SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24
 SECTION 6 HYDRAULIC SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. HYDRAULIC CIRCUIT
1) 35DS/40DS/45DS-7

L R
3 7 6
10

PS B1 B2 A2 B3 A3 B4 A4

X
X

X
X
2
12.5MPa 21.0MPa 13.5MPa

T Rst
T LS P R2
R1
LS
P

G X

B
P S
4
2 MPa

1
T/M

9
8
11

D357SHS01

1 Hydraulic gear pump 7 Lift cylinder

2 Main control valve 8 Suction filter
3 Steering unit 9 Return filter
4 Brake valve 10 Down safety valve
5 Steering cylinder 11 Hydraulic oil tank
6 Tilt cylinder

6-1
 2) 35D/40D/45D-7

L R
4 8 7
11

PS B1 B2 A2 B3 A3 B4 A4

X
X

X
X
3
12.5MPa 21.0MPa 13.5MPa

T Rst
T LS P R2
R1
LS
P

G X

B
P S
5
2 MPa

2 1
E/G T/M

10
9
12

D357HS01

1 Hydraulic gear pump 7 Tilt cylinder

2 Brake pump 8 Lift cylinder
3 Main control valve 9 Suction filter
4 Steering unit 10 Return filter
5 Brake valve 11 Down safety valve
6 Steering cylinder 12 Hydraulic oil tank

6-2
 1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION

7 6
10

PS B1 B2 A2 B3 A3 B4 A4

X
X

X
X
2
12.5MPa 21.0MPa 13.5MPa

T Rst
R2
R1
Steering system LS
P

Steering return line

G X
Brake system
Brake return line

35D/40D/45D-7 ONLY
1 1' 1
T/M
E/G T/M

9
8
11

D357HS02

When the lift control lever is pulled back, the spool on the first block is moves to lift position.
The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large
chamber of lift cylinder(7) by pushing the load check valve of the spool.
The oil from the small chamber of lift cylinder(7) returns to hydraulic oil tank(11) at the same time.
When this happens, the forks go up.

6-3
 2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION

7 6
10

PS B1 B2 A2 B3 A3 B4 A4

X
X

X
X
2
12.5MPa 21.0MPa 13.5MPa

T Rst
R2
R1
Steering system LS
P

Steering return line

G X
Brake system
Brake return line

35D/40D/45D-7 ONLY
1 1' 1
T/M
E/G T/M

9
8
11

D357HS03

When the lift control is pushed forward, the spool on the first block is moved to lower position.
The work port(B1) and the small chamber and the large chamber are connected to the return
passage, so the lift will be lowered due to its own weight.

6-4
 3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION

7 6
10

PS B1 B2 A2 B3 A3 B4 A4

X
X

X
X
2
12.5MPa 21.0MPa 13.5MPa

T Rst
R2
R1
Steering system LS
P

Steering return line

G X
Brake system
Brake return line

1 1' 1
T/M
E/G T/M

9
8 35D/40D/45D-7 ONLY
11

D357HS04

When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward
position.
The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large
chamber of tilt cylinder(6) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder(6) returns to hydraulic tank(11) at the same time.
When this happens, the mast tilt forward.

6-5
 4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION

7 6
10

PS B1 B2 A2 B3 A3 B4 A4

X
X

X
X
2
12.5MPa 21.0MPa 13.5MPa

T Rst
R2
R1
Steering system LS
P

Steering return line

G X
Brake system
Brake return line

1 1' 1
T/M
E/G T/M

9
8 35D/40D/45D-7 ONLY
11

D357HS05

When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward
position.
The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the small
chamber of tilt cylinder(6) by pushing the load check valve of spool.
The oil at the large chamber of tilt cylinder(6) returns to hydraulic tank(11) at the same time.
When this happens, the mast tilt backward.

6-6
2. HYDRAULIC GEAR PUMP
1) 35DS/40DS/45DS-7

22

11 16

10 5
13
9

24 8
2
14
25
18

1 27
22

25 16
18
23
15
26
21

4
17 3
7 6

23
19
4

21
20
15

D357SHS06

1 Body 11 Screw 20 Ring

2 Rear cover 12 Grub screw 21 Back up ring
3 Front cover 13 Washer 22 Ring
4 Thrust plate 14 Washer 23 Sleeve bearing
5 Thrust plate 15 Seal 24 Hub
6 Drive gear 16 Seal 25 Dowel pin
7 Driven gear 18 Parker ring 26 Steel bushing
8 Drive shaft 17 Seal 27 Body
9 Driven gear 18 Seal
10 Screw 19 Shaft seal

6-7
(2) 35D/40D/45D-7

11
10
9

3
12

9
10

11

7
D357HS06

1 Flange 5 Washer 9 Channel seal

2 Cover 6 Bolt 10 Back up ring
3 Body 7 Lip seal 11 O-ring
4 Set gear 8 Bushing block assy 12 Dowel pin

6-8
3. MAIN CONTROL VALVE
1) STRUCTURE (2 Spool)

39 38 37
Port name Size

Inlet port 1-1/16-12UNF

Outlet port 1-1/16-12UNF
LS PS Gauge port PF1/4
F F
Work port 2-3/4-16UNF
STEERING PORT
LOAD SENSING PORT

PUMP PORT
CYLINDER PORT

A A
41
B1

B2 A2

CYLINDER PORT

2 4 2

SECTION F-F

9 6 5

SECTION A-A
D357HS07

2 Plug assy 8 Orifice 39 Bolt

4 Spring 9 Steering relief valve 41 Plug
5 Valve seat assy 37 Plug
6 Unloading spring 38 Plug

6-9
2) OPERATION (2 Spool)
(1) Flow divider(Priority valve)

Piston

PS
P

LS

T
T

Steering relief valve

To steering control unit

PS
T
Rst

LS

P
CV

D357MCV21

Oil flows from pump(P) line to steering(PS) line and control valve(CV) line.
The control flow rate for steering line decides by the demand of steering control unit.
Maximum pressure of steering line controls by steering relief valve.

6-10
(2) Inlet section

PS
P

LS

T
T

Unloading valve piston Primary relief valve

PS

T
Rst

R1
LS
P

Max work port pressure line

D357MCV22

At spool neutral position, oil flows from pump line to tank line through unloading valve piston.
Also unloading valve piston controls flow rate work section.
Maximum pressure of the system controls by primary relief valve.

6-11
(3) Lift section
Η Lift position

Lift lock valve B1

Return spring

P
T T

Load sensing passage

D357MCV23

When the spool for lift section is pulled back, the oil supplied from the pump pushes up the lift lock
valve and flow into lift cylinder port(B1).
Flow rate is supplied to cylinder depends on opening area of the spool.
Work pressure is led to unloading valve through load sensing passage.
The spool is returned to neutral position by the return spring.

6-12
Θ Lower position

Lift lock spring chamber

Lift lock valve B1

P
T T

Lowering flow compensator

D357MCV24

When the spool for lift section is pulled forward, the oil in lift cylinder is released to tank due to its
own weight.
First the pressure in the lift lock spring chamber is released.
Therefore the lift lock valve is pushed up due to the difference pressure.
Flow rate for lowering is controlled by lowering flow compensator.
Maximum flow rate for lowering depends on opening area of spool.

6-13
(4) Tilt section
Η Tilt forward position

B2 A2
Load check vavle

Tilt lock valve

D357MCV25

When the spool for lift section is pushed forward, the oil supplied from the pump pushes up the load
check valve and flow into tilt cylinder port(A2).
The return oil from cylinder port(B2) flows into the tank through the tilt lock valve.
Flow rate is supplied to cylinder depends on opening area of the spool.
Work pressure is led to unloading valve through load sensing passage.
The spool is returned to neutral position by the return spring.

6-14
Θ Tilt backward position

B2 A2
Load check vavle

D357MCV26

When the spool for tilt section is pulled back, the oil supplied from the pump pushes up the load
check valve and flow into tilt cylinder port(B2).
The return oil from cylinder port(A2) flows into the tank.
Flow rate is supplied to cylinder depends on opening area of the spool.
Work pressure is led to unloading valve through load sensing passage.
The spool is returned to neutral position by the return spring.

6-15
3) MAIN RELIEF VALVE
(1) Pressure setting
A good pressure gauge must be installed in
the line which is in communication with the
work port relief. A load must be applied in a
manner to reach the set pressure of the relief
unit.
Procedure
Η Loosen lock nut.
Θ Set adjusting nut to desired pressure
setting.
Ι If desired pressure setting cannot be
achieved, add or remove shims as required.
Κ Tighten lock nut.
Λ Retest in similar manner as above.
D503HS99

(2) Function
Η As work port relief
The relief valve is in communication
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the
differential area between diameters A
and B relief valve poppet D and check
valve poppet K are tightly seated as
shown. D353HS18

The oil pressure in the high pressure port

HP has reached the setting of the pilot
poppet spring force and unseats the pilot
poppet E and oil flows around the poppet
through the cross drilled holes and to the
low pressure area LP.

D353HS19

6-16
 The loss of oil behind poppet C, effected
by the opening of pilot poppet E, causes
poppet C to move back and seat against
pilot puppet E. This shuts off the oil flow
to the area behind relief valve poppet D,
and causes a low pressure area
internally.

D353HS20

The imbalance of pressure on the inside

as compared to that of the high pressure
port HP, forces the relief valve poppet D
to open and relieve the oil directly to the
low pressure chamber LP in the valve.

D353HS21

Θ As anti void
The anti-void unit supplies oil to the high
K G
pressure port HP when cavitation has
occurred. A lower pressure exists in the A
port HP compared to the low pressure
chamber LP. The difference between the HP
effective area of diameter A and G
causes imbalance of the check valve
LP

poppet K which unseats, thus allowing oil

from the low pressure chamber LP to 7406S6-28(1)
enter the port HP and fill the void.

6-17
4. LIFT CYLINDER

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

D357HS12

1 Tube assy 7 Retaining ring 13 DU busing

2 Rod 8 Gland 14 O-ring
3 Piston 9 Dust wiper 15 Spacer
4 Piston seal 10 Rod seal 16 O-ring
5 Back up ring 11 O-ring
6 Wear ring 12 Guide

5. TILT CYLINDER

18 19 20, 21, 22 7, 8 3 11 12 5, 6 4 9, 10 2 1 13 16 14 15 17

23

D357HS13
1 Tube assy 9 O-ring 17 Nylon nut
2 Rod 10 Back up ring 18 Rod eye
3 Gland 11 Lock washer 19 DU bushing
4 DU bushing 12 O-ring 20 Hexagon bolt
5 Rod seal 13 Piston 21 Hexagon nut
6 Back up ring 14 Glyd ring 22 Spring washer
7 Dust wiper 15 Wear ring 23 O-ring
8 Snap ring 16 O-ring

6-18