Hyster Forklift RS46-40CH

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?

!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 Derricking Circuit Maintenance

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.

Cab Manifold Installation successful?

Sign off on the cab manifold installation

Lower boom completely and close shutoff valves on the bottom of the hydraulic tank

Shut down the engine and apply the parking brake

Apply brakes minimum 10 times to relieve hydraulic pressure

Drain hydraulic oil from hydraulic tank

Remove bolts retaining the inspection cover

Remove suction filters by turning each filter counterclockwise

Install new suction filters by turning each filter clockwise

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.