HYDRAULIC SYSTEM

E1.50-3.20XM (E25-65XM, E25-65XM 2)

[D114, F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416/B416];
N30XMH, N30XMH 2 [C210]; V30ZMD [D210/E210];
E1.50-2.00XM (E25-35Z, 40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

PART NO. 897639 1900 SRM 559

 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.
Hydraulic System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Hydraulic System .......................................................................................................................................... 2
Operation............................................................................................................................................................ 12
Hydraulic System .......................................................................................................................................... 12
Hydraulic Gear Pump ................................................................................................................................... 23
Rotator Actuator Valve .................................................................................................................................. 23
Steering Pump ............................................................................................................................................... 23
Hydraulic Tank Repair ...................................................................................................................................... 34
Tank, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108); E1.50-2.00XM (E25-35Z,
40ZS) (E114/F114); E2.00-3.20XM (E45-65Z) (G108); N30XMH and N30XMH 2 (C210); V30ZMD
(D210/E210)] .................................................................................................................................................. 34
Tank, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM (J40-60Z)
(A416)] ............................................................................................................................................................ 35
Tank, Remove [J2.00-3.20XM (J40-60Z) (B416)] ......................................................................................... 36
Hyraulic Tank [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)] ........................................... 36
Inspect ............................................................................................................................................................ 38
Small Leaks, Repair ...................................................................................................................................... 38
Large Leaks, Repair ...................................................................................................................................... 38
Clean .............................................................................................................................................................. 38
Steam Method............................................................................................................................................ 38
Chemical Solution Method........................................................................................................................ 39
Additional Methods for Tank Repair ............................................................................................................ 39
Tank, Install [E1.50-3.20XM (E25-65XM, E25-65XM 2), (D114, F108); E1.50-2.00XM (E25-35Z,
40ZS) (E114/F114); E2.00-3.20XM (E45-65Z) (G108); N30XMH and N30XMH 2 (C210); and
V30ZMD (D210/E210)] .................................................................................................................................. 39
Tank, Install [J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM (J40-65Z)
(A416)] ............................................................................................................................................................ 40
Tank, Install [J2.00-3.20XM (J40-65Z) (B416)] ........................................................................................... 40
Filter Replacement ............................................................................................................................................ 41
All Lift Trucks Except [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098);
J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM (E45-65Z) (G108)]..................................................... 41
Remove....................................................................................................................................................... 41
Install ......................................................................................................................................................... 42
Lift Truck Models [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)] ..................................... 42
Remove....................................................................................................................................................... 42
Install ......................................................................................................................................................... 42
Lift truck Models [E2.00-3.20XM (E45-65Z) (G108) and E1.50-2.00XM (E25-35Z, E40ZS)
(E114/F114)] ................................................................................................................................................... 43
Remove....................................................................................................................................................... 43
Install ......................................................................................................................................................... 43
Lift Truck Models [J2.00-3.20XM (J40-65Z) (B416)] ................................................................................... 45
Remove....................................................................................................................................................... 45
Install ......................................................................................................................................................... 45
Hydraulic Pump Repair..................................................................................................................................... 48
Hydraulic Pump, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108); N30XMH,
and N30XMH 2 (C210); E1.50-1.75XM, E2.00XMS (E25-35Z, 40ZS) (E114/F114); E2.00-3.20XM
(E45-65Z) (G108); V30ZMD (D210/E210); and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098)] .................................................................................................................................................. 48

©2009 HYSTER COMPANY i

Table of Contents Hydraulic System

TABLE OF CONTENTS (Continued)

Hydraulic Pump, Disassemble E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108); N30XMH,
and N30XMH 2 (C210); E1.50-1.75XM, E2.00XMS (E25-35Z, 40ZS) (E114/F114); E2.00-3.20XM
(E45-65Z) (G108); and V30ZMD (D210/E210).............................................................................................. 49
Inspect ............................................................................................................................................................ 50
Clean .............................................................................................................................................................. 50
Pump Seal Replace and Pump Assemble ..................................................................................................... 50
Assemble Pump on Motor ............................................................................................................................. 50
Hydraulic Pump and Motor, Install [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108);
N30XMH, and N30XMH 2 (C210); E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114); E2.00-3.20XM
(E45-65Z) (G108); V30ZMD (D210/E210); and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098)] ................................................................................................................................................. 52
Hydraulic Pump, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216); J2.00-3.20XM
(J40-65Z) (A416); and J2.00-3.20XM (J40-65Z) (B416)] .............................................................................. 53
Hydraulic Pump, Disassemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) and
J2.00-3.20XM (J40-65Z) (B416)] ................................................................................................................... 54
Hydraulic Pump, Inspect [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) and
J2.00-3.20XM (J40-65Z) (B416)] ................................................................................................................... 56
Hydraulic Pump, Clean [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) and
J2.00-3.20XM (J40-65Z) (B416)] ................................................................................................................... 56
Hydraulic Pump, Assemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) and
J2.00-3.20XM (J40-65Z) (B416)] ................................................................................................................... 56
Hydraulic Pump and Motor, Install [J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216);
J2.00-3.20XM (J40-65Z) (A416); and J2.00-3.20XM (J40-65Z) (B416)] ...................................................... 56
Main Control Valve Repair ................................................................................................................................ 58
Steering Pump Repair ....................................................................................................................................... 59
Pump, Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108);
N30XMH and N30XMH 2 (C210); E1.50-1.75XM 2.00XMS (E25-35Z, E40ZS) (E114)] ............................. 59
Pump, Remove and Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216); J2.00-3.20XM
(J40-65Z) (A416); E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114); E2.00-3.20XM (E45-65Z) (G108);
V30ZMD (D210/E210); E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098); and
J2.00-3.20XM (J40-65Z) (B416)] ................................................................................................................... 60
Pump, Assemble and Install ......................................................................................................................... 62
Rotary Actuator Valve Repair ........................................................................................................................... 63
Disassemble, Clean, and Inspect .................................................................................................................. 63
Assemble ........................................................................................................................................................ 63
Steering Control Unit Replacement.................................................................................................................. 64
Remove ........................................................................................................................................................... 64
Install ............................................................................................................................................................. 65
Steering Cylinder Repair................................................................................................................................... 71
Main Control Valve Check and Adjust.............................................................................................................. 71
Steering Relief Valve Check and Adjust ........................................................................................................... 72
Specifications...................................................................................................................................................... 73
Relief Valve Pressures* ................................................................................................................................. 73
Hydraulic Tank Capacity (dipstick full mark) ............................................................................................. 73
Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) ................................................................................................................................................... 73
Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) ........ 73
Troubleshooting.................................................................................................................................................. 74

ii
Hydraulic System Table of Contents

TABLE OF CONTENTS (Continued)

This section is for the following models:

E1.50-3.20XM (E25-65XM, E25-65XM 2) [D114, F108];

J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416/B416];
N30XMH, N30XMH 2 [C210];
V30ZMD [D210/E210];
E1.50-2.00XM (E25-35Z, 40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1900 SRM 559
General
This section describes the hydraulic system and
the steering system. The section includes repairs,
checks, adjustments, and troubleshooting. This
section has repair procedures for the main hydraulic
pump and the steering pump. Other repair proce-
dures are in the following sections:
• Manual hydraulic Control Valve 2000 SRM 562
for models E1.50-2.00XM (E25-40XM, E25-40XM 2)
(D114), E1.50-2.00XM (E25-35Z, 40ZS) (E114),
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM
(J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM
(J40-65Z) (A416), and for J2.00-3.20XM (J40-65Z)
(B416) lift trucks with a manual hydraulic control
valve.
• Manual hydraulic Control Valve 2000 SRM 591
for N30XMH, N30XMH 2 (C210), V30ZMD (D210/
E210) lift truck models,
• Manual hydraulic Control Valve 2000 SRM 77
for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) lift truck models, and
• Electro-Hydraulic Control Valve 2000
SRM 1224 for lift truck models J2.00-3.20XM
(J40-65Z) (B416), E1.50-2.00XM (E25-35Z, 40ZS)
(F114), E2.00-3.20XM (E45-65Z) (G108) and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098) with an electronic hydraulic control valve.
• Mast Repairs, 2 and 3-Stage Masts 4000 SRM
522
• Four-Stage Mast 4000 SRM 563
• Mast, Repair 4000 SRM 482 lift truck mod-
els N30XMH, N30XMH 2 (C210), and V30ZMD
(D210/E210)
• Mast Repairs, 2, 3, and 4-Stage Masts 4000
SRM 1148
• Masts, Description and Repairs 4000 SRM
736 for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098)
• Tilt Cylinders 2100 SRM 103
• Lift Cylinders 4000 SRM 481 for lift trucks
N30XMH, N30XMH 2 (C210), and V30ZMD
(D210/E210)
General
• Lift Cylinders 4000 SRM 741 for lift truck mod-
els E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098)
• Steering Housing and Control Unit 1600 SRM
512 or Steering Housing and Control Unit 1600
SRM 720
• Steering Axle 1600 SRM 258 for E2.00-3.20XM
(E45-65XM, E45-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108), N30XMH, N30XMH 2 (C210),
and V30ZMD (D210/E210) lift trucks
• Steering Axle 1600 SRM 316 for J2.00-3.20XM
(J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM
(J40-65Z) (A416), and J2.00-3.20XM (J40-65Z)
(B416) lift trucks
• Steering Axle 1600 SRM 619 for E1.50-2.00XM
(E25-40XM, E25-40XM 2) (D114) and E1.50-
2.00XM (E25-35Z, 40ZS) (E114/F114) model lift
trucks
• Steering Axle 1600 SRM 326 for lift truck mod-
els E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098)
• DC Motor Maintenance 620 SRM 294 for
E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114),
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
E2.00-3.20XM (E45-65Z) (G108), N30XMH,
N30XMH 2 (C210), V30ZMD (D210/E210),
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216),
J2.00-3.20XM (J40-65Z) (A416) and J2.00-3.20XM
(J40-65Z) (B416) lift trucks
• AC Motor Repair 620 SRM 1053 for lift truck
models J2.00-3.20XM (J40-65Z) (A416) and J2.00-
3.20XM (J40-65Z) (B416)
• AC Motor Repair 620 SRM 1098 for lift truck
models V30ZMD (D210/E210), E1.50-2.00XM
(E25-35Z, 40ZS) (E114/F114), E2.00-3.20XM
(E45-65Z) (G108), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098)
1
Description
Description
HYDRAULIC SYSTEM
The parts of the hydraulic system for the E1.50-
3.20XM (E25-65XM, E25-65XM 2) (D114, F108),
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114), and
E2.00-3.20XM (E45-65Z) (G108) (early models),
V30ZMD (D210/E210) are shown in Figure 1. The
parts of the hydraulic system for the J2.00-3.20XM
(J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM
(J40-65Z) (A416) are shown in Figure 4. The parts
for the hydraulic system for E2.00-3.20XM (E45-65Z)
(G108) and V30ZMD (D210/E210) are shown in Fig-
ure 2 and Figure 3. The parts of the hydraulic system
for the N30XMH and N30XMH 2 (C210), are shown
in Figure 5. The parts of the hydraulic system for lift
truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
2
1900 SRM 559
E100ZS) (D098/E098), are shown in Figure 6. The
parts of the hydraulic system for lift truck models
J2.00-3.20XM (J40-65Z) (B416) with an electronic
hydraulic control valve are shown in Figure 7. The
parts of the hydraulic system for lift truck models
J2.00-3.20XM (J40-65Z) (B416) with a manual hy-
draulic control valve are shown in Figure 8. The
diagrams show components and interconnections
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
systems. The steering system and the lift system
have separate pumps. Both pumps are gear pumps.
1900 SRM 559 Description

1. TILT CYLINDER (2) 7. PRIMARY RELIEF VALVE

2. FILTER 8. SECONDARY RELIEF VALVE
3. BREATHER 9. TO AUXILIARY HYDRAULIC FUNCTIONS
4. HYDRAULIC TANK (CAN BE DIFFERENT 10. TO LIFT CYLINDERS
SHAPE) 11. STEERING CONTROL UNIT
5. STEERING CYLINDER 12. STEERING PUMP
6. MAIN CONTROL VALVE (4-SPOOL VALVE 13. HYDRAULIC PUMP
SHOWN)

Figure 1. Hydraulic System for E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108); E1.50-2.00XM
(E25-35Z, 40ZS) (E114/F114); and E2.00-3.20XM (E45-65Z) (G108) (Early Model)

3
Description 1900 SRM 559

Figure 2. Hydraulic System for E2.00-3.20XM (E45-65Z) (G108) and V30ZMD (D210/E210) Lift
Trucks With Manual Hydraulic Controls (Later Model)

4
1900 SRM 559 Description

Legend for Figure 2

1. STEERING CONTROL UNIT 9. STEERING CYLINDER
2. STEERING HOSES 10. HYDRAULIC PUMP AND MOTOR
3. TILT CYLINDERS 11. STEERING PUMP AND MOTOR
4. TILT CYLINDER HOSES 12. BREATHER
5. HYDRAULIC CONTROL VALVE 13. HYDRAULIC FILTER GAUGE
6. HYDRAULIC TANK 14. HYDRAULIC FILTER ASSEMBLY
7. STEERING PUMP AND MOTOR HOSE 15. RETURN TO TANK HOSE
8. HYDRAULIC PUMP AND MOTOR HOSE

5
Description 1900 SRM 559

Figure 3. Hydraulic System for E2.00-3.20XM (E45-65Z) (G108) and V30ZMD (E210) Lift Trucks
With E-Hydraulic Controls

6
1900 SRM 559 Description

Legend for Figure 3

1. STEERING CONTROL UNIT 9. STEERING CYLINDER
2. STEERING HOSES 10. HYDRAULIC PUMP AND MOTOR
3. TILT CYLINDERS 11. STEERING PUMP AND MOTOR
4. TILT CYLINDER HOSES 12. BREATHER
5. HYDRAULIC CONTROL VALVE 13. HYDRAULIC FILTER GAUGE
6. HYDRAULIC TANK 14. HYDRAULIC FILTER ASSEMBLY
7. STEERING PUMP AND MOTOR HOSE 15. RETURN TO TANK HOSE
8. HYDRAULIC PUMP AND MOTOR HOSE

1. TILT CYLINDER (2) 8. STEERING CYLINDER

2. PRIMARY RELIEF VALVE 9. SECONDARY RELIEF VALVE
3. STEERING MOTOR AND PUMP 10. MAIN CONTROL VALVE (4-SPOOL VALVE
4. HYDRAULIC MOTOR AND PUMP SHOWN)
5. HYDRAULIC TANK 11. STEERING CONTROL UNIT
6. FILTER 12. TO AUXILIARY HYDRAULIC FUNCTIONS
7. BREATHER, FILL, AND DIPSTICK 13. TO LIFT CYLINDERS

Figure 4. Hydraulic System for J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM
(J40-65Z) (A416)

7
Description 1900 SRM 559

1. FILTER 8. TO AUXILIARY HYDRAULIC FUNCTIONS

2. BREATHER 9. TO LIFT CYLINDERS
3. HYDRAULIC TANK 10. STEERING CONTROL UNIT
4. STEERING CYLINDER 11. HYDRAULIC PUMP - STEERING
5. MAIN CONTROL VALVE (4-SPOOL VALVE 12. HYDRAULIC PUMP - LIFT
SHOWN) 13. TRAVERSE CYLINDER
6. PRIMARY RELIEF VALVE 14. ROTARY ACTUATOR
7. SECONDARY RELIEF VALVE

Figure 5. Hydraulic System for N30XMH and N30XMH 2 (C210), V30ZMD (D210)

8
1900 SRM 559 Description

NOTE: THE ORIENTATION OF THE MAIN CONTROL VALVE IS SHOWN OUT OF POSITION FOR CLARITY.
1. TILT CYLINDER (2) 8. SECONDARY RELIEF VALVE
2. HYDRAULIC FILTER (INSIDE TANK) 9. TO AUXILIARY HYDRAULIC FUNCTIONS
3. HYDRAULIC BREATHER 10. TO LIFT CYLINDERS
4. HYDRAULIC TANK 11. STEERING CONTROL UNIT
5. STEERING CYLINDER 12. STEERING PUMP
6. MAIN CONTROL VALVE (4-SPOOL VALVE 13. HYDRAULIC PUMP
SHOWN) 14. FILTER HEAD ASSEMBLY
7. PRIMARY RELIEF VALVE

Figure 6. Hydraulic System for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) Lift Trucks

9
Description 1900 SRM 559

1. AUXILIARY HYDRAULIC HOSES 10. HYDRAULIC TANK BREATHER

2. STEERING CONTROL UNIT 11. HYDRAULIC PUMP AND MOTOR
3. TILT CYLINDERS 12. STEER CYLINDER
4. TILT CYLINDER HOSES 13. STEER CYLINDER HOSES
5. VALVE DRIVER MODULE 14. STEERING PUMP AND MOTOR
6. MAIN CONTROL VALVE 15. HYDRAULIC PUMP AND MOTOR HOSES
7. HOSES TO STEERING CONTROL UNIT 16. HOSES TO STEER PUMP AND MOTOR
8. HYDRAULIC FILTER 17. HOSES TO HYDRAULIC TANK
9. HYDRAULIC TANK

Figure 7. Hydraulic System for J2.00-3.20XM (J40-65Z) (B416) Lift Trucks With E-Hydraulic
Controls

10
1900 SRM 559 Description

1. AUXILIARY HYDRAULIC HOSES 9. HYDRAULIC TANK

2. STEERING CONTROL UNIT 10. HYDRAULIC PUMP AND MOTOR
3. TILT CYLINDERS 11. STEER CYLINDER
4. TILT CYLINDER HOSES 12. STEER CYLINDER HOSES
5. MAIN CONTROL VALVE 13. STEERING PUMP AND MOTOR
6. HOSES TO STEERING CONTROL UNIT 14. HYDRAULIC PUMP AND MOTOR HOSES
7. HYDRAULIC BREATHER 15. HOSES TO STEER PUMP AND MOTOR
8. HYDRAULIC FILTER 16. HOSES TO HYDRAULIC TANK

Figure 8. Hydraulic System for J2.00-3.20XM (J40-65Z) (B416) Lift Trucks With Manual Hydraulic
Controls

11
Operation 1900 SRM 559

Operation
HYDRAULIC SYSTEM
The hydraulic pump causes oil to flow from the
tank to the main control valve. See Figure 9, Fig-
ure 10, Figure 12, or Figure 13. For lift truck models
V30ZMD (D210/E210). See Figure 11 and Figure 14.
The main control valve controls the flow of oil to the
lift cylinders, tilt 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
control valve provides lower pressure for auxiliary
functions.
The steering pump causes oil to flow from the tank
to the steering control unit. The steering control unit
is a metering pump actuated by the steering wheel.
When the steering wheel is turned, oil flows to actu-
ate the steering cylinder. Oil returns from the steer-
ing control unit to the main control valve. A relief
valve in the pump keeps pressure within the design
limits of the steering system.
The oil returns from the main control valve and flows
through a filter in the hydraulic tank. The filter re-
moves small particles from the oil. The filter has a
bypass valve so that the oil can flow through the sys-
tem if the filter becomes too dirty.

Legend for Figure 9

NOTE: THE PRESSURE SWITCH FOR ON-DEMAND STEERING IS NOT USED ON J2.00-3.20XM (J40-65Z)
(A416), E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114), AND E2.00-3.20XM (E45-65Z) (G108), V30ZMD
(D210/E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098), AND J2.00-3.20XM (J40-65Z) (B416)
LIFT TRUCK MODELS.
A. INSTALL AT CHECK PORT
1. TILT CYLINDERS 12. STEERING CONTROL UNIT
2. LIFT CYLINDERS 13. STEERING CYLINDER
3. LOWERING CONTROL VALVES 14. HAND PUMP
4. MAIN CONTROL VALVE 15. STEERING VALVE
5. LIFT SPOOL 16. LINE PRESSURE TAP
6. TILT SPOOL 17. PRESSURE SWITCH FOR ON-DEMAND
7. AUXILIARY SPOOL STEERING
8. HYDRAULIC PUMP 18. CHECK PORT
9. FILTER 19. STEERING PUMP
10. PRIMARY RELIEF VALVE 20. STEERING RELIEF VALVE
11. SECONDARY RELIEF VALVE 21. HYDRAULIC TANK

12
1900 SRM 559 Operation

Figure 9. Hydraulic Schematic for Models E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108);
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114): E2.00-3.20XM (E45-65Z) (G108); J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216); J2.00-3.20XM (J40-65Z) (A416); E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098); and J2.00-3.20XM (J40-65Z) (B416) With Manual Hydraulic Controls

13
Operation 1900 SRM 559

Figure 10. Hydraulic Schematic With Manual Hydraulics Controls for N30XMH and N30XMH 2
(C210) and V30ZMD (D210) (Early Models)

14
1900 SRM 559 Operation

Legend for Figure 10

1. LIFT CYLINDERS 15. STEERING VALVE
2. LOWERING CONTROL VALVES 16. LINE PRESSURE TAP
3. MAIN CONTROL VALVE 17. PRESSURE SWITCH FOR ON-DEMAND
4. LIFT SPOOL STEERING (INSTALL AT CHECK PORT)
5. AUXILIARY SPOOL 18. CHECK PORT
6. TRAVERSE SPOOL 19. STEERING PUMP
7. ROTARY SPOOL 20. STEERING RELIEF VALVE
8. HYDRAULIC PUMP 21. HYDRAULIC TANK
9. FILTER 22. BYPASS VALVE
10. PRIMARY RELIEF VALVE 23. ROTARY ACTUATOR VALVE
11. SECONDARY RELIEF VALVE 24. SHUTTLE
12. STEERING CONTROL UNIT 25. ROTARY ACTUATOR
13. STEERING CYLINDER 26. TRAVERSE CYLINDER
14. HAND PUMP

15
Operation 1900 SRM 559

Figure 11. Hydraulic Schematic With Manual Hydraulics Controls for Lift Trucks Model V30ZMD
(D210/E210) (Later Models)

16
1900 SRM 559 Operation

Legend for Figure 11

1. SINGLE ACTING PIVOT CYLINDERS 13. LINE PRESSURE TAP
2. ADJUSTABLE FLOW RESTRICTOR 14. CHECK PORT
3. LOCK/CROSS OVER RELIEF VALVE 15. STEERING PUMP
4. TRAVERSE HYDRAULIC MOTOR 16. HYDRAULIC TANK
5. SIDESHIFT CYLINDER 17. HYDRAULIC FILTER
6. LIFT CYLINDERS 18. MAIN HYDRAULIC PUMP
7. SECONDARY LOWERING CONTROL 19. MAIN HYDRAULIC CONTROL VALVE
8. PRIMARY LOWERING CONTROL 20. LIFT SPOOL
9. STEERING CYLINDER 21. TILT SPOOL
10. HAND PUMP 22. AUXILIARY SPOOLS
11. STEERING VALVE 23. RELIEF CARTRIDGE
12. STEERING CONTROL

17
Operation 1900 SRM 559

Figure 12. Hydraulic Schematic for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, 40ZS)
(F114); and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks With E-Hydraulic Controls (Standard Flow)

18
1900 SRM 559 Operation

Legend for Figure 12

1. AUXILIARY 2 VALVE (SP5) 15. STEERING RELIEF VALVE
2. AUXILIARY 1 VALVE (SP4) 16. HYDRAULIC TANK
3. TILT CYLINDERS 17. HYDRAULIC FILTER
4. LIFT CYLINDER 18. HYDRAULIC PUMP
5. SECONDARY LOWERING CONTROL INTEGRAL 19. PRIMARY RELIEF VALVE (3300 PSI) (RV1)
WITH LIFT CYLINDERS 20. SECONDARY RELIEF VALVE (2250 PSI) (RV2)
6. PRIMARY LOWERING CONTROL (MOUNTED 21. TILT SOLENOID VALVE (SP3)
ON MAST) 22. LIFT SOLENOID VALVE (SP1)
7. STEERING CYLINDER 23. PRIORITY COMPENSATOR VALVE (EC1)
8. STEERING WHEEL 24. LOWERING COMPENSATOR VALVE (EC2)
9. CHECK PORT 25. TILT COUNTERBALANCE VALVE (CB1)
10. STEERING CONTROL UNIT 26. CHECK VALVE LIFT CIRCUIT (CV1)
11. HAND PUMP 27. FLOW REGULATOR VALVE (FR1)
12. STEERING VALVE 28. LOWER SOLENOID VALVE WITH MANUAL
13. MAIN CONTROL VALVE OVERRIDE (SP2)
14. STEERING PUMP

19
Operation 1900 SRM 559

Figure 13. Hydraulic Schematic for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, 40ZS)
(F114); and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks With E-Hydraulic Controls (High Flow)

20
1900 SRM 559 Operation

Legend for Figure 13

1. PILOT OPERATED SPOOL VALVE (PE1) 16. HYDRAULIC TANK
2. PILOT OPERATED SPOOL VALVE (PE2) 17. HYDRAULIC FILTER
3. TILT CYLINDERS 18. HYDRAULIC PUMP
4. LIFT CYLINDER 19. PRIMARY RELIEF VALVE (3300 PSI) (RV1)
5. SECONDARY LOWERING CONTROL INTEGRAL 20. SECONDARY RELIEF VALVE (2250 PSI) (RV2)
WITH LIFT CYLINDERS 21. TILT SOLENOID VALVE (SP3)
6. PRIMARY LOWERING CONTROL (MOUNTED 22. LIFT SOLENOID VALVE (SP1)
ON MAST) 23. PRIORITY COMPENSATOR VALVE (EC1)
7. STEERING CYLINDER 24. LOWERING COMPENSATOR VALVE (EC2)
8. STEERING WHEEL 25. PILOT OPERATED SOLENOID VALVE (EHPR1
9. CHECK PORT THROUGH 4)
10. STEERING CONTROL UNIT 26. TILT COUNTERBALANCE VALVE (CB1)
11. HAND PUMP 27. FLOW REGULATOR VALVE (FR1)
12. STEERING VALVE 28. LOWER SOLENOID VALVE WITH MANUAL
13. MAIN CONTROL VALVE OVERRIDE (SP2)
14. STEERING PUMP 29. CHECK VALVE LIFT CIRCUIT (CV1)
15. STEERING RELIEF VALVE

21
Operation 1900 SRM 559

Figure 14. Hydraulic Schematic With E-Hydraulic Controls for Lift Trucks Model V30ZMD (E210)

22
1900 SRM 559 Operation

Legend for Figure 14

1. SINGLE ACTING PIVOT CYLINDER 19. LOWERING COMPENSATOR VALVE (EC2)
2. ADJUSTABLE FLOW RESTRICTOR 20. LOWERING SOLENOID VALVE WITH MANUAL
3. LOCK/CROSS OVER RELIEF VALVE OVERRIDE (SP2)
4. TRAVERSE HYDRAULIC MOTOR 21. PRIORITY COMPENSATOR VALVE (EC1)
5. SIDESHIFT CYLINDER 22. LIFT SOLENOID VALVE (SP1)
6. LIFT CYLINDERS 23. STEERING VALVE
7. SECONDARY LOWERING CONTROL 24. PRIMARY RELIEF VALVE (RV1)
8. PRIMARY LOWERING CONTROL 25. SECONDARY RELIEF VALVE (RV2)
9. STEERING CYLINDER 26. FLOW REGULATOR VALVE (FR1)
10. HAND PUMP 27. TILT CYLINDER VALVE (SP3)
11. STEERING WHEEL 28. TILT COUNTERBALANCE VALVE (CB1)
12. LINE PRESSURE TAP 29. CHECK VALVE LIFT CIRCUIT (CV1)
13. CHECK PORT 30. GAUGE PORT
14. STEERING PUMP 31. PILOT OPERATED SOLENOID VALVE (EHPR 1
15. HYDRAULIC TANK THROUGH 4)
16. HYDRAULIC FILTER 32. PILOT OPERATED SPOOL VALVE (PE1)
17. HYDRAULIC PUMP 33. PILOT OPERATED SPOOL VALVE (PE2)
18. MAIN CONTROL VALVE

HYDRAULIC GEAR PUMP
For all lift truck models covered in this manual,
except for E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098), there can be two different
sizes of hydraulic pumps used: a 12 cc/revolution
gear pump or a 19 cc/revolution gear pump. The
larger pump is standard. See Figure 33. The smaller
pump is used when there is a contactor motor control
with a closed motor or for a slower speed require-
ment. For lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098), a 29 cc/revolution
gear pump is used. See Figure 36.
These hydraulic pumps are all single-section gear
pumps that fasten to the end of the motor housing. A
hose connects the pump inlet to the hydraulic tank.
A hose connects the pump outlet to the main control
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
bushings also have passages for the oil flow to the
pump outlet and for lubrication. Seals prevent leaks
between sections of the pump housing.
ROTATOR ACTUATOR VALVE
On the N30XMH and N30XMH 2 (C210), V30ZMD
(D210/E210) only, the rotary actuator valve is con-
nected between the rotary spool and the rotary actu-
ator. 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 posi-
tion. 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
pushes 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 valve opens when
the rotary actuator moves to the end of its stroke.
One relief valve is installed for each direction of ro-
tary actuator travel. These relief valves also protect
the rotary actuator from damage if the forks hit an
object. An adjustable bypass valve for the rotary ac-
tuator is connected in parallel to the rotary actuator
valve. The bypass valve permits some of the oil from
the main control valve to flow directly to the return
line. The bypass valve decreases the speed of the ro-
tary actuator.
For the location of the pressure check fitting for steer-
ing pressure, see Figure 15, Figure 16, Figure 17, or
Figure 18.
STEERING PUMP
NOTE: Lift truck models J2.00-3.20XM (J40-65Z)
(A416), E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108), V30ZMD (D210/
E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), and J2.00-3.20XM (J40-65Z) (B416) do
not contain a pressure switch on the steering pump
for the On-Demand Steering system.
The steering pump is a small gear pump connected
to the bottom of the steering motor. See Figure 15,
Figure 16, Figure 17, Figure 18 or Figure 19.
The steering pump and motor are in a horizon-
tal mount under the battery compartment on the
E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114) and
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114) trucks.
The steering pump and motor are in a vertical

23
Operation 1900 SRM 559

mount under the floor plate on the E2.00-3.20XM
(E45-65XM, E45-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108), N30XMH, N30XMH 2 (C210),
V30ZMD (D210/E210), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098) trucks. The steering
pump and motor are also in a vertical mount that
is located behind the battery on the J2.00-3.20XM
(J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM
(J40-65Z) (A416), and J2.00-3.20XM (J40-65Z)
(B416). 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 housing. The pressure switch at
the bottom of the pump is used with On-Demand
Steering only.

Figure 15. Steering Pump and Hydraulic Circuit for E1.50-1.75XM, E2.00XMS (E25-40XM,
E40XMS 2) (D114) and E1.50-1.75XM, 2.00XMS (E25-35Z, 40ZS) (E114/F114) Lift Truck Models

24
1900 SRM 559 Operation

Legend for Figure 15

NOTE: MOTOR CAN BE DIFFERENT THAN SHOWN.

1. STEERING CYLINDER 6. PRESSURE SWITCH (ON-DEMAND STEERING
2. TO STEERING CONTROL UNIT ONLY)
3. PRESSURE CHECK FITTING 7. RETURN TO HYDRAULIC TANK
4. PUMP MOTOR 8. FROM HYDRAULIC TANK
5. STEERING PUMP 9. MOUNT FOR STEERING MOTOR

25
Operation 1900 SRM 559

Figure 16. Steering Pump and Hydraulic Circuit for E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108)
and N30XMH and N30XMH 2 (C210) Lift Truck Models

26
1900 SRM 559 Operation

Legend for Figure 16

NOTE: MOTOR CAN BE DIFFERENT THAN SHOWN.

1. STEERING CYLINDER 6. PRESSURE SWITCH (ON-DEMAND STEERING
2. TO STEERING CONTROL UNIT ONLY)
3. PRESSURE CHECK FITTING 7. RETURN TO HYDRAULIC TANK
4. PUMP MOTOR 8. FROM HYDRAULIC TANK
5. STEERING PUMP 9. MOUNT FOR STEERING MOTOR

27
Operation 1900 SRM 559

Figure 17. Steering Pump and Hydraulic Circuit for J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
Lift Truck Models

28
1900 SRM 559 Operation

Legend for Figure 17

NOTE: MOTOR CAN BE DIFFERENT THAN SHOWN.

1. TO STEERING CONTROL UNIT 6. PRESSURE SWITCH (ON-DEMAND STEERING
2. MOUNT FOR STEERING MOTOR ONLY)
3. FROM HYDRAULIC TANK 7. STEERING CYLINDER
4. PUMP MOTOR 8. RETURN TO HYDRAULIC TANK
5. STEERING PUMP 9. PRESSURE CHECK FITTING

29
Operation 1900 SRM 559

Figure 18. Steering Pump and Hydraulic Circuit for J2.00-3.20XM (J40-65Z) (A416, B416);
E2.00-3.20XM (E45-65Z) (G108), and V30ZMD (D210/E210) Lift Truck Models

30
1900 SRM 559 Operation

Legend for Figure 18

1. TO STEERING CONTROL UNIT 7. RETURN TO HYDRAULIC TANK
2. METAL BAND (HOLDS PUMP MOTOR TO 8. PRESSURE CHECK FITTING
MOUNTING WELDMENT) 9. RUBBER CHANNELS
3. FROM HYDRAULIC TANK 10. MOUNTING BRACKETS
4. PUMP MOTOR 11. CAPSCREW
5. STEERING PUMP 12. WASHER
6. STEERING CYLINDER 13. MOUNTING WELDMENT

31
Operation 1900 SRM 559

Figure 19. Steering Pump and Hydraulic Circuit for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) Lift Truck Models

32
1900 SRM 559 Operation

Legend for Figure 19

1. TO STEERING CONTROL UNIT 8. PRESSURE CHECK FITTING
2. METAL BAND (HOLDS PUMP MOTOR TO 9. RUBBER CHANNELS
MOUNTING WELDMENT) 10. MOUNTING BRACKETS
3. FROM HYDRAULIC TANK 11. CAPSCREW
4. PUMP MOTOR 12. WASHER
5. STEERING PUMP 13. MOUNTING WELDMENT
6. STEERING CYLINDER 14. NUT
7. RETURN TO HYDRAULIC TANK 15. GROMMET

33
Hydraulic Tank Repair 1900 SRM 559

Hydraulic Tank Repair

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.
1. Install container under drain plug of hydraulic
tank with enough capacity. See the Specifica-
tions table at the back of this section. See Fig-
ure 20 or Figure 21.
2. Remove drain plug and let oil drain from hy-
draulic tank. Install and tighten drain plug.

WARNING
Hydraulic oil is HOT at operating temperature.
DO NOT permit the hot oil to contact the skin
and cause a burn.

CAUTION
DO NOT permit dirt to enter the hydraulic
system when doing repairs to the tank. Dirt
can cause damage to the components of the
hydraulic system.

Clean the outside of the hydraulic filter, hoses,

and hydraulic tank before disconnecting and
removing tank from lift truck to prevent dirt
from entering hydraulic system.

NEVER operate the hydraulic pump with out

oil in the hydraulic system. The operation of
the hydraulic pump without oil will damage
the pump.
See General at the beginning of this service manual
section, for a list of sections of the Service Manuals
for hydraulic parts other than the pumps and tank.
A. E1.50, 1.75XM, 2.00XMS (E25-35XM, E40XMS)
(D114), E1.50-1.75XM, E2.00XMS (E25-35Z,
E40ZS) (E114)
B. E1.50-1.75XM, E2.00XMS (E25-35Z, E40ZS)
(E114/F114)

NOTE: To repair leaks in the hydraulic tank, See the 1. BREATHER

2. DIPSTICK ASSEMBLY
sections Inspect, Small Leaks, Repair, Large Leaks, 3. MOUNTING BRACKET
Repair, Clean, and Additional Methods for Tank Re- 4. TANK
pair in this SRM for the procedures. 5. HYDRAULIC PUMP SUPPLY PORT
6. STEERING PUMP SUPPLY PORT
TANK, REMOVE [E1.50-3.20XM (E25-65XM, 7. FILL CAP
8. SEAL
E25-65XM 2) (D114, F108); E1.50-2.00XM 9. BREATHER HOSE
(E25-35Z, 40ZS) (E114/F114); E2.00-3.20XM 10. CLAMP
11. STRAP CLAMP
(E45-65Z) (G108); N30XMH AND N30XMH 2 12. PLUG
(C210); V30ZMD (D210/E210)] 13. PAD
14. RETURN PORT

WARNING Figure 20. Hydraulic Tank Assembly for

Never put tools or other metal on the battery. E1.50-1.75XM, E2.00XMS (E25-40XM, E40XMS 2)
Metal on the battery can cause a short circuit (D114) and E1.50-1.75XM, 2.00XMS (E25-35Z,
and possible damage or injury. 40ZS) (E114/F114)

34
1900 SRM 559 Hydraulic Tank Repair

5. Remove and install plugs in all hoses fastened to

hydraulic tank. Remove fill cap and short tube.
Install plug in opening of tank.

6. Remove traction motor as described in one of the

following the frame SRM for your lift truck.

7. Remove screws that fasten bracket holding hy-

draulic tank in truck frame. Remove bracket as-
sembly.

8. Carefully remove hydraulic tank from frame.

9. Make repairs to hydraulic tank.

TANK, REMOVE [J2.00-3.20XM (J40-60XM,

J40-60XM 2) (A216) AND J2.00-3.20XM
(J40-60Z) (A416)]
1. Turn key to OFF position and remove key.

WARNING
Never put tools or other metal on the battery.
A. E2.00-3.20XM (E45-65XM, E45-65XM 2), (F108),
AND N30XMH, AND N30XMH 2 (C210) Metal on the battery can cause a short circuit
B. E2.00-3.20XM (E45-65Z) (G108) AND V30ZMD and possible damage or injury.
(D210/E210)
2. Open hood and install cardboard or plywood
1. BREATHER AND HOSE cover on top of battery to prevent accidental
2. FILL CAP short circuits.
3. MOUNT BRACKET
4. HYDRAULIC TANK 3. Turn steering wheel for a full left turn for ac-
5. PLUG
6. STEERING PUMP SUPPLY PORT cess to drain plug near front of right rear wheel.
7. HYDRAULIC PUMP SUPPLY PORT Install container under drain plug of hydraulic
8. RETURN PORT tank with enough capacity. See the Specifica-
9. PAD tions table at the back of this section.
10. BREATHER HOSE
11. STRAP CLAMP 4. Remove drain plug and let oil drain from hy-
12. CLAMP
13. DIPSTICK ASSEMBLY draulic tank. Install and tighten drain plug.
14. SEAL
15. ADAPTER 5. Remove and install plugs in all hoses fastened
to hydraulic tank. Remove breather/dipstick/fill
Figure 21. Hydraulic Tank Assembly for cap and install plug in opening of fill tube.
E2.00-3.20XM (E45-65XM, E45-65XM 2),
(F108); E2.00-3.20XM (E45-65Z) (G108); and 6. Remove screws from bracket that fastens bracket
N30XMH, and N30XMH 2 (C210); and V30ZMD holding hydraulic tank in truck frame. See Fig-
(D210/E210) ure 22. Remove bracket assembly.

3. Remove floor plate for access to hydraulic tank. 7. Carefully lift hydraulic tank up out of frame.

4. Remove Battery to access hoses fastened to the 8. Make repairs to hydraulic tank.
hydraulic tank.

35
Hydraulic Tank Repair 1900 SRM 559

5. Remove the drain plug and let the oil drain from
the hydraulic tank. Install and tighten the drain
plug.

6. Disconnect the hydraulic lines and install plugs

in all hoses fastened to the hydraulic tank and
hydraulic filter assembly.

7. Remove the screws from the bracket that fastens

the hydraulic tank to truck frame and remove
bracket. See Figure 23.

8. Carefully lift hydraulic tank up out of frame.

1. HYDRAULIC TANK
2. FILTER
3. MOUNT BRACKET ASSEMBLY
4. FILL CAP/BREATHER/DIPSTICK
5. RETURN TO TANK
6. RETURN FROM SYSTEM
7. SUPPLY PORT

Figure 22. Hydraulic Tank Assembly for

J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
and J2.00-3.20XM (J40-65Z) (A416)

TANK, REMOVE [J2.00-3.20XM (J40-60Z)

(B416)] 1. MOUNTING 9. BREATHER HOSE
BRACKET 10. PIPE
1. Turn key to OFF position and remove key. 2. CAPSCREW 11. DIPSTICK
3. WASHER AND FILL CAP
4. NUT ASSEMBLY
WARNING 5. STRAP CLAMP 12. PLATE
Never put tools or other metal on the battery. 6. CLAMP 13. ADAPTER
7. DRAIN PLUG 14. HYDRAULIC
Metal on the battery can cause a short circuit 8. BREATHER FILTER
and possible damage or injury. 15. GAUGE
2. Open hood and install cardboard or plywood Figure 23. Hydraulic Tank Assembly for
cover on top of battery to prevent accidental J2.00-3.20XM (J40-65Z) (B416)
short circuits.
HYRAULIC TANK [E3.50-5.50XL, E4.50XLS
3. Turn steering wheel for a full left turn for ac-
cess to drain plug near front of right rear wheel. (E70-120Z, E100ZS) (D098/E098)]
Install container under drain plug of hydraulic NOTE: The hydraulic tank is a part of the frame and
tank with enough capacity. See the Specifica- cannot be removed or installed separately from the
tions table at the back of this section. frame weldment. The tank can be inspected, cleaned
4. Remove dipstick and fill cap. and leaks repaired if necessary. See the sections
Inspect, Small Leaks, Repair, Large Leaks, Repair,
Clean, and Additional Methods for Tank Repair for
the procedures.

36
1900 SRM 559 Hydraulic Tank Repair

5. Remove drain plug and let oil drain from hy-

WARNING draulic tank. See Figure 24. Install and tighten
Never put tools or other metal on the battery. drain plug.
Metal on the battery can cause a short circuit
and possible damage or injury. 6. Connect hydraulic hoses.

To change the hydraulic oil in the tank, perform the 7. Fill hydraulic tank with new hydraulic oil as
following steps: specified in the section Periodic Maintenance
8000 SRM 1201.
1. Put lift truck on level surface and lower mast.
a. Operate lift and steering system.
2. Turn key to OFF position and remove key.
b. Check for leaks
3. Disconnect hydraulic hoses.
c. Check oil level
4. Install a drain container, with enough capacity,
under drain plug of hydraulic tank See the Spec-
ifications table at the back of this section.

NOTE: THE HYDRAULIC FILTER IS INSIDE THE HYDRAULIC TANK AND ATTACHED TO THE FILTER HEAD
ASSEMBLY. IT IS NOT SHOWN HERE FOR CLARITY (SEE FIGURE 28). THE HYDRAULIC FILTER AND TANK
ARE ON THE RIGHT SIDE.
1. HYDRAULIC FILTER HEAD ASSEMBLY 4. HYDRAULIC FILTER
2. FRAME 5. DRAIN PLUG
3. HYDRAULIC TANK 6. SUPPLY OUTLET

Figure 24. Hydraulic Tank for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) Lift Truck
Models

37
Hydraulic Tank Repair
INSPECT
Make visual inspection of all sides of tank. Inspect
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 mir-
ror and a light that is approved for locations with
flammable vapors.
For all lift truck models covered in this manual,
except for E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) truck models, 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. On lift truck mod-
els E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), the hydraulic tank is a part of the
frame and cannot be removed or installed sepa-
rately from the frame weldment. However, it can be
checked for leaks.
Repairs for leaks in the hydraulic 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 of tank by removing drain plug and letting tank
drain until there is no water in oil.
SMALL LEAKS, REPAIR
Use the following procedure to seal small leaks:
1. Use steam to clean area around leak. Remove all
paint and dirt around leak.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
2. Apply Loctite® 290 to leak. Follow instructions
of manufacturer.
LARGE LEAKS, REPAIR
1. Use one of the procedures described under Clean,
Steam Method or Chemical Solution Method of
cleaning tank to clean and prepare tank for re-
pairs.
2. Use acceptable welding practices to repair tank.
See the American National Standard Safety In
Welding and Cutting AWS Z 49.1 - 1999.
38
1900 SRM 559
CLEAN
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 ventila-
tion. See the following manuals for additional
information:
• Safe Practices for Welding and Cutting Con-
tainers that Have Held Combustibles by the
American Welding Society, F4.1 - 1999
• Safety In Welding and Cutting, American Na-
tional Standard, AWS Z 49.1 - 1999
When cleaning tank, do not use solutions that make
dangerous gases at normal temperatures or when
heated. Wear eye and face protection. Protect body
from burns.
Steam Method
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
When cleaning with steam, use a hose with a min-
imum diameter of 19 mm (0.75 in.). Control pres-
sure of 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 elec-
trical connection between nozzle and tank. Connect
ground wire to tank to prevent static electricity.
Use the following procedure to clean the tank with
steam:
NOTE: Remove battery before cleaning the tank
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098).
1. Remove all parts from tank. Install drain plug.
2. Fill tank 1/4 full with a solution of water and
sodium bicarbonate (baking soda) or sodium car-
bonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of wa-
ter.
1900 SRM 559
3. Mix solution in tank using air pressure. Make
sure all surfaces on inside of tank are flushed
with solution. Drain tank.
4. Put steam into tank until tank does not have
odors and metal is hot. Steam vapors must come
from all the openings.
5. Flush inside of tank with boiling water. Make
sure all loose material is removed from inside of
tank.
6. Make an inspection of inside of tank. If it is not
clean, repeat Step 4 and Step 5 and make another
inspection. When making inspections, use a light
that is approved for locations with flammable va-
pors.
7. Put plugs in all openings in tank. Wait 15 min-
utes, then remove inlet and outlet plugs. Test a
sample of the vapor with a special indicator for
gas vapors. If the amount of flammable vapors is
above the lower flammable limit, repeat cleaning
procedures.
Chemical Solution Method
If the tank cannot be cleaned with steam, use the
following procedure:
NOTE: Remove battery before cleaning the tank
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098).
1. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Fol-
low instructions given by manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
2. Fill tank with cleaning solution. Use compressed
air to mix solution in tank.
3. Drain tank. Flush inside of tank with hot (boil-
ing) water. Make sure all cleaning compound is
removed.
4. Make an inspection of the inside of the tank.
If the tank is not clean, repeat Step 1 through
Step 3. Make another inspection of the tank.
Hydraulic Tank Repair
When making inspections, use a light that is ap-
proved for locations with flammable vapors.
5. Check tank for flammable vapors as described
in the previous section Step 7. If the amount
of flammable vapors is not below the lower
flammable limit, repeat cleaning procedures.
ADDITIONAL METHODS FOR TANK
REPAIR
If nitrogen gas or carbon dioxide gas is available, pre-
pare tank for welding using these gases. See the
manual Safe Practices for Welding and Cutting Con-
tainers that Have Held Combustibles by the Ameri-
can Welding Society, F4.1 - 1999. If these gases are
not available, another method using water can be
used as follows:
1. Fill 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.
2. Use acceptable welding practices to repair the
tank. See the American National Standard
"Safety in Welding and Cutting," AWS Z 49.1 -
1999.
TANK, INSTALL [E1.50-3.20XM (E25-65XM,
E25-65XM 2), (D114, F108); E1.50-2.00XM
(E25-35Z, 40ZS) (E114/F114); E2.00-3.20XM
(E45-65Z) (G108); N30XMH AND N30XMH 2
(C210); AND V30ZMD (D210/E210)]
NOTE: Make sure to install tank so fill neck is cen-
tered in opening in step of frame. Make sure to in-
stall all plugs, hoses, and clamps to prevent leaks
when oil is added to the tank.
1. Install repaired or replacement hydraulic tank in
truck frame. See Figure 20 and Figure 21. Make
sure tank is correctly aligned for connection of
the hoses. Make sure pads are installed between
tank and truck frame.
2. Install bracket assembly to hold tank in position.
Do not tighten screws.
3. Remove plugs and install all hoses at the same lo-
cations as during removal. Do NOT remove drain
plug. Align tank so fill tube and fill cap will be
in the center of the access hole. Install fill tube
and fill cap. Tighten screws that fasten mount
bracket assembly.
39
Hydraulic Tank Repair
CAUTION
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
of the following Service Manual sections:
Periodic Maintenance 8000 SRM 552 for
the E1.50-2.00XM (E25-40XM, E25-40XM 2)
(D114) and E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108) models and Peri-
odic Maintenance 8000 SRM 1060 for
models E1.50-2.00XM (E25-35Z, 40ZS)
(E114/F114) and E2.00-3.20XM (E45-65Z)
(G108), V30ZMD (D210/E210).
Periodic Maintenance 8000 SRM 555 for
the N30XMH and N30XMH 2 (C210) trucks
Loosen clamp at inlet hose of hydraulic pump to
let air out until hose fills with oil. Tighten hose
clamp as soon as oil leaks out of hose. Do the
same procedure for steering pump.
5. Remove traction motor as described in one of the
following the frame SRM for your lift truck.
6. Operate lift and steering systems and check for
leaks and check oil level.
TANK, INSTALL [J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216) AND J2.00-3.20XM
(J40-65Z) (A416)]
1. Turn key to OFF position and remove key.
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 hood and install cardboard or plywood
cover on top of battery to prevent accidental
short circuits.
3. Carefully position hydraulic tank over correct po-
sition in frame and install hoses on bottom of
tank. Lower tank into correct position in frame.
4. Install other hoses and if removed, the filter on
the tank. Install bracket that fastens hydraulic
tank in truck frame. See Figure 22.
40
1900 SRM 559
CAUTION
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.
5. Make sure all hoses and plugs are installed and
tight. Fill tank to the FULL mark on dipstick
using the oil specified in the following Service
Manual section and install breather and fill
cap. See Periodic Maintenance 8000 SRM
552 for J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216) and Periodic Maintenance 8000 SRM
1060 for J2.00-3.20XM (J40-65Z) (A416) for
ERP20-30ALF (ERP040-060DH) (D216) lift
truck models.
6. Operate lift and steering systems and check for
leaks and check oil level.
TANK, INSTALL [J2.00-3.20XM (J40-65Z)
(B416)]
1. Turn key to OFF position and remove key.
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 hood and install cardboard or plywood
cover on top of battery to prevent accidental
short circuits.
3. Carefully position hydraulic tank over correct po-
sition in frame and connect hoses to bottom of
tank. Lower tank into correct position in frame.
4. Connect the hoses to the hydraulic tank and hy-
draulic filter assembly. Install the bracket that
fastens the hydraulic tank to lift truck frame.
See Figure 23.
CAUTION
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.
5. Make sure all hoses and plugs are installed and
tight. Fill tank to the FULL mark on dipstick
using the oil specified in the following Service
1900 SRM 559 Filter Replacement

Manual section and install dipstick and fill cap. 6. Operate lift and steering systems and check for
See Periodic Maintenance 8000 SRM 1060 leaks and check oil level.

Filter Replacement
ALL LIFT TRUCKS EXCEPT [E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098);
J2.00-3.20XM (J40-65Z) (B416); AND
E2.00-3.20XM (E45-65Z) (G108)]
Remove

WARNING
The hydraulic oil is HOT at operating temper-
ature. Do not permit the hot oil to contact the
skin and cause a burn.

CAUTION
Do not permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter Figure 25. Hydraulic Filter for E1.50-1.75XM,
is changed. Dirt can cause damage to compo- E2.00XMS (E25-40XMS and E25-40XMS 2) (D114)
nents of the hydraulic system.

Never operate the pump without oil in the hy-

draulic system. The operation of the hydraulic
pump without oil will damage the pump.

1. Turn key to the OFF position and remove key.

2. On the E1.50-3.20XM, E2.00XMS (D114),

E2.00-3.20XM (E45-65XM and E45-65XM 2)
(F108) and N30XMH, N30XMH 2 (C210) and
V30ZMD (D210) trucks, remove the floor
plates. See Figure 25 and Figure 26. On
the J2.00-3.20XM (J40-60XM and J40-60XM
(A216/A416) 2) trucks, open the hood for access
to the filter. See Figure 27. Clean the hydraulic
filter and hoses at the filter.

3. Loosen the hose clamp at the filter for the hose

from the control valve. Lift the filter as high as 1. BREATHER
possible, and remove the hose from the filter. Tip 2. MAIN CONTROL VALVE
the filter up to let the oil drain into the hydraulic 3. RELIEF VALVE
tank. 4. FILTER

4. After the oil has drained, loosen the other hose Figure 26. Hydraulic Filter for E2.00-3.20XM
clamp. On the J2.00-3.20XM (J40-60XM and (E45-65XM and E45-65XM 2) (F108); N30XMH
J40-60XM 2) (A216/A416) units, remove the two and N30XMH 2 (C210); and V30ZMD (D210)
screws that fasten the filter. Remove the filter.

41
Filter Replacement
Figure 27. Hydraulic Filter for J2.00-3.20XM
(J40-60XM and J40-60XM 2) (A216/A416)
Install
NOTE: The hydraulic oil filter has a bypass relief
valve that is part of the filter. Make sure the cor-
rect replacement filter with a bypass relief valve is
installed.
1. Install the new filter. Make sure the flow arrow
points toward the hydraulic tank hose. Tighten
the hose clamps and on the J2.00-3.20XM
(J40-60XM and J40-60XM 2) (A216/A416) units,
install and tighten the two screws that fasten
the filter and close hood.
2. Install floor plate and floor mat for lift truck
models E1.50-3.20XM, E2.00XMS (D114),
E2.00-3.20XM (E45-65XM and E45-65XM 2)
(F108), N30XMH and N30XMH 2 (C210) and
V30ZMD (D210)
3. Turn the key to the ON position and operate the
hydraulic system, check for leaks and check oil
level.
42
1900 SRM 559
LIFT TRUCK MODELS [E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098)]
Remove
WARNING
The hydraulic oil is HOT at operating temper-
ature. Do not permit the hot oil to contact the
skin and cause a burn.
CAUTION
Do not permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to compo-
nents of the hydraulic system.
Never operate the pump without oil in the hy-
draulic system. The operation of the hydraulic
pump without oil will damage the pump.
1. Turn key to the OFF position and remove key.
2. Remove floor mate and floor plate.
3. Disconnect hoses that go to the control valve and
mast, from the filter head assembly. If truck
is equipped with a two-stage full free lift mast,
there is no hose connection between filter head
assembly and mast. There is a plug in place of
the fitting. Drain oil from hoses into container.
See Figure 28.
4. Remove screw, nuts, spacer, and lockwasher and
remove clamp that holds the filter and filter head
assembly to tank.
5. Lift filter and filter head assembly from hy-
draulic tank.
Install
1. Remove filter from filter head assembly and in-
stall new filter. Install new O-ring between filter
and filter head assembly.
1900 SRM 559 Filter Replacement

4. Turn the key to the ON position and operate the

hydraulic system, check for leaks and check oil
level.

LIFT TRUCK MODELS [E2.00-3.20XM

(E45-65Z) (G108) AND E1.50-2.00XM
(E25-35Z, E40ZS) (E114/F114)]
Remove

WARNING
The hydraulic oil is HOT at operating temper-
ature. Do not permit the hot oil to contact the
skin and cause a burn.

CAUTION
Do not permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to compo-
nents of the hydraulic system.

Never operate the pump without oil in the hy-

draulic system. The operation of the hydraulic
pump without oil will damage the pump.

1. Turn key to the OFF position and remove key.

2. Remove floor mat and floor plate.

3. Remove the four socket head screws from filter

cover. See Figure 29
1. O-RING
2. CAP 4. Remove filter element from filter housing.
3. DIPSTICK
4. FILTER HEAD ASSEMBLY Install
5. FILTER
6. SCREW 1. Lubricate oil seal on new filter element. If debris
7. NUT
8. SPACER cap was removed from filter element, install cap
9. CLAMP onto new filter element and install filter element
10. LOCKWASHER into filter housing. See Figure 31.
11. BREATHER
12. FITTING 2. Lubricate new O-ring and install new O-ring into
13. FITTING (HOSE TO CONTROL VALVE) filter cover. See Figure 31.
14. PLUG (TWO-STAGE FFL MAST ONLY)
15. FITTING (HOSE TO MAST) 3. Place filter cover onto housing, making sure the
Figure 28. Hydraulic Filter and Filter Head pin on the cover lines up with the notch on the
Assembly for E3.50-5.50XL, E4.50XLS (E70-120Z, housing, and secure cover to housing with four
E100ZS) (D098/E098) Lift Truck Models socket head screws. See Figure 30.

2. Install filter and filter head assembly into hy-
draulic tank. Install the screw, nuts, spacer, and
lockwasher for the clamp. Secure filter and filter
head assembly to tank with clamp.
3. Install floor plate and floor mat.
4. Install floor plate and floor mat.
5. Turn key to the ON position and operate hy-
draulic system, check for leaks and check oil
level.

43
Filter Replacement 1900 SRM 559

NOTE: COMPONENTS OF FRAME HAVE BEEN REMOVED FOR CLARITY

1. RETURN HOSE 6. CAPSCREW
2. CLAMP 7. LOCKWASHER
3. BREATHER 8. INSERT
4. GAUGE 9. MOUNTING BRACKET
5. FILTER COVER 10. SOCKET HEAD SCREWS

Figure 29. Hydraulic Filter Removal for E2.00-3.20XM (E45-65Z) (G108), V30ZMD (D210/E210) and
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) Lift Truck Models

44
1900 SRM 559
LIFT TRUCK MODELS [J2.00-3.20XM
(J40-65Z) (B416)]
Remove
WARNING
The hydraulic oil is HOT at operating temper-
ature. Do not permit the hot oil to contact the
skin and cause a burn.
CAUTION
Do not permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to compo-
nents of the hydraulic system.
Never operate the pump without oil in the hy-
draulic system. The operation of the hydraulic
pump without oil will damage the pump.
1. Turn key to the OFF position and remove key.
2. Remove top counterweight cover and open hood
for access to hydraulic filter assembly. See Fig-
ure 30.
3. Remove the four socket head screws from filter
cover. See Figure 30. Remove O-ring seal from
filter cover and discard O-ring. See Figure 31.
Filter Replacement
4. Remove filter element from filter housing and
discard filter element. If debris cap was removed
with filter element, remove cap from filter ele-
ment. See Figure 31.
Install
1. Lubricate oil seal on new filter element. If debris
cap was removed from filter element, install cap
onto new filter element and install filter element
into filter housing. See Figure 31.
2. Lubricate new O-ring and install new O-ring into
filter cover. See Figure 31.
3. Place filter cover onto housing, making sure the
pin on the cover lines up with the notch on the
housing, and secure cover to housing with four
socket head screws. See Figure 30.
4. Close hood and install counterweight cover.
5. Turn key to the ON position and operate hy-
draulic system, check for leaks and check oil
level.
45
Filter Replacement 1900 SRM 559

1. HOOD 7. HYDRAULIC BREATHER

2. WASHER 8. HYDRAULIC MOTOR
3. CAPSCREW 9. SOCKET HEAD SCREWS
4. COUNTERWEIGHT COVER 10. ALIGNMENT PIN AND NOTCH
5. HYDRAULIC TANK 11. FILTER HOUSING
6. HYDRAULIC FILTER 12. FILTER COVER

Figure 30. Hydraulic Filter Removal for J2.00-3.20XM (J40-65Z) (B416) Lift Truck Models

46
1900 SRM 559 Filter Replacement

Legend for Figure 31

1. COVER O-RING
2. FILTER ELEMENT
3. OIL SEAL
4. DEBRIS CAP

Figure 31. Hydraulic Filter Components for

J2.00-3.20XM (J40-65Z) (B416), E2.00-3.20XM
(E45-65Z) (G108), V30ZMD (D210/E210) and
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) Lift
Truck Models

47
Hydraulic Pump Repair 1900 SRM 559

Hydraulic Pump Repair

NOTE: Worn 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 hydraulic pump.
HYDRAULIC PUMP, REMOVE
[E1.50-3.20XM (E25-65XM, E25-65XM 2)
(D114, F108); N30XMH, AND N30XMH 2
(C210); E1.50-1.75XM, E2.00XMS (E25-35Z,
40ZS) (E114/F114); E2.00-3.20XM
(E45-65Z) (G108); V30ZMD (D210/E210);
AND E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098)]
1. Turn key to OFF position and remove key.
4. Remove pressure hose from pump. Put cap on
open hydraulic hose.
NOTE: In Step 5, remove clamps from pin in pivot
mount bracket to remove pump and motor under bat-
tery. Remove clamps under floor plate for pump and
motor to disconnect pivot mount bracket at motor.
See Figure 34. The motor under the battery will tip
down with force when the bracket is removed. Use
lifting device to keep motor vertical. Make sure lift-
ing device will securely hold motor before disconnect-
ing mount at bottom of motor.
5. Connect sling and crane to motor. See Figure 32.
Make sure crane and sling have a capacity of ap-
proximately 50 kg (110 lb) or more. Disconnect
power cables and mark cables for correct instal-
lation. Disconnect pivot mount bracket from mo-
tor. Use crane to lift hydraulic pump and motor
from lift truck.

WARNING 6. Make a note of the position of the inlet and out-

let ports of the pump for correct alignment to the
Never put tools or other metal on the battery.
motor during assembly. Loosen two setscrews in
Metal on the battery can cause a short circuit
coupling. Remove capscrews that fasten pump
and possible damage or injury.
to motor and carefully remove pump. Do not lose
2. Open hood and remove battery and battery tray. two keys between coupling and each shaft. Re-
See one of the following Service Manual sec- move coupling from shaft.
tions below for battery removal procedure.
Periodic Maintenance 8000 SRM 552 for
the E1.50-2.00XM (E25-40XM, E25-40XM 2)
(D114) and E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108) lift trucks
Periodic Maintenance 8000 SRM 555
for the N30XMH and N30XMH 2 (C210) lift
trucks.
Periodic Maintenance 8000 SRM 1201
for the E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) lift trucks.
Periodic Maintenance 8000 SRM 1060
for E2.00-3.20XM (E45-65Z) (G108), E1.50-
1.75XM, E2.00XMS.(E25-35Z, E40ZS)
(E114/F114), and V30ZMD (D210/E210) lift
trucks.

3. Drain the hydraulic system, turn steering wheel

for a full left turn for access to drain plug near
front of right rear wheel. Install container under
drain plug of hydraulic tank with enough capac- Figure 32. Hydraulic Pump and Motor Removal
ity. See Specifications table at the back of this
section.

48
1900 SRM 559 Hydraulic Pump Repair

HYDRAULIC PUMP, DISASSEMBLE 1. Remove pump coupling from shaft by loosening

E1.50-3.20XM (E25-65XM, E25-65XM 2)
(D114, F108); N30XMH, AND N30XMH 2
(C210); E1.50-1.75XM, E2.00XMS (E25-35Z,
40ZS) (E114/F114); E2.00-3.20XM (E45-65Z)
(G108); AND V30ZMD (D210/E210)
NOTE: If the pump is held in a vise for disassembly,
make sure vise does not hold pump too tightly and
cause distortion of pump body. The O-ring surface of
the outlet port can also be damaged.
Make sure you make careful notes of the location and
orientation of the parts and seals during disassembly.
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.
NOTE: Place an alignment mark on each section of
the pump body to aid in reassembly.
setscrews. Do not lose keys between coupling and
each shaft. See Figure 34.
2. Remove four capscrews that hold pump together.
NOTE: Make note of seal arrangement.
3. Carefully remove end housing.
4. Push shaft through oil seal in flange end housing
as flange end housing is removed from pump.
5. Remove snap ring and oil seal from flange end
housing. Discard oil seals.
6. Carefully remove outer and inner seals from
bushings. Discard seals.
7. Remove and discard seals from pump body.

Figure 33. Hydraulic Gear Pump Assembly for E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114,
F108); N30XMH, and N30XMH 2 (C210); E1.50-1.75XM, E2.00XMS (E25-35Z, 40ZS) (E114/F114);
E2.00-3.20XM (E45-65Z) (G108); and V30ZMD (D210/E210) Lift Truck Models

49
Hydraulic Pump Repair
Legend for Figure 33
1. SNAP RING
2. OIL SEAL
3. END HOUSING
4. OUTER BUSHING SEAL
5. INNER BUSHING SEAL
INSPECT
NOTE: Some pump bodies will show gear marks
where the gears rotate because of the small clear-
ances between the parts. These gear marks do not
indicate a worn or damaged pump unless the pump
will not supply the volume and pressure shown in
the specifications.
Check parts for wear and damage. Remove and dis-
card all seals, replace with new seals. If pump bear-
ings, gears, and shafts are worn or damaged, replace
the pump.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
Clean all parts in solvent. Dry parts with compressed
air. Do not dry the parts with a cloth. Make sure all
surfaces are free of scratches and sharp edges.
PUMP SEAL REPLACE AND PUMP
ASSEMBLE
NOTE: Install new seals during assembly.
50
1900 SRM 559
6. BUSHINGS
7. SEAL
8. PUMP BODY
9. GEAR SET
10. FLANGE END HOUSING
1. Make sure internal parts of pump are clean. Lu-
bricate parts with hydraulic oil as they are in-
stalled in pump.
2. Install new outer and inner seals in bushings.
3. Install gears set and bushing assembly in pump
body. Make sure each bushing is aligned cor-
rectly.
4. Install new seals in flange end and end housing
of pump body. See Figure 33.
5. Make sure all parts are in correct position and
install four capscrews. Tighten capscrews.
6. Install new oil seal on input shaft. Install snap
ring.
ASSEMBLE PUMP ON MOTOR
NOTE: Inspect coupling. If the cushion material
has pieces missing or has distortion, replace cushion
ring.
1. If the coupling half was removed from the pump
or the motor, install coupling and key on pump
shaft. Install key and coupling on motor shaft as
pump is aligned to motor.
2. Make sure the halves of the coupling are cor-
rectly engaged. Make sure Allen screws that fas-
ten coupling to shafts are tight. Make sure pump
is aligned to motor as marked during disassem-
bly. Install capscrews that fasten pump to motor,
and tighten to 31 N•m (23 lbf ft). See Figure 34.
1900 SRM 559 Hydraulic Pump Repair

Figure 34. Hydraulic Pump and Motor Assembly With Mount

51
Hydraulic Pump Repair 1900 SRM 559

Legend for Figure 34

NOTE: ASSEMBLY SHOWN IS FOR E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108), N30XMH AND
N30XMH 2 (C210) AND IS SIMILAR TO J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z)
(A416), E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114), AND E2.00-3.20XM (E45-65Z) (G108), AND V30ZMD
(D210/E210).

NOTE: MOUNT BRACKET (3) INSTALLED FACING OTHER DIRECTION ON J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z) (A416), E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114), AND
E2.00-3.20XM (E45-65Z) (G108), V30ZMD (D210/E210) UNITS.

NOTE: PUMP AND MOTOR CAN BE DIFFERENT THAN SHOWN.

A. MOTOR USED ON J2.00-3.20XM (J40-60XM, B. MOTOR USED ON J2.00-3.20XM (J40-65Z)
J40-60XM 2) (A216) (A416), E1.50-2.00XM (E25-35Z, 40ZS)
(E114/F114), AND E2.00-3.20XM (E45-65Z)
(G108), V30ZMD (D210/E210)
1. PUMP 5. WASHER (2)
2. FLEXIBLE COUPLING 6. PIVOT PIN
3. PIVOT MOUNT BRACKET [E2.00-3.20XM 7. CLAMP ASSEMBLY
(E45-65XM, E45-65XM 2)(F108)] 8. MOTOR
3A. PIVOT MOUNT BRACKET [E1.50-2.00XM 9. SUPPORT [E2.00-3.20XM (E45-65XM,
(E25-40XM, E25-40XM 2) (D114)] E45-65XM 2) (F108) AND E2.00-3.20XM
4. RUBBER BUSHING (2) (E45-65Z) (G108), V30ZMD (D210)/E210]

HYDRAULIC PUMP AND MOTOR, INSTALL
[E1.50-3.20XM (E25-65XM, E25-65XM 2)
(D114, F108); N30XMH, AND N30XMH 2
(C210); E1.50-2.00XM (E25-35Z, 40ZS)
(E114/F114); E2.00-3.20XM (E45-65Z)
(G108); V30ZMD (D210/E210); AND
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098)]
1. Apply Loctite™ 243 to threads of the capscrews
and connect pivot mount bracket to motor.
Tighten capscrews to 16 N•m (142 lbf in). Make
sure bracket is installed so tube of bracket is
on pump side NOT motor side as shown in Fig-
ure 34. Connect sling and crane to motor. See
Figure 32. Make sure crane and sling have a
capacity of approximately 50 kg (110 lb) or more.
Use crane to lift hydraulic pump and motor into
correct position in motor compartment. Connect
power cables as marked during removal.
NOTE: Tighten connections for power cables at M8 ×
1.25 or 5/16 UNC terminals on General Electric mo-
tors to 18 to 22 N•m (159.3 to 195.0 lbf in). Tighten
all other connections for power cables as follows:
5/16 UNC threads - 13.5 to 17.5 N•m (119.5 to
155.0 lbf in)
1/4 UNC threads - 4.0 to 6.0 N•m (35.4 to
53.1 lbf in)
#6 UNC threads - 0.73 to 1.02 N•m (6.5 to
9.0 lbf in)
M8 × 1.25 threads - 13.5 to 17.5 N•m (119.5 to
155.0 lbf in)
M10 × 1.5 threads - 15.0 to 18.0 N•m (132.8 to
159.3 lbf in)
NOTE: If rubber bushings of pivot mount bracket
were removed, use soap or rubber lubricant to in-
stall bushings. Do NOT use oil. The oil will soften
bushings and they will need replacement.
2. Keep motor vertical. Install clamps on rear bulk-
head of battery compartment to mount pump and
motor. Align pivot mount bracket of motor. See
Figure 34. Install clamps over pin in pivot mount
bracket. Make sure to install washers and wire
(ground connection) between mount and clamp
brackets.
3. Remove cap on pressure hose. Install pressure
hose on outlet of pump. Remove plug in inlet hose
and quickly connect inlet hose at pump. Leave
fittings loose.
4. If oil was drained from hydraulic system, make
sure drain plug is installed in tank. If necessary,
turn steering wheel for a full left turn for access
to drain plug near front of right rear wheel. If
drained, fill hydraulic tank with type and quan-
tity of hydraulic oil shown in the Service Man-
ual section Install battery tray and battery and

52
1900 SRM 559
close hood. See one of the following Service
Manual sections below for battery install proce-
dure.
Periodic Maintenance 8000 SRM 552 for
the E1.50-2.00XM (E25-40XM, E25-40XM 2)
(D114) and E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108) trucks
Periodic Maintenance 8000 SRM 555 for
the N30XMH and N30XMH 2 (C210) trucks.
Periodic Maintenance 8000 SRM 1060
for E2.00-3.20XM (E45-65Z) (G108), E1.50-
1.75XM, E2.00XMS.(E25-35Z, E40ZS)
(E114/F114), and V30ZMD (D210/E210)
trucks.
Periodic Maintenance 8000 SRM 1201 for
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) lift trucks.
for lift truck models ERC35-55HG (ERC70-
120HH) (B839/C839) lift trucks.
5. Fill tank to FULL mark on dipstick. If tank
was not drained, remove plug from fill tube. Let
some oil leak from around inlet fitting on pump;
then, tighten capscrews on flanges of fittings to
49 N•m (36 lbf ft). The smaller pump has O-ring
fittings. Tighten outlet hose fitting. Use this pro-
cedure to make sure the pump has oil for first op-
eration.
6. Install top bracket to fasten motor to bulkhead.
7. Operate lift system and check for leaks and check
for leaks.
8. Install battery tray and battery and close hood.
See one of the following Service Manual sec-
tions below for battery install procedure.
Periodic Maintenance 8000 SRM 552 for
the E1.50-2.00XM (E25-40XM, E25-40XM 2)
(D114) and E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108) trucks
Periodic Maintenance 8000 SRM 555 for
the N30XMH and N30XMH 2 (C210) trucks.
Periodic Maintenance 8000 SRM 1060
for E2.00-3.20XM (E45-65Z) (G108), E1.50-
1.75XM, E2.00XMS.(E25-35Z, E40ZS)
(E114/F114), and V30ZMD (D210/E210)
trucks.
Periodic Maintenance 8000 SRM 1201 for
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) lift trucks.
for lift truck models ERC35-55HG (ERC70-
120HH) (B839/C839) lift trucks.
Hydraulic Pump Repair
HYDRAULIC PUMP, REMOVE
[J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216); J2.00-3.20XM (J40-65Z) (A416);
AND J2.00-3.20XM (J40-65Z) (B416)]
NOTE: For removal procedures for lift model
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) see the section Hydraulic Pump,
Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2)
(D114, F108); N30XMH, and N30XMH 2 (C210);
E1.50-1.75XM, E2.00XMS (E25-35Z, 40ZS) (E114/
F114); E2.00-3.20XM (E45-65Z) (G108); V30ZMD
(D210/E210); and E3.50-5.50XL, E4.50XLS (E70-
120Z, E100ZS) (D098/E098)] to remove hydraulic
pump and motor from lift truck.
1. Turn key to OFF position and remove key.
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 hood and install cardboard or plywood
cover on top of battery to prevent accidental
short circuits.
3. Drain the hydraulic system, turn steering wheel
for a full left turn for access to drain plug near
front of right rear wheel. Install container under
drain plug of hydraulic tank with enough capac-
ity. See Specifications table at the back of this
section.
4. Remove pressure hose from pump. Put cap on
open hydraulic hose.
5. Remove the steer motor and mounting bracket.
See the section Steering Pump Repair in this
SRM for the procedures.
6. Connect sling and crane to motor. See Figure 34
and Figure 35. Make sure crane and sling have
a capacity of approximately 50 kg (110 lb) or
more. Disconnect power cables and mark cables
for correct installation. Disconnect pivot mount
bracket from motor. Use crane to lift hydraulic
pump and motor from lift truck.
53
Hydraulic Pump Repair 1900 SRM 559

NOTE: HYDRAULIC MOTOR FOR J2.00-3.20XM (J40-

60XM, J40-60XM 2) (A216) SHOWN, OTHERS SIMI-
LAR.
1. CRANE SLING 4. INLET HOSE
2. MOTOR 5. PUMP
3. MOTOR BRACKET 6. PRESSURE HOSE
7. PIVOT MOUNT
BRACKET

Figure 35. Hydraulic Pump and Motor Removal

7. Make a note of the position of the inlet and out-

let ports of the pump for correct alignment to the
motor during assembly. Loosen two setscrews in
coupling. Remove capscrews that fasten pump
to motor and carefully remove pump. Do not lose
two keys between coupling and each shaft. Re-
move coupling from shaft.

HYDRAULIC PUMP, DISASSEMBLE

[E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) AND J2.00-3.20XM
(J40-65Z) (B416)]
1. Put the pump body in a vise. Put an alignment
mark on each section of the pump body to aid in
reassembly.

2. Remove the capscrews that hold the pump to-

gether. Remove the flange end housing. Remove
the rear valve housing. Do not let the seals and
gears fall. See Figure 36.

3. Make a note of the position of the plate seals

and pressure plates. Carefully remove the plate
seals, backup seals and pressure plates, and
gears from the housings. Discard backup seals
and plate seals. Remove the snap ring and shaft
seal from the flange end housing. Discard shaft
seal.

54
1900 SRM 559 Hydraulic Pump Repair

1. SNAP RING 7. DRIVEN GEAR

2. SHAFT SEAL 8. DRIVE GEAR
3. FLANGE END HOUSING 9. REAR VALVE HOUSING
4. PLATE SEAL 10. CAPSCREW
5. PRESSURE PLATE 11. BACKUP SEAL
6. GEAR HOUSING

Figure 36. Hydraulic Pump, Disassembly for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) and J2.00-3.20XM (J40-65Z) (B416) Lift Truck Models

55
Hydraulic Pump Repair
HYDRAULIC PUMP, INSPECT
[E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) AND J2.00-3.20XM
(J40-65Z) (B416)]
Check parts for wear and damage. If any parts are
worn or damaged, replace the damaged parts. If the
pump housing is damaged, replace the pump.
HYDRAULIC PUMP, CLEAN [E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098)
AND J2.00-3.20XM (J40-65Z) (B416)]
WARNING
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
Clean all parts in solvent. Dry parts with compressed
air. Do not dry the parts with a cloth. Make sure all
surfaces are free of scratches and sharp edges.
HYDRAULIC PUMP, ASSEMBLE
[E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) AND J2.00-3.20XM
(J40-65Z) (B416)]
1. Put oil on all parts of the pump. Use the hy-
draulic oil shown in the maintenance table of the
section Periodic Maintenance 8000 SRM 1201
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098) and Periodic
Maintenance 8000 SRM 1226 for lift truck
models J2.00-3.20XM (J40-65Z) (B416). Make
sure to keep the parts clean.
2. Use new plate and backup seals and install the
pressure plates and gears. Make sure to install
the pressure plates as removed during disas-
sembly. See the notes made during disassembly.
Make sure all seals are complete and in the
correct positions. See Figure 36.
56
1900 SRM 559
3. Install a new shaft seal in the flange end housing.
Carefully install the flange end housing. Do not
move the pressure plates. Make sure the seals
do not move out of the correct position.
4. Carefully install the valve end housing on the
pump body using the four capscrews and lock-
washers. Make sure the pressure plates do not
move and that the seals stay in the correct posi-
tion. Make sure the marks made during disas-
sembly are aligned. Tighten the capscrews to 46
to 49 N•m (34 to 36 lbf ft).
HYDRAULIC PUMP AND MOTOR, INSTALL
[J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216); J2.00-3.20XM (J40-65Z) (A416);
AND J2.00-3.20XM (J40-65Z) (B416)]
1. Turn key to OFF position and remove key.
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 hood and install cardboard or plywood
cover on top of battery to prevent accidental
short circuits.
3. Install coupling onto pump shaft. Install pump
to motor and tighten capscrews to 31 N•m
(23 lbf ft). Connect sling and crane to motor.
See Figure 35. Make sure crane and sling have
a capacity of approximately 113 kg (250 lb) or
more. Use crane to lift hydraulic pump and mo-
tor into correct position in motor compartment.
Make sure isolator mounts are between motor
and chassis bracket. See Figure 36.
4. Connect the temperature and speed sensors (see
Figure 37).
5. Connect the power cables as marked during re-
moval. Tighten connections for power cables to
18 to 22 N•m (159.3 to 195.0 lbf in).
6. Keep motor horizontal and secure motor and
pump to lift truck frame.
7. Install steer motor and mounting bracket. See
the section Steering Pump Repair in this SRM
for the procedures.
1900 SRM 559 Hydraulic Pump Repair

NOTE: HOSES REMOVED FOR CLARITY.

1. GEAR PUMP 8. LOCK NUT
2. CAPSCREW 9. MOTOR MOUNT (ISOLATOR)
3. LOCKWASHER 10. INLET HOSE
4. COUPLING 11. PRESSURE HOSE
5. HYDRAULIC MOTOR 12. SETSCREW
6. MOUNTING BRACKET 13. KEYS
7. WASHER 14. SENSOR CONNECTION

Figure 37. Hydraulic Pump and Motor Assembly With Mounting Brackets for E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098) and J2.00-3.20XM (J40-65Z) (B416) Lift Truck Models

57
Main Control Valve Repair
8. Remove cap on pressure hose. Install pressure
hose on outlet of pump. Remove plug in inlet hose
and quickly connect inlet hose at pump. Leave
fittings loose.
9. If oil was drained from hydraulic system, make
sure drain plug is installed in tank. If neces-
sary, turn steering wheel for a full left turn for
access to drain plug near front of right rear
wheel. If drained, fill hydraulic tank with type
and quantity of hydraulic oil shown in the sec-
tion Periodic Maintenance 8000 SRM 1201
for lift truck models E3.50-5.50XL, E4.50XLS
Main Control Valve Repair
The operation, removal, and repair of the man-
ual hydraulic control valve is described in the
Service Manual sections Manual hydraulic
Control Valve 2000 SRM 562 for lift truck
models E1.50-2.00XM (E25-40XM, E25-40XM 2)
(D114), E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216),
J2.00-3.20XM (J40-65Z) (A416), J2.00-3.20XM
(J40-65Z) (B416) and E2.00-3.20XM (E45-65Z)
(G108).
For lift trucks N30XMH and N30XMH 2 (C210) and
V30ZMD (D210), see Manual hydraulic Control
Valve 2000 SRM 591.
58
1900 SRM 559
(E70-120Z, E100ZS) (D098/E098) and Periodic
Maintenance 8000 SRM 1226 for lift truck
models J2.00-3.20XM (J40-65Z) (B416). Fill
tank to FULL mark on dipstick. If tank was
not drained, remove plug from fill tube. Let
some oil leak from around inlet fitting on pump;
then, tighten capscrews on flanges of fittings to
49 N•m (36 lbf ft). Tighten outlet hose fitting.
Use this procedure to make sure the pump has
oil for first operation.
10. Turn the key to the ON position and operate lift
system, check for leaks and check oil level.
See Manual hydraulic Control Valve 2000
SRM 77 for lift trucks E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098).
The operation, removal, and repair of the electronic
hydraulic control valve is described in the Service
Manual sections Electro-Hydraulic Control
Valve 2000 SRM 1224. For lift trucks models
J2.00-3.20XM (J40-65Z) (B416), E2.00-3.20XM
(E45-65Z) (G108), E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098) and E1.50-2.00XM
(E25-35Z, 40ZS) (F114).
1900 SRM 559
Steering Pump Repair
NOTE: A worn or damaged steering pump is normally
replaced instead of repaired. The cost of repair can
often be more than the cost of a new pump. The fol-
lowing procedure does not include repair.
PUMP, REMOVE AND DISASSEMBLE
[E1.50-3.20XM (E25-65XM, E25-65XM 2)
(D114, F108); N30XMH AND N30XMH 2
(C210); E1.50-1.75XM 2.00XMS (E25-35Z,
E40ZS) (E114)]
1. Disconnect battery connector. Remove floor
plate. Remove battery as described in one of
the following Service Manual sections for the
correct procedure:
Periodic Maintenance 8000 SRM 552 for
the E1.50-2.00XM (E25-40XM, E25-40XM 2)
(D114), E1.50-1.75XM 2.00XMS (E25-35Z,
E40ZS) (E114) and E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108) lift trucks.
Periodic Maintenance 8000 SRM 555
for the N30XMH and N30XMH 2 (C210) lift
trucks.
1. MOTOR
2. HYDRAULIC PUMP - STEERING
3. WASHER (4)
4. RUBBER BUSHINGS (4)
5. CAPSCREW AND NUT (2)
Figure 38. Steering Pump and Motor for E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114) and
E1.50-1.75XM 2.00XMS (E25-35Z, E40ZS) (E114)
Steering Pump Repair
Remove breather for hydraulic tank and install
plug in breather hose. Make sure dipstick/fill cap
is tight. This will help prevent oil flow when the
hydraulic line is disconnected. See Figure 38 or
Figure 39.
2. Put drain pan under steering pump and remove
hose at pump that comes from hydraulic tank.
Oil will flow from hose, so quickly install plug in
hose fitting.
3. Disconnect other hose for steering pump. Install
plug at fitting for hose. If installed, disconnect
electrical plug at pressure switch on bottom of
motor.
4. Install tags for correct connection during instal-
lation and disconnect electrical cables at pump
motor terminals.
5. Install a sling around steering pump and motor
assembly. Connect crane to sling and raise crane
so it is a support for assembly. Make sure crane
and sling have a capacity of 18.5 kg (41 lb) or
more.
6. MOUNT BRACKET
7. FRAME BRACKET
8. MOUNT PIN
9. MOTOR BASE
59
Steering Pump Repair 1900 SRM 559

6. Make a note of the positions of the rubber Legend for Figure 39

bushings at the mount brackets and remove
capscrews that fasten brackets. See Figure 39. 1. MOTOR
2. CAPSCREW (2)
3. BATTERY BULKHEAD
7. Carefully lift steering pump and motor assembly 4. MOTOR BASE
up out of frame. Do not damage pressure switch 5. NUT
on bottom of pump. 6. RUBBER BUSHINGS (4)
7. WASHER (4)
8. CLIP NUT
9. MOUNT BRACKET (2)
10. HYDRAULIC PUMP - STEERING
11. PRESSURE SWITCH FOR ON-DEMAND
STEERING

NOTE: Do not remove mount brackets from motor

base unless motor will be replaced. These brackets
must be correctly aligned on 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 two capscrews
that fasten pump to motor and carefully remove
pump. Remove O-ring at pump shaft.

PUMP, REMOVE AND DISASSEMBLE

[J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216); J2.00-3.20XM (J40-65Z) (A416);
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114);
E2.00-3.20XM (E45-65Z) (G108); V30ZMD
(D210/E210); E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098); AND
J2.00-3.20XM (J40-65Z) (B416)]
1. Turn key to OFF position and remove key.

2. Disconnect battery connector. Remove floor

plate. Remove battery as described in one of
the following Service Manual sections for the
correct procedure:
Periodic Maintenance 8000 SRM 1060
for the J2.00-3.20XM (J40-65Z) (A416),
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108) and V30ZMD
(D210/E210) lift trucks.
Periodic Maintenance 8000 SRM 1201
for the E3.50-5.50XL, E4.50XLS (E70-120Z,
Figure 39. Steering Pump and Motor for E100ZS) (D098/E098) lift trucks.
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108), Periodic Maintenance 8000 SRM 1226 for
N30XMH, N30XMH 2 (C210), and J2.00-3.20XM the J2.00-3.20XM (J40-65Z) (B416) lift trucks.
(J40-60XM, J40-60XM 2) (A216)

60
1900 SRM 559 Steering Pump Repair

3. Put drain pan under steering pump. Remove dip- that fasten pump to motor and carefully remove
stick and install plug in fill tube. Remove hose at pump. Remove O-ring at pump shaft.
pump that comes from hydraulic tank. Oil will
flow from the hose, so quickly install plug in hose
fitting.

4. Disconnect other hose for steering pump. Install

plug at fitting for hose. If installed, disconnect
electrical plug at pressure switch on bottom of
motor.

5. Install tags for correct connection during instal-

lation and disconnect electrical cables at pump
motor terminals.

6. Install sling around steering pump and motor as-

sembly. Connect crane to sling and raise crane so
it is a support for assembly. Make sure crane and
sling have a capacity of 18.5 kg (41 lb) or more.

7. For J2.00-3.20XM (J40-60XM, J40-60XM 2)

(A216) models, make a note of the positions of
the rubber bushings at the mount brackets and
remove capscrews that fasten brackets. See
Figure 39.

8. For J2.00-3.20XM (J40-65Z) (A416, B416),

E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108), V30ZMD
(D210/E210), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098) models, re-
move the two capscrews and washers holding
the motor and pump to mounting weldment.
Remove the metal strap. See Figure 40.

9. Carefully lift steering pump and motor assembly

up out of frame. On J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216) models, do not damage pres-
sure switch on bottom of pump.

NOTE: For J2.00-3.20XM (J40-60XM, J40-60XM 2)

(A216) models, do not remove mount brackets from
motor base unless motor will be replaced. These
brackets must be correctly aligned on motor base.
See Figure 39.
10. Make a note of the position of the inlet and outlet
ports of the pump for correct alignment to the
motor during assembly. Remove two capscrews
Figure 40. Steering Pump and Motor
for J2.00-3.20XM (J40-65Z) (A416, B416);
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114);
E2.00-3.20XM (E45-65Z) (G108); V30ZMD
(D210/E210); and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098) Lift Truck
Models

61
Steering Pump Repair
Legend for Figure 40
A. MOUNTING BRACKET AND HARDWARE
FOR J2.00-3.20XM (J40-65Z) (A416, B416),
E1.50-2.00XM (E25-35Z, 40ZS) (E114F114),
AND E2.00-3.20XM (E45-65Z) (G108), V30ZMD
(D210/E210) LIFT TRUCK MODELS.
B. MOUNTING BRACKET AND HARDWARE FOR
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) LIFT TRUCK MODELS.
1. STEERING MOTOR 6. WASHER
2. STEERING PUMP 7. BRACKET
3. METAL STRAP 8. RUBBER CHANNEL
4. CAPSCREW 9. TRUCK FRAME
5. BRACKET 10. NUT
WELDMENT 11. GROMMET
PUMP, ASSEMBLE AND INSTALL
1. Install new O-ring at shaft of replacement pump.
Install replacement pump on motor using two
capscrews. Make sure pump is correctly aligned
with motor as noted during disassembly.
2. On all models except J2.00-3.20XM (J40-65Z)
(A416, B416), E1.50-2.00XM (E25-35Z, 40ZS)
(E114/F114), E2.00-3.20XM (E45-65Z) (G108),
V30ZMD (D210/E210), and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098),
if the pressure switch was removed, install pres-
sure switch in pump end frame.
3. For E1.50-3.20XM (E25-65XM, E25-65XM 2)
(D114, F108), N30XMH, N30XMH 2 (C210), and
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
model trucks, if mount brackets were removed
from motor base, brackets must be correctly
aligned before installation of assembly. Align
brackets as follows:
a. Install mount brackets on motor base. See
Figure 39. Leave capscrews and nuts loose
so brackets can move.
b. Align two brackets so center lines of cap-
screw holes are 160 mm (6-19/64 in.) apart as
shown in Figure 39. Keep brackets centered
in slots of motor base as much as possible.
c. Carefully tighten capscrews at motor base
without changing alignment.
4. Install sling around steering pump and motor as-
sembly. Use crane to lift and align assembly on
62
1900 SRM 559
the mounts or mounting weldment in lift truck
frame.
5. For E1.50-3.20XM (E25-65XM, E25-65XM 2)
(D114, F108), N30XMH, N30XMH 2 (C210), and
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
model trucks, install mount capscrews, washers,
and rubber bushings as noted during disassem-
bly. See Figure 39. Install clip nut at top left
mount of frame. Tighten capscrews without
compressing rubber bushings.
6. For J2.00-3.20XM (J40-65Z) (A416, B416),
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108), V30ZMD
(D210/E210), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098) trucks, install
the two capscrews and washers that hold the
motor and pump assembly to the mounting
weldment. Install the metal strap around the
mounting weldment and steering motor. See
Figure 40.
7. Connect hydraulic line to outlet port of pump.
Install drain pan under pump and quickly install
hose from hydraulic tank to inlet port.
8. Install electrical plug on terminals of pressure
switch. Install electrical cables on motor termi-
nals as noted during removal.
NOTE: E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) lift trucks use M6 × 1.0 hardware only.
NOTE: Tighten connections for power cables at M8 ×
1.25 or 5/16 UNC terminals on General Electric mo-
tors to 18 to 22 N•m (159.3 to 195.0 lbf in). Tighten
all other connections for power cables as follows:
5/16 UNC threads - 13.5 to 17.5 N•m (119.5 to
155.0 lbf in)
1/4 UNC threads - 4.0 to 6.0 N•m (35.4 to
53.1 lbf in)
#6 UNC threads - 0.73 to 1.02 N•m (6.5 to
9.0 lbf in)
M8 × 1.25 threads - 13.5 to 17.5 N•m (119.5 to
155.0 lbf in)
M10 × 1.5 threads - 15.0 to 18.0 N•m (132.8 to
159.3 lbf in)
M6 × 1.0 threads - 6.5 to 7.0 N•m (57.5 to
62.0 lbf in)
1900 SRM 559
9. Remove plug from breather hose and install
breather. Install battery as described in one of
the following Service Manual sections for the
correct procedure:
Periodic Maintenance 8000 SRM 552
for the E1.50-2.00XM (E25-40XM, E25-
40XM 2) (D114), J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216), and E2.00-3.20XM
(E45-65XM, E45-65XM 2) (F108) trucks.
Periodic Maintenance 8000 SRM 555 for
the N30XMH and N30XMH 2 (C210) trucks.
Periodic Maintenance 8000 SRM 1060
for the J2.00-3.20XM (J40-65Z) (A416),
Rotary Actuator Valve Repair
The rotating actuator valve and the bypass valve
are found on the attachment for the N30XMH and
N30XMH 2 (C210), V30ZMD (D210/E210) lift trucks.
See Figure 41. The instructions for the removal,
installation, and adjustment procedures for these
valves are in the section Attachment 5000 SRM
580.
DISASSEMBLE, CLEAN, AND INSPECT
1. Turn cap with a wrench to remove check valve
assembly from valve body. Push shuttle out of
valve body.
2. Inspect 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 shuttle and bore for dirt or scratches.
The shuttle must slide freely in the bore.
4. Remove two relief valves from valve body by
turning bushings with wrench.
CAUTION
The adjustment of the relief valves is set at the
factory. DO NOT loosen the cap or jam nut from
the bushings. DO NOT turn the adjuster screw.
5. Inspect poppet, ball, and seat for dirt or
scratches. Make sure spring is not bent or
broken.
Rotary Actuator Valve Repair
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108), and
V30ZMD (D210/E210) lift trucks.
Periodic Maintenance 8000 SRM 1201
for lift trucks E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098)
Periodic Maintenance 8000 SRM 1226 for
lift trucks J2.00-3.20XM (J40-65Z) (B416).
10. Install floor plate. Operate steering system and
check for leaks and check oil level.
WARNING
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
6. Clean all parts of rotating actuator valve with
solvent. Use compressed air to dry parts and to
remove dirt from passages.
ASSEMBLE
1. Lubricate relief valve parts with hydraulic oil.
Install new O-rings on bushing.
2. Install relief valves into valve body. Use a
wrench to tighten bushing.
3. Lubricate and install new O-rings and install one
check valve into valve body. Lubricate shuttle
and slide it into bore for check valves. Lubricate
and install other check valve.
4. Install new O-rings on fittings that were re-
moved. Lubricate and install fittings.
63
Steering Control Unit Replacement
Figure 41. Rotary Actuator Valve
Steering Control Unit Replacement
NOTE: See the section Steering Housing and Con-
trol Unit 1600 SRM 512 or Steering Housing and
Control Unit 1600 SRM 720 to repair the steering
control unit. The following is the correct procedure
to remove and install the steering control unit.
NOTE: The repair procedures for the instrument
cluster are in the sections Electrical System,
Replacement, Checks, and Adjustments
Trucks with EV-100/200ZX or SR (SEM) and
SP Motor Controllers 2200 SRM 560 for models
E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114,
F108); J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216); and N30XMH and N30XMH 2 (C210).
For models J2.00-3.20XM (J40-65Z) (A416, B416),
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114), E2.00-
3.20XM (E45-65Z) (G108), V30ZMD (D210/E210),
and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) see the section Electrical System
(Trucks With AC Controllers) 2200 SRM 1055 for
the repair procedures for the display panel.
REMOVE
1. Disconnect battery connector. Move steering col-
umn to forward position. Remove panel under
steering column for access to hoses of steering
control unit.
2. Remove front and rear covers for steering col-
umn. Install tags and disconnect wires for horn
connector and if installed, on-demand power
steering and forward/reverse switches. If in-
stalled, remove parts for on-demand power
64
1900 SRM 559
Legend for Figure 41
1. CHECK VALVES 3. RELIEF VALVES
2. SHUTTLE 4. VALVE BODY
steering and forward/reverse switches and lever.
See the section Steering System for Elec-
tric Lift Trucks 1600 SRM 485 for models
E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114,
F108); J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216); and N30XMH and N30XMH 2 (C210).
See the section Steering System for AC
Electric Lift Trucks 1600 SRM 1054 for
models J2.00-3.20XM (J40-65Z) (A416, B416),
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108), V30ZMD
(D210/E210), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098). Also see the
section Steering Housing and Control Unit
1600 SRM 512 or Steering Housing and Con-
trol Unit 1600 SRM 720.
WARNING
The hydraulic hoses MUST be connected to
the correct 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. Put tags for identification on hydraulic hoses at
steering control unit so they can be connected
correctly during assembly. Disconnect hydraulic
hoses at bottom of steering control unit. Install
plugs at all hose fittings and control unit ports
to prevent dirt from entering steering hydraulic
system.
1900 SRM 559
4. Hold steering column and remove capscrews that
hold steering column and pivot shaft to bracket.
See Figure 42, Figure 43, or Figure 44, depending
on your model of lift truck. Remove two plates,
pivot shaft, and return spring. Remove steering
column assembly. Do not lose push rod, washer,
and spring for latch.
5. Make a note of the alignment of the steering con-
trol unit in the bracket for correct installation.
Remove four capscrews that fasten steering shaft
assembly and steering control unit in steering
column bracket. Do not let steering control unit
or steering wheel and shaft assembly fall. Do not
let washers fall. It is not necessary to remove
steering wheel or on-demand steering parts from
shaft.
INSTALL
1. Install steering control unit in bracket. See Fig-
ure 42, Figure 43, or Figure 44, depending on
your model of lift truck. Make sure it is in correct
alignment, as noted during removal, so hoses can
be correctly connected. Install washers, spacers,
steering shaft assembly, and capscrews to hold
all parts in bracket.
2. Hold bracket assembly in alignment and install
pivot shaft, return spring, plates, washers, and
capscrews to hold assembly on mount. Install
spring, washer, and push rod for latch. Install
column tilt lever on latch. Install Allen screw and
nut.
WARNING
The hydraulic hoses MUST be connected to
the correct 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.
Steering Control Unit Replacement
3. Connect hydraulic hoses at steering control unit
as marked during removal OR see the section
Steering Housing and Control Unit 1600
SRM 512 or Steering Housing and Control
Unit 1600 SRM 720 a for correct connections.
4. If removed, install parts for on-demand power
steering and forward/reverse switches and lever.
See the section Steering System for Elec-
tric Lift Trucks 1600 SRM 485 for models
E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114,
F108); J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216); and N30XMH and N30XMH 2 (C210).
See the section Steering System for AC
Electric Lift Trucks 1600 SRM 1054 for
models J2.00-3.20XM (J40-60Z) (A416, B416),
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108), V30ZMD
(D210/E210), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098). Also see the
section Steering Housing and Control Unit
1600 SRM 512 or Steering Housing and Con-
trol Unit 1600 SRM 720.
5. Connect wires for horn connector and if installed,
on-demand power steering and forward/reverse
switches. Install front and rear covers for steer-
ing column.
WARNING
After making repairs, do not extend hands or
arms through the center of the steering wheel.
Wrong assembly 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 steering system and check for leaks and
correct operation.
65
Steering Control Unit Replacement 1900 SRM 559

Figure 42. Steering Column Assembly for E1.50-3.20XM (E25-65XM) (D114, F108); J2.00-3.20XM
(J40-60XM) (A216); and N30XMH and N30XMH 2 (C210) (Early Models)

66
1900 SRM 559 Steering Control Unit Replacement

Legend for Figure 42

1. STEERING WHEEL, SHAFT, AND ON-DEMAND 15. MOUNT
STEERING PARTS 16. ALLEN HEAD CAPSCREW
2. FRONT COVER 17. CAPSCREW (4)
3. BRACKET 18. PLATE (2)
4. WASHERS 19. PIVOT SHAFT
5. STEERING CONTROL UNIT 20. OPTICAL ENCODER HOUSING
6. SPRING 21. GEAR
7. WASHER 22. OPTICAL ENCODER
8. PUSH ROD 23. SCREW
9. COTTER PIN 24. HORN BUTTON
10. PIN 25. RETURN
11. LATCH 26. INPUT
12. COLUMN TILT LEVER 27. LEFT TURN
13. SCREW 28. RIGHT TURN
14. REAR COVER

67
Steering Control Unit Replacement 1900 SRM 559

Figure 43. Steering Column Assembly for E1.50-3.20XM (E25-65XM 2) (D114, F108) and J2.00-3.20XM
(J40-60XM 2) (A216) (Later Models)

68
1900 SRM 559 Steering Control Unit Replacement

Legend for Figure 43

1. ON-DEMAND STEERING COMPONENTS 18. PIN
2. UPPER COVER 19. STEERING CONTROL UNIT
3. BRACKET 20. PLUG
4. PIVOT SHAFT 21. OPTICAL ENCODER HOUSING
5. PLATE 22. GEAR
6. LOCKWASHER 23. OPTICAL ENCODER
7. CAPSCREW 24. HORN BUTTON
8. LOCK NUT 25. STEERING WHEEL
9. SCREW 26. STEERING COLUMN
10. STATIC GROUND PATCH 27. RETURN SPRING
11. LOWER COVER 28. LARGE HEX NUT
12. COLUMN TILT LEVER 29. INPUT
13. PUSH ROD 30. RIGHT TURN
14. LATCH 31. LEFT TURN
15. SPRING 32. RETURN
16. WASHER 33. PLASTIC RIVET
17. COTTER PIN

69
Steering Control Unit Replacement 1900 SRM 559

Figure 44. Steering Column Assembly for J2.00-3.20XM (J40-65Z) (A416, B416); E1.50-2.00XM
(E25-35Z, 40ZS) (E114/F114); E2.00-3.20XM (E45-65Z) (G108); V30ZMD (D210/E210),; and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) Lift Truck Models

70
1900 SRM 559 Main Control Valve Check and Adjust

Legend for Figure 44

1. ON-DEMAND STEERING COMPONENTS 17. COTTER PIN
2. UPPER COVER 18. PIN
3. BRACKET 19. STEERING CONTROL UNIT
4. PIVOT SHAFT 20. PLUG
5. PLATE 21. HORN BUTTON
6. LOCKWASHER 22. STEERING WHEEL
7. CAPSCREW 23. STEERING COLUMN
8. LOCK NUT 24. RETURN SPRING
9. SCREW 25. STEERING SENSOR (ON-DEMAND)
10. STATIC GROUND PATCH 26. LARGE HEX NUT
11. LOWER COVER 27. INPUT
12. COLUMN TILT LEVER 28. RIGHT TURN
13. PUSH ROD 29. LEFT TURN
14. LATCH 30. RETURN
15. SPRING 31. PLASTIC RIVET
16. WASHER

Steering Cylinder Repair

NOTE: The correct procedure for the removal and re-
pair of the steering cylinder is in the following sec-
tions:
Steering Axle 1600 SRM 619 for the E1.50-
2.00XM (E25-40XM, E25-40XM 2) (D114) and
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114)
trucks
Steering Axle 1600 SRM 258 for E2.00-3.20XM
(E45-65XM, E45-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108), N30XMH and N30XMH 2
(C210), and V30ZMD (D210/E210) trucks.
Steering Axle 1600 SRM 316 for the J2.00-
3.20XM (J40-60XM, J40-60XM 2) (A216) and
J2.00-3.20XM (J40-65Z) (A416, B416) trucks.
Steering Axle 1600 SRM 326 for the E3.50-
5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/
E098) trucks.

Main Control Valve Check and Adjust

NOTE: The adjustments of the relief valves of the
main control valve can be found in one of the follow-
ing Service Manual sections:
• Manual hydraulic Control Valve 2000 SRM 562
for lift truck models E1.50-2.00XM (E25-40XM,
E25-40XM 2) (D114), E1.50-2.00XM (E25-35Z,
40ZS) (E114/F114), E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108), J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216), and J2.00-3.20XM (J40-65Z)
(A416), and for lift truck models J2.00-3.20XM
(J40-65Z) (B416) and E2.00-3.20XM (E45-65Z)
(G108) with a manual hydraulic main control
valve.
• Manual hydraulic Control Valve 2000 SRM 591
For lift trucks N30XMH and N30XMH 2 (C210) and
V30ZMD (D210/E210).
• Manual hydraulic Control Valve 2000 SRM
77 for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098). The adjustment
procedure for the switches of the linkage are also
in the above sections.
• Electro-Hydraulic Control Valve 2000 SRM
1224 for lift truck models J2.00-3.20XM (J40-65Z)
(B416), E1.50-2.00XM (E25-35Z, 40ZS) (F114),
E2.00-3.20XM (E45-65Z) (G108) V30ZMD (E210),
and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098) with a electronic main hydraulic control
valve.

71
Steering Relief Valve Check and Adjust 1900 SRM 559

Steering Relief Valve Check and Adjust

1. Connect pressure gauge to pressure check fitting increase to specification, replace worn or dam-
in pump hydraulic line for steering system under aged pump or relief valve. If pump output is cor-
floor plate. For the E1.50-2.00XM (E25-40XM, rect and steering still does not operate correctly,
E25-40XM 2) (D114) units, see Figure 15. For the check for internal leakage in steering control unit
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108), or steering cylinder.
and N30XMH and N30XMH 2 (C210) units, see
Figure 16. For the J2.00-3.20XM (J40-60XM, 5. When adjustments are complete, install cap on
J40-60XM 2) (A216) units, see Figure 17. relief valve. Remove pressure gauge and install
For J2.00-3.20XM (J40-65Z) (A416, B416), cap on pressure check fitting.
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108), and V30ZMD
(D210/E210) trucks, see Figure 18. For the
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) units, see Figure 19. The pressure
gauge can also be installed at the port on the
bottom of the pump. See Figure 45.

2. Operate hydraulic system to warm oil until oil

temperature is 54 to 66 C (129 to 151 F). Turn
steering wheel to stop and hold it in that position.

CAUTION
Do not hold the steering against the stop for
more than 3 to 5 seconds or the power steering
fuse will open. Also, the oil in the pump will NOTE: PRESSURE SWITCH IS NOT FOUND ON
quickly become hot and cause damage to the J2.00-3.20XM (J40-65Z) (A416, B416), E1.50-2.00XM
pump. (E25-35Z, 40ZS) (E114/F114), E2.00-3.20XM
(E45-65Z) (G108), V30ZMD (D210/E210) AND
3. Check pressure on gauge against correct pres- E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
sure in the Specifications table at the back of this (D098/E098) LIFT TRUCK MODELS.
section.
1. RELIEF VALVE
4. If the pressure on the gauge is not correct, re- 2. PRESSURE SWITCH INSTALLS AT THIS PORT
move cap on relief valve at steering pump. Adjust
Figure 45. Steering Pump
relief valve to correct pressure. Turn adjustment
clockwise to increase pressure or counterclock-
wise to decrease pressure. If pressure will not

72
1900 SRM 559
Specifications
RELIEF VALVE PRESSURES*
E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114)
and E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114)
Hydraulic System 17.9 ±0.7 MPa (2600 ±100 psi)
Steering System 5690 ±248 kPa (828 ±36 psi)
Tilt and Auxiliary Systems 15.50 ±0.7 MPa
(2250 ±100 psi)
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
and N30XMH and N30XMH 2 (C210)
Hydraulic System 20.7 ±0.7 MPa (3000 ±100 psi)
Steering System 8620 ±345 kPa (1250 ±50 psi)
Tilt and Auxiliary Systems 15.5 ±0.7 MPa
(2250 ±100 psi)
J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216), J2.00-3.20XM (J40-65Z) (A416,
B416), E2.00-3.20XM (E45-65Z) (G108),
and V30ZMD (D210/E210)
Hydraulic System 20.7 ±0.7 MPa (3000 ±100 psi)
Hydraulic System - J2.00-3.20XM (J40-65Z)
(B416) Models 20.7 ±0.70 MPa (3000 ±100 psi)
Steering System 8909 ±345 kPa (1292 ±50 psi)
Steering System - E2.00-3.20XM (E45-65Z)
(G108) Models 8620 ±248 kPa (1250 ±36 psi)
Tilt and Auxiliary Systems 15.5 ±0.7 MPa
(2250 ±100 psi)
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098)
Hydraulic System 20.7 ±0.7 MPa (3000 ±100 psi)
Steering System 10,342 ±345 kPa (1500 ±50 psi)
Tilt and Auxiliary Systems 15.75 ±0.7 MPa
(2250 ±100 psi)
HYDRAULIC TANK CAPACITY (DIPSTICK
FULL MARK)
E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114)
11.3 liter (3.0 gal)
*Oil temperature at 54 to 66 C (130 to 150 F).
Specifications
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108);
E2.00-3.20XM (E45-65Z) (G108); N30XMH
and N30XMH 2 (C210); V30ZMD (D210/E210);
J2.00-3.20XM (J40-60XM, J40-60XM 2
(A216); J2.00-3.20XM (J40-65Z) (A416); and
E2.00-3.20XM (E45-65Z) (G108)
22.0 liter (5.6 gal)
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098)
Short Frame 33.3 liter (8.8 gal)
Long Frame 39.7 liter (10.5 gal)
J2.00-3.20XM (J40-65Z) (B416); J2.00-3.20XM
(J40-60XM, J40-60XM 2 (A216); J2.00-3.20XM
(J40-65Z) (A416);
27.4 liter/min (7.25 gal)
HYDRAULIC PUMP CAPACITIES - ALL
MODELS EXCEPT E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098)
Large Hydraulic Pump 19 cc/revolution
(1.16 in 3/revolution)
Small Hydraulic Pump 12 cc/revolution
(0.73 in 3/revolution)
Steering Pump 4.23 cc/revolution (0.26
in 3/revolution)
HYDRAULIC PUMP CAPACITIES -
MODELS E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098)
Hydraulic Pump 29 cc/revolution (1.77
in 3/revolution)
Steering Pump 6.36 cc/revolution (0.39
in 3/revolution)
73
Troubleshooting 1900 SRM 559

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

STEERING

The steering wheels do not The oil level is low or there is no oil Fill tank. Check for leaks.
move when the steering in the tank.
wheel is turned.

The steering control unit is dam- Repair or install new control unit.
aged.

No oil flow from the steering control Repair or install new components.
unit to the steering cylinder. Check for leaks.

Slow or difficult steering. Relief valve for the steering system Adjust or install new relief valve.
needs adjustment.

Low oil pressure from the steering Check for restrictions. See Trou-
pump. bleshooting Chart Hydraulic Sys-
tem.

Seal in the steering cylinder has a Install new seal.

leak.

Steering control unit is worn or has Repair or install new control unit.
damage.

Steering wheel turns the The hydraulic lines are not con- Connect lines properly. Remove air
tires in the wrong direction. nected correctly at the steering from system.
cylinder or at the steering control
unit.

Steering function contin- The steering control unit was assem- Repair or install new control unit.
ues after the steering wheel bled wrong or has damage.
stops.

There is air in the steering The oil level in the tank is low. Add hydraulic oil as necessary.
system. Check for leaks.

Air was not removed after repair to Remove air from system.
the hydraulic or steering system.

The steering pump has an air leak at Repair system. Remove air from sys-
the inlet. tem.

74
1900 SRM 559 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

STEERING HOUSING AND STEERING CONTROL UNIT

The wheels do not move The oil level is low or there is no oil Fill tank to correct level. Check for
when the steering wheel is in the tank. leaks.
turned.

The steering control unit is dam- Repair or install new control unit.
aged.

No oil flow from the steering control Repair or install new components.
unit to the steering cylinder. Check for leaks.

The sleeve and spool in the control Install new components.

unit will not move.

Hydraulic hoses not connected or Check for leaks. Tighten connec-

have damage. tions. Install new components as
necessary.

Slow or difficult steering. Relief valve for the steering system Adjust or install new relief valve.
is not adjusted correctly.

Low oil pressure from the steering Check for restrictions. See Trou-
pump. bleshooting Chart, Hydraulic Sys-
tem.

Seal in the steering cylinder has a Repair cylinder. Install new seal or
leak. new cylinder.

Hydraulic lines are too small or have Remove restrictions. Install larger or
restrictions. new hydraulic lines.

Steering control unit is worn, not as- Repair or install new control unit.
sembled correctly, or has damage.

Steering wheel turns the The hydraulic lines are not con- Connect lines correctly. Remove air
tires in the wrong direction. nected correctly at the steering from system.
cylinder or at the steering control
unit.

Steering function contin- The steering control unit is assem- Repair or install new control unit.
ues after the steering wheel bled wrong or has damage.
stops.

75
Troubleshooting 1900 SRM 559

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The steering operation is not The oil level in the tank is low. Fill tank. Check for leaks.
smooth.

Air was not removed after repair to Remove air from system.
the hydraulic system.

The steering control unit is assem- Repair or install new control unit.
bled wrong or has damage.

The steering pump has a leak at the Fix leaks. Remove air from system.
inlet.

HYDRAULIC SYSTEM

The pump makes more noise The oil level is not correct or there is Check oil level and fill as required.
than normal. no oil in the tank (cavitation). Check for leaks.

Wrong type or grade of hydraulic Check, drain tank, and fill with cor-
oil for the temperature or operation rect specified oil.
(cavitation).

The suction screen has a restriction Clean or install new screen.

(cavitation).

The inlet fitting is loose or hoses are Tighten fitting. Install new hoses.
allowing air to enter the system (aer- Remove air from system.
ation).

The pump bearings or gears have Repair or install new pump.

damage.

The capscrews that hold the pump Tighten capscrews to specified

together are loose. torque.

The pump is loose at the motor Tighten fasteners to specified torque.

mounting.

The pump drive mechanism is loose, Check, repair, or install new parts as
is worn, or has damage. required.

76
1900 SRM 559
PROBLEM POSSIBLE CAUSE
The output of the pump is See Possible Cause for the Prob-
less than specifications. lem The pump makes more noise
than normal above.
The pump has leaks. The fittings or hoses on the outlet
side of the pump are loose or dam-
aged.
The capscrews that hold the pump
together are loose.
The seals in the pump are damaged.
Troubleshooting
PROCEDURE OR ACTION
See the section Capacities and
Specifications 8000 SRM 561 for
trucks E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108); N30XMH and
N30XMH 2 (C210); and J2.00-3.20XM
(J40-60XM, J40-60XM 2) (A216); Ca-
pacities and Specifications 8000
SRM 621 for the E1.50-1.75XM,
E2.00XMS (E25-35XM, E40XMS,
E25-40XM 2) (D114) trucks; Capaci-
ties and Specifications 8000 SRM
1061 for J2.00-3.20XM (J40-65Z)
(A416); and Capacities and Spec-
ifications 8000 SRM 1083 for
E1.50-2.00XM (E25-35Z, 40ZS)
(E114/), E2.00-3.20XM (E45-65Z)
(G108), and V30ZMD (D210)
trucks, and Capacities and Spec-
ifications 8000 SRM 1202 for
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) lift trucks
Capacities and Specifications
8000 SRM 1227 for lift truck models
J2.00-3.20XM (J40-65Z) (B416) 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 new pump.
77
Troubleshooting 1900 SRM 559

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The pressure for the steer- The relief valve at the pump is not Adjust or install new relief valve.
ing system is below specifi- adjusted correctly.
cations.

The relief valve has damage. Repair or install new relief valve.

The pump is worn. Repair or install new pump.

The flow for the steering sys- The pump has damage, is worn, or Check that inlet hose is not soft or
tem is below specifications. has a restriction. has a restriction or air leak. Check,
and if necessary, replace pump.

The relief valve is not adjusted cor- Adjust or install new relief valve.
rectly.

NOTE: Troubleshooting for the main control valve is
in the section Manual hydraulic Control Valve
2000 SRM 562 for the E1.50-2.00XM (E25-40XM,
E25-40XM 2) (D114), E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108), J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216), and E1.50-2.00XM (E25-35Z,
40ZS) (E114/F114), and for J2.00-3.20XM (J40-65Z)
(B416), and E2.00-3.20XM (E45-65Z) (G108) trucks
with a manual hydraulic control valve. For the
N30XMH and N30XMH 2 (C210), and V30ZMD
(D210) model trucks, see the section Manual hy-
draulic Control Valve 2000 SRM 591. For lift
truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098), see the section Manual hy-
draulic Control Valve 2000 SRM 77. For lift
truck models J2.00-3.20XM (J40-65Z) (B416) with
a electronic hydraulic control valve, see the sec-
tion Electro-Hydraulic Control Valve 2000 SRM
1224.

78
 TECHNICAL PUBLICATIONS

1900 SRM 559 2/09 (11/06)(3/06)(1/06)(3/05)(5/04)(11/03)(3/03)(5/96)(2/96)(5/95)(11/94) Printed in U.S.A.