HYDRAULIC SYSTEM

RS45-27CH, RS45-31CH, RS46-36CH, RS46-

40CH, RS46-41S CH, RS46-41L CH, RS46-41LS
CH, RS45-24IH, RS45-28IH, RS46-33IH,
RS46-37IH, RS46-38S IH, RS46-38L IH,
RS46-38LS IH (HR45-27, HR45-31,
HR45-36, HR45-40, HR45-41S, HR45-41L,
HR45-41LS) [B222]

PART NO. 1638189 1900 SRM 1257

 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 Plate.............................................................................................................................................. 1
Hydraulic Pumps ........................................................................................................................................... 2
LS System ...................................................................................................................................................... 2
Load Limiter .................................................................................................................................................. 3
Control Blocks................................................................................................................................................ 3
General....................................................................................................................................................... 3
Main Manifold ........................................................................................................................................... 3
Cab Manifold ............................................................................................................................................. 3
Derricking Functions..................................................................................................................................... 3
Load Holding Valve (Derricking) .............................................................................................................. 3
Load Holding Valve (Extension) ............................................................................................................... 3
Balance Selector Valve .............................................................................................................................. 3
Heat Exchanger System................................................................................................................................ 3
Steering Control System ............................................................................................................................... 3
Flow Amplifier ........................................................................................................................................... 3
Brake System................................................................................................................................................. 4
Oil Cooled Brakes (Service Brakes).............................................................................................................. 4
Hydraulic Pump Repair..................................................................................................................................... 4
General ........................................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Disassemble ................................................................................................................................................... 6
Hydraulic Pump Assembly ....................................................................................................................... 6
Variable Displacement Pump ................................................................................................................... 6
Clean and Inspect .......................................................................................................................................... 7
Assemble ........................................................................................................................................................ 8
Variable Displacement Pump ................................................................................................................... 8
Hydraulic Pump Assembly ....................................................................................................................... 8
Install ............................................................................................................................................................. 8
Pump Output Check ...................................................................................................................................... 9
First Method .............................................................................................................................................. 9
Second Method .......................................................................................................................................... 10
Cab Manifold ...................................................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Disassemble Valves and Pressure Switches................................................................................................. 11
Clean and Inspect .......................................................................................................................................... 11
Assemble Valves and Pressure Switches...................................................................................................... 13
Install ............................................................................................................................................................. 13
Derricking Circuit .............................................................................................................................................. 14
Repair ............................................................................................................................................................. 14
Load Holding Valve ................................................................................................................................... 14
Remove .................................................................................................................................................. 14
Disassemble........................................................................................................................................... 14
Clean and Inspect ................................................................................................................................. 14
Assemble................................................................................................................................................ 15
Install..................................................................................................................................................... 16
Derricking Cylinders................................................................................................................................. 16
Boom Extension Circuit..................................................................................................................................... 16
Repair ............................................................................................................................................................. 16
Load Holding Valve ................................................................................................................................... 16

©2007 HYSTER COMPANY i

Table of Contents Hydraulic System

TABLE OF CONTENTS (Continued)

Remove .................................................................................................................................................. 16
Disassemble........................................................................................................................................... 16
Clean and Inspect ................................................................................................................................. 17
Assemble................................................................................................................................................ 18
Install..................................................................................................................................................... 18
Boom Extension Cylinder ......................................................................................................................... 18
Attachment Circuit Valves ................................................................................................................................ 18
Description and Operation ............................................................................................................................ 18
Other Hydraulic Components ........................................................................................................................... 19
Description and Operation ............................................................................................................................ 19
Relief Valves in Steering System.............................................................................................................. 19
Pilot Pressure Valve .................................................................................................................................. 19
Dampening Cylinders ............................................................................................................................... 19
Hydraulic Filters ....................................................................................................................................... 19
Hydraulic Filters ........................................................................................................................................... 19
Suction Filters ........................................................................................................................................... 19
High Pressure Filter ................................................................................................................................. 20
Brake Filter ............................................................................................................................................... 20
Return Line Filters ................................................................................................................................... 21
Hydraulic Tank Breathers ............................................................................................................................ 22
Hydraulic Hose Repair .................................................................................................................................. 22
Checks and Adjustments............................................................................................................................... 22
Pilot Setting, Check................................................................................................................................... 22
Main Function Relief Valve Pressure, Check .......................................................................................... 23
Specifications...................................................................................................................................................... 24
Hydraulic Pumps Output at 2100 rpm (Governed Speed) .......................................................................... 24
Cummins 300Hp (224 kW)/335 Hp (250 kW) Engine.............................................................................. 24
Relief Valves (Approximate Operating Pressures) ...................................................................................... 24
Check Port Pressures .................................................................................................................................... 24
Main Hydraulic Filters.................................................................................................................................. 25
Tank Capacity ................................................................................................................................................ 25
Torque Specifications ......................................................................................................................................... 25
Remote Control Valves .................................................................................................................................. 25
Attachment Control Valve............................................................................................................................. 25
Carriage Solenoid Valve ................................................................................................................................ 25
Troubleshooting.................................................................................................................................................. 26
Diagrams, Schematics, or Arrangements ......................................................................................................... 29

This section is for the following models:

RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L

CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH,RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222]

ii
1900 SRM 1257 Description and Operation

General
This section has the description and operation of the • Service Brake 1800 SRM 1038
hydraulic system. The section also has repair pro- • Hydraulic Plate 2000 SRM 1258
cedures and troubleshooting for most of the compo- • Stabilizer 2120 SRM 1361
nents of the derricking, telescoping, and attachment • Extendable Container Attachment (Elme)
systems. The complete hydraulic system includes 5000 SRM 776
the circuits for the steering system, brake system, • Intermodal Container Attachment 5000 SRM
stabilizer (if equipped), and attachment. See the fol- 777
lowing sections for description, operation, and repair
information of hydraulic components in these sys- Also, see the following sections for other hydraulic
tems: components:
• Steering System 1600 SRM 1109 • Brake Accumulator 1800 SRM 1036
• Parking Brake 1800 SRM 1117 • Boom 4500 SRM 1260

Description and Operation

The hydraulic system is based on a variable load HYDRAULIC PLATE
sensed system that is hydraulically operated.
Most of the valves in the hydraulic system are in-
The main components are as follows: stalled on the hydraulic plate. See Figure 1. The
• Two variable displacements pumps and one gear module is installed on isolators in a compartment in
pump the middle of the frame. Covers give access to the
• The main control valve module, which can be removed on the top side of the
• Control blocks frame.
• Load holding valves
• Hydraulic joystick valve The hydraulic plate has four distinct sections:
• Orbitrol and flow amplifier for the steering system
Section 1 Manifold Section
• Cooling Circuit
Section 2 Main Control Valve Section
Three hydraulic pumps supply the flow of oil for the
components of the hydraulic system. These pumps Section 3 Brake Manifold Section
are driven by a power takeoff arrangement on both Section 4 Flow Amplifier Section
sides of the transmission housing. The inlet hoses for
the pumps are connected at the manual pilot shut-off
For further information, see the section Hydraulic
valve.
Plate 2000 SRM 1258

1
Description and Operation 1900 SRM 1257

1. MANIFOLD SECTION 3. BRAKE MANIFOLD SECTION

2. MAIN CONTROL VALVE SECTION 4. FLOW AMPLIFIER SECTION

Figure 1. Hydraulic Plate Sections

HYDRAULIC PUMPS LS SYSTEM

There are three hydraulic pumps (two variable dis- The LS (load sense pressure) system works on the
placement pumps and one gear pump) on the Lift following principles:
Truck. See the sectionDiagrams 8000 SRM 1261. • When flow is passing a spool of the main valve it
On the RH side variable displacement pump is the will cause a pressure drop. The spool acts as a
single gear pump mounted that supplies flow for the (variable) restrictor. This causes pressure between
brake cooling system. The function of these three the pump and the spool to be higher then between
pumps are as follows: the spool and cylinder.
• Variable Displacement Pump LH - supplies oil • The pump will maintain a preset pressure drop be-
directly to the main control Valve for derricking tween the pump pressure and the LS pressure. The
up/down, extend/retract, and ELME attachment. LS pressure is always the required function pres-
• Variable Displacement Pump RH- supplies oil to sure. The pump pressure is the LS pressure + the
the flow amplifier to supply flow to the steering preset pressure drop. When two or more functions
system when needed. All excess flow is supplied are operated at the same time, the highest required
to the main control valve. function pressure will be the LS pressure.
• Gear Pump - supplies oil for the brake cooling sys- • When no function is operated, the pump will pres-
tem. surize the line to the functions. The pump pres-
sure will be the preset pressure drop + LS pres-
The variable displacement pumps are based on the sure, which will be 0 bar (0 psi). When a function
load sense principle, when means that they only will requests partial or the maximum pump flow, the
supply the requested flow and are limited by the re-
quested torque.

2
1900 SRM 1257 Description and Operation

pumps will supply the necessary amount of flow to Load Holding Valve (Extension)
generate the preset pressure drop.
This block mounted on the base of the telescope cylin-
LOAD LIMITER der has the following two functions:
• Blocks the piston side of the cylinder for unwanted
The maximum torque that the pumps can take from leakage. When telescope retract function is applied
the transmission is limited by a preset value. When the rod side must be pressurized to open the blocks.
the requested torque is higher then this preset value • Regeneration valve, connects the rod side with the
the displacement of the pump will be reduced so that piston side when two speed telescope extend is ap-
the supplied torque is equal this pre set value. This plied.
means that the function speed will be reduced when
higher pressures are required. Balance Selector Valve
CONTROL BLOCKS The balance selector valve is located at the accumu-
lator valve and is connected with hydraulic hoses to
General the left and right derricking cylinder. During lower-
ing of the derricking cylinders the balance selector
There are two control blocks in the hydraulic system. valve will be open and regulates the pressure so that
One is positioned on the hydraulic plate and one is the pressure is equal in the left and right derricking
located underneath the cab. cylinder. During lifting of the derricking cylinders
the balance selector valve is closed.
Main Manifold
HEAT EXCHANGER SYSTEM
For further explanation of the main manifold, see the
section Hydraulic Plate 2000 SRM 1258. The heat exchanger system is used to cool the hy-
draulic system oil. The pump circulates oil from
Cab Manifold the hydraulic tank through the thermostatic bypass
valve to the brakes. If the oil is above 70 C (158 F),
The cab manifold regulates the pilot supply to the the valve sends the oil through the air-to-oil heat
main valve. The selector valve CM10, CM11, and exchanger for cooling. See the section Diagrams
CM 12 are used to interrupt the function when the 8000 SRM 1261.
LMI requires this. The selector valve (CM13) is used
for two speed retract of the telescope function. The STEERING CONTROL SYSTEM
pressure switches supplies output signals when main
functions are used. The steering control system has a steering unit and a
flow amplifier. See Hydraulic Schematic. The steer-
The cab manifold is fastened at the underside of the ing unit is actuated by the steering wheel. Hydraulic
cab floor, and has inlet and outlet sections. pilot lines connect the steering unit in the cab to the
flow amplifier on the hydraulic plate in the frame.
DERRICKING FUNCTIONS Two large hydraulic lines connect the flow amplifier
and the steering cylinder. See the section Steering
Load Holding Valve (Derricking) System 1600 SRM 1109
This block mounted on the base of each derrick cylin-
Oil not used for steering flows to the inlet of the main
der has the following four functions:
control valve. Oil returning from the steering cylin-
• Blocks the piston side of the cylinder for unwanted
der flows to the flow amplifier, return manifold, and
leakage. This logical element will be closed when
back to the tank.
LH2 is not applied.
• Lowering control valve, limits the max. flow of the Flow Amplifier
piston side during lowering.
• Regeneration valve, connects the rod side with the The steering unit is a manual metering pump that
piston side when two speed lifting is applied. gives hydraulic control of several valves in the flow
• Impact relief valve, to release the pressure on the amplifier. The action of steering sends hydraulic sig-
piston side when the boom is hit during backing up. nals from the control unit to the flow amplifier. The
flow amplifier then sends a regulated flow of oil to the
steering cylinder. The output from the flow amplifier

3
Hydraulic Pump Repair 1900 SRM 1257

to the steering cylinder is five times larger than the Table 1. Brake Treadle Settings
input from the steering unit.
Service Brake
BRAKE SYSTEM Service Brake (MSB1)
Treadle (MSB4)

Oil from the hydraulic pump goes to an accumulator 17.0 to 17.5 MPa Maximum 16 MPa
charge valve to make sure the brake system has (2466 to 2538 psi) (2320 psi)
enough pressure to operate the brakes. See Hy-
draulic Schematic. A pressure switch connected to OIL COOLED BRAKES (SERVICE
the brake circuit operates a warning light for the
BRAKES)
operator when brake pressure is low. The pump,
accumulator valve, and accumulator maintain the Oil for activating the service brakes comes from the
brake pressure and oil flow to brakes at each drive main manifold. The service brake pedal (treadle
wheel. The system also supplies oil flow and pres- valve) controls the pressure of the oil to the service
sure to operate the parking brake on the drive line brake piston at each drive wheel. See the section
near the differential. See the section Service Brake Service Brake 1800 SRM 1038.
1800 SRM 1038
The pressure of the hydraulic oil supplied to the
Oil pressure from the accumulator is supplied to the brake manifold can be checked at check port MSB4
brake treadle. The right-hand pedal only activates on the cab manifold.
the service brakes. The left hand pedal first activates
an electrical signal, and via the APC 200 controller, The hydraulic line to the brake manifold is also func-
will fully disengage the transmission. The service tioning as a return line when the brake/inching trea-
brakes will then be activated. The left hand pedal is dle is not operated. Oil flows back through the brake/
the brake pedal. Both pedals will engage the brake inching treadle and return manifold to the hydraulic
pressure switch to operate the stop lights. For ser- tank.
vice brake and service brake treadle pressures, see
Table 1. Brake pressure can be measured at check
port MSB1 and MSB4.

Hydraulic Pump Repair

GENERAL make sure that the boom cannot lower sud-
denly and cause injury or death.
NOTE: Worn or damaged seals are the most common
cause of hydraulic pump repair. The seals can be 1. Place the truck on a solid and level surface.
replaced in the hydraulic pump. The pump thrust
plates, bearings, gears, and shafts also wear. Replace 2. Lower boom and close the shutoff valves at the
a worn or damaged hydraulic pump. For making re- bottom of the hydraulic tank platform.
pairs to components within the hydraulic system, see
3. Shut down the engine.
the following sections:
• Service Brake 1800 SRM 1038 4. Remove covers on the topside of the frame.
• Steering System 1600 SRM 1109
• Parking Brake 1800 SRM 1117 NOTE: The pump assembly has two suction hoses
and two high-pressure lines.
REMOVE
NOTE: When disconnecting the suction hose at the
variable displacement pump, raise hose quickly and
WARNING
install a plug to avoid leakage from the hose.
Lower boom completely before working on
control valve or hydraulic system. The boom 5. Disconnect suction hose at the variable displace-
can lower suddenly and cause injury if the ment pump.
boom is not lowered. This procedure will

4
1900 SRM 1257 Hydraulic Pump Repair

6. Disconnect high-pressure line at the outlet port it falls. Verify that the pump assembly is prop-
on the pump side of the variable displacement erly supported before removing capscrews.
pump. Raise the end of the line above hydraulic
tank platform until a plug is installed in the line. 8. Remove the four capscrews (RH-pump) or two
capscrews (LH-pump) and remove pump assem-
7. Disconnect the suction hose and high-pressure bly from the torque converter housing. See Fig-
line at the gear-type pump. Install plugs. ure 2.

9. Remove the O-ring.

WARNING
Each pump assembly weighs approximately 10. Repeat Step 4 through Step 8 for the second hy-
45 kg (100 lb) and can cause injury or damage if draulic pump assembly.

1. CAPSCREWS
2. VARIABLE DISPLACEMENT PUMP (LH)
3. CAPSCREW
4. HYDRAULIC GEAR PUMP
5. VARIABLE DISPLACEMENT PUMP (RH)

Figure 2. Hydraulic Pump Assembly

5
Hydraulic Pump Repair 1900 SRM 1257

DISASSEMBLE 4. Remove the four socket head bolts that hold the
port plate to the pump housing.
Hydraulic Pump Assembly
5. Separate the port plate from the pump housing.
1. Remove the two capscrews that hold the hy-
draulic pump to the variable displacement 6. Remove the bearing from the drive shaft.
pump. See Figure 2.
7. Remove the adjustment shim from the drive
Variable Displacement Pump shaft.

1. Disconnect the hydraulic line between the two 8. Remove the O-rings from the pump housing.
control valves. See Figure 3. 9. Remove the swash plate section out of the pump
2. Remove the hydraulic line. Put caps on the fit- housing.
tings. 10. Repeat Step 1 through Step 9 for the second vari-
3. Remove the splined hub from the drive shaft. See able displacement pump.
Figure 4.

1. CONTROL VALVE 2. HYDRAULIC LINE 3. CONTROL VALVE

Figure 3. Variable Displacement Pump Assembly

6
1900 SRM 1257 Hydraulic Pump Repair

1. DRIVE SHAFT 7. O-RING

2. PUMP HOUSING 8. PORT PLATE
3. SWASH PLATE SECTION 9. O-RING
4. O-RING 10. ADJUSTMENT SHIM
5. SOCKET HEAD BOLTS 11. BEARING
6. SPLINED HUB 12. CYLINDER PIN

Figure 4. Variable Displacement Pump

CLEAN AND INSPECT parts. Pieces of cloth can cause restrictions in hy-
draulic system.
WARNING Inspect gear assemblies and housing parts for wear
Cleaning solvents are flammable and toxic and and damage. Replace a damaged or worn hydraulic
can cause skin irritation. When using cleaning pump. If gears are replaced, they must be replaced
solvents, always follow the solvent manufac- as matched sets.
turer’s recommended safety procedures. Wear
protective goggles or a face shield to prevent NOTE: Some pump bodies will show gear marks
eye injuries. where the gears rotate because of the small clear-
ances between parts. These gear marks do not
Clean all parts of pump with solvent. Use com- indicate a worn or damaged pump unless the pump
pressed air to dry parts. Do not use a cloth to dry will not supply the volume and pressure shown in
the Specifications.

7
Hydraulic Pump Repair 1900 SRM 1257

ASSEMBLE
WARNING
Variable Displacement Pump Each pump assembly weighs approximately
45 kg (100 lb) and can cause injury or damage
NOTE: Use new O-rings during assembly if it falls.
NOTE: Lubricate parts with hydraulic oil before as- 2. Install pump assembly on the torque convert-
sembly. ing housing. Use a sealant on the flange of the
pump assembly. Tighten capscrews to 90 N•m
1. Verify internal parts of the pump are clean. (66 lbf ft).
2. Install the swash plate section in the pump hous- 3. Connect the hydraulic hoses to the pump assem-
ing. bly. Tighten capscrews for flange of high-pres-
3. Install the O-rings in the pump housing. sure hoses to 190 N•m (140 lbf ft). If necessary,
tighten capscrews for flange of suction hose to
4. Install the adjustment shim on the drive shaft. 88 N•m (65 lbf ft).

5. Install the bearing on the drive shaft. 4. Repeat Step 1 through Step 3 for the second hy-
draulic pump.
6. Align the port plate to the pump housing with the
cylinder pin. See Figure 4.
WARNING
7. Assemble the port plate to the pump hous- Never start the engine when pumps are not
ing with four socket head bolts and tighten to filled with oil. Verify that the pumps are filled
310 N•m (229 lbf ft). with oil by removing the drain line and fill the
pump chamber by using the drain opening.
8. Install the splined hub on the drive shaft. Otherwise this can cause serious damage and
loss of durability to the pump(s).
9. Install and connect the hydraulic line between
the two control valves.
CAUTION
10. Repeat Step 1 through Step 9 for the second vari- Never start the engine with closed shutoff
able displacement pump. valves. Open the shutoff valves before starting
the engine to prevent damage to hydraulic
Hydraulic Pump Assembly components.
NOTE: Use new O-rings during assembly.
5. Start engine and operate hydraulic system.
1. Install the two capscrews that hold the hydraulic Check that functions work correctly.
pump to the variable displacement pump and
tighten to 45 N•m (33 lbf ft). WARNING
Do not try to locate hydraulic leaks by putting
INSTALL hands on pressurized hydraulic components.
1. Clean flange of the pump assembly and mount- Hydraulic oil can be injected into the body by
ing surface on the torque converting housing. pressure.

6. Check for leaks.

7. Install covers on the topside of the frame.

8
1900 SRM 1257 Hydraulic Pump Repair

PUMP OUTPUT CHECK no load on hydraulic system. Note reading of flow

meter. Compare output rate of pump with speci-
Two methods are given for checking the volume of fication found in the Specifications section.
flow from the hydraulic pump. The first method uses
a flow meter, a pressure gauge, and a needle valve.
The second method uses a needle valve, a pressure WARNING
gauge, a container, and a timer. Hydraulic oil can be hot. Do not touch oil dur-
ing tests.
First Method
2. Run engine at high limit. Slowly close needle
1. If the flow meter is available, install flow meter valve until gauge indicates a pressure just below
between needle valve and outlet port of pump. specification for relief valve setting. Pump out-
See Figure 5. Pressure gauge must be between put at high pressure must be within 25% of out-
needle valve and pump. Make a separate check put with no load. If output at high pressure is
for each system. When hydraulic oil is at oper- less than 75% of low pressure output, pump has
ating temperature, run engine at 2100 rpm with a problem.

1. HYDRAULIC PUMP 5. PRESSURE GAUGE

2. INLET PORT 6. TEE FITTING
3. OUTLET PORT 7. FLOW METER
4. HYDRAULIC TANK 8. NEEDLE VALVE

Figure 5. Check Output of Hydraulic Pump With Flow Meter

9
Hydraulic Pump Repair 1900 SRM 1257

Second Method 2. Needle valve must be fully open. Start engine

and run engine at its governed RPM for 5 sec-
1. Another method of checking pump output is to onds. Stop engine. Measure volume of oil that
measure the amount of oil moved in a given entered container in 5 seconds. Multiply quan-
amount of time. See Figure 6. Run engine until tity in container by 12 to find output per minute.
oil is 55 to 65 C (130 to 150 F). Disconnect line Compare pump output rate with specifications
from outlet port of pump. Install a 0 to 21 MPa found in the Specifications section. Pump output
(0 to 3050 psi) pressure gauge on a tee fitting rate must be within 20% of specifications.
connected to a hose from outlet port. Install
needle valve on end of hose. Connect another 3. Start engine and run engine at its governed
hose to needle valve. Put other end of hose in a RPM. Close needle valve until pressure increases
container with an 18 liter (5 gal) capacity. Make to just below relief valve setting. Measure vol-
sure reservoir is full. ume of fluid that pump moves in 5 seconds.
Compare this quantity with results from test of
CAUTION pump output at low pressure. Output of pump
at high pressure must be within 25% of volume
This test must be done quickly to prevent hy-
of oil flow at low pressure.
draulic tank from becoming empty. Do not op-
erate engine when there is no oil in hydraulic
tank.

1. HYDRAULIC PUMP 6. TEE FITTING

2. INLET PORT 7. NEEDLE VALVE
3. OUTLET PORT 8. CONTAINER
4. HYDRAULIC TANK 9. TIMER
5. PRESSURE GAUGE

Figure 6. Check Output of Hydraulic Pump With Container

10
1900 SRM 1257 Cab Manifold

Cab Manifold
REMOVE NOTE: Cartridge valves and switches are not field
serviceable with exception of external seals and elec-
NOTE: All pressure switches, valves, and other as- trical solenoids. In event of a defective component,
sociated items installed on the manifold can be re- completely replace valve or switch.
placed. Before removal of any part, check that the
area is clean and protected against dirt and fluid con- NOTE: Check manifold for cracks. If there are cracks
tamination. in manifold, the manifold must be replaced.

The valves and pressure switch seals are serviceable

WARNING parts of the manifold. Use the following procedures
Lower boom completely before working on for repair:
control valve or hydraulic system. The boom
can lower suddenly and cause injury if the 1. Unscrew the cartridge valve or switch from man-
boom is not lowered. This procedure will ifold. See Figure 7.
make sure that the boom cannot lower sud-
denly and cause injury or death. 2. Check that all seals are attached to cartridge
valve or switch.
1. Place the truck on a solid and level surface.
3. Install a temporary plug in place of cartridge
2. Lower boom and close the shutoff valves at the valve or switch.
bottom of the hydraulic tank platform.
CLEAN AND INSPECT
3. Shut down the engine.
WARNING
WARNING Cleaning solvents can be flammable and toxic
Move all control levers back and forth a mini- and can cause skin irritation. When using
mum of 20 times to remove all hydraulic pres- cleaning solvents, always follow the solvent
sure from pilot system. manufacturer’s recommended safety precau-
tions.
4. Remove the covers on the topside of the frame.
Compressed air can move particles and cause
5. Put tags for identification on hydraulic lines. injury to the user or to other personnel. Make
Disconnect the hydraulic lines from the cab sure compressed air path is away from all per-
manifold. Put caps on the open lines, ports or sonnel. Wear eye protection.
other connectors.
1. Clean cartridge valve or switch in solvent and
6. Remove the three capscrews that fasten the cab carefully dry the parts with compressed air.
manifold under the cab floor.
2. Inspect the bores for damage. If there are
7. Remove the cab manifold. scratches or other damage, the manifold must
be replaced.
DISASSEMBLE VALVES AND PRESSURE
SWITCHES 3. Inspect the fittings, O-rings, and check valves for
damage. Replace damaged parts.
NOTE: Only use plugs that have been cleaned in sol-
vent.

NOTE: In the event that seals are missing, check

manifold for missing seals and remove.

11
Cab Manifold 1900 SRM 1257

1. VALVE 6. FITTING
2. FITTING 7. FITTING
3. O-RING 8. O-RING
4. SEAL 9. PRESSURE SWITCH
5. PRESSURE SWITCH 10. QUICK DISCONNECT FITTING

Figure 7. Cab Manifold

12
1900 SRM 1257 Cab Manifold

ASSEMBLE VALVES AND PRESSURE

WARNING
SWITCHES
Do not try to locate hydraulic leaks by putting
1. Install new seals. hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
2. Lubricate component/valve with clean hydraulic pressure.
oil before installation.

3. Remove temporary plug. CAUTION

Never start the engine with closed shutoff
4. Install and torque component/valve or switch to valves. Open the shutoff valves before starting
value listed in the Torque Specifications. the engine to prevent damage to hydraulic
components.
INSTALL
4. Start the engine and operate the hydraulic sys-
1. Position the cab manifold under the cab floor. tem. Check that functions of the cab manifold
2. Install the three capscrews that fasten the cab work correctly. Check for any leaks.
manifold under the cab floor. 5. Install the covers at the top side of the frame.
3. Remove caps and connect the hydraulic lines to
the cab manifold according to the identification
tags made during removal.

13
Derricking Circuit 1900 SRM 1257

Derricking Circuit
REPAIR Disassemble

Load Holding Valve NOTE: Only use plugs that have been cleaned in sol-
vent.
Remove
NOTE: In the event that seals are missing, check
manifold for missing seals and remove.
WARNING
Lower boom completely before working on NOTE: Cartridge valves are not field serviceable with
control valve or hydraulic system. The boom exception of external seals and electrical solenoids.
can lower suddenly and cause injury if the In event of a defective component, completely replace
boom is not lowered. This procedure will valve.
make sure that the boom cannot lower sud-
denly and cause injury or death. NOTE: Check load holding valve for cracks. If there
are cracks in load holding valve, the load holding
NOTE: All valves and other associated items in- valve must be replaced.
stalled on the load holding valve can be replaced.
Before removal of any part, check that the area is The valve seals are serviceable parts of the load hold-
clean and protected against dirt and fluid contami- ing valve. Use the following procedures for repair:
nation. 1. Unscrew the cartridge valve from the load hold-
ing valve. See Figure 8.
1. Place the truck on a solid and level surface. 2. Check that all seals are attached to cartridge
valve.
2. Lower boom and close the shutoff valves at the 3. Install a temporary plug in place of cartridge
bottom of the hydraulic tank platform. valve.
3. Shut down the engine. Clean and Inspect

WARNING WARNING
Move all control levers back and forth a mini- Cleaning solvents can be flammable and toxic
mum of 20 times to remove all hydraulic pres- and can cause skin irritation. When using
sure from pilot system. cleaning solvents, always follow the solvent
4. Put tags for identification on electrical wires. manufacturer’s recommended safety precau-
Disconnect the electrical wires from the load tions. Compressed air can move particles and
holding valve. cause injury to the user or to other personnel.
Verify compressed air path is away from all
5. Put tags for identification on hydraulic lines. personnel. Wear eye protection.
Disconnect the hydraulic lines from the load
holding valve. Put caps on the open lines, ports 1. Clean cartridge valve in solvent and carefully dry
or other connectors. the parts with compressed air.

6. Remove the four capscrews that fasten the load 2. Inspect the bores for damage. If there are
holding valve to the derricking cylinder. scratches or other damage, the load holding
valve must be replaced.
7. Remove the load holding valve.
3. Inspect the fittings, O-rings, and check valves for
damage. Replace damaged parts.

14
1900 SRM 1257 Derricking Circuit

1. PLUG 9. VALVE (DIRECTIONAL CONTROL)

2. VALVE 10. PLUG
3. VALVE 11. PLUG
4. VALVE (DIRECTIONAL CONTROL) 12. CHECK VALVE
5. RELIEF VALVE 13. PLUG
6. PLUG 14. VALVE
7. SCREW 15. SCREW
8. PLUG

Figure 8. Load Holding Valve

Assemble 3. Remove temporary plug.

1. Install new seals. 4. Install and torque component/valve to value

listed in the section .
2. Lubricate component/valve with clean hydraulic
oil before installation.

15
Boom Extension Circuit 1900 SRM 1257

Install Hydraulic oil can be injected into the body by

pressure.
1. Position the load holding valve on the derricking
cylinder.
CAUTION
2. Install the four capscrews that fasten the load Never start the engine with closed shutoff
holding valve onto the derricking cylinder. valves. Open the shutoff valves before starting
the engine to prevent damage to hydraulic
3. Remove caps and connect the hydraulic lines to
components.
the load holding valve according to the identifi-
cation tags made during removal. 5. Start the engine and operate the hydraulic sys-
tem. Check that functions of the load holding
4. Connect the electrical wires to the load holding
valve work correctly. Check for any leaks.
valve according to the identification tags made
during removal. Derricking Cylinders

WARNING See the section Boom 4500 SRM 1260 for descrip-
tion, operation and repair information of the derrick-
Do not try to locate hydraulic leaks by putting
ing cylinders.
hands on pressurized hydraulic components.

Boom Extension Circuit

REPAIR 4. Put tags for identification on electrical wires.
Disconnect the electrical wires from the load
Load Holding Valve holding valve.

Remove 5. Put tags for identification on hydraulic lines.

Disconnect the hydraulic lines from the load
WARNING holding valve. Put caps on the open lines, ports
Lower boom completely before working on or other connectors.
control valve or hydraulic system. The boom 6. Remove the four capscrews that fasten the load
can lower suddenly and cause injury if the holding valve to the rear side of the outer boom.
boom is not lowered. This procedure will
make sure that the boom cannot lower sud- 7. Remove the load holding valve.
denly and cause injury or death.
Disassemble
NOTE: All valves, and other associated items in-
stalled on the load holding valve can be replaced. NOTE: Only use plugs that have been cleaned in sol-
Before removal of any part, check that the area is vent.
clean and protected against dirt and fluid contami-
nation. NOTE: In the event that seals are missing, check
manifold for missing seals and remove.
1. Place the truck on a solid and level surface.
NOTE: Cartridge valves are not field serviceable with
2. Lower boom and close the shutoff valves at the exception of external seals and electrical solenoids.
bottom of the hydraulic tank platform. In event of a defective component, completely replace
valve.
3. Shut down the engine.
NOTE: Check load holding valve for cracks. If there
are cracks in load holding valve, the load holding
WARNING valve must be replaced.
Move all control levers back and forth a mini-
mum of 20 times to remove all hydraulic pres- The valve seals are serviceable parts of the load hold-
sure from pilot system. ing valve. Use the following procedures for repair:

16
1900 SRM 1257 Boom Extension Circuit

1. Unscrew the cartridge valve from the load hold- cause injury to the user or to other personnel.
ing valve. See Figure 9. Verify compressed air path is away from all
2. Check that all seals are attached to cartridge personnel. Wear eye protection.
valve.
3. Install a temporary plug in place of cartridge 1. Clean cartridge valve in solvent and carefully dry
valve. the parts with compressed air.

Clean and Inspect 2. Inspect the bores for damage. If there are
scratches or other damage, the load holding
valve must be replaced.
WARNING
Cleaning solvents can be flammable and toxic 3. Inspect the fittings, O-rings, and check valves for
and can cause skin irritation. When using damage. Replace damaged parts.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions. Compressed air can move particles and

1. VALVE 7. PLUG
2. VALVE 8. PLUG
3. CHECK VALVE 9. SCREW
4. PLUG 10. VALVE (DIRECTIONAL CONTROL)
5. PLUG 11. VALVE (DIRECTIONAL CONTROL)
6. PLUG 12. SCREW

Figure 9. Load Holding Valve

17
Attachment Circuit Valves 1900 SRM 1257

Assemble
WARNING
1. Install new seals. Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
2. Lubricate component/valve with clean hydraulic Hydraulic oil can be injected into the body by
oil before installation. pressure.
3. Remove temporary plug.
CAUTION
4. Install and torque component/valve to value
Never start the engine with closed shutoff
listed in the section .
valves. Open the shutoff valves before starting
Install the engine to prevent damage to hydraulic
components.
1. Position the load holding valve on the extension
cylinder. 5. Start the engine and operate the hydraulic sys-
tem. Check that functions of the load holding
2. Install the four capscrews that fasten the load valve work correctly. Check for any leaks.
holding valve onto the rear side of the outer
boom. Boom Extension Cylinder
3. Remove caps and connect the hydraulic lines to See the section Boom 4500 SRM 1260 for descrip-
the load holding valve according to the identifi- tion, operation and repair information of the boom
cation tags made during removal. extension cylinder.

4. Connect the electrical wires to the load holding

valve according to the identification tags made
during removal.

Attachment Circuit Valves

DESCRIPTION AND OPERATION See the following sections for description, operation,
and repair information of hydraulic components in
Two variable displacement pumps supplies oil (70 to these systems:
110 liter/min (18 to 29 gal/min)) to operate the attach- • Extendable Container Attachment (Elme)
ment circuit. 5000 SRM 776
• Intermodal Container Attachment 5000 SRM
777

18
1900 SRM 1257 Other Hydraulic Components

Other Hydraulic Components

DESCRIPTION AND OPERATION • High pressure filter (20 micron).
The high pressure filter is located at the main man-
Relief Valves in Steering System ifold on the hydraulic plate. The high pressure fil-
ter is the last catch filter to filter oil flow to the pilot
See the section Steering System 1600 SRM 1109 for system.
more information on the steering relief valve. • Brake filter (20 micron).
The brake filter is located inside the frame on the
Pilot Pressure Valve right hand side. The brake filter is filtering the
The 5 MPa (725 psi) reducer valve controls the pres- return line from the cooling chamber of the brakes.
sure and supply of oil to the pilot circuits for the re- • Two return line filters (10 micron).
mote control valves and the directional control valve. The two return line filters are located in the hy-
draulic tank and accessible on the topside of the
Dampening Cylinders hydraulic tank. One of the return line filters is
equipped with an indicator. The return line filters
See the section Boom 4500 SRM 1260 for descrip- are filtering the flow of oil returned by the return
tion, operation, and repair information of the damp- manifold to the hydraulic tank.
ening cylinder.
HYDRAULIC FILTERS
Hydraulic Filters
WARNING
NOTE: Hydraulic filter cartridge needs to be replaced
when indicator has popped out. Lower boom completely before working on
control valve or hydraulic system.
From the hydraulic tank, the flow of oil goes through
two 150 micron filters to the hydraulic pumps. The The boom can lower suddenly and cause injury
main hydraulic pump provides flow of oil to the accu- if the boom is not lowered. This procedure will
mulator circuit, flow of oil to the pilot system, and oil make sure that the boom cannot lower sud-
will pass through a high pressure filter (20 micron). denly and cause injury or death.
The high pressure filter is attached to the main man- To remove and replace the filter cartridges, proceed
ifold. The secondary hydraulic pump provides flow of as follows:
oil to the cooling circuit and will pass through a hy-
draulic filter (20 micron). Both flows of oil are for the Suction Filters
brake circuit. Finally, the flow of oil returned by the
return manifold, is filtered through two return line 1. Lower boom completely and close shutoff valves
filters (10 micron) and then flows into the hydraulic on the bottom of the hydraulic tank.
tank.
2. Shut down the engine and apply the parking
The following hydraulic filters are used in the hy- brake.
draulic system:
• Two suction filters (150 micron). 3. Apply brakes minimum 10 times to relieve hy-
draulic pressure.
NOTE: Drain the hydraulic tank before removing
the inspection cover. 4. Drain hydraulic oil from hydraulic tank.

The suction filters are located in the hydraulic tank 5. Remove bolts retaining the inspection cover. See
and are accessible through the inspection cover. Figure 10.
All flow of oil to the hydraulic pumps is filtered
through the suction filters.

19
Other Hydraulic Components 1900 SRM 1257

14. Start engine and check system operation.

High Pressure Filter

1. Lower boom completely.

2. Shut down the engine and apply the parking

brake.

3. Apply brakes minimum 10 times to relieve hy-

draulic pressure.

4. Loosen the bowl by using a wrench to turn the

bowl counterclockwise. See Figure 11.

1. HYDRAULIC TANK
2. SUCTION FILTER
3. INSPECTION COVER
4. SEAL RING, 10 EACH
5. BOLT, 10 EACH

Figure 10. Suction Filters

6. Remove seal rings.

7. Remove inspection cover.

8. Remove suction filters by turning each filter

counterclockwise.

9. Install new suction filters by turning each filter

clockwise.

NOTE: Only use seal rings specified by your local 1. MAIN MANIFOLD
Hyster dealer. Using seal rings other than specified 2. BOWL
can lead to hydraulic oil leakage. Figure 11. High Pressure Filter
10. Install inspection cover using seal rings and 5. Remove filter cartridge.
bolts.
6. Insert new filter cartridge.
11. Torque bolts to 51 N•m (38 lbf ft).
7. Install the bowl by turning the bowl clockwise.
12. Fill hydraulic tank with hydraulic oil, as speci-
fied in the section Periodic Maintenance 8000 8. Torque the bowl to 20 N•m (14.7 lbf ft).
SRM 1263.
9. Start engine and check system operation.
13. Open shutoff valves.
Brake Filter
CAUTION 1. Lower boom completely and close shutoff valves
Never start the engine with closed shutoff on the bottom of the hydraulic tank.
valves. Open the shutoff valves before starting
the engine to prevent damage to hydraulic 2. Shut down the engine and apply the parking
components. brake.

20
1900 SRM 1257 Other Hydraulic Components

3. Apply brakes minimum 10 times to relieve hy- 4. Remove the capscrews retaining the cover of the
draulic pressure. filters. See Figure 13.

4. Loosen the brake filter by using a wrench to turn

the bowl counterclockwise. See Figure 12.

1. BRAKE FILTER
2. TRANSMISSION FILTERS

Figure 12. Brake Filter

5. Remove filter cartridge.

6. Insert new filter cartridge.

7. Install the bowl by turning the bowl clockwise.

8. Torque the bowl to 20 N•m (14.7 lbf ft).

9. Open shutoff valves.

CAUTION
Never start the engine with closed shutoff
valves. Open the shutoff valves before starting
the engine to prevent damage to hydraulic
components.

10. Start engine and check system operation.

Return Line Filters 1. CAPSCREW

2. PLUG
3. COVER
1. Lower the boom completely. 4. O-RING
5. SPRING
2. Shut down the engine and apply the parking 6. FILTER CARTRIDGE
brake.
Figure 13. Return Line Filters
3. Apply brakes minimum 10 times to relieve hy-
draulic pressure.

21
Other Hydraulic Components 1900 SRM 1257

5. Remove the cover and O-ring.

6. Remove the spring.

NOTE: The filter cartridge has a tray on the bottom

outside edge of the filter which catches rough dirt
and particles. Be careful not to spill the rough dirt or
particles from the tray when removing the cartridge.

7. Carefully remove the filter cartridge.

8. Install new filter cartridge.

NOTE: Verify the O-ring is in good condition. Replace

if necessary.

NOTE: Only use an O-ring specified by your local

Hyster dealer. Using an O-ring other than specified
can lead to hydraulic oil leakage.

9. Lightly grease the O-ring with lubrication grease 1. HOUSING

and position the O-ring correctly in the cover. 2. SAFETY STAND PIPE
3. FILTER CARTRIDGE
10. Install spring. 4. CAP
5. INDICATOR
11. Place the cover in position and retain with cap- 6. INDICATOR BUTTON
screws.
Figure 14. Hydraulic Tank Breathers
12. Torque capscrews to 26 N•m (19 lbf ft).
HYDRAULIC HOSE REPAIR
13. Start engine and check system operation.
When lift truck is used in dirty conditions, it is rec-
HYDRAULIC TANK BREATHERS ommended to replace hoses every 5 years or 10,000
hours of service regardless of condition.
NOTE: Never remove the safety stand pipe to avoid
dirt from entering the hydraulic system. CHECKS AND ADJUSTMENTS
To remove and replace the filter cartridge, proceed as Pilot Setting, Check
follows:
1. Shut down the engine and apply the parking NOTE: The pressure reducer valve is adjustable. If
brake. a setting pressure is not within specifications, adjust
2. Press the yellow button on the indicator to re- the valve.
lease pressure to replace the filter cartridge.
3. Loosen the cap by turning cap counterclockwise. 1. Lower lift cylinders completely. Connect a 0 to
See Figure 14. 7 MPa (0 to 1015 psi) gauge to check port MPLT.
4. Remove filter cartridge.
5. Clean the inside of the housing with solvent. 2. Start engine. Run engine until temperature of
6. Insert the new filter cartridge. hydraulic oil is 55 to 65 C (130 to 150 F). Check
7. Install the cap by turning cap clockwise. pressure at idle speed.
8. Start the engine and check operation of indicator. NOTE: Correct measurement can be achieved during
movement (flow) of the main spool.

3. Check if pressure is 5 MPa (725 psi). If pressure

is not correct, adjust pressure reducer valve.

22
1900 SRM 1257 Other Hydraulic Components

Main Function Relief Valve Pressure, 3. Check pressure gauge according to the specifica-
Check tions shown in Table 3.

NOTE: The relief valves in the main manifold, main 4. To adjust a relief valve setting, remove cap.
control valve, and flow amplifier are adjustable. If a Loosen lock nut and use an Allen wrench to turn
relief pressure is not within specifications, adjust the adjuster screw. Turn adjuster screw clockwise
relief valve. to increase pressure. To lower pressure, first
lower pressure below required value by turning
1. Connect a gauge to the check port to check relief adjuster screw counterclockwise and then in-
valve pressure. See Table 2 for the correct gauge crease pressure to required level. When relief
used on the check ports. pressure is correct, tighten lock nut and install
cap. Check the setting after tightening the lock
2. Start engine. Run engine until temperature of nut. During tightening the lock nut, the setting
hydraulic oil is 55 to 65 C (130 to 150 F). can be influenced. Adjust again, if necessary.

Table 2. Gauge Ranges

Check Port Valve Pressure Gauge Range

M STEER Steering Relief Pressure 0 to 28 MPa (0 to 4000 psi)
MSB1 Service Brake Pressure 0 to 28 MPa (0 to 4000 psi)
MSB4 Service Brake Treadle Pressure 0 to 28 MPa (0 to 4000 psi)
MPD Dampening Pressure 0 to 10 MPa (0 to 1450 psi)
MLS1 Load Sense Pressure to Pump 1 0 to 28 MPa (0 to 4000 psi)
MLS2 Load Sense Pressure to Pump 2 0 to 28 MPa (0 to 4000 psi)

Table 3. Pressure Settings

Check Port Correct Pressure Procedure

M STEER 21.0 to 22.5 MPa (3046 to 3263 psi) Engine running at full throttle (2100 rpm).
Turn steering wheel until steering wheel
spindle is against stop on axle. Remain
operating.
MACC upper limit: 20 to 21.5 MPa (2901 Engine running at idle (850 rpm). Measure
to 3118 psi) complete charge cycle.
lower limit: 16 to 17.5 MPa (2321
to 2538 psi) NOTE: The readout can be done from the
display.
MSB1 17.0 to 17.5 MPa (2466 to 2538 psi) Engine running at idle (850 rpm). Brake
pedal fully pressurized.
MSB4 maximum: 16 MPa (2320 psi) Engine running at idle (850 rpm). Brake
pedal fully pressurized.
MPD 2.5 to 3.0 MPa (363 to 435 psi) No special action required. Pressure must
always be available.

23
Specifications 1900 SRM 1257

Table 3. Pressure Settings (Continued)

Check Port Correct Pressure Procedure

MLS1 16.5 to 20.5 MPa (2393 to 2973 psi) Engine running at idle (850 rpm). Measure
during charging. complete charge cycle.

NOTE: The readout can be performed from

the display.
25.5 to 27.0 MPa (3699 to 3916 psi) Engine running at idle (850 rpm). Extend
main relief pressure. derricking cylinders. Remain operating.
MLS2 21.0 to 22.5 MPa (3046 to 3263 psi) Engine running at idle (850 rpm). Turn
steering relief pressure. steering wheel until steering wheel is
against stop on axle. Remain operating.
25.5 to 27.0 MPa (3699 to 3916 psi) Engine running at idle (850 rpm). Extend
main relief pressure. derricking cylinders. Remain operating.

Specifications
HYDRAULIC PUMPS OUTPUT AT 2100 Power Pile Slope Circuit
RPM (GOVERNED SPEED) 21.0 MPa (3046 psi)

Cummins 300Hp (224 kW)/335 Hp (250 kW) Dampening Circuit

2.5 to 3.0 MPa (363 to 435 psi)
Engine
Twist Lock Circuit
Main Valve Pump [130 cm 3 (7.93 in. 3 ) 8.3 MPa (1204 psi)
per revolution]
266.5 liter/min (70.4 gal/min) Sideshift Circuit
12.4 MPa (1799 psi)
Steering Pump [130 cm 3 (7.93 in. 3 )
per revolution] Extend/Retract Circuit
266.5 liter/min (70.4 gal/min) 8.6 MPa (1247 psi)
Brake Pump [45 cm 3 (2.75 in. 3 ) per revolution] CHECK PORT PRESSURES
92.2 liter/min (24.4 gal/min)
MACC - Accumulator Charge Valve (lower
RELIEF VALVES (APPROXIMATE limit) (start charging)
OPERATING PRESSURES) 16 to 17.5 MPa (2321 to 2538 psi)

Main Control Valve MACC - Accumulator Charge Valve (upper

26.0 MPa (3771 psi) limit) (stop charging)
20 to 21.5 MPa (2901 to 3118 psi)
Pilot Circuit
5 MPa (725 psi) MLS1 - Load Sense Pressure to Pump 1
(accumulator charging)
Parking Brake Circuit 16.5 to 20.5 MPa (2393 to 2973 psi)
17.0 to 17.5 MPa (2466 to 2538 psi)
MLS1 - Load Sense Pressure to Pump
Steering Circuit 1 (main relief pressure)
21.5 MPa (3118 psi) 25.5 to 27.0 MPa (3699 to 3916 psi)
Container Attachment
14.0 MPa (2030 psi)

24
1900 SRM 1257 Torque Specifications

MLS2 - Load Sense Pressure to Pump 2 MSB4 - Service Brake Treadle Pressure
(steering relief pressure) (at 2100 rpm)
21.0 to 22.5 MPa (3046 to 3263 psi) Maximum 16 MPa (2321 psi)

MLS2 - Load Sense Pressure to Pump M STEER - Steering Circuit (at 2100 rpm)
2 (main relief pressure) 21.0 to 22.5 MPa (3046 to 3263 psi)
25.5 to 27.0 MPa (3699 to 3916 psi)
MAIN HYDRAULIC FILTERS
MP1 - Pressure Pump 1 (not fully stroked)
(higher than LS1) Main Return Line Filter (bypass pressure)
2.5 MPa (363 psi) 250 to 350 kPa (36 to 51 psi)

MP1 - Pressure Pump 2 (not fully stroked) Brake Filter (bypass pressure)
(higher than LS2) 35 kPa (5.0 psi)
1.5 MPa (218 psi)
TANK CAPACITY
MPD - Dampening Pressure
2.5 to 3.0 MPa (363 to 435 psi) Dipstick FULL Mark
605 liter (160 gal)
MPLT - Pilot Circuit (at 2100 rpm)
4.5 to 5 MPa (653 to 725 psi)

MSB1 - Service Brake Pressure (at 2100 rpm)

17.0 to 17.5 MPa (2466 to 2538 psi)

Torque Specifications
REMOTE CONTROL VALVES Mount Capscrews
14 N•m (124 lbf in)
Screw of Pin Set
1.4 N•m (12 lbf in) Solenoid Capscrews
2.3 N•m (20 lbf in)
Plate Screws
5 N•m (44 lbf in) Pilot Valve Mount Capscrews
9 N•m (80 lbf in)
Lock Nut of Hand Lever
30 N•m (22 lbf ft) CARRIAGE SOLENOID VALVE
Nuts of Through-Bolts Solenoid Capscrews
5 N•m (44 lbf in) 6.3 N•m (56 lbf in)
Lock Nut of Adjustment Screw Mount Capscrews
5 N•m (44 lbf in) 14 N•m (124 lbf in)

ATTACHMENT CONTROL VALVE

Cover Capscrews
11 N•m (97 lbf in)

25
Troubleshooting 1900 SRM 1257

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Oil leaks at the end caps of End cap seals have defects. Replace seals.
the spools.

Valve body has a defect. Replace control valve section.

Spool will not move. No pilot pressure. Check and repair pilot valve if neces-
sary.

Spool is bent or damaged. Replace defective spool.

No electrical signal (auxiliary sec- Check electrical system and repair.

tion only).

Spool will not return to Return spring is damaged. Replace damaged spring.
NEUTRAL.

Spool is bent or damaged. Replace defective spool.

Cylinders move slowly or do Pressure relief valve has a defect. Repair or adjust relief valve.
not move.

Hydraulic pump has a defect. Repair or replace hydraulic pump.

Cylinder seal has defects. Repair or replace cylinder.

Hydraulic pressure is high. Pressure relief valve has a defect. Repair or replace relief valve.

Pressure relief valve is not adjusted Adjust relief valve.

correctly.

Restriction in return line. Replace hydraulic line.

Delay occurs between com- Pilot return line is blocked. Repair or replace hydraulic lines.
mand and movement.

Air in system. Bleed the system.

26
1900 SRM 1257 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Boom extension cylinder re- Cylinder seal has defects. Repair cylinder.
tracts when lever is in NEU-
TRAL position.

Pilot pressure activated. Check remote control valve springs.

Pump does not switch back Main relief is set lower than LS relief Check and adjust if necessary.
at relief pressure. in main valve.

Derricking UP: No move- Cartridge CM10 not activated. 1. Check if spool is on hand temper-
ment. ature.
2. Push manual override button
CM10 (under plastic cap). When
operating is possible during but-
ton pushed, electrical signal is
not applied or solenoid is defect.
When 24 volts are available, then
solenoid defect.

LMI signal overload is active. 1. Check display (overload signal).

2. Electrical wire damage (LMI
line).

Relief valve incorrect values. Check correct value and adjust if nec-
essary.

Impact relief in left-hand valve too Adjust LS relief.

low.

Derricking UP: Not possible LH1 still active (2-speed signal). 1. Check electrical signal of both
lift load or maximum load. LH valves (right-hand and
left-hand). Electrical signal must
be 0 volts.
2. Check if spool 1 and/or 2 are
sticking. Check pressure MP1
(relief pressure must be 26 MPa
(3,771 psi)). Be sure to first
use the emergency lowering to
lower the load, then check spools.
Clean if necessary.

27
Troubleshooting 1900 SRM 1257

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Derricking DOWN: No LH2 no signal when function is ap- 1. CM1 activated but no signal
movement. plied. when function is applied. 24
volts must be available.
2. Check if spool 1 and/or 2 are
sticking. Be sure to first use the
emergency lowering to lower the
load, then check spools. Clean if
necessary.
3. Electrical wire damage.

LMI input signals are not correct. Check for correct value and adjust if
necessary.

Telescope OUT: No move- CM11 no signal. 1. Check if spool is on hand temper-

ment. ature.
2. Push manual override button
CM11 (under plastic cap). When
operating is possible during but-
ton pushed, electrical signal is
not applied or solenoid is defect.
When 24 volts are available, then
solenoid defect.

LMI signal overload is active. 1. Check display (overload signal).

2. Electrical wire damage (LMI
line).

Telescope OUT: Slow move- No 2-speed function. LH3 no signal. Check electrical signal. Must be 24
ment. volts.

Telescope IN: No movement. CM12 no signal. 1. Check if spool is on hand temper-

ature.
2. Push manual override button
CM12 (under plastic cap). When
operating is possible during but-
ton pushed, electrical signal is
not applied or solenoid is defect.
When 24 volts are available, then
solenoid defect.
3. Check if spool 4 is sticking. Be
sure to first use the emergency
lowering to lower the load, then
check spool. Clean if necessary.

28
1900 SRM 1257 Diagrams, Schematics, or Arrangements

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Telescope IN: Slow move- No 2-speed function. CM13 no sig- 1. Check if spool is on hand temper-
ment. nal. ature.
2. Push manual override button
CM13 (under plastic cap). When
operating is possible during but-
ton pushed, electrical signal is
not applied or solenoid is defect.
When 24 volts are available, then
solenoid defect.
3. Check if spool 4 is sticking. Clean
if necessary.

Telescope function slow with/ No signal. Check if spool 4 and/or 5 are sticking.
without load. Be sure to first use the emergency
lowering to lower the load, then check
spools. Clean if necessary.

Unintended slow movement Electrical signal LH2 and/or LH4 1. Check switch on dashboard is in
derrick down or telescope in. available. operating position.
2. Check if spool 1 and/or 2 and/or 4
are not sticking. Be sure to first
use the emergency lowering to
lower the load, then check spools.
Clean if necessary.

For the Hydraulic Schematic, see the section Dia-

grams 8000 SRM 1261.

29
 NOTES

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 TECHNICAL PUBLICATIONS

1900 SRM 1257 7/07 (8/06)(6/06) Printed in United Kingdom