Hydraulic System

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
General
This section describes the hydraulic system and • Lift Cylinders 4000 SRM 741 for lift truck mod-
the steering system. The section includes repairs, els E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
checks, adjustments, and troubleshooting. This (D098/E098)
section has repair procedures for the main hydraulic • Steering Housing and Control Unit 1600 SRM
pump and the steering pump. Other repair proce- 512 or Steering Housing and Control Unit 1600
dures are in the following sections: SRM 720
• Manual hydraulic Control Valve 2000 SRM 562 • Steering Axle 1600 SRM 258 for E2.00-3.20XM
for models E1.50-2.00XM (E25-40XM, E25-40XM 2) (E45-65XM, E45-65XM 2) (F108), E2.00-3.20XM
(D114), E1.50-2.00XM (E25-35Z, 40ZS) (E114), (E45-65Z) (G108), N30XMH, N30XMH 2 (C210),
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108), and V30ZMD (D210/E210) lift trucks
E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM • Steering Axle 1600 SRM 316 for J2.00-3.20XM
(J40-60XM, J40-60XM 2) (A216), 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) (J40-65Z) (A416), and J2.00-3.20XM (J40-65Z)
(B416) lift trucks with a manual hydraulic control (B416) lift trucks
valve. • Steering Axle 1600 SRM 619 for E1.50-2.00XM
• Manual hydraulic Control Valve 2000 SRM 591 (E25-40XM, E25-40XM 2) (D114) and E1.50-
for N30XMH, N30XMH 2 (C210), V30ZMD (D210/ 2.00XM (E25-35Z, 40ZS) (E114/F114) model lift
E210) lift truck models, trucks
• Manual hydraulic Control Valve 2000 SRM 77 • Steering Axle 1600 SRM 326 for lift truck mod-
for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) els E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) lift truck models, and (D098/E098)
• Electro-Hydraulic Control Valve 2000 • DC Motor Maintenance 620 SRM 294 for
SRM 1224 for lift truck models J2.00-3.20XM E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114),
(J40-65Z) (B416), E1.50-2.00XM (E25-35Z, 40ZS) E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
(F114), E2.00-3.20XM (E45-65Z) (G108) and E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) E2.00-3.20XM (E45-65Z) (G108), N30XMH,
(E098) with an electronic hydraulic control valve. N30XMH 2 (C210), V30ZMD (D210/E210),
• Mast Repairs, 2 and 3-Stage Masts 4000 SRM J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216),
522 J2.00-3.20XM (J40-65Z) (A416) and J2.00-3.20XM
• Four-Stage Mast 4000 SRM 563 (J40-65Z) (B416) lift trucks
• Mast, Repair 4000 SRM 482 lift truck mod- • AC Motor Repair 620 SRM 1053 for lift truck
els N30XMH, N30XMH 2 (C210), and V30ZMD models J2.00-3.20XM (J40-65Z) (A416) and J2.00-
(D210/E210) 3.20XM (J40-65Z) (B416)
• Mast Repairs, 2, 3, and 4-Stage Masts 4000 • AC Motor Repair 620 SRM 1098 for lift truck
SRM 1148 models V30ZMD (D210/E210), E1.50-2.00XM
• Masts, Description and Repairs 4000 SRM (E25-35Z, 40ZS) (E114/F114), E2.00-3.20XM
736 for lift truck models E3.50-5.50XL, E4.50XLS (E45-65Z) (G108), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098) (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)
1
Description 1900 SRM 559
Description
HYDRAULIC SYSTEM E100ZS) (D098/E098), are shown in Figure 6. The
parts of the hydraulic system for lift truck models
The parts of the hydraulic system for the E1.50- J2.00-3.20XM (J40-65Z) (B416) with an electronic
3.20XM (E25-65XM, E25-65XM 2) (D114, F108), hydraulic control valve are shown in Figure 7. The
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114), and parts of the hydraulic system for lift truck models
E2.00-3.20XM (E45-65Z) (G108) (early models), J2.00-3.20XM (J40-65Z) (B416) with a manual hy-
V30ZMD (D210/E210) are shown in Figure 1. The draulic control valve are shown in Figure 8. The
parts of the hydraulic system for the J2.00-3.20XM diagrams show components and interconnections
(J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM that are typical of all models. It does not show all
(J40-65Z) (A416) are shown in Figure 4. The parts hydraulic systems. Not all units have a four-spool
for the hydraulic system for E2.00-3.20XM (E45-65Z) valve.
(G108) and V30ZMD (D210/E210) are shown in Fig-
ure 2 and Figure 3. The parts of the hydraulic system The hydraulic system includes the steering system
for the N30XMH and N30XMH 2 (C210), are shown and the lift system. One hydraulic tank supplies both
in Figure 5. The parts of the hydraulic system for lift systems. The steering system and the lift system
truck models E3.50-5.50XL, E4.50XLS (E70-120Z, have separate pumps. Both pumps are gear pumps.
2
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
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
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
Figure 3. Hydraulic System for E2.00-3.20XM (E45-65Z) (G108) and V30ZMD (E210) Lift Trucks
With E-Hydraulic Controls
6
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
1. FILTER 8. TO AUXILIARY HYDRAULIC FUNCTIONS

2. BREATHER 9. TO LIFT CYLINDERS
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
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
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
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
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 steering pump causes oil to flow from the tank
to the steering control unit. The steering control unit
The hydraulic pump causes oil to flow from the is a metering pump actuated by the steering wheel.
tank to the main control valve. See Figure 9, Fig- When the steering wheel is turned, oil flows to actu-
ure 10, Figure 12, or Figure 13. For lift truck models ate the steering cylinder. Oil returns from the steer-
V30ZMD (D210/E210). See Figure 11 and Figure 14. ing control unit to the main control valve. A relief
The main control valve controls the flow of oil to the valve in the pump keeps pressure within the design
lift cylinders, tilt cylinders, traverse cylinder, rotary limits of the steering system.
actuator, and auxiliary functions when applicable. A
relief valve on the main control valve keeps pressure The oil returns from the main control valve and flows
within the design limits of the hydraulic system. A through a filter in the hydraulic tank. The filter re-
test port for checking the pressure when the relief moves small particles from the oil. The filter has a
valve opens is on the main control valve. bypass valve so that the oil can flow through the sys-
tem if the filter becomes too dirty.
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.
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
Figure 10. Hydraulic Schematic With Manual Hydraulics Controls for N30XMH and N30XMH 2
(C210) and V30ZMD (D210) (Early Models)
14
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
Figure 11. Hydraulic Schematic With Manual Hydraulics Controls for Lift Trucks Model V30ZMD
(D210/E210) (Later Models)
16

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
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

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
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

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
Figure 14. Hydraulic Schematic With E-Hydraulic Controls for Lift Trucks Model V30ZMD (E210)
22

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 the inlet check valve and at the same time the shuttle
pushes against the return check valve. The shuttle
For all lift truck models covered in this manual, moves the check valve from its seat and permits oil to
except for E3.50-5.50XL, E4.50XLS (E70-120Z, flow to the hydraulic tank. A relief valve opens when
E100ZS) (D098/E098), there can be two different the rotary actuator moves to the end of its stroke.
sizes of hydraulic pumps used: a 12 cc/revolution One relief valve is installed for each direction of ro-
gear pump or a 19 cc/revolution gear pump. The tary actuator travel. These relief valves also protect
larger pump is standard. See Figure 33. The smaller the rotary actuator from damage if the forks hit an
pump is used when there is a contactor motor control object. An adjustable bypass valve for the rotary ac-
with a closed motor or for a slower speed require- tuator is connected in parallel to the rotary actuator
ment. For lift truck models E3.50-5.50XL, E4.50XLS valve. The bypass valve permits some of the oil from
(E70-120Z, E100ZS) (D098/E098), a 29 cc/revolution the main control valve to flow directly to the return
gear pump is used. See Figure 36. line. The bypass valve decreases the speed of the ro-
tary actuator.
These hydraulic pumps are all single-section gear
pumps that fasten to the end of the motor housing. A For the location of the pressure check fitting for steer-
hose connects the pump inlet to the hydraulic tank. ing pressure, see Figure 15, Figure 16, Figure 17, or
A hose connects the pump outlet to the main control Figure 18.
valve. A flexible coupling connects the motor shaft to
the pump shaft. Bushings at each side of each gear STEERING PUMP
of the pump are the bearings for the gear shafts. The
bushings also have passages for the oil flow to the NOTE: Lift truck models J2.00-3.20XM (J40-65Z)
pump outlet and for lubrication. Seals prevent leaks (A416), E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
between sections of the pump housing. E2.00-3.20XM (E45-65Z) (G108), V30ZMD (D210/
E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
ROTATOR ACTUATOR VALVE (D098/E098), and J2.00-3.20XM (J40-65Z) (B416) do
not contain a pressure switch on the steering pump
On the N30XMH and N30XMH 2 (C210), V30ZMD for the On-Demand Steering system.
(D210/E210) only, the rotary actuator valve is con-
nected between the rotary spool and the rotary actu- The steering pump is a small gear pump connected
ator. The rotary actuator valve has two check valves, to the bottom of the steering motor. See Figure 15,
a shuttle, and two relief valves. The check valves Figure 16, Figure 17, Figure 18 or Figure 19.
prevent the rotary actuator from rotating when the The steering pump and motor are in a horizon-
lever on the main control valve is in the center posi- tal mount under the battery compartment on the
tion. The check valves prevent any oil flow from the E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114) and
rotary actuator until pressure from the main control E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114) trucks.
valve pushes on the shuttle. The oil pressure opens The steering pump and motor are in a vertical
23
mount under the floor plate on the E2.00-3.20XM (J40-65Z) (A416), and J2.00-3.20XM (J40-65Z)
(E45-65XM, E45-65XM 2) (F108), E2.00-3.20XM (B416). trucks. Capscrews hold the motor mount
(E45-65Z) (G108), N30XMH, N30XMH 2 (C210), to the frame mount bracket that has isolators. A
V30ZMD (D210/E210), and E3.50-5.50XL, E4.50XLS relief valve and a pressure switch are mounted at
(E70-120Z, E100ZS) (D098) trucks. The steering ports in the pump housing. The pressure switch at
pump and motor are also in a vertical mount that the bottom of the pump is used with On-Demand
is located behind the battery on the J2.00-3.20XM Steering only.
(J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM
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
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
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

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
Figure 17. Steering Pump and Hydraulic Circuit for J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
Lift Truck Models
28

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
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

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
Figure 19. Steering Pump and Hydraulic Circuit for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) Lift Truck Models
32

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

1. Install container under drain plug of hydraulic
WARNING tank with enough capacity. See the Specifica-
Before making any repairs, fully lower all parts tions table at the back of this section. See Fig-
of the mast and tilt it forward until the tips of ure 20 or Figure 21.
the forks touch the ground. This action will
prevent the mast from lowering suddenly when 2. Remove drain plug and let oil drain from hy-
hydraulic lines are disconnected. 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. A. E1.50, 1.75XM, 2.00XMS (E25-35XM, E40XMS)
(D114), E1.50-1.75XM, E2.00XMS (E25-35Z,
See General at the beginning of this service manual E40ZS) (E114)
section, for a list of sections of the Service Manuals B. E1.50-1.75XM, E2.00XMS (E25-35Z, E40ZS)
for hydraulic parts other than the pumps and tank. (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
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
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.
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
INSPECT CLEAN
Make visual inspection of all sides of tank. Inspect
welds for cracks and leakage. Check for wet areas,
WARNING
accumulation of dirt, and loose or missing paint Special procedures must be followed when
caused by leakage. Areas of the tank that are not large leaks or other repairs need welding or
easily seen can be checked with an inspection mir- cutting. All work must be done by authorized
ror and a light that is approved for locations with personnel. If the tank is cleaned inside of a
flammable vapors. building, make sure there is enough ventila-
tion. See the following manuals for additional
For all lift truck models covered in this manual, information:
except for E3.50-5.50XL, E4.50XLS (E70-120Z, • Safe Practices for Welding and Cutting Con-
E100ZS) (D098/E098) truck models, the hydraulic tainers that Have Held Combustibles by the
tank is a separate sheet metal tank and can be American Welding Society, F4.1 - 1999
removed from the lift truck if necessary to check • Safety In Welding and Cutting, American Na-
for leaks or for replacement. On lift truck mod- tional Standard, AWS Z 49.1 - 1999
els E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), the hydraulic tank is a part of the When cleaning tank, do not use solutions that make
frame and cannot be removed or installed sepa- dangerous gases at normal temperatures or when
rately from the frame weldment. However, it can be heated. Wear eye and face protection. Protect body
checked for leaks. from burns.
Repairs for leaks in the hydraulic tank can require Steam Method
special procedures described in the next paragraphs.
The most common cause of leaks is from rust caused WARNING
by the moisture of condensation. Drain any water Compressed air can move particles so that they
out of tank by removing drain plug and letting tank cause injury to the user or to other personnel.
drain until there is no water in oil. Make sure that the path of the compressed air
is away from all personnel. Wear protective
SMALL LEAKS, REPAIR goggles or a face shield to prevent injury to the
Use the following procedure to seal small leaks: eyes.
1. Use steam to clean area around leak. Remove all When cleaning with steam, use a hose with a min-
paint and dirt around leak. 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
WARNING material that does not make sparks. Make an elec-
Do not use tools that can make sparks, heat, or trical connection between nozzle and tank. Connect
static electricity. The vapors in the tank can ground wire to tank to prevent static electricity.
cause an explosion.
Use the following procedure to clean the tank with
2. Apply Loctite® 290 to leak. Follow instructions steam:
of manufacturer.
NOTE: Remove battery before cleaning the tank
LARGE LEAKS, REPAIR for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098).
1. Use one of the procedures described under Clean,
Steam Method or Chemical Solution Method of 1. Remove all parts from tank. Install drain plug.
cleaning tank to clean and prepare tank for re-
pairs. 2. Fill tank 1/4 full with a solution of water and
sodium bicarbonate (baking soda) or sodium car-
2. Use acceptable welding practices to repair tank. bonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of wa-
See the American National Standard Safety In ter.
Welding and Cutting AWS Z 49.1 - 1999.
38
3. Mix solution in tank using air pressure. Make When making inspections, use a light that is ap-
sure all surfaces on inside of tank are flushed proved for locations with flammable vapors.
with solution. Drain tank.
5. Check tank for flammable vapors as described
4. Put steam into tank until tank does not have in the previous section Step 7. If the amount
odors and metal is hot. Steam vapors must come of flammable vapors is not below the lower
from all the openings. flammable limit, repeat cleaning procedures.
5. Flush inside of tank with boiling water. Make ADDITIONAL METHODS FOR TANK
sure all loose material is removed from inside of REPAIR
tank.
If nitrogen gas or carbon dioxide gas is available, pre-
6. Make an inspection of inside of tank. If it is not pare tank for welding using these gases. See the
clean, repeat Step 4 and Step 5 and make another manual Safe Practices for Welding and Cutting Con-
inspection. When making inspections, use a light tainers that Have Held Combustibles by the Ameri-
that is approved for locations with flammable va- can Welding Society, F4.1 - 1999. If these gases are
pors. not available, another method using water can be
7. Put plugs in all openings in tank. Wait 15 min- used as follows:
utes, then remove inlet and outlet plugs. Test a 1. Fill tank with water to just below the point where
sample of the vapor with a special indicator for the work will be done. Make sure the space above
gas vapors. If the amount of flammable vapors is the level of the water has a vent.
above the lower flammable limit, repeat cleaning
procedures. 2. Use acceptable welding practices to repair the
tank. See the American National Standard
Chemical Solution Method "Safety in Welding and Cutting," AWS Z 49.1 -
1999.
If the tank cannot be cleaned with steam, use the
following procedure: TANK, INSTALL [E1.50-3.20XM (E25-65XM,
NOTE: Remove battery before cleaning the tank E25-65XM 2), (D114, F108); E1.50-2.00XM
for lift truck models E3.50-5.50XL, E4.50XLS (E25-35Z, 40ZS) (E114/F114); E2.00-3.20XM
(E70-120Z, E100ZS) (D098/E098). (E45-65Z) (G108); N30XMH AND N30XMH 2
1. Mix a solution of water and trisodium phosphate (C210); AND V30ZMD (D210/E210)]
or a cleaning compound with an alkali base. Fol-
NOTE: Make sure to install tank so fill neck is cen-
low instructions given by manufacturer.
tered in opening in step of frame. Make sure to in-
stall all plugs, hoses, and clamps to prevent leaks
WARNING when oil is added to the tank.
Compressed air can move particles so that they
cause injury to the user or to other personnel. 1. Install repaired or replacement hydraulic tank in
Make sure that the path of the compressed air truck frame. See Figure 20 and Figure 21. Make
is away from all personnel. Wear protective sure tank is correctly aligned for connection of
goggles or a face shield to prevent injury to the the hoses. Make sure pads are installed between
eyes. tank and truck frame.
2. Fill tank with cleaning solution. Use compressed 2. Install bracket assembly to hold tank in position.
air to mix solution in tank. Do not tighten screws.
3. Drain tank. Flush inside of tank with hot (boil- 3. Remove plugs and install all hoses at the same lo-
ing) water. Make sure all cleaning compound is cations as during removal. Do NOT remove drain
removed. plug. Align tank so fill tube and fill cap will be
in the center of the access hole. Install fill tube
4. Make an inspection of the inside of the tank. and fill cap. Tighten screws that fasten mount
If the tank is not clean, repeat Step 1 through bracket assembly.
Step 3. Make another inspection of the tank.
39
CAUTION CAUTION
Do NOT fill the tank above the FULL mark on Do NOT fill the tank above the FULL mark on
the dipstick. If the tank is too full, oil will come the dipstick. If the tank is too full, oil will come
out the breather during operation. out the breather during operation.
4. Make sure all hoses and plugs are installed and 5. Make sure all hoses and plugs are installed and
tight. Fill the tank using the oil specified in one tight. Fill tank to the FULL mark on dipstick
of the following Service Manual sections: using the oil specified in the following Service
Periodic Maintenance 8000 SRM 552 for Manual section and install breather and fill
the E1.50-2.00XM (E25-40XM, E25-40XM 2) cap. See Periodic Maintenance 8000 SRM
(D114) and E2.00-3.20XM (E45-65XM, 552 for J2.00-3.20XM (J40-60XM, J40-60XM 2)
E45-65XM 2) (F108) models and Peri- (A216) and Periodic Maintenance 8000 SRM
odic Maintenance 8000 SRM 1060 for 1060 for J2.00-3.20XM (J40-65Z) (A416) for
models E1.50-2.00XM (E25-35Z, 40ZS) ERP20-30ALF (ERP040-060DH) (D216) lift
(E114/F114) and E2.00-3.20XM (E45-65Z) truck models.
(G108), V30ZMD (D210/E210).
Periodic Maintenance 8000 SRM 555 for 6. Operate lift and steering systems and check for
the N30XMH and N30XMH 2 (C210) trucks leaks and check oil level.
Loosen clamp at inlet hose of hydraulic pump to TANK, INSTALL [J2.00-3.20XM (J40-65Z)
let air out until hose fills with oil. Tighten hose (B416)]
clamp as soon as oil leaks out of hose. Do the
same procedure for steering pump. 1. Turn key to OFF position and remove key.
5. Remove traction motor as described in one of the

following the frame SRM for your lift truck.
WARNING
6. Operate lift and steering systems and check for Metal on the battery can cause a short circuit
leaks and check oil level. and possible damage or injury.
TANK, INSTALL [J2.00-3.20XM (J40-60XM, 2. Open hood and install cardboard or plywood
J40-60XM 2) (A216) AND J2.00-3.20XM cover on top of battery to prevent accidental
short circuits.
(J40-65Z) (A416)]
3. Carefully position hydraulic tank over correct po-
1. Turn key to OFF position and remove key. sition in frame and connect hoses to bottom of
tank. Lower tank into correct position in frame.
WARNING
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.
and possible damage or injury.
See Figure 23.
2. Open hood and install cardboard or plywood
cover on top of battery to prevent accidental CAUTION
short circuits.
Do NOT fill the tank above the FULL mark on
3. Carefully position hydraulic tank over correct po- the dipstick. If the tank is too full, oil will come
sition in frame and install hoses on bottom of out the breather during operation.
tank. Lower tank into correct position in frame.
5. Make sure all hoses and plugs are installed and
4. Install other hoses and if removed, the filter on tight. Fill tank to the FULL mark on dipstick
the tank. Install bracket that fastens hydraulic using the oil specified in the following Service
tank in truck frame. See Figure 22.
40
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 1900 SRM 559
LIFT TRUCK MODELS [E3.50-5.50XL,

E4.50XLS (E70-120Z, E100ZS) (D098/E098)]
Remove
WARNING
CAUTION
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to compo-

Figure 27. Hydraulic Filter for J2.00-3.20XM 1. Turn key to the OFF position and remove key.
(J40-60XM and J40-60XM 2) (A216/A416)
2. Remove floor mate and floor plate.
Install
3. Disconnect hoses that go to the control valve and
NOTE: The hydraulic oil filter has a bypass relief mast, from the filter head assembly. If truck
valve that is part of the filter. Make sure the cor- is equipped with a two-stage full free lift mast,
rect replacement filter with a bypass relief valve is there is no hose connection between filter head
installed. assembly and mast. There is a plug in place of
the fitting. Drain oil from hoses into container.
1. Install the new filter. Make sure the flow arrow See Figure 28.
points toward the hydraulic tank hose. Tighten
the hose clamps and on the J2.00-3.20XM 4. Remove screw, nuts, spacer, and lockwasher and
(J40-60XM and J40-60XM 2) (A216/A416) units, remove clamp that holds the filter and filter head
install and tighten the two screws that fasten assembly to tank.
the filter and close hood.
5. Lift filter and filter head assembly from hy-
2. Install floor plate and floor mat for lift truck draulic tank.
models E1.50-3.20XM, E2.00XMS (D114),
E2.00-3.20XM (E45-65XM and E45-65XM 2) Install
(F108), N30XMH and N30XMH 2 (C210) and
V30ZMD (D210) 1. Remove filter from filter head assembly and in-
stall new filter. Install new O-ring between filter
3. Turn the key to the ON position and operate the and filter head assembly.
hydraulic system, check for leaks and check oil
level.
42
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
CAUTION
is changed. Dirt can cause damage to compo-

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- 4. Install floor plate and floor mat.
draulic tank. Install the screw, nuts, spacer, and 5. Turn key to the ON position and operate hy-
lockwasher for the clamp. Secure filter and filter draulic system, check for leaks and check oil
head assembly to tank with clamp. level.
3. Install floor plate and floor mat.
43
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
LIFT TRUCK MODELS [J2.00-3.20XM 4. Remove filter element from filter housing and
(J40-65Z) (B416)] discard filter element. If debris cap was removed
with filter element, remove cap from filter ele-
Remove ment. See Figure 31.
WARNING Install
The hydraulic oil is HOT at operating temper- 1. Lubricate oil seal on new filter element. If debris
ature. Do not permit the hot oil to contact the cap was removed from filter element, install cap
skin and cause a burn. onto new filter element and install filter element
into filter housing. See Figure 31.
CAUTION
2. Lubricate new O-ring and install new O-ring into
Do not permit dirt to enter the hydraulic sys- filter cover. See Figure 31.
is changed. Dirt can cause damage to compo- 3. Place filter cover onto housing, making sure the
nents of the hydraulic system. pin on the cover lines up with the notch on the
housing, and secure cover to housing with four
Never operate the pump without oil in the hy- socket head screws. See Figure 30.
pump without oil will damage the pump. 4. Close hood and install counterweight cover.
1. Turn key to the OFF position and remove key. 5. Turn key to the ON position and operate hy-
draulic system, check for leaks and check oil
2. Remove top counterweight cover and open hood level.
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.
45
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

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 4. Remove pressure hose from pump. Put cap on
cause of pump repair. The pump bearings, gears, open hydraulic hose.
and shafts also wear. Most service persons do not
repair a worn pump because the cost of repairs can NOTE: In Step 5, remove clamps from pin in pivot
be greater than the cost of a new pump. The seals in mount bracket to remove pump and motor under bat-
the hydraulic pump can be replaced. Replace a worn tery. Remove clamps under floor plate for pump and
or damaged hydraulic pump. motor to disconnect pivot mount bracket at motor.
See Figure 34. The motor under the battery will tip
HYDRAULIC PUMP, REMOVE down with force when the bracket is removed. Use
[E1.50-3.20XM (E25-65XM, E25-65XM 2) lifting device to keep motor vertical. Make sure lift-
ing device will securely hold motor before disconnect-
(D114, F108); N30XMH, AND N30XMH 2 ing mount at bottom of motor.
(C210); E1.50-1.75XM, E2.00XMS (E25-35Z,
40ZS) (E114/F114); E2.00-3.20XM 5. Connect sling and crane to motor. See Figure 32.
Make sure crane and sling have a capacity of ap-
(E45-65Z) (G108); V30ZMD (D210/E210);
proximately 50 kg (110 lb) or more. Disconnect
AND E3.50-5.50XL, E4.50XLS (E70-120Z, power cables and mark cables for correct instal-
E100ZS) (D098/E098)] lation. Disconnect pivot mount bracket from mo-
tor. Use crane to lift hydraulic pump and motor
1. Turn key to OFF position and remove key. 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
motor during assembly. Loosen two setscrews in
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.
for the E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) lift trucks.
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) setscrews. Do not lose keys between coupling and
(D114, F108); N30XMH, AND N30XMH 2 each shaft. See Figure 34.
(C210); E1.50-1.75XM, E2.00XMS (E25-35Z, 2. Remove four capscrews that hold pump together.
40ZS) (E114/F114); E2.00-3.20XM (E45-65Z)
NOTE: Make note of seal arrangement.
(G108); AND V30ZMD (D210/E210)
3. Carefully remove end housing.
NOTE: If the pump is held in a vise for disassembly,
make sure vise does not hold pump too tightly and 4. Push shaft through oil seal in flange end housing
cause distortion of pump body. The O-ring surface of as flange end housing is removed from pump.
the outlet port can also be damaged.
5. Remove snap ring and oil seal from flange end
Make sure you make careful notes of the location and housing. Discard oil seals.
orientation of the parts and seals during disassembly.
Some of the parts are similar but are not exactly the 6. Carefully remove outer and inner seals from
same. It can be difficult to make an identification if bushings. Discard seals.
the parts are mixed.
7. Remove and discard seals from pump body.
NOTE: Place an alignment mark on each section of
the pump body to aid in reassembly.
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

1. SNAP RING 6. BUSHINGS
2. OIL SEAL 7. SEAL
3. END HOUSING 8. PUMP BODY
4. OUTER BUSHING SEAL 9. GEAR SET
5. INNER BUSHING SEAL 10. FLANGE END HOUSING
INSPECT 1. Make sure internal parts of pump are clean. Lu-

bricate parts with hydraulic oil as they are in-
NOTE: Some pump bodies will show gear marks stalled in pump.
where the gears rotate because of the small clear-
ances between the parts. These gear marks do not 2. Install new outer and inner seals in bushings.
indicate a worn or damaged pump unless the pump
will not supply the volume and pressure shown in 3. Install gears set and bushing assembly in pump
the specifications. body. Make sure each bushing is aligned cor-
rectly.
Check parts for wear and damage. Remove and dis-
card all seals, replace with new seals. If pump bear- 4. Install new seals in flange end and end housing
ings, gears, and shafts are worn or damaged, replace of pump body. See Figure 33.
the pump.
5. Make sure all parts are in correct position and
install four capscrews. Tighten capscrews.
CLEAN
6. Install new oil seal on input shaft. Install snap
WARNING ring.
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using ASSEMBLE PUMP ON MOTOR
cleaning solvents, always follow the recom-
NOTE: Inspect coupling. If the cushion material
mendations of the manufacturer.
has pieces missing or has distortion, replace cushion
ring.
WARNING
Compressed air can move particles so that they 1. If the coupling half was removed from the pump
cause injury to the user or to other personnel. or the motor, install coupling and key on pump
Make sure that the path of the compressed air shaft. Install key and coupling on motor shaft as
is away from all personnel. Wear protective pump is aligned to motor.
goggles or a face shield to prevent injury to the
eyes. 2. Make sure the halves of the coupling are cor-
rectly engaged. Make sure Allen screws that fas-
Clean all parts in solvent. Dry parts with compressed ten coupling to shafts are tight. Make sure pump
air. Do not dry the parts with a cloth. Make sure all is aligned to motor as marked during disassem-
surfaces are free of scratches and sharp edges. bly. Install capscrews that fasten pump to motor,
and tighten to 31 N•m (23 lbf ft). See Figure 34.
PUMP SEAL REPLACE AND PUMP
ASSEMBLE
NOTE: Install new seals during assembly.
50
Figure 34. Hydraulic Pump and Motor Assembly With Mount
51
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 #6 UNC threads - 0.73 to 1.02 N•m (6.5 to
[E1.50-3.20XM (E25-65XM, E25-65XM 2) 9.0 lbf in)
(D114, F108); N30XMH, AND N30XMH 2 M8 × 1.25 threads - 13.5 to 17.5 N•m (119.5 to
155.0 lbf in)
(C210); E1.50-2.00XM (E25-35Z, 40ZS) M10 × 1.5 threads - 15.0 to 18.0 N•m (132.8 to
(E114/F114); E2.00-3.20XM (E45-65Z) 159.3 lbf in)
(G108); V30ZMD (D210/E210); AND
NOTE: If rubber bushings of pivot mount bracket
E3.50-5.50XL, E4.50XLS (E70-120Z,
were removed, use soap or rubber lubricant to in-
E100ZS) (D098/E098)] stall bushings. Do NOT use oil. The oil will soften
1. Apply Loctite™ 243 to threads of the capscrews bushings and they will need replacement.
and connect pivot mount bracket to motor. 2. Keep motor vertical. Install clamps on rear bulk-
Tighten capscrews to 16 N•m (142 lbf in). Make head of battery compartment to mount pump and
sure bracket is installed so tube of bracket is motor. Align pivot mount bracket of motor. See
on pump side NOT motor side as shown in Fig- Figure 34. Install clamps over pin in pivot mount
ure 34. Connect sling and crane to motor. See bracket. Make sure to install washers and wire
Figure 32. Make sure crane and sling have a (ground connection) between mount and clamp
capacity of approximately 50 kg (110 lb) or more. brackets.
Use crane to lift hydraulic pump and motor into
correct position in motor compartment. Connect 3. Remove cap on pressure hose. Install pressure
power cables as marked during removal. hose on outlet of pump. Remove plug in inlet hose
and quickly connect inlet hose at pump. Leave
NOTE: Tighten connections for power cables at M8 × fittings loose.
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 4. If oil was drained from hydraulic system, make
all other connections for power cables as follows: sure drain plug is installed in tank. If necessary,
5/16 UNC threads - 13.5 to 17.5 N•m (119.5 to turn steering wheel for a full left turn for access
155.0 lbf in) to drain plug near front of right rear wheel. If
1/4 UNC threads - 4.0 to 6.0 N•m (35.4 to drained, fill hydraulic tank with type and quan-
53.1 lbf in) tity of hydraulic oil shown in the Service Man-
ual section Install battery tray and battery and
52
close hood. See one of the following Service HYDRAULIC PUMP, REMOVE
Manual sections below for battery install proce- [J2.00-3.20XM (J40-60XM, J40-60XM 2)
dure. (A216); J2.00-3.20XM (J40-65Z) (A416);
the E1.50-2.00XM (E25-40XM, E25-40XM 2) AND J2.00-3.20XM (J40-65Z) (B416)]
(D114) and E2.00-3.20XM (E45-65XM, NOTE: For removal procedures for lift model
E45-65XM 2) (F108) trucks E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
Periodic Maintenance 8000 SRM 555 for (D098/E098) see the section Hydraulic Pump,
the N30XMH and N30XMH 2 (C210) trucks. Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2)
Periodic Maintenance 8000 SRM 1060 (D114, F108); N30XMH, and N30XMH 2 (C210);
for E2.00-3.20XM (E45-65Z) (G108), E1.50- E1.50-1.75XM, E2.00XMS (E25-35Z, 40ZS) (E114/
1.75XM, E2.00XMS.(E25-35Z, E40ZS) F114); E2.00-3.20XM (E45-65Z) (G108); V30ZMD
(E114/F114), and V30ZMD (D210/E210) (D210/E210); and E3.50-5.50XL, E4.50XLS (E70-
trucks. 120Z, E100ZS) (D098/E098)] to remove hydraulic
Periodic Maintenance 8000 SRM 1201 for pump and motor from lift truck.
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) lift trucks. 1. Turn key to OFF position and remove key.
for lift truck models ERC35-55HG (ERC70-
120HH) (B839/C839) lift trucks.
WARNING
5. Fill tank to FULL mark on dipstick. If tank Never put tools or other metal on the battery.
was not drained, remove plug from fill tube. Let Metal on the battery can cause a short circuit
some oil leak from around inlet fitting on pump; and possible damage or injury.
then, tighten capscrews on flanges of fittings to
49 N•m (36 lbf ft). The smaller pump has O-ring 2. Open hood and install cardboard or plywood
fittings. Tighten outlet hose fitting. Use this pro- cover on top of battery to prevent accidental
cedure to make sure the pump has oil for first op- short circuits.
eration.
3. Drain the hydraulic system, turn steering wheel
6. Install top bracket to fasten motor to bulkhead. for a full left turn for access to drain plug near
front of right rear wheel. Install container under
7. Operate lift system and check for leaks and check drain plug of hydraulic tank with enough capac-
for leaks. ity. See Specifications table at the back of this
section.
8. Install battery tray and battery and close hood.
See one of the following Service Manual sec- 4. Remove pressure hose from pump. Put cap on
tions below for battery install procedure. open hydraulic hose.
the E1.50-2.00XM (E25-40XM, E25-40XM 2) 5. Remove the steer motor and mounting bracket.
(D114) and E2.00-3.20XM (E45-65XM, See the section Steering Pump Repair in this
E45-65XM 2) (F108) trucks SRM for the procedures.
6. Connect sling and crane to motor. See Figure 34
the N30XMH and N30XMH 2 (C210) trucks.
and Figure 35. Make sure crane and sling have
a capacity of approximately 50 kg (110 lb) or
for E2.00-3.20XM (E45-65Z) (G108), E1.50-
more. Disconnect power cables and mark cables
1.75XM, E2.00XMS.(E25-35Z, E40ZS)
for correct installation. Disconnect pivot mount
(E114/F114), and V30ZMD (D210/E210)
bracket from motor. Use crane to lift hydraulic
trucks.
pump and motor from lift truck.
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.
53
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
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, INSPECT 3. Install a new shaft seal in the flange end housing.
[E3.50-5.50XL, E4.50XLS (E70-120Z, Carefully install the flange end housing. Do not
E100ZS) (D098/E098) AND J2.00-3.20XM move the pressure plates. Make sure the seals
do not move out of the correct position.
(J40-65Z) (B416)]
4. Carefully install the valve end housing on the
Check parts for wear and damage. If any parts are pump body using the four capscrews and lock-
worn or damaged, replace the damaged parts. If the washers. Make sure the pressure plates do not
pump housing is damaged, replace the pump. move and that the seals stay in the correct posi-
tion. Make sure the marks made during disas-
HYDRAULIC PUMP, CLEAN [E3.50-5.50XL, sembly are aligned. Tighten the capscrews to 46
E4.50XLS (E70-120Z, E100ZS) (D098/E098) to 49 N•m (34 to 36 lbf ft).
AND J2.00-3.20XM (J40-65Z) (B416)]
HYDRAULIC PUMP AND MOTOR, INSTALL
WARNING [J2.00-3.20XM (J40-60XM, J40-60XM 2)
Cleaning solvents can be flammable and toxic, (A216); J2.00-3.20XM (J40-65Z) (A416);
and can cause skin irritation. When using AND J2.00-3.20XM (J40-65Z) (B416)]
mendations of the manufacturer. 1. Turn key to OFF position and remove key.
WARNING WARNING
Compressed air can move particles so that they Never put tools or other metal on the battery.
cause injury to the user or to other personnel. Metal on the battery can cause a short circuit
Make sure that the path of the compressed air and possible damage or injury.
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the 2. Open hood and install cardboard or plywood
eyes. cover on top of battery to prevent accidental
short circuits.
Clean all parts in solvent. Dry parts with compressed
air. Do not dry the parts with a cloth. Make sure all 3. Install coupling onto pump shaft. Install pump
surfaces are free of scratches and sharp edges. to motor and tighten capscrews to 31 N•m
(23 lbf ft). Connect sling and crane to motor.
HYDRAULIC PUMP, ASSEMBLE See Figure 35. Make sure crane and sling have
a capacity of approximately 113 kg (250 lb) or
[E3.50-5.50XL, E4.50XLS (E70-120Z, more. Use crane to lift hydraulic pump and mo-
E100ZS) (D098/E098) AND J2.00-3.20XM tor into correct position in motor compartment.
(J40-65Z) (B416)] Make sure isolator mounts are between motor
and chassis bracket. See Figure 36.
1. Put oil on all parts of the pump. Use the hy-
draulic oil shown in the maintenance table of the 4. Connect the temperature and speed sensors (see
section Periodic Maintenance 8000 SRM 1201 Figure 37).
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098) and Periodic 5. Connect the power cables as marked during re-
Maintenance 8000 SRM 1226 for lift truck moval. Tighten connections for power cables to
models J2.00-3.20XM (J40-65Z) (B416). Make 18 to 22 N•m (159.3 to 195.0 lbf in).
sure to keep the parts clean.
6. Keep motor horizontal and secure motor and
2. Use new plate and backup seals and install the pump to lift truck frame.
pressure plates and gears. Make sure to install
7. Install steer motor and mounting bracket. See
the pressure plates as removed during disas-
the section Steering Pump Repair in this SRM
sembly. See the notes made during disassembly.
for the procedures.
Make sure all seals are complete and in the
correct positions. See Figure 36.
56
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 1900 SRM 559
8. Remove cap on pressure hose. Install pressure (E70-120Z, E100ZS) (D098/E098) and Periodic
hose on outlet of pump. Remove plug in inlet hose Maintenance 8000 SRM 1226 for lift truck
and quickly connect inlet hose at pump. Leave models J2.00-3.20XM (J40-65Z) (B416). Fill
fittings loose. tank to FULL mark on dipstick. If tank was
not drained, remove plug from fill tube. Let
9. If oil was drained from hydraulic system, make some oil leak from around inlet fitting on pump;
sure drain plug is installed in tank. If neces- then, tighten capscrews on flanges of fittings to
sary, turn steering wheel for a full left turn for 49 N•m (36 lbf ft). Tighten outlet hose fitting.
access to drain plug near front of right rear Use this procedure to make sure the pump has
wheel. If drained, fill hydraulic tank with type oil for first operation.
and quantity of hydraulic oil shown in the sec-
tion Periodic Maintenance 8000 SRM 1201 10. Turn the key to the ON position and operate lift
for lift truck models E3.50-5.50XL, E4.50XLS system, check for leaks and check oil level.
Main Control Valve Repair

The operation, removal, and repair of the man- See Manual hydraulic Control Valve 2000
ual hydraulic control valve is described in the SRM 77 for lift trucks E3.50-5.50XL, E4.50XLS
Service Manual sections Manual hydraulic (E70-120Z, E100ZS) (D098/E098).
Control Valve 2000 SRM 562 for lift truck
models E1.50-2.00XM (E25-40XM, E25-40XM 2) The operation, removal, and repair of the electronic
(D114), E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114), hydraulic control valve is described in the Service
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108), Manual sections Electro-Hydraulic Control
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), Valve 2000 SRM 1224. For lift trucks models
J2.00-3.20XM (J40-65Z) (A416), J2.00-3.20XM J2.00-3.20XM (J40-65Z) (B416), E2.00-3.20XM
(J40-65Z) (B416) and E2.00-3.20XM (E45-65Z) (E45-65Z) (G108), E3.50-5.50XL, E4.50XLS
(G108). (E70-120Z, E100ZS) (E098) and E1.50-2.00XM
For lift trucks N30XMH and N30XMH 2 (C210) and (E25-35Z, 40ZS) (F114).
V30ZMD (D210), see Manual hydraulic Control
Valve 2000 SRM 591.
58
1900 SRM 559 Steering Pump Repair
Steering Pump Repair

NOTE: A worn or damaged steering pump is normally Remove breather for hydraulic tank and install
replaced instead of repaired. The cost of repair can plug in breather hose. Make sure dipstick/fill cap
often be more than the cost of a new pump. The fol- is tight. This will help prevent oil flow when the
lowing procedure does not include repair. hydraulic line is disconnected. See Figure 38 or
Figure 39.
PUMP, REMOVE AND DISASSEMBLE
[E1.50-3.20XM (E25-65XM, E25-65XM 2) 2. Put drain pan under steering pump and remove
hose at pump that comes from hydraulic tank.
(D114, F108); N30XMH AND N30XMH 2 Oil will flow from hose, so quickly install plug in
(C210); E1.50-1.75XM 2.00XMS (E25-35Z, hose fitting.
E40ZS) (E114)]
3. Disconnect other hose for steering pump. Install
1. Disconnect battery connector. Remove floor plug at fitting for hose. If installed, disconnect
plate. Remove battery as described in one of electrical plug at pressure switch on bottom of
the following Service Manual sections for the motor.
correct procedure:
Periodic Maintenance 8000 SRM 552 for 4. Install tags for correct connection during instal-
the E1.50-2.00XM (E25-40XM, E25-40XM 2) lation and disconnect electrical cables at pump
(D114), E1.50-1.75XM 2.00XMS (E25-35Z, motor terminals.
E40ZS) (E114) and E2.00-3.20XM (E45-65XM,
5. Install a sling around steering pump and motor
E45-65XM 2) (F108) lift trucks.
assembly. Connect crane to sling and raise crane
so it is a support for assembly. Make sure crane
for the N30XMH and N30XMH 2 (C210) lift
and sling have a capacity of 18.5 kg (41 lb) or
trucks.
more.
1. MOTOR 6. MOUNT BRACKET

2. HYDRAULIC PUMP - STEERING 7. FRAME BRACKET
3. WASHER (4) 8. MOUNT PIN
4. RUBBER BUSHINGS (4) 9. MOTOR BASE
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)
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)]
2. Disconnect battery connector. Remove floor

plate. Remove battery as described in one of
the following Service Manual sections for the
correct procedure:
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.
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
Figure 40. Steering Pump and Motor
motor base unless motor will be replaced. These
for J2.00-3.20XM (J40-65Z) (A416, B416);
brackets must be correctly aligned on motor base.
E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114);
See Figure 39.
E2.00-3.20XM (E45-65Z) (G108); V30ZMD
10. Make a note of the position of the inlet and outlet (D210/E210); and E3.50-5.50XL, E4.50XLS
ports of the pump for correct alignment to the (E70-120Z, E100ZS) (D098/E098) Lift Truck
motor during assembly. Remove two capscrews Models
61
Steering Pump Repair 1900 SRM 559
Legend for Figure 40 the mounts or mounting weldment in lift truck

frame.
A. MOUNTING BRACKET AND HARDWARE
FOR J2.00-3.20XM (J40-65Z) (A416, B416), 5. For E1.50-3.20XM (E25-65XM, E25-65XM 2)
E1.50-2.00XM (E25-35Z, 40ZS) (E114F114),
AND E2.00-3.20XM (E45-65Z) (G108), V30ZMD (D114, F108), N30XMH, N30XMH 2 (C210), and
(D210/E210) LIFT TRUCK MODELS. J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
B. MOUNTING BRACKET AND HARDWARE FOR model trucks, install mount capscrews, washers,
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) and rubber bushings as noted during disassem-
(D098/E098) LIFT TRUCK MODELS. bly. See Figure 39. Install clip nut at top left
1. STEERING MOTOR 6. WASHER mount of frame. Tighten capscrews without
2. STEERING PUMP 7. BRACKET compressing rubber bushings.
3. METAL STRAP 8. RUBBER CHANNEL
4. CAPSCREW 9. TRUCK FRAME 6. For J2.00-3.20XM (J40-65Z) (A416, B416),
5. BRACKET 10. NUT E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
WELDMENT 11. GROMMET E2.00-3.20XM (E45-65Z) (G108), V30ZMD
(D210/E210), and E3.50-5.50XL, E4.50XLS
PUMP, ASSEMBLE AND INSTALL (E70-120Z, E100ZS) (D098/E098) trucks, install
1. Install new O-ring at shaft of replacement pump. the two capscrews and washers that hold the
Install replacement pump on motor using two motor and pump assembly to the mounting
capscrews. Make sure pump is correctly aligned weldment. Install the metal strap around the
with motor as noted during disassembly. mounting weldment and steering motor. See
Figure 40.
2. On all models except J2.00-3.20XM (J40-65Z)
(A416, B416), E1.50-2.00XM (E25-35Z, 40ZS) 7. Connect hydraulic line to outlet port of pump.
(E114/F114), E2.00-3.20XM (E45-65Z) (G108), Install drain pan under pump and quickly install
V30ZMD (D210/E210), and E3.50-5.50XL, hose from hydraulic tank to inlet port.
E4.50XLS (E70-120Z, E100ZS) (D098/E098), 8. Install electrical plug on terminals of pressure
if the pressure switch was removed, install pres- switch. Install electrical cables on motor termi-
sure switch in pump end frame. nals as noted during removal.
3. For E1.50-3.20XM (E25-65XM, E25-65XM 2) NOTE: E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D114, F108), N30XMH, N30XMH 2 (C210), and (D098/E098) lift trucks use M6 × 1.0 hardware only.
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
model trucks, if mount brackets were removed NOTE: Tighten connections for power cables at M8 ×
from motor base, brackets must be correctly 1.25 or 5/16 UNC terminals on General Electric mo-
aligned before installation of assembly. Align tors to 18 to 22 N•m (159.3 to 195.0 lbf in). Tighten
brackets as follows: all other connections for power cables as follows:
5/16 UNC threads - 13.5 to 17.5 N•m (119.5 to
a. Install mount brackets on motor base. See 155.0 lbf in)
Figure 39. Leave capscrews and nuts loose 1/4 UNC threads - 4.0 to 6.0 N•m (35.4 to
so brackets can move. 53.1 lbf in)
b. Align two brackets so center lines of cap- #6 UNC threads - 0.73 to 1.02 N•m (6.5 to
screw holes are 160 mm (6-19/64 in.) apart as 9.0 lbf in)
shown in Figure 39. Keep brackets centered M8 × 1.25 threads - 13.5 to 17.5 N•m (119.5 to
in slots of motor base as much as possible. 155.0 lbf in)
M10 × 1.5 threads - 15.0 to 18.0 N•m (132.8 to
c. Carefully tighten capscrews at motor base 159.3 lbf in)
without changing alignment. M6 × 1.0 threads - 6.5 to 7.0 N•m (57.5 to
62.0 lbf in)
4. Install sling around steering pump and motor as-
sembly. Use crane to lift and align assembly on
62
1900 SRM 559 Rotary Actuator Valve Repair
9. Remove plug from breather hose and install E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
breather. Install battery as described in one of E2.00-3.20XM (E45-65Z) (G108), and
the following Service Manual sections for the V30ZMD (D210/E210) lift trucks.
correct procedure: Periodic Maintenance 8000 SRM 1201
Periodic Maintenance 8000 SRM 552 for lift trucks E3.50-5.50XL, E4.50XLS
for the E1.50-2.00XM (E25-40XM, E25- (E70-120Z, E100ZS) (D098/E098)
40XM 2) (D114), J2.00-3.20XM (J40-60XM, Periodic Maintenance 8000 SRM 1226 for
J40-60XM 2) (A216), and E2.00-3.20XM lift trucks J2.00-3.20XM (J40-65Z) (B416).
(E45-65XM, E45-65XM 2) (F108) trucks.
Periodic Maintenance 8000 SRM 555 for 10. Install floor plate. Operate steering system and
the N30XMH and N30XMH 2 (C210) trucks. check for leaks and check oil level.
for the J2.00-3.20XM (J40-65Z) (A416),
Rotary Actuator Valve Repair

The rotating actuator valve and the bypass valve
WARNING
are found on the attachment for the N30XMH and
N30XMH 2 (C210), V30ZMD (D210/E210) lift trucks. Compressed air can move particles so they
See Figure 41. The instructions for the removal, cause injury to the user or to other personnel.
installation, and adjustment procedures for these Make sure the path of the compressed air is
valves are in the section Attachment 5000 SRM away from all personnel. Wear protective gog-
580. gles or a face shield to prevent injury to the
eyes.
DISASSEMBLE, CLEAN, AND INSPECT
WARNING
1. Turn cap with a wrench to remove check valve
Cleaning solvents can be flammable and toxic
assembly from valve body. Push shuttle out of
and can cause skin irritation. When using
valve body.
2. Inspect seat and poppet for dirt or scratches. The mendations of the manufacturer.
poppet must slide freely in the seat sleeve. The
6. Clean all parts of rotating actuator valve with
spring must not be bent or broken.
solvent. Use compressed air to dry parts and to
3. Inspect shuttle and bore for dirt or scratches. remove dirt from passages.
The shuttle must slide freely in the bore.
ASSEMBLE
4. Remove two relief valves from valve body by
turning bushings with wrench. 1. Lubricate relief valve parts with hydraulic oil.
Install new O-rings on bushing.
CAUTION 2. Install relief valves into valve body. Use a

The adjustment of the relief valves is set at the wrench to tighten bushing.
factory. DO NOT loosen the cap or jam nut from
3. Lubricate and install new O-rings and install one
the bushings. DO NOT turn the adjuster screw.
check valve into valve body. Lubricate shuttle
5. Inspect poppet, ball, and seat for dirt or and slide it into bore for check valves. Lubricate
scratches. Make sure spring is not bent or and install other check valve.
broken.
4. Install new O-rings on fittings that were re-
moved. Lubricate and install fittings.
63
Steering Control Unit Replacement 1900 SRM 559

1. CHECK VALVES 3. RELIEF VALVES
2. SHUTTLE 4. VALVE BODY
Figure 41. Rotary Actuator Valve
Steering Control Unit Replacement

NOTE: See the section Steering Housing and Con- steering and forward/reverse switches and lever.
trol Unit 1600 SRM 512 or Steering Housing and See the section Steering System for Elec-
Control Unit 1600 SRM 720 to repair the steering tric Lift Trucks 1600 SRM 485 for models
control unit. The following is the correct procedure E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114,
to remove and install the steering control unit. F108); J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216); and N30XMH and N30XMH 2 (C210).
NOTE: The repair procedures for the instrument See the section Steering System for AC
cluster are in the sections Electrical System, Electric Lift Trucks 1600 SRM 1054 for
Replacement, Checks, and Adjustments models J2.00-3.20XM (J40-65Z) (A416, B416),
Trucks with EV-100/200ZX or SR (SEM) and E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
SP Motor Controllers 2200 SRM 560 for models E2.00-3.20XM (E45-65Z) (G108), V30ZMD
E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, (D210/E210), and E3.50-5.50XL, E4.50XLS
F108); J2.00-3.20XM (J40-60XM, J40-60XM 2) (E70-120Z, E100ZS) (D098/E098). Also see the
(A216); and N30XMH and N30XMH 2 (C210). section Steering Housing and Control Unit
1600 SRM 512 or Steering Housing and Con-
For models J2.00-3.20XM (J40-65Z) (A416, B416),
trol Unit 1600 SRM 720.
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) WARNING
(D098/E098) see the section Electrical System The hydraulic hoses MUST be connected to
(Trucks With AC Controllers) 2200 SRM 1055 for the correct ports or the steering system will
the repair procedures for the display panel. not operate as expected. This operation that
is not expected can cause damage or personal
REMOVE injury. Make sure the hoses are identified and
connected correctly.
1. Disconnect battery connector. Move steering col-
umn to forward position. Remove panel under 3. Put tags for identification on hydraulic hoses at
steering column for access to hoses of steering steering control unit so they can be connected
control unit. correctly during assembly. Disconnect hydraulic
hoses at bottom of steering control unit. Install
2. Remove front and rear covers for steering col- plugs at all hose fittings and control unit ports
umn. Install tags and disconnect wires for horn to prevent dirt from entering steering hydraulic
connector and if installed, on-demand power system.
steering and forward/reverse switches. If in-
stalled, remove parts for on-demand power
64
1900 SRM 559 Steering Control Unit Replacement
4. Hold steering column and remove capscrews that 3. Connect hydraulic hoses at steering control unit
hold steering column and pivot shaft to bracket. as marked during removal OR see the section
See Figure 42, Figure 43, or Figure 44, depending Steering Housing and Control Unit 1600
on your model of lift truck. Remove two plates, SRM 512 or Steering Housing and Control
pivot shaft, and return spring. Remove steering Unit 1600 SRM 720 a for correct connections.
column assembly. Do not lose push rod, washer,
and spring for latch. 4. If removed, install parts for on-demand power
steering and forward/reverse switches and lever.
5. Make a note of the alignment of the steering con- See the section Steering System for Elec-
trol unit in the bracket for correct installation. tric Lift Trucks 1600 SRM 485 for models
Remove four capscrews that fasten steering shaft E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114,
assembly and steering control unit in steering F108); J2.00-3.20XM (J40-60XM, J40-60XM 2)
column bracket. Do not let steering control unit (A216); and N30XMH and N30XMH 2 (C210).
or steering wheel and shaft assembly fall. Do not See the section Steering System for AC
let washers fall. It is not necessary to remove Electric Lift Trucks 1600 SRM 1054 for
steering wheel or on-demand steering parts from models J2.00-3.20XM (J40-60Z) (A416, B416),
shaft. E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114),
E2.00-3.20XM (E45-65Z) (G108), V30ZMD
INSTALL (D210/E210), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098). Also see the
1. Install steering control unit in bracket. See Fig- section Steering Housing and Control Unit
ure 42, Figure 43, or Figure 44, depending on 1600 SRM 512 or Steering Housing and Con-
your model of lift truck. Make sure it is in correct trol Unit 1600 SRM 720.
alignment, as noted during removal, so hoses can
be correctly connected. Install washers, spacers, 5. Connect wires for horn connector and if installed,
steering shaft assembly, and capscrews to hold on-demand power steering and forward/reverse
all parts in bracket. switches. Install front and rear covers for steer-
ing column.
2. Hold bracket assembly in alignment and install
pivot shaft, return spring, plates, washers, and
capscrews to hold assembly on mount. Install WARNING
spring, washer, and push rod for latch. Install After making repairs, do not extend hands or
column tilt lever on latch. Install Allen screw and arms through the center of the steering wheel.
nut. Wrong assembly or connections can make the
steering wheel rotate with a strong force when
WARNING the steering pump operates. This strong force
can cause serious injury. If this action occurs,
The hydraulic hoses MUST be connected to
disassemble the control unit and correct the
the correct ports or the steering system will
problem.
not operate as expected. This operation that
is not expected can cause damage or personal 6. Operate steering system and check for leaks and
injury. Make sure the hoses are identified and correct operation.
connected correctly.
65
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

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
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

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
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

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

NOTE: The adjustments of the relief valves of the • Manual hydraulic Control Valve 2000 SRM
main control valve can be found in one of the follow- 77 for lift truck models E3.50-5.50XL, E4.50XLS
ing Service Manual sections: (E70-120Z, E100ZS) (D098/E098). The adjustment
procedure for the switches of the linkage are also
• Manual hydraulic Control Valve 2000 SRM 562 in the above sections.
for lift truck models E1.50-2.00XM (E25-40XM, • Electro-Hydraulic Control Valve 2000 SRM
E25-40XM 2) (D114), E1.50-2.00XM (E25-35Z, 1224 for lift truck models J2.00-3.20XM (J40-65Z)
40ZS) (E114/F114), E2.00-3.20XM (E45-65XM, (B416), E1.50-2.00XM (E25-35Z, 40ZS) (F114),
E45-65XM 2) (F108), J2.00-3.20XM (J40-60XM, E2.00-3.20XM (E45-65Z) (G108) V30ZMD (E210),
J40-60XM 2) (A216), and J2.00-3.20XM (J40-65Z) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(A416), and for lift truck models J2.00-3.20XM (E098) with a electronic main hydraulic control
(J40-65Z) (B416) and E2.00-3.20XM (E45-65Z) valve.
(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).
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
Specifications
RELIEF VALVE PRESSURES* E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108);
E2.00-3.20XM (E45-65Z) (G108); N30XMH
E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114) and N30XMH 2 (C210); V30ZMD (D210/E210);
and E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114) J2.00-3.20XM (J40-60XM, J40-60XM 2
Hydraulic System 17.9 ±0.7 MPa (2600 ±100 psi) (A216); J2.00-3.20XM (J40-65Z) (A416); and
Steering System 5690 ±248 kPa (828 ±36 psi) E2.00-3.20XM (E45-65Z) (G108)
Tilt and Auxiliary Systems 15.50 ±0.7 MPa 22.0 liter (5.6 gal)
(2250 ±100 psi)
E3.50-5.50XL, E4.50XLS (E70-120Z,
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108), E100ZS) (D098/E098)
and N30XMH and N30XMH 2 (C210) Short Frame 33.3 liter (8.8 gal)
Hydraulic System 20.7 ±0.7 MPa (3000 ±100 psi) Long Frame 39.7 liter (10.5 gal)
Steering System 8620 ±345 kPa (1250 ±50 psi)
Tilt and Auxiliary Systems 15.5 ±0.7 MPa J2.00-3.20XM (J40-65Z) (B416); J2.00-3.20XM
(2250 ±100 psi) (J40-60XM, J40-60XM 2 (A216); J2.00-3.20XM
(J40-65Z) (A416);
J2.00-3.20XM (J40-60XM, J40-60XM 2) 27.4 liter/min (7.25 gal)
(A216), J2.00-3.20XM (J40-65Z) (A416,
B416), E2.00-3.20XM (E45-65Z) (G108), HYDRAULIC PUMP CAPACITIES - ALL
and V30ZMD (D210/E210) MODELS EXCEPT E3.50-5.50XL, E4.50XLS
Hydraulic System 20.7 ±0.7 MPa (3000 ±100 psi)
Hydraulic System - J2.00-3.20XM (J40-65Z) (E70-120Z, E100ZS) (D098/E098)
(B416) Models 20.7 ±0.70 MPa (3000 ±100 psi) Large Hydraulic Pump 19 cc/revolution
Steering System 8909 ±345 kPa (1292 ±50 psi) (1.16 in 3/revolution)
Steering System - E2.00-3.20XM (E45-65Z)
(G108) Models 8620 ±248 kPa (1250 ±36 psi) Small Hydraulic Pump 12 cc/revolution
Tilt and Auxiliary Systems 15.5 ±0.7 MPa (0.73 in 3/revolution)
(2250 ±100 psi)
Steering Pump 4.23 cc/revolution (0.26
E3.50-5.50XL, E4.50XLS (E70-120Z, in 3/revolution)
E100ZS) (D098/E098)
Hydraulic System 20.7 ±0.7 MPa (3000 ±100 psi) HYDRAULIC PUMP CAPACITIES -
Steering System 10,342 ±345 kPa (1500 ±50 psi) MODELS E3.50-5.50XL, E4.50XLS
Tilt and Auxiliary Systems 15.75 ±0.7 MPa
(E70-120Z, E100ZS) (D098/E098)
(2250 ±100 psi)
Hydraulic Pump 29 cc/revolution (1.77
HYDRAULIC TANK CAPACITY (DIPSTICK in 3/revolution)
FULL MARK)
Steering Pump 6.36 cc/revolution (0.39
E1.50-2.00XM (E25-40XM, E25-40XM 2) (D114) in 3/revolution)
11.3 liter (3.0 gal)
*Oil temperature at 54 to 66 C (130 to 150 F).
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
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
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 Troubleshooting
The output of the pump is See Possible Cause for the Prob- See the section Capacities and
less than specifications. lem The pump makes more noise Specifications 8000 SRM 561 for
than normal above. 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.
The pump has leaks. The fittings or hoses on the outlet Tighten fittings. Install new parts as
side of the pump are loose or dam- necessary.
aged.
The capscrews that hold the pump Tighten capscrews to specified

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

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

PART NO. 897639 1900 SRM 559

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2009 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

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

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

Legend for Figure 2

Legend for Figure 3

1. TILT CYLINDER (2) 8. STEERING CYLINDER

1. FILTER 8. TO AUXILIARY HYDRAULIC FUNCTIONS

1. AUXILIARY HYDRAULIC HOSES 10. HYDRAULIC TANK BREATHER

1. AUXILIARY HYDRAULIC HOSES 9. HYDRAULIC TANK

Legend for Figure 9

Legend for Figure 10

Legend for Figure 11

Legend for Figure 12

Legend for Figure 13

Legend for Figure 14

Legend for Figure 15

NOTE: MOTOR CAN BE DIFFERENT THAN SHOWN.

Legend for Figure 16

NOTE: MOTOR CAN BE DIFFERENT THAN SHOWN.

Legend for Figure 17

NOTE: MOTOR CAN BE DIFFERENT THAN SHOWN.

Legend for Figure 18

Legend for Figure 19

Hydraulic Tank Repair

Clean the outside of the hydraulic filter, hoses,

NEVER operate the hydraulic pump with out

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

WARNING Figure 20. Hydraulic Tank Assembly for

5. Remove and install plugs in all hoses fastened to

6. Remove traction motor as described in one of the

7. Remove screws that fasten bracket holding hy-

8. Carefully remove hydraulic tank from frame.

9. Make repairs to hydraulic tank.

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

6. Disconnect the hydraulic lines and install plugs

7. Remove the screws from the bracket that fastens

8. Carefully lift hydraulic tank up out of frame.

Figure 22. Hydraulic Tank Assembly for

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

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

5. Remove traction motor as described in one of the

Never operate the pump without oil in the hy-

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

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

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

LIFT TRUCK MODELS [E3.50-5.50XL,

Never operate the pump without oil in the hy-

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