Maintenance

HYDRAULIC SYSTEM
ESC030-040FA [A883]

PART NO. 524153635 1900 YRM 998

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

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

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Multifunction Control Handle ............................................................................................................................... 1
Description ...................................................................................................................................................... 1
Manual Lowering ................................................................................................................................................. 2
How to lower mast manually ........................................................................................................................... 2
Main Hydraulic Control Valve............................................................................................................................... 3
Description ...................................................................................................................................................... 3
Check and Adjust ............................................................................................................................................ 3
Manifold Pressures ..................................................................................................................................... 3
Counter Balance Valve ............................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Repair.............................................................................................................................................................. 5
Disassemble ............................................................................................................................................... 5
Clean .......................................................................................................................................................... 6
Assemble .................................................................................................................................................... 6
Install............................................................................................................................................................... 6
Lift Pump and Motor ............................................................................................................................................ 8
Description ...................................................................................................................................................... 8
Remove ........................................................................................................................................................... 8
Motor........................................................................................................................................................... 8
Lift Pump..................................................................................................................................................... 9
Install............................................................................................................................................................... 9
Lift Pump..................................................................................................................................................... 9
Motor........................................................................................................................................................... 10
Lift Pump ............................................................................................................................................................. 10
Description ...................................................................................................................................................... 10
Disassemble.................................................................................................................................................... 10
Assembly......................................................................................................................................................... 11
Hydraulic Tank ..................................................................................................................................................... 12
Inspect............................................................................................................................................................. 12
Remove ........................................................................................................................................................... 12
Clean............................................................................................................................................................... 14
Steam Method ............................................................................................................................................ 14
Trisodium Phosphate Method ..................................................................................................................... 15
Install............................................................................................................................................................... 15
Troubleshooting ................................................................................................................................................... 16

This section is for the following models:

ESC030-040FA [A883]

©2003 Yale Materials Handling Corp. i

1900 YRM 998 Multifunction Control Handle

General
The hydraulic system for these lift trucks is comprised Figure 2. This valve is custom designed to provide full
of three subsystems. These subsystems are: proportional control of all hydraulic functions except
• Main Hydraulic - Lift and lower steering. To provide maximum control, each function
• Auxiliary Hydraulic - Tilt and optional sideshift is operated electronically using an electro-hydraulic
• Power steering EPV valve. Separate lift and auxiliary relief valves are
provided to allow operation at different pressures and
The hydraulic system includes two pumps. The lift minimize energy consumption.
pump will only operate when the control handle is
moved to start the lift function, the tilt/sideshift disk is The electro-hydraulic control valve is actuated by the
pressed, or an auxiliary function button is pressed. The control handle. The multifunction control handle is a
steering pump operates when the key is turned ON and two axis control used for both hydraulic and traction op-
the traction contactor is in. The lift pump and steering eration.
pump are located under the hydraulic cover.

The main and auxiliary hydraulic functions are con-

trolled by an electro-hydraulic control valve. See

Multifunction Control Handle

DESCRIPTION Travel is activated by moving the control handle in the
direction of travel. Moving the control handle forward
WARNING (toward the forks) provides forward travel. For travel
in reverse (away from the forks), the control handle is
Unintentional mast lowering can cause damage or
moved rearward. The travel speed for both directions
injury.
is proportional to the distance the handle is moved; the
The Multifunction Control Handle (control handle) pro- further the distance, the faster the lift truck travels.
vides operator control for travel, lift, lower, tilt, sideshift,
The control handle also controls the direction and speed
horn, and auxiliary hydraulic functions. See Figure 1.
at which the carriage moves on the mast. The lift/lower
function is activated by tilting the control handle left or
right. When the control handle is moved to the right,
the carriage lifts. When the control handle is moved to
the left, the carriage lowers. The speed of the carriage
is also proportional to the distance the control handle is
pushed.

The auxiliary functions are controlled by two buttons lo-

cated on the underside of the control handle. A button
to activate the horn is located on the top of the handle,
to the left of the tilt/sideshift disk.

A thumb-operated tilt/sideshift disk, located at the top

of the control handle, controls tilt and sideshift. See
1. TILT/SIDESHIFT DISK Figure 1. To tilt forward, the top of the disk is pressed.
2. HORN BUTTON
3. AUXILIARY HYDRAULIC BUTTONS To tilt back press the bottom of the disk. To activate
the sideshift function, press the right side of the disk to
Figure 1. Multifunction Control Handle move the carriage to the right. Press the left side of the
disk to move the carriage to the left.

1
Manual Lowering 1900 YRM 998

NOTE: Diagonal movement of the handle will control the control handle. The MCU, in turn, detects the po-
both travel and a hydraulic function simultaneously. sition of the control handle and/or position change and
outputs a signal to the control valve. The MCU also con-
NOTE: During lift truck operation, only one auxiliary trols the operation of the lift pump.
function can be selected at a time.

In response to operator commands, control signals are

sent to the Curtis 1310 Master Control Unit (MCU) via

Manual Lowering
HOW TO LOWER MAST MANUALLY

WARNING
Allow no one under or near the lift mechanism or
load during the manual lowering procedure.

WARNING
Always verify that there are no obstructions be-
neath the lift mechanism or load before attempting
to lower manually.

Manual lowering is accomplished by first pushing in the

Load Holding check valve button (button A), turning it
counterclockwise 180 and releasing it. See Figure 2.
In this position, the valve will remain open and the mast
will begin lowering at a slow rate. To increase the lower-
ing rate carefully turn the manual override thumb screw
(button B) slowly clockwise until the forks begin to lower
at a faster rate. Be sure to return the screw to the orig-
inal position once the manual lowering process is com-
plete by slowly turning the screw counterclockwise until
it stops. Then push in the Load Holding check valve
button and turn it clockwise 180 to close it.
Figure 2. Hydraulic Control Valve

2
1900 YRM 998 Main Hydraulic Control Valve

Main Hydraulic Control Valve

DESCRIPTION there should not be any pressure for the two ports going
back to the tank. For pressure settings, see Table 1.
The main hydraulic control valve (control valve) is lo-
cated under the hydraulic cover and is secured to the 1. Connect a 28 MPa (4050 psi) gauge to the the
frame by four capscrews and washers. pump pressure port. See Figure 3.

The control valve consists of a manifold block containing

electrically controlled solenoid valves and electro-pro-
portional valves. These valves control and direct the
flow of hydraulic oil for the various hydraulic functions.
Lift and auxiliary circuits provide pressure compensated
operation. The lift and lower functions of the mast are
proportionally controlled by way of handle position. The
auxiliary functions are programmable and are controlled
through selectable settings.

Primary Relief Valve Setting.

19.3 ± 0.69 MPa (2800 ± 100 psi)

Counterbalance Relief Valve Setting.

20.7 ± 0.69 MPa (3000 ± 100 psi)

Auxiliary Relief Valve Setting.

13.8 ± 0.69 MPa (2000 ± 100 psi)

CHECK AND ADJUST 1. TANK PRESSURE PORT

2. PUMP PRESSURE PORT
3. HOIST PRESSURE POST
Manifold Pressures
Figure 3. Pressure Check
NOTE: Hoist pressure should be the same pressure as
pump pressure when lifting at full speed. When lifting
Table 1. Pressure Settings

No Load 1361 kg (3000 lb) 1588 kg (3500 lb) 1814 kg (4000 lb)
Free Lift Main Free Lift Main Free Lift Main Free Lift Main Relief
kPa (psi) Hoist kPa (psi) Hoist kPa (psi) Hoist kPa (psi) Hoist kPa (psi)
kPa (psi) kPa (psi) kPa (psi) kPa (psi)
Pump 4123 5495 10,301 13,597 11,128 14,562 12,500 16,341 19,651
Pressure (598) (797) (1494) (1972) (1614) (2112) (1813) (2370) (2850)

3
Main Hydraulic Control Valve 1900 YRM 998

Counter Balance Valve

WARNING
1. Tilt the mast to the full back position with a load on Make sure the brake pedal is released and the
the forks. brakes are applied. Put blocks on both sides (front
and back) of the drive tires.
2. Dissable the hydraulic motor.
2. Turn key switch ON.
NOTE: If after completing Step 3 the mast does not be-
gin to drift forward, the counter balance valve is good. If 3. To relieve hydraulic pressure from lift circuit, hold
after completing Step 3 the mast begins to drift forward, control handle in lower position to completely lower
the counter balance valve is bad. forks, then press tilt/sideshift disk to tilt forks forward
completely.
3. Press the tilt forward button on the control tiller to
open the tilt solenoid. 4. Turn key switch OFF.

REMOVE 5. Disconnect battery.

1. Move lift truck to a safe, level area. 6. Remove electrical cover. See Frame 100 YRM
994, Covers and Pads, Remove.

1. HOUSING 6. TILT CONTROL

2. LIFT/LOWER CONTROL 7. PRESSURE REDUCER
3. LIFT PROPORTIONAL CONTROL 8. AUXILIARY CONTROL FUNCTION 2
4. LOWER PROPORTIONAL CONTROL 9. AUXILIARY CONTROL FUNCTION 1
5. AUXILIARY PROPORTIONAL CONTROL 10. RELIEF VALVE

Figure 4. Main Hydraulic Control Valve

4
1900 YRM 998 Main Hydraulic Control Valve

7. Remove hydraulic cover. See Frame 100 YRM 19. Remove two bottom capscrews and washers that
994, Covers and Pads, Remove. hold control valve to frame.

8. Tag all wires connected to control valve for identifi-

cation and later installation.
WARNING
The main hydraulic control valve is heavy, it weighs
9. Disconnect all wires connected to control valve. approximately 15.9 kg (35 lb).

10. Tag all hydraulic hoses connected to control valve 20. Carefully remove two top capscrews and washers
for identification and later installation. that hold control valve to frame.

21. Remove control valve and place it on a clean work-

WARNING bench for further disassembly.
Hydraulic oil is hot after system operation and can
cause burns. Do not disconnect any hydraulic lines REPAIR
until the oil in the system is cool.

11. Place a large drip pan under lift truck, in area below CAUTION
control valve. Make certain that the work area is clean. The con-
trol valve and its components are manufactured
12. Place rags under and around control valve to pro- to close tolerances. Any dirt in the system could
tect drive motors from oil spillage. cause the components to stick and the valve could
malfunction.
13. Obtain a clean bucket to drain excess oil into.
The disassembly and repair of the control valve is lim-
CAUTION ited to the replacement of the coils, solenoid valves,
Extra care must be taken to prevent any dirt or con- proportional valves, main relief valve, pressure reducer,
taminants from entering the hydraulic system. counter balance, flow control, and check valve. New
O-rings and backup rings must be installed when re-
14. Disconnect control valve hydraulic return hose at placing any of the above items.
hydraulic tank top connector.
Disassemble
15. Bend return hose away from tank and drain excess
hydraulic oil into bucket. 1. Remove all hydraulic fittings from control valve.

16. Disconnect hydraulic hoses from control valve one 2. Inspect all hydraulic fittings for any damage. Re-
at a time. place any damaged fittings.

NOTE: To prevent contamination of the hydraulic sys- NOTE: For assembly purposes pay special attention to
tem immediately plug any open ports or hoses. the orientation of the writing (embossed letters) on the
coil(s) to be removed. It is important that they are as-
17. Plug control valve ports and plug hoses to prevent sembled with the writing facing that direction. Also pay
dirt from entering the system and oil from leaking. special attention to placement of all O-rings installed
with the coils.
WARNING 3. Remove nuts securing coils.
The battery is heavy and should by removed care-
fully to avoid causing damage or injury. Remove the 4. Slide coil(s) off.
battery using a battery puller and stand. Use care
to avoid injury. Do NOT put hands, arms, feet, and 5. Remove defective cartridge(s).
or legs between the battery and a solid object.
6. Inspect cavity for burrs or other machining irregu-
18. Remove battery to gain access to two bottom larities which could damage O-rings during instal-
capscrews and washers that hold control valve to lation.
frame.
7. Plug cavities to keep contaminants out.

5
Main Hydraulic Control Valve 1900 YRM 998

Clean Table 2. Main Hydraulic Control Valve Cartridges

1. Inspect cartridge to ensure that no external contam- Item No. Item Torque Value
inant is present and that cartridge(s) is not dam-
aged. 2 Lift/Lower Control 47.4 N•m
(35 lbf ft)
2. Clean contaminated cartridge(s), replace damaged
3 Lift Proportional 47.4 N•m
cartridge(s).
Control (35 lbf ft)
3. Inspect coil(s) for damage. 4 Lower Proportional 47.4 N•m
Control (35 lbf ft)
4. Replace damaged coil(s).
5 Auxiliary 47.4 N•m
5. Inspect control valve housing for contaminants, Proportional (35 lbf ft)
wear, or damage. Control
6. If control valve housing is contaminated, worn, or 6 Tilt Control 27.1 N•m
damaged. Replace control valve housing. (20 lbf ft)

7. Replace all O-rings that are worn or damaged. 7 Pressure Reducer 33.9 N•m
(25 lbf ft)
8. Using clean hydraulic oil, lubricate all O-rings and 8 Auxiliary Control 33.9 N•m
backup rings before installation. Function 2 (25 lbf ft)
Assemble 9 Auxiliary Control 27.1 N•m
Function 1 (20 lbf ft)
1. Dip cartridge in clean oil.
10 Relief Valve 33.9 N•m
2. Screw cartridge in by hand until top O-ring is met, (25 lbf ft)
then wrench tighten to torque specifications listed Not Counterbalance 44.7 N•m
in Table 2. Refer to Figure 4 for correct placement Illustrated (33 lbf ft)
of cartridges of main hydraulic control valve.
Not Check Valve 47.4 N•m
3. Install coils onto solenoid valves and proportional Illustrated (35 lbf ft)
valves.
Not Flow Control 27.1 N•m
NOTE: Pay special attention to the orientation of the Illustrated (20 lbf ft)
writing (embossed letters) on the coil(s) to be installed.
It is important that they are assembled with the writing INSTALL
facing the correct direction. Also pay special attention
to placement of all O-rings installed with the coils.
WARNING
4. Install coil retaining nut and torque to maximum The main hydraulic control valve is heavy, it weighs
torque of 8.1 N•m (72 lbf in). approximately 15.9 kg (35 lb).

5. When installing lift/lower control or lower propor- 1. Use a wire brush to clean threads of four capscrews
tional control, make sure the manual lowering con- that hold control valve to frame.
trols are in the correct position. See Figure 2.
2. Apply a few drops of adhesive sealant (HCE-92) to
6. Install hydraulic fittings. threads of capscrews.

3. Align control valve with mounting holes in frame.

6
1900 YRM 998 Main Hydraulic Control Valve

4. Insert four capscrews and washers into mounting 10. Remove plugs from hydraulic hoses.
holes and screw them into control valve.
11. Install hydraulic hoses to control valve ports.
CAUTION 12. Tighten connections and remove tags.
Do not over torque the four capscrews that hold the
control valve to the frame as this will damage the 13. Connect all wires to control valve.
control valve.
14. Check hydraulic fluid in hydraulic tank and replenish
5. Torque capscrews to 23 N•m (17 lbf ft). as needed.

WARNING WARNING
The battery is heavy and should by installed care-
Extra care must be taken to prevent any dirt or con-
fully to avoid causing damage or injury. Remove the
taminants from entering the hydraulic system.
battery using a battery puller and stand. Use care
6. Install control valve hydraulic return hose to hy- to avoid injury. Do NOT put hands, arms, feet, and
draulic tank top connector. or legs between the battery and a solid object.

7. Install control valve hydraulic return hose to control 15. Install battery.
valve.
16. Connect battery.
8. Remove plugs from control valve ports.
17. Turn key ON.
NOTE: All hydraulic fitting connections without O-rings
18. Operate lift truck through all hydraulic functions.
are to receive hydraulic sealant (male threads only).
19. Check for oil leaks.
9. Apply hydraulic sealant to hydraulic fitting connec-
tions by following these steps. 20. Check hydraulic fluid in hydraulic tank and replenish
as needed.
a. Wipe threads clean to remove oil, grease, or
excess metal scraps. 21. Remove drip pan.
b. If cleaner and/or primer is used, allow fittings to 22. Remove blocks from drive wheels.
dry.

c. Fill second and third threads (approximately 2 WARNING

drops) completely for 360 . Always test drive the lift truck in a level, open, safe
area. Never test drive it around personnel, build-
d. For system cleanliness, do not fill leading ings, landing docks, or other vehicles.
thread.
23. Operate lift truck through all functions.
e. Apply sealant behind leading threads. Wipe off
any excess sealant on seat part of fitting. 24. Check for oil leaks.

f. Assemble hydraulic fittings. 25. Clean up any residual oil from lift truck surfaces.

g. Let harden 30 minutes at 22 C (72 F), longer if 26. Install hydraulic and electrical covers.
colder, before applying pressure.

7
Lift Pump and Motor 1900 YRM 998

Lift Pump and Motor

DESCRIPTION
The lift pump and motor for these lift trucks are located
under the hydraulic cover.

REMOVE

WARNING
To prevent personal injury or damage to equipment,
completely lower the mast and carriage before re-
pairing the lift system.

WARNING
The lift pump and motor are heavy. Together they
can weigh 37.2 kg (82 lb). Make sure that all lifting
devices (hoists, cables, chains, slings, etc.) are
suitable and of adequate capacity to lift the lift
pump and motor.

CAUTION
The lift pump and motor draw hydraulic oil directly
from the bottom of the hydraulic tank and will drain
most of the tank when the hydraulic hoses are re-
moved. Always use a hose clamping plier to close
off the hydraulic line before it is disconnected to
avoid spilling oil.

The lift pump and motor are two separate parts that
1. MOTOR 5. CAPSCREW
are connected by two capscrews. No hydraulic oil flows 2. PUMP 6. LOCKWASHER
through the motor. The lift pump motor can be removed 3. O-RING 7. 45 ELBOW
from the truck without removing the lift pump or spilling 4. 90 ELBOW
any oil. See Figure 5.
Figure 5. Lift Pump and Motor
Motor
4. Disconnect battery.
1. Move lift truck to a safe, level area.
5. Remove hydraulic cover to allow access to lift pump
and motor.
WARNING
Make sure the brake pedal is released and the 6. Tag all power cables and wires connected to motor
brakes are applied. Put blocks on both sides (front for identification and later installation.
and back) of the drive wheels to prevent movement
7. Disconnect power cables and wires from lift motor.
of the lift truck and avoid injury or damage.
8. Remove two capscrews and lockwashers holding
2. Block both drive wheels (front and back) to prevent
pump to motor.
movement of lift truck.
9. Gently push down on pump to remove from motor.
3. Turn ignition key OFF.

8
1900 YRM 998 Lift Pump and Motor

3. Remove high pressure outlet hose from control

WARNING valve and hold the open end downward into the
The lift motor is heavy. The motor can weigh ap- drip pan until oil stops dripping.
proximately 33.6 kg (74 lb). Make sure that all lift-
ing devices (hoists, cables, chains, slings, etc.) are
suitable and of adequate capacity to lift the motor. CAUTION
Extra care must be taken to prevent dirt or any con-
10. Install lifting device to motor. taminants from entering the hydraulic system.

4. Plug control valve port to prevent dirt from entering

WARNING the system and oil from leaking.
The battery is heavy and should be removed care-
fully to avoid causing damage or injury. Remove the 5. When hydraulic oil has stopped dripping from high
battery using a battery puller and stand. Use care pressure outlet hose, remove hose from pump.
to avoid injury. Do NOT put hands, arms, feet, and
or legs between the battery and a solid object. 6. Plug outlet hose pump port to prevent dirt from en-
tering the system and oil from leaking.
11. Remove battery to gain access to four capscrews
that hold lift motor to frame. 7. Loosen hose clamp holding intake hose to pump.

12. Remove four capscrews that hold lift motor to 8. Remove pump from intake hose.
frame.
9. Plug intake hose pump port and intake hose to pre-
13. Using lifting device, remove lift motor from truck and vent dirt from entering the system and oil from leak-
place on a clean workbench for further repairs. ing.

10. Clean up any spilled oil.

WARNING
Make sure to block the lift motor so it will not roll 11. Place pump on a clean workbench for further re-
off the workbench and cause damage or injury. pairs. See Lift Pump.

14. Block lift motor so it will not roll off workbench. INSTALL
NOTE: For further repair of the lift motor refer to 2200 WARNING
SRM 995, Maintenance Instructions.
The lift pump and motor are heavy. Together they
If repairing or replacing the lift motor, then no further can weigh approximately 37.2 kg (82 lb). Make
removal is necessary. sure that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capacity
Lift Pump to lift the lift pump and motor.

If both the lift pump and motor were removed then install
WARNING the pump to the motor before installing them to the lift
To prevent personal injury or damage to equipment truck. Torque the two capscrews to 61 N•m (45 lbf ft).
completely lower the mast and carriage before re-
pairing the lift system. Lift Pump
1. Apply moly grease lubricant HCE-38 on splined
WARNING shaft of pump.
Hydraulic oil is hot after system operation and can
cause burns. Do not disconnect any hydraulic lines 2. Align and insert splined shaft of pump in motor.
until the oil in the system is cool.
3. Install two capscrews and lockwashers through
1. Place a large drip pan under lift truck below lift pump mounting flange into motor.
pump.
4. Torque capscrews to 61 N•m (45 lbf ft).
2. Before attempting to remove lift pump, use hose
clamping plier to close off intake hose to pump.

9
Lift Pump 1900 YRM 998

5. Install high pressure hose to control valve and outlet 1. Remove battery to gain access to four holes in
port of pump. frame.

6. Install low pressure intake hose to intake port of

pump.
WARNING
The lift pump and motor are heavy. Together they
7. Align and tighten hose clamp on low pressure in- can weigh approximately 37.2 kg (82 lb). Make
take hose. sure that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capacity
8. Remove hose clamping plier from intake hose. to lift the lift pump and motor.

Motor 2. Using a lifting device to hold motor, align it with

holes in frame.
WARNING 3. Insert four capscrews with lockwashers through
The battery is heavy and should be removed care- frame into welded-on nuts of motor.
fully to avoid causing damage or injury. Remove the
battery using a battery puller and stand. Use care 4. Torque capscrews to 61 N•m (45 lbf ft).
to avoid injury. Do NOT put hands, arms, feet, and
or legs between the battery and a solid object while 5. Install lift pump onto motor, see Lift Pump, Step 1
battery is being removed. through Step 4.

Lift Pump
DESCRIPTION 2. Remove pump from motor.

The lift pump is driven by a splined shaft that fits into the 3. Remove elbows and O-rings from pump.
lift pump motor. See Figure 6. Bushings are installed on
both sides of the gears inside the pump. The bushings
WARNING
are designed with passages to direct the flow of oil to
the pump outlet and for lubrication. O-rings and seals Be careful when removing or installing snap rings.
prevent leakage between the body and covers. A shaft These snap rings can come loose during removal
seal is also installed on the shaft between the pump and or installation with enough force to cause injury. Al-
motor to prevent leaks. A hydraulic hose connects the ways use the correct snap ring pliers and wear eye
pump discharge to the control valve. and face protection during removal and installation.

4. Remove snap ring from housing.

DISASSEMBLE
5. Remove shaft seal.
Seals that are worn or damaged are the most common
cause of pump failure. The pump bearings, gears, and 6. Remove idler gear and drive gear.
shafts also wear. Most service personal do not repair a
pump that is worn. The cost of repairs can be greater 7. Visually inspect drive gear, idler gear, and pump
than the cost of a new pump. The special backup rings, housing for obvious damage.
seals, and bushings in the hydraulic pump are replace-
able. These parts come in the repair kit. The end covers 8. If any damage to drive gear, idler gear, or pump
also can be replaced. Replace the pump if other pump housing, replace pump.
parts are damaged. 9. If no damage replace old O-rings, backup rings, and
1. Remove two capscrews and lockwashers holding snap rings with new ones.
pump to motor. See Figure 5.

10
1900 YRM 998 Lift Pump

1. SNAP RING 8. DOWEL PIN

2. OIL SEAL 9. HOUSING
3. MOUNTING FLANGE 10. IDLER GEAR
4. BACKUP RING 11. DRIVE GEAR
5. SEAL 12. COVER
6. BUSHING 13. CAPSCREW
7. O-RING

Figure 6. Lift Pump Disassembled

ASSEMBLY 7. Install four capscrews.

1. Apply clean hydraulic fluid to all pump components, 8. Install new shaft seal on drive gear shaft.
including O-rings and seals prior to assembly.

2. Align and install idler gear and drive gear. WARNING

Be careful when removing or installing snap rings.
3. Install both bushings on the shafts. These snap rings can come loose during removal
or installation with enough force to cause injury. Al-
4. Install seals and backup rings in body of each bush- ways use the correct snap ring pliers and wear eye
ing. and face protection during removal and installation.
5. Install new O-rings in pump housing. 9. Install new snap ring.
6. Align end cover, pump housing, and mounting 10. Install new O-rings on elbow fittings.
flange.
11. Install elbow fittings on pump.

11
Hydraulic Tank 1900 YRM 998

12. Apply moly grease lubricant HCE-38 on splined 14. Install two capscrews and lockwashers through
shaft of pump. pump mounting flange into motor.

13. Align and insert splined shaft of pump in motor. 15. Torque capscrews to 61 N•m (45 lbf ft).

Hydraulic Tank
INSPECT 7. Remove top of filter assembly.

The hydraulic tank is located under the hydraulic cover 8. Remove filter element.
and is used to store hydraulic oil for both the steering
and mast functions of the lift truck. The tank has a ca- 9. The filter assembly can be completely removed
pacity of 23.8 liter (6.3 gal). from the tank. Torque capscrews to 25-27 N•m
(18-20 lbf ft) when remounting assembly to tank.
1. Move lift truck to a safe, level area.
NOTE: Replace filter element and hydraulic oil more of-
ten if lift truck is operated in dusty or dirty environments.
WARNING
To prevent personnel injury or damage to equip- 10. Replace filter element after initial 350 hours of op-
ment, completely lower the mast and carriage be- eration and every 2000 hours thereafter.
fore repairing the lift system.
11. Replace hydraulic oil after initial 350 hours of oper-
2. Remove hydraulic cover. ation and every 2000 hours thereafter.

3. Visually inspect hydraulic tank for any damage or oil REMOVE

leaks. Check welds for cracks and leakage. Check
for wet areas, accumulation of dirt, and loose or 1. Move lift truck to a safe, level area.
missing paint caused by leakage. Areas of the tank
that are not easily seen can be checked with an WARNING
inspection mirror. See Figure 7.
Make sure the brake pedal is released and the
brakes are applied. Put blocks on both sides (front
CAUTION and back) of the wheels.
If hydraulic oil is discolored, milky, black, or brown
2. To prevent movement of lift truck, block wheels.
the entire hydraulic system must be cleaned and the
hydraulic oil replaced.
WARNING
4. Check hydraulic oil level inside tank using sight To prevent personnel injury or damage to equip-
glass on front of tank. Oil level should be at center ment, completely lower the mast and carriage be-
of tank sight glass. If oil color is not correct, then fore repairing the lift system.
entire system may need to be changed.
3. Turn ignition key OFF and disconnect battery.
5. Remove breather cap and inspect oil strainer for
blockage. If blocked, remove strainer and clean or 4. Remove hydraulic cover.
replace strainer.
5. Obtain a drip pan large enough to hold 28 liter
6. Remove four capscrews on top of filter assembly. (7.4 gal).
NOTE: Torque capscrews to 5-7 N•m (44-62 lbf in) 6. Place drip pan underneath front of hydraulic tank.
when replacing top of filter assembly.

12
1900 YRM 998 Hydraulic Tank

Figure 7. Hydraulic Tank

13
Hydraulic Tank 1900 YRM 998

Legend for Figure 7

1. HYDRAULIC TANK 7. CAPSCREW
2. FILTER ASSEMBLY 8. DRAIN PLUG
3. INLET FITTING 9. THREAD SEALANT
4. SIGHT WINDOW 10. CAPSCREW
5. BREATHER/STRAINER 11. WASHER
6. LOCKWASHER 12. LOCK NUT
When cleaning with steam, use a hose with a minimum
WARNING diameter of 19 mm (0.75 in.). Control the pressure of
Hydraulic oil is hot after system operation and the steam using a valve installed at the nozzle of the
can cause burns. Do not disconnect any hydraulic hose. If a metal nozzle is used, it must be made of a
hoses until the oil in the system is cool. non-sparking material. Maintain an electrical connec-
tion between the nozzle and tank. Connect a ground
7. Drain hydraulic tank into drip pan by removing drain
wire to the tank to prevent buildup of static electricity.
plug.

8. Disconnect inlet hose on top of tank. Be sure to Steam Method

catch any oil that spills from tank and hose in drip The hydraulic tank can be cleaned using steam and the
pan. following steps.
9. Clean up any spilled oil. 1. Remove filter assembly, breather/strainer assem-
bly, and sight window from tank.
WARNING
2. Install drain plug.
The battery is heavy and should be removed care-
fully to avoid causing damage or injury. Remove the 3. Plug two outlet pipes.
battery using a battery puller and stand. Use care
to avoid injury. Do NOT put hands, arms, feet, and NOTE: Fill the tank 1/4 full with a solution of water and
or legs between the battery and a solid object. sodium bicarbonate or sodium carbonate. Mix 0.5 kg
(1.1 lb) per 4 liter (1 gal) of water.
10. Remove battery to gain access to two outlet hoses
on bottom of tank and lower capscrew that holds 4. Create a 6 liter (1.5 gal) solution of water and
hydraulic tank to frame. sodium bicarbonate or sodium carbonate in a
clean bucket.
11. Place drip pan under rear of hydraulic tank.
5. Pour solution into tank and mix using compressed
12. Disconnect two outlet hoses on bottom of tank. Be air. Make sure all surfaces on inside of tank are
sure to catch any oil that spills from tank and hoses flushed with solution.
in drip pan.
6. Drain tank.
13. Plug hoses to prevent any dirt or contaminants from
entering system. 7. Put steam into tank until tank does not have odors
and metal is hot. Steam vapors must come from all
14. Remove lower capscrew and nut. openings.
15. Remove electrical cover to gain access to two upper 8. Flush inside of tank with boiling water.
capscrews that hold hydraulic tank to frame.
9. Make sure all loose material is removed from inside
16. Remove tank. of tank.

CLEAN 10. Inspect inside of tank using a light approved for lo-
cations with inflammable vapors.
When cleaning the tank, do not use solutions that
produce dangerous gases at normal temperatures, or 11. If the tank is not clean, repeat Step 7 and Step 8
when heated. Wear eye and face protection. Wear until tank is clean.
protective clothing to prevent burns.

14
1900 YRM 998 Hydraulic Tank

Trisodium Phosphate Method 5. Install three capscrews, washers, and locking nuts.

If the tank cannot be cleaned with steam, use the fol- a. Install lower capscrew, washer, and locking nut
lowing procedure: first.

1. Mix a solution of water and trisodium phosphate or b. Install upper two capscrews, washers, and
a cleaning compound with an alkali base. Follow locking nuts.
instructions given by manufacturer.
c. Torque to 34 N•m (25 lbf ft).
2. Fill tank cleaning solution. Use compressed air to
mix solution in tank. 6. Place drip pan under hydraulic tank.

3. Drain tank. 7. Remove plugs from lower hydraulic hoses and in-
stall hoses to tank.
4. Flush inside of tank with hot (boiling) water. Make
sure all cleaning compound and all loose material 8. Remove plug from upper hydraulic hose and install
is removed from inside of tank. hose to tank.

5. Inspect inside of tank using a light approved for lo- NOTE: Do not fill hydraulic tank for four hours after ap-
cations with inflammable vapors. plying HCE-83 to allow sealant to cure.

6. If the tank is not clean, repeat Step 1 through Step 4 9. Fill hydraulic tank with new hydraulic oil until oil level
until tank is clean. is at center of sight glass.

INSTALL WARNING
Before installing the hydraulic tank in the lift truck, The battery is heavy and should be installed care-
be sure to clean the area where the hydraulic tank fully to avoid causing damage or injury. Install the
mounts. Make sure the drain plug, sight window, battery using a battery puller and stand. Use care
breather/strainer assembly, and filter assembly are to avoid injury. Do NOT put hands, arms, feet, and
clean before installing them to the hydraulic tank. or legs between the battery and a solid object.

NOTE: To prevent contamination of hydraulic oil, do not 10. Install and connect battery.
apply too much HCE-83 pipe thread sealant to threads 11. Turn ignition key ON and operate mast several
of drain plug. Do not fill hydraulic tank for four hours times.
after applying HCE-83 to allow sealant to cure.
12. Check tank hose connections for leaks and tighten
1. Apply HCE-83 pipe thread sealant to threads of connections as required.
drain plug and install drain plug into hydraulic tank.
Torque plug to 38-41 N•m (28-30 lbf ft). 13. Clean any spilled oil.
2. Install sight window, breather/strainer assembly, 14. Check hydraulic oil level and refill as required.
and filter assembly to hydraulic tank.
15. Remove drip pan.
3. Clean any oil spilled during removal.
16. Install covers.
4. Align hydraulic tank with mounting holes in frame.
17. Remove blocks from wheels.
a. Tank back should sit flat against front battery
wall of frame.

b. Front corner of tank should rest on drive wheel

fender of frame.

15
Troubleshooting 1900 YRM 998

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Low hydraulic pressure. Hydraulic oil low in tank. Refill tank.

Relief valve contaminated. Inspect and clean or replace relief

valve.

Pump damaged or worn. Clean, repair, or replace pump.

Jerky hydraulic action. Air trapped somewhere in hydraulic Exercise hydraulic system completely
system. until operation is smooth.

Breather on tank damaged or clogged. Clean or replace breather.

Control valve contaminated. Clean or replace control valve.

Leak in suction line between tank and Tighten hose connections, or replace
pump causes air to enter pump. hoses.

Hydraulic system relief valve Restriction in the system. Inspect system for kink in line.
opens frequently.

The pump noise is not normal. Hydraulic oil low in tank. Refill tank.

Restriction in the inlet hose. Drain system and clean hose.

Inlet hose clamp is loose. Tighten clamp.

The bearings or gears are damaged. Replace motor bearings or pump.

The pump housing is damaged. Replace pump.

Loose capscrews holding pump hous- Tighten capscrews holding pump

ing together. housing together.

Pump motor is damaged or worn. Repair or replace pump motor.

The pump has low output. The pump is worn. Repair or replace pump.

Seals or gaskets are damaged and Repair or replace pump.

leaking.

The fitting at the pump leaks. Repair or replace fitting or replace

pump.

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1900 YRM 998 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The pump has leaks. Fittings are loose or defective. Tighten or replace fittings.

Capscrews holding pump housing to- Tighten capscrews holding pump

gether are loose. housing together.

Seals are defective. Repair pump and replace seals.

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 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

1900 YRM 998 8/03 (1/02) Printed in U.S.A.