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MAIN CONTROL VALVE
S30FT, S35FT, S40FTS [E010];H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100,
120FTBCS; S120FTPRS ) [G004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) [N005]
This manual contains information that is confidential and/or proprietary to HysterCompany, its subsidiaries and/or vendors. Copying or distribution of any sections of
this manual marked "Confidential/Proprietary" is prohibited.
PART NO. 1580515 2000 SRM 1137
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SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
Do not lift heavy parts by hand, use a lifting mechanism.
Wear safety glasses.
DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
Keep the unit clean and the working area clean and orderly.
Use the correct tools for the job.
Keep the tools clean and in good condition.
Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
Be sure to follow the WARNING and CAUTION notes in the instructions.
Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNINGIndicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
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Main Control Valve Table of Contents
TABLE OF CONTENTS
General ...............................................................................................................................................................
Electro-Hydraulic Main Control Valve .............................................................................................................
Description .....................................................................................................................................................
Remove ........................................................................................................................................................... 2
Electro-Hydraulic Control Valve Sections .................................................................................................... 5General....................................................................................................................................................... 5
Outlet Control Valve Section .................................................................................................................... 5
Remove .................................................................................................................................................. 5
Disassemble........................................................................................................................................... 5
Clean ...................................................................................................................................................... 6
Inspect ...................................................................................................................................................
Assemble................................................................................................................................................
Install.....................................................................................................................................................
Auxiliary Control Valve Section ...............................................................................................................
Remove ..................................................................................................................................................
Disassemble........................................................................................................................................... 9
Clean ...................................................................................................................................................... 9Inspect ................................................................................................................................................... 10
Assemble................................................................................................................................................ 10
Install..................................................................................................................................................... 10
Tilt Control Valve Section ......................................................................................................................... 10
Remove .................................................................................................................................................. 10
Disassemble........................................................................................................................................... 1
Clean ...................................................................................................................................................... 12
Inspect ................................................................................................................................................... 12
Assemble................................................................................................................................................ 12
Install..................................................................................................................................................... 12
Lift/Lower Control Valve Section.............................................................................................................. 12
Remove .................................................................................................................................................. 12
Disassemble........................................................................................................................................... 12Clean ...................................................................................................................................................... 14
Inspect ................................................................................................................................................... 14
Assemble................................................................................................................................................ 15
Install..................................................................................................................................................... 15
Install ............................................................................................................................................................. 15
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment.................................................................. 1
Lift Pilot Pin .............................................................................................................................................. 18
Lower Pilot Pin .......................................................................................................................................... 19
Abnormal/Erroneous EHPV Adjustment ................................................................................................. 20
Manual Main Control Valve .............................................................................................................................. 2
Description ..................................................................................................................................................... 2
Remove ........................................................................................................................................................... 22
Manual Control Valve Sections..................................................................................................................... 25General....................................................................................................................................................... 25
Outlet Control Valve Section .................................................................................................................... 25
Remove .................................................................................................................................................. 25
Disassemble........................................................................................................................................... 25
Clean ...................................................................................................................................................... 2
Inspect ................................................................................................................................................... 2
Assemble................................................................................................................................................ 2
Install..................................................................................................................................................... 2
2006 HYSTER COMPANY
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Table of Contents Main Control Valve
TABLE OF CONTENTS (Continued)
Auxiliary Control Valve Section ............................................................................................................... 27
Remove .................................................................................................................................................. 27
Disassemble........................................................................................................................................... 29
Clean ...................................................................................................................................................... 29Inspect ................................................................................................................................................... 29
Assemble................................................................................................................................................ 29
Install..................................................................................................................................................... 29
Lift/Tilt Control Valve Section .................................................................................................................. 30
Remove .................................................................................................................................................. 30
Disassemble........................................................................................................................................... 30
Clean ...................................................................................................................................................... 30
Inspect ................................................................................................................................................... 32
Assemble................................................................................................................................................ 32
Install..................................................................................................................................................... 32
Install ............................................................................................................................................................. 33
Steering Control Unit Repair ............................................................................................................................ 35
Steering Control Unit, Remove ..................................................................................................................... 35Steering Control Unit, Disassemble ............................................................................................................. 37
Steering Control Unit, Clean ........................................................................................................................ 39
Steering Control Unit, Inspect...................................................................................................................... 39
Steering Control Unit, Assemble .................................................................................................................. 39
Relief Valve, Disassemble.............................................................................................................................. 39
Relief Valve, Clean......................................................................................................................................... 40
Relief Valve, Inspect ...................................................................................................................................... 40
Relief Valve, Assemble................................................................................................................................... 40
Steering Control Unit, Install ....................................................................................................................... 40
This section is for the following models:
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100,
120FTBCS; S120FTPRS ) [G004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) [N005]
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
General
This section contains description and repair proce-
dures for both manual and electronic main control
valves used in the hydraulic system for this series of
lift trucks.
There are two main control valves available for this
series of lift trucks. One is controlled manually
and the other is controlled electronically. The main
control valves are mounted to the cowl using three
mounting bolts. See Figure 1.
NOTE: MAJOR COMPONENTS NOT SHOWN FOR
CLARITY. VIEW IS FROM THE FRONT.
1. COWL2. INSERT3. WASHER4. CAPSCREW
5. MAIN CONTROLVALVE
6. FRAME
Figure 1. Main Control Valve Mounting
Electro-Hydraulic Main Control Valve
DESCRIPTION
This E-Valve is an electronically-controlled,
closed-center, load-sensing stack valve. It uses
an unloader valve (single functions only) and has
parallel hydraulic circuitry. Operating multiple
functions simultaneously will result in a nonpropor-
tionate increase in pump flow to functions which
receive the lowest amount of pressurized fluid. A
fixed displacement pump is used in conjunction
with the inlet compensator to achieve the required
load-sense logic. Lift function is on main relief
pressure setting. Tilt and auxiliary functions are onsecondary relief pressure setting. Lift pressure is
unaffected by secondary relief operation.
The electronic main control valve incorporates an
emergency lowering valve. See Figure 2. This valv
allows the operator or service technician to lower th
lift trucks mast assembly if the electrical signal t
the electronic main control valve is disrupted.
The electronic main control valve assembly is divide
in the following sections. See Figure 2.
Steering Control Unit (SCU)
Lift/Lower
Tilt
Auxiliary
Outlet
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Electro-Hydraulic Main Control Valve 2000 SRM 1137
1. STEERING CONTROL UNIT (SCU)2. SCU MOUNTING CAPSCREW3. LIFT/LOWER SECTION4. EMERGENCY LOWER VALVE5. ELECTRO-HYDRAULIC POPPET VALVE (EHPV)6. PROPORTIONAL PRESSURE REDUCING
VALVE (PPRV)
7. AUXILIARY I SECTION8. AUXILIARY II SECTION9. SECONDARY RELIEF VALVE (ADJUSTABLE)10. OUTLET SECTION11. TILT SECTION12. PRIMARY RELIEF VALVE (NONADJUSTABLE)
Figure 2. Electronic Control Valve
REMOVE
WARNINGLower carriage completely before working on
control valve or hydraulic system. Do not work
under a raised carriage. Put mast in a verti-
cal position, with no forward or back tilt, and
lower carriage completely before disconnect-
ing any parts of hydraulic system. The mast
can lower suddenly and cause injury if the car-
riage is not lowered.
NOTE: Most of the individual valve components can
be removed and replaced while the control valve is in-
stalled in the truck. Removal of the control valve for
repairs is normally only required to replace a valve
section, or to replace the O-rings between the sec-
tions.
1. Power wash the interior of the operator compart-
ment to remove any dirt or debris.
2. Move truck to disassembly area and shut off en-
gine.
WARNINGCleaning solvents can be flammable and toxic
and cause skin irritation. When cleaning
solvents are used, always follow the solvent
manufacturers recommended safety proce-
dures. Wear protective goggles or a face shield
to prevent eye injuries.
NOTE: Take all necessary steps to prevent debris,
dust, or other contaminants from entering the valve
cavities, hydraulic lines, or replacement parts.
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
3. Remove the floor plate, kick panel, seal plate,
and dashboard. See the section Frame 100 SRM
1120 for S30FT, S35FT, S40FTS (E010); H1.6FT,
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177) and Frame 100
SRM 1243 for S4.0, 5.0, 5.50FT ([S80, 100,120FT; S120FTS]) S80, 100FTBCS; S120FTPRS
(G004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
lift trucks. Before disconnecting any hydraulic
hoses or removing any parts from the control
valve, clean the outside of the valve either by
steam cleaning or with cleaning solvent.
4. To remove the accelerator pedal or MONOTROL
pedal assembly, disconnect the cowl wiring har-
ness from the pedal assembly wiring harness and
remove three capscrews. See Figure 3.
NOTE: To aid in installation, tag all connectors prior
to disconnecting from the solenoids.
5. Disconnect the cowl wiring harness connectors
from the hoist and lower Electro-Hydraulic Pop-
pet Valve (EHPV) solenoids. Disconnect the cowl
wiring harness from the top auxiliary function
Proportional Pressure Reducing Valve (PPRV)
solenoids.
CAUTION
To prevent any foreign matter from getting
into either the hydraulic hoses or the hy-draulic control valve sections, all openings
must have plugs or covers installed immedi-
ately after hoses are disconnected from the
control valve. This also applies if any other
items are removed from the control valve.
NOTE: To aid in correctly connecting hydraulic hoses
during installation, tag each hose prior to disconnect-
ing from the control valve.
6. Disconnect hydraulic hoses from the control
valve. Install plugs or caps on all open hose ends
and control valve ports to prevent contamina-tion. See Figure 4.
7. Remove the two SCU mounting capscrews and
move the SCU approximately 1.3 cm (0.5 in.) to
the left, and lower the SCU until the steering
shaft is disengaged. Remove the SCU from th
lift truck. See Figure 2.
WARNINGThe main control valve weighs approximately
29.5 kg (65 lb). Use a lifting device capable o
lifting the main control valve to avoid the pos
sibility of injury to personnel.
8. Support the main control valve. Remove thre
mounting capscrews and the main control valv
from the lift truck. See Figure 5.
NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW
EVER, REMOVAL IS THE SAME.
1. MOUNTING BOLT2. MONOTROL PEDAL ASSEMBLY
Figure 3. MONOTROL Pedal Removal
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Electro-Hydraulic Main Control Valve 2000 SRM 1137
1. STEERING SYSTEM HOSES
2. HYDRAULIC INLET HOSE3. STEERING CONTROL UNIT (SCU)4. STEERING COLUMN5. SCU MOUNTING CAPSCREWS
6. LIFT/LOWER HOSE
7. TILT HOSE8. AUXILIARY I HOSE9. AUXILIARY II HOSE10. RETURN HOSE
Figure 4. Hydraulic Hose Removal
NOTE: To aid in installation, tag all connectors prior
to disconnecting from the solenoids.
9. Raise the main control valve approximately
25.4 cm (10 in.) to gain access to the lower tilt
and auxiliary function Proportional Pressure Re-
ducing Valve (PPRV) solenoids. Disconnect the
cowl harness from the lower tilt and auxiliary
function (PPRV) solenoids.
10. Remove the main control valve from the lift
truck.
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
1. COWL2. INSERT3. WASHER4. CAPSCREW
5. MAIN CONTROLVALVE
6. FRAME
Figure 5. Main Control Valve Removal
ELECTRO-HYDRAULIC CONTROL VALVE
SECTIONS
General
CAUTION
While working on the electro-hydraulic controlvalve sections, place a cover over the remain-
ing sections of the control valve to prevent
the possibility of contaminants getting into
the control valve openings which could cause
damage to the control valve.
CAUTIONIf O-rings are to be replaced between two sec-
tions that have a hydraulic oil leak, replace all
O-rings between all sections. This eliminates
the possibility of a subsequent oil leak or pos-
sible damage to another O-ring.
Disassemble the electro-hydraulic control valve only
as necessary for repairs. Most repairs to the contro
valve will be for the replacement of O-rings to sto
leaks between sections.
Outlet Control Valve Section
Remove
1. Remove four nuts from the control valve tie rods
See Figure 6.
2. Remove the outlet control valve section from th
four tie rods and discard 10 O-rings from the aux
iliary control valve section.
Disassemble
1. Remove the plug from the outlet control valv
section and discard the O-ring.
2. If the secondary relief valve has been leaking
remove it from the outlet control valve section
See Step 3 through Step 7 to disassemble the sec
ondary relief valve.
3. Remove the plug from the adjusting nut. Remov
and discard the O-ring from the plug. Remov
and discard the backup rings and O-ring from th
adjusting nut. See Figure 6.
4. While holding the adjustment nut, loosen the jam
nut.
NOTE: While performing Step 5, count and note thnumber of turns used to remove the adjusting nut.
5. Remove the adjusting nut and jam nut assembly
from the relief valve plug and discard the O-rin
on the adjusting nut.
6. Remove the spring, washer, and poppet from th
relief valve plug.
7. Remove and discard the backup ring from th
relief valve plug.
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Electro-Hydraulic Main Control Valve 2000 SRM 1137
1. O-RING2. PLUG3. OUTLET VALVE SECTION4. BACKUP RING5. RELIEF VALVE PLUG6. POPPET
7. WASHER8. SPRING9. JAM NUT10. ADJUSTING NUT11. CONTROL VALVE TIE ROD12. NUT
Figure 6. Outlet Control Valve Section
Clean
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturers recommended safety proce-
dures.
Compressed air can move particles so theycause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
1. If all components of the outlet control valve sec-
tion have been removed, clean the outlet control
valve section using cleaning solvent and dry us-
ing compressed air.
2. If not all components have been removed, clean
the outlet control valve section using a lint-freecloth.
Inspect
Inspect the outlet control valve section mating sur-
faces and the bore of the secondary relief valve, if re-
moved, for damage. If either the mating surface or
the secondary relief valve bore are damaged, replace
the outlet control valve section.
If disassembled, inspect the components of the sec-
ondary relief valve. If any components other than
O-rings, backup rings, and the spring are damaged,
replace the secondary relief valve.
NOTE: If the outlet control valve section is not to be
reassembled immediately, coat surfaces with clean
hydraulic oil to prevent the possibility of rust. Cover
the outlet control valve section with a clean, dry, lint-
free cloth to prevent the possibility of contaminants
entering the outlet control valve section.
Assemble
NOTE: Coat all backup rings and O-rings with a light
coat of clean hydraulic oil to make installation easier.
NOTE: Perform Step 1 through Step 7 only if the sec-
ondary relief valve was repaired.
1. Install a new backup ring on the relief valve plug.
See Figure 6.
2. Install the poppet, washer, and spring into the
relief valve plug.
3. Install a new O-ring on the adjusting nut, and in-
stall the adjusting nut and jam nut assembly into
the relief valve plug the number of turns noted
during disassembly.
4. While holding the adjusting nut in place, tighten
the jam nut to 24 3 Nm (18 2 lbf ft).
5. Install a backup ring, O-ring, and backup ring
into the adjusting nut.
6. Install a new O-ring onto the plug. Install the
plug into the adjusting nut.
7. If removed, install secondary relief valve an
tighten to 45 Nm (33 lbf ft).
8. Install new O-ring on plug and install in the out
let valve section.
Install
NOTE: Coat all O-rings with light coat of clean hy
draulic oil to make installation easier.
1. Install 10 new O-rings into the auxiliary valv
section. Install the outlet control valve sectio
on the four tie rods.
2. Install the four nuts on the tie rods and tighten
to 19 2 Nm (168 18 lbf in).
Auxiliary Control Valve Section
NOTE: There is the possibility of having two auxiliary control valve sections depending upon how man
functions are on the lift truck. If the main contro
valve is a four-function control valve, there will b
two auxiliary control valve sections. These section
are repaired the same with one exception. The auxil
iary control valve section next to the tilt control valv
will always have the anti-stall valve installed as
part of that control valve section.
Remove
1. Remove the outlet control valve section. See Out
let Control Valve Section, Remove.
NOTE: Step 2 and Step 3 are for a three-function con
trol valve. If a four-function control valve is bein
disassembled, go to Step 4.
2. Remove the anti-stall valve from the auxiliary
control valve section. See Figure 7. If the anti
stall valve is to be repaired, go to Step 5.
3. Remove the auxiliary control valve section from
the four tie rods. Remove and discard 10 O-ring
from the tilt control valve section.
4. Remove the auxiliary II control valve sectionfrom the four tie rods. Remove and discard 1
O-rings from the auxiliary I control valve sec
tion.
5. Remove the anti-stall valve from the auxiliary
control valve section. If the anti-stall valve i
to be repaired, go to Step 5 of the disassembly
procedure for the auxiliary control valve section
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Electro-Hydraulic Main Control Valve 2000 SRM 1137
Figure 7. Auxiliary I and II Control Valve Sections
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
Legend for Figure 7
A. AUXILIARY I CONTROL VALVE SECTION B. AUXILIARY II CONTROL VALVE SECTION
1. PLUG2. O-RING3. SPRING4. WASHER5. SOCKET HEAD CAPSCREW6. PROPORTIONAL PRESSURE REDUCING
VALVE (PPRV)
7. SPOOL8. POPPET9. AUXILIARY I CONTROL VALVE BODY10. BACKUP RING11. ANTI-STALL VALVE SLEEVE12. AUXILIARY II CONTROL VALVE BODY
6. Remove the auxiliary I control valve section from
the four tie rods. Remove and discard 10 O-rings
from the tilt control valve section.
Disassemble
NOTE: Disassemble the auxiliary control valve only
as needed to accomplish the repairs required.
1. Remove four capscrews and two proportional
pressure reducing valves (PPRV) from the auxil-iary control valve section. Remove and discard
the backup ring, two O-rings, backup ring, and
O-ring from each PPRV. See Figure 7.
2. Remove the plug, spring, washer, and spool from
the auxiliary control valve section. Discard the
O-ring on the plug.
3. Remove the plug, spring, and washer from the
auxiliary control valve section. Discard the
O-ring on the plug.
4. Remove two plugs, two springs, and two poppetsfrom the auxiliary control valve. Discard one
O-ring from each plug.
5. Remove spring from the large end of the anti-
stall valve sleeve. See Figure 8.
6. Remove the spool from the small end of the anti-
stall valve sleeve.
NOTE: Note the orientation of the O-rings and
backup rings for installation.
7. Remove and discard two backup rings and two
O-rings from the anti-stall valve sleeve. To re-assemble the anti-stall sleeve valve, see Step 5
of the assembly procedure.
1. SPOOL2. BACKUP RING3. O-RING
4. ANTI-STALL VALVESLEEVE
5. SPRING
Figure 8. Anti-Stall Valve
Clean
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solven
manufacturers recommended safety proce
dures.
Compressed air can move particles so they
cause injury to the user or to other personnel
Make sure the path of the compressed air i
away from all personnel. Wear protective gog
gles or a face shield to prevent injury to the
eyes.
1. If all components of the auxiliary control valv
section have been removed, clean the auxiliary
control valve section and components, except th
two PPRVs, using cleaning solvent and dry usin
compressed air.
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Electro-Hydraulic Main Control Valve 2000 SRM 1137
2. If not all components have been removed, clean
the auxiliary control valve section using a lint-
free cloth.
3. If the anti-stall valve was disassembled, clean
the spool, anti-stall valve sleeve, and spring with
cleaning solvent. Dry with a lint-free cloth.
Inspect
Inspect the auxiliary control valve section mating
surfaces and any open bores for damage. If damage
is found, replace the auxiliary control valve section.
If the spool has been removed, inspect the spool
and the bore for the spool for damage. If damage
to either the spool or the bore is found, replace the
auxiliary control valve section.
If the anti-stall valve was disassembled, inspect the
spool, anti-stall valve sleeve, and spring for damage.
If the spring is damaged, replace the spring. If thespool or anti-stall valve sleeve is damaged, replace
the anti-stall valve assembly.
NOTE: If the auxiliary control valve section is not to
be reassembled immediately, coat surfaces with clean
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 contami-
nants entering the auxiliary control valve section.
Assemble
NOTE: Coat all backup rings and O-rings with a lightcoat of clean hydraulic oil to make installation easier.
1. Install the spool, washer, spring, and plug, with
new O-ring, into the bore of the auxiliary control
valve section. Tighten the plug to 14 1 Nm
(120 12 lbf in). See Figure 7.
2. Install the washer, spool, and plug, with new
O-ring, into the auxiliary control valve section.
Tighten the plug to 14 1 Nm (120 12 lbf in).
3. Install two poppets, two springs, and two plugs,
with new O-rings installed, into the auxiliary
control valve section. Tighten the plugs to 818 Nm (60 6 lbf ft).
4. Install the new O-ring, backup ring, two O-rings,
and backup ring on each PPRV. Install two
PPRVs and four capscrews into the auxiliary
control valve section. Tighten the capscrews to 3
0.3 Nm (24 2 lbf in).
5. Install two backup rings and two O-rings on the
anti-stall valve sleeve as noted during disassem-
bly. See Figure 8.
6. Install the spool in the small end of the anti-stall
valve sleeve.
7. Install the spring in the large end of the anti-stall
valve sleeve.
Install
NOTE: Step 1 through Step 3 are for a three-function
control valve. Step 4 through Step 7 are for a four-
function control valve.
1. Install 10 new O-rings into the tilt control valve
section. Install the auxiliary I control valve sec-
tion on the four tie rods.
2. Install the anti-stall valve into the auxiliary Icontrol valve section.
3. Install the outlet control valve section. See Out-
let Control Valve Section, Install.
4. Install 10 new O-rings into the tilt control valve
section. Install the auxiliary I control valve sec-
tion on the four tie rods.
5. Install the anti-stall valve into the auxiliary I
control valve section. Install 10 new O-rings into
the auxiliary I control valve section.
6. Install the auxiliary II control valve section onthe four tie rods.
7. Install the outlet control valve section. See Out-
let Control Valve Section, Install.
Tilt Control Valve Section
Remove
1. Remove the outlet control valve section. See Out-
let Control Valve Section, Remove.
2. Remove the auxiliary control valve section. See
Auxiliary Control Valve Section, Remove.
3. Remove the tilt control valve section from the lift/
lower control valve section.
4. Remove and discard five O-rings from the lift/
lower control valve section.
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
Disassemble
NOTE: Disassemble the tilt control valve section only
as needed to accomplish the repairs required.
1. Remove four capscrews and two proportional
pressure-reducing valves (PPRV) from the tilt
control valve section. See Figure 9. Remove and
discard the backup ring, two O-rings, backup
ring, and O-ring from each PPRV.
2. Remove the plug, spring, washer, and spool from
the tilt control valve section. Discard the O-ring
on the plug.
3. Remove the socket head capscrew, spring, and
piston from the spool.
4. Remove the plug, spring, and washer from th
tilt control valve section. Discard the O-ring on
the plug.
5. Remove two plugs, two springs, and two poppet
from the tilt control valve section. Discard on
O-ring from each plug.
1. PLUG2. O-RING3. SPRING
4. WASHER5. SOCKET HEAD CAPSCREW6. PISTON7. PROPORTIONAL PRESSURE-REDUCING
VALVE (PPRV)
8. TILT CONTROL VALVE BODY9. SETSCREW10. POPPET
11. BACKUP RING12. SPOOL
Figure 9. Tilt Control Valve Section
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Electro-Hydraulic Main Control Valve 2000 SRM 1137
Clean
WARNINGCleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturers recommended safety proce-dures.
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles 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 compressedair.
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 thebore 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, lint-
free 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 cap-
screw in the spool. See Figure 9.
2. Install the spool, washer, spring, and plug, with
new O-ring, into the bore of the tilt control valve
section. Tighten the plug to 14 1 Nm (120
12 lbf in).
3. Install the washer, spring, and plug, with new
O-ring, into the tilt control valve section. Tighten
the plug to 14 1 Nm (120 12 lbf in).
4. Install two poppets, two springs, and two plugs,
with new O-rings installed, into the tilt control
valve section. Tighten the plugs to 81 8 Nm
(60 6 lbf ft).
5. Install the new O-ring, backup ring, two O-rings,
and backup ring on each PPRV. Install two
PPRVs and four capscrews into the tilt con-
trol valve section. Tighten the capscrews to 3
0.3 Nm (24 2 lbf in).
Install
1. Install five new O-rings on the lift/lower controlvalve section.
2. Install the tilt control valve section on the lift/
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 Out-
let Control Valve Section, Install.
Lift/Lower Control Valve Section
Remove
1. Remove the outlet control valve. See Outlet Con-
trol 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-hy-
draulic poppet valve (EHPV). See Figure 10.
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
1. LOCK NUT2. ADJUSTING SCREW3. O-RING4. SPRING5. PISTON6. PRIMARY RELIEF VALVE CARTRIDGE7. BACKUP RING
8. SPOOL9. LIFT/LOWER CONTROL VALVE SECTION10. SOCKET HEAD PLUG11. EMERGENCY LOWERING VALVE12. PLUG
13. SETSCREW14. SHUTTLE15. POPPET16. HOIST POPPET17. SOLENOID TUBE18. COIL19. COIL NUT
20. LOWER POPPET21. SLEEVE ASSEMBLY22. LIFT POPPET VALVE ASSEMBLY23. LOWER POPPET VALVE ASSEMBLY24. PILOT PIN
Figure 10. Lift/Lower Control Valve Section
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3. Using special socket (Hyster P/N 1585481), re-
move the lift solenoid tube assembly from lift/
lower control valve section. Take care to pull the
tube assembly straight out so that the pilot pin
does not get damaged. See Figure 10.
4. Remove the spring from the poppet assembly un-less it came out with the solenoid tube assembly
in which case remove it from the solenoid tube
assembly.
NOTE: The lower poppet valve assembly is approx-
imately 7 mm (0.28 in.) longer than the lift poppet
valve assembly.
5. Remove the lift poppet assembly from the lift/
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 sec-tion.
CAUTION
Use care, when removing the emergency low-
ering valve, not to damage the tip of the emer-
gency lowering valve.
7. Remove the emergency lowering valve from the
lift/lower control valve section. Remove and dis-
card the O-ring.
8. Remove the plug from the lift/lower control valve
section. Remove and discard the O-ring.
9. Remove the socket head plug from the lift/lower
control valve section. Remove and discard the
O-ring.
10. Remove the socket head plug, spring, and poppet
from the lift/lower control valve section. Remove
and discard the O-ring.
11. Remove the shuttle and setscrew from the lift/
lower control valve section.
12. Remove the primary relief valve, spring, andspool from the lift/lower control valve section.
NOTE: Step 13 through Step 16 are for the disassem-
bly of the primary relief valve.
13. While holding the adjustment screw in place,
loosen the lock nut.
NOTE: While performingStep 14, count and note the
number of turns used to remove the adjusting screw.
14. Remove the adjusting screw from the primary re-
lief valve. Remove and discard the O-ring on the
adjusting screw.
15. Remove the spring and piston from the primary
relief valve.
16. Remove and discard the small O-ring, backup
ring, and large O-ring from the primary relief
valve.
Clean
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solventmanufacturers recommended safety proce-
dures.
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles 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 lint-
free cloth.
Inspect
Inspect the lift/lower control valve section mating
surfaces and any open bores for damage. If damage
is found, replace the lift/lower control valve section.
If the spool has been removed, inspect the spool
and the bore for the spool for damage. If damageto either the spool or the bore is found, replace the
lift/lower control valve section.
If disassembled, inspect the components of the pri-
mary relief valve. If any components other than
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
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 contami-
nants entering the lift/lower control valve section.
Assemble
NOTE: Step 1 through Step 6 are for the assembly
of the primary relief valve, if disassembled. If the
primary relief valve has not been disassembled, go
to Step 6.
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 re-lief valve. Install the new backup ring and small
O-ring on the primary relief valve. See Figure 10.
2. Install the piston and spring into the primary
relief valve.
3. Install a new O-ring on the adjusting screw, and
install the adjusting screw into the primary re-
lief valve the number of turns noted during dis-
assembly.
4. Install the lock nut onto the adjusting screw
while holding the adjustment screw so that it
will not turn. Tighten the lock nut to 9 1 Nm
(84 12 lbf in).
5. Install the spool, spring, and primary relief
valve into the lift/lower control valve section.
Tighten the primary relief valve to 65 7 Nm
(48 5 lbf ft).
6. Install the shuttle and setscrew into the body of
the lift/lower control valve section. Tighten the
setscrew to 4 0.6 Nm (36 6 lbf in).
7. Install plug with new O-ring installed into the
lift/lower control valve section. Tighten the plugto 45 5 Nm (33 4 lbf ft).
8. Install poppet, spring, and plug with new O-ring
installed, into the lift/lower control valve section.
Tighten the plug to 65 7 Nm (48 5 lbf ft).
9. Install the emergency lowering valve, with a new
O-ring installed, into the lift/lower control valve
section. Tighten to 14 1 Nm (120 12 lbf in).
NOTE: Ensure that the correct poppet is being in
stalled in the proper position. The lower poppet valv
assembly is approximately 7 mm (0.28 in.) longe
than the lift poppet valve assembly.
10. Install the lift poppet into the lift/lower contro
valve section until the poppet "bottoms out."
11. Install the spring onto the solenoid tube.
12. Install the solenoid tube into the lift/lower con
trol valve section. Tighten to 100 11 Nm (7
8 lbf ft).
13. Install the coil and coil nut on the solenoid tube
Tighten the coil nut to 2.3 Nm (20 lbf in).
14. Repeat Step 10 through Step 13 for the lowe
EHPV. Before installing the lower poppet int
the lower control valve section in Step 10, in
stall sleeve assembly into the lift/lower controvalve section first. Tighten sleeve assembly t
122 12 Nm (90 9 lbf ft).
Install
1. Install four tie rods into the lift/lower contro
valve section.
2. Install the tilt control valve section. See Tilt Con
trol Valve Section, Install.
3. Install the auxiliary control valve section. Se
Auxiliary Control Valve Section, Install.
4. Install the outlet control valve section. See Out
let Control Valve Section, Install.
INSTALL
WARNING
The main control valve weighs approximately
29.5 kg (65 lb). Use a lifting device capable o
lifting the main control valve, to avoid the pos
sibility of injury to personnel.
1. Lower the control valve enough to allow th
cowl wiring harness to be connected to the lowePPRV solenoid connectors as noted during re
moval.
2. While supporting the main control valve in
place on the cowl, install three mounting cap
screws through the front of the cowl into th
control valve. Tighten the capscrews to 19 Nm
(14 lbf ft). See Figure 11.
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Electro-Hydraulic Main Control Valve 2000 SRM 1137
1. COWL2. INSERT3. WASHER4. CAPSCREW
5. MAIN CONTROLVALVE
6. FRAME
Figure 11. Main Control Valve Installation
3. Position the SCU under the steering shaft and
raise the SCU to engage the steering shaft.
When the steering shaft is completely engaged,
position the SCU against the main control valve,
and install two mounting capscrews and wash-
ers. Tighten to 45-55 Nm (33-41 lbf ft). See
Figure 12.
4. Remove all caps and plugs from the control valve
and hose fittings. Connect hydraulic hoses to the
control valve as noted during removal. See Fig-
ure 12.
5. Connect the cowl wiring harness to the top PPRV
solenoids and the lift/lower EHPV solenoids asnoted during removal.
6. Apply adhesive compound, Hyster Part No.
251099, to the three mounting capscrews. Using
the three capscrews that hold the throttle base
to the cowl, install the pedal assembly on the
lift truck. Connect the cowl wiring harness to
the pedal assembly wiring harness. Tighten the
bolts to 19 to 25 Nm (168 to 221 lbf in). See
Figure 13.
7. Install the dashboard, seal plate, kick panel,
and floor plate. See the section Frame 100 SRM
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 Cali-
bration Procedures 8000 SRM 1134.
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
1. STEERING SYSTEM HOSES
2. HYDRAULIC INLET HOSE3. STEERING CONTROL UNIT (SCU)4. STEERING COLUMN5. SCU MOUNTING CAPSCREWS
6. LIFT/LOWER HOSE
7. TILT HOSE8. AUXILIARY I HOSE9. AUXILIARY II HOSE10. RETURN HOSE
Figure 12. Hydraulic Hose Installation
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NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
EVER, INSTALL IS THE SAME.
1. MOUNTING BOLT2. 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 re-
quired if a new poppet assembly is installed.
These procedures assume the poppet assembly, tube
assembly, and coil have been replaced and installed
correctly. These procedures also assume the forks are
initially on the ground.
The coil nut should be removed to access the adjust-
ment screw and re-installed for proper operation.
Figure 14.
Lift Pilot Pin
WARNINGHot hydraulic oil can cause serious burns to
skin. Do not touch hydraulic components or oil
during test. Make sure hydraulic oil has cooled
to safe temperature before installing or remov-ing test equipment.
WARNING
Hydraulic oil under pressure can be injected
into skin. Lower forks to ground and relieve all
circuit pressure before removing or installing
test equipment.
CAUTIONDo not permit dirt or other contaminants to en-
ter the hydraulic system. Disconnected hoses,tubes, open valves, cylinder fittings, and ports
should be protected with clean caps or plugs.
NOTE: Always attempt to re-calibrate the threshold
setting through the display switch cluster (DSC) to
eliminate the symptoms below before adjusting the
pilot pin.
NOTE: The lift poppet should be bled prior to per-
forming this adjustment if the control valve has been
disassembled or hose has been disconnected by fol-
lowing the procedure in Calibration Procedures
8000 SRM 1134.
1. Remove side covers, floor plates, seal plate and
dash per Frame 100 SRM 1120 for lift truck
models S30FT, S35FT, S40FTS (E010); H1.6FT,
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.
a. Method 1: Connect a current probe to either
of the lift EHPV coil leads.
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2000 SRM 1137 Electro-Hydraulic Main Control Valve
b. Method 2: Monitor the current using the dis-
play switch cluster (DSC). See Diagnostic
Troubleshooting Manual 9000 SRM 1112
for the procedure.
5. Loosen pilot pin adjustment. Figure 14.
6. Start vehicle.
7. Slowly increase current to the lift function by
pulling back on the lever or joystick.
NOTE: A 1/4 turn will change the value approxi-
mately 130 mA. Turn clockwise or IN to increase
value and counterclockwise or OUT to decrease
value.
8. If the forks move before the current reaches 550
mA or appear to jump, turn pilot pin adjustment
screw approximately 15 clockwise to increase
the value.
9. Repeat the adjustment until the forks begin to
move between 550 mA and 650 mA.
10. If the forks have not started to move prior to
reaching 650 mA, turn the pilot adjustment
screw approximately 15 counterclockwise to
reduce the value.
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 screwto prevent slipping. Slipping of the adjustment
screw will cause threshold to increase. See Fig-
ure 14.
13. Replace coil nut.
14. Repeat test to verify that fork movement occurs
between 550mA and 650mA.
Lower Pilot Pin
WARNING
Hot hydraulic oil can cause serious burns toskin. Do not touch hydraulic components or oil
during test. Make sure hydraulic oil has cooled
to safe temperature before installing or remov-
ing test equipment.
WARNING
Hydraulic oil under pressure can be injected
into skin. Lower forks to ground and relieve all
circuit pressure before removing or installing
test equipment.
CAUTION
Do not permit dirt or other contaminants to en
ter the hydraulic system. Disconnected hoses
tubes, open valves, cylinder fittings, and port
should be protected with clean caps or plugs.
1. Remove side covers, floor plates, seal plate and
dash per Frame 100 SRM 1120 for lift truck
models S30FT, S35FT, S40FTS (E010); H1.6FT
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H2.0-3.5FT (H40-70FT) (L177) and Fram
100 SRM 1243 for lift truck model S4.0, 5.0
5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS
S120FTPRS) (G004); H4.0FT5/FT6; H4.5FTS5
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT(N005).
2. To prevent truck from moving, block wheels fron
and rear while the engine is operating.
3. Ensure hydraulic oil is at operating temperature
which is 122 to 150 .
NOTE: Always attempt to re-calibrate the threshol
setting through the display switch cluster (DSC) t
eliminate the symptoms below before adjusting th
pilot pin.
4. Monitor the EHPV coil current.
a. Method 1: Connect a current probe to eithe
of the lift EHPV coil leads.
b. Method 2: Monitor the current using the dis
play switch cluster (DSC). See Diagnosti
Troubleshooting Manual 9000 SRM 111
for the procedure.
5. Start vehicle and raise forks to approximately
2 m (6.5 ft) above the ground.
6. Turn the engine off, and turn the display switch
cluster (DSC) key back on.
7. Loosen pilot pin adjustment screw lock nut. Se
Figure 14.
8. Slowly increase the current to the lower function
by pushing forward on the lever or joystick.
NOTE: A 1/4 turn will change the value approxi
mately 130 mA. Turn clockwise or IN to increas
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Electro-Hydraulic Main Control Valve 2000 SRM 1137
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
to prevent slipping. Slipping of the adjustment
screw will cause threshold to increase. See Fig-
ure 14.
14. Replace coil nut.
15. Repeat test to verify that fork movement occurs
between 550mA and 650mA.
Abnormal/Erroneous EHPV Adjustment
CAUTIONWhile only minor adjustments may be neces-
sary, the design of the EHPV is such that the
adjustment screw could erroneously be backed
out to the point where the EHPV is normally
open. This presents an extreme condition that
is not likely, but is possible.
1. COIL NUT2. PILOT PIN ADJUSTMENT SCREW3. PILOT PIN ADJUSTMENT LOCK NUT4. COIL
5. SOLENOID TUBE ASSEMBLY6. BIAS SPRING7. O-RING8. POPPET ASSEMBLY
Figure 14. Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment
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2000 SRM 1137 Manual Main Control Valve
If this occurs on lift function and lower function si-
multaneously, the pump flow will bypass directly to
tank and there will be no hydraulic functionality. If
this occurs on the lift function only (with lower func-
tion calibrated correctly), the mast will raise as soon
as the engine is turned on. If this occurs on the lowe
function only (with the lift function calibrated cor
rectly, the auxiliary and tilt functions will be opera
tional, but the forks will not raise. See Figure 14.
Manual Main Control Valve
DESCRIPTION
The manual control valve is an open-center valve
which utilizes parallel hydraulic circuitry. The valve
is used with a fixed displacement pump. The hy-
draulic circuitry incorporates dual pressure logic.
The lift function operates on the primary relief pres-
sure setting. The tilt and auxiliary functions operate
on the lower secondary relief pressure setting. If the
lift function is operated simultaneously with the tilt
and/or auxiliary function, the maximum lift pressur
is limited to the secondary relief pressure setting.
The manual main control valve assembly is divided
in the following sections. See Figure 15.
Steering Control Unit (SCU)
Monoblock (lift and tilt control)
Auxiliary
Outlet
1. STEERING CONTROL UNIT (SCU)2. SCU MOUNTING CAPSCREW3. MONOBLOCK VALVE SECTION4. HOIST/LOWER SPOOL5. TILT SPOOL
6. AUXILIARY I VALVE SECTION/SPOOL7. AUXILIARY II VALVE SECTION/SPOOL8. SECONDARY RELIEF VALVE9. OUTLET SECTION10. PRIMARY RELIEF VALVE
Figure 15. Manual Control Valve
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Manual Main Control Valve 2000 SRM 1137
REMOVE
WARNINGLower carriage completely before working on
control valve or hydraulic system. Do not work
under a raised carriage. Put mast in a verti-
cal position, with no forward or back tilt, andlower carriage completely before disconnect-
ing any parts of hydraulic system. The mast
can lower suddenly and cause injury if the car-
riage is not lowered.
NOTE: Most of the individual valve components can
be removed and replaced while the control valve is in-
stalled in the truck. Removal of the control valve for
repairs is normally only required to replace a valve
section, replace the O-rings between the sections, or
to remove a manual valve control spool.
1. Power wash the interior of the operator compart-ment to remove any dirt or debris.
2. Move truck to disassembly area and shut off en-
gine.
WARNING
Cleaning solvents can be flammable and toxic
and cause skin irritation. When cleaning
solvents are used, always follow the solvent
manufacturers recommended safety proce-
dures. Wear protective goggles or a face shield
to prevent eye injuries.
NOTE: Take all necessary steps to prevent debris,
dust, or other contaminants from entering the valve
cavities, hydraulic lines, or replacement parts.
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)
lift trucks. Before disconnecting any hydraulic
hoses or removing any parts from the control
valve, clean the outside of the valve either by
steam cleaning or with cleaning solvent.
4. Disconnect the hydraulic levers by removing the
locking ring cotter pins and rod end pins that con-nect the hydraulic lever linkages to the spools.
Remove three capscrews and the hydraulic lever
assembly from the cowl. See Figure 16.
1. CAPSCREW2. HYDRAULIC LEVER ASSEMBLY
Figure 16. Hydraulic Lever Relocation
5. To remove the accelerator pedal or MONOTROL
pedal assembly, disconnect the cowl wiring har-
ness from the pedal assembly wiring harness and
remove three capscrews. See Figure 17.
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2000 SRM 1137 Manual Main Control Valve
NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
EVER, REMOVAL IS THE SAME.
1. MOUNTING BOLT2. MONOTROL PEDAL ASSEMBLY
Figure 17. MONOTROL Pedal Removal
CAUTION
To prevent any foreign matter from gettin
into either the hydraulic hoses or the hy
draulic control valve sections, all opening
must have plugs or covers installed immedi
ately after hoses are disconnected from thcontrol valve. This also applies if any othe
items are removed from the control valve.
NOTE: To aid in correctly connecting hydraulic hose
during installation, tag each hose prior to disconnect
ing from the control valve.
6. Disconnect hydraulic hoses from the contro
valve. Install plugs or caps on all open hose end
and control valve ports to prevent contamina
tion. See Figure 18.
7. Remove the two SCU mounting capscrews and
move the SCU approximately 1.3 cm (0.5 in.) tthe left, and lower the SCU until the steering
shaft is disengaged. Remove the SCU from th
lift truck. See Figure 15.
WARNING
The main control valve weighs approximately
29.5 kg (65 lb). Use a lifting device capable o
lifting the main control valve to avoid the pos
sibility of injury to personnel.
8. Support the main control valve. Remove thre
mounting capscrews and the main control valvfrom the lift truck. See Figure 19.
9. Remove the main control valve from the lif
truck.
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Manual Main Control Valve 2000 SRM 1137
1. STEERING SYSTEM HOSES
2. HYDRAULIC INLET HOSE3. STEERING CONTROL UNIT (SCU)4. STEERING COLUMN5. SCU MOUNTING CAPSCREWS
6. LIFT/LOWER HOSE
7. TILT HOSE8. AUXILIARY I HOSE9. AUXILIARY II HOSE10. RETURN HOSE
Figure 18. Hydraulic Hose Removal
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2000 SRM 1137 Manual Main Control Valve
1. COWL2. INSERT3. WASHER4. CAPSCREW
5. MAIN CONTROLVALVE
6. FRAME
Figure 19. Main Control Valve Removal
MANUAL CONTROL VALVE SECTIONS
General
CAUTIONWhile working on the manual control valve sec-
tions, place a cover over the remaining sectionsof the control valve to prevent the possibility
of contaminants getting into the control valve
openings which could cause damage to the con-
trol valve.
CAUTION
If O-rings are to be replaced between two sec-
tions that have a hydraulic oil leak, replace all
O-rings between all sections. This eliminates
the possibility of a subsequent oil leak or pos-
sible damage to another O-ring.
NOTE: Disassemble the manual control valve only
as necessary for repairs. Most repairs to the control
valve will be for the replacement of O-rings to sto
leaks between sections.
The manual control valve will be disassembled start
ing with the outlet control valve section.
Outlet Control Valve SectionRemove
1. Remove four nuts from the control valve tie rods
See Figure 20.
2. Remove the outlet control valve section from th
four tie rods and discard three O-rings from th
auxiliary control valve section. See Figure 21.
Disassemble
1. Remove the plug from the outlet control valv
section and discard the O-ring.
NOTE: Perform Step 1 through Step 6 only if it is ab
solutely necessary to disassemble the secondary re
lief valve.
2. Remove the plug from the adjusting nut. Remov
and discard the O-ring from the plug. Remov
and discard the backup rings and O-ring from th
adjusting nut. See Figure 20.
3. While holding the adjusting nut in place, loosen
the jam nut.
NOTE: While performing Step 4, count and note thnumber of turns used to remove the adjusting nut.
4. Remove the adjusting nut and jam nut assembly
from the relief valve plug and discard the O-rin
on the adjusting nut.
5. Remove the spring, washer, and poppet from th
relief valve plug.
6. Remove and discard the backup ring from th
relief valve plug.
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Manual Main Control Valve 2000 SRM 1137
1. PLUG2. O-RING3. OUTLET VALVE SECTION4. BACKUP RING5. RELIEF VALVE PLUG6. POPPET
7. WASHER8. SPRING9. JAM NUT10. ADJUSTING NUT11. CONTROL VALVE TIE ROD12. NUT
Figure 20. Outlet Control Valve Section
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2000 SRM 1137 Manual Main Control Valve
Clean
WARNINGCleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturers recommended safety proce-dures.
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
1. If all components of the outlet control valve sec-
tion have been removed, clean the outlet control
valve section using cleaning solvent and dry us-
ing compressed air.
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 sur-
faces and the bore of the secondary relief valve, if re-
moved, for damage. If either the mating surface or
the secondary relief valve bore are damaged, replace
the outlet control valve section.
If disassembled, inspect the components of the sec-
ondary relief valve. If any components other than
O-rings, backup rings, and the spring are damaged,
replace the secondary relief valve.
NOTE: If the outlet control valve section is not to be
reassembled immediately, coat surfaces with clean
hydraulic oil to prevent the possibility of rust. Cover
the outlet control valve section with a clean, dry, lint-
free cloth to prevent the possibility of contaminants
entering the outlet control valve section.
Assemble
NOTE: Coat all backup rings and O-rings with a light
coatof clean hydraulic oil to make installation easier.
NOTE: Perform Step 1 through Step 7 only if the sec-
ondary relief valve was repaired.
1. Install a new backup ring on the relief valve plug.
See Figure 20.
2. Install the poppet, washer, and spring into th
relief valve plug.
3. Install a new O-ring on the adjusting nut, and in
stall the adjusting nut and jam nut assembly int
the relief valve plug the number of turns note
during disassembly.
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 rin
into the adjusting nut.
6. Install a new O-ring onto the plug. Install th
plug into the adjusting nut.
7. If removed, install secondary relief valve, an
tighten to 45 Nm (33 lbf ft).
8. Install new O-ring on plug and install in the outlet valve section.
Install
1. Install three new O-rings into the auxiliary valv
section. Install the outlet control valve section on
the four tie rods. See Figure 21.
2. Install the four nuts on the tie rods and tighten
to 19 2 Nm (168 18 lbf in).
Auxiliary Control Valve Section
Remove
1. Remove the outlet valve. See Outlet Contro
Valve Section, Remove.
NOTE: Step 2 and Step 3 are used if a four-section
control valve is being disassembled. If a three-sec
tion control valve is being disassembled, go to Step 3
2. Remove the auxiliary II control valve section
from the four tie rods. Remove and discar
three O-rings from the auxiliary I control valv
section.
3. Remove the auxiliary I control valve sectionfrom the four tie rods. Remove and discar
three O-rings from the lift and tilt control valve
section. See Lift/Tilt Control Valve Section.
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Manual Main Control Valve 2000 SRM 1137
1. CAPSCREW2. END CAP3. SPOOL END4. SPRING SEAT
5. SPRING6. SEAL PLATE7. WIPER
8. O-RING9. SPOOL10. POPPET11. SPRING
12. PLUG13. AUXILIARY CONTROL VALVE SECTION
Figure 21. Auxiliary Control Valve Section
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2000 SRM 1137 Manual Main Control Valve
Disassemble
NOTE: On lift trucks equipped with a four-function
control valve, the disassembly procedures are the
same for both auxiliary I and II control valve sec-
tions.
1. Remove two socket head capscrews, end cap, and
seal plate from the auxiliary control valve sec-
tion. See Figure 21.
2. Remove the spool assembly and wiper from the
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 dis-
card the O-rings from the plugs.
Clean
WARNINGCleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturers recommended safety proce-
dures.
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles 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, cleanthe auxiliary control valve section using a lint-
free cloth.
Inspect
Inspect the auxiliary control valve section mating
surfaces and the bore of the spool, if removed, for
damage. If either the mating surfaces or the spool
bore are damaged, replace the auxiliary contro
valve section.
If disassembled, inspect the components of the spool
If any components are damaged, replace the compo
nents. If the spool is damaged, replace the auxiliar
control valve section.
NOTE: If the auxiliary control valve section is not t
be reassembled immediately, coat surfaces with clean
hydraulic oil to prevent the possibility of rust. Cove
the auxiliary control valve section with a clean, dry
lint-free cloth to prevent the possibility of contami
nants entering the auxiliary control valve section.
Assemble
NOTE: Coat all backup rings and O-rings with a ligh
coat of clean hydraulic oil to make installation easier
1. Install two poppets, springs, and plugs, with newO-rings installed, into the auxiliary control valv
section. Tighten the plugs to 45 5 Nm (3
4 lbf ft). See Figure 21.
2. Install new O-ring, new wiper, seal plate, an
two socket head capscrews on the auxiliar
control valve section. Tighten the socket hea
screws to 9.5 1 Nm (84 12 lbf in).
3. Install the new O-ring, spring seat, spring
spring seat, spool end fastener, and O-ring on
the spool. Tighten the spool end fastener to 9.
1 Nm (84 12 lbf in).
4. Install the new wiper and spool assembly into th
auxiliary control valve section.
5. Install seal plate, end cap, and two socket head
capscrews into the auxiliary control valve sec
tion. Tighten the socket head screws to 9.
1 Nm (84 12 lbf in).
Install
NOTE: Step 1 and Step 2 are used if a four-section
control valve is being assembled. If a three-section
control valve is being disassembled, use Step 1, thengo to Step 3.
1. Install three new O-rings on the lift and tilt con
trol valve section. Install the auxiliary I contro
valve section on the four tie rods.
2. Install three new O-rings on the auxiliary I con
trol valve section. Install the auxiliary II contro
valve section on the four tie rods.
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Manual Main Control Valve 2000 SRM 1137
3. Install the outlet valve. See Outlet Control Valve
Section, Install.
Lift/Tilt Control Valve Section
Remove
1. Remove the outlet control valve section valve.See Outlet Control Valve Section, Remove.
2. Remove the auxiliary control valve section. See
Auxiliary Control Valve Section, Remove.
Disassemble
NOTE: Remove only those components required to re-
pair the lift/tilt control valve section.
NOTE: Step 1 through Step 3 are for the disassembly
of the tilt side of the lift/tilt control valve section.
1. Remove two socket head screws, end cap, seal
plate, and tilt spool assembly from the tilt side
of the lift/tilt control valve section. Remove and
discard the wiper from the tilt bore of the lift/tilt
control valve section. See Figure 22.
2. Remove the spool end fastener, spring seat,
spring, spring seat, spring, and piston from the
tilt spool. Remove and discard the O-ring from
the tilt spool.
3. Remove two socket head screws and seal plate
from the tilt side of the lift/tilt control valve sec-
tion. Remove and discard the wiper and O-ringfrom the tilt bore of the lift/tilt control valve sec-
tion.
NOTE: Step 4 through Step 6 are for the disassembly
of the lift side of the lift/tilt control valve section.
4. Remove two socket head screws, end cap, seal
plate, and lift spool assembly from the lift side
of the lift/tilt control valve section. Remove and
discard the wiper from the lift bore of the lift/tilt
control valve section. See Figure 22.
5. Remove the spool end, spring seat, spring, springseat, and O-ring from the lift spool assembly. Dis-
card the O-ring.
6. Remove two socket head screws and seal plate
from the lift side of the lift/tilt control valve sec-
tion. Remove and discard the wiper and O-ring
from the lift bore of the lift/tilt control valve sec-
tion.
7. Remove three plugs, springs, and poppets from
the lift/tilt control valve section. Remove and dis-
card the O-rings from the plugs.
NOTE: Perform Step 8 through Step 12 only if it is
necessary to disassemble the primary relief valve.
8. Remove the plug from the adjusting nut. Remove
and discard the O-ring from the plug. Remove
and discard the backup rings and O-ring from the
adjusting nut.
9. While holding the adjusting nut in place, loosen
the jam nut.
NOTE: While performingStep 10, count and note the
number of turns used to remove the adjusting nut.
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
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solventmanufacturers recommended safety proce-
dures.
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
1. If all components of the lift/tilt control valve sec-
tion have been removed, clean the lift/tilt control
valve section using cleaning solvent and dry us-ing compressed air.
2. If not all components have been removed, clean
the lift/tilt control valve section using a lint-free
cloth.
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2000 SRM 1137 Manual Main Control Valve
1. SOCKET HEAD CAPSCREW2. END CAP3. O-RING4. SPOOL END FASTENER5. SPRING6. PISTON7. SPRING SEAT8. SEAL PLATE9. WIPER10. O-RING11. SPOOL
12. PLUG13. POPPET14. SEAL PLATE15. LIFT/TILT CONTROL VALVE SECTION16. BACKUP RING17. RELIEF VALVE PLUG18. POPPET19. WASHER20. JAM NUT21. ADJUSTING NUT22. PLUG
Figure 22. Lift/Tilt Control Valve Section
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Inspect
Inspect the lift/tilt control valve section mating sur-
faces. Inspect the bore of the primary relief valve, if
removed, for damage. Inspect the bores of the lift and
tilt spools, if removed. If the mating surface, the pri-
mary relief valve bore, or either the lift or tilt spoolbores are damaged, replace the lift/tilt control valve
section.
If disassembled, inspect the components of the pri-
mary relief valve. If any components other than
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 contami-
nants 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 pri-
mary relief valve was repaired.
1. Install the new backup ring on the relief valve
plug. See Figure 22.
2. Install the poppet, washer, and spring into the
relief valve plug.
3. Install a new O-ring on the adjusting nut. Install
the adjusting nut and jam nut assembly in the re-
lief valve plug the number of turns noted during
removal.
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 theplug into the adjusting nut.
7. Install secondary relief valve, and tighten to
45 Nm (33 lbf ft). See Figure 22.
8. Install three poppets, springs, and plugs, with
new O-rings installed, in the lift/tilt control valve
section.
9. Install the new O-ring and wiper in the lift bore of
the lift/tilt control valve section. Install the seal
plate and two socket head screws on the lift sideof the lift/tilt control valve section. Tighten the
socket head screws to 9.5 1 Nm (84 12 lbf in).
10. Install a new O-ring on the lift spool. Install the
spring seat, spring, spring seat, and spool end
fastener on the lift spool assembly. Tighten the
spool end fastener to 9.5 1 Nm (84 12 lbf in).
11. Install new the wiper into the lift bore of the
lift/tilt control valve section. Install the lift spool
assembly, seal plate, end cap, and two socket
head screws into the lift side of the lift/tilt control
valve section. Tighten the socket head screws to
9.5 1 Nm (84 12 lbf in).
12. Install the new O-ring and wiper in the tilt
bore of the lift/tilt control valve section. Install
the seal plate and two socket head screws on
the tilt side of the lift/tilt control valve section.
Tighten the socket head screws to 9.5 1 Nm
(84 12 lbf in).
13. Install a new O-ring on the tilt spool. Install the
piston, spring, spring seat, spring, spring seat,
and spool end fastener on the tilt spool assembly.
Tighten the spool end fastener to 9.5 1 Nm (84
12 lbf in).
14. Install new the wiper into the tilt bore of the
lift/tilt control valve section. Install the tilt spool
assembly, seal plate, end cap, and two socket
head screws into the tilt side of the lift/tilt control
valve section. Tighten the socket head screws to
9.5 1 Nm (84 12 lbf in).
Install
1. Install the auxiliary control valve section. See
Auxiliary Control Valve Section, Install.
2. Install the outlet valve. See Outlet Control Valve
Section, Install.
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2000 SRM 1137 Manual Main Control Valve
INSTALL