HYDRAULIC SYSTEM

1. Specifications ............................................................................................................. 12-3

2. Structure..................................................................................................................... 12-4
2.1 Hydraulic line ...................................................................................................................................... 12-4 1
2.2 Hydraulic tank ..................................................................................................................................... 12-6
2.3 Priority valve ....................................................................................................................................... 12-7
2.4 Control Valve ...................................................................................................................................... 12-8
2
2.5 Lift and tilt cylinder .............................................................................................................................. 12-9
2.6 Flow regulator valve.......................................................................................................................... 12-10 3
3. Suggestions for Removal and Installation................................................................ 12-11
3.1 Control Valve .................................................................................................................................... 12-11
4
3.1.1 Removal .................................................................................................................................................. 12-11
3.1.2 Removal sequence ................................................................................................................................. 12-11 5
3.1.3 Preparation.............................................................................................................................................. 12-11
3.1.4 Suggestions for Removal ........................................................................................................................ 12-12
6
3.2 Lift cylinder........................................................................................................................................ 12-13
3.2.1 Removal .................................................................................................................................................. 12-13
3.2.2 Removal sequence ................................................................................................................................. 12-13 7
3.2.3 Suggestions for Removal ........................................................................................................................ 12-13
3.2.4 Installation ............................................................................................................................................... 12-15 8
3.3 Tilt cylinder........................................................................................................................................ 12-16
3.3.1 Removal .................................................................................................................................................. 12-16
3.3.2 Removal sequence ................................................................................................................................. 12-16
9
3.3.3 Preparation.............................................................................................................................................. 12-16
3.3.4 Suggestions for Removal ........................................................................................................................ 12-17 10
4. Priority valve............................................................................................................. 12-19
4.1 Disassembly and Reassembly.......................................................................................................... 12-19
11
4.1.1 Disassembly sequence ........................................................................................................................... 12-19
4.1.2 Suggestion for disassembly .................................................................................................................... 12-19 12
4.1.3 Suggestion for reassembly...................................................................................................................... 12-19

13
5. Flow regulator valve ................................................................................................. 12-20
5.1 Disassembly...................................................................................................................................... 12-20
5.1.1 Disassembly sequence ........................................................................................................................... 12-20
14
5.2 Inspection and Repair ....................................................................................................................... 12-20
5.3 Reassembly ...................................................................................................................................... 12-20 15

12-1
HYDRAULIC SYSTEM

6. Lift cylinder ............................................................................................................... 12-21

6.1 Disassembly...................................................................................................................................... 12-21
6.1.1 Disassembly sequence ........................................................................................................................... 12-21
6.1.2 Suggestion for disassembly .................................................................................................................... 12-21
6.2 Inspection and Repair ....................................................................................................................... 12-22
6.3 Reassembly ...................................................................................................................................... 12-24
6.3.1 Reassembly sequence............................................................................................................................ 12-24
6.3.2 Suggestion for reassembly...................................................................................................................... 12-24

7. Tilt cylinder ............................................................................................................... 12-25

7.1 Disassembly...................................................................................................................................... 12-25
7.1.1 Disassembly sequence ........................................................................................................................... 12-25
7.1.2 Suggestion for disassembly .................................................................................................................... 12-26
7.2 Inspection and Repair ....................................................................................................................... 12-27
7.3 Reassembly ...................................................................................................................................... 12-28
7.3.1 Reassembly sequence............................................................................................................................ 12-28
7.3.2 Suggestion for reassembly...................................................................................................................... 12-28

8. Inspection and Adjustment....................................................................................... 12-30

8.1 Hydraulic oil ...................................................................................................................................... 12-30
8.2 Test operation of gear pump............................................................................................................. 12-30
8.3 Control Valve .................................................................................................................................... 12-31
8.4 Adjusting main relief valve ................................................................................................................ 12-31
8.5 Functional inspection of priority relief valve ...................................................................................... 12-32

9. Tests ........................................................................................................................ 12-33

10.Troubleshooting....................................................................................................... 12-34

11.Service Data ............................................................................................................ 12-38

12-2
 HYDRAULIC SYSTEM

1. Specifications

Truck model P22000 P26500 P30000 P33000 P36000

Type Gear type
Maker model KFP51100CSMSL
Gear pump
Control flow rate 205 L/min (54.2 U.S. gal.) (at 2200 rpm)
Drive method Directly coupled to torque converter
Maker model VLH71C160B
Priority valve
Relief pressure 15.7 MPa (160 kgf/cm2) [2277.3 psi]
Maker model MW(P) 25
Hydraulic system

Control Valve +0.5

Relief pressure 20.6 0 MPa (210.1 kgf/cm2) [2988.1 psi]
Flow regulator Type Cylindrical valve type
valve Control flow rate 120 L/min (31.7 U.S. gal.) 150 L/min (39.6 U.S. gal.)
120 mm
Inside diameter 105 mm (4.13 in.) φ115 mm (4.5 in.)
Lift cylinder (4.7 in.)
Stroke 1500 mm (59.1 in.)
Inside diameter 120 mm (4.7 in.)
Tilt cylinder
Stroke 270 mm (10.6 in.)
N level: 184
N level: 168 L
Service oil quantity (tank level) N level: 140 L (37.0 U.S. gal.) L (48.6 U.S.
(44.4 U.S. gal.)
gal.)

12-3
HYDRAULIC SYSTEM

2. Structure
2.1 Hydraulic line

10,9 10,9

11
15
11

8
5

7
13

12

14 4

1 2 3
211967

1 Hydraulic tank 9 Flow regulator valve

2 Return filter 10 Lift cylinder
3 Suction strainer 11 Tilt cylinder
4 Gear pump (oil pump) 12 Check valve
5 Priority valve 13 Steering valve
6 Control valves for work machines 14 Power cylinder
7 Lift valve 15 Lift return valve
8 Tilt valve

12-4
 HYDRAULIC SYSTEM

The gear pump draws oil from the hydraulic tank and sends
it to the priority valve. The oil pressure is metered and
divided by this priority valve into two systems, one for the
hydraulic system and the other for the steering system. The
oil that goes to the hydraulic system is sent through the con-
trol valve to the hydraulic cylinders.

NOTE
The steering control valve is described in “11 STEERING
SYSTEM”. Also for power cylinder, refer to “9 REAR
AXLE”.

12-5
HYDRAULIC SYSTEM

2.2 Hydraulic tank

5 4 3

211968

1 Breather 3 Suction strainer

2 Drain plug 4 Return filter

The hydraulic tank is an integral structure with the frame

and is provided with a strainer at the oil supply port, suction
strainer, and return filter to keep the oil clean.
Oil in the hydraulic tank will be drawn into the gear pump
through the suction strainer (105 μ ).The return oil from the
lift cylinder will merge the return oil from the control valve
and steering control valve and return to the hydraulic tank
through the return filter (25 μ ).

12-6
 HYDRAULIC SYSTEM

2.3 Priority valve

LS
T

1
4

EF

CF

6
205648

1 Relief Valve P: Pump port

2 Plug T: Tank port
3 Housing CF: Control flow port
4 Control spring EF: Main flow port (control valve for service equipment)
5 Spool LS: Load sensing port
6 Plug

Of the service oil discharged from the gear pump, only the When the steering is in neutral position, almost all of the
amount required for steering operation will be supplied by service oil will be used for operating all the other service
the priority valve to the steering control valve, the remain- equipment.
ing oil will be forwarded to circuits of other service equip-
11.8 MPa
ment. Priority relief pressure (120.3 kgf/cm2)
[2988.1 psi]

12-7
HYDRAULIC SYSTEM

2.4 Control Valve

B2

2 T

A2 A1 1
211932

1 Inlet valve P: From priority valve

2 Block T: To tank
3 Main relief valve adjustment screw A1: To lift cylinder
4 Tie bolt A2: To tilt cylinder
B2: From tilt cylinder

The control valve is an assembly of more than one valve

block which are mounted together by three tie bolts.
Each block has a pump port and tank port, and is mounted
with a cartridge-type pilot-operate relief valve.

12-8
 HYDRAULIC SYSTEM

2.5 Lift and tilt cylinder

Bottom-side port

Flow regulator valve

Rod-side port
Lift cylinder
210468
The lift cylinder is a single working type of which the pres-
surized oil reacts only in one direction for pressing the pis-
ton.
The bottom-side port has a flow regulator valve built in, and
oil return pipe at the rod side port.

Socket Collar

Tilt cylinder

211969

The tilt cylinder is a dual working type and has the rod end
threaded for adjusting the balance between the right and left
when the mast is mounted.
The tilt angle setting can be modified through an optional
adjustment of collar and socket.

12-9
HYDRAULIC SYSTEM

2.6 Flow regulator valve

To lift cylinder
From lift cylinder

From control
valve To control valve

To other
flow regulator
valve
210470 210471

The flow regulator valve will pass the entire amount of ser-
vice oil fed from the pump as-is while the lift cylinder is
raising the mast, but controls the flow rate passing through
it by automatically closing down the orifice when the lift
cylinder is lowering the mast.
As the result, the descending speed of mast can be main-
tained constant irrespectively of whether the load is light or
heavy.
In addition, since the right and left flow regulator valves are
linked together, the lowering speed of mast by both cylin-
ders can be even.

12-10
 HYDRAULIC SYSTEM

3. Suggestions for Removal and Installation

3.1 Control Valve
3.1.1 Removal

10

10

7
2 3

211970

3.1.2 Removal sequence

1 Pipe 6 Pipe, O-ring, Bolt, Washer
2 Flow regulator valve, Pipe, O-ring, Bracket, Bolt, Wash- 7 Pipe, O-ring, Bolt, Washer
er, Collar,
3 Hose, Clamp, Pipe 8 Pipe, O-ring
4 Hose 9 Pipe, O-ring
5 Hose 10 Connector

3.1.3 Preparation NOTE

Before disconnecting each pipe, prepare oil receivers to
(1) Remove the floor plate.
catch oils remaining in the pipes and hoses. Further, take
(2) Before disconnecting each pipe, put the mast in neutral
appropriate measures for the connections of pipes and con-
position and lower the fork to the bottom in order to
trol valves to prevent dust and dirt from entering in the
purge the residual pressure in the pipe.
openings.

12-11
HYDRAULIC SYSTEM

3.1.4 Suggestions for Removal

Removing control valve
When removing the control valve, support it by lifting it
with a rope, etc. beforehand.
Type Weight
3-valve 45 kg (99.2 lb)
4-valve 55 kg (121.3 lb)
5-valve 65 kg (143.3 lb)

12-12
 HYDRAULIC SYSTEM

3.2 Lift cylinder

3.2.1 Removal

Connector
5

1
2

4
3

211971
3.2.2 Removal sequence
1 Lift bracket 5 Stopper bolt
2 Return hose, Hose clamp 6 Cylinder clamp, Cushion, Collar, Shim
3 High-pressure hose 7 Stopper bolt
4 Constant descending hose 8 Lift cylinder

Push the lift lever of the control valve forward slowly to

3.2.3 Suggestions for Removal lower the mast.
(1) Removing return hose
NOTE
Start the engine and raise the mast to the top, then stop
During this operation never touch the lift lever of the con-
the engine. Disconnect the return hose on the right and
trol valve. Push the lift lever of the control valve forward
left lift cylinders at their connectors.
slowly to lower the mast.
(2) Lower the lift bracket.

12-13
HYDRAULIC SYSTEM

(3) Removing high-pressure hose and constant descending

hose
Remove the hose from the joint at the bottom of the lift
cylinder. Prepare containers to catch oil, which should
remain in the high-pressure hose.

(4) Removing stopper bolt

(a) Remove the stopper bolt at the upper section of the lift
cylinder, and lift the inner mast up to separate the cylin-
der rod end from the mast.
Before lifting up the inner mast, wrap the inner mast
channel with a protective cloth and attach a wire rope
around the inner mast in such a way that includes an ex-
tra turn.

NOTE
The rod end section of the lift cylinder has some shims
inserted, record the number of shims inserted in each cylin-
der, right or left, before removal.

210475
(b) Place wooden blocks with enough strength to support
the weight of the inner mast under the mast, then
remove the wire rope.

(5) Removing lift cylinder

Hoist the lift cylinder from the rear of the mast with a
rope to carefully remove it. Attach a wire rope on the lift
cylinder before removing the cylinder clamp.

3.2.4 Installation
Follow the removal procedure in reverse while noting the
following instructions.
(1) Bleed air by repeating full upstroke and downstroke
under no load, and make sure the operation is normal.
210476
(2) After making sure the operation is normal, inspect the
service oil level with an oil level gauge (Refer to the
paragraph of “Service oil quantity and raised height of
mast”).
(3) Check whether the raised height of mast is at the nor-
mal value.

12-14
 HYDRAULIC SYSTEM

(4) When either the lift cylinder or piston rod has been
replaced, always inspect the balance or racking (for the
inspection and adjustment method, refer to “13 Mast
and Fork”).

12-15
HYDRAULIC SYSTEM

3.3 Tilt cylinder

3.3.1 Removal

3 4

1
211972

3.3.2 Removal sequence

1 Tilt socket pin, Collar, Washer, Spring washer, Bolt 4 Tilt cylinder pin, Collar, Washer, Spring washer, Bolt
2 Bearing, Snap ring, Spacer 5 Tilt cylinder
3 Hose

3.3.3 Preparation
(1) Block the front wheels.
(2) Fully tilt the mast forward and slowly lower the lift
bracket.
When the fork tips reach the ground, stop the engine.
(3) Open the overhead cover.

12-16
 HYDRAULIC SYSTEM

3.3.4 Suggestions for Removal

Remove the tilt cylinder in the following order.
(1) Removing tilt socket pin
(a) Lift and support the right and left cylinders at position
A shown in the figure. (Use two pieces of wire rope.)
(b) Remove the socket pin mounting bolt, washer, and col- Tilt
A
lar. cylinder
pin
(c) Screw in the jack bolt (M10 ∞ 1.25) at section B shown
in the figure to remove the tilt socket pin.
(2) Retract the tilt cylinder rod.
Start the engine and retract the cylinder rod to minimum B
while lowering the crane. Then, stop the engine.
(3) Lower the right and left cylinder to the ground one at a Protective cloth 210479
time, and unhook the wire rope from the crane.

(4) Disconnecting hose

(a) Disconnect hose 2 from the connector of the cylinder.
(b) At this time, cap the connector end at the socket side of Cap
the tilt cylinder.

Cap (G1/2) 05530 - 40400

NOTE
This cap serves as to confine the oil to within the cylinder
and prevent the cylinder rod from extending. Before lifting Entrapped oil
211973
the tilt cylinders, be sure to attach both the right and left
caps.

12-17
HYDRAULIC SYSTEM

(5) Removing tilt cylinder

(a) Lift the tilt cylinder to be removed by a crane.
(b) Remove the tilt cylinder pin mounting bolt.
(c) Screw in the jack bolt (M10 × 1.25) at section A shown A
in the figure to remove the tilt cylinder pin.
(d) Pull out the seat frame in the forward direction while
lifting the tilt cylinder by the crane.

211978

12-18
 HYDRAULIC SYSTEM

4. Priority valve
4.1 Disassembly and Reassembly

205657

4.1.1 Disassembly sequence

1 Spool, Plug, O-ring, Spring 3 Relief valve, O-ring
2 Plug, O-ring 4 Housing

4.1.2 Suggestion for disassembly

Do not disassemble relief valve 3 further than that shown in
the figure.

4.1.3 Suggestion for reassembly

44.1 N•m
Tightening torque of plugs 1 and 2 (4.50 kgf•m)
[32.55 lbf•ft]
20.6 N•m
Tightening torque of relief valve 3 (2.10 kgf•m)
[15.20 lbf•ft]

12-19
HYDRAULIC SYSTEM

5. Flow regulator valve

5.1 Disassembly

4 3

210492

5.1.1 Disassembly sequence

1 Plug, Ring, O-ring 4 Valve, Spring pin
2 Snap ring 5 Spring, Washer, Shim
3 Piston 6 Sleeve

5.2 Inspection and Repair

(1) Check the spring for deterioration.
(2) Check each contact surface and sliding surface of the
check valve seat for damage.
(3) Check each sliding surface of support and sleeve for
damage.

NOTE
When any of the parts are damaged, replace the whole
assembly.

5.3 Reassembly
Reassembly should be followed in the reverse order of dis-
assembly.

12-20
 HYDRAULIC SYSTEM

6. Lift cylinder
6.1 Disassembly

∗
∗

2 ∗
∗

∗ 3

∗ Seal kit parts 210493

6.1.1 Disassembly sequence

1 Rod cover, Dash seal, Rod packing, O-ring, Bushing 3 Wear ring, Backup ring, Packing
2 Piston rod, Collar 4 Cylinder tube

6.1.2 Suggestion for disassembly

Removing piston rod

(1) Wrap the lift cylinder with a piece of waste cloth, and
hold it in a vise. Remove the cylinder head and rod
cover with Hook Wrench A.
Special tool

P30000,
P22000,
Truck model P33000,
P26500
P36000
Hook wrench A 05312 - 11000 05312 - 11200 A

(2) When pulling out the piston rod from the cylinder, be
602303
careful not to damage the wear ring.

12-21
HYDRAULIC SYSTEM

6.2 Inspection and Repair

Cylinder tube
(1) Check the inside surface of the cylinder for wear, dam-
age, or rust.
(2) Check the welds for cracks, damage, and dents.

Piston rod
(1) Check the piston rod if it may cause runout.
Support both ends of the piston rod with V-shaped
blocks, and measure its runout using a dial gauge at the
center while turning the piston rod. If 1/2 of dial indica-
tor reading exceeds the limit, replace the piston rod. 200319
(2) Check the rod surfaces for rust, damage, sliding trace,
and dent.Replace the piston rod, if it is seriously dam-
aged in the threaded part.

Ring and packing

(1) Check the packing and wear ring for damage or distor-
tion.
(2) Check each ring for deterioration.

Truck model P22000 P26500 P30000 P33000

Standard
115 mm (4.53 in.)
value
Inside diameter of cylinder tube 1
Repair or
Piston 115.15 mm (4.534 in.)
service limit
Deflection of piston rod 2 (1/2 of dial Repair or
0.5 mm (0.02 in.)
indicator reading) service limit
-0.030 -0.0012
Standard 60 -0.104 mm [2.36 -0.0041 in.] (Mast height 5500 to 7000 mm
Outside diameter of piston rod 3
value [18.04 to 22.97 ft]: 75
+0.035
-0.039 mm [2.95
+0.0014
-0.0015 in.]) Note 1
+0.11 +0.0043
Rod cover Standard 60 0 mm [2.36 0 in.] (Mast height 5500 to 7000 mm
Inside diameter of rod cover bushing 4
value +0.19 +0.0075
[18.04 to 22.97 ft]: 75 +0.06 mm [2.95 +0.0024 in.]) Note 1
Standard
Rod cover tightening torque 5 1.18±0.1 kN•m (120.3 ± 10.2 kgf•m) [870.8 ± 73.8 lbf•ft]
value

Note 1: The mast height for P30000 and P33000 is from 5000 to 7000 mm.

12-22
 HYDRAULIC SYSTEM

5 2

4 3 1

210494

12-23
HYDRAULIC SYSTEM

6.3 Reassembly

∗ Seal kit parts

4 1 3 2

∗ ∗ ∗ ∗ ∗ ∗
210495

6.3.1 Reassembly sequence

1 Piston rod, Collar 4 Rod cover, Bushing, O-ring, Packing, Dust seal
2 Wear ring, Backup ring, Packing
3 Cylinder tube

6.3.2 Suggestion for reassembly

(1) During reassembly, always replace the Seal Kit parts
marked with an asterisk (*) in the figure.
(2) Thoroughly clean all parts before reassembly making
sure they are completely free from dirt or dust.
(3) Apply a coat of oil to each inside surface of rings,
bushings, and cylinder tube before reassembly.
(4) When holding the cylinder’s outer circumference on a
vise, be careful not to tighten the vise excessively as to
distort the cylinder.
(5) Before tightening the rod cover, apply Loctite #638 to
the threaded part of the cylinder tube.
1.18 ± 0.1 kN•m
Rod cover tightening torque (120.3 ± 10.2 kgf•m)
[870.8 ± 73.8 lbf•ft]

12-24
 HYDRAULIC SYSTEM

7. Tilt cylinder
7.1 Disassembly

4
∗

∗ 3
∗

∗ 2
∗
∗

211974

7.1.1 Disassembly sequence

1 Socket, Nut 4 Piston, Self-locking nut, Piston seal
2 Guide bushing, Dust seal, Packing, Buffer ring, O-ring, 5 Piston rod
Backup ring
3 Collar 6 Cylinder tube, Bushing

NOTE
The bushing press-fit in cylinder tube 6 does not have to be
disassembled unless defective.

12-25
HYDRAULIC SYSTEM

7.1.2 Suggestion for disassembly

Removing guide bushing
(1) Wrap the tilt cylinder with a piece of waste cloth, and
hold it on a vise. Remove the guide bushing using
Hook wrench A.
Special tool

Hook wrench A 05312 - 11000

(2) Before removing the guide bushing, wrap the threaded

part of the piston rod with vinyl tape so that the thread
edges do not damage the buffer ring and packing.
200351

12-26
 HYDRAULIC SYSTEM

7.2 Inspection and Repair

Cylinder tube
(1) Check the inside surface of the cylinder for wear, dam-
age, or rust.
(2) Check the welded area for cracks, damage, and dent.
Piston rod
(1) Check the runout of piston rod.
Support both ends of the piston rod with V-shaped
blocks, and measure its runout using a dial gauge at the
center while turning the piston rod. If 1/2 of dial indica-
tor reading exceeds the limit, replace the piston rod.
(2) Check the rod surfaces for rust, damage, sliding flaws,
and dents. Replace the piston rod, if it is seriously dam-
aged in the threaded part.
Ring and packing
200319
(1) Check the lips of packing and buffer ring for damage or
distortion.
(2) Check each ring for deterioration.

Truck model P22000 P26500 P30000 P33000

Standard value 120 mm (4.7 in.) 130 mm (5.1 in.)
Inside diameter of cylinder tube 1 120.12 mm
Repair or service limit 130.12 mm (5.123 in.)
(4.729 in.)
Outside diameter of piston rod 2 Standard value 55 mm (2.17 in.)
Guide bushing Clearance between rod and guide Standard value 0.1 mm (0.004 in.)
bushing Repair or service limit 0.2 mm (0.008 in.)
+0.100 +0.0039
Standard value 60 +0.070 mm (2.36 +0.0028 in.)
Inside diameter of bushing 3 (under press-fit)
Repair or service limit 60.6 mm (2.39 in.)
637±63.7 N•m 696.5±69 N•m
Tightening torque of guide bushing 4 Standard value (64.95±6.5 kgf•m) (71.02±7.03 kgf•m)
[470.1±47.0 lbf•ft] [514.0±50.9 lbf•ft]
1178 to 1472 N•m (120.1 to 150.1 kgf•m)
Tightening torque of socket nut 5 Standard value
[869.4 to 1086.3 lbf•ft]
Deflection of piston rod 6 (1/2 of dial indicator
Repair or service limit 0.5 mm (0.02 in.)
reading)

5 4 2 1 6

211975

12-27
HYDRAULIC SYSTEM

7.3 Reassembly

∗ Seal kit parts

∗ ∗

4 3 1 2
211976

7.3.1 Reassembly sequence

1 Piston rod, Collar, Piston, Self-locking nut, Piston seal 3 Guide bushing, Packing, Buffer ring, Dust seal, Backup
ring, O-ring
2 Cylinder tube, Bushing 4 Socket, Nut

7.3.2 Suggestion for reassembly

(1) During reassembly, always replace the Seal Kit parts
marked with an asterisk (*) in the figure.
(2) Thoroughly clean all parts before reassembly making
sure they are completely free from dirt or dust.
(3) Coat each inside surface of the piston seal, O-ring,
packing, dust seal and cylinder with service oil before
reassembly.
(4) When holding the cylinder’s outer circumference in a
vise, be careful not to tighten the vise excessively as to
distort the cylinder.

200352

12-28
 HYDRAULIC SYSTEM

(5) Procedure to install piston seal into tilt cylinder

(a) Lightly compress and release a piston seal 5 to 6 times
by hand to make it soft.
(b) Hold the piston with a vise while taking care so as not
to damage the piston rod, and apply a thin coat of oil on
the piston seal. First fit the one side of the piston seal
into the mounting groove provided on the piston, then
press-in the other side.
(6) Make sure each direction of the packing and dust seal
to be inserted into the guide bushing. 204641

12-29
HYDRAULIC SYSTEM

8. Inspection and Adjustment

8.1 Hydraulic oil
Cloudy oil should be changed, since water is suspected be
mixed in. When the oil is checked immediately after operat-
ing the control lever, be careful not to mistake the bubbles
of oil as a mixture with water.
Suction strainer, Return filter
Check for damage or clogging, and clean or replace.
8.2 Test operation of gear pump
Test operation is to perform break-in of the pump and make
check the performance. This test operation is desirable to be
performed on the test stand, however, since the actual ser-
vice is impossible, use the following method with the gear
pump installed on the truck.
(1) Connect an oil pressure gauge (gauge, 25 MPa (254.9
kgf/cm2) [3626.3 psi]) to the upper right surface of the
control valve.
Installing oil pressure indicator:
Remove the plug from the connector of delivery hose
and attach the following tool instead.

Connector 64309 -17734(R (PT) 1/4 thread screw)

Hose 64309 - 17722
Connector 64309 - 17731 (for gauge installation)

64309 - 17712 (25 MPa (254.9 kgf/cm2)

Gauge
[3626.3 psi])

Adjusting screw
NOTE 211977
Tools mentioned above are included in the Gauge Kit
64309-17701.
(2) Make the control lever to the neutral position and run
the engine at 500 to 1000 rpm. At the neutral position
the oil pressure meter must read 1 MPa (10.2 kgf/cm2)
[145.1 psi] or less.
Continue to run the engine in this condition for 10 min-
utes and listen to see if the pump generates abnormal
sound.
(3) After 10 minutes, raise the engine speed to 1500 to
2000 rpm, and continue to run the engine under no load
for more 10 minutes.
(4) Loosen the adjusting screws of the relief valve under
the condition of paragraph (3) and shift the control
lever to the active position. Then, adjust the adjusting
screw to set the pressure to 3 MPa (30.6 kgf/cm2)
[435.2 psi], and run the engine for 5 minutes. Continu-
ously raise the pressure further by 2 MPa (20.4 kgf/
cm2) [290.1 psi] increments and run the engine for 5
minutes each time until the relief valve reaches the
specified pressure setting.
12-30
 HYDRAULIC SYSTEM

(5) During the process of raising the pressure, watch the oil
temperature, pump surface temperature, and listen for
abnormal sound from the pump, etc. If the oil tempera-
ture or pump temperature abnormally rises, cancel the
load and lower the temperature to continue the test
operation, or disassemble the pump again to inspect the
inside.
(6) Complete the operations of (2) to (5), then re-adjust the
relief valve to the specified pressure setting, and make
sure that the operation speed is normal.

8.3 Control Valve

Oil leak to the outside
(1) Oil leak from O-ring between housings
(2) Oil leak from O-ring of the scraper
(3) Oil leak at fastening screws

8.4 Adjusting main relief valve

(1) Connect an oil pressure indicator (gauge, 25 MPa
(254.9 kgf/cm2) [3626.3 psi]) on the left side of the
control valve.
The gauge, connector, hose, etc. to be used are same as
with the gear pump test operation.
(2) Start the engine and raise the speed to the maximum.
(3) The relief valve is normal, if the oil pressure is relieved
+0.5
and the pressure meter hand points to 20.6 0 MPa
2
(210.1 kgf/cm ) [2988.1 psi] when the tilt cylinder
reaches the backward tilt limit as the result of turning
the tilt lever to the backward tilt position.
(4) If the relief pressure is not satisfactory, loosen the lock
nut of the relief valve adjusting screw and adjust the
pressure while observing the gauge reading. Adjusting screw
211977

NOTE
The reference amount of tightening-in of adjusting screw
for relief valve is such that one turn varies the pressure for
approx. 10.6 MPa (108.1 kgf/cm2) [1537.6 psi].

(5) Tighten the lock nut to secure the adjusting screw while
holding it by hand.
(6) After securing the adjusting screw, recheck the relief
valve pressure setting.
+0.5
20.6 0 MPa
Main relief valve pressure set-
ting (210.1 kgf/cm2)
[2988.1 psi]

12-31
HYDRAULIC SYSTEM

8.5 Functional inspection of priority relief valve

(1) Set an oil pressure indicator (gauge, 25 MPa (254.9
kgf/cm2) [3626.3 psi]) to the shown position in the fig-
ure at the right.

Ref- 211946
erenc Tool name Part No.
e No.
1 Connector 91268 - 01700 5
64309 - 17733(R (PT) 1/8 thread
2 Connector
screw) 4
3 Hose 64309 - 17722
4 Connector 64309 - 17731 (for gauge installation) 3
64309 - 17712 (25 MPa (254.9 kgf/
5 Gauge
cm2) [3626.3 psi])
2

NOTE
(a) Tools numbered as 2 to 5 are included in the Gauge Kit
64309-17701. 1
(b) Oil pressure indicators (gauge) that are used can have 211947
twice the capacity of the oil pressure to be measured, how-
ever, in this case, use an appropriate device included in the
Gauge Kit.

(2) Start the engine and raise the speed to the maximum.
(3) The relief valve is turned to be normal, if the oil pres- Adjusting plug
sure is relieved and the pressure indicator hand shows
+0.5 +5.1 +72.5
11.8 0 MPa (120.3 0 kgf/cm2) [1711.6 0 psi] when
the steering wheel is turned all the way to the left and
the steering cylinder stroke reaches the upper limit.
(4) If the relief pressure is not satisfactory, disconnect the
T-port piping of the priority valve and adjust the relief
pressure by turning the adjusting plug of the relief
valve.

NOTE
The reference amount of tightening-in of adjusting plug is 205668
such that one turn produces a change of approx. 7.4 MPa
(75.5 kgf/cm2) [1073.4 psi].

12-32
 HYDRAULIC SYSTEM

9. Tests

Free descending amount test

(1) Using a capacity load, tilt the mast to vertical position
and raise the forks 1 to 1.5 m (3 to 5 ft.) from the
ground, and stop the engine.
(2) Mark the mast with a reference line and measure the
free descending amount after 15 minutes.
Rod contraction length
P22000: 40 mm (1.57 in.)/15 min
on free descending
P26500: 45 mm (1.77 in.)/15 min
(with capacity load)
P30000: 38 mm (1.50 in.)/15 min
(oil temperature 45˚C
P33000: 42 mm (1.65 in.)/15 min
[113˚F])

211951
Free forward tilt test
(1) Using a capacity load, tilt the mast to vertical position
and raise the forks 50 cm (2.0 in.) from the ground, and
stop the engine.
(2) Measure the extension stroke of the tilt cylinder, and
measure the extension stroke again after 15 minutes.
Rod extension length
P22000: 41 mm (1.61 in.)/15 min
on free descending
P26500: 47 mm (1.85 in.)/15 min
(with capacity load)
P30000: 35 mm (1.38 in.)/15 min
(oil temperature 45˚C
P33000: 39 mm (1.54 in.)/15 min
[113˚F])

211952

12-33
HYDRAULIC SYSTEM

10.Troubleshooting

• Not enough oil • Refill.

• Inappropriate oil viscosity • Refer to “List of Applicable Lubricant”,
and replace oil.
• Operating conditions are hard and over-loaded. • Check the working conditions, and if over-
loaded, urge the operator to stay within the
Hydraulic load limit.
tank heats
• Local overheating of oil line due to a large restric- • Clean oil line.
excessively
tion to flow
Hydrau- • Relief valve adjustment improper • Adjust pressure setting.
lic tank
• Hydraulic pump worn • Replace pump.
• Outlet-side line flattened or restriction to flow • Repair or replace.
• Clogging of oil cooler • Clean.
• Shortage of oil due to a natural loss • Refer to “List of Applicable Lubricant”,
Cylinders and refill oil.
move too • Oil leakage due to damaged oil line, seal, etc. • Repair or replace.
slow
• Oil viscosity is too high • Refer to “List of Applicable Lubricant”,
and replace oil.

12-34
 HYDRAULIC SYSTEM

• Gear pump does not pump-in oil • Check pump and piping. Repair or replace
if required.
Cylinders • Oil leaks from part of the hydraulic line • Check the oil level and contamination. Add
move too or change oil if necessary.
slow • Oil level abnormally high • Check the control valve spools for mis-
alignment. Repair or replace.
• Oil leaks inside of gear pump • Replace pump.
• Poor pumping of oil • Refer to “List of Applicable Lubricant”,
and refill oil.
• Cavitation (1) Check suction pipe for any flat portion
or loose connection. Retighten or
Pump too
noisy replace.
(2) Check shaft oil seal for air-tightness.
Gear Replace pump.
pump
(3) Check pump body for any outside inter-
ference. Repair.
• Subjected to pressure greater than that rated • Check if pressure control valve operates
normally. Replace pump.
Pump case,
drive gear or • Distortion or damage due to external strain or • Replace pump.
pump port stress (1) Check if return line has been blocked or
flange dam- restricted to flow.
aged
(2) Check if pipe connection has been exter-
nally strained or stressed.
• Oil leakage from oil seal • Replace seal.
Oil leakage • Oil leakage through sliding surfaces of drive shaft • Replace pump assembly.
from pump • Pump securing bolt loose • Retighten, and replace parts if required.
• Sealing inside pump deteriorated • Replace O-ring.

12-35
HYDRAULIC SYSTEM

• Too low valve opening pressure setting • Adjust pressure.

Slow or no • Relief valve piston jamming • Clean piston and check to see if it moves
motions of smoothly; or replace relief valve assembly.
lift and tilt • Outer O-ring on relief valve body damaged • Replace O-ring.
cylinders
• Control lever installed loose, resulting in not • Readjust.
Control enough spool stroke
Valve Lift drops or • Control valve spool internal leakage • Replace each block assembly.
tilts forward
• Oil leakage from spool ring cap • Replace O-ring; check spool. If necessary,
repair or replace each block assembly.
Oil leakage
• Plug loose • Retighten.
• O-ring damaged • Replace O-ring.

• Insufficient oil in hydraulic tank • Refer to “List of Applicable Lubricant”,

and refill oil.
Mast will
not ascend, • Relief valve defects
tilt forward (1) Main valve jamming • Replace.
or backward. (2) Valve spring fracture
• Replace.
• Hydraulic pump defects • Replace.
• Relief valve defects
(1) Too low valve opening pressure setting • Adjust pressure.
(2) Plunger or poppet seat defects • Replace.
Unable to
(3) Spring fatigued
lift rated • Replace.
load (4) O-ring in valve case damaged
Lift and • Replace.
tilt cylin- • Hydraulic pump defects • Replace.
der
• Piston seal worn or damaged • Replace.
• Engine speed too slow • Adjust engine.
Lifting • Control lever installed loose, resulting in not • Readjust.
speed too enough spool stroke
slow • Clogging of tank strainer • Wash or replace.
• Gear pump delivery rate too low • Repair or replace.
• Sleeve seized in flow regulator valve • Repair.
Lowering
• Hydraulic line extremely restricted from smooth • Clean or repair hydraulic system or replace
speed of lift
cylinder too flowing due to dirt clogged in flow regulator defective hose.
slow valve, or hydraulic hose fractured or locally
stopped.

12-36
 HYDRAULIC SYSTEM

• Piston rod bend • Repair or replace.

Cylinder
vibrates dur- • Air mixed in hydraulic line • Bleed air by operating cylinder across full
ing opera- stroke.
tion
• Insufficient oil in tank • Refill.
• Control valve spool internal leakage • Replace each block assembly.
• Scratches on sliding surface of cylinder tube that • Repair or replace.
Lift cylinder can be felt by finger nail
descend
excessively • Sliding surface of cylinder tube badly grooved • Replace cylinder assembly.
• Piston seal damaged or distorted • Replace seal.
• Oil leakage from hydraulic line • Repair or replace.
• Control valve spool internal leakage • Replace each block assembly.
Tilt cylinder • Foreign matter lodged in packing • Replace packing.
Lift and
tilt cylin- tilt forward • Piston seal damaged • Replace seal.
der excessively
• Abnormal distortion or oil leakage from hydraulic • Repair or replace.
line
Lift cylinder • Inside surface of cylinder badly grooved • Repair or replace.
or tilt cylin-
• Cylinder distortion • Replace.
der will
descend or
tilt forward
at a certain
point
• Foreign matter lodged in oil seal or dust seal • Replace.
Oil leakage • Inner or outer diameter of oil seal or dust seal • Replace.
from bush- damaged
ing • O-ring damaged • Replace O-ring.
• Abnormal distortion • Repair or replace.

12-37
HYDRAULIC SYSTEM

11.Service Data
Truck model P22000 P26500 P30000 P33000
Fork ascending speed (under the rated load) 330 mm 340 mm 290 mm 280 mm
Standard value
[Simplex mast] (at maximum engine speed) (65.0 fpm) (66.92 fpm) (57.1 fpm) (55.1 fpm)
Fork ascending speed (under no load)
Standard value 360 mm (70.9 fpm) 310 mm (61.0 fpm)
(at maximum engine speed)
Fork descending speed (under the rated load)
Standard value 450 mm (88.6 fpm) 380 mm (74.8 fpm)
[Simplex mast] (at maximum engine speed)
Forward tilt angle [Standard simplex mast truck] Standard value 6˚
Backward tilt angle [Standard simplex mast
Standard value 12˚
truck]
Lift cylinder free fall (under the rated load)
40 mm 45 mm 38 mm 42 mm
(rod contraction length) (oil temperature 45˚C Standard value
(1.6 in.) (1.8 in.) (1.5 in.) (1.7 in.)
[113˚F])
Tilt cylinder free forward tilt amount (under the
rated load) 45 mm 50 mm 40 mm 45 mm
Standard value
(rod contraction length) (oil temperature 45˚C (1.8 in.) (2.0 in.) (1.6 in.) (1.8 in.)
[113˚F])
Discharge capacity Standard value 205 L/min (54.2 U.S. gal./min) (at 2200 rpm)
Mounting bolt and nut tightening
Standard value 59.8 N•m (6.1 kgf•m) [44.1 lbf•ft]
torque 1
Gear
pump Delivery hose mounting bolt tight-
Standard value 76.5 N•m (7.8 kgf•m) [56.5 lbf•ft]
ening torque 2
Cover mounting bolt tightening
Standard value 108.9 to 122.6 N•m (11.1 to 12.5 kgf•m) [80.4 to 90.5 lbf•ft]
torque 3

1
210504

12-38
 HYDRAULIC SYSTEM

Truck model P22000 P26500 P30000 P33000

+0.5 +5.1 +72.5
Main relief pressure 1 Standard value 20.6 0 MPa (210.1 0 kgf/cm2) [2988.1 0 psi]
Control
Valve Tie bolt nut tightening torque 2 Standard value 98 to 118 N•m (10.0 kgf•m) [72.3 lbf•ft]
Control valve mounting bolt tightening torque 3 Standard value 60 N•m (6.1 kgf•m) [44.3 lbf•ft]

3
2 3

Front 1 Rear

212003

Truck model P22000 P26500 P30000 P33000

2
Set relief pressure 1 Standard value 11.8 MPa (120.3 kgf/cm ) [1711.6 psi]
Priority
Plug tightening torque 2 Standard value 44.1 N•m (4.5 kgf•m) [32.5 lbf•ft]
valve
Relief valve tightening torque 3 Standard value 20.6 N•m (2.1 kgf•m) [15.2 lbf•ft]

2
2

210506

12-39
HYDRAULIC SYSTEM

Truck model P22000 P26500 P30000 P33000

Return filter tightening torque 1
Hydrau- Suction strainer tightening torque 2
lic tank
Drain plug tightening torque 3
Standard value 49 N•m (5.0 kgf•m) [36.2 lbf•ft]
Standard value 49 N•m (5.0 kgf•m) [36.2 lbf•ft]
177 to 196 N•m (18.0 to 20.0 kgf•m)
Standard value
[130.6 to 144.6 lbf•ft]

1 2 3
211980

Truck model P22000 P26500 P30000 P33000 P36000

Flow 120 L/min (31.7
Control flow rate (under no load) Standard value 150 L/min (39.6 U.S. gal./min)
regula- U.S. gal./min)
tor valve Plug tightening torque 1 Standard value 343 (35.0 kgf•m) [253.1 lbf•ft]

1
210508

12-40
 HYDRAULIC SYSTEM

Truck model P22000 P26500 P30000 P33000

Standard value 115 mm (4.53 in.) 120 mm (4.7 in.)
Inside diameter of cylinder tube 1 Repair or service
115.15 mm (4.534 in.) 125.15 mm (4.927 in.)
limit
Deflection of piston rod 2 Repair or service
0.5 mm (0.02 in.)
(1/2 of dial indicator reading) limit
-0.030 -0.0012 -0.030 -0.0012
60 -0.104 mm (2.36 -0.0041 in.) 65 -0.104 mm (2.56 -0.0041 in.)
Mast height Mast height
(3 to 5 m [9.8 to 16.4 ft]) (3 to 4.5 m [9.8 to 14.8 ft])
Lift Outside diameter of piston rod 3 Standard value +0.035 +0.0014 +0.035 +0.0014
cylinder 75 -0.039 mm (2.95 -0.0015 in.) 80 -0.039 mm (3.15 -0.0015 in.)
Mast height Mast height
(5.5 to 7 m [18.0 to 23.0 ft]) (5 to 7 m [16.4 to 23.0 ft] )
+0.11 +0.0043 +0.11 +0.0043
60 0 mm (2.36 0 in.) 65 0 mm (2.56 0 in.)
Mast height Mast height
Inside diameter of rod cover bush- (3 to 5 m [9.8 to 16.4 ft]) (3 to 4.5 m [9.8 to 14.8 ft] )
Standard value
ing 4 75
+0.19
+0.06 mm (2.95 +0.0024
+0.0075
in.) 80
+0.19
+0.06 mm (3.15 +0.0024
+0.0075
in.)
Mast height Mast height
(5.5 to 7 m [18.0 to 23.0 ft]) (5 to 7 m [16.4 to 23.0 ft])
Rod cover tightening torque 5 Standard value 1.18±0.1 kN•m (120.3±10.2 kgf•m) [870.8±73.8 lbf•ft]

5 2

4 3 1

210509

12-41
HYDRAULIC SYSTEM

Truck model P22000 P26500 P30000 P33000

120 mm
Standard value 130 mm (5.118 in.)
(4.724 in.)
Inside diameter of cylinder tube 1
Repair or service
120.12 mm (4.729 in.) 130.12 mm (5.123 in.)
limit
Outside diameter of
piston rod 2 Standard value 55 mm (2.1 in.)
(bushing)
Guide bushing
Clearance between Standard value 0.1 mm (0.0039 in.)
rod and guide bushing Repair or service
2 0.2 mm (0.0079 in.)
limit
+0.100 +0.0039
Standard value 60 0.070 mm (2.36 +0.0028 in.)
Inside diameter of bushing 3 (under
press-fit) Repair or service
60.6 mm (2.39 in.)
Tilt cylinder limit
637±63.7 N•m 696±68.6 N•m
Tightening torque of guide bushing 4 Standard value (65.0±6.5 kgf•m) (71.0±7.0 kgf•m)
[470.1±47 lbf•ft] [513.6±50.6 lbf•ft]
1178 to 1472 N•m (120 to 150 kgf•m)
Tightening torque of socket nut 5 Standard value
[869.4 to 1086.3 lbf•ft]
0 0
Standard value 60-0.046 mm (2.36 -0.002 in.)
Outside diameter of tilt socket pin 6 Repair or service
59 mm (2.3 in.)
limit
Tilt socket pin mounting bolt tightening
Standard value 33 N•m (3.37 kgf•m) [24.35 lbf•ft]
torque 7
Deflection of piston rod 8 (1/2 of dial Repair or service
0.5 mm (0.02 in.)
indicator reading) limit

5 2
4 8
3
6

7
211981

12-42