Hyster RS46-29, RS46-33, RS46-36CH, RS46 41L-S-LS-XLS CH (E222) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 3004

File Size: 260.47 MB (Speed Download Link)

Brand: Hyster

Model: RS46-29-33-36CH, RS46 41L-S-LS-XLS CH (E222) Forklift

Type of Document: Service Manual

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Hyster RS46-29, RS46-33, RS46-36CH, RS46 41L-S-LS-XLS CH (E222) Forklift Service Manual

Hyster RS46-29-33-36CH, RS46 41L-S-LS-XLS CH (E222) Forklift Service Manual

Hyster RS46-29-33-36CH, RS46 41L-S-LS-XLS CH (E222) Forklift Index:

Series Code / Model Designation Reference Table
General
- Precautions
Special Tools
Section 1 – Drive Shaft Repair
- Drive Shaft Assembly
  - Remove
  - Disassemble
  - Inspect
  - Assemble
  - Install
Section 2 – Engine and Transmission Repair
- Engine and Transmission Assembly
  - Preparations
  - Remove Engine and Transmission
  - Install Engine and Transmission
  - Finalizing
- Engine Repair
- Transmission Assembly
  - Remove
  - Install
- Transmission Components
  - Transmission Disassemble
  - Clean and Inspect
  - Assemble
  - Transmission Full Flow Control Valve
- Transmission Test and Calibration
  - Precautions
  - Transmission Oil Sampling
  - Stall Test
  - Inching Calibration
  - Clutch Filling Calibration
- Electrical Specifications
Section 3 – Engine Intake and Exhaust Repair
- Air Filter Assembly
  - Remove
  - Install
- Fuel Tank
  - Remove
  - Clean and Repair
  - Install
- DEF System
- DEF System Assembly
- DEF System Components
  - DEF Tank
  - DEF Tank Fill Cap
  - DEF Tank Unit
  - DEF Tank Suction Filter
  - DEF Pump Assembly
  - DEF Pump Filter
  - DEF Dosing Valve
- Checks and Adjustments
  - DEF Dosing Valve
  - DEF Pump
- Exhaust System
  - Exhaust System (Tier 3/Stage IIIA)
  - Exhaust System (Tier 4F/Stage IV)
Section 4 – Drive Axle Repair
- Drive Axle Assembly
  - Remove
  - Install
- Drive Axle Components
  - Planetary Gear Assembly
  - Differential Assembly
  - Parking Brake
- Drive Axle Checks and Adjustments
  - Oil Drain and Refill Procedures
- Drive Axle Torque Specifications
Section 5 – Steering Axle Repair
- Steering Axle Assembly
  - Remove
  - Install
- Steer Axle Components
  - Tie Rods
  - Steering Cylinder
  - Wheel Hub
  - Wheel Stud Replacement
  - Spindle
- Steer Axle Torque Specifications

Series Code / Model Designation Reference Table
General
- Precautions
Special Tools
Section 1 – Drive Shaft Repair
- Drive Shaft Assembly
  - Remove
  - Disassemble
  - Inspect
  - Assemble
  - Install
Section 2 – Engine and Transmission Repair
- Engine and Transmission Assembly
  - Preparations
  - Remove Engine and Transmission
  - Install Engine and Transmission
  - Finalizing
- Engine Repair
- Transmission Assembly
  - Remove
  - Install
- Transmission Components
  - Transmission Disassemble
  - Clean and Inspect
  - Assemble
  - Transmission Full Flow Control Valve
- Transmission Test and Calibration
  - Precautions
  - Transmission Oil Sampling
  - Stall Test
  - Inching Calibration
  - Clutch Filling Calibration
- Electrical Specifications
Section 3 – Engine Intake and Exhaust Repair
- Air Filter Assembly
  - Remove
  - Install
- Fuel Tank
  - Remove
  - Clean and Repair
  - Install
- DEF System
- DEF System Assembly
- DEF System Components
  - DEF Tank
  - DEF Tank Fill Cap
  - DEF Tank Unit
  - DEF Tank Suction Filter
  - DEF Pump Assembly
  - DEF Pump Filter
  - DEF Dosing Valve
- Checks and Adjustments
  - DEF Dosing Valve
  - DEF Pump
- Exhaust System
  - Exhaust System (Tier 3/Stage IIIA)
  - Exhaust System (Tier 4F/Stage IV)
Section 4 – Drive Axle Repair
- Drive Axle Assembly
  - Remove
  - Install
- Drive Axle Components
  - Planetary Gear Assembly
  - Differential Assembly
  - Parking Brake
- Drive Axle Checks and Adjustments
  - Oil Drain and Refill Procedures
- Drive Axle Torque Specifications
Section 5 – Steering Axle Repair
- Steering Axle Assembly
  - Remove
  - Install
- Steer Axle Components
  - Tie Rods
  - Steering Cylinder
  - Wheel Hub
  - Wheel Stud Replacement
  - Spindle
- Steer Axle Torque Specifications

Series Code / Model Designation Reference Table
General
Section 1 – Electrical
- General Fault Finding
  - Preparation
  - Define the Problem Area
  - Identify Possible Causes of Malfunction
  - Determine the Most Probable Cause
  - Fuse Check
  - Wiring Check
  - Component Check
  - Repair and Test
- Harnesses and Connectors
  - Harnesses Overview
  - Harness Connectors and Terminals
  - Wire Harness Identification and Connector Location
  - Fuses, Relays and Fly-Back Diodes
- CANbus Circuit
- Information Display
- Greasing System Electrical
Section 2 – Software
- Hydraulic Control System
  - Safety precautions and tips
  - List of abbreviations
  - Installing the Hydraulic User Interface Program
  - Service Tool instructions
  - Warning screen/Language selection
  - Truck Configuration
  - Installed Features
  - Operator Input
  - Flow settings
  - Valve settings
  - Ramp Settings
  - Diagnostics
  - Active Errors
  - Fault Cause PVE Actuator
  - Controller pinning
- File Uploads/Downloads
  - Connecting to the Hydraulic Control Unit
  - Check the current software version
  - Download a P1T (Parameter-file)
  - Download a ROP file
  - Tips and Tricks
- Truck Configuration Options
Section 3 – Controls
- Instrument Panel
  - Central Warning Lights
  - Instrument Panel Overview
  - Instrument Panel Connectors
- Fault Codes on LCD Display
  - Fault Code Mode
  - Transmission Calibration
  - Fault Code Log Mode

Series Code / Model Designation Reference Table
General
Section 1 – Electrical
- General Fault Finding
  - Preparation
  - Define the Problem Area
  - Identify Possible Causes of Malfunction
  - Determine the Most Probable Cause
  - Fuse Check
  - Wiring Check
  - Component Check
  - Repair and Test
- Harnesses and Connectors
  - Harnesses Overview
  - Harness Connectors and Terminals
  - Wire Harness Identification and Connector Location
  - Fuses, Relays and Fly-Back Diodes
- CANbus Circuit
- Information Display
- Greasing System Electrical
Section 2 – Software
- Hydraulic Control System
  - Safety precautions and tips
  - List of abbreviations
  - Installing the Hydraulic User Interface Program
  - Service Tool instructions
  - Warning screen/Language selection
  - Truck Configuration
  - Installed Features
  - Operator Input
  - Flow settings
  - Valve settings
  - Ramp Settings
  - Diagnostics
  - Active Errors
  - Fault Cause PVE Actuator
  - Controller pinning
- File Uploads/Downloads
  - Connecting to the Hydraulic Control Unit
  - Check the current software version
  - Download a P1T (Parameter-file)
  - Download a ROP file
  - Tips and Tricks
- Truck Configuration Options
Section 3 – Controls
- Instrument Panel
  - Central Warning Lights
  - Instrument Panel Overview
  - Instrument Panel Connectors
- Fault Codes on LCD Display
  - Fault Code Mode
  - Transmission Calibration
  - Fault Code Log Mode

Series Code / Model Designation Reference Table
General
Precautions
Section 1 – Cab Repair
- Operator’s Cab Assembly
  - Preparations before Removal
  - Remove
  - Install
- Cab Sliding System
  - Powered Cab Sliding System
- Cab Windows
  - Window Replacement
  - Window Wipers
  - Window Washer System
  - Window Washer Spray Nozzles
- Cab Door Assembly
  - Cab Door
  - Door Hinge
  - Door Latch
  - Door Handle
  - Door Release
  - Door Push Button
- Steering Wheel and Steering Column Assembly
  - Steering Wheel and Horn
  - Steering Column Assembly
  - Adjustment Handle
  - Main Warning Lights
  - Shift Lever
  - Turn Signal Lever
- Pedals
  - Brake and Inching Pedal
  - Accelerator Pedal and Sensor
- Instrument Panel
  - Key Switch and Override Key Switch
  - 12V Power Socket
  - Electric-Operated Heat Control and Air Recirculation Control (Airco Only)
  - Cable-Operated Heater Control (Heater Only)
  - Air Conditioning Switch Replacement
  - Instrument Panel Rocker Switches Replacement
  - Parking Brake Switch
  - Information Display
  - Instrument Cluster
  - Instrument Panel Top Console
- Seat Assembly
  - Remove
  - Install
- Seat Components
  - Seat Cushion
  - Back Cushion
  - Seat Suspension Replacement
  - Boot Replacement
- Power Assist Armrest
  - Release Cable
  - Gas Spring
  - Joystick
  - Electrical Levers
  - Armrest Rocker Switches
  - Armrest Top Cover
- Cab Interior
  - Floor Mat
  - Radio Console
  - Air Duct Replacement
- Accessories
  - Mirror Replacement
  - Sunshade Replacement
  - Map Light Replacement
  - Interior Fan Replacement
  - Training Seat
- Checks and Adjustments
  - Label Check and Replacement
  - Door Striker Pin Adjustment
  - Brake and Inching Pedal Adjustment
Section 2 – Cab Heater and Air Conditioner Repair
- Heater Assembly
  - Access
  - Remove
  - Install
- Heater Parts
  - Heater Core
  - Blower
  - Water Valve
- Push/Pull Cable
  - Water Valve Cable
  - Heater/Air Conditioning Assembly
- Heater/Air Conditioner Parts
  - Vent Door
  - Heater Core
  - Evaporator Core
  - Blower
  - Thermostat
  - Water Valve
- Filtration
  - Fresh Air Filter
  - Recirculation Air Filter
- Air Conditioning Technical Detail
- Maintenance Procedures and Required Equipment
  - Maintenance Procedures
  - Installing Manifold Gauges
  - Refrigerant Recovery
  - Refrigerant Leak Check
  - Evacuation and Dehydration
  - Procedure For Evacuation and DehydratingSystem (One Time Evacuation)
  - Adding Refrigerant to a System
  - Filter Drier