Maintenance

HYDRAULIC SYSTEM
ESC030-040FA [A883]

PART NO. 524153635 1900 YRM 998

 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
Multifunction Control Handle ............................................................................................................................... 1
Description ...................................................................................................................................................... 1
Manual Lowering ................................................................................................................................................. 2
How to lower mast manually ........................................................................................................................... 2
Main Hydraulic Control Valve............................................................................................................................... 3
Description ...................................................................................................................................................... 3
Check and Adjust ............................................................................................................................................ 3
Manifold Pressures ..................................................................................................................................... 3
Counter Balance Valve ............................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Repair.............................................................................................................................................................. 5
Disassemble ............................................................................................................................................... 5
Clean .......................................................................................................................................................... 6
Assemble .................................................................................................................................................... 6
Install............................................................................................................................................................... 6
Lift Pump and Motor ............................................................................................................................................ 8
Description ...................................................................................................................................................... 8
Remove ........................................................................................................................................................... 8
Motor........................................................................................................................................................... 8
Lift Pump..................................................................................................................................................... 9
Install............................................................................................................................................................... 9
Lift Pump..................................................................................................................................................... 9
Motor........................................................................................................................................................... 10
Lift Pump ............................................................................................................................................................. 10
Description ...................................................................................................................................................... 10
Disassemble.................................................................................................................................................... 10
Assembly......................................................................................................................................................... 11
Hydraulic Tank ..................................................................................................................................................... 12
Inspect............................................................................................................................................................. 12
Remove ........................................................................................................................................................... 12
Clean............................................................................................................................................................... 14
Steam Method ............................................................................................................................................ 14
Trisodium Phosphate Method ..................................................................................................................... 15
Install............................................................................................................................................................... 15
Troubleshooting ................................................................................................................................................... 16

This section is for the following models:

ESC030-040FA [A883]

©2003 Yale Materials Handling Corp. i

1900 YRM 998
General
The hydraulic system for these lift trucks is comprised
of three subsystems. These subsystems are:
• Main Hydraulic - Lift and lower
• Auxiliary Hydraulic - Tilt and optional sideshift
• Power steering
The hydraulic system includes two pumps. The lift
pump will only operate when the control handle is
moved to start the lift function, the tilt/sideshift disk is
pressed, or an auxiliary function button is pressed. The
steering pump operates when the key is turned ON and
the traction contactor is in. The lift pump and steering
pump are located under the hydraulic cover.
The main and auxiliary hydraulic functions are con-
trolled by an electro-hydraulic control valve. See
Multifunction Control Handle
DESCRIPTION
WARNING
Unintentional mast lowering can cause damage or
injury.
The Multifunction Control Handle (control handle) pro-
vides operator control for travel, lift, lower, tilt, sideshift,
horn, and auxiliary hydraulic functions. See Figure 1.
1. TILT/SIDESHIFT DISK
2. HORN BUTTON
3. AUXILIARY HYDRAULIC BUTTONS
Figure 1. Multifunction Control Handle
Multifunction Control Handle
Figure 2. This valve is custom designed to provide full
proportional control of all hydraulic functions except
steering. To provide maximum control, each function
is operated electronically using an electro-hydraulic
EPV valve. Separate lift and auxiliary relief valves are
provided to allow operation at different pressures and
minimize energy consumption.
The electro-hydraulic control valve is actuated by the
control handle. The multifunction control handle is a
two axis control used for both hydraulic and traction op-
eration.
Travel is activated by moving the control handle in the
direction of travel. Moving the control handle forward
(toward the forks) provides forward travel. For travel
in reverse (away from the forks), the control handle is
moved rearward. The travel speed for both directions
is proportional to the distance the handle is moved; the
further the distance, the faster the lift truck travels.
The control handle also controls the direction and speed
at which the carriage moves on the mast. The lift/lower
function is activated by tilting the control handle left or
right. When the control handle is moved to the right,
the carriage lifts. When the control handle is moved to
the left, the carriage lowers. The speed of the carriage
is also proportional to the distance the control handle is
pushed.
The auxiliary functions are controlled by two buttons lo-
cated on the underside of the control handle. A button
to activate the horn is located on the top of the handle,
to the left of the tilt/sideshift disk.
A thumb-operated tilt/sideshift disk, located at the top
of the control handle, controls tilt and sideshift. See
Figure 1. To tilt forward, the top of the disk is pressed.
To tilt back press the bottom of the disk. To activate
the sideshift function, press the right side of the disk to
move the carriage to the right. Press the left side of the
disk to move the carriage to the left.
1
Manual Lowering 1900 YRM 998

NOTE: Diagonal movement of the handle will control
both travel and a hydraulic function simultaneously.
NOTE: During lift truck operation, only one auxiliary
function can be selected at a time.
the control handle. The MCU, in turn, detects the po-
sition of the control handle and/or position change and
outputs a signal to the control valve. The MCU also con-
trols the operation of the lift pump.

In response to operator commands, control signals are

sent to the Curtis 1310 Master Control Unit (MCU) via

Manual Lowering
HOW TO LOWER MAST MANUALLY

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

WARNING
Always verify that there are no obstructions be-
neath the lift mechanism or load before attempting
to lower manually.

Manual lowering is accomplished by first pushing in the

Load Holding check valve button (button A), turning it
counterclockwise 180 and releasing it. See Figure 2.
In this position, the valve will remain open and the mast
will begin lowering at a slow rate. To increase the lower-
ing rate carefully turn the manual override thumb screw
(button B) slowly clockwise until the forks begin to lower
at a faster rate. Be sure to return the screw to the orig-
inal position once the manual lowering process is com-
plete by slowly turning the screw counterclockwise until
it stops. Then push in the Load Holding check valve
button and turn it clockwise 180 to close it.
Figure 2. Hydraulic Control Valve

2
1900 YRM 998 Main Hydraulic Control Valve

Main Hydraulic Control Valve

DESCRIPTION
The main hydraulic control valve (control valve) is lo-
cated under the hydraulic cover and is secured to the
frame by four capscrews and washers.
there should not be any pressure for the two ports going
back to the tank. For pressure settings, see Table 1.
1. Connect a 28 MPa (4050 psi) gauge to the the
pump pressure port. See Figure 3.

The control valve consists of a manifold block containing

electrically controlled solenoid valves and electro-pro-
portional valves. These valves control and direct the
flow of hydraulic oil for the various hydraulic functions.
Lift and auxiliary circuits provide pressure compensated
operation. The lift and lower functions of the mast are
proportionally controlled by way of handle position. The
auxiliary functions are programmable and are controlled
through selectable settings.

Primary Relief Valve Setting.

19.3 ± 0.69 MPa (2800 ± 100 psi)

Counterbalance Relief Valve Setting.

20.7 ± 0.69 MPa (3000 ± 100 psi)

Auxiliary Relief Valve Setting.

13.8 ± 0.69 MPa (2000 ± 100 psi)

CHECK AND ADJUST 1. TANK PRESSURE PORT

2. PUMP PRESSURE PORT
3. HOIST PRESSURE POST
Manifold Pressures
Figure 3. Pressure Check
NOTE: Hoist pressure should be the same pressure as
pump pressure when lifting at full speed. When lifting
Table 1. Pressure Settings

No Load 1361 kg (3000 lb) 1588 kg (3500 lb) 1814 kg (4000 lb)
Free Lift Main Free Lift Main Free Lift Main Free Lift Main Relief
kPa (psi) Hoist kPa (psi) Hoist kPa (psi) Hoist kPa (psi) Hoist kPa (psi)
kPa (psi) kPa (psi) kPa (psi) kPa (psi)
Pump 4123 5495 10,301 13,597 11,128 14,562 12,500 16,341 19,651
Pressure (598) (797) (1494) (1972) (1614) (2112) (1813) (2370) (2850)

3
Main Hydraulic Control Valve 1900 YRM 998

Counter Balance Valve

1. Tilt the mast to the full back position with a load on
the forks.
2. Dissable the hydraulic motor.
NOTE: If after completing Step 3 the mast does not be-
gin to drift forward, the counter balance valve is good. If
after completing Step 3 the mast begins to drift forward,
the counter balance valve is bad.
3. Press the tilt forward button on the control tiller to
open the tilt solenoid.
WARNING
Make sure the brake pedal is released and the
brakes are applied. Put blocks on both sides (front
and back) of the drive tires.
2. Turn key switch ON.
3. To relieve hydraulic pressure from lift circuit, hold
control handle in lower position to completely lower
forks, then press tilt/sideshift disk to tilt forks forward
completely.
4. Turn key switch OFF.

REMOVE 5. Disconnect battery.

1. Move lift truck to a safe, level area. 6. Remove electrical cover. See Frame 100 YRM
994, Covers and Pads, Remove.

1. HOUSING 6. TILT CONTROL

2. LIFT/LOWER CONTROL 7. PRESSURE REDUCER
3. LIFT PROPORTIONAL CONTROL 8. AUXILIARY CONTROL FUNCTION 2
4. LOWER PROPORTIONAL CONTROL 9. AUXILIARY CONTROL FUNCTION 1
5. AUXILIARY PROPORTIONAL CONTROL 10. RELIEF VALVE

Figure 4. Main Hydraulic Control Valve

4
1900 YRM 998
7. Remove hydraulic cover. See Frame 100 YRM
994, Covers and Pads, Remove.
8. Tag all wires connected to control valve for identifi-
cation and later installation.
9. Disconnect all wires connected to control valve.
10. Tag all hydraulic hoses connected to control valve
for identification and later installation.
WARNING
Hydraulic oil is hot after system operation and can
cause burns. Do not disconnect any hydraulic lines
until the oil in the system is cool.
11. Place a large drip pan under lift truck, in area below
control valve.
12. Place rags under and around control valve to pro-
tect drive motors from oil spillage.
13. Obtain a clean bucket to drain excess oil into.
CAUTION
Extra care must be taken to prevent any dirt or con-
taminants from entering the hydraulic system.
14. Disconnect control valve hydraulic return hose at
hydraulic tank top connector.
15. Bend return hose away from tank and drain excess
hydraulic oil into bucket.
16. Disconnect hydraulic hoses from control valve one
at a time.
NOTE: To prevent contamination of the hydraulic sys-
tem immediately plug any open ports or hoses.
17. Plug control valve ports and plug hoses to prevent
dirt from entering the system and oil from leaking.
WARNING
The battery is heavy and should by removed care-
fully to avoid causing damage or injury. Remove the
battery using a battery puller and stand. Use care
to avoid injury. Do NOT put hands, arms, feet, and
or legs between the battery and a solid object.
18. Remove battery to gain access to two bottom
capscrews and washers that hold control valve to
frame.
Main Hydraulic Control Valve
19. Remove two bottom capscrews and washers that
hold control valve to frame.
WARNING
The main hydraulic control valve is heavy, it weighs
approximately 15.9 kg (35 lb).
20. Carefully remove two top capscrews and washers
that hold control valve to frame.
21. Remove control valve and place it on a clean work-
bench for further disassembly.
REPAIR
CAUTION
Make certain that the work area is clean. The con-
trol valve and its components are manufactured
to close tolerances. Any dirt in the system could
cause the components to stick and the valve could
malfunction.
The disassembly and repair of the control valve is lim-
ited to the replacement of the coils, solenoid valves,
proportional valves, main relief valve, pressure reducer,
counter balance, flow control, and check valve. New
O-rings and backup rings must be installed when re-
placing any of the above items.
Disassemble
1. Remove all hydraulic fittings from control valve.
2. Inspect all hydraulic fittings for any damage. Re-
place any damaged fittings.
NOTE: For assembly purposes pay special attention to
the orientation of the writing (embossed letters) on the
coil(s) to be removed. It is important that they are as-
sembled with the writing facing that direction. Also pay
special attention to placement of all O-rings installed
with the coils.
3. Remove nuts securing coils.
4. Slide coil(s) off.
5. Remove defective cartridge(s).
6. Inspect cavity for burrs or other machining irregu-
larities which could damage O-rings during instal-
lation.
7. Plug cavities to keep contaminants out.
5
Main Hydraulic Control Valve 1900 YRM 998

Clean Table 2. Main Hydraulic Control Valve Cartridges

1. Inspect cartridge to ensure that no external contam- Item No. Item Torque Value
inant is present and that cartridge(s) is not dam-
aged. 2 Lift/Lower Control 47.4 N•m
(35 lbf ft)
2. Clean contaminated cartridge(s), replace damaged
3 Lift Proportional 47.4 N•m
cartridge(s).
Control (35 lbf ft)
3. Inspect coil(s) for damage. 4 Lower Proportional 47.4 N•m
Control (35 lbf ft)
4. Replace damaged coil(s).
5 Auxiliary 47.4 N•m
5. Inspect control valve housing for contaminants, Proportional (35 lbf ft)
wear, or damage. Control
6. If control valve housing is contaminated, worn, or 6 Tilt Control 27.1 N•m
damaged. Replace control valve housing. (20 lbf ft)

7. Replace all O-rings that are worn or damaged. 7 Pressure Reducer 33.9 N•m
(25 lbf ft)
8. Using clean hydraulic oil, lubricate all O-rings and 8 Auxiliary Control 33.9 N•m
backup rings before installation. Function 2 (25 lbf ft)
Assemble 9 Auxiliary Control 27.1 N•m
Function 1 (20 lbf ft)
1. Dip cartridge in clean oil.
10 Relief Valve 33.9 N•m
2. Screw cartridge in by hand until top O-ring is met, (25 lbf ft)
then wrench tighten to torque specifications listed Not Counterbalance 44.7 N•m
in Table 2. Refer to Figure 4 for correct placement Illustrated (33 lbf ft)
of cartridges of main hydraulic control valve.
Not Check Valve 47.4 N•m
3. Install coils onto solenoid valves and proportional Illustrated (35 lbf ft)
valves.
Not Flow Control 27.1 N•m
NOTE: Pay special attention to the orientation of the Illustrated (20 lbf ft)
writing (embossed letters) on the coil(s) to be installed.
It is important that they are assembled with the writing INSTALL
facing the correct direction. Also pay special attention
to placement of all O-rings installed with the coils.
WARNING
4. Install coil retaining nut and torque to maximum The main hydraulic control valve is heavy, it weighs
torque of 8.1 N•m (72 lbf in). approximately 15.9 kg (35 lb).

5. When installing lift/lower control or lower propor-
tional control, make sure the manual lowering con-
trols are in the correct position. See Figure 2.
6. Install hydraulic fittings.
1. Use a wire brush to clean threads of four capscrews
that hold control valve to frame.
2. Apply a few drops of adhesive sealant (HCE-92) to
threads of capscrews.

3. Align control valve with mounting holes in frame.

6
1900 YRM 998
4. Insert four capscrews and washers into mounting
holes and screw them into control valve.
CAUTION
Do not over torque the four capscrews that hold the
control valve to the frame as this will damage the
control valve.
5. Torque capscrews to 23 N•m (17 lbf ft).
WARNING
Extra care must be taken to prevent any dirt or con-
taminants from entering the hydraulic system.
6. Install control valve hydraulic return hose to hy-
draulic tank top connector.
7. Install control valve hydraulic return hose to control
valve.
8. Remove plugs from control valve ports.
NOTE: All hydraulic fitting connections without O-rings
are to receive hydraulic sealant (male threads only).
9. Apply hydraulic sealant to hydraulic fitting connec-
tions by following these steps.
a. Wipe threads clean to remove oil, grease, or
excess metal scraps.
b. If cleaner and/or primer is used, allow fittings to
dry.
c. Fill second and third threads (approximately 2
drops) completely for 360 .
d. For system cleanliness, do not fill leading
thread.
e. Apply sealant behind leading threads. Wipe off
any excess sealant on seat part of fitting.
f. Assemble hydraulic fittings.
g. Let harden 30 minutes at 22 C (72 F), longer if
colder, before applying pressure.
Main Hydraulic Control Valve
10. Remove plugs from hydraulic hoses.
11. Install hydraulic hoses to control valve ports.
12. Tighten connections and remove tags.
13. Connect all wires to control valve.
14. Check hydraulic fluid in hydraulic tank and replenish
as needed.
WARNING
The battery is heavy and should by installed care-
fully to avoid causing damage or injury. Remove the
battery using a battery puller and stand. Use care
to avoid injury. Do NOT put hands, arms, feet, and
or legs between the battery and a solid object.
15. Install battery.
16. Connect battery.
17. Turn key ON.
18. Operate lift truck through all hydraulic functions.
19. Check for oil leaks.
20. Check hydraulic fluid in hydraulic tank and replenish
as needed.
21. Remove drip pan.
22. Remove blocks from drive wheels.
WARNING
Always test drive the lift truck in a level, open, safe
area. Never test drive it around personnel, build-
ings, landing docks, or other vehicles.
23. Operate lift truck through all functions.
24. Check for oil leaks.
25. Clean up any residual oil from lift truck surfaces.
26. Install hydraulic and electrical covers.
7
Lift Pump and Motor 1900 YRM 998

Lift Pump and Motor

DESCRIPTION
The lift pump and motor for these lift trucks are located
under the hydraulic cover.

REMOVE

WARNING
To prevent personal injury or damage to equipment,
completely lower the mast and carriage before re-
pairing the lift system.

WARNING
The lift pump and motor are heavy. Together they
can weigh 37.2 kg (82 lb). Make sure that all lifting
devices (hoists, cables, chains, slings, etc.) are
suitable and of adequate capacity to lift the lift
pump and motor.

CAUTION
The lift pump and motor draw hydraulic oil directly
from the bottom of the hydraulic tank and will drain
most of the tank when the hydraulic hoses are re-
moved. Always use a hose clamping plier to close
off the hydraulic line before it is disconnected to
avoid spilling oil.

The lift pump and motor are two separate parts that
1. MOTOR 5. CAPSCREW
are connected by two capscrews. No hydraulic oil flows 2. PUMP 6. LOCKWASHER
through the motor. The lift pump motor can be removed 3. O-RING 7. 45 ELBOW
from the truck without removing the lift pump or spilling 4. 90 ELBOW
any oil. See Figure 5.
Figure 5. Lift Pump and Motor
Motor
4. Disconnect battery.
1. Move lift truck to a safe, level area.
5. Remove hydraulic cover to allow access to lift pump
and motor.
WARNING
Make sure the brake pedal is released and the 6. Tag all power cables and wires connected to motor
brakes are applied. Put blocks on both sides (front for identification and later installation.
and back) of the drive wheels to prevent movement
7. Disconnect power cables and wires from lift motor.
of the lift truck and avoid injury or damage.
8. Remove two capscrews and lockwashers holding
2. Block both drive wheels (front and back) to prevent
pump to motor.
movement of lift truck.
9. Gently push down on pump to remove from motor.
3. Turn ignition key OFF.

8
1900 YRM 998
WARNING
The lift motor is heavy. The motor can weigh ap-
proximately 33.6 kg (74 lb). Make sure that all lift-
ing devices (hoists, cables, chains, slings, etc.) are
suitable and of adequate capacity to lift the motor.
10. Install lifting device to motor.
WARNING
The battery is heavy and should be removed care-
fully to avoid causing damage or injury. Remove the
battery using a battery puller and stand. Use care
to avoid injury. Do NOT put hands, arms, feet, and
or legs between the battery and a solid object.
11. Remove battery to gain access to four capscrews
that hold lift motor to frame.
12. Remove four capscrews that hold lift motor to
frame.
13. Using lifting device, remove lift motor from truck and
place on a clean workbench for further repairs.
WARNING
Make sure to block the lift motor so it will not roll
off the workbench and cause damage or injury.
14. Block lift motor so it will not roll off workbench.
NOTE: For further repair of the lift motor refer to 2200
SRM 995, Maintenance Instructions.
If repairing or replacing the lift motor, then no further
removal is necessary.
Lift Pump
WARNING
To prevent personal injury or damage to equipment
completely lower the mast and carriage before re-
pairing the lift system.
WARNING
Hydraulic oil is hot after system operation and can
cause burns. Do not disconnect any hydraulic lines
until the oil in the system is cool.
1. Place a large drip pan under lift truck below lift
pump.
2. Before attempting to remove lift pump, use hose
clamping plier to close off intake hose to pump.
Lift Pump and Motor
3. Remove high pressure outlet hose from control
valve and hold the open end downward into the
drip pan until oil stops dripping.
CAUTION
Extra care must be taken to prevent dirt or any con-
taminants from entering the hydraulic system.
4. Plug control valve port to prevent dirt from entering
the system and oil from leaking.
5. When hydraulic oil has stopped dripping from high
pressure outlet hose, remove hose from pump.
6. Plug outlet hose pump port to prevent dirt from en-
tering the system and oil from leaking.
7. Loosen hose clamp holding intake hose to pump.
8. Remove pump from intake hose.
9. Plug intake hose pump port and intake hose to pre-
vent dirt from entering the system and oil from leak-
ing.
10. Clean up any spilled oil.
11. Place pump on a clean workbench for further re-
pairs. See Lift Pump.
INSTALL
WARNING
The lift pump and motor are heavy. Together they
can weigh approximately 37.2 kg (82 lb). Make
sure that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capacity
to lift the lift pump and motor.
If both the lift pump and motor were removed then install
the pump to the motor before installing them to the lift
truck. Torque the two capscrews to 61 N•m (45 lbf ft).
Lift Pump
1. Apply moly grease lubricant HCE-38 on splined
shaft of pump.
2. Align and insert splined shaft of pump in motor.
3. Install two capscrews and lockwashers through
pump mounting flange into motor.
4. Torque capscrews to 61 N•m (45 lbf ft).
9
Lift Pump
5. Install high pressure hose to control valve and outlet
port of pump.
6. Install low pressure intake hose to intake port of
pump.
7. Align and tighten hose clamp on low pressure in-
take hose.
8. Remove hose clamping plier from intake hose.
Motor
WARNING
The battery is heavy and should be removed care-
fully to avoid causing damage or injury. Remove the
battery using a battery puller and stand. Use care
to avoid injury. Do NOT put hands, arms, feet, and
or legs between the battery and a solid object while
battery is being removed.
Lift Pump
DESCRIPTION
The lift pump is driven by a splined shaft that fits into the
lift pump motor. See Figure 6. 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 covers. 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.
DISASSEMBLE
Seals that are worn or damaged are the most common
cause of pump failure. The pump bearings, gears, and
shafts also wear. Most service personal do not repair a
pump that is worn. The cost of repairs can be greater
than the cost of a new pump. The special backup rings,
seals, and bushings in the hydraulic pump are replace-
able. These parts come in the repair kit. The end covers
also can be replaced. Replace the pump if other pump
parts are damaged.
1. Remove two capscrews and lockwashers holding
pump to motor. See Figure 5.
10
1900 YRM 998
1. Remove battery to gain access to four holes in
frame.
WARNING
The lift pump and motor are heavy. Together they
can weigh approximately 37.2 kg (82 lb). Make
sure that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capacity
to lift the lift pump and motor.
2. Using a lifting device to hold motor, align it with
holes in frame.
3. Insert four capscrews with lockwashers through
frame into welded-on nuts of motor.
4. Torque capscrews to 61 N•m (45 lbf ft).
5. Install lift pump onto motor, see Lift Pump, Step 1
through Step 4.
2. Remove pump from motor.
3. Remove elbows and O-rings from pump.
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal
or installation with enough force to cause injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
4. Remove snap ring from housing.
5. Remove shaft seal.
6. Remove idler gear and drive gear.
7. Visually inspect drive gear, idler gear, and pump
housing for obvious damage.
8. If any damage to drive gear, idler gear, or pump
housing, replace pump.
9. If no damage replace old O-rings, backup rings, and
snap rings with new ones.
1900 YRM 998 Lift Pump

1. SNAP RING 8. DOWEL PIN

2. OIL SEAL 9. HOUSING
3. MOUNTING FLANGE 10. IDLER GEAR
4. BACKUP RING 11. DRIVE GEAR
5. SEAL 12. COVER
6. BUSHING 13. CAPSCREW
7. O-RING

Figure 6. Lift Pump Disassembled

ASSEMBLY 7. Install four capscrews.

1. Apply clean hydraulic fluid to all pump components, 8. Install new shaft seal on drive gear shaft.
including O-rings and seals prior to assembly.

2. Align and install idler gear and drive gear. WARNING

3. Install both bushings on the shafts.
4. Install seals and backup rings in body of each bush-
ing.
5. Install new O-rings in pump housing.
6. Align end cover, pump housing, and mounting
flange.
Be careful when removing or installing snap rings.
These snap rings can come loose during removal
or installation with enough force to cause injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
9. Install new snap ring.
10. Install new O-rings on elbow fittings.
11. Install elbow fittings on pump.

11
Hydraulic Tank
12. Apply moly grease lubricant HCE-38 on splined
shaft of pump.
13. Align and insert splined shaft of pump in motor.
Hydraulic Tank
INSPECT
The hydraulic tank is located under the hydraulic cover
and is used to store hydraulic oil for both the steering
and mast functions of the lift truck. The tank has a ca-
pacity of 23.8 liter (6.3 gal).
1. Move lift truck to a safe, level area.
WARNING
To prevent personnel injury or damage to equip-
ment, completely lower the mast and carriage be-
fore repairing the lift system.
2. Remove hydraulic cover.
3. Visually inspect hydraulic tank for any damage or oil
leaks. Check welds for cracks and leakage. Check
for wet areas, accumulation of dirt, and loose or
missing paint caused by leakage. Areas of the tank
that are not easily seen can be checked with an
inspection mirror. See Figure 7.
CAUTION
If hydraulic oil is discolored, milky, black, or brown
the entire hydraulic system must be cleaned and the
hydraulic oil replaced.
4. Check hydraulic oil level inside tank using sight
glass on front of tank. Oil level should be at center
of tank sight glass. If oil color is not correct, then
entire system may need to be changed.
5. Remove breather cap and inspect oil strainer for
blockage. If blocked, remove strainer and clean or
replace strainer.
6. Remove four capscrews on top of filter assembly.
NOTE: Torque capscrews to 5-7 N•m (44-62 lbf in)
when replacing top of filter assembly.
12
1900 YRM 998
14. Install two capscrews and lockwashers through
pump mounting flange into motor.
15. Torque capscrews to 61 N•m (45 lbf ft).
7. Remove top of filter assembly.
8. Remove filter element.
9. The filter assembly can be completely removed
from the tank. Torque capscrews to 25-27 N•m
(18-20 lbf ft) when remounting assembly to tank.
NOTE: Replace filter element and hydraulic oil more of-
ten if lift truck is operated in dusty or dirty environments.
10. Replace filter element after initial 350 hours of op-
eration and every 2000 hours thereafter.
11. Replace hydraulic oil after initial 350 hours of oper-
ation and every 2000 hours thereafter.
REMOVE
1. Move lift truck to a safe, level area.
WARNING
Make sure the brake pedal is released and the
brakes are applied. Put blocks on both sides (front
and back) of the wheels.
2. To prevent movement of lift truck, block wheels.
WARNING
To prevent personnel injury or damage to equip-
ment, completely lower the mast and carriage be-
fore repairing the lift system.
3. Turn ignition key OFF and disconnect battery.
4. Remove hydraulic cover.
5. Obtain a drip pan large enough to hold 28 liter
(7.4 gal).
6. Place drip pan underneath front of hydraulic tank.
1900 YRM 998 Hydraulic Tank

Figure 7. Hydraulic Tank

13
Hydraulic Tank
Legend for Figure 7
1. HYDRAULIC TANK
2. FILTER ASSEMBLY
3. INLET FITTING
4. SIGHT WINDOW
5. BREATHER/STRAINER
6. LOCKWASHER
WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hydraulic
hoses until the oil in the system is cool.
7. Drain hydraulic tank into drip pan by removing drain
plug.
8. Disconnect inlet hose on top of tank. Be sure to
catch any oil that spills from tank and hose in drip
pan.
9. Clean up any spilled oil.
WARNING
The battery is heavy and should be removed care-
fully to avoid causing damage or injury. Remove the
battery using a battery puller and stand. Use care
to avoid injury. Do NOT put hands, arms, feet, and
or legs between the battery and a solid object.
10. Remove battery to gain access to two outlet hoses
on bottom of tank and lower capscrew that holds
hydraulic tank to frame.
11. Place drip pan under rear of hydraulic tank.
12. Disconnect two outlet hoses on bottom of tank. Be
sure to catch any oil that spills from tank and hoses
in drip pan.
13. Plug hoses to prevent any dirt or contaminants from
entering system.
14. Remove lower capscrew and nut.
15. Remove electrical cover to gain access to two upper
capscrews that hold hydraulic tank to frame.
16. Remove tank.
CLEAN
When cleaning the tank, do not use solutions that
produce dangerous gases at normal temperatures, or
when heated. Wear eye and face protection. Wear
protective clothing to prevent burns.
14
1900 YRM 998
7. CAPSCREW
8. DRAIN PLUG
9. THREAD SEALANT
10. CAPSCREW
11. WASHER
12. LOCK NUT
When cleaning with steam, use a hose with a minimum
diameter of 19 mm (0.75 in.). Control the pressure of
the steam using a valve installed at the nozzle of the
hose. If a metal nozzle is used, it must be made of a
non-sparking material. Maintain an electrical connec-
tion between the nozzle and tank. Connect a ground
wire to the tank to prevent buildup of static electricity.
Steam Method
The hydraulic tank can be cleaned using steam and the
following steps.
1. Remove filter assembly, breather/strainer assem-
bly, and sight window from tank.
2. Install drain plug.
3. Plug two outlet pipes.
NOTE: Fill the tank 1/4 full with a solution of water and
sodium bicarbonate or sodium carbonate. Mix 0.5 kg
(1.1 lb) per 4 liter (1 gal) of water.
4. Create a 6 liter (1.5 gal) solution of water and
sodium bicarbonate or sodium carbonate in a
clean bucket.
5. Pour solution into tank and mix using compressed
air. Make sure all surfaces on inside of tank are
flushed with solution.
6. Drain tank.
7. Put steam into tank until tank does not have odors
and metal is hot. Steam vapors must come from all
openings.
8. Flush inside of tank with boiling water.
9. Make sure all loose material is removed from inside
of tank.
10. Inspect inside of tank using a light approved for lo-
cations with inflammable vapors.
11. If the tank is not clean, repeat Step 7 and Step 8
until tank is clean.
1900 YRM 998
Trisodium Phosphate Method
If the tank cannot be cleaned with steam, use the fol-
lowing procedure:
1. Mix a solution of water and trisodium phosphate or
a cleaning compound with an alkali base. Follow
instructions given by manufacturer.
2. Fill tank cleaning solution. Use compressed air to
mix solution in tank.
3. Drain tank.
4. Flush inside of tank with hot (boiling) water. Make
sure all cleaning compound and all loose material
is removed from inside of tank.
5. Inspect inside of tank using a light approved for lo-
cations with inflammable vapors.
6. If the tank is not clean, repeat Step 1 through Step 4
until tank is clean.
INSTALL
Before installing the hydraulic tank in the lift truck,
be sure to clean the area where the hydraulic tank
mounts. Make sure the drain plug, sight window,
breather/strainer assembly, and filter assembly are
clean before installing them to the hydraulic tank.
NOTE: To prevent contamination of hydraulic oil, do not
apply too much HCE-83 pipe thread sealant to threads
of drain plug. Do not fill hydraulic tank for four hours
after applying HCE-83 to allow sealant to cure.
1. Apply HCE-83 pipe thread sealant to threads of
drain plug and install drain plug into hydraulic tank.
Torque plug to 38-41 N•m (28-30 lbf ft).
2. Install sight window, breather/strainer assembly,
and filter assembly to hydraulic tank.
3. Clean any oil spilled during removal.
4. Align hydraulic tank with mounting holes in frame.
a. Tank back should sit flat against front battery
wall of frame.
b. Front corner of tank should rest on drive wheel
fender of frame.
Hydraulic Tank
5. Install three capscrews, washers, and locking nuts.
a. Install lower capscrew, washer, and locking nut
first.
b. Install upper two capscrews, washers, and
locking nuts.
c. Torque to 34 N•m (25 lbf ft).
6. Place drip pan under hydraulic tank.
7. Remove plugs from lower hydraulic hoses and in-
stall hoses to tank.
8. Remove plug from upper hydraulic hose and install
hose to tank.
NOTE: Do not fill hydraulic tank for four hours after ap-
plying HCE-83 to allow sealant to cure.
9. Fill hydraulic tank with new hydraulic oil until oil level
is at center of sight glass.
WARNING
The battery is heavy and should be installed care-
fully to avoid causing damage or injury. Install the
battery using a battery puller and stand. Use care
to avoid injury. Do NOT put hands, arms, feet, and
or legs between the battery and a solid object.
10. Install and connect battery.
11. Turn ignition key ON and operate mast several
times.
12. Check tank hose connections for leaks and tighten
connections as required.
13. Clean any spilled oil.
14. Check hydraulic oil level and refill as required.
15. Remove drip pan.
16. Install covers.
17. Remove blocks from wheels.
15
Troubleshooting 1900 YRM 998

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Low hydraulic pressure. Hydraulic oil low in tank. Refill tank.

Relief valve contaminated. Inspect and clean or replace relief

valve.

Pump damaged or worn. Clean, repair, or replace pump.

Jerky hydraulic action. Air trapped somewhere in hydraulic Exercise hydraulic system completely
system. until operation is smooth.

Breather on tank damaged or clogged. Clean or replace breather.

Control valve contaminated. Clean or replace control valve.

Leak in suction line between tank and Tighten hose connections, or replace
pump causes air to enter pump. hoses.

Hydraulic system relief valve Restriction in the system. Inspect system for kink in line.
opens frequently.

The pump noise is not normal. Hydraulic oil low in tank. Refill tank.

Restriction in the inlet hose. Drain system and clean hose.

Inlet hose clamp is loose. Tighten clamp.

The bearings or gears are damaged. Replace motor bearings or pump.

The pump housing is damaged. Replace pump.

Loose capscrews holding pump hous- Tighten capscrews holding pump

ing together. housing together.

Pump motor is damaged or worn. Repair or replace pump motor.

The pump has low output. The pump is worn. Repair or replace pump.

Seals or gaskets are damaged and Repair or replace pump.

leaking.

The fitting at the pump leaks. Repair or replace fitting or replace

pump.

16
1900 YRM 998 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The pump has leaks. Fittings are loose or defective. Tighten or replace fittings.

Capscrews holding pump housing to- Tighten capscrews holding pump

gether are loose. housing together.

Seals are defective. Repair pump and replace seals.

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

1900 YRM 998 8/03 (1/02) Printed in U.S.A.