INTRODUCTION

GENERAL and pulley arrangement. On Perkins diesel equipped

This section has the description and operation of the
complete hydraulic system. There are also brief de-
scriptions of the components of the hydraulic system.
A troubleshooting guide for the hydraulic system is
also included.
DESCRIPTION AND OPERATION
(See FIGURE 1. and FIGURE 3.)
The hydraulic system includes the circuits for the mast,
steering system, brake system and the oil clutch. Two
hydraulic pumps supply the flow of oil for the compo-
nents of the hydraulic system. The main hydraulic
pump (for the mast and attachments) is driven by a
drive shaft connected to the engine crankshaft pulley.
The hydraulic pump for the steering, brake and clutch
systems is driven by the engine. On GM engine
equipped units, the steering pump is driven by a belt
units, the pump is driven by the timing gears. Both of
the hydraulic pumps get their oil supply from the hy-
draulic tank.
Hydraulic Pumps (See FIGURE 2.)
The main hydraulic pump is a gear pump and supplies
oil only to the main control valve. Oil that is not used
by the mast or attachment cylinders flows through the
control valve and back to the hydraulic tank.
In normal applications, the steering hydraulic pump is a
vane pump. In heavy duty applications, a gear pump is
used. The pump supplies oil first to the steering control
unit. Excess oil from the steering control unit flows to
the brake valve. From the brake valve the oil then flows
to the oil clutch housing (if equipped) and then back to
the hydraulic tank. The steering hydraulic pump has an
internal relief valve that is set at 11.7 to12.4 MPa (1700
to 1800 psi).

11650

1. HYDRAULIC TANK 6. BRAKE VALVE 10. LIFT CYLINDERS

2. MAIN HYDRAULIC PUMP 7. OIL CLUTCH 11. RETURN LINE (WITH
3. STEERING HYDRAULIC PUMP HOUSING POWERSHIFT TRANSMISSION)
4. MAIN CONTROL VALVE 8. STEERING CYLINDER
5. STEERING CONTROL UNIT 9. TILT CYLINDERS

FIGURE 1. HYDRAULIC SYSTEM DIAGRAM

1

MAIN HYDRAULIC PUMP
STEERING HYDRAULIC PUMP
(DIESEL SHOWN)
FIGURE 2. HYDRAULIC PUMPS
Main Control Valve
The main control valve controls the lift, lower, tilt and
attachment functions. The control valve receives oil
from the main hydraulic pump. Oil flow in the main
control valve goes first to the relief valve and the lift
spool. From the lift spool, oil goes to the tilt spool and
then the auxiliary spools. Oil that is not used by one
spool can be used by any of the following spools. If one
spool uses all of the oil, there is no flow to the follow-
ing spools.
The main relief valve for the system is set at 21.0 MPa
(3050 psi). If the lift truck has attachments, the control
valve has a twostage relief valve, with the auxiliary
relief pressure set at 15.5 MPa (2250 psi). The two
stage relief valve uses a pilot line from the lift spool to
2
change its operation. When the lift spool is in the Lift
position, pressure is applied through the pilot line to the
top of the relief valve. This additional pressure on the
spool in the relief valve causes the higher relief pres-
sure for the lift circuit.
The return oil from the main control valve flows into
the hydraulic tank and through the oil filter.
Steering Control Unit
The steering control unit is a rotary valve that controls
the movement of the steering cylinder. The supply of
oil for the unit comes from the steering hydraulic
pump. The control unit has a minimum restriction to oil
flow when the steering wheel is not moved. The control
unit has four ports. A manifold block is installed on the
steering control unit over the four ports. The inlet port
in the manifold block has a check valve and a relief
valve and is connected to the hydraulic pump. The re-
lief valve is set at 11.7 to12.4 MPa (1700 to 1800 psi).
Two of the ports are connected to the steering cylinder.
The port for the drain circuit is connected to the inlet of
the brake valve. All of the oil that flows to the steering
control unit flows to the brake valve.
Brake Valve (See FIGURE 4.)
The brake system on this series of lift trucks uses a hy-
draulic actuator (brake valve) to actuate the master cyl-
inder. The operation of the brake valve decreases the
foot pressure necessary to apply the brakes. The oil
pressure from the outlet of the steering control unit is
used to operate the brake valve. A relief valve in the
brake valve is set at 1310 kPa (190 psi). On lift trucks
with a powershift transmission, oil from the brake
valve goes to the hydraulic tank. On lift trucks with a
manual transmission, oil from the brake valve goes to
the oil clutch housing.
Oil Clutch (See FIGURE 5.)
The oil supply for the oil clutch comes from the brake
valve. At the clutch housing the oil goes to two fittings.
One fitting supplies oil for cooling the clutch disc. The
other fitting supplies the oil to operate the jet pump at
the bottom of the clutch housing. The jet pump re-
moves the cooling oil from the clutch housing and
sends it back to the hydraulic tank.
 3

9
2
1

13
5
4

1. HYDRAULIC TANK
2. STEERING
HYDRAULIC PUMP
3. HYDRAULIC PUMP
4. MAIN CONTROL
VALVE
5. MANIFOLD BLOCK
6. STEERING
CONTROL UNIT
7. STEERING
CYLINDER
8. BRAKE VALVE
9. OIL CLUTCH
HOUSING
11656
10. TILT CYLINDER
11. LIFT CYLINDER
12 12. LIFT SYSTEM
CHECK PORT
10 11 13. CHECK PORT

10
POWERSHIFT TRANSMISSION UNITS MANUAL TRANSMISSION UNITS
FIGURE 3. HYDRAULIC SYSTEM SCHEMATIC

3
 1

2
11624

1. BRAKE VALVE 4
2. MASTER CYLINDER
FIGURE 4. BRAKE VALVE 5
1
1. SUPPLY LINE 2
2. JET PUMP
3. NOZZLE FOR 4. DRAIN LINE
CLUTCH DISC 5. RETURN LINE

FIGURE 5. OIL CLUTCH

TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE
Hydraulic functions will not operate. There is no oil or not enough oil in the hydraulic tank.

The hydraulic pump(s) are damaged.

The hydraulic pump(s) are not connected to the engine.

Hydraulic pressure is above or below Relief valve is damaged.
specifications.
Relief valve is not adjusted correctly

Restriction in the return line(s).

LIFT, LOWER AND TILT CIRCUIT

Slow or no movement of cylinder(s). Pressure relief valve is damaged or is not adjusted correctly.
Large leaks between spool and bore.
Spool not fully extended or retracted.

Broken spring(s) for the spool(s).

The drive shaft for the hydraulic pump is not connected.
Air is in the system.
Load is greater than capacity of the system.

4
 PROBLEM
Slow or no movement of cylinder(s).
Lift cylinders retract when the spool is in
the Neutral position.
Tilt cylinders move Forward when the
spool is in the Neutral position.
Lift cylinders permit mast to lower
when spool is moved to LIFT position.
STEERING, BRAKE AND OIL CLUTCH SYSTEM
There is no action when the steering
wheel is turned.
The lift truck steers slowly, or the steering
wheel is hard to turn.
The steering wheel turns the tires in the
wrong direction.
The brake valve does not operate correctly.
There is no oil supply for the oil clutch.
POSSIBLE CAUSE
Restriction in the return line(s).
Cylinder seals are damaged.
Oil leaks between spool and bore.
Cylinder seals or check valves leak.
Hydraulic line to cylinder(s) leak.
Tilt control spool inside tilt spool does not work correctly.
Oil leaks between spool and bore.
Hydraulic lines leak.
Tilt cylinder seals leak.
Load check valve is damaged.
There is no oil or not enough oil in the the
Hydraulic lines to the steering cylinder are damaged or have a
restriction.
The drive belt for the steering pump is not installed (GM
engines).
The drive gear for the hydraulic pump is damaged or loose
(Perkins engine).
The relief valve in the manifold block is not adjusted correctly.
The steering control unit is damaged.
There is air in the system.
There is a restriction in the hydraulic lines.
The relief valve in the steering pump is not adjusted correctly or
is damaged.
The relief valve in the manifold block is not correctly adjusted or
is damaged.
The hydraulic pump is worn or damaged.
The steering control unit is worn or damaged.
The hydraulic lines at the steering control unit or steering
cylinder are not connected correctly.
The hydraulic line from the steering operate correctly.
The hydraulic line from the brake valve to the hydraulic tank has
a restriction.
The hydraulic line from the brake valve for the oil clutch, has a
restriction or a leak.
The fittings or tubing on the clutch housing have leaks or
damage.