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Hyster HR45, HR45H Reach Stacker Service Manual

542 pages · Publication 1470227

$69.97
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Models
HR45, HR45H
Manual type
Service Manual
Pages
542
Publication
1470227
Condition
Brand new
Hyster HR45, HR45H Reach Stacker Service Manual, publication 1470227

What's inside

From the manual's own table of contents: 154 sections, 561 entries. See sample pages (PDF, 213 KB)

Four-Speed Powershift Transmission
Safety Precautions Maintenance and Repair
General
Automatic Powershift Control2 topics
  • Transmission Control System
  • Transmission Control Lever
Mechanical Description and Operation23 topics
  • General
  • Torque Converter
    • Description
    • Operation
  • Clutch Assemblies
    • Description
    • Operation
  • Transmission Operation in Neutral
  • Input Shaft, Forward Shaft, and Clutch Assembly
    • Description
    • Operation
  • Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli
    • Description
    • Operation
  • Third-Speed Shaft, Gear, and Clutch Assembly
    • Description
    • Operation
  • Fourth-Speed Shaft and Clutch
    • Description
    • Operation
  • Output Shaft
    • Description
    • Operation
Hydraulic Description and Operation9 topics
  • Sump, Filter, and Pump
  • Transmission Charge Pump
    • Pressure Regulator Valve
    • Relief Valve
  • Transmission Control Valve
    • Solenoid Valves
    • Direction Spools
    • Range Spools
    • Modulator Valves
Table 1. Gear, Solenoid, and Clutch Selections
Torque Converter Repair9 topics
  • Torque Converter, Remove
  • Torque Converter, Disassemble
  • Clean and Inspect
  • Torque Converter, Assemble
  • Torque Converter (Turbine) Housing, Disassemble
  • Relief Valve for Lube Pressure, Disassemble and Assemble
  • Oil Sealing Rings Sleeve, Replace
  • Torque Converter Housing, Assemble
  • Torque Converter, Install
Transmission Repair19 topics
  • Remove, Transmission Only
  • Remove, Transmission and Engine Assembly
  • Transmission, Disassemble
    • Output Shaft, Disassemble and Assemble
    • Fourth-Speed Shaft, Disassemble and Assemble
    • Third-Speed Shaft, Disassemble and Assemble
    • Forward Shaft and Clutch, Disassemble and Assemble
    • Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem
    • First-Speed Shaft and Clutch, Disassemble and Assemble
    • Input Shaft, Disassemble and Assemble
  • Speed Sensor, Install
  • Transmission, Clean and Inspect
  • Transmission, Assemble
  • Control Valve
    • Clean and Inspect
    • Assemble and Install
  • Install, Transmission
  • Install, Transmission and Engine Assembly
  • Clean Oil System of Transmission after Major Repair
Automatic Powershift Control (APC 100)2 topics
  • Functional Description
  • Fuses
First-Speed Shaft Bearings Adjustment
Torque Converter Stall Speed Check
Transmission Oil Pressures Check2 topics
  • Clutch Pressures Check
  • Torque Converter (Torque Converter Regulator) Oil Pressure Check
Troubleshooting1 topic
  • Transmission Controller (APC 100)
Table 1. Flange Nut Torque
Table 2. APC 100 Control Module (Pin Connections)
Table 3. Hobbs Gear Selector Connections
Table 4. Example Torque Values at Dimensions Shown
Table 5. Transmission Pressures
Planetary Gear Axle
Description
Operation
Planetary Gear Axle Repair5 topics
  • Remove
  • Disassemble
    • Planetary Axle, Disassemble
  • Assemble and Install
    • Planetary Axle, Assemble
Torque Specifications
Show all 154 sections
Table 1. Axle-to-Frame Fasteners
Table 2. Standard Torque Values for Axle Fasteners
Table 3. Drive Wheel Nut Torque
Differential
Differential Repair20 topics
  • Differential Carrier From Axle Housing, Remove
    • Differential and Ring Gear From Differential Carrier, Remove
    • Drive Pinion and Pinion Carrier From Differential Carrier, Remov
    • Differential and Ring Gear Assembly, Disassemble
    • Drive Pinion and Pinion Carrier, Disassemble
  • 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
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
Metric and Inch (SAE) Fasteners6 topics
  • Threaded Fasteners
  • Nomenclature, Threads
  • Strength Identification
  • Cotter (Split) Pins
  • Fastener Torque Tables
  • Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data
Extendable Container Attachment3 topics
  • Extend and Retract Circuit
  • Twist Lock Circuit
  • Rotator Circuit
Container Attachment Repair
Dampening Cylinders Repair
Extension Cylinders Repair
Twist Lock Repair
Adjustments4 topics
  • Twist Lock Angle Adjustment
  • LOCKED/NOT LOCKED Proximity Switches Adjustment
  • SEATED Signal Adjustment
  • Dual-Speed Rotation Block Adjustment
Additional Spreader Maintenance
Spreader Maintenance Schedule
Steering System YardMaster®
Steering Control Unit Repair4 topics
  • Description
  • Operation
  • Load-Sensing Steering
  • Clean
Steering Axle Repair
Steering Cylinder Repair
Hubs Repair
Spindles Repair
System Air Removal
Relief Valve Adjustment for Steering System
Antitipping Device Adjustment
Hydraulic System YardMaster®1 topic
  • Main Hydraulic Tank
Main Hydraulic Pump10 topics
  • Load Sensing Pressure
  • Main Pump Controller
    • LS Servo
    • LS Control Valve
    • Power Servo
  • Adjust
    • Load Sensing Pressure LS1
    • Load Sensing Pressure LS2
    • Standby Pressure
    • Power Control Valve
Main Control Valve6 topics
  • Adjustment
    • Relief Pressures
    • Flow Control Settings
    • Derricking Down Speed
    • Derricking Up Speed
    • Telescoping Speeds
Steering
Pilot System6 topics
  • Pilot Pump
    • Telescoping Retract Control Valve
    • Engine Radiator Fan Motor
    • Manipulator Pressure Valve
    • Engine Accelerator System
    • Joystick
Hydraulic Cooling System
Brake Oil Cooling System1 topic
  • Bar Relief Valve
Service Brakes
Parking Brake
Table 1. Main Control Valve Torque Specifications
Table 2. Pressures in Relation to the Position of Solenoids and
Boom YardMaster®
Boom1 topic
  • Description and Operation
Hydraulic System14 topics
  • Derricking
    • Description
    • Derricking Up
    • Derricking Down
    • Holding Valve
    • Adjustments
  • Telescoping
    • Description
    • Telescoping Out (Extend)
    • Telescoping In (Retract)
    • Adjustments
  • Dampening
    • Description
    • Adjustment of the 4 bar ( 58 psi) Pressure Reducer
Boom Repair25 topics
  • Spreader
    • Remove
    • Install
  • Yoke
    • Remove
    • Install
  • Dampening Cylinder
    • Remove
    • Install
  • Pivot Bearing
    • Removal
    • Install
  • Derricking Cylinder
    • Remove
    • Install
  • Boom
    • Remove
    • Disassemble
    • Clean, Inspect, and Repair
    • Assemble
    • Install
  • Telescoping Cylinder
    • Remove
    • Install
    • Shimming Key Clearance
Wear Pads13 topics
  • Side Wear Pads
    • Remove
    • Clean and Inspect
    • Install
    • Adjust
  • Horizontal Front Wear Pads
    • Remove
    • Clean and Inspect
    • Install
  • Horizontal Rear Wear Pads
    • Remove
    • Clean and Inspect
    • Install
Hydraulic Cylinder Repair13 topics
  • General Inspection and Assembly Instructions
    • Disassembly
    • Clean and Inspect
    • Assemble
    • Test
    • Disassemble
    • Clean and Inspect
    • Assemble
    • Test
    • Disassemble
    • Clean and Inspect
    • Assemble
    • Test
Diagrams
Periodic Maintenance YardMaster®6 topics
  • Serial Number Data
  • How to Move Disabled YardMaster
    • How to Tow YardMaster
  • How to Put YardMaster on Blocks
    • How to Raise Drive Tires
  • How to Raise Steering Tires
Maintenance Schedule6 topics
  • Daily Inspections
  • First Inspection After First 100 Hours of Operation
  • Periodic Maintenance Schedule
  • Boom Maintenance
  • Spreader Maintenance
  • PPM Spreader Maintenance
Maintenance Procedures Every 8 Hours or Daily27 topics
  • How to Make Checks With Engine Stopped
    • Tires and Wheels
    • Safety Labels
    • Fuel, Oil, or Coolant Leaks Check
    • Drive Belts
    • Battery
    • Engine Oil
    • Drain Water From Fuel Filter
    • Hydraulic System
    • Brake System Oil
    • Cooling System
    • Boom and Spreader
    • Hook, Winch, and Boom (HR45H)
  • How to Make Checks With Engine Running
    • Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays
    • Air Filter
    • Air Conditioning
    • Control Levers and Pedals
    • Electrical System
    • Transmission Oil
    • Steering System
    • Service Brakes
    • Parking Brake
    • Engine Oil
    • Cooling System
    • Hydraulic System
    • Boom and Spreader Operation
Maintenance Procedures Every 50 Hours or Weekly7 topics
  • PPM Spreader
    • Rotator and Extension Transmissions
    • Rotator Motor
    • Rotator Assembly
    • Twistlocks
    • Wear Pads (Extension Beam)
    • Sideshift Cylinders
Maintenance Procedures Every 250 Hours or 6 Weeks14 topics
  • Engine Oil and Filter
  • Fuel Filter/Water Separator
  • Drive Belts
  • Steering Axle
  • Battery
  • Wheel Nuts
  • Winch Oil Level
  • Steering Axle Tie Rods and King Pins
  • Drive Shaft Joints
  • General Lubrication
  • Elme Spreader
    • Rotator and Extension Transmission
    • Rotator Assembly
    • Twistlocks
Maintenance Procedures Every 500 Hours or 3 Months11 topics
  • Air Filter
  • Hydraulic Oil Filters
  • Transmission Oil Filter
  • Differential and Wheel End Housings Oil
  • Hydraulic Tank Breather
  • Boom Horizontal Wear Pads
  • Boom Side Wear Pads
  • Sideshift Cylinder
  • Stop Cylinders (Elme Option)
  • Elme Sideshift Wear Pads
  • Wear Pads (Extension Beams)
Maintenance Procedures Every 1000 Hours or 6 Months14 topics
  • Coolant Filter
  • Hydraulic Accumulators
    • Brake Accumulator
  • Transmission Oil
  • Disc Brake
    • Inspect
  • Brake System Oil and Filter
  • Air Filter Primary Element
    • Extension Beam Horizontal Pads
    • Extension Beam Side Wear Pads
    • Ring Gear Fixation Bolts
    • Wear Pads (Extension Cylinder)
  • Winch Oil
  • Pedals, Levers, Hinges, and Seat Rails (General Lubrication)
Maintenance Procedures Every 2000 Hours or Yearly11 topics
  • Engine Valve Adjustment
  • Hydraulic Relief Pressures
  • Counterweight Fixation
  • Load Sensing System
  • Door and Window Seals
  • Drive Axle and Differential Oil
  • Hydraulic Oil
    • Change Hydraulic Oil
  • Steer Wheel Hub Bearing Cavity
  • Rotor and Extension Transmission Fixation Bolts
  • Rotator and Extension Transmission Oil
Maintenance Procedures Every 6000 Hours or 2 Years3 topics
  • Engine Coolant
  • Vibration Damper
  • Twistlocks
Maintenance Procedures Every 8000 Hours
Wheel and Tire Replacement6 topics
  • Wheels, Remove
  • Remove Tire From Wheel
  • Install Tire on Wheel
  • Install Wheel in Tire
  • Add Air to Tires
  • Wheels, Install
General Maintenance11 topics
  • Twist Locks
    • Rotator Assembly
  • How to Store YardMaster
    • Short-Term Storage
    • Long-Term Storage
  • How to Move YardMaster On Transport
    • Loading
    • Unloading
  • Preparation for Use
    • Preparation After Transport
    • Preparation After Storage
Table 1. Condition Check
Table 2. Fluid Level Check
Table 3. Checks With Engine Running
Table 4. Initial 100-Hour Inspection
Table 5. Inspect and Adjust
Table 6. Lubricate
Table 7. Change
Table 8. Inspect and Adjust
Table 9. Lubricate
Table 10. Initial 100-Hour Inspection
Table 11. Inspect and Adjust
Table 12. Lubricate
Table 13. Change
Table 14. Initial 100-Hour Inspection
Table 15. Inspect and Adjust
Table 16. Lubricate
Table 17. Change
Brake System YardMaster®
Description and Operation4 topics
  • Service Brakes
  • Parking Brake
  • Pump for Brake System
  • Oil Cooler Circuit
Pressure Switch Replacement
Accumulator Replacement
Brake Pedal Valves Repair1 topic
  • Remove and Disassemble
Parking Brake Valve Repair1 topic
  • Repairs
Parking Brake Caliper Repair2 topics
  • Inspect
  • Install and Adjust
Service Brake Assembly Repair
Brake System Air Removal
Service Brakes Wear Check
Oil Cooler Circuit Adjustment
Service Brake
Repair16 topics
  • Brake Assembly
    • Spindle and Brake Cover
    • Ground and Polished Parts
    • Parts With Rough Finish
    • Wet Disc Brake and Axle Assembly
    • Face Seals
    • Disc
  • Replace
    • Parts
    • Brake Housings
    • Hub Oil Seals
    • Spindle and Brake Cover
    • Brake Housing
  • Brake Coolant
    • Coolant Change Intervals
  • Hydraulic Fluid
Table 1. FRICTION DISC
Table 2. STATIONARY DISC
Table 3. Wheel Hub and Brake Housing Torque Chart
Table 4. Brake Housing Cover Torque Chart
Extendable Container Attachment, PPM3 topics
  • Dampening Circuit
  • Sideshift Circuit
  • Pile Slope Circuit
Slide Pad Repair12 topics
  • Extension Chain Support Pads
    • Remove
    • Install
  • Extension Beam Support Pads
    • Central Beam
    • Extension Beam
  • Beam Side Wear Pads
    • Type G
    • Type B
    • Type C and E
  • Carriage Side Wear Pads
    • Adjust
Extension Beam Repair2 topics
  • Extension Chain
    • Adjust
Hydraulic Extension Motor Repair1 topic
  • Disassemble and Assemble
Hydraulic Rotator Transmission Repair
Rotator Ring Gear Repair
Sideshift Roller Repair
Sideshift Cylinder Repair
Twistlock Assembly Repair26 topics
  • Twistlock Cylinder
    • Remove
    • Disassemble
    • Assemble
    • Install
  • Twistlock
    • Remove
    • Inspect
    • Install
    • Adjust
  • Locked/Unlocked Sensor
    • Check and Adjust
  • Seated Sensor
    • Adjust
  • Seated Pin
    • Remove, Disassemble, Inspect, and Install
  • Spreader System Pressure
  • Spreader Function Pressure
    • Spreader Extension Out
    • Spreader Extension In
    • Spreader Sideshift Left
    • Spreader Sideshift Right
    • Twist Locks Locked
    • Twist Locks Unlocked
    • Spreader Rotation Left
    • Spreader Rotation Right
Table 1. Initial 100 Hour Inspection
Table 2. Inspect and Adjust
Table 3. Lubricate
Table 4. Change
Table 5. Spreader Solenoid Locations and Pressure
Electrical System24 topics
  • Location Numbers
    • Components
    • Leads/Wires
    • Common Parts
  • Electrical Components
  • Circuit Explanation
    • Key-Switch in OFF Position
    • Key-Switch in ON Position
    • Key-Switch in Engine START Position
    • Engine SHUTDOWN
    • Parking Brake
    • Warning Lights
    • Manual Selection Transmission Control
    • APC 100 Electronic Transmission Control
    • Outrigger Circuits
    • Lights
    • Sliding Cab
    • Boom Up
    • Boom Down
    • Tilting Cab
    • Spreader Rotation
    • Spreader Sideshift
    • Spreader Extend/Retract
    • Container Seating/Locking/Releasing
Part Numbers of Electrical Components
Table 1. Symbols and Components
Table 2. Solenoids on the Yardmaster
Table 3. Solenoids on the Spreader
Table 4. Solenoids on the Boom
Table 5. Components on the Yardmaster
Table 6. Service and Parking Brake Switches and Sensors
Table 7. Relays in the Cab
Table 8. Spreader Relays and Components in Spreader Electrical B
Table 9. Fuses

Inside this manual

Real pages from this service manual (542 pages). Open the sample pages (PDF, 212 KB)

Sample pages from the Hyster HR45, HR45H Reach Stacker Service Manual: Diagram, Troubleshooting, Specifications
  • Diagram, page 192: Diagrams, Schematics, or Arrangements
  • Troubleshooting, page 448: Troubleshooting
  • Specifications, page 496: Extension Beam Repair

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, 542 pages

Quantity one is the manual described above.

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