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Hydraulic System
Description
Schematic for Trucks with MicroCommand II Controller
8609092
1. Hydraulic tank 4. Steer gear 7. Down safety valve 10. Steering cylinder
2. Hydraulic pump 5. Mast operating valve 8. Lift cylinder 11. Steering pressure
switch
3. Integral priority valve 6. Flow regulator valve 9. Tilt cylinder
General Information
The hydraulic pump draws oil from the oil tank via
an integral priority valve. Priority flow is directed
to the steer gear and excess flow is diverted to
the mast operating valve.
The steer gear and steer pump are covered in the
STEERING SYSTEM section and the steering
cylinder is covered in the REAR AXLE section.
7.1
HYDRAULIC SYSTEM: DESCRIPTION
8609136
1. Hydraulic tank 4. Steer gear 7. Down safety valve 10. Steering cylinder
2. Hydraulic lift pump 5. Mast operating valve 8. Lift cylinder
3. Steer pump 6. Flow regulator valve 9. Tilt cylinder
General Information
The hydraulic pump draws oil from the oil tank
and delivers it to the main control valve, which
dispenses it for lift and tilt functions.
The steer gear and steer pump are covered in the
STEERING SYSTEM section and the steering
cylinder is covered in the REAR AXLE section.
7.2
HYDRAULIC SYSTEM: DESCRIPTION
Hydraulic Tank
1
6 5
4
3 8609093
General Information
The tank contains internal filtering means including
a strainer on the suction line and a filter on the
return line.
The lift cylinder return pipe allows the cylinders to
draw fluid when they retract, providing the bore
walls with oil which inhibits corrosion.
7.3
HYDRAULIC SYSTEM: DESCRIPTION
8609094
General Information
This gear pump is capable of developing very
high pressure on its discharge side. A special
arrangement is incorporated in the pump
construction for the purpose of keeping the side
clearances minimized between bushings on the
one side and pump gears on the other. Note, in
illustration 203585 (page 7.6), that discharge
pressure is applied to the back of each bushing
through internal oilways.
7.4
HYDRAULIC SYSTEM: DESCRIPTION
8609094A
General Information
This gear pump is capable of developing very
high pressure on its discharge side. A special
arrangement is incorporated in the pump
construction for the purpose of keeping the side
clearances minimized between bushings on the
one side and pump gears on the other. Note, in
illustration 203585 (page 7.6), that discharge
pressure is applied to the back of each bushing
through internal oilways.
7.5
HYDRAULIC SYSTEM: DESCRIPTION
Hydraulic Pump Operation Pressure Loading Principle
Essentially the pump consists of two gears—the This pump is a self-balanced type based on the
drive gear and the driven gear—closely fitted in principle of pressure loading, balancing for equal
the housing. The oil is carried around the periph- pressure on all sides of the revolving gear. This
ery of the revolving gears from the suction to the reduces bushing and gear wear. In operation, the
discharge side. The teeth meshing between the high-pressure oil on the discharge side is fed
two gears prevents the return of oil from the dis- back to the suction side. On the suction side,
charge to the suction side. pressure is exerted equally on both sides of the
gears and shafts, thereby cancelling out unequal
pressure to balance the pump.
Driven Gear
Clearance
Drive Gear
203585
Discharge side
200333
7.6
HYDRAULIC SYSTEM: DESCRIPTION
Control Valve
9
12
1 11
10
11
10
7
5
8
2 4
3 12
203486
General Information
The control valve consists of three valve blocks,
all spool-type. The spools are finished by lap-
ping for their respective blocks and their combi-
nation should not be changed. The lift valve
assembly has a built-in load check valve. The tilt
valve spool has a built-in tilt lock valve. When
necessary, the attachment valve assembly has
a built-in overload relief valve. If the overload
relief valve is not used, a shutoff valve is
installed.
7.7
HYDRAULIC SYSTEM: DESCRIPTION
200345
205979
General Information
The left and right lift cylinders are single-acting
type. A return pipe is tied into its rod-side port in
order to admit hydraulic oil from the oil tank
when the piston goes down. By this feature, the
top portion of the cylinder wall is protected
against rusting.
The left and right tilt cylinders are double-acting
type. The piston rod carries a screw-on socket.
The socket is repositioned as necessary by
turning when the cylinder is connected to the
outer mast. This feature allows the tilt cylinders
to move in unison.
The tilt angle is increased or decreased with the
spacer and shim of each cylinder.
7.8
HYDRAULIC SYSTEM: DESCRIPTION
203558
General Information
The flow regulator valve is located between each
lift cylinder and control valve. It limits the flow of
oil forced out of the cylinder when the loaded
forks are lowered to keep a safe constant lower-
ing speed regardless of load.
7.9
HYDRAULIC SYSTEM: DESCRIPTION
Burst
General Information
The down safety valve is built in the oil pipe joint
at the bottom end of the lift cylinder. This valve is
internally provided with an orifice to prevent shock
when the valve is closed. In the valve having no
orifice, the oil leaks around the valve to prevent
shock.
Valve Types
Down safety valves are available in six types dif-
a
fering in terms of shutoff flow and identified by the
number punched on the flat (indicated as “a” on
illustration 201731A). The numbers are: 50, 70,
90, 100, 120, and 150. No. 90 and No. 120 valves
each come in two kinds differing in screw thread
size. a
7.10
REMOVAL: GENERAL WARNING
7.11
HYDRAULIC PUMP: REMOVAL
Hydraulic Pump
Removal
Trucks with MicroCommand II Controller
8609095
Sequence
1. Hardware
2. Pump
Start By:
1. Disconnect the battery from the truck. 5. Secure the motor from above with a crane,
hoist, or other adequate device, or support it
2. Disconnect the hoses attached to the pump
at its center with a garage jack.
fittings.
6. Remove the motor and pump assembly from
3. Disconnect the power cables and wire leads
the truck.
from the pump motor.
7. Remove the hydraulic fittings from the pump.
4. Raise the truck enough to allow the pump
and motor assembly to be removed from
below the truck. Make sure that the truck is
stable and secure in the raised position.
7.12
HYDRAULIC PUMP: REMOVAL
8609094A
Sequence
1. Hardware
2. Pump
Start By:
1. Disconnect the battery from the truck. 5. Secure the motor from above with a crane,
hoist, or other adequate device, or support it
2. Disconnect the hoses attached to the pump
at its center with a garage jack.
fittings.
6. Remove the motor and pump assembly from
3. Disconnect the power cables and wire leads
the truck.
from the pump motor.
7. Remove the hydraulic fittings from the pump.
4. Raise the truck enough to allow the pump
and motor assembly to be removed from
below the truck. Make sure that the truck is
stable and secure in the raised position.
7.13
HYDRAULIC PUMP: INSTALLATION
Installation
Trucks with MicroCommand II Trucks with Optional EV100ZX
Controller Controller
1. To install, follow the reverse sequence of the 1. To install, follow the reverse sequence of the
disassembly procedure. Before installing disassembly procedure. Before installing
hydraulic fittings in the pump, inspect all hydraulic fittings in the pump, inspect all
O-rings for damage or aging and replace O-rings for damage or aging and replace
them as required. them as required.
2. Tighten hose to the following specifications. 2. Tighten hose to the following specifications.
8609137
A
3. Lube pump splines before installing into pump
motor. Use molybdenum disulfide grease.
8609096
7.14
HYDRAULIC PUMP: DISASSEMBLY
Disassembly
Trucks with MicroCommand II Controller
2 8
9
7
6
4 8609099
Sequence
1. Priority valve 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes
7.15
HYDRAULIC PUMP: DISASSEMBLY
Disassembly
Trucks with Optional EV100ZX Controller
2
9
5
3
7
6
4
8609139A
Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes
Start By:
Externally clean the pump to make sure that it is
free of all matter that may contaminate the pump
parts during disassembly, inspection, or reassembly.
7.16
HYDRAULIC PUMP: DISASSEMBLY
7.17
HYDRAULIC PUMP: DISASSEMBLY
Suggestions
Trucks with MicroCommand II Controller: Removing the Flange
Removing the Priority Valve Turn the unit over and lightly tap the mounting
1. Lightly mark the priority valve body, pump flange to disengage it from the locating dowels.
body, and mounting flange to ensure proper Slide the flange squarely off the shaft.
reassembly.
2. Remove the rear bolts, spring washers, and
the priority valve.
NOTE
For trucks with MicroCommand II Controller:
Set the priority valve assembly aside or go on to
the next page which discusses the disassembly
and the reassembly of the priority valve.
8609101
8609102
8609100
7.18
HYDRAULIC PUMP: DISASSEMBLY
8609103
8609104
7.19
HYDRAULIC PUMP: DISASSEMBLY
7.20
HYDRAULIC PUMP: REASSEMBLY
Reassembly
Trucks with MicroCommand II Controller
9
1
10 2
4 5
8609106
Sequence
1. Body and rear bushes 6. O-ring, bush seal, and back-up seal
2. Priority valve 7. Shaft seal
3. Driveshaft and idler shaft 8. Flange
4. Gear pack 9. O-ring, bush seal, and back-up seal
5. Front bushes 10. Bolts
Start By:
Ensure that all parts are perfectly clean. Lubricate
the bushes and gears with clean hydraulic fluid.
Ensure that the O-ring recess and end faces of
the body remain dry. This will assist the assembly
of the components with the body bores.
7.21
HYDRAULIC PUMP: REASSEMBLY
Reassembly
Trucks with Optional EV100ZX Controller
3
6
10
4 5
7
8609140
Sequence
1. End cover 6. O-ring, bush seal, and back-up seal
2. Priority valve 7. Shaft seal
3. Driveshaft and idler shaft 8. Flange
4. Gear pack 9. O-ring, bush seal, and back-up seal
5. Front bushes 10. Bolts
Start By:
Ensure that all parts are perfectly clean. Lubricate
the bushes and gears with clean hydraulic fluid.
Ensure that the O-ring recess and end faces of
the body remain dry. This will assist the assembly
of the components with the body bores.
7.22
HYDRAULIC PUMP: REASSEMBLY
Reassembling the Rear Bushes Trucks with MicroCommand II Controller:
1. Install the rear bushes (marked CD and CI) Fixturing with the Priority Valve
into the undowelled end of the body. Use the priority valve to temporarily fixture the
parts as they are reassembled. Place the priority
valve on its back and set the undowelled end of the
body against it so that the dowels are pointing up.
Cusp
Removal
Inlet
Position of
driveshaft
Counterclockwise Rotation
8609108
8609109
7.23
HYDRAULIC PUMP: REASSEMBLY
Reassembling the Gear Pack Reassembling the Front Bushes
1. Fit the key into the keyway in the driveshaft Refit the front bushes (FD and FI) into their origi-
and then carefully fit the gear over the key. nal bores, remembering that the C-cutout must
Fit the second gear on the idler shaft. be to the side of the body with the cusp removal
2. Keeping the gear pack together, carefully feed flat. They must match the rear end bushes.
the assembly into the body bores with the
driveshaft positioned as previously shown.
8609111
8609110
7.24
HYDRAULIC PUMP: REASSEMBLY
8609112
8609102
7.25
HYDRAULIC PUMP: REASSEMBLY
8609113
8609114
7.26
HYDRAULIC PUMP: REASSEMBLY
Reassembling the Priority Valve: Trucks Reassembling the End Cover: Trucks with
with MicroCommand II Controller Optional EV100ZX Controller
Replace the priority valve and refit the bolts and Replace end cover and refit the bolts and washers.
washers. Tighten the bolts. Tighten the bolts.
End cover
(for Optional
EV100ZX
Controller)
8609115 8609115A
2EC20/25/ 2EC20/25/
2EC15/18 2EC15/18
25E/30 25E/30
4.7 to 5.2 kgf•m 9.0 to 10.4 kgf•m 4.7 to 5.2 kgf•m 9.0 to 10.4 kgf•m
Tightening torque Tightening torque (34 to 38 lbf•ft) (65 to 75 lbf•ft)
(34 to 38 lbf•ft) (65 to 75 lbf•ft)
for bolts for bolts [46 to 51 N•m] [88 to 102 N•m]
[46 to 51 N•m] [88 to 102 N•m]
NOTE
Lube splines before installing in pump motor.
Use molybdenum disulfide grease.
7.27
HYDRAULIC PUMP: INSPECTION
Pressure
Test gauge
unit Micronic Variable
filter restrictor
Flow
Strainer Relief meter
Tank
valve
8609116
7.28
PRIORITY VALVE: DISASSEMBLY
Priority Valve
Disassembly
Trucks with MicroCommand II Controller Only
1 11
10
9 7
8
5 6 4
3 2
8609117
Sequence
1. Body plug 4. Spool 7. Core plug 10. Spring
2. Spring seat 5. Spool plug 8. Relief valve seat 11. Valve body
3. Spring and spacer 6. Filter 9. Relief valve
NOTE
For information on removing the pump from
the truck and the priority valve from the pump,
see page 7.12.
7.29
PRIORITY VALVE: DISASSEMBLY
8609121
8609118
8609122
8609123
NOTE
The relief valve is preset for optimum opera-
tion of the steering system and should not be
8609120
removed unless absolutely necessary.
7.30
PRIORITY VALVE: DISASSEMBLY
8609126
8609124
8609127
7.31
PRIORITY VALVE: REASSEMBLY
Reassembly
2 1
3 4
6
8609128
Sequence
1. Relief valve 4. Spring
2. Filter 5. Body plug
3. Spool and plug 6. Spring seat
7.32
PRIORITY VALVE: REASSEMBLY
8609132
8609129
8609130
1.4 kgf•m
Tightening torque for plug (10 lbf•ft)
[14 N•m]
8609131
7.33
PRIORITY VALVE: REASSEMBLY
2EC15/18 2EC20-30
2 2
51 kg/cm 81.5 kgf/cm
Relief
(725 psi) (1160 psi)
pressure setting
[50 bar] [80 bar]
8609115
4. Peen the valve seat in position using a center
punch to prevent movement during operation.
Fit a new core plug.
7.34
CONTROL VALVE: REMOVAL
Control Valve
Removal
Trucks with MicroCommand II Controller
8
1 2
3
6
5
8609097
Sequence
1. Clevis pins and rods 6. Steering return hose and connector
2. Tilt lines, connectors, and O-rings 7. Return hose
3. Auxiliary lines 8. Switches
4. Delivery hose, connector, and O-ring 9. Control valve
5. Lift pipe
Start By:
1. Remove the floorplates and the dashboard 3. Disconnect the battery.
cover.
4. Disconnect the wire leads to the valve switches.
2. Tilt the mast to vertical position, lower the (trucks with MicroCommand II Controller only)
forks all the way, and relieve the pressure in
the hydraulic lines.
7.35
CONTROL VALVE: REMOVAL
Removal
Trucks with Optional EV100ZX Controller
1 2
3
6
5
8609138
Sequence
1. Clevis pins and rods 6. Steering return hose and connector
2. Tilt lines, connectors, and O-rings 7. Return hose
3. Auxiliary lines 8. Switches
4. Delivery hose, connector, and O-ring 9. Control valve
5. Lift pipe
Start By:
1. Remove the floorplates and the dashboard 3. Disconnect the battery.
cover.
4. Disconnect the wire leads to the valve switches.
2. Tilt the mast to vertical position, lower the (trucks with MicroCommand II Controller only)
forks all the way, and relieve the pressure in
the hydraulic lines.
7.36
CONTROL VALVE: INSTALLATION
Installation
8609098
1. To install, follow the reverse of the disas- Tightening Torque for Hoses
sembly sequence. Before installing hydraulic 2.5 to 3.5 kgf•m
fittings in the pump, inspect all O-rings for A Tilt hoses (18 to 25 lbf•ft)
damage or aging and replace them as [24 to 34 N•m]
required. 8.9 to 9.7 kgf•m
Delivery hose
2. Tighten hoses to the following specifications. B (64 to 70 lbf•ft)
2EC15/18
[87 to 95 N•m]
10.3 to 11.7 kgf•m
Delivery hose
C (74 to 85 lbf•ft)
2EC20-30
[101 to 115 N•m]
7.37
CONTROL VALVE: DISASSEMBLY
Disassembly
8609135
7.38
CONTROL VALVE: DISASSEMBLY
Sequence
1. Tie rod nuts 18. Plate, wiper, O-ring, and screw
2. End cover 19. Elbow and O-ring
3. Spring and poppet 20. Plug and O-ring
4. O-ring 21. Plug, O-ring, poppet, and spring
5. Attachment section 22. Cap
6. Spring and poppet 23. Spool
7. O-ring 24. Screw, seat, O-ring, spring
8. Tilt section 25. Plate, wiper, and O-ring
9. O-ring 26. Tilt lock valve and spring
10. Lift section 27. Plate, wiper, O-ring, and screw
11. O-ring 28. Cap
12. Inlet section 29. Spool
13. Main relief valve 30. Screw, seat, and spring
14. Cap 31. Plate, wiper, and O-ring
15. Spool 32. Plate, wiper, O-ring, and screw
16. Screw, seat, and spring 33. Shut-off valve assembly
17. Plate, wiper, and O-ring
7.39
CONTROL VALVE: INSPECTION & REASSEMBLY
Plug
203517
Lock nut
18 to 22 kgf
Spool operating force (40 to 49 lbf)
[177 to 216 N]
205025
205028
7.40
LIFT & TILT CYLINDERS/EARLIER VERSION: REMOVAL & INSTALLATION
5
6
205967
Sequence
1. Return hose 4. Set bolt and shims
2. Hose guard 5. Cylinder clamp (cushion, collar, and shims)
3. High pressure hose 6. Lift cylinder and bracket
7.41
LIFT & TILT CYLINDERS/EARLIER VERSION: REMOVAL & INSTALLATION
Connector
To tank
204933
From right-hand
lift cylinder 205968
NOTE
7.42
LIFT & TILT CYLINDERS/LATER VERSION: REMOVAL & INSTALLATION
5 4
1
207068
Sequence
1. Hose guard 4. Cylinder clamp (cushion, collar, and shims)
2. High-pressure hose 5. Lift cylinder and bracket
3. Set bolt and shims
7.43
LIFT & TILT CYLINDERS/LATER VERSION: REMOVAL & INSTALLATION
Suggestions
1. Removing hose guard:
With the lift bracket raised to the maximum
height, remove each hose guard from the
front side of the mast.
! CAUTION
Right-hand cylinder
Left-hand cylinder
204933
7.44
LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION
204935
204934
Installation
NOTE
Lift Cylinders
The rod end of either lift cylinder is shim-
adjusted to eliminate the difference in stroke To install, reverse the removal sequence and do
between the cylinders. Before removing the the following steps.
stopper bolts, make a record of the number of 1. Extend and retract the lift cylinders several
shims and the cylinder to which the shims are times under no-load conditions to expel air
fitted. from the cylinder circuits and to make sure
the cylinders move smoothly.
2. Check the oil level in the hydraulic tank with
2. Place wood blocks under the inner mast and
the oil level gauge.
detach the sling. Use blocks strong enough to
support the mast. 3. Check that the lift height is correct.
4. After the lift cylinders or piston rods have
been replaced, check for difference in stroke
between the two cylinders (refer to MAST
AND FORKS).
202983
7.45
LIFT & TILT CYLINDERS/EARLIER VERSION: REMOVAL & INSTALLATION
Removal
Tilt Cylinders/Earlier Version
1
3
205969
Sequence
1. Tilt socket pin (spacer)
2. Rubber hose (O-ring)
3. Cylinder pin (spacer)
4. Tilt cylinder
Start By:
1. Lower the forks all the way and tilt the mast
fully forward.
2. Hitch lifting slings to the top crossmember
of the outer mast by passing them through
the round holes. Take up the weight of the
mast with a hoist.
205970
7.46
LIFT & TILT CYLINDERS/LATER VERSION: REMOVAL & INSTALLATION
Removal
Tilt Cylinders/Later Version
3
1
206883
Sequence
1. Tilt socket pin (spacer)
2. Rubber hose (O-ring)
3. Cylinder pin (spacer)
4. Tilt cylinder
Start By:
1. Lower the forks all the way and tilt the mast
fully forward.
2. Hitch lifting slings to the top crossmember
of the outer mast by passing them through
the round holes. Take up the weight of the
mast with a hoist.
Suggestions
1. Retracting piston rod:
Remove tilt cylinder pin (item 1), and retract
207085
the piston rod all the way.
2. Disconnecting hoses:
Disconnect hoses (item 2) from the cylinder
at the connectors. Use a container to catch
oil from flowing out of the cylinder. Attach
caps to the connectors of the cylinder to
protect the threads of the connectors and to
prevent oil from flowing out of the cylinder
when the cylinder is removed.
7.47
LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION
Suggestions
Removing Tilt Socket
Earlier Version Later Version
! WARNING ! WARNING
If both tilt cylinders are to be removed at If both tilt cylinders are to be removed at
the same time, make sure that the mast is the same time, make sure that the mast is
held either by a hoist or is securely sup- held either by a hoist or is securely sup-
ported and held in place by blocks. ported and held in place by blocks.
Mark
2 3 206883
201737
1. Rubber hose
2. Tilt socket pin, bolt, washer
NOTE 3. Tilt cylinder pin, bolt, washer
NOTE
Loosen the nut just enough to permit turning
of the piston rod. Do not change the position
of the nut.
7.48
LIFT & TILT CYLINDERS: DISASSEMBLY
Disassembly
Lift Cylinders
5
4
204948
Sequence
1. Bracket assembly 4. Piston rod, snap ring, holder, U-ring, nylon
heel, and piston ring
2. Holder, wiper ring, U-ring and O-ring
5. Cylinder tube
3. Bushing and bearing
Suggestions
Removing Piston Rod
Draw the piston rod out gently, taking care not to
damage the sealing members fitted to the piston.
200349
7.49
LIFT & TILT CYLINDERS: DISASSEMBLY
Disassembly
Tilt Cylinders/Earlier Version
205971
Sequence
1. Tilt socket, nut, bushing, and grease fitting 3. Piston rod, piston seal, and nut
2. Bushing, O-ring, dust seal, and packing 4. Cylinder tube and bushing
NOTE
Do not remove the tilt socket and cylinder tube
bushing unless they are defective.
Suggestions
Removing Bushing
1. Wrap the cylinder with a wad of cloth and
hold 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 rub the buffer ring,
packing, etc., against the threads of the pis-
ton rod.
200351
7.50
LIFT & TILT CYLINDERS: DISASSEMBLY
Disassembly
Tilt Cylinders/Later Version
✱ Parts contained in seal kit
3
✱
1 ✱
✱
✱
1
207050
Sequence
1. Tilt socket, bushing, bolt, washer, nut, and 3. Piston rod, piston seal, and nut
grease fitting
4. Cylinder tube and bushing
2. Bushing, O-ring, dust seal, packing and
buffer ring
NOTE
Do not remove the tilt socket and cylinder tube
bushing unless they are defective.
Suggestions
Removing Bushing
1. Wrap the cylinder with a wad of cloth and
hold 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 rub the buffer ring,
packing, etc., against the threads of the pis-
ton rod.
200351
7.51
LIFT & TILT CYLINDERS: DISASSEMBLY
200319
200353
7.52
LIFT & TILT CYLINDERS: FLOW REGULATOR VALVE
1
5
203559
NOTE
Replace the flow regulator valve as an assem-
bly if any part is defective.
7.53
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT
! WARNING
Suction Strainer
Remove the hydraulic tank filler cap only Check the suction strainer for clogging or damage.
after the truck has been stopped and the
fill cap is cool enough to remove with your Return Filter
bare hand. Check the return filter for clogging or damage.
7.54
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT
Control Valve
External Leakage
1. Check for oil leaks from the joint between 2. Quickly disconnect the oil return hose and
adjacent valve housings sealed by O-ring. start collecting the oil coming out of this hose
2. Check for oil leaks from the scrapers sealed as shown.
by O-rings.
3. Check for oil leaks from the screw
connections.
Internal Leakage
It is not practical to check the control valve alone
for internal leakage. The correct way to check the
control valve in place under normal operating
conditions follows.
The internal leakage to be checked includes
leakage occurring at the lift spool, tilt spool, tilt 203522
lock valve, and check valves.
[Test oil temperature: approx. 50°C (122°F)]
Amount of oil collected 500 cc (30.5 cu. in.)
1. Pick up a load equal to the rated capacity. Lift for 15 minutes maximum
it approximately 1 meter (3 ft) high. Tilt the
mast forward 3° - 4° and stop the truck.
3° - 4°
3. If the tilt cylinders or lift cylinders drift (the
mast tilts forward or the fork lowers) exces-
sively even though the amount of oil collected
in 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.)
approx.
1 meter
(3 feet)
203521A
7.55
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT
Main Relief Valve Adjustment
1. Attach a pressure gauge capable of measur- 3. If the setting is incorrect, loosen the lock nut
ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa] of the adjusting screw and, while observing
to the delivery hose connector. the pressure gauge reading, slowly turn the
2. Start the truck and move the control lever to adjusting screw in either direction until the
the backward tilt position and hold. If the relief gauge indicates the prescribed set value.
pressure reading is 4. While holding the adjusting screw, tighten the
185 ± 5 kgf/cm2 lock nut to secure the adjusting screw.
(2631 ± 71 psi) 5. After securing the adjusting screw, recheck
[18,142 ± 490 kPa] the setting.
when the tilt cylinders reach the end of their
185 ± 5 kgf/cm2
stroke, the main relief valve setting is correct.
Main relief valve setting (2631 ± 71 psi)
[18,142 ± 490 kPa]
203523
7.56
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT
204893
(Later Version)
4. To adjust the tilt angle, loosen bolt A of the tilt
cylinder socket, and adjust the cylinder stroke
by turning the rod on either cylinder so that 204698
207054
7.57
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT
Adjusting Method
1. Raise the inner mast, place blocks under the 3. Extend the piston rod and tighten the cylinder
right and left sides of the mast, and lower the stopper bolt. Remove the blocks from under
mast until it rests on the blocks. the inner mast.
4. Slowly lower the inner mast all the way to
make sure that the piston rods move smoothly.
202983
Stopper bolt
205972
Shims
200365
NOTE
To retract the piston rod, move the lift control
lever to the lowering position to let the oil
escape from the lift cylinder.
7.58
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT
Testing
Lift Cylinder Drift Test Tilt Cylinder Drift Test
1. Pick up a load equal to the rated value, tilt the 1. Pick up a load equal to the rated value, tilt the
mast to the vertical position, raise the forks 1 mast to the vertical position, raise the forks
to 1.5 m (3.3 to 4.9 ft) and stop the truck. about 50 cm (20 in.) and stop the truck.
2. Scribe a line on the mast column and measure 2. Measure the drift extension of the tilt cylinder
the drift of the lift cylinder (drop for 15 minutes). for (extension) 15 minutes.
(Earlier Version) (Earlier Version)
200366 200367
206891 207056
Piping
1. Check each hydraulic circuit for leaks.
2. Check to make sure that each hose is free
from twisting or excessive loops.
7.59