HYDRAULIC SYSTEM

B60ZAC [C230];B60ZAC [D230];B60ZHD [B262];B80ZHD [

B257];B60HD2 [C262];B80ZHD2 [C257];B60ZAC2 [E230]

PART NO. 4096089 1900 SRM 1639

 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 Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use 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 hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General .....................................................................................................................................................................1
Description of Operation .........................................................................................................................................1
Lifting a Load ...................................................................................................................................................... 2
Lowering a Load .................................................................................................................................................. 6
Hydraulic Lines ................................................................................................................................................... 6
Hydraulic Oil ....................................................................................................................................................... 6
Clean .................................................................................................................................................................... 6
Sound Level ......................................................................................................................................................... 6
Special Precautions ................................................................................................................................................. 6
Hydraulic Reservoir ................................................................................................................................................ 7
Drive Unit Compartment Covers ........................................................................................................................... 7
Lift Pump and Motor ...............................................................................................................................................9
General .................................................................................................................................................................9
Remove .................................................................................................................................................................9
Lift Pump and Motor Assembly ......................................................................................................................9
Disassemble ....................................................................................................................................................... 10
Remove Reservoir .......................................................................................................................................... 10
Remove Pump Motor ..................................................................................................................................... 12
Disassemble Pump ........................................................................................................................................ 12
Assemble ............................................................................................................................................................ 12
Assemble Pump ............................................................................................................................................. 12
Install Pump Motor ....................................................................................................................................... 12
Install Reservoir to Pump ............................................................................................................................. 13
Install ................................................................................................................................................................. 13
Lift Pump and Motor Assembly ....................................................................................................................13
Valve Repair .......................................................................................................................................................... 14
Lowering Valve ..................................................................................................................................................14
Remove ........................................................................................................................................................... 14
Install ............................................................................................................................................................. 14
Relief Valve ........................................................................................................................................................15
Remove ........................................................................................................................................................... 15
Install ............................................................................................................................................................. 15
Check Valve ....................................................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Install ............................................................................................................................................................. 16
Lift Cylinder .......................................................................................................................................................... 16
Remove ...............................................................................................................................................................16
Disassemble ....................................................................................................................................................... 18
Assemble ............................................................................................................................................................ 18
Install ................................................................................................................................................................. 19
Relief Valve Pressure Check .................................................................................................................................19
Relief Valve Adjust ............................................................................................................................................21
Troubleshooting .....................................................................................................................................................21
Lift Assemblies .................................................................................................................................................. 21
Lift Cylinders .....................................................................................................................................................22
Lift Pump and Motor Assembly ........................................................................................................................23

©2018 HYSTER COMPANY i

Table of Contents

This section is for the following models:

(B60ZAC) [C230];
(B60ZAC) [D230];
(B60ZHD) [B262];
(B80ZHD) [B257];
(B60HD2) [C262];
(B80ZHD2) [C257];
(B60ZAC2) [E230]

ii
1900 SRM 1639 General

General
This section covers the troubleshooting and repair • See Periodic Maintenance 8000SRM1644
procedures for the lift pump and motor assembly on for unit codes B257, B262 and C230.
B60-80ZHD, B60-80ZHD2, B60ZAC and B60ZAC2 lift • See Periodic Maintenance 8000SRM2105
trucks. for unit codes C257, C262 and E230.
It also includes information on the lowering valve, • See Electrical System 2200SRM1640 for
unit codes B257, B262 and C230.
the lift cylinder, hydraulic system, and valve repair
and adjustment. Additional information concerning • See Electrical System 2200SRM2102 for
the hydraulic system may be included in other unit codes C257, C262 and E230.
sections when the information is more closely
related to other systems. Sections that may contain
related information include:

Description of Operation
The hydraulic system of the B60-80ZHD,
B60-80ZHD2, B60ZAC and B60ZAC2 lift trucks CAUTION
includes: Protect the hydraulic system from dirt and
• Reservoir contaminants when servicing the hydraulic
system.
• Pump
Check Valve Never operate the pump without the proper
•
amount of oil in the hydraulic system. The
• Relief Valve operation of the hydraulic pump with low oil levels
• Lowering Valve will damage the pump.
• Lift Cylinder
The reservoir contains the hydraulic fluid necessary
• Connecting Hoses and Tubes for the operation of the system. It acts as a heat
sink to provide cooling. As the hydraulic oil leaves
the reservoir, it passes through a strainer in the
WARNING reservoir. See Figure 1.
Always wear the proper protective equipment
including eye protection and petroleum-resistant The hydraulic pump provides the flow of the
gloves when handling hydraulic oil. Thoroughly hydraulic oil which activates the cylinder.
wash oil from exposed areas of skin as soon as
possible.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
the skin.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of the lift
pump or disconnecting any hydraulic hoses.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the oil.

1
Description of Operation 1900 SRM 1639

A check valve allows flow of the hydraulic oil in one

direction only. In this hydraulic system, it prevents
the oil from flowing backwards through the pump.
A relief valve limits maximum system pressure to
protect the hydraulic system components.
The lowering valve is a normally closed valve. When
it opens, hydraulic oil from the lift cylinder is
allowed to return to the reservoir, and the forks
lower.
The lift cylinder rod extends to operate the lift
linkages to raise the forks.
The connecting hoses and tubing connect the
various hydraulic components in the lift truck to
complete the hydraulic circuit. See Figure 2 and
Figure 3.

LIFTING A LOAD
To raise a load, the lift button must be depressed.
1. LOWERING SOLENOID VALVE Depressing this button will activate the lift pump
2. TO LIFT CYLINDER motor. Torque is transferred to the pump from the
3. CHECK VALVE motor through the motor shaft and the coupling.
4. RELIEF VALVE
5. RESERVOIR Hydraulic oil is pumped through the system as the
6. INLET LINE pump begins to operate. Atmospheric pressure
7. PUMP MOTOR forces oil into the low pressure area at the pump
8. LIFT PUMP inlet. Air, which is drawn into the reservoir through
9. ORIFICE
the breather, displaces the pumped oil, allowing oil
Figure 1. Lift Pump and Motor Assembly to be sent through the system. See Figure 1.
Schematic

2
1900 SRM 1639 Description of Operation

Figure 2. Hydraulic System for Lift Trucks B60ZAC and B60ZAC2

3
Description of Operation 1900 SRM 1639

Legend for Figure 2.

1. SOCKET-HEAD SCREW 9. ADAPTER

2. LOCKWASHER 10. FITTING
3. MOUNTING BRACKET 11. TUBE ASSEMBLY
4. LOCKWASHER 12. ADAPTER
5. CAPSCREW 13. ELBOW FITTING
6. LOCKWASHER 14. HOSE ASSEMBLY
7. CAPSCREW 15. ELBOW FITTING
8. LIFT PUMP AND MOTOR ASSEMBLY 16. LIFT CYLINDER ASSEMBLY

4
1900 SRM 1639 Description of Operation

1. CAPSCREW 9. PUMP AND MOTOR ASSEMBLY

2. WASHER 10. ADAPTER
3. CAPSCREW 11. FITTING
4. WASHER 12. HOSE
5. MOUNTING BRACKET 13. TUBE
6. NUT 14. CYLINDER ASSEMBLY
7. SCREW 15. FITTING
8. WASHER 16. FITTING

Figure 3. Hydraulic System for Lift Trucks B60-80ZHD and B60-80ZHD2

As oil is displaced by the pump, it passes through a When the piston is fully extended to the end of its
one-way check valve to the lift cylinder. The check stroke or if the load is too heavy, pressure will
valve prevents oil from flowing back to the pump continue to build until the rated pressure needed to
when lifting ceases, which holds the lift cylinder in operate the relief valve is reached. When this
the raised position until lowered. occurs, the relief valve, which is normally closed, is
forced back against its spring, creating a path for
The piston will begin to lift the load when fluid
the fluid to flow back to the reservoir.
pressure acting against it is high enough to
overcome the weight of the load. When relief pressure is reached, hydraulic oil will
continue to be diverted from the relief valve to the

5
Special Precautions 1900 SRM 1639

reservoir until the lift button is released, controller CLEAN

time-out is reached, or electrical power is
interrupted. Adhere to the following precautionary steps to
ensure that the hydraulic system remains clean.
LOWERING A LOAD 1. Clean the reservoir and pump area to prevent
A load is lowered by depressing the lower button. contaminants from entering the hydraulic
When the lower button is depressed, electric current system.
is sent to the normally closed solenoid lowering
valve, which causes it to change position and open a 2. Clean (flush) the entire system when a failure
path for the trapped hydraulic oil to flow from the is encountered to make sure all paint, metal
cylinder back to the reservoir. chips, welding shot, and debris are removed.

HYDRAULIC LINES 3. Filter each change of oil to prevent the

introduction of contaminants into the system.
1. All hydraulic hoses and tubes must be
thoroughly cleaned before installation. 4. Provide continuous protection from airborne
contamination by keeping the breather cap
2. When making repairs, use the least number of clean and serviceable.
fittings and connections to minimize flow
resistance and the possibility of leakage. SOUND LEVEL
HYDRAULIC OIL Hydraulic system noise may be caused by both
improperly selected oil and loose or damaged system
The hydraulic oil in the system performs the dual components.
function of the power transmission and lubrication.
Using the correct fluid is essential to proper system • Cavitation - Can be caused by high fluid
viscosity, cold fluid temperatures, or a
operation. See the appropriate Periodic
restriction in the inlet screen or inlet tubing.
Maintenance manual for the recommended At startup, low temperatures can cause pump
hydraulic oil. noises due to cavitation.
• See Periodic Maintenance 8000SRM1644 • Aerated Hydraulic Oil - Results in system
for unit codes B257, B262 and C230. noise that is similar to cavitation. Aerated oil
• See Periodic Maintenance 8000SRM2105 is caused by the ingestion of air through the
for unit codes C257, C262 and E230. joints of the inlet lines and high-velocity
discharge lines. Aeration can also be caused
The hydraulic oil level should be checked first when by oil discharging above the fluid level in the
troubleshooting lifting problems. Low oil levels may hydraulic reservoir. Aerated hydraulic oil
make it appear that a problem exists with the occurs when air does not have sufficient time
battery or hydraulic system. to escape from the fluid while in the reservoir
before recycling through the system.

Special Precautions

WARNING CAUTION
The capacitor in the transistor controller can hold To avoid controller damage, always disconnect the
an electrical charge after the battery is battery, discharge the capacitor, and never put
disconnected. To prevent an electrical shock and power to the controller while any power wires are
personal injury, discharge the capacitor before disconnected. Never short any controller terminal
inspecting or repairing any component in the drive or motor terminal to the battery. Make sure to use
unit compartment. Wear safety glasses. Make proper procedure when servicing the controller.
certain that the battery has been disconnected.

6
1900 SRM 1639 Hydraulic Reservoir

1. Verify that the key switch is in the OFF

position and the battery connector is completely
disconnected.

2. Discharge the capacitors in the controllers by

connecting a 200-ohm, 2-watt resistor across
the controller's B+ and B− terminals. DO NOT
short across the motor controller terminals
with a screwdriver or jumper wire. Remove the
200-ohm, 2-watt resistor before reconnecting
the battery. See Figure 4.

1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR

Figure 4. Discharging the Capacitors

Hydraulic Reservoir
The hydraulic reservoir is made of a durable, unit compartment. The reservoir has MIN and
translucent plastic that allows the operator to see MAX marks on the side. With the truck on level
how much hydraulic oil is in the reservoir. The surface, the forks lowered completely, and the oil at
reservoir is clamped to the adapter plate on the room temperature, the reservoir should be filled to
bottom of the pump and motor assembly in the drive the MIN mark.

Drive Unit Compartment Covers

The drive unit compartment is concealed behind a 4. Block load wheels to prevent lift truck from
molded cover which fits securely around the drive moving. Refer to the section - How to Put A
unit and steer support to the frame. The floor mat Lift Truck on Blocks in Periodic
fits snugly in the operator platform after the drive Maintenance.
unit cover is installed. See Periodic Maintenance 8000SRM1644
•
for unit codes B257, B262 and C230.
1. Move the lift truck to a safe and level area.
• See Periodic Maintenance 8000SRM2105
2. Lower the forks completely to relieve pressure for unit codes C257, C262 and E230.
from the hydraulic system.
5. Lift the corners of the floor mat and pull it out
3. Turn the key switch to the OFF position and away from the drive unit. See Figure 5.
disconnect battery.

7
Drive Unit Compartment Covers 1900 SRM 1639

6. Reach under the side of the drive unit cover

near the bottom and find the grip slot. See
Figure 6. With both hands, pull up and away
from the truck until the bottom of the cover
kicks out from the retaining clips. Repeat this
for the other side of the cover. Work around the
edge of the cover until free from the truck.

7. To replace the covers, make sure the floor mat

is pulled away from the drive unit. Place the
bottom of the drive unit cover onto the operator
platform and position the lower edges partially
into the lower retaining clips.

8. Push the top of the cover partially into the

upper retaining clips. DO NOT push either
edge of the cover in completely before starting 1. DRIVE UNIT COMPARTMENT COVER
all edges into the proper place. 2. RETAINER TABS
3. GRIP SLOT
9. When the cover is aligned and started properly, 4. FRAME
press the cover completely into the retaining
Figure 6. Drive Unit Compartment Cover
clips and place the floor mat into the operator
platform around the cover.

1. FLOOR MAT
2. DRIVE UNIT COMPARTMENT COVER
3. FRAME
4. CASTER MOUNTING ACCESS

Figure 5. Floor Mat

8
1900 SRM 1639 Lift Pump and Motor

Lift Pump and Motor

GENERAL 1. Move the lift truck to a safe and level area.
The lift pump and motor assembly consist of: 2. Lower the forks completely to relieve pressure
• Electric Motor from the hydraulic system.
• Lift Pump
3. Turn the key switch to the OFF position and
• Lowering Valve disconnect battery.
• Relief Valve
4. Block load wheels to prevent lift truck from
• Check Valve
moving. Refer to the section - How to Put A
• Reservoir Lift Truck on Blocks in Periodic
• Inlet Tube and Strainer Maintenance.
• Breather/Filler Cap • See Periodic Maintenance 8000SRM1644
for unit codes B257, B262 and C230.
The lift pump and motor assemblies are
mechanically joined together as a compact unit, • See Periodic Maintenance 8000SRM2105
for unit codes C257, C262 and E230.
combining the reservoir, pump, valves, and motor.
The lift pump is located inside the hydraulic
5. Remove the drive unit compartment covers. See
reservoir and coupled to the motor by an adapter
Drive Unit Compartment Covers.
plate, coupling, and four capscrews.
Lift pump and motor assembly servicing is best 6. Discharge the capacitor. See Special
performed by removing the unit from the truck to a Precautions.
clean work area.
7. Tag and disconnect all power wires and control
NOTE: It is not necessary to remove the complete wires to the lift pump and motor assembly.
lift pump and motor assembly to remove the
reservoir. When removing only the reservoir, see 8. Disconnect the hydraulic hoses.
Remove Reservoir.

REMOVE WARNING
Lift Pump and Motor Assembly Batteries are heavy and can cause personal injury.
Use care to avoid injury. DO NOT put hands, arms,
feet, and/or legs between the battery and a solid
WARNING object. Make sure the capacity of the crane and
Always wear the proper protective equipment spreader bar is greater than the weight of the
including eye protection and petroleum-resistant battery. The weight of the battery is normally
gloves when handling hydraulic oil. Thoroughly shown on the battery case. The maximum battery
wash oil from exposed areas of skin as soon as weight is shown on the lift truck nameplate. The
possible. spreader bar must NOT be made of metal or it
Completely lower forks to relieve hydraulic must have insulated straps.
pressure before disassembling any part of the lift
9. If necessary, remove the battery. Use a
pump or disconnecting any hydraulic hoses.
spreader bar and an overhead lifting device
(crane) to remove the battery. DO NOT let the
battery move from side to side. Make sure the
CAUTION battery cables have clearance. See Figure 7.
Make certain the hydraulic cylinder rod is fully
retracted.
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.

9
Lift Pump and Motor 1900 SRM 1639

10. Loosen and remove the three capscrews and 2. Remove the four capscrews retaining the
lockwashers retaining the lift pump and motor reservoir to the lift pump. See Figure 8.
assembly to the frame. Support the lift pump
and motor assembly as the capscrews are being 3. Carefully remove the reservoir from the lift
removed. Remove lift pump and motor pump and motor.
assembly.
4. Place the pump and motor assembly on a clean
11. Place lift pump and motor assembly in a vise on drip pan.
a workbench in an upright position.
5. Remove and inspect the O-ring seal located
between the lift pump assembly and the
hydraulic reservoir. Verify that the O-ring seal
is not damaged. Replace as needed.

6. Inspect the inlet strainer. Also inspect the

return strainer. If necessary, remove the
retaining clip to access the screen. Replace
parts that are damaged or cannot be cleaned.

CAUTION
Disposal of lubricants and fluids must meet local
and environmental regulations.

7. Pour oil from reservoir in a container suitable

for disposal.

CAUTION
If oil is contaminated or excessively dirty, the
entire hydraulic system should be thoroughly
cleaned.

1. CRANE 8. Examine the hydraulic reservoir. Inspect the

2. SPREADER BAR hydraulic reservoir for dirt, foreign materials,
3. INSULATOR STRAPS or contamination. Clean and flush the
4. BATTERY hydraulic reservoir as necessary.
Figure 7. Battery Removal 9. Remove the breather/filler cap. Using a small
pry bar, separate the top and bottom of the
DISASSEMBLE breather/filler cap. Clean and inspect the
Remove Reservoir breather element and the flat seal. Replace
parts that are damaged or cannot be cleaned.
1. If the lift pump and motor assembly has not Assemble the breather/filler cap.
been previously removed, perform Step 1
through Step 6 in RemoveLift Pump and Motor
Assembly.

10
1900 SRM 1639 Lift Pump and Motor

Figure 8. Lift Pump and Motor Assembly

11
Lift Pump and Motor 1900 SRM 1639

Legend for Figure 8.

1. CAPSCREW 11. SCREEN 22. LOWERING ORIFICE

2. LIFT PUMP MOTOR 12. RETAINER 23. CAPSCREW
3. ADAPTER PLATE 13. TWO PIECE CLAMP 24. WASHER
4. COUPLING 14. CAPSCREW 25. LOWERING VALVE COIL
5. TUBE 15. WASHER 26. LOWERING VALVE CARTRIDGE
6. INLET TUBE 16. RESERVOIR 27. O-RING
7. RETURN TUBE 17. FILLER ELBOW 28. CHECK VALVE
8. STRAINER 18. FLAT SEAL 29. CHECK VALVE BALL
9. CLAMP 19. BREATHER/FILLER CAP 30. LIFT PUMP
10. STRAINER HOUSING 20. O-RING 31. RELIEF VALVE
21. O-RING

Remove Pump Motor 5. Install tubes and related items to bottom of

pump as removed.
1. Remove the two capscrews from top of motor.

2. Lift the motor from the pump assembly.

Install Pump Motor

3. Inspect the motor output shaft, the pump input WARNING

shaft, and the coupling. Replace worn or Always wear the proper protective equipment
damaged parts. including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
Disassemble Pump wash oil from exposed areas of skin as soon as
1. Tag and identify each tube with their possible.
corresponding location.

2. Remove tubes and associated items from the CAUTION

bottom of pump. Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
3. Remove the lowering valve from pump system.
assembly. See Valve Repair, Lowering Valve, in
this section. 1. Lubricate the motor output shaft and the pump
input shaft with a light coating of Molykote® G-
4. Remove the check valve from pump assembly.
N paste.
See Valve Repair, Check Valve, in this section.
2. Install the coupling on the pump shaft.
5. Remove the relief valve from pump assembly.
See Valve Repair, Relief Valve, in this section. 3. Align the slot in the motor shaft with the
coupling. Lower the motor onto the pump,
ASSEMBLE rotating the body as necessary, to engage the
Assemble Pump coupling.

1. Clean and lubricate all components using clean 4. Use the following procedure that applies to
hydraulic oil. your lift truck:

2. Install the relief valve. See Valve Repair, Relief a. Align the pump assembly mounting holes
Valve. with the holes in the pump motor. Install the
capscrews and tighten to 8 N•m (71 lbf in).
3. Install the check valve. See Valve Repair,
Check Valve. b. Align the pump motor mounting holes with
the holes in the adapter plate. Install the
4. Install the lowering valve. See Valve Repair, capscrews and tighten to 8 N•m (71 lbf in).
Lowering Valve.

12
1900 SRM 1639 Lift Pump and Motor

Install Reservoir to Pump

NOTE: If only the reservoir has been removed,
perform Step 3 through Step 7.
1. Place reservoir in an upright position on the
workbench.

2. Install breather/filler cap to reservoir.

NOTE: The reservoir may be filled at this point or it

may be filled after the lift pump and motor
assembly have been installed.
3. Fill the hydraulic reservoir to proper level. See
Hydraulic Reservoir.

4. Install O-ring seal on pump assembly. If

necessary, use a small amount of grease to hold
the O-ring seal in position.

5. Position lift pump and motor assembly onto the

reservoir.

6. Install two piece clamp to reservoir and pump

assembly.

7. Install four capscrews and torque to

Location 1 Location 2 Location 3
8 N•m (71 lbf in).
26 N•m 39 N•m 10 N•m
INSTALL (19 lbf ft) (29 lbf ft) (7 lbf ft)

Lift Pump and Motor Assembly NOTE: APPLY LOCTITE® 242 TO ALL LOCATIONS
SHOWN DURING ASSEMBLY.
1. Align the lift pump and motor assembly with
the mounting holes in the frame. Figure 9. Torque Values
2. Apply Loctite® 242 to the threads of the 3. Install hydraulic hoses to lift pump and motor
mounting capscrews. Install three capscrews assembly.
with lockwashers and torque to the proper
torque. See Figure 9. 4. Connect power wires and control wires to lift
pump and motor assembly.

CAUTION
Never operate the pump without the proper
amount of oil in the hydraulic system. The
operation of the hydraulic pump with low oil levels
will damage the pump.

5. Remove breather/filler cap and fill the

hydraulic reservoir to proper level. See
Hydraulic Reservoir.

6. Install breather/filler cap.

13
Valve Repair 1900 SRM 1639

7. If removed, install the battery.

11. Test lift truck by lifting and lowering several
times. Visually inspect for leaks.
8. Remove blocks from wheels.
12. Recheck hydraulic oil level in reservoir, and fill
9. Connect the battery and turn the key switch to
to proper level if needed. See Hydraulic
the ON position.
Reservoir.
10. Operate the hydraulic functions several times
13. Install drive unit compartment covers. See
to purge air from the hydraulic circuit.
Drive Unit Compartment Covers.

WARNING
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
the skin.

Valve Repair
LOWERING VALVE Install
Remove 1. Verify that the O-rings on the valve cartridge
are not damaged. Replace as needed.
1. Move lift truck to a safe and level area.
2. Verify that the valve cartridge, cartridge filter,
2. Lower the forks completely to relieve pressure and pump assembly housing are clean and not
from the hydraulic system. damaged.
3. Turn the key switch to the OFF position and 3. Lubricate the valve cartridge threads and O-
disconnect battery. rings with clean hydraulic oil.
4. Block load wheels to prevent lift truck from 4. Install the valve cartridge and torque to
moving. See the section - How to Put A Lift 28 to 38 N•m (20.7 to 28.0 lbf ft).
Truck on Blocks in Periodic Maintenance.
• See Periodic Maintenance 8000SRM1644 5. Slide the coil onto the valve cartridge with the
for unit codes B257, B262 and C230. lettering out toward the coil retainer.
• See Periodic Maintenance 8000SRM2105
for unit codes C257, C262 and E230. 6. Install washer and capscrew and torque to
7 N•m (62 lbf in).
5. Remove the drive unit compartment covers. See
Drive Unit Compartment Covers. 7. Connect the control wiring to the coil.

6. Discharge the capacitor. See Special 8. Remove blocks from wheels.

Precautions.
9. Connect battery and turn the key switch to the
7. Tag and disconnect the control wiring from the ON position.
coil.
10. Operate the hydraulic functions several times
8. Remove the capscrew and washer retaining the to purge air from the hydraulic circuit.
coil to the valve cartridge.
11. Test the lift truck by lifting and lowering
9. Slide the coil off the valve cartridge. several times. Visually inspect for leaks.

10. Slowly loosen and remove the valve cartridge. 12. Check hydraulic oil level in the reservoir and
fill to proper level. See Hydraulic Reservoir.

14
1900 SRM 1639 Valve Repair

13. Install the drive unit compartment covers. See Install

Drive Unit Compartment Covers.
1. Verify that the O-rings on the valve cartridge
are not damaged. Replace as needed.
RELIEF VALVE
Remove 2. Verify that the valve cartridge and pump
assembly housing are clean and not damaged.

WARNING 3. Lubricate the valve cartridge threads and O-

Always wear the proper protective equipment rings with clean hydraulic oil.
including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly 4. Install the valve cartridge and torque to
wash oil from exposed areas of skin as soon as 32 N•m (24 lbf ft).
possible.
5. Install lift pump and motor assembly. See Lift
Completely lower forks to relieve hydraulic Pump and Motor.
pressure before disassembling any part of the lift
pump or disconnecting any hydraulic hoses. 6. Remove blocks from wheels.

7. Connect the battery and turn the key switch to

CAUTION the ON position.
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic 8. Operate the hydraulic functions several times
system. to purge air from the hydraulic system.

1. Move the lift truck to a safe and level area. 9. Verify that the relief valve settings are correct.
See Relief Valve Pressure Check.
2. Lower the forks completely to relieve pressure
from the hydraulic system. 10. Test lift truck by lifting and lowering several
times. Visually inspect for leaks.
3. Turn the key switch to the OFF position and
disconnect battery. 11. Check hydraulic oil level in reservoir and fill to
proper level. See Hydraulic Reservoir.
4. Block load wheels to prevent lift truck from
moving. See the section - How to Put A Lift 12. Install drive unit compartment covers. See
Truck on Blocks in Periodic Maintenance. Drive Unit Compartment Covers.
• See Periodic Maintenance 8000SRM1644
for unit codes B257, B262 and C230. CHECK VALVE
• See Periodic Maintenance 8000SRM2105 Remove
for unit codes C257, C262 and E230.
1. Move lift truck to a safe and level area.
5. Remove the drive unit compartment covers. See
Drive Unit Compartment Covers. 2. Lower the forks completely to relieve pressure
from the hydraulic system.
6. Discharge the capacitor. See Special
Precautions. 3. Turn the key switch to the OFF position and
disconnect battery.
7. Remove the lift pump and motor assembly. See
Lift Pump and Motor. 4. Block load wheels to prevent lift truck from
moving. See the section - How to Put a Lift
8. Slowly loosen and remove the relief valve Truck on Blocks in Periodic Maintenance.
cartridge. • See Periodic Maintenance 8000SRM1644
for unit codes B257, B262 and C230.
• See Periodic Maintenance 8000SRM2105
for unit codes C257, C262 and E230.

15
Lift Cylinder 1900 SRM 1639

5. Remove the drive unit compartment covers. See 4. Install the check valve ball.
Drive Unit Compartment Covers.
5. Install the valve cartridge and torque to
6. Discharge the capacitor. See Special 20 N•m (15 lbf ft).
Precautions.
6. Remove blocks from wheels.
NOTE: The check valve ball is located behind the
spring at the end of the check valve. 7. Connect the battery and turn the key switch to
the ON position.
7. Slowly loosen and remove the check valve
cartridge and check valve ball. 8. Operate the hydraulic functions several times
to purge air from the hydraulic system.
Install
1. Verify that the O-rings on the valve cartridge 9. Test lift truck by lifting and lowering a load
are not damaged. Replace as needed. several times. Visually inspect for leaks.

2. Verify that the valve cartridge, cartridge filter, 10. Check hydraulic oil level in reservoir and fill to
and pump assembly housing are clean and not proper level. See Hydraulic Reservoir.
damaged.
11. Install drive unit compartment covers. See
3. Lubricate the valve cartridge threads and O- Drive Unit Compartment Covers.
rings with clean hydraulic oil.

Lift Cylinder
REMOVE
1. Raise the forks to one half its maximum height.
WARNING
Always wear the proper protective equipment
2. Block load wheels to prevent lift truck from including eye protection and petroleum-resistant
moving. Refer to section - How to Put a Lift gloves when handling hydraulic oil. Thoroughly
Truck on Blocks in Periodic Maintenance. wash oil from exposed areas of skin as son as
possible.
• See Periodic Maintenance 8000SRM1644
for unit codes B257, B262 and C230. The hydraulic oil is hot at normal operating
• See Periodic Maintenance 8000SRM2105 temperatures. Be careful when draining the oil.
for unit codes C257, C262 and E230. Never check for leaks by putting hands on
hydraulic lines or components under pressure.
3. Turn the key switch to the OFF position and Hydraulic oil under pressure can be injected into
disconnect battery. the skin.
4. Remove the drive unit compartment covers. See
Drive Unit Compartment Covers.
CAUTION
5. Discharge the capacitor. See Special Protect the hydraulic system from dirt and
Precautions. contaminants when servicing the hydraulic
system.
6. Separate the frames. Disposal of lubricants and fluids must meet local
• See Periodic Maintenance 8000SRM1644 environmental regulations.
for unit codes B257, B262 and C230.
• See Periodic Maintenance 8000SRM2105 7. Position a drain pan in the floor under the lift
for unit codes C257, C262 and E230. cylinder and slowly loosen the hydraulic hose
and tube fittings at the lift cylinder to relieve
pressure from the lift cylinder. Clean up spilled
oil immediately.

16
1900 SRM 1639 Lift Cylinder

8. Disconnect the hydraulic hose and tubes. 10. Remove the four capscrews retaining the two
cylinder blocks to the frame. Remove the
9. Loosen and remove the locking nut and washer cylinder blocks and set aside.
from the end of the lift cylinder rod. See
Figure 10. 11. Unscrew the trunnion mount from the end of
the cylinder rod.

12. Manually collapse the rod into the cylinder.

13. Remove the capscrew retaining the bottom

clevis pin to the frame and remove the clevis
pin.

14. Remove the cylinder from the frame.

1. CAPSCREW 5. CYLINDER
2. TRUNNION 6. TRUNNION
MOUNT 7. WASHER
3. PIN 8. LOCK NUT
4. CAPSCREW

Figure 10. Cylinder Mounting

17
Lift Cylinder 1900 SRM 1639

1. TUBE 4. PISTON SEAL 7. SEAL

2. LOCK NUT 5. O-RING 8. WIPER
3. PISTON 6. ROD 9. GLAND NUT

Figure 11. Lift Cylinder

DISASSEMBLE 1. Install the seals and O-rings as necessary into

the gland and piston after coating them with
clean hydraulic oil.
CAUTION
Lubricate the seals and O-rings with clean 2. Carefully install the rod through the gland nut.
hydraulic oil before assembling. Make certain to Install the piston, spacer (if necessary), and the
install spacers, if any were removed. lock nut. Tighten the lock nut (lubricated) to
150 N•m (110 lbf ft).
1. Loosen the gland nut. Extract the piston, gland
nut, and rod from the cylinder. See Figure 11.
CAUTION
2. Disassemble the nut and piston from the
Make certain that none of the sealant gets into the
cylinder rod. Remove the spacers, if used, and
cylinder. Allowing sealant to get into the hydraulic
slide the rod out of the gland nut.
system may cause damage to the components
within the hydraulic system.
3. Remove all seals and O-rings.
3. Carefully install the rod assembly into the
ASSEMBLE cylinder. Apply sealant Hyster P/N 2064554 or
NOTE: Special care should be used, to avoid equivalent to the threads of the gland nut.
damage to the seals from the cylinder rod threads, Tighten the gland nut to 27 N•m (20 lbf ft).
when installing the gland to the cylinder rod.

18
1900 SRM 1639 Relief Valve Pressure Check

INSTALL Never check for leaks by putting hands on

hydraulic lines or components under pressure.
1. Align the bottom of the cylinder with the frame Hydraulic oil under pressure can be injected into
and install the pin in the frame and the the skin.
cylinder. Install the clevis pin retaining
capscrew into the frame.

2. Install the trunnion onto the end of the cylinder CAUTION

rod and screw it down onto the cylinder rod. Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
3. Install the two trunnion mounting blocks to the system.
ends of the trunnion. Never operate the pump without the proper
amount of oil in the hydraulic system. The
4. Install the mounts onto the frame and install operation of the hydraulic pump with low oil levels
the capscrews through the mounts into the will damage the pump.
frame.
9. Remove the breather/filler cap and fill the
5. Install the lockwasher and lock nut onto the hydraulic reservoir to proper level. See
end of the cylinder rod. Hydraulic Reservoir.
6. Adjust fork height to specification as outlined 10. Install breather/filler cap.
in the manual Lifting Mechanism
4000SRM1641. 11. Connect battery and turn the key switch to the
ON position.
7. Assemble the frame. Refer to the manual
Lifting Mechanism 4000SRM1641. 12. Operate the hydraulic functions several times
to purge air from the hydraulic circuit.
8. Remove blocks from wheels.
13. Test lift truck by lifting and lowering a load
several times while checking for leaks.
WARNING
Always wear the proper protective equipment 14. Check hydraulic oil level in reservoir and fill to
including eye protection and petroleum-resistant proper level. See Hydraulic Reservoir.
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as 15. Install the drive unit compartment covers. See
possible. Drive Unit Compartment Covers.

Relief Valve Pressure Check

Always wear the proper protective equipment
WARNING including eye protection and petroleum resistant
DO NOT make repairs or adjustments unless you gloves when servicing hydraulic components.
have been properly trained and authorized to do Thoroughly wash oil from exposed areas of skin
so. Improper repairs and adjustments can create as soon as possible.
dangerous operating conditions. DO NOT operate Completely lower forks to relieve hydraulic
a lift truck that needs repair. Report the problem to pressure before disassembling any part of the lift
your supervisor immediately. If repairs are pump or disconnecting any hoses.
necessary, turn the key switch to the OFF position,
The hydraulic oil is hot at normal operating
attach a DO NOT OPERATE tag to the control
temperatures. Be careful when draining the oil.
handle, and disconnect the battery.

19
Relief Valve Pressure Check 1900 SRM 1639

Never check for leaks by putting hands on 9. Install a tee fitting and a pressure gauge
hydraulic lines or components under pressure. having at least a 24.8 MPa (3600 psi) rating.
Hydraulic oil under pressure can be injected into
the skin. 10. Verify the oil is at an operating temperature of
43 to 49°C (110 to 120°F).

11. Raise the forks completely and continue to hold

CAUTION
the lift button. Read the pressure gauge while
DO NOT OVERFILL RESERVOIR. Oil will leak from
the pump is in relief.
the breather/filler cap during operation if reservoir
is over filled. NOTE: The pump will stop after a short period of
time. Release the lower button then press and hold
NOTE: Check the hydraulic oil level in the reservoir again to continue.
when oil is at room temperature. Remove breather
cap and add recommended hydraulic oil to proper 12. The relief pressure should be
level, as required. See Hydraulic Reservoir in this 24.2 (+0.6 -0.0) MPa (3500 (+87 -0) psi). If the
section. pressure is incorrect, refer to Relief Valve
Adjust.
1. Operate lift truck until hydraulic oil reaches
operating temperature
13. After the proper relief pressure is obtained,
[43 to 49°C (110 to 120°F)].
lower the forks completely to relieve pressure
from hydraulic circuit.
2. Lower the forks completely to relieve pressure
from hydraulic circuit.
14. Turn the key switch to the OFF position.
Disconnect the battery.
3. Turn the key switch to the OFF position and
disconnect the battery.
15. Discharge the capacitor. See Special
Precautions.
4. Block load wheels to prevent lift truck from
moving. Refer to the section - How to Put a
16. Remove the pressure gauge and tee.
Lift Truck on Blocks in Periodic
Maintenance. 17. Reconnect the hydraulic hose to pump.
• See Periodic Maintenance 8000SRM1644
for unit codes B257, B262 and C230. 18. Connect the battery and turn the key switch to
• See Periodic Maintenance 8000SRM2105 ON position.
for unit codes C257, C262 and E230.
19. Operate the hydraulic functions several times
5. Remove the drive unit compartment covers. See to purge the air from the hydraulic circuit.
Drive Unit Compartment Covers.
20. Remove blocks from wheels.
6. Discharge the capacitor. See Special
Precautions. 21. Test the lift truck by lifting and lowering a load
several times. Visually check for leaks.
7. Clean any buildup of dirt from around the lift
pump and motor assembly.
CAUTION
DO NOT OVERFILL. Oil will leak from the breather/
CAUTION filler cap if too full.
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic 22. Check the hydraulic oil level in the reservoir.
system. Remove breather cap and add recommended
hydraulic oil to proper level, as required. See
8. Disconnect the hydraulic hose at the pump. Hydraulic Reservoir.

20
1900 SRM 1639 Troubleshooting

23. Install the drive unit compartment covers. See Relief Valve Pressure Check to see if replacement of
Drive Unit Compartment Covers. the relief valve is required.

RELIEF VALVE ADJUST

The relief valve is non-adjustable and comes preset
to the correct pressure from the factory. Refer to

Troubleshooting
LIFT ASSEMBLIES
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Forks fail to elevate. Oil in the hydraulic reservoir is Fill reservoir to correct level.
low. Check for leaks.
Faulty hydraulic equipment. See Lift Pump and Motor
Assembly, and Lift Cylinders
Broken pull rods.
(below).
Deformed lifting components.
Disassemble and replace damaged
parts.
Disassemble and replace damaged
parts.

Slow lifting speed and insufficient Oil in the hydraulic reservoir is Fill reservoir to correct level.
handling capacity. low. Check for leaks.
Faulty hydraulic equipment. See Lift Pump and Motor
Assembly, and Lift Cylinders
Deformed lifting components.
(below).
Disassemble and replace damaged
parts.

Forks fail to lower. Deformed forks. Disassemble, repair, or replace.

Deformed lifting components. Disassemble, repair, or replace.
Bent lift cylinder piston rod. See Lift Pump and Motor
Assembly, and Lift Cylinders
(below).

21
Troubleshooting 1900 SRM 1639

LIFT CYLINDERS
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Oil leaks from cylinder gland Restriction in the return tube. Remove restriction or install new
around piston rod (an oil ring tube.
Score on piston rod.
appears on the piston rod).
Remove any foreign matter.
Scores on wiper ring lip.
Smooth rod surface with an oil
Unusual distortion of wiper ring. stone. If oil still leaks, replace
Chrome plating is stripped. cylinder seals and O-rings.
Replace wiper ring.
Replace wiper ring.
Replace piston rod or renew
chrome plating.

Oil leaks from welded portion. Cylinder tube damaged. Replace cylinder tube.

Rod spontaneously retracts. Defective lowering valve. Replace lowering valve.

Defective check valve. Replace check valve.
Scores on inner surface of tube. Smooth surface with an oil stone.
Score on tube. Replace cylinder tube.
Score on piston ring. Replace piston ring.

Wear limit (clearance between Excessive clearance between Replace cylinder.

cylinder tube and wear ring). cylinder tube and wear ring.

22
1900 SRM 1639 Troubleshooting

LIFT PUMP AND MOTOR ASSEMBLY

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Low hydraulic pressure. Pump is worn or damaged. Repair or install new pump.
Relief valve needs adjustment. Replace relief valve.

Hydraulic system relief valve Excessive load on forks. Reduce load.

opens frequently.
Lift linkage jammed or sticky. Repair lift linkage.
Relief valve needs adjustment, or Replace relief valve.
relief valve is defective.
Remove restriction or install new
Restriction in the pressure side of line.
the hydraulic system.

The pump noise is not normal. Oil in the hydraulic reservoir is Fill reservoir to correct level.
low. Check for leaks.
Restriction in the inlet hose. Remove restriction, clean screen,
or install new line.
Inlet fitting or inlet hose clamp is
loose. Tighten fitting. Install new hoses.
Remove air from system.
The pump bearings or gears are
damaged. Repair or install new pump.
The pump housing is damaged. Repair or replace pump housing.
Loose capscrews holding the pump Tighten capscrews to specified
housing together. torque.
Loose capscrews in the pump Tighten capscrews to specified
mounting. torque.
Relief valve is stuck open. Clean, adjust, or replace the relief
valve.

The pump has low output. The pump is worn. Check, repair, or install new parts
as required.
Oil in the hydraulic reservoir is
low. Fill reservoir to correct level.
Check for leaks.
Lift cylinder has leaks.
Repair or replace lift cylinder.
Restriction in the inlet hose.
Remove restriction, clean screen,
Inlet fitting or inlet hose clamp is
or install new line.
loose.
Tighten fitting. Install new hoses.
Seals or gaskets are damaged and
Remove air from system.
cause leaks.
Install new seals or gaskets.
The fitting at the pump leaks.
Tighten fittings. Install new parts
as necessary.

23
Troubleshooting 1900 SRM 1639

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The pump has leaks. Fittings are loose or defective. Tighten fittings. Install new parts
as necessary.
Loose capscrews holding the pump
housing together. Tighten capscrews to specified
torque.
Seals are defective.
Install new seals or gaskets.

Lift pump and motor operates but Excessive load on forks. Reduce load.
the forks will not raise. The
Relief valve defective. Replace relief valve.
button is in the raise position.
Relief valve pressure is incorrect. Replace relief valve.
Oil in the hydraulic reservoir is Fill reservoir to correct level.
low. Check for leaks.
Lower cartridge is defective. Check the valve cartridge for
contamination and damage.
Replace cartridge.

Lift pump and motor operates but Lower cartridge is defective. Check the valve cartridge for
the forks will not lower. The contamination and damage.
Lowering solenoid is disconnected
button is in the lower position. Replace cartridge.
or damaged.
Connect or replace solenoid.
The LOWER switch is
disconnected or damaged. Connect or replace switch.
The lift cylinder has damage. Replace or repair cylinder.

Lift pump motor does not operate. Battery is disconnected. Connect battery.
Battery is discharged. Charge or replace battery.
Key switch is damaged. Repair or replace key switch.
The fuse is damaged. Replace fuse.
The LIFT switch is disconnected Connect or replace switch.
or damaged.
Connect or repair wires.
Wires to the motor are
Repair or replace motor.
disconnected or damaged.
The motor is damaged

24
 TECHNICAL PUBLICATIONS

1900 SRM 1639 12/18 (10/18)(2/17)(10/13)