Sistema Hidraulico

HYDRAULIC SYSTEM
N30ZDRS2, N35-40ZRS2 [B265];

N35ZDR2, N45ZR2 [D264];
N30ZDR2, N35-40ZR2 [E470]
PART NO. 4075035 1900 SRM 1616

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.
Hydraulic System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 2
Description ......................................................................................................................................................... 3
Control Handle................................................................................................................................................... 3
Sidestance Control Handle............................................................................................................................ 3
Fore/Aft Stance .............................................................................................................................................. 4
Maintenance....................................................................................................................................................... 5
Oil Level and Leaks....................................................................................................................................... 5
Operation ....................................................................................................................................................... 5
Oil Change ..................................................................................................................................................... 6
Drain .......................................................................................................................................................... 6
Cylinder Identification .............................................................................................................................. 7
Fill .............................................................................................................................................................. 8
Main Lift Cylinders............................................................................................................................... 9
Free-Lift Cylinders................................................................................................................................ 9
Breather Cap.................................................................................................................................................. 10
Inspect........................................................................................................................................................ 10
Oil Filter......................................................................................................................................................... 10
Change ....................................................................................................................................................... 10
Oil Strainer .................................................................................................................................................... 11
Check.......................................................................................................................................................... 11
Hydraulic System............................................................................................................................................... 12
General ........................................................................................................................................................... 12
Cleaning ..................................................................................................................................................... 12
Noise Levels............................................................................................................................................... 12
Hoses .............................................................................................................................................................. 12
Fittings ........................................................................................................................................................... 14
Lift Pump and Motor ......................................................................................................................................... 15
Complete Unit................................................................................................................................................ 15
Remove....................................................................................................................................................... 15
Install ......................................................................................................................................................... 16
Lift Pump ....................................................................................................................................................... 18
Components ............................................................................................................................................... 18
Pressure Flange Fitting........................................................................................................................ 18
Supply and Return Fittings.................................................................................................................. 19
Manual Lowering Valve........................................................................................................................ 19
Pressure Test Ports ............................................................................................................................... 20
Pressure Transducer............................................................................................................................. 20
Relief Valve............................................................................................................................................ 21
Lowering Control Valve ........................................................................................................................ 22
Remove Pump ............................................................................................................................................ 22
Install Pump .............................................................................................................................................. 22
Auxiliary Hydraulics.......................................................................................................................................... 23
Auxiliary Pump and Motor ........................................................................................................................... 23
Remove....................................................................................................................................................... 23
Disassemble ............................................................................................................................................... 24
Assemble .................................................................................................................................................... 25
Install ......................................................................................................................................................... 25
Front Selector Valve ...................................................................................................................................... 26
Rear Selector Valve........................................................................................................................................ 26
Hydraulic Tank .................................................................................................................................................. 28
©2013 HYSTER COMPANY i

Table of Contents Hydraulic System
TABLE OF CONTENTS (Continued)

Remove ........................................................................................................................................................... 28
Disassemble ................................................................................................................................................... 29
Breather Assembly .................................................................................................................................... 30
Filter Assembly ......................................................................................................................................... 31
Tank Fittings ............................................................................................................................................. 32
Clean and Inspect .......................................................................................................................................... 32
Assemble ........................................................................................................................................................ 32
Breather Assembly .................................................................................................................................... 32
Filter Assembly ......................................................................................................................................... 32
Tank Fittings ............................................................................................................................................. 32
Install ............................................................................................................................................................. 33
Specifications...................................................................................................................................................... 34
Troubleshooting ................................................................................................................................................. 34
This section is for the following models:
N30ZDRS2, N35-40ZRS2 [B265];

N35ZDR2, N45ZR2 [D264];
N30ZDR2, N35-40ZR2 [E470]
ii
1900 SRM 1616 General
General
and lowering the mast sections and carriage. The
CAUTION auxiliary functions can include: extend and retract,
Electrical components on this truck are po- tilt up and tilt down, and sideshift left and right.
larity sensitive and may be damaged if wired Both pumps draw their oil supply from a common
incorrectly. Make sure each electrical wire hydraulic tank. See Figure 1.
connection is tagged and properly identified
before removal or installation. If the proper The lift pump is a gear-type pump driven by an AC
location for connection is unclear, consult the induction motor which activates only when the lift
wiring diagram for the truck. Make sure test- controls are operated. When the mast is lowered, an
ing meters have adequate voltage and current electro-hydraulic lowering control valve opens to al-
capacities to handle the output of the electri- low the hydraulic oil to exit back through the pump
cal components they are used to check. Never into the hydraulic tank. The hydraulic oil passing
wire aftermarket components to this truck through the pump on its way back to the tank turns
without factory approval. the lift pump and motor in reverse. The lift motor en-
ters regeneration mode during lowering which gen-
The hydraulic system consists of two separately erates a small charge to the battery. This action re-
powered hydraulic circuits for main lift and auxil- covers some of the energy used to raise the mast and
iary functions. Main lift functions refer to raising maximizes battery economy.
1. LIFT MOTOR 7. FILTER ASSEMBLY

2. LIFT PUMP 8. TANK
3. AUXILIARY MOTOR 9. BREATHER ASSEMBLY
4. AUXILIARY PUMP 10. AUXILIARY RETURN HOSE
5. LIFT SUPPLY HOSE 11. AUXILIARY SUPPLY HOSE
6. LIFT RETURN HOSE 12. LIFT PRESSURE HOSE
Figure 1. Hydraulic System
1
General 1900 SRM 1616
Selector valves are used to control the reach carriage of the frame. Pull the battery cable connector
assembly hydraulic functions. These valves con- handle to separate the battery connector from
sist of valve blocks with electro-hydraulic solenoid the truck connector.
valves. The rear selector valve is located in the rear
frame of the reach carriage assembly and controls 3. Remove the operator compartment cover. See the
the reach and retract modes of the reach cylinders. section Periodic Maintenance 8000 SRM 1617.
The front selector valve is mounted in the front
4. Discharge the capacitor in the controllers by
frame of the reach carriage assembly and controls
connecting a 200-ohm, 2-watt resistor across the
tilt and sideshift functions. An optional auxiliary
controller B+ and B terminals of the motor
function selector valve is available for use with other
controller for 10 seconds. Remove the resistor
approved auxiliary hydraulic devices.
after discharging the capacitors. See Figure 2.
This section addresses the lift pump and motor
assembly, auxiliary pump and motor assembly,
hydraulic hoses, the hydraulic tank, and control
handle functions. Components that are sometimes
associated with the hydraulic system, but more
closely related to other systems, are covered in other
sections. For additional information see the sections:
Electrical System 2200 SRM 1612
A/C Motor Repair 0620 SRM 1621
Mast, Repair 4000 SRM 1195
Reach Carriages 4500 SRM 1196
DISCHARGING THE CAPACITORS
WARNING
Capacitors inside the controllers can hold an
electrical charge after the battery has been
disconnected. Discharge the capacitors before
servicing the electrical system to prevent in-
jury or electronic damage.
1. POSITIVE CONNECTION (B+)
2. NEGATIVE CONNECTIONS (B )
1. Move the lift truck to a safe, level area and com- 3. INSULATED JUMPER WIRES
pletely lower the mast. Turn the key switch to 4. 200-OHM, 2-WATT RESISTOR
the OFF position and attach a DO NOT OPER-
ATE tag to the control handle. Block the drive Figure 2. Discharging the Capacitors
wheel to prevent unexpected movement.
2. Disconnect the battery power cable connector

from the truck connector located on the right side
2
1900 SRM 1616 Control Handle
Description
The hydraulic system uses an AC induction motor Table 1. Main Lift Pump and Motor
and gear-type pump to supply hydraulic pressure for Configurations
the main lift functions. Lift pump and motor assem-
blies are available in a variety of combinations. See Motor Pump Availability
Table 1.
36V 25cc N30ZDR2 and
N35-40ZR2
36V EE Option 20cc All Models
36V 4500 lb 25cc All Models
Standard
36V 4500 lb 28cc N30ZDR2 and
High N35-40ZR2
Performance
Control Handle
SIDESTANCE CONTROL HANDLE A thumb operated Reach/Retract and Tilt up/Tilt
down control located on the face of the operator’s
The control handle provides operator control for control handle, controls tilt and reach/retract. See
travel, lift, lower, tilt, sideshift, horn, and reach Figure 4. To tilt forward, move the thumb control
functions. See Figure 3. down. To tilt back, move the thumb control up. To
reach, move the thumb control to the left. To retract,
Travel is activated by moving the control handle in
move the thumb control to the right.
the direction of travel. Pushing the handle away
from operator provides Forward Travel. Pulling
the handle toward operator provides Reverse
Travel. The travel speed for both forward and re-
verse directions is proportional to the distance 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.
The control handle also controls the lift/lower func-

tions. When the control handle is pushed downward,
the carriage lowers. When the handle is pulled up-
ward, the carriage lifts. The speed of the mast is pro-
portional to the distance the control handle is moved.
NOTE: During lift truck operation, the auxiliary

1. TILT/SIDESHIFT/REACH AND RETRACT
functions can only be operated one at a time. CONTROL
2. HORN BUTTON
The sideshift left and sideshift right functions are 3. AUXILIARY FUNCTION SELECT BUTTON
controlled by simultaneously depressing the func- 4. TRAVEL
tion select button and moving the auxiliary function 5. LIFT/LOWER
control into the Reach (sideshift left) or Retract
(sideshift right) command position. See Figure 4. Figure 3. Control Handle
3
Control Handle 1900 SRM 1616
1. TILT BACK
2. SIDESHIFT LEFT /
SIDESHIFT RIGHT
3. RETRACT / REACH
4. TILT FORWARD
5. THUMB CONTROL
Figure 4. Auxiliary Function Control
FORE/AFT STANCE
The fore/aft stance trucks utilize a different control
configuration than the multifunction control handle
on sidestance models. The operator directs forward
and reverse movement by pushing the control han-
dle in the desired direction. There is no side-to-side
movement of the fore/aft control handle. The lift/
lower function is controlled by a paddle switch on the
face of the control handle. Sideshift and tilt functions
are controlled by button switches located to the right
1. TILT DOWN
of the paddle switch facing the operator. A button 2. SS LEFT
switch located below the lift/lower paddle activates 3. SS RIGHT
the horn. Another paddle switch which controls the 4. TILT UP
extend/retract functions is located on the opposite 5. HORN BUTTON
side of the grip and is operated with the index fin- 6. CONTROL HANDLE GRIP
7. REAR GRIP
ger. See Figure 5. 8. HORN BUTTON
The control handle is designed to allow operation of 9. CONTROL HANDLE HARNESS
the directional functions of the control handle while 10. BOOT
facing the rear of the truck by using the rear grip. A 11. REAR GRIP HARNESS
thumb-operated button located at the end of the rear 12. EXTEND/RETRACT PADDLE
(BACKSIDE OF HANDLE)
grip operates the horn when facing the rear of the 13. LIFT/LOWER PADDLE
truck.
Figure 5. Control Handle (Fore/Aft Stance)
4
1900 SRM 1616 Maintenance
Maintenance
OIL LEVEL AND LEAKS operation of the hydraulic pump with low oil
levels will damage the pump.
WARNING Check for leaks by looking for oil under the lift truck
Always wear the proper protective equipment and where the lift truck has been parked. Make sure
including eye protection and petroleum-resis- the key switch is in the OFF position, remove the op-
tant gloves when handling hydraulic oil. Thor- erator compartment covers, and open the drive unit
oughly wash oil from exposed areas of skin as compartment door to visually inspect the hydraulic
soon as possible. system and hoses. Small oil leaks may appear as
wet, oily leaks or unusually dirty areas where dirt
Completely lower all mast components and
and dust sticks to oil that has slowly leaked out.
relieve pressure by opening the manual low-
ering valve before disassembling any part of Check the hydraulic oil level. Make sure the key
the lift pump or disconnecting any hydraulic switch is in the OFF position, and remove the op-
hoses. Refer to Manual Lowering Valve in this erator compartment covers to access the hydraulic
section. Make sure manual lowering valve is tank. The hydraulic oil should be filled to 25 mm
closed when repairs are complete. (1 in.) below the bottom of the hydraulic filter hous-
ing on the tank. Refer to Figure 9. Add hydraulic
The hydraulic oil is hot at normal operating
oil only as needed. DO NOT overfill the hydraulic
temperatures. Be careful when draining the
tank. If too much hydraulic oil is added, hydraulic
oil.
oil will be forced out through the breather cap during
Never put your hands on pressurized hydraulic operation. An indicator light notifies the operator if
components. Highly-pressurized hydraulic oil the hydraulic oil level drops below the minimum level
escaping through pin-hole leaks can be in- during operation.
jected into the skin. Visually inspect to find
hydraulic leaks. OPERATION
Turn the key switch to the ON position. Raise and
CAUTION lower the mast repeatedly. The mast should move
Protect the hydraulic system from dirt and smoothly and should not bounce or jerk when stop-
contaminants by cleaning hydraulic compo- ping or starting. Check each function of the control
nent areas before servicing the hydraulic handle for proper operation. See Control Handle for
system. explanations of hydraulic functions.
Never operate the pump without the proper

amount of oil in the hydraulic system. The
5
Maintenance 1900 SRM 1616
OIL CHANGE 4. Remove the breather cap from the top of the tank.
See Breather Assembly.
Drain
5. Position a suitable container oil with a minimum
capacity of 19 liter (5 gal) next to the lift truck to
WARNING
drain the oil.
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor- CAUTION
oughly wash oil from exposed areas of skin as DO NOT cut the hose when removing the wire
soon as possible. tie.
Completely lower all mast components and 6. Locate the drain hose at the bottom of the hy-
relieve pressure by opening the manual low- draulic tank. See Figure 6. Carefully clip the
ering valve before disassembling any part of wire tie securing the hose. Loosen and remove
the lift pump or disconnecting any hydraulic the hose clamp securing the plug in the end of the
hoses. Refer to Manual Lowering Valve in this hose. Remove the plug from the hose and drain
section. Make sure manual lowering valve is the hydraulic oil into the container.
closed when repairs are complete.
7. Some lift trucks use displacement-type, main lift
The hydraulic oil is hot at normal operating cylinders, which retain some amounts of oil even
temperatures. Be careful when draining the when at rest. Refer to Cylinder Identification.
oil. These cylinders may be further drained to re-
duce levels of contaminants left in the hydraulic
Never put your hands on pressurized hydraulic system. If your truck is equipped with displace-
components. Highly-pressurized hydraulic oil ment-type, main lift cylinders:
escaping through pin-hole leaks can be in-
jected into the skin. Visually inspect to find a. Loosen both main lift cylinder bleed screws
hydraulic leaks. 1/2 turn.
b. Open the manual lowering valve. Refer to

CAUTION Manual Lowering Valve in this section.
Disposal of lubricants and fluids must meet lo-
cal environmental regulations. c. Allow time for the oil to gravity feed into the
tank.
The hydraulic oil should be changed every 2000
hours or yearly. When the hydraulic system com- d. Turn the manual lowering valve to the OFF
ponents such as the pump or cylinders have been position. Refer to Manual Lowering Valve in
damaged or the oil has otherwise been contaminated, this section.
the hydraulic system should be drained, flushed,
e. Retighten the bleed screws at the top of the
and refilled with new hydraulic oil.
main lift cylinder shells.
1. Park the lift truck on a level surface and lower
8. Drain the remaining oil from the tank. Place the
the mast. Turn the key switch to the OFF po-
plug into the hose and secure with hose clamp
sition, and attach a DO NOT OPERATE tag to
as removed. Coil the drain hose and secure with
the control handle. Block the wheels to prevent
wire tie as removed.
unexpected movement.
9. Inspect the tank. Check for damage to the tank
or hoses. Clean the tank, if necessary. See Hy-
draulic Tank.
of the frame. Pull the battery cable connector
handle to separate the battery connector from 10. Reinstall the breather cap as removed. See
the truck connector. Breather Assembly.
3. Remove the operator compartment cover and the
drive unit compartment door to access the hy-
draulic tank.
6
piston-type. Certain cylinder types require different

hydraulic oil drain and fill procedures.
The main lift cylinders may be identified by the pres-

ence of a bleed screw near the top of the cylinder shell
on displacement-type cylinders. Piston-type, main
lift cylinders are not equipped with bleed screws. See
Figure 7. Free-lift cylinders can be identified by the
cylinder rod diameter. Measure the diameter of the
free-lift cylinder rod to determine your lift truck con-
figuration. See Figure 8 and Table 2.
1. PLUG 4. TANK 1. TOP OF INTERMEDIATE MAST

2. HOSE 5. WIRE TIE 2. CYLINDER ROD
3. ELBOW (WITH 6. CLAMP 3. BLEED SCREW
CLAMP) (INDICATES DISPLACEMENT-TYPE CYLINDER)
4. CYLINDER SHELL
Figure 6. Drain Hose
Figure 7. Main-Lift Cylinder Identification
Cylinder Identification
Two main lift cylinders and one free-lift cylinder are
present on all models of this series lift truck. How-
ever, cylinders may be either displacement-type or
7
Table 2. Cylinder Identification
Type Free-Lift Cylinders

Displacement 73.00 mm (2.87 in.)
Piston 44.40 mm (1.75 in.)
Fill
NOTE: Refer to Specifications in this section, for the
proper hydraulic oil selection.
1. Fill the hydraulic tank to the proper level with

new hydraulic oil. The hydraulic oil should be
filled to even with the tank flange on trucks
with a 21.5 inch battery compartment or 40 mm
(1.6 in.) below the tank flange on all other
battery compartment configurations. DO NOT
overfill the hydraulic tank. See Figure 9.
1. CROSSHEAD ASSEMBLY
2. CYLINDER ROD DIAMETER
3. BLEED OR FILL SCREW
4. RETAINER BRACKET
5. CYLINDER SHELL
6. GLAND
Figure 8. Free-Lift Cylinder Rod 1. HYDRAULIC FILTER HOUSING

2. HYDRAULIC RETURN FITTING
3. TANK FLANGE
4. HYDRAULIC OIL FILL LEVEL
5. HYDRAULIC TANK
Figure 9. Hydraulic Oil Level
8
For oil capacities for your lift truck see Periodic d. Slightly open the bleed screw of either main
Maintenance 8000 SRM 1617. lift cylinder by turning it counterclockwise
until air and/or oil foam is expelled. Allow
2. Install the breather cap. air/foam to bleed from cylinder until clear hy-
draulic oil is present. Close the bleed screw
3. Determine the types of main lift cylinders and
and tighten to 6 to 8 N•m (53 to 71 lbf in). If
free-lift cylinders used. Refer to Cylinder Iden-
the free-lift cylinder completely lowers before
tification.
all the air is expelled, close the bleed screw
Main Lift Cylinders and return to Step a. Wipe up the expelled
oil and repeat procedure for the other main
1. Piston-type, main lift cylinders do not require lift cylinder.
bleeding. If your lift truck is equipped with pis-
ton-type, main lift cylinders, skip to Free-Lift Free-Lift Cylinders
Cylinders.
1. Piston-type, free-lift cylinders are not bled but
do have an oil chamber that must be filled for
WARNING cylinder cushion functions to work properly:
Keep clear of the mast when bleeding the cylin-
ders. Mast parts may shift or lower unexpect- a. Completely lower the mast and carriage.
edly. Turn the key switch to the OFF position and
disconnect the battery.
Never put your hands on pressurized hydraulic
components. Highly-pressurized hydraulic oil b. Slightly open the fill screw on the side of
escaping through pin-hole leaks can be in- the free-lift cylinder shell near the gland by
jected into the skin. Visually inspect to find turning it counterclockwise to make sure the
hydraulic leaks. cylinder is not pressurized. Slowly remove
the fill screw and seal.
2. Displacement-type, main lift cylinders must be
bled: NOTE: Use a clean oil can to measure and inject hy-
draulic oil into the cylinder fill hole.
a. Engage the battery connector and turn the
key switch to the ON position. c. Measure approximately 150 cc (5 oz) of clean
hydraulic oil and fill the oil chamber through
b. Activate the lift function using the operator the fill hole. Fill until all the oil is used or
controls. Continue until the free-lift cylinder until oil flows out of the fill hole.
rod extends approximately 150 mm (6 in.) to
apply pressure to the hydraulic system. d. Install the fill screw and seal and tighten to
6 to 8 N•m (53 to 71 lbf in). Wipe up any
c. Turn the key switch to the OFF position and spilled oil.
remove the key.
e. Connect the battery and turn the key switch
to the ON position. Completely raise and
WARNING lower the mast several times to check for
Use a personnel lift or a ladder to access the proper operation. The free-lift cylinder
bleed screws. DO NOT climb on the mast or lift should slow smoothly near the end of its
truck. stroke. Check the hydraulic oil level in the
tank and fill as necessary. Replace all covers
CAUTION as removed, remove blocks from the wheels,
and return the lift truck to service.
DO NOT completely remove the bleed screw.
Loosen it slowly and gradually.
NOTE: Use a cloth to wipe up foam and oil as it is

expelled to minimize cleanup.
9
located in the end of the cylinder rod. In-

WARNING spect the cylinder rod where it emerges from
Keep clear of the mast when bleeding the cylin- the crosshead. If the rod is equipped with
ders. Mast parts may shift or lower unexpect- the additional bleed screw, repeat the bleed
edly. procedure using the additional bleed screw.
Never put your hands on pressurized hydraulic e. Connect the battery and turn the key switch
components. Highly-pressurized hydraulic oil to the ON position. Completely raise and
escaping through pin-hole leaks can be in- lower the mast several times to check for
jected into the skin. Visually inspect to find proper operation. Repeat the bleed proce-
hydraulic leaks. dure until no air is present when bleeding
the free-lift cylinder. Check the hydraulic oil
2. Displacement-type, free-lift cylinders must be level in the tank and fill as necessary. Re-
bled: place all covers as removed, remove blocks
a. Engage the battery connector and turn the from the wheels, and return the lift truck to
key switch to the ON position. service.
b. Activate the lift function using the operator BREATHER CAP

controls. Continue until the free-lift cylinder
rod extends approximately 150 mm (6 in.) to Inspect
apply pressure to the hydraulic system.
The hydraulic breather cap allows air to enter the hy-
c. Turn the key switch to the OFF position and draulic tank when the hydraulic oil is pumped out to
disconnect the battery. the cylinders. When the hydraulic oil returns to the
tank, air is expelled through the hydraulic breather
cap. A filter in the cap protects the hydraulic system
CAUTION from particles of dirt and other contaminants. If the
DO NOT completely remove the bleed screw. filter becomes excessively dirty, air flow can be re-
stricted, causing pressures and vacuums to build in-
NOTE: Use a cloth to wipe up foam and oil as it is side the tank. If air flow becomes restricted through
expelled to minimize cleanup. the hydraulic breather cap, replace the breather cap.
d. Slightly open the bleed screw on the side Keep the hydraulic breather area clean and DO NOT
of the free-lift cylinder shell near the gland overfill the hydraulic tank.
by turning it counterclockwise until air
and/or oil foam is expelled. Allow air/foam to OIL FILTER
bleed from the cylinder until clear hydraulic
oil is present. Close the bleed screw and
Change
tighten to 6 to 8 N•m (53 to 71 lbf in). If the Replace the filter element after the first 50 hours of
free-lift cylinder completely lowers before all service and every 2000 hours or yearly thereafter.
air/foam is expelled, close the bleed screw
and repeat Step a. Wipe up the expelled
oil. Some displacement-type, free-lift cylin-
ders also have an additional bleed screw
10
8. Engage the battery connector and remove the

WARNING DO NOT OPERATE tag from the control han-
Always wear the proper protective equipment dle. Remove the drive wheel blocks and test for
including eye protection and petroleum-resis- proper operation.
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
Completely lower all mast components and

relieve pressure by opening the manual low-
ering valve before disassembling any part of
the lift pump or disconnecting any hydraulic
hoses. Refer to Manual Lowering Valve in this
section. Make sure manual lowering valve is
closed when repairs are complete.

oil.
CAUTION
cal environmental regulations.
1. Move the lift truck to a safe, level area and com-

pletely lower the mast. Turn the key switch to 1. HYDRAULIC TANK
the OFF position and disconnect the battery. At- 2. COVER
3. FILTER
tach a DO NOT OPERATE tag to the control 4. PUMP RETURN HOSE
handle. Block the drive wheel to prevent unex- 5. HYDRAULIC FILTER HOUSING
pected movement. 6. SPRING
2. Remove the operator compartment cover(s) to ac- Figure 10. Cover Removal
cess the hydraulic tank.
OIL STRAINER
3. Loosen the four capscrews securing cover to the
hydraulic oil filter housing. Check
4. Press the cover down by hand to depress the el- Clean around the breather assembly to prevent
ement retainer spring, and remove the four cap- contamination to the hydraulic system. Remove the
screws. breather cap from the top of the hydraulic tank.
Visually inspect the hydraulic oil strainer located
5. Remove the cover and spring from housing.
inside the fill hole. The screen must be kept clean
Check the O-ring seal on the cover for cracks
in order to strain the new oil added to the system.
or deterioration. Replace, if damaged. See Fig-
If dirt, trash, rust, or sludge is present, remove and
ure 10.
clean the strainer. If the strainer cannot be cleaned
6. Remove element from housing and replace with or is broken, it should be replaced. See Hydraulic
a new element. Tank for oil strainer and breather assembly replace-
ment.
7. Position the cover and spring to the housing.
Press the cover down by hand to depress the
element retainer spring, and install the four cap-
screws. Torque capscrews to 6 N•m (53 lbf in).
11
Hydraulic System 1900 SRM 1616
Hydraulic System
GENERAL 1. Clean the reservoir and pump area before servic-
ing to prevent contaminants from entering the
WARNING hydraulic system.
Always wear the proper protective equipment 2. Clean (flush) the entire system when a failure is
including eye protection and petroleum-resis- encountered to make sure all paint, metal chips,
tant gloves when handling hydraulic oil. Thor- and debris are removed.
oughly wash oil from exposed areas of skin as
soon as possible. 3. Filter each change of oil to prevent the introduc-
tion of contaminants into the system.
Completely lower all mast components and re-
lieve pressure by opening the manual lowering 4. Provide continuous protection from airborne con-
valve before disassembling any part of the lift tamination by keeping the breather cap clean
pump or disconnecting any hydraulic hoses. and serviceable.
The hydraulic oil is hot at normal operating Noise Levels

oil. Hydraulic system noise may be caused by both im-
properly selected oil and loose or damaged system
Never check for leaks by putting hands on components.
hydraulic lines or components under pressure. • Cavitation - Can be caused by high fluid viscosity,
Hydraulic oil under pressure can be injected cold fluid temperatures, or a restriction in the in-
into the skin. let screen or inlet tubing. At startup, low tempera-
tures can cause pump noises due to cavitation.
CAUTION • Aerated Hydraulic Oil - Results in system noise
Protect the hydraulic system from dirt and that is similar to cavitation. Aerated oil is caused
contaminants when servicing the hydraulic by the ingestion of air through the joints of the in-
system. let lines and high-velocity discharge lines. Aera-
tion can also be caused by oil discharging above the
Never operate the pump without the proper fluid level in the hydraulic reservoir. Aerated hy-
amount of oil in the hydraulic system. The draulic oil occurs when air does not have sufficient
operation of the hydraulic pump with low oil time to escape from the fluid while in the reservoir
levels will damage the pump. before recycling through the system.
The hydraulic oil in the system performs the dual HOSES

function of power transmission and lubrication. Us-
ing the proper oil is essential to system operation. The hydraulic hoses carry hydraulic fluid from the
Refer to Specifications in this section. The hydraulic tank to the hydraulic pumps, to the hydraulic func-
oil level should be checked first when troubleshooting tions, and back to the tank. Hoses may be pressur-
hydraulic system problems. Refer to Maintenance in ized or non-pressurized. Non-pressurized hoses slide
this section. Low oil levels may cause it to appear onto barbed fittings and are secured in place with
that a problem exists with the battery or hydraulic hose clamps. Pressurized hoses are reinforced with
components. steel mesh molded into the rubber to support the high
pressures created by the pump. These hoses have hy-
Cleaning draulic fittings crimped onto each end. The lift pump
has separate supply, return, and pressure hoses. The
Take precautionary measures to ensure that the hy- auxiliary pump has a supply and a pressure hose.
draulic system remains clean. See Figure 11 and Figure 12.
12
1900 SRM 1616 Hydraulic System
1. AUXILIARY RETURN HOSE 8. FILTER ASSEMBLY

2. AUXILIARY PRESSURE HOSE 9. LIFT RETURN HOSE
3. AUXILIARY RETURN ELBOW 10. LIFT PUMP
4. AUXILIARY PRESSURE ELBOW 11. HYDRAULIC TANK
5. LIFT PUMP PRESSURE HOSE 12. LIFT MOTOR
6. MAST CONNECTION FITTING 13. CLAMP
7. BREATHER CAP 14. LOW OIL INDICATOR SWITCH
Figure 11. Hoses (Top)
13
Hydraulic System 1900 SRM 1616
NOTE: The hydraulic oil must drained well below the

height of the hoses being removed before servicing.
Refer to Drain for the proper procedures for your lift
truck. Oil will remain in the hoses even when the
hydraulic system has been drained.
Visually inspect the hoses for leaks. Small oil leaks

may appear as wet, oily leaks or unusually dirty ar-
eas where dirt and dust sticks to oil that has slowly
leaked out. Check around fittings and hose con-
nections for seeping oil. Replace hoses immediately
when damage or significant wear is found. Loosen
fittings slowly and cover with a cloth to make sure
pressure has been relieved in the system. Empty the
hoses into a drain pan and cap or plug all open ports
and hoses at once to prevent contaminants from
entering the system. All hydraulic hoses and tubes
must be thoroughly cleaned before installation.
WARNING
Failure to return the manual lowering valve to
the full clockwise position will cause the forks
1. CLAMP to lower unexpectedly.
2. AUXILIARY PUMP AND MOTOR ASSEMBLY
3. AUXILIARY PRESSURE HOSE
4. AUXILIARY SUPPLY HOSE NOTE: The hydraulic system (including the mast)
5. MAIN-LIFT SUPPLY HOSE must be purged of air when refilling the hydraulic
6. TANK system with oil.
Figure 12. Hoses (Auxiliary) When making repairs, use the least number of fit-
tings and connections to minimize flow resistance
and the possibility of leakage. Route new hoses prop-
WARNING erly to avoid contact that may cause premature wear.
Always wear the proper protective equipment Close the manual lowering valve and refill the hy-
including eye protection and petroleum resis- draulic system with oil when repairs are complete.
tant gloves when handling hydraulic oil. Thor- Refer to Fill for the proper procedures for your lift
oughly wash oil from exposed areas of skin as truck.
soon as possible.
FITTINGS
lieve pressure by opening the manual lowering Various types of fittings are used to connect hoses
valve before disassembling any part of the lift and hydraulic system components. Some of these in-
pump or disconnecting any hydraulic hoses. clude flared fittings, O-ring fittings, and flat-faced
O-ring fittings. Certain fittings have properties that
The hydraulic oil is hot at normal operating make them better suited for particular applications.
temperatures. Be careful when draining the Check the threads and mating surfaces of each fit-
oil. ting when removed. Fittings with O-rings should be
inspected carefully and the O-ring replaced if it is
Never check for leaks by putting hands on brittle, cracked, or otherwise damaged. Make sure
hydraulic lines or components under pressure. mating surfaces are clean and smooth and DO NOT
Hydraulic oil under pressure can be injected overtighten fittings. Inspect fittings for leaks often
into the skin. following repairs.
14
1900 SRM 1616 Lift Pump and Motor
Lift Pump and Motor

COMPLETE UNIT the capscrews securing the drive unit compart-
ment door, and pull the door open. See the sec-
WARNING tion Periodic Maintenance 8000 SRM 1617.
Always wear the proper protective equipment 4. Tag and disconnect the electrical connections
including eye protection and petroleum-resis- from the lift motor terminals.
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as 5. Open the manual lowering valve to relieve any
soon as possible. pressure present in the hydraulic system. See
Manual Lowering Valve.
lieve pressure by opening the manual lowering NOTE: Models with displacement-type cylinders can
valve before disassembling any part of the lift retain significant quantities of oil in the cylinders
pump or disconnecting any hydraulic hoses. and hoses even when the hydraulic tank is empty.
Properly drain the hydraulic system of your model to
The hydraulic oil is hot at normal operating avoid large spills. Refer to Drain.
oil. 6. Drain the oil from the hydraulic system well be-
low the height of the hoses being removed. See
Never put your hands on pressurized hydraulic Oil Change. Store the oil in clean, approved con-
components. Highly pressurized hydraulic oil tainers if it is to be reused.
escaping through pin-hole leaks can be in-
jected into the skin. Visually inspect to find 7. Disconnect the hoses from the lift pump. Se-
hydraulic leaks. cure the hose ends above the fluid level in the
tank. Cap and plug the ports and hoses to pre-
vent contamination to the system. Remove the
CAUTION
hose clamp securing the lift pump pressure hose
Disposal of lubricants and fluids must meet lo- to the terminal end mounting plate by remov-
cal environmental regulations. ing the four capscrews and washers securing the
The following procedures outline the steps for remov- clamp halves.
ing the entire lift pump and motor assembly as a com- 8. Close the manual lowering valve. See Manual
plete unit. If it is not necessary to remove the lift mo- Lowering Valve.
tor, follow the procedures for removing the lift pump
only. See Lift Pump, Remove Pump. Perform only 9. Attach a sling and an overhead lifting device to
the procedures necessary to safely complete the re- the lift pump and motor assembly.
quired service.
10. Remove the capscrews from the mounting bush-
Remove ing of each motor mount.
1. Park the lift truck on a level surface and lower

the mast. Turn the key switch to the OFF po- CAUTION
sition, and attach a DO NOT OPERATE tag to Carefully route the assembly from the truck to
the control handle. Block the wheels to prevent avoid damaging the threads of the forward mo-
unexpected movement. tor mount studs.
2. Disconnect the battery power cable connector 11. Lift the lift pump and motor assembly from the
from the truck connector located on the right side lift truck and position on a clean workbench. Re-
of the frame. Pull the battery cable connector move the sling and lifting device.
handle to separate the battery connector from
the truck connector. 12. Remove the capscrews securing mounting brack-
ets to the lift motor. See Figure 13.
3. Remove the operator compartment cover(s) to ac-
cess the lift pump and motor assembly. Remove 13. Inspect the motor mount bushings. Replace as
necessary.
15
Lift Pump and Motor 1900 SRM 1616
1. AUXILIARY RETURN HOSE

2. HYDRAULIC TANK
3. HOSE CLAMP
4. ATTACHING HARDWARE
5. MOUNTING BRACKET (TERMINAL END)
6. MOUNTING BUSHING
7. LIFT PUMP PRESSURE HOSE
8. LIFT MOTOR
9. MOUNTING CAPSCREW
10. MOUNTING BUSHING
11. LIFT PUMP
12. MOUNTING BRACKET (PUMP END)
Figure 13. Lift Pump and Motor
Install
1. Install the motor mount brackets to the lift motor
as removed. See Figure 14 or Figure 15.
2. Attach a sling and an overhead lifting device to A. STANDARD 24 OR 36 VOLT

the lift pump and motor assembly. B. 4500 LB OR EE OPTION
1. CAPSCREW
3. Position the lift pump and motor assembly into 2. MOUNTING BRACKET
the lift truck as removed. 3. MOTOR END HEAD
4. Install the capscrew into the mounting bushing Figure 14. Mounting Brackets (Pump End)
of each motor mount.
5. Install the return and supply hoses as removed.
16
6. Install the pressure hose end with new O-ring

into the pressure port. Install the retaining
flanges onto the pump and hose, and install the
four capscrews and washers. Tighten each screw
until the retaining flanges are pressed lightly to
the pump. Alternately tighten each screw 1/8 th
turn until each capscrew is torqued to 40 N•m
(30 lbf ft).
7. Connect the wiring to the motor terminals as re-

moved.
NOTE: Models with displacement-type cylinders

have significantly different filling procedures than
models with piston-type cylinders. Fill the hydraulic
system using the appropriate procedures for your
model to ensure proper operation. Refer to Fill.
8. Fill the hydraulic system to the proper level.
9. Engage the battery connector, turn the key

switch to the ON position, and fully cycle the hy-
draulic system several times to check for proper
operation.
10. Install the operator compartment cover(s) as re-

moved. Remove the DO NOT OPERATE tag
from the control handle and remove the blocks
from the wheels.
A. STANDARD 24- OR 36-VOLT

B. 4500 LB OR EE OPTION
1. CAPSCREW
2. MOUNTING BRACKET
3. MOTOR END HEAD
Figure 15. Mounting Brackets (Terminal End)
17
LIFT PUMP lowering valve IMMEDIATELY after verifying

pressure has been removed.
WARNING
Components
including eye protection and petroleum-resis- Some components may be serviced without removing
tant gloves when handling hydraulic oil. Thor- the lift pump. Perform only the procedures necessary
oughly wash oil from exposed areas of skin as to safely complete the required service.
soon as possible.
Pressure Flange Fitting
lieve pressure by opening the manual lowering NOTE: Certain lift truck models retain significant
valve before disassembling any part of the lift quantities of oil in the cylinders and hoses even when
pump or disconnecting any hydraulic hoses. the hydraulic tank is empty. Drain the hydraulic sys-
tem using the appropriate procedures for your model
The hydraulic oil is hot at normal operating before servicing to avoid large spills. Refer to Oil
temperatures. Be careful when draining the Change.
oil.
1. Drain the oil from the hydraulic system. Refer
CAUTION to Drain. Make sure any oil remaining in the
tank is well below the height of the components
being removed. Store the oil in clean, approved
containers if the oil is to be reused.
When repairing damaged lift pump compo-
nents, it is recommended to change the oil CAUTION
filter. Clean the pressure flange area and protect the
surrounding area from oil spills. Have shop
The following procedures outline the steps for servic-
rags and containers ready to catch oil from the
ing, removing, and installing the lift pump. If it is not
pump pressure hose.
necessary to remove the lift pump, follow the proce-
dures for servicing the components only. See Compo- 2. Loosen the four capscrews securing each half of
nents. the retaining flanges to the pump 1/8 th turn al-
If the gears or housing of the pump are damaged, ternately to avoid breaking the retaining flanges.
the pump assembly must be replaced. See Remove. Remove the capscrews, washers, and retaining
Perform only the procedures necessary to safely com- flanges.
plete the required service.
3. Remove the hose end from the pressure port.
1. Park the lift truck on a level surface and lower Drain the hose into a suitable container and cap
the mast. Turn the key switch to the OFF po- the end.
sition, and attach a DO NOT OPERATE tag to
the control handle. Block the wheels to prevent 4. Check the O-ring. Replace if brittle, torn, or
unexpected movement. cracked. Inspect the hose end for damage and
wear. If the hose end is damaged, the pressure
2. Disconnect the battery power cable connector hose must be replaced.
of the frame. Pull the battery cable connector 5. Inspect the pump for cracks and damage. Check
handle to separate the battery connector from that the port receiving the hose end is smooth
the truck connector. and clean. If the hose and the port do not mate to-
gether properly, the connection will leak. A pump
3. Remove the operator compartment cover(s) to ac- with cracks cannot be repaired and must be re-
cess the lift pump and motor assembly. placed.
4. Open the manual lowering valve to relieve any 6. Install the hose end into the pressure port. In-
pressure present in the hydraulic system. See stall the retaining flanges onto the pump and
Manual Lowering Valve. Close the manual
18
hose, and install the four capscrews and wash- NOTE: Models with displacement-type cylinders
ers. Tighten each capscrew until the retaining have significantly different filling procedures than
flanges are pressed lightly to the pump. models with piston-type cylinders. Fill the hydraulic
7. Alternately tighten each capscrew 1/8 th turn un- model to ensure proper operation. Refer to Fill.
til all are torqued to 40 N•m (30 lbf ft).
7. Fill the hydraulic system to the proper level. See
NOTE: Models with displacement-type cylinders Oil Change.
models with piston-type cylinders. Fill the hydraulic Manual Lowering Valve
model to ensure proper operation. See Oil Change. The manual lowering valve can be opened by turning
the manual lowering valve knob counterclockwise to
8. Fill the hydraulic system to the proper level. Re- relieve pressure from the hydraulic system. This can
fer to Fill. be used to manually lower the mast in case of mal-
function. If the mast leaks down during operation,
Supply and Return Fittings lower the mast and check that the knob is completely
closed (turn clockwise). Always close the manual low-
NOTE: Certain lift truck models retain significant
ering valve after use. See Figure 16.
quantities of oil in the cylinders and hoses even when
the hydraulic tank is empty. Drain the hydraulic sys-
before servicing to avoid large spills. Refer to Oil
Change.

to Drain. Make sure any oil remaining in the
tank is well below the height of the components
containers if the oil is to be reused.
2. Disconnected the supply and/or return hose from

the lift pump. Secure the hose ends above the
fluid level in the tank. Cap and plug the ports
and hoses to prevent contamination to the sys-
tem.
NOTE: Inspect fittings for damage to the threads and

sealing surfaces. Replace damaged fittings as neces-
sary.
3. Remove the fittings as necessary.
4. Inspect the pump for cracks and damaged

threads.
1. LOWERING CONTROL VALVE
5. Install new fittings as removed. 2. UPPER MOUNTING HOLE
3. M2 TEST PORT
NOTE: Hose clamps are properly positioned centered 4. MANUAL LOWERING VALVE
between the end of the hose and the barb end of the 5. M1 TEST PORT
6. RETURN FITTING
fitting inside the hose. 7. RELIEF VALVE
8. SUPPLY FITTING
6. Place hose clamps loosely over the lift pump 9. LOWER MOUNTING HOLE
supply and return hoses, and install hoses onto 10. OVERRUN CHECK VALVE
the lift pump fittings. Position hose clamps and 11. PRESSURE FLANGE
tighten to 13 N•m (108 lbf in).
Figure 16. Pump (Valve Manifold)
19
Pressure Test Ports using a voltmeter with the key switch in

the ON position. There should be 5 volts
Two ports on the lift pump are available for test- present. Turn the key switch to the OFF
ing hydraulic pressures. These ports are normally position when complete. Voltage must be
plugged except when the second test port (M2) is fit- present to test the transducer.
ted with the pressure transducer for the load sens-
ing option (see Pressure Transducer). Both test ports c. Attach jumper wires from the transducer
can be accessed by removing the plug and installing terminal to the wiring harness connector to
a male, 7/16 20 UNF-2A thread O-ring fitting into complete the ground and the supply circuits.
the port. Connect a pressure gauge [24.1 to 27.6 MPa See Figure 18.
(3500 to 4000 psi) range] to the fitting to monitor hy-
draulic pressures. d. Connect a voltmeter between the transducer
terminal and the wiring harness to complete
The first test port (M1) taps directly into the main the output circuit. Turn the key switch to the
lift pressure circuit before the lowering control valve. ON position and check the voltage. Voltage
This allows a technician to install a pressure gauge should measure 0.5 volts.
into the port to check the pressures generated when
the lift pump is activated without pressure from the e. Raise the load approximately 305 mm
weight of the load. The relief valve setting can also (12 in.). Voltage should increase from 0.5
be checked by completely raising the mast and then volts to between 1.5 and 3.5 volts.
continuing to activate the UP function of the control
f. Remove the load from the forks and com-
handle for 1-second intervals.
pletely raise the mast. With the mast fully
The second test port (M2) taps directly into the main raised, press the lift button for one second
lift pressure circuit beyond the lowering control intervals to cause the hydraulic system to
valve. When the pump is at rest, the pressure in reach maximum relief valve pressure. The
this circuit is produced by the weight of the mast voltage should measure 4.5 volts at maxi-
components and load. When the pump is activated, mum relief valve pressure.
pressures should remain below the maximum relief
valve pressure until the mast is fully extended.
Pressures reaching the maximum relief valve pres-
sure before the mast is completely extended may
indicate obstructions in the hoses or cylinders or a
load greater than lift truck capacity. This allows the
technician to verify that pressure is present beyond
the lowering control valve and rule out obstructions
in the pump valves when troubleshooting. Refer to
Figure 17.
Pressure Transducer
1. Test the transducer:
a. Load a 3/4 capacity load onto the forks and

lower the forks to the floor. Open the manual
lowering valve to relieve all pressure from
the hydraulic system. Close the manual low-
ering valve immediately after relieving the 1. M1 TEST PORT 4. RETURN PORT
2. M2 TEST PORT 5. SUPPLY INTAKE
pressure. 3. PRESSURE PORT
b. Unplug the transducer connector from the Figure 17. Lift Pump and Motor Schematic
wiring harness. Check between the supply
and the ground pins of the wiring harness
20
1. GROUND TERMINAL 1. UPPER MOUNTING CAPSCREW

2. OUTPUT TERMINAL 2. M2 TEST PORT
3. SUPPLY TERMINAL 3. PRESSURE TRANSDUCER
4. MANUAL LOWERING VALVE
Figure 18. Transducer Terminals 5. M1 TEST PORT
6. LOWER MOUNTING CAPSCREW
2. Remove and replace the pressure transducer: 7. LOWERING CONTROL VALVE
NOTE: Certain lift truck models retain significant Figure 19. Transducer Removal
Relief Valve
tem using the appropriate procedures for your model 1. Check the relief valve:
before servicing to avoid large spills. Refer to Oil
Change. a. The pressure at which the relief valve should
open is 20.68 ±0.70 MPa (3000 ±100 psi).
a. Drain the oil from the hydraulic system. Re- This can be checked using the pressure test
fer to Drain. Make sure any oil remaining ports (see Pressure Test Ports). If the relief
in the tank is well below the height of the pressure is not within the acceptable range,
components being removed. Store the oil in repair or replace the relief valve.
clean, approved containers if the oil is to be
reused. 2. Replace:
b. Remove the pressure transducer by unscrew- NOTE: Certain lift truck models retain significant
ing it from the lift pump. See Figure 19. quantities of oil in the cylinders and hoses even when
c. Install the pressure transducer by screwing tem using the appropriate procedures for your model
it in the lift pump as removed. before servicing to avoid large spills. Refer to Oil
Change.
have significantly different filling procedures than a. Drain the oil from the hydraulic system. Re-
models with piston-type cylinders. Fill the hydraulic fer to Drain. Make sure any oil remaining
system using the appropriate procedures for your in the tank is well below the height of the
model to ensure proper operation. See Oil Change. components being removed. Store the oil in
clean, approved containers if the oil is to be
d. Fill the hydraulic system to the proper level.
reused.
Refer to Fill.
21
b. Remove the relief valve from the pump. models with piston-type cylinders. Fill the hydraulic
c. Install new relief valve as removed. model to ensure proper operation. Refer to Fill.
d. Tighten the jam nut. 6. Fill the hydraulic system to the proper level.
Remove Pump
models with piston-type cylinders. Fill the hydraulic The following procedures outline the steps for remov-
system using the appropriate procedures for your ing the lift pump only. This step may be performed
model to ensure proper operation. Refer to Fill. with the lift pump and motor assembly installed or
removed from the lift truck. If it is necessary to re-
e. Fill the hydraulic system to the proper level.
move the lift motor, remove the entire assembly first.
f. Test for proper operation. Refer to Complete Unit, Remove.
OR NOTE: Certain lift truck models retain significant

3. Adjust: the hydraulic tank is empty. Drain the hydraulic sys-
a. Loosen the jam nut on the relief valve. before servicing to avoid large spills. Refer to Oil
Change.
b. Adjust the valve as required.
c. Tighten the jam nut.
to Drain. Make sure any oil remaining in the
d. Test for proper operation. tank is well below the height of the components
e. Repeat until the relief pressure is within the containers if the oil is to be reused.
acceptable range.
2. Remove the pressure hose end by loosening the
Lowering Control Valve four capscrews securing each half of the retaining
flanges to the pump. Turn each capscrew 1/8 th
NOTE: Certain lift truck models retain significant turn alternately to avoid breaking the retaining
quantities of oil in the cylinders and hoses even when flanges. Remove the capscrews, washers, and re-
the hydraulic tank is empty. Drain the hydraulic sys- taining flanges. Remove the hose end from the
tem using the appropriate procedures for your model pressure port. Drain the hose into a suitable con-
before servicing to avoid large spills. Refer to Oil tainer and cap the end.
Change.
3. Disconnect the supply and return hoses from the
1. Drain the oil from the hydraulic system. Refer lift pump. Secure the hose ends above the fluid
to Drain. Make sure any oil remaining in the level in the tank. Cap and plug the ports and
tank is well below the height of the components hoses to prevent contamination to the system.
containers if the oil is to be reused. 4. Loosen each of the two retaining capscrews 1/4 th
turn alternately to gradually loosen the pump as-
2. Disconnect the lowering control valve wiring sembly. Remove the lift pump with the capscrews
from the main wiring harness. in place to steady the assembly.
3. Remove the lowering control valve from the Install Pump
pump.
The following procedures outline the steps for in-
4. Install new lowering control valve as removed. stalling the lift pump to the lift motor. This step
5. Connect the lowering control valve wiring to the may be performed with the lift motor installed or
main wiring harness as removed. removed from the lift truck.
NOTE: Models with displacement-type cylinders 1. Apply antiseize lubricant to the splines of the lift
have significantly different filling procedures than motor shaft.
22
1900 SRM 1616 Auxiliary Hydraulics
2. Assemble lift pump end head and housing and the four capscrews and washers. Tighten each
position pump assembly to motor as removed. screw until the retaining flanges are flush with
the pump. Alternately tighten each screw 1/8 th
3. Apply Loctite® 271 to threads of pump retaining turn until each capscrew is tightened to 40 N•m
capscrews, and install through the pump into the (30 lbf ft).
motor as removed. Turn capscrews by hand to
ensure they start into the mounting holes prop- NOTE: Models with displacement-type cylinders
erly. have significantly different filling procedures than
4. Tighten each screw until the pump is lightly se- system using the appropriate procedures for your
cured to the end head of the motor. Alternately model to ensure proper operation. Refer to Oil
tighten each screw 1/8 th turn until each capscrew Change.
is torqued to 47 N•m (35 lbf ft).
7. Fill the hydraulic system to the proper level. Re-
NOTE: Hose clamps are properly positioned centered fer to Fill.
between the end of the hose and the barb end of the
fitting inside the hose. 8. Engage the battery connector and turn the key
to the ON position. Operate the hydraulic sys-
5. Place hose clamps loosely over the lift pump tem several times to remove air from the system.
supply and return hoses, and install hoses onto Check for leaks and to ensure proper operation.
the lift pump fittings. Position hose clamps and
tighten to 13 N•m (108 lbf in). 9. Install the operator compartment covers. Re-
move the blocks from the wheels and the DO
6. Install the pressure hose end with new O-ring NOT OPERATE tag from the control handle.
into the pressure port. Install the retaining
flanges onto the pump and hose, and install
Auxiliary Hydraulics
Lift trucks are equipped with either a 24v or 36v aux-
iliary pump and motor assembly which supplies hy- CAUTION
draulic pressure to the auxiliary hydraulics. The auxiliary motor power cable connections
must be installed on the proper terminals. Fail-
AUXILIARY PUMP AND MOTOR ure to install the power cables on the correct
terminals will damage other electrical compo-
Remove nents.
NOTE: Disposal of lubricants and fluids must meet

WARNING local environmental regulations.
including eye protection and petroleum-resis- The auxiliary pump and motor must be removed as a
tant gloves when handling hydraulic oil. Thor- unit. The unit cannot be removed until the hydraulic
oughly wash oil from exposed areas of skin as oil has been drained from the tank, and the battery
soon as possible. removed from the lift truck.
Completely lower all mast components and re- 1. Park the lift truck on a level surface and lower
lieve pressure by opening the manual lowering the mast. Turn the key switch to the OFF po-
valve before disassembling any part of the lift sition and attach a DO NOT OPERATE tag to
pump or disconnecting any hydraulic hoses. the control handle. Block the wheels to prevent
unexpected movement.
oil.
23
Auxiliary Hydraulics 1900 SRM 1616
2. Disconnect the battery power cable connector 11. Remove the three nuts securing the auxiliary
from the truck connector located on the right side pump and motor assembly to the frame. Slide
of the frame. Pull the battery cable connector the assembly off the studs, and guide the assem-
handle to separate the battery connector from bly out of the lift truck. Place on a clean work
the truck connector. bench.
3. Remove the battery from the lift truck. 12. If the any of the studs are damaged, drive them
backward into the battery compartment using a
4. Remove the operator compartment cover(s) to ac- hammer and a long punch. Collect the damaged
cess the lift pump and motor assembly. Open the studs and discard.
drive unit compartment by removing the two cap-
screws securing the door closed and pull the door
open.
NOTE: Certain lift truck models retain significant

tem using the appropriate procedures for your model.
5. Drain the oil from the hydraulic system. See Oil

Change.
NOTE: Remove the electric brake assembly from the

top of the traction motor for easier access to the auxil-
iary pump. Refer to Brake System 1800 SRM 1188.
6. Disconnect the auxiliary bearing sensor connec-

tor from the main wiring harness.
NOTE: Tag and identify each cable removed for cor-

rect reinstallation.
1. LIFT PUMP AND MOTOR ASSEMBLY
7. Remove the auxiliary motor cable connections 2. AUXILIARY UNIT MOUNTING BRACKET
from the motor. 3. MOUNTING HARDWARE
4. BATTERY COMPARTMENT
8. Loosen the three nuts securing the auxiliary 5. ACCESS HOLE
6. AUXILIARY PUMP AND MOTOR
pump and motor assembly bracket to the battery
compartment wall to allow greater access to the Figure 20. Auxiliary Pump and Motor
hydraulic fittings. See Figure 20.
9. Position a drip pan underneath the lift truck be-

Disassemble
low the auxiliary pump and motor assembly. 1. Remove the two capscrews securing the auxiliary
pump to the motor. Remove the pump from the
NOTE: Access the hydraulic pump fittings through
motor. See Figure 21.
the access hole in the battery compartment.
2. Remove the auxiliary supply fitting.
10. Disconnect the hydraulic hoses from the auxil-
iary pump. Cap and plug the hoses and ports to 3. Remove the auxiliary pressure fitting.
prevent contamination and leakage.
24
1. Install new auxiliary pump and motor retaining

studs as required into the battery compartment
wall.
2. Guide the auxiliary pump and motor assembly

into the lift truck, and position the unit onto the
three studs in the battery compartment wall.
3. Loosely install the nuts and washers onto the

studs.
NOTE: Access the hydraulic pump fittings through

the access hole in the battery compartment.
4. Remove the caps and plugs from the hoses and

ports. Install the hydraulic hoses to the pump
fittings as removed.
NOTE: Refer to tags attached to cables during re-

moval for proper locations.
5. Reinstall the motor power cable connections to

the proper terminals as removed.
1. COUPLING
2. PRESSURE FITTING (90°) 6. Connect the auxiliary sensor bearing connector
3. PUMP HOUSING to the main wiring harness as removed.
4. SUPPLY FITTING (BARBED)
5. MOUNTING CAPSCREWS
7. Tighten the auxiliary unit mounting hardware.
Figure 21. Auxiliary Pump
Assemble
NOTE: Lubricate the pump splines with Molykote® system using the appropriate procedures for your
G-N paste before assembling to the motor. model to ensure proper operation. Refer to Oil
Change.
1. Position the auxiliary pump to the motor. Install
the two capscrews securing the auxiliary pump 8. Fill the hydraulic system to the correct level with
to the motor. Tighten to 26 N•m (19 lbf ft). the proper oil. See Fill.
2. Install the auxiliary supply fitting. Tighten to 9. Test for proper operation and inspect for leaks:
88 N•m (65 lbf ft).
a. Engage the battery connector BEFORE in-
3. Install the auxiliary pressure fitting. Tighten to stalling the battery, and turn the key switch
61 N•m (45 lbf ft). to the ON position.
b. Cycle the auxiliary functions several times to

Install
check for proper operation. Inspect for leaks.
CAUTION c. Turn the key switch to the OFF position

The auxiliary motor power cable connections again, and disconnect the battery connector.
must be installed on the proper terminals. Fail-
10. Install the electric brake assembly to the top of
ure to install the power cables on the correct
the traction motor, if removed. Refer to Brake
terminals will damage other electrical compo-
System 1800 SRM 1188. Test the electric brake
nents.
for proper operation.
25
Auxiliary Hydraulics 1900 SRM 1616
11. Install the battery to the lift truck, and engage The front selector valve is an electro-hydraulic valve
the battery connector. block that directs hydraulic flow to the tilt and
sideshift cylinders (where applicable). The relay
12. Install the operator compartment cover as re- controls the front selector valve by receiving signals
moved. Secure the drive unit compartment door through a wiring harness, which runs to the front
closed. frame inside the hose guard along side the hydraulic
hoses and activating the electro-hydraulic valves in
13. Remove the DO NOT OPERATE tag from the
the selector valve. See Figure 23.
control handle. Remove the blocks from the
wheels.
FRONT SELECTOR VALVE

The front selector valve is located in the front frame
of the reach carriage assembly. It is secured to a cover
plate with three capscrews. A relay is mounted below
the front selector valve on the cover plate. The cover
plate is mounted to the front of the front frame, just
above the tilting frame. See Figure 22.
1. TILT (DOWN)
2. TILT (UP)
3. SIDESHIFT (EXTEND RIGHT)
4. SIDESHIFT (EXTEND LEFT)
Figure 23. Front Selector Valve (From Rear)
REAR SELECTOR VALVE

The rear selector valve is mounted inside the top of
the rear frame with three capscrews. A cover mounts
to the front side of the valve and shields it from expo-
sure. The rear selector valve is an electro-hydraulic
valve block that directs hydraulic flow to the reach
cylinders and supplies the front frame (front selector
valve) hydraulics. See Figure 24.
1. FRONT SELECTOR 3. BRACKET
VALVE 4. COVER
2. RELAY
Figure 22. Front Frame
26
1. REACH CYLINDER (LH) 6. FRONT SELECTOR VALVE LINE

2. REACH CYLINDER (RH) 7. HOSE GUARD
3. SUPPLY LINE 8. FRONT SELECTOR VALVE
4. RETURN LINE 9. REAR SELECTOR VALVE
5. FRONT SELECTOR VALVE LINE
Figure 24. Reach Carriage Hydraulics
27
Hydraulic Tank 1900 SRM 1616
Hydraulic Tank
REMOVE 5. Drain the oil from the hydraulic system. See
Drain in this section.
WARNING 6. Remove the battery from the lift truck for access
Always wear the proper protective equipment to rear tank line hose fittings.
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor- NOTE: Secure hoses as high as possible, and cap or
oughly wash oil from exposed areas of skin as plug hoses and fittings to minimize leakage.
soon as possible.
7. Tag and disconnect the lower hose fitting clamps
Completely lower all mast components and re- from the bottom of the tank. These fittings and
lieve pressure by opening the manual lowering hoses can be reached through the access slots in
valve before disassembling any part of the lift the battery compartment. See Figure 25.
pump or disconnecting any hydraulic hoses.
8. Disconnect the lift pump return hose from the oil
The hydraulic oil is hot at normal operating filter assembly.
oil. 9. Disconnect the auxiliary pump return hose from
the top of the tank.
CAUTION
Certain components such as the oil filter assembly

and breather assembly may be disassembled from
the hydraulic tank without removing the tank. See
Disassemble. Perform only the steps necessary to
safely perform the required service.
1. Park the lift truck on a level surface and com-

pletely lower the mast. Turn the key switch to
the OFF position and attach a DO NOT OPER-
ATE tag to the control handle. Block the wheels
to prevent unexpected movement.

from the truck connector located on the right
side of the frame.
3. Remove the battery from the lift truck for access

to rear tank line hose fittings.
4. Remove the operator compartment cover(s) to ac-

cess the hydraulic tank. Open the drive unit com-
partment by removing the two capscrews secur- 1. LIFT PUMP RETURN FITTING
ing the door closed. Refer to Periodic Main- 2. FILTER ASSEMBLY
3. LOW OIL SWITCH WIRING
tenance 8000 SRM 1617 for more information 4. BREATHER ASSEMBLY
about covers removal and installation. 5. RETURN
6. FOAM PAD
NOTE: Models with displacement-type cylinders can 7. AUX PUMP SUPPLY FITTING
retain significant quantities of oil in the cylinders 8. LIFT PUMP SUPPLY FITTING
and hoses even when the hydraulic tank is empty. 9. DRAIN HOSE ASSEMBLY
Properly drain the hydraulic system to avoid large
Figure 25. Tank (Profile)
spills. Refer to Oil Change.
28
1900 SRM 1616 Hydraulic Tank
10. Disconnect the low oil indicator switch wiring NOTE: The various assemblies and the auxiliary
from the main wiring harness. pump return fitting may be removed without drain-
ing or removing the hydraulic tank. It may not be
11. Remove the tank ground wire from the hydraulic necessary to completely disassemble the hydraulic
filter housing and breather housing by removing tank. Perform only the steps necessary to complete
the capscrews and washers. the required service.
12. Lift the tank from the truck and position on its If removing components with the hydraulic tank in-
side on a clean work area. stalled:
DISASSEMBLE 1. Position the lift truck on a level surface and lower

the mast. Turn the key switch to the OFF posi-
CAUTION tion and attach a DO NOT OPERATE tag to the
control handle. Block the wheels to prevent un-
Clean around the various assemblies before
expected movement.
removing to ensure dirt and debris does not
fall into the tank. If the tank becomes con- 2. Disconnect the battery power cable connector
taminated, it must be drained and cleaned to from the truck connector located on the right side
prevent damage to the hydraulic system. See of the frame. Pull the battery cable connector
Clean and Inspect in this section for proper handle to separate the battery connector from
cleaning procedures. the truck connector.
29
Breather Assembly 3. Remove the breather assembly screen and gas-

kets from the tank. See Figure 26.
1. Remove the breather cap.
2. Remove the three screws securing the breather

assembly to the tank.
1. BREATHER CAP 6. LOWER GASKET

2. SCREW 7. HYDRAULIC TANK
3. CAP MOUNT 8. AUXILIARY RETURN
4. UPPER GASKET 9. LOW OIL INDICATOR SWITCH
5. SCREEN ASSEMBLY
Figure 26. Breather Assembly
30
Filter Assembly
NOTE: For instructions on replacing the filter ele-
ment, refer to Oil Filter in this section.
1. Remove the hose clamp and disconnect the lift

pump return hose, if attached. Cap and plug all
hoses and ports to prevent spills and contamina-
tion.
2. The lift pump return fitting may be removed at

this time, if necessary.
3. Remove the two capscrews securing the filter as-

sembly to the tank. See Figure 27.
4. Lift the assembly from the tank and position it

in a clean drip pan.
5. Recover and discard the oil seal.
A. TOP VIEW B. SIDE VIEW

1. FILTER ASSEMBLY MOUNTING LOBES
2. FILTER CAP RETAINING CAPSCREWS
3. LIFT PUMP RETURN
4. FILTER CAP
5. FILTER ASSEMBLY MOUNTING FLANGE
6. OIL DIFFUSER
Figure 27. Filter Assembly
31
Tank Fittings The breather assembly and the auxiliary pump re-
turn fitting may be removed without draining or re-
The tank must be drained and removed to remove the moving the tank.
two lower tank fittings. See Oil Change. However,
the auxiliary pump return, on top of the tank, may be 1. Position the new breather assembly into the
removed while the tank is full. The following instruc- tank.
tions refer to removing fittings (one at a time) from a
tank which has been drained and removed from the CAUTION
lift truck. Perform only the steps necessary to safely
DO NOT overtighten screws.
complete the repair.
2. Install the three screws securing the breather to
1. Loosen the jam nut of the fitting to be removed.
the tank.
2. Turn the fitting counterclockwise until com-
3. Install the breather cap.
pletely removed from the tank.
3. Inspect the threads of the tank to ensure they are Filter Assembly
not damaged before replacing the fitting.
1. Install the new seal to the assembly flange and
4. Repeat as necessary to remove the remaining fit- position the new filter assembly into the tank.
tings.
2. Install the two retaining capscrews. Tighten to
8 N•m (72 lbf in).
CLEAN AND INSPECT
3. Install lift pump return fitting, if removed.
Clean the outside of the tank with mild soap solu-
tion sprayed on a cleaning cloth. Inspect the inside 4. Place hose clamp loosely over the end of the lift
for contamination and flush with clean oil if neces- pump return hose, and install hose onto the filter
sary. Do not use cleaning solutions on the inside of assembly return fitting. Position hose clamp and
the tank. tighten to 13 N•m (108 lbf in).
Inspect the inside and outside of the tank for cracks,
Tank Fittings
leaks, holes, distortion, and abrasion. Inspect the
tank threaded fitting mounts for cracks and dam- 1. Install the upper and lower hydraulic tank fit-
aged threads. Inspect the molded-in filter housing tings:
area and breather area for bond separation, leaks,
and damaged threads. Replace the tank as neces- a. Completely loosen the jam nut of each fitting
sary. until it reaches the top of its threads.
ASSEMBLE b. Start each fitting into the tank by turning

clockwise by hand.
Breather Assembly
c. Turn each fitting all the way in (until the end
of the threads reach the tank).
CAUTION
Be careful that dirt and debris does not fall d. Turn counterclockwise (if necessary) until
into the tank when removing the various as- fittings are aligned as shown in Figure 28.
semblies. If the tank becomes contaminated, it e. Hold each fitting in position while turning
must be drained and cleaned to prevent dam- the jam nut clockwise until it touches the
age to the hydraulic system. tank. Then tighten an additional 1/8 th turn.
32
as removed. Position hose clamps and tighten to

13 N•m (108 lbf in).
4. Place hose clamps loosely over end of lift pump

return hose, and install hose to filter return fit-
ting. Position hose clamp and tighten to 13 N•m
(108 lbf in).
5. Connect the switch wiring to the main wiring

harness.
Install the drain hose to the bottom of tank, if re-

moved. Turn clockwise until the head of the drain
plug touches the bottom of the tank, then tighten an
1. DRAIN HOSE ASSEMBLY additional 1/8 th turn.
2. AUXILIARY PUMP SUPPLY
3. GROUND WIRE (ABOVE)
4. LIFT PUMP SUPPLY CAUTION
5. LIFT PUMP RETURN (ABOVE)
6. HYDRAULIC TANK (BOTTOM) DO NOT overfill the hydraulic tank.
Figure 28. Tank (Bottom) Use ONLY the hydraulic oil specified for your
lift truck.
INSTALL NOTE: Refer to Specifications for the proper hy-
1. Position tank into lift truck and align on frame draulic oil selection.
and support bracket.
6. Fill the hydraulic tank to the proper level with
NOTE: Hose clamps are properly installed centered new hydraulic oil using the proper procedure for
between the end of the hose and the barb end of the your truck. See Oil Change in this section.
fitting inside the hose.
7. Install the breather cap and test for proper oper-
2. Place hose clamps loosely over ends of lower ation.
hoses, and install hoses to bottom of tank as
8. Install the operator compartment covers as re-
removed. Position hose clamps and tighten to
moved. Remove the blocks from the wheels.
13 N•m (108 lbf in). Reconnect ground wire as
removed.
3. Place hose clamp loosely over end of auxiliary

pump return hose and install hose to top of tank
33
Troubleshooting 1900 SRM 1616
Specifications
Hydraulic Oil
Battery Specification
Compartment Tank Capacity Usable Oil
Size Standard Freezer
368 mm (14.5 in.) ISO VG 46 Exxon™ Univis 27.0 liter (7.13 gal) 19.6 liter (5.17 gal)
Antiwear HVI 26
419 mm (16.5 in.) ISO VG 46 Exxon™ Univis 27.0 liter (7.13 gal) 19.6 liter (5.17 gal)
Antiwear HVI 26
Component Specification
Main Relief Valve 20.68 ±0.70 MPa (3000 ±100 psi)
Auxiliary Relief Valve 17.23 ±0.70 MPa (2500 ±100 psi)
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Low hydraulic pressure. Manual lowering valve is open or Close manual lowering valve or re-
damaged. place pump.
Relief valve damaged or out of ad- Check relief pressure. Adjust or re-
justment. place relief valve.
Pump is worn or damaged. Repair or install new pump.
Hydraulic system relief Restriction in the system. Remove restriction or install new
valve opens frequently. line.
Load beyond capacity. Handle only loads rated within the

working capacity of your model lift
truck. See the nameplate.
Relief valve needs adjustment or re- Adjust or replace relief valve.

lief valve is defective.
The pump noise is not nor- Oil in the hydraulic tank is low. Fill tank to correct level. Check for
mal. leaks.
Restriction in the inlet hose. Remove restriction or install new

line.
Inlet fitting or inlet hose clamp is Tighten fitting. Install new hoses.
loose. Remove air from system.
The bearings or gears are damaged. Repair or install new pump.
34
1900 SRM 1616 Troubleshooting
The pump noise is not nor-

mal. (Cont.)
The housing is damaged. Repair or replace pump housing.
Loose capscrews holding the pump Tighten capscrews to specified

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

ing. torque.
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.
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

housing together. torque.
Seals are defective. Install new seals or gaskets.
Pump housing is damaged. Repair or install new pump.
Slow auxiliary functions Oil in the hydraulic tank is low. Fill tank to correct level. Check for
leaks.
Auxiliary speeds require adjustment Adjust auxiliary speeds in the dash

using the dash display menus. display parameter setup procedures.
Auxiliary relief pressure is low. Check auxiliary relief pressure. Re-

place as necessary.
Auxiliary relief valve is damaged. Check auxiliary relief pressure and

auxiliary pump relief valve for con-
tamination or damage. Replace as
necessary.
35
Troubleshooting 1900 SRM 1616
Lift pump and motor oper- Oil in the hydraulic tank is low. Fill tank to correct level. Check for
ates but the mast will not leaks.
raise.
Relief valve is defective. Replace relief valve.
36
TECHNICAL PUBLICATIONS
1900 SRM 1616 7/13 Printed in U.S.A.

Sistema Hidraulico

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HYDRAULIC SYSTEM

N30ZDRS2, N35-40ZRS2 [B265];

PART NO. 4075035 1900 SRM 1616

• 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)

This section is for the following models:

N30ZDRS2, N35-40ZRS2 [B265];

1. LIFT MOTOR 7. FILTER ASSEMBLY

Figure 1. Hydraulic System

DISCHARGING THE CAPACITORS

2. Disconnect the battery power cable connector

NOTE: Diagonal movement of handle will control

The control handle also controls the lift/lower func-

NOTE: During lift truck operation, the auxiliary

Figure 4. Auxiliary Function Control

Never operate the pump without the proper

b. Open the manual lowering valve. Refer to

piston-type. Certain cylinder types require different

The main lift cylinders may be identified by the pres-

1. PLUG 4. TANK 1. TOP OF INTERMEDIATE MAST

Table 2. Cylinder Identification

Type Free-Lift Cylinders

1. Fill the hydraulic tank to the proper level with

Figure 8. Free-Lift Cylinder Rod 1. HYDRAULIC FILTER HOUSING

Figure 9. Hydraulic Oil Level

NOTE: Use a cloth to wipe up foam and oil as it is

located in the end of the cylinder rod. In-

b. Activate the lift function using the operator BREATHER CAP

8. Engage the battery connector and remove the

Completely lower all mast components and

The hydraulic oil is hot at normal operating

1. Move the lift truck to a safe, level area and com-

The hydraulic oil is hot at normal operating Noise Levels

The hydraulic oil in the system performs the dual HOSES

1. AUXILIARY RETURN HOSE 8. FILTER ASSEMBLY

Figure 11. Hoses (Top)

NOTE: The hydraulic oil must drained well below the

Visually inspect the hoses for leaks. Small oil leaks

Lift Pump and Motor

1. Park the lift truck on a level surface and lower

1. AUXILIARY RETURN HOSE

Figure 13. Lift Pump and Motor

2. Attach a sling and an overhead lifting device to A. STANDARD 24 OR 36 VOLT

5. Install the return and supply hoses as removed.

6. Install the pressure hose end with new O-ring

7. Connect the wiring to the motor terminals as re-

NOTE: Models with displacement-type cylinders

8. Fill the hydraulic system to the proper level.

9. Engage the battery connector, turn the key

10. Install the operator compartment cover(s) as re-

A. STANDARD 24- OR 36-VOLT

Figure 15. Mounting Brackets (Terminal End)

LIFT PUMP lowering valve IMMEDIATELY after verifying

1. Drain the oil from the hydraulic system. Refer

2. Disconnected the supply and/or return hose from

NOTE: Inspect fittings for damage to the threads and

3. Remove the fittings as necessary.

4. Inspect the pump for cracks and damaged