HYDRAULIC SYSTEM E1.50—3.20XM (E25—65XM) J2.00—3.20XM (J40—65XM) N30XMH _E PART NO. 897639 1900 SRM 559SAFETY PRECAUTIONS MAINTENANCE AND REPAIR When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and that the load being lifted is balanced, Make sure ‘that 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 lft 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 and working area clean and in order. Use the correct tools forthe 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 that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when ‘making repairs or if the unit needs repai ‘Make sure you follow the DANGER, WARNIN the instructions. Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels. Make sure that you 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 has ventilation,CONTENTS INTRODUCTION GENERAL . DESCRIPTION Hydraulic System, OPERATION ...... Hydraulic System Hydraulic Gear Pump . Rotator Actuator Valve... Steering Pump REPAIRS ........... HYDRAULIC TANK ..... E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal ...... 12,00-3.20XM (J40-65XM) Tank Removal . ink Inspection... ik Repairs, Small Leaks. ‘Tank Repairs, Large Leaks Tank Cleaning Steam Method Of Cleaning Tank . Chemical Solution Method Of Cleaning Tank Additional Preparations For Tank Repair... . - 12 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation... 12 4J2.00-3.20XM (J40-65XM) Tank Installation ........600eeeccee ery FILTER REPLACEMENT ..... 13 HYDRAULIC PUMP .... 13 Removing E1.50-3.20XM (E28-65XM) and NSOXMHL Hydraulic Pu Pump 13 Remove The J2,00-3.20XM (J40-65XM) Hydraulic Pump... 14 Pump Seal Replacement And Pump Assembly ..... : see Assemble Pump On The Motor ....... oe 16 Install The Hydraulic Pump And Motor Assembly [EI 50-3.20XM (E25-65XM) and N30XMH | 7 Install J2,00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly . 7 MAIN CONTROL VALVE 18 STEERING PUMP . 18, Pump Removal And nd Disassembly, E1.50-3.20XM (E25 6SKM) a and N30XMH .. 18 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM) ... Pee) Pump Assembly And Installation 20 ROTARY ACTUATOR VALVE . 21 @HYSTER COMPANY 1996Disassembly, Cleaning and Inspection... seve 2 veces ou STEERING CONTROL UNIT wees 2 Control Unit Removal . 2 Control Unit Installation . 2 STEERING CYLINDER .. we 2 CHECKS AND ADJUSTMENTS ..........00000008 MAIN CONTROL VALVE . STEERING RELIEF VALVE 24 TROUBLESHOOTING CHART .. seers 24 SPECIFICATIONS .. pee This section is for the following models: E1.SOXM, E1.75XM, E2.00XMS E25XM, E30XM, E35XM, E40XMS E2.00XM, E2.50XM(SHORT), E2.50XM, E3.00XM(SHORT), E3.00XM, E3.20XM, EASXM, E4SXM(SHORT), E50XM, ESOXM(SHORT), ESSXM, E60XM, E65XM 32.00XM, J2.50XM(SHORT), J2.50XM, 13.00XM, J3.20XM, J40XM, J50XM, J50XM(SHORT), J6OXM, J6SXM, N30XMH_ @HYSTER COMPANY 1996,INTRODUCTION GENERAL This section describes the hydraulic system and the steering system. The section includes REPAIR, CHECKS AND — ADJUSTMENTS and TROUBLESHOOTING. This section has repair proce- dures for the main hydraulic pump and the steering pump. Other repair procedures are in the following sec- tions: * MAIN CONTROL VALVE, 2000 SRM 562 © MAST - Repair, 4000 SRM 522 TILT CYLINDER (2) FILTER |. BREATHER HYDRAULIC TANK (Can Be Different Shape) STEERING CYLINDER MAIN CONTROL VALVE (4-SPOOL VALVE SHOWN) FOUR STAGE MAST - Repair, 4000 SRM 563 VISTA MAST - Repair, 4000 SRM 482 (N30XMH ONLY) TILT CYLINDERS, 2100 SRM 103 LIFT CYLINDERS, 4000 SRM 481 (N30XMH ONLY) STEERING HOUSING AND CONTROL UNIT, 1600 SRM 512 STEERING AXLE, 1600 SRM 258 DC MOTOR MAINTENANCE, 620 SRM 294 13 PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE 1. TO AUXILIARY HYDRAULIC FUNCTIONS TO LIFT CYLINDERS STEERING CONTROL UNIT . STEERING PUMP. HYDRAULIC PUMP FIGURE 1. E1.50-3.20XM (E25-65XM) HYDRAULIC SYSTEMTILT CYLINDER (2) PRIMARY RELIEF VALVE |. STEERING MOTOR AND PUMP. HYDRAULIC MOTOR AND PUMP . HYDRAULIC TANK FILTER 5 7. BREATHER, FILL AND DIPSTICK 8. STEERING CYLINDER 9. SECONDARY RELIEF VALVE 10. MAIN CONTROL VALVE (4-SPOOL VALVE SHOWN) 11, STEERING CONTROL UNIT 12. TO AUXILIARY HYDRAULIC FUNCTIONS 13. TO LIFT CYLINDERS FIGURE 2. J2.00-3.20XM (J40-65XM) HYDRAULIC SYSTEM DESCRIPTION Hydraulic System (See FIGURE 1., FIGURE 2. or FIGURE 3.) ‘The parts of the hydraulic system for the E1.50-3.20XM (E25-65XM) are shown in FIGURE | ‘The parts of the hydraulic system for the 12.00-3.20XM (J40-65XM) are shown in FIGURE 2. The parts of the hhydraulic system for the N30XMH are shown in FIGURE 3. The diagrams show components and inter- connections that are typical of all models. It does not show all hydraulic systems. Not all units have a four spool valve. ‘The hydraulic system includes the steering system and the lift system, One hydraulic tank supplies both sys- tems, The steering system and the lift system have sepa- rate pumps, Both pumps are gear pumps. OPERATION Hydraulic System (See FIGURE 4. or FIGURE 5.) ‘The hydraulic pump causes oil to flow from the tank to 2 the main control valve. The main control valve controls the flow of oil to the lift cylinders, tlt cylinders, traverse cylinder, rotary actuator and auxiliary functions when applicable. A relief valve on the main control valve keeps pressure within the design limits of the hydraulic system. A test port for checking the pressure when the relief valve opens is on the main control valve. ‘Some auxiliary functions require less pressure than the lift function, A secondary relief valve on the main con- trol valve provides lower pressure for auxiliary func- tions. ‘The steering pump causes oil to flow from the tank to the steering control unit. The steering control unit is a me- tering pump actuated by the steering wheel. When the steering wheel is turned, ol flows to actuate the steering cylinder. Oil retums from the steering control unit to the main control valve. A relief valve in the pump keeps: pressure within the design limits of the steering system.. FILTER BREATHER . HYDRAULIC TANK |. STEERING CYLINDER MAIN CONTROL VALVE (4-SPOOL VALVE SHOWN) PRIMARY RELIEF VALVE ”. SECONDARY RELIEF VALVE |. TO AUXILIARY HYDRAULIC FUNCTIONS 12 TO LIFT CYLINDERS STEERING CONTROL UNIT HYDRAULIC PUME ~ STEERING HYDRAULIC PUMB - LIFT ‘TRAVERSE CYLINDER ROTARY ACTUATOR FIGURE 3. N30XMH HYDRAULIC SYSTEM. ‘The oil retums from the main control valve and flows through a filter in the hydraulic tank. The filter removes small particles from the oil. The filter has a by-pass valve so that the oil can flow through the system if the filter becomes too dirty. Hydraulic Gear Pump (See FIGURE 14.) ‘There can be two different sizes of hydraulic pumps used on these lift trucks: a 12 ce/revolution gear pump or 19 ce/revolution gear pump. The larger pump is stan- Gard, The smaller pump is used when there is a contactor ‘motor control with a closed motor or for a slower speed requirement, These hydraulic pumps are all single-sec~ tion gear pumps that fasten to the end of the motor hous- ing. A hose connects the pump inlet to the hydraulic tank. A hose connects the pump outlet to the main con- trol valve. A flexible coupling connects the motor shaft to the pump shaft. Bushings at each side of each gear of the pump are the bearings for the gear shafts. The bush- ings also have passages for the oil low to the pump out- let and for lubrication. Seals prevent leaks between sec- tions of the pump housing. Rotator Actuator Valve ‘On the N30XMH only, the rotary actuator valve is con- nected between the rotary spool and the rotary actuator. ‘The rotary actuator valve has two check valves, a shuttle,and two relief valves. The check valves prevent the rotary actuator from rotating when the lever on the main control valve is in the center position. The check valves prevent any oil flow from the rotary actuator until pressure from the main control valve pushes on the shuttle, The oil pressure opens the inlet check valve and at the same time the shuttle pustes against the return ‘check valve. The shuttle moves the check valve from its seat and permits oil to flow to the hydraulic tank. A relief 3TILT CYLINDERS ( LIFT CYLINDERS. eeu LOWERING CONTROL VALVES y MAIN CONTROL VALVE 5. LIFT SPOOL TILT SPOOL AUXILIARY SPOOL |. HYDRAULIC PUMP. . FILTER, PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE . STEERING CONTROL UNIT |. STEERING CYLINDER HAND PUMP STEERING VALVE . LINE PRESSURE TAP PRESSURE SWITCH FOR ON-DEMAND STEERING / CHECK PORT 1 1. STEERING PUMP ). STEERING RELIEF VALVE HYDRAULIC TANK FIGURE 4. E1.50-3.20XM (E25-65XM) AND J2.00-3.20XM (J40-65XM)HYDRAULIC SCHEMATIC1, LIFT CYLINDERS 2. LOWERING CONTROL VALVES, 3, MAIN CONTROL VALVE 4, LIFT SPOOL, 5. AUXILIARY SPOOL 6. TRAVERSE SPOOL 7. ROTARY SPOOL a 9 10. HYDRAULIC PUMP FILTER PRIMARY RELIEF VALVE 11. SECONDARY RELIEF VALVE 12. STEERING CONTROL UNIT 13. STEERING CYLINDER 14, HAND PUMP 15. STEERING VALVE 16. LINE PRESSURE TAP 17. PRESSURE SWITCH FOR ON-DEMAND q ‘STEERING (INSTALL AT CHECK PORT) # i 18. CHECK PORI oa 19. STEERING PUMP. 20. STEERING RELIEF VALVE 25. L* 4g, FO [ 7 a 21. HYDRAULIC TANK 22. BYPASS VALVE 23. ROTARY ACTUATOR VALVE 24, SHUTTLE 25. ROTARY ACTUATOR 26. TRAVERSE CYLINDER FIGURE 5. N30XMH HYDRAULICvalve opens when the rotary actuator moves to the end of its stroke, One relief valve is installed for each direction of rotary actuator travel. These relief valves also protect the rotary actuator from damage if the forks hit an ob- ject. An adjustable bypass valve for the rotary actuator is connected in parallel to the rotary actuator valve. The bypass valve permits some of the oil from the main con- trol valve to flow directly to the return line. The bypass valve decreases the speed of the rotary actuator. For the location of the pressure check fitting for steering pressure, see FIGURE 6., FIGURE 7. or FIGURE 8. Steering Pump (See FIGURE The steering pump, FIGURE 7. or FIGURE 8.) ‘a small gear pump connected toa . STEERING CYLINDER TO STEERING CONTROL UNIT |. PRESSURE CHECK FITTING . PUMP MOTOR ‘STEERING PUMP permanent-magnet DC motor. The steering pump and motor are in a horizontal mount under the battery ‘compartment on the E1.50-2.00XM (E25-40XM) trucks. The steering pump and motor are in a vertical mount under the floor plate on the E2,00-3.20XM (E45-65XM) and N30XMH trucks. The steering pump and motor are also in a vertical mount that is located be~ hhind the battery on the 12,00-3.20XM (J40-65XM) trucks. Capscrews hold the motor mount to the frame ‘mount bracket that has isolators. A relief valve and a pressure switch are mounted at ports in the pump hous- ing. The pressure switch at the bottom of the pump is used with On-Demand Steering only. PRESSURE SWITCH (ON-DEMAND STEERING ONLY) RETURN TO HYDRAULIC TANK FROM HYDRAULIC TANK MOUNT FOR STEERING MOTOR i 00 06G0<0 FIGURE NOTE: MOTOR CAN BE DIFFERENT THAN SHOWN. .. E1,50-2.00XM (E25-40XM) STEERING PUMP AND HYDRAULIC CIRCUIT|. STEERING CYLINDER TO STEERING CONTROL UNIT PRESSURE CHECK FITTING PUMP MOTOR 5. STEERING PUMP . PRESSURE SWITCH (ON-DEMAND STEERING ONLY) RETURN TO HYDRAULIC TANK 3. FROM HYDRAULIC TANK ). MOUNT FOR STEERING MOTOR ae ~* @_ NOTE: MOTOR CAN BE DIFFERENT THAN SHOWN. 9 : 8 FIGURE 7. E2.00-3.20XM (E45-65XM) AND N30XMH STEERING PUMP AND HYDRAULIC CIRCUITNOTE: MOTOR CAN BE DIFFERENT THAN SHOWN. . TO STEERING CONTROL UNIT . MOUNT FOR STEERING MOTOR FROM HYDRAULIC TANK PUMP MOTOR . STEERING PUMP. . PRESSURE SWITCH (ON-DEMAND STEERING ONLY) . STEERING CYLINDER |. RETURN TO HYDRAULIC TANK ). PRESSURE CHECK FITTING FIGURE 8. J2.00-3.20XM (J40-65XM) STEERING PUMP AND HYDRAULIC CIRCUITo6 4. TANK 1. BREATHER 5. MAIN PUMP SUPPLY RONT 2 FILUDIPSTICK 6. STEERING PUMP 3, BRACKET MOUNT _ SUPPLY BREATHER AND HOSE FIGURE 9. E1.50-2.00XM, (E25—40XM) ALIN BRNG Ke AEceMELY HYDRAULIC TANK ASSEMBLY eo eRACKeT PLUG . STEERING PUMP SUPPLY PORT HYDRAULIC PUMP SUPPLY PORT RETURN PORT PAD FIGURE 11. E2.00-3.20XM (E45-65XM) and N30XMH HYDRAULIC TANK ASSEMBLY. HYDRAULIC TANK FILTER MOUNT BRACKET ASSEMBLY . FILL CAP/BREATHERIDIPSTICK RETURN TO TANK RETURN FROM SYSTEM . SUPPLY PORT FIGURE 10. J2.00-3.20XM (J40-65XM) HYDRAULIC TANK ASSEMBLYREPAIRS See the INTRODUCTION for a list of sections of the SERVICE MANUAL for hydraulic parts other than the pumps and tank. A warning Before making any repairs, fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast. from lowering suddenly when hydraulic lines are disconnected. HYDRAULIC TANK NOTE: To repair leaks in the hydraulic tank, see one of the following SERVICE MANUAL sections: FRAME, 100 SRM 617 for the E1.50-2.00XM (E26-40XM) FRAME, 100 SRM 558 for the E2.00-3.20XM (E45-65XM) and N30XMBH trucks FRAME, 100 SRM 582 for the J2.00-3.20XM (140-65XM) E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal (See FIGURE 9. or FIGURE 11.) 1. Install a container urder the drain plug of the hydrau- lic tank with enough capacity. See the SPECIFI- CATIONS table at the back of this section, 2, Remove the drain plug and let the oil drain from the hydraulic tank. Install and tighten the drain plug. 3, Remove the floor plate for access to the hydraulic tank. 4, Remove and install plugs in all the hoses fastened to the hydraulic tank, Remove the fill cap and the short tube. Install a plug in the opening of the tank, 5. Remove the traction motor as described in one of the following SERVICE MANUAL sections: DRIVE AXLE, SPEED REDUCER AND DIFFER- ENTIAL, 1400 SRM 618 for the E1.50-2.00XM (E25-40XM) trucks DRIVE AXLE, SPEED REDUCER AND DIFFER- ENTIAL, 1400 SRM 285 for the E2,00-3.20XM (EAS-65XM) and N30XMH trucks 10 6. Remove the screws that fasten the bracket holding the hydraulic tank in the truck frame. Remove the bracket assembly. 7. Carefully remove the hydraulic tank from the frame. 8. Make repairs to the hydraulic tank. 1J2.00-3.20XM (J40-65XM) Tank Removal (See FIGURE 10.) 1. Turn the key to the OFF position and remove the key. A warNING Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury. 2. Open the hood and install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits. 3. Tum the steering wheel fora full left tum for access to the drain plug near the front of the right rear wheel. Install a container under the drain plug of the hydraulic tank with enough capacity. See the SPECIFICATIONS table at the back of this section. 4, Remove the drain plug and let the oil drain from the hhydraulic tank. Install and tighten the drain plug. ‘5, Remove and install plugs in all the hoses fastened to the hydraulic tank, Remove the breather/dipstick/fll cap and install a plug in the opening of the fill tube. 6. Remove the screws from the bracket that fastens the bracket holding the hydraulic tank in the truck frame. See item 3 of FIGURE 10. Remove the bracket assem- bly. 7. Carefully lift the hydraulic tank up out of the frame. 8, Make repairs to the hydraulic tank. Tank Inspection Make a visual inspection of all sides ofthe tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.‘The hydraulic tank is a separate sheet metal tank and can be removed from the lift truck if necessary to check for leaks or for replacement. Repairs for leaks in the hy- draulic tank can require special procedures described in the next paragraphs. The most common cause of leaks is from rust caused by the moisture of condensation. Drain any water out ofthe tank by removing the drain plug and letting the tank drain until there is no water in the oil. ‘Tank Repairs, Small Leaks Use the following procedure to seal small leaks: a. Use steam to clean the area around the leak. Re- ‘move all paint and dirt around the leak. A warning Do not use tools that can make sparks, heat or static "The vapors in the tank can cause an ex- b. Apply Loctite® 290 to the leak. Follow the in- structions of the manufacturer, Tank Repairs, Large Leaks 1. Use one of the procedures described under Tank Cleaning, Steam Method Of Cleaning Tank or Chemical Solution Method Of Cleaning Tank to clean and prepare the tank for repairs. 2. Use acceptable welding practices to repair the tank, See the American National Standard Safety In Welding And Cutting ANSI Z.49.1 ~ 1973. Tank Cleaning A warning Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation. See the following manuals for additional information: * Safe Practices For Welding And Cutting Con- tainers That Have Held Combustibles” by the American Welding Society, A6.0-65, Safety In Welding And Cutting”, American National Standard, ANSI Z 49.1 - 1973. ‘When cleaning the tank, do not use solutions that make dangerous. gases. at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns. Steam Method Of Cleaning Tank When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 inch). Control the pressure of, the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection be- tween the nozzle and the tank. Connect a ground wire to the tank to prevent static electricity. Use the following procedure to clean the tank with steam: a. Remove all the parts from the tank. Install the drain plug. b. Fill the tank 1/4 full with a solution of water and sodium bicarbonate (baking soda) or sodium car- Donate. Mix 0.5 kg (Ib) per 4 litres (I gal) of wa- ter, ‘c, Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed with the solution, Drain the tank. 4. Put steam into the tank until the tank does not hhave odors and the metal is hot. Steam vapors ‘must come from all the oenings. . Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank, £, Make an inspection of the inside of the tank. If it is not clean, repeat Steps dand ¢ and make anoth- er inspection. When making inspections, use a light that is approved for locations with flam- mable vapors. g. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable va- pors is above the lower flammable limit, repeat the cleaning procedures. Chemical Solution Method Of Cleaning Tank If the tank cannot be cleaned with steam, use the follow- ing procedure: a. Mix a solution of water and trisodium phosphate oa cleaning compound with an alkali base. Fol- ow the instructions given by the manufacturer. "b. Fill the tank with the cleaning solution, Use com- pressed air to mix the solution in the tank. . Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning ‘compound is removed 4d, Make an inspection of the inside ofthe tank. Ifthe tank is not clean, repeat Steps a through c. Make another inspection of the tank. When making in- spections, use a light that is approved for loca- tions with flammable vapors. e. Check the tank for flammable vapors as de- scribed in the previous section Step g. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning proce- dures. Additional Preparations For Tank Repair If nitrogen gas or carbon dioxide gas is available, pre- ppare the tank for welding using these gases. See the manual Safe Practices For Welding and Cutting Con- tainers That Have Held Combustibles by the American Welding Society, A6.0-65. If these gases are not avail- able, another method using water can be used as fol- lows: a. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent. b. Use acceptable welding practices to repair the tank. See the American National Standard “Safe- ty in Welding and Cutting,” ANSI Z. 49.1 ~ 1973. E1.50-3.20XM (E25~65XM) And N30XMH Tank Installation (See FIGURE 9. or FIGURE 11.) NOTE: Make sure to install the tank so that the fill neck. is centered in the opening in the step of the frame. Make sure to install all plugs, hoses and clamps to prevent leaks when oil is added to the tank. 1. Install the repaired or replacement hydraulic tank in the truck frame, Make sure the tank is correctly aligned for connection of the hoses. Make sure the pads are installed between the tank and truck frame. 2. Install the bracket assembly to hold the tank in posi- tion, Do not tighten the screws. 3. Remove the plugs and install all hoses at the same locations as during removal. Do NOT remove the drain 2 plug. Align the tank so thatthe fill tube and fill cap will be in the center of the access hole. Install the fll tube and fill cap. Tighten the screws that fasten the mount bracket assembly. Acaution Do NOT fill the tank above the FULL mark on the dipstick, If the tank is too full, oil will come out the breather during operation. 4, Make sure all hoses and plugs are installed and tight, Fill the tank using the oil specified in one ofthe follow- ing SERVICE MANUAL sections: PERIODIC MAINTENANCE, 8000 SRM 632 for the E1.50-2,00XM (E25-40XM) trucks PERIODIC MAINTENANCE, 8000 SRM 552 for the E2.00-3.20XM (E45-65XM) trucks PERIODIC MAINTENANCE, 8000 SRM 555 for the N30XMH trucks Loosen the clamp at the inlet hose of the hydraulic pump to let the air out until the hose fills with oil. Tighten the hose clamp as soon as oil leaks out of the hose. Do the same procedure for the steering pump. 5. Install the traction motor as described in one of the following SERVICE MANUAL sections: DRIVE AXLE, SPEED REDUCER AND DIFFER- ENTIAL, 1400 SRM 618 for the E1.50-2.00XM (E25-40XM) trucks DRIVE AXLE, SPEED REDUCER AND DIFFER- ENTIAL, 1400 SRM 285 for the E2.00-3.20XM (E45-65XM) and N30XMH trucks 6. Operate the lift and steering systems and check for leaks. +J2.00-3.20XM (J40-65XM) Tank Installation (See FIGURE 10.) 1. Turn the key to the OFF position and remove the key. A warning Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury. 2. Open the hood and install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits. 3. Carefully position the hydraulic tank over the correct, position inthe frame and instal the hoses on the bottomof the tank, Lower the tank into the correct position in the frame. 4, Install the other hoses and if removed, the filter on the tank, Install the bracket that fastens the hydraulic tank in the truck frame. See item 3 of FIGURE 10. 5. Fill the tank to the FULL mark on the dipstick and install the breather/dipstick/fill cap. 6. Operate the lift and steering systems and check for leaks. FILTER REPLACEMENT 1. Loosen the hose clamp near the control valve end of the filter (system dump), Carefully remove the hose and raise the filter to let the oil drain out of the filter into the hydraulic tank. 2. Loosen the other hose clamp and remove the filter from the hose. 3, Install a new filter in the hose to the hydraulic tank. Make sure the filter is installed for the correct direction of flow (control valve to tank). Align and tighten the hose clamp. 4, Install the hose on the other end of the filter. Align and tighten the hose clamp. 5, Operate the hydraulic system and check for leaks. HYDRAULIC PUMP: NOTE: Wom or damaged seals are the most common cause of pump repair. The pump bearings, gears and shafts also wear, Most service persons do not repair a worn pump because the cost of repairs can be greater than the cost of a new pump. The seals in the hydraulic pump can be replaced. Replace a worn or damaged hy- draulic pump. Removing E1.50-3.20XM (E25~65XM) and N3OXMH Hydraulic Pump (See FIGURE 12. and FIGURE 15.) 1. Remove the battery and the access panel in the bottom of the battery compartment. See one of the following SERVICE MANUAL sections: PERIODIC MAINTENANCE, 8000 SRM 632 for the E1.50-2,00XM (E25-40XM) trucks PERIODIC MAINTENANCE, 8000 SRM 552 for the E2.00-3.20XM (B4S-65XM) trucks PERIODIC MAINTENANCE, 8000 SRM $55 for the N30XMH trucks 2. Put a drain pan under the hydraulic pump and put a clamp on the inlet hose from the hydraulic tank, Remove the breather for the hydraulic tank and install a plug in the breather hose. Make sure the dipstick/fll cap is tight ‘This will help prevent oil flow when the hydraulic line is disconnected, Disconnect the inlet hose at the pump and quickly raise the end of the hose above the level of the oil in the hydraulic tank. Install a plug in the hose. If it is necessary to drain the hydraulic system, use a drain pan with enough capacity. See the SPECIFICATIONS table at the back of this section, FIGURE 12, REMOVE THE HYDRAULIC PUMP AND MOTOR 3, Remove the pressure hose from the pump. Put a cap on the open hydraulic hose. NOTE: In Step, remove the clamps from the pin in the pivot mount bracket to remove the pump and motor un- der the battery. Remove the clamps under the floor plate for the pump and motor to disconnect the pivot mount bracket at the motor. See FIGURE 15. The motor under the battery will tip down with force when the bracket is removed. Use a lifting device to keep the motor vertical Make sure the lifting device will securely hold the motor before disconnecting the mount at the bottom of the mo- tor. 4, Connect a sling and crane to the motor. See FIGURE 12. Make sure the crane and sling have a ca- pacity of approximately 50 kg (110 Ib) or more, Discon- Bnect the power cables and mark the cables for correct in- stallation, Disconnect the pivot mount bracket from the ‘motor. Use the crane to lift the hydraulic pump and mo- tor from the lift truck. '5, Make a note of the position ofthe inlet and outlet ports of the pump for correct alignment to the motor during assembly. Loosen the two set screws in the coupling. Remove the capscrews that fasten the pump to the motor and carefully remove the pump. Do not lose the two keys between the coupling and each shaft. Remove the coupling from the shaft. Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump (See FIGURE 13. and FIGURE 15.) 1. Tum the key to the OFF position and remove the key. A warning Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury. 2. Open the hood and install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits. 3. If the oil will not be drained from the hydraulic tank, remove the dipstick and install a plug in the fill tube. Disconnect the inlet hose at the pump and quickly raise the end of the hose above the level of the oil in the hy- raulic tank, Install a plug in the hose. 4. Ifit is necessary to drain the hydraulic system, turn the steering wheel for a full left tum for access to the drain plug near the front of the right rear wheel. Install a con- tainer under the drain plug of the hydraulic tank with enough capacity. See the SPECIFICATIONS table at the back of this section. 5, Remove the pressure hose from the pump. Put a cap oon the open hydraulic hose. 6. Connect a sling and crane to the motor. See FIGURE 13, Make sure the crane and sling have a ca- pacity of approximately 50 kg (110 Ib) or more. Discon- nect the power cables and mark the cables for correct in- stallation, Disconnect the pivot mount bracket from the motor. Use the crane to lift the hydraulic pump and mo- tor from the lift truck. 4 1J2,00-3.20XM (J40-65XM) 1. CRANE SLING. 2, MOTOR 3. MOTOR BRACKET 4, INLET HOSE 5. PUMP 6. PRESSURE HOSE 7. PIVOT MOUNT BRACKET NOTE: 19¢¢ pump shown. 112ce pump similar. FIGURE 13. REMOVE THE J2,00-3.20XM (J40-65XM) HYDRAULIC PUMP AND MOTOR 7. Make a note of the position of the inlet and outlet ports of the pump for correct alignment to the motor during, assembly. Loosen the two set screws in the coupling. Remove the capscrews that fasten the pump to the motor and carefully remove the pump. Do not lose the two keys between the coupling and each shaft. Remove the coupling from the shaft. Pump Seal Replacement And Pump ‘Assembly (See FIGURE 14.) NOTE: If the pump is held in a vise for disassembly, make sure the vise does not hold the pump too tightly and cause distortion of the pump body. The O-ring sur- face of the outlet port can also be damagedSNAP RING s OIL SEAL END HOUSING OUTER BUSHING SEAL INNER BUSHING SEAL BUSHINGS ‘SEAL PUMP BODY GEAR SET FIGURE 14. HYDRAULIC GEAR PUMP ASSEMBLY Make sure that you make careful notes of the location and orientation of the parts and seals during disassem- bly. Some of the parts are similar but are not exactly the same. It can be difficult to make an identification if the parts are mixed, 1. Remove the pump coupling from the shaft by loosen- ing the set screws. Do not lose the keys between the cou- pling and each shaft. 2. Remove the four capscrews that hold the pump to- gether. Carefully remove the end housings. Push the shaft through the oil seal in the end housing as the end housing is removed from the pump. Make a note of the seal arrangement, Do not disassemble the pump gear as- sembly. 3. Carefully remove the oil seals from the bushings. Re- move the snap ring and the shaft seal from the end hous- ing with the flange. 4, Inspec: the pump gear assembly and the pump body for wear and damage. Replace a damaged or worn hy- draulic pump. NOTE: Some pump bodies will show gear marks where the gears rotate because of the small clearances between the parts, These gear marks do not indicate a wom or damaged pump unless the pump will not supply the vol- ‘ume and pressure shown in the specifications. 5, Make sure the internal parts of the pump are clean, Lubricate the parts with hydraulic oil as they are in- stalled in the pump. Install new seals in the bushings. 6. Install the gears and bushing assembly in the pump body. Make sure each bushing is aligned correctly. 7. Install the seals and the end of the pump with the flat face, See FIGURE 14, 8, Install ihe seals in the end of the pump with the flange. Install the end of the pump. Is9, Make sure that all of the parts are in the correct posi- tion and install the four capscrews. Tighten the caps- crews. 10, Install a new oil seal on the input shaft. Install the snap ring. ‘Assemble Pump On The Motor (See FIGURE 15.) NOTE: Inspect the coupling. Ifthe cushion material has pieces missing or has distortion, replace the cushion ring. 1. Ifthe coupling half was removed from the pump or the ‘motor, install the coupling and key on the pump shaft. Install the key and coupling on the motor shaft as the pump is aligned to the motor. 2. Make sure thatthe halves of the coupling are correctly engaged. Make sure the Allen screws that fasten the coupling to the shafts are tight. Make sure the pump is aligned to the motor as marked during disassembly. Install the capscrews that fasten the pump to the motor. ‘See FIGURE 15. ASSEMBLY SHOWN IS FOR THE E1.50-3.20XM (E25-65XM) AND N3OXMH, AND IS SIMILAR TO THE J2.00-3.20XM (J40-65XM). PUMP FLEXIBLE COUPLING |. PIVOT MOUNT BRACKET [E2.00-3.20XM (E45-65XM)] PIVOT MOUNT BRACKET [E1.50-2.00XM (E25-40XM)] . RUBBER BUSHING (2) . WASHER (2) PIVOT PIN CLAMP ASSEMBLY MOTOR . £2,00-3,20XM (E45-65XM) NOTE: MOUNT BRACKET (3) INSTALLED FACING OTHER DIRECTION ON ‘J2.00-3.20XM (J40-65XM) UNITS. NOTE: PUMP AND MOTOR CAN BE DIFFERENT THAN SHOWN, FIGURE 15. HYDRAULIC PUMP AND MOTOR ASSEMBLY WITH MOUNT 16Install The Hydraulic Pump And Motor ‘Assembly [E1.50-3.20XM (E25~65XM) and N3OXMH ] 1. Connect the pivot mount bracket to the motor as shown in FIGURE 15, Connect a sting and crane to the motor. See FIGURE 12. Make sure the crane and sling have a capacity of approximately 50 kg (110 1b) or more. Use the crane to lift the hydraulic pump and motor into the correct position in the lift truck. Connect the power ‘cables as marked during removal. NOTE: Tighten the connections for power cables at MS X 1.25 or 5/16 UNC terminals on General Electric mo- tors to 18 to 22 Nm (13 to 16 by ft), Tighten all other con- nections for power cables as follows: 5/1 UNC threads ~ 13.5 to 17.5 Nm (10,0 to 12.9 Iby ft) 1/4 UNC threads — 4.0 to 6.0 Nm (3.0 to 4.4 Ibs ft) #6 UNC threads ~ 0.73 to 1.02 Nm (0.5 to 0.8 Ibe ft) MB X 1.25 threads ~ 13.5 to 17.5 Nm (10.0 to 12.9 Iby ft) MIO X 15 threads ~ 15.0 to 18.0 Nm (L1.1 to 13.3 Iby ft) NOTE: Ifthe rubber bushings of the pivot mount bract et were removed, use soap or rubber lubricant to install the bushings. Do NOT use oil. The oil will soften the bushings and they will need replacement. 2. Install the clamps on the frame to mount the pump and motor. Align the pivot mount bracket of the motor. See FIGURE 15. Install the clamps over the pin in the pivot mount bracket, Make sure to install the washers and wire (ground connection) between the mount and clamp brackets. 3. Remove the cap on the pressure hose, Install the pres~ sure hose on the outlet of the pump. Remove the plug in the inlet hose and quickly connect the inlet hose at the pump. Leave the fittings loose. 4. Ifthe oil was drained from the hydraulic system, make sure the drain plug is installed in the tank. If drained, fill the hydraulic tank with the type and quantity of hydrau- lic oil shown in one of the following SERVICE MANUAL sections: PERIODIC MAINTENANCE, 8000 SRM 632 for the E1.50-2.00XM (E25-40XM) trucks PERIODIC MAINTENANCE, 8000 SRM 552 for the E2.00-3.20XM (E45-65XM) trucks PERIODIC MAINTENANCE, 8000 SRM 555 for the N30XMH trucks Fill the tank to the FULL mark on the dipstick. If the tank was not drained, remove the plug from the breather hose and install the breather. Let some of the oil leak from around the inlet fitting on the pump, then tighten the capscrews on the flanges of the fittings. The smaller pump has O-ring fittings. Tighten the outlet hose fitting. Use this procedure to make sure the pump has oil for first operation, 5. Install the access panel in the bottom of the battery ‘compartment and install the battery. See one of the fol- lowing SERVICE MANUAL sections for the correct procedure.: PERIODIC MAINTENANCE, 8000 SRM 632 for the E1.50-2.00XM (E25-40XM) trucks PERIODIC MAINTENANCE, 8000 SRM 552 for the E2.00-3.20XM (E45-65XM) trucks PERIODIC MAINTENANCE, 8000 SRM 555 for the N30XMH trucks Operate the lift system and check for leaks. Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly 1. Tum the key to the OFF position and remove the key. A warning ‘Never put tools or other metal on the battery, Metal on the battery can cause a short circuit and possible damage or injury. 2. Open the hood and install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits. 3. Connect the pivot mount bracket to the motor. Make sure the bracket is installed so thatthe tube of the bracket is on the pump side NOT the motor side as shown in FIGURE 15. Connect a sling and crane to the motor. See FIGURE 13. Make sure the crane and sling have a ca- pacity of approximately 50 kg (110 Ib) or more. Use the ‘crane to lift the hydraulic pump and motor into the cor- rect position in the motor compartment. Connect the power cables as marked during removal. NOTE: Tighten the connections for power cables at MB8X1.25 or 5/16 UNC terminals on General Electric motors fo 18 (0 22 Nm (13 to 16 Iby ft). Tighten all other connections for power cables as follow: 7She UNC threads ~ 13.5 to 17.5 Nm (10.0 to 12.9 Ibs ft) Vig UNC threads ~ 4.0 to 6.0 Nm (3.0 to 4.4 Iby ft) #6 UNC threads — 0.73 to 1.02 Nm (0.5 to 0.8 lbs ft) MB X 1.25 threads ~ 13.5 to 17.5 Nm (10.0 to 12.9 tbe ft) MIO X 1.5 threads ~ 15.0 to 18.0 Nm (1.1 t0 13.3 Iby f) NOTE: Ifthe rubber bushings ofthe pivot mount brack- et were removed, use soap or rubber lubricant to install the bushings. Do NOT use oil. The oil will soften the bushings and they will need replacement. 4, Keep the motor vertical, Install the clamps on the rear bulkhead of the battery compartment to mount the pump and motor. Align the pivot mount bracket of the motor. ‘See FIGURE 15. Install the clamps over the pin in the pivot mount bracket. Make sure to install the washers and wire (ground connection) between the mount and clamp brackets. 5, Remove the cap on the pressure hose, Install the pres- sure hose on the outlet of the pump. Remove the plug in the inlet hose and quickly connect the inlet hose at the pump. Leave the fittings locse. 6. If the oil was drained from the hydraulic system, make sure the drain plug is installed in the tank. If necessary, tum the steering wheel for a full left tur for access to the drain plug near the front of the right rear wheel. If drained, fill the hydraulic tank with the type and quan- tity of hydraulic oil shown in the SERVICE MANUAL section PERIODIC MAINTENANCE, 8000 SRM ‘552, Fill the tank to the FULL mark on the dipstick. If the tank was not drained, remove the plug from the fill tube. Let some of the oil leak from around the inlet fit- ting on the pump, then tighten the capscrews on the flanges of the fittings. The smaller pump has O-ring fit- tings. Tighten the outlet hose fitting. Use this procedure to make sure the pump has cil for first operation, 7. Install the top bracket to fasten the motor to the bulk- head. Operate the lift system and check for leaks. MAIN CONTROL VALVE NOTE: The operation, removal and repair of the control valve is described in the SERVICE MANUAL section MAIN CONTROL VALYE, 2000 SRM 562. ‘STEERING PUMP NOTE: A worn or damaged steering pump is normally replaced instead of repaired. The cost of repair can often 18 ‘be more than the cost of a new pump. The following pro- cedure does not include repair. Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N3OXMH (See FIGURE 16. or FIGURE 17. ) 1. Disconnect the battery connector. Remove the floor plate. Remove the battery as described in one of the fol- lowing SERVICE MANUAL sections for the correct procedure.: PERIODIC MAINTENANCE, 8000 SRM 632 for the E1.50-2.00XM (E25-40XM) trucks PERIODIC MAINTENANCE, 8000 SRM $52 for the E2,00-3.20XM (E45-65XM) trucks PERIODIC MAINTENANCE, 8000 SRM 535 for the N30XMH trucks Remove the breather for the hydraulic tank and install a plug in the breather hose. Make sure the dipstick/fill cap is tight, This will help prevent oil flow when the hydrau- lic line is disconnected, 2. Put a drain pan under the steering pump and remove the hose at the pump that comes from the hydraulic tank, il will tlow from the hose, so quickly installa plug in the hose fitting, 3. Disconnect the other hose for the steering pump. Install a plug at the fitting for the hose. If installed, dis- connect the electrical plug at the pressure switch on the bottom of the motor. 4, Install tags for correct connection during installation and disconnect the electrical cables at the pump motor terminals. 5, Install a sling around the steering pump and motor as- sembly. Connect a crane to the sling and raise the crane so that it is a support for the assembly. Make sure the crane and sling have a capacity of 18.5 kg (41 Ibs) or more. 6. Make a note of the positions ofthe rubber bushings at the mount brackets and remove the capscrews that fas- ten the brackets, See FIGURE 17. 7. Carefully lift the steering pump and motor assembly up out of the frame. Do not damage the pressure switch ‘on the bottom of the pump.MOTOR . HYDRAULIC PUMP ~ STEERING WASHER (4) RUBBER BUSHINGS (4) CAPSCREW AND NUT (2) 6. MOUNT BRACKET 7. FRAME BRACKET 8 MOUNT PIN 9. MOTOR BASE FIGURE 16, E1.50-2.00XM (E25-40XM) STEERING PUMP AND MOTOR NOTE: Do not remove the mount brackets from the mo- tor base unless the motor will be replaced. These brack- ‘ets must be correctly aligned on the motor base. 8. Make a note of the position of the inlet and outlet ports of the pump for correct alignment to the motor during assembly. Remove the two capscrews that fasten the pump to the motor and carefully remove the pump. Re- move the O-ring at the pump shaft. Pump Removal And Disassembly, +J2.00-3.20XM (J40-65XM) (See FIGURE 17.) 1. Tum the key to the OFF position and remove the key. A warning Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury. 2. Open the hood and install a cardboard or plywood Cover on the top of the battery to prevent accidental short cireuits. 3. Put a drain pan under the steering pump. Remove the dipstick and installa plug in the fill tube. Remove the hose at the pump that comes from the hydraulic tank. Oil will flow from the hose, so quickly install a plug in the hose fitting. 4, Disconnect the other hose for the steering pump. Install a plug at the fitting for the hose. If installed, dis- connect the electrical plug at the pressure switch on the bottom of the motor. 5, Install tags for correct connection during installation and disconnect the electrical cables at the pump motor terminals. 6. Install a sling around the steering pump and motor as- sembly. Connect a crane to the sling and raise the crane so that it is a support for the assembly. Make sure the cerane and sling have a capacity of 18.5 kg (4I Ibs) oF more. 7. Make a note of the positions of the rubber bushings at the mount brackets and remove the capscrews that fas- ten the brackets. See FIGURE 17. 8, Carefully lift the steering pump and motor assembly up out of the frame. Do not damage the pressure switch oon the bottom of the pump. 19NOTE: Do not remove the mount brackets from the mo- tor base unless the motor will be replaced. These brack- ets must be correctly aligned on the motor base. 9. Make a note ofthe position of the inlet and outlet ports of the pump for correct alignment to the motor during assembly. Remove the two capscrews that fasten the pump to the motor and carefully remove the pump. Re- move the O-ring at the pump shaft. Pump Assembly And Installation (See FIGURE 16. or FIGURE 17.) 1. Install a new O-ring at the shaft of the replacement pump. Install the replacement pump on the motor using the two capscrews. Make sure the pump is correctly aligned with the motor as noted during disassembly. 2. If removed, install the pressure switch in the pump end frame. 3. If the mount brackets were removed from the motor base, the brackets must be correctly aligned before installation of the assembly. Align the brackets as fol- lows: a, Install the mount brackets on the motor base, See FIGURE 17. Leave the capscrews and nuts loose so that the brackets can move. b. Align the two brackets so that the center lines of the capscrew holes are 160 mm (61% in) apart as shown in FIGURE 17. Keep the brackets cen- tered in the slots of the motor base as much as possible ©. Carefully tighten the capscrews at the motor base without changing the alignment. 4, Install a sling around the steering pump and motor as- sembly. Use a crane to lift and align the assembly on the ‘mounts in the lift truck frame, 5. Install the mount capscrews, washers and rubber bushings as noted during disassembly. See FIGURE 17. Install the clip nut at the top left mount of the frame, Tighten the capscrews without compressing the rubber bushings. 6. Connect the hydraulic line to the outlet port of the pump. Install a drain pan under the pump and quickly install the hose from the hydraulic tank to the inlet port. 20 4 160 mm (6°%qq in) " |. MOTOR CAPSCREW (2) |. BATTERY BULKHEAD |. MOTOR BASE NUT RUBBER BUSHINGS (4) WASHER (4) . CLIP NUT ). MOUNT BRACKET (2) HYDRAULIC PUMP ~ STEERING . PRESSURE SWITCH FOR ON-DEMAND STEERING FIGURE 17. E2.00-3.20XM (B45-65XM), N30XMH AND J2.00-3.20XM (J40-65XM) ‘STEERING PUMP AND MOTOR 7. Install the electrical plug on the terminals of the pres- sure switch, Install the electrical cables on the motor ter~ minals as noted during removal.NOTE: Tighten the connections for power cables at MS X 1.25 or 5/16 UNC terminals on General Electric mo- tors to 18 t0 22 Nm (13 t0 16 Iby ft). Tighten all other con- nections for power cables as follows: 5/4 UNC threads ~ 13,5 to 17.5 Nm (10.0 to 12.9 Ib ft) Wg UNC threads ~ 4,0 t0 6.0 Nm (3.0 to 4.4 by ft) #6 UNC threads ~ 0.73 to 1.02. Nm (0.5 to 0.8 Ibe ft) MB8 X 1,25 threads ~ 13.5 to 17.5 Nm (10.0 to 12.9 Iby ft) MIOX 1,5 threads ~ 15.0 to 18.0 Nm (11.1 to 13.3 Iby f) 8. Remove the plug from the breather hose and install the breather. Install the battery as described in one of the following SERVICE MANUAL sections for the cor- rect procedure, PERIODIC MAINTENANCE, 8000 SRM 632 for the E1.50-2.00XM (E25-40XM) trucks PERIODIC MAINTENANCE, 8000 SRM 552 for the E2.00-3.20XM (E45-65XM) trucks PERIODIC MAINTENANCE, 8000 SRM 555 for the N30XMH trucks Install the floor plate. Operate the steering system and check for leaks. Tes) ESS 1. CHECK VALVES 2, SHUTTLE FIGURE 18, ROTARY ACTUATOR VALVE 3. RELIEF VALVES. 4. VALVE BODY ROTARY ACTUATOR VALVE (See FIGURE 18.) The rotating actuator valve and the bypass valve are found on the attachment for the N30XMH. ‘The instruc- tions for the removal and installation and the adjustment procedures for these valves are in the ATTACHMENTS section, 5000 SRM 580. Disassembly, Cleaning and Inspection 1. Tur the cap with a wrench to remove the check valve assembly from the valve body. Push the shuttle out of the valve body. 2. Inspect the seat and poppet for dirt or scratches. ‘The poppet must slide freely in the seat sleeve. The spring. must not be bent or broken. 3. Inspect the shuttle and bore for dirt or scratches. The shuttle must slide freely in the bore. 4, Remove the two relief valves from the valve body by turing the bushings with a wrench. Acaution ‘The adjustment of the relief valves is set at the facto- ry. DO NOT loosen the cap or jam nut from the bush- ings. DO NOT turn the adjuster screw. 5, Inspect the poppet, ball, and seat for dirt or scratches. Make sure the spring is not bent or broken. 6. Clean all parts of the rotating actuator valve with sol- vent. Use compressed air to dry the parts and to remove dirt from the passages. Assembly 1. Lubricate the relief valve parts with hydraulic oil. Install new O-rings on the bushing, 2, Install the relief valves into the valve body. Use a ‘wrench to tighten the bushing. 3, Lubricate and install new O-rings and install one check valve into the valve body. Lubricate the shuttle and slide it into the bore for the check valves. Lubricate and install the other check valve. 4, Install new O-rings on the fittings that were removed. Lubricate and install the fittings. STEERING CONTROL UNIT NOTE: See the SERVICE MANUAL section STEERING HOUSING AND CONTROL UNIT, 1600 SRM 512 to repair the steering control unit. Fol- owing is the correct procedure to remove and install the steering control unit NOTE: The repair procedures for the instrument cluster are in the SERVICE MANUAL section ELEC- ‘TRICAL SYSTEM, 2200 SRM 560. aControl Unit Removal (See FIGURE 19.) 1. Disconnect the battery connector. Move the steering, column to the forward position, Remove the panel under the steering column for access to the hoses of the steer- ing control unit. 2, Remove the front and rear covers forthe steering col- ‘umn, The instrument cluster is fastened to the front cov- er. Install tags and disconnect the wires for the hom con- nector and if installed, on-demand power steering and the forward/reverse switches. If installed, remove the parts for on-demand power steering and the forward/re- verse switches and lever, See the SERVICE MANUAL sections STEERING SYSTEM, 1600 SRM 485 and STEERING HOUSING AND CONTROL UNIT, 1600 SRM 512. 3. Put tags for identification on the hydraulic hoses at the steering control unit so that they can be connected cor- rectly during assembly. Disconnect the hydraulic hoses at the bottom of the steering control unit. Install plugs at all hose fittings and control unit ports to prevent dirt from entering the steering hydraulic system. 4. Hold the steering column and remove the capserews that hold the steering column and pivot shaft to the bracket. See FIGURE 19. Remove the two plates, pivot shaft and spring. Remove the steering column assembly. Do not lose the rod, washer and spring for the latch, 5, Make a note of the alignment of the steering control unit in the bracket for correct installation. Remove the four capscrews that fasten the steering shaft assembly and steering control unit in te steering column bracket. Do not let the steering contrcl unit or steering wheel and shaft assembly fall. Do not let the washers fall, tis not necessary to remove the stezring wheel or on-demand steering parts from the shaft. Control Unit Installation (See FIGURE 19.) 1. Install the steering contrel unit in the bracket. Make sure itis in correct alignmert, as noted during removal, so that the hoses can be correctly connected. Install the ‘washers, spacers, steering shaft assembly and caps- crews to hold all parts in the bracket. 2. Hold the bracket assembly in alignment and install the pivot shaft, spring, plates, washers and capscrews to 2 hold the assembly on the mount. Install the spring, washer and rod for the latch, Install the knob on the latch. Install the allen serew and nut. A warninc ‘The hydraulic hoses MUST be connected to the cor- rect ports or the steering system will not operate as expected. This operation that is not expected can ‘cause damage or personal injury. Make sure the hoses are identified and connected correctly. 3. Connect the hydraulic hoses at the steering control unit as marked during removal OR see the SERVICE MANUAL section STEERING HOUSING AND CONTROL UNIT, 1600 SRM 512 for correct connec- tions. 4, If removed, install the parts for on-demand power steering and the forward/reverse switches and lever. See the SERVICE MANUAL sections STEERING SYS ‘TEM, 1600 SRM 485 and STEERING HOUSING AND CONTROL UNIT, 1600 SRM 512. 5. Connect the wires for the hom connector and if installed, the on-demand power steering and forward) reverse switches. Install the front and rear covers for the steering column, A warning After making repairs, do not extend hands or arms through the center of the steering wheel. Wrong as- sembly or connections can make the steering wheel rotate with a strong force when the steering pump. operates. This strong force can cause serious injury. If this action occurs, disassemble the control unit and correct the problem, 6. Operate the steering system and check for leaks and correct operation, STEERING CYLINDER NOTE: The correct procedure for the removal and re- pair of the steering cylinder is in the following sections of the SERVICE MANUAL: STEERING AXLE, 1600 SRM 619 for the E1.50-2.00XM (E25-40XM) trucks STEERING AXLE, 1600 SRM 258 for the other trucks. STEERING WHEEL, SHAFT & ‘ON-DEMAND STEERING PARTS FRONT COVER BRACKET WASHERS. ‘STEERING CONTROL UNIT 5. SPRING ”. WASHER, . ROD |. COTTER PIN . PIN LaTCH KNOB SCREW REAR COVER MOUNT ALLEN HEAD CAPSCREW CAPSCREW (4) . PLATE (2) |. PIVOT SHAFT FIGURE 19, STEERING COLUMN ASSEMBLYCHECKS AND ADJUSTMENTS MAIN CONTROL VALVE NOTE: The adjustments of the relief valves of the main control valve is in the SERVICE MANUAL section MAIN CONTROL VALVE, 2000 SRM 562. The ad- jjustment procedure for the switches of the linkage is also in that section. STEERING RELIEF VALVE (See FIGURE 7. or FIGURE 8.) 1. Connect a pressure gauge to the pressure check fitting in the pump hydraulic line for the steering system under the floorplate. For the E1.50-2.00XM (E25-40XM) units, see FIGURE6. For the E2.00-3.20XM (E43-65XM) and N30XMH units, see FIGURE 7. For the J2,00-3.20XM (J40-65XM) units, see FIGURE 8. ‘The pressure gauge can also be installed at the port on the bottom of the pump. See FIGURE 20. 2. Operate the hydraulic system to warm the oil until the oil temperature is 54-66? C (130-150° F). Tum the steering wheel to the stop and hold it in that position. Acaution Do not hold the steering against the stop for more than 3-5 seconds or the power steering fuse will open. Also, the ofl in the pump will quickly become hot and cause damage to the pump. 3. Check the pressure on the gauge against the correct pressure in the SPECIFICATIONS table at the back of this section, 4, Ifthe pressure on the gauge is not correct, remove the ‘cap on the relief valve at the steering pump. Adjust the relief valve to the correct pressure. Tum the adjustment clockwise to increase the pressure, or counterclockwise to decrease the pressure. Ifthe pressure will not increase to the specification, replace the wom or damaged pump or relief valve. If the pump output is correct and the steering still does not operate correctly, check for inter- nal leakage in the steering control unit or the steering cylinder. 5. When the adjustments are complete, install the cap on the relief valve, Remove the pressure gauge and install the cap on the pressure check fitting. O 1. RELIEF VALVE 2. PRESSURE SWITCH INSTALLS AT THIS PORT FIGURE 20. STEERING PUMP. TROUBLESHOOTING CHART TROUBLE PROBABLE CAUSE CHECKOUT PROCEDURE! REMEDIAL ACTION STEERING The steering wheels do not move when the steering wheel is turned. damaged. The oil level is low or there is ‘no oil in the tank. The steering control unit is Fill tank. Check for leaks. Repair or install new control unit. No oil flow from the steering control unit to the steering cyl- inder. Repair or install new compo- nents. Check for leaks.TROUBLESHOOTING CHART TROUBLE PROBABLE CAUSE CHECKOUT PROCEDURE! REMEDIAL ACTION ‘Slow or difficult steering. Relief valve for the steering system needs adjustment. Low oil pressure from the steer- ing pump. Seal in the steering cylinder has a leak. Steering control unit is worn or has damage. ‘Adjust or install new relief valve. ‘Check for restrictions. See Troubleshooting Chart "Hy- draulic System’. Install new seal. Repair or install new control unit. ‘Steering wheel turns the tires in the wrong direction. Steering function continues af- ter the steering wheel stops. There is air in the steering sys- tom. The hydraulic fines are not con- nected correctly at the steering cylinder or at the steering con- trol unit. The steering control unit was assembled wrong or has dam- age. The oil level in the tank is low. Air was not removed after re- pair to the hydraulic or steering system. The steering pump has an air leak at the inlet ‘Connect lines properly. Re- ‘move air from the system, Repair or install new control unit. ‘Add hydraulic oil as necessary. Check for leaks. Remove air from the system. Repair system. Remove air from the system. STEERING HOUSING AND STEERING CONTROL UNIT The wheels do not move when’ the steering wheel is turned. The oll level is low or there is no oil in the tank. The steering control unit is damaged. No oil flow from the steering control unit to the steering oyl- inder. The sleeve and spool in the control unit will not move. Hydraulic hoses not connected or have damage. Fill tank to the correct level. Check for leaks. Repair or install new control unit. Repair or install new compo- nents. Check for leaks. Install new components. Check for leaks. Tighten con- nections. Install new compo- nents as necessary. Slow or difficult steering. Relief valve for the steering system is not adjusted correct- ly. ‘Adjust or install new relief valve.TROUBLESHOOTING CHART TROUBLE PROBABLE CAUSE (CHECKOUT PROCEDURE/ REMEDIAL ACTION STEERING HOUSING AND STEERING CONTROL UNIT (Con’t) ‘Slow or dificult steering. (Cont.) Low oil pressure from the steer- ing pump. Seal in the steering cylinder has a leak. Hydraulic lines are too small or have restrictions. Steering control unit is worn, ot assembled correctly or has damage. ‘Check for restrictions. See Troubleshooting Chart, "Hy- draulic System”. Repair cylinder. Install new seal ‘or new cylinder. Remove restrictions. Install larger or new hydraulic lines. Repair or install new control unit. ‘Steering wheel tums the tires in the wrong direction. Steering function continues af- ter the steering wheel stops. The hydraulic lines are not con- nected correctly at the steering cylinder or at the steering con- trol unit. The steering control unit is as- sembled wrong or has dam- age. ‘Connect lines correctly. Re- move air from the system. Repair or install new control unit. The steering operation is not smooth The oil level in the tank is low. Air was not removed after re- pair to the hydraulic system. The steering control unit is as- sembled wrong or has dam- age. ‘The steering pump has a leak at the inlet. HYDRAULIC SYSTEM Fill tank. Check for leaks. Remove air from the system. Repair or install new control unit Fix leaks. Remove air from the system. The pump makes more noise than normal. The oil level is not correct or there is no oil in the tank (ca- Vitation).. Wrong type or grade of hydrau- lic oll for the temperature or operation.(cavitation).. The suction screen has a re- striction (cavitation) The inlet fiting is loose or hoses are allowing air to enter the system (aeration). The pump bearings or gears have damage. ‘Check oil level and fill as re- ‘quired. Check for leaks. Check. drain tank, and with the correct specified oil Clean or install new screen. Tighten fitting. Install new hoses. Remove air from the system. Repair or install new pump. 6TROUBLE The pump makes more noise than normal. (Cont.) The output of the pump is less than specifications. The pump has leaks. The pressure for the steering system is below specifications. The flow for the steering sys- tem is below specifications. TROUBLESHOOTING CHART PROBABLE CAUSE HYDRAULIC SYSTEM (Con't) The capscrews that hold the pump together are loose. The pump is loose at the motor mounting. The pump drive mechanism is loose, worn or has damage. ‘See, "Probable Cause” for, The ‘pump makes more noise than normal. The fittings or hoses on the out- let side of the pump are loose or damaged. The capscrews that hold the pump together are loose. The seals in the pump are dam- aged. The relief valve at the pump is not adjusted correctly. The relief valve has damage. The pump is worn. The pump has damage, or has a restriction. The relief valve is not adjusted correctly. CHECKOUT PROCEDURE/ REMEDIAL ACTION Tighten capscrews to specified torque. Tighten fasteners to the speci- fied torque. Check, repair or install new parts as required. See the section CAPACITIES ‘AND SPECIFICATIONS, 8000 ‘SRM 561 for the correct lifting speeds of your lift truck model and mast. If the relief pressure is correct and the lift speeds are too slow, the pump is worn or has damage or there is a problem in other parts of the lift system. If the pump is worn it will usually make more noise than normal. Tighten fittings. Install new parts as necessary. Tighten capscrews to specified torque. Install new seals or anew pump. ‘Adjust or install new relief valve. Repair or install new relief valve. Repair or install new pump. ‘Check that inlet hose is not soft or has a restriction or air leak. Check, and if necessary, re- place pump. Adjust or install new relief valve. NOTE: Troubleshooting for the main control valve is in the section THE MAIN CONTROL VALVE, 2000 SRM 562. 2”SPECIFICATIONS RELIEF VALVE PRESSURES" E1.50-2.00XM (E25~40XM) Hydraulic System 17.9 + 0.3 MPa (2600 + 45 psi) Steering System 5400 + 345KPa (783 + S0psi) Tilt And Auxiliary Systems 15.75 + 0.3 MPa (2250 + 45 psi) RELIEF VALVE PRESSURES" E2.00-3.20XM (E45-65XM) E2.00-3.20XM (E45-65XM), N3OXMH and J2.00-3.20XM (J40-65XM) Hydraulic System Steering System Tilt And Auxiliary Systems HYDRAULIC TANK CAPACITY (dipstick full mark) E1.50-2.00XM (E25-40XM) 11.3 litres (3.0 gal) 2.00-3.20XM (E45-65XM),.N3OXMH and J2.00-3.20XM 21.2 litre (5.6 gallons) (J40-65XM) HYDRAULIC PUMP CAPACITIES Large Hydraulic Pump ‘Small Hydraulic Pump Steering Pump 21.4 + 0.5 MPa (3100 + 75 psi) 8620 KPa (1250 psi) 15.5 + 0.5 MPa (2250 + 75 psi) 19 ce/revolution (1.16 in®/revolution) 12 ccirevolution (0.73 in°/revolution) 4.23 co/revolution (0.26 in®/revolution) * Oil temperature at 55 to 65°C (130 to 150°F)NOTESNOTESNOTESSa es Hyster Easy Language Program HYSTER tecunicat pustications 1900 SRM 559 5/96 (2'96)(5/95)(11/94) Litho in U.S.A.