+<'5267$7,&

75$160,66,21
H2.00-3.20XM (H40-65XM) [H177]

PART NO. 1458836 1300 SRM 717

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Hydrostatic Transmission Table of Contents

TABLE OF CONTENTS

General ................................................................................................................................................................. 1
Hydrostatic Components ................................................................................................................................. 1
Location........................................................................................................................................................ 1
Description................................................................................................................................................... 1
Theory of Operation......................................................................................................................................... 1
Features of the Hydrostatic Transmission ..................................................................................................... 6
Travel Control.............................................................................................................................................. 6
Dynamic Braking ........................................................................................................................................ 6
Inching ......................................................................................................................................................... 6
Throttle-Up (Option) ................................................................................................................................... 6
Hydraulic Circuit ............................................................................................................................................. 7
Loop.............................................................................................................................................................. 7
Charge.......................................................................................................................................................... 7
Control ......................................................................................................................................................... 7
Cooling ......................................................................................................................................................... 9
Repairs - General Information .......................................................................................................................... 11
Hydrostatic Transmission Fluid ................................................................................................................... 11
Transmission Fluid Change Intervals .......................................................................................................... 11
Operation Following Service or Repairs (Commissioning).......................................................................... 12
Towing the Lift Truck ........................................................................................................................................ 12
Hydrostatic Transmission Repair ..................................................................................................................... 13
Remove ........................................................................................................................................................... 13
Clean and Inspect .......................................................................................................................................... 15
Repairs ........................................................................................................................................................... 15
Install ............................................................................................................................................................. 18
Drive Axle Repair............................................................................................................................................... 19
Remove ........................................................................................................................................................... 19
Inspect ............................................................................................................................................................ 20
Install ............................................................................................................................................................. 21
MONOTROL® Pedal Repair .............................................................................................................................. 22
Remove and Disassemble .............................................................................................................................. 22
Assemble and Install ..................................................................................................................................... 22
Direction Control Lever Repair......................................................................................................................... 25
Remove and Disassemble .............................................................................................................................. 25
Assemble and Install ..................................................................................................................................... 25
Throttle-Up System Repair ............................................................................................................................... 26
Remove and Install........................................................................................................................................ 26
Switches ..................................................................................................................................................... 27
Module, Relays, and Fuse ......................................................................................................................... 28
Throttle Motor ........................................................................................................................................... 28
Inching/Brake Pedal Adjustment...................................................................................................................... 29
Variable Relief Valve Adjustment ..................................................................................................................... 30
Hydrostatic Pump Oil Pressure Check ............................................................................................................. 31
Loop and Pilot Pressure Checks ................................................................................................................... 31
Charge Pressure Check ................................................................................................................................. 32
Case Pressure Check ..................................................................................................................................... 32
Axle Leakage ...................................................................................................................................................... 32
Inching Adjustment ........................................................................................................................................... 32
Swashplate Positioning Cylinder Check and Adjustment............................................................................... 32
Throttle-Up System Checks .............................................................................................................................. 32
Check Switches .............................................................................................................................................. 32

Copyright © HYSTER COMPANY 2001 i

Table of Contents Hydrostatic Transmission

TABLE OF CONTENTS (Continued)

Check Throttle Motor .................................................................................................................................... 33
Check Control Module ................................................................................................................................... 33
Troubleshooting.................................................................................................................................................. 34
Torque Specifications ......................................................................................................................................... 42

This section is for the following models:

H2.00-3.20XM (H40-65XM) [H177]

ii HYSTER COMPANY 2001

1300 SRM 717
General
This section has a description and repair procedures
for the hydrostatic transmission.
NOTE: Some parts of the hydrostatic transmission
cannot be repaired by the user. A hydrostatic pump
or drive axle with damaged or worn parts must be
exchanged for a replacement assembly.
HYDROSTATIC COMPONENTS
Location
The lift truck with a hydrostatic transmission uses
many components in common with those equipped
with a powershift transmission. New and existing
components can be installed in different areas of the
lift truck. See Figure 1.
The power unit with a powershift transmission is a
transaxle design. With the transaxle, the drive axle
is mounted solid to the frame, while the engine is
supported by rubber mounts.
The power unit with a hydrostatic transmission is
supported independently from the frame on three
rubber mounts. The hydrostatic power unit consists
of the engine, flywheel housing, hydrostatic drive
pump, and hydrostatic drive axle. The hydrostatic
pump is connected to the drive axle through flexible
hydraulic hoses.
Description
An adapter plate, common with the powershift unit,
is mounted to the rear face of the engine block. See
Figure 2. The flywheel housing for the hydrostatic
unit is installed on the adapter plate. The flywheel
housing encloses the flywheel and the drive coupling
and also serves as a mount for the hydrostatic
drive pump. The hydrostatic drive pump is driven
through a nylon flange coupling that is installed on
the flywheel. A metal drive gear, which mounts to
the splines of the input shaft of the hydrostatic drive
pump, engages with the nylon flange coupling.
The fan end of the hydrostatic power unit is sup-
ported by rubber mounts in the same manner as the
General
powershift units. The forward end of the hydrostatic
power unit is supported by a rubber isolator installed
between the hydrostatic transmission bracket and
the drive axle bracket.
The bracket on the hydrostatic transmission also
serves as a mounting flange for the lift system hy-
draulic lift pump. The lift pump is driven at engine
speed by the shaft in the hydrostatic drive pump.
The basic function of the lift and steering systems
remains the same as with the powershift units. The
hydraulic plumbing for the lift system in the hydro-
static units is common with the powershift units ex-
cept for the lift pump hoses.
An aluminum radiator/oil cooler assembly, unique to
the hydrostatic transmission option, provides cooling
for the engine and transmission. The upper portion
of the assembly is the radiator for the engine. The
lower portion is an air-to-oil cooler that provides cool-
ing for the hydrostatic transmission. A fan, driven by
the engine, moves air through the radiator/oil cooler.
THEORY OF OPERATION
The hydrostatic transmission converts mechanical
power from the engine into hydraulic power through
the hydrostatic drive pump. See Figure 3. This hy-
draulic power is then transmitted to the hydrostatic
drive axle motors through high-pressure tubes and
hoses. The drive axle motors convert the hydraulic
power back into mechanical power, which rotates
the drive wheels.
The hydrostatic transmission operates as a closed-
loop circuit. In a closed-loop circuit, hydraulic fluid
moves from the drive pump to the axle motors and
back to the pump without returning fluid to the oil
tank.
The hydrostatic drive pump is a variable displace-
ment axial piston pump of swashplate design. The
drive axle motors are radial piston motors of fixed
displacement. The control for the speed and direc-
tion of the lift truck is the output flow from the hy-
drostatic drive pump.
1
General 1300 SRM 717

Figure 1. Hydrostatic Power Unit Arrangement

2
1300 SRM 717 General

Legend for Figure 1

1. HYDROSTATIC DRIVE AXLE 7. FLYWHEEL HOUSING
2. HYDROSTATIC SUCTION LINE 8. ADAPTER PLATE
3. LIFT PUMP 9. ENGINE
4. HYDROSTATIC TANK 10. FAN SHROUD
5. HYDROSTATIC DRIVE PUMP 11. RADIATOR/OIL COOLER
6. FLEXIBLE HOSES

1. ENGINE 6. HYDROSTATIC DRIVE PUMP

2. ADAPTER PLATE 7. TRANSMISSION BRACKET
3. NYLON FLANGE COUPLING 8. RUBBER MOUNTS
4. DRIVE GEAR 9. AXLE BRACKET
5. FLYWHEEL HOUSING 10. LIFT PUMP

Figure 2. Hydrostatic Transmission

3
General 1300 SRM 717

1. DRIVE AXLE MOTOR 7. TRANSMISSION CONTROL CARTRIDGE

2. DRIVE AXLE ASSEMBLY 8. ENGINE
3. DRIVE WHEEL 9. CHARGE (BOOST) PUMP
4. SWASHPLATE CONTROL PISTON 10. OIL TANK
5. DIRECTIONAL CONTROL SOLENOID 11. DRIVE PUMP
6. HYDROSTATIC DRIVE PUMP 12. HIGH-PRESSURE TUBES AND HOSES

Figure 3. Hydrostatic Transmission Schematic

The output flow from the hydrostatic drive pump is

determined by both the speed and displacement of
the pump. See Figure 4. The displacement is con-
trolled by the angle of the swashplate. (A swashplate
is a tilted plate in an axial piston pump.) The swash-
plate causes the pistons to reciprocate as the cylinder
barrel rotates.

With the swashplate in the NEUTRAL position,

the drive pump flow is zero, and the lift truck will
not move. Applying hydraulic control pressure to
the swashplate control piston moves the swashplate
from the NEUTRAL position. See Figure 3. At this
time, the pump begins to deliver oil to the drive axle,
and the lift truck will move. Full pump output is
produced when the swashplate is at its maximum
angle.
Figure 4. Hydrostatic Pump Rotary Group

4
1300 SRM 717 General

Legend for Figure 4 cylinder block that houses the radial pistons and a
distributor that directs fluid to and from the pistons.
1. DRIVE SHAFT 5. PISTON STROKE A stationary cam works with the piston assembly to
2. SWASHPLATE 6. CYLINDER
3. PISTON 7. CYLINDER transfer the hydraulic power to mechanical energy
4. PISTON AREA BARREL to rotate the drive wheels. Each cylinder block is
connected to the splines of an axle shaft. The outer
Swiveling the swashplate angle through the NEU- ends of the axle shafts are connected to the hubs of
TRAL position smoothly reverses the direction of oil the drive wheels. The drive wheels rotate as oil is
flow and the direction of travel of the lift truck. pumped through the individual motors.
Swashplate control pressure (pilot pressure) is gen- The differential action of the drive axle is achieved by
erated by flow from a charge pump. The charge pump parallel hydraulic flow through the motors. The total
is installed in the housing for the hydrostatic drive input flow equals the total output flow, but within
pump. The charge pump supplies oil to the hydro- the axle, the oil can be divided between the motors
static system for charging the closed loop, controlling as required to provide the differential action.
the swashplate, lubrication, and cooling.

The hydrostatic drive axle contains two hydraulic

motors. See Figure 5. Each motor contains a

1. AXLE SHAFT 5. SLIDE ROLLER

2. CYLINDER BLOCK 6. CAM
3. PISTON ASSEMBLY 7. DISTRIBUTOR
4. PISTON 8. AXLE HOUSING

Figure 5. Hydrostatic Drive Motor

5
General
FEATURES OF THE HYDROSTATIC
TRANSMISSION
The features of the hydrostatic transmission include
travel control, dynamic braking, inching, and the
throttle-up option.
Travel Control
The throttle pedal assembly includes a travel control
feature that is operated by a variable relief valve.
The variable relief valve is installed under the throt-
tle pedal. With the throttle pedal released, the vari-
able relief valve drains oil from the pilot circuit to the
tank, preventing movement of the swashplate and
lift truck travel. Depressing the throttle pedal re-
duces oil loss from the pilot circuit. This action in-
creases pilot pressure, strokes the swashplate, and
allows lift truck travel. This means that movement of
the lift truck is initiated by depression of the throttle
pedal and not just an increase in engine speed. The
throttle pedal operation is independent of the throt-
tle-up system.
Dynamic Braking
Dynamic braking refers to vehicle deceleration that
results when the operator releases the throttle pedal.
The deceleration is a product of the retarding forces
of the lift truck engine. (Dynamic braking with a
hydrostatic transmission is more abrupt than with
a powershift transmission. This is because the hy-
drostatic components change functions; the motors
become pumps and the pumps become motors.) Dy-
namic braking is the result of: (a) the drive axle mo-
tors "pumping" fluid to the hydrostatic drive pump,
(b) the "motoring" drive pump rotating the decelerat-
ing engine, and (c) the engine absorbing the energy
of the lift truck. There is no "coasting" as with some
types of transmission systems.
Inching
The inching function allows the lift truck to move
slowly while keeping a high engine speed for the mast
operations. A brake line from the master cylinder
is connected to the inching port on the hydrostatic
6
1300 SRM 717
pump. When the brakes are applied, the inching
valve reduces the pilot pressure. The stroke of the
hydrostatic drive pump (swashplate angle) decreases
in proportion to the brake pressure, and the travel
speed of the lift truck is reduced.
Throttle-Up (Option)
The throttle-up feature increases the speed of the en-
gine for lift, tilt, or auxiliary operations without the
operator depressing the throttle pedal. The feature
functions when the operator moves any of the hy-
draulic levers.
For the lift lever, the engine speed is increased up
to near full governed engine speed. For the tilt and
auxiliary levers, the engine speed is increased to ap-
proximately 1/2 of governed speed.
The throttle-up system senses hydraulic pressure
with a pressure switch at the hydraulic valve and
the lift lever position with a microswitch at the
lever linkage. The switches provide inputs to the
throttle-up control module. There is also an engine
rpm input to the control module. This input comes
from the distributor on LPG units and from the
alternator on diesel units.
The control module receives power from a relay that
is controlled by the key switch. A second relay on
the module circuit board is used by the module to
disable the throttle motor if a program malfunction
is found. Disabling the throttle motor prevents the
system from increasing engine speed. The module,
relays, and fuse are located on a bracket near the
engine air cleaner. See Figure 26.
The throttle motor moves the throttle linkage to in-
crease engine speed as needed to improve hydraulic
operation. This throttle motor is located at the throt-
tle pedal on diesel units and at the carburetor on LPG
units as shown in Figure 26. The throttle pedal op-
eration is independent of the throttle-up system.
NOTE: Some movement of a stationary lift truck
with throttle-up occurs until the system oil temper-
ature exceeds 10 C (50 F).
1300 SRM 717
HYDRAULIC CIRCUIT
There are four hydraulic subcircuits in the hydro-
static transmission. These are:
1. Loop
2. Charge
3. Control (pilot pressure)
4. Cooling
The hydraulic circuit for the hydrostatic transmis-
sion is separate from the lift, tilt, and auxiliary cir-
cuits of the lift truck.
Loop
The loop is a closed circuit, where oil is circulated
from the hydrostatic drive pump to the drive axle mo-
tors. See Figure 6. The loop flow and pressure pro-
vide the energy to move the lift truck.
When the lift truck is traveling in a forward direc-
tion, high-pressure oil leaves the pump at port A,
flows to and through the motors, and returns to the
pump at port B. When the lift truck is traveling in a
reverse direction, oil leaves the pump at port B and
returns at port A.
Charge
The charge circuit uses a gear pump to draw oil from
the hydrostatic oil tank through a screen and to push
the oil through a pump-mounted filter to the trans-
mission control cartridge. See Figure 6. If the filter
has a restriction due to contamination or cold oil, a
filter relief valve directs oil back to the inlet of the
charge pump. A restricted filter reduces the perfor-
mance of the hydrostatic transmission.
Maximum charge pressure is limited by the charge
relief valve. Some of the charge oil flows into the loop
through makeup check valves to replace closed-loop
leakage and prevent system cavitation. Excess
charge flow drains across the charge pump pressure
relief valve into the case of the hydrostatic drive
pump for lubrication and cooling of internal rotating
parts.
The oil tank for the hydrostatic transmission is
mounted to the inside of the left-hand frame plate.
The tank can be removed without removing the
engine or drive axle.
General
A dipstick and 10-micron breather are mounted to
the top of the tank. The dipstick is not intended to
be a daily check point because a low oil level sender
is installed in the side of the tank. In the case of
low oil level, the transmission warning light on the
instrument panel illuminates and the horn sounds.
An oil temperature warning switch is also mounted
in the tank. When the oil temperature reaches 93 C
(199 F), the transmission warning light on the in-
strument panel illuminates and the horn sounds.
Control
Charge pump flow (a function of lift truck engine
speed) passes through an orifice in the transmission
control cartridge. See Figure 6. The cartridge takes
the pressure differential across its orifice and ampli-
fies it into pilot pressure to control the swashplate
angle. Note that as engine speed increases, pilot
pressure increases.
As the engine speed decreases in response to heav-
ier drive loads, the control system will automatically
reduce the pump displacement to avoid lugging the
engine. The feedback control of pump displacement,
as a function of engine speed, results in the pump al-
ways being set to take advantage of the maximum
available engine torque. This feedback also provides
priority power to the hydraulic lift system when re-
quired.
Pilot pressure moves to the swashplate control pis-
ton through a solenoid directional valve. Electric
solenoids, actuated by the operator’s directional shift
control, direct the pilot pressure to move the swash-
plate in either a forward or reverse direction.
The hydrostatic transmission also incorporates
an inching function that is consistent with the
powershift transmission. The inching valve is hy-
draulically connected to the brake system through
port Z. When the lift truck brakes are applied, the
inching valve reduces the pilot pressure in pro-
portion to brake pressure, thus decreasing pump
displacement, oil flow, and movement of the vehicle.
7
General 1300 SRM 717

Figure 6. Hydrostatic Transmission Hydraulic Schematic

8
1300 SRM 717 General

Legend for Figure 6

A Forward Port PS Pilot Pressure Port

B Reverse Port G Charge Pressure Port
MA Forward Pressure Port Z Inching Brake Port
MB Reverse Pressure Port

1. INCHING VALVE 10. DRIVE AXLE MOTORS 19. SWASHPLATE CONTROL

2. DIRECTIONAL SOLENOID 11. OIL TANK PISTON
VALVE 12. SCREEN 20. HYDROSTATIC DRIVE PUMP
3. FILTER (10 MICRON) 13. PRESSURE OVERRIDE (POR) 21. CHECK VALVE - 2 bar (29 psi)
4. FILTER RELIEF VALVE RELIEF VALVE 22. CHECK VALVE - 0.14 bar
5. THROTTLE PEDAL 14. CHARGE RELIEF VALVE (2.04 psi)
6. VARIABLE RELIEF VALVE 15. TRANSMISSION CONTROL 23. OIL COOLER
7. HYDROSTATIC PUMP CARTRIDGE ORIFICE 24. DRIVE AXLE ASSEMBLY
ASSEMBLY 16. TRANSMISSION CONTROL
8. CHARGE PUMP CARTRIDGE
9. PRESSURE OVERRIDE (POR) 17. MAKEUP CHECK VALVE
SHUTTLE VALVE 18. CROSS-LINE RELIEF VALVE

The travel control feature of the hydrostatic trans-
mission drains pilot pressure to the tank through a
variable relief valve that is under the throttle pedal.
Only when the operator depresses the throttle pedal
does the variable relief valve close and make pilot
pressure available to increase pump displacement
and allow lift truck travel. Releasing the throttle
pedal automatically slows the lift truck using dy-
namic braking.
Maximum loop pressure is regulated by controlling
the pilot pressure with the pressure override (POR)
relief valve. Loop pressure activates the POR relief
valve and loop pressure communicates with the POR
relief valve through a shuttle valve.
The cross-line relief valves remove oil from the high-
pressure side of the loop and route it through check
valves into the low-pressure side of the loop. These
relief valves protect the loop during shock or over-
load.
NOTE: Cross-line relief valves in the closed-loop
circuit are normally adjusted approximately 10%
higher than the POR setting.
NOTE: To move a hydrostatic lift truck with engine
problems by towing or pushing, the cross-line relief
valves must be adjusted so that oil flows freely across
the relief valve and through the check valve from
the high-pressure side of the loop to the low-pressure
side. See REPAIRS for more information.
Cooling
There are three pathways in the cooling circuit (see
Figure 7):
1. Hydrostatic pump case oil is routed externally to
the oil cooler through a 0.14 bar (2.04 psi) valve.
An oil return line sends the cooled oil back to the
tank. Oil flowing from the case to the cooling cir-
cuit comes from flow over the charge pump relief
valve and leakage from the rotating axial piston
group. Oil flowing into the case surrounds the
rotating group to provide lubrication and absorb
heat from those parts.
2. Some case oil is forced by the 0.14 bar (2.04 psi)
check valve to flow through the hydrostatic axle.
This oil absorbs heat from the axle before passing
to the oil cooler. Leakage from the axle enters
this pathway.
3. During cold oil conditions, a 2 bar (29 psi) check
valve routes oil directly to the hydrostatic tank
and bypasses the oil cooler.

9
General 1300 SRM 717

Figure 7. Hydrostatic Transmission Arrangement

10
1300 SRM 717 Repairs - General Information

Legend for Figure 7

1. HYDROSTATIC DRIVE AXLE 11. HYDROSTATIC PUMP CASE DRAIN HOSE
2. HYDROSTATIC PUMP SUCTION LINE 12. HYDROSTATIC OIL COOLER TO TANK HOSE
3. AXLE COOLING SUPPLY HOSE 13. OIL COOLER BYPASS HOSE
4. AXLE COOLING DRAIN HOSE 14. DIPSTICK
5. HYDROSTATIC PUMP FILL PORT 15. TANK BREATHER
6. HYDROSTATIC PUMP 16. HYDROSTATIC OIL TANK
7. ENGINE 17. LOW OIL LEVEL SENDER
8. RADIATOR 18. OIL COOLER BYPASS CHECK VALVE (ITEM 21,
9. OIL COOLER FIGURE 6)
10. AXLE COOLING CHECK VALVE (ITEM 22, 19. OIL TEMPERATURE SENDER
FIGURE 6)

Repairs - General Information

Oil with a minimum purity grade of ISO 4406 18/15
CAUTION is required.
The reliable operation of a hydrostatic drive
system has the following requirements: Table 1. Hydrostatic Transmission Oil
• The fluid in the system must be kept clean.
The parts of the variable displacement pump ARAL Vitam HF 46
and the fixed displacement motors are ma- BP Bartran HV 46
chined to very fine tolerances. Dirt or par-
ticles in the fluid can damage the efficiency EXXON UNIVIS N 46
of the system or even destroy the pumps and FINA HYDRAN HV 46
motors.
• The minimum viscosity of the hydrostatic MOBIL Mobil DTE 15M
fluid must be carefully controlled. This is SHELL Shell Tellus Oil T 46
achieved by controlling the maximum tem-
perature of the fluid. The drive system has a
special radiator that controls the hydrostatic TRANSMISSION FLUID CHANGE
tank temperature. INTERVALS
• Maximum tank temperature is 92 C (198 F).
Maximum operating temperature in any part To avoid introducing contamination into the hydro-
of the closed loop is 100 C (212 F). Minimum static transmission tank, a daily fluid check at the
operating temperature is -25 C (-13 F). dipstick is not recommended. Check the oil level with
the dipstick every 250 hours. During daily operation,
Observe previous CAUTION before doing any re- the warning light for low oil level will warn the oper-
pairs. ator when the oil level is low.

HYDROSTATIC TRANSMISSION FLUID
Use one of the hydrostatic transmission fluids shown
in Table 1. More detailed information regarding the
selection of hydraulic fluids and their application
limits is found in the following REXROTH data
sheets:
NOTE: After each filter change, operate engine 5
minutes at idle speed before engaging the transmis-
sion and moving the lift truck.
Change the oil and filter on new units after the first
250 hours. The normal change interval for hydro-
static oil and filter is every 2000 hours or yearly.

Petroleum Oil RA90220

Biodegradable Fluids RA90221
Fire Resistant/Synthetic Fluids RA90223

11
Towing the Lift Truck
OPERATION FOLLOWING SERVICE OR
REPAIRS (COMMISSIONING)
WARNING
When starting a hydrostatic system after ser-
vice or repairs, all air must be removed from
the system. Air in the system can cause erosion
of the components.
To prevent damage to the hydrostatic pumps
and motors, completely fill the housing with
the correct oil. See Table 1.
1. Fill hydrostatic pump through fill port. See Fig-
ure 7. Fill drive axle motors through drain hose.
Connect hose. Make sure the oil level in the hy-
drostatic tank is correct.
2. Connect a tachometer to the engine (gasoline or
LPG) or use a special tachometer for the diesel
engine.
3. Connect pressure gauges to the test ports shown
in Figure 9. Connect a 550 bar (8000 psi) gauge
to check port MA (A) (forward loop pressure) for
the high-pressure checks of the loop circuit. Use
50 bar (800 psi) gauges for the charge and pilot
pressure checks.
4. Connect a 6 mm (0.236 in.) hose to port MB (B)
and put the other end in the fill tube of the oil
Towing the Lift Truck
CAUTION
On units with a hydrostatic transmission, the
high-pressure relief valve must be released (ro-
tated counterclockwise). After towing, return
the relief valve to its original position. See Fig-
ure 8.
1. The towed lift truck must have an operator.
2. Tow the lift truck slowly. The towing speed must
be less than 2 km/h (1.2 mph). The towing dis-
tance must be less than 1 km (0.6 mi).
3. Raise the carriage and forks approximately
30 cm (11.8 in.) from the surface. Install a chain
12
1300 SRM 717
tank. Put a 2 mm (0.787 in.) orifice in the fit-
ting that connects to port MB. This orifice re-
stricts the leakage flow to less than 11 liter/min
(3 gal/min). (This hose routes loop circuit flow
from the low-pressure side back to the tank and
helps force air from the closed loop during com-
missioning.)
5. Start the engine. Make sure the parking brake
is applied and the transmission is in NEUTRAL.
Run the engine at 1200 rpm for 8 seconds. Check
that the charge pressure is greater than 24 bar
after 8 seconds. Stop the engine.
6. Check the fluid level in the hydrostatic oil tank.
7. Use the following procedure to circulate the oil
through the transmission. Lift the right-hand
drive tire from the surface so that it is free to ro-
tate. Start the engine and shift the transmission
to FORWARD. Run the engine 2 to 3 minutes at
less than 1200 rpm. Stop the engine and lower
the right-hand tire. Lift the left-hand drive tire
from the surface so that it is free to rotate. Start
the engine and shift the transmission to FOR-
WARD. Run the engine 2 to 3 minutes at less
than 1200 rpm. Stop the engine and lower the
left-hand tire.
8. Check the fluid level in the hydrostatic oil tank.
to prevent the carriage and mast channels from
moving.
4. If another lift truck is used to tow the disabled
lift truck, that lift truck must have an equal or
larger capacity than the disabled lift truck. In-
stall approximately 1/2 of a capacity load on the
forks of the lift truck that is being used to tow the
disabled lift truck. This 1/2 capacity load will in-
crease the traction of the towing lift truck. Keep
the load as low as possible.
1300 SRM 717
5. Use a towing link made of steel that fastens to
the tow pins in the counterweights of both lift
trucks.
Hydrostatic Transmission Repair
REMOVE
WARNING
Always disconnect the cables at the battery.
Disconnect the cable at the negative terminal
first.
CAUTION
Do not disassemble or remove parts from the
hydrostatic pump. See Figure 9. The pump is
available only as a complete unit and cannot be
repaired.
1. Remove floorplates. Remove hood and side cov-
ers.
2. Disconnect hydraulic lines from variable relief
valve for travel control system. Disconnect throt-
tle bracket from crossmember. Move the assem-
bly to the side.
3. Disconnect brake lines from master cylinder.
Disconnect brake pedal bracket from crossmem-
ber.
CAUTION
Do not permit any dirt or other contamination
to enter the hydrostatic pump or hydraulic
Hydrostatic Transmission Repair
1. RELIEF VALVE
Figure 8. Hydrostatic Transmission Relief
Valves (Top View)
lines. Any dirt or particles in the fluid can
damage the system.
4. Disconnect hydraulic lines at hydraulic system
pump. Put plugs in open ports. Remove hy-
draulic pump.
5. Disconnect and remove all hydraulic lines at hy-
drostatic pump. Put plugs in fittings and open
ports.
6. Disconnect wires and wiring harnesses at hydro-
static pump.
7. Remove capscrew from pump mount. See Fig-
ure 10.
CAUTION
When raising the engine, make sure the fan
does not hit the radiator.
8. Raise the engine approximately 12 mm (0.5 in.)
and put a block under the flywheel housing as a
support.
13
Hydrostatic Transmission Repair 1300 SRM 717

Figure 9. Hydrostatic Pump

14
1300 SRM 717
Legend for Figure 9
Check Port
A High-Pressure Check Port MA
B High-Pressure Check Port MB
C Charge Pressure Port
D Pilot Pressure Port
A. TOP VIEW
B. VIEW FROM LEFT SIDE
C. VIEW FROM FLYWHEEL OF ENGINE
1. CHARGE PRESSURE RELIEF VALVE
2. HIGH-PRESSURE RELIEF VALVE "A"
3. OIL FILL PORT
4. INPUT SHAFT (TO ENGINE FLYWHEEL)
5. STROKE LIMITER FOR SWASHPLATE
6. POSITIONING CYLINDER FOR SWASHPLATE
7. MECHANICAL CENTER ADJUSTMENT
8. INCHING VALVE
9. DIRECTION SOLENOID
WARNING
The hydrostatic pump can weigh as much as
50 kg (110 lb). Make sure that any lifting device
has enough capacity to lift the weight.
9. Connect a lifting device to the hydrostatic pump.
Remove capscrews that hold pump to flywheel
housing. Use the lifting device to carefully re-
move pump. Make sure all hoses, wires, and ca-
bles are disconnected from pump, then lift pump
from frame.
10. Remove pump mount by removing center ring
and socket capscrews.
11. Remove the drive gear from shaft of hydrostatic
pump. See Figure 11. Loosen capscrew and pull
drive gear from shaft. Inspect drive gear and
flange coupling. Make sure they are not dam-
aged.
CLEAN AND INSPECT
Clean the outside of the hydrostatic pump.
REPAIRS
NOTE: If there was internal damage to the hydro-
static pump or drive axle motors, the hydraulic lines,
oil cooler, and oil tank must be flushed to remove all
contaminants.
Hydrostatic Transmission Repair
Thread Size
7/16-20 UNF
7/16-20 UNF
3/4-16 UNF
9/16-18 UNF
10. ELECTRICAL CONNECTION FOR FORWARD
AND REVERSE SOLENOIDS
11. HIGH-PRESSURE RELIEF VALVE "B"
12. TRANSMISSION CONTROL PRESSURE
CARTRIDGE
13. FILTER
14. PRESSURE OVERRIDE (POR) RELIEF VALVE
15. HIGH-PRESSURE PORT "B" TO DRIVE AXLE
MOTORS
Repairs to the hydrostatic drive pump are limited to
replacing the charge pump and direction solenoids.
The inching valve assembly can be serviced.
1. Replace the charge pump as follows:
a. Remove hydraulic system pump from hydro-
static pump.
b. Raise engine approximately 12 mm (0.5 in.)
and put a block under flywheel housing as a
support. Remove pump mount by removing
center ring and socket capscrews. See Fig-
ure 10.
c. Remove capscrews for charge pump. Remove
charge pump. See Figure 12.
d. Install new charge pump, port plate, and
O-rings. Tighten capscrews for charge pump.
e. Install center ring and O-ring in mount for
hydrostatic pump. See Figure 10. Install hy-
draulic pump on mount. Connect hydraulic
lines.
f. Follow the remaining Installation proce-
dures for the hydrostatic pump.
15
Hydrostatic Transmission Repair 1300 SRM 717

1. DRIVE AXLE 8. PUMP MOUNT O-RING

2. AXLE BRACKET 9. BLEED PORT OF INCHING VALVE
3. WASHER 10. HYDROSTATIC PUMP
4. PUMP MOUNT 11. INCHING SCREW
5. SOCKET CAPSCREW 12. RUBBER MOUNT
6. CENTER RING 13. CAPSCREW
7. CENTER RING O-RING

Figure 10. Hydrostatic Pump Mounting

2. The forward and reverse solenoids are located on
the left side of the hydrostatic pump. The top so-
lenoid is reverse and the bottom solenoid is for-
ward. Replace the direction solenoids as follows:
a. Remove socket head capscrews that hold so-
lenoid to valve body. See Figure 13. Discon-
nect wiring harness and remove solenoid. Be
careful when removing solenoid at the bot-
tom of pump as the spring and retainer can
fall from the valve.
b. Use new O-rings when installing solenoid.
Tighten capscrews.
c. Connect wiring harness.

16
1300 SRM 717 Hydrostatic Transmission Repair

1. WIRING HARNESS 3. SOLENOID

CONNECTOR 4. O-RING
1. PUMP SHAFT 4. NYLON FLANGE 2. VALVE BODY
2. DRIVE GEAR COUPLING
3. CAPSCREW 5. FLYWHEEL Figure 13. Direction Solenoids
Figure 11. Hydrostatic Pump Coupling 3. The inching valve is located on the solenoid side
of the pump between the positioning cylinder
and the directional control. Service the inching
valve when brake or hydraulic fluid drips from
the drain holes in the inching valve. The drain
holes are hard to see. Look for drips off the
bottom of the hydrostatic pump.

a. Service the inching spring and spool as fol-

lows. See Figure 14. (Inching spool must
be removed to service the brake pressure pis-
ton.)

(1) Remove lower cover plate. Make sure to

measure dimension X of the adjustment
screw if screw will be removed from the
cover plate.

(2) With the cover plate removed, the inch-

ing spring and retainers will drop from
the pump. The inching spool can now
be removed using a magnet.

(3) Check the spool for scratches and dents

and make sure that it slides smoothly
in its bore.
1. HYDROSTATIC 2. CHARGE PUMP
PUMP 3. O-RING (4) Assemble using the reverse procedure
and set the adjustment screw to dimen-
Figure 12. Charge Pump sion X if it was removed.

17
Hydrostatic Transmission Repair 1300 SRM 717

1. BLEED SCREW - BRAKE FLUID 12. LOCK NUT

2. BRAKE PRESSURE PORT 13. ADJUSTING SCREW
3. BRAKE PRESSURE PISTON 14. COVER PLATE
4. PISTON SEAL 15. O-RING
5. TRANSFER PIN 16. LOCATION SPACER
6. TRANSITION DISC 17. TRANSFER BUSHING I.D. O-RING
7. INCHING VALVE BODY 18. TRANSFER BUSHING O.D. O-RING
8. INCHING SPOOL 19. FLUID DRAIN HOLES
9. INCHING SPRING RETAINER 20. BRAKE PRESSURE PISTON SECTION
10. INCHING SPRING 21. SOCKET CAPSCREW
11. SOCKET CAPSCREW

Figure 14. Inching Valve Assembly

b. Service the brake pressure piston as follows (7) Install brake pressure piston section, if
(see Figure 14): required.

(1) Disconnect brake line.
(2) Remove socket capscrews and lift piston
section up off the pump.
(3) Examine the brake pressure piston for
brake fluid leakage past the brake pis-
ton seal.
(4) Remove air bleed fitting when replacing
seal for brake pressure piston.
(5) A bronze transition disc and transfer
pin will stay with the main body of the
valve. Remove by pushing up through
the inching spool bore from the bottom
of the pump. Do NOT damage the inch-
ing spool bore.
(6) Replace both O-rings for transition disc.
Replace transfer pin.
(8) Assemble brake pressure piston using
the reverse procedure.
INSTALL
1. Install drive gear against shoulder of pump
shaft. See Figure 11. Use Loctite 242 on the
threads of the capscrew. Install capscrew and
tighten it to 44 N•m (32.5 lbf ft).
2. Install pump mount, using a new O-ring. See
Figure 10. Tighten capscrews to 19 N•m
(168 lbf in).
WARNING
The hydrostatic pump weighs approximately
50 kg (110 lb). Make sure that any lifting de-
vice has enough capacity to lift the weight.
3. Put the pump in position on flywheel hous-
ing. Carefully align drive gear with splines in

18
1300 SRM 717
coupling on flywheel. See Figure 11. Install
capscrews that hold pump to flywheel housing.
Tighten capscrews to 225 N•m (166 lbf ft).
4. Install capscrew at the mount on drive axle.
Tighten capscrew to 66 N•m (49 lbf ft).
5. Connect all lines at hydrostatic pump. Tighten
capscrews that hold hydraulic lines from drive
axle and oil tank to pump to 70 N•m (52 lbf ft).
Connect hydraulic line to tank.
6. Install center ring and O-ring in mount for hy-
draulic pump. Install hydraulic pump on mount.
Connect hydraulic lines.
Drive Axle Repair
REMOVE
WARNING
Always disconnect the cables at the battery.
Disconnect the cable at the negative terminal
first.
WARNING
When putting the lift truck on blocks, make
sure the surface is solid, even, and level. Any
blocks used to support the lift truck must be
solid, one-piece units.
CAUTION
Do not disassemble any parts of the drive axle.
The drive axle is available only as a complete
unit and cannot be repaired.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck. See Figure 15.
2. Raise the lift truck and put blocks under the
frame so that the drive wheels just touch the
floor. Put blocks under the counterweight for
stability.
3. Remove floor plates.
4. Remove mast assembly as described in the sec-
tion Mast 4000 SRM 522.
Drive Axle Repair
7. Install brackets for throttle and brake pedals on
crossmember. Connect brake lines. Connect hy-
draulic lines to variable relief valve for travel
control system.
8. Connect wires and wiring harness at hydrostatic
pump.
9. Remove air from brake system as described in
the section Brake System 1800 SRM 506. Re-
member that air must be removed from the bleed
port of the inching valve (Figure 10).
10. Fill pump with oil at fill port. See Figure 7. Fol-
low the Operation Following Service or Repairs
(Commissioning) procedures.
WARNING
Deflate the tires completely before removing
them from the lift truck. Air pressure in the
tires can cause the tire and rim parts to ex-
plode, causing serious injury or death.
Never loosen the nuts that hold the inner and
outer wheel halves together when there is air
pressure in the tire.
5. Remove wheels. Remove capscrews that hold
axle shafts to brake drums. Remove axle shafts.
6. Disconnect hydraulic lines at axle housing. Put
plugs in openings of lines and axle ports.
7. Remove clamp that supports supply tube from
axle mount.
8. Bend lock plate and remove nut from spindle. Re-
move washer and bearing cone. Slide hub/brake
drum from spindle. If the assembly cannot be
removed easily, loosen the brake shoes. Put a
screwdriver through the hole in the back plate
to turn adjuster wheel and loosen brake shoes.
Pull actuator away from adjuster wheel while ad-
juster wheel is turned up.
9. Disconnect brake lines to wheel cylinders. Dis-
connect parking brake cables at parking brake
lever. Loosen cable clamps for parking brake ca-
bles.
10. Put a block under hydrostatic pump. Remove
capscrew from mount between hydrostatic pump
and axle housing. See Figure 10.
19
Drive Axle Repair 1300 SRM 717

1. AXLE SHAFT 7. BEARING CUP 13. AXLE HOUSING FILL PORT

2. WHEEL 8. DOWEL PIN 14. AXLE MOUNT
3. NUT 9. BRAKE DRUM/HUB 15. AXLE MOUNT CAPSCREW
4. LOCKWASHER 10. SEAL 16. AXLE MOUNT TO AXLE
5. KEY WASHER 11. DRIVE AXLE ASSEMBLY HOUSING CAPSCREW
6. BEARING CONE 12. HYDROSTATIC MOTOR 17. BRAKE ASSEMBLY

Figure 15. Drive Axle

11. Remove capscrews that hold axle housing
mounts to frame of lift truck. See Figure 15.
Remove drive axle assembly from frame.
12. Disassemble brake assembly as described in the
section Brake System 1800 SRM 506. Remove
back plates from the mounts for axle housing.
13. Remove capscrews that hold left-hand mount to
axle housing. Remove mounts from axle housing.
INSPECT
Inspect bearings and seals for damage. The splines
for the axle shafts must not be damaged.

20
1300 SRM 717 Drive Axle Repair

INSTALL torque must be less than 25 N•m (221 lbf in).

Tighten nut to 35 N•m (310 lbf in) or until the
1. Lubricate spindles with Never Seez® and slide first alignment position after 35 N•m (310 lbf in).
mounts over spindles. See Figure 15 and Fig- Bend a lock tab over the nut. See Figure 18.
ure 16. Install mounts on frame. Install cap-
screws that hold left-hand mount to axle hous-
ing. Tighten capscrews to 145 N•m (107 lbf ft).

Figure 17. Seal Installation

Figure 16. Spindle Lubrication

2. Install axle housing to frame. Install capscrews

that hold mounts to frame. Tighten capscrews to
320 N•m (236 lbf ft).

3. Install capscrew and mount between hydrostatic

pump and drive axle. See Figure 10. Tighten
capscrew to 66 N•m (49 lbf ft).

4. Connect hydraulic lines between hydrostatic

pump and drive axle. Tighten capscrews that
hold hydraulic lines from pump to drive axle to
70 N•m (52 lbf ft).

5. Assemble brake assembly to mount for axle hous-

ing as described in the section Brake System
1800 SRM 506.
6. Install new grease seals in hub. See Figure 17.
Install outer seal with the lip toward the outer
bearing. Install inner bearing and seal. See Fig-
ure 17. Put wheel bearing grease in the bearing
that is between the seals.
Figure 18. Lockwasher Installation
9. Adjust clearance of brake shoes as described in
the section Brake System 1800 SRM 506.
10. Put sealant on flange of axle shaft. Install axle
shafts and capscrews. Tighten capscrews to
98 N•m (72 lbf ft).

7. Install hub/brake drum assembly on axle hous- 11. Install wheels and nuts. Tighten nuts for the
ing. wheels to 610 to 680 N•m (450 to 502 lbf ft).

8. Install outer bearing cone on axle housing. In- 12. Connect brake lines and parking brake cables.
stall key washer and lockwasher. Install nut. Remove air from brake system as described in
Tighten nut to 205 N•m (151 lbf ft) while rotat-
ing hub. Loosen nut until hub turns freely. The

21
MONOTROL® Pedal Repair 1300 SRM 717

the section Brake System 1800 SRM 506. Re-
member that air must be removed from the inch-
ing valve (Figure 10).
13. The drive axle assembly has three separate fluid
chambers. The center chamber includes the hy-
drostatic motors and is filled with hydrostatic
transmission fluid. Fill this chamber at the cen-
ter top fitting where cooling oil leaves the axle,
item A, Figure 7. The other two chambers have
the lubricant for the axle shafts and bearings.
Fill these chambers with 85W-140 lubricant at
the fill plugs (Figure 15) at the front of each hous-
ing. Fill the chambers until the oil level is even
with the bottom of the fill plugs.
14. Install the mast as described in the section Mast
4000 SRM 522.

MONOTROL® Pedal Repair

REMOVE AND DISASSEMBLE a. Put pedal assembly in a vise. Use a dial in-
dicator to measure movement of pedal pad.
1. Disconnect wires at transmission. Remove cap-
screw that holds pedal to bracket, then remove
pedal. See Figure 19 and Figure 20.

2. Remove straps that hold wires to pedal. Loosen

setscrews in the pedal pad three to four turns and
remove pivot pin. Remove pedal pad and spring.

3. Remove retainer for wires. Loosen screws for

switches, then remove switches and wires.

4. If necessary, remove lock nuts for magnets, then

remove magnets from pedal frame. Make sure
screws are tight in magnets. Use a thread-lock-
ing compound on screws if they are loose in mag-
nets.

ASSEMBLE AND INSTALL

1. Install switches and wires in pedal pad. Align
surface of switches with machined surface of
mount in pedal pad. The switches must be even
with or below the alignment surface as shown in
Figure 21. Install retainer for wires.

NOTE: These sealed switches can only be repaired as

an assembly.

2. Put wires through hole in pedal frame. Install

1. PEDAL PAD 5. SPRING
spring and pedal pad on pedal frame. Install 2. PEDAL FRAME 6. MAGNET PLATE
pivot pin. Apply a thread-locking compound to 3. MAGNET 7. SWITCH
setscrews. Install and tighten setscrews. Use 4. PIVOT SHAFT
straps to hold wires to pedal frame.
Figure 19. MONOTROL Pedal
3. Do the following procedure to check and adjust
the pedal assembly (see Figure 22):

22
1300 SRM 717 MONOTROL® Pedal Repair

1. THROTTLE PEDAL 7. VARIABLE RELIEF VALVE

2. MONOTROL PEDAL 8. RELIEF VALVE LINK
3. THROTTLE CRANK 9. RETURN SPRINGS
4. LINK 10. TO TRANSMISSION OIL TANK
5. PEDAL STOP 11. TO HYDROSTATIC PUMP
6. PEDAL BRACKET

Figure 20. Throttle Pedal Arrangement

b. Push the REVERSE side of the pedal. Put

the dial indicator on the REVERSE side of
the pedal pad as shown. Loosen lock nut and
rotate screw for magnet counterclockwise
until it stops. Set dial indicator to zero.
Rotate screw for magnet clockwise until
gauge needle moves 0.25 mm (0.0008 in.)
from zero. This adjustment makes sure the
magnet is in contact with the plate in the
pedal pad. Rotate screw for magnet counter-
clockwise until gauge needle indicates zero.
Rotate screw for magnet clockwise until
gauge needle indicates0.05 mm (0.0020 in.) 1. PEDAL PAD
movement. Tighten lock nut to 5.2 N•m 2. SWITCH
(46 lbf in) without changing the adjustment. 3. ALIGNMENT SURFACE
4. SURFACE OF SWITCH

Figure 21. Switches Alignment Check

23
MONOTROL® Pedal Repair
A. FORWARD
1. LOCK NUT
2. MAGNET
3. PLATE
Figure 22. MONOTROL Pedal Adjustment
c. Push on the FORWARD side of the pedal.
Put the dial indicator on the FORWARD
side of the pedal pad as shown. Loosen lock
nut and rotate screw for magnet counter-
clockwise until it stops. Set dial indicator to
zero. Rotate screw for magnet clockwise un-
til gauge needle moves 0.25 mm (0.0008 in.)
from zero. This adjustment makes sure the
magnet is in contact with the plate in the
pedal pad. Rotate screw for magnet counter-
clockwise until gauge needle indicates zero.
Rotate screw for magnet clockwise until
gauge needle indicates 0.05 mm (0.0020 in.)
movement. Tighten lock nut to 5.2 N•m
(46 lbf in) without changing the adjustment.
d. Use an ohmmeter to check the operation of
the switches. When the FORWARD side of
the pedal is depressed, there must be a com-
plete circuit between the red (battery) and
black (forward solenoid) wires. When the
REVERSE side of the pedal is depressed,
there must be a complete circuit between the
red (battery) and yellow (reverse solenoid)
wires.
e. Push on the FORWARD side of the pedal.
Put the dial indicator on the FORWARD
side of the pedal pad as shown. Connect
24
1300 SRM 717
B. REVERSE
4. DIAL INDICATOR
5. PEDAL FRAME
6. PEDAL PAD
an ohmmeter between the red and black
wires. Check that there is a complete circuit
between the wires. Push on the REVERSE
side of the pedal. The pedal must move 1 mm
(0.039 in.) minimum from the FORWARD
position before the circuit is disconnected.
4. Test the strength of the magnets as follows (see
Figure 23):
NOTE: It is important for the correct operation of the
MONOTROL pedal that the magnets have the cor-
rect strength.
a. Put pedal assembly in a vise. Use a spring
scale to change pedal from the FORWARD
and REVERSE positions as shown in Fig-
ure 23.
b. When pushing on the spring scale, it must
take 13.3 to 31.1 N (0.225 to 71 lbf) to change
from FORWARD to REVERSE and RE-
VERSE to FORWARD positions. If the
force is not within the specifications, replace
the magnet(s).
5. With the pad located in either FORWARD or
REVERSE, check to ensure a minimum of 2 mm
(0.079 in.) total pad travel when changed to the
1300 SRM 717 Direction Control Lever Repair

opposite position. If 2 mm (0.079 in.) is not ob-

tained, do the adjustment again. If the 2 mm
(0.079 in.) is still not obtained, replace the pedal
pad.

6. Install capscrew, washers, tube, and nut that

hold pedal assembly to bracket. Connect link be-
tween pedal and crank as shown in Figure 28.

7. Install pedal return springs. Make sure throttle

cable is connected to correct position as shown in
Figure 28.

1. PEDAL PAD 2. SPRING SCALE

Figure 23. MONOTROL Pedal Magnets Check

Direction Control Lever Repair

REMOVE AND DISASSEMBLE
1. Remove steering wheel.

2. Remove back cover from steering column. If

equipped, remove turn signal switch.

3. Disconnect wires at switches for transmission

lever. Make sure wires have identification marks
for correct installation.

4. Remove capscrews that hold the bracket for the

control lever to the steering housing. Remove
control lever assembly and switches.

5. Disassemble control lever assembly as necessary.

See Figure 24.

ASSEMBLE AND INSTALL

1. Assemble control lever assembly as shown in Fig-
ure 24. Tighten nuts that hold control lever to
crank to 6.3 N•m (56 lbf in). Make sure spring
washers are between cranks and actuator plate.
Tighten nuts for cranks to 7.9 N•m (70 lbf in). In-
stall detent plungers until they touch the crank,
then loosen one turn. Fill detent areas with mul- 1. MOUNT 7. LOCK NUT
tipurpose grease. 2. ACTUATOR PLATE 8. DETENT PLUNGER
3. DETENT CRANK 9. SHOULDER BOLT
2. Install four switches on switch plate as shown in 4. CRANK 10. NUT
Figure 25. 5. LEVER 11. SPRING WASHER
6. BOLT
3. Use four capscrews and install control lever as-
sembly and switches on steering housing. Figure 24. Direction Control Lever

4. Connect wires to switches as shown in Figure 25.

25
Throttle-Up System Repair 1300 SRM 717

5. Start lift truck and operate direction control 6. If equipped, install turn signal switch. Install
lever in FORWARD and REVERSE to make back cover on steering housing. Install steering
sure lever operates correctly. wheel. Tighten nut for steering wheel to 40 to
54 N•m (30 to 40 lbf ft).

Color Codes
Y = White CB = Light Green
W = Green CC = Orange/Black
X = Red

1. CONTROL LEVER ASSEMBLY 5. NEUTRAL START SWITCH

2. DIRECTION INDICATOR 6. FORWARD CONTROL SWITCH
3. SWITCH PLATE 7. WIRING HARNESS
4. REVERSE CONTROL SWITCH 8. CONNECTOR-TO-COWL WIRING HARNESS

Figure 25. Direction Control Lever

Throttle-Up System Repair

The parts of the throttle-up system are as follows:
• Microswitch (engine compartment near hydraulic
control levers)
• Pressure switch (engine compartment near hy-
draulic control levers)
• Controller, relays, and fuse (engine compartment
near air cleaner)
• Throttle motor (LPG - engine compartment
at carburetor) (Diesel - under floor plate near
MONOTROL or accelerator pedal)
REMOVE AND INSTALL
NOTE: This procedure includes removal and instal-
lation of all parts of the throttle-up system. See Fig-
ure 26. Do only the steps necessary to replace the
damaged part.

26
1300 SRM 717 Throttle-Up System Repair

A. DIESEL B. LPG
1. THROTTLE MOTOR 7. MODULE RELAY 14. MICROSWITCH AND
2. MOTOR STOP 8. ELECTRICAL CONNECTOR BRACKET
3. MOUNT SCREWS, NUTS, AND 9. POWER RELAY 15. HYDRAULIC CONTROL
WASHERS 10. MOUNT BRACKET VALVES
4. THROTTLE PEDAL 11. FUSE AND HOLDER 16. HYDRAULIC CONTROL
5. LPG CARBURETOR 12. ENGINE AIR CLEANER LEVERS
6. CONTROL MODULE 13. PRESSURE SWITCH

Figure 26. Throttle-Up Components

Switches switch to bracket. Install switch using the re-

verse procedure.
1. Make sure the ignition key is in the OFF position
and the parking brake is set. Open hood and 3. Disconnect two leads from pressure switch. Re-
disconnect battery negative cable. move switch from hydraulic elbow. Install switch
using the reverse procedure.
2. Disconnect two leads from the microswitch. Re-
move two screws, nuts, and washers that fasten

27
Throttle-Up System Repair
Module, Relays, and Fuse
1. Make sure the ignition key is in the OFF position
and the parking brake is set. Open hood and
disconnect battery negative cable.
2. Both relays and the blade fuse can be replaced
without removing the module assembly from the
bracket. The relays are the plug-in type (one con-
nects directly to the module circuit board). The
fuse is inside the electrical connector. Remove
side panel for clearance.
3. Replace the complete module assembly as fol-
lows:
a. Disconnect all electrical connectors from
module assembly.
b. Remove two screws, nuts, and washers that
fasten module to bracket.
c. Remove module, relays, and fuse as an as-
sembly.
d. Install module assembly using the reverse
procedure.
Throttle Motor
1. Make sure ignition key is in the OFF position
and the parking brake is set. Open hood and
disconnect battery negative cable.
2. Replace throttle motor on LPG units as follows:
a. Make sure key is in the OFF position and
disconnect negative battery cable.
b. Disconnect electrical connector from throttle
motor.
c. Remove rod between throttle motor assembly
and carburetor.
d. Remove two screws, nuts, and lockwashers
that fasten plate to throttle motor.
e. Remove four capscrews, nuts, and washers
that fasten throttle motor to bracket. Re-
move throttle motor assembly.
28
1300 SRM 717
f. Install throttle motor using reverse proce-
dure.
3. To replace throttle motor on diesel units, it is eas-
ier to remove the complete pedal assembly and
pedal bracket as one assembly. See Figure 28.
Remove the assembly and replace the throttle
motor as follows:
a. Make sure key is in the OFF position and
disconnect negative battery cable.
b. Remove floor plates for access.
c. Disconnect electrical connector from throttle
motor.
d. Disconnect throttle cable from crank and re-
move cable from bracket.
e. Disconnect connector for MONOTROL pedal.
f. Disconnect hoses from variable relief valve
and install plugs on all hose and valve fit-
tings.
g. Remove two screws, nuts, and washers
that fasten hydraulic filter to throttle pedal
bracket.
h. Remove three capscrews, nuts, and wash-
ers that fasten throttle pedal bracket to lift
truck. Remove throttle pedal and bracket as-
sembly.
i. Remove rod between throttle motor assembly
and crank.
j. Remove four capscrews, nuts, and washers
that fasten throttle motor to bracket. Re-
move throttle motor assembly.
k. Remove two screws, nuts, and lockwashers
that fasten plate to throttle motor.
l. Install throttle motor and throttle pedal and
bracket assembly using reverse procedure.
1300 SRM 717 Inching/Brake Pedal Adjustment

Inching/Brake Pedal Adjustment

1. If the lift truck has been operated for more than pedal height. Tighten lock nut when com-
25 hours since the brake shoes were installed, plete. Be sure to measure the pedal height
and the operation of the brakes is normal, go to from the top of the module plate to the bot-
Step 4. tom edge of the pedal pad.

2. If the lift truck has new brake shoes, adjust the c. Loosen lock nut on push rod for master cylin-
brake shoes as described in Step 3. der. Rotate push rod clockwise until pin in
rod end just touches hole in pedal. Rotate
3. Adjust the brake shoes as follows (see Figure 27): push rod 1/8 turn counterclockwise to give
clearance for the pin. Tighten lock nut. This
a. Put blocks at either side of steer tires to
clearance lets the brake fully return when
prevent forward or reverse movement of lift
the pedal is released.
truck. Put lift truck on solid blocks so that
the drive wheels can be removed. Remove
drive wheels.

b. Use an adjuster tool (or a screwdriver) to

rotate adjuster wheel so that the teeth of
the wheel move downward. This adjustment
moves the brake shoes. Move brake shoes so
that the brake drum will not rotate.

c. Push the automatic adjuster lever away from

the adjuster wheel with a small screwdriver.
Use the adjuster tool to loosen adjuster wheel
approximately 10 teeth.

d. Install drive wheels. Remove lift truck from

blocks. Operate lift truck in the FORWARD
and REVERSE directions. Stop the lift
truck 10 times in each direction. This proce-
dure causes the brake shoes to wear a small
amount and fit the brake drums better.
1. MODULE PLATE 4. CAPSCREW
4. Adjust the pedal height as follows: 2. INCHING/BRAKE 5. PIN
PEDAL 6. LOCK NUT
3. CAPSCREW 7. PUSH ROD
a. Remove floor plate.
Figure 27. Inching/Brake Pedal Adjustment
b. Adjust height of inching/brake pedal to
82 mm (3.23 in.). Use capscrew to change

29
Variable Relief Valve Adjustment 1300 SRM 717

Variable Relief Valve Adjustment

After all pedal adjustments are complete, move variable relief valve toward rear of lift truck so the linkage pins
are loose. Tighten capscrews for valve. See Figure 28.

NOTE: MONOTROL PEDAL SHOWN.

A. GM, PERKINS ENGINES C. GM ENGINE
B. NOT USED D. PERKINS ENGINES
1. PEDAL 6. PILOT PRESSURE TO TANK
2. PEDAL STOP 7. PILOT PRESSURE FROM PUMP
3. RELIEF VALVE LINK 8. VARIABLE RELIEF VALVE
4. LINK 9. GM 3.0L ENGINE
5. PEDAL FRAME 10. PERKINS 2.6L ENGINE

Figure 28. Throttle Pedal with Travel Control System

30
1300 SRM 717 Hydrostatic Pump Oil Pressure Check

Hydrostatic Pump Oil Pressure Check

See Troubleshooting for causes of pressures that are
not within the specified limits.
Before making the oil pressure checks, do Steps 1
to 3 of the Operation Following Service or Repairs
(Commissioning) procedures.
Connect a 7 bar (100 psi) gauge to the hydrostatic
pump fill port ( Figure 7). Disconnect pilot pressure
line ( Figure 28) from variable relief valve and put
plugs in the line and valve ports.
Heat the oil in the transmission to 55 C (131 F) for
the pressure tests. To heat the oil, put a load on
the forks and put the load or forks against a station-
ary barrier. Apply the throttle and run the engine
at 2000 rpm. Do not use the brake pedal or parking
brake.
Do the pressure tests while the lift truck is in the
same condition as used to heat the oil. Table 2 shows
the engine speeds and pressures that are required.

System pressures are measured during a static test

when the hydrostatic pump is operating but the lift
truck is not moving.

Table 2. Hydrostatic Transmission Pressure Tests

Engine Engine Speed Loop Pressure Charge Pressure Pilot Pressure

GM 3.0L 800 rpm 132 to 172 bar 18 bar 5 to 7 bar
(1915 to 2495 psi) (261 psi) minimum (73 to 102 psi)
GM 3.0L 1800 rpm 250 bar - -
(3626 psi) minimum
GM 3.0L 2800 rpm 460 to 470 bar 27 to 33 bar A
(6672 to 6817 psi) (392 to 479 psi)
Perkins 2.6L 800 rpm 132 to 172 bar 18 bar 5 to 7 bar
(1915 to 2495 psi) (261 psi) minimum (73 to 102 psi)
Perkins 2.6L 1800 rpm 250 bar - -
(3626 psi) minimum
Perkins 2.6L 2800 rpm 460 to 470 bar 27 to 33 bar A
(6672 to 6817 psi) (392 to 479 psi)
A- Transmission Disengaged Pilot = 24 to 30 bar B- Transmission Disengaged Pilot = 26 to 32 bar
(348 to 435 psi) (377 to 464 psi)
Transmission Engaged Pilot = 17 to 23 bar (247 Transmission Engaged Pilot = 21 to 27 bar
to 334 psi) (305 to 392 psi)

LOOP AND PILOT PRESSURE CHECKS Loop pressure at governed speed is controlled by the
POR valve ( Figure 9). Loosen lock nut and rotate
Loop and pilot pressure are the result of internal set- screw clockwise to increase pressure. If pressure
tings and charge pump flow. Normally these settings does not increase, the problem can be the high-pres-
are not changed. sure relief valve ( Figure 9). Add insert to increase
relief pressure. If there is no pressure change, the
Loop pressure at 800 rpm can be adjusted with the
problem is POR related. Return the pump for repair.
screw at the top of the transmission control cartridge
( Figure 9). Loosen lock nut and rotate screw clock-
wise to decrease pressure or counterclockwise to in-
crease pressure.

31
Throttle-Up System Checks
CHARGE PRESSURE CHECK
This pressure check tests the circuit for the charge
pump. The setting is adjusted with internal shims.
Add shims to increase the pressure.
Axle Leakage
Disconnect axle supply hoses and put plugs in them.
See Figure 7. Disconnect axle drain hose at port A
and put a plug in it. Attach a short hose at port A that
can drain into a container. Raise a drive tire from the
Inching Adjustment
The inching valve uses brake pressure working
against a spring to move a spool and reduce pilot
pressure. No preload is applied to the spring.
When adjustment is correct, the adjusting screw
Swashplate Positioning Cylinder Check and Adjustment
To check and adjust the centering of the swashplate
positioning cylinder, do the following:
1. Connect a 100 bar (1500 psi) gauge to ports MA
(A) and MB (B).
2. Disconnect pilot pressure line ( Figure 28) from
variable relief valve. Put a plug in the line.
3. Raise one of the drive tires from the surface so
that it is free to rotate.
4. Run engine at 1000 rpm. Do not use brake pedal
or parking brake.
Throttle-Up System Checks
CHECK SWITCHES
Check switches (pressure and micro) as follows:
1. Check that switches are correctly connected.
One terminal of each switch is connected to
+12 volts and the other terminal of each switch
is connected to the module.
2. If necessary, loosen mount screws of the mi-
croswitch for adjustment. Adjust switch position
32
1300 SRM 717
CASE PRESSURE CHECK
Case pressure is a function of restriction in the cool-
ing circuit and the oil cooler bypass valve ( Figure 7).
If case pressure is more than the limits, the oil cooler
bypass valve is not operating correctly and the cool-
ing circuit has a restriction.
ground so that the lift truck will not move. With the
transmission engaged and the engine running at ap-
proximately 1200 rpm, the leakage from port A must
not be more than 6 liter/min (1.6 gal/min).
(Figure 10) will just touch the inching spring. The
adjusting screw cap can be removed to inspect the
parts. Make sure the inching spool is free to move
in its bore.
5. Shift directional control to forward travel and
record MA pressure.
6. Shift directional control to reverse travel and
record MB pressure.
7. If MA is not equal to MB±5 bar (±73 psi), loosen
lock nut and adjust screw until MA is equal to
MB±5 bar (±73 psi).
8. Remove pressure gauges before driving lift truck.
for 1 mm (0.039 in.) clearance to the linkage of
the lift control lever. See Figure 26.
CAUTION
Make sure there is clearance above the mast
to fully extend the mast. Do not allow anyone
near the mast during lifting or lowering.
3. Start engine and move lift control lever fully to
lift position. Check for continuity (switch closed)
1300 SRM 717
between the terminals of each switch. Both ter-
minals of each switch must have +12 volts to bat-
tery negative (chassis ground).
4. Replace the switch if there is +12 volts at only
one terminal.
CHECK THROTTLE MOTOR
To check the throttle motor, it is necessary to bypass
the control module. Check throttle motor as follows:
1. Disconnect electrical connector at throttle motor.
GM LPG
2. Apply +12 volts to throttle motor terminal for the
Perkins
violet/white wire. Apply chassis ground or bat-
tery negative to the throttle motor terminal for
the green wire.
3. The throttle motor must operate. If it does not,
replace motor.
4. Connect electrical connector to throttle motor.
CHECK CONTROL MODULE
1. Use the red and green lights on the control mod-
ule to check the control module.
CAUTION
The following checks are done with the engine
operating. Raise the drive wheels and install
blocks at the steer wheels as described in the
Operating Manual.
Make sure there is clearance above the mast
to fully extend the mast. Do not allow anyone
near the mast during lifting or lowering.
2. Start engine and move lift control lever. The fol-
lowing light conditions indicate operating condi-
tions:
a. Flashing green light - control module is
good and is receiving engine rpm signal. If
the throttle-up system is not operating, re-
lease lift control lever and do Step b through
Step d.
b. Check that microswitch is good and the
correct wires are connected. See Check
Switches in this section.
Throttle-Up System Checks
c. Move tilt control lever. If the system does
not operate, check that the pressure switch
is good and the correct wires are connected.
See Step 1.
d. If the system still does not operate, check
that the wires going to pins 8 and 9 have the
correct voltage as shown in Table 3.
Table 3. Control Module Pin Voltages
Engine Pin 8 Pin 9
Batt. Neg. +12 V
+12 V Batt. Neg.
e. Red light on - control module has detected
a fault. Possible faults are:
• Connection from control module to throttle
motor disconnected
• +12 volts to throttle motor is disconnected
• Module relay has welded contacts
• Module has internal fault
f. Check connections and module relay. Re-
place module relay or module as necessary.
g. Red and green lights both off - many pos-
sible causes. Check the following:
• Check that the key is on and the engine is
operating. Throttle-up only operates with
the engine operating.
• Check that the module has power. A bad
or missing fuse or power relay will cause
no power.
• Check that there is an engine rpm signal to
the module. Without this signal, the mod-
ule thinks the engine is off. Start the en-
gine as described in Step 2. Check for 3 to
12 volts with a pin-type probe inserted into
the wire for pin 4 of the module on units
with the Perkins engine. Check for 1 to
4 volts with a pin-type probe inserted into
the wire for pin 5 of the module on units
with the GM engine.
33
Troubleshooting 1300 SRM 717

Troubleshooting
NOTE: Before doing any of the troubleshooting procedures, make sure the engine is operating correctly. If
necessary, check that the fuel system, ignition timing, and other engine systems, and the brake system are
adjusted to specifications.

Figure 29. Lift Truck Will Not Move When Operator Applies Throttle (Hy-
draulic Problems) (Sheet 1 of 2)

34
1300 SRM 717 Troubleshooting

Figure 29. Lift Truck Will Not Move When Operator Applies Throttle (Hy-
draulic Problems) (Sheet 2 of 2)

Figure 30. Lift Truck Will Not Move Forward, Reverse, or Both When Operator Applies Throttle
(Electrical Problems)

35
Troubleshooting 1300 SRM 717

Figure 31. Lift Truck Has Poor Acceleration

Figure 32. Lift Truck Moves at Idle Speed With Throttle in Up Position

36
1300 SRM 717 Troubleshooting

Figure 33. Poor Grade Climbing

Figure 34. Oil Level/Oil Temperature Light is On

37
Troubleshooting 1300 SRM 717

Figure 35. Lift Truck Will Not Inch

38
1300 SRM 717 Troubleshooting

Figure 36. Lift Truck Will Not Reach Maximum Travel Speed (Sheet 1 of 2)

Figure 36. Lift Truck Will Not Reach Maximum Travel Speed (Sheet 2 of 2)

39
Troubleshooting 1300 SRM 717

Figure 37. Low Travel Speed in One Direction

Figure 38. Hydrostatic Transmission or Drive Axle Motors are Noisy

40
1300 SRM 717 Troubleshooting

Figure 39. Lift Truck Does Not Slow Down When Operator Removes Foot from Throttle

Figure 40. Throttle-Up Does Not Function

41
Torque Specifications 1300 SRM 717

Torque Specifications
Axle Mount to Axle Housing Capscrews Hydrostatic Pump Mount at Drive
145 N•m (107 lbf ft) Axle Capscrew
66 N•m (49 lbf ft)
Axle Mounts to Frame
320 N•m (236 lbf ft) Wheel Cylinder Capscrews
18 to 27 N•m (159 to 239 lbf in)
Axle Shaft Capscrews
98 N•m (72 lbf ft) Wheel Nuts
610 to 680 N•m (450 to 501 lbf ft)
Back Plate to Axle Mount Capscrews
225 N•m (166 lbf ft)

Hydrostatic Pump to Flywheel

Housing Capscrews
225 N•m (166 lbf ft)

42
 TECHNICAL PUBLICATIONS

1300 SRM 717 6/01 (2/99)(11/98) Printed in United Kingdom