HYDRAULIC

Hydraulic Pumps

Hydraulic Pumps You must prime the lift pump after you do any of the
items that follow:

Lift Pump (P1) • Replace the lift pump.

The lift pump (P1) is located at the base of the lift pump
motor (M2) in the traction motor compartment.
The pump rotates clockwise, as viewed from the top,
when acting as a pump to supply oil flow to the primary
and secondary cylinders. It rotates counter-clockwise
when acting as a motor for the regenerative lowering
system. Refer to the Hydraulic Circuits section for de-
tailed information on the hydraulic circuitry of the lift
pump.
The lift pump has no serviceable parts.
CAUTION
Contamination in the hydraulic system can cause se-
vere damage to the system. Do all hydraulic system
maintenance in a clean work area. Keep the compo-
nents as clean as possible during maintenance. Hy-
draulic oil added to the system must be clean and
strained as described in Adding Hydraulic Oil in the Hy-
draulic System section.
CAUTION
It is critical that the lift pump is completely primed be-
fore you operate the pump at high speeds or elevated
pressure. Failure to do so will result in pump damage.
NOTE
• Remove and reinstall the lift pump.
• Remove and reinstall or replace the lift pump suc-
tion line.
• Drain and refill the reservoir.
• Any other operations that can cause the lift pump
to lose its prime.
CAUTION
Before priming the lift pump, make sure that the hy-
draulic reservoir is filled, but not overfilled, with clean
hydraulic oil. Failure to do so can result in damage to
the lift pump.
Prepare the truck
1. Lockout/Tagout the truck as described in Control of
Hazardous Energy.
2. With the truck OFF, open MVL.
3. Remove the quick-disconnect fitting from Port G1
(1) of the hoist manifold.
4. Install a clean, male fitting to Port G1.
5. Attach a clean tube to the fitting.
6. Prepare to catch spilled hydraulic oil as shown in
Figure 26435.

In this section, there are circumstances which require

the collection of hydraulic oil that may leak or be re-
moved from components. Be prepared to catch hy-
draulic oil with a catch pan or absorbent material. Do
not reuse hydraulic oil. Obey applicable laws and envi- 1
ronmental standards when disposing of used hydraulic
oil.

Lift Pump (P1) Priming

CAUTION
Failure to prime P1 after service to the hoist circuit or
replacement of P1 will result in pump failure and could
also result in metal contamination of the entire hydrau- Figure 26435
lic system.

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93
HYDRAULIC
Hydraulic Pumps

Remove air from the circuit 27. Check the hydraulic oil level in the reservoir.
7. Remove the battery connector lockout device. 28. Add hydraulic oil as necessary. Do not overfill.
8. Connect the battery. 29. Close and secure all covers.
9. Turn the truck ON 30. Remove the lockout/tagout device and wheel
chocks.
10. Carefully operate mast raise as slowly as possible
to run the pump at minimum speed and minimum
pump pressure. Gradually increase the pump Accessory Pump (P2)
speed to a maximum speed of 1000 rpm (approxi-
mately 30% of the maximum lift speed). The accessory pump (1) is located at the base of the
accessory pump motor on top of the console.
The pump rotates clockwise, as viewed from the top.
CAUTION
The accessory pump provides hydraulic oil to drive the
Do not operate the pump more than 30 seconds. reach accessories.
11. Continue to operate mast raise at a slow speed un- The accessory pump has no serviceable parts.
til a clear stream of oil, with no trapped air, flows
into the catch pan. After a clear stream of oil flows
from the drain hose, the pump is primed.
12. Stop hoist raise.
1
13. Turn the truck OFF.
14. Disconnect the battery and lockout/tagout the
truck.

Reinstall the original fitting

15. Remove the tubing and male fitting from the hoist
manifold.
16. Check the O-ring on the quick-disconnect fitting re-
moved in Step 3. Replace the O-ring if needed.
17. Install the quick-disconnect fitting into Port G1 of Figure 26436
the hoist manifold.
18. Torque the quick-disconnect fitting to 14-15 Nm
(10-11 ft lb).
19. Close MVL.
20. Clean up any spilled hydraulic oil.

Check for hydraulic oil leaks

21. Remove the lockout device.
22. Connect the battery.
23. Turn the truck ON.
24. Use the multi-task control handle to operate hoist
raise.
25. Check the quick-disconnect fitting to make sure it
is not leaking.
26. Fully lower the mast.

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94