1800SRM1498 (03 2013) Us en PDF

BRAKE AND
HYDRAULIC COOLING
SYSTEM
H8.0-12.0XM-6 (H190-280HD 2) [J007];
H13.0-14.0XM-6 (H300-330HD 2) [H019];
H16.0XM-6 (H360HD 2) [H019];
H10.0-12.0XM-12EC (H360HD 2-EC) [H019];
H8-12XM-6, H10XMS-6 (H190-280HD 2,
H230HDS) [K007]; H13-16XM-6,
H10-12XM-12EC (H300-360HD 2,
H360HD 2-EC) [J019]
PART NO. 4034076 1800 SRM 1498

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. Updated technical service information may be available from your local authorized Hyster® dealer. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.
• 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 Maintenance 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 hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Brake and Hydraulic Cooling System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Basic Principles of Flow Control Systems ........................................................................................................ 1
Basic Principles of Flow Control Systems .................................................................................................... 1
Orifice (Fixed/Variable) ................................................................................................................................. 2
Basic Principle........................................................................................................................................... 2
Pressure Compensated Flow Control Valve ................................................................................................. 2
Basic Principle........................................................................................................................................... 2
Pressure Compensated Flow Control Valve Functional Description...................................................... 2
Priority Valve ................................................................................................................................................. 3
Basic Principle........................................................................................................................................... 3
Priority Valve Functional Description ..................................................................................................... 3
Load Sense (LS) ............................................................................................................................................. 4
Basic Principle........................................................................................................................................... 4
Load Sense Functional Description.......................................................................................................... 4
Example 1.............................................................................................................................................. 5
Example 2.............................................................................................................................................. 5
Basic Principles of Pressure Control Systems.................................................................................................. 5
Basic Principles of Pressure Control Systems ............................................................................................. 5
Direct Acting Relief Valves............................................................................................................................ 6
Basic Principle........................................................................................................................................... 6
Direct Acting Relief Valve Functional Description.................................................................................. 6
Two-Stage Relief Valve (Pilot-Operated Relief Valve) ................................................................................. 7
Basic Principle........................................................................................................................................... 7
Two-Stage Relief Valve (Pilot Operated Relief Valve) Functional Description...................................... 7
Unloading Valve (Accumulator Charging Valve) ......................................................................................... 8
Basic Principle........................................................................................................................................... 8
Unloading Valve (Accumulator Charging Valve) Functional Description.............................................. 8
Counterbalance Valve.................................................................................................................................... 9
Basic Principle........................................................................................................................................... 9
Counterbalance Valve Functional Description ........................................................................................ 9
Pressure Reducer Valve................................................................................................................................. 10
Basic Principle........................................................................................................................................... 10
Pressure Reducer Valve Functional Description ..................................................................................... 10
Brake System Main Component Identification................................................................................................ 10
Description ......................................................................................................................................................... 16
Brake Pressure System ..................................................................................................................................... 16
Main System .................................................................................................................................................. 16
Introduction ............................................................................................................................................... 16
Service Brakes....................................................................................................................................... 16
Park Brake ............................................................................................................................................ 16
Description................................................................................................................................................. 16
Hydraulic Oil Flow Path ........................................................................................................................... 16
Brake Accumulator Charging System ................................................................................................. 16
Service Brake System ........................................................................................................................... 17
Park Brake System ............................................................................................................................... 17
Priority Valve ................................................................................................................................................. 17
Fundamentals............................................................................................................................................ 17
Description................................................................................................................................................. 17
Operation ................................................................................................................................................... 17
Component Validation for Correct Operation .......................................................................................... 17
Brake Control Manifold................................................................................................................................. 17
©2013 HYSTER COMPANY i

Table of Contents Brake and Hydraulic Cooling System
TABLE OF CONTENTS (Continued)

Description................................................................................................................................................. 17
Orifice (F)................................................................................................................................................... 17
Fundamentals ....................................................................................................................................... 17
Description ............................................................................................................................................ 18
Operation............................................................................................................................................... 18
Component Validation for Correct Operation...................................................................................... 19
Unloading Valve ........................................................................................................................................ 19
Fundamentals ....................................................................................................................................... 19
Operation............................................................................................................................................... 19
Screen......................................................................................................................................................... 19
Description ............................................................................................................................................ 19
Check Valve ............................................................................................................................................... 19
Description ............................................................................................................................................ 19
Pressure Reducer Valve ............................................................................................................................ 19
Fundamentals ....................................................................................................................................... 19
Operation............................................................................................................................................... 19
Park Brake Selector Valve ........................................................................................................................ 19
Fundamentals ....................................................................................................................................... 19
Operation............................................................................................................................................... 19
Brake Accumulator........................................................................................................................................ 20
Fundamentals............................................................................................................................................ 20
Operation ................................................................................................................................................... 20
Brake Treadle Valve ...................................................................................................................................... 20
Fundamentals............................................................................................................................................ 20
Description................................................................................................................................................. 20
Operation ................................................................................................................................................... 20
Wet Disc Brake Cooling System........................................................................................................................ 20
Main System .................................................................................................................................................. 20
Introduction ............................................................................................................................................... 20
Description................................................................................................................................................. 20
Gear Pump ..................................................................................................................................................... 21
Fundamentals............................................................................................................................................ 21
Operation ................................................................................................................................................... 21
Brake Cooling Valve ...................................................................................................................................... 21
Description................................................................................................................................................. 21
Operation ................................................................................................................................................... 21
Thermostatic Bypass Valve....................................................................................................................... 21
Fundamental ......................................................................................................................................... 21
Operation............................................................................................................................................... 21
Brake Flow Distribution Manifold................................................................................................................ 22
Fundamentals............................................................................................................................................ 22
Operation ................................................................................................................................................... 23
ii

Hydraulic Oil Cooler Core ............................................................................................................................. 23
Fundamentals............................................................................................................................................ 23
Operation ................................................................................................................................................... 23
Brake Return Line Filter (J007 & H019 Only) ........................................................................................... 23
Operation ................................................................................................................................................... 23
Cooling System Air Brakes ........................................................................................................................... 23
Main System .............................................................................................................................................. 23
Description................................................................................................................................................. 23
Component Explanation ........................................................................................................................... 23
Brake Treadle Valve Repair .............................................................................................................................. 24
Remove ........................................................................................................................................................... 24
Install ............................................................................................................................................................. 24
Accumulator ....................................................................................................................................................... 25
Remove ........................................................................................................................................................... 25
Disassemble ................................................................................................................................................... 26
Clean .............................................................................................................................................................. 27
Inspect ............................................................................................................................................................ 27
Repair ............................................................................................................................................................. 28
Assemble ........................................................................................................................................................ 28
Install ............................................................................................................................................................. 28
Pre-Charge Filling ......................................................................................................................................... 29
Parking Brake .................................................................................................................................................... 30
Parking Brake Caliper .................................................................................................................................. 30
Remove....................................................................................................................................................... 30
Disassemble ............................................................................................................................................... 32
Clean and Inspect...................................................................................................................................... 32
Assemble .................................................................................................................................................... 32
Install ......................................................................................................................................................... 32
Parking Brake Caliper Pads ......................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34
Parking Brake Bleed ................................................................................................................................. 34
Parking Brake Emergency Release .......................................................................................................... 35
Brake Flow Distribution Manifold .................................................................................................................... 35
Remove ........................................................................................................................................................... 35
Pressure Relief Valve..................................................................................................................................... 37
Disassemble ............................................................................................................................................... 37
Clean and Inspect .......................................................................................................................................... 37
Assemble ........................................................................................................................................................ 37
Install ............................................................................................................................................................. 37
Brake Control Manifold ..................................................................................................................................... 38
Remove ........................................................................................................................................................... 38
Orifices F and G ........................................................................................................................................ 39
Disassemble........................................................................................................................................... 39
Assemble................................................................................................................................................ 39
Orifice H..................................................................................................................................................... 39
Disassemble........................................................................................................................................... 39
Assemble................................................................................................................................................ 39
Unloading Valve (B) .................................................................................................................................. 39
Disassemble........................................................................................................................................... 39
iii
Table of Contents Brake and Hydraulic Cooling System

Assemble................................................................................................................................................ 40
Screen......................................................................................................................................................... 40
Disassemble........................................................................................................................................... 40
Assemble................................................................................................................................................ 40
Check Valve (E) ......................................................................................................................................... 40
Disassemble........................................................................................................................................... 40
Assemble................................................................................................................................................ 40
Pressure Reducer Valve (C) ...................................................................................................................... 40
Disassemble........................................................................................................................................... 40
Assemble................................................................................................................................................ 41
Park Brake Selector Valve (A) .................................................................................................................. 41
Disassemble........................................................................................................................................... 41
Assemble................................................................................................................................................ 41
Install ............................................................................................................................................................. 41
Brake Cooling Valve........................................................................................................................................... 42
Remove ........................................................................................................................................................... 42
Install ............................................................................................................................................................. 42
Filter Restriction Indicator (Optional) ......................................................................................................... 43
Remove....................................................................................................................................................... 43
Install ......................................................................................................................................................... 43
Filter............................................................................................................................................................... 44
Remove....................................................................................................................................................... 44
Install ......................................................................................................................................................... 44
Brake Return Line Filter (J007 & H019 Only) ............................................................................................... 45
Brake Return Line Filter Assembly ............................................................................................................. 45
Remove....................................................................................................................................................... 45
Install ......................................................................................................................................................... 46
Filter............................................................................................................................................................... 46
Remove....................................................................................................................................................... 46
Install ......................................................................................................................................................... 46
Gear Pump ......................................................................................................................................................... 46
Remove ........................................................................................................................................................... 46
Disassemble ................................................................................................................................................... 46
Clean .............................................................................................................................................................. 48
Inspect ............................................................................................................................................................ 48
Assemble ........................................................................................................................................................ 49
Install ............................................................................................................................................................. 49
Hydraulic Troubleshooting Flowcharts ............................................................................................................ 50
Mechanical Troubleshooting ............................................................................................................................. 54
Checks and Adjustments ................................................................................................................................... 56
Hydraulic Pressure Checks Preparation ...................................................................................................... 56
Park Brake Selector Valve Check ................................................................................................................. 56
Park Brake Selector Valve Coil Check.......................................................................................................... 56
Accumulator Pre-Charge Check ................................................................................................................... 56
Parking Brake Adjustment ........................................................................................................................... 57
Condition Check, Shuttle Valve L in the Main Control Valve .................................................................... 58
Condition Check, Shuttle Valve N in the Main Control Valve .................................................................... 58
Condition Check, Priority Valve on the Main Control Valve....................................................................... 59
Pressure Check, Port MLS1 .......................................................................................................................... 59
Torque Specifications ......................................................................................................................................... 60
Hydraulic Hose Torque Specifications.......................................................................................................... 60
iv

This section is for the following models:
H8.0-12.0XM-6 (H190-280HD 2) [J007];

H13.0-14.0XM-6 (H300-330HD 2) [H019];
H16.0XM-6 (H360HD 2) [H019];
H10.0-12.0XM-12EC (H360HD 2-EC) [H019];
H8-12XM-6, H10XMS-6 (H190-280HD 2, H230HDS) [K007];
H13-16XM-6, H10-12XM-12EC (H300-360HD 2, H360HD 2-EC) [J019]
v
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1800 SRM 1498 Basic Principles of Flow Control Systems
General
This manual covers the description and operation for For the replacement of the hydraulic oil cooler core,
the brake system. refer to the manual Cooling System 700 SRM 1350.
This manual also covers the repairs for the brake sys- For the replacement/repair procedures for the gear
tem components except for the replacement of the pump, variable displacement pump, and the brake
wet disc brakes, the replacement of the air brakes, control manifold which is integrated with the main
the replacement of the hydraulic oil cooler core, and control valve, refer to the manual Hydraulic Sys-
the adjustment procedure for the brake pedal. tem 1900 SRM 1478.
For the replacement of the wet disc brakes, refer to For the adjustment procedures for the brake pedal,
the manual Planetary Drive Axle, (Wet System) refer to the manual Operator’s Cab 100 SRM 1390.
1400 SRM 944.
The partial schematics and values shown in this
For the replacement of the air brakes, refer to the manual may vary from the complete schematics. For
manual Planetary Drive Axle, (Dry System) 1400 the most recent schematics and values, refer to the
SRM 945. manual Diagrams 8000 SRM 1500.
Basic Principles of Flow Control Systems

BASIC PRINCIPLES OF FLOW CONTROL system to another. Flow control valves perform one
SYSTEMS or more of the following control functions:
• Limit the maximum speed of cylinders or hydraulic
NOTE: It is strongly recommended that this section motors.
is read from the beginning [Orifice (Fixed/Variable)] • Proportionally divide or regulate the hydraulic
through the end [Load Sense (LS)], without skipping flow to various sections of the hydraulic system.
over sections.
For the definition of some of the terms used in this
This section explains the basic principles of flow con- section, refer to Table 1.
trol systems.
Flow control valves are used in hydraulic systems to

control the rate of flow from one part of the hydraulic
Table 1. Definition of Terms
Term Definition
Proportional Valve Proportional valves differ from conventional on/off valves through their ability to
assume an infinitely varying spool selection between 0 to 100% selection.
Pressure Differential The pressure difference between the pressures at two different locations in the
hydraulic system at the same time.
System Pressure The pressure that is supplied to a valve.
Function Pressure The pressure that is present in the activated side of the cylinder.
Absolute Pressure The pressure value calibrated on absolute zero pressure.
Working Area The area of a piston or component that is exposed to pressure.
1
Basic Principles of Flow Control Systems 1800 SRM 1498
ORIFICE (FIXED/VARIABLE)
Orifices (flow restrictors) are used in hydraulic sys-
tems to control the rate of flow from one section of
the hydraulic system to the next.
Basic Principle
When the oil flow is pressed through an orifice (A),
the pressure (P1) before the orifice (A) is greater than
the pressure (P2) after the orifice (A). See Figure 1
and Figure 2.
Depending on the pressure differential (pressure

drop) and the opening area of the orifice (A), a cer-
tain reduced flow will pass through the orifice (A).
Any change in the opening area (variable orifice) or

any increase or decrease of the pressure differen-
A Fixed Orifice
tial over the orifice (A) will change the rate of flow
through the orifice (A). P1 System Pressure
P2 Function Pressure
PRESSURE COMPENSATED FLOW
CONTROL VALVE
Figure 1. Fixed Orifice Example Schematic
Pressure compensated flow control valves are used
in hydraulic systems to control the rate of flow from
one section of the hydraulic system to the next, inde-
pendent of the system pressure.
Basic Principle
The output flow of an orifice (A) is constant when
the pressure differential created by the orifice (A) is
constant. The absolute pressure before and after the
orifice (A) does not affect the output flow. For more
information on an orifice (A), see Orifice (Fixed/Vari-
able).
Pressure Compensated Flow Control

Valve Functional Description
When the flow supply to the orifice (A) is regulated by
the pressure differential (P1 – P2) created by the ori-
fice (A), then the flow will be regulated by the spring A Variable Orifice
force (B) and will not be dependent on the absolute
P1 System Pressure
pressures at P1 and P2 but on the pressure differen-
tial. See Figure 3. P2 Function Pressure
Therefore, the system is balanced by the following Figure 2. Variable Orifice Example Schematic
equation:
(Pressure P1 – Pressure P2) × Working Area =
Spring Force (B)
2
1800 SRM 1498 Basic Principles of Flow Control Systems
The priority spool will supply flow to the variable ori-

fice (A) to balance the equation:
(Pressure P1 – Pressure P2) × Working Area =
Spring Force (B)
For more information on flow control valves, see

Pressure Compensated Flow Control Valve.
Priority Valve Functional Description

The priority valve is normally controlled by a pres-
sure differential (P1 – P2) over a variable orifice (A).
A typical variable orifice (A) is a steering control
valve. See Figure 4.
The system will balance the pressure differential (P1

– P2) against the spring force (B). By doing this, it
guarantees the flow to the prioritized system.
A Orifice
B Spring Force
P1 System Pressure
Figure 3. Pressure Compensated Flow Control

Valve Example Schematic
With a fixed orifice (A), the hydraulic system will

maintain a fixed and constant output flow regardless
of pressure fluctuations in the system pressure.
With a variable orifice (A), the hydraulic valve will

control the rate of flow based on the opening area of
the variable orifice (A).
PRIORITY VALVE
A Orifice (Variable)
The priority valve prioritizes the flow to one system
over another when there is a limited flow supply to B Spring Force
both systems. PS Priority Spool
Basic Principle P1 System Pressure

The pressure differential created by the variable ori-
fice (A) controls the selection of the priority spool PF Priority Flow
(PS). See Figure 4. EF Excessive Flow
Figure 4. Priority (Flow Control) Valve

Example Schematic
3
Basic Principles of Flow Control Systems 1800 SRM 1498
By using a variable orifice (A), as done with a steer- in the increase of output flow from the variable dis-
ing control valve, the opening area of the orifice (A) placement pump.
varies due to the proportional selection of the vari-
able orifice (A). The LS system will balance the pressure differential
(P1 – P2) against the preset spring force (B). By doing
By increasing the opening area of the variable orifice this, it guarantees the required output flow from the
(A), it will supply an increased flow to the prioritized variable displacement pump.
function to maintain the same pressure differential.
By using a variable orifice (A), such as a propor-
When the pump supplies more flow than the priority tional control valve, the opening area of the orifice
function (PF) requires, the excessive flow (EF) will be (A) varies during the stroke of the proportional
directed to the other sections of the hydraulic system. control valve. To maintain the preset pressure dif-
See Figure 4. ferential (P1 – P2), the output flow of the variable
displacement pump will also vary.
LOAD SENSE (LS)
The LS system uses the LS pressure regulator (D)
and the pressure differential created by the orifice
(A) to control the output flow of the variable displace-
ment pump. See Figure 5.
Basic Principle
The pressure differential (P1 – P2) created by the
orifice (A) controls the output pressure (E) of the LS
pressure regulator (D) which controls the servo pis-
ton (C).
The position of the servo piston (C) determines the

output flow of the variable displacement pump.
For more information on flow control valves, see

Pressure Compensated Flow Control Valve.
Load Sense Functional Description

NOTE: An orifice (A) can be any type of flow control
valve if it adds restriction to the flow of the hydraulic
system. The type of restriction can range from a stan-
dard orifice (A) up to a proportional directional con-
trol valve.
A Orifice
The output pressure (E) of the LS pressure regulator B Spring Force
(D) is controlled by the pressure differential (P1 – P2)
created by the orifice (A). C Servo Piston
When the output pressure (E) of the LS pressure reg- D LS Pressure Regulator
ulator (D) increases, the variable displacement pump E Output Pressure (LS Pressure
servo piston (C) will increase the stroke, resulting in Regulator)
the reduction of output flow from the variable dis-
placement pump. P1 System Pressure
When the output pressure (E) of the LS pressure
regulator (D) decreases, the variable displacement
Figure 5. Load Sense (LS) Example Schematic
pump servo piston (C) will be de-stroked, resulting
4
1800 SRM 1498 Basic Principles of Pressure Control Systems
When no functions of the hydraulic system are acti- Example 1

vated, the function pressure (P2) will be 0 bar (0 psi)
and the hydraulic pressure at the variable displace- No hydraulic function selected:
ment pump will drop to the preset pressure of the LS Required function pressure (P2) = 0 bar (0 psi)
pressure regulator (D) generated by the spring force LS pressure regulator (D) preset setting = 30 bar
(B). Refer to Example 1. (435 psi)
System pressure (P1) = 30 bar (435 psi)
If a function is activated, function pressure (P2) will
increase and the variable displacement pump pres- Example 2
sure would be equal to the function pressure (P2) +
Hydraulic function selected:
LS pressure regulator (D) preset setting. Refer to Ex-
Required function pressure (P2) = 100 bar
ample 2.
(1450 psi)
LS pressure regulator (D) preset setting = 30 bar
(435 psi)
System pressure (P1) = 130 bar (1885 psi)
Basic Principles of Pressure Control Systems

BASIC PRINCIPLES OF PRESSURE Pressure control valves (relief valves) are used in hy-
CONTROL SYSTEMS draulic systems to perform the following functions:
• Limit maximum system pressure in a hydraulic cir-
NOTE: It is strongly recommended that this section is cuit or subsystem to provide overload protection.
read from the beginning [Direct Acting Relief Valves] • Provide resistance to flow at a different selectable
through the end [Pressure Reducer Valve], without pressure range.
skipping over sections. • Reduce/lower pressure from the main hydraulic
system to a lower pressure in a subsystem.
This section explains the basic principles of pressure
control systems. For the definition of some of the terms used in this
section, refer to Table 2.
Table 2. Definition of Terms
Term Definition
Relief Valve Limits the maximum allowable pressure in the hydraulic system and will direct part
or all of the hydraulic pump flow to the hydraulic tank when the preset pressure
setting is reached.
Cracking Pressure The pressure at which the relief valve begins to open and divert flow to the hydraulic
tank.
Full Flow Pressure The measured system pressure when all of the hydraulic pump flow is diverted by
the relief valve to the hydraulic tank.
Pressure-Rise The difference between the full flow pressure and the cracking pressure.
Metering In Hydraulic oil flow into the actuator.
Metering Out Hydraulic oil flow out of the actuator.
5
Basic Principles of Pressure Control Systems 1800 SRM 1498
DIRECT ACTING RELIEF VALVES As soon as the pressure drops below the valve setting,
the spring force (C) will re-seat the poppet valve (B)
Basic Principle and close the relief valve.
When the hydraulic system pressure increases and

the hydraulic oil force becomes greater than the op-
posing spring force, the relief valve will open to re-
lieve pressure and divert flow to the hydraulic tank.
Direct Acting Relief Valve Functional

Description
The system pressure (P1) in the hydraulic system
works against the exposed area of the poppet valve
(B). See Figure 6. As the pressure increases and the
hydraulic oil force becomes greater than the opposing
force of the spring (C) behind the poppet valve (sys-
tem pressure exceeds the valve setting), the poppet
valve (B) will begin to be forced from its seat (crack-
ing pressure) to open the passage and divert flow to
the hydraulic tank.
If the flow to the hydraulic tank continues to in-

crease, the poppet valve (B) will further compress
the spring (C) to increase the open area of the pas- B Poppet Valve
sage to relieve pressure and increase the flow to the
hydraulic tank. C Spring
P1 System Pressure
The further the poppet valve (B) is forced from its
seat and the spring (C) is compressed, the greater the T Hydraulic Tank
relief pressure and open area to the hydraulic tank
will be until full flow has been reached. Figure 6. Relief Valve
6
TWO-STAGE RELIEF VALVE

(PILOT-OPERATED RELIEF VALVE)
Two-stage relief valves, with the use of pilot valves,
are used to minimize the pressure-rise and eliminate
pressure peaks.
Basic Principle
The two-stage relief valve operates in two stages.
The pilot valve (D), which is backed by a relief set-
ting spring (E), is used to control the relief spool (B).
Two-Stage Relief Valve (Pilot Operated

Relief Valve) Functional Description
When the pressure in the hydraulic system is low (no
pressure relief required), the pressure on both sides
of the relief spool (B) are equal. Both, the pilot valve
(D) and relief spool (B) are closed at this time. See
Figure 7.
When a hydraulic function is selected and the sys-

tem pressure begins to increase and exceeds the pilot
valve (D) setting (cracking pressure), the pilot valve
(D) will begin to compress the relief setting spring
(E) to open a passage and divert flow to the hydraulic
tank. This action will generate a flow over the orifice
(A) and cause a pressure differential between P1 and
P2 (Pressure P1 will be less than P2). The pressure
differential will act against the return spring (C) and
will force the relief spool (B) upward, opening a pas-
sage to the hydraulic tank. See Figure 7.
As the flow increases through the valve, the relief A Orifice

spool (B) will be forced further upward and will fur- B Relief Spool
ther compress the spring. As soon as the pressure
drops below the opening pressure of the pilot valve C Return Spring (Neutral Position)
(D), the flow through the pilot valve (D) and the ori- D Pilot Valve
fice (A) will be stopped and the pressure differential
will be eliminated. The return spring (C) will force E Relief Setting Spring
the relief spool (B) downward, closing the passage to P System Pressure
the hydraulic tank and stopping the relief flow.
P1 Pressure 1
P2 Pressure 2
T Hydraulic Tank
Figure 7. Two-Stage Relief Valve
7
Basic Principles of Pressure Control Systems 1800 SRM 1498
UNLOADING VALVE (ACCUMULATOR The amount of flow dumped to tank line (T) is limited
CHARGING VALVE) by orifice (F).
Unloading valves are used to maintain the required

pressure in the hydraulic system between two set
values.
Basic Principle
An Unloader valve is a direct acting relief valve with
a differential spool.
The selection of this differential spool (E) is con-

trolled by pressures (P and Pacc) acting against
two different sized areas (A1 and A2) in opposite
direction.
The selection of the differential spool (E) determines

if the LS line is pressurized or relieved to tank. See
Figure 8.
The variable displacement pumps will supply charge

flow to this function when the LS line is pressurized.
Unloading Valve (Accumulator Charging

Valve) Functional Description
When the accumulator pressure (PACC) drops below
the minimum preset pressure (cut-in pressure) of the
unloading valve, the spool is positioned to block the
passage that connects the pressure line (P) to the hy-
draulic tank line (T). See Figure 8.
The pressure in the LS line will be equal to the

system pressure in the P line and will provide the
variable displacement pump the signal to supply
hydraulic oil flow.
In this stage, the pressures at lines P, P1 and PACC PACC Pressure at Accumulator
are equal and therefore the position of the differen- A1 Area 1 of the Spool
tial spool (E) is controlled by:
A2 × P = Spring Force + A1 × P which is equal to A2 Area 2 of the Spool
(A2-A1) × P = Spring Force D Spring (Unloading Setting)
Due to the reduced area (A2 - A1), a high pressure E Differential Spool
(cut-out pressure) is required to shift the differential
F Orifice (Limits flow to the
spool (E) against the spring force to open the passage
unloading valve.)
and connect the pressure line (P) with the hydraulic
tank line (T). LS Load Sense
When the pressure in the accumulator reaches the P System Pressure

maximum preset pressure (cut-out pressure) of the T Hydraulic Tank
unloading valve, the spool spring (D) will be com-
pressed and the differential spool (E) will open the
Figure 8. Unloading Valve (Accumulator
passage that connects the pressure line (P) with the
Charging Valve)
hydraulic tank line (T).
8
The pressure in the LS line will drop to a minimum Due to the area size of A2, the required external pi-
pressure due to the limited hydraulic oil flow that lot pressure at P2 is limited to control the position of
is supplied by the orifice (F) and the open hydraulic spool (C). When the actuator is selected in the direc-
tank line (T) connection. tion that the counterbalance valve controls the me-
tering out flow (at P1), then the system will supply
In this stage, the pressure at line P is zero and the flow and pressure to the metering in line.
pressure at line PACC is equal with the pressure in
the accumulator, therefore the position of the differ- P2 is connected to this metering in line and when
ential spool (E) is controlled by: both pressures (P1 and P2) are adequate, the spool
A2 × P (Acc) = Spring Force (C) will shift and open a passage that will connect P1
to hydraulic tank
Due to the increased area [A2 against (A2-A1)], a
lower pressure (cut-in pressure) is required to main- If the actuator speed overruns the controlled func-
tain the spool position against the spring force. tion speed, the external pilot pressure (P2) in the me-
tering in line will drop and the opposing force of the
COUNTERBALANCE VALVE spring (B) will shift the spool (C) downward, closing
the opening to the hydraulic tank (counterbalance
Counterbalance valves are used to control the output valve will close), which will slow down or stop the
flow of an actuator with a pulling load to prevent an speed of the actuator.
uncontrolled or unintended movement. An example
of an actuator can be a cylinder or hydraulic motor.
A counterbalance valve is normally combined with

a check valve that allows free flow to the opposite
direction.
Basic Principle
A counterbalance valve is a direct acting relief valve
that can be controlled by two different pressures or a
combination of these two pressures.
Both pressures are acting against two separate areas

(A1 and A2) that are substantially different in size.
See Figure 9.
The first pressure is the system pressure (P1), which

is connected to the metering out side of the actuator.
The second pressure is the external pilot pressure

(P2), which is connected to the metering in side of A1 Area 1 of the Spool
the actuator. A2 Area 2 of the Spool
Counterbalance Valve Functional B Spring

Description C Spool
The counterbalance valve operates as a direct acting P1 System Pressure

relief valve that is controlled by two pressures (P1 P2 External Pilot Pressure
and P2). See Figure 9.
T Hydraulic Tank
The selection of the spool (C) is balanced by the fol-
lowing equation: Figure 9. Counterbalance Valve
Spring Force = (P1 × A1) + (P2 × A2)
9
Brake System Main Component Identification 1800 SRM 1498
PRESSURE REDUCER VALVE

Pressure reducer valves are used to operate a hy-
draulic subsystem at a lower pressure than the main
hydraulic system.
Basic Principle
The pressure reducer valve is a two-way valve that
is normally open and will close when the pressure is
sufficient in the hydraulic subsystem.
Pressure Reducer Valve Functional

Description
When the subsystem pressure is below the operating
pressure of the pressure reducer valve, the spring (D)
will hold the spool in the maximum open position.
See Figure 10.
As the subsystem pressure (P2) increases and the hy-

draulic force against the spool (C) becomes greater
than the opposing force of the spring (D), the spool (C)
will shift, compressing the spring (D) and partially
P1 System Pressure
closing the passage to the subsystem. This action
will allow only enough flow to maintain the predeter- P2 Subsystem Pressure
mined subsystem pressure (P2). The hydraulic force (Controlled Pressure)
against the spool (C) and the opposing force of the
C Spool
spring (D) will maintain the balance of the spool (C)
and the subsystem pressure (P2) by the spool (C) re- D Spring
ducing or increasing the passage opening to the sub-
T Hydraulic Tank
system.
When the subsystem pressure (P2) increases above Figure 10. Pressure Reducer Valve
the maximum valve setting, the spool (C) will close
the passage to the subsystem and open the passage
to the hydraulic tank to relieve the pressure from the
subsystem.
Brake System Main Component Identification

Figure 11, Figure 12, Figure 13, Figure 14, and Fig- and air brake systems main components between the
ure 15 show the relation and locations of the wet schematic and the lift truck.
Legend for Figure 11

1. PRIORITY VALVE 9. BRAKE FLOW DISTRIBUTION MANIFOLD
2. BRAKE CONTROL MANIFOLD 10. VARIABLE DISPLACEMENT PUMP
3. LOW BRAKE PRESSURE SWITCH 11. GEAR PUMP
4. BRAKE ACCUMULATOR 12. BRAKE COOLING VALVE
5. BRAKE TREADLE VALVE 13. HYDRAULIC OIL COOLER CORE
6. BRAKE LIGHT SWITCH 14. BRAKE RETURN LINE FILTER (J007 & H019
7. PARK BRAKE ONLY)
8. SERVICE BRAKES 15. HYDRAULIC TANK
10
1800 SRM 1498 Brake System Main Component Identification
Figure 11. Wet Brake System Schematic
11
10. VARIABLE DISPLACEMENT PUMP 13. HYDRAULIC OIL COOLER CORE

11. GEAR PUMP 14. HYDRAULIC TANK
12. BRAKE COOLING VALVE
Figure 12. Air Brake Cooling System Schematic
12
1. PRIORITY VALVE 5. BRAKE TREADLE VALVE

2. BRAKE CONTROL MANIFOLD 6. VARIABLE DISPLACEMENT PUMP
3. LOW BRAKE PRESSURE SWITCH 7. GEAR PUMP
4. BRAKE LIGHT SWITCH 8. BRAKE FLOW DISTRIBUTION MANIFOLD
Figure 13. Wet Brake Pressure System
13
1. BRAKE RETURN LINE FILTER (J007 & H019 4. HYDRAULIC TANK

ONLY) 5. COOLER
2. GEAR PUMP 6. SERVICE BRAKES
3. HYDRAULIC FILTER 7. BRAKE FLOW DISTRIBUTION MANIFOLD
Figure 14. Wet Disc Brake Cooling System
14
1. AIR BRAKES 4. HYDRAULIC TANK

2. GEAR PUMP 5. COOLER
3. HYDRAULIC FILTER
Figure 15. Air Brake Cooling System
15
Brake Pressure System 1800 SRM 1498
Description
The brake system is divided into two subsystems For the description and operation of the brake pres-
which operate on different circuits of the hydraulic sure system, refer to the section Brake Pressure Sys-
system. The two subsystems are as follows: tem.
• Brake Pressure System - Operates the service
brakes and the parking brake. For the description and operation of the brake cooling
• Brake Cooling System - Keeps the hydraulic sys- system, refer to the section Wet Disc Brake Cooling
tem and the wet disc brakes in the drive axle from System.
overheating.
Brake Pressure System

NOTE: Not Applicable for trucks with AIR brake accumulator. See Figure 11, Figure 12 and Fig-
BRAKE configuration. ure 13..
MAIN SYSTEM The hydraulic pressure in the brake accumulator is

maintained between two pressures by the unload-
Introduction ing valve (accumulator charging valve). See Table 3.
When the unloading valve is activated to charge the
The service brakes and the park brake for this lift brake accumulator, it will direct an LS pressure sig-
truck operate on two different subsystems but share nal to the priority valve and the variable displace-
the same brake accumulator. ment pump to supply hydraulic oil flow. When the
unloading valve is not functioning correctly and the
Service Brakes brake accumulator pressure drops below the set pres-
The service brakes for this lift truck are accom- sure, the low brake pressure switch will supply a
plished by the use of multiple friction discs which warning signal to the instrument cluster.
are hydraulically pressed together. The hydraulic The priority valve not only supplies hydraulic oil flow
pressure used to press the friction discs together to the unloading valve, but also to the steering sys-
is controlled by the brake treadle valve. The hy- tem when required/requested.
draulic pressure is supplied to the brake treadle
valve through the functions inside the brake control When both functions are active at the same time, the
manifold and the brake accumulator. See Figure 11, shuttle valve will allow the function with the highest
Figure 12 and Figure 13. LS pressure signal to pass to the priority valve and
variable displacement pump.
Park Brake
The park brake for this lift truck is accomplished by

Hydraulic Oil Flow Path
the use of a brake caliper with a spring-backed pis- The brake pressure system is divided into three sub-
ton. When the park brake is applied, there is no hy- systems:
draulic pressure force against the piston and there- • Brake Accumulator Charging System
fore the spring forces the piston against the pads to • Service Brake System
clamp them against the brake disc. • Parking Brake System
When the park brake is released, the brake control Brake Accumulator Charging System
manifold will direct hydraulic pressure against the
caliper piston which will compress the spring and re- The hydraulic oil pressure in the brake accumulator
lease the brakes pads from the brake disc. is maintained between two pressures by the unload-
ing valve. When the brake accumulator pressure
Description drops below the minimum pressure, the unloading
valve will direct an LS signal to the priority valve
The service brake and park brake systems are both and to the variable displacement pump to supply
controlled by hydraulic pressure that is stored in the hydraulic oil flow. When the brake accumulator
reaches the maximum pressure setting, the charge
16
1800 SRM 1498 Brake Pressure System
cycle will stop by the unloading valve opening the The priority valve will divide the flow between the
LS signal to the hydraulic tank. The check valve will priority functions and other hydraulic functions. The
prevent back flow from the brake accumulator to the priority valve will guarantee that the required flow
hydraulic system. is supplied to the priority functions.
Service Brake System The selection (position) of the priority spool is di-
rectly related with the output flow to the priority
A constant (reduced) pressure from the brake accu- functions. This spool selection is controlled by the
mulator is supplied to the brake pedal by the pres- pressure differential between the pressure directly
sure reducer valve (A) located in the brake control behind the priority spool and the LS signal (function
manifold. When the brake pedal is applied, the brake pressure of the priority function that is active), to the
treadle valve will supply an output pressure related priority valve.
to the position of the brake pedal to the brake flow
distribution manifold. The brake flow distribution When more flow is supplied by the variable displace-
manifold will direct the hydraulic oil pressure to the ment pump to the priority valve than required for the
left and right side wet disc brakes. The hydraulic oil priority function, the pressure differential will not
pressure will act against the wet disc brake pistons, be in balance with the priority valve setting (spring)
which will compress the friction discs and steel discs and the priority spool will shift to relieve the exces-
together, resulting in the braking of the lift truck. sive flow to the pressure gallery of the main control
The brake light switch will be activated with the in- valve. For additional information on the main con-
creased output pressure in the brake treadle valve. trol valve, refer to the manual Hydraulic System
1900 SRM 1478.
Park Brake System
Component Validation for Correct
When the park brake selector valve is activated, it
will direct hydraulic oil pressure supplied by the Operation
brake accumulator to the park brake caliper piston Remove the priority valve from the main control
to compress the spring behind the piston and release valve. With a clean suitable tool, press the spool into
the park brake. the cartridge. If the spool moves smoothly against
When the park brake selector valve is deactivated, the spring, the priority valve is functioning properly
it will close the pressure line and open the tank line and may be reinstalled. When installing the priority
to relieve the hydraulic oil pressure to the hydraulic valve, DO NOT exceed the maximum torque of 217
tank. The spring force will then force the piston for- to 231 N•m (160 to 170 lbf ft).
ward to activate the park brake.
BRAKE CONTROL MANIFOLD
PRIORITY VALVE
Description
Fundamentals The brake control manifold controls the hydraulic
Priority valves are based on pressure compensated oil supply flow and pressure that is required by the
flow control valves. For additional information on brake systems.
flow control valves, refer to the section Basic Prin- There are several internal components in the brake
ciples of Flow Control Systems. control manifold. Refer to Table 3 for the list and
schematic view of the internal components and their
Description basic functions.
The priority valve is used to prioritize the required
flow to the steering system and brake accumulator Orifice (F)
charging system above flow requirements of other Fundamentals
functions.
Orifice (F) is a fixed orifice based on a flow control
Operation valve. For additional information on flow control
valves, refer to the section Basic Principles of Flow
The primary variable displacement pump will sup-
Control Systems.
ply the flow that is required by the hydraulic system.
17
Brake Pressure System 1800 SRM 1498
This fixed orifice is used within an LS system. For to supply hydraulic oil flow to the brake systems.
additional information on LS systems, refer to the When the hydraulic oil flow passes orifice (F), it will
section Basic Principles of Flow Control Systems. create a pressure differential (pressure drop). The
LS signal line is connected directly behind orifice (F)
Description and will supply the active pressure behind orifice (F)
as an LS signal to the priority valve and the variable
Orifice (F) controls the charge flow to the brake ac-
displacement pump.
cumulator.
The priority valve will maintain a fixed pressure dif-
Operation
ferential over the orifice (F) which will control the
When the unloading valve (accumulator charging amount of hydraulic oil flow to the brake accumula-
valve) is activated, the priority valve is signaled tor.
Table 3. Internal Components of the Brake Control Manifold
Component Item Basic Function

Number
Orifice (F) 1 Controls the rate of hydraulic oil flow to the brake accumulator
during charging.
Orifice (G) 2 Limits flow to the unloading valve (accumulator charging valve).
Unloading Valve 3 Controls the charging cut-in (starts charging) and cut-out (stops
charging) pressures of the brake accumulator.
Screen 4 Filters the hydraulic oil flow to the brake accumulator.
Check Valve 5 Prevents back flow from the brake accumulator.
Pressure Reducer 6 Limits the maximum hydraulic oil pressure to the brake systems.
Valve
Park Brake Selector 7 Supplies or relieves hydraulic oil pressure for the park brake.
Valve
Orifice (H) 8 Controls the selection speed of the LS signal.
18
1800 SRM 1498 Brake Pressure System
Component Validation for Correct Operation Pressure Reducer Valve

Refer to the section Checks and Adjustments. Fundamentals
Unloading Valve The pressure reducer valve is based on a pressure

control valve. For additional information on pressure
Fundamentals control valves, refer to the section Basic Principles of
Pressure Control Systems.
The unloading valve (accumulator charging valve) is
based on a pressure control valve. For additional in- Operation
formation on pressure control valves, refer to the sec-
tion Basic Principles of Pressure Control Systems. The pressure reducer valve reduces the hydraulic oil
pressure from the brake accumulator to the set pres-
Operation sure to protect the brake system components from ex-
cessively high hydraulic oil pressures.
The unloading valve controls the amount of hydraulic
oil pressure in the brake accumulator between two Component Validation for Correct Operation
set pressures (cut-in and cut-out pressures). By con-
trolling the two set pressures, the unloading valve, Refer to the section Checks and Adjustments.
in combination with the pre-charged nitrogen gas in
the brake accumulator, will control the pressurized Park Brake Selector Valve
hydraulic oil volume stored in the brake accumula-
Fundamentals
tor.
The park brake selector valve is an electric activated
Component Validation for Correct Operation
directional control valve.
Refer to the section Checks and Adjustments.
Operation
Screen The park brake selector valve has three connections:
• Supply Line - Connection to the brake accumulator.
Description
• Function Line - Connection to the park brake
The screen in the brake control manifold is used to caliper.
protect the components in the brake circuit against • Tank Line - Connection to the hydraulic tank.
large particles.
When 24 volts are present at the park brake selector
Component Validation for Correct Operation valve, it will connect the supply line to the function
line which will disengage the park brake caliper.
Inspect the screen. If particles are found, clean the
screen. If the screen is damaged, replace the screen. When 24 volts are not present at the park brake se-
Refer to the section Checks and Adjustments. lector valve, it will connect the function line to the
tank line to relieve pressure which will engage the
Check Valve park brake caliper.
Description Component Validation for Correct Operation
The check valve in the brake manifold is used to stop Refer to the section Checks and Adjustments.
back flow leakage from the brake accumulator to the
rest of the hydraulic system.
Component Validation for Correct Operation
Remove and visually inspect the check valve seats.

19
Wet Disc Brake Cooling System 1800 SRM 1498
BRAKE ACCUMULATOR BRAKE TREADLE VALVE

Fundamentals Fundamentals
The accumulator used for the brake system is a ni- The brake treadle valve is a pedal-operated, variable-
trogen gas pre-charged piston accumulator. The com- pressure reducing valve.
pressibility of the nitrogen gas used allows the brake
accumulator to store hydraulic oil under pressure. A pressure reducer valve is based on a pressure con-
trol valve. For additional information on pressure
Operation control valves, refer to the section Basic Principles
of Pressure Control Systems.
When the unloading valve is activated to charge the
brake accumulator, it will increase the hydraulic oil Description
supply pressure to the brake accumulator. When the
hydraulic oil supply pressure exceeds the nitrogen The brake treadle valve is used to apply a controlled
gas pressure in the brake accumulator, hydraulic oil hydraulic oil pressure to the service brake which will
will be forced into the brake accumulator. A fur- press the friction discs and steel discs together, re-
ther increase in the hydraulic oil supply pressure will sulting in the braking of the lift truck speed.
cause the nitrogen gas to compress and allow more
hydraulic oil to be forced into the brake accumula- Operation
tor. When the charger cut-out pressure is reached,
The spring package in the brake treadle valve that
the supply pressure will decrease to zero.
controls output pressure is directly connected to the
The hydraulic oil volume stored in the brake accumu- position of the brake pedal. When the brake pedal is
lator can be used by the brake functions without the applied, the spring package will be compressed and
hydraulic pumps having to supply hydraulic oil flow. will adjust the setting (output pressure) of the brake
The pre-charge pressure of the nitrogen gas deter- treadle valve.
mines the amount of usable pressurized oil volume
When the brake pedal is released, the spring force
and therefore needs to be within the specified pres-
will be reduced and will adjust the output pressure
sure range as shown in the schematics and diagrams.
to a lower setting. When the brake pedal is fully re-
Refer to the manual Diagrams 8000 SRM 1500.
leased, the service brake pistons will release pres-
sure to the hydraulic tank.
Component Validation for Correct
Operation
Wet Disc Brake Cooling System

MAIN SYSTEM Description
Introduction The hydraulic oil absorbs the heat from the brake
discs and other components throughout the hy-
The cooling system has two functions: draulic system. When the temperature of the
• Cooling the brake discs. hydraulic oil exceeds the set value, the hydraulic oil
• Cooling the hydraulic system oil. flow from the gear pump will be directed to the hy-
draulic oil cooler core. As the hydraulic oil circulates
See Figure 11, and Figure 14. through the core, it will be cooled by the forced air
from the engine fan.
20
1800 SRM 1498 Wet Disc Brake Cooling System
Hydraulic Oil Flow Path BRAKE COOLING VALVE

Under normal operating conditions, the gear pump Description
supplies the hydraulic oil flow to the brake cool-
ing valve, where the hydraulic oil is then filtered. The brake cooling valve filters the hydraulic oil
Depending on the hydraulic oil temperature, the and directs the hydraulic oil flow to the hydraulic
thermostatic bypass valve in the brake cooling valve oil cooler core when the hydraulic oil temperature
will direct the hydraulic oil flow via the hydraulic exceeds a set value.
oil cooler core to the brake flow distribution valve if
the temperature of the hydraulic oil is above 65°C There are several internal components in the brake
(149°F) or directly to the brake flow distribution cooling valve. Refer to Table 4 for the list and
valve if the temperature is below 65°C (149°F). schematic view of the internal components and their
basic functions.
The brake flow distribution manifold will divide the
hydraulic oil flow evenly into both drive axle cool- Operation
ing chambers. The hydraulic oil will cool the brake
discs and then be directed via the brake flow distribu- The hydraulic oil is filtered through the brake cooling
tion valve and the brake return filter to the hydraulic valve as it cycles through the hydraulic oil cooling
tank. system.
Remark: (K007 & J019) series are not equipped To protect the filter element from pressure spikes
with a Brake Return Line Filter. when the hydraulic oil is below operating tempera-
ture or the filter is restricted, the bypass valve will
Under cold conditions, to prevent excessive back open to bypass the hydraulic filter and direct the hy-
pressures in the brake disc cooling chambers a check draulic oil flow to the thermostatic bypass valve.
valve in the brake flow distribution manifold will
open at a set pressure to relieve the hydraulic oil Thermostatic Bypass Valve
flow to the suction line of the gear pump.
Fundamental
GEAR PUMP The thermostatic bypass valve is a proportional di-
rectional control valve which operates off a wax ele-
Fundamentals ment.
The gear pump is a gear driven pump used to create
Operation
hydraulic oil flow for the hydraulic oil cooling system.
The position of the spool in the thermostatic bypass
Operation valve is based on the temperature of the wax ele-
ment which is positioned in the hydraulic oil. As the
The gear pump can be driven by the shaft of the vari-
hydraulic oil temperature increases and reaches the
able displacement pump or by the auxiliary Power
set value, the wax element will begin to shift due to
Take Off (PTO) of the engine.
thermal expansion which will force the spool to shift,
When the shaft rotates, the internal gears of the opening the passage to the hydraulic oil cooler core.
gear pump will create a partial vacuum to draw the
When the hydraulic oil temperature decreases, the
hydraulic oil from the hydraulic tank into the gear
thermostatic bypass valve will gradually return to
pump. The mechanical action of the gear pump will
the original position, closing the passage to the hy-
trap the hydraulic oil within the pump cavities and
draulic oil cooler core.
then force the hydraulic oil from the pump into the
hydraulic oil cooling system. Component Validation for Correct Operation
The gear pump has a fixed displacement, which Refer to the section Checks and Adjustments.
means that the output flow is directly related to the
size of the pump and the drive speed of the pump
drive shaft.
21
Wet Disc Brake Cooling System 1800 SRM 1498
Table 4. Internal Components of the Brake Cooling Valve
Component Item Basic Function

Number
Filter 1 Maintains the hydraulic oil cleanliness level in the hydraulic system.
Thermostatic Bypass 2 Controls the hydraulic oil work temperature.
Valve
Bypass Valve 3 Protects the filter element against hydraulic pressure spikes.
Filter Restriction 4 Provides a signal to the instrument cluster when the filter needs
Indicator (Optional) to be replaced.
BRAKE FLOW DISTRIBUTION MANIFOLD

Fundamentals
The brake flow distribution manifold contains an in-
ternal pressure relief valve. See Figure 16. For addi-
tional information on pressure relief valves, refer to
the section Basic Principles of Pressure Control Sys-
tems.
Legend for Figure 16

1. INTERNAL PRESSURE RELIEF VALVE
2. BRAKE LIGHT SWITCH
Figure 16. Internal Pressure Relief Valve
22
1800 SRM 1498 Wet Disc Brake Cooling System
Operation The hydraulic oil return flow from the hydraulic cool-
ing system is filtered before entering the hydraulic
The brake flow distribution manifold divides the hy- tank.
draulic oil flow to the different functions of the drive
axle disc brake housings and will combine the return To protect the brake housing cooling chamber and
flow from the functions to the hydraulic system. the filter element from pressure spikes when the hy-
draulic oil is below working temperature or the fil-
The relief valve in the brake flow distribution mani- ter is restricted, the bypass valve will open to bypass
fold will relieve the hydraulic oil flow and pressure to the hydraulic filter and direct the hydraulic oil flow
the suction line of the gear pump when the hydraulic to the hydraulic tank.
oil pressure exceeds the set value in the brake hous-
ing cooling chambers. COOLING SYSTEM AIR BRAKES
NOTE: To bleed the air out of the service brakes, an Main System
air bleed screw is located at port AX.
The cooling system filters and cools the hydraulic
Component Validation for Correct system oil.
Operation
See Figure 12 and Figure 15.
Description
HYDRAULIC OIL COOLER CORE
The hydraulic oil absorbs the heat from the com-
Fundamentals ponents throughout the hydraulic system. When
the temperature of the hydraulic oil exceeds the set
The hydraulic oil cooler core is based on an oil to air value, the hydraulic oil flow from the gear pump will
radiator core and is combined with the cooling system be directed to the hydraulic oil cooler core. As the
of the lift truck. hydraulic oil circulates through the core, it will be
cooled by the forced air from the engine fan.
Operation
Hydraulic Oil Flow Path
When the hydraulic oil temperature from the differ-
ent lift truck hydraulic functions exceeds the thermo- Under normal operating conditions, the gear pump
static bypass valve set temperature, the hydraulic oil supplies hydraulic oil flow to the brake cooling valve,
flow will be directed to the hydraulic oil cooler core. where the hydraulic oil is then filtered.
The hydraulic oil cooler core will absorb the heat from
the hydraulic oil and use the forced air from the en- Depending on the hydraulic oil temperature, the
gine fan to cool the hydraulic oil. thermostatic bypass valve in the brake cooling valve
will direct the hydraulic oil flow directly to the tank
BRAKE RETURN LINE FILTER (J007 & or when the hydraulic oil temperature is above 65°C
H019 ONLY) (149°F) via the hydraulic oil cooler core to the tank.
Operation Component Explanation
NOTE: (K007 & J019) series are not equipped with For explanation of the gear pump, brake cooling
a Brake Return Line Filter. valve and cooler see Main System.
23
Brake Treadle Valve Repair 1800 SRM 1498
Brake Treadle Valve Repair

REMOVE 16. Remove the two capscrews and washers that re-
tain the brake treadle valve to the underside of
1. Place the lift truck on a solid, level surface. the operator’s cab, and remove the brake treadle
valve.
2. Lower the carriage until the lift cylinders are ap-
proximately 25 cm (10 in.) before the completely
INSTALL
retracted position.
1. Position the brake treadle valve to the under-
3. Tilt the mast to the maximum forward position.
side of the operator’s cab and install the two cap-
4. Shut down the engine. screws and washers that retain the brake treadle
valve to the underside of the operator’s cab. See
5. Place blocks in front of and behind the tires to Figure 17.
prevent movement of the lift truck.
2. Position the manifold to the brake treadle valve.
6. Turn the key switch to the ON position.
3. Connect the swivel nut that retains the manifold
to the brake treadle valve.
WARNING
Step 7, Step 8, and Step 9 must be performed 4. Remove the cap from the hydraulic hoses and
to relieve the trapped or stored hydraulic pres- open ports of the brake treadle valve.
sure from the hydraulic system, or serious per-
sonal injury may occur. 5. Connect the two hydraulic hoses to the brake
treadle valve, according to the identification tags.
7. Apply the brake pedal 10 to 20 times until the ac- Refer to the section Torque Specifications for the
cumulated hydraulic brake pressure is released. correct torque procedure.
8. Use the emergency lowering button and operate

the tilt function fully backward to remove the hy-
draulic pressure from the tilt system.

the lowering function to remove the hydraulic
pressure from the lift system. Make sure the lift
cylinders are completely retracted.
10. Turn the key switch to the OFF position.
11. Raise (side tilt) the cab to the fully open position
to gain access to the brake treadle valve. Refer
to the manual Operator’s Cab 100 SRM 1390.
NOTE: Slowly disconnect the hydraulic hoses to re-

lease any hydraulic pressure.
12. Tag and disconnect the two hydraulic hoses from

the brake treadle valve. See Figure 17.
13. Place a cap on the hydraulic hoses and open ports

of the brake treadle valve. 1. MANIFOLD
2. SWIVEL NUT
14. Disconnect the swivel nut that retains the mani- 3. BRAKE TREADLE VALVE
fold to the brake treadle valve. 4. CAPSCREW
5. HYDRAULIC HOSE
15. Remove the manifold from the brake treadle
valve. Figure 17. Brake Treadle Valve
24
1800 SRM 1498 Accumulator
6. Lower the cab until it is in the fully lowered and 8. Operate the brake treadle valve and check for
latched position. Refer to the manual Opera- leaks.
tor’s Cab 100 SRM 1390.
7. Check the pedal position and adjust if necessary.

Refer to the manual Operator’s Cab 100 SRM
1390.
Accumulator
REMOVE NOTE: Slowly disconnect the hydraulic hose to re-
1. Place the lift truck on a solid, level surface.
13. Tag and disconnect the hydraulic hose from the
2. Apply the parking brake. accumulator located at the left inside of the
frame. See Figure 18.
proximately 25 cm (10 in.) before the completely 14. Place a cap on the hydraulic hose and open the
retracted position. port of the accumulator.
4. Tilt the mast to the maximum forward position. 15. Loosen the capscrews and nuts that retain the
two brackets to the frame. See Figure 18.
5. Shut down the engine.
16. Remove the accumulator from the frame.
6. Place blocks in front of and behind the tires to
8. Operate the tilt function backward to remove the

hydraulic pressure from the tilt system.
WARNING
Step 9, Step 8, and Step 10 must be performed
to relieve the trapped or stored hydraulic pres-
sonal injury may occur.
9. Apply the brake pedal 10 to 20 times until the ac-

cumulated hydraulic brake pressure is released.

cylinders are completely retracted. 1. NUT 4. HYDRAULIC HOSE
2. ACCUMULATOR 5. BRACKET
11. Turn the key switch to the OFF position. 3. CAPSCREW 6. CAPSCREW
12. Raise (side tilt) the cab to the fully open position Figure 18. Accumulator
to gain access to the brake accumulator. Refer to
the manual Operator’s Cab 100 SRM 1390.
25
Accumulator 1800 SRM 1498
DISASSEMBLE 8. Remove the swivel nut from the gas valve. Keep
the gas valve in place while loosening the swivel
1. Close the bleed valve on the gauge assembly. See nut.
Figure 19.
9. Place the accumulator in a horizontal position
2. Turn the T-handle at the gauge assembly all the and keep it in place with a strap wrench or a vise.
way out.
10. Remove the gas valve from the gas cap. See Fig-
3. Remove the gas valve guard located on the gas ure 20.
cap of the accumulator.
11. Remove the O-ring from the gas valve.
4. Remove the dust cap from the gas valve.
12. Install three pins into the holes in the gas cap.
5. Attach the swivel nut from the gauge assembly
to the gas valve on the accumulator and tighten 13. Using a long bar, work against the pins to un-
to 1.13 to 1.69 N•m (10 to 15 lbf in). screw the gas cap from the shell.
6. Turn the T-handle at the gauge assembly all the 14. Install three pins into the holes in the hydraulic
way in to open the gas valve. cap.
15. Using a long bar, work against the pins to un-

WARNING screw the hydraulic cap from the shell.
Nitrogen gas is a colorless, odorless gas and
may cause dizziness or asphyxiation without 16. Remove the O-ring and O-ring backup washer
warning. Nitrogen gas is initially heavier than from the gas cap and hydraulic cap.
air and will spread along the ground. Make
sure to wear hand gloves and eye protection 17. Remove the piston by pushing a bar into the shell
and always work in a well-ventilated area. from the hydraulic cap location.
7. Open the bleed valve until all the nitrogen gas is 18. Remove the wear rings from the piston.
relieved from the accumulator. 19. Remove the V O-ring and V O-ring backup wash-
ers from the piston with a smooth pointed instru-
ment by moving the tool around the piston while
pushing the V O-ring from the piston.
A. GAUGE WITH CHARGING HOSE B. GAUGE WITHOUT CHARGING HOSE

1. T-HANDLE 3. GAS CHUCK
2. BLEED VALVE 4. SWIVEL NUT
Figure 19. Bleed Valve
26
CLEAN INSPECT
1. Inspect the piston for cracks, burrs, and damage
WARNING around the O-ring grooves.
Compressed air can move particles so they
cause injury to the user or other personnel. 2. Use a light to inspect the shell bore for scratches
Make sure the path of the compressed air is and scoring.
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the 3. Inspect the gas cap and hydraulic cap for dam-
eyes. aged threads and cracks, burrs, and damage
around the O-ring grooves.
NOTE: The shell bore must be clean of any particles
detectable to the touch. 4. Inspect the thread undercuts at both ends of the
shell for evidence of wear, damage, and stress
1. Thoroughly clean the metal parts in solvent and cracks.
dry with compressed air.
2. Clean the shell bore with a clean, lint-free cloth

soaked in clean solvent.
1. SHELL 6. BACKUP WASHER 11. O-RING

2. HYDRAULIC END CAP 7. WEAR RING 12. GAS VALVE GUARD
3. GAS VALVE CAP 8. O-RING 13. SCREW
4. PISTON 9. BACKUP WASHER
5. V O-RING 10. GAS VALVE
Figure 20. Removing Gas Valve
27
Accumulator 1800 SRM 1498
REPAIR 6. Install the O-ring backup washer first on the

gas cap and hydraulic cap, and then install the
NOTE: Minor nicks, scratches, and light scoring of O-ring on the gas cap and hydraulic cap. Make
the shell bore can be removed by using crocus cloth. sure the O-ring backup washer is installed in
the groove nearest to the outside of the gas cap
1. Polish the shell bore until all apparent imperfec-
and hydraulic cap, with the flat face facing out-
tions have been removed.
ward. Do not drag the O-ring and O-ring backup
2. Replace the wear rings, V O-rings, V O-ring washer over the threads.
backup washers, O-rings, and O-ring backup
NOTE: The O-ring is not dependent on cap tightness.
washers.
Excessive tightening of the cap is not required. The
caps should not extend more than 3 mm (0.12 in.)
ASSEMBLE
above the end of the shell.
CAUTION 7. Install the gas cap and hydraulic cap into the
DO NOT let the V O-ring drag on the threads. shell bore. Make sure the gas cap is facing to-
The piston must be installed into the shell bore ward the hollow side of the piston. The gas cap
exactly square and very slowly. The V O-ring and hydraulic cap will stop against the chamfer
will compress as it rides up the chamfer in the leading into the shell bore.
shell bore. The V O-ring will be damaged if it is
8. Install the O-ring on the gas valve.
forced into the shell bore quickly. The piston
should fit snugly. 9. Install the gas valve on the gas cap and tighten
to 25 to 29 N•m (18.5 to 21.5 lbf ft).
NOTE: Coat all internal parts with clean hydraulic
oil before reassembly. 10. Fill the accumulator to the required pre-charge
pressure of 10.35 MPa (1,500 psi). Refer to the
NOTE: Always use new wear rings, V O-rings, V
section Pre-Charge Filling for the correct fill pro-
O-ring backup washers, O-rings, and O-ring backup
cedure.
washers.
11. Install the dust cap on the gas valve and tighten
1. Install the V O-ring and V O-ring backup wash-
to 1.5 to 1.7 N•m (13.28 to 15.05 lbf in).
ers on the piston.
12. Install the capscrews that retain the gas valve
2. Install the wear rings on the piston.
guard to the gas cap.
3. Install the piston into the shell bore.
INSTALL
CAUTION 1. Install the accumulator to the brackets inside the
If force is not continuously applied against the frame. Make sure the hose connection is facing
piston while tapping the V O-ring through the toward the front of the lift truck.
bore chamfer, the piston will spring back and
2. Install the capscrews and nuts that retain the
cause damage to the V O-ring.
two brackets and accumulator to the frame.
4. Use a hammer and a wooden block to tap the
3. Remove the cap from the hydraulic hose and from
piston into place until the complete piston passes
the open port of the accumulator.
the beginning of the chamfer inside the shell bore
by at least 51 mm (2 in.). 4. Connect the hydraulic hose to the accumulator,
according to the identification tag. Refer to
5. Cover the shell opening to keep the dirt out of the
the section Torque Specifications for the correct
bore.
torque procedure.
NOTE: The O-ring backup washers have a flat face
5. Lower the cab until it is in the fully lowered and
and a convex face to allow the O-ring and O-ring
latched position. Refer to the manual Opera-
backup washer to seat correctly.
28
6. Operate the system and check for leaks. 9. Use the emergency lowering button and operate
PRE-CHARGE FILLING draulic pressure from the tilt system.

WARNING
Nitrogen gas is a colorless, odorless gas and pressure from the lift system. Make sure the lift
may cause dizziness or asphyxiation without cylinders are completely retracted.
warning. Nitrogen gas is initially heavier than
air and will spread along the ground. Make 11. Turn the key switch to the OFF position.
sure to wear hand gloves and eye protection
and always work in a well-ventilated area. 12. Raise (side tilt) the cab to the fully open position
to gain access to the brake accumulator. Refer to
NOTE: If water-pumped nitrogen is not available, oil- the manual Operator’s Cab 100 SRM 1390.
pumped nitrogen may be used.
NOTE: The nitrogen pre-charge filling of the accu- WARNING

mulator requires a charging and gauging assembly. Nitrogen gas is a colorless, odorless gas and
Contact your Hyster dealer for the required assem- may cause dizziness or asphyxiation without
bly. warning. Nitrogen gas is initially heavier than
NOTE: Accumulator refill kits are available through sure to wear hand gloves and eye protection
the aftermarket direct ship program or locally. and always work in a well-ventilated area.
1. Place the lift truck on a solid, level surface. 13. Make sure the nitrogen bottle valve is SHUT
OFF (CLOSED).
2. Apply the parking brake.
14. Attach a hose between the nitrogen bottle valve
and the gauge assembly.
retracted position. 15. Close the bleed valve on the gauge assembly. See
Figure 19.
16. Turn the T-handle at the gauge assembly all the
way out.
17. Remove the gas valve guard located on the gas
cap of the accumulator.
18. Remove the dust cap from the gas valve.
WARNING 19. Attach the swivel nut from the gauge assembly
Step 8, Step 9, and Step 10 must be performed to the gas valve on the accumulator and tighten
to relieve the trapped or stored hydraulic pres- to 1.13 to 1.69 N•m (10 to 15 lbf in).
sure from the hydraulic system, or serious per- 20. Turn the T-handle at the gauge assembly all the
sonal injury may occur. way in to get the pressure reading.
29
Parking Brake 1800 SRM 1498
assembly. Close the bleed valve when the correct

WARNING value is obtained.
Nitrogen gas is a colorless, odorless gas and
may cause dizziness or asphyxiation without 23. Turn the T-handle at the gauge assembly all the
warning. Nitrogen gas is initially heavier than way out.
sure to wear hand gloves and eye protection 24. Remove the swivel nut from the gas valve. Keep
and always work in a well-ventilated area. the gas valve in place while loosening the swivel
nut.
CAUTION 25. Install the dust cap on the gas valve and tighten
Only fill the accumulator when the nitrogen to 1.5 to 1.7 N•m (13.28 to 15.05 lbf in).
gas and the accumulator are at the tempera-
26. Install the capscrews that retain the gas valve
ture of approximately 20°C (68°F).
guard to the gas cap and tighten to 1.13 to
21. Open the nitrogen bottle valve, slowly fill the ac- 1.69 N•m (10 to 15 lbf in).
cumulator to the required pre-charge pressure of
10.35 MPa (1,500 psi), and then close the nitro-
gen bottle valve.
22. Allow the pre-charge to set for 10 to 15 min-
28. Remove and properly store the hose between the
utes until the nitrogen gas temperature stabi-
nitrogen bottle and the gauge assembly.
lizes. If the required pre-charge pressure is ex-
ceeded, slowly open the bleed valve on the gauge
Parking Brake
PARKING BRAKE CALIPER 8. Use the emergency lowering button and operate
Remove draulic pressure from the tilt system.
1. Place the lift truck on a solid, level surface. 9. Use the emergency lowering button and operate
2. Lower the carriage until the lift cylinders are ap- pressure from the lift system. Make sure the lift
proximately 25 cm (10 in.) before the completely cylinders are completely retracted.
retracted position.
4. Shut down the engine. to gain access to the parking brake caliper. Refer
to the manual Operator’s Cab 100 SRM 1390.
prevent movement of the lift truck. NOTE: Slowly disconnect the hydraulic hose to re-
12. Tag and disconnect the hydraulic hose from the
WARNING parking brake. See Figure 21.
13. Place a cap on the hydraulic hose and open the
port of the parking brake.
sonal injury may occur. 14. Remove the parking brake caliper pads. Refer to
the section Parking Brake Caliper Pads, Remove.
30
1800 SRM 1498 Parking Brake
15. Remove the cotter pin that retains the castle nut
in place on the guide bolt. See Figure 22.
16. Remove the castle nut from the guide bolt.
17. Remove the guide bolt from the parking brake

and parking brake bracket.
18. Remove the parking brake from the parking

brake bracket.
1. PARKING BRAKE
2. HYDRAULIC HOSE
Figure 21. Hydraulic Hose 1. COTTER PIN 3. PARKING BRAKE

2. CASTLE NUT 4. GUIDE BOLT
Figure 22. Cotter Pin, Castle Nut, and Guide

Bolt
31
Disassemble 1. Install the friction sleeve, retainer ring, and mag-

net to the thrust bolt.
1. Remove the screw cap from the pressure ring.
See Figure 23. 2. Install the O-ring on the thrust bolt.
2. Loosen the lock nut.

CAUTION
3. Turn the adjustment screw counterclockwise un- Incorrect assembly of the piston seals will re-
til the adjustment screw extends 27 to 30 mm (1.1 sult in leakage and loss of pressure. Make sure
to 1.2 in.) outside the piston. to install the piston seals as shown in Figure 24.
4. Remove the large snap ring that retains the pres- 3. Use a suitable tool with round edges and install
sure ring to the parking brake housing. the piston seals into the parking brake housing.
Make sure not to damage the piston seal lips.
5. Remove the pressure ring from the parking brake
housing. 4. Install the O-rings on the pressure ring.
6. Remove the disc springs from the parking brake 5. Use a suitable seal driver and a screw-type clamp
housing. Make sure to maintain the disc spring to press a new dust cap into the parking brake
orientation. housing.
7. Remove the wear plate from the parking brake 6. Lightly grease the sliding and seal surfaces of the
housing. piston with silicon grease (Dow Corning® DC-4
or equivalent).
8. Remove the piston from the parking brake hous-
ing. 7. Install the piston and thrust bolt assembly and
place the dust cap lip into the thrust bolt groove.
9. Remove the thrust bolt from the parking brake
housing. 8. Install the wear plate into the parking brake
housing against the piston.
10. Use a suitable tool to pry out the dust cap from
the parking brake housing. 9. Install the disc springs into the parking brake
housing in the original orientation against the
11. Remove the O-rings from the pressure ring.
wear plate.
12. Remove the piston seals from the parking brake
10. Install the pressure ring into the parking brake
housing.
housing against the disc springs.
13. Remove the magnet, retainer ring, and friction
11. Install the large snap ring that retains the pres-
sleeve from the thrust bolt.
sure ring inside the parking brake housing.
14. Remove the O-ring from the thrust bolt.
Install
Clean and Inspect 1. Position the parking brake to the parking brake
1. Inspect the piston and parking brake housing bracket and install one guide bolt to retain the
bores for scratches and corrosion. Use a fine parking brake to the parking brake bracket.
emery cloth to remove scratches or corrosion.
2. Install the castle nut to the guide bolt.
2. Replace worn or damaged components.
3. Install the cotter pin that retains the castle nut
3. Replace components that are heavily corroded or to the guide bolt.
have large scratches.
4. Install the parking brake caliper pads. Refer to
the section Parking Brake Caliper Pads, Install.
Assemble
5. Remove the cap from the hydraulic hose and the
NOTE: Always use new O-rings, dust cap, and piston
open port of the parking brake.
seals.
32
1800 SRM 1498 Parking Brake
6. Connect the hydraulic hose to the parking brake, 8. Remove the air from the parking brake. Refer to
according to the identification tag. Refer to the section Parking Brake Bleed.
the section Torque Specifications for the correct
torque procedure. 9. Adjust the parking brake. Refer to the section
Parking Brake Adjustment.
latched position. Refer to the manual Opera- 10. Operate the parking brake and check for leaks.
1. PARKING BRAKE HOUSING 10. FRICTION SLEEVE 19. O-RING

2. LARGE SNAP RING 11. MAGNET 20. O-RING
3. PRESSURE RING 12. PISTON SEAL 21. DISC SPRING
4. PISTON 13. PISTON SEAL 22. WEAR PLATE
5. SCREW CAP 14. ADJUSTMENT SCREW 23. THRUST BOLT
6. GUIDE BOLTS 15. LOCK NUT 24. BLEEDER SCREW
7. RETAINER CUP 16. CASTLE NUT 25. WASHER
8. DUST CAP 17. COTTER PIN 26. INLET ADAPTER
9. BRAKE PADS 18. O-RING
Figure 23. Parking Brake Caliper
33
11. Remove the parking brake caliper pads from the

parking brake in the same direction that the
guide bolt was removed.
Install
1. Install the new parking brake caliper pads to the
parking brake.
2. Install the guide bolt that retains the parking

brake caliper pads to the parking brake.
3. Install the castle nut to the guide bolt.
4. Install the cotter pin that retains the castle nut

to the guide bolt.
1. CUP SPRING 4. PISTON SEALS 5. Lower the cab until it is in the fully lowered and
2. SNAP RING 5. DUST CAP latched position. Refer to the manual Opera-
3. PRESSURE RING tor’s Cab 100 SRM 1390.
Figure 24. Piston Seals 6. Adjust the parking brake. Refer to the section
Parking Brake Adjustment.
PARKING BRAKE CALIPER PADS
7. Operate the parking brake and check for leaks.
Remove
Parking Brake Bleed
NOTE: The parking brake must be bled to remove all
2. Place blocks in front of and behind the tires to air after the hydraulic hose has been disconnected.
to gain access to the parking brake. Refer to the 2. Place blocks in front of and behind the tires to
manual Operator’s Cab 100 SRM 1390. prevent movement of the lift truck.
4. Remove the screw cap from the pressure ring. 3. Tilt the mast to the maximum forward position.
5. Loosen the lock nut. 4. Raise (side tilt) the cab to the fully open position
to gain access to the parking brake. Refer to the
6. Turn the adjustment screw counterclockwise un- manual Operator’s Cab 100 SRM 1390.
til the parking brake is released.
5. Place a clear tube on the bleeder screw. See Fig-
7. Use a screwdriver to push the parking brake ure 25.
pads away from the parking brake disc to cre-
ate clearance for the new parking brake caliper 6. Place the other end of the clear tube in a suitable
pads. container.
NOTE: Only one guide bolt needs to be removed to 7. Apply the parking brake.
replace the parking brake caliper pads.
8. Loosen the bleeder screw until no air bubbles ap-
8. Remove the cotter pin that retains the castle nut pear in the clear tube and suitable container and
in place on the guide bolt. tighten the bleeder screw.
9. Remove the castle nut from the guide bolt. 9. Tighten the bleeder screw to 12 to 16 N•m (9 to
12 lbf ft).
10. Remove the guide bolt from the parking brake
and parking brake bracket. 10. Remove the clear tube from the bleeder screw.
34
1800 SRM 1498 Brake Flow Distribution Manifold
11. Lower the cab until it is in the fully lowered and 10. Install and hand-tighten the screw cap.
tor’s Cab 100 SRM 1390. 11. Lower the cab until it is in the fully lowered and
12. Apply the parking brake several times. tor’s Cab 100 SRM 1390.
13. Check for hydraulic leaks. 12. After the cab has been fully lowered and latched,
adjust the parking brake prior to lift truck oper-
Parking Brake Emergency Release ation. Refer to the section Parking Brake Adjust-
ment.
NOTE: When no hydraulic pressure is available, the
parking brake can be released manually.


manual Operator’s Cab 100 SRM 1390.
7. Turn the adjustment screw counterclockwise un-

til the parking brake is released. Emergency re-
lease requires approximately 40 N•m (30 lbf ft)
torque on the adjustment screw.
1. BLEEDER SCREW 3. CLEAR TUBE
8. Use a screwdriver to push the parking brake 2. PARKING BRAKE
caliper pads away from the parking brake disc
to create clearance. Figure 25. Clear Tube and Bleeder Screw
9. Keep the adjustment screw in position and

tighten the lock nut securely.
Brake Flow Distribution Manifold

REMOVE 5. Raise (side tilt) the cab to the fully open position
to gain access to the brake flow distribution man-
1. Place the lift truck on a solid, level surface. ifold. Refer to the manual Operator’s Cab 100
SRM 1390.
prevent movement of the lift truck. 6. Remove the hydraulic plate to gain access to the
brake flow distribution manifold. Refer to the
manual Hydraulic System 1900 SRM 1478.
4. Place a clean and suitable container under the
NOTE: Before disconnecting the hydraulic hoses,
hydraulic tank. Remove the drain plug at the
place a suitable container under the hydraulic hose
bottom of the hydraulic tank and drain the hy-
connections to catch the hydraulic oil from the hy-
draulic oil [approximately 325 liter (86 gal)] from
draulic hoses.
the hydraulic tank.
35
Brake Flow Distribution Manifold 1800 SRM 1498
7. Tag and disconnect the hydraulic return line fil- 11. Tag and disconnect the hydraulic hose from the
ter hose, hydraulic brake treadle valve hose, and brake flow distribution manifold that leads to the
hydraulic brake cooling valve hose on top of the gear pump. Place a cap on the hydraulic hose and
brake flow distribution manifold. Place a cap on on the open port of the brake flow distribution
the hydraulic hoses and on the open ports of the manifold.
brake flow distribution manifold.
12. Remove the four capscrews and washers that re-
8. Tag and disconnect the coolant supply and retain the brake flow distribution manifold to the
turn hoses from the brake flow distribution man- inside of the frame. See Figure 28.
ifold. Place a cap on the coolant supply and re-
turn hoses and on the open ports of the brake flow
distribution manifold. See Figure 26.
9. Tag and disconnect the brake hoses from the

brake flow distribution manifold. Place a cap
on the brake hoses and on the open ports of the
brake flow distribution manifold. See Figure 27.
10. Loosen the hose clamp that retains the hydraulic

hose that leads to the gear pump.
A. TURNED 180 DEGREES

1. COOLANT RETURN HOSE
1. BRAKE RETURN LINE FILTER HOSE 2. BRAKE FLOW DISTRIBUTION MANIFOLD
2. BRAKE TREADLE VALVE HOSE 3. COOLANT SUPPLY HOSE
3. BRAKE FLOW DISTRIBUTION MANIFOLD 4. BRAKE HOSE
4. BRAKE COOLING VALVE HOSE 5. GEAR PUMP HOSE
6. HOSE CLAMP
Figure 26. Coolant Supply and Return Hoses
Figure 27. Brake Hoses
36
1800 SRM 1498 Brake Flow Distribution Manifold
CLEAN AND INSPECT

1. Inspect the brake flow distribution manifold bore
for scratches and corrosion. Use a fine emery
cloth to remove scratches or corrosion.
ASSEMBLE
NOTE: Always use new O-rings.
1. Install the new O-ring(s) to the cartridge. See

Figure 29.
2. Install the cartridge in the brake flow distribu-

tion manifold and tighten. Refer to the section
1. CAPSCREW Torque Specifications for the correct torque pro-
2. WASHER cedure.
3. PART OF FRAME
4. BRAKE FLOW DISTRIBUTION MANIFOLD INSTALL
Figure 28. Flow Manifold 1. Position the brake flow distribution manifold to
the inside of the frame. Install the four cap-
PRESSURE RELIEF VALVE screws and washers that retain the brake flow
distribution manifold to the inside of the frame.
Disassemble
2. Remove the cap from the hydraulic hoses and the
1. Remove the cartridge from the brake flow distri- open ports of the brake flow distribution mani-
bution manifold. See Figure 29. fold.
2. Remove the O-ring(s) from the cartridge. 3. Connect the hydraulic hose that leads to the gear
pump to the brake flow distribution manifold and
tighten the hose clamp.
4. Connect the brake hoses to the brake flow distri-

bution manifold, according to the identification
tags. Refer to the section Torque Specifications
for the correct torque procedure.
5. Connect the coolant supply and return hoses to

the brake flow distribution manifold, according
to the identification tags. Refer to the section
Torque Specifications for the correct torque pro-
cedure.
6. Connect the hydraulic return line filter hose, hy-

draulic brake treadle valve hose, and hydraulic
brake cooling valve hose on top of the brake flow
distribution manifold, according to the identifi-
cation tags. Refer to the section Torque Specifi-
cations for the correct torque procedure.
7. Install the hydraulic plate inside the frame. Re-

fer to the manual Hydraulic System 1900 SRM
1. BRAKE FLOW DISTRIBUTION MANIFOLD 1478.
2. REMOVABLE CARTRIDGE
Figure 29. Brake Flow Distribution Manifold
37
Brake Control Manifold 1800 SRM 1498
the manual Periodic Maintenance 8000 SRM

CAUTION 1475.
Use a filtration system when filling the hy-
draulic tank to prevent dirt and contamination 9. Lower the cab until it is in the fully lowered and
from entering the hydraulic system. If dirt or latched position. Refer to the manual Opera-
contamination enters the hydraulic system, tor’s Cab 100 SRM 1390.
damage may occur to the components of the
10. Operate the brake system and check for leaks.
hydraulic system.
8. Fill the hydraulic tank with clean hydraulic oil

as specified in the maintenance table. Refer to
Brake Control Manifold

REMOVE 8. Apply brake pedal 10 to 20 times until the accu-
mulated hydraulic brake pressure is released.
WARNING 9. Use the emergency lowering button and operate
Lower the carriage completely before working the tilt function fully backward to remove the hy-
on the main control valve or hydraulic system. draulic pressure from the tilt system.
DO NOT work under a raised carriage. The 10. Use the emergency lowering button and operate
mast can lower suddenly and cause injury if the lowering function to remove the hydraulic
the carriage is not lowered. This procedure pressure from the lift system. Make sure the lift
will make sure that the carriage cannot lower cylinders are completely retracted.
suddenly and cause injury or death.
WARNING 12. Raise (side tilt) the cab to the fully open posi-
The engine must be at room temperature be- tion to gain access to the brake control manifold.
fore starting disassembly or personal injury Refer to the manual Operator’s Cab 100 SRM
may occur. 1390.
1. Place the lift truck on a solid, level surface. 13. Tag and disconnect the electrical connector from
the low pressure brake switch located on the
brake control manifold.
14. Tag and disconnect the three hydraulic hoses
from the brake control manifold. See Figure 30.
retracted position.
15. Place caps on the hydraulic hoses and the open
ports of the brake control manifold.
16. Remove the two capscrews that retain the brake
6. Place blocks on both sides (front and back) of the control manifold to the main control valve and
tires to prevent movement of the lift truck. remove the main control valve.
7. Turn the key switch to the ON position. DO 17. Place the brake control manifold on a clean and
NOT START THE ENGINE. level surface.
WARNING
38
1800 SRM 1498 Brake Control Manifold
Orifices F and G Orifice H

Disassemble Disassemble
1. Remove orifice F and/or orifice G from the brake NOTE: The brake control manifold must be separated
control manifold. from the main control valve before removal from ori-
fice H.
2. Visually inspect orifice to ensure cleanliness and
there is no damage. 1. Remove the brake control manifold from the
main control valve.
3. Clean or replace if necessary.
2. Visually inspect orifice to ensure cleanliness and
Assemble there is no damage.
1. Replace O-ring and re-install the orifice back into 3. Clean or replace if necessary.
the brake control manifold.
Assemble
1. Replace O-ring and re-install the orifice back into

Unloading Valve (B)

Disassemble
1. Remove the unloading valve (B) from the brake

control valve. See Figure 30.
2. Remove the seals from the unloading valve (B).

See Figure 31.
1. HIC, BRAKE/ACCUMULATOR
2. SCREW
3. O-RING
4. O-RING
5. PRESSURE REDUCING VALVE
6. CHECK VALVE
7. UNLOADING VALVE
8. SOLENOID VALVE 1. UNLOADING VALVE
Figure 30. Brake Control Manifold Figure 31. Unloading Valve (B)
39
Brake Control Manifold 1800 SRM 1498
Assemble Pressure Reducer Valve (C)

NOTE: Always use new seals. Disassemble
1. Install a new seal kit on the unloading valve (B). 1. Remove the pressure reducer valve (C) from the
See Figure 31. brake control manifold. See Figure 30.
2. Remove the seals from the pressure reducer

CAUTION valve (C). See Figure 33.
DO NOT exceed the maximum torque when
tightening the unloading valve (B) as damage
can occur.
2. Install the unloading valve (B) into the brake

control manifold. Tighten the unloading valve
(B) to 41 to 47 N•m (30 to 35 lbf ft).
Screen
Disassemble
1. Remove the Screen cartridge from the mid inlet.

Visually inspect the screen for damage and/or
contamination.
Assemble
1. Clean the screen or replace it.
Check Valve (E)

1. CHECK VALVE
Disassemble
Figure 32. Check Valve (E)
1. Remove the check valve (E) from the brake con-
trol manifold. See Figure 30.
2. Remove the seals from the check valve (E). See

Figure 32.
Assemble
NOTE: Always use new seals.
1. Install a new seal kit on the check valve (E). See

Figure 32.
CAUTION
tightening the check valve, as damage can
occur.
2. Install the check valve into the brake control

manifold. Tighten the check valve to 27 to
34 N•m (20 to 25 lbf ft). 1. PRESSURE REDUCER VALVE (C)
Figure 33. Pressure Reducer Valve (C)
40
1800 SRM 1498 Brake Control Manifold
Assemble 4. Remove the seals from the park brake selector

valve (A).
NOTE: Always use new seals.
Assemble
1. Install a new seal kit on the pressure reducer
valve. See Figure 33. NOTE: Always use new seals.
1. Install a new seal kit on the park brake selector

CAUTION valve (A). See Figure 34.
tightening the pressure reducer valve, as dam-
age can occur.
CAUTION
2. Install the pressure reducer valve into the brake tightening the park brake selector valve, as
control manifold. Tighten the pressure reducer damage can occur.
valve to 45 to 50 N•m (33 to 37 lbf ft).
2. Install the park brake selector valve into the
Park Brake Selector Valve (A) brake control manifold. Tighten the park brake
selector valve to 35 to 40 N•m (26 to 30 lbf ft).
Disassemble
1. Remove the nut that retains the coil to the park CAUTION
brake selector valve (A). See Figure 34. DO NOT exceed the maximum torque when
tightening the park brake selector valve coil
2. Remove the coil from the park brake selector nut, as damage can occur.
valve (A).
3. Install the park brake selector valve coil and nut.
3. Remove the park brake selector valve (A) from Tighten the nut to 4 to 6 N•m (35 to 53 lbf in).
INSTALL
1. Install the two capscrews that retain the brake
control manifold to the main control valve.
2. Connect the three hydraulic hoses to the brake

control manifold, according to the identification
tags. Refer to the section Torque Specifications
for the correct torque procedure.
3. Connect the electrical connector to the low pres-

sure brake switch.

5. Apply the parking brake several times.
6. Make sure the parking brake functions properly.
1. PARK BRAKE SELECTOR VALVE (A) 7. If necessary, bleed the parking brake. Refer to
2. COIL NUT the section Parking Brake Bleed.
Figure 34. Park Brake Selector Valve (A)
41
Brake Cooling Valve 1800 SRM 1498
Brake Cooling Valve

REMOVE CAUTION
1. Place the lift truck on a solid, level surface. Use a filtration system when filling the hy-
draulic tank to prevent dirt and contamination
2. Tilt the mast to the maximum forward position. from entering the hydraulic system. If dirt or
contamination enters the hydraulic system,
3. Place a clean and suitable container under the damage may occur to the components of the
hydraulic tank. Remove the drain plug at the hydraulic system.
draulic oil [approximately 325 liter (86 gal)] from 5. Fill the hydraulic tank with clean hydraulic oil
the hydraulic tank. as specified in the maintenance table. Refer to
the manual Periodic Maintenance 8000 SRM
4. Raise (side tilt) the cab to the fully open position 1475.
to gain access to the brake cooling valve. Refer to
the manual Operator’s Cab 100 SRM 1390. 6. Lower the cab until it is in the fully lowered and
NOTE: Slowly disconnect the hydraulic hoses to re- tor’s Cab 100 SRM 1390.
5. Tag and disconnect the four hydraulic hoses from
the brake cooling valve. See Figure 35.
6. Place a cap on the four hydraulic hoses and on

the open ports of the brake cooling valve.
7. Disconnect the electrical filter restriction indica-

tor connector, if equipped, from the filter restric-
tion indicator located on the brake cooling valve.
See Figure 35.
8. Remove the two capscrews and washers that re-

tain the brake cooling valve to the inside the
frame and remove the brake cooling valve.
INSTALL
1. Position the brake cooling valve to the inside
of the frame and install the two capscrews and
washers that retain the brake cooling valve to
the inside of the frame.
2. Connect the electrical filter restriction indicator 1. HYDRAULIC HOSE

connector, if equipped, to the filter restriction in- 2. CAPSCREW AND WASHER
3. BRAKE COOLING VALVE
dicator on the brake cooling valve. 4. ELECTRICAL FILTER RESTRICTION INDICATOR
CONNECTOR (OPTIONAL)
open ports of the brake cooling valve. Figure 35. Brake Cooling Valve
4. Connect the four hydraulic hoses to the brake
cooling valve, according to the identification tags.
Refer to the section Torque Specifications for the
correct torque procedure.
42
1800 SRM 1498 Brake Cooling Valve
FILTER RESTRICTION INDICATOR the manual Periodic Maintenance 8000 SRM

(OPTIONAL) 1475.
Remove 5. Lower the cab until it is in the fully lowered and

1. Place the lift truck on a solid, level surface. tor’s Cab 100 SRM 1390.
2. Tilt the mast to the maximum forward position. 6. Operate the brake system and check for leaks.

draulic oil approximately 325 liter (86 gal)] from
the hydraulic tank.

5. Disconnect the electrical filter restriction indica-

tor connector from the filter restriction indicator
located on the brake cooling valve. See Figure 35.
6. Remove the filter restriction indicator from the

brake cooling valve. See Figure 36.
7. Remove the O-ring and seal from the filter re-

striction indicator. See Figure 37.
Install
NOTE: Always use a new O-ring and seal.
1. Install a new O-ring and new seal on the filter

restriction indicator. See Figure 36.
2. Install the filter restriction indicator to the brake

cooling valve and torque to 30 N•m (22 lbf ft).
3. Connect the electrical filter restriction indica-

tor connector to the filter restriction indicator
located on the brake cooling valve.
CAUTION
from entering the hydraulic system. If dirt or 1. FILTER ELEMENT
2. ELECTRICAL FILTER RESTRICTION INDICATOR
damage may occur to the components of the Figure 36. Electrical Filter Restriction
hydraulic system. Indicator
43
Brake Cooling Valve 1800 SRM 1498
2. Insert the new filter cartridge.
3. Install the bowl by turning the bowl clockwise

hand tight and then 1/4 revolution back.
CAUTION
from entering the hydraulic system. If dirt or
damage may occur to the components of the
hydraulic system.

1. FILTER RESTRICTION INDICATOR
2. O-RING the manual Periodic Maintenance 8000 SRM
1475.
Figure 37. Filter Restriction Indicator
FILTER latched position. Refer to the manual Opera-
Remove

draulic oil approximately 325 liter (86 gal) from
the hydraulic tank.

5. Loosen the brake filter by using a hexagon tool

size 27 mm (1 1/16 in.) to turn the bowl counter-
clockwise. See Figure 38.
6. Remove the filter cartridge.
Install
1. HYDRAULIC HOSE
NOTE: Check the condition of the O-ring. Replace if 2. CAPSCREW AND WASHER
required. 3. BRAKE COOLING VALVE
4. ELECTRICAL FILTER RESTRICTION INDICATOR
1. If required, install the new O-ring inside the CONNECTOR (OPTIONAL)
brake cooling valve head in the O-ring groove.
See Figure 38. Figure 38. Brake Cooling Valve
44
1800 SRM 1498 Brake Return Line Filter (J007 & H019 Only)
Brake Return Line Filter (J007 & H019 Only)

BRAKE RETURN LINE FILTER ASSEMBLY 13. Tag and disconnect the two hydraulic hoses from
the brake return line filter assembly. Place a cap
Remove on the two hydraulic hoses and the open ports of
the brake return line filter assembly. See Fig-
NOTE: (K007 & J019) series are not equipped with ure 39.
a Brake Return Line Filter.
14. Remove the two capscrews and washers that re-
1. Place the lift truck on a solid, level surface. tain the brake return line filter assembly inside
the frame and remove the brake return line filter
assembly.
retracted position.

WARNING



cylinders are completely retracted.
to gain access to the brake return line filter as-
sembly. Refer to the manual Operator’s Cab 1. HYDRAULIC HOSE
100 SRM 1390. 2. HOSE CLAMP
3. CAPSCREW AND WASHER
4. FRAME
NOTE: Before disconnecting the hydraulic hoses, 5. BRAKE RETURN LINE FILTER ASSEMBLY (J007
place a suitable container under the hydraulic hose & H019) ONLY
connections to catch the hydraulic oil from the hy-
draulic hoses. Figure 39. Hydraulic Hoses
12. Loosen the two hose clamps that retain the hy-
draulic hoses to the brake return line filter as-
sembly.
45
Gear Pump 1800 SRM 1498
Install 3. Raise (side tilt) the cab to the fully open position
1. Position the brake return line filter assembly in- the manual Operator’s Cab 100 SRM 1390.
side the frame and install the two capscrews and
washers that retain the brake return line filter 4. Loosen the brake filter by using a wrench to turn
assembly to the inside of the frame. See Fig- the bowl counterclockwise. See Figure Figure 39.
ure 39.
5. Remove the filter cartridge.
open ports of the brake return line filter assem- Install
bly.
NOTE: Check the condition of the O-ring. Replace if
3. Connect the two hydraulic hoses to the brake re- required.
turn line filter assembly and tighten the two hose
clamps. 1. If required, install the new O-ring to the bowl.
4. Lower the cab until it is in the fully lowered and 2. Insert the new filter cartridge.
3. Install the bowl by turning the bowl clockwise
hand tight and then 1/4 revolution back.
FILTER
Remove 5. Operate the brake system and check for leaks.
Gear Pump
REMOVE 2. Disconnect hoses from pump. Put caps on all fit-
tings. Be careful so inlet hose is not damaged
WARNING during removal.
Make sure the carriage is lowered before dis-
connecting any parts of the hydraulic system. WARNING
Some of the hydraulic pumps are very heavy.
NOTE: Worn or damaged seals are the most common Use a lifting device when removing or in-
cause of pump failure. The pump bearings, gears, stalling the pump.
and shafts also wear. Many service persons do not
repair a worn pump because the cost of repairs can 3. Remove two capscrews securing the gear pump
be greater than the cost of a new pump. The seals housing to the variable displacement pump.
can be replaced in the hydraulic pump. If the pump
will be rebuilt, the following general procedures are 4. Remove pump from lift truck.
for repairing gear pumps.
DISASSEMBLE
1. If the lift truck is equipped with a valve on the
tank, the valve must be closed before removing 1. Remove gear or sprocket from input shaft.
the pump. If there is no valve on the tank, re-
move breather and install a plug. This action 2. Before disassembling the pump, make alignment
prevents the tank from draining too fast when marks on all housings. Some housings can be as-
the inlet line is disconnected. sembled in the wrong positions, which will cause
failure or increased wear. Carefully clean the
outside of the pump.
46
1800 SRM 1498 Gear Pump
NOTE: The inlet ports in most gear pumps are larger same and it can be difficult to make an identification
than the outlet ports. if they are mixed.
NOTE: If the pump is held in a vise for disassembly, 3. Remove capscrews that hold housings together.
make sure the vise does not hold the pump too tightly Use a plastic hammer to separate housings. Do
and cause distortion of the pump body. not damage machined surfaces. See Figure 40.
NOTE: The position of the seals is important. In some 4. Remove gears, thrust plates and bearing blocks.
pumps the direction of pump rotation is changed by Make a note of the positions of the thrust plates,
changing the position of the seals and housings. The seals, and gaskets. Do not use a punch to mark
holes in the seals must be aligned with the oil pas- the parts. See Figure 40.
sages in the housing sections. The oil passage for the
thrust plates is in the outlet chamber. 5. Remove bearings with a puller.
Make sure you make careful notes of the location and 6. Remove front seal. See Figure 40.
orientation of the parts and seals during disassem-
bly. Some of the parts are similar, but not exactly the
1. CAPSCREWS 9. BEARING BLOCKS 17. THRUST PLATE

2. WASHERS 10. BACK UP RING 18. SEAL
3. SNAP RING 11. SEAL 19. BACK UP RING
4. FRONT SEAL 12. THRUST PLATE 20. SEAL
5. REAR COVER 13. GEAR HOUSING 21. BEARING BLOCKS
6. DOWEL PINS 14. SEAL 22. FRONT COVER
7. SEAL 15. DRIVEN GEAR 23. CAPSCREWS
8. SEAL 16. DRIVE GEAR
Figure 40. Gear Pump
47
Gear Pump 1800 SRM 1498
CLEAN If the gear housing is worn, inspect bearings for

wear. If the system pressure is too high, the gear
WARNING housings will wear quickly. Grooves in the gear
chamber indicate dirt is in the oil. Small holes in
Cleaning solvents can be flammable and toxic
the outlet side of the gear chamber indicate that
and can cause skin irritation. When using
cavitation has occurred. Make sure inlet hose,
cleaning solvents, always follow the solvent
fittings, and tank have no restrictions. Cavita-
manufacturer’s recommended safety precau-
tion can also occur when the engine speed is too
tions.
high.
WARNING If the surfaces of the gear chamber or gear teeth

have blue marks, the pump was too hot. Heat
damage in the pump can be caused by hot oil or
CAUTION
lack of oil. Check front seal surface to see if air
Compressed air can move particles so they was entering the pump through the front seal.
cause injury to the user or to other personnel. Make sure the oil is the correct viscosity. The
Make sure the path of the compressed air is wrong viscosity oil can increase leakage within
away from all personnel. Wear protective gog- the pump. Leakage inside the pump increases
gles or a face shield to prevent injury to the the oil temperature.
eyes.
4. Check thrust plates for wear or grooves. If
Clean all parts of the pump with solvent. Use com- the thrust plate is worn more than 0.05 mm
pressed air to dry the parts. Do not use a cloth to dry (0.002 in.), it must be replaced. Replace thrust
the parts. Pieces of the cloth can cause restrictions in plate if it has grooves or holes. Dirty oil causes
the hydraulic system. Make sure the work area and the thrust plate to wear near where the gears
tools are very clean. engage. Small holes on the outlet side the thrust
plate are caused by cavitation. Lack of oil can
INSPECT also cause small holes in the thrust plates. If the
1. Inspect outside edges of gear teeth for grooves color of the thrust plates has changed, the pump
or scratches. If the edges of the gear teeth are was too hot.
sharp, use emery cloth to break the edges. Re-
5. Inspect all machined surfaces for scratches or
place gears if there are deep grooves on the gears.
damage. Remove with emery cloth any metal
2. If the gear shafts have grooves or are worn more that is above the flat surface. Check surfaces
than 0.05 mm (0.002 in.), they must be replaced. with a straight edge. Inspect grooves for the seals
Wear on the seal area of the shaft indicates there for dirt or scratches.
is dirt in the oil or a hard seal. Inspect seal to
6. Inspect bearings for wear or damage. Replace
see if it has been too hot. Look for small cracks in
bearings if there is any small hole on the bearing
seal surfaces. If the seal was too hot or the wrong
surface. Replace bushing if it is not round.
oil was used, the seal will be too hard or too soft.
Inspect splines or key groove for damage. 7. Look for damage on seals. Replace all seals and
O-rings, even if they are in good condition. Look
NOTE: Some pump bodies will show gear marks
for cuts or changes in shape that can cause dam-
where the gears rotate because of the small clear-
age. Find out what damage caused the pump
ances between the parts. These gear marks do not
to fail. A damaged seal for the thrust plate can
indicate a worn or damaged pump unless the pump
cause the shaft seal to leak. A damaged shaft
will not supply the volume and pressure shown in
seal can cause air to enter the hydraulic system.
the specifications.
3. Inspect gear housing for wear or grooves. Most CAUTION

wear occurs on the inlet side of the gear cham- Do not permit dirty oil to enter the gear pump.
ber. Put a straight edge across the inlet side of
the gear chamber. If a 0.13 mm (0.005 in.) thick- 8. If any parts of the pump have damage from dirt
ness gauge fits between the straight edge and in the oil, inspect hydraulic tank. Drain tank,
the housing, the gear housing must be replaced. clean screen and tank, and replace filter.
48
1800 SRM 1498 Gear Pump
9. Inspect inlet hose to the gear pump. Use a lamp Install seal in outer groove in front cover. Install
to look inside the hose. Look for pieces of rubber bearing blocks in the same positions from which
that are separating from the hose. Inspect hose they were removed.
for restrictions at bends. Check for loose fittings
or damaged O-rings. 5. Install gears and bearing blocks in pump cham-
ber housing. Make sure gear housing is installed
ASSEMBLE in the correct position. The small hole in some
housings must be in the outlet chamber. The
large channels in the inlet and outlet chambers
CAUTION must be toward the rear cover. The arrow indi-
Make sure no dirt enters the pump during as- cating the direction of rotation on the gear hous-
sembly. ing must be toward the front cover. Align marks
on gear housing with marks on covers. See Fig-
1. Lubricate all parts with hydraulic oil before they
ure 40.
are installed into the pump.
6. Put connecting shaft in drive gear shaft on the
2. Put Loctite 290® sealant around outside of front
pumps with two pump chambers. Install thrust
seal. Install seal in front cover. Make sure seal
plates and seals. Put gears and pump cham-
is installed straight. If pump has a ball bearing
ber housing on center bearing housing with the
for the shaft, install it in the front cover. Install
marks aligned. See Figure 40.
snap rings.
7. Install seal and rear cover. Use a plastic ham-
3. Use a press to push bearings into position within
mer to join the sections. Apply a small mount
the bearing blocks.
of Loctite 290® sealant to threads of capscrews
or studs. Install capscrews or studs and tighten
CAUTION with your fingers. Rotate drive shaft to make
Make sure the holes in the gaskets and seals are sure pump is assembled correctly. Tighten cap-
aligned with the hole in the output side of the screws or nuts to the specification using an "X"
pump. The pump will not operate correctly if sequence. Refer to the section Hydraulic Hose
the oil from the outlet chamber cannot flow to Torque Specifications for the correct torque pro-
the thrust plate. cedure. See Figure 40.
4. Install seals for thrust plate. Install rubber seal INSTALL

with lips away from gears. Install paper gasket
against the rubber seal. The plastic gasket is in-
CAUTION
stalled between the paper gasket and the thrust
Always install a new filter when repairs are
plate. Install thrust plate with the bronze side
made to the hydraulic system. Drain and re-
toward the gears. See Figure 40.
place the hydraulic oil if the oil is dirty or
Some pumps have thrust plates with small burned.
grooves for the seals. The seals must be cut
1. Install new gasket or O-ring on front cover of
to the correct length. Cut two strips that are
pump. Put a thin layer of Never-Seez® on splines
5.5 mm (0.22 in.) long from seal strip. Put
of drive shaft. Fill inlet port of the pump with
grease on seals and install them in grooves in
hydraulic oil. Turn drive shaft in the direction of
center of thrust plate. Cut thrust plate on front
rotation until oil comes out of the outlet port.
cover. Hit thrust plate with a plastic hammer
to 0.8 mm (0.031 in.) from machined surface.
Cut four strips 6 mm (0.24 in.) from seal strip. WARNING
Push strips into slots in thrust plate. Lightly hit Some of the pumps are very heavy. Use a lifting
thrust plate against the machined surface. Use device to help install the pump.
a sharp blade to cut the seals even with the edge
of the thrust plate. 2. Install pump in lift truck.
Install seal that has a W shape and spacer in

groove in front cover. Do not bend metal seal.
49
Hydraulic Troubleshooting Flowcharts 1800 SRM 1498
3. Install and tighten capscrews. Refer to the sec- 4. Remove plug from breather on tank. Install
tion Hydraulic Hose Torque Specifications for the breather. Open valve on tank. Fill tank with
correct torque procedure. Remove caps from fit- clean hydraulic oil.
tings and connect hoses.
5. Run engine at idle speed for 3 min. Touch pump
with your hand. If pump is hot, it has a problem.
CAUTION If pump is not hot, then increase engine speed to
Do not permit hot oil to enter a cold pump. high limit.Check for leaks and top of hydraulic
Make sure the relief valve in each system is at tank if necessary.
the lowest setting.
Hydraulic Troubleshooting Flowcharts

For all check and adjustment procedures referred to in the flowchart, refer to the section Checks and Adjust-
ments in this manual unless the flowchart specifies to refer to another manual.
50
1800 SRM 1498 Hydraulic Troubleshooting Flowcharts
Table 5. Low Brake Pressure Warning Is Intermittent or Constantly Active
WET DISC BRAKE

Check the cut-in
CONFIGURA-
pressure of the
TION ONLY
unloading valve at port Adjust the pressure
"START PRO- Is the steering
M ACC on the brake at the unloading
CEDURE HERE" —YES— system operating —YES— —YES—
control manifold. valve in the brake
Low brake pressure correctly?
Is the pressure control manifold.
warning light is inter-
less than 16 MPa
mittent or constantly
(2,321 psi)
illuminated.
| |
| NO
| |
|
|
NO Check the brake
| accumulator Charge the brake
| pre-charge valve accumulator to the
—YES—
| at port M ACC. correct pre-charge
| Is the pressure less pressure.
——————————— —— than 9 MPa (1,305 psi)
| |
| NO
| |
|
|
| Is the time required
| to charge the brake
Is the unloading valve Repair/replace
| accumulator between
charging the brake —YES— —YES— the brake
| the cut-in and cut-out
accumulator? accumulator.
| pressure less than
| 8 seconds?
|
| | |
| NO NO
| | |
|
|
| Check the condition
| of the following Check the condition
| components in the of orifice F and orifice
| main control valve. G in the brake
| 1) Shuttle valve N. control manifold.
| 2) Shuttle valve L. Clean/replace as
| Repair/replace as needed.
| needed.
|
|
|
Check the pressure at

port MLS1 on the main
Check the position Is the maximum control valve while the
of the transmission lifting speed brake accumulator Check the condition
calibration switch. —YES— greater than 50% —YES— is charging or —YES— of priority valve.
Is the switch in the of the normal while operating the Replace as needed.
correct position? lifting speed? steering system.
Is the pressure greater
than 3 MPa (435 psi)?
| | |
NO NO NO
| | |
Check the condition

Troubleshoot the
of the following
main hydraulic
components in the
system. Refer
Place the switch in the main control valve.
to the manual
correct position. 1) Shuttle valve N.
Hydraulic
2) Shuttle valve L.
System 1900
Repair/replace as
SRM 1478.
needed.
51
Hydraulic Troubleshooting Flowcharts 1800 SRM 1498
Table 6. Service Brake Is Soft or Spongy
Check the
WET DISC
pressure Does the free
BRAKE Check the
at port M play in the Adjust
CONFIG- output pressure
BRK on mechanical the brake
URATION on the brake
Is the the brake linkage pedal. Re-
ONLY treadle valve.
brake control or the fer to the
"START Is the output
—YES— system —YES— manifold. —YES— —YES— adjustment —YES— manual
PROCE- pressure less than
properly Is the screw for the Opera-
DURE 10 MPa (1,450 psi)
bled? pressure brake pedal tor’s Cab
HERE" when the brake
greater limit the full 100 SRM
Service brake pedal is fully
than stroke of the 1390.
is soft or applied/depressed?
12 MPa brake pedal?
spongy.
(1,740 psi)?
| | | |
NO | NO NO
| | | |
|
|
|
|
|
Troubleshoot and
|
repair the service
|
brake internal
Bleed |
components on
brake NO
the drive axle.
system by | Was the Remove the
Refer to
applying | service trapped
the manual
brakes | brake air in the
Planetary —YES—
until soft/ | system service
Drive Axle,
spongy | recently brake
(Wet System)
brake | serviced? system.
1400 SRM 944
problem is |
or Planetary
resolved. |
Drive Axle, (Dry
|
System) 1400
|
SRM 945.
|
|
| —————————————————————— |
| NO
| |
|
NO
| Replace
| the brake
| treadle
valve.
Check the Adjust the

pressure pressure
at port M at the
ACC on the pressure
brake control reducer
manifold. —YES— valve on
Is the the brake
pressure control
greater than manifold.
14 MPa
(2,031 psi)?
|
NO
|
Is the
low brake Refer to
—YES—
pressure Table 5.
signal active?
|
NO
|
Replace the
low pressure
brake switch
and then
refer to
Table 5.
52
1800 SRM 1498 Hydraulic Troubleshooting Flowcharts
Table 7. Hydraulic Oil is Overheating
Replace the brake

"START Is only the hydraulic Continue to
return line filter.
PROCEDURE oil in the brake monitor the
Did replacing
HERE" —YES— cooling chambers —YES— —YES— condition of the
the filter resolve
Hydraulic oil is overheating higher service brakes in
the hydraulic oil
overheating. than 90°C (194°F)? the drive axle.
overheating.
| |
| |
NO NO
| |
| |
—————————————————— Replace the relief

valve in the brake
| flow distribution
| manifold.
NO
|
|
Is the hydraulic oil Clean/replace the

cooler core blocked —YES— hydraulic oil cooler
or restricted? core.
|
|
NO
|
Check/replace the
thermostatic bypass
valve in the brake
cooling valve.
Table 8. Parking Brake Will Not Disengage With the Parking Brake Switch
WET DISC BRAKE CON-

Is 24 volts present Check the coil on Replace the
FIGURATION ONLY
at the coil when the park brake park brake
’START PROCE-
parking brake selector valve for selector
DURE HERE’ —YES— —YES— —YES—
switch is in correct operation. valve on the
Parking brake will not
the disengaged Is the coil operating brake control
disengage with the
position? correctly? manifold.
parking brake switch.
| |
| |
NO NO
| |
Troubleshoot
the lift truck
electrical
system. Refer
Replace the coil.
to the manual
Electrical
System 2200
SRM 1499.
53
Mechanical Troubleshooting 1800 SRM 1498
Mechanical Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Vehicle does not move. Damaged hydraulic system. Repair hydraulic system.
Brakes dragging. Damaged piston return spring as- Repair or replace piston return
sembly. spring assembly.
Piston not returning. Check piston seals and seal separator

for swelling or damage. Replace as
necessary.
Wrong cooling and/or actuation fluid Check piston seals and seal separa-
used. tor for swelling or damage. Replace
as necessary. Purge system and use
specified fluid.
Noticeable change or de- Inadequate pressure to apply Check brake apply system. Check
crease in stopping perfor- brakes. for leakage in brake system or brakes
mance. and correct cause.
Worn or damaged discs. Inspect and replace discs if necessary.
Overheated seals and/or discs. Inspect and replace discs and seals if
necessary.
Dirty or contaminated cooling fluid. Drain and flush hydraulic oil. Re-
place with approved fluid. In some
cases, it may be necessary to replace
discs. Replace filter.
Brake does not fully apply. Damaged hydraulic system. Repair hydraulic system.
Leakage of brake actuation fluid. See brake leaks actuation fluid in

this troubleshooting section.
Brakes feel spongy/soft. Brake system not properly bled. Bleed brakes and brake system.
Brake pressure system not operating Refer to the flowchart in Table 6.

properly.
Brake leaks actuation fluid. Worn or damaged piston seal. Replace piston seals.
Melted or extruded piston seals. Correct cause of overheating and re-

place seals.
54
1800 SRM 1498 Mechanical Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Brake leaks actuation fluid.

(Cont.)
Corrosion, pitting, wear or other Clean, smooth, rework, or replace af-
damage, marks, scratches to piston fected parts.
and/or brake housing bore in area of
seal/sealing lips.
Loose bleeder screw Tighten bleeder screw to 20 to

27 N•m (15 to 20 lbf ft).
Loose inlet fitting or plugs. Tighten inlet fitting to 34 to 47 N•m

(25 to 35 lbf ft).
Damaged inlet fitting, plugs, or Replace inlet fitting or plug and

seats. O-ring if used. Repair or resurface
area or replace as necessary.
Coolant leaking out of brake Face seal damaged, worn, or improp- Reinstall and/or replace face seal.
housing. erly installed.
Loose drain plug, fill plug, or forced Tighten plug.

cooling plug.
Damaged plug. Replace plug.
Deteriorated or inadequate sealant Disassemble, clean, reseal, and re-

used at joint. assemble joint.
Axle housing filling with oil, Worn or damaged spindle to hub Replace spindle to hub seal. Check
forced cooling systems only, seal. seal and journals.
and may be forced out the
breather.
Brush hair lodged in grease under Do not use brush to apply grease to
hub-to-spindle seal lip. seal areas.
55
Checks and Adjustments 1800 SRM 1498
Checks and Adjustments

HYDRAULIC PRESSURE CHECKS 3. With a clean suitable tool, press the spool into the
PREPARATION cartridge. If the spool moves smoothly against
the spring, the park brake selector valve is func-
tioning properly and may be reinstalled. Replace
WARNING
as needed.
The engine must be at room temperature be-
fore starting disassembly or personal injury
may occur. CAUTION
1. Place the lift truck on a solid, level surface. tightening the park brake selector valve as
damage can occur.
4. Install the park brake selector valve and tighten
3. Lower the carriage until the lift cylinders are ap- to 35 to 40 N•m (26 to 30 lbf ft).
retracted position.
CAUTION
4. Tilt the mast to the maximum forward position. DO NOT exceed the maximum torque when
tightening the park brake selector valve coil
nut as damage can occur.
6. Place blocks on both sides (front and back) of the
5. Install the park brake selector valve coil and nut.
tires to prevent movement of the lift truck.
Tighten the nut to 4 to 6 N•m (35 to 53 lbf in).
7. Turn the key switch to the ON position. DO
NOT START THE ENGINE. PARK BRAKE SELECTOR VALVE COIL
CHECK
WARNING 1. Make sure there is an electric signal to the coil by
Step 8, Step 9, and Step 10 must be performed checking if the coil is warm when the park brake
to relieve the trapped or stored hydraulic pres- is not engaged. If the coil is warm, there is an
sure from the hydraulic system, or serious per- electric signal.
2. Loosen the nut that retains the coil to the park
8. Apply brake pedal 10 to 20 times until the accu- brake selector valve enough to slightly pull the
mulated hydraulic brake pressure is released. coil away from the valve to see if there is any
magnetic draw when the park brake is not en-
gaged. If there is a magnetic draw, the coil is
good. Replace as needed.
10. Use the emergency lowering button and operate CAUTION

the lowering function to remove the hydraulic DO NOT exceed the maximum torque when
pressure from the lift system. Make sure the lift tightening the park brake selector valve coil
cylinders are completely retracted. nut as damage can occur.
11. Turn the key switch to the OFF position. 3. Tighten the park brake selector valve nut to 4 to
6 N•m (35 to 53 lbf ft).
PARK BRAKE SELECTOR VALVE CHECK
1. Remove the coil from the park brake selector ACCUMULATOR PRE-CHARGE CHECK
valve. 1. Place the lift truck on a solid, level surface.
2. Remove the park brake selector valve from the 2. Apply the parking brake.
brake control manifold.
3. Lower the mast completely.
56
1800 SRM 1498 Checks and Adjustments
4. Tilt the mast completely forward.

WARNING
5. Shut down the engine. Nitrogen gas is a colorless odorless gas and
may cause dizziness or asphyxiation without
6. Place blocks in front of and behind the tires to warning. Nitrogen gas is initially heavier than
prevent movement of the lift truck. air and will spread along the ground. Make
7. Raise (side tilt) the cab to the fully open position sure to wear hand gloves and eye protection
to gain access to the main control valve. Refer to and always work in a well ventilated area.
the manual Operator’s Cab 100 SRM 1390. 12. Refill the accumulator with nitrogen gas at
8. Remove the cap from check port M ACC on the approximately 20°C (68°F) to the required
main control valve. See Figure 41. pre-charge pressure of 10.35 MPa (1,500 psi).
For the correct nitrogen gas refilling procedure,
9. Connect a 0 to 30 MPa (0 to 4,351 psi) hydraulic refer to the section Pre-Charge Filling.
pressure gauge at port M ACC.
13. After refilling the accumulator, raise (side tilt)
10. Lower the cab until it is in the fully lowered and the cab to the fully open position to gain access
latched position. Refer to the manual Opera- to the main control valve. Refer to the manual
tor’s Cab 100 SRM 1390. Operator’s Cab 100 SRM 1390.
11. Apply the brake pedal and observe the gauge 14. Remove the pressure gauge from port M ACC.
reading. Repeat this procedure until the brake
pedal pressure nears the accumulator pressure. 15. Install the cap on check port M ACC on the main
A sudden sharp pressure drop will be observed. control valve.
The gauge reading immediately before the sharp
pressure drop represents the pre-charge pres-
PARKING BRAKE ADJUSTMENT
sure of the accumulator. NOTE: Parking brake adjustment is required when
new parking brake caliper pads or a new parking
brake disc is installed, and after repairs to improve
braking performance. Always make parking brake
adjustments when the parking brake is cold. The
parking brake must be in the released position dur-
ing the adjustment procedure.


manual Operator’s Cab 100 SRM 1390.

1. CHECK PORT MLS1
2. CHECK PORT M BRK 7. Turn the adjustment screw clockwise until both
3. CHECK PORT M ACC
4. PRIORITY VALVE brake pads have made contact with the parking
brake disc.
Figure 41. Check Port MLS1, Check Port M
BRK, Check Port M ACC, and Priority Valve 8. Turn the adjustment screw counterclockwise to
set the TOTAL clearance specified in Table 9.
57
Checks and Adjustments 1800 SRM 1498
Table 9. Lining-to-Disc Clearance CONDITION CHECK, SHUTTLE VALVE N

IN THE MAIN CONTROL VALVE
Total Lining-to-Disc Adjustment
Clearance Screw
WARNING
Revolutions
Before performing the following procedure,
Minimum 0.5 mm 1/4 the Hydraulic Pressure Checks Preparation
(0.02 in.) procedure must be performed or serious per-
Rated 1 mm (0.04 in.) 1/2 sonal injury may occur.
Maximum 1.5 mm 3/4 1. Remove the shuttle valve at port N on the main
(0.06 in.) control valve. See Figure 42.
2. Check the condition of the shuttle valve for signs

9. Keep the adjustment screw in position and
of wear, grooves, and damage. If any signs of
tighten the lock nut securely.
wear, grooves, or damage are present, replace the
10. Install and hand-tighten the screw cap. shuttle valve.
11. Lower the cab until it is in the fully lowered and 3. Install new O-rings on the shuttle valve.
4. Install the shuttle valve in port N on the main
control valve and tighten to 34 to 40 N•m (25 to
12. Apply the parking brake several times. 30 lbf ft).
13. Make sure the parking brake functions properly

on a slope.
CONDITION CHECK, SHUTTLE VALVE L IN

THE MAIN CONTROL VALVE
WARNING
Before performing the following procedure,
the Hydraulic Pressure Checks Preparation
procedure must be performed or serious per-
1. Remove the shuttle valve at port L on the main

control valve. See Figure 42.
2. Check the condition of the shuttle valve for signs

of wear, grooves, and damage. If any signs of
1. SHUTTLE VALVE L
wear, grooves, or damage are present, replace the 2. SHUTTLE VALVE N
shuttle valve.
Figure 42. Shuttle Valve L and Shuttle Valve N
3. Install new O-rings on the shuttle valve.
4. Install the shuttle valve at port L on the main

control valve and tighten to 34 to 40 N•m (25 to
30 lbf ft).
58
1800 SRM 1498 Checks and Adjustments
CONDITION CHECK, PRIORITY VALVE ON PRESSURE CHECK, PORT MLS1

THE MAIN CONTROL VALVE
WARNING
WARNING Before performing the following procedure,
Before performing the following procedure, the Hydraulic Pressure Checks Preparation
the Hydraulic Pressure Checks Preparation procedure must be performed or serious per-
procedure must be performed or serious personal injury may occur.
1. Remove the cap from check port MLS1 on the
1. Remove the priority valve from the main control main control valve. See Figure 41.
valve. See Figure 41.
2. Connect a 0 to 30 MPa (0 to 4,351 psi) hydraulic
2. With a clean, suitable tool, press the spool pressure gauge at port MLS1.
into the cartridge. If the spool moves smoothly
against the spring, the priority valve is function- 3. Start the engine and check the pressures with
ing properly and may be reinstalled. If the spool the engine at idle speed.
does not move smoothly, replace the priority
4. Compare the pressures with the pressures stated
valve.
in the flowchart step that referred to this proce-
3. Install a new seal kit on the priority valve. dure. See Figure 41.

CAUTION
DO NOT exceed the maximum torque when in- WARNING
stalling the priority valve, as component dam- Before performing the following procedure,
age may occur. Step 7 through Step 11 in the section Hy-
4. Install the priority valve into the main con- draulic Pressure Checks Preparation must
trol valve. Tighten the priority valve to 217 to be performed or serious personal injury may
231 N•m (160 to 170 lbf ft). occur.
6. Remove the pressure gauge from port MLS1.
7. Install the cap on check port MLS1 on the main

control valve.
59
Torque Specifications 1800 SRM 1498
Torque Specifications
HYDRAULIC HOSE TORQUE Parking Brake
SPECIFICATIONS Item Torque
Bleeder Screw 12 to 16 N•m
CAUTION (9 to 12 lbf ft)
Make sure the hose is correctly aligned before
Adjustment Screw 40 N•m
tightening the swivel on the corresponding fit-
(30 lbf ft)
ting.
1. Install the swivel hand so that it is tight. Brake Cooling Valve
2. Tighten the swivel hand an extra 1/4 turn with a Item Torque
spanner to set the final tightening torque. Filter Restriction 30 N•m
Indicator (22 lbf ft)
Accumulator
Item Torque Park Brake Selector Valve
Gas Valve 25 to 29 N•m Item Torque
(18.5 to 21.5 lbf ft)
Park Brake 35 to 40 N•m
Dust Cap 1.5 to 1.7 N•m Selector Valve (26 to 30 lbf ft)
(13.28 to 15.05 lbf in)
Park Brake 4 to 6 N•m
Gas Valve Guard 1.13 to 1.69 N•m Selector Valve Nut (35.4 to 53.1 lbf in)
(10 to 15 lbf in)
Gauge Assemble 1.13 to 1.69 N•m Main Control Valve
on Gas Valve (10 to 15 lbf in)
Item Torque
Shuttle Valve L 34 to 40 N•m
(26 to 30 lbf ft)
Shuttle Valve N 34 to 40 N•m
(26 to 30 lbf ft)
Priority Valve 217 to 231 N•m
Cartridge (160 to 170 lbf ft)
60
TECHNICAL PUBLICATIONS
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BRAKE AND

PART NO. 4034076 1800 SRM 1498

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2013 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

H8.0-12.0XM-6 (H190-280HD 2) [J007];

Basic Principles of Flow Control Systems

Flow control valves are used in hydraulic systems to

Table 1. Definition of Terms

Depending on the pressure differential (pressure

Any change in the opening area (variable orifice) or

Pressure Compensated Flow Control

The priority spool will supply flow to the variable ori-

For more information on flow control valves, see

Priority Valve Functional Description

The system will balance the pressure differential (P1

Figure 3. Pressure Compensated Flow Control

With a fixed orifice (A), the hydraulic system will

With a variable orifice (A), the hydraulic valve will

Basic Principle P1 System Pressure

Figure 4. Priority (Flow Control) Valve

The position of the servo piston (C) determines the

For more information on flow control valves, see

Load Sense Functional Description

When no functions of the hydraulic system are acti- Example 1

Basic Principles of Pressure Control Systems

Table 2. Definition of Terms

When the hydraulic system pressure increases and

Direct Acting Relief Valve Functional

If the flow to the hydraulic tank continues to in-

TWO-STAGE RELIEF VALVE

Two-Stage Relief Valve (Pilot Operated

When a hydraulic function is selected and the sys-

As the flow increases through the valve, the relief A Orifice

Figure 7. Two-Stage Relief Valve

Unloading valves are used to maintain the required

The selection of this differential spool (E) is con-

The selection of the differential spool (E) determines

The variable displacement pumps will supply charge

Unloading Valve (Accumulator Charging

The pressure in the LS line will be equal to the

When the pressure in the accumulator reaches the P System Pressure

A counterbalance valve is normally combined with

Both pressures are acting against two separate areas

The first pressure is the system pressure (P1), which

The second pressure is the external pilot pressure

Counterbalance Valve Functional B Spring

The counterbalance valve operates as a direct acting P1 System Pressure

PRESSURE REDUCER VALVE

Pressure Reducer Valve Functional

As the subsystem pressure (P2) increases and the hy-

Brake System Main Component Identification

Legend for Figure 11

Figure 11. Wet Brake System Schematic

10. VARIABLE DISPLACEMENT PUMP 13. HYDRAULIC OIL COOLER CORE

Figure 12. Air Brake Cooling System Schematic