Hyster HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS (B222) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 2624

File Size: 144.04 MB (Speed Download Link)

Brand: Hyster

Model: HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS (B222) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS (B222) Forklift Service Manual

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Hyster HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS (B222) Forklift Index:

Series Code / Model Designation Reference Table
General
Transmission Repair
- Remove
- Disassemble
  - Reverse and Second-Speed Clutch
- Clean and Inspect
  - Housings
  - Oil Seals and Gaskets
  - Bearings
  - Gears and Shafts
- Assemble
  - Reverse and Second-Speed Clutch
- Install
Control Valve With Solenoid Cover
- Remove
- Install
- Control Valve Disassemble and Assemble
- Control Valve Cover Removal
- Control Valve Components
  - Disassemble
  - Install
- Control Valve Cover Installation
Full Flow Control Valve Repair
- Remove
- Install
- Control Valve Components

Series Code / Model Designation Reference Table
General
Transmission Repair
- Remove
- Disassemble
  - Reverse and Second-Speed Clutch
- Clean and Inspect
  - Housings
  - Oil Seals and Gaskets
  - Bearings
  - Gears and Shafts
- Assemble
  - Reverse and Second-Speed Clutch
- Install
Control Valve With Solenoid Cover
- Remove
- Install
- Control Valve Disassemble and Assemble
- Control Valve Cover Removal
- Control Valve Components
  - Disassemble
  - Install
- Control Valve Cover Installation
Full Flow Control Valve Repair
- Remove
- Install
- Control Valve Components

Series Code / Model Designation Reference Table
General
Description of Operation
- Cab Structure
- Cab Tilt System
- Cab Tip-Up System
- Tilting the Cab
  - Raising
  - Lowering
Remove and Install
- Cab Door Assembly
  - Cab Door
  - Door Hinge
  - Door Latch
  - Door Handle
  - Door Release
  - Door Push Button
- Cab Tilt System
  - Electric Tilt Pump
  - Hand Tilt Pump
  - Cab Tilt Cylinder
  - Latch
- Brake and Inching Pedal
  - Remove
  - Install
- Accelerator Pedal and Sensor
  - Remove
  - Install
  - Adjust Sensor
- Seat Assembly
  - Seat
  - Seat Cushion
  - Back Cushion
  - Seat Suspension Replacement
  - Boot Replacement
- Power Assist Armrest
  - Release Cable
  - Gas Spring
  - Joystick
  - Electrical Levers
  - Armrest Rocker Switches
  - Armrest Top Cover
- Instrument Panel
  - Key Switch
  - 12V Power Socket
  - Electric-Operated Heat Control and Air Recirculation Control (Airco Only)
  - Cable-Operated Heater Control (Heater Only)
  - Air Conditioning Switch Replacement
  - Instrument Panel Rocker Switches Replacement
  - Parking Brake Switch
  - Indicator Display Replacement
  - Instrument Panel Top Console
- Steering Wheel and Column Assembly
  - Steering Wheel and Horn
  - Steering Column Assembly
  - Adjustment Handle
  - Main Warning Lights
  - Shift Lever
  - Turn Signal Lever
- Window Wipers
  - Window Wiper Assembly Replacement
  - Window Wiper Motor Replacement
  - Rear Window Wiper Motor Assembly
  - Top Window Wiper Motor Assembly
- Window Washer System
  - Window Washer Reservoir and Pumps
  - Window Washer Hoses
- Window Washer Spray Nozzles
  - Front Window
  - Rear Window
  - Top Window
- Window Replacement
  - Front Window
  - Rear Window
  - Top Window
  - Door, Upper/Lower Window
  - Sliding Window and Sliding Tracks
  - Weather Strip Replacement
  - Window Stopper Replacement
  - Window Seal Replacement
  - Sliding Window Frame
- Floor Mat
  - Front Floor Mat
  - Rear Floor Mat
- Radio Console
  - Remove
  - Install
- Air Duct Replacement
  - Remove Front
  - Remove Rear
  - Install
- Accessories
  - Mirror Replacement
  - Sunshade Replacement
  - Map Light Replacement
  - Interior Fan Replacement
  - Training Seat
- Label Replacement
Checks and Adjustments
- Check Oil Level for Cab Tilt System
- Door Striker Pin Adjustment
- Brake Pedal Adjustment
  - Dry Brake
  - Wet Brake
- Inching Pedal Adjustment
- Inching Pedal Sensor Adjustment
  - Sensor Adjustment Using Dana Dashboard Software
  - Sensor Adjustment using the APC200 Display
  - Sensor Adjustment for Trucks with ZF Transmission
- Inching Pedal Sensor Calibration
  - Sensor Calibration using Dana Dashboard Software
  - Sensor Calibration using APC200 Display
  - Sensor Calibration for Trucks with ZF Transmission

Series Code / Model Designation Reference Table
General
Description of Operation
- Cab Structure
- Cab Tilt System
- Cab Tip-Up System
- Tilting the Cab
  - Raising
  - Lowering
Remove and Install
- Cab Door Assembly
  - Cab Door
  - Door Hinge
  - Door Latch
  - Door Handle
  - Door Release
  - Door Push Button
- Cab Tilt System
  - Electric Tilt Pump
  - Hand Tilt Pump
  - Cab Tilt Cylinder
  - Latch
- Brake and Inching Pedal
  - Remove
  - Install
- Accelerator Pedal and Sensor
  - Remove
  - Install
  - Adjust Sensor
- Seat Assembly
  - Seat
  - Seat Cushion
  - Back Cushion
  - Seat Suspension Replacement
  - Boot Replacement
- Power Assist Armrest
  - Release Cable
  - Gas Spring
  - Joystick
  - Electrical Levers
  - Armrest Rocker Switches
  - Armrest Top Cover
- Instrument Panel
  - Key Switch
  - 12V Power Socket
  - Electric-Operated Heat Control and Air Recirculation Control (Airco Only)
  - Cable-Operated Heater Control (Heater Only)
  - Air Conditioning Switch Replacement
  - Instrument Panel Rocker Switches Replacement
  - Parking Brake Switch
  - Indicator Display Replacement
  - Instrument Panel Top Console
- Steering Wheel and Column Assembly
  - Steering Wheel and Horn
  - Steering Column Assembly
  - Adjustment Handle
  - Main Warning Lights
  - Shift Lever
  - Turn Signal Lever
- Window Wipers
  - Window Wiper Assembly Replacement
  - Window Wiper Motor Replacement
  - Rear Window Wiper Motor Assembly
  - Top Window Wiper Motor Assembly
- Window Washer System
  - Window Washer Reservoir and Pumps
  - Window Washer Hoses
- Window Washer Spray Nozzles
  - Front Window
  - Rear Window
  - Top Window
- Window Replacement
  - Front Window
  - Rear Window
  - Top Window
  - Door, Upper/Lower Window
  - Sliding Window and Sliding Tracks
  - Weather Strip Replacement
  - Window Stopper Replacement
  - Window Seal Replacement
  - Sliding Window Frame
- Floor Mat
  - Front Floor Mat
  - Rear Floor Mat
- Radio Console
  - Remove
  - Install
- Air Duct Replacement
  - Remove Front
  - Remove Rear
  - Install
- Accessories
  - Mirror Replacement
  - Sunshade Replacement
  - Map Light Replacement
  - Interior Fan Replacement
  - Training Seat
- Label Replacement
Checks and Adjustments
- Check Oil Level for Cab Tilt System
- Door Striker Pin Adjustment
- Brake Pedal Adjustment
  - Dry Brake
  - Wet Brake
- Inching Pedal Adjustment
- Inching Pedal Sensor Adjustment
  - Sensor Adjustment Using Dana Dashboard Software
  - Sensor Adjustment using the APC200 Display
  - Sensor Adjustment for Trucks with ZF Transmission
- Inching Pedal Sensor Calibration
  - Sensor Calibration using Dana Dashboard Software
  - Sensor Calibration using APC200 Display
  - Sensor Calibration for Trucks with ZF Transmission

General
- 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
Maintenance Schedule
- Container Attachment Maintenance
Maintenance Procedures Every 8 Hours or Daily
- How to Make Checks With the Engine Stopped
  - Warning and Safety Labels
  - Wheels, Tires and Tire Pressure
  - Wheel Nuts
  - Boom, Rotator, and Spreader
  - Boom Pivot Pin Retention
  - Air Precleaner Dust Bowl
  - Hydraulic Tank Breathers
  - Engine Air Intake Piping and Charge Air Piping
  - Drive Belt
  - Engine Compartment
  - Radiator Sections for Engine Coolant, Charge Air Cooler, Transmission and Hydraulic Oil
  - 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
  - Engine Air Filter
  - Coolant Level
  - High Pressure Brake Cooling Filter
  - Brake Return 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 Operation
- Bearing Pretorque in Steer Wheel Hubs
- Transmission Oil Filter
- Brake Return Oil Filter
- High Pressure Brake Cooling Filter
- Oil in Rotator Transmission
Maintenance Procedures Every 250 Hours or 3 Months
- Warnings and Safety Labels
- Wheels, Tires, and Tire Pressure
- Wheel Nuts
- Hydraulic Tank Breathers
- 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, Transmission and Hydraulic Oil
- 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
- Pivot Pin Securing Nuts
- Drive Shaft
Maintenance Procedures Every 500 Hours or 3 Months
- 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 Months
- Boom Wear Pads
- Boom Side Wear Pads
- Cab Air Filter
- Cooling Fan
- Engine Oil and Oil Filter
- Fuel Filter/Water Separator
Maintenance Procedures Every 1000 Hours or 6 Months
- Parking Brake and Service Brakes
- Coolant Quality
- Cab Door Hinges
- Transmission Oil and Oil Filter
  - Change
Maintenance Procedures Every 1500 Hours or 6 Months
- Axle Tech, Drive Axle and Differential
Maintenance Procedures Every 2000 Hours or 1 Year
- Drive Shaft
- Brake System Accumulator
- Engine Cleaning
- Engine and Transmission Mounts
- Engine Valve Adjustment
  - Adjust
- Turbo Charger
- Transmission Clutch Calibration
- Inching Pedal Sensor Calibration
- Engine Coolant Filter
- Brake Return Line Filter
Maintenance Procedures Every 2500 Hours or 12 Months
- PIVOT PIN SECURING NUTS
Maintenance Procedures Every 3000 Hours or 3 Years
- Hydraulic System Oil and Hydraulic System Suction Filter
- Hydraulic Return Filters
Maintenance Procedures Every 5000 Hours or 3 Years
- Air Conditioning
Maintenance Procedures Every 6000 Hours or 2 Years
- Vibration Damper
- Fan Belt and Tensioner
- Fan Drive Idler Pulley
- Fan Hub
Maintenance Procedures Every 10,000 Hours or 36 Months
- Boom Pivot Pins
  - Disassemble
  - Inspect
  - Install
Maintenance Procedures Every 10,000 Hours or 5 Years
- High Pressure FilterHydraulic Oil
Container Attachment Maintenance Procedures Every 100 Hours
- 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 Hours
- Attachment
- Signals from the Spreader Control System
- Container Locking Mechanism – Twist Locks
- Oil Level in Rotator Transmissions
Container Attachment Maintenance Procedures Every 500 Hours
- Attachment Wear Pads
- Sideshift Cylinder Bearings
- Stop Cylinders
- Locking Plate for Stop Cylinder
Container Attachment Maintenance Procedures Every 1000 Hours
- Extension Cylinder Support Pads
Container Attachment Maintenance Procedures Every 5000 Hours
- Twist Locks (ELME Models 817 and 857)
Pneumatic Tires and Wheels
- Remove Wheels From Lift Truck
- Remove Tire From Wheel
- Install Tire on Wheel
- Add Air Pressure to Tires
- Install Wheels on Lift Truck