HYDRAULIC SYSTEM

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

RS46-30IH, RS46-36CH, RS46-33IH (First Used
on 1563, 1566, 1567, 1568, 1570, and Up) [A222]

PART NO. 1597926 1900 SRM 1212

 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
General ........................................................................................................................................................... 1
Hydraulic Pumps ........................................................................................................................................... 1
Main Control Valves ...................................................................................................................................... 1
Pilot Pressure Valve ...................................................................................................................................... 1
Over-Center Valve ......................................................................................................................................... 1
Heat Exchanger System................................................................................................................................ 2
Steering System............................................................................................................................................. 2
Brake System................................................................................................................................................. 2
Hydraulic Pump Repair..................................................................................................................................... 2
General ........................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Disassemble ................................................................................................................................................... 3
Hydraulic Pump Assembly ....................................................................................................................... 3
Variable Displacement Pump ................................................................................................................... 3
Clean and Inspect .......................................................................................................................................... 4
Hydraulic Gear Pump ............................................................................................................................... 4
Assemble ........................................................................................................................................................ 5
Variable Displacement Pump ................................................................................................................... 5
Hydraulic Pump Assembly ....................................................................................................................... 6
Install ............................................................................................................................................................. 6
Pump Output Check ...................................................................................................................................... 6
First Method .............................................................................................................................................. 6
Second Method .......................................................................................................................................... 7
Main Control Valve Repair ................................................................................................................................ 8
Remove ........................................................................................................................................................... 8
Disassemble ................................................................................................................................................... 9
Outlet Section ............................................................................................................................................ 9
Actuator Section ........................................................................................................................................ 11
Inlet Section............................................................................................................................................... 16
Clean and Inspect .......................................................................................................................................... 18
Assemble ........................................................................................................................................................ 18
Inlet Section............................................................................................................................................... 18
Actuator Section ........................................................................................................................................ 19
Outlet Section ............................................................................................................................................ 20
Install ............................................................................................................................................................. 21
Control Valve Solenoid .................................................................................................................................. 21
Disassemble ............................................................................................................................................... 21
Clean .......................................................................................................................................................... 22
Inspect........................................................................................................................................................ 22
Assemble .................................................................................................................................................... 22
Lift and Lower Circuit ....................................................................................................................................... 23
Description ..................................................................................................................................................... 23
Operation ....................................................................................................................................................... 23
Lift Circuit ................................................................................................................................................. 23
Lower Circuit............................................................................................................................................. 23
Lift Cylinders............................................................................................................................................. 23
Repair ............................................................................................................................................................. 23
Over-Center Valve ..................................................................................................................................... 23
Description ............................................................................................................................................ 23

©2005 HYSTER COMPANY i

Table of Contents Hydraulic System

TABLE OF CONTENTS (Continued)

Remove .................................................................................................................................................. 23
Disassemble........................................................................................................................................... 24
Assemble................................................................................................................................................ 24
Install..................................................................................................................................................... 24
Pilot Controlled Over-Center Valve.......................................................................................................... 25
Remove .................................................................................................................................................. 25
Disassemble........................................................................................................................................... 25
Assemble................................................................................................................................................ 25
Install..................................................................................................................................................... 25
Telescoping Circuit............................................................................................................................................. 27
Description ..................................................................................................................................................... 27
Operation ....................................................................................................................................................... 27
Telescoping In ............................................................................................................................................ 27
Telescoping Out ......................................................................................................................................... 27
Extension Cylinder.................................................................................................................................... 27
Repair ............................................................................................................................................................. 27
Pilot-Assisted, Over-Center Valve ............................................................................................................ 27
Remove .................................................................................................................................................. 27
Disassemble........................................................................................................................................... 28
Assemble................................................................................................................................................ 28
Install..................................................................................................................................................... 28
Attachment Circuit ............................................................................................................................................ 28
Description and Operation ............................................................................................................................ 28
Other Hydraulic Components ........................................................................................................................... 28
Description and Operation ............................................................................................................................ 28
Relief Valves in Steering System.............................................................................................................. 28
Pilot Pressure Valve .................................................................................................................................. 28
Dampening Cylinder ................................................................................................................................. 29
Hydraulic Filters ....................................................................................................................................... 29
Brake Filter ........................................................................................................................................... 29
Return Line Filters ............................................................................................................................... 29
Hydraulic Filters ........................................................................................................................................... 29
Remove and Replace ................................................................................................................................. 29
Brake Filter ........................................................................................................................................... 29
Return Line Filters ............................................................................................................................... 30
Hydraulic Tank Breathers ............................................................................................................................ 30
Remove and Replace ................................................................................................................................. 30
Checks and Adjustments ................................................................................................................................... 31
Pilot Setting ................................................................................................................................................... 31
Main Function Relief Valve Pressure ........................................................................................................... 31
Hydraulic Hose................................................................................................................................................... 32
Replace ........................................................................................................................................................... 32
Specifications...................................................................................................................................................... 32
Hydraulic Pumps Output at 2100 rpm (Governed Speed) .......................................................................... 32
Relief Valves (Approximate Operating Pressures) ...................................................................................... 32
Check Port Pressures .................................................................................................................................... 33
Tank Capacity ................................................................................................................................................ 33
Torque Specifications ......................................................................................................................................... 33
Hydraulic Pump Assembly............................................................................................................................ 33
Variable Displacement Pump........................................................................................................................ 33
Main Control Valve........................................................................................................................................ 33

ii
Hydraulic System Table of Contents

TABLE OF CONTENTS (Continued)

Hydraulic Filters ........................................................................................................................................... 34
Troubleshooting.................................................................................................................................................. 34
Diagrams, Schematics, or Arrangements ......................................................................................................... 36

This section is for the following models:

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

RS46-33IH (First Used on 1563, 1566, 1567, 1568, 1570, and Up) [A222]

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1900 SRM 1212
General
This section has the description and operation of the
hydraulic system. The section also has repair pro-
cedures and troubleshooting for most of the compo-
nents of the lift, telescoping, and attachment sys-
tems. The complete hydraulic system includes the
circuits for the steering system, brake system, and
attachment. See the following sections for descrip-
tion, operation, and repair information of hydraulic
components in these systems:
• Steering System 1600 SRM 1183
• Brake System 1800 SRM 979
• Parking Brake 1800 SRM 1037
Description and Operation
GENERAL
Two hydraulic pump sets supply the flow of oil for the
components of the hydraulic system. These pumps
are driven by a power takeoff arrangement on both
sides of the transmission housing. The inlet hoses for
the pumps are connected at the manual pilot shutoff
valve.
Main Pump 1 supplies oil to the flow amplifier for the
steering system. A relief valve in the flow amplifier
controls the oil pressure in the steering system. The
relief valve is set at 18.5 MPa (2683 psi). Oil not
needed for the steering, flows from the flow amplifier
to main valve 4. When the operator is not steering,
all of the oil from the pump flows to main valve 4.
Main Pump 2 supplies oil to main valve 3.
Brake Pump supplies oil to the accumulator charge
valve for the brake system. Before the oil reaches the
accumulator charge valve, it passes through a pres-
sure relief valve. This relief valve is set at 21 MPa
(3046 psi). Oil from the accumulator charge valve
also supplies oil through the heat exchanger circuit.
This same oil also circulates through the oil-cooled
brakes.
HYDRAULIC PUMPS
There are four hydraulic pumps on the ReachStacker
(see Diagrams, Schematics, or Arrangements).
• Main Pump 1 and Main Pump 2 - supply oil for
steering, lifting/lowering, and extend/retract.
• Brake Pump - supplies oil for the brakes.
• Attachment Pump - supplies oil for the Elme At-
tachment.
Description and Operation
• Service Brake 1800 SRM 1038
• Extendable Container Attachment (Elme)
5000 SRM 776
• Intermodal Container Attachment 5000 SRM
777
See the following sections for other hydraulic compo-
nents:
• Accumulator 1800 SRM 1036
• Hydraulic Pumps 2000 SRM 644
• Boom, ReachStacker 4500 SRM 649
The main hydraulic pumps are variable displace-
ment pumps. The swash plate controls the flow
quantity by changing the angle of the swash plate.
The flow quantity is related to the RPM and is lim-
ited by the torque controller. The brake pump and
attachment pump are gear-type pumps.
MAIN CONTROL VALVES
The two main control valves control the flow and
pressure oil to the boom hoist and boom extension
functions. The main control valves contain three sec-
tions, inlet and two outlet control sections. The two
control sections of the main control valves control the
boom extension and the boom hoist functions. The
outer control section controls the boom hoist func-
tions.
PILOT PRESSURE VALVE
The pilot pressure valve provides a constant hy-
draulic pressure of 5 MPa (725 psi) at the main
control valve.
OVER-CENTER VALVE
The over-center valve performs the following func-
tions:
• Blocking the return flow when the directional valve
is not operated or when the pump is stopped.
• Cavitation-free lowering, controlled by the pilot ac-
tion through the lowering pressure supplied by the
directional valve, preventing the actuator from ac-
celerating downward.
• Pressure relief for any pressure surge caused by
inertia of the load.
1
Hydraulic Pump Repair
HEAT EXCHANGER SYSTEM
The heat exchanger system is used to cool the hy-
draulic system oil. The hydraulic oil circulates
through the thermostatic bypass valve to the brakes.
If the oil is above 71 C (160 F), the valve sends the
oil through the air-to-oil heat exchanger for cooling.
STEERING SYSTEM
The ReachStacker use a hydraulic steering system.
The steering pump is driven by the engine and
supplies hydraulic oil to the flow amplifier and the
steering control unit. When the operator turns the
steering wheel, the MONOTROL pressurizes the
load sense (LS) line. The LS line activates the prior-
ity valve of the steering and activates the pump to
provide the required flow. The monotrol supplies oil
to the flow amplifier.
The flow amplifier regulates and directs the flow of
oil to the steering cylinder. The flow amplifier in-
creases the output oil flow five times more than the
input flow to the MONOTROL. The rate of oil flow to
the steering cylinder is directly proportional to the
rate of the pilot flow from the monotrol. The pres-
sure of hydraulic oil supplied to the flow amplifier
can be checked at check port M5. When the steering
wheel is not being turned, the flow amplifier sends
the flow from the pump to the main control valve
Hydraulic Pump Repair
GENERAL
For making repairs to components within the hy-
draulic system, see the following sections:
• Steering System 1600 SRM 1183
• Parking Brake 1800 SRM 1037
• Service Brake 1800 SRM 1038
REMOVE
WARNING
Lower boom completely before disconnecting
any parts of the hydraulic system. The boom
can lower suddenly and cause personal injury.
1. Lower boom and close the shutoff valves at the
bottom of the hydraulic tank platform.
2. Shut down the engine.
2
1900 SRM 1212
for the lift/lower and telescoping circuit. For further
information, see the section Steering System 1600
SRM 1183.
BRAKE SYSTEM
Oil from the hydraulic pump (brake pump) goes to
the accumulator charge valve to verify the brake
system has enough pressure to operate the brakes.
A pressure switch connected to the brake circuit op-
erates a warning light for the operator when brake
pressure is low. The pump, accumulator charge
valve, and accumulator maintain the brake pressure
and oil flow to the brakes at each drive wheel. The
system also applies oil flow and pressure to operate
the parking brake on the drive line near the differ-
ential. See the section Service Brake 1800 SRM
1038.
Oil pressure from the accumulator is supplied to the
brake treadle. The right-hand pedal only activates
the service brakes. The left-hand pedal first acti-
vates an electrical signal, and via the APC 100 con-
troller, will fully engage the transmission. The ser-
vice brake will then be activated. The left-hand pedal
is the brake pedal. Both pedals will engage the brake
pressure switch to operate the stop lights. The brake
pressure can be checked at check port M3 (accumu-
lator pressure).
3. Remove covers on the topside of the frame.
NOTE: The pump assembly has two suction hoses
and two high-pressure lines.
NOTE: When disconnecting the suction hose at the
variable displacement pump, raise hose quickly and
install a plug to avoid leakage from the hose.
4. Disconnect suction hose at the variable displace-
ment pump.
5. Disconnect high-pressure line at the outlet port
on the pump side of the variable displacement
pump. Raise the end of the line above hydraulic
tank platform until a plug is installed in the line.
6. Disconnect the suction hose and high-pressure
line at the gear-type pump. Install plugs.
1900 SRM 1212 Hydraulic Pump Repair

WARNING
Each pump assembly weighs approximately
45 kg (100 lb) and can cause injury or damage if
it falls. Verify that the pump assembly is prop-
erly supported before removing capscrews.
7. Remove the four capscrews in the pump flange
and remove pump assembly from the torque con-
verter housing. See Figure 1.
DISASSEMBLE
Hydraulic Pump Assembly
1. Remove the two capscrews that hold the pump
flange to the variable displacement pump. See
Figure 1.
2. Remove the O-ring from the pump flange.
3. Remove the two capscrews that hold the hy-
draulic gear pump to the variable displacement
pump.

4. Repeat Step 1 through Step 3 for the second hy-

draulic pump assembly.

Variable Displacement Pump

NOTE: Worn or damaged seals are the most common
cause of variable displacement pump repair. The
pump thrust plates, bearings, gears, and shafts also
wear. Replace a worn or damaged part of the vari-
able displacement pump.

1. Disconnect the hydraulic line between the two

control valves. See Figure 2.

2. Remove the hydraulic line. Put caps on the fit-

tings.

3. Remove the splined hub from the drive shaft. See

Figure 3.

4. Remove the four socket head bolts that hold the

port plate to the pump housing.
A. HYDRAULIC PUMP ASSEMBLY
5. Separate the port plate from the pump housing.
1. CAPSCREWS
2. PUMP FLANGE 6. Remove the bearing from the drive shaft.
3. CAPSCREW
4. VARIABLE DISPLACEMENT PUMP 7. Remove the adjustment shim from the drive
5. CAPSCREW shaft.
6. HYDRAULIC GEAR PUMP
8. Remove the O-rings from the pump housing.
Figure 1. Hydraulic Pump Assembly
9. Remove the swash plate section out of the pump
8. Remove the O-ring. housing.
9. Repeat Step 4 through Step 8 for the second hy- 10. Repeat Step 1 through Step 9 for the second vari-
draulic pump assembly. able displacement pump.

3
Hydraulic Pump Repair
1. CONTROL VALVE 2. HYDRAULIC LINE
Figure 2. Variable Displacement Pump Assembly
CLEAN AND INSPECT
WARNING
Cleaning solvents are flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety procedures. Wear
protective goggles or a face shield to prevent
eye injuries.
Clean all parts of pump with solvent. Use com-
pressed air to dry parts. Do not use a cloth to dry
parts. Pieces of cloth can cause restrictions in hy-
draulic system.
4
1900 SRM 1212
3. CONTROL VALVE
Hydraulic Gear Pump
NOTE: Some pump bodies will show gear marks
where the gears rotate because of the small clear-
ances between parts. These gear marks do not
indicate a worn or damaged pump unless the pump
will not supply the volume and pressure shown in
the Specifications.
Inspect gear assemblies and housing parts for wear
and damage. Replace a damaged or worn hydraulic
gear pump. If gears are replaced, they must be re-
placed as matched sets.
1900 SRM 1212 Hydraulic Pump Repair

1. DRIVE SHAFT* 8. PORT PLATE

2. PUMP HOUSING 9. O-RING*
3. SWASH PLATE SECTION 10. ADJUSTMENT SHIM
4. O-RING* 11. BEARING*
5. SOCKET HEAD BOLTS 12. CYLINDER PIN
6. SPLINED HUB 13. BEARING*
7. O-RING*

* = WEAR ITEM

Figure 3. Variable Displacement Pump

ASSEMBLE 2. Install the swash plate section in the pump hous-

ing.
Variable Displacement Pump
3. Install the O-rings in the pump housing.
NOTE: Use new O-rings during assembly
4. Install the adjustment shim on the drive shaft.
NOTE: Lubricate parts with hydraulic oil before as-
sembly. 5. Install the bearing on the drive shaft.

1. Verify internal parts of the pump are clean. 6. Align the port plate to the pump housing with the
cylinder pin. See Figure 3.

5
Hydraulic Pump Repair
7. Assemble the port plate to the pump hous-
ing with four socket head bolts and tighten to
310 N•m (229 lbf ft).
8. Install the splined hub on the drive shaft.
9. Install and connect the hydraulic line between
the two control valves.
10. Repeat Step 1 through Step 9 for the second vari-
able displacement pump.
Hydraulic Pump Assembly
NOTE: Use new O-rings during assembly
1. Install the two capscrews that hold the hydraulic
pump to the variable displacement pump and
tighten to 45 N•m (33 lbf ft).
2. Install the O-ring to the pump flange.
3. Install the two capscrews that hold the pump
flange to the variable displacement pump and
tighten to 90 N•m (66 lbf ft).
4. Repeat Step 1 through Step 3 for the second hy-
draulic pump assembly.
INSTALL
1. Clean flange of the pump assembly and mount-
ing surface on the torque converting housing.
WARNING
Each pump assembly weighs approximately
45 kg (99 lb) and can cause injury.
2. Install pump assembly on the torque convert-
ing housing. Use a sealant on the flange of the
pump assembly. Tighten capscrews to 90 N•m
(66 lbf ft).
3. Connect the hydraulic hoses to the pump assem-
bly. Tighten capscrews for flange of high-pres-
sure hoses to 190 N•m (140 lbf ft). If necessary,
tighten capscrews for flange of suction hose to
88 N•m (65 lbf ft).
4. Repeat Step 1 through Step 3 for the second hy-
draulic pump.
6
1900 SRM 1212
CAUTION
Never start the engine with closed shutoff
valves. Open the shutoff valves before starting
the engine to prevent damage to hydraulic
components.
5. Start engine and operate hydraulic system.
Check that functions work correctly.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
6. Check for leaks.
7. Install covers on the topside of the frame.
PUMP OUTPUT CHECK
Two methods are given for checking the volume of
flow from the hydraulic pump. The first method uses
a flow meter, a pressure gauge, and a needle valve.
The second method uses a needle valve, a pressure
gauge, a container, and a timer.
First Method
1. If the flow meter is available, install flow meter
between needle valve and outlet port of pump.
See Figure 4. Pressure gauge must be between
needle valve and pump. Make a separate check
for each system. When hydraulic oil is at oper-
ating temperature, run engine at 2100 rpm with
no load on hydraulic system. Note reading of flow
meter. Compare output rate of pump with speci-
fication found in the Specifications section.
WARNING
Hydraulic oil can be hot. Do not touch oil dur-
ing tests.
2. Run engine at high limit. Slowly close needle
valve until gauge indicates a pressure just below
specification for relief valve setting. Pump out-
put at high pressure must be within 25% of out-
put with no load. If output at high pressure is
less than 75% of low pressure output, pump has
a problem.
1900 SRM 1212
1. HYDRAULIC PUMP
2. INLET PORT
3. OUTLET PORT
4. HYDRAULIC TANK
Figure 4. Check Output of Hydraulic Pump With Flow Meter
Second Method
1. Another method of checking pump output is to
measure the amount of oil moved in a given
amount of time. See Figure 5. Run engine until
oil is 55 to 65 C (130 to 150 F). Disconnect line
from outlet port of pump. Install a 0 to 21 MPa
(0 to 3050 psi) pressure gauge on a tee fitting
connected to a hose from outlet port. Install
needle valve on end of hose. Connect another
hose to needle valve. Put other end of hose in a
container with an 18 liter (5 gal) capacity. Make
sure reservoir is full.
CAUTION
This test must be done quickly to prevent hy-
draulic tank from becoming empty. Do not op-
erate engine when there is no oil in hydraulic
tank.
Hydraulic Pump Repair
5. PRESSURE GAUGE
6. TEE FITTING
7. FLOW METER
8. NEEDLE VALVE
2. Needle valve must be fully open. Start engine
and run engine at its governed RPM for 5 sec-
onds. Stop engine. Measure volume of oil that
entered container in 5 seconds. Multiply quan-
tity in container by 12 to find output per minute.
Compare pump output rate with specifications
found in the Specifications section. Pump output
rate must be within 20% of specifications.
3. Start engine and run engine at its governed
RPM. Close needle valve until pressure increases
to just below relief valve setting. Measure vol-
ume of fluid that pump moves in 5 seconds.
Compare this quantity with results from test of
pump output at low pressure. Output of pump
at high pressure must be within 25% of volume
of oil flow at low pressure.
7
Main Control Valve Repair 1900 SRM 1212

1. HYDRAULIC PUMP 6. TEE FITTING

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

Figure 5. Check Output of Hydraulic Pump With Container

Main Control Valve Repair

REMOVE 1. Place the lift truck on a solid and even surface.

2. Shut down the engine.

WARNING
Lower boom completely before working on 3. Put blocks on both sides (front and back) of the
control valve or hydraulic system. Do not tires to prevent movement of the ReachStacker.
work under a raised boom. The boom can
lower suddenly and cause injury if the car- 4. Turn the key switch to the ON position.
riage is not lowered. This procedure will make
sure that the boom cannot lower suddenly and
cause injury or death.

8
1900 SRM 1212 Main Control Valve Repair

Keep the spring package together. Put tags

WARNING
Apply brake pedal 10 to 20 times until accumu-
lated hydraulic brake pressure is released.
5. Turn the key switch to the OFF position.
6. Close shutoff valves on the bottom of the tank.
7. Remove the covers on the topside of the frame.
8. Tag and disconnect the electric wires at the
spools of the main control valve.
on spools that are removed. Spools must be
installed into the same sections in which they
were removed.
2. Remove O-rings and wipers from both ends of the
section of the valve and spring packages.
NOTE: The main control valve is divided into an out-
let section, actuator section, and inlet section. Each
section has a different spool or spools, and spring
packages.

9. Put tags for identification on hydraulic lines. 3. Remove outlet section, actuator section, and inlet
Disconnect the hydraulic lines from the main section as follows.
control valve. Keep the end of the hose above
the hydraulic tank until a plug is installed in the Outlet Section
hose. Put caps on the open lines, ports, or other
connectors. CAUTION
Make sure to protect machined surfaces for
NOTE: Only remove the main control valve from the O-rings when sections are separated. Small
mounting plate when the part to be repaired is not defects can cause leaks.
accessible. Disassemble the main control valve as
necessary for repairs. Most repairs are for replace- 1. Place the main control valve on a clean and level
ment of O-rings. surface.
10. Remove the four bolts that fasten the main con- 2. Carefully remove the two connector pipes (A and
trol valve on the mounting plate. B side) between the inlet and outlet section. See
Figure 6.
WARNING 3. Loosen the three nuts. See Figure 7.
The main control valve weighs approximately
65 kg (145 lb) and can cause serious injury if
the main control valve is not lifted properly or
falls. Verify that the main control valve has
proper support before removing the mounting
bolts.

Use a lifting device to remove the main control

valve, and verify that the main control valve is
secure and cannot fall out of the lifting device.

11. Remove the control valve from the mounting

plate.

DISASSEMBLE
NOTE: For the spool designation, each spool has an
imprinted letter code to facilitate identification dur- 1. O-RING
2. CONNECTOR PIPE
ing tuning or servicing in the field.
Figure 6. Connector Pipe Assembly
1. To remove a spool, remove end cap from valve
section. Carefully pull spool from valve section.

9
Main Control Valve Repair 1900 SRM 1212

1. NUT 5. O-RING
2. WASHER 6. ACTUATOR SECTION
3. TIE ROD 7. INLET SECTION
4. OUTLET SECTION

Figure 7. Main Control Valve Assembly

4. Carefully remove the three nuts and washers.
5. Carefully separate the outlet section from the ac-
tuator section and slide over the tie rods.
6. Remove O-rings installed between the outlet sec-
tion and the inlet section.
NOTE: Disassemble outlet valve section as may be
necessary to repair valve.
CAUTION
All O-rings removed during disassembly are to
be discarded. Failure to replace O-rings with
new O-rings could result in damage to equip-
ment.
7. Remove supply connector assembly from
adapter. See Figure 8.
8. Remove control valve solenoid assembly
(PVE102) from adapter, located at the A-side.
For the removal of the control valve solenoid
assembly, see the section Control Valve Solenoid,
Disassemble.
9. Remove manifold (EHC2) from the adapter, lo-
cated at the A-side.
10. Remove adapter (EHC2) from cylinder, located at
the A-side.
NOTE: Record number of turns required to remove
adjustment screw.
11. If adjustment screw is to be removed from cylin-
der, loosen nut while holding adjustment screw
in place.
12. Remove screws, cylinder, poppet, spring, piston,
and spring (EHC2) from outlet section valve
body, located at the A-side.
13. Remove control valve solenoid assembly
(PVE102) from adapter, located at the B-side.
For the removal of the control valve solenoid

10
1900 SRM 1212
assembly, see the section Control Valve Solenoid,
Disassemble.
14. Remove manifold (EHC2) from the adapter, lo-
cated at the B-side.
15. Remove adapter (EHC2) from cylinder, located at
the B-side.
NOTE: Record number of turns required to remove
adjustment screw.
16. If adjustment screw is to be removed from cylin-
der, loosen nut while holding adjustment screw
in place.
17. Remove screws, cylinder, poppet, spring, piston,
and spring (EHC2) from outlet section valve
body, located at the B-side.
NOTE: Remove plugs only if there is evidence of hy-
draulic oil leakage.
18. Remove plug, O-ring, spring, and spool (PR/A)
from outlet section valve body, located at the
A-side.
19. Remove plug and O-ring (PR/B) from the outlet
section valve body, located at the B-side.
20. Remove plug, O-ring, poppet, and piston (LS/A)
from the outlet section valve body, located at the
A-side.
21. Remove plug, O-ring, poppet, and piston (LS/B)
from the outlet section valve body, located at the
B-side.
22. Remove plug O-ring, piston, and spring (LD/A)
from outlet section valve body, located at the
A-side.
23. Remove plug and O-ring (LD/B) from the outlet
section valve body, located at the B-side.
24. Remove plug and O-rings (Y2/A) from the outlet
section valve body, located at the A-side.
25. Remove plug and O-rings (Y2/B) from the outlet
section valve body, located at the B-side.
26. Remove plug and O-ring (LSUB) from the outlet
section valve body, located at the B-side.
Main Control Valve Repair
Actuator Section
CAUTION
Make sure to protect machined surfaces for
O-rings when sections are separated. Small
defects can cause leaks.
1. Place the main control valve on a clean and level
surface.
2. Carefully remove the two connector pipes (A and
B side), between the inlet and outlet section. See
Figure 6.
3. Disassemble the outlet section. See Outlet Sec-
tion, Disassemble
4. Carefully remove the tie rods from the actuator
section and inlet section. See Figure 7.
5. Carefully separate the actuator section from the
inlet section.
6. Remove O-rings installed between the actuator
section and inlet section.
CAUTION
All O-rings that are removed during disassem-
bly are to be discarded. Failure to replace
O-rings with new O-rings could result in dam-
age to equipment.
7. Remove plug, O-rings, washer, spool, backup
rings, and piston (R) from housing, located at
the A-side. See Figure 9.
8. Remove housing from adapter, located at the
A-side.
9. Remove control valve solenoid assembly
(PVE102) from adapter, located at the A-side.
For the removal of the control valve solenoid
assembly, see the section Control Valve Solenoid,
Disassemble.
10. Remove manifold (EHC2) from adapter, located
at the A-side.
11. Remove adapter (EHC2) from cylinder, located at
the A-side.
11
Main Control Valve Repair 1900 SRM 1212

Figure 8. Outlet Section

12
1900 SRM 1212 Main Control Valve Repair

Legend for Figure 8

EHC2 Cylinder Assembly

LD/A LS, Pressure Compensated
LD/B LS, Pressure Compensated
LS/A LS Spool
LS/B LS Spool
LSUB LS Connection Blocked
PR/A Priority Valve
PR/B Priority Valve
PVE102 Solenoid Valve, 24 VDC
Y2/A Port Relief Valve
Y2/B Port Relief Valve

1. SPRING 26. PLUG

2. PISTON 27. O-RING
3. SPRING 28. O-RING
4. POPPET 29. O-RING
5. O-RING 30. PLUG
6. CYLINDER 31. O-RING
7. WASHER 32. O-RING
8. SCREW 33. O-RING
9. NUT 34. PLUG
10. O-RING 35. O-RING
11. ADJUSTMENT SCREW 36. PISTON
12. PLUG 37. SPRING
13. O-RING 38. PISTON
14. O-RING 39. POPPET
15. SCREW 40. O-RING
16. MANIFOLD 41. PLUG
17. O-RING 42. SPOOL
18. ADAPTOR 43. SPRING
19. O-RING 44. O-RING
20. PLUG 45. PLUG
21. SUPPLY CONNECTOR PIPE 46. INNER CONNECTOR PIPE
22. A AND B SIDE SOLENOID 47. OUTER CONNECTOR PIPE
23. SOLENOID VALVE ASSEMBLY 48. FLANGE
24. WASHER 49. SCREW
25. SCREW

13
Main Control Valve Repair 1900 SRM 1212

Figure 9. Actuator Section

14
1900 SRM 1212 Main Control Valve Repair

Legend for Figure 9

EHC2 Cylinder Assembly

LS/A LS Spool
LS/B LS Spool Blocked
N1 Check Valve
PA/A Port Relief Valve
PA/B Port Relief Valve
PVE102 Solenoid Valve, 24 VDC
R Reducer Valve

1. SPRING 29. O-RING

2. PISTON 30. FLANGE
3. SPRING 31. SCREW
4. POPPET 32. SCREW
5. O-RING 33. COVER
6. CYLINDER 34. O-RING
7. WASHER 35. O-RING
8. SCREW 36. PLUG
9. NUT 37. PLUG
10. O-RING 38. O-RING
11. ADJUSTMENT SCREW 39. SPRING
12. PLUG 40. PISTON
13. O-RING 41. PLUG
14. O-RING 42. O-RING
15. O-RING 43. PISTON
16. CONNECTOR PIPE 44. POPPET
17. ADAPTER 45. PISTON
18. O-RING 46. PLUG
19. PLUG 47. O-RING
20. HOUSING 48. SPRING
21. SCREW 49. WASHER
22. A AND B SIDE SOLENOID 50. SPOOL
23. SCREW 51. BACKUP RING
24. WASHER 52. O-RING
25. SOLENOID VALVE ASSEMBLY 53. PISTON
26. PLUG 54. BACKUP RING
27. SPRING 55. O-RING
28. CARTRIDGE

15
Main Control Valve Repair
NOTE: Record number of turns required to remove
adjustment screw.
12. If adjustment screw is to be removed from cylin-
der, loosen nut while holding adjustment screw
in place.
13. Remove screws, cylinder, poppet, spring, piston,
and spring (EHC2) from actuator section valve
body, located at the A-side.
14. Remove cover from adapter, located at the B-side.
15. Remove control valve solenoid assembly
(PVE102) from adapter, located at the B-side.
For the removal of the control valve solenoid
assembly, see the section Control Valve Solenoid,
Disassemble.
16. Remove manifold (EHC2) from adapter, located
at the B-side.
17. Remove adapter (EHC2) from cylinder, located at
the B-side.
NOTE: Record number of turns required to remove
adjustment screw.
18. If adjustment screw is to be removed from cylin-
der, loosen nut while holding adjustment screw
in place.
19. Remove screws, cylinder, poppet, spring, piston,
and spring (EHC2) from actuator section valve
body, located at the B-side.
NOTE: Remove plugs only if there is evidence of hy-
draulic oil leakage.
20. Remove plug, spring, cartridge, and O-ring
(PA/A) from actuator section valve body, located
at the A-side.
21. Remove plug, spring, cartridge, and O-ring
(PA/B) from actuator section valve body, located
at the B-side.
22. Remove plug, O-ring, poppet, and piston (LS/A)
from actuator section valve body, located at the
A-side.
23. Remove plug, O-ring, and piston (LS/B) from ac-
tuator section valve body, located at the B-side.
16
1900 SRM 1212
24. Remove plug O-ring, spring, and piston (N1)
from actuator section valve body, located at the
B-side.
25. Remove plug and O-ring from actuator section
valve body, located at the B-side.
Inlet Section
CAUTION
Make sure to protect machined surfaces for
O-rings when sections are separated. Small
defects can cause leaks.
1. Place the main control valve on a clean and level
surface.
2. Carefully remove the two connector pipes (A and
B side), between the inlet and outlet section. See
Figure 6.
3. Loosen the three nuts. See Figure 7.
4. Carefully remove the three nuts and washers.
5. Carefully separate the inlet section from the ac-
tuator section and slide from the tie rods.
6. Remove O-rings installed between the inlet sec-
tion and actuator section.
NOTE: Disassemble inlet valve section as necessary
to repair valve.
7. Remove four screws, cover, O-ring, spring, and
piston (PT) from inlet section valve body, located
at the B-side. See Figure 10.
NOTE: Remove plugs only if there is evidence of hy-
draulic oil leakage.
8. Remove plug and backup ring (AB) from inlet sec-
tion valve body, located at the A-side.
9. Remove plug, O-ring, spring, and piston (PLS/A)
from inlet section valve body, located at the
A-side.
10. Remove piston, backup ring, and O-ring from in-
let section valve body, located at the A-side.
11. Remove outer cartridge assembly (PLS/B) from
inner cartridge, located at the B-side.
1900 SRM 1212 Main Control Valve Repair

AB Blocked Idling Signal

PLS/A Main Relief Valve
PLS/B Main Relief Valve
PT Counter Pressure Valve

1. SCREW 15. INNER CARTRIDGE

2. COVER 16. O-RING
3. O-RING 17. BACKUP RING
4. SPRING 18. O-RING
5. PISTON 19. BACKUP RING
6. PLUG 20. O-RING
7. BACKUP RING 21. ORIFICE
8. STOP 22. PISTON
9. SPRING 23. O-RING
10. O-RING 24. BACKUP RING
11. OUTER CARTRIDGE 25. PISTON
12. PISTON 26. SPRING
13. POPPET 27. O-RING
14. O-RING 28. PLUG

Figure 10. Inlet Section

17
Main Control Valve Repair
12. Remove O-ring, spring, stop, poppet, piston, and
O-ring (PLS/B) from outer cartridge assembly, lo-
cated at the B-side.
13. Remove inner cartridge assembly (PLS/B) from
inlet section valve body, located at the B-side.
14. Remove O-rings and backup rings from inner car-
tridge assembly, located at the B-side.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.
Compressed air can move particles and cause
injury to the user or to other personnel. Make
sure compressed air path is away from all per-
sonnel. Wear eye protection.
NOTE: Do not try to repair a relief valve. Replace
a relief valve if it is damaged or cannot be properly
adjusted.
1. Clean all parts of control valve with solvent.
Carefully dry parts with compressed air.
2. Check spools and bores for defects. If a spool or
bore has damage, replace valve section that has
the damaged part or parts. Make sure the bores
and grooves for the O-rings are smooth and do
not have dirt or defects.
3. Check the check valves and relief valves for dam-
age. Replace valves as necessary.
ASSEMBLE
Inlet Section
CAUTION
Before installing parts in the valve body, make
sure all parts are clean. Replace all seals and
O-rings. Lubricate all parts with clean hy-
draulic oil during assembly.
CAUTION
Verify that nuts and bolts torque specifications
are to the values listed. Incorrect torque values
may cause a malfunction of the spools.
18
1900 SRM 1212
NOTE: For the spool designation, each spool has an
imprinted letter code to facilitate identification dur-
ing tuning or servicing in the field.
1. Install new seals in bore of each section.
2. Install backup rings and O-rings on inner car-
tridge assembly (PLS/B), located at the B-side.
3. Install inner cartridge assembly (PLS/B) in inlet
section valve body, located at the B-side. Tighten
inner cartridge assembly to 80 N•m (59 lbf ft).
4. Install O-ring, spring, stop, poppet, piston, and
O-ring (PLS/B) on outer cartridge assembly
(PLS/B), located at the B-side.
5. Install outer cartridge assembly (PLS/B) in in-
ner cartridge assembly, located at the B-side.
Tighten outer cartridge assembly to 10 N•m
(89 lbf in).
6. Install piston, O-ring, and backup ring in inlet
section valve body, located at the A-side.
7. Install piston, spring, O-ring, and plug (PLS/A)
in inlet section valve body, located at the A-side.
Tighten to 80 N•m (59 lbf ft).
8. Install the backup ring and plug (AB) in inlet
section valve body, located at the A-side. Tighten
to 30 N•m (22 lbf ft).
9. Install piston, spring, O-ring, cover, and four
screws in inlet section valve body, located at the
B-side. Tighten screws to 22 N•m (195 lbf in).
10. Install new O-rings between sections.
CAUTION
When positioning the sections, do not damage
the O-rings.
11. Carefully slide the inlet section over the tie rods
and position the inlet section in line with the ac-
tuator section.
12. Install nuts and washers finger tight, on the
three tie rods.
13. Torque the three nuts to 80 N•m (59 lbf ft).
14. Install springs.
15. Lubricate spools with clean hydraulic oil. Make
sure that dirt does not get on any of the parts.
1900 SRM 1212
Carefully install spools in valve body. Make sure
that spools move freely in bores. Install end caps.
16. Install the two connector pipes (A and B side)
between the inlet and outlet section. Tighten to
15 N•m (11 lbf ft).
Actuator Section
CAUTION
Before installing parts in the valve body, make
sure all parts are clean. Replace all seals and
O-rings. Lubricate all parts with clean hy-
draulic oil during assembly.
CAUTION
Verify that nuts and bolts torque specifications
are to the values listed. Incorrect torque values
may cause a malfunction of the spools.
NOTE: For the spool designation, each spool has an
imprinted letter code to facilitate identification dur-
ing tuning or servicing in the field.
1. Install new seals in bore of each section.
2. Install plug and O-ring in actuator section valve
body, located at the B-side. Tighten to 15 N•m
(11 lbf ft).
3. Install plug, O-ring, spring, and piston (N1) in
actuator section valve body, located at the B-side.
Tighten to 80 N•m (59 lbf ft).
4. Install plug, O-ring, and piston (LS/B) in actu-
ator section valve body, located at the B-side.
Tighten to 15 N•m (11 lbf ft).
5. Install plug, O-ring, poppet, and piston (LS/A) in
actuator section valve body, located at the A-side.
Tighten to 15 N•m (11 lbf ft).
6. Install plug, spring, cartridge, and O-ring (PA/B)
in actuator section valve body, located at the
B-side. Tighten to 80 N•m (59 lbf ft).
7. Install plug, spring, cartridge, and O-ring (PA/A)
in actuator section valve body, located at the
A-side. Tighten to 80 N•m (59 lbf ft).
8. Install screws, cylinder, poppet, spring, piston,
and spring (ECH2) in actuator section valve body,
Main Control Valve Repair
located at the B-side. Tighten screw to 10 N•m
(89 lbf in).
NOTE: Perform Step 9 only if adjustment screw has
been removed from cylinder.
9. Install adjustment screw the number of turns
recorded during removal. While holding adjust-
ment screw in place, tighten nut to 10 N•m
(89 lbf in).
10. Install adapter (ECH2) on cylinder, located at the
B-side.
11. Install manifold (ECH2) on adapter, located at
the B-side.
12. Install control valve solenoid assembly (PVE102)
on adapter, located at the B-side. Tighten screws
to 10 N•m (89 lbf in).
13. Install cover on adapter, located at the B-side.
Tighten to 10 N•m (89 lbf in).
14. Install screws, cylinder, poppet, spring, piston,
and spring (ECH2) in outlet section valve body,
located at the A-side. Tighten screw to 10 N•m
(89 lbf in).
NOTE: Perform Step 15 only if adjustment screw has
been removed from cylinder.
15. Install adjustment screw the number of turns
recorded during removal. While holding adjust-
ment screw in place, tighten nut to 10 N•m
(89 lbf in).
16. Install adapter (ECH2) on cylinder, located at the
A-side.
17. Install manifold (ECH2) on adapter, located at
the A-side.
18. Install control valve solenoid assembly (PVE102)
on adapter, located at the A-side. Tighten screws
to 10 N•m (89 lbf in).
19. Install housing on adapter, located at the A-side.
Tighten to 10 N•m (89 lbf in).
20. Install plug, washer, spool, backup rings, and
piston (R) in housing, located at the B-side.
21. Install new O-rings between sections.
19
Main Control Valve Repair
CAUTION
When positioning the sections, do not damage
the O-rings.
22. Carefully position the actuator section in line
with the outlet section.
23. Carefully slide the three tie rods with a nut and
washer on one end through the sections.
24. Carefully slide the outlet section over the tie rods
and position the outlet section in line with the
subassembly of the actuator section and inlet sec-
tion.
25. Install nuts and washers finger tight, on the
three tie rods.
26. Torque the three nuts to 80 N•m (59 lbf ft).
27. Install springs.
28. Lubricate spools with clean hydraulic oil. Make
sure that dirt does not get on any of the parts.
Carefully install spools in valve body. Make sure
that spools move freely in bores. Install end caps.
29. Install the two connector pipes (A and B side)
between the inlet and outlet section. Tighten to
15 N•m (11 lbf ft).
Outlet Section
CAUTION
Before installing parts in the valve body, make
sure all parts are clean. Replace all seals and
O-rings. Lubricate all parts with clean hy-
draulic oil during assembly.
CAUTION
Verify that nuts and bolts torque specifications
are to the values listed. Incorrect torque values
may cause a malfunction of the spools.
NOTE: For the spool designation, each spool has an
imprinted letter code to facilitate identification dur-
ing tuning or servicing in the field.
1. Install new seals in bore of each section.
2. Install plug and O-ring (LSUB) in outlet section
valve body, located at the B-side. Tighten to
30 N•m (22 lbf ft).
20
1900 SRM 1212
3. Install plug and O-rings (Y2/B) in outlet section
valve body, located at the B-side. Tighten to
80 N•m (59 lbf ft).
4. Install plug and O-rings (Y2/A) in outlet section
valve body, located at the A-side. Tighten to
80 N•m (59 lbf ft).
5. Install plug and O-ring (LD/B) in outlet section
valve body, located at the B-side. Tighten to
30 N•m (22 lbf ft).
6. Install plug, O-ring, piston and spring (LD/A) in
outlet section valve body, located at the A-side.
Tighten to 30 N•m (22 lbf ft).
7. Install plug, O-ring, poppet and piston (LS/B) in
outlet section valve body, located at the B-side.
Tighten to 15 N•m (11 lbf ft).
8. Install plug, O-ring, poppet and piston (LS/A) in
outlet section valve body, located at the A-side.
Tighten to 15 N•m (11 lbf ft).
9. Install plug and O-ring (PR/B) in outlet section
valve body, located at the B-side. Tighten to
80 N•m (59 lbf ft).
10. Install plug, O-ring, spring, and spool (PR/A) in
outlet section valve body, located at the A-side.
Tighten to 80 N•m (59 lbf ft).
11. Install screws, cylinder, poppet, spring, piston,
and spring (ECH2) in outlet section valve body,
located at the B-side. Tighten screw to 10 N•m
(89 lbf in).
NOTE: Perform Step 12 only if adjustment screw has
been removed from cylinder.
12. Install adjustment screw the number of turns
recorded during removal. While holding adjust-
ment screw in place, tighten nut to 10 N•m
(89 lbf in).
13. Install adapter (ECH2) on cylinder, located at the
B-side.
14. Install manifold (ECH2) on adapter, located at
the B-side.
15. Install control valve solenoid assembly (PVE102)
on adapter, located at the B-side. Tighten screws
to 10 N•m (89 lbf in).
16. Install screws, cylinder, poppet, spring, piston,
and spring (ECH2) in outlet section valve body,
1900 SRM 1212
located at the A-side. Tighten screw to 10 N•m
(89 lbf in).
NOTE: Perform Step 17 only if adjustment screw has
been removed from cylinder.
17. Install adjustment screw the number of turns
recorded during removal. While holding adjust-
ment screw in place, tighten nut to 10 N•m
(89 lbf in).
18. Install adapter (ECH2) on cylinder, located at the
A-side.
19. Install manifold (ECH2) on adapter, located at
the A-side.
20. Install control valve solenoid assembly (PVE102)
on adapter, located at the A-side. Tighten screws
to 10 N•m (89 lbf in).
21. Install supply connector assembly in adapter, lo-
cated at the A- and B-side.
22. Install new O-rings between sections.
CAUTION
When positioning the sections, do not damage
the O-rings.
23. Carefully slide the outlet section over the tie rods
and position the outlet section in line with the
subassembly of the actuator section and inlet sec-
tion.
24. Install nuts and washers finger tight, on the
three tie rods.
25. Torque the three nuts to 80 N•m (59 lbf ft).
26. Install springs.
27. Lubricate spools with clean hydraulic oil. Make
sure that dirt does not get on any of the parts.
Carefully install spools in valve body. Make sure
that spools move freely in bores. Install end caps.
28. Install the two connector pipes (A and B side)
between the inlet and outlet section. Tighten to
15 N•m (11 lbf ft).
INSTALL
1. Position the control valve on the mounting plate.
Main Control Valve Repair
2. Install the four bolts that fasten the control valve
to the mounting plate.
3. Connect electrical cables at solenoids.
4. Remove caps and connect hydraulic lines to the
main control valve according to the tags made
during removal. Connect return line after con-
necting other lines.
5. Add clean hydraulic oil to tank. For correct spec-
ifications, refer to the section Periodic Main-
tenance, Tier 2 Emission Engine 8000 SRM
1051.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
CAUTION
Never start the engine with closed shutoff
valves. Open the shutoff valves before starting
the engine to prevent damage to hydraulic
components.
6. Operate hydraulic system and check for leaks
and correct operation. If necessary, adjust the
relief valves as described in Checks and Adjust-
ments.
7. Install the covers on the topside of the frame.
CONTROL VALVE SOLENOID
Disassemble
1. Remove four screws and separate front and rear
housings. See Figure 11.
2. Remove spacer and O-ring from front housing.
Discard O-ring.
3. Remove retaining ring, spacer, spring, and piston
from plug.
4. Remove plug from rear housing.
5. Remove three rear housing O-rings, backup ring,
and large rear housing O-ring from plug. Discard
O-rings.
21
Main Control Valve Repair 1900 SRM 1212

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.
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 flow amplifier with solvent. Use
compressed air to dry parts. Do not use a cloth to
dry parts. Pieces of the cloth can cause restrictions
in hydraulic system. Make sure work area and tools
are very clean.
Inspect
Inspect front and rear housings for damaged bores
and threads. Replace backup rings if damaged. In-
spect plug for damaged threads or damaged spanner
wrench holes.
Assemble
1. Install large rear housing O-ring, backup ring,
and three rear housing O-rings on plug. See Fig-
ure 11.
2. Install plug in rear housing. Tighten to 19.5 N•m
(173 lbf in).
3. Install piston, spring, spacer, and retaining ring
in plug.
4. Install new O-ring and spacer in front housing.
5. Place front and rear housings together and in-
stall four screws. Tighten screws to 1.5 N•m
(13 lbf in).

1. SCREW 9. PISTON
2. FRONT HOUSING 10. SPRING
3. PLUG 11. SPACER
4. REAR HOUSING O-RING 12. RETAINING RING
5. REAR HOUSING O-RING 13. SPACER
6. REAR HOUSING O-RING 14. O-RING
7. BACKUP RING 15. REAR HOUSING
8. LARGE REAR HOUSING O-RING

Figure 11. Control Valve Solenoid

22
1900 SRM 1212
Lift and Lower Circuit
DESCRIPTION
A remote control valve in the operator compartment
operates the spools in the main control valves that
controls the boom extension and boom hoist func-
tions.
The remote control valve is installed in the console
at the right-hand side of the seat. Two potentiome-
ters in the joystick box are connected to the remote
control valve. A load sensing line (electrical) is con-
nected to the main control valves to provide the flow
demanded for functioning. The load sensing line is
also connected to the pump pressure and connected
to the load.
OPERATION
The main pump maintains pressure and flow for the
spool operation, and is controlled by a shuttle valve.
With the joystick in the NEUTRAL Position, the po-
tentiometers are not activated and the remote control
valve doesn’t send an electrical signal. When the joy-
stick is moved forward or backward, a potentiometer
activates the load sensing line. The load sensing line
activates the correct pilot solenoid valve of the main
control valve and the spool will activated.
The movement of the spools in the main control valve
is proportional to the movement of the joystick. This
oscillating action keeps the spools in the main control
valves in the position selected by the operator.
When the joystick is released, the potentiometer will
send a signal to the pilot solenoid valve and the spool
of the main control valve will go to the NEUTRAL
position.
Lift Circuit
When the joystick is moved backward, two main
pumps supplies the flow of oil. The flow of oil passes
the two main control valves, and provides oil and
pressure to the two tilt cylinders at the piston side.
At the same time, the return oil from the rod side
will pass main control valve 3 and return to the
hydraulic oil tank.
Lift and Lower Circuit
Lower Circuit
When the joystick is moved forward, main pump 2
supplies the flow of oil. The flow of oil passes main
control valve 3, and provides oil and pressure to the
two tilt cylinders at the rod side. At the same time,
the return oil from the piston side will pass the two
main control valves and return to the hydraulic oil
tank.
Lift Cylinders
See the section Boom, ReachStacker 4500 SRM
649 for description, operation, and repair informa-
tion of the lift cylinders.
REPAIR
Over-Center Valve
Description
There are four over-center valves in the hydraulic
system as follows:
• Over-Center Valve
• Pilot-Assisted, Over-Center Valve
• Pilot-Controlled, Over-Center Valves (2)
The over-center valve is located in the hydraulic com-
partment. The pilot-assisted, over-center valve is lo-
cated on the extension cylinder. The pilot-controlled,
over-center valves are located on the lift cylinders.
The over-center valve and the pilot-assisted, over-
center valve (located on the extension cylinder) are
the same part.
Remove
1. Place the ReachStacker on a solid, level surface.
2. Lower the boom completely.
3. Shut down the engine.
4. Remove the hood panels in front of the cab.
5. Disconnect hydraulic hoses and tubes from the
over-center valve. Use a pan to catch oil that is
in hydraulic lines. Put tags on lines and tubes
for identification. Put caps on open lines and fit-
tings. See Figure 12.
23
Lift and Lower Circuit 1900 SRM 1212

1. CARTRIDGE AND SPOOL 4. O-RING

2. RETAINING RING 5. CAP
3. HOUSING 6. WASHER

Figure 12. Over-Center Valve/Pilot-Assisted, Over-Center Valve

6. Remove the over-center valve from the mounting Assemble

plate.
NOTE: If cartridge or spool assemblies are defective,
Disassemble discard and replace with a new assembly. See Fig-
ure 12.
NOTE: Remove only those components that are de-
fective. 1. Install new O-ring and retaining ring into hous-
ing.
1. Remove cartridge and spool from the housing.
See Figure 12. 2. Install new O-rings and backup rings onto car-
tridge and spool assembly.
2. Remove and discard O-rings and backup rings
from cartridge and spool assembly. Install

3. Remove retaining ring and O-ring from the hous- 1. Install over-center valve on the mounting
ing. bracket. See Figure 13.

24
1900 SRM 1212
1. OVER-CENTER VALVE
Figure 13. Boom Hoist Over-Center Valve
2. Connect hydraulic lines and tubes to the over-
center valve.
3. Start engine and check system operation.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
4. Check for leaks.
Pilot Controlled Over-Center Valve
Remove
1. Place the ReachStacker on a solid, level surface.
2. Lower the boom completely.
3. Shut down the engine.
4. Disconnect hydraulic hoses and tubes from the
pilot-controlled, over-center valve. Use a pan to
catch oil that is in hydraulic lines. Put tags on
lines and tubes for identification. Put caps on
open lines and fittings.
Lift and Lower Circuit
5. Remove the pilot-controlled, over-center valve
from the lift cylinders.
Disassemble
NOTE: Only remove components that are defective.
1. Remove cap, plug, or valve from housing. See
Figure 14.
2. Remove and discard O-rings and backup rings
from the cap, plug, or valve assembly.
3. Remove O-rings from the housing.
Assemble
NOTE: If cap, plug, or valve assemblies are defective,
discard and replace with a new assembly. See Fig-
ure 14.
1. Install new O-rings into the housing.
2. Install new O-rings and backup rings onto cap,
plug, or valve assembly.
3. Install cap, plug, or valve assembly into housing.
Install
1. Install pilot-controlled, over-center valve to the
lift cylinders.
2. Connect hydraulic lines and tubes to the pilot-
controlled, over-center valve.
3. Start engine and check system operation.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
4. Check for leaks.
25
Lift and Lower Circuit 1900 SRM 1212

1. CAP 7. O-RING
2. PLUG 8. PLUG
3. RELIEF PLUG 9. BREATHER PLUG
4. VALVE 10. PILOT PLUG
5. HOUSING 11. CAP
6. O-RING

Figure 14. Pilot-Controlled, Over-Center Valve

26
1900 SRM 1212
Telescoping Circuit
DESCRIPTION
A remote control valve in the operator compartment
operates the spools in the main control valves that
control the boom extension and boom hoist functions.
The remote control valve is installed in the console
at the right-hand side of the seat. Two potentiome-
ters in the joystick box are connected to the remote
control valve. A load sensing line (electrical) is con-
nected to the main control valves to provide the flow
demanded for functioning. The load sensing line is
also connected to the pump pressure and connected
to the load.
OPERATION
The main pump maintains pressure and flow for the
spool operation, and is controlled by a shuttle valve.
With the joystick in the NEUTRAL Position, the po-
tentiometers are not activated and the remote con-
trol valve does not send an electrical signal. When
the joystick is moved to the left side or right side, a
potentiometer activates the load sensing line. The
load sensing line activates the correct pilot solenoid
valve of the main control valve and the spool will ac-
tivated.
The movement of the spools in the main control valve
is proportional to the movement of the joystick. This
oscillating action keeps the spools in the main control
valves in the position selected by the operator.
When the joystick is released, the potentiometer will
send a signal to the pilot solenoid valve and the spool
of the main control valve will go to the NEUTRAL
position.
Telescoping In
When the joystick is moved to the left, main pump
1 supplies the flow of oil. The flow of oil passes the
flow amplifier, main control valve 4, and provides oil
and pressure to the boom extension cylinder at the
piston side. At the same time, the return oil from the
rod side will pass the two main control valves and
return to the hydraulic oil tank.
Telescoping Circuit
Telescoping Out
When the joystick is moved to the right, two main
pumps supplies the flow of oil. The flow of oil from
main pump 1 passes the flow amplifier and main con-
trol valve 4. The flow of oil from main pump 2 passes
main control valve 3. As a combined line, oil and
pressure is supplied to the boom extension cylinder
at the piston side. At the same time, the return oil
from the rod side will pass main control valve 4 and
return to the hydraulic oil tank.
Extension Cylinder
See the section Boom, ReachStacker 4500 SRM
649 for description, operation, and repair informa-
tion of the extension cylinder.
REPAIR
Pilot-Assisted, Over-Center Valve
Remove
1. Fully retract and lower the boom.
2. Apply parking brake.
WARNING
Do not disconnect any hydraulic lines when the
engine is running or personal injury may oc-
cur.
3. Shut down the engine.
4. Put identification tags on the hoses and tubes at
the pilot-assisted, over-center valve at the rear
side of the boom.
NOTE: Move all control levers back and forth a min-
imum of 20 times to remove all hydraulic pressure
from pilot system.
5. Disconnect the hoses and tubes from the pilot-
assisted, over-center valve. Put caps or plugs in
all open fittings.
6. Remove the pilot-assisted, over-center-valve
from the extension cylinder.
27
Other Hydraulic Components
Disassemble
NOTE: Remove only those components that are de-
fective.
1. Remove cartridge and spool from the housing.
See Figure 12.
2. Remove and discard O-rings and backup rings
from cartridge and spool assembly.
3. Remove retaining ring and O-ring from the hous-
ing.
Assemble
NOTE: If cartridge or spool assemblies are defective,
discard and replace with a new assembly. See Fig-
ure 12.
1. Install new O-ring and retaining ring into hous-
ing.
2. Install new O-rings and backup rings onto car-
tridge and spool assembly.
Attachment Circuit
DESCRIPTION AND OPERATION
A gear pump supplies oil (120 liter (32 gal)) to oper-
ate the attachment circuit. The oil from the pump is
divided by the reduce valve. Part of the oil (70 liter
(18 gal)) flows through a reducer valve which regu-
lates the necessary flow of oil. The remainder of the
oil will return to the hydraulic tank through a re-
turn manifold. A maximum pressure valve prevents
pressure higher than 16 MPa (2321 psi). When the
Other Hydraulic Components
DESCRIPTION AND OPERATION
Relief Valves in Steering System
See the section Steering System 1600 SRM 1183 for
more information on the steering relief valve.
28
1900 SRM 1212
Install
1. Mount the pilot-assisted, over-center valve onto
the extension cylinder in the boom.
2. Install the hoses and fittings into the pilot-as-
sisted, over-center valve.
3. Start the engine and operate the boom functions.
Check that functions of the boom assembly work
correctly.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
4. Check for leaks.
pressure is higher than 16 MPa (2321 psi), a sole-
noid will activate the bypass of the maximum pres-
sure valve and flow of oil will return to the hydraulic
tank through the return manifold.
See the following sections for description, operation,
and repair information of hydraulic components in
these systems:
• Extendable Container Attachment (Elme)
5000 SRM 776
• Intermodal Container Attachment 5000 SRM
777
Pilot Pressure Valve
The 5 MPa (725 psi) reducer valve controls the pres-
sure and supply of oil to the pilot circuits for the re-
mote control valves and the directional control valve.
1900 SRM 1212 Other Hydraulic Components

Dampening Cylinder
See the section Boom, ReachStacker 4500 SRM
649 for description, operation, and repair informa-
tion of the dampening cylinder.

Hydraulic Filters
NOTE: Hydraulic filters provide filtering of the hy-
draulic oil during operation of the ReachStacker.

Hydraulic filter cartridge need to be replaced when

indicator has popped out.

Brake Filter

The brake filter is located inside the hydraulic tank

platform compartment at the right side of the cooling
system. This filter is for filtering the return line from
the cooling chamber of the brakes.

Return Line Filters

The two return line filters are located in the hy-

draulic tank platform and are accessible on the 1. HYDRAULIC FILTER
topside of the hydraulic tank platform. One of the Figure 15. Hydraulic Filter
return line filters is equipped with an indicator.
These filters are for filtering the flow of oil returned 6. Remove filter cartridge.
by the hydraulic components to the hydraulic tank.
7. Insert new filter cartridge.
HYDRAULIC FILTERS
8. Install the filter housing by turning the housing
Remove and Replace clockwise.

Brake Filter 9. Torque the housing to 20 N•m (15 lbf ft).

WARNING
Lower boom completely before disconnecting
any parts of the hydraulic system. Boom can
lower suddenly and cause injury.
NOTE:
1. Lower boom and close shutoff valves on the bot-
tom of the hydraulic tank platform.
WARNING
Never start the engine with closed shutoff
valves. Open the shutoff valves before starting
the engine to prevent damage to hydraulic
components.
10. Open shutoff valves.
11. Start engine and check system operation.

2. Shut down the engine.

3. Apply the parking brake.
4. Apply brakes a minimum of 10 times to relieve
hydraulic pressure.
5. Loosen the filter housing by using a wrench to
turn the bowl counterclockwise. See Figure 15.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
12. Check for leaks.

29
Other Hydraulic Components 1900 SRM 1212

Return Line Filters 9. Lightly grease the O-ring with lubrication grease
and position the O-ring correctly in the cover.
1. Lower the boom.
10. Place the cover in position and fasten with cap-
2. Shut down the engine. screws and washers.
3. Apply the parking brake. 11. Torque capscrews to 26 N•m (19 lbf ft).
4. Apply brakes a minimum 10 times to relieve hy- 12. Start the engine and check system operation.
draulic pressure.
HYDRAULIC TANK BREATHERS
5. Remove the capscrews and washers retaining the
top cover of the filters. See Figure 16. Remove and Replace
1. Shut down the engine and apply parking brake.

2. Press the yellow button on the indicator to re-

lease pressure to replace the filter cartridge.

3. Loosen the cap by turning the cap counterclock-

wise. See Figure 17.

4. Remove filter cartridge.

1. CAPSCREW
2. WASHER
3. COVER
4. O-RING
5. FILTER

Figure 16. Return Line Filters

6. Remove the cover and O-ring.

7. Carefully remove the filter cartridge.

8. Install new filter cartridge.

1. HOUSING
NOTE: Verify the O-ring is in good condition. Replace 2. SAFETY STAND PIPE
if necessary. 3. FILTER CARTRIDGE
4. CAP
NOTE: Only use an O-ring specified by your local 5. INDICATOR
Hyster dealer. Using an O-ring other than specified 6. INDICATOR BUTTON
can lead to hydraulic oil leakage.
Figure 17. Hydraulic Tank Breather

30
1900 SRM 1212
5. Clean the inside of the housing with solvent.
6. Insert the new filter cartridge.
Checks and Adjustments
PILOT SETTING
NOTE: The pressure reducer is adjustable. If a pres-
sure setting is not within specifications, adjust the
valve.
1. Lower lift/tilt cylinders completely. Connect a 0
to 7 MPa (0 to 1015 psi) gauge to check port M2.
2. Start the engine. Run the engine until the tem-
perature of the hydraulic oil is 55 to 65 C (130 to
150 F). Check the pressure at idle speed.
NOTE: Correct measurement can be achieved during
movement (flow) of the main spool.
3. Check if the pressure is 5 MPa (725 psi). If the
pressure is not correct, adjust the pressure re-
ducer valve.
MAIN FUNCTION RELIEF VALVE
PRESSURE
NOTE: The relief valves in the main control valve and
flow amplifier are adjustable. If a relief valve is not
within specifications, adjust the relief valve.
Table 1. Check Port Pressures
Check Port Valve Pressure
M1 Boom Extension Relief Pressure
M3 Accumulator Charge Pressure
M5 Steering Relief Pressure
M6 Boom Lift Relief Pressure
M7 Boom Lowering Relief Pressure
M9 Boom Retracting Relief Pressure
Checks and Adjustments
7. Install the cap by turning cap clockwise.
8. Start the engine and check operation.
1. Connect a gauge to the port to check the relief
valve pressure. See Table 1 for the correct gauge
used on the check ports.
2. Start the engine. Run the engine until the tem-
perature of the hydraulic oil is 55 to 65 C (130 to
150 F).
3. Check the pressure gauge according to the spec-
ifications shown in Table 2.
4. To adjust a relief valve setting, use the following
procedure:
a. Remove the cap. Loosen the lock nut and use
an Allen wrench to turn the adjuster screw.
Turn the adjuster screw clockwise to increase
pressure. To lower the pressure, first lower
the pressure below required value by turning
the adjuster screw counterclockwise. Then
increase the pressure to the required value.
When relief pressure is correct, tighten lock
nut and install the cap. Check the setting
after tightening the lock nut. During tight-
ening the lock nut, the setting can be influ-
enced. If necessary, adjust again.
Gauge Range
0 to 30 MPa (0 to 4351 psi)
0 to 28 MPa (4061 psi)
0 to 28 MPa (4061 psi)
0 to 30 MPa (0 to 4351 psi)
0 to 30 MPa (0 to 4351 psi)
0 to 30 MPa (0 to 4351 psi)
31
Specifications 1900 SRM 1212

Table 2. Check Port Pressures Procedures

Check Port Correct Pressure Gauge Range

M1 28 MPa (4061 psi) Engine running at full throttle (2286 rpm).
Fully extend the boom.
M3 upper limit: 19 MPa (2756 psi) Engine running at idle (800 rpm). Measure
lower limit: 16 MPa (2321 psi) complete charge cycle.
M5 28 MPa (4061 psi) Engine running at full throttle (2286 rpm).
Turn steering wheel until steering wheel
spindle is against stop on axle.
M6 28 MPa (4061 psi) Engine running at full throttle (2286 rpm).
Fully raise the boom.
M7 28 MPa (4061 psi) Engine running at full throttle (2286 rpm).
Fully lower the boom.
M9 28 MPa (4061 psi) Engine running at full throttle. (2286
rpm). Fully retract the boom.

Hydraulic Hose
REPLACE
When the ReachStacker is used in dirty conditions, it is recommended to replace hoses every 5 years or 10,000
hours of service regardless of condition.

Specifications
HYDRAULIC PUMPS OUTPUT AT 2100 Pilot Assisted Over-Center Valve
RPM (GOVERNED SPEED) 35 MPa (5076 psi)

Main Pump 1 [93 cm 3 (5.67 in. 3 ) per revolution] Pilot Controlled Over-Center Valve
193 liter/min (51 gal/min) 35 MPa (5076 psi)

Main Pump 2[93 cm 3 (5.67 in. 3 ) per revolution] Maximum Pressure Valve
193 liter/min (51 gal/min) 16 MPa (2321 psi)

Attachment Pump [58.7 cm 3 (3.58 in. 3 ) Steering Circuit

per revolution] 18.5 MPa (2683 psi)
124 liter/min (33 gal/min)
Main Pump
3 3
Brake Pump [50 cm (3.05 in. ) per revolution] 28 MPa (4061 psi)
105 liter/min (28 gal/min)
Pressure Relief Valve
RELIEF VALVES (APPROXIMATE 21 kPa (3046 psi)
OPERATING PRESSURES) Accumulator Charge Valve
15.86 to 18.96 MPa (2300 to 2750 psi)
Main Control Valves
32 MPa (4641 psi) Parking Brake Circuit
15.86 to 18.96 MPa (2300 to 2750 psi)
Over-Center Valve
35 MPa (5076 psi)

32
1900 SRM 1212 Torque Specifications

Pilot Pressure M4 - Park Brake Pressure

5 MPa (725 psi) 16 to 19 MPa (2321 to 2756 psi)

Thermostatic Bypass Pressure M5 - Steering Circuit

345 kPa (50 psi) 18.5 MPa (2683 psi)

Twist Lock Circuit M6 - Boom Hoisting

8.3 MPa (1204 psi) 28 MPa (4061 psi)

Sideshift Circuit M7 - Boom Lowering

12.4 MPa (1798 psi) 28 MPa (4061 psi)

Extend/Retract Circuit M8 - Spreader Circuit

8.6 MPa (1247 psi) 16.5 MPa (2393 psi)

CHECK PORT PRESSURES M9 - Boom Retracting

28 MPa (4061 psi)
M1 - Boom Extension
28 MPa (4061 psi) M10 - Sliding Cab
2 MPa (290 psi)
M2 - Pilot Circuit
5 MPa (725 psi) TANK CAPACITY
M3 - Accumulator Charge Valve (upper Dipstick FULL Mark
limit) (stop charging) 850 liter (225 gal)
19 MPa (2756 psi)

M3 - Accumulator Charge Valve (lower

range) (start charging)
16 MPa (2321 psi)

Torque Specifications
HYDRAULIC PUMP ASSEMBLY MAIN CONTROL VALVE
Hydraulic pump to variable displacement Tie rod nut
pump capscrew 80 N•m (59 lbf ft)
45 N•m (33 lbf ft)
Inlet section lock nut
Pump flange to variable displacement 5 N•m (44 lbf in)
pump capscrew
90 N•m (66 lbf ft) Inlet section plug
80 N•m (59 lbf ft)
Pump assembly to torque converter capscrew
90 N•m (66 lbf ft) Inlet section inner cartridge assembly
80 N•m (59 lbf ft)
Flange of high pressure hose capscrew
190 N•m (140 lbf ft) Inlet section outer cartridge assembly
10 N•m (89 lbf in)
Flange of suction hose capscrew
88 N•m (65 lbf ft) Inlet section screw
22 N•m (195 lbf in)
VARIABLE DISPLACEMENT PUMP
Actuator section cover on control section
Port plate to pump housing socket head bolt valve body screw
310 N•m (229 lbf ft) 5 N•m (44 lbf in)

33
Troubleshooting 1900 SRM 1212

Actuator section HVB cartridge assembly Outlet section cylinder on control section
80 N•m (59 lbf ft) valve body screw
9.5 N•m (84 lbf in)
Actuator section check valve assembly
80 N•m (59 lbf ft) Outlet section adjustment screw nut
9.5 N•m (84 lbf in)
Actuator section LS plug assembly
15 N•m (133 lbf in) Outlet section manifold on adapter screw
9.5 N•m (84 lbf in)
Actuator section priority valve assembly
80 N•m (59 lbf ft) Outlet section control valve solenoid
assembly on adapter screw
Actuator section cylinder on control 9.5 N•m (84 lbf in)
section valve body screw
9.5 N•m (84 lbf in) Control valve solenoid rear housing plug
19.5 N•m (173 lbf in)
Actuator section adjustment screw nut
9.5 N•m (84 lbf in) Control valve solenoid front and rear
housing screw
Actuator section control valve solenoid 1.5 N•m (13 lbf in)
assembly on adapter screw
9.5 N•m (84 lbf in) HYDRAULIC FILTERS
Actuator section housing on adapter screw Brake filter housing
10 N•m (89 lbf in) 20 N•m (15 lbf ft)
Outlet section plug assembly Return line filter capscrew
80 N•m (59 lbf ft) 26 N•m (19 lbf ft)
Outlet section LS plug assembly
15 N•m (133 lbf in)

Outlet section priority valve assembly

80 N•m (59 lbf ft)

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).

34
1900 SRM 1212 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Slow or no movement of Control sections have damage or Repair control section(s).

boom lift cylinder(s). (Cont.) 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.

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.

35
Diagrams, Schematics, or Arrangements 1900 SRM 1212

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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.

Diagrams, Schematics, or Arrangements

See the section Diagrams, Tier 2 Engine 8000 SRM 1182.

36
 TECHNICAL PUBLICATIONS

1900 SRM 1212 9/05 Printed in United Kingdom