TABLE OF CONTENTS

Chapter 7: Hydraulic System

Hydraulic System
Description ................................................................................................................................... 7.1
Schematics .............................................................................................................................. 7.1
Hydraulic Tank.......................................................................................................................... 7.5
Hydraulic Pump ....................................................................................................................... 7.6
Control Valve ............................................................................................................................ 7.8
Lift and Tilt Cylinders................................................................................................................ 7.9
Down Safety Valve ................................................................................................................... 7.10
Removal and Installation Warning................................................................................................ 7.11
Hydraulic Pump
Removal ....................................................................................................................................... 7.12
Installation .................................................................................................................................... 7.13
Disassembly ................................................................................................................................. 7.14
Working Rules and Tips ........................................................................................................... 7.14
Suggestions ............................................................................................................................. 7.16
Inspection after Disassembly ....................................................................................................... 7.18
Body ......................................................................................................................................... 7.18
Mounting Flange Face ............................................................................................................. 7.18
Bushes and Balance Plate....................................................................................................... 7.18
Gears ....................................................................................................................................... 7.18
Reassembly.................................................................................................................................. 7.19
Inspection after Reassembly........................................................................................................ 7.23
Control Valve
Removal ....................................................................................................................................... 7.24
Installation .................................................................................................................................... 7.25
Disassembly ................................................................................................................................. 7.26
Suggestions ................................................................................................................................. 7.27
Reassembly.................................................................................................................................. 7.27
Lift and Tilt Cylinders
Removal
Lift Cylinders ............................................................................................................................ 7.28
Tilt Cylinders ............................................................................................................................ 7.31
Disassembly
Lift Cylinders ............................................................................................................................ 7.33
Tilt Cylinders ............................................................................................................................ 7.34
Inspection after Disassembly ................................................................................................... 7.35
Precautions for Reassembly ........................................................................................................ 7.35

Inspection and Adjustment

Hydraulic Tank.............................................................................................................................. 7.36
TABLE OF CONTENTS

Control Valve ................................................................................................................................ 7.37

Lift and Tilt Cylinders.................................................................................................................... 7.40
Adjusting Method ..................................................................................................................... 7.41
Testing ...................................................................................................................................... 7.42
 HYDRAULIC SYSTEM

Hydraulic System
Description
Schematic for Trucks

1. Hydraulic tank 4. Steer gear 7. Down safety valve 10. Steering cylinder
2. Hydraulic lift pump 5. Main control valve 8. Lift cylinder
3. Steer pump 6. Flow regulator valve 9. Tilt cylinder

General Information
The hydraulic pump draws oil from the oil tank
and delivers it to the main control valve, which dis-
penses it for lift and tilt functions.
The steer gear and steer pump are covered in the
STEERING SYSTEM section and the steering
cylinder is covered in the REAR AXLE section.

99759-8B110
7.1
NOTES

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99759-7B110
7.2
 3000-6500 lb Capacity Four Section Hydraulic Schematic
GAUGE
GAGE
 HYDRAULIC SYSTEM

Hydraulic Tank
1

6 5

4
3 8609093

1. Cap 3. Drain plug 5. Suction line strainer

2. Oil level gauge 4. Return line filter 6. Lift cylinder pipe

General Information
The tank contains internal filtering means including
a strainer on the suction line and a filter on the
return line.
The lift cylinder return pipe allows the cylinders to
draw fluid when they retract, providing the bore
walls with oil which inhibits corrosion.

99759-8B110
7.5
HYDRAULIC SYSTEM

Hydraulic Pump

8609094A

General Information
This gear pump is capable of developing very high
pressure on its discharge side. A special arrange-
ment is incorporated in the pump construction for
the purpose of keeping the side clearances mini-
mized between bushings on the one side and
pump gears on the other. Note, in illustration
203585 (page 7.6), that discharge pressure is
applied to the back of each bushing through inter-
nal oilways.

99759-8B110
7.6

Hydraulic Pump Operation
Essentially the pump consists of two gears—the
drive gear and the driven gear—closely fitted in
the housing. The oil is carried around the periph-
ery of the revolving gears from the suction to the
discharge side. The teeth meshing between the
two gears prevents the return of oil from the dis-
charge to the suction side.
Driven Gear
Drive Gear
203585
99759-8B110
HYDRAULIC SYSTEM
Pressure Loading Principle
This pump is a self-balanced type based on the
principle of pressure loading, balancing for equal
pressure on all sides of the revolving gear. This
reduces bushing and gear wear. In operation, the
high-pressure oil on the discharge side is fed back
to the suction side. On the suction side, pressure
is exerted equally on both sides of the gears and
shafts, thereby cancelling out unequal pressure to
balance the pump.
Clearance
Discharge side
200333
7.7
HYDRAULIC SYSTEM

Control Valve
9 8 7
10

14

2 6

3 6

11
12 13

Sequence
1. Inlet / Unloader Spool 8. From Hydraulic Pump
2. Tilt Spool 9. To Tank
3. Auxiliary Spool 10. Main Relief Valve, Auxiliary Valve (back)
4. Auxiliary Attachment Spool 11. Auxiliary Relief Valve (front)
5. Outlet Spool 12. Tie bolt
6. Flow Control Screws 13. Nut
7. Lift Port 14. Switches

General Information
The control valve consists of three valve blocks, all
spool-type. The spools are finished by lapping for
their respective blocks and their combination
should not be changed. The lift valve assembly has
a built-in load check valve. The tilt valve spool has
a built-in tilt lock valve. The attachment valve
assembly has a built-in overload relief valve.

99759-8B110
7.8
 HYDRAULIC SYSTEM

Lift and Tilt Cylinders

200345

205979

General Information
The left and right lift cylinders are single-acting
type.
The left and right tilt cylinders are double-acting
type. The piston rod carries a screw-on socket.
The socket is repositioned as necessary by turn-
ing when the cylinder is connected to the outer
mast. This feature allows the tilt cylinders to move
in unison.
The tilt angle is increased or decreased with the
spacer and shim of each cylinder.

99759-8B110
7.9
HYDRAULIC SYSTEM

Down Safety Valve

Burst

Normal When hose burst

204971

General Information
The down safety valve is built in the oil pipe joint at
the bottom end of the lift cylinder. This valve is
internally provided with an orifice to prevent shock
when the valve is closed. In the valve having no ori-
fice, the oil leaks around the valve to prevent
shock.

Valve Types
Down safety valves are available in six types differ- a
ing in terms of shutoff flow and identified by the
number punched on the flat (indicated as “a” on
illustration 201731A). The numbers are: 50, 70, 90,
100, 120, and 150. No. 90 and No. 120 valves each
come in two kinds differing in screw thread size. a

Truck Dual stage Dual-stage full Triple-stage full

panoramic free-lift panoramic free-lift panoramic
1st lift 2nd lift 1st lift 2nd lift
cylinder cylinder cylinder cylinder 201731A

E3000 -
EC4000 70 90 70 90 70 Top View: • Dual-stage panoramic lift cylinder
E4000 - • Dual-stage full free-lift panoramic,
EX5000 70 120 70 120 70
E5500 - 1st and 2nd cylinders
E6500 90 90 120 120 90 • Triple-stage full free-lift panoramic,
2nd lift cylinder
Bottom View: • Triple-stage full free-lift panoramic
1st lift cylinder
99759-8B110
7.10
 HYDRAULIC SYSTEM

Removal and Installation

Warning

! WARNING

Hydraulic oil under pressure can remain in

the hydraulic system after the truck and
pump have been stopped. To avoid
personal injury, this pressure must be
released before any work is done on the
hydraulic system.
To prevent possible injury, lower the lift
bracket to the ground, turn the truck off,
and move the control levers to make sure
all hydraulic pressure is released before
any fitting, plug, or hose is loosened,
tightened, removed, or adjusted.
Always move the lift truck to a clean and
level location away from the path of other
machines.
Be sure that no personnel are near the
machine when the truck is running and
tests or adjustments are being made.

99759-8B110
7.11
HYDRAULIC SYSTEM

Hydraulic Pump
Removal

Sequence
1. Hardware
2. Pump

Start By:
1. Disconnect the battery from the truck. 5. Secure the motor from above with a crane,
hoist, or other adequate device, or support it
2. Disconnect the hoses attached to the pump
at its center with a garage jack.
fittings.
6. Remove the motor and pump assembly from
3. Disconnect the power cables and wire leads
the truck.
from the pump motor.
7. Remove the hydraulic fittings from the pump.
4. Raise the truck enough to allow the pump and
motor assembly to be removed from below the
truck. Make sure that the truck is stable and
secure in the raised position.

99759-8B110
7.12
 HYDRAULIC SYSTEM

Installation
1. To install, follow the reverse sequence of the
disassembly procedure. Before installing
hydraulic fittings in the pump, inspect all
O-rings for damage or aging and replace
them as required.
2. Tighten hose to the following specifications.

Tightening Torque for Hose

E3000-EC4000 E4000-E6500

Supply hose from 6.5 ± 0.7 kgf•m 10.3 to 11.7 kgf•m

pump to mast (48 ± 5 lbf•ft) (74 to 85 lbf•ft)
operating valve [65 ± 7 N•m] [101 to 115 N•m]

3. Lube pump splines before installing into pump

motor. Use molybdenum disulfide grease.

HYDRAULIC PUMP APPLICATIONS

97E71-00030 97E71-00040 97271-00700
23cc 25cc 29cc
Pump Cast-Iron Gear Cast-Iron Gear Cast-Iron Gear
Market Models UL Motor Voltage w/ bronze wear pl. w/ bronze wear pl. split gear (quiet)
E3000-EC4000 E & ES 8" DC & AC 36/48 
No. Am.
E4000-E6500 E & ES 9" DC & AC 36/48 
Europe EC15N-EC18N N/A 8" AC 36/48 
EC20N-EC30N N/A 9" AC 36/48 
E3000-EC4000 EE 8" DC & AC 36/48 
E4000-E6500 EE 9" AC 36/48 
No. Am. E4000, E5000, EX5000 EE 9" DC 36/48 
E5500, E6000, E6500 EE 9" DC 36/48 

99759-8B110
7.13
HYDRAULIC SYSTEM

Disassembly
Standard Pump (1 ton)

5
3

1
4

7
9
6

Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes

Working Rules and Tips

The hydraulic pump is a precision-machined com- Oil Seal
ponent and as such must be handled with extreme An oil seal, once removed, must not be reused.
care. Cleanliness is imperative: use clean tools and After disassembly, examine the oil seal in place (in
work in a clean place. the pump flange) and, if in good condition, leave it
1. Clean the disassembled parts with a volatile in place. When installing a replacement oil seal,
solvent such as trichlene or chlorobenzene be careful not to score or scratch its lip portion.
and dry them with compressed air. This does
not apply to rubber parts.
2. Oil seals, O-rings, and the like are rubber
parts. Never clean them with solvent. Blow
dirt off rubber parts with compressed air, and
keep them immersed in hydraulic oil until they
are ready for reassembly. A rubber part show-
ing even slight wear and tear must be
replaced. Rubber parts are expendable items
that should be replaced once a year.
3. Parts that are installed by pressing or forcing
need special treatment.

99759-8B110
7.14
 HYDRAULIC SYSTEM

Disassembly
Standard Pump (2/3.3 ton)

1 5

9
4
7
6

Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes

Start By:
Externally clean the pump to make sure that it is free
of all matter that may contaminate the pump parts
during disassembly, inspection, or reassembly.

99759-8B110
7.15
HYDRAULIC SYSTEM

Suggestions Removing the Flange

Removing the End Cover Turn the unit over and lightly tap the mounting
flange to disengage it from the locating dowels.
1. Lightly mark the end cover, pump body, and
Slide the flange squarely off the shaft.
mounting flange to ensure proper reassembly.
2. Remove the rear bolts, spring washers, and
the end cover.

Removing the Seals

Remove the O-ring from the pump body. Remove
the bush seal and the backup seal from the rear
bushings.

8609101

Removing the Shaft Seal

Remove the internal retaining clip in the front of
the flange. Push the shaft seal squarely out of the
mounting flange.

8609100

8609102

99759-8B110
7.16
 HYDRAULIC SYSTEM

Removing the O-ring and Seals Separating the Gear Pack

Remove the O-ring from the groove in the body of 1. Separate the gears, key, and balance plate
the pump. Remove the bush seal and the backup from the drive shaft and driven idler shaft.
seal from the front bushings. 2. Note the position of the balance plate to
ensure proper location during reassembly.

Removing the Rear Bushes

Remove the remaining rear bushes from the body
bore.

8609103

Removing the Bushings

Before removing the internal components, mark
the bushings to denote the location in the body on
8609105
a plain area away from the seal location mark.
FD = Bush on flange end of the drive shaft
FI = Bush on flange end of idler shaft
CD = Bush on the cover of priority valve end
of the drive shaft
CI = Bush on the cover end of the idler shaft

Removing the Drive Shaft

With the unit lying on its side, hold the drive shaft
and pull it squarely out of the body, bringing with it
the bushings and the complete gear pack.

8609104

99759-8B110
7.17
HYDRAULIC SYSTEM
Inspection after Disassembly
Body
1. Inspect the body bore cut-in where gears wipe
into the body.
2. The body can only be reused if the cut-in is
bright and polished in appearance and the
depth does not exceed .08 mm.
3. The body should be replaced if the surface is
scored, has a matte appearance, or shows
signs that the tips of the gears have dug in
and torn away the surface material.
4. The body should be inspected to ensure that
there is no superficial damage which may
adversely affect performance or sealing. Pay
particular attention to the port threads and
body O-ring seal recesses.
Mounting Flange Face
1. The inner surfaces should be inspected to
ensure that there is no unusual wear or scoring
in the regions where the body O-rings and bush
seals contact, which could result in external leakage.
2. Check the shaft seal recess for scoring or dam-
age that could result in oil leakage around the
outer diameter of the shaft seal. A replacement
shaft seal can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
Bushes and Balance Plate
1. The side faces which abut the gears should be
perfectly flat and show no signs of scoring.
Characteristically there are bright polished
areas on this surface caused by loading
against the gear side faces. This is often more
pronounced on the low-pressure side. These
should be replaced if there is any general
scoring or fine scoring with a matte appearance
or tearing of the surface material.
2. Often, the tips of the opposing gears have
wiped an overlap in a half-moon shape. There
must be no noticeable wear step as it is criti-
cal that the bush side face and balance plate
are completely flat to the gear side face.
7.18
3. The bush bearing liners are acceptable if they
are not scored or do not show other damage.
The general outside area of the bush should
not show any prominent signs of wear.
Gears
1. The gear side faces should be examined for
bushing or scoring. Often operation on con-
taminated fluid shows scoring between the
root of the gear and the journal, which leaves
a wear step. If a wear step can be felt, coinci-
dental with the root diameter, by drawing a
sharp-pointed tool across the surface from the
journal outward towards the tip of the gear,
then the gear must be replaced.
2. The gear teeth should be carefully examined
to ensure that there are no signs of bruising or
pitting.
3. The journal bearing surfaces should be com-
pletely free from scoring or bruising. The sur-
face should be highly polished and smooth to
the touch.
4. Examine the area where the shaft seal lips run
on the drive shaft. This shows up as polished
ring or rings. If a noticeable groove can be felt,
or if there is scoring, the shaft should be
replaced.
5. Examine drive keyway in driveshaft journal
extension to ensure it is not damaged or
chipped.
6. If the driveshaft is not damaged from the drive
coupling and the gears have not been harmed
as described above, then the gears can be
reused. If the gears are damaged, they must
be replaced as a matched set.
7. As a matter of good practice, when pumps
have been dismantled, all the seals should be
replaced.
99759-8B110
 HYDRAULIC SYSTEM

Reassembly
Trucks with Standard Hydraulic Pump

5
3

1
4

7
9
6

Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes

Start By:
Ensure that all parts are perfectly clean. Lubricate
the bushes and gears with clean hydraulic fluid.
Ensure that the O-ring recess and end faces of the
body remain dry. This will assist the assembly of
the components with the body bores.

99759-8B110
7.19
HYDRAULIC SYSTEM

Reassembling the Rear Bushes Fixturing with the End Cover

1. Install the rear bushes (marked CD and CI) Use the end cover to temporarily fixture the parts
into the undowelled end of the body. as they are reassembled. Place the end cover on
its back and set the undowelled end of the body
against it so that the dowels are pointing up.

Reassembling the Balance Plate

1. Hold the driveshaft and driven gear of the idler
shaft together and refit the balance plate in its
original position.
2. The two grooves in the plate must be to the
low-pressure side of the pump (the side where
the body bores meet in a point). With the drive
8609107 shaft nearest to you, these grooves will be on
the left-hand side as shown for the counter-
2. The C-shaped cutout in the bushes must be to clockwise rotation.
the side of the body with the cusp removal flat.
3. The diagram below shows the location of the
driveshaft and the front bushes and seals
installed.

Location Flange end

dowels

Cusp
Removal
Inlet 8609109

Position of
driveshaft

Counterclockwise Rotation
8609108

99759-8B110
7.20
 HYDRAULIC SYSTEM

Reassembling the Gear Pack Reassembling the O-ring and Seals

1. Fit the key into the keyway in the driveshaft Fit a new O-ring, bush seal and backup seal,
and then carefully fit the gear over the key. Fit ensuring that the seals locate correctly in the seal
the second gear on the idler shaft. grooves.
2. Keeping the gear pack together, carefully feed
the assembly into the body bores with the
driveshaft positioned as previously shown.

8609112

Reassembling the Shaft Seal

8609110

Premium pump configuration 1. Fit a new shaft seal into the recess in the
mounting flange with the “garter” spring facing
into the pump.
2. If the seal recess was scored, then Loctite
hydraulic sealant must be applied to the outer
diameter of the seal.
3. Apply a coat of high-melting-point grease to
the shaft seal lips.
4. Reinstall the retaining ring. Ensure that it is
located in its groove.

Standard pump configuration

Reassembling the Front Bushes

Refit the front bushes (FD and FI) into their origi-
nal bores, remembering that the C-cutout must be
to the side of the body with the cusp removal flat.
They must match the rear end bushes.

8609102

8609111

99759-8B110
7.21
HYDRAULIC SYSTEM

Reassembling the Flange Reassembling the End Cover:

Slip the shaft seal and flange assembly over the Replace end cover and refit the bolts and wash-
driveshaft and carefully refit the mounting flange, ers. Tighten the bolts.
ensuring that it is positioned squarely onto the
dowels in the body.

End
cover

8609115A
8609113

Reassembling the Rear O-ring and Seals E3000 - EC4000 E4000 - E6500
1. Hold the whole unit together and carefully turn 4.7 to 5.2 kgf•m 9.0 to 10.4 kgf•m
it over. Ensure that it is supported on the Tightening torque (34 to 38 lbf•ft) (65 to 75 lbf•ft)
mounting flange, not the driveshaft. for bolts [46 to 51 N•m] [88 to 102 N•m]
2. Remove the end cover and install a new O-
ring, bush seal, and backup seal.

NOTE

Lube splines before installing in pump

motor. Use molybdenum disulfide grease.

8609114

99759-8B110
7.22
 HYDRAULIC SYSTEM

Inspection after Reassembly

Pour a small amount of clean hydraulic fluid into a
port and check that the shaft can be rotated with-
out undue force using a smooth-jawed vise.
Running In After Reassembly
A unit which has been reassembled with either new
gears, bushes, or body, must be carefully run in
before it is subjected to full working conditions.
Ideally, this should be done on a test rig, where
pressure can be applied gradually and any wipings
from the body cut-in can be arrested by filters.
It is recommended that, initially, the unit is run in at
1500 rpm at zero pressure for one minute. The
pressure should then be increased in intervals of
35 bars a minute until maximum pressure is
reached. Check the system temperature frequently,
ensuring that it does not exceed the maximum per-
missible temperature of 80°C. If the temperature
exceeds the system or unit specification, the test
must be delayed and operated off-load until the
temperature is lowered to an acceptable range.
Typical pump ratings are shown in the table below.

Pressure
Test gauge
unit Micronic Variable
filter restrictor

Flow
Strainer Relief meter
Tank
valve

Typical pump test circuit

8609116

Typical performance applicable when using

ISOVG 32 at 40°C (104°F)
Pump Part Test Speed Max. Flow Rate
Number Continuous
Pressure
97L71-00030 1500 rpm [180 bar] 9.11 GPM
(2683 psi) 32.1 L/min
204 kg/cm2
97L71-00040 1500 rpm [180 bar] 9.91 GPM
(2683 psi) 34.2 L/min
209 kg/cm2
97271-00700 1500 rpm [185 bar] 11.49 GPM
(2683 psi) 43.5 L/min
204 kg/cm2

99759-8B110
7.23
HYDRAULIC SYSTEM

Control Valve Removal

Sequence Start By:

1. Auxiliary lines 1. Remove the floorplates and the front
2. Tilt lines, connectors, and O-rings dashboard cover.
3. Delivery hose, connector, and O-ring 2. Tilt the mast to vertical position, lower the forks
4. Return Hose
all the way, and relieve the pressure in the
5. Lift hose and connector
6. Steering return hose hydraulic lines.
7. Solenoid 3. Disconnect the battery.
8. Lower Switch 4. Disconnect the wire leads to the valve
9. Control Valve
switches.
10. Steering Return Connector
11. Switches 5. Disconnect the hydraulic lines per the listed
sequence solenoid, and lower switch.
6. Remove the 3 mounting bolts from the front of
the dash.
7. Remove the valve from the truck.

99759-8B110
7.24
 HYDRAULIC SYSTEM

Control Valve Installation

1. To install, follow the reverse of the Tightening Torque for Hoses

disassembly sequence. Before installing
25 ± 0.5 N•m
hydraulic fittings, inspect all O-rings for A Tilt hoses 2.5 ± 0.5 kgf•m
damage or aging and replace them as 18 ± 3.6 lbf•ft
required. 65 ± 7 N•m
B Delivery hose 6.5 ± 0.7 kgf•m
2. Tighten hoses to the specifications shown in
47 ± 5 lbf•ft
the chart. 82 ± 8 N•m
C Lift Hose 6.5 ± 0.7 kgf•m
47 ± 5 lbf•ft
82 ± 8 N•m
D Aux Hoses 5.0 ± 0.5 kgf•m
36.2 ± 3.6 lbf•ft
Steer Gear 48 ± 5 N•m
E Return Connector 5 ± 0.5 kgf•m
36.2 ± 3.6 lbf•ft
98 ± 10 N•m
F Return Connector 10 ± 1.0 kgf•m
72 ± 7.2 lbf•ft

99759-8B110
7.25
HYDRAULIC SYSTEM

Disassembly

99759-8B110
7.26
 HYDRAULIC SYSTEM

Suggestions
Main Relief Valve
NOTE
To remove main relief valve for cleaning or
inspection, loosen its plug. Loosening the
lock nut will disturb the pressure setting.
Reassembly
Before Reassembly:
1. Wash all parts except for O-rings with solvent.
2. Apply hydraulic oil to O-rings when installing
them.
3. Make sure that each spool moves freely.

1. Lay out valve components on a clean, flat

Do not remove the main relief valve unless it is
working surface. The inlet assembly will
defective. This also applies to shut-off valve
include an o-ring, and the spool sections
assembly.
include an o-ring, a load check poppet and a
load check spring. Tools required for basic
Plug valve assembly include 1/2” and 9/16” open or
box end wrenches and a torque wrench with
thin wall sockets.
2. Assemble tie rod nuts to one end of each tie
rod with one or two threads showing. Insert
Lock nut rods through tie rod holes of inlet (larger tie
rod at top). Lay inlet on end with tie rods up,
place o-ring into position.
205025 3. Place first spool section (o-ring side up) on
inlet section, position o-ring and insert load
check poppet (nose down) and spring (behind
Auxiliary Relief Valve poppet) into load check cavity as shown.
Repeat this procedure for each spool section;
the load check springs are compressed by the
NOTE
following sections during assembly.
To remove auxiliary relief valve for 4. Position end section on last spool section and
cleaning or inspection, loosen its plug. hand tighten tie rod nuts. The end section is a
Loosening the lock nut will disturb the “turn around” section without ports. Universal
pressure setting. outlet / power beyond section and power
beyond and closed center sections are also
used as end sections. These end sections do
Do not remove the auxiliary relief valve unless it is
not have o-ring grooves.
defective. This also applies to shut-off valve
assembly. 5. Position valve assembly with the mounting
pads of the end sections on a flat surface. To
obtain proper alignment of end sections rela-
Plug tive to the spool sections apply downward
pressure to the end sections; snug tie rod nuts
to about 10 ft-lb.
Final torque the two 1.2” nuts to 14 ft-lb; final
torque the 9/16” nut to 33 ft-lb. check for prop-
Lock nut er spool movement.
6. Install auxiliary valves and plugs and torque to
proper specifications
205025
99759-8B110
7.27
HYDRAULIC SYSTEM

Lift and Tilt Cylinders

Removal
Lift Cylinders

5 4

1
207068

Sequence
1. Hose guard 4. Cylinder clamp (cushion, collar, and shims)
2. High-pressure hose 5. Lift cylinder and bracket
3. Set bolt and shims

99759-8B110
7.28
 HYDRAULIC SYSTEM

Suggestions
1. Removing hose guard:
With the lift bracket raised to the maximum
height, remove each hose guard from the front
side of the mast.

! CAUTION
Be careful not to touch the lift control
lever.

2. Lowering lift bracket:

Lower the lift bracket by carefully operating the
lift control lever.
3. Disconnecting high-pressure hoses:
Disconnect the high-pressure hoses at the
joints indicated by arrows. Use a container to
catch oil flowing out of the hoses.

Right-hand cylinder
Left-hand cylinder

204933

99759-8B110
7.29
HYDRAULIC SYSTEM
Removing Set Bolts
1. Remove the set bolt at the top of each lift cylin-
der. Lift the inner mast to separate the cylinder
rod ends. To lift the inner mast, clove-hitch a
sling to the mast with protective wad.
204934
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 record
of the number of shims and the cylinder to
which the shims are fitted.
2. Place wood blocks under the inner mast and
detach the sling. Use blocks strong enough to
support the mast.
202983
7.30
Removing Lift Cylinders
Attach a lift sling to the lift cylinder from the rear
side of the mast and remove the cylinder. Attach
the sling before removing the cylinder clamp.
204935
Installation
Lift Cylinders
To install, reverse the removal sequence and do
the following steps.
1. Extend and retract the lift cylinders several
times under no-load conditions to expel air
from the cylinder circuits and to make sure the
cylinders move smoothly.
2. Check the oil level in the hydraulic tank with
the oil level gauge.
3. Check that the lift height is correct.
4. After the lift cylinders or piston rods have been
replaced, check for difference in stroke
between the two cylinders (refer to MAST
AND FORKS).
99759-8B110
 HYDRAULIC SYSTEM

Removal
Tilt Cylinders

3
1

206883

Sequence
1. Tilt socket pin (spacer) 3. Cylinder pin (spacer)
2. Rubber hose (O-ring) 4. Tilt cylinder

Start By:
1. Lower the forks all the way and tilt the mast
fully forward.
2. Hitch lifting slings to the top crossmember of
the outer mast by passing them through the
round holes. Take up the weight of the mast
with a hoist.

Suggestions
1. Retracting piston rod:
207085
Remove tilt cylinder pin (item 1), and retract
the piston rod all the way.
2. Disconnecting hoses:
Disconnect hoses (item 2) from the cylinder at
the connectors. Use a container to catch oil
from 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 cylin-
der is removed.
99759-8B110
7.31
HYDRAULIC SYSTEM

Suggestions
Removing Tilt Socket
Later Version

! WARNING

If both tilt cylinders are to be removed at

the same time, make sure that the mast is
held either by a hoist or is securely
supported and held in place by blocks.

1
4

2 3 206883

1. Rubber hose
2. Tilt socket pin, bolt, washer
3. Tilt cylinder pin, bolt, washer
4. Tilt cylinder

NOTE

When the tilt cylinders are to be replaced,

it is necessary to adjust the cylinder
stroke and tilt.

99759-8B110
7.32
 HYDRAULIC SYSTEM

Disassembly
Lift Cylinders

5
4

204948

Sequence
1. Bracket assembly 4. Piston rod, snap ring, holder, U-ring, nylon
heel, and piston ring
2. Holder, wiper ring, U-ring and O-ring
5. Cylinder tube
3. Bushing and bearing

Suggestions
Removing Piston Rod
Draw the piston rod out gently, taking care not to
damage the sealing members fitted to the piston.

200349

99759-8B110
7.33
HYDRAULIC SYSTEM

Disassembly
Tilt Cylinders
✱ Parts contained in seal kit

3
✱

1 ✱
✱
✱

1
207050

Sequence
1. Tilt socket, bushing, bolt, washer, nut, and 3. Piston rod, piston seal, and nut
grease fitting
4. Cylinder tube and bushing
2. Bushing, O-ring, dust seal, packing and
buffer ring

NOTE

Do not remove the tilt socket and cylinder

tube bushing unless they are defective.

Suggestions
Removing Bushing
1. Wrap the cylinder with a wad of cloth and hold
it in a vise. Using a wrench, remove the bush-
ing from the cylinder.
2. When removing the bushing from the piston
rod, be careful not to rub the buffer ring, pack-
ing, etc., against the threads of the piston rod.
200351

99759-8B110
7.34

Inspection after Disassembly
Lift and Tilt Cylinders
Cylinder Tube
1. Check the bore wall for wear, grooving,
scratch marks, and rusting.
2. Check the welds for cracks.
Piston Rod
1. Check for deflection in the manner shown.
200319
2. Check for surface flaws such as grooving,
scratch marks, rusting, and wear. The rod
must be replaced if its threads show signs of
stripping or any other damage.
Packings and Rings
1. Check the packings and the lips of dust seals
for damage, distortion, and deterioration due
to aging.
2. Check each ring for deterioration due to aging.
99759-8B110
HYDRAULIC SYSTEM
Precautions for Reassembly
1. Wash all parts clean, making sure that each
part is clear of any gritty particles.
2. Before inserting the piston rod complete with
the piston, apply hydraulic oil to the bore wall
of the cylinder tube and to the sealing parts:
O-rings, U-rings, wiper rings, nylon heels, pis-
ton seals, dust seals, and packings—so they
will slide smoothly into the bore.
3. When clamping the cylinder tube in the vise in
order to run the head into the cylinder tube, be
careful not to distort the tube #4 and #117.
Before fitting the piston seal to the tilt cylinder
piston, squeeze the seal by hand 5 or 6 times
to soften it. Hold the piston steady by clamping
the rod in a vise and apply a small amount of
hydraulic oil to the seal. Fit a portion of the
seal to the groove and push the rest of the
seal into place a little at a time until the seal is
in the groove.
4. Be sure to torque the nut, not the bolt when
re-installing the tilt cylinder.
Torque to 108 to 118 N•m; 11 to 12 kgf•m.
200352
200353
7.35
HYDRAULIC SYSTEM

Inspection and Adjustment

Hydraulic Tank
Hydraulic Oil
1. Check the hydraulic oil in the tank for cleanli-
ness. Oil appearing dirty or whitish (showing
more or less emulsification) must be changed.
2. Refill capacities in the amount of oil required.
NOTE
A general rule: in any machine, regardless
of the mast-and-attachment combination,
the oil level should not be above the “H”
mark on the level gauge when the mast is
all the way down.

Suction Strainer
! WARNING
Check the suction strainer for clogging or damage.
Remove the hydraulic tank filler cap only
after the truck has been stopped and the Return Filter
fill cap is cool enough to remove with your
bare hand. Check the return filter for clogging or damage.

Hydraulic Tank Refill Capacities

E3000 - EC4000 E4000 - E5000 EX5000 - E6500

18 (4.8) 24 (6.3) 30 (7.9)

Unit: liter (U.S. gal)

99759-8B110
7.36
 HYDRAULIC SYSTEM

Control Valve

External Leakage
1. Check for oil leaks from the joint between 2. Quickly disconnect the oil return hose and
adjacent valve housings sealed by O-ring. start collecting the oil coming out of the valve
2. Check for oil leaks from the scrapers sealed from the oil return port A.
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. The correct way to check the
control valve in place under normal operating con-
ditions follows.
The internal leakage to be checked includes leak-
age occurring at the lift spool, tilt spool, tilt lock A
valve, and check valves.
[Test oil temperature: approx. 50°C (122°F)]
Amount of oil collected 500 cc (30.5 cu. in.)
1. Pick up a load equal to the rated capacity. Lift for 15 minutes maximum
it approximately 1 meter (3 ft) high. Tilt the
mast forward 3° - 4° and turn off key.
3. If the tilt cylinders or lift cylinders drift (the mast
tilts forward or the fork lowers) excessively even
3° - 4°
though the amount of oil collected in 15 min-
utes 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.)
approx.
1 meter
(3 feet)

203521A

99759-8B110
7.37
HYDRAULIC SYSTEM
Main Relief Valve Adjustment
1. Screw in special tool (6V3965) pressure port
with o-ring into gauge port on valve (B).
2. Attach a pressure gauge capable of measur-
ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa]
to the pressure port.
3. Start the truck and move the control lever to
the backward tilt position and hold. If the relief
pressure reading is
197 ± 3 kgf/cm2
(2630 ± 50 psi)
[19,650 ± 34 kPa]
when the tilt cylinders reach the end of their
stroke, the main relief valve setting is correct.
B
C
4. If the setting is incorrect, loosen the lock (C)
nut of the adjusting screw and, while observ-
ing the pressure gauge reading, slowly turn
the adjusting screw in either direction until the
gauge indicates the prescribed set value.
5. While holding the adjusting screw, tighten the
lock nut to secure the adjusting screw.
6. After securing the adjusting screw, recheck the
setting.
197 ± 3 kgf/cm2
Main relief valve setting (2630 ± 50 psi)
[19,650 ± 34 kPa]
7.38
Auxiliary Relief Valve Adjustment
1. Screw in special tool (6V3965) pressure port
with o-ring into delivery hose port on valve(B).
2. Attach a pressure gauge capable of measur-
ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa]
to the pressure port.
3. Start the truck and move the Auxiliary 1 con-
trol lever to the far right position and hold. If
the relief pressure reading is
158 ± 5 kgf/cm2
(2250 ± 71 psi)
[15,513 ± 490 kPa]
the auxiliary relief valve setting is correct.
A
4. If the setting is incorrect, loosen the lock nut of
the adjusting screw and, while observing the
pressure gauge reading, slowly turn the
adjusting screw in either direction until the
gauge indicates the prescribed set value.
5. While holding the adjusting screw, tighten the
lock nut to secure the adjusting screw.
6. After securing the adjusting screw, recheck the
setting.
158 ± 5 kgf/cm2
Auxiliary relief valve setting (2250 ± 71 psi)
[15,513 ± 490 kPa]
99759-8B110
 HYDRAULIC SYSTEM

Basic Hydraulic Switch Adjustments Install switch on Tilt spool or Auxiliary spool per
Install switch on Lift spool per Photo 1. Adjust and Photo 3 centered on spool lobe. Adjust and torque
torque bolts on switches to 7 ± 1 in-lbs [0.79 N•m bolts on switches to 7 ± 1 in-lbs [0.79 N•m ± 0.11
± 0.11 N•m] (0.08 kgf•m ± 0.01 kgf•m). N•m] (0.08 kgf•m ± 0.01 kgf•m).

Switch 1 Switch has Switch 3 Switch acti-

to activate
vates once
before
leaving
reaching
point C
point A (the
(the spool
top of the
Groove).
A cam).
C

Photo 1 Photo 3

Install switch 2 on Lift spool per Photo 2 centered

on identification groove. Adjust and torque bolts on
the switches to 7 ± 1 in-lbs [0.79 N•m ± 0.11 N•m]
(0.08 kgf•m ± 0.01 kgf•m).

Switch 2

Switch has
to activate
before
reaching
B
point B (the
top of the
cam).

Switch 2

Photo 2

99759-8B110
7.39
HYDRAULIC SYSTEM

Lift and Tilt Cylinders NOTE

Mast Tilt Angle Adjustment
It is not necessary to adjust the forward tilt
1. Place machine in a horizontal position. angle, provided that the backward tilt
2. Tilt the mast all the way backward, and stop angle is properly adjusted.
the truck.
3. Measure the tilt angle of the mast at both sides.
4. To adjust the tilt angle, loosen bolt A of the tilt
cylinder socket, and adjust the cylinder stroke Forward/backward tilt angle 5° – 6°
by turning the rod on either cylinder so that
there is no difference in stroke between the
cylinders.
Lift Cylinder Stroke Adjustment
1. Slowly raise the inner mast and check the
stopping manner of the left and right piston
rods at the moment the inner mast reaches its
maximum lift height.

207054

Tightening torque 127 to 152

for tilt cylinder (13 to 15.5)
socket bolt [94 to 112] 204698

2. If the top of the mast rocks at that moment, it

should be adjusted with shims. Abnormal con-
ditions will appear as a time lag in stopping
between right- and left-hand piston rods and
rocking of the rod with a longer cylinder
stroke.

99759-8B110
7.40
 HYDRAULIC SYSTEM

Adjusting Method
1. Raise the inner mast, place blocks under the
right and left sides of the mast, and lower the
mast until it rests on the blocks.
3. Extend the piston rod and tighten the cylinder
stopper bolt. Remove the blocks from under
the inner mast.
4. Slowly lower the inner mast all the way to make
sure that the piston rods move smoothly.

202983

1. Remove the stopper bolt at the top of the lift

cylinder which stopped first, retract the piston
rod, and insert the shims at the top of the pis-
ton rod end.

Stopper bolt

Shims

200365

NOTE

To retract the piston rod, move the lift

control lever to the lowering position to let
the oil escape from the lift cylinder.

99759-8B110
7.41
HYDRAULIC SYSTEM

Testing
Lift Cylinder Drift Test
1. Pick up a load equal to the rated value, tilt the
mast to the vertical position, raise the forks 1
to 1.5 m (3.3 to 4.9 ft) and stop the truck.
2. Scribe a line on the mast column and measure
the drift of the lift cylinder (drop for 15 minutes)
Tilt Cylinder Drift Test
1. Pick up a load equal to the rated value, tilt the
mast to the vertical position, raise the forks
about 50 cm (20 in.) and stop the truck.
2. Measure the drift extension of the tilt cylinder
for (extension) 15 minutes.

206891 207056

E3000 - EX5000 E5500 - E6500 E3000 - EC4000 E4000 - EX5000 E5500 - E6500

Lift cylinder drift 50 (2.0) 40 (1.6) Tilt cylinder drift 22 (0.9) 20 (0.8) 15 (0.6)
(rated load) maximum (rated load) maximum
Unit: mm (in.)/15 min Unit: mm (in.)/15 min

Piping
1. Check each hydraulic circuit for leaks.
2. Check to make sure that each hose is free
from twisting or excessive loops.

99759-8B110
7.42