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MAIN CONTROL VALVE

S30FT, S35FT, S40FTS [E010];H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177];

S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100,

120FTBCS; S120FTPRS ) [G004];

H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,

100, 110, 120FT) [N005]

This manual contains information that is confidential and/or proprietary to HysterCompany, its subsidiaries and/or vendors. Copying or distribution of any sections of

this manual marked "Confidential/Proprietary" is prohibited.

PART NO. 1580515 2000 SRM 1137

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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 Mainte-

nance 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:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

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Main Control Valve Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

Electro-Hydraulic Main Control Valve .............................................................................................................

Description .....................................................................................................................................................

Remove ........................................................................................................................................................... 2

Electro-Hydraulic Control Valve Sections .................................................................................................... 5General....................................................................................................................................................... 5

Outlet Control Valve Section .................................................................................................................... 5

Remove .................................................................................................................................................. 5

Disassemble........................................................................................................................................... 5

Clean ...................................................................................................................................................... 6

Inspect ...................................................................................................................................................

Assemble................................................................................................................................................

Install.....................................................................................................................................................

Auxiliary Control Valve Section ...............................................................................................................

Remove ..................................................................................................................................................

Disassemble........................................................................................................................................... 9

Clean ...................................................................................................................................................... 9Inspect ................................................................................................................................................... 10

Assemble................................................................................................................................................ 10

Install..................................................................................................................................................... 10

Tilt Control Valve Section ......................................................................................................................... 10

Remove .................................................................................................................................................. 10

Disassemble........................................................................................................................................... 1

Clean ...................................................................................................................................................... 12

Inspect ................................................................................................................................................... 12

Assemble................................................................................................................................................ 12

Install..................................................................................................................................................... 12

Lift/Lower Control Valve Section.............................................................................................................. 12

Remove .................................................................................................................................................. 12

Disassemble........................................................................................................................................... 12Clean ...................................................................................................................................................... 14

Inspect ................................................................................................................................................... 14

Assemble................................................................................................................................................ 15

Install..................................................................................................................................................... 15

Install ............................................................................................................................................................. 15

Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment.................................................................. 1

Lift Pilot Pin .............................................................................................................................................. 18

Lower Pilot Pin .......................................................................................................................................... 19

Abnormal/Erroneous EHPV Adjustment ................................................................................................. 20

Manual Main Control Valve .............................................................................................................................. 2

Description ..................................................................................................................................................... 2

Remove ........................................................................................................................................................... 22

Manual Control Valve Sections..................................................................................................................... 25General....................................................................................................................................................... 25

Outlet Control Valve Section .................................................................................................................... 25

Remove .................................................................................................................................................. 25

Disassemble........................................................................................................................................... 25

Clean ...................................................................................................................................................... 2

Inspect ................................................................................................................................................... 2

Assemble................................................................................................................................................ 2

Install..................................................................................................................................................... 2

2006 HYSTER COMPANY

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Table of Contents Main Control Valve

TABLE OF CONTENTS (Continued)

Auxiliary Control Valve Section ............................................................................................................... 27

Remove .................................................................................................................................................. 27

Disassemble........................................................................................................................................... 29

Clean ...................................................................................................................................................... 29Inspect ................................................................................................................................................... 29

Assemble................................................................................................................................................ 29

Install..................................................................................................................................................... 29

Lift/Tilt Control Valve Section .................................................................................................................. 30

Remove .................................................................................................................................................. 30

Disassemble........................................................................................................................................... 30

Clean ...................................................................................................................................................... 30

Inspect ................................................................................................................................................... 32

Assemble................................................................................................................................................ 32

Install..................................................................................................................................................... 32

Install ............................................................................................................................................................. 33

Steering Control Unit Repair ............................................................................................................................ 35

Steering Control Unit, Remove ..................................................................................................................... 35Steering Control Unit, Disassemble ............................................................................................................. 37

Steering Control Unit, Clean ........................................................................................................................ 39

Steering Control Unit, Inspect...................................................................................................................... 39

Steering Control Unit, Assemble .................................................................................................................. 39

Relief Valve, Disassemble.............................................................................................................................. 39

Relief Valve, Clean......................................................................................................................................... 40

Relief Valve, Inspect ...................................................................................................................................... 40

Relief Valve, Assemble................................................................................................................................... 40

Steering Control Unit, Install ....................................................................................................................... 40

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177];

S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100,

120FTBCS; S120FTPRS ) [G004];

H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,

100, 110, 120FT) [N005]

ii

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2000 SRM 1137 Electro-Hydraulic Main Control Valve

General

This section contains description and repair proce-

dures for both manual and electronic main control

valves used in the hydraulic system for this series of

lift trucks.

There are two main control valves available for this

series of lift trucks. One is controlled manually

and the other is controlled electronically. The main

control valves are mounted to the cowl using three

mounting bolts. See Figure 1.

NOTE: MAJOR COMPONENTS NOT SHOWN FOR

CLARITY. VIEW IS FROM THE FRONT.

1. COWL2. INSERT3. WASHER4. CAPSCREW

5. MAIN CONTROLVALVE

6. FRAME

Figure 1. Main Control Valve Mounting

Electro-Hydraulic Main Control Valve

DESCRIPTION

This E-Valve is an electronically-controlled,

closed-center, load-sensing stack valve. It uses

an unloader valve (single functions only) and has

parallel hydraulic circuitry. Operating multiple

functions simultaneously will result in a nonpropor-

tionate increase in pump flow to functions which

receive the lowest amount of pressurized fluid. A

fixed displacement pump is used in conjunction

with the inlet compensator to achieve the required

load-sense logic. Lift function is on main relief

pressure setting. Tilt and auxiliary functions are onsecondary relief pressure setting. Lift pressure is

unaffected by secondary relief operation.

The electronic main control valve incorporates an

emergency lowering valve. See Figure 2. This valv

allows the operator or service technician to lower th

lift trucks mast assembly if the electrical signal t

the electronic main control valve is disrupted.

The electronic main control valve assembly is divide

in the following sections. See Figure 2.

Steering Control Unit (SCU)

Lift/Lower

Tilt

Auxiliary

Outlet

Confidential/Proprietary - Do Not Copy or Duplicate

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Electro-Hydraulic Main Control Valve 2000 SRM 1137

1. STEERING CONTROL UNIT (SCU)2. SCU MOUNTING CAPSCREW3. LIFT/LOWER SECTION4. EMERGENCY LOWER VALVE5. ELECTRO-HYDRAULIC POPPET VALVE (EHPV)6. PROPORTIONAL PRESSURE REDUCING

VALVE (PPRV)

7. AUXILIARY I SECTION8. AUXILIARY II SECTION9. SECONDARY RELIEF VALVE (ADJUSTABLE)10. OUTLET SECTION11. TILT SECTION12. PRIMARY RELIEF VALVE (NONADJUSTABLE)

Figure 2. Electronic Control Valve

REMOVE

WARNINGLower carriage completely before working on

control valve or hydraulic system. Do not work

under a raised carriage. Put mast in a verti-

cal position, with no forward or back tilt, and

lower carriage completely before disconnect-

ing any parts of hydraulic system. The mast

can lower suddenly and cause injury if the car-

riage is not lowered.

NOTE: Most of the individual valve components can

be removed and replaced while the control valve is in-

stalled in the truck. Removal of the control valve for

repairs is normally only required to replace a valve

section, or to replace the O-rings between the sec-

tions.

1. Power wash the interior of the operator compart-

ment to remove any dirt or debris.

2. Move truck to disassembly area and shut off en-

gine.

WARNINGCleaning solvents can be flammable and toxic

and cause skin irritation. When cleaning

solvents are used, always follow the solvent

manufacturers recommended safety proce-

dures. Wear protective goggles or a face shield

to prevent eye injuries.

NOTE: Take all necessary steps to prevent debris,

dust, or other contaminants from entering the valve

cavities, hydraulic lines, or replacement parts.

2 Confidential/Proprietary - Do Not Copy or Duplicate

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3. Remove the floor plate, kick panel, seal plate,

and dashboard. See the section Frame 100 SRM

1120 for S30FT, S35FT, S40FTS (E010); H1.6FT,

H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)

(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);

H2.0-3.5FT (H40-70FT) (L177) and Frame 100

SRM 1243 for S4.0, 5.0, 5.50FT ([S80, 100,120FT; S120FTS]) S80, 100FTBCS; S120FTPRS

(G004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

lift trucks. Before disconnecting any hydraulic

hoses or removing any parts from the control

valve, clean the outside of the valve either by

steam cleaning or with cleaning solvent.

4. To remove the accelerator pedal or MONOTROL

pedal assembly, disconnect the cowl wiring har-

ness from the pedal assembly wiring harness and

remove three capscrews. See Figure 3.

NOTE: To aid in installation, tag all connectors prior

to disconnecting from the solenoids.

5. Disconnect the cowl wiring harness connectors

from the hoist and lower Electro-Hydraulic Pop-

pet Valve (EHPV) solenoids. Disconnect the cowl

wiring harness from the top auxiliary function

Proportional Pressure Reducing Valve (PPRV)

solenoids.

CAUTION

To prevent any foreign matter from getting

into either the hydraulic hoses or the hy-draulic control valve sections, all openings

must have plugs or covers installed immedi-

ately after hoses are disconnected from the

control valve. This also applies if any other

items are removed from the control valve.

NOTE: To aid in correctly connecting hydraulic hoses

during installation, tag each hose prior to disconnect-

ing from the control valve.

6. Disconnect hydraulic hoses from the control

valve. Install plugs or caps on all open hose ends

and control valve ports to prevent contamina-tion. See Figure 4.

7. Remove the two SCU mounting capscrews and

move the SCU approximately 1.3 cm (0.5 in.) to

the left, and lower the SCU until the steering

shaft is disengaged. Remove the SCU from th

lift truck. See Figure 2.

WARNINGThe main control valve weighs approximately

29.5 kg (65 lb). Use a lifting device capable o

lifting the main control valve to avoid the pos

sibility of injury to personnel.

8. Support the main control valve. Remove thre

mounting capscrews and the main control valv

from the lift truck. See Figure 5.

NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW

EVER, REMOVAL IS THE SAME.

1. MOUNTING BOLT2. MONOTROL PEDAL ASSEMBLY

Figure 3. MONOTROL Pedal Removal

Confidential/Proprietary - Do Not Copy or Duplicate 3

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1. STEERING SYSTEM HOSES

2. HYDRAULIC INLET HOSE3. STEERING CONTROL UNIT (SCU)4. STEERING COLUMN5. SCU MOUNTING CAPSCREWS

6. LIFT/LOWER HOSE

7. TILT HOSE8. AUXILIARY I HOSE9. AUXILIARY II HOSE10. RETURN HOSE

Figure 4. Hydraulic Hose Removal

NOTE: To aid in installation, tag all connectors prior

to disconnecting from the solenoids.

9. Raise the main control valve approximately

25.4 cm (10 in.) to gain access to the lower tilt

and auxiliary function Proportional Pressure Re-

ducing Valve (PPRV) solenoids. Disconnect the

cowl harness from the lower tilt and auxiliary

function (PPRV) solenoids.

10. Remove the main control valve from the lift

truck.


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6. FRAME

Figure 5. Main Control Valve Removal

ELECTRO-HYDRAULIC CONTROL VALVE

SECTIONS

General

CAUTION

While working on the electro-hydraulic controlvalve sections, place a cover over the remain-

ing sections of the control valve to prevent

the possibility of contaminants getting into

the control valve openings which could cause

damage to the control valve.

CAUTIONIf O-rings are to be replaced between two sec-

tions that have a hydraulic oil leak, replace all

O-rings between all sections. This eliminates

the possibility of a subsequent oil leak or pos-

sible damage to another O-ring.

Disassemble the electro-hydraulic control valve only

as necessary for repairs. Most repairs to the contro

valve will be for the replacement of O-rings to sto

leaks between sections.

Outlet Control Valve Section

Remove

1. Remove four nuts from the control valve tie rods

See Figure 6.

2. Remove the outlet control valve section from th

four tie rods and discard 10 O-rings from the aux

iliary control valve section.

Disassemble

1. Remove the plug from the outlet control valv

section and discard the O-ring.

2. If the secondary relief valve has been leaking

remove it from the outlet control valve section

See Step 3 through Step 7 to disassemble the sec

ondary relief valve.

3. Remove the plug from the adjusting nut. Remov

and discard the O-ring from the plug. Remov

and discard the backup rings and O-ring from th

adjusting nut. See Figure 6.

4. While holding the adjustment nut, loosen the jam

nut.

NOTE: While performing Step 5, count and note thnumber of turns used to remove the adjusting nut.

5. Remove the adjusting nut and jam nut assembly

from the relief valve plug and discard the O-rin

on the adjusting nut.

6. Remove the spring, washer, and poppet from th

relief valve plug.

7. Remove and discard the backup ring from th

relief valve plug.


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1. O-RING2. PLUG3. OUTLET VALVE SECTION4. BACKUP RING5. RELIEF VALVE PLUG6. POPPET

7. WASHER8. SPRING9. JAM NUT10. ADJUSTING NUT11. CONTROL VALVE TIE ROD12. NUT

Figure 6. Outlet Control Valve Section

Clean

WARNING

Cleaning solvents can be flammable and toxic

and can cause skin irritation. When using

cleaning solvents, always follow the solvent


dures.

Compressed air can move particles so theycause injury to the user or to other personnel.

Make sure the path of the compressed air is

away from all personnel. Wear protective gog-

gles or a face shield to prevent injury to the

eyes.


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1. If all components of the outlet control valve sec-

tion have been removed, clean the outlet control

valve section using cleaning solvent and dry us-

ing compressed air.

2. If not all components have been removed, clean

the outlet control valve section using a lint-freecloth.

Inspect

Inspect the outlet control valve section mating sur-

faces and the bore of the secondary relief valve, if re-

moved, for damage. If either the mating surface or

the secondary relief valve bore are damaged, replace

the outlet control valve section.

If disassembled, inspect the components of the sec-

ondary relief valve. If any components other than

O-rings, backup rings, and the spring are damaged,

replace the secondary relief valve.

NOTE: If the outlet control valve section is not to be

reassembled immediately, coat surfaces with clean

hydraulic oil to prevent the possibility of rust. Cover

the outlet control valve section with a clean, dry, lint-

free cloth to prevent the possibility of contaminants

entering the outlet control valve section.

Assemble

NOTE: Coat all backup rings and O-rings with a light

coat of clean hydraulic oil to make installation easier.

NOTE: Perform Step 1 through Step 7 only if the sec-

ondary relief valve was repaired.

1. Install a new backup ring on the relief valve plug.

See Figure 6.

2. Install the poppet, washer, and spring into the

relief valve plug.

3. Install a new O-ring on the adjusting nut, and in-

stall the adjusting nut and jam nut assembly into

the relief valve plug the number of turns noted

during disassembly.

4. While holding the adjusting nut in place, tighten

the jam nut to 24 3 Nm (18 2 lbf ft).

5. Install a backup ring, O-ring, and backup ring

into the adjusting nut.

6. Install a new O-ring onto the plug. Install the

plug into the adjusting nut.

7. If removed, install secondary relief valve an

tighten to 45 Nm (33 lbf ft).

8. Install new O-ring on plug and install in the out

let valve section.

Install

NOTE: Coat all O-rings with light coat of clean hy

draulic oil to make installation easier.

1. Install 10 new O-rings into the auxiliary valv

section. Install the outlet control valve sectio

on the four tie rods.

2. Install the four nuts on the tie rods and tighten

to 19 2 Nm (168 18 lbf in).

Auxiliary Control Valve Section

NOTE: There is the possibility of having two auxiliary control valve sections depending upon how man

functions are on the lift truck. If the main contro

valve is a four-function control valve, there will b

two auxiliary control valve sections. These section

are repaired the same with one exception. The auxil

iary control valve section next to the tilt control valv

will always have the anti-stall valve installed as

part of that control valve section.

Remove

1. Remove the outlet control valve section. See Out

let Control Valve Section, Remove.

NOTE: Step 2 and Step 3 are for a three-function con

trol valve. If a four-function control valve is bein

disassembled, go to Step 4.

2. Remove the anti-stall valve from the auxiliary

control valve section. See Figure 7. If the anti

stall valve is to be repaired, go to Step 5.

3. Remove the auxiliary control valve section from

the four tie rods. Remove and discard 10 O-ring

from the tilt control valve section.

4. Remove the auxiliary II control valve sectionfrom the four tie rods. Remove and discard 1

O-rings from the auxiliary I control valve sec

tion.

5. Remove the anti-stall valve from the auxiliary

control valve section. If the anti-stall valve i

to be repaired, go to Step 5 of the disassembly

procedure for the auxiliary control valve section


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Figure 7. Auxiliary I and II Control Valve Sections


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Legend for Figure 7

A. AUXILIARY I CONTROL VALVE SECTION B. AUXILIARY II CONTROL VALVE SECTION

1. PLUG2. O-RING3. SPRING4. WASHER5. SOCKET HEAD CAPSCREW6. PROPORTIONAL PRESSURE REDUCING

VALVE (PPRV)

7. SPOOL8. POPPET9. AUXILIARY I CONTROL VALVE BODY10. BACKUP RING11. ANTI-STALL VALVE SLEEVE12. AUXILIARY II CONTROL VALVE BODY

6. Remove the auxiliary I control valve section from

the four tie rods. Remove and discard 10 O-rings

from the tilt control valve section.

Disassemble

NOTE: Disassemble the auxiliary control valve only

as needed to accomplish the repairs required.

1. Remove four capscrews and two proportional

pressure reducing valves (PPRV) from the auxil-iary control valve section. Remove and discard

the backup ring, two O-rings, backup ring, and

O-ring from each PPRV. See Figure 7.

2. Remove the plug, spring, washer, and spool from

the auxiliary control valve section. Discard the

O-ring on the plug.

3. Remove the plug, spring, and washer from the

auxiliary control valve section. Discard the

O-ring on the plug.

4. Remove two plugs, two springs, and two poppetsfrom the auxiliary control valve. Discard one

O-ring from each plug.

5. Remove spring from the large end of the anti-

stall valve sleeve. See Figure 8.

6. Remove the spool from the small end of the anti-

stall valve sleeve.

NOTE: Note the orientation of the O-rings and

backup rings for installation.

7. Remove and discard two backup rings and two

O-rings from the anti-stall valve sleeve. To re-assemble the anti-stall sleeve valve, see Step 5

of the assembly procedure.

1. SPOOL2. BACKUP RING3. O-RING

4. ANTI-STALL VALVESLEEVE

5. SPRING

Figure 8. Anti-Stall Valve

Clean

WARNING



cleaning solvents, always follow the solven

manufacturers recommended safety proce

dures.

Compressed air can move particles so they

cause injury to the user or to other personnel

Make sure the path of the compressed air i

away from all personnel. Wear protective gog


eyes.

1. If all components of the auxiliary control valv

section have been removed, clean the auxiliary

control valve section and components, except th

two PPRVs, using cleaning solvent and dry usin

compressed air.


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the auxiliary control valve section using a lint-

free cloth.

3. If the anti-stall valve was disassembled, clean

the spool, anti-stall valve sleeve, and spring with

cleaning solvent. Dry with a lint-free cloth.

Inspect

Inspect the auxiliary control valve section mating

surfaces and any open bores for damage. If damage

is found, replace the auxiliary control valve section.

If the spool has been removed, inspect the spool

and the bore for the spool for damage. If damage

to either the spool or the bore is found, replace the

auxiliary control valve section.

If the anti-stall valve was disassembled, inspect the

spool, anti-stall valve sleeve, and spring for damage.

If the spring is damaged, replace the spring. If thespool or anti-stall valve sleeve is damaged, replace

the anti-stall valve assembly.

NOTE: If the auxiliary control valve section is not to

be reassembled immediately, coat surfaces with clean


the auxiliary control valve section with a clean, dry,

lint-free cloth to prevent the possibility of contami-

nants entering the auxiliary control valve section.

Assemble

NOTE: Coat all backup rings and O-rings with a lightcoat of clean hydraulic oil to make installation easier.

1. Install the spool, washer, spring, and plug, with

new O-ring, into the bore of the auxiliary control

valve section. Tighten the plug to 14 1 Nm

(120 12 lbf in). See Figure 7.

2. Install the washer, spool, and plug, with new

O-ring, into the auxiliary control valve section.

Tighten the plug to 14 1 Nm (120 12 lbf in).

3. Install two poppets, two springs, and two plugs,

with new O-rings installed, into the auxiliary

control valve section. Tighten the plugs to 818 Nm (60 6 lbf ft).

4. Install the new O-ring, backup ring, two O-rings,

and backup ring on each PPRV. Install two

PPRVs and four capscrews into the auxiliary

control valve section. Tighten the capscrews to 3

0.3 Nm (24 2 lbf in).

5. Install two backup rings and two O-rings on the

anti-stall valve sleeve as noted during disassem-

bly. See Figure 8.

6. Install the spool in the small end of the anti-stall

valve sleeve.

7. Install the spring in the large end of the anti-stall

valve sleeve.

Install

NOTE: Step 1 through Step 3 are for a three-function

control valve. Step 4 through Step 7 are for a four-

function control valve.

1. Install 10 new O-rings into the tilt control valve

section. Install the auxiliary I control valve sec-

tion on the four tie rods.

2. Install the anti-stall valve into the auxiliary Icontrol valve section.

3. Install the outlet control valve section. See Out-

let Control Valve Section, Install.

4. Install 10 new O-rings into the tilt control valve

section. Install the auxiliary I control valve sec-

tion on the four tie rods.

5. Install the anti-stall valve into the auxiliary I

control valve section. Install 10 new O-rings into

the auxiliary I control valve section.

6. Install the auxiliary II control valve section onthe four tie rods.



Tilt Control Valve Section

Remove

1. Remove the outlet control valve section. See Out-

let Control Valve Section, Remove.

2. Remove the auxiliary control valve section. See

Auxiliary Control Valve Section, Remove.

3. Remove the tilt control valve section from the lift/

lower control valve section.

4. Remove and discard five O-rings from the lift/



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Disassemble

NOTE: Disassemble the tilt control valve section only

as needed to accomplish the repairs required.

1. Remove four capscrews and two proportional

pressure-reducing valves (PPRV) from the tilt

control valve section. See Figure 9. Remove and

discard the backup ring, two O-rings, backup

ring, and O-ring from each PPRV.

2. Remove the plug, spring, washer, and spool from

the tilt control valve section. Discard the O-ring

on the plug.

3. Remove the socket head capscrew, spring, and

piston from the spool.

4. Remove the plug, spring, and washer from th

tilt control valve section. Discard the O-ring on

the plug.

5. Remove two plugs, two springs, and two poppet

from the tilt control valve section. Discard on

O-ring from each plug.

1. PLUG2. O-RING3. SPRING

4. WASHER5. SOCKET HEAD CAPSCREW6. PISTON7. PROPORTIONAL PRESSURE-REDUCING

VALVE (PPRV)

8. TILT CONTROL VALVE BODY9. SETSCREW10. POPPET

11. BACKUP RING12. SPOOL

Figure 9. Tilt Control Valve Section


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Clean




manufacturers recommended safety proce-dures.


cause injury to the user or to other personnel.




eyes.

1. If all components of the tilt control valve section

have been removed, clean the tilt control valve

section and components, except the two PPRVs,

using cleaning solvent and dry using compressedair.


the tilt control valve section using a lint-free

cloth.

Inspect

Inspect the tilt control valve section mating surfaces

and any open bores for damage. If damage is found,

replace the tilt control valve section. If the spool has

been removed, inspect the spool and the bore for the

spool for damage. If damage to either the spool or thebore is found, replace the tilt control valve section.

NOTE: If the tilt control valve section is not to be



the tilt control valve section with a clean, dry, lint-


entering the tilt control valve section.

Assemble



1. Install the piston, spring, and socket head cap-

screw in the spool. See Figure 9.

2. Install the spool, washer, spring, and plug, with

new O-ring, into the bore of the tilt control valve

section. Tighten the plug to 14 1 Nm (120

12 lbf in).

3. Install the washer, spring, and plug, with new

O-ring, into the tilt control valve section. Tighten

the plug to 14 1 Nm (120 12 lbf in).

4. Install two poppets, two springs, and two plugs,

with new O-rings installed, into the tilt control

valve section. Tighten the plugs to 81 8 Nm

(60 6 lbf ft).

5. Install the new O-ring, backup ring, two O-rings,

and backup ring on each PPRV. Install two

PPRVs and four capscrews into the tilt con-

trol valve section. Tighten the capscrews to 3

0.3 Nm (24 2 lbf in).

Install

1. Install five new O-rings on the lift/lower controlvalve section.

2. Install the tilt control valve section on the lift/


3. Install the auxiliary control valve section. See

Auxiliary Control Valve Section, Install.



Lift/Lower Control Valve Section

Remove

1. Remove the outlet control valve. See Outlet Con-

trol Valve Section, Remove.


Auxiliary Control Valve Section Remove.

3. Remove the tilt control valve section. See Tilt

Control Valve Section, Remove.

Disassemble

1. Remove four tie rods from the lift/lower control

valve section.

2. Remove coil nut and coil from the lift electro-hy-

draulic poppet valve (EHPV). See Figure 10.


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1. LOCK NUT2. ADJUSTING SCREW3. O-RING4. SPRING5. PISTON6. PRIMARY RELIEF VALVE CARTRIDGE7. BACKUP RING

8. SPOOL9. LIFT/LOWER CONTROL VALVE SECTION10. SOCKET HEAD PLUG11. EMERGENCY LOWERING VALVE12. PLUG

13. SETSCREW14. SHUTTLE15. POPPET16. HOIST POPPET17. SOLENOID TUBE18. COIL19. COIL NUT

20. LOWER POPPET21. SLEEVE ASSEMBLY22. LIFT POPPET VALVE ASSEMBLY23. LOWER POPPET VALVE ASSEMBLY24. PILOT PIN

Figure 10. Lift/Lower Control Valve Section


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3. Using special socket (Hyster P/N 1585481), re-

move the lift solenoid tube assembly from lift/

lower control valve section. Take care to pull the

tube assembly straight out so that the pilot pin

does not get damaged. See Figure 10.

4. Remove the spring from the poppet assembly un-less it came out with the solenoid tube assembly

in which case remove it from the solenoid tube

assembly.

NOTE: The lower poppet valve assembly is approx-

imately 7 mm (0.28 in.) longer than the lift poppet

valve assembly.

5. Remove the lift poppet assembly from the lift/


6. Repeat Step 2 through Step 5 for the lower

EHPV. After completing Step 5, remove the

sleeve assembly from lower control valve sec-tion.

CAUTION

Use care, when removing the emergency low-

ering valve, not to damage the tip of the emer-

gency lowering valve.

7. Remove the emergency lowering valve from the

lift/lower control valve section. Remove and dis-

card the O-ring.

8. Remove the plug from the lift/lower control valve

section. Remove and discard the O-ring.

9. Remove the socket head plug from the lift/lower

control valve section. Remove and discard the

O-ring.

10. Remove the socket head plug, spring, and poppet

from the lift/lower control valve section. Remove

and discard the O-ring.

11. Remove the shuttle and setscrew from the lift/


12. Remove the primary relief valve, spring, andspool from the lift/lower control valve section.

NOTE: Step 13 through Step 16 are for the disassem-

bly of the primary relief valve.

13. While holding the adjustment screw in place,

loosen the lock nut.

NOTE: While performingStep 14, count and note the

number of turns used to remove the adjusting screw.

14. Remove the adjusting screw from the primary re-

lief valve. Remove and discard the O-ring on the

adjusting screw.

15. Remove the spring and piston from the primary

relief valve.

16. Remove and discard the small O-ring, backup

ring, and large O-ring from the primary relief

valve.

Clean

WARNING



cleaning solvents, always follow the solventmanufacturers recommended safety proce-

dures.






eyes.

1. If all components of the lift/lower control valve

section have been removed, clean the lift/lower

control valve section and components, except the

two PPRVs, using cleaning solvent and dry using

compressed air.


the lift/lower control valve section using a lint-

free cloth.

Inspect

Inspect the lift/lower control valve section mating

surfaces and any open bores for damage. If damage

is found, replace the lift/lower control valve section.

If the spool has been removed, inspect the spool

and the bore for the spool for damage. If damageto either the spool or the bore is found, replace the

lift/lower control valve section.

If disassembled, inspect the components of the pri-

mary relief valve. If any components other than


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replace the primary relief valve.

NOTE: If the lift/lower control valve section is not to



the lift/lower control valve section with a clean, dry,lint-free cloth to prevent the possibility of contami-

nants entering the lift/lower control valve section.

Assemble

NOTE: Step 1 through Step 6 are for the assembly

of the primary relief valve, if disassembled. If the

primary relief valve has not been disassembled, go

to Step 6.



1. Install the new large O-ring on the primary re-lief valve. Install the new backup ring and small

O-ring on the primary relief valve. See Figure 10.

2. Install the piston and spring into the primary

relief valve.

3. Install a new O-ring on the adjusting screw, and

install the adjusting screw into the primary re-

lief valve the number of turns noted during dis-

assembly.

4. Install the lock nut onto the adjusting screw

while holding the adjustment screw so that it

will not turn. Tighten the lock nut to 9 1 Nm

(84 12 lbf in).

5. Install the spool, spring, and primary relief

valve into the lift/lower control valve section.

Tighten the primary relief valve to 65 7 Nm

(48 5 lbf ft).

6. Install the shuttle and setscrew into the body of

the lift/lower control valve section. Tighten the

setscrew to 4 0.6 Nm (36 6 lbf in).

7. Install plug with new O-ring installed into the

lift/lower control valve section. Tighten the plugto 45 5 Nm (33 4 lbf ft).

8. Install poppet, spring, and plug with new O-ring

installed, into the lift/lower control valve section.

Tighten the plug to 65 7 Nm (48 5 lbf ft).

9. Install the emergency lowering valve, with a new

O-ring installed, into the lift/lower control valve

section. Tighten to 14 1 Nm (120 12 lbf in).

NOTE: Ensure that the correct poppet is being in

stalled in the proper position. The lower poppet valv

assembly is approximately 7 mm (0.28 in.) longe

than the lift poppet valve assembly.

10. Install the lift poppet into the lift/lower contro

valve section until the poppet "bottoms out."

11. Install the spring onto the solenoid tube.

12. Install the solenoid tube into the lift/lower con

trol valve section. Tighten to 100 11 Nm (7

8 lbf ft).

13. Install the coil and coil nut on the solenoid tube

Tighten the coil nut to 2.3 Nm (20 lbf in).

14. Repeat Step 10 through Step 13 for the lowe

EHPV. Before installing the lower poppet int

the lower control valve section in Step 10, in

stall sleeve assembly into the lift/lower controvalve section first. Tighten sleeve assembly t

122 12 Nm (90 9 lbf ft).

Install

1. Install four tie rods into the lift/lower contro

valve section.

2. Install the tilt control valve section. See Tilt Con

trol Valve Section, Install.

3. Install the auxiliary control valve section. Se


4. Install the outlet control valve section. See Out


INSTALL

WARNING

The main control valve weighs approximately


lifting the main control valve, to avoid the pos


1. Lower the control valve enough to allow th

cowl wiring harness to be connected to the lowePPRV solenoid connectors as noted during re

moval.

2. While supporting the main control valve in

place on the cowl, install three mounting cap

screws through the front of the cowl into th

control valve. Tighten the capscrews to 19 Nm

(14 lbf ft). See Figure 11.


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6. FRAME

Figure 11. Main Control Valve Installation

3. Position the SCU under the steering shaft and

raise the SCU to engage the steering shaft.

When the steering shaft is completely engaged,

position the SCU against the main control valve,

and install two mounting capscrews and wash-

ers. Tighten to 45-55 Nm (33-41 lbf ft). See

Figure 12.

4. Remove all caps and plugs from the control valve

and hose fittings. Connect hydraulic hoses to the

control valve as noted during removal. See Fig-

ure 12.

5. Connect the cowl wiring harness to the top PPRV

solenoids and the lift/lower EHPV solenoids asnoted during removal.

6. Apply adhesive compound, Hyster Part No.

251099, to the three mounting capscrews. Using

the three capscrews that hold the throttle base

to the cowl, install the pedal assembly on the

lift truck. Connect the cowl wiring harness to

the pedal assembly wiring harness. Tighten the

bolts to 19 to 25 Nm (168 to 221 lbf in). See

Figure 13.

7. Install the dashboard, seal plate, kick panel,

and floor plate. See the section Frame 100 SRM



(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);


SRM 1243 for S4.0, 5.0, 5.50FT ([S80, 100,

120FT]; S80, 100, 120FTBCS; S120FTPRS)

(G004);.H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

lift trucks.

8. For electro-hydraulic control valves only, perform

the calibration procedures in the section Cali-

bration Procedures 8000 SRM 1134.


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6. LIFT/LOWER HOSE


Figure 12. Hydraulic Hose Installation


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NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-

EVER, INSTALL IS THE SAME.


Figure 13. MONOTROL Pedal Install

ELECTRO HYDRAULIC POPPET VALVE

(EHPV) PILOT PIN ADJUSTMENT

This section outlines the procedures for adjusting the

lift and lower EHPV pilot pin. This adjustment is

preset at the valve supplier and should not need to

be altered, however, minor adjustments may be re-

quired if a new poppet assembly is installed.

These procedures assume the poppet assembly, tube

assembly, and coil have been replaced and installed

correctly. These procedures also assume the forks are

initially on the ground.

The coil nut should be removed to access the adjust-

ment screw and re-installed for proper operation.

Figure 14.

Lift Pilot Pin

WARNINGHot hydraulic oil can cause serious burns to

skin. Do not touch hydraulic components or oil

during test. Make sure hydraulic oil has cooled

to safe temperature before installing or remov-ing test equipment.

WARNING

Hydraulic oil under pressure can be injected

into skin. Lower forks to ground and relieve all

circuit pressure before removing or installing

test equipment.

CAUTIONDo not permit dirt or other contaminants to en-

ter the hydraulic system. Disconnected hoses,tubes, open valves, cylinder fittings, and ports

should be protected with clean caps or plugs.

NOTE: Always attempt to re-calibrate the threshold

setting through the display switch cluster (DSC) to

eliminate the symptoms below before adjusting the

pilot pin.

NOTE: The lift poppet should be bled prior to per-

forming this adjustment if the control valve has been

disassembled or hose has been disconnected by fol-

lowing the procedure in Calibration Procedures

8000 SRM 1134.

1. Remove side covers, floor plates, seal plate and

dash per Frame 100 SRM 1120 for lift truck

models S30FT, S35FT, S40FTS (E010); H1.6FT,


(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);

H2.0-3.5FT (H40-70FT) (L177) and Frame

100 SRM 1243 for lift truck model S4.0, 5.0,

5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS;

S120FTPRS) (G004); H4.0FT5/FT6; H4.5FTS5,

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)

(N005).

2. To prevent truck from moving, block wheels front

and rear while the engine is operating.

3. Ensure hydraulic oil is at operating temperature,

which is 122 to 150 .

4. Monitor the EHPV coil current.

a. Method 1: Connect a current probe to either

of the lift EHPV coil leads.


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b. Method 2: Monitor the current using the dis-

play switch cluster (DSC). See Diagnostic

Troubleshooting Manual 9000 SRM 1112

for the procedure.

5. Loosen pilot pin adjustment. Figure 14.

6. Start vehicle.

7. Slowly increase current to the lift function by

pulling back on the lever or joystick.

NOTE: A 1/4 turn will change the value approxi-

mately 130 mA. Turn clockwise or IN to increase

value and counterclockwise or OUT to decrease

value.

8. If the forks move before the current reaches 550

mA or appear to jump, turn pilot pin adjustment

screw approximately 15 clockwise to increase

the value.

9. Repeat the adjustment until the forks begin to

move between 550 mA and 650 mA.

10. If the forks have not started to move prior to

reaching 650 mA, turn the pilot adjustment

screw approximately 15 counterclockwise to

reduce the value.



12. Tighten pilot pin adjustment screw lock nut

while holding the pilot pin adjustment screwto prevent slipping. Slipping of the adjustment

screw will cause threshold to increase. See Fig-

ure 14.

13. Replace coil nut.

14. Repeat test to verify that fork movement occurs

between 550mA and 650mA.

Lower Pilot Pin

WARNING

Hot hydraulic oil can cause serious burns toskin. Do not touch hydraulic components or oil

during test. Make sure hydraulic oil has cooled

to safe temperature before installing or remov-

ing test equipment.

WARNING

Hydraulic oil under pressure can be injected

into skin. Lower forks to ground and relieve all

circuit pressure before removing or installing

test equipment.

CAUTION

Do not permit dirt or other contaminants to en

ter the hydraulic system. Disconnected hoses

tubes, open valves, cylinder fittings, and port

should be protected with clean caps or plugs.

1. Remove side covers, floor plates, seal plate and

dash per Frame 100 SRM 1120 for lift truck

models S30FT, S35FT, S40FTS (E010); H1.6FT

H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS

(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187)

H2.0-3.5FT (H40-70FT) (L177) and Fram

100 SRM 1243 for lift truck model S4.0, 5.0

5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS

S120FTPRS) (G004); H4.0FT5/FT6; H4.5FTS5

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT(N005).

2. To prevent truck from moving, block wheels fron

and rear while the engine is operating.

3. Ensure hydraulic oil is at operating temperature

which is 122 to 150 .

NOTE: Always attempt to re-calibrate the threshol

setting through the display switch cluster (DSC) t

eliminate the symptoms below before adjusting th

pilot pin.

4. Monitor the EHPV coil current.

a. Method 1: Connect a current probe to eithe

of the lift EHPV coil leads.

b. Method 2: Monitor the current using the dis

play switch cluster (DSC). See Diagnosti

Troubleshooting Manual 9000 SRM 111

for the procedure.

5. Start vehicle and raise forks to approximately

2 m (6.5 ft) above the ground.

6. Turn the engine off, and turn the display switch

cluster (DSC) key back on.

7. Loosen pilot pin adjustment screw lock nut. Se

Figure 14.

8. Slowly increase the current to the lower function

by pushing forward on the lever or joystick.

NOTE: A 1/4 turn will change the value approxi

mately 130 mA. Turn clockwise or IN to increas


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value and counterclockwise or OUT to decrease

value.

9. If the forks move before the current reaches

550mA or appear to drop suddenly, turn the

pilot pin adjustment screw approximately 15

clockwaise to increase the value.



11. If the forks have not started to move prior to

reaching 650 mA, turn the pilot adjustment

screw approximately 15 counterclockwise to

reduce the value.



13. Tighten pilot pin adjustment screw lock nut

while holding the pilot pin adjustment screw

to prevent slipping. Slipping of the adjustment

screw will cause threshold to increase. See Fig-

ure 14.

14. Replace coil nut.

15. Repeat test to verify that fork movement occurs

between 550mA and 650mA.

Abnormal/Erroneous EHPV Adjustment

CAUTIONWhile only minor adjustments may be neces-

sary, the design of the EHPV is such that the

adjustment screw could erroneously be backed

out to the point where the EHPV is normally

open. This presents an extreme condition that

is not likely, but is possible.

1. COIL NUT2. PILOT PIN ADJUSTMENT SCREW3. PILOT PIN ADJUSTMENT LOCK NUT4. COIL

5. SOLENOID TUBE ASSEMBLY6. BIAS SPRING7. O-RING8. POPPET ASSEMBLY

Figure 14. Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment


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2000 SRM 1137 Manual Main Control Valve

If this occurs on lift function and lower function si-

multaneously, the pump flow will bypass directly to

tank and there will be no hydraulic functionality. If

this occurs on the lift function only (with lower func-

tion calibrated correctly), the mast will raise as soon

as the engine is turned on. If this occurs on the lowe

function only (with the lift function calibrated cor

rectly, the auxiliary and tilt functions will be opera

tional, but the forks will not raise. See Figure 14.

Manual Main Control Valve

DESCRIPTION

The manual control valve is an open-center valve

which utilizes parallel hydraulic circuitry. The valve

is used with a fixed displacement pump. The hy-

draulic circuitry incorporates dual pressure logic.

The lift function operates on the primary relief pres-

sure setting. The tilt and auxiliary functions operate

on the lower secondary relief pressure setting. If the

lift function is operated simultaneously with the tilt

and/or auxiliary function, the maximum lift pressur

is limited to the secondary relief pressure setting.

The manual main control valve assembly is divided

in the following sections. See Figure 15.

Steering Control Unit (SCU)

Monoblock (lift and tilt control)

Auxiliary

Outlet

1. STEERING CONTROL UNIT (SCU)2. SCU MOUNTING CAPSCREW3. MONOBLOCK VALVE SECTION4. HOIST/LOWER SPOOL5. TILT SPOOL

6. AUXILIARY I VALVE SECTION/SPOOL7. AUXILIARY II VALVE SECTION/SPOOL8. SECONDARY RELIEF VALVE9. OUTLET SECTION10. PRIMARY RELIEF VALVE

Figure 15. Manual Control Valve


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Manual Main Control Valve 2000 SRM 1137

REMOVE

WARNINGLower carriage completely before working on

control valve or hydraulic system. Do not work

under a raised carriage. Put mast in a verti-

cal position, with no forward or back tilt, andlower carriage completely before disconnect-

ing any parts of hydraulic system. The mast

can lower suddenly and cause injury if the car-

riage is not lowered.

NOTE: Most of the individual valve components can

be removed and replaced while the control valve is in-

stalled in the truck. Removal of the control valve for

repairs is normally only required to replace a valve

section, replace the O-rings between the sections, or

to remove a manual valve control spool.

1. Power wash the interior of the operator compart-ment to remove any dirt or debris.

2. Move truck to disassembly area and shut off en-

gine.

WARNING


and cause skin irritation. When cleaning

solvents are used, always follow the solvent


dures. Wear protective goggles or a face shield

to prevent eye injuries.

NOTE: Take all necessary steps to prevent debris,

dust, or other contaminants from entering the valve

cavities, hydraulic lines, or replacement parts.

3. Remove the floor plate, kick panel, seal plate,

and dashboard. See the section Frame 100 SRM



(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);


SRM 1243 for S4.0, 5.0, 5.50FT ([S80, 100,

120FT]; S80, 100, 120FTBCS; S120FTPRS)

(G004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

lift trucks. Before disconnecting any hydraulic

hoses or removing any parts from the control

valve, clean the outside of the valve either by

steam cleaning or with cleaning solvent.

4. Disconnect the hydraulic levers by removing the

locking ring cotter pins and rod end pins that con-nect the hydraulic lever linkages to the spools.

Remove three capscrews and the hydraulic lever

assembly from the cowl. See Figure 16.

1. CAPSCREW2. HYDRAULIC LEVER ASSEMBLY

Figure 16. Hydraulic Lever Relocation

5. To remove the accelerator pedal or MONOTROL

pedal assembly, disconnect the cowl wiring har-

ness from the pedal assembly wiring harness and

remove three capscrews. See Figure 17.


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NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-

EVER, REMOVAL IS THE SAME.


Figure 17. MONOTROL Pedal Removal

CAUTION

To prevent any foreign matter from gettin

into either the hydraulic hoses or the hy

draulic control valve sections, all opening

must have plugs or covers installed immedi

ately after hoses are disconnected from thcontrol valve. This also applies if any othe

items are removed from the control valve.

NOTE: To aid in correctly connecting hydraulic hose

during installation, tag each hose prior to disconnect

ing from the control valve.

6. Disconnect hydraulic hoses from the contro

valve. Install plugs or caps on all open hose end

and control valve ports to prevent contamina

tion. See Figure 18.

7. Remove the two SCU mounting capscrews and

move the SCU approximately 1.3 cm (0.5 in.) tthe left, and lower the SCU until the steering

shaft is disengaged. Remove the SCU from th

lift truck. See Figure 15.

WARNING

The main control valve weighs approximately


lifting the main control valve to avoid the pos


8. Support the main control valve. Remove thre

mounting capscrews and the main control valvfrom the lift truck. See Figure 19.

9. Remove the main control valve from the lif

truck.


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6. LIFT/LOWER HOSE


Figure 18. Hydraulic Hose Removal


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6. FRAME

Figure 19. Main Control Valve Removal

MANUAL CONTROL VALVE SECTIONS

General

CAUTIONWhile working on the manual control valve sec-

tions, place a cover over the remaining sectionsof the control valve to prevent the possibility

of contaminants getting into the control valve

openings which could cause damage to the con-

trol valve.

CAUTION

If O-rings are to be replaced between two sec-

tions that have a hydraulic oil leak, replace all

O-rings between all sections. This eliminates

the possibility of a subsequent oil leak or pos-

sible damage to another O-ring.

NOTE: Disassemble the manual control valve only

as necessary for repairs. Most repairs to the control

valve will be for the replacement of O-rings to sto

leaks between sections.

The manual control valve will be disassembled start

ing with the outlet control valve section.

Outlet Control Valve SectionRemove

1. Remove four nuts from the control valve tie rods

See Figure 20.

2. Remove the outlet control valve section from th

four tie rods and discard three O-rings from th

auxiliary control valve section. See Figure 21.

Disassemble

1. Remove the plug from the outlet control valv

section and discard the O-ring.

NOTE: Perform Step 1 through Step 6 only if it is ab

solutely necessary to disassemble the secondary re

lief valve.

2. Remove the plug from the adjusting nut. Remov

and discard the O-ring from the plug. Remov

and discard the backup rings and O-ring from th

adjusting nut. See Figure 20.

3. While holding the adjusting nut in place, loosen

the jam nut.

NOTE: While performing Step 4, count and note thnumber of turns used to remove the adjusting nut.


from the relief valve plug and discard the O-rin


5. Remove the spring, washer, and poppet from th

relief valve plug.

6. Remove and discard the backup ring from th

relief valve plug.


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1. PLUG2. O-RING3. OUTLET VALVE SECTION4. BACKUP RING5. RELIEF VALVE PLUG6. POPPET

7. WASHER8. SPRING9. JAM NUT10. ADJUSTING NUT11. CONTROL VALVE TIE ROD12. NUT

Figure 20. Outlet Control Valve Section


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Clean




manufacturers recommended safety proce-dures.






eyes.

1. If all components of the outlet control valve sec-

tion have been removed, clean the outlet control

valve section using cleaning solvent and dry us-

ing compressed air.


the outlet control valve section using a lint-free

cloth.

Inspect

Inspect the outlet control valve section mating sur-

faces and the bore of the secondary relief valve, if re-

moved, for damage. If either the mating surface or

the secondary relief valve bore are damaged, replace

the outlet control valve section.

If disassembled, inspect the components of the sec-

ondary relief valve. If any components other than


replace the secondary relief valve.

NOTE: If the outlet control valve section is not to be



the outlet control valve section with a clean, dry, lint-


entering the outlet control valve section.

Assemble


coatof clean hydraulic oil to make installation easier.

NOTE: Perform Step 1 through Step 7 only if the sec-

ondary relief valve was repaired.

1. Install a new backup ring on the relief valve plug.

See Figure 20.

2. Install the poppet, washer, and spring into th

relief valve plug.

3. Install a new O-ring on the adjusting nut, and in

stall the adjusting nut and jam nut assembly int

the relief valve plug the number of turns note

during disassembly.



5. Install a backup ring, O-ring, and backup rin


6. Install a new O-ring onto the plug. Install th

plug into the adjusting nut.

7. If removed, install secondary relief valve, an

tighten to 45 Nm (33 lbf ft).

8. Install new O-ring on plug and install in the outlet valve section.

Install

1. Install three new O-rings into the auxiliary valv

section. Install the outlet control valve section on

the four tie rods. See Figure 21.

2. Install the four nuts on the tie rods and tighten

to 19 2 Nm (168 18 lbf in).

Auxiliary Control Valve Section

Remove

1. Remove the outlet valve. See Outlet Contro

Valve Section, Remove.

NOTE: Step 2 and Step 3 are used if a four-section

control valve is being disassembled. If a three-sec

tion control valve is being disassembled, go to Step 3

2. Remove the auxiliary II control valve section

from the four tie rods. Remove and discar

three O-rings from the auxiliary I control valv

section.

3. Remove the auxiliary I control valve sectionfrom the four tie rods. Remove and discar

three O-rings from the lift and tilt control valve

section. See Lift/Tilt Control Valve Section.


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1. CAPSCREW2. END CAP3. SPOOL END4. SPRING SEAT

5. SPRING6. SEAL PLATE7. WIPER

8. O-RING9. SPOOL10. POPPET11. SPRING

12. PLUG13. AUXILIARY CONTROL VALVE SECTION

Figure 21. Auxiliary Control Valve Section


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Disassemble

NOTE: On lift trucks equipped with a four-function

control valve, the disassembly procedures are the

same for both auxiliary I and II control valve sec-

tions.

1. Remove two socket head capscrews, end cap, and

seal plate from the auxiliary control valve sec-

tion. See Figure 21.

2. Remove the spool assembly and wiper from the


3. Remove the spool end, spring seat, spring, spring

seat, and O-ring from the spool assembly.

4. Remove two socket head capscrews, seal plate,

wiper, and O-ring from the auxiliary control

valve section.

5. Remove two plugs, springs, and poppets from the

auxiliary control valve section. Remove and dis-

card the O-rings from the plugs.

Clean





dures.






eyes.

1. If all components of the auxiliary control valve

section have been removed, clean the auxiliary

control valve section using cleaning solvent and

dry using compressed air.

2. If not all components have been removed, cleanthe auxiliary control valve section using a lint-

free cloth.

Inspect

Inspect the auxiliary control valve section mating

surfaces and the bore of the spool, if removed, for

damage. If either the mating surfaces or the spool

bore are damaged, replace the auxiliary contro

valve section.

If disassembled, inspect the components of the spool

If any components are damaged, replace the compo

nents. If the spool is damaged, replace the auxiliar

control valve section.

NOTE: If the auxiliary control valve section is not t


hydraulic oil to prevent the possibility of rust. Cove

the auxiliary control valve section with a clean, dry

lint-free cloth to prevent the possibility of contami

nants entering the auxiliary control valve section.

Assemble

NOTE: Coat all backup rings and O-rings with a ligh

coat of clean hydraulic oil to make installation easier

1. Install two poppets, springs, and plugs, with newO-rings installed, into the auxiliary control valv

section. Tighten the plugs to 45 5 Nm (3

4 lbf ft). See Figure 21.

2. Install new O-ring, new wiper, seal plate, an

two socket head capscrews on the auxiliar

control valve section. Tighten the socket hea

screws to 9.5 1 Nm (84 12 lbf in).

3. Install the new O-ring, spring seat, spring

spring seat, spool end fastener, and O-ring on

the spool. Tighten the spool end fastener to 9.

1 Nm (84 12 lbf in).

4. Install the new wiper and spool assembly into th


5. Install seal plate, end cap, and two socket head

capscrews into the auxiliary control valve sec

tion. Tighten the socket head screws to 9.

1 Nm (84 12 lbf in).

Install

NOTE: Step 1 and Step 2 are used if a four-section

control valve is being assembled. If a three-section

control valve is being disassembled, use Step 1, thengo to Step 3.

1. Install three new O-rings on the lift and tilt con

trol valve section. Install the auxiliary I contro

valve section on the four tie rods.

2. Install three new O-rings on the auxiliary I con

trol valve section. Install the auxiliary II contro

valve section on the four tie rods.


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3. Install the outlet valve. See Outlet Control Valve

Section, Install.

Lift/Tilt Control Valve Section

Remove

1. Remove the outlet control valve section valve.See Outlet Control Valve Section, Remove.


Auxiliary Control Valve Section, Remove.

Disassemble

NOTE: Remove only those components required to re-

pair the lift/tilt control valve section.

NOTE: Step 1 through Step 3 are for the disassembly

of the tilt side of the lift/tilt control valve section.

1. Remove two socket head screws, end cap, seal

plate, and tilt spool assembly from the tilt side

of the lift/tilt control valve section. Remove and

discard the wiper from the tilt bore of the lift/tilt

control valve section. See Figure 22.

2. Remove the spool end fastener, spring seat,

spring, spring seat, spring, and piston from the

tilt spool. Remove and discard the O-ring from

the tilt spool.

3. Remove two socket head screws and seal plate

from the tilt side of the lift/tilt control valve sec-

tion. Remove and discard the wiper and O-ringfrom the tilt bore of the lift/tilt control valve sec-

tion.

NOTE: Step 4 through Step 6 are for the disassembly

of the lift side of the lift/tilt control valve section.

4. Remove two socket head screws, end cap, seal

plate, and lift spool assembly from the lift side

of the lift/tilt control valve section. Remove and

discard the wiper from the lift bore of the lift/tilt

control valve section. See Figure 22.

5. Remove the spool end, spring seat, spring, springseat, and O-ring from the lift spool assembly. Dis-

card the O-ring.

6. Remove two socket head screws and seal plate

from the lift side of the lift/tilt control valve sec-

tion. Remove and discard the wiper and O-ring

from the lift bore of the lift/tilt control valve sec-

tion.

7. Remove three plugs, springs, and poppets from

the lift/tilt control valve section. Remove and dis-

card the O-rings from the plugs.

NOTE: Perform Step 8 through Step 12 only if it is

necessary to disassemble the primary relief valve.

8. Remove the plug from the adjusting nut. Remove

and discard the O-ring from the plug. Remove

and discard the backup rings and O-ring from the

adjusting nut.

9. While holding the adjusting nut in place, loosen

the jam nut.

NOTE: While performingStep 10, count and note the

number of turns used to remove the adjusting nut.


from the relief valve plug and discard the O-ring


11. Remove the spring, washer, and poppet from the

relief valve plug.

12. Remove and discard the backup ring from the

relief valve plug.

Clean

WARNING



cleaning solvents, always follow the solventmanufacturers recommended safety proce-

dures.






eyes.

1. If all components of the lift/tilt control valve sec-

tion have been removed, clean the lift/tilt control

valve section using cleaning solvent and dry us-ing compressed air.


the lift/tilt control valve section using a lint-free

cloth.


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1. SOCKET HEAD CAPSCREW2. END CAP3. O-RING4. SPOOL END FASTENER5. SPRING6. PISTON7. SPRING SEAT8. SEAL PLATE9. WIPER10. O-RING11. SPOOL

12. PLUG13. POPPET14. SEAL PLATE15. LIFT/TILT CONTROL VALVE SECTION16. BACKUP RING17. RELIEF VALVE PLUG18. POPPET19. WASHER20. JAM NUT21. ADJUSTING NUT22. PLUG

Figure 22. Lift/Tilt Control Valve Section


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Inspect

Inspect the lift/tilt control valve section mating sur-

faces. Inspect the bore of the primary relief valve, if

removed, for damage. Inspect the bores of the lift and

tilt spools, if removed. If the mating surface, the pri-

mary relief valve bore, or either the lift or tilt spoolbores are damaged, replace the lift/tilt control valve

section.

If disassembled, inspect the components of the pri-

mary relief valve. If any components other than


replace the primary relief valve.

NOTE: If the lift/tilt control valve section is not to



the lift/tilt control valve section with a clean, dry,

lint-free cloth to prevent the possibility of contami-

nants entering the lift/tilt control valve section.

Assemble



NOTE: Perform Step 1 through Step 7 only if the pri-

mary relief valve was repaired.

1. Install the new backup ring on the relief valve

plug. See Figure 22.

2. Install the poppet, washer, and spring into the

relief valve plug.

3. Install a new O-ring on the adjusting nut. Install

the adjusting nut and jam nut assembly in the re-

lief valve plug the number of turns noted during

removal.



5. Install a backup ring, O-ring, and backup ring


6. Install a new O-ring onto the plug. Install theplug into the adjusting nut.

7. Install secondary relief valve, and tighten to

45 Nm (33 lbf ft). See Figure 22.

8. Install three poppets, springs, and plugs, with

new O-rings installed, in the lift/tilt control valve

section.

9. Install the new O-ring and wiper in the lift bore of

the lift/tilt control valve section. Install the seal

plate and two socket head screws on the lift sideof the lift/tilt control valve section. Tighten the

socket head screws to 9.5 1 Nm (84 12 lbf in).

10. Install a new O-ring on the lift spool. Install the

spring seat, spring, spring seat, and spool end

fastener on the lift spool assembly. Tighten the

spool end fastener to 9.5 1 Nm (84 12 lbf in).

11. Install new the wiper into the lift bore of the

lift/tilt control valve section. Install the lift spool

assembly, seal plate, end cap, and two socket

head screws into the lift side of the lift/tilt control

valve section. Tighten the socket head screws to

9.5 1 Nm (84 12 lbf in).

12. Install the new O-ring and wiper in the tilt

bore of the lift/tilt control valve section. Install

the seal plate and two socket head screws on

the tilt side of the lift/tilt control valve section.

Tighten the socket head screws to 9.5 1 Nm

(84 12 lbf in).

13. Install a new O-ring on the tilt spool. Install the

piston, spring, spring seat, spring, spring seat,

and spool end fastener on the tilt spool assembly.

Tighten the spool end fastener to 9.5 1 Nm (84

12 lbf in).

14. Install new the wiper into the tilt bore of the

lift/tilt control valve section. Install the tilt spool

assembly, seal plate, end cap, and two socket

head screws into the tilt side of the lift/tilt control

valve section. Tighten the socket head screws to

9.5 1 Nm (84 12 lbf in).

Install

1. Install the auxiliary control valve section. See


2. Install the outlet valve. See Outlet Control Valve

Section, Install.


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INSTALL

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