Hyster Forklift HR 45-40

!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 precautions.

Compressed air can move particles and cause injury to the user or to other personnel. Verify compressed air path is away from all personnel. Wear eye protection.

Clean cartridge valve in solvent and carefully dry the parts with compressed air.

Inspect the bores for damage. If there are scratches or other damage, the load holding valve must be replaced.

Inspect the fittings, O-rings, and check valves for damage. Replace damaged parts.

Sign off on the Boom Extension Circuit Maintenance

!WARNING: Lower boom completely before working on control valve or hydraulic system. The boom can lower suddenly and cause injury if the boom is not lowered. This procedure will make sure that the boom cannot lower suddenly and cause injury or death.

!NOTE: All valves and other associated items installed on the load holding valve can be replaced. Before removal of any part, check that the area is clean and protected against dirt and fluid contamination.

Place the truck on a solid and level surface.

Lower boom and close the shutoff valves at the bottom of the hydraulic tank platform.

!WARNING: Move all control levers back and forth a minimum of 20 times to remove all hydraulic pressure from pilot system.

Put tags for identification on electrical wires. Disconnect the electrical wires from the load holding valve.

Put tags for identification on hydraulic lines. Disconnect the hydraulic lines from the load holding valve. Put caps on the open lines, ports or other connectors.

Remove the four capscrews that fasten the load holding valve to the derricking cylinder.

NOTE: The relief valves in the main manifold, main control valve, and flow amplifier are adjustable. If a relief pressure is not within specifications, adjust the relief valve.

Upload a photo of the correct gauge used on the check ports.

Enter the temperature of hydraulic oil

Is the pressure gauge according to the specifications shown in Table 3?

To adjust a relief valve setting, remove cap. Loosen lock nut and use an Allen wrench to turn adjuster screw. Turn adjuster screw clockwise to increase pressure.

To lower pressure, first lower pressure below required value by turning adjuster screw counterclockwise and then increase pressure to required level. When relief pressure is correct, tighten lock nut and install cap.

Is the setting correct after tightening the lock nut?

Sign off on the relief valve check

NOTE: The pressure reducer valve is adjustable. If a setting pressure is not within specifications, adjust the valve.

Lower lift cylinders completely

Connect a 0 to 7 MPa (0 to 1015 psi) gauge to check port MPLT

Start engine and run until temperature of hydraulic oil is 55 to 65 C (130 to 150 F)

NOTE: Correct measurement can be achieved during movement (flow) of the main spool.

Check if pressure is 5 MPa (725 psi)

If pressure is not correct, adjust pressure reducer valve

Position the cab manifold under the cab floor.

Install the three capscrews that fasten the cab manifold under the cab floor.

Remove caps and connect the hydraulic lines to the cab manifold according to the identification tags made during removal.

Warning: Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body by pressure.

Caution: Never start the engine with closed shutoff valves. Open the shutoff valves before starting the engine to prevent damage to hydraulic components.

Start the engine and operate the hydraulic system. Check that functions of the cab manifold work correctly. Check for any leaks.

Install the covers at the top side of the frame.

Sign off on the cab manifold installation