This document provides repair procedures for manual and electronic main control valves used in hydraulic lift trucks. It describes:
- There are two main control valve types - manual and electronic. Both are mounted to the cowl.
- The electronic main control valve incorporates an emergency lowering valve and is divided into steering control, lift/lower, tilt, auxiliary, and outlet sections.
- Removal procedures include disconnecting wiring harnesses and hydraulic hoses, removing the steering control unit, and removing O-rings from the main control valve.
Hyster g004 (s120 ft) forklift service repair manualufjjsjkfkmsem
This document provides repair procedures for manual and electronic main control valves used in hydraulic lift trucks. There are two main types of control valves - manual and electro-hydraulic. The electro-hydraulic valve uses electronics to control lift, lower, tilt and auxiliary functions. It also has an emergency manual lowering valve. The document describes removing the control valve which involves disconnecting hydraulic hoses, electrical connectors, removing mounting bolts, and removing O-rings between valve sections. Safety precautions are provided when working on the hydraulic system and control valve.
Hyster e098 (e4.00 xl europe) forklift service repair manualdkddmdd
This document provides descriptions and repair procedures for a steering housing assembly and steering control unit. It consists of 3 sections: Description, Operation, and Steering Wheel and Column Assembly Repair. The description section outlines the components of the steering system including the steering column, control unit, and housing. It notes the system is hydraulic and does not have a mechanical connection between the steering wheel and axle. The operation section describes how the control unit directs hydraulic flow to move the steering cylinder. The repair section provides steps to remove and replace components like the steering wheel, column, and control unit.
Hyster d024 (s155 ft) forklift service repair manualfjjskkefksme
This document provides instructions for repairing the hydraulic gear pump assembly for various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid from the tank. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed. Reassembly involves installing new seals and plates and reattaching the housings. Finally, the pump is reinstalled on the transmission housing with fittings attached to hydraulic lines.
Hyster d024 (s135 ft) forklift service repair manualfusjfjskekmsme
This document provides instructions for repairing the hydraulic gear pump assembly for various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid from the tank. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed. Reassembly involves installing new seals and plates and reattaching the housings. Finally, the pump is reinstalled on the transmission housing with fittings attached to hydraulic lines.
Hyster d024 (s135 ft) forklift service repair manualfujsjefkksekmm
This document provides instructions for repairing the hydraulic gear pump assembly on various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed before reassembling the pump. Finally, the pump is reinstalled on the transmission housing with new fittings and fasteners. The repair procedures are similar for different pump types equipped on the listed lift truck models.
Hyster d024 (s155 ft) forklift service repair manualfusjejfjskekem
This document provides instructions for repairing the hydraulic gear pump assembly for various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid from the tank. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed. Reassembly involves installing new seals and plates and reattaching the housings. Finally, the pump is reinstalled on the transmission housing with fittings attached to hydraulic lines.
Hyster c098 (e120 xl3) forklift service repair manualfjskefkksem
This document provides descriptions and repair procedures for hydraulic brake systems on certain lift truck models. It describes the operation of brake boosters, master cylinders, and service brake assemblies. The brake booster on some models uses hydraulic pressure to multiply the force applied by the brake pedal. The master cylinder houses a piston that pushes brake fluid to wheel cylinders when the pedal is pressed. Service brake assemblies use wheel cylinders and shoe assemblies to slow the wheels. The document also covers parking brakes, seat brakes, and procedures for removing, cleaning, and inspecting brake components.
Hyster c098 (e80 xl3) forklift service repair manualjfjkskekfsmem
This document provides descriptions and repair procedures for hydraulic brake systems on certain lift truck models. It describes the operation of the brake booster and master cylinder, which differ between models. It also describes the service brake assembly, parking brake, and optional seat brake. The repair section provides instructions for removing and disassembling brake shoe assemblies, including warnings about the hazards of brake dust. Diagrams are included to illustrate the components.
Hyster g004 (s120 ft) forklift service repair manualufjjsjkfkmsem
This document provides repair procedures for manual and electronic main control valves used in hydraulic lift trucks. There are two main types of control valves - manual and electro-hydraulic. The electro-hydraulic valve uses electronics to control lift, lower, tilt and auxiliary functions. It also has an emergency manual lowering valve. The document describes removing the control valve which involves disconnecting hydraulic hoses, electrical connectors, removing mounting bolts, and removing O-rings between valve sections. Safety precautions are provided when working on the hydraulic system and control valve.
Hyster e098 (e4.00 xl europe) forklift service repair manualdkddmdd
This document provides descriptions and repair procedures for a steering housing assembly and steering control unit. It consists of 3 sections: Description, Operation, and Steering Wheel and Column Assembly Repair. The description section outlines the components of the steering system including the steering column, control unit, and housing. It notes the system is hydraulic and does not have a mechanical connection between the steering wheel and axle. The operation section describes how the control unit directs hydraulic flow to move the steering cylinder. The repair section provides steps to remove and replace components like the steering wheel, column, and control unit.
Hyster d024 (s155 ft) forklift service repair manualfjjskkefksme
This document provides instructions for repairing the hydraulic gear pump assembly for various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid from the tank. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed. Reassembly involves installing new seals and plates and reattaching the housings. Finally, the pump is reinstalled on the transmission housing with fittings attached to hydraulic lines.
Hyster d024 (s135 ft) forklift service repair manualfusjfjskekmsme
This document provides instructions for repairing the hydraulic gear pump assembly for various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid from the tank. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed. Reassembly involves installing new seals and plates and reattaching the housings. Finally, the pump is reinstalled on the transmission housing with fittings attached to hydraulic lines.
Hyster d024 (s135 ft) forklift service repair manualfujsjefkksekmm
This document provides instructions for repairing the hydraulic gear pump assembly on various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed before reassembling the pump. Finally, the pump is reinstalled on the transmission housing with new fittings and fasteners. The repair procedures are similar for different pump types equipped on the listed lift truck models.
Hyster d024 (s155 ft) forklift service repair manualfusjejfjskekem
This document provides instructions for repairing the hydraulic gear pump assembly for various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid from the tank. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed. Reassembly involves installing new seals and plates and reattaching the housings. Finally, the pump is reinstalled on the transmission housing with fittings attached to hydraulic lines.
Hyster c098 (e120 xl3) forklift service repair manualfjskefkksem
This document provides descriptions and repair procedures for hydraulic brake systems on certain lift truck models. It describes the operation of brake boosters, master cylinders, and service brake assemblies. The brake booster on some models uses hydraulic pressure to multiply the force applied by the brake pedal. The master cylinder houses a piston that pushes brake fluid to wheel cylinders when the pedal is pressed. Service brake assemblies use wheel cylinders and shoe assemblies to slow the wheels. The document also covers parking brakes, seat brakes, and procedures for removing, cleaning, and inspecting brake components.
Hyster c098 (e80 xl3) forklift service repair manualjfjkskekfsmem
This document provides descriptions and repair procedures for hydraulic brake systems on certain lift truck models. It describes the operation of the brake booster and master cylinder, which differ between models. It also describes the service brake assembly, parking brake, and optional seat brake. The repair section provides instructions for removing and disassembling brake shoe assemblies, including warnings about the hazards of brake dust. Diagrams are included to illustrate the components.
Hyster f007 h12.00 xm forklift service repair manualfujsjefjkskefksem
The document provides instructions for repairing the service frame, counterweight, fenders, hood, hydraulic tank, and other parts of a lift truck. It describes removing and installing the counterweight, fenders, and hydraulic tank. It also details cleaning and repairing the hydraulic tank, including procedures for small leaks, large leaks, and cleaning the tank using steam or chemical solutions. Welding repairs require disconnecting electronics to avoid damage.
Hyster d138 (n40 fr) forklift service repair manualfujsjefjkskefksem
This document provides repair procedures for single and double reach carriages on lift trucks. It describes the components of the reach carriages, including the inner and outer frames connected by scissor linkages. It also describes the hydraulic systems that control the reach, tilt, and optional side-shift functions. The summary provides repair procedures for replacing parts like forks, the load backrest extension, and removing/disassembling the side-shift frame.
Hyster d010 (s25 xm) forklift service repair manualfujsjefjkskefksem
The document provides an overview of the components and operation of a single-speed powershift transmission, including:
1) The transmission contains forward and reverse clutch assemblies, a torque converter, transmission pump, control valve, and differential assembly to transfer power from the engine to the wheels.
2) The torque converter uses fluid coupling between an impeller and turbine to transfer power from the engine to the transmission, and can multiply engine torque through a stator clutch mechanism.
3) The forward and reverse clutch assemblies use hydraulic pressure to engage friction discs and transfer power between the input shaft and either the forward or reverse gears to select transmission direction.
Hyster d005 (h110 e europe) forklift service repair manualfujsjefjkskefksem
This document provides instructions for servicing GM engines. It describes removing and installing the cylinder head and valve mechanism. Key steps include using a compressor tool to remove the valve springs, cleaning carbon from the combustion chambers, inspecting the valves and valve guides for wear, and checking clearances. The valve seats can be repaired with a cutter tool if damaged, or the cylinder head replaced if not repairable. Rocker arm studs should also be replaced if damaged.
Hyster c187 (s60 xl) forklift service repair manualfujsjefjkskefksem
This document provides instructions for disassembling and repairing a Ross HydraGuide steering control unit. It describes the unit's control valve and metering sections. The disassembly process is outlined step-by-step and cautions safety hazards. Components are identified in an illustrated parts list. A fixture is shown for securely holding the unit during disassembly.
Hyster a917 (h970 hds) forklift service repair manualfujsjefjkskefksem
This document provides repair procedures for differentials used in lift trucks. It describes the components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures describe how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Safety precautions are provided and components are labeled in diagrams.
Cummins onan generator set with power command 3100 controller model (dfed ) s...fujsjefjkskefksem
This document is a service manual that provides information for troubleshooting and servicing generator sets equipped with PowerCommand 3100 controllers. It includes sections on control operation, circuit boards and modules, troubleshooting, control service and calibration, servicing the generator, day tank fuel transfer pumps, optional enclosure fuel tank systems, and wiring diagrams. The manual contains important safety instructions and details regarding the various components, their functions, and maintenance/repair procedures.
This document provides service information for W8, W9, and W10 series E loaders. It includes sections on general engine specifications, maintenance and lubrication schedules, engine systems like fuel, cooling, and electrical. It also covers other vehicle systems like power train, steering, brakes, and hydraulics. The document provides information on maintenance intervals, recommended lubricants, fluid capacities, and procedures for servicing components.
New holland w270 c tier 4 wheel loader service repair manualfujsjefjkskefksem
This document is a service manual for a wheel loader that provides specifications and repair instructions. It contains sections on the engine, transmission, drivetrain, brakes, hydraulics, frames, steering, wheels, climate control, electrical systems, loader attachments, cab, and safety features. Torque specifications are provided for decimal hardware.
New holland w190 d zbar eh, new cab tier 4b wheel loader service repair manualfujsjefjkskefksem
This document is a service manual for a Stage IV Wheel Loader. It provides part numbers and specifications for removing the engine. The 3-step process includes draining fluids, removing panels to access the engine, and using straps to lift the engine hood and remove tension on the lifting motor. Safety precautions and instructions are included throughout.
New holland w170 c wheel loader service repair manualfujsjefjkskefksem
This section provides instructions for removing and installing the engine and radiator on a W170C Wheel Loader. The engine removal process involves disconnecting battery cables, draining fluids, removing mounted components, and lifting the engine out. Installation is the reverse of removal. Radiator removal involves draining coolant and removing mounting hardware, while installation reconnects hoses and mounts the radiator.
Case 1121 g tier 2 wheel loader service repair manualfujsjefjkskefksem
This 3-page service manual provides maintenance instructions for CNH Industrial Italia S.p.A. wheel loaders models 1021G and 1121G. It contains sections on the engine, transmission, four-wheel drive system, front and rear axle systems, brakes, hydraulic systems, frames and ballasting, steering, wheels, cab climate control, electrical systems, front loader and bucket, platform/bodywork, and safety procedures. Technicians are instructed to follow all safety precautions and only perform authorized repairs after stopping the engine and relieving hydraulic pressure.
New holland w110 c tier 4 wheel loader service repair manualfujsjefjkskefksem
This document is a service manual that provides instructions for removing the engine from a W110C Wheel Loader. It is a 12-step process that includes parking the machine, discharging pressure from hydraulic and brake systems, draining coolant and oil, disconnecting batteries, and using lifting straps to remove the engine. Safety precautions like loosening the hydraulic reservoir cap and putting the master disconnect in the off position are emphasized. The document provides detailed photos and descriptions to guide the removal process.
Case 1121 f tier 4 wheel loader service repair manualfujsjefjkskefksem
This document is a service manual that contains contents, introduction, and torque specifications for various components of an engine, transmission, drivetrain, axles, brakes, hydraulics, steering, wheels, cab climate control, and electrical systems. The document provides over 50 section references to more detailed information about each system, and includes over 30 torque specifications for fasteners and components throughout the machine.
Case 1121 f tier 2 wheel loader service repair manualfujsjefjkskefksem
This document provides instructions to remove the engine from a Case 1021F or 1121F wheel loader. The key steps include draining fluids, disconnecting electrical connections and hoses, removing panels and covers, and then lifting the engine out once all mounting bolts are removed. Proper labeling and capping of connections is emphasized to prevent contamination during the process.
This service manual provides information for servicing wheel loaders. It includes sections on the engine, transmission, axle systems, brakes, hydraulics, frames, steering, wheels, climate control, electrical systems, loader attachments, cab, and decals. The document provides specifications, component locations, removal and installation instructions, and repair procedures. Safety precautions are provided to ensure safe service of the equipment.
Case 721 g wheel loader zbar eh, new cab tier4b na wheel loader service repai...fujsjefjkskefksem
This document is a service manual for Case 621G and 721G wheel loaders with Tier 4B engines. It contains sections covering the engine, transmission, axles, brakes, hydraulics, frames, steering, wheels, cab climate control, and electrical systems. It also includes sections specific to the front loader arms and buckets.
New holland w50 c tc tier 4a (interim) compact wheel loader service repair ma...fujsjefjkskefksem
This document is a service manual for New Holland compact wheel loaders that provides information on maintenance and repair of components. It includes sections on the engine, fuel tanks, drive train, axles, brakes, hydraulic and electrical systems, frames, steering, climate control, and the front loader and bucket. The manual instructs technicians on proper procedures for tasks like shimming, installing seals, and applying sealing compounds.
Case 721 f tier 4b (final) wheel loader service repair manualfujsjefjkskefksem
This service manual provides instructions for maintenance and repair of Case wheel loaders models 621F and 721F with Tier 4B engines. The manual covers the engine, transmission, four-wheel drive system, front and rear axle systems, brakes, hydraulic systems, frames, steering, wheels, cab climate control, electrical systems, front loader and bucket, platform, cab, and decals. Safety precautions are provided, and only authorized personnel should perform repairs.
New holland w50 btc wheel loader service repair manualfujsjefjkskefksem
This repair manual provides technical information for engineers to service wheel loaders models W50BTC, W60BTC, W70BTC, and W80BTC. It consists of two volumes, one covering the wheel loaders and one covering the engine. The manual contains information on repair procedures, necessary tools, and service standards. It is intended as a reference for maintenance and repair work on the machines and engines. Safety instructions are provided to prevent accidents during repair work.
Hyster f007 h12.00 xm forklift service repair manualfujsjefjkskefksem
The document provides instructions for repairing the service frame, counterweight, fenders, hood, hydraulic tank, and other parts of a lift truck. It describes removing and installing the counterweight, fenders, and hydraulic tank. It also details cleaning and repairing the hydraulic tank, including procedures for small leaks, large leaks, and cleaning the tank using steam or chemical solutions. Welding repairs require disconnecting electronics to avoid damage.
Hyster d138 (n40 fr) forklift service repair manualfujsjefjkskefksem
This document provides repair procedures for single and double reach carriages on lift trucks. It describes the components of the reach carriages, including the inner and outer frames connected by scissor linkages. It also describes the hydraulic systems that control the reach, tilt, and optional side-shift functions. The summary provides repair procedures for replacing parts like forks, the load backrest extension, and removing/disassembling the side-shift frame.
Hyster d010 (s25 xm) forklift service repair manualfujsjefjkskefksem
The document provides an overview of the components and operation of a single-speed powershift transmission, including:
1) The transmission contains forward and reverse clutch assemblies, a torque converter, transmission pump, control valve, and differential assembly to transfer power from the engine to the wheels.
2) The torque converter uses fluid coupling between an impeller and turbine to transfer power from the engine to the transmission, and can multiply engine torque through a stator clutch mechanism.
3) The forward and reverse clutch assemblies use hydraulic pressure to engage friction discs and transfer power between the input shaft and either the forward or reverse gears to select transmission direction.
Hyster d005 (h110 e europe) forklift service repair manualfujsjefjkskefksem
This document provides instructions for servicing GM engines. It describes removing and installing the cylinder head and valve mechanism. Key steps include using a compressor tool to remove the valve springs, cleaning carbon from the combustion chambers, inspecting the valves and valve guides for wear, and checking clearances. The valve seats can be repaired with a cutter tool if damaged, or the cylinder head replaced if not repairable. Rocker arm studs should also be replaced if damaged.
Hyster c187 (s60 xl) forklift service repair manualfujsjefjkskefksem
This document provides instructions for disassembling and repairing a Ross HydraGuide steering control unit. It describes the unit's control valve and metering sections. The disassembly process is outlined step-by-step and cautions safety hazards. Components are identified in an illustrated parts list. A fixture is shown for securely holding the unit during disassembly.
Hyster a917 (h970 hds) forklift service repair manualfujsjefjkskefksem
This document provides repair procedures for differentials used in lift trucks. It describes the components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures describe how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Safety precautions are provided and components are labeled in diagrams.
Cummins onan generator set with power command 3100 controller model (dfed ) s...fujsjefjkskefksem
This document is a service manual that provides information for troubleshooting and servicing generator sets equipped with PowerCommand 3100 controllers. It includes sections on control operation, circuit boards and modules, troubleshooting, control service and calibration, servicing the generator, day tank fuel transfer pumps, optional enclosure fuel tank systems, and wiring diagrams. The manual contains important safety instructions and details regarding the various components, their functions, and maintenance/repair procedures.
This document provides service information for W8, W9, and W10 series E loaders. It includes sections on general engine specifications, maintenance and lubrication schedules, engine systems like fuel, cooling, and electrical. It also covers other vehicle systems like power train, steering, brakes, and hydraulics. The document provides information on maintenance intervals, recommended lubricants, fluid capacities, and procedures for servicing components.
New holland w270 c tier 4 wheel loader service repair manualfujsjefjkskefksem
This document is a service manual for a wheel loader that provides specifications and repair instructions. It contains sections on the engine, transmission, drivetrain, brakes, hydraulics, frames, steering, wheels, climate control, electrical systems, loader attachments, cab, and safety features. Torque specifications are provided for decimal hardware.
New holland w190 d zbar eh, new cab tier 4b wheel loader service repair manualfujsjefjkskefksem
This document is a service manual for a Stage IV Wheel Loader. It provides part numbers and specifications for removing the engine. The 3-step process includes draining fluids, removing panels to access the engine, and using straps to lift the engine hood and remove tension on the lifting motor. Safety precautions and instructions are included throughout.
New holland w170 c wheel loader service repair manualfujsjefjkskefksem
This section provides instructions for removing and installing the engine and radiator on a W170C Wheel Loader. The engine removal process involves disconnecting battery cables, draining fluids, removing mounted components, and lifting the engine out. Installation is the reverse of removal. Radiator removal involves draining coolant and removing mounting hardware, while installation reconnects hoses and mounts the radiator.
Case 1121 g tier 2 wheel loader service repair manualfujsjefjkskefksem
This 3-page service manual provides maintenance instructions for CNH Industrial Italia S.p.A. wheel loaders models 1021G and 1121G. It contains sections on the engine, transmission, four-wheel drive system, front and rear axle systems, brakes, hydraulic systems, frames and ballasting, steering, wheels, cab climate control, electrical systems, front loader and bucket, platform/bodywork, and safety procedures. Technicians are instructed to follow all safety precautions and only perform authorized repairs after stopping the engine and relieving hydraulic pressure.
New holland w110 c tier 4 wheel loader service repair manualfujsjefjkskefksem
This document is a service manual that provides instructions for removing the engine from a W110C Wheel Loader. It is a 12-step process that includes parking the machine, discharging pressure from hydraulic and brake systems, draining coolant and oil, disconnecting batteries, and using lifting straps to remove the engine. Safety precautions like loosening the hydraulic reservoir cap and putting the master disconnect in the off position are emphasized. The document provides detailed photos and descriptions to guide the removal process.
Case 1121 f tier 4 wheel loader service repair manualfujsjefjkskefksem
This document is a service manual that contains contents, introduction, and torque specifications for various components of an engine, transmission, drivetrain, axles, brakes, hydraulics, steering, wheels, cab climate control, and electrical systems. The document provides over 50 section references to more detailed information about each system, and includes over 30 torque specifications for fasteners and components throughout the machine.
Case 1121 f tier 2 wheel loader service repair manualfujsjefjkskefksem
This document provides instructions to remove the engine from a Case 1021F or 1121F wheel loader. The key steps include draining fluids, disconnecting electrical connections and hoses, removing panels and covers, and then lifting the engine out once all mounting bolts are removed. Proper labeling and capping of connections is emphasized to prevent contamination during the process.
This service manual provides information for servicing wheel loaders. It includes sections on the engine, transmission, axle systems, brakes, hydraulics, frames, steering, wheels, climate control, electrical systems, loader attachments, cab, and decals. The document provides specifications, component locations, removal and installation instructions, and repair procedures. Safety precautions are provided to ensure safe service of the equipment.
Case 721 g wheel loader zbar eh, new cab tier4b na wheel loader service repai...fujsjefjkskefksem
This document is a service manual for Case 621G and 721G wheel loaders with Tier 4B engines. It contains sections covering the engine, transmission, axles, brakes, hydraulics, frames, steering, wheels, cab climate control, and electrical systems. It also includes sections specific to the front loader arms and buckets.
New holland w50 c tc tier 4a (interim) compact wheel loader service repair ma...fujsjefjkskefksem
This document is a service manual for New Holland compact wheel loaders that provides information on maintenance and repair of components. It includes sections on the engine, fuel tanks, drive train, axles, brakes, hydraulic and electrical systems, frames, steering, climate control, and the front loader and bucket. The manual instructs technicians on proper procedures for tasks like shimming, installing seals, and applying sealing compounds.
Case 721 f tier 4b (final) wheel loader service repair manualfujsjefjkskefksem
This service manual provides instructions for maintenance and repair of Case wheel loaders models 621F and 721F with Tier 4B engines. The manual covers the engine, transmission, four-wheel drive system, front and rear axle systems, brakes, hydraulic systems, frames, steering, wheels, cab climate control, electrical systems, front loader and bucket, platform, cab, and decals. Safety precautions are provided, and only authorized personnel should perform repairs.
New holland w50 btc wheel loader service repair manualfujsjefjkskefksem
This repair manual provides technical information for engineers to service wheel loaders models W50BTC, W60BTC, W70BTC, and W80BTC. It consists of two volumes, one covering the wheel loaders and one covering the engine. The manual contains information on repair procedures, necessary tools, and service standards. It is intended as a reference for maintenance and repair work on the machines and engines. Safety instructions are provided to prevent accidents during repair work.
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
EV Charging at MFH Properties by Whitaker JamiesonForth
Whitaker Jamieson, Senior Specialist at Forth, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
At ASP Cranes, we understand the importance of reliable and efficient crane operations in various industries, from construction and manufacturing to logistics and infrastructure development. That's why we strive to deliver top-notch solutions that enhance productivity, safety, and cost-effectiveness for our clients.
Our services include:
Crane Rental: Whether you need a crawler crane for heavy lifting or a hydraulic crane for versatile operations, we have a diverse fleet of well-maintained cranes available for rent. Our rental options are flexible and can be customized to suit your project requirements.
Crane Sales: Looking to invest in a crane for your business? We offer a wide selection of new and used cranes from leading manufacturers, ensuring you find the perfect equipment to match your needs and budget.
Crane Maintenance and Repair: To ensure optimal performance and safety, regular maintenance and timely repairs are essential for cranes. Our team of skilled technicians provides comprehensive maintenance and repair services to keep your equipment running smoothly and minimize downtime.
Crane Operator Training: Proper training is crucial for safe and efficient crane operation. We offer specialized training programs conducted by certified instructors to equip operators with the skills and knowledge they need to handle cranes effectively.
Custom Solutions: We understand that every project is unique, which is why we offer custom crane solutions tailored to your specific requirements. Whether you need modifications, attachments, or specialized equipment, we can design and implement solutions that meet your needs.
At ASP Cranes, customer satisfaction is our top priority. We are dedicated to delivering reliable, cost-effective, and innovative crane solutions that exceed expectations. Contact us today to learn more about our services and how we can support your project in Raipur, Chhattisgarh, and beyond. Let ASP Cranes be your trusted partner for all your crane needs!
Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
Awareness: Increase your awareness about catalytic converter theft and its impact on vehicle owners.
Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
Expanding Access to Affordable At-Home EV Charging by Vanessa WarheitForth
Vanessa Warheit, Co-Founder of EV Charging for All, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
2. 2000 SRM 1137 General
General
This section contains a description and repair pro-
cedures for both manual and electronic main control
valves used in the hydraulic system for this series of
lift trucks.
There are two main control valves available for this
series of lift trucks. One is controlled manually (man-
ual main control valve) and the other is controlled
electronically (electro-hydraulic main control valve).
The main control valves are mounted to the cowl us-
ing three mounting bolts. See Figure 1.
NOTE: MAJOR COMPONENTS NOT SHOWN FOR
CLARITY. VIEW IS FROM THE FRONT.
NOTE: ELECTRO-HYDRAULIC CONTROL VALVE
FOR LIFT TRUCK MODELS S30FT, S35FT, S40FTS
(E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS)
(F187), H2.0-3.5FT (H40-70FT) (L177), S4.0, 4.5,
5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), AND H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005) SHOWN.
1. COWL
2. INSERT
3. WASHER
4. MOUNTING CAPSCREW
5. MAIN CONTROL VALVE
6. FRAME
Figure 1. Main Control Valve Mounting
Confidential/Proprietary - Do Not Copy or Duplicate 1
3. Electro-Hydraulic Main Control Valve 2000 SRM 1137
Electro-Hydraulic Main Control Valve
DESCRIPTION
The E-Valve is an electronically-controlled, closed-
center, load-sensing stack valve. It uses an un-
loader valve (single functions only) and has parallel
hydraulic circuitry. Operating multiple functions
simultaneously will result in a nonproportionate
increase in pump flow to functions which receive
the lowest amount of pressurized fluid. A fixed
displacement pump is used in conjunction with the
inlet compensator to achieve the required load-sense
logic. Lift function is on main relief pressure setting.
Tilt and auxiliary functions are on secondary relief
pressure setting. Lift pressure is unaffected by
secondary relief operation.
The electronic main control valve incorporates an
emergency (manual) lowering valve. See Figure 2
and Figure 3. This valve allows the operator or
service technician to lower the lift truck’s mast as-
sembly if the electrical signal to the electronic main
control valve is disrupted.
The electronic main control valve assembly is divided
into the following sections. See Figure 2 and Fig-
ure 3.
• Steering Control Unit (SCU)
• Lift/Lower
• Tilt
• Auxiliary
• Outlet
• Mid-Inlet* (Primary Pump Inlet)
*Mid-inlet (primary pump inlet) section is used only
on the main control valve of lift truck models S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024) and H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006). See Fig-
ure 3.
Figure 2. Electronic Control Valve, Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT
(H40-70FT) (L177), S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), and H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
2 Confidential/Proprietary - Do Not Copy or Duplicate
4. 2000 SRM 1137 Electro-Hydraulic Main Control Valve
Legend for Figure 2
1. STEERING CONTROL UNIT (SCU)
2. SCU MOUNTING CAPSCREW
3. LIFT/LOWER SECTION
4. EMERGENCY LOWER VALVE
5. ELECTRO-HYDRAULIC POPPET VALVE (EHPV)
6. PROPORTIONAL PRESSURE REDUCING
VALVE (PPRV)
7. AUXILIARY I SECTION
8. AUXILIARY II SECTION
9. SECONDARY RELIEF VALVE (ADJUSTABLE)
10. OUTLET SECTION
11. TILT SECTION
12. PRIMARY RELIEF VALVE (ADJUSTABLE)
13. EF PORT
Confidential/Proprietary - Do Not Copy or Duplicate 3
5. Electro-Hydraulic Main Control Valve 2000 SRM 1137
1. STEERING CONTROL UNIT (SCU)
2. SCU MOUNTING CAPSCREW
3. MID-INLET SECTION (PRIMARY PUMP INLET)
4. ELECTRO-HYDRAULIC POPPET VALVE (EHPV)
(LIFT)
5. ELECTRO-HYDRAULIC POPPET VALVE (EHPV)
(LOWER)
6. PROPORTIONAL PRESSURE REDUCING
VALVE (PPRV)
7. AUXILIARY I SECTION
8. AUXILIARY II SECTION
9. SECONDARY RELIEF VALVE (ADJUSTABLE)
10. OUTLET SECTION
11. TILT SECTION
12. PRIMARY RELIEF VALVE (ADJUSTABLE)
13. EMERGENCY LOWER VALVE
14. EF PORT
15. LIFT/LOWER SECTION
Figure 3. Electronic Control Valve, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
4 Confidential/Proprietary - Do Not Copy or Duplicate
6. 2000 SRM 1137 Electro-Hydraulic Main Control Valve
REMOVE
WARNING
Lower carriage completely before working on
control valve or hydraulic system. Do not work
under a raised carriage. Put mast in a verti-
cal position, with no forward or back tilt, and
lower carriage completely before disconnect-
ing any parts of hydraulic system. The mast
can lower suddenly and cause injury if the car-
riage is not lowered.
NOTE: Most of the individual valve components can
be removed and replaced while the control valve is in-
stalled in the truck. Removal of the control valve for
repairs is normally only required to replace a valve
section, or to replace the O-rings between the sec-
tions.
1. Power wash the interior of the operator compart-
ment 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 proce-
dures. 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 cloth-
ing, 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 one of the following service
manual sections for your lift truck’s procedures:
• Frame 100 SRM 1120 for S30FT, S35FT,
S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS
(H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT
(S40-70FT, S55FTS) (F187); H2.0-3.5FT
(H40-70FT) (L177)
• Frame 100 SRM 1243 for S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004); H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005)
• Frame 100 SRM 1316 for S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024)
• Frame 100 SRM 1321 H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006)
Before disconnecting any hydraulic hoses or re-
moving any parts from the control valve, clean
the outside of the valve either by steam cleaning
or with cleaning solvent.
4. To remove the accelerator pedal or MONOTROL®
pedal assembly, disconnect the cowl wiring har-
ness from the pedal assembly wiring harness and
remove three mounting capscrews. See Figure 4.
NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
EVER, REMOVAL IS THE SAME.
1. MOUNTING CAPSCREW
2. MONOTROL PEDAL ASSEMBLY
3. PEDAL ASSEMBLY WIRING HARNESS
Figure 4. MONOTROL Pedal Removal
Confidential/Proprietary - Do Not Copy or Duplicate 5
7. Electro-Hydraulic Main Control Valve 2000 SRM 1137
NOTE: To aid in installation, tag all connectors prior
to disconnecting from the solenoids.
5. Disconnect the cowl wiring harness connectors
from the lift and lower Electro-Hydraulic Poppet
Valve (EHPV) solenoids. Disconnect the cowl
wiring harness from the top auxiliary function
Proportional Pressure Reducing Valve (PPRV)
solenoids. See Figure 5.
CAUTION
To prevent any foreign matter from getting
into either the hydraulic hoses or the hy-
draulic control valve sections, all openings
must have plugs or covers installed immedi-
ately after hoses are disconnected from the
control valve. This also applies if any other
items are removed from the control valve.
NOTE: To aid in correctly connecting hydraulic hoses
during installation, tag each hose prior to disconnect-
ing from the control valve.
6. Disconnect hydraulic hoses from the control
valve (see Figure 5 and Figure 6). Install plugs
or caps on all open hose ends and control valve
ports to prevent contamination.
7. Remove the two SCU mounting capscrews and
move the SCU approximately 1.3 cm (0.5 in.) to
the left, and lower the SCU until the steering
shaft is disengaged. Remove the SCU from the
lift truck. See Figure 2 and Figure 3.
Figure 5. Hydraulic Hose Removal and Harness Disconnection, Lift Truck Models S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
6 Confidential/Proprietary - Do Not Copy or Duplicate
8. 2000 SRM 1137 Electro-Hydraulic Main Control Valve
Legend for Figure 5
NOTE: HARNESS CONNECTORS FOR S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) AND H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006) LIFT TRUCKS SHOWN. HARNESS CONNECTORS FOR ALL OTHER LIFT
TRUCK MODELS COVERED IN THIS SRM ARE SIMILAR.
1. LIFT ELECTRO-HYDRAULIC POPPET VALVE
(EHPV) HARNESS CONNECTOR
2. LOWER ELECTRO-HYDRAULIC POPPET VALVE
(EHPV) HARNESS CONNECTOR
3. AUXILIARY FUNCTION PROPORTIONAL
PRESSURE REDUCING VALVE (PPRV)
HARNESS CONNECTOR
4. STEERING SYSTEM HOSES
5. SECONDARY HYDRAULIC PUMP HOSE
6. MID INLET HOSE (MAIN PUMP HOSE)
7. LIFT/LOWER HOSE
8. TILT HOSE
9. AUXILIARY I HOSE
10. AUXILIARY II HOSE
11. RETURN HOSE
12. STEERING COLUMN
13. STEERING CONTROL UNIT (SCU)
14. SCU MOUNTING CAPSCREWS
1. STEERING SYSTEM HOSES
2. HYDRAULIC INLET HOSE
3. STEERING CONTROL UNIT (SCU)
4. STEERING COLUMN
5. SCU MOUNTING CAPSCREWS
6. LIFT/LOWER HOSE
7. TILT HOSE
8. AUXILIARY I HOSE
9. AUXILIARY II HOSE
10. RETURN HOSE
Figure 6. Hydraulic Hose Removal, Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT
Confidential/Proprietary - Do Not Copy or Duplicate 7
9. Electro-Hydraulic Main Control Valve 2000 SRM 1137
(H40-70FT) (L177), S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), and H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
8. Remove and discard two O-rings from the
main control valve. For lift truck mod-
els S30FT, S35FT, S40FTS (E010), H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
H2.0-3.5FT (H40-70FT) (L177), S4.0, 4.5,
5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005) the
two O-rings are located on the lift/lower control
valve section, on the side where the SCU and
lift/lower control valve section are connected
(item 3 between items 9 and 10 in Figure 14).
For lift truck models S6.0FT, S7.0FT (S135FT,
S155FT) (D024, E024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006), the two O-rings
are located on the mid-inlet control valve section,
on the side where the SCU and mid-inlet control
valve section are connected (item 3 between item
5 in Figure 7).
1. MID-INLET SECTION
2. SOCKET HEAD PLUG
3. O-RING
4. SOCKET HEAD CAPSCREW
5. WASHER
Figure 7. Mid-Inlet Section
WARNING
The main control valve weighs approximately
30.5 kg (67 lb). Use a lifting device capable of
lifting the main control valve to avoid the pos-
sibility of injury to personnel.
9. Support the main control valve. Remove three
mounting capscrews, washers, inserts, and the
main control valve from the lift truck. See Fig-
ure 8.
1. COWL
2. INSERT
3. WASHER
4. MOUNTING
CAPSCREW
5. MAIN CONTROL
VALVE
6. FRAME
Figure 8. Main Control Valve Removal
NOTE: To aid in installation, tag all connectors prior
to disconnecting from the solenoids.
10. Raise the main control valve approximately
25.4 cm (10 in.) to gain access to the lower tilt
and auxiliary function Proportional Pressure
Reducing Valve (PPRV) solenoids. Disconnect
the cowl harness from the lower tilt and aux-
iliary function (PPRV) solenoids. See Figure 2
and Figure 3.
11. Remove the main control valve from the lift
truck.
8 Confidential/Proprietary - Do Not Copy or Duplicate
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for your reading. Please
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11. 2000 SRM 1137 Electro-Hydraulic Main Control Valve
ELECTRO-HYDRAULIC CONTROL VALVE
SECTIONS
General
CAUTION
While working on the electro-hydraulic control
valve sections, place a cover over the remain-
ing sections of the control valve to prevent
the possibility of contaminants getting into
the control valve openings which could cause
damage to the control valve.
CAUTION
If O-rings are to be replaced between two sec-
tions that have a hydraulic oil leak, replace all
O-rings between all sections. This eliminates
the possibility of a subsequent oil leak or pos-
sible damage to another O-ring.
Disassemble the electro-hydraulic control valve only
as necessary for repairs. Most repairs to the control
valve will be for the replacement of O-rings to stop
leaks between sections.
Outlet Control Valve Section
Remove
1. Remove four nuts from the control valve tie rods.
See Figure 9.
2. Remove the outlet control valve section from the
four tie rods and discard 10 O-rings (item 13 in
Figure 10) from the auxiliary control valve sec-
tion.
Disassemble
1. Remove the plug from the outlet control valve
section and discard the O-ring.
2. If the secondary relief valve has been leaking,
remove it from the outlet control valve section.
See Step 3 through Step 7 to disassemble the sec-
ondary relief valve. See Figure 9.
3. Remove the plug from the adjusting nut. Remove
and discard the O-ring from the plug. Remove
and discard the backup rings and O-ring from the
adjusting nut. See Figure 9.
4. While holding the adjustment nut, loosen the jam
nut.
NOTE: While performing Step 5, count and note the
number of turns used to remove the adjusting nut.
5. Remove the adjusting nut and jam nut assembly
from the secondary relief valve plug and discard
the O-ring on the adjusting nut.
6. Remove the spring, washer, and poppet from the
secondary relief valve plug.
7. Remove and discard the backup ring from the
secondary relief valve plug.
Clean
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
WARNING
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
1. If all components of the outlet control valve sec-
tion have been removed, clean the outlet control
valve section using cleaning solvent and dry us-
ing compressed air.
2. If not all components have been removed, clean
the outlet control valve section using a lint-free
cloth.
Inspect
Inspect the outlet control valve section mating sur-
faces and the bore of the secondary relief valve, if re-
moved, for damage. If either the mating surface or
the secondary relief valve bore are damaged, replace
the outlet control valve section.
If disassembled, inspect the components of the sec-
ondary relief valve. If any components other than
O-rings, backup rings, and the spring are damaged,
replace the secondary relief valve.
Confidential/Proprietary - Do Not Copy or Duplicate 9
12. Electro-Hydraulic Main Control Valve 2000 SRM 1137
1. O-RING
2. PLUG
3. OUTLET VALVE SECTION
4. BACKUP RING
5. SECONDARY RELIEF VALVE PLUG
6. POPPET
7. WASHER
8. SPRING
9. JAM NUT
10. ADJUSTING NUT
11. CONTROL VALVE TIE ROD
12. NUT
Figure 9. Outlet Control Valve Section
10 Confidential/Proprietary - Do Not Copy or Duplicate
13. 2000 SRM 1137 Electro-Hydraulic Main Control Valve
NOTE: If the outlet control valve section is not to be
reassembled immediately, coat surfaces with clean
hydraulic oil to prevent the possibility of rust. Cover
the outlet control valve section with a clean, dry, lint-
free cloth to prevent the possibility of contaminants
entering the outlet control valve section.
Assemble
NOTE: Coat all backup rings and O-rings with a light
coat of clean hydraulic oil to make installation easier.
NOTE: Perform Step 1 through Step 7 only if the sec-
ondary relief valve was repaired.
1. Install a new backup ring on the secondary relief
valve plug. See Figure 9.
2. Install the poppet, washer, and spring into the
secondary relief valve plug.
3. Install a new O-ring on the adjusting nut, and in-
stall the adjusting nut and jam nut assembly into
the secondary relief valve plug using the same
number of turns noted during disassembly.
4. While holding the adjusting nut in place, tighten
the jam nut to 24 ±3 N•m (18 ±2 lbf ft).
5. Install a backup ring, O-ring, and backup ring
into the adjusting nut.
6. Install a new O-ring onto the plug. Install the
plug into the adjusting nut.
7. If removed, install secondary relief valve into
outlet control valve section. Tighten relief valve
plug to 45 N•m (33 lbf ft). See the section
Pressure Relief Valve Check and Adjustment to
adjust the secondary relief valve and check the
pressure.
8. Install new O-ring on plug and install in the out-
let valve section.
Install
NOTE: Coat all O-rings with light coat of clean hy-
draulic oil to make installation easier.
1. Install 10 new O-rings (13, Figure 10) into the
auxiliary valve section. Install the outlet control
valve section on the four tie rods.
2. Install the four nuts on the tie rods and tighten
to 19 ±2 N•m (168 ±18 lbf in).
Auxiliary Control Valve Sections
NOTE: There is the possibility of having two or three
auxiliary control valve sections depending upon how
many functions are on the lift truck. If the main con-
trol valve is a four-function control valve, there will
be two auxiliary control valve sections. If the main
control valve is a five-function control valve, there
will be three auxiliary control valve sections.
These sections are repaired the same way with one
exception. The auxiliary control valve section next to
the tilt control valve will always have the anti-stall
valve installed as a part of that control valve section.
Remove
1. Remove the outlet control valve section. See Out-
let Control Valve Section, Remove.
NOTE: Step 2 and Step 3 are for a three-function con-
trol valve. If a four or five-function control valve is
being disassembled, go to Step 4.
2. Remove the anti-stall valve from the auxiliary
control valve section. See Figure 10. If the anti-
stall valve is to be repaired, go to Step 5 of the
Disassemble procedure for the auxiliary control
valve section.
3. Remove the auxiliary control valve section from
the four tie rods. Remove and discard 10 O-rings
from the tilt control valve section. See Figure 12.
4. Remove the auxiliary III control valve section
from the four tie rods. Remove and discard 10
O-rings (13, Figure 10, illustration B) from the
auxiliary II control valve section. Remove the
auxiliary II control valve section from the four
tie rods. Remove and discard 10 O-rings (13, Fig-
ure 10, illustration B) from the auxiliary I control
valve section.
5. Remove the anti-stall valve from the auxiliary I
control valve section. If the anti-stall valve is
to be repaired, go to Step 5 of the Disassemble
procedure for the auxiliary control valve section.
6. Remove the auxiliary I control valve section from
the four tie rods. Remove and discard 10 O-rings
from the tilt control valve section.
Confidential/Proprietary - Do Not Copy or Duplicate 11
14. Electro-Hydraulic Main Control Valve 2000 SRM 1137
Figure 10. Auxiliary I, II, and III Control Valve Sections
12 Confidential/Proprietary - Do Not Copy or Duplicate
15. 2000 SRM 1137 Electro-Hydraulic Main Control Valve
Legend for Figure 10
A. AUXILIARY I CONTROL VALVE SECTION B. AUXILIARY II AND III CONTROL VALVE SECTION
1. PLUG
2. O-RING
3. SPRING
4. WASHER
5. SOCKET HEAD CAPSCREW
6. PROPORTIONAL PRESSURE REDUCING
VALVE (PPRV)
7. SPOOL
8. POPPET
9. AUXILIARY I CONTROL VALVE BODY
10. BACKUP RING
11. ANTI-STALL VALVE SLEEVE
12. AUXILIARY II CONTROL VALVE BODY
13. O-RING
Disassemble
NOTE: Disassemble the auxiliary control valve only
as needed to accomplish the repairs required. The
disassemble procedures for the auxiliary I, II, and III
sections are the same. The auxiliary I section is used
in the procedures described below because it contains
the anti-stall valve.
1. Remove four capscrews and two proportional
pressure reducing valves (PPRV) from the auxil-
iary control valve section. Remove and discard
the backup ring, two O-rings, backup ring, and
O-ring from each PPRV. See Figure 10.
2. Remove the plug, spring, washer, and spool from
the auxiliary control valve section. Discard the
O-ring on the plug.
3. Remove the plug, spring, and washer from the
auxiliary control valve section. Discard the
O-ring on the plug.
4. Remove two plugs, two springs, and two poppets
from the auxiliary control valve. Discard one
O-ring from each plug.
5. Remove spring from the large end of the anti-
stall valve sleeve. See Figure 11.
6. Remove the spool from the small end of the anti-
stall valve sleeve.
NOTE: Note the orientation of the O-rings and
backup rings for correct installation.
7. Remove and discard two backup rings and two
O-rings from the anti-stall valve sleeve. To re-
assemble the anti-stall sleeve valve, see Step 5
of the assembly procedure.
1. SPOOL
2. BACKUP RING
3. O-RING
4. ANTI-STALL VALVE
SLEEVE
5. SPRING
Figure 11. Anti-Stall Valve
Confidential/Proprietary - Do Not Copy or Duplicate 13
16. Electro-Hydraulic Main Control Valve 2000 SRM 1137
Clean
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
WARNING
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
1. If all components of the auxiliary control valve
section have been removed, clean the auxiliary
control valve section and components, except the
two PPRVs, using cleaning solvent and dry using
compressed air.
2. If not all components have been removed, clean
the auxiliary control valve section using a lint-
free cloth.
3. If the anti-stall valve was disassembled, clean
the spool, anti-stall valve sleeve, and spring with
cleaning solvent. Dry with a lint-free cloth.
Inspect
Inspect the auxiliary control valve section mating
surfaces and any open bores for damage. If damage
is found, replace the auxiliary control valve section.
If the spool has been removed, inspect the spool and
the bore for damage. If damage to either the spool or
the bore is found, replace the auxiliary control valve
section.
If the anti-stall valve was disassembled, inspect the
spool, anti-stall valve sleeve, and spring for damage.
If the spring is damaged, replace the spring. If the
spool or anti-stall valve sleeve is damaged, replace
the anti-stall valve assembly.
NOTE: If the auxiliary control valve section is not to
be reassembled immediately, coat surfaces with clean
hydraulic oil to prevent the possibility of rust. Cover
the auxiliary control valve section with a clean, dry,
lint-free cloth to prevent the possibility of contami-
nants entering the auxiliary control valve section.
Assemble
NOTE: Coat all backup rings and O-rings with a light
coat of clean hydraulic oil to make installation easier.
NOTE: The assembly procedures for the auxiliary I,
II, and III sections are the same. The auxiliary I
section is used in the procedures described below be-
cause it contains the anti-stall valve.
1. Install the spool, washer, spring, and plug, with
new O-ring, into the bore of the auxiliary control
valve section. Tighten the plug to 14 ±1 N•m
(120 ±12 lbf in). See Figure 10.
2. Install the washer, spring, and plug, with new
O-ring, into the auxiliary control valve section.
Tighten the plug to 14 ±1 N•m (120 ±12 lbf in).
3. Install two poppets, two springs, and two plugs,
with new O-rings installed, into the auxiliary
control valve section. Tighten the plugs to 81
±8 N•m (60 ±6 lbf ft).
4. Install the new O-ring, backup ring, two O-rings,
and backup ring on each PPRV. Install two
PPRVs and four capscrews into the auxiliary
control valve section. Tighten the capscrews to 3
±0.3 N•m (24 ±2 lbf in).
5. Install two backup rings and two O-rings on the
anti-stall valve sleeve as noted during disassem-
bly. See Figure 11.
6. Install the spool in the small end of the anti-stall
valve sleeve.
7. Install the spring in the large end of the anti-stall
valve sleeve.
Install
NOTE: Step 1 through Step 3 are for a three-function
control valve. Step 4 through Step 7 are for a four
and five-function control valves.
1. Install 10 new O-rings into the tilt control valve
section. Install the auxiliary I control valve sec-
tion on the four tie rods. See Figure 12.
2. Install the anti-stall valve into the auxiliary I
control valve section. See Figure 10.
3. Install the outlet control valve section. See Out-
let Control Valve Section, Install.
14 Confidential/Proprietary - Do Not Copy or Duplicate