HYDRAULIC SYSTEM

H8.00-12.00XM (H170-280HD)
[F007, G007, H007];
H13.00-14.00XM (H300-330HD)
[E019, F019, G019];
H16.00XM-6 (H360HD)
[E019, F019, G019];
H10.00-12.00XM-12EC (H360HD-EC)
[E019, F019, G019]

PART NO. 1494142 1900 SRM 938

Hydraulic System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Hydraulic Tank .............................................................................................................................................. 1
Hydraulic Pump............................................................................................................................................. 2
Steering Priority Flow Valve......................................................................................................................... 2
Pilot Valve ...................................................................................................................................................... 3
Main Control Valve........................................................................................................................................ 5
Unloader Valve............................................................................................................................................... 6
Hydraulic Operation...................................................................................................................................... 7
Checks and Adjustments ................................................................................................................................... 10
Quick Disconnect Fittings ............................................................................................................................. 10
Steering Priority Flow Valve......................................................................................................................... 10
Steering Relief Pressure................................................................................................................................ 10
Modulator Valve............................................................................................................................................. 11
Pilot Valve and Pressure Reducing Valve..................................................................................................... 11
Accumulator................................................................................................................................................... 12
Filter............................................................................................................................................................... 12
Main Control Valve........................................................................................................................................ 12
Relief Pressure Check ............................................................................................................................... 12
Check Valves .................................................................................................................................................. 13
Unloader Valve............................................................................................................................................... 13
Hydraulic Pump Repair..................................................................................................................................... 14
Remove ........................................................................................................................................................... 14
Disassemble ................................................................................................................................................... 14
Clean and Inspect .......................................................................................................................................... 14
Assemble ........................................................................................................................................................ 15
Install ............................................................................................................................................................. 16
Pilot Accumulator Replacement ....................................................................................................................... 16
Remove ........................................................................................................................................................... 16
Install ............................................................................................................................................................. 16
Pilot Valve Repair .............................................................................................................................................. 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 18
Clean and Inspect .......................................................................................................................................... 18
Assemble ........................................................................................................................................................ 18
Install ............................................................................................................................................................. 18
Control Levers and Joystick Repair.................................................................................................................. 19
Remove ........................................................................................................................................................... 19
Install ............................................................................................................................................................. 19
Calibration and Diagnostics .............................................................................................................................. 20
General ........................................................................................................................................................... 20
Description ..................................................................................................................................................... 20
Lever and Joystick Calibration ................................................................................................................ 20
Flow Adjustment ....................................................................................................................................... 20
Dead Band Value Setting.......................................................................................................................... 21
Lowering Delay.......................................................................................................................................... 22
PWM and I/O Module Readouts ............................................................................................................... 22
Function Disable ....................................................................................................................................... 23
General Startup ............................................................................................................................................. 23
Minimum system requirements ............................................................................................................... 23
Install the Hydraulic Controls Program .................................................................................................. 23

©2007 HYSTER COMPANY i

Table of Contents Hydraulic System

TABLE OF CONTENTS (Continued)

DelayTimeFile (Reset)............................................................................................................................... 23
Select the Processor Speed........................................................................................................................ 24
Hydraulic Controls Program......................................................................................................................... 24
Calibration ..................................................................................................................................................... 26
Joystick/Lever Calibration........................................................................................................................ 26
Levers .................................................................................................................................................... 26
Joystick .................................................................................................................................................. 26
Valve Flow Adjustment ................................................................................................................................. 27
Diagnostics ..................................................................................................................................................... 27
Calibration System Shutdown ...................................................................................................................... 27
LED Diagnostics ................................................................................................................................................ 28
Electrical Connections ....................................................................................................................................... 31
Specifications...................................................................................................................................................... 35
Diagrams, Schematics, or Arrangements ......................................................................................................... 35

This section is for the following models:

H8.00-12.00XM (H170-280HD) [F007, G007, H007];

H13.00-14.00XM (H300-330HD) [E019, F019, G019];
H16.00XM-6 (H360HD) [E019, F019, G019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019, G019]

ii
1900 SRM 938 Description and Operation

General
This section describes the operation of the hydraulic Steering System 1600 SRM 936
system and its main components. Hydraulic systems Main Control Valve 2000 SRM 943
of sub components are separately described in follow-
ing publications:

Description and Operation

The hydraulic system includes the circuits for lift, directed from the steering priority valve to the main
steering, tilt, and auxiliary functions. See Figure 1. control valve.

The main control valve is operated by a hydraulic

pilot system. Oil supply for the pilot system is con-
trolled by the pilot valve.

The electric solenoids are operated by a separate elec-

tronic system that also allows for setting and diag-
nostics of the main control valve.

HYDRAULIC TANK
The hydraulic tank is located at the left hand side of
the frame. The hydraulic tank stores oil for the main
hydraulic system, steering, and wet brakes system.
See Figure 2.

Oil level is indicated by a sight glass. Topping up

occurs by removing a plug above the hydraulic return
filter, which is installed inside the tank. Draining is
by removing a plug at the bottom of the tank.

Hydraulic oil demand causes oil volume to change.

The resulting air flow entering and escaping from the
tank is filtered by the tank breather.

The hydraulic system and the wet brake system have

separate suction and return lines. The return fil-
1. PUMP ter for the wet brake system is outside the hydraulic
2. STEERING PRIORITY VALVE tank.
3. STEERING SYSTEM
4. PILOT VALVE The return filter for the hydraulic system incorpo-
5. MAIN CONTROL VALVE rates a relief valve. A spring between the filter and
6. LIFT, TILT, AND AUXILIARY FUNCTIONS
7. TANK the filter cover keeps the filter seated.

Figure 1. Hydraulic System Diagram
A pump supplies oil from the tank to the main con-
trol valve and to the steering priority valve. Oil sup-
ply, that is not required by the steering system, is
For trucks with air brakes, the suction and return
connections for the wet brakes system have been
blocked off with a plug.

1
Description and Operation 1900 SRM 938

of the pump supplies oil to the steering priority flow

valve.

STEERING PRIORITY FLOW VALVE

The steering priority flow valve provides priority oil
flow to the steering system and directs the remainder
of the oil supply to the pilot system and the main
control valve.

Oil flow is controlled by a modulating flow divider,

which receives pressure signals from the steering
system (port P) and the modulator valve (port LS1
and port A2). Depending on these pressure signals,
the flow divider allows more or less flow to the main
control valve (port EF). See Figure 3 and Table 1.

1. BREATHER
2. HYDRAULIC SYSTEM RETURN
3. BRAKE SYSTEM RETURN
4. INSPECTION COVER
5. DRAIN PLUG
6. SIGHT GLASS
7. FILTER ELEMENT 1. MODULATOR VALVE
8. SPRING 2. PILOT SYSTEM PRESSURE (A2)
9. FLANGE 3. PILOT VALVE SUPPLY LINE (A1)
10. FILL PLUG 4. STEERING SYSTEM SUPPLY LINE (P)
5. TO MAIN CONTROL VALVE (EF)
6. MODULATOR FLOW DIVIDER
Figure 2. Hydraulic Tank 7. STEERING PRIORITY FLOW VALVE SUPPLY
LINE (S)
HYDRAULIC PUMP 8. TANK (T)
9. STEERING LOAD SENSE LINE (LS1)
The hydraulic pump is a tandem gear-type pump.
The two sections have a common inlet and separate Figure 3. Steering Priority Flow Valve
outlets. The large section of the pump supplies oil to Schematic
the lift section of the main valve. The small section

2
1900 SRM 938 Description and Operation

Table 1. Main Control Valve Port Settings

More Flow to Ports P and A1 More Flow to Port EF

Steering Activated P low P high No steering
Steering Activated LS1 high LS1 low No steering
Low Pilot Pressure A2 low A2 high High pilot pressure

The resulting oil pressure at port A1, that leads to
the pilot valve, depends on the position of the flow
divider and the actual flow through ports P and A1.
Pressure may vary 20 to 165 bar (290 to 2393 psi).
Pressure will raise when the flow divider sends more
oil to ports P and port A1 while oil flow is restricted.
to 29 bar (218 to 421 psi), it will result in more oil
flow from the steering priority flow valve to the pilot
valve. When pilot pressure is getting higher, 35 to
38 bar (493 to 551 psi), it will result in a reduction of
oil flow to the pilot valve. See Figure 4 and Figure 5.

The force of a spring in the flow divider causes a cer-

tain minimum pressure to be reached at port P, be-
fore the connection to port EF is opened.

If port EF is opened at too low of an oil pressure, it

will result in a low oil supply for the steering sys-
tem. This will result in difficulty in turn the steering
wheel quickly. If port EF is opened at too high of an
oil pressure, this will result in heat generation at the
pressure reducer in the pilot valve.

The pressure level at which port EF will open can be

adjusted by turning a screw at the modulator valve.
See Checks and Adjustments.

Restrictors in the steering priority flow valve assist

in the smooth operation of the modulating flow di-
vider, to prevent pressure shocks for the hydraulic
pump and the pump drive.

The 185 bar (2683 psi) relief valve has no particular

function, because the relief valve in the steering hand
pump determines the maximum pressure of 165 bar
(2393 psi) for line LS1.

PILOT VALVE 1. CHECK VALVE

2. FROM STEERING PRIORITY VALVE
The function of the pilot valve is to create a constant 3. FROM HOIST CYLINDER
level of oil pressure for the pilot circuit of the main 4. MANUAL VALVE
control valve. 5. TANK BYPASS VALVE
6. FILTER
Port A1 of the steering priority flow valve sends fluc- 7. ACCUMULATOR
tuating oil pressure to port P1 of the pilot valve. The 8. PILOT PRESSURE
9. FILTER BYPASS VALVE
pressure reducing valve in the pilot valve limits pilot 10. PRESSURE REDUCING VALVE
system oil pressure to 45 to 50 bar (653 to 725 psi).
Excess oil pressure is returned to the tank. Figure 4. Pilot Valve Schematic
Pilot system pressure is also connected with the mod-
ulator valve. When pilot pressure is low, between 15

3
Description and Operation 1900 SRM 938

When the steering system requires more oil flow, it

will result in elevated pressures both at port P and
at port A1 of the steering priority flow valve. Despite
a pressure of 45 to 50 bar (580 to 725 psi) in the pilot
system, and modulator valve, the pressure in port A1
will continue to raise and will exceed 50 bar (725 psi).

An accumulator compensates for differences in oil

supply and oil demand for the pilot system. The
accumulator starts using oil volume at pressures
higher than 16 bar (232 psi). With increasing pres-
sure the additional volume of used oil reduces. When
the pressure in the accumulator is 27 bar (392 psi),
the used volume allows operating the control valve
at a minimum of 5 times. When the pressure in the
accumulator is higher, the used volume will allow
operating the control valve more than five times. See
Checks and Adjustments to inspect the accumulator
for proper functioning.

Oil flow to the pilot lines and to the accumulator has

to pass through a filter, that is protected by a bypass
valve. The 10 micron filter can be replaced by remov-
ing the plug at the bottom of the block. The filter by-
pass valve is located on top of the valve block.

The bypass valve that maintains pressure in the pilot

system is incorporated in the cartridge of the pres-
sure reducing valve. The excess flow leading to the
tank leaves the valve at port T.

The pilot valve also has a manual valve, that allows

lowering the hoist cylinders when there is insuffi-
1. ACCUMULATOR cient pilot pressure to operate the hoist spool. By
2. SEAL opening the manual valve the hoist cylinders will
3. TANK BYPASS VALVE drain to the tank.
4. SETSCREW
5. FILTER
6. PLUG
7. MANUAL VALVE
8. PRESSURE REDUCING VALVE
9. FILTER BYPASS VALVE

Figure 5. Pilot Valve

4
1900 SRM 938 Description and Operation

MAIN CONTROL VALVE
The main control valve collects oil supply from the
tandem pump, distributes oil to the lift, tilt, and aux-
iliary functions, and collects returning oil and leads
it back to the tank. See Figure 6 and Figure 7.
The hydraulic functions are divided over two sections
of the main control valve. One section contains the
tilt and auxiliary functions. Flanged at one side is
the inlet that receives oil from the steering priority
flow valve. A primary relief valve limits pressure
for this section to 193 bar (2799 psi). Spools direct
the oil to the related functions when actuated. When
the tilt or the auxiliary functions are not being used,
the excess oil flows either to the tank through the
unloader valve, or to the lift section of the control
valve. See Unloader Valve for the description of the
unloader valve.
The lift section has an inlet section, the lift/lower con-
trol valve, and an outlet section. The inlet section
receives oil from the large pump and under certain
conditions from the auxiliary section. A primary re-
lief valve limits pressure to 210 bar (3046 psi). When
the spool for the lift function is moved, then oil is sup-
plied to the hoist cylinders. When the lift function is
not used, or when the lowering function is applied,
then oil supply is drained to the tank port.

1. INLET SECTION 9. PARALLEL PASSAGE

2. TILT SECTION 10. CHECK VALVE
3. AUXILIARY SECTION 11. UNLOADER VALVE
4. CENTER SECTION 12. PILOT SUPPLY
5. LIFT SECTION 13. SUPPLY CAVITY
6. OUTLET SECTION 14. DRAIN CAVITY
7. DRAIN PASSAGE 15. PILOT DRAIN LINE
8. OPEN-CENTER PASSAGE

Figure 6. Main Control Valve Schematic

5
Description and Operation 1900 SRM 938

UNLOADER VALVE
Oil that is not used for the tilt or the auxiliary func-
tions, flows to the lift section of the control valve, or
to the tank through the unloader valve. See Figure 8
and Figure 13.

1. FROM LIFT PUMP

2. TO LIFT SECTION
3. CHECK VALVE
1. INLET SECTION 4. UNLOADER PISTON
2. TILT SECTION 5. FROM SMALL PUMP
3. AUXILIARY SECTION 6. TO TANK
4. CENTER SECTION 7. 140 bar (2031 psi) RELIEF VALVE
5. LIFT SECTION 8. 56 bar (812 psi) CHARGE VALVE
6. OUTLET SECTION
7. PILOT DRAIN LINE Figure 8. Unloader Valve
8. TO RIGHT HAND HOIST CYLINDER
9. LARGE PUMP INLET
10. OUTLET PORT Oil passes the check valve to the lift section when
11. STEERING RETURN (T) the pressure of the small pump is higher than the
12. TO LEFT HAND HOIST CYLINDER pressure of the large lift pump. The pressure of the
13. AUXILIARY PISTON SIDE small pump is higher when the lift function is not
14. TILT FORWARD applied or when the lift function is beginning to be
15. FROM PILOT VALVE (T)
16. PILOT PRESSURE (X) applied.
17. FROM STEERING PRIORITY VALVE
18. TILT BACKWARD When the lift function is not applied, oil supply
19. AUXILIARY ROD SIDE drains directly to the tank through the central pas-
sage of he lift section.
Figure 7. Main Control Valve

6
1900 SRM 938
When the lift function is beginning to be applied, the
small pump will assist with delivering oil until pres-
sure has reached 140 bar (2031 psi). The additional
supply below 140 bar (2031 psi) allows quicker hoist
speeds when the load weighs less than 2/3 of the
truck capacity. When supply from the small pump
has reached 140 bar (2031 psi), the relief valve in
the unloader valve will open. The resulting pressure
drop will open the unloader piston, causing the sup-
ply from the small pump to drain to the tank. Be-
cause of the very weak return spring, the unloader
piston will remain in the drain position. Once the
140 bar (2031 psi) relief valve is opened, the 56 bar
(812 psi) charge valve will keep the relief valve in the
opened position, until the pressure from the lift pump
has dropped below 56 bar (812 psi). Below 56 bar
(812 psi) bar the relief valve will close. The unloader
piston will close when the relief valve is closed and
when the check valve to the lift section is open again.
The check valve to the lift section will reopen when
lift pump pressure has returned to near zero.
HYDRAULIC OPERATION
The operation of the tilt, auxiliary, and hoist spool
sections is similar. An electric current activates a so-
lenoid, which causes a pressure reducing cartridge to
Description and Operation
open. Oil from the pilot line enters the cavity of the
spool and moves the spool against the spring force.
See Figure 6 for the schematic and Figure 9 and Fig-
ure 10 for cross sections. The movement of the spool
relates to the pressure admitted to the cavity. The
pressure in the cavity relates to the current through
the solenoid. For a detailed description and setting of
the solenoid signals, see Calibration and Diagnostics.
When the solenoid is deactivated, the cartridge shuts
off pilot oil pressure and opens a connection with the
external tank return line. A spring at the opposite
side of the activated solenoid returns the spool to its
neutral position and moves pilot oil into the external
return line to the tank.
When a spool is moved, it shuts off the connection
with the outlet port of the control valve, and it opens
the connection between the supply cavity and the se-
lected function. Because the outlet has been shut off,
inlet oil will flow to the parallel passage and pass a
check valve that leads to the supply cavity of the se-
lected function. The check valve prevents oil from
flowing in the incorrect direction.
7
Description and Operation 1900 SRM 938

A. SPOOL SELECTED TO EXTEND CYLINDER C. SPOOL SELECTED TO RETRACT CYLINDER

B. NEUTRAL
1. COMPRESSED SPRING 6. PRESSURED CAVITY
2. DRAIN CAVITY 7. CARTRIDGE
3. PORT TO CYLINDER 8. ACTIVATED SOLENOID
4. CHECK VALVE 9. PARALLEL PASSAGE
5. SPOOL 10. OPEN-CENTER PASSAGE

Figure 9. Tilt and Auxiliary

8
1900 SRM 938 Description and Operation

A. SPOOL SELECTED TO RAISE B. NEUTRAL C. SPOOL SELECTED TO

LOAD LOWER LOAD
1. COMPRESSED SPRING 5. PRESSURED CAVITY 9. SUPPLY CAVITY
2. DRAIN CAVITY 6. CARTRIDGE 10. PARALLEL PASSAGE
3. PORT TO LIFT CYLINDER 7. ACTIVATED SOLENOID 11. CHECK VALVE
4. OPEN-CENTER PASSAGE 8. SPOOL

Figure 10. Lifting and Lowering

9
Checks and Adjustments 1900 SRM 938

Checks and Adjustments

QUICK DISCONNECT FITTINGS
These trucks use quick disconnect test fittings for hy-
draulics, transmissions, and air systems. The test
ports are course thread. The recommended hose and
adaptor fittings, for testing these trucks, are shown
on Figure 11 and Figure 12.

1. CHARGE VALVE ADJUSTMENT

A. LENGTH = 800 mm (31.5 in.)
B. M16 X 2.0 THREAD Figure 13. Steering Priority Valve Ports

Figure 11. Flexible Hose STEERING RELIEF PRESSURE

NOTE: The relief valve for the steering system is in
the steering control unit. The relief pressure is set at
the factory.

1. Connect a 0 to 20 MPa (0 to 2900 psi) gauge to

test port.

2. Start engine. Operate hydraulic system until

temperature of hydraulic oil is 55 to 65 C (130 to
150 F). Run engine at approximately 2300 RPM
(turbo) or 2200 RPM (nonturbo) when checking
pressure.

3. Steer in one direction until wheels will not turn

further. Keep steering wheel fully turned and
A. 1/4-18 NPT read gauge. Correct relief pressure is 16.5 MPa
B. 19 MM (2400 psi).
C. M16 X 2.0
D. 56.4 mm (2.22 in.)
WARNING
Figure 12. Gauge Adaptor The adjustment screw compresses a spring.
Use caution and wear eye protection when
STEERING PRIORITY FLOW VALVE adjusting relief valve.
The steering priority flow valve cannot be repaired.
4. If relief pressure is not correct, remove plug and
In case of malfunction, plugs and fittings may be re-
adjust pressure by turning adjustment screw.
moved to inspect for debris that may cause the prob-
See Figure 14.
lem. Screen filters are behind port S and behind the
cartridge for the charge valve adjustment. Only the NOTE: If you cannot correctly adjust relief pressure,
cut in and cut out pressure of the modulator valve replace parts of relief valve.
can be adjusted. See Figure 13.

10
1900 SRM 938
5. When checks are complete, remove gauge and in-
stall cap on fitting.
1. STEERING RELIEF VALVE PLUG
2. MANIFOLD
Figure 14. Manifold, Steering Control Unit
MODULATOR VALVE
NOTE: After warming up the engine, keep the engine
at idle speed.
1. Warm up the hydraulic system by operating for
two minutes the tilt relief valve in 10 second
on/off intervals. The oil temperature should be
near 60 C (140 F).
2. Connect a 70 bar (1015 psi) pressure gauge at
port X2 of the pilot valve. See Figure 4.
NOTE: Record the pressure setting when the gauge
stops declining.
3. Operate the lowering function until the pressure
at the gauge stops declining.
4. At the recorded pressure in Step 3 (cut in set-
ting), the pressure will start rising until the pilot
pressure reaches the cut out setting. Record this
pressure reading.
5. Verify if the recorded pressures are within spec-
ification. Cut in should be between 25 to 29 bar
Checks and Adjustments
(363 to 421 psi). Cut out should be between 34 to
38 bar (493 to 551 psi).
6. If the pressure are not within the specified range
in Step 5, remove the plug from the charge valve
adjustment cartridge and proceed Step 7.
7. Loosen the lock nut two turns with a 10 mm
socket head wrench.
8. Insert a 3 mm socket head wrench and adjust the
cut in and cut out pressures as required. Turn-
ing the socket head wrench clockwise increases
(both) the cut in and the cut out pressure, turn-
ing anti-clockwise decreases (both) pressures. It
may be necessary to repeat Step 3, Step 4, and
Step 5 until the correct pressures are achieved.
9. Tighten the lock nut.
10. Reinstall the plug with silicon sealant, and dis-
connect the test hose from port X2.
PILOT VALVE AND PRESSURE REDUCING
VALVE
The pressure reducing valve cannot be adjusted and
must be replaced if malfunctioning. For the loca-
tion of the pressure reducing valve, see Figure 5.
Proper operation of the pressure reducing valve can
be indicated by connecting pressure gauges at the
quick disconnect fittings at port P1 and port X2 of
the pilot valve, see Figure 15. When pressure at
port P1 is above 60 bar (870 psi), pressure reading
at port X2 should be between 45 to 50 bar (653 to
725 psi). Supply pressure at port P1 will be at least
25 bar (363 psi) when the engine is idling. When
using the steering system, pressure at P1 will raise
above 60 bar (870 psi). Maximum pressure is ob-
tained, when the pressure relief valve of the tilt/aux-
iliary section reaches its maximum value of 193 bar
(2799 psi).
11
Checks and Adjustments
Figure 15. Pilot Valve Pressure Check Ports
ACCUMULATOR
NOTE: Check the accumulator pre-charge pressure
every 6 months.
The pre-charge pressure of the accumulator should
be 16 bar (232 psi). To check the pre-charge pres-
sure, connect a pressure gauge at port X2 of the pi-
lot valve. See Figure 15. Run the engine until the
gauge reads a minimum of 27 bar (392 psi). Stop the
engine and turn the key switch to ON. Gently oper-
ate one of the hydraulic functions. Pressure reading
at port X2 will drop gradually each time a hydraulic
lever is moved. At a value close to 16 bar (232 psi),
the pressure will suddenly drop quickly. The pres-
sure reading just before the pressure started drop-
ping quickly is the accumulator pre-charge pressure.
12
1900 SRM 938
Replace the accumulator if the pre-charge pressure
is below 12 bar (174 psi).
An indication of insufficient pre-charge pressure is
the reduced number of times the control valve can
be operated while the engine is not running. When
starting with a pressure of 27 bar (392 psi) at port X2,
it should still be possible to lower the mast five times
after the engine has stopped. To check this, the mast
has to be raised halfway first, to allow observing the
actual lowering.
FILTER
NOTE: Replace the filter every year.
If the filter is clogged, the filter bypass valve causes
a pressure drop of about 3 bar (44 psi). An indication
for a clogged filter can only be obtained by observing
the pressure differences between port P1 and port
X2 of the pilot valve. A pressure increase at port
P1 will result in a delayed pressure increase at port
X2. When the filter is not clogged, there will be a
simultaneous pressure increase at ports P1 and X2.
MAIN CONTROL VALVE
Relief Pressure Check
The main control valve has two quick disconnect fit-
tings. See Figure 16. To check the relief pressures,
the hydraulic oil must be between 55 to 65 C (131 to
149 F). Run the engine at maximum rpm when mak-
ing pressure checks.
Check the relief pressure in the lift section by raising
the mast until it stops.
Check the relief pressure in the tilt/auxiliary section
by tilting the mast fully forward.
To change the setting, release the jam nut. Tighten
the adjustment cap to increase pressure, loosen the
adjustment cap to lower pressure. Retighten the jam
nut to 55 to 67 N•m (41 to 49 lbf ft).
1900 SRM 938
1. 193 bar (2799 psi) CHECK PORT
2. 193 bar (2799 psi) RELIEF VALVE
3. CHECK VALVE
4. 210 bar (3046 psi) RELIEF VALVE
Figure 16. Main Control Valve Check Ports
CHECK VALVES
To check proper functioning of the check valves, the
related cylinder(s) must be under load. Operate the
hydraulic lever until the cylinders move. Hold the
lever and let the engine run at idle speed. If the cylin-
ders return in the opposite direction, the check valve
leaks. Replace a leaking check valve.
UNLOADER VALVE
NOTE: When lifting a capacity load, pressure read-
ing at the tilt check port will remain zero. Pressure
Checks and Adjustments
5. 210 bar (3046 psi) CHECK PORT
6. UNLOADER CARTRIDGE
7. UNLOADER PISTON
reading at the lift check port will be near 210 bar
(3046 psi).
Attach a pressure gauge at the 193 bar (2799 psi) and
210 bar (3046 psi) pressure check ports. When lifting
a light load, pressure readings at these ports will be
similar. When the lift cylinders have reached the ex-
tended position, pressure at the tilt check port will
drop to zero and pressure at the lift check port will
raise to 210 bar (3046 psi). When lowering, pressure
at the lift check port will drop to zero.
13
Hydraulic Pump Repair
Hydraulic Pump Repair
See other sections of the Service Manual for making
repairs to components within the hydraulic system.
See the section Main Control Valve 2000 SRM 943,
Lift Cylinders for your lift truck, Masts 4000 SRM
445 or Masts and Carriages, Starting 2003 4000
SRM 1062, Steering System 1600 SRM 936, and
Tilt Cylinders 2100 SRM 103 for your lift truck.
NOTE: Worn or damaged seals are the most common
cause of hydraulic pump repair. The seals can be
replaced in the hydraulic pump. The pump thrust
plates, bearings, gears, and shafts also wear. Replace
a worn or damaged hydraulic pump.
REMOVE
WARNING
Tilt mast forward and lower carriage com-
pletely before disconnecting any parts of
hydraulic system. Mast can lower suddenly
and cause injury if mast and carriage are not
lowered.
1. Tilt cab. See the section Operator’s Cab for
your lift truck.
2. Turn key OFF and shut down engine.
3. Get a plug that will fit suction hose. Disconnect
suction hose at pump and quickly raise end of
hose. Install plug in hose.
4. Disconnect high-pressure line at outlet port on
side of pump. Keep end of line above hydraulic
tank until a plug is installed in line.
5. Disconnect second pump supply line at fitting in
end of pump. Install plug in line.
WARNING
The pump weighs approximately 45 kg (100 lb)
and can cause injury or damage if it falls. Ver-
ify that the pump has support before removing
capscrews.
6. Remove four capscrews in pump flange and re-
move pump from torque converter housing.
14
1900 SRM 938
DISASSEMBLE
CAUTION
If pump is held in a vise for disassembly, verify
that vise does not hold pump too tightly and
cause damage to pump body.
NOTE: Take careful notes of locations of parts and
seals during disassembly. Some parts are similar but
not exactly the same. Use a punch to make align-
ment marks on parts of housing.
1. Remove four studs from end housing. See Fig-
ure 17. Carefully separate housing pieces.
2. Remove thrust plates and seals from end hous-
ing.
3. Remove nuts from studs in center section of
pump. Carefully separate center housing from
end housing and remove connection shaft.
4. Separate center housing from shaft end housing.
Remove thrust plates and seals from center hous-
ing.
5. Remove seal for shaft end from housing.
CLEAN AND INSPECT
WARNING
Cleaning solvents are flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety procedures. Wear
protective goggles or a face shield to prevent
eye injuries.
Clean all parts of pump with solvent. Use com-
pressed air to dry parts. Do not use a cloth to dry
parts. Pieces of cloth can cause restrictions in hy-
draulic system.
Inspect gear assemblies and housing parts for wear
and damage. Replace a damaged or worn hydraulic
pump. If gears are replaced, they must be replaced
as matched sets.
1900 SRM 938 Hydraulic Pump Repair

NOTE: Some pump bodies will show gear marks ASSEMBLE

where the gears rotate because of the small clear-
ances between parts. These gear marks do not NOTE: Use new seals during assembly.
indicate a worn or damaged pump unless the pump
1. Verify internal parts of pump are clean. Lu-
will not supply the volume and pressure shown in
bricate parts with hydraulic oil as parts are
Specifications.
installed. See Figure 17.

1. HOUSING, GEAR 6. THRUST PLATE 11. SEAL

2. GEAR, SHAFT SET 7. THRUST PLATE 12. SEAL
3. HOUSING 8. SEAL 13. SEAL
4. GEAR SET 9. SEAL
5. SEAL 10. SEAL

Figure 17. Hydraulic Pump

15
Pilot Accumulator Replacement
2. Install seal in shaft end housing.
3. Verify alignment pins are in shaft end housing.
Install seals, thrust plates, and center housing
on shaft end housing.
4. Install connection shaft. Tighten nuts in a cross
pattern.
5. Verify that alignment pins are in center housing.
Install thrust plates and gear housing in center
housing. Verify that seals for housing and thrust
plate are installed.
6. Verify that alignment pins and seals are in-
stalled. Install end housing with studs, nuts, and
washers. Tighten nuts to 271 N•m (200 lbf ft).
Pilot Accumulator Replacement
REMOVE
WARNING
The accumulator has a pressure charge and
can cause an injury if the pressure is released
too fast. Follow the manufacturer’s instruc-
tions during removal and installation.
Before disconnecting the pilot accumulator, release
pressure from the hydraulic circuit as follows:
• Shut off engine and completely lower the mast. In-
stall blocks at wheels to prevent truck from mov-
ing.
• Operate the levers until no pressure is left in the
hydraulic system (at least 20 times).
1. Slowly disconnect the pilot accumulator from the
pilot valve by unscrewing the accumulator. Re-
move the pilot accumulator and put a cap on the
pilot valve connection.
16
1900 SRM 938
INSTALL
1. Clean flange of pump and mounting surface on
torque converter housing.
2. Install pump on torque converter housing. Use
a sealant (Hyster Part No. 264159) on flange of
pump. Tighten capscrews to 77 N•m (57 lbf ft).
3. Connect hydraulic line(s) to pump. Tighten
capscrews for flange of high-pressure hose to
50 N•m (37 lbf ft). If necessary, tighten cap-
screws for flange of suction hose to 77 N•m
(57 lbf ft).
INSTALL
NOTE: Follow the manufacturer’s instructions dur-
ing installation of the new pilot accumulator.
1. Operate the system and check for leaks.
2. Check if the pilot accumulator pressure charge is
between 2.7 to 3.6 MPa (391 to 522 psi). See the
section Periodic Maintenance, Perkins Tier
2 Emission Engine 8000 SRM 1066 for E019
and F007 trucks, Periodic Maintenance 8000
SRM 1099 for F019 and G007 trucks, and Pe-
riodic Maintenance 8000 SRM 1347 for G019
and H007 trucks, for the correct pressure charge
check.
1900 SRM 938 Pilot Valve Repair

Pilot Valve Repair

REMOVE
WARNING
Tilt mast forward and lower carriage com-
pletely before disconnecting any parts of
hydraulic system. Mast can lower suddenly
and cause injury if mast and carriage are not
lowered.
1. Shut down engine.
all pressure has been removed from hydraulic
system.
4. Tilt cab. See the section Operator’s Cab for
your lift truck.
5. Disconnect hydraulic lines at valve. Put tags for
identification on lines. Put caps on open lines.
6. Remove nuts and bolts that hold valve to mount-
ing plate. See Figure 18. Remove pilot valve.

2. Turn key switch to ON position.

3. Shift all hydraulic control levers together, back

and forth, a minimum of 20 repetitions to ensure

1. PILOT VALVE 4. NUT

2. BOLT 5. PILOT BLOCK MANUAL TAP
3. WASHER

Figure 18. Pilot Valve Mounting

17
Pilot Valve Repair 1900 SRM 938

DISASSEMBLE 4. Operate system and check for leaks.

5. Lower cab until latched.

CAUTION
If pilot valve is held in vise for disassembly, ver-
ify that vise does not hold valve too tightly and
cause damage to valve body.

NOTE: Take careful notes of locations of parts and

seals during disassembly. Some parts are similar but
not exactly the same.

1. Remove parts as necessary to replace defective or

worn components. See Figure 19.

CLEAN AND INSPECT

WARNING
Cleaning solvents are flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety procedures. Wear
protective goggles or a face shield to prevent
eye injuries.

Clean all parts of valve with solvent. Use compressed

air to dry parts. Do not use a cloth to dry parts.
Pieces of cloth can cause restrictions in hydraulic sys-
tem.

ASSEMBLE
NOTE: Use new seals during assembly.

1. Verify internal parts of valve are clean. See Fig-

ure 19. Lubricate parts with hydraulic oil as they
are installed.

2. Replace defective or worn components as neces-

sary.
1. BLOCK 9. PLUG
INSTALL 2. ACCUMULATOR 10. FILTER
3. PROTECTING CAP 11. PILOT BLOCK
1. Tilt cab. See the section Operator’s Cab for 4. BOLT MANUAL TAP
5. SEAL 12. CHECK VALVE
your lift truck. 6. NUT 13. SEAL KIT
7. VALVE 14. O-RING
2. Put valve on mounting plate. See Figure 18. In- 8. SEAL
stall nuts and bolts that hold valve to mounting
plate. Figure 19. Pilot Valve

3. Connect hydraulic lines at valve. Verify connec-

tions are correct and tight.

18
1900 SRM 938 Control Levers and Joystick Repair

Control Levers and Joystick Repair

REMOVE 3. Connect electrical connector.

4. Attach bottom cover plate to armrest with six

WARNING screws.
Tilt mast forward and lower carriage com-
pletely before disconnecting any parts of 5. Calibrate new control levers. See Calibration
hydraulic system. Mast can lower suddenly and Diagnostics.
and cause injury if mast and carriage are not
lowered. NOTE: The joystick is removed and installed using
the same procedures as noted for control levers ex-
1. Shut down engine. cept that four screws are used to fasten the joystick
to mounting plate rather than two screws, as used
2. Turn key switch to ON position. for control levers.
3. Shift all hydraulic control levers together, back
and forth, a minimum of 20 repetitions to ensure
all pressure has been removed from hydraulic
system.

4. Remove six screws from cover/mounting plate on

bottom side of armrest and remove plate. See
Figure 20.

5. Disconnect electrical connector.

6. Remove two screws and washers that attach con-

trol lever to mounting plate.

7. Remove defective control lever.

1. ELECTRICAL CONNECTOR
INSTALL 2. SCREW
3. WASHER
1. Place new control lever in mounting plate. See 4. COVER/MOUNTING PLATE
Figure 20. 5. CONTROL LEVER
2. Fasten two screws and washers that hold control Figure 20. Control Levers
lever into mounting plate.

19
Calibration and Diagnostics 1900 SRM 938

Calibration and Diagnostics

GENERAL the lever positions neutral, fully forward, and fully
backward. To prevent unjustified error codes, verify
By moving hydraulic levers, electrical signals are the lever has fully reached these positions during cal-
sent to the PWM (Pulse Width Modulation) module ibration.
and to the I/O (Input/Output) modules when in-
stalled. The PWM module communicates with the
I/O module by use of the CAN bus wires. The PWM
and I/O module translates the signal received into a
current that is connected with the solenoids on the
main control valve, causing the selected function to
operate.

The CAN bus wires also lead to a connector that can

be linked to a PC. When a related software program
has been installed, the PC allows setting and diag-
nostics of the hydraulic system.

To verify proper functioning without a PC, the PWM

and I/O module have LED’s, that flash a code that
relates to either proper functioning or a specific error.

DESCRIPTION
Lever and Joystick Calibration
The PWM module (Pulse Width Modulation) and I/O
module (Input/Output) generate a base signal to the
potentiometers (potmeters) in the hydraulic levers.
Depending on the lever position, the lever returns a
signal voltage to the PWM module. In positions close A. FORWARD LEVER POSITION
to the neutral position, the lever signal remains at B. BACKWARD LEVER POSITION
C. NEUTRAL LEVER POSITION
a fixed value. See Figure 21. The signal voltages D. SIGNAL VOLTAGE TO PWM
assigned to the neutral position, and to the extreme E. LEVER BIT POSITION
positions are essential for proper functioning. Signal F. SIGNALS GENERATING ERROR CODE
voltages lower than 0.5 Volt or higher than 4.5 volt
are considered false, and will generate an error code. Figure 21. Lever Signal
The neutral position provides a signal voltage of 2.5
volt, causing the control valve to NOT be activated by Flow Adjustment
the control valve. Signal voltages between 0.5 Volt
NOTE: Flow adjustment is only possible for the auxil-
2.5 volt and 2.5 volt and 4.5 volt will activate the
iary function. If two auxiliary functions are operated
control valve.
at the same time, then the highest output signal de-
A random replacement lever will send different sig- termines the flow of the control valve.
nal voltages to the PWM module. These different sig-
To adjust the response of the control valve, the valve
nal voltages may generate error codes, or activate the
flow adjustment program allows entering the lowest
control valve, although the lever is in the neutral po-
and highest PWM output signal to the control valve.
sition. By calibrating a lever, the PWM module is
programed to know which signal voltages belong to

20
1900 SRM 938
The PWM output signal results in an electrical cur-
rent through the solenoid of the control valve. The
direct relation between output signal (in bit) and cur-
rent (in mAmps) is shown on the horizontal axis in
Figure 22.
The electric current activates a solenoid, which
causes a pressure reducing cartridge to move. De-
pending on the electric current, the cartridge takes
a certain position and provides a related pilot oil
pressure to the cavity of the control valve spools.
The relation between current and admitted pilot
pressure is shown in Figure 22.
A minimum of 320 mAmp (20 bit) is required to start
cartridge movement. At 1100 mAmp (69 bit) the car-
tridge is at its maximum stroke. A further increase
in current does not result in a further increase of the
admitted pilot oil pressure.
The purpose of the pilot pressure is to move the spool
of the control valve. It takes a minimum pilot pres-
sure of 5 bar (73 psi), before the spool of the control
valve moves and the activated function will start op-
erating. To obtain 5 bar (73 psi) pilot pressure at the
spool cavity requires a PWM output of 0.51 Amp (32
bit). Maximum movement of the control valve spool
is achieved when pilot pressure is 24 bar (348 psi), at
a PWM output of 1.10 Amp (69 bit). It is suggested to
adjust the function flow settings between 30 and 70.
A. PILOT PRESSURE
B. VALVE FLOW ADJUSTMENT LEVEL
C. PWM OUTPUT SIGNAL IN MILLIAMPERE’S
D. START SPOOL STROKE
E. FULL SPOOL STROKE
Figure 22. Pilot Pressure
Calibration and Diagnostics
Dead Band Value Setting
NOTE: The dead band value entered will be applied
to all levers. It is not possible to select different dead
band values for each individual lever.
Selection of an auxiliary function causes the solenoid
of the selected function to open and to operate the
auxiliary spool of the main control valve. When re-
leasing the auxiliary function, these two valves close
simultaneously. This results in trapped pressured
oil between the auxiliary spool and the selected sole-
noid, affecting service life of hoses and valves. By re-
leasing the auxiliary spool earlier than the solenoid
of the selected function, remaining pressure in the
hose between these two valves is limited. Timing of
the earlier release of the auxiliary spool is achieved
by widening the dead band. When the dead band
is widened, it will also take longer until the PWM
module will start sending output currents. Therefore
the dead band must be set as low (narrow) as possi-
ble, but as high (wide) as necessary to avoid trapping
pressured oil. A small dead band value provides im-
mediate lever response. A wider dead band value re-
quires a longer lever stroke before the PWM module
activates the selected solenoid. See Figure 23.
A. B-SIDE SOLENOID
B. A-SIDE SOLENOID
C. DEAD BAND
D. PWM BIT OUTPUT
E. LEVER SIGNAL VOLTAGE
Figure 23. Dead Band
21
Calibration and Diagnostics 1900 SRM 938

Lowering Delay
A capacity load will induce quick lowering move-
ments when applying the lowering lever. To facilitate
a smooth start of the lowering movement, the signal
increase as provided by the actual lever movement is
delayed with a maximum of 150 milli-seconds. Set-
ting the lowering delay at a maximum value of 150,
provides a delayed response. A setting at a lower
value provides a quicker response. See Figure 24.

Figure 25. PV3 Readouts Screen

A. PWM BIT OUTPUT

B. TIME IN MILLI-SECONDS
C. LEVER MOVEMENT
D. DELAYED PWM OUTPUT

Figure 24. Lowering Delay

PWM and I/O Module Readouts

This function indicates the position of the function Figure 26. I/O Readouts Screen
lever, the programmed output current that belongs to
that lever position, and the actual solenoid coil cur-
rent. See Figure 25 and Figure 26.

For the PWM Readout, current A refers to hoist, tilt

forward, and auxiliary out. Current B refers to low-
ering, tilt backward, and auxiliary in. For the I/O
Board Readouts the pin numbers 9 through 12 refer
to the 12-pole plug (C3) just below the LED’s on the
I/O board. See Figure 27.

1. LED ROWS 2. MODULE

Figure 27. Module Connectors

22
1900 SRM 938 Calibration and Diagnostics

Function Disable 4. Double click on file "delayTimeFile.dat" and open

it with "Notepad" or "Wordpad". When the file
NOTE: When re-enabling these functions, recalibra- opens, a default number that corresponds to the
tion is necessary. For description see Hydraulic Con- processor speed will be listed (Example: 85555).
trols Program. Replace this number by highlighting and enter-
ing the value as described in step 6.
It is possible to disable the 3rd and the 4th propor-
5. From Table 2, chose the number that corresponds
tional function and the sideshift function. In case you
to the processor speed. If the actual processor
want to disable or re-enable, select the following pro-
speed is not listed, select the next lowest value.
grams in the Hydraulic Controls Program:
Do not select a speed that is greater than the
• Lever Calibration, for 3rd and 4th Proportional
actual processor speed.
Function.
6. Highlight and replace the number in the "delay-
• Joystick Calibration, for Sideshift.
Timefile.dat" file as discussed in step 4. Replace
the number with one from Table 2. Save the new
GENERAL STARTUP
number by opening "file" in the toolbar and se-
Minimum system requirements lecting "Save". Exit the file. Reboot the PC be-
fore using the Hydraulic Controls Program.
• IBM compatible laptop computer with minimum
Pentium 133 MHz processor Table 2. Processor Speed Settings
• Windows 98, Windows NT, Windows 2000, or Win-
dows XP Number Processor Speed
• CD reader 33333 150 MHz
• An open PC serial communication port: Communi-
cation port 1 or 2. 44444 250 MHz
• Communication cable (Hyster Part Number 55555 350 MHz
2045306)
65535 450 MHz
• Hydraulic Controls Program (Hyster Part Number
1508366) 75555 550 MHz
85555 600 MHz
Install the Hydraulic Controls Program
140000 775 MHz
Install the Hydraulic Controls Program on the PC ac-
cording to the directions received with the software. 198000 950 MHz
255000 1.1 GHz (1100 MHz)
DelayTimeFile (Reset)
312000 1.3 GHz (1300 MHz)
By default, the synchronization speed of older User-
369000 1.5 GHz (1500 MHz)
Interface programs is set at 600 MHz. Laptops with
higher processor speeds can experience communica- 426000 1.8 GHz (1800 MHz)
tion synchronization issues, that show up after open-
483000 2.0 GHz (2000 MHz)
ing the program and selecting "PWM". Typical error
messages include: "Run time error 13", "Run time er- 540000 2.2 GHz (2200 MHz)
ror 6", and "No Communication with PV3". Starting
597000 2.4 GHz (2400 MHz)
with User-Interface program V3.3, this issue can be
resolved as follows: 654000 2.5 GHz (2500 MHz)
1. Install the Hydraulic User-Interface program
711000 2.71 GHz (2700 MHz)
V3.3.
2. Go to "Start", "Control Panel" and "System Prop- 768000 2.9 GHz (2900 MHz)
erties" on the computer and record the processor 825000 3.0 GHz (3000 MHz)
speed.
3. Open Microsoft Explorer (File Manager) and go
to directory "c:\program files\node_syst".

23
Calibration and Diagnostics 1900 SRM 938

Select the Processor Speed

For correct operation of the software, the processor
speed in the Hydraulic Controls Program must be se-
lected. Select setup, the processor speed screen will
be displayed. See Figure 28. Select the processor
speed of your computer. Quit the program. Reboot
the computer.

1. PLUG
Figure 28. Processor Speed Screen
Figure 29. Electronic Diagnostic Plug Location
HYDRAULIC CONTROLS PROGRAM 5. Turn on laptop computer.

CAUTION NOTE: The first time this diagnostic test is per-

formed, the Hydraulic Controls Program will have
Do not start engine while performing diagnos-
to be installed on computer according to directions
tic test. Engine should not be running at any
received with software.
time during test.
6. Select Start, Programs, then Hydraulic Controls
CAUTION Program. Click to start program. The first pro-
Irreparable damage may occur to the PWM gram menu will be displayed. See Figure 30.
board and/or the I/O board if the calibration
system shutdown procedure is not precisely
followed.

1. Remove cover to gain access to electronic control

compartment.

2. Remove plug from electronic diagnostic port. See

Figure 29.

3. Connect communication interface cable between

laptop computer and hydraulic diagnostic port. Figure 30. Board Connection Screen

4. Turn ignition key to ON position. 7. Select PWM.

8. Select number of I/O boards. The top module

installed at the left hand side of the fuse panel

24
1900 SRM 938 Calibration and Diagnostics

is the PWM module. The modules installed be-

low the PWM module are I/O modules. There
can be 2, 1 or zero I/O modules installed. Select
the number of I/O boards on the screen. See Fig-
ure 31, Figure 32, and Figure 33.

Figure 33. Hydraulic Controls Program

Interface Screen, FLT Fixed Supply

9. Select Attachment. If the truck has an empty

container attachment, select (E)CH. If the truck
does not have an empty container attachment,
select FLT altering supply and return or FLT
fixed supply. Altering or fixed supply depends
on the hydraulic system configuration. After se-
Figure 31. Hydraulic Controls Program
lection, the appropriate screen will be displayed.
Interface Screen, (E)CH
See Figure 31, Figure 32, and Figure 33.

10. Select clamp options. Clamp options for these

3rd or 4th proportional functions can be recog-
nized by the operating lever, that must be pushed
in before lever movement is possible. If the lever
must be pushed in, select 3rd or 4th Proportional
Function.

11. Select language.

NOTE: The following step is only available with the

FLT altering supply.

12. Select PWM number listed on the PWM label,

i.e., 8507741. Otherwise, select other.

Figure 32. Hydraulic Controls Program

Interface Screen, FLT Altering Supply and
Return

25
Calibration and Diagnostics
CALIBRATION
Joystick/Lever Calibration
Select Joystick/Lever Calibration. The Calibration
screen will be displayed. See Figure 34 for FLT or
Figure 35 for ECH.
Figure 34. Lever Calibration Screen, FLT
Shown
Levers
1. For calibration of levers, select Lever.
2. Select function to be calibrated: Lift, Tilt, 3rd
Proportional Function, or 4th Proportional Func-
tion.
3. Move lever BACKWARD and hold. Click on
Lever Backward. Allow value to be saved, then
release lever.
4. Move lever to NEUTRAL position. Click on
Lever Centered. Allow value to be saved, then
release lever.
5. Move lever FORWARD and hold. Click on Lever
Forward. Allow value to be saved, then release
lever.
6. Select next function to be calibrated and repeat
Step 3, Step 4, and Step 5.
NOTE: It is possible to select a deadband value for
levers. With lever centered, select required dead-
band value and save by clicking on deadband. Saved
deadband value is for all levers; individual setting
is not possible. It is also possible to disable a lever.
26
1900 SRM 938
Click on 3rd Proportional Function or 4th Propor-
tional Function to activate the disable function. Af-
ter the problem has been cured, recalibration of the
function is required.
Joystick
NOTE: It is possible to select a deadband value for
joystick/wheel. With joystick/wheel centered, select
required deadband value, and save by clicking on
Deadband. Saved deadband value is for all joystick;
individual setting is not possible. It is also possible
to disable the function sideshift. Click on Sideshift to
activate the disable function. After the problem has
been cured, recalibration of the re-enabled function
is required.
1. For calibration of joystick, select Joystick. See
Figure 35.
Figure 35. Joystick Calibration Screen
2. Select function to be calibrated: Lift, Tilt, or
Sideshift for ECH and Lift, Tilt, 3rd Propor-
tional Function, or 4th Proportional Function for
FLT.
3. Move joystick or rotate wheel in direction de-
pendant upon function selected and hold. Click
on appropriate button. Allow value to be saved,
then release joystick/wheel.
4. Move joystick or rotate wheel to NEUTRAL po-
sition. Click on Joystick/wheel Centered to save
value.
5. Move joystick or rotate wheel in direction de-
pendant upon function selected and hold. Click
on appropriate button. Allow value to be saved,
then release joystick/wheel.
1900 SRM 938
6. Select next function to be calibrated and repeat
Step 3, Step 4, and Step 5.
7. After calibration of levers or joystick/wheel, click
on Go Back. Main menu will be displayed. See
Figure 31, Figure 32, and Figure 33.
VALVE FLOW ADJUSTMENT
1. Click on Valve Flow Adjustment. Flow Adjust-
ment screen will be displayed. See Figure 36 or
Figure 37.
Figure 36. Flow Adjustment Screen, ECH
Figure 37. Flow Adjustment Screen, FLT
2. Select function to be adjusted, Step 1 on the ad-
justment screen.
Calibration and Diagnostics
NOTE: The following procedure is for lowering only.
3. Adjust lower flow delay.
4. Adjust function flow settings, Step 2 on the ad-
justment screen.
5. Click on Save, Step 3 on the adjustment screen.
6. Repeat procedure for next function.
7. Click on Go Back and main menu will be dis-
played. See Figure 31, Figure 32, and Figure 33.
DIAGNOSTICS
1. Click on Diagnostics. Diagnostics screen will be
displayed. See Figure 38.
Figure 38. Diagnostics Screen
2. View Diagnostic screen for possible error codes.
3. Click on Go Back. Main menu screen be dis-
played. See Figure 31, Figure 32, and Figure 33.
CALIBRATION SYSTEM SHUTDOWN
1. Click on Quit to close the Hydraulic Controls Pro-
gram.
2. Turn off laptop computer.
3. Turn ignition key to OFF position.
4. Disconnect communication cable.
5. Install plug for diagnostic port.
6. Install cover.
27
LED Diagnostics 1900 SRM 938

LED Diagnostics
Within the system, there is always a PWM Driver then A2, and then A1. After this test sequence, LED
module. The PWM module has an advanced micro- row A1 blinks one time per second to indicate that no
processor with 32K of memory. system errors are present.

When the truck is switched on, LED row A1 to A4 When a system error occurs, LED row A indicates
are tested. See Figure 27. First A4 blinks, then A3, error conditions. See Table 3.

Table 3. PWM Board LED Error Codes

Error Code
No. of
1=LED "ON" Fault Description
Flashes
0=LED "OFF"
A1 A2 A3 A4
0 1 0 0 1 CAN communication error with I/O 1
0 1 0 0 2 CAN communication error with I/O 2
0 1 0 0 6 Over current on valve 1 (Lift)
0 1 0 0 7 Over current on valve 2 (Tilt)
0 1 0 0 8 Over current on valve 3
0 1 0 0 9 Supply voltage greater than 32 volts
0 1 0 0 10 Supply voltage less than 9 volts
0 1 0 0 11 5-volt supply too low
1 1 0 0 1 I/O module 1, output 1 over current
1 1 0 0 2 I/O module 1, output 2 over current
1 1 0 0 3 I/O module 1, output 3 over current
1 1 0 0 4 I/O module 1, output 4 over current
1 1 0 0 5 I/O module 1, voltage greater than 32 volts
1 1 0 0 6 I/O module 1, voltage less than 9 volts
1 1 0 0 7 I/O module 1, 5-volt supply failure
1 1 0 0 8 I/O module 1, 4-volt supply failure
1 1 0 0 9 I/O module 1, 1-volt supply failure
0 1 1 0 1 I/O module 2, output 1 over current
0 1 1 0 2 I/O module 2, output 2 over current
0 1 1 0 3 I/O module 2, output 3 over current
0 1 1 0 4 I/O module 2, output 4 over current
0 1 1 0 5 I/O module 2, voltage greater than 32 volts
0 1 1 0 6 I/O module 2, voltage less than 9 volts
0 1 1 0 7 I/O module 2, 5-volt supply failure
0 1 1 0 8 I/O module 2, 4-volt supply failure
0 1 1 0 9 I/O module 2, 1-volt supply failure

28
1900 SRM 938 LED Diagnostics

Table 3. PWM Board LED Error Codes (Continued)

Error Code
No. of
1=LED "ON" Fault Description
Flashes
0=LED "OFF"
A1 A2 A3 A4
0 0 1 1 1 Joystick 1 error (Lift)
0 0 1 1 2 Joystick 2 error (Tilt)
0 0 1 1 3 Joystick 3 error (Sideshift)
0 0 1 1 4 Joystick 4 error (Aux/clamp)

In addition to the PWM module, an I/O module might appropriate output signals. LED rows A and B indi-
be present. This I/O module has a less advanced cate the status of the input and output commands.
microprocessor with 2K of memory. The module is See Table 4, Table 5, Table 6, and Table 7.
used to process operator commands and generate

Table 4. Altering PT FLT I/O Board LED’s (Old Logic)

Input Signal Output Signal

Command Remark
Indication Indication
A1 will blink if CAN communication error
Standby A1
occurs
Aux 2 switch input A1 On B1 On
Aux 3 switch input A2 On B2 On
Inhibit switch on the Inhibit switch enables fourth lever solenoids
A3 On
fourth lever
Fourth lever A4 On B1 and B2 On
Third lever B3 and B4 On

Table 5. Altering PT FLT I/O Board LED’s (New Logic)

Input Signal Output Signal

Command Remark
Indication Indication
A1 will blink if CAN communication error
Standby A1
occurs
Auxiliary 2 switch A1 On B1 On
Auxiliary 3 switch A2 On B2 On
Inhibit switch on the Inhibit switch enables fourth lever solenoids
A3 On
fourth lever
Fourth lever A4 On B4 On
Third lever B3 On

29
LED Diagnostics 1900 SRM 938

Table 6. Fixed PT Logic I/O Boards LED’s

Input Signal Output Signal

Command Remark
Indication Indication
A1 will blink if CAN communication error
Standby A1
occurs
I/O 1
Auxiliary 2 switch A1 On
Auxiliary 3 switch A2 On
Inhibit switch on the Inhibit switch enables fourth lever solenoids
A3 On
fourth lever on I/O 1
Depending on direction of lever and inhibit
Fourth lever A4 On B3 or B4 On
switch
Depending on direction of lever and inhibit
Third lever B1 or B2 On
switch
I/O 2
Inhibit switch on the Inhibit switch enables third lever solenoids on
A3 On
third lever I/O 1
Depending on direction of lever and inhibit
Fourth lever B3 or B4 On
switch
Depending on direction of lever and inhibit
Third lever B1 or B2 On
switch

Table 7. ECH

Input Signal Output Signal

Command Remark
Indication Indication
A1 will blink if CAN communication error
Standby A1
occurs
Twist lock A1 On
Sideshift B3 or B4 On Depending on direction of lever
Extend/Retract A2 or A3 On B1 or B2 On Depending on direction of switch

30
1900 SRM 938 Electrical Connections

Electrical Connections
The PWM and I/O modules have three connectors;
C1, C2, and C3. See Figure 27.
Electric supply for the PWM and I/O modules is at
module connector C1 through wires 112 and 621, 622,
and 623. See Figure 39. The connector references for
the side console harness are C300, C330, and C360.
CAN bus communication is at C2 through wires 453
and 454. Connector references for the harness are
C280, C310, and C340.
The standard electrical schematic does not show all
optional wiring connections. In addition, the PWM
and I/O module have an internal logic that cannot
be made visible on the electrical schematic. Tables
Table 8, Table 9, and Table 10 assist with the verifi-
cation of electrical circuits.
Table 11, Table 12, and Table 13 shows the interac-
tion of the modules depending on the input signals
received.

Input and output signals are received and sent at

plug C3. Connector references are C290, C320, and
C350.

Figure 39. Connector Reference

Table 8. PWM Driver Module

Before Starting Starting Starting

February 2003 February 2003 February 2003 February 2003
PIN WIRE Alternating Alternating Fixed PT ECH
A/B (FLT) A/B (FLT) (FLT)
1 408 Lift Joystick Lift Lift Lift
Input Potentiometer Potentiometer Potentiometer
Input Input Input
2 409 Tilt Joystick Tilt Tilt Tilt
Input Potentiometer Potentiometer Potentiometer
Input Input Input
3 410 Aux Joystick Aux 0 Aux 0 Aux 0
Input Potentiometer Potentiometer Potentiometer
Input Input Input
4 405 5V Joystick 5V 5V 5V
Supply Potentiometer Potentiometer Potentiometer
Supply Supply Supply

31
Electrical Connections 1900 SRM 938

Table 8. PWM Driver Module (Continued)

Before Starting Starting Starting

February 2003 February 2003 February 2003 February 2003
PIN WIRE Alternating Alternating Fixed PT ECH
A/B (FLT) A/B (FLT) (FLT)
5 406 Digital Ground Digital Ground Digital Ground Digital Ground
6 Not Used Not Used Not Used Not Used
7 425 Aux Valve Aux Valve Aux Valve Aux Valve
Output B Output B Output B Output B
8 424 Aux Valve Aux Valve Not Used Not Used
Output A Output A
9 423 Tilt Valve Tilt Valve Tilt Valve Tilt Valve
Output B Output B Output B Output B
10 422 Tilt Valve Tilt Valve Tilt Valve Tilt Valve
Output A Output A Output A Output A
11 468 Lift Valve Lift Valve Lift Valve Lift Valve
Output B Output B Output B Output B
12 457 Lift Valve Lift Valve Lift Valve Lift Valve
Output A Output A Output A Output A

Table 9. Input/Output Module 1

Before Starting Starting Starting

February 2003 February 2003 February 2003 February 2003
PIN WIRE Alternating Alternating Fixed PT ECH
A/B (FLT) A/B (FLT) (FLT)
1 411 Clamp Joystick Aux 1 Aux 1 Unused Analog
Input Potentiometer Potentiometer Input
Input Input
2 413 Aux 2 Switch Aux 2 Switch Aux 2 Switch Aux 2 Switch
Input Input Input Input
3 414 Aux 3 Switch Aux 3 Switch Aux 3 Switch Pressure Signal
Input Input Input Input
4 412 Deadman Inhibit 1 Switch Inhibit 1 Switch Unused Analog
Switch Input Input Input Input
5 405 5V Joystick 5V 5V 5V
Supply Potentiometer Potentiometer Potentiometer
Supply Supply Supply
6 406 Digital Ground Digital Ground Digital Ground Digital Ground
7 404 4V Switch 4V Switch 4V Switch 4V Switch
Supply Supply Supply Supply

32
1900 SRM 938 Electrical Connections

Table 9. Input/Output Module 1 (Continued)

Before Starting Starting Starting

February 2003 February 2003 February 2003 February 2003
PIN WIRE Alternating Alternating Fixed PT ECH
A/B (FLT) A/B (FLT) (FLT)
8 407 1V Switch 1V Switch 1V Switch 1V Switch
Supply Supply Supply Supply
9 429 Sideshift Aux 1 Output Aux 0 Output Sideshift RH
Output Output
10 428 Sideshift Aux 0 Output Aux 0 Output Sideshift LH
Output Output
11 427 Clamp/Aux 3 Aux 3 Output Aux 1 Output Retraction
Output Output
12 426 Clamp/Aux 2 Aux 2 Output Aux 1 Output Extension
Output Output

Table 10. Input/Output Module 2

Before Starting Starting Starting

February 2003 February 2003 February 2003 February 2003
PIN WIRE Alternating Alternating Fixed PT ECH
A/B (FLT) A/B (FLT) (FLT)
1 Aux 4 Switch Aux 4 Switch Aux 4 Switch Unused Analog
Input Input Input Input
2 Aux 5 Switch Aux 5 Switch Aux 5 Switch Unused Analog
Input Input Input Input
3 Aux 6 Switch Unused Analog Aux 6 Switch Unused Analog
Input Input Input Input
4 470 Unused Analog Inhibit 0 Switch Inhibit 0 Switch Unused Analog
Input Input Input Input
5 405 5V Supply 5V Supply 5V Supply Not Used
6 406 Digital Ground Digital Ground Digital Ground Not Used
7 404 4V Switch 4V Switch 4V Switch Not Used
Supply Supply Supply
8 407 1V Switch 1V Switch 1V Switch Not Used
Supply Supply Supply
9 Unused Output Aux 1 Output Aux 0 Output Unused Output
10 Aux 6 Output Aux 0 Output Aux 0 Output Unused Output
11 Aux 5 Output Aux 5 Output Aux 1 Output Unused Output
12 Aux 4 Output Aux 4 Output Aux 1 Output Unused Output

33
Electrical Connections 1900 SRM 938

Table 11. Altering PT FLT

Input Output
Without Inhibit Switch With Inhibit Switch
C290 1 C290 11/12 C290 11/12
C290 2 C290 9/10 C290 9/10
C290 3 C290 7/8 + C320 10 C290 7/8 + C350 10
C350 4 + C290 3 N/A C290 7/8 + C320 10
C320 1 C290 7/8 + C320 9 C290 7/8 + C350 9
C320 4 + C320 1 N/A C290 7/8 + C320 9
C320 2 C290 7/8 + C320 12 C290 7/8 + C320 12
C320 3 C290 7/8 + C320 11 C290 7/8 + C320 11
C350 1 C290 7/8 + C350 12 C290 7/8 + C350 12
C350 2 C290 7/8 + C350 11 C290 7/8 + C350 11

Table 12. Fixed PT FLT

Input Output
Without Inhibit Switch With Inhibit Switch
C290 1 C290 11/12 C290 11/12
C290 2 C290 9/10 C290 9/10
C290 3 C290 7 + C320 9/10 C290 7 + C350 9/10
C350 4 + C290 3 N/A C290 7 + C320 9/10
C320 1 C290 7 + C320 11/12 C290 7 + C350 11/12
C320 4 + C320 1 N/A C290 7 + C320 11/12
C320 2 C290 7 C290 7
C320 3 C290 7 C290 7
C350 1 C290 7 C290 7
C350 2 C290 7 C290 7
C350 3 C290 7 C290 7

34
1900 SRM 938 Diagrams, Schematics, or Arrangements

Table 13. ECH

Input Output
C290 1 C290 11/12
C290 2 C290 9/10
C290 3 C290 7 + C320 9/10
C320 2 C290 7 + C320 11/12
C320 3 C290 7

Specifications
Item Specification
Hydraulic Pump Capacity* Turbo Engine 1006-60T, 1106C-E60TA
Large Section 192.0 liter/min (51 gal/min) at 21.0 MPa (3045 psi)
Small Section 93.0 liter/min (24.6 gal/min) at 19.3 MPa (2800 psi)
Hydraulic Pump Capacity Naturally Aspirated Engine 1006-60
Large Section 160.0 liter/min (42.3 gal/min) at 21.0 MPa (3045 psi)
Small Section 78.0 liter/min (20.6 gal/min) at 19.3 MPa (2800 psi)
Hydraulic Pump Capacity Turbo Engine, Cummins BT 5.9
Large Section 208.0 liter/min (54.9 gal/min) at 21.0 MPa (3045 psi)
Small Section 101.0 liter/min (26.7 gal/min) at 19.3 MPa (2800 psi)
Relief Pressures*
Main Control Valve
Lift Circuit 21.0 MPa (3045 psi)
Tilt and Sideshift Circuits 19.3 MPa (2400 psi)
Steering Circuit 16.5 MPa (2800 psi)
Hydraulic Tank Capacity
Dipstick FULL mark 109 liter (28.8 gal)
Hydraulic System Capacity 139 liter (36.7 gal)
*Oil temperature 60 C (140 F) and engine speed at 2300 RPM (Turbo) 2200 RPM (Non-turbo).

NOTE: For all hydraulic schematics, see Diagrams 8000 SRM 1103 for F019 and G007 trucks, and Dia-
8000 SRM 941 for E019 and F007 trucks, Diagrams grams 8000 SRM 1346 for G019 and H007 trucks.

35
 NOTES

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