HYDRAULIC SYSTEM

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

RS46-36CH, RS46-33IH Up to 1528, 1530,
1531, and 1532 [A222]

PART NO. 897955 1900 SRM 641

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

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

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

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

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Main Control Valve........................................................................................................................................ 1
Pilot Supply Valve.......................................................................................................................................... 1
Boom Hoist Over Center Valve ..................................................................................................................... 1
Flow Amplifier ............................................................................................................................................... 1
Main Control Valve ............................................................................................................................................ 3
Description ..................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Disassemble ................................................................................................................................................... 3
Clean .............................................................................................................................................................. 4
Inspect ............................................................................................................................................................ 4
Assemble ........................................................................................................................................................ 5
Install ............................................................................................................................................................. 5
Outlet Section..................................................................................................................................................... 5
Disassemble ................................................................................................................................................... 5
Clean .............................................................................................................................................................. 5
Inspect ............................................................................................................................................................ 5
Assemble ........................................................................................................................................................ 7
Control Section................................................................................................................................................... 7
Disassemble ................................................................................................................................................... 7
Clean .............................................................................................................................................................. 7
Inspect ............................................................................................................................................................ 8
Assemble ........................................................................................................................................................ 9
Control Valve Solenoid....................................................................................................................................... 9
Disassemble ................................................................................................................................................... 9
Clean .............................................................................................................................................................. 9
Inspect ............................................................................................................................................................ 9
Assemble ........................................................................................................................................................ 9
Inlet Section ....................................................................................................................................................... 10
Disassemble ................................................................................................................................................... 10
Clean .............................................................................................................................................................. 12
Inspect ............................................................................................................................................................ 12
Assemble ........................................................................................................................................................ 12
Pilot Pressure Relief Valve ................................................................................................................................ 12
Description ..................................................................................................................................................... 12
Remove ........................................................................................................................................................... 12
Disassemble ................................................................................................................................................... 13
Clean .............................................................................................................................................................. 13
Inspect ............................................................................................................................................................ 13
Assemble ........................................................................................................................................................ 13
Install ............................................................................................................................................................. 13
Boom Hoist Over Center Valve ......................................................................................................................... 14
Description ..................................................................................................................................................... 14
Remove ........................................................................................................................................................... 14
Disassemble ................................................................................................................................................... 14
Assemble ........................................................................................................................................................ 14
Install ............................................................................................................................................................. 14
Flow Amplifier.................................................................................................................................................... 16
General ........................................................................................................................................................... 16
Description ..................................................................................................................................................... 16

©2005 HYSTER COMPANY i

Table of Contents Hydraulic System

TABLE OF CONTENTS (Continued)

Operation ....................................................................................................................................................... 18
Neutral Position ........................................................................................................................................ 18
During Steering Function ......................................................................................................................... 18
Manual Steering Function ........................................................................................................................ 18
Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Disassemble ............................................................................................................................................... 18
Pressure Relief Valve ................................................................................................................................ 18
End Cover at PP Port ................................................................................................................................ 19
End Cover at LS Port ................................................................................................................................ 19
Spools ......................................................................................................................................................... 19
Directional Valve Spool ............................................................................................................................. 19
Priority Valve Spool................................................................................................................................... 20
Pressure Control/Amplifier Valve Spool................................................................................................... 20
Check Valve ............................................................................................................................................... 21
Cushion/Suction Valves............................................................................................................................. 21
Clean .......................................................................................................................................................... 21
Assemble .................................................................................................................................................... 22
Hydraulic Test Block.......................................................................................................................................... 22
Remove ........................................................................................................................................................... 22
Clean .............................................................................................................................................................. 22
Inspect ............................................................................................................................................................ 22
Install ............................................................................................................................................................. 22
Troubleshooting.................................................................................................................................................. 23
Diagrams, Schematics, or Arrangements ......................................................................................................... 24
Figure 24. Hydraulic Schematic............................................................................................................... 26

This section is for the following models:

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

Up to 1528, 1530, 1531, and 1532 [A222]

ii
1900 SRM 641
General
This manual has the description and operation of
the hydraulic system. The section also has repair
procedures and troubleshooting for most of the com-
ponents of the hydraulic system. See the sections
Steering System 1600 SRM 637 and Brake Sys-
tem 1800 SRM 640 for information on these systems.
The section Hydraulic Pumps 2000 SRM 644 has
the repair procedures for hydraulic pumps. The
sections Container Attachment, ReachStacker
4500 SRM 648 and Boom, ReachStacker 4500
SRM 0649 have the repair procedures for the attach-
ment.
Most hydraulic component failure can usually be at-
tributed to dirty hydraulic oil. Dirty hydraulic oil
may be the result of not following a strict mainte-
nance regimen. It is, therefore, extremely important
that hydraulic oil condition be closely monitored, and
Description and Operation
The hydraulic system includes the circuits for the
boom, steering system, brake system, and attach-
ment. There are two sets of hydraulic pumps con-
nected together in series. One set consists of a swash
plate pump and two gear pumps. The other set is a
swash plate pump and gear pump. The pumps are
driven by a power takeoff arrangement on both sides
of the transmission housing. The inlet hoses for the
pumps are connected to the hydraulic tank.
MAIN CONTROL VALVE
The main control valves control the flow and pressure
of oil to the boom hoist and boom extension functions.
The main control valves contain three sections, inlet
and two control outlet sections. See Figure 1. The
two control sections of the main control valve con-
trol the boom extension and the boom hoist functions.
The middle control section controls the boom exten-
sion functions. The outer control section controls the
boom hoist functions.
PILOT SUPPLY VALVE
The pilot pressure relief valve provides a constant
hydraulic pressure of 6 MPa (735 psi) at the main
control valve.
Description and Operation
that the schedules for hydraulic oil and hydraulic fil-
ter changes be strictly followed. For proper inter-
vals and quantities see the section Periodic Main-
tenance, ReachStacker 8000 SRM 592.
To help decrease hydraulic failures due to contami-
nation the list below is to be followed:
Use only the hydraulic filters and hydraulic oil
specified in the ReachStacker Parts Book.
Inspect all parts, after disassembly, for scratches,
or gouges which would compromise the effective-
ness of the part.
Replace all O-rings when a component is disas-
sembled.
Clean all parts completely prior to assembly. Use
only a lint-free cloth to dry those parts not dried
using compressed air.
BOOM HOIST OVER CENTER VALVE
The overcenter valve performs the following func-
tions:
1. Blocking the return flow when the directional
valve is not operated or when the pump is
stopped.
2. Cavitation free lowering, controlled by the pilot
action through the lowering pressure supplied
by the directional valve, preventing the actuator
from accelerating downwards.
3. Pressure relief for any pressure surge caused by
inertia of the load.
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
pilot input flow from the steering control unit. The
rate of oil flow to the steering cylinder is directly pro-
portional to the rate of the pilot flow from the steer-
ing control unit.
1
Description and Operation 1900 SRM 641

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

Figure 1. Hydraulic Valve Layout

2
1900 SRM 641 Main Control Valve

Main Control Valve

DESCRIPTION 3. Remove the control valve(s) from the mounting
plate.
The main control valves control the flow and pressure
of oil to the boom hoist and boom extension functions.
The main control valves contain three sections, inlet
and two control outlet sections. The middle control
section controls the boom extension functions. The
outer control section controls the boom hoist func-
tions.

The lower port of the middle control section of the

top control valve assembly is connected to the lower
port of the outer control section of the lower control
valve. The lower port of the outer control section of
the top control valve assembly is connected to the
lower port of the middle control section of the lower
control valve.

The pressure for boom lowering is supplied from the

upper port of the lower control valve.

The pressure for boom retraction is supplied from the

upper port of the middle control valve.

The hydraulic oil pressure required to perform the

functions is originated from two different areas.
One of which is the swash plate pump located on
the right side of the transmission, the other is from
the flow amplifier when the steering function is not
being used.
1. ELECTRICAL CONNECTOR
2. CONTROL VALVES
REMOVE 3. PILOT PRESSURE RELIEF VALVE
4. LIFTING VALVE
WARNING Figure 2. Main Control Valves
Rotate the battery disconnect switch to the off
position before disconnecting any electrical DISASSEMBLE
connectors.
1. Remove the nuts, washers, and bracket from the
1. Disconnect all electrical connectors and tag con- tie rods. See Figure 3.
nectors to aid in installation. See Figure 2.
2. Remove each of the sections from the tie rods and
2. Disconnect the hydraulic hoses and tubes from discard the O-rings.
the control valve(s). Use a pan to catch the oil
that is in the hydraulic lines. Put tags on the 3. Remove the two lower tie rods and bracket from
lines and tubes for identification. Put caps on the the inlet section. The upper tie rod will be re-
open lines and the fittings. moved if the Inlet section is to be repaired.

3
Main Control Valve 1900 SRM 641

1. NUT 7. TIE ROD

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

Figure 3. Main Control Valve Assembly

CLEAN injury to personnel. Wear hearing and eye

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
protection.
Clean all parts of the pump with solvent. Use com-
pressed air to dry the parts. Do not use a cloth to dry
the parts. Pieces of the cloth can cause restrictions in
the hydraulic system. Make sure the work area and
tools are very clean.
INSPECT
Inspect the control valve section oil passages to en-
sure they have not been damaged, and they are clear
of any dirt or other debris.

4
1900 SRM 641
ASSEMBLE
1. Install the bracket and two lower tie rods onto
the inlet section. See Figure 3.
NOTE: Apply a light coat of grease on the O-rings to
help hold them in place.
2. Install the O-rings onto the control section.
3. Install the control and outlet sections onto the tie
rods.
4. Install the bracket, washers, and nuts onto the
tie rods. Tighten the nuts to the torque specified
Outlet Section
DISASSEMBLE
CAUTION
All O-rings that are removed during disassem-
bly are to be discarded. Failure to replace the
O-rings with new O-rings could result in dam-
age to equipment.
NOTE: Disassemble the outlet valve section as may
be necessary to repair the valve. See Figure 4.
1. Remove the supply connector assembly from the
adapter.
2. Remove the control valve solenoid assembly from
the adapter. See Control Valve Solenoid for re-
pair procedures.
3. Remove the manifold from the adapter.
4. Remove the adapter from the cylinder.
5. If the adjustment screw is to be removed from the
cylinder, loosen the nut while holding the adjust-
ment screw in place. Note the number of turns
required to remove the adjustment screw.
6. Remove the cylinder, poppet, spring, piston, and
spring from the outlet section valve body.
7. Remove the priority valve assembly from the out-
let section valve body.
8. Remove the LS plug assembly from the outlet
section valve body.
Outlet Section
for their size in the section Metric and Inch
(SAE) Fasteners 8000 SRM 231.
INSTALL
1. Install the control valve(s) onto the mounting
plate. See Figure 2.
2. Connect the hydraulic hoses and tubes to the con-
trol valve(s) as tagged during removal.
3. Connect all electrical connectors as tagged dur-
ing removal.
NOTE: Remove the plugs only if there is evidence of
hydraulic oil leakage.
9. Remove the plug assembly from the outlet sec-
tion valve body.
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 the flow amplifier with solvent. Use
compressed air to dry the parts. Do not use a cloth
to dry the parts. Pieces of the cloth can cause restric-
tions in the hydraulic system. Make sure the work
area and tools are very clean.
INSPECT
Inspect the machined surfaces, bores, and threads
in the outlet section body for damage. Inspect the
removed components for damage.
5
Outlet Section 1900 SRM 641

1. SOLENOID 18. SPRING

2. SCREW 19. O-RING
3. WASHER 20. SPOOL
4. SUPPLY CONNECTOR ASSEMBLY 21. SPRING
5. PLUG 22. O-RING
6. O-RING 23. PLUG
7. ADAPTER 24. O-RING
8. NUT 25. MANIFOLD
9. ADJUSTMENT SCREW 26. SCREW
10. O-RING 27. PLUG
11. SCREW 28. PISTON
12. WASHER 29. O-RING
13. CYLINDER 30. O-RING
14. O-RING 31. PLUG
15. POPPET 32. O-RING
16. SPRING 33. O-RING
17. PISTON 34. LS PLUG ASSEMBLY

Figure 4. Outer Outlet Section

6
1900 SRM 641
ASSEMBLE
1. Install the plug assembly in the outlet section
valve body. See Figure 4. Tighten the plug to
80 N•m (59 lbf ft).
2. Install the LS plug assembly in the control sec-
tion valve body. Tighten the plug to 15 N•m
(133.5 lbf in).
3. Install the priority valve assembly in the control
section valve body. Tighten the plug to 80 N•m
(59 lbf ft).
4. Install the spring, piston, spring, and poppet in
the control section valve body.
5. Install the cylinder on the control section valve
body. Tighten the screws to 9.5 N•m (125 lbf in).
Control Section
DISASSEMBLE
CAUTION
All O-rings that are removed during disassem-
bly are to be discarded. Failure to replace the
O-rings with new O-rings could result in dam-
age to equipment.
NOTE: Disassemble the control valve section as may
be necessary to repair the valve. See Figure 5.
1. Remove the reducer spool assembly from the
housing.
2. Remove the housing from the adapter.
3. Remove the supply connector assembly from the
adapter.
4. Remove the control valve solenoid assembly from
the adapter. See Control Valve Solenoid for re-
pair procedures.
5. Remove the adapter from the cylinder.
6. If the adjustment screw is to be removed from the
cylinder, loosen the nut while holding the adjust-
ment screw in place. Note the number of turns
required to remove the adjustment screw.
7. Remove the cylinder, poppet, spring, piston, and
spring from the control section valve body.
Control Section
NOTE: Perform Step 6 only if the adjustment screw
has been removed from the cylinder.
6. Install the adjustment screw the number of
turns noted during the removal. Tighten the
nut, while holding the adjustment screw in
place, to 9.5 N•m (125 lbf in).
7. Install the adapter on the cylinder.
8. Install the manifold on the adapter. Tighten the
screws to 9.5 N•m (125 lbf in).
9. Install the control valve solenoid assembly on
the adapter. Tighten the screws to 9.5 N•m
(125 lbf in).
10. Install the supply connector assembly in the
adapter.
8. Remove the priority valve assembly from the con-
trol section valve body.
9. Remove the LS plug assembly from the control
section valve body.
10. Remove the check valve assembly from the con-
trol section valve body.
11. Remove the HVB cartridge assembly from the
control section valve body.
12. Remove the cover from the control section valve
body.
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 the control section valve body with
solvent. Use compressed air to dry the parts. Do
7
Control Section 1900 SRM 641

not use a cloth to dry the parts. Pieces of the cloth
can cause restrictions in the hydraulic system. Make
sure the work area and tools are very clean.
INSPECT
Inspect the machined surfaces, bores, and threads in
the section body for damage. Inspect the removed
components for damage.

1. PLUG 17. SOLENOID ASSEMBLY 34. PLUG

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

Figure 5. Middle Outlet Section

8
1900 SRM 641
ASSEMBLE
1. Install the cover on the control section valve body.
Tighten screws to 5 N•m (44.5 lbf in). See Fig-
ure 5.
2. Install the HVB cartridge assembly in the control
section valve body. Tighten the plug to 80 N•m
(59 lbf ft).
3. Install the check valve assembly in the control
section valve body. Tighten the plug to 80 N•m
(59 lbf ft).
4. Install the LS plug assembly in the control sec-
tion valve body. Tighten the plug to 15 N•m
(133.5 lbf in).
5. Install the priority valve assembly in the control
section valve body. Tighten the plug to 80 N•m
(59 lbf ft).
6. Install the spring, piston, spring, and poppet in
the control section valve body.
Control Valve Solenoid
DISASSEMBLE
1. Remove four screws, and separate the front and
rear housings. See Figure 6.
2. Remove the spacer and O-ring from the front
housing. Discard the O-ring.
3. Remove the retaining ring, spacer, spring, and
piston from the plug.
4. Remove the plug from the rear housing.
5. Remove three O-rings (4, 5, and 6), backup ring
(7), and O-ring (8) from the plug. Discard the
O-rings.
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.
Control Valve Solenoid
7. Install the cylinder on the control section valve
body. Tighten the screws to 9.5 N•m (125 lbf in).
NOTE: Perform Step 8 only if the adjustment screw
has been removed from the cylinder.
8. Install the adjustment screw the number of
turns noted during the removal. Tighten the
nut, while holding the adjustment screw in
place, to 9.5 N•m (125 lbf in).
9. Install the adapter on the cylinder.
10. Install the control valve solenoid assembly on
the adapter. Tighten the screws to 9.5 N•m
(125 lbf in).
11. Install the supply connector assembly in the
adapter.
12. Install the housing on the adapter. Tighten the
screws to 10 N•m (89 lbf in).
13. Install the reducer spool assembly in the hous-
ing.
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 the flow amplifier with solvent. Use
compressed air to dry the parts. Do not use a cloth
to dry the parts. Pieces of the cloth can cause restric-
tions in the hydraulic system. Make sure the work
area and tools are very clean.
INSPECT
Inspect the front and rear housings for damaged
bores and threads. Replace backup rings if they are
damaged. Inspect the plug for damaged threads or
damaged spanner wrench holes.
ASSEMBLE
1. Install O-ring (8), backup ring (7), and three
O-rings (4, 5, and 6) on the plug. See Figure 6.
2. Install the plug in the rear housing. Tighten to
19.5 N•m (173.5 lbf in).
9
Inlet Section 1900 SRM 641

3. Install the piston, spring, spacer, and retaining
ring in the plug.
4. Install the new O-ring and the spacer in the front
housing.
5. Place the front and rear housings together and
install the four screws. Tighten the screws to
1.5 N•m (8.9 lbf in).

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

Figure 6. Control Valve Solenoid

Inlet Section
DISASSEMBLE 3. Remove the outer cartridge assembly from the
inner cartridge assembly.
NOTE: Disassemble the inlet valve section as may
be necessary to repair the valve. The disassembly 4. Remove the O-ring, spring, stop, poppet, piston,
procedure is divided into sections according to the and O-ring from the outer cartridge assembly.
numbered callouts. See Figure 7. Discard the O-rings.

1. Remove four screws, cover, O-ring, spring, and
piston from the inlet valve section. Discard the
O-ring.
2. Remove the wire seal from the outer cartridge
assembly.
5. Remove the inner cartridge assembly from the
inlet valve section.
6. Remove the O-rings and backup rings from the
inner cartridge assembly. Discard the O-rings.

10
1900 SRM 641 Inlet Section

1. SCREW 11. POPPET 21. O-RING 31. SPRING

2. COVER 12. PISTON 22. PISTON 32. PISTON
3. O-RING 13. O-RING 23. SPRING 33. NUT
4. SPRING 14. CARTRIDGE 24. PISTON 34. PLUG
5. PISTON 15. O-RING 25. BACKUP RING 35. O-RING
6. WIRE SEAL 16. BACKUP RING 26. O-RING 36. SCREW
7. CARTRIDGE 17. O-RING 27. SPRING 37. BACKUP RING
8. O-RING 18. BACKUP RING 28. POPPET 38. PISTON
9. SPRING 19. O-RING 29. PLUG 39. O-RING
10. STOP 20. PLUG 30. O-RING 40. PISTON

Figure 7. Inlet Section

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

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

11
Pilot Pressure Relief Valve 1900 SRM 641

CLEAN nut in the inlet valve section. See Figure 7.

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 the inlet section with solvent. Use
compressed air to dry the parts. Do not use a cloth
to dry the parts. Pieces of the cloth can cause restric-
tions in the hydraulic system. Make sure the work
area and tools are very clean.
INSPECT
Inspect the machined surfaces, bores, and threads in
the section body for damage. Inspect the threads of
screws, nuts, and plugs for damage.
ASSEMBLE
1. Install the four O-rings, four backup rings, four
pistons, adjusting screw, O-ring, plug, and lock
Tighten the lock nut to 5 N•m (44.5 lbf in) while
holding the screw.
2. Install the piston, spring, O-ring, and plug in the
inlet valve section. Tighten the plug to 80 N•m
(59 lbf ft).
3. Install the poppet, spring, O-ring, backup ring,
and piston in the inlet valve section.
4. Install the spring, O-ring, piston, and plug in the
inlet valve section.
5. Install the backup rings and O-rings on the inner
cartridge assembly.
6. Install the inner cartridge assembly in the inlet
valve section. Tighten the inner cartridge assem-
bly to 80 N•m (59 lbf ft).
7. Install the O-ring, piston, poppet, stop, spring,
and O-ring on the outer cartridge assembly.
8. Install the outer cartridge assembly in the inner
cartridge assembly.
9. Install the wire seal on the outer cartridge as-
sembly.
10. Install the piston, spring, O-ring, four screws,
and cover in the inlet valve section. Tighten the
screws to 22 N•m (196 lbf in).

Pilot Pressure Relief Valve

DESCRIPTION
The pilot pressure relief valve provides a constant
hydraulic pressure of 6 MPa (735 psi) at the main
control valve.

REMOVE
1. Disconnect the hydraulic hoses from the pilot
pressure relief valve. See Figure 2 and Figure 8.
Use a pan to catch the oil that is in the hydraulic
lines. Put tags on the lines for identification.
Put caps on the open lines and the fittings.
1. PILOT PRESSURE RELIEF VALVE
2. Remove the pilot pressure relief valve from the 2. MOUNTING BRACKET
mounting bracket.
Figure 8. Pilot Pressure Relief Valve

12
1900 SRM 641 Pilot Pressure Relief Valve

DISASSEMBLE CLEAN
NOTE: Count the number of turns required to remove
the valve in Step 1.
WARNING
Cleaning solvents can be flammable and toxic
1. Loosen the nut, and remove the valve from the and can cause skin irritation. When using
valve body. See Figure 9. 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 the pilot pressure relief valve with

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

INSPECT
Inspect all parts for damage and wear. If any parts
other than O-rings, backup ring, and washer are
damaged, replace the valve.

ASSEMBLE
1. Install the new washer into the valve body. See
Figure 9.
1. NUT 6. O-RING
2. VALVE CAP 7. VALVE SEAT
3. O-RING 8. WASHER 2. Install the valve seat into the valve body.
4. VALVE 9. VALVE BODY
5. BACKUP RING 3. Install the new backup ring and O-ring onto the
valve.
Figure 9. Pilot Pressure Relief Valve
4. Install the valve into the valve body the number
2. Remove and discard the O-ring and backup ring of turns noted during disassembly, and tighten
from the valve. the nut.

3. Remove the valve seat from the valve body. INSTALL

4. Remove and discard the washer from the valve 1. Install the pilot pressure relief valve on the
body. mounting bracket. See Figure 2 and Figure 8.

2. Connect the hydraulic hoses to the pilot pressure

relief valve.

13
Boom Hoist Over Center Valve
Boom Hoist Over Center Valve
DESCRIPTION
There are four over center valves in the hydraulic
system. One is located in the hydraulic compart-
ment (see Figure 10). The other three are located
on the hoist cylinders and the extension cylinder.
More information on these over center valves may
be found in the sections Container Attachment,
ReachStacker 4500 SRM 648 and Boom, Reach-
Stacker 4500 SRM 0649.
Figure 10. Boom Hoist 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 downwards.
• Pressure relief for any pressure surge caused by
inertia of the load.
14
1900 SRM 641
REMOVE
1. Disconnect the hydraulic hoses and tubes from
the boom hoist over center valve. See Figure 10.
Use a pan to catch the oil that is in the hydraulic
lines. Put tags on the lines and tubes for identi-
fication. Put caps on the open lines and the fit-
tings.
2. Remove the boom hoist over center valve from
the mounting plate.
DISASSEMBLE
NOTE: Remove only those components that appear to
be defective.
1. Remove the cartridge and spool assembly from
the housing. See Figure 11.
2. Remove and discard the O-rings and backup
rings from the cartridge and spool assembly.
3. Remove the retaining ring and O-ring from the
housing.
ASSEMBLE
1. If either of the cartridge and spool assemblies are
defective discard and replace with a new assem-
bly. See Figure 11.
2. Install a new O-ring and retaining ring into the
housing.
3. Install the new O-rings and backup rings onto
the cartridge and spool assembly.
INSTALL
1. Install the boom hoist over center valve on the
mounting bracket. See Figure 10.
2. Connect the hydraulic hoses and tubes to the
boom hoist over center valve.
1900 SRM 641 Boom Hoist Over Center Valve

1. CARTRIDGE AND SPOOL 4. O-RING

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

Figure 11. Boom Hoist Over Center Valve

15
Flow Amplifier 1900 SRM 641

Flow Amplifier
GENERAL
The flow amplifier regulates and directs the flow of
oil to the steering cylinder. See Figure 12 and Fig-
ure 13. The flow amplifier increases the output oil
flow five times more than the pilot input flow from
the steering control unit. The rate of oil flow to the
steering cylinder is directly proportional to the rate
of the pilot flow from the steering control unit.

Figure 13. Flow Amplifier

DESCRIPTION
The following valves are part of the flow amplifier.
See Figure 14.

PRIORITY VALVE. This valve selects and directs the

oil flow for steering. The priority is determined in
response to pilot pressure from the steering control
unit. In the neutral position (no steering demand),
the priority valve allows oil to flow from the pump to
the main control valve.

DIRECTIONAL VALVE. This valve opens the correct

cylinder supply and return passages when it senses
the pilot pressure from the steering control unit. The
directional valve checks steering overrun by direct-
ing return flow from the cylinder to make sure there
is control under all conditions.

AMPLIFIER VALVE. This valve is moved by pilot

pressure and opens to pump flow directly from the
1. PP = PILOT PRESSURE priority valve. This oil flow is then combined with
2. HP = HYDRAULIC (STEERING) PUMP the pilot flow.
3. EF = SYSTEM PRESSURE
4. LS = LOAD SENSING CUSHION AND SUCTION VALVES. The "cushion"
5. R = RIGHT TURN function of these valves makes a hydraulic cushion
6. P = PUMP PRESSURE to reduce sharp increases of pressure in the steer-
7. CR = CYLINDER, RIGHT ing cylinder. The "suction" function of these valves
8. HT = HYDRAULIC TANK
9. CL = CYLINDER, LEFT uses the cylinder return flow to prevent cavitation of
10. T = TANK oil inside the cylinder if steering "overrun" forces are
11. L = LEFT TURN sensed.

Figure 12. Flow Amplifier

16
1900 SRM 641 Flow Amplifier

1. O-RING 14. PRESSURE CONTROL/AMPLIFIER VALVE

2. SEAL ASSEMBLY
3. HOUSING, FLOW AMPLIFIER 15. AMPLIFIER VALVE SPOOL
4. SCREW 16. RELIEF VALVE
5. CAPSCREW 17. PLUG
6. SPRING WASHER 18. ORIFICE
7. COVER, PP END 19. THROTTLE CHECK VALVE
8. COVER, LS END 20. SPRING
9. CUSHION/SUCTION VALVE ASSEMBLY 21. SPRING CONTROL
10. DIRECTIONAL VALVE ASSEMBLY 22. STOP
11. DIRECTIONAL VALVE SPOOL 23. PIN
12. PRIORITY VALVE 24. AMPLIFIER VALVE PISTON
13. PRIORITY VALVE SPOOL

Figure 14. Flow Amplifier Assembly

17
Flow Amplifier
RELIEF VALVE. This valve senses high pressure
from the load sensing line from the steering control
unit. The relief valve opens and directs the oil flow
to the hydraulic tank.
OPERATION
Neutral Position
In the neutral position, the oil flows from the steering
pump to the priority valve and discharges through
the port EF. The EF port is connected to the working
pressure of the hydraulic system at the main control
valve.
During Steering Function
When the steering wheel is turned, pilot pressure
causes oil to flow from the steering control unit to the
priority valve. The priority valve is shifted. Oil flows
from the steering control unit to the flow amplifier.
The directional valve is shifted by pressure across the
bore of the spool.
The pilot pressure moves the spool and causes oil to
flow through the pressure control/amplifier valve to
the directional valve.
The main oil flow passes from the priority valve to the
pressure control/amplifier valve where the spool is in
the "left turn" position. Oil now flows through holes
in the valve to a chamber in one end of the spool.
The spool shifts to a position so the pressure is the
same at both ends of the spool. Oil now flows through
the valve to the directional valve.
The main flow and pilot flow of oil combine, in-
creasing the flow through the directional valve to
the steering cylinder. The return oil flows from
the cylinder through the directional valve to the
hydraulic tank.
The flow amplifier has cushion valves to prevent
pressure peaks in the steering cylinder. Suction
valves are installed to prevent cavitation in the
steering cylinder.
Manual Steering Function
If the steering pump fails, or the engine looses power,
the lift truck can be steered manually. The steering
effort, however, will be increased.
The steering control unit has the characteristics of a
hand pump when the steering wheel is turned (when
18
1900 SRM 641
there is no pressure input). The pressure developed
by the steering control unit (when the steering wheel
is turned) operates all the valves in the flow amplifier
as if operating conditions were normal. There is no
amplification because only the oil from the steering
control unit flows to the steering cylinder.
Remove
1. Disconnect the hydraulic hoses from the flow am-
plifier. See Figure 2. Use a pan to catch the oil
that is in the hydraulic lines. Put tags on the
lines and tubes for identification. Put caps on the
open lines and the fittings.
2. Remove the flow amplifier from the frame.
Install
1. Install the flow amplifier on the frame. See Fig-
ure 2.
2. Connect the hydraulic hoses and tubes to the flow
amplifier.
Disassemble
See Figure 14.
Pressure Relief Valve
1. Remove the plug and washer. See Figure 15. Use
an 8 mm allen wrench.
2. Use a 10 mm allen wrench to remove the relief
valve assembly.
3. Remove the washer with a magnetic rod.
1. CARTRIDGE BODY 3. SPRING
2. PISTON 4. ADJUSTMENT
SCREW
Figure 15. Pressure Relief Valve
1900 SRM 641 Flow Amplifier

4. Hold the relief valve cartridge with pliers and

remove the adjusting screw with 5 mm allen head
wrench.

End Cover at PP Port

1. Remove the capscrews, spring washers, and end
cover. See Figure 16.

1. SPRINGS 2. PLATE

Figure 17. End Cover at LS Port

Spools
1. STOP 4. O-RING Remove the three spools (directional valve, pressure
2. SPRING 5. SPRING GUIDE control/amplifier valve, and priority valve) from the
3. PLATE housing. These spools will slide easily from the hous-
ing.
Figure 16. End Cover at PP Port

2. Remove the stop and two springs. Directional Valve Spool

3. Remove the single spring. Remove the orifice from the directional valve spool
with a 4 mm allen wrench. See Figure 18. Hold the
4. Remove the plate and six O-rings (4 large, 2 spool through a hole with a mandrel.
small). Remove the spring guide.

End Cover at LS Port

1. Remove the capscrews, spring washers, and end
cover. See Figure 17.

2. Remove the stop and two springs.

3. Remove the stop and single spring.

4. Remove the plate and four O-rings. Remove the

spring guide.

1. SPOOL 2. ORIFICE

Figure 18. Directional Valve Spool

19
Flow Amplifier 1900 SRM 641

Priority Valve Spool

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

1. THROTTLE CHECK VALVE

Figure 19. Priority Valve Spool

2. Remove the two spring rings from the grooves

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

Pressure Control/Amplifier Valve Spool

1. Use a finger and press out the first pin. See Fig-
ure 20. Remove the plug and spring.

2. Remove the second pin, then remove the inner

spool. Make a note of how the inner spool is in-
stalled. The square end on the inner spool must
be installed in the same direction. If the inner
spool is rotated 180 and then installed, the flow
amplifier will not operate correctly.

3. Remove the inner spool (check valve) from the

other end of the spool. Use a hexagon socket for a
17 mm external hexagon and a mandrel through
a pin hole on the surface that is not machined.
Do not damage the spool surface.

4. Remove the orifice from the plug with a 4 mm

allen head wrench and a mandrel.

Figure 20. Pressure Control/Amplifier Valve

Spool

20
1900 SRM 641 Flow Amplifier

Legend for Figure 20

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

Check Valve
Put the check valve in a 17 mm socket wrench. See
Figure 21. Use an allen head wrench and remove the
plug from the check valve. Remove the spring and
ball.

1. PLUG 3. BALL 1. LOCK NUT

2. SPRING 4. O-RING 2. PILOT VALVE
3. PILOT VALVE CARTRIDGE
4. DISC
Figure 21. Check Valve 5. SPOOL
6. SPRING
Cushion/Suction Valves 7. VALVE HOUSING
8. PISTON
Remove the cushion/suction valves with a flat tip 9. ADJUSTMENT SCREW
screwdriver. Put an allen head wrench under the 10. O-RING
screwdriver so it is a fulcrum for removal.
Figure 22. Cushion/Suction Valve
1. Remove the lock nut from inside the valve hous-
ing. See Figure 22. Use a socket for a 13 mm 4. Remove the adjustment screw, spring, and piston
external hexagon and a mandrel through a hole from the pilot valve.
in the pilot valve cartridge.
Clean
NOTE: When assembling the cushion/suction valve,
hold the valve with a 13 mm ring spanner. WARNING
Cleaning solvents can be flammable and toxic
2. Remove the disc and spring from the valve hous-
and can cause skin irritation. When using
ing. Remove the housing from the pilot valve.
cleaning solvents, always follow the solvent
3. Loosen the pilot valve from the cartridge with a manufacturer’s recommended safety precau-
19 mm socket wrench. Use a mandrel to hold the tions.
cartridge. Remove the pilot valve, spring, and
Clean all the parts in solvent. Dry the parts with
spool from the cartridge.
compressed air. Do not dry the parts with a cloth.
Make sure all surfaces are free of scratches and sharp
edges.

21
Hydraulic Test Block
Assemble
1. Use new seals, O-rings, and neutral position
springs during assembly. See Figure 14. Lubri-
cate all parts with clean hydraulic oil.
Hydraulic Test Block
REMOVE
1. Disconnect the hydraulic hoses and tubes from
the hydraulic test block. See Figure 23. Use a
pan to catch the oil that is in the hydraulic lines.
Put tags on the lines and tubes for identification.
Put caps on the open lines and the fittings.
Figure 23. Hydraulic Test Block
2. Remove the hydraulic test block from the mount-
ing plate.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
22
1900 SRM 641
2. Assemble the flow amplifier assembly using the
reverse of the procedure as described in Disas-
semble. See Figure 14, Figure 15, Figure 16,
Figure 17, Figure 18, Figure 19, Figure 20, Fig-
ure 21, and Figure 22.
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 the hydraulic test block with solvent. Use com-
pressed air to dry the block. Do not use a cloth to dry
the parts. Pieces of the cloth can cause restrictions in
the hydraulic system. Make sure the work area and
tools are very clean.
INSPECT
Inspect all parts for damage and wear. If any parts
other than O-rings, backup ring, and washer are
damaged, replace the valve.
INSTALL
1. Install the hydraulic test block on the mounting
plate. See Figure 23.
2. Install the hydraulic hoses and tubes on the hy-
draulic test block as tagged during removal.
1900 SRM 641 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

Pilot pressure is not correct. See PILOT PRESSURE IS NOT

CORRECT.

The pilot lines are damaged or have Replace pilot lines.

leaks.

The lift and/or steering hydraulic Repair the hydraulic pump that has
pump is damaged or has leaks. the defect.

The electric solenoids are not operat- Repair or replace the defective sole-
ing correctly. noid(s).

The control sections have damage or Repair the control section(s).

leaks.

The relief valves in the control sec- Repair the damaged relief valve.
tions have damage.

The cylinders have leaks. Repair the leaking cylinder.

Pressure relief valve is damaged. Repair the pressure relief valve.

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

Restriction in the hydraulic lines. Clear the restriction or replace the

restricted hydraulic line.

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

Cylinder seals are damaged. Repair the cylinder.

Flow amplifier has damage. Repair or replace the flow amplifier.

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

Hydraulic pump has damage. Repair the hydraulic pump.

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

23
Diagrams, Schematics, or Arrangements 1900 SRM 641

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

Pilot lines are damaged or leak. Replace pilot lines.

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

Pilot pressure is not correct. See PILOT PRESSURE IS NOT

CORRECT.

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

Cylinder seals leak. Replace the cylinder seals.

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

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

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

Boom control valve spool will Dirt between spool and bore. Disassemble and clean the valve.
not return to the neutral po-
sition

Spool is damaged. Replace the spool.

Large leaks between spool and bore. Repair the valve.

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

Restriction in the return line. Remove the restriction or replace the

return line.

24
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25
Diagrams, Schematics, or Arrangements 1900 SRM 641

26
1900 SRM 641 Diagrams, Schematics, or Arrangements

Figure 24. Hydraulic Schematic (Sheet 1 of 2)

27
Diagrams, Schematics, or Arrangements 1900 SRM 641

28
1900 SRM 641 Diagrams, Schematics, or Arrangements

Figure 24. Hydraulic Schematic (Sheet 2 of 2)

29
 NOTES

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 TECHNICAL PUBLICATIONS

1900 SRM 641 3/05 (1/98) Printed in United Kingdom