HYDRAULIC SYSTEM

H20.00-32.00F (H440-700F/FS) [E008]

PART NO. 897463 1900 SRM 492

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 Mainte-
nance 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 condition that can cause immediate death or injury!

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

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Hydraulic Module .......................................................................................................................................... 1
Main Control Valves ...................................................................................................................................... 1
Remote Control Valve .................................................................................................................................... 1
Lift Manifold .................................................................................................................................................. 2
Accumulator Charge Valve............................................................................................................................ 2
Relief Valve and Pressure Reducing Valves ................................................................................................. 2
Directional Control Valve .............................................................................................................................. 2
Return Control Solenoid Valves .................................................................................................................... 2
Carriage Solenoid Valves............................................................................................................................... 2
Heat Exchanger System................................................................................................................................ 2
Steering Control System ............................................................................................................................... 3
Brake System................................................................................................................................................. 3
Lift and Lower Circuit ....................................................................................................................................... 3
Description ..................................................................................................................................................... 3
Operation ....................................................................................................................................................... 4
Lift Circuit, Normal Speed (Heavy Load) ................................................................................................ 6
Lift Circuit, High Speed (Light Load) ...................................................................................................... 6
Two-Speed Cartridge................................................................................................................................. 6
Lowering .................................................................................................................................................... 7
Lowering Control Valves ........................................................................................................................... 7
Repairs ........................................................................................................................................................... 7
General....................................................................................................................................................... 7
Hydraulic Module, Remove....................................................................................................................... 7
Hydraulic Module, Install......................................................................................................................... 8
Remote Control Valve................................................................................................................................ 8
Remove .................................................................................................................................................. 8
Disassemble........................................................................................................................................... 8
Clean and Inspect ................................................................................................................................. 9
Assemble................................................................................................................................................ 9
Install..................................................................................................................................................... 11
Adjust..................................................................................................................................................... 11
Main Control Valves.................................................................................................................................. 11
Remove .................................................................................................................................................. 11
Disassemble........................................................................................................................................... 11
Clean and Inspect ................................................................................................................................. 13
Assemble................................................................................................................................................ 13
Install..................................................................................................................................................... 13
Lift Manifold.............................................................................................................................................. 14
Remove .................................................................................................................................................. 14
Clean and Inspect ................................................................................................................................. 14
Assemble and Install ............................................................................................................................ 14
Checks and Adjustments............................................................................................................................... 15
Pilot Pressure, Check ................................................................................................................................ 15
Main Control Valves Relief Pressure, Check ........................................................................................... 16
Two-Speed Cartridge, Check .................................................................................................................... 16
Tilt Control Circuit ............................................................................................................................................ 16
Description ..................................................................................................................................................... 16
Operation ....................................................................................................................................................... 17
Tilt Spool.................................................................................................................................................... 17

©2003 HYSTER COMPANY i

Table of Contents Hydraulic System

TABLE OF CONTENTS (Continued)

Relief Valves in Main Control Valve......................................................................................................... 17
Relief Valves, Tilt Lock.............................................................................................................................. 18
Repairs ........................................................................................................................................................... 18
General....................................................................................................................................................... 18
Relief Valves, Tilt Lock, Disassemble....................................................................................................... 18
Clean and Inspect...................................................................................................................................... 19
Checks and Adjustments............................................................................................................................... 19
Main Control Valve Relief Pressure, Check............................................................................................. 19
Flow Control Valves Repair............................................................................................................................... 19
Description ..................................................................................................................................................... 19
Accumulator Charge Valve ....................................................................................................................... 19
Relief Valves .............................................................................................................................................. 21
Pressure Reduction Valves........................................................................................................................ 21
Repairs ........................................................................................................................................................... 21
Accumulator Charge Valve ....................................................................................................................... 21
Relief Valve ................................................................................................................................................ 21
Pressure Reduction Valves........................................................................................................................ 22
Checks and Adjustments............................................................................................................................... 22
Relief Valves, Check and Adjust............................................................................................................... 22
Pressure Reduction Valves Check ............................................................................................................ 22
Solenoid Valves Repair ...................................................................................................................................... 23
Description ..................................................................................................................................................... 23
Directional Control Valve, Carriage/Attachment .................................................................................... 23
Repairs ........................................................................................................................................................... 24
Directional Control Valve, Carriage/Attachment .................................................................................... 24
Remove .................................................................................................................................................. 24
Disassemble........................................................................................................................................... 24
Clean and Inspect ................................................................................................................................. 26
Assemble................................................................................................................................................ 26
Install..................................................................................................................................................... 28
Return Control Solenoid Valves................................................................................................................ 28
Remove .................................................................................................................................................. 28
Install..................................................................................................................................................... 29
Return Control Solenoid ........................................................................................................................... 29
Remove .................................................................................................................................................. 29
Install..................................................................................................................................................... 29
Carriage Solenoid Valves .......................................................................................................................... 30
Remove .................................................................................................................................................. 30
Disassemble........................................................................................................................................... 31
Clean and Inspect ................................................................................................................................. 31
Assemble................................................................................................................................................ 31
Install..................................................................................................................................................... 31
Over Lowering Interrupt............................................................................................................................... 31
Lift Interrupt ................................................................................................................................................. 31
Checks and Adjustments............................................................................................................................... 32
Torque Specifications ......................................................................................................................................... 32
Control Valves ................................................................................................................................................ 32
Remote Control Valve .................................................................................................................................... 32
Control Valve, Carriage/Attachment ............................................................................................................ 32
Carriage Solenoid Valve ................................................................................................................................ 32
Specifications...................................................................................................................................................... 32

ii
Hydraulic System Table of Contents

TABLE OF CONTENTS (Continued)

Hydraulic Pump Output at 2500 rpm and 13.8 MPa (2000 psi) ................................................................. 32
Pressure Reduction Valves ............................................................................................................................ 32
Relief Pressures at 2500 rpm ........................................................................................................................ 32
Main Hydraulic Filters.................................................................................................................................. 33
Tank Capacity ................................................................................................................................................ 33
Troubleshooting.................................................................................................................................................. 33
Control Valves ................................................................................................................................................ 33
Remote Control Valve .................................................................................................................................... 36
Flow Control Valves....................................................................................................................................... 36
Solenoid Valves .............................................................................................................................................. 38
Diagrams, Schematics, or Arrangements ......................................................................................................... 40
Figure 22. Hydraulic System Arrangement ............................................................................................ 40
Figure 23. Hydraulic System Schematic ................................................................................................. 44
Figure 24. Container Attachment Schematic (Until E008E 01811)....................................................... 46
Figure 25. Container Attachment Schematic (E008 E 01811 and After)............................................... 48

This section is for the following models:

H20.00-32.00F (H440-700F/FS) [E008]

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1900 SRM 492
General
This section has the description and operation of the
hydraulic system. The section also has repair pro-
cedures and troubleshooting for most of the compo-
nents of the lift, tilt, and attachment systems. The
complete hydraulic system includes the circuits for
the steering system, brake system, mast, and attach-
ments. See the following sections for description, op-
eration, and repair information of hydraulic compo-
nents in these systems:
• Steering System 1600 SRM 429
• Brake System 1800 SRM 472
Description and Operation
Two gear pumps, a tandem pump, and a single pump
supply the flow of oil for the components of the hy-
draulic system. These pumps are driven by a gear
arrangement in the torque converter housing. The
inlet hose for each pump is connected to the hydraulic
tank.
The small section of the tandem pump supplies oil to
the single-spool main control valve. The small sec-
tion has a capacity of 35.23 ml (2.15 in. 3 ) per revolu-
tion.
The large section of the tandem pump supplies oil to
the flow amplifier for the steering system. A relief
valve in the flow amplifier, set at 17.2 MPa (2500 psi),
controls the oil pressure in the steering system. Oil
that is not needed for steering flows from the flow
amplifier to the two-spool main control valve. When
the operator is not steering, all of the oil from the
pump flows to the main control valve. The large sec-
tion of the tandem pump has a capacity of 96.0 ml
(5.86 in. 3 ) per revolution.
Oil from the single hydraulic pump goes to the ac-
cumulator charge valve for the brake system. The
auxiliary relief valve limits the pressure to 22.0 MPa
(3200 psi). The single hydraulic pump has a capacity
of 41.62 ml (2.54 in. 3 ) per revolution.
HYDRAULIC MODULE
Most of the valves in the hydraulic system are in-
stalled on a module. The module is installed on rub-
ber isolators in a compartment on the left side of the
frame. Doors give access to the module, which can be
removed as a unit. See Figure 22.
Description and Operation
• Mast 4000 SRM 491
• Fixed Container Attachment 5000 SRM 266
• Container Attachment 5000 SRM 723
Also see the following sections for other hydraulic
components:
• Hydraulic Gear Pumps 1900 SRM 97
• Tilt Cylinder 2100 SRM 103
MAIN CONTROL VALVES
The two-spool and single-spool main control valves
control the lift, lower, and tilt functions. The two-
spool main control valve receives oil from the 96 ml
(5.86 in. 3 ) per revolution pump via the flow amplifier.
The single-spool main control valve receives oil from
the 35.23 ml (2.15 in. 3 ) per revolution pump. See
Figure 23.
Relief valves in the main control valves control the
pressure of the supply oil in the lift and tilt circuits.
These relief valves are set at 16.9 MPa (2450 psi).
Two additional relief valves are set at 690 kPa
(100 psi) for the return circuits.
The remote control valve actuates the main control
valves. There is also a two-speed valve in the lift
circuit that operates with the main control valves to
let the mast lift at two different speeds.
REMOTE CONTROL VALVE
The remote control valve is controlled by the oper-
ator for lift and tilt operations. The valve has two
sections. One section controls the lifting and lower-
ing function and the other section controls the tilt
function. Pilot lines for hydraulic oil are connected
between the remote control valve and the main con-
trol valve. Movement of the spools in the remote
control valve actuates the spools in the main control
valve. The supply of oil for the remote control valve
comes through the 41.62 ml (2.54 in. 3 ) per revolution
pump, accumulator charging valve, and the 2.1 MPa
(300 psi) pressure reduction valve.
1
Description and Operation
LIFT MANIFOLD
The lift manifold is in the circuit between the main
control valves and the lift cylinders. The manifold is
installed on top of the fuel tank. The lift manifold
has four check valves and two cartridge valves. The
two cartridge valves are a differential sensing valve
and an unloading valve. The check valves direct the
flow of oil. The two cartridge valves operate together
to let the mast lift at two different speeds, depending
on the weight of the load.
ACCUMULATOR CHARGE VALVE
The accumulator charge valve controls the charging
rate and the pressure of the oil in the accumulator
circuit for the brake system. See Brake System
1800 SRM 472. Oil from this valve goes to the brake
treadle, declutch/brake treadle, pressure reducing
valve, the relay valve for the operation of the auxil-
iary brake, and the directional control valve for the
operation of the carriage/attachment. The supply
of oil for this valve is from the 41.62 ml (2.54 in. 3 )
per revolution pump. The valve verifies that the
accumulator circuit has enough oil flow and pressure
to operate the brakes and the other circuits. The
accumulator charge valve stops charging when the
accumulator reaches the upper limit and allows oil
from the pump to charge the accumulator when the
pressure reaches the lower limit. See Table 1.
Table 1. Accumulator Charge Valve Pressures
Upper Limit Lower Limit
18.6 to 19.3 MPa 14.1 to 14.8 MPa
(2700 to 2800 psi) (2050 to 2150 psi)
RELIEF VALVE AND PRESSURE
REDUCING VALVES
There are two pressure reducing valves and one aux-
iliary relief valve in the accumulator circuit. The
22.06 MPa (3200 psi) relief valve limits the input
oil pressure to the accumulator charge valve. The
2.1 MPa (300 psi) pressure reducing valve controls
the pressure and supply of the oil to the pilot cir-
cuits for the remote control valves and the directional
control valve. The 10.3 MPa (1500 psi) pressure re-
ducing valve limits the pressure to the parking brake
caliper. A pressure switch connected to the parking
brake circuit operates a warning light for the opera-
tor when brake pressure is low. See Brake System
1800 SRM 472.
2
1900 SRM 492
DIRECTIONAL CONTROL VALVE
The directional control valve is a solenoid-controlled
valve controlled by the operator. The directional con-
trol valve controls the flow of oil that operates the
hydraulic attachment or other auxiliary function on
the carriage. The directional control valve receives
oil through the accumulator charge valve to operate
the attachment functions. The valve also receives pi-
lot pressure from the 2.1 MPa (300 psi) pressure re-
ducing valve. Oil not used to operate auxiliary func-
tions adds to the flow from the 35.23 ml (2.15 in. 3 )
hydraulic pump to the inlet of the single-spool main
control valve. See Figure 15 and Figure 16.
RETURN CONTROL SOLENOID VALVES
NOTE: First used with dedicated carriage container
attachment, serial number E008 01811.
The directional control valve will, depending on the
function selected by the operator, cause either out-
put Y or Z to supply hydraulic oil to carriage/attach-
ment. When output Y supplies the oil, solenoid valve
xx provides the return to hydraulic tank. When out-
put Z provides the oil, solenoid yy provides the return
to hydraulic tank. When no functions are selected
by the operator, both solenoid valves provide return
to hydraulic tank. This prevents damage to cylin-
ders in case attachment/container gets accidentally
obstructed. See Figure 15.
CARRIAGE SOLENOID VALVES
The carriage solenoid valves are solenoid valves that
are assembled together and installed on the car-
riage. The supply and return ports in the manifold
are connected to the directional control valve with
hoses on the mast. Each carriage solenoid valve
opens or closes a hydraulic circuit to a cylinder or
cylinders for a specific function. Each carriage sole-
noid valve is actuated by a switch that also actuates
the directional control valve at the same time.
HEAT EXCHANGER SYSTEM
The hydraulic oil cooler is used to cool the hydraulic
system oil. The oil cooler is positioned before the re-
turn manifold. The oil cooler ventilator is switched
on if the oil temperature is above 55 C (131 F) and
switched off at 44 C (111 F).
1900 SRM 492
STEERING CONTROL SYSTEM
The steering control system has a steering control
unit and a flow amplifier. Oil flow and pressure is
from the 96.0 ml (5.86 in. 3 ) per revolution pump. The
steering unit is actuated by the steering wheel. Hy-
draulic pilot lines connect the steering unit in the cab
to the flow amplifier on the hydraulic module on the
frame. Two large hydraulic lines connect the flow
amplifier and the steering cylinder. See Steering
System 1600 SRM 429.
The steering control unit is a manual metering
pump that gives hydraulic control of several valves
in the flow amplifier. The action of steering sends
hydraulic signals from the control unit to the flow
amplifier. The flow amplifier responds by send-
ing a regulated flow of oil to the steering cylinder.
The output from the flow amplifier to the steering
cylinder is five times larger than the input from the
steering unit.
Oil that is not used for steering flows to the inlet of
the two spool main control valve. Oil that returns
from the steering cylinder flows to the flow amplifier
and back to the tank.
BRAKE SYSTEM
Oil from the 41.62 ml (2.54 in. 3 ) per revolution hy-
draulic pump goes via the accumulator charge valve
Lift and Lower Circuit
DESCRIPTION
A remote control valve in the operator compartment
operates spools in the main control valves that con-
trol the lifting and lowering functions. See Figure 2
and Figure 3.
The remote control valve is installed in the console
at the right-hand side of the seat. The remote con-
trol valve is an assembly of two sections with spools
and a spacer block. One section controls the lift and
lower functions. The other section controls the tilt
function.
The remote control valve has two spool assemblies
actuated by a hand lever. One spool assembly actu-
ates the lift function, and the other spool assembly
actuates the lower function. The spool assemblies
are the same. The lift/lower spool assembly controls
Lift and Lower Circuit
to an accumulator to ensure that the brake system
has enough pressure to operate the brakes. A pres-
sure switch connected to the brake circuit operates a
warning light for the operator when brake pressure
is low. The pump, accumulator charge valve, and ac-
cumulator maintain the brake pressure and oil flow
to operate the brakes at each drive wheel. The sys-
tem also supplies oil flow and pressure to operate the
parking brake and auxiliary brake on the drive line
near the differential.
Oil pressure from the accumulator is supplied to de-
clutch/brake treadle and brake treadle. The right-
hand pedal only activates the brakes. The left-hand
pedal first activates the brakes and further pushing
of the pedal will also fully disengage the transmis-
sion. When activating either the left-hand or right-
hand pedal, hydraulic oil flows to the shuttle valve
and then through the sequence valve to the caliper
brakes and through the 4.5 MPa (650 psi) relay valve
to the auxiliary brakes. The brake and declutch/
brake treadle are set at 13.8 MPa (2000 psi). See Fig-
ure 23.
The parking brake is controlled by a solenoid valve
operated by a switch in the operator compartment.
the pilot pressure to the lift/lower spools in the main
control valves. Springs move the spool to close the
passage that supplies pilot pressure when the oper-
ator releases the hand lever.
Two main control valves control the flow and direc-
tion of the oil to the lift cylinders. Each main con-
trol valve has a lift spool, two relief valve assemblies
with restrictions, and two load check valves. There
is a 16.9 MPa (2450 psi) relief valve in each control
valve. There is also a 690 kPa (100 psi) cylinder re-
lief valve in each control valve.
A two-speed valve on the lift manifold lets the mast
lift at two different speeds, depending upon the
weight of the load being lifted. This two-speed valve
operates with the main control valves.
3
Lift and Lower Circuit 1900 SRM 492

OPERATION Legend for Figure 1

Oil from the accumulator circuit supplies oil to the A. FORWARD LEVER MOVEMENT
remote control valves at 2.1 MPa (300 psi). This pilot
1. LIFT/LOWER 5. SUPPLY OIL
circuit oil is controlled by the remote control valves LEVER 6. LOWER
to move the spools of the main control valves. See 2. TILT LEVER 7. BACKWARD TILT
Figure 1 and Figure 3. The accumulator maintains 3. DRAIN CIRCUIT 8. FORWARD TILT
pressure and flow for spool operation, even with the 4. LIFT
engine off. Lowering is the only function that will op-
erate without pump and engine operation; however,
with the engine off, braking is possible for a short
time.

With the control lever in the NEUTRAL position,

both spools in the remote control valve are closed.
They will not let the pilot pressure flow to the main
control valves. The spools will, however, let the oil in
the pilot lines flow to the drain circuit.

When the lift/lower control lever is moved forward

or backward, the control lever pushes on one of the
plunger pins. The plunger pin and guide push the
springs and pilot spool. As the spool moves, the pas-
sage in the open-center spool allows oil to flow from
the inlet port through the open center of the pilot
spool to one of the pilot lines. The pilot pressure
pushes directly on the lift/lower spools in the main
control valves.

The movement of the spools in the main control

valves is proportional to the movement of the spool
in the remote control valve. The first 3 to 5 degrees
of lever movement do not move the spool.

A. ACTUATED B. NEUTRAL
1. CONTROL VALVE LEVER
2. NEUTRAL POSITION PLUNGER
3. ACTUATED PLUNGER
4. DRAIN PORT
5. SPRINGS
6. INLET PORT
7. PILOT SPOOL
8. INLET PRESSURE TO PILOT LINE
9. PILOT LINE PRESSURE TO DRAIN

Figure 2. Remote Control Valve Operation

Figure 1. Remote Control Valves Schematic

4
1900 SRM 492 Lift and Lower Circuit

Figure 3. Main Control Valves Lift/Lower

5
Lift and Lower Circuit
Legend for Figure 3
1. LIFT CYLINDERS
2. TILT CYLINDERS
3. LIFT CONTROL LEVER
4. REMOTE CONTROL VALVES
5. LOWERING CONTROL VALVES
6. LIFT MANIFOLD
7. DIFFERENTIAL SENSING POOL
8. UNLOADING SPOOL
9. LIFT SPOOL
Lift Circuit, Normal Speed (Heavy Load)
When the lift control lever is moved to the lift po-
sition, the lift spools in the control valves move to
change the path of the oil flow from the pumps.
See Figure 3. Flows to the hydraulic tank are now
blocked, so the oil flows through the load check
valves, through the lift spools, through lines AB and
AC to the two-speed valve ports M1 and HS2, out
ports C1 and C4, then through the lowering control
valves to enter the bases of the lift cylinders.
A pilot passage exists between the inlet ports (M1
and HS2) of the two-speed lift valve and the unload-
ing spool. The unloading spool senses the pressure at
the base of the lift cylinders through this pilot pas-
sage. When the load is heavy, the pressure at the
base of the lift cylinders is higher than when there
is no load. Another pilot passage from the spring
chamber of the differential sensing valve senses the
pressure at the tops of the lift cylinders. The two pi-
lot pressures work together to move the unloading
spool against the tension of the spring. Spool move-
ment opens a drain circuit to the tank. The unload-
ing spool stays open because the pilot pressures are
greater than the spring tension.
This action causes a difference in pressure across the
orifice at the spring chamber of the differential sens-
ing spool. The difference in pressure causes the dif-
ferential sensing spool to move. As the lift cylinders
extend, oil from the tops of the cylinders flows to port
C2, port C3, and the differential sensing spool. The
oil then flows through the open spool to check balls
B and C and to ports HS1 and M2. The cylinder base
pressure on check balls B and C is greater than the
pressure at ports HS1 and M2, so the oil flows out
of the ports. The oil flows through lines AD and AE,
through the lift spools of the main control valves, and
to the hydraulic tank.
During lifting, oil can also go to the accumulator
charge circuit through hydraulic line AC and a check
6
1900 SRM 492
10. MAIN CONTROL VALVES
11. STEERING CIRCUIT
12. 96.03 cm 3 (5.86 in. 3 ) PUMP
13. 41.62 cm 3 (2.54 in. 3 ) PUMP
14. 35.23 cm 3 (2.15 in. 3 ) PUMP
15. HYDRAULIC TANK
16. RELIEF VALVE TILT LOCK
17. TILT SPOOL
valve. Flow to the accumulator circuit will only occur
when the pressure at the bases of the lift cylinders is
greater than the pressure in the accumulator circuit.
Lift Circuit, High Speed (Light Load)
The unloading spool senses the pressure at the base
and tops of the lift cylinders through the pilot pas-
sages. When there is no load, or when the load is
light, the pilot pressures are too low to move the un-
loading spool. The return circuit to the hydraulic
tank remains closed by the unloading spool. See Fig-
ure 4.
As the lift cylinders extend, oil from the tops of the
cylinders flows to the C2 and C3 ports of the two-
speed valve. It also flows to the differential sensing
spool. The oil flow is blocked at the differential sens-
ing spool, so it must flow past check balls A and D.
This flow from the tops of the lift cylinders adds to the
oil flow from the main control valves. This added flow
to the base of the lift cylinders increases the lifting
speed. If the cylinders lift too fast, the pressure from
the tops of the lift cylinders can increase too much.
This pressure can momentarily move the unloading
and differential sensing spools to decrease the pres-
sure.
Two-Speed Cartridge
The mast lifts in high speed with a light load or no
load. See Figure 4. In this condition, the pilot pres-
sure is too low to move the two-speed spool against
the tension of the spring. The two-speed spool keeps
the drain passage closed. Oil from the tops of the lift
cylinders cannot flow to the hydraulic tank. This oil
must flow into the bases of the lift cylinders with the
flow from the pumps. The combined flow increases
lifting speed.
1900 SRM 492 Lift and Lower Circuit

rod ends of the lift cylinders must be filled with oil

so the two-speed lifting function will operate.

Lowering Control Valves

There is a lowering control valve at the base of each
lift cylinder. These valves prevent the mast and load
from lowering too fast if a hydraulic line breaks or
if another major malfunction occurs, causing loss of
cylinder pressure. The valve limits the return flow
rate to control lowering speed if these conditions oc-
cur. See the section Mast 4000 SRM 491 for addi-
tional information.

REPAIRS
General
Repair procedures for hydraulic components used in
the steering, brake, mast, or attachment hydraulic
A. LIFTING - HIGH B. LIFTING - LOW circuits are in the sections for those circuits. See the
SPEED SPEED list of those sections in the Contents of this section.
1. PILOT LINE PORT 6. ORIFICE Hydraulic Module, Remove
2. CHECK BALL 7. SHIMS
3. TWO-SPEED 8. END PLUG
SPOOL 9. PLUG WARNING
4. DRAIN PASSAGE 10. BODY
5. FROM TOP OF Never work under a raised carriage or forks.
LIFT CYLINDERS Lower the carriage or use blocks and chains
on the mast weldments and carriage so they
Figure 4. Two-Speed Cartridge cannot move. Make sure moving parts are at-
tached to a part that does not move. Before dis-
When the load is heavy, the check ball will sense
connecting any hydraulic connections, release
higher pilot pressure. When the pressure is high
the accumulated pressure by applying brakes
enough to push the check ball off the seat, the spring
8 to 10 times.
chamber is connected to the drain passage. This ac-
tion causes a difference in pressure between the pi- NOTE: Most repairs can be made without removing
lot line port and the spring chamber across the ori- the hydraulic module. The hydraulic module can be
fice. The difference in pressure causes the two-speed removed from the frame as a unit if necessary.
spool to move and connect the top of the lift cylinders
to the drain passage. The oil in the tops of the lift 1. Lower the mast completely.
cylinders can now flow to the hydraulic tank. The
lift cylinders will lift at low speed. 2. Shut down the engine and apply the parking
brake.
Lowering
3. Apply brakes 8 to 10 times until hydraulic pres-
When the lift spools of the main control valves are sure is relieved.
moved to the lowering positions, oil from the hy-
4. Open doors of hydraulic compartment on the left
draulic pumps flows through the lift spools to the
side of the frame.
tank. Oil from the base of the lift cylinders flows
through the lowering control valves, ports C1 and 5. Put caps and identification tags on the pilot lines.
C4 of the two-speed valve, and out of ports M1 and
HS2. It then flows through lines AB and AC, main 6. Disconnect the pilot lines at the flow amplifier,
control valves lift spools, lines AD and AE, then back pressure reduction valves, and main control
to the two-speed valve, through check valves B and valves.
C, to the tops of the lift cylinders. See Figure 3. The

7
Lift and Lower Circuit
7. Put identification tags on the lines in the hose
support plate.
8. Disconnect and place caps on the lines at the
plate
9. Remove the nuts and bolts that fasten the hy-
draulic module to the frame.
10. Remove the hydraulic module and place on a
workbench.
Hydraulic Module, Install
NOTE: Use new seals/O-rings where applicable.
1. Place hydraulic module on frame and fasten with
nuts and bolts.
2. Remove caps and reconnect lines at the plate.
3. Remove identification tags on the lines at the
hose support plate.
4. Reconnect lines at the flow amplifier, pressure
reduction valves, and main control valves.
5. Remove caps and identification tags on the pilot
lines.
6. Close doors of hydraulic compartment on the left
side of the frame.
7. Start engine and operate system. Check for
leaks.
Remote Control Valve
Remove
WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in the
section Periodic Maintenance 8000 SRM 1023.
1. Lower the mast completely and tilt mast forward
for access. Put blocks between the mast and the
lift truck.
2. Shut off engine and apply the parking brake.
WARNING
Before disconnecting hydraulic lines, proceed
as follows:
8
1900 SRM 492
• Shut off engine.
• Lower carriage.
• Operate lift/lower lever and brake pedals un-
til hydraulic pressure is released.
3. Remove the rear cover from the console beside
the seat. See Figure 5.
4. Put tags for identification on hydraulic lines.
5. Disconnect the six hydraulic lines from the re-
mote control valve.
6. Put caps on open lines, ports, and other connec-
tors.
7. Remove the two screws that fasten the cover and
the valve assembly as a unit.
8. Remove the capscrews and nuts that fasten the
remote control valve to the cover.
9. Remove the cover from the valve.
Disassemble
WARNING
Compressed springs can release with great
force. Wear eye protection when disassem-
bling valves.
NOTE: Keep the parts from the bore separate. The
parts must be installed in the original bores. The
parts are adjusted with spacers. Make a note of the
number and location of spacers in the spring set.
Changing the spacers will affect the operation of the
valve. See Figure 6.
1. Put identification marks on the sections of the
remote control valve and the spacer block.
2. Remove the nuts and the through bolts that hold
the sections and spacer block together.
3. Disassemble each valve section as follows:
a. Remove the rubber boot from the plate and
the pivot pin for the control lever.
b. Put identification marks on the plates at the
top of the valve section.
1900 SRM 492 Lift and Lower Circuit

c. Carefully remove the capscrews that hold the

plates to the top of the valve section and re-
move the plates.

d. Remove pin and guide assembly from the

valve body.

e. Carefully remove the spring set and spacers

from the bore of the valve section. Remove
the return spring.

f. Carefully remove the second spring set and

spacers from the other bore of the valve sec-
tion. Remove the return spring.

g. Repeat steps Step d and Step e to remove the

second 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 precau-
tions.

Compressed air can move particles and cause

injury to the user or to other personnel. Make
sure compressed air path is away from all per-
sonnel. Wear eye protection.

Clean all parts in solvent and dry the parts with com-
pressed air. Inspect the spools and bores for damage.
Inspect the parts of the valve assemblies for dam-
age. Replace damaged parts. If there are scratches
or other damage, the valve must be replaced. Spools
are not available as separate parts.

Assemble
NOTE: A = LIFT, B = LOWER, C = SUPPLY, E = TILT
1. Install the return spring in the valve body.
FORWARD, F = TILT BACKWARD, GG = DRAIN.
A. BOTTOM VIEW 2. Verify that the same shims are used with each
spring assembly. Install the spring assemblies
1. REMOTE 5. TILT LEVER and the spools in the bores. Verify that the parts
CONTROL VALVE 6. CONSOLE are installed in the same bores from which they
2. NUT 7. SCREW were removed.
3. CAPSCREW 8. COVER
4. LIFT/LOWER
LEVER 3. Assemble the guide and pin assemblies.

Figure 5. Remote Control Valve Arrangement 4. Install O-rings and guides in the valve body.

9
Lift and Lower Circuit 1900 SRM 492

1. MOUNT, HAND LEVER 16. WASHER

2. LOCK RING (2) 17. SHIM
3. SCREW (2) 18. SCREW 1.3 N•m (12 lbf in)
4. PRESSURE PLATE 19. O-RING
5. SCREW (2) 20. SHIM(S)
6. PLATE 21. LOCK RING
7. PIVOT PIN 22. SNAP RING
8. NUT (2) 23. SEAL
9. ADJUSTMENT SCREW (2) 24. O-RING
10. RETURN SPRING 25. GUIDE
11. PILOT SPOOL 26. PIN
12. GUIDE 27. RETAINER
13. SPRING 28. LOCK WIRE
14. SHIM 29. VALVE BODY
15. SPRING GUIDE

Figure 6. Remote Control Valve Parts

10
1900 SRM 492
5. Install the plates at the top of the valve. Tighten
the screws to 5 N•m (44 lbf in).
6. Install the control lever and the rubber boot. If
necessary, tighten the lock nut on the hand lever
to 30 N•m (22 lbf ft).
7. Assemble the valve sections and the intermedi-
ate block. Verify the O-rings are in position.
8. Install the through bolts. Tighten the nuts to
5 N•m (44 lbf in).
Install
1. Use the capscrews and nuts to install the console
cover on the remote control valve. Verify the cov-
ers is installed in the correct direction.
2. Install the valve and the cover as a unit. Fasten
the cover to the console with two screws.
3. Connect the hydraulic lines to the sections of the
valve as shown in Figure 5.
4. Start the engine and operate the hydraulic sys-
tem. Check that all functions of the remote con-
trol valve work correctly.
5. If necessary, check the pressure to the remote
control valve. See Flow Control Valves Repair.
6. Install the back cover on the console.
Adjust
Figure 7. Lever Adjustment
Lift and Lower Circuit
Legend for Figure 7
1. PIN
2. ADJUSTMENT SCREW
3. LOCK NUT
1. When the hand lever is in the NEUTRAL posi-
tion, turn the adjustment screw to obtain 0.13 to
0.25 mm (.005 to 0.010 in.) clearance between the
pin and the adjustment screw. Tighten the lock
nut to 5 N•m (44 lbf in). See Figure 7.
Main Control Valves
Remove
WARNING
Never work under a raised carriage or forks.
Lower carriage or use blocks and chains on
mast weldments and carriage so they cannot
move. Make sure moving parts are attached to
a part that does not move.
1. Lower the mast completely.
2. Shut down the engine and apply the parking
brake.
3. Apply brakes 8 to 10 times until hydraulic pres-
sure is relieved.
4. Open doors of hydraulic compartment on the left
side of the frame.
5. Clean outside of main control valves.
6. Put identification tags on hydraulic lines at the
valves.
7. Disconnect hydraulic lines at the valves.
8. Place caps on open hydraulic lines.
9. Remove the nuts and bolts that fasten the main
control valves to the hydraulic module.
10. Remove valves and place on a workbench.
Disassemble
Disassemble the main control valve(s) as necessary.
Mark spools to be able to install in same bores. See
Figure 8.
11
Lift and Lower Circuit 1900 SRM 492

Figure 8. Main Control Valves

12
1900 SRM 492 Lift and Lower Circuit

Legend for Figure 8

1. NUT AND STUD ASSEMBLY 25. SCREW 49. CAP ASSEMBLY
2. INLET SECTION 26. SPACER 50. RETAINER
3. SPOOL 27. SPOOL SECTION 51. SPRING
4. INLET BODY 28. BODY 52. GUIDE
5. POPPET 29. RELIEF VALVE 53. CAP
6. SPRING 30. SPRING 54. SPRING CAP
7. RELIEF VALVE 31. PLUG 55. SCREW
8. SPRING 32. RELIEF VALVE ASSEMBLY 56. SCREW
9. PLUG 33. O-RING 57. SCREW
10. POPPET 34. RETAINER 58. SPACER
11. SHIM 35. SPRING 59. PLUG
12. PLUNGER 36. PLUG 60. CHECK VALVE PLUG
13. CHECK VALVE PLUG 37. BODY 61. PLUG
14. PLUG 38. PLUNGER 62. O-RING
15. PLUG 39. SPOOL SECTION 63. O-RING
16. SPRING 40. PLUG 64. O-RING
17. CAP ASSEMBLY 41. PLUG 65. O-RING
18. RETAINER 42. PLUG 66. O-RING
19. SPRING 43. BODY 67. BACKUP RING
20. GUIDE 44. SPOOL SECTION 68. O-RING
21. CAP 45. BODY 69. O-RING
22. CAP SPRING 46. SPOOL 70. O-RING
23. SCREW 47. POPPET 71. O-RING
24. SCREW 48. SPRING 72. BACKUP RING

Clean and Inspect 4. Install the load check valve assemblies.

5. Install the relief valve assemblies.

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow solvent man-
ufacturer’s recommended safety precautions.
6. Install the O-rings between the valve sections
and assemble the sections together using the
through bolts. Tighten nuts on the through bolts
to 61 to 68 N•m (45 to 50 lbf ft).

Compressed air can move particles and cause Install

injury to the user or to other personnel. Make
sure compressed air path is away from all per- 1. Install the control valves on the hydraulic mod-
sonnel. Wear eye protection. ule.

Clean all parts in solvent and dry the parts with com-
pressed air. Keep the spool assemblies separate. In-
spect the spools and bores for damage. Inspect the
parts of valve assemblies for damage. Replace dam-
aged parts.
Assemble
1. Lubricate all parts with hydraulic oil.
2. Install spools, guides, springs, and O-rings in the
housing for the pilot piston.
2. Install bolts, washers, and nuts.
3. Connect the hydraulic lines to the valves. Check
identification tags to verify the lines are correctly
connected to the ports.
4. Start the engine and operate the valves. Check
for leaks.
5. Check the relief pressure as described in Checks
and Adjustments.

3. Install the spools in the valve body. Verify spools

were installed in the same bores they were re-
moved from.

13
Lift and Lower Circuit 1900 SRM 492

Lift Manifold Replace damaged parts. If there are any scratches

or other damage, the valve must be replaced. Spools
Remove are not available as separate parts.
The lift manifold is mounted on top of the fuel tank.
This manifold has four check valves, a differential
sensing valve, and an unloading valve. All of these
valves are cartridge valves in bores of the housing
block of the two-speed lift valve. There are also sev-
eral plugs of different sizes in the housing block. The
housing block is fastened to the fuel tank with four
small brackets. See Figure 9.

WARNING
Before disconnecting hydraulic lines, proceed
as follows:
• Shut off engine.
• Lower carriage.
• Operate lift/lower lever and brake pedals un-
til hydraulic pressure is released.

1. Lower mast and close shutoff valves on bottom of

hydraulic tank.

2. Shut down engine and apply parking brake. Ap-

ply brake 8 to 10 times to relieve hydraulic pres-
sure.

3. Remove hydraulic lines and put tags for identifi-

cation on lines. Put caps on open lines. 1. FUEL TANK 2. BRACKET (4)

4. Remove O-rings and discard. Figure 9. Lift Manifold, Removal

5. Loosen four screws and brackets from the fuel
tank. Remove valve from the fuel tank.
6. Loosen four screws and brackets from plate. Re-
move valve from plate.
Clean and Inspect
Assemble and Install
NOTE: All cartridge valves (check, differential sens-
ing, and unloading) are part of seal kits with neces-
sary O-rings. Install new cartridge valve kits if old
valves were removed. Always use new O-rings when
installing plugs and fittings.

1. Install all cartridge valve kits and plugs removed

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 precau-
tions.
Compressed air can move particles and cause
injury to the user or to other personnel. Make
sure compressed air path is away from all per-
sonnel. Wear eye protection.
Clean all parts in solvent and dry parts with com-
pressed air. Inspect the spools and bores for damage.
during disassembly.
2. Install the lift manifold on the fuel tank using
the four small brackets and capscrews. See Fig-
ure 10.
3. Connect hydraulic lines as removed during the
removal procedure. Check identification tags to
make sure all lines are correctly connected to
ports.
4. Start engine and operate lift and lower control
lever. Check for leaks at valve ports.

14
1900 SRM 492 Lift and Lower Circuit

1. BODY 7. PLUG AND O-RING

2. UNLOADER VALVE 8. BRACKET
3. VALVE 9. WASHER
4. CHECK VALVE 10. HEX HEAD BOLT
5. PLUG AND O-RING ASSEMBLIES 11. LOCKWASHER
6. PLUG AND O-RING 12. NUT

Figure 10. Lift Manifold

CHECKS AND ADJUSTMENTS
Pilot Pressure, Check
NOTE: The pressure reducing valve is adjustable. If
pressure cannot be adjusted to required value, re-
place the pressure reducing valve.
1. Connect a 3500 kPa (500 psi) gauge to check
port 2.
2. Start engine and operate hydraulic system until
oil temperature is 54 to 65 C (130 to 150 F).
3. Check that pressure is 2100 kPa (300 psi). If
pressure is not correct, replace relief valve.

15
Tilt Control Circuit
Main Control Valves Relief Pressure,
Check
NOTE: The relief valves in main control valves are
not adjustable. If a relief pressure is not within spec-
ifications, replace the control valve.
1. Connect a 20 MPa (3000 psi) gauge to check port
5 (single-spool control valve) or 6 (two-spool con-
trol valve).
2. Start engine and operate hydraulic system until
oil temperature is 54 to 65 C (130 to 150 F).
CAUTION
Make sure there is enough room above top of
mast to extend mast fully without hitting any-
thing.
Do NOT hold control lever in lift position for
more than 30 seconds after mast is fully ex-
tended.
3. For check port 5 (single-spool), fully raise mast.
Pressure must be 18.3 to 19.0 MPa (2650 to
2750 psi) at 2500 rpm. If pressure cannot be
adjusted to required value, replace the control
valve.
4. Connect gauge to check port 6 and do procedure
in Step 3 again to check relief valve in two-spool
control valve.
Tilt Control Circuit
DESCRIPTION
A remote control valve in the operator compartment
operates a spool in the main control valve that con-
trols the tilting function. See Figure 1, Figure 2, and
Figure 3.
The remote control valve is installed in the console at
the right side of the seat. The remote control valve is
an assembly of two sections with spools and a spacer
block. One section controls the tilt function. The
other section controls the lift and lower functions.
The remote control valve has two spool assemblies
actuated by a hand lever. One spool assembly ac-
tuates the tilt forward function, and the other spool
assembly actuates the tilt-back function. The spool
assemblies are the same. The tilt spool assembly
16
1900 SRM 492
Two-Speed Cartridge, Check
NOTE: The differential sensing valve and unloading
valve in two-speed valve are not adjustable. If pres-
sure is not within specifications, replace valves by
installing new seal kits that include valves. See Fig-
ure 10.
1. Connect a 20 MPa (3000 psi) gauge to gauge port
on left end (facing valve) of two-speed valve near
top.
2. Put a load on forks. The load must be nearly
equal to capacity of truck.
3. Start engine and operate hydraulic system until
oil temperature is 54 to 65 C (130 to 150 F).
4. Slowly move control lever to lift position. The
gauge will indicate an increase in pressure and
then indicate a sudden decrease in pressure.
This is the point at which a change in lifting
speed occurs.
5. The pressure reading just before the pressure
decreases must be 13.5 to 14.1 MPa (1950 to
2050 psi).
6. If pressure reading is not correct, adjust socket
head screw.
7. If the pressure cannot properly be adjusted, or
there is no sudden decrease in pressure, replace
the cartridge.
controls the pilot pressure to the tilt spool in the
main control valve (two-spool only). Springs move
the spool to close the passage that supplies pilot pres-
sure when the operator releases the hand lever.
The main control valve with two spools controls the
flow and direction of the oil to the tilt cylinders. This
main control valve has a tilt spool, two relief valve as-
semblies with restrictions, and two load check valves.
There is a 16.5 MPa (2400 psi) relief valve in this con-
trol valve. There is also a 690 kPa (100 psi) cylinder
relief valve in this control valve.
Supply pressure oil flows through the flow amplifier
to the control valve with two spools. When the spools
in the main control valve are in the neutral position,
oil flows through the valves to the hydraulic tank.
The movement of the tilt spool is controlled by pilot
1900 SRM 492
pressure from the remote control valve. The distance
the spool moves is proportional to the movement of
the control lever at the remote control valve.
OPERATION
Oil from the accumulator circuit supplies oil to the
remote control valves at 2.1 MPa (300 psi). See Fig-
ure 1 and Figure 3. This pilot circuit oil is controlled
by the remote control valves to move the spools of
the main control valves. The accumulator maintains
pressure and flow for spool operation, even with the
engine off. Lowering is the only function that will op-
erate without pump and engine operation.
With the control lever in the NEUTRAL position,
both spools in a remote control valve are closed. They
will not let the pilot pressure flow to the main control
valve. The spools will, however, let the oil in the pilot
lines flow to the drain circuit.
When the tilt control lever is moved forward or back-
ward, the control lever pushes on one of the plunger
pins. The plunger pin and guide push the springs
and pilot spool down. As the spool moves down, the
passage in the open-center spool allows oil flow from
the inlet port through the open center of the pilot
spool to one of the pilot lines. The pilot pressure
pushes directly on the tilt spool in the main control
valve. The oil in the opposite pilot line flows through
the center of the spool in the remote control valve and
out of the drain port.
The movement of the spool in the main control valves
is proportional to the movement of the spool in the
remote control valve. The first 3 to 5 degrees of lever
movement do not move the spool. When a hand lever
is moved a small amount, the spool in the remote
control valve moves down and then back up against
spring tension. The spool moves back up and closes
because the pilot pressure is sensed, through the
spool, at the bottom of the spool. The spool opens
and closes as necessary at any one position setting
of the control lever. This oscillating action keeps a
constant and correct pressure in the pilot circuit to
the control valves.
This action keeps the spool in the main control valve
in the position selected by the operator. The remote
control spool can move down to let pressure in, or it
can move up to open the pressure circuit to the drain
circuit.
Tilt Control Circuit
When the control lever is released, the spool in the
remote control valve returns to the neutral position.
The pilot line and pressure at the bottom of the spool
are now open to the drain circuit. This action per-
mits the spool in the main control valve to return to
neutral.
Tilt Spool
When the tilt control lever is moved, the tilt spool
in the control valve moves. See Figure 3. The tilt
spool controls the direction and quantity of oil to the
tilt cylinders from the pump and steering circuit.
This oil normally flows through the lift spool and the
tilt spool to the hydraulic tank. When the tilt spool
is moved to the forward tilt position, pump flow to
the hydraulic tank is blocked. The oil must flow
through the load check valve for tilt, through the
tilt spool, through hydraulic line to the tilt manifold,
and through the bases of the tilt cylinders. Oil from
the rod end of each tilt cylinder returns through a
tilt lock (relief) valve, a tilt manifold, hydraulic line,
and the tilt spool. The oil then flows back to the
hydraulic tank.
Relief Valves in Main Control Valve
The 16.5 MPa (2400 psi) relief valve sets the limit for
the maximum pressure within the tilt circuit. The
relief valve is installed in the body of the two-spool
control valve. The relief valve has a primary and a
secondary spool.
During normal operation, oil flows past the relief
valves. The pressure of the oil is sensed through a re-
striction orifice. If oil pressure increases to the limit,
the pressure moves the primary spool against the
spring tension. This spool movement allows some
oil to flow through the spool to the hydraulic tank.
This flow will reduce the pressure if the pressure is
not too great. This flow, however, is limited by the
restriction orifice. If the flow through the orifice is
not enough to reduce the pressure, a difference in
pressure will occur across the restriction orifice. The
difference in pressure can continue to increase until
the pressure moves the secondary spool against
spring tension. This secondary spool movement
allows additional oil to flow to the hydraulic tank
and to reduce the pressure. The action of the two
spools continues to keep the pressure at or below the
maximum limit.
17
Tilt Control Circuit 1900 SRM 492

Relief Valves, Tilt Lock
The tilt lock valves are relief valves at the rod end
of each tilt cylinder. These valves prevent the mast
from tilting forward too fast by keeping some back
pressure at the rod ends of the tilt cylinders. Check
valves allow oil to flow easily into the rod ends of the
cylinders for back tilt.
REPAIRS
General
Repair procedures for hydraulic components used in
the steering, brake, mast, or attachment hydraulic
circuits are in the sections for those circuits.
NOTE: The procedures for repair of the remote con-
trol and main control valve are described in the sec-
tion Lift and Lower Circuit.
Relief Valves, Tilt Lock, Disassemble
WARNING
Never work under a raised carriage or forks.
Lower the carriage or use blocks and chains on
the mast weldments and carriage so they can-
not move. Make sure the moving parts are at-
tached to a part that does not move.
Remove valve parts from body as shown in Figure 11.

1. PLUG 5. HOUSING
2. O-RING 6. BODY
3. PLUG SPACER 7. FITTING
4. SPRINGS

Figure 11. Relief Valve, Tilt Lock

18
1900 SRM 492
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 precau-
tions.
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure compressed air path is away from
all personnel. Wear eye protection.
Clean all parts in solvent and dry the parts with com-
pressed air. Inspect the spools and bores for damage.
Inspect the parts of the valve assemblies for dam-
age. Replace damaged parts. If there are scratches
or other damage, the valve must be replaced. Spools
are not available as separate parts.
CHECKS AND ADJUSTMENTS
NOTE: The procedures for checking the pilot relief
pressure is the same as described in the section Pilot
Flow Control Valves Repair
DESCRIPTION
The hydraulic system has several valves to control
the flow of oil within the system. These valves are
as follows: accumulator charge valve, two pressure
reduction valves, and two relief valves.
Accumulator Charge Valve
The accumulator charge valve controls the charging
rate and the pressure of the oil in the accumulator for
the brake system. This valve also supplies oil to the
two pressure reduction valves and the control valve
for the carriage and attachment. See Figure 12.
The accumulator charge valve has a charging valve
spool, check valve, and a pilot valve assembly. Oil
Flow Control Valves Repair
Pressure, Check. Refer to this section to check the
pilot relief pressure for the tilt circuit.
Main Control Valve Relief Pressure, Check
NOTE: The relief valves in the control valve are not
adjustable. If a relief pressure is not within specifi-
cations, replace the control valve.
1. Connect a 20 MPa (3000 psi) gauge to check
port 6.
2. Start engine and operate hydraulic system until
oil temperature is 54 to 65 C (130 to 150 F).
CAUTION
Do NOT hold the tilt control lever in the
back-tilt position more than 30 seconds after
the mast is fully in the back-tilt position.
3. Tilt mast to full back position. Pressure must be
17.6 to 18.3 MPa (2550 to 2650 psi) at 2500 rpm.
If pressure is not correct, replace control valve
(two-spool).
from the single pump enters the valve at the charg-
ing valve spool. A relief valve limits this oil to
22.1 MPa (3200 psi). Oil flows past the charging
valve spool to the accumulator and the pressure
reduction valves. Oil also flows to the control valve
for the carriage and attachment. The accumulator
charge valve stops charging automatically when
the accumulator pressure reaches its high limit
of 18.6 to 19.3 MPa (2700 to 2800 psi). When the
accumulator pressure reaches its low limit of 14.1
to 14.8 MPa (2050 to 2150 psi), the accumulator
charge valve allows oil from the pump to charge the
accumulator. Two check valves in the circuit keep oil
from flowing out of the accumulator. See the section
Brake System 1800 SRM 472 for more information
on this valve.
19
Flow Control Valves Repair 1900 SRM 492

1. PLUG 12. O-RING 23. PILOT VALVE SPOOL

2. O-RING 13. SPRING 24. INSERT
3. ROD 14. POPPET 25. O-RING
4. SPRING 15. SEAT 26. O-RING
5. O-RING 16. O-RING 27. UPPER LIMIT BALL
6. CHARGING VALVE SPOOL 17. WASHER 28. RETAINER
7. VALVE BODY 18. PLUG 29. PILOT VALVE SPRING
8. O-RING 19. O-RING 30. SCREW
9. PLUG 20. SPRING 31. O-RING
10. NUT 21. STOP 32. PLUG
11. ADJUSTING SCREW 22. LOWER LIMIT BALL 33. SCREW PLUG

PORTS: A = TO ACCUMULATOR, O = FLOW THROUGH, P = INLET PRESSURE, T = TO DRAIN (TANK)

Figure 12. Accumulator Charge Valve

20
1900 SRM 492 Flow Control Valves Repair

Relief Valves
In addition to the relief valves in the control valves
and the flow amplifier (steering), the hydraulic sys-
tem has two other relief valves. One of these re-
lief valves is connected to the outlet of the large sec-
tion of the tandem pump. This relief valve is for the
steering system and limits the pressure to 22.1 MPa
(3200 psi). The other relief valve is connected to the
outlet of the single pump. This relief valve is for
the carriage and attachment circuit and limits the
pressure to 22.1 MPa (3200 psi). Oil from both relief
valves goes to the drain circuit (hydraulic tank). See
Figure 13.
spring are adjusted to open at the set pressure. Oil
flows through an orifice in the spool to the spring
chamber. The oil in the spring chamber goes through
another orifice to push on the pilot ball. When the
pressure reaches the set limit, the ball moves against
the spring and oil flows from the spring chamber
to the tank. The pressure in the spring chamber
decreases when the oil flows to the drain circuit. The
system pressure then decreases and the ball and
spool return to their closed positions.
Pressure Reduction Valves
There are two pressure reduction valves in the
hydraulic system. One of the pressure reduction
valves controls the flow of oil to the pilot circuits for
the following: remote control valve, the attachment
control valve, the parking brake valve, and the
inching control valve. This pressure reduction valve
limits the pressure in the pilot circuits to 2.1 MPa
(300 psi). The other pressure reduction valve lim-
its the pressure to the parking brake caliper to
10.3 MPa (1500 psi). See Figure 14.

Each pressure reduction valve has an adjustable car-

tridge.

REPAIRS
Accumulator Charge Valve
NOTE: The repair procedures for the accumulator
charge valve are in the section Brake System 1800
SRM 472.

Relief Valve

WARNING
Compressed springs can release with great
force. Wear eye protection and be careful
1. SPOOL 6. CARTRIDGE
2. SLEEVE 7. PILOT SPRING when disassembling valves.
3. SPRINGS 8. CHECK BALL
4. ORIFICE 9. TO TANK Each relief valve has a cartridge that is installed in
5. ADJUSTMENT 10. INLET PORT a valve body. See Figure 13. Repair a relief valve by
SCREW replacing the seals on the cartridge that leak or by
replacing a cartridge that is damaged. Do not disas-
Figure 13. Relief Valve semble or try to repair a relief valve cartridge. See
Each relief valve has a pilot check ball that senses Checks and Adjustments to adjust the relief setting.
pressure at the inlet port. The check ball and pilot

21
Flow Control Valves Repair 1900 SRM 492

2. Start the engine. Run the engine until the tem-

perature of the hydraulic oil is 55 to 65 C (130 to
150 F). Do Step a for the relief valve for the steer-
ing system (check port number 7). Do Step b for
the relief valve for the auxiliary system (check
port number 1).

a. Disconnect the line between the relief valve

and the flow amplifier. Install a plug at the
outlet fitting on the relief valve. Check the
pressure gauge with the engine running at
2250 rpm. The correct pressure with full flow
is 22.1 MPa (3200 psi).

b. Check the pressure gauge with the engine

running at 2250 rpm. Operate the sideshift
carriage in either direction until it stops mov-
ing. The correct pressure is 21.7 to 22.4 MPa
(3150 to 3250 psi).

3. To adjust a relief valve setting, remove the cap.

Loosen the lock nut and use an Allen wrench to
turn the adjuster screw. Turn the adjuster screw
clockwise to increase the pressure. When the re-
lief pressure is correct, install the cap.

Pressure Reduction Valves Check

Each pressure reduction valve has a check port. See
Figure 22 and Figure 14. Check the pressures as
follows:

1. INLET 5. VALVE BODY WARNING

2. TO DRAIN CIRCUIT 6. O-RING
3. REGULATED FLOW 7. BACKUP RING Before disconnecting any hydraulic lines, re-
4. CARTRIDGE lease pressure from the hydraulic circuit as fol-
lows:
Figure 14. Pressure Reduction Valve a. Shut the engine off and completely lower
the carriage.
Pressure Reduction Valves b. Operate the lift/lower lever and the brake
pedals until the hydraulic pressure is re-
The parts in the pressure reduction valves cannot be
leased.
repaired, but some parts can be replaced. Repair a
pressure reduction valve by replacing the seals on the 1. Lower the lift cylinders completely. Connect a
cartridge or by replacing the cartridge that is dam- 4 MPa (600 psi) gauge to check port number 2 for
aged. See Figure 14. When you install the valve, the 300 psi pressure reduction valve. Connect a
connect the hydraulic lines as shown in Figure 22. 14 MPa (2000 psi) gauge to check port number 3
for the 1500 psi pressure reduction valve.
CHECKS AND ADJUSTMENTS
2. Start the engine and check the pressure gauge(s).
Relief Valves, Check and Adjust The correct pressure is 2.1 MPa (300 psi) for one
valve and 10.3 MPa (1500 psi) for the other valve.
1. Each relief valve has a check port. Connect a
28 MPa (0 to 4000 psi) pressure gauge to the 3. If the pressures are not correct, replace the parts
check ports for the relief valves. See Figure 22 for the relief valve as necessary.
and Figure 13.

22
1900 SRM 492 Solenoid Valves Repair

Solenoid Valves Repair

DESCRIPTION
Directional Control Valve,
Carriage/Attachment
The directional control valve for the carriage and
attachment controls the flow of oil that operates a
hydraulic attachment or another auxiliary function.
The directional control valve has two sections. One
of the sections is a pilot valve. The spool in the pilot
valve is actuated by two solenoids that are controlled
by switches. The other section is a directional con-
trol valve. The pilot valve controls the movement of
the spool in the directional control valve. Hydraulic
lines connect the directional control valve to the car-
riage solenoid valves on the carriage. See Figure 15,
Figure 17, and Figure 18.

1. RETURN CONTROL SOLENOID VALVE 6. PILOT SUPPLY

2. TO TANK 7. PILOT DRAIN
3. DIRECTIONAL CONTROL VALVE 8. TO MAIN CONTROL VALVE
4. PILOT VALVE 9. CHECK VALVE
5. FROM ACCUMULATOR CHARGE VALVE 10. TO CARRIAGE/ATTACHMENT

Figure 15. Directional Control Valve, Carriage/Attachment (E008 01811 and After)

23
Solenoid Valves Repair 1900 SRM 492

REPAIRS valve. Disconnect the lines at the fittings on the

mount plate. Put caps on the open lines. See
Directional Control Valve, Figure 16.
Carriage/Attachment
4. Remove the nuts, washers, and bolts that fasten
Remove the bracket for the directional control valve to
the plate. Remove the bracket and the valve as
1. Stop the engine and lower the mast completely. a unit.
Open the doors for the hydraulic module on the
left side of the frame. Disassemble

2. Disconnect the electrical cable for the pilot valve WARNING

solenoids at the connector.
Compressed springs can release with great
force. Wear eye protection and be careful
when disassembling valves.

NOTE: Do Step 3 to remove and disassemble the pilot

valve of the directional control valve.

1. To remove the bracket from the valve, remove the

nuts and the bolts. See Figure 17. The bracket
and the mount plate can be removed as a unit in
Step 2.

2. To remove the mount plate from the valve, re-

move the four capscrews from the bores in the
body of the valve. Remove the mount plate and
the O-rings. See Figure 17 and Figure 18.
1. MOUNT PLATE 3. Remove and disassemble the pilot valve as fol-
2. PILOT DRAIN lows:
3. INLET
4. PILOT SUPPLY (FROM PRESSURE REDUCTION
a. Remove the plate and the seal from the ter-
VALVE)
5. TO CARRIAGE SOLENOID VALVES (ROD SIDE) minal box. Disconnect the electrical cable.
6. TO CARRIAGE SOLENOID VALVES (PISTON
SIDE) b. Remove the capscrews, terminal box, and
7. OUTLET (TO DIRECTIONAL CONTROL VALVE) seal from the housing.

Figure 16. Hydraulic Connections - Directional NOTE: The pilot valve and the terminal box can be
Control Valve Carriage/Attachment removed as an assembly.

c. Remove the capscrews and remove the pi-

WARNING
Before disconnecting any hydraulic lines, re-
lease pressure from the hydraulic circuit as fol-
lows:
a. Shut the engine off and completely lower
the carriage.
b. Operate the lift/lower lever and the brake
pedals until the hydraulic pressure is re-
leased.
3. Put tags for identification on all the hydraulic
lines that are connected to the directional control
lot valve from the housing for the directional
control valve. Remove the O-rings.
d. Make marks on each solenoid and the hous-
ing. The marks are for alignment during as-
sembly. Remove the capscrews and one of the
solenoids.
e. Remove the O-ring, spring, and spring re-
tainer. Carefully remove the spool.
f. Remove the other solenoid and parts.

24
1900 SRM 492 Solenoid Valves Repair

Figure 17. Directional Control Valve, Return Control Solenoid Valve Assembly

25
Solenoid Valves Repair
Legend for Figure 17
1. DIRECTIONAL CONTROL VALVE
2. FITTING
3. WIRE HARNESS
4. Disassemble the directional control valve as fol-
lows:
a. Remove the capscrews and one of the covers.
b. Remove the O-rings, spring, and spring re-
tainer. Carefully remove the spool.
c. Remove the other cover and parts.
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 precau-
tions.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the compressed air path is away
from all personnel. Wear eye protection.
Use solvent to clean the metal parts. Carefully dry
the parts with compressed air. Inspect the bores for
the spools. Inspect the surfaces of the spools that
slide on the bores. If a bore or a spool has scratches,
pits, or cracks, replace parts or replace a complete
valve section as necessary. Inspect the other parts
and replace parts that are damaged.
Assemble
NOTE: Install new seals during assembly. See Fig-
ure 18 and Figure 19.
1. Assemble the directional control valve as follows:
a. Lubricate the spool with clean hydraulic oil
and install the spool in the housing.
b. Install the O-rings in a cover. Install the
spring retainer, spring, cover, and capscrews.
26
1900 SRM 492
4. CAPSCREW
5. RETURN CONTROL SOLENOID VALVE
6. ADAPTER
Push the other end of the spool so that the
spool moves in the bore. If the spool does
not move freely, replace the directional con-
trol valve.
c. Install the O-rings in the other cover. Install
the cover and parts. Tighten the capscrews
for the covers to 11 N•m (8 lbf ft).
d. Install the O-rings in the housing. Install the
mount plate on the housing. Make sure that
the ports in the mount plate and the housing
have alignment. Tighten the capscrews to
14 N•m (10 lbf ft).
2. Assemble and install the pilot valve as follows:
a. Lubricate the spool with clean hydraulic oil.
Install the spool in the housing.
b. Install a spring retainer, spring, O-ring, and
solenoid. Push the other end of the spool so
that the spool moves in the bore. If the spool
does not move freely, replace the pilot valve.
c. Install the other solenoid and parts. Tighten
the capscrews for the solenoids to 2.3 N•m
(20 lbf in).
d. Install the O-rings in the housing. Install the
pilot valve on the directional control valve.
Tighten the capscrews to 9 N•m (80 lbf in).
e. If the terminal box was removed, install the
seal, terminal box, and capscrews. If the elec-
trical cable was removed, connect the wires
as shown in Figure 19. Make sure that the
fitting for the cable is tight. The fitting must
be tightened on the cable to make a seal.
f. Install the seal and cover on the terminal
box.
1900 SRM 492 Solenoid Valves Repair

Figure 18. Directional Control Valve

27
Solenoid Valves Repair 1900 SRM 492

Legend for Figure 18

1. CAPSCREW 10. CAPSCREW
2. SOLENOID 11. CAPSCREW
3. SPACER 12. COVER
4. WASHER 13. O-RING
5. HOUSING 14. O-RING
6. FITTING 15. O-RING
7. SCREW 16. O-RING
8. PLUG 17. O-RING
9. PLATE 18. O-RING
bracket. Make sure that the ports in the mount
plate are in the correct position.

2. Put the assembly in the correct position on the

hydraulic module. Install the bolts and nuts but
do not tighten the nuts.

3. Connect the steel lines at the mount plate.

Tighten the nuts that fasten the bracket to the
hydraulic module.

4. Connect the hoses at the mount plate. Make sure

that the hoses and the lines are correctly con-
nected. See Figure 16 and Figure 22.

5. Connect the electrical cable at the connector on

the wire harness.

Return Control Solenoid Valves

NOTE: The following procedures are for the com-
plete removal and replacement of the return control
solenoid valves. To remove and replace the solenoid
1. CABLE 7. FROM SOLENOID electrical coil of the return control solenoid valves,
2. CABLE FITTING A see Return Control Solenoid.
3. SOLENOID B 8. DIRECTIONAL
4. SOLENOID A CONTROL VALVE NOTE: First used with dedicated carriage container
5. TERMINAL BLOCK 9. GREEN attachment. Serial number E008 01811 and after.
6. FROM SOLENOID 10. BLACK
B 11. WHITE
Remove
Figure 19. Electrical Connections, Directional
1. Stop the engine and lower the mast completely.
Control Valve - Carriage/Attachment
2. Open the doors for the hydraulic module on the
Install
left side of the frame.
1. If the bracket was removed from the mount
plate, use the bolts and nuts to install the

28
1900 SRM 492 Solenoid Valves Repair

3. Disconnect the electrical cables for the solenoids Install

at the connector. See Figure 17.
1. Turn cap clockwise to install.

WARNING 2. Connect plug to solenoid.

Before disconnecting any hydraulic lines or
components, release pressure from the hy- 3. Tighten screw.
draulic circuit as follows:

a. Shut the engine off and completely lower the

carriage.

b. Operate the lift/lower lever and the brake

pedals until the hydraulic pressure is re-
leased.

4. Put tags for identification on all the hydraulic

lines that are connected to the directional control
valve.

5. Disconnect the lines at the fittings on the mount

plate. Put caps on the open lines.

Install

1. Remove caps on the open lines. Replace lines at

the fittings on the mount plate.

2. Remove tags for identification on all the hy-

draulic lines that are connected to the directional
control valve.

3. Reconnect the electrical cables for the solenoids

at the connector. See Figure 17.

4. Close the doors for the hydraulic module on the

left side of the frame.

Return Control Solenoid

Remove

NOTE: The following procedure is for the removal

and replacement of the solenoid electrical coil of the
return control solenoid valves. See Figure 20. 1. CAP 2. SCREW
1. Loosen screw. Figure 20. Directional Control Valve, Return
Control Solenoid Valve
2. Disconnect plug from solenoid.

3. Turn cap counterclockwise and remove.

29
Solenoid Valves Repair 1900 SRM 492

Carriage Solenoid Valves
Remove
NOTE: The carriage solenoid valves are installed on
the carriage.
1. Disconnect the electrical cable for the carriage
solenoid valve as follows. See Figure 21.
a. Remove the screws. Remove the cover and
the gasket from the frame.
b. Make a note of the connections of the wires
on the terminal blocks. Disconnect the wires
at the terminal blocks.
c. Remove the electrical cable with the frame.
If you must remove the frame from the cable,
loosen the fitting for the cable.

1. COVER 6. SCREW 11. SEAL 16. SPOOL

2. SCREW (4) 7. LOCKWASHER 12. O-RING 17. BOLT
3. GASKET 8. WASHER 13. HOUSING 18. PIPE
4. PLUG 9. BRIDGE 14. SPRING 19. COIL
5. FRAME 10. TERMINAL BLOCK 15. RETAINER 20. NUT

Figure 21. Carriage Solenoid Valve

30
1900 SRM 492
2. Remove the four capscrews from the housing and
remove the carriage solenoid valve from the man-
ifold.
Disassemble
NOTE: The solenoid for the carriage solenoid valve
can be replaced without completely disassembling
the valve.
1. Remove the nut and the solenoid coil from the
housing. See Figure 21. Remove the O-ring.
2. Carefully remove the pipe, O-rings, springs,
spring retainers, and the spool. Keep the parts
together.
3. Remove the screws, cover, and seal from the
housing.
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 precau-
tions.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the compressed air path is away
from all personnel. Wear eye protection.
Use solvent to clean the metal parts. Carefully dry
the parts with compressed air. Inspect the bore for
the spool in the housing. Inspect the surfaces of the
spool that slide in the bore. If either the bore or the
spool has scratches, pits, or cracks, replace the car-
riage solenoid valve. Inspect the other parts and re-
place parts that are damaged.
Assemble
NOTE: Install new seals during assembly.
1. Lubricate the spool with clean hydraulic oil. In-
stall the spring retainers and springs on the spool
and install the spool in the housing. See Fig-
ure 21.
2. Install the O-ring and pipe in the housing. In-
stall the coil, O-ring, and nut. Push the other
end of the spool so that the spool compresses
Solenoid Valves Repair
the spring. If the spool does not move freely in
the bore, the carriage solenoid valve must be re-
placed. Install the plug and O-ring for the spool.
3. Install the seal, cover, and screws.
Install
1. Put the carriage solenoid valve on the manifold.
See Figure 21. Align the ports in the valve with
the ports in the manifold. Make sure that the
O-rings are installed.
NOTE: The manifold is not drilled for one of the ports
in the valve.
2. Install the capscrews and tighten them to
14 N•m (10 lbf ft).
3. If the frame was removed from the electrical ca-
ble, install the cable through the fitting. Put the
seal on the housing. Connect the wires at the ter-
minal block.
4. Install the frame, gasket, cover, and screws.
5. Make sure that the fitting for the cable is tight.
The fitting must be tightened on the cable to
make a seal.
OVER LOWERING INTERRUPT
The antislack lift interrupt valve is mounted on the
hydraulic module. See Figure 22. The purpose of this
valve is to prevent the lift chains from getting too
loose. Loose chains can hit the rod of the lift cylinders
and may cause damage.
The valve is activated by the pressure switches.
These switches monitor the load pressures at the
bases of the lift cylinders. There will not be enough
load pressure if the carriage and mast are fully
lowered or there is no carriage or attachment load.
Without this load pressure, the pressure switch will
activate the valve and the pilot pressure will return
to the hydraulic tank. This will prevent further
lowering or forward tilt.
LIFT INTERRUPT
The lift interrupt is active when the attachment is
seated and any of the twist locks of the attachment
are between locked and unlocked. See Figure 22. The
lift interrupt solenoid valve connects the pilot pres-
sure to the hydraulic tank, preventing lift or back-
ward tilt.
31
Specifications 1900 SRM 492

CHECKS AND ADJUSTMENTS

The solenoid valves have no adjustments. The di-
rectional control valve for the carriage and attach-
ment must have correct pilot pressure to operate. See
Pressure Reduction Valves Check in this section to
check the pilot pressure.

Torque Specifications
CONTROL VALVES CONTROL VALVE,
CARRIAGE/ATTACHMENT
Nuts on Through Bolts
61 to 68 N•m (45 to 50 lbf ft) Capscrews, Direction Control Valve Covers
11 N•m (8 lbf ft)
REMOTE CONTROL VALVE
Capscrews, Housing to Mount Plate
Capscrews for Top Plates 14 N•m (10 lbf ft)
5 N•m (44 lbf in)
Solenoid Capscrews
Nuts for Through Bolts 2.3 N•m (20 lbf in)
5 N•m (44 lbf in)
Pilot Valve Mount Capscrews
Hand Lever Lock Nut 9 N•m (80 lbf in)
30 N•m (22 lbf ft)
CARRIAGE SOLENOID VALVE
Adjustment Screw Lock Nut
5 N•m (44 lbf in) Solenoid Capscrews
6.3 N•m (56 lbf in)

Mount Capscrews
14 N•m (10 lbf ft)

Specifications
HYDRAULIC PUMP OUTPUT AT 2500 RPM RELIEF PRESSURES AT 2500 RPM
AND 13.8 MPa (2000 psi)
Control Valves
Tandem Pump (Steering) 17.6 to 18.3 MPa (2550 to 2650 psi)
242 liter/min (64 gal/min)
Two-Speed Cartridge
Tandem Pump (Brakes) 13.5 to 14.1 MPa (1950 to 2050 psi)
91 liter/min (24 gal/min)
Flow Amplifier (Steering)
Auxiliary Circuit Pump 17.2 MPa (2500 psi)
106 liter/min (28 gal/min)
External Relief Valves
PRESSURE REDUCTION VALVES Steering Circuit 21.7 to 22.4 MPa (3150
to 3250 psi)
Pilot Circuits Auxiliary Circuit 21.7 to 22.4 MPa (3150
2.1 MPa (300 psi) to 3250 psi)

Park Brake System

10.3 MPa (1500 psi)

32
1900 SRM 492 Troubleshooting

MAIN HYDRAULIC FILTERS TANK CAPACITY

Relief Setting Dipstick FULL mark
69 to 103 kPa (10 to 15 psi) 325 liter (85.9 gal)

Troubleshooting
CONTROL VALVES

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Oil leaks from end of spool. Caps for spools leak. Tighten or replace caps.

Pilot lines are damaged or leak. Tighten or replace lines.

Spool(s) will not move. The pressure from the remote control Adjust or replace valve.
valve is not correct.

Remote control valve is damage. Replace valve.

Pilot lines are damaged or leak. Tighten or replace lines.

Valve body is not installed correctly. Replace valve.

Spool will not return to the Return spring or springs are dam- Replace springs.
neutral position. aged.

Dirt between spool and bore. Remove dirt. Replace valve.

Spool is damaged. Replace spool.

Spool(s) does not move smoothly be- Replace valve.

cause valve body is not installed cor-
rectly.

Slow or no movement of lift Pressure relief valve(s) is damaged Replace or adjust valve.
cylinder(s). or not correctly adjusted.

Large leaks between spool(s) and Replace valve.

bore(s).

Spool(s) not fully extended or re- Adjust spool or replace valve.

tracted.

Hydraulic pump is damaged. Repair or replace hydraulic pump.

Air is in the system. Remove air from system.

Restriction in the hydraulic lines. Replace lines.

33
Troubleshooting 1900 SRM 492

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Slow or no movement of lift Load is greater than capacity of the Reduce load.
cylinder(s). (Cont.) system.

Damaged check valves in control Replace valve.

valve(s).

Cylinder seals are damaged. Replace seals.

The pressure from the remote control Adjust or replace valve.

valve is not correct.

Remote control valve is damaged. Replace valve.

Check valves for two-speed spool are Replace valve.

damaged.

Hydraulic pressure is above Relief valve is damaged. Replace valve.

or below specifications.

Restriction in the return line. Replace line.

Lift cylinders retract when Oil leaks between spool and bore of Replace valve.
the spool is in the neutral the control valve.
position.

Cylinder seals leak or check valves in Replace seals. Replace valve.

manifold block leak.

Hydraulic lines to cylinder(s) leak. Tighten or replace lines. Remove air

from system.

Tilt cylinders move forward Tilt relief valve(s) does not operate Replace valve.
when the spool is in the neu- correctly.
tral position.

Tilt cylinder seals leak. Replace seals.

Oil leaks between spool and bore. Replace valve.

Hydraulic lines leak. Replace lines.

34
1900 SRM 492 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Tilt cylinders move forward Hydraulic lines between the spool Connect lines properly. Remove air
when the spool is in the back- and the manifold on the tank are from system.
ward tilt position. incorrectly connected.

Lift cylinders retract when Load check valve(s) is damaged. Replace valve.
lift spool is moved to the lift
position.

Check valves for two-speed spool are Replace valve.

open.

Lift cylinders lift slowly with Dirt or damage keeps two-speed Remove dirt. Replace valve.
a light load. spool open. Spool does not move
freely.

Lift cylinders only lift in fast Dirt or damage keeps two-speed Remove dirt. Replace valve.
speed. spool closed. Spool does not move
freely.

Lift cylinders will not lower The circuit between the accumulator Connect or repair circuit.
when the engine is off. and the remote control valve is dam-
aged or not connected.

The accumulator or remote control Replace accumulator or valve.

valve is damaged.

The mast cannot move because of a Remove restriction.

mechanical restriction.

Check valve at base of lift cylinder(s) Replace valve.

is closed.

35
Troubleshooting 1900 SRM 492

REMOTE CONTROL VALVE

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The cylinders that are con- A spool or spools in the remote con- Replace valve.
trolled by the remote control trol valve do not move completely.
valve do not move or move
slowly.

Pilot pressure from the pressure re- Adjust pressure. Replace valve.
duction valve is not correct.

The pilot lines are damaged or have Replace lines.

leaks.

FLOW CONTROL VALVES

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

ACCUMULATOR CHARGE VALVE AND ACCUMULATOR

Remote control valve does Accumulator charge valve does not Replace the valve.
not operate correctly. operate correctly.

Carriage/attachment func- Accumulator charge valve does not Replace valve.

tions do not operate. operate correctly.

Electrical wires are damaged or dis- Connect or replace wires.

connected.

Mast does not lower when Accumulator does not operate cor- Replace accumulator.
the engine is not running. rectly.

Check valve from base of lift cylinder Replace valve.

does not operate.

PRESSURE REDUCTION VALVE 2.1 MPa (300 psi)

Remote control valve does Pressure reduction valve is not ad- Adjust or replace valve.
not operate correctly. justed correctly.

Pressure reduction valve is dam- Replace valve.

aged.

Hydraulic line(s) has a restriction. Replace lines.

36
1900 SRM 492 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Remote control valve does Accumulator charge valve does not Replace valve.
not operate correctly. (Cont.) operate correctly.

Electrical wires are damaged or dis- Connect or replace wires.

connected.

Carriage/attachment func- Pressure reduction valve is not ad- Adjust valve.

tions do not operate. justed correctly.

Pressure reduction valve is dam- Replace valve.

aged.

Hydraulic line(s) has a restriction. Replace lines.

Accumulator charge valve does not Replace valve.

operate correctly.

Parking brake will not re- Pressure reduction valve is not ad- Adjust or replace valve.
lease or inching function for justed correctly.
transmission does not oper-
ate.

Pressure reduction valve is dam- Replace valve.

aged.

Hydraulic line(s) has a restriction. Replace lines.

Accumulator charge valve does not Replace valves.

operate correctly.

PRESSURE REDUCTION VALVE 10.3 MPa (1500 psi)

Parking brake will not re- Pressure reduction valve is not ad- Adjust or replace valve.
lease. justed correctly.

Pressure reduction valve is dam- Replace valve.

aged.

Hydraulic line(s) has a restriction. Replace lines.

Accumulator charge valve does not Replace valve.

operate correctly.

37
Troubleshooting 1900 SRM 492

SOLENOID VALVES

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

An auxiliary function does The switch for the function does not Replace switch.
not operate. operate correctly.

A circuit from the switch to a sole- Replace circuit.

noid is damaged.

Pilot pressure is not correct. Adjust pressure.

The accumulator charge valve does Replace valve.

not operate correctly.

The tandem pump is damaged. Replace pump.

The relief valve for the pump is dam- Replace valve.

aged.

The lines from the attachment con- Replace lines.

trol valve to the selector valves have
damage.

All auxiliary functions have The lines from the attachment con- Connect lines correctly.
reverse operation. trol valve are incorrectly connected
at the manifold for selector valves.

One auxiliary function has The switch is incorrectly connected Reconnect switch.
reverse operation. to the solenoids on the pilot valve.

CONTROL VALVE FOR CARRIAGE AND ATTACHMENT

An auxiliary function does A solenoid for the pilot spool is dam- Replace solenoid.
not operate. aged.

Dirt or damage keeps the pilot spool Remove dirt. Replace spool.
from moving.

Dirt or damage keeps the direction Remove dirt. Replace spool.

control spool from moving.

A spool return spring is damaged. Replace spring.

The line for pilot pressure has a leak Replace line.

or a restriction.

The control valve for the carriage Repair leaks. Replace valve.
and attachment has internal or ex-
ternal leaks.

38
1900 SRM 492 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

An auxiliary function does The solenoid does not work correctly. Replace solenoid.
not operate.

Dirt or damage keeps the spool from Remove dirt. Replace spool.
moving.

A spool return spring is damaged. Replace spring.

The selector valve is incorrectly in- Install valve correctly.

stalled on the manifold.

The lines from the selector valve Replace lines.

(manifold) to the cylinder(s) have
damage.

39
Diagrams, Schematics, or Arrangements 1900 SRM 492

40
1900 SRM 492 Diagrams, Schematics, or Arrangements

Figure 22. Hydraulic System Arrangement

41
Diagrams, Schematics, or Arrangements 1900 SRM 492

Legend for Figure 22

1. HYDRAULIC TANK
2. DRAIN LINE
3. TANDEM HYDRAULIC PUMP
4. SUCTION LINE
5. SUPPLY TO BRAKE SYSTEM (ACCUMULATOR CHARGE VALVE)
6. SUPPLY TO STEERING SYSTEM (FLOW AMPLIFIER)
7. SINGLE HYDRAULIC PUMP
8. SUPPLY TO ATTACHMENT CONTROL VALVE
9. FLOW AMPLIFIER
10. DRAIN MANIFOLD
11. TWO-SPOOL CONTROL VALVE
12. CHECK PORT 7 (STEERING SYSTEM)
13. CHECK PORT 6 (TWO-SPOOL CONTROL VALVE)
14. CHECK PORT 5 (SINGLE-SPOOL CONTROL VALVE)
15. CHECK PORT 4 (ACCUMULATOR CHARGE VALVE)
16. CHECK PORT 3 (PRESSURE REDUCTION VALVE)
17. CHECK PORT 2 (PRESSURE REDUCTION VALVE)
18. CHECK PORT 1 (AUXILIARY CIRCUIT)
19. SINGLE-SPOOL CONTROL VALVE
20. AUXILIARY CIRCUIT RELIEF VALVE
21. PRESSURE REDUCTION VALVE [2.1 MPa (300 psi)]
22. CHECK VALVE
23. VALVE MOUNTING PLATE
24. DIRECTIONAL CONTROL VALVE
25. BRAKE SYSTEM RELAY VALVE
26. ACCUMULATOR
27. PRESSURE REDUCTION VALVE [10.3 MPa (1500 psi)]
28. BRAKE SYSTEM PILOT VALVE
29. TO/FROM BASE OF LIFT CYLINDERS
30. TO/FROM TOP OF LIFT CYLINDERS
31. TO/FROM TILT CYLINDERS
32. TO/FROM AUXILIARY CIRCUIT
33. TILT CYLINDER JUNCTION BLOCK
34. PILOT LINE
35. MANIFOLD BLOCK
36. ACCUMULATOR CHARGE VALVE
37. PUMP PRESSURE
38. DRAIN TO TANK
39. RIGHT-SIDE STEERING CYLINDER
40. FROM STEERING CONTROL UNIT (LEFT TURN)
41. LEFT-SIDE STEERING CYLINDER
42. FROM STEERING CONTROL UNIT (RIGHT TURN)
43. INLET
44. PILOT DRAIN
45. TO SELECTOR VALVES (ROD SIDE)
46. TO SELECTOR VALVES (PISTON SIDE)
47. OUTLET
48. PILOT SUPPLY
49. HYDRAULIC OIL COOLER (OPTIONAL)
50. ANTISLACK OR LIFT INTERRUPT SOLENOID VALVE

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Diagrams, Schematics, or Arrangements 1900 SRM 492

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1900 SRM 492 Diagrams, Schematics, or Arrangements

Figure 23. Hydraulic System Schematic

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Diagrams, Schematics, or Arrangements 1900 SRM 492

Figure 24. Container Attachment Schematic (Until E008E 01811)

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Diagrams, Schematics, or Arrangements 1900 SRM 492

48
1900 SRM 492 Diagrams, Schematics, or Arrangements

Figure 25. Container Attachment Schematic (E008 E 01811 and After)

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 TECHNICAL PUBLICATIONS

1900 SRM 492 3/03 (5/02)(5/92) Printed in U.S.A.