BL-CB33-0115 - 03-01-2018 9-1
SECTION 9
HYDRAULIC SYSTEM SERVICING
9-1. LINES AND FITTINGS
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To
ensure release of pressure, forks must
be fully lowered and the batteries discon-
nected before performing any mainte-
nance on the hydraulic system.
NOTE: Leaking hydraulic fittings may be remedied by
simply tightening fittings. If this does not rem-
edy the leak, the fittings or line must be
replaced.
1. Lower forks fully.
2. Turn off the key switch and disconnect the batter-
ies.
3. Remove the front compartment covers as
described in paragraph 5-3.
CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
under the line or fitting before discon-
necting.
4. Refer to Figure 9-1, Figure 9-2 and Figure 9-5 and
remove leaking line or fitting and replace it with a
new line or fitting.
5. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use hydraulic
oil listed in Table 3-2.
6. Reconnect the batteries and turn on the key-
switch.
7. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
8. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use hydraulic
oil listed in Table 3-2.
9. Install the front compartment covers as described
in paragraph 5-3.
9-2. HYDRAULIC PUMP, AND MOTOR ASSY
WARNING: When forks are raised. pressure exists in
the hydraulic system lines and fittings. To
ensure release of pressure, forks must
be fully lowered and the batteries discon-
nected before performing any mainte-
nance on the hydraulic system.
9-2.1. Removal
1. Lower forks fully.
2. Turn off the key switch and disconnect the batter-
ies.
3. Remove the front compartment covers as
described in paragraph 5-3.
4. Tag and disconnect electrical leads from pump
and motor.
NOTE: Place a container under the pump assembly
to catch any hydraulic oil.
5. Tag and disconnect two hoses and hose from
pump and motor.
6. Remove two screws, two lock washers four wash-
ers and six washers.
7. Remove the pump and motor assembly with res-
ervoir.
8. Remove four bolts, four lock washers and reser-
voir from pump and motor assembly.
9. Refer to Figure 12-30 and Figure 12-31 for disas-
sembly and reassembly of the pump and motor.
9-2.2. Installation
1. Install pump and motor assy on reservoir and
secure with four bolts and four lock washers.
2. Position pump and motor assy on mounting
bracket and secure with two screws, two lock
washers four washers and six washers.
3. Reconnect the hoses to pump and motor.
4. Connect electrical leads to pump and motor.
5. Fill the hydraulic reservoir. Use hydraulic oil listed
in Table 3-2.
6. Reconnect the batteries and turn on the key-
switch.
7. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
8. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use hydraulic
oil listed in Table 3-2.
9. Install the front compartment covers as described
in paragraph
5-3.
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