Hyster Forklift RS45-27CH

Component/valve lubricated with clean hydraulic oil

Component/valve or switch installed and torqued to value listed in the Torque Specifications

Sign off on the Boom Extension Circuit Assemble

!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 rear side of the outer boom.

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.

Loosen the brake filter by using a wrench to turn the bowl counterclockwise. See Figure 12.

Install the bowl by turning the bowl clockwise.

Torque the bowl to 20 N•m (14.7 lbf ft).

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?

Shut down the engine and apply the parking brake

Apply brakes minimum 10 times to relieve hydraulic pressure

Remove the capscrews retaining the cover of the filters. See Figure 13

Carefully remove the filter cartridge

Verify the O-ring is in good condition. Replace if necessary