ASSEMBLY GUIDE
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. 1638197 8000 SRM 1265
Assembly Guide Table of Contents
TABLE OF CONTENTS
List of All Special Tools and Equipment Needed for the Assembly ................................................................ 1
General Considerations Before Starting the Job ............................................................................................. 3
Preparation of the Components Before Assembly............................................................................................ 3
Checking of the Wheels ..................................................................................................................................... 4
Air Pressure ................................................................................................................................................... 4
Drive Wheels ............................................................................................................................................. 4
Steer Wheels .............................................................................................................................................. 10
Wheel Nut Torque .......................................................................................................................................... 13
Preparation of the Container Attachment........................................................................................................ 14
Attachment Labels ........................................................................................................................................ 14
Installation Preparations .................................................................................................................................. 15
Installation Procedures ..................................................................................................................................... 15
Boom............................................................................................................................................................... 15
Install ......................................................................................................................................................... 15
Air Filter ........................................................................................................................................................ 17
Disassemble ............................................................................................................................................... 17
Derricking Cylinders ..................................................................................................................................... 17
Install ......................................................................................................................................................... 17
Container Attachment ................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Dampening Cylinder ..................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Air Filter ........................................................................................................................................................ 19
Assemble .................................................................................................................................................... 19
Function Checks ............................................................................................................................................ 19
General Procedures After Assembly ................................................................................................................. 20
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]
©2007 HYSTER COMPANY i
8000 SRM 1265 List of All Special Tools and Equipment Needed for the Assembly
List of All Special Tools and Equipment Needed for the Assembly
WARNING
Read all the instructions contained in this
manual before starting any work on the unit.
Also read all procedures contained in the Op-
erating Manual before operating the truck.
1. LIFT tools:
• A crane with a minimum capacity of 30,000 kg
(66,139 lb).
• Approved chains, cables or slings of sufficient
capacity (see components weight chart).
• A personnel lift with a operating height of 4.5 m
(15 ft).
2. Tooling:
• A complete set of imperial and metric ring and
open-end spanners/wrenches.
• A torque tool/wrench with a capacity up to
1,875 N•m (approximately 1,383 lbf ft).
• Gloves and protective clothing.
• Safety glasses and helmets.
• A hydraulic jack with a minimum capacity of
50,000 kg (110,231 lb).
• A safety cage for inflating tires.
• Blocks of hard wood of various lengths, widths,
and thickness.
• 6.1 m (20 ft) or 12.2 m (40 ft) container with
pockets at 6.1 m (20 ft) position, this item may
be substituted by a fork lift truck with a mini-
mum lifting capacity of 15 ton.
• Hydraulic manual press with a minimum ca-
pacity of 10 ton.
3. Trained mechanics:
• It is recommended that personnel involved in
the assembly of the machine have followed a
specific training session on those units or have
a proven understanding of the product to be
able to perform the job professionally.
• The minimum personnel required to do the job
is at least two mechanics.
4. Refer to Table 1 and Table 2 for basic truck
weights and components weights and check the
loading list for final details.
1
List of All Special Tools and Equipment Needed for the Assembly 8000 SRM 1265
Table 1. Component Weight Chart
Model Height Width Length Weight
RS45-27CH,
RS45-24IH,
HR45-27
44,170 kg
(97,395 lb)
RS45-31CH,
RS45-28IH,
HR45-31
8,070 mm
(317.7 in.)
48,070 kg
(105,994 lb)
RS46-36CH,
RS46-33IH,
HR45-36
56,040 kg
(123,568 lb)
RS46-40CH,
RS46-37IH,
HR45-40
8,150 mm
(320.9 in.)
58,950 kg
(129,985 lb)
RS46-41S CH,
RS46-38S IH,
HR45-41S
8,250 mm
(324.8 in.)
60,960 kg
(134,417 lb)
RS46-41L CH,
RS46-38L IH,
HR45-41L
9,150 mm
(360.2 in.)
61,930 kg
(136,556 lb)
RS46-41LS CH,
RS46-38LS IH,
HR45-41LS
3,820 mm
(150.4 in.)
4,220 mm
(166.1 in.)
9,250 mm
(364.2 in.)
63,930 kg
(140,966 lb)
Table 2. Component Weight Chart
Component Height Width Length Weight
Boom 1,910 mm
(75.2 in.)
2,140 mm
(84.3 in.)
11,120 mm
(441.3 in.)
16,000 kg
(35,280 lb)
Extended Container
Attachment without PPS
1,900 mm
(74.8 in.)
9,200 kg
(20,283 lb)
Extended Container
Attachment with PPS
1,950 mm
(76.8 in.)
10,000 kg
(22,046 lb)
Intermodal Container
Attachment
2,450 mm
(96.5 in.)
2,420 mm
(95.3 in.)
6,040 mm
(237.8 in.)
13,100 kg
(28,881 lb)
2
8000 SRM 1265 Preparation of the Components Before Assembly
General Considerations Before Starting the Job
NOTE: This assembly guide is extensive to cover dif-
ferent situations. Assembly of new trucks depends
primarily upon how the truck was transported and
which carriage is supplied. If the truck was trans-
ported overseas, it will be more disassembled than if
only shipped by land. Use the portions of the assem-
bly guide that meet your needs.
CAUTION
The following assembly procedures are for as-
sembling the lift truck after shipment from the
factory. Be sure to check all fluid levels and
tire pressures before removing the truck from
the trailer. If in doubt, check the torque of all
relevant hardware.
1. Safety is always the most important item!
When lifting parts or assemblies, make sure that
all slings, chains, or cables are correctly fastened
and balanced before lifting. Make sure that all
lifting devices have enough capacity to lift the
weight. If in doubt, do not hesitate to use a device
with a higher capacity than required. Always use
your common sense and avoid dangerous situa-
tions.
2. Plan enough personnel to do the job. Never
lift heavy parts by hand. Always use a lifting
mechanism.
3. The rental price of the crane, which you will
need to lift the major components, is very expen-
sive. Plan the job as well as possible in order to
limit the costs to the minimum required.
4. Check that all the items ordered are available
upon receipt of the machine and its components.
Unpack the case accompanying the machine
and identify all the components contained in it.
Check that all capscrews, nuts, pins, washers,
and brackets are all presented.
5. Prepare the job. Do all possible preparation and
preassembly of parts, cleaning, or lubrication in
advance. Allowing yourself half a day before the
arrival of the crane will enable you to mount the
drive wheels and prepare the mast for direct as-
sembly, and will reduce the rental charges of the
crane.
6. Take enough time to read the instructions con-
tained in this guide and to familiarize yourself
with the procedures. It is advised to read those
procedures when the machine and components
have arrived, in order to have a better practical
understanding of the instructions.
7. It is recommended to perform all assembly pro-
cedures outside. During the carriage assembly,
the inner boom will be almost fully retracted.
Preparation of the Components Before Assembly
1. As previously mentioned, first check that all the
components, which will be needed later during
installation, are available. (Check this according
to the specific packaging list.)
2. If needed, clean all parts before installation.
3. Check that the following hanging points are
clean and free of paint and grease:
• Attachment rotator holes at the boom tip
• Attachment rotator holes at the attachment
• Dampening cylinder bushings in the attach-
ment
• Dampening cylinder rod ends
3
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$52.99
Hyster B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH EUROPE) Diesel Counter Balanced Truck Service Repair Factory Manual
Viewed 47 Times Today
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$52.99
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
Get the Hyster B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH EUROPE) Diesel Counter Balanced Truck Service Repair Factory Manual for comprehensive maintenance and repair guidance. This electronic manual offers the advantage of zooming in anywhere on your computer for clear visibility. It covers various models and includes detailed information on assembly, brake accumulator, electrical system, hydraulic system, and more. Whether you're a professional mechanic or a DIY enthusiast, this manual provides step-by-step instructions to facilitate easy and cost-effective repairs.
The manual is available in PDF format, compatible with all versions of Windows and Mac. It is written in English and requires Adobe Reader and Win for access. Enhance your repair capabilities with this valuable resource.
