SECTION 6 HYDRAULIC SYSTEM

GROUP 1 STRUCTURE AND FUNCTION

1. HYDRAULIC CIRCUIT

7
9 8
L R
3
12 13

2 B1 A2 B2 A3 B3 A4 B4

P T
T LS P

R
LS CF EF
4
G

6
P

E/G T/M 1
TO BRAKE
11
10
14

35D7EHS01

1 Hydraulic gear pump 8 Tilt cylinder

2 Main control valve 9 Lift cylinder
3 Steering unit 10 Suction filter
4 Priority valve 11 Return filter
5 Brake valve 12 Down safety valve
6 Check valve 13 Down control valve
7 Steering cylinder 14 Hydraulic oil tank

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

9 8

12 13

2 B1 A2 B2 A3 B3 A4 B4

P T

Steering syetem
Lift

LS CF EF
Load check valve
Steering return line
4
G

P
Brake syetem
E/G T/M 1

Brake return line 11

10

35D7EHS02

When the lift control lever is pulled back, the spool on the first block is moves to lift position.
The oil from hydraulic gear pump(1) flows into main control valve(2) through the priority valve(4) and
then goes to the large chamber of lift cylinder(9) by pushing the load check valve of the spool.
The oil from the small chamber of lift cylinder(9) returns to hydraulic oil tank at the same time.
When this happens, the forks go up.

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

9 8

12 13

2 B1 A2 B2 A3 B3 A4 B4

Lower

P T

Steering syetem

LS CF EF
Steering return line
4
G

P
Brake syetem
E/G T/M 1

Brake return line 11

10

35D7EHS03

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

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

9 8

12 13

2 B1 A2 B2 A3 B3 A4 B4

P T

Steering syetem

LS CF EF
Steering return line
4
G

P
Brake syetem
E/G T/M 1

Brake return line 11

10

35D7EHS04

When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward
position.
The oil from hydraulic gear pump(1) flows into main control valve(2) through the priority valve(4) and
then goes to the large chamber of tilt cylinder(8) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder(8) returns to hydraulic tank at the same time.
When this happens, the mast tilt forward.

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

9 8

12 13

2 B1 A2 B2 A3 B3 A4 B4

P T

Steering syetem
Tilt
backward

LS CF EF
Load check valve
Steering return line
4
G

P
Brake syetem
E/G T/M 1

Brake return line 11

10

35D7EHS05

When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward
position.
The oil from hydraulic gear pump(1) flows into main control valve(2) through the priority valve(4) and
then goes to the small chamber of tilt cylinder(8) by pushing the load check valve of spool.
The oil at the large chamber of tilt cylinder(8) returns to hydraulic tank at the same time.
When this happens, the mast tilt backward.

6-5
2. HYDRAULIC GEAR PUMP
1) STRUCTURE

D353HS06

1 Bolt 6 Seal 11 Drive gear

2 Spring washer 7 Bushing 12 Flange
3 End cover 8 Bushing 13 Shaft seal
4 O-ring 9 Body 14 Circlip
5 Back up seal 10 Driven gear

2) OPERATION
This pump comprised of an end cover, a body, bushings and a mounting flange bolted together with
through bolts. The gear journals are supported in plane bearings within pressure balanced
bushings to give high volumetric and mechanical efficiencies.

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

Port name Size

Inlet port 1-5/16-12UN

Outlet port 1-5/16-12UN
Gauge port PF1/4
D 3 Work port 1-1/16-12UN

6 4
Inlet port
14
3 15
D

B B

5 SECTION B - B
1

23 22 31
Outlet port 3 Work ports
28
25 29
20
32
27
30 21
Gauge port

A
A

7 12

13

2
19
18
17
VIEW D - D 33
16 8 9 10 11
SECTION A - A 35DS7HS07

1 Special nut 12 Outlet section assy 23 Spool end

2 Main relief valve 13 O-ring 25 Spring seat
3 Aux relief valve 14 Poppet 27 Spring
4 Tie rod 15 Spring 28 Spring
5 Tie rod 16 Screw 29 Piston
6 Special nut 17 Seal plate 30 Spool end
7 Inlet section assy 18 Wiper 31 Spool end
8 Spool section-lift 19 Spool seal 32 Spool cap
9 Spool section-tilt 20 Spool cap 33 Solenoid valve
10 Spool section-A1 21 Screw cap
11 Spool section-A2 22 Screw cap

6-7
2) LIFT SECTION OPERATION
(1) Lift position

D353HS08

When the lift control lever is pulled back, the spool moves to the right and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into lift cylinder port(B1).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off
of the neutral passage.
The return oil from cylinder flows into the tank.

6-8
(2) Lower position

D353HS09

When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is
closed.
The spool moves to the lift lower position, opening up the neutral passage to tank and (B1)→T.
In lift lower position the fork drops due to its own weight.

6-9
3) TILT SECTION OPERATION
(1) Tilt forward position

D353HS10

When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into tilt cylinder port(A2).
The pump pressure reaches proportionally the load of cylinders and fine control finished by closing
the neutral passage.
The return oil from cylinder port(B2) flows into the tank through the hole of the tilt lock spool.

6-10
(2) Tilt backward position

D353HS11

When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flows into tilt cylinder
port(B2). The pump pressure reaches proportionally the load of cylinder and fine control finished by
shut off of the neutral passage.
The return oil from cylinder port(A2) flows into the tank via the low pressure passage.

6-11
4) MAIN RELIEF VALVE
(1) Pressure setting
A good pressure gauge must be installed in
the line which is in communication with the
work port relief. A load must be applied in a
manner to reach the set pressure of the relief
unit.
Procedure
① Loosen lock nut.
② Set adjusting nut to desired pressure
setting.
③ If desired pressure setting cannot be
achieved, add or remove shims as required.
④ Tighten lock nut.
⑤ Retest in similar manner as above.
35DS7HS10

(2) Function
① As work port relief
The relief valve is in communication
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the
differential area between diameters A
and B relief valve poppet D and check
valve poppet K are tightly seated as
shown. D353HS18

The oil pressure in the high pressure port

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

D353HS19

6-12
 The loss of oil behind poppet C, effected
by the opening of pilot poppet E, causes
poppet C to move back and seat against
pilot puppet E. This shuts off the oil flow
to the area behind relief valve poppet D,
and causes a low pressure area
internally.

D353HS20

The imbalance of pressure on the inside

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

D353HS21

② As anti void

The anti-void unit supplies oil to the high

K G
pressure port HP when cavitation has
occurred. A lower pressure exists in the A
port HP compared to the low pressure
chamber LP. The difference between the HP
effective area of diameter A and G
causes imbalance of the check valve
LP

poppet K which unseats, thus allowing oil

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

6-13
4. LIFT CYLINDER

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

D357HS12

1 Tube assy 7 Retaining ring 13 DU busing

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

5. TILT CYLINDER

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

23

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

6-14