Hyster RS45-27CH Manual
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Hyster RS45-27CH Manual

Hyster RS45-27CH Manual

Hydraulic system
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HYDRAULIC SYSTEM
RS45-27CH, RS45-31CH, RS46-36CH, RS46-
40CH, RS46-41S CH, RS46-41L CH, RS46-41LS
CH, RS45-24IH, RS45-28IH, RS46-33IH,
RS46-37IH, RS46-38S IH, RS46-38L IH,
RS46-38LS IH (HR45-27, HR45-31,
HR45-36, HR45-40, HR45-41S, HR45-41L,
HR45-41LS) [B222]
PART NO. 1638189
1900 SRM 1257

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Summary of Contents for Hyster RS45-27CH

  • Page 1 HYDRAULIC SYSTEM RS45-27CH, RS45-31CH, RS46-36CH, RS46- 40CH, RS46-41S CH, RS46-41L CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH, RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222] PART NO. 1638189 1900 SRM 1257...
  • Page 2 • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 3: Table Of Contents

    Clean and Inspect ............................Assemble Valves and Pressure Switches...................... Install ................................Derricking Circuit .............................. Repair ................................Load Holding Valve ........................... Remove ..............................Disassemble............................Clean and Inspect ..........................Assemble..............................Install..............................Derricking Cylinders..........................Boom Extension Circuit............................. Repair ................................Load Holding Valve ........................... ©2007 HYSTER COMPANY...
  • Page 4 Troubleshooting..............................Diagrams, Schematics, or Arrangements ......................This section is for the following models: RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH, RS46-38S IH, RS46-38L IH,RS46-38LS IH (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222]...

  • Page 5: General

    1900 SRM 1257 Description and Operation General This section has the description and operation of the • Service Brake 1800 SRM 1038 hydraulic system. The section also has repair pro- • Hydraulic Plate 2000 SRM 1258 cedures and troubleshooting for most of the compo- •...

  • Page 6: Hydraulic Pumps

    Description and Operation 1900 SRM 1257 1. MANIFOLD SECTION 3. BRAKE MANIFOLD SECTION 2. MAIN CONTROL VALVE SECTION 4. FLOW AMPLIFIER SECTION Figure 1. Hydraulic Plate Sections HYDRAULIC PUMPS LS SYSTEM There are three hydraulic pumps (two variable dis- The LS (load sense pressure) system works on the placement pumps and one gear pump) on the Lift following principles: Truck.

  • Page 7: Load Limiter

    1900 SRM 1257 Description and Operation Load Holding Valve (Extension) pumps will supply the necessary amount of flow to generate the preset pressure drop. This block mounted on the base of the telescope cylin- der has the following two functions: LOAD LIMITER •...

  • Page 8: Brake System

    Hydraulic Pump Repair 1900 SRM 1257 to the steering cylinder is five times larger than the Table 1. Brake Treadle Settings input from the steering unit. Service Brake Service Brake (MSB1) BRAKE SYSTEM Treadle (MSB4) 17.0 to 17.5 MPa Maximum 16 MPa Oil from the hydraulic pump goes to an accumulator (2466 to 2538 psi) (2320 psi)
  • Page 9 1900 SRM 1257 Hydraulic Pump Repair 6. Disconnect high-pressure line at the outlet port it falls. Verify that the pump assembly is prop- on the pump side of the variable displacement erly supported before removing capscrews. pump. Raise the end of the line above hydraulic 8.

  • Page 10: Disassemble

    Hydraulic Pump Repair 1900 SRM 1257 DISASSEMBLE 4. Remove the four socket head bolts that hold the port plate to the pump housing. Hydraulic Pump Assembly 5. Separate the port plate from the pump housing. 1. Remove the two capscrews that hold the hy- 6.

  • Page 11: Clean And Inspect

    1900 SRM 1257 Hydraulic Pump Repair 1. DRIVE SHAFT 7. O-RING 2. PUMP HOUSING 8. PORT PLATE 3. SWASH PLATE SECTION 9. O-RING 4. O-RING 10. ADJUSTMENT SHIM 5. SOCKET HEAD BOLTS 11. BEARING 6. SPLINED HUB 12. CYLINDER PIN Figure 4.

  • Page 12: Assemble

    Hydraulic Pump Repair 1900 SRM 1257 ASSEMBLE WARNING Variable Displacement Pump Each pump assembly weighs approximately 45 kg (100 lb) and can cause injury or damage NOTE: Use new O-rings during assembly if it falls. NOTE: Lubricate parts with hydraulic oil before as- 2.

  • Page 13: Pump Output Check

    1900 SRM 1257 Hydraulic Pump Repair PUMP OUTPUT CHECK no load on hydraulic system. Note reading of flow meter. Compare output rate of pump with speci- Two methods are given for checking the volume of fication found in the Specifications section. flow from the hydraulic pump.

  • Page 14: Second Method

    Hydraulic Pump Repair 1900 SRM 1257 Second Method 2. Needle valve must be fully open. Start engine and run engine at its governed RPM for 5 sec- 1. Another method of checking pump output is to onds. Stop engine. Measure volume of oil that measure the amount of oil moved in a given entered container in 5 seconds.

  • Page 15: Cab Manifold

    1900 SRM 1257 Cab Manifold Cab Manifold REMOVE NOTE: Cartridge valves and switches are not field serviceable with exception of external seals and elec- NOTE: All pressure switches, valves, and other as- trical solenoids. In event of a defective component, sociated items installed on the manifold can be re- completely replace valve or switch.
  • Page 16 Cab Manifold 1900 SRM 1257 1. VALVE 6. FITTING 2. FITTING 7. FITTING 3. O-RING 8. O-RING 4. SEAL 9. PRESSURE SWITCH 5. PRESSURE SWITCH 10. QUICK DISCONNECT FITTING Figure 7. Cab Manifold...

  • Page 17: Assemble Valves And Pressure Switches

    1900 SRM 1257 Cab Manifold ASSEMBLE VALVES AND PRESSURE WARNING SWITCHES Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components. 1. Install new seals. Hydraulic oil can be injected into the body by 2. Lubricate component/valve with clean hydraulic pressure.

  • Page 18: Derricking Circuit

    Derricking Circuit 1900 SRM 1257 Derricking Circuit REPAIR Disassemble NOTE: Only use plugs that have been cleaned in sol- Load Holding Valve vent. Remove NOTE: In the event that seals are missing, check manifold for missing seals and remove. WARNING Lower boom completely before working on NOTE: Cartridge valves are not field serviceable with control valve or hydraulic system.

  • Page 19: Assemble

    1900 SRM 1257 Derricking Circuit 1. PLUG 9. VALVE (DIRECTIONAL CONTROL) 2. VALVE 10. PLUG 3. VALVE 11. PLUG 4. VALVE (DIRECTIONAL CONTROL) 12. CHECK VALVE 5. RELIEF VALVE 13. PLUG 6. PLUG 14. VALVE 7. SCREW 15. SCREW 8. PLUG Figure 8.

  • Page 20: Install

    Boom Extension Circuit 1900 SRM 1257 Install Hydraulic oil can be injected into the body by pressure. 1. Position the load holding valve on the derricking cylinder. CAUTION 2. Install the four capscrews that fasten the load Never start the engine with closed shutoff holding valve onto the derricking cylinder.

  • Page 21: Clean And Inspect

    1900 SRM 1257 Boom Extension Circuit 1. Unscrew the cartridge valve from the load hold- cause injury to the user or to other personnel. ing valve. See Figure 9. Verify compressed air path is away from all 2. Check that all seals are attached to cartridge personnel.

  • Page 22: Assemble

    Attachment Circuit Valves 1900 SRM 1257 Assemble WARNING 1. Install new seals. Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components. 2. Lubricate component/valve with clean hydraulic Hydraulic oil can be injected into the body by oil before installation.

  • Page 23: Other Hydraulic Components

    1900 SRM 1257 Other Hydraulic Components Other Hydraulic Components DESCRIPTION AND OPERATION • High pressure filter (20 micron). The high pressure filter is located at the main man- Relief Valves in Steering System ifold on the hydraulic plate. The high pressure fil- ter is the last catch filter to filter oil flow to the pilot See the section Steering System 1600 SRM 1109 for system.

  • Page 24: High Pressure Filter

    1. MAIN MANIFOLD NOTE: Only use seal rings specified by your local 2. BOWL Hyster dealer. Using seal rings other than specified can lead to hydraulic oil leakage. Figure 11. High Pressure Filter 10. Install inspection cover using seal rings and 5.

  • Page 25: Return Line Filters

    1900 SRM 1257 Other Hydraulic Components 3. Apply brakes minimum 10 times to relieve hy- 4. Remove the capscrews retaining the cover of the draulic pressure. filters. See Figure 13. 4. Loosen the brake filter by using a wrench to turn the bowl counterclockwise.

  • Page 26: Hydraulic Tank Breathers

    NOTE: Verify the O-ring is in good condition. Replace if necessary. NOTE: Only use an O-ring specified by your local Hyster dealer. Using an O-ring other than specified can lead to hydraulic oil leakage. 9. Lightly grease the O-ring with lubrication grease 1.

  • Page 27: Main Function Relief Valve Pressure, Check

    1900 SRM 1257 Other Hydraulic Components Main Function Relief Valve Pressure, 3. Check pressure gauge according to the specifica- tions shown in Table 3. Check 4. To adjust a relief valve setting, remove cap. NOTE: The relief valves in the main manifold, main Loosen lock nut and use an Allen wrench to turn control valve, and flow amplifier are adjustable.

  • Page 28: Specifications

    Specifications 1900 SRM 1257 Table 3. Pressure Settings (Continued) Check Port Correct Pressure Procedure MLS1 16.5 to 20.5 MPa (2393 to 2973 psi) Engine running at idle (850 rpm). Measure during charging. complete charge cycle. NOTE: The readout can be performed from the display.

  • Page 29: Main Hydraulic Filters

    1900 SRM 1257 Torque Specifications MLS2 - Load Sense Pressure to Pump 2 MSB4 - Service Brake Treadle Pressure (steering relief pressure) (at 2100 rpm) 21.0 to 22.5 MPa (3046 to 3263 psi) Maximum 16 MPa (2321 psi) MLS2 - Load Sense Pressure to Pump M STEER - Steering Circuit (at 2100 rpm) 2 (main relief pressure) 21.0 to 22.5 MPa (3046 to 3263 psi)

  • Page 30: Troubleshooting

    Troubleshooting 1900 SRM 1257 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Oil leaks at the end caps of End cap seals have defects. Replace seals. the spools. Valve body has a defect. Replace control valve section. Spool will not move. No pilot pressure.
  • Page 31 1900 SRM 1257 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Boom extension cylinder re- Cylinder seal has defects. Repair cylinder. tracts when lever is in NEU- TRAL position. Pilot pressure activated. Check remote control valve springs. Pump does not switch back Main relief is set lower than LS relief Check and adjust if necessary.
  • Page 32 Troubleshooting 1900 SRM 1257 PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Derricking DOWN: LH2 no signal when function is ap- 1. CM1 activated but no signal movement. plied. when function is applied. volts must be available. 2. Check if spool 1 and/or 2 are sticking.

  • Page 33: Diagrams, Schematics, Or Arrangements

    1900 SRM 1257 Diagrams, Schematics, or Arrangements PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Telescope IN: Slow move- No 2-speed function. CM13 no sig- 1. Check if spool is on hand temper- ment. nal. ature. 2. Push manual override button CM13 (under plastic cap). When operating is possible during but- ton pushed, electrical signal is not applied or solenoid is defect.
  • Page 34 NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________...

  • Page 36: Technical Publications

    TECHNICAL PUBLICATIONS 1900 SRM 1257 7/07 (8/06)(6/06) Printed in United Kingdom...

This manual is also suitable for:

Rs45-31chRs46-36chRs46-40chRs46-41s chRs46-41l chRs46-41lsch ... Show all

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