Hyster Forklift B222

NOTE: Use new O-rings during assembly

NOTE: Lubricate parts with hydraulic oil before assembly.

Verify internal parts of the pump are clean.

Install the swash plate section in the pump housing.

Install the O-rings in the pump housing.

Install the adjustment shim on the drive shaft.

Install the bearing on the drive shaft.

Align the port plate to the pump housing with the cylinder pin.

Position the load holding valve on the derricking cylinder.

Install the four capscrews that fasten the load holding valve onto the derricking cylinder.

Remove caps and connect the hydraulic lines to the load holding valve according to the identification tags made during removal.

Connect the electrical wires to the load holding valve according to the identification tags made during removal.

Warning: Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body by pressure.

Caution: Never start the engine with closed shutoff valves. Open the shutoff valves before starting the engine to prevent damage to hydraulic components.

Start the engine and operate the hydraulic system. Check that functions of the load holding valve work correctly. Check for any leaks.

Did the load holding valve work correctly?

Two methods are given for checking the volume of flow from the hydraulic pump. The first method uses a flow meter, a pressure gauge, and a needle valve. The second method uses a needle valve, a pressure gauge, a container, and a timer.

1. If the flow meter is available, install flow meter between needle valve and outlet port of pump. See Figure 5. Pressure gauge must be between needle valve and pump. Make a separate check for each system.

When hydraulic oil is at operating temperature, run engine at 2100 rpm with no load on hydraulic system. Note reading of flow meter. Compare output rate of pump with specification found in the Specifications section.

!WARNING: Hydraulic oil can be hot. Do not touch oil during tests.

2. Run engine at high limit. Slowly close needle valve until gauge indicates a pressure just below specification for relief valve setting. Pump out- put at high pressure must be within 25% of out- put with no load. If output at high pressure is less than 75% of low pressure output, pump has a problem.

1. Another method of checking pump output is to measure the amount of oil moved in a given amount of time. See Figure 6. Run engine until oil is 55 to 65 C (130 to 150 F).

Disconnect line from outlet port of pump. Install a 0 to 21 MPa (0 to 3050 psi) pressure gauge on a tee fitting connected to a hose from outlet port. Install needle valve on end of hose.

NOTE: The pressure reducer valve is adjustable. If a setting pressure is not within specifications, adjust the valve.

Lower lift cylinders completely

Connect a 0 to 7 MPa (0 to 1015 psi) gauge to check port MPLT

Run engine until temperature of hydraulic oil is 55 to 65 C (130 to 150 F)

NOTE: Correct measurement can be achieved during movement (flow) of the main spool.

Check if pressure is 5 MPa (725 psi)

If pressure is not correct, adjust pressure reducer valve

!WARNING: Lower boom completely before working on control valve or hydraulic system. The boom can lower suddenly and cause injury if the boom is not lowered. This procedure will make sure that the boom cannot lower suddenly and cause injury or death.

!NOTE: All valves and other associated items installed on the load holding valve can be replaced. Before removal of any part, check that the area is clean and protected against dirt and fluid contamination.

Place the truck on a solid and level surface.

Lower boom and close the shutoff valves at the bottom of the hydraulic tank platform.

!WARNING: Move all control levers back and forth a minimum of 20 times to remove all hydraulic pressure from pilot system.

Put tags for identification on electrical wires. Disconnect the electrical wires from the load holding valve.

Put tags for identification on hydraulic lines. Disconnect the hydraulic lines from the load holding valve. Put caps on the open lines, ports or other connectors.

Remove the four capscrews that fasten the load holding valve to the derricking cylinder.