1900 SRM 964 Valve Repair
B80Z, B80Z
AC
, C80Z, C80Z
AC
, W65Z, and
W80Z
Remove
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic
hoses.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
1. Move the lift truck to a safe and level area.
2. Lower the forks completely to relieve pressure
from the hydraulic system.
3. Turn the key switch to the OFF position and dis-
connect battery.
4. Block load wheels to prevent lift truck from mov-
ing. See the section Periodic Maintenance
8000 SRM 919, Periodic Maintenance 8000
SRM 1032, Periodic Maintenance 8000 SRM
1368, or Periodic Maintenance 8000 SRM
1298 - How to Put A Lift Truck on Blocks.
5. Remove the drive unit compartment covers. See
Drive Unit Compartment Covers.
6. Discharge the capacitor. See Special Precau-
tions.
7. Remove the lift pump and motor assembly. See
Lift Pump and Motor, Remove.
8. Remove the cap on the relief valve.
9. Remove the locking nut from the relief valve.
10. Slowly loosen and remove the relief valve car-
tridge.
Install
1. Verify that the O-rings on the valve cartridge are
not damaged. Replace as needed.
2. Verify that the valve cartridge and pump assem-
bly housing are clean and not damaged.
3. Lubricate the valve cartridge threads and
O-rings with clean hydraulic oil.
4. Install the valve cartridge and torque to 32 N•m
(24 lbf ft).
5. Install the relief valve locking nut and torque to
15 N•m (11 lbf ft).
6. Install lift pump and motor assembly. See Lift
Pump and Motor, Install.
7. Remove blocks from wheels.
8. Connect the battery and turn the key switch to
the ON position.
9. Operate the hydraulic functions several times to
purge air from the hydraulic circuit.
10. Verify that the relief valve settings are correct.
See Relief Valve Adjustment.
11. Install the cap on the relief valve.
12. Test lift truck by lifting and lowering a load sev-
eral times. Check for leaks.
13. Check hydraulic oil level in reservoir and fill to
proper level. See Hydraulic Reservoir, Table 1.
14. Install drive unit compartment covers. See Drive
Unit Compartment Covers.
CHECK VALVE
B80Z, B80Z
AC
, C80Z, C80Z
AC
, W65Z, and
W80Z
Remove
1. Move lift truck to a safe and level area.
2. Lower the forks completely to relieve pressure
from the hydraulic system.
3. Turn the key switch to the OFF position and dis-
connect battery.
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