Hyster Forklift RS46-36CH

!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: Each pump assembly weighs approximately 45 kg (100 lb) and can cause injury or damage if it falls.

Clean flange of the pump assembly and mounting surface on the torque converting housing.

Install pump assembly on the torque converting housing. Use a sealant on the flange of the pump assembly. Tighten capscrews to 90 N•m (66 lbf ft).

Connect the hydraulic hoses to the pump assembly. Tighten capscrews for flange of high-pressure hoses to 190 N•m (140 lbf ft). If necessary, tighten capscrews for flange of suction hose to 88 N•m (65 lbf ft).

Warning: Never start the engine when pumps are not filled with oil. Verify that the pumps are filled with oil by removing the drain line and fill the pump chamber by using the drain opening. Otherwise this can cause serious damage and loss of durability to the pump(s).

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

Start engine and operate hydraulic system. Check that functions work correctly.

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.

!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. Make sure compressed air path is away from all personnel. Wear eye protection.

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

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

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

Sign off on the cab manifold maintenance

Position the load holding valve on the derricking cylinder.

Install the four capscrews that fasten the load holding valve onto the derricking cylinder.

Remove caps and connect the hydraulic lines to the load holding valve according to the identification tags made during removal.

Connect the electrical wires to the load holding valve 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 load holding valve work correctly. Check for any leaks.

Did the load holding valve work correctly?

NOTE: Only use plugs that have been cleaned in solvent.

NOTE: In the event that seals are missing, check manifold for missing seals and remove.

NOTE: Cartridge valves and switches are not field serviceable with exception of external seals and electrical solenoids. In event of a defective component, completely replace valve or switch.

NOTE: Check manifold for cracks. If there are cracks in manifold, the manifold must be replaced.

The valves and pressure switch seals are serviceable parts of the manifold.

Unscrew the cartridge valve or switch from manifold.

Check that all seals are attached to cartridge valve or switch.

Install a temporary plug in place of cartridge valve or switch.

Upload a photo of the disassembled manifold.