Manual Hydraulic Control Valve - (02-2009) - Us-En

MANUAL HYDRAULIC
CONTROL VALVE
E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];
E2.00-3.20XM (E45-65XM, E45-65XM 2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416/B416];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108]
PART NO. 897642 2000 SRM 562

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 hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Manual hydraulic Control Valve Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Operation............................................................................................................................................................ 4
E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108); E1.50-2.00XM (E25-35Z, E40ZS)
(E114/F114); and E2.00-3.20XM (E45-65Z) (G108)...................................................................................... 4
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM (J40-65Z) (A416/B416) ...................... 4
Lift Section..................................................................................................................................................... 6
Tilt Section ..................................................................................................................................................... 6
Tilt Backward ............................................................................................................................................ 6
Tilt Forward............................................................................................................................................... 6
Relief Valve .................................................................................................................................................... 8
Main Control Valve Repair ................................................................................................................................ 9
Main Control Valve Without OPS Solenoid.................................................................................................. 9
Remove....................................................................................................................................................... 9
Disassemble ............................................................................................................................................... 9
Clean and Inspect...................................................................................................................................... 13
Assemble .................................................................................................................................................... 13
Install [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108); E1.50-2.00XM (E25-35Z,
E40ZS) (E114/F114); and E2.00-3.20XM (E45-65Z) (G108)] ................................................................... 14
Install [J2.00-3.20XM (J40-65XM, J40-60XM 2) (A216) and J2.00-3.20XM (J40-65Z)
(A416/B416)] .............................................................................................................................................. 14
Main Control Valve With OPS Solenoid ....................................................................................................... 14
Remove....................................................................................................................................................... 15
Disassemble ............................................................................................................................................... 15
Clean and Inspect...................................................................................................................................... 17
Relief Valve Repair .................................................................................................................................... 19
Assemble .................................................................................................................................................... 20
Install ......................................................................................................................................................... 21
Control Lever Linkage Repair........................................................................................................................... 21
Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108), E1.50-2.00XM (E25-35Z, E40ZS)
(E114/F114), and E2.00-3.20XM (E45-65Z) (G108)] .................................................................................... 21
Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108), E1.50-2.00XM (E25-35Z,
E40ZS) (E114/F114), and E2.00-3.20XM (E45-65Z) (G108)] ....................................................................... 21
Assemble and Install [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108), E1.50-2.00XM
(E25-35Z, E40ZS) (E114/F114), and E2.00-3.20XM (E45-65Z) (G108)] ...................................................... 23
Control Valve Linkage Repair ........................................................................................................................... 23
Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108), E1.50-2.00XM
Assemble and Install [E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108), E1.50-2.00XM
Control Lever Linkage Repair........................................................................................................................... 24
Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM (J40-65Z)
(A416/B416)] .................................................................................................................................................. 24
Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM (J40-65Z)
(A416/B416)] .................................................................................................................................................. 26
Assemble and Install [J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM
(J40-65Z) (A416/B416)].................................................................................................................................. 26
Pressure Relief Valve Check and Adjustment.................................................................................................. 27
Primary Relief Valve...................................................................................................................................... 27
Secondary Relief Valve .................................................................................................................................. 28
Troubleshooting.................................................................................................................................................. 29
©2009 HYSTER COMPANY i

Table of Contents Manual hydraulic Control Valve
TABLE OF CONTENTS (Continued)

This section is for the following models:
E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];

E2.00-3.20XM (E45-65XM, E45-65XM 2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416/B416];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108]
ii
2000 SRM 562 Description
General
This section has a description and the repair procedures for the main control valve and the linkage arrange-
ment.
Description
The main control valve controls the operation of the The sections are held together with three through
lift, tilt, and auxiliary cylinders. The main control bolts.
valve is installed to the right of the operator, below
the floor plate. The main control valve has the fol- Each function of the main control valve is made as a
lowing sections (see Figure 1): separate section having a spool and valve body. Each
• Inlet section with the primary relief valve valve body casting is the same. The control spools are
• Lift and lower section with the secondary relief different for each function. Other sections are added
valve to the main control valve to control optional auxiliary
• Tilt section functions.
• Auxiliary section(s)
Each spool has a spring that returns the spool to the
Lift truck models E1.50-2.00XM (E25-35Z, E40ZS) neutral position when the control lever is released.
(F114) may be equipped with a main control valve Each valve section has a check valve in the valve
with an Operator Presence System (OPS). A main body. The check valve and spring is held in the valve
control valve with OPS contains the same sections body by the next section.
as listed above, along with two solenoids that make
up the OPS. See Figure 2.
1
Description 2000 SRM 562
1. INLET SECTION 5. TILT SPOOL

2. LIFT SECTION 6. AUXILIARY SPOOL
3. LIFT/LOWER SPOOL 7. AUXILIARY SECTION
4. TILT SECTION 8. TILT CONTROL SPOOL
Figure 1. Main Control Valve without OPS
2
2000 SRM 562 Description
1. SECONDARY RELIEF VALVE 5. TILT SECTION

2. PRIMARY RELIEF VALVE 6. OPS SOLENOID
3. INLET SECTION 7. AUXILIARY I SECTION
4. LIFT SECTION 8. AUXILIARY II SECTION
Figure 2. Main Control Valve with OPS, Lift Truck Models E1.50-2.00XM (E25-35Z, E40ZS) (F114)
3
Operation 2000 SRM 562
Operation
The main control valve is an open center, parallel • Control Lever Without a Detent - Attach-
circuit valve. When open center valve spools are in ments Without a Clamp Action: The lever is
the neutral position, the hydraulic oil flows through operated by moving forward or backward.
the valve with minimum restriction. The oil returns
through the drain passage and returns to the steer- The fourth control lever has a detent and is spring-
ing control unit and hydraulic tank. Except during loaded toward the operator. The lever is operated by
lifting, each spool can be operated without prevent- moving it to the right, then forward or backward.
ing the flow of oil to another spool.
E1.50-3.20XM (E25-65XM, E25-65XM 2)
This valve has three parallel passages through the (D114, F108); E1.50-2.00XM (E25-35Z,
valve. See Figure 3. When the spools are in the E40ZS) (E114/F114); AND E2.00-3.20XM
neutral position, the oil flows through the open cen-
ter passage. At the end of the valve, the oil returns
(E45-65Z) (G108)
through the drain passage and returns to the hy- NOTE: Lift trucks with contactor control hydraulics
draulic tank. When a spool is moved from the neu- use one switch for each function. Lift trucks with
tral position, it makes a restriction in the open center SCR control hydraulics use two switches for lift
passage. This restriction causes an increase in pres- speeds and two switches for the fourth function.
sure in the parallel passage. The parallel passage
is common to all sections of the valve, but oil can- Each of the control levers actuate a switch for the
not flow freely through it. The increased pressure in hydraulic pump. Movement of the tilt or auxiliary
the parallel passage causes the oil to flow through levers in either direction cause a switch to start the
a check valve into a supply cavity in the valve body. hydraulic pump. The lift/lower control lever actuates
The spool gives a path from the supply cavity to the its switch only in the lift position.
hydraulic cylinder to do work.
J2.00-3.20XM (J40-60XM, J40-60XM 2)
The first lever to the right of the operator controls the
(A216) AND J2.00-3.20XM (J40-65Z)
lifting and lowering of the mast. The second lever
controls the tilt function. The third control lever is (A416/B416)
for attachments and has two methods of operation Each of the control levers actuate an optical switch
depending on the attachment. for the hydraulic pump. Movement of the tilt or aux-
• Control Lever With Detent - Required for At- iliary levers in either direction causes a switch to
tachments With a Clamp Action: The lever is start the hydraulic pump. The lift/lower control lever
spring-loaded toward the operator. The lever is op- actuates its switch only in the lift position.
erated by moving it to the right, then forward or
backward.
4
2000 SRM 562 Operation
1. TILT CYLINDER 9. HYDRAULIC TANK

2. LOWERING CONTROL VALVE (EXTERNAL) 10. FILTER
3. LIFT CYLINDER 11. FROM STEERING CIRCUIT
4. LOWERING CONTROL VALVE (INTERNAL) 12. RELIEF VALVE (TILT AND AUXILIARY CIRCUITS)
5. MAIN CONTROL VALVE 13. TILT SPOOL
6. LIFT/LOWER SPOOL 14. AUXILIARY SPOOL
7. RELIEF VALVE (LIFT CIRCUIT) 15. AUXILIARY SPOOL
8. HYDRAULIC PUMP
Figure 3. Control Valve Schematic, Main Control Valve Without OPS
5
LIFT SECTION When the spool is in the Lower position, the spool
opens a path from the lift cylinders to the drain cav-
When the spool is moved to the Lift position, the spool ity. The spool is made so the open center passage has
makes a restriction in the open center passage. See no restriction.
Figure 4. The increased pressure in the parallel pas-
sage causes oil to flow through the check valve to the TILT SECTION
supply cavity. The oil flows from the supply cavity
through a section of the spool to the lift cylinders. The basic operation of the tilt spool is the same as
the other spools in this control valve. The tilt control
spool that is inside the tilt spool adds an additional
sequence to the tilt forward function.
Tilt Backward
When the spool is moved to the Back tilt position, the
tilt spool causes a restriction of the oil flow through
the open center passage. See Figure 5. The increased
pressure in the parallel passage causes the oil to flow
through the check valve to the supply cavity. The oil
flows from the supply cavity through a section of the
spool to the rod side of the tilt cylinders. The check
valve prevents the movement of the load until the
system pressure is great enough to control the load.
Oil from the piston end of the tilt cylinders returns
through the main control valve to the hydraulic tank.
Tilt Forward
The tilt control spool that is inside of the tilt spool
operates during the Forward tilt function. See Fig-
ure 5. The tilt control spool prevents cavitation in
the piston end of the tilt cylinders. Cavitation occurs
when the available fluid does not fill the space in a
closed system. The high vacuum causes some of the
fluid to change to bubbles of gas. When cavitation
occurs in the tilt cylinders, the tilt forward function
is not smooth.
The tilt control spool permits the regulation of the

tilt speed by using the pressure from the hydraulic
pump.
The pressure must be 550 kPa (80 psi) on the piston

end of the tilt cylinders. The tilt control spool pre-
vents oil flow from the rod end of the tilt cylinders
A. LOWER B. LIFT
until the pressure is 550 kPa (80 psi). This action
1. LIFT/LOWER 5. OPEN CENTER makes sure that a vacuum cannot occur at the piston
SPOOL PASSAGE end of the tilt cylinders.
2. SUPPLY CAVITY 6. TO LIFT
3. TO/FROM LIFT CYLINDERS
CYLINDERS 7. TO HYDRAULIC
4. DRAIN CAVITY TANK
Figure 4. Lift and Lower
6
2000 SRM 562 Operation
A. TILT BACKWARD B. TILT FORWARD

1. OPEN CENTER PASSAGE 5. TILT SPOOL
2. SUPPLY CAVITY 6. TO/FROM ROD END OF TILT CYLINDERS
3. TO/FROM PISTON END OF TILT CYLINDERS 7. TILT CONTROL SPOOL
4. DRAIN CAVITY
Figure 5. Tilt Spool Operation
7
RELIEF VALVE one of the hydraulic circuits reaches the relief valve
setting, the relief valve opens a path between the
The relief valves control the maximum pressure inlet and drain circuits.
within a hydraulic circuit. The control valve has a
primary relief valve and a secondary relief valve. The relief valve is a poppet valve that is pilot op-
The primary relief valve is installed in the inlet erated. There are four poppet spools in this valve.
section of the control valve and is for the lift circuit. Spools C, D, and E are used for pressure relief. This
The secondary relief valve is for the tilt and auxil- relief valve gives almost constant relief pressure over
iary circuits and is installed in the "lift" section of the range of the hydraulic pump flow. The sequence
the control valve. Both relief valves are the same of operation is described in Figure 6.
in description and operation. When the pressure in
1. STEP 1 - THE RELIEF VALVE IS CLOSED BETWEEN THE HIGH PRESSURE INLET (HP) AND THE LOW
PRESSURE (LP) DRAIN. HIGH PRESSURE OIL ENTERS THE PASSAGE AT C. THE DIFFERENCE IN
AREA BETWEEN DIAMETERS A AND B HOLDS THE POPPET SPOOL D AGAINST THE VALVE SEAT.
2. STEP 2 - THE OIL PRESSURE IN THE HIGH PRESSURE INLET BECOMES GREATER THAN THE SPRING
FORCE OF THE PILOT POPPET E. THE PILOT POPPET E IS PUSHED FROM ITS SEAT. OIL FLOWS
AROUND THE POPPET E AND THROUGH THE PASSAGES TO THE DRAIN.
3. STEP 3 - WHEN PILOT POPPET E OPENS, THE LOSS OF OIL PRESSURE BEHIND POPPET C CAUSES
POPPET C TO MOVE AGAINST POPPET E. THIS MOVEMENT STOPS THE FLOW OF OIL THROUGH C
AND CAUSES A LOWER PRESSURE BEHIND RELIEF VALVE POPPET D.
4. STEP 4 - THE DIFFERENCE IN PRESSURE ON EACH SIDE OF POPPET D CAUSES POPPET D TO OPEN.
THE HIGH PRESSURE OIL THEN HAS A DIRECT PATH TO THE LOW PRESSURE DRAIN.
Figure 6. Relief Valve Operation
8
2000 SRM 562 Main Control Valve Repair
Main Control Valve Repair

There are two types of main control valves covered in and washers that hold the hand lever support to
this service manual. One type of control valve does the bracket. Remove the nuts and washers at
not have an Operator Presence System (OPS) and the rubber bushings. Lift the control valve and
the other type does. Only lift truck models E1.50- bracket from the battery box.
2.00XM (E25-35Z, E40ZS) (F114) may be equipped
with a main control valve with an Operator Presence 5. Disconnect the links at the control valve spools.
System (OPS). Remove the control valve from the mount plate.
MAIN CONTROL VALVE WITHOUT OPS Disassemble

SOLENOID NOTE: Disassemble the main control valve as nec-
essary for repairs. Most repairs to the main control
Remove valve are for the replacement of O-rings and seals to
stop leaks. The passages in the tilt spool are small
WARNING and can need cleaning if the hydraulic oil becomes
Before making repairs to the control valve or dirty. The section normally must be replaced if the
its linkage, fully lower all parts of the mast spool or valve section is damaged.
and tilt it fully forward. This action will pre-
vent the mast from lowering suddenly when 1. Remove nuts at inlet section end and pull
hydraulic lines are disconnected. through bolts out of control valve to separate
valve sections. See Figure 9.
1. Remove the cover for the control valve linkage.
Remove the floor plate. 2. Remove O-ring, spring, and check valve from be-
tween the sections. Discard O-rings. See Fig-
2. For lift truck models E1.50-3.20XM (E25-65XM, ure 9.
E25-65XM 2) (D114, F108), E1.50-2.00XM (E25-
35Z, E40ZS) (E114/F114), and E2.00-3.20XM 3. Remove screws, retainer, seal, and O-ring at top
(E45-65Z) (G108), remove the cotter pins and end of auxiliary spool. Discard seal and O-ring.
link pins that connect the upper links to the
4. Remove socket head capscrews and end cap from
control lever linkage. See Figure 7.
bottom of auxiliary section(s).
For lift truck models J2.00-3.20XM (J40-60XM,
5. Remove spool end, spring seats and spring, re-
J40-60XM 2) (A216) and J2.00-3.20XM (J40-65Z)
tainer, seal, and O-ring from bottom end of aux-
(A416/B416), remove the cotter pins and link
iliary spool. Discard seal and O-ring. See Fig-
pins that connect the linkage to the control valve
ure 9.
spools. See Figure 8.
6. Remove screws, retainer, seal, and O-ring at top
3. Disconnect the lines at the control valve. Put
end of tilt spool. Discard seal and O-ring.
caps on the open lines.
7. Remove socket head capscrews and end cap from
4. On lift truck models E1.50-3.20XM (E25-65XM,
bottom of tilt section.
E25-65XM 2) (D114, F108); E1.50-2.00XM (E25-
35Z, E40ZS) (E114/F114); and E2.00-3.20XM 8. Remove tilt control spool, spring seats and
(E45-65Z) (G108), remove the two mounting spring, retainer, seal, O-ring, spring, and O-ring
nuts from the control valve mount plate. Tilt the from bottom end of tilt spool. Discard seal and
mount plate forward and lift it from the mount O-rings. See Figure 9.
on the battery box.
On lift truck models J2.00-3.20XM (J40-65XM, end of lift/lower spool. Discard seal and O-ring.
J40-60XM 2) (A216) and J2.00-3.20XM (J40-65Z)
(A416/B416), remove the cotter pins, pivot pins,
9
Main Control Valve Repair 2000 SRM 562
1. CLAMP 10. CIRCUIT STEERING FITTING

2. SWITCH 11. INLET FITTING
3. GUIDE/SWITCH MOUNT 12. OUTLET FITTING
4. UPPER LINK 13. LIFT CYLINDERS FITTING
5. LOWER LINK 14. ROD END OF TILT CYLINDERS FITTING
6. SWITCH PAD 15. PISTON END OF TILT CYLINDERS FITTING
7. CONTROL VALVE MOUNT PLATE 16. THIRD FUNCTION FITTINGS
8. FLOOR PLATE MOUNT 17. FOURTH FUNCTION FITTINGS
9. CONTROL VALVE
Figure 7. Control Valve Mounting for E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, F108);
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks
10
1. RUBBER BUSHINGS 8. OUTLET FITTING

2. CONTROL VALVE BRACKET 9. LIFT CYLINDERS FITTING
3. ISOLATOR 10. ROD END OF TILT CYLINDERS FITTING
4. BRACKET 11. THIRD FUNCTION FITTINGS
5. STEERING CIRCUIT FITTING 12. FOURTH FUNCTION FITTINGS
6. INLET FITTING 13. PISTON END OF TILT CYLINDERS FITTING
7. CONTROL VALVE
Figure 8. Control Valve Mounting for J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and J2.00-3.20XM
(J40-65Z) (A416/B416) Lift Trucks
11
1. THROUGH BOLT 8. CHECK VALVE 15. INLET SECTION

2. AUXILIARY SECTION 9. TILT SPOOL 16. PLUG
3. O-RING 10. TILT SECTION 17. SPRING CUP
4. SEAL 11. LIFT/LOWER SECTION 18. SCREW
5. RETAINER 12. LIFT/LOWER SPOOL 19. END CAP
6. AUXILIARY SPOOL 13. SECONDARY RELIEF VALVE 20. TILT CONTROL SPOOL
7. SPRING 14. PRIMARY RELIEF VALVE
Figure 9. Main Control Valve without OPS
12
10. Remove socket head capscrews and end cap from 3. Install primary relief valve into top end of inlet
bottom of lift/lower section. See Figure 9. section. See Figure 9. Tighten nut to 5 N•m
(44 lbf in).
11. Remove secondary relief valve from top end of
lift/lower section. 4. Install new O-ring onto plug, then install plug
into lift/lower section.
end of lift/lower spool. Discard seal and O-ring. 5. Install new O-ring, new seal, retainer, spring
seats and spring, and spool end onto bottom end
13. Remove spool end, spring seats and spring, re- of lift/lower spool. See Figure 9.
tainer, seal, and O-ring from bottom end of lift/
lower spool. Discard seal and O-ring. See Fig- 6. Install end cap to bottom of lift/lower section with
ure 9. two socket head capscrews.
14. Remove plug with O-ring from lift/lower section. 7. Install new O-ring, new seal, retainer, and
Discard O-ring. screws onto top end of lift/lower spool.
15. Remove primary relief valve from top end of inlet 8. Install secondary relief valve into top end of
section. See Figure 9. lift/lower section. See Figure 9. Tighten nut to
5 N•m (44 lbf in).
16. Remove plug with O-ring and fitting with O-ring
from inlet section. Discard O-rings. 9. Install tilt control spool, spring and spring seats,
retainer, new seal, new O-ring, spring, and new
Clean and Inspect O-ring onto bottom end of tilt spool.
10. Install end cap to bottom of tilt section with two

WARNING socket head capscrews.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 11. Install new O-ring, new seal, retainer, and
cleaning solvents, always follow the solvent screws onto top end of tilt spool. See Figure 9.
manufacturer’s recommended safety proce-
dures. 12. Install new O-ring, new seal, retainer, spring
seats and spring, and spool end onto bottom end
1. Clean only the parts of the control valve with of auxiliary spool.
solvent. Do not get solvent in the electrical
switches. 13. Install end cap to bottom of auxiliary section with
two socket head capscrews. See Figure 9.
2. Check the spools and bores for wear or damage.
If a spool or the bores have damage, the control 14. Install new O-ring, new seal, retainer, and
valve section must be replaced. Make sure the screws onto top end of auxiliary spool.
spools move freely in the bores.
15. Install check valves, springs, and new O-rings
3. Check the check valves and relief valve(s) for onto side face of auxiliary, tilt, lift/lower, and
damage. Replace the parts as necessary. inlet sections as sections are connected. Install
through bolts through outlet section, auxiliary
4. Check the parts of the linkage for the control section(s), tilt section, lift/lower section, and
valve levers. Replace worn parts as necessary. finally inlet section. Install nuts onto end of
through bolts. See Figure 9. Tighten large nut
Assemble to 24 N•m (212 lbf in). Tighten small nuts to
10 N•m (89 lbf in).
1. Install new O-ring onto plug, then install plug
into inlet section. See Figure 9.
2. Install new O-ring onto fitting, then install fit-

ting into inlet section.
13
Install [E1.50-3.20XM (E25-65XM, 3. Adjust the position of the control valve to obtain
E25-65XM 2) (D114, F108); E1.50-2.00XM dimension A as shown in Figure 10. Tighten the
(E25-35Z, E40ZS) (E114/F114); and capscrew and nuts for the control valve.
E2.00-3.20XM (E45-65Z) (G108)] 4. Install the rubber bushings in the mount plate.
Install the mount plate in the mounts on the bat-
1. Install the control valve on the mount plate. See tery box. Install and tighten the nuts and bolts
Figure 7. Be sure to install the mounting cap- at the center of the mount plate.
screw at the back of the control valve. Do not
tighten the capscrew or nuts. 5. Connect the hydraulic lines at the control valve.
Connect the linkages for the control levers.
2. Follow the procedures described in the section
Control Valve Linkage Repair and install the 6. Add the hydraulic oil to the tank. See the section
linkage on the mount plate. Periodic Maintenance for the correct specifi-
cations.
7. Operate the system and check for leaks and

correct operation. If necessary, adjust the relief
valves as described in Pressure Relief Valve
Check and Adjustment.
Install [J2.00-3.20XM (J40-65XM,

J40-60XM 2) (A216) and J2.00-3.20XM
(J40-65Z) (A416/B416)]
1. Install the control valve on the bracket. See Fig-
ure 8.
2. Install the rubber bushings in the bracket. In-

stall the bracket and control valve at the front of
the battery box. Install the capscrews, washers,
and nuts for the bushings.
3. Install the isolators on the control valve bracket.

Install the brackets for the isolators.
4. Connect the hydraulic lines at the control valve.

Connect the linkages for the control levers.
5. Add the hydraulic oil to the tank. See the section

Periodic Maintenance for the correct specifi-
cations.
NOTE: DIMENSION A = 195 ±0.5 mm (7.68 ±0.02 in.) 6. Operate the system and check for leaks and
WITH STANDARD HOOD AND 227 ±0.5 mm (8.94 correct operation. If necessary, adjust the relief
±0.02 in.) WITH OPTIONAL (HIGHER) HOOD. valves as described in Pressure Relief Valve
1. CONTROL VALVE
2. MOUNT PLATE (CONTROL VALVE)
3. LOWER LINK MAIN CONTROL VALVE WITH OPS
SOLENOID
Figure 10. Control Valve Linkage for
E1.50-3.20XM (E25-65XM, E25-65XM 2) (D114, NOTE: Only lift truck models E1.50-2.00XM
F108); E1.50-2.00XM (E25-35Z, E40ZS) (E25-35Z, E40ZS) (F114) may be equipped with
(E114/F114); and E2.00-3.20XM (E45-65Z) a main control valve with an Operator Presence
(G108) Lift Trucks System (OPS).
14
Remove 3. Remove screws, retainer, seal, and O-ring at top

end of auxiliary spool. See Figure 12. Discard
WARNING seal and O-ring.
Before making repairs to the control valve or 4. Remove socket head capscrews and end cap from
its linkage, fully lower all parts of the mast bottom of auxiliary section(s).
and tilt it fully forward. This action will pre-
vent the mast from lowering suddenly when 5. Remove spool end, spring seats and spring, re-
hydraulic lines are disconnected. tainer, seal, and O-ring from bottom end of aux-
iliary spool. Discard seal and O-ring.
1. Remove the cover for the control valve linkage.
Remove the floor plate. 6. Remove screws, retainer, seal, and O-ring from
top end of tilt spool. See Figure 12. Discard seal
2. Remove the cotter pins and link pins that connect and O-ring.
the upper links to the control lever linkage. See
Figure 11. 7. Remove socket head capscrews and OPS solenoid
end cap from bottom of tilt spool. Unscrew and
3. Disconnect OPS solenoids from wire harness. remove OPS solenoid from OPS solenoid end cap.
See Figure 11. Discard O-ring.
4. Remove the special washer and two nuts from 8. Remove spool end, spring seats and spring, re-
OPS lift solenoid. Remove four nuts and cap- tainer, seal, O-ring, piston spring, and piston
screws from brackets. Remove brackets and rod from bottom end of tilt spool. See Figure 12.
from control valve. See Figure 11. Discard seal and O-ring.
5. Disconnect the lines at the control valve. Put 9. Remove secondary relief valve from top end of
caps on the open lines. lift/lower section.
6. Remove the two mounting nuts from the control 10. Remove screws, retainer, seal, and O-ring from
valve mount plate. Tilt the mount plate forward top end of lift/lower spool. See Figure 12. Discard
and lift it from the mount on the battery box. seal and O-ring.
7. Disconnect the links at the control valve spools. 11. Remove socket head capscrews and OPS solenoid
Remove the control valve from the mount plate. end cap from bottom or lift/lower spool. Unscrew
and remove OPS solenoid from OPS solenoid end
Disassemble cap. Discard O-ring.
NOTE: Disassemble the main control valve as nec- 12. Remove spool end, spring seats and spring, re-
essary for repairs. Most repairs to the main control tainer, seal, and O-ring from bottom end of lift/
valve are for the replacement of O-rings and seals to lower spool. See Figure 12. Discard seal and
stop leaks. The passages in the tilt spool are small O-ring.
and can need cleaning if the hydraulic oil becomes
dirty. The section normally must be replaced if the 13. Remove plug with O-ring from lift/lower section.
spool or valve section is damaged. Discard O-ring.
1. Remove nuts at inlet section end and pull 14. Remove primary relief valve from top end of inlet
through bolts out of control valve to separate section. See Figure 12.
valve sections. See Figure 12.
15. Remove fitting with O-ring and plug with O-ring
2. Remove O-ring, spring, and poppet from between from inlet section. Discard O-rings.
sections. Discard O-rings.
15
Figure 11. Control Valve Mounting for Lift Truck Models E1.50-2.00XM (E25-35Z, E40ZS) (F114)
with OPS
16
Legend for Figure 11

1. CLAMP 12. OUTLET FITTING
2. SWITCH 13. LIFT CYLINDERS FITTING
3. GUIDE/SWITCH MOUNT 14. ROD END OF TILT CYLINDERS FITTING
4. UPPER LINK 15. PISTON END OF TILT CYLINDERS FITTING
5. LOWER LINK 16. THIRD FUNCTION FITTINGS
6. SWITCH PAD 17. FOURTH FUNCTION FITTINGS
7. CONTROL VALVE MOUNT PLATE 18. OPS SOLENOID
8. FLOOR PLATE MOUNT 19. BRACKET
9. CONTROL VALVE 20. SPECIAL WASHER
10. CIRCUIT STEERING FITTING 21. ROD
11. INLET FITTING
Clean and Inspect 1. Clean only the parts of the control valve with
solvent. Do not get solvent in the electrical
switches. Dry parts with compressed air.
WARNING
Cleaning solvents can be flammable and toxic 2. Check the spools and bores for wear or damage.
and can cause skin irritation. When using If a spool or the bores have damage, the control
cleaning solvents, always follow the solvent valve section must be replaced. Make sure the
manufacturer’s recommended safety proce- spools move freely in the bores.
dures.
3. Check the check valves and relief valve(s) for
WARNING damage. Replace the parts as necessary as de-
scribed in Relief Valve Repair.
Compressed air can move particles so that they
cause injury to the user or to other personnel. 4. Check the parts of the linkage for the control
Make sure that the path of the compressed air valve levers. Replace worn parts as necessary.
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
17
Figure 12. Main Control Valve with OPS
18

1. THROUGH BOLT 15. INLET SECTION
2. AUXILIARY SECTION 16. PLUG
3. O-RING 17. SPRING CUP
4. SEAL 18. TILT CONTROL SPOOL (OPS)
5. RETAINER 19. OPS SOLENOID END CAP
6. AUXILIARY SPOOL 20. SOCKET HEAD CAPSCREW
7. SPRING 21. OPS SOLENOID (TILT SECTION)
8. POPPET 22. LIFT CONTROL SPOOL (OPS)
9. TILT SPOOL 23. OPS SOLENOID (LIFT SECTION)
10. TILT SECTION 24. SCREW
11. LIFT/LOWER SECTION 25. END CAP
12. LIFT/LOWER SPOOL 26. NUTS
13. SECONDARY RELIEF VALVE 27. PISTON
14. PRIMARY RELIEF VALVE 28. PISTON SPRING
Relief Valve Repair NOTE: Before disassembling the relief valves, match
mark the adjuster cap and the relief valve body and
Repair of the relief valves is limited to the replace- count the number of turns used to remove the ad-
ment of items in the seal kits on both relief valve as- juster cap.
semblies. Seal kit items are shown in Figure 13 and
Figure 14. 1. Loosen the lock nut and disassemble the relief
valve as shown in Figure 13 and Figure 14.
1. PRIMARY RELIEF VALVE 2. SEAL KIT 3. SEAL KIT WITH SPRING
Figure 13. Primary Relief Valve
19
1. SECONDARY RELIEF VALVE 2. SEAL KIT
Figure 14. Secondary Relief Valve
2. Replace components with those in seal kit or seal 5. Install new O-ring, new seal, retainer, spring
kit with spring. If the piston seal is worn or dam- seats and spring, and spool end onto bottom end
aged, replace the relief valve assembly. See Fig- of lift/lower spool. See Figure 12.
ure 13 and Figure 14.
6. Install new O-ring, new seal, retainer, and
3. Assemble the relief valve; install the adjuster cap screws onto top end of lift lower spool.
the same number of turns noted during disas-
sembly. Tighten the lock nut to 8 to 11 N•m (72 7. Install secondary relief valve into top end of lift/
to 96 lbf in). lower section. See Figure 12. Tighten nut to
5 N•m (44 lbf in).
Assemble
8. Install piston, piston spring, new O-ring, new
1. Install new O-ring onto plug, then install plug seal, retainer, spring seats and spring, and spool
into inlet section. See Figure 12. end onto bottom end of tilt spool.
2. Install new O-ring onto fitting, then install fit- 9. Install new O-ring, new seal, retainer, and
ting into inlet section. screws onto top end of tilt spool. See Figure 12.
3. Install primary relief valve into top end of inlet 10. Install new O-ring, new seal, retainer, spring
section. See Figure 12. Tighten nut to 5 N•m seats and spring, and spool end onto bottom end
(44 lbf in). of auxiliary spool.
4. Install new O-ring onto plug, then install plug 11. Install new O-ring, new seal, retainer, and
into lift/lower section. screws onto top end of auxiliary spool. See Fig-
ure 12.
20
2000 SRM 562 Control Lever Linkage Repair
12. Install poppet, spring, and new O-ring onto side Secure rod to control valve by installing special
face of auxiliary, tilt, lift/lower, and inlet sec- washer and two nuts. See Figure 11.
tions as sections are connected. Install through
bolts through outlet section, auxiliary section(s), 3. Follow the procedures described in the section
tilt section, lift/lower section, and finally inlet Control Valve Linkage Repair and install the
section. Install nuts onto end of through bolts. linkage on the mount plate.
See Figure 12. Tighten large nut to 24 N•m
4. Adjust the position of the control valve to obtain
(212 lbf in). Tighten small nuts to 10 N•m
dimension A as shown in Figure 10. Tighten the
(89 lbf in).
capscrew and nuts for the control valve.
13. Install end cap and socket head capscrews onto
5. Install the rubber bushings in the mount plate.
lift/lower and tilt sections.
Install the mount plate in the mounts on the bat-
14. Install new O-rings and install OPS solenoids tery box. Install and tighten the nuts and bolts
onto lift/lower and tilt sections by screwing into at the center of the mount plate.
end cap. See Figure 12.
6. Connect the hydraulic lines at the control valve.
15. Install end cap and capscrews onto auxiliary sec- Connect the linkages for the control levers.
tion(s).
7. Add the hydraulic oil to the tank. See the section
Periodic Maintenance for the correct specifi-
Install
cations.
1. Install the control valve on the mount plate. See
8. Operate the system and check for leaks and
Figure 11. Be sure to install the mounting cap-
correct operation. If necessary, adjust the relief
screw at the back of the control valve. Do not
valves as described in Pressure Relief Valve
tighten the capscrew or nuts.
2. Install the bracket and rod to control valve and
mount plate using four capscrews and nuts.
Control Lever Linkage Repair

REMOVE [E1.50-3.20XM (E25-65XM, DISASSEMBLE [E1.50-3.20XM (E25-65XM,
E25-65XM 2) (D114, F108), E1.50-2.00XM E25-65XM 2) (D114, F108), E1.50-2.00XM
(E25-35Z, E40ZS) (E114/F114), AND (E25-35Z, E40ZS) (E114/F114), AND
E2.00-3.20XM (E45-65Z) (G108)] E2.00-3.20XM (E45-65Z) (G108)]
1. Remove the cover from the control levers. See 1. Remove the nuts and bolts that hold the control
Figure 15. levers to the cranks. Remove the levers and boot
as an assembly. See Figure 15.
2. Remove the cotter pins and link pins that connect
the upper links to the lower links. 2. Remove the cotter pins and link pins that con-
nect the control lever cranks to the upper links.
3. Remove the spring between the hood and the Remove the upper links.
linkage.
3. Remove the anchor pin that holds the shaft for
4. Remove the mount for the linkage bracket on the the cranks in the bracket. Remove the shaft,
right-hand side of the hood. Remove the linkage cranks, and spacers.
bracket and levers.
21
Control Lever Linkage Repair 2000 SRM 562
1. THIRD OR FOURTH FUNCTION LEVER WITH 9. CRANK

DETENT 10. SPACER
2. THIRD FUNCTION LEVER WITHOUT DETENT 11. SHAFT
3. TILT LEVER 12. LINKAGE BRACKET
4. LIFT/LOWER LEVER 13. WASHER
5. BOOT 14. SHIM
6. COVER 15. MOUNT
7. SPRING 16. UPPER LINK
8. WASHER
Figure 15. Control Lever Linkage
22
2000 SRM 562 Control Valve Linkage Repair
ASSEMBLE AND INSTALL [E1.50-3.20XM 2. Install the control levers and boot as an assem-
(E25-65XM, E25-65XM 2) (D114, F108), bly. Install the screws and nuts that hold the con-
E1.50-2.00XM (E25-35Z, E40ZS) trol levers to the cranks.
(E114/F114), AND E2.00-3.20XM (E45-65Z) 3. Use the link pins to connect the upper links to
(G108)] the cranks. Install the washers and cotter pins.
1. Install the shaft, cranks, spacers, and shims in 4. Install the linkage bracket and levers on the
the bracket. See Figure 15. Make sure the spring hood. Make sure the bracket is on the pivot
is on the spacer. Check that the cranks are in the shaft for the hood. Install the mount for the
correct sequence; then, install the anchor pin for bracket on the right-hand side of the hood. Con-
the shaft. If used, install the detent lock on the nect the spring to the hook on the hood.
bracket.
Control Valve Linkage Repair

REMOVE AND DISASSEMBLE
[E1.50-3.20XM (E25-65XM, E25-65XM 2)
(D114, F108), E1.50-2.00XM (E25-35Z,
E40ZS) (E114/F114), AND E2.00-3.20XM
(E45-65Z) (G108)]
1. Remove the cover for the control valve link-
age. See Figure 16. If necessary, remove the
switch(es) from the guides.

the upper links to the lower links.

the lower links to the spools.
4. Remove the nuts that hold the pad for the

switches to the plate for the control valve. Re-
move the switch assembly and the lower links.

1. LOWER LINK
2. GUIDE/SWITCH MOUNT
3. CLAMP
4. LIFT SWITCH (CONTACT OR CONTROL)
OR
HIGH SPEED LIFT SWITCH (SCR CONTROL)
5. SLOW SPEED LIFT SWITCH (SCR CONTROL)
6. TILT SWITCH
7. AUXILIARY FUNCTION SWITCH
8. AUXILIARY FUNCTION SWITCH
(CONTACT OR CONTROL)
OR Figure 16. Control Valve Linkage
LOW SPEED AUXILIARY FUNCTION SWITCH
(SCR CONTROL)
9. HIGH SPEED AUXILIARY FUNCTION SWITCH
(SCR CONTROL)
23
ASSEMBLE AND INSTALL [E1.50-3.20XM

(E25-65XM, E25-65XM 2) (D114, F108),
E1.50-2.00XM (E25-35Z, E40ZS)
(E114/F114), AND E2.00-3.20XM (E45-65Z)
(G108)]
1. Install the pad for the switches. See Figure 16.
Make sure the two parts of the lower link are
assembled. Install the lower links and connect
them at the spools. Install the guides over the
lower links. Install the nuts, washers, and clamp
for the guides.
2. Install the switches on the guides. The switch(es)

for the lift/lower lever fits on the upper mount-
ing holes. The switches for the tilt and auxiliary
levers fit on the lower mounting holes.
3. Adjust the switches as follows (see Figure 17):
a. Adjust the position of the guide so the roller

for the lift switch contacts the cam on the
lower link at position A.
b. Adjust the position of the guides for the tilt

or auxiliary switches so the roller is in the
center of cam positions B and C. 1. LOWER LINK
2. SECOND, THIRD, AND FOURTH FUNCTION
c. Loosen the screws for a switch; then, move SWITCHES
the switch toward the cam until it is actu- 3. LIFT SWITCH
ated. Slowly move the switch away from
the cam until the switch is OFF. Tighten the Figure 17. Switch Adjustments
screws for the switch.
4. Connect the wires to the switches.
Control Lever Linkage Repair

REMOVE [J2.00-3.20XM (J40-60XM, 3. Remove the pivot pins for the hand lever support
J40-60XM 2) (A216) AND J2.00-3.20XM on the control valve bracket.
(J40-65Z) (A416/B416)] 4. Release the latch. Remove the hand lever
1. Remove the cover from the control valve linkage. bracket, support, and control levers as an as-
See Figure 18. sembly.

the lower links to the control valve spools.
24
2000 SRM 562 Control Lever Linkage Repair
1. THIRD OR FOURTH FUNCTION LEVER WITH 13. SHAFT

DETENT 14. ADJUSTMENT LEVER
2. THIRD FUNCTION LEVER WITHOUT DETENT 15. ADJUSTER
3. TILT LEVER 16. KEEPER
4. LIFT/LOWER LEVER 17. PLATE
5. BOOT 18. STRIKER
6. COVER 19. LATCH
7. SHIM 20. HAND LEVER SUPPORT
8. SPACER 21. STOP SCREW
9. CRANK 22. UPPER LINK
10. PRINTED CIRCUIT BOARD 23. LOWER LINK
11. GUIDE 24. SWITCH PLATE
12. HAND LEVER BRACKET
Figure 18. Control Lever Linkage
25
DISASSEMBLE [J2.00-3.20XM (J40-60XM, 8. Install the links between the control levers and
J40-60XM 2) (A216) AND J2.00-3.20XM the control valve spools.
(J40-65Z) (A416/B416)] 9. Adjust each control lever to the position shown
1. Remove the cotter pins and link pins that connect in Figure 19. Measure from the front side of
the control lever cranks to the upper links. See the support to the back of each control lever
Figure 18. Remove the upper links. knob. Tighten the nuts on the links to 5-7 N•m
(44-62 lbf in)when the position is correct.
2. Remove the nuts and bolts that hold the hand
lever bracket to the hand lever support. Remove
the parts for the adjuster. Remove the hand lever
bracket, levers, and boot as an assembly.
3. Remove the anchor pin and spring pin that holds

the shaft for the cranks in the bracket. Remove
the shaft. If necessary, remove the cranks from
the levers to remove the levers from the boot.
ASSEMBLE AND INSTALL [J2.00-3.20XM

(J40-60XM, J40-60XM 2) (A216) AND
J2.00-3.20XM (J40-65Z) (A416/B416)]
1. Install the shaft, cranks, spacers, and shims in
the bracket. Use the shims to remove any clear-
ance between the bracket and the spacers. Check
that the cranks are in the correct sequence; then,
install the anchor pin for the shaft. If used, in-
stall the detent lock on the bracket.
2. Install the control levers and boot as an assem-

bly. See Figure 18. Install the screws and nuts
that hold the control levers to the cranks.
3. If removed, install the guide, latch, and printed

circuit board.
4. Install the hand lever bracket on the hand lever

support. Install the capscrew, adjuster, and
keeper. Make sure the adjuster is in the approx-
imate position shown in Figure 19.
5. Assemble the upper and lower links and the

switch plates. Do not tighten the nuts at this
time. Make sure the switch plates are in the
correct positions as shown in Figure 20.
6. Connect the hand lever support and bracket as-

sembly to the control valve bracket. Install the
pivot pins and washers.
1. UPPER LINK 4. PRINTED CIRCUIT
7. Install the stop screw and jam nut. Adjust the 2. SWITCH PLATE BOARD
stop screw so the latch locks the hand lever sup- 3. LOWER LINK
port tight against the frame.
Figure 19. Linkage Adjustment
26
2000 SRM 562 Pressure Relief Valve Check and Adjustment

1. PRINTED CIRCUIT BOARD
2. LIFT/LOWER FUNCTION SWITCH PLATE
3. TILT AND AUXILIARY FUNCTIONS SWITCH
PLATE
10. Adjust each switch plate so the optical sensors

are activated (pump motor starts) when a control
lever is moved. If necessary, move the printed cir-
cuit board so the switch plates are in the center
of the optical sensors.
11. Install the cover for the linkage.
Figure 20. Switch Plates
Pressure Relief Valve Check and Adjustment

NOTE: The main control valve has two relief valves:
a primary relief valve and a secondary relief valve.
The primary relief valve is in the inlet section of the
control valve. The secondary relief valve is in the
lift/lower section of the control valve.
PRIMARY RELIEF VALVE
WARNING
Never allow anyone under a raised carriage.
Do not put any part of your body in or through
the lift mechanism unless all parts of the mast
are completely lowered and the key switch is
OFF.
1. Connect a 25 MPa (3500 psi) gauge to the test

port at the inlet section of the control valve. See
Figure 21.
2. Loosen the jam nut. See Figure 21 or Figure 22. NOTE: LOCATION OF TEST PORT ON MAIN CON-
TROL VALVE WITH OPS IS THE SAME AS WHAT IS
3. Operate the hydraulic system to warm the oil SHOWN IN FIGURE 21.
temperature to 55 to 65 C (131 to 149 F).
1. ADJUSTMENT 4. TEST PORT
SCREW 5. SECONDARY
2. JAM NUT RELIEF VALVE
3. PRIMARY RELIEF
VALVE
Figure 21. Relief Valve Locations - Main

Control Valves without OPS
27
Pressure Relief Valve Check and Adjustment 2000 SRM 562
valve opens. Turn the adjustment screw as nec-

essary to change the setting.
• For E1.50-1.75XM, E2.00XMS (E25-35XM,
E40XMS) (D114) and E1.50-2.00XM (E25-35Z,
E40ZS) (E114/E114) lift trucks, the correct
setting is 17.9 ±0.7 MPa (2600 ±100 psi)
• For E2.00-3.20XM (E40-65XM) (F108), E2.00-
3.20XM (E45-65Z) (G108), J2.00-3.20XM (J40-
60XM, J40-60XM 2) (A216), and J2.00-3.20XM
(J40-65Z) (A416/B416) lift trucks, the correct
setting is 20.7 ±0.7 MPa (3000 ±100 psi).
Tighten the jam nut when the adjustment is cor-

rect.
5. Remove the gauge when the checks are complete.
SECONDARY RELIEF VALVE

1. Connect a 20 MPa (3000 psi) gauge to the test
port at the inlet section of the control valve. See
Figure 21.
2. Loosen the jam nut on the relief valve. See Fig-

ure 21 or Figure 22.
3. Operate the hydraulic system to warm the oil

temperature to 55 to 65 C (131 to 149 F).
4. Tilt the mast backward until it stops. Hold the

NOTE: ONLY LIFT TRUCK MODELS E1.50-2.00XM
lever and check the reading of the gauge when
(E25-35Z, E40ZS) (F114) MAY BE EQUIPPED WITH
the relief valve opens. Turn the adjustment
MAIN CONTROL VALVE WITH OPS.
screw as necessary to change the setting.
1. ADJUSTMENT 3. PRIMARY RELIEF • For E1.50-1.75XM, E2.00XMS (E25-35XM,
SCREW VALVE E40XMS) (D114) and E1.50-2.00XM (E25-35Z,
2. JAM NUT 4. SECONDARY E40ZS) (E114/F114) lift trucks, the correct
RELIEF VALVE setting is 15.5 ±0.7 MPa (2250 ±100 psi)
Figure 22. Relief Valve Locations - Main • For E2.00-3.20XM (E40-65XM) (F108); E2.00-
Control Valve with OPS 3.20XM (E45-65Z) (G108); J2.00-3.20XM (J40-
60XM, J40-60XM 2) (A216); and J2.00-3.20XM
(J45-65Z) (A416/B416) lift trucks, the correct
CAUTION setting is 15.5 ±0.5 MPa (2250 ±75 psi).
During this test, the mast must be fully ex-
tended. Make sure there is enough overhead Tighten the jam nut when the adjustment is cor-
clearance in the building or do the test out- rect.
doors.
5. Remove the gauge when the checks are complete.
4. Raise the mast until it stops. Hold the lever and
check the reading of the gauge when the relief
28
2000 SRM 562 Troubleshooting
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Slow or no movement of Air is in the hydraulic system. Remove air from hydraulic system.
cylinders.
The hydraulic pump is worn or dam- Repair or replace hydraulic pump.

aged.
Restriction in the hydraulic lines. Repair hydraulic lines.
Cylinder seals are damaged. Repair cylinders.
Load is greater than capacity. Reduce load.
Linkage is disconnected or damaged. Repair and adjust linkage for control

levers.
Pressure relief valve(s) is not ad- Repair or adjust relief valve(s).

justed correctly or is damaged.
Large leaks between spool and bore. Replace valve section.
Spool is not fully extended or re- Adjust linkage to spool.

tracted.
Switch plates are not installed or ad- Check position of switch plates.
justed correctly.
Optical sensors on printed circuit Install new printed circuit board.

board do not work.
Oil leaks at the end of a Seal for spool is damaged. Replace seal.
spool.
Spool is damaged. Replace valve section.
Valve body is damaged. Replace valve section.
Hydraulic pressure is above Pressure relief valve(s) is not ad- Repair or adjust relief valve(s).
specifications. justed correctly or is damaged.
Restriction in return line. Clean or replace return line or filter.
29
Troubleshooting 2000 SRM 562
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Tilt cylinders extend when Cylinder seal have leaks. Repair tilt cylinders.
the tilt spool is in the NEU-
TRAL position.
Oil leaks between control valve spool Replace valve section.

and bore.
Hydraulic lines have leaks. Repair or tighten lines or fittings.
Tilt cylinders extend sud- Check valve for tilt spool is damaged. Replace check valve.
denly when the tilt spool is
moved to BACK TILT posi-
tion.
Tilt cylinders extend sud- Tilt control spool inside the tilt spool Replace valve section.
denly when the tilt spool is is damaged.
moved to FORWARD TILT
position.
Lift cylinders retract when Check valve for the lift spool is dam- Replace check valve.
the lift spool is in the NEU- aged.
TRAL position.
Cylinder seals have leaks. Repair lift cylinders.
Hydraulic lines have leaks. Repair or tighten lines or fittings.
Leaks between the lift spool and the Replace valve section.
bore.
Spool will not move or is dif- Linkage is disconnected or damaged. Repair and adjust linkage.
ficult to move.
Return spring is damaged. Replace spring.
The spool or bore is damaged. Replace valve section.
Spool will not return to Linkage is disconnected or damaged. Repair and adjust linkage.
NEUTRAL.
Return spring is damaged. Replace spring.
Dirt between spool and the bore. Clean valve.
Spool is bent or damaged. Replace valve section.
30
TECHNICAL PUBLICATIONS
2000 SRM 562 2/09 (7/07)(3/06)(1/06)(5/04)(3/04)(11/03)(3/03)(5/96)(7/95)(6/95)(10/94) Printed in U.S.A.

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MANUAL HYDRAULIC

PART NO. 897642 2000 SRM 562

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2009 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];

1. INLET SECTION 5. TILT SPOOL

Figure 1. Main Control Valve without OPS

1. SECONDARY RELIEF VALVE 5. TILT SECTION

1. TILT CYLINDER 9. HYDRAULIC TANK

Figure 3. Control Valve Schematic, Main Control Valve Without OPS

The tilt control spool permits the regulation of the

The pressure must be 550 kPa (80 psi) on the piston

Figure 4. Lift and Lower

A. TILT BACKWARD B. TILT FORWARD

Figure 5. Tilt Spool Operation

Figure 6. Relief Valve Operation

Main Control Valve Repair

MAIN CONTROL VALVE WITHOUT OPS Disassemble

1. CLAMP 10. CIRCUIT STEERING FITTING

1. RUBBER BUSHINGS 8. OUTLET FITTING

1. THROUGH BOLT 8. CHECK VALVE 15. INLET SECTION

Figure 9. Main Control Valve without OPS

10. Install end cap to bottom of tilt section with two

2. Install new O-ring onto fitting, then install fit-

7. Operate the system and check for leaks and

Install [J2.00-3.20XM (J40-65XM,

2. Install the rubber bushings in the bracket. In-

3. Install the isolators on the control valve bracket.

4. Connect the hydraulic lines at the control valve.

5. Add the hydraulic oil to the tank. See the section

Remove 3. Remove screws, retainer, seal, and O-ring at top

Legend for Figure 11

Figure 12. Main Control Valve with OPS

Legend for Figure 12

1. PRIMARY RELIEF VALVE 2. SEAL KIT 3. SEAL KIT WITH SPRING

Figure 13. Primary Relief Valve

1. SECONDARY RELIEF VALVE 2. SEAL KIT

Figure 14. Secondary Relief Valve

Control Lever Linkage Repair

1. THIRD OR FOURTH FUNCTION LEVER WITH 9. CRANK

Figure 15. Control Lever Linkage

Control Valve Linkage Repair

2. Remove the cotter pins and link pins that connect

3. Remove the cotter pins and link pins that connect

4. Remove the nuts that hold the pad for the

Legend for Figure 16

ASSEMBLE AND INSTALL [E1.50-3.20XM

2. Install the switches on the guides. The switch(es)

3. Adjust the switches as follows (see Figure 17):

a. Adjust the position of the guide so the roller

b. Adjust the position of the guides for the tilt

4. Connect the wires to the switches.

Control Lever Linkage Repair

2. Remove the cotter pins and link pins that connect