bd ‘SENB8229-01 CATERPILLAR See es Specifications Systems Operation Testing & Adjusting V60E, V70E, V80E, V90E Lift Trucks Vehicle Systems 37W2525-UP 58A478-UP 40X2569-UP 62A500-UP 41X3050-UP 42ZB1-UP 74X749-UP 7LB1-UP 75X669-UP 77X533-UPIMPORTANT SAFETY NOTICE Proper repair is important to the safe and reliable operation of a machine. This Service Manual outlines basic recommended procedures, some of which require special tools, devices or work methods. Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to safely perform repairs is provided in the SAFETY section of this Manual. Improper repair procedures can be dangerous and could result in injury or death. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS MACHINE Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in the descriptions of operations where hazards exist. Waring labels have also been put on the machine to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons, These labels identify hazards which may not be apparent toa trained mechanic. There are many potential hazards during repair for an untrained mechanic and there is no way to label the machine against all such hazards. These ‘warnings in the Service Manual and on the machine are identified by this symbol Operations that may result only in machine damage are identified by labels on the machine and in the Service Manual by the word NOTICE. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this Manual are therefore not all inclusive. If a procedure, tool, device or work method not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the machine will not be damaged or made unsafe by the procedures you choose IMPORTANT ‘The information, specifications and illustrations in this book are on the basis of information available at the time it was written. The specifications, torques, pressures of operation, measurements, adjustments, illustrations and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1139F. 67200-1X1\V60E THRU V90E VEHICLE SYSTEMS INDEX SYSTEMS OPERATION Brake System 22 Steering System ‘Master Cylinder and Wheel Cylinders 2 Hydraulic Oi Flow Parking Brake 2 il Flow for Left Turn ‘Whee Brakes 2 (i Fiow for Right Turn ‘Automatic Adjustment 23 Oil Fiow in Neutral, eae i Manual Operation of Steering Gear Basic Ol Flow 4 ‘Control Vaive 5 Steering Cylinder ‘Double Stage Fle! Vaive Modes (righ-Visibiity) 10 ‘Steering Gear ‘Single Stage Relief Valve Models 5 Control Valve Section Lift Cylinders and Mast 12 Metering Section ‘All Other Models 4 Rotor Group Operation High Visibity Models or ‘Steering Pump TESTING AND ADJUSTING Brake System 48 Load Roller Adjustment ‘Brake Adjustment 48 Tit Cylinder Aignment Brake System Air Removal Parking Brake Adjustment Parking Brake Test Pecal Adjustment Hycraule System =. [Ltt Cynder Air Removal Sideshift Speed Chock. ‘Sideshit Speed Adjustment Rolie! Valve Pressure Chock Doubie Stage Rebet Vaive Single Stage Relief Valve Mast and Garriage Carriage Adjustment Load Rolie Adjustment Carriage Height Acjustment Chain Adjustments Chain Adjustment Chain Adjustment Check Chain Wear Test rit Test Dit Test for Lift Systom Drit Test for Tit Systom Forks Parallel Check Mast Adjustment Cartage... Carriage Height Contrl Valve General Tightening Torques Hycraulic Pumps. Hycraulc Schematics Lift and Tit Mounting Group Lit Cylinders Lit Relay Groups Lines, Plugs and Fittings Mast re 8 50 5 a 30 32 3 3 20 30 30 “at Ange Check Tit Cylinder Adjustment “Tit. Cylinder Length Check ‘Steering System ‘Ai Removal from the Stoering System ‘Steer Wheel Bearing Adjustment Steering Axle Adjustments ‘Steer Axle Stops Adjustment ‘Storing Knuckle Bearing Pretoad Adjustment Steering Gear Adjustments Stooring Hygraulc System Pressure Chock 33 Toubeshootng a Brake Stor = Paring Bakes a ‘a Braces 36 yori Sat ard as = "ysrate Cons vate 38 saute Gear mp = Uta Tt ends = Petomance fot o ycraue Ol Tempra * ‘erase Sytem a as 2 stew System a Wsul Groce SPECIFICATIONS 4 Mast Hinge §5 Paring bre Group 56 Parking Brake Iterock Linkage 52 ‘Sideshifter Carriage 57 Sheanfte Cytnore 7 Steer Ae and What $$ Seorng Gear & Steerna Pump STHGyindes 8 Wheel Brakes NOTE: This book is completely changed from the former issue. INDEX areeeee eessarneesHYDRAULIC SYSTEM ‘SYSTEMS OPERATION HYDRAULIC SYSTEM BASIC OIL FLOW 1 2 1 12 1 32 12 co798xs 10 7 BASIC HYDRAULIC SCHEMATIC WITH STANDARD LIFT 1. Primary lit cylinders. 2. Lowering flow contol valve. S.Excess flow protectors. 4. Restrictor valve. 5. Side- ‘shitter cylinder. 6. Tilt cylinders. 7. Hydraulic control valve. 8. Double stage rliet valve._9. Hydraulic oi iter. 10. Hydraulic ol tank. 11. Hydraulic pump. NOTE: The basic hydraulic schematic for the earlier ‘models is not shown. The two schematics shown are for High Visibility Models. The earlier models did not have excess flow protectors and only had one STD lift cylinder and one FFTL cylinder. The earlier models also had a single stage relief valve instead of a double stage. The hydraulic system has hydraulic tank (10), which holds the oil for hydraulic pump (11). Oil from tank (10) is pulled to pump (11) and sent to hydraulic con- trol valve (7). The control valve levers move the valve spools in control valve (7) to let pump oil in the valve go to lift cylinders (1) and/or (12), tilt cylinders (6) or side- shifter cylinder (5). The return oil from the cylinders flows back through the control valve, filter (9)and into hydraulic tank (10). Double stage relief valve (8) is installed in the con- trol valve body. The high pressure side of the relief valve will release the extra pressure when the mast is at 4 u BASIC HYDRAULIC SCHEMATIC WITH FULL FREE TRIPLE LIFT 1. Primary lit ylinders. 2. Lowering flow control valve. 3. Excess flow protectors (secondary cylinders). 4 Res tctor valve.” 5 Sideshifter cylinder. 6. it cylinders. T-Hydraulc control valve. 8. Double stage reliet valve. Hydraulic ol fiter. 10. Hydraulic ol tank. 1. Hydraulic cil pump. 12. Secondary it eylinders. 13. Excess flow protector (primary cylinder. full extension or fully tilted. The low pressure side of the relief valve will release the extra pressure when the carriage is fully sideshifted in either direction. When the relief valve opens, oil flows back to the hydraulic tank. coateoxs Ww ‘The speed at which the lift cylinders are lowered is controlled by lowering flow control valve (2), which is not adjustable, The tilt forward speed is controlled by an anticavitation valve inside the tilt spool. This valve prevents cavitation (development of air pockets) in the tilt cylinders. The sideshifier speed is limited by res- trictor valve (4), which is adjustable. Excess flow protectors (3) and (13) will act asa flow control valve if an oil line is broken between them and flow control valve (2) when the mast is raised or low- ered. This prevents a sudden fall of the mast or car- riage if an oil line is broken. For a complete hydraulic schematic, see the back of | this module.HYDRAULIC SYSTEM CONTROL VALVE Single Stage Relief Valve Models Neutral Position mmm resunt Sermon 1 ses n ‘SYSTEMS OPERATION NOTE: The control valve shown is the one used in earlier models. The later valve isa three bolt mounting instead of four. The operation of the two valves is the same. 4 5 ‘CONTROL VALVE IN NEUTRAL POSITION Springs in the control valve keep valve spools (3), (4), (5) and the control levers in NEUTRAL position €). The hydraulic pump sends oil under pressure into the control valve through inlet (12). The oil flows around attachment spool (3), through passage (13) to tilt spool (4). It then flows around the tilt spool, through passage (14) and around lift spool (5). Oil then ‘g0es through outlet (15), through the oil filter, and into 7. Passage (rom check 10. Rolie valve piston. 11. Reliet valve pilot 8. Passage (to rod end of, ‘it eylinder). (tohead end of —_—_13. Passage (tilt spoo). 14, Passage (to lift spoo). 15, Outlet to tank. the hydraulic tank, ‘The mast stops and is held in any position when the tilt or lift contro! levers go back to the NEUTRAL, position. This is because the flow to and from the cylinders is stopped. In the NEUTRAL position, the lift spool will not let oil flow through passage (9) and the tilt spool will not let oil flow through passage (6) and (8). The attachment spool stops the flow of oil to the sideshifter cylinder.HYDRAULIC SYSTEM ‘SYSTEMS OPERATION 4 5 ‘CONTROL VALVE IN LIFT POSITION Luft Position 1 2 mmm rncssune On, Srevmon el 0, I i peveaxt 2 Ww ALTittback. 41. Chock valve. B. Tilt forward. 2. Passage (to outlet), cuit. 3. attachment spool D. Lower. {sideshiter). E. Neutral 4. Tit spool. 5. Lift spool 6. Passage (to head end of tit eylinaen). When the control lever is moved to lift position (C), Lift spool (5) is moved until flow from passage (14) to outlet (15) is stopped. This causes check valve (1) to ‘open (there is a check valve for each spool). The pres- sure oil from the hydraulic pump is now available at passage (7). The oil flows from passage (7), at the lift spool, to passage (9) and into the lift cylinder. The oil in the head end of the lift cylinder moves the cylinder rod up and the mast is raised Ifthe control lever is held in lift position (C) after the cylinder rod is extended completely, the flow of oil 7 sage (from chock 10, Rolie valve piston. valve) 11. Relist valve pilot {8 Passage (to rod end of plunger. ‘it cylinaen), 12. Inlet 8.Passage (to head end of 13, Passage (to tit spo). it eytinder. 14. Passage (to litt spool). 15. Outlet to tank. from passage (7) to the lift cylinder is stopped. This will let check valve (1) close. The oil will then flow through orifice (17). The pressure will move pilot plunger (11) and let the oil flow through passage (2), to outlet (15), and then through the filter to the tank. As the oil flows through orifice (17), the pressure will be lower in spring chamber (18) than on the inlet side of piston (10). The higher pressure on the inlet side of the piston causes compression of the spring, and causes the piston to move. This lets oil flow past the piston into passage (16). The oil returns to outlet (15). This action goes on until the control lever is returned toHYDRAULIC SYSTEM NEUTRAL position (E). When the control lever is moved to lower position (D), lift spool (5) moves until the oil in the cylinder can flow through passage (9), into passage (2), and to outlet as). Tilt Back Position When the control lever is moved to tilt back position (A), tilt spool (4) is moved until flow from passage (13) to passage (14) is stopped. This causes check valve (1) to open. The pressure oil from the hydraulic pump is, now available at passage (7). The oil flows from pas- sage (7) atthe tlt spool, to passage (8) and into the rod end of the tlt cylinder. The oil in the rod end of the tit, cylinder moves the eylinder rod into the housing and the mast is pulled back. The oil that is pushed from the head end of the cylinder flows through passage (6) and then to outlet (15). 1, x 3 0, ‘SYSTEMS OPERATION = 2 RELIEF VALVE 2.Passage. 10.Piston. 11. Pilot plunger. 16. Passage. 17. Orifice. 18. Spring chamber. 4 5 ‘ ewe, 2 Ww ‘CONTROL VALVE IN TILT BACK POSITION 1. Check valve. 2. Passage (to outlet) 3. Attachment spool (sidesniten). 4. Tit spool. 5. Lift spool 6. Passage (to head end of ‘ulteytinder. -|-[E ‘ +t ° « 8 7. Passage (rom check 410. Reliet valve piston. valve). 11. Relie valve pilot 8. Passage (1 rod end of ‘at eytindr). 9. Passage (to head end of Iteytingen). 14 Passage (to litt spoo)) 15. Outlet to tank.HYDRAULIC SYSTEM Tilt Forward Position 1, 2 x poms 2 a ‘SYSTEMS OPERATION CONTROL VALVE IN TILT FORWARD POSITION ATitback. 1.check valve. B. Tilt forward. 2. Passage (to outlet). Lit. 8. attachment spool D. Lower. (sideshiter- E. Neutral. 4. Tit spool. 5 Litt spool 6. Passage (to head end of ‘it eytinder. When the mast is tilted forward, past its center of gravity, the mast and load weight try to pull the tilt cylinder rods from the cylinder housings. With the engine at low rpm, the cylinder rods an be pulled from the housings faster than pump oil is sent to the head ends. This will cause an air pocket on the head end of the tilt cylinders (cavitation). Cavitation can also be the result of an engine stall, or the loss of pump pres- sure, The tlt spool is made (designed) to prevent this air pocket. When the operator moves the spool to tilt forward position (B), the spool again blocks the flow of oil from 7. Passage (from check 10. Reliet valve piston valve) 11. Reliet valve pilot 8, Passage (to rod end of plunger. tit eyinder sa.inlet 9.Passage (tohead end ot 1. Passage (to tit spoat. itt eylinden. 114, Passage (to litt spool). 15. Outlet to tank. passage (13) to passage (14). Then check valve (1) ‘opens. The pressure oil from the hydraulic pump can now flow into passage (7), around tilt spool (4), and into passage (6) 0 the head end of the tlt cylinders (see DETAIL E). At this moment, piston (18) has not yet started to move. Oil can not flow from the rod end of the tilt cylinder, through passage (8), and back to the outlet. The tilt cylinders now have a hydraulic lock (equal forces on all sides of an effective area that pre- vents any movement) and can not move. This condi- ion will not change until the oil under pressure (at tlt cylinder head ends) ftom pump can move piston (18).HYDRAULIC SYSTEM 0 ‘SYSTEMS OPERATION Zi Re DETAIL OF TILT SPOOL (FORWARD POSITION) 2. Passage (to outlet). 4. Tit spool 18.Passage (to piston. Oil in passage (6) flows through orifice (20) into passage (19) and it puts pressure on piston (18). When ‘the oil pressure becomes higher than the force of piston spring (21), piston (18) starts to move. Oil in spring. (21) chamber moves out through passage (22)as piston (18) causes a displacement. Piston (18) movement ‘opens passage (17) to passage (16) and oil in the rod end of the tilt cylinders flows through passage (8), (17), (16), (2) and to the outlet opening, Increased oil pres- sure in passage (19) will move piston (18) further until passage (22) is closed (See DETAIL F). At this time, the oil in spring (21) chamber is sealed and can not get, ‘out. A hydraulic lock is made and piston (18) move- ment is stopped. The valve is also fully open to com- plete a hydraulic tilt forward circuit. When there is a decrease in oil pressure in passage (6)(caused when the engine stalls, pump has a pressure Passage (to head end of tit cylinder). 7. Pas (from check valve). 8. Passage (to rod end of tit cylinder). 16. Passage. 17. Passat 20. Orifice. 21. Spring. 22. Passage. 23. Check loss, or cylinder rod is pulled from cylinder housing by weight of load), spring (21) pushes piston (18) to stop oil flow from passage (17) to passage (16). As piston (18) moves to the closed position, the oil pressure in spring (21) chamber is removed and a development of, a vacuum is made in the chamber. The oil pressure in passage (2) is higher than the oil pressure in the cham- ber, the higher oil pressure moves check valve ball (23) and oil flows into the space in the spring chamber as shown in DETAILE. The oil flow removes the vacuum which gives a smooth movement of piston (18). This stops the cylinder rods until the oil pressure in passage (6) and (19) is high enough to move piston (18) again. The piston will go back to the position shown in DETAIL F and the cylinder rods can move again. This action goes on to keep a positive control of the mast.HYDRAULIC SYSTEM Double Stage Relief Valve Models (High-Visibility) ‘SYSTEMS OPERATION 14 3B (B51962x1 DOUBLE STAGE RELIEF VALVE - HIGH PRESSURE RELIEF ‘Typical Example) 1 GB puwe on FLow (Es retunn ot To Tank 18 10 17 2, 18 " B % a 2 1.check vane. 10. Rele ave piston. 2. passage (owt) 11-Relet valve pit ahi epool pngers Passage (rom check 14. Passage (tt spo0), vue) NOTE: The control valve shown is a typical example for High-Visibility Models. On V60E-V90E models, the tilt spool moves into the valve body during lift. This makes the cavity above passage (8) empty and the cavity below passage (8) the pressure cavity where oil flows to the head end of the lift cylinder. The relief valve operation is the same as shown. This type of relief valve lets the pressure of the oil be the same between the lift and tilt systems. The attach- ‘ment system operates at a lower oil pressure to protect the lines and components. 10 25. Springs (pilot plunger 26. Piston. 2, Opening (elet valve) 28 Opening. High Pressure Reliet When control valve lever is held in the position to cause a completely extended lift cylinder, the flow of oil from passage (8) to the cylinder is stopped. This will ‘cause check valve (1) to close. Some oil will then flow ‘through orifice (17) against pilot plunger (11). At the same time, oil in passage (14) flows through opening (28) in the control valve housing through a tube to opening (27) to the relief valve. This oil moves piston (26) which causes a compression on pilot plunger spring (25).HYDRAULIC SYSTEM The oil that is against the inlet side of pilot plunger (11) increases in pressure. Pilot plunger (11) moves to let oil flow through passage (2) to outlet (15). As the oil flows through orifice (17), the pressure will be lower in spring chamber (18) than on the inlet side of piston (10). The higher pressure on the inlet side of the piston causes compression of the spring and causes the piston to move. This lets oil flow past the piston into passage (16). The oil returns to outlet (15). This action goes on until the control lever is returned to NEUTRAL position. Low Pressure Relief When the control valve lever is held in the position ‘SYSTEMS OPERATION for the sideshifter cylinder to be completely sideshift- ed right or left, the flow of oil is the same as in the High Pressure Relief, except the sideshifter valve spool stops the flow of oil to passage (14) and opening (28). Since oil cannot flow through opening (28) into open- ing (27), the only force on pilot plunger (11) is spring (25). The oil moves pilot plunger (11), ata much lower pressure, which allows oil to flow through passage (2) to outlet (15). As the oil flows through orifice (17), the pressure will be lower in spring chamber (18) than on the inlet side of piston (10). The higher pressure on the inlet side of the piston causes compression of the spring and causes the piston to move. This lets oil flow past the piston into passage (16). The oil returns to outlet (15). This action goes on until the control lever is returned to NEUTRAL position. ulHYDRAULIC SYSTEM LIFT CYLINDERS AND MAST High-Visibility Models Standard Litt ‘STANDARD LIFT MAST (Typical Example) ‘A. Free lift period ‘The pistons and rods of Standard Lift Cylinders (1) and (2) re moved up by oil under pressure and go back to their original position by gravity. ‘The combination of the single-acting hydraulic lift cylinders with other mechanical lifting components will operate as follows: ‘When the control valve lift lever is pulled back, the hydraulic oil under pressure, pushes against the pis- tons at the bottom of the lift cylinders. The inner mast crossbar, which is connected to the top of the cylinder rods, begins to move up. At this time, the carriage also starts to move up because it is connected to the inner ‘mast through the lift chains arrangement. From the start of the lift cycle until the top of the inner mast becomes equal to the top of the outer mast, the carriage and mast are in their FREE LIFT period (A). ‘The inner mast moves at a1 to 1 ratio and the carriage moves at a 2to | ratio with the rods of the lift cylinders, The inner mast and carriage will continue to move up until they are in the extended position. If the con- trol valve lift lever is held in the lift position with the mast fully extended, the pressure relief valve in the control valve will release the extra pressure until the lift lever is released. The oil flows through the relief valve and the control valve and into the hydraulic 12 ‘SYSTEMS OPERATION tank. The carriage and inner mast will be stationary at, this full height until the lift lever is moved to the lowered position. STANDARD LIFT MAST AT FULL EXTENSION Cypical Example) 1L.Lifteylinder. 2. Lit eytinder. When the lift lever is moved forward, the oil under pressure is released in the lift cylinders, Gravity and the weight of a load will cause the carriage to move down at ato | ratio and the inner mast to move down, at Ito | ratio with the rods of the lift cylinders until the carriage and mast are completely lowered. The flow control valve, located at the rear of the mast between the channels, permits 114 liter/min (30 U.S. gpm) of oil flow back through the control valve and into the hydraulic tank. The lift cylinders also have excess flow protectors that act as a lowering flow control valve if an oil line is broken between them and the flow control valve locat- ed near the base of the lift cylinders. The carriage and inner mast move up and down smoothly on load bearings (rollers). Stability of the ‘mast and carriage is controlled by shims behind the bearings (rollers).HYDRAULIC SYSTEM Full Free Triple Lift 92686x1 5 FULL FREE TRIPLE LIFT MAST (Typical Example) 3. Primary lift cylinder. 4. Crosshead. 5. Intermediate mast. 6. Inner mast. On trucks equipped with a Full Free Triple Lift Mast, the carriage can move the full length of inner ‘mast (6) before any increase in height of the inner mast. This is possible because primary lift cylinder (3) moves the carriage only. The carriage is lifted when the lift control lever is, pulled back. Oil under pressure flows from the control valve into the base of primary lift cylinder (3) and secondary lift cylinders (7). Since the primary lift cyl inder has the larger diameter for the oil to work against, the primary lift cylinder moves up first. The carriage moves up with the primary lift cylinder, with the assistance of crosshead (4) and the lift chains, until the carriage reaches the top of inner mast (6). From the start of the lft cycle until the carriage reaches the top of the inner mast, the mast isin its free lift period. During this lift cycle, the carriage moves up at a 2 to I ratio with the rod movement of primary lift cylinder (3). When the movement of the primary cylinder is com- pleted, pressure oil then works against the pistons in secondary cylinders (7). The movement of secondary cylinders (7) starts the movement of intermediate ‘mast (5) and inner mast (6) on the Full Free Triple lift models. The inner mast moves at a2 to I ratio and the intermediate mast moves ata 1 to | ratio with the rods of secondary cylinders (7) until they reach the top of their travel. ‘SYSTEMS OPERATION ozs05% FULL FREE TRIPLE LIFT MAST AT FREE LIFT (Cypical Example) 3. Primary lit cylinder. At this position, the pressure relief valve in the con- trol valve will open if the lift control lever is held back and release the extra pressure until the lift control lever is released. The oil flows through the relief valve and the control valve and then into the hydraulic tank. The carriage will be stationary at this full height until the lift control lever is moved to the lowered position. FULL FREE TRIPLE LIFT MAST IN THE EXTENDED POSITION (Typical Example) Primary it cylinder. 5.Intormediate mast. 6. Inne mast. 7. Secondary eylinder. 13,HYDRAULIC SYSTEM The oil under pressure in the primary and secondary cylinders is released when the lift control lever is moved forward. Gravity and the weight of a load will cause the cylinders to move back into their housings. The secondary cylinders move completely back into their housings before the primary cylinder starts to ‘move down. The flow control valve, located at the rear of the mast between the channels, permits 114 liter/min (30 U.S. gpm) of oil to flow back through the control valve and into the hydraulic tank. ‘The Full Free Triple Lift Mast also has excess flow protectors connected to the primary lift cylinder and in the inlet of the secondary lift cylinders. They will act as.a lowering flow control valve if an oil line is broken between any of them and the flow control valve. The carriage and inner mast move up and down smoothly on load bearings (rollers). Stability of the ‘mast and carriage is controlled by shims behind the bearings (rollers). All Other Models ‘Standard Lift ‘STANDARD LIFT CYLINDER 1. Standard litt cylinder. 2. Pull down rod. A. Free lit period. ‘The piston and rod of Standard Lift Cylinder (1) are moved up by oil under pressure and go back to their original position by gravity, ‘The combination of the single-acting Hydraulic Lift Cylinder with other mechanical lifting components will operate as follows: 14 ‘SYSTEMS OPERATION ‘When the control valve lift lever is pulled back, the hydraulic oil, under pressure, pushes against the piston at the bottom of the lift cylinder. Crosshead (3), which, is connected to the top of the cylinder rod, begins to move up. At this time, the carriage also starts to move ‘up because it is connected to the chains which move on the rollers of crosshead (3). From the start of the lift cycle until the crosshead makes contact with the top of the tie bar of the inner mast, the carriage is in its FREE. LIFT period (A). ‘Most of the mast components have not moved yet, while the carriage has moved at a 2 to I ratio with the rod of the lift cylinder. When the crosshead makes contact with the top of the tie bar, the inner mast starts to move with the same speed as the cylinder rod (at a 1 to I ratio), and the carriage still moves up at a2 to | ratio with the cylinder rod. ‘STANDARD LIFT CYLINDER AT FREE LIFT 3. Crosshead. This movement of the mast and carriage goes on until the stop screws of the carriage contact the top of the inner mast. The cylinder rod now goes up, which moves the carriage up (at a 2 to I ratio with cylinder rod). At the same time, the carriage pushes against the inner mast and moves it up. This movement of the ‘mast (at a 2 to 1 ratio with the cylinder rod) causes pull down rod (2) to be pulled part way out of the cylinder rod and completes the lift cycle. At this position, the pressure relief valve in the con- trol valve will release the extra pressure, until the lift lever is released. The oil flows through the relief valve and the control valve, filter and into the hydraulic tank. The carriage and inner mast will be stationary atHYDRAULIC SYSTEM this full height until the lift lever is moved to the lowered position. When the lift lever is moved forward, the oil under pressure is released in the lift cylinder. Gravity and the weight of a load will cause the carriage and the inner mast to move down at a 2 to 1 ratio with the lift cylinder rod until pull down rod (2) is retracted. The regulator in the base of the lift cylinder permits 87 liter/min (23 U.S. gpm) (for the V60E) or 132 liter/min (35 U.S. gpm) (for the V70E and V80E) of ol flow back through the control valve, filter and into the hydraulic tank. The carriage continues to move down at @ 2 to 1 ratio with the lift cylinder rod and the inner mast now moves down at a I to I ratio with the lift cylinder rod. This movement of the carriage and the inner mast goes on until the inner mast has lowered completely. Cross- head (3) and the carriage continue to be lowered until the forks are on the floor and pull down rod (2) is, extended, The carriage and inner masts move up and down smoothly on load rollers. Stability of the mast and carriage is held by the rollers that have shim adjustments. Full Free Litt FULL FREE LIFT CYLINDER 1. Full tree lift cylinder. 3. crosshead. (On lift trucks equipped with a Full Free Lift Mast, the carriage can move the length of the stationary mast before any increase in height of the inner mast. This is possible because the chains are connected to the hous- ing of a two stage lift cylinder. Full Free Lift Cylinder (1) has two cylinders one inside the other, primary cylinder and secondary cylinder. The carriage is lifted when the lift control lever is ‘SYSTEMS OPERATION pulled back. Oil under pressure, flows from the control valve into the base of the lift cylinder. Oil flows through the secondary cylinder and into the primary cylinder. Since the primary cylinder has the larger diameter for the oil to work against, the primary cylin- der moves up first. The carriage moves up with the primary cylinder with the assistance of crosshead (3) and the lift chains, until the carriage gets to the top of the stationary mast (full ree lift). During this lift cycle the carriage moves up at a 2 to | ratio with the move- ment of the primary cylinder. When movement of the primary cylinder is complet- ed, pressure oil then works against the secondary cylin- der. The movement of the secondary cylinder starts the movement of the inner mast. The inner mast and. the carriage move up ata I to | rato with the secondary cylinder until they reach the top of their travel. FULL FREE LIFT CYLINDER AFTER FREE LIFT PERIOD At this position, the pressure relief valve in the con- trol valve will open (ifthe lift control lever is held back) and release the extra pressure until the lift control lever is released. The oil flows through the relief valve and the control valve, to the filter, and then into the hy~ draulic tank. The carriage will be stationary at this full height until the lift control lever is moved to the low- ered position, ‘The oil under pressure in the primary and secondary cylinders is released when the lift control lever is moved forward. Gravity and the weight of a load will ‘cause the cylinders to move back into the housing. The secondary cylinder moves completely back into the housing before the primary cylinder starts to move down, The flow control valve in the base of the lift cylinder permits 87 liter/min (23 U.S. gpm) of oil to flow back through the control valve, filter, and into the hydraulic tank.‘STEERING SYSTEM ‘SYSTEMS OPERATION STEERING SYSTEM 9 70188x1 [STEERING SCHEMATIC 1. Oiltine. 2 Hydraulic tank. 3. illine. 4.0illine. 5. Steering gear. 6. Steering cylinder. 7. Oiline. 8. Ol line. 9. Steering pump. ‘The power steering system uses the oil from hydrau- lic tank (2). Hydraulic oil comes from tank (2) through line (3) to steering pump (9). Pressure oil flows through line (8) to steering gear (5). When the steering gear is in NEUTRAL position the oil goes through the steering gear, then through line (1), the filter and into hydraulic tank (2). During a right turn, pressure oil comes from the pump, into the steering gear and flows through line (7) to steering cylinder (6). The return oil flows through line (4) back through the steering gear, line (1), the filter and into hydraulic tank (2). During a left turn, pressure oil comes from the ump, into the steering gear and flows through line (4) to steering cylinder (6). The return oil flows through line (7) back through the steering gear, line (1), the filter and into hydraulic tank (2). STEERING PUMP Steering pump (9) is a vane type pump. The vanes are held in a rotor which is keyed to the drive shaft. The drive shaft is driven by a set of gears from the 16 engine. The vanes and rotor turn inside of a bore that is not round. The action of the vanes and rotor as they are turned in the bore causes the oil to be put under pressure, A flow control valve in the pump, keeps the steering action the same when there are changes in the engine speed. The pump relief valve controls the maximum pressure of the steering system. 701612 ‘STEERING PUMP ‘8. Steering pump.‘STEERING SYSTEM ‘STEERING CYLINDER Steering cylinder (6) gives power assistance through the use of pressure oil at either end of the cylinder. The steering cylinder is double ended and the body of the cylinder is mounted stationary to the steer axle. The rod assembly is connected to the steering link assemblies at both ends of the cylinder which allows, the cylinder to move the link assemblies. STEERING CYLINDER 6. Steering eytinde STEERING GEAR The steering gear is equipped with control valve section (2) and oil metering section (1). The two sec- tions are connected inside the unit, both hydraulically and mechanically. 1 2 STEERING GEAR 1.Metering section. 2. Control valve section. 3. Rotor group. 4. Commutator. 5. Manifold. 6. Drivelink. 7..Con- {ol valve spool. 8. Torsion bar. SYSTEMS OPERATION Control Valve Section Control valve section (2) of the steering gear has spool (7) that is operated mechanically. The spool is held in its center position by torsion bar (8). Torsion bar (8) is connected to the steering shaft and drive link (6). Drive link (6) has splines on each end. The splines on one end of the drive link are in the splines of control valve spool (7) and the splines on the other end are in rotor group (3) of metering section (1). ‘The purpose of the control valve section is to send oil to and from metering section (1) and to and from the steering cylinder. Control valve section (2) will also control the pressure of the oil sent to the cylinder. Metering Section The main parts of metering section (1) are commu- tator (4), manifold (5) and rotor group (3). The com- ‘mutator and rotor turn with the steer wheel, and can operate in either direction, The metering section controls (meters) the oil that ‘0s to the steering cylinder. It will keep the relation the same between the steering wheel and steer wheels, ‘The metering section is also used as a manually operat- ed pump to give manual steering if there is a pump failure. Rotor Group Operation ‘The rotor group and commutator are parts of the ‘metering section that control (meter) the oil that flows to the steering cylinder. Oil from the steering pump is. sent by the control valve spool to the commutator. The commutator then sends the oil to the rotor group. Rotor (3) and stator (11) are parts of the rotor group. ‘The rotor is turned by the torsion bar and drive link as. the steering wheel is turned. The rotor and stator are made so that when one lobe (12) is in a cavity (13), the ‘opposite lobe is on the part of the stator with the curve. As the rotor is turned, each lobe in sequence is moved out of its cavity to the top of the stator’s curve. This will push each opposite lobe, in sequence, into a cavity. As this action goes on, oil from the pump will always flow into three of the cavities, while oil flows out through three other cavities back to the control valve section. The other cavity will be closed. 17‘STEERING SYSTEM ‘SYSTEMS OPERATION [surety pressure (FROM powen PUMP) [Ei] erence on cro steenine evuinoem 92607%3, 3 W ROTOR GROUP OPERATION 3, Rotor. 9, Vanes. 10. Direction or rotor. 11. Stator. 12. Rotor lobes. 13, Oil cavity HYDRAULIC OIL FLOW Oil Flow in Neutral 1 2 3 4 ™ 7 HB surety pnessune (rom pump) : RETURN olL FLOW (TO TANK) n8s252x2 10 STEERING GEAR - NEUTRAL POSITION 1. Flow from steering pump. 2.No flow to cylinder. 3.No low trom cylinder. 4. Return oll 6. Commutator. 6.Drive link. 7. Rotor group. 8. Torsion bar. 9, Valve spool. 10. Bal When the steering wheel is in its center position or spool and returns to the hydraulic tank. This isan open when itis held in a turned position, the steering gearis center type. in NEUTRAL position. The hydraulic oil from the steering pump, comes into the steering gear and flows around spool (9). The oil flows past the land of the With the spool in this position, the oil flow is stopped (blocked) to or from the steering cylinder. This holds the steer wheels and keeps them in position, 18STEERING SYSTEM Oil Flow for Right Turn —— SYSTEMS OPERATION 3 A Sy aS f HB svrecvenessune erom pum) GBD ccruenon ro 000 \ [EBB] eveneo on tro evunoen) t ‘ag0sazx2 [STEERING GEAR - RIGHT TURN 1.01 supply flow. 2. Oil flow from steering cylinder. 3. flow to steering cylinder. 4. Ol return flow. 11. Direction of spool movement. 12. Direction of steering wh When the steering wheel is turned to the right, a ball ‘movesin the helical groove on the steering shaft. A ball, seat in the spool holds the ball soit can not move along, the inside diameter of the spool. Because the ball can not move inside the spool, the spool must move axially as the ball moves in the helical groove. The spool will move in the direction of arrow (11). ‘When the spool is moved, a passage is opened to let oil from the steering pump flow around the outside of the valve spool into the metering section. The oil flows through the metering section to commutator (5). The ‘urn. commutator sends the oil into rotor group (7). The ‘movement of the rotor will control (meter) the amount of oil that is sent from the metering section. The oil that flows from the metering section goes through the inside of the spool. Holes in the spool let the oil flow from the inside of the spool, into a passage in the body. The oil then goes from the steering gear to the head end of the steering cylinder. NOTE: The check valves are used to prevent internal leakage across the lands of the spool.‘STEERING SYSTEM Oil Flow for Left Turn ace apa RA Eo —_ SUPPLY pnEssunt GH cerumon sro " ‘9905202 STEERING GEAR - 41.0 supply flow. 2. Ol low to steering cylinder. 3. 11, Direction of spool movement. 12, Direction of steer When the steering wheel is turned to the left, the ball will move in the helical groove in the steering shaft. This will cause the spool to be moved in the direction of arrow (11). When the spool is moved, supply oil can flow through the holes in the spool. From the inside of the spool, the oil flows to commutator (5) and then to rotor group (7). As the rotor is turned, it will control 20 a oe METERED OIL (TO CYLINDER) ‘SYSTEMS OPERATION * — EE 1E (FROM PUMP) TANK) 12 LEFT TURN Oil flow from steering cylinder. 4, Oil return flow. ing whee! turn. (meter) the amount of oil that is sent from the metering, system. The oil that is sent from the rotor group flows from the commutator, through the metering section, to the outside of the valve spool. The spool then seftds the oil to the rod end of the steering cylinder.‘STEERING SYSTEM MANUAL OPERATION OF STEERING GEAR 2 ‘SYSTEMS OPERATION ‘as0saax2 " 13 \ HB oncrtow enom cnecx vatve Ea (METERED OIL (TO CYLINDER) MANUAL STEERING - RIGHT TURN 2. Olt low from st tion of steering whe turn, 13. Check valve If there is a steering pump failure, the steering gear ‘can be manually operated. The rotor group will work as a pump when the steering wheel is turned. The oil flow is almost the same as for power operation. The oil is not sent from the steering cylinder back to the tank. — " agosaix2 GB a rtow terom cuecx vatve) (Bi rerun on ro neox vaiver METERED OIL (TO CYLINDER) rng cylinder. 3. Ol flow to steering cylinder. 11. irection of spool movement. 12. Direc- The suction of the rotor group will open check valve (13) to let return oil from the cylinder go back to the inlet side of the rotor group. During power operation, supply pressure keeps the check valve closed. —? 3 (MANUAL STEERING - LEFT TURN 2.0llflow to steering cylinder. 3. Oil flow from steering oylinder. 11. Direction of spool movement. 12. Direc: tion of steering wheel turn 13. Check valve. aiBRAKE SYSTEM SYSTEMS OPERATION BRAKE SYSTEM MASTER CYLINDER AND WHEEL CYLINDERS 1 raat sos 8 iy s NEE END) ci MASTER CYLINDER AND WHEEL CYLINDER 1.Piston. 2. Spring. 5. Spring. 6.Piston. 7. Check valve. 8. Outlet. 10.Cupseal. 11. Wheel cylinders. 12. Wheeleylinderpis- tons. 13: Brake shoes. The master cylinder has two pistons (1) and (6) which push brake fluid into the brake lines. Reservoir (3) is in the top of the master cylinder to give fluid to the system. ‘When the brake pedal is first pushed, both pistons move into the master cylinder and push brake fluid through outlet (8) into the brake lines. When floating piston (6) seats on seal (9), the brake fluid that is pushed by piston (1) goes around cup seal (10), out through floating piston (6) and outlet (8). This action continues until the brake fluid pressure in piston (1) bore reaches the pressure that opens relief valve (4). The fluid being pushed by piston (1) now returns to reservoir (3). Cup seal (10) seals and the brake fluid inside piston (1) is pushed through piston (6) and out- let (8). The brake fluid pushed through outlet (8) goes through the brake lines to wheel cylinders (11), The brake fluid pressure in the wheel cylinders push wheel 22 cylinder pistons (12) out of the wheel cylinders and against the brake shoes. When the brake pedal is released, the brake shoe springs pull the brake shoes and push wheel cylinder pistons (12) back into wheel cylinders (11). The brake fluid is pushed from the wheel cylinders back through master cylinder outlet (8) and into the master cylinder. Springs (2) and (5) move pistons (1) and (6) respective- ly back to their original positions, Check valve (7) keeps a small amount of pressure on the brake lines and wheel cylinders (11). This small amount of pressure helps the wheel cylinder piston cup seal seat, which keeps air out of the brake system, WHEEL BRAKES [BRAKES WITH AUTOMATIC ADJUSTMENT (RIGHT SIDE SHOWN) 4.Upper adjustment link. 2. Cylinder assembly. 3. Pis- ton. 4. Secondary shoe. 5.Primary shoe. 6. Toggle Ver. 7.Support piste. 8. Lower adjustment link. 8. Ad- justment lever. "10. Adjustment screw. 11. Adjustment ‘pring, When the brake pedal is pushed down, the master cylinder sends brake fluid to wheel cylinder (2). Wheel cylinder pistons (3) are pushed out and move primary shoe (5) and secondary shoe (4). The brake shoes move until they make contact with the brake drum, When the brake action first starts, primary shoe (5) comes in contact with the brake drum as itis in rota- tion. This contact ofthe primary shoe puts some force ‘on secondary shoe (4) to help put it in position against the drum.BRAKE SYSTEM ‘Automatic Adjustment Brakes with automatic adjustment are adjusted on the reverse braking action. In this example the drum rotation is counterclockwise (in reverse) which causes a counterclockwise rotation of the brake shoes. Sec- ondary shoe (4) moves away from cylinder (2) that causes link (1) to move toggle lever (6) in a clockwise rotation. Link (8) is connected to the lower part of toggle lever (6) and to adjustment lever (9). By this connection, adjustment lever (9) is moved in a coun- terclockwise rotation, When the brakes are released at the end of a reverse brake application, adjustment spring (11) puts adjust- ‘ment lever (9) into its original position. If the brake shoe lining has worn enough to let lever (9) engage, a tooth on adjustment screw (10), lever (9) will rotate screw (10) to put the brakes into the correct adjustment. PARKING BRAKE ‘The disc-type parking brake is installed on the rear of the differential. The parking brake control lever location is at the cowl. ‘SYSTEMS OPERATION ‘When the parking brake lever is engaged, pucks (3), ‘one on each side of disc (1), contact disc (1) and stop any truck movement. (On power shift transmission models, the parking brake is also connected to the transmission linkage so that the transmission control levers can not be moved out of neutral when the parking brake is engaged. PARKING BRAKE (POWER SHIFT MODEL SHOWN) 1. Diee. 2. Brake assembly. 3. Puck. 23