Maintenance

HYDRAULIC SYSTEM
NDR030GB, NR045GB [B861];
NDR030AE, NR035/040/045AE [C815];
NS040/050AF [C816];
NDR030CB, NR045CB [D829]

PART NO. 524164467 1900 YRM 973

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

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

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

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

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

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

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

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

CAUTION
Indicates a condition that can cause property damage!
Hydraulic System Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Control Handle..................................................................................................................................................... 2
Description ...................................................................................................................................................... 2
Control Valve ....................................................................................................................................................... 3
Description ...................................................................................................................................................... 3
Trucks Built Before 15 July, 2002 ................................................................................................................ 3
Trucks Built After 15 July, 2002 ................................................................................................................... 3
Control Valve-Manual Lowering ...................................................................................................................... 3
Trucks Built Before 15 July, 2002 ................................................................................................................ 3
Trucks Built After 15 July, 2002 ................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Install............................................................................................................................................................... 4
Check and Adjust ............................................................................................................................................ 5
Main Relief Valve (NDR030AE, NR035/040/045AE, NS040/050AF, NDR030CB, NR045CB) ................... 5
Main Relief Valve (NDR030GB, NR045GB)................................................................................................ 5
Auxiliary Relief Valve ................................................................................................................................. 6
Lift Pump and Motor ............................................................................................................................................ 7
Description ...................................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Install............................................................................................................................................................... 9
Disassemble.................................................................................................................................................... 9
Assemble ........................................................................................................................................................ 10
Steering Pump..................................................................................................................................................... 10
Hydraulic Tank ..................................................................................................................................................... 10
Description ...................................................................................................................................................... 10
Remove and Disassemble .............................................................................................................................. 10
Assemble and Install ....................................................................................................................................... 11
Troubleshooting ................................................................................................................................................... 12
Diagrams, Schematics, or Arrangements ............................................................................................................ 13
Figure 11. Hydraulic Schematic (Trucks Built Before July 15, 2002) .......................................................... 14
Figure 12. Hydraulic Schematic (Trucks Built After July 15, 2002) ............................................................. 15
Figure 13. Hydraulic Tank - Exploded View (Small Chassis)...................................................................... 16
Figure 14. Hydraulic Tank - Exploded View (Large Chassis)...................................................................... 17

This section is for the following models:

NDR030GB, NR045GB [B861];

NDR030AE, NR035/040/045AE [C815];
NS040/050AF [C816];
NDR030CB, NR045CB [D829]

©2004 Yale Materials Handling Corp. i

1900 YRM 973
General
This manual describes the removal, disassembly, as-
sembly, and installation of the hydraulic system com-
ponents as applicable. The hydraulic system consists
of a lift pump and motor used for lifting the truck forks.
Additionally, a separate pump and motor is used for ve-
hicle steering and system auxiliary functions. The aux-
iliary functions can include: extend and retract, tilt up
and tilt down, and sideshift left and right. Both pumps
draw their oil supply from a common hydraulic tank. A
spin-on hydraulic filter is located on the hydraulic control
valve return line. This section addresses the lift pump,
Description
The hydraulic system includes two pumps: the steer/
auxiliary pump and the lift pump. The steer/auxiliary
pump provides hydraulic oil for steering and auxiliary
functions. It has a built-in priority valve to ensure pri-
ority flow for steering. When an auxiliary function and
steering function concurrently occur, the priority valve
ensures that the required flow goes to the steering con-
trol unit and the remainder is made available for the aux-
iliary function. The steer/auxiliary pump and motor are
located in the drive unit compartment. To further clar-
ify how the whole system operates refer to Figure 11 or
Figure 12.
The lift pump operates only when the control handle is
moved to start the lift function. The lift pump and motor
is cradle-mounted and located above the battery in the
front compartment.
In response to operator commands, control signals are
sent to the Main Interface Board (MIB) via the control
handle. The MIB, in turn, detects the position of the
control handle and/or position change and outputs a
signal to the control valve. The MIB also controls the
operation of the lift and steer/auxiliary pumps. See the
section Diagrams 8000 YRM 982 or Diagrams 8000
YRM 980 and the section Electrical System 2200 YRM
978 for additional information.
Description
control valve, hydraulic tank, and control handle. See
the section Steering System 1600 YRM 974 for main-
tenance coverage of the steering pump. See the sec-
tion Reach Carriages 4500 YRM 971 for the descrip-
tion and repair procedures for the carriage components
of the auxiliary functions. See the section Mast, Repair
4000 YRM 482 for repair procedures for the lift system
hydraulic cylinders. See the section Diagrams 8000
YRM 982 or Diagrams 8000 YRM 980 and Electrical
System 2200 YRM 978 for additional information on the
control handle.
The control valve controls the main hydraulic and aux-
iliary hydraulic functions. See Figure 3. The valve pro-
vides full proportional control of the lift and lower func-
tions. Each function is electrically operated to provide
maximum control and uses a valve for the lift/lower func-
tions. Separate lift and auxiliary relief valves are also
provided to minimize energy consumption.
The hydraulic system also includes a molded plastic
tank. See Figure 13 or Figure 14.
The tank is common to all hydraulic functions. The size
of the tank is determined by the size of the battery com-
partment. See Table 1 under Hydraulic Tank description
for capacities. A dipstick is provided for checking the
hydraulic oil level and is located in the filler cap. The
cap must be removed when checking the oil level and
when servicing the hydraulic tank. A strainer, located in
the filler neck of the tank, filters oil being added to the
reservoir. A breather is mounted on the lift truck mast.
A 10 micron spin-on filter is provided on the return line
to the hydraulic tank. The breather assembly, strainer,
and filter are serviced in accordance with the instruc-
tions contained in the Maintenance Schedule. See the
section Periodic Maintenance 8000 YRM 970 or the
Operating Manual for servicing instructions.
1
Control Handle 1900 YRM 973

Control Handle
DESCRIPTION
The control handle provides operator control for travel,
lift, lower, tilt, sideshift, horn, and reach functions. See
Figure 1.

Travel is activated by moving the control handle in the

direction of travel. Moving the control handle forward
provides forward travel. For travel in reverse, the control
handle is moved backward. The travel speed for both
forward and reverse directions is proportional to the dis-
tance the handle is moved; the further the distance, the
faster the lift truck travels.

NOTE: Diagonal movement of handle will control both

travel and a hydraulic function simultaneously. 1. TILT/SIDESHIFT DISK
2. HORN BUTTON
The control handle also controls the direction and speed 3. EXTEND/RETRACT BUTTONS ARE ON THE
at which the carriage moves on the mast. This lift/lower UNDERSIDE OF THE HANDLE
function is activated by tilting the control handle left or
right. When the control handle is moved to the right, the Figure 1. Control Handle
carriage lifts. When the handle is moved to the left, the
carriage lowers. The speed of the carriage is also pro-
portional to the distance the control handle is pushed.

NOTE: During lift truck operation, only one auxiliary

function can be selected at one time.

The extend and retract functions, including speed, are

controlled by two buttons located on the shaft of the
control handle. A button to activate the horn is located
on the side of the handle.

A thumb-operated tilt/sideshift disk, located at the top

of the control handle, controls tilt and sideshift. See
Figure 2. To tilt forward, press the top of the disk. To
tilt back, press the bottom of the disk. To activate the 1. TILT BACK 3. SIDESHIFT RIGHT
sideshift function, press the right side of the disk to 2. SIDESHIFT LEFT 4. TILT FORWARD
move the carriage to the right. Press the left side of
Figure 2. Tilt/Sideshift Disk
the disk to move the carriage to the left.

2
1900 YRM 973 Control Valve

Control Valve
DESCRIPTION
The control valve controls the main hydraulic and aux-
iliary hydraulic functions. The control valve provides
full proportional control of the lift and lower functions.
Each function is electrically operated to provide maxi-
mum control and uses a valve for the lift/lower functions.
Separate lift auxiliary relief valves are also provided to
minimize energy consumption. The control valve is se-
cured to a mounting bracket by capscrews. The mount-
ing bracket is welded to the lift truck frame.
valve will remain open and button A is popped out. But-
ton A is found on the side of the control valve next to the
frame wall of the truck. Turn the manual override thumb
screw (button B), slowly clockwise until the forks begin
to lower. Be sure to return the manual override thumb
screw to the original position once the manual lowering
process is complete by slowly turning the screw coun-
terclockwise until it stops. Push in the Load Holding
check valve button (button A) and turn it clockwise 180
to close it.

Trucks Built Before 15 July, 2002

Lift Relief Valve Setting 19.3 ±0.7 MPa
(2800 ±100 psi)
Auxiliary Relief Valve Setting 15.2 ±0.35 MPa
(2200 ±50 psi)

Trucks Built After 15 July, 2002

Lift Relief Valve Setting 19.3 ±0.7 MPa
(2800 ±100 psi)
Auxiliary Relief Valve Setting 15.2±0.35 MPa
(2200 ±50 psi)

NOTE: The identification for all ports is stamped on the

body of the control valve.

CONTROL VALVE-MANUAL LOWERING

Trucks Built Before 15 July, 2002 Figure 3. Control Valve

WARNING
Allow no one under or near the lift mechanism or
load during the manual lowering procedure.

See Figure 3 and Figure 4 for the following instructions.

WARNING
Failure to return the manual lowering screw to the
full counterclockwise position will cause the forks
to lower unexpectedly.

A provision is provided on the lowering valve to allow

manual lowering of the forks, if necessary. Manual low-
ering is accomplished by first pushing in the Load Hold-
ing check valve button (button A), turning it counter-
clockwise 180 , and releasing it. In this position, the Figure 4. Control Valve

3
Control Valve
Trucks Built After 15 July, 2002
WARNING
Allow no one under or near the lift mechanism or
load during the manual lowering procedure.
WARNING
Failure to return the manual lowering screw to the
full clockwise position will cause the forks to lower
unexpectedly.
Refer to Figure 5 for the following instructions.
A provision is provided on the lowering valve to allow
manual lowering of the forks, if necessary. Manual low-
ering is accomplished by turning the setscrew in a coun-
terclockwise direction using a hex driver. Always return
the setscrew to the full clockwise position prior to oper-
ating the lift truck
Figure 5. Manual Lowering
REMOVE
WARNING
Make sure the brake pedal is released and the brake
is applied. Put blocks on both sides (front and back)
of the drive tire and the caster wheels to prevent
movement of the lift truck. Put a block on each side
(front and back) of the load wheels to prevent move-
ment of the lift truck.
1. Turn the key switch to the ON position. Hold the
control handle in the lower position to completely
lower the forks and relieve any hydraulic pressure
from the lift circuit.
4
1900 YRM 973
2. Turn the key switch to the OFF position and discon-
nect the battery.
3. Open the drive unit compartment door.
4. Remove the front and steer compartment covers.
See the section Frame 100 YRM 975 for removal
procedure. Refer to Covers, Panels, and Plates.
5. Tag and disconnect the connectors from the lift and
lower cartridge and proportional valves.
6. Cover electric brake and drive motor to prevent hy-
draulic oil from spilling onto them and ruining them.
7. Place rags around the hydraulic ports to absorb any
leakage during removal.
8. Tag and disconnect the hydraulic hoses. Install
plugs in the hoses and valve ports to minimize leak-
age and prevent dirt from entering the system.
WARNING
The electro-hydraulic control valve is heavy. Be
sure to always use both hands when lifting it. The
electro-hydraulic control valve can weigh approxi-
mately 12 kg (26 lb).
9. Remove the capscrews, flat washers, and nuts at-
taching the control valve to the frame. Carefully re-
move the valve and take it to a clean work station
for disassembly.
10. Wipe up any hydraulic fluid that may have leaked
during removal.
INSTALL
WARNING
The electro-hydraulic control valve is heavy. Be
sure to always use both hands when lifting it. The
electro-hydraulic control valve can weigh approxi-
mately 12 kg (26 lb).
1. Align the control valve with the mounting holes on
the frame. Secure the valve with the capscrews, flat
washers, and nuts.
2. Remove the plugs from the hydraulic hoses and
valve ports. Connect the hoses to the ports, tighten
the connections, and remove the tags.
3. Connect the wire connectors to the lift and lower
cartridges and proportional valves and remove the
tags.
1900 YRM 973 Control Valve

4. Check the hydraulic fluid in the reservoir and re-

plenish as needed. See the section Periodic Main-
tenance 8000 YRM 970 or the Operator Manual
for fluid specifications.

5. Remove the blocks from under the drive/steer

wheel, caster wheels, and load wheels.

6. Reconnect the battery.

7. Operate the lift truck through all functions. Check

for oil leaks.

8. Recheck the hydraulic oil level. Add fluid if required.

9. Install the front and steer compartment covers. See

the section Frame 100 YRM 975 for installation pro-
cedure. Refer to Covers, Panels, and Plates.

CHECK AND ADJUST

Main Relief Valve (NDR030AE, 1. LIFT/LOWER RELIEF VALVE
2. AUX RELIEF VALVE
NR035/040/045AE, NS040/050AF,
NDR030CB, NR045CB) Figure 6. Relief Valves

Fully lower the mast. Turn the key switch to the OFF
position and disconnect the battery.
Remove the front and steer compartment covers. See
the section Frame 100 YRM 975 for removal proce-
dures.
Disconnect the mast supply hose from the hydraulic
control valve at the bulkhead fitting at the front of the
frame and place a tee fitting in the line. Loosen the
fitting slowly to relieve any residual pressure that may
be in the line. Place a cloth rag underneath the fitting
to absorb any hydraulic oil lost from the fitting. Install
a hydraulic line and a 20.68 MPa (3000 psi) pressure
gauge to the tee fitting.
Fully extend the mast and observe the pressure gauge
reading while holding the mast at relief. Do not hold the
mast at relief for longer than 3 seconds to keep from
overheating the hydraulic motor. The gauge should
read 19.30 MPa (2800 psi) +/- 0.68 MPa (100 psi).
If the pressure is not within the allowable range, the
main pressure relief valve must be adjusted.
To adjust the main relief valve, locate the valve marked
RV2 on the main control valve. See Figure 6.
Remove the plug covering the adjusting screw on the
top of the relief valve. Use an Allen wrench to make
the adjustment as required. Turning the screw clock-
wise will increase the pressure and turning the screw
counterclockwise will decrease the pressure. When the
proper pressure has been obtained, install the plug into
the top of the relief valve.
Remove the pressure gauge line and the tee fitting.
Reattach the mast supply hose to the bulkhead fitting.
Ensure all fittings are tight and do not leak.
Connect the battery and operate the mast to remove
any air from the hydraulic lines.
Main Relief Valve (NDR030GB, NR045GB)
Fully lower the mast. Turn the key switch to the OFF
position and disconnect the battery.
Open the drive unit compartment door.
Remove the front and steer compartment covers. See
the section Frame 100 YRM 975 for removal proce-
dures.
Locate the PT port on the main control valve and re-
move the plug from the port. Place a cloth rag under-
neath the port to absorb any hydraulic oil lost from the
port. Install a hydraulic line and a 20.68 MPa (3000 psi)
pressure gauge in the port and tighten all fittings.

5
Control Valve
Fully extend the mast and observe the pressure gauge
reading while holding the mast at relief. Do not hold the
mast at relief for longer than 3 seconds to keep from
overheating the hydraulic motor. The gauge should
read 19.30 MPa (2800 psi) +/- 0.68 MPa (100 psi).
If the pressure is not within the allowable range, the
main pressure relief valve must be adjusted.
To adjust the main relief valve, locate the lift/lower relief
valve on the main control valve. See Figure 7.
1. LIFT/LOWER RELIEF VALVE
2. AUX RELIEF VALVE
Figure 7. Relief Valves
Remove the plug covering the adjusting screw on the
top of the relief valve. Use an Allen wrench to make
the adjustment as required. Turning the screw clock-
wise will increase the pressure and turning the screw
counterclockwise will decrease the pressure. When the
proper pressure has been obtained, install the plug into
the top of the relief valve.
Remove the pressure gauge line from the control valve.
Install the plug into the control valve port. Ensure the
plug is tight and does not leak.
Connect the battery and operate the mast to remove
any air from the hydraulic lines.
6
1900 YRM 973
Auxiliary Relief Valve
Fully lower the mast. Turn the key switch to the OFF
position and disconnect the battery.
Remove the front and steer compartment covers. See
the section Frame 100 YRM 975 for removal proce-
dures.
Locate and disconnect the top auxiliary supply hose
from the hydraulic control valve at the bulkhead fitting at
the front of the frame and place a tee fitting in the line.
Loosen the fitting slowly to relieve any residual pressure
that may be in the line. Place a cloth rag underneath the
fitting to absorb any hydraulic oil lost from the fitting.
Install a hydraulic line and a 20.68 MPa (3000 psi) pres-
sure gauge to the tee fitting.
Fully sideshift the reach attachment to the left and
observe the pressure gauge reading while holding the
sideshift at relief. The gauge should read 15.17 MPa
(2200 psi) +/- 0.34 MPa (50 psi).
If the pressure is not within the allowable range, the
auxiliary relief valve must be adjusted.
To adjust the auxiliary relief valve in models
NDR030AE, NR035/040/045AE; NS040/050AF; and
NDR030CB, NR045CB, locate the valve marked RV1
on the main control valve. See Figure 6.
To adjust the auxiliary relief valve in model NDR030GB,
NR045GB, locate the auxiliary relief valve on the main
control valve. See Figure 7.
Remove the plug covering the adjusting screw on the
top of the relief valve. Use an Allen wrench to make
the adjustment as required. Turning the screw clock-
wise will increase the pressure and turning the screw
counterclockwise will decrease the pressure. When the
proper pressure has been obtained, install the plug into
the top of the relief valve.
Remove the pressure gauge line and the tee fitting.
Reattach the auxiliary supply line to the bulkhead fit-
ting. Ensure all fittings are tight and do not leak.
Connect the battery and operate the auxiliary functions
to remove any air from the hydraulic lines.
1900 YRM 973 Lift Pump and Motor

Lift Pump and Motor

DESCRIPTION any component. Wear safety glasses. Make cer-
tain the battery has been disconnected. Discharge
The lift pump and motor, which are joined together by the capacitors in the controller by connecting a load
attaching hardware, rests on a cradle mounted to the (such as a contactor coil or a horn) across the con-
lift truck frame. The pump and motor is secured to the troller’s B+ and B terminals. DO NOT use a screw-
cradle by capscrews. The lift pump operates only when driver to discharge the traction motor controller.
the control handle is moved to start the lift function. See
Figure 8. 4. Discharge the controller by connecting a load
across terminals B+ and B . See Figure 10.
The lift pump is driven by a splined shaft that fits into the
lift pump motor. See Figure 8 and Figure 9. Bushings
are installed on both sides of the gears inside the pump.
The bushings are designed with passages to direct the
flow of oil to the pump outlet and for lubrication. O-rings
and seals prevent leakage between the body and cov-
ers. A shaft seal is also installed on the shaft between
the pump and motor to prevent leaks. A hydraulic hose
connects the pump discharge to the control valve.

REMOVE

WARNING
Make sure that the brake pedal is in the up position
and the brake is applied. Put blocks on both sides
(front and back) of the drive/steer tire and the caster
wheels to prevent movement of the lift truck. Put
a block on each side (front and back) of the load
wheels to prevent movement of the lift truck. See
the section Periodic Maintenance 8000 YRM 970 or
the Operator Manual for more detailed instructions.

1. Turn the key switch to the ON position. Hold the

control handle in the lower position to completely
lower the forks and relieve any hydraulic pressure
from the lift circuit.

2. Turn the key switch to the OFF position and discon-

nect the battery.

3. Remove the front and steer compartment covers.

1. MOTOR 5. CAPSCREW
See the section Frame 100 YRM 975 for removal 2. PUMP 6. LOCKWASHER
procedure. Refer to Covers, Panels, and Plates. 3. O-RING 7. 45 ELBOW
4. 90 ELBOW
WARNING Figure 8. Lift Pump and Motor
The capacitor in the traction motor controller can
hold an electrical charge after the battery is discon-
nected. To prevent electrical shock and injury, dis-
charge the capacitor before inspecting or repairing

7
Lift Pump and Motor 1900 YRM 973

1. SNAP RING 5. SEAL 9. IDLER GEAR

2. SHAFT SEAL 6. BUSHING 10. DRIVE GEAR
3. MOUNTING FLANGE 7. O-RING 11. END COVER
4. BACKUP RING 8. PUMP BODY 12. CAPSCREW

Figure 9. Lift Pump - Exploded View

5. Open the drive unit compartment door. Position a

drain pan on the floor under the hoist pump. Tag,
loosen, and disconnect the feed and return lines to
the hoist pump. Install plugs in the hydraulic lines to
prevent dirt from entering the system and to prevent
hydraulic oil from draining out.
6. Tag and disconnect the two power cables from the
motor.
7. Place rags under the lift pump suction and return
ports to absorb any oil leakage during removal.
8. Position a lifting device around the hoist pump mo-
tor. Remove the four capscrews, lockwashers, flat
washers, and isolator mounts retaining the hoist
pump and motor to the lift truck frame.
WARNING
The lift pump and motor is heavy. Be sure that
all lifting devices (lifts, cables, chains, or slings)
are suitable and of adequate capacity to lift the lift
pump and motor. The lift pump and motor assem-
bly can weigh approximately 52.2 kg (115 lb).
9. Mark the approximate location where the pump and
motor rest on the cradle with chalk. Using an appro-
priate lifting device with adequate capacity, care-
fully raise the lift pump and motor from the cradle
and move it to a clean work station for disassembly.
Wipe up any hydraulic fluid that may have leaked
during removal.

8
1900 YRM 973 Lift Pump and Motor

5. Check the hydraulic fluid in the reservoir. Add fluid

to the reservoir, if required. See the section Peri-
odic Maintenance 8000 YRM 970 or the Operator
Manual for fluid specifications.

6. Remove the blocks from under the drive/steer

wheel, caster wheels, and load wheels.

7. Reconnect the battery.

8. Operate the lift truck through all functions. Check

for oil leaks.

9. Recheck the hydraulic oil level. Add fluid if required.

10. Install the front and steer compartment covers. See

the section Frame 100 YRM 975 for installation pro-
cedure. Refer to Covers, Panels, and Plates.

DISASSEMBLE
1. Separate the pump from the motor by removing the
two capscrews and lockwashers. See Figure 8.
1. NEGATIVE CONNECTION 2. Disassemble the elbows and O-rings from the
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES pump body.
4. 200-OHM, 2-WATT RESISTOR
3. Remove the four capscrews from the pump body
Figure 10. Discharging the Capacitors and take off the mounting flange and the end cover.
Remove the backup rings, seals, bushings, and
INSTALL O-rings. See Figure 9.

WARNING
The lift pump and motor is heavy. Be sure that
all lifting devices (lifts, cables, chains, or slings)
are suitable and of adequate capacity to lift the lift
pump and motor. The lift pump and motor assem-
bly can weigh approximately 52.2 kg (115 lb).
1. Using an appropriate lifting device, carefully lower
the pump and motor on to the cradle in the location
from which it was removed.
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal
or installation with enough force to cause an injury.
Always use the correct snap ring pliers, and wear
eye and face protection during removal and instal-
lation.
4. Remove the snap ring from the housing and remove
the shaft seal.

2. Install the four isolator mounts, flat washers, lock-
washers, and capscrews.
3. Remove the plugs from the suction and pressure
hoses and pump ports. Connect the hoses to the
lift pump, tighten the connections, and remove the
tags. Clean up any oil spills.
5. Remove the idler gear and drive gear.
6. Inspect the drive gear, idler gear, and the pump
body for damage. If any of these parts are dam-
aged, the pump must be replaced with a new pump.
All seals, O-rings, backup rings, and snap ring must
be replaced if the present pump is to be used.

4. Connect the two power cables to the motor and re-

move the tags.

9
Hydraulic Tank 1900 YRM 973

ASSEMBLE
1. Apply clean hydraulic fluid to all pump components,
including O-rings and seals, prior to assembly.
2. Align and install the idler, drive gears, and the two
O-rings in the pump body.
3. Install both bushings on the shafts. Install the seals
and backup rings in the body of each bushing.
4. Align the end cover, pump body, and mounting
flange. Install the four capscrews.
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal
or installation with enough force to cause an injury.
Always use the correct snap ring pliers, and wear
eye and face protection during removal and instal-
lation.
5. Install a new shaft seal on the drive gear shaft and
retain with a new snap ring.
6. Install new O-rings on the elbow fittings and install
the elbows in the pump.
7. Lubricate splined shaft with #2 lithium grease. See
the section Periodic Maintenance 8000 YRM 970.
8. Align and insert the splined shaft of the pump in the
motor. Secure the pump to the motor by installing
two capscrews and lockwashers through the pump
mounting flange.

Steering Pump
The steering pump provides hydraulic pressure for lift description, operation, checks, adjustments, and repair
truck steering and auxiliary hydraulic functions. See of this pump.
the section Steering System 1600 YRM 974 for the

Hydraulic Tank
DESCRIPTION
The hydraulic tank stores hydraulic fluid used for the
steer, lift/lower, and auxiliary hydraulic functions. See
Figure 13 or Figure 14. The tank is fabricated from
molded plastic. The capacity of the tank is dependent
upon the size of the battery compartment. See Table 1
for tank capacities. The tank, which is located in the
front compartment, rests on the lift truck frame without
attaching hardware.
REMOVE AND DISASSEMBLE
WARNING
Make sure the brake pedal is released and the brake
is applied. Put blocks on both sides (front and back)
of the drive tire and the caster wheels to prevent
movement of the lift truck. Put a block on each side
(front and back) of the load wheels to prevent move-
ment of the lift truck.

Table 1. Hydraulic Tank Capacities 1. Turn the key switch to the ON position. Hold the
control handle in the lower position to completely
Battery Compartment Oil Tank Capacity to lower the forks and to relieve any hydraulic pressure
Size Full Mark from the lift circuit.

317.5 mm (12.5 in.) 21.4 liter (5.66 gal) 2. Turn the key switch to the OFF position and dis-
connect the battery. Position block on both sides
370.8 mm (14.6 in.) 24.1 liter (6.37 gal)
(front and back) of the drive/steer tire and the caster
421.6 mm (16.6 in.) 24.1 liter (6.37 gal) wheels. Put a block on each side (front and back)
of the load wheels.
447.7 mm (17.6 in.) 28.2 liter (7.45 gal)
535.9 mm (21.1 in.) 28.2 liter (7.45 gal) 3. Open the drive unit compartment door.

Hydraulic System + Tank Capacity 4.01 liter 4. Remove the battery and steer compartment covers.
(1.06 gal) in lines See the section Frame 100 YRM 975 for removal

10
1900 YRM 973
procedure. Refer to Covers, Panels, and Plates
Repair.
5. The following items must be removed to allow ac-
cess to the hydraulic tank:
• Tiller and knob assembly (see the section Steer-
ing System 1600 YRM 974 )
• Dash panel with display (see the section Electri-
cal System 2200 YRM 978)
• Hydraulic control valve (see the section Control
Valve for your truck)
• Forward cover mounting clip and bulkhead fittings
• Control handle and bracket assembly (see the
section Electrical System 2200 YRM 978)
• Mast cable wires (positioned out of the way)
• Accessory alarm module (if supplied)
See the appropriate section of the service manual
for removal of the above components.
6. Remove the filler cap from the tank.
7. Remove two screws and lockwashers attaching
the strainer-filter to the tank cover. Remove the
strainer-filter.
8. Using a siphoning pump, insert the suction hose
into the hydraulic tank. Siphon out the hydraulic
fluid from the tank into a container of suitable size.
9. Remove any necessary lines from the hydraulic
valve. Cap all lines and install the fitting plugs in
the manifold block. Tag and disconnect any wire
connections from the valve solenoids.
10. On top of the tank, tag and remove three hoses
which connect to breather, hydraulic filter, and
steering control unit. Install plugs into the hose
connections to prevent dirt from entering the sys-
tem. Wipe up any hydraulic fluid that may have
leaked during removal.
11. To access the lower hoses, first remove the hy-
draulic oil filter element. Then, tag and remove the
two suction hoses which connect to the steer pump
and lift pump. Install plugs into the hose connec-
tions to prevent dirt from entering the system. Wipe
up any hydraulic fluid that may have leaked during
removal.
12. Tag and remove the power cables from the lift pump
motor. Position cables away from the tank to allow
room for removal.
Hydraulic Tank
13. If required, tag and remove the hoses which con-
nect between the control valve and the mast as-
sembly, and between the control valve and the lift
pump. Install plugs into hose connections.
14. Remove the hydraulic tank from the lift truck.
ASSEMBLE AND INSTALL
1. Replace the tank cover and gasket, if removed, with
four lock nuts and washers.
2. Replace the hydraulic tank in the lift truck.
3. If disconnected, remove tags and plugs and re-
connect hoses between the control valve and mast
assembly, and between the control valve and lift
pump.
4. Reconnect the power cables to the lift pump and
remove the tags.
5. On the bottom of the tank, remove the tags and
plugs and replace the two suction hoses which con-
nect to the steer pump and lift pump. Replace the
hydraulic oil filter element.
6. On top of the tank, remove the tags and plugs,
and replace the three hoses which connect to the
breather, hydraulic filter, and steering control unit.
7. Attach the strainer filter to the tank cover with two
screws and lockwashers.
8. Reinstall the following items removed earlier:
• Tiller and knob assembly (see the section Steer-
ing System 1600 YRM 974 )
• Dash panel with display (see the section Electri-
cal System 2200 YRM 978)
• Hydraulic control valve (see the section Control
Valve for your truck)
• Forward cover mounting clip and bulkhead fittings
• Control handle and bracket assembly (see the
section Electrical System 2200 YRM 978)
• Mast cable wires
• Accessory alarm module (if supplied)
9. Fill the hydraulic tank with the recommended hy-
draulic oil. Refer to Table 1 for hydraulic tank capac-
ities. See the section Periodic Maintenance 8000
YRM 970 or the Operator Manual for fluid specifi-
cations.
10. Remove the blocks from under the drive/steer
wheel, caster wheels, and load wheels.
11. Reconnect the battery.
11
Troubleshooting 1900 YRM 973

12. Operate the lift truck through all functions. Check 13. Install the front and rear compartment covers. See
for oil leaks. Recheck the hydraulic tank for the the section Frame 100 YRM 975 for installation pro-
correct oil level. Add oil if required. cedure. Refer to Covers, Panels, and Plates.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Low hydraulic pressure. Pump is worn or damaged. Repair or install new pump.

Relief valve needs adjustment. Adjust or replace relief valve.

Hydraulic system relief valve Relief valve needs adjustment or relief Adjust or replace relief valve.
opens frequently. valve is defective.

Restriction in the system. Remove restriction or install new line.

The pump noise is not normal. Oil in the hydraulic tank is low. Fill tank to correct level. Check for
leaks.

Restriction in the inlet hose. Remove restriction or install new line.

Inlet fitting or inlet hose clamp is loose. Tighten fitting. Install new hoses. Re-
move air from system.

The bearings or gears are damaged. Repair or install new pump.

The housing is damaged. Repair or replace pump housing.

Loose capscrews holding the pump Tighten capscrews to specified torque.

housing together.

Loose capscrews in the pump mount- Tighten capscrews to specified torque.

ing.

Pump motor is damaged or worn. Check, repair, or install new parts as

required.

The pump has low output. The pump is worn. Check, repair, or install new parts as
required.

Seals or gaskets are damaged and Install new seals or gaskets.

cause leaks.

The fitting at the pump leaks. Tighten fittings. Install new parts as
necessary.

12
1900 YRM 973 Diagrams, Schematics, or Arrangements

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The pump has leaks. Fittings are loose or defective. Tighten fittings. Install new parts as
necessary.

Loose capscrews holding the pump Tighten capscrews to specified torque.

housing together.

Seals are defective. Install new seals or gaskets.

Slow auxiliary functions Oil in the hydraulic tank is low. Fill tank to correct level. Check for
leaks.

Auxiliary speeds require adjustment in Adjust auxiliary speeds in the MIB

the MIB. setup procedures.

Auxiliary proportional valve is defec- Check auxiliary pressure for 15.2

tive. ±0.35 MPa (2200 ±50 psi)

Auxiliary proportional valve is defec- Remove valve and inspect for contam-
tive. ination or damage to the spool and re-
taining bushing. Replace if damaged.

Lift pump and motor operates Oil in the hydraulic tank is low. Fill tank to correct level. Check for
but the mast will not raise. The leaks.
handle is in the raise position
and the dash display shows
raise.

MIB settings improperly adjusted. Refer to the section Electrical System

2200 YRM 978.

Lift/lower coil is defective. Measure the resistance on the coil and

replace if not correct. Refer to the sec-
tion Electrical System 2200 YRM 978.

Lift/lower spool is defective. Check for 0.5 to 0.8 amps of current

at the coil of the spool. Check wiring
for loose or bad connections. Check
the valve spool for contamination and
damage. Replace spool.

13
Diagrams, Schematics, or Arrangements 1900 YRM 973

Figure 11. Hydraulic Schematic (Trucks Built Before July 15, 2002)

14
1900 YRM 973 Diagrams, Schematics, or Arrangements

Figure 12. Hydraulic Schematic (Trucks Built After July 15, 2002)

15
Diagrams, Schematics, or Arrangements 1900 YRM 973

Legend for Figure 13

1. DIPSTICK
2. CAP
3. STRAINER
4. TANK COVER
5. LOCK NUT
6. LOCKWASHER
7. WASHER
8. GASKET
9. NUT
10. THREAD SEAL
11. WASHER
12. SCREW
13. HYDRAULIC TANK
14. LOCKWASHER
15. SCREW

Figure 13. Hydraulic Tank - Exploded View (Small

Chassis)

16
1900 YRM 973 Diagrams, Schematics, or Arrangements

1. CAP 8. GASKET
2. STRAINER 9. CAPSCREW
3. TANK COVER 10. THREAD SEAL
4. CAPSCREW 11. HYDRAULIC TANK
5. LOCKWASHER 12. AUXILIARY RETURN TUBE
6. FLAT WASHER 13. HOIST RETURN TUBE
7. LOCK NUT

Figure 14. Hydraulic Tank - Exploded View (Large Chassis)

17
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 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

1900 YRM 973 12/04 (5/04)(3/04)(7/02) Printed in U.S.A.