Hyster Fortis S40FT User manual

Hyster U005 (H80FT, H90FT, H100FT, H110FT,
H120FT) Forklift Service Repair Manual

MAIN CONTROL VALVE
WITH VARIABLE
DISPLACEMENT PUMP
S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
[J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, H120FT) [U005]
PART NO. 4128559 2000 SRM 1899

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 in-
structions 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 ex-
ceed 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 flamma-
ble. 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.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Main Control Valve Repair .....................................................................................................................................3
Remove ................................................................................................................................................................ 3
Main Control Valve Sections ..............................................................................................................................5
General ............................................................................................................................................................5
Outlet Control Valve Section ......................................................................................................................... 5
Remove ........................................................................................................................................................5
Disassemble ................................................................................................................................................ 5
Clean ........................................................................................................................................................... 7
Inspect .........................................................................................................................................................7
Assemble ..................................................................................................................................................... 7
Install ..........................................................................................................................................................7
Auxiliary Control Valve Section .................................................................................................................... 7
Remove ........................................................................................................................................................7
Disassemble ................................................................................................................................................ 9
Clean ........................................................................................................................................................... 9
Inspect .........................................................................................................................................................9
Assemble ................................................................................................................................................... 10
Install ........................................................................................................................................................10
Tilt Control Valve Section ............................................................................................................................ 10
Remove ......................................................................................................................................................10
Disassemble .............................................................................................................................................. 10
Clean ......................................................................................................................................................... 11
Inspect .......................................................................................................................................................12
Assemble ................................................................................................................................................... 12
Install ........................................................................................................................................................12
Lift/Lower Control Valve Section .................................................................................................................12
Remove ......................................................................................................................................................12
Disassemble .............................................................................................................................................. 12
Clean ......................................................................................................................................................... 13
Inspect .......................................................................................................................................................14
Assemble ................................................................................................................................................... 14
Install ........................................................................................................................................................14
Transition Section .........................................................................................................................................14
Remove ......................................................................................................................................................14
Disassemble .............................................................................................................................................. 14
Clean ......................................................................................................................................................... 14
Inspect .......................................................................................................................................................15
Assemble ................................................................................................................................................... 16
Install ........................................................................................................................................................16
Install .................................................................................................................................................................16
Pressure Relief Valve Check and Adjustment .....................................................................................................20
General .............................................................................................................................................................. 20
Secondary Relief Valve ..................................................................................................................................... 20
Steering Control Unit Repair ............................................................................................................................... 22
Remove .............................................................................................................................................................. 22
Disassemble .......................................................................................................................................................22
Clean ..................................................................................................................................................................26
Inspect ............................................................................................................................................................... 26
Assemble ............................................................................................................................................................26
Table of Contents
i

TABLE OF CONTENTS (Continued)
Install .................................................................................................................................................................27
System Relief Valve .......................................................................................................................................... 28
Disassemble .................................................................................................................................................. 28
Clean ..............................................................................................................................................................28
Inspect ........................................................................................................................................................... 28
Assemble ....................................................................................................................................................... 28
Accumulator Replacement ....................................................................................................................................29
Remove .............................................................................................................................................................. 29
Install .................................................................................................................................................................30
This section is for the following models:
S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, H120FT)
[U005]
Table of Contents
ii

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General
This section contains a description and repair
procedures for a electro-hydraulic main control
valve with variable displacement pump used in the
hydraulic system for this series of lift trucks.
The electro-hydraulic (E-Valve) main control valve
is controlled electronically. It is mounted to the
cowl using three mounting bolts. See Figure 1.
NOTE: MAJOR COMPONENTS NOT SHOWN FOR
CLARITY. VIEW IS FROM THE FRONT.
1. COWL
2. INSERT
3. WASHER
4. MOUNTING CAPSCREW
5. MAIN CONTROL VALVE
6. FRAME
Figure 1. Main Control Valve Mounting
The E-Valve with variable displacement pump
(VDP) is electronically-controlled, closed-center,
single function compensated, and utilizes parallel
hydraulic circuitry. Load sensing is done through
the VDP. Operating multiple functions
simultaneously will result in a non-proportionate
increase in pump flow to functions which receive
the lowest amount of pressurized fluid. The
hydraulic circuitry will incorporate dual pressure
relief logic.
Lift function pressure is regulated by the pump
pressure compensator. The pump compensator will
be set to the maximum system pressure and a
clipper relief valve will be present in the transition
section of the valve and set slightly higher. The
clipper relief valve adjustment is tamper proof. Tilt
and auxiliary functions are on secondary relief
pressure setting. Lift pressure is not affected by
secondary relief operation.
The electronic main control valve with variable
displacement pump assembly is divided into the
following sections (see Figure 2):
• Steering Control Unit (SCU)
• Transition section
• Lift/Lower section
• Tilt section
• Auxiliary section(s)
• Outlet section
2000 SRM 1899 General
1

NOTE: FOUR FUNCTION CONTROL VALVE SHOWN.
1. STEERING CONTROL UNIT (SCU)
2. SCU MOUNTING CAPSCREW
3. CLIPPER RELIEF VALVE WITH TAMPER
PROOF CAP
4. LIFT/LOWER SECTION
5. PROPORTIONAL PRESSURE REDUCING
VALVE (PPRV)
6. TILT SECTION
7. SECONDARY RELIEF VALVE
8. AUXILIARY I SECTION
9. AUXILIARY II SECTION
10. ACCUMULATOR PORT
11. EMERGENCY LOWERING VALVE
12. TRANSITION SECTION
13. LOAD SENSING (LS) PORT
14. EF PORT
Figure 2. Electronic Control Valve With Variable Displacement Pump
General 2000 SRM 1899
2

Main Control Valve Repair
REMOVE
WARNING
Lower carriage completely before working on con-
trol valve or hydraulic system. DO NOT work un-
der a raised carriage. Put mast in a vertical posi-
tion, with no forward or back tilt, and lower car-
riage completely before disconnecting any parts
of hydraulic system. The mast can lower suddenly
and cause injury if the carriage is not lowered.
NOTE: Most of the individual valve components
can be removed and replaced while the control
valve is installed in the truck. Removal of the con-
trol valve for repairs is normally only required to
replace a valve section, or to replace the O-rings be-
tween the sections.
1. Power wash the interior of the operator com-
partment to remove any dirt or debris.
2. Move truck to disassembly area and shut off en-
gine.
WARNING
Cleaning solvents can be flammable and toxic and
cause skin irritation. When cleaning solvents are
used, always follow the solvent manufacturer’s
recommended safety procedures. Wear protective
goggles or a face shield to prevent eye injuries.
WARNING
Be careful when cleaning with steam. Steam can
cause serious burns. Wear protective clothing,
gloves, and eye protection. Never expose your
skin to steam.
NOTE: Take all necessary steps to prevent debris,
dust, or other contaminants from entering the valve
cavities, hydraulic lines, or replacement parts.
3. Remove the floor plate, kick panel, seal plate,
and dashboard. See Frame 0100SRM1891 for
the procedures.
4. Before disconnecting any hydraulic hoses or re-
moving any parts from the control valve, clean
the outside of the valve either by steam clean-
ing or with cleaning solvent.
5. To remove the accelerator pedal or MONO-
TROL® pedal assembly, disconnect the cowl
wiring harness from the pedal assembly wiring
harness and remove three mounting capscrews.
See Figure 3.
NOTE: To aid in installation, tag all connectors
prior to disconnecting from the solenoids.
6. Disconnect the cowl wiring harness from the
top auxiliary function Proportional Pressure
Reducing Valve (PPRV) solenoids. See Figure 4.
NOTE: ACCELERATOR PEDAL NOT SHOWN,
HOWEVER, REMOVAL IS THE SAME.
1. MOUNTING CAPSCREW
2. MONOTROL PEDAL ASSEMBLY
3. PEDAL ASSEMBLY WIRING HARNESS
Figure 3. MONOTROL Pedal Removal
2000 SRM 1899 Main Control Valve Repair
3

CAUTION
To prevent any foreign matter from getting into ei-
ther the hydraulic hoses or the hydraulic control
valve sections, all openings must have plugs or
covers installed immediately after hoses are dis-
connected from the control valve. This also ap-
plies if any other items are removed from the con-
trol valve.
NOTE: To aid in correctly connecting hydraulic ho-
ses during installation, tag each hose prior to dis-
connecting from the control valve.
7. Disconnect hydraulic hoses from the control
valve. See Figure 4. Install plugs or caps on all
open hose ends and control valve ports to pre-
vent contamination.
8. Remove the two SCU mounting capscrews and
move the SCU approximately 1.3 cm (0.5 in.) to
the left. Lower the SCU until the steering shaft
is disengaged. Remove the SCU from the lift
truck. See Figure 4.
9. Remove and discard three O-rings located be-
tween the transition section and the SCU.
1. STEERING SYSTEM HOSES
2. HYDRAULIC INLET HOSE
3. STEERING CONTROL UNIT (SCU)
4. STEERING SHAFT
5. SCU MOUNTING CAPSCREWS
6. LOAD SENSE LINE
7. LIFT/LOWER HOSE
8. TILT HOSE
9. AUXILIARY I HOSE
10. AUXILIARY II HOSE
11. ACCUMULATOR
12. RETURN HOSE
13. AUXILIARY FUNCTION PROPORTIONAL
PRESSURE REDUCING VALVE HARNESS
(PPRV)
14. VEHICLE SYSTEMS MANAGER
Figure 4. Hydraulic Hose Removal
Main Control Valve Repair 2000 SRM 1899
4