Hyster Forklift RS45-31CH

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 to relieve hydraulic pressure. Enter the number of times brakes were applied

Loosen the brake filter by using a wrench to turn the bowl counterclockwise

Install the bowl by turning the bowl clockwise

Torque the bowl. Enter the torque value in N•m

!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.

Select the parts that need to be replaced

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.

Sign off on the cab manifold installation

Two methods are given for checking the volume of flow from the hydraulic pump. The first method uses a flow meter, a pressure gauge, and a needle valve. The second method uses a needle valve, a pressure gauge, a container, and a timer.

1. If the flow meter is available, install flow meter between needle valve and outlet port of pump. See Figure 5. Pressure gauge must be between needle valve and pump. Make a separate check for each system.

When hydraulic oil is at operating temperature, run engine at 2100 rpm with no load on hydraulic system. Note reading of flow meter. Compare output rate of pump with specification found in the Specifications section.

!WARNING: Hydraulic oil can be hot. Do not touch oil during tests.

2. Run engine at high limit. Slowly close needle valve until gauge indicates a pressure just below specification for relief valve setting. Pump out- put at high pressure must be within 25% of out- put with no load. If output at high pressure is less than 75% of low pressure output, pump has a problem.

1. Another method of checking pump output is to measure the amount of oil moved in a given amount of time. See Figure 6. Run engine until oil is 55 to 65 C (130 to 150 F).

Disconnect line from outlet port of pump. Install a 0 to 21 MPa (0 to 3050 psi) pressure gauge on a tee fitting connected to a hose from outlet port. Install needle valve on end of hose.

NOTE: Use new O-rings during assembly

NOTE: Lubricate parts with hydraulic oil before assembly.

Verify internal parts of the pump are clean.

Install the swash plate section in the pump housing.

Install the O-rings in the pump housing.

Install the adjustment shim on the drive shaft.

Install the bearing on the drive shaft.

Align the port plate to the pump housing with the cylinder pin.