to a level below the maximum pressure.
valve is also called “flow divider valve.”)
Another safety valve is the overload relief valve which
The tilt valve 3 has a spool with a built-in tilt lock prevents the attachment hydraulic devices from being
valve. The purpose of the tilt lock valve is to prevent damaged by excessive pressures.
the mast from tilting when the engine is not in
operation.

10-4
HYDRAULIC SYSTEM

Inlet Cover

208697

1 Inlet cover P: From hydraulic pump


2 Flow priority valve spool PF: To steering control valve
3 Main relief valve P1: To mast control valve (for lifting, tilting and
4 Steering system relief valve attachment control)
T2: Low pressure port (to hydraulic tank)

The illustration above shows the state when oil is not To summarize, the flow priority valve, regardless of the
being supplied from the port P into the inlet cover. pump delivery rate, ensures that the steering system
When a small amount of pump oil is being supplied to receive a constant volume of oil at all times while
the inlet cover: diverting surplus oil to the mast control circuits.

The oil from port P flows through a passage in the flow The main relief valve 3 is a safety valve that prevents
priority valve spool 2, past an orifice, and then enters the pressure in port (P1) from becoming higher than
port PF without flowing to port (P1). This means that the permissible maximum pressure. The valve has been
the steering system can always receive oil by priority. set to open at 19.1 + 00.5 MPa (195 + 05 kgf/cm2) [2773 + 071
psi]. The valve allows oil to flow from port (P1) to
When the pump starts supplying an increased amount
port T2 if the pressure in port (P1) exceeds the limit.
of oil to the inlet cover:
The steering system relief valve 4 is a safety valve that
Oil flows through the flow priority valve spool 2 in the
prevents the pressure in port PF from becoming higher
same way as when the inlet oil supply amount is small.
than the permissible maximum pressure. The valve has
However, increase in flow of oil causes the difference
been set to open at 8.3 + 00.4 MPa (85 + 05 kgf/cm2) [1209
in pressure before and after the orifice to become larger + 71
0 psi]. The valve allows oil to flow from port PF to
than before. In addition, the pressure oil from the
port T2 if the pressure in port PF exceeds the limit.
pump flows into the cavity on the right-hand end of the
valve spool 2. As a result, the valve spool 2 is pushed
against the force of the spring to the left, opening port
P to port (P1), which allows surplus oil to flow into
port (P1).

10-5
HYDRAULIC SYSTEM

Lift Valve

208698

1 Spool A1: To lift cylinder


2 Return spring B1: Blind (plugged)
3 Load check valve T2: Drain port (to hydraulic tank)

The illustration above shows the lift valve with the Lift down position:
spool 1 in the neutral position. The spool moves to the left (in the illustration), opening
Neutral position: port A1 to port T2. The oil in the lift cylinder is then
pushed out by the load acting on the cylinder piston and
The high pressure port of the lift valve is open to the
flows through ports A1 and T2 and back to the tank, at
passage leading to port (P1) of the inlet cover. As the
a rate controlled by the flow regulator valve.
center bypass port is open in this state, the oil in the
high pressure port eventually returns to the hydraulic Pump-delivered oil flows through the high pressure port
tank via port T1 in the end cover. and then through the center bypass port to the hydraulic
tank. The spool 1 is returned to the neutral position by
Lift up position: the force of the return spring 2.
When the lift lever is pulled towards the operator, the
spool 1 moves up (moves to the right in the
illustration), opening passage A to port A1 while at the
same time closing the center bypass port. This causes
the pressure in the high pressure port to rise. The
increased pressure pushes open the load check valve 3.
As passage A opens to the high pressure port as a
result, pressure oil eventually flows into port A1.

10-6
HYDRAULIC SYSTEM

Tilt Valve

208699

1 Spool 4 Tilt lock valve A2: To tilt cylinder rod end


2 Return spring 5 Tilt lock valve spring B2: To tilt cylinder head end
3 Load check valve T2: Drain port

The illustration above shows the state of the tilt valve Tilt backward position:
with the spool 1 in the neutral position. The spool 1 is moved to the right, closing the center
Neutral position: bypass port. Since this blocks the flow of oil from the
high pressure port, the oil of increased pressure pushes
The center bypass port is open. This allows the pump- open the load check valve 3 and makes its way into
delivered oil to flow to the hydraulic tank through the passage A. As the spool 1 has moved to the right
center bypass port and port T1 in the end cover. The opening passage A to port A2, the oil flows to port A2
oil does not flow to ports A2 and B2 as the passages to and its pressure acts in the direction in which the tilt
the ports are blocked by spool 1. cylinder rod is retracted in the cylinder.
Tilt forward position: As ports B2 and T2 are now open to each other, the oil
The spool 1 is pushed to the left, closing the center in the head end of the tilt cylinder returns to the tank.
bypass port. This causes the pressure in the high In combination with the oil flow mentioned above, this
pressure port to rise. The increased pressure pushes enables the tilt cylinder rod to be retracted in the
open the load check valve 3 allowing pressure oil to cylinder or the mast to be tilted rearward.
flow into passage A. The pressure oil in passage A then The tilt lock valve 4 is a safety valve, provided to
flows into port B2 and acts on the tilt cylinder rod to prevent the mast from tilting forward when the engine
extend it forward, that is, to tilt the mast forward. is not running. To be more specific, with the engine
The pressure oil in passage A also flows to the tilt lock shut down, pump pressure does not act on the tilt lock
valve 4 and pushes the valve to the left against the force valve, so the valve blocks the oil in port A2. Since the
of the spring 5. This opens port A2 to port T2, oil cannot move anywhere, the tilt cylinder rod is kept
allowing the oil in the rod end of the tilt cylinder to unextended. The oil in port A2 remains blocked even if
return to the tank. In combination with the oil flow the valve is moved to “the tilt forward” side while the
mentioned above, this enables the tilt cylinder rod to engine is stationary. This means that the mast does not
extend forward. tilt forward.
10-7
HYDRAULIC SYSTEM

Attachment Valve

208700

1 Spool A3: To attachment actuator


2 Return spring B3: To attachment actuator
3 Load check valve T2: Drain port
4 Plug assembly

The illustration above shows the attachment valve with Spool in the extended position:
the spool 1 in the neutral position. The flow of oil is reverse to that for when the spool is
Spool in the neutral position: retracted. The spool 1 is returned to the neutral
position by the force of the return spring 2.
The center bypass port is open. This allows the pump-
delivered oil to flow to the hydraulic tank through the The plug assembly 4 provides the operator with means
center bypass port and port T1 in the end cover. The to manually operate the actuator by loosening the plug
oil does not flow to ports A3 and B3 as the passages to 4 should the actuator become inoperative for some
the ports are blocked by spool 1. reasons.

Spool in the retracted position: The attachment actuator circuit pressure can be
regulated below a certain limit pressure if a pressure
When the spool 1 is retracted, the center bypass port is
relief valve is installed in place of the plug.
closed. This results in the pressure in the high pressure
port being increased. The increased pressure pushes
open the load check valve 3 allowing the pump
pressure oil to flow through passage A and into port
B3. The attachment actuator is then operated. The oil
in port A3 flows through the passage shown on the left-
hand side of the illustration to port T2 and then to the
tank.

10-8
HYDRAULIC SYSTEM

Flow Regulator Valve

C 1 3 2 5
D

A1 B

Flow of oil to be regulated


To lift cylinder
208701

1 Piston A1: Cavity communicating with port A1 in lift


2 Spring control valve
3 Check valve B: Opening in piston 1 (4 pieces)
4 Plug C: Opening in piston 1 (8 pieces)
5 Lock nut D: Cavity

The flow regulator valve regulates the lowering rate of In addition to giving the spring chamber a damping
the mast lift cylinder. effect that regulates the return speed of the spring, the
The arrow in the illustration indicates the direction in check valve 3 prevents the mast from lowering in a
which oil flows when the fork is lowering. jerky manner. The flow rate of oil can be adjusted by
loosening or tightening the plug 4 to change the force
When the mast is lowering, the oil in the bottom end of
of spring 2.
the lift cylinder is pushed out by the weight of the load
carried by the mast and, after passing through the flow When the mast is rising, the oil goes to the lift cylinder
regulator valve, flows back to port A1 in the lift control flowing in the direction reverse to that of the lowering
valve. phase. As the piston 1 now moves fully to the left, no
restriction is given to the flow of oil.
The oil from the lift cylinder enters cavity D and flows
into the piston 1 through eight openings C. The oil
then flows through four openings B, into cavity A1, and
back to port A1 in the lift control valve.
When the flow rate of the return oil becomes excessive,
the piston 1 moves to the right against the force of the
spring 2. As the result of the piston movement,
openings B are narrowed and thus the flow rate of oil
passing these openings is reduced. In this way, the
maximum flow rate of the return oil and thus the
maximum lowering speed of the mast is regulated
regardless of the weight of the load on the mast.

10-9
HYDRAULIC SYSTEM

Down Safety Valve

Unregulated flow (from regulator valve)

Stamped 1
identification
number

3
4

2
Opening

Regulated flow (from bottom of cylinder)

208582

1 Connector 3 Spring
2 Valve 4 Spring pin

The down safety valve is located at the bottom of the If the hose becomes damaged, for example, an
LH lift cylinder (applicable only to the simplex mast). unusually large volume of oil flows out of the relevant
Even if the flow of the oil returning from the lift cylinder's bottom towards the flow regulator valve.
cylinders becomes excessive due to a defect in the This oil flow forces the valve 2 to move up against the
piping between the lift cylinders and flow regulator force of the spring 3, The valve then narrows the
valve or due to a poor adjustment of the flow regulator opening in it and thus the flow of oil from the cylinder
valve, the down safety valve prevents sudden drop of is restricted. This prevents the mast from dropping
the mast by regulating the outgoing oil flow of the lift suddenly.
cylinders.

Identification
Truck Model
No.

GP40K, GP40KL, DP40K, DP40KL 90

GP45K, GP50K, DP45K, DP50K 120

10-10
HYDRAULIC SYSTEM

Lift Cylinder
Simplex Mast Cylinder/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
Chambar A Space B
8 9 Passage C
208702

Main components
1 Retainer *4 Spacer 7 Wear ring
*2 Shell assembly 5 Check valve 8 Cushion sleeve
*3 Rod 6 Piston seal 9 Piston

NOTE
Dimensions of the parts marked * vary according to Oil passage at bottom of
piston becomes narrower
specifications (lift height). as piston moves down.
8

The lift cylinder raises and lowers the mast.


When the operator performs mast raising control, the
pressure oil from port A1 of the lift valve acts on the 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 assembly 2 and the rod 3 flow
through passage C and into chamber A. When the pressure
in chamber A has reached 1.9 MPa (19 kgf/cm2) [275 psi], 208703
the check valve 5 starts to open, releasing the trapped oil
and air into pressure oil.
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 bottom 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 contact between the piston and
cylinder head, providing the cylinder with a down-stroke
cushioning feature.
10-11
HYDRAULIC SYSTEM

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

208704

Main components
1 Retainer 5 Piston
*2 Shell assembly 6 Piston seal
*3 Rod 7 Wear ring
4 Stand tube 8 Check valve

NOTE
Dimensions of the parts marked * vary according to
specifications (lift height).

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


to operate in the rising phase of the mast.
When the operator performs mast raising control, the
pressure oil from port A1 of the lift valve acts on 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, releasing 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.
10-12
HYDRAULIC SYSTEM

Second Cylinder of Duplex Mast

GP40K, GP40KL, DP40K, DP40KL


To lift valve 7 6 5 4 3 2 1 To first cylinder
From lift valve
From first cylinder

Bottom end Top end

Plug (shipped and


Plug (shipped and 9 8 storage)
storage) 208705
GP45K, GP50K, DP45K, DP50K
7 6 5 4 3 2 1

9 8 208706

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

NOTE
Dimensions of the parts marked * vary according to
specifications (lift height).

The duplex mast second cylinder has a function of In the mast lowering phase, the second cylinder
raising and lowering the duplex inner mast. This operates before the first cylinder.
cylinder starts to operate after the first cylinder has The cushion sleeve 9 prevents the bottom of the piston
completed its operations. 5 from ramming onto the cylinder head at the last stage
When the operator performs mast raising control, the of the piston down-stroke through the process described
pressure oil from port A1 of the lift valve enters the below.
inlet port of the cylinder. The oil then flows through During a down-stroke of the piston, the oil at the
the inside of the rod 3, comes out of the outlet port, and bottom of the piston is forced to flow through the gap
goes to the first cylinder. Since the bore of the first between the inner wall of the sleeve 9 and the cylinder
cylinder is larger than that of the second cylinder, the head. The gap becomes smaller as the piston moves
piston in the first cylinder receives oil pressure with a down, further limiting the flow of oil. This prevents
larger area than the piston in the second cylinder. This large impact that would otherwise occur by hard
makes the first cylinder operate at a lower oil pressure contact between the piston and cylinder head, providing
than the second cylinder. In other words, the first the cylinder with a down-stroke cushioning feature.
cylinder operates first, with the second cylinder starting See the illustration (illustration No. 208703) on page 10-
to operate only after the first cylinder has completed its 11.
operations.
The bleed screw 8 is provided to purge air from the
Pressure oil acts on the bottom of the piston 5, pushing system.
up the piston and rod 3 together.
10-13
HYDRAULIC SYSTEM

Tilt cylinder

208707

Main components
1 Cylinder tube 6 Guide bushing 11 Spacer
2 Rod 7 Dust seal 12 Shim
3 Piston 8 Packing 13 Tilt socket
4 Piston seal 9 O-ring 14 Clamp bolt
5 Self-locking nut 10 Collar

The tilt cylinder is of a double-acting design that Tilting forward:


enables it to tilt the mast both forward and rearward. Pressure oil enters port B while the oil in the other end
Hydraulically, port A2 of the tilt valve is connected to of the cylinder being forced out through port A . As a
the rod end of the cylinder while port B2 of the tilt result, the rod 2 is extended from the cylinder, which
valve is connected to the head end of the cylinder. tilts the mast forward.
Tilting mast rearward: The forward tilt angle can be altered substantially by
Pressure oil enters port A while the oil in the other end replacing the collar 10. Using a longer collar reduces
of the cylinder being forced out through port B . As a the forward tilt angle.
result, the rod 2 is retracted into the cylinder 1, which On the standard-specification models, the forward and
tilts the mast rearward. rear tilt angles are set at 6° and 10°, respectively; they
The rear tilt angle can be altered substantially by are not provided with the collar 10, spacer 11 and
replacing the spacer 11 and shims 12. Using a longer shims 12.
spacer reduces the rear tilt angle. The LH and RH cylinders can be equalized by
loosening the relevant clamp bolt 14 and then turning
the cylinder rod in or out. This adjustment should be
carried out with the cylinders connected to the mast.

10-14
Hydraulic control valve
T1
Steering valve

A5 B5
R L

A4 B4
T P Steering cylinder
Schematic of Hydraulic System

A3 B3
STD tilt cylinder

Flow reg. valve

A2 B2
Engine
GP/DP40K, 40KL: TB45: 72 kW/2450 rpm
100 liter (26.4 U.S. gal.)/min P S6S : 62.7 kW/2450 rpm
GP/DP45K thru 50K: T M Coupling: Universal joint ratio 1:1

B1
115 liter (30.4 U.S. gal.)/min

10-15
A1
Return Suction
filter strainer Hydraulic Pump
Displacement:
3
50 cm (3.05 cu in.)/REV

P PF T2

Lift cylinder
with down safety
Steering relief Main relief
+0.4 +0.5
11.8 0 MPa 19.1 0 MPa
+2 +5
(120 0 kgf/cm2) (195 0 kgf/cm2)
+71 +71
[1714 0 psi] [2773 0 psi]

208806
HYDRAULIC SYSTEM
Steering cylinder
Tilt cylinder
HYDRAULIC SYSTEM

Lift cylinder
(R.H.) Steering valve
Piping of Hydraulic System

Return hose

Pump delivery hose

T1 Hydraulic pump
(gear pump)
End cover

10-16
Breather Cap
Attachment
Lift cylinder
(L.H.) Tilt
B2 A2
A1 Lift Level gauge
P PF
Down safty
valve

T2 Inlet cover
(with flow priority valve) Suction strainer Return filter

Flow regulator valve Flare


Tube
High-pressure hose
Tilt cylinder Low-pressure hose

208807
HYDRAULIC SYSTEM

Removal and Installation

Hydraulic Pump (Gear Pump)


Removal

208583

Sequence
1 Universal joint 4 Suction hose, Elbow, O-ring
2 Drive pulley, Lock nut, Boss 5 Hydraulic pump
3 Main delivery hose, Connector, O-ring

Start by: Installation


(1) Remove the counterweight. To install, follow the reverse of removal sequence.
(2) Loosen the fan belt. Tighten the counterweight mounting bolts, pump
(3) Using the two wrenches indicated below, unscrew lock outlet connector and main hose to the specified
nut 2 of the drive pulley. torques.

Special tools needed


490 to 539 N·m
Counterweight
Wrench 91268 - 00100 (49 to 54 kgf·m)
bolts
[361 to 397 lbf·ft]
Wrench 91868 - 00100
118 N·m
Tightening Pump outlet
(12 kgf·m)
torque connector
NOTE [87 lbf·ft]

The drive pulley lock nut has a left-hand thread. 118 N·m
Main hose (12 kgf·m)
[87 lbf·ft]

10-17
HYDRAULIC SYSTEM

Control Valve
Removal

1
3

8
4

6
7

208584

Sequence
1 Control lever assembly, Clevis pin 6 Steering delivery pipe
2 Attachment pipe 7 Pipe and hose assembly
3 Tilt pipes, Connectors, O-rings 8 Return hose, Connector
4 Lift pipe 9 Control valve
5 Main delivery hose, Elbow, O-ring

Start by:
(1) Before disconnecting the pipes from the control valve,
bring the mast to the vertical position and place the fork
to the lowest position in order to release the residual
pressure in the pipes.
(2) Support the weight of the mast with a crane.
(3) If an attachment is connected, take necessary measures
to prevent it from moving.
(4) Remove the floor plate and dashboard cover.

10-18
HYDRAULIC SYSTEM

Installation
Perform installation by following the removal sequence in
reverse. Also follow the instruction given below.
(1) When screwing connectors into the control valve,
tighten them to the following torque.

118 N·m
Tightening torque (12 kgf·m)
[87 lbf·ft]

(2) Tighten the fittings of steering delivery valve pipe 6 to


a torque within the following range.

39 to 49 N·m
Tightening torque (4 to 5 kgf·m)
[28.7 to 36.1 lbf·ft]

(3) Tighten the fittings of pipe and hose assembly 7 to a


torque within the following range.

39 to 49 N·m
Tightening torque (4 to 5 kgf·m)
[28.7 to 36.1 lbf·ft]

(4) Adjust the center-to-center distance A of the devices on


both ends of the control lever to the following
dimension.

193 ± 0.5 mm
in.)

Distance A
(7.6 ± 0.02 in.)
0.8
m(
20m

208585

10-19
HYDRAULIC SYSTEM

Lift Cylinders
Removal (Simplex Masts)

208711

Sequence
1 Nuts 5 Stopper bolt, Shims
2 Lift bracket, Forks 6 Cylinder clamp, Cushion, Collar, Shims
3 Cylinder guard 7 Lift cylinder, Bracket
4 High-pressure hose

Suggestions for Removal

1. Separating lift bracket


(1) Tilt the mast forward, and lower the inner mast to the
bottom. Unscrew the chain anchor bolts, and put the
chains over the backrest. It is not necessary to remove
the forks.
(2) Place the mast to a vertical position. Raise the inner
mast, and back the truck away, leaving the lift bracket
assembly standing on the floor.

207084

10-20
HYDRAULIC SYSTEM

2. Disconnecting high-pressure hoses


Right cylinder Left cylinder
Disconnect the high-pressure hoses at the joints indicated
by arrows. Use a drip pan to catch oil flowing out of the
hoses.

208587

3. Removing stopper bolts


(1) Remove the stopper bolts at the top of each lift cylinder.
Lift the inner mast to separate the cylinder rod ends. To
lift the inner mast, hitch a sling to the mast with
protective rag.

NOTE
The rod end of either lift cylinder is shim adjusted to
eliminate the difference in stroke between the
cylinders. Before removing the stopper bolts, make a Shim
record of the amount of shims and a cylinder to which 208588

the shims are fitted.

(2) Place wood blocks and fasten them under the inner mast
and detach the sling. Use the blocks strong enough to
support the mast.

202983

10-21
HYDRAULIC SYSTEM

4. Removing lift cylinders


Attach a sling before removing the cylinder clamp. Lift the
cylinder from the rear side of the mast, and remove the
cylinder.

Shim

208589

Installation
To install, follow the reverse of removal sequence, and do
the following steps:
(1) Extend and retract the lift cylinders several times under
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
(2) Check the oil level in the hydraulic tank with an oil
level gauge. (Refer to the topics “Hydraulic Tank” in
the following section “Inspection and Adjustment.”)
(3) Check the lift height.
(4) After the lift cylinders or piston rods have been
replaced, check for difference in stroke between the two
cylinders. (Refer to the “GROUP 11 MASTS AND
FORKS.”)

10-22
HYDRAULIC SYSTEM

Lift Cylinders
Removal (Duplex and Triplex Masts)
Note that the Triplex Mast is used as an example.

207785

Sequence
1 Nuts 4 Chain wheel support assembly
2 Lift bracket assembly 5 Second lift cylinders
3 First lift cylinder

Suggestions

1. Removing lift bracket assembly 2


(1) Lower lift bracket assembly 2, and place wood blocks
under the assembly. Tilt the mast forward, lower the
inner mast to the bottom, then remove nuts 1 from the
anchor bolts of the first lift chains.

207786

10-23
HYDRAULIC SYSTEM

(2) Position the mast vertical. Raise the inner mast until
main rollers 6 of lift bracket assembly 2 become free.
Then, slowly move the truck backward to separate from
lift bracket 2.

201735

2. Removing first lift cylinder 3


(1) Hitch a sling to first lift cylinder 3, and suspend the
cylinder with a crane. Wind the sling securely to
prevent from slipping.
(2) Remove the lift cylinder connecting and mounting
bolts, and gently dismount first lift cylinder 3.

207787

3. Removing second lift cylinders 5


(1) Disconnect hoses from second lift cylinders 5.
(2) Remove stopper bolts at the upper sections of second
lift cylinders 5, and lift the inner mast (for simplex
mast) or middle mast (for triplex mast) approximately
550 mm (21.67 in.) using slings.

207788

10-24
HYDRAULIC SYSTEM

(3) Place wood blocks under the inner mast (for duplex
mast) or middle mast (for triplex mast).
Make sure the right and left wood blocks are the same
in height.

202983

(4) Hitch a sling to second lift cylinder 5 behind the mast,


remove cylinder clamp retaining bolts, and gently
remove second lift cylinder 5.
Wind the sling securely to the cylinder. The cylinder
cannot be lifted straight up since the mast cross-
member is located above the cylinder. Tilt the cylinder
and move it away from the cross-member to remove.
Be careful not have the hands caught between the
cylinder and mast.

207789

Installation
To reinstall, follow the removal sequence in reverse, and
service as follows.
(1) Install chain wheel support assembly 4 parallel to a line
connecting the centers of chain anchor bolt holes on
first lift cylinder 3 to prevent chains from twisting.
(2) Adjust the chain tensions.
(See the “Inspection and Adjustment” section.)
(3) Extend and retract the lift cylinders several times under 207638
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
(4) After proper operation is confirmed, check the oil level.

10-25
HYDRAULIC SYSTEM

Tilt Cylinders
Removal
Sequence
1 Tilt cylinder pin
2 Hoses
3 Tilt cylinder pin
4 Tilt cylinder
2

208590

Start by:
(1) Lower the forks to the bottom, and tilt the mast
fully forward.
(2) Attach a sling to the round holes, right and left, in
the top cross-member of outer mast, and support
the weight of the mast with a hoist.

202778

Suggestions for Removal Suggestions for Installation

1. Retracting piston rod Tighten the hose fittings to the following torque.
Remove tilt cylinder pin 1, start the engine and retract 47 ± 4.7 N·m
the piston rod fully, then stop the engine. Tightening torque (4.8 ± 0.5 kgf·m)
[34.6 ± 3.5 lbf·ft]
2. Disconnecting hoses
Disconnect hoses 2 from the cylinder at the connectors.
Use a drip pan to catch oil flowing out of the cylinder.
Attach caps to the connectors of the cylinder to protect
the threads of the connectors and to prevent oil from
flowing out of the cylinder when the cylinder is
removed.

10-26
HYDRAULIC SYSTEM

Hydraulic Pump (Gear Pump)

Disassembly

12
8

9
❋ 15
7
❋ 13
6
15
17 15
16 ❋ 14
❋ 3
❋ 15
5
4 ❋

11
1

10

208591

Sequence
1 Bolt 6 Front cover 10 Body 14 Driven gear
2 Rear cover 7 Gasket 11 Side plate 15 Bushing
3 Gasket 8 Gasket 12 Side plate 16 Snap ring
4 Gasket 9 Backup strip 13 Drive gear 17 Oil seal
5 Backup strip

NOTE
Marked ❋ are the repair kit parts. The parts
marked are not available individually.

NOTE Suggestions for disassembly


(1) The hydraulic pump is to be overhauled by the (1) If gears 13, 14 and side plates 11, 12 are separated
manufacturer. Where it has to be overhauled in from body 10, it might be difficult to restore them
field, be sure to follow the suggestions for to the original state, resulting in defective pump
disassembly. Remember, field overhauling will performance. For this reason, remove the gears,
side plates and body as a set for replacement of the
release the manufacturer from any guarantee.
gaskets 3, 7.
(2) Do not remove oil seal 17 and bushings 15 (2) Front cover 6 and rear cover 2 are made of
unless they are defective to require replacement. aluminum alloy which is apt to be marred; never
give blows of a hammer to them.
Start by:
Remove the snap ring after removing the fan drive
pulley.
10-27
HYDRAULIC SYSTEM

Inspection and Repair

1. Drive and driven gears


(1) Check the gear teeth for wear, chipping or other defects.
(2) Check the end faces of the gears for wear or damage.
(3) Check the journals and splines of the shafts for wear or
damage.

2. Covers, body and bushings


Check these parts for wear or damage.

200344

10-28
HYDRAULIC SYSTEM

Reassembly

10❋,
2 7❋ 5❋, 6❋ 14 11❋ 12❋
9
18

15 4❋ 3❋ 1 16 13 17 8
208577
Sequence
Preassemble parts 1 to 7 before Preassemble parts 8 to 12 before Preassemble parts 13 to 17 before
installation. installation. installation.
1 Front cover 8 Rear cover 13 Body
2 Bushing 9 Bushing 14 Driven gear
3 Shaft seal 10 Gasket 15 Drive gear
4 Retaining ring 11 Backup strip 16 Side plate
5 Gasket 12 Gasket 17 Side plate
6 Backup strip 18 Bolt
7 Gasket

NOTE

Marked ❋ are the parts included in the repair kit.

Suggestions for Reassembly


(1) Replace the repair kit parts marked ❋ in the (7) Tighten the bolts progressively and evenly.
illustration when reassembling the hydraulic pump. (8) The pump is assembled properly if the pipe wrench
(2) Install rear cover 8 in the correct direction. fitted on the pump shaft can be turned easily by
(3) Completely remove oil or grease on the mating hand.
surfaces of covers 1, 8, and body 13.
(4) Visually check all the parts for cleanliness and
apply hydraulic oil to the inside surfaces of the
body 13 before reassembly.
(5) Apply grease to the lip of the shaft seal.
(6) Be careful not to give damage to the lip of shaft
seal by spline edges of drive gear 15.

10-29
HYDRAULIC SYSTEM

Control Valve

Disassembly

202999

Sequence
1 Main relief valve 13 Lift valve spool
2 Flow divider relief valve 14 Bolt, Cap
3 Bolt, Nut, End cover 15 Cap screw, Spring seat, Spring
4 Load check valve, Spring, O-ring 16 Plate, Wiper, O-ring
5 Plug 17 Tilt valve spool
6 Spring 18 Poppet (Tilt lock valve), Spring
7 Orifice plug 19 Bolt, Cap
8 Spool 20 Plug, O-ring
9 Housing (inlet) 21 Cap screw, Spring seat, Spring
10 Bolt, Cap 22 Plate, Wiper, O-ring
11 Cap screw, Spring seat, Spring 23 Plate, Wiper, O-ring
12 Plate, Wiper, O-ring 24 Attachment valve spool

10-30
HYDRAULIC SYSTEM

Suggestions for Disassembly


(1) Do not disassemble main relief valve 1 or flow divider
relief valve 2 unless it is impossible to adjust the setting
of the valve.
(2) Do not change the combination of valve housing and
spool.

Inspection and Repair


(1) Check the valve housings for cracks and sliding
surfaces for wear. Also, inspect the check valve seat for
wear.
(2) Check the spools for damage, seizure or distortion.
Also, check for operating effort.

Neutral
Operating 127 (12.9) [28.4]
N (kgf) [lbf]
effort of
spool Full stroke
158 (16.1) [35.5]
N·m (kgf·m) [lbf·ft]

(3) Check the poppet (tilt lock valve) for damage or


seizure.

Reassembly
To reassemble, follow the reverse of disassembly sequence,
and do the following steps:
(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Apply hydraulic oil to the spools when inserting them
into the valve blocks.
(3) Position the poppet (tilt lock valve) correctly.
(4) Apply grease to the O-rings when fitting them between
the valve housings to prevent them from twisting.
(5) Do not use any type of sealant. A

(6) Tighten the tie bolts (securing the valve housings) as


evenly as possible to prevent distortion of the housings.
Remember, a failure to follow this precaution will result
in sluggish movement of the spools.

Unit: N·m (kgf·m) [lbf·ft]


B
Tightening torque for tie bolts A 65 (6.6) [48]
205530
Tightening torque for tie bolt B 101 (10.3) [74]

10-31
HYDRAULIC SYSTEM

Lift Cylinders

Simplex Mast Cylinder/Triplex Mast Second Cylinder


Disassembly

208713

Sequence
Remove parts 1 to 5 as a subassembly. Remove parts 6 to 18 as a subassembly. 13 Circlip
1 Retainer 6 Rod 14 Washer
2 Wiper seal 7 Spacer 15 O-ring
3 Rod seal 8 Wear ring 16 Check valve
4 Backup ring 9 Piston seal 17 Pull-in wire
5 O-ring 10 Nylon seal 18 Piston
11 Retaining ring 19 Shell assembly
12 Sleeve

NOTE NOTE
Do not remove the wiper seal 2, rod seal 3 and The parts marked with an asterisk (❋) are repair kit
check valve 16 unless they are defective. parts.

10-32
HYDRAULIC SYSTEM

Suggestion for Disassembly

Removing piston rod


When withdrawing the piston rod from the shell, take care
not to damage the rings.

208714

Inspection and Repair

1. Shell assembly
(1) Check the bore wall for wear, grooving, scratching or
rusting.
(2) Check the welds for cracks or other defects.

2. Piston rod
(1) Check the rod for deflection on V-blocks with a dial
gauge as shown.
(2) Check for surface flaws such as grooving, scratching,
rusting or wear.

3. Piston seal and wear ring


(1) Check the piston seal and wear ring for damage or
deformation.
(2) Also check for deterioration due to aging.
200319

10-33
HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item

Inside diameter of shell 1 A 65 (2.56) 70 (2.76)

Outside diameter of rod 2 A 50.8 (2.0) 50.8 (2.0)

74.95 ± 0.05 83.00 ± 0.05


Outside diameter of retainer 3 A
(2.950± 0.002) (3.2677 ± 0.002)

39.85 ± 0.05 44.85 ± 0.05


Outside diameter of rod top 4 A
(1.568 ± 0.002) (1.765 ± 0.002)

1863 kPa 1863 kPa


Check valve set pressure 5 A (19 kgf/cm2) (19 kgf/cm2)
[275 psi] [275 psi]

325 to 353 N·m 352 to 380 N·m


Tightening torque for retainer 6 A (33 to 36 kgf·m) (36 to 39 kgf·m)
[240 to 260 lbf·ft] [260 to 280 lbf·ft]

5 6

2 1 4 3

208702A

10-34
HYDRAULIC SYSTEM

Reassembly

19 12 11 10 8 7 9 6 5 4 3 1
2

18 17 15, 16 14 13

208702B

Sequence
(1) Subassemble parts 1 to 5 prior to assembly.
(2) Subassemble parts 6 to 18 prior to assembly.
(3) Install the subassembly (piston and rod) of step (2)
above in the shell assembly 19, then install the
subassembly of step (1).

Suggestions for Reassembly


(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Apply hydraulic oil to the bore surface of shell and also
to the wiper seal, rod seal, piston seal and wear seal.
(3) When holding the shell in a vise, take care not to distort
the shell.
(4) Fill the cavity between the shell and rod with 25 to 30
cm 3 (1.53 to 1.83 cu in.) of hydraulic oil before
installing the retainer.
(5) Install the cushion sleeve with the slot at the front.
(6) Tighten the retainer to the torque specified below.

Truck Model
GP40K, GP40KL, GP45K, GP50K,
DP40K, DP40KL DP45K, DP50K
Item
325 to 353 N·m 352 to 380 N·m
Tightening torque
(33 to 36 kgf·m) (36 to 39 kgf·m)
for retainer
[240 to 260 lbf·ft] [260 to 280 lbf·ft]

10-35
HYDRAULIC SYSTEM

First Cylinder of Duplex Mast and Triplex Mast


Disassembly

208715

Sequence
Remove parts 1 to 5 as a subassembly. 9 Nylon ring
1 Retainer 10 Circlip
2 Wiper seal 11 Washer
3 Rod seal 12 O-ring
4 Backup ring 13 Check valve
5 O-ring 14 Pull-in wire
Remove parts 6 to 16 as a subassembly. 15 Stand tube
6 Rod 16 Piston
7 Wear ring 17 Shell assembly
8 Piston seal

NOTE NOTE
Do not remove the wiper seal 2, rod seal 3 and The parts marked with an asterisk (❋) are repair kit
check valve 13 unless they are defective. parts.

10-36
HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item

Inside diameter of shell 1 A 100 (3.937) 110 (4.330)

Outside diameter of rod 2 A 65 (2.559) 65 (2.559)

Outside diameter of retainer 3 A 117.16 (4.612) 130.00 (5.118)

516 kPa 516 kPa


Check valve set pressure 4 A (5.27 kgf/cm2) (5.27 kgf/cm2)
[75 psi] [75 psi]

515 to 542 N·m 569 to 596 N·m


Tightening torque for retainer 5 A (52 to 55 kgf·m) (58 to 61 kgf·m)
[380 to 400 lbf·ft] [420 to 440 lbf·ft]

4 5

2 1 3

208704A

10-37
HYDRAULIC SYSTEM

Inspection and Repair


Follow the instruction on page 10-33 for inspection.

Reassembly

17 14 12 8 9 10 11 16 7 15 6 5 4 3 1
2

13
208704B

Sequence
(1) Subassemble parts 1 to 5 prior to assembly.
(2) Subassemble parts 6 to 16 prior to assembly.
(3) Install the subassembly (piston and rod assembly) of
step (2) above in the shell assembly 17, then install the
subassembly (retainer assembly) of step (1).

Suggestions for Reassembly


(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Apply hydraulic oil to the bore surface of shell and also
to the wiper seal, rod seal, piston seal and wear seal.
(3) When holding the shell in a vise, take care not to distort
the shell.
(4) Fill the cavity between the shell and rod with 60 to 65
cm 3 (3.66 to 4.00 cu in.) of hydraulic oil before
installing the retainer.
(5) Tighten the retainer to the torque specified below.

Truck Model
GP40K, GP40KL, GP45K, GP50K,
DP40K, DP40KL DP45K, DP50K
Item
515 to 542 N·m 569 to 596 N·m
Tightening torque
(52 to 55 kgf·m) (58 to 61 kgf·m)
for retainer
[380 to 400 lbf·ft] [420 to 440 lbf·ft]

10-38
HYDRAULIC SYSTEM

Second Cylinder of Duplex Mast (GP40K, GP40KL, DP40K, DP40KL)


Disassembly

208716

Sequence
Remove parts 1 to 5 as a subassembly. 9 Nylon ring
1 Retainer 10 Circlip
2 Wiper seal 11 Sleeve
3 Rod seal 12 Pull-in wire
4 Backup ring 13 Piston
5 O-ring 14 Bleed screw
Remove parts 6 to 13 as a subassembly. 15 Washer seal
6 Rod 16 Shell assembly
7 Wear ring
8 Piston seal

NOTE NOTE
Do not remove the wiper seal 2 and rod seal 3 The parts marked with an asterisk (❋) are repair kit
unless they are defective. parts.

10-39
HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item

Inside diameter of shell 1 A 55 (2.165) 60 (2.362)

Outside diameter of rod 2 A 45 (1.771) 50.8 (2.000)

Outside diameter of retainer 3 A 70 (2.755) 75 (2.952)

270 to 298 N·m 298 to 325 N·m


Tightening torque for retainer 4 A (27.5 to 30.0 kgf·m) (30.0 to 33.0 kgf·m)
[200 to 220 lbf·ft] [220 to 240 lbf·ft]

4.5 to 5.0 N·m 4.5 to 5.0 N·m


Tightening torque for air bleed screw 5 A (45 to 55 kgf·cm) (45 to 55 kgf·cm)
[3.25 to 3.6 lbf·ft] [3.25 to 3.6 lbf·ft]

Duplex mast second cylinder (GP40K, GP40KL, DP40K, DP40KL)

2 1 3

5
208705A

Duplex mast second cylinder (GP45K, GP50K, DP45K, DP50K)

2 1 3

5
208706A

10-40
HYDRAULIC SYSTEM

Inspection and Repair


Follow the instruction on page 10-33 for inspection.

Reassembly

14 9 8 7 6 13 12 5 4 3 1 2

11 10 15 16
208705B

Sequence
(1) Subassemble parts 1 to 5 prior to assembly.
(2) Subassemble parts 6 to 13 prior to assembly.
(3) Install the subassembly (piston and rod assembly) of
step (2) above in the shell assembly 14, then install the
subassembly (retainer assembly) of step (1).

Suggestions for Reassembly


(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Apply hydraulic oil to the bore surface of shell and also
to the wiper seal, rod seal, piston seal and wear seal.
(3) When holding the shell in a vise, take care not to distort
the shell.
(4) Fill the cavity between the shell and rod with 25 to 30
cm 3 (1.53 to 1.83 cu in.) of hydraulic oil before
installing the retainer.
(5) Tighten the retainer to the torque specified below.

Truck Model
GP40K, GP40KL,
DP40K, DP40KL
Item
270 to 298 N·m
Tightening torque for retainer (28 to 30 kgf·m)
[200 to 220 lbf·ft]

10-41
HYDRAULIC SYSTEM

Second Cylinder of Duplex Mast (GP45K, GP50K, DP45K, DP50K)


Disassembly

208717

Sequence
Remove parts 1 to 5 as a subassembly. 10 Wear ring
1 Retainer 11 Piston seal
2 Wiper seal 12 Nylon ring
3 Rod seal 13 Circlip
4 O-ring 14 Sleeve
5 Backup ring 15 Pull-in wire
6 Sleeve 16 Piston
7 O-ring 17 Bleed screw
Remove parts 8 to 16 as a subassembly. 18 Washer seal
8 Rod 19 Shell assembly
9 Spacer

NOTE NOTE
Do not remove the wiper seal 2 and rod seal 3 The parts marked with an asterisk (❋) are repair kit
unless they are defective. parts.

10-42
HYDRAULIC SYSTEM

Inspection and Repair


Follow the instruction on page 10-33 for inspection.

Reassembly

16 14 13 12 11 10 8 7 6 4, 5 1 3 2

15 9 17 18 19
208706B

Sequence
(1) Subassemble parts 1 to 5 prior to assembly.
(2) Subassemble parts 8 to 16 prior to assembly.
(3) Install the subassembly (piston and rod assembly) of
step (2) above in the shell assembly 17, then install
sleeve 6 and the subassembly (retainer assembly) of
step (1).

Suggestions for Reassembly


(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Apply hydraulic oil to the bore surface of shell and also
to the wiper seal, rod seal, piston seal and wear seal.
(3) When holding the shell in a vise, take care not to distort
the shell.
(4) Fill the cavity between the shell and rod with 25 to 30
cm 3 (1.53 to 1.83 cu in.) of hydraulic oil before
installing the retainer.
(5) Tighten the retainer to the torque specified below.

Truck Model
GP50K, DP50K
Item
298 to 325 N·m
Tightening torque for retainer (30 to 33 kgf·m)
[220 to 240 lbf·ft]

10-43
HYDRAULIC SYSTEM

Tilt Cylinders

Disassembly

208718

Sequence
1 Socket, Bolt, Washer 4 Cylinder tube, Bushing, Grease nipple
2 Bushing, Buffer ring, Packing, Dust seal, 5 Shims
O-ring 6 O-ring
3 Rod, Collar, Piston, Piston seal, 7 Spacer
Self-locking nut

NOTE
(1) Collar 3, spacer 7, O-ring 6 and shims 5 are used
only in the tilt cylinder for the optional-
specification models; the cylinder for the standard-
specification models does not include them.
(2) Do not remove the buffer ring, packing and dust
seal from bushing 2 unless they are damaged.

10-44
HYDRAULIC SYSTEM

Suggestion for Disassembly

Removing bushing
(1) Wrap the cylinder tube with rag, and hold it in a vise.
Using wrench A, remove the bushing from the tube.
Special tool needed
Truck Model GP40K, GP45K,
GP40KL, GP50K,
DP40K, DP45K,
Part Name DP40KL DP50K

Wrench A 09305 - 01000 09305 - 01120


A
(2) When removing the bushing from the piston rod, cover 200351
the threads of the rod with vinyl tape to prevent buffer
ring and packing from damaging.
(3) Do not remove the self-lock nut unless the piston has to
be repaired.

Inspection and Repair

1. Cylinder tube
(1) Check the bore wall for wear, grooving, scratching or
rusting.
(2) Check the welds for cracks or other defects.

2. Piston rod
(1) Check the rod for deflection on V-blocks with a dial
gauge as shown.
(2) Check for surface flaws such as grooving, scratching,
rusting or wear. Replace the rod if its thread is badly
damaged.

3. Rings and packing


(1) Check each ring and packing for damage or distortion.
(2) Also check for deterioration due to aging. 200319

10-45
HYDRAULIC SYSTEM

A: Standard value B: Repair or service limit


Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
+ 0.10 + 0.0039 + 0.10 + 0.0039
A 80 0 (3.15 0 ) 90 0 (3.54 0 )
Inside diameter of cylinder tube 1
B 80.12 (3.1543) 90.12 (3.5480)
− 0.025 − 0.00098
Diameter of piston rod 2 A 40 − 0.064 (1.57 − 0.00252 )
+ 0.140 + 0.00555
A 40 + 0.020 (1.57 + 0.00078 )
Inside diameter of frame side bushing 3
(as installed)
B 40.6 (1.598)

Outside diameter of bushing 4 A 95 110

520 ± 54 N·m 628 ± 64 N·m


Tightening torque for bushing 5 A (53 ± 5.5 kgf·m) (64 ± 6.5 kgf·m)
[383 ± 40 lbf·ft] [463 ± 47 lbf·ft]

Tightening torque for bolt 6 A 262 ± 13 N·m (27 ± 1.4 kgf·m) [195 ± 10 lbf·ft]

Tightening torque for self-lock nut 7 A 588 ± 29 N·m (60 ± 3 kgf·m) [434 ± 22 lbf·ft]

208707A

10-46
HYDRAULIC SYSTEM

Reassembly

208707B

Sequence
Assemble parts 1 to 6 into subassembly A. Assemble parts 11 to 13 into subassembly C.
1 Rod 11 Cylinder tube
2 Piston 12 Bushing
3 Nut 13 Grease nipple
4 Piston seal Insert subassembly A into subassembly C, then install
5 Collar subassembly B in position.
Assemble parts 6 to 10 into subassembly B. 14 Tilt socket
6 Bushing 15 Clamp bolt
7 Buffer ring
8 Packing
9 Dust seal
10 O-ring

Suggestions for Reassembly


(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Apply hydraulic oil to the bore surface of cylinder and
also to the piston seal, O-ring, backup ring, buffer ring,
packing and dust seal.
(3) When holding the cylinder tube in a vise, take care not 200352
distort the tube.
(4) Install the piston seal as follow:
(a) Before fitting the inner piston seal, squeeze it by
hand five or six times to soften it.
(b) Hold the piston in a vise, taking care not to
damage any part of the piston. Apply a thin coat
of hydraulic oil to the seal. Fit a portion of the
seal to the groove, and push the other portion into
the groove as shown. 200353

(5) Make sure buffer ring 7, packing 8 and dust seal 9 are
installed correctly in terms of the direction.
10-47
HYDRAULIC SYSTEM

Flow Regulator Valve

Disassembly
Sequence
5
6 9 1 Lock nut
10 2 Plug, O-ring
11
3 Spring
4 Elbow, O-ring
13 Remove parts 5 to 11 as an assembly.
5 Snap ring
6 Spring pin
4
7 Washer
8 Spring
9 Plate
10 Valve
11 Piston
12 Connector, O-ring
13 Valve body
12

2
3
7
8
208596

NOTE
(1) Before disassembling the valve, measure the
distance between the end of the valve body and the
projected end of the plug 2. This distance must be
referred when reassembling the valve.
(2) Disassemble pin 6 to piston 10 after removing the
piston.

Inspection and Repair


(1) Check the spring for fatigue.
(2) Check the contact and sliding surfaces of the valve and
piston for damage.
(3) Check the sliding surfaces of the piston and valve body
for damage.
NOTE
If any part is damaged, replace the entire assembly.

Reassembly
Follow the disassembly sequence in reverse.
10-48
HYDRAULIC SYSTEM

Down Safety Valve

Disassembly

4
200355

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

Inspection
(1) Check the valve orifice for clogging or damage.
(2) Check the spring for fatigue.
(3) Check for stripped threads.

NOTE
Replace the down safety valve as an assembly if any
part is defective.

Reassembly
To reassemble, follow the reverse of disassembly sequence.

10-49
HYDRAULIC SYSTEM

Inspection and Adjustment

Hydraulic Tank
Refill Capacities and Amount of Oil Required

Refill
Refill capacities (liter)
capacities GP45K,
(liter) Lift height (meter)
GP50K,
GP40K, DP45K,
7.0 DP50K
GP40KL,
6.5
DP40K, 6.0 + 6.8 H
DP40KL 6.0
5.5 5.5
H + 5.7 5.0 5.0 69.3 N
25 4.7
N 58.5 − 2.7 L
4.5
10
4.3
L − 2.3
45 4.0 4.0 4.0
3.7 3.7
3.5 3.5
3.3 3.3
3.0 3.0
2.5
2.0
GP40K, GP40KL Equivalents:
models
DP40K, DP40KL Simplex Duplex Triplex Meter = approx. 3.3 ft
GP45K, GP50K models mast mast mast Liter = approx. 0.26 U.S. gal.
DP45K, DP50K

202988

Remarks
(1) How to read the chart
[Example]
GP40K, GP40KL, DP40K, DP40KL: In the truck equipped with a 5.0 m (16.4 ft) triplex mast, maintain the oil level at N mark
on the level gauge with the mast lowered to the bottom. In the case of 5.5 to 7.0 m (18.0 to
23.0 ft) masts, maintain it at H mark with the mast lowered to the bottom.
GP45K, GP50K, DP45K, DP50K: In the truck equipped with any of the duplex masts up to 6.0 m (19.7 ft) lift height,
maintain the oil level at N mark. In the case of 6.0 to 7.0 m (19.7 to 23.0 ft) masts,
maintain it at H mark with the mast lowered to the bottom.
(2) Another simple method of checking the oil level is this:
In any truck, maintain the oil level above N mark but below H mark with (a) the mast lowered to the bottom, (b) the fork or
attachment kept in travel position and (c) the truck held level.

Hydraulic Oil Suction Strainer and Return Filter


Check the hydraulic oil in the tank for water-in-oil Check for clogging or damage, and clean or replace the
emulsion, and change the oil if its color has changed to strainer and filter.
a milky appearance. Remember, the oil appears as it
were emulsified immediately after the hydraulic control
levers are operated.

10-50
HYDRAULIC SYSTEM

Hydraulic Pump Test Run


The purpose of test run is to break-in the overhauled pump
and verify its performance. The use of a pump testing
equipment, specially designed as such and commonly used
in the service shop, is recommended but is not mandatory.
The following procedure, however, assumes that the pump
is installed on the truck:
(1) Install a pressure gauge capable of measuring up to
25000 kPa (250 kgf/cm2) [3555 psi].
To install the pressure gauge, remove the plug from the
delivery hose connector and attach the following tools:

Connector 64309 - 17733 (Rc 1/8 thread)


Hose 64309 - 17722
Connector 64309 - 17731 (for gauge)
Gauge 64309 - 17712
{25000 kPa (250 kgf/cm2) [3555 psi]} 203838

NOTE

These tools are included in the gauge kit 64309 - 17701.

(2) With the control levers in neutral, run the engine at a


speed between 500 and 1000 rpm, holding the discharge
pressure at a level not higher than 981 kPa (10 kgf/cm2)
[142 psi]. Run the pump under this condition for 10
minutes for break-in, listening for noise.
(3) Raise the engine speed to a speed between 1500 and
2000 rpm, and run the engine for another 10 minutes in
the no-load condition.
(4) While the pump is being so run, loosen the adjusting
screw, and shift the control levers into operating
positions. Next set the adjusting screw, to obtain a
gauge reading of 2942 kPa (30 kgf/cm2) [427 psi], and
run for 5 minutes at this pressure. Following this, raise
the pressure by changing the setting of adjusting screw
in increments of 1961 kPa (20 kgf/cm2) [284 psi] each,
running the pump for 5 minutes at each raised pressure 203839
until, finally, the prescribed set pressure of the relief
valve is reached.

10-51
HYDRAULIC SYSTEM

(5) Pay attention to the temperatures of oil and pump


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

Control Valve

External leakage
(1) Check for oil leaks from the joint between adjacent
valve housings sealed by O-ring.
(2) Check for oil leaks from the scrapers sealed by O-rings.
(3) Check for oil leaks from the screw connections.

Internal leakage
It is not practical to check the control valve alone for
internal leakage. How to check the control valve in place
(under normal operating conditions) will be described.
The internal leakage to be checked includes leakages
occurring at the lift spool, tilt spool, tilt lock valve and
check valves.

Test oil temperature 50°C (122°F), approx.

(1) Pick up a load equal to the rated capacity, and lift it


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

Amount of oil collected for


500 cc (30.5 cu in.)
15 minutes

202991

10-52
HYDRAULIC SYSTEM

(3) If the lift cylinders or tilt cylinders drift (the mast tilts
forward or the fork lowers) excessively in spite of that
the amount of oil collected for 15 minutes is less than
500 cc (30.5 cu in.), measure the internal leakage of
each cylinder. (The measurement is the assembly
standard and not the service limit.)

203840

Main Relief Valve


(1) Install a pressure gauge capable of measuring up to
25000 kPa (250 kgf/cm2) [3555 psi] to the delivery hose
connector. Use the gauge, connectors and hose used for
testing the gear pump.
(2) Start the engine and run it at the maximum speed.
Move the tilt control lever to the backward tilt position.
If the pressure is relieved at 19123 + 0490 kPa (195 + 05
kgf/cm2) [2773 + 071 psi] when the tilt cylinders reach the
end of their stroke, the main relief valve setting is
correct.
(3) If the setting is incorrect, loosen the lock nut of 203838
adjusting screw and, while observing the pressure
gauge reading, slowly rotate the adjusting screw until
the gauge indicates the prescribed set value.

NOTE
One rotation of the adjusting screw changes the
pressure by approximately 17750 kPa (181 kgf/cm2)
[2574 psi].

(4) While holding the adjusting screw, tighten the lock nut
to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the setting.

19123 + 0490 kPa


Main relief valve setting (195 + 05 kgf/cm2)
[2773 + 071 psi]

10-53
HYDRAULIC SYSTEM

Steering System Relief Valve


(1) Install a hydraulic pressure gauge to the position
indicated in the figure to the right.

Connector 1 91268 - 01700


Hose 2 64309 - 17722
Gauge 3 64309 - 17712
{35200 kPa (352 kgf/cm2) [5000 psi]}

NOTE
206983
Tools 1 to 3 are included in the gauge kit.

(2) Start the engine, and turn the steering wheel fully to the
left at the maximum engine speed. When the steering
wheel stroke reaches the limit, check the pressure
gauge. The steering system relief valve is in good
condition if the oil pressure is relieved and the gauge
reading becomes as the following standard value.

11800 + 0490 kPa


Steering system relief valve
(120 + 05 kgf/cm2)
setting
[1714 + 071 psi]

(3) If the steering system relief valve opening pressure is


out of specification, adjust the valve properly.

g y
208808

10-54
HYDRAULIC SYSTEM

Flow Regulator Valve


Measure the lowering speed with rated load. If the lowering
speed is incorrect, loosen the lock nut of set bolt and turn
the set bolt in either direction.

Change in lowering speed 40 mm/sec (7.9 fpm),


per rotation of set bolt approx.

Unit: mm/sec (fpm)


Truck Model
GP40K thru GP45K
DP40K thru DP45K GP50K, DP50K 208599
Item
Lowering speed 500 500
adjustable range (100) (100)
(rated load) (standard) (standard)

Lift and Tilt Cylinders


Mast tilt angle adjustment
(1) Adjust the tire pressure correctly, and keep the truck
level.
(2) Tilt the mast fully backward, and stop the engine.
(3) Measure the backward tilt angle of the mast at both
sides.
(4) To adjust the tilt angle, loosen the lock nuts of tilt
cylinder rods, and turn the rods so that there is no 200362
difference in length between the cylinders, right and
left.

NOTE
It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted.

Forward – backward tilt angle 6° – 10° (standard)

10-55
HYDRAULIC SYSTEM

Lift cylinder stroke


(1) Slowly raise the inner mast, and check if the piston
rods, right and left, stop at the moment the inner mast
reaches its maximum height.
(2) If the top of the inner mast jolts at that moment, make a
shim adjustment. Abnormal condition can be told by a
little time lag in stopping between the piston rods, right
and left, and shaking of the rod with a longer cylinder
stroke.

200363

Adjusting method
(1) Raise the inner mast, place blocks under the right and
left side of the mast, and lower the mast until it rests on
the blocks.

202983

(2) Remove the stopper bolt at the top of lift cylinder which
stopped first. Retract the piston rod by operating the
lift control lever and insert shims at the top of piston
rod end. Shims
(3) Extend the piston rod, and tighten the cylinder stopper
bolt. Remove the blocks from under the inner mast.
(4) Raise the inner mast again to make sure there is no time
lag in stopping between the piston rods, right and left.
(5) Slowly lower the inner mast fully to make sure that the
200365
piston rods move smoothly.

10-56
HYDRAULIC SYSTEM

Testing

1. Lift cylinder drift test


(1) Pick up a load equal to the rated capacity, place the
mast to a vertical position, lift the fork 1 to 1.5 m (3.3
to 4.9 ft), and stop the engine.
(2) Mark a reference line on the mast, and measure the drift
(retraction of the piston rods) for 15 minutes.
Unit: mm (in.)
Lift cylinder drift 50 (2),
(in 15 minutes under rated load weight) maximum
200996

2. Tilt cylinder drift test


(1) Pick up a load equal to the rated capacity, place the
mast to a vertical position, lift the fork about 50 cm (20
in.), and stop the engine.
(2) Measure the extension of tilt cylinder piston rods for 15
minutes.
Unit: mm (in.)
Tilt cylinder drift 30 (1.2),
(in 15 minutes under rated load weight) maximum

208601

10-57
HYDRAULIC SYSTEM

Troubleshooting

Not enough oil in hydraulic tank Add oil.


Oil viscosity improper Change oil.
Overload Check working conditions and,
if over-loaded, urge the operator
to stay within the load limit.
Hydraulic tank Local overheating of oil line due Repair or replace.
heats excessively to a large restriction to flow
Relief valve adjustment improper Readjust pressure setting.
Pressure drop due to fatigued or Repair or replace and readjust.
broken springs
Hydraulic pump worn Replace.
Hydraulic
tank Outlet pipe or tube flattened, or Repair or replace.
restriction to flow

Shortage of oil due to a natural Add oil.


loss
Cylinders move
Oil leakage due to damaged oil Repair or replace.
too slow
line seals
Oil viscosity too higher Change oil.

Hydraulic pump defective Check pump and piping; repair


or replace.
Oil leakage from oil line Check oil for level and condition;
Cylinders move add or change oil.
too slow
Abnormal oil temperature rise Check control valve spools for
misalignment; repair or replace.
Hydraulic
Hydraulic pump internally leaking Replace pump.
pump

Poor pumping Check oil level; add oil if


Noisy necessary.
Cavitation 1) Check suction pipe for any
flat portion or loose connection;
retighten or replace.
2) Check shaft oil seal for
airtightness; replace pump.
3) Check pump body for any
outside interference; repair.

10-58
HYDRAULIC SYSTEM

Pump case, drive Pressure too high Replace pump. (Check to see if
gear or pump port relief valve setting is correct.)
flange damaged Distortion or damage due to Replace pump.
external strain or stress
1) Check to see if return line
is restricted.
2) Check to see if pipe
Hydraulic connection have been
pump externally strained or stressed.

Oil leakage past oil seal Replace seal.


Oil leakage past sliding surfaces Replace whole pump assembly.
Oil leakage from of drive shaft
pump
Pump securing bolts loose Retighten.
Excessive internal leakage Replace O-ring.

Relief valve setting too low Readjust.


Relief valve piston seizure Clean piston and check to see if
Slow or no motion it moves smoothly; or replace
of lift and tilt whole relief valve assembly.
cylinders O-ring on relief valve body Replace O-ring.
damaged
Control lever installed loose, Readjust.
resulting in not enough spool stroke

Control
valve Load drops or
mast tilts forward Control valve internally leaking Replace a leaky block
with control lever assembly.
in neutral
Oil leakage from spool ring cap Replace O-ring; check spool
for flaws and if any, repair or
Oil leakage replace a leaky block assembly.
Loose plugs Retighten.
O-ring damaged Replace.

10-59
HYDRAULIC SYSTEM

Not enough oil in hydraulic tank Add oil.


Relief valve out of order,
Will not lift nor because of:
tilt • Seized main valve Replace.
• Broken valve spring Replace.
Hydraulic pump defective Replace.

Relief valve out of order,


because of:
• Too low a relief valve setting Readjust.

Will not lift rated • Defective plunger or poppet seat Replace.


load • Fatigued spring Replace.
• Damaged O-ring in valve case Replace O-ring.
Hydraulic pump defective Replace.
Piston seals worn or damaged Replace.

Lift and tilt


cylinders Engine speed too low Adjust.
Control lever installed loose, Repair or replace.
Lifting speed is resulting in not enough spool stroke
too low
Tank strainer clogged Clean or replace.
Pump not delivering enough oil Repair or replace.

Sleeve seized in flow regulator Repair.


valve
Lowering speed is
too low Dirt in flow regulator valve Clean, repair system and
replace defective hose.
Abnormal resistance to flow due Replace hose.
to flattened hose or local clogging

Piston rod distorted Repair or replace.


Cylinder vibrates Air in oil circuit Bleed air by operating cylinder
when actuated through full stroke.
Not enough oil in hydraulic tank Add oil.

10-60
HYDRAULIC SYSTEM

Control valve spool internally Replace.


leaking
Sliding (inside) surface of cylinder Repair or replace cylinder
tube slightly grooved assembly.
Load will not hold
Sliding (inside) surface of cylinder Replace.
tube badly grooved
Piston seals broken or distorted Replace seal kit.
Oil leakage from piping Repair or replace.

Control valve spool internally Replace.


leaking
Mast tilts forward Foreign particles lodged between Replace packing.
(drift) packing and mating surface

Lift and tilt Piston seals damaged Replace.


cylinders Cylinder distorted Repair or replace.

Lift cylinders drop Sliding surface of cylinder tube Repair or replace.


or tilt cylinders tilt badly grooved or rusted at one
forward (drift) at a point
certain point of
stroke Cylinder tube distorted Replace.

Foreign particles lodged between Replace.


sealing members such as oil seals
and dust seals
Bushing leaks Oil seals and dust seals defective Replace.
O-rings damaged Replace.
Cylinder distorted Repair or replace.

10-61
HYDRAULIC SYSTEM

Service Data
A: Standard value
Unit: mm (in.)

GP40KL

DP40KL
Truck Model

GP40K

DP40K

DP45K

GP45K

GP50K

DP50K
Item
Lift speed (rated load) (simplex mast) 510 440 420
A
mm/sec [fpm] (100) (85) (80)
Lift speed (no load) 530 450 440
A
mm/sec [fpm] (105) (90) (85)
Lowering speed (rated load) (simplex mast) 500
A
mm/sec [fpm] (100)
Forward tilt angle (standard model with simplex mast) A 6°
Backward tilt angle (standard model with simplex mast) A 10°
Lift cylinder drift (retraction of piston rod)
A 50 (2), maximum
(rated load for 15 minutes) [Oil temperature: 45°C (113°F)]
Tilt cylinder drift (extension of piston rod)
A 30 (1.2), maximum
(rated load for 15 minutes) [Oil temperature: 45°C (113 °F)]
+ 490 +5 + 71
Main relief valve setting kPa (kgf/cm2) [psi] A 19123 0 (195 0 ) [2773 0 ]
Hydraulic pump (gear pump) displacement cm3 (in3)/rev A 50 (3.0)/rev
Spool operating Neutral N (kgf) [lbf] A 127 (12.9) [28.4]
effort (at maximum
Control engine rpm) Full stroke N (kgf) [lbf] A 158 (16.1) [35.5]
valve 7/16” N·m (kgf·m) [lbf·ft] A 65 (6.6) [48]
Tightening torque
for tie bolts 1/2” N·m (kgf·m) [lbf·ft] A 101 (10.3) [74]
Steering system relief valve setting + 490 +5 + 71
A 11800 0 (120 0 ) [1714 0 ]
kPa (kgf/cm2) [psi]
Tightening torque of return filter N·m (kgf·m) [lbf·ft] A 49 (5) [36]
Tightening torque of suction strainer N·m (kgf·m) [lbf·ft] A 49 (5) [36]
Flow
Flow rate (no load)
regulator A 100 (26.4) 115 (30.4)
liter (U.S. gal.)/min
valve
Tightening torque of hydraulic pump (gear pump) universal
A 22 (2.2) [16]
joint N·m (kgf·m) [lbf·ft]
Tightening torque of hydraulic hose joints at hydraulic pump
A 118 (12) [87]
(gear pump) and control valve N·m (kgf·m) [lbf·ft]
Tightening torque of hydraulic pipe joints at control valve and
A 118 (12) [87]
flow regulator valve N·m (kgf·m) [lbf·ft]

10-62
HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
Inside diameter of shell 1 A 100 (3.937) 110 (4.330)

Outside diameter of rod 2 A 65 (2.559) 65 (2.559)

Outside diameter of retainer 3 A 117.16 (4.612) 130.00 (5.118)

516 516
Check valve set pressure 4
A (5.27) (5.27)
kPa (kgf/cm2) [psi]
[75] [75]

Lift 515 to 542 569 to 596


Tightening torque for retainer 5
cylinder A (52 to 55) (58 to 61)
N·m (kgf·m) [lbf·ft]
(duplex [380 to 400] [420 to 440]
mast first)
(triplex
mast first) 4 5

2 1 3

208704A

10-63
HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
Inside diameter of shell 1 A 65 (2.56) 70 (2.76)

Outside diameter of rod 2 A 50.8 (2.0) 50.8 (2.0)

74.95 ± 0.05 83.00 ± 0.05


Outside diameter of retainer 3 A
(2.950± 0.002) (3.2677 ± 0.002)

39.85 ± 0.05 44.85 ± 0.05


Outside diameter of rod top 4 A
(1.568 ± 0.002) (1.765 ± 0.002)

1863 1863
Check valve set pressure 5
A (19) (19)
kPa (kgf/cm2) [psi]
Lift [275] [275]
cylinder
(simplex 325 to 353 352 to 380
Tightening torque for retainer 6
mast) A (33 to 36) (36 to 39)
N·m (kgf·m) [lbf·ft]
(triplex [240 to 260] [260 to 280]
mast
second)

5 6

2 1 4 3

208702A

10-64
HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
Inside diameter of shell 1 A 55 (2.165) 60 (2.362)

Outside diameter of rod 2 A 45 (1.771) 50.8 (2.000)

Outside diameter of retainer 3 A 70 (2.755) 75 (2.952)

270 to 298 298 to 325


Tightening torque for retainer 4
A (27.5 to 30.0) (30.0 to 33.0)
N·m (kgf·m) [lbf·ft]
[200 to 220] [220 to 240]

4.5 to 5.0 4.5 to 5.0


Tightening torque for air bleed screw 5
A (45 to 55) (45 to 55)
N·m (kgf·cm) [lbf·ft]
[3.25 to 3.6] [3.25 to 3.6]

GP40K, GP40KL, DP40K, DP40KL


4

Lift
cylinder
(duplex
mast 2 1 3
second)

5
208705A

GP45K, GP50K, DP45K, DP50K

2 1 3

5
208706A

10-65
HYDRAULIC SYSTEM

A: Standard value B: Repair or service limit


Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
+ 0.10 + 0.0039 + 0.10 + 0.0039
A 80 0 (3.15 0 ) 90 0 (3.54 0 )
Inside diameter of cylinder tube 1
B 80.12 (3.1543) 90.12 (3.5480)
− 0.025 − 0.00098
Diameter of piston rod 2 A 40 − 0.064 (1.57 − 0.00252 )
+ 0.140 + 0.00555
A 40 + 0.020 (1.57 + 0.00078 )
Inside diameter of frame side bushing 3
(as installed)
B 40.6 (1.598)

Outside diameter of bushing 4 A 95 110

520 ± 54 628 ± 64
Tightening torque for bushing 5
A (53 ± 5.5) (64 ± 6.5)
N·m (kgf·m) [lbf·ft]
[383 ± 40] [463 ± 47]

Tilt Tightening torque for bolt 6 N·m (kgf·m) [lbf·ft] A 262 ± 13 (27 ± 1.4) [195 ± 10]
cylinder
Tightening torque for self-lock nut 7
A 588 ± 29 (60 ± 3) [434 ± 22]
N·m (kgf·m) [lbf·ft]

208707A

10-66