HYDRAULIC SYSTEM: DESCRIPTION

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

Schematic for Trucks with Optional EV100ZX Controller

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

1. Cap 3. Drain plug 5. Suction line strainer

2. Oil level gauge 4. Return line filter 6. Lift cylinder pipe

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

Hydraulic Pump for Trucks with MicroCommand II Controller

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

Hydraulic Pump for Trucks with Optional EV100ZX Controller

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
Essentially the pump consists of two gears—the
drive gear and the driven gear—closely fitted in
the housing. The oil is carried around the periph-
ery of the revolving gears from the suction to the
discharge side. The teeth meshing between the
two gears prevents the return of oil from the dis-
charge to the suction side.
Driven Gear
Drive Gear
203585
7.6
Pressure Loading Principle
This pump is a self-balanced type based on the
principle of pressure loading, balancing for equal
pressure on all sides of the revolving gear. This
reduces bushing and gear wear. In operation, the
high-pressure oil on the discharge side is fed
back to the suction side. On the suction side,
pressure is exerted equally on both sides of the
gears and shafts, thereby cancelling out unequal
pressure to balance the pump.
Clearance
Discharge side
200333
Integral Priority Valve (Trucks with
MicroCommand II Controller Only)
This pump is equipped with an integral priority
valve which provides oil flow on demand to the
steering system based on an external pilot signal.
Excess flow is diverted to the mast operating
valve for the lift, tilt, and auxiliary functions.
 HYDRAULIC SYSTEM: DESCRIPTION

Control Valve

9
12

1 11

10

11

10

7
5

8
2 4
3 12
203486

1. Inlet cover 7. From steering control valve

2. Lift valve assembly 8. To tank
3. Tilt valve assembly 9. Main relief valve
4. Attachment valve assembly 10. Tie bolt
5. End cover 11. Nut
6. Pump port 12. Shutoff valve

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

Lift and Tilt Cylinders

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

Flow Regulator Valve

From control valve To control valve

To lift cylinder From lift cylinder

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

Down Safety Valve

Burst

Normal When hose burst

204971

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

Truck Dual stage Dual-stage full Triple-stage full

panoramic free-lift panoramic free-lift panoramic
1st lift 2nd lift 1st lift 2nd lift
cylinder cylinder cylinder cylinder 201731A

2EC15 70 90 70 90 70 Top View: • Dual-stage panoramic lift cylinder

2EC20/25 70 120 70 120 70 • Dual-stage full free-lift panoramic,
2EC25E/
1st and 2nd cylinders
2EC30
90 90 120 120 90
• Triple-stage full free-lift panoramic,
2nd lift cylinder
Bottom View: • Triple-stage full free-lift panoramic
1st lift cylinder

7.10
 REMOVAL: GENERAL WARNING

Removal and Installation

Warning
! WARNING

Hydraulic oil under pressure can remain in

the hydraulic system after the truck and
pump have been stopped. To avoid person-
al injury, this pressure must be released
before any work is done on the hydraulic
system.
To prevent possible injury, lower the lift
bracket to the ground, turn the truck off,
and move the control levers to make sure
all hydraulic pressure is released before
any fitting, plug, or hose is loosened, tight-
ened, removed, or adjusted.
Always move the lift truck to a clean and
level location away from the path of other
machines.
Be sure that no personnel are near the
machine when the truck is running and
tests or adjustments are being made.

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

Trucks with Optional EV100ZX Controller

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
Controller
1. To install, follow the reverse sequence of the
disassembly procedure. Before installing
hydraulic fittings in the pump, inspect all
O-rings for damage or aging and replace
them as required.
2. Tighten hose to the following specifications.
Trucks with Optional EV100ZX
Controller
1. To install, follow the reverse sequence of the
disassembly procedure. Before installing
hydraulic fittings in the pump, inspect all
O-rings for damage or aging and replace
them as required.
2. Tighten hose to the following specifications.

Tightening Torque for Hose Tightening Torque for Hose

Supply hose from 10.3 to 11.7 kgf•m 2EC15/18 2EC20-30
A pump to mast (74 to 85 lbf•ft)
operating valve [101 to 115 N•m] Supply hose from 8.9 to 9.7 kgf•m 10.3 to 11.7 kgf•m
Supply hose from 5.6 to 6.0 kgf•m pump to mast (64 to 70 lbf•ft) (74 to 85 lbf•ft)
B pump to (40 to 43 lbf•ft) operating valve [87 to 95 N•m] [101 to 115 N•m]
steer gear [55 to 59 N•m]
Load sense feedback 1.7 to 2.2 kgf•m
C hose from (12 to 16 lbf•ft)
steer gear [17 to 22 N•m]

8609137

A
3. Lube pump splines before installing into pump
motor. Use molybdenum disulfide grease.
8609096

3. Lube pump splines before installing into pump

motor. Use molybdenum disulfide grease.

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

Working Rules and Tips

The hydraulic pump, complete with the priority Oil Seal
valve, is a precision-machined component and as An oil seal, once removed, must not be reused.
such must be handled with extreme care. Clean- After disassembly, examine the oil seal in place
liness is imperative: use clean tools and work in a (in the pump flange) and, if in good condition,
clean place. leave it in place. When installing a replacement
1. Clean the disassembled parts with a volatile oil seal, be careful not to score or scratch its lip
solvent such as trichlene or chlorobenzene portion.
and dry them with compressed air. This does
not apply to rubber parts.
2. Oil seals, O-rings, and the like are rubber
parts. Never clean them with solvent. Blow
dirt off rubber parts with compressed air, and
keep them immersed in hydraulic oil until they
are ready for reassembly. A rubber part show-
ing even slight wear and tear must be
replaced. Rubber parts are expendable items
that should be replaced once a year.
3. Parts that are installed by pressing or forcing
need special treatment.

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

Trucks with Optional EV100ZX Controller: Removing the Shaft Seal

Removing the End Cover Remove the internal retaining clip in the front of
1. Lightly mark the end cover, pump body, and the flange. Push the shaft seal squarely out of
mounting flange to ensure proper reassembly. the mounting flange.

2. Remove the rear bolts, spring washers, and

the end cover.

Removing the Seals

Remove the O-ring from the pump body. Remove
the bush seal and the backup seal from the rear
bushings.

8609102

8609100

7.18
 HYDRAULIC PUMP: DISASSEMBLY

Removing the O-ring and Seals Separating the Gear Pack

Remove the O-ring from the groove in the body 1. Separate the gears, key, and balance plate
of the pump. Remove the bush seal and the from the drive shaft and driven idler shaft.
backup seal from the front bushings. 2. Note the position of the balance plate to
ensure proper location during reassembly.

Removing the Rear Bushes

Remove the remaining rear bushes from the
body bore.

8609103

Removing the Bushings

Before removing the internal components, mark
the bushes to denote the location in the body on
8609105
a plain area away from the seal location mark.
FD = Bush on flange end of the drive shaft
FI = Bush on flange end of idler shaft
CD = Bush on the cover of priority valve end
of the drive shaft
CI = Bush on the cover end of the idler shaft

Removing the Drive Shaft

With the unit lying on its side, hold the drive shaft
and pull it squarely out of the body, bringing with
it the bushes and the complete gear pack.

8609104

7.19
HYDRAULIC PUMP: DISASSEMBLY
Inspection after Disassembly
Body
1. Inspect the body bore cut-in where gears wipe
into the body.
2. The body can only be reused if the cut-in is
bright and polished in appearance and the
depth does not exceed .08 mm.
3. The body should be replaced if the surface is
scored, has a matte appearance, or shows
signs that the tips of the gears have dug in and
torn away the surface material.
4. The body should be inspected to ensure that
there is no superficial damage which may
adversely affect performance or sealing. Pay
particular attention to the port threads and body
O-ring seal recesses.
Mounting Flange Face and Priority
Valve Face
1. The inner surfaces should be inspected to en-
sure that there is no unusual wear or scoring in
the regions where the body O-rings and bush
seals contact, which could result in external leakage.
2. Check the shaft seal recess for scoring or dam-
age that could result in oil leakage around the
outer diameter of the shaft seal. A replacement
shaft seal can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
Bushes and Balance Plate
1. The side faces which abut the gears should be
perfectly flat and show no signs of scoring.
Characteristically there are bright polished
areas on this surface caused by loading
against the gear side faces. This is often more
pronounced on the low-pressure side. These
should be replaced if there is any general
scoring or fine scoring with a matte appearance
or tearing of the surface material.
2. Often, the tips of the opposing gears have
wiped an overlap in a half-moon shape. There
must be no noticeable wear step as it is critical
that the bush side face and balance plate are
completely flat to the gear side face.
7.20
3. The bush bearing liners are acceptable if they
are not scored or do not show other damage.
The general outside area of the bush should
not show any prominent signs of wear.
Gears
1. The gear side faces should be examined for
bushing or scoring. Often operation on con-
taminated fluid shows scoring between the
root of the gear and the journal, which leaves
a wear step. If a wear step can be felt, coinci-
dental with the root diameter, by drawing a
sharp-pointed tool across the surface from
the journal outwards towards the tip of the
gear, then the gear must be replaced.
2. The gear teeth should be carefully examined
to ensure that there are no signs of bruising
or pitting.
3. The journal bearing surfaces should be com-
pletely free from scoring or bruising. The sur-
face should be highly polished and smooth to
the touch.
4. Examine the area where the shaft seal lips
run on the drive shaft. This shows up as pol-
ished ring or rings. If a noticeable groove can
be felt, or if there is scoring, the shaft should
be replaced.
5. Examine drive keyway in driveshaft journal
extension to ensure it is not damaged or
chipped.
6. If the driveshaft is not damaged from the
drive coupling and the gears have not been
harmed as described above, then the gears
can be reused. If the gears are damaged,
they must be replaced as a matched set.
7. As a matter of good practice, when pumps
have been dismantled, all the seals should be
replaced.
 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

Reassembling the Rear Bushes
1. Install the rear bushes (marked CD and CI)
into the undowelled end of the body.
HYDRAULIC PUMP: REASSEMBLY
Trucks with MicroCommand II Controller:
Fixturing with the Priority Valve
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.

Trucks with Optional EV100ZX Controller:

Fixturing with the End Cover
Use the end cover to temporarily fixture the parts
as they are reassembled. Place the end cover on
its back and set the undowelled end of the body
against it so that the dowels are pointing up.
8609107
Reassembling the Balance Plate
1. Hold the driveshaft and driven gear of the
2. The C-shaped cutout in the bushes must be idler shaft together and refit the balance plate
to the side of the body with the cusp removal in its original position.
flat.
2. The two grooves in the plate must be to the
3. The diagram below shows the location of the low-pressure side of the pump (the side
driveshaft and the front bushes and seals where the body bores meet in a point). With
installed. the drive shaft nearest to you, these grooves
will be on the left-hand side as shown for the
Location Flange end
dowels
counterclockwise rotation.

Cusp
Removal
Inlet

Position of
driveshaft

Counterclockwise Rotation
8609108

8609109

7.23
HYDRAULIC PUMP: REASSEMBLY
Reassembling the Gear Pack
1. Fit the key into the keyway in the driveshaft
and then carefully fit the gear over the key.
Fit the second gear on the idler shaft.
2. Keeping the gear pack together, carefully feed
the assembly into the body bores with the
driveshaft positioned as previously shown.
Reassembling the Front Bushes
Refit the front bushes (FD and FI) into their origi-
nal bores, remembering that the C-cutout must
be to the side of the body with the cusp removal
flat. They must match the rear end bushes.

8609111

8609110

7.24
 HYDRAULIC PUMP: REASSEMBLY

Reassembling the O-ring and Seals Reassembling the Shaft Seal

Fit a new O-ring, bush seal and backup seal,
ensuring that the seals locate correctly in the
seal grooves.
1. Fit a new shaft seal into the recess in the
mounting flange with the “garter” spring fac-
ing into the pump.
2. If the seal recess was scored, then Loctite
hydraulic sealant must be applied to the outer
diameter of the seal.
3. Apply a coat of high-melting-point grease to
the shaft seal lips.
4. Reinstall the retaining ring. Ensure that it is
located in its groove.

8609112

8609102

7.25
HYDRAULIC PUMP: REASSEMBLY

Reassembling the Flange Reassembling the Rear O-ring and Seals

Slip the shaft seal and flange assembly over the
driveshaft and carefully refit the mounting flange,
ensuring that it is positioned squarely onto the
dowels in the body.
1. Hold the whole unit together and carefully
turn it over. Ensure that it is supported on the
mounting flange, not the driveshaft.
2. Remove the priority valve (or the end cover
for trucks with Optional EV100ZX Controller)
and install a new O-ring, bush seal, and
backup seal.

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

Inspection after Reassembly

Pour a small amount of clean hydraulic fluid into
a port and check that the shaft can be rotated
without undue force using a smooth-jawed vise.
Running In After Reassembly
A unit which has been reassembled with either
new gears, bushes, or body, must be carefully run
in before it is subjected to full working conditions.
Ideally, this should be done on a test rig, where
pressure can be applied gradually and any wipings
from the body cut-in can be arrested by filters.
It is recommended that, initially, the unit is run in
at 1500 rpm at zero pressure for one minute. The
pressure should then be increased in intervals of
35 bars a minute until maximum pressure is
reached. Check the system temperature frequent-
ly, ensuring that it does not exceed the maximum
permissible temperature of 80°C. If the tempera-
ture exceeds the system or unit specification, the
test must be delayed and operated off-load until
the temperature is lowered to an acceptable
range. Typical pump ratings are shown in the
table below.

Pressure
Test gauge
unit Micronic Variable
filter restrictor

Flow
Strainer Relief meter
Tank
valve

Typical pump test circuit

8609116

Typical performance applicable when using

ISOVG 32 at 40°C (104°F)
Pump Part Test Speed Max. Flow Rate
Number Continuous
Pressure
97171-13200 1500 rpm 253 kg/cm2 33.8 l/min
(3335 psi) (7.44 gpm)
[227 bar]
97271-00800 1500 rpm 255 kg/cm2 42.88 l/min
(3625 psi) (9.43 gpm)
[247 bar]

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

Removing the Body Plug Removing the Spool

Remove the body plug from the valve body. Remove the spool from the valve body.
Remove the O-ring from the plug.

8609121
8609118

Removing the Spool Plug

Removing the Spring Seat Unscrew the spool plug (damping orifice) from
Remove the spring seat from the valve body. the end of the spool by holding the spool on the
Remove the O-ring from the seat. unground surfaces to prevent damage.

8609122

8609119 Removing the Internal Filter

Remove the filter from the inside of the spool.
Removing the Spring
Remove the spacer (if present) and the spring
from the valve body through the opening created
when the spring seat was removed.

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

Removing the Core Plug Removing the Valve

Remove the core plug to gain access to the relief Remove the filter valve from the valve body.
valve seat.

8609126
8609124

Removing the Spring

Removing the Valve Seat Remove the spring from the valve body.
Unscrew the valve seat. This item is peened in
position as part of the setting process and it may
be necessary to locally drill to ease removal.

8609127

8609125 Priority Valve Inspection after Disassembly

Examine the spool and bore for signs of damage.
Check the orifices in the spring seat, the spool
plug, and the spool to make sure that they are
free and clear of contaminants.
Inspect the relief valve seat for wear or damage.

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

Reassembling the Relief Valve Reassembling the Spring

1. Replace the relief valve components. Ensure Replace the spring in the valve body. Insert the
that the valve remains properly located in the spacer if the valve had one originally.
valve seat.
2. Screw the valve seat in just far enough to take
up the spring load. The relief valve pressure
will require setting on the truck or on a test rig.

8609132
8609129

Reassembling the Body Plug

Reassembling the Internal Filter Install a new O-ring on the body plug and screw
Insert a new filter into the spool. the plug into the valve body. Tighten the plug.

7.6 to 8.2 kgf•m

Tightening torque for plug (55 to 59 lbf•ft)
[75 to 80 N•m]

8609130

Reassembling the Spool

1. Apply a small amount of Loctite 542 to the
threads of the plug (dampening orifice) and
screw into the spool to hold the filter in place.
Tighten the plug.
8609133

1.4 kgf•m
Tightening torque for plug (10 lbf•ft)
[14 N•m]

2. Reinstall the spool in the valve body.

8609131

7.33
PRIORITY VALVE: REASSEMBLY

Reassembling the Spring Seat Running In Priority Valve

1. Install a new O-ring on the spring seat. Screw after Reassembly
the spring seat into the valve and tighten. 1. If new components have been fitted to the
pump in addition to disassembly of the priority
9.8 to 10.7 kgf•m valve, the pump must be run in before it is
Tightening torque for
(74 to 78 lbf•ft) subjected to full working pressures. See the
spring seat
[100 to 105 N•m]
requirements for running in the pump in the
pump section.
2. To do this after changes have been made to
the priority valve, make sure that the relief
valve is screwed in solidly and the main valve
spool and spring are removed, but the cap is
replaced.
3. Blank port P and the load sense connection
and fit the test rig loading circuit to port EF.
4. Run the pump in at up to:
2
15.3 kg/cm (218 psi) [15 bar]
8609134 below the maximum pressure quoted in the
pump run-in section table. Refit the main
spool and spring and unscrew the relief valve
Reassembling the Pump and Valve for resetting.
1. Replace the priority valve on the pump.
Ensure that the inlet to the valve in the rear Resetting the Relief Valve
face is over the high pressure-side of the
pump (semicircular cutout in the bushes). 1. Install the pump and priority valve in the test
rig or in the application.
2. Tighten the bolts.
2. Fit a pressure gauge and variable restrictor to
the line from valve port P. The gauge should
2EC15/18 2EC20-30 be between the port and the restrictor.
Connect the LS port between the valve and
4.7 to 5.2 kgf•m 9.0 to 10.4 kgf•m
Tightening torque the variable restrictor to ensure that flow is
(34 to 38 lbf•ft) (65 to 75 lbf•ft)
for bolts demanded from port P.
[46 to 51 N•m] [88 to 102 N•m]
3. Run the pump at normal operating speed,
close restrictor, and adjust the relief pressure
by screwing the valve seat in or out until the
correct level is reached.

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

Suggestions Inspection after Disassembly

Main Relief Valve
NOTE
To remove main relief valve for cleaning or
inspection, loosen its plug. Loosening the
lock nut will disturb the pressure setting.
Sections, Spools, and Return Springs
1. Check each section for cracks and defective
sliding surfaces. Also inspect the check valve
seat for wear.
2. Check the spools for burns or distortions.
Also check for operating force.

Do not remove the main relief valve unless it is

defective. This also applies to shut-off valve
assembly.

Plug

203517

Lock nut
18 to 22 kgf
Spool operating force (40 to 49 lbf)
[177 to 216 N]
205025

3. Check the tilt lock valve for damage and

Lift, Tilt, and Attachment Sections
1. Remove the spool from the section, together
with the screw and plate, when disassem-
bling the tilt or attachment spools.
2. Hold the spool in a vise with protective jaw
caps and remove the screw with an Allen
wrench.
seizure.
Reassembly
To reassemble, reverse the disassembly sequence
and do the following steps.
1. Wash all parts except for O-rings with solvent.
2. Apply hydraulic oil to O-rings when installing
them.
3. Make sure that each spool moves freely.

205028

7.40
 LIFT & TILT CYLINDERS/EARLIER VERSION: REMOVAL & INSTALLATION

Lift and Tilt Cylinders/Earlier Version

Removal
Lift Cylinders

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

Disconnecting Return Hoses Lowering Lift Bracket

Start the truck. Raise the lift bracket to the maxi-
mum height and stop the truck. Disconnect the
return hoses of the left and right lift cylinders at
their connectors.
Removing Hose Guard
With the lift bracket raised to the maximum
height, remove each hose guard from the front
side of the mast.
From left-hand
lift cylinder
Lower the lift bracket by carefully operating the lift
control lever.
Disconnecting High-Pressure Hoses
Disconnect the high-pressure hoses at the joints
indicated by the arrows in the drawing below. Use
a container to catch oil flowing out of the hoses.
Right-hand cylinder
Left-hand cylinder

Connector

To tank
204933
From right-hand
lift cylinder 205968

NOTE

Be careful not to touch the lift control lever.

7.42
 LIFT & TILT CYLINDERS/LATER VERSION: REMOVAL & INSTALLATION

Lift and Tilt Cylinders/Later Version

Removal
Lift Cylinders

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

Be careful not to touch the lift control lever.

2. Lowering lift bracket:

Lower the lift bracket by carefully operating
the lift control lever.
3. Disconnecting high-pressure hoses:
Disconnect the high-pressure hoses at the
joints indicated by arrows. Use a container to
catch oil flowing out of the hoses.

Right-hand cylinder
Left-hand cylinder

204933

7.44
 LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION
Removing Set Bolts
1. Remove the set bolt at the top of each lift
cylinder. Lift the inner mast to separate the
cylinder rod ends. To lift the inner mast, clove-
hitch a sling to the mast with protective wad.
204934
NOTE
The rod end of either lift cylinder is shim-
adjusted to eliminate the difference in stroke
between the cylinders. Before removing the
stopper bolts, make a record of the number of
shims and the cylinder to which the shims are
fitted.
2. Place wood blocks under the inner mast and
detach the sling. Use blocks strong enough to
support the mast.
202983
Removing Lift Cylinders
Attach a lift sling to the lift cylinder from the rear
side of the mast and remove the cylinder. Attach
the sling before removing the cylinder clamp.
204935
Installation
Lift Cylinders
To install, reverse the removal sequence and do
the following steps.
1. Extend and retract the lift cylinders several
times under no-load conditions to expel air
from the cylinder circuits and to make sure
the cylinders move smoothly.
2. Check the oil level in the hydraulic tank with
the oil level gauge.
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).
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.

1. Mark the tilt cylinder sockets and nuts. 1

4

Mark

2 3 206883

201737
1. Rubber hose
2. Tilt socket pin, bolt, washer
NOTE 3. Tilt cylinder pin, bolt, washer

When the tilt cylinders are to be replaced, it is 4. Tilt cylinder

necessary to adjust the cylinder stroke and tilt.
2. Using a wrench, turn the piston rods to dis-
connect the tilt cylinders from the tilt sockets.
NOTE
When the tilt cylinders are to be replaced, it is
necessary to adjust the cylinder stroke and tilt.

NOTE
Loosen the nut just enough to permit turning
of the piston rod. Do not change the position
of the nut.

3. Retract the tilt cylinders and disconnect them

from the tilt sockets.

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
Inspection after Disassembly
Lift and Tilt Cylinders
Cylinder Tube
1. Check the bore wall for wear, grooving,
scratch marks, and rusting.
2. Check the welds for cracks.
Piston Rod
1. Check for deflection in the manner shown.
200319
2. Check for surface flaws such as grooving,
scratch marks, rusting, and wear. The rod
must be replaced if its threads show signs of
stripping or any other damage.
Packings and Rings
1. Check the packings and the lips of dust seals
for damage, distortion, and deterioration due
to aging.
2. Check each ring for deterioration due to aging.
7.52
Precautions for Reassembly
1. Wash all parts clean, making sure that each
part is clear of any gritty particles.
2. Before inserting the piston rod complete with
the piston, apply hydraulic oil to the bore wall
of the cylinder tube and to the sealing parts:
O-rings, U-rings, wiper rings, nylon heels, pis-
ton seals, dust seals, and packings—so they
will slide smoothly into the bore.
3. When clamping the cylinder tube in the vise
in order to run the head into the cylinder tube,
be careful not to distort the tube #4 and #117.
Before fitting the piston seal to the tilt cylinder
piston, squeeze the seal by hand 5 or 6 times
to soften it. Hold the piston steady by clamp-
ing the rod in a vise and apply a small
amount of hydraulic oil to the seal. Fit a por-
tion of the seal to the groove and push the
rest of the seal into place a little at a time
until the seal is in the groove.
200352
200353
 LIFT & TILT CYLINDERS: FLOW REGULATOR VALVE

Flow Regulator Valve

Disassembly

1
5

203559

Sequence Inspection after Disassembly

1. Lock nut 1. Check the springs for fatigue.
2. Plug and O-ring 2. Check the valve seats for damage. Check the
sliding surfaces for evidence of binding and
3. Spring and shims repair as necessary.
4. Piston, pin, washer, spring, and valve 3. Check the sliding surfaces of the piston and
valve body for damage.
5. Valve body

NOTE
Replace the flow regulator valve as an assem-
bly if any part is defective.

7.53
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Inspection and Adjustment

Hydraulic Tank
Hydraulic Oil
1. Check the hydraulic oil in the tank for cleanli-
ness. Oil appearing dirty or whitish (showing
more or less emulsification) must be changed.
2. Refill capacities in the amount of oil required.
NOTE
A general rule: in any machine, regardless of
the mast-and-attachment combination, the oil
level should not be above the “H” mark on the
level gauge when the mast is all the way down.

! WARNING
Remove the hydraulic tank filler cap only
after the truck has been stopped and the
fill cap is cool enough to remove with your
bare hand.
Suction Strainer
Check the suction strainer for clogging or damage.
Return Filter
Check the return filter for clogging or damage.

Hydraulic Tank Refill Capacities

2EC15/18 2EC20/25 2EC25E/30

18 (4.8) 24 (6.3) 30 (7.9)

Unit: liter (U.S. gal)

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-
ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa]
to the delivery hose connector.
2. Start the truck and move the control lever to
the backward tilt position and hold. If the relief
pressure reading is
185 ± 5 kgf/cm2
(2631 ± 71 psi)
[18,142 ± 490 kPa]
when the tilt cylinders reach the end of their
stroke, the main relief valve setting is correct.
203523
7.56
3. If the setting is incorrect, loosen the lock nut
of the adjusting screw and, while observing
the pressure gauge reading, slowly turn the
adjusting screw in either direction until the
gauge indicates the prescribed set value.
4. While holding the adjusting screw, tighten the
lock nut to secure the adjusting screw.
5. After securing the adjusting screw, recheck
the setting.
185 ± 5 kgf/cm2
Main relief valve setting (2631 ± 71 psi)
[18,142 ± 490 kPa]
 HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Lift and Tilt Cylinders

Mast Tilt Angle Adjustment
NOTE
1. Place machine in a horizontal position.
It is not necessary to adjust the forward tilt
2. Tilt the mast all the way backward, and stop
angle, provided that the backward tilt angle is
the truck.
properly adjusted.
3. Measure the tilt angle of the mast at both sides.
(Earlier Version)
4. To adjust the tilt angle, loosen the lock nut of
the tilt cylinder rod and adjust the cylinder Forward/backward tilt angle 5° – 6°
stroke by turning the rod on either cylinder so
that there is no difference in stroke between
the cylinders.
Lift Cylinder Stroke Adjustment
1. Slowly raise the inner mast and check the
stopping manner of the left and right piston
rods at the moment the inner mast reaches
its maximum lift height.

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

there is no difference in stroke between the

cylinders. 2. If the top of the mast rocks at that moment, it
should be adjusted with shims. Abnormal
conditions will appear as a time lag in stop-
ping between right- and left-hand piston rods
and rocking of the rod with a longer cylinder
stroke.

207054

7.57
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Adjusting Method
1. Raise the inner mast, place blocks under the
right and left sides of the mast, and lower the
mast until it rests on the blocks.
3. Extend the piston rod and tighten the cylinder
stopper bolt. Remove the blocks from under
the inner mast.
4. Slowly lower the inner mast all the way to
make sure that the piston rods move smoothly.

Flow Regulator Valve

Measure the lowering speed with rated load. If
the speed is out of specification, repair or replace
the flow regulator valve. For the specification of
lowering speed, refer to SERVICE DATA.

202983

1. Remove the stopper bolt at the top of the lift

cylinder which stopped first, retract the piston
rod, and insert the shims at the top of the pis-
ton rod end.

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
1. Pick up a load equal to the rated value, tilt the
mast to the vertical position, raise the forks 1
to 1.5 m (3.3 to 4.9 ft) and stop the truck.
2. Scribe a line on the mast column and measure
the drift of the lift cylinder (drop for 15 minutes).
(Earlier Version)
Tilt Cylinder Drift Test
1. Pick up a load equal to the rated value, tilt the
mast to the vertical position, raise the forks
about 50 cm (20 in.) and stop the truck.
2. Measure the drift extension of the tilt cylinder
for (extension) 15 minutes.
(Earlier Version)

200366 200367

(Later Version) (Later Version)

206891 207056

2EC15/18/20/25/25E 2EC30 2EC15/18 2EC20/25/25E 2EC30

Lift cylinder drift 50 (2.0) 40 (1.6) Tilt cylinder drift 22 (0.9) 20 (0.8) 15 (0.6)
(rated load) maximum (rated load) maximum
Unit: mm (in.)/15 min Unit: mm (in.)/15 min

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