Mono Trol

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 Hyster Company, 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
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 Maintenance 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:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Main Control Valve
Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... Electro-Hydraulic Main Control Valve ............................................................................................................. Description ..................................................................................................................................................... Remove ........................................................................................................................................................... Electro-Hydraulic Control Valve Sections .................................................................................................... General....................................................................................................................................................... Outlet Control Valve Section .................................................................................................................... Remove .................................................................................................................................................. Disassemble........................................................................................................................................... Clean...................................................................................................................................................... Inspect ................................................................................................................................................... Assemble................................................................................................................................................ Install..................................................................................................................................................... Auxiliary Control Valve Section ............................................................................................................... Remove .................................................................................................................................................. Disassemble........................................................................................................................................... Clean...................................................................................................................................................... Inspect ................................................................................................................................................... Assemble................................................................................................................................................ Install..................................................................................................................................................... Tilt Control Valve Section ......................................................................................................................... Remove .................................................................................................................................................. Disassemble........................................................................................................................................... Clean...................................................................................................................................................... Inspect ................................................................................................................................................... Assemble................................................................................................................................................ Install..................................................................................................................................................... Lift/Lower Control Valve Section.............................................................................................................. Remove .................................................................................................................................................. Disassemble........................................................................................................................................... Clean...................................................................................................................................................... Inspect ................................................................................................................................................... Assemble................................................................................................................................................ Install..................................................................................................................................................... Install ............................................................................................................................................................. Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment.................................................................. Lift Pilot Pin .............................................................................................................................................. Lower Pilot Pin .......................................................................................................................................... Abnormal/Erroneous EHPV Adjustment ................................................................................................. Manual Main Control Valve .............................................................................................................................. Description ..................................................................................................................................................... Remove ........................................................................................................................................................... Manual Control Valve Sections..................................................................................................................... General....................................................................................................................................................... Outlet Control Valve Section .................................................................................................................... Remove .................................................................................................................................................. Disassemble........................................................................................................................................... Clean...................................................................................................................................................... Inspect ................................................................................................................................................... Assemble................................................................................................................................................ Install..................................................................................................................................................... 1 1 1 2 5 5 5 5 5 6 7 7 7 7 7 9 9 10 10 10 10 10 11 12 12 12 12 12 12 12 14 14 15 15 15 18 18 19 20 21 21 22 25 25 25 25 25 27 27 27 27
2006 HYSTER COMPANY
Table of Contents
Main Control Valve
TABLE OF CONTENTS (Continued)

Auxiliary Control Valve Section ............................................................................................................... Remove .................................................................................................................................................. Disassemble........................................................................................................................................... Clean...................................................................................................................................................... Inspect ................................................................................................................................................... Assemble................................................................................................................................................ Install..................................................................................................................................................... Lift/Tilt Control Valve Section .................................................................................................................. Remove .................................................................................................................................................. Disassemble........................................................................................................................................... Clean...................................................................................................................................................... Inspect ................................................................................................................................................... Assemble................................................................................................................................................ Install..................................................................................................................................................... Install ............................................................................................................................................................. Steering Control Unit Repair ............................................................................................................................ Steering Control Unit, Remove..................................................................................................................... Steering Control Unit, Disassemble ............................................................................................................. Steering Control Unit, Clean ........................................................................................................................ Steering Control Unit, Inspect...................................................................................................................... Steering Control Unit, Assemble .................................................................................................................. Relief Valve, Disassemble.............................................................................................................................. Relief Valve, Clean......................................................................................................................................... Relief Valve, Inspect ...................................................................................................................................... Relief Valve, Assemble................................................................................................................................... Steering Control Unit, Install ....................................................................................................................... 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] 27 27 29 29 29 29 29 30 30 30 30 32 32 32 33 35 35 37 39 39 39 39 40 40 40 40
ii
2000 SRM 1137
Electro-Hydraulic Main Control Valve
General
This section contains description and repair procedures 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. 2. 3. 4. COWL INSERT WASHER CAPSCREW 5. MAIN CONTROL VALVE 6. FRAME
Figure 1. Main Control Valve Mounting

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 nonproportionate 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 on secondary 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 valve allows the operator or service technician to lower the lift trucks mast assembly if the electrical signal to the electronic main control valve is disrupted. The electronic main control valve assembly is divided in the following sections. See Figure 2. Steering Control Unit (SCU) Lift/Lower Tilt Auxiliary Outlet
Confidential/Proprietary - Do Not Copy or Duplicate
2000 SRM 1137
1. 2. 3. 4. 5. 6.
STEERING CONTROL UNIT (SCU) SCU MOUNTING CAPSCREW LIFT/LOWER SECTION EMERGENCY LOWER VALVE ELECTRO-HYDRAULIC POPPET VALVE (EHPV) PROPORTIONAL PRESSURE REDUCING VALVE (PPRV)
7. 8. 9. 10. 11. 12.
AUXILIARY I SECTION AUXILIARY II SECTION SECONDARY RELIEF VALVE (ADJUSTABLE) OUTLET SECTION TILT SECTION PRIMARY RELIEF VALVE (NONADJUSTABLE)
Figure 2. Electronic Control Valve
REMOVE WARNING
Lower carriage completely before working on control valve or hydraulic system. Do not work under a raised carriage. Put mast in a vertical position, with no forward or back tilt, and lower carriage completely before disconnecting any parts of hydraulic system. The mast can lower suddenly and cause injury if the carriage is not lowered. NOTE: Most of the individual valve components can be removed and replaced while the control valve is installed 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 sections.
1. Power wash the interior of the operator compartment to remove any dirt or debris. 2. Move truck to disassembly area and shut off engine.
WARNING
Cleaning solvents can be flammable and toxic and cause skin irritation. When cleaning solvents are used, always follow the solvent manufacturers recommended safety procedures. 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.
2000 SRM 1137 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 harness 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 Poppet Valve (EHPV) solenoids. Disconnect the cowl wiring harness from the top auxiliary function Proportional Pressure Reducing Valve (PPRV) solenoids.
Electro-Hydraulic Main Control Valve shaft is disengaged. Remove the SCU from the lift truck. See Figure 2.
WARNING
The main control valve weighs approximately 29.5 kg (65 lb). Use a lifting device capable of lifting the main control valve to avoid the possibility of injury to personnel. 8. Support the main control valve. Remove three mounting capscrews and the main control valve from the lift truck. See Figure 5.
CAUTION
To prevent any foreign matter from getting into either the hydraulic hoses or the hydraulic control valve sections, all openings must have plugs or covers installed immediately 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 disconnecting 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 contamination. 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
NOTE: ACCELERATOR PEDAL NOT SHOWN, HOWEVER, REMOVAL IS THE SAME. 1. MOUNTING BOLT 2. MONOTROL PEDAL ASSEMBLY Figure 3. MONOTROL Pedal Removal
2000 SRM 1137
1. 2. 3. 4. 5.
STEERING SYSTEM HOSES HYDRAULIC INLET HOSE STEERING CONTROL UNIT (SCU) STEERING COLUMN SCU MOUNTING CAPSCREWS
6. 7. 8. 9. 10.
LIFT/LOWER HOSE TILT HOSE AUXILIARY I HOSE AUXILIARY II HOSE 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 Reducing 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.
2000 SRM 1137
Electro-Hydraulic Main Control Valve Disassemble the electro-hydraulic control valve only as necessary for repairs. Most repairs to the control valve will be for the replacement of O-rings to stop 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 the four tie rods and discard 10 O-rings from the auxiliary control valve section. Disassemble 1. Remove the plug from the outlet control valve section and discard the O-ring. 1. 2. 3. 4. COWL INSERT WASHER CAPSCREW 5. MAIN CONTROL VALVE 6. FRAME 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 secondary relief valve. 3. 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. See Figure 6. 4. While holding the adjustment nut, loosen the jam nut. NOTE: While performing Step 5, count and note the number 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-ring on the adjusting nut. 6. Remove the spring, washer, and poppet from the relief valve plug. 7. Remove and discard the backup ring from the relief valve plug.
Figure 5. Main Control Valve Removal
ELECTRO-HYDRAULIC CONTROL VALVE SECTIONS General CAUTION

While working on the electro-hydraulic control valve sections, place a cover over the remaining 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.
CAUTION
If O-rings are to be replaced between two sections that have a hydraulic oil leak, replace all O-rings between all sections. This eliminates the possibility of a subsequent oil leak or possible damage to another O-ring.
2000 SRM 1137
1. 2. 3. 4. 5. 6.
O-RING PLUG OUTLET VALVE SECTION BACKUP RING RELIEF VALVE PLUG POPPET
7. 8. 9. 10. 11. 12.
WASHER SPRING JAM NUT ADJUSTING NUT CONTROL VALVE TIE ROD NUT
Figure 6. Outlet Control Valve Section Clean Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures.
2000 SRM 1137 1. If all components of the outlet control valve section have been removed, clean the outlet control valve section using cleaning solvent and dry using compressed air. 2. If not all components have been removed, clean the outlet control valve section using a lint-free cloth. Inspect Inspect the outlet control valve section mating surfaces and the bore of the secondary relief valve, if removed, 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 secondary 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, lintfree 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 secondary 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 install 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.
Electro-Hydraulic Main Control Valve 7. If removed, install secondary relief valve and tighten to 45 Nm (33 lbf ft). 8. Install new O-ring on plug and install in the outlet valve section. Install NOTE: Coat all O-rings with light coat of clean hydraulic oil to make installation easier. 1. Install 10 new O-rings into the auxiliary valve section. Install the outlet control valve section 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 many functions are on the lift truck. If the main control valve is a four-function control valve, there will be two auxiliary control valve sections. These sections are repaired the same with one exception. The auxiliary control valve section next to the tilt control valve will always have the anti-stall valve installed as a part of that control valve section. Remove 1. Remove the outlet control valve section. See Outlet Control Valve Section, Remove. NOTE: Step 2 and Step 3 are for a three-function control valve. If a four-function control valve is being disassembled, go to Step 4. 2. Remove the anti-stall valve from the auxiliary control valve section. See Figure 7. If the antistall 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-rings from the tilt control valve section. 4. Remove the auxiliary II control valve section from the four tie rods. Remove and discard 10 O-rings from the auxiliary I control valve section. 5. Remove the anti-stall valve from the auxiliary I control valve section. If the anti-stall valve is to be repaired, go to Step 5 of the disassembly procedure for the auxiliary control valve section.
2000 SRM 1137
Figure 7. Auxiliary I and II Control Valve Sections
2000 SRM 1137 Legend for Figure 7 A. AUXILIARY I CONTROL VALVE SECTION 1. 2. 3. 4. 5. 6. PLUG O-RING SPRING WASHER SOCKET HEAD CAPSCREW PROPORTIONAL PRESSURE REDUCING VALVE (PPRV)
B. AUXILIARY II CONTROL VALVE SECTION 7. 8. 9. 10. 11. 12. SPOOL POPPET AUXILIARY I CONTROL VALVE BODY BACKUP RING ANTI-STALL VALVE SLEEVE 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 auxiliary 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 poppets from the auxiliary control valve. Discard one O-ring from each plug. 5. Remove spring from the large end of the antistall valve sleeve. See Figure 8. 6. Remove the spool from the small end of the antistall 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 reassemble the anti-stall sleeve valve, see Step 5 of the assembly procedure.
1. SPOOL 2. BACKUP RING 3. O-RING
4. ANTI-STALL VALVE SLEEVE 5. SPRING
Figure 8. Anti-Stall Valve Clean
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. If all components of the auxiliary control valve section have been removed, clean the auxiliary control valve section and components, except the two PPRVs, using cleaning solvent and dry using compressed air.
Electro-Hydraulic Main Control Valve 2. If not all components have been removed, clean the auxiliary control valve section using a lintfree 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 the spool 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 hydraulic oil to prevent the possibility of rust. Cover the auxiliary control valve section with a clean, dry, lint-free cloth to prevent the possibility of contaminants entering the auxiliary control valve section. Assemble NOTE: Coat all backup rings and O-rings with a light coat 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 81 8 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).
2000 SRM 1137 5. Install two backup rings and two O-rings on the anti-stall valve sleeve as noted during disassembly. 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 fourfunction control valve. 1. Install 10 new O-rings into the tilt control valve section. Install the auxiliary I control valve section on the four tie rods. 2. Install the anti-stall valve into the auxiliary I control valve section. 3. Install the outlet control valve section. See Outlet Control Valve Section, Install. 4. Install 10 new O-rings into the tilt control valve section. Install the auxiliary I control valve section 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 on the four tie rods. 7. Install the outlet control valve section. See Outlet Control Valve Section, Install.
Tilt Control Valve Section

Remove 1. Remove the outlet control valve section. See Outlet 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/ lower control valve section.
10
2000 SRM 1137 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.
Electro-Hydraulic Main Control Valve 3. Remove the socket head capscrew, spring, and piston from the spool. 4. Remove the plug, spring, and washer from the tilt control valve section. Discard the O-ring on the plug. 5. Remove two plugs, two springs, and two poppets from the tilt control valve section. Discard one O-ring from each plug.
1. 2. 3. 4. 5. 6. 7.
PLUG O-RING SPRING WASHER SOCKET HEAD CAPSCREW PISTON PROPORTIONAL PRESSURE-REDUCING VALVE (PPRV)
8. 9. 10. 11. 12.
TILT CONTROL VALVE BODY SETSCREW POPPET BACKUP RING SPOOL
Figure 9. Tilt Control Valve Section
11
Electro-Hydraulic Main Control Valve Clean
2000 SRM 1137 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 control 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 control valve section. 2. Install the tilt control valve section on the lift/ lower control valve section. 3. Install the auxiliary control valve section. See Auxiliary Control Valve Section, Install. 4. Install the outlet control valve section. See Outlet Control Valve Section, Install.
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the 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 compressed air. 2. If not all components have been removed, clean 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 the bore is found, replace the tilt control valve section. NOTE: If the tilt control valve section is not to be reassembled immediately, coat surfaces with clean hydraulic oil to prevent the possibility of rust. Cover the tilt control valve section with a clean, dry, lintfree cloth to prevent the possibility of contaminants entering the tilt control valve section. Assemble NOTE: Coat all backup rings and O-rings with a light coat of clean hydraulic oil to make installation easier. 1. Install the piston, spring, and socket head capscrew 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
Lift/Lower Control Valve Section

Remove 1. Remove the outlet control valve. See Outlet Control Valve Section, Remove. 2. Remove the auxiliary control valve section. See 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-hydraulic poppet valve (EHPV). See Figure 10.
12
2000 SRM 1137
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
LOCK NUT ADJUSTING SCREW O-RING SPRING PISTON PRIMARY RELIEF VALVE CARTRIDGE BACKUP RING SPOOL LIFT/LOWER CONTROL VALVE SECTION SOCKET HEAD PLUG EMERGENCY LOWERING VALVE PLUG
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
SETSCREW SHUTTLE POPPET HOIST POPPET SOLENOID TUBE COIL COIL NUT LOWER POPPET SLEEVE ASSEMBLY LIFT POPPET VALVE ASSEMBLY LOWER POPPET VALVE ASSEMBLY PILOT PIN
Figure 10. Lift/Lower Control Valve Section
13
Electro-Hydraulic Main Control Valve 3. Using special socket (Hyster P/N 1585481), remove 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 unless 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 approximately 7 mm (0.28 in.) longer than the lift poppet valve assembly. 5. Remove the lift poppet assembly from the lift/ lower control valve section. 6. Repeat Step 2 through Step 5 for the lower EHPV. After completing Step 5, remove the sleeve assembly from lower control valve section.
2000 SRM 1137 NOTE: While performing Step 14, count and note the number of turns used to remove the adjusting screw. 14. Remove the adjusting screw from the primary relief 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 can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the 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. 2. If not all components have been removed, clean the lift/lower control valve section using a lintfree 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 damage to either the spool or the bore is found, replace the lift/lower control valve section. If disassembled, inspect the components of the primary relief valve. If any components other than
CAUTION
Use care, when removing the emergency lowering valve, not to damage the tip of the emergency lowering valve. 7. Remove the emergency lowering valve from the lift/lower control valve section. Remove and discard 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/ lower control valve section. 12. Remove the primary relief valve, spring, and spool from the lift/lower control valve section. NOTE: Step 13 through Step 16 are for the disassembly of the primary relief valve. 13. While holding the adjustment screw in place, loosen the lock nut.
14
2000 SRM 1137 O-rings, backup rings, and the spring are damaged, replace the primary relief valve. NOTE: If the lift/lower control valve section is not to be reassembled immediately, coat surfaces with clean hydraulic oil to prevent the possibility of rust. Cover the lift/lower control valve section with a clean, dry, lint-free cloth to prevent the possibility of contaminants 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. NOTE: Coat all backup rings and O-rings with a light coat of clean hydraulic oil to make installation easier. 1. Install the new large O-ring on the primary relief 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 relief valve the number of turns noted during disassembly. 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 plug to 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).
Electro-Hydraulic Main Control Valve NOTE: Ensure that the correct poppet is being installed in the proper position. The lower poppet valve assembly is approximately 7 mm (0.28 in.) longer than the lift poppet valve assembly. 10. Install the lift poppet into the lift/lower control valve section until the poppet "bottoms out." 11. Install the spring onto the solenoid tube. 12. Install the solenoid tube into the lift/lower control valve section. Tighten to 100 11 Nm (74 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 lower EHPV. Before installing the lower poppet into the lower control valve section in Step 10, install sleeve assembly into the lift/lower control valve section first. Tighten sleeve assembly to 122 12 Nm (90 9 lbf ft). Install 1. Install four tie rods into the lift/lower control valve section. 2. Install the tilt control valve section. See Tilt Control Valve Section, Install. 3. Install the auxiliary control valve section. See Auxiliary Control Valve Section, Install. 4. Install the outlet control valve section. See Outlet Control Valve Section, Install.
INSTALL WARNING
The main control valve weighs approximately 29.5 kg (65 lb). Use a lifting device capable of lifting the main control valve, to avoid the possibility of injury to personnel. 1. Lower the control valve enough to allow the cowl wiring harness to be connected to the lower PPRV solenoid connectors as noted during removal. 2. While supporting the main control valve in place on the cowl, install three mounting capscrews through the front of the cowl into the control valve. Tighten the capscrews to 19 Nm (14 lbf ft). See Figure 11.
15
2000 SRM 1137 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 Figure 12. 5. Connect the cowl wiring harness to the top PPRV solenoids and the lift/lower EHPV solenoids as noted 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 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]; 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 Calibration Procedures 8000 SRM 1134.
1. 2. 3. 4.
COWL INSERT WASHER CAPSCREW
5. MAIN CONTROL VALVE 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 washers. Tighten to 45-55 Nm (33-41 lbf ft). See Figure 12.
16
2000 SRM 1137
1. 2. 3. 4. 5.
6. 7. 8. 9. 10.
Figure 12. Hydraulic Hose Installation
17
2000 SRM 1137
Lift Pilot Pin WARNING

Hot 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 removing 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 enter 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 performing this adjustment if the control valve has been disassembled or hose has been disconnected by following 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, 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 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. The coil nut should be removed to access the adjustment screw and re-installed for proper operation. Figure 14. a. Method 1: Connect a current probe to either of the lift EHPV coil leads.
NOTE: ACCELERATOR PEDAL NOT SHOWN, HOWEVER, INSTALL IS THE SAME. 1. MOUNTING BOLT 2. MONOTROL PEDAL ASSEMBLY 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 required 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.
18
2000 SRM 1137 b. Method 2: Monitor the current using the display 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 approximately 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. 11. Repeat the adjustment until the forks begin to move between 550 mA and 650 mA. 12. 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 Figure 14. 13. Replace coil nut. 14. Repeat test to verify that fork movement occurs between 550mA and 650mA.
Electro-Hydraulic Main Control Valve circuit pressure before removing or installing test equipment.
CAUTION
Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports 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 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 . 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. 4. Monitor the EHPV coil current. a. Method 1: Connect a current probe to either of the lift EHPV coil leads. b. Method 2: Monitor the current using the display switch cluster (DSC). See Diagnostic Troubleshooting Manual 9000 SRM 1112 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. See 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 approximately 130 mA. Turn clockwise or IN to increase
Lower Pilot Pin WARNING

Hot 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 removing test equipment.
WARNING
Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all
19
Electro-Hydraulic Main Control Valve 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. 10. Repeat the adjustment until the forks begin to move between 550 mA and 650 mA. 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. 12. Repeat the adjustment until the forks begin to move between 550 mA and 650 mA. 13. Tighten pilot pin adjustment screw lock nut while holding the pilot pin adjustment screw
2000 SRM 1137 to prevent slipping. Slipping of the adjustment screw will cause threshold to increase. See Figure 14. 14. Replace coil nut. 15. Repeat test to verify that fork movement occurs between 550mA and 650mA.
Abnormal/Erroneous EHPV Adjustment CAUTION

While only minor adjustments may be necessary, 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. 2. 3. 4.
COIL NUT PILOT PIN ADJUSTMENT SCREW PILOT PIN ADJUSTMENT LOCK NUT COIL
5. 6. 7. 8.
SOLENOID TUBE ASSEMBLY BIAS SPRING O-RING POPPET ASSEMBLY
Figure 14. Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment
20
2000 SRM 1137 If this occurs on lift function and lower function simultaneously, 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 function calibrated correctly), the mast will raise as soon
Manual Main Control Valve as the engine is turned on. If this occurs on the lower function only (with the lift function calibrated correctly, the auxiliary and tilt functions will be operational, 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 hydraulic circuitry incorporates dual pressure logic. The lift function operates on the primary relief pressure 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 pressure 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. 2. 3. 4. 5.
STEERING CONTROL UNIT (SCU) SCU MOUNTING CAPSCREW MONOBLOCK VALVE SECTION HOIST/LOWER SPOOL TILT SPOOL
6. 7. 8. 9. 10.
AUXILIARY I VALVE SECTION/SPOOL AUXILIARY II VALVE SECTION/SPOOL SECONDARY RELIEF VALVE OUTLET SECTION PRIMARY RELIEF VALVE
Figure 15. Manual Control Valve
21
2000 SRM 1137 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 connect the hydraulic lever linkages to the spools. Remove three capscrews and the hydraulic lever assembly from the cowl. See Figure 16.
REMOVE WARNING
Lower carriage completely before working on control valve or hydraulic system. Do not work under a raised carriage. Put mast in a vertical position, with no forward or back tilt, and lower carriage completely before disconnecting any parts of hydraulic system. The mast can lower suddenly and cause injury if the carriage is not lowered. NOTE: Most of the individual valve components can be removed and replaced while the control valve is installed 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 compartment to remove any dirt or debris. 2. Move truck to disassembly area and shut off engine.
WARNING
Cleaning solvents can be flammable and toxic and cause skin irritation. When cleaning solvents are used, always follow the solvent manufacturers recommended safety procedures. 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 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]; S80, 100, 120FTBCS; S120FTPRS) (G004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) 1. CAPSCREW 2. HYDRAULIC LEVER ASSEMBLY Figure 16. Hydraulic Lever Relocation 5. To remove the accelerator pedal or MONOTROL pedal assembly, disconnect the cowl wiring harness from the pedal assembly wiring harness and remove three capscrews. See Figure 17.
22
2000 SRM 1137
CAUTION
To prevent any foreign matter from getting into either the hydraulic hoses or the hydraulic control valve sections, all openings must have plugs or covers installed immediately 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 disconnecting 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 contamination. See Figure 18. 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 the lift truck. See Figure 15.
WARNING
The main control valve weighs approximately 29.5 kg (65 lb). Use a lifting device capable of lifting the main control valve to avoid the possibility of injury to personnel. NOTE: ACCELERATOR PEDAL NOT SHOWN, HOWEVER, REMOVAL IS THE SAME. 1. MOUNTING BOLT 2. MONOTROL PEDAL ASSEMBLY Figure 17. MONOTROL Pedal Removal 8. Support the main control valve. Remove three mounting capscrews and the main control valve from the lift truck. See Figure 19. 9. Remove the main control valve from the lift truck.
23
2000 SRM 1137
1. 2. 3. 4. 5.
6. 7. 8. 9. 10.
Figure 18. Hydraulic Hose Removal
24
2000 SRM 1137
Manual Main Control Valve valve will be for the replacement of O-rings to stop leaks between sections. The manual control valve will be disassembled starting with the outlet control valve section.
Outlet Control Valve Section

Remove 1. Remove four nuts from the control valve tie rods. See Figure 20. 2. Remove the outlet control valve section from the four tie rods and discard three O-rings from the auxiliary control valve section. See Figure 21. Disassemble 1. Remove the plug from the outlet control valve section and discard the O-ring. NOTE: Perform Step 1 through Step 6 only if it is absolutely necessary to disassemble the secondary relief valve. 2. 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. See Figure 20. 3. While holding the adjusting nut in place, loosen the jam nut. NOTE: While performing Step 4, count and note the number of turns used to remove the adjusting nut. 4. Remove the adjusting nut and jam nut assembly from the relief valve plug and discard the O-ring on the adjusting nut. 5. Remove the spring, washer, and poppet from the relief valve plug. 6. Remove and discard the backup ring from the relief valve plug.
1. 2. 3. 4.
Figure 19. Main Control Valve Removal
MANUAL CONTROL VALVE SECTIONS General CAUTION

While working on the manual control valve sections, place a cover over the remaining 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.
CAUTION
If O-rings are to be replaced between two sections that have a hydraulic oil leak, replace all O-rings between all sections. This eliminates the possibility of a subsequent oil leak or possible damage to another O-ring. NOTE: Disassemble the manual control valve only as necessary for repairs. Most repairs to the control
25
2000 SRM 1137
1. 2. 3. 4. 5. 6.
PLUG O-RING OUTLET VALVE SECTION BACKUP RING RELIEF VALVE PLUG POPPET
7. 8. 9. 10. 11. 12.
WASHER SPRING JAM NUT ADJUSTING NUT CONTROL VALVE TIE ROD NUT
Figure 20. Outlet Control Valve Section
26
2000 SRM 1137 Clean
Manual Main Control Valve 2. Install the poppet, washer, and spring into the relief valve plug. 3. Install a new O-ring on the adjusting nut, and install 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, and 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 valve 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).
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. If all components of the outlet control valve section have been removed, clean the outlet control valve section using cleaning solvent and dry using compressed air. 2. If not all components have been removed, clean the outlet control valve section using a lint-free cloth. Inspect Inspect the outlet control valve section mating surfaces and the bore of the secondary relief valve, if removed, 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 secondary 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, lintfree 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 secondary relief valve was repaired. 1. Install a new backup ring on the relief valve plug. See Figure 20.
Auxiliary Control Valve Section

Remove 1. Remove the outlet valve. Valve Section, Remove. See Outlet Control
NOTE: Step 2 and Step 3 are used if a four-section control valve is being disassembled. If a three-section control valve is being disassembled, go to Step 3. 2. Remove the auxiliary II control valve section from the four tie rods. Remove and discard three O-rings from the auxiliary I control valve section. 3. Remove the auxiliary I control valve section from the four tie rods. Remove and discard three O-rings from the lift and tilt control valve section. See Lift/Tilt Control Valve Section.
27
2000 SRM 1137
1. 2. 3. 4. 5. 6. 7.
CAPSCREW END CAP SPOOL END SPRING SEAT SPRING SEAL PLATE WIPER
8. 9. 10. 11. 12. 13.
O-RING SPOOL POPPET SPRING PLUG AUXILIARY CONTROL VALVE SECTION
Figure 21. Auxiliary Control Valve Section
28
2000 SRM 1137 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 sections. 1. Remove two socket head capscrews, end cap, and seal plate from the auxiliary control valve section. See Figure 21. 2. Remove the spool assembly and wiper from the auxiliary control valve section. 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 discard the O-rings from the plugs. Clean
Manual Main Control Valve bore are damaged, replace the auxiliary control valve section. If disassembled, inspect the components of the spool. If any components are damaged, replace the components. If the spool is damaged, replace the auxiliary control valve section. NOTE: If the auxiliary control valve section is not to be reassembled immediately, coat surfaces with clean hydraulic oil to prevent the possibility of rust. Cover the auxiliary control valve section with a clean, dry, lint-free cloth to prevent the possibility of contaminants entering the auxiliary control valve section. Assemble NOTE: Coat all backup rings and O-rings with a light coat of clean hydraulic oil to make installation easier. 1. Install two poppets, springs, and plugs, with new O-rings installed, into the auxiliary control valve section. Tighten the plugs to 45 5 Nm (33 4 lbf ft). See Figure 21. 2. Install new O-ring, new wiper, seal plate, and two socket head capscrews on the auxiliary control valve section. Tighten the socket head 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 9.5 1 Nm (84 12 lbf in). 4. Install the new wiper and spool assembly into the auxiliary control valve section. 5. Install seal plate, end cap, and two socket head capscrews into the auxiliary control valve section. Tighten the socket head screws to 9.5 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, then go to Step 3. 1. Install three new O-rings on the lift and tilt control valve section. Install the auxiliary I control valve section on the four tie rods. 2. Install three new O-rings on the auxiliary I control valve section. Install the auxiliary II control valve section on the four tie rods.
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the 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, clean the auxiliary control valve section using a lintfree 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
29
Manual Main Control Valve 3. Install the outlet valve. See Outlet Control Valve Section, Install.
2000 SRM 1137 7. Remove three plugs, springs, and poppets from the lift/tilt control valve section. Remove and discard 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 performing Step 10, count and note the number of turns used to remove the adjusting nut. 10. Remove the adjusting nut and jam nut assembly from the relief valve plug and discard the O-ring on the adjusting nut. 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
Lift/Tilt Control Valve Section

Remove 1. Remove the outlet control valve section valve. See Outlet Control Valve Section, Remove. 2. Remove the auxiliary control valve section. See Auxiliary Control Valve Section, Remove. Disassemble NOTE: Remove only those components required to repair 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 section. Remove and discard the wiper and O-ring from the tilt bore of the lift/tilt control valve section. 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, spring seat, and O-ring from the lift spool assembly. Discard the O-ring. 6. Remove two socket head screws and seal plate from the lift side of the lift/tilt control valve section. Remove and discard the wiper and O-ring from the lift bore of the lift/tilt control valve section.
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. If all components of the lift/tilt control valve section have been removed, clean the lift/tilt control valve section using cleaning solvent and dry using compressed air. 2. If not all components have been removed, clean the lift/tilt control valve section using a lint-free cloth.
30
2000 SRM 1137
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
SOCKET HEAD CAPSCREW END CAP O-RING SPOOL END FASTENER SPRING PISTON SPRING SEAT SEAL PLATE WIPER O-RING SPOOL
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
PLUG POPPET SEAL PLATE LIFT/TILT CONTROL VALVE SECTION BACKUP RING RELIEF VALVE PLUG POPPET WASHER JAM NUT ADJUSTING NUT PLUG
Figure 22. Lift/Tilt Control Valve Section
31
Manual Main Control Valve Inspect Inspect the lift/tilt control valve section mating surfaces. 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 primary relief valve bore, or either the lift or tilt spool bores are damaged, replace the lift/tilt control valve section. If disassembled, inspect the components of the primary relief valve. If any components other than O-rings, backup rings, and the spring are damaged, replace the primary relief valve. NOTE: If the lift/tilt control valve section is not to be reassembled immediately, coat surfaces with clean hydraulic oil to prevent the possibility of rust. Cover the lift/tilt control valve section with a clean, dry, lint-free cloth to prevent the possibility of contaminants entering the lift/tilt 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 primary 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 relief valve plug the number of turns noted during removal. 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. Install secondary relief valve, and tighten to 45 Nm (33 lbf ft). See Figure 22.
2000 SRM 1137 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 side of 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 Auxiliary Control Valve Section, Install. 2. Install the outlet valve. See Outlet Control Valve Section, Install.
32
2000 SRM 1137
Manual Main Control Valve the valve section spool clevis. Install the rod end pins and lock ring cotter pins. 7. Install the dashboard, seal plate, kick panel, and floor plate. 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]; S80, 100, 120FTBCS; S120FTPRS) (G004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) lift trucks.
INSTALL WARNING
The main control valve weighs approximately 29.5 kg (65 lb). Use a lifting device capable of lifting the main control valve, to avoid the possibility of injury to personnel. 1. While supporting the main control valve in place on the cowl, install three mounting capscrews through the front of the cowl into the control valve. Tighten the capscrews to 19 Nm (14 lbf ft). See Figure 23. 2. Coat the two O-rings to be installed on the main control valve with hydraulic oil. Install the two O-rings on the main control valve. 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 washers. Tighten to 45-55 Nm (33-41 lbf ft). See Figure 24. 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 Figure 24. 5. 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 25. 6. Using three capscrews, mount the hydraulic lever assembly to the cowl. Install the rods into
1. 2. 3. 4.
Figure 23. Main Control Valve Installation
33
2000 SRM 1137
1. 2. 3. 4. 5.
6. 7. 8. 9. 10.
Figure 24. Hydraulic Hose Installation
34
2000 SRM 1137
Steering Control Unit Repair Legend for Figure 25 NOTE: ACCELERATOR PEDAL NOT SHOWN, HOWEVER, INSTALL IS THE SAME. 1. MOUNTING BOLT 2. MONOTROL PEDAL ASSEMBLY
Figure 25. MONOTROL Pedal Install
Steering Control Unit Repair

STEERING CONTROL UNIT, REMOVE WARNING
Lower carriage completely before working on control valve or hydraulic system. Do not work under a raised carriage. Put mast in a vertical position and lower carriage completely before disconnecting any parts of hydraulic system. The mast can lower suddenly and cause injury if the carriage is not lowered. 1. Power wash the interior of the operator compartment to remove any dirt or debris. 2. Move truck to disassembly area and shut off engine.
WARNING
Cleaning solvents can be flammable and toxic and cause skin irritation. When cleaning solvents are used, always follow the solvent manufacturers recommended safety procedures. Wear protective goggles or a face shield to prevent eye injuries. NOTE: Take any 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 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,
35
Steering Control Unit Repair 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 the steering control unit, clean the outside of the valve either by steam cleaning or with cleaning solvent.
2000 SRM 1137 must have plugs or covers installed immediately 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 the correct connection of hydraulic hoses during installation, tag each hose prior to disconnecting from the control valve. 4. Disconnect hydraulic hoses from the steering control unit. Install plugs or caps on all open hose ends and control valve ports to prevent contamination. See Figure 26.
CAUTION
To prevent any foreign matter from getting into either the hydraulic hoses or the hydraulic control valve sections, all openings
1. "L" STEERING SYSTEM HOSE 2. "R" STEERING SYSTEM HOSE 3. HYDRAULIC INPUT HOSE
4. SCU MOUNTING CAPSCREWS 5. STEERING CONTROL UNIT (SCU) 6. STEERING COLUMN Figure 26. Steering Control Unit
36
2000 SRM 1137 5. Remove the two SCU mounting bolts 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 the lift truck. See Figure 26. 6. Remove and discard two O-rings from the main control valve, and coat the machined surface of the main control valve with a light coat of hydraulic oil to prevent the possibility of rust. Cover the exposed machined surface of the main control valve to prevent the possibility of foreign matter getting into the main control valve.
Steering Control Unit Repair 6. Remove the thrust washer, thrust bearing, and thrust washer from the shaft end of the spool assembly. 7. Remove the retaining ring from the spool assembly. 8. Press the cross pin out of the spool assembly. 9. Press the spool from the sleeve. springs from the spool. Remove the
STEERING CONTROL UNIT, DISASSEMBLE

1. Place the steering pump into a soft-jaw vise with the splined end facing down. NOTE: Note the position of the special screws when removed, so that they will be installed in the same positions at assembly of the steering control unit. 2. Remove the capscrews, special screws, and washers. Rotate the steering pump 90 degrees sideways in the vise. See Figure 27. 3. Remove the end cover, O-ring, gear housing, O-ring, gear, distributor plate, and O-ring from the steering control unit. Discard the O-rings. 4. Remove the cardan shaft from the spool assembly. 5. Remove the spool assembly from the steering control unit housing.
NOTE: To aid in installation of the emergency steering seat and emergency steering check ball, note the hole position of the emergency steering seat and emergency steering check ball during removal. 10. Remove the emergency steering seat and emergency steering check ball from the steering control unit housing. NOTE: To aid in installation of the load sense check ball and seat, note the hole position of the load sense seat and load sense check ball during removal. 11. Remove the load sense seat and load sense check ball from the steering control unit. 12. Remove the shaft seals from the pump housing. Discard the seals. 13. Remove the cap and system relief valve from the steering control unit. If the system relief valve needs to be repaired, go to Relief Valve, Disassemble.
37
2000 SRM 1137
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
CAPSCREW SPECIAL SCREW WASHER END COVER O-RING GEAR RING GEAR DISTRIBUTOR PLATE CARDAN SHAFT SPRING SET SLEEVE CROSS PIN SPOOL RETAINING RING
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
THRUST WASHER THRUST BEARING SEAL EMERGENCY STEER SEAT EMERGENCY STEER CHECK BALL STEERING CONTROL UNIT HOUSING SYSTEM RELIEF VALVE CAP MOUNTING BOLT LOCKWASHER LOAD SENSE PLUG LOAD SENSE CHECK BALL LOAD SENSE SEAT
Figure 27. Steering Control Unit
38
2000 SRM 1137
Steering Control Unit Repair 5. Install the cross pin into the spool assembly. 6. Install the thrust washer, thrust bearing, and thrust washer on the spool. 7. Place the pump housing in a soft-jawed vise in the horizontal position. Install the spool assembly into the housing while holding the cross pin in a horizontal position. 8. With the pump housing still in the horizontal position, install the spool so that the pin in the spool is in the horizontal position. When the spool is installed rotate the steering control unit to the vertical position. 9. Install the emergency steering check ball, and emergency steering seat in the steering control unit housing as noted during removal. Tighten the emergency steering seat to 1.5 0.3 Nm (13 2.5 lbf in). 10. Install the load sense check ball and load sense orifice in the steering control unit as noted during removal. Tighten the load sense orifice to 1.5 0.3 Nm (13 2.5 lbf in). 11. Install a new O-ring on the steering control unit housing, and place the distributor plate on the steering control unit housing, with the holes properly aligned with the steering control unit housing. 12. Install the cardan shaft and rotate it until it is engaged with the pin in the spool assembly. 13. Install the gear wheel onto the cardan shaft. 14. Install new O-ring onto the gear ring and install the gear ring onto the distributor plate, making sure that the holes are properly aligned. 15. Install a new O-ring onto the gear ring. Install end cover, special capscrews, as noted during disassembly, and capscrews. Tighten all capscrews to 30 6 Nm (265 53 lbf in). 16. If removed, install the system relief valve and tighten to 18 6 Nm (160 53 lbf in). Install the tamper proof cap into the steering control unit housing.
STEERING CONTROL UNIT, CLEAN WARNING

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety precautions.
WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean all the parts in solvent. Dry the parts with compressed air. Do not dry the parts with a cloth. Make sure all surfaces are free of scratches and sharp edges.
STEERING CONTROL UNIT, INSPECT

Inspect all parts for damage, if any parts other than those parts contained in parts kits Hyster P/N 1579908 (seal kit) or Hyster P/N 1581858 (capscrew kit) are damaged, replace the steering control unit. If the Steering control unit is not going to be installed on the main control valve immediately, coat the machined mating surface with a light coat of hydraulic oil and install plugs in any open ports to prevent the possibility of any foreign matter getting into the steering control unit.
STEERING CONTROL UNIT, ASSEMBLE

NOTE: Apply a light coat of clean hydraulic oil to O-rings and seals to assist in installation. 1. Using a seal installer, install the shaft seals in the steering control unit housing. 2. Install the spool into the sleeve with the key slots opposite each other. See Figure 27. 3. Insert the curved springs between the flat springs. NOTE: The retaining ring must be able to rotate unimpeded by the springs. 4. Center the springs in the spool assembly, and install the retaining ring over the springs.
RELIEF VALVE, DISASSEMBLE

1. Remove the snap ring and anti-tamper ring from the cartridge body. See Figure 28.
39
2000 SRM 1137 1579908 (seal kit) are damaged, replace the relief valve. If the relief valve is not going to be installed in the steering control housing immediately, coat the valve with a light coat of hydraulic oil.
RELIEF VALVE, ASSEMBLE

NOTE: Apply a light coat of clean hydraulic oil to O-rings and seals to assist in installation. 1. Install the large O-ring, backup ring, and small O-ring on the cartridge body. See Figure 28. 2. Install the seat, spring, and plug into the cartridge body. 1. SNAP RING 2. ANTI-TAMPER RING 3. PLUG 4. SPRING 5. 6. 7. 8. SEAT CARTRIDGE BODY O-RING BACKUP RING 3. Install the anti-tamper ring and snap ring into the cartridge body. 4. Install the system relief valve and cap into the steering control unit housing. Tighten the relief valve to 18 6 Nm (160 53 lbf in).
Figure 28. System Relief Valve 2. Remove the plug, spring, and seat from the cartridge body. 3. Remove and discard small O-ring, backup ring, and large O-rings from the cartridge body.
STEERING CONTROL UNIT, INSTALL

1. Coat the two O-rings to be installed on the main control valve with hydraulic oil. Install the two O-rings on the main control valve. NOTE: During the performance of Step 2, use care not to damage the O-rings on the main control valve. 2. Position the SCU under the steering shaft and raise the SCU to completely 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 washers. Tighten to 45 to 55 Nm (33 to 41 lbf ft). 3. Remove all plugs and caps and install the hydraulic hoses as noted during removal. 4. Install dashboard, seal plate, kick panel, and floor plate. 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]; S80, 100, 120FTBCS; S120FTPRS) (G004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) lift trucks.
RELIEF VALVE, CLEAN WARNING

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety precautions.
WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean all the parts in solvent. Dry the parts with compressed air. Do not dry the parts with a cloth. Make sure all surfaces are free of scratches and sharp edges.
RELIEF VALVE, INSPECT

Inspect all parts for damage, if any parts other than those parts contained in parts kits Hyster P/N
40
TECHNICAL PUBLICATIONS
2000 SRM 1137 6/06 (3/06)(6/05)(5/05)(12/04) Printed in United Kingdom

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MAIN CONTROL VALVE

PART NO. 1580515

2000 SRM 1137

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

Main Control Valve

2006 HYSTER COMPANY

Main Control Valve

TABLE OF CONTENTS (Continued)

2000 SRM 1137

Electro-Hydraulic Main Control Valve

Figure 1. Main Control Valve Mounting

Electro-Hydraulic Main Control Valve

Confidential/Proprietary - Do Not Copy or Duplicate

Electro-Hydraulic Main Control Valve

2000 SRM 1137

7. 8. 9. 10. 11. 12.

Figure 2. Electronic Control Valve

Confidential/Proprietary - Do Not Copy or Duplicate

Confidential/Proprietary - Do Not Copy or Duplicate

Electro-Hydraulic Main Control Valve

2000 SRM 1137

Confidential/Proprietary - Do Not Copy or Duplicate

2000 SRM 1137

Outlet Control Valve Section

Figure 5. Main Control Valve Removal

ELECTRO-HYDRAULIC CONTROL VALVE SECTIONS General CAUTION

Confidential/Proprietary - Do Not Copy or Duplicate

Electro-Hydraulic Main Control Valve

2000 SRM 1137

7. 8. 9. 10. 11. 12.

Confidential/Proprietary - Do Not Copy or Duplicate

Auxiliary Control Valve Section

Confidential/Proprietary - Do Not Copy or Duplicate

Electro-Hydraulic Main Control Valve

2000 SRM 1137

Figure 7. Auxiliary I and II Control Valve Sections

Confidential/Proprietary - Do Not Copy or Duplicate

Electro-Hydraulic Main Control Valve

1. SPOOL 2. BACKUP RING 3. O-RING

4. ANTI-STALL VALVE SLEEVE 5. SPRING

Figure 8. Anti-Stall Valve Clean

Confidential/Proprietary - Do Not Copy or Duplicate

Tilt Control Valve Section

Confidential/Proprietary - Do Not Copy or Duplicate

8. 9. 10. 11. 12.

TILT CONTROL VALVE BODY SETSCREW POPPET BACKUP RING SPOOL

Figure 9. Tilt Control Valve Section

Confidential/Proprietary - Do Not Copy or Duplicate

Electro-Hydraulic Main Control Valve Clean

Lift/Lower Control Valve Section

Confidential/Proprietary - Do Not Copy or Duplicate

2000 SRM 1137

Electro-Hydraulic Main Control Valve

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Figure 10. Lift/Lower Control Valve Section

Confidential/Proprietary - Do Not Copy or Duplicate

Confidential/Proprietary - Do Not Copy or Duplicate

Confidential/Proprietary - Do Not Copy or Duplicate

Electro-Hydraulic Main Control Valve

COWL INSERT WASHER CAPSCREW

5. MAIN CONTROL VALVE 6. FRAME

Confidential/Proprietary - Do Not Copy or Duplicate

2000 SRM 1137