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Hyster RS45, RS46 Reach Stacker Service Manual

904 pages · Publication 1458785

$99.93
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Models
RS45, RS46
Manual type
Service Manual
Pages
904
Publication
1458785
Condition
Brand new
Hyster RS45, RS46 Reach Stacker Service Manual, publication 1458785

What's inside

From the manual's own table of contents: 135 sections, 495 entries. See sample pages (PDF, 127 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 135 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
Instrument Panel Indicators and Senders14 topics
  • Steering Column Gauges, Meters, and Indicators
  • LED Display Panel
    • Battery Discharge Indicators
    • Brush Wear Indicators
    • Motor Temperature Indicators
  • LX Series Display Panel
    • Hourmeter Functions
    • Battery Indicator Function
    • Status Code Function
  • ZX Series Display Panels
    • Display Panel
    • Basic Display Panels
    • Performance Display
    • Brush Wear Indicators
Adjustments - General
Replacement - General Information
Meter Replacement
Sender Replacement2 topics
  • Fuel Level Sender
  • Pressure and Temperature Sender
ITW Display Panel Replacement
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl7 topics
  • Display Panel Assembly, Replace
  • Indicator LEDs
  • Battery Indicators
  • Digital Display (Performance Display Panel Only)
  • Status Code or Performance Level Switches and Indicator LEDs (Pe
  • Basic Display Panel, Replace Parts
  • Performance Display Panel, Replace Parts
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace4 topics
  • Remove and Replace
  • Meter Specifications
  • Sender Specifications
  • Meter
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
Periodic Maintenance7 topics
  • Serial Number Data
  • Engine Shutoff System
  • How to Move Disabled ReachStacker
    • How to Tow ReachStacker
  • How to Put ReachStacker on Blocks
    • How to Raise Drive Tires
    • How to Raise Steering Tires
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily24 topics
  • How to Make Checks With Engine Stopped
    • Tires and Wheels
    • Safety Labels
    • Check for Fuel, Oil, or Coolant Leaks
    • Drive Belts
    • Battery
    • Engine Oil
    • Drain Water from Fuel Filter
    • Hydraulic System
    • Cooling System
    • Air Filter
    • Boom and Spreader
  • How To Make Checks With Engine Running
    • Gauges, Indicator Lights, Horn, Fuses, and Relays
    • 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 250 Hours or Monthly7 topics
  • Engine Oil and Filter
  • Battery
  • Wheel Nuts
  • Steering Axle Tie Rods
  • Drive Shaft Joints
  • Drive Axle and Differential Oil
  • General Lubrication
Maintenance Procedures Every 500 Hours or 3 Months4 topics
  • Hydraulic Filter
  • Fuel Filter/Water Separator
  • Transmission Oil and Filter
  • Coolant Filter
Maintenance Procedures Every 1000 Hours or 6 Months3 topics
  • Brake System Oil Filter
  • Disc Brakes
    • Inspect
Maintenance Procedures Every 2000 Hours or Every Year4 topics
  • Engine Coolant
  • Hydraulic Oil
    • Change Hydraulic Oil
    • Hydraulic Tank Breather
Wheel and Tire Replacement6 topics
  • Remove Wheels
  • Remove Wheel From Tire
  • Install Tire on Wheel
  • Install Wheel in Tire
  • Add Air to Tires
  • Install Wheels
How to Store ReachStacker2 topics
  • Short-Term Storage
  • Long-Term Storage
How to Move ReachStacker on a Transport2 topics
  • Loading
  • Unloading
Preparation for Use2 topics
  • Preparation After Transport
  • Preparation After Storage
Table 1. Maintenance Schedule
Table 2. Spreader Maintenance Schedule
Diagrams
Capacities and Specifications
Vehicle Weights
Capacities
Electrical System
Engine Specifications
Tire Sizes4 topics
  • Counterweight
  • Drive Axle
  • Drive Shaft
  • Steering Axle
Container Spreader Without Powered Pile Slope Lifting Capacities
Container Spreader With Powered Pile Slope Lifting Capacities
Intermodal Spreader Lifting Capacities
Hydraulic System
Description and Operation4 topics
  • Main Control Valve
  • Pilot Pressure Valve
  • Boom Hoist Over Center Valve
  • Flow Amplifier
Main Control Valve30 topics
  • Description
    • Left-Hand Main Valve
    • Right-Hand Main Valve
    • Left- and Right-Hand Main Valve Combined Functions
    • Remove
    • Disassemble
    • Clean
    • Inspect
    • Assemble
    • Install
  • Outlet Section
    • Disassemble
    • Clean
    • Inspect
    • Assemble
  • Control Section
    • Disassemble
    • Clean
    • Inspect
    • Assemble
  • Control Valve Solenoid
    • Disassemble
    • Clean
    • Inspect
    • Assemble
  • Inlet Section
    • Disassemble
    • Clean
    • Inspect
    • Assemble
Pilot Pressure Relief Valve2 topics
  • Clean
  • Inspect
Boom Hoist Over Center Valve
Flow Amplifier19 topics
  • Operation
    • Neutral Position
    • During Steering Function
    • Manual Steering Function
    • Remove
    • Install
    • Pressure Relief Valve
    • Disassemble
    • End Cover at PP Port
    • End Cover at LS Port
    • Spools
    • Directional Valve Spool
    • Priority Valve Spool
    • Pressure Control/Amplifier Valve Spool
    • Check Valve
    • Cushion/Suction Valves
    • Clean
    • Assemble
  • Pressure Checkports
Brake System12 topics
  • Accumulator Charge Valve
  • Relief Valves
  • Check Valve
  • Throttle Treadle
    • Operation
  • Brake Pedal Valves
    • Operation
  • Shuttle Valve
  • Solenoid Valve for Park Brake
  • Thermostatic Bypass Valve
  • Parking Brake
  • Oil-Cooled Service Brakes
Pressure Switches Replacement
Accumulator Charge Valve Repair2 topics
  • Remove and Disassemble
  • Adjust
Accumulator Replacement
Relief Valves Repair
Shuttle Valve Repair
Brake Pedal Valves (Treadle Valves) Repair
Parking Brake Valve Repair
Parking Brake Caliper Repair1 topic
  • Install and Adjust
Service Brake Assemblies Repair
Brake System Air Removal
Service Brakes Wear Check
Throttle Lever Adjustment
Pressure Checkports1 topic
  • Accumulator Charge Valve (See Figure 8 )
Accumulator
Accumulator Maintenance56 topics
  • Precharge Check
  • Precharge Filling
  • Repair
  • Replace
  • Diagnostics
    • How to Tow ReachStacker
    • How to Raise Drive Tires
    • How to Raise Steering Tires
    • Tires and Wheels
    • Safety Labels
    • Check for Fuel, Oil, or Coolant Leaks
    • Drive Belts
    • Operator Restraint System
    • Battery
    • Precleaner for Air Filter
    • Air Filter
    • Engine Oil
    • Drain Water From Fuel Filter
    • Hydraulic System
    • Cooling System
    • Boom and Spreader
    • Gauges, Indicator Lights, Horn, Fuses, and Relays
    • Control Levers and Pedals
    • Electrical System
    • Transmission Oil
    • Steering System
    • Service Brakes
    • Parking Brake
    • Engine Oil
    • Cooling System
    • Hydraulic System
    • Boom and Spreader Operation
  • Steering Axle Kingpins
  • Rotator and Extension Transmission
  • Rotator Assembly
  • Twistlocks
  • Wear Pads
    • Boom Side Wear Pads
    • Boom Horizontal Wear Pads
  • Hydraulic Tank Breather
  • Sideshift Wear Pads
  • Extension Beam Wear Pads
  • Sideshift Cylinder
  • Stop Cylinders
    • Inspect
  • Service Brakes
  • Accumulator
  • Engine Valve Adjustment
  • Extension Cylinder Wear Pads
  • Hydraulic Oil and Filters
    • Change Hydraulic Oil Filters
    • Change Hydraulic Oil
  • Hub Bearing Cavity
  • Rotator and Extension Transmission Fixation Bolts
  • Rotator and Extension Transmission Oil
  • Window Seals, Door Locks and Seals
Maintenance Procedures Every 6000 Hours
Table 1. Daily Inspections
Table 2. Daily Inspections
Table 3. Daily Inspections
Table 4. First Inspection After First 100 Hours Of Operation
Table 5. Periodic Maintenance Schedule
Table 6. Periodic Maintenance Schedule
Table 7. Periodic Maintenance Schedule
Table 8. First Inspection After First 100 Hours Of Operation
Table 9. Spreader Maintenance Schedule
Table 10. Spreader Maintenance Schedule
Table 11. Spreader Maintenance Schedule
Auxiliary Brake Caliper
Auxiliary Brake Caliper Repair13 topics
  • Brake Linings
    • Remove
    • Clean and Inspect
    • Install
  • Auxiliary Caliper
    • Remove
    • Disassemble
    • Clean
    • Inspect
    • Assemble
    • Install
    • Bleed Brakes
    • Adjust
Table 1. Rotor Wear Limits
Parking Brake8 topics
  • Release Brake Manually
    • Hydraulic Pressure Available
    • Hydraulic Pressure not Available
    • Linings
    • Disc
    • Caliper Parts
  • Bleed Brakes
  • Test
Table 1. Disc Wear Limits
Table 2. Torque Requirements
Table 3. Wear Limits
Table 4. Lining to Disc Clearance
Service Brake
Repair15 topics
  • Brake Assembly
    • 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
  • 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

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, 904 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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