HYDRAULIC PLATE

SERIAL NUMBERS 1642, 1644, 1664, 1665, 1679,

1682, AND AFTER (D117 ONLY)

H36.00-48.00E (H800-1050E) [D117];

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

PART NO. 1513622 1900 SRM 1012

 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 Plate Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 2
Hydraulic Oil Supply..................................................................................................................................... 2
D117 ........................................................................................................................................................... 2
E008 ........................................................................................................................................................... 2
Manifold, Section 1 of Hydraulic Plate......................................................................................................... 2
Two-Spool and Single-Spool Main Control Valves, Section 2 and 3 of Hydraulic Plate ............................ 4
Flow Amplifier, Section 4 of Hydraulic Plate ............................................................................................... 4
Return Manifold, Section 5 of Hydraulic Plate ............................................................................................ 4
Hydraulic Filter ............................................................................................................................................. 8
Relay Valve (D117 Only)................................................................................................................................ 8
Manual Override (E008 Only) ...................................................................................................................... 8
Main Manifold Repair........................................................................................................................................ 9
General ........................................................................................................................................................... 9
Valves and Pressure Switches....................................................................................................................... 10
Main Control Valves Repair .............................................................................................................................. 12
Single Spool and Two Spool........................................................................................................................... 12
Flow Amplifier Repair ....................................................................................................................................... 12
Hydraulic Hose Repair ...................................................................................................................................... 12
Torque Values ..................................................................................................................................................... 12
Measurements and Adjustments ...................................................................................................................... 13
Measurements ............................................................................................................................................... 13
Adjustments ................................................................................................................................................... 13
Diagrams, Schematics, or Arrangements ......................................................................................................... 16
Figure 13. Hydraulic Schematic (D117)................................................................................................... 16
Figure 14. Hydraulic Schematic (E008)................................................................................................... 20
Figure 15. Relay Valve and Auxiliary Brake to Manifold Schematic (D117 Only) ............................... 23

This section is for the following models:

H36.00-48.00E (H800-1050E) [D117];

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

©2003 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1900 SRM 1012 General

General
This section has the description and operation of • Section 2 contains the two spool main control valve.
the hydraulic components that are assembled on the • Section 3 contains the single spool main control
Hydraulic Plate. The section also has disassembly, valve.
assembly, repair, calibration, and troubleshooting • Section 4 contains the flow amplifier.
for most components that are assembled on the • Section 5 contains the return manifold with hose
Hydraulic Plate. assemblies.

The five sections of the Hydraulic Plate are as follows The Hydraulic Plate is an integral part of the total
(see Figure 1): hydraulic system. See the following sections for de-
• Section 1 contains the manifold with most of the scription, operation, and repair information of hy-
hydraulic system valves, test ports, and adapters draulic components in these systems:
for hose/tube connections.

D117 E008
Hydraulic System 1900 SRM 1013 1900 SRM 492
Steering System 1600 SRM 429 1600 SRM 429
Oil Cooled Brakes 1800 SRM 678 1800 SRM 678
Service Brakes 1800 SRM 1038 1800 SRM 1038
Mast 4000 SRM 432 4000 SRM 491
Hydraulic Gear Pumps 1900 SRM 97 1900 SRM 97
Tilt Cylinders 2100 SRM 103 2100 SRM 103
Extendable Container Attachment 5000 SRM 723 5000 SRM 265

Figure 1. Hydraulic Plate Sections (D117 Shown)

1
Description and Operation 1900 SRM 1012

Legend for Figure 1

1. MANIFOLD SECTION 4. FLOW AMPLIFIER SECTION
2. TWO-SPOOL MAIN CONTROL VALVE SECTION 5. RETURN MANIFOLD SECTION
3. SINGLE-SPOOL MAIN CONTROL VALVE
SECTION

Description and Operation

HYDRAULIC OIL SUPPLY E008
Two tandem gear pumps supply the flow of oil for the The cover end section of the right-hand tandem cir-
components of the hydraulic system. These pumps culates oil in the tank through the oil-cooled brakes.
are driven by a gear arrangement in the torque con- The cover end section has a capacity of 48 cm 3
verter housing. The inlet hose for each tandem pump (2.93 in. 3 ) per revolution. The shaft end section of
is connected to the hydraulic tank at a manual shut- this tandem pump supplies oil for the single spool
off valve. See Figure 13 and Figure 14. main control valve. The shaft end section has a
capacity of 42 cm 3 (2.56 in. 3 ) per revolution.
D117
The cover end section of the left-hand tandem pump
The cover end section of the right-hand tandem pump supplies oil to the accumulator charge valve for the
supplies oil to the accumulator charge valve for the brake system. The cover end section has a capacity
brake system. The cover end section has a capacity of 36 cm 3 (2.2 in. 3 ) per revolution. The shaft end
of 42.4 cm 3 (2.59 in. 3 ) per revolution. The shaft end section of this pump supplies oil to the flow amplifier
section of this tandem pump supplies oil for the sin- for the steering system. The shaft end section has
gle spool main control valve. The shaft end section a capacity of 97 cm 3 (5.9 in. 3 ) per revolution. Oil
has a capacity of 96.5 cm 3 (5.89 in. 3 ) per revolution. that is not needed for the steering flows from the flow
amplifier to the two spool main control valve. When
The cover end section of the left-hand tandem pump the operator is not steering, all of the oil from the
circulates oil in tank through heat exchanger circuit pump flows to the main control valve.
and oil-cooled brakes. The cover end section of this
pump has a capacity of 48 cm 3 (2.93 in. 3 ) per revo- NOTE: Oil that is returned to the hydraulic tank is
lution. The shaft end section of this pump supplies filtered.
oil to flow amplifier for steering system. The shaft
end section of this pump has a capacity of 128.8 cm 3 MANIFOLD, SECTION 1 OF HYDRAULIC
(7.86 in. 3 ) per revolution. Oil that is not needed for PLATE
steering flows from flow amplifier to the two spool
main control valve. When the operator is not steer- The relief valve (1) limits input oil pressure supplied
ing, all of oil from pump flows to main control valve. to accumulator charge valve to 22.06 MPa (3200 psi).
See Figure 2, Figure 13 and Figure 14. The accu-
NOTE: Oil that is returned to the hydraulic tank is mulator charge valve controls charging rate and
filtered. pressure of oil in the accumulator for brake system.

2
1900 SRM 1012 Description and Operation

The accumulator charge valve stops charging when or right hand pedal, hydraulic oil flows to the shuttle
accumulator pressure reaches upper limit. See Ta- valve and then to service brakes. Both pedals will
ble 1. When accumulator pressure reaches lower engage the brake pressure switch to operate the
limit, see Table 1, the accumulator charge valve stop lights. For declutch/brake treadle and brake
allows oil from pump to charge accumulator. Adjust- treadle pressures, see Table 2. Brake pressure can
ment at the spring of check valve in accumulator be measured at check port M8.
charge valve sets high limit pressure at accumulator.
This pressure can be measured at check port M4. Oil pressure from accumulator is also supplied to the
For detailed information on accumulator charging pressure switch that operates the warning light in
circuit, see Oil Cooled Brakes 1800 SRM 678. event of low brake pressure and to the solenoid valve
(8) for the parking brake. See Figure 2 and Figure 13.
Oil pressure from accumulator is supplied to de- The solenoid valve can be operated by a switch lo-
clutch/brake treadle and brake treadle. The right cated on the instrument panel. The solenoid valve is
hand pedal only activates the service brakes. The normally energized during operation for oil pressure
left hand pedal first activates service brakes and to compress the spring to release parking brake. For
further pushing of pedal will also fully disengage further information on brake circuit, see Oil Cooled
transmission. When activating either the left hand Brakes 1800 SRM 678.

Table 1. Accumulator Charge Valve Pressures

Upper Limit Lower Limit

D117 18.61 to 19.30 MPa 14.13 to 14.82 MPa
(2700 to 2800 psi) (2050 to 2150 psi)
D117 (1644, 1720 wide axle, 1724 18.3 to 19.0 MPa 15.5 to 16.2 MPa
narrow axle and after) (2650 to 2750 psi) (2250 to 2350 psi)
E008 (wet brakes) 18.61 to 19.30 MPa 14.13 to 14.82 MPa
(2700 to 2800 psi) (2050 to 2150 psi)

Table 2. Brake Treadle Settings

Declutch/Brake Treadle Brake Treadle

D117 with auxiliary brakes 10.7 MPa (1550 psi) 10.7 MPa (1550 psi)
D117 without auxiliary brakes 10.7 MPa (1550 psi) 15.2 MPa (2200 psi)
E008 (wet brakes) 10.7 MPa (1550 psi) 10.7 MPa (1550 psi)

3
Description and Operation 1900 SRM 1012

The reducer valve (9) is set at 2068 kPa (300 psi) and Figure 13 and Figure 14. The two- spool main con-
controls the pressure and supply of hydraulic oil to trol valve receives oil from the, 128.8 cm 3 (7.86 in. 3 )
pilot circuits for remote control valves for lift and tilt. (D117), or, 97 cm 3 (5.9 in. 3 ) (E008), per revolution
See Figure 2, Figure 13 and Figure 14. This valve pump through the flow amplifier. The single- spool
can be checked at check port M2. Pilot pressure is main control valve receives oil from the, 96.5 cm 3
also supplied to the directional control valve. The (5.89 in. 3 ) (D117), or, 42 cm 3 (2.56 in. 3 ) (E008), per
directional control valve receives oil from the accu- revolution pump. Relief valves in the main control
mulator charge valve to operate the carriage or at- valves control pressure of supply oil in lift and tilt cir-
tachments functions. This accumulator charge valve cuits. These relief valves are set at 15.5 to 16.2 MPa
oil pressure can be measured at check port M1. The (2250 to 2350 psi). Two additional relief valves are
directional control valve will, depending on the func- set at 690 kPa (100 psi) for the return circuits. The
tion selected by operator, cause either output Y or remote control valve actuates the main control valve
output Z to supply hydraulic oil to carriage/attach- to let mast lift at two different speeds. The pressure
ment. When output Y supplies the oil, solenoid valve of the hydraulic oil supplied to the single-spool main
(14) provides the return to hydraulic tank. When valve can be checked at check port M6. For further
output Z supplies the oil, solenoid (13) provides the information, see Hydraulic System 1900 SRM 1013
return to hydraulic tank. See Figure 13 and Fig- for D117 models and Hydraulic System 1900 SRM
ure 14. When no function is selected by the opera- 492 for E008 models.
tor, both solenoid valves provide return to hydraulic
tank. This prevents damage to cylinders in case at- FLOW AMPLIFIER, SECTION 4 OF
tachment/container get accidentally obstructed dur- HYDRAULIC PLATE
ing truck movement. Oil that is not used to operate
auxiliary functions is added via the non-return valve The flow amplifier regulates and directs flow of oil
to the flow from main pump to inlet of single spool to the steering cylinder. See Figure 3 and Figure 13.
main control valve. The pressure of the oil to the sin- The flow amplifier increases oil flow five times more
gle spool main control valve can be checked at check than pilot input flow from steering control unit. The
port M6. Over lowering and loose chain protection is rate of oil flow to steering cylinder is directly propor-
given by the solenoid valve (17). See Figure 2, Fig- tional to rate of pilot flow from steering control unit.
ure 13 and Figure 14. This solenoid prohibits fur- The flow amplifier receives oil from the, 128.8 cm 3
ther lowering and forward tilt by connecting the pi- (7.86 in. 3 ) (D117), or, 97 cm 3 (5.9 in. 3 ) (E008), per
lot command lines to the hydraulic tank. This valve revolution pump. When there is no steering demand,
is activated by the pressure switches. Lift interrupt, the priority valve in the flow amplifier allows oil to
no lift of tilt function, is given by the solenoid valve flow from pump to main control valve. The pressure
(19). See Figure 2, Figure 13 and Figure 14. This of hydraulic oil supplied to amplifier can be checked
solenoid prohibits back tilt and lift by connecting the at check port M7. For further information, see Steer-
pilot command lines to the hydraulic tank. For fur- ing System 1600 SRM 429.
ther information, see Hydraulic System 1900 SRM
1013 for D117 models and Hydraulic System 1900 RETURN MANIFOLD, SECTION 5 OF
SRM 492 for E008 models. HYDRAULIC PLATE
TWO-SPOOL AND SINGLE-SPOOL MAIN Hydraulic return lines from components on the Hy-
CONTROL VALVES, SECTION 2 AND 3 OF draulic Plate are connected to the return manifold.
See Figure 3, Figure 4 and Figure 13. One hydraulic
HYDRAULIC PLATE line connects manifold to filter section in the hy-
The two- spool and single- spool main control valve draulic tank. The pressure of hydraulic oil that is
controls lift, lower, and tilt functions. See Figure 3, returned to tank can be checked at check port M9.

4
1900 SRM 1012 Description and Operation

Figure 2. Manifold (D117 Shown)

5
Description and Operation 1900 SRM 1012

Legend for Figure 2

NOTE: THE FOLLOWING TABLE INDICATES HYDRAULIC CONNECTIONS TO/FROM THE MANIFOLD. LETTER-
ING IN PARENTHESIS INDICATES LOCATION AND IS STAMPED ON MANIFOLD.

Hydraulic Line Connections

Location Connection Location Connection
From Remote Control Valves
(A) From Remote Control Valves (lift up) (F)
(tilt backward)
From Remote Control Valves
(ACCU) To/From Accumulator (GH)
(return to tank)
From 96.5 cm 3 (5.89 in. 3 )
Pump (D117)
(AF) To Hydraulic Tank (KK)
From 42 cm 3 (2.56 in. 3 ) Pump (E008)
From 42.4 cm 3 (2.59 in. 3 )
From Remote Control Valves Pump (D117)
(B) (MM)
(lift lower)
From 36 cm 3 (2.2 in. 3 ) Pump (E008)
To Remote Control Valves
(C) (WW) From Service Brake Pedal
(pilot pressure)
(CC) From Declutch/Brake Pedal (XX) To Service Brakes
(D) To Brake Treadle (Y) To carriage or attachment
From Remote Control Valves
(E) (Z) To carriage or attachment
(tilt forward)
(EE) To Parking Brake

NOTE: 1 THROUGH 19 ARE VALVES, MEASUREMENT PORTS, AND PRESSURE SWITCHES. NUMBERS IN
PARENTHESIS INDICATE LOCATION AND ARE STAMPED ON MANIFOLD.

Item Description Stamping on Manifold

1 Relief Valve (114)
2 Accumulator Charge Valve (116)
3 Check Port M4 N/A
4 Shuttle Valve (232)
5 Brake Pressure Switch (120)
6 Check Port M8 N/A
7 Pressure Switch (54)
8 Solenoid Valve (Parking Brake) (115)
9 Reducer Valve (112)
10 Check Port M2 N/A
11 Directional Control Valve (107)
12 Check Port M1 N/A

6
1900 SRM 1012 Description and Operation

Legend for Figure 2 (Continued)

Item Description Stamping on Manifold

13 Solenoid Valve (Bleeder Aux. Y) (490)
14 Solenoid Valve (Bleeder Aux. X) (490)
15 Nonreturn Valve (168)
16 Check Port M5 N/A
17 Solenoid Valve (Lower Interrupt) (430)
18 Solenoid Valve (Lift Interrupt) (460)

Figure 3. Hydraulic Plate Layout (D117)

Legend for Figure 3

Main Control Valve Connections

Line Connection Line Connection
(AB) To Lift Manifold (AE) To Lift Manifold
(AC) To Lift Manifold (UU) To Tilt Manifold
(AD) To Lift Manifold (VV) To Tilt Manifold

1. RETURN MANIFOLD 5. SINGLE-SPOOL MAIN CONTROL VALVE

2. CHECK PORT M9 6. TWO-SPOOL MAIN CONTROL VALVE
3. FLOW AMPLIFIER 7. CHECK PORT M6
4. CHECK PORT M7

7
Description and Operation 1900 SRM 1012

Figure 4. Hydraulic Plate Layout (E008)

Legend for Figure 4

Main Control Valve Connections

Line Connection Line Connection
(AB) To Lift Manifold (AN) To Hydraulic Oil Cooler
(AC) To Lift Manifold (AP) From Hydraulic Oil Cooler
(AD) To Lift Manifold (UU) To Tilt Manifold
(AE) To Lift Manifold (VV) To Tilt Manifold

1. RETURN MANIFOLD 5. SINGLE-SPOOL MAIN CONTROL VALVE

2. CHECK PORT M9 6. TWO-SPOOL MAIN CONTROL VALVE
3. FLOW AMPLIFIER 7. CHECK PORT M6
4. CHECK PORT M7 8. HYDRAULIC TANK RETURN

HYDRAULIC FILTER D117 1720 (wide axle) and D117 1724 (narrow axle)
and after, there is no auxiliary brake and the relay
The hydraulic filter provides filtering of hydraulic oil valve has been removed. For further information on
before it is supplied to hydraulic plate. See Figure 5. relay valve, see Oil Cooled Brakes 1800 SRM 678.
For further information on the hydraulic filter, see
Hydraulic System 1900 SRM 1013 for D117 mod- MANUAL OVERRIDE (E008 ONLY)
els and Hydraulic System 1900 SRM 492 for E008
models. The push and twist manual override, in the event
of a hydraulic system power failure, can be operated
RELAY VALVE (D117 ONLY) to create pilot pressure which makes lowering of the
mast possible. See Figure 6.
The relay valve is used to regulate the pressure to
the auxiliary disc brake. See Figure 15. For models

8
1900 SRM 1012 Main Manifold Repair

Figure 5. Hydraulic Filter and Relay Valve

(D117 Only)

Legend for Figure 5

1. HYDRAULIC 2. RELAY VALVE
FILTER

Figure 6. Push and Twist Override (E008 Only)

Legend for Figure 6
1. MANUAL OVERRIDE

Main Manifold Repair

GENERAL Some parts have compressed springs under
them that can have enough force to cause dam-
All pressure switches, valves, and other associated age or injury. Always use caution and wear eye
items installed on the manifold can be replaced. Be- protection when removing parts.
fore removal of any part, check that the area is clean
and protected against dirt and fluid contamination. Before removing any hydraulic components or
disconnecting any hydraulic lines, release the
For removal, cleaning, inspection, assembly, and in- hydraulic pressure from the hydraulic circuit
stallation of the accumulator charge valve and direc- as follows:
tional control valve, see Oil Cooled Brakes 1800 • Shut engine off and completely lower car-
SRM 678, Hydraulic System 1900 SRM 1013 for riage. Install blocks at wheels to prevent lift
D117 models and Hydraulic System 1900 SRM 492 truck from moving.
for E008 models. • Operate lift/lower lever and brake pedals un-
til hydraulic pressure is released.
WARNING
The manifold (see Figure 2) is an integral part of the
Never work under a raised carriage or forks.
Hydraulic Plate. For more information on the repairs
Lower the carriage or use blocks and chains on
to all parts of the Hydraulic Plate, see Hydraulic
the mast weldments and carriage so that they
System 1900 SRM 1013 for D117 models and Hy-
cannot move. Verify the moving parts are at-
draulic System 1900 SRM 492 for E008 models.
tached to parts that do not move.

9
Main Manifold Repair 1900 SRM 1012

VALVES AND PRESSURE SWITCHES

WARNING
Cleaning solvents can be flammable and toxic.
Cleaning solvents can also cause skin irrita-
tion. When using cleaning solvents, always fol-
low the solvent manufacturer’s recommended
safety precautions.

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.
Figure 7. Solenoid Control Valve Cartridge
NOTE: Cartridge valves and switches are not field- (Lower Interrupt Valve)
serviceable with exception of external seals and elec-
trical solenoids. In event of a defective component, Legend for Figure 7
completely replace valve of switch.
1. O-RING 3. BACKUP RING
2. O-RING
NOTE: Check manifold for cracks. If there are cracks
in manifold, the manifold should be replaced.

The valves and pressure switch seals are serviceable

parts of the manifold. Use the following procedures
for repair:

1. Unscrew the cartridge valve of switch from man-

ifold.

2. Check that all seals are attached to cartridge

valve or switch.

3. Install a temporary plug in place of cartridge

valve or switch.
Figure 8. Shuttle Valve Cartridge
4. Clean cartridge valve or switch in solvent and
Legend for Figure 8
inspect component for damage.
1. O-RING 5. BACKUP RING
5. Install new seals. For correct order of backup 2. BACKUP RING 6. O-RING
rings and O-rings. See Figure 7, Figure 8, Fig- 3. O-RING 7. BACKUP RING
ure 9, Figure 10, Figure 11, and Figure 12. 4. BACKUP RING

6. Lubricate component/valve with clean hydraulic

oil before installation.

7. Remove temporary plug.

8. Install and torque component/valve or switch to

value listed in Torque Values.

10
1900 SRM 1012 Main Manifold Repair

Legend for Figure 10

1. O-RING 5. BACKUP RING
2. BACKUP RING 6. O-RING
3. O-RING 7. BACKUP RING
4. BACKUP RING

Figure 11. Check Valve Cartridge

Legend for Figure 11

1. O-RING 3. BACKUP RING
2. O-RING
Figure 9. Solenoid Control Valve Cartridge
(Lift Interrupt/Bleeder Valve)
Legend for Figure 9
1. O-RING 5. BACKUP RING
2. BACKUP RING 6. O-RING
3. O-RING 7. BACKUP RING
4. BACKUP RING

Figure 12. Relief Valve, Fixed Cap /Tamper

Resistant Version

Legend for Figure 12

1. O-RING 3. O-RING
2. BACKUP RING

Figure 10. Pressure Reducing Valve, Regulated

11
Torque Values 1900 SRM 1012

Main Control Valves Repair

SINGLE SPOOL AND TWO SPOOL
There are no repairable components in these valves. If there is a malfunction of a valve, replace defective valve.
See Figure 3 and Figure 4.

Flow Amplifier Repair

The flow amplifier regulates and directs the flow of oil to the steering system. See Figure 3 and Figure 4. For
the removal, cleaning, inspection, assembly, and installation of the flow amplifier, see Steering System 1600
SRM 429.

Hydraulic Hose Repair

When lift truck is used in dirty conditions, it is recommended to replace hoses every 5 years or 10,000 hours of
service regardless of condition.

Torque Values
Valve/Cartridge Torque Specifications
Cartridge Size 210 bar (3046 psi) 345 bar (5004 psi)
#04 7 N•m (5 lbf ft) 9 N•m (7 lbf ft)
#06 14 N•m (10 lbf ft) 16 N•m (12 lbf ft)
#07 20 N•m (15 lbf ft) 31 N•m (23 lbf ft)
#08 20 N•m (15 lbf ft) 31 N•m (23 lbf ft)
#09 20 N•m (15 lbf ft) 31 N•m (23 lbf ft)
#10 22 N•m (16 lbf ft) 65 N•m (48 lbf ft)
#12 28 N•m (21 lbf ft) 76 N•m (56 lbf ft)
#16 54 N•m (40 lbf ft) 99 N•m (73 lbf ft)
#20 113 N•m (83 lbf ft) 133 N•m (98 lbf ft)

Nonadjustable Adapter Assembly Torques

Size Port Thread Assembly Torque
#04 7/16" - 20UNF-2A 20 to 22 N•m (15 to 16 lbf ft)
#06 9/16" - 18UNF-2A 45 to 50 N•m (33 to 37 lbf ft)
#08 3/4" - 16UNF-2A 80 to 88 N•m (59 to 65 lbf ft)
#12 1 1/16" - 12UNF-2A 185 to 204 N•m (136 to 150 lbf ft)
#16 1 5/16" - 12UNF-2A 270 to 297 N•m (199 to 219 lbf ft)
#20 1 5/8" - 12UNF-2A 340 to 374 N•m (251 to 276 lbf ft)

12
1900 SRM 1012 Measurements and Adjustments

Adjustable Adapter Assembly Torques

Size Port Thread Assembly Torque
#04 7/16" - 20UNF-2A 20 to 22 N•m (15 to 16 lbf ft)
#06 9/16" - 18UNF-2A 45 to 50 N•m (33 to 37 lbf ft)
#08 3/4" - 16UNF-2A 80 to 88 N•m (59 to 65 lbf ft)
#12 1 1/16" - 12UNF-2A 185 to 204 N•m (136 to 150 lbf ft)
#16 1 5/16" - 12UNF-2A 270 to 297 N•m (199 to 219 lbf ft)
#20 1 5/8" - 12UNF-2A 340 to 374 N•m (251 to 276 lbf ft)

Swivel Fitting Assembly Torques

Size Port Thread Assembly Torque
#6 11/16" - 18UNF-2A 24 to 27 N•m (18 to 20 lbf ft)
#8 13/16" - 16UNF-2A 43 to 47 N•m (32 to 35 lbf ft)
#12 1 3/16" - 16UNF-2A 90 to 95 N•m (66 to 70 lbf ft)
#16 1 7/16" - 12UNF-2A 125 to 135 N•m (92 to 100 lbf ft)
#20 1 11/16" - 12UNF-2A 170 to 190 N•m (125 to 140 lbf ft)

Tube Side Assembly Torques

Size Tube Diameter Nut Thread Assembly Torque
#6 10 mm 11/16" - 18UNF-2A 33 to 36 N•m (24 to 27 lbf ft)
#12 20 mm 13/16" - 16UNF-2A 115 to 127 N•m (85 to 94 lbf ft)

Measurements and Adjustments

MEASUREMENTS ADJUSTMENTS
• Always check service manual before checking or Normally, replacement valves are delivered with cor-
adjusting pressures. See Table 3. rect pressure preset. Should adjustment be required,
• Always check pressures at working temperature of observe the following:
hydraulic oil. 60 to 80 C (140 to 176 F). • To raise pressure, turn adjustment screw/knob
• Always check pressures at required engine speed. clockwise.
• To lower pressure, turn adjustment screw/knob
counterclockwise.
• When lowering pressure, first lower pressure to be-
low required value and then increase pressure to
required level.

13
Measurements and Adjustments 1900 SRM 1012

Table 3. Pressure Settings

Port Description Valve Setting Condition

M1 Front end auxiliary relief 21.7 to 22.4 MPa Measure at full throttle
pressure (3150 to 3250 psi)
M2 Pilot pressure 2.1 to 2.2 MPa
Measure at idle
(300 to 325 psi)
M4 Accumulator pressure 18.6 to 19.3 MPa Measure lower limit pressure
(2700 to 2800 psi) 14.13 to 14.82 MPa (2050
to 2150 psi) and upper limit
pressure 18.61 to 19.30 MPa
(2700 to 2800 psi).
Accumulator pressure D117 18.3 to 19.0 MPa Measure lower limit pressure
(1644, 1720 wide axle, 1724 (2650 to 2750 psi) 15.5 to 16.2 MPa (2250 to
M4 narrow axle and after) 2350 psi) and upper limit
pressure 18.3 to 19.0 MPa
(2650 to 2750 psi).
M5 Single-spool main control 18.2 to 18.9 MPa Measure at full throttle
valve (2650 to 2750 psi)
M6 Two-spool main control valve 18.2 to 18.9 MPa Measure at full throttle
(2650 to 2750 psi)
M7 Steering relief 18.6 to 19.3 MPa Measure at full throttle
(2700 to 2800 psi)
M8 Brake pressure 10.3 to 10.7 MPa Apply service brakes
(1500 to 1550 psi)
M8 Brake pressure without 15.2 to 15.5 MPa Apply service brakes
auxiliary brakes (D117 only) (2200 to 2250 psi)
10.3 to 10.7 MPa Apply declutch\brake
(1500 to 1550 psi)
M9 Return manifold N/A

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Diagrams, Schematics, or Arrangements 1900 SRM 1012

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1900 SRM 1012 Diagrams, Schematics, or Arrangements

Figure 13. Hydraulic Schematic (D117)

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Diagrams, Schematics, or Arrangements 1900 SRM 1012

Legend for Figure 13

NOTE: NUMBERS IN BOX INDICATE STAMPING ON MANIFOLD. SEE FIGURE 13.

Item Stamping on Manifold Description

1 114 Relief Valve
2 116 Accumulator Charge Valve
3 N/A Check Port M4
4 232 Shuttle Valve
5 120 Brake Pressure Switch
6 N/A Check Port M8
7 54 Pressure Switch
8 115 Solenoid Valve
9 112 Reducer Valve
10 N/A Check Port M2
11 107 Directional Control Valve
12 N/A Check Port M1
13 490 Solenoid Valve
14 490 Solenoid Valve
15 168 Nonreturn Valve
16 N/A Check Port 5
17 430 Solenoid Valve
18 460 Solenoid Valve
19 N/A Two-Spool Main Control Valve
20 N/A Single-Spool Main Control Valve
21 N/A Check Port M6
22 N/A Flow Amplifier
23 N/A Check Port M7
24 N/A Return Manifold
25 N/A Check Port M9

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Diagrams, Schematics, or Arrangements 1900 SRM 1012

20
1900 SRM 1012 Diagrams, Schematics, or Arrangements

Figure 14. Hydraulic Schematic (E008)

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Diagrams, Schematics, or Arrangements 1900 SRM 1012

Legend for Figure 14

NOTE: NUMBERS IN BOX INDICATE STAMPING ON MANIFOLD. SEE FIGURE 13.

Item Stamping on Manifold Description

1 114 Relief Valve
2 116 Accumulator Charge Valve
3 N/A Check Port M4
4 232 Shuttle Valve
5 120 Brake Pressure Switch
6 N/A Check Port M8
7 54 Pressure Switch
8 115 Solenoid Valve
9 112 Reducer Valve
10 N/A Check Port M2
11 107 Directional Control Valve
12 N/A Check Port M1
13 490 Solenoid Valve
14 490 Solenoid Valve
15 168 Nonreturn Valve
16 N/A Check Port 5
17 430 Solenoid Valve
18 460 Solenoid Valve
19 N/A Two-Spool Main Control Valve
20 N/A Single-Spool Main Control Valve
21 N/A Check Port M6
22 N/A Flow Amplifier
23 N/A Check Port M7
24 N/A Return Manifold
25 N/A Hydraulic Oil Cooler
26 N/A Manual Override

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1900 SRM 1012 Diagrams, Schematics, or Arrangements

Figure 15. Relay Valve and Auxiliary Brake to Manifold Schematic (D117 Only)

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 TECHNICAL PUBLICATIONS

1900 SRM 1012 9/03 (12/02)(3/02)(12/01) Printed in United Kingdom