Hyster D222 (RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L-CH, RS46-41S-CH, RS46-41LS-CH) Reach Stacker Service Manual
1,297 pages · Publication D222
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- Models
- D222 (RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L-CH, RS46-41S-CH, RS46-41LS-CH)
- Manual type
- Service Manual
- Pages
- 1,297
- Publication
- D222
- Condition
- Brand new
What's inside
From the manual's own table of contents: 165 sections, 625 entries. See sample pages (PDF, 251 KB)
Differential
Safety Precautions Maintenance and Repair
General
Description
Differential Repair23 topics
- Remove
- Differential Carrier From Axle Housing, Remove
- Differential and Ring Gear From Differential Carrier, Remove
- Drive Pinion and Pinion Carrier From Differential Carrier, Remov
- Disassemble
- Differential and Ring Gear Assembly, Disassemble
- Drive Pinion and Pinion Carrier, Disassemble
- Clean and Inspect
- Assemble
- Pinion, Bearings, and Pinion Carrier, Assemble
- Pinion Bearings, Adjust Preload
- Triple-Lip Seal, Install
- Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)
- Differential and Ring Gear, Assemble
- Differential Gears Rotating Torque, Check
- Differential and Ring Gear Assembly, Install
- Differential Bearings, Preload Adjust
- Ring Gear, Runout Check
- Ring Gear Backlash, Adjust
- Gear Set, Tooth Contact Pattern Check
- Thrust Screw, Install and Adjust
- Install
- Differential Assembly Into Axle Housing, Install
Specifications
Troubleshooting
Table 1. Ring Gear Backlash Adjustment Specifications
Table 2. Ring and Pinion Tooth Contact Adjustment
Table 3. General Specifications
Table 4. Rivet Installation Pressure
Table 5. Pinion Adjustment
Table 6. Pinion Preload Pressure
Table 7. Torque Specifications
Table 8. Torque Specifications for Metric Hardware
Table 9. Torque Specifications for Metric (Fine) Hardware
Extendable Container Attachment (Elme)
Operation15 topics
- General
- Pressure Valve
- Damping
- Optional Power Damping
- Rotator Circuit
- Rotator Transmission
- Optional Powered Pile Slope
- Optional Tilt Float
- Extend and Retract Circuit
- Twist Lock Circuit
- Seated Signal
- Electrical Circuit
- Fault Finding
- Additional Functions
- Automatic Locking
Container Attachment Repair
Swivel Repair
Extension Cylinders Repair2 topics
- Clean
- Inspect
Sideshift Cylinder Repair
Power Pile Slope Cylinder Repair
Pendular Twist Locks Repair
Show all 165 sections
Adjustments9 topics
- Twist Lock Angle
- LOCKED/NOT LOCKED Proximity Switches
- Maximum Pressure
- Swivel Valve
- Damping Pressure
- Power Pile Slope Pressure
- Rotation/Brake Valve
- Sideshift Valve
- Extension Valve
Maintenance2 topics
- General Maintenance
- Additional Spreader Maintenance
Torque Specifications
Maintenance Schedule
Table 1. Maintenance Schedule
Intermodal Container Attachment1 topic
- Folding Legs Circuit
Folding/Clamping Cylinder Repair
Upper Leg Folding Cylinder Repair
Lower Leg Folding Cylinder Repair
Table 2. ELME Schematic Overview
Brake Accumulator
Description and Operation
Accumulator Maintenance4 topics
- Pre-Charge Check
- Pre-Charge Filling
- Repair
- Replace
Table 1. Accumulator Pressures
Service Brake1 topic
- B222 Only
Repair17 topics
- Drive Wheels and Tires
- Brake Housing
- Spindle and Brake Cover
- Ground and Polished Parts
- Parts With Rough Finish
- Wet Disc Brake and Axle Assembly
- Face Seals
- Disc
- Parts
- Brake Housings
- Hub Oil Seals
- Spindle and Brake Cover
- Brake Housing
- Drive Wheels and Tires
- Pressure Switch
- Replace
- Accumulator
Brake Pedal Valves (Treadle Valves) Repair6 topics
- Remove
- Clean and Inspect
- Install
- Remove
- Clean and Inspect
- Install
Brake System Air Removal3 topics
- Brake Coolant
- Coolant Change Intervals
- Hydraulic Fluid
Measurements and Adjustments
Table 1. Friction Disc
Table 2. Stationary Disc
Table 3. Wheel Hub and Brake Housing Torque Chart
Table 4. Brake Housing Cover Torque Chart
Parking Brake
Parking Brake Valve Replacement
Parking Brake Caliper Repair2 topics
- Bleed Brakes
- Adjust
Brake Pad Repair
Seals Repair3 topics
- Torque Requirements
- Wear Limits
- Lining to Disc Clearance
Table 1. Brake Pad Adjustment
Table 2. Torque Requirements
Table 3. Wear Limits
Table 4. Lining to Disc Clearance
Planetary Gear Axle
Planetary Gear Axle Repair24 topics
- Drive Wheels and Tires
- Drive Axle
- Planetary Gear Carrier
- Ring Gear, Ring Gear Hub, and Wheel Hub
- Hub Oil Seal and Bearings
- Axle Shaft
- Spindle
- Repairing or Replacing Parts
- Welding
- Ground or Polished Parts
- Parts With Rough Finishes
- Axle Assemblies
- Drying Cleaned Parts
- Preventing Corrosion
- Parts Inspection
- Spindle
- Axle Shaft
- Hub Oil Seal and Bearings
- Ring Gear, Ring Gear Hub, and Wheel Hub
- Wheel Bearing Preload
- Planetary Gear Carrier
- Drive Axle
- Wheel Ends
- Drive Wheels and Tires
Table 1. Wheel Bearing Adjustment Torque
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi
Table 3. Standard Torque Values for Axle Fasteners
Boom1 topic
- Hydraulic System
Boom Repair
Dampening Cylinder Repair
Boom Extension Cylinder Repair
Derricking Cylinder Repair
Stabilizer38 topics
- Slave Unit
- Pressure Transducers
- General
- Pressure Transducers Stabilizer Cylinders
- Pressure Transducer Steering System
- Stabilizer Manifold
- Applying the Stabilizer
- Returning to Drive Mode
- Electrical Wire Harnesses
- Controller Harness
- Remove
- Install
- Stabilizer Harness
- Remove
- Install
- Stabilizer Manifold Harness
- Remove
- Install
- Remove
- Install
- Pressure Transducers Stabilizer Cylinders
- Pressure Transducers Steering Function
- Stabilizer Plate
- Remove
- Install
- Stabilizer Cylinders
- Remove
- Disassemble
- Clean
- Inspect
- Assemble
- Install
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Stabilizer Cylinder
Table 1. Component Purpose Description
Grease Type Steering Axle
How to Put Lift Truck on Blocks1 topic
- How to Lift Steer Tires
Steering Axle Assembly
Wheels and Hubs2 topics
- Remove and Disassemble
- Assemble and Install
Tie Rod8 topics
- Steering Cylinder Side
- Spindle Side
- Steering Cylinder Side
- Spindle Side
- Steering Cylinder Side
- Spindle Side
- Steering Cylinder Side
- Spindle Side
Spindles
Steering Cylinder4 topics
- Steering Axle Mounting
- Wheels and Hub Mounting
- Spindle Mounting
- Steering Cylinder Mounting
Frame
Engine Air Cleaner Removal and Replacement
Exhaust System Removal and Replacement
Covers
Floor Plates, Handrails, and Steps
Hydraulic Tank Removal and Replacement9 topics
- Small Leaks
- Large Leaks
- Steam Method
- Chemical Solution Method
- Other Methods of Preparation for Repair
- Suction Filter and Cover Plate
- Remove
- Clean and Inspect
- Install
Fuel Tank Removal and Replacement
Cab Removal Repair4 topics
- Cab Removal
- Remove
- Install
- Powered and Non-Powered Cab Slide Options
Engine and Transmission Removal and Replacement
Cooling System Repair
Counterweight Removal and Replacement
Label Replacement
Table 1. Counterweight Weights
Hydraulic Control System45 topics
- Control Valve
- Analog Inputs
- Joysticks
- Sensors
- Digital Inputs
- Hydraulic Control Switches
- Interrupts
- Operator Presence System (OPS)
- Lift Interrupt (Twist Module)
- Lift Interrupt (Boom End Position Switch)
- Derrick-Up Cut Off (LMI System)
- Derrick-Down Cut Off (LMI System)
- Telescope-Out Cut Off (LMI System)
- Telescope-In Cut Off (LMI System)
- Function Override
- Digital Switched Inputs
- ECO eLo HiP Switch
- Disable Two Speed
- Not Locked Signal
- Calibration Switch
- Ignition Switch Signal
- Brake Filter Pressure Switch
- Pressure Signal
- No Feet Seated and First Foot Seated
- CAN Bus Communication
- Output Signals
- Analog Outputs
- Digital Outputs
- Programmed Features
- Loaded Speed Reduction (Optional)
- High Temperature Protection (Optional)
- Two Speed Lift (Standard)
- Two Speed Lift at Weight (Optional)
- Anti-Stall (Standard)
- Temperature Protection (Standard)
- Low-Temperature Protection (Standard)
- Load Position Vehicle Speed Reduction (Standard)
- Automatic Throttle Up (Standard)
- HiP/ECO eLo Operating Mode (Standard)
- Mandatory Vehicle Speed Limit (Inter Modal Handler only)
- FAN Drive System (Standard)
- Hibernate Idle (Standard, Tier 4 Only)
- Second Pump Enable (Standard)
- Settings
- Adjustable Parameters
General Functions of the Interface29 topics
- Main Functional Requirements
- What is Needed for the Hydraulic User Interface Program
- Installation of the Program
- Start Screen
- Warning Screen
- Basic Screen Layout of the Hydraulic User Interface Program
- Truck Configuration Screen
- Responsiveness Definition Screen
- Installed Features Screen
- Loaded Speed Reduction Screen
- Temperature Protection Screen
- Two Speed Lift At Weight Screen
- Anti-Stall Screen
- Load Position Vehicle Speed Reduction Screen
- Automatic Throttle Up-Derrick Screen
- HiP/ECO eLo Operating Mode Screen
- Fan Drive Settings Screen
- Hibernate Idle Screen
- Second Pump Enable Screen
- Calibration Screen
- Profile Derrick-Up Screen
- Flow Settings Screen
- Valve Settings Screen
- Maximum Derrick-Up Current Screen
- Diagnostic Screen
- Active Errors Screen
- Error History Screen
- All Parameters Screen
- Installing the Hydraulic Controller Software and Read-Only Param
Calibration4 topics
- Calibrating the Lever With the Hydraulic User Interface Program
- Calibrating the Joystick With the Hydraulic User Interface Progr
- Calibrating the Lever Without the Hydraulic User Interface Progr
- Calibrating the Joystick Without the Hydraulic User Interface Pr
Fault Codes
Controller Pinning
Table 1. Temperature and Maximum Engine Speed
Table 2. Hydraulic User Interface Program Overview
Table 3. Parameters
Table 4. Temperature & Maximum Rpm
Table 5. XML Parameter File Content
Table 6. Fault Code Table
Table 7. Cab Controller
Table 8. Frame Controller
Hydraulic System20 topics
- Hydraulic Pumps
- LS System
- Hydraulic Plate
- Manifold Section
- Service Brake
- Parking Brake
- Main Control Valve
- Description
- Operation
- Brake Manifold
- Cooling Circuit
- Flow Amplifier
- Derricking Functions
- Load Holding Valve (Derricking)
- Load Holding Valve (Extension)
- Heat Exchanger System
- Steering Control System
- Flow Amplifier
- Brake System
- Oil-Cooled Brakes (Service Brakes)
Hydraulic Pump Repair6 topics
- Load Sense and Pressure Controller Valve on Pump
- Remove
- Clean
- Inspect
- Assemble
- Install
Derricking Circuit2 topics
- Load Holding Valve
- Derricking Cylinders
Boom Extension Circuit2 topics
- Load Holding Valve
- Boom Extension Cylinder
Attachment1 topic
- Description and Operation
Other Hydraulic Components17 topics
- Relief Valves in Steering System
- Dampening Cylinders
- Hydraulic Filters
- Suction Filters
- High Pressure Filter
- Brake Filter
- Return Line Filters
- Hydraulic Tank Breathers
- Checks and Adjustments
- Main Function Relief Valve Pressure, Check
- Hydraulic Pumps Output at 2100 rpm (Governed Speed)
- Relief Valves (Approximate Operating Pressures)
- Check Port Pressures
- Main Hydraulic Filters
- Tank Capacity
- Attachment Control Valve
- Carriage Solenoid Valve
Table 1. Brake Treadle Settings
Table 2. Gauge Ranges
Table 3. Pressure Settings
Diagrams
Periodic Maintenance8 topics
- Serial Number Data
- How to Move a Disabled Lift Truck
- How to Tow Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Drive Tires
- How to Raise Steering Tires
- How to Clean a Lift Truck
- Container Attachment Maintenance
Maintenance Procedures Every 8 Hours or Daily34 topics
- How to Make Checks With the Engine Stopped
- Warning and Safety Labels
- Wheels, Tires and Tire Pressure
- Wheel Nuts
- Boom, Rotator, and Spreader
- Air Precleaner Dust Bowl
- Hydraulic Tank Breathers
- Radiator Sections for Engine Coolant, Charge Air Cooler, Transmi
- Windshield Washer Fluid
- Hydraulic System Oil
- Engine Oil Level
- How to Make Checks With Engine Running
- Seat Belt, Seat Rails, and Steering Column
- Steering Column Latch
- Gauges, Lights, Horn, Fuses, and Relays
- Windows and Mirrors
- Fault Codes
- Exhaust System High Temperature Light
- Engine Air Filter
- Coolant Level
- Hydraulic Filter Warning Light
- High Pressure Brake Cooling Filter
- Engine Oil Pressure
- Fuel Level
- Control Levers and Pedals
- Parking Brake
- Service Brakes
- Steering System
- Boom, Rotator, and Spreader Operation
- Signals from the Spreader Control System
- Signals from the LMI System
- Transmission
- Operator Presence System
- Transmission Oil Level
First Inspection After First 100 Hours of Operation3 topics
- Transmission Oil Filter
- High Pressure Brake Cooling Filter
- Oil in Rotator Transmission
First Inspection After First 250 Hours Of Operation3 topics
- Steer Wheel Hub, Oil Change and Bearing Adjustment
- Kessler Drive Wheel Hubs, Oil Change and Bearing Adjustment
- Remove Wheels From Lift Truck
Maintenance Procedures Every 250 Hours or 3 Months22 topics
- Warnings and Safety Labels
- Wheels, Tires, and Tire Pressure
- Wheel Nuts
- Air Precleaner
- Fuel, Oil, and Coolant Leaks
- Engine Air Intake Piping and Charge Air Piping
- Coolant Hoses
- Drive Belts
- Engine Compartment
- Radiator Sections for Engine Coolant, Charge Air Cooler, Transmi
- Drive Axle and Differential
- Oil in Steer Wheel Hubs
- Windshield Washer Fluid
- Hydraulic System Oil
- Coolant Level
- Engine Oil Level
- Fuel Filter/Water Separator
- Transmission Oil Level
- Seat Belt, Seat Rails, and Steering Column
- Steering Column Latch
- Operator Presence System
- Tracks for Boom Wear Pads
Maintenance Procedures Every 500 Hours or 3 Months7 topics
- Boom Pivot to Attachment
- Dampening Cylinder Pivot Points
- Boom Pivot to Frame
- Steering Axle Tie Rod Pins
- Kingpins
- Steering Axle Pivots
- Stabilizer Cylinder Rod End
Maintenance Procedures Every 500 Hours or 6 Months4 topics
- Boom Wear Pads
- Boom Side Wear Pads
- Cab Air Filter
- Engine Oil and Oil Filter
Maintenance Procedures Every 1000 Hours or 6 Months5 topics
- Parking Brake and Service Brakes
- Coolant Quality
- Cab Door Hinges
- Transmission Oil and Oil Filter
- Change
Maintenance Procedures Every 1500 Hours or 6 Months1 topic
- Axle Tech, Drive Axle and Differential
Maintenance Procedures Every 2000 Hours or 1 Year5 topics
- Drive Shaft
- Brake System Accumulator
- Turbo Charger
- Transmission Clutch Calibration
- Inching Pedal Sensor Calibration
Maintenance Procedures Every 2500 Hours or 12 Months1 topic
- Remove Wheels From Lift Truck
Maintenance Procedures Every 3000 Hours or 3 Years7 topics
- Hydraulic System Oil and Hydraulic System Suction Filter
- Hydraulic Return Filters
- Engine Coolant Filter
- Brake Return Line Filter
- Engine Cleaning
- Engine and Transmission Mounts
- Wet Brakes Lining Wear
Maintenance Procedures Every 5000 Hours or 3 Years9 topics
- Air Conditioning
- Automatic Greasing System Filter
- Engine Valve Adjustment
- Adjust
- Diesel Particulate Filter (DPF)
- Remove
- Disassemble
- Assemble
- Install
Maintenance Procedures Every 6000 Hours or 2 Years4 topics
- Vibration Damper
- Fan Belt and Tensioner
- Fan Drive Idler Pulley
- Fan Hub
Container Attachment Maintenance Procedures Every 100 Hours4 topics
- Rotator Ring Gear
- Rotator Ring Gear Bearing
- Leg Folding Group (ELME Model 857)
- Foot at Bottom of Legs (ELME Model 857)
Container Attachment Maintenance Procedures Every 250 Hours4 topics
- Attachment
- Signals from the Spreader Control System
- Container Locking Mechanism - Twist Locks
- Oil Level in Rotator Transmissions
Container Attachment Maintenance Procedures Every 500 Hours4 topics
- Attachment Wear Pads
- Sideshift Cylinder Bearings
- Stop Cylinders
- Locking Plate for Stop Cylinder
Container Attachment Maintenance Procedures Every 1000 Hours1 topic
- Extension Cylinder Support Pads
Container Attachment Maintenance Procedures Every 5000 Hours1 topic
- Twist Locks (ELME Models 817 and 857)
Pneumatic Tires and Wheels7 topics
- Remove Wheels From Lift Truck
- Remove Tire From Wheel
- Remove Tire From Five-Piece Wheel
- Install Tire on Wheel
- Install Tire on Five-Piece Wheel
- Add Air Pressure to Tires
- Install Wheels on Lift Truck
Automatic Greasing System1 topic
- Description
Table 1. Daily Inspections − Condition Check
Table 2. Daily Inspections − Fluid Level Check
Table 3. Daily Inspections − Checks With the Engine Running
Table 4. First Inspection After First 100 Hours of Operation
Table 5. First Inspection After First 250 Hours of Operation
Table 6. Periodic Maintenance Schedule − Inspect and Adjust
Table 7. Periodic Maintenance Schedule − Lubricate
Table 8. Periodic Maintenance Schedule − Change
Table 9. Approved Fuels and Engine Oils
Table 10. Initial 100 Hour Inspection
Table 11. Inspect and Adjust
Table 12. Lubricate
Table 13. Change
Table 14. Valve and Injector Adjustment Specifications
Table 15. Injector and Valve Measurement Sequence
Assembly Guide
List of All Special Tools and Equipment Needed for the Assembly
General Considerations Before Starting the Job
Weight and Dimensions
Loading Procedures2 topics
- Loading Complete Truck or Basic Truck on a Transport
- Loading Disassembled Components
Unloading Procedures4 topics
- Unloading Complete Truck or Basic Truck From Transport
- Lifting
- Driving On/Off a Trailer
- Unloading Disassembled Components
How to Move a Disabled Lift Truck1 topic
- How to Tow the Lift Truck
Preparation of the Components Before Assembly
Preparation of the Container Attachment1 topic
- Attachment Labels
Installation Preparations
Installation Procedures11 topics
- Counterweight
- Install
- Derricking Cylinders
- Install
- Container Attachment
- Install
- Dampening Cylinder
- Install
- Function Checks
- Exhaust Extension
- Lights
Lubrication
Pre-Delivery Inspection1 topic
- Empty Seat Engine Shut Down
General Procedures After Assembly
Table 1. Basic Truck
Table 2. Counterweight
Table 3. Boom
Table 4. Attachment
Inside this manual
Real pages from this service manual (1,297 pages). Open the sample pages (PDF, 250 KB)
- Troubleshooting, page 154: Troubleshooting
- Diagram, page 1,014: Diagrams, Schematics, or Arrangements
- Specifications, page 1,154: Installation Procedures
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,297 pages
Quantity one is the manual described above.
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Other editions and similar models
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