GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
1) CHECK ITEM
Within 100mm(3.91in)
(1) Check visually for deformation, cracks or
damage of rod.
(2) Set mast vertical and raise 1 m from
(after 10min)
ground. Wait for 10 minutes and measure
hydraulic drift (amount forks move down
and amount mast tilts forward).
·Check condition 20B7HS08
- Hydraulic oil : Normal operating temp
(50˚C)
- Mast substantially vertical.
- Rated capacity load. Within 5 (after 10min)
·Hydraulic drift
- Down (Downward movement of forks)
: Within 100 mm (3.9 in)
- Forward (Extension of tilt cylinder)
: Within 5。
(3) If the hydraulic drift is more than the
specified value, replace the control valve
or cylinder packing.
Check that clearance between tilt cylinder
20B7HS09
bushing and mounting pin is within
standard range.
mm (in)
Standard Under 0.6 (0.02)
2) HYDRAULIC OIL
(1) Using dipstick, measure oil level, and oil if
Highest
necessary. level
(2) When changing hydraulic oil, clean
suction strainer (screwed into outlet port
pipe) and line filter (screwed into inlet
pipe). Line filter uses paper element, so Lowest
level
replace periodically(every 6 months or
1000 hours) B15AOM116
3) CONTROL VALVE
(1) Raise forks to maximum height and
measure oil pressure.
Check that oil pressure is 210kgf/cm2.
(2990 psi)
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2. TROUBLESHOOTING
1) SYSTEM
Problem Cause Remedy
Large fork lowering speed ·Seal inside control valve defective. ·Replace spool or valve body.
·Oil leaks from joint or hose. ·Replace.
·Seal inside cylinder defective. ·Replace packing.
Large spontaneous tilt of ·Tilting backward : Check valve defec- ·Clean or replace.
mast tive.
·Tilting forward : tilt lock valve defect- ·Clean or replace.
ive.
·Oil leaks from joint or hose. ·Replace.
·Seal inside cylinder defective. ·Replace seal.
Slow fork lifting or slow mast ·Lack of hydraulic oil. ·Add oil.
tilting ·Hydraulic oil mixed with air. ·Bleed air.
·Oil leaks from joint or hose. ·Replace.
·Excessive restriction of oil flow on ·Clean filter.
pump suction side.
·Relief valve fails to keep specified ·Adjust relief valve.
pressure.
·Poor sealing inside cylinder. ·Replace packing.
·High hydraulic oil viscosity. ·Change to ISO VG46.
·Mast fails to move smoothly. ·Adjust roll to rail clearance.
·Oil leaks from lift control valve spool. ·Replace spool or valve body.
·Oil leaks from tilt control valve spool. ·Replace spool or valve body.
Hydraulic system makes ·Excessive restriction of oil flow pump ·Clean filter.
abnormal sounds suction side.
·Gear or bearing in hydraulic pump ·Replace gear or bearing.
defective.
Control valve lever is locked ·Foreign matter jammed between sp- ·Clean.
ool and valve body.
·Valve body defective. ·Tighten body mounting bolts uniformly.
High oil temperature ·Lack of hydraulic oil. ·Add oil.
·High oil viscosity. ·Change to ISO VG46.
·Oil filter clogged. ·Clean filter.
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2) HYDRAULIC GEAR PUMP
Problem Cause Remedy
Pump does not develop full ·System relief valve set too low or ·Check system relief valve for proper
pressure leaking. setting.
·Oil viscosity too low. ·Change to proper viscosity oil.
·Pump is worn out. ·Repair or replace pump.
Pump will not pump oil ·Reservoir low or empty. ·Fill reservoir to proper level.
·Suction strainer clogged. ·Clean suction strainer.
Noisy pump caused by ·Oil too thick. ·Change to proper viscosity.
cavitation ·Oil filter plugged. ·Clean filters.
·Suction line plugged or too small. ·Clean line and check for proper size.
Oil heating ·Oil supply low. ·Fill reservoir to proper level.
·Contaminated oil. ·Drain reservoir and refill with clean oil.
·Setting of relief valve too high or too ·Set to correct pressure.
low.
·Oil viscosity too low. ·Drain reservoir and fill with proper
viscosity.
Foaming oil ·Low oil level. ·Fill reservoir to proper level.
·Air leaking into suction line. ·Tighten fittings, check condition of
line.
·Wrong kind of oil. ·Drain reservoir, fill with non-foaming
oil.
Shaft seal leakage ·Worn shaft seal. ·Replace shaft seal.
·Worn shaft in seal area. ·Replace drive shaft and seal.
3) MAIN RELIEF VALVE
Problem Cause Remedy
Can’t get pressure ·Poppet D, E or K stuck open or ·Check for foreign matter between
contamination under seat. poppets D, E or K and their mating
parts. Parts must slide freely.
Erratic pressure ·Pilot poppet seat damaged. ·Replace the relief valve.
·Poppet C sticking in D. ·Clean and remove surface
marks for free movement.
Pressure setting not correct ·Normal wear. Lock nut & adjust ·See ★Test of main control valve.
screw loose.
Leaks ·Damaged seats. ·Replace the relief valve.
·Worn O-rings. ·Install seal and spring kit.
·Parts sticking due to contamination. ·Disassemble and clean.
★ A good pressure gauge must be installed in the line which is in communication with the main relief. A
load must be applied in a manner to reach the set pressure of the main relief unit.
Then, follow these steps:
· Loosen lock nut.
· Set adjusting nut to desired pressure setting.
· If desired pressure setting cannot be achieved, add or remove shims as required.
· Tighten lock nut.
· Retest in similar manner as above.
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4) LIFT CYLINDER
Problem Cause Remedy
Oil leaks out from rod cover ·Foreign matters on packing. ·Replace packing.
through rod ·Unallowable score on rod. ·Smooth rod surface with an oil stone.
·Unusual distortion of dust seal. ·Replace dust seal.
·Chrome plating is striped. ·Replace rod.
Oil leaks out from cylinder rod ·O-ring damaged. ·Replace O-ring.
cover thread
Rod spontaneously retract ·Scores on inner surface of tube. ·Smooth rod surface with an oil stone.
·Unallowable score on the inner ·Replace cylinder tube.
surface of tube.
·Foreign matters in piston seal. ·Replace piston seal.
Wear (clearance between ·Excessive clearance between ·Replace wear ring.
cylinder tube and wear ring) cylinder tube and wear ring.
Abnormal noise is produced ·Insufficient lubrication of anchor pin ·Lubricate or replace.
during tilting operation or worn bushing and pin.
·Bent tilt cylinder rod. ·Replace.
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