Complete service repair manual for Hyster YARDMASTER HR45-EC, HR48-EC, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster Service Manual HR45-EC, HR48-EC workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
1472541 – Hyster Service Manual HR45-EC, HR48-EC.pdf
Total Pages: 181 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section | Part No. | SRM Number | Rev Date |
| COOLING SYSTEM | 897934 | 0700 SRM 0626 | 11/01 |
| DIFFERENTIAL | 910072 | 1400 SRM 0046 | 11/03 |
| PLANETARY GEAR DRIVE AXLE | 1472543 | 1400 SRM 0789 | 03/00 |
| EXTENDABLE CONTAINER ATTACHMENT | 1472595 | 5000 SRM 0790 | 03/00 |
| INCH (SAE) and METRIC FASTENERS | 910442 | 8000 SRM 0231 | 03/03 |
| DIAGRAMS | 1473181 | 8000 SRM 0791 | 03/00 |
| PERIODIC MAINTENANCE | 1472539 | 8000 SRM 0792 | 12/02 |
| For service and repair information on Cummins engines, | |||
| see a dealer for Cummins engines. | |||
| PART NO. 1472541 | |||
| Rev. 11/03 | |||
Periodic Maintenance…..2
Safety Precautions Maintenance and Repair…..3
General…..8
How to Move Disabled YardMaster…..8
How to Tow YardMaster…..8
How to Put YardMaster on Blocks…..9
How to Raise Drive Tires…..9
How to Raise Steering Tires…..9
Maintenance Schedule…..10
Spreader Maintenance Schedule…..15
Maintenance Procedures Every 8 Hours or Daily…..17
How to Make Checks With Engine Stopped…..17
Tires and Wheels…..17
Safety Labels…..17
Boom and Spreader…..18
Drive Belts…..18
Fuel, Oil, or Coolant Leak Check…..18
Drain Water From Fuel Filter…..18
Engine Compartment…..18
Radiators…..18
Brake System Oil…..19
Hydraulic System…..19
Battery…..19
Engine Oil…..20
Cooling System…..20
How to Make Checks With Engine Running…..20
Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays…..20
Transmission Oil…..22
Air Filter…..23
Service Brakes…..23
Parking Brake…..23
Boom and Spreader Operation…..23
Steering System…..24
Control Levers and Pedals…..24
Electrical System…..24
Engine Oil…..24
Cooling System…..24
Hydraulic System…..24
Maintenance Procedures Every 50 Hours or Weekly…..24
Boom…..24
Maintenance Procedures Every 100 Hours…..25
Rotator Brake…..25
Rotator Motor…..25
Rotator Assembly…..26
Maintenance Procedures Every 250 Hours or 6 Weeks…..26
Engine Oil and Filter…..26
Battery…..26
Wheel Nuts…..26
Steering Axle Tie Rods, King Pins, and Pivot Shaft…..26
Drive Shaft Joints…..26
Maintenance Procedures Every 500 Hours or 3 Months…..27
Air Filter…..27
Hydraulic Oil Filters…..27
Fuel Filter/Water Separator…..27
Hydraulic Tank Breather…..27
Brake Tank Breather…..27
Drive Axle and Differential Oil…..27
Front Boom Stops…..27
Twist Locks…..27
Sideshift Cylinder…..27
Telescoping Cylinder…..27
Boom Wear Pad Play and Condition …..27
Front Side Pads…..27
Front Upper Pads…..27
Front Lower Pads…..27
Rear Upper and Lower Pads…..28
Centering Rear End of Inner Boom Section…..28
Sideshift Wear Pads…..30
Attachment Wear Pads …..30
Stop Cylinders (Optional)…..30
Maintenance Procedures Every 1000 Hours or 6 Months…..30
Drive Belts…..30
Fuel Pre-Filter Sight Glass…..30
Brake Accumulator…..30
General Lubrication…..31
Brake System Oil and Filter…..31
Transmission Oil and Filter…..31
Remove…..31
Install…..31
Air Filter…..31
Differential and Wheel End Housings Oil…..31
Disc Brake…..31
Inspect…..32
Wear Pads (Extension Cylinders)…..32
Maintenance Procedures Every 2000 Hours or Yearly…..32
Engine Valve Adjustment…..32
Counterweight Fasteners…..32
Steering Wheel Hub Bearings…..32
Door, Window seals, and Door Lock…..32
Axle Brakes Hoses…..32
Brake System Oil and Filter…..32
Rotator Gear Fasteners…..32
Rotator Brake Oil…..33
Rotator Transmission Oil…..33
Wheel Rims…..33
Attachment Function and Condition…..33
Maintenance Procedures Every 4000 Hours or 2 Years…..33
Engine Vibration Damper…..33
Engine Coolant…..33
Air Conditioner Filter…..33
Hydraulic system…..33
Hydraulic Oil…..34
Change…..34
Maintenance Procedures Every 5000 Hours…..34
Twist Locks…..34
Wheel and Tire Replacement…..34
Wheels, Remove…..34
Remove Tire From Wheel…..35
Install Tire on Wheel…..36
Install Wheel in Tire…..37
Add Air to Tires…..38
Wheels, Install…..38
General Maintenance…..39
Spreader…..39
Twist Locks…..39
How to Store YardMaster…..39
Short-Term Storage…..39
Long-Term Storage…..40
How to Move YardMaster on Transport…..40
Loading…..40
Unloading…..41
Preparation for Use…..41
Preparation After Transport…..41
Preparation After Storage…..41
tables…..2
Table 1. Daily Inspections – Condition Check…..11
Table 2. Daily Inspections – Fluid Level Check…..11
Table 3. Daily Inspections – Checks With Engine Running…..11
Table 4. First Inspection After First 100 Hours of Operation…..12
Table 5. Periodic Maintenance Schedule – Inspection and Adjustme…..12
Table 6. Periodic Maintenance Schedule – Lubrication…..13
Table 7. Periodic Maintenance Schedule – Change…..14
Table 8. Spreader Maintenance Schedule – Inspection and Adjustme…..15
Table 9. Spreader Maintenance Schedule – Lubrication…..16
Table 10. Spreader Maintenance Schedule – Change…..16
Table 11. Engine Oil Specifications…..20
hyster-1472543-03-00-srm0789…..44
toc…..44
Planetary Drive Axle…..44
Safety Precautions Maintenance and Repair…..45
General…..48
Description…..48
Drive Axle Repair…..51
Remove…..51
Install…..51
Planetary Axle and Service Brake Repair…..52
Disassemble…..52
Clean and Inspect…..55
Assemble…..55
Axle Hardware Torque…..59
Troubleshooting…..60
tables…..44
Table 1. Metric Standard Threads…..59
Table 2. Metric Fine Pitch Threads…..59
hyster-1472595-03-00-srm0790…..64
toc…..64
Extendable Container Attachment…..64
Safety Precautions Maintenance and Repair…..65
General…..68
Description…..68
Operation…..69
Extend and Retract Circuit…..69
Twist Lock Circuit…..69
Rotator Circuit…..69
Container Attachment Repair…..69
Remove…..69
Inspect…..70
Install…..70
Dampening Cylinders Repair…..71
Remove…..71
Disassemble…..71
Clean and Inspect…..71
Assemble…..71
Install…..71
Extension Cylinders Repair…..72
Remove…..72
Disassemble…..72
Clean and Inspect…..72
Assemble…..72
Install…..73
Sideshift Cylinder Repair…..74
Remove…..74
Disassemble…..74
Clean and Inspect…..74
Assemble…..74
Install…..74
Twist Locks Repair…..75
Disassemble…..75
Clean and Inspect…..76
Assemble…..76
Twist Lock Cylinders Repair…..77
Disassemble…..77
Clean and Inspect…..77
Assemble…..77
Adjustments…..77
Twist Lock Angle Adjustment…..77
Engaged/Released Proximity Switches Adjustment…..78
Push Rod Signal Adjustment…..78
Rotator Block Adjustment…..78
Additional Attachment Maintenance…..79
Torque Specifications…..79
Troubleshooting…..87
hyster-1473181-03-00-srm0791…..92
toc…..92
Diagrams…..92
Safety Precautions Maintenance and Repair…..93
hyster-897934-11-01-srm0626…..112
toc…..112
Cooling System…..112
Safety Precautions Maintenance and Repair…..113
General…..116
Description…..117
Radiator…..117
Radiator Cap…..117
Thermostat…..117
Water Pump…..118
Fan and Fan Shroud…..118
Cooling System Checks…..118
Radiator…..118
Thermostat…..118
Water Pump…..119
Exhaust Leaks…..119
Fan and Fan Shroud…..119
Radiator Cleaning…..119
Drain…..119
Clean…..119
Fill…..120
Troubleshooting…..121
hyster-910072-11-03-srm0046…..124
toc…..124
Differential…..124
Safety Precautions Maintenance and Repair…..125
General…..128
Description…..128
Differential Repair…..128
Remove…..128
Differential Carrier From Axle Housing, Remove…..128
Differential and Ring Gear From Differential Carrier, Remove…..132
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…..134
Disassemble…..135
Differential and Ring Gear Assembly, Disassemble…..135
Drive Pinion and Pinion Carrier, Disassemble…..137
Clean and Inspect…..139
Assemble…..140
Pinion, Bearings, and Pinion Carrier, Assemble…..140
Pinion Bearings, Adjust Preload…..141
Press Method…..141
Yoke or Flange Method…..141
Triple-Lip Seal, Install…..142
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…..143
Differential and Ring Gear, Assemble…..145
Differential Gears Rotating Torque, Check…..148
Differential and Ring Gear Assembly, Install…..149
Differential Bearings, Preload Adjust…..150
Ring Gear, Runout Check…..151
Ring Gear Backlash, Adjust…..151
Gear Set, Tooth Contact Pattern Check…..153
Thrust Screw, Install and Adjust…..155
Install…..156
Differential Assembly Into Axle Housing, Install…..156
Specifications…..158
Troubleshooting…..162
tables…..124
Table 1. Ring Gear Backlash Adjustment Specifications…..152
Table 2. Ring and Pinion Tooth Contact Adjustment…..154
Table 3. General Specifications…..158
Table 4. Rivet Installation Pressure…..158
Table 5. Pinion Adjustment…..158
Table 6. Pinion Preload Pressure…..159
Table 7. Torque Specifications…..160
Table 8. Torque Specifications for Metric Hardware…..161
Table 9. Torque Specifications for Metric (Fine) Hardware…..161
Metric and Inch (SAE) Fasteners…..166
Safety Precautions Maintenance and Repair…..167
General…..170
Threaded Fasteners…..170
Nomenclature, Threads…..170
Strength Identification…..171
Cotter (Split) Pins…..171
Fastener Torque Tables…..176
Conversion Table…..178
Table 1. Bolts and Screws…..172
Table 2. Studs and Nuts…..173
Table 3. Torque Nuts…..174
Table 4. Torque Nuts With Nylon Insert…..175
Table 5. Torque Values for Metric Fasteners*…..176
Table 6. Torque Values for Inch Fasteners*…..177
Table 7. Conversion Table for Metric and English units…..178
Table 8. Cotter Pin Dimensional Data…..179
Hyster HR45-EC, HR48-EC Repair Service Manual