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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APPROVED
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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