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Hydraulic System

1) The hydraulic system uses a pump to draw oil from a tank and divide it between control valves to operate lift, tilt, and steering cylinders. 2) The control valve consists of inlet, lift, tilt, and attachment sections to direct oil to the appropriate cylinders. It also contains relief valves to prevent over-pressurization. 3) Double-acting lift and tilt cylinders extend and retract booms and attachments, while flow regulator and safety valves control lowering speeds.

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Ricardo Vieira
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© © All Rights Reserved
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100% found this document useful (1 vote)
342 views51 pages

Hydraulic System

1) The hydraulic system uses a pump to draw oil from a tank and divide it between control valves to operate lift, tilt, and steering cylinders. 2) The control valve consists of inlet, lift, tilt, and attachment sections to direct oil to the appropriate cylinders. It also contains relief valves to prevent over-pressurization. 3) Double-acting lift and tilt cylinders extend and retract booms and attachments, while flow regulator and safety valves control lowering speeds.

Uploaded by

Ricardo Vieira
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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HYDRAULIC SYSTEM

Description
Hydraulic Line
11
9 8 9

10 10

6 7
3

5 2
1
207118A

1 Hydraulic tank 6 Control valve


2 Hydraulic pump 7 Flow regulator valve
3 Inlet section (with built-in flow divider 8 Down safety valve
valve) 9 Lift cylinder
4 Steering control valve 10 Tilt cylinder
5 Steering cylinder assembly 11 First lift cylinder (three-stage and two-
stage full-free panorama mast system)

The hydraulic pump draws oil from the oil tank. the other for controlling the steering cylinder.
The discharged oil flows through the flow Steering control valve and steering cylinder are
divider, and is divided into two control valves, covered in other groups titled STEERING SYS-
one for controlling the lift and tilt cylinders and TEM and REAR AXLE.

10-1
HYDRAULIC SYSTEM

Hydraulic Tank

1
2

To hydraulic
pump

From control
valve

From lift
cylinder

3 6 5 4

207117

1 Air breather and Cap 4 Suction strainer


2 Oil level gauge 5 Return filter
3 Drain plug 6 Return pipe

The tank is internally provided with two filtering


means, suction strainer 4 with a 150-mesh screen
for catching gritty particles in the oil, and return
filter with the relief valve and capable of catching
15-micron and larger particles in the oil returning
from the control valve.

10-2
HYDRAULIC SYSTEM

Hydraulic Pump

Hydraulic pump
Engine
Universal joint

204970

This is a gear pump capable of developing very


high pressure on its discharge side. A special
arrangement is incorporated in the pump construc-
tion for the purpose of keeping the side clearances
minimized between bushings on the one side and
pump gears on the other. Note, in the illustration,
that discharge pressure is applied to the back of
each bushing through internal oilways.
Operation
Driven gear
Essentially the pump consists of two gears —
drive gear and driven gear — smoothly fitted in
the housing. The oil is carried around the periph-
ery of the revolving gears from the suction to dis-
charge side. The teeth are meshing between the
two gears and thus prevent return of oil from the
discharge to the suction side.

Drive gear 203585

10-3
HYDRAULIC SYSTEM

Pressure loading mechanism


The oil leak in pump decreases the pump efficiency. End clearance
The pressure loading mechanism, where the high
discharge pressure is applied to the bush back
faces, reduces this leak by minimizing the clear-
ance between pump gears and bushes. Even when
sliding faces of gear or bushes are worn, this
mechanism keeps the clearance between gears and
bushes, and maintains the good pump efficiency.
Outlet
200333

10-4
HYDRAULIC SYSTEM

Control Valve

6
6
8

P 5

T2

T1
7
PF A1 2 3 8 4

207135

1 Inlet section (with built -in flow divider P From hydraulic pump
valve) PF To steering control valve
2 Lift section T1 To hydraulic tank
3 Tilt section (with built-in tilt lock valve) T2 From steering control valve
4 Attachment section A1 To lift cylinders
5 End cover
6 Main relief valve
7 Relief valve for flow divider valve (PF
port relief valve)
8 Shutoff valve assembly [overload relief
valve (option)]

The control valve consists of four sections; main relief valve is in the oil passage from the
namely, inlet, lift, tilt and attachment, all being oil pump and prevents high oil pressure which
of spool type. The inlet section has a built-in could damage the pump. The relief valve for
flow divider valve. The tilt section has a built-in flow divider valve controls the oil pressure
tilt lock valve. below the maximum pressure in the steering cir-
The attachment section has a built-in shutoff cuit. The overload relief valve prevents high oil
valve or an optional overload relief valve. The pressure occurring in the attachment circuit.

10-5
HYDRAULIC SYSTEM

Lift and Tilt Cylinders


Lift cylinder (Simplex mast)
(Triplex mast second cylinder)

1 2 3
207073

(Duplex and triplex mast first cylinder)

207604
1 2 3
(Duplex mast second cylinder)

207605

Tilt cylinder

207033

The lift cylinders, left and right, are of single- The tilt cylinders, left and right, are of double-
acting type. Air and oil remaining inside air acting type. The piston rod carries a screw-on
chamber 1 of the rod and inside rod chamber 2 socket. This socket is to be repositioned by turn-
between the tubes open check valve 3 when ing, as necessary, when the cylinder is connect-
compressed, thus the air and oil flow out of the ed to the outer mast. The right and left cylinders
cylinder. are hydraulically connected to each other. The
Only the second cylinders of the Duplex Mast tilt angle can be increased or decreased by
are provided with bleeding valves. means of spacer and shim of each cylinder.
10-6
HYDRAULIC SYSTEM

Flow Regulator Valve

From control valve To control valve

To lift cylinder From lift cylinder


203558
The flow regulator valve is located between loaded forks are lowered to keep a constant safe
each lift cylinder and control valve. It limits the lowering speed regardless of load.
flow of oil forced out of the cylinder when the

Down Safety Valve

Normal

Burst

When hose burst


204971

The down safety valve is located at the bottom side


of right-hand lift cylinder. This valve provides a
means of preventing the load from lowering,
unsafely, rapidly, when the hose bursts.
10-7
HYDRAULIC SYSTEM

Removal and Installation


Hydraulic Pump

206471

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

Start by:
1. Remove the counterweight.
2. Loosen the fan belt.

10-8
HYDRAULIC SYSTEM

Suggestions
1. Remove the drive pulley lock nut 2 with special
tools.
Special tool needed
GP15K thru 35K
DP20K thru 35K
DP15K/18K
91268-00100 91268-00100
Wrench 91268-00200 91868-00100
(to be used in (to be used in
combination) combination) 204929

NOTE
The drive pulley lock nut has left-hand
threads.

2. To reassemble, follow the reverse of disas-


sembly sequence. Tighten the counterweight
bolts, pump outlet joint and main delivery
hose to the specified torque.
Tightening torque
Unit: N·m (kgf·m) [lbf·ft]
412 to 490
Counterweight bolts (42 to 50)
[304 to 362]
Pump outlet joint 167 (17) [123]
Main delivery hose 118 (12) [87]

10-9
HYDRAULIC SYSTEM

Control Valve

1 2

6
4

207048

Sequence
1 Clevis pin, Rod 5 Steering delivery pipe
2 Tilt pipe, Connector, O-ring 6 Steering return hose, Pipe
3 Main delivery hose, Joint, O-ring 7 Return hose
4 Lift pipe 8 Control valve

Start by:
1. Remove the floor plate and dashboard cover.
2. Before disconnecting pipes, tilt the mast to
vertical position, lower the forks all the way,
and relieve the pressure in the pipes.

10-10
HYDRAULIC SYSTEM

Lift Cylinders
Dual-stage Panoramic Mast (Simplex Mast)

7 6

1
3

2
207637

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

Suggestions
1. Lift bracket removal
(1) Tilt the mast forward, and lower the inner mast
to the bottom. Slacken the lift chains, and
remove the nuts from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise
the inner mast until the lift bracket becomes
free. Then, back the truck away from the lift
bracket and fork assembly.

204873A

10-11
HYDRAULIC SYSTEM

2. Disconnecting high-pressure hoses


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

204933

3. Removing set bolts


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

NOTE
The rod end of either lift cylinder is shim
adjusted to eliminate the difference in stroke
between the cylinders. Before removing the
set bolts, make a record of the amount of 204934
shims and cylinders to which the shims are
fitted.

(2) Tie wood blocks under the inner mast and


detach the sling. Use blocks strong enough to
support the mast.

202983

10-12
HYDRAULIC SYSTEM

4. Removing lift cylinders


Hitch a sling to the lift cylinder from the rear side
of the mast, and remove the cylinder. Hitch the
sling before removing the cylinder clamp.

204935

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. (Make reference to
Hydraulic Tank section, Inspection and
Adjusment.)
3. Check to make sure that the lift height is cor-
rect.
4. After the lift cylinders or piston rods have
been replaced, check for difference in stroke
between the two cylinders. (Make reference to
Group 11 MAST AND FORKS.)

10-13
HYDRAULIC SYSTEM

Lift Cylinders
The following describes the procedures for removing and installing the lift cylinders in dual-stage
full free panoramic mast (Duplex Mast) and triple-stage full free panoramic mast (Triplex mast).
Note that the Triplex Mast is used as an example.

Triple-stage Full Free Panoramic Mast (Triplex Mast)

3
1

207612

Sequence

1 Nuts 3 First lift cylinder


2 Lift bracket assembly 4 Chain wheel support assembly
5 Second lift cylinder

Suggestions

1. Removing lift bracket assembly 2

(1) Lower lift bracket assembly 2, and place wood


blocks under the assembly. Tilt the mast for- 1
ward, lower the inner mast to the bottom, then
remove nuts 1 from the anchor bolts of the
first lift chains. 207613

10-14
HYDRAULIC SYSTEM

(2) Position the mast upright. Raise the inner mast


until main rollers 6 of lift bracket assembly 2
become free. Then, slowly move the vehicle in
reverse to separate from lift bracket 2.

201735

3. Disconnecting high-pressure hoses


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

204933

4. Removing first lift cylinder 3

(1) Hitch a sling to first lift cylinder 3, and sus-


pend the cylinder with a crane. Wind the sling
securely to prevent slipping.

(2) Remove the lift cylinder connecting and


mounting bolts, and gently dismount first lift 3
cylinder 3.
207616

5. Removing second lift cylinders 5

(1) Disconnect hoses from second lift cylinders 5.

(2) Remove stopper bolts at the upper sections of


second lift cylinders 5, and lift the inner mast 5
[dual-stage full free panoramic mast] or mid-
dle mast [triple-stage full free panoramic
mast] approximately 550 mm (21.67 in.) using
slings.
207617

10-15
HYDRAULIC SYSTEM

(3) Place wood blocks under the inner mast (dual-


stage full free panoramic mast) or middle mast
(triple-stage full free panoramic mast).
Make sure the right and left wood blocks are
the same in height.

202983

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


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

Installation
207618
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 pre-
vent chains from twisting.

(2) Adjust the chain tensions.


(See the section on inspection and adjust-
Good Bad
ment.)

(3) After proper operation is confirmed, check the 207638


oil level.

10-16
HYDRAULIC SYSTEM

Tilt Cylinders
1. Tilt socket pin (spacer)
2. Rubber hose
3. Cylinder pin (spacer) 2
4. Tilt cylinder

207049

Start by:
1. Lower the forks to the bottom, and tilt the
mast fully forward.
2. Hitch lifting slings to the top crossmember of
outer mast by using eye-bolts, and support the
weight of the mast with a hoist.

204845

Suggestions
1. Retracting piston rod
Remove tilt cylinder pin 1. Start the engine and
retract the piston rod to the full stroke, then stop
the engine.
2. Disconnecting hoses
Disconnect hoses 2 from the cylinder at the con-
nectors. Use a container to catch oil from floating
out of the cylinder. Attach caps to the connectors
of the cylinder to protect the threads of the con-
nectors and to prevent oil from flowing out of the
cylinder when the cylinder is removed.

10-17
HYDRAULIC SYSTEM

Disassembly and Reassembly


Hydraulic Pump

GP15K thru 35K


DP15K/18K

6
4

3
1

3
8
204937

Sequence
1 Cover, Bolts 5 Drive gear
2 Mounting flange, Snap ring, Oil seal 6 Driven gear
3 Body seal, Bushing seal 7 Backing rings, Bushings
4 Backing rings, Bushings 8 Body

General working tips


(1) Do not use a hammer or similar hard tool in (4) Replace seals and seal rings once disturbed.
an attempt to loosen or force out cover 1 and (5) Give a thin coat of grease to the lip of each
mounting flange 2. Use a plastic hammer. oil seal and to the seals just before fitting
(2) Prepare suitable containers to place parts in them.
the disassembled order. This applies in par- (6) There are four bushings for the two pump
ticular to the pump gears and their bushings gears. Assemble them in their original loca-
to ensure the correct reassembly. tions.
(3) Before starting reassembly, visually inspect
all parts to be for cleanliness, and apply
hydraulic oil to the sliding surfaces of the
pump body.

10-18
HYDRAULIC SYSTEM

(7) Each bushing has a flat. Be sure to locate (9) The fit of the pump gears in the reassem-
the flat correctly in the pump body. bled pump may be deemed satisfactory if
(8) Tighten the cover those bolts to the specifi- the pump shaft rotates smoothly and lightly
cation. when turned over by hand with an
adjustable wrench.

DP20K thru 35K 2

4
6

3
1 204938

Sequence
1 Cover, Bolt 5 Drive gear
2 Mounting flange, Snap ring, Oil seal 6 Driven gear
3 Backup ring, Plate seal 7 Pressure plate
4 Pressure plate 8 Gear plate

General working tips


(1) Do not use a hammer or similar hard tool in (3) Before starting reassembly, visually inspect
an attempt to loosen or force out cover 1 all parts to be sure they are perfectly clean,
and mounting flange 2. Use a plastic ham- and apply hydraulic oil to the sliding sur-
mer. faces of the gear plate.
(2) Prepare suitable containers to place parts in (4) Replace oil seals; backup rings and plate
the disassembled order. This applies in par- seals once disturbed.
ticular to the pump gears and their bushings
to ensure the correct reassembly.

10-19
HYDRAULIC SYSTEM

(5) Give a thin coat of grease to the lip of each oil


seal and to the seals just before fitting them.
(6) Tightening torque for the cover securing bolts
is specified. Tighten those bolts to the specifi-
cation.
(7) The fit of the pump gears in the reassembled
pump may be deemed satisfactory if the pump
shaft rotates smoothly and lightly when turned
over by hand with an adjustable wrench.
Inspection after disassembly
1. Drive and driven gears
Inspect the gear teeth for wear and damage.
Inspect the journals and splines as above.

200344

2. Pump covers, body and bushings


Inspect these parts for wear and damage.

200346

10-20
HYDRAULIC SYSTEM

Control Valve

32 39
1
33 34
2

36

39
37

40

35 25

31
38
24 27

28
29 14

23
21

26 15
20
30
17

5
18
7
13
22
3
16 9
8
10
19 11
6
12

4
207340

10-21
HYDRAULIC SYSTEM

Sequence
1 Tie rod bolts, Nuts 22 Lift section
2 End cover 23 O-ring
3 O-ring 24 Spring, Poppet
4 Main relief valve, O-ring 25 Cap, Screw
5 Connector, O-ring 26 Spool
6 Plug, O-ring 27 Screw, O-ring, Seat, Spring
7 Sleeve, Snap ring 28 Plate, Wiper, O-ring
8 Spool, Spring 29 Tilt lock valve, Spring
9 Plug 30 Plate, Wiper, O-ring, Screw
10 Housing, O-ring, Poppet 31 Tilt section
11 Spring 32 O-ring
12 Inlet section 33 Spring, Poppet
13 O-ring 34 Cap, Screw
14 Spring, Poppet 35 Spool
15 Cap, Screw 36 Screw, Seat, Spring
16 Spool 37 Plate, Wiper, O-ring
17 Screw, Seat, Spring 38 Plate, Wiper, O-ring, Screw
18 Plate, Wiper, O-ring 39 Shutoff valve assembly (or Overload
19 Plate, Wiper, O-ring, Screw relief valve (option))
20 Plug, O-ring 40 Attachment section
21 Connector, O-ring

Suggestions
1. Main relief valve
Do not remove main relief valve 4 unless it is Plug
defective. This applies to overload relief valve 39
(option) of the attachment section.

NOTE
To remove the main relief valve for cleaning Lock nut
or inspection, loosen its plug. Loosening the
lock nut will disturb the pressure setting.
205025

2. Inlet section
(1) To remove connector 5, loosen plug 6 two or
three full turns.
(2) To remove spool 8, screw a bolt into the hole
(M6 × 1) of the spool and pull out the spool
squarely by gripping the bolt before removing
sleeve 7.

205026

10-22
HYDRAULIC SYSTEM

NOTE
1. Do not force spool 8 to pull it out. Snap ring
2. Do not remove the snap ring from sleeve 7
unless absolutely necessary. The snap ring
would be distorted if it should be removed.
3. Do not disassemble connector 5 any more.

205027

3. Lift, tilt and attachment sections


(1) Remove the spool from the section, together
with plate 18 and screw 17. This applies to
spools 26 and 35.
(2) Hold the spool in a vise with soft jaw caps, and
remove the screw 17 with an Allen wrench.

205028

Inspection after disassembly


Sections, spools and return springs
(1) Check each sliding surfaces for cracks and
defects. Also, check the check-valve seat for
wear.
(2) Check the spools for burns and distortion.
Also, check for operating force.
177 to 216N
Spool operating force (18 to 22 kgf)
[40 to 49 lbf]
(3) Check the tilt lock valve for damage and
seizure.
Reassembly Tilt lock valve
To reassemble, follow the reverse of disassembly
sequence and do the following steps:
1. Clean 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. 203517

10-23
HYDRAULIC SYSTEM

Lift Cylinders
(Simplex mast, triplex mast second cylinder)
* : Parts contained in seal kit

4
8
1 * 2

*7

6
*
5

207064

Disassembly sequence
1 Retainer 6 Check valve, O-ring
2 Wiper, Rod seal, Backup rings, O-ring 7 Wiper ring, Piston seal, Backup ring
3 Spacer 8 Cylinder rod
Remove parts 4 through 8 as assembly. 9 Cylinder tube
4 Circlip, Sleeve
5 Washer

10-24
HYDRAULIC SYSTEM

Reassembly

* : Parts contained in seal kit


3
7
1 2 * 4 5 6

13 * * * * * 12 11 * * *
15 14 16 17 18 8 9 10

207073

Reassembly sequence
1 Piston rod, Piston 7 Circlip 13 Retainer
Install parts 2 through 10 8 Backup ring Install parts 14 through 18
to part 1. 9 Piston seal to part 13.
2 Check valve 10 Wiper ring 14 Rod seal
3 O-ring 11 Spacer 15 Wiper
4 Washer 12 Cylinder tube 16 Backup ring
5 Circlip 17 O-ring
6 Sleeve 18 Backup ring

Suggestions
1. Use all parts in the seal kit to replace
GP/DP15K GP/DP20K GP/DP30K
removed parts.
GP/DP18K GP/DP25K GP/DP35K
2. After installing seal kit parts, apply
hydraulic oil before installing to the Retainer
cylinder tube or piston rod. tightening
torque 170 to 240 200 to 270 270 to 304
3. Fill the space between the cylinder tube (17.3 to 24.5) (20.4 to 27.5) 27.5 to 31.0)
N·m
and piston rod with the specified (kgf·m) [125 to 175] [150 to 200] [200 to 225]
amount of hydraulic oil before installing [lbf·ft]
the retainer.
GP/DP15K GP/DP20K GP/DP30K
GP/DP18K GP/DP25K GP/DP35K
Amount of 75 to 85 75 to 85 90 to 100
hydraulic (4.57 to (4.57 to (5.49 to
oil cc (cu.in.) 5.19) 5.19) 6.10)

4. Tighten the retainer to the specified


torque.

10-25
HYDRAULIC SYSTEM

Lift Cylinders
(Duplex mast, triplex mast fast cylinder)

* : Parts contained in seal kit

1 *2

3*

* 4

207642

Diasssembly sequence

1 Retainer 3 Wear ring, Nylon ring, Piston seal


2 O-ring, Backup ring, Rod seal, Wiper 4 Circlip, Washer, O-ring, Check valve
Remove parts 3 through 5 as sub-assembly 5 Piston rod, Piston
from part 6. 6 Cylinder tube

10-26
HYDRAULIC SYSTEM

Reassembly

* : Parts contained in seal kit


13 12 14 15 6 7 8 9
* * 1 * * *
* * *

11 10 2 * 4 5
3

207604

Reassembly sequence 8 Nylon ring


1 Piston rod, Piston 9 Wear ring
Install parts 2 through 9 to part 1. 10 Cylinder tube
2 Check valve 11 Retainer
3 O-ring Install parts 12 through 15 to part 11.
4 Washer 12 Rod seal
5 Circlip 13 Wiper
6 Nylon ring 14 Backup ring
7 Piston seal 15 O-ring

Suggestions
1. Use all parts in the seal kit to replace 4. Tighten the retainer to the specified torque.
removed parts.
GP/DP15K GP/DP20K GP/DP30K
2. After installing seal kit parts, apply GP/DP18K GP/DP25K GP/DP35K
hydraulic oil before installing to the cylin- Retainer
der tube or piston rod. tightening
305 to 370 340 to 405 440 to 475
torque (31 to 37.7) (34.7 to 41.3) (44.9 to 48.5)
3. Fill the space between the cylinder tube N·m (kgf·m) [225 to 275] [250 to 300] [325 to 350]
[lbf·ft]
and piston rod with the specified amount
of hydraulic oil before installing the
retainer.

GP/DP15K GP/DP20K GP/DP30K


GP/DP18K GP/DP25K GP/DP35K
Amount of
70 to 80 85 to 90 125 to 130
hydraulic oil
(4.27 to 4.88) (5.18 to 5.49) (7.62 to 7.93)
cc (cu.in.)

10-27
HYDRAULIC SYSTEM

Lift Cylinders
(Duplex mast second cylinders)
*: Parts contained in seal kit

6
3
2

1
*5

7 4

207641

Disassembly sequence
1 Holder
Remove parts 1 through 6 4 Cylinder head, Bushing
as sub-assembly from part 1. 5 Wiper ring, O-ring, U-ring, Backup ring
2 Slide ring, Set screw, Piston 6 Piston rod
3 Spacer, Snap ring 7 Cylinder tube, Set screw, Steel ball

NOTE
Spacer is installed in cylinders with lifting
height of 3.7 mm (145.7 in.) or more.

10-28
HYDRAULIC SYSTEM

Reassembly

*: Parts contained in seal kit


2 7 8 16 15 12

* 11
* * * 14 1 9 10 13 207605
6 3 4 5

Reassembly sequence
1 Piston rod 4 U-ring 11 Piston
Install parts 2 through 13 5 O-ring 12 Set screw
to part 1. 6 Wiper ring 13 Slide ring
2 Holder 7 Cylinder head 14 Cylinder tube
Install parts 3 through 6 8 Bushing 15 Steel ball
to part 2. 9 Spacer 16 Set screw
3 Backup ring 10 Snap ring

Suggestions

1. Use all parts in the seal kit to replace


removed parts.
2. Apply hydraulic oil to the sliding sections
on the cylinder tube inner surface and pis-
ton rod outer surface before installation.
3. Tighten the piston and holder to the speci-
fied torque.
Unit: N·m (kgf·m) [lbf·ft]
GP/DP15K GP/DP20K
GP/DP18K GP/DP25K GP/DP30K GP/DP35K
245 ± 44.1
Piston 196 ± 35 (20 ± 3.6) [145 ± 26] (25 ± 4.5)
[180 ± 32.5]
206 ± 39.2 235 ± 54 304 ± 70.6
Holder (21 ± 4) (24 ± 5.5) (31 ± 7.2)
[152 ± 29] [174 ± 39.8] [224 ± 52]

4. Tighten the set screws (2 locations) to the


specified torque.
Set screw tightening torque 3.92 ± 0.98 (0.4 ± 0.1)
N·m (kgf·m) [lbf·ft] [2.9 ± 0.72]

10-29
HYDRAULIC SYSTEM

Tilt Cylinders

* : Parts contained in seal kit


4

3
*

1 *
**

1
207140

Sequence
1 Tilt socket, Bolt, Nut, Bearing, Grease 3 Piston rod, Piston, Piston seal, Nut
nipple 4 Cylinder tube, Bushing
2 Guide bushing, O-ring, Dust seal,
Packing, Buffer ring

NOTE
Do not remove the tilt socket bearing and
cylinder tube bushing unless they are defec-
tive.

Suggestions
Removing bushing
(1) Wrap the cylinder with a rag, and clamp it in a
vise. Using a wrench, remove the bushing
from the cylinder.
(2) When removing the bushing from the piston
rod, be careful not to damage the buffer ring,
packing, O-ring against the threads of the pis-
ton rod.

200351

10-30
HYDRAULIC SYSTEM

Inspection after disassembly


1. Cylinder tube
(1) Check the bore wall for wear, grooving,
scratch marks and rusting.
(2) Check the welds for cracks.
2. Piston rod
(1) Check for deflection in as shown.
(2) Check for surface flaws such as grooving,
scratch marks, rusting and wear. The rod must
be replaced if its threads show a sign of strip- 200319
ping or any other damage.
3. Packings and rings
Replace all parts contained in the seal kit, once
disturbed.

Precautions for reassembly of lift and tilt


cylinders
(1) Carefully clean all parts to remove any gritty
particle.
(2) Reassemble the cylinder in the reverse
sequence of the disassembling, apply
hydraulic oil to the bore wall of the cylinder
tube, and also to sealing parts — O-rings, U-
rings, wiper rings, nylon heels, piston seals,
dust seals and packings — so that they will
smoothly slide into the bore.
(3) When clamping the cylinder tube in the vise in 200352
order to run the head into the cylinder tube, be
careful not to distort the tube.
(4) Before fitting the piston seal to the tilt-cylin-
der piston, squeeze the seal by hand 5 or 6
times to soften it. Hold the piston steady by
clamping the rod in the vise; apply a small
amount of hydraulic oil to the seal; fit a por-
tion of the seal to the groove; and push the
other portions just a little at a time into the
groove.
200353

10-31
HYDRAULIC SYSTEM

Flow Regulator Valve

1
5

203559

Sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring, Shims

Inspection after disassembly


1. Check the springs for fatigue.
2. Check seat and sliding faces of valve and pis-
ton.
3. Check the sliding surfaces of the piston and
valve body for damage.

NOTE
Replace the flow regulator valve as an assem-
bly if any part is defective.

10-32
HYDRAULIC SYSTEM

Inspection and Adjustment


Hydraulic Tank
1. Hydraulic oil
Check the hydraulic oil in the tank for cleanliness.
Oil showing discoloring (Slightly whitish color is
allowed as it always appears after the operation.)
must be changed.
2. Refill capacities and the amount of oil
required.

”H” high level


“N” neutral level
“L” low level

Refill Refill Refill


capacity H+5 capacity
capacity Lift height (meter) Refill Lift height (meter) (1 liter,
(7.0) capacity (7.0) approx.)
GP/DP20K GP/DP30K GP/DP35K
(6.5) (6.5)
GP/DP25K
(6.0) 6.0 GP15K “H” 45 6.0 45
(5.5) 5.5 GP18K “H” (45.1 ) 5.5 (45.1 ) “H”
45 “N”
“H” (45.1 ) 5.0 5.0 43.1 5.0 5.0
4.78 (30.9 ) “L” “N” 40.1 40.1 “N”
4.7
“N” 40.1 4.5 4.5
–1.8 –1.8
27.8 “L” (38.3 ) (38.3 ) “L”
–1.8 4.33 4.3
“L” (38.3 ) 4.0 4.0 4.0 –1.2 4.0 4.0 4.0
3.7 3.7 3.7 (26.6 ) 3.7 3.7 3.7
3.5 3.5 10 3.5 3.5
3.3 3.3 3.3 3.3
3.0 3.0 3.0 3.0
2.7 2.7
2.5 2.5
2.0 2.0

*1 *2 *3 Bottom of *1 *2 *3
hydraulic tank

*1 Dual stage panoramic Equivalents:


*2 Dual stage full free panoramic Meter = approx. 3.3 feet
Liter = approx. 0.26 U.S.gal
*3 Triple stage full free panoramic
207162

Remarks
(1) How to read the chart
[Example]
1.5, 1.8 ton models: In the truck equipped with a triple-stage full free 5.0 m (165.5 ft)
panoramic 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 (18.2 to
23.1 ft) masts, maintain the level at “H” mark with the mast lowered to the
bottom.
3.5 ton models: In the truck equipped with any of the dual-stage full free masts up to 3.7
m (12.2 ft) lift height, maintain the oil level at “N” mark. In the case of
4.0 m (13.2 ft) masts, maintain the level at “H” mark with the mast low-
ered all the way.
(2) Another general rules: In any machine, regardless of the mast-and-attachment combination, the
oil level should not be above “H” mark on the level gauge when the mast is at the bottom. In addi-
tion, the oil level must be 5 mm (0.12 in.) from the bottom end of the gauge or higher when the
mast is at the top.
10-33
HYDRAULIC SYSTEM

3. Suction strainer
Check the suction strainer for clogging or damage.
4. Return filter
Check the return filter for clogging or damage.
Hydraulic Pump
The purpose of test run is to break-in the over-
hauled pump and verify its performance. The use
of a pump testing equipment, specially designed as
such and commonly used in the service shop, is
recommended but is not mandatory. The follow-
ing procedure, however, assumes that the pump is
installed on the truck:

1. Install a pressure gauge capable of measuring


up to 25000 kPa (250 kgf/cm 2) [3555 psi]. To
install the pressure gauge, remove the plug
from the delivery hose joint and attach the fol-
lowing tools:
Special tools needed
64309-17733
Connector
[R(PT) 1/8 thread]
Hose 64309-17722
Connector 64309-17731 (for gauge)
64309-17712
Gauge 25000 kPa (250kgf/cm 2)
[3555 psi]

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

2. Position the control levers in neutral. Run the


engine at 500 to 1000 rpm, keeping the dis-
charge pressure at a level not higher than 981
kPa (10 kgf/cm2) [142 psi] or below. Maintain
this condition for 10 minutes to break-in the
pump.
3. Raise the engine speed from 1500 to 2000
rpm, and run the engine for another 10 min-
utes in the no-load condition.

10-34
HYDRAULIC SYSTEM

4. While the pump is being run, loosen the


adjusting screw, and shift the control levers
into operating positions. Next, set the adjust-
ing screw to obtain a gauge reading of 2942
kPa (30 kgf/cm2) [427 psi], and run for 5 min-
utes at this pressure. Following this, raise the
pressure by changing the setting of adjusting
screw in increments of 1961 kPa (20 kgf/cm2)
[284 psi] each, running the pump for 5 min-
utes at each raised pressure until, finally, the
prescribed set pressure of the relief valve is
reached.
207137
5. Pay attention to the temperatures of oil and
pump surfaces and to the running noise while
raising the pressure and, if any abnormal con-
dition is noted, bring the pump to no-load con-
dition to cool the oil or pump or, as necessary,
discontinue the test run, and overhaul the
pump once again. Do not keep on raising the
pressure when an abnormal condition is noted.
6. After doing Steps 2. thru 5. above, reset the
relief valve as specified and operate the fork
and mast to see if the tilt and lift cylinders
work with the specified speeds.
Control Valve
1. 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 connec-
tions.

10-35
HYDRAULIC SYSTEM

2. Internal leakage 3 to 4°
It is not practical to check the control valve alone
for internal leakage. The leakage to be checked
includes leakages occurring at the lift spool, tilt
spool, tilt lock valve and check valves.
[Test oil temperature: 50 °C (122 °F), approx.]
(1) Pick up a load equal to the rated capacity, and
lift it approximately 1 meter (3 feet) high. Tilt
the mast about 3° to 4° forward, and stop the 1 meter (3 ft.),
approx.
engine.
(2) Quickly disconnect the oil return hose, and
start collecting the oil coming out of this hose 204942
as shown.
The amount of oil 500 cc (30.5 cu.in.),
collected for 15 minutes maximum

(3) If the tilt cylinders or lift cylinders drift (the


mast tilts forward or the fork lowers) exces-
sively in spite of that the amount of oil col-
lected 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.)

3. Main relief valve adjustment 207138


(1) Attach a pressure gauge capable of measuring
up to 25000 kPa (250 kgf/cm2) [3555 psi] to
the delivery hose connector. Use the gauge,
connectors and hose used for testing the gear
pump.
(2) Start the engine and run it at the maximum
speed. Move the tilt control lever to the back-
ward tilt position. If the pressure is relieved at
18142 + kPa (185 + kgf/cm 2) [2631+ psi]
when the tilt cylinders reach the end of their
stroke, the main relief valve setting is correct.

207137

10-36
HYDRAULIC SYSTEM

(3) If the setting is incorrect, loosen the lock nut


of adjusting screw and, while observing the
pressure gauge reading, slowly turn the adjust-
ing screw in either direction until the gauge
indicates the prescribed set valve.
(4) While holding the adjusting screw, tighten the
lock nut to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the
setting.
18142 + 490 kPa
Main relief valve setting (185 + 5 kgf/cm 2)
[2631 + 71 psi]

4. Flow divider relief valve adjustment


(1) Set up a pressure gauge capable of measuring
up to 25000 kPa (250 kgf/cm2) [3555 psi] as 5
shown.
Special tools needed 4
1 Connector 91268-06200 3
2 Connector 64309-17733[R(PT)1/8 thread]
3 Hose 64309-17722
4 Connector 64309-17731 (for gauge)
64309-17712 2
5 Gauge 25000 kPa (250 kgf/cm 2)
[3555 psi]
1
NOTE 207045
1) The tools 2 thru 5 are included in the gauge
kit 64309-17701.
2) Use the gauge included in this gauge kit.

(2) Start the engine. With the engine running at


the maximum speed, turn the steering wheel
counterclockwise to the lock, and check the
flow divider valve for setting.

10-37
HYDRAULIC SYSTEM

Unit: kPa (kgf/cm 2) [psi]


Flow divider
+ + +71
relief valve 7355 (75 ) [1066 ]
setting

(3) If the setting is incorrect, loosen the lock nut


of adjusting screw and, while observing the
pressure gauge reading, slowly turn the adjust-
ing screw until the gauge indicates the pre-
scribed set value.
(4) While holding the adjusting screw, tighten the
lock nut to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the
setting.
207139
5. Overload relief valve adjustment (OP.)
(1) Attach a pressure gauge capable of measuring
up to 25000 kPa (250 kgf/cm2) [3555 psi] to
the delivery hose connector.

NOTE
Use the tools used for adjusting the main
relief valve.

(2) Start the engine. With the engine running at


the maximum speed, move the attachment
control lever forward or backward. If the
pressure is relieved when the attachment actu-
ator is moved, the overload relief valve setting
is correct.
(3) If the setting is incorrect, loosen the lock nut
of adjusting screw and, while observing the
pressure gauge reading, turn the adjusting
screw.
(4) While holding the adjusting screw, tighten the
lock nut to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the
setting.

10-38
HYDRAULIC SYSTEM

Lift and Tilt Cylinders


1. Mast tilt angle adjustment
(1) Adjust the tire pressure correctly, and place on
a flat and level ground.
(2) Tilt the mast fully backward, and stop the
engine.
(3) Measure the tilt angle of mast at both sides.
(4) To adjust the tilt angle, loosen the bolt A on
the tilt cylinder socket and adjust the rod
length by turning the rod. Adjust a cylinder so
that there is no difference in stroke tilt angle
between the cylinders. A
207054
Tightening torque Unit N•m(kgf•m)[lbf•ft]
Tilt cylinder socket bolt 127-152(12.9 to 15.4)
[936 to 112]

NOTE
It is not necessary to adjust the forward tilt
angle, provided that the backward tilt angle is
properly adjusted.

Forward — backward tilt angle 6° — 10°

2. Lift cylinder stroke adjustment


(1) Slowly raise the inner mast, and observe the
stopping of piston rod, right and left, at the
moment the inner mast reaches its maximum
lift height.
(2) If the top of mast rolls at that moment, it
should be adjusted with shims. Abnormal
condition can be detected by a little time lag 204698
in stopping between right-hand and left-
hand piston rods and rolling of the rod with
a longer cylinder stroke.

10-39
HYDRAULIC SYSTEM

[Adjusting method]
(1) Raise the inner mast, tie blocks under the right
and left sides of the mast, and lower the mast
until it rests on the blocks.

202983

(2) Remove the stopper bolt at the top of lift cylin-


der which stopped first, retract the piston rod, Set bolt
and insert shims at the top of piston rod end.
Shims

NOTE
To retract the piston rod, move the lift control
lever to the lowering position to let the oil
escape from the lift cylinder.

(3) Extend the piston rod, and tighten the cylinder 200365
stopper bolt. Remove the blocks from under
the inner mast.
(4) Slowly lower the inner mast to the bottom to
ensure the piston rods move smoothly.

Flow Regulator Valve


Measure the lowering speed with rated load. If the
speed is out of specification, readjust, or replace
the flow regulator valve. Lock nut

1 to 2.5 ton 500 mm/sec


models (98 fpm)
Lowering 530 mm/sec
3 ton models
speed (104 fpm) Adjustment
440 mm/sec screw
3.5 ton models
(87 fpm) 205972

Bleeding lift cylinder


Air and oil remaining inside air chamber of the rod
and inside rod chamber between the tubes open the
check valve and flow out when they are com-
pressed. Therefore, there is no need to bleed the
lift cylinder.

10-40
HYDRAULIC SYSTEM

Testing
1. Load drift test
(1) Pick up a rated load, tilt the mast substantially
vertical, raise the forks 1 to 1.5 m (3.3 to 4.9
ft) from the floor, and stop the engine.
(2) Mark a line on the mast column, and measure
the amount of descent for 15 minutes.
Unit: mm (in.)/15 min
1 to 2.5 ton 3 ton 3.5 ton
models models models
Load drop
50 (1.97),
test (rated 40 (1.57) 35 (1.38) 207055
maximum
load)

2. Forward tilt test


(1) Pick up a rated load, tilt the mast substantially
vertical, raise the forks about 50 cm (20 in.)
from the floor, and stop the engine.
(2) Measure the extension of tilt cylinder for 15
minutes.
Unit: mm (in.)/15 min
1 to 1.8 ton 2 to 2.5 ton 3 to 3.5 ton
models models models
Forward tilt
test (rated 22 (0.87) 20 (0.79) 15 (0.59)
207056
load)

3. Piping
(1) Check each hydraulic circuit for leaks.
(2) Make sure that each hose is free from twisting
or excessive loops.

10-41
HYDRAULIC SYSTEM

Hydraulic Circuit Diagram

10-42
HYDRAULIC SYSTEM

Troubleshooting
Complaints Possible causes Remedies
Will not lift nor tilt a) Oil low level Refill.
b) Relief valve out of order, because of:
• Main valve seized Replace.
• Valve spring broken Replace.
c) Oil pump defective Replace.
Will not lift rated load a) Relief valve out of order, because of:
• Relief pressure setting too low Readjust.
• Plunger or poppet seat defective Replace.
• Spring fatigued Replace.
• O-ring in valve case damaged Replace O-ring.
b) Oil pump defective Replace.
c) Piston seals worn or damaged Replace.
Lift speed is too low a) Engine idle speed too low Tune up engine.
b) Control lever installed loosely, resulting in Repair or replace.
short spool stroke
c) Tank strainer clogged Clean or replace.
d) Pump not delivering enough oil Repair or replace
Lowering speed is a) Sleeve seized in flow regulator valve Repair.
too low b) Dirt in flow regulator valve Clean, repair system and
replace defective hose.
c) Abnormal resistance to flow due to deformation Replace hose.
or partial clogging of huse
Cylinder vibrates a) Piston rod distorted Repair or replace.
when actuated b) Air in oil circuit Bleed air by operating
cylinders through full
strokes.
c) Not enough oil in hydraulic tank Refill.
Load descends too fast a) Control valve spool internally leaking Replace.
(drift) b) Sliding (inside) surface of cylinder tube Repair or replace
slightly grooved cylinder assy.
c) Sliding (inside) surface of cylinder tube Replace cylinder assy.
badly grooved
d) Piston seals broken or distorted Replace seal kit.
e) Oil leakage from piping Repair or replace.
Mast tilts forward a) Control valve spool internally leaking Replace.
(drift) b) Foreign particles lodged between packing Replace packing.

10-43
HYDRAULIC SYSTEM

Complaints Possible causes Remedies


Bushing leaks a) Foreign particles lodged between sealing Replace.
members such as oil seals and dust seals
b) Oil seals and dust seals defective Replace.
c) O-rings damaged Replace.
d) Cylinder distorted Repair or replace.
Hydraulic tank heats a) Oil viscosity improper Change oil.
excessively b) Overload Check working condi-
tions and, if overloaded,
advise the operator to
stay within the load limit.
c) Local overheating of oil line due to a large Repair or replace.
restriction to flow
d) Relief valve adjustment improper Readjust pressure setting.
18142 kPa (185 kgf/cm 2)
[2631 psi]
e) Pressure drop due to fatigued or broken Repair or replace and
springs readjust.
f) Hydraulic pump worn Replace.
g) Outlet pipe or tube deformed, or restricted Repair or replace.
Cylinders move too a) Shortage of oil due to a natural loss Refill.
slow b) Oil leakage due to damaged oil line seals Repair or replace.
c) Oil viscosity too higher Change oil.
Cylinders move too a) Hydraulic pump defective Check pump and piping;
slow repair or replace.
b) Oil leakage from oil line Check oil for level and
condition; add or change
oil.
c) Abnormal oil temperature rise Check control valve
spools for misalignment;
repair or replace.
d) Hydraulic pump internally leaking Replace pump.
Noise a) Poor pumping Refill.
b) Cavitation 1)Check suction pipe for
any flat portion or
loose connection;
retighten or replace.
2) Check shaft oil seal
for airtightness;
replace pump.
3) Check pump case for
any outside interfer-
ence; repair.

10-44
HYDRAULIC SYSTEM

Complaints Possible causes Remedies


Pump case, drive a) Pressure too high Replace pump. (Check
gear and pump port to see if relief valve
flange damaged setting is correct.)
b) Distortion or damage due to external strain Replace pump.
or stress 1) Check to see if return
line is restricted.
2) Check to see if pipe
connections have been
externally stressed.
Oil leakage from a) Oil leakage past oil seal Replace oil seal.
pump b) Oil leakage past sliding surfaces of drive shaft Replace whole pump
assembly.
c) Pump securing bolts loose Retighten.
d) Excessive internal leakage Replace O-ring.
Slow or no motion a) Relief pressure setting too low Readjust. 18142 kPa
of lift and tilt cylinders (185 kgf/cm 2) [2631 psi]
b) Relief valve piston seizure Clean piston and check
to see if it moves
smoothly; or replace
whole relief valve
assembly.
c) O-ring on relief valve body damaged Replace O-ring.
d) Control lever installed loosely, resulting in Readjust.
short spool stroke
Load descends or mast
tilts forward (drifts) Control valve internally leaking Replace a leaky block
with control lever in assembly.
neutral
Oil leakage a) Oil leakage from spool ring cap Replace O-ring; check
spool for flaws and if
any, repair or replace a
leaky block assembly.
b) Loose plugs Retighten.
c) O-ring damaged Replace.

10-45
HYDRAULIC SYSTEM

Service Data

A= Assembly standard
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
GP30K:
GP15K/18K: GP20K/25K: 470/500 (93/98)
490/520 510/550 DP30K:
Lift speed (rated load/no load)
(96/102) (100/108) 510/550 (100/108)
A
DP15K/18K: DP20K/25K: GP35K:
mm/sec (fpm) 600/640 640/660 400/430 (79/85)
Simplex mast (118/126) (126/130) DP35K:
430/460 (85/91)
GP/DP30K:
Lowering speed (rated load)
530 (104)
mm/sec (fpm) A 500 (98)
GP/DP35K:
Simplex mast
440 (87)
Forward tilt angle A 6°
Backward tilt angle A 10°
GP/DP30K:
Lift cylinder rod drift (rated load)
40 (1.57)
mm (in.)/15 min. A 50 (1.97), max
GP/DP35K:
[Oil temperature 45 °C (113 °F)]
35 (1.38)
Tilt cylinder rod drift (forward) (rated load)
mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max 15 (0.59), max
[Oil temperature 45 °C (113 °F)]
Main relief valve setting
A 18142 +490 +5 +71
+0 (185 +0 ) [2631+0 ]
kPa (kgf/cm 2) [psi]
Power steering relief valve setting +490 +5 +71
A 7355 +0 (75 +0 ) [1066 +0 ]
kPa (kgf/cm2) [psi]
GP15K/18K: GP20K/25K: GP30K/35K:
63.6 (3881) / 72 (4394) / 79.9 (4876) /
2400 rpm 2400 rpm 2400 rpm
Capacity A
DP15K/18K: DP20K/25K: DP30/35K:
liter (cu. in.)/min
66 (4028) / 88 (5370) / 88 (5370) /
2200 rpm 2200 rpm 2200 rpm
GP20K/25K: GP30K/35K:
47 to 49 47 to 49
(4.75 to 5.0) (4.75 to 5.0)
47 to 49
Tightening torque for oil pump bolts [34 to 36] [34 to 36]
A (4.75 to 5.0)
N·m (kgf·m) [lbf·ft] DP20K/25K: DP30K/35K:
[34 to 36]
123 to 132 123 to 132
(12.5 to 13.5) (12.5 to 13.5)
[90 to 98] [90 to 98]

Tie bolts (M10) A 46 (4.7) [34]


Tightening torque
N·m (kgf·m) [lbf·ft]
Tie bolts (M8) A 19 (1.9) [14]

10-46
HYDRAULIC SYSTEM

A= Assembly standard
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
GP30K:
GP20K/25K: 440/455 (86/89)
450/490 555/570 DP30K:
Lift speed (rated load/no load)
(88/96) (109/112) 460/490 (90/96)
A
DP20K/25K: GP35K:
mm/sec (fpm) 640/635 370/385 (73/75)
duplex mast (125/125) DP35K:
390/415 (76/81)
GP/DP30K:
Lowering speed (rated load)
450 (88)
mm/sec (fpm) A 480 (94)
GP/DP35K:
duplex mast
390 (76)
Forward tilt angle A 6° 6° 6°
Backward tilt angle A 10° 10° 10°
No. 1
Lift cylinder rod drift (rated load)
mm (in.)/15 min. A — — —
[Oil temperature 45 °C (113 °F)]
No. 2
Tilt cylinder rod drift (forward) (rated load)
mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max 15 (0.59), max
[Oil temperature 45 °C (113 °F)]
GP30K:
GP20K/25K: 460/480 (90/94)
560/575 DP30K:
Lift speed (rated load/no load)
465/505 (110/113) 400/515 (94/101)
A
(91/99) DP20K/25K: GP35K:
mm/sec (fpm) 595/640 395/415 (77/81)
triplex mast (117/125) DP35K:
415/445 (81/87)
GP/DP30K:
Lowering speed (rated load)
470 (92)
mm/sec (fpm) A 490 (96) 470 (92)
GP/DP35K:
triplex mast
430 (82)
Forward tilt angle A 6° 6° 6°
Backward tilt angle A 6° 6° 6°
No. 1
Lift cylinder rod drift (rated load)
mm (in.)/15 min. A — — —
[Oil temperature 45 °C (113 °F)]
No. 2
Tilt cylinder rod drift (forward) (rated load)
mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max 15 (0.59), max
[Oil temperature 45 °C (113 °F)]

10-47
HYDRAULIC SYSTEM

A : Assembly standard
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K

GP/DP30K:
[piston] 45 50 55.2 (2.17)
A
Inside diameter of cylinder tube 1 (1.77) (1.97) GP/DP35K:
60 (2.36)

GP/DP30K:
42 (1.65)
Diameter of piston rod 2 A 35(1.38) 40 (1.57)
GP/DP35K:
45 (1.77)
170 to 240 200 to 270 270 to 304
Tightening torque for retainer 3
A (17.3 to 24.5) (20.4 to 27.5) (27.5 to 31.0)
N·m (kgf·m) [lbf·ft]
[125 to 175] [150 to 200] [200 to 225]
75 to 85 75 to 85 90 to 100
Amount of hydraulic oil 4 cc (cu.in.) A
(4.57 to 5.19) (4.57 to 5.19) (5.49 to 6.10)

2 1

3 4
207073

Tightening torque
A 49 ± 10 (5 ± 1) [36 ± 7.2]
N·m (kgf·m) [lbf·ft]

Flow rate at no load liter (cu.in.)/min A 50 (3051) 65 (3967) 75 (4577)

10-48
HYDRAULIC SYSTEM

A : Assembly standard
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K
Items GP/DP18K GP/DP25K GP/DP30K GP/DP35K
[piston] 70 75 85.2 90
Inside diameter of cylinder A (2.76) (2.95) (3.35) (3.54)
tube 1
Diameter of piston rod 2 A 50.8 (2) 50.8 (2) 55 (2.16) 55 (2.16)
Tightening torque for 305 to 370 340 to 405 420 to 455 440 to 475
retainer 3 A (31 to 37.7) (34.7 to 41.3) (42.8 to 46.4) (44.9 to 48.5)
N·m (kgf·m) [lbf·ft] [225 to 275] [250 to 300] [310 to 335] [325 to 350]
Amount of hydraulic oil 4 A 70 to 80 85 to 90 125 to 130 125 to 130
cc (cu.in.) (4.27 to 4.88) (5.18 to 5.49) (7.62 to 7.93) (7.62 to 7.93)

1
2

3 4

207604

10-49
HYDRAULIC SYSTEM

A: Assembly standard
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K
Items GP/DP18K GP/DP25K GP/DP30K GP/DP35K

[piston] 45 45 50 55
Inside diameter of cylinder A (1.77) (1.77) (1.97) (2.16)
tube 1

Diameter of piston rod 2 A 32 35 40 42


(1.26) (1.38) (1.57) (1.65)
Tightening torque for 206 ± 39.2 206 ± 39.2 235 ± 54.0 304 ± 70.6
holder 3 A (21 ± 4) (21 ± 4) (24 ± 5.5) (31 ± 7.2)
N·m (kgf·m) [lbf·ft] [152 ± 29] [152 ± 29] [174 ± 39.8] [224 ± 52]

Holder thread diameter 3 A M52 × 2 M52 × 2 M57 × 2 M63 × 2

Piston tightening torque 4 196 ± 35 196 ± 35 196 ± 35 245 ± 44.1


N·m (kgf·m) [lbf·ft] A (20 ± 3.6) (20 ± 3.6) (20 ± 3.6) (25 ± 4.5)
[145 ± 26] [145 ± 26] [145 ± 26] [180 ± 32.5]
Set screw tightening 3.92 ± 0.98 3.92 ± 0.98 3.92 ± 0.98 3.92 ± 0.98
torque 5 A (0.4 ± 0.1) (0.4 ± 0.1) (0.4 ± 0.1) (0.4 ± 0.1)
N·m (kgf·m) [lbf·ft] [2.9 ± 0.72] [2.9 ± 0.72] [2.9 ± 0.72] [2.9 ± 0.72]

5 1 2 5

3 4
207605

10-50
HYDRAULIC SYSTEM

A= Assembly standard B= Repair or service limit


Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
+0.1 +0.1 +0.1
6300
+0 7000
+0 8000
+0
A +0.004 +0.004 +0.004
(2.48 +0 ) (2.76 +0 ) (3.15 +0 )
Inside diameter of cylinder tube 1
63.12 70.12 80.12
B
(2.4850) (2.7606) (3.1543)
+0.045 +0.045 +0.04
[Guide bushing] 250000
+0.025 30000
+0.025 3500
+0.030
A +0.0018 +0.0018 +0.0015
Diameter of piston rod 2 (0.98 +0.0010 ) (1.18 +0.0010 ) (1.38 +0.0012 )
Inside diameter of tilt socket A 35 –0 –0
–0.012 (1.38 –0.0005 )

bushing (fitted) 3 B 35.5 (1.39)

Inside diameter of cylinder tube head A 32 +0.085


+0
+0.0033
(1.26 +0 )
bushing (fitted) 4
B 32.6 (1.283)
[Guide bushing]
A M68 × 2 M75 × 2 M85 × 2
Thread diameter 5
[Guide bushing] 265 ± 29 314 ± 31 373 ± 37
Tightening torque 5 A (27 ± 3) (32 ± 3.2) (38 ± 3.8)
N·m (kgf·m) [lbf·ft]
[195 ± 21.7] [231 ± 23] [275 ± 27]
[Tilt socket]
A M24 × 1.5 M27 × 1.5 M30 × 1.5
Thread diameter 6
Tilt socket bolt 7 A 127 to 152 (13 to 15.5) [94 to 112]
Tightening torque 127 ± 9.8 235 ± 19.6 392 ± 25
N·m (kgf·m) [lbf·ft] Self-locking nut 8 A (13 ± 1.0) (24 ± 2.0) (40 ± 2.5)
[94 ± 7.2] [173 ± 14.4] [289 ± 18]

3 4

6 7 5 1 2 8
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