Hydraulic System

HYDRAULIC SYSTEM
PART NO. 4220156 1900 SRM 2132

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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.
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
Description and Operation ......................................................................................................................................1
Component Location and Identification .............................................................................................................2
Main Control Valve ............................................................................................................................................. 5
Introduction ..................................................................................................................................................... 5
Flow Path ......................................................................................................................................................... 5
Main Manifold ..................................................................................................................................................... 5
Introduction ..................................................................................................................................................... 5
Priority Valve (A) .................................................................................................................................................5
Fundamentals ..................................................................................................................................................5
Description .......................................................................................................................................................5
Operation ......................................................................................................................................................... 5
Component Functionality Test ....................................................................................................................... 6
Check Valve (I) .................................................................................................................................................... 6
Function Description ....................................................................................................................................... 6
Pilot Supply Circuit .............................................................................................................................................6
Pilot Supply Valve (F) ......................................................................................................................................... 6
Fundamentals ..................................................................................................................................................6
Function Operation ......................................................................................................................................... 6
Lift Pressure Selector Valve (B) ......................................................................................................................... 7
Check Valve (K) ................................................................................................................................................... 7
Check Valve (Q) ................................................................................................................................................... 7
2ND Pump Selector Valve (E) .............................................................................................................................7
Screen (O) .............................................................................................................................................................7
Relief Valve ..........................................................................................................................................................8
Load Sense Relief Valve (H) ............................................................................................................................... 8
Fundamentals ..................................................................................................................................................8
Functional Operation ...................................................................................................................................... 8
Pressure Controller on Pump ............................................................................................................................. 8
Fundamentals ..................................................................................................................................................8
Full Flow Relief Valve (C) and (G) ..................................................................................................................... 8
Fundamentals ..................................................................................................................................................8
©2017 HYSTER COMPANY i

Table of Contents
TABLE OF CONTENTS (Continued)

Shuttle Valve (L) and (M) ................................................................................................................................... 9
Logic Valve (N) .................................................................................................................................................... 9
Load Sense Selector Valve (D) ............................................................................................................................ 9
Directional Control Valve Section ...................................................................................................................... 9
Functional Operation (System Level) .............................................................................................................9
Directional Control Valve ................................................................................................................................. 10
Fundamentals ................................................................................................................................................10
Description .....................................................................................................................................................10
Functional Operation .................................................................................................................................... 10
Electrical Actuation Module (Solenoid End Cap) ............................................................................................ 11
Component Functionality Test ..................................................................................................................... 11
Lift Function ......................................................................................................................................................11
Function Description ..................................................................................................................................... 11
Pilot-Operated Check Valve ..............................................................................................................................12
Fundamentals ................................................................................................................................................12
Function Operation ....................................................................................................................................... 12
Emergency Lowering Valve (LH Lift Section ONLY) ..................................................................................... 12
Lowering Control Valve .................................................................................................................................... 12
Fundamentals ................................................................................................................................................12
Tilt Function ...................................................................................................................................................... 12
Counterbalance Valve ....................................................................................................................................... 12
Fundamentals ................................................................................................................................................12
Auxiliary Function ............................................................................................................................................ 13
Variable Displacement Pump ........................................................................................................................... 14
Basic Functional Operation .......................................................................................................................... 14
Pressure Control Valve ..................................................................................................................................... 14
Fundamentals ................................................................................................................................................14
Operation ....................................................................................................................................................... 14
Load Sense Pressure Regulator ........................................................................................................................15
Fundamentals ................................................................................................................................................15
Repair .....................................................................................................................................................................15
Main Control Valve ........................................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Clean .............................................................................................................................................................. 17
Inspect ............................................................................................................................................................17
ii
Table of Contents

Assemble ........................................................................................................................................................ 17
Install ............................................................................................................................................................. 19
Priority Valve (A) ...............................................................................................................................................20
Remove ........................................................................................................................................................... 20
Clean .............................................................................................................................................................. 20
Inspect ............................................................................................................................................................20
Install ............................................................................................................................................................. 20
Check Valve (K) ................................................................................................................................................. 20
Remove ........................................................................................................................................................... 20
Clean .............................................................................................................................................................. 20
Inspect ............................................................................................................................................................20
Install ............................................................................................................................................................. 21
Check Valve (I) .................................................................................................................................................. 21
Remove ........................................................................................................................................................... 21
Clean .............................................................................................................................................................. 21
Inspect ............................................................................................................................................................21
Install ............................................................................................................................................................. 21
Check Valve (Q) ................................................................................................................................................. 22
Remove ........................................................................................................................................................... 22
Clean .............................................................................................................................................................. 22
Inspect ............................................................................................................................................................22
Install ............................................................................................................................................................. 22
Screen Cartridge (O) ......................................................................................................................................... 22
Disassemble ................................................................................................................................................... 22
Assemble ........................................................................................................................................................ 22
Shuttle Valves (L) and (M) ................................................................................................................................22
Remove ........................................................................................................................................................... 22
Clean .............................................................................................................................................................. 22
Inspect ............................................................................................................................................................22
Install ............................................................................................................................................................. 22
Logic Valve (N) .................................................................................................................................................. 23
Remove ........................................................................................................................................................... 23
Clean .............................................................................................................................................................. 23
Inspect ............................................................................................................................................................23
Install ............................................................................................................................................................. 23
Full Flow Relief Valve (C) (Relief Spool) ..........................................................................................................24
Remove ........................................................................................................................................................... 24
Clean .............................................................................................................................................................. 24
Inspect ............................................................................................................................................................24
Assemble ........................................................................................................................................................ 24
Install ............................................................................................................................................................. 24
Pilot Supply Valve (F) ....................................................................................................................................... 24
Remove ........................................................................................................................................................... 24
Clean .............................................................................................................................................................. 24
Inspect ............................................................................................................................................................24
iii
Table of Contents

Assemble ........................................................................................................................................................ 24
Install ............................................................................................................................................................. 25
Load Sense (LS) Relief Valve (H) and Full Flow Relief Valve (G) ..................................................................25
Remove ........................................................................................................................................................... 25
Clean .............................................................................................................................................................. 25
Inspect ............................................................................................................................................................25
Install ............................................................................................................................................................. 25
Load Sense Relief Valve (H) Adjustment ..................................................................................................... 25
Full Flow Relief Valve (G) Adjustment ........................................................................................................ 25
Lift Pressure Selector Valve (B) or Load Sense Selector Valve (D) ................................................................26
Remove ........................................................................................................................................................... 26
Clean .............................................................................................................................................................. 26
Inspect ............................................................................................................................................................26
Assemble ........................................................................................................................................................ 26
Install ............................................................................................................................................................. 26
2nd Pump Selector Valve (E) ............................................................................................................................ 27
Remove ........................................................................................................................................................... 27
Clean .............................................................................................................................................................. 27
Inspect ............................................................................................................................................................27
Assemble ........................................................................................................................................................ 27
Install ............................................................................................................................................................. 27
Variable Displacement Pump (Primary and Secondary) ................................................................................ 28
Remove ........................................................................................................................................................... 28
Clean .............................................................................................................................................................. 28
Inspect ............................................................................................................................................................28
Assemble ........................................................................................................................................................ 29
Install ............................................................................................................................................................. 29
Tilt Cylinder ...................................................................................................................................................... 30
Remove ........................................................................................................................................................... 30
Disassemble ....................................................................................................................................................... 30
Clean .................................................................................................................................................................. 30
Assemble ............................................................................................................................................................ 30
Install ................................................................................................................................................................. 31
Tilt Cylinder Leak Check ..................................................................................................................................32
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment ................................................................................... 32
Counterbalance Valve Manifold ....................................................................................................................... 32
Remove ........................................................................................................................................................... 32
Clean .............................................................................................................................................................. 32
Inspect ............................................................................................................................................................32
Assemble ........................................................................................................................................................ 32
Install ............................................................................................................................................................. 33
Electrical Actuation Module ............................................................................................................................. 33
Remove ........................................................................................................................................................... 33
Clean .............................................................................................................................................................. 33
Inspect ............................................................................................................................................................34
Assemble ........................................................................................................................................................ 34
Install ............................................................................................................................................................. 34
Emergency Lowering Valve (Left Lift Slice Only) ...........................................................................................35
Remove ........................................................................................................................................................... 35
Clean .............................................................................................................................................................. 35
iv
Table of Contents

Inspect ............................................................................................................................................................35
Install ............................................................................................................................................................. 35
Load Sense and Pressure Controller Valve on Pump ......................................................................................36
Remove ........................................................................................................................................................... 36
Clean .............................................................................................................................................................. 36
Inspect ............................................................................................................................................................36
Assemble ........................................................................................................................................................ 36
Install ............................................................................................................................................................. 36
Adjustment of Pressure Controller on Pump ...................................................................................................37
Adjustment of Load Sense Controller on the Primary and Secondary Pump ................................................38
Pump Margin Pressure Measurement ......................................................................................................... 38
Pump Margin Pressure Adjustment .............................................................................................................39
Lowering Control Valve .................................................................................................................................... 40
Remove ........................................................................................................................................................... 40
Clean .............................................................................................................................................................. 40
Inspect ............................................................................................................................................................41
Install ............................................................................................................................................................. 41
Troubleshooting .....................................................................................................................................................41
Lift, Tilt, and/or Aux function does not move when applied. Steering is operating normal. ........................ 41
The truck is not capable to lift rated load at expected max lift speed. ...........................................................42
Tilt function shakes. ..........................................................................................................................................42
It is not possible to lower the mast with ignition key turned to ON. ............................................................. 42
Steer and brake accumulator charge function does not operate. ....................................................................43
The truck is hydraulically loaded during engine start. Accumulator charge and steering is
possible during XMSN calibration. .................................................................................................................. 43
Torque Specifications ............................................................................................................................................ 43
Torque Specifications ........................................................................................................................................ 43
This section is for the following models:
v
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1900 SRM 2132 Series Code / Model Designation Reference Table
Series Code / Model Designation Reference Table

This section is for the following models:
Series Code European Model Americas Model

H8XM-EC6, H8XM-EC7, H9XM-EC7, H180HD-EC6, H180HD-EC7, H200HD-
H9XM-EC8, H9XM-ECD7, H9XM-ECD8, EC7, H200HD-EC8, H200HD-ECD7,
E214
H10XM-ECD8, H11XM-ECD8, H11XM- H190HD-ECD8, H210HD-ECD8,
ECD9 H230HD-ECD8, H230HD-ECD9
1
Description and Operation 1900 SRM 2132
Description and Operation

COMPONENT LOCATION AND System of a lift truck configured with two Variable
IDENTIFICATION Displacement Pumps and Wet Disc Brakes.
NOTE: The Hydraulic System of this Lift Truck See Figure 1, Figure 2 and Figure 3 for component
Series can deviate depending on the Lift Truck locations and identification.
configuration. This manual describes the Hydraulic
1. SIDESHIFT/PPS MANIFOLD BLOCK

2. PPS DIRECTIONAL SOLENOID VALVE
3. SIDE SHIFT DIRECTIONAL SOLENOID VALVE
4. EXTENSION/TWISTLOCK MANIFOLD BLOCK
5. TWIST LOCK DIRECTIONAL SOLENOID VALVE
6. EXTEND/RETRACT DIRECTIONAL SOLENOID VALVES
Figure 1. Component Location on the Attachment
2
1900 SRM 2132 Description and Operation
NOTE: COMPONENTS SHOWN FOR PLACEMENT ONLY, ACTUAL TRUCK MAY VARY.
1. LOWERING CONTROL VALVE 7. LOAD SENSE CONTROLLER ON PUMP

2. TILT SECTION 8. PRESSURE CONTROLLER ON PUMP
3. LH LIFT SECTION 9. SECONDARY VARIABLE DISPLACEMENT PUMP
4. MAIN CONTROL VALVE 10. PRIMARY VARIABLE DISPLACEMENT PUMP
5. RH LIFT SECTION 11. COUNTERBALANCE VALVE MANIFOLD
6. AUXILIARY SECTION
Figure 2. Hydraulic Component Location on the Truck
3
Figure 3. Hydraulic Schematic Base Truck
4
Legend for Figure 3.
1. HYDRAULIC TANK 17. LOAD SENSE RELIEF VALVE (H)

2. PRIMARY VARIABLE DISPLACEMENT PUMP 18. LOAD SENSE SELECTOR VALVE (D)
3. SECONDARY VARIABLE DISPLACEMENT 19. LIFT PRESSURE SELECTOR VALVE (B)
PUMP 20. CHECK VALVE (Q)
4. PRESSURE CONTROLLER ON PUMP 21. CHECK VALVE (I)
5. LOAD SENSE CONTROLLER ON PUMP 22. 2ND PUMP SELECTOR VALVE (E)
6. MAIN CONTROL VALVE 23. PRIORITY VALVE (A)
7. GEAR PUMP 24. CHECK VALVE (K)
8. LH LIFT SECTION 25. SCREEN (O)
9. TILT SECTION 26. PILOT SUPPLY VALVE (F)
10. LOWERING CONTROL VALVE 27. LOGIC ELEMENT (N)
11. AUXILIARY SECTION 28. ORIFICE (R)
12. RH LIFT SECTION 29. ORIFICE (P)
13. COUNTERBALANCE VALVE 30. LIFT ACCUMULATOR
14. BRAKE CONTROL MANIFOLD 31. BRAKE ACCUMULATOR
15. SHUTTLE VALVES (L) AND (M)
16. FULL FLOW RELIEF VALVE ( C ) AND (G)
MAIN CONTROL VALVE See Figure 2 for the location of the Main Control
Valve on the truck.
Introduction
The main control valve is based on a closed center PRIORITY VALVE (A)
load sense principle.
Fundamentals
The main control valve contains a manifold and four
Priority valves are based on pressure compensated
directional control valve sections, each controlling
flow control valves.
one main function.
Description
Flow Path
The priority valve prioritizes the oil flow, ensuring
Oil flow to the Main Control valve is provided by the
adequate flow to the steering system and brake
Primary and Secondary variable Displacement
accumulator charging system at all times.
pumps.
The Primary pump provides the oil flow when Operation
demand is low. Actuating a hydraulic function
When steer and/or Brake Accumulator Charge
increases the oil flow demand and provides a load
function are operated, the (highest) load sense
sense signal at the variable displacement pumps.
pressure of these functions is directed to the
The load sense signal controls pump swash plate
Priority Valve and the Primary Variable
movement, providing oil flow that is proportional to
Displacement pump.
demand. If the oil flow demand increases beyond the
primary pumps available output, the secondary Due to this Load Sense pressure the primary
pump activates, providing additional flow Variable Displacement pump will supply the
capabilities. requested flow to the Priority Valve.
Oil flow from the primary pump goes through the The priority Valve will ensure adequate flow is
priority valve, ensuring adequate supply to the supplied to the priority functions by maintaining a
steering system and brake accumulator. fixed pressure drop over the priority functions.
When the Primary Variable Displacement pump
MAIN MANIFOLD supplies more flow than requested by the priority
function the Priority Valve will direct the excessive
Introduction flow to the main pressure/supply gallery of the Main
The Main Manifold controls the functionality of Control Valve.
several components in the hydraulic system. See
Table 1 for a list of those components.
5
Displacement pump, which would cause system

Table 1. Component Functions instability and pump damage.
Components Function
Component Functionality Test
Priority Valve (A) Prioritize flow to steer
and charge function. To functionally test this component, see
Check Valve (I), for component removal, inspection,
Pilot Supply Valve (F) Generate pilot pressure functionality test, and reinstall information.
Lift Pressure Selector for lift, tilt and auxiliary
Valve (B) sections. PILOT SUPPLY CIRCUIT
Check Valve (K) Function Description
Check Valve (Q) The pilot supply system controls the pilot pressure
Screen (O) to the lift, tilt, and auxiliary sections.
Shuttle Valves (L) Control load sense When the engine is running, pressure is supplied to
signals. the pilot supply circuit by the Primary Variable
Shuttle Valves (M)
Displacement Pump through Priority Valve (A).
Logic Valve (N)
When the engine is not running, pressure from the
Load Sense Selector Lift Cylinders is supplied to the pilot supply circuit
Valve (D) through Selector Valve (B). The selection of Selector
Orifice (P) Valve (B) is done by the Hydraulic Controller, when
the ignition key is ON and the Hoist Lever is
Orifice (R) selected to the lower position.
Load Sense Relief Valve Limit "MAX" working
(H) pressures. PILOT SUPPLY VALVE (F)
Full Flow Relief Valve Fundamentals
(C) and (G)
Pilot supply valve (F) is a pressure-reducer valve
Check Valve (I) Prevents back flow based on a pressure control valve.
between the two variable
displacement pumps. Function Description
2nd Pump Selector Valve Disables secondary Pilot Supply Valve (F) provides constant pilot
(E) variable displacement pressure to the Directional Control valve End Caps,
pump in case engine ensuring accurate, positional control of the main
torque is not sufficient to spools.
drive both pumps.
Additional information about the Directional
Control Valve and the Electrical Actuation Module
(Solenoid End Cap) can be found on
To functionally test this component, see Directional Control Valve Section and
Priority Valve (A), for component removal, Electrical Actuation Module (Solenoid End Cap).
inspection, functionality test, and reinstall
information. Function Operation
During operation the system pressure supplied to
CHECK VALVE (I)
the Pilot supply valve (F) will vary depending on the
Prevents back flow between the two variable system requirements.
displacement pumps.
Pilot Supply Valve (F), maintains a constant pilot
pressure to the Electrical Actuation Module
Function Description (Solenoid End Cap), regardless of the valve input
When only the Primary Variable Displacement pressure.
pump is operating, Check Valve (I) prevents oil back
flow from entering into the Secondary Variable
6
Component Functionality Test Component Functionality Test

To functionally test this component, see To functionally test this component, see
Pilot Supply Valve (F) for component removal, Screen Cartridge (O) for component removal,
inspection, functionality test and re-install inspection, functionality test, and reinstall
information. information.
The pressure setting for the Pilot Supply Valve (F),
can be measured at port MLPT on the Main Control 2ND PUMP SELECTOR VALVE (E)
Valve.
Function Description
LIFT PRESSURE SELECTOR VALVE (B) 2ND Pump Selector valve (E) blocks the LS2
pressure signal to the secondary variable
Function Description displacement pump under defined conditions.
Lift Pressure Selector valve (B) provides pressure to
the Pilot Supply valve (F) under defined conditions. Function Operation
When the Engine is running at low speed and high
Function Operation engine load the Hydraulic Controller energizes the
When the Engine is not running, the ignition key is 2ND Pump Selector valve (E).
switched to ON and the Hoist Lever is selected to
the Lower position the Hydraulic Controller When 2ND Pump Selector valve (E) is energized it
energizes the Lift Pressure Selector Valve (B). will block the LS2 pressure signal to the secondary
When Lift Pressure Selector Valve (B) is energized variable displacement pump. Any pressure trapped
it will allow pressure from the Lift Cylinders to pass pressure in the LS circuit of this pump is drained to
through providing pressure to the Pilot Supply tank. As a result the second pump will not
Valve (F). contribute to the total oil flow thus limiting the
power demand on the engine.
To functionally test this component, see
Lift Pressure Selector Valve (B), for component To functionally test this component, see
removal, inspection, functionality test, and reinstall 2nd Pump Selector Valve (E), for component
information. removal, inspection, functionality test, and reinstall
information.
CHECK VALVE (K)
SCREEN (O)
Check Valve (K) blocks the oil flow path from the
Lift Pressure Selector Valve (B) to Priority Valve Screen (0) filters the oil used in the Pilot System,
(A). protecting the components from contamination.

To functionally test this component, see To functionally test this component, see
Check Valve (K) for component removal, inspection, Screen Cartridge (O) for component removal,
functionality test, and reinstall information. inspection, functionality test, and reinstall
information.
CHECK VALVE (Q)
Check Valve (Q) blocks the oil flow path from
Priority Valve (A) to the lift cylinders.
7
RELIEF VALVE When the pump pressure is greater than the

pressure controller setting, the pressure controller
Function Description will open and supply the pump pressure to the servo
The functions inside the Hydraulic Main Valve are piston inside the pump to de-stroke (reduce the
protected against excessive pressure by the flow) the variable displacement pump and such to
following relief valves: control the maximum pump pressure.
The Load Sense Relief Valve (H), which when The pressure controller on the pump is only
activated will relieve the Load Sense pressure activated when the load sense relief valve (H) is not
to the hydraulic tank. This will limit the working properly.
pump pressure by de-stroke (reduces the
output flow) from the pumps to limit the Component Functionality Test
pressure.
The Pressure Controller on the pumps, which
when activated de-stroke (reduces the output Variable Displacement Pump (Primary and
flow) the pump to limit the pressure. Secondary), for component removal, inspection,
functionality test and re-install information.
The Full Flow Relief Valve (C) + (G), which
when activated will dump the pump flow to The pressure setting of the pressure controller on
tank. Pump can be measured at port MP on the Main
Controller.
LOAD SENSE RELIEF VALVE (H)
FULL FLOW RELIEF VALVE (C) AND (G)
Fundamentals
The Load Sense Relief Valve (H) is a direct- acting Fundamentals
relief valve based on a pressure control valve. The full flow relief valve (C) + (G) is a two-stage
relief valve based on a pressure control valve.
Functional Operation
When the highest function pressure in the hydraulic Functional Operation
system exceeds the setting of the Load Sense Relief The full flow relief valve (C) + (G) is connected to
Valve (H), it will open in order to control the the pressure gallery inside the main valve. When
maximum Load Sense pressure to the Variable the (pump) pressure exceeds than the pressure
Displacement pumps. setting of the Full flow relief valve (G), the full flow
relief valve (C) + (G) will open and dump the flow of
Component Functionality Test the Variable Displacement pumps to tank.
To functionally test this component, reference The full flow relief valve (C) + (G) is only activated
Load Sense (LS) Relief Valve (H) and Full Flow when the load sense relief valve (H) and the
Relief Valve (G) for component removal, inspection, pressure controller on the pump is not working
functionality test, and reinstall information. properly and during activation it can stall the
engine.
The pressure setting for the Load Sense Relief Valve
(H) can be measured at port MLS2 on the Main
Control Valve. Component Functionality Test
PRESSURE CONTROLLER ON PUMP Load Sense (LS) Relief Valve (H) and Full Flow
Relief Valve (G), for component removal, inspection,
Fundamentals functionality test and re-install information.
The pressure controller on the pump is a direct The pressure setting of the Full Flow Relief Valve
acting relief valve based on a pressure control valve. (C) + (G) can be measured at Port MP on the Main
Control Valve.
The pressure controller regulates the maximum
output pressure of the pump.
8
SHUTTLE VALVE (L) AND (M) The flow supplied by Orifice (R) will pass via Logic
Valve (N) and the Steering Control Unit to Tank.
The shuttle valve is a check valve with two inlet LOAD SENSE SELECTOR VALVE (D)
ports and one outlet port.
Both inlet ports are connected to a Load Sense
Load Sense Selector Valve (D) when activated will
pressure of a single or a combined function. The
disable the Steer and Brake Accumulator Charge
shuttle valve will pass the highest pressure through
functions by dumping the Load Sense pressure of
to the outlet port.
these functions to tank.
The shuttle valves inside the main control valve will
The Load Sense Selector Valve (D) is operated by
make sure that from all the hydraulic functions the
the Engine start up sequence and the Calibration
function with the highest load sense pressure will
switch in the side console of the cabin.
be passed through to the variable displacement
pumps.
Component Functionality Test To functionally test this component, see
Lift Pressure Selector Valve (B) or Load Sense
Selector Valve (D) for component removal,
Shuttle Valves (L) and (M), for component removal,
inspection, functionality test and re-install
inspection, functionality test and re-install
information.
information.
DIRECTIONAL CONTROL VALVE SECTION
LOGIC VALVE (N)
The Directional Control Valve sections (DCV) used
NOTE: Logic Valve (N) is only applicable for
for the lift, tilt, and auxiliary functions is an electric
configurations with Wet Disc Brakes.
hydraulic controlled load independent proportional
control valve.
Logic Valve (N) regulates the pressure in the Functional Operation (System Level)
Dynamic Load Sense line when the Brake The Directional Control Valve section contains the
Accumulator Charger is activated. Directional Control Valve and the Electrical
Actuation Module (Solenoid End Cap). When the
Function Operation operator activates the function, the Electrical
Actuation Module (Solenoid End Cap) will receive a
When Steer and Brake Accumulator Charge
signal from the Hydraulic Controller to supply flow.
function are not active the flow supplied by Orifice
The Electrical Activation Module will generate a
(R) will pass via Logic Valve (N) and Steering
pilot pressure to shift the main spool in the
Control Unit to Tank. The pressure in the Load
Directional Control Valve to the correct position.
Sense line will be equal to the required pressure to
See Figure 4.
open Logic Valve (N) against the spring force.
When the Brake Accumulator Charge is activated
the Logic Valve (N) is pressurized at spring side by
a pressure signal of the Brake Accumulator charger.
The pressure in the Load Sense (signal to VDP) line
will increase, so that it will be equal to the required
pressure to open Logic Valve (N) against the Brake
Accumulator charge pressure + spring force.
9
DIRECTIONAL CONTROL VALVE

Fundamentals
The pressure compensator inside the directional
control valve is based on the pressure compensated
flow control valve.
Description
The Directional Control Valve controls the flow by:
• Main spool: Directs and controls the amount
of flow to a function
• Pressure Compensator Valve: Equalizes the
required function pressure for all functions
controlled by the main valve.
The Directional Control Valve has the ability, due to
the Pressure Compensator Valve, to control
multifunction operation when flow demand exceeds
pump capacity.
This means that all functions controlled by the main
valve will continue to operate regardless of
differences in their load (pressure) and regardless of
the pump capacity. The flow relationships specified
between the functions will be maintained over the
full flow range of the pump.
When the main spool shifts, it will connect the five
functions listed below:
• Function 1 - Connects the working side of the
cylinder pressure with the LS line
• Function 2 - Connects the pump line with the
pressure compensator (Metering function).
• Function 3 - Connects the compensator with
the working side of the cylinder (Direction
1. ELECTRICAL ACTUATION MODULE (SOLENOID function)
END CAP)
2. DIRECTIONAL CONTROL VALVE • Function 4 - Connect the not working side of
3. PRESSURE COMPENSATOR VALVE the cylinder with tank.
4. MAIN SPOOL • Function 5 - Connect pilot pressure to the
5. SOLENOID VALVE BRIDGE pilot operated check valves (when included).
Figure 4. Directional Control Valve Section The highest load sense pressure in the system is fed
through the shuttle valve circuit to the spring
chamber behind the compensator valve. The
compensator valve will be closed till the pump
pressure matches an equal pressure. (Ability for
multifunction)
10
ELECTRICAL ACTUATION MODULE (Only included in directional control valve

section located at the left side of the main
(SOLENOID END CAP) control valve.)
Functional Operation Additionally, lowering control valves are mounted in
The Electrical Actuation Module features: each lift cylinder bottom to limit the maximum
lowering speed. See Figure 5. For location on the
• Solenoid Valve Bridge, which controls the truck, see Figure 2.
pilot pressure at both sides of the Main Spool
in the Directional Control Valve.
• Integrated Feedback Transducer, which
measures the position of the Main Spool in
the Directional Control Valve.
• Integrated Electronics, which controls the
exact position of the Main spool in the Main
Control valve by the input signal supplied by
the Controller (Lever/Joystick), the Feedback
Transducer and the pilot pressure generated
by the Solenoid Valve Bridge.

The integrated electronics includes a fault
monitoring system that communicates by the LED
on each Electrical Actuation Module (Solenoid End
Cap) and will be reset by each time the ignition key
is turned OFF.
The monitoring signals are:
• Constant Green LED - Directional Control
Valve section is operating normal.
• Flashing Red LED - Input signal faults
• Constant Red LED - Sticking spool or internal
error in Electrical Actuation Module (Solenoid
End Cap).
When the fault monitoring system detects a fault
the main spool will return to or stay in neutral.
LIFT FUNCTION
The Lift/Lower function is executed by two
Directional Control Valve sections of the Main
Control Valve.
Besides the standard functionality of the Directional
Control valve section, these sections include these
1. PILOT-OPERATED CHECK VALVES
additional features: 2. PILOT OPERATED SELECTOR VALVE
1 Pilot-operated check valves, to guarantee load 3. EMERGENCY LOWERING VALVE (LH LIFT
position. SECTION ONLY)
2 Emergency lowering valve, to lower the load Figure 5. Directional Control Valve Section (Lift)
manual during a severe break down.
11
PILOT-OPERATED CHECK VALVE When the truck has a severe brake down and the
hydraulic system is inoperable it is possible to lower
Fundamentals the load to the ground safely under controlled
The Pilot-Operated Check valve is based on a conditions with the (ELV).
pressure control valve. The emergency lowering valve is located on the left
lift directional control valve section.
It is manually operated turning its red knob
The Pilot Operated Check Valve is considered an clockwise, it will open a line to relieve the oil inside
Anti-leakage valve, minimizing the internal leak the lift cylinder to tank.
rate of the lift spools, preventing load downward
creep. LOWERING CONTROL VALVE
Function Operation Fundamentals
The Pilot Operated Check valve circuit consist of the The lowering control valve is a pressure-
following two components, see Figure 5: compensated flow control valve based on a flow
control valve.
1 Pilot Operated Check Valve
2 Pilot Operated Selector Valve Function Description
The Check Valve is pilot pressure operated and The lowering control valve limits the maximum
balanced on both sides of the Check Valve with lowering speed of the mast. When the oil flow out of
equal pressure from the lift cylinders. The the lift cylinders exceed the designed limit of the
additional spring force on the Check Valve, biases it Lowering Control Valve, the spool inside the
to check valve position, preventing load downward Lowering Control Valve shifts, restricting the oil
creep. See Figure 4. flow to limit the lift cylinder lowering speed.
The Pilot operated Selector Valve holds the lift
cylinder pilot pressure at the spring side of the Pilot TILT FUNCTION
Operated Check Valve, locking the lift cylinder Function Description
position.
The Tilt function is executed by one Directional
When the lower function is actuated, the main lift Control Valve section of the Main Control Valve.
spool sends pilot pressure to the Pilot Operated
Selector Valve, shifting the spool and opening a flow Additionally, an external counterbalance valve is
path for the pilot pressure from the lift cylinders to located between the directional control valve section
dump to tank. Once the lift cylinder pilot pressure is and the tilt cylinders to protect the tilt forward
removed from the spring side of the Check Valve, function against over run. See Figure 2, Figure 3.
the lift cylinder pilot pressure on the opposite side of
the Check Valve, shifts the Check Valve and opens a COUNTERBALANCE VALVE
flow path for the oil from the lift cylinders to tank,
Fundamentals
allowing lowering.
E214 truck series uses a counterbalance valve for
EMERGENCY LOWERING VALVE (LH LIFT improved dynamic tilt control. This valve has a
SECTION ONLY) common relief valve for the rod side and a common
relief valve for the piston side of both tilt cylinders.
Different check valves prevent the mast from falling
Function Description forward in case one of the rod side hoses would fail.
NOTE: Under normal operation the knob has to be See Figure 6.
turned completely out and then ONE FULL TURN
IN to avoid sticking of the emergency lowering valve
over time.
12
When not operated, the four check valves prevent

exchange of oil between the cylinders, contributing
to the rigidness of the mast.
AUXILIARY FUNCTION
The auxiliary function is executed by one directional
control valve section in the main control valve.
Additional valve banks are installed on the
attachment. The auxiliary directional control valve
section of the main control valve will only control
the flow to the valve banks and the sections of the
attachment valve banks will control the direction of
the attachment function, e.g. side shift. See
Extendable Container Attachment (ELME)
5000SRM2067 for attachment hydraulic system.
1. TILT CYLINDER
2. PILOT OPERATED CHECK VALVE
3. PISTON SIDE RELIEF VALVE
4. ROD SIDE RELIEF VALVE
5. COUNTERBALANCE VALVE
6. CHECK VALVE
Figure 6. Counterbalance Valve Schematic
When tilting forward, supply pressure through Port
A opens a pilot operated check valve in the normal
flow direction to connect Port A with the piston side
of the tilt cylinders. When supply pressure through
Port A is higher than 22 % (1 : 4.5) of the rod return 1. PORT A, TILT FORWARD
pressure in ports B1 and B2, then the 2. PORT B, TILT BACKWARD
counterbalance valve opens to allow extruded oil 3. PISTON SIDE RELIEF VALVE
from the rod sides to return to tank. 4. ROD SIDE RELIEF VALVE
5. PORT B2, TO ROD SIDE LH CYLINDER
When pressure at the piston side has reached 19 6. PORT A2, TO PISTON SIDE LH CYLINDER
MPa, the piston side relief valve opens to port B. 7. PORT B1, TO ROD SIDE RH CYLINDER
8. PORT A1, TO PISTON SIDE RH CYLINDER
When tilting backward, supply pressure through
Port B opens two check valves to directly connect Figure 7. Counter Balance Valve
Port B with the rod side of the tilt cylinders. The
same supply pressure opens the pilot operated check
valve allowing oil from the cylinder A ports to
return to tank. When supply pressure at Port B has
reached 19 MPa (2756 psi), the rod side relief valve
opens to port A.
13
VARIABLE DISPLACEMENT PUMP

The variable displacement pump is load sense
controlled. The load sense controller is based on a
flow control valve.
Basic Functional Operation

The variable displacement pump is a piston-type
pump. The pistons are located in a cylinder block
that rotates with a fixed ratio to the engine RPM.
When the cylinder block rotates, the pistons will
follow the stationary swash plate. The angle of the
swash plate determines the stroke of the pistons,
and by this, the displacement of the pump.
The swash plate is held in its position by the servo
piston. By increasing the pressure inside the servo
piston, it will extend and de-stroke (reducing the
displacement) the pump.
The pressure inside the servo piston (angle of the
swash plate) is controlled by the pressure and load
sense control valve.
For location of components in the variable
displacement pump, see Figure 8.
Inside the pump a certain amount of oil leakage is
generated between the components. This leakage is
used to create an oil film between the components
and to cool the pump.
PRESSURE CONTROL VALVE

Fundamentals
The pressure controller on the pump is a direct-
acting relief valve based on a pressure control valve.
Operation 1. LOAD SENSE VALVE

2. PRESSURE CONTROL VALVE
NOTE: The pressure controller on the pump will 3. SERVO PISTON
only be activated when the load sense relief valve 4. BIAS SPRING
(H) of the main control valve is not working 5. PISTON
6. INPUT SHAFT
properly. 7. SWASH PLATE
The pressure controller on the pump is connected to 8. CYLINDER BLOCK
the output pressure of the pump. When the pump
Figure 8. Variable Displacement Pump
pressure is greater than the pressure controller
setting, the pressure controller will open and supply
the pump pressure to the servo piston inside the
pump to de-stroke (reduce the flow) the variable
displacement pump and such to control the
maximum pump pressure.
14
1900 SRM 2132 Repair
LOAD SENSE PRESSURE REGULATOR regulator is controlled by:
Fundamentals 1. The output pressure of the pump.

2. The function pressure (LS).
The load sense controller is based on a pressure
regulator. 3. Spring force (Margin setting).
The load sense pressure regulator regulates the
Functional Operation pressure to the servo piston. The regulated pressure
The output pressure of the load sense pressure determines the position (stroke) of the swash plate.
Repair
MAIN CONTROL VALVE 6. Remove the four capscrews and isolators
retaining the hydraulic plate to the frame of
Remove the lift truck. See Figure 9.
7. Lift the complete assembly hydraulic plate and

WARNING
hydraulic control valve attached and place on
Make sure the attachment is lowered before flat surface.
disconnecting any parts of the hydraulic system.
Make sure the hydraulic accumulator has released 8. Remove the four retaining screw that retain
all stored pressure by operating the brake pedal the hydraulic valve to the hydraulic plate. See
approx. 30 times with the engine switched OFF. Figure 9.
Tilt the mast fully forward to release all the
hydraulic pressure from the tilt cylinders. 9. Pull the hydraulic control valve from the
hydraulic control plate.
WARNING 10. Place the hydraulic control valve on a flat

The hydraulic control valve with the hydraulic surface for disassembly.
plate weigh 125 kg (275 lb). Use a lifting device
when removing or installing the Hydraulic control 11. Remove the two capscrews that retain the
valve. brake control manifold to the Main Control
Valve and set it aside for reassembly. See
1. Place the lift truck on a solid, level surface. Figure 10.
2. Tilt the mast to the maximum forward position. 12. Label each section and remove the six nuts and
washers that retain the auxiliary, RH lift, LH
3. Remove the two front covers to gain access to lift, and the tilt sections to the Main Control
the hydraulic compartment. Valve.
4. Place a drain pan under the hoses that will be 13. Slowly slide the sections off of the threaded
disconnected from the Hydraulic Control Valve. studs and set aside for reassembly.
See Figure 2 for the Main Control Valve
location on the truck. 14. Remove the six threaded studs from the Main
Control Valve and set aside for reassembly.
5. Tag and remove the hydraulic hoses and
electrical connectors from the Hydraulic 15. Label and remove all valves from Main Control
Control Valve. See Figure 9. Valve as shown in Figure 11. Set aside for
reassembly.
15
Repair 1900 SRM 2132
1. NUT 8. EMERGENCY LOWERING VALVE

2. WASHERS 9. LH LIFT SECTION
3. ISOLATORS 10. BRAKE CONTROL MANIFOLD
4. CAPSCREWS 11. MAIN CONTROL VALVE
5. LOCK WASHER 12. RH LIFT SECTION
6. HYDRAULIC PLATE 13. AUXILIARY SECTION
7. TILT SECTION
Figure 9. Hydraulic Control Valve Removal
16
Clean 3. If any of these components fail inspection,

replace.
WARNING Assemble
Solvent cleaners are flammable and poisonous,
and can cause burns. Examples of solvent 1. Install new O-rings on all valves removed from
cleaners are carbon tetrachloride, emulsion-type the Main Control Valve. See Figure 11.
cleaners, and petroleum-based cleaners. To avoid
2. Reinstall all valves that were removed and
serious personal injury when using solvent
labeled from the Main Control Valve. See
cleaners, carefully follow the manufacturer’s
Figure 11. Refer to the section
product instructions and the following procedures.
Torque Specifications for the correct torque
procedure.
WARNING NOTE: When reinstalling the threaded stud into

the Main Control Valve, use medium strength
• Wear safe eye protection. Loctite® on the threads to prevent loosening of the
Wear clothing that protects your skin. studs.
•
• Work in a well-ventilated area. 3. Install the six threaded studs that were
removed from the Main Control Valve. See
• DO NOT use gasoline or solvents that
Figure 10.
contain gasoline. Gasoline can explode.
• Use hot solution tanks or alkaline solutions 4. Next install all new O-rings into the four lift
correctly. Follow the manufacturer’s sections before installation. See Figure 10.
instructions carefully.
5. Slide the sections onto the threaded studs the
same way they were removed and labeled. See
CAUTION Figure 10.
• Use only solvent cleaners to clean ground or 6. Install the six nuts and washers. Refer to the
polished metal parts. Hot solution tanks or section Torque Specifications for the correct
water and alkaline solutions will damage torque procedure. See Figure 10.
these parts. Isopropyl alcohol, kerosene, or
diesel fuel can be used for this purpose. 7. Install the new O-rings into the brake control
• If required, use a sharp knife to remove manifold. See Figure 10.
gasket material from parts. Be careful not to
damage the ground or polished surfaces. 8. Using the two capscrews, reinstall the brake
control manifold to the Main Control Valve.
1. Remove all old O-rings and gasket material. Refer to the section Torque Specifications for
the correct torque procedure. See Figure 10.
2. Clean all dirt and debris from all components
disassembled or removed. 9. Place the Hydraulic control valve onto the
hydraulic place in same position as removed
Inspect and install the four capscrews and washers.
Refer to the section Torque Specifications for
1. Inspect each component removed or
the correct torque procedure. See Figure 9.
disassembled for abnormal wear, cracks, and
deformities.
2. Check threads on all ports, capscrews, and

studs.
17
Figure 10. Main Control Valve Disassembly and Assembly
18
1. NUT 7. BRAKE CONTROL MANIFOLD

2. WASHER 8. CAPSCREWS
3. THREADED STUD 9. RH LIFT SECTION
4. TILT SECTION 10. AUXILIARY SECTION
5. LH LIFT SECTION 11. ELECTRICAL CONNECTORS
6. MAIN CONTROL VALVE
Install 6. Release the clamps of the suction hoses at the

main pumps. Slide the hoses partly from their
fittings allowing trapped air to escape and oil
WARNING from the hydraulic tank to reach the pumps.
The hydraulic control valve is very heavy. Use a Reinstall the hoses and tighten the clamps.
lifting device when removing or installing the
Hydraulic control valve.
WARNING
1. Using lifting device lower the complete
Never start the engine when pumps are not filled
hydraulic control valve and plate assembly into
with oil. Verify that the pumps are filled with oil by
the same position as removed.
removing the drain line and fill the pump chamber
by using the drain opening. Otherwise this can
2. Install the four capscrews, nuts, and isolators
cause serious damage and loss of durability to the
that retain the hydraulic plate to the lift truck
pump(s).
frame. Refer to the section
Torque Specifications for the correct torque NOTE: Maximum tilt speed is available at idle, it is
procedure. See Figure 9. NOT necessary to increase engine RPM to achieve
maximum tilt speed.
3. Reinstall all hydraulic hoses and electric
connectors onto the hydraulic control valve as 7. Start the engine while operating the tilt
they are labeled. See Figure 9. function. Release the tilt function when
pressure 5 MPa (725 psi) has been built up.
4. Remove the hydraulic pump drain hoses from Operate other connected hydraulic functions to
the two main pumps. Fill the pumps through remove air from the system. DO NOT operate
the drain ports with clean hydraulic oil. Relief Pressure for fifteen minutes after
Reinstall the drain hoses. installing a new Variable Displacement Pump.
Turn the engine OFF.
CAUTION 8. Check all components that were disassembled

Use a filtration system when filling the hydraulic or removed for leaks.
tank to prevent dirt and contamination from
entering the hydraulic system. If dirt or 9. Check hydraulic tank oil level. If needed, top off
contamination enters the hydraulic system, the hydraulic tank with clean hydraulic oil as
damage may occur to the components of the specified in the maintenance table. Refer to the
hydraulic system. manual Periodic Maintenance
8000SRM2068.
5. Fill the hydraulic tank with clean hydraulic oil
as specified in the maintenance table. Refer to
the manual Periodic Maintenance
8000SRM2068.
19
PRIORITY VALVE (A) Install

Remove 1. Reinstall Priority Valve (A) back into the Main
Control Valve. Tighten by hand.
1. Remove Priority Valve (A) from the Main
Control Valve Mid Section. See Figure 11. 2. Torque Priority Valve (A) to
217 to 231 N•m (160 to 170 lbf ft).
Clean
1. Remove the old O-rings and clean the valve CHECK VALVE (K)
with a petroleum based solvent. See Figure 12.
Remove
Inspect 1. Remove Check Valve (K) from the Main Control
Valve Mid Section. See Figure 11.
1. Inspect Priority Valve (A) for damage or
abnormal wear. If none is found, replace all O-
Clean
rings. See Figure 12.
1. Clean Check Valve (K) remove all old O-rings.
Component Functionality Test See Figure 13.
With a clean, suitable tool, press the priority spool
Inspect
into the cartridge. If the priority spool moves
smoothly against the spring, the Priority Valve is 1. Inspect Check Valve (K) for damage or
functioning properly and may be reinstalled. abnormal wear. If none is present, replace all
O-rings. See Figure 13.
1. MAIN CONTROL VALVE 9. LOAD SENSE SELECTOR VALVE (D)

2. FULL FLOW RELIEF VALVE (H) 10. 2ND PUMP SELECTOR VALVE (E)
3. LOAD SENSE RELIEF VALVE (G) 11. CHECK VALVE (I)
4. CHECK VALVE (O) 12. PRIORITY VALVE (A)
5. PILOT SUPPLY VALVE (F) 13. SCREEN CARTRIDGE (O)
6. CHECK VALVE (K) 14. SHUTTLE VALVE (N)
7. LIFT PRESSURE SELECTOR VALVE (B) 15. SHUTTLE VALVE (M)
8. FULL FLOW RELIEF VALVE, SPOOL (C) 16. SHUTTLE VALVE (L)
Figure 11. Main Control Valve, Mid-Section
20
Clean
1. Remove the old O-rings and clean the valve
Inspect
1. Inspect Check Valve (I) for damage or
abnormal wear. If none is present, replace all
O-rings. See Figure 13.

With a clean, suitable tool, press the spool into the
cartridge. If the spool moves smoothly against the
spring and no visual damages are shown on the
spool and the seat, the Check Valve (I) is
functioning properly and may be reinstalled.
Install
1. Reinstall Check Valve (I) back into the Main
2. Torque Check Valve (I) to

122 to 136 N•m (90 to 100 lbf ft).
1. PRIORITY VALVE (A)

2. O-RINGS
Figure 12. Priority Valve (A)

With a clean, suitable tool, press the spool into the
cartridge. If the spool moves smoothly against the
spring and no visual damages are shown on the
spool and seat, the Check Valve is functioning
properly and may be reinstalled.
Install
1. Reinstall Check Valve (K) back into the Main
2. Torque Check Valve (K) to

27 to 34 N•m (20 to 25 lbf ft). 1. CHECK VALVE
2. O-RINGS
CHECK VALVE (I)
Figure 13. Check Valve
Remove
1. Remove Check Valve (I) from the Main Control
21
CHECK VALVE (Q) SHUTTLE VALVES (L) AND (M)

Remove Remove
1. Remove Check Valve (Q) from the Main Control 1. Remove the three Shuttle Valves from the
Valve Mid Section See Figure 11. Main Control Valve Mid Section. See Figure 11.
Clean Clean
1. Clean Check Valve (Q) and remove all old O- 1. Clean the Shuttle Valves and remove all old O-
rings. rings. See Figure 15.
Inspect Inspect
1. Inspect Check Valve (Q) for damage or 1. Check all Shuttle Valves for damage or
abnormal wear. If none is present, replace all abnormal wear. If none is present, replace all
O-rings. O-rings. See Figure 15.

With a clean, suitable tool, press the spool into the If visual inspection reveals no damages on the ball
cartridge. If the spool moves smoothly against the and seats, the Shuttle Valve is functioning properly
spring and no visual damages are shown on the and may be reinstalled.
spool and seat, the Check Valve is functioning
properly and may be reinstalled. Install
1. Reinstall each Shuttle Valve back into the
Install Main Control Valve. Tighten by hand.
1. Reinstall Check Valve (Q) back into the Main
Control Valve. Tighten by hand. 2. Torque the Shuttle Valves to
26 to 30 N•m (34 to 40 lbf ft).
2. Torque Check Valve (Q) to
9 to 12 N•m (7 to 9 lbf ft).
SCREEN CARTRIDGE (O)

Disassemble
1. Remove the screen cartridge from the Main
Control Valve Mid Section.

Visually inspect the screen cartridge for damage
and/or contamination. Clean the screen cartridge or
replace it.
Assemble
1. Clean or replace the screen cartridge. See
Figure 14.
2. Torque screen cartridge (O) to

9 to 12 N•m (7 to 9 lbf ft). 1. SCREEN CARTRIDGE (O)
2. O-RINGS
Figure 14. Screen (O)
22

With a clean, suitable tool, press the logic spool into
the cartridge. If the logic spool moves smoothly
against the spring, the Logic Valve is functioning
properly and may be reinstalled.
Install
1. Reinstall Logic Valve into Main Control Valve
Mid Section. Tighten by hand.
2. Torque Logic Valve to

45 to 50 N•m (33 to 37 lbf ft).
1. SHUTTLE VALVES
2. O-RINGS
Figure 15. Shuttle Valves
LOGIC VALVE (N)

NOTE: Logic Valve (N) is only applicable on those
Lift Trucks configured with a Wet Brake System.
Remove
1. Remove Logic Valve (N) from Main Control
1. LOGIC VALVE
2. O-RINGS
Clean
1. Clean Logic Valve and remove O-rings. See Figure 16. Logic Valve
Figure 16.
Inspect
1. Check Logic Valve for damage or abnormal
wear. If none is present, replace O-rings. See
Figure 16.
23
FULL FLOW RELIEF VALVE (C) (RELIEF Install

SPOOL) 1. Reinstall Full Flow Relief valve into the Main
Remove Control Valve. Torque to
217 to 231 N•m (169 to 170 lbf ft).
1. Remove the Full Flow Relief Valve (C) from the
Main Control Valve Mid Section. See Figure 11. PILOT SUPPLY VALVE (F)
Clean Remove
1. Remove the old O-rings and clean the valve 1. Remove the Pilot Supply Valve (F) from the
with a petroleum based solvent. See Figure 17. Main Control Valve Mid Section. See Figure 11.
Inspect Clean
1. Check the Full Flow Relief valve for damage or 1. Remove the old O-rings and clean the valve
abnormal wear. with a petroleum based solvent. See Figure 18.
Assemble Inspect
1. Replace all O-rings on the valve. See Figure 17. 1. Inspect Pilot Supply Valve (F) for damage or
abnormal wear.
Assemble
1. Replace all O-rings. See Figure 18.
1. PILOT SUPPLY VALVE (F)

2. O-RINGS
1. FULL FLOW RELIEF VALVE (C) (RELIEF
SPOOL) Figure 18. Pilot Supply Valve (F)
2. O-RINGS
Figure 17. Full Flow Relief Valve (C) (Relief Spool)
24
Component Functionality Test Inspect

The setting of the Pilot Supply Valve (F) can be 1. Check relief valves for damage or abnormal
measured on measurement port MPLT. Refer to the wear. If none is present, replace all O-rings.
section Hydraulic pressure checks for trouble See Figure 19.
shooting flow charts.
Install The pressure setting for the Relief Valves (H) and
1. Reinstall Pilot Supply Valve (F) back into the (G), can be measured at port MLS2 on the Main
Main Control Valve. Tighten by hand. Control Valve. For trouble shooting procedures on
the Relief Valves, reference Troubleshooting.
2. Torque Pilot Supply Valve (F) to
45 to 50 N•m (33 to 37 lbf ft). Install
1. Using a Relief Valve Installation Tool, Hyster
LOAD SENSE (LS) RELIEF VALVE (H) AND
P/N 4036137 (see Figure 20), reinstall the
FULL FLOW RELIEF VALVE (G) relief valves back into the Main Control Valve
Remove Mid Section by pressing each into Main Control
Valve, then twisting to lock in. After installing
1. Remove the two Load Sense Relief Valves (H) both, reinstall the plastic protective caps back
and (G) from the Main Control Valve Mid onto the tops of the relief valves.
Section. See Figure 11.
Load Sense Relief Valve (H) Adjustment
Clean
1. Measure Load Sense pressure at MLS2.
1. Clean the load sense relief valve and remove all
old O-rings. See Figure 19. 2. Adjust relief valve (H) until pressure is set at
22.5 MPa (3263 psi).
Full Flow Relief Valve (G) Adjustment

1. Measure Pump pressure at MP.
2. Adjust relief valve (H) to max setting (screw

valve all the way in).
3. Adjust relief valve (G) to 24.0 MPa (3481 psi).
1. RELIEF VALVE
2. O-RINGS Figure 20. Special Tool
Figure 19. Relief Valve
25
4. Adjust relief valve (G) with additional ½ turn 2. Install coil back onto valve and torque nut to
inward (increase setting with ½ turn). Relief 4 to 6 N•m (35 to 53 lbf in). See Figure 11.
valve (G) is now set at 30 MPa (4351 psi).
5. Adjust relief valve (H) to proper setting. See

Load Sense Relief Valve (H) Adjustment in this
manual.
LIFT PRESSURE SELECTOR VALVE (B)

OR LOAD SENSE SELECTOR VALVE (D)
Remove
1. Remove the nut that retains the coil to the Lift
Pressure Selector Valve (B) or Load Sense
Selector Valve (D), see Figure 21.
2. Remove Lift Pressure Selector Valve (B) or

Load Sense Selector Valve (D) from the Main
Control Valve Mid Section. See Figure 11.
Clean
Inspect
1. Inspect Lift Pressure Selector Valve (B) or Load
Sense Selector Valve (D) and coil for damage or
abnormal wear.
Assemble
1. Replace the O-rings. See Figure 21.
Install 1. NUT
2. COIL
1. Install Lift Pressure Selector Valve (B) or Load 3. LIFT PRESSURE SELECTOR VALVE (B) OR
Sense Selector Valve (D) back into the Main LOAD SENSE SELECTOR VALVE (D)
Control Valve. Torque to 4. O-RINGS
35 to 40 N•m (26 to 30 lbf ft). See Figure 11.
Figure 21. Lift Pressure Selector Valve (B) or Load
Sense Selector Valve (D)
26
2ND PUMP SELECTOR VALVE (E)

Remove
1. Remove the nut that retains the coil to the 2nd
Pump Selector Valve (E), see Figure 22.
2. Remove 2nd Pump Selector Valve (E) from the

Main Control Valve Mid Section. See Figure 11.
Clean
Inspect
1. Inspect 2nd Pump Selector Valve (E) and coil
for damage or abnormal wear.
Assemble
1. Replace the O-rings. See Figure 22.
Install
1. Install 2nd Pump Selector Valve (E) back into
Main Control Valve. Torque to
35 to 40 N•m (26 to 30 lbf ft).
2. Install the coil back onto valve and torque the

nut to 4 to 6 N•m (35 to 53 lbf in).
1. NUT
2. COIL
3. 2ND PUMP SELECTOR VALVE (E)
4. O-RINGS
Figure 22. 2nd Pump Selector Valve (E)
27
VARIABLE DISPLACEMENT PUMP secondary pump out and away from the
(PRIMARY AND SECONDARY) pump until splines are clear of primary
pump. Place on flat surface. See Figure 23.
Remove
c. Primary pump removal: Remove four
capscrews and four washers holding the
WARNING Primary Pump to the transmission housing.
Make sure the carriage is lowered before Pull the primary pump away from the
disconnecting any parts of the hydraulic system. transmission housing until the splines are
clear of the housing. Place on flat surface.
See Figure 23.
WARNING
Some of the hydraulic pumps are very heavy. Use 7. To remove the LS and pressure controller from
a lifting device when removing or installing the the pump refer to the section
pump. Load Sense and Pressure Controller Valve on
PumpRemove.
1. Place the lift truck on a solid, level surface.
Clean
2. Tilt the mast to the maximum forward position.
1. Clean and remove all O-rings from the mating
surfaces of the pump, gear pump if applicable,
3. Place a clean and suitable container under the
and transmission housing.
hydraulic tank. Remove the drain plug at the
bottom of the hydraulic tank and drain the
hydraulic oil approximately Inspect
130 to 160 liter (34 to 42 gal) from the 1. Inspect all mating surfaces for scratches or
hydraulic tank. gouges that may hinder a proper seal and
operation of the pressure controller or pump.
4. Place drain pan underneath the hoses you will
be disconnecting from the pump. For location of
the primary and secondary variable
displacement pumps on the lift truck see
Figure 2.
NOTE: Prior to removing any components, ensure

that there is a clean work area to place components
as they come off the lift truck.
5. Tag and remove the hoses from the pump that
you are removing.
6. Pump removal follows:
a. Hydraulic Oil Cooling Pump removal:

Remove two capscrews and two washers
from Hydraulic Oil Cooling Pump. Remove
Hydraulic Oil Cooling Pump from engine.
Remove and discard O-ring. Place pump on
flat surface.
1. PRIMARY PUMP
b. Secondary pump removal: Remove the 2. SECONDARY PUMP
four capscrews and four washers holding the 3. LS AND PRESSURE CONTROLLER VALVE
secondary pump to the Primary Pump.
Remove and discard O-ring. Pull the Figure 23. Variable Displacement Pumps
28
4. Fill the pump through the drain ports with

clean hydraulic oil. Install the fittings into the
hydraulic pump. Install drain hoses to fittings.
See Figure 25.
5. Install the suction and pressure hose that

connect with the hydraulic pump.
CAUTION
Use a filtration system when filling the hydraulic
tank to prevent dirt and contamination from
entering the hydraulic system. If dirt or
contamination enters the hydraulic system,
damage may occur to the components of the
hydraulic system.
6. Fill the hydraulic tank with clean hydraulic oil

as specified in the maintenance table. Refer to
the manual Periodic Maintenance
8000SRM2068.
1. COOLING PUMP
7. Release the flange connection of the suction
Figure 24. Cooling Pump on Engine hose at the pump. Slightly open this connection
allowing trapped air to escape and tank oil to
Assemble reach the pump. Reinstall the flange connection
and tighten the capscrews.
1. Secondary pump: Install four washers and
four capscrews that hold the Secondary pump
to the Primary pump and hand tighten. Then
refer to the section Torque Specificationsfor the
correct torque procedure.
2. Hydraulic Oil Cooling Pump: Install a new

O-ring to mounting area on Hydraulic Oil
Cooling Pump. Using two washers and two
capscrews, install Hydraulic Oil Cooling Pump
to the engine.
Install
1. Lube the splines on the pump assembly driven
shaft.
2. Install new O-ring and install the pump into

the transmission housing ensuring that the
splines on the pump driven shaft are properly
aligned in the transmission housing.
1. DRAIN HOSE
2. FITTING
3. Install the four capscrews and washers that 3. DRAIN PORT
retain the pump to the transmission housing
and hand tighten. Refer to the section Figure 25. Hydraulic Fluid Fill
Torque Specifications for the correct torque
procedure.
29
1. Disconnect the hydraulic lines at the tilt

WARNING cylinder. Install caps on the hydraulic lines and
Never start the engine when pumps are not filled ports.
with oil. Verify that the pumps are filled with oil by
removing the drain line and fill the pump chamber
by using the drain opening. Otherwise, this can WARNING
cause serious damage and loss of durability to the DO NOT push the anchor pins out of the rod end
pump(s). with your fingers. DO NOT permit the tilt cylinders
to drop and cause damage.
NOTE: DO NOT operate the pump against relief
pressures for fifteen minutes after installing a new 2. Remove the retainers for the anchor pins. Push
Variable Displacement Pump. the anchor pins out of the rod end with a tool.
NOTE: Maximum tilt speed is available at idle, it is 3. Use a lifting device to move large tilt cylinders.
NOT necessary to increase engine RPM to achieve Remove the anchor pins from the frame
maximum tilt speed. anchors. Remove the tilt cylinder from the
8. Start the engine while operating the tilt frame.
function. Release the tilt function when
pressure 5 kPa (725 psi) has been built up. DISASSEMBLE
Operate all other connected hydraulic functions
1. Put tilt cylinder in a vise with soft jaws.
to remove air from the system. Turn the engine
Remove rod end from the rod.
OFF.
2. Remove retainer from the tilt cylinder. Remove
9. Check all components that were disassembled
rod and piston from the cylinder.
or removed for leaks.
3. Disassemble tilt cylinder as necessary. See
10. Check hydraulic tank oil level. Fill the
Figure 26.
hydraulic tank with clean hydraulic oil as
specified in the maintenance table. Refer to the
manual Periodic Maintenance
CLEAN
8000SRM2068.
WARNING
TILT CYLINDER Cleaning solvents can be flammable and toxic and
Remove can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer's
recommended safety procedures.
WARNING
Compressed air can move particles so that they
Before removing the tilt cylinder(s), tilt the mast
cause injury to the user or to other personnel.
forward. Use a chain to hold the mast to the frame
Make sure that the path of the compressed air is
and prevent the mast from moving forward.
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
WARNING Clean all parts in solvent and dry with compressed

DO NOT disconnect any hydraulic lines when the air.
engine is running or personal injury may occur.
ASSEMBLE
WARNING NOTE: Always use new seals and O-rings. Make

sure all parts are clean. Lubricate all parts with
Relieve the trapped or stored hydraulic pressure
clean hydraulic oil.
from the hydraulic system, or serious personal
injury may occur.
30
NOTE: If a new piston was not installed, the piston INSTALL

rod nut must be retightened to the value shown in
Torque Specifications. 1. Use a lifting device to move large tilt cylinders.
Put the cylinder in the lift truck. Install the
1. Install the piston seal and O-ring(s) onto the anchor pin in the frame. Install the retainer pin
piston. See Figure 26. Install the piston onto or cotter pin.
the cylinder rod. Make sure the piston seal is
not damaged. Tighten the nut on the piston rod 2. Install the anchor pin at the mast mount.
to the value shown in Torque Specifications. Install the retainer pin or cotter pin for the
anchor pin. Tighten the capscrews for the
2. Install a new wiper and rod seal. Install O-ring retainer pins.
and backup ring onto retainer.
3. Connect the hydraulic lines to the tilt cylinder.
3. Install retainer assembly onto the rod.
NOTE: Maximum tilt speed is available at idle, it is
4. Install piston and rod assembly into the NOT necessary to increase engine RPM to achieve
cylinder. Tighten retainer to the value shown maximum tilt speed.
in Torque Specifications.
4. Operate the tilt cylinders. Check for correct
NOTE: After assembly is complete, install rod end operation and leakage. Adjust the tilt cylinders
on the cylinder rod. Tighten capscrew on the rod end as described in Tilt Cylinder Leak Check and
as specified in Mast section for your specific lift Tilt Cylinder Stroke and Mast Tilt Angle
truck. Adjustment.
1. ROD WIPER 7. CYLINDER SHELL

2. ROD SEAL 8. NUT
3. BACKUP RING / O-RING 9. PISTON
4. O-RING 10. PISTON ROD
5. PISTON SEAL / O-RING 11. RETAINER
6. PISTON GUIDE RING
Figure 26. Tilt Cylinder
31
TILT CYLINDER LEAK CHECK TILT CYLINDER STROKE AND MAST TILT
ANGLE ADJUSTMENT
WARNING Adjust the tilt cylinders as described in the Mast
Never allow anyone under a raised carriage. Do section.
not put any part of your body in or through the lift
mechanism unless all parts of the mast are COUNTERBALANCE VALVE MANIFOLD
completely lowered and the engine is STOPPED.
Remove
Do not try to find hydraulic leaks by putting your
hand on hydraulic components under pressure.
Hydraulic oil can be injected into the body by the WARNING
pressure. Make sure the carriage is lowered before
disconnecting any parts of the hydraulic system.
1. Put a capacity load in the attachment. Raise
the load approximately 2.5 m (8 ft). Put the
mast in a vertical position. WARNING
Relieve the trapped or stored hydraulic pressure
2. Measure the distance that the rod for tilt
from the hydraulic system, or serious personal
cylinder extends from the shell. Check the
injury may occur.
distance the rod moves in five or ten minutes.
Multiply the rate in Table 2 by the time of the 1. Place the lift truck on a solid, level surface.
test and compare the numbers.
Table 2. Movement Rates (Maximum) for Tilt
Cylinders 3. Raise the cab to the fully open position to gain
Hydraulic Oil Temperature/Mast Tilt Rate access to the tilt lock manifold and
counterbalance valves.
60°C (140°F)
mm/min in./min 4. Place drain pan underneath the valves you will
be removing from the valve assembly. See
15 0.6 Figure 27. For location of the counterbalance
valves on the lift truck, see Component
3. If the tilt rate is greater than the specifications, Location of the Lift Truck.
lower the mast and remove the load. Install a
gate valve between the port at the front of the 5. Remove the counterbalance valve from the
tilt cylinder and the hydraulic line. Put the valve assembly.
load in the attachment again. Close the gate
valve. Tilt the mast forward just past the Clean
vertical position. If the mast continues to tilt
slowly forward, the seals on the piston are 1. Make sure to remove all old O-rings. Clean the
leaking. ports from where the valves were removed.
4. If the mast does not move, open the gate valve Inspect
and check the movement again. If the mast 1. Inspect the threads and valves for damage and
moves forward when the gate valve is open, abnormal wear.
check for leaks in the hydraulic lines, fittings
and tilt lock valve (check valves and Assemble
counterbalance valves, relief valves). If no leaks
are found, the main control valve can be worn 1. Replace O-rings on the valve.
or damaged. Remove the load when the checks
are complete.
32
Install
1. Reinstall the counterbalance valve back into
the valve assembly.
NOTE: Maximum tilt speed is available at idle, it is

NOT necessary to increase engine RPM to achieve
maximum tilt speed.
2. Start the lift truck and operate the tilt function
check for leaks.
3. Turn the lift truck OFF and check the

hydraulic tanks oil level if needed top off the
manual Periodic Maintenance
8000SRM2068.
1. COUNTERBALANCE VALVE ASSEMBLY ELECTRICAL ACTUATION MODULE

2. TILT CYLINDERS
Remove
Figure 27. Counterbalance Valve Location
1. Loosen each of the four capscrews gradually to
ensure that the spool does not fall out of the
valve section. See Figure 29.
Clean
WARNING
and can cause burns. Examples of solvent
cleaners are carbon tetrachloride, emulsion-type
cleaners, and petroleum-based cleaners. To avoid
serious personal injury when using solvent
cleaners, carefully follow the manufacturer’s
product instructions and the following procedures.
WARNING
• Wear safe eye protection.

1. PORT A, TILT FORWARD • Wear clothing that protects your skin.
2. PORT B, TILT BACKWARD
3. PISTON SIDE RELIEF VALVE • Work in a well-ventilated area.
4. ROD SIDE RELIEF VALVE • DO NOT use gasoline or solvents that
5. PORT B2, TO ROD SIDE LH CYLINDER contain gasoline. Gasoline can explode.
6. PORT A2, TO PISTON SIDE LH CYLINDER
7. PORT B1, TO ROD SIDE RH CYLINDER • Use hot solution tanks or alkaline solutions
8. PORT A1, TO PISTON SIDE RH CYLINDER correctly. Follow the manufacturer’s
Figure 28. Counter Balance Valve
33
Assemble
CAUTION 1. Replace all O-rings.
• Use only solvent cleaners to clean ground or Install

polished metal parts. Hot solution tanks or
water and alkaline solutions will damage 1. Place the Electrical Actuation Module on to the
these parts. Isopropyl alcohol, kerosene, or valve body. Install top two capscrews and hand
diesel fuel can be used for this purpose. tighten to hold in position. See Figure 29.
1. Make sure to remove all old O-rings. 2. Install remaining capscrews and torque all four
in a X pattern to ensure even torque. Refer to
Inspect the section Torque Specifications for the correct
torque procedure.
1. Inspect Electrical Actuation Module for damage
or abnormal wear.
Figure 29. End Cap and Selector Valves
34
1. CAPSCREWS 6. SPOOL
2. ELECTRICAL ACTUATION MODULE 7. O-RINGS
3. DOWEL PINS 8. MANUAL END CAP
4. O-RINGS 9. CAPSCREWS
5. VALVE ASSEMBLY
EMERGENCY LOWERING VALVE (LEFT Turn the ELV so that it comes completely out,
LIFT SLICE ONLY) then turn the ELV one complete rotation the
opposite direction.
Remove
3. Start lift truck and check for leaks.
1. Open Emergency Lowering Valve (ELV) to
relieve pressure in the lift cylinders. 4. Turn the lift truck OFF and check the
hydraulic tanks oil level. If needed, top off the
2. Place drain pan underneath the valve you will
be removing from the valve assembly. See
Figure 9 for location of emergency lowering
manual Periodic Maintenance SRM .
valve. For location of the lift section LH on the
lift truck see Figure 11.
3. Using a wrench loosen the valve slide the

emergency lowering valve out of the lift section
left slice. See Figure 30.
Clean
1. Make sure to remove the old O-ring.
Inspect
1. Check all emergency lowering valve for damage
or abnormal wear. If none is present, replace
all O-rings.
Install
1. Reinstall the emergency lowering valve into the
lift section left slice.
2. Close Emergency Lowering Valve (ELV). Figure 30. Emergency Lowering Valve
35
LOAD SENSE AND PRESSURE 1. Place the pressure controller into its original
CONTROLLER VALVE ON PUMP position on the variable displacement pump.
Remove 2. Install the four capscrews that retain the

pressure controller to the pump and hand
NOTE: These steps apply to removal and
tighten.
installation of the pressure controller on both
primary and secondary variable displacement 3. Torque the capscrews. Refer to the section
pumps. Torque Specifications for the correct torque
1. Remove the four capscrews and washers that procedure.
retain the pressure controller to the variable
displacement pump. See Figure 31. For location
of the primary and secondary variable
displacement pumps on the lift truck, see
Figure 2.
Clean
1. Clean the mating surfaces of the variable
displacement pump and the pressure
controller. Remove all O-rings.
Inspect
1. Inspect all mating surfaces for scratches or
gouges that may hinder a proper seal and
operation of the pressure controller or pump.
Assemble
1. Install all new O-rings and ensure they are
seated properly.
Install 1. CAPSCREWS
NOTE: If you are installing a new load sense or 2. VARIABLE DISPLACEMENT PUMP
pressure controller after installation, proceed to 3. PRESSURE CONTROLLER ON PUMP
Adjustment of Pressure Controller on Pump for the
Figure 31. Load and Pressure Controller on Pump
adjustment procedures.
36
ADJUSTMENT OF PRESSURE
CONTROLLER ON PUMP
1. Install the pressure gauge into port M1 (also
applicable for secondary pump) or on MP on
Main Control Valve (also applicable for
secondary pump) to measure system pressure.
See Figure 33 for the location of port M1.
2. Start the lift truck and allow the hydraulic

fluid to reach normal operating temperature.
External system relief valve must be set above
the pressure controller setting for proper
operation. Therefore increase LS relief valve on
the main valve to less than or equal to
29 MPa (4,206 psi) before adjusting the
pressure controller setting in order to be able to
reach 28 MPa (4,061 psi) on the pump. [1 turn
clockwise on item 1 in Figure 32 equals
13 MPa (1,885 psi)].
1. LS RELIEF ADJUSTMENT
3. Operate the hydraulic function “Lift Up” to its
Figure 32. LS Relief Adjustment Point
full extension, loading the pump at maximum
pressure and zero flow while executing the
pressure test.
4. Loosen the pressure control setscrew and turn

the pressure control adjusting plug until the
desired setting 28 MPa (4,061 psi) is indicated
on the pressure gauge at port M1
(SECONDARY PUMP) or MP (PRIMARY
PUMP). Clockwise rotation increases pressure,
counterclockwise rotation decreases;
approximate gain 4.2 MPa (609 psi) per turn. If
the pressure does not increase, an external
system relief valve may require adjustment.
See Figure 33 for location of setscrew and
adjusting plug.
5. While holding the position of the pressure

control adjusting plug, torque the pressure
control setscrew to
7.6 to 10.8 N•m (5.5 to 8 lbf ft). See Figure 33
for the location of the pressure control 1. CASE DRAIN PORT L1
2. GAUGE PORT M1
adjusting plug and setscrew. 3. PRESSURE CONTROLLER SETSCREW
4. PRESSURE CONTROLLER ADJUSTING PLUG
NOTE: Remember to make sure the LS relief valve
on the Main Control Valve is placed back to the Figure 33. Pressure Controller Adjustment Points
original setting after completing Step 6.
6. Turn the lift truck OFF, remove the pressure
gauges, and return the system to its normal
operating configuration.
37
ADJUSTMENT OF LOAD SENSE Measure the pump margin pressure at the pump
CONTROLLER ON THE PRIMARY AND control valve. See Figure 35 for pressure test port
SECONDARY PUMP locations.
The margin pressure for the Primary (Steering) and 1. Execute all pressure measurements with NO
Secondary (Hydraulic) Variable Displacement load on the hydraulic system, engine at idle
Pumps (VDP) are set at a 4 bar (58 psi) pressure and the hydraulic oil at operating temperature,
differential, allowing pump staging to prevent peak 60°C (140°F).
engine loading. See Figure 34.
2. Place the forks on the ground, set the park
brake and switch the engine OFF before
installing and removing the pressure test port
fittings and gauges.
3. Remove the LS1 and LS2 pressure to the

pumps by moving the calibration switch in the
side console to the DOWN position.
4. Measure the primary and secondary pumps

individually. Install digital pressure gauges
with a range of 0 - 400 bar (0 - 5000 psi), one
gauge in the pump pressure port and one gauge
in the LS pressure port on the pump control
valve, see Table 3 and Figure 35.
NOTE: Do not exceed 10 mm (3/8 inch) maximum
screw-in depth of the pressure test port fittings.
NOTE: Digital pressure gauges are required to
accurately measure the pump margin pressures.
1. PRIMARY PUMP
2. SECONDARY PUMP 5. Start the engine and allow the hydraulic
3. LS AND PRESSURE CONTROLLER VALVE system pressure to stabilize.
Figure 34. Variable Displacement Pumps 6. Measure the LS pressure with the calibration
switch in the down position and verify that the
Pump Margin Pressure Measurement pressure is at or close to 0.
7. Measure both pump margin pressures. If

WARNING pressures are not within the range specified in
To prevent serious personal injury or equipment Table 3 adjust by following the Pump Margin
damage, do not operate the hydraulic functions Pressure Adjustment instructions.
while measuring and adjusting the pump margin
pressure.
Table 3. Pump Margin Pressures

Pump Pump Margin Pressure
Primary (Steering) 34 ± 0.5 bar (493 ± 7 psi)
Secondary (Hydraulic) 30 ± 0.5 bar (435 ± 7 psi)
38
Pump Margin Pressure Adjustment 4. Remove the pressure gauges and re-install the
Pump pressure and LS pressure port plugs.
1. Loosen the setscrew that locks the pump Torque to 12 N•m (9 lbf ft).
margin pressure adjustment plug. See Table 4
and Figure 35. 5. Check for oil leaks.
2. Turn the pump margin pressure adjustment 6. Return the Calibration switch to the UP
plug either direction, until you achieve the position.
correct pressure. See Table 3.
NOTE: One rotation of the pump margin pressure Move the calibration switch in the side console to
adjustment plug = 17 bar (250 psi). the down position to remove the LS1 and LS2
pressure to the pumps.
3. Retighten the setscrew that locks the pump
margin pressure adjustment plug. Torque to 9
N•m (7 lbf ft).
Table 4. Pump Control Valve

Test Port Function Pressure Gauge Port Thread Size / Allen
Range Wrench Size
Pump Pressure Pump Pressure 0 to 400 bar #4 ORB Female (7/16-20 UN-2A)
(0 to 5000 psi) 3/16 inch Allen Wrench
LS Pressure Load Sense Pressure 0 to 400 bar #4 ORB Female (7/16-20 UN-2A)
(0 to 5000 psi) 3/16 inch Allen Wrench
Pump Margin Adjust the Pump Margin Pressure 6 mm Allen Wrench
Pressure
Set Screw Locks the Pump Margin Pressure Adjustment 4 mm Allen Wrench
Plug
39
Examples of solvent cleaners are carbon

tetrachloride, emulsion-type cleaners, and
petroleum-based cleaners. To avoid serious
personal injury when using solvent cleaners,
carefully follow the manufacturer’s product
instructions and the following procedures.
WARNING
• Wear safe eye protection.

• Wear clothing that protects your skin.
• Work in a well-ventilated area.
• DO NOT use gasoline or solvents that
contain gasoline. Gasoline can explode.
• Use hot solution tanks or alkaline solutions
correctly. Follow the manufacturer’s
1. PRESSURE CONTROL VALVE
2. PUMP MARGIN PRESSURE ADJUST
3. LS PRESSURE PORT
4. PUMP PRESSURE PORT
Figure 35. Pump Control Valve
LOWERING CONTROL VALVE

Remove
1. Place the lift truck on a solid, level surface.
3. Lower the mast completely.
4. Place drain pan underneath the hoses you will

be disconnecting from the lift cylinders. For
location of the lowering control valves on the
lift truck, see Figure 11.
5. Remove the main hose from the bottom of the

lift cylinder.
6. Remove Lowering Control Valve with

1. LOWERING CONTROL VALVE
appropriate socket wrench. See Figure 36. 2. LIFT CYLINDER
Clean Figure 36. Lowering Control Valve and Lifting
Cylinder
WARNING
and can cause burns.
40
1900 SRM 2132 Troubleshooting
2. Hand tighten the fitting into the lift cylinder.

Refer to the section Torque Specifications for
CAUTION
the correct torque procedure.
• Use only solvent cleaners to clean ground or 3. Reinstall hydraulic hose onto fitting on bottom
polished metal parts. Hot solution tanks or of lift cylinder. Refer to the section
water and alkaline solutions will damage Torque Specifications for the correct torque
these parts. Isopropyl alcohol, kerosene, or
procedure.
diesel fuel can be used for this purpose.
• If required, use a sharp knife to remove 4. Start the lift truck and operate each lift and
gasket material from parts. Be careful not to lower function to ensure the lowering control
damage the ground or polished surfaces. valve is operating correctly.
1. Clean fittings and threads. Ensure valve is
5. Check all components that were disassembled
clear of debris. See Figure 36.
or removed for leaks.
Inspect 6. Check hydraulic tank oil level. If needed, top off
1. Inspect O-ring on Lowering Control Valve. If O- the hydraulic tank with clean hydraulic oil as
ring is damaged, replace the Lowering Control specified in the maintenance table. Refer to the
Valve assembly. See Figure 36. manual Periodic Maintenance
8000SRM2068.
2. Inspect the threads on the fitting and the
inside of the lift cylinder.
Install
1. Install Lowering Control Valve in cylinder port
with width appropriate socket wrench.
Troubleshooting
LIFT, TILT, AND/OR AUX FUNCTION DOES c. Replace leaking Electrical Activation Module
NOT MOVE WHEN APPLIED. STEERING IS (End Cap). Check if pilot pressure at MPLT
is not higher than 1.5 MPa (217 psi).
OPERATING NORMAL.
NOTE: Turning the ignition key OFF will reset the 2. Measure pressure at MPLT. Is pressure at
LEDs. MPLT above 1 MPa (145 psi)? If yes, go to
Step a. If no, go to Step b
1. Check which LEDs are illuminated on the
Electrical Actuation Modules (End Caps) on a. Check the flow output values of the
each Main Control valve section. Are the LEDs hydraulic controller to the main valve (refer
green? If yes, go to Step a. If no, go to Step 3. to Hydraulic Flow Control Settings.
a. Are any of the Electrical Actuation Modules b. Replace Pilot Supply Valve (F).
(End Caps) leaking? If yes, go to Step b.
3. Is LED flashing RED? If yes, go to Step a. If no,
b. Measure pilot pressure at MPLT. Is pilot go to Step 4.
pressure higher than 1.6 MPa (232 psi)? If
yes, go to Step c. If no, replace leaking a. Validate electric input signals of this specific
Electrical Activation Module (End Cap). Electrical Actuation Module.
41
Troubleshooting 1900 SRM 2132
4. Is LED constant RED? If yes, go to Step a. If 5. Measure pressure on port MP and MLS1 with
no, Resume operation. running engine and no functions applied. Is the
difference between pressure at MP and MLS1
a. Turn ignition key OFF. Add spanner/ greater than 3 MPa (435 psi)? If yes, go to
manual lever to the connection point on the Step a. If no, replace load sense controller on
side of the mechanical end cap. Is it possible the primary pump.
to smoothly rotate the spanner for 15
degrees both ways? If yes, go to Step b. If no, a. Connect the hose connecting to port LS1 on
go to Step c. the main valve to the LS connection on the
primary pump. Plug port LS2 on main valve
b. Replace Electrical Activation Module (End and LS connection Primary pump. Measure
Cap). pressure on port MP and MLS1 with
running engine and no functions applied. Is
c. Replace the Directional Control Valve the difference between the pressure at MP
Section. and MLS1 greater than 2.8 MPa (406 psi)? If
yes, go to Step b. If no, replace load sense
THE TRUCK IS NOT CAPABLE TO LIFT control on the secondary pump.
RATED LOAD AT EXPECTED MAX LIFT
SPEED. b. Restore plumbing to original. Disconnect
load sense line between the primary pump
1. Measure pressure at MPLT. Is pressure and port LS1. Measure tilt relief pressure on
measured at MPLT with engine running below MLS2. Is relief pressure higher than
1.4 MPa (203 psi)? If yes, replace pilot supply 21 MPa (3,045 psi)? If yes, validate hydraulic
valve (F). If no, go to Step 2. controller settings (Flow settings). If no,
replace pressure controller secondary
2. Measure pressure at MLS2 and Mlift during variable displacement pump.
lift. Is measured pressure at MLS2 lower than
at Mlift? If yes go to Step a. If no, go to Step 3. TILT FUNCTION SHAKES.
a. Are there external oil leakages in the 1. Are tilt cylinders correctly aligned and pivot
hydraulic system? If yes, fix leakages. points in correct conditions? If yes, go to Step a.
Replace load sense controller on secondary If no, fix mechanical conditions.
pump. If no, go to Step b.
a. Is the Hydraulic Oil free of air? If yes,
b. Is steer relief pressure measured at MLS1 replace counterbalance valve. If no, go to
higher than 15 MPa (2175 psi), refer to Step b
Steering System 1600SRM1479). If no,
replace load sense controller on the primary b. Does air/oil flow occur in drain line when
pump. extending the lift cylinder completely? If yes,
repair lift cylinder piston seals. If no, repair
3. Measure the pressure at MLS2 while back leaks in the pump suction lines.
tilting over relief. Is the relief pressure above
21 MPa (3,046 psi)? If yes, go to Step a IT IS NOT POSSIBLE TO LOWER THE
MAST WITH IGNITION KEY TURNED TO
a. Is steer relief measured at MLS1 above
ON.
15 MPa (2175 psi), refer to Steering
System 1600SRM1479. If yes, go to Step 5. 1. Validate if correct voltage signal is supplied to
If no, go to Step 4. selector valve (B). Is voltage signal supplied to
selector valve (B)? If yes, unscrew the coil of the
4. Is engine loaded when tilt relief is applied? If lift pressure selector valve (B). Is the coil
yes, replace Full Flow Relief Valve (G). If no, magnetized when activated? If yes, replace lift
replace Load Sense Relief Valve (H). pressure selector valve (B) cartridge. If no,
replace coil. .
42
1900 SRM 2132 Torque Specifications
STEER AND BRAKE ACCUMULATOR THE TRUCK IS HYDRAULICALLY LOADED

CHARGE FUNCTION DOES NOT DURING ENGINE START. ACCUMULATOR
OPERATE. CHARGE AND STEERING IS POSSIBLE
1. Is calibration switch (located in side console DURING XMSN CALIBRATION.
cab) in correct position? If yes, go to Step a. If 1. Unscrew the coil of the load sense selector
no, switch calibration switch. valve (D). Is the coil magnetized when
activated? If yes, replace load sense selector
a. Remove the coil of the load sense selector valve (D) cartridge. If no, replace coil.
valve (D). Do both functions operate normal?
If yes, go to . If no, replace load sense
selector valve (D).
b. When truck is running, is the coil supplied

with 24 volts? If yes, check wiring. If no,
replace coil
Torque Specifications
TORQUE SPECIFICATIONS Lift Pressure Selector Valve (B)
35 to 40 N•m (26 to 30 lbf ft)
Priority Valve (A)
217 to 231 N•m (160 to 170 lbf ft) Coil Retaining Nut for Lift Pressure Selector
Valve (B)
Check Valve (K) 4-6 N•m (35-53 lbf in)
27 to 34 N•m (20 to 25 lbf ft)
Solenoid Capscrews
Check Valve (L) 6.3 N•m (56 lbf in)
122 to 136 N•m (90 to 100 lbf ft)
Mount Capscrews
Check Valve (Q) 14 N•m (124 lbf in)
9 to 12 N•m (7 to 9 lbf ft)
Pump Flangehead Screws
Shuttle Valves 46 to 49 N•m (34 to 36 lbf ft)
26 to 30 N•m (34 to 40 lbf ft)
Pump to Motor Capscrews
Full Flow Relief Valve (C) and (G) 25 N•m (221 lbf in)
217 to 231 N•m (169 to 170 lbf ft)
Suction Hose Adapter to Hydraulic Pump
Pilot Supply Valve (F) 91 to 100 N•m (67 to 74 lbf ft)
45 to 50 N•m (33 to 37 lbf ft)
Pressure Line Fitting to Hydraulic Pump
Load Sense Selector Valve (D) 49 to 59 N•m (36 to 44 lbf ft)
35 to 40 N•m (26 to 30 lbf ft)
Counterbalance Valves
Coil Retaining Nut for Load Sense Selector 60 N•m (44.3 lbf ft)
Valve (D)
4-6 N•m (35-53 lbf in)
43
NOTES
44
TECHNICAL PUBLICATIONS
1900 SRM 2132 12/17

Hydraulic System

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Hydraulic System

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HYDRAULIC SYSTEM

PART NO. 4220156 1900 SRM 2132

©2017 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

Series Code / Model Designation Reference Table

Series Code European Model Americas Model

Description and Operation

1. SIDESHIFT/PPS MANIFOLD BLOCK

Figure 1. Component Location on the Attachment

1. LOWERING CONTROL VALVE 7. LOAD SENSE CONTROLLER ON PUMP

Figure 2. Hydraulic Component Location on the Truck

Figure 3. Hydraulic Schematic Base Truck

Legend for Figure 3.

1. HYDRAULIC TANK 17. LOAD SENSE RELIEF VALVE (H)

Displacement pump, which would cause system

Component Functionality Test Component Functionality Test

Component Functionality Test Component Functionality Test

RELIEF VALVE When the pump pressure is greater than the

DIRECTIONAL CONTROL VALVE

ELECTRICAL ACTUATION MODULE (Only included in directional control valve

Component Functionality Test

When not operated, the four check valves prevent

Figure 6. Counterbalance Valve Schematic

VARIABLE DISPLACEMENT PUMP

Basic Functional Operation

PRESSURE CONTROL VALVE

Operation 1. LOAD SENSE VALVE

LOAD SENSE PRESSURE REGULATOR regulator is controlled by:

Fundamentals 1. The output pressure of the pump.

7. Lift the complete assembly hydraulic plate and

WARNING 10. Place the hydraulic control valve on a flat

1. NUT 8. EMERGENCY LOWERING VALVE

Figure 9. Hydraulic Control Valve Removal

Clean 3. If any of these components fail inspection,

WARNING NOTE: When reinstalling the threaded stud into

2. Check threads on all ports, capscrews, and

Figure 10. Main Control Valve Disassembly and Assembly

Legend for Figure 10.

1. NUT 7. BRAKE CONTROL MANIFOLD

Install 6. Release the clamps of the suction hoses at the

CAUTION 8. Check all components that were disassembled

PRIORITY VALVE (A) Install

1. MAIN CONTROL VALVE 9. LOAD SENSE SELECTOR VALVE (D)

Figure 11. Main Control Valve, Mid-Section

Component Functionality Test

2. Torque Check Valve (I) to

1. PRIORITY VALVE (A)

Figure 12. Priority Valve (A)

Component Functionality Test

2. Torque Check Valve (K) to

CHECK VALVE (Q) SHUTTLE VALVES (L) AND (M)

Component Functionality Test Component Functionality Test

SCREEN CARTRIDGE (O)

Component Functionality Test

2. Torque screen cartridge (O) to

Figure 14. Screen (O)

Component Functionality Test

2. Torque Logic Valve to

Figure 15. Shuttle Valves