HYDRAULIC SYSTEM

RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,

RS46-36CH, RS46-33IH First Used on 1529, 1533
Up to 1562, 1564, 1565, and 1569 [A222]

PART NO. 1496130 1900 SRM 953

 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
Main Control Valve........................................................................................................................................ 1
Pilot Pressure Valve ...................................................................................................................................... 1
Boom Hoist Over Center Valve ..................................................................................................................... 1
Flow Amplifier ............................................................................................................................................... 1
Main Control Valve ............................................................................................................................................ 2
Description ..................................................................................................................................................... 2
Left-Hand Main Valve............................................................................................................................... 3
Right-Hand Main Valve ............................................................................................................................ 3
Left- and Right-Hand Main Valve Combined Functions......................................................................... 3
Remove....................................................................................................................................................... 3
Disassemble ............................................................................................................................................... 3
Clean .......................................................................................................................................................... 3
Inspect........................................................................................................................................................ 3
Assemble .................................................................................................................................................... 4
Install ......................................................................................................................................................... 4
Outlet Section ................................................................................................................................................ 5
Disassemble ............................................................................................................................................... 5
Clean .......................................................................................................................................................... 7
Inspect........................................................................................................................................................ 7
Assemble .................................................................................................................................................... 7
Control Section .............................................................................................................................................. 7
Disassemble ............................................................................................................................................... 7
Clean .......................................................................................................................................................... 9
Inspect........................................................................................................................................................ 9
Assemble .................................................................................................................................................... 9
Control Valve Solenoid .................................................................................................................................. 9
Disassemble ............................................................................................................................................... 9
Clean .......................................................................................................................................................... 9
Inspect........................................................................................................................................................ 10
Assemble .................................................................................................................................................... 10
Inlet Section ................................................................................................................................................... 10
Disassemble ............................................................................................................................................... 10
Clean .......................................................................................................................................................... 12
Inspect........................................................................................................................................................ 12
Assemble .................................................................................................................................................... 12
Pilot Pressure Relief Valve ................................................................................................................................ 12
Remove ........................................................................................................................................................... 12
Disassemble ................................................................................................................................................... 12
Clean .............................................................................................................................................................. 13
Inspect ............................................................................................................................................................ 13
Assemble ........................................................................................................................................................ 13
Install ............................................................................................................................................................. 13
Boom Hoist Over Center Valve ......................................................................................................................... 13
Description ..................................................................................................................................................... 13
Remove ........................................................................................................................................................... 13
Disassemble ................................................................................................................................................... 14
Assemble ........................................................................................................................................................ 15
Install ............................................................................................................................................................. 15
Flow Amplifier.................................................................................................................................................... 15

©2005 HYSTER COMPANY i

Table of Contents Hydraulic System

TABLE OF CONTENTS (Continued)

Description ..................................................................................................................................................... 15
Operation ....................................................................................................................................................... 17
Neutral Position ........................................................................................................................................ 17
During Steering Function ......................................................................................................................... 17
Manual Steering Function ........................................................................................................................ 18
Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Pressure Relief Valve ................................................................................................................................ 18
Disassemble ............................................................................................................................................... 18
End Cover at PP Port ................................................................................................................................ 18
End Cover at LS Port ................................................................................................................................ 18
Spools ......................................................................................................................................................... 19
Directional Valve Spool ............................................................................................................................. 19
Priority Valve Spool................................................................................................................................... 19
Pressure Control/Amplifier Valve Spool................................................................................................... 19
Check Valve ............................................................................................................................................... 20
Cushion/Suction Valves............................................................................................................................. 20
Clean .......................................................................................................................................................... 21
Assemble .................................................................................................................................................... 21
Pressure Checkports...................................................................................................................................... 21
Troubleshooting.................................................................................................................................................. 23
Diagrams, Schematics, or Arrangements ......................................................................................................... 24
Figure 30. Main Hydraulic Schematic (Up to 1536 Except 1529) .......................................................... 26
Figure 31. Main Hydraulic Schematic (1529, 1537 and Up) .................................................................. 28

This section is for the following models:

RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH, RS46-33IH

First Used on 1529, 1533 Up to 1562, 1564, 1565, and 1569 [A222]

ii
1900 SRM 953 Description and Operation

General
This section has the description and operation of the that the schedules for hydraulic oil and hydraulic
hydraulic system. See Figure 30 or Figure 31. The filter changes be strictly followed. For proper in-
section also has repair procedures and troubleshoot- tervals and quantities, see Periodic Maintenance,
ing for most of the components of the hydraulic sys- ReachStacker 8000 SRM 950.
tem. See the sections Steering System 1600 SRM
637 and Brake System 1800 SRM 640 for infor- To help decrease hydraulic failures due to contami-
mation on these systems. The section Hydraulic nation, the list below is to be followed:
Pumps 2000 SRM 644 has the repair procedures for Use only hydraulic filters and hydraulic oil speci-
hydraulic pumps. The sections Container Attach- fied in the ReachStacker Parts Book.
ment, ReachStacker 4500 SRM 648 and Boom, Inspect all parts after disassembly for scratches or
ReachStacker 4500 SRM 0649 have the repair pro- gouges which would compromise the effectiveness
cedures for the attachment. of the part.
Replace all O-rings when a component is disas-
Most hydraulic component failures can usually be at- sembled.
tributed to dirty hydraulic oil. Dirty hydraulic oil Clean all parts completely prior to assembly. Use
may be the result of not following a strict mainte- only a lint-free cloth to dry those parts not dried
nance regimen. It is, therefore, extremely important using compressed air.
that hydraulic oil condition be closely monitored, and

Description and Operation

The hydraulic system includes the circuits for the BOOM HOIST OVER CENTER VALVE
boom, steering system, brake system, and attach-
ment. There are two sets of hydraulic pumps con- The over center valve performs the following func-
nected together in series. The two sets consist of a tions:
swash plate pump and two gear pumps. The pumps • Blocking the return flow when the directional valve
are driven by a power takeoff arrangement on both is not operated or when the pump is stopped.
sides of the transmission housing. The inlet hoses for • Cavitation-free lowering, controlled by the pilot ac-
the pumps are connected to the hydraulic tank. tion through the lowering pressure supplied by the
directional valve, preventing the actuator from ac-
MAIN CONTROL VALVE celerating downward.
• Pressure relief for any pressure surge caused by
The two main control valves control the flow and inertia of the load.
pressure of oil to the boom hoist and boom extension
functions. The main control valves contain three sec- FLOW AMPLIFIER
tions, inlet and two control outlet sections. The two
control sections of the main control valves control the The flow amplifier regulates and directs the flow of
boom extension and the boom hoist functions. The oil to the steering cylinder. The flow amplifier in-
outer control section controls the boom hoist func- creases the output oil flow five times more than the
tions. pilot input flow from the steering control unit. The
rate of oil flow to the steering cylinder is directly pro-
PILOT PRESSURE VALVE portional to the rate of the pilot flow from the steer-
ing control unit.
The pilot pressure relief valve provides a constant
hydraulic pressure of 6 MPa (870 psi) at the main
control valve.

1
Main Control Valve 1900 SRM 953

Main Control Valve

DESCRIPTION The main control valves contain three sections, inlet
and two control outlet sections. See Figure 1.
The main control valves control the flow and pressure
of oil to the boom hoist and boom extension functions.

NOTE: THIS ILLUSTRATION HAS BEEN ROTATED FOR CLARITY. THE CORRECT ORIENTATION OF THE TWO
MAIN CONTROL VALVES MAY BE SEEN IN FIGURE 2.
1. INLET SECTION 2. MIDDLE CONTROL SECTION 3. OUTER CONTROL SECTION

Figure 1. Hydraulic Valve Layout

2
1900 SRM 953 Main Control Valve

Left-Hand Main Valve 2. Disconnect hydraulic hoses and tubes from con-
trol valve(s). Use a pan to catch oil that is in
The left port of the inlet section returns oil to the hy- hydraulic lines. Put tags on lines and tubes for
draulic tank. The right port of this section supplies identification. Put caps on open lines and fit-
high-pressure hydraulic oil for the outlet sections. tings.
The left control port of the middle section controls
the retraction of the boom. The right control port of 3. Remove control valve(s) from mounting plate.
this section controls the extension of the boom. The
right control port of the second section controls the Disassemble
hoisting of the boom.
1. Remove nuts, washers, and bracket from tie rods.
Right-Hand Main Valve See Figure 3.

The left port of the inlet section returns oil to the 2. Remove each section from tie rods and discard
hydraulic tank. The right port of this section sup- O-rings.
plies high-pressure hydraulic oil for the outlet sec-
3. Remove two lower tie rods and bracket from inlet
tions. The left control port of the middle section con-
section. Upper tie rod will be removed if inlet
trols the lowering of the boom. The right control port
section is to be repaired.
of this section controls the hoisting of the boom. The
right control port of the second section controls the
Clean
extension of the boom.

Left- and Right-Hand Main Valve Combined WARNING

Functions Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
For boom hoisting the right port of the second con- cleaning solvents, always follow the solvent
trol section of the left-hand main control valve is con- manufacturer’s recommended safety precau-
nected to the right port of the middle controlled sec- tions.
tion of the right-hand main control valve. For boom
extension, the right port of the middle control sec- WARNING
tion of the left-hand main control valve is connected
Do not use compressed air at more than
to the right port of the second control section of the
206 kPa (30 psi). Airborne debris can cause
right-hand main control valve.
injury to personnel. Wear hearing and eye
NOTE: The hydraulic oil pressure required to per- protection.
form the functions is originated from two different ar-
Clean all parts of pump with solvent. Use com-
eas. One is the variable displacement pump located
pressed air to dry parts. Do not use a cloth to dry
on the right side of the transmission. The other is
parts. Pieces of the cloth can cause restrictions in
from the flow amplifier when the steering function is
the hydraulic system. Make sure work area and
not being used.
tools are very clean.
Remove Inspect
WARNING Inspect control valve section oil passages to ensure
Rotate battery disconnect switch to off posi- that they have not been damaged and are clear of
tion before disconnecting any electrical con- any dirt or other debris.
nectors.

1. Disconnect all electrical connectors and tag con-

nectors to aid in installation. See Figure 2.

3
Main Control Valve 1900 SRM 953

1. ELECTRICAL CONNECTOR 4. LIFTING VALVE

2. CONTROL VALVES 5. THROTTLE VALVE
3. PILOT PRESSURE RELIEF VALVE

Figure 2. Hydraulic Valves Layout

Assemble the section Metric and Inch (SAE) Fasteners

8000 SRM 231.
1. Install bracket and two lower tie rods onto inlet
section. See Figure 3. Install
NOTE: Apply a light coat of grease on O-rings to help 1. Install control valve(s) onto mounting plate. See
hold them in place. Figure 2.
2. Install O-rings onto control section. 2. Connect hydraulic hoses and tubes to control
valve(s) as tagged during removal.
3. Install control and outlet sections onto tie rods.
3. Connect all electrical connectors as tagged dur-
4. Install bracket, washers, and nuts onto tie rods.
ing removal.
Tighten nuts to torque specified for their size in

4
1900 SRM 953 Main Control Valve

1. NUT 7. TIE ROD

2. WASHER 8. BRACKET
3. RING 9. O-RING
4. O-RING 10. INLET SECTION
5. O-RING 11. MIDDLE CONTROL SECTION
6. O-RING 12. OUTER CONTROL SECTION

Figure 3. Main Control Valve Assembly

OUTLET SECTION 1. Remove supply connector assembly from

adapter. See Figure 4.
Disassemble
2. Remove control valve solenoid assembly from
NOTE: Disassemble outlet valve section as may be adapter. See Control Valve Solenoid for repair
necessary to repair valve. procedures.

3. Remove manifold from adapter.

CAUTION
All O-rings removed during disassembly are to 4. Remove adapter from cylinder.
be discarded. Failure to replace O-rings with
new O-rings could result in damage to equip-
ment.

5
Main Control Valve 1900 SRM 953

1. SOLENOID 12. WASHER 24. O-RING

2. SCREW 13. CYLINDER 25. MANIFOLD
3. WASHER 14. O-RING 26. SCREW
4. SUPPLY CONNECTOR 15. POPPET 27. PLUG
ASSEMBLY 16. SPRING 28. PISTON
5. PLUG 17. PISTON 29. O-RING
6. O-RING 18. SPRING 30. O-RING
7. ADAPTER 19. O-RING 31. PLUG
8. NUT 20. SPOOL 32. O-RING
9. ADJUSTMENT SCREW 21. SPRING 33. O-RING
10. O-RING 22. O-RING 34. LS PLUG ASSEMBLY
11. SCREW 23. PLUG

Figure 4. Outer Outlet Section

6
1900 SRM 953 Main Control Valve

5. If adjustment screw is to be removed from cylin- 3. Install priority valve assembly in control section
der, loosen nut while holding adjustment screw valve body. Tighten plug to 80 N•m (59 lbf ft).
in place. Note number of turns required to re-
move adjustment screw. 4. Install spring, piston, spring, and poppet in con-
trol section valve body.
6. Remove cylinder, poppet, spring, piston, and
spring from outlet section valve body. 5. Install cylinder on control section valve body.
Tighten screws to 9.5 N•m (84 lbf in).
7. Remove priority valve assembly from outlet sec-
tion valve body. NOTE: Perform Step 6 only if adjustment screw has
been removed from cylinder.
8. Remove LS plug assembly from outlet section
valve body. 6. Install adjustment screw the number of turns
noted during removal. While holding adjustment
NOTE: Remove plugs only if there is evidence of hy- screw in place, tighten nut to 9.5 N•m (84 lbf in).
draulic oil leakage.
7. Install adapter on cylinder.
9. Remove plug assembly from outlet section valve
body. 8. Install manifold on adapter. Tighten screws to
9.5 N•m (84 lbf in).
Clean
9. Install control valve solenoid assembly on
adapter. Tighten screws to 9.5 N•m (84 lbf in).
WARNING
Cleaning solvents can be flammable and toxic 10. Install supply connector assembly in adapter.
and can cause skin irritation. When using
cleaning solvents, always follow the solvent CONTROL SECTION
manufacturer’s recommended safety precau-
tions. Disassemble
NOTE: Disassemble control valve section as may be
WARNING necessary to repair valve.
Do not use compressed air at more than
206 kPa (30 psi). Airborne debris can cause
injury to personnel. Wear hearing and eye CAUTION
protection. All O-rings that are removed during disassem-
bly are to be discarded. Failure to replace
Clean all parts of flow amplifier with solvent. Use O-rings with new O-rings could result in dam-
compressed air to dry parts. Do not use a cloth to age to equipment.
dry parts. Pieces of the cloth can cause restrictions
in the hydraulic system. Make sure work area and 1. Remove reducer spool assembly from housing.
tools are very clean. See Figure 5.

2. Remove housing from adapter.

Inspect
3. Remove supply connector assembly from
Inspect machined surfaces, bores, and threads in out-
adapter.
let section body for damage. Inspect removed compo-
nents for damage. 4. Remove control valve solenoid assembly from
adapter. See Control Valve Solenoid for repair
Assemble procedures.
1. Install plug assembly in outlet section valve body. 5. Remove adapter from cylinder.
See Figure 4. Tighten plug to 80 N•m (59 lbf ft).

2. Install LS plug assembly in control section valve

body. Tighten plug to 15 N•m (133 lbf in).

7
Main Control Valve 1900 SRM 953

1. PLUG 17. SOLENOID ASSEMBLY 34. PLUG

2. O-RING 18. PLUG SERVICE SET 35. O-RING
3. SPRING 19. CARTRIDGE 36. SPRING
4. WASHER 20. PLUG 37. SPOOL
5. SPOOL 21. ADAPTER 38. LS PLUG ASSEMBLY
6. BACKUP RING 22. NUT 39. PLUG
7. O-RING 23. ADJUSTMENT SCREW 40. SPRING
8. PISTON 24. O-RING 41. O-RING
9. BACKUP RING 25. O-RING 42. PISTON
10. O-RING 26. SCREW 43. SCREW
11. SCREW 27. WASHER 44. COVER
12. HOUSING 28. CYLINDER 45. PLUG
13. O-RING 29. POPPET 46. REDUCER SPOOL ASSEMBLY
14. SUPPLY CONNECTOR 30. SPRING 47. HVB CARTRIDGE
ASSEMBLY 31. PISTON 48. CHECK VALVE
15. SCREW 32. SPRING 49. PRIORITY VALVE
16. WASHER 33. O-RING

Figure 5. Middle Outlet Section

6. If adjustment screw is to be removed from cylin- 9. Remove LS plug assembly from control section
der; loosen nut while holding adjustment screw valve body.
in place. Note number of turns required to re-
move adjustment screw. 10. Remove check valve assembly from control sec-
tion valve body.
7. Remove cylinder, poppet, spring, piston, and
spring from control section valve body. 11. Remove HVB cartridge assembly from control
section valve body.
8. Remove priority valve assembly from control sec-
tion valve body. 12. Remove cover from control section valve body.

8
1900 SRM 953 Main Control Valve

Clean 9. Install adapter on cylinder.

10. Install control valve solenoid assembly on

WARNING adapter. Tighten screws to 9.5 N•m (84 lbf in).
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 11. Install supply connector assembly in adapter.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau- 12. Install housing on adapter. Tighten screws to
tions. 10 N•m (89 lbf in).

13. Install reducer spool assembly in housing.

WARNING
Do not use compressed air at more than CONTROL VALVE SOLENOID
206 kPa (30 psi). Airborne debris can cause
injury to personnel. Wear hearing and eye Disassemble
protection.
1. Remove four screws and separate front and rear
Clean all parts of control section valve body with sol- housings. See Figure 6.
vent. Use compressed air to dry parts. Do not use a
cloth to dry parts. Pieces of the cloth can cause re- 2. Remove spacer and O-ring from front housing.
strictions in hydraulic system. Make sure work area Discard O-ring.
and tools are very clean.
3. Remove retaining ring, spacer, spring, and piston
from plug.
Inspect
4. Remove plug from rear housing.
Inspect machined surfaces, bores, and threads in sec-
tion body for damage. Inspect removed components 5. Remove three rear housing O-rings, backup ring,
for damage. and large rear housing O-ring from plug. Discard
O-rings.
Assemble
1. Install cover on control section valve body. See
Clean
Figure 5. Tighten screws to 5 N•m (44 lbf in).
WARNING
2. Install HVB cartridge assembly in control section Cleaning solvents can be flammable and toxic
valve body. Tighten plug to 80 N•m (59 lbf ft). and can cause skin irritation. When using
cleaning solvents, always follow the solvent
3. Install check valve assembly in control section
manufacturer’s recommended safety precau-
valve body. Tighten plug to 80 N•m (59 lbf ft).
tions.
4. Install LS plug assembly in control section valve
body. Tighten plug to 15 N•m (133 lbf in). WARNING
Do not use compressed air at more than
5. Install priority valve assembly in control section
206 kPa (30 psi). Airborne debris can cause
valve body. Tighten plug to 80 N•m (59 lbf ft).
injury to personnel. Wear hearing and eye
6. Install spring, piston, spring, and poppet in con- protection.
trol section valve body.
Clean all parts of flow amplifier with solvent. Use
7. Install cylinder on control section valve body. compressed air to dry parts. Do not use a cloth to
Tighten screws to 9.5 N•m (84 lbf in). dry parts. Pieces of the cloth can cause restrictions
in hydraulic system. Make sure work area and tools
NOTE: Perform Step 8 only if adjustment screw has are very clean.
been removed from cylinder.

8. Install adjustment screw the number of turns

noted during removal. While holding adjustment
screw in place, tighten nut to 9.5 N•m (84 lbf in).

9
Main Control Valve 1900 SRM 953

1. SCREW 7. BACKUP RING 12. RETAINING RING

2. FRONT HOUSING 8. LARGE REAR HOUSING 13. SPACER
3. PLUG O-RING 14. O-RING
4. REAR HOUSING O-RING 9. PISTON 15. REAR HOUSING
5. REAR HOUSING O-RING 10. SPRING
6. REAR HOUSING O-RING 11. SPACER

Figure 6. Control Valve Solenoid

Inspect INLET SECTION

Inspect front and rear housings for damaged bores Disassemble
and threads. Replace backup rings if damaged. In-
spect plug for damaged threads or damaged spanner NOTE: Disassemble inlet valve section as necessary
wrench holes. to repair valve. Disassembly procedure is divided
into sections according to numbered callouts.
Assemble
1. Remove four screws, cover, O-ring, spring, and
1. Install large rear housing O-ring, backup ring, piston from inlet valve section. See Figure 7. Dis-
and three rear housing O-rings on plug. See Fig- card O-ring.
ure 6.
2. Remove wire seal from outer cartridge assembly.
2. Install plug in rear housing. Tighten to 19.5 N•m
(173 lbf in). 3. Remove outer cartridge assembly from inner car-
tridge assembly.
3. Install piston, spring, spacer, and retaining ring
in plug. 4. Remove O-ring, spring, stop, poppet, piston, and
O-ring from outer cartridge assembly. Discard
4. Install new O-ring and spacer in front housing. O-rings.

5. Place front and rear housings together and in- 5. Remove inner cartridge assembly from inlet
stall four screws. Tighten screws to 1.5 N•m valve section.
(13 lbf in).
6. Remove O-rings and backup rings from inner car-
tridge assembly. Discard O-rings.

10
1900 SRM 953 Main Control Valve

1. SCREW 15. O-RING 29. PLUG

2. COVER 16. BACKUP RING 30. O-RING
3. O-RING 17. O-RING 31. SPRING
4. SPRING 18. BACKUP RING 32. PISTON
5. PISTON 19. O-RING 33. NUT
6. WIRE SEAL 20. PLUG 34. PLUG
7. CARTRIDGE 21. O-RING 35. O-RING
8. O-RING 22. PISTON 36. SCREW
9. SPRING 23. SPRING 37. BACKUP RING
10. STOP 24. PISTON 38. PISTON
11. POPPET 25. BACKUP RING 39. O-RING
12. PISTON 26. O-RING 40. PISTON
13. O-RING 27. SPRING
14. CARTRIDGE 28. POPPET

Figure 7. Inlet Section

7. Remove plug, piston, O-ring, and spring from in- 9. Remove plug, O-ring, spring, and piston from in-
let valve section. Discard O-ring. let valve section.

8. Remove piston, backup ring, O-ring, spring, and 10. Remove lock nut, plug, O-ring, adjusting screw,
poppet from inlet valve section. Discard O-ring. four pistons, four backup rings, and four O-rings
from inlet valve section. Discard O-rings.

11
Pilot Pressure Relief Valve 1900 SRM 953

Clean in inlet valve section. See Figure 7. Tighten lock

nut to 5 N•m (44 lbf in) while holding screw.
WARNING 2. Install piston, spring, O-ring, and plug in inlet
Cleaning solvents can be flammable and toxic valve section. Tighten plug to 80 N•m (59 lbf ft).
and can cause skin irritation. When using
cleaning solvents, always follow the solvent 3. Install poppet, spring, O-ring, backup ring, and
manufacturer’s recommended safety precau- piston in inlet valve section.
tions.
4. Install spring, O-ring, piston, and plug in inlet
valve section.
WARNING
Do not use compressed air at more than 5. Install backup rings and O-rings on inner car-
206 kPa (30 psi). Airborne debris can cause tridge assembly.
injury to personnel. Wear hearing and eye
protection. 6. Install inner cartridge assembly in inlet valve
section. Tighten inner cartridge assembly to
Clean all parts of inlet section with solvent. Use com- 80 N•m (59 lbf ft).
pressed air to dry parts. Do not use a cloth to dry
parts. Pieces of the cloth can cause restrictions in hy- 7. Install O-ring, piston, poppet, stop, spring, and
draulic system. Make sure work area and tools are O-ring on outer cartridge assembly.
very clean.
8. Install outer cartridge assembly in inner car-
Inspect tridge assembly.

Inspect machined surfaces, bores, and threads in 9. Install wire seal on outer cartridge assembly.
section body for damage. Inspect threads of screws,
10. Install piston, spring, O-ring, four screws, and
nuts, and plugs for damage.
cover in inlet valve section. Tighten screws to
22 N•m (195 lbf in).
Assemble
1. Install four O-rings, four backup rings, four pis-
tons, adjusting screw, O-ring, plug, and lock nut

Pilot Pressure Relief Valve

REMOVE
1. Disconnect hydraulic hoses from pilot pressure
relief valve. See Figure 2 and Figure 8. Use a
pan to catch oil that is in hydraulic lines. Put
tags on lines for identification. Put caps on open
lines and fittings.

2. Remove pilot pressure relief valve from mount-

ing bracket.

DISASSEMBLE
NOTE: Count number of turns required to remove
valve in Step 1.

1. Loosen nut and remove valve from valve body. 1. PILOT PRESSURE RELIEF VALVE
See Figure 9. 2. THROTTLE VALVE

Figure 8. Pilot Pressure Relief Valve

12
1900 SRM 953 Boom Hoist Over Center Valve

WARNING
Do not use compressed air at more than
206 kPa (30 psi). Airborne debris can cause
injury to personnel. Wear hearing and eye
protection.

Clean all parts of pilot pressure relief valve with sol-

vent. Use compressed air to dry parts. Do not use a
cloth to dry parts. Pieces of the cloth can cause re-
strictions in hydraulic system. Make sure work area
and tools are very clean.

INSPECT
1. VALVE BODY 2. NUT Inspect all parts for damage and wear. If any parts
other than O-rings, backup ring, and washer are
Figure 9. Pilot Pressure Relief Valve
damaged, replace valve.
2. Remove and discard O-ring and backup ring from
valve. ASSEMBLE
3. Remove valve seat from valve body. 1. Install new washer into valve body. See Figure 9.

4. Remove and discard washer from valve body. 2. Install valve seat into valve body.

3. Install new backup ring and O-ring onto valve.

CLEAN
4. Install valve into valve body the number of turns
WARNING noted during disassembly and tighten nut.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using INSTALL
cleaning solvents, always follow the solvent
1. Install pilot pressure relief valve on mounting
manufacturer’s recommended safety precau-
bracket. See Figure 2 and Figure 8.
tions.
2. Connect hydraulic hoses to pilot pressure relief
valve.

Boom Hoist Over Center Valve

DESCRIPTION REMOVE
There are four over center valves in the hydraulic 1. Disconnect hydraulic hoses and tubes from boom
system. One is located in the hydraulic compart- hoist over center valve. See Figure 10. Use a pan
ment. The other three are located on the hoist cylin- to catch oil that is in hydraulic lines. Put tags
ders and the extension cylinder. More information on on lines and tubes for identification. Put caps on
these over center valves may be found in Container open lines and fittings.
Attachments 4500 SRM 648 and Boom 4500 SRM
649. 2. Remove boom hoist over center valve from
mounting plate.

13
Boom Hoist Over Center Valve 1900 SRM 953

DISASSEMBLE
NOTE: Remove only those components that appear to
be defective.

1. Remove cartridge and spool assembly from hous-

ing. See Figure 11.

2. Remove and discard O-rings and backup rings

from cartridge and spool assembly.

3. Remove retaining ring and O-ring from housing.

1. VALVE

Figure 10. Boom Hoist Over Center Valve

1. CARTRIDGE AND SPOOL 3. HOUSING 5. CAP

2. RETAINING RING 4. O-RING 6. WASHER

Figure 11. Boom Hoist Over Center Valve

14
1900 SRM 953 Flow Amplifier

ASSEMBLE INSTALL
1. If either of the cartridge and spool assemblies is 1. Install boom hoist over center valve on mounting
defective, discard and replace with a new assem- bracket. See Figure 10.
bly. See Figure 11.
2. Connect hydraulic hoses and tubes to boom hoist
2. Install new O-ring and retaining ring into hous- over center valve.
ing.

3. Install new O-rings and backup rings onto car-

tridge and spool assembly.

Flow Amplifier
DESCRIPTION PRIORITY VALVE. This valve selects and directs the
oil flow for steering. The priority is determined in
NOTE: The following valves are part of the flow am- response to pilot pressure from the steering control
plifier. See Figure 12 and Figure 13. unit. In the NEUTRAL position (no steering de-
mand), the priority valve allows oil to flow from the
pump to the main control valve.

Figure 12. Flow Amplifier

15
Flow Amplifier 1900 SRM 953

1. O-RING 10. DIRECTIONAL VALVE 17. PLUG

2. SEAL ASSEMBLY 18. ORIFICE
3. FLOW AMPLIFIER HOUSING 11. DIRECTIONAL VALVE SPOOL 19. THROTTLE CHECK VALVE
4. SCREW 12. PRIORITY VALVE 20. SPRING
5. CAPSCREW 13. PRIORITY VALVE SPOOL 21. SPRING CONTROL
6. SPRING WASHER 14. PRESSURE 22. STOP
7. PP END COVER CONTROL/AMPLIFIER VALVE 23. PIN
8. LS END COVER ASSEMBLY 24. AMPLIFIER VALVE PISTON
9. CUSHION/SUCTION VALVE 15. AMPLIFIER VALVE SPOOL
ASSEMBLY 16. RELIEF VALVE

Figure 13. Flow Amplifier Assembly

16
1900 SRM 953 Flow Amplifier

DIRECTIONAL VALVE. This valve opens the correct The spool shifts to a position so the pressure is the
cylinder supply and return passages when it senses same at both ends of the spool. Oil now flows through
the pilot pressure from the steering control unit. The the valve to the directional valve.
directional valve checks steering overrun by direct-
ing return flow from the cylinder to make sure there The main flow and pilot flow of oil combine, in-
is control under all conditions. creasing the flow through the directional valve to
the steering cylinder. The return oil flows from
AMPLIFIER VALVE. This valve is moved by pilot the cylinder, through the directional valve to the
pressure. When open, it pumps hydraulic fluid di- hydraulic tank.
rectly from the priority valve. The oil flow is then
combined with the pilot flow. The flow amplifier has cushion valves to prevent
pressure peaks in the steering cylinder. Suction
CUSHION AND SUCTION VALVES. The "cushion" valves are installed to prevent cavitation in the
function of these valves makes a hydraulic cushion steering cylinder.
to reduce sharp increases of pressure in the steer-
ing cylinder. The "suction" function of these valves
uses the cylinder return flow to prevent cavitation of
oil inside the cylinder if steering "overrun" forces are
sensed.

RELIEF VALVE. This valve senses high pressure

from the load-sensing line from the steering control
unit. The relief valve opens and directs the oil flow
to the hydraulic tank.

OPERATION
Neutral Position
In the neutral position, the oil flows from the steering
pump to the priority valve and discharges through
the EF port. See Figure 14. The EF port is connected
to the working pressure of the hydraulic system at
the main control valve.

During Steering Function

When the steering wheel is turned, pilot pressure
causes oil to flow from the steering control unit to the
priority valve. The priority valve is shifted. Oil flows
from the steering control unit to the flow amplifier.

The directional valve is shifted by pressure across the

bore of the spool. 1. PP - PILOT PRESSURE
2. HP - HYDRAULIC (STEERING) PUMP
The pilot pressure moves the spool and causes oil to 3. EF - SYSTEM PRESSURE
flow through the pressure control/amplifier valve to 4. LS - LOAD SENSING
the directional valve. 5. R - RIGHT TURN
6. P - PUMP PRESSURE
The main oil flow passes from the priority valve to the 7. CR - CYLINDER, RIGHT
8. HT - HYDRAULIC TANK
pressure control/amplifier valve where the spool is in 9. CL - CYLINDER, LEFT
the "left turn" position. Oil now flows through holes 10. T - TANK
in the valve to a chamber in one end of the spool. 11. L - LEFT TURN

Figure 14. Flow Amplifier

17
Flow Amplifier 1900 SRM 953

Manual Steering Function Disassemble

If the steering pump fails, or the engine loses power, 1. Remove plug and washer. See Figure 13. Use an
the lift truck can be steered manually. The steering 8-mm Allen wrench.
effort, however, will be increased.
2. Use a 10-mm Allen wrench to remove relief valve
The steering control unit has the characteristics of a assembly.
hand pump when the steering wheel is turned (when
there is no pressure input). The pressure developed 3. Remove washer with magnetic rod.
by the steering control unit (when the steering wheel
4. Hold relief valve cartridge with pliers and re-
is turned) operates all the valves in the flow amplifier
move adjusting screw with a 5-mm Allen wrench.
as if operating conditions were normal. There is no
See Figure 15.
amplification because only the oil from the steering
control unit flows to the steering cylinder.
End Cover at PP Port
Remove 1. Remove capscrews, spring washers, and end
cover.
1. Disconnect hydraulic hoses from flow amplifier.
See Figure 13. Use a pan to catch oil that is 2. Remove stop and two springs. See Figure 16.
in hydraulic lines. Put tags on lines and tubes
for identification. Put caps on open lines and fit- 3. Remove single spring.
tings.
4. Remove plate and six O-rings (4 large, 2 small).
2. Remove flow amplifier from frame. Remove spring guide.

Install
1. Install flow amplifier on frame. See Figure 13.

2. Connect hydraulic hoses and tubes to flow ampli-

fier.

Pressure Relief Valve

See Figure 15.

1. STOP 4. O-RING
2. SPRING 5. SPRING GUIDE
3. PLATE

Figure 16. End Cover at PP Port

End Cover at LS Port

1. Remove capscrews, spring washers, and end
cover.
1. CARTRIDGE BODY 4. ADJUSTMENT 2. Remove stop and two springs. See Figure 17.
2. PISTON SCREW
3. SPRING 3. Remove stop and single spring.
Figure 15. Pressure Relief Valve 4. Remove plate and four O-rings. Remove spring
guide.

18
1900 SRM 953 Flow Amplifier

Priority Valve Spool

1. Remove plug or throttle check valve (whichever
is installed) from priority valve spool. Hold end
of spool on small diameter with pliers. See Fig-
ure 19.

2. Remove two spring rings from grooves with a

small screwdriver and carefully guide rings back
on spool. Do not damage spring rings.

1. SPRINGS 2. PLATE

Figure 17. End Cover at LS Port

Spools
1. THROTTLE CHECK VALVE
Remove three spools (directional valve, pressure con-
trol/amplifier valve, and priority valve) from hous- Figure 19. Priority Valve Spool
ing. These spools will slide easily from housing.
Pressure Control/Amplifier Valve Spool
Directional Valve Spool
1. Use a finger and press out first pin. Remove plug
Remove orifice from directional valve spool with a and spring. See Figure 20.
4-mm Allen wrench. Hold spool through hole with
mandrel. See Figure 18. 2. Remove second pin, then remove inner spool.
Make note of how inner spool is installed. The
square end on inner spool must be installed in
the same direction. If the inner spool is rotated
180 degrees and then installed, the flow ampli-
fier will not operate correctly.

3. Remove inner spool (check valve) from other end

of spool. Use a hexagon socket for a 17-mm ex-
ternal hexagon and a mandrel through a pin hole
on surface that is not machined. Do not damage
spool surface.

4. Remove orifice from plug with a 4-mm Allen

wrench and mandrel.

1. SPOOL 2. ORIFICE

Figure 18. Directional Valve Spool

19
Flow Amplifier 1900 SRM 953

Legend for Figure 20

A. STEP 1 C. STEP 3
B. STEP 2 D. STEP 4
1. ORIFICE 5. INNER SPOOL
2. PLUG 6. SECOND PIN
3. FIRST PIN 7. SPOOL
4. SPRING

Check Valve
Put check valve in a 17-mm socket wrench. Use an
Allen wrench and remove plug from check valve. Re-
move spring and ball. See Figure 21.

1. PLUG 3. BALL
2. SPRING 4. O-RING

Figure 21. Check Valve

Cushion/Suction Valves
NOTE: Remove cushion/suction valves with flat tip
screwdriver. Put an Allen wrench under screwdriver
as a fulcrum for removal.

1. Remove lock nut from inside valve housing. See

Figure 22. Use a socket for a 13-mm external
hexagon and a mandrel through a hole in pilot
valve cartridge.

NOTE: When assembling cushion/suction valve, hold

valve with a 13-mm ring spanner.

2. Remove disc and spring from valve housing. Re-

move housing from pilot valve.

3. Loosen pilot valve from cartridge with a 19-mm

socket wrench. Use a mandrel to hold cartridge.
Remove pilot valve, spring, and spool from car-
tridge.

4. Remove adjustment screw, spring, and piston

Figure 20. Pressure Control/Amplifier Valve from pilot valve.
Spool

20
1900 SRM 953 Flow Amplifier

2. Assemble flow amplifier assembly using the re-

verse of the procedure as described in Disassem-
ble. See Figure 13, Figure 14, Figure 15, Fig-
ure 16, Figure 17, Figure 18, Figure 19, Fig-
ure 20, Figure 21, and Figure 22.

PRESSURE CHECKPORTS
See Figure 23, Figure 24, Figure 25, Figure 26, Fig-
ure 27, Figure 28, and Figure 29 for pressure check-
ports location.

1. LOCK NUT 6. SPRING 1. PRESSURE CHECKPORT

2. PILOT VALVE 7. VALVE HOUSING
3. PILOT VALVE 8. PISTON Figure 23. Boom Extension Pressure Checkport
CARTRIDGE 9. ADJUSTMENT
4. DISC SCREW
5. SPOOL 10. O-RING

Figure 22. Cushion/Suction Valve

Clean

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.

Clean all parts in solvent. Dry parts with compressed

air. Do not dry parts with a cloth. Make sure all 1. PRESSURE CHECKPORT
surfaces are free of scratches and sharp edges.
Figure 24. Pilot Pressure Checkport
Assemble
1. Use new seals, O-rings, and neutral position
springs during assembly. Lubricate all parts
with clean hydraulic oil.

21
Flow Amplifier 1900 SRM 953

1. PRESSURE CHECKPORT 1. PRESSURE CHECKPORT

Figure 25. Steering Pressure Checkport Figure 28. Spreader Supply Pressure
Checkport

1. PRESSURE CHECKPORT
1. PRESSURE CHECKPORT
Figure 26. Boom Hoisting Pressure Checkport
Figure 29. Boom Retraction Pressure
Checkport

1. PRESSURE CHECKPORT

Figure 27. Boom Lowering Pressure Checkport

22
1900 SRM 953 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Slow or no movement of Performing steering and lift func- Stop one of the functions until the
boom lift cylinder(s). tions at the same time. other has been completed.

Pilot pressure is not correct. See PILOT PRESSURE IS NOT

CORRECT.

Pilot lines are damaged or have Replace pilot lines.

leaks.

Lift and/or steering hydraulic pump Repair hydraulic pump that has de-
is damaged or has leaks. fect.

Electric solenoids are not operating Repair or replace defective sole-

correctly. noid(s).

Control sections have damage or Repair control section(s).

leaks.

Relief valves in the control sections Repair damaged relief valve.

have damage.

Cylinders have leaks. Repair leaking cylinder.

Pressure relief valve is damaged. Repair pressure relief valve.

Control section spool not fully ex- Repair main control valve.
tended or retracted.

Restriction in hydraulic lines. Clear restriction or replace restricted

hydraulic line.

Load is greater than capacity of the Decrease load to capacity of system.

system.

Cylinder seals are damaged. Repair cylinder.

Flow amplifier has damage. Repair or replace flow amplifier.

Pilot pressure is not correct. Pilot valve has damage. Replace pilot valve.

Hydraulic pump has damage. Repair hydraulic pump.

Hydraulic hoses between the hy- Clear any restriction or replace hy-
draulic pump and pilot valve are draulic hoses.
damaged or restricted.

23
Diagrams, Schematics, or Arrangements 1900 SRM 953

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Oil leaks from end of control Solenoid attaching screws are loose. Tighten solenoid attaching screws.
section.

Pilot lines are damaged or leak. Replace pilot lines.

Boom control valve spool will Pilot lines are damaged or leak. Replace pilot lines.
not move.

Pilot pressure is not correct. See PILOT PRESSURE IS NOT

CORRECT.

Boom lift cylinders retract Oil leaks between spool and bore of Repair or replace valve.
when spool is in NEUTRAL control valve(s).
position.

Cylinder seals leak. Replace cylinder seals.

Cylinder over center valve leaks. Repair cylinder over center valve.

Boom hoist over center valve has a Repair boom over center valve.
leak.

Hydraulic lines to cylinder(s) leak. Replace hydraulic lines.

Boom control valve spool will Dirt between spool and bore. Disassemble and clean valve.
not return to neutral posi-
tion.

Spool is damaged. Replace spool.

Large leaks between spool and bore. Repair valve.

Supply pressure is above or Relief valve is damaged. Repair or replace relief valve.
below specifications.

Restriction in return line. Remove restriction or replace return

line.

24
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Diagrams, Schematics, or Arrangements 1900 SRM 953

26
1900 SRM 953 Diagrams, Schematics, or Arrangements

Figure 30. Main Hydraulic Schematic (Up to 1536 Except 1529)

27
Diagrams, Schematics, or Arrangements 1900 SRM 953

28
1900 SRM 953 Diagrams, Schematics, or Arrangements

Figure 31. Main Hydraulic Schematic (1529, 1537 and Up)

29
 NOTES

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 TECHNICAL PUBLICATIONS

1900 SRM 953 3/05 (2/01) Printed in United Kingdom