Maintenance

HUSCO™ MAIN
CONTROL VALVE
ERP1.60-1.80-2.00ATF (ERP030-040TH) [F807]

PART NO. 524204502 2000 YRM 1085

 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!
HUSCO™ Main Control Valve Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Operation............................................................................................................................................................. 2
Lift Section ...................................................................................................................................................... 4
Tilt Section ...................................................................................................................................................... 4
Tilt Backward .............................................................................................................................................. 4
Tilt Forward ................................................................................................................................................. 5
Relief Valve ..................................................................................................................................................... 6
Main Control Valve Repair ................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Disassemble.................................................................................................................................................... 7
Clean and Inspect ........................................................................................................................................... 9
Assemble ........................................................................................................................................................ 9
Install............................................................................................................................................................... 11
Switch Plate Adjustment ................................................................................................................................. 13
Pressure Relief Valve Check and Adjustment ..................................................................................................... 14
Primary Relief Valve........................................................................................................................................ 14
Secondary Relief Valve ................................................................................................................................... 14
Troubleshooting ................................................................................................................................................... 15

This section is for the following models:

ERP1.60-1.80-2.00ATF (ERP030-040TH) [F807]

©2006 Yale Materials Handling Corp. i

2000 YRM 1085 Description

General
This section describes the main control valve and the The hydraulic oil is hot at normal operating temper-
linkage arrangement. Procedures are outlined for the atures. Be careful when draining the oil.
maintenance, adjustment, and repair that may be re-
quired when servicing these lift trucks. Never check for leaks by putting hands on hydraulic
lines or components under pressure. Hydraulic oil
under pressure can be injected into the skin.
WARNING
Do not make repairs or adjustments unless you are
properly trained and have authorization to do so. CAUTION
Repairs and adjustments that are not correct can Protect the hydraulic system from dirt and contam-
create dangerous operating conditions. Do not op- inants when servicing the hydraulic system.
erate a lift truck that needs repairs. Report the need
Never operate the pump without the proper amount
for repairs to your supervisor immediately. If repair
of oil in the hydraulic system. The operation of the
is necessary, attach a DO NOT OPERATE tag to the
hydraulic pump with low oil levels will damage the
steering wheel and remove the key.
pump.
Always wear the proper protective equipment in-
Before making any checks, repairs or adjustments, park
cluding eye protection and petroleum resistant
the lift truck on a smooth, level surface. Turn the key to
gloves when handling hydraulic oil. Thoroughly
the OFF position. Block the lift truck so the drive tire
wash oil from exposed areas of skin as soon as
is raised slightly off the floor to prevent any unexpected
possible.
movement.
Completely lower forks to relieve hydraulic pres-
sure before servicing any hydraulic components or
disconnecting any hydraulic hoses.

Description
The main control valve controls the operation of the lift,
tilt, and auxiliary cylinders. The main control valve is
installed to the right of the operator, at the level of the
floor plate. The main control valve has the following
sections:
• Inlet section with the primary relief valve
• Lift and lower section
• Tilt section
• Auxiliary section(s) with the secondary relief valve
The sections are held together with three through-bolts.
valve body casting is the same. The control spools are
different for each function. Other sections are added
to the main control valve to control optional auxiliary
functions.
Each spool has a spring that returns the spool to the
neutral position when the control lever is released.
Each valve section has a check valve in the valve body.
The check valve and spring are held in the valve body
by the next section. See Figure 1.

Each function of the main control valve is made as a

separate section having a spool and valve body. Each

1
Operation 2000 YRM 1085

1. INLET SECTION 5. TILT SPOOL

2. LIFT SECTION 6. AUXILIARY SPOOL
3. LIFT/LOWER SPOOL 7. AUXILIARY SECTION
4. TILT SECTION 8. TILT CONTROL SPOOL

Figure 1. Main Control Valve

Operation
The main control valve is an open-center, parallel circuit
valve. When open-center valve spools are in the neu-
tral position, the hydraulic oil flows through the valve
with minimum restriction. The oil returns through the
drain passage and returns to the hydraulic tank. Ex-
cept during lifting, each spool can be operated without
preventing the flow of oil to another spool.
This valve has three parallel passages through the
valve. See Figure 2. When the spools are in the neutral
position, the oil flows through the open center passage.
At the end of the valve, the oil returns through the drain
passage and returns to the hydraulic tank. When a
spool is moved from the neutral position, it makes a
restriction in the open-center passage. This restriction
causes an increase in pressure in the parallel passage.

2
2000 YRM 1085 Operation

The parallel passage is common to all sections of oil to flow through a check valve into a supply cavity in
the valve, but oil cannot flow freely through it. The the valve body. The spool gives a path from the supply
increased pressure in the parallel passage causes the cavity to the hydraulic cylinder to do work.

A. UPPER PORT B. LOWER PORT

1. TILT CYLINDER 9. HYDRAULIC TANK
2. LOWERING CONTROL VALVE (EXTERNAL) 10. FILTER
3. LIFT CYLINDER 11. SECONDARY RELIEF VALVE
4. LOWERING CONTROL VALVE (INTERNAL) 12. TILT SPOOL
5. MAIN CONTROL VALVE 13. AUXILIARY SPOOL
6. LIFT/LOWER SPOOL 14. AUXILIARY SPOOL
7. PRIMARY RELIEF VALVE 15. SUPPLY PRESSURE TEST PORT
8. HYDRAULIC PUMP

Figure 2. Control Valve Schematic

3
Operation 2000 YRM 1085

The first lever to the right of the operator controls the through the check valve to the supply cavity. The oil
lifting and lowering of the mast. Move the lever forward flows from the supply cavity through a section of the
to lower the mast. Pull the lever back to lift the mast. spool to the rod side of the tilt cylinders. The check
The second lever controls the tilt function. Move the valve prevents the movement of the load until the sys-
lever forward to tilt the mast forward. Pull the lever back tem pressure is great enough to control the load. Oil
to tilt the mast back. The optional third control lever from the piston end of the tilt cylinders returns through
is for attachments and has two methods of operation the main control valve to the hydraulic tank.
depending on the attachment.
• Control Lever With Detent – Required for Attach-
ments With a Clamp Action: The lever is spring-
loaded toward the operator. The lever is operated by
moving it to the right, then forward or backward.
• Control Lever Without a Detent – Attachments
Without a Clamp Action: The lever is operated by
moving forward or backward.

The optional fourth control lever has a detent and is

spring-loaded toward the operator. The lever is oper-
ated by moving it to the right, then forward or backward.

Each of the control levers actuate a mechanical switch

for the hydraulic pump. Movement of the tilt or auxiliary
levers in either direction causes a switch to start the
hydraulic pump. The lift/lower control lever actuates its
switch only in the lift position.

LIFT SECTION
When the spool is in the Lower position, the spool opens
a path from the lift cylinders to the drain cavity. See Fig-
ure 3. The spool is made so the open center passage
has no restriction.

When the spool is moved to the Lift position, the spool

makes a restriction in the open center passage. The
increased pressure in the parallel passage causes oil to
flow through the check valve to the supply cavity. The
oil flows from the supply cavity through a section of the
spool to the lift cylinders.

TILT SECTION
The basic operation of the tilt spool is the same as the
other spools in this control valve. The tilt control spool
that is inside the tilt spool adds an additional sequence A. LOWER B. LIFT
to the tilt forward function. 1. LIFT/LOWER 5. OPEN CENTER
SPOOL PASSAGE
Tilt Backward 2. SUPPLY CAVITY 6. TO LIFT
3. TO/FROM LIFT CYLINDERS
When the spool is moved to the Back Tilt position, the CYLINDERS 7. TO HYDRAULIC
tilt spool causes a restriction of the oil flow through the 4. DRAIN CAVITY TANK
open center passage. See Figure 4. The increased
Figure 3. Lift and Lower Spools
pressure in the parallel passage causes the oil to flow

4
2000 YRM 1085 Operation

A. TILT BACKWARD B. TILT FORWARD

1. OPEN CENTER PASSAGE 5. TILT SPOOL
2. SUPPLY CAVITY 6. TO/FROM ROD END OF TILT CYLINDERS
3. TO/FROM PISTON END OF TILT CYLINDERS 7. TILT CONTROL SPOOL
4. DRAIN CAVITY

Figure 4. Tilt Spool Operation

Tilt Forward
The tilt control spool that is inside of the tilt spool oper-
ates during the Forward Tilt function. See Figure 4. The
tilt control spool prevents cavitation in the piston end of
the tilt cylinders. Cavitation occurs when the available
fluid does not fill the space in a closed system. The high
vacuum causes some of the fluid to change to bubbles
of gas. When cavitation occurs in the tilt cylinders, the
tilt forward function is not smooth.

5
Operation 2000 YRM 1085

The tilt control spool permits the regulation of the tilt
speed by using the pressure from the hydraulic pump.
The pressure must be 550 kPa (80 psi) on the piston
end of the tilt cylinders. The tilt control spool prevents
oil flow from the rod end of the tilt cylinders until the
pressure is 550 kPa (80 psi). This action makes sure
that a vacuum cannot occur at the piston end of the tilt
cylinders.
RELIEF VALVE
The relief valves control the maximum pressure within a
hydraulic circuit. The control valve has a primary relief
valve and a secondary relief valve. The primary relief
valve is installed in the inlet section of the control valve
and is for the lift and tilt circuits. The secondary relief
valve is for the auxiliary circuits and is installed in the
outlet section of the control valve. Both relief valves are
the same in description and operation. When the pres-
sure in one of the hydraulic circuits reaches the relief
valve setting, the relief valve opens a path between the
inlet and drain circuits.
The relief valve is a poppet valve that is pilot operated.
There are four poppet spools in this valve. Spools C,
D, and E are used for pressure relief. This relief valve
gives almost constant relief pressure over the range of
the hydraulic pump flow. The sequence of operation is
described in Figure 5.

1. STEP 1 - THE RELIEF VALVE IS CLOSED BETWEEN THE HIGH PRESSURE (HP) INLET AND THE LOW
PRESSURE (LP) DRAIN. HIGH PRESSURE OIL ENTERS THE PASSAGE AT C. THE DIFFERENCE IN
AREA BETWEEN DIAMETERS A AND B HOLDS THE POPPET SPOOL D AGAINST THE VALVE SEAT.
2. STEP 2 - THE OIL PRESSURE IN THE HIGH PRESSURE INLET BECOMES GREATER THAN THE SPRING
FORCE OF THE PILOT POPPET E. THE PILOT POPPET E IS PUSHED FROM ITS SEAT. OIL FLOWS
AROUND THE POPPET E AND THROUGH THE PASSAGES TO THE DRAIN.
3. STEP 3 - WHEN PILOT POPPET E OPENS, THE LOSS OF OIL PRESSURE BEHIND POPPET C CAUSES
POPPET C TO MOVE AGAINST POPPET E. THIS MOVEMENT STOPS THE FLOW OF OIL THROUGH C
AND CAUSES A LOWER PRESSURE BEHIND RELIEF VALVE POPPET D.
4. STEP 4 - THE DIFFERENCE IN PRESSURE ON EACH SIDE OF POPPET D CAUSES POPPET D TO OPEN.
THE HIGH PRESSURE OIL THEN HAS A DIRECT PATH TO THE LOW PRESSURE DRAIN.

Figure 5. Relief Valve Operation

6
2000 YRM 1085
Main Control Valve Repair
REMOVE
The hydraulic control valve assembly is mounted to a
supporting bracket, which is secured to the frame of the
truck. To remove these parts, use the following proce-
dures and see Figure 6.
WARNING
Before making any repairs to the control valve, tilt
the forks until they are parallel to the floor. Lower
the mast until the forks rest on the floor. This action
will prevent the mast from lowering suddenly when
the hydraulic lines are disconnected.
1. Fully lower the mast.
2. Disconnect the battery. Remove the battery to gain
access to the mounting capscrews for the hydraulic
control valve. Follow the instructions in Periodic
Maintenance 8000 YRM 1079 for battery removal
information.
3. Remove the battery spacer plates, if required.
WARNING
Hydraulic oil is hot at normal operating tempera-
ture.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
4. Operate the control valve levers in both directions
to relieve any hydraulic pressure.
5. Remove the screws (1) securing the lower cover.
Remove the cover.
NOTE: Install plugs and caps to the hydraulic hoses
and fittings to prevent leaking and to prevent dirt from
entering the system.
6. Tag and disconnect the pressure and supply line
from the pump. This line can be accessed through
the battery compartment.
7. Tag and disconnect all remaining hydraulic hoses
at the fittings. Drain any excess hydraulic oil into a
suitable container.
8. Disconnect the hydraulic wiring harness connector
from the main wiring harness.
Main Control Valve Repair
WARNING
The hydraulic control valve is heavy. Be sure that all
lifting devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the hy-
draulic control valve. The hydraulic control valve
can weigh 11.4 to 13.6 kg (25 to 30 lb) without any
attachments.
9. Support the hydraulic control valve assembly. Re-
move the three capscrews (16), washers (17), lock-
washers (18), nuts (19), and brackets (15) secur-
ing the top of the supporting bracket to the frame.
Loosen the two capscrews (16), washers (17), lock-
washers (18), nuts (19), and brackets (15) securing
the bottom of the supporting bracket to the frame.
Carefully lift the entire hydraulic control valve as-
sembly and supporting bracket out of the truck.
10. Move the hydraulic control valve assembly and sup-
porting bracket to a clean workbench.
11. Remove the cotter pins (7), washers (28), if appli-
cable, and pins (8) connecting the lower linkage to
the hydraulic control valve.
12. Remove the three mounting capscrews (23), wash-
ers (24), lockwashers (25), and nuts (26) secur-
ing the hydraulic control valve to the supporting
bracket. Remove the hydraulic control valve from
the supporting bracket.
NOTE: Refer to Figure 7 for upper linkage and control
lever assembly.
DISASSEMBLE
1. Clean the exterior of the hydraulic control valve.
NOTE: Disassemble the main control valve as neces-
sary for repairs. Most repairs to the main control valve
are for the replacement of O-rings and seals to stop
leaks. The passages in the tilt spool are small and may
need cleaning if the hydraulic oil becomes dirty. The
section normally must be replaced, if the spool or valve
section is damaged.
2. Remove the end cap from the valve section. See
Figure 8. Carefully pull the spool from the valve
section. Do not remove the spring retainers, unless
a spring must be replaced.
7
Main Control Valve Repair 2000 YRM 1085

Figure 6. Main Control Unit Mounting

8
2000 YRM 1085 Main Control Valve Repair

Legend for Figure 6

1. SCREW 15. BRACKET
2. LOWER COVER 16. CAPSCREW
3. STANDOFF 17. WASHER
4. STANDOFF 18. LOCKWASHER
5. CAPSCREW 19. NUT
6. LINK 20. LOWER RUBBER CHANNEL
7. COTTER PIN 21. UPPER RUBBER CHANNEL
8. PIN 22. CONTROL VALVE
9. PIN 23. CAPSCREW
10. SNAP RING 24. WASHER
11. SPACER 25. LOCKWASHER
12. PIN 26. NUT
13. SPRING 27. SUPPORT BRACKET
14. STUD 28. WASHER

3. Tag and disconnect all electrical connections from 4. The relief valve is normally replaced as an assem-
the valve switches. bly if it is damaged.

4. The valve sections can be separated when the
three through-bolts are removed. The check valves
are held in the valve body by the next section.
5. Remove the tilt control spool by removing the end of
the tilt spool. Carefully remove the tilt control spool
from the tilt spool.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.
1. Clean only the parts of the control valve with sol-
vent. Do not get solvent in the electrical switches.
2. Check the spools and bores for wear or damage. If
a spool or the bores have damage, the control valve
section must be replaced. Make sure the spools
move freely in the bores.
3. Check the check valves and relief valve(s) for dam-
age. Replace the parts as necessary.
5. Check the parts of the linkage for the control valve
levers. Replace worn parts as necessary.
ASSEMBLE
CAUTION
Before installing the parts into the valve body, make
sure all parts are clean. Replace all the seals and
the O-rings. Lubricate the moving parts with clean
hydraulic oil during assembly.
1. Install new seals in the bores of the sections. See
Figure 8. Install new O-ring seals between the sec-
tions. Install the check valves and springs and as-
semble the sections. Tighten the nuts on the small
through-bolts to 10 N•m (7 lbf ft). Tighten the nuts
on the large through-bolt to 24 N•m (18 lbf ft).
2. If the return springs were removed from the control
spools, install the spring retainers. During assem-
bly, use new O-rings for the parts of the tilt control
spool. Do not damage the O-rings during installa-
tion.

9
Main Control Valve Repair 2000 YRM 1085

Figure 7. Main Control Valve Upper Lever Mounting

10
2000 YRM 1085 Main Control Valve Repair

Legend for Figure 7

1. UPPER COVER 20. WASHER
2. SCREW 21. CAPSCREW
3. LINKAGE FRAME 22. WASHER
4. LIFT HAND LEVER 23. LOCKOUT STRAP
5. TILT HAND LEVER 24. NUT PLATE
6. 3RD FUNCTION HAND LEVER 25. NUT
7. 4TH FUNCTION HAND LEVER 26. PIN
8. CAPSCREW 27. SPRING
9. WASHER 28. PIVOT
10. LOCKWASHER 29. CRANK
11. NUT 30. CRANK
12. STANDOFF 31. SPACER (NOT SHOWN)
13. STANDOFF 32. LINK
14. CAPSCREW 33. COTTER PIN
15. KNOB 34. PIN
16. PIN 35. ROCKER ARM
17. LATCH ROD 36. SNAP RING
18. LATCH 37. PIVOT PIN
19. CAPSCREW 38. FLANGE BEARING

3. Lubricate the spools with clean hydraulic oil. En-
sure spool is free of contamination. Carefully install
the spools in the valve body. Install the seal retain-
ers and the covers for the return springs.
4. Install the relief valves. Adjust the relief settings
for the hydraulic system as described in Pressure
Relief Valve Check and Adjustment.
5. Connect all electrical connections to the valve
switches.
INSTALL
The hydraulic control valve assembly is mounted to a
supporting bracket, which is secured to the frame of the
truck. To install these parts, use the following proce-
dures and see Figure 6.
WARNING
The hydraulic control valve is heavy. Be sure that all
lifting devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the hy-
draulic control valve. The hydraulic control valve
can weigh 11.4 to 13.6 kg (25 to 30 lb) without any
attachments.
1. Align and secure the hydraulic control valve to the
supporting bracket by installing the three mounting
capscrews (23), washers (24), lockwashers (25),
and nuts (26).
2. Install the pins (8), washers (28), if applicable, and
cotter pins (7) connecting the lower linkage to the
hydraulic control valve.
3. Ensure that the three upper rubber channels (21)
are properly installed on the supporting bracket.
While supporting the hydraulic control valve assem-
bly, carefully position the supporting bracket in the
lower rubber channels (20) and tighten the two cap-
screws (16), washers (17), lockwashers (18), nuts
(19), and brackets (15) securing the bottom of the
supporting bracket to the frame.
4. Install the three brackets (15), capscrews (16),
washers (17), lockwashers (18), and nuts (19)
securing the top of the supporting bracket to the
frame.
5. Connect the hydraulic wiring harness connector to
the main wiring harness.
6. Remove caps and plugs from the hydraulic hoses
and fittings. Connect the pressure and supply line
to the pump. Connect all remaining hydraulic hoses
at the fittings. See Figure 9.

11
Main Control Valve Repair 2000 YRM 1085

1. THROUGH-BOLT 9. TILT SPOOL 17. SPRING CUP

2. AUXILIARY SECTION 10. TILT SECTION 18. SCREW
3. O-RING 11. LIFT/LOWER SECTION 19. END CAP
4. SEAL 12. LIFT/LOWER SPOOL 20. TILT CONTROL SPOOL
5. RETAINER 13. SECONDARY RELIEF VALVE 21. BRACKET
6. AUXILIARY SPOOL 14. PRIMARY RELIEF VALVE 22. SWITCH
7. SPRING 15. INLET SECTION 23. OUTLET SECTION
8. CHECK VALVE 16. PLUG

Figure 8. Main Control Valve

12
2000 YRM 1085 Main Control Valve Repair

1. AUXILIARY 2 3. TILT 5. TO FILTER

2. AUXILIARY 1 4. LIFT 6. FEED FROM PUMP

Figure 9. Hydraulic Line Arrangement

7. Check the level of hydraulic oil in the tank. If nec-
essary, add hydraulic oil.
8. Install the battery. Follow the instructions in Peri-
odic Maintenance 8000 YRM 1079 for battery in-
stallation information. Connect the battery connec-
tor.
9. Operate the lift, tilt, and auxiliary controls. Check
for leaks from the hydraulic hoses and valve con-
nections.
10. Install the lower cover.
1. Remove the two screws holding the lower cover in
place, and lift off the cover. Check that all the hy-
draulic control handles are in the neutral position.
2. Loosen the two screws mounting the first switch.
Position the switch so that the switch actuator rests
against the groove in the spool, but not so firmly
that it causes the actuator to depress. Tighten the
two screws.
3. Confirm that the switch activates when the handle
is pushed or pulled, and that the switch is not de-
pressed when the spool is in the neutral position.

SWITCH PLATE ADJUSTMENT 4. Adjust the remaining switch plates, and verify that
each switch is in proper working order.
CAUTION 5. Install the lower cover.
DO NOT overtighten screws.

See Figure 8.

13
Pressure Relief Valve Check and Adjustment 2000 YRM 1085

Pressure Relief Valve Check and Adjustment

NOTE: The main control valve has two relief valves: a
primary relief valve and a secondary relief valve. The
primary relief valve is in the inlet section of the control
valve. The secondary relief valve is in the outlet section
of the control valve. See Figure 10.
PRIMARY RELIEF VALVE
WARNING
Never allow anyone under a raised carriage. Do not
put any part of your body in or through the lift mech-
anism unless all parts of the mast are completely
lowered and the key switch is OFF.
2. Loosen the jam nut on the relief valve.
3. Operate the hydraulic system to warm the oil tem-
perature to 55 to 65 C (131 to 149 F).
4. Tilt the mast backward until it stops. Hold the lever
and check the reading of the gauge when the relief
valve opens. Turn the adjustment screw, as neces-
sary, to change the setting. The correct setting is
13.8 MPa (2000 psi). Tighten the jam nut when the
adjustment is correct.
5. Remove the gauge when the checks are complete.

1. Insert a tee fitting into the pressure supply line to

the mast. Connect a 25 MPa (3600 psi) gauge to
the tee fitting.

2. Loosen the jam nut.

3. Operate the hydraulic system to warm the oil tem-

perature to 55 to 65 C (131 to 149 F).

CAUTION
During this test, the mast must be fully extended.
Make sure there is enough overhead clearance in
the building, or do the test outdoors.

4. Raise the mast until it stops. Hold the lever and

check the reading of the gauge when the relief valve
opens. Turn the adjustment screw, as necessary, to
change the setting. The correct setting is 17.9 MPa
(2600 psi). Tighten the jam nut when the adjust-
ment is correct.

5. Remove the gauge when the checks are complete. 1. ADJUSTMENT SCREW
2. JAM NUT
3. PRIMARY RELIEF VALVE
SECONDARY RELIEF VALVE 4. SECONDARY RELIEF VALVE
1. Insert a tee fitting into the tilt or auxiliary circuit. Figure 10. Relief Valve Locations
Connect a 20 MPa (3000 psi) gauge to the tee fit-
ting.

14
2000 YRM 1085 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Slow or no movement of cylin- Air is in the hydraulic system. Remove air from hydraulic system.
ders.

The hydraulic pump is worn or dam- Repair or replace hydraulic pump.

aged.

Restriction in the hydraulic lines. Repair hydraulic lines.

Cylinder seals are damaged. Repair cylinders.

Load is greater than capacity. Reduce load.

Linkage is disconnected or damaged. Repair and adjust linkage for control

levers.

Pressure relief valve(s) is not adjusted Repair or adjust relief valve(s).

correctly or is damaged.

Large leaks between spool and bore. Replace valve section.

Switch plates are not installed or ad- Check position of switch plates.
justed correctly.

Pump motor fails to turn on. Failed control valve switch. Replace switch.

Open circuit. Check wiring connections. Check

wiring continuity.

Switch plates are not installed or ad- Check position of switch plates.
justed correctly.

Oil leaks at the end of a spool. Seal for spool is damaged. Replace seal.

Spool is damaged. Replace valve section.

Valve body is damaged. Replace valve section.

Hydraulic pressure is above Pressure relief valve(s) is not adjusted Repair or adjust relief valve(s).
specifications. correctly or is damaged.

Restriction in return line. Clean or replace return line or filter.

15
Troubleshooting 2000 YRM 1085

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Tilt cylinders extend when the Cylinder seal has leaks. Repair tilt cylinders.
tilt spool is in the NEUTRAL
position.

Oil leaks between control valve spool Replace valve section.

and bore.

Hydraulic lines have leaks. Repair or tighten lines or fittings.

Tilt cylinders extend suddenly Check valve for tilt spool is damaged. Replace check valve.
when the tilt spool is moved to
BACK TILT position.

Tilt cylinders extend suddenly Tilt control spool inside the tilt spool is Replace valve section.
when the tilt spool is moved to damaged.
FORWARD TILT position.

Lift cylinders retract when the Check valve for the lift spool is dam- Replace check valve.
lift spool is in the NEUTRAL aged.
position.

Cylinder seals have leaks. Repair lift cylinders.

Hydraulic lines have leaks. Repair or tighten lines or fittings.

Leaks between the lift spool and the Replace valve section.
bore.

Spool will not move or is diffi- Linkage is disconnected or damaged. Repair and adjust linkage.
cult to move.

Return spring is damaged. Replace spring.

The spool or bore is damaged. Replace valve section.

Spool will not return to NEU- Linkage is disconnected or damaged. Repair and adjust linkage.
TRAL.

Return spring is damaged. Replace spring.

Dirt between spool and the bore. Clean valve.

Spool is bent or damaged. Replace valve section.

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