GP 45N CT29D Hyd

CHAPTER 11 HYDRAULIC SYSTEM
Chapter 11 HYDRAULIC SYSTEM

1. Structure and Functions
1.1 Outline
8
9
7
4 18
7
5 11
10 16
3
6 17
12 15
2 1
13
14
501341
1. Pump suction strainer 7. Tilt cylinder
100-mesh metal strainer 8. Piping to tilt cylinder
2. Hydraulic pump (gear pump) 9. Steering valve
A normal gear pump. Directly coupled to the
transmission PTO. Refer to "Hydraulic Pump." 10. Oil feed line to steering valve P port
3. Delivery hose of hydraulic pump 11. Return oil line from steering valve
4. Hydraulic control valve 12. Knob deviation control valve (with solenoid valve)
MC valve is standard. FC valve is available as an option. 13. Oil line to steering cylinder
MC valve has the built-in flow regulator valve. FC valve 14. Steering cylinder
does not have the built-in valve.
MC and FC models have almost the same piping 15. Return line
arrangement. For details, refer to "Piping." 16. Return filter
5. Lift cylinder A cartridge type filter. Replace the filter every oil
change.
6. Oil line to lift cylinder
FC models have a flow regulator valve in a downstream 17. Level gauge
section of this line. 18. Oil filler cap
11-1
1.3
1.2
11-2
MAXIMUM FLOW 15 L(4.0 US gal)/min
HYDRAULIC CONTROL VALVE MAXIMUM PRESSURE 12.7 MPa(129.50 kgf/cm2)[1841.98 psi]
POWER SUPPLY OF SOLENOID DC12V
CURRENT OF SOLENOID 1.5A
PRESSURE REDUCE: 6 MPa(61.18 kgf/cm2)[870.23 psi]
STEERING VALVE
B4 A4
BRAKE VALVE
P port:MAX11 MPa(112.17 kgf/cm2)[870.23 psi]
A port:MAX 9 MPa(91.77 kgf/cm2)[1305.34 psi]
L A P
Refer to “BRAKE SYSTEM.”

T
R DRUM BRAKE UNIT
B3 A3
LS T1
T2 P
T P STEERING CYLINDER
(D80 d60 ST265) FA ASSY
GEAR PUMP RELIEF 9 MPa
DISPLACEMENT 52 cc (3.173 cu. in.)/rev (91.77 kgf/cm2)

GEAR PUMP FOR BRAKE [1305.34 psi]
A2
DISPLACEMENT 3.46 cc (0.211 cu. in.)/rev at 2.0 L(0.5 US gal)/min
DRUM BRAKE UNIT
B2
TILT CYLINDER
PTO
FLOW REG.VALVE PARKING BRAKE

100 L(26.4 US gal)/min(4.0-5.0C) RELEASE PRESS.: OVER 4.9 MPa(49.97 kgf/cm2)[710.69 psi] SETTING PRESS:
115 L(30.4 US gal)/min(50-55) PROOF PRESS.: OVER 7 MPa(71.38 kgf/cm2)[1015.27 psi]
4.9 MPa(49.97 kgf/cm2)
ENGINE [710.69 psi]
Hydraulic Lines Diagram (Wet Disc Brake)

(TB :71.8kW/2450rpm)
TM ASSY (S6S:60.3kW/2300rpm)
PTO GEAR RATIO 1:1
A1
Hydraulic Lines Diagram (with MC Control Valve)
100MESH
MAX 120 L(31.70 US gal)/min
RETURN FILTER
34μm
MAX 125 L(33.0 US gal)/min
PF
LS
T2
LIFT CYLINDER
WITH DOWN SAFETY
P T
MAIN RELIEF
LS PORT RELIEF
19.1 MPa(194.77 kgf/cm2)[2770.23 psi]
11.8 MPa(120.33 kgf/cm2)[1711.45 psi]
at 120 L(31.70 US gal)/min
at 1.5 L(0.4 US gal)/min
501567
1.4 Hydraulic tank
2
3
4
3) 5
1
6
2)
1)
10 7
9
12 11
501344
1. Hydraulic tank 7. Suction strainer
2. Cap 8. Return filter
3. Ring 9. Hydraulic pump
4. Element 10. Pump suction line
5. Level gauge 11. Pump delivery line
6. Tank cover 12. Drain plug
Parts 1) thru 3) are welded to tank cover
1) Suction pipe
2) Return pipe
3) Pipe for level gauge (oil filler port)
The hydraulic tank is located in the middle of right side Return filter is attached to the end of return pipe 2). The
frame, and forms part of the frame structure. return filter is a 34 μm (1338.58 μin) cartridge filter with a
built-in relief valve. When the filter is clogged, the relief
Three pipes 1) thru 3) are welded to the tank cover, and
valve activates to allow the unfiltered oil flowing into the
suction strainer, return filter, level gauge and cap are
tank. Periodic replacement is important. Also, the oil filter
installed on the each end of these pipes.
replacement is recommended one month after the
Thus, all of the parts inside the tank can be removed
purchase of the truck or after a major overhaul that involves
together by removing the tank cover.
parts replacement.
Filter replacement or strainer cleaning can easily be
performed by removing tank cover. Pump suction strainer is a 100 mesh metal strainer. The
suction strainer must be washed every oil change.
Level gauge is inserted in the level gauge pipe 3) where the
opening is blocked by the cap equipped with an element. The drain plug is installed at the bottom of the tank.
The two holes on the side of cap are vent holes to allow air
to pass out or in according to the oil level in the tank.
Element installed in the cap serves as an air filter to prevent
unclean outside air from entering the hydraulic tank.
11-3
1.5 Hydraulic Pump (Gear Pump)
4 13 12 9 6 3 11 10
1 7 5 8 2
501345
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 type
The pump in a standard truck is a single-gear pump as
shown above.
Installation of pump
The pump is directly coupled to the transmission PTO.
11-4
1.6 MC Control Valve
1
2
1) 7
4
7)
3
5
4)
6)
2) 5)
501348
1. Lift control lever 1) P: Inflow port of pump pressure oil
2. Tilt control lever 2) PF: Pressure oil supply port to steering system
3. Inlet section 3) T1: Return port to tank
(with built-in flow priority valve) 4) T2: Return port from steering system
4. Combination section 5) A1: Port to lift cylinder
(with built-in lift, tilt and flow divider valves)
6) A2: Port to tilt cylinder rod
5. End section
(with built-in unload valve) 7) B3: Port to tilt cylinder head
6. Unload valve (with solenoid)
7. Lift lock valve (with solenoid)
Most of the hydraulic control valves move mechanically.

When the control lever is operated, the spool valve starts to
move up and down, and exchanges pressure oils with the
corresponding hydraulic cylinders.
For detailed explanations on structure and operation, and
disassembly and reassembly, refer to "35. MC Control Valve."
11-5
1.7 Down Safety Valve
1) 2)
501364
1) Normal condition 2) When hose is damaged
The down safety valve is located at the bottom of the right This valve serves as a safety valve which prevents sudden
lift cylinder. fall of the forks in case hoses are damaged.
11-6
1.8 Lift Cylinder (Second Lift Cylinder for Simplex Mast and Triplex Mast)
- The second lift cylinder for simplex mast and triplex mast has two types: the cylinder with a return pipe, and the one
without a return pipe. For the one without a return pipe, a check valve, instead of the return pipe, is installed inside the
piston. This type is called an internal drain type cylinder.
- Regardless of the presence or absence of a return pipe, a cushion mechanism is installed at the bottom of the piston for
soft landing.
Main components of cylinder without a return pipe
- Simplex mast with a lift height of 4.0 m (4.37 yd) [157.480 in.] or less
- Duplex and triplex masts
9 10 3 3) 4) 1 2) 2 7 8 5
2)
OD
5)
ID
d
6 1) 501368
1. Cylinder tube 9. Wiper ring
2. Piston rod assembly 10. X-ring
3. Cylinder head 1) Cushion stroke: 23 mm
4. Pipe 2) Groove
(Integrated with cylinder tube) 3) Space
5. Cushion bearing 4) Only one side
6. Check valve 5) Oil inflow, outflow
7. U-ring, Back-up ring
8. Bushing
Main components of cylinder with a return pipe
- Simplex mast with a lift height of 4.5 m (4.92 yd) [177.165 in.] or higher
8 9 3 10 1 2 7 6 5
2)
OD
ID
d
1) 501370
1. Cylinder tube 7. Bushing
2. Piston rod assembly 8. Wiper ring
3. Cylinder head 9. U-ring
4. Pipe 10. Return pipe
(Integrated with cylinder tube) 1) Cushion stroke
5. Cushion bearing 2) Oil inflow, outflow
6. U-ring, Back-up ring
11-7
Lift cylinder dimensions (second for simplex and triplex masts) (the length and stroke of cylinder vary depending on lift
height.)
Cylinder Cylinder
Rod
inside outside Cushion Presence of
Truck class Mast type Height diameter
diameter diameter stroke return pipe
(d)
(ID) (OD)
4 m (157.48 in.) 50 mm 65 mm 73 mm 23 mm
No
or less (1.97 in.) (2.56 in.) (2.87 in.) (0.91 in.)
Simplex mast
4.5 m (177.17 in.) 50 mm 65 mm 73 mm 23 mm
Yes
or more (1.97 in.) (2.56 in.) (2.87 in.) (0.91 in.)
4.0 ton
45 mm 55 mm 65 mm 21 mm
Duplex mast - No
(1.77 in.) (2.17 in.) (2.56 in.) (0.83 in.)
50 mm 65 mm 73 mm 23 mm
Triplex mast - No
(1.97 in.) (2.56 in.) (2.87 in.) (0.91 in.)
4 m (157.48 in.) 50 mm 65 mm 73 mm 23 mm
No
or less (1.97 in.) (2.56 in.) (2.87 in.) (0.91 in.)
Simplex mast
4.5 m (177.17 in.) 50 mm 65 mm 73 mm 23 mm
Yes
or more (1.97 in.) (2.56 in.) (2.87 in.) (0.91 in.)
4.5 ton
45 mm 55 mm 65 mm 21 mm
Duplex mast - No
(1.77 in.) (2.17 in.) (2.56 in.) (0.83 in.)
50 mm 65 mm 73 mm 23 mm
Triplex mast - No
(1.97 in.) (2.56 in.) (2.87 in.) (0.91 in.)
4 m (157.48 in.) 50 mm 70 mm 79 mm 23 mm
No
or less (1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
Simplex mast
4.5 m (177.17 in.) 50 mm 70 mm 79 mm 23 mm
Yes
or more (1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
5.0C ton
50 mm 60 mm 69 mm 21 mm
Duplex mast - No
(1.97 in.) (2.36 in.) (2.72 in.) (0.83 in.)
50 mm 70 mm 79 mm 23 mm
Triplex mast - No
(1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
4 m (157.48 in.) 50 mm 70 mm 79 mm 23 mm
No
or less (1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
Simplex mast
4.5 m (177.17 in.) 50 mm 70 mm 79 mm 23 mm
Yes
or more (1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
5.0 ton
50 mm 60 mm 69 mm 21 mm
Duplex mast - No
(1.97 in.) (2.36 in.) (2.72 in.) (0.83 in.)
50 mm 70 mm 79 mm 23 mm
Triplex mast - No
(1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
4 m (157.48 in.) 50 mm 70 mm 79 mm 23 mm
No
or less (1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
Simplex mast
4.5 m (177.17 in.) 50 mm 70 mm 79 mm 23 mm
Yes
or more (1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
5.5 ton
50 mm 60 mm 69 mm 21 mm
Duplex mast - No
(1.97 in.) (2.36 in.) (2.72 in.) (0.83 in.)
50 mm 70 mm 79 mm 23 mm
Triplex mast - No
(1.97 in.) (2.76 in.) (3.11 in.) (0.91 in.)
11-8
Cushionmechanism when piston descends
1 2 2) 3) 1)
5 4) 4
501373
The figure above shows the condition at which the pipe 4

and the cushion bearing 5 start to contact each other after
the piston rod assembly 2 descends by its own weight.
The cushion bearing 5 is pushed upward by trapped oil 1),
and the surfaces of both the piston and cushion bearing 5
meet at area 2). This blocks the passage 3). The only outflow
passage for the trapped oil 1) is the clearance 4) between
the bore of the cushion bearing 5 and the outside of the
pipe 4. The deeper the piston descends, the narrower the
clearance 4) becomes. As a result, the descending speed of
the piston becomes gradually slower, which helps to avoid
the crash impact.
Movement during piston ascent (initial stage)
1 2 2) 3)
5 4) 4 501376
The above figure shows a condition immediately after the

piston rod assembly starts to ascend.
Incoming oil acts on the center of the piston, causing the
piston rod assembly 2 to slightly ascend. At the same time,
the cushion bearing 5 descends by the force of the
incoming oil pressure.
This action opens area 2), causing the passage 3) to open.
Oil from passage 3) and an initially-opened passage 4) flows
into the bottom of the piston, and generates pressure on
the bottom surface of the piston to push the piston rod
assembly 2 upward.
11-9
Internal drain type lift cylinder
1)
2)
3)
501377
1) Trapped oil and air 3) Check valve
(Normally this area is under slight negative pressure)
2) Groove
The above figure shows the position of the piston rod

assembly near the ascending stroke end. When oil or air,
which is trapped inside the space between the rod and
cylinder, exceeds the preset pressure of the check valve, the
check valve is opened to release the oil or air (internal drain).
On the lift cylinder with a return pipe, this area is connected
to the hydraulic tank.
11-10
Movement during piston ascent
The figure on the right represents the movement of the
check valve when the piston ascends. 6
7
(1) It shows the position of the piston just before it starts to
ascend.
Oil which flows through the hollow area in the cushion
spool 6 acts on the check valve 7.
3
501380
(2) Pressure oil pushes the check valve 7 to the right.

Pressure oil flows through the check valve flat face into
the piston bottom. 7
The triangular shape of the check valve increases the
initial oil inflow.
The piston starts to ascend.
501381
(3) The figure shows a condition in which the cushion

spool 6 is moving away from the cylinder bottom to 7
ascend. 6
501382
1
1)
2)
501383
1. Check valve 1) Initial stage of ascending
Oil flows over this flat surface.
2) Seat face
This face is seated when
descending.
11-11
1.9 Lift Cylinder (First for Duplex and Triplex Masts)
Main components
1)
6 3 5 4 1 2 10 7 8 9
OD
ID
d
2) 3) 11
501387
1. Cylinder tube assembly 7. Seal ring assembly
2. Piston rod assembly 8. Slide ring
3. Cylinder head 9. Check valve
4. Bushing 10. Stand tube
5. U-ring 11. Piston
6. Wiper ring
Operation
This cylinder, which is mounted on the center of the mast, Surplus oil such as oil leaks around the piston and oil in the
moves during the first stage of forks ascending. space 1), will return to the cylinder bottom through the
check valve 9 from the stand tube 10 during the last stage of
The piston rod 2 is extended from the cylinder tube 1 by
the piston rod ascending.
pressure oil which acts on the piston bottom. Cushion oil is
always present in the space 1) between the cylinder tube The stand tube always retains a certain amount of oil as
and the piston rod in order to prevent a sudden approach cushion oil. Note that a certain amount of cushion oil must
between the piston and the cylinder head 3 during the last be enclosed in the overhauled cylinders.
stage of its ascending. Since the piston rod ascends while
pushing the cushion oil into the air chamber 2), the
approach speed of the piston rod slows down during the
last stage of its ascending.
During the descending stroke of the piston rod, cushion oil
in the air chamber 2) is sucked into the space 1). The air
chamber, stand tube, and check valve are components used
for cushioning.
Lift cylinder dimensions (first for simplex and triplex masts) (the length and stroke of cylinder vary depending on lift height.)
Cylinder inside Cylinder outside

Truck class Mast type Rod diameter (d)
diameter (ID) diameter (OD)
4.0 to 4.5 ton Cylinders for the duplex mast and 70.0 mm (2.756 in.) 100.0 mm (3.937 in.) 115.0 mm (4.528 in.)
the triplex mast are of the same
5.0C to 5.5 ton dimension and same type. 75.0 mm (2.953 in.) 110.0 mm (4.331 in.) 127.0 mm (5.000 in.)
11-12
1.10 Lift Cylinder (Second for Duplex Mast)
Main components
9
4 5 2 1 6 3 7 8
3) 2)
1) 501393
1. Cylinder tube 7. Check valve
2. Piston rod 8. Spring
3. Piston 9. Bleed valve
4. Holder 1) Cushion stroke: 21 mm (0.83 in.)
5. Cylinder head 2) Inflow, outflow
6. Cushion spool 3) To first cylinder
Operation
Pressure oil first flows through the hollow area inside piston This cylinder is provided with a cushion mechanism which
rod 2 and enters the first lift cylinder. Since the inside prevents the piston bottom from collision to the cylinder
diameter of the first lift cylinder is larger than that of the bottom during piston descent. The bleed valve 9 is a valve
second lift cylinder, the first lift cylinder ascends first. The for bleeding air out of the hydraulic system after the system
second lift cylinder starts to ascend after the first lift cylinder is overhauled.
ascent has been completed.
11-13
Cushion mechanism when piston descends
The figure on the right shows the movement of the cushion
spool 6 when the piston descends. (To the right of the figure
is the bottom of the cylinder.)
(1) This figure shows the position of the cushion spool 6

before it contacts the cylinder bottom.
The cushion spool 6 is extended by the spring 8. 7 8 6
501394
(2) This figure shows a condition in which cushion spool 6

is in contact with the cylinder bottom and slightly
moves into check valve 7. The check valve moves to the 6 7 2)
left, blocking area 1). Oil 2) trapped below the piston is 1)
discharged through holes (two rows on the right) of the
cushion spool 6.
For check valve shape, see the figure on the next page.
501395
(3) As the piston descends further, cushion spool 6 moves

into the check valve further. As a result, the number of
escape holes are decreased and the discharge of
trapped oil 2) is restricted. The descending speed of the
piston becomes slower, thereby collision is avoided.
501396
11-14
1.11 Tilt Cylinder
3
1) 8 1 2 6 14
5 4
13 9 10
11 7
12
501388
1. Cylinder 8. O-ring
2. Piston rod 9. Dust seal
3. Guide bushing 10. Packing
4. Piston 11. Buffer ring
5. Socket 12. Nut
6. Bushing 13. Clamp bolt
7. Piston seal 14. Grease nipple
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 13 and
then turn the piston rod 2 with a spanner fitted to area 1) of
the piston rod.
Piston seal 7 helps to extend greasing intervals of the grease
nipples 14. Installation of this seal has extended greasing
intervals to 500 hundred hours.
Tilt cylinder dimensions
(Cylinder length and stroke vary depending on forward and
backward tilt angle.)
Truck class Rod diameter (d) Cylinder inside diameter (ID) Cylinder outside diameter (OD)
4.0 to 4.5 ton 40.0 mm (1.575 in.) 80.0 mm (3.150 in.) 95.0 mm (3.740 in.)
5.0C to 5.5 ton 40.0 mm (1.575 in.) 90.0 mm (3.543 in.) 110.0 mm (4.331 in.)
11-15
2. Removing Hydraulic Pump
2.1 Removal Sequence
2
501389
1. Pump suction hose 3. Pump mounting bolt
2. Pump delivery hose 4. Hydraulic pump
2.2 Suggestions for Removal
(1) Wrap a cloth around the pump to catch oil spill.

(2) Take care to prevent any foreign materials from
entering the pump and hose from disconnected
sections.
3. Installing Hydraulic Pump
To install, follow the removal sequence in reverse.
3.1 Suggestions for Installation
- Apply grease to the spline of the pump shaft before

installation.
- Insert the gasket between the pump and transmission
PTO.
- Perform operation test after installation of pump. Refer
to "6.2 Operation test."
11-16
4. Disassembling Hydraulic Pump
4.1 Disassembly Sequence
5 1
7 1
3
*
*
*
* * *
2 4 3
8
501397
1. Rear cover, Bolt, Washer, Bushing 5. Drive gear
2. Front cover, Snap ring*, 6. Driven gear
Shaft seal*, Bushing 7. Side plate
3. Gasket*, Gasket (shaped like 3)* 8. Body
4. Side plate
Parts marked with * are included in the seal kit.

There is no spare part supply for parts without * mark.
Note:
(1) As a general rule, only the gear pump manufacturer
should perform disassembly, repair, and reassembly.
Only in the case of an emergency or unavoidable
situation, the disassembly and reassembly of the gear
pump is allowed. In such case, follow the instructions
described below. Note that a field overhaul will release
the pump manufacturer from any warranty claims if
you decide to perform by yourself.
(2) Do not disassemble shaft seal 2 and bushing 1 unless
they are defective.
4.2 Suggestions for Disassembly
(1) Do not forcibly tap the rear cover 1 and front cover 2
with a hammer as they are made of aluminum alloy and
easily damaged. Use either a wooden hammer or a
plastic hammer.
(2) When disassembling, do not forcibly remove the body,
gear, bushing, etc. by tapping with a hammer.
(3) Place the disassembled parts in an orderly sequence.
Note the relative position of the gear and bushing side
plate for correct reassembly.
11-17
5. Inspecting and Repairing Hydraulic Pump
(1) Drive and driven gears
- Check the gear teeth flank and top faces for wear or
damage.
- Check the side faces of the gears for wear or damage.
- Check the shafts for wear or damage.
(2) Check the covers, body and bushings for wear or
damage.
501400
6. Reassembling Hydraulic Pump

For reassembly, follow the disassembly sequence in reverse.
6.1 Suggestions for Reassembly
(1) Replace the seal kit parts marked with * with new ones.
(2) Completely remove oil or grease from the mating
surfaces of the front cover, rear cover and the body.
(3) Visually check every part for cleanliness and apply
hydraulic oil to the inside surfaces of the body before
reassembly.
(4) Apply grease to the shaft seal lips.
(5) Be careful not to cause damage to the lip of shaft seal
by the spline edges of drive gear.
(6) Tighten the bolts evenly.
(7) The pump shaft should be lightly turned with a pipe
wrench when assembled.
6.2 Operation Test
Operation test should be performed after installation of

pump.
(1) Check that there is sufficient oil in the hydraulic tank.
(2) Attach a pressure gauge to the pump delivery hose.
Refer to "32.2 Control Valve, Inspecting and Adjusting
main relief valve."
(3) Start the engine, and gradually turn the adjusting screw
of the main relief valve from 0 to 19.1 MPa (0 to 194.8
kgf/cm2) [0 to 2770.2 psi], and check the temperature
rise of the pump body by touching it by hand. If the
pump body temperature rises significantly compared
to the rise in oil temperature, disassemble the pump
again to check it.
(4) Set the relief valve to the specified pressure.
(5) Measure lifting speed of the forks with no load. If the
measured speed meets the specification, the pump oil
discharge amount is normal.
(6) Place load on forks, and check that the forks move up
and down smoothly.
11-18
7. Removing Lift Cylinders (Simplex Mast)
6 5
3
1
501403
1. Hose guard 4. Set bolt, Shim
2. Return hose (if equipped) 5. Cylinder clamp (Cushion, Collar, Shim)
3. High-pressure hose 6. Lift cylinder, Bracket

Removing return hose (if equipped)
Remove the hose guard. Start the engine, raise the lift
bracket to the top, and then stop the engine. Disconnect the
right and left cylinder return hoses from the connectors.
1) 2)
Note: DO NOT touch the lift lever during removal.
3)
501404
1) To right side lift cylinder 3) To hydraulic tank
2) To left side lift cylinder
Lowering lift bracket

Slowly lower the lift bracket with the lift lever.
11-19
Disconnecting high-pressure hoses
Remove the high-pressure hose. Place an oil pan
underneath to catch remaining oil inside the hoses. 1) 2)
501405
1) Right cylinder 2) Left cylinder
Removing set bolts

(1) Remove the set bolt from the top of each lift cylinder.
Lift the inner mast to separate the cylinder rod ends. To
lift the inner mast, wrap a cloth around it for protection,
and hitch a wire rope winding a full circle around the
mast.
Note: Shims are inserted at the rod end section of the lift
cylinders. Record the location and number of shims to
ensure proper assembly.
501407
(2) Place wood blocks under the inner mast that can
withstand the weight of mast, and untie the wire rope.
501408
Removing lift cylinders

Attach a wire rope to the lift cylinder from the back of the
mast, and slowly remove the lift cylinder. Attach the wire
rope to the cylinder before removing the cylinder clamps.
501409
11-20
8. Installing Lift Cylinders (Simplex Mast)
For installation, follow the removal sequence in reverse.
(1) Extend and retract the lift cylinders to the full stroke
several times without load to bleed air out of the
cylinders. Make sure that the cylinders move smoothly.
(2) After the verification, check the level of the hydraulic oil
with the oil level gauge.
(Refer to "Inspecting and Adjusting 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 the stroke imbalance between the two
cylinders.
(For inspection and adjustment, refer to "MAST AND
FORKS.")
9. Removing Lift Cylinders (Duplex and Triplex Masts)
In the following instructions, triplex mast is used as an example.
4
2
3
1 501412
1. Nut 4. Chain wheel support assembly
2. Lift bracket assembly (with forks) 5. Second lift cylinder
3. First lift cylinder
11-21
Removing lift bracket assembly
(1) 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 from
the anchor bolts of the first lift chains.
501415
(2) Place the mast in a vertical position, and lift the inner
mast until the upper rollers of the lift bracket become
free. Then, slowly move the truck backward.
501417
Removing first lift cylinders

(1) Attach a wire rope to the first lift cylinder, and suspend
it with a hoist. Secure the wire rope firmly so that it will
not slip.
(2) Remove the mounting bolts from the first lift cylinder,
and slowly raise the first lift cylinder to remove.
501419
11-22
Removing second lift cylinders
(1) Disconnect hoses from the second lift cylinders.
(2) Remove the set bolts located at the top of the second
lift cylinders. Attach a wire rope either to the middle or
inner mast, and raise the mast by approximately 550
mm (21.65 in.).
501420
(3) Place wood blocks of the same height under the both
sides of the inner mast (for duplex mast) or the middle
mast (for triplex mast).
501408
(4) Attach a wire rope to the second lift cylinder from

behind the mast, and support the cylinder with a hoist.
Remove the clamp bolts from the cylinder and separate
the cylinder from the mast. Then slowly lift the cylinder.
When lifting the lift cylinder, do not lift the lift cylinder
straight up because the lift cylinder will hit 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.
501421
11-23
10. Installing Lift Cylinders (Duplex and Triplex Masts)
(1) Install chain wheel support in parallel with the chain

anchor bolt holes on the first lift cylinder. Improper
installation shown in the figure (bad example) will
cause a twist in the chain.
(2) Adjust chain tensions.
Refer to "Checking and Adjusting Chain Tension" of
“MAST AND FORKS.”.
(3) Extend and retract the lift cylinders to the full stroke
several times without load to bleed air out of the
cylinders. Make sure that the cylinders move smoothly.
1) 2)
(4) After the verification, check the level of the hydraulic oil
with the oil level gauge.
501424
1) Good 2) Bad
11. Disassembling Lift Cylinder

(Second for Simplex Mast and Triplex Mast)
2 3
16 12 15
6 7 58 9 8 1 4 10 17 11 13 14
501426
1. Plug 10. Piston rod assembly
2. Head subassembly 11. Back-up ring
3. Piston rod subassembly 12. U-ring
4. Cylinder tube subassembly 13. Bushing
5. Cylinder head 14. Snap ring
6. Wiper ring 15. Cushion bearing
7. X-ring 16. Check valve
8. O-ring 17. O-ring
9. Bushing
Note: The figure shows the internal drain type cylinder without a return pipe. For the cylinder with a return pipe, refer to "(2) of
1.10 Lift Cylinder."
11-24
Removing piston
Be careful not to damage the piston seals and cylinder bore
surface when pulling out the piston from the cylinder.
12. Inspecting Lift Cylinder
Cylinder tube
- Check the bore surface for excessive wear, scratches
and rust.
- Check welds for cracks or dents.
Piston rod
- Check rod deflection.
- Check the rod surface for scratches, rust or wear.
Rings and gaskets

- Check the lips for damage, wear, or deterioration.
11-25
13. Reassembling Lift Cylinder
2) 3)
1)
4) 5) 501427
1) Apply liquid packing around the periphery when 4) Fill with grease (acceptable if adhering to bushing)
installing. 5) Apply ThreeBond 1901 when installing
2) Apply grease during assembly.
3) 3.92 ± 0.98 N·m (0.40 ± 0.10 kgf·m) [2.89 ± 0.72 lbf·ft]
(Cylinder disassembly should be carried out after
removing the plug.)
(1) Clean the disassembled parts with a cleaning solvent.

Blow off foreign materials such as dust with
compressed air. Do not apply compressed air to rubber
parts.
(2) Apply a clean coat of hydraulic oil to every sliding
surface and sealing surface.
(3) Apply ThreeBond 1901 (anti-seize) to the threads of the
cylinder head, and tighten the cylinder head to the
specified torque with a hook wrench.
Truck class
Item
4.0 to 4.5 ton 5.0C to 5.5 ton
Second cylinder head thread size M69 x 1.5 M75 x 2
Second cylinder head tightening 343 ± 78.5 N·m 382 ± 87.3 N·m
torque (34.98 ± 8.00 kgf·m) [252.98 ± 57.90 lbf·ft] (38.95 ± 0.00 kgf·m) [64.389 ± 0.00 lbf·ft]
11-26
14. Removing Lift Cylinders (Second for Duplex Mast)
14.1 Disassembly Sequence (4.0 to 4.5 ton classes)
1 2 4 3
21
578 9 1011 20 12 19 17 15 14 16 1318
6
501428
1. Holder subassembly 12. Rod
2. Head subassembly 13. Piston
3. Piston rod subassembly 14. Slide ring
4. Cylinder tube subassembly 15. Set screw
5. Holder 16. Check valve
6. Wiper ring 17. Cushion spool
7. Back-up ring 18. Spring
8. U-ring 19. Snap ring
9. O-ring 20. Tube assembly
10. Head 21. Plug
11. Bushing
11-27
14.2 Disassembly Sequence (5.0C to 5.5 ton classes)
7 8
2 10 3 1 4 5 6
501429
1. Cylinder head 7. Spacer, Snap ring
2. Wiper ring 8. Slide ring, Set screw, Piston
3. O-ring 9. Snap ring, Check valve, Spring, Washer Spool
4. U-ring 10. Bushing
5. Spacer
6. Piston rod

Removing piston
Be careful not to damage the piston seals and cylinder bore
surface when pulling out the piston from the cylinder.
15. Inspecting Lift Cylinder (Second for Duplex Mast)
Cylinder tube
and rust.
- Check welds for cracks or dents.
Piston rod
Rings, packings, and threaded portions

- Check seal lips for damage, wear, or deterioration.
- Check threaded portions for damage.
11-28
16. Reassembling Lift Cylinder (Second for Duplex Mast)
16.1 Suggestions for Reassembly (4.0 to 4.5 ton classes)
1)
2) 3)
4) 5) 6)
501432
1) 3.92 ± 0.98 N·m (0.40 ± 0.10 kgf·m) [2.89 ± 0.72 lbf·ft] 3) Pay attention to installation orientation
(M6 x 1) Slit side should face to spring side.
2) 3.92 ± 0.98 N·m (0.40 ± 0.10 kgf·m) [2.89 ± 0.72 lbf·ft] 4) Apply liquid packing around the periphery when
(M5 x 0.8) installing.
Apply screw lock. 5) Apply ThreeBond 1901 when installing
After tightening, caulking with a 2 point punch.
6) 245 ± 4.4 N·m (24.98 ± 0.45 kgf·m) [180.7 ± 3.25 lbf·ft]
(M40 x 1.5)

parts.
Truck class
Item
4.0 to 4.5 ton
Second cylinder head thread size M63 x 2
Second cylinder head tightening torque 304 ± 71 N·m (31.0 ± 7.24 kgf·m) [224.22 ± 52.37 lbf·ft]
11-29
16.2 Suggestions for Reassembly (5.0C to 5.5 ton classes)
1) 2) 3) 4) 5)
501436
1) Apply liquid packing around the periphery when 4) 3.92 ± 0.98 N·m (0.40 ± 0.10 kgf·m) [2.89 ± 0.72 lbf·ft]
installing. (M5 x 0.8)
2) 343 ± 78.5 N·m (34.98 ± 8.0 kgf·m) [252.98 ± 57.90 After tightening, caulking with a 2 point punch.
lbf·ft] 5) Pay attention to installation orientation
3) 294 ± 52.9 N·m (29.98 ± 5.39 kgf·m) [216.84 ± 39.02 Slit side should face to spring side.
lbf·ft]

parts.
11-30
17. Disassembling Lift Cylinder
(First for Duplex and Triplex Masts)
1 2 3
5 48 6 7 9 17 16 10 11 13 1214 15
501437
1. Cylinder head subassembly 10. Rod
2. Piston rod subassembly 11. Piston
3. Cylinder tube subassembly 12. Slide ring
4. Cylinder head 13. Seal ring assembly
5. Wiper ring 14. Check valve
6. U-ring 15. Snap ring
7. Bushing 16. Cylinder tube
8. O-ring subassembly
9. O-ring 17. Plug

Removing piston rod
Be careful not to cause damage to the cylinder bore surface
when pulling out the piston rod from the cylinder.
18. Inspecting Lift Cylinder
Cylinder tube
and rust.
- Check welds for cracks.
Piston rod
Rings, packings, and threaded portions

- Check lips for damage, wear, or deterioration.
- Check threaded portions for damage.
11-31
19. Reassembling Lift Cylinder
2) 3)
1)
4) 6)
5) 501438
1) Apply liquid packing around the periphery when 4) Apply ThreeBond 1901 when installing
installing. 5) Cushion oil (hydraulic oil sealed-in amount) during
2) Cylinder for 4.0 to 4.5 ton class: reassembly
647 ± 150 N·m (65.97 ± 15.30 kgf·m) [477.19 ± 110.63 Cylinder for 4.0 to 4.5 ton classes: 160 to 180 cc (9.76 to
lbf·ft] (M105 x 2) 10.98 cu.in.)
Cylinder for 5.0C to 5.5 ton class: Cylinder for 5.0C to 5.5 ton classes: 190 to 210 cc (11.60
834 ± 191 N·m (85.04 ± 19.48 kgf·m) [615.12 ± 140.87 to 12.82 cu.in.)
lbf·ft] (M115 x 2) 6) R side
3) 3.92 N·m (0.40 kgf·m) [2.89 lbf·ft]

parts.
(3) Pay attention to the orientation when installing the
check valve snap ring.
(4) Before installing the cylinder head, fill the space
between the tube and rod with the specified amount of
hydraulic oil as cushion oil.
11-32
20. Removing Tilt Cylinders
20.1 Preparation
(1) Lower the forks to the ground, and tilt the mast fully
forward.
(2) Install eyebolts into the bolt holes on the cross member
of the outer mast, and attach a lifting slings to the
eyebolts, and support the mast with a hoist.
4
3 2
501439
1. Tilt cylinder pin 3. Tilt cylinder pin
2. Hoses (2 places per cylinder) 4. Tilt cylinder
Retracting piston rod

Remove tilt cylinder pin 1, start the engine, and fully retract
the piston rod. Stop the engine.
Removing hoses
Disconnect hoses 2 from the connectors on cylinder side.
Prepare an empty can to catch oil that will flow out. Attach
caps to the cylinder nipples to protect the threads from
damage and to prevent oil from flowing out through them
during cylinder removal.
Removing tilt cylinders

Remove tilt cylinder pin 3, and remove the cylinder.
11-33
21. Installing Tilt Cylinders
After installing tilt cylinders, check balance of the mast tilt

angle. Adjust as required. For adjustment, refer to "CHAPTER
MAST AND FORKS."
22. Disassembling Tilt Cylinder
1 2 3
6 5 7 8 910 11 16 151314 12
5 17 19 18
4
501444
1. Tilt socket subassembly 11. O-ring
2. Guide bushing subassembly 12. Nut
3. Piston rod subassembly 13. Piston
4. Cylinder subassembly 14. Piston seal
5. Bolt, Nut 15. Spacer
6. Tilt socket 16. Rod
7. Guide bushing 17. Cylinder assembly
8. Dust seal 18. Bushing
9. Packing 19. Grease nipple
10. Buffer ring
Note:
(1) Before disassembly, record the distance from the
holder end face to the socket end face when the rod is
fully retracted. 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 nuts unless a defect
is found during inspection.
11-34
Removing guide bushing
(1) Wrap a cloth around the tilt cylinder, 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.
501448
23. Inspecting Tilt Cylinder
Cylinder tube
- Check the cylinder inner surface for wear, damage, or
rust.
- Check the welded area for cracks, damage or dent.
Piston rod
- Check the rod surface for rust, damage, scratch marks
and dents.
- Replace if significant damage is found on its threads.
Rings and packings

- Check packings, dust seals, and piston seal lips for
damage and distortion.
- Check rings for deterioration.
11-35
24. Reassembling Tilt Cylinder
1) 2) 3)
501445
1) 262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 3) 588 ± 29 N·m (59.96 ± 2.96 kgf·m)
lbf·ft] [433.68 ± 21.39 lbf·ft]
2) 4.0 to 4.5 ton class: 520 ± 54 N·m (53.02 ± 5.51 kgf·m)
[383.53 ± 39.83 lbf·ft]
5.0C to 5.5 ton class: 628 ± 63 N·m (64.04 ± 6.42 kgf·m)
[463.18 ± 46.47 lbf·ft]
(1) Before reassembly, thoroughly clean each part and

make sure that they are free from foreign materials
such as dust.
(2) Reassemble the cylinder in the reverse order of the
disassembly. Apply hydraulic oil to O-rings, piston seals,
dust seals, packings and the bore surface of the cylinder
tube before assembly. Also, pay attention to the
installation orientation.
(3) When holding the cylinder tube in a vise, be careful not
to distort the tube.
Installing piston seal
(1) Before fitting the inner piston seal, squeeze it by hand
five or six times to soften it.
501450
11-36
(2) 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.
501451
25. Piping
(For piping for the mast, refer to "MAST AND FORKS.")
25.1 Piping for MC Valve on Diesel Engine Models
9
7
5
8 4
13
6
14
10 1
12
11
3 2
501455
1. Suction strainer 8. Left side tilt cylinder
2. Pump suction line (low pressure) 9. Steering valve
3. Hydraulic pump (located on the right side of the truck) 10. Knob deviation control valve
4. Pump delivery line (high pressure) 11. Steering hydraulic line
5. MC control valve 12. Steering cylinder
6. Lift line (high pressure) 13. Return line (low pressure)
7. Tilt line 14. Return filter
11-37
26. Removing Suction Strainer and Return Filter
2 1
504267
1. Suction hose 4. Suction strainer
2. Return hose 5. Return filter
3. Tank cover
(1) Remove the suction hose from the pump.

(2) Remove the hose of the return line from the control
valve.
(3) Remove all the tank cover mounting bolts.
(4) Lift the tank cover. Cover can be removed from the tank
in assembled condition shown in the figure.
(5) Remove the suction strainer and return filter.
27. Inspecting Suction Strainer and Return Filter
(1) Wash the suction strainer.
(2) The return filter requires periodic replacements.
Replace the filter every oil change. Also replace the
filter one month after the purchase a new lift truck or
one month after every overhaul.
11-38
28. Installing Suction Strainer and Return Filter
To install, follow the removal sequence in reverse.
(1) Tighten the strainer and filter to the specified torque.
Part name Tightening torque

Return filter 49 ± 9.8 N·m (5.0 ± 1.0 kgf·m) [36.14 ± 7.23lbf·ft]
Suction filter 49 ± 9.8 N·m (5.0 ± 1.0 kgf·m) [36.14 ± 7.23lbf·ft]
(2) Securely install the pump suction hose to prevent air

from being sucked.
29. Inspection and Adjustment
29.1 Inspecting and Adjusting Hydraulic Tank
Oil daily inspection

Check oil level and check oil for contamination and white
turbidity (air and water intrusion).
Proper oil level
Check oil level with the mast fully lowered.
501459
Item 4.0 to 4.5 ton 5.0C to 5.5 ton

Simplex mast L level 62 L (16.38 US gal.) 74.5 L (19.683 US gal.)
Duplex mast L level 62 L (16.38 US gal.) 74.5 L (19.683 US gal.)
3.7 to 5.5 m (145.67 to 216.54 in.) L level 62 L (16.38 US gal.) 74.5 L (19.683 US gal.)
Triplex mast
6.0 to 7.0 m (236.22 to 275.59 in.) H level 67 L (17.70 US gal.) 81 L (21.40 US gal.)
R CAUTION
The oil level must be higher than the L level and lower than the H level when the mast is fully lowered, regardless of mast type
or any combination of the mast and attachment.
Filling hydraulic tank with oil

For recommended oil, refer to "SERVICE DATA."
(1) With the mast fully lowered, fill the hydraulic tank with
oil.
(2) Move the mast up and down, and repeat this several
times, and then lower the mast.
(3) Check the oil level with the level gauge.
If the oil level is low, add oil.
11-39
Inspecting suction strainer

Check for damage and clogging. Wash if contaminated.
Inspecting return filter
Check for damage. The filter requires periodic replacements.
Replace if replacement interval has been reached.
Refer to "29. Removing Suction Strainer and Return Filter."
29.2 Inspecting Control Valve
External oil leak

(1) Check for oil leaks from the joint between adjacent
valve housings sealed with O-ring.
(2) Check for oil leaks from threaded connections.
Valve internal oil leak
To check oil leaks of the control valve, connect the control
valve to each cylinder for inspection. Follow the instructions
(1) through (3) below for inspection.
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.
(Oil temperature for measurement: 50°C [122°F])
(1) Place a load equal to the rated capacity on the forks,
and lift the forks approximately 1 m (39.37 in.) high. Tilt
the mast about 3° to 4° forward from the vertical
position, and stop the engine.
501460
(2) Quickly disconnect the oil return hose, and catch the oil
that comes out.
501461
Amount of oil discharged in 15 minutes

25 cc (1.53 cu.in.) or less
(3) 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 in 15 minutes is less than 25 cc
(1.53 cu.in.), measure the internal oil leak of each
cylinder. (The value given above is the average value,
not the service limit.)
11-40
Adjusting main relief valve
(1) Install a pressure gauge capable of measuring up to 25
MPa to the delivery hose connector.
(2) Move the tilt lever to the tilt back position. If the 3
pressure gauge reading when the tilt cylinders are
reached to the end of their stroke is in the specified 2
range, the main relief valve setting is correct.
(3) If the relief pressure is incorrect, loosen the lock nut of
the relief valve, and then adjust by rotating the
adjusting screw while observing the pressure gauge
reading.
(4) While holding the adjusting screw, tighten the lock nut
to secure the adjusting screw.
(5) After securing the adjusting screw, check the main 1
relief valve set pressure again.
501463
1. Pressure gauge 3. Main relief valve
2. R 1/8 4. Pump delivery hose
Item Specifications
Main relief valve set pressure 19.1 MPa (194.8 kgf/cm2) [2770.2 psi]
Remove the R 1/8 plug from the metal end fittings of the
pump delivery hose and attach a pressure gauge to it.
Adjusting steering system relief valve
(1) Install a pressure gauge capable of measuring up to 25
MPa (255 kgf/cm2) [3626 psi] to the pump delivery hose 3
connector.
(2) Place the control levers in the neutral position. 1
(3) Start the engine and run it at medium speed. Turn the 2
steering wheel to the extreme right or extreme left to
release oil in the steering system. The relief pressure
must be within the range in the table below.
(4) If the relief pressure is outside the range, remove the
cap and turn the adjusting screw for adjustment.
(5) After adjustment, tighten the lock nut. Check the relief
pressure again.
501464
1. Pressure gauge 3. Main relief valve
2. R 1/8 4. Pump delivery hose
Item Specifications
Steering system relief valve

11.8 MPa (120.3 kgf/cm2) [1711.4 psi]
set pressure
11-41
Vertical drift test
(1) Carry 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) in 15
minutes. Divide the measured value by two to obtain
the natural descent.
501466
Item Value
Vertical drift amount
50 mm (1.97 in.)/15 minutes or less
(when loaded)
Tilt drift test

(1) Carry a load equal to the rated capacity, place the mast
in a vertical position, lift the fork about 500 mm (19.7
in.) high, and stop the engine.
(2) Measure the extension of tilt cylinder piston rod for 15
minutes.
501467
Item Value
Tilt drift amount
20 mm (0.79 in.)/15 minutes or less
(when loaded)
11-42
30. Troubleshooting
Item Condition Possible cause Actions

Hydraulic tank oil level is too low. Refill.
Oil viscosity is improper. Change, refer to "SERVICE DATA."
Check working conditions and, if
Overload overloaded, instruct the operator to stay
within the load limit.
Line is clogged, which generates a
Hydraulic tank heats restriction to oil line flow and causes local Clean oil line.
excessively. overheating.
Relief valve is improperly adjusted. Adjust pressure setting.
Hydraulic
tank Set pressure decrease due to fatigued or Disassemble or replace, and adjust
broken springs. pressure.
Gear pump is worn. Replace pump.
Discharge line tube is flattened and flow
Repair or replace.
is restricted.
Shortage of oil due to a natural loss. Add oil, refer to "SERVICE DATA."
Cylinders move too Oil leaks due to damaged oil line, seals,
Repair or replace.
slow. etc.
Oil viscosity is too high. Change oil, refer to "SERVICE DATA."
11-43

Check pump and piping. Repair or
Gear pump does not suck oil.
replace.
Cylinders move too
Check oil level and condition, add or
slow. Oil leaks from hydraulic line.
change.
Gear pump internal leakage Replace pump.
Poor pumping of oil. Add oil, refer to "SERVICE DATA."
Check suction pipe for any flat
(1) portion or loose connection.
Retighten or replace if necessary.
Pump is too noisy.
Cavitation Check shaft oil seal for airtightness,
(2)
replace pump.
Check pump body for any outside
(3)
interference. Repair.
Gear pump
Replace pump. (Check if pressure control
Pressure is higher than rated.
valve had been working at rated valve.)
Replace pump.
Pump case, drive gear
or pump port flange is Check if return line has been
(1)
damaged. Distortion or damage due to external blocked or excessively restricted.
force.
Check to see if pipe connections
(2) have been externally strained or
stressed.
Oil leaks from oil seal. Replace shaft seal.
Oil leaks through sliding surfaces of drive
Replace the pump assembly.
Oil leaks from pump. shaft.
Bolts that secure the pump are loosened. Retighten. Replace parts if required.
Seal inside pump is deteriorated. Replace gasket.
Valve opening pressure setting is too low. Adjust pressure.
Relief valve piston does not move Wash piston and check to see if it moves
smoothly. smoothly; or replace relief valve assembly.
Outer O-ring on relief valve body is
Slow or no motions of Replace O-ring.
damaged.
lift and tilt cylinders.
Spool stroke is not enough due to control
Adjustment
lever looseness.
Control Check if spool is not in proper position,
Oil temperature rises abnormally.
valve and repair or replace as required.
Lift/tilt drift (descent
Control valve spool internal leaks. Replace leaking block assembly.
or forward tilt)
Replace O-ring, also check spool for
Oil leaks at spool ring cap. scratches. If scratches are found, repair or
replace block assembly.
Oil leaks.
Plug loose. Retighten plug.
O-ring damaged Replace O-ring.
11-44

Hydraulic tank oil level is too low. Add oil, refer to "SERVICE DATA."
Relief valve malfunction
Mast will neither
ascend nor tilt (1) Main valve jamming. Replace.
forward or backward.
(2) Valve spring fracture. Replace.
Gear pump malfunction Replace.
Relief valve malfunction
(1) Relief valve setting pressure
Adjust pressure.
decrease
(2) Plunger or poppet seat defects. Replace.
Unable to lift rated
load. (3) Spring settling. Replace.
Lift and tilt (4) O-ring in valve case damaged. Replace.
cylinders
Gear pump malfunction Replace.
Piston seal worn or damaged. Replace.
Engine speed too slow Adjust the engine.
Spool stroke is not enough due to loose
Lifting speed is too Adjustment
control lever.
slow.
Tank strainer is clogged. Clean or replace.
Gear pump delivery volume is too low. Repair or replace.
Sleeve seized in flow regulator valve. Repair.
Lowering speed of lift Excessive oil flow resistance due to dirt
cylinder is too slow. Clean or repair hydraulic line. Replace a
contamination in the flow regulator valve,
defective hose.
flattened hose or local clogging.
11-45

Piston rod deflection Repair or replace.
Cylinder vibrates Bleed air by extending cylinder through
Air inclusion in hydraulic line.
during operation. its full stroke.
Hydraulic oil level in the tank is too low. Refill.
Scratches, which can be felt by finger nail,
Repair or replace.
on sliding surface of cylinder tube
Too much lift cylinder
Sliding surface of cylinder tube badly
drift. Replace cylinder assembly.
grooved.
Piston seals are damaged or distorted. Replace seal kit.
Oil leaks from hydraulic line. Repair or replace.
Foreign particles are lodged in packing. Replace packing.
Lift and tilt Too much tilt cylinder
cylinders drift. Piston seal damaged. Replace seal.
Abnormal distortion or oil leaks from
Repair or replace.
hydraulic line.
Lift cylinder or tilt Local severe scoring or rust on inner
Repair or replace.
cylinder will drift surface of cylinder.
(descend or tilt
forward) at a certain Cylinder distortion. Replace.
point.
Foreign particles are lodged between
sealing members such as oil seals and Replace.
dust seals.
Oil leaks from Inner or outer diameter of oil seal or dust
bushing. Replace.
seal damaged.
O-ring damaged. Replace O-ring.
Cylinder is abnormally distorted. Repair or replace.
11-46
31. Service Data
Item Value
Forward tilt angle (standard model with simplex
Standard value 6°
mast)
Backward tilt angle (standard model with simplex
Standard value 12 °
mast)
Lift cylinder vertical drift (at rated load)
(Retracted Length of rod, oil temperature at 45 °C Standard value 50 mm (1.97 in.)/15 minutes or less
[113 °F])
Tilt cylinder forward drift (at rated load)
(Extended length of rod, oil temperature at 45 °C Standard value 20 mm (0.79 in.)/15 minutes or less
[113 °F])
+0.5 +5.1 +72.52
Main relief valve set pressure Standard value 19.1 0 MPa (194.8 0 kgf/cm2) [2770.2 0 psi])
+0.5 +5.1 +72.52

Steering system relief valve set pressure Standard value 11.8 0 MPa (120.3 0 kgf/cm2) [1711.5 0 psi])
Return filter Tightening torque 49 ± 9.8 N·m (5.0 ± 1.0 kgf·m) [36.14 ± 7.23 lbf·ft]
Suction strainer Tightening torque 49 ± 9.8 N·m (5.0 ± 1.0 kgf·m) [36.14 ± 7.23 lbf·ft]
11-47
31.1 Second Cylinder for Simplex and Triplex Masts
Truck class (4.0 to 4.5 ton)

Ref. Item
Simplex Mast Triplex mast
Rod outside Standard
1 50 mm (1.97 in.) 50 mm (1.97 in.)
diameter value
Cylinder inside Standard
2 65 mm (2.56 in.) 65 mm (2.56 in.)
diameter value
Cylinder outside Standard
3 73 mm (2.87 in.) 73 mm (2.87 in.)
diameter value
Cylinder head Standard
4 M69 x 1.5 M69 x 1.5
thread size value
Tightening 343 ± 78.5 N·m 343 ± 78.5 N·m
5 Cylinder head
Tightening 3.92 ± 0.98 N·m 3.92 ± 0.98 N·m
6 Plug
5 4 6 7
1 2 3
501469
5 4
1 2 3
501470
11-48
31.2 Second Cylinder for Simplex and Triplex Masts
Truck class (5.0C to 5.5 ton)

Ref. Item
Simplex Mast Triplex mast
Rod outside Standard
1 50 mm (1.97 in.) 50 mm (1.97 in.)
diameter value
2 70 mm (2.76 in.) 70 mm (2.76 in.)
diameter value
3 79 mm (3.11 in.) 79 mm (3.11 in.)
diameter value
Cylinder head Standard
4 M75 x 2 M75 x 2
thread size value
Tightening 382 ± 87.3 N·m 382 ± 87.3 N·m
5 Cylinder head
Tightening 3.92 ± 0.98 N·m 3.92 ± 0.98 N·m
6 Plug
Cushion oil Standard
7 75 to 85 cc (4.58 to 5.19 cu.in.) 90 to 100 cc (5.49 to 6.10 cu.in.)
sealed-in amount value
5 4 6 7
1 2 3
501469
5 4
1 2 3
501470
11-49
31.3 Second Cylinder for Duplex Mast
Truck class
Ref. Item
4.0 to 4.5 ton 5.0C to 5.5 ton
Rod inside
1 Standard value 24 mm (0.94 in.) 30 mm (1.18 in.)
diameter
Rod outside
diameter
Cylinder inside
diameter
Cylinder outside
diameter
5 Holder thread size Standard value M63 x 2 -
304 ± 71 N·m 343 ± 78.5 N·m
6 Holder Tightening torque
(31.0 ± 7.23 kgf·m) [224.22 ± 52.36 lbf·ft] (35.0 ± 8.00 kgf·m) [252.98 ± 57.89 lbf·ft]
7 Piston thread size Standard value M40 x 1.5 -
245 ± 44 N·m 294 ± 52.9 N·m
8 Piston Tightening torque
(25.0 ± 4.48 kgf·m) [180.70 ± 32.45 lbf·ft] (30.0 ± 5.39 kgf·m) [216.84 ± 39.01 lbf·ft]
3.92 ± 0.98 N·m (0.400 ± 0.09 kgf·m)
9 Plug Tightening torque -
[2.8912 ± 0.72 lbf·ft] (M6 x 1)
3.92 ± 0.98 N·m (0.400 ± 0.09 kgf·m) 3.92 ± 0.98 N·m (0.400 ± 0.09 kgf·m)
10 Set screw Tightening torque
[2.8912 ± 0.72 lbf·ft] (M40 x 1.5) [2.8912 ± 0.72 lbf·ft](M5 x 0.8)
6 5 9 10 7 8
1 2 3 4
501472
6 5 7 8
1 2 3 4
501473
11-50
31.4 First Cylinder for Duplex and Triplex Masts
Truck class
Ref. Item
4.0 to 4.5 ton 5.0C to 5.5 ton
Standard
1 Rod outside diameter 70 mm (2.76 in.) 75 mm (2.95 in.)
value
Standard
2 Cylinder inside diameter 100 mm (3.94 in.) 110 mm (4.33 in.)
value
Standard
3 Cylinder outside diameter 115 mm (4.53 in.) 127 mm (5.00 in.)
value
Standard
4 Cylinder head thread size M105 x 2 M115 x 2
value
647 ± 150 N·m 834 ± 191 N·m
Tightening
5 Cylinder head (66.0 ± 15.29 kgf·m) (85.0 ± 19.47 kgf·m)
torque
[477.20 ± 110.63 lbf·ft] [615.13 ± 140.87 lbf·ft]
3.92 ± 0.98 N·m 3.92 ± 0.78 N·m
Tightening (0.400 ± 0.09 kgf·m) (0.400 ± 0.07 kgf·m)
6 Plug
torque [2.8912 ± 0.72 lbf·ft] [2.8912 ± 0.57 lbf·ft]
(M5 x 0.8) (M5 x 0.8)
Cushion oil sealed-in Standard
7 160 to 180 cc (9.76 to 10.98 cu.in.) 190 to 210 cc (11.60 to 12.82 cu.in.)
amount value
5 4 6 7
1 2 3
501474
11-51
31.5 Tilt Cylinder
Truck class
Ref. Item
4.0 to 4.5 ton 5.0C to 5.5 ton
Standard
1 Rod outside diameter 40 mm (1.57 in.)
value
2 80 mm (3.15 in.) 90 mm (3.54 in.)
diameter value
3 95 mm (3.74 in.) 110 mm (4.33 in.)
diameter value
Bushing inside Standard

4 41 mm (1.61 in.) 41 mm (1.61 in.)
diameter on head side value
Bushing inside Standard

5 4.0 mm (0.158 in.) 4.0 mm (0.158 in.)
diameter on rod side value
520 ± 54 N·m 628 ± 63 N·m
Tightening
6 Guide bushing (53.0 ± 5.50 kgf·m) (64.0 ± 6.42 kgf·m)
torque
[383.53 ± 39.82 lbf·ft] [463.19 ± 46.46 lbf·ft]
Tightening
7 Nut 588 ± 29 N·m (60.0 ± 2.95 kgf·m) [433.69 ± 21.38 lbf·ft]
torque
Tightening
8 Tilt socket clamp bolt 262 ± 13 N·m (26.7 ± 1.32 kgf·m) [193.24 ± 9.58 lbf·ft]
torque
6 7
4 1 2 3 5
8
501475
11-52
32. Outline of MC Control Valve
This control valve 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.
32.1 Hydraulic Lines of MC Control Valve
A hydraulic control system of this valve is of an open center

parallel line arrangement. It has a center bypass function so
that an oil pressure source becomes free of load when a 2
spool is in the neutral position. When more than one spool is T P 1
fully stroked, their moving sections act simultaneously, but T2
they do not always act in the same manner. This is because 3
of the pressure difference between moving sections, as they
)(
have different loads and areas. In this situation, a moving
LS PF
)(
section under the smallest load pressure acts first, and the
one under the largest load acts last. In a hydraulic control
system it is necessary to adjust a stroke of each valve 10
according to its load pressure so that all moving sections
operate in the same manner. For example, a change-over 9
valve under a heavy load pressure must be fully stroked
while change-over valves under smaller load pressure may
need only half of the full stroke. 12 4
A1
)(
)(
5
13
6
11
)( )(
7
B2
A2
8
B3
A3
501476
1. Priority valve 7. Tilt valve
(with LS) 8. Attachment valve
2. Main relief valve 9. Unloader valve
3. Steering system relief valve 10.Solenoid for unloader valve
4. Lift valve 11.Center bypass port
5. Lift lock valve 12.Parallel feeder
6. Solenoid for lift lock valve 13.Flow regulator valve
11-53
32.2 Names of Parts
Outline (3-way valve)
1 2 3 4
10) 7)
1)
9)
6)
2)
5)
8) 3)
4)
501478
1. Inlet section 4) A2 port
2. Tilt valve assembly 5) A3 port
3. Attachment valve assembly 6) B2 port
4. End cover section 7) B3 port
1) P port 8) PF port
2) T port 9) LS port
3) A1 port 10) T2 port
11-54
Lift lines
1 3
2 6
501479
1. Flow regulator valve 4. Return spring
2. Spool 5. A1 port
3. Lock puppet 6. Tank line
11-55
Electromagnetic controlling section
4
1
6
2
9
5
7
3 8
501480
1. Lift lock valve control solenoid valve 6. Tank line
2. Unloader valve control solenoid valve 7. Tank line
3. Unloader valve 8. A1 load check
4. Lift lock valve unlocking screw 9. To lift spool
5. Unloader valve control line
11-56
Priority valve section
6 3
1 5
4
7
9
8
501482
1. Main relief valve 6. P line
2. Steering system 7. Tank line
3. Priority valve 8. LS line
4. Control orifice 9. To load valve
5. PF port
11-57
33. MC Control Valve Function
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 integrated
combination of steering control circuits and lift control
circuits, and to which the tilt section or attachments 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
electromagnetic 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.
33.1 Priority Valve Function
A steering priority valve has a valve mechanism that feeds

hydraulic oil to a power steering unit in preference to a load 5
handling unit. This priority valve is a load-sensing priority- 1
type valve that provides a dynamic signal to the steering
4
unit, incorporating a built-in relief valve in the LS circuit. 1)
2
3
7 6 2)
501483
1. Main relief valve 6. LS line
2. PF relief valve 7. Tank line
3. Control orifice 1) To steering valve
4. PF port 2) To load valve
5. P line
Hydraulic oil flow in the LS circuit

The hydraulic oil from P port passes through a PF throttle
section and a control orifice inside the spool, and flows out 2 1
of LS port. When the flow from P port increases, the flow
that passes through the control orifice also increases. Then a P PF
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 input oil exceeds certain limits, the
EF throttle is opened to drain excess oil, and thereby LS EF
controlling the increases in pressure difference. As a result,
1)
the flow of oil out of LS port remains constant.
501484
1. PF throttle 1) Priority valve movement
2. EF throttle
11-58
Motion when LS port under load pressure
When the pressure in the LS port increases, the spool moves
in the direction to close the EF throttle because the pressure 2 1
difference before and after the control orifice decreases.
This causes EF throttle resistance to increase, and thereby
P PF
increasing the pump pressure.
LS EF
1)
501485
2. EF throttle
Motion by load pressure

When the pressure in the downstream from the EF throttle
valve is increased due to a load handling operation, the 2 1
pressure in the P port is increased, causing an increase in the
pressure difference before and after the control orifice. Then P PF
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, the increase in the pressure difference
before and after the control orifice is limited so that the flow LS EF
from LS port as well as the pressure difference before and W
after the control orifice remains constant. 1)
501486
2. EF throttle
Motion by steering operation

When the PF flow occurs, the pressure in the P port is
decreased, causing an increase in the pressure difference 2 1
before and after the control orifice. Then the spool moves in P PF
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 difference before and
after the control orifice remains constant. Based on these LS EF
characteristics, the pressure difference before and after the 1)
throttle of the steering unit located in the downstream from
PF port is maintained at a constant level, and the PF flow
rate can be changed by adjusting throttle angle.
501491
2. EF throttle
11-59
33.2 Unload Solenoid Valve Function
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:
When an electromagnetic solenoid is de-energized:
The hydraulic oil that passed through the orifice inside the
unload poppet flows into the tank passage through a 1
solenoid valve. This flow creates a pressure difference
before and after the orifice, causing the unload poppet to
open so that the high pressure circuit is opened to the tank
passage. As a result, the hydraulic oil from the high pressure 2
passage cannot flow into load operation sections, and
thereby locking the load handling operation.
501492
1. Tank line 2. High-pressure passage
When an electromagnetic solenoid is energized:

When the electromagnetic solenoid is energized, the flow of
oil from the solenoid valve is blocked so that the flow in the 1
orifice inside the unload poppet stops. As a result, the
unload poppet is closed, thereby allowing oil to flow from
the high pressure passage to the load handling operation
sections. 2
501493
1. Tank line 2. High-pressure passage
11-60
33.3 Lift Section Function
Neutral
The discharged oil from the pump returns to the tank
through the unload passage. As the A1 port is blocked, the 1 5
hydraulic oil will not flow into the lift cylinder. 3
2
6 7 501495
1. Flow regulator valve 5. A1 port
2. Spool 6. Unload passage
3. Lock poppet 7. Tank line
4. Return spring
Spool in pulled-out position (Lift up)

The unload passage is closed so that the discharged oil from
the pump flows into the high pressure passage, and flows 5
1
out of A1 port by opening the load check valve and the lock
poppet. The return spring returns the spool to the neutral 3
position.
4
2 6 7 501496
4. Return spring
Spool in pushed position (Lift down)

Even when the spool is moved in the pushed position, the
unload passage is not closed so that the discharged oil from 5
1
the pump will return to the tank passage.
3
2 6 7 501497
4. Return spring
11-61
When lift lock solenoid is de-energized:
The return oil from A1 port is blocked by a lock poppet so
that the lowering operation is locked.
501498
When lift lock solenoid is energized:

The return oil from A1 port flows to the solenoid valve after
passing through a control orifice 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 neutral
position.
501499
33.4 Tilt Section Function

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.
3 4
2 1
5 6 501500
1. A2 port 5. Unload passage
2. B2 port 6. Tank line
3. Parallel passage 7. Pilot spool
4. Load check
11-62
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 line. 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 line. The
return spring returns the spool to the neutral position.
3 4 1
2
5 501501
1. A2 port 4. Load check
2. B2 port 5. Unload passage
3. Parallel passage
11-63
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 line. The return spring returns the spool to the neutral position.
2 3 4 1
5 501502
3. Parallel passage
11-64
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.
2 3 4 1
5 501503
3. Parallel passage
11-65
33.5 Attachment Section Function
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 cylinder.
3 4
2 1
5 6 501504
3. Parallel passage 6. Tank line
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 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 line. The
2 3 4 1
5
501505
3. Parallel passage
11-66
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 line. The
2 3 4 1
5
501506
3. Parallel passage
11-67
33.6 Pressure Control Valve Function
Four types of relief valves are available for this control valve.
A main relief valve controls maximum pressure in a circuit,
and a LS (load sensing) relief valve that is incorporated 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 maximum pressure at the port.
This port relief valve also incorporates the anti-cavitation
function when the port is under negative pressure.
Main relief valve
(1) When the relief valve is not activated:
The relief valve remains balanced when circuit pressure 5 1
is sufficiently lower than a set pressure. The hydraulic 6
oil fills the spring chamber after passing through the 4
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 due to area differences. As a result, 100%
volume of oil that is fed to the circuit flows into
operating sections. 2
3 501507
1. Main poppet 4. Pilot poppet
2. Orifice 5. Seat
3. Spring chamber 6. Sleeve
(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 loses 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. This oil flow creates a
differential pressure before and after the orifice in the
main poppet, 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 result, the
maximum pressure is adjusted.
501510
11-68
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.
501511
501512
11-69
Port relief valve
(1) When the port relief valve is not activated:
When the pressure in the circuit is sufficiently lower 2 3
than a set pressure, a relief valve remains balanced. The 7 1
hydraulic oil from A or B port fills a spring chamber by 6
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 against the sleeve seat by a spring and
hydraulic force created by area differences. As a result,
100% volume of oil that is fed to the circuit flows into 4
operating sections. 5 8 501513
1. A or B port 5. Spring chamber
2. Main poppet 6. Pilot poppet
3. Middle piston 7. Seat
4. Orifice 8. To tank line
(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 loses 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 created in the orifice of the middle piston, and by the
differential pressure, the middle piston is pressed
against the end of the pilot poppet. And then the
pressure in the spring chamber starts to decrease, and a
pressure fluctuation before and after the main poppet 1
is created. This pressure opens the main poppet so that
oil flows into tank through the tank port passage. As a 501514
result, the pressure in the circuit is maintained to a set
pressure.
1. To tank line
(3) Anti-cavitation function:

When the pressure in the A or B port is decreased with
respect to the pressure in the tank line, a force is
created in the direction to open the main poppet due
to area differences before and after the main poppet.
By this force, the main poppet is opened, allowing the
flow from the tank line to A or B port. As a result, the
generation of negative pressure in the actuator is
prevented.@
11-70
Flow regulator 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 cylinder 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.
(1) When flow rates are less than a specified limit:

The hydraulic oil returning from A1 port passes through 3 2
a variable throttle valve, a secondary pressure chamber 5 4
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 operation is allowed without restriction.
1 501515
1. Variable throttle 4. Spool
2. Secondary pressure chamber 5. Spring chamber
3. Control orifice
(2) When flow rates reach a specified limit:

When flow rates from A1 port increases and a
differential pressure across the control orifice exceeds a
specified limit, the spool moves leftward by the force of
the pressure difference before and after the spool. Then
the variable throttle limits the input flow rates to keep a
differential pressure constant. This operation makes it
possible to keep the maximum flow rates constant and
to limit the flow rate.
501516
11-71
34. Handling Precautions of MC Control Valve
R CAUTION
Conduct transportation, installation, pipe installation and operation safely and properly by observing the instructions below.
34.1 Transportation
When carrying MC control valves, hold the valve bodies and

handle them with care. Do not hold an exposed section of
the spool, electromagnetic solenoid coil, and spool cap
section, and do not drop or hit them against other hard
objects.
34.2 Installation
(1) A mounting surface should be sufficiently flat. If a

mounting surface is uneven, tightening the mounting
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.
34.3 Piping
(1) Do not remove plugs from each port before piping

connection is made. Plugs prevent entry of dirt and
dust.
(2) Be sure to tighten piping joints to the specified torque.
Overtightening may cause valve body distortion, which
may result in interference with the spool movement.
M16 flare
Port size G1 G3 / 4 G1 / 2 G3 / 8
couplings
147 ± 14.7 N·m 98.1 ± 9.8 N·m 58.8 ± 5.9 N·m 39.2 ± 3.9 N·m 39 to 49 N·m
Tightening
(15.0 ± 1.49 kgf·m) (10.00 ± 0.99 kgf·m) (6.00 ± 0.60 kgf·m) (4.00 ± 0.39 kgf·m) (4.0 to 5.0 kgf·m)
torque
[108.42 ± 10.84 lbf·ft] [72.355 ± 7.22 lbf·ft] [43.369 ± 4.35 lbf·ft] [28.912 ± 2.87 lbf·ft] [28.76 to 36.14 lbf·ft]
(3) Thoroughly wash the inside of pipes, hoses and

couplings before assembly. Keep the hydraulic oil clean
during operation. If the hydraulic oil is contaminated by
foreign materials, it may cause trouble by entering into
the orifices or passages in the spools of relief valves.
34.4 Miscellaneous
(1) When painting in the vicinity of valve after the control

valve installation, care should be taken to prevent 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 pressure gauge.
11-72
11-73

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CHAPTER 11 HYDRAULIC SYSTEM

Chapter 11 HYDRAULIC SYSTEM

Refer to “BRAKE SYSTEM.”

DISPLACEMENT 52 cc (3.173 cu. in.)/rev (91.77 kgf/cm2)

FLOW REG.VALVE PARKING BRAKE

Hydraulic Lines Diagram (Wet Disc Brake)

Most of the hydraulic control valves move mechanically.

The figure above shows the condition at which the pipe 4

The above figure shows a condition immediately after the

The above figure shows the position of the piston rod

(2) Pressure oil pushes the check valve 7 to the right.

(3) The figure shows a condition in which the cushion

Cylinder inside Cylinder outside

(1) This figure shows the position of the cushion spool 6

(2) This figure shows a condition in which cushion spool 6

(3) As the piston descends further, cushion spool 6 moves

The tilt cylinder is a double-acting type.

2.2 Suggestions for Removal

(1) Wrap a cloth around the pump to catch oil spill.

- Apply grease to the spline of the pump shaft before

Parts marked with * are included in the seal kit.

6. Reassembling Hydraulic Pump

Operation test should be performed after installation of

7.2 Suggestions for Removal

Lowering lift bracket

Removing set bolts

Removing lift cylinders

Removing first lift cylinders

(4) Attach a wire rope to the second lift cylinder from

(1) Install chain wheel support in parallel with the chain

11. Disassembling Lift Cylinder

Rings and gaskets

(1) Clean the disassembled parts with a cleaning solvent.

14.3 Suggestions for Disassembly

Rings, packings, and threaded portions

(1) Clean the disassembled parts with a cleaning solvent.

(1) Clean the disassembled parts with a cleaning solvent.

17.2 Suggestions for Disassembly

Rings, packings, and threaded portions

(1) Clean the disassembled parts with a cleaning solvent.

20.3 Suggestions for Removal

Retracting piston rod

Removing tilt cylinders

After installing tilt cylinders, check balance of the mast tilt

23. Inspecting Tilt Cylinder

Rings and packings

(1) Before reassembly, thoroughly clean each part and

(2) Secure the piston in a vise, while taking care not to

26.2 Suggestions for Removal

(1) Remove the suction hose from the pump.

(1) Tighten the strainer and filter to the specified torque.

Part name Tightening torque

(2) Securely install the pump suction hose to prevent air

Oil daily inspection

Item 4.0 to 4.5 ton 5.0C to 5.5 ton

Filling hydraulic tank with oil

Inspecting suction strainer

External oil leak

Amount of oil discharged in 15 minutes

Steering system relief valve

Tilt drift test

Item Condition Possible cause Actions