Hyster E210 Operating instructions

Hyster E210 (V30ZMD) Forklift

ELECTRO-HYDRAULIC
CONTROL VALVE
J2.00-3.20XM (J40-65Z) [B416];
E1.50-2.00XM (E25-35Z, E40ZS) [F114];
E2.00-3.20XM (E45-65Z) [G108];
V30ZMD [E210]; E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) [E098]
PART NO. 1616865 2000 SRM 1224

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
•Donotliftheavypartsbyhand,usealiftingmechanism.
•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.

Electro-Hydraulic Control Valve Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Electro-Hydraulic Control System................................................................................................................ 1
Electro-Hydraulic Control Valve................................................................................................................... 4
Electro-Hydraulic Valve Driver Module ....................................................................................................... 21
Mini-Lever Module (MLM)............................................................................................................................ 22
Joystick........................................................................................................................................................... 23
Electro-Hydraulic Control Valve Repair........................................................................................................... 23
Remove ........................................................................................................................................................... 23
Disassemble ................................................................................................................................................... 33
Solenoid Coil Replacement ....................................................................................................................... 35
Cartridge Replacement ............................................................................................................................. 39
Electro-Hydraulic Pressure Reducing Valve (EHPR) Replacement ....................................................... 40
Lift Circuit Check Valve Replacement ..................................................................................................... 40
Compensator Cartridge Replacement ...................................................................................................... 41
Primary and Secondary Relief Valves Replacement ............................................................................... 41
Tilt Counterbalance Valve Replacement.................................................................................................. 41
Flow Regulator Valve Replacement.......................................................................................................... 42
Assemble ........................................................................................................................................................ 42
Install ............................................................................................................................................................. 42
E-Hydraulics Calibration .............................................................................................................................. 50
Mini-Lever Module............................................................................................................................................. 52
Mini-Lever Module (MLM)............................................................................................................................ 52
Remove....................................................................................................................................................... 52
Install......................................................................................................................................................... 52
Mini-Lever Replacement ............................................................................................................................... 52
Remove....................................................................................................................................................... 52
Clean and Inspect...................................................................................................................................... 53
Install......................................................................................................................................................... 53
Push Button Switch Replacement ................................................................................................................ 54
Remove....................................................................................................................................................... 54
Install......................................................................................................................................................... 55
Test ................................................................................................................................................................. 56
Mini-levers................................................................................................................................................. 56
Full Stroke Test ......................................................................................................................................... 56
Function Returns to Neutral Test ............................................................................................................ 56
Push Button Switch .................................................................................................................................. 57
Joystick........................................................................................................................................................... 57
Remove and Disassemble.......................................................................................................................... 57
Inspect........................................................................................................................................................ 57
Assemble and Install................................................................................................................................. 57
Troubleshooting.................................................................................................................................................. 58
This section is for the following models:
J2.00-3.20XM (J40-65Z) [B416];
E1.50-2.00XM (E25-35Z, E40ZS) [F114];
E2.00-3.20XM (E45-65Z) [G108];
V30ZMD [E210];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098]
©2008 HYSTER COMPANY i

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QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

2000 SRM 1224 Description
General
This section has a description and the repair procedures for the Electro-Hydraulic control valve.
Description
ELECTRO-HYDRAULIC CONTROL
SYSTEM
The electro-hydraulic control system controls all hy-
draulic functions, to include, lift/lower, tilt, and aux-
iliary functions. The system consists of the following
components:
•Electro-Hydraulic Control Valve
•Electro-Hydraulic Valve Driver Module
•Mini-Levers or Joystick controls
•Vehicle Master Controller
•Hydraulic Pump Motor Controller
•Dash Display
•Pump Motor and Fixed Displacement Gear Pump
•Operator’s Seat and Armrest
•PC Based Service Software (ETACC)
See Figure 1, Figure 2, or Figure 3 for component
location. The vehicle master controller, electro-hy-
draulic valve driver module, mini-levers or joystick
controls, and hydraulic pump motor controller
communicate with each other via the CANbus com-
munication system. The master controller controls
the hydraulic pump motor and the electro-hydraulic
control valve based upon the inputs received from
the mini levers or joystick controls. The master
controller converts the operator’s input into con-
trolled oil flow by simultaneously commanding the
hydraulic pump motor controller to deliver a specific
motor speed, and by commanding the electro-hy-
draulic valve drive module to deliver specific valve
metering. Pump speed is variable up to the maxi-
mum speed preset in the master controller for the
required hydraulic function. See Figure 4.
1. TRACTION MOTOR
2. DRIVE WHEEL
3. ELECTRO-HYDRAULICS CONTROL VALVE
4. ELECTRO-HYDRAULICS VALVE DRIVER
MODULE
5. MINI-LEVER HYDRAULIC CONTROL CONSOLE
6. HYDRAULIC OIL TANK
7. STEER WHEEL
8. HYDRAULIC PUMP MOTOR
9. STEERING PUMP MOTOR
10. OPERATOR SEAT
Figure 1. Component Location J2.00-3.20XM
(J40-65Z) (B416)
1

Description 2000 SRM 1224
1. DRIVE AXLE
2. DRIVE WHEEL
3. ELECTRO-HYDRAULICS CONTROL VALVE
4. MINI-LEVER HYDRAULIC CONTROL CONSOLE
5. TRACTION MOTOR
6. COUNTERWEIGHT
7. OPERATOR SEAT
8. MASTER CONTROLLER
9. ELECTRO-HYDRAULICS VALVE DRIVER
MODULE
10. STEERING PUMP MOTOR
Figure 2. Component Location E2.00-3.20XM
(E45-65Z) (G108); V30ZMD (E210)
1. DRIVE AXLE
2. DRIVE WHEEL
3. ELECTRO-HYDRAULIC CONTROL VALVE
4. ELECTRO-HYDRAULIC VALVE DRIVER
5. MINI-LEVER HYDRAULIC CONTROL CONSOLE
6. HYDRAULIC TANK FILL
7. STEERING WHEEL
8. STEERING PUMP MOTOR
9. TRACTION MOTOR
10. HYDRAULIC OIL FILTER
11. OPERATOR SEAT
12. COUNTERWEIGHT
Figure 3. Component Location for Lift Truck
Model E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
2

2000 SRM 1224 Description
Figure 4. Logic Diagram - Electro-Hydraulic Controls
3

Description 2000 SRM 1224
ELECTRO-HYDRAULIC CONTROL VALVE
The electro-hydraulic control valve is modular in de-
sign. Two valve blocks are stacked together to as-
semble a three- or four-function valve assembly. See
Figure 5 and Figure 6. The main block consists of lift
and tilt sections. The additional block consists of ei-
ther a single or double auxiliary hydraulic functions.
The following electro-hydraulic control valve options
are available:
•3 function (single auxiliary) standard flow 23 liter/
min (6 gal/min)
•4 function (dual auxiliary) standard flow 23 liter/
min (6 gal/min)
•4 function (dual auxiliary) high flow 40 liter/min
(10.5 gal/min)
•3 function (single auxiliary) high flow for lift
truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) only 57 liter/min (15 gal/min)
•4 function (dual auxiliary) high flow for lift
truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) only 38 liter/min (10 gal/min)
Figure 5. Electro-Hydraulic Control Valve Assembly for Lift Truck Models J2.00-3.20XM (J40-65Z)
(B416), E2.00-3.20XM (E45-65Z) (G108), E1.50-2.00XM, E2.00XMS (E25-35Z, E40ZS) (F114), and
V30ZMD (E210)
4

2000 SRM 1224 Description
Legend for Figure 5
1. ELECTRO-HYDRAULIC PRESSURE REDUCING
VALVE (EHPR)
2. CARTRIDGE (TILT, STANDARD FLOW
AUXILIARY)
3. COIL RETAINING NUT
4. TWO-PIECE SOLENOID VALVE
5. SPACER
6. PUMP PRESSURE PORT
7. MAIN VALVE SECTION
8. LIFT CIRCUIT CHECK VALVE
9. COMPENSATOR VALVE
10. PRIMARY RELIEF VALVE (SEE TABLE 1)
11. SINGLE SECTION SOLENOID VALVE
12. LOWERING CARTRIDGE AND MANUAL
LOWERING VALVE
13. FITTING
14. HOSE NIPPLE
15. LIFT CARTRIDGE
16. TILT COUNTERBALANCE VALVE
17. SECONDARY RELIEF VALVE (SEE TABLE 1)
18. PROPORTIONAL PILOT-OPERATED VALVE
19. CAPSCREW
20. AUXILIARY VALVE SECTION FUNCTIONS 3
AND 4 (HIGH FLOW)
21. AUXILIARY VALVE SECTION FUNCTIONS 3
AND 4 (STANDARDFLOW)
22. AUXILIARY VALVE SECTION FUNCTION 3
(STANDARD FLOW)
23. FLOW REGULATOR VALVE
24. PRESSURE PORT (P)
25. STEERING RETURN PORT (T2)
26. MAST PORT (M)
27. TANK PORT (T)
28. TILT ROD PORT (2B)
29. TILT ROD PORT (2A)
30. AUXILIARY WORK PORT (4A)
31. AUXILIARY WORK PORT (3A)
5

Description 2000 SRM 1224
1. PILOT OPERATED SOLENOID VALVE (EHPR)
2. PRIORITYCOMPENSATORVALVE(EC1)
3. PROPORTIONAL SOLENOID VALVE (SP1 AND
SP2)
4. COIL (CL1)
5. LOWERING COMPENSATOR VALVE (EC2)
6. CHECK VALVE LIFT CIRCUIT (CV1)
7. KNOB (KN1)
8. MANUAL LOWERING VALVE (NV1)
9. DIAGNOSTIC COUPLING (TP1)
10. COUNTERBALANCED CARTRIDGE
11. FLOW REGULATOR VALVE (FR1)
12. PRIMARY RELIEF VALVE (SEE TABLE 1) (RV1)
13. PROPORTIONAL PILOT OPERATED VALVE
(PE1)
14. MAIN VALVE SECTION
15. FITTING
16. HOSE NIPPLE
17. SECONDARY RELIEF VALVE (SEE TABLE 1)
(RV2)
18. SINGLE AUXILIARY VALVE SECTION (HIGH
FLOW)
19. DOUBLE AUXILIARY VALVE SECTION (HIGH
FLOW)
20. MAST PORT (1A)
21. PRESSURE PORT (P)
22. TILT ROD PORT
23. STEERING RETURN PORT (T1)
24. AUXILIARY WORK PORT (3A)
25. TILT ROD PORT (2A)
26. AUXILIARY WORK PORT (4A)
Figure 6. Electro-Hydraulic Control Valve Assembly for Lift Truck Model E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
6

2000 SRM 1224 Description
Table 1. Primary and Secondary Relief Valve Values
Hydraulic Control
Valve Lift Truck Model Primary Relief Pressure Secondary Relief Pressure
Valve Assembly 3
Function Standard Flow E1.50-2.00XM (E25-35Z,E40ZS) (F114) 17.9MPa(2600psi) 15.5 MPa (2250 psi)
Valve Assembly 3
Function Standard Flow J2.00-3.20XM (J40-65Z) (B416), E2.00-3.20
(E45-65Z) (G108),
V30ZMD (E210)
22.7MPa(3300psi) 15.5 MPa (2250 psi)
Valve Assembly 4
Function Standard Flow E1.50-2.00XM (E25-35Z,E40ZS) (F114) 17.9MPa(2600psi) 15.5 MPa (2250 psi)
Valve Assembly 4
Function Standard Flow J2.00-3.20XM (J40-65Z) (B416), E2.00-3.20
(E45-65Z) (G108),
V30ZMD (E210)
22.7MPa(3300psi) 15.5 MPa (2250 psi)
Valve Assembly 4
Function High Flow E1.50-2.00XM (E25-35Z,E40ZS) (F114) 17.9MPa(2600psi) 15.5 MPa (2250 psi)
Valve Assembly 4
Function High Flow J2.00-3.20XM (J40-65Z) (B416), E2.00-3.20
(E45-65Z) (G108),
V30ZMD (E210)
22.7MPa(3300psi) 15.5 MPa (2250 psi)
Valve Assembly 3 and 4
Function
(High Flow)
E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098) 22.06 ±0.7 MPa (3200 ±100 psi) 15.5 ±0.7 MPa (2250 ±100 psi)
7

Description 2000 SRM 1224
The electro-hydraulic control valve is a fully-propor-
tional, closed centered valve. The circuit was de-
signed for an on-demand variable pumping system.
A priority flow compensator divides the circuit into
a primary and secondary circuit. The primary cir-
cuit is protected at the inlet port by a direct acting,
differential area relief valve. The secondary circuit
pressure is limited by a secondary relief valve.
Control of velocity for the hoist function primarily
comes from the fixed displacement pump running at
variable speed proportional to the operator’s input
or demand. The lift flow has priority over the aux-
iliary functions because of the priority flow compen-
sator on the inlet port. If a second function is oper-
ated simultaneously with the lift function, the pro-
portional valve in the lift circuit will control the lift
velocity and the pump rotational speed is increased
so the input flow exceeds the demand for hoist flow.
The inlet compensator provides priority to the hoist
function regardless of the load pressure in either the
primary circuit or the secondary circuit.
The opening of the lowering solenoid valve controls
lowering velocity. The valve is compensated by the
lowering compensator. This results in a consistent
lowering speed for a given input regardless of load
pressure.
The opening of the tilt solenoid valve combined with
the pump speed controls the velocity of the tilt func-
tion.
Overrunning load and load holding of the tilt func-
tion is controlled by the counterbalance valve CB1.
The valve has a 3:1 pilot ratio which reduces the
amount of pressure required to open the valve when
tilting forward. The counterbalance valve has an in-
ternal bypass check valve which allows the tilt back
with minimal resistance. The inherent low leakage
of the counterbalance valve holds the tilt function in
place when under load.
The standard flow auxiliary valves are also propor-
tional valves similar to the tilt valve.
The high flow auxiliary valves are pilot operated pro-
portional directional control valves. The opening of
the valves is proportional to the pilot pressure ap-
plied to the ends of the spool. The EHPR proportional
pressure reducing/relieving valves provide the pilot
pressure. There are two EHPR valves per auxiliary
function. The directional valves are internally pres-
surecompensated.SeeFigure7,Figure8,Figure9,
and Figure 10.
Legend for Figure 7
1. AUXILIARY 2 VALVE (SP5)
2. AUXILIARY 1 VALVE (SP4)
3. TILT CYLINDERS
4. LIFT CYLINDER
5. SECONDARY LOWERING CONTROL INTEGRAL
WITH LIFT CYLINDERS
6. PRIMARY LOWERING CONTROL (MOUNTED
ON MAST)
7. STEERING CYLINDER
8. STEERING WHEEL
9. STEERING CHECK PORT
10. STEERING CONTROL UNIT
11. HAND PUMP
12. STEERING VALVE
13. MAIN CONTROL VALVE
14. STEERING PUMP
15. STEERING RELIEF VALVE
16. HYDRAULIC TANK
17. HYDRAULIC FILTER
18. HYDRAULIC PUMP
19. PRIMARY RELIEF VALVE (RV1)
20. SECONDARY RELIEF VALVE (RV2)
21. TILT SOLENOID VALVE (SP3)
22. LIFT SOLENOID VALVE (SP1)
23. PRIORITY COMPENSATOR VALVE (EC1)
24. LOWERING COMPENSATOR VALVE (EC2)
25. TILT COUNTERBALANCE VALVE (CB1)
26. CHECK VALVE LIFT CIRCUIT (CV1)
27. FLOW REGULATOR VALVE (FR1)
28. LOWER SOLENOID VALVE WITH MANUAL
OVERRIDE (SP2)
29. GAUGE PORT
30. AUXILIARY VALVE SECTION
8

2000 SRM 1224 Description
Figure 7. Electro-Hydraulic Control Valve Schematic (Standard Flow), all Trucks Except V30ZMD
(E210) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
9

Description 2000 SRM 1224
Figure 8. Electro-Hydraulic Control Valve Schematic (High Flow) for Lift Truck Models
J2.00-3.20XM (J40-65Z) (B416), E2.00-3.20XM (E45-65Z) (G108), and E1.50-2.00XM, E2.00XMS
(E25-35Z, E40ZS) (F114)
10

2000 SRM 1224 Description
Legend for Figure 8
1. PILOT-OPERATED SPOOL VALVE (PE1)
2. PILOT-OPERATED SPOOL VALVE (PE2)
3. TILT CYLINDERS
4. LIFT CYLINDER
5. SECONDARY LOWERING CONTROL INTEGRAL
WITH LIFT CYLINDERS
6. PRIMARY LOWERING CONTROL (MOUNTED
ON MAST)
7. STEERING CYLINDER
8. STEERING WHEEL
9. STEERING CHECK PORT
10. STEERING CONTROL UNIT
11. HAND PUMP
12. STEERING VALVE
13. MAIN CONTROL VALVE
14. STEERING PUMP
15. STEERING RELIEF VALVE
16. HYDRAULIC TANK
17. HYDRAULIC FILTER
18. HYDRAULIC PUMP
19. PRIMARY RELIEF VALVE (RV1)
20. SECONDARY RELIEF VALVE (RV2)
21. TILT SOLENOID VALVE (SP3)
22. LIFT SOLENOID VALVE (SP1)
23. PRIORITY COMPENSATOR VALVE (EC1)
24. LOWERING COMPENSATOR VALVE (EC2)
25. PILOT-OPERATED SOLENOID VALVE (EHPR1
THROUGH 4)
26. TILT COUNTERBALANCE VALVE (CB1)
27. FLOW REGULATOR VALVE (FR1)
28. LOWER SOLENOID VALVE WITH MANUAL
OVERRIDE (SP2)
29. CHECK VALVE LIFT CIRCUIT (CV1)
30. GAUGE PORT
31. AUXILIARY VALVE SECTION
11

Description 2000 SRM 1224
Figure 9. Hydraulic Schematic With Electro-Hydraulics for Lift Truck Model V30ZMD (E210)
12

2000 SRM 1224 Description
Legend for Figure 9
1. SINGLE ACTING PIVOT CYLINDER
2. ADJUSTABLE FLOW RESTRICTOR
3. LOCK/CROSS OVER RELIEF VALVE
4. TRAVERSE HYDRAULIC MOTOR
5. SIDESHIFT CYLINDER
6. LIFT CYLINDERS
7. SECONDARY LOWERING CONTROL
8. PRIMARY LOWERING CONTROL
9. STEERING CYLINDER
10. HAND PUMP
11. STEERING WHEEL
12. LINE PRESSURE TAP
13. CHECK PORT
14. STEERING PUMP
15. HYDRAULIC TANK
16. HYDRAULIC FILTER
17. HYDRAULIC PUMP
18. MAIN CONTROL VALVE
19. LOWERING COMPENSATOR VALVE (EC2)
20. LOWERING SOLENOID VALVE WITH MANUAL
OVERRIDE (SP2)
21. PRIORITY COMPENSATOR VALVE (EC1)
22. LIFT SOLENOID VALVE (SP1)
23. STEERING VALVE
24. PRIMARY RELIEF VALVE (RV1)
25. SECONDARY RELIEF VALVE (RV2)
26. FLOW REGULATOR VALVE (FR1)
27. TILT CYLINDER VALVE (SP3)
28. TILT COUNTERBALANCE VALVE (CB1)
29. CHECK VALVE LIFT CIRCUIT (CV1)
30. GAUGE PORT
31. PILOT OPERATED SOLENOID VALVE (EHPR 1
THROUGH 4)
32. PILOT OPERATED SPOOL VALVE (PE1)
33. PILOT OPERATED SPOOL VALVE (PE2)
34. AUXILIARY VALVE SECTION
13

Description 2000 SRM 1224
1. PILOT-OPERATED SPOOL VALVE (PE1)
(AUXILIARY 4)
2. PILOT-OPERATED SPOOL VALVE (PE2)
(AUXILIARY 3)
3. TILT CYLINDERS
4. LIFT CYLINDERS
5. SECONDARY LOWERING CONTROL
(INTEGRAL W/LIFT CYLINDERS)
6. PRIMARY LOWERING CONTROL (MOUNTED
ON MAST)
7. STEERING CYLINDER
8. STEERING WHEEL
9. STEERING CHECK PORT
10. STEERING CONTROL UNIT
11. HAND PUMP
12. STEERING VALVE
13. MAIN CONTROL VALVE
14. STEERING PUMP
15. STEERING RELIEF VALVE
16. HYDRAULIC TANK
17. HYDRAULIC FILTER
18. HYDRAULIC PUMP
19. PRIMARY RELIEF VALVE (RV1)
20. SECONDARY RELIEF VALVE (RV2)
21. PROPORTIONAL SOLENOID VALVE (LIFT) (SP1)
22. PROPORTIONAL SOLENOID VALVE
(LOWERING) (SP2)
23. PRIORITY COMPENSATOR VALVE (EC1)
24. LOWERING COMPENSATOR VALVE (EC2)
25.PILOT-OPERATEDSOLENOIDVALVE(EHPR1
THROUGH 6)
26. TILT COUNTER BALANCED VALVE (CBI)
27. FLOW REGULATOR VALVE (FRV)
28. MANUAL LOWERING VALVE (NV1)
29. CHECK VALVE LIFT CIRCUIT (CV1)
30. GAUGE PORT
31. AUXILIARY VALVE SECTION (DUAL AUXILIARY
VALVE SHOWN)
Figure 10. Hydraulic Schematic With Electro-Hyraulics for Lift Truck Models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098)
14