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Hydraulic Line
7 15
16
12
11 2
19
20
5 18
14
10
4 17 1 13
9 6
208749
The hydraulic system of this truck includes the mast (1) Lift control valve section
control circuit and the full-hydraulic steering system (2) Tilt control valve section
circuit. (3) Attachment control valve section
The oil drawn by the hydraulic pump 2 from the The lift control valve section controls the operation of
hydraulic tank 18 flows into the control valve inlet the lift cylinders 8 and 9 to raise or lower the mast.
cover section 4 through the pump delivery hose 3. The tilt control valve section controls extension and
The flow priority valve in the control valve inlet cover retraction of the tilt cylinders 6 and 7 to cause the mast
section 4 preferentially distributes the oil to the steering to lean forward or backward.
valve 15 through the oil feed line 14. The priority valve The attachment control valve section controls the
distributes the remainder of the oil to the mast control operation of the attachment actuators.
circuit. In the standard configuration, the following
three valve sections are used for the mast control The return oils from the steering valve and mast control
purposes: cylinders go to the hydraulic tank through the control
valve's end cover section 11 and return hose 12.
10-1
HYDRAULIC SYSTEM
Hydraulic Tank
1 2 8 7
To hydraulic
6 pump
Closed by a plug.
3 5 4
208750
10-2
HYDRAULIC SYSTEM
Hydraulic Pump
Hydraulic pump
Engine
Universal joint
208805
208696
10-3
HYDRAULIC SYSTEM
Control Valve
6 2 3 4
7 8
This illustration shows the three-valve type. 202974A
The control valve is a combination of different valves The main relief valve 6 is a safety valve that regulates
as shown above. The inlet cover 1 incorporates the flow the pump delivery pressure below the maximum level
priority valve which distributes oil to the steering to prevent the hydraulic system from being damaged by
system in an amount sufficient for assisting the steering an excessive pressure.
operation regardless of the delivery rate of the The steering system relief valve 7 is also a safety valve.
hydraulic pump. The flow priority valve distributes the This valve regulates the power steering system pressure
excess oil for the forklift operation. (The flow priority to a level below the maximum pressure.
valve is also called “flow divider valve.”)
Another safety valve is the overload relief valve which
The tilt valve 3 has a spool with a built-in tilt lock prevents the attachment hydraulic devices from being
valve. The purpose of the tilt lock valve is to prevent damaged by excessive pressures.
the mast from tilting when the engine is not in
operation.
10-4
HYDRAULIC SYSTEM
Inlet Cover
208697
The illustration above shows the state when oil is not To summarize, the flow priority valve, regardless of the
being supplied from the port P into the inlet cover. pump delivery rate, ensures that the steering system
When a small amount of pump oil is being supplied to receive a constant volume of oil at all times while
the inlet cover: diverting surplus oil to the mast control circuits.
The oil from port P flows through a passage in the flow The main relief valve 3 is a safety valve that prevents
priority valve spool 2, past an orifice, and then enters the pressure in port (P1) from becoming higher than
port PF without flowing to port (P1). This means that the permissible maximum pressure. The valve has been
the steering system can always receive oil by priority. set to open at 19.1 + 00.5 MPa (195 + 05 kgf/cm2) [2773 + 071
psi]. The valve allows oil to flow from port (P1) to
When the pump starts supplying an increased amount
port T2 if the pressure in port (P1) exceeds the limit.
of oil to the inlet cover:
The steering system relief valve 4 is a safety valve that
Oil flows through the flow priority valve spool 2 in the
prevents the pressure in port PF from becoming higher
same way as when the inlet oil supply amount is small.
than the permissible maximum pressure. The valve has
However, increase in flow of oil causes the difference
been set to open at 8.3 + 00.4 MPa (85 + 05 kgf/cm2) [1209
in pressure before and after the orifice to become larger + 71
0 psi]. The valve allows oil to flow from port PF to
than before. In addition, the pressure oil from the
port T2 if the pressure in port PF exceeds the limit.
pump flows into the cavity on the right-hand end of the
valve spool 2. As a result, the valve spool 2 is pushed
against the force of the spring to the left, opening port
P to port (P1), which allows surplus oil to flow into
port (P1).
10-5
HYDRAULIC SYSTEM
Lift Valve
208698
The illustration above shows the lift valve with the Lift down position:
spool 1 in the neutral position. The spool moves to the left (in the illustration), opening
Neutral position: port A1 to port T2. The oil in the lift cylinder is then
pushed out by the load acting on the cylinder piston and
The high pressure port of the lift valve is open to the
flows through ports A1 and T2 and back to the tank, at
passage leading to port (P1) of the inlet cover. As the
a rate controlled by the flow regulator valve.
center bypass port is open in this state, the oil in the
high pressure port eventually returns to the hydraulic Pump-delivered oil flows through the high pressure port
tank via port T1 in the end cover. and then through the center bypass port to the hydraulic
tank. The spool 1 is returned to the neutral position by
Lift up position: the force of the return spring 2.
When the lift lever is pulled towards the operator, the
spool 1 moves up (moves to the right in the
illustration), opening passage A to port A1 while at the
same time closing the center bypass port. This causes
the pressure in the high pressure port to rise. The
increased pressure pushes open the load check valve 3.
As passage A opens to the high pressure port as a
result, pressure oil eventually flows into port A1.
10-6
HYDRAULIC SYSTEM
Tilt Valve
208699
The illustration above shows the state of the tilt valve Tilt backward position:
with the spool 1 in the neutral position. The spool 1 is moved to the right, closing the center
Neutral position: bypass port. Since this blocks the flow of oil from the
high pressure port, the oil of increased pressure pushes
The center bypass port is open. This allows the pump- open the load check valve 3 and makes its way into
delivered oil to flow to the hydraulic tank through the passage A. As the spool 1 has moved to the right
center bypass port and port T1 in the end cover. The opening passage A to port A2, the oil flows to port A2
oil does not flow to ports A2 and B2 as the passages to and its pressure acts in the direction in which the tilt
the ports are blocked by spool 1. cylinder rod is retracted in the cylinder.
Tilt forward position: As ports B2 and T2 are now open to each other, the oil
The spool 1 is pushed to the left, closing the center in the head end of the tilt cylinder returns to the tank.
bypass port. This causes the pressure in the high In combination with the oil flow mentioned above, this
pressure port to rise. The increased pressure pushes enables the tilt cylinder rod to be retracted in the
open the load check valve 3 allowing pressure oil to cylinder or the mast to be tilted rearward.
flow into passage A. The pressure oil in passage A then The tilt lock valve 4 is a safety valve, provided to
flows into port B2 and acts on the tilt cylinder rod to prevent the mast from tilting forward when the engine
extend it forward, that is, to tilt the mast forward. is not running. To be more specific, with the engine
The pressure oil in passage A also flows to the tilt lock shut down, pump pressure does not act on the tilt lock
valve 4 and pushes the valve to the left against the force valve, so the valve blocks the oil in port A2. Since the
of the spring 5. This opens port A2 to port T2, oil cannot move anywhere, the tilt cylinder rod is kept
allowing the oil in the rod end of the tilt cylinder to unextended. The oil in port A2 remains blocked even if
return to the tank. In combination with the oil flow the valve is moved to “the tilt forward” side while the
mentioned above, this enables the tilt cylinder rod to engine is stationary. This means that the mast does not
extend forward. tilt forward.
10-7
HYDRAULIC SYSTEM
Attachment Valve
208700
The illustration above shows the attachment valve with Spool in the extended position:
the spool 1 in the neutral position. The flow of oil is reverse to that for when the spool is
Spool in the neutral position: retracted. The spool 1 is returned to the neutral
position by the force of the return spring 2.
The center bypass port is open. This allows the pump-
delivered oil to flow to the hydraulic tank through the The plug assembly 4 provides the operator with means
center bypass port and port T1 in the end cover. The to manually operate the actuator by loosening the plug
oil does not flow to ports A3 and B3 as the passages to 4 should the actuator become inoperative for some
the ports are blocked by spool 1. reasons.
Spool in the retracted position: The attachment actuator circuit pressure can be
regulated below a certain limit pressure if a pressure
When the spool 1 is retracted, the center bypass port is
relief valve is installed in place of the plug.
closed. This results in the pressure in the high pressure
port being increased. The increased pressure pushes
open the load check valve 3 allowing the pump
pressure oil to flow through passage A and into port
B3. The attachment actuator is then operated. The oil
in port A3 flows through the passage shown on the left-
hand side of the illustration to port T2 and then to the
tank.
10-8
HYDRAULIC SYSTEM
C 1 3 2 5
D
A1 B
The flow regulator valve regulates the lowering rate of In addition to giving the spring chamber a damping
the mast lift cylinder. effect that regulates the return speed of the spring, the
The arrow in the illustration indicates the direction in check valve 3 prevents the mast from lowering in a
which oil flows when the fork is lowering. jerky manner. The flow rate of oil can be adjusted by
loosening or tightening the plug 4 to change the force
When the mast is lowering, the oil in the bottom end of
of spring 2.
the lift cylinder is pushed out by the weight of the load
carried by the mast and, after passing through the flow When the mast is rising, the oil goes to the lift cylinder
regulator valve, flows back to port A1 in the lift control flowing in the direction reverse to that of the lowering
valve. phase. As the piston 1 now moves fully to the left, no
restriction is given to the flow of oil.
The oil from the lift cylinder enters cavity D and flows
into the piston 1 through eight openings C. The oil
then flows through four openings B, into cavity A1, and
back to port A1 in the lift control valve.
When the flow rate of the return oil becomes excessive,
the piston 1 moves to the right against the force of the
spring 2. As the result of the piston movement,
openings B are narrowed and thus the flow rate of oil
passing these openings is reduced. In this way, the
maximum flow rate of the return oil and thus the
maximum lowering speed of the mast is regulated
regardless of the weight of the load on the mast.
10-9
HYDRAULIC SYSTEM
Stamped 1
identification
number
3
4
2
Opening
208582
1 Connector 3 Spring
2 Valve 4 Spring pin
The down safety valve is located at the bottom of the If the hose becomes damaged, for example, an
LH lift cylinder (applicable only to the simplex mast). unusually large volume of oil flows out of the relevant
Even if the flow of the oil returning from the lift cylinder's bottom towards the flow regulator valve.
cylinders becomes excessive due to a defect in the This oil flow forces the valve 2 to move up against the
piping between the lift cylinders and flow regulator force of the spring 3, The valve then narrows the
valve or due to a poor adjustment of the flow regulator opening in it and thus the flow of oil from the cylinder
valve, the down safety valve prevents sudden drop of is restricted. This prevents the mast from dropping
the mast by regulating the outgoing oil flow of the lift suddenly.
cylinders.
Identification
Truck Model
No.
10-10
HYDRAULIC SYSTEM
Lift Cylinder
Simplex Mast Cylinder/Triplex Mast Second Cylinder
Inlet and
7 6 5 4 3 2 1
outlet port
Plug (shipping
and storage)
Head of shell
Chambar A Space B
8 9 Passage C
208702
Main components
1 Retainer *4 Spacer 7 Wear ring
*2 Shell assembly 5 Check valve 8 Cushion sleeve
*3 Rod 6 Piston seal 9 Piston
NOTE
Dimensions of the parts marked * vary according to Oil passage at bottom of
piston becomes narrower
specifications (lift height). as piston moves down.
8
Inlet and 7 6 5 4 3 2 1
outlet port
(2 pieces)
208704
Main components
1 Retainer 5 Piston
*2 Shell assembly 6 Piston seal
*3 Rod 7 Wear ring
4 Stand tube 8 Check valve
NOTE
Dimensions of the parts marked * vary according to
specifications (lift height).
9 8 208706
Main components
1 Retainer *4 Spacer 7 Wear ring
*2 Shell assembly 5 Piston 8 Bleed screw
*3 Rod 6 Piston seal 9 Sleeve
NOTE
Dimensions of the parts marked * vary according to
specifications (lift height).
The duplex mast second cylinder has a function of In the mast lowering phase, the second cylinder
raising and lowering the duplex inner mast. This operates before the first cylinder.
cylinder starts to operate after the first cylinder has The cushion sleeve 9 prevents the bottom of the piston
completed its operations. 5 from ramming onto the cylinder head at the last stage
When the operator performs mast raising control, the of the piston down-stroke through the process described
pressure oil from port A1 of the lift valve enters the below.
inlet port of the cylinder. The oil then flows through During a down-stroke of the piston, the oil at the
the inside of the rod 3, comes out of the outlet port, and bottom of the piston is forced to flow through the gap
goes to the first cylinder. Since the bore of the first between the inner wall of the sleeve 9 and the cylinder
cylinder is larger than that of the second cylinder, the head. The gap becomes smaller as the piston moves
piston in the first cylinder receives oil pressure with a down, further limiting the flow of oil. This prevents
larger area than the piston in the second cylinder. This large impact that would otherwise occur by hard
makes the first cylinder operate at a lower oil pressure contact between the piston and cylinder head, providing
than the second cylinder. In other words, the first the cylinder with a down-stroke cushioning feature.
cylinder operates first, with the second cylinder starting See the illustration (illustration No. 208703) on page 10-
to operate only after the first cylinder has completed its 11.
operations.
The bleed screw 8 is provided to purge air from the
Pressure oil acts on the bottom of the piston 5, pushing system.
up the piston and rod 3 together.
10-13
HYDRAULIC SYSTEM
Tilt cylinder
208707
Main components
1 Cylinder tube 6 Guide bushing 11 Spacer
2 Rod 7 Dust seal 12 Shim
3 Piston 8 Packing 13 Tilt socket
4 Piston seal 9 O-ring 14 Clamp bolt
5 Self-locking nut 10 Collar
10-14
Hydraulic control valve
T1
Steering valve
A5 B5
R L
A4 B4
T P Steering cylinder
Schematic of Hydraulic System
A3 B3
STD tilt cylinder
A2 B2
Engine
GP/DP40K, 40KL: TB45: 72 kW/2450 rpm
100 liter (26.4 U.S. gal.)/min P S6S : 62.7 kW/2450 rpm
GP/DP45K thru 50K: T M Coupling: Universal joint ratio 1:1
B1
115 liter (30.4 U.S. gal.)/min
10-15
A1
Return Suction
filter strainer Hydraulic Pump
Displacement:
3
50 cm (3.05 cu in.)/REV
P PF T2
Lift cylinder
with down safety
Steering relief Main relief
+0.4 +0.5
11.8 0 MPa 19.1 0 MPa
+2 +5
(120 0 kgf/cm2) (195 0 kgf/cm2)
+71 +71
[1714 0 psi] [2773 0 psi]
208806
HYDRAULIC SYSTEM
Steering cylinder
Tilt cylinder
HYDRAULIC SYSTEM
Lift cylinder
(R.H.) Steering valve
Piping of Hydraulic System
Return hose
T1 Hydraulic pump
(gear pump)
End cover
10-16
Breather Cap
Attachment
Lift cylinder
(L.H.) Tilt
B2 A2
A1 Lift Level gauge
P PF
Down safty
valve
T2 Inlet cover
(with flow priority valve) Suction strainer Return filter
208807
HYDRAULIC SYSTEM
208583
Sequence
1 Universal joint 4 Suction hose, Elbow, O-ring
2 Drive pulley, Lock nut, Boss 5 Hydraulic pump
3 Main delivery hose, Connector, O-ring
The drive pulley lock nut has a left-hand thread. 118 N·m
Main hose (12 kgf·m)
[87 lbf·ft]
10-17
HYDRAULIC SYSTEM
Control Valve
Removal
1
3
8
4
6
7
208584
Sequence
1 Control lever assembly, Clevis pin 6 Steering delivery pipe
2 Attachment pipe 7 Pipe and hose assembly
3 Tilt pipes, Connectors, O-rings 8 Return hose, Connector
4 Lift pipe 9 Control valve
5 Main delivery hose, Elbow, O-ring
Start by:
(1) Before disconnecting the pipes from the control valve,
bring the mast to the vertical position and place the fork
to the lowest position in order to release the residual
pressure in the pipes.
(2) Support the weight of the mast with a crane.
(3) If an attachment is connected, take necessary measures
to prevent it from moving.
(4) Remove the floor plate and dashboard cover.
10-18
HYDRAULIC SYSTEM
Installation
Perform installation by following the removal sequence in
reverse. Also follow the instruction given below.
(1) When screwing connectors into the control valve,
tighten them to the following torque.
118 N·m
Tightening torque (12 kgf·m)
[87 lbf·ft]
39 to 49 N·m
Tightening torque (4 to 5 kgf·m)
[28.7 to 36.1 lbf·ft]
39 to 49 N·m
Tightening torque (4 to 5 kgf·m)
[28.7 to 36.1 lbf·ft]
193 ± 0.5 mm
in.)
Distance A
(7.6 ± 0.02 in.)
0.8
m(
20m
208585
10-19
HYDRAULIC SYSTEM
Lift Cylinders
Removal (Simplex Masts)
208711
Sequence
1 Nuts 5 Stopper bolt, Shims
2 Lift bracket, Forks 6 Cylinder clamp, Cushion, Collar, Shims
3 Cylinder guard 7 Lift cylinder, Bracket
4 High-pressure hose
207084
10-20
HYDRAULIC SYSTEM
208587
NOTE
The rod end of either lift cylinder is shim adjusted to
eliminate the difference in stroke between the
cylinders. Before removing the stopper bolts, make a Shim
record of the amount of shims and a cylinder to which 208588
(2) Place wood blocks and fasten them under the inner mast
and detach the sling. Use the blocks strong enough to
support the mast.
202983
10-21
HYDRAULIC SYSTEM
Shim
208589
Installation
To install, follow the reverse of removal sequence, and do
the following steps:
(1) Extend and retract the lift cylinders several times under
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
(2) Check the oil level in the hydraulic tank with an oil
level gauge. (Refer to the topics “Hydraulic Tank” in
the following section “Inspection and Adjustment.”)
(3) Check the lift height.
(4) After the lift cylinders or piston rods have been
replaced, check for difference in stroke between the two
cylinders. (Refer to the “GROUP 11 MASTS AND
FORKS.”)
10-22
HYDRAULIC SYSTEM
Lift Cylinders
Removal (Duplex and Triplex Masts)
Note that the Triplex Mast is used as an example.
207785
Sequence
1 Nuts 4 Chain wheel support assembly
2 Lift bracket assembly 5 Second lift cylinders
3 First lift cylinder
Suggestions
207786
10-23
HYDRAULIC SYSTEM
(2) Position the mast vertical. Raise the inner mast until
main rollers 6 of lift bracket assembly 2 become free.
Then, slowly move the truck backward to separate from
lift bracket 2.
201735
207787
207788
10-24
HYDRAULIC SYSTEM
(3) Place wood blocks under the inner mast (for duplex
mast) or middle mast (for triplex mast).
Make sure the right and left wood blocks are the same
in height.
202983
207789
Installation
To reinstall, follow the removal sequence in reverse, and
service as follows.
(1) Install chain wheel support assembly 4 parallel to a line
connecting the centers of chain anchor bolt holes on
first lift cylinder 3 to prevent chains from twisting.
(2) Adjust the chain tensions.
(See the “Inspection and Adjustment” section.)
(3) Extend and retract the lift cylinders several times under 207638
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
(4) After proper operation is confirmed, check the oil level.
10-25
HYDRAULIC SYSTEM
Tilt Cylinders
Removal
Sequence
1 Tilt cylinder pin
2 Hoses
3 Tilt cylinder pin
4 Tilt cylinder
2
208590
Start by:
(1) Lower the forks to the bottom, and tilt the mast
fully forward.
(2) Attach a sling to the round holes, right and left, in
the top cross-member of outer mast, and support
the weight of the mast with a hoist.
202778
1. Retracting piston rod Tighten the hose fittings to the following torque.
Remove tilt cylinder pin 1, start the engine and retract 47 ± 4.7 N·m
the piston rod fully, then stop the engine. Tightening torque (4.8 ± 0.5 kgf·m)
[34.6 ± 3.5 lbf·ft]
2. Disconnecting hoses
Disconnect hoses 2 from the cylinder at the connectors.
Use a drip pan to catch oil flowing out of the cylinder.
Attach caps to the connectors of the cylinder to protect
the threads of the connectors and to prevent oil from
flowing out of the cylinder when the cylinder is
removed.
10-26
HYDRAULIC SYSTEM
Disassembly
12
8
❋
9
❋ 15
7
❋ 13
6
15
17 15
16 ❋ 14
❋ 3
❋ 15
5
4 ❋
❋
11
1
10
208591
Sequence
1 Bolt 6 Front cover 10 Body 14 Driven gear
2 Rear cover 7 Gasket 11 Side plate 15 Bushing
3 Gasket 8 Gasket 12 Side plate 16 Snap ring
4 Gasket 9 Backup strip 13 Drive gear 17 Oil seal
5 Backup strip
NOTE
Marked ❋ are the repair kit parts. The parts
marked are not available individually.
200344
10-28
HYDRAULIC SYSTEM
Reassembly
10❋,
2 7❋ 5❋, 6❋ 14 11❋ 12❋
9
18
15 4❋ 3❋ 1 16 13 17 8
208577
Sequence
Preassemble parts 1 to 7 before Preassemble parts 8 to 12 before Preassemble parts 13 to 17 before
installation. installation. installation.
1 Front cover 8 Rear cover 13 Body
2 Bushing 9 Bushing 14 Driven gear
3 Shaft seal 10 Gasket 15 Drive gear
4 Retaining ring 11 Backup strip 16 Side plate
5 Gasket 12 Gasket 17 Side plate
6 Backup strip 18 Bolt
7 Gasket
NOTE
10-29
HYDRAULIC SYSTEM
Control Valve
Disassembly
202999
Sequence
1 Main relief valve 13 Lift valve spool
2 Flow divider relief valve 14 Bolt, Cap
3 Bolt, Nut, End cover 15 Cap screw, Spring seat, Spring
4 Load check valve, Spring, O-ring 16 Plate, Wiper, O-ring
5 Plug 17 Tilt valve spool
6 Spring 18 Poppet (Tilt lock valve), Spring
7 Orifice plug 19 Bolt, Cap
8 Spool 20 Plug, O-ring
9 Housing (inlet) 21 Cap screw, Spring seat, Spring
10 Bolt, Cap 22 Plate, Wiper, O-ring
11 Cap screw, Spring seat, Spring 23 Plate, Wiper, O-ring
12 Plate, Wiper, O-ring 24 Attachment valve spool
10-30
HYDRAULIC SYSTEM
Neutral
Operating 127 (12.9) [28.4]
N (kgf) [lbf]
effort of
spool Full stroke
158 (16.1) [35.5]
N·m (kgf·m) [lbf·ft]
Reassembly
To reassemble, follow the reverse of disassembly sequence,
and do the following steps:
(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Apply hydraulic oil to the spools when inserting them
into the valve blocks.
(3) Position the poppet (tilt lock valve) correctly.
(4) Apply grease to the O-rings when fitting them between
the valve housings to prevent them from twisting.
(5) Do not use any type of sealant. A
10-31
HYDRAULIC SYSTEM
Lift Cylinders
208713
Sequence
Remove parts 1 to 5 as a subassembly. Remove parts 6 to 18 as a subassembly. 13 Circlip
1 Retainer 6 Rod 14 Washer
2 Wiper seal 7 Spacer 15 O-ring
3 Rod seal 8 Wear ring 16 Check valve
4 Backup ring 9 Piston seal 17 Pull-in wire
5 O-ring 10 Nylon seal 18 Piston
11 Retaining ring 19 Shell assembly
12 Sleeve
NOTE NOTE
Do not remove the wiper seal 2, rod seal 3 and The parts marked with an asterisk (❋) are repair kit
check valve 16 unless they are defective. parts.
10-32
HYDRAULIC SYSTEM
208714
1. Shell assembly
(1) Check the bore wall for wear, grooving, scratching or
rusting.
(2) Check the welds for cracks or other defects.
2. Piston rod
(1) Check the rod for deflection on V-blocks with a dial
gauge as shown.
(2) Check for surface flaws such as grooving, scratching,
rusting or wear.
10-33
HYDRAULIC SYSTEM
A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
5 6
2 1 4 3
208702A
10-34
HYDRAULIC SYSTEM
Reassembly
19 12 11 10 8 7 9 6 5 4 3 1
2
18 17 15, 16 14 13
208702B
Sequence
(1) Subassemble parts 1 to 5 prior to assembly.
(2) Subassemble parts 6 to 18 prior to assembly.
(3) Install the subassembly (piston and rod) of step (2)
above in the shell assembly 19, then install the
subassembly of step (1).
Truck Model
GP40K, GP40KL, GP45K, GP50K,
DP40K, DP40KL DP45K, DP50K
Item
325 to 353 N·m 352 to 380 N·m
Tightening torque
(33 to 36 kgf·m) (36 to 39 kgf·m)
for retainer
[240 to 260 lbf·ft] [260 to 280 lbf·ft]
10-35
HYDRAULIC SYSTEM
208715
Sequence
Remove parts 1 to 5 as a subassembly. 9 Nylon ring
1 Retainer 10 Circlip
2 Wiper seal 11 Washer
3 Rod seal 12 O-ring
4 Backup ring 13 Check valve
5 O-ring 14 Pull-in wire
Remove parts 6 to 16 as a subassembly. 15 Stand tube
6 Rod 16 Piston
7 Wear ring 17 Shell assembly
8 Piston seal
NOTE NOTE
Do not remove the wiper seal 2, rod seal 3 and The parts marked with an asterisk (❋) are repair kit
check valve 13 unless they are defective. parts.
10-36
HYDRAULIC SYSTEM
A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
4 5
2 1 3
208704A
10-37
HYDRAULIC SYSTEM
Reassembly
17 14 12 8 9 10 11 16 7 15 6 5 4 3 1
2
13
208704B
Sequence
(1) Subassemble parts 1 to 5 prior to assembly.
(2) Subassemble parts 6 to 16 prior to assembly.
(3) Install the subassembly (piston and rod assembly) of
step (2) above in the shell assembly 17, then install the
subassembly (retainer assembly) of step (1).
Truck Model
GP40K, GP40KL, GP45K, GP50K,
DP40K, DP40KL DP45K, DP50K
Item
515 to 542 N·m 569 to 596 N·m
Tightening torque
(52 to 55 kgf·m) (58 to 61 kgf·m)
for retainer
[380 to 400 lbf·ft] [420 to 440 lbf·ft]
10-38
HYDRAULIC SYSTEM
208716
Sequence
Remove parts 1 to 5 as a subassembly. 9 Nylon ring
1 Retainer 10 Circlip
2 Wiper seal 11 Sleeve
3 Rod seal 12 Pull-in wire
4 Backup ring 13 Piston
5 O-ring 14 Bleed screw
Remove parts 6 to 13 as a subassembly. 15 Washer seal
6 Rod 16 Shell assembly
7 Wear ring
8 Piston seal
NOTE NOTE
Do not remove the wiper seal 2 and rod seal 3 The parts marked with an asterisk (❋) are repair kit
unless they are defective. parts.
10-39
HYDRAULIC SYSTEM
A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
2 1 3
5
208705A
2 1 3
5
208706A
10-40
HYDRAULIC SYSTEM
Reassembly
14 9 8 7 6 13 12 5 4 3 1 2
11 10 15 16
208705B
Sequence
(1) Subassemble parts 1 to 5 prior to assembly.
(2) Subassemble parts 6 to 13 prior to assembly.
(3) Install the subassembly (piston and rod assembly) of
step (2) above in the shell assembly 14, then install the
subassembly (retainer assembly) of step (1).
Truck Model
GP40K, GP40KL,
DP40K, DP40KL
Item
270 to 298 N·m
Tightening torque for retainer (28 to 30 kgf·m)
[200 to 220 lbf·ft]
10-41
HYDRAULIC SYSTEM
208717
Sequence
Remove parts 1 to 5 as a subassembly. 10 Wear ring
1 Retainer 11 Piston seal
2 Wiper seal 12 Nylon ring
3 Rod seal 13 Circlip
4 O-ring 14 Sleeve
5 Backup ring 15 Pull-in wire
6 Sleeve 16 Piston
7 O-ring 17 Bleed screw
Remove parts 8 to 16 as a subassembly. 18 Washer seal
8 Rod 19 Shell assembly
9 Spacer
NOTE NOTE
Do not remove the wiper seal 2 and rod seal 3 The parts marked with an asterisk (❋) are repair kit
unless they are defective. parts.
10-42
HYDRAULIC SYSTEM
Reassembly
16 14 13 12 11 10 8 7 6 4, 5 1 3 2
15 9 17 18 19
208706B
Sequence
(1) Subassemble parts 1 to 5 prior to assembly.
(2) Subassemble parts 8 to 16 prior to assembly.
(3) Install the subassembly (piston and rod assembly) of
step (2) above in the shell assembly 17, then install
sleeve 6 and the subassembly (retainer assembly) of
step (1).
Truck Model
GP50K, DP50K
Item
298 to 325 N·m
Tightening torque for retainer (30 to 33 kgf·m)
[220 to 240 lbf·ft]
10-43
HYDRAULIC SYSTEM
Tilt Cylinders
Disassembly
208718
Sequence
1 Socket, Bolt, Washer 4 Cylinder tube, Bushing, Grease nipple
2 Bushing, Buffer ring, Packing, Dust seal, 5 Shims
O-ring 6 O-ring
3 Rod, Collar, Piston, Piston seal, 7 Spacer
Self-locking nut
NOTE
(1) Collar 3, spacer 7, O-ring 6 and shims 5 are used
only in the tilt cylinder for the optional-
specification models; the cylinder for the standard-
specification models does not include them.
(2) Do not remove the buffer ring, packing and dust
seal from bushing 2 unless they are damaged.
10-44
HYDRAULIC SYSTEM
Removing bushing
(1) Wrap the cylinder tube with rag, and hold it in a vise.
Using wrench A, remove the bushing from the tube.
Special tool needed
Truck Model GP40K, GP45K,
GP40KL, GP50K,
DP40K, DP45K,
Part Name DP40KL DP50K
1. Cylinder tube
(1) Check the bore wall for wear, grooving, scratching or
rusting.
(2) Check the welds for cracks or other defects.
2. Piston rod
(1) Check the rod for deflection on V-blocks with a dial
gauge as shown.
(2) Check for surface flaws such as grooving, scratching,
rusting or wear. Replace the rod if its thread is badly
damaged.
10-45
HYDRAULIC SYSTEM
Tightening torque for bolt 6 A 262 ± 13 N·m (27 ± 1.4 kgf·m) [195 ± 10 lbf·ft]
Tightening torque for self-lock nut 7 A 588 ± 29 N·m (60 ± 3 kgf·m) [434 ± 22 lbf·ft]
208707A
10-46
HYDRAULIC SYSTEM
Reassembly
208707B
Sequence
Assemble parts 1 to 6 into subassembly A. Assemble parts 11 to 13 into subassembly C.
1 Rod 11 Cylinder tube
2 Piston 12 Bushing
3 Nut 13 Grease nipple
4 Piston seal Insert subassembly A into subassembly C, then install
5 Collar subassembly B in position.
Assemble parts 6 to 10 into subassembly B. 14 Tilt socket
6 Bushing 15 Clamp bolt
7 Buffer ring
8 Packing
9 Dust seal
10 O-ring
(5) Make sure buffer ring 7, packing 8 and dust seal 9 are
installed correctly in terms of the direction.
10-47
HYDRAULIC SYSTEM
Disassembly
Sequence
5
6 9 1 Lock nut
10 2 Plug, O-ring
11
3 Spring
4 Elbow, O-ring
13 Remove parts 5 to 11 as an assembly.
5 Snap ring
6 Spring pin
4
7 Washer
8 Spring
9 Plate
10 Valve
11 Piston
12 Connector, O-ring
13 Valve body
12
2
3
7
8
208596
NOTE
(1) Before disassembling the valve, measure the
distance between the end of the valve body and the
projected end of the plug 2. This distance must be
referred when reassembling the valve.
(2) Disassemble pin 6 to piston 10 after removing the
piston.
Reassembly
Follow the disassembly sequence in reverse.
10-48
HYDRAULIC SYSTEM
Disassembly
4
200355
Sequence
1 Spring pin
2 Valve
3 Spring
4 Connector, O-ring
Inspection
(1) Check the valve orifice for clogging or damage.
(2) Check the spring for fatigue.
(3) Check for stripped threads.
NOTE
Replace the down safety valve as an assembly if any
part is defective.
Reassembly
To reassemble, follow the reverse of disassembly sequence.
10-49
HYDRAULIC SYSTEM
Hydraulic Tank
Refill Capacities and Amount of Oil Required
Refill
Refill capacities (liter)
capacities GP45K,
(liter) Lift height (meter)
GP50K,
GP40K, DP45K,
7.0 DP50K
GP40KL,
6.5
DP40K, 6.0 + 6.8 H
DP40KL 6.0
5.5 5.5
H + 5.7 5.0 5.0 69.3 N
25 4.7
N 58.5 − 2.7 L
4.5
10
4.3
L − 2.3
45 4.0 4.0 4.0
3.7 3.7
3.5 3.5
3.3 3.3
3.0 3.0
2.5
2.0
GP40K, GP40KL Equivalents:
models
DP40K, DP40KL Simplex Duplex Triplex Meter = approx. 3.3 ft
GP45K, GP50K models mast mast mast Liter = approx. 0.26 U.S. gal.
DP45K, DP50K
202988
Remarks
(1) How to read the chart
[Example]
GP40K, GP40KL, DP40K, DP40KL: In the truck equipped with a 5.0 m (16.4 ft) triplex mast, maintain the oil level at N mark
on the level gauge with the mast lowered to the bottom. In the case of 5.5 to 7.0 m (18.0 to
23.0 ft) masts, maintain it at H mark with the mast lowered to the bottom.
GP45K, GP50K, DP45K, DP50K: In the truck equipped with any of the duplex masts up to 6.0 m (19.7 ft) lift height,
maintain the oil level at N mark. In the case of 6.0 to 7.0 m (19.7 to 23.0 ft) masts,
maintain it at H mark with the mast lowered to the bottom.
(2) Another simple method of checking the oil level is this:
In any truck, maintain the oil level above N mark but below H mark with (a) the mast lowered to the bottom, (b) the fork or
attachment kept in travel position and (c) the truck held level.
10-50
HYDRAULIC SYSTEM
NOTE
10-51
HYDRAULIC SYSTEM
Control Valve
External leakage
(1) Check for oil leaks from the joint between adjacent
valve housings sealed by O-ring.
(2) Check for oil leaks from the scrapers sealed by O-rings.
(3) Check for oil leaks from the screw connections.
Internal leakage
It is not practical to check the control valve alone for
internal leakage. How to check the control valve in place
(under normal operating conditions) will be described.
The internal leakage to be checked includes leakages
occurring at the lift spool, tilt spool, tilt lock valve and
check valves.
202991
10-52
HYDRAULIC SYSTEM
(3) If the lift cylinders or tilt cylinders drift (the mast tilts
forward or the fork lowers) excessively in spite of that
the amount of oil collected for 15 minutes is less than
500 cc (30.5 cu in.), measure the internal leakage of
each cylinder. (The measurement is the assembly
standard and not the service limit.)
203840
NOTE
One rotation of the adjusting screw changes the
pressure by approximately 17750 kPa (181 kgf/cm2)
[2574 psi].
(4) While holding the adjusting screw, tighten the lock nut
to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the setting.
10-53
HYDRAULIC SYSTEM
NOTE
206983
Tools 1 to 3 are included in the gauge kit.
(2) Start the engine, and turn the steering wheel fully to the
left at the maximum engine speed. When the steering
wheel stroke reaches the limit, check the pressure
gauge. The steering system relief valve is in good
condition if the oil pressure is relieved and the gauge
reading becomes as the following standard value.
g y
208808
10-54
HYDRAULIC SYSTEM
NOTE
It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted.
10-55
HYDRAULIC SYSTEM
200363
Adjusting method
(1) Raise the inner mast, place blocks under the right and
left side of the mast, and lower the mast until it rests on
the blocks.
202983
(2) Remove the stopper bolt at the top of lift cylinder which
stopped first. Retract the piston rod by operating the
lift control lever and insert shims at the top of piston
rod end. Shims
(3) Extend the piston rod, and tighten the cylinder stopper
bolt. Remove the blocks from under the inner mast.
(4) Raise the inner mast again to make sure there is no time
lag in stopping between the piston rods, right and left.
(5) Slowly lower the inner mast fully to make sure that the
200365
piston rods move smoothly.
10-56
HYDRAULIC SYSTEM
Testing
208601
10-57
HYDRAULIC SYSTEM
Troubleshooting
10-58
HYDRAULIC SYSTEM
Pump case, drive Pressure too high Replace pump. (Check to see if
gear or pump port relief valve setting is correct.)
flange damaged Distortion or damage due to Replace pump.
external strain or stress
1) Check to see if return line
is restricted.
2) Check to see if pipe
Hydraulic connection have been
pump externally strained or stressed.
Control
valve Load drops or
mast tilts forward Control valve internally leaking Replace a leaky block
with control lever assembly.
in neutral
Oil leakage from spool ring cap Replace O-ring; check spool
for flaws and if any, repair or
Oil leakage replace a leaky block assembly.
Loose plugs Retighten.
O-ring damaged Replace.
10-59
HYDRAULIC SYSTEM
10-60
HYDRAULIC SYSTEM
10-61
HYDRAULIC SYSTEM
Service Data
A: Standard value
Unit: mm (in.)
GP40KL
DP40KL
Truck Model
GP40K
DP40K
DP45K
GP45K
GP50K
DP50K
Item
Lift speed (rated load) (simplex mast) 510 440 420
A
mm/sec [fpm] (100) (85) (80)
Lift speed (no load) 530 450 440
A
mm/sec [fpm] (105) (90) (85)
Lowering speed (rated load) (simplex mast) 500
A
mm/sec [fpm] (100)
Forward tilt angle (standard model with simplex mast) A 6°
Backward tilt angle (standard model with simplex mast) A 10°
Lift cylinder drift (retraction of piston rod)
A 50 (2), maximum
(rated load for 15 minutes) [Oil temperature: 45°C (113°F)]
Tilt cylinder drift (extension of piston rod)
A 30 (1.2), maximum
(rated load for 15 minutes) [Oil temperature: 45°C (113 °F)]
+ 490 +5 + 71
Main relief valve setting kPa (kgf/cm2) [psi] A 19123 0 (195 0 ) [2773 0 ]
Hydraulic pump (gear pump) displacement cm3 (in3)/rev A 50 (3.0)/rev
Spool operating Neutral N (kgf) [lbf] A 127 (12.9) [28.4]
effort (at maximum
Control engine rpm) Full stroke N (kgf) [lbf] A 158 (16.1) [35.5]
valve 7/16” N·m (kgf·m) [lbf·ft] A 65 (6.6) [48]
Tightening torque
for tie bolts 1/2” N·m (kgf·m) [lbf·ft] A 101 (10.3) [74]
Steering system relief valve setting + 490 +5 + 71
A 11800 0 (120 0 ) [1714 0 ]
kPa (kgf/cm2) [psi]
Tightening torque of return filter N·m (kgf·m) [lbf·ft] A 49 (5) [36]
Tightening torque of suction strainer N·m (kgf·m) [lbf·ft] A 49 (5) [36]
Flow
Flow rate (no load)
regulator A 100 (26.4) 115 (30.4)
liter (U.S. gal.)/min
valve
Tightening torque of hydraulic pump (gear pump) universal
A 22 (2.2) [16]
joint N·m (kgf·m) [lbf·ft]
Tightening torque of hydraulic hose joints at hydraulic pump
A 118 (12) [87]
(gear pump) and control valve N·m (kgf·m) [lbf·ft]
Tightening torque of hydraulic pipe joints at control valve and
A 118 (12) [87]
flow regulator valve N·m (kgf·m) [lbf·ft]
10-62
HYDRAULIC SYSTEM
A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
Inside diameter of shell 1 A 100 (3.937) 110 (4.330)
516 516
Check valve set pressure 4
A (5.27) (5.27)
kPa (kgf/cm2) [psi]
[75] [75]
2 1 3
208704A
10-63
HYDRAULIC SYSTEM
A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
Inside diameter of shell 1 A 65 (2.56) 70 (2.76)
1863 1863
Check valve set pressure 5
A (19) (19)
kPa (kgf/cm2) [psi]
Lift [275] [275]
cylinder
(simplex 325 to 353 352 to 380
Tightening torque for retainer 6
mast) A (33 to 36) (36 to 39)
N·m (kgf·m) [lbf·ft]
(triplex [240 to 260] [260 to 280]
mast
second)
5 6
2 1 4 3
208702A
10-64
HYDRAULIC SYSTEM
A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
Inside diameter of shell 1 A 55 (2.165) 60 (2.362)
Lift
cylinder
(duplex
mast 2 1 3
second)
5
208705A
2 1 3
5
208706A
10-65
HYDRAULIC SYSTEM
520 ± 54 628 ± 64
Tightening torque for bushing 5
A (53 ± 5.5) (64 ± 6.5)
N·m (kgf·m) [lbf·ft]
[383 ± 40] [463 ± 47]
Tilt Tightening torque for bolt 6 N·m (kgf·m) [lbf·ft] A 262 ± 13 (27 ± 1.4) [195 ± 10]
cylinder
Tightening torque for self-lock nut 7
A 588 ± 29 (60 ± 3) [434 ± 22]
N·m (kgf·m) [lbf·ft]
208707A
10-66