SERVICE MANUAL

Machine: PLL PSD

Manual No: 119000

Edition 2003

8 Hydraulic system

Design and function ....................................................................................................... 8.3

General ................................................................................................................ 8.3
Lift ................................................................................................................................... 8.3
Lower .............................................................................................................................. 8.3
Hose rupture valve .............................................................................................. 8.3
Electric solenoid valve ......................................................................................... 8.3
General ........................................................................................................................... 8.3
Lifting function ................................................................................................................ 8.4
Lowering function ........................................................................................................... 8.4
Hydraulic diagram ................................................................................................ 8.4
Hydraulic diagram PLL ................................................................................................... 8.6
Hydraulic diagram PSD .................................................................................................. 8.8

Repair instructions ....................................................................................................... 8.10

Hydraulic system ............................................................................................... 8.10
General rules ................................................................................................................ 8.10
Installation .................................................................................................................... 8.10
Connections ................................................................................................................. 8.11
Start up ......................................................................................................................... 8.11
Hydraulic oil ........................................................................................................8.11
Properties of the hydraulic oil ....................................................................................... 8.11
Motor, hydraulic unit .......................................................................................... 8.12
When to replace the brushes ....................................................................................... 8.12
When to replace the brushes ....................................................................................... 8.12
Tips to prolong the life of the motor .............................................................................. 8.13
Hose rupture valve ............................................................................................ 8.14
Dismantling and assembling ........................................................................................ 8.14
Solenoid valve ................................................................................................... 8.15
General instructions when working with solenoid valve ............................................... 8.15
Solenoid valve, dismantling and assembling ................................................................ 8.16
Installation instruction for pipe couplings ........................................................... 8.16

Diagnostics and trouble shooting .............................................................................. 8.19

Symptom and Action ......................................................................................... 8.19

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8.2

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 Hydraulic system / Design and function / General 8.3

Edition 2003

8 Hydraulic system
Design and function

General

Lift
The driver operates a lift switch, which activates the lift motor by means of a contactor.
The motor drives the hydraulic pump, which pumps hydraulic oil to the lift cylinders.
In the hydraulic system there is a pressure limiting valve, which limits the maximum hy-
draulic oil pressure. The pressure of the hydraulic oil is built up when the cylinder goes
towards its end position. A pressure limiting valve opens when the maximum system
pressure is reached, which leads the oil from the pump back to the tank. The opening pres-
sure of the pressure limiting valve is set at the factory, so that the machine will be able to
do the work it is designed for.

Warning!
The pressure limiting valve must only be adjusted by authorised and trained per-
sonnel, since it is a safety part. All work with the hydraulic system should be carried
out in a pressureless state, and in a clean environment.

Lower
Between the hydraulic pump and the cylinder there is a check device, on certain trucks in
the form of a lowering brake valve, which regulates the lowering speed by checking the
return flow of hydraulic oil.

Hose rupture valve

Hose rupture valves, the purpose of which is to prevent the forks dropping down out of
control if, for example, a hydraulic hose ruptures, are fitted in most of the lift cylinders.
They are placed in front of the nipple connected for the supply of hydraulic oil.

Electric solenoid valve

General
The electric solenoid valve controls the lifting and lowering movements on the truck. The
solenoid valve is actuated electronically by the driver by means of a lift switch.

SM_PLL PSD_08_119000_2003.fm
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8.4 Hydraulic system / Design and function / Hydraulic diagram

Lifting function
The pump produces pressure to the lift cylinders through the open solenoid valve. If the
lift cylinders are obstructed, have an excessive load, or if there is a fault on the solenoid
valve so that it does not open, the oil will return to the tank through the pressure limiting
valve.

Lowering function
The solenoid valve opens to release the oil from the lift cylinders. When the fork carriage
presses down the lift cylinder the oil flow goes through the lowering valve,which regu-
lates the lowering speed.

Hydraulic diagram
Table 8.1 List of hydraulic diagrams for PLL/PSD

Description Reference Page

Hydraulic diagram PLL 8.6

Hydraulic diagram PSD 8.8

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Hydraulic system / Design and function / Hydraulic diagram 8.5

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8.6 Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram PLL

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Hydraulic system / Design and function / Hydraulic diagram 8.7

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8.8 Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram PSD

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Hydraulic system / Design and function / Hydraulic diagram 8.9

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8.10 Hydraulic system / Repair instructions / Hydraulic system

Repair instructions

Hydraulic system

General rules

Important!
Cleanliness during all work with hydraulic components is of the greatest impor-
tance for the operating safety and service-life of the system. The following should be
taken into consideration:

• Dirt particles must not get into components.

• Do not use cloths that release fibres or particles.
• Only use clean tools.
• Carefully clean tanks, pipes and hoses before installation.
• Welded or hot-bent pipes must be pickled (cleaned with acid bath) and washed
before they are built-in.
• The oil tank must be closed and provided with an efficient air filter to prevent dirt
contaminating the hydraulic system.
• Sealing compounds such as flax, cement or thread tape are not permitted.
• Take into consideration the specified operating data.
• Do not exceed permitted pressures and volume flows.
• Do not exceed or go below the specified temperature range.
• Pay attention to specified electrical voltages and power consumption.

Note!
All work with the hydraulic system should be carried in a pressureless state and in
a clean environment.

Installation
To prevent dirt and corrosion in the hydraulic system all hydraulic components should be
provided with plastic plugs in the connections before they are delivered. Only remove
these plugs just before the component is to be installed in the machine. Retaining screws
and connections must correspond with those on the drawing. Retaining screws should not
be tightened with a higher torque than what is specified on the drawing. If such informa-
tion is missing, the torque should not exceed what is specified in section 1.

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 Hydraulic system / Repair instructions / Hydraulic oil 8.11

Connections
Couplings should be fitted according to the torque specified in section 1. We recommend
couplings with elastic seals. Such couplings are necessary for control valves. Ring cou-
plings do not seal at the low torque generally applicable for proportional valves.
Connect pipes and hoses in accordance with the hydraulic diagram. Pay attention to the
connection designations. Do not use force, and avoid building-in tensions in pipes, etc.

Start up
Check that everything is connected in accordance with the hydraulic diagram. Set the
pressure limiting valves down to a very low pressure if they are not sealed. Start-up with
low pressure and volume flows.
Test the function and tightness of the system. Clean the system by allowing oil to pass
over the filter for a while, without loading the system (replace the filter insert at the rec-
ommended intervals). Check the oil level. Set the pressure and volume flows slowly to
the values they should have. Check the connected measuring equipment regularly, where
appropriate. Pay attention to the noise level since abnormal noise implies defects. Test
during variable loads that components are correctly fitted, and that the system is tight.
In the event of returning equipment to the manufacturer, protect polished surfaces from
damage and dirt by covering them with foil and protective paper. Fit plastic plugs in all
connections. Send the complete components, not loose parts.

Hydraulic oil

Properties of the hydraulic oil

The hydraulic oils recommended in this manual, section 1, have properties that promote
a long service-life and good functionality, and these are the oils that should be used in the
truck. The hydraulic oil used in Atlet trucks should comply with Atlet quality require-
ments:
• Smooth action.
• Long service-life.
• High viscosity index with wide range of temperature applications.
• Good low-temperature properties.
• High filterability.
• Good air and water separating capacity.
• Good wear protection.
• Good oxidation stability.
• Minimum foaming.
• Provide protection from rust and corrosion.
• Good adhesive capacity.

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8.12 Hydraulic system / Repair instructions / Motor, hydraulic unit

Motor, hydraulic unit

When the performance of a motor changes it should be inspected internally, immediately.
One of the most common reasons for trouble is some form of malfunction in the area of
the brushes.
The brushes can be worn out, or get stuck in the brush holders. In either case insufficient
electrical contact between the brushes and the commutator can lead to serious damage to
the commutator surface.

When to replace the brushes

• If a brush cannot move freely in its brush holder. To establish this the brush carrier
must be removed from the brush rigging. The force of the brush spring should then
push the brush as far out of the carrier as it is allowed by the cable.
• If a brush is at the end of its useful length. The length of the brushes should never
fall below 10 mm (the length of a new brush is 17 mm). As this is difficult to mea-
sure, there is an alternative suggestion. Measure the difference between the cable
wire and the end of the slot in the brush holder, which should be at least 1 mm.
Even if this difference is a little more than this, it is recommended to change the
brushes anyway since the remaining life of the brush may be less than the time to
the next inspection.

When to replace the brushes

The brushes cannot be replaced but are part of a kit, comprising the brush, brush holder
and spring. They can be installed by following these instructions.

1
3

2
4

Figure 8.1

1. Disconnect the supply voltage from the motor by removing the cables from the
motor terminals (pos. 1 figure 8.1).
2. Undo the through bolts from the rear of the motor (pos. 2 figure 8.1).
3. Remove the motor from the application.
4. Stand the motor on the drive end.
5. Release the terminal nuts (pos. 3 figure 8.1). In the case of an earth return motor
the earth connection on the rear bracket of the motor must also be disconnected
(pos. 4 figure 8.1).

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 Hydraulic system / Repair instructions / Motor, hydraulic unit 8.13

6. Remove the rear bracket (pos. 5 figure 8.1). The terminals should stay in position,
however, if they remain located in the rear casting then a slight tap should be
enough to release them.

brush ridging
spring
Step 1
brush holder
brush
commutator

Step 2
1

Step 3

Figure 8.2

7. Disconnect all four brushes by undoing the screws (pos. 1 figure 8.2) - step 1, then
push each brush kit towards the commutator - step 2. Now remove it from the
brush rigging - step 3. Replace the old brush kit with a new one by following the
above instructions in reverse. It is recommended that each brush is changed in turn
to avoid confusion. Make sure that each brush kit is replaced with the correct part
that has the brush cable on the same side. (Service kits consist of two matching
pairs of brush kits!)
8. Re-tighten the screw (pos. 1 figure 8.2) with a torque of 1.3-1.8 Nm.
9. Relocate the terminals into the slots in the rear bracket and replace it on the motor.
Ensure that a washer is in place between the armature and the bracket (pos. 2 figure
8.2) and that the bracket is positioned by a tooth and a slot respectively on the yoke
and bracket.
10. Insert the through bolts and remount the motor on the application and tighten the
bolts. The torque required is 4.8-6.8 Nm.
11. Re-torque the terminal nuts to 10-14 Nm (pos. 3 figure 8.1).
12. Reconnect the supply voltage.

Tips to prolong the life of the motor

• Rapid wear of the brushes and commutator is often caused by oil. The oil or grease
burns because of the sparks produced by the brushes leaving behind an abrasive
ash. In the event of any oil or grease being found in the motor, the cause of this
must be eliminated immediately.
• Never overload the motor. Brushes that have been badly overheated irreversibly
expand, and can stick in the brush holder.

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8.14 Hydraulic system / Repair instructions / Hose rupture valve

• The service-life of the brushes depends not only on the loading conditions, but also
on the degree of commutator wear. The commutator surface should have a smooth,
flat, grey/black appearance. A worn down commutator must be remachined (never
use abrasive paper, abrasive stones or files!) to a roughness of Ra=0.8-1.8µm and a
maximum run-out of 0.03 mm (with the armature supported at the bearing points).
For the service-life of the commutator it is better to turn it down little and often,
rather than infrequently but heavily. The minimum diameter of the commutator is
40.8 mm.
• The motor must never be subjected to full load immediately after the brushes have
been changed.
• Check the field and armature windings for signs of overloading (overheating),
dark-stained, brittle or burned insulation, and damage to the solder on the commu-
tator. Motors with this kind of damage are no longer serviceable.
• Whenever possible, remove any dust or powder from the inside of the motor with
compressed air.
• Dirty commutators should always be cleaned with a clean duster moistened with
gasoline (do not use cotton waste, this leaves fibres behind) and dry thoroughly
with compressed air.
• If a bearing bush looks as if it is out of oil (i.e. a lot of oil is seen on the armature
washer or brush bracket), then lubricate it with some bearing grease.

Hose rupture valve

Dismantling and assembling

1. Lower down the forks and relieve the pressure.
2. Place protective paper under the cylinder to be repaired.
3. Loosen the pipe or hose that goes to the cylinder, and plug it.
4. Remove the nipple placed in the cylinder.
5. Unscrew the hose rupture valve, pos. 1 figure 8.3, that is screwed into the cylinder.

Figure 8.3 Hose rupture valve

6. If a fault is suspected, check the length of the spring in relation to the table or data
sheet. Adjust, or fit a new valve.

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 Hydraulic system / Repair instructions / Solenoid valve 8.15

7. Fit the nipple, connect the pipes, and wipe clean.

8. Test run.

Figure 8.4 Hose rupture valve

Solenoid valve

General instructions when working with solenoid valve

1. Cleanliness

• Dirt particles must not get into components.

• Cloths must not shed fibres and particles.
• Tools must be clean.
• Tanks, pipes and hoses must be carefully cleaned before installation.
• Welded or hot-bent pipes must be pickled and cleaned before they
are built-in
• The oil tank must be closed and provided with an efficient breather
filter that prevent the penetration of dirt.

2. Sealing compound

• Hemp, cement or sealing tape is not permitted.

3. Operating data

• Do not exceed permitted pressures and volume flows.

• Do not go beyond the specified temperature range.
• Pay attention to specified electrical voltages and maximum power
consumption.

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8.16 Hydraulic system / Repair instructions / Installation instruction for pipe couplings

Solenoid valve, dismantling and assembling

1. Lower down the forks and relieve the pressure in the hydraulic system.
2. Place protective paper under the valve and release the electric cables to the valve.
3. Loosen all the oil pipes connected to the valve and plug them.
4. Loosen the valve from the truck, and lift it out.
5. When fitting, tighten the valve and then the oil pipes.
6. Adjust the pressure limiting valve to the rated weight in accordance with the
machine name-plate.
7. Seal the setting.

Installation instruction for pipe couplings

To achieve a safe and tight connection when installing pipe couplings in the hydraulic
system, the following points should be taken into consideration:
1. The pipe should be cut at right angles by means of a pipe cutter (see figure 8.5 and
8.6), after which it is deburred internally and externally, and carefully cleaned.

Important!
When using a pipe cutter the end of the pipe becomes skew, with the formation of
substantial burrs internally and externally. It is therefore important to straighten
the end of the pipe and remove the burrs, both internally and externally.

Figure 8.5 Cut at right-angles!

Figure 8.6 Pipe cutter

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 Hydraulic system / Repair instructions / Installation instruction for pipe couplings 8.17

2. Oil the thread and ring (not grease). Put the nut and ring over the pipe end as
shown in the figure. If the ring cannot be worked over the pipe end it must abso-
lutely not be enlarged. File down the pipe end instead.
3. Small pipe dimensions can be fitted directly in the coupling connected to the
machine part. Screw the nut by hand until it lies flush with ring, press the pipe
towards the shoulder in the coupling cone, and tighten the nut a ¾ turn.

Important!
The pipe must not follow round.

4. The ring will now have gripped the pipe, and no longer needs to be pressed against
the shoulder. Complete the fitting with an additional ¾ turn of the nut. A mark on
the nut simplifies following the specified torque, see figure8.7.

Figure 8.7 A mark on the nut simplifies the specified torque

5. Larger pipe dimensions and couplings in free pipes are preferably fitted by placing
the coupling body in a vice. The U-ring spanner should be 15 times the nut width
(can be extended with a piece of pipe). Otherwise fit according to point 3.
If several couplings of the same type are to be fitted, make sure that each pipe end
goes in the same coupling cone it was previously fitted in.
Fitting is simplified if the nut is loosened and oil is applied between the friction
surfaces.

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8.18 Hydraulic system / Repair instructions / Installation instruction for pipe couplings

6. After fitting, release the cap nut and check that the ring has pressed up a visible
swelling in the area in front of it, see figure 8.8. If not, give it another short turn. It
is of no importance whether the ring can still be turned.

Figure 8.8 A visible swelling should have formed after tightening

After a visible swelling has formed the nut should be fitted without extension of
the U-ring spanner, and without excessive force.

Important!
Refitting: After a visible swelling has formed the nut should be fitted without exten-
sion of the U-ring spanner, and without excessive force.

7. If the pipe is to be bent after a coupling, the straight pipe end should have a length
of at least 2 nut heads, H.
Long and heavily loaded pipes should be provided with pipe clips.

H
2H

Figure 8.9 Straight pipe length between bend and coupling

8. The final assembly should be done with at least 1 turn of the nut from the point
where it cannot be turned by hand.

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 Hydraulic system / Diagnostics and trouble shooting / Symptom and Action 8.19

Diagnostics and trouble shooting

Symptom and Action

A number of fault symptoms have been listed in the table below, with a number of pos-
sible faults and repair procedures. It is therefore possible for other faults to have occurred
in addition to the ones listed.
Table 8.2

Symptom Possible fault Action

The lift motor runs, but The lowering valve has 1. Close the valve.
the fork carriage does jammed and is open.
2. Adjust, or remove any dirt from
not lift.
the valve.

The lift motor runs, but The machine is overloaded. Lighten the load.
the fork carriage lifts
very slowly. The overflow valve is defec- Adjust the valve to the rated weight.
tive.

A foreign object has partially Take apart and clean.

blocked a hose, hydraulic
pipe or valve.

Hydraulic hose has been Rearrange the hose and clamp secure.
clenched.

The lift motor emits a The oil level is too low in the 1. Fill with hydraulic oil.
screeching noise just hydraulic tank. When the tank is almost full, try
before the fork carriage with 0.1 litre at at time to avoid
reaches the top. overfilling.
2. Find out the reason for the low
level, and rectify the fault.

The fork carriage will Valve does not open on Dismantle valve and clean.
not lower. return because of foreign
object in the system.

The hose rupture valve is Limit the lowering speed.

closed because the lowering
speed is too high.

The hose rupture valve is Replace the hose rupture valve.

closed because the spring in
the valve is defective.

The fork carriage low- Lowering valve or lowering 1. Run the lift motor for a maximum
ers too slowly. brake valve is dirty or defec- of 1 minute to see if the dirt
tive. releases.
2. If not, dismantle the valve and
clean, or replace defective parts.

The oil filter is blocked and Change filter.

dirty.

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8.20 Hydraulic system / Diagnostics and trouble shooting / Symptom and Action

Table 8.2

Symptom Possible fault Action

The fork carriage low- The lowering brake valve is Replace the lower brake valve.
ers too quickly. defective.

The lowering brake valve is Adjust the lowering brake valve.

incorrectly adjusted.

Hydraulic oil flows out Oil level too high. Reduce the oil level to correct level.
via the air filter.
The oil foams. Change the oil with oil that has the
correct properties.

Condensation water in oil Empty the tank of oil and fill with
tank. new hydraulic oil to correct level.

The fork carriage rocks Air in the hydraulic system. Bleed the system via the air cylin-
when lifting. ders.

The hydraulic oil has a The oil separators in the 1. Change the oil and filter.
bad smell, sulphur. hydraulic oil are ruined.
2. Flush the complete system with
Motor oil has been used and new hydraulic oil.
caused the hydraulic oil to
emulsify with water and then
rot.

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