OK, my email is in my profile. The board automatically deletes all links and email addresses inside posts.

my email is [email address removed]
i took some pics of the machine today- i will send to you via email.

Put your email in your profile or in a post written out like "person AT blahblah DOT com" so I can send you a picture of a similar valve. That way we'll be sure to be talking about the same things.

The relief valve should be an allen headed screw (usually with an acorn cap nut on top) in the same spool that the pressure line goes into. Some older trucks also had a relief valve in the pump. (I can't remember if old Hysters had them or not)

If the relief valve on the control valve is the problem, you may be able to feel the oil rushing through the return line from control valve back to the sump.

If you're careful you should be able to remove and inspect the relief valve parts without a problem.

By the way, do NOT hook the pressure line directly into a gauge. This "dead heads" the pump and blows it up instantly.

Thanks Lumberjack. I will check the relief valve below the flow control valve more carefully. How do i know if there is another bypass valve on the machine? There is a big dual in/ dual out valve (block?) on the mast - could that have a bypass inside?

Ha it censored me. A collapsed hose could cause you to s u c k in air.
Like you do with a straw. Or how you start a siphon. It's the word used to describe Michael Moore's movies.

The relief valve may have a broken spring. Unscrew it completely and the spring and ball will fall out, or can be gotten out with a magnet. Be prepared for a little oil as well. Everything needs to be kept clean for reassembly. There is also the chance that a bit of dirt or debris got trapped in the valve. It's probably worthwhile to inspect the port with mirrors and a flashlight.

The only other thoughts I had: Check that the supply hose from the sump to the pump isn't collapsing when the pump is operated. This starves the pump for oil and could cause you to be *** in air. The other thing - check to make sure you only have one relief valve. If there's more than one, you want the one closest to the pressure supply hose.

Good luck with it.

Thank you for the reply. I adjusted the relief valve screw all the way one direction then all the way the other. No change in the pressure reading during and after.
Where is the bypass located? is it possible this is stuck open?
Battery is strong and at full charge.

Your relief valve screw is way out of adjustment. You may have proper flow but if the pressure on the spring isn't set correctly than the bypass will open and dump back to tank.

Put a gauge in the test port hold over relief and slowly adjust pressure to spec.

Of course if your battery is shot than this is all pointless

batterys were recently tested - all ok. full charge.
that is the reading with the lever at full pull.

how is the battery?
is that 200 PSI with the tilt lever pulled back to "stall"